Purpose:

To Carry out cleanup activity

Status:
WSDT pressure hold at 50 Kg/cm2 for hydraulic test

WSDT pressure is hold at 50 Kg/cm2 for internal inspection of boiler. Sky climber is erected for inspection if BTL
is in first pass or secondary Superheater coil. Platform is erected at neck portion for sky climber. If WSDT pr is
50 kg/cm2 then hotwell sample may get deviate due to boiler water passing through WDC vavles, if these valves
are passing. Hotwell sample should therefore be analyzed by chemist. If parameters are within range then first
CEP can be started after back charging

(CEP back charging: ensure boiler fill pump is in service. DMCW TG is required for CEP bearing cooling. Open
vent on CEP discharge line. Open quick fill line MIV at local and ensure water from CEP vent line. Start CEP on
GSC RC open. Close vent)

Status:
1) WSDT pressure 50 kg/cm2
2) CEP 1 Nos in service
3) Aux steam charged upto gland steam control MIV
4) Boiler fill pump to be in service till long recirculation is achieved

1. After clearance from BM for successful hydraulic test boiler, bring BFP scoop to minimum.
2. Stop BFP
3. Open boiler side vents(S/H, economizer, wsdt etc).
4. Drain wsdt on priority to carry out further clean up activity
5. Drain economizer, water wall, superheater as per availability of drain pit pumps
6. Charge gland steam header
7. Apply gland sealing
8. Start vacuum pump and carry out vacuum pulling
9. If hotwell samples are ok then condensate flow can be extended upto Dearator with LPH first in bypass mode
then in service mode. Dearator blow will continue till clearance is received from chemist.
10. When samples are ok stop blow and connect to condenser. Short recirculation
11. Start Dearator pegging from aux line. ( Ensure that drains at 24 mtrs and at Dearator level on aux line are
open prior to pegging)
12. Start BFP on recirculation. Maintain Dearator level around 1100
13. Monitor Rise in temperature and at 120 deg c monitor DO
14. After clearance from chemist for DO hot water filling in boiler can be started only after clearance from BM.
( BM work may be in process such as RAPH work or removal of scaffolding from first pass, sky climber
removal after hydraulic work or removal of scaffolding in RAPH etc)
15. Boiler filling has to be a very slow process. Feed water flow should be initially kept at 100 TPH which can be
increased to 150 to 200 TPH after some time (around 1 hr). This feed water flow may not be reliable. Ensure
before filling of boiler that all drains on boiler side except superheater drains are closed and all vents on boiler
including superheater vents are open. To ensure proper feed water flow during boiler filling CEP flow to
Dearator can be considered as best guide.
16. Ensure that wdc mov are closed, and wdc blow mov is open
17. Ensure that short recirculation is stopped and then boiler filling is started
18. During filling of water first appearance of water will be observed at intermediate header vents. Close these
vents. eco vents can be closed after this if air free continuous water is observed at eco vents
19. When level is observed in WSDT, open WDC CV full and flush wsdt
20. Achieve proper level in WSDT by CV and give sample to chemist
21. Continue blow through wsdt till clearance is received from chemist
22. After clearance from chemist blow can be stopped and boiler to be put on long recirculation
23. Wait for chemist clearance for boiler lightup.
Purpose:
To Carry boiler lightup
Status:
Boiler on long Recirculation with clearance from Chemist for lightup
Although clearance is received from chemist for lightup, clearance may be pending from BM for lightup due to
pending works like manhole ,door box up of main boiler or RAPH etc. This may not permit to take air cycle in
service. On the contrary if clearance is received from BM and pending from Chemist then air cycle may be put in
service in advance. Take trials of all IGVs and suction discharge damper of all fans well in advance so that cycle
are available in all respect. Monitor all lub oil, control oil levels, temperature and coolers healthiness. Ensure
that all flue gas path dampers, Hot and cold PA path dampers (RAPH Outlet), FD path dampers (RAPH outlet)
are open. 4 nos of dampers in flue gas path and 2 nos of dampers in FD path should be ensured open from local
and its MCB should be kept off. These dampers are double flap dampers. Air flow can be maintained minimum
possible such that furnace draft is maintained as well as stall on either FD fan is reset till final lightup clearance
is received
Establishing both air cycle:
1. Start ID fan . check instantaneous current drop to normal current. check both suction and discharge
dampers open. Ensure from local. Check flow .IGV should be on manual and zero. Draft set point can be
kept at minus 8 mmwcl
2. Put ID fan IGV on auto and start FD fan on cross limb (if ID A is started then start FD B). check current
drops to normal value. Check discharge damper open and ensure from local. Check flow. IGV is on
manual and zero. Start other FD fan ensuring it is not rotating in reverse direction. check current drops to
normal value. Check discharge damper open and ensure from local. Check flow. IGV is on manual and
zero. Increase both FD fan IGV equally so that flow is balanced and ID fan can maintain draft at set point.
Check that no stall is operated on either FD fan. (While starting FD fan other fan damper may shift to
manual mode. Ensure that all suction discharge damper of all fans should be on auto before starting any
fan). Single ID fan can maintain draft with both FD fan in service and there is no chance of reverse
rotation of stand by ID fan. After achieving minimum secondary air flow say around 400 to 500 TPH ,
other ID fan can be started and flow on both ID can be balanced. Here both ID fan IGVs cn be put on auto
and then further secondary air flow can be increased. FD can be put on auto when set point of FD master
and actual FD matches. Negative bias of 10 can be given to maintain secondary air flow equal to 900
TPH.

FEED Water flow:

Feed water flow is maintained initially upto minimum possible till lightup clearance is received. It has to be
increased minimum upto 376 TPH to reset MFT during furnace purge cycle

Air Flow:
Minimum 30 % is required. If Air cycle has to be on auto 900 TPH with minus 10 bias to FD control can do.

Furnace Purge and MFT reset:

Furnace purge can be carried out well in advance even if light up clearance is held from chemist. MFT can be
reset only after furnace purge is complete.LDO leak check and HFO leak check can be carried out during furnace
purge to open LO TV and HO TV. This trip valve gets open after MFT is reset.

Steam atomizing or air atomizing valve is open only after MFT is reset. Hence to carry out successful remote
purging of oil guns prior to lightup this MFT bit has to be bypassed from CNI. This can be done as follows
1. Ensure air atomizing and steam atomizing header is charged and drains at various locations are
operated well in advance to get water free air or steam
2. Check air atomizing and steam atomizing pressure is sufficient
3. Bypass MFT bit
4. Ensure FO is selected in AB elevation so that gun purging can be done by steam
5. Carry out AB and CD elevation gun purging well in advance so that after successful gun purging oil
changeover can be done in AB elevation
6. If gun purging is ensured reset the MFT bit
7. Further carry out furnace purge and MFT reset as stated above
Turbine rolling and synchronizing:
1. Reset turbine
2. Ensure trip oil pressure = 120 kg/cm2
3. Ensure RSV equalizing valve open , RSV open and then equalizing valve close
4. Ensure all GV open 100 percent
5. Ensure gland seal float pump is in service
6. Ensure thermal stress is in service
7. Start rolling from ATS
(ATS → ATS_START_MODE → IN.
ATS_START_UP_BP-1_MODE → IN.)
8. MSV will open such that turbine rolls to 500 rpm. At this speed MSV close and RUB check is in service
to ensure any abnormal sound at local. Speed starts dropping. After clearance from local put RUB check
out
9. Speed set point will be 500 rpm. Soaking will be carried out as follows
(Cold- 9.5 min
Warm- 8.3 min
Hot- no soaking)
10. Ensure thermal stress is IN. Monitor bearing vibration and turbovisory as turbine speeds up further
11. Speed set point will be 1950 rpm. Turbine speeds up
12. Ensure JOP stops at 900 rpm
13. Thermal stress should be between -60 to +110 oC
14. Soaking will be carried out at 1950 rpm as follows
(Cold- 180 min
Warm- no soaking
Hot- no soaking)
15. Speed set point will be 3000 rpm. Turbine speeds up.( Ensure sufficient margin is available in HPBP, if
not then increase HFO oil pressure)
16. Ensure AOP, TOP stop at 2950 rpm. Ensure MOP discharge pressure is 25 kg/cm2 and auto stop oil
pressure is 10 kg/cm2
17. Valve transfer will be carried out if PV >= SP of steam chest temperature.( In valve transfer ensure all
GVs get throttled and MSVs are full open. Valve transfer in case of cold rolling takes a long time as
actual steam chest temp i.e. PV is very low compared to SP. SP is derived from steam temperature and
pressure. Hence during cold rolling try to maintain main steam temperature near to 380 oC) . Ensure BP1
on ATS complete
18. Ensure auto sync is selected, breaker selection on ECP panel and TCS should be same, lock out relays
reset, LBB link IN, AVR on auto
19. Start BP2 on ATS as follows
ATS_START_UP_BP-2_MODE → IN
20. Ensure sufficient margin is available in HPBP, if not then increase HFO oil pressure as HPBP may close
after synchronizing
21. Ensure Excitation breaker closes. Generator field voltage and current is developed
22. Generator voltage and current increases
23. Set synchronize on auto with 5% load ( 30 t0 40 MW) on preselected generator breaker
24. Take another generator breaker in service
25. APS link gets transfer after holding period as follows
(Cold- 40 min
Warm- 20 min
Hot- 12 min)
26. After link transfer ATS BP2 is completed. Ensure LL-APC link gets selected (IF GOV-APC link is
selected perform this operation…..)
Loading
1. When link is transferred to DCS , load can be increased from DCS
2. PUT coal mill in service one by one and withdraw oil support gradually keeping balance of water and fuel
to avoid temperature excursions
3. Put mills in service one by one( C,D,B,E ) .
4. At 20 % to 30 % load (about 132 MW) wet to dry mode transfer takes place. At this stage pressure
control mode gets shifted to backup control mode. HP Bypass closes and remains close till pressure
deviation is more than 10 kg/cm2. Once wet to dry mode is achieved bcp gets tripped
5. MDBFP can take only 30% load i.e. 198 mw ,hence TDBFP should be on 2500 rpm well in advance so that
it can be put in service at 198 MWD
6. Also 30 % to 100 % Feed control station valve transfer takes place at 235 MWD. Sufficient boiler heat has
to be maintained for this
7. HPH has to be put on flushing after 150 MW when extraction NRVs are open.
8. LPH are put in service at about 90 MW
9. Various activities are carried out between 180 MW to 240 MW . At 198 MWD TDBFP inservice takes
place. MDBFP may get unload hence positive bias should be given.( about 100 to 200 TPH will serve the
purpose). As per our L and T manual MDBFP should be out service once TDBFP is in, hence Fx are
designed in this fashion but we don’t allow MDBFP to be out service for safer operation. Feedwater may
increase upto 1000 TPH hence once TDBFP is inservice give load set point of 240 MW so that valve
transfer also starts and excess feedwater is also compensated at increased BID.
10. MDBFP can be withdrawn after second TDBFP is inservice
11. Every steps should be taken to control temperature excurtions during raising load. For this try to
maintain negative MS pressure deviation( -4 to -5 kg/cm2)
12. While putting coal master on auto after three or four mills in service, try to maintain difference between
actual combustion demand and set point of combustion demand to minimum possible.