Adani Power Limited

Power Business Goal - 20,000 MW

 ADANI POWER AT A GLANCE

• Power Business Goal - 20,000 MW BY 2020

• MUNDRA– 330MW X 4 + 660MW X 5

• TIRODA– 660MW X 5 (UNDER COMMISSIONING)

• KAWAI– 660MW X 2 (UNDER ERECTION)

• BITTA– 40MW BIGGEST SOLAR IN INDIA

 ACHIEVEMENTS

• INDIA’S FIRST 66O MW SUPER

CRITICAL UNIT SYNCHRONISED BY
ADANI POWER LTD, MUNDRA IN OCT
2010 IN RECORD TIME OF 36
MONTHS.
• COMMISSIONED 4Nos. 660MW UNITS
IN A YEAR.
• ADANI IS THE FIRST COMPANY IN
INDIA TO EARN CARBON CREDIT.
WELCOME
TO

PRESENTED BY
B.K.PANDEY
APML, TIRODA
 START-UP SEQUENCE
• BOP SYSTEM READYNESS
• BOILER FLUSHING: COLD/HOT
• BOILER LINE UP AND LIGHT UP.
• TURBINE LINE UP.
• TURBINE ROLLING.
• SYNCHRONISATION
• PHASE CHANGE OVER
• FULL LOAD
 START UP MODES

• COLD START UP:HP & IP SHAFT METAL

TEMP <204°C

• WARM START UP: HP & IP METAL TEMP IN

BETWEEN 204 TO 400°C

• HOT START UP :HP & IP METAL TEMP

>400°C
 Boiler

Economiser

11+1 8 2x7 2x7

FCS

HPT IPT LPT A LPT B

5 6 5 6
7 7 7 7
3 8 8 8 8
1 LPH -7A
LPH -7B
RH
HPH - 1

LPH -8A
LPH -8B

Condensor
(HP) Condensor
Deaerator
HPH - 2

(LP)
EXT From
CRH
(MD BFBP 1x35%)
TDBFP 2X50%
HPH -3

CEP
1994 TPH 3x50%

GSC

CPP
1482 TPH
LPH -5 LPH -6
 PRE STARTUP READYNESS
• HT/LT POWER SUPPLY READINESS

• WATER SYSTEM: FIRE WATER,SERVICE WATER,DMP,CW &

ACW.

• CCCW SYSTEM

• COMPRESSOR SYSTEM

• AUXILIARY STEAM. (S/B UNIT OR AUX BOILER).

• START CEP AND MDBFP.

• CHECK THE BCP SYSTEM IS READY.

 WHY BCP ?

• TO ASSIST CIRCULATION IN BOILER WATER WALL

• TO INCREASE THE CIRCULATION VELOCITY

• TO AVOID DNB (Departure from Nucleate Boiling) IN LOW LOAD.

• TO REDUCE THE OVER HEATING AND UNDUE STRESSES ON

WATER WALL TUBES.

• TO AVOID DRY OUT OF WATER WALL TUBES WHEN LOAD IS

REDUCED.
 BCP FILLING ,PURGING & FLUSHING
• PURPOSE-
- TO FILL THE MOTOR CAVITY.

• RECOMMENDED MOTOR FILLING WATER QUALITY

- CONDUCTIVITY <1 µs/cm
- BOILER FEED WATER
- TEMP.<= 45 OC
- CL- <= 50 PPM
- pH >= 6.5
- SUSPENDED SOLIDS <= 5 PPM

• FILLING,PURGING & FLUSHING WATER REQUIREMENT

- MOTOR INITIAL FILLING FLOW RATE : MAX. 5 L/MIN

 PRE BOILER FLUSHING
• START CEP.

• FILL & DRAIN FROM DEAERATOR UNTIL

REQUIRED WATER QUALITY IS ACHIEVED.
( Fe<500 Ppb.)

• START MDBFP.

• START THE BOILER COLD/HOT FLUSHING

TO REDUCE THE Fe & SiO2 CONTENT IN
FEED WATER.
SP SP Boiler flushing

START-UP
LINE

Sampling Fe+

Below
Above
MIXER 500ppb
500ppb

BCP

WW

ECO
CW HOTWELL
LINE
 BOILER COLD FLUSHING
COLD FLUSHING

• WATER WALL TEMP REQUIRED 105-120 DEG.C

(TEMP MAINTAINED BY DEAERATOR PEGGING
STEAM)

• COLD OPEN FLUSHING QUALIFIES Fe < 500PPB

SiO2 < 100PPB
• THEN CPU WILL BE TAKEN IN SERVICE TO REDUCE WATER
LOSS AND IMPROVE QUALITY.

• COLD CYCLIC FLUSHING QUALIFIES Fe < 100PPB

SIO2 < 50PPB

(ALL ANALYSIS FROM SEPARATOR DRAIN)

 BOILER HOT FLUSHING
HOT FLUSHING

• WATER WALL TEMP REQUIRED 150-190 DEG.C (TAKE

OIL GUNS OF BC ELEVATION)

• HOT OPEN FLUSHING START UP CRITERIA FE > 100PPB

SIO2 > 50PPB

• IF HOT CYCLIC FLUSHING CRITERIA IF FE < 100PPB

SIO2 < 50PPB

• HOT CYCLIC FLUSHING QUALIFIES IF FE < 50PPB

SIO2 < 30PPB

• AFTER COLD FLUSHING START BCP WITH MINIMUM 30%

FEED FLOW & THROTTLE FRS VALVE.
 BOILER LINE UP AND LIGHT UP
• FUEL OIL SYSTEM: LDO/HFO PUMPS

• ESP HEATERS & RAPPERS

• AIR FLUE GAS SYSTEM: APH,IDF, FDF &

SCANNER FAN.

• MAINTAIN AIR FLOW : 30% - 40%.

• FURNACE PURGE: 300 Sec.

• LIGHT UP BOILER WITH OIL GUNS AT BC (LDO)

ELEVETION.

• CONTINUE HOT FLUSHING UNTIL REQD.WATER

QUALITY IS ACHIEVED

• THEN TAKE CD ELEVETION GUNS. IF REQUIRED

TAKE 2 NO. GUNS IN AB ELEVETION.
 BOILER LINE UP AND LIGHT UP

• CONTINUOUS APH SOOT BLOWING TO BE DONE AT THE

TIME OF OIL FIRING.

• PR RISING RATE- 0.05 MPA/MIN. BETWEEN 0-1 MPA

• PR RISING RATE 0.1 MPA/MIN. BETWEEN 1 – 2 MPA
• PR RISING RATE 0.2 MPA/MIN. ABOVE 2 MPA

• FURNACE EXIT GAS TEMP MUST BE BELOW 538°C FOR

REHEATER PROTECTION (UNTIL HP-LPBP IS CHARGED).

• CLOSE SH DRAINS AND VENTS AFTER ACHIEVING DEGREE

OF SH 50 °C ( CLOSE IT AFTER CHARGING HP-LP BYPASS).
 LDO/HFO GUN
Fuel Light Oil

Fuel Pressure 0.8MPa-2.0MPa

Fuel Flow 500kg/h -3000kg/h

Atomizing Air Pressure 0.6MPa-1.2MPa

Atomizing Air Flow 100-600kg/h

Ignition Method HESI (20 joules/spark)

Fuel Heavy Oil

Fuel Pressure 0.8MPa- 2.0MPa

Fuel Flow 1000-4000 kg/h

Atomizing Steam Pressure 0.8MPa-1.2MPa

Atomizing Steam Flow 100-400kg/h

Ignition Method HESI (20 joules/spark)

 TURBINE LINE UP
• ENSURE:

• LUBE OIL SYSTEM: IN SERVICE (0.8 MPA)

• JACKING OIL SYSTEM:IN SERVICE ( 14 MPA)

• TURBINE BARRING GEAR: 3-4 RPM

• SEAL OIL SYSTEM: AIR & H2 SIDE. CHARGED

• STATOR AND H2 COOLING WATER SYSTEM:CHARGED TEMP CONTROL

IN AUTO)

• H2 FILLED IN GENERATOR AND MAINTAIN PR 0.35 MPA.

• EH OIL SYSTEM: IN SERVICE (14 MPA)

 TURBINE LINE UP
• ENSURE TDBFP IN BARRING.

• GLAND STEAM CHARGING: ENSURE STEAM TEMP. IS 56°C

- 111 °C MORE THAN ROTOR TEMP & DEGREE OF SH >
50°C.

• CHARGE THE GLAND SEAL SYSTEM OF TDBFP.

• START THE VACUUM PULLING WITH VACUUM PUMP.

MAINTAIN VACUUM -0.9 KG/CM2.

• CHARGE THE HP-LP BYPASS SYSTEM .MAINTAIN THE MS

STEAM PRESSURE AND FIRING RATE FOR ACHIEVING
TURBINE ROLLING PARAMETERS.
COLD START UP CURVE
HOT ROLLING

MS TEMP
RH TEMP
SPEED
MS FLOW
LOAD
MS PRESS
 PRE HEATING OF HP CASING.
• PREHEATING OF HPT REQUIRED WHEN INNER METAL TEMP <150°C.

• CRH PR 0.5-0.7 MPA/220-380°C.

• OPEN PRE HEATING VALVE (REVERSE FLOW VALVE) GRADUALLY.

• OPEN BDV VALVE FULLY.

• OPEN CRH DRAIN BEFORE NRV AND HPT-IPT CASING DRAINS.

• HEATING RATE SHOULD NOT BE MORE THAN 50°C PER HR.

• HP CASING TOP-BOTTOM & INNER-OUTER WALL METAL TEMP

DIFFRENCE SHOULD BE WITHIN 50°C.

• AFTER ATTAINING THE CASING TEMP > 150°C CLOSE THE RFV
VALVE AND OPEN HP CYLINDER VENTILATION VALVE TO
CONDENSOR.
 TURBINE WARM UP OPERATION

MS

HPBP

HPT IPT

Ventilator valve
CRH NRV TO CONDENSER
BDV
RFV
TO CONDENSER

CRH LINE

TURBINE STARUP PROCEDUR

 TURBINE ROLLING
• AS PER REQUIREMENT OF START UP CURVE, FIRING TO BE
INCREASED.
• REQUIRED STEAM PARAMETERS BEFORE ROLLING
– MS PR: 8.73 MPA, TEMP: 330-380 °C
– RH PR: 1.1 MPA , TEMP: 330°C
- THE DEGREE OF SUPER HEAT > 56°C.

• AFTER LATCHING THE TURBINE, START IP ROLLING WITH HP VENT

TO CONDENSER IN OPEN CONDITION TO KEEP THE HPT IN
VACUUM.

• MSV 1&2 AND RSV 1&2 ARE IN OPEN CONDITION.

• GIVE THE SPEED SET POINT TO 600 RPM

• CHECK THE TURBINE SUPERVISORY INSTRUMENT PARAMETER.

• THE ECCENTRICITY SHOULD BE LESS THAN 0.076 MM.

 TURBINE ROLLING
• SELECT TARGET SPEED 1500 RPM WITH RAMP RATE OF 100
RPM/MIN.
• ENSURE ALL HP CV’S OPENS TO 12% TO WARM UP THE HP
CASING.
• WHEN HP CASING TEMP >320°C.CLOSE THE HP CV’S.
• SOAK THE TURBINE FOR 4 HRS ACCORDING TO THE START UP
CURVE.
• CHARGE THE LP HEATER 5 & 6 BEFORE 3000 RPM

• SELECT TARGET SPEED TO 3000 RPM WITH RAMP RATE OF 100

RPM/MIN.SOAK IT FOR 30 MIN AS PER S/U CURVE.

• AS PER PROCEDURE SYNCHRONISE THE UNIT.

 LOADING
• AFTER SYNCHRONISATION INITIAL LOAD WILL BE 30 MW.HOLD IT
FOR 30 MIN AND CHEK THE VIBRATION, BEARING TEMP, DIFF
EXPANSION, CASING EXPANSION.

• CHARGE EXTRACTION STEAM TO DEAERATOR.

• TAKE MORE OIL GUNS IN EF/AB ELEVETION.

• TAKE PA FANS & SEAL AIR FAN.

• AFTER ACHIEVING FURNACE TEMP. MORE THEN 450°C. TAKE COAL

MILL-B AT. STEAM T/PR 380°C/8.7 MPA.

• INCREASE FUEL FLOW MAINTAINING STEAM TEMP.& RAISE LOAD

• AT 70 MW IP TO HP CHANGE OVER. CV’S WILL START OPENING,

CLOSE THE BDV AND VENTILATING VALVE.

• INCREASE THE LOAD AT 3MW/MIN

• CLOSE THE HP-LP BYPASS GRADULLY.

 (MW)
LOAD

165
330
495
660
SYNCHRONISE

350
&CHARGE D/A

33MW
MILL-B CUT IN

400
IP TO HP CHANGE OVER (70MW

60MW
MILL-C CUT IN AT 100MW
HPH CHARGED(150 MW)

2ND TDBFP CUT IN(180MW)

450
WET TO DRY CHANGE OVER

MILL-A CUT IN(210MW)

OIL GUN CUT OUT (260MW)

198MW
MILL-D CIT IN (300MW)

500
MINUTES
330MW

MILL-E CUT IN (430MW)

550
MILL-F CUT IN (540MW)

600
660 MW

650
 LPT A FROM IPT EXHAUST LPT B

2nd 2nd
4th
4th
5th 5th 5th 5th
6th 6th
6th
6th

LP HEATER 7A LP HEATER 7B
LP HEATER 8A LP HEATER 8B
CONDENSER CONDENSER

HP HEATER
LP HEATER 5
5 HP HEATER
LP HEATER 6
6
 TDBFP START UP
• TAKE ONE TDBFP IN SERVICE( CHANGE OVER WITH MD BFP) WHILE
DRIVING STEAM IS AVAILABLE. SECOND TD BFP WILL BE TAKEN AT
180 MW.

• WARM UP THE TURBINE.

• SLOWLY OPEN THE AUX STEAM MOV TO TURBINE.

• PARAMETERS FOR ROLLING TDBFP.

STEAM PRESSURE: 0.6～1.3MPA, STEAM TEMP: 50 DEG C MORE THAN

CASING TEMP.

• ROLL THE TDBFP AS PER PROCEDURE.

• GIVE THE TARGET SPEED 500 RPM AND THAN TO 1000 HOLD FOR 40
MIN.CHECK THE TSI PARAMETER

• WHEN SPEED REACHES 2840 RPM, GIVE REQUEST COMMAND FROM

FW MENU. THEN SELECT CCS CONTROL IN FROM MEH MENU.
 TDBFP STEAM SOURCES

HP IP
1.12 Mpa 1.3 MPa
378 ºC 350 ºC

Aux. Steam
Header
To M

CRH Changeover Valve

M E M M

From
E
M

CRH
M M
4 MPa
315.3 ºC

TDBFP-B
To
Condenser TDBFP-A
Booster
pumps
Deaerator
 LOADING
• TAKE THE MILL-C IN SERVICE AT 100 MW. STEAM T/PR:400°C/8.7
MPA.

• GRADUALLY WITH DRAW THE OIL SUPPORT AS PER THE FLAME

CONDITION.

• INCREASE THE LOAD TO 150 MW AND TAKE THE HPH-3, HPH-2 &
HPH-1 IN SERVICE. MS T/PR 410°C/8.7 MPA.

• AT 180 MW TAKE SECOND TDBFP IN SERVICE.

 MS LINE HRH LINE

IP EXHAUST

CRH LINE

5th stage
9th stage

TDBFP A TDBFP B

HP HEATER HP
HP HEATER
HEATER
1 33
HP HEATER
2

DEAERATOR
 PHASE CHANGE FROM WET TO DRY MODE
• DURING LOAD RAISING >25% BMCR, THE BCP FLOW AND FEED
WATER FLOW TO BE MONITORED CLOSELY.

• THE BCP FLOW NEED TO BE ADJUSTED W.R.T SEPERATOR TANK

LEVEL AND THE SAME FLOW TO BE ADJUSTED IN FEED WATER FLOW
TO MAINTAIN TOTAL FEED WATER FLOW TO ECONOMISER
CONSTANT.

• WHEN BOILER STEAMING RATE RISES TO >30% BMCR, W.R.T FUEL

FIRING, THE SEPERATOR LEVEL REDUCES .

• ONCE THE CONDITION FULFILLS THE BCP STOPS AND FEED FLOW
CONTROL CHANGES OVER FRS.

• AFTER STOPPING BCP IT ACTS AS SUB-CRITICAL ONCE THROUGH“.

• WHEN THE STEAM PR REACHES 22.1 MPA IT IS IN “SUPERCRITICAL

ZONE”
 LOADING
• TAKE MILL-A AT 210 MW.

• CUT THE OIL SUPPORT AT 260 MW AS PER THE FLAME CONDITION.

• TAKE MILL-D AT 300 MW. MS T/PR 475°C/10 MPA.

• TAKE MILL-E AT 430 MW. MS T/PR 566°C/17 MPA.

• TAKE MILL-F AT 540 MW. MS T/PR 566°C/24.1 MPA.

• INCREASE THE LOAD TO “FULL LOAD 660 MW” GRADUALLY.

 Boiler Design Parameters
NO. Parameters Unit
100% BMCR Coal consumption (Design) 390.37
1 t/h

2 Design fuel Indian coal

3 Superheated steam flow 2111 t/h
4 Superheater outlet pressure 25.4 MPa
5 Superheater outlet temperature 569 ℃
6 Reheated steam flow 1749.1 t/h
7 Reheater inlet pressure 4.73 MPa
8 Reheater outlet pressure 4.49 MPa
9 Reheater inlet temperature 324 ℃
10 Reheater outlet temperature 569 ℃
Feedwater pressure 28.8 MPa.g
11 Feedwater temperature 280 ℃
12 Separator’s steam temperature 421 ℃

Air preheater’s outlet air temperature, uncorrected 153.3 ℃

13
After correcting 147.2 ℃
14 Calculating thermal efficiency of boiler 87.19%（BMCR）
 TURBINE PARAMETERS
Steam Admission Parameters at Turbine Inlet

HPT IPT LPT

Pressure (MPa) 24.2 3.961 1.12
I/L Temp (Deg C) 566 566 378
O/L Temp(deg C) 315.3 378
Steam Flow (tph) 1959.25 1649
TURBINE HEAT RATE( KCL/KWH) 1885
No of Stop valves 2 2
No of Control valves 4 4
 TURBINE AT FULL LOAD

3.96MPa / 566°c

HRH
24.2MPa/566ºC 1.12MPa / 378°c
RSV
MS LINE
MSV CV CV

CV CV
TO BLR RH

CRH

HPT IPT LPT #1 LPT #2 GEN

CRH

RCV
CV
CV RCV
CV

CONDENSOR A CONDENSOR B
MSV CV CV
RSV
RSV
MS LINE

HRH
 SHUT DOWN
• EXCEPT IN AN EMERGENCY, LOAD SHOULD BE REDUCED
GRADUALLY.

• CUT THE MILL-F AT 540 MW.

• CUT THE MILL-E AT 470MW.

• CUT THE MILL-D AT 300 MW.

• TAKE OIL SUPPORT FOR FURNACE STABILITY ( AT THE TIME OF 3

MILL OPERATION).

• CUT THE MILL-A AT 210 MW.

• TAKE THE HPH-1,2,3 OUT OF SERVICE.

• WHEN THE LOAD < 30% BOILER COMES IN WET MODE FROM
DRY MODE. START THE BCP AND MAINTAIN THE SEPEARTOR
LEVEL.
 SHUT DOWN
• WHEN THE LOAD HAS DECREASED TO 20% OF RATED LOAD TRIP
THE TURBINE ON TURBINE PROTECTION. THIS CLOSES THE
THROTTLE VALVES, GOVERNOR VALVES, REHEAT STOP VALVES AND
INTERCEPTOR VALVES

• CHECK DRAIN VALVES OPENS IN AUTO.

• HP LP BYPASS VALVE OPENS TO MAINTAIN THE FLOW.

• REDUCE THE BOILER LOAD GRADULLY.

• TRIP THE BOILER.

• THE VACUUM BREAKER VALVES SHOULD NOT BE OPENED UNTIL THE
TURBINE UNIT HAS COASTED DOWN.

• VACUUM SHOULD BE KILLED BEFORE GLAND SEALING STEAM IS

SHUT OFF.

• AUX OIL PUMP STARTS IN AUTO AT 2850 RPM.

• JOP START IN AUTO AT 1200 RPM.
 SHUT DOWN
• WHEN THE VACUUM REACHES ZERO, SHUT OFF THE SEALING STEAM
TO THE GLAND STEAM CONTROL VALVES.

• SHUT DOWN THE GLAND STEAM CONDENSER EXHAUSTER. SHUT

DOWN CONDENSATE PUMP.

• SHUT DOWN THE VACUUM PUMP.

• SHUT OFF THE COOLING WATER SUPPLY TO THE GENERATOR

HYDROGEN COOLERS.

• ENSURE THAT BARRING GEAR HAS CUT IN.

SHUT DOWN CURVE
COOL DOWN CURVE
THANK YOU