RAICHUR THERMAL POWER STATION

UNIT START UP PROCEDURES

By
MANJUNATHA HALEGOUDAR
BE(Mech),MBA(Finance), BOE, CEA.
Assistant Executive Engineer
BEE Certified Energy Auditor
 PROCESS FLOW CHART OF FLUID AT RTPS

LP BYPASS
o
36 ksc 540 C HRH 49o C 0.1 ksc

BOILER 155 ksc 315o C 49o C CONDENSOR

HPT IPT LPT CONDENSOR
RH 540oC 7 ksc 0.1 ksc
HOT WELL
o
155 ksc CRH 338 C

EXT from LPT 7th STAGE, 0.2 ksc, 61

243o C 38 ksc 46o C
EXT from CRH 0.1 ksc
HPH-6
338o C 38 ksc HP BYPASS
160 ksc CEP
198o C Spray to HPBP
EXT from IPT 11th STAGE
HPH-5
433o C 16.8 ksc 46o C
160 ksc EXT from IPT EXHAUST 21 ksc
164o C 315o C 7.1 ksc Spray to LPBP
rd
BFP EXT EXT from LPT 3 STAGE Gland Steam
from CRH 200o C 2.36 ksc Condensor
7 ksc EXT from LPT 5th STAGE 47o C
161o C 107o C 0.85 ksc

O
19 ksc

C
8 ksc 10 ksc 14 ksc 17 ksc
D/A
DEAERATOR LPH-3 LPH-2 LPH-1 Drain Cooler
EXT 120o C 90o C 56o C 47o C
from APRDS

COLOUR CODE
STEAM
CONDENSATE
FEED WATER
 UNIT START UPS

 COLD STATRT UP

 WARM STATRT UP

 HOT STATRT UP

Operation Procedures. Manjunath H 3

 UNIT START UPS

COLD START WARM START HOT START

UP UP UP

HPT SHAFT / <150OC 150OC TO 350OC > 350OC

CASING TEMP

DOWN TIME > 36 Hrs 8 Hrs TO 36 < 8 Hrs

Hrs

BOILER START LDO HFO / LDO HFO

UP WITH

Operation Procedures. Manjunath H 4

 COLD START UP

1. Preparation.
2. Start Up of Turbo Generator.
3. Pre Light Up Activities.
4. Boiler Light Up and Pressure Raising.
5. Steam Admission to Turbine and Rolling,

6. Synchronisation and Loading,

Operation Procedures. Manjunath H 5

 COLD START UP
1. PREPARATION
CHECKS
 Check Work Permits Returned
 Normalise Isolated Systems

 Make Electrical Supply Ready

 Make Ciculating Water System Ready

 Make Compressed Air System Ready
 Check all the Protections

Operation Procedures. Manjunath H 6

 COLD START UP
1. PREPARATION
CHECKS
 Make Fire Fighting System Ready
 Make LDO/HFO/COAL Available

 Make DM Water Available

 Make Ash Handling System Ready

 Make sure Chemical Dosing System is Ready
 Make Sure CO2 and H2 Cylinders Available

Operation Procedures. Manjunath H 7

 COLD START UP
1. PREPARATION
ACTIVITIES
 CW System Charging
 Open CW inlet and Outlet Valves
 Open Cold Tunnel, Hot Tunnel and
Condensor Vents
 Tunnel Filling from Neighbouring Units
 Start One CWP
 Close Vents
 Close Neighbouring Unit CW Supply

Operation Procedures. Manjunath H 8

 COLD START UP
1. PREPARATION
ACTIVITIES
 Charging ACW System
 CST Filling
 FCW Tank Filling and Charging FCW System
 Start Air Compressors and air Driers
 Hot Well Filling
 Dearator Filling
 Boiler Filling
 Charge Stator Water System (Unit 1, 2 and 3)

Operation Procedures. Manjunath H 9

 COLD START UP
2. Start Up of Turbo Generator
CHECKS
• Make Turbine lub oil system ready.
• Make Generator seal oil system ready.
• Ensure Hydrogen available for filling.

Operation Procedures. Manjunath H 10

 COLD START UP
2. Start Up of Turbo Generator

ACTIVITIES
• Charge Generator seal oïl system.
• Generator Hydrogen filling.
• Open Gate Valve Gearing

Operation Procedures. Manjunath H 11

C
O
3. Pre Light Up Activities.
L  Boiler, Turbine & Generator
D Protection system ready.
 Generator Excitation system ready.
S  ATRS, FSSS, SADS system ready.
T  Flue Gas path ready.
A  Ash Handling system ready.
R  Seal trough filled.
T

U
P Operation Procedures. Manjunath H 12
 COLD START UP
4. Boiler Light Up and Pressure Raising

• Start LDO pump.

• Start HFO pump & keep on Recirculation.
• Charge HFO Heating station.
• Start both APHs
• Start AC Scanner Air Fan
• Start One set of ID and FD Fans
• Maintain Air Flow >30% and Furnace Draft -10 to -15
mmWCL

Operation Procedures. Manjunath H 13

 COLD START UP
4. Boiler Light Up and Pressure Raising

• Check for all the Boiler Purge Permissives

• Initiate Boiler Purge - 5 Minutes
• Adjust Wind Box to Furnace DP to 40 mmWCL
• Put SADC on Auto
• Select LDO for AB Elevation
• Light Up Boiler with AB Elavation Oil Guns One Pair with
LDO

Operation Procedures. Manjunath H 14

 COLD START UP
4. Boiler Light Up and Pressure Raising

Boiler Pressure ‘0’ ksc

• Keep AB Elavation Oil Guns One Pair with LDO for 30
minutes
• After 30 minutes cut in 2nd pair and cut out 1st pair
• After next 30 minutes keep both the pairs ( 4 Guns) in
Service

Operation Procedures. Manjunath H 15

 COLD START UP
4. Boiler Light Up and Pressure Raising

Boiler Pressure ‘0’ ksc

Ensure
• Flue Gas Temperature at Furnace Exit does not exceed
450o C
• Steam Temperature Raise in Boiler is limited to 110 o C
per Hour
• Drum Metal Temperature Difeerence between top and
bottom does not exceed 55o C

Operation Procedures. Manjunath H 16

 COLD START UP
4. Boiler Light Up and Pressure Raising

Boiler Pressure ‘2’ ksc

• Close Drum and Economiser Air Vents
• Cut in CD Elevation 4 Guns with HFO
• Change Over AB Elevation from LDO to HFO
• Start Dearator Pegging Steam From APRDS

Operation Procedures. Manjunath H 17

 COLD START UP
4. Boiler Light Up and Pressure Raising

Boiler Pressure ‘5’ ksc

• Close SH Header Drains and SH start up Vents
• Throttle RH start up vents
• Cut in one BFP and one CEP
• Carry out Vacuum Pulling and maintain Vacuum above
0.75 ksc
• Open IBP Valves of S 40 and S 60 Valves

Operation Procedures. Manjunath H 18

 COLD START UP
4. Boiler Light Up and Pressure Raising

Boiler Pressure ‘10’ ksc

• Open S 40 and S 60 Valves
• Charge HP and LP Bypass
• Close RH Start Up Vents

Operation Procedures. Manjunath H 19

 COLD START UP
4. Boiler Light Up and Pressure Raising

Boiler Pressure ‘15’ ksc

Ensure
• Generator Protection Trip Relays Resetted
• Stator Water Flow is > 17 m3 per hour
• H2 Pressure in Generator Casing is > 3 ksc
• Seal Oil to H2 DP is > 1.4 ksc
• No liquid presence in Generrator Casing

Operation Procedures. Manjunath H 20

 5. Steam Admission and Roling.
C
O
Boiler Pressure ‘20’ ksc and 250o C
L
D • Generate Trip Oil
S • Open HP and IP Stop Valves
T • Carry out APH Soot blowing through
A APRDS
R
T
U
P
Operation Procedures. Manjunath H 21
C
5. Steam Admission and Roling.
O
L Boiler Pressure ‘25’ ksc and 300o C
D
• Rolling Turbine to 600 RPM
• Adjusting Stator Water Flow and
S Hydrogen Cooler Water Flow
T • Ensur Gate Valve Gearing Closes at 240
A RPM
• Ensure JOP cut out at 540 RPM
R
• Observe Turbine Shaft Vibrations and
T Temperatures
U
P Operation Procedures. Manjunath H 22
C 5. Steam Admission and Roling.
O
L Boiler Pressure ‘30’ ksc and 350o C
D
• Rolling Turbine to 3000 RPM
• Ensure AOP cut out at 2850 RPM
S • Monitor Turbine Shaft Vibrations and
T Bearing Temperatures and vibrations
A • Observe Turbovisory Readings
R
T
U
P Operation Procedures. Manjunath H 23
 COLD START UP
6. Synchronisation and Loading

Boiler Pressure ‘35’ ksc and 360o C

• Ensure GT is ready
• Raise Stator Water Flow to 28 m3 per hour
• Get ODY Clearance regarding Isolators and Breakers
• Keep Block Load of 20 MW
• Synchronise the unit to Grid and Raise the Load above
20 MW

Operation Procedures. Manjunath H 24

 COLD START UP
After Synchronisation

At Load 20 MW, 40 ksc, 360oC

• Cut in one PA Fan.
• Cut in one Seal Air Fan.
• Raise the Unit load to 40 MW.
• Start Dearator Pegging from CRH.
• Line up Coal Mill.
• Charge SH/RH Spray Line.

Operation Procedures. Manjunath H 25

 COLD START UP
LOADING

At Load 40 MW, 50 ksc, 400oC

• Charge LPH 2 and 3.

• Start Second BFP and CWP.
• Cut in Mill C
• Raise the Unit load to 80 MW.
• Change over Unit Supply from Station to UATs

Operation Procedures. Manjunath H 26

 COLD START UP
LOADING

At Load 80 MW, 70 ksc, 450oC

• Charge Extraction-4 to Dearator.

• Charge ESP ECs and Rapping Motors.
• Cut in Mill B
• Raise the Unit load to 100 MW.

Operation Procedures. Manjunath H 27

 COLD START UP
LOADING

At Load 100 MW, 100 ksc, 480oC

• Cut in Second set of ID, FD and PA Fans.

• Cut in Mill A
• Raise the Unit load to 140 MW.

Operation Procedures. Manjunath H 28

 COLD START UP
LOADING

At Load 140 MW, 120 ksc, 540oC

• Charge HP Heaters.
• Cut in Mill D
• Raise the Unit load to 180 MW.
• Cut out Oil Support

Operation Procedures. Manjunath H 29

 COLD START UP
LOADING

At Load 180 MW, 140 ksc, 540oC

• Cut in Mill E
• Raise the Unit load to 210 MW.

Operation Procedures. Manjunath H 30