500 MW Unit Startup Procedure

CONTENTS
SL. N O .
DESCRIPTION
01.
CO L D ST AR T - U P
02.
IN T E GRA T E D ST AR T U P PR O C EDU R E C O LD S TAR T U P
03.
H O T AN D WA RM S TA RT U PS.
04.
IN T E GRA T E D ST AR T U P PR O C EDU R E WAR M S TAR T UP
05.
IN T E GRA T E D ST AR T U P PR O C EDU R E H O T ST AR T U P .
06.
10.
STA RT U P B Y CU RV ES F O R ABS O LU T E CO L D ST AR T W IT H HP /L P B YP ASS

SYS T E M.
STA RT UP CU RV ES AFT E R 4 8 H OUR S SH AT D O W N W IT H H P/ LP BY PA SS
SYS T E M.
STA RT U P P RO C E DU RE A FT E R 8 H O URS S HU T D O W N W IT H HP/ L P B YP ASS
SYS T E M.
T EC H N ICA L DA TA L IM IT CUR V ES F O R T URB IN E VA LV E S WA LL OF T H E
CAS IN G S HA FT S.
WAR M IN G UP A N D S TAR T IN G T H E TUR B IN E T EM P ER AT UR E CR IT E R IA.
11.
T EC H N ICA L DA TA RE AC T IV E CA PAC IT Y CU RV E F OR TUR B O G E N ERA T ORS .
07.
08.
09.
COLD START UP
(With Aux Steam available)
A cold start up is by definition, one of which the maximum of HP casing and HP shaft is less
than 1500C. This normally means that the unit is shut down from the maximum load for
more than five days. If machine is started from ambient temperature (HPC/HP shaft temp
approx. 400C), heating up of casting is required. This is accomplished by soaking the
machine at 360 rpm at warming up steam parameters (40kg/cm2, 3600 C), till the TSE
margin are satisfactory.
The rifle construction of the water wall combined with the boiler circulating water
pumps permits very high rate of pressure rising of boiler. An upper limit of 2000C/hr
saturation temperature gradient can be allowed, i.e. approximately the boiler pressure can
be brought to 20 kg/cm2 within an hour of cold start up. But actual temperature gradient is
limited by the thick walled Y piece provided in the main steam and HRH lines. A main steam
line heating is to be started as early as possible (at approx. 4 kg/cm 2) as maximum
differential temperature allowed between inner (98%) and mid wall temperature (50%)
is 400C. So boiler loading is accordingly regulated. It may be preferably to start only two
CC pumps in order to minimise flashing in down comers (and subsequent vibration) when
the boiler water is in range of 850C to 1250C. The third pump should be started before drum
pressure reaches 7 kg/cm2 to minimise the temperature transients experienced by the
pump casing (this is to avoid fast load out back on the boiler in the event of any CC pump
tripping).
To get the rolling parameters, normally two elevation oil guns are taken with
approx. 70 to 80t/hr flow through HP-LP bypass. At that time M.S. parameters would be 40
kg/cm2 and 3600C, HRH parameters would be 12 kg/cm2 and 3600C.
As soon as the turbine loading has started, HP/LP bypass closes and gets completely closed
as the turbine reaches the boiler load. First mill is put into operation around 10% of
generator load. Second mill is put into operation around 25% while third mill is at 40% of
generator load. Fourth and fifth mills are put into operation at 60% and 80% of generator
load respectively. Sixth mill is taken to reach full generator load.
During loading the RH outlet steam temperature has to be kept as close as possible to
SH outlet steam temperature Burner tilt, SH spray, RH spray controls has to be adjusted
accordingly. The turbine-loading rate is decided by a selection circuit which compares the
external load gradient, TSE margin and time dependant gradient (set internally) and
frequency influence.
INTEGRATED START-UP PROCEDURE

COLD START-UP
(AUXILIARY STEAM AVAILABLE)
REF. DRG NO. 20 BPE 691
STEP
TIME
UNIT CONDITION
OPERATION
NOTES
..
Boiler pr. 0 kg/cm (g) Charge Aux. Steam

and Ambient
header 16 ata, 2600C,
temperature
from existing units.
Charge steam to fuel oil

pump house, atomising
steam and tracing steam
deaerator warming up.
Start tank heating of

LSHS oil.
Start one LSHS pump on

recirculation as soon as
the sufficient oil
temperature at inlet is
achieved.
Charge LSHS to boiler

front and keep it on long
recirculation, with
heaters control set on
Auto to maintain 1101290C.
All the steam tracing

lines and electrical
tracings in pump house
& boiler to be charged.
Fill water in drum upto

+200mm.
Ensure that the suction

and discharge valves of
all the CC pumps are
open and the pump
suction and discharge
lines are vented.
Start Bearing cooling

water system pumps for
Boiler, Turbine and TG
auxiliaries .
Check all circuits have

sufficient flow. Before
starting the pumps, the
emergency cooling water
tank level to be checked
and made normal.
Start instrument air

compressor and check
that all the lines to
Boiler and TG are
charged.
Check that all circuits

have sufficient air
pressure.
Start service air

compressor and fill the
air receiver tanks of
SRAPH & PRAPH are
filled.
Ensure that purge air to

HEA is open in all
corners.
Line up Air and flue gas

circuits for startup.
ESP ready in all

respects.
Furnace bottom ash

system and seal through
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.
Generator H2 gas
pressure is 4 kg/cm2
Check purity of H2 gas is

normal.
Generator stator water

system ready in all
respects.
Check purity of
generator stator water is
normal.
Check dampers and

gates register position.
H2 cooling water system

ready in all respects with
SLC on.
Check for level in

LP & HP chemical dozing Hydrazine, Ammonia
system is ready.
and phosphate
preparation tanks.
SADC panel readiness.
Check for air pressure in

all the corners and
elevations.
Power supply for all the

valves and dampers are
ON.
Ensure Aux. air dampers

and modulating.
Supply for all auxiliaries

of SG, Turbine and
Generator is ensured.
Readiness of HP bypass
panel in all respects.
Ensure the oil unit is

running and all the
bypass and spray valves
are closed.
Ensure drum level is
+200 mm, and the drum
air vents are closed.
Ensure drum level is
normal.
Start one of the CC

pumps.
Start the second CC

pump.
Start scanner air fan.
Ensure that all the inlet

Start both the secondary
and outlet air gas
air preheaters.
dampers are open.
Start both the primary

air preheaters.
Ensure that the gas

dampers are closed.
Start one set of ID and

FD fans.
Adjust 30% air flow, and

furnace draft minus 5 to
10 mm WCL.
After purge completion
Boiler trip valves will get
reset.
Charge steam coil

preheater concerned
with the running FD
fans.
Initiate Boiler Purge

(duration 5 minutes).
Also, after purge, adjust

the wind box dampers to
get 30-40 mm
WCL. Wind box dp.
Lub oil system

stopped.
Start one vapour

extraction fan, keep
other fan standby.
Check oil level in MOT.
Line up lub oil cooler

and thrust bearing filter
Start one AOP.
Put on SLCs for other

AOP and EOP.
--
Put lub oil temperature

controller on.
Start one JOP.
--
Put off SLCs JOP 1, 2 &

3. Stop running JOP.
Open gate valve

gearing.
Start one JOP and switch

on SLCs for JOPs.
Check out auto start of

AOP and EOP.
Put on SLCs for other
JOP and DC-JOP.
Check out auto start of
JOP and DC-JOP.
Switch on SLC gate
valve gearing.
-
M/c. comes on barring.
MOT level 50 mm oil

temp. 450C JOP header
pr. 140 kg/cm2 speed 80
100 rpm.
The sequential operation

narrated above on Lub
oil system stopped is
achieved by SGC
mode.
If the programme gets

interrupted, the step
and criteria to be
checked and to be
fulfilled for the
programme to proceed
further.
M/c on barring.
FRF system in stopped

Check FRF tank level.
condition.
Start centrifuge with

both heaters
Line up FRF cooler and

duplex filters in 32-bar
system start one CEP.
Check auto start of
standby CEP.
Establish control fluid

supply to various
services.
Start one VEF.
+200 mm.
FRF tank level O

(normal).
-
Start one recirculation

pump and include one
Filters earth and ultra
fine.
Switch on FRF heater

and keep SLC ON for
FRF temperature 550C.
temperature control, and
control fluid pumps.
Switch ON control fluid

SGC.
FRF system, SGC is

on.
The sequential operation

narrated above in FRF
system stopped
condition is achieved by
SGC-FRF system on
starting programme
mode.
01
oo
Boiler ready for light

up and Turbine on
Turning gear.
Start 4 burners in AB
elevation with LSHS.
SH & RH drains are

open.
MSVs closed and drains

before MSV open.
Regulate oil pressure to

8-10 kg/cm2.
Ensure atomising steam

pressure about 6
kg/cm2.
Insert furnace probe and
ensure that the
temperature is below
5350C.
If the programme gets

interrupted the step and
criteria to be checked
and fulfilled for the
further.
Check that SH & RH
vents are open.
After 30 minutes, take

additional burners, so as
to ensure a drum metal
temperature raise of
about 20C/min.
Check drum level and

give blow down.
Keep open the Eco.

recirculation valve when
there is no feeding to
drum.
Start motor driven feed

pump on recirculation.
Charge the feed line

upto feed control
station.
Charge heating steam to

deaerator from Aux.
PRDS.
Check deaerator level.
Start condensate pumps

and feed to deaerator as Check hotwell level.
and when required.
--
Start hotwell make up

pumps and feed hotwell
as and when required.
Aux. PRDS steam

15kg/cm2 (g) 2600C
CW system is charged.
CW boxes to ensure
ventilating 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
0.2kg/cm2(g).
Vacuum building can be

done through SGC
vacuum on starting
programme mode, gland
steam exhauster has to
be started manually.
Open all drains

connected to flash tanks
and flash boxes
connected to condenser.
Vacuum 09kg/cm2 (g).
Ensure gland steam

admission temperature
is always above 2000C.
--
Open HPBP warm up

valves.
Switch on SLC drains.
02
60'
Close SH & RH header

vents.

drains.
Open MSV by pass lines.
MS, HRH, & CRH lines

will get warmed up.
03
100
Switch on automatic
control interface of LP
bypass.
As soon as the fixed set

point reaches 12
kg/cm2, it seizes.
Boiler pressure 2kg

/cm2
Boiler pressure 5kg

/cm2.
Automatic control
interface gets switched
off when the hot reheat
steam pressure reaches
13kg/cm2 i.e. after
synchronisation.
Open Main steam

valves.
Open HP by pass.
Start third C.C. pump

when boiler pressure
reaches 9 kg/cm2.
Take additional guns in

CD & EF elevation.
Close HPBP warm up

valves.
Air heater soot blowing

to be carried out.
-
A ROLLING THROUGH HYDRAULIC GOVERNOR

Boiler pressure:15
kg/cm2
04
150
Temperature:1802000C
Open HPESVs & IPESVs

for warming up by
operating starting device
to approximately 42%.
Check and ensure that

speed set point is zero
and speeder gear is 0%
position.
Ensure TSE influence is

switched on and
available margins are
greater than = 300 K.
HRH Pressure:812Kg/cm2
-
M. S. Pr. 50 kg/cm2
M.S. temp. 3500C
05
-300
H. R. H. Pr. 12 kg/cm2
Raise the speed set

point of EHC to 3200
rpm
If the oil system of EHC

is isolated at speed Gov.
rack, speed set point
need not be raised.
Gradually raise the

starting device to bring
the speed to 360 rpm
Starting device position

approximately 56%.
Hold the speed at 360

rpm for about 35 to 40
mts.
Ensure closure of gate

valve gearing at 240
rpm. Monitor bearing
vibrations, shaft
vibrations, TSE margins,
bearing temperature &
Turbosupervisory
readings at 360 rpm.
HRH temp. : 3500C

-
Turbine ready for

Rolling.
06
-360
Raise the speed upto

M. S. Pr. 50
2400 rpm through
2
0
kg/cm /350 C. Turbine
starting device at the
running at 360 rpm.
rate of 600 rpm.
Ensure tripping of JOP at

540 rpm.
Raise further speed upto

Starting device will be at
3000 rpm through
90%.
speeder gear.
Monitoring bearing
temperature and
vibrations, shaft
vibrations, TSE margins
and Turbovisory
readings, Seal oil,
Primary water and gas
temperatures &
Generator winding
temperature.
Ensure trippinf of AOP at

2950 rpm.
Speeder gear position

will be approximately at
50 to 60%.
MS Pr. 50 kg/cm2.
Temperature:
Put AVR on Auto.
3500C Turbine running
at 3000 rpm.
07
370
Close field breaker.
Set manually the

generator voltage to grid
voltage.
Synchronise the
generator with grid.
-
Pick up 50 MW load by
operating speeder gear.
Ensure closure of HPBP

Increase HPBP set point. steam valves & spray
valves.
Drain pot drains of MS,

CRH & HRH and
Close other drains, M.S.
extraction steam lines
HRH, keeping SLC drains
will operate as per the
on.
actuation of level
switches.
B - ROLLING THROUGH EHC.
04
150'
MS Pr.: 15 kg/cm2.
Temperature:1802000C HRH
Pressure:8to12kg/cm2.

Open HPESVs & IPESVs TSE influences is
for warming up by
switched on and
operating starting device available margins are
to approximately 42%.
0
greater than 30 K.
-

and speeder gear is 0%
position.
MS Pressure: 50
kg/cm2
MS
Temperature:3500C
05
300'
HRH Pressure:
12kg/cm2
HRH Temperature:
3500C.
Check and ensure

opening of valves in
Raise the starting device
HP/IP secondary fluid
to about 70%.
lines to EHC at speed
control rack.
Turbine Ready for

rolling
Raise the speed set

point to 360 rpm and
watch the actual speed.
Raise the speeder gear

to 100%

rpm for about 35 to 40
mts.
MS Pressure:50
kg/cm2
06
360'
MS
Temperature:3500C
Turbine speed: 360

rpm.
Raise the speed set

point to 3000 rpm.
If tracking device is
switched ON, starting
device position will
automatically track the
EHC position

rpm.
Monitoring bearing
vibrations, bearing
temperatures, shaft
and Turbovisory
readings.
Ensure tripping of
jacking oil pump at 540
rpm.
The rate of acceleration
will be 600 to 850 rpm.
Monitor bearing
vibration and
temperatures, shaft
vibrations, Turbovisory
readings and TSE
margins
Monitor and control,

SEAL oil temperatures,
Primary water temp.
Hydrogen gas
temperature and
winding temperature.
Ensure tripping of AOP

at 2950 rpm.
MS Pressure: 50
kg/cm2
07
370'
MS Temperature:
3500C
Put AVR on auto, Close

Field Breaker.
Set manually generator

voltage to grid voltage.
Turbine speed: 3000

rpm.
-
Speed set point will raise

automatically by 8 rpm
and load will be picked
upto 20MW.
Synchronise the
Raise the speed set

point and pick up the
load to 50 MW.

Increase HPBP set point. steam valves & spray
valves.

CRH, HRH and
actuation of level
switches.
Close other drains of

MS, CRH, HRH, keeping
SLC drains 'ON'.
C - ROLLING THROUGH SGC - TURBINE.

MS Pressure: 15
kg/cm2
04
150'
MS Temp.:180-200 C
HRH Pressure: 12
Switch on the start up

programme of SGC
Turbine.

switched on.
kg/cm2
If the programme
interrupts the particular
step and criteria to be
checked and corrected
for the programme to
proceed further.
All operations as
explained under EHC
rolling will be carried out
by SHC Turbine
programme sequentially.
MS Pressure: 50
kg/cm2
MS Temperature:
3500C
05
300'
HRH Pressure: 12
kg/cm2
Turbine speed will be

raised to 360 rpm
through SGC
Programme.

rpm.
HRH Temp.: 3500C.

Turbine Ready for
rolling
Monitor bearing
vibration, bearing
temperature, shaft
vibration, TSE margins
and Turbovisory
readings.
To achieve the
programme as per the
starting curve, the main
steam temperature
should be maintained
steadily till loading upto
50 MW.
MS Pressure: 50
kg/cm2
06
360'
MS Temperature:
3500C

raised upto 3000rpm
through SGCprogramme.
Ensure tripping of JOP at

540 rpm.
Turbine running at 360

rpm.
-
MS Pressure: 50
kg/cm2
07
370'
MS Temperature:
3500C
Turbine
speed:3000rpm.

at 2950 rpm.
Monitor bearing temp

and vibrations, shaft
and turbovisory readings
seal oil, primary water,
Hydrogen gas and
Generator winding
temperatures.
SGC programme will

switch ON field breaker, Ensure SGC start up
put AVR on auto,
programme is
synchronise and pick up completed.
load upto 20 MW.
Raise the speed set

load upto 50 MW.

Increase HPBP set point. steam valves and spray
valves.

CRH, HRH extraction
M.S. CRH and HRH,
steam lines will operate
keeping SLC drains ON. as per the actuation of
level switches.
Load : 55 MW
08
390'
M.S. :
54kg/cm2/3500C
HRH : 12
kg/cm2/3400C
Before starting P.A. fan,

Start seal air fan and PA
ensure that air and gas
fan and take first mill in
dampers of Primary Air
service.
Preheaters are open.
Charge ESP fields
Ensure Ash handling

system is ready.
Start the second set of

ID & FD fans.
Make ready SH & RH

spray systems.
Cut in L.P. heaters 2 &

3.
Ensure switching on of
load controller above
60MW.
Cut out heating steam

from Aux. P.R.D.S. to
Deaerator.
Peg Deaerator from CRH

steam gradually upto 2
kg/cm2.
Cut in auto controllers.
Load : 55 MW
M.S. :
54kg/cm2/3500C
HRH : 12
kg/cm2/3400C
Charge Aux. PRDS

station from CRH. Cut in
spray and maintain a
temperature of 2500C.
Ensure energizing of
solenoid in trimming
device at and above 100
MW load.
Raise the pressure set

Peg Deaerator gradually point of Deaerator
to 4 kg/cm2.
pressure controller
gradually.
Cut in IInd mill and cut

in auto controllers.
Start withdrawing oil

support gradually.
Control main steam and

reheat steam
temperatures by using
spray if required.
Increase the wind box to

furnace differential
pressure to 100mm
W.C. by adjusting SADC.
Ensure fire ball scanner

healthiness
Load : 160 MW
M.S. :
90kg/cm2/3800C
10
440'
HRH : 20
kg/cm2/3800C
Steam flow : 580t/hr.
Charge H.P. heaters 5A,

5B, 6A and 6B.
Put controllers on auto.
Start first TDBFP &

second CEP.
Charge Deareator
Ensure Deareator
pegging steam flow CRH
Pressure controller
to Extraction around 200
remains as auto.
MW load.
Load : 250 MW
M.S. :
120kg/cm2/4200C
11
480'
HRH : 26
kg/cm2/3400C
Cut in IIIrd mill and cut


-
Start second P.A. Fan.
Before starting P.A. fan

dampers of PAPHs are
open.
Load : 320 MW
M.S. :
125kg/cm2/3500C
12
510'
HRH : 28-30
kg/cm2/3400C
Cut in IVth mill and cut


-
Cut of oil support

completely.
Ensure healthiness of
fire ball scanners.
Load : 405 MW
M.S. :
145kg/cm2/4600C
13
550'
HRH : 33
kg/cm2/4600C
Cut in Vth mill and cut in

auto controllers.
Cut in second TD BFP

and switch off motor
driven BFP.
If full load is not reached

cut in VIth mill along
with its controllers.
Increase the set point of
SH & RH spray
controllers such that
rated parametes are
Steam flow : 1310

t/hr.
-
Load : 500 MW
14
590'
M.S. : 170
kg/cm2/4750C
HRH : 40.5
kg/cm2/4750C
achieved gradually.
Load : 405 MW
M.S. :
145kg/cm2/4600C
15
670'
HRH : 33
kg/cm2/4600C
Steam flow : 1310

t/hr.
WARM AND HOT START UPS

(With Aux. Steam Available).
A warm start up is, by definition, one which the maximum of HP casing/HP shaft
temperature is between 1500C and 3500C. This normally means that the unit is shut down
from the maximum load for one to four days. Depending upon the absolute temperature of
HP casing and HP shaft, steam parameters are derived. A hot start up is by definition one
which the maximum of HP casing/shaft temperature is more than 3500C. In this case to get
the rolling parameters two mills are taken into service keeping HP, LP by pass in
operation. (Again the flow rate is restricted by the Y pieces constraints i.e., 400C). In
both the cases, curves are given to derive the rolling parameters. In case when machine is
rolled through EAST, curve generators, calculate and give permissive for rolling.
INTEGRATED START-UP PROCEDURE

WARM START UP (AFTER 48 HOURS SHUT DOWN).
TIME IN
MINUTES
UNIT CONDITION
OPERATION
NOTES.
One CC pump in
operation and scanner
fan in operation.
Motor operated BFP is

run as and when
required to maintain the
drum level.
Both SAPHs and PAPHs

in operation.
STEP
Turbine on bearing
gear with AOP, JOP
and seal oil pumps in
operation.
Control fluid system

ready in all respects.
One circulating pump
in operation with one
earth filter and ultra
fine filter in circuit.
Generator gas system,

seal oil system and
primary water system
in operation.
Bearing cooling water

system in operation.
HT and LT auxiliaries
power supply available.
HP bypass system
ESP ready in all

respects.
EAST panels ready in

all respects.
Furnace bottom ash

system and seal trough
lined up.
Vacuum pumps lined

up and ready for
operation.
Gland steam and leak

steam controllers are
lined up and ready for
operation.
panel and exciter
panels ready in all
respects.
Boiler drum pressure =

0 kg/cm2.
SH
temperature between
1300C and 1500C.
1. Charge auxiliary
steam header from
existing units. Pr. 16ata
temp. 2600C.
2. Charge steam to fuel

oil pump house,
atomising steam and
tracing steam.
3. Start tank heating of

LSHS oil.
4. Start one LSHS pump

on recirculation as soon
as sufficient oil temp. at
inlet is achieved.
Start instrument oil

compressor and service
air compressors and
check that all lines to
boiler and TG are
charged.
Charge LSHS pump to

boiler front and keep it
on long recirculation
with heaters control set
on auto to maintain
1200C.
Start circulating water

pump for condenser and
deaerate the condenser
water boxes.
Ensure running of
motor driven BFP
continuously for
maintaining drum
level.
Start second CC Pump.
Start one set of ID and

FD fans.
Initiate boiler purge.
Start one CEP and keep

the hot well make up in
service.
Start one of the control

fluid pumps and keep
the second as auto
standby.
Keep the control fluid

temperature control on
auto.
Line up main steam,

CRH and HRH steam
lines for charging by
opening respective line
drains.
Line up FSSS panels in

all respects
01
oo
SH & RH drains are

open.
MSVs closed and

drains before MSV
open.
Ensure atomising
steam pressure of
about 6 kg/cm2
Ensure motor operated

BFP is in service.
Start Gland steam

Exhauster.
Start one by one

vacuum pumps.
Admit gland steam

Ensure gland steam
when vacuum reaches admission temperature
0.2 kg/cm2.

done through SGC
vacuum on starting
programme mode.
Gland steam exhauster
has to be started
manually.
Charge heating steam

line to Deaerator from
Aux. PRDS.

up and turbine on
turning gear.
Check that SH & RH

vents are open.
Open all drains

connected to flash tanks Ensure condenser
and flash boxes
vacuum of 0.8
connected to
kg/cm2.
condenser.
Switch on SLC drains.

vents and drains.
Ensure boiler pressure

is 2kg/cm2.
Open HPBP warming up

valves.
Open MSV bypass lines.
Switch Automatic
bypass.
As soon as the fixed

set point reaches
12kg/cm2, it seizes.
Automatic control
off when the hot
reheat steam pressure
reaches 13kg/cm2(i.e.)
after synchronisation.
Open Main steam stop

valves.
Open HP bypass and

Ensure Boiler pressure
close the HPBP warm up
is 5kg/cm2.
valves.
Start third CC pump.
Ensure MS, CRH & HRH

lines get warmed up.

is 9kg/cm2.
Put HP bypass controller

on auto and vary the
set point according to
is 10kg/cm2
the gradient of pipeline
temperatures.
Put HP bypass spray

control on auto.
Take additional guns

according to the
requirement.

to be carried out.
A ROLLING THROUGH HYDRAULIC GOVERNOR.

MS: 50 kg/cm2/3650C
02
180'
Open HPESV and IPESV

HRH: 12 kg/cm2/3250C for warming up by
operating starting
device to approx. 42%
By pass steam flow:
170t/hr.
MS: 60 kg/cm2/4000C
Raise the speed set
HRH: 12 kg/cm2/3500C
rpm.
By pass steam flow:
200t/hr.

and speeder gear is
0%.
switched on and
0
greater than 30 K.
If the oil system of
EHC is isolated at
speed Gov. rack, speed
set point need not be
raised.
03
210'
Gradually rise the

the speed to 360 rpm.
Starting device
position approximately
56%.

rpm for about 5
minutes.

rpm.
04
215'
Raise the speed upto

Turbine running at 360 2400 rpm through
rpm.
starting device at the
rate of 600 rpm.
-
Monitor bearing
vibrations, shaft
vibrations, TDE
margins, bearing temp.
& Turbovisory readings
at 360rpm.
Ensure tripping of JOP
at 540 rpm.
Raise further speed

Starting device will be
upto 3000 rpm through
at 90%.
speeder gear.

& vibrations, shaft
vibrations, TSE
margins and
Turbovisory readings.
Seal oil, Primary water
and gas temperatures
& Generator winding
temperature.

at 2950 rpm.

will be approx. at 50 to
60 %.
05
220'
Turbine running at
3000 rpm
Put AVR on auto.
Set manually the

generator voltage to
grid voltage.
Synchronise the
Increase HPBP set

point.

CRH, and HRH and
HRH, keeping SLC
drains on.
actuation of level
switches.

steam valves & spray
valves.
Further load raising will

be done by operating
the speeder gear
according to the start
up curve.
B ROLLING THROUGH EHC

MS: 50 kg/cm2/3650C
02
180'
Open HPESVs and

HRH: 12 kg/cm2/3250C IPESVs for warming up
by operating starting
device to approx. 42%.
By pass steam flow:
170t/hr.
-

TSE influence is
switched on and
0
greater than 30 K.
and speeder gear is
0%.
MS: 60 kg/cm2/4000C
03
210'
By pass steam flow:

200t/hr.
Raise the starting

device to about 70%.
Check and ensure

control rack.
Turbine ready for

rolling.
Raise the speed set
switched on starting
watch the actual speed. automatically track the
EHC position

to 100%.

rpm.

rpm for about 5
minutes.
Monitor bearing
vibrations bearing
temperatures, shaft
vibrations, TSE
margins & turbovisory
readings.
Raise the speed set

point to 3000 rpm.
Ensure tripping of
Jacking oil pump at
340 rpm.
04
215'
Turbine running at
360rpm.
Monitor bearing
vibrations and temps,
shaft vibration,
turbovisory readings
and TSE margins.
05
225'
Turbine speed: 3000

rpm.

at 2950 rpm.
Put AVR on auto close

Field breaker.
Set manually generator

Speed set point will be

raise automatically by
about 8 rpm & load will
be picked upto 20 MW.
Synchronise the
Raise the speed set

load to 50 MW.
Increase HPBP set

points.

steam valves and
spray valves.

MS, CRH, and HRH
keeping SLC drains
ON.

CRH, HRH and
actuation of level
switches.
C ROLLING THROUGH SGC TURBINE.

MS: 50 kg/cm2/3650C
02
180'
By pass steam flow:
170t/hr.

programme of SGC
Turbine.

switched on.
If the programme
interrupts the
particular step and
and corrected for the
further.
All operations as
explained under EHC
rolling will be carried
out by SGC Turbine
programme
sequentially.
MS: 50 kg/cm2/3650C
03
210'
By pass steam flow:

170t/hr.
Turbine ready for
rolling.

raised to 360 rpm
through SGCProgramme.

rpm.
Monitor bearing
vibration, bearing
temp, shaft vibration,
TSE margins and
Turbovisory readings.
To achieve the
starting curve, the
main steam
temperature should be
maintained steadily till
loading upto 50 MW.
MS: 60 kg/cm2/4000C
04
215'

Turbine running at 360 raised upto 3000 rpm
rpm.
through SGC
Programme.
MS: 60 kg/cm2/4000C
05
225'
Turbine speed: 3000

rpm.

at 540 rpm. Ensure
tripping of A.O.P. at
2950 rpm.
& vibrations, shaft
vibrations, TSE margin
and turbovisory
readings, seal oil,
primary water,
Hydrogen gas and
Generator winding
temperatures.
SGC programme will

switch ON field breaker, Ensure SGC Start up
put AVR on auto,
programme is
synchronise and pick up completed.
load upto 20 MW.
Raise the speed set
point and pick up load
upto 50 MW.

Increase HPBP set point steam valves and
spray valves.

M.S., CRH and HRH,
keeping SLC drains
ON.
Drain pot drains of

M.S., CRH, HRH and
Extraction steam lines
actuator of level
switches.
Cut in L.P. heaters 2

and 3.
load controller at 60
MW.
Load: 60 MW
06
230'
MS: 60 kg/cm2/4100C

from Aux. PRDS to
Deaerator.
Peg Deaerator from

CRH steam gradually
upto 2 kg/cm2.
Cut in all auto

controllers.
Start seal air fan and

P.A. fan
Cut in further oil guns

for raising parameters.
Before starting P.A.

fan, ensure that air
and gas dampers of
Primary Air Preheaters
are open.
-
Load: 110 MW
MS: 80 kg/cm2/4200C
07
Cut in 1st coal mill and

cut in Auto controllers.
Make ready SH & RH

spray system.
Charge ESP Fields.
Ensure Ash handling

system is ready.
Charge Aux. PRDS

station from CRH. Cut
in spray and maintain a
245'
Main steam flow:
470t/hr.
Trimming device is in
OFF.

Peg Deaerator gradually point of Deaerator
upto 4 kg/cm2.
pressure controller
gradually
Cut in H.P. heaters and

put the level controls on
auto.
Start first TD BFP and

second CEP around a
load of 170 MW.
Increase the windbox to

furnace diff. pressure to
100mm. W.C. by
adjusting SADC.
Load: 200 MW
MS: 100 kg/cm2/4350C
08
270'
Cut in IInd mill and cut

HRH: 19 kg/cm2/4000C in auto controllers.
Main steam flow:

750t/hr.
-

support gradually.

reheat steam
temperature by using
spray if required.
Change Deaerator
pegging steam from
CRH to Extraction
steam.

Start second P.A. fan.
fire ball scanners.
-
Ensure Deaerator
pressure controller
remains on auto.
Before starting P.A. fan
dampers of PAPH are
open.
Load: 320 MW
MS: 125 kg/cm2/4500C
09
300'

HRH: 30 kg/cm2/4300C in auto controllers.
Main steam flow:
1080t/hr.
Cut off oil support

completely.
fire ball scanners.
Cut in Vth coal mill and

cut in auto controllers.
Start second TDBFP and

switch off motor driven
BFP.
Cut in VIth coal mill and

Check all parameters at

full load and ensure
them within limits.
Increase the set point

of SH & RH spray
rated parameters are
achieved.
Load: 500 MW
MS: 170 kg/cm2/4800C
10
340'
HRH: 40.5
kg/cm2/4800C
Main steam flow:
1620t/hr.
Load: 500 MW
MS: 170 kg/cm2/5350C
11
420'
HRH: 40.5
kg/cm2/5350C
Main steam flow:

1570t/hr.
INTEGRATED START UP PROCEDURE

HOT START UP (AFTER 8 HOURS SHUT DOWN)
STEP
TIME IN
MINUTES.
UNIT CONDITION
OPERATION
NOTES.
Two CC pumps in
operation and scanner
fan in operation.
Motor operated BFP is

run as and when
required to maintain the
drum level. If necessary
BFP should be kept
running continuously.
Both SAPHs and PAPHs

in operation.
Turbine on barring
gear with AOP, JOP
and seal oil pumps in
operation.
Control fluid pump in

operation. One
circulating pump in
operation with one
earth filter and ultra
fine filter in circuit.
Generator gas system,

seal oil system and
primary water system
in operation.
Bearing cooling water

system in operation.
Condenser circulating
water system in
operation.
Service air and

instrument air
compressors in
operation.
One condensate pump

in operation and hot
well make up in
service.
Aux. steam header

charged from existing
units (16ata 2600C).
LSHS pump in
operation on long
recirculation upto
boiler front with
heaters control set on
HP bypass system
LP & HP and chemical

dosing system ready.
ESP panels ready in all

respects.
EAST panels ready in

all respects.
Furnace bottom ash

system and seal trough
lined up.
Vacuum pumps lined

up and ready for
operation.
Gland steam and leak

steam controllers are
lined up and ready for
operation.
panel and exciter
panels ready in all
respects.
FSSS panel ready in all

respects.
Boiler drum Pr. 75

kg/cm2 SH. Temp.
between 4150C and
4300C.
Start one gland steam

exhauster.
Start one by one

vacuum pumps.
Admit gland steam

Ensure gland steam
when vacuum reaches admission temperature
0.2 kg/cm2.

done through SGC
vacuum on starting
programme mode.
Gland steam exhauster
has to be started
manually.
Line up main steam,

CRH and HRH steam
lines for charging by
opening respective line
drains.
Ensure MSV is closed.
Open all drains

connected to flash tanks
Ensure condenser
and flash boxes
vacuum of 0.8 kg/cm2.
connected to
condenser.
Ensure condenser
vacuum of 0.8 kg/cm2.
Open HPBP warming up

valves.
Switch Automatic
bypass.
Start third CC pump.
As soon as the fixed

set point reaches 12
kg/cm2, it seizes.
Automatic control
off when the hot
reheat steam pressure
reaches 13
kg/cm2(i.e.) after
synchronisation.
Ensure differential
temp. is within
permissible limits.
Ensure running of
motor driven BFP
continuously for
maintaining drum
level.
Start both ID & FD fans
Initiate boiler purge.
Charge heating steam

line to Deaerator from
Aux. PRDS.
01
oo

up and turbine on
turning gear.
Ensure atomising
steam pressure of
about 6kg/cm2.
Drum Pr. 75 kg/cm2

SH. Temp. 4150C and
4300C.
Ensure motor operated

BFP is in service.
Open drains before

MSV.
Open MSV by pass

lines.
Open Main steam stop

valves.
Open HP bypass and

close the HPBP warm up
valves.
Put HP bypass
controllers on auto and
vary the set point
according to the
gradient of pipeline
Ensure MS, CRH, HRH

lines got warmed up.
temperatures.
Put HP bypass spray

control on auto.
Take additional guns

according to the
requirement.

to be carried out.
Before starting P.A.

Fans ensure that air
Start both P.A. fans and
and gas dampers of
seal air fans.
Primary air preheaters
are open.
Line up milling system

for starting.
A ROLLING THROUGH HYDRAULIC GOVERNOR

MS: 85 kg/cm2/4850C
02
40'
HRH: 12 kg/cm2/4400C Cut in first coal mill &

Bypass steam flow:
280t/hr.
Make ready SH and RH

spray system.
Ensure Ash handling

system is ready.
Charge ESP fields.

furnace diff. Pressure to
100mm W.C. by
adjusting S.A.D.C.
Cut in second mill and

Peg the deaerator from

CRH gradually upto 2
kg/cm2.
Open HPESVs and

IPESVs for warming up
device to approximately
42%.

and speeder gear is at
0%.

switched on and
0
greater than 30 K.
MS Pressure: 85
kg/cm2
MS Temperature:
5000C
HRH Pressure: 12
kg/cm2
03
50'
HRH Temperature:
4500C.
Raise the speed set

rpm.
If the oil of EHC is

isolated at speed Gov.
rack, speed set point
need not be raised.
Gradually raise the

the speed to 360 rpm
Starting device
position approximately
56%.
Bypass steam flow:

360t/hr.
Turbine Ready for
rolling
-
04
Turbine running at
360rpm.
52'

rpm.
Monitoring bearing
vibrations, shaft
vibrations, TSE
margins, bearing temp
& Turbovisory readings
at 360 rpm.
Raise speed upto 2400

rpm through starting
device at the rate of
600 rpm.

at 540 rpm.
Raise further speed

upto 300 rpm through
speeder gear.
Starting device will be

at 90%.

and vibrations, shaft
vibrations, TSE
margins and
turbovisory readings.
Seal oil Primary water
and gas temperatures
and Generator winding
temperature.

at 2950 rpm.
05
56'
Turbine running at
3000rpm

will be approximately
at 50 to 60%.
Put AVR on auto.
Set manually the

generator voltage to
grid voltage.
Synchronise the
Generator with grid.
Increase HPBP set

point.

CRH, and HRH and
CRH, HRH, keeping SLC
drains on.
actuation of level
switches.
Further load raising will

be done by operating
the speeder gear
according to the start
up curve.

valves.
B ROLLING THROUGH EHC

MS Pressure: 85
kg/cm2
MS Temperature:
4850C
02
40'
HRH Pressure: 12
kg/cm2
Cut in first coal mill &

Make ready SH & RH

spray systems.
Charge ESP fields.
Ensure Ash handling

system is ready.
HRH Temperature:
4400C.
Bypass steam flow:
280t/hr.
-

100mm W.C. by
adjusting S.A.D.C.

Peg the deareator from

kg/cm2.
Open HPESVs and

IPESVs for warming up
device to approximately
42%.

and speeder gear is at
0%.

switched on and
0
greater than 30 K.
MS Pressure: 85
kg/cm2
MS Temperature:
5000C
03
50'
HRH Pressure: 12
kg/cm2
Raise the starting

device to about 70%.
HRH Temperature:
4500C.
Check and ensure

control rack.
Turbine Ready for

rolling. Bypass steam
flow: 360t/hr.
Raise the speed set
switched on starting
watch the actual speed. automatically track the
EHC position.

to 100%.

rpm.

rpm for about 5
minutes.
Monitor bearing
vibrations, bearing
temperatures, shaft
vibrations, TSE
margins and
turbovisory readings.
04
52'
Turbine reading at 360 Raise the speed set

rpm.
point to 300 rpm.
-
Ensure tripping of
Jacking oil pump at
540 rpm.
The rate of
acceleration will be
600 to 800 rpm2.
Monitor bearing
vibrations and
temperatures, shaft
vibration, turbovisory
readings and TSE
margins.
Monitor and control,

seal oil temperatures,
primary water
temperature. Hydrogen
gas temperature and
winding temperature.

at 2950 rpm.
05
56'
Turbine speed: 3000

rpm.
-
Put AVR on auto Close

field breaker.
Set Manually generator

Synchronise the
Speed set point will be

raised automatically by
about 8 rpm and load
will be picked upto 20
MW.
Synchronise the
Increase HPBP set

point.

steam valves and
spray valves.

MS. CRH and HRH,
keeping SLC drains
ON.

CRH, HRH and
actuation of level
switches.
C ROLLING THROUGH SGC TURBINE.

MS: 85 kg/cm2/4850C
02
40'
HRH: 12kg/cm2.
Bypass steam flow:
280t/hr.
Cut in first coal mill &

Make ready SH & RH

spray systems.
Ensure Ash handling

system is ready.
Charge ESP fields.

100mm W.C. by
adjusting S.A.D.C.

Peg the deaerator from

kg/cm2.

programme of SGCTurbine.

switched ON.
If the programme
interrupts, the
particular step and
and corrected for the
further.
All operations as
explained under EHC
rolling will be carried
out by SGC-Turbine
programme
sequentially.
Turbine ready for

rolling.
raised to 360 rpm
through SGCHRH: 12kg/cm2/4500C
programme.
MS: 85 kg/cm2/5000C
03
50'

rpm.
Bypass steam flow:

360t/hr.
Monitor bearing
vibration, bearing
temperature, shaft
vibration, TSE margins
and Turbovisory
readings.
To achieve the
start up curve, the
main steam
temperature should be
maintained steadily till
loading of 50 MW.
04
52'

Turbine reading at 360 raised upto 3000 rpm
rpm.
through SGCprogramme.
-

at 540 rpm.

at 2950 rpm.
Monitor bearing
temperature and
vibrations, shaft
vibrations, TSE
margins, Turbovisory
readings, seal oil,
primary water,
Hydrogen gas and
Generator winding
temperatures.
Turbine speed: 3000

rpm.
SGC Programme will
switch ON field breaker, Ensure SGC-start up
put AVR on auto
programme is
HRH: 12kg/cm2/4500C synchronise and pick up completed.
load upto 20 MW.
Bypass steam flow:
360t/hr.
MS: 85 kg/cm2/5000C
05
56'
Raise the speed set

point and pick up load
upto 50 MW.
Increase HPBP set

point.

valves.

M.S, CRH and HRH,
keeping SLC drains
ON.

CRH, HRH and
Extraction steam lines
actuation of level
switches.
Cut in L.P. heaters 2

and 3.
load controller at 60
MW.
LOAD: 60 MW.
06
60'
MS: 85 kg/cm2/5000C
HRH: 16kg/cm2/4700C

from Aux. PRDS to
Deaerator.
Raise the generator

pressure from
2kg/cm2 to 4kg/cm2.
Cut in auto controller.

support gradually.

point of Deaerator
pressure controller.
fire ball scanners.
LOAD: 150 MW.

MS: 100 kg/cm2/5000C
HRH: 20kg/cm2/4800C
07
65'
Main steam flow:
1620t/hr.
Charge Aux. PRDS

station from CRH. Cut
in spray and maintain a
Trimming device is in
OFF.
-
Cut in H.P. heaters and

put the level controls on
auto.
Start first TD BFP and

second CEP around a
load of 170 MW.

reheat steam
temperature by using
spray if required.
Change deaerator
pegging steam from
CRH to Extraction
steam.


HRH: 20kg/cm2/4950C in auto controllers.
Ensure Deaeator
pressure controller
remains on auto.
LOAD: 230 MW.

MS: 120 kg/cm2/5000C
08
70'
Main steam flow:

820t/hr.
-
Cut off oil support

completely.
fire ball scanners.
Cut in Vth coal mill and

Start second TD BFP

and switch off motor
driven BFP.
Cut in VIth coal mill and

Check all parameters at

full load and ensure
them within limits.
Increase the set point

of SH & RH spray
rated parameters are
achieved.
LOAD: 500 MW.

MS: 170 kg/cm2/5000C
09
86'
HRH:
40.5kg/cm2/5000C
Main steam flow:
1620t/hr.
LOAD: 500 MW.

MS: 170 kg/cm2/5000C
10
135'
HRH: 40.5
kg/cm2/4800C
Main steam flow: 1570

t/hr.
********************

500 MW Unit Startup Procedure

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500 MW Unit Startup Procedure

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CONTENTS

IN T E GRA T E D ST AR T U P PR O C EDU R E C O LD S TAR T U P

IN T E GRA T E D ST AR T U P PR O C EDU R E WAR M S TAR T UP

STA RT U P B Y CU RV ES F O R ABS O LU T E CO L D ST AR T W IT H HP /L P B YP ASS

T EC H N ICA L DA TA RE AC T IV E CA PAC IT Y CU RV E F OR TUR B O G E N ERA T ORS .

INTEGRATED START-UP PROCEDURE

Boiler pr. 0 kg/cm (g) Charge Aux. Steam

Charge steam to fuel oil

Start tank heating of

Start one LSHS pump on

Charge LSHS to boiler

All the steam tracing

Fill water in drum upto

Ensure that the suction

Start Bearing cooling

Check all circuits have

Start instrument air

Check that all circuits

Start service air

Ensure that purge air to

Line up Air and flue gas

ESP ready in all

Furnace bottom ash

FSSS panel ready in all

EAST panel ready in all

Excitation panel ready in

Check purity of H2 gas is

Generator stator water

Check dampers and

H2 cooling water system

Check for level in

SADC panel readiness.

Check for air pressure in

Power supply for all the

Ensure Aux. air dampers

Supply for all auxiliaries

Ensure the oil unit is

Start one of the CC

Start the second CC

Start scanner air fan.

Ensure that all the inlet

Start both the primary

Ensure that the gas

Start one set of ID and

Adjust 30% air flow, and

Charge steam coil

Initiate Boiler Purge

Also, after purge, adjust

Lub oil system

Start one vapour

Check oil level in MOT.

Line up lub oil cooler

Put on SLCs for other

Put lub oil temperature

Start one JOP.

Put off SLCs JOP 1, 2 &

Open gate valve

Start one JOP and switch

Check out auto start of

M/c. comes on barring.

MOT level 50 mm oil

The sequential operation

If the programme gets