PROCEDURE FOR COLD STARTUP

(TYPICAL FOR 500MW)

AJAY KUMAR

ID FD DMCW LOP CT FOP CWP ACWP RH SH

INDUCED DRAFT FORCED DRAFT DE-MINERALIZED COOLING WATER LUBE OIL PUMP CONDENSATE TRANSFER FUEL OIL PUMP COOLING WATER PUMP AUXILIARY COOLING WATER PUMP RE - HEATER SUPER HEATER

MMWC BFP BCW VFD IGV RAPH CC SADC DP NWL LOFCV

MILLIMETER OF WATER COLUMN BOILER FEED PUMP BOILER CIRCULATING WATER VARIABLE FREQUENCY DRIVE INLET GUIDE VANES ROTARY AIR PRE-HEATER CONTROLLED CIRCULATION SECONDARY AIR DAMPER CONTROL DIFFERENTIAL PRESSURE NORMAL WATER LEVEL LIGHT OIL FUEL CONTROL VALVE

CHARGE 11 KV BUS, REQUIRED FOR ID FAN CHARGE 3.3/6.6 KV BUS, REQUIRED FOR DMCW, INSTR./PLANT AIR COMPRESSORs, & FD FAN CHARGE 415V BUS, REQUIRED FOR LOPs , CTs & FOPs

START CWPs (BOTH 1 & 2) START ACWPs (BOTH A & B, KEEP ACWP-C AS STANDBY) LINE UP DM MAKEUP, DMCW & CT PUMPs START CW BOOSTER PUMPs (BOTH A & B)

START INSTRUMENT AIR COMPRESSOR

START PLANT /SERVICE AIR COMPRESSOR

OPEN BOILER DRUM VENTS OPEN DIVISIONAL PANEL SUPER HEATER AIR VENTS OPEN FINAL SUPER HEATER OUTLET HEADER AIR VENTS OPEN STARTUP VENTS OPEN ROOF SUPER HEATER AIR VENTS OPEN SUPER HEATER HEADER DRAIN

 CLOSE ECO / WATER WALL DRAINS OPEN ECO RECIRCULATION VALVE OPEN RH VENTS

START BOILER FILL PUMPs FILL WATER IN BOILER DRUM UPTO NWL (-50MM). FILL DEAERATOR WITH WATER UPTO 1000MMWC START ONE OF THE BFPs START BCW PUMPs (CC PUMPs)

6. PREPARE AIR & FLUE GAS PATH

ENSURE ALL MANHOLES IN AIR & FLUE GAS PATH ARE CLOSED OPEN ALL GATES & KEEP THE ALL DAMPERS IN MAXIMUM POSITION CLOSE I/L & O/L GATES OF ID FANS CLOSE O/L GATE OF FD FANS

START ID FAN START FD FAN REGULATE O/L DAMPER OF FD FAN & VFD / IGV OF ID FAN TO ACHIEVE A FURNACE PRESSURE CLOSE TO -10MMWC START RAPH START SCANNER AIR FAN

ENSURE AVAILABILITY OF PURGE PERMISSIVES START PURGE CYCLE AFTER COMPLETION OF PURGING, SET SADC IN AUTO ENSURE WIND BOX DP IS MAINTAINED AT 40MMWC

START LDO PUMP

ENSURE OPENING OF MANUAL ISO. VALVES FOR ATM. STEAM & LIGHT OIL AT EACH CORNOR PURGE OIL GUNS WITH STEAM ENSURE OIL GUNS ARE ENGAGED PROPERLY & IN RETRACTED POSITION. ENSURE ATOMIZING AIR PRESSURE IS 7Kg/SQ CM ENSURE LDO PRESSURE IS ABOUT 9 Kg/SQ.CM

INITIALIZE LIGHT UP - OPEN LOFCV & IGNITE

CORNOR PAIR 1 & 3, & THEN CORNOR PAIR 2 &4

 CLOSE BOILER DRUM AIR VENTS ONCE DRUM PRESSURE REACHES 2 Kg/SQ. CM CLOSE SUPER HEATER HEADER DRAINS ONCE THE DRUM PRESSURE REACHES 6Kg/SQ CM, CLOSE ALL SH VENTS ENSURE STARTUP VENTS REMAIN OPEN & MAIN STOP VALVES (BOTH OF BOILER & TURBINE) REMAINS CLOSED

CHARGING
MAIN STEAM LINE CHARGING OBSERVE MS PRESSURE EXCEEDING 8 KG/CM2 CD- HEAVY OIL START-UP: SWITCH ON HFO PUMP-A IN HFO SYSTEM SWITCH ON PAIR 2&4 WHEN MAIN STEAM PRESSURE CROSSES 8.0 KG/SQ.CM CHARGE HP & LP BYPASS

KEEP ON OPENING HP BYPASS VALVES 1&2 TILL THE FOLLOWING ROLLING PARAMETERS ARE REACHED Drum Pressure >50 KG/CM2 MS flow > 200TPH MAIN STEAM Pressure >40 KG/CM2 MAIN STEAM TEMPERATURE >3500C RH STEAM TEMPERATURE >3200C

TURBINE START-UP SGC TURBINE STARTUP OPEN DRAIN BEFORE HPCV1&HPCV2 SET SPEED REF. TO 180 RPM AND SWITCH ON THE LOAD CONTROLLER SELECT TSC MODE TO NORMAL OBSERVE THE X2 CRITERIA FULFILLNESS

SELECT SGC TURBINE OBSERVE ESVS OPENING OBSERVE TURBINE SPEED CROSSING 300 RPM OBSERVE TURBINE SPEED CROSSING 2950RPM OBSERVE GENERATOR FIELD BREAKER IS ON

OBSERVE SYNCHRONISER SWITCHES ON & CLOSES THE GENERATOR BREAKER OBSERVE GENERATOR LOAD CROSSES 50 MW AND EHTC SWITCHES OVER TO LOAD CONTROL MODE AT IF THE LOAD DOESNOT CROSS 50 MW RAISE SPEED REF CLOSE HP BYPASS VALVES SET HP BYPASS PRESSURE SP TO 175 KG/CM2 SET HP BYPASS PRESSURE CONTROLLER TO AUTO OBSERVE THAT LP BYPASS VALVES CLOSED CLOSE START UP VENTS

UNIT SYNCHRONISED AND LOAD >50 MW MILLS IN SERVICE AND INCREASE THE LOAD