1

C-1

Ensure that all works permits are cancelled and all men/material are removed. All manholes and peepholes are enclosed. Ensure that A.C. plant is running normal. DAS room tempt is @ 23 0c and humidity is 70%. UPS is normal Normal UPS parameters Inverter voltage Amperes - 240 V AC - 35 to 40 A

a) b)

c) d) e) f) g) h) i) J) C-2

Data Acquisition system is available. All the panels i.e. DDC/FSSS/EAST/HP/LP/ bypass system, are charged. 6.6 KV/415V AC supply is normal. DG set is available 220 V DC/ 24 V DC supply is normal Fire fighting system is normal LCR I/II/III/IV supply is normal Intake water supply is normal and one day reservoir level is @ 6.0 M Ensure that GS sump level is normal (@ 290 to 290.3 MEL) Ensure that inlet gate from CW channel is open. Line up GS pump for OHGS tanks and ensure that GS system is ready start the pump. Its discharge valve will open on interlock (if not, open it manually) observe the normalized current (38AC) and discharge pressure 5.0 kgl/cm2. Check that GS pump recirculation valve (CW 45/44) are enclosed. Check that GS tank over flow back to channel is established (GS overflow is locate at 0 m level in turbine house). Ensure that GS tan level indication is reset check that adequate GS water pressure (i.e. 3.5 to 3.8 kg/cm 2) is available at all places. Observe motor winding temperature (<120 0 c) and motor bearing temp (<750 c) start the pump as per requirement but normally one pump is sufficient for each unit. Check that GS inter connecting valve (CW 43) between unit I/II is closed if not required. Ensure that GS tanks inter connecting valve for Unit I/II (GS 138) is closed. Start service air compressor and instrument air compressor. Ensure 7 to 8.0 kg/cm2 header pr in PCR and check that Service air or inst air pressure low indication is not present in PCR. Ensure adequate instrument air pressure (@ 3.5 kg/cm 2) to all pneumatically operated valves/ dampers etc. Ensure that inst. air dryer is in service and inst. air is moisture free. Check that moisture separators are in service and functioning normal. Check for proper loading/ unloading of compressors (8.3/8.1 kg/cm 2) Ensures that no abnormal indication is present on local panel in compressor room. Ensure that inst. air / service air interconnection valve between U1/U2 is closed. (if not required) Operate the drains of inst air receivers located in various areas regularly to get moisture free air.
2

C-3

C-4

Line up CW system. Ensures that CW sump level is slightly higher than the normal value while starting the first pump (@ 291 MEL). Open softened water make up valves (CW 5 & CW 6). Ensure that pump discharge valve is closed. Start the pump and the discharge valve will open @ 100 for priming the system. After the system is primed and pressure is built up, the valve will further open to full. Observe the normalized current (@ 155 A) and pump discharge pressure (@ 1.8 kg/cm2) observe the CW inlet pressure to condenser (@ 1.60 to 1.65 kg/cm 2 ) and CW differential pressure across cond. Inlet / outlet (< 0.35 kg/cm 2 ). Watch motor winding temperature (<1200 c) and pump / motor bearing temperature (< 70 0 ) charge the aux. cooling system to the following by opening the valve (GS 6 and GS 5) (a) Turb.oil coolers (b) seal oil coolers (c) Transformer oil coolers (d) Stator water coolers (NOTE 1. If CW system i.e. pump is to be started on manual, open the discharge valve to @ 100 -150 and after normalizing the current, open the valve full manually. 2. If CW system is not running, open GS water system recirculation valve online (GS 140) to enable part GS water to return via cooling tower. This cold water will intermix with hot GS water return from auxiliaries and provide adequately cold water. Close GS 140 when CW system is started.

C-5

Start DM transfer pump after ensuring sufficient DM water in DM storage tank. Observe the normal current (@ 52 A). Take normal level in OHDM tank (3000 mm) as per bar indicator in PCR. Take water in condensate surge tank through DM 12 valves from OHDM ensure that DM 12 functions normal on level interlock. Line up boiler fill pump for boiler filling. Ensure that all drum vents (B 5, B 6, B 51, and B 52), S.H. vents (S 23, S 25, S 27, S 26) start up vent (S 32, S 33), and S.H. drains (S 19, S 20, S 17, S 18, S 15, S 16) are open. Open ring header drain B 95 and eco drain valve E 8 for filling boiler. Ensure that drain valves B 96, E 9 going to IBD are closed. Ensure that eco recirculation valve E 12 is open. Ensure that valve for feed tank filling by filling pump is closed. Start boiler fill pump and close its recirculation valve. Observe discharge pressure (12 kg/cm2 ) and normal current (@ 60 A). After filling the boiler to 3 to 4 ports, stop fill pump and close its discharge valve. Check that hydra step level indicator, Local, Yarways, level indicators in PCR are showing level. Check that both drum level gauge glasses are in service. Close drain valves B 95 / E 8 through which boiler is filled.

C-6

C-7

Check that seal oil pump is running normal (@ 3.9 A). Check that H 2 / Seal oil differential pressure is @ 1.3 to 1.5 kg/cm 2 (on barring gear, differential pressure may vary considerably, but it should be between 1.0 to 1.7 kg/cm 2 ) Ensure that 240 V AC supply / 220 V DC supply for annunciation to local panels at 15.5 M / 4.5 M level is normal and no abnormal indication is present on that panel. Check H2 gas pressure (between 3.3 to 3.5 kg/cm 2 ) and H2 gas purity is @ 99% (>97%) Check that selector switch on local panel is in remote. Check that auto selection switch for seal oil pump on control desk is in proper position i.e. If seal oil pump A is running, S/S should be in position 1 and if pump B is running, it should be in position 3 position 2 indicates that both pumps are on manual. Auto/manual

selector switch for DC seal oil pump is by passed and pump is always on auto selection. Ensure that isolation valve on control oil line to DPR B is open. Ensure that one of the seal oil cooler is in service from water side and cooler is primed properly. Maintain seal oil temperature at @ 400 c. Ensure that float valves of IOT / SOT are working normal and their by pass valves are closed. Watch level (@ g.g.) Ensure that pump recirculation valve to SOST is closed. Check that one of the seal oil / H2 vapor extractors is running. Cooling water to oil separator of vapor fans should be through. Check that filter in the seal oil system at the outlet of seal oil cooler is not clogged (which will be indicated by red optical indication on the filter). Check the seal oil system parameters. 1. Seal oil pump discharge pressure 2. H2 gas pressure 3. Relief oil pressure EE / TE 4. Seal oil pressure after filter 5. Seal oil pressure EE / TE 6. Seal oil flow EE / TE 7. SOT vacuum @ 7.0 kg/cm2 3.3 3.5 @ 7.0 @ 6.5 @ 5.8 @ 32 / 45 lit / Sec. 300 400 mm Hg.

(NOTE: - (a) Seal oil pressure EE/TE will vary as per generator casing H2 gas pressure and diff. pressure regulator. The seal oil pressure mentioned at (5) also includes the static head of @ 1.2 kg/cm 2. (b) Relief oil pressure is always constant or varies only if discharges pressure of AOP varies. C-8 Ensure sufficient MOT level (@ + 350 mm) check the readiness of AOP- I and AOP II. Ensure that MOT basket strainers are cleaned. Check that fire protection shut off valve is closed and solenoid is reset at turb floor and in MOT room. Aop can be started manually from PCR or on auto through SLC ON check that sub group control of oil system is Auto ON. Watch Aop amperes (@ 110 A) and AOP discharge pressure (@ 7.5 kg/cm 2) put SLC ON of AOP-II. Ensure availability of DC LOP by starting the pump & put its SLC ON. Watch drop in MOT level after AOP started (@ 280 mm). Ensure that one of the lub oil coolers is in service from oil side. Optical indication (Large red arrow) on cooler change over valve gives the direction of flow of oil indicating the cooler in service. The small black arrow shows the stand by cooler. Do not adjust any intermediate position of change over valve. Keep GS water inlet / outlet valves open for the cooler in service from oil side. Charge the cooler from water side by properly venting it. The stand by cooler should be kept drained from water side to avoid deposits on tubes causing corrosive attacks on tubes. Check lub oil flow through brg. Pedestals by opening the caps on pedestal outlet pipes. Watch lub oil temperature at cooler outlet and ensure that it maintains @ 40 0 - 450 c through temperature control valve, put SLC of oil temperature control ON and its reference set point at @ 40 0 - 450 c observe bearing drain oil temperature (> 600 c ) at local. Observe journal Babbitt metal temperature / thrust bearing temperature (>900 c & >1100c respectively) on recorder and DAS4

Watch MOT level regularly (@ 25 mm) and ensure that there is no sudden appreciable drop in MOT level. Ensure sufficient stock of turbine oil (at least 5 barrels). Ensure that at least one centrifuge is available for service and run it at least 8 Hrs. per day. Ensure that no filter supervisory alarm (for thrust bearing filter) is present. If clogged, change over the filter and clean it. Optical large red arrow shows filter in service and black arrow shows the stand by filter. Watch the level in dirty oil tank and ensure that high level indication is not present on DAS. Following drains are connected to dirty oil tank a) MOT room floor drain b) leak off drains of ESVs, IVs, CVs and LP by pass valves c) H2 vapor fan exhaust pipe drains. Ensure that one vapor extractor fan on MOT is running and the other fan is standing by. Check the following parameters at local / PCR a) Discharge pressure of AOP b) Oil pressure before cooler c) Oil pressure after cooler d) MOT level C-9 @ 7.2 kg/cm2 @ 5.4 @ 4.8

@ + 25 mm

Start jacking oil pump I on manual and put its SLC ON put ON the SLC of JOP-II (NOTE : JOP will also start if SGC of oil supply system is auto ON). Observe the normal Current (42 A) and JOP discharge header pressure (@ 120 kg/cm 2). Check jacking oil pressure at each bearing (The pressure gauges are located inside the box near each brg.) normally, following readings of pressure are observed. Brg. No.-1-25 kg/cm2, B2 (50 kg/cm2 , B3 50 kg/cm2 , B4 60 kg/cm2, B5 60 kg/cm2, B6 - 60 kg/cm2. It may be noted that there are two jacking oil lines for brg. No. 1, 2, 6, Check the freeness of rotor by hand barring. Ensure that barring gear handle is available near brg. No.2 Ensure that hand barring gear pin is turned properly in position (away from the shaft ) and is not touching the shaft.

C-10 Ensure 415 V AC supply to turning gear gate valve. Check that following permissive for starting turning gear are satisfied a) Seal oil / H2 diff. pressure > 1.0 kg/cm 2, b) Seal oil pressure TE/EE > 4.4 kg/cm 2, c) H2 gas pressure > 3.3 kg/cm2, d) H2 purity > 97%, e) Liquid in gen not present. Open gate gearing valve and observe that turb speed increases to @ 110 rpm watch drop in MOT level (@ 45 mm) ensure that barring gear handle is available near bearing no. 2 put ON SLC of turning gear. Check and note down the turbovisory parameters i.e. HP/IP overall expansions HP/IP/LP diff. expansions, axial shift. Observe barring gear oil pressure (@ 7.0 kg/cm 2) after turning gear is ON AOP amp. Will increase to @ 125 A from 105 A. C-11 Open hot well make up valve DM 32 / DM 35 to fill up condenser to slightly higher than normal level (i.e. 2/3 g.g. or @ 900 mm on bar indicator in PCR) check
5

discharge valve CD-2/CD-4 of CEPS are operating from PCR. Check that pneumatic valves CD-14/ CD-19 are operative from PCR. Ensure that AOP (turbine) is already running. This is to keep LP bypass spray valves in closed condition. Ensure the line up for starting CEP. Select the pump for starting by keeping preselection switch in proper position 1 or 2 i.e. if pump I is to be started, keep it in position 1. When SLC is made ON the preselected pump will get ON the corresponding discharge valve will open on auto. Solenoid operated vent valve on CEP discharge line will open for 20 sec and will again close. Observe the normalized current (@ 30 A) and discharge header pressure (22 kg/cm2). The discharge valve of stand by pump will open when the pressure before NRV of running pump develop more than 22 kg/cm 2 check that no abnormal indication is present check thrust bearing temperature (<600c) charge LPH 1,2,3, by properly venting the heaters. Maintain hot well level by normal make up valve (DM-32) or high capacity valve (DM-35) Put level control on auto and observe the performance of make up valves (DM 32/35) recirculation valve (CD 19) and level control valve (CD 14). Also observe the behavior of (CD 23) valve (Connecting gland steam cooler to CST). This valve diverts main condensate to CST when DM 32/35 are in closed condition and dea. level is still rising. Check that manually operated main steam ejector by pass valve (CD-9) is in closed condition. C-12 Check that deaerator drain (DR 315) is closed. Line up boiler fill pump to deaerator (valve ....................... open) take dea. level to @ 2300 mm on PCR bar indicator (OR deaerator can be filled up running CEP as in C .) Verify line up for starting BFP check 220 V DC supply to local BFP panel. Ensure that both pneumatic and manual operated recirculation valves are open. Ensure Blr. Filling pump stopped. Start BFP and observe the normalized current (@ 120 A). Ensure that cooling water valve for motor opens on auto within one minute. Open discharge valve . Observe suction flow (@ 60 T/hr.) and main pump suction pressure (16.0 kg/cm 2) observe feed water temperature dift. at inlet and outlet of main pump. This diff should be less than 80c Watch motor winding temperature (<70 0c) observe BFP discharge pressure and ensure that it is more than that low discharge pressure trip value (i.e. @ 60 kg/cm2). Adjust the pressure with the help of BFP scoop. Observe FST level and temperature will rise if pegging is given. Maintain dea. Level (@ 2300 mm with the help of CD 14 / CD 19) C-13 Verify the line up for establishing feed water flow to boiler. Open integral by pass of discharge valve of BFP observe pressure in BFP discharge header. Observe pressure at inlet of feed regulating station. Open BFP main discharge valve. Check ECO inlet valve (E2) is open. Start feeding water to boiler by opening low load control valve (FD 20) increase BFP scoop position such that a flow of @ 50 T to 80 T/hr. at a min discharge
6

pressure (60 kg/cm 2) is established. Observe feed water pressure/temperature keep close watch on dea level and maintain it at 2300 mm. Maintain hot well level at @ 830 mm with the help of (CD 14/ CD 19/ DM 32/35). Observe that BFP suction flow increases by same amount as feed flow to boiler. As the level starts coming up in the drum, slow down the feeding rate by low load valve (FD-20) and when the level is at Zero on indicator stop feeding water to boiler. Bring down scoop position such that BFP discharge pressure is (@ 60 kg/cm2). Select other BFP for remote / auto operation. (NOTE : (1) boiler fill pump is lined up for deaerator if CEP is not running. If CEP is running, boiler fill pump need not be used. (2) BFP can be used for boiler filling instead of fill pump as described in step ( c .) C-14 Ensure that both LOPS for air heater guide bearing and for air heater support bearing are available. Select any one LOP for A.H. guide bearing and any one LOP for A.H. support bearing through selector on control desk. Put sub group sequence auto-ON. The selected LOP for guide bearing will start if the guide bearing temperature is more than 35 0c. The 2nd stand by LOP will start if the guide bearing temperature does not drop below 350c within 120 sec. both will remain off if the temperature is less than 350c. The selected pump for support bearing will start if the support bearing temperature is more than 450c. The stand by LOP will pick up if temperature does not drop below 450c. Within 120 sec. both LOPS will remain off if the temperature is less than 450c. Ensure cooling water inlet / outlet valves to cooler are open. Check & note LOP discharge pressure ( kg/cm 2). Observe guide / support bearing temperature on DAS and ensure that they do not exceed 70 0c. Ensure that oil defector probes are inserted properly and cooling water is established. Check the probes for oil ingress in A.H. carry out soot blowing regularly. Observe through glass window for any air heater fire. C-15 Ensure that inlet dampers of ESPA and ESP B i.e. GD 3A & GD 3B are opened. Put air heater A/B switchgear selector switch in remote position. Initiate the starting sequence for air heater (Say A) then following operation will take place. 1) Air heater A flue gas inlet / outlet dampers (GD 1A / GD 2A) closes. 2) Air heater A inlet / outlet sec. air damper (SAD 3A / SAD 4A) closes. 3) Air heater A starts. 4) If air heater B is off its flue gas inlet / outlet dampers (GD 1B / GD 2B) and SA inlet / outlet dampers (SAD 3B / SAD 4B) closes. 5) Air heater A SA inlet damper SAD 3A opens. 6) Air heater A SA outlet damper SAD 4A opens. 7) Air heater FG outlet damper GD 2A opens. 8) Air heater A FG inlet damper GD 1A opens. Observe the normalized current of air heater A (@ 6.0 A) Ensure that Auxiliary motor (DC Motor) is ready. Trip AC motor and check that DC motor picks up on auto (3.5 A). Restart AC motor.
7

In similar way start air heater B (only step 4 will not take place as air heater A is already running.) C-16 Start LDO pumps after ensuring its line up. Observe the normalized current (..A) Adjust the pump discharge pressure to @ 15 kg/cm 2 or as per requirement. Check that LDO recirculation valve LO11 (located in OHP near the pump) is functioning normal. Open isolating valve on line going to either boiler I or boiler II as per the requirement. Check that manual isolating valve on LDO line to package boiler is closed as it is normally not required. Check that LDO pressure at firing floor before LO trip valve is @ 10 kg/cm2 and adjust the oil pressure by LO 11 valve. Put LO 11 valve control on auto. (NOTE: LDO pressure control valve LO 11 is operative from both the PCR-I and PCR-II. The valve accepts the command which is maximum. Hence suitable coordination between two PCRS is required when LDO is used) If LDO is also to be used at CD or EF elevation, ensure that HFO inlet isolating valve and HFO return line isolating valves are closed. This is to avoid LDO return to HFO tank. When LDO is to be used at CD/EF elevation, oil temperature Prot. is required to be by passed. C-17 Line up HFO circuit ensures proper functioning of HO-11 pressure control valve located in OHP near the pump. Keep the valve open and start the pump. Observe normalized current (@ 15 to 16 A). Ensure that HFO inlet isolating valve at F/F is open and LDO interconnecting valve is closed. Ensure that isolating valve on HFO return line to oil tank is opened. Open HO recirculation valve Ho 35 (Located at FF) by depressing its open push button. Recirculation valve will open provided a) all nozzle valves are proved closed (i.e. AB 1 to AB 4, CD 1 to CD 4, EF 1 to EF 4) b) HO trip valve (HO 29) is proved closed. When Ho 35 is open depress HO trip valve open PB. This will open HO trip valve HO 29 placing HO recirculation system in service at CD / EF elevation. Adjust the HO pressure at FF as per requirement with the help of HO 11 and put it on auto. Ensure that manually operated by pass valve of HO 11 is closed and also manual operated pump recirculation valve (Located in OHP near pump) is closed. Also manually operated short recirculation valve at FF should be closed (However, it may be adjusted to get required HO pressure. Start steam tracing if steam is available from nearly running unit. Check that oil tank heating is already in service and tank temperature is @ 50 0c. If nearby unit is not running FO tank heating can be started at @ 25 to 30 kg/cm 2 drum pressure. Ensure that all steam traps are in service and are functioning normal. Watch HFO pressure watch HFO temperature which would slowly rise to 110 0 / 1200c watch HFO flow. Once the FO temperature is achieved 1200c HO recirculation valve (HO 35) may be closed from PCR, however after ensuring that its by pass line is in service. Its by pass line is envisaged with an orifice to maintain minimum return oil flow. HO recirculation valve (HO 35) is only required during start ups to get the required FO/LSHS temperature.
8

C-18 Check that FD fan LOPS are ready for service. Select any one LOP A or B for service through LOP selector. Put sub group sequence of LOP on Auto-ON The preselected pump will start. Observe discharge pressure (@ 12 kg/cm 2) control oil pressure (@ 10kg/cm2) bearing lub oil pressure (1.2 kg/cm 2). Observe that lub oil pressure low and control oil pressure low indications get reset. The stand by pump will pick up if FD fan is ON and if control oil pressure drops below 5 kg/cm 2 or running pump trips. C-19 Verify line up for starting ID fan. Check that Air heater is running. The fan and motor bearing temperature of selected ID fan to be run are normal. Ensure that selector switches on switch gear is in Control Room (CR) position. Initiate the start sequence of selected ID fan (say A) then following operations will take please. a. Seal Air blower for discharge gate starts. b. I.D. Fan inlet gate (GD5A) closes. c. I.D. Fan Outlet gate (GD7A) closes. d. I.D. Fan A regulating inlet vane (GD6A) closes. I.D. Fan A starts. Observe normalized current (@ 65A) then, e. I.D. Fan A inlet gate (GD5A) opens. f. I.D. Fan A outlet gate (GD7A) opens. g. Operate the inlet regulating vanes to get a furnace draft of 10 mm WCL on narrow range recorder and on desk indication. If ID Fan B is off then, h. ID Fan B inlet gate (GD5B) closes. i. ID Fan B inlet regulating vanes (GD4B) goes to minimum. Observe motor / fan bearing temperature (<60C), motor winding temperature (<55C) on DAS. Observe fan current and vane position. C-20 Verify line up for starting FD fan. Ensure that at least one ID fan is running. Ensure that fan / motor bearing temp. Of selected FD fan to be run are not high and selector switch of selected FD fan on switch gear is in CR position. Initiate the start sequence (say for FD A) and the following operations will take place. a) FD Fan A outlet damper (SAD 2A) closes. b) FD Fan A inlet guide vanes (SAD 1A) come to minimum. c) FD Fan LOP starts as per selection. d) If FD fan A control oil pressure is >8 kg/cm FD fan A starts. If FD fan B is off then. e) FD fan B outlet damper (SAD 2B) closes. f) FD fan B inlet guide vanes (SAD 1B) come to minimum. then g) FD fan A outlet damper (SAD 2A) opens. h) Inlet guide vanes are released for operation and sequence is completed.
9

Observe the normalized current (@35A) The Seal air blower for hot air shut off gates will get ON as soon as FD fan is made ON. Check that they are working normal. C-21 Ensure that A.C. Scanner fan is already running. Prior to starting of FD fan, it is taking suction from atmosphere and its emergency damper is open. When FD fan is started, emergency damper closes and the scanner fan takes suction from FD fan duct. Ensure that stand by DC scanner fan is ready for service by taking its trial, keep it standby. Ensure that it is not rotating in reverse direction. Watch scanner fan discharge pressure and scanner / furnace difference pressure and check that its filters are not choked up (<20 mm WCL p). (NOTE: Scanner fan boosts up the air pressure by @ 300 320 mm WCL. Its discharge pressure is more than wind box pressure by @ 300 320 mm WCL. C-22 Check the selection of auxiliary air dampers control. This will control 6 Nos. of coal elevation dampers i.e. secondary air dampers in A,B,C,D,E,F elevations 3 Nos. of heavy oil elevations damper in AB, CD, EF elevations and 6 Nos. of auxiliary dampers in AB, BC, CD, DE, EF and FF elevations (AA damper being Locked in 25% open position at Local). There is facility of two types of programmes of damper control. Programme - I : When the selector key notch is in horizontal position (_______) the set point is said to be auto and it is sliding set point. During furnace purge period and initial operation of unit up to 30% loading, all elevations of auxiliary dampers (AB BC CD DE EF FF) shall modulate to maintain as approximate. 40 mm WCL difference pressure between furnace / W.B. As the Load increases above 30% the set point automatically ramps up and finally settles down at @100 mm WCL. Programme II: - This programme facilitates the operator to vary the set point. The selector key notch is in vertical (0.1) position. Furn / WB diff. pr. Set point can be slided as per requirement. Put the aux. air dampers on auto and keep master control on manual. Adjust the set point as follows. Sr. No 1 2 3 4 5 Load (MW) 60 120 140 160 210 Furn / WB mm WCL 40 60 70 80 100 P Wind box mm WCL 35 55 65 75 95

Check that sec. air dampers (i.e. A, B, C, D, E, F) close on interlock as they modulate as a function of feeder speed and open max. to 20% irrespective of feeder speed. The dampers remain closed if feeder is OFF C-23 Operate the inlet vanes of ID fan and inlet guide vanes of FD fan so as to get the following parameters. a) Total air flow @ 300 T/Hrs. (i.e. slightly more than 30% and less than 40%)
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b) Furnace draft (-5 to -10 mm WCL) c) Wind box pressure @ 35 mm WCL and furn / WB diff. pressure @ 40 mm WCL Check that indication air flow less than 30% is reset. Observe pressure drops in air flow system and flue gas system on DAS. Observe ID/FD fan amperes (120 A / 45 A). Observe FD fan disch pressure, FG diff. pressure across the air heater and ensure that it is within limit. C-24 Line up aux. steam supply line to SCAPH. Charge steam coil air preheated by admitting aux. steam by steam supply valve (AS 323). This valve is tobe regulated such that secondary air temperature of @ 80 0 C is achieved at inlet to air heaters. This temperature rise will also be reflected in secondary air temperature after air heater and in flue gas temperature gradually. SCAPH can be cut off when flue gas temperature after APH is more than 120 0C. C-25 Verify the line up for boiler light up a) Ensure power supply to FSSS panel 1. + 24 V DC supply 2. 220 V DC supply 3. 110 V AC 1 supply b) Check that drum level is normal. c) Air flow is slightly more than 30% (and less than 40%) and the indication air flow less than 30 % trip is reset. d) AB elevation LO nozzle valves are closed. e) AB/CD/EF elevations HO nozzle valves are closed. f) LO/HO trip valves are closed. g) All PA fans are off h) All coal feeders are off i) All hot air gates are closed. j) All scanners show NO flame (both in fire ball and discriminating scanners) k) No boiler trip command persists. If all above conditions are satisfied, a yellow purge ready indicating lamp glows. Depress the purge start push button and a five minute purge timer is energized as white lamp being ON At the end of five minutes, the boiler trip circuit is reset provided no boiler trip condition is present. The white purge light goes OFF and green purge complete light comes ON C-26 Check that burner tilt is at horizontal position and its control is on manual. Ensure corresponding position at local. Put furnace probe IN and check it at local. Observe furnace temperature at furnace exit. (Note: Normally furnace probe is not used even though facility is given)
11

Check that atomizing steam to HO / LS HS burners is lined up and steam control valve is working. Check atomizing steam pressure before control valve (@ 10kg/cm2 , at local) put the atomizing steam pressure control valve (OS 27) on auto with pressure set point at @ 6.0 kg/cm 2 and observe that control valve is maintaining the pressure. Check that steam traps are in service and working normal. Also ensure that atomizing air i e service air is available for LDO and pressure is @ 7.0 kg/cm2. Ensure that air is moist free. Check oil guns for correct tip and for proper assembly of nozzles. Check that HEA igniter spark plug is cleaned. Switch ON the EP rapping mechanism and insulator heaters and ash hopper tip heaters well in advance i.e. at least 4 hrs. in advance of boiler light up Check that rapping cycle is normal field wise i.e. 1st field 2nd field 3rd field 4th field 5th field Emitting electrodes 12 raps/hr 10 raps/hr 6 raps/hr 2 raps/hr 1 raps/hr 10 raps/hr

Check that tip heaters are getting ON/OFF properly to maintain hopper tip temperature at @ 1200C Check that rapping motors are moving in correct direction. C-27 Select LDO at AB elevation after ensuring the following. 1) All LO nozzle valves are closed. 2) All HO nozzle valves are closed. 3) Atomizing air manual isolating valve is open. Steam atomizing manual isolating valve is closed and limit switch is acted. 4) The oil gun is properly positioned at firing position and oil gun engaged red indication lamp glows. 5) Local oil gun maintenance control switch is in remote position. 6) Scavenge valve is closed. 7) LDO manual isolating valve is open and LO trip valve is open. 8) Boiler is reset. Ensure inst. air supply to HEA igniter operation. LDO at AB elevation can be selected from the oil console insert by pressing oil selection push button. (NOTE: LO trip valve opens only when) a) b) c) d) LO pressure is adequate i.e. > 3.5 kg/cm2 Atomizing air pressure is normal i.e. > 3.5 kg/cm2 Master fuel trip not operated. LO nozzle valves are closed.

C-28 Light up the boiler by pressing the push button for pair start (1-3 or 2-4) on FSSS console AB elevation. This will initiate a 90 sec start time trial.

12

1) A start command is sent to oil corner 1 (when corner 1-3 is started) or to oil corner 2 (when 2-4 are started) 2) 15 sec. later, a start command is sent to corner 3 (or to corner 4) The following sequence of operation is executed for each gun. a) Command is given to open air atomizing hydro motor valve. b) When air hydro motor valve is open, command is given to advance HEA igniter and operating LO hydro motor. c) When LFO hydro motor opens around 50% command is given to operate HEA igniter. The igniter gets command for sparking only if it is in advanced condition, and relevant limit switch is operated and spark tip is clean. d) For each gun, trial time is fixed as 25 Sec. from opening of oil hydro motor. e) If the safe scan for that particular corner picks up and flame ON indication appears, the gun will sustain. The gun trips if the discriminating scanner shows no flame. The LFO pressure goes down very fast as LFO nozzle valve starts opening. Ensure that LFO pressure is maintained as per required (@ 6.0 kg/cm 2 ) By LO 11 valve on auto. Other wise, the gun will trip on low oil pressure watch closely and maintain furnace draft and drum level whenever any heat input to boiler is changed. Check that atomizing air pressure is constant at 6.0/6.5 kg/cm 2. Charge ESP fields. Initially keep the current setting low (@ 50 MA ) the fields need to be charged during oil firing to avoid chloride corrosions on emitting electrodes. C-29 As warning up of the boiler has started the temperature of flue gas and air would rise gradually. Steaming would start. Water would swell and drum level would rise. Check that boiler emergency drain valves B 99 B 100 open on interlock of high drum level to maintain level. Maintain drum level normal with the help of blow down valves and low load feed control valve FD 20. Check that electrically assisted pressure relief valve (ERV) is in auto mode and is closed as indicated by green lamp. Watch flame visually frequently. Flame should be bright yellow without any smoking. If it is smoky, oil pressure may be reduced. If it is too bright and lengthy air pressure may be reduce. If the flame is pulsating with intermittent smoke, burners need cleaning to remove choke up. Observe the drafts at various points on DAS and ensure that they are normal. Watch drum metal temperature on DAS (analytical Para) and ensure that they are steadily rising. Observe that difference between Top / bottom drum metal temperature and ensure that it is less than 50 0C while pressurizing the boiler, recommended curve, for boiler pressurizing may be followed. This curve is mostly governed by even heating of furnace and limitations of drum metal temperature difference at Top / bottom. If the temperature difference is more than 50 0C, reduce firing rate. Firing rate is to be adjusted such that saturation steam temperature rise is limited to 1100C / hr and maximum flue gas temperature at furnace exit is not more than 5400C until steam flow through super heater and reheater is established. While boiler is under pressurizing stage, frequent checks should be made for boiler expansion. Special attention should be given to the expansion of the lower part of the boiler relative to steam pressure compare the readings with the previous readings during commissioning. Watch the flue gas temperature at air heater outlet frequently. Abnormal increase in gas outlet temperature would indicate that fire has developed in air heater. Observe the air heater through its peephole (glass window) for any fire. Check the
13

air heater for any oil ingress by with drawing oil detection probe, carry out air heater soot blowing every 8 hrs. interval. Adjust the heating / steam flow rate by regulating superheat start up vent. Start up vent not only expels the air but also helps to quickly dry out the super heaters. Initially, flow through super heater is improper due to condensed water; lack of pressure etc. and as such super heaters are likely to be overheated. C-30 When the boiler drum pressure reaches 2 to 3 Kgcm 2, close drum vents, super heater vents. Observe saturation steam temperature at drum (@ 120 to 130 0C) and drum metal temperature (130 to 1400C). Before closing the vents, ensure that steam is freely coming out through the vents. Check S.H. drain line physically and ensure that it is hot. At @ 5.0 kg/cm2 drum pressure throttle the super heater drains and further close at @ 8 to 10 kg/cm2 pressure. Charge main steam line by opening the boiler outlet by pass valves (MS 301 A/ 302 A) prior to this, ensure that line drains MS 202/204, MS 212/214 are open along with their isolating valves. Throttle the start up vent to regulate steam flow. Ensure that there is no hammering in MS line. Watch MS line steam temperature which should slowly rise. (MSL can be charged at 5 to 6 Kgcm2 drum pressure also) C-31 As per recommendations of chemist arrange chemical activities i.e. boiler header blow downs at recommended drum pressure i.e. 10 Kg/cm 2, 20 Kg/cm2 as per procedure. Fire should be killed prior to giving blow down. Reduce total air flow to avoid cooling. Light up boiler after blow down is over. C-32 When MS line is charged and a constant feed flow through economizer is established, (i.e. normally after 10 kg/cm 2 blow down & MSL charging) close economizer recirculation valve (E -12) C-33 Increase firing rate, if necessary by inserting two more AB Elevation guns as per procedure described in earlier paragraphs. Watch oil pressure, furnace draft and drum level. C-34 After 20 kg/cm2 boiler blow down is over charge APRDS from self if it is already charged from nearly unit. Ensure that PRDS lined up for charging. Ensure that all the drains are wide open. Check that manually operated valves are full open. Charge pressure control loop by crack opening the control valve AS 308 (high capacity line). Watch APRDS pressure and temperature which will gradually rise. Ensure that there is no hammering in the system. Gradually increase the opening of valve AS 308. Once the APRDS temperature reaches 1200C, check APRDS drains for free draining and then close the drains. Raise the pressure up to 12 to 14 kg/cm 2 or as per requirement. (Maximum 16 kg/cm2) and put the pressure control valve on auto. Watch for proper auto functioning. Select any spray line (either high capacity or low capacity) for service and charge APRDS spray so as to maintain temperature at @ 220 0C put the spray valve on auto. Open main boiler outlet valves (MS 301/302) on MS line to get adequate PRDS pressure regulate start up vent to adjust steam flow. Keep the other pressure and temperature control loops in APRDS ready for service.
14

(NOTE: Aux. PRDS system consists of) a) Pressure control loop. b) Temperature control loop. c) Spray water pressure control loop. The PRDS pressure control system consists of one high capacity valve (AS 308) one low capacity valve (AS 305) and one motor operated low capacity by pass valve (AS 311) Normally, when the steam consumption in APRDS is more, (Which is the case during start ups) high capacity valve (AS 308) may be used. When consumption is less i.e. during normal running of the set low capacity line is to be used. The PRDS temperature control system also consists of one high capacity line (FD 343, 347 valves) one low capacity line (FD 336, FD346) and motor operated low capacity by pass line (FD 339, FD346). Each of low/high capacity line consists of two no of spray water control valves in series and are operated to equal percentage of opening by common control signal. Charge SCAPH as described in previous paras if not charged so far by opening main isolating valve. Charge atomizing steam line. Charge steam to oil handling station after ensuring that steam traps are in service. Check that FOH heating interconnecting valve between U1/U2 is closed if not required. C-35 Check that steam ejectors are lined up. Charge the steam line to ejectors after ensuring that its drains are wide open. Open the valves (AS 378) for charging. Watch steam line pressure and temperature which will slowly rise. Close the drain when the temperature is @ 120 0C and pressure @ 2.0 Kg/cm 2. Raise steam pressure to @ 6.5 kg/cm2 and put the ejector steam pressure control on auto. Observe APRDS pressure / temperature. Ensure 220 V, DC supply to the solenoid of vacuum breaker valve. Close the valve. Ensure water sealing to vacuum breaker valve and to the glands of other valves which are under vacuum. Ensure that gland steam cooler siphoned is filled up. Observe and note down turb. Rotor differential expansions, axial shift and turb overall expansions. Ensure electrical supply to the motors of seal steam leak off controller and seal steam supply controller (MAW 50 AA 001 and MAW 10 AA 001) respectively. Its local push button should be in pulled out conditions. Ensure that oil pumps of the controllers are working on auto to maintain oil pressure of @ 60 kg/cm 2. Check that valve AS 301 (CRH steam to glands) is in closed position. Keep gland steam pressure controller on manual and the gland steam supply valve (MAW 10 AA 001) in closed position open manually operated gland steam supply isolating valve after confirming that header drain MAL 81 and drain before supply valve MAW 10 AA 001 i.e. (M AW-10) is open. The gland steam line is now charged up to supply valve (MAW 10 AA 01) start gland steam seal condition exhauster. Check that its outlet valve is open and by pass valve to atmosphere is closed. Keep other fan stand by after taking its trial (outlet valve of stand by fan maybe required to keep closed as the fan rotates in reverse direction). Start vacuum pulling through start air ejector. Open steam valve (AS 04) first and then air valve (SM 16) watch ejector steam pressure (@ 6.0 to 6.5 kg/cm2). It may be required to open by pass valve As 377 slightly to maintain
15

steam pressure when start ejector is in service. This valve may be closed when start ejector is out off. Watch vacuum is improving At @ 0.04 kgcm vacuum, admit steam to turbine glands by opening gland seal supply valve (MAW 10 AA01) such that a pressure of 0.01 kgcm to 0.015 kgcm is available. Put the controller on auto. The rate of vacuum pulling will be faster now when gland sealing is established. Keep the drain valve MAW 10. Crack open observe supply valve opening (@ 30 %) Observe gland steam pressure at local (100 to 150 mm WCL) and gland steam temperature (@ 1800 C) Observe APRDS pressure & temperature observe and note HPT/IPT/LPT/difference expansion, axial shift, LPT exhaust hood temperature. Start one main ejector by opening its steam valve (AS 02 or AS 03) to speed up vacuum pulling rate. Watch steam pressure & maintain it @ 6.0 kg/cm2 When vacuum is @ 0.80 kg/cm2 cut off start ejector, first by closing air valve (SM 16) and then by closing steam valve (AS 04) observe that vacuum is stable. Note the final value of vacuum at which it stabilizes (@ 0.92 kg/cm2) and note HPT/IPT/LPT differential expansions. C-36 Ensure that drum pressure is @ 30 kg/cm2 and firing rate is adjusted accordingly. Check that HP by pass control oil pumps are running. It is better to start them as soon as boiler is lighted up. Check that oil pumps are working normal on auto. The pump starts at 110 kg/cm2 oil pressure and stops at 150 kgcm2. Check that all (P T L) i.e. supply/ return/ leak off oil lines to HPBP sulzer valves are open and there is no oil leakage in the system. Ensure the following. a) HP BP oil tank level in normal b) ESV/IVs are closed. c) Cooling water to HP BP valve steam from CEP is open d) Isolating spray valve before BP valve is open and BD valve is closed on auto. Ensure that it is not passing. e) All controls of HP by pass inserts are on manual mode and all valves in closed position. f) HP BP warm up valves are in closed position. g) Ensure power supply to HP BP panel. 1) Control panel 240 V AC, 1 From ACDB 1 F 24 2) Oil unit a) 415 V 3 AC from turb. MCC feeder. b) 415 V 3 AC from emergency board Ensure the following for LP by pass system. a) All manually operated valves behind LPBP control stand are open. b) LP BP control oil pressure is @ 5.5 kg/cm 2 Rotate the filters in LP BP system to keep them in healthy condition c) All manually operated by pass valves of LP BP water injection valves (V1/V2/V3/V4) in closed position. d) Put LP BP controller on auto and ensure that it is not faulted. Check that Automatic control interface is on auto.
16

Set the fixed set point of LP BP at @ 10 kg/cm2. Ensure that condenser vacuum is deeper than 0.75 kg/cm 2 and condenser discharge header pressure is @ 22 kg/cm 2. Open the following motorized drains along with their manual isolating valves. 1) CRH drain after HP BP (CR 206) 208 2) HRH strainers drain (HR 206) 208 3) LP BP line drain HR 230/232/233 4) LP BP warm up line drain (HR 234) 312 Open HP BP warm up valves from local (as they are manually operated) and charge HP BP for warming up. Ensure that there is no hammering in the system. After adequate warming up say for 15 min, open HP BP valves HP-I and BP-II or @ 5%. Set the temperature set point at @ 320 0C slowly increase opening of HP BP valves watching drum level. Observe drum pressure close start up vent completely (if not closed so for) and adjust firing to maintain drum pressure at @ 30-32 kg/cm2. Set the Pr. Set point of HP BP at @ 5 kg/cm2 less than MSL pressure and put HP BP on auto. Observe that HP by pass pressure and temperature control loops are working normal on auto. Check LP BP valves are also working on auto to maintain HRH pressure as per set point watch condenser level which will rise when LP BP valves start opening. Observe water injection valves V1/V2 open to maintain the LP BP VALVES START OPENING. Observe water injection valves V1/V2 to maintain down stream temperature water CEP header pressure which may drop when water injection valves open. Observe condenser vacuum which may improve when HRH system is pressurized. Observe following parameters. 1) HRH pressure which will maintain at @ 10 kg/cm2 or as per set point. 2) CRH temperature after attemperation which should rise 3) HRH/MS temperature should rise. To raise HRH temperature burner tilt may be taken upwards. Close economizer recirculation valve (E-12 if not closed so far. C-37 Line up stator water system and start stator water pump on recirculation with the help of recirculation valve and pump discharge valve, adjust stator water flow to @ 30 m/hr. observe S/W conductivity (@ 1 to 2 mhos/cm) & (< 5 mhos/cm). Observe the normalized current (@ 16 to 18 A) Check that gas trap is in service and all the three valve on inlet/outlet return line to gas trap are open. This is also necessary to vent out air from S/W system at the time of starting the system. Ensure that there are no gas bubbles in the gas trap. The gas bubbles in gas trap indicate H2 gas leakage in the system. Ensure that only one S/W cooler is in service. Check that polishing unit is in service and working normal. Ensure that other S/W pump is ready for service by taking its trial. Put stand by pump on auto selection (i.e. local/ remote switch at local panel at 4.5 M level on remote and selector on control desk in proper position).
17

Check the following parameters in the system. 1. 2. 3. 4. 5. 6. 7. Pump discharge pressure S/W pressure before/ after filter S/W pressure at inlet to stator S/W pressure at outlet from stator Cooling water pressure at inlet to cooler S/W temperature at cooler outlet H2 gas pressure @ 5.5 Kg/cm2 @ 4.8/4.5 kg/cm2 @ 3.5 kg/cm2 @ 1.7 kg/cm2 @ 1.2 kg/cm2 400C @ 3.5 kg/cm2

Ensure that H2 gas pressure > S/w pressure inlet to stator > cooling water pressure at inlet to cooler. (Stator water pressure at inlet to stator is measured at @ 10.5 m level. Hence actual pressure at inlet to stator is @ (3.5 0.5 0 3.0 kgcm ).

C-38 Line up H2 cooling water system. Charge H2 coolers one by one. Keep H2 cooler inlet pressure @ 2.5 kgcm (i.e. less than H2 gas casing pressure). Close the cooler vents. Ensure that one of the H2 gas dryer is in service and the other gas dryer is in reactivation change over gas dryer regularly. Check that dryer heaters are functioning normal & get switched off at 120 c. C-39 Feed water is being fed to the boiler bypassing HPH s through group by pass valve FD 16/FD 17. HPHs inlet/outlet valves (FD-7, FD-8, FD-10, FD-11) are closed and by pass valves FD 9/FD 12 are open. HPHs group by pass protection scheme consists of the following main elements. 1. 2. 3. 4. 5. 6. By pass inlet valve Non return valve Solenoid operated group by pass test valves Chagrining valves Vent Valve Dump Valve FD 16 FD 17 FD 130 / FD 131 FD 18 / FD 19 FD 132 FD 125

Now, proceed to charge HPHs from feed side as follows. 1. Close all the drain valves feed water loop lines. 2. Open feed side vent valves (FD 117/FD 118) located on HPH-6 FW outlet. 3. Open feed side inlet / outlet valves of HPHs HPH-5 Inlet valve FD-7
18

HPH-5 HPH-6 HPH-6

Outlet valve Inlet valve Outlet valve

FD-8 FD-10 FD-11

(NOTE: If any of the heaters i.e. HPH-5 or HPH-6 is not to be charged, its inlet / outlet feed valves to be kept closed and by pass valve to be opened) 4. Close HPH-5 feed side by pass valves i.e. FD-9 for HPH-5 and FD-12 for HPH-6 (However, refer note in point No. 3) 5. Open shell drains for a while for HPH-5 / HPH-6 and close them subsequently. Close watch may be kept on vacuum which may drop. 6. Ensure 24 V DC supply to heater group by pass solenoid valves FD 130 / FD 131. Ensure that inst. Air supply to these valves is also available (FD 130 / FD 131). Close these valves from PCR and ensure that these valves are closed at site. It will be indicated by the plunger moved inside. 7. Ensure that manual isolating valves FD 126 / FD 127 before FD 131 and FD 128 / 129 before FD 130 are open. 8. Ensure that inlet valve FD 16 and NRV FD 17 are in de-locked condition. They can be de-locked by manual hand wheel provided at the top of the valves FD 16/17. 9. Open vent valve FD 132 to charge the control liquid i.e. feed water in the chamber on the top of servomotor piston in FD 16 / FD 17. 10. Close dump valve FD 125 from PCR. 11. Check that all the drip valves on HPH 5/6 are working normal and put them on auto (DR2, DR6, DR34, DR11, and DR14) 12. Ensure that various pressure gauges and temperature gauges are available. 13. Check that float switches and gauge glasses are in service. Float switches for HPH-6 a) Two for very high level. b) One for high level c) One for low level

Float switches for HPH-5 a) Three for very high level. b) One for high level c) One for low level

19

14. Put group by pass proof. on manual selection. 15. Open charging valve FD 18/ FD 19 in initial filling line a inlet to valve FD 16. While charging HPHs from feed side, care is to be taken to watch feed water pressure and flow and to maintain them unchanged till charging is over (If so required, by changing scoop position of feed pump) Warming up of HPH s from feed side has started and will be indicated by rise in feed water temperature at various points in the system. Watch the parameters on DAS. 16. Close the vents FD 117/118 when water comes out clearly through them. 17. Close the vents FD 132 when water comes out clearly through it. 18. When down stream pressure of FD 16 reaches 90% of up stream pressure, the group by pass inlet valve FD 16 and group by pass NRV FD17 start opening. It is full open when the steam is lifted fully upwards touching the open position limit switch. Red lamp on HPH group prof. module will glow when valve opens full. 19. Ensure that feed water pressure is stabilized. 20. Close charging valves FD 18/19. Group by pass protection can be tested from PCR in the following manner. Simulate HPH very high level conditions and following will take place. 1) 2) 3) 4) 5) 6) 7) HPH level very high annunciation will appear. Extraction steam valves Ex 12 / Ex 13 will close (if opened) and drain valve Ex 112 / 110 will open. Group by pass solenoid valve FD 130/ FD 131 will opens. Dump valve FD 125 in feed line from Gr HP to HP H-5 will open. Feed water by pass valve FD 9/12 will open first and then corresponding inlet/outlet valves will close. Alternate drip valve (high level) will open full (i.e. DR 14/ DR 34). DR-2 for HPH-5 closes full. After testing is over, de-energize the solenoids manually and normalize the circuit for recharging. During testing, watch feed flow and feed pressure which should remain constant through out the test.

C-40 When boiler fire is killed for 20 kgcm boiler blow down, this opportunity can be utilized for change over of LDO to FO/LSHS (however changeover can be done at any time) 1) Change over of LDO to LSHS at CD / EF elevation. (a) Close isolating valves on atomizing air line loop to steam line.
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(b) Close isolating valves on LDO line loop to HFO line. (c) Open atomizing steam main isolating valve (before 0S-27) (d) Open (0S-27) valve and maintain pressure @6.0 kgcm and put the valve on auto (e) Open HFO recirculation iso valve at the downstream of (Ho 35) open short recirculation valve as per requirement to maintain oil pressure. (f) Maintain oil pressure as per requirement through (H0 11) valve. (g) Put FO / LSHS temperature interlock in service (if it is by passed for LDO firing) (h) Check that Fo / LSHS oil temperature is 110 c.

Try 1 or 2 guns at CD / EF elevations to ensure that proper changeover is carried out 2) Oil changeover at AB elevation. (a) Take oil guns at CD or EF elevation in service if load is less than 140 MW (b) Close LDO oil isolating valve (before hydromotor) near each corner (c) Close air atomizing isolating valve (before hydromotor) at each corner (d) Open HFO / Steam atomizing isolating valve at each corner (e) Ensure FO / LSHS temp. @110c and temperature protection is in service (f) Select LSHS / FO by depressing push button on oil selection console. Change over is complete. Try 1 or 2 guns and confirm the change over.

C-41 Steam conditioning is in progress through HP / LP by pass system. When temperature of MS lines. CRH and HRH lines are more than 100c, following drains can be closed. MS 202 / 204 / MS 212 / 214, MS 222/224 CR 206/208, HR 206/208, HR 230/232 HR 233/234 HR 311/312

Line up and prepare turbine for rolling. 1. Ensure that turbine lub oil temperature control SLC is ON and is working on auto set the temperature set point @40 c. 2. Ensure that manually operated test valves of ESVs and extraction NRVs are open. 3. Check that electro hydraulic turbine control is ON and change over from EHC to hydraulic governor is possible. Normally turbine is controlled by EHC.
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4. Check that TSE is not faulted and TSE disc has not attended any unreasonable position. Check that TSE influence is ON (Located in EAST panel GJJ02) 5. Check that following valves are in closed position. ESVs / IVs / HPCVs / IPCVs / CRHNRVs / Extraction NRVS A2 A3 A4 A5 A6. 6. Check that turbine drain valves SLC is ON and all the drains have acquired their proper position as per the temperature criteria. (NOTE : During cold rolling, all the drains should be wide open)

Particular
1) Downstream of HPCVs MAL 15/16

Criteria
(Valve casing temperature Sat temperature of steam) a) When < 20 c

Position

Open Closed

b) When >50 c
2) HP Casing drain MAL 22 (HP casing top or bottom temperature a) When < 300 c & Gen load > 2%

Open

b) When > 350c &

Gen load > 5 % 3) Drain ahead of swing check NRV MAL 65/66 4) Drain before IPCV MAL 31/32 a) If NRV Closed b) If NRV Open (Valve casing temperature Sat steam temperature) a) When < 20 % b) When > 50 % 5) Drain before IV MAL 26/27 (Valve casing temperature Sat steam temperature) a) When < 20 % b) When > 50 % 6) Extraction line drains (A2/A3/A4/A5) 7) Drains extraction Valve A5/A3/A2 a) Position < 5 % & Load > 2 % b) b) Position > 15 % & Load > 10 % 8) Drain extraction NRV (A4) Pressure across NRV a) 9) Drain gland steam MAL 81 If < 100 mm wcl If extraction valves closed

Closed Open Closed Open Closed

Open Closed Open Open Closed

Open Close Closed Open

b) If > 300 mm wcl Gland steam temperature a) If > 150 c b) If < 120 c 10) Drain before gland steam control Gland steam temperature

22

valve, MAW 10
(NOTE : MAW-10 is manually operated drain)

a) If < 190 c b) If > 200 c

Open Close

Check and note down following parameters and ensure that they are within limit. 1. (HPT middle Top HPT middle bottom) Temperature diff < 30 c 2. (IPT front Top IPT front bottom) Temperature diff < 30 c 3. (IPT rear Top IPT rear bottom) Temperature diff < 30 c Check and note down the turbovisory parameters and ensure that they are within limit. 1. HPT / IPT over all expansions 2. HTP diff expansion ( - 4 to + 5.5 mm) 3. IPT diff expansion (- 3.2 to 7.2 mm) 4. LPT diff expansion ( - 7 to + 30.0 mm) These are trip values Check that lub oil pressure to turbine oil bearing (i.e. after cooler) is @ 4.8 kgcm and ensure adequate oil flow to each bearing. (NOTE: alarm values for exp. HP E + 4.5 / -3, IP E + 6 / -2.2, LPDE + 27/-6.0)

C-42 Observe the steam parameters suitable for rolling from the various criteria given in characteristic curves on DAS. Following is the criteria for opening HP Stop valves (ESVS) a) Criteria x 1 Temperature before HP by pass > midwall Temperature HP Control valve + T1

This criteria ensures that steam temperature before HBP is always more than midwall temperature of HPCV. Otherwise warming up would not take place. It is also necessary to ensure that main steam temperature is at least 50 c superheat than saturation temperature at that pressure. b) Criteria x 2 Saturated main steam temperature mid wall temperature HP control valve + T2 ( T2 represents the temperature diff. between 100% and 50% metal temperature
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of HPCVs.) If steam sat. Temperature is selected too high (i.e. if steam pressure is too high) the surface metal will be heated up to sat. Steam temperature and will increases. If C) Criteria x 3 Main Steam temperature < Mid wall temperature HP CV + T3 cold metal temperature increase up-to saturation steam temperature. T2 T2 increases machine will be overstressed. It is assumed that

This criteria ensures that main steam temperature is not too high for warming up. Normally, the steam parameters required for cold start up are as follows. a) Live steam pressure @ 32 to 35 kgcm b) S.H. Steam temperature at boiler outlet 320 c c) Reheat steam pressure 10 kgcm d) Reheat steam temperature 320 c - Check that TSE margin is more than 300 c. C-43 Once the required steam conditions are achieved and critera are fulfilled for opening stop valves, proceed to roll the machine. Normally rolling is done through electro hydraulic governor (EHG) 1) Starting device to be brought to 0% 2) Set speeder gear position to 100% (hydraulic governor) This ensures that turbine is reset. Check that all turbine tripping orders are cancelled i.e. a) Over speed trip b) Thrust bearing temperature trip c) Electrical trip Note down the following governing system parameters a) b) c) d) e) Control Oil Pressure Trip Oil Pressure Start Oil Pressure Auxiliary Start Oil Pressure Auxiliary Trip Oil Pressure 6.5 kgcm2 6.0 kg/cm2 6.0 kg/cm2 6.0 kg/cm2 5.5 kg/cm2 > kgcm2 > kgcm2

If control oil pressure is less, rotate the filters in governing and ATT circuit to increase the oil pressure. (NOTE: Mode of operation of plate type filters use the hard wheel to turn the filter cartridges. The sludge and the dirt removed collects at the bottom. The hand wheel should be turned through 2-3 turns daily and sludge can be removed during shut down) By operating the starting device to zero position, control oil is first admitted in the start up oil circuit and auxiliary start up oil circuit. The auxiliary start up oil further raises and builds up trip oil pressure.

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Select TSE in ADMISSION MODE Raise starting device to more than 42% HP stop valves (ESVs) will open. Check that HP stop valves OPEN indication has appeared and CLOSE indication has disappeared. Raise starting device further to more than 56% IP stop valves (IVS) will open. Check that OPEN indication has appeared and close indication disappeared. (NOTE: When starting device is raised, the control oil is allowed to drain first from auxiliary start up oil circuit. The auxiliary start up oil pressure goes down to zero. This also indicates that turbine is reset or latched properly. Check that trip oil and auxiliary trip oil pressure does not drop. Further control oil is allowed to drain from start up oil circuit. Check that start up oil pressure drops to zero. Then trip oil drain proportionately to open HP stop valves and IP stop valves and are held open under the pressure of trip oil). Note down the following parameters in governing system. a) b) c) d) e) Control Oil Pressure Trip Oil Pressure Start Oil Pressure Auxiliary Start Oil Pressure Auxiliary Trip Oil Pressure 6.5 kgcm2 5.5 kg/cm2 0 0 5.5 kg/cm2

This has started the warming up of HP stop valves / IP stop valves up-to the control valves. Check that SLCs of AOP I/II, DCLOP are ON confirms the normalcy of the pumps by talking trials. Check the stand by seal oil pump by taking trial and put it on auto. The warming up is carried out till the turbine stress evaluator upper margin is more than 35. For this purpose. TSE is selected in ADMISSION MODE in which MSV and MCV are monitored. During warming up of HPCVs and MSVs, Observe the following a) Wall Stress Evaluator Recorder 1. Vi MSV MS Valve 2. Vm MSV MS Valve 3. Vi MCV MC Valve 4. Vm MCV MC Valve Pt. No. 3 Pt. No. 4 Pt. No. 5 Pt. No. 6

These temperatures should rise continuously. Warming up can be concluded when above temperature stabilise. Normally, a period of 40 minutes is sufficient. C-44 Before the machine is rolled, the following criteria are required to be fulfilled. a) Criteria x 4 Main steam temperature > Main steam
25

Saturation temperature + T 4 This criteria ensures that main steam is properly super heated (i.e. @50c at least) b) Criteria x 5 Main steam temperature before HP stop valve >midwall temperature HP shaft T5. This criteria ensures that steam temperature is above HP shaft metal temperature (@30 c).
c)

TSE Margin > 35 k

Now, turbine is ready for rolling. Raise starting device to > 90% And put the tracking device on Put TSE selection to Turbine mode Set speed reference to 600 rpm. The M/o will start rolling through control valve. Observe that M/o speed is rising steadily. Turning gear gate valve closes at @ 240 rpm. JOP I trips at @ 540 rpm. (If JOP II is running, it is required to be hand tripped at @ 540 rpm Check that turbine speed stabilises at @ 600 rpm. Allow the machine to soak at 600 rpm for @ 1 hr.

CHECK THAT: -

Watch drum level and control it during speed raising. Watch drum pressure and increase firing rate if required (Normally 6 to 8 LV guns are sufficient at 7 kgcm oil pressure) Maintain drum pressure at @ 35 kgcm. Observe and note down the following parameters at 600 rpm. a. b. c. d. e. f. Turbine overall and diff. expansions axial shift. All diff expansions should move towards positive. Absolute shaft vibrations (especially HP rear/front) and bearing pedestal vibrations. Bearing metal temperature (<90 c) Bearing drain oil temperature (<65 c) And drain oil flow (Observation to be made at local) HPT Top / bottom temperature, inlet HP casing, temperature, HPT exhaust IPT Top / bottom temperature LP exhaust / vaccum. (NOTE: Normally observed parameters are as follows : HP T/B (M) @ 160 / 150 c Inlet HP casing @ 270 c HP exhaust @ 200 c IP T/ B (M) @ 90 c Vaccum 0.91 / kg/cm
26

Observe HPCV and IPCV position (HPCV @ 20% and IPCV just start opening) Soaking is complete when the above parameters stabilise and TSE upper margin is achieved @ 35 K (TSE to be selected in Turbine mode which monitors HP shaft and IP shaft). During soaking period, ensure that none of the above parameters drop drastically. Normally, one hour soaking is sufficient. g. Observe governing system parameters a. Trip fluid b. Control fluid c. Auxiliary trip fluid e. Secondary fluid HP f. Secondary fluid IP 5.2 kg/cm 6.2 kg/cm 5.5 kg/cm 2.6 kg/cm 1.7 kg/cm

d. Auxiliary secondary fluid 3.8 kg/cm

Auxiliary Start up / Start up fluid zero. C-45 Line up heaters from drip side, ensure that LP heaters are already in charged condition from condensate side. Check that LP heaters are properly vented. Put the following drip valves on auto after ensuring that they are operative from PCR. Put the level set point at @ 0 or slightly less as per requirement. HEATER LPH-2 LPH-3 Valve No. DR 21, DR 24 DR 16, DR 19

(NOTE: LPH-1 does not have any level control valve in the drip line) Check that extraction valves Ex-9, Ex-10, Ex- 11 are in closed position and extraction line drain valves Ex-101/102 (LPH2), Ex-103 (LHP-3), Ex-113 (LHP-1) are in open position. (Ex-113 is manual valve) Check that test valves of extraction NRV actuators are open & 220 V supply to NRV solenoid is available. Check that red indication showing de energized condition of that solenoid is persisting. The red indication shows that valves are ready to open. The green indication shows that solenoids energized and valve can not open.

C-46 Inform GCR staff to close the isolators of generators circuit breaker with proper bus selection. Ensure that GCB spring is in charged condition and indication to that effect is available in PCR, Check for semaphore indications of isolators in PCR. Check 220 KV bus voltage in PCR.

C-46 After soaking the M/C at 600 rpm, proceed to raise the speed further. Raise speed ref. set point to 3000 rpm (or slightly more is 3040 rpm) Watch that speed is rising continuously and steadily at specified rate of 600 rpm/minute. Turbine critical speeds fall in this zone only. (1545 rpm, 2126 rpm) Watch and note down absolute
27

shaft vibrations of HP/IP rear / front respectively and bearing pedestal vibrations when the m/o is passing through critical speeds. Observe that AOPI trips at @ 2800 rpm. Check MOP discharge pressure (@ 9.7 kgcm ) & lub oil pr. After cooler (@5.5 Kg/cm2) Observe the following: a. Turbine expansions and axial shift. Expansions should steadily increase. b. Absolute shaft vibrations (< 140 ) c. Bearing metal temperature (< 100 c) d. Bearing drain oil temperature (< 65 c) and oil flow e. HPT T/B, inlet HP casing temperature HP exhaust, IP T/B LP exhaust and vaccum. LP exhaust may increase. Check that SLC for LP injection valve is ON it opens at 90 c LP exhaust. Observe governing system parameters. a. Control fluid b. Trip fluid c. d. e. Auxiliary trip fluid pressure Auxiliary secondary fluid pr Secondary fluid pr for HP Secondary fluid pr for IP f. Prim oil pressure @ 8.5 kg/cm @ 7.5 kg/cm @ 7.5 kg/cm @ 3.8 kg/cm @ 3.0 kg/cm @ 2.8 kg/cm @ 2.3 kg/cm

Observe that temperature after lub oil cooler (@ 40 42 c) and seal oil cooler (35-40 c) check that lub oil temperature control is working normal. Observe seal oil/H2 diff. pr and H2 pr (1.5 kgcm and 3.5 kgcm respectively) Watch and maintain drum level, dea. Level and hot well level during speeding up of the turbine. Watch drum pressure and slowly allow it to rise up-to 40-45 kg/cm till the M/C is synchronized. Watch CW inlet temperature and start CT fans (@ 4 Nos) as per requirement. Check CW inlet temperature (> 30 c) and CW diff. pressure across condenser (> 0.4 kg/cm) watch hot well temp. (> 420 c) watch flue gas temp. At furnace exit till the unit is synchronized. Check that hydraulically operated extraction swing check valves (Except A4) open as soon as sec. oil pressure reaches @3.0 kgcm (NOTE : The mechanical design of the valve is such that they are brought into free swinging position by means of trip oil pressure through actuator & then opened by diff. pressure present. The valves are actuated in proportion to secondary oil pressure) Allow the machine to soak at 3000 rpm for @ 15 to 20 minutes. (NOTE I: When starting device is raised to 90% all CVs start opening in proportion to secondary oil pressure HP and IP which starts building up. Maximum Secondary Fluid Pressure Minimum Secondary Fluid Pressure 5.0 kgcm 2.5 kgcm
28

The diff between max & min pressure (2.5 kgcm) correspond to 100% valve opening. (NOTE II: Influence of TSE margin during rolling. The rate of rise of speed is controlled by TSE margin is 0 to 30 c K 0 to 600 rpm/min. If the margin is more than 30 c, the sped increases at constant rate of 600 rpm/min. The rate of change of speed is directly proportional to TSE margin. If TSE is faulted it blocks the further raising the speed or load any how between 600 to 3000 rpm while raising the speed. TSE influence gets bypassed so as to cross the critical speed smoothly. (NOTE III: If rolling is required to be done by hydraulic governing, EHG controller should be kept in max. position. The start up device is operated and at 56% HPCVs start opening first followed by IPCVs. The speed is kept 600 rpm. For soaking till TSE margin is achieved 35 k. Further speed is raised by operating start up device to max. Position. With this the speed can be raised to 2400 rpm. Further speed is raised by speeder gear. As the M/C is soaking at 3000 rpm, check and line up excitation system. Ensure that following electrical supply to excitation system is ON 1) 48V DC Source I and II from 24 V battery charger feeder No 07E/10 F respectively. 2) 220 V DC Main DCDB feeder No.01 D 3) 415 V 3 , AC supply for field flashing Turb MCC (2 KA 15 B) 4) 220 V DC for field flashing Main DCDB 2 FA @ 1A 5) 1 , 240 V AC supply from UPS - Check that pressurizing fans for thyrister panel room are running normal. C-49 TA Set is ready for synchronization now. Check drum pressure (@ 40 42 kgcm ). Increase firing rate if required by adding additional guns. Watch drum level and maintain it slightly on lower side as it swells very fast after synchronization. Now proceed to built up voltage & synchronize the set on auto check that, 1) 2) 3) 4) 5) 6) 7) Load control is ON Adjust load limit to suitable valve (@ 30 MW). However, it can be adjusted as per requirement. Load gradient @ 10% to 12 % Load reference 20 MW HP/IP trimming device ON AVR on auto selection Field breaker selection on Remote
29

Switch ON field breaker. Field flashing will get (ON automatically check the semaphore indication of field breaker and Red indication of field flashing on control desk. Voltage will start building up fast up-to 7 KV and then slowly up-to 15.75 KV. Observe generator field voltage and field current. Check generator voltage phase to phase and phase to neutral. Check that GTR cooling oil pump selection switch is on AUTO ON selection and cooling control selection switch on AUTO check that pump selection is also normal. Check that 415V AC 3 supply (Source I/II) to GT marshalling panel is available. Check both the isolator switches in marshalling panel are ON and either of the two control supply switches is ON Check that Supply ON lamp on unit transformer panel in PCR is glowing. Select synchronizer selector switch to Check position. Observe the displayed parameters as follows. a) Running voltage and incoming voltage. Adjust the incoming voltage by Raise or Lower push button to the running (grid) voltage. b) Running frequency and incoming frequency. Adjust the incoming frequency to running frequency (grid) through key-lock switch . Observe that needle of sychronoscope by suitably varying the turb- speed by speed reference. Switch ON synchroscope is rotating slowly in clock wise fast direction. If this rotation is very fast or anticlockwise or if the needle is stationery, then speed of the incoming machine is to be adjusted by speed reference such that the needle is rotating Slowly in Clock wise fast direction. When proper position of synchronizing is achieved Check synchronizing

indication appears (i.e. the needle is just approaching the mark of correct phase on synchroscope). Synchronize the set to grid and pick up 5 to 7 MW load with the help of speed ref. The TSE disc will switch over to load side and will start showing upper load margin. (NOTE: If AVR is on manual and voltage is built up on manual mode, Then to put the excitation control on auto, Adjust the null point to zero on matching voltmeter and put the excitation control on auto). Auto Synchronizing 1) Keep AVR on Auto 2) Keep synchronizing selector switch on Auto 3) Switch ON auto synchronizer in turbine desk. Synchronizer started and Synchronizer ON lamps will glow. 4) Speed and voltage will be matched on auto. 5) As soon as check synchronizer and auto synchronizer commands match, the set gets a synchronized and @ 5 to 7 MW load will be picked up on auto. Check that HT cooling oil pump has picked up on auto. Switch off synchronizer selector
30

switch and synchroscope on generator desk. Watch drum level and control it carefully as it has tendency to swell. Watch and maintain drum pressure. Observe and adjust power factor @ 0-85 to 0.9 lagging. Check RMVA observe rotor temp. Check HP/IP tracking device is ON. Observe generator current in each phase. Charge the generator transformer oil cooler from water side. Observe the following parameters of GTR. a. Winding temperature HV/LV b. Oil temperature c. Cooling water pressure to GTR before APRV d. Cooling water pressure inlet to cooler e. Oil pressure at inlet to cooler f. Diff pressure between oil / water (< 90 c) (< 90 c) @ 1.0 kgcm @ 0.35 kgcm @ 0.7 kgcm @ 0.35 kgcm

Check that oil pressure is always more than water pressure. Take out furnace probe and check its out position at local. Switch off its module from boiler MCC. Close all the drains on turbine side (i.e. SLC drains) if drains are on manual or check that they close on auto as per temperature criteria. Check and note the following parameters. a) Turbine expansion and axial shift. b) Bearing metal temperature c) Absolute shaft and bearing pedestal vibrations. d) HP exhaust, LP exhaust, vacuum. e) Gen slot temperature / core temperature Let the M/C soak at 5 to 7 MW for @ 15-20 min. or till further margin is available. Following are the expected parameters. Drum Pressure SH Steam temperature R.H. Steam temperature 50 kg/cm 380 C 360 C

Check that CRH NRVs have opened and the indication has appeared in PCR (These NRVs are also operated in proportion to the pressure in secondary oil circuit. The check valve open fully when main control valves have reached a lift a 5 to 10% of max. Turbine output. During start up, when the steam pressure upstream of check valves is approx 1 bar greater than the down stream and at the same time secondary oil pressure has not built up to open the valve , the steam pressure opens the valve & the Open position is indicated in PCR by limit switch. Charge LP heaters I, II, III one by one by opening their respective steam extraction valves. (Ex 9, 10, and 11). Check that line drain valves (Ex 113, 102 Ex 101/102) close on auto. Watch the drip levels in LPHS on DAS and on bar indicators (for LPH 2/3 only) Watch LPHs levels are maintained at normal valve and note the drip valve positions. Check the extraction steam pressure, condensate temperature at each heater outlet. Watch drip level in gauge glass and compare it with levels in bar indicators.
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C-50 Watch TSE upper margin for load and slowly increase the load through speed reference. Up-till now Speed Control is active. With the help of speed ref. and load ref. try to put Load Control in service so as to have better load control. Up-till now, HP/LP bypass is in service. If HP bypass is on auto then valves will close down to maintain the set drum pressure and if bypass is not on auto slowly close the valves watching drum pressure and drum level. LP bypass sliding set point comes into action after synchronization. This set point is generated from the 1 st stage pressure at HP blading. LP bypass valves get closed on auto. Watch hot well level and CEP discharge pressure in header (If two CEPs are running, one can be stopped now) As soon as sliding set point comes into service, LPBP auto interface get off. Put HP bypass control on auto (If it is not on auto) HP bypass sliding set point generated from UDC will maintain pressure always 08 to 10 kgcm above MS pressure, provided. a) HPBP desk set point is in auto mode. b) GCB is closed. c) Boiler MS outlet pressure is less than superheat safety valve setting pressure. If MS outlet pressure is more than safety valve setting, it will load to fast opening of HPBP valves. Desk normal set point will track to auto set point. In case of tripping of unit, it will automatically switch over to desk set point mode and will maintain at last valve of pressure. Set HPBP temperature setting at @ 380 c (Or at least 50 c higher than CRH temperature but not more than 380 c) (NOTE: at @ 20% of the load, load reference comes into action and now load can be raised by load reference. Load ref active indication will appear and Speed ref. active Indication will disappear). Slowly raise the drum pressure to @ 70 kgcm and load to @ 35 MW firing rate to be increased if required. Normally, following parameters can be maintained.
Drum Pr kgcm 50 60 70 Load 15 20/22 30/35 SH temperature 360/370 400/410 420/430 LV guns. 8 9 10

Adjust burner till to maintain reheat temperature. Reheat spray may be avoided as far as possible. Maintain load at @ 30 MW for 20 mm for soaking and observe various parameters as per previous steps. Observe feed flow and check that recirculation valve closes when feed flow exceeds 220 T/hr. observe H2 cold gas temperature (44c) and hot gas
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temperature, stator water temperature at inlet and outlet from generator. Observe stator water diff pressure across the filters. When machine is soaked at 3000 rpm. It is better to carry out ATT for protective device to confirm their healthiners. a) Over speed test by injection b) Axial shift trip c) Low vaccum (hydraulic) trip d) Remote trip solenoid 1 and 2 Tests b.c. d, are fortnightly test and over speed testing may be done after a hot trip once in a month (A) Over-speed Testing : 1. Stand facing towards governing stand. 2. Press left hand side know (i.e. valve KA03) and hold it in the depressed position. This isolates aux. trip oil circuit from over-speed trips. 3. Open hand wheel (KA01) till test pressure goes to @ 1.6/1.8 kgcm Operation of hand wheel moves centre valve downwards and blocks the drain. Now control oil flows into over-speed trip. 4. Auxiliary trip oil pressure will drop to zero and striker will operate compare the result with previous one. Any deviation will indicate defect in over speed trip. Raise test oil pressure further to 2 kgcm . 5. As soon as aux. trip oil pressure drops to zero close the hand wheel (KA01) till test pressure drops to zero. 6. Press knob on RHS downwards till aux. trip oil circuit pressure builds up-to 6.0 kgcm. 7. Release knob (KA03) If when knob KA02 is released and aux. trip oil pressure collapses, than KA02 should be held in depressed position for longer time. It is necessary that aux. trip oil pressure must remain steady before KA03 is released.

C-52

As soon as the PRDS is charged and stabilized, start dea pegging by opening dea steam pressure regulating valve CR 306. Ensure that valve As 365 is open. Open CR 306 and start deaerating the incoming condensate water. Watch dea temperature which should rise. Once the dea temperature exceeds @120c the pressure starts building up. Once the pressure reaches @3.5 kgcm , put control valve CR 306 on auto. Observe deaerator level and hot-well level. Check that pressure control by pass valve CR 309 is in closed condition. It is a motorised inching type valve.
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(NOTE: Variable pressure operation of deaerator has been envisaged in the system. Under normal conditions, dea is supplied with steam from turb., extractions. The dea pressure varies from 3.5 ata at approx 55% load (i.e. @ 120 MW) to 6.6 ata at 100% load. Minimum 3.5 ata is pressure is always maintained. At load below 55% the turb extraction pressure is less than 3.5 ata, dea is provided with steam from CRH. When turb extraction is not available during condition such as load rejection, the pressure decay rate is arrested by modulating CPV to avoid flashing. During cold start up dea pressure is maintained at 3.5 ata through pressure control valve (CR 306). The steam is supplied from aux PRDS by keeping electrically operated ON/OFF control valve AS 365 open and by keeping motorised valve CR 303 (in CRH line) closed. When CRH pressure reaches 6 ata, switch PS 201 in CRH line opens the valve CR 303 and dea pressure is maintained through CR 306. When load exceeds 55% (@ 120 exceeds 3.5 ata, the motorised valve Ex 301 in extraction line (A4) allows flow of steam to dea Extraction A4 NRV also opens when diff. pressure of 300 mm WCL is created ahead of NRV)

C-53

When load on Unit is @ 20-25 MW UAT may be taken into service. Total 4 breakers of 6.6 KV for each unit are involved in change over. a) Unit Boards 1CA and 1CB 2CA and 2CB b) Station Boards 0 CA/ 0 CB 0 CC/ 0 CD for Unit I for Unit II for Unit I for Unit II

The unit boards are supplied by respective unit aux. transformers and station boards are supplied by Station transformer I (for Unit I) and station transformer No. II (for Unit II). Total 8 panels are involved in bus change over (4 far each Unit) BTS 1 to 4 ( For Unit I) BTS 5 to 8 (For Unit II) The system is provided with different selectable modes of transfer through switch S2 . a) Manual fast Manually through fast mode and this mode is usually used. b) Manual slow Manually through slow mode. It will give trip command to preselected auxiliaries.
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c) Momentary paralleling manually by paralleling the two supplies momentarily. This is not used. d) Auto Mode : The system would first select fast mode and in the event of any problem, it will switch over to slow mode. Charge over can be initiated manually in both direction but automatic changeover is possible only from UAT to Station bus. Functions of various actuators and push buttons in the panes. Designation 1 2 3 4 PB I PB II PB III PB 4 Test Test Rest Lamp Test DF failed Ready for Transfer Legend Function Scheme Testing For resetting after test operation For lamp test and if DC fails on bus transfer parameters Used for all manual change over if all conditions are of bus transfer are fulfilled Used for reseting after transfer failure, conditions are removed DC Control supply to the closing circuit of the bus transfer system

5 6

PB 5 S I Switch

Blocking Reset D Control Supply

(S-I Switch is located in BTS-I) for Unit No. 1 and BTS-5 for Unit No.2 The aux. DC Supply is derived from two independent DC supply sources DCDB-I and DCDB-II one of the source is selected by selector switch S-I with three 1) DCDB-I 2) DCDB-II 3) Off 7 8 Selector Switch S2 Selector Switch S3 For selection mode of transfer Bus transfer selector switch IN position to carry out change over

Before carrying out change over ensure the following : 1) Unit bus PT5 (ie ICA / ICB or 2 CA/CB), Station bus PTs (OCA/OCB or OCC/OCD) and incomer PTs are racked in service position. 2) 6.6 KV breakers of Unit incomer tie breaker from station bus to unit bus (ie on ICA/ICB or 2CA/2CB) in service position with DC supply ON
35

3) AC Supply to marshalling panel of unit aux. transformer to be made available and cooling fans are ready for service. 4) Tap position of UAT is properly selected. Check the healthiness of all the components involved in change over by pressing PB-I (Test). This helps in checking the operations of concerned circuit breakers for continuity. Fictitious indications I/o breaker CB I close (Test mode and Tie breaker CB-2 open (Test mode) will appear without actually operating the breakers. During test following indications will appear. a) b) After test, push PB-2 to reset the after test indication. Check that ready for fast change over indication is glowing. This will be available only if. a) Aux. D.C. supply is ON (i.e. switch S-I ON) b) I/o breaker CB-I trip supply ON (Trip circuit supervision I/c breaker CB-I actual) indication will be persisting. c) Tie breaker CB-2 trip supply ON (i.e. trip circuit supervision tie breaker CB-2 actual) indication will be persisting. d) I/c breaker and tie breaker closing supply ON (Closing circuit supervision CB-1 and tie breaker CB-2 actual) indication will be persisting. e) Over current relay on I/c breaker and tie breaker should be reset. Push the push button PB-4 and supply change over will take place. I/c breaker CB-1 close actual and tie breaker CB-2 open actual remain persisting. Observe that load has actually transferred which is in dictated by the respective, ammeters, MW meters. Check the voltage of unit boards. Check UAT oil winding temperature. Check that cooling fans start at proper temperature. indication will appear and

C-54 Check that drum level control is properly working with low load line valve FD 20. Up-to 30% load i.e. 70MW low load line may be continued. Single element drum level control is working only. During this, FD 20 may be put on auto and level to be controlled by scoop on manual. Line up main feed lines (i.e. FD 21 and FD 22) and ensure that they are ready for service.

C-55 Line up preferably lower most coal cycle A or B. Start the first seal air fan after ensuring the following
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a) Suction filter is clean and diff. pressure across filter is normal is @35 mm WCL b) FSSS supply is OK c) Seal air dampers to mills and feeders are open (SLD for mills and SLD for feeder) Start the fan and observe normal current (50A to 150A variation) Ensure that other fans are also ready for service. Ensure that the C/o to be started is lined up. Check that all permissives for starting PA fan are available. The PA fan ready amber lamp will glow only when, following permissives are fulfilled. 1) Seal air blower diff pressure is OK (> 200 mm WCL) is at least one seal air fan is running and seal air damper to mills is open. 2) Hot air gate closed 3) No MFR trip 4) Inlet damper PAD 5 in min. position 5) Pulveriser ignition permit (i.e. at least 3 oil guns of associated elevation are already in service) ] 6) Cold air damper PAD2 is open more than 5% Start PA fan and observe the normalized current (@ 22A) Check that following permissives are available for starting the coal mill. 1. Lub oil permissive, Lub oil pressure OK will be available only when. a) Lub oil pressure is not low (> 1.5 kgcm) b) Oil sump level is normal (If not, pumps will not start) c) Sump oil temperature normal (> 15) d) Lub oil filter is clean and diff pressure across filters is less than 1.5 kgcm check that one lub oil pump is running and other is auto load. 2. Seal air blower p > 200 mm WCL is seal air fan running and seal air damper to mill is open 3. Pulveriser discharge valve (i.e. MBV) open 4. Pulveriser outlet temperature < 94 c 5. Associated PA fan ON 6. Ignition permissive is associated guns in service 7. Feeder inlet gate open (This interlock is by passed. But it is necessary to check that feeder inlet knife gate (at least one out of two) is open. 8. Cold air gate open 9. Trap iron hopper (i.e. Reject gate valve open. This interlock is by passed. Hence it is necessary to check it physically. 10. All burner gates open (Not included hence necessary to check at site) 11. Pulveriser / feeder start permissive
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12. No auto pulveriser unsuccessful start. (This is also by passed) Check that feeder inlet rod gates are open and bunker level in normal. Start mill from PSSS contacts (Say 1). Watch furnace draft and drum level and maintain it carefully. Observe till normalized current (22A). Open hot air shut off gate. Check that seal air blower starts on auto or otherwise start the blower. Now open hot air and cold air dampers and manipulate their openings in such a way that primary flow to the mill is @ 75 T/hr.. The temperature at mill outlet gradually rises to @ 77c. Watch furnace draft. Observe PA discharge pressure. (@700 to 750 mm WCL) and PA temperature at mill inlet (@180 to 200 c) Observe total air flow and gradually bring it down to original valve with the help of FD fans. Watch furnace draft. Check that fuel air damper control is on auto (If control is on manual open the associated damper manually after 50 Sec of start of feeder to max 20%) Start raw coal feeder. Observe feeder current (8A) Raise the feeder speed as per requirement watch furnace draft and drum level and maintain it watch mill loading and feeder loading (@ 10 to 12 A). As mill gate loaded (@ 25A) the mill temperature starts dropping. Maintain mill temperature @ 77 c by modulating hot / cold air damper keeping PA flow to mill constant @ 55 T/hr. Observe blower diff pressure (@ 200 t0 250 mm WCL) and maintain it. Now, the fire ball scanners will sense the flame and will be indicated by red lamp on desk. Ensure that flame stable. Check the scanner intensity in FSSS panel and ensure that it is > 40%. As the coal cycle has come in service, the steam parameters (pressure/temperature) will start rising. Raise the load production-etely and allow pressure to rise to 80 kg/cm by adjusting coal feeding and reduce oil pressure suitably to conserve oil. Watch and maintain drum level hot well level, deaerator level. Observe gradual rise in flue gas temperature, air temperature and steam temperature. Following are expected parameters. Drum pressure (kg/cm) 80 90 100 110 Load (MW) 35 40 50 70 Steam temperature (c) 420 / 430 430 / 440 440 / 450 480 / 490

Observe feed-flow and check that recirculation valve closes when feed flow exceeds 220 T/hr. Raise the load to 40 / 45 MW watching TSE margin and maintaining drum pressure as above. Let the machine soak for some time (@ 20 min.) at 40 / 45 MW till load margin is available. Slowly raise the load to 70 MW in a period of 50 min. and soak the machine for @ 30 minutes. Watch steam temperature and pressure as far as possible, SH spray and HH spray is not required. Watch furnace draft (- 3mm WCL) drum level (0 on recorder) dea level (@ 1900 mm), hot well level (850mm). Watch DM make up on DAS and make up valve opening DM 32/35 on desk. Watch OH RM CST, levels and maintain them. Observe gradual rise in flue gas temperature and air temperature at different points. Watch draft ganges at various points. Observe sup & R/H metal temperature (< 550c). As boiler load is being raised, air flow should be adjusted proportionately with steam flow (air / steam ration approx 1.2) Check that oxygen percentage at air heater outlet is @ 4.5% (NOTE : Approximate air quantity required for various loads as calculated from the curve given is as follows. Load MW up-to 80 MW Total air flow T/hr. 300 T/hr.
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90 100 120 130 140 150 160 170 180 190 200 210

320 360 440 492 532 563 603 643 682 714 754 792

C-56 Line up attempt perator circuit from S.H. and R.H. Ensure that isolating valves before / after spray control valves are open and attemperation line drains are closed. Check that both main / stand by lines are ready for service. Check that SH spray block valve (S 52) and RH spray block valve (R 7) are operative from PCR. Ensure that 220 V DC supply to RH block valve solenoid is available. S.H. spray can be cut in and / or burner filt position can be varied. When so required by manual control of spray valves (S67, S68 or S70 & S60, S61 or S58 for superheat. R16 or R10 and R22 & R25 for reheater) Observe SH atlemperation flow (L/R) when spray is given and burner tlt position when it is varied. Reheat temperature is controlled by tilting the burhers, thus shifting the fire ball up or down to increase or decrease the heat transfer in reheat zone. As a back up, spray in reheater is used. When tilt comes down (-10c) or below and reheat temperature is still more than set point (540c) both CVs come into operation (if on auto) to maintain the temperature. However, whenever the tilt is above. -10 position & control is on auto, then RH spray valves remain closed on auto. Observe SH temperature before / after attemperation. Check that steam temperature after attemperation does not drop below the saturation temperature corresponding to drum pressure. This is to avoid the quenching of steady. Ensure that there is no diff. between LHs / RHs steam temperature.

C-57 Gradually raise the load to @70 MW and soak the M/o for @ 20 minutes. Observe steam parameters. Observe generator currents in all phases. Observe generator transformer winding temperature (HV/LV) and oil temperature. Observe generator rotor temperature.
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Proceed to put S/H and R/H spray water controls and burner tilt control on auto. Set the desired temperature of S.H. steam with the help of set point setter. Observe deviation in desired temperature at SH outlet. Bring deviation to zero by raise / lower push button, and then put the system on auto. Put burner tilt and RH spray on auto similarly. The set points of SH and RH temperature control is to be slided up as per requirement such that desired temperature at boiler outlet is achieved. If settler is put on auto the sliding set points as per drum pressure / load will come in service.

C-58 Put the available next coal cycle in service (Preferably consecutive) as per the load requirement and when the running coal feeder reaches feeding @80% i.e. (700 rpm). When 2nd coal cycle is proven in service, equalize coal feeder feedings. The oil guns need to be continued in service until the feeder ratting of the two feeders exceed 50% of the maximum i.e. 600 rpm each. (NOTE : If the adjacent coal cycle is not available for service, place coal cycle serving the next closest elevation in service. Do not remove the oil support till two adjacent coal cycles are in service with coal feeding on each more than 50% i.e. 600 rpm) C-59 When coal cycle is taken in service, the steam parameters will start rising and hence load should be increased accordingly to maintain required steam temperature and pressure.

C-59 When load on machine stabilises at @ 85 to 90 MW, HPH-5 may be charged from steam side and when load stabilises at 100 / 110 MW HPH-6 may be put in service. Ensure that HPHs are already charged from feed side. Proceed to charge HPHs from steam side as follows. Ensure that drip valves DR-2, DR-34, DR-11 are in neutral position and air supply for their operation is available. Check that these valves are operative from PCR. Check that manual iso, valves before after the valves are open. Check that motorised valves DR-36, DR-312, DR-304 are available for service and are in closed position.

DR 2 DR 36 DR 14 DR 11 DR 34 DR 6 DR 312

Drip of HPH 6 to HPH 5 By pass of DR-2 Drip of HPH-5 to flash-box Drip of HPH-5 to dea. Drip of HPH-6 to flash box Drip of HPH-6 to dea. By pass of DR-6
40

DR 304

By pass of DR-11

Ensure that all the float switches (i.e. low, high, very high) for both the HPHs are in service, and GG are also available. Put the drip valves on auto after putting the level set point a zero or slightly less as per requirement. Open extraction valve Ex-113 for HPH-5 Check that extraction line drain Ex-112 closes on interlock.

Observe that drip level in HPH 5/6 start rising and are maintained at normal level as per setting. Check that drip valves are functioning normal on auto. Check levels in gauge glass. Observe the rise in feed water temperature at HPH outlet. Observe rise in feed-water temperature before and after economiser. Observe rise in-total steam flow. Watch drum level, dea level, hot well level and maintain them. Observe flue gas temperature and air temperature after air heater. Observe flue gas temperature after economiser which would rise.

(NOTE : The HPH level control is normally as follows : HPH 6 : The normal level of HPH 6 is controlled by DR-2 cascading to HPH-5. When HPH-5 level is high or HPH-5 pressure is low, DR-2 valve is closed on priority and level is controlled through DR-6 taking HPH-6 drip to dea. In case of HPH-6 high level drip is cascaded to condenser through DR-34. HPH-5 During low load operation (50%) HPH-5 drip will be diverted to condenser through DR-14. When load exceeds 50% level is controlled through DR-11 diverting it to dea. When level reaches high DR-14 will be opened.

C-60 At the load is reached 70 MW, main feed line is required to be taken in service. Check that both main feed line loops are available (i.e. FD-21 and FD-22) Up-to 30% load i.e (@ 70 MW) Single element control is effective. When the load exceeds 30% three element control is used to take care of swelling and shrinking effect with load fluctuations. Three parameters including are drum level, steam flow, and feed flow. Either of the full load regulation valve i.e. FD-21 or FD-22 can be taken in service depending upon availability. During process of change over, closely watch feed water pressure at BFP discharge header and at Eco inlet. Watch feed flow which should remain constant during changeover. Take control of low load feed valve FD-20 on manual. Open slowly main feed valve i.e. FD-21 or FD-22 simultaneously closing the low load valve FD-20 such that the feed pressure and feed flow remain constant. Close FD-20 fully and keep it ready
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for service. Ensure that other full load line is also available. After changeover, put the control valve and scope on auto and select diff pressure mode for auto. (NOTE : Normally, it is better to keep valve on manual and operate it as per requirement to get sufficient p for spray i.e. 3 element control to be used)

C-61 Load is gradually raised as per TSE margin as coal mill capacity. When the load is @100 MW proceed to start the 2nd air cycle if only one air cycle is running. Line up ID / FD fans to be started IF fan selector switch to be selected carefully. This key selector switch is provided on boiler desk I a) ID Fan selector switch When key selector notch is vertical the 1) ID Fan B will trip (i.e. it also means ID fan A is selected to run) b) When key selector notch is vertical the 1) ID Fan A will trip (i.e. it also means ID fan B is selected to run)

Now it may please be remembered that whichever fan is started, the selector switch should kept Trip position of that particular fan to be started. If initially i.e. in the beginning ID fan A is started, then keep selector switch in vertical position so that ID fan A is selected to run and ID fan B can be started when ever required. Start the fan (Say A) as per FSSS sequence with proper selection of switch observe normalized current (65 A) Watch furnace draft and maintain if at @-5 mm WCL by regulating the inlet vanes of running ID fan A. Check that all dampers of ID Fan B open on interlock as per FSSS logic. Slowly increase the inlet vanes of ID fan B at the same time decreasing that of ID fan A But all the time watching and maintaining furnace draft normal (.-5) Check that loading on each fan is equalized as shown by their amperes and vane position. Put both ID fans on auto.

C-62 Selector switch positions for FD fans are similar to ID fan. a) When key selector notch is vertical FD fan B will trip.

b) When key selector notch is horizontal FD fan A will trip.

Keep the selector notch in trip position of that particular fan to be started.
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(NOTE : The selector switch is for selective tripping of FD fan when one of the ID fan trips) Observe secondary air flow of running FD fan A which is to be equally shared by the two tans now. Start FD fan B with selector notch is vertical position. Observe the acceleration time (< 5 sec.) and normal current (@ 35 A) Watch furnace draft. Watch total air flow and maintain it at the same level by regulating the inlet guide vanes of FD Fan A Check that discharge damper of FD fan B opens on interlock. Slowly increase the inlet vanes of FD fan B at the same time decreasing that of A such that total air flow remains constant and secondary air flow is shared equally by both the fans. Watch ampere loading on each fan and ensure equal loading. Observe vane position. Charge 2nd steam co air pre-heater by admitting aux. steam. Maintain air temperature @ 70c at inlet to air heater. Observe secondary air pressure at various points of the system. Observe gas drafts at various points. Observe flue gas / air temperature. (NOTE : Although it is sufficient to operate one set of fans till 100 MW load is picked up, but it may be desirable to run both air cycles before light up or during 20 kg/cm boiler blow down in order to avoid unbalancing of air flow when carrying load.)

C-63 If only one CW pump is running, the other CW pump is required to be started before increasing load above 120 MW. CW PUMP NO. I & II CW PUMP NO. 4 & 5 CW PUMP NO. 3 FOR UNIT I FOR UNIT II COMMONSTAND BY

Start 2nd CW pump as per procedure, described in previous paragraphs. Observe normalized current after discharge valve is fully opened (@ 160A) Observe pump discharge pressure (@ 2.2 /cm ) and CW pressure at condenser inlet / outlet (2.1 0 1.9 kgcm) Watch CW sump level (290.4 MEL) and start make up if required. Observe CW inlet / outlet temperature at condenser. Start more CT fans as per requirement to maintain CW inlet temperature @ 30 30 c. Observe condenser vacuum / LPT exhaust hood temperature. Observe H 2 cooler inlet / outlet temperature lub oil temperature.

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C-64 2nd Boiler feed pump is required to be started raising load above 120 MW. Line up the BFP to be started. Check booster pump suction pressure (@ 6.0 kgcm) Start the pump and observe the normalized current (120 A) Check that its cooling water valve open on interlock. Observe BFP suction flow, suction pressure, discharge pressure, diff temperature across main pump suction / discharge (4 - 6 c), Watch motor winding temperature (< 50 c) and pump bearing temperature (< 60 c). Open main pump discharge valve slowly open scoop tube of the pump started at the same time decreasing the scoop of already running BFP such that total feed flow remains constant, check that ampere loading of both BFPs is almost equal which is further ensured by equal suction flow, equal scoop position. Care is to be taken while manipulating scoop tube position so that BFP discharge pressure does not drop below trip value. Observe that recirculation valves close on inter lock when its discharge flow go above 220 T/hr. Observe feed pressure / temperature observe booster pump suction pressure of 3rd pump. Ensure that pump is lined up. Put the pump on auto selection and check that its scoop is tracking the running pump scoop position and its discharge valve is open.

C-65 Mill system are to be cut in service one by one allowing sufficient time for stabilization and as per requirements of steam parameters and load. Load is to raised gradually to NCR value. (Say mill 'C' is to be taken is service) Before starting mill 'C' check that coal mill 'B' is locked more than 50% (Oil guns at AB elevation are already in service) or minimum 3 out of 4 guns are proven at CD elevation. Start the coal cycle as per procedure. Watch different parameters as observed while taking previous coal mills. Gradually increase the load as steam parameters are increasing.

Maintain drum level / Dea level / hot-well level.

Watch and maintain SH and RH temperature.

As per load margin and mill availability, cut in next cycle. C/c can be cut in after verifying that either three out of four guns are proved at CD elevation or mill C is loaded more than 50% and boiler load is greater than 30% This ensures the ignition energy for mill 2D. As load is increased, watch flame visually, Check that fire ball discriminating scanners are showing healthy flame. Reduce oil support or
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with draw the support to conserve the oil. The oil elevation is shut down by depressing the 'Pair Stop' push button. When pair '1-3' Stop push button is depressed, the following will happen. 1. A stop command is established for associated pair and "375 Sec" pair stop counting is started. Corner I gets stop command first. 2. When a corner gets stop command the HO nozzle valve is closed and scavenge valve is opened provided atomizing steam nozzle valve is opened, provided atomizing steam nozzle valve is open. 3. The start scavenge signal gives command to HEA igniter to advance HEA igniter will give sparks for loses and will retract. 4. 15 Sec. after the PB is depressed, corner 3 gets command as corner I and scavenge valve will close. The sequence is similar for pair (2 - 4) A back - up trip command is provided after 360 Sec. after both the parts are stopped. Watch closely HP pressure, furnace draft, drum level and flame scanners. The oil pressure will scoop up which would be controlled by HO 11 on auto observe atomizing steam pressure (6.0 kgcm) (NOTE : Stable and good combustion is recognized as follows. The colour of the flame as observed through peephole should be pale orange on coal firing and @300 to 400 mm away from burner tip. For removing oil support, keep adjacent mills in service as for as possible. Do not skip more than one tier otherwise oil support is required. Flame is stable when mill is loaded more than 50%)

C-66 When load is @ 120 MW and condensate flow is @ 350 T/ht, open manually operated bypass valve CD 9 of main ejectors. Watch main condensate flow closely.

C-67 Gradually raise the load on machine to 210 MW in @70 minutes as the heat input to boiler is increased by running four cycles and steam parameters are increasing. If coal cycle E is required to be put in service (because C/c c or D is not available or due to poor coal quantity 5 tg mill is required) Check that either minimum three out of four, oil guns are proved at EF elevation or pulveriser D is loaded more than 50% and boiler load is more than 30% get ignition permissive for C/c E. Start C/c E as per procedure At full load, following steam parameters are to be maintained. Main Steam temperature Hot reheat steam temperature Main steam pressure 535 c 535 c 149 kgcm
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Observe the opening of HPCV I/II and IPCV I/II. Normally IPCVS are full open and HPCVs are open @ 35 to 45% at rated inlet pressure. Observe the gradual rise and ten stabilized parameters of flue gas temperature, air temperature, steam temperature, compare the readings with rated parameters. Observe generator currents In R/Y/B phases, gen. field current, gen. transformer winding / oil temperature, rotor temperature and neg. phase seq. value. Observe the gradual rise and then stabilized parameters and pressure drops of flue gas / air feed water / steam pressures. Observe stabilized values of total air flow, steam flow and feed water flow. Observe DM water make up flow. Observe the diff. between feed flow / steam flow. Check ow inlet / outlet temperature at condenser and ensure that diff. temperature is less than 10 c. Check H2 cylinder consumption (> 2 cylinder per day) and H 2 purity. Check H2 / CO2 cylinder stock (Min. 15 CO 2 cylinder should be available) Check that all auto loops are functioning normal. Check excitation system and ensure that all thyrister bridges are in service. Note down their currents and check that they are sharing equal load check that there is no sparking at the slip-ring. Ensure that slip stabilization circuit is in service and is working normal. It comes into service at @ 70MW load. Check auxiliary consumption of the unit (which should not exceed 10%) Check stack emission. Ensure that ESP fields are normal. Check that ash evacuation is normal. Check excess air by carrying out gas analysis by or stat apparatus and compare the readings with PCR indicators. Check turbine expansions on local gauges and compare them with PCR indicators.

C-68 When coal mills are stabilized over 50% of its own loading, put the control of PA flow through mill and mill outlet temperature on auto. Keep a watch on loadings of the mill differentials ( P 250mm WCL), PA flow through mills ( < 50 T/hr) and mills current (@ 32A) and mill temperature (70c - 75c). If any individual mill is getting overloaded as indicated by above parameters then reduce the feeder speed to get the parameters normal. Watch the mill reject and remove it periodically depending upon reject quantity. If mills differentials of all the four running mills is going high, cut into operation the 5th coal cycle to reduce the general trend of overloading. Check PE fitness and ensure that it is normal (70% through 200 mesh.) Adjust the classifier angle to get proper fitness. Check for any mills coal pipe checking. If coal pipe is choked up, no coal powder comes out at that particular corner in the furnace and pipe is too cold to touch.

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Ensure the following when coal mills are running. a) Reject handling system is running normal. b) Fire quenching system for coal mills is in service. c) No coal leakages are present or if developed, they are attended on priority to avoid fire hazards and dust nuisance. C-69 Deaerator pegging is from APRDS so for and pressure is maintained at @3.5 kgcm. When CRH pressure reaches @ 6 to 7 kgcm , ensure that electrically operated valve (CR 303) opens on interlock and As 365 valve in APRDS line closes. Check that pressure is maintained constant @ 3.5 kgcm . Watch APRDS flow which would reduce. Watch APRDS pressure and temperature. When load exceeds 55% is @ 110 t0 120 MW Check that steam supply to dea. Changes from CRH to extraction IV (Extraction IV comes into service when a diff. pressure of 300mm WCL is created ahead of extraction. NRV and it takes place at @120MW) EX 301 valve opens and CR 303 closes. Watch dea pressure. Now dea pressure will vary as per load and will maximum reach to 6.5 kgcm . Check that extraction NRV is reset which is indicated by red indication on control desk. Check that steam trap on extraction line IV is in service and its by pass valve Ex 108 is closed.

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C-70 Between load 30 to 60% i.e. 70 MW to 125 MW feed control made may be kept on P mode. When load exceeds 60% i.e. @ 125 MW an indication lamp of load > 60% will appear on drum level control desk. Then pump mode can be selected by depressing the push button for drum level control. Both scoop and valve are kept on auto. Check that diff pressure across valve is maintained @ 6.0 kgcm for better temperature control.

C-71 Check station transformers. Check its tap position, oil/winding temperature. Check the healthiness of supply changeover system from station Xmer No. I to II and vice versa. Following procedures is adopted for changing over load from station Xmer I to II or vice versa. When change over from PCR-I is done, following should be the switch position on bus transfer panel. PCR I a) Switch Ss b) Switch S2 PCR I a) Switch Ss b) Switch S2 If change over is done from PCR-II PCR I a) Switch Ss b) Switch S2 PCR I a) Switch Ss b) Switch S2 tap positions suitably. IN OFF IN Manual Fast IN Manual Fast IN OFF

After changeover, observe the loading and 6.6 KV side voltages. If required adjust

C-72 When HO firing to boiler withdrawn and average cold and temperature of airheater is @70 72 c. take out SCAPH from service by closing steam supply valve AS 323, Observe APRDS flow which should reduce. Observe the response of APRDS i.e. pressure temperature control loops on auto. Observe the gradual falling of air temperature before APH (i.e. after SCAPH) to ambient temperature. Observe secondary air temperature after APH. (NOTE: Average Air heater cold end temperature= Flue gas temperature at AH (Outlet+Ambient temperature)
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When average cold end temperature is @70 72 c, flue gas temperature at air heater outlet will be @ 120 130 c) C-73 When the unit is in operation and if changeover from electro-hydraulic governing to hydraulic governing or vice-versa is to be carried out, then the following procedure is adopted. a. Changeover from hydraulic to electric hydraulic control : If the turbine is operated with hydraulic governor, the speed set point of EHC is set at maximum which prevents EHG from coming into action. To bring in EHC into service, the speed set point of EHC is reduced slowly until secondary oil pressure drops slightly. When this occurs, it indicates that EHC has taken over. The reference speed settler of hydraulic speed governor is set to max. speed. b. Changeover from EHC to hydraulic control : Reduce the set point at the ref. speed settler of hydraulic speed governing till sec. oil pressure drops slightly. Then set EHC set point to maximum, In short following. Procedure is adopted stepwise : 1. Switch off tracking device. 2. Reduce speeder gear till sec. oil pressure drops slightly or load drops slightly. 3. Starting device to be taken to maximum position. 4. Speed reference set point to be taken to maximum.

C-74 Observe the stabilized parameters of the unit and proceed to put boiler master control on auto. Procedure to put boiler master control on auto when unit is run on a) Start up fuel mode b) Coordinated mode (UDC) c) Start up mode pressure will be controlled on auto by adjusting feeder speed provided load is maintained constant. Sequence of operation is as follows. 1) Ensure that fuel master loop is on manual in boiler desk. This will make fuel master as well as start up fuel set point station track to fuel flow. 2) By changing the bias of individual coal feeders, make control deviation zero in feeder auto / manual station take the feeder on auto to achieve bump less transfer. Later the bias station can be adjusted as per requirement. 3) Keep at least two feeders on auto. 4) Press Start up fuel set point RUN push button. This ensures that fuel master station receives set point from start up fuel set point station.
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5) Match the pressure set point on UDC with actual pressure wait till the control deviation becomes zero. 6) Take turbine load control to unit pressure mode. Now load ref. has to be manually raised or lowered as per requirement. 7) Boiler feed flow mode push button has to be pressed to put boiler pressure control on auto. Boiler follow mode and start up fuel mode LEDs will glow in turbine desk. (NOTE : In case of shear pin failure or any other problem in feeder, take feeder control on manual) C-75 Check the bus bar distribution of the units, station transformers and outgoing lines from GCR. There are three buses 1) Main bus I 2) Main bus II 3) Transfer bus Change over iron main bus to transfer bus is carried out as follows from GCR. 1. Close the isolators of GTR towards transfer bus ( 2. Close the transfer bus isolator of transfer bus breakes ( ) )

3. Close the transfer bus isolator of bus I or bus II on which GTR is loaded ( ) 4. Put protection transfer switch from N to I 5. Close transfer bus breaker from generator desk in PCR 6. Open CRR breaker from generator desk in PCR 7. Put protection transfer switch from I position to T position 8. Open isolations of GTR breaker ( 9. Open of GTR breakers ( connected. ) on generator side ) towards main bus to which GTR was

C-76 Check that following miscellaneous systems are available and are working manual : a. Station transformer, UAT and GTR mulsifyre protection system. Check the air compressors working normal on auto and are getting loaded / unloaded at 3.4 / 3.6 kgcm. Check that air header pressure is normal @3.5 kgcm . Check that water line is charged and pressure is @10 kgcm and isolating valves are open. The quartz bulbs in the system are supposed to break when the temperature in the vicinity of transformer is @ 70c.

b. L.T. transformers Ensures that fire fighting indication panel in PCR is in service. Whenever indication regarding L/T transformers appeared in PCR
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check that particular transformer and open the fire fighting isolating valve for spray / remember that LT transformers system is not on auto. c. Check that chimney duct pressurization system is in service. It is desired that a pressure of @50 mm WCL is available at chimney top. d. Ensure that unnecessary lighting is switched off during daytime to reduce auxiliary consumption. e. Ensure that generator bus duct is pressurized and system is working normal (Pressure of @150 mm WCL is required in the duct). #######################################

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