500MW Starting Procedures

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

SYS T E M.
STA RT UP CU RV ES AFT E R 4 8 H OUR S SH AT D O W N W IT H H P/ LP BY PA SS
SYS T E M.
STA RT U P P RO C E DU RE A FT E R 8 H O URS SHU T D O W N W IT H HP/ L P B YP ASS
SYS T E M.
T EC H N ICA L DA TA L IM IT CUR V ES F O R T URB IN E VA LV E S WA LL OF T H E
CAS IN G S HA FT S.
WAR M IN G UP A N D S TAR T IN G T H E TUR B IN E T EM P ER AT UR E CR IT E R IA.
11.
T EC H N ICA L DA TA RE AC T IV E CA PAC IT Y CU RV E F OR TUR B O G E N ERA T ORS .
07.
08.
09.
COLD START UP
(With Aux Steam available)
A cold start up is by definition, one of which the maximum of HP casing and HP shaft is
less than 1500C. This normally means that the unit is shut down from the maximum load
for more than five days. If machine is started from ambient temperature (HPC/HP shaft
temp approx. 400C), heating up of casting is required. This is accomplished by soaking
the machine at 360 rpm at warming up steam parameters (40kg/cm2, 3600 C), till the
TSE margin are satisfactory.
The rifle construction of the water wall combined with the boiler circulating water
pumps permits very high rate of pressure rising of boiler. An upper limit of 2000C/hr
saturation temperature gradient can be allowed, i.e. approximately the boiler pressure
can be brought to 20 kg/cm2 within an hour of cold start up. But actual temperature
gradient is limited by the thick walled Y piece provided in the main steam and HRH lines.
A main steam line heating is to be started as early as possible (at approx. 4 kg/cm 2) as
maximum differential temperature allowed between inner (98%) and mid wall
temperature (50%) is 400C. So boiler loading is accordingly regulated. It may be
preferably to start only two CC pumps in order to minimise flashing in down comers (and
subsequent vibration) when the boiler water is in range of 85 0C to 1250C. The third
pump should be started before drum pressure reaches 7 kg/cm2 to minimise the
temperature transients experienced by the pump casing (this is to avoid fast load out
back on the boiler in the event of any CC pump tripping).
To get the rolling parameters, normally two elevation oil guns are taken with
approx. 70 to 80t/hr flow through HP-LP bypass. At that time M.S. parameters would be
40 kg/cm2 and 3600C, HRH parameters would be 12 kg/cm2 and 3600C.
As soon as the turbine loading has started, HP/LP bypass closes and gets completely
closed as the turbine reaches the boiler load. First mill is put into operation around 10%
of generator load. Second mill is put into operation around 25% while third mill is at
40% of generator load. Fourth and fifth mills are put into operation at 60% and 80% of
generator load respectively. Sixth mill is taken to reach full generator load.
During loading the RH outlet steam temperature has to be kept as close as possible
to SH outlet steam temperature Burner tilt, SH spray, RH spray controls has to be
adjusted accordingly. The turbine-loading rate is decided by a selection circuit which
compares the external load gradient, TSE margin and time dependant gradient (set
internally) and frequency influence.
INTEGRATED START-UP PROCEDURE

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

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

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

LSHS oil.
Start one LSHS pump

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

front and keep it on
long recirculation, with
heaters control set on
Auto to maintain 1101290C.
Fill water in drum upto

+200mm.
Ensure that the suction

and discharge valves of
all the CC pumps are
open and the pump
suction and discharge
lines are vented.
All the steam tracing

lines and electrical
tracings in pump house
& boiler to be charged.
Start Bearing cooling

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

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

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

have sufficient air
pressure.
Start service air

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

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

circuits for startup.
gates register position.
ESP ready in all

respects.
Furnace bottom ash

system and seal
through lined up.
FSSS panel ready in all

respects.
EAST panel ready in all

respects.
Excitation panel ready

in all respects.
Generator protection
panel ready in all
respects.
Generator H2 gas
pressure is 4 kg/cm2
Check purity of H2 gas

is normal.
Generator stator water

system ready in all
respects.
Check purity of
generator stator water
is normal.
H2 cooling water
system ready in all
respects with SLC on.
Check for level in

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

in all the corners and
elevations.
SADC panel readiness.
Power supply for all the Ensure Aux. air

valves and dampers are dampers and
ON.
modulating.
Supply for all

auxiliaries of SG,
Turbine and Generator
is ensured.
Ensure the oil unit is

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

pumps.
Start the second CC

pump.
Start scanner air fan.
Start both the

secondary air
preheaters.
Ensure that all the inlet

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

air preheaters.
Ensure that the gas

dampers are closed.
Adjust 30% air flow,

Start one set of ID and and furnace draft
FD fans.
minus 5 to 10 mm
WCL.
After purge completion
Boiler trip valves will
get reset.
Charge steam coil

preheater concerned
with the running FD
fans.
Initiate Boiler Purge

(duration 5 minutes).
Lub oil system

stopped.
Start one vapour

extraction fan, keep
other fan standby.
Also, after purge,

adjust the wind box
dampers to get 30-40
mm WCL. Wind box
dp.
Check oil level in MOT.
Line up lub oil cooler

Put on SLCs for other
and thrust bearing filter
AOP and EOP.
Start one AOP.
-
Check out auto start of

AOP and EOP.
--
Put lub oil temperature

controller on.
Start one JOP.
--
Check out auto start of

JOP and DC-JOP.
Put off SLCs JOP 1, 2 &

3. Stop running JOP.
Open gate valve

gearing.
Start one JOP and

switch on SLCs for
JOPs.
MOT level 50 mm oil

temp. 450C JOP header
M/c. comes on barring.
pr. 140 kg/cm2 speed
80 100 rpm.
The sequential
operation narrated
above on Lub oil
system stopped is
achieved by SGC
mode.
If the programme gets

interrupted, the step
and criteria to be
checked and to be
fulfilled for the
programme to proceed
further.
Start centrifuge with

both heaters
M/c on barring.
FRF system in stopped

Check FRF tank level.
condition.
Put on SLCs for other

JOP and DC-JOP.
Switch on SLC gate

valve gearing.
-
+200 mm.
Line up FRF cooler and

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

supply to various
services.
Start one VEF.
Start one recirculation

pump and include one
Filters earth and ultra
fine.
FRF temperature 550C.
Switch on FRF heater

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

SGC.
FRF tank level O

(normal).
FRF system, SGC is

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

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

open.
MSVs closed and

drains before MSV
open.
Ensure atomising
Regulate oil pressure to
steam pressure about 6
2
8-10 kg/cm .
kg/cm2.
Insert furnace probe
and ensure that the
temperature is below
5350C.
If the programme gets

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

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

give blow down.
Keep open the Eco.

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

Check deaerator level.
pump on recirculation.
Charge the feed line

upto feed control
station.
Charge heating steam

to deaerator from Aux.
PRDS.
Start condensate
pumps and feed to
Check hotwell level.
deaerator as and when
required.
--
Start hotwell make up

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

15kg/cm2 (g) 2600C
CW system is charged.
CW boxes to ensure
ventilating of water
boxes.
Start one gland steam

exhauster fan.
Line up vacuum pumps

and start one by one
Ensure gland steam
Gradually admit gland
admission temperature
steam when condenser
is always above 2000C.
vacuum reaches
0.2kg/cm2 (g).
Vacuum building can be

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

connected to flash
tanks and flash boxes
connected to
condenser.
Vacuum 09kg/cm2 (g).
--
Open HPBP warm up

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

vents.

drains.
Open MSV by pass

lines.
MS, HRH, & CRH lines

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

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

/cm2
Boiler pressure 5kg

/cm2.
Open Main steam

valves.
Automatic control
interface gets switched
off when the hot reheat
steam pressure reaches
13kg/cm2 i.e. after
synchronisation.
Open HP by pass.
Start third C.C. pump

when boiler pressure
reaches 9 kg/cm2.
Take additional guns in Air heater soot blowing

CD & EF elevation.
to be carried out.
Close HPBP warm up

valves.
A ROLLING THROUGH HYDRAULIC GOVERNOR
Boiler pressure:15
kg/cm2
04
150
Temperature:1802000C
HRH Pressure:812Kg/cm2
Open HPESVs & IPESVs

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

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

switched on and
available margins are
greater than = 30 0 K.
M. S. Pr. 50 kg/cm2
M.S. temp. 3500C
05
-300
H. R. H. Pr. 12 kg/cm2
Raise the speed set

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

is isolated at speed
Gov. rack, speed set
point need not be
raised.
HRH temp. : 3500C

-
06
-360
Turbine ready for

Rolling.
Gradually raise the

Starting device position
starting device to bring
approximately 56%.
the speed to 360 rpm
Ensure closure of gate
valve gearing at 240
rpm. Monitor bearing
Hold the speed at 360 vibrations, shaft
rpm for about 35 to 40 vibrations, TSE
mts.
margins, bearing
temperature &
Turbosupervisory
readings at 360 rpm.
Raise the speed upto

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

at 540 rpm.
Raise further speed

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

at 2950 rpm.
MS Pr. 50 kg/cm2.
Temperature:
Put AVR on Auto.
3500C Turbine running
at 3000 rpm.
Speeder gear position

will be approximately
at 50 to 60%.
07
370
Close field breaker.
Set manually the

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

steam valves & spray
valves.
Increase HPBP set

point.
Drain pot drains of MS,

CRH & HRH and
Close other drains,
extraction steam lines
M.S. HRH, keeping SLC
will operate as per the
drains on.
actuation of level
switches.
B - ROLLING THROUGH EHC.
04
150'
Open HPESVs & IPESVs

MS Pr.: 15 kg/cm2.
for warming up by
Temperature:180operating starting
2000C HRH
device to
Pressure:8to12kg/cm2.
approximately 42%.
-

TSE influences is
switched on and
0
greater than 30 K.
speed set point is zero
and speeder gear is 0%
position.
MS Pressure: 50
kg/cm2
MS
Temperature:3500C
05
300'
HRH Pressure:
12kg/cm2
HRH Temperature:
3500C.
Turbine Ready for
rolling
Raise the starting

device to about 70%.
Check and ensure

opening of valves in
HP/IP secondary fluid
lines to EHC at speed
control rack.
If tracking device is
Raise the speed set
switched ON, starting
point to 360 rpm and
device position will
watch the actual speed. automatically track the
EHC position
Raise the speeder gear

to 100%
Hold the speed at 360 Ensure closure of gate

rpm for about 35 to 40 valve gearing at 240
mts.
rpm.
MS Pressure:50
kg/cm2
06
360'
MS
Temperature:3500C
Turbine speed: 360

rpm.
Raise the speed set

point to 3000 rpm.
Monitoring bearing
vibrations, bearing
temperatures, shaft
and Turbovisory
readings.
Ensure tripping of
jacking oil pump at 540
rpm.
The rate of acceleration

will be 600 to 850 rpm.
Monitor bearing
vibration and
temperatures, shaft
vibrations, Turbovisory
readings and TSE
margins
Monitor and control,

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

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

Field Breaker.
Turbine speed: 3000

rpm.
-
Set manually generator

voltage to grid voltage.
Synchronise the
Speed set point will

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

point and pick up the
load to 50 MW.
Increase HPBP set

point.

CRH, HRH and
Close other drains of
MS, CRH, HRH, keeping
SLC drains 'ON'.
actuation of level
switches.

steam valves & spray
valves.
C - ROLLING THROUGH SGC - TURBINE.

MS Pressure: 15
kg/cm2
04
150'
MS Temp.:180-2000C
Switch on the start up

programme of SGC
Turbine.
Ensure TSE influence is

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

raised to 360 rpm
through SGC
Programme.

rpm.
HRH Temp.: 3500C.

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

raised upto 3000rpm
through SGCprogramme.

at 540 rpm.
Turbine running at 360

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

at 2950 rpm.
Monitor bearing temp

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

switch ON field
breaker, put AVR on
auto, synchronise and
pick up load upto 20
MW.
Ensure SGC start up

programme is
completed.
Raise the speed set

load upto 50 MW.
Increase HPBP set

point.

steam valves and spray
valves.

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

CRH, HRH extraction
steam lines will operate
as per the actuation of
level switches.
Load : 55 MW
08
390'
M.S. :
54kg/cm2/3500C
Start seal air fan and

PA fan and take first
mill in service.
Before starting P.A.

fan, ensure that air and
gas dampers of Primary
Air Preheaters are
open.
HRH : 12
kg/cm2/3400C
-
Charge ESP fields
Ensure Ash handling

system is ready.
Start the second set of

ID & FD fans.
Make ready SH & RH

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

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

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

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

station from CRH. Cut
in spray and maintain a
temperature of 2500C.
Ensure energizing of
solenoid in trimming
device at and above
100 MW load.
Raise the pressure set
point of Deaerator
pressure controller
gradually.
Peg Deaerator
gradually to 4 kg/cm2.
Cut in IInd mill and cut

in auto controllers.
Start withdrawing oil

support gradually.
Control main steam

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

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

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

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

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


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

ensure that air and gas
dampers of PAPHs are
open.
Cut in IVth mill and cut

Load : 320 MW
M.S. :
125kg/cm2/3500C
12
510'
HRH : 28-30
kg/cm2/3400C
Cut of oil support

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

Cut in second TD BFP

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

reached cut in VIth mill
along with its
controllers. Increase
the set point of SH &
Steam flow : 1310

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

t/hr.
WARM AND HOT START UPS

(With Aux. Steam Available).
A warm start up is, by definition, one which the maximum of HP casing/HP
shaft temperature is between 1500C and 3500C. This normally means that the unit is
shut down from the maximum load for one to four days. Depending upon the absolute
temperature of HP casing and HP shaft, steam parameters are derived. A hot start up is
by definition one which the maximum of HP casing/shaft temperature is more than
3500C. In this case to get the rolling parameters two mills are taken into service keeping
HP, LP by pass in operation.
(Again the flow rate is restricted by the Y pieces
constraints i.e., 40 C). In both the cases, curves are given to derive the rolling
parameters. In case when machine is rolled through EAST, curve generators, calculate
and give permissive for rolling.
INTEGRATED START-UP PROCEDURE

WARM START UP (AFTER 48 HOURS SHUT DOWN).
STEP
TIME IN
MINUTES
UNIT CONDITION
OPERATION
Motor operated BFP is

One CC pump in
run as and when
operation and scanner
required to maintain
fan in operation.
the drum level.
Both SAPHs and

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

ready in all respects.
One circulating pump
in operation with one
earth filter and ultra
fine filter in circuit.
Generator gas
system, seal oil
system and primary
water system in
operation.
Bearing cooling water

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

respects.
EAST panels ready in

all respects.
Furnace bottom ash

system and seal
trough lined up.
Vacuum pumps lined

up and ready for
operation.
Gland steam and leak

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

= 0 kg/cm2.
SH
temperature between
1300C and 1500C.
1. Charge auxiliary
steam header from
existing units. Pr.
16ata temp. 2600C.
2. Charge steam to
fuel oil pump house,
atomising steam and
tracing steam.
3. Start tank heating

of LSHS oil.
4. Start one LSHS

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

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

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

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

FD fans.
Initiate boiler purge.
Start one CEP and

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

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

temperature control on
auto.
Line up main steam,

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

all respects

line to Deaerator from
Aux. PRDS.

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

vents are open.
01
oo
SH & RH drains are

open.
MSVs closed and

drains before MSV
open.
Ensure atomising
steam pressure of
about 6 kg/cm2
Ensure motor
operated BFP is in
service.
Start Gland steam

Exhauster.
Start one by one

vacuum pumps.
Admit gland steam

when vacuum reaches
0.2 kg/cm2.
Ensure gland steam

admission
temperature is always
above 2000C.
Vacuum building can

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

connected to flash
connected to
condenser.
Switch on SLC drains.

vents and drains.
Ensure boiler pressure

is 2kg/cm2.
Open HPBP warming

up valves.
Open MSV bypass

lines.
Switch Automatic
bypass.
Ensure condenser
vacuum of 0.8
kg/cm2.
As soon as the fixed

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

valves.
Ensure MS, CRH &

HRH lines get warmed
up.
Open HP bypass and

close the HPBP warm
up valves.
Ensure Boiler pressure

is 5kg/cm2.
Start third CC pump.

is 9kg/cm2.

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

control on auto.
Take additional guns

according to the
requirement.
Air heater soot

blowing to be carried
out.
A ROLLING THROUGH HYDRAULIC GOVERNOR.

MS: 50 kg/cm2/3650C
02
180'
HRH: 12
kg/cm2/3250C
By pass steam flow:
170t/hr.
Open HPESV and

IPESV for warming up
by operating starting
device to approx. 42%
Check and ensure

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

is switched on and
0
greater than 30 K.
MS: 60 kg/cm2/4000C
03
210'
HRH: 12
kg/cm2/3500C
Raise the speed set

rpm.
By pass steam flow:

200t/hr.
If the oil system of

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

Starting device
starting device to bring position
the speed to 360 rpm. approximately 56%.
Hold the speed at 360

rpm for about 5
minutes.

rpm.
04
215'
Turbine running at
360 rpm.
Monitor bearing
vibrations, shaft
vibrations, TDE
margins, bearing
temp. & Turbovisory
readings at 360rpm.
Raise the speed upto

2400 rpm through
starting device at the
rate of 600 rpm.

at 540 rpm.
Raise further speed

upto 3000 rpm
through speeder gear.

at 90%.

& vibrations, shaft
vibrations, TSE
margins and
Turbovisory readings.
Seal oil, Primary
water and gas
temperatures &
Generator winding
temperature.
Ensure tripping of
AOP at 2950 rpm.

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

grid voltage.
Synchronise the
operating speeder
gear.
Increase HPBP set

point.
Drain pot drains of

MS, CRH, and HRH
Close other drains,
and extraction steam
M.S. HRH, keeping SLC
lines will operate as
drains on.
per the actuation of
level switches.
Ensure closure of
HPBP steam valves &
spray valves.
Further load raising

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

MS: 50 kg/cm2/3650C
02
180'
HRH: 12
kg/cm2/3250C
By pass steam flow:
170t/hr.
Check and ensure

Open HPESVs and
that TSE influence is
IPESVs for warming up switched on and
device to approx. 42%.
0
greater than 30 K.
Check and ensure

is 0%.
MS: 60 kg/cm2/4000C
HRH: 12
kg/cm2/3500C
03
210'
By pass steam flow:

200t/hr.
Raise the starting

Check and ensure

control rack.
switched on starting
automatically track
the EHC position
Turbine ready for

rolling.
Raise the speed set

watch the actual
speed.

to 100%.
rpm.

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

point to 3000 rpm.
Ensure tripping of
Jacking oil pump at
340 rpm.
04
215'
Turbine running at
360rpm.
Monitor bearing
vibrations and temps,
shaft vibration,
turbovisory readings
and TSE margins.
Ensure tripping of
AOP at 2950 rpm.
05
225'
Turbine speed: 3000

rpm.
-
Put AVR on auto close

Field breaker.
Set manually
grid voltage.

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

load to 50 MW.
Increase HPBP set

points.
Ensure closure of
HPBP steam valves
and spray valves.

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

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

MS: 50 kg/cm2/3650C
02
180'
HRH: 12
kg/cm2/3250C

programme of SGC
Turbine.

is switched on.
By pass steam flow:

170t/hr.
If the programme
interrupts the
particular step and
criteria to be checked
and corrected for the
programme to
proceed further.
All operations as
explained under EHC
out by SGC Turbine
programme
sequentially.
MS: 50 kg/cm2/3650C
HRH: 12
kg/cm2/3250C
03
210'
By pass steam flow:

170t/hr.

raised to 360 rpm
through SGCProgramme.

rpm.
Turbine ready for

rolling.
Monitor bearing
vibration, bearing
temp, shaft vibration,
TSE margins and
To achieve the
starting curve, the
main steam
temperature should
be maintained
steadily till loading
upto 50 MW.
MS: 60 kg/cm2/4000C
04
215'
05
225'
Turbine running at
360 rpm.

raised upto 3000 rpm
through SGC
Programme.
MS: 60 kg/cm2/4000C SGC programme will

switch ON field
Turbine speed: 3000 breaker, put AVR on
rpm.
auto, synchronise and
MW.
-
Raise the speed set

point and pick up load
upto 50 MW.

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

up programme is
completed.
Increase HPBP set

point
Ensure closure of
HPBP steam valves
and spray valves.

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

M.S., CRH, HRH and
Extraction steam lines
actuator of level
switches.
Load: 60 MW
MS: 60 kg/cm2/4100C Cut in L.P. heaters 2
and 3.
HRH: 14
kg/cm2/3600C
Ensure switching on
of load controller at
60 MW.
06
230'

from Aux. PRDS to
Deaerator.
Peg Deaerator from

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

controllers.
Start seal air fan and

P.A. fan
Cut in further oil guns

for raising parameters.

fan, ensure that air
and gas dampers of
Primary Air
Preheaters are open.
-
Load: 110 MW
MS: 80 kg/cm2/4200C
07
245'
HRH: 19
kg/cm2/3800C
Cut in 1st coal mill and Make ready SH & RH

cut in Auto controllers. spray system.
Main steam flow:

470t/hr.
Trimming device is in
OFF.
-
Charge ESP Fields.
Charge Aux. PRDS

in spray and maintain
a temperature of
2500C.
Ensure Ash handling

system is ready.

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

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

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

to furnace diff.
pressure to 100mm.
W.C. by adjusting
SADC.
Cut in IInd mill and cut

Load: 200 MW
MS: 100
kg/cm2/4350C
08
270'
HRH: 19
kg/cm2/4000C
Main steam flow:
750t/hr.

support gradually.
fire ball scanners.
Control main steam

and reheat steam
temperature by using
spray if required.
Change Deaerator
pegging steam from
CRH to Extraction
steam.
Cut in IIIrd mill and

cut in auto controllers.
Start second P.A. fan.
Ensure Deaerator
pressure controller
remains on auto.
fan ensure that air
and gas dampers of
PAPH are open.
Load: 320 MW
MS: 125
kg/cm2/4500C
09
300'
HRH: 30
kg/cm2/4300C
Main steam flow:
1080t/hr.

Cut off oil support

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

Start second TDBFP

driven BFP.
Cut in VIth coal mill

and cut in auto
controllers.
Check all parameters

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

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

1570t/hr.
INTEGRATED START UP PROCEDURE

HOT START UP (AFTER 8 HOURS SHUT DOWN)
STEP
TIME IN
UNIT CONDITION
MINUTES.
OPERATION
Motor operated BFP is

Two CC pumps in
run as and when
operation and scanner required to maintain
fan in operation.
the drum level. If
necessary BFP should
NOTES.
be kept running
continuously.
Both SAPHs and

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

operation. One
circulating pump in
operation with one
earth filter and ultra
fine filter in circuit.
Generator gas
system, seal oil
system and primary
water system in
operation.
Bearing cooling water

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

instrument air
compressors in
operation.
One condensate pump

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

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

dosing system ready.
ESP panels ready in

all respects.
EAST panels ready in

all respects.
Furnace bottom ash

system and seal
trough lined up.
Vacuum pumps lined

up and ready for
operation.
Gland steam and leak

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

all respects.
Boiler drum Pr. 75

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

exhauster.
Start one by one

vacuum pumps.
Admit gland steam

when vacuum reaches
0.2 kg/cm2.
Ensure gland steam

admission
temperature is always
above 2000C.
Vacuum building can

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

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

connected to flash
connected to
condenser.
Ensure condenser
vacuum of 0.8 kg/cm2.
Open HPBP warming

up valves.
Switch Automatic
bypass.
Ensure condenser
vacuum of 0.8
kg/cm2.
As soon as the fixed

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

fans
Initiate boiler purge.

line to Deaerator from
Aux. PRDS.
01
oo

up and turbine on
turning gear.
Drum Pr. 75 kg/cm2

0
SH. Temp. 415 C and

4300C.
Ensure atomising
steam pressure of
about 6kg/cm2.
Ensure motor
operated BFP is in
service.
Open drains before

MSV.
Open MSV by pass

lines.
Open Main steam stop

valves.
Open HP bypass and

close the HPBP warm
up valves.
Put HP bypass
controllers on auto and
vary the set point
according to the
gradient of pipeline
temperatures.
Put HP bypass spray

control on auto.
Take additional guns

according to the
requirement.
Ensure MS, CRH, HRH

lines got warmed up.
Air heater soot

blowing to be carried
out.
Start both P.A. fans

and seal air fans.
Line up milling system

for starting.

Fans ensure that air
and gas dampers of
Primary air preheaters
are open.
-
A ROLLING THROUGH HYDRAULIC GOVERNOR

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

cut in auto controllers. RH spray system.
Bypass steam flow:

280t/hr.
-
Ensure Ash handling

system is ready.
Charge ESP fields.

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

Peg the deaerator from

CRH gradually upto 2
kg/cm2.
Open HPESVs and

IPESVs for warming up
device to
approximately 42%.
Check and ensure

is at 0%.

is switched on and
0
greater than 30 K.
MS Pressure: 85
kg/cm2
MS Temperature:
5000C
03
50'
HRH Pressure: 12
kg/cm2
HRH Temperature:
4500C.
Bypass steam flow:
360t/hr.
Raise the speed set

rpm.
If the oil of EHC is

isolated at speed Gov.
rack, speed set point
need not be raised.
Turbine Ready for

rolling
04
Turbine running at
360rpm.
52'
Gradually raise the

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

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

rpm through starting
device at the rate of
at 540 rpm.
600 rpm.
Raise further speed
upto 300 rpm through
speeder gear.

at 90%.

and vibrations, shaft
vibrations, TSE
margins and
turbovisory readings.
Seal oil Primary water
and gas temperatures
and Generator
Ensure tripping of
AOP at 2950 rpm.

will be approximately
at 50 to 60%.
05
56'
Turbine running at
3000rpm
Put AVR on auto.
Set manually the

grid voltage.
Synchronise the
Generator with grid.
operating speeder
gear.
Increase HPBP set

point.
Drain pot drains of

MS, CRH, and HRH
Close other drains,
and extraction steam
M.S. CRH, HRH,
lines will operate as
keeping SLC drains on.
per the actuation of
level switches.
Ensure closure of
HPBP steam valves &
spray valves.
Further load raising

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

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

cut in auto controllers. spray systems.
HRH Temperature:
4400C.
Bypass steam flow:
280t/hr.
-
Ensure Ash handling

system is ready.
Charge ESP fields.

to furnace diff.
Pressure to 100mm
W.C. by adjusting
S.A.D.C.

Peg the deareator from

kg/cm2.
Open HPESVs and

IPESVs for warming up
device to
approximately 42%.
Check and ensure

is at 0%.

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

Check and ensure

control rack.
switched on starting
automatically track
the EHC position.
HRH Temperature:
4500C.
Turbine Ready for
rolling. Bypass steam
flow: 360t/hr.
Raise the speed set

watch the actual
speed.

to 100%.
rpm.
04
52'
Turbine reading at
360 rpm.
-

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

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

seal oil temperatures,
primary water
temperature.
Hydrogen gas
temperature and
05
56'
Turbine speed: 3000

rpm.
-
Ensure tripping of
AOP at 2950 rpm.
Put AVR on auto Close

field breaker.
Set Manually generator

voltage to grid voltage.
Synchronise the

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

point.
Ensure closure of
HPBP steam valves
and spray valves.

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

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

MS: 85 kg/cm2/4850C
02
40'
HRH: 12kg/cm2.
Cut in first coal mill & Make ready SH & RH

cut in auto controllers. spray systems.
Bypass steam flow:

280t/hr.
-
Ensure Ash handling

system is ready.
Charge ESP fields.

to furnace diff.
Pressure to 100mm
W.C. by adjusting
S.A.D.C.

Peg the deaerator from

kg/cm2.

programme of SGCTurbine.

is switched ON.
If the programme
interrupts, the
particular step and
criteria to be checked
and corrected for the
programme to
proceed further.
All operations as
explained under EHC
out by SGC-Turbine
programme
sequentially.
Turbine ready for

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

rpm.
Bypass steam flow:

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

raised upto 3000 rpm
through SGCprogramme.

at 540 rpm.
Ensure tripping of
AOP at 2950 rpm.
Monitor bearing
temperature and
vibrations, shaft
vibrations, TSE
margins, Turbovisory
readings, seal oil,
primary water,
Hydrogen gas and
Generator winding
temperatures.
Turbine speed: 3000

rpm.
SGC Programme will

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

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

point.
Ensure closure of
HPBP steam valves &
spray valves.

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

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

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

from Aux. PRDS to
Deaerator.
Raise the generator

pressure from
2kg/cm2 to 4kg/cm2.

point of Deaerator
pressure controller.
Cut in auto controller.

support gradually.
fire ball scanners.
LOAD: 150 MW.

MS: 100
kg/cm2/5000C
07
65'
Charge Aux. PRDS

HRH: 20kg/cm /480 C
in spray and maintain
a temperature of
Main steam flow:
2500C.
1620t/hr.
2
Trimming device is in
OFF.
-
Cut in H.P. heaters and

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

second CEP around a
load of 170 MW.
Control main steam

and reheat steam
temperature by using
spray if required.
Change deaerator
pegging steam from
CRH to Extraction
steam.
Cut in IIIrd mill and


Ensure Deaeator
pressure controller
remains on auto.
LOAD: 230 MW.

MS: 120
kg/cm2/5000C
08
70'
HRH: 20kg/cm2/4950C
Main steam flow:
820t/hr.
Cut off oil support

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

Start second TD BFP

driven BFP.
Cut in VIth coal mill

and cut in auto
controllers.
Check all parameters

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

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

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

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

1570 t/hr.
********************

500MW Starting Procedures

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500MW Starting Procedures

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CONTENTS

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

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

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

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

INTEGRATED START-UP PROCEDURE

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

Charge steam to fuel

Start tank heating of

Start one LSHS pump

Charge LSHS to boiler

Fill water in drum upto

Ensure that the suction

All the steam tracing

Start Bearing cooling

Check all circuits have

Start instrument air

Check that all circuits

Start service air

Ensure that purge air to

Line up Air and flue gas Check dampers and

ESP ready in all

Furnace bottom ash

FSSS panel ready in all

EAST panel ready in all

Excitation panel ready

Check purity of H2 gas

Generator stator water

Check for level in

Check for air pressure

SADC panel readiness.

Power supply for all the Ensure Aux. air

Supply for all

Ensure the oil unit is

Start one of the CC

Start the second CC

Start scanner air fan.

Start both the

Ensure that all the inlet

Start both the primary

Ensure that the gas

Adjust 30% air flow,

Charge steam coil

Initiate Boiler Purge

Lub oil system

Start one vapour

Also, after purge,

Line up lub oil cooler

Check out auto start of

Put lub oil temperature

Start one JOP.

Check out auto start of

Put off SLCs JOP 1, 2 &

Open gate valve

Start one JOP and

MOT level 50 mm oil

If the programme gets

Start centrifuge with

FRF system in stopped

Put on SLCs for other

Switch on SLC gate

Line up FRF cooler and

Establish control fluid

Start one VEF.