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OPERATOR TRAINING MANUAL


FOR
600 MW UNIT
OF
SEL JHARSUGUDA IPP

STEAG ENERGY SERVICES (INDIA) PVT LTD.


(A WHOLLY OWNED SUBSIDIARY OF
STEAG ENERGY SERVICES GMBH, GERMANY)
SIMULATOR STARTUP PROCEDURE SUMMARY

INITIAL CONDITION:

a. Boiler is in cold mode: Boiler shutdown is longer than 72 hours and pressure is
zero. Shutdown for over 72h (Metal Temperature declines to below 40% of
full-load temperature of the measuring point.
b. Vessels are already filled to some level.
c. Hydrogen has been filled in the Generator and the Generator Seal Oil System is in
service.
d. Electrical System is already charged.
e. Instrument (Control) Air Compressors and Plant (Service) Air Compressors are in
service.
f. Fuel Oil System is lined up & put in service.

MAJOR STEPS INVOLVED IN THIS EXERCISE:

1. Lineup and place the Circulating Water System in service establish flow through
the main condenser.
2. Lineup and place OPEN Cooling and CLOSED Cooling Water system in service
and establish flow through various equipment coolers.
3. Lineup the Condensate Water System and fill the Condenser Hot Well to around
800 mm. Also line up and fill Deaerator.
4. Lineup the Feedwater System. Line up and fill the Boiler Drum.
5. Lineup and place in operation the Main Turbine Lube Oil System.
6. Lineup and place in service the lube oil systems for Turbine Driven Boiler
Feedwater Pump (BFPT) A and B. Place both BFPTs on Turning Gear.
7. Place the Main Turbine Turning Gear and the Electro-Hydraulic Oil systems in
service.
8. Lineup and place the Generator Hydrogen and Stator Cooling Water system in
service.
9. Lineup and place the Draft Plant (Air) System in service and establish 30%
airflow while maintaining a furnace pressure of ~ -50Pa with two Induced Draft
(ID) Fans and two Forced Draft (FD) Fans in service including both Air Heaters.
10. Ensure that the Startup/Auxiliary Boiler is on. After achieving steam parameters
in Auxiliary Boiler, charge the Auxiliary Steam Header (Auxiliary Steam is at
0.9-1.0 MPa, 340-350 C).
11. After charging the Auxiliary Steam Header, place the Gland Seal Steam System
in service using Auxiliary Steam with Gland Seal Steam parameters of ~ 30-35
kPa, 340-350 C (HP/IP Turbine Sealing), ~ 14-18 kPa, 140-150 C (LP Turbine
Sealing).
12. Lineup and place the Condenser Vacuum System in service and evacuate the
condenser. After evacuating the Condenser, configure the Condenser Vacuum
System for NORMAL operation, raising Condenser Vacuum to ~ -90 kPa.
13. Place LDO Elevation/Layer AB Oil Guns in service. Place Deaerator Pegging
Steam in service. Raise the Main Steam Pressure & Temperature parameters.
14. Before the drum pressure increases above 1.2 MPa, START the Motor Driven
Boiler Feed Pump (MDBFP). Use the MDBFP to control Drum Level during boiler
pressurization and place it in AUTO only when steam flow from the drum is
sufficient and stable.
15. Lineup and START the Turbine Bypass System. Increase Firing and raise the
Main Steam Pressure & Temperature parameters to ~ 6 MPa & 350 C to
prepare for the main Turbine Startup.
a. Lineup and START the Turbine Bypass System to establish Steam flow
through the system.
b. Raise Main Steam parameters to ~ 6 MPa. 350 C by taking into service
HFO Oil Guns as required.
16. Preheat the HP Turbine and RESET the Main Turbine. Warm the Control Valve
Chest until the CV Inner to Outer Wall Metal Temperature Differential is within
permissible limits. Warm and roll the Main Steam Turbine to 3000 rpm. As the
Turbine accelerates monitor the Turbine Stress parameters and other critical
parameters.
17. Synchronize the Unit to the Grid and Load up to the Block Load.
18. Lineup and place in service PA Fans A and B. START the Fly Ash Handling
System.
19. Prepare and initiate warming for Pulverizer/Mill A. When the Secondary Air
Temperature is ~ > 177 C, and the Primary Air system is operating normally,
START the first coal mill MillA.
20. START and place in service to provide Feedwater to the Boiler Drum.
21. At ~ 50-100 MW, charge the LP Heaters from the Steam side.
22. At ~ 150 MW, switch over to Unit Auxiliary Transformer from the Station
Transformers to feed Auxiliary Equipment.
23. When Load ~ 150 MW, START the 2nd Coal Mill.
24. When Load ~ 180 MW, maintain it for 20 minutes. Charge the HP Heaters from
Steam side.
25. After warming up for 20 minutes at Load ~ 180 MW, raise the Load to ~ 300 MW,
rate of rise of Load is 3 MW/ min, rate of rise of Main Steam Temperature is 1.5
C/min, rate of rise of Main Steam Pressure is 0.1 MPa/min.
26. When Load is ~ 270 MW, START the 3rd Coal Mill. When the Unit Load is ~ 300
MW, maintain it for 20 minutes, raise Main Steam Temperature to ~ 520 C,
Reheat Steam Temperature to ~ 510 C. Confirm that furnace combustion is
stable, Boiler parameters are NORMAL, all oil guns are stopped, And that Fuel
Oil is placed in Long Re-circulation mode.
27. START the 2nd TDBFP. Gradually reduce the flow of MDBFP. When both
TDBFPs are running normally, stop the MDBFP.
28. After maintaining the load at 300 MW for 20 minutes, place Turbine Master,
Boiler Master and other controls in AUTO and raise the Load to 600 MW at the
rate of 6 MW/min, Main Steam temperature is raised at 1.50 C/min, Main Steam
Pressure is raised at < 0.2 MPa/min
c. When the load rise to 360 MW, START the 4th Mill.
d. When load rises to 480 MW, START the 5th Mill; increase the load to 600
MW.
29. Raise Load to 600 MW, maintain Main Steam Pressure ~ 16.7 MPa, MS
Temperature ~ 540 C, Reheat Steam Pressure ~ 3.0 MPa, Reheat Steam
Temperature ~ 538 C. Have a thorough check of the systems and check for any
abnormal conditions.

ST.01 CIRCULATING WATER SYSTEM STARTUP


INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

CIRCULATING WATER SYSTEM STARTUP


Ensure Lube Oil Tank Level is NORMAL and Lube Oil
1. LOCAL OPERATION
System is in service (Pumps are running).

2. Check CT pond/sump level is NORMAL. LOCAL OPERATION

3. Ensure that the Drains of Water Box are CLOSED. LOCAL OPERATION

OPEN the Inlet valves (10PAB10AA001,


CIRCULATING
4. 10PAB20AA001) and Outlet Valves (10PAB30AA001, WATER PUMP
10PAB40AA001) of Condenser.

Ensure that Service & Circulating Water MOVs


(10PAX70AA007, 10PAX71AA002, 10PAX72AA007,
5.
10PAX73AA002) of both Circulating Water Pumps
(CWPs) are OPEN.

START the CW Pump A (10PAC10AP001) and place CIRCULATING


6. WATER PUMP
CW Pump B (10PAC20AP001) in STANDBY mode.

Post Checks:

a. Check for any abnormal sounds/vibrations from


Motor & Pump.
CIRCULATING
7. b. CLOSE all Air/Water Vent Valves after WATER PUMP
sufficient flow is established.

c. Check that the Discharge Valve is fully OPEN.

d. Monitor all the parameters.

ST.01 FINISHED
ST.02 OPENED & CLOSED CYCLE COOLING WATER
SYSTEM STARTUP
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

OPEN Cycle Cooling Water System Supplies to


1 CCW Cooling System
2 Generator H2 cooler
3 Generator stator water coolers
4 Oil cooler of motor
5 Oil cooler of TDBFP
6 Working & lube oil cooler
7 Motor of MDBFP
8 CEP motor
9 Vacuum Pump Separator tank
10 Coal Mill lube oil etc.

CLOSED Cycle Cooling Water System Supplies to


CBCW (Boiler Forced Circulating water Pump)
Cooling system and cleaning
Steam water sampling (SWAS room)
Fire resistant oil Cooler
CEP motor bearing cooling
Gland cooling of CEP Pump

OPEN CYCLE COOLING WATER SYSTEM


Check Oil Level in all bearings of the Open Cycle
1. Cooling Water Pumps (OCCWPs) is NORMAL.
LOCAL OPERATION

OPEN CYCLE
OPEN the Inlet Valve (10PAK10AA002) to the
2. Suction Strainer for the OCCWP A.
COOLING WATER
SYSTEM

Check that the Water Strainer Bypass Valve OPEN CYCLE


3. (10PAK15AA001) is OPEN before starting OCCWP COOLING WATER
A. SYSTEM

START the Electrical Water Strainer OPENCYCLE


4. (10PAK10GH001) and OPEN its Outlet Valve COOLING WATER
(10PAK10AA001). SYSTEM

OPEN CYCLE
5. OPEN OCCWP A Inlet Valve (10PAK20AA001). COOLING WATER
SYSTEM

Put all the Cooling Control Valves in AUTO and give OPEN CYCLE
6 suitable Setpoint. COOLING WATER
SYSTEM

CIRCULATING WATER
7. Ensure that at least one CWP is in service. PUMP

Ensure electrical supply to Motor is available.

START OCCWP A (10PGB20AP001) and observe OPEN CYCLE


8. that the OOCWP A Discharge Valve COOLING WATER
(10PAK25AA001) will OPEN automatically. SYSTEM
Manually, CLOSE the Strainer Bypass Valve
(10PAK15AA001).

Put the OCCWP B (10PGB25AP001) in STANDBY OPEN CYCLE


9. after the OCCWP A Discharge Valve has fully COOLING WATER
OPENED. SYSTEM

OPEN CYCLE
According to requirement, charge the Cooling
10. COOLING WATER
Systems of individual auxiliaries. SYSTEM

Post Checks.

a. Check for any abnormal sound/vibrations


from Motor & Pump. OPEN CYCLE
11. COOLING WATER
b. Monitor Bearing Temperatures, Discharge/ SYSTEM
Suction Pressures.

c. Check Inlet & Outlet Valve are OPEN.

CLOSED CYCLE COOLING WATER SYSTEM

CLOSED CYCLE
12. Ensure that the Expansion Tank Level is NORML. COOLING WATER
SYSTEM

OPEN the Make-Up Water Valve in between


13. Expansion Tank and suction header of Closed Cycle LOCAL OPERATION
Cooling Water Pumps (CCCWPs).

CLOSED CYCLE
14. OPEN CCCWP A Inlet Valve (10PGB10AA001). COOLING WATER
SYSTEM

OPEN Closed Cycle Cooling Water Cooler Inlet &


CLOSED CYCLE
Outlet Valves (10PGB12AA001, 10PGB20AA001,
15. COOLING WATER
10PGB11AA001, 10PGB21AA001) and Recirculation SYSTEM
Valve (10PGB22AA001).

Ensure electrical supply to CCCWP A Motor is


CLOSED CYCLE
available, START the CCCWP A (10PGB10AP001),
16. COOLING WATER
observe that the Discharge Valve opens SYSTEM
automatically.
CLOSED CYCLE
Put CCCWP B (10PGB11AP001) in STANDBY, after
17. COOLING WATER
the Discharge Valve of CCCWP A has fully opened. SYSTEM

According to requirement, charge Cooling Systems CLOSED CYCLE


18. of individual auxiliaries like Condensate Extraction COOLING WATER
Pumps, Boiler Circulating Water Pumps etc. SYSTEM

Post Checks:

a. Check for any abnormal sounds/vibrations CLOSED CYCLE


19. from Motor & Pump. COOLING WATER
SYSTEM
b. Monitor Bearing Temperatures and
Discharge/Suction Pressures.

ST.02 FINISHED
ST.03 CONDENSATE WATER SYSTEM LINEUP;
CONDENSER HOTWELL, DEAERATOR FILLING
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

CONDENSER HOTWELL FILLING


Ensure that the Suction and Discharge Valves of
1. the Condensate Delivery Pumps (DPs) are OPEN. LOCAL OPERATION
If not, ask AO to OPEN them.

Ensure Electrical Supply is available to the DPs.


CONDENSATE WATER
2. START DP A (10LCP10AP001) and place DP B SYSTEM
(10LCP11AP001) on STANDBY.

Fill the Condenser Hotwell Level to ~ 60% using CONDENSATE WATER


3. SYSTEM
Condenser Water Filling MOV (10LCP30AA002).

Maintain the Hot Well Level using Condenser


Water PCV and Condenser Water Storage Tank
PCV in manual. CONDENSATE WATER
4. SYSTEM
After maintaining level at ~ 800 mm, place the
Control Valves in AUTO and set suitable Setpoint.

CONDENSATE WATER SYSTEM LINEUP


Ensure the Condensate Flow path for all the Low
Pressure (LP) Heaters and Gland Steam
Condenser (GSC) is through. If not, OPEN the
GSC Inlet & Outlet Valves(10LCA30AA001,
10LCA40AA001), LP Heater 7A & 8A Inlet & CONDENSATE WATER
5. SYSTEM
Outlet Valves (10LCA40AA007, 10LCA50AA001),
LP Heater 6 Inlet & Outlet Valves
(10LCA50AA003, 10LCA60AA001), LP Heater
5 Inlet & Outlet Valves (10LCA60AA002,
10LCA70AA001).

Before starting Condensate Extraction Pumps


(CEPs), ensure that the following permits are met: CONDENSATE WATER
6. SYSTEM
Condenser Level > 600 mm
CEP Inlet MOV OPEN

CEP Motor Bearing Temperature < 90 C

CEP Motor Winding Temperature < 120 C

OPEN CEP A Suction Valve (10LCA10AA001).


CONDENSATE WATER
7. Ensure CEPs Discharge Valves (10LCA11AA002, SYSTEM
10LCA21AA002) are CLOSED.

Place Recirculation Control Valve in MANUAL and CONDENSATE WATER


8. SYSTEM
fully OPEN.

START Condensate Extraction Pump (CEP) A


CONDENSATE WATER
9. (10LCB10AP001) and establish Recirculation flow SYSTEM
through the GSC back to the Condenser.

CONDENSATE WATER
10. Place CEP B (10LCB20AP001) on STANDBY. SYSTEM

To cool the CEPs, ask AO to OPEN the Valves to


supply Cooling Water to the CEPs from the
11. LOCAL OPERATION
Discharge or from the DP Discharge as per
requirement.

DEAERATOR FILLING
OPEN Deaerator Level Control Station Isolating
CONDENSATE WATER
12. Valves (10LCA40AA002, 10LCA40AA003, SYSTEM
10LCA40AA005, 10LCA40AA006).

Maintain Deaerator Level using the Normal and


CONDENSATE WATER
13. Sub Control Valves by manually varying their SYSTEM
positions.

After maintaining Deaerator Level, place the Level


CONDENSATE WATER
14 Control in AUTO and set a suitable Setpoint. Also, SYSTEM
place the Recirculation Valve in AUTO.

Post Checks:

a. Check for any abnormal sounds/vibrations


15. from the Motor or Pump.

b. Monitor the Bearing Temperatures and


Vibrations of Motor and Pump.
Keep monitoring the Deaerator Level as Control
CONDENSATE WATER
16. Valves may switch to MANUAL mode due to high SYSTEM
magnitude of Deviations and other reasons.

ST.03 FINISHED
ST.04 BOILER DRUM FILLING
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

BOILER DRUM FILLING


Lineup the Boiler Filling Water Line from DP A & B by
opening Boiler Hot Water Filling MOV (10LCP31AA001) CONDENSATE
1. and 30% capacity line Valves (10LAB80AA003, WATER SYSTEM,
10LAB80AA004) and also the 30% Capacity Feedwater BOILER DRAIN
Control Valve. Ensure that at least one DP is in service.

Ensure that the Boiler Filling Water Temperature and


2. BOILER DRAIN
Drum Wall Temperature difference must be < 90 C.

OPEN Economizer Recirculation Valve


3. BOILER DRAIN
(10HAC90AA001).

When Drum Level appears in the Boiler Drum, reduce the


4. feedwater flow and stop the feeding at Drum Level ~ 250 BOILER DRAIN
mm.

Check if the BCWPs Discharge Valves are OPEN, if not


5. LOCAL OPERATION
request AO to OPEN them.

START two of the Boiler Circulating Water Pumps


(BCWPs) (10HAG21AP001, 10HAG22AP001,
10HAG23AP001) and place the third in STANDBY.
6. Notice the sudden drop in Drum Level on starting the BOILER DRAIN
BCWPs.

Maintain the Boiler Drum Level around 0 ~ 50 mm


throughout the Unit Startup.

ST.04 FINISHED
ST.05 MAIN TURBINE LUBE OIL SYSTEM STARTUP
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:
1. The main turbine lube oil system supplies oil to the
following:
a. Turbine bearings
b. Generator bearings
c. Thrust bearing wear detector
d. Hydrogen seal oil system backup

Notes:
1. Before Starting the Turbine Lube Oil System, the
CLOSED Cooling Water System should be in service.
2. Turbine will trip when the bearing lube oil header
pressure < 0.17 MPa
3. EHC System will alarm when the EHC pump header
pressure < 9 MPa, the Turbine will trip when the EHC
pump header pressure < 8 MPa

Questions:
1. If the Lube Oil System NORMAL operating
temperature is between 43.3 ~ 46.1 C, why is the
temperature maintained at 32.2 C during Startup?

ANSWER: During turning gear or low speed operation the


turbine journal can climb the walls off of the bearing
then suddenly drop, causing vibration in the low
pressure turbine blades. With the oil temperature at
lower temperature, the oil is more viscous, thus
supporting the weight of the journal better.

TURBINE LUBE OIL SYSTEM STARTUP


Complete Lube Oil System Pre-START Checks.

a. Check Main Oil Tank Oil Level is NORMAL (i.e.


1. 850 to 1000 mm). LOCAL OPERATION

b. Check electric supply is available to related


equipment.

Ensure Lube Oil Coolers are charged from the Cooling TURBINE LUBE OIL
2. SYS
Water side (Oil Temp >= 38 C)

Put one Oil Vapor Exhauster (12MAV48AP001) into


TURBINE LUBE OIL
3. service and put the other (12MAV48AP002) on SYS
STANDBY mode.
Check if the Oil Vapour Exhauster Outlet Valves are
4. LOCAL OPERATION
OPEN, if not request AO to OPEN them.

Put Lube Oil Temperature Control Valve in AUTO. TURBINE LUBE OIL
5. SYS

Request AO to OPEN all the Lube Oil Supply Valves


6. supplying Lube Oil to the different bearings and shafts LOCAL OPERATION
of the main Turbine.

START the Main Supply Pump (MSP)


TURBINE LUBE OIL
7. (12MAV40AP001)), which is in service during Unit SYS
Startup and Shutdown.

START Turbine Oil Pump (TOP) (12MAV40AP002),


TURBINE LUBE OIL
8 which is also in service during Unit Startup and SYS
Shutdown.

Request AO to OPEN the MSP and TOP Oil Discharge


9. LOCAL OPERATION
Valves to supply Lube Oil to the header.

TURBINE LUBE OIL


10. Check whether the Oil Flow Pressures are NORMAL. SYS

Put the DC Emergency Oil Pump (EOP) TURBINE LUBE OIL


11. (12MAV40AP003) in STANDBY mode. SYS

Verify that the Turbine Lube Oil Pressure increases to TURBINE LUBE OIL
12. SYS
0.18 MPa

Check whether the currents of all the motors in service TURBINE LUBE OIL
13. SYS
are NORMAL.

ELECTRO HYDRAULIC OIL SYSTEM

Complete EH Oil System Pre-START Checks.

a. Check EH Oil Tank Oil Level is NORMAL.


14. LOCAL OPERATION
b. Check electric supply is available to related
equipment.

15. START the EH # 1 or # 2 Main Oil Pump. EH OIL SYSTEM

OPEN the corresponding EH Oil Discharge Valve


16. EH OIL SYSTEM
(10MAX11AA001, 10MAX12AA001).

17. Verify that the Oil Pressure rises to 11.51 MPa EH OIL SYSTEM

18. START the EH Circulating #1 or #2 Pump. EH OIL SYSTEM


Verify that the system is NORMAL and that
19. EH OIL SYSTEM
temperatures are not high.

ST.05 FINISHED
ST.06 STARTING LUBE OIL SYSTEMS & TURNING GEARS
OF TURBINE DRIVEN FEED PUMPS
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

TURBINE DRIVEN BFP-A LUBE OIL SYSTEM


Complete BFPT-A Lube Oil System Pre-START
Checks.

a. Check Lube Oil Tank Oil Level is NORMAL (i.e.


1. LOCAL OPERATION
900 to 1100 mm).

b. Check electric supply is available to related


equipment.

Ensure Lube Oil Coolers are charged from the Cooling


2. BFPT-A SYSTEM
Water side (Oil Temperature ~ 34-38 C)

START Vapor Exhauster Fan (10XAA10AN001) in Oil


3. BFPT-A SYSTEM
Tank, to create vacuum in tank.

Check Lube Oil Temperature and put Lube Oil


4. BFPT-A SYSTEM
Temperature Control Valve in AUTO.

START any one of the Main Oil Pumps (#1 or #2)


5. (10XAA10AP001, 10XAA11AP001).Check that current BFPT-A SYSTEM
is NORMAL.

Request AO to OPEN the Lube Oil Discharge Valves


6. LOCAL OPERATION
and line up the Oil path to the shafts and bearings.

Put the other Main Oil Pump (10XAA11AP001) on


7. BFPT-A SYSTEM
STANDBY.

8. Check whether Oil Flow Pressures are NORMAL. BFPT-A SYSTEM

Put the DC Emergency Oil Pump (EOP)


9. BFPT-A SYSTEM
(10XAA10AP011) on STANDBY.

After verifying that the Lube Oil Pressure is adequate,


10. START the Turning Gear Motor (1deg. CAA10AP001) BFPT-A SYSTEM
of BFPT-A.

11. Verify that the BFP-A Turbine speed rises ~ 10 rpm. BFPT-A SYSTEM
TURBINE DRIVEN BFP-B LUBE OIL SYSTEM
Complete BFPT-B Lube Oil System Pre-START
Checks.

a. Check Lube Oil Tank Oil Level is NORMAL (i.e.


12. LOCAL OPERATION
900 to 1100 mm).

b. Check electric supply is available to related


equipment.

Ensure Lube Oil Coolers are charged from the Cooling


13. BFPT-B SYSTEM
Water side (Oil Temperature ~ 34-38 C)

START Vapor Exhauster Fan (10XAA20AN001) in Oil


14. BFPT-B SYSTEM
Tank, to create vacuum in tank.

Check Lube Oil Temperature and put Lube Oil


15. BFPT-B SYSTEM
Temperature Control Valve in AUTO.

START any one of the Main Oil Pumps (#1 or #2)


16. (10XAA20AP001, 10XAA21AP001). Check that current BFPT-B SYSTEM
is NORMAL.

Request AO to OPEN the Lube Oil Discharge Valves


17. LOCAL OPERATION
and line up the Oil path to the shafts and bearings.

18. Put the other Main Oil Pump on STANDBY mode. BFPT-B SYSTEM

19. Check whether Oil Flow pressures are NORMAL. BFPT-B SYSTEM

Put the DC Emergency Oil Pump (EOP)


20. BFPT-B SYSTEM
(10XAA20AP011) in STANDBY mode.

After verifying that the Lube Oil Pressure is adequate,


21. START the Turning Gear Motor (1deg. CAA20AP001) BFPT-B SYSTEM
of BFPT-B.

22. Verify that the BFP-B Turbine speed rises to 10 rpm. BFPT-B SYSTEM

ST.06 FINISHED
ST.07 MAIN TURBINE TURNING GEAR SYSTEM STARTUP
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

TURBINE TURNING GEAR SYSTEM


Complete Pre-Start Checks.

a. Check that the Turbine Lube Oil System


1. is in service. LOCAL OPERATION

b. Check electric supply is available to


related equipment.

Ensure Lube Oil Coolers are charged from the


2. Cooling Water side and Lube Oil Temperature TURBINE LUBE OIL SYS
Control Valve in AUTO. (Oil Temp >= 38 C)

Put both Jacking Oil Pumps (JOPs)


(10MAV70AP001, 10MAV71AP001) on
3. TURBINE LUBE OIL SYS
STANDBY, and check that one of them comes
into service.

Check that Jacking Oil Pressure rises to ~ 16


4. TURBINE LUBE OIL SYS
MPa.

START the Turbine Turning Gear Motor


5. TURBINE LUBE OIL SYS
(12MAK10AP001).

Check that the Lube Oil Pressures are


6. TURBINE LUBE OIL SYS
NORMAL.

Verify that the Turbine Speed gradually


7. TURBINE LUBE OIL SYS
increases to ~ 2 rpm.

ST.07 FINISHED
ST.08 GENERATOR STATOR COOLING WATER SYSTEM
STARTUP
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

GENERATOR STATOR COOLING


WATER SYSTEM
Complete Generator Cooling Water System
Pre-START Checks.

a. Check that the Generator Seal Oil


System is in service and NORMAL.
1. LOCAL OPERATION
b. Check electric supply is available to
related equipment.

c. Check that the Conductivity of Water is


~ 0.2 0.3 us/cm.

Ensure Water Coolers are charged from the GENERATOR STATOR


2. Cooling Water side (Inlet Water Temp ~ 34-38 WINDING COOLING
C) WATER SYSTEM

GENERATOR STATOR
3. Ensure Stator Water Tank Level is NORMAL. WINDING COOLING
WATER SYSTEM

Verify that DM Make-up Water is available to the


Stator Water Tank. If not, request AO to OPEN
the Isolating valves before and after the Open
4. LOCAL OPERATION
Return Water Flow Control Valve
(10MKF60AA001). Open This valve as per
requirement to fill up the Tank.

Put the Temperature Controller and Cooler GENERATOR STATOR


5. Outlet Temperature Control on AUTO mode. Set WINDING COOLING
a suitable Setpoint as per requirement. WATER SYSTEM

GENERATOR STATOR
Ensure Open Circuit Cooling Water supply is
6. WINDING COOLING
available. WATER SYSTEM

Request AO to OPEN the Stator Cooling Water


7. Pumps (SCWPs) Suction Valves, and the Inlet LOCAL OPERATION
& Outlet Isolating Valves of the Coolers.

START any one SCWP (10MKF10AP001, GENERATOR STATOR


8.
10MKF10AP002). WINDING COOLING
WATER SYSTEM

Request AO to OPEN the started SCWPs


9. LOCAL OPERATION
Discharge Valve.

GENERATOR STATOR
10. Put the other SCWP on STANDBY. WINDING COOLING
WATER SYSTEM

GENERATOR STATOR
Put the Stator Water Pressure Control Valve in
10. WINDING COOLING
AUTO set the Pressure Setpoint ~ 250 kPa. WATER SYSTEM

Verify that the Stator Cooling Water Flow GENERATOR STATOR


11. increases to ~ 1500 l/min and Pressure to ~ 250 WINDING COOLING
kPa. WATER SYSTEM

ST.08 FINISHED
ST.09 DRAFT PLANT (AIR) SYSTEM STARTUP & BOILER
PURGING
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

DRAFT PLANT STARTUP


START Guiding Bearing & Support Bearing Oil
1. FLUE AND AIR SYS
Circulating Pumps of Air Pre-Heater A & B.

START Air Pre-Heater A & B actuating motor. Place


2. FLUE AND AIR SYS
Auxiliary Motors on STANDBY.

Notice that the Air Pre-Heater Inlet & Outlet Dampers ()


3. FLUE AND AIR SYS
OPEN utomatically.

START ID Fan A Lube Oil System:

a. Ensure that the manual valves are OPEN

b. START ID Fan A and B Cooling Fan.

c. START ID Fan A and B Bearing Cooling Fan


4. IDFA
d. START ID Fan A LO Pump 1
(10HNC11AP001).

e. Place ID Fan A LO Pump 2


(10HNC12AP001) on STANDBY.

Check that lube oil pressure rises to NORMAL.

CLOSE ID Fan Inlet Valve (10HNA10AA001) and


5. FLUE AND AIR SYS
OPEN ID Fan A Outlet Valve (10HNA10AA002).

6. Ensure ID Fan Inlet Guide Vane position is minimum. FLUE AND AIR SYS

After meeting ID Fan A START permissive, START I.D.


Fan A. Observe that ID Fan A Inlet Damper opens
automatically within 60 sec. Also, Interconnecting
Damper (10HNA30AA001) opens Automatically.
7. FLUE AND AIR SYS
Maintain Furnace Draft of ~ 50 Pa.

Note: Instead of step 4,5 and 6, ID Fan START


Sequence can be initiated.
Check that Motor Winding, Bearing Temperatures and
8. IDFA
vibration are NORMAL.

START FD Fan A Lube Oil System:

a. Ensure the manual valves are OPEN.

9. b. START FD Fan A LO Pump -1. FDFA

c. Place FD Fan A LO Pump 2 in STANDBY.

Check that lube oil pressure is NORMAL.

CLOSE Discharge Damper of FD Fan A. Ensure FD


10. FLUE AND AIR SYS
Fan A Inlet Guide Vane position is minimum.

After meeting FD Fan permissive, START FD Fan.


Notice that Discharge Damper of FD Fan A opens
automatically after a time delay (60 s). Interconnecting
11. Damper will also OPEN automatically. FLUE AND AIR SYS

Note: Instead of step 9 and 10, FD Fan START


Sequence can be initiated.

FLUE AND AIR SYS


Following the same procedure, START other side ID
12.
and FD Fan. i.e. ID Fan B and FD Fan B. IDFB, FDFB

START ID Fan B Lube Oil System:

a. Ensure that the manual valves are OPEN

b. START ID Fan B LO Pump 1


13. (10HNC11AP001). IDFB

c. Place ID Fan A LO Pump 2


(10HNC12AP001) on STANDBY.

Check that lube oil pressure rises to NORMAL.

START FD Fan B Lube Oil System:

d. Ensure the manual valves are OPEN.

14. e. START FD Fan B LO Pump -1. FDFB

f. Place FD Fan B LO Pump 2 in STANDBY.

Check that lube oil pressure is NORMAL.

CLOSE Discharge Damper of FD Fan B. Ensure FD


15. FLUE AND AIR SYS
Fan B Inlet Guide Vane position is minimum.

After meeting FD Fan permissive, START FD Fan B.


Notice that Discharge Damper of FD Fan B opens
16. automatically after a time delay (60 s). Interconnecting FLUE AND AIR SYS
Damper will also OPEN automatically.

Note: Instead of step 9 and 10, FD Fan START


Sequence can be initiated.

Maintain Furnace Draft by manually varying the ID Fan FLUE AND AIR SYS
Guide Vane positions and once stabilized place ID Fan
17. FDF AND IDF
Controls on AUTO. Set a suitable setpoint of ~ -50 Pa
and ensure that the ID Fans Master Control is in AUTO. CONTROL

Adjust the FD Fan Guide Vane positions manually and


18. FLAME SUPERVISE
increase the air flow around 30% MCR (~ 660 t/hr).

Adjust the Auxiliary Air Dampers and maintain the Wind


19. SECOND AIR
Box to Furnace Differential Pressure at ~ 381 Pa.

BOILER PURGING
20. Bring the Burner Tilts into Horizontal position (50%). SECOND AIR

START one of the Scanner Air Fans and put the other
21. FLAME SUPERVISE
on STANDBY.

After ensuring that Purge Permissives are satisfied,


22. START Boiler Purge. PURGE
Bypass the Leak Tests.

23. Boiler Purge completes after 300 seconds. PURGE

Reset Master Fuel Trip (MFT) by pressing


24. ACKOWLEDGE button. MFT FIRST OUT
Similarly RESET the OFT.

ST.09 FINISHED
ST.10 CHARGING THE AUXILIARY STEAM HEADER
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

AUXILIARY BOILER STARTUP


Complete Checks.

a. Ensure that steam from the Auxiliary


Boiler is available.

b. Check electric supply is available to


related equipment.

c. Ensure the Air Pre-Heaters A & B


SCAPH Cold End Temperature Control
Valves are CLOSED.

d. Ensure that the Deaerator Pegging


Steam Supply Control Valve is
CLOSED.
1.
e. Check if Auxiliary Steam Header
Pressure and Temperature Control
Valves are CLOSED.

f. Ensure the Motorized Steam Isolation


Valves to Boiler Feed Pump Turbines
and Deaerator Motor Operated Valves
are CLOSED.

g. Ensure the Gland Sealing Steam Valve


is in CLOSED condition.

h. Ensure the Cold Reheat Steam to


Auxiliary Steam Header Block Valve is
CLOSED.

2. OPEN the Auxiliary Steam Header Drain Valve. LOCAL OPERATION

OPEN the Auxiliary Steam Interconnection


Valve (10LBH10AA001, 10LBG10AA003) from AUXILIARY STEAM
3. SYSTEM
Startup Boiler Unit Header to charge the
Auxiliary Steam Header.

CLOSE the Vents and Drain Valves after


4. sufficient air venting and Condensate Draining of LOCAL OPERATION
the Auxiliary Steam Header.
Check the Pressure and Temperature of the AUXILIARY STEAM
5. SYSTEM
Auxiliary Steam Header rises to NORMAL.

OPEN the Primary and Secondary SCAPH A or


AUXILIARY STEAM
6. B Inlet and Outlet Isolating Valves as per SYSTEM
requirement.

OPEN the Deaerator Pegging Steam Supply ` AUXILIARY STEAM


7. SYSTEM
Motorized Isolating Valves as per requirement.

OPEN the Gland Steam Supply Valve as per AUXILIARY STEAM


8. SYSTEM
requirement.

ST.10 FINISHED
ST.11 TURBINE GLAND STEAM SEALING SYSTEM
STARTUP
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

GLAND SEALING STEAM SYSTEM


STARTUP
Complete Pre-START Checks.

a. Check that Auxiliary Boiler is in service


and Auxiliary Steam Header parameters
are NORMAL.

b. Check that at least one Condensate


Extraction Pump) is running.
TURBINE GLAND SEAL
1. c. Ensure that Seal oil System is in STEAM SYSTEM
service.

d. Ensure that Turbine Lube Oil System is


in service and Main Turbine is on
Turning Gear.

e. Check that electrical supply is available


to all related equipment.

START any one of the Gland Sealing Blowers TURBINE GLAND SEAL
2. STEAM SYSTEM
(10LCC10AN001).

Put the other Gland Sealing Blower TURBINE GLAND SEAL


3. STEAM SYSTEM
(10LCC11AN001) on STANDBY mode.

OPEN Auxiliary Steam to Gland Seal MOV TURBINE GLAND SEAL


4. STEAM SYSTEM
(10LBG25AA001).

Put Auxiliary Steam to Seal Steam PCV on


TURBINE GLAND SEAL
5. AUTO by giving the set point of 35Kpa and STEAM SYSTEM
maintain Seal Steam Pressure ~ 30 kPa.

Put Seal Steam Overflow PCV on AUTO and set


the Setpoint ~ 45 kPa and OPEN the Overflow TURBINE GLAND SEAL
6. STEAM SYSTEM
to Condenser Motorized Valve
(10LBW10AA403).

Open the Condensate for LP Gland Seal Steam TURBINE GLAND SEAL
7. STEAM SYSTEM
Attemperation Supply MOV (10LCE22AA003).

8. Put the LP Gland Seal Steam Attemperation TURBINE GLAND SEAL


PCV on Auto and set the Setpoint ~ 150 C. STEAM SYSTEM

Request AO to open the LP Gland Seal Steam


9. LOCAL OPERATION
Attemperation Isolation Valve.

Verify that Temperature and Pressure


parameters are NORMAL. Maintain HP/IP TURBINE GLAND SEAL
10. STEAM SYSTEM
Sealing Steam at ~ 30-35 kPa, 340-350 C and
LP Sraling Steam at ~ 15-18 kPa, 145-150 C.

After Synchronization and subsequent Loading


of Main Turbine, when Steam is available at
suitable parameters from the No. 4 Extraction,
initiate Turbine Self-Sealing.

a. Open the Main Steam to Seal Steam


MOV (10LBW10AA002). TURBINE GLAND SEAL
11. STEAM SYSTEM
b. Put the Main Steam to Seal Steam
Pressure PCV on AUTO and set the
Setpoint ~ 30 kPa.

c. Simultaneously, CLOSE Auxiliary Steam


to Gland Seal MOV (10LBG25AA001).

ST.11 FINISHED
ST.12 CONDENSER VACUUM SYSTEM LINEUP AND
STARTUP
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

TURBINE DRIVEN BOILER


FEEDWATER PUMP A STARTUP
Complete Pre-START Checks.

a. Check CWPs are in service.

b. Check that at least one Extraction


Pump) is running.

c. Ensure that Seal oil System is in


service.

d. Ensure that Turbine Lube Oil System is


in service and Main Turbine is on
TURBINE VACUUM
1. Turning Gear.
EXTRACTION SYSTEM
e. Ensure Gland Sealing Steam System is
in service and Sealing Pressure ~ 30
kPa.

f. Ensure that all possible air paths to


Condenser are blocked (i.e. Turbine
Glands, Hot Reheat Vents and Drains,
Vacuum Breaker Valve etc.)

g. Check electric supply is available to


related equipment.

CLOSE Vacuum Breaker Valve TURBINE VACUUM


2. EXTRACTION SYSTEM
(10MAJ20AA001).

START any one Condenser Vacuum Pump


(CVP) (10MAJ10AP001, 10MAJ20AP001, TURBINE VACUUM
3. EXTRACTION SYSTEM
10MAJ10AP001). Observe that the Outlet Valve
opens automatically.

Ensure Condenser Vacuum reaches ~ -90 kPa,


TURBINE VACUUM
4. and if not START the second Condenser EXTRACTION SYSTEM
Vacuum Pump.

ST.12 FINISHED
ST.13 LDO FIRING, DEAERATOR PEGGING AND
INCREASING PRESSURE
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

Questions:
1. Why are the Drum Vents CLOSED at 2 MPa?

Answer: The drum vents are used to vent oxygen


dissolved gases from the boiler so they do not react
with the boiler tubes to cause corrosion. At 2 MPa,
the drum is considered free of air and the venting
process in complete.

LDO FIRING
1. Ensure that HFO OFT and LDO OFT are RESET. OFT FIRST OUT

Put SADC Dampers (all blue line dampers) on AUTO


and set a suitable Setpoint. Put Wind Box to Furnace SECONDARY AIR
2. SYSTEM
DP Control Valve on AUTO with a Setpoint of 381
kPa.

3. Request AO to OPEN the Boiler Drains and Vents LOCAL OPERATION

4. Ensure that the Fuel Oil System is in service LOCAL OPERATION

OPEN LDO Input and Return Oil Isolation Valves


5. LIGHT OIL
(10HJF75AA007, 10HJF85AA001).

OPEN Atomizing Air Pressure Control Valve and


6. LIGHT OIL
maintain Atomizing Air Pressure.

OPEN LDO Pressure Control Valve and maintain Fuel


7. LIGHT OIL
Oil Pressure.

FUEL IGNITION
8. Ensure that the Fuel Ignition Condition is satisfied.
CONDITION

AB Layer can be started in AUTO or Manual. The


9. whole elevation may be started or individual corners
may be started.

10a) AUTO Operation and Individual Oil gun Startup:


START pair AB1-AB3.

Procedure for placing any corner in service:

a. Place corner AB1 in AUTO.

b. If NO PURGE indication is glowing then


press STOP button. Observe that the
following steps will be executed:

-7 Oil Gun Advances

-8 Ignition Actuator Advances

-9 Purging Steam SHOVV Opens

-10 Ignition Actuator Energizes

-11 Oil Gun Purge Completes

-12 Oil Gun Actuator Retracts

-13 Purging steam SHOVV Closes

c. Press Startup button to START AB1


elevation. Notice Following steps will execute:

-14 Oil Gun Advance

-15 Ignition Actuator Advance

-16 Energize Ignition Actuator

-17 OPEN Fuel SHOVV

-18 Flame On.

d. If there is any failure then press reset.

Similarly place AB3 in operation.

Take the other remaining pair in service as well.

Manual and Individual gun Startup:

START pair AB1-AB3.

Procedure for placing any corner in service:

10b) a. Place corner AB1 in Manual.

b. The same steps as indicated earlier can be


performed manually.

Similarly place AB3 in operation and take the other


remaining pair i.e. AB2-AB4 in service as well.

10c) Whole layer or corner 13, 24 can be AUTO Started as


well by placing all corners in AUTO and performing
STOP (to Reset Purge) and START operations by
using AUTO START/STOP CORNER 13/24 and
AUTO START/STOP LAYER AB.

11. Maintain Furnace Exit Temperature < 600 C.

12. Notice the increase in Boiler Pressure.

Boiler Steam Pressure rises at 0.15MPa/min. & Temp.


13. rises ~ 1.74 C/min. Boiler Drum level should be BOILER DRAIN
maintained ~ +50mm to -50mm.

DEAERATOR PEGGING

FEEDWATER
14. Ensure Deaerator Level is NORMAL (300~350 mm). SYSTEM

Ensure Deaerator Manual/Motorized Air Vent Valves FEEDWATER


15. SYSTEM
(10LAA10AA501 & 10LAA10AA505) are OPEN.

OPEN Auxiliary Steam Header to Deaerator steam


16. LOCAL OPERATION
line Drains and Vent Valves.

Ensure Steam Extraction No.4 Motorized Valve FEEDWATER


17. SYSTEM
(10LBS40A003) is CLOSED

OPEN Auxiliary Steam Header to Deaerator Pegging


AUXILIARY STEAM
18. Steam line MOV & Isolation Valves (10LBG35AA001, SYSTEM
10LBG35AA002).

CLOSE Air Vents and Drains in Pegging Steam line


19. LOCAL OPERATION
after proper air venting

Observe that Deaerator Pressure and Temperature FEEDWATER


20. SYSTEM
gradually increases (0. 8 MPa, 150 C)

Once the Deaerator is sufficiently warmed and


FEEDWATER
21. pressurized, place the Auxiliary Steam to Deaerator SYSTEM
Control Valve on AUTO.

At Drum Pressure 0.20 0.25 MPa, request AO to


22. LOCAL OPERATION
CLOSE all Boiler Drains and Vents.

ST.13 FINISHED
ST.14 MOTOR DRIVEN BOILER FEEDWATER PUMP
STARTUP
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

MOTOR DRIVEN BOILER FEEDWATER


PUMP STARTUP
Check Deaerator Level NORMAL (+250 mm to
+350 mm). The Motor Driven Boiler Feed Pumps
1. (MDBFP) may be prepared for Startup before FEEDWATER SYSTEM
LDO Light Up but may be Started after Boiler
Drum Pressure crosses 0.2 MPa

OPEN the Suction Valve (10LAH10AA001) of


2. FEEDWATER SYSTEM
MDBFP Booster Pump.

Ensure that Priming of Booster Pump and


MDBFP is carried out, Casing Drains and Vent
3. LOCAL OPERATION
Valves are kept OPEN and Working Oil and Lube
Oil Cooler taken in service.

START Lube oil Pump (). Check Lube Oil


4. FEEDWATER SYSTEM
Pressure is NORMAL (~ 0.1 MPa).

OPEN the Recirculation Isolation Valves


5. (10LAH35AA001, 10LAH35AA002) are open and FEEDWATER SYSTEM
check that Re-Circulation Valve is fully OPEN

Ensure that electrical supply to motor is available.


6. After meeting the permissive, START the MDBFP FEEDWATER SYSTEM
(10LAJ10AP001).

Post Check:

a. Ensure that there is no abnormal


sound/vibration from Motor MOTOR DRIVEN FP AND
7. OIL SYSTEM
b. Check the Bearing Temperatures &
Vibrations of Pumps are within
permissible limits.

Line up the Feedwater path to Boiler Drum.


8. Ensure that the 30% Capacity Feedwater line FEEDWATER SYSTEM
Isolation Valves are OPEN (10LAB80AA003,
10LAB80AA004).

As per Boiler Drum level requirement, increase


decrease Feedwater flow by manually modulating
9. the position of the 30% Feedwater line Control BOILER DRAIN
Valve. Keep MDBFP Scoop Control at Minimum
opening (0%)

After Drum Level stabilizes, at ~ 20 -25% opening


of the 30% Feedwater line PCV, first put this valve
FEEDWATER SYSTEM,
10. on AUTO and set a suitable Drum Level Setpoint BOILER DRAIN
(~ 50-80 mm). Subseqiently put the MDBFP
Scoop on AUTO.

Monitor the Drum Level closely. Observe that in


order to control Boiler Drum Level, the 30% Valve
11. BOILER DRAIN
modulates in AUTO to 100% opening first and
then the MDBFP SCOOP increases.

ST.14 FINISHED
ST.15 A HP-LP BYPASS SYSTEM STARTUP

INSTRUCTOR ACTIVITY/ STUDENT REFERENCE


#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

HP-LP BYPASS SYSTEM STARTUP


Complete System Pre-START Checks.

a. Check that one BFP is in service

b. Check that one CEP is in service

c. Check HP-LP Bypass Control Oil


System is in service.
1. BYPASS
d. Check Condenser Vacuum is NORMAL
(< -88 kPa).

e. Ensure all the Drains in Hot Reheat &


Cold Reheat lines are Opened.

f. Ensure Drum Pressure > ~ 1.2 MPa


before Opening HP-LP Bypass System.

2. If not in service, START the HPU Oil Pump. BYPASS

OPEN the Superheater Outlet Main Steam MAIN AND REHEAT


3. SYSTEM
MOVs (10LBA10AA001 & 10LBA10AA002).

Ensure that the Feedwater Isolation Valves for


4. HP-LP Bypass Temperature Control are OPEN LOCAL OPERATION
and Feedwater is available for Attemperation.

Set HP Bypass Outlet Temperature Setpoint ~


5. 300340 C and put in AUTO mode. Put both LP BYPASS
Bypass Temperautre Control Valves in AUTO.

Put both HP and LP Bypass Valves in MANUAL


6. BYPASS
mode.

OPEN both the LP Bypass Valves by 0-2% and


7. slightly OPEN HP Bypass < 4% to warm up the BYPASS
channel.

According to Boiler Main Steam Outlet Pressure,


8. operate HP and LP Bypass manually in order to BYPASS
raise boiler parameters.

9. After 25% Opening of HP Bypass, put LP BYPASS


Bypass on AUTO mode, and then HP Bypass in
AUTO.

Slowly rise the Setpoints of HP & LP Bypass in


order to establish Main Steam flow as well as
raise Boiler parameters for Turbine Rolling (Main BYPASS
Steam ~ 6 MPa, 350 C, Reheat Steam ~ 1.2
MPa, 340 C).

After 6 MPa Main Steam Pressure and ~ 1.2-1.3


Reheat Steam Pressure is achieved, the Bypass
10. BYPASS
system should be in AUTO mode before rolling
of Main Turbine.

After Synchronization, the Bypass Valves will


tend to CLOSE as steam will be taken up by the
Turbine. When the Bypass Valves reach
11. BYPASS
Opening of ~ 2%, put them in manual and
CLOSE them: first HP Bypass and then LP
Bypass.

Observe that there is no abnormal rise of Main


12.
Steam Pressure in the system.

ST.15 A FINISHED
ST.15 B HFO FIRING AND INCREASING BOILER
PRESSURE ~ 6 MPA
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

HFO FIRING
Take HFO Oil Guns into service after meeting HFO
1. OFT FIRST OUT
Ignition Conditions. [BC, DE, EF Elevations]

OPEN Auxiliary Steam to Atomizing Steam for Fuel Oil


MOV (10LBG50AA001) and Auxiliary Steam to HFO HFO IGNITION
10. CONDITION
Heaters MOV (10LBG10AA001) to meet HFO Ignition
Condition.

2. Ensure that Fuel Oil System is in service LOCAL OPERATION

OPEN HFO Input and Return Oil Isolation Valves


3. OIL BC
(10HJF70AA007, 10HJF80AA001).

OPEN Atomizing Air Pressure Control Valve and


4. OIL BC
maintain Atomizing Air Pressure.

OPEN HFO Pressure Control Valve and maintain


5. OIL BC
Fuel Oil Pressure.

FUEL IGNITION
6. Ensure that the Fuel Ignition Condition is satisfied.
CONDITION

BC Layer can be started in AUTO or Manual. The


7. whole elevation may be started or individual corners OIL BC
may be started.

AUTO Operation and Individual Oilgun Startup:

START pair BC1-BC3.

Procedure for placing any corner in service:

8a) a. Place corner BC1 in AUTO. OIL BC

b. If NO PURGE indication is glowing then


press STOP button. Observe that the
following steps will be executed:

-19 Oil Gun Advances


-20 Ignition Actuator Advances

-21 Purging Steam SHOVV Opens

-22 Ignition Actuator Energizes

-23 Oil Gun Purge Completes

-24 Oil Gun Actuator Retracts

-25 Purging steam SHOVV Closes

c. Press Startup button to START BC1 Corner.


Observe that the following steps will occur in
sequence:

-26 Oil Gun Advance

-27 Ignition Actuator Advance

-28 Energize Ignition Actuator

-29 OPEN Fuel SHOVV

-30 Flame On.

d. If there is any failure then press reset.

Similarly place BC3 in operation.

Take the other remaining pair in service as well.

Manual and Individual gun Startup:

START pair BC1-BC3. Procedure for placing any


corner in service:

c. Place corner BC1 in Manual.


8b). OIL BC
d. The same steps as indicated earlier can be
performed manually.

Similarly place BC3 in operation and take the other


remaining pair i.e BC2-BC4 in service as well.

Whole layer or corner 13, 24 can be AUTO Started


as well by placing all corners in AUTO and
8c) performing STOP (to Reset Purge) and START OIL BC
operations by using AUTO START/STOP CORNER
13/24 and AUTO START/STOP LAYER BC.

Simultaneously, operate the Bypass Valves and also BYPASS, BOILER


9. DRAIN
keep monitoring the Boiler Drum Level and Pressure.

10. Take HFO Oil Guns into service as per requirement. OIL DE, OIL EF

11. Notice the increase in Boiler Pressure. Boiler Steam


Pressure rises at 0.15MPa/min. & Temp. rises ~ 1.74
C/min.

ST.15 B FINISHED
ST.16 TURBINE PREHEATING, WARMING AND ROLLING

INSTRUCTOR ACTIVITY/ STUDENT REFERENCE


#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

TURBINE PREHEATING, WARMING


AND ROLLING
Request AO to OPEN Main Steam, CRH, HRH
1. Pipe Line High Press. & Low Pressure Drains LOCAL OPERATION
going to Flash Tanks.
IP Rolling can be Started when following
parameters are reached
For Cold Startup (Long time shutdown)
-3 Drum Pressure ~ 6.0 MPa,
2. -4 Main Steam Temperature ~ 335 C
-5 Reheat Temperature to 315 C,
-6 Reheat Steam Pressure ~ 1.10 MPa
-7 Condenser Vacuum >74 KPa,
-8 HP Bypass Flow Rate > 140 t/h
HP Cylinder Casing Preheating is to be done in
order to achieve HP Casing Temperature ~ 160
3.
C (if HP Casing Inner Wall Temp. > 160 C no
Preheating is required).

HP Turbine Preheating can be done as Main


4. Steam Parameters of ~ 3-4 MPa, 250 C are
achieved.

TURBINE PREHEATING

Ensure that the Auxiliary Header is charged and


5. Auxiliary Steam Parameters are NORMAL (~ 0.9 AUXILIARY STEAM
MPa, 340 C).

OPEN the HP Cylinder Exhaust Check Valve


6. MAIN STEAM AND BYPASS
BDV.

7. CLOSE the HP Cylinder Ventilation Valve. MAIN STEAM AND BYPASS

8. CLOSE CRH Drain Valve After Check Valve. MAIN STEAM AND BYPASS

OPEN the Auxiliary Steam to Turbine Preheat AUXILIARY STEAM


9. SYSTEM
PCV gradually.
Using the Preheat Spray CV maintain
AUXILIARY STEAM
10. temperature of Preheat Steam at not more than SYSTEM
160 C.

Adjust the Auxiliary Steam to Turbine Preheat


AUXILIARY STEAM
11. PCV in order to maintain ~ 0.5 MPa Preheat SYSTEM
Steam Pressure.

Maintain Preheat Steam Temperature and


Pressure and heat the Turbine for ~ 45 minutes AUXILIARY STEAM
12. SYSTEM
to achieve HP Casing Inner Wall Temp > 160
C.

CLOSE the Auxiliary Steam to Turbine Preheat AUXILIARY STEAM


13. SYSTEM
PCV.

14. OPEN the HP Cylinder Exhaust Check Valve. MAIN STEAM AND BYPASS

15. OPEN the HP Cylinder Ventilation Valve. MAIN STEAM AND BYPASS

16. OPEN CRH Drain Valve After Check Valve. MAIN STEAM AND BYPASS

TURBINE WARMING AND ROLLING

20. Select START mode as IP START.

Turbine will be TRIPPED initially. Reset or latch


21. AUTO CONTROL
the Turbine

22. Select mode as AUTO AUTO CONTROL

If CV Temperature is less than 180 C, then


23. AI MONITOR
CV warming is needed.

Put CV Warming IN.

24. Notice MSV2 OPENs to around 21%. Ensure AUTO CONTROL


that all other stop valves are CLOSE. All
Drains and BDV should be OPEN.

CV Inner and Outer Temp diff should not be


more than 50/30 C else need to do Chest AUTO CONTROL
25. Warming Out. Chest heating is done till temp
of about 180 C is achieved. It takes around AI MONITOR
1.5 hrs to do CV warming.

Provide the RUN Command. Notice that both


25. AUTO CONTROL
MSVs and RSVs OPEN fully.

26. Perform Heat Soak IN. AUTO CONTROL

Set Target of 200 rpm. Acceleration rate get set


27. AUTO CONTROL
to 100 rpm/min/min. Press GO.
Notice corresponding Opening of IPCVs and
notice 200 rpm speed is achieved.

During entire rolling, CLOSE the Bypass valves


accordingly.

Set Speed target of 1500 rpm. Choose


28. acceleration set as 100. Turbine will speed up at AUTO CONTROL
the rate of 100 rpm per minute up to 1500 rpm.

Notice the corresponding Opening of HPCVs


and IP CVs begin to CLOSE. IPCVs will OPEN
one minute delay after speed reaches 400 rpm
and HPCVs position gets locked.
30. AUTO CONTROL
Notice that acceleration rate changes to 300
rpm/min/min Automatically when speed is within
critical range.

Turbine Soak time is around 120-240 minutes if


31. AUTO CONTROL
IP cylinder is Starting after long shut down.

During warm up, monitor metal temp. at HP & IP


cylinder exhaust. When HP exhaust metal temp
32. reaches 250 C, adjust the manual valve after AUTO CONTROL
VV valve and control HP exhaust hood temp.250
C.

Set Speed target of 3000 rpm and press GO.


Check and confirm that HPCVs are gradually
33. AUTO CONTROL
CLOSED; IPCV valves will control unit speed.
Close HP Exhaust Check Valve BDV.

After the following target values are achieved,


Heat Soak OUT can be performed.

34 Target values IP inner casing wall admission AUTO CONTROL


side temp 320 C, HP regulating stage internal
casing reaches 320 C, IP exhaust will be 240
C

Stop TOP after Turbine speed > 2900 rpm and


35. put in STANDBY, stop MSP also. Check Lube AUTO CONTROL
Oil Pressure at all bearings is NORMAL.

Check JOP stops automatically, or should be


36. AUTO CONTROL
stopped manually and put on STANDBY.

Maintain the following parameters:

-9 Maintain MS Press. 6.0 MPa, Temp. 385


37. C, MS flow 250 t/hr AUTO CONTROL

-10 Maintain RH Press. 0.5 MPa, Temp. 365


C, RH flow 140 t/hr
After warm up at 3000 rpm is completed and
38. electrical parameters are achieved, Unit may be AUTO CONTROL
synchronized

After Synchronisation, OPEN the Hp Exhaust to


39. CRH Check Valve and CLOSE the HP MAIN STEAM AND BYPASS
Ventilation Valve.

ST.16 FINISHED
ST.17 EXCITATION AND SYNCHRONISATION

INSTRUCTOR ACTIVITY/ STUDENT REFERENCE


#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

EXCITATION
Check that TURBINE is running near 3000 rpm
1. AUTO CONTROL
and all Turbine/T-G parameters are NORMAL.

Ensure all the cooling fans of Excitation Panel


2. LOCAL OPERATION
and Excitation Transformer are in service.

Ensure that AVR AUTO Command is ON. Also


ensure that AVR Channel (AVR-1 or AVR-2)
3. EXCITATION SYSTEM
through which voltage build-up shall be done is
selected.

Click the excitation system button to OPEN the


4. excitation system menu. Then see that EXCITATION SYSTEM
PROBHITION OPERATION is de-activated.

Click the Excitation System ON button. After


this command, ensure that the DMAG switch
is CLOSED and EXCITATION SYSTEM
5. EXCITATION SYSTEM
WORKING becomes RED. Then the
Generator terminal voltage STARTs building up
Automatically upto 22kV.

Ensure that the Generator terminal


6. voltage/Frequency should be around 22 kV/50 MAIN SYSTEM
Hz without any fluctuation and are stable.

SYNCHRONISATION

Switch ON the DC Power supply MCB in the


back side of the synchronization panel to
1. LOCAL OPERATION
extend the DC power to the synchroscope &
aux. relays.

Ensure the following button are in RED colour

2. -3 DMAG switch is CLOSED, SYN SYSTEM

-4 Turbine speed >2900 RPM


-5 Gen. frequency >48.5 Hz

-6 Gen. AC Voltage >90%

Select the synchronizing breaker through which


Generator synchronization is to be done. Click
3. SYN SYSTEM
the concerned breaker button and ensure that
the colour changes to RED.

4. Ask Turbine desk to put AUTO SYNC. IN. AUTO CONTROL

Notice that 2 blocks for synchronizing breaker


are generated in the SYNC. SYSTEM menu.
5. SYN SYSTEM
Click the concerned breaker to be
synchronized.

Click the sync. RESET button and then click


6. SYN SYSTEM
START SYNCHRONISATION

Then see that, the synchroscope is in action


7. and it will give CLOSEcommand to the LOCAL OPERATION
selected breaker after permissive are satisfied.

Then Switch OFF the DC Power MCB at the


8. LOCAL OPERATION
back side of Synchronisation Panel

Check the terminal voltage, load current,


9. active/reactive power, PF of the generator is MAIN SYSTEM
NORMAL.

Ensure that the cooling fans of Excitation Panel


10. NOT MODELLED
& Excitation Transformer are in service.

Notice that Turbine goes to Valve Position


11. Control. Gradually increase the position to AUTO CONTROL
30%.

ST.17 FINISHED
ST.18 PRIMARY AIR FAN STARTUP

INSTRUCTOR ACTIVITY/ STUDENT REFERENCE


#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

PA FAN STARTUP
Pre Checks:

a. Ensure Pulverize side equipments such


as seal air fans and valves, hot and cold
air duct dampers etc. are CLOSED.

b. Equipment cooling water system is


1. running and oil coolers are in charged FLUE AND AIR SYS
condition.

c. At least one set of ID fan and FD fan are


running with furnace purging completed

d. One Air preheated is in service with air /


gas dampers in OPEN condition.

Line up PA Fan A Lube Oil System:

a. Check Lube Oil Supply Tank Level is


NORMAL.

b. Line up the PA fan lube oil circuit, OPEN


2. LP and HP pumps' discharge valves. PAF A

c. START any one LP oil pump. START any


one HP oil pump. Put the other LP and HP
lube oil pumps in interlock mode.

Ensure Lube Oil pressure is OK.

Ensure that blade pitch controller is in minimum


3. FLUE AND AIR SYS
position.

OPEN corresponding APH primary air outlet


4. damper; CLOSE discharge damper of PA Fan to FLUE AND AIR SYS
be taken in service.

After ensuring electrical supply, START PA Fan


5. FLUE AND AIR SYS
A.

6. Check that outlet damper for PA fan OPENs after FLUE AND AIR SYS
a time delay and discharge damper for other PA
fan CLOSEs on interlock.

7. Check the bearing temperatures and vibrations. PAFA

Increase the loading of PA fan, bring PA


8. header pressure to around 8-9 KPa. Place the FLUE AND AIR SYS
controller in AUTO mode.

After ensuring electrical supply, OPEN suction


9. SEALING AIR SYS
damper of Seal Air fan to be Started.

Ensure Seal Air header outgoing dampers to


10. various coal feeders and mills are in CLOSED SEALING AIR SYS
condition

START Seal Air Fan A and place other Seal Air


11. SEALING AIR SYS
Fan B in STANDBY.

OPEN seal air header to coal mill or coal feeder


12. SEALING AIR SYS
seal air dampers as per requirement.

START PA Fan B by same procedure as and


13. PAFB , FLUE AND AIR SYS
when required.

ST.18 FINISHED
ST.19 PULVERISER/MILL A WARMING AND STARTUP

INSTRUCTOR ACTIVITY/ STUDENT REFERENCE


#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

MILL STARTUP
Pre Checks:

e. Ensure Pulverize side equipments such


as seal air fans and valves, hot and cold
air duct dampers etc. are CLOSED.

f. Equipment cooling water system is MILL A ,


1. running and oil coolers are in charged
condition. FLUE AND AIR SYS

g. At least one set of ID fan and FD fan are


running with furnace purging completed

h. One Air preheater is in service with air /


gas dampers in OPEN condition.

Line up Mill A Lube Oil System:

d. Check Lube Oil Supply Tank Level is


NORMAL.

e. START Mill Motor Lube Oil Pump.

f. START the lube oil pumps ( LP and HP) for


the pulveriser and notice that outlet
LUBE OIL AND JACKING
pressure is OK. OIL A;
2.
LP: 0.5 MPa HP:16 MPa. MILL A
g. START any one LP oil pump. START any
one HP oil pump. Put the other LP and HP
lube oil pumps in interlock mode.

h. START Reducing Oil Pump and Mill


Cooling Fan.

Ensure Lube Oil pressure is OK.

3. Ensure that Mill A path is lined up. MILL A

4. START Mill bull gear seal air fan. MILL A


Ensure that ignition energy permit is available as
5. given in FSSS logic for the elevation in which mill MILL A
is to be put into operation.

OPEN the cold air damper and ensure air flow


6. MILL A
through mill.

Establish hot air flow through the mill by


Opening the respective hot air damper and
7. bypass and capacity air dampers. Raise the MILL A
mill outlet temperature to a value of around 75
C to 80 C.

8. After meeting Mill A permissives, START Mill A. MILL A

OPEN the bunker outlet gate and feeder inlet


gate and charge the coal up to feeder.

OPEN the feeder outlet gate.


9. MILL A

After meeting the permissives, START the


feeder he feeder STARTs and coal flow rate
comes to approximately 12 t/h

Increase the loading on the mill by raising the


coal from the feeder gradually.
10. MILL A
Maintain the pulveriser outlet temperature to
about 77 C by controlling Hot & Cold PA flow.

ST.19 FINISHED
ST.20 TURBINE DRIVEN BOILER FEEDWATER PUMP - A
STARTUP
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

TURBINE DRIVEN BOILER


FEEDWATER PUMP A STARTUP
Complete Checks.

a. Check that the Deaerator Level is


NORMAL

b. Check electric supply is available to


related equipment.

c. Check that the Turbine Exhaust Valve to


1. Condenser is fullly CLOSED and
BFPT A SYSTEM
Turbine is on Turning Gear rotating at
10 rpm.

d. Check that Condenser Vacuum is


NORMAL.

e. Check that all the Bearing Temperatures


of Motor/Pumps are NORMAL (< 75 C).

Check Recirculation line is OPEN, put


2. Recirculation Valve in MANUAL mode and
OPEN fully.

OPEN Steam Stop & Control Valve Before and


3. BFPT A SYSTEM
After Drain Valves.

Check electrical supply is available to Booster


Pump and OPEN Inlet MOV. Verify that all
4. FEEDWATER SYSTEM
permissive conditions are satisfied for Booster
Pump START.

Charge Gland Sealing to Turbine (Pressure ~


0.124 MPa, Temperature ~ 150-180 C) by
5. BFPT A SYSTEM
Opening Front and Back Shaft Sealing Valves of
BFPT-A.

Lineup No. 4 Extraction Steam path to BFPT-A TURBINE EXTRACTION


6. SYS
by Opening the (10LBR11AA001).

7. Lineup Auxiliary Steam path to BFPT-A by AUXILIARY STEAM


Opening the (10LBG30AA001). SYSTEM

OPEN No. 4 Extraction to BFPT-A MOV and


8. BFPT A SYSTEM
Cold Reheat Steam to BFPT-A MOV.

START Booster Pump. Verify that there is


10. BFPT A SYSTEM
Recirculation Flow.

Check MEH-A is NORMAL. Press RESET to


11. MEHA
Latch the Turbine. Also, put MEH in AUTO.

12. OPEN Turbine Exhaust Valve to Condenser. BFPT A SYSTEM

13 Verify that the Stop Valve is fully OPEN. MEHA

Set TARGET as 500 rpm and press GO. Wait


14. MEHA
for ~ 5 minutes.

15. Set TARGET to 2000 rpm and press GO. MEHA

CLOSE all drains once Turbine crosses 2400


16. BFPT A SYSTEM
rpm.

17. Set TARGET to 3400 rpm and press GO. MEHA

Verify that MEH is in AUTO and CCS DEMAND


18. is approximately equal to the MEH TARGET. MEHA
Also verify that Turbine Speed > 2840 rpm.

Press MEH-A CCS REQUEST and verify that it


19. shows MEH-A CCS CUT. This means that FEEDWATER SYSTEM
TDBFP may be taken on to CCS control.

Press CCS IN. Verify that the indication shows


20. MEHA
CCS IN.

BFPT-A may now be operated from CCS


21. FEEDWATER SYSTEM
Control in AUTO or MANUAL.

Gradually increase BFPT-A discharge pressure


22. to match the Feedwater Header Pressure. FEEDWATER SYSTEM
OPEN BFPT-A Outlet MOV.

After required flow from BFPT-A is achieved,


23. FEEDWATER SYSTEM
CLOSE Recirculation Valve.

ST.20 FINISHED
ST.21 CHARGING THE LOW PRESSURE HEATERS FROM
STEAM SIDE
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

CHARGING THE LP HEATERS


Complete Pre-START Checks.

a. The Unit should on load and HP-LP


Bypass Valves should be CLOSED.
1.
b. Check electric supply is available to
related equipment.

c. Check Condenser Vacuum is NORMAL.

Check that for LP Heaters - 7A, 8A, 7B, 8B, the


Condensate Inlet/Outlet Valves are in OPEN LP HEATER DRAIN
2. SYSTEM
condition and Bypass Valves are in CLOSED
condition.

Ensure all the shell side Heater Vents are in LP HEATER DRAIN
3. SYSTEM
OPEN condition.

Check that all the isolating valves of the LP


LP HEATER DRAIN
4. heater level controllers are full OPEN for all the SYSTEM
heaters.

For LPH 7A, 8A and LPH 7B, 8B put the


NORMAL drain valve control switch to control LP HEATER DRAIN
5. SYSTEM
mode. The valve STARTs modulating to
maintain the LP heater level.

Check that LPH-6 Condensate Inlet & Outlet


LP HEATER DRAIN
6. Valves are in OPEN condition and Bypass Valve SYSTEM
is CLOSED.

OPEN the Extraction Steam Isolating Valve to LP HEATER DRAIN


7. SYSTEM
LPH-6.

OPEN the Extraction Steam NRV Solenoid to Lp


LP HEATER DRAIN
8. Heater 6. The NRV position STARTs increasing SYSTEM
and the steam enters LPH-6.

Put the NORMAL Drain Valve Control to AUTO LP HEATER DRAIN


10. SYSTEM
mode. The valve STARTs modulating to
maintain the LP Heater Level.

Check the Condensate Inlet & Outlet Valves for


LP HEATER DRAIN
11. the LPH-5 are OPEN and Bypass Valve SYSTEM
CLOSED.

OPEN the Extraction Steam Isolation Valve to LP HEATER DRAIN


12. SYSTEM
LPH-5

Put the NORMAL Drain Valve Control to AUTO


LP HEATER DRAIN
13 mode. The valve STARTs modulating to SYSTEM
maintain the LP Heater Level.

OPEN the Extraction Steam NRV Solenoid to LP


LP HEATER DRAIN
14. Heater 5. The NRV position STARTs increasing
SYSTEM
and the steam enters LPH-5.

Check the condensate temperature after


LP HEATER DRAIN
15. LPH-7A, 8A, 7B, 8B and LPH 6 and LPH 5 The SYSTEM
temperature should gradually increase.

16. CLOSE the Heater Vents. LOCAL OPERATION

ST.21 FINISHED
ST.22 SWITCHOVER TO UNIT AUXILIARY TRANSFORMER
FROM STATION TRANSFORMER AT ~150 MW TO FEED
AUXILIARY EQUIPMENT
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

TURBINE DRIVEN BOILER


FEEDWATER PUMP B STARTUP
Complete Pre-START Checks.

a. Ensure that the Generator is


Synchronized and Unit is on Load..
1. ELEC MAIN SYSTEM
b. Check that Unit Load is ~ 150 MW and
that there is no fault in the Electrical
System.

Check that the Bus Voltages of 11 kV COMMON


2. SWGR A & 11kV COMMON SWGR B are COMMON 11 KV SYSTEM
NORMAL.

CLOSE COMM 1101A Breaker to supply 11 kV


3. COMMON 11 KV SYSTEM
COMMON SWGR A Bus.

CLOSE COMM 1101B Breaker to supply 11 kV


4. COMMON 11 KV SYSTEM
COMMON SWGR B Bus.

Observe that the COMM 1102A Breaker and the


5. COMMON 11 KV SYSTEM
COMM1102B Breaker OPEN Automatically.

Verify that the Bus Voltages of 11 kV COMMON


6. SWGR A & 11kV COMMON SWGR B are COMMON 11 KV SYSTEM
NORMAL.

Verify that no electrical equipment has tripped


7.
and Electrical System is NORMAL.

ST.22 FINISHED
ST.23 MILL B STARTUP

INSTRUCTOR ACTIVITY/ STUDENT REFERENCE


#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

MILL B STARTUP
Place Mill B in service following the same
1. MILL B
procedure as used for Mill A.

Maintain Boiler Drum Level, Superheat & Reheat BOILER DRAIN, SH AND
2. RH
Steam Temperatures.

3. Monitor the parameters. BOILER DRAIN

START removing Oil Guns from service as


4.
required.

ST.23 FINISHED
ST.24 CHARGING THE HIGH PRESSURE HEATERS FROM
STEAM SIDE AT ~ 180 MW
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

CHARGING THE HP HEATERS


Complete Pre-START Checks.

a. The Unit should on Load and HP-LP


Bypass Valves should be CLOSED.

b. The Unit Load should be ~ 30 % (180


MW) with both set of Auxiliaries (Boiler
1. as well as Turbine) running.

c. The Boiler Pressure should be ~ 10.0


MPa.

d. Check electric supply is available to


related equipment.

e. Check Condenser Vacuum is NORMAL.

Request AO to OPEN the Shell Side Drains and


2. LOCAL OPERATION
Vents.

Ensure that the HP Heaters 3, 2, 1 streams are


charged from Feedwater side i.e. HP Heater
3. Feedwater Inlet and Outlet Valves FEEDWATER SYSTEM
(10LAB70AA001, 10LAB80AA001) OPEN With
Bypass Valve CLOSED.

OPEN the Extraction Steam to HP Heater 3


4. FEEDWATER SYSTEM
Non-Return Valve (10LBQ30AA001).

OPEN the Extraction Steam to HP Heater 3 by


5. opening MOV after Non Return Valve FEEDWATER SYSTEM
(10LBQ30AA002).

Put No. 3 HP Heater NORMAL Drain Valve in


6. FEEDWATER SYSTEM
AUTO.

Check that the Heater 3 Levels are NORMAL


7. and controller modulates valve position to FEEDWATER SYSTEM
maintain level.

8. CLOSE the Extraction Steam Line Drain Valve FEEDWATER SYSTEM


before & after HP Heater 3 Non-Return Valve
(10LBQ30AA402, 10LBQ30AA412,
10LBQ30AA422).

Check that HP Heater 3 Feedwater Outlet


10. FEEDWATER SYSTEM
Temperature increases.

In the same manner, charge HP Heater 2 and


HP Heater 1 also. Check that HP Heater
11. FEEDWATER SYSTEM
NORMAL Drain Valves maintain the HP
Heaters levels.

Check that the HP Heater 2 & 1 Feedwater


12. FEEDWATER SYSTEM
Outlet Temperatures increase.

Request AO to CLOSE the HP Heaters Shell


13 LOCAL OPERATION
Side Drains and Vents.

ST.24 FINISHED
ST.25 LOAD RAISING 180 - 300 MW

INSTRUCTOR ACTIVITY/ STUDENT REFERENCE


#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

LOAD INCREASE
After warming up for 20 minutes at Unit Load ~
1. 180 MW, put the Throttler Pressure (TP) control AUTO CONTROL
IN.

Raise the Load to ~ 300 MW by raising Coal Mill


loading, at rate of Load rise ~ 3 MW/ min, rate of
2. rise of Main Steam Temperature ~ 1.5 C/min, AUTO CONTROL
rate of rise of Main Steam Pressure ~ 0.1
MPa/min.

Maintain Boiler Drum Level, SH, RH


3. BOILER DRAIN
Temperatures simultaneously.

4. Monitor all the parameters for any abnormality.

5. Remove Oil Guns from service as required.

ST.25 FINISHED
ST.26 LOAD 270 MW

INSTRUCTOR ACTIVITY/ STUDENT REFERENCE


#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

LOAD INCREASE
When Load rises to ~ 270 MW, START the third
1. MILL C
Coal Mill

The Turbine may be placed in Load Control if


2. AUTO CONTROL
desired. Put LOAD Control IN for this.

When the Unit Load is ~ 300 MW, maintain it for


20 minutes, and raise the Main Steam Pressure
3.
to ~ 10.0 MPa, Main Steam Temperature to ~
520 C, Reheat Steam temperature to ~ 510 C.

When the Unit Load reaches ~ 300 MW, confirm


that the Furnace Combustion is stable, and
4.
Boiler parameters are NORMAL, all oil guns are
stopped, and Oil is put into Long Re-Circulation.

ST.26 FINISHED
ST.27 TURBINE DRIVEN BOILER FEEDWATER PUMP - B
STARTUP
INSTRUCTOR ACTIVITY/ STUDENT REFERENCE
#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

TURBINE DRIVEN BOILER


FEEDWATER PUMP B STARTUP
Complete Checks.

a. Check that the Deaerator Level is


NORMAL

b. Check electric supply is available to


related equipment.
1. c. Check that the Turbine Exhaust Valve to
BFPT B SYSTEM
Condenser is fully CLOSED and Turbine
is on Turning Gear rotating at 10 rpm.

d. Check Condenser Vacuum is NORMAL.

e. Check that all the Bearing Temperatures


of Motor/Pumps are NORMAL (< 75 C).

Check Recirculation line is OPEN, put


2. Recirculation Valve in MANUAL mode and
OPEN fully.

OPEN Steam Stop & Control Valve Before and


3. BFPT B SYSTEM
After Drain Valves.

Check electrical supply is available to Booster


Pump and OPEN Inlet MOV. Verify that all
4. FEEDWATER SYSTEM
permissive conditions are satisfied for Booster
Pump START.

Charge Gland Sealing to Turbine (Pressure ~


0.124 MPa, Temperature ~ 150-180 C) by
5. BFPT B SYSTEM
Opening Front and Back Shaft Sealing Valves of
BFPT-B.

Lineup No. 4 Extraction Steam path to BFPT-B. TURBINE EXTRACTION


6. SYS

Lineup Auxiliary Steam path to BFPT-B. AUXILIARY STEAM


7. SYSTEM
OPEN No. 4 Extraction to BFPT-B MOV and
8. BFPT B SYSTEM
Cold Reheat Steam to BFPT-B MOV.

START Booster Pump. Verify that there is


10. BFPT B SYSTEM
Recirculation Flow.

Check MEH-B is NORMAL. Press RESET to


11. MEHB
Latch the Turbine. Also, put MEH in AUTO.

12. OPEN Turbine Exhaust Valve to Condenser. BFPT B SYSTEM

13 Verify that the Stop Valve is fully OPEN. MEHB

Set TARGET as 500 rpm and press GO. Wait


14. MEHB
for ~ 5 minutes.

15. Set TARGET to 2000 rpm and press GO. MEHB

CLOSE all drains once Turbine crosses 2400


16. BFPT B SYSTEM
rpm.

17. Set TARGET to 3400 rpm and press GO. MEHB

Verify that MEH is in AUTO and CCS DEMAND


18. is approximately equal to the MEH TARGET. MEHB
Also verify that Turbine Speed > 2840 rpm.

Press MEH-B CCS REQUEST and verify that it


19. shows MEH-B CCS CUT. This means that FEEDWATER SYSTEM
TDBFP may be taken on to CCS control.

Press CCS IN. Verify that the indication shows


20. MEHB
CCS IN.

BFPT-B may now be operated from CCS


21. FEEDWATER SYSTEM
Control in AUTO or MANUAL.

Gradually increase BFPT-B discharge pressure


22. to match the Feed water Header Pressure. FEEDWATER SYSTEM
OPEN BFPT-B Outlet MOV.

After required flow from BFPT-B is achieved,


23. FEEDWATER SYSTEM
CLOSE Recirculation Valve.

SHUTTING DOWN MD BFP

After Feed water flow has stabilized and Boiler


24. Drum Level is also NORMAL, START the FEEDWATER SYSTEM
process of taking the MD BFP out of service.

25. OPEN the MD BFP Recirculation Valve fully. FEEDWATER SYSTEM

26. CLOSE the MD BFP Outlet Discharge Valve. FEEDWATER SYSTEM

27. Stop the MD BFP. FEEDWATER SYSTEM


Verify that the Booster Pump as well as the
28. Feed Pump is out of service and all parameters FEEDWATER SYSTEM
are NORMAL.

ST.27 FINISHED
ST.28 LOAD RAISING 300 - 600 MW

INSTRUCTOR ACTIVITY/ STUDENT REFERENCE


#
OPERATING PROCEDURE RESPONSE SCREEN
Instructor Information

Discuss:

LOAD INCREASE
After maintaining the Load at 300 MW for 20 MILL , FDF AND IDF
1. CONTROL
minutes, place all Controls in AUTO.

Boiler Master (BM), Turbine Master (TM) can be


put on AUTO. For BM to be in AUTO, Capacity Air
Controls should be in AUTO. Place Air Master FD
UNIT COMMAND
2. Fan Control on AUTO also. CONTROL
For TM to be in AUTO, CCS Control should be put
IN from AUTO Control screen in the DEH Menu.

Keep the BM, TM in either Boiler Follow Turbine


UNIT COMMAND
3. (BFT) or Turbine Follow Boiler (TFB) mode and CONTROL
appropriately give Setpoints for Load & Pressure.

Raise the Load ~ 600 MW at the rate of 6 MW/min,


Main Steam Temperature to rise at 1.5 deg. C/min,
MS Pressure at < 0.2 MPa/min

a. When the Load rise to 360 MW, START the


fourth Coal Mill.
4. b. When load rises to 360 MW, boiler soot
MILL D, MILL E
blowing can be started and APH Soot
Blowing can be operated as required.

c. When the Load rises to 480 MW, START


the fifth Coal Mill and increase the load to
600 MW.

5. Observe the system and the parameters

ST.28 FINISHED
SIMULATOR PLANNED SHUTDOWN PROCEDURE

MAJOR STEPS INVOLVED IN PLANNED SHUTDOWN:


1. Reduce the Unit Load to 540 MW, and simultaneously reduce the Main Steam
Pressure and Temperature as per the Turbine Stop Curves.
2. Gradually reduce the Unit Load to 300 MW.
3. Set Main Steam Pressure change rate < 0.1 MPa/min, Main Steam Temperature
change rate < 1.0 deg. C/min, reduce Load to 30% of rated capacity (~ 180
MW).
4. When the Load reduces to 180 MW, increase the number of oil guns and stop
one Coal Mill.
5. Reduce the Unit Load to 60 MW.
6. When the Unit Load reduces below 60 MW, keep Main Steam Temperature at ~
400 deg. C, Reheat Steam Temperature at ~ 325 deg. C, Main Steam Pressure
at ~ 8.62 MPa..
7. Stop the last Coal Mill, stop Primary Air Fans and Seal Air Fans.
8. Start the Turbine Oil Pump, Main Supply Pump, and check for any abnormality
in the Turbine Lube Oil system.
9. Trip the Turbine manually, and observe that Load MW and MVAR reduce to
zero and that the Generator is ahnhnlso tripped.
10. After TG trip, control the Oil flow, maintain Furnace Outlet Temperature < 538
deg. C.
11. After TG trip, stop all Oil Guns. Confirm MFT acted.
12. Close all the Oil Gun Valves, confirm Economizer Recirculation Valve is open.
13. Maintain 30% Air flow, purge the Furnace, and after Purge is complete, stop the
FD Fans, ID Fans, and close all Flue Gas path dampers.
14. Fill the Boiler Drum, till level indication shows +200 mm..
15. Confirm Economizer Recirculation Valve is open. If required the MD BFP may
be stopped.
16. When Air Pre-Heaters Inlet Flue Gas Temperature is < 125 deg. C, stop both Air
Pre-Heaters.
17. When Furnace Temperature drops below < 500 deg. C, stop Furnace
Temperature Probe Cooling Fan.
18. Stop two Boiler Circulating Water Pumps, and when Boiler Temperature drops
below 150 deg. C, stop the third Boiler Circulating Water pump.
19. When Boiler Drum Pressure drops to 0.5 MPa, open all Air vents, Superheater
drains and start up vents.
20. After confirming that there is no slag in the bottom ash, the bottom scrap
conveyor can be stopped.
21. Keep the Electrostatic Precipitators Rapping device and Ash Handling systems
in service till Ash is completely removed.
22. After shutdown for six hours, open forced draft fan inlet and relative dampers for
boiler natural cooling.
23. After Unit Shutdown for eighteen hours, start Forced Draft Fans, Induced Draft
Fans, and maintain 30% MCR Air flow for Forced Cooling.