Unit start-up at cold state

Sequence of operations

1. Preparation for unit start-up

1 All units should do some work of preparation and inspection for unit start by the Operation Manual after receiving
the chief engineer’s demand.

2 The unit maintenance has been finished and all work permissions have been transacted.

3 Tests for related interlock、protection of the main equipment and auxiliaries are all qualified and partially related
auxiliaries can run normally.

4 The air compress system for utilization of meters should be put into operation, and these meters’ pressure is
Mpa.

5 Acknowledge the normal operation of DCS by contacting thermal control room, and delivery power to DEH operating
station, FSSS operating station and thermal alarm devices of turbine, generator and boiler.

6 Delivery power to all aux equipments and devices. To deliver the motive power after the qualified test of insulating
for 400V equipment, and deliver the operation power after the qualified test of 6KV device;

7 The interlock and protection test of main or auxiliary equipments should be completed according to their testing
card, then deliver the motive power to 6KV equipment after they can normally operate.

8 Inspecting the oil level and water level of diesel generator and the voltage of accumulator is normal or not, and then
run the generator to test whether it can operate normally.

9 Running the DC lube oil pump, hydrogen side DC seal oil pump and air side DC seal oil to test whether they can
normally operate.

10 To inspect following bearings level and oil quality whether they are normal: A、B、C electrical pump, A、B inner water
cooling pump, A、B condensate water conveying pump, A、B induced air fan, A、B primary air fan, A、B air pre-heater
transmission gear, the supporting bearing and radial bearing; and main oil tank, EH oil tank, lube oil tank of coal mills,
reduction gears of coal feeder belts, and A、B forced air fan’s lube oil control tank.

11 FDF oil station, coal mill oil stations and motor-driven water feed system should be put into operation and circulate
the oil system

12 To put the valve of drain water system, air exhaust system and sampling system into specified position according to
the boiler start-up valve inspection card.

13 The boiler has been ignited. The auxiliary steam header should be put into operation when the water in the steam
pipes for supplying the auxiliary steam header was exhausted completely with an inspection, the manual valve of
turbine body and its drain water pipes should be fully opened.

14 Purge the fuel oil by aux steam; blow pulverized coal power inside the air pre-heater; open the water drain valves of
extinguishing steam of coal mills and deaerator so as to drain the water completely.

15 Opening the hydraulic shutting valve of boiler bottom, putting boiler bottom water seal into operation and water-
 filling in slag tank is normal.

16 Start the slag pump and slag dredger.

17 Put gas temperature probe into operation, inspect its cooling, and input air purging.

18 Put the local water level monitor of drum into operation, to ensure the clearness and flexible operating of monitor.

19 Inspect the demineralised water level tank whether it is normal, start one condensate water pump to fill water into
condenser, inner water cooling tank and closed cooling water expansion tank till they reach a normal level.

Ⅱ Unit start-up

1 Start service AC lube oil pump and fill oil into the oil system at a pressure 0.096-0.124Mpa, and put the other oil
pump into standby position.

2 Start ‘A’ main oil tank or ‘B’ flue exhausting fan, and put standby flue exhausting fan into interlock;

3 Start A or B jacking oil pump and adjust the outlet oil pressure at 8-15 Mpa, put the standby jacking oil pump into
interlock;

4 Turning gear in operation and inspect the current of turning gear at A, the eccentricity value should be in a normal
scope and listen to the dynamic and static part without friction inside the turbine.

5 Start A or B fire resistant pump, put the standby pump into interlock and keep the oil pressure between 12.4 to
14.5M pa.

6 Start generator air side and hydrogen side seal oil pump; put the oil cooler of air side and hydrogen side seal oil
pump into operation; air side and hydrogen side DC seal oil pump in interlock.

7 Generator seal oil air side differential pressure valve in operation; both air side and hydrogen side seal oil balance
valve in operation.

8 Start A air side oil tank or B flue exhausting fan, and put standby flue exhausting fan into interlock;

9 Change the air with CO2, the exchange finish while the purity of Co2 ≥96%.

Changing CO2 with H2, rise up the pressure at 0.3 Mpa while the purity ≥98% reached a dead corner exhausting.
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Then put the generator hydrogen cooler water side into operation.

11 Start seawater booster pump to fill water into water circulation system and prepare for starting the circulation pump.

Put circulation pump fresh water cooling system into operation when water circulation industrial cooling water tank
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level is normal, and put the cooling water temperature adjustment control into automatic.

Open inlet\outlet valve of A、B side condenser water circulation; start vacuum pump inside condenser water house,
13
then open water side air exhaust valve;

Start A or B water circulation pump; close the air valve while the air in condenser water side is exhausted out; stop
14 the vacuum pump of water house; a complete leakage inspection for system; put standby circulation pump into
interlock.
15 Inform the persons on duty of chemical nitrogen to input nitrogen manufacturing system;

Start one closed water pump while the water filling of closed cooling expansion tank is normal, then input closed
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water system, another closed water pump in interlock.

Start one open water pump, then input open circulated water system of turbine; input standby open water pump
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into interlock until all inspection are normal.

Start one inner water cooling pump and adjust the outlet pressure at 0.35-0.4 Mpa when the water filling in inner
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water cooling tank is normal, put another pump into standby interlock.

Start one condensate water pump after the water filling in condensate system to a normal water level and adjust the
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outlet pressure at1.2 Mpa or above; put another pump into standby interlock.

Fill water into deaerator at 1040mm and heat the water temperature of deaerator over 70℃ by the steam of aux
20
header;

21 Inspect and record the indicating value of various expansion parts of boiler before filling water.

22 Inspect the conditions whether the electrical pumps are suitable for start-up; and start one water feeding pump.

Fill water to boiler by 30% bypass water feed, and the water filling flow is 30-60t\h; stop water filling while the water
23
level reaches -100mm.

24 Close the air exhaust valve of economizer; open the recirculation system of economizer.

25 Do a qualified test for truly transmission on drum water level protection.

Contact persons on duty of chemical to test the quality of water in boiler; open the water exhaust valve of water
26 cooling wall to exchange water if the water is unqualified, then the boiler ignition is allowed when feed water
Fe≤75ug\1.

27 Start one fire detection cooling fan and inspect the outlet air pressure ≥6KPa;Another one is input as standby.

28 Inspect the air pre-heaters whether they have enough conditions to start, start two of them.

29 Start IDF shaft cooling fan, another in standby interlock.

Inspect the conditions whether IDF is suitable for start, then start one IDF and adjust the furnace pressure as -
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0.05KPa. Rfer

31 Inspect the forced draft fans whether they have enough conditions to start, start one of them.

32 Start another side IDF and FDF, and keep total air flow of boiler between 30%-40%.

33 Do a qualified test for fuel oil leakage.

34 Acknowledge satisfied conditions for furnace purging, then purge the furnace.

35 Secondary air adjusting damper should be put at the ignition position when the purging finished.

Open the oil filling valve and return to quick-closure valve, and then adjust the fuel oil pressure as 3.2Mpa in front of
36
boiler.
37 Input furnace flue temperature probe;

Close condenser vacuum breaker valve, and then start two vacuum pumps; stop one of the two pumps when vacuum
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reached 0.085MPa, and standby interlock in utilization.

39 Start one gland seal fan and another one in interlock.

40 Open HP\LP side shaft seal steam supply pipeline water drain valve and warm up the shaft seal pipes.

Put shaft seal system into operation; inspect the temperature of LP shaft seal at 121-177℃, paying more attention to
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the temperature of shaft seal steam and temperature of metal within shaft seal area are not higher than 111℃.

Inspect the unit for the second time when condenser vacuum reached 0.087Mpa; after all the inspections qualified,
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report it to chief engineer and prepare to ignite the boiler.

Ⅲ Boiler ignition, rising up the temperature and pressure

Undertake the ignition by chief engineer’s order, one by one input ＃1,＃3, ＃2,＃4 oil gun at AB layer and observe
1
the combustion situation in furnace at local site;

2 After ignition, input purging by air pre-heater (continuously operating to 10%MCR).

3 Following items should be paid attention during the temperature and pressure rising up after ignition:

4 A、when steam pressure is below 1MPa, the temperature rising rate＜0.5℃\min;

5 B、when steam pressure is above 1MPa, the temperature rising rate＜1℃\min;

C、according to the requirements of combustion and temperature rising curve, the other oil guns should be put into
6
operation by a sequence AB, BC and DE layer.

At the beginning of oil input, each corner should shift one time so as to make the water cooling wall receive an
7
average heat.

8 E、strictly control the temperature differential of drum wall not higher than 50℃.

9 F、open all water drain valve of boiler and turbine;

10 G、the outlet temperature of furnace should be controlled ＜540℃.

Record the expansion readings for each stage, such as the pressure of drum is at 1.0MPa、10.0MPa and MCR
11 condition, after the boiler maintenance finished; The pressure rising should be stopped if some shortages prevented
its expansion; continuous pressure rising can be executed after the treatment finished.

When the drum pressure reached 0.15-0.20MPa, the air valve on the drum、each stage outlet air valves of super-
12
heater should be closed by a sequence.

Wash the local water level meters of drum and check each water meters when the pressure of drum reached 0.2-
13
0.4MPa, and then inform persons of thermal control room to wash the meter pipelines.

14
Close the roof super-heater inlet header water drain valve and enclosure wall pipes lower header water drain valve
 when the drum pressure reached 0.5 MPa.

15 Input HP\LP bypass to control the main steam pressure’s rising speed when the pressure of drum rose to 0.5MPa.

With the requirements of chemical, input continuous drain valve and the adjustment valve open size of continuous
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drain valve is %.

Ⅳ Rotor impulse 、grid connection and load rising

1 Conditions before turbine rotor impulse:

2 (1)main steam pressure 3.5～4.2MPa，main steam temperature 320～360℃

3 (2)reheat steam pressure 0.1～0.2MPa，reheat steam temperature 260～300℃

4 Condenser vacuum 87KPa above

5 (4)EH oil pressure 12.4MPa～14.5MPa，oil temperature 43～54℃

6 (5)lube oil pressure 0.096MPa～0.124MPa，oil temperature 38～49℃

7 Generator hydrogen pressure 0.28MPa, purity of hydrogen ＞96%, seal oil pressure differential 0.085MPa;

8 7 large axis eccentricity degree ≯0.076mm.

9 8 the temperature differential between upper and lower inner wall of inner HP\LP cylinder ＜ 35 ℃;

10 9 inspect ﹟3、﹟4、﹟5、﹟6 jacking oil pressure ＞5MPa;

Analysis for steam & water quality by chemical sampling, prepare to impulse turbine according to the qualified
11
analysis.

12 Manual open for HP cylinder steam exhaust breaker valve

13 Input HP standby seal oil pump

Full inspection to turbine; latch the turbine、impulse the rotor and target rotation speed 600rpm, speed rising rate is
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100r\min;

15 Stop the turning gear when the rotation speed reached 3r\min.

16 Execute local inspection when rotation reached 600 rpm:

1 inspect the metal temperature of each supporting bearings, and their temperature should be ＜107℃, and thrust
17
bearing pad temperature ＜99℃.

18 2. inspect each bearing’s vibration and oil returning situation, the oil returning temperature should be ＜77℃.

19 3 inspect each bearing’s lube oil and the oil filling temperature is between 38-45℃.

20 4 inspect the oil resistance, and its temperature is between 43-54℃.

21 5 inspect seal oil system and ensure the system is in normal operation;

6 inspect LP cylinder water spray valve that has been opened, the control switch is at “auto" position, and LP cylinder
22
steam exhaust temperature＜79℃.

7 inspect unit vibration, differential expansion, absolutely expansion and axial movement, and upper and lower
23 temperature of inner\outer cylinder is in a scope of permission; listen to sounds from turbine unit rotation parts,
which should be normal.

At the same time, start the LP heater, inspect 5th 、6th extraction electricity valve and start them, low pressure heater
24
water auto-drain to condenser step by step.

25 Turbine rotation speed rising, target speed is 2200rpm, speed rising rate is 100rpm\min.

27 Inspect the roof shaft whether stopped automatically when the turbine rotation reached 1050rpm.

The turbine rotation speed rising to 2200rpm, it start to accumulate the unit warm time when IP main steam valve
28
front steam temperature reached 260℃. Warm unit minute. (approximately 3 hours)

29 After finishing warm unit, set rotation rising rate as 100r\min, rise rotation speed to 2900rpm and transfer the valves;

30 Set rising rotation rate as 50r\min, rise turbine rotation speed to 3000rpm.

31 Turbine constant-speed is 3000rpm.

Full inspection for the unit, inspect the axial movement, expansion difference, cylinder expansion and expansion,
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which in a good state. And each bear of turbine-generator is of normal vibration.

2 inspect the bearing and seal oil, the oil returning temperature, bearing temperature, excitator, carbon brush device
33
are in normal operation.

34 3 Record the situation of boiler expansion indicator.

35 Allowed by chief engineer, test for remote stop and manual tripping.

36 Allowed by chief engineer, test for emergency protector filling oil.

Inspect and acknowledge the main oil pump and oil filler in normal operation, stop lube oil pump and HP standby seal
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oil pump, input the lube oil pump to interlock.

38 Inspect HP drain breaker valve back pressure and exit HP drain pressure ratio protection.

Inspect the unit without abnormal and alarm signals, the generator connect to the grid when parallel conditions for
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voltage rising satisfied.

40 When the unit load is at 15MW-30MW, warm up the unit, adjust fuel flow to stabilize main steam parameters.

42 Inspection for each parameter in normal, HP drain pressure ratio ＞1.7, input HP drain pressure ratio protection;

43 Inspect turbine HP group water drain valve which closed automatically when load rise up to 30MW.

Inspect the furnace flue probes which they should be exited from boiler when the outlet gas temperature reached
46
540℃.
47 Prepare mills for boiler, and preparations must be done before starting of mills

Acknowledge the start conditions whether primary air fan can be satisfied, then start primary air fan and adjust the
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pressure larger than 7Kpa.

49 Start one seal air fan and input all pulverizer system seal air.

50 Inspect boiler for the first time of pulverized coal input and satisfy following conditions:

51 A、air temperature of PA and SA reached 177℃

B、at least the combustion of lower and middle layer oil gun in normal state, and both pulverized coal system has
52
been input and its related oil gun are in normal combustion.

53 C furnace pressure control system is in normal state;

54 D、 stabilized parameters for drum water level, main steam & re-heat steam pressure & temperature and unit load

55 Start ﹟ mill and start ﹟ coal feeder

56 With the requirements of main & re-heat steam temperature controlling, input de-superheat water adjustment.

Inspect LP cylinder water spray valve whether it is stopped automatically when the load rise up to 45MW, otherwise
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it should be closed by hands.

58 Inspect turbine body LP group water drain valve which closed automatically when load rise up to 60MW.

59 Auxiliary steam is supplied by cool re-heater when load reached 75MW and cool reheat pressure ≥2.45MPa.

Inspect and start the second motor-driven water feed pump when the load rose up to 90 MW, and pay attention to
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the pressure of water feed bus tube ,in which the undulation can not be too large.

61 Start the second coal pulverizer

62 Input #3、#2、#1 high pressure heater side step by step when the load is 90MW, and pay attention to the change of
water feeding temperature.
Transfer the water feed bypass to main water feed pipeline and input auto-control for water feed when the load is
63
120MW

Warm the unit for 20minutes when the load reached 105 MW, and inspect overall unit completely. At this moment,
64 main steam pressure should be 9.5MPa, main steam temperature should be 450℃ and reheat steam temperature
should be 400℃.

Warm the unit for 20minutes when the load reached 150MW. Record the situation from boiler expansion indicator, at
65 this moment the main steam pressure should be 12.2MPa, main steam temperature should be 530℃ and re-heat steam
temperature should be 490℃ The unit parameters should close to the normal operation parameters;

Wash silicon to keep a stable unit load, after qualified silicon washing continuously rise up load; when the silicon
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quantity in the boiler water exceed the standard, it is necessary to adjust in time.

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Transfer the power supply of deaerator, start 4th extraction air filling bus valve and the 4th extraction to deaerator air
 filling motor-driven valve, then close auxiliary steam to the air filling motor-driven valve of deaerator.

Inspect all equipment of turbine and boiler side to be in normal operation; then transfer the power supply from plant
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service power to plant service higher transformer.

69 With the requirements of load, start the 3rd mill, start mill, and rise up load to 210MW.

Input the auto-control system of steam temperature when the load rose to 60% and main & re-heat steam temperature
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reached a constant value of 538℃.

71 Adjust the combustion stability; stop all oil guns, to ensure the fuel oil system as standby in front of boiler.

72 Contact and input electrical decipretator

Inspect all unit when load reached 210MW, main steam pressure at 16.7MPa and main & re-heat steam temperature is
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at stably 538℃.

Fully soot-blow in the boiler when load is 240MW , corresponding main steam pressure 17.3MPa, main steam
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temperature 540℃ and re-heat steam temperature 540℃.

75 By the requirements of parameters, start mill and increase combustion quantity gradually till full load operation.

76 After the unit belts in full load, fully inspect the boiler body and record the expansion for one time.