WORK INSTRUCTIONS

UNIT COLD START UP REPORT

No. OST-IV/1502 FF- 1352 Page :
Unit :- 5 Date :-
Activity Estimated time Action time
Note
No Start Finish Start Finish
 ACW, CCW System, Instrument air and Service
Initial Air System, Cooling Tower, AHP and CHP are in
1 activities Service.
 All Boiler vents and S/H drains are open.
 Clearance received for Boiler Filling.
 Boiler filling started with fill pump.
(00 – 0.30)
2  Bottom Ash Hopper and Seal Trough filled.
 Run AC scanner Fan.
 Start one LDO pump. Set pressure 7 kg/cm2.
(0.30 – 0.40)
3  Start all Air Preheaters.
 Isolate PAHs from FG and Air side
 Start one BCW Booster pump.
 Charge Aux. steam header from other unit.
(0.40 – 1.15)  Open AS 210 Valve.
4
 Extend aux. steam to OHP.
 Put HFO tank heating in service to get tank temp.
700C.
 Start one HFO pump. Take one steam heater in
service.
 Insert AB & CD oil elevation guns. Normalize
the valves.
(1.15 – 1.40)
5  Open atomizing steam valves and tracing line
valves.
 At drum water level +300 mm start one BCW
pump after closing purge and vent valves.
 Drum level will drop to +100 mm.
 Start second BCW pump at +100 mm drum level
and normalize the level.
 Put Boiler Fill Pump on recirculation and close
filling valve.
 Line up air and flue gas path. Put aux. control
(1.40 – 1.50)
6 damper on auto.
 Ensure turbine is on barring gear and SLC of
lub oil and JOP ‘ON’. Boost H2 pressure to 3.2
kg/cm2. Purity > 98 %.
 Check turbovisory, bearing temp and
Generator system parameters.
 Start one ID fan and one FD fan.
 Start second ID fan and adjust air flow 700 T/Hr.
(1.50 – 2.10)
7 Adjust Furnace draft -20 mmwcl.
 Start furnace purge.
 Purge Complete
  Open LDO trip valve. Set oil pressure 7 kg/cm2
and atomizing air pressure to 7 kg/cm2.
 Select LDO and air in AB elevation and give a
start command.
 Light up boiler with AB elevation. Close drum
(2.10 – 2.30) vent B72, 73, 74 and 75.
8
 Open E19 eco-recirculation valve.
 Set furnace draft to -5 mmwc.
 Inform chemist on duty.
 Run ESP rapping motors on programmer mode.
 Start HP control fluid pump.
 Start deaerator filling with boiler fill pump.
 Charge MDBFP and line up low load line.
(2.30 – 3.30)  Open turbine side MS line, CRH line and
9
HRH line atmospheric drains.
 Line up CEP to deaerator and start one CEP
 Extend deaerator pegging from aux. steam.
 Start APH soot blowing with air.
 At boiler drum pressure 2 kg/cm2, close SH, RH,
ECO and drum vents and throttle start up vents.
(3.30 – 5.0)
10  Start MDBFP on recirculation.
 Start gland drain pump.
 Open CBD 50% to control drum level if
necessary.
 At drum pressure 5 kg/cm2, close SH drains.
 At drum pressure 7 kg/cm2, Start 3rd BCW
pump.
(5.0 – 5.30)  At drum pressure 10 kg/cm2, charge turbine
11
gland steam header. Open AS2 valve.
 At drum pressure 15 kg/cm2, start second HFO
pump and take second heater in service.
 Start oil elevation CD as soon as furnace exit FG
temp is more than 200°C.
 Ensure HFO oil temp. at firing floor 1100C.
 Change LDO to HFO in AB elevation.
 Close MS line, CRH line, HRH line
atmospheric drains at turbine side. Before
closing ensure that water is not coming from
(5.30 – 6.00)
12 drains.
 Start both vacuum pumps one by one and
apply gland sealing at -2000 mmwcl vacuum.
Start seal steam exhauster.
 Adjust gland steam pressure to 0.015 kg/cm2
and put control on auto.
 Ensure Gland steam header temp. > 1700C.
 Raise drum pressure to 25 kg/cm2.
 At -8000 mmwcl vacuum in condenser, open
MS, CRH, HRH, strainers, drain valves
(6 – 6.15) going to flash tank.
13
 Open boiler O/L MSV bypass valves.
 Open boiler O/L MSV.
 Open HP bypass warm up valves.
  Start second CEP.
 Open LP bypass. Open HP bypass. Set temp.
to 320°C.
 Close generator breaker isolators.
 Start one PA fan. Set PA Header pressure 780
mmwcl.
 PAHs to be taken in service from FG and air side.
 Open SH spray, RH spray block valves, if
necessary.
Steam conditions
SH O/L Pre/Temp= 35-40 kg/ cm2 /380°C
RH O/L Pre/Temp = 12 kg/cm2 /360°C

 Open HP bypass @60 % slowly.

 Open drains after stop valves. MAL
11,12,13,14.
 Set speed reference ‘ZERO’, starting device
0% and speeder gear 100%.
 Ensure stop valve opening criteria X1,X2,X3
fulfilled.
(6.15 – 7.30)  Open stop valve HP/ IP by raising starting
14
device upto 70%.
 Rolling of Turbine :- Ensure criteria X4,X5
fulfilled.
 TSE influence is 'ON'.
 Load limit set ’60 MW’. Load reference
‘50MW”.
 Pressure control on 'Limit ’ mode.
 Load control ‘ON’. Load gradient '25
MW/Min’.
 Load gradient 'ON'.
 Tracking device 'ON'.
 Set speed reference '360 rpm‘.
 Turbine rolled to 360 rpm. Ensure turning
gear cuts off at 240 RPM.
 Check turbovisory and bearing temp. Soak the
turbine till TSE margin +/- 300K.
 Gland steam charged through CRH (if
required). GS Temp > 170°C
 Ensure speed up criteria X6 are fulfilled.
 Check turbovisory and other parameters of
TG set.
(7.30 – 7.45)
15  Ensure drum level -100mm. Raise speed
reference to 3000 rpm without stopping in
between. Observe turbine vibration.
 Ensure critical speed 900,1548, 1896, 2700
passed quickly.
• Turbine rolled to 3000 rpm.
• JOP cuts off at 540 rpm. AOP cuts off
at 2850 rpm.
 Ensure turbovisory and other parameters of
TG set.
  Close field breaker. Switch AVR set point on
'AUTO'.
(7.45 – 8.00) Voltage build up and increase set point to rated value
16
21 KV
 Synchronizing:

• Put synchronization switch 'ON' (COD-
8).
• Turn generator synchronization
selector switch to Auto mode (ATRS)
(COD-8)
• Release the synchronization (COD-7).
Put the synchronizer 'ON'.
• After matching voltage and frequency,
M/c is synchronized and 50 MW load
(7.45 – 8.00)
17 picked up on the machine by raising
speed reference.
• Check changeover from speed control
to load control (if not, slowly raise load
reference).
• Raise load limit to 200 MW.
• Put generator synchronization on
‘OFF’ and synchronization switch
'OFF position (COD-8)
• Put synchronizer “locked’. Put
synchronizer 'OFF' (COD-7).

PCR I/C SHIFT I/C