Unit Startup Procedure

Operation Procedures
1. General requirements before proceeding for line up 2. General procedure for lining up and taking into service a pressure filter/ suction strainer 3. General procedure for line up and taking into service heat exchanger 4. General procedure for lining up pumps 5. General procedure for line up, charging and taking into service of forced lubricating system 6. General line up procedure for oil receipt 7. Line up, charging and taking into service 220/110KV main bus and station transformers 8. Line up, charging and taking into service 6.6KV station bus system 9. Line up, charging and taking into service Unit auxiliary buses 10. Line up and taking sea water filtration system in service
11.Line up of circulating water system 12.Charging and taking circulating water system in to service. 13.Line up and taking water box priming system in service. 14. Line up and taking chlorination system in service. 15. Line up for washing travelling water screens. 16. Line up and taking auxiliary cooling water system into service. 17.Line up and taking compressed air system in service. 18. Line up and filling of hot well 19. Line up, priming and starting of condensate extraction pump. 20. Filling of dearator. 21. Line up of Boiler Feed Pumps 22. Procedure for initial filling and venting of steam generator water circulating pump (SGWCP) 23. Line up, charging and taking SGWCP in service
24. Line up and filling of steam generator 25. Line up charging and taking RAPH lube oil system in service. 26.Line up and taking RAPH into service. 27. Lining up of flue gas path. 28.Line up of secondary air path. 29. Taking air and flue gas system into service. 30.Line up, charging and taking SCAPH into service. 31. Line up and taking Igniter Air system into service. 32. Line up and taking into service scanner air system. 33. Line up and taking into service Gas Recirculation path. 34. Taking furnace probe into service. 35. General line up procedure for oil receipt. 36. Line up and taking Fuel Tank Heating system in service. 37. Line up and taking Condensate Recovery System into service.
38. General procedure for line up, charging and taking into service fuel oil system. 39. Taking fuel oil heater in service. 40. Line up and taking turbine lube oil system in service. 41. Line up and taking jacking oil system in service. 42. Place turbine on Turning Gear (TG). 43. Line up and taking Control Fluid(CF) system in service. 44. Line up and taking Primary Water system in service. 45.Line up and taking generator seal oil system in service. 46. Filling generator with air, carbon dioxide and finally with hydrogen. 47. Line up and taking turbine gland steam in service. 48. Line up and taking vacuum pump/air evacuation system in service. 49. Taking turbine generator on Turning Gear (TG). 50.Preparation for Boiler Purge.
51. Boiler Purge 52. Opening Main Trip Valve. 53. Lighting up of boiler with start up oil. 54. Bringing up steam conditions. 55. Silica purging 56. Turbine rolling, synchronizing and loading the machine. 57.Putting the unit controls on auto. 58. Charging and taking feed water heaters in service. 59.Starting and taking STBFP in service. 60. Load pick to 300 MW. 61. Load pick to 500 MW. 62.Taking coal mills in service.
CHARGING OF ELECTRICAL SYSTEM

1. Ensure electrical supply to C.W. Pumps and other associated auxiliaries are available. 2. Charge Station Transformer TOC or TOD and respective station buses SE/SF. 3. Ensure that all the electrical breakers are racked IN and OFF Service mode. 4. Ensure that D.C. Supply to all the breakers is available. 5. Charge Unit Bus A/B through Station Bus SE. 6. Charge Unit Service Switch Gear, Emergency Bus through normal Breaker. 7. Ensure that supply is available to various MCCs, (Turbine MCC, Boiler MCC, TVDC, BVDC, Lube oil MCC). 8. Charge ESP and Ash Handling Transformers. 9. Ensure that supply is available to all Electrical Buses. 10. Check Unit Bus Voltage, Voltage can be adjusted by changing the tap position of Station Transformer. 11. Normalise MDBFP Breaker through Station Bus SF.
CHARGING OF EMERGENCY BUS THROUGH D.G. SET 1. Check the D.G.Set physically for fuel level, oil, cooling water. 2. Control supply and starter motor D.C. voltage are O.K. 3. Start D.G.Set from CSSAEP (Common Services Supply Auxiliaries Equipment Panel). 4. Adjust the voltage/Frequency by using switches provided in the panel. 5. Put the Synchronizer on manual. 6.Close the D.G.Set Breaker to Emergency Bus. 7. Check the D.G.Set for any abnormality.
CHARGING OF AUXILIARY STEAM HEADER

OBJECTIVE : To line up and charge auxiliary steam header (16 to 20 bar pressure)and charge steam to various equipments. PRE -REQUISITES & STATE OF PLANT 1. Work permit on auxiliary steam header , auxiliary PRDS and associated system such as SCAPH, atomising steam, HFO heater, etc., cancelled and men, material removed from these areas. 2. All drains and manholes are closed and the equipment and system are in service worthy condition. 3. All level gauges, indicating instruments, pressure and flow switches and other Protective devices are lined up for services. 4. 415 V supply available to valve actuators. 5. 220 V DC supply available. 6. Control panel supply available 7. UCB instruments for boiler side available. 8. Service air and instrument air is charged.

9. PRE -START CHECKS AND LINE UP 10. Ensure that the primary and secondary RAPH A/B cold end temperature control valves are closed. 11. Ensure the Dearator pressure control by auxiliary steam control valve is closed. 12. Auxiliary steam header pressure and temperature controller are closed. 13. Open the auxiliary steam header drain valve from local. 14. Ensure all the manual isolating valves to fuel oil tank heating, burner atomising, SCAPHs, etc. are close. 15. Ensure the motorised steam isolation valves to BFP and deaerator are closed. 16. Ensure the gland sealing steam valve is in closed condition. 17. Ensure that the auxiliary steam is available from other running units and inform UCB engineers. 18.Ensure the cold reheat to auxiliary steam block valve is closed.

1. Open the auxiliary steam interconnection form other running units header to charge the auxiliary steam header. 2. Check the pressure and temperature of the auxiliary steam header comes to normal. 3. Open the primary and secondary SCAPH A or B inlet and outlet isolating valves. 4. Open the deaerator pegging motorised valve. 5. Open the gland steam supply valve. 6. Close the drain of the auxiliary steam header from local. *Auxiliary Steam Header is Charged*
CHARGING OF AUXILIARY RAW COOLING WATER (ARCW) SYSTEM

OBJECTIVE To line up and start the auxiliary raw cooling water pumps. To charge the auxiliary raw cooling water to various equipments. PRE -REQUISITES & STATE OF PLANT 1. Work permit on circulating water duct, auxiliary cooling water pump, plate type heat exchanger and associated system cancelled. 2. All level gauges, indicating instruments, pressure and flow switches and other protective devices are lined up for service. 3.All filters and coolers are cleaned and necessary lubrication of equipments are done. 4. 415 V supply available for LT drives , valves & actuators. 5. Control panel supply is available. 6. 6.6KV switch gear charged and breakers are kept in service mode. 7. Circulating water (CW) pumps are running and CW duct is charged
PRE -START CHECKS AND LINE UP

1. Ensure that suction valve for all three pumps are open from local. 2. Check that the gland sealing is in service (i.e. sealing water valves are open), bearing lubrication is satisfactory, pump rotor is free. 3. Close the pump drain and open the vent to ensure no air is coming. 4.Line up the discharge filter by opening the isolating valves. 5. Ensure that isolating valves for the plate type heat (PHE) exchangers are open to CW discharge seal pit. 6. Ensure the recirculation valve is opened. 7. Ensure the motorized discharge valves for all three pumps are closed. 8. Ensure that the EPB (Emergency push button) is released from local.
OPERATIONAL STEPS
1. Change the selector switch to A position. 2. Start ARCW pump A motor by turning the hand switch position to on and release it. 3. Check the starting current and discharge pressure. 4.The pump discharge valve will start opening and red light will come indicating discharge valve has fully opened. 5.Close the recirculation valve from local once the discharge valve is fully opened. 6. Check the return flow of the raw cooling water in the CW discharge seal pit. 7. Check the differential pressure across the discharge strainer. 8. Ask local operator to check for any abnormal sound from the motor or pump 9. Check the bearing temperatures
*ARCW pump is in service*
CHARGING OF EQUIPMENT COOLING WATER (ECW) SYSTEM

OBJECTIVE : To line up and start equipment cooling water pumps. To charge the equipment cooling water to various equipment. PRE -REQUISITES & STATE OF PLANT 1. Work permit on equipment cooling system overhead DM water tank, boiler feed pump coolers, auxiliary coolers for generator package, fan coolers, etc., cancelled. 2. All level gauges, indicating instruments, pressure and flow switches are lined up. 3. All the filters and coolers are cleaned and necessary lubrication of equipment are done. 4. 415V supply available for LT drives valves & actuators. 5.Instrument air and service air is charged to the controllers. 6. ARCW pumps are running normal. 7. Ensure that 6.6 KV switch gear is charged and the breakers are kept in service mode.

1.Ensure that suction valve for all three pump is open from local. 2. Ensure adequate level in the overhead DM water cooling tank. 3. Check that the gland sealing is in service, bearing lubrication is satisfactory, pump rotor is free. 4. Open the inlet valve to the suction header from the over head DM water cooling tank. 5. Close the pump drain and open vent to ensure no air is coming. 6. Ensure that isolating valves are open for the plate type heat exchanger which is already charged from the auxiliary raw cooling water side. 7. Ensure the motorized discharge valves for all the three pumps are closed.
OPERATIONAL STEPS
1. Change the selector switch to A position 2. Start ECW pump A motor by turning the hand switch position to on. 3. Check the starting current and discharge pressure. 4.The pump discharge valve to be opened and red light will come indicating discharge valve has fully opened. 5. Maintain the level in the DM water cooling tank by taking additional make up either from DM plant or from CTP(Condensate Transfer Pump), if running. 6. Charge the ECW to various auxiliary coolers and check the differential pressure is maintained by the control valve, for Boiler, BFP coolers , for CEP, etc. *ECW pump is in service*
START UP OF CONDENSATE SYSTEM

OBJECTIVE To line up and take hot well make up system in service. To line up and start Condensate Extraction Pumps (CEP) to fill the deaerator. PRE -REQUISITES & STATE OF PLANT 1. Unit ECW system in service. 2. Work permit on various LP heaters, drip system, drain cooler, etc., cancelled and men, material removed from these areas. 3. Instrument air is charged to various valves and valve actuators. 4. Local pressure, temperature, flow, level gauges & transmitters charged. 5. Check that the hot well drains are closed. 6. Sufficient quantity of DM water available in the unit C.S.T. 7. Ensure that 6.6 KV switch gear is charged and breakers are kept in the service mode. 8. Ensure that EPB is released from LOCAL.
PRE -START CHECK AND LINE UP

1. Establish ECW flow to CEP motor cavity air coolers. 2. Open ECW inlet and outlet valves to CEP bearing oil cooler. 3. Line up the hot well normal make up line from local . 4. Line up the hot well emergency make up line from local . 5. Open the GSC minimum flow isolating valve from local . 6. Ensure that condensate spill valve bypass and condensate fill valves are closed. 7. Open the suction valve for all three CEPS from LOCAL 8. Open the recirculation isolation valve from local . 9. Rack in the CEP breakers from Switch gear in service remote position. 10.Open the sealing line valve from common discharge from local . 11.Ensure the common isolation valve for exhaust hood spray and drain manifold is closed from local . 12.Open the manual isolating valves for Deaerator level controller from local. 13.Line up the hot well high level controller from local .

14.Ensure the line up of the LP heaters from water side is through up to the deaerator and water side vent is crack open . 15.Ensure all the CEP discharge valves are closed. 16.Ensure that all the recirculation valves are full open and are in manual mode. OPERATION STEPS 1. Change the emergency make -up pump A status from manual to auto mode from UCB. 2. Check that emergency make -up pump A should start. 3. Start any two hot well make -up pumps from DM plant. 4. Open the hot well make up emergency control valves to fill the hot well. 5. Observe the steady rise in the condensate make -up flow and hot well level. 6Keep the control mode for emergency make -up pump B in auto. 7. Close both the controllers when hot well level comes to about +50 mm. .

8. Check the hot well level adequate permissive appears on all the three CEP start permissive indication. 9.Check that all permissive lamps are on to start CEP. 10.Start the CEP-A by turning the hand switch to close position and release it. 11. Check that discharge valve opens and discharge pressure gradually builds up. 12. Check that the pump is running OK and no abnormal noise at local. 13. Keep the lead / lag switch of pump B and C to lead and lag mode respectively. 14. Open the block valve of the Deaerator level control valve. 15. Open the deaerator level control valve to about 20%. 16. Condensate flow to deaerator increases and condensate discharge pressure drops

17. Check that deaerator level gradually builds up. 18. Open the emergency make-up control valve to make -up hot well level to normal value. 19. Close the Deaerator level controller once the Deaerator level has come above normal level. 20. Close the emergency make-up controller as the condensate pump is running on recirculation only. 21. Check the bearing temperature and vibration of the pump. 22. Keep the block valve of Deaerator level controller B station also in open state. *CEP in service *
MOTOR DRIVEN BOILER FEED PUMP ( BFP -C )

OBJECTIVE To line up and take boiler feed pump -in service. PRE -REQUISITES & STATE OF PLANT 1. Unit ECW system in service. 2. Work permit on various HP heaters, drip system, deaerator, etc. cancelled and men, material removed from these areas. 3. Instrument air is charged to various valves and actuators. 4. Local pressure, temperature, flow, level gauges and transmitters charged. 5. Check that deaerator over flow valve and drain valves are closed. 6.The condensate pump is running on recirculation as per the startup instruction 7. Check the interlocks of AC & DC LOPs.
PRE -START CHECKS AND LINE UP 1. Establish the ECW flow to the working oil and lube oil coolers. 2. Charge the booster pump mechanical seal coolers. 3. Ensure that seal quench valve is open and seal quench pressure is more than 15 Kg/cm2. 4. Line up the BFP system from local (Lube oil coolers, working oil coolers etc). 5. Open the recirculation valve isolating valve for all the three pumps from local 6. Check that AOP of BFP is taking start from UCB and recirculation valve controller, scoop controller is operative from UCB 7. Rack in the BFP C breaker from local . 8. Ensure that HP BP desuperheating station manual valve is in close condition 9. Open the BFP A/B/C suction valve from local . 10. Line up the emergency seal quench water pump from local . 11. Line up the LP dosing and HP dosing system from local . 12. Ensure that HP heaters are bypassed .
13. Start the auxiliary oil pump of BFP-C 14. Ensure that all the permissive lamps are ON in the UCB for boiler feed pump C. OPERATIONAL STEPS 1. Check once more the scoop tube controller is minimum and recirculation valve is full open. 2. Start BFP by turning the hand switch to breaker close position and release it. 3. Open the discharge valve of BFP C. 4. Check the BFP discharge pressure and motor current from UCB 5. Ensure that motor cooling water valve has opened on interlock and red lamp is on. 6. Raise the scoop tube position by about 10% to raise the discharge pressure 7. Check the bearing temperature and vibrations from the UCB indicators. 8. Open the HP BP desuperheating station manual valve from local. * MD BFP-C is in service. *
BOILER FILLING
OBJECTIVE : To line up to fill the water wall, down comers, drum & economiser by boiler feed pump. PRE -REQUISITES & STATE OF PLANT 1. Boiler water circulating pumps motor cavity is properly filled and vented. 2. Sufficient quantity of DM water available in condensate storage tank. 3. Hot well make-up pump available for chemical mixing and diluting. 4. Local drum gauge glass charged. Hydrastep and drum level recorder available in UCB. 5. Unit ECW system in service. 6. At least one CEP is available to make up the deaerator level. 7. Hot well make-up system lined up from hot well make-up pump. 8. DC seal water pump for BFP is available. 9. MD BFP with all its auxiliaries/controls is available. 10. Instrument air supply to the entire controller is available. 11. Sufficient quantity of Ammonia and Hydrazine put in mixing tank and diluted with DM water.
BOILER FILLING PRE -START CHECKS AND LINE UP 1. Close boiler low point drain valve to IBD tank. Close economiser inlet 2. Header drain and inlet lead drain valves at low point drain station. 3. Ensure that emergency blow down regulating valves is closed from UCB. 4. Ensure that all the three SGCW pump casing drains are closed. 5. Check SH and RH fill valve at low point drain station are closed. 6. Open all three SGCW pump suction spool vent valves from local. 7. Open all the drain vent valves from UCB. *Line up for initial boiler filling over. *
DRUM FILLING
OBJECTIVE : To fill the boiler water wall, down comers, drum and economiser by boiler feed pump. To line up and start SGCW Pump A & B. PRE -REQUISITES & STATE OF PLANT 1. Check that condensate pump discharge header pressure is OK. 2. Equipment cooling water pumps are running. PRE -START CHECKS AND LINE UP 1. Open the economiser inlet valve and Economiser recirculation valves from the UCB. 2. Open the low range feed control station isolating valves, close high range isolating and control valves. Check low range control valve operation. 3. Check HP heaters feed water bypass valve full open. 4. Ensure MD BFP/ TD BFP is running 5. Start LP dosing pump to dose hydrazine and ammonia solution to BFP suction.
Boiler Filling and Running SGWCPs : 1. Gradually open the low range feed control valve and control the flow to boiler as per rate of make up to deaerator. 2.Close the recirculation valve of the BFP if sufficient feed flow is established. 3. Close the SGCW pump suction spool vents once air free water comes out of them. 4. Check for level rise in local gauge glass, hydra step and recorders. 5. Close the low range feed control valve and open the recirculation valve once the level comes to about 300 mm. 6. Stop chemical dosing pump and isolate the dosing line. 7. Ensure the pump discharge valve are fully open, permissive lamp 1 and 2 are ON.
Boiler Filling and Running SGWCPs contd. :

8.Rack in the breakers of all the three pumps from SWGR. 9. Ensure the pump cooling water system is lined up from local . 10. Ensure the status of SG booster pump A as lined up . 11. Start the SGCW pump A. Ensure the pump draws about 60 amps. If current drawn is less, stop the pump immediately and vent thoroughly. 13. Check that drum level is adequate, if not open the low range feed control valve to make it up. 14.Repeat the procedure for SGCW pump B also. 15. Check the following ; a) Motor current b) Motor cavity temp c) Pump diff. press. and pump running condition OK at local.
START UP AND WARM UP OF THE FUEL OIL SYSTEM.

HEAVY FUEL OIL SYSTEM OBJECTIVE : To line up and start heavy fuel oil pump. To warm up the fuel oil to required temperature for boiler light up. PRE -REQUISITES & STATE OF PLANT 1. Adequate oil level in the HFO storage tank for pump operation. 2. Auxiliary steam header charged and steam is available. 3. Local pressure, temperature, flow, level gauges and transmitters charged. 4. Duplex strainer of the HFO pump is in clean condition. 5.Work permit on the associated equipment cancelled. 6. The oil in the day tank is pre-warmed. 7. Day tank level (indicator at local) checked for proper working. 8. Ensure that instrument air supply is available.

HEAVY FUEL OIL SYSTEM 1. Open the suction valve and discharge valve of any one pump. 2. Charge the steam tracing system and heat sufficiently before the pump is taken in service. 3. Vent the pump thoroughly and close the vent valve. 4. Ensure the recirculation valve is open with its isolating valves. 5. Since the discharge line is empty crack open the oil valve inlet to the heater, out let may be opened fully. 6. Ensure that H.O. short recirculation valve is closed and operative from UCB 7. Ensure that H.O. delivery valve and inlet to the firing floor Valves are fully open. 8. Open the riser vent at GH elevation initially. 9. Ensure that constant circulation orifice is lined up (by pass of HO long recirculation valve).
OPERATIONAL STEPS 1. Start one HFO pump from local. 2. Check the pressure of fuel oil at the boiler front starts increasing gradually as indicated. 3. Once the header is pressurised open the inlet valve to the heater fully. 4. Open the vent of the HFO heater before charging the steam. 5. Crack open the HFO heating steam by pass valve. 6. Close the drain and vent once the heater is thoroughly vented. 7. Open the short recirculation valve from UCB. 8. Take the temperature controller of the HFO heater in service to maintain the fuel oil temperature to about 125 0 C. * HFO pump in service *
LINE UP OF FLUE GAS PATH & APHs

OBJECTIVE : To line up the flue gas path for boiler light up. To line up and take secondary RAPH in service. PRE -REQUISITES & STATE OF PLANT 1. Work permit on various boiler areas such as furnace, APH, ID, fans, ESP, ducts, dampers, etc., cancelled and men, material removed from these areas. 2. Instrument air charged in boiler side pneumatic valves & dampers. 3. Unit equipment cooling system in running condition with SG side charged. 4. APH fire sensing device available. 5. Fire fighting water available for boiler and APHs. 6. APH soot blowing system available. 7. All the wall blowers and LRSB are in retracted condition. 8. Bottom ash equipment such as scrapper conveyer, clinker-grinder, hydraulic oil Pumps, blowers, etc, available for taking into service.
LINE UP OF FLUE GAS PATH & APHs contd. 9. Boiler slag bath, trough seal, economiser hopper, APH hoppers & ESP flushing Apparatus are filled with water and over flowing. HP-LP & service water pump in Service (ASH). 10. Local pressure, temperature, flow, level gauges and transmitters charged. 11. Check all peepholes and manholes are closed. PRE -START CHECKS AND LINE UP 1. Check oil level in guide bearing and support bearing by dip stick and if necessary top up with the correct oil to bring the level normal. 2. Establish ECW supply through guide bearing oil coolers. 3. Open the suction valve of the lube oil pump for APHs. 4. Open the inlet/outlet dampers for all the four ESP pass from GD11 to GD 18.
LINE UP OF FLUE GAS PATH & APHs contd.

5. Open the equaliser dampers GD9 and GD10 before ESP from local. 6. Ensure that flue gas inlet damper and outlet damper to secondary RAPH A, GD 3 and GD 7 are closed. 7. Ensure that secondary air inlet and out let dampers SAD3 & SAD5 for secondary RAPH A are closed. 8. Ensure that primary RAPH A gas inlet/outlet dampers GD1 & GD 2 and GD5, GD6 are fully closed. 9. Ensure that all the dampers for secondary RAPH B are closed. 10. Line up the boiler bottom ash hopper system from local . 11. Switch on any of the three ash slurry pump from local .
OPERATIONAL STEPS 1. Turn the secondary RAPH -A LOP A for guide bearing to lead mode. 2. Turn the secondary RAPH -A LOP B for guide bearing to lag mode. 3. Repeat the above two steps for the support bearing LOPs also 4. Repeat the above three steps for the secondary RAPH-B also 5. Check the permissive for secondary RAPH -a are all available 6. Line up air motor and start RAPH-A on air motor and ensure smooth running of RAPH from local . 7. With the same sequence take secondary RAPH -B also in service on air motor. 8. Establish 415V supply and start RAPH electric motor by turning the hand switch to close position. 9. Ensure that air motor cuts out on interlock. 10. Open the secondary air out let damper SAD5 followed by the inlet damper SAD 11. Open the flue gas out let damper GD7 followed by the inlet damper GD3. * RAPH in service *
START UP AND LINE UP OF ONE ID FAN

OBJECTIVE : To line up and start ID fan for boiler light up. PRE -REQUISITES & STATE OF PLANT 1. Work permit on various boiler areas such as furnace, APH, ID, FD fans, ESP, ducts, damper, etc., cancelled and men material removed from these areas. 2. Ensure the flue gas path is lined up . 3. At least one secondary air-pre heater is running. 4. HP/LP ash water pumps are running. 5. Boiler slag bath trough seal, economiser hopper, air pre heater hoppers and ESP flushing apparatus are filled with water and over flowing . 6. Instrument air is charged to various actuators and dampers, etc. 7. Boiler man holes, peep holes are in closed condition cooling water charged in access doors through SG booster pumps .

1. Check that adequate oil level is in the tank, if necessary top up with the correct oil to bring the level to normal. 2. Charge the hydraulic coupling cooler and one lube oil cooler with Equipment Cooling Water. 3. Open the suction and discharge valve for the lube oil pump. 4. Ensure the line up of lube oil through cooler and filter up to the bearing from local. 5. Ensure that inlet vane position controller is minimum and operative. 6. Rack in the 6.6 KV motor breaker for ID fan A from switch gear. 7. Keep the selector of ID fan oil pump in lead mode. 8. Ensure that hydraulic scoop position is minimum and permissive lamp is on.
OPERATIONAL STEPS 1. Give ID fan A breaker a start command and check the hydraulic oil pump A takes start, red lamp comes on. 2. Ensure that inlet/Outlet dampers starts closing on interlock green lamp comes on. 3. Hydraulic coupling oil pressure adequate permissive lamp comes on. 4. The moment inlet/outlet dampers get fully closed the fan will take start. Check the starting and no load current. 5. Check that inlet/outlet dampers for the ID fan A opens after a time delay and inlet/outlet dampers for the other fans close on interlock GD 20,21 and GD23 to GD25 6. Check the bearing temperature and vibration from the UCB and are normal. Also motor winding temperature is normal. 7. The hydraulic oil pump for the non running fans may be put in service after line up. 8. Increase the inlet vane position to load the fan by raising the controller. *ID fan taken in service*
FLUE GAS SYSTEM FLUE GAS SYSTEM

START UP AND LINE UP OF ONE FD FAN OBJECTIVE : To line up and start FD fan for boiler light up. PRE -REQUISITES & STATE OF PLANT 1. Work permit on various boiler areas such as furnace, APH, ID, FD fans, SCAPHS, wind box, burner tilts, etc., cancelled and men, material removed from these areas. 2. At least one secondary air pre heater is running. 3. The ID fan is running normal. 4. Instrument air is charged to all the secondary air damper actuators. 5. Secondary air damper control (SADC) checked for remote operation. 6. Wind box manholes are closed. 7. Unit equipment cooling system is in running condition.
START UP AND LINE UP OF ONE FD FAN PRE -START CHECKS AND LINE UP 1. Check that adequate oil level is in the tank, if necessary top up with correct oil to bring the level to normal. 2. Establish the ECW supply through fan lube oil coolers from local. 3. Ensure the line up of the lube oil through cooler and filter up to the bearing. 4. Ensure that blade pitch controller is minimum and operative. 5. Rack in the 6.6 KV motor breaker for FD fan A from Sw.GR. 6. Start the lube oil pump B in auto mode once lube oil pressure is adequate. 7. Keep the lube oil pump B in auto mode once lube oil pressure is adequate. 8. Interlocks of LOPs motor start/stop to be checked by tripping the running.
START UP AND LINE UP OF ONE FD FAN : OPERATIONAL STEPS 1. Give FD fan a start command 2. Ensure that outlet damper SAD -1 starts closing and permissive lamp comes on. 3. All the permissive will be available the moment discharge damper is closed the fan will take start. Check its starting and no load current and also the motor winding temperature. 4. Check that outlet damper for FD fan A reopens after a time delay and discharge damper for FD fan B Closes on inter lock. 5. Check the bearing temperatures and vibrations from the UCB are normal. 6. Start the lube oil pump for the FD fan B. 7. Check the FD fan discharge pressure and wind box pressure should show same value. 8. Increase the blade pitch of FD fan A to load the fan and observe that air flow should increase. 9. Open the scanner air fan inlet dampers SID -1/2 from local. * FD fan in service *
LINE UP, CHARGING AND TAKING SCAPHS INTO SERVICE

OBJECTIVE
To charge the SCAPHs from steam side. PRE -REQUISITES & STATE OF PLANT 1. The secondary air supply through the SCAPH is established. 2.Ensure 16 ata steam header is charged . 3. Ensure that drain valve down stream of SCAPH line supply header is open. 4. Ensure that final condensate outlet valve to IBD is open. 5. The instrument air is charged to all the pneumatic actuator.

1. Open all the four inlet and outlet valves for Secondary air SCAPHs. 2. Ensure that secondary RAPH -A/B cold end temperature controllers are in closed condition in UCB 3. Ensure the power supply is available to the motorised SCAPH valves. OPERATIONAL STEPS 1. Open the Secondary SCAPH A/B steam inlet valve from local. 2. Open the motorised valves upstream and downstream of SCAPH control valve 3. Crack open the Secondary air cold end temperature controller to warm up all the lines. 4. Throttle drain valves when steam comes out of them. 5. After sufficient warm up, control valve can be opened more to achieve the required cold end temperature. 6. Close all the drain valves downstream of the SCAPH 7. If required, adjust the temperature setter of the cold end temperature controller and transfer the controller in auto mode. * SCAPHS ARE CHARGED *
LINE UP FOR BOILER LIGHT UP

OBJECTIVE To line up all the associated equipment for boiler light up. PRE -REQUISITES & STATE OF PLANT 1. Work permit on various boiler areas such as furnace, APH, ID, FD fans, ESP, ducts, damper, etc., cancelled and men, material removed from these areas. 2. Instrument air charged in boiler side for pneumatic valves and damper operation, oil guns, etc. 3. Service air charged in boiler side for air heater, air motor ignitor cooling air,etc. 4. Ensure 16 ata steam header is charged 5. 6.6 KV switchgear charged . 6.415 V supply available for LT drives and valve, damper actuators. 7. Unit equipment cooling system is in running condition. 8.Local pressure temperature, flow, level gauges and transmitters charged. 9. Oil guns and Ignitors checked to be proper fitted.

10. Secondary air damper control system (SADC) checked for remote operation. 11. Boiler manholes, peep holes are in closed condition. cooling water charged in access doors. 12. DC/AC scanner air fan should be in service and interlocks should be checked. 13. All the wall blowers and LRSB are in retracted condition. 14. Boiler spring loaded safety valve gags are in removed condition (if light up is being done after safety valve floating activity). 15. Bottom ash equipment such as scrapper conveyer, clinker grinder, hydraulic oil pump, blowers, etc. available for taking into service. 16. Boiler slag bath, trough seal, economiser hopper, APH hoppers and ESP hoppers, flushing apparatus are filled with water and overflowing.

17. Following boiler side equipments are available for taking in service with their interlocks and protections checked. At least two numbers of CC pumps. Both Sec. APHs. AC scanner air fan. At least one ID fan. At least one FD fan. Both sec. APH SCAPHs. 18. Following equipment should also be made ready for requirements at later stage. At least one PA fan and one seal air fan. 3-4 nos. of coal mills and feeders. Both primary air preheaters SCAPHs. ESP Transfirmers,ESP rectifier transformers, rapping motors, hopper heaters etc. 19. Ensure that boiler drum filling is carried out . 20. Ensure S/H spray and R/H spray station block valves and control valves are closed. 21. Open the S/H drain header drain valve to IBD full.
PRE -START CHECKS AND LINE UP 1. Boiler drains and vents should be lined up as follows. Low point drain station to IBD isolating valves is closed. Bottom ring header drain valve at low point header is closed. Economiser inlet lead drain valve at low point header is closed. Emergency blow down valves are operable and are closed. 2. Ensure both the economiser recirculation valves are open. 3. Open HP dosing isolating valve at drum level. 4. Open S-H steam, saturated steam, CBD water and feed water sampling isolating valves. 5. Open all S/H header drains full for draining any where in S/H and leave them crack open. 6. Open the S/H header vents manual valve fully. 7. Open the motorised boiler drum vent valves from section. 8. Open all four SH header vent valve 9. Ensure that main steam stop valve (boiler side)is closed along with bypass valves.

10. Open the motorised RH outlet header vent 11. Ensure sufficient cold end temperature of the Sec. RAPHs before light up. 12. Change the status of local oil gun station from local to remote for all four corners and all four elevations. 13. Line up the boiler CBD lines from local . 14. Ensure that heavy oil pumps are running and warmed up. 15. Check that atomizing steam is charged up to the firing floor. Also all the steam tracing lines should be charged. * Boiler lined up for light up *
BOILER LIGHT UP
OIL FIRING SYSTEM OBJECTIVE To start a purge cycle. To light up the boiler. PRE -START CHECKS AND LINE UP 1. All the pre-start checks and line up mentioned earlier . 2. Ensure that all the operational steps mentioned before are carried out before the boiler is ready for a purge cycle. OPERATIONAL STEPS 1. Adjust the ID fan and FD fan blade pitch to maintain air flow above 30 % but below 40 %. 2. Adjust the burner tilt position to horizontal with burner tilt controller 3. Keep the furnace pressure to about -10 mmwcl with ID inlet valve control.
4. Ensure that following purge permissives are satisfied : Mode permit (Nozzle tilt horizontal and air flow less than 40 %). PA fans off. Drum level satisfactory. Air flow > 30% All feeders off. All nozzle valves closed Wind box/furnace DP satisfactory. No boiler trip command. Aux. air dampers modulating. All hot air gates closed. All scanners sensing no flame. All pulverisers off. . H. O. Trip valve is closed 5. If wind box/furnace DP permissive is not available wait for all the fuel air dampers to close from top, once air flow is between 30 to 40 % pre-purge damper reset timer will take 5 min.
6. Ensure that PURGE READY & PURGE START lamps are glowing at FSSS panel. 7. Push Purge start push button and see purging lamp comes on the panel. After purging time of 5 min. is over see purge complete lamp glows. 8. Ensure that master fuel trip relays MFR A and MFR B relay reset and green lamp comes on. 9. Open H.O. trip valve. Valve opens, if not, open the long recirculation valve and then open the H.O. trip valve. 10. Increase the H.F.O. pressure controller output. 11. Adjust the set point of the controller to about 10 -12 Kg/cm2 and transfer the controller to auto mode. 12. Wait till HFO temperature at boiler front comes to about 110 o C. 13. In between once again ensure that superheater vents etc. are fully open and also drains are opened. 14. Close on oil recirculation valve, green lamp comes on and HFO supply pressure momentarily increases
15. Insert the furnace probe LHS/RHS till it advances to about 80 to 100 %. Push park button. 16. Depress the Pair 1-3 START push button on AB elevation. corner No. 1 is placed in service initially and following occurs. AB-1 oil gun advances. The spark rod advance yellow lamp comes on. The spark rod lamp comes for 15 sec. Heavy fuel oil nozzle valve start opening. Discriminating scanners starts sensing the flame. HEA ignitor spark signal is removed HEA ignitor is retracted Heavy oil nozzle valve open fully red open lamp comes on. . AB-3 gun will advance after 30 sec delay and same seq. as above will follow
17. Depress the pair 2-4 START push button on AB elevation. AB-2 is placed in service similarly to AB-3 mentioned above. 18. The furnace pressure goes up slightly, increase the ID fan loading to maintain the value to about -10 mmwc. 19. Increase the heavy oil controller output to maintain the H.O. supply pressure to about 10 Kg/cm2. (Increase the set point if controller is in auto). 20. HFO temperature may drop as number of guns in service are more. Check the HFO temperature is kept on auto mode at pump house. 21. Check the 16 ata header pressure is also maintained. 22. Adjust the CBD opening as per the chemist recommendations. 23. Maintain the drum level with low range feed control valve. 24. Maintain rate of rise of drum metal temp. less than 2 degree per minute and that of main steam temp. less than 50C by controlling oil firing. 25. At drum pressure of 2 Kg/ cm2 close the boiler drum vents
26. Close all the superheater header manual vents and drains once pressure exceeds 2 Kg/cm2 Perform APH soot blowing to avoid deposition of oil unburnts. 27. Ensure that S.H. header vents (start up vents) are full open. 28. Check the furnace temperature by the furnace probes should not exceed 540degC. 29. Open emergency blow down valves if drum level is swelling to higher level. 30. Check the drum top bottom metal temperatures should not exceed 50 degC. ** Boiler lighted up **
CONDENSER CHARGING
OBJECTIVE To line up and start CW pumps. To charge condenser from water side. PRE-REQUISITES & STATE OF PLANT 1. Work permit on various condenser/circulating water equipments such as travelling water screen, circulating water pumps, ducts, condenser water box, seal pit, etc., cancelled and men, material removed from these areas. 2. Adequate water level in the CW intake canal. 3. Electrical power available for circulating water pumps and associated auxiliaries. 4. One condensate pump is running on recirculation . 5. CW priming pump is available. 6. Check that travelling water screen is clear and cleaning system is available for operation.

1. Open the CW duct vents. 2. Close the condenser water box drains . 3. Establish the 415 V supply to the condenser inlet valves. 4. Ensure that discharge valves for all the three pumps are in closed position. OPERATIONAL STEPS 1. Start any one of the CW pump. 2. Line up the CW priming pump. 3. Open the CW inlet valve at condenser A and B. 4. After the system is filled up gradually open the condenser inlet valve to ensure complete priming of the condenser water box. 5. Close duct outlet vents when water flows continuously from the vents. 6. Start the condenser water box priming pump 7. Line up and start the second CW pump and open the condenser inlet valve to maintain the condenser water box pressure within limits . 8. After sometime switch off the condenser water box priming pump. 9. Close the CW duct vents also.
LINE UP AND CHARGING OF TURBINE LUB OIL/SEAL OIL SYSTEM OBJECTIVE : To line up the turbine lube oil system. To start the generator seal oil system. PRE -REQUISITES & STATE OF PLANT 1. Work permit on various turbine lubricating equipments such centrifuge system, main oil tank, turbine lube oil coolers, vapour extractors, injectors, main oil pump and associated pipe line thrust bearing filter etc., cancelled and men, material removed. 2. Equipment cooling water pumps are running. 3. Instrument air is charged to various actuators. 4. Local pressure, temperature, flow, level gauges and transmitters charged. 5. Control power to turbine side instruments in UCB available. 6. 415 V power to various TG MCC ,TVDC charged. 7. Adequate oil in the main oil tank is available. 8. The centrifuge and other oil purifier system is available. 9. Both the oil vapour extractors are available.

1. Check that gate valve gearing closed with its SLC off. 2. Line up the lube oil cooler as per the standard practice (thorough venting of cooler should be carried out). 3. Line up the thrust bearing lube oil filter and that ensure standby filter is available. 4. Open the oil temperature controller manually to about 30 %. 5. Check the lube oil supply valves to turbine and generator bearings are open. These valves are normally adjusted at the time of commissioning. 6. Line up the seal oil cooling system from local . OPERATIONAL STEPS 1. Turn on the oil vapour extractor by pressing from UCB. 2. Start the generator bearing chamber exhaust fan 1from local. 3. Start one auxiliary oil pump from the insert
4. Check the lube oil pressure and AOP current are normal. 5. Switch on the SLC for the AOP2 and EOP from the control insert 6. Check the auto start of AOP2/EOP by switching off the AOP1. 7. Ensure that AOP 1 is running with its SLC on. 8. Transfer the lube oil temperature controller to auto mode 9. Line up and take in service seal oil coolers and oil filters . 10. Line up and start seal oil pumps 11. Ensure that air is purged out & generator is filled with CO2 12. Open the hydrogen supply valve to generator from local 13. Check the hydrogen pressure once the pressure reaches 4 Kg/cm2 then close the valve. 14. Check the hydrogen purity from indicator in UCB and, get the measurement of moisture in H2 is done 15. Check that seal oil tank levels are normal. * Hydrogen filling done, seal oil pumps are in service *
TO TAKE HYDRAULIC BARRING GEAR IN SERVICE JACKING OIL SYSTEM/TURNING GEAR OBJECTIVE To line up and start the jacking oil pump. To keep the turbine on turning gear. PRE -REQUISITES & STATE OF PLANT 1. Work permit on various turbine oil system as main oil tank turbine lube oil coolers, vapour extractors, pressurising valves, etc., cancelled and men, material removed from the area. 2. Local pressure, temperature, flow, level gauges and transmitters charged. 3. Turbine lube oil system charged.
JACKING OIL SYSTEM/TURNING GEAR

PRE -START CHECKS AND LINE UP 1. Check the fine control valve supplying high pressure jacking oil for open. 2. Check that pressure relief valve is properly set and the bypass valve is closed. 3. Ensure that turbine lube oil temperature controller is kept on auto. 4. Ensure the turbine differential expansions are within limits.
OPERATIONAL STEPS
1. Start jacking oil pump. Check that jacking oil press. is normal. 2. Standby and DC jacking oil pumps available for service. Check winding temperature locally. 3. Transfer the SLC mode of all the jacking oil pumps to auto. 4. Check the jacking oil pressure comes to about 125 Kg/cm2 5. Turn on the SLC turning gear. The gate valve gearing starts opening and turbine speed goes up. 6. The speed should come up to approximately 80 RPM without vacuum, check the lube oil temperature controller maintains the set lube oil temperature. 7. Check that bearing vibrations and bearing temperature are normal and lube oil flow should be normal. *Turbine on turning gear *
LINE UP AND START UP OF CONTROL FLUID PUMPS

OBJECTIVE To lineup and start control fluid pumps. To charge the 8bar and 32 bar fluid to control system. PRE -REQUISITES & STATE OF PLANT 1. Work permit on various turbine control oil system such as control fluid tank, governing rack, coolers, accumulator, LP bypass valves actuators, pumps and various interconnecting pipe -lines. 2. Control fluid tank level is adequate. 3. All the drains in the system are closed. 4. Local pressure, temperature, flow level gauges and transmitters charged. PRE -START CHECKS AND LINE UP 1. Check the line up of the duplex filters provided in the high pressure and low pressure control system. 2. Charge the control fluid oil coolers from water side. 3. Open high pressure accumulator isolating valves provided at various high pressure service points.
LINE UP AND START UP OF CONTROL FLUID PUMPS

OPERATIONAL STEPS
1. Start any one of the control fluid tank vapour extractor. 2. Start control fluid pump, and check the discharge pressure and motor amps. 3. Keep the SLC of both the pumps to auto mode from console. 4. Establish control fluid supply to various services. Control fluid pump in service *
VACUUM PULLING
OBJECTIVE To line up the condenser circulating water system. To line up and start the vacuum pump for establishing the vacuum. PRE -REQUISITES & STATE OF PLANT 1. Work permit on various equipment such as condenser water box ,valves, vacuum pumps, flash tanks, hot well, etc., cancelled and men, material removed from the area. 2. Ensure condenser water box is charged. 3. Ensure Equipment cooling water is charged. 4. One condensate pump is running. 5. Turbine lube oil system is in service and turbine on barring gear. 6. The auxiliary steam header is charged. 7. All the possible air paths are blocked, i.e., turbine glands, hot reheat vents and drains vacuum breaker valve, atmospheric lines coming to auxiliary flash box.
VACUUM PULLING
PRE -START CHECKS AND LINE UP 1. Close drains and fill the air/water separator tank of ELMO vacuum pump. 2. Line up tank level controller by opening isolating valve. 3. Vacuum pump A/B system lined up from local. 4. Charge, vent and take into service the condensate cooler.
OPERATIONAL STEPS 1. Open air isolating valve, bypass valve and close the air ejector valve to put the pump in hogging mode. 2. Open the drain valve of the gland steam supply from console 3. Open the aux steam block valve to gland seal system. 4. Increase the opening of the steam seal supply valve to warm-up the header and watch the gland steam temp.
VACUUM PULLING
OPERATIONAL STEPS 5. Switch on the seal steam condenser exhauster from insert 6. Slowly increase the output of the seal steam pressure controller to maintain pressure of 0.01 Kg/cm2. 7. Close the vacuum breaker 8. Pre-select the vacuum pump no. 1 from the selector switch 9. Open the vacuum pump air isolation valve no. 1. 10. Start the pump from the UCB console. 11. Check the vacuum builds up to about -0.9 Kg/cm2 . 12. Close the air ejector 1 bypass valve and open the air ejector valve 1 to keep the vacuum pump in hold mode. 13. Close the gland seal steam drain valve after gland steam temperature reaches 140 to 150 deg C (Alternatively above steps can be done automatically if SGC evacuation is on Auto.) * Condenser vacuum pulled *
MAIN STEAM LINE WARMING AND CHARGING

OBJECTIVE To warm-up and charge the main steam line up to Emergency stop valves PRE -REQUISITES & STATE OF PLANT 1. Work permit on various boiler areas such as main steam stop valve, safety valves, main steam strainer, various lines etc., cancelled and men, material are removed from these areas. 2. Boiler is in lighted up condition and boiler drum pressure is about 6 to 8 Kg/cm2. 3. Condenser vacuum is pulled. 4. Boiler drum vents and superheater vents / drains are closed. PRE -START CHECKS AND LINE UP 1. Ensure that main steam header drain valve MSD-050 valve is open. 2. Open the main steam strainer drain valve MSD -054 to MSD -060 3. Open the hot reheat strainer drain valve MSD -034 to MSD -040 4. Check that SLC drain is kept on auto and drains are open as per the logic.
MAIN STEAM LINE WARMING AND CHARGING

OPERATIONAL STEPS 1. Turn the main steam stop valves MS-001 equaliser isolating valve to open position and wait till it is fully open. Repeat the above step for MS -002 valve also. 2. Crack open the regulating valve by holding the switch to open position for MS001 and MS -002. 3. Wait for sometime; observe the main steam temperature rises before ESV. 4. Open further the bypass regulating valve to about 50 % and wait. 5. Open the main steam stop valve 1 and 2 after opening the bypass valve fully. 6. Check that bypass equaliser valves should close once the main steam stop valves are full open. * Main steam line warmed and charged. *
HP BYPASS CHARGING
OBJECTIVE To line up HP bypass system. To take HP bypass into service. PRE -REQUISITES & STATE OF PLANT 1. Work permit on various HP bypass oil unit, valves, desuperheater, lines, etc., cancelled and men, material removed from the area. 2. Oil level in HP bypass tank is normal. 3. Both HP bypass pumps auto start and stop with oil pressure < 110 Kg/cm2 and >160 Kg/cm2 checked OK. 4. All the five numbers hydraulic operated valves, i.e. BP1/2, BD, BPE1/2 oil line valves are operative. 5. HP bypass control and instrumentation side checked and made available. 6. All the five numbers of hydraulic operated valves open and close operation checked from local and control room in manual mode.
HP BYPASS CHARGING
7. ECW system running and bypass valves BP1 and BP2 gland cooling water inlet and outlet valves are in open condition. 8. Any one of the BFP is running and common feed discharge line is charged to supply HP bypass spray water. 9. Turbine on barring gear, condenser vacuum pulled. 10. R/H start up vents electrical supply available. Also LP bypasses system lined up and available to take care of RH steam flow and pressure. 11. Main steam line in charged condition with line drain open to flash tank -6 and HP strainer drain open to HP/LP Flash tank PRE -START CHECKS AND LINE UP 1. Open HP bypass flow nozzle down stream drain manual valves. 2. Close HP bypass spray water line manual drain valves after BD, BPE-1 and BPE-2 valves. 3. Ensure that spray water line hydraulic valves BD, BPE1 and BPE2 are in fully closed condition. 4. Open the HP bypass spray water line manual isolating valve.
HP BYPASS OPERATIONAL STEPS 1. Set the pressure setter of HP BP about 12 Kg/cm 2 from the console. 2. Adjust the temperature set point of BPE-1 and BPE-2 to about 220degC. 3. Adjust the LP bypass fixed set point to about 4 Kg/cm 2 and ensure that LP bypass is kept on auto. 4. Ensure that the water spray pressure controller is in manual mode. 5. Open the BP1 and BP2 valve manually to about 5 % from the console. Check that BD valves and both BPE valves get transferred to auto mode. 6. Check that HP Bypass down stream temperature increases, temperature will be maintained by the spray valves BPE1/2 at about 220 deg C. 7. Raise the boiler firing by raising the heavy oil pressure to increase the steam pressure. 8. Ensure that LP bypass has opened and hot reheat pressure is maintained as per fixed set point.
HP BYPASS OPERATIONAL STEPS 9. Bypass valves can be put in auto mode with main steam pressure matching the HP bypass pressure setter to have bumpless transfer after adequate boiler firing is achieved. 10. Close the superheater header vents and start up vents. 11. The downstream temperature set point can be varied depending on the final hot reheat temperature requirements during start up which is about 300degC. (280degC to 340degC) 12. Close the reheater outlet header vents once the LP bypass valves are sufficiently open to maintain minimum flow through reheater. 13. The HP bypass pressure setter should be gradually increased to about 40 Kg/cm2 to bring the main steam parameters for rolling the turbine.
Note 1 : HP bypass valves will force close / not open under following condition. I) If the downstream temperature is more than 380degC. II) If vacuum is <0.8 Kg/Cm2 In case by pass valve closes fully, the corresponding spray valve should be closed immediately to prevent water entry. The downstream temperature should be allowed to come down naturally before opening the bypass valve again. The start up vents should be opened to avoid stagnation of steam in superheater. Note 2 : Once unit is synchronised the main steam pressure and down stream temperature set point of HP bypass system should be increased to more than operating full load parameter but less than minimum MS safety valve setting. The values can be 175 Kg/cm 2 and 340 o C. This is to be done to prevent unwanted opening of bypass and spray water valves if controllers are kept in auto. * HP bypass system taken in service *
LP BYPASS CHARGING
OBJECTIVE To line up LP bypass system To take up LP bypass into service. PRE -REQUISITES & STATE OF PLANT 1. Work permit on various LP bypass valves, spray water valves, pipelines condenser, etc., cancelled and men, material removed from these areas. 2. Control fluid pump is running, 32 bars and 8 bar control oil available. 3. Turbine lube oil and jacking oil system in service with turbine on barring gear. 4. At least one pass of condenser is charged with cooling water. 5. Atleast one condensate extraction pump is in service. 6. Condenser vacuum pumps in operation with condenser vacuum > 0.6 Kg/cm2. 7. HP bypass lined up and available for service. 8. Boiler steaming with drum pressure about 6 to 8 Kg/cm2.
LP BYPASS CHARGING PRE -START CHECKS AND LINE UP 1. Open the manual isolation valves for exhaust hood spray and drain manifold. 2. Open the LP bypass spray manual valve from local. 3. Injection water pressure switch, low vacuum protection switch in LP by pass rack are in operating position. 4. Ensure that all the 8 bar control fluid line and various valves are open and charged condition, e.g. main supply isolating valve to bypass rack, to temperature dependent solenoid valves, injection water pressure switch, etc. are open and in charged condition. 5. Check that individual injection water manual bypass valves are closed. 6.Check that isolating valves downstream of duplex filter in 32 bar control fluid line for both LP BP control valves are open. 7. Check that drains, vents of both duplex filters are closed. 8. Check the main isolating valve in the injection water line from CEP discharge header is open.
LP BYPASS OPERATIONAL STEPS 1. Set the hot reheat pressure set point reference to 4 Kg/cm2 in LP bypass console. 2. Check that both temperature dependent solenoid valves are in reset condition in LP bypass console, otherwise reset them. 3. Charge the main steam line and open the HP bypass valves up to 5 %. 4. With LP bypass valves in manual mode, give increase command to LP bypass controller gradually till the injection water valves 1 and 3 opens full and then both the bypass stop valves opens full as indicated in the console. 5. Increase the controller further till both the bypass control valves open about 25%. 6. As HP and LP Bypass in service, the boiler start up vents, hot reheat vents can be closed. 7. As HP Bypass valves open more (either in manual or auto), hot reheat pressure will gradually approach 12 Kg/cm2, raise the LP bypass fixed set point to 12 Kg/cm2.
LP BYPASS OPERATIONAL STEPS

8. Check the control error deviation in the console. When it becomes zero the LP bypass controller can be switched to auto with automatic control interface (ACI) off. 9. If LP Bypass downstream flow increases above 45 % , check that second set of injection water valves open automatically and will be indicated on the console. Note -1 : LP bypass operation can be done with automatic interface kept ON. It will automatically open the bypass control valve to 25 % and will hold it till the actual Hot reheat pressure reaches 12 Kg/cm2. The ACI will be switched off.
LP BYPASS OPERATIONAL STEPS

Note 2 : Both the LP bypass stop and control valves will close if i) Condenser vacuum is less than -0.6 Kg/cm2. ii) Injection water pressure after injection valves is less than set value(18Kg/Cm2). iii) Either of the stop and control valve will close if the corresponding condenser wall temperature is more than 90 o C. Note 3 When turbine is on load, the LP bypass pressure set point (sliding set point) is a function of HP turbine first stage pressure. The maximum of fixed and sliding set point will be the operating set point and LP bypass will open if in auto mode, when actual reheat pressure is more than this set point. * LP bypass taken in service *
LINE UP FOR TURBINE ROLLING

OBJECTIVE To line up the turbine governing system and drains for rolling. To line up and charge the stator water system. PRE -REQUISITES & STATE OF PLANT 1. Work permits on various turbine side equipments like main oil pump HP/IP/LP turbine, generator, extraction system, drains, reheat steam lines, extraction NRVs, etc., are cancelled and men material removed from these areas. 2. The turbine lube oil system and jacking oil system charged and turbine is on barring gear. 3. Atleast one control fluid pump is in running condition and 32 bar and 8 bar fluid charged to various parts of governing system. 4. The boiler is lit up condition with HP/LP bypass in operation and main steam pressure/temperature to about 40 Kg /cm 2with 350 OC. 5. Adequate water level in the primary water tank and nitrogen charging system available. 6. The control power supply to the governing panels/insert available.
TURBINE ROLLING PRE -START CHECKS AND LINE UP 1. Open the drain before HP control valve 1 to 4 to about 60 % in manual mode from UCB console 2. Open the drain upstream and before seat of interceptor valve MSD093 to MSD 096 3. Open the ESV seat drain MSD-091/92 4. Check that primary water line drains are closed. 5. Line up the primary water system by opening the suction and discharge valve and taking one cooler and one filter in service. 6. Open the stator water cooling system manual inlet isolating valve from local. 7. Ensure that generator lockout relay is reset from GRP panel 8. Ensure that SLC drain is ON. 9. Check the TSE indicator and recorders are healthy and showing the correct values. 10. Check the main steam pressure about 40 Kg/cm2 and temperature < 350degC with hot reheat pressure about 12 Kg/cm 2 and temperature around 360degC.
TURBINE ROLLING OPERATIONAL STEPS 1. Start the primary cooling water pump from local . 2. Open the exciter cooler and hydrogen cooler isolating valves. 3. Check the primary water flow & temperature from the UCB. 4. Ensure that unit is on the limit pressure mode with deviation positive on console. 5. Switch on the tracking device from the insert 6. Reduce the starting device to zero value. Check that trip oil pressure is built and auxiliary start up oil pressure should come up to more than 5 Kg/cm2. 7. Ensure the TSE effect is ON. 8. GT / UAT cooler control system lined up . 9. Ensure that hydrogen temperature controller and primary water temperature controller are healthy and are available. 10. Raise the speeder gear to 100 % position. 11. Adjust the load limiter to about 50 MW
TURBINE ROLLING SYNCHRONISATION OBJECTIVE To roll and soak the turbine at rated speed. To synchronise the machine and achieve the block load. PRE-REQUISITES & STATE OF PLANT 1. Work permit on various generator side equipments such as exciter, AVR, field breaker, generator transformers, unit auxiliary transformers, etc., cancelled and men, material are removed from these area. 2. The line up for the turbine rolling is done. 3. The switchyard 400 KV buses are charged with bus coupler close. 4. The main steam parameters are available and HP / LP bypass in service. 5. All the lockout relays in the generator protection panel are reset. 6. A minimum of three / four pulverisers are available to be taken into service. 7. Steam driven BFPs are also available. 8. Hydrogen pressure is adequate( 4.0 Kg/cm2 ) and spare bottles are available.
TURBINE ROLLING SYNCHRONISATION PRE-START CHECKS AND LINE UP 1. Check the excitation not blocked, signal is available in the control panel. 2.Check that the load limit is greater than 50 MW. 3.Check that hot reheat and cold reheat drain valves are open 4. Ensure that main generator voltmeter selector is not in off position. 5.Check the operation of Gen. Transformer tap position selector. 6. Close the 400 KV generator -6 bay main bus -2 line isolator (SEM 6004) from switch yard . 7. Ensure the Earthling switch ( SEM -6008 ) is in open condition from switch yard . 8.Close the 400 KV generator -6 bay breaker, incoming isolator (SEM6006). 9.Ensure all other isolators are in open condition. 10.Line up the G.T. cooling water circuit from local .
TURBINE ROLLING SYNCHRONISATION PRE-START CHECKS AND LINE UP 11.Switch on the generator transformer control supply for all the three phases from local Ensure that exciter air cooler isolating, hydrogen cooler isolating, stator water coolers are charged 12.Switch on the control supply for both the unit auxiliary transformers by changing the status 13.Ensure that GT/UAT cooler control system is in lined up condition 14.Ensure that speed reference set point is zero. 15.Ensure that turbine is kept on turbine follow mode with the minimum load limited about 100 MW on the coordinated control system insert. 16.Ensure that trip oil pressure and start up oil pressure values are normal
Turbine Startup Rolling / Synchronising

OPERATIONAL STEPS 1.Raise the starting device slowly to about 42 % . 2.Ensure that start up oil pressure has decreased and at about 42 % of the starting device position the HP stop valves open. 3.Further raise the starting device position to open the hot reheat stop valves. 4.Check the temperature of the turbine stop valves at 50 % depth and control valve temperature at 50 % and 100 % depth from TSE recorders. 5.Keep the warm-up controllers in auto mode. The output of the controller will modulate to maintain the TSE margin for stop valves. 6.Raise the starting device position to about 80 % and check that secondary oil pressure has build to open the control valves. 7.Put the load gradient on from UCB console.
TURBINE ROLLING 8.Ensure the pressure controller deviation is on positive side. 9.Ensure that drum level is on lower side to avoid sudden swing which may cause water carry over. 10.Raise the speed reference to about 360 RPM from UCB. 11. Check the uniform opening of control valves and turbine acceleration rate. 12. Ensure that gate valve gearing has closed when turbine speed exceeds 240RPM. 13. Check that Jacking oil pump has switched off at speed of about 540 RPM 14. Check all the bearing temperature rise and bearing vibrations to be normal. 15. Check the thrust bearing temperature and the differential expansions. 16.Soak the turbine at the soaking speed till the HP shaft temperature at 50 % depth (Calculated) reaches to about 180degC with respect to existing main steam temperature as per the X curves.
TURBINE ROLLING 17. Check the TSE margin for various channels. First it will reduce and then gradually will increase once the difference between surface and mean temperature reduces. 18. Raise the speed reference to 3000 RPM in one stroke. 19. The turbine speed starts increasing opening of IP control valves can be seen at this stage. 20. At speed of about 2960 RPM the AOP should be switched off as main oil pump takes over (ensure that SLC for all the oil pumps are on). 21. Soak the turbine at 3000 RPM till IP shaft mean temperature (50 % depth) with respect to hot reheat temperature as per the rolling X curves is satisfied. 22. Check that a minimum of about 30 K margin is available before unit is to be synchronised.
TURNINE ROOLING AND SYNCHRONISING 23. Close the generator field breaker from AVR console. 24. Raise the AVR set point to build the Generator voltage to about 21.5 KV 25. Match the auto and manual set point of the AVR and transfer the AVR to auto mode. 26. Ensure that load controller is on with load gradient kept at 20 MW/min. 27. Turn on the synchroscope switch to check mode. All the meters showing incoming and running voltage and frequency energises. The synchroscope rate of rotation reflects the difference between incoming and running frequency. 28. Adjust the voltage so that incoming and running voltage values are same. 29. Adjust the turbine speed so that synchroscope is slowly rotating in clockwise direction showing incoming frequency is slightly higher than grid.
TURBINE SYNCHRONISING 30. Check the breaker closing permissive green lamp glows once synchroscope is between 11 to 12 Oclock position. 31. Close the generator breaker when Gen. breaker closing permissive green lamp comes. The synchroscope indicator locks at the 12 Oclock position. The generator breaker closed red lamp comes on. 32. Immediately raise speed reference to pick up the load on the machine to avoid reverse power trip or low forward power trip. 33. Increase the load as per the TSE margin and at the earliest close HP/LP bypass valves. 34. Ensure that warm-up controllers have closed, otherwise close them manually. 35. Close all the drains which were opened during rolling. 36. Turn off the synchroscope switch to de energise the synchroscope. 37. Check that Prlim value slowly increase. Also ensure that load reference set point is higher than the actual load value.
TURBINE SYNCHRONISING AND LOADING 38. Observe that change over from speed controller to load controller takes place once output of load controller is greater than that of speed controller. The load controller active facia glows on the insert. 39. Raise the starting device position to 100 %. Check the increase in auxiliary secondary oil pressure. Also ensure that tracking device is switched on. 40. Increase the load limiter value to about 150 MW from insert 41. Check the generator slot, core, exciter air and hydrogen cold gas temperatures 42. Check from the multipoint selector switches, generator stator core temperature. 43. Raise the HP bypass pressure set point to about 160 Kg/cm2 and temperature set point to about 340 degC to avoid HP bypass opening on auto. 44. Ensure that LP bypass stop valves and spray valves have closed fully. * Unit synchronised with load controller in service *
LP HEATER CHARGING
OBJECTIVE To line up LP heater from water side. To charge the LP heater from steam side. PRE-REQUISITES & STATE OF PLANT 1. Work permit on various LP heaters, drip valves, level gauges, water side valves, NRVs, etc., cancelled and men, material removed from these areas. 2. The unit is synchronised and HP/LP bypass valves are closed. 3. The instrument air is charged to various drip valves and valves are checked for the operation on auto. 4. All the pressure gauges, local level gauges, root valves and various instrument impulses lines are charged or in service. 5. The 415 V power to various motorised valves are available.
LP HEATER CHARGING PRE-START CHECKS AND LINE UP 1. Check that LPH-1condensate inlet/outlet valves are in open condition and bypass valve is in closed condition. 2. Ensure all the shell side heater vents are in open condition represented 3. Check that all the isolating valves of the LP heater level controllers are full open for all the three heaters. 4. Charge the local level gauges for all the three heaters. OPERATIONAL STEPS 1. For LPH1 put the normal drain valve control switch to control mode from section. The valve starts modulating to maintain the LP heater level. 2. Check that LPH-2 condensate inlet/outlet valves are in open condition and bypass valve close. 3. Open the extraction steam isolating valve to LPH2.
LP HEATER CHARGING
4. De-energise the extraction NRV solenoid from ATRS console by pressing the left side push button. The NRV position starts increasing as the steam goes to LPH2. 5. Put the normal drain valve control switch to control mode. The valve starts modulating to maintain the LP heater level. 6. Check the condensate inlet / Outlet valves for the LPH3 are open and bypass valve closed. 7. Open the extraction steam isolation valve to LPH3 8. Put the normal drain valve control switch to control mode. The valve starts modulating to maintain the heater level. 9. De-energise the extraction NRV solenoid from ATRS console. 10. Check the condensate temperature after LPH-1,2,3. The temperature should gradually increase(in DAS ). 11. Close the heater vents from local . * LP heaters charged *
TO TAKE PULVERISER INTO SERVICE OBJECTIVE To line up start primary air fans. To line up and start pulveriser. PRE-REQUISITES & STATE OF PLANT 1. Work permit on various pulveriser side equipment such as seal air fans and valves, pulveriser discharge valves, cold air damper, hot air gate and dampers, feeder, coal bunker mill reject system etc., cancelled and men, material are removed from these areas. 2. The equipment cooling water system is charged and all the coolers are in charged condition. 3. Atleast one set of ID fan and FD fan are running with furnace purging carried out. 4. FSSS start command to start the PA fan should be available. 5. Instrument air is charged to all cold and hot air damper actuators. 6. Primary air preheater is in service with air / gas dampers in open condition.
TO TAKE PULVERISER INTO SERVICE

7. Auxiliary steam should be available for cold End temperature controllers. 8. Secondary air temperature should be adequate (about 200deg C). PRE -START CHECKS AND LINE UP 1. Check that adequate oil level is Ok. 2. Take any one primary RAPH in service and ensure the dampers are open. 3. Establish the equipment cooling water supply through the lube oil coolers for PA fan . 4. Line up the PA fan A lube oil circuit . 5. Rack in the 6.6 KV breaker for PA fan A. The green lamp in UCB glows. 6. Switch on the lube oil pump A for PA fan A and keep the selector switch of B in lead mode. Check auto interlocks of the lube oil pumps. 7. Ensure that blade pitch is minimum and operative. 8. Ensure that the control / lube oil pressure is adequate. 9. Open the cooling water inlet valve to PA fan A and B .
TO TAKE PULVERISER INTO SERVICE

10. Lube oil sump level for the pulveriser is normal. 11. The pulveriser discharge valves are open. 12. Open the cold air gate for all the pulverisers. 13. Ensure the tramp iron valve is open. 14. Start the lube oil pump for the pulveriser. 15. Check the lube oil pressure satisfactory permissive appears on the FSSS console. 16. Ensure that both the hot air damper and cold air dampers are operable from UCB. 17. Ensure the feeder inlet gate is open and corresponding permissive lamp is glowing in FSSS console.
TAKING PULVERISER IN SERVICE OPERATIONAL STEPS 1. Take the primary RAPH A in service similar to the secondary RAPH. 2. Give PA fan A start command 3. Ensure that outlet damper PAD-1 starts closing. 4. All the permissive will be available the moment discharge damper is closed the fan will take start. Check its starting and no load current. 5. Check that outlet damper for PA fan A reopens after a time delay and discharge damper for PA fan B closes on interlock. 6. Check the bearing temperature and vibration from UCB are normal. 7. Ensure that lube oil pump for PA fan B is running with standby pump in lead mode for both the fans.
TAKING PULVERISER IN SERVICE OPERATIONAL STEPS

8. Increase the blade pitch of PA fan A, and observe that PA fan A discharge pressure increases. 9. Bring the PA header pressure to about 800 mmwcl by raising blade pitch further. 10. Improve the cold end temperature by charging the SCAPH. 11. Ensure that 2 nos. of seal air fan are running, otherwise standby fan will get start command from the FSSS console. 12. Open the pulveriser discharge valve by pressing the open push button. 13. Ensure that the pulveriser mode is in manual. 14. Check that ignition permit is available for the pulveriser to be taken into service and all 4 oil guns are in service.
TAKING PULVERISER IN SERVICE OPERATIONAL STEPS 15. Ensure that the following pulveriser start permissives are satisfied. Start permit (nozzle tilts horizontal and air flow less than 40 %). Outlet temperature less than 93 0C. Coal feeder in remote. No auto unsuccessful start. Pulveriser lube oil pressure satisfactory. Tramp iron valve open. Ignition permit. Discharge valves open. Cold air gate open. Primary air permit. No pulveriser trip command. Feeder inlet gate open.
TAKING PULVERISER IN SERVICE OPERATIONAL STEPS 16. Momentarily press the pulveriser start push button. The following events will occur. The pulveriser seal air valve opens and red open light comes Once seal air header to pulveriser under bowl differential pressure is more than 8 inch WCl, seal air pressure OK permissive comes All the permissive on the console appear and pulveriser ready lamp glows. Pulveriser ammeter pegs out to draw the starting current and comes down to no load value. Pulveriser cold air damper opens 100 % and primary air flow to mill comes to 95 T/hr. 17. Maintain the furnace pressure by raising the ID fan inlet guide vanes.
TAKING PULVERISER IN SERVICE OPERATIONAL STEPS 18. Open the hot air gate by pressing the Open push button. Hot air gate opens and red open lamp comes on. 19. Open the hot air damper and simultaneously decrease the primary air flow controller to maintain about 95 T/hr of primary air flow. 20. Check the pulveriser outlet temperature increases gradually since hot primary air is going through the mill. 21. Start the feeder by depressing the start push button. The feeder starts and coal flow rate comes to approximately 12 T/hr 22. Increase the loading on the mill by raising the feeder speed and maintain the pulveriser outlet temperature to about 770 C. 23. Check the furnace pressure and maintain it to about -15 mmwcl by loading the ID fan.
TAKING PULVERISER IN SERVICE OPERATIONAL STEPS 24. Increase the opening of the fuel air damper as per the feeder speed. Start the feeder B 25. Check that the fire ball scanners should start sensing flame and flame failure protection gets armed corresponding red lamp comes on 26. Check the pulveriser bowl differential pressure and mill motor current and raise the coal feeding accordingly. 27. The drum level and other parameters are to be maintained during this operation. 28. Electro Static Precipitator can be put in service, when coal firing has stabilised considerably in 3 to 4 mills. * Pulveriser taken in service *
STEAM TEMPERATURE CONTROL OBJECTIVE To line up and charge superheater attemperation system. To line up and charge reheater attemperation system. PRE-REQUISITES & STATE OF PLANT 1. Work permit on various attemperating side equipments such as block valve, control valves, impulse pipeline, isolating valves and associated piping cancelled and men, material are removed from these areas. 2. Minimum one BFP is running with feed water charged up to the feed control station after HP heaters. 3. Instrument air is charged to all the control valve actuators. 4. Valve power is available to the SH attemperation/RH spray block valves. 5. The boiler load (steam flow) is more than 30 % with drum pressure around 80 Kg/cm2
STEAM TEMPERATURE CONTROL PRE-START CHECKS AND LINE UP 1. Line up the SH attemperation circuit. 2. Line up RH attemperation circuit. 3. Check the trend of the main steam and reheat temperature rise during the load raising operation. OPERATIONAL STEPS 1. Open the SH attemperation isolation block valve S -82. 2. Open the SH outlet temperature controller LHS isolating block valve S -83. The pressure equalising valve opens first and then main valve opens fully. 3. Open the SH outlet temperature controller RHS isolating block valve S -86 similarly. 4. Increase the controller output to about 10 % manually. Check the valve position indicator also goes 10 % open. 5. Check that superheater spray water flow increases on recorder. 6. Increase the controller output for the RHS also. Check the valve position indicator also goes up.
STEAM TEMPERATURE CONTROL 7. Open the isolating block valve for the RH attemperation control 8. Open the isolating valves for each left and right hand side reheater attemperation station R -32 or R -33 and R -34 or R -35 9. Reduce the burner tilt first by the controller, if the HRH temperature is rising rapidly. 10. Increase the RH spray on LHS and RHS to maintain the HRH outlet steam temperature. 11. Check the temperature variation in the recorders, which is a positive indication of spray flow. 12. Check that rate of increase of SH and RH temperature should slow down, otherwise further raise the attemperation control valves to increase the flow rate. Note 1 : To control RH temperature, first the burner tilts should be used. The attemperation is to be used only in emergency condition. * SH and RH attemperation is in service *
CHARGING OF UNIT AUXILIARY TRANSFORMERS OBJECTIVE To charge 6.6 KV unit bus through unit auxiliary transformers. PRE-REQUISITES & STATE OF PLANT 1. Work permit on both the unit auxiliary transformers, associated system cancelled and men, material removed from the areas. 2. The unit is in synchronised condition with load more than 75 MW. 3. The unit auxiliary transformer cooler control system in lined up condition. 4. Ensure that 6.6 KV unit Swgr Normal incomer breaker from UAT is reset. 5. Ensure that UAT A / B control supply is on.
6.6 KV BUSES CHARGING FROM UATs OPERATIONAL STEPS 1. Turn the 6.6 KV Unit Swgr No. A, UAT-A incomer Syn. hand switch to check mode. The synchroscope indicator locks up at 12 O clock position and voltages for incoming and running are shown. 2. Adjust the voltage of the incoming by changing the excitation set point from AVR console to match the running station supply voltage 3. Check the breaker closing permissive green lamp glows as soon as the voltage is matched (Keep the incoming slightly on higher side). 4. Close the 6.6 KV unit Swgr 6A, UAT-A incomer breaker. The breaker closes and ammeter starts showing the current drawn. 5. Open the 6.6 KV tie breaker. 6. Switch off the synchroscope by turning it to off position. 7. Check the UAT A winding temperature & oil temperature. 8. Repeat the above procedure Sl.No. 1 to charge the Unit Auxiliary Transformer B also. 9. Check the UAT-B winding temperature & oil temp.. ** 6.6 KV buses charged from UATs **
LOAD RAISING OPERATION OBJECTIVE To remove oil support once coal firing is established. To raise the unit load up to 50 %. PRE -REQUISITES & STATE OF PLANT 1. The unit load is about 75 MW with Unit Auxiliary Transformers charged. 2. Three to four pulverisers are ready with all associated equipments. 3. The superheater and reheater attemperation is lined up. 4. Check that sufficient margin is available on TSE to raise the load. 5. Raise the load limit on both EHG and CCS consoles to about 300 MW.
LOAD RAISING OPERATION OPERATIONAL STEPS 1. Checks that the upper load margin in the TSE indicator and IPS temperature margin in TSE recorder are adequate to load the turbine further. 2. Take two more pulverisers in service as per the standard procedure mentioned earlier. 3. Increase the loading on all the three pulverisers equally and check for better combustion condition in the furnace. 4. If oil elevations at AB/CD/EF are in service, then oil guns at EF elevation can be removed for economic operation. 5. Depress the PAIR 1-3 stop push button on oil console at EF elevation. 6. Check that the oil nozzle valve closes and associated closed light comes on, spark rod of igniter advances and sparks for 15 secs then retracts back. 7. Ensure that oil gun at corner 1 and 3 retracts back once the 5 min scavenge operation of oil gun is complete.
LOAD RAISING OPERATION 8. Repeat the same for the pair 2-4 also, check till both the oil guns retracts back. 9. Reduce the heavy oil pressure. 10. Increase the feeder speed for all the three feeders beyond 60 % and check the flame intensity at AB as well as BC should improve 11. Raise the load reference on EHG control insert to pickup the load as the drum pressure increases. 12. Maintain the SH and RH outlet temperatures by increasing the opening of the attemperation control valves or reducing the burner tilts. 13. Change the set point of mill A outlet temperature and PA flow by turning the knob till it comes to 770C and 95 T/ hr respectively. 14. Check the error deviation of the controllers to be zero and transfer the controller in auto mode by pressing the middle A/M push button.
LOAD RAISING OPERATION 15. Repeat the above operation for other pulverisers, watch the outlet temperature and bowl differential pressure 16. Keep the bias setter for all the three pulverisers at 1 . 17. Raise the output of the fuel master till the error deviation in each feeder speed comes to zero. (Adjust the bias setter if loading is unequal.) 18. Transfer all the feeders to auto mode and raise the fuel master output. All the three feeders will get loaded simultaneously. 19.Keep on increasing the load set point as the parameters are building. 20. Maintain the air flow / furnace pressure / wind box pressure as the firing is changing by adjusting the respective controls in UCB. 21. Check the loading of the auxiliaries as the load approaches 50 % approximately. * Unit load is brought to 50 % *
TAKING SECOND SET OF AUXILIARIES
OBJECTIVE :
To start the second set of auxiliaries. To keep various control loops on auto. PRE-REQUISITES & STATE OF PLANT 1. Work permit on the second set of auxiliaries second stream of flue gas / secondary air and primary air ducts, etc., cancelled and men, material are removed from these areas. 2. The unit load is about 50 % .Cold reheat pressure is more than 12 Kg / cm2 to start TD BFP. 3. TD BFP and its associated auxiliary are normalised and a re available.
TAKING SECOND SET OF AUXILIARIES OPERATIONAL STEPS 1. Keep the selector switch of second condensate pump in normal mode. 2. Ensure the suction valve and recirculation valve of CEP-B are full open. 3. Start the condensate pump B and observe that motor current is normal. 4. Check the condensate pump discharge header pressure increases slightly. 5. Adjust the set point of the recirculation controller and transfer the controller to auto mode. 6. Start the TD BFP A Auxiliary oil pump A . 7. Ensure that the BFPT-A Exhaust valve to condenser is open. 8. Open the suction valve, recirculation isolation valve. 9. Reduce the starting device to zero from BFPT governing console. 10. Select the EHTC mode from the insert.
11. Open the cold reheat steam to BFPT-A block valve Ex-20. 12. Raise the starting device position to about 60 % to open the stop valve and further increase the speed of the BFP. 13. Raise the speed reference to increase the BFP discharge pressure. Check that BFP suction flow also increases. 14. Stop the motor driven boiler feed pump once the TD BFP is taken in service. 15. Similarly line up and start the TD BFP B for load raising operation. 16. Line up and start the ID fan B and balance the loading of both the fans. 17. Line up and start the FD fan B and balance the loading of both the fans. 18. Increase the output of fuel flow control master manually to increase the firing. 19. Check that all the coal feeder loading has increased and pulveriser amps have increased.
20. Adjust the output of the boiler master so that deviation on the fuel master and FD Fan blade pitch comes to zero. 21. Transfer the FD controller in auto for a smooth change over and check that the air flow doesnt change drastically. 22. The boiler master can be used now to increase or decrease the load on the boiler. The unit may be kept in Boiler Follow mode with limit pressure mode in operation (after having kept first Fuel Master on Auto and then Boiler Master on Auto). 23. Start PA fan B along with primary RAPH B. 24. Take pulveriser D in service and load the feeder. The coal flow in all three pulveriser will reduce to compensate additional coal flow. 25. Increase the Boiler Master output slowly to raise the firing if Boiler Master is kept manual. 26. The boiler temperature, pressure rapidly increases as a result of increased coal firing. 27. Raise the load set point Pref. check that opening of the HP control valve increases.
28. Increases the attemperation, if the rate of rise of SH and RH temperature becomes very high. 29. Increase the maximum load limit set point on the CMC console as well on the EHG panel to about 500 MW. 30. Adjust the furnace pressure set point to about -15 mmwcl and keep the bias setter to about 1 and transfer the controllers to auto mode. 31. Remove the oil guns at CD elevation. 32. Check that both the PA fans are equally loaded. Raise the set point for PA header pressure to about 800 mmwcl and set the bias setter to 1.0 by turning the knob. Transfer both the controller to auto mode after ensuring the control deviation is zero. 33. Repeat the above step for FD fans; note that FD set point is generated by the Boiler Master. * Second set of auxiliaries in service *
LOAD RAISING OPERATION WITH CCS. OBJECTIVE To line up and take HP heater in service. To raise the load to rated value. PRE-REQUISITES & STATE OF PLANT 1. Work permit on the HP heaters, drains, control valves, associated piping, etc., cancelled and men, material are removed from these areas. 2. The unit load is around 50 % with both set of auxiliaries running. 3. The boiler pressure is around 100 Kg /cm2. OPERATIONAL STEPS 1. Ensure that HPH both the streams are charged through water side i.e. HPH inlet and outlet valves open with bypass valve closed. 2. Open the extraction steam to HPH 5 block valve EX-008 3. Open the extraction steam to heater 5A and 5B by opening EX-005 and EX-006 respectively. 4. De-energise the FC NRVs from ATRS console.
5. Turn the control switch of HP heater 5A and 5B drip to deaerator valve LCV0712, 034 to control position and release it. 6. Check that the heater levels are normal and controller modulates to maintain level. 7. Close the Extraction steam line drain valve after NRV, MSD-063 8. Check that HPH 5A feed water outlet temperature increases. 9. Check that HPH 5B feed water outlet temperature increases. 10. In the same manner charge HPH 6A and 6B also. Check that drip control valve LCV-0701 and LCV-0723 maintains the HP heater level. 11. HPH 6A and 6B outlet feed water temperature increases. 12. Take two more pulverisers in service (preferably E and F in continuation) maintain their outlet temperature. 13. Transfer the feeder control of the above pulverisers to Auto. 14. Match the load demand signal to actual load by raising the unit master output from coordinated control system console. 15. Ensure the load gradient to about 5 MW/min for better result. 16. Increase gradually the throttle pressure set point above the actual pressure value by 2 to 3 Kg/cm2.
LOAD RAISING OPERATION 17. Transfer the boiler master to auto mode. Check the output of the boiler master increases to maintain the set throttle pressure. 18. Ensure the minimum load and maximum load set point are 50 and 500 MW respectively. 19. Place the unit in coordinated mode. The Unit control mode Coordinate facia glows on the insert. 20. Raise the Unit Master set point to about 350 MW. 21. Watch all the unit critical parameters carefully and check that they are not going beyond limit. 22. Check that the generator reactive power is within limits as per the generator capability curve. 23. Raise the throttle pressure set point gradully and check that the boiler firing rate also goes up. 24. Increase the Unit Master set point to 450 MW and check that sufficient upper margin for load raising is available. 25. Check that steam flow, air flow, fuel flow increases as a result of higher load set point as the unit is in Co-ordinated mode.
LOAD RAISING OPERATION

26. Adjust the set point of the Reheater and Main steam temperature set points to 540 o C and transfer the spray controllers to auto mode. 27. Watch the trend of main steam and reheat temperature, it may come down since HP heaters are charged, however same shall be controlled as spray controllers are in auto. 28. Check the unit load limiter on both console is beyond 500 MW. Raise the unit master set point to 500 MW. 29. Check that the control valve opening increases, load comes to 500 MW. * Load raised up to 500 MW *
TURBINE START-UP CURVES

WARMING-UP AND STARTING THE TURBINE TEMPERATURE CRITERIA
Fig: 1 STEAM WITH 50 deg SUPERHEAT Fig: 2 RECOMMENDED MINIMUM CURVE (CURVE-A) AND MAXIMUM (CURVE-B) MAIN STEAM TEMPERATURE AHEAD OF TURBINE WHEN OPENING THE MAIN STOP VALVES. Fig: 3 ALLOWABLE MAXIMUM MAIN STEAM PRESSURE AHEAD OF TURBINE WHEN OPENING THE MAIN STEAM STOP VALVES. Fig: 4 RECOMMENDED MINIMUM MAIN STEAM TEMPERATURE HEAD OF TURBINE BEFORE OPENING THE MAIN CONTROL VALVES Fig: 5 RECOMMENDED MINIMUM REHEAT TEMPERATURE AHEAD OF IP TURBINE BEFORE OPENING THE REHEAT Fig: 6 RECOMMENDED MAXIMUM MAIN STEAM TEMPERATURE AHEAD OF TURBINE BEFORE THE TURBINE IS BROUGHT TO RATED SPEED Fig: 7 RECOMMENDED MAXIMUM MAIN REHEAT TEMPERATURE BEFORE TURBINE IS LOADED
Fig: 1 STEAM WITH 50 deg SUPERHEAT
Fig: 2 RECOMMENDED MINIMUM CURVE (CURVE-A) ANDMAXIMUM (CURVE-B) MAIN STEAM TEMPERATURE AHEADOF TURBINE WHEN OPENING THE MAIN STOP VALVES.
Fig: 3 ALLOWABLE MAXIMUM MAIN STEAM PRESSURE AHEAD OF TURBINE WHEN OPENING THE MAIN STEAM STOP VALVES.
Fig: 4 RECOMMENDED MINIMUM MAIN STEAM TEMPERATURE AHEAD OF TURBINE BEFORE OPENING THEMAIN CONTROL VALVES
Fig: 5 RECOMMENDED MINIMUM REHEAT TEMPERATURE AHEAD OF IP TURBINE BEFORE OPENING THE REHEATCONTROL VALVES
Fig: 6 RECOMMENDED MAXIMUM MAIN STEAM TEMPERATURE AHEAD OF TURBINE BEFORE THE TURBINEIS BROUGHT TO RATED SPEED
Fig: 7 RECOMMENDED MAXIMUM MAIN REHEAT TEMPERATURE BEFORE TURBINE IS LOADED
HOT START UP PROCEDURE

Check the following conditions exist immediately after the Unit Tripping. Generator /Field Breaker are tripped. UATs Supply to Unit Buses are tripped and Station Supply takes over automatically. Generator AVR trips to manual mode. All the turbine Stop valves are closed. CRH NRV at HPT Exhaust closed. Turbine trip oil , Aux Sec oil & Secondary oil pressure became Zero. All the Feed Water Heaters Extraction Block valves are closed automatically. Drain before HP control valves are closed.
HOT START UP PROCEDURE

Verify the following Main Turbine Aux.Oil Pump1 starts automatically (if SLC is on). Turbine Gate valve Gearing is opened automatically at 210 rpm(if SLC is on ). JOP1 starts automatically if at 510 rpm SLC is on. Drum, SH/RH pressures rise on interruption of steam to turbine. HP/LP by pass open, if on Auto with proper set points. Condenser vacuum breaker may open if tripping is because of fire protection or Axial shift. SH/RH attemperation Block valves are closed if spray control valves are less than 5% open. Drum level may sink. All mills & Feeders with both PA fans tripped. HFO trip valve may close as per oil gun logics. Furnace pressure dips to very low value due to MFT. All wind box dampers open up after unit tripping. Stop one set of ID/FD fans to avoid forced cooling of the boiler. Stablise & maintain the draught & air flow.
BOILER PURGE: Ensure all purge permissives are available & do furnace purging for 5 minutes. Boiler MFR (A&B) gets reset after a time delay of 5 minutes. The first cause of unit tripping gets reset along with the MFR reset. Deaerator: Ensure Deaerator pressure is maintained at 3.5 Kg/cm2 & auxiliary steam pressure is 14 Kg/cm2 Condenser: Establish condenser vacuum if it has deteriorated on protection. Turbo Generator reset: Reset Generator trip relay & Turbine trip. Starting device is brought to 0% and trip oil pressure comes to 6.8 Kg/cm2(approximately).
Boiler Light up: Light up the boiler with the upper elevation oil guns and a mill or two is put in service if required to hold the temperature. Ensure that minimum stable fire is established in the boiler. Charging steam lines and heating: Open the following drain valves:
1. Drain before ESV seats. 2. Drain before IV seats. 3. MS strainer drain valves. 4. MS header drain valves. 5. HRH header drain valves. 6. CRH header drain valves. 7. Drain before Extraction NRVs and HPT exhaust NRV. 8. Drain after control valves. 9. HP casing drain. 10. Drain before and after IP control valves.
HP/LP BP charging and temperature raising: Open HP Bypass valves so as to establish 15% flow through them,taking care to see that temperature control loop is functioning normally. Ensure LP Bypass system is functioning normally on Auto. Adjust the fixed set point to 8 Kg/cm2. Steam flow thus established shall assist in heating Main Steam, Cold Reheat and Hot Reheat lines. HP Bypass valves can further be opened to assist in increasing steam parameters. TURBINE ROLLING AND SYNCHRONISING: Turbine can be rolled to rated speed either by ATRS rolling or manual rolling through Electro Hydraulic Governor. The following conditions are to be checked before rolling. The turbine should be on barring gear(115 rpm). Condenser pressure is less than 0.5 Kg/cm2 At least one condensate extraction pump is on. Trip fluid pressure is more than 5 Kg/ cm2.
Differential temperature between HP casing mid section top and bottom is less than 300C. Differential temperature between IP casing mid section top/bottom (Both front and rear) is less than 30degC. HP control fluid temperature is maintained between 50degC to 55degC. Lube oil temperature after cooler is more than 35degC.(38-47degC) Degree of superheat of Main Steam before HP Bypass is more than midmetal temperature of H.P.Control valves. Main Steam pressure before turbine is function of mid wall temperature of H.P.Control Valves. Raise the Starting Device above 42% and then to 56%. 1) Verify that all ESVs have opened. 2) Verify that drains before HP Control valves are in Auto and these valves have opened. 3) Put Seal Steam controller on Auto.
4) Verify that the following Generator conditions are fulfilled Any Generator bearing vapour Exhaust fan is on. Hydrogen Temperature controller is in auto. Hydrogen purity is more than 97%. Hydrogen pressure is more than 3 Kg/cm2. One Air side Seal oil pump is on. One Hydrogen Seal oil pump is on. Differential pressure between Seal oil Air side and Hydrogen side (both turbine and Exciter end is more than 0.7 Kg/cm2) Turbine side prechamber level is low. Generator bushing box liquid level is low(less than 90mm) One Primary water pump is on. Primary water temperature controller is on Auto Primary water conductivity is less than 1.5 Micro mho/cm. Primary water flow is adequate (>13.3dm3/sec)
Before Opening the control valves, verify the following: a) The degree of Superheat of Main steam before turbine is more than 50c. b) M.S.Temperature before turbine is more than either midwall temperature of HP casing or Simulated mid section temperature of HP Shaft. c) HRH temperature before turbine is more than simulated mid section temperature of IP Shaft. During the warm up and hot start up of the turbine, observe the following parameters. Differential Expansions. Axial Shift Temperature difference between top and bottom of the HP/IP casings. Bearing temperature and vibration. Steam parameters. TSE margin recorders for the following components HPS/HPC/IPS. Operating parameters of condensing system.
Operating parameters of turbine oil & control fluid systems. Maintain MS Temperature and Pressure at turbine inlet as per Start up Curve. Turbine Rolling Raise the speed set point so as to admit steam to steam to the turbine & Start rolling. Raise the speed to 360 rpm for warming up the casing. Verify that Gate valve gearing has closed. Close all the drains valves as mentioned earlier for warm up of steam lines. While admitting steam to the turbine, ensure that permissible wall temperature of limit curves are not exceeded. Hold the speed at 360 rpm for soaking purpose. Close the drains before HPCVs. Close the drains after HPCV if differential temperature between HPCV & Saturated steam is more than 50C.
Raise the speed to 3000 rpm provided the following parameters are with in the limits. a. The Differential Expansion of the casing. HP Turbine ,IP Turbine ,LP Turbine +5mm to -3mm +8mm to -2mm +30mm to -3mm b. The differential temperature between the top & bottom of the casing less than + / 45degC. c. Bearing temperature and vibration are less than 90degC and 45 microns respectively. d. HP Turbine exhaust hood temperature is less than 500degC. AT 3000 rpm Verify that the following conditions are fulfilled. 1) Both AOPs are off. 2) HRH temperature before LP bypass is greater than IP shaft mid metal temperature. 3) Cold Hydrogen gas temperature is less than 45degC. 4) Main Exciter hot air temperature is less than 45degC. 5) Cold primary water temperature is less than 50degC.
6) Cold Primary water flow through bushing is more than 0.37 dm3/sec and windings is more than 13.3 dm3/sec. 7) Differential temperature between primary water & Hydrogen is more than 10C. Synchronising and Load Raising: a) Put AVR on Auto & Switch on field Breaker. b) Verify that Generator terminal voltage is 95%. c) Switch on the Synchroniser & synchronise the Generator with Grid when incoming Frequency, Voltage and Phase sequence match with the running system. d) Raise the Starting device and take a block load of 10% by raising Nref from AVR console/Turbine console. e) Close HP Bypass and check LP Bypass closes on Auto, when sliding set point is more than Hot reheat Pressure. f) Charge Unit Auxiliary Transformer to change over 6.6 KV supplies from Station to UAT.
g) Raise the Turbine inlet Main Steam Pressure at the rate of 0.8 Kg/cm2 per minute up to Kg/cm2 at 25 % load and after wards at 1.65 Kg/cm2 per minute such that rated throttle pressure is achieved at 55 % load. h) Raise turbine inlet Main steam temperature at the rate of 1.60C /minute up to 485C at 50% load. i) Close HP casing drain valve provided HP casing bottom temperature is more than 300degC. j) Verify that drains before HP Turbine exhaust NRVs have closed with the opening of NRVs. Close the drains before and after IPCVs when difference between IPCV and Hot Reheat steam is more than 500C.Open the Extract steam block valves to LPH 2, 3 & Deaerator. Main steam temperature can be raised at the rate 1.60C up to 485degC and at the rate of 0.60C above 485degC till it reaches 540degC. Raise the turbine load at the rate of 4 MW/min up to 125 MW.
Verify that drain before LPH 2&3 closed when opening of respective extraction NRV is more than 15%. Verify that drain before Deaerator extraction line NRV closes when opening extraction NRV is more than 15% & differential pressure across NRV is more than 300mm wc. Put Hot well level control and deaerator level control on auto. Above 20% Boiler Load Index, drum level three element control can be put on auto. Raise the Turbine load at the rate of 2 MW/min to 485 MW. AT 27% Turbine load, cut in the first mill and at 43% turbine cut in the second mill. AT 40% Turbine load, combustion controls can be put on auto. HP Heaters 5 & 6 can be taken into service. Around 50 % Turbine load, cut in the second set of Boiler and Turbine Auxiliaries such as I.D.Fan, F.D.Fan, P.A.Fan, Boiler Circulating Pump, Condensate Extraction Pump and the second Boiler Feed Pump.
Mills are put in operation in the following sequence: No of mills Turbine load IIIrd 50% IVth 60% Vth 70% VIth 74% Above 55% Boiler MCR,SH,RH temperature controls can be put on Auto. Between 50% and 75% load, maintain turbine inlet main steam temperature at 485degC. From 97% to 100% turbine load, raise the turbine inlet temperature at the rate of 0.60C per minute to 535degC.

Unit Startup Procedure

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Unit Startup Procedure

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Operation Procedures

CHARGING OF ELECTRICAL SYSTEM

CHARGING OF AUXILIARY STEAM HEADER

CHARGING OF AUXILIARY STEAM HEADER

CHARGING OF AUXILIARY STEAM HEADER

CHARGING OF AUXILIARY RAW COOLING WATER (ARCW) SYSTEM

PRE -START CHECKS AND LINE UP

*ARCW pump is in service*

CHARGING OF EQUIPMENT COOLING WATER (ECW) SYSTEM

PRE -START CHECKS AND LINE UP

START UP OF CONDENSATE SYSTEM

PRE -START CHECK AND LINE UP

START UP OF CONDENSATE SYSTEM

START UP OF CONDENSATE SYSTEM

START UP OF CONDENSATE SYSTEM

MOTOR DRIVEN BOILER FEED PUMP ( BFP -C )

Boiler Filling and Running SGWCPs contd. :

START UP AND WARM UP OF THE FUEL OIL SYSTEM.

PRE -START CHECKS AND LINE UP

LINE UP OF FLUE GAS PATH & APHs

LINE UP OF FLUE GAS PATH & APHs contd.

START UP AND LINE UP OF ONE ID FAN

PRE -START CHECKS AND LINE UP

FLUE GAS SYSTEM FLUE GAS SYSTEM

LINE UP, CHARGING AND TAKING SCAPHS INTO SERVICE

PRE -START CHECKS AND LINE UP

LINE UP FOR BOILER LIGHT UP

LINE UP FOR BOILER LIGHT UP

LINE UP FOR BOILER LIGHT UP

PRE -START CHECKS AND LINE UP

PRE -START CHECKS AND LINE UP

PRE -START CHECKS AND LINE UP

JACKING OIL SYSTEM/TURNING GEAR

LINE UP AND START UP OF CONTROL FLUID PUMPS

LINE UP AND START UP OF CONTROL FLUID PUMPS

MAIN STEAM LINE WARMING AND CHARGING

MAIN STEAM LINE WARMING AND CHARGING

LP BYPASS OPERATIONAL STEPS

LP BYPASS OPERATIONAL STEPS

LINE UP FOR TURBINE ROLLING

Turbine Startup Rolling / Synchronising

TO TAKE PULVERISER INTO SERVICE

TO TAKE PULVERISER INTO SERVICE

TAKING PULVERISER IN SERVICE OPERATIONAL STEPS

TAKING SECOND SET OF AUXILIARIES

LOAD RAISING OPERATION

TURBINE START-UP CURVES

Fig: 1 STEAM WITH 50 deg SUPERHEAT

Fig: 7 RECOMMENDED MAXIMUM MAIN REHEAT TEMPERATURE BEFORE TURBINE IS LOADED

HOT START UP PROCEDURE

HOT START UP PROCEDURE

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ARCW pump is in service