Cold Start Up Salaya

ESSAR POWER GUJARAT LTD,
2X600 MW – SALAYA, JAMNAGAR

Revision No :
Doc No: EPGL / OPR/ BLR/01:
2×600MW SALAYA THERMAL

POWER PLANT
SCHEME FOR Boiler Cold

Start Up
Prepared By Checked By Approved By

Commissioning Team DGM - Operation JGM-Operation
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 TABLE OF CONTENTS -
SR DESCRIPTION PAGE
NO.
1 COMMISSIONING SKETCH 3
2 PRE REQUISITES FOR BOILER LIGHT UP 4
3 CHARGING OF THE SYSTEM 14
4 BOILER START UP 15
5 BOILER LIGHT UP 17
6 MAIN STEAM AND BYPASS STEAM LINE 19
CHARGING
7 TURBINE ROLLING AND SYNCRONISATION 20
8 DO’S AND DONT’S 24
9 CHECKLIST 25
10 COLD STARTUP CURVE 28

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 COMMISSIOING SKETCH FOR BOILER

INTEGERATED START UP

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PRE-REQUISITES FOR COLD START UP –
1) The RB test and load rejection test must be finished, or carried out at the initial stage of
unit integrated start-up.
2) Steam blow-out is completed and accepted.
3) Flue gas system
 The air leak test of boiler has been finished and checked to be qualified and the burners
have been set as per design requirement.
 The installation and heat preservation works of boiler’s body and flue gas duct have
been finished.
 The single commissioning and trial run in divided systems of induced draft fan, forced
draft fan, primary air fan and air-preheater have been finished.
 APH water flushing system possesses the condition of putting in to operation.
 The inspection and adjusting works of each air valve and damper of flue gas system has
been finished and checked to be qualified.
 Temporary fixing devices on the expansion joint of air and flue system should be
totally removed to make it expand freely without blocking.
 The installation and heat preservation work of Hot air recirculation line of primary air
has been finished.
4) Flame Detection System-
 The single commissioning of cooling air fan of flame detection system has been
finished and checked to be qualified.
Test the cooling air system of flame scanners
No. Step
1 Confirm all manual valves at each flame scanner are fully open
2 Start one cooling air fan, check the flowing parameters:
Cooling air pressure ≥ 6.5 kPa
Filter DP ≤ 3.7 kPa
3 Stop the cooling air fan, start another fan, check these parameters
Note: Refer to I&C procedure to get interlock information of these fans.
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 The commissioning of industrial TV system has been finished and it can be put in to
operation at any time.
 The commissioning of flue gas temperature probe has been checked to be qualified.
5) ESP system-
 The installation and heat preservation works of ESP have been finished and checked
to be qualified.
 The electric current distribution test, pressure rising test and vibration / rapping test of
the ESP are qualified.
 The installation of soot bucket heating device of ESP has been finished and checked to
be qualified.
6) Fuel oil ignition system-
 The installation and heat preservation works of the fuel oil system in front of the boiler
and the oil depot have been finished, with single trial operation.
 The hydrostatic test of the fuel oil system and atomizing steam pipe in front of the
boiler has been finished. The washing by water or blowing by steam is qualified.
 The commissioning of each electric and aerodynamic valve of the fuel system has been
 The simulation test of relevant interlock protection (MFT, OFT) of the fuel system is
qualified.
 The advance and retreat test of each oil gun and high-energy igniter has been finished.
 The static commissioning of each flame detection system has been finished.
7) Boiler main -
 The installation and heat preservation works of boiler’s body has been finished and
checked to be qualified.
 Boiler Circulation pump is commissioned along with its cooling system and ready
to be put in to operation.

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LP cooling water has two water sources: taken from cooling water booster pumps
(CCCW) and from emergency cooling water pump (DM water).
HP flushing water has two water sources: taken from SH Desuperheating water and from
DM water pump.
No. Step
1 Prepare all manual valve in LP cooling water system to make the LP cooling
water loop clear
2 Start one cooling water booster pump
3 Slowly open outlet valve
4 Open the standby cooling water booster pump inlet and outlet valve to place
the pump in standby
5 Check the following cooling water parameters:
Motor cooler: Rated flow 11m3/h
Temperature 30～39℃
Inlet pressure 2～3bar
Thermal shield: Rated flow 2m3/h
Temperature 30～39℃
Inlet pressure 2～3bar
6 Stop the working pump, start the standby pump and check these parameters
7 Stop the cooling water booster pump, start emergency cooling water pump
8 Check these parameters
Note 1: Prior to test, DM water pump and CCCW pump should be started.
Note 2: Refer to I&C procedure to get interlock information of these pumps.
 The hydrostatic test of boiler has been finished and checked to be qualified.
 The installation and heat preservation works of water draining and venting system
has been finished.
 Safety valve calibration is completed.
 All the spring hangers and support are finished and adjusted as per design
requirement.

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 Make sure that there’s no obstructive expansion of the expansion system of boiler.
Each expansion indicator should be well prepared with an indication of zero
position.
 After the pickling of boiler, drum should be cleaned up, internals should be
recovered to normal condition, the steam drum should be sealed, the temporary
facilities should be removed, and the formal system should have been recovered.
 The installation and commissioning of the water level gauge, electrode water level
gauge and water level TV of steam drum has been finished and can be put into
operation at any.
 The installation of water sampling (SWAS), chemical dosing and nitrogen filling
system has been finished and checked to be qualified.
 The erection of Deaerator, feed water pipe, Attemperation water system and
emergency spraying system has been finished, the water washing is qualified, and
the commissioning of each electric and aerodynamic valve has been finished and
checked to be qualified.
 Boiler expansion system has been checked and expansion indicators set at right
place and in right position.
 Soot blower operation tests (cold condition) -Check the stroke of each soot blower, fill
the results in check tables.
 Motorized BFP and at least one BFPT are ready to be put in to operation at any
time.
 The erection of ladder, platform and railings are complete, temporary supports
removed, the lighting is sufficient, and the boiler area is clean from any garbage and
explosive material.
 The commissioning of the electric and aerodynamic valve of each steam pipe has
been checked to be qualified. Similarly the test is also qualified for all the dampers.
 The manhole door and inspection hole have been erected and sealed.
 The cold adjustment of burner has been finished and checked to be qualified.

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8) Coal conveying, Soot & slag handling system -
 The single trial run of the equipment of the coal conveying system of boiler has
been finished, and the found defects have been eliminated.
 The installation and heat preservation work of the boiler bottom cold ash hopper
(including water seal at the bottom of boiler) have been finished and checked to be
qualified.
 The single trial run of the equipment of slag-handling system has been finished, and
the open/close test of hydraulic cutoff valve has been checked to be qualified.
 The installation and heat preservation works of boiler’s body, soot blower of
convection gas flue and its pipe (including water-dispersing pipe and valve) have been
 ESP erection, ESP and economiser ash hopper and their ash conveying pipes are
finished and inspection qualified.
 The installation and commissioning of electric and aerodynamic valve on the steam
source pipe of soot blower have been finished.
 The soot blowing operation test of air preheater has been finished and it can be put
into operation at any time.
 The installation and heat preservation works of coal pulverizing system have been
finished.
 The trial run of sealed air fan is qualified.
 The primary air leveling of coal pulverizing system is qualified.
 The calibrating of the inlet air volume meter of coal pulverizer is qualified.
 The trial run of the lubricating oil system of coal pulverizer is finished.
 The trial run of coal pulverizer and coal feeder has been finished.
 The drive test of all dampers and air valve of the coal pulverizing system has been
finished.
 The calibration and adjustment of the coal weighting system of coal feeder have been
finished.

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9) Auxiliary steam system -

 The installation and heat preservation works of each auxiliary steam system have been
finished.
 Steam blowing of steam line from Auxiliary steam header to APH has been finished
and soot blower ready to be put in to operation.
 The electric valve of auxiliary steam system has been verified to be qualified so that it
can be put into use.
 The isolation works of relevant public system and 2# unit have been finished.
10) Sampling and dosing system-

 Installation and completion of sampling and dosing system and readiness to be put in to
operation should be qualified.
11) Compressed air system-
 The single and divided system trial run of air compressor for instrument or other use has
been finished.
 The installation of each air storage tank for instrument and service air has been done and
Calibration of safety valve has been finished.
 The blowing of each air pipe for instrument or other use is qualified.
12) Fire protection system -
 The installation of fire protection water system has been finished.
 The fire facilities are well prepared and the water-passing test of fire protection water
pipe is qualified.
 The fire protection devices at the control room, electrical room and fuel oil system are
well prepared.
13) Cooling water, make up and Industrial water system –

 The installation work of industrial water system has been finished and the hydrostatic
test is qualified.
 Flushing of ACW, make up and CCW water system has been finished and can be put in
to operation at any time.
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 The divided system trial run of industrial water pump, ACW and CCW pumps has been
finished so that it can be put into operation at any time.
14) Requirements for steam Turbine
 The steam condenser and hot water well is cleaned, the condensate pump is tested,
and the whole system is washed to be qualified so that it’s able to supply water for the
deaerator.
 The inner of deaerator has been cleaned up and washed by water and the steam
heating pipe has been blown and recovered. The heating and operation conditions have
been qualified.
 The electric water feed pump has been tested to be qualified, the water supply pipe
has been washed to be qualified, and they have been recovered with normal operating
condition.
 The measures used to prevent supplying steam to the steam turbine have been
implemented and checked to be qualified.
 The commissioning work of the vacuum system of steam turbine has been finished so
that it’s qualified with normal operating condition.
 The commissioning work of the lubricating oil, sealing oil and jacking oil system of
steam turbine has been finished and the jigger system is qualified with normal operating
condition.
 The water-dispersing valve of the main steam pipe, cold reheating pipe, hot reheating
pipe, high-pressure bypass and low-pressure bypass of the steam turbine has been
verified to be qualified and can be put into use.
 The commissioning and calibration of the cylinder temperature measuring point of
steam turbine has been finished and the cylinder temperature can be correctly displayed.
 Each steam extraction electric cutoff valve has been verified to be qualified and has
been closed tightly.
 The dispersed water at each part of all introduced steam condenser has been isolated
reliably.
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 The low pressure cylinder water spraying system can be put into operation.
14) Requirements of Electrical and Thermal Control
14.1 The static test of boiler FSSS has been finished.
 Interlock test of the cooling air fan of flame detection.

 Inspection test of the furnace blowing condition.
 MFT test and linkage test after MFT.
 Fuel oil OFT test and linkage test after OFT.
 Leakage test of fuel oil.
 Test of the combustion management (including advance and retract of guns) system
of each oil gun.
 Control and interlock test of coal pulverizer.
14.2 The sequence control and interlock and protection test (part of SCS) of each
auxiliary machine have been finished.
 The starting and tripping conditions of APH main motor, auxiliary and air motor
has been finished.
 The interlock action of APH oil station and FD fan oil station is normal.
 The startup and trip conditions of induced draft fan （A and B）.
 The startup and trip conditions of forced draft fan （A and B）.
 The startup and trip conditions of PA fan （A and B）.
 The startup and trip condition of coal feeder and pulverizers.
 The startup and trip conditions of sealed air fan.
 The static test of DAS system and the installation of the point for measuring the
temperature of the metal wall of heated surface at each level have been finished and
checked to be qualified by cold-state and the professional personnel has taken the
original record. The commissioning work of the item related to DAS system and
pipe blowing has been finished, and the indication is correct and reliable: steam
drum, superheater, pressure of reheater, steam temperature, wall temperature,
pressure and temperature of feeding water, flux of feeding water, water level gauge
of electric contact, furnace flame TV, furnace negative pressure gauge, furnace gas
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temperature probe, secondary air volume, primary air volume, air pressure, air
temperature, other thermal measuring point of steam water and flue gas system,
pressure of fuel oil, temperature of fuel oil, flow meter, electric current, bearing
temperature and bearing vibration of each auxiliary machine, etc.
 The commissioning and transmission of the sound and light signal of each
protection, alarm, light-word plate have been finished, which can give alarm
normally.
 The emergency power supply is qualified to be put into operation.
15) Requirements for civil Construction.
 The commissioning site should be provided with smooth road, enough lighting and
reliable accident lighting.
 The communication facilities at the commissioning site should be convenient and
available so as to ensure that the communication is smooth. And enough fire
protection facilities should be prepared.
 The air-condition system has been tested and can be put into operation so as to
satisfy the requirements of computer equipments.
 Drainage work of the whole plant is finished including trench system covered
with plate.
16) Other requirements
 Organize the construction, supervision, production, commissioning and other units
to take overall inspection and handle found problems.
 The preparation works for production commissioning have been ready and the
operators have been trained and tested to be qualified. The operation regulations and
system drawings have been approved, the operation tools have been arranged, and the
operation log has been well prepared.
 The chemicals, water, fuel and materials used for trial run should be arranged in
advance
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 The necessary maintenance tools and materials should be prepared.

 The trial run commanding organization should have complete system and definite
duty division.

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CHARGING OF THE SYSTEM
 Charge auxiliary steam to the boiler from auxiliary boiler. Ensure proper draining of the
lines before charging .Auxiliary steam for oil heating, oil tracing lines, atomizing steam,
APH, Soot blowers should be made available.
 Charge service air and instrument air to boiler, turbine, auxiliaries and off-sites.
 Start CCW pumps and charge the coolers for all the equipments.
 Charge HFO up to the Burner front and keep it on short recirculation.
 Start DM makeup pump for taking makeup in CST.
 Fill and flush all boiler circulation pumps as per operation manual.

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BOILER START UP
The sequences of starting of the equipments are given below. For details refer to the
standard operating procedure of the individual equipment.
 Keep the drum level +200mm stop filling and open economizer recirculation valve
(close this valve when cont. feed-water flow is built).
 Start B boiler circulation pump. When the drum level decreases to lowest visible level,
shut down the pump and drum is filled again to +200mm.
 After the drum level is stabilized start 2 boiler circulation pumps.
 Start the air heaters one by one and keep the associated dampers open.
 Start the first ID fan. Ensure that its suction & discharge dampers open to full. Also
check for the closure of the suction / discharge damper / inlet vane of the other fan.
 Gradually raise the scoop and then vane of the running fan and maintain a furnace draft
of about –50Pa.
 Start the corresponding FD fan (if it is not available the other FD fan can be started).
Ensure that the discharge damper of the running fan opens full and the blade pitch and
discharge damper of the non-running fan closes full.
 Gradually raise the load on the FD fan. In parallel control the scoop and vane of the
running ID fan to maintain the furnace draft. (Ensure that the secondary air dampers are
open and modulating). Raise the total air flow to more than 30%, which is the purge
requirement.
 Put the wind box pressure control (aux. air dampers) in auto and maintain the desired
wind box to furnace differential pressure.
 Start the second ID fan. Ensure fuel opening of its suction and discharge damper.
 Slowly raise the scoop and vane of the second ID fan and reduce those of the first ID
fan to equalize the loading on both fans, always maintaining the furnace draft within limits.
 Start the second FD fan. Ensure that its discharge damper opens fully.
 Gradually raise the blade pitch of the second FD fan and reduce that of the first FD fan
to equalize the loading on both fans maintaining the minimum air flow and normal furnace
draft.
 NOTE: If so desired, the second set of ID / FD fans can be started at a later stage (after
synchronization and auxiliary supply changeover) to reduce the auxiliary power
consumption and loading on station transformer. But keeping both the fans in service is
preferable from the operation flexibility point of view. It avoids tripping of the boiler on
protection in the event of outage of one fan and reduces the furnace disturbance at a later

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stage while starting the second set of fans.
 Put the furnace draft control in auto. However, the performance of the auto loop should
be kept under observation during low load operation.
 Start the AC scanner fan and keep it in service. Keep the other fan as auto standby.
Ensure that the scanner air pressure is normal.
 Put ESP heaters into operation.
 Put slag handling system into operation.
 Fill boiler bottom water seal, open boiler bottom shut-off gate.
 Put the heating devices of ESP hoppers and ash silo into operation.
 Put all lube oil stations into operation.
 Put flue gas temperature probe into operation
 Open the vent and drain valves at drum, SH and RH.
 Start flame scanner cooling air fan, air preheater, forced draft fans and induced draft
fans.
 After completing the above activities, ensure that the following Purge Permissive are
satisfied and the ‘PURGE READY’ is ‘ON’:
All HFO nozzle valves are closed. b) All mills are OFF. c) No boiler trip. d) All feeders
are OFF. e) All scanners sense ‘No Flame’. f) All auxiliary air dampers are modulating. g)
Both PA fans are OFF. h) All hot air gates are closed. i) Air flow > 30% and <40%. j) HFO
Trip valve is closed. k) Wind box to furnace difference pressure is normal.
 Ensure that the cold start-up checklist is completed in all respects and the deviations are
noted.

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 BOILER LIGHT UP
 Start the furnace purge cycle and purging continues for 5 minutes (if the purge time is
disturbed, it should be corrected).
 If the purging is interrupted due to any reason (loss of one or more of the purge
permissive), purging should be restarted.
 On completion of purge (‘PURGE COMPLETE’), MFT gets reset.
 Open the LDO Recirculation Valve and LDO Trip Valve.
 Bring the HFO header pressure and temperature to normal value. Ensure that atomizing
steam pressure is normal.
 Ensure that Burner tilt is horizontal.
 Put A1 and A3 oil gun into operation (or A2 and A4) and control the oil and atomizing
steam parameter as follow:
Inlet oil pressure of oil gun 1.37MPa
Inlet atomizing steam pressure of oil gun 0.86MPa
Inlet atomizing steam temperature of oil gun 250～280 0C
 Check and ensure that the burner is firing properly. In case of poor flame or a leak, take
out the burner immediately. Identify the cause and attend it.
 According to boiler cold start-up curve, put the subsequence oil guns into operation
 Keep the furnace draft at normal values while cutting in oil burners.
 Ensure that the auxiliary air dampers of the burners in service are open.
 Check the chimney exit. If excessive black smoke is observed, adjust air flow.
 Start Air pre heater soot blowers. Check for any oil carry over with the help of oil carry
over probe. Inspect the air heater through the inspection doors provided on the air side.
 When drum pressure reaches the following valve, carry out corresponding works:
0.1MPa flush drum local level gauge
0.2 Mpa close all vent valves (leave drain valves open)
Put HP and LP bypass system into operation. Use bypass system and
Combustion rate to control steam pressure and temperature
0.5 Mpa Compare local drum level indication with DCS display
Flush instrument tube

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Flush sampling tube
Hot tight Screw
0.689MPa start the third boiler circulation pump
1.0MPa put cont. blowdown system into operation
(Leading to periodic blowdown vessel)
2.0MPa stop flushing the motor cavity of boiler circulation pumps
 Start the dosing pumps and do chemical dosing as per Chemist’s advice. Open CBD as
per the Chemist’s advice.

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MAIN STEAM AND BYPASS LINE CHARGING
 When drum pressure reaches about 0.5 Mpa, start charging main steam line by
gradually opening the bypass (warm up) valves of Boiler Stop Valves on both sides.
{Ensure that the main valves are not in Auto. In auto the valves gets open command when
the bypass valves are full open).
 Monitor the pressure rise of MS line bypass valves to full. Open HP Bypass warm-up
valves, to warm-up the CRH lines. Observe for any abnormality (like hammering etc.) in
the system.
 Open HP bypass valves partially and ensure that the pressure control valves, spray
valves and the protection system are working properly.
 Monitor the pressure rise in the boiler. When the pressure exceeds 0.5Mpa, open Boiler
Stop Valves and regulate HP Bypass Valves to control the pressure. Close start-up vents.
Close HP Bypass worm-up valves.
 Open LP Bypass Valves and keep it partially open at lower pressures. When the
pressure improves control the LP Bypass Valve opening so as to maintain a pr. of about 1.2
Mpa in the HRH.
 When drum pressure increases to 2.07 Mpa, stop the boiler water pump continuous
filling.

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TURBINE ROLLING & SYNCHRONISING
 Raise the boiler parameters (by controlling the firing rate) as per the requirements of
Turbine by following the allowable ramp rate.
 When steam parameters reach the requirements of turbine impulse starting condition (MS
pressure-5.9 Mpa, MS temperature-340 0C, RH temperature- 300 0C,), start turbine rolling.
 After turbine rolling and paralleling in, steam flow is built in RH, the flue gas limit
(538℃) is not necessary and close all drain valves, HP and LP bypass.
 Close CRH, HRH and MS drains.
 Carry Generator throwing off, turbine over speed protection test and Parallel in.
 Open all desuperheating water manual valves.
 Start one sealing air fan.
 Warm up mill A as per operation manual.
 Put mill system A into operation.
 Increase boiler load according to the requirement of commissioning committee.
 control boiler parameters-
A. Load adjustment
1) Adjust boiler load
 Change the speed of coal feeders, adjust primary air flow of each mill according to mill
air/coal curve provided by manufacture and adjust hot/cold primary air ratio to keep mill
outlet temperature about 65℃.
 Prior to stopping mill, thoroughly blow mill and primary air pipes.
 Before putting the mill having been tripped into operation, thoroughly blow mill and
blow primary air pipes one by one to prevent the fluctuations of drum level, steam
pressure and steam temperature.
 When boiler load decreases to about 45%, put oil guns into operation to stabilize
combustion.
 After primary air fan recover from stall, clean up the stone box of each mill immediately.

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2) Normal load change rate

 2.5%/min during normal variable pressure operation.
 5%/min in constant pressure operation.
 The maximum term of normal load change rate is 5 minutes, then keep for 5～10
minutes.
 When main steam pressure is higher than set point by 0.5MPa during load decrease,
prohibit decreasing boiler load by control logic.
 When main steam pressure is lower than set point by 1.0MPa during load increase,
prohibit increasing boiler load by control logic.
3) Maximum load change rate
 3%/min during variable pressure operation
 5%/min during constant pressure operation
B. Combustion adjustment
1) Primary air
 When the different pressure between primary air and furnace is less than 635mm
H2O(6.35kPa), the alarm of primary air pressure low is ON.
 When the different pressure between primary air and furnace is less than 500mm
H2O(5.0kPa), trip mill.
2) Secondary air
 According to the different pressure curve of wind box/furnace, adjust the auxiliary air
dampers.
 Operate the OFA dampers as per boiler load: 50～75%MCR, open the first layer damper;
75～100%MCR, open the top layer damper.
 The other requirements should be configured in control logic and carried out
automatically.
3) Furnace pressure
 Furnace pressure＜-100mm H2O(1.0kPa), alarm, prohibit increasing ID fan load and
decreasing FD load by interlock.
 Furnace pressure＞+100mm H2O(1.0kPa), alarm, prohibit decreasing ID fan load and

increasing FD load by interlock.
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C. Steam temperature adjustment
 De superheating water system is allowed to work after boiler reaches 20%MCR.
D. Adjustment of feed water and drum level
 Drum level should be controlled within ±50mm.
 Drum level +127/-178, alarm.
 Drum level +254/-381, MFT
E. Adjustment of Axial fans
 Two parallel axial fans should be working under same load.
 When stall happens to one axial fan, decrease the blade opening of two fans at the same
time. After the stalled fan come back to work, balance two fans’ load and increase fans’
load simultaneously with same margin.
F. Blowout the soot blowing steam pipes
 When the RH inlet pressure is over 1.0 Mpa, purge the boiler proper soot blowing pipes.
No. Step
1 Set the set point of the soot blowing steam pressure at 0.8～1.0 Mpa
2 Open the general soot blowing steam valves
3 Open all drain valves to warm up the soot blowing steam pipes
4 When the drain water temperature is about 150℃, start blowout
5 Close the drain valve of the loop planed to blowout
6 Close the general soot blowing steam valves
7 Disconnect the inlet flange of soot blower
8 Open the general soot blowing steam valves to blowout the soot blowing steam
pipe
9 Close the general soot blowing steam valves
10 Connect the inlet flange of soot blower
11 Repeat steps 5-10 to blowout the soot blowing steam pipe one by one
12 Carry out stroke test of each soot blower, record the result
13 Put sequence control of boiler proper soot blowing system into operation by
I&C group
 Economizer recirculation valves should be closed after establishing a constant feed

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water flow.
 Boiler pressures boost rate-0.1Mpa/min.
 Load change rate of 3MW/min.
 Steam pressure and temperature change rate are 0.10 Mpa/min & 1.80 C/min.
 Initial load of the generator is 30MW for 25 min. for the warm up operation.
 When the load is 100 MW the second set of coal pulversing system put in to operation.
 When the boiler load is more than 25% MCR drum level is put in auto mode.
 When the load is 200 MW the third set of coal pulversing system put in to operation.
 When MS pressure 10 Mpa turn up the CBD system to blowdown the silica.
 When the load is 300 MW stop all the oil guns but ensure stable combustion.
 When the load is 360 MW the fourth set of coal pulversing system put in to operation
 When the load is 360 MW the RH steam temperature 538 0C the swing control of the
boiler is set up for auto. Also the desuperheating spray of RH system is set to auto.
 When the load is 450 MW the fifth set of coal pulversing system put in to operation.
 Control all the parameters to reach the full load of 600MW.
DO’S AND DON’TS-

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 Only commissioning engineer team members should be allowed in the restricted

area.
 Use of safety apparatus is compulsory due to high temperature and pressure steam.
 Control the boiler pressure temperature boost rate.
 No oil gun should be taken out for cleaning when it’s running.
 Oil line filter to be checked regularly.
 Fire fighting system availability is must before light up.
 Barricade the firing floors and allow only the authenticated persons to inspect.
 Follow the operation manual instruction for safe and reliable operation practices.
 Reliable communication is needed between the Field & the control room.
 COLD START-UP CHECK LIST

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SR DESCRIPTION REMARKS
No.
A ACTIVITY BEFORE LIGHT UP
1 All / Required permits to work (PTW) have been
received
2 At least one CW pump & one condenser pass in service
3 ACW pumps in service
4 DMWST, CST, Deaerator levels are normal
5 DMCW pumps & heat exchangers are in service
6 DMCW Booster pump in service
7 Scaffold & Access doors DMCW water flow established
8 I A & Service air available. Pressure normal.
9 Bottom ash hopper refractory cooling established
10 Seal trough of bottom ash hopper over flow optimized
11 All oil guns are clean
12 Scanner & oil gun cooling hose are connected.
13 Bottom ash handling system ready and available
14 At least one ESP pass available
15 Fly ash & silo available
16 Boiler drum level normal
17 Boiler drum vents, SH vents are in open condition(Cold
startup)
18 Drain before Main Stop Valve (MS101 & 104) is open
19 S/H drains are open & header drain also open
20 Eco-bottom ring header recirculation valve open (E024)
21 Furnace probe available
22 All soot blowers are in home position
23 Burner Tilts at horizontal condition
24 Stack path available
25 All manholes & peep holes are in close condition
26 Drum level normal & check with local gauge glass
B ACTIVITY FOR BOILER LIGHT UP (WITH AB
ELEVATION GUN)
1 Before lit up ensure TG rotor on Barring (TG check list)
2 AC scanner fan in service & DC Scanner fan is healthy
3 Start Air Pre-Heater & check availability of Air Motor
4 One ID Fan in service
5 One FD fans in service
6 Establish air flow between 340 to 380ton/Hrs and draft -
8mmWC
7 Purge permissive satisfied
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Revision No :
8 Purge start
9 Purge completed
10 LDO Pump Discharge Pressure control on manual &
recirculation valve is >50% open
11 Start one LDO pump & put pump dis. Pressure control in
auto with set point of 18 kg/cm2.
12 Open LOTV after >1 Minute of Purge completion to reset
SADC
13 Maintain LDO pressure as required >14Kg/cm2 after
LOFCV
14 Take guns in service as required
15 Establish oil guns and regulate LDO pressure around
7Kg/cm2
16 Regulate startup vent as required to raise steam pressure
17 Close drum vent at Drum Pr > 2 kg/cm2
18 Close SH drain and vents at drum Pr > 5Kg/cm2
19 Open Main Steam Strainer Drain (MS105,106,109)
20 Raise drum pressure up to 15 kg/cm2
C MAIN STEAM LINE CHARGING
1 Open S110, 111, 120, 121 Valves for MS line heating
2 Slowly open S109, 119 after heating
Close drain (MS101 & 104) before Main Steam Stop
3
Valve
D APRDS CHARGING
1 Open all drains in APRDS line
2 Ensure sealing steam line valve (AS 09) at APRDS is
close
3 Ensure manual isolation valve before gland steam supply
valve is close
4 Ensure bypass valve of gland steam supply valve is close
5 Ensure spray control valve is lined up and in auto with set
point 320 dreg’s
6 Open APRDS motorized valve ( )
7 Open APRDS pressure control valve ( ) gradually
8 Put APRDS pressure control valve in auto with set point
of 8 kg/cm2
E TAKING CD ELEVATION GUN
1 Ensure HFO Tank heating in service through other unit
2 Ensure / charge the steam tracing line.
3 HFO Pump Discharge Pressure control on manual &
recirculation valve is >50% open
4 Open long recirculation valve (HORV)
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Revision No :
5 Line up one HFO heater from HFO side.
6 Start one HFO Pump & put pump dis. Pressure control in
auto with set point of 18 kg/cm2.
7 Charge steam to HFO Heater & put steam control valve in
auto with HFO temp. set point 110 deg.c
8 Ensure HFO temp. at firing floor is 100 deg.c
9 Charge steam atomizing line & maintain header pressure
7.0 kg/cm2
10 Close HORV before taking gun in service.
11 Take gun in CD elevation as per requirement
F STARTING OF MILLS
1 Complete vacuum pulling (TG check list)
2 Take HP/LP BP in service (TG check list)
3 Start One PA Fan & establish PA header pressure
>850mmWC
4 Ensure at least one seal air fan is in service
5 Coal available in bunkers
6 Ensure all per missives of mill is available and start mill
7 Open hot air gate & coal air gate
8 Open HAD & CAD to establish mill air flow 60 ton/hr
and mill outlet temp. 70 deg.c
9 Start coal feeder.
10 Close Recirculation valve of ECO- bottom Ring Header
11 Regulate HPBP to control MS pressure
12 Take other mills in service as required
13 After establishing steam flow the drum level control
transfer to 3-element control
COLD STARTUP CURVE

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Revision No :

28

Cold Start Up Salaya

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ESSAR POWER GUJARAT LTD,

2X600 MW – SALAYA, JAMNAGAR

2×600MW SALAYA THERMAL

SCHEME FOR Boiler Cold

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

 COMMISSIOING SKETCH FOR BOILER

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

PRE-REQUISITES FOR COLD START UP –

4) Flame Detection System-

2X600 MW – SALAYA, JAMNAGAR

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

8) Coal conveying, Soot & slag handling system -

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

9) Auxiliary steam system -

10) Sampling and dosing system-

13) Cooling water, make up and Industrial water system –

2X600 MW – SALAYA, JAMNAGAR

2X600 MW – SALAYA, JAMNAGAR

 Interlock test of the cooling air fan of flame detection.

2X600 MW – SALAYA, JAMNAGAR

15) Requirements for civil Construction.

2X600 MW – SALAYA, JAMNAGAR

 The necessary maintenance tools and materials should be prepared.

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

CHARGING OF THE SYSTEM

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

MAIN STEAM AND BYPASS LINE CHARGING

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

TURBINE ROLLING & SYNCHRONISING

Prepared By Checked By Approved By

2X600 MW – SALAYA, JAMNAGAR

2) Normal load change rate

 Furnace pressure＞+100mm H2O(1.0kPa), alarm, prohibit decreasing ID fan load and

2X600 MW – SALAYA, JAMNAGAR

 Economizer recirculation valves should be closed after establishing a constant feed

2X600 MW – SALAYA, JAMNAGAR

DO’S AND DON’TS-

2X600 MW – SALAYA, JAMNAGAR

 Only commissioning engineer team members should be allowed in the restricted

 Control the boiler pressure temperature boost rate.

 Oil line filter to be checked regularly.

 Fire fighting system availability is must before light up.