Work Instructions

Start-Up After 8 Hours of Shutdown ( Hot start-UP)

Unit condition

1	At least 2 BCW pump in Serrvice
2	Both SAPH and PAPH Running
3	Turbine : On Barring (AOP,JOP,SOP, HPCF in service)
4	Generator: PW system, Seal Oil system, Gas system
5	Condenser Pass : Both Charged
6	PAC & IAC : 1 PAC & 2 IAC in Service
7	CEP & Make-up : 1 CEP with H/W Make-up on auto
8	PRDS : 13.5 ksc , Temp>260 Deg		Line-up from other units
9	ESP : Ready (Fields, Rapcon, Heaters etc)
10	EAST Panel : Ready
11	LP & HP dosing system : Ready
12	Bottom & Seal Trough : Lined -Up
13	Evacuation system : Lined -Up / charged (Pulled)
14	GRP Panel & Excitation: Ready
15	Boiler Drum Pr=75 ksc, Ms Temp=415-430 eg		BSVs Closed
16	LDO & Atomizing system : Ready		LDO=16 ksc, Atomizing Steam=6 ksc

Sequence

00'	Drum Pr=75 ksc	Take 4 guns in AB elevation		Start APH soot Blowing prior to firing
	MST: 415-430	Open Drain Before BSVs
		Open BSV IBvs		MS strainer drain to SDFT, UFT, CRH drain pot, Open
		Open BSvs
		Open Warm-up Of HPBP and then HPBP and LPBP		HRH Pr=2 ksc, Close CRH Drain pot
		Start PA fan & seal air fans		Ensure FG & air Damper of PAPH Open Prior PA Fans
		Line-Up Milling system		Open CAG/CAD of at least 3 mills before PA Fan start
40'	MS= 85/485	Take 1st Mill		Make Ready SH/RH spray
	HR=12/440	Charge ESP fields		Ensure Ash Handling System Ready
		Cut in 2nd Mill		Peg Deaerator with CRH (Pr=2 ksc)
		Reset turbine		Bring Starting Device to 0, Put TG LO TCV on auto-45 Deg
50'	MS=85/500	Open Turbine SGC seq/Switch ON/Select Start-up		105-Starting Device (42 %) 109- Tracking Device ON
	HR=12/450	Raise Starting Device to 100% once ESVs Opened		110-Speeder Gear goes 100 %(If LT100%)
	Bypass flow BLI = 360 TPH	Hold for 5 minutes at 360 rpm		112- Turbine Speed 360 rpm command
52'		Raise Turbine speed to 3000 rpm		116-Turbine speed 3000 rpm command
		(Rate of Acceleration b/w 600-850 rpm2)		(OFF : Turning gear=240 rpm, JOP=540 rpm )
		Switch Off ATRS Program (After 116)		Monitor-Bearing Temp/Pedestal-shaft Vibration ,TSI
56'		Put AVR on auto		Ensure AOP: Off
		Close Field Breaker		Check starting GT cooling Fans
		Select GCB from ECP, put sync-ON
		Select Auto-synchronizer made ON		Load Ref=50 MW . Pr Max=75 MW
		Synchronize Generator with Grid		Speed set point raised by 8rpm and 20 MW load will come
		Raise speed SP by small pulse
		Put HPBP in Auto with increased SP
60'	Load=60 MW	Cut in LPH-2,3		Change-Over of ST to UT
	MS=85 /500	Cutout Heating system from PRDS to Deaerator
	HRH=16/470	Raise D/A Pr from 2 ksc to 4ksc
		Cut in all Controllers
65'	Load=150 MW	Charge PRDS from CRH
	MS=100/500	Cut in HP Heaters
	HRH=20/480	Start 2nd CEP, 1st TDBFP at Load=170 MW
	BLI= 600 TPH	Control MS/HRH Temp by spray (If Required)
	Trim Dev : Off	Change D/A Pegging from CRH to Extraction
		Cut in 3rd Mill
70'	Load=230 MW	Cut in 4th Mill
	MS=120/500	Cut off Oil Support		Ensure Healthiness of Scanners
	HRH=25/495	Cut in 5th Mill
	BLI=820 TPH	Start 2nd TDBFP and Switch off MDBFP
		Cut in 6th Mill
86'	Load=500 MW	Ensure all controllers in auto
	MS=170/500
	HRH=40/500
	BLI=1620 TPH
135'	Load=500 MW	MS=170/535, HRH=45/535

Emergency Instructions:

220 V DC Failure

Unit condition

• DCDB section-1 & 2 under voltage alarm in LVS-5
• All HT/LT Breakers Indication Becomes Bad
• Boiler will Trip on MFT ( after 2 Sec)
• Turbine will Trip on MFT
• Generator will not Trip as GCB Protection will not act
• Generator will run as Synchronous Motor
• HP/IP/LP Casing Exhaust Temperature will start increasing
• 400 KV Breakers can be Operable
• Feeders of Mill will Trip on MFT
• Fans(ID, FD, PA), Mills, BCW Pumps etc will continue to run

• DC Drives can not come in service

Actions

• Sequence to Trip Drives:

• PA fan
• Mills
• One set ID/FD
• Another set of ID/FD
• BCW Pumps
• MDFP
• CEP
• SG ECW
• TG ECW
• Air compressors
• CW Pumps

• Start DG set
• Start AOP-1, SOP-1, AOP-1 of TDBFPs, PW-1
• Trip Normal Incomer breaker from unit service Board to Emergency board from Switchgear
• Close DG set incomer breaker to emergency Board from Switchgear
• Start AOP-2, SOP-2, AOP-2 of TDBFPs, PW-2
• Trip 400 KV Main/Tie GCB from CCR/Switchyard
• Trip Station Transformer after shifting critical equipments
• This will result in Total Power Failure with Emergency Board in charged condition

Furnace Air Tightness Test

• Scope- Boiler Furnace, Air and FG Duct upto ID Fan Inlet
• Why- To test Tightness of Furnace wrt Environment not for Strength
• Ensure- All PTWs of BMD( PP, Rotary, Mills, Ash handling) cancelled and Clearance Available

S.No	Area/system	Status Req	Actual Status
1	Bottom Ash Hopper / CG Manholes
2	Seal Trough
3	APH & Eco hopper Flushing Apparatus
4	ESP / ESP Duct Manholes
5	Mill/Scrapper Manhole
6	Boiler Manholes/ Peep Holes
7	SADC
8	Feeders Doors ( front, Rear)
9	SA/ PA duct Manholes/Drains

• Start SAPH-A/B &PAPH-A/B Main Motors
• Start one Set of ID/FD fans. Slowly raise Airflow and Furnace Pressure . Start AC Scanner
• Start another Set of ID/FD fans increase Pressure further
• Start Both PA fans, Slowly raise PA Header Pr to 800 mmWC. Start Seal air fan also
• Keep Furnace Pressure to +120 mmWC
• For Identification of any leakage, Local round to be taken with Maintenance Person. Following area to be visted :-
• Boiler 1^st Pass, 2^nd Pass, APH Flue Gas duct, ESP i/l and o/l ducts, ESP Passes, Secondary Air duct, Hot & Cold Primary duct, Mill HAG/HAD/CAG/CAD
• APH guide and support Bearing area
• Dead Zone chamber in s-Panel & Reheater Goose Neck Area
• Boiler Pent House
• Slowly reduce Furnace Pressure to Normal and Stop PA/FD/ID Fans
• FATT Completed.

DG Load Trial and Regular checks

Requirements:

1	Inform & Ensure availability of TMD/EMD/C&I
2	SG/TG/BOP source-2 AC Power Supply Interruption. Inform C&I for Standby chargers
3	Ensure DG Set Tank Oil Level Adequate
4	Evacuate and Isolate Boiler Passenger, Service Building Lift and Isolate. Inform EMD(temporary supply )
5	Arrange 3 Walky Talky : 1-CR 2-DG board 3-DG Set room
6	Note Down Initial Parameters of DG Set

Status of Unit:

1	TG on Barring
2	Generator Depressurized(H2/CO2 Purged out)
3	Seal Oil system in Service
4	All Drives in DG Bus in available condition( Plan within 1-2 days of Unit shut down)
5	DG Board charged from Normal Incomer Breaker from Unit Service Board

Sequence:

• Start all drives on DG Bus from other standby source(other board)

Ex- SOP-2 to Sop-1, FD/ID/PA Lop-2 to LOP-1

• Start Main DG set & Note Down: Volatge, RPM, Tank Level, LO Pr/Temp, Battery Voltage
• Trip Normal Incomer from USS and Close DG set Incoming breaker to charge DG Bus
• Start Loading Drives by starting them which are on DG Bus
• Continue Test run fro ½ -1 Hour.

Normalisation:

• Start all drives on DG Bus from other standby source(other board)
• Trip DG Set Incoming Breaker and Close Normal Incomer From USS
• Switch Off DG Set

Regular checks:

• DG Set Fuel Tank Level Normal
• DG Set engine Oil Level Normal
• Battery charger OK
• Engine Coolant level is OK
• DG Set Incomers to DG Bus Healthy

UPS Failure

Condition

• All LVS, OWS will not be available
• Scanner Supply Off. Hence Scanner sense NO flame
• Boiler will trip on Flame failure. Turbine on MFT. Generator on Low Forward Power Protection
• LLD High Level Switch will act
• ID Fans : VFD will trip
• APH Air motor will take Auto start
• MDBFP Scoop will be Inoperative from Remote
• All Drives vibration/Turbine Vibration Data will not Available

Actions:

Instrument Air supply Failure

Reasons of Failure:

• Failure of control supply of compressor
• Loss of Cooling Water (SG ECW Pump Trip)
• Massive leakage in IA supply Header
• One Unit Under Overhaul. Unit Aux Board/ Station Aux board got Tripped of that Unit
• Total Black Out of any stage

Problems/Actions:

• No Oil guns can be taken in service: Oil/steam Valves remain Inoperative. Igniter Will not advance
• If Unit on only Oil guns: Boiler will Trip. (HOTV/LOTV will close)
• Stay Put :

• HAG/HAD/CAG/CAD. No mill can be taken in service.
• SADC,
• Burner tilt (if leakage the it will go Up),
• SH/RH spray control valves( close due to leakage),
• Seal Air Fan discharge /damper,
• Scanner air fain Discharge Damper
• D/A Level controllers ( close if Air Leakage)- Maintain Level through Motorized Bypass Valve
• TDBFP Seal steam supply/dump –Maintain through Bypass motorized valve
• FRS 30%(FDV-14) if Open (Close on leakage)- control Drum through Scoop, TDBFP Scoop may Increase or Decrease, Open High Range FRs 100 % line

• Close:

• SH/RH spray Block .Open SH/RH block v/v manually if Temperature is running high
• Vacuum Pump inlet v/v will start closing(vacuum will fall)
• HP/LP Heaters normal Drip

• Open:

• Running BFPs Recirculation Valve ( Start MDBFP or Reduce Load)
• CEP recirculation – start Standby CEP to maintain H/W, D/A OR Reduce Load
• GSC Recirculation will Open: Reduce condensate to D/A- Close its Manual valve
• Normal Make-Up –maintain level through Bypass valve OR through Manual valve
• HP/LP Heaters emergency Drip
• Deaerator Overflow valve

• Open PAC-IAC Interconnection.
• Isolate Plant Air Supply to boiler of both Units.
• Inform other stage to run Additional IAC and Open Interconnection b/w stages
• C&I should periodically check the healthiness of the lock out relay for maintaining stay put condition and maintain records of such checking.

Important Points at IAC Failure:

• Steam Temperature
• Condenser Vacuum
• Drum Level
• Deaerator & Hotwell Level

Main Equipments Tripped

S.No	Fault	Consequence	Actions
1	1 mill Tripped out of 6	Runback will Act Capability - 466 MW Machine Comes in IP mode	Reduce Load Observe Drum Level( will go up) Reduce Throttle Pressure SP Take another Mill
2	2 mills Tripped out of 6	Runback will Act Capability - 372 MW Machine Comes in IP mode	Reduce Load Observe Drum Level( will go up) Observe Flame Scanner If Necessary take Oil gun at an elevation Reduce Throttle Pressure SP Take another Mill
3	Any one ID Fan Trips	Runback will Act Unit Capability-300 MW Trip command to Respective FD Fan/ If not Tripped, Trip FD Only 5 mills will Remain , rest will trip from top/ If not tripped, Trip from top leaving only 5 mills Machine Comes in IP Mode	Observe Furnace Pressure Observe Total Air Flow Ensure Tripped FD Discharge Damper Closed Ensure running FD Fan current in limit Ensure Tripped ID Fan IGV closed on auto Observe Drum Level Observe Scanner Reduce throttle Pr SP Inform Maintenance for check
4	Both ID Fans Tripped	Unit will trip on MFT	Do shutdown Activities
5	Any one FD Fan Trips	Runback will Act Unit Capability-300 MW Trip command to Respective ID Fan/ If not Tripped, Trip ID Only 5 mills will Remain , rest will trip from top/ If not tripped, Trip from top leaving only 5 mills Machine Comes in IP Mode	Observe Furnace Pressure Observe Total Air Flow Ensure Tripped FD Discharge Damper Closed Ensure running FD Fan current in limit Ensure Tripped ID Fan IGV closed on auto Observe Drum Level Observe Scanner Reduce throttle Pr SP Inform Maintenance for check
4	Both FD Fans Tripped	Unit will trip on MFT	Do shutdown Activities
5	Anyone PA Fans Trip	Unit Capability-300 MW If PA Header comes to 625 mmWC and not increased within 5 Seconds, all Mills will Trip on PA Header Pressure Low and Unit will trip on Loss of All Fuel If PA Header comes to 500 mmWC, all Mills will Trip on PA Header Pressure Low and Unit will trip on Loss of All Fuel	Observe PA Header Pressure Ensure Discharge Damper of PA Fan got closed Observe Drum, Furnace, Total air flow Observe Flame Scanner, Take Oil gun in elevation if required Inform concerned Department for Tripping of Fan
4	Both PA Fans Tripped	all Mills will Trip on PA Header Pressure Low and Unit will trip on Loss of All Fuel(MFT)	Do shutdown Activities
5	Any1 BCW trips out of 2	Standby will come If standby BCW pump do not come, runback will Act Capability- 300 MW Only 5 mills will Remain , rest will trip from top/ If not tripped, Trip from top leaving only 5 mills	Inform Concerned /department for the Tripping Observe Drum level Observe Flame Scanner Observe running Pump DP
6	2 BCW pumps Trip	Standby BCW will come Runback will Act Only 5 mills will Remain , rest will trip from top/ If not tripped, Trip from top leaving only 5 mills If standby donot come, Boiler will trip on MFT due to Waterwall Circulation Incorrect	Observe Drum,Furnace, BCW DP, flame Scanner If unit trips, Follow the shutdown activities
7	Anyone SAPH Trips	Air Motor Comes in auto If air Motor do not come, runback will act Capability:300 MW Only 5 mills will Remain , rest will trip from top/ If not tripped, Trip from top leaving only 5 mills	Observe SAPH FG /Air Outlet Temperature Inform concerned deptt for Tripping of SAPH If air Motor does not come , Ensure Closing of SAPH FG & Air Inlet & Outlet dampers Observe Secondary air temperature at Windbox inlet
8	Both SAPH Trips	Air motor comes in auto Air motor do not come, Unit will trip on Both SAPH Tripped (MFT)	Observe SAPH FG /Air Outlet Temperature Inform concerned deptt for Tripping of SAPH If air motor do not come, Follow the shutdown activities
9	Anyone SAPH Trips	Air Motor Comes in auto If air Motor do not come,	Observe PAPH FG /Air Outlet Temperature Inform concerned deptt for Tripping of SAPH Ensure Closing of PAPH FG & Air Inlet & Outlet dampers Observe PAPH FG /Air Outlet Temperature Reduce load to 300 MW Keep 4/5 Mills in service Observe Mill Outlet temp
10	Both PAPH Trips	Air Motor Comes in auto If air Motor do not come,	Observe PAPH FG /Air Outlet Temperature Inform concerned deptt for Tripping of SAPH Try to restore at least one PAPH Take Maximum Oil guns Stop All Mills One by One, Stop PA Fan Observe Furnace Pr, Total air Flow, Reduce Throttle Pr SP Take MDBFP & Maintain Drum Level Load May get stabilized at 100 MW
11	Anyone TDBFP Trips	MDBFP will come in auto MDBFP do not come in 10 seconds, Runback will Act Unit Capability: 270 MW Only 4 mills will remain Machine will come in IP mode	MDBFP R/C Valve close on Auto, If not Close it Inform Concerned Deptt Ensure running TDBFP in auto, Drum Level in auto. Otherwise Increase Speed Reference Observe Difference b/w BLI and FW, If its still High, Reduce Coal flow Still Drum is not Rising, Trip 1 mill and take one oil gun Reduce Th Pr SP Inform concerned Deptt
12	Both TDBFP trips	MDBFP comes in Auto Only 4 mills remains Machine comes in IP Mode	Increase MDBFP Scoop to maintain Drum Level. Close its r/c valve Still Drum is not Rising, Trip 1 mill and take one oil gun Reduce Th Pr SP Inform concerned Deptt
13	Both TDBFP Trips	MDBFP does not come in auto Unit will trip on MFT(No BFP)	Do shutdown activities Inform concerned Deptt
14	Any 1 CEP Trips	Standby CEP comes in auto If standby does not come , runback will act, Capability: 275 MW Only 5 mills will Remain , rest will trip from top/ If not tripped, Trip from top leaving only 5 mills Machine comes in IP Mode	Inform concerned Deptt Close D/A CV to raise CEP discharge Header Pr Observe D/A level Reduce Pressure SP
15	Both CEP Trips	Standby CEP comes in auto Only 5 mills will Remain , rest will trip from top/ If not tripped, Trip from top leaving only 5 mills Machine comes in IP Mode Standby CEP does not come in auto Only 5 mills will Remain , rest will trip from top/ If not tripped, Trip from top leaving only 5 mills Machine comes in IP Mode	Close D/A CV to raise CEP discharge Header Pr Observe D/A level Reduce Pressure SP Try to restore at least one CEP Trip Mills one by one & Reduce load < 100 MW Take one/two elevation guns Observe D/A , H/W and Vacuum Take MDBFP to maintain Drum Unit May trip on D/A Level Low, Vacuum if any of the CEPs cannot be revived

IBT Outage

Consequences on Stage-2 ( Station Transformer Tripped)

• 132 KV Switchyard dead results in tripping of -Station Transformers, Construction Transformer, Misc Transformer
• All colony power( Lighting,Water supply) will get interrupted
• Power Supply to DM Plant, HFO Pump house, PTCW Pump house, Offsite Board, ADPH,
• Following Board will get dead:

• OBA,OBB,OBC,OBD (11 KV station Board)
• OCA,OCB (3.3 KV Station aux Board), ADPH MCC, CHP Transformers
• DMPT, CWST, WTPT,BTST,ODA,ODB(Station Service), ODC(FW Pump House),ODD ( Offsite ): 3.3 KV
• OQA,OQB(St. Serv),3SA,4SA(Air Washer MCC),3TA,4TA(Unit Ventilation MCC),OTA(HVAC ) : 415 V
• OSA(SW MCC), OTB(Serv Bldg Ventilation MCC), FOPH : 415 V

• Following Equipments will Trip ( If running)

• MDBFP
• ECW pump (TG)-C, PAC-1, PAC-2, IAC-3
• DM Make-up Pumps, Boiler Fill Pumps, CW BFV OSU, MOT Centrifuge,
• Electric Hydrant/Spray Pumps, Service Water Pumps, APH Wash Pump, Ash Water Make-up Pumps,
• HFO/LDO Pumps , Raw Water Pumps, HVAC Make-up Pumps,
• Clarified Water Pumps, SW Tank Make-up Valve
• Unit-3: ACW pumps-B,C | Unit-4 : ACW Pumps-A,C
• HVAC Equipments ( Air Washers, Chilled Pump, Condensate Pump etc)

• Actions:

• Charge IBT asap after informing EMD, if cannot be revived go For Safe Shut own Or otherwise follow
• Stage-3 IAC Interconnection : Open
• Stop soot Blowing
• ACW-3A and ACW-4B will keep on running, Start 4th CW pump if not running
• Observe Hotwell level, if decreasing Reduce load
• Close PRDS Supply from Unit to reduce water consumption
• If IBT cannot be revived, Before Tripping Unit, Start DG Set, Start AOP-1, SOP-1, PW-1 and then close DG incomer braeker of DG board and shift essential drives on this bus after tripping normal incomer from unit
• As IBT revives, Charge ST, SATs, SSTs and run drives essential for normal condition of unit

Cold start-up

Points to Remember

• maximum of HP casing and HP shaft is less than 150C(more than 5 days)
• It requires soaking of Turbine at 360 rpm with steam(40ksc,360 Deg)
• An upper limit of 200 C/hr. saturation temp gradients can be allowed, i.e. approximately the boiler pressure can be brought to 20 Kg/ Cm² within an hour of cold start up
• But actual temp gradient is limited by the thick walled Y piece provided in the main steam and HRH lines
• maximum differential temp allowed between inner (98%) and mid wall temp (50%) is ±40C
• Start only two CC pumps in order to minimize flashing in down comers (and subsequent vibration) when the boiler water is in the range of 85 to 125 C
• third pump should be started before drum pressure reaches 7 Kg/Cm² to minimize the temperature transients experienced by the pump casing ( this is to avoid fast load out back on the boiler in the event of any CC pump tripping).
• To get the rolling parameters, normally two elevation oil guns are taken with approx. 70 to 80 t/hr. flow through HP-LP bypass. At that time MS parameters would be 40 Kg/Cm² and 360 C.
• As soon as the turbine loading has started, HP/LP by pass closes
• First mill is put into operation around 10% of generator load
• Second mill is put into operation around 25%
• Third mill at 40% of generator load
• Fourth and fifth mills are put into operation at 60% and 80% of generator load respectively
• Sixth mill is taken to reach full generator load
• During loading the RH outlet steam temperature has to be kept as close as possible to SH outlet steam temp. Burner tilt, SH spray, RH-spray controls have to be adjusted accordingly

Procedure

SNo	Time	Condition	Action	Follow-up	Status
1		0 ksc	Charge PRDS from other Units (14ksc,>260 Deg)	Open drains at PRDS,TG Floor,8.5 m
			Charge Atomizing steam(Pr 6.5 ksc)	Open drains at 4 elevation
			Fill Water upto +200 mm One CEP i/s LPH,HPH charged from FW side Deaerator Level =175 mm Hotwel b/w -100 to -200 mm FRS 30 % to fill Drum /load upto 180 MW	Drum, SH, RH Vents , SH Drains : Open LPD : Drains Closed BSV : closed Drain Before BSV :Closed MS strainer drains UFT/SDFT: Open HRH strainer Drain UFT/SDFT : Open ECO Recirculation E20 Manual : Open
			Charge LDO upto HOTV
			ESP ready in charge Condition	Open i/l, o/l damper of passes
			Bottom Hopper & Seal Trough Lined-up
			EAST, Excitation panel, GRP Panel Ready
			Generator gas Pr= 3.5 ksc
			H2 cooler,PW system Ready
			Start one CC pump	Drum >+200 mm, Vents B3,B4,B5,B6 Closed
			Start second CC Pump	Drum normal =+50 mm, B3, B4,B5,B6 Closed
			Start Scanner Fan
			Start Both SAPH	Air Motor availability to be checked FG/Air Inlet/Outlet Dampers Open
			Start Both PAPH	Air Motor availability to be checked Air Inlet/Outlet Dampers Open FG Inlet/Outlet Dampers closed
			Start one set ID/FD, Air>30% (600 TPH)	SADC 100 % (auto)
			Charge SCAPH for Running FD Fan	Check for Increase in Air Temp at SAPH i/l
			Start Purge (Duration : 5 min)	HOTV, LOTV got reset SADC will released from 100 % in auto
			Machine on Barring	LO Temp=45 Deg, Speed=80-100 rpm JOP Header Pr=140 ksc Start MOT Centrifuge HPCF Charged, Temp=55 Deg
2	0'	Boiler Ready & turbine on Barring	Start 4 guns in AB elevation After 30', Start 4 guns in CD elevation To match Drum MTM Raise 2 Deg/Min	LDO control Pressure =9 ksc Start : Pair AB 1/3 and after 7 sec AB 2/4 Check scanner Intensity / Local Verfied Start : Pair CD 1/3 and after 7 sec CD 2/4 Open E20 R/C valve, if MDBFP not feeding in Drum Check Drum Level/ Open CBD Check D/A Level & H/W level
			Start GSC Exhauster fan Charge Seal steam upto Supply Motorized v/v of GS supply station Start Vacuum Pumps one by one	Open dtain before NRV Steam Temp >250 Deg Drain Casing of Pumps, Fill Receiver tank >80 % in VG
			At -0.2 ksc, charge seal steam	By bringing controller from 50 % towards zero Build Vacuum upto -0.9 ksc
			Open HPBP Warm-Up drains
			Switch on SLC Drains	Verify: Manual v/v Opened
3	60'	Drum Pr= 2ksc	Close SH/RH Header Vents Close SH Header drains at Dr Pr =10 ksc Open BSV Bypass Lines	To Warm up Ms/CRH/HRH lines
4	100'	Drum Pr= 5ksc	Open LP Bypass 10% Open BSVs Open HPBP by 10% at Dr Pr=7 ksc Start 3rd CC pumps at Dr Pr=9 ksc Take Additional EF gun ( If Required) Close HPBP Warm-up valves	Open 1st HPBP Warm-up valves Close CRH drain Pot at TG 0m
			Rolling through SGC
5	150'	MS =15 ksc/ 180-200 Deg HRH=8 ksc	Switch On start-up Sequence of SGC-turbine	TSE Influence comes ON
6	300'	MS =50 ksc/ 350 Deg HRH=8 ksc/350 Deg Turbine Ready to Roll	Turbine Speed raised to 360 rpm through SGC sequence	Ensure LO TCV on auto with SP=45 Deg Gas Controller on auto PW controller on auto Ensure closure of Barring valve at 240 rpm Monitor TG Vibrations, TSI, Bearing Temp MS Pressure/Temp to be maintained upto load 50 MW
7	360'	MS =50 ksc/ 350 Deg Turbine at 360 rpm	Turbine Speed raised to 3000 rpm through SGC sequence	Check X6 criteria Ensure Tripping of JOP at 540 rpm Ensure Tripping of AOP at 2950 rpm
8	370'	MS =50 ksc/ 350 Deg Turbine at 3000rpm	Switch Off SGC Program Put AVR on auto Close Field Breaker Select Main GCB Switch on Synchroscope after select Check Synchronise unit through synchroscope from OWS Raise Speed SP by 15 rpm Close MAL drains and other HE drains	Check X7 criteria GT Cooler Fan starts on auto/ Verify Load Ref=50 MW . Pr Max=75 MW Turbine Speed will Decrease
9	390'	Load=55 Mw MS Pr=54 ksc/350 Deg HRH=12 /340 Deg	Start PA Fan, Seal air Fans starts in auto Take 1st Mill Start 2nd set of ID/FD Fans Cut in LPH-2, 3 Cut out Deaerator steam from PRDS Peg Deaerator form CRH =2 ksc Cut in all controllers	Open PAPH FG/Air inlet/outlet Damper Open PA Header Pr=800 mmWC, SA Disch Hdr=1500 mmWC
10	420'	Load= 110 MW MS=70ksc/370 Deg	Charge PRDS from CRH Peg D/A upto 4ksc( gradually) Cut in 2nd Mill Start withdrawing Oil support Control MS/HRH Temp with Burner Tilt and spray(if Required)	Ensure energizing of Trim Device at 100 MW load Ensure Fireball scanners Healthiness
11	440'	Load= 160 MW

Hydrogen Purging:

• SLC AS SOP Off, SLC DC SOP Off, SLC H2 SOP Off
• Suppy of DC SOP Off
• Start one AC SOP ( DP=1.5 ksc)
• Dew Point Air=<-10 Deg, clearance from Chemist
• H2 (Isolated Position), CO2(Isolated Position), Air Inlet(Open), Casing vent ( Closed)
• Fill and Pressurise upto 0.5 ksc
• After that, cut out Air supply and Detach Hose of air to Filter
• CO2 cylinders in rack, CO2 Flash Evaporator On(SLc made ON), Hot Water Lined up to Filling room, Pour water on cylinder
• Maintain Manifold Pr=50 ksc
• Filling CO2: H2 (Vent Position), CO2(Inlet Position), Air Inlet(Close), Manitain Co2 (0.3-0.8 ksc) by Casing vent
• Continue Till purity of Co2 comes more than, 99%, Purge other Drier by changeover, Purge LLD, clearance from Chemist(25-35 Cylinders)
• CO2 supply Out: CO2 (Vent Position), H2 (inlet position), Air inlet(Close), mainatain b/w 0.3 t0 o.8 ksc Pressure by Casing Vent
• Continue Till purity of H2 comes more than, 99%, Purge other Drier by changeover, Purge LLD, clearance from Chemist: (90-100 Cylinders)
• Pressurization: Co2 (Isolated), H2 (Inlet Position), Air( Closed Position), Casing Vent( Close ): (50-70 cylinders)
• Start H2 SOP when As SOP reaches 4.5 ksc,SLC AS SOP, SLC H2 SOP, DC SOP to be normalised
• Build Pressure of H2 upto 3.35 ksc, cut out H2 supply
• H2(ISolated), CO2(Isolated), AIr(Close), Casing Vent ( Close)

Important Procedures

Vacuum Pulling : Procedure:

• Close RH Vents, CRH, HRH UFT drains
• Close Vacuum Breaker
• Open 8.5 m steam Manual valve full Both (100%), Temp> 250 Deg ( Open
• Start GSC Exhauster Fan
• Start Both Vacuum pumps ( Casing Empty, Receiver tank Level adeq)
• At -0.2 ksc charge steam gradually ( lower Controller from 50%  0 %)
• Build Vacuum upto -0.9 ksc

Vacuum Killing : Procedure:

• Stop Vacuum Pumps
• Open Vacuum Breaker at -0.3 ksc Vacuum
• At -0.2 ksc, Close steam supply from Controller(50%), Closing Manual valve at 8.5 m(Both)
• Stop GSC Fans
• Open chimney Vents to Atmosphere

Turbine Fast cooling: Procedure:

• Gag Test valves of ESVs and IVs, CRH, close IPCV Sec Oil Pressure line(8.5 m)
• Open MAL Drains with their Manuals
• HP Casing Temp<= 300 Deg, Turbine on Barring
• Start Vacuum pumps (Maintain vacuum b/w -0.2 to -0.3 ksc)
• Switch Off RTS Supply, Reset Turbine(SD=0%)
• Close EHG sec Oil Supply to CV by Manually isolating at Gov Rack
• Open ESVs at SD=40%
• Open HPCVs at 55% (According to cooling rate : 5-6 Deg/hour)
• Observe TSI: DE, SE, CE
• Stop Fast cooling & Close Barring when HP Casing reaches 110 Deg

Boiler Forced Cooling: Procedure:

• Boiler Tripped, one set of ID/FD Running after Purging, BCWs Running
• Keep Running FD fan till APH FG inlet comes 205 Deg
• After that Trip FD Fan, Keep Running ID Fan in VFD Min position
• At Boiler Water Temp (s/c manifold temp 93 Deg), Trip all BCW Pumps
• Boiler washing to be done after that

Air/Co2/H2 Pressurizing in Generator: Procedure:

• Start AC SOP
• Keep SLC DC SOP Off/ DC SOP Module Off. Keep SLC AC AOP Off
• Start filling Air after measuring Dew point (Preferably <-10deg)
• Fill Air Upto 0/5 ksc
• Then Fill Co2 and vent Air through casing vent. Purity>99% . Vary(0.25-0.75 ksc)
• Purge CO2 with H2 (0.25-0.75 ksc), vent through H2 Casing vent. Purity>98% (at least two continuous ample)
• Pressurize H2 upto 3.5 ksc
• While Pressurising , start H2 seal oil pump at 4.5 ksc AS SOP Pressure. SLC As SOP On/DC SOP Module ON/DC SOP On
• Take Trial o0f DC SOP/other As SOP too

Centrifuge : Operation

• Drain anti-Flood Tank
• Start Separator
• At speed nearly constant , Charge sealing water,
• After 1 minute, Close seal water inlet valve
• Open Suction valve of Centrifuge
• Check flow through rotameter

Reheater Metal Temperature

• Depends on: Total air Flow, Burner tilt, Mill combination, Total coal/PA Flow, Reheater spray etc
• RH Tube Leakge : Causes- Coal Ash Corrosion for Tubing, Uneven Temp distribution across Boiler
• Coal Ash Corrosion: Tube temp Higher than ash-fusion temperature. Liquid slag deposition. Oxidizes the metal at rate many times than normal rate of 0.001”-0.002” /Year
• Uneven Tmperature Distribution: Rupture due to Creep.
• FG Temp Distribution Across Furnace:

Div SH (900)Final SH(850)Reheater(750)LTSH(550)Eco outlet(390)

Turbine Governing system

Key Points

• Governing- Regulation of Turbine Speed under No Load and Varying Load
• Others Works: CV Actuation/ Initial Run-up & Synchronization/ Load Variation to meet Grid Freq
• 500 MW KWU: Throttle Governed Machine
• 2 Governors , EHC and HG connected in Parallel: Only One at a time through Hyd Minimum slection
• CVs Open according to Secondary oil Pressure
• Between 100 MW to 525 MW , Load variation done by HPCV throttling

Hydraulic Governor

• Only one control Loop: Speed controller

• Machine Speed: measured & Indicated by Primary Oil Pressure
• Range of Speed Control : 2800-3210 rpm
• Speed Regulation Range( Droop) of HG= 7%
• HG acts as a Back-up to EHG
• HG Cannot be isolated Mechanically
• HG is the Primary Governor of KWU turbine

Electro-Hydraulic Governor

• EHG has 3 control loops for speed, Load, Pressure
• EHG enhance Turbine life by TSE
• Faster Response and Precise Frequency control
• Actual Speed Measured by Hall Probes
• Range of speed Control : 0-3210 rpm
• Speed Regulation( Droop) can be changed from 2.5% to 8% in step of 0.5% on Load, Usual setting: 5%
• EHG Can be mechanically isolated by closing secondary oil from local

RTS:

• Running condition: De-energized(Drain : closed), Tripping condition: Energized( Drain : Open)
• Running: Control Oil To Trip Gear
• Tripped Condition: Control Oil Path Locked & Trip oil from Trip Gear Drained through Drain Port
• 02 in Nos in Series

Turbine Trip Gear

• Main Protection Mechanism | 02 in Nos
• Control OilRTSControl OilTrip Gear spool Spool MovementTrip Oil (from top) & Aux Trip Oil ( From Bottom)
• Aux Trip Oil Keeps Spool in Lifted Position
• Aux Trip Oil is connected to hydraulic Safety Devices: Over-speed, Low Vacuum & Thrust Bearing Trip Devices

SLLD

• Resets Turbine after Tripping
• Opens : SVs and Release CVs for Opening
• AT 0% starting Device:

Bellows compressed ( CVs Closed)

Aux start up Oil Resets Trip Devices

Start up oil Resets SVs ( ESVs & IVs)

• Raising starting Device:

Start-up Oil & aux start-up Oil circuits drained

ESV Opens at 42% and IVs open at 56%

Speeder Gear

• Bellow + Spring
• Bellow compression controlled by

Starting Device Position

Speeder Gear Position ( alerts Spring Tension)

Primary Oil Pressure

• Draining /closing of oil drains happens through Aux FUP connected through link with speeder Gear

Test Valves

• HP/IP SVs receive Trip Oil Through their Test valves
• Port Opening for start-up oil and Trip Oil
• Resets SVs after Turbine Tripping
• Test valve can be operated with Handwheel

Working of Governing system

Control OilStarting DeviceAux Start-Up oil Trip GearHydraulic Protection Devices

Start-Up oil Trip GearESVs

(Speeder Gear linked with Starting Device)

Trip Oil Aux FUP(movement according to SG)Aux secondary Oil  Input to Hydraulic Converter

Control Oil + Aux Sec OilHydraulic converter(trip oil FUPs)HP/IP Secondary oil to CVs

Switchyard Breaker arrangement:

Stage-I

GT#1  1-52 Main (GCB to Bus Bar-1)  2-52 (Tie-GCB to bus Bar-2)  3-52(IBT-1 i/c)

GT#2  7-52Main (GCB to Bus Bar-2)  8-52((Tie-GCB to bus Bar-1)

Bus bar-1  4-52 (H1)  5-52(Tie H1-S2)  6-52(S2)  Bus Bar-2

Bus bar-2  10-52 (S1)  11-52(Tie S1-H2)  12-52(H2)  Bus Bar-1

Bus-1 13-52(Bus-coupler-1)  Bus-3

Bus-2 14-52(Bus-coupler-2)  Bus-4

Stage-II

GT#3 15-52 Main (GCB to Bus Bar-3)  16-52 ( Tie-GCB to bus Bar-4)  17-52(IBT-2 i/c)

GT#4 21-52 Main (GCB to Bus Bar-2)  22-52 ((Tie-GCB to bus Bar-1)

Bus Bar-318-5219-52(Tie)20-52(A1)Bus Bar-4

Bus Bar-318-5219-52(Tie)20-52(A1)Bus Bar-4

Bus Bar-424-52(A2)25-52(Tie)Bus Bar-3

IBT (132 KV)

IBT-1(Transformer)LT of IBT-1(12-52) (12-89 Isolator-Bus-1 & 12-89A Isolator to bus -2)]12-89Bus-1ST-1(10-52), ST-3(3-52)

IBT-2(Transformer)LT of IBT-2(13-52) (13-89 Isolator-Bus-1 & 13-89A Isolator to bus -2)]13-89ABus-2ST-2(7-52),St-4(14-52)

Bus-15-895-52(Bus-Coupler)5-89ABus-2

4-52(Miscellaneous Transformer)

6-52(Overhead Transformer)

Check List (Light-Up)

Unit:

Date:

S.No	Activity	Status	Remark
1	Drum Level, RH Protection Bypass
2	Seal Trough charged & Bottom Hopper filled
3	ESP field Ready & Off
4	SADC In auto
5	LPD close, Drum SH Vents Open, SH drains Open, Eco-Recirculation Open
6	APH blowing Lined-up
7	All 3 BCW Running
8	CBD Manual Open, EBD Auto close Bypass
9	LP dosing & Both CPU i/s
10	FG & Air path OK/ PAPH-A/B FG outlet Damper closed
11	All Mills & Feeders Ready
12	Hotwell & Deaerator Normal
13	SH/RH/HPBP spray Manual closed(Turbine Side)
14	MAL Drains/SDFT/UFT Manual Open
15	MS/HRH strainers drain to UFT,SDFT Open
16	Vacuum Pulled,TDBFPs on Barring/Rolled upto 1000 rpm through PRDS
A	Light-UP
1	Note Boiler Light-up Time ( 1st gun I/s)		Time of BLU:
2	Feed Drum through 30% line by TDBFP(Maintain DP>10 ksc) Or MDBFP
3	Close Drum/SH Vents at 2 ksc Drum Pressure
4	BSV Open at 5ksc Drum Pressure
5	HPBP/LPBP Open at 8 ksc Drum Pressure
6	Start-up vents Close after HPBP/LPBP Charging
7	Close SH Drains at 10 ksc Drum Pressure
B	Before Rolling		Time Before rolling:
1	Before PA Fan start,Open 2 Mills CAG/CAD, start PA Fan,Open PAPH FG o/l
2	Ensure only one Seal air Fan Running
3	One Mill A/C to be taken i/s as per HP Casing Metal Temp
4	Bring Rolling Parameter, Note Time Before rolling
5	Turbine EHTC Normal from Local
6	HP ESV/IV/CV /CRH gagging Removed
7	Decrease TG LO SP to 45 Deg
8	Turbine LP Mode, Load Ref 50 MW, Pr Max 75 MW, Th Pr SP=30 Ksc
C	Before Synchronization
1	GT Isolators from s/Y Closed
2	GRP relays Reset
3	One Mill i/s and Other Warmed-up(Hot Air charged)
4	HPBP spray Manual Open when Downstream Temp crosses 330 Deg
D	After Synchronization		Time Of sync:
1	SH/RH sprays from turbine Side Normalized. Monitor MS/HRH Temp
2	PW/CG Controller on auto
3	LPH/Deaerator charged
4	MAL/SDFT/UFT Manual drains closed
5	ST/UT Change-over at 100 MW
6	FRS High Range at 180 MW from 30 % line change-Over
7	Oil guns taken out (>5 Mills i/s: scanner Healthy), Note time of Oil w/d
8	ESP field charging after Oil guns taken out
9	Boiler silica to be monitored Before Load Increase

	Checked By
Name
Sign
Designation

Rolling of TDBFP: Turbine

Points to Remember:

• AT Load 100/150/200/250 MW, Single TD rolled, Steam available for TDBFP=20/25/30/38 TPH

(CRH Extraction(0-250MW), IPT(250-300)

• AT Load 100/150/200/250 MW, Both TD rolled, Steam available for TDBFPs=15/18/22/25TPH

• Design Parameers: 7.2 ksc /300 Deg/ 0.12 ksc /5325 rpm/