HOT START-UP

STAGE-I(60 MW)

START-UP IS TO LIGHT UP THE BOILER,BRINGING THE

REQUIRED STEAM PARAMETERS FOR ROLLING &
SYNCHRONISING THE TG SET WITH GRID AND ATTAIN
FULL LOAD.
WHETHER ITS A COLD,WARM OR HOT START-UP,THE
CRITERIA BEHIND IT IS THE MAX. TURBINE METAL
TEMPERATURE.
1. 150 deg C COLD START-UP
2.150300 deg C WARM START-UP
3. 300 deg C HOT START-UP

SEQUENCE OF HOT START-UP

1.
2.

3.
4.
5.

6.

PREPARATION FOR LIGHT UP

PRESSURE,TEMP. RAISING & VACUUM PULLING
STOP VALVE OPENING,RESETING
TG ROLLING (500,1200,3000 RPM)
SYNCHRONISATION
GRADUAL LOADING & OTHER ACTIVITIES

PREPARATION FOR LIGHT UP

-FIRST NO PTW AGAINST BOILER,TG,GT,UAT & ESP IS PENDING.
-ENSURE APH IS RUNNING.ITS AIR MOTOR IS AVAILABLE.
-IA,SA PR NORMAL.
-SS,CBD,MS,FW & D/A SAMPLING LINES ROOT V/V OPEN & SAMPLE COOLERS
ARE CHARGED.
-PHOSPHATE DOZING LINE,SPARAY LINE V/V AT BOILER TOP OPEN.
-ALL EXTRACTION DRAINS OPEN TO ATM.
-TURBINE STOP V/V IS CLOSED.
-FREE FLOW DRAIN,HOGGER DRAIN & EJECTOR DRAIN OPEN.
-BSOP IS RUNNING & TG ON TG.
-CW IS RUNNING & CONDENSER CW LINE IS CHARGED.CONDENSER,H2
COOLERS,MOT COOLERS,GT COOLERS SHOULD BE PROPERLY VENTED.
-CEP IS RUNNING,PROPERLY VENTED.LLR IS OPENED & CONDENSATE CIRCUIT
IS IN AUTO.
-ATLEAST ONE BFP IS AVAILABLE WITH ALL PROCESS NORMALISATION.FW
CIRCUIT IS THROUGH TO ECONOMIZER.
-ATLEAST 2 ELEVATION MILL GROUPS SHUOLD BE AVAILABLE.

FURNACE PURGING & LIGHT UP

-FILL THE DRUM TO NORMAL LVL. BY BFP IF BOILER PRESSURE IS 30-40 KSC.
-RUN ID FAN AFTER ENSURING. ITS START PERMISSIVE.THEN START FD
FAN.MAINTAIN FURNACE DRAFT AT -5 mmWC.ALL ARDS SHOULD BE OPEN.
-RUN AC SCANNER FAN & CORE AIR FAN.
ALL OILGUNS/IGNITORS ARE AVAILABLE.OIL GUNS SHOULD BE IN ENGAGED
CONDITION.
AS FURNACE RATED AIR FLOW IS 306TPH,THEN WE HAVE TO MAINTAIN 2535 % AIR FLOW DURING PURGING.TO AVOID ANY VARIATION WE PUT AIR
FLOW TAG IN CAL MODE AT 100 TPH.
AFTER 5 MINUTES PURGE COMPLETES,THEN RESET MFT.
THEN TAKE OIL GUNS ONE BY ONE BY COORDINATING WITH LOCAL
OPERATOR.ENSURE FLAME IS PROPER,NO OIL LEAKAGE IS THERE.
OPEN CBD,SSH DRAIN & SOOT BLOWER DRAIN FOR STEAM FLOW

VACUUM PULLING
(MS PR 45-50 KSC.,THROTTLE STEAM TEMP AROUND 300 DEG.)
- ENSURE THAT CT FANS ARE RUNNING,THEIR WATER LINES ARE
OPENED.CONDENSER CW LINES ARE OPENED.
-

CLOSE VACUUM BREAKER,OPEN SEAL WATER & ADJUST TO OPTIMUM.

START ONE GSEB,KEEP ITS DRAIN OPEN TO CONDENSER.ITS WATER LINE
SHOULD BE OPEN
OPEN GLAND SEALING STEAM V/V,KEEP SSR IN SERVICE & MAINTAIN
AROUND 0.2 KSC
OPEN HOGGER STEAM V/V (PR-20KSC),THEN OPEN HOGGER AIR V/V.
CLOSE EXTRACTION NRV DRAINS(BEFORE) AT -200 MMHG VACUUM.AFTER
NRV DRAINS TO BE CLOSED AFTER CHARGING LP/HP
HEATERS,DEAERATORS
AFTER VACUUM ATTAINING -450 MMHG,TAKE MAIN EJECTOR I/S.(PUT IT IN
AUTO)
TAKE HOGGER OUT.WE CAN KEEP HOGGER STEAM VALVE OPEN FOR
HIGHER STEAM FLOW.
AFTER VACUUM PULLING WE CAN TAKE ONE MILL TO INCREASE PRESSURE
& TEMP QUICKLY.

STOP VALVE OPENING,RESETING

-

WHEN MS PR AROUND 60 KSC,TEMP AROUND 420 deg C,WE CAN GO FOR

STOP V/V OPENING.
START AOP (AS IT PROVIDES THE HYDRAULIC PRESSURE NEEDED FOR
STOP V/V LIFTING)
STEAM CHEST WARM UP CAN BE DONE IF NEEDED.

TG ROLLING (500,1200,3000 RPM)

-

WHEN DIFF BETWEEN THROTTLE STEAM & STEAM CHEST INNER IS LESS
THAN 70 DEG,NOTE DOWN TSI PARAMETERS,MS SILICA SHOULD BE LESS
THAN 0.02 PPM (CONFIRM THROUGH CHEMISTRY)
ROLL THE M/C TO 500 RPM BY GOVERNER.CHECK FOR ANY ABNORMAL
VIBRATION & TSI PARAMETERS.
SOAK FOR 5-10 MINUTES.
THEN ROLL THE M/C TO 1200 RPM.HERE WE HAVE TO STAY FOR AROUND 1
HR.
THEN INCREASE SPEED TO 3000 RPM.NOTE TSI PARAMETERS &
VIBRATIONS.AOP SHOULD TRIP AT 2850 RPM.OTHER WISE STOP IT
MANUALLY.
SYNCHRONISE THE UNIT WITH GRID WITH SYNCHRONOUS
SCOPE(MATCHING FREQUENCY,PHASE & VOLTAGE).INCREASE LOAD TO 5-6
MW TO AVOID LOW FORWARD POWER PROTECTION.
TAKE THE GOVERNER OUT.
PUT EXHAUST HOOD SPRAY LINE IN AUTO.D/L IN LOWER SIDE.
IN BETWEEN WE CAN CHARGE GT COOLERS,H2 COOLERS AFTER
SYNCHRONISATION.

GRADUAL LOADING & OTHER ACTIVITIES

- AFTER SYNCHRONISATION CLOSE SSH,SOOT BLOWER,HOGGER STEAM LINE
& ITS DRAIN.
- INCREASE 1ST MILL LOADING.
- AT 10 MW OPEN SH SPRAY MANUAL ISOLATION V/V,BLOCK V/V & SPRAY LINE
MOTORISED ISOLATION V/V.AFTER MS TEMP REACHING 450 DEG,OPEN
CONTROL V/V AND PUT IT IN AUTO.KEEP A VIGIL ON THE MS TEMP.
- AT 15 MW TAKE LPH1 & 2 I/S.CLOSE AFTER NRV DRAINS.
- CHARGE D/A AT 20 MW.CLOSE AFTER NRV DRAINS.CHARGE ESP FIELDS.
- CHARGE ESP FIELDS.
- AT AROUND 30 MW TAKE UAT I/S.USUALLY ITS DONE BEFORE TAKING 2ND
SET OF PAFAN & MILL SO THAT TIE FEEDER IS NOT LOADED.
- CHARGE MOT COOLERS.
INCREASE H2 PRESSURE TO 1.8KSC.
NORMALISE ALL PROTECTIONS.
AT 40 MW CHARGE HPHEATERS.CLOSE LLR.
WHEN LOAD REACHES 60 MW,ADJUST AIR FLOW TO MAINTAIN O2 AROUND
4%.AFTER WITHDRAWAL OF OIL GUNS,DO APH SOOT BLOWING.
NOTE DOWN ALL PROCESS PARAMETERS FOR ANY ABNORMALITY.ADJUST
CBD V/V AS PER CHEM REPORT.
ASK THE BOILER OPERATOR FOR A ROUND UP OF WHOLE BOILER ISLAND
PROPER FOR ANY ABNORMALITY.

REFERENCE1.NTPC-TTPS 4*60 MW OPERATION MANUAL BY

MITSUI-BABCOCK ENERGY INDIA LTD.
2.SCE(GROUP-C),ALL GROUP-C MEMBERS

THANK YOU ALL