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START-UP OF TURBINE

COLD START-UP PROCEDURE FOR 4 X 210 MW TPS-II UNITS


TIME

ACTIVITIES:

PREPARATION OF BOILER FOR COLD LIGHT UP.


THOROUGH INSPECTION OF FURNACE FOR COMPLETE CLOSING OF PEEP HOLES
AND MANHOLES. AFTER FILLING THE SLAG BATH, ENSURE RUNNING OF SLAG
CONVEYOR AND ABG'S.
-04.30 HRS

TURBINE:
START PREHEATING OF FEED WATER IN DEAERATOR AND RAISE THE WATER
TEMPERATURE TO 70 C TO 80 C.
START WARM-UP OF BFPS, KEEPING CASING DRAINS, VENT CRACK OPEN
CONDITION.

BOILER:
CLOSE WATER SIDE DRAINS VALVES.
OPEN SH1 I/L AIR VENT, OTHER AIR VENTS, STARTUP VENTS AND DRAINS OF SH
& RH.
-03.00HRSTURBINE:
START ONE CWP, ACWP AND ACWBP.
CHARGE THE CONDENSER, PHES AND TURBINE LUB OIL COOLERS.
-02.30HRSTURBINE:
MAKE UP SYSTEM IS MADE READY.
-02.00HRSTURBINE:
START ONE BFP. START BOILER FEEDING.
PEGGING STEAM TO DEAERATOR CAN BE MADE THROUGH AND PRE HEATING
STEAM MAY BE ISOLATED.
KEEP THE OIL IN CIRCULATION.
BOILER:
KEEP THE OIL IN RE-CIRCULATION.
CHARGE TRACE-HEATING SYSTEM IN BOILER.
CHECK THE POSSIBLE LEAKS IN EACH OIL BURNERS.
ENSURE THE HEALTHINESS OF OIL BURNER SYSTEM.

AFTER BOILER CONTOUR FILLING, CHECK WHETHER ALL AIR VENTS, STARTUP
VENTS AND SH, RH DRAINS ARE IN OPEN CONDITION.
ENSURE THAT LSHS OIL TEMPERATURE IS MORE THAN 90 C.
GENERAL INTERLOCKING FOR OIL FIRE EXISTING' IS AVAILABLE NOW.
BOILER IS READY FOR LIGHT UP.
START ID & FD FANS.
CHARGE SCAPH.
START PURGING.
-00.00 HRS

BOILER:

LIGHT UP BOILER BY CUTTING IN 2 OBS WITH LDO.


CHANGE OVER TO HFO AFTER 10 MINUTES ONE BY ONE.
OIL PRESSURE IS 6 KSC.KEEP DRUM LEVEL AT 300 MM.
NOTE DOWN THE DRUM METAL TEMPERATURE (DMT), OIL FLOW AND OIL
PRESSURE.
WHILE CUTTING IN OB RAISE OIL PRESSURE TO 12 KSC. THEN REDUCE PRESSURE
TO 6 KSC.
TURBINE:
CONDENSER VACUUM RISING CAN BE STARTED.
AST HEADER TEMPERATURE SHOULD BE BETWEEN 250C -280C.
KEEP OPEN THE FOLLOWING DRAIN VALVES.
MS 25 & 26, HR 47 & 48, CR 51 &52,HR 15 & 16,CR 11 &12,HP B/P ATMOSPHERIC
DRAIN VALVES,ALL MAL DRAIN VALVES AND THEIR BEFORE GATE VALVES.
-01.00 HRS

BOILER:

WATCH THE DMT. WHEN IT REACHES 90 C, SURGING OF DRUM LEVEL MAY START. WHEN
SURGING OF DRUM LEVEL IS OBSERVED, OPEN EBD.
CUT OUT ONE BURNER AND IF NECESSARY OPEN CBD ALSO TO CONTAIN DRUM
LEVEL.
DOZING PUMPS ARE TO BE STARTED.
OIL PRESSURE TO BE RAISED TO 12 KSC.
01.30 HRS

BOILER:

CUT IN 3RD OB WITH HFO 4TH OB AFTERWARDS.

AFTER NORMALISING DRUM LEVEL CLOSE CBD & EBD, CUT IN 3RD OB.
WHEN SH1 -I/L TEMPERATURE IS MORE THAN 110 C, CLOSE SH1 INLET VENT &
ALL VENTS AT 44 ML.
CLOSE THE SH DRAINS IN ORDER, WHEN STEAM TEMPERATURE IN SH SHOWS RISING
TREND AND STEAM TEMPERATURE AT O/L HEADER IS GREATER THAN I/L
HEADER.
WHEN SH3 O/L PRESSURE IS 1KSC START CLOSING START UP VENT GRADUALLY
WITHIN 10 MINUTES.
WHEN SH3 O/L PRESSURE IS 5KSC OPEN HP BYPASS AND CHARGE RE HEATERS.
OPEN MS25&26, MAL-11&12&HR-47&48.
REDUCE OIL PRESSURE TO 10 KSC.
BEFORE OPENING HP BYPASS VALVES CHECK FOR
1) SAFE DRUM LEVEL.
2) FULL OPEN CONDITION OF MS-001 & 002.
3) CLOSING OF STARTUP VENT VALVES.
4) VACUUM IS STABLE.
02.00 HRS

BOILER:

RAISE OIL PRESSURE TO 8 KSC.


TURBINE:
OPEN HP BYPASS ACCORDING TO THE SH3 O/L PRESSURE RISE.

WHEN

THE RH PRESSURE IS 2KSC OPEN LP BYPASS WITHOUT AFFECTING VACUUM.


SWITCH ON LPB/P AUTOMATIC CONTROL INTERFACE AND CHECK THE
PERFORMANCE OF LPB/P THERE AFTER.
(AT THIS STAGE HP BYPASS OPENING SHALL BE AROUND 30 %.)

RATE OF

PRESSURE RAISE IS MS: 1KSC / 2 MIN & HRH: 1KSC / 4 MIN


RATE OF TEMP RISE IS 2.5 C /MIN UPTO 350 C.
02.30 HRS

BOILER:

RAISE OIL PRESSURE TO 10 KSC.


PREPARE INJECTION SCHEME FOR TEMPERATURE CONTROL.
CHECK INJECTION STATION DRAINS AND VENTS FOR CLOSED CONDITION.

HAND OPERATED

ISOLATION VALVES IN OPEN CONDITION.


S-92 BYPASS VALVE IS TO BE USED FOR INJECTION TO HAVE FINE CONTROL.

TURBINE:
HP BYPASS SHALL BE OPERATED MANUALLY SO AS TO MAINTAIN MS PRESSURE AT 23 KSC.
SELECT LP BYPASS IN AUTO AT AT HRH PRESSURE OF 7 KSC.
AT MS PRESSURE 23 KSC & MS TEMPERATURE 300 C
START WARMING UP OF STOP & CONTROL VALVES.
MAINTAIN MS TEMPERATURE NOT MORE THAN 350 C.
FOR 23 KSC SAT. TEMPERATURE IS 225 C.
IN TSE RECORDER AND CONFIRM RISE IN TEMPERATURE.
03.00 HRS

RAISE OIL PRESSURE TO 12 KSC.

RAISE MS PRESSURE AT A RATE OF 1KSC/MIN UP TO 40KSC AND WHEN THE PRESSURE IS


STEADY AT 40 KSC SELECT HP BYPASS IN AUTO.
DURING WARMING UP MS & HRH TEMP SHOULD NOT DROP BELOW 320 C.
03.30 HRS

START ROLLING.

MS PRESSURE: 40 KSC & MS TEMP: 350 C.


HRH PRESSURE: 7 KSC & HRH TEMP: 350 C.
HP B/P OPENING > 50%.
ROLLING CAN BE STARTED AFTER CONFIRMING 5TH & 6TH POINTS TO REACH ITS
SATURATION VALUE.
REACH 600 RPM.
04.00 HRS

AFTER WATCHING HP SHAFT & HP CASING (PTS.7TH & 9TH AND 8TH & 10TH)
FOR ITS WARMING UP AND CROSS CHECKING WITH HP SHAFT & HP CASING
STRESS MARGIN (NOT LESS THAN 30 K) FURTHER SPEED RAISING TO 3000 RPM
CAN BE STARTED.

04.05 HRS

SYNCHRONISATION.

SYNCHRONISE THE UNIT WITH THE GRID AND KEEP THE TEMPERATURE STEADY AT 350 C
FOR 20 MINUTES AND OBSERVE FOR THE STRESS MARGINS.
ACCORDINGLY LOADING CAN BE DONE AND HP B/P CLOSED.
WATCH DRUM LEVEL.
WAIT TILL HP CASING & IP SHAFT MARGIN (7TH & 9TH POINT) SATURATES.
PREPARE THE MILL & FEEDER SYSTEM.
04.35 HRS

RAISE OIL PRESSURE SLOWLY SUCH THAT FLOW RISES TO 16 T/HR.

RAISE THE LOAD TO 50 MW.

MS PRESSURE: 60 KSC MS TEMPERATURE : 400 C .


LP HEATERS MAY BE TAKEN INTO SERVICE.
FOR FURTHER LOAD RAISING HP CASING MARGIN MUST BE MORE THAN 10 K
05.00 HRS

START 1ST MILL


RAISE THE LOAD TO 70 MW (RATE 2 MW/MIN)
MS PRESSURE: 80 KSC & MS TEMPERATURE: 440 C (RATE 4 C/MINUTE)
OPEN S-92 VALVE & CLOSE ITS BYPASS VALVE FOR MORE INJECTION FLOW.
COMMISSION ESP. SH1 INLET TEMP. SHALL BE > 450 C

05.15 HRS

START 2ND MILL.

RAISE THE LOAD TO 90 MW.


MS PRESSURE: 100 KSC

MS TEMPERATURE : 440 C .

REDUCE OIL PR. 10 TO 12 KSC.


START WARM-UP OF HP HEATERS ON STEAM SIDE AT 70 MW.
WARM-UP OF HP HEATERS AT LEAST FOR 20 MINUTES.
05.30 HRS

START 3RD MILL.


REDUCE OIL FLOW TO 7 T/HR.
RAISE THE LOAD TO 110 MW .
MS PRESSURE: 120 KSC &

05.45HRS

MS TEMPERATURE : 490 C

START 4TH MILL & CUT OUT OIL BURNERS ONE BY ONE.

RAISE THE LOAD TO 125 MW .


MS PRESSURE: 130 KSC & MS TEMPERATURE : 490 C .
BEFORE TAKING OUT OIL BURNERS, STABLE CONDITION OF FIRING SHOULD BE ENSURED WITH
IR SCANNERS.
TAKE EHC INTO IP MODE
06.00 HRS

START 5TH MILL

RAISE THE LOAD TO 150 MW.


MS PRESSURE: 140 KSC & MS TEMPERATURE : 500 C .
TAKE CMC IN AUTO.
06.30 HRS

RAISE FIRING TO FULL LOAD.

RAISE THE LOAD TO 210 MW.


MS PRESSURE: 150 KSC MS TEMPERATURE : 540 C

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