Documente Academic
Documente Profesional
Documente Cultură
Sl. No.
1
Page No.
All Pages
1&3
All Pages
Summary
of Change
New for
Operation of
Boiler & Turbine
25.02.20
12
1-Jan
04.05.201
2
New
Key
Performance
Indicators
has
been introduced.
1/0
04.05.20
12
2/0
20.06.201
3
New format of
has been
introduced &
entire reviewed.
Old
-
Issued by: MR
1.0
1.0 Objective:
2.0
Scope: This is applicable for operation of boiler and turbine by adapting operational parameter.
Issued by: MR
5.0 Procedure:
This standard operating procedure shall comprise of the following Standard Operation
Procedures (s), describing the operation methods for the process equipments.
INDEX:1: OPERATION OF LDO STORAGE & HANDLING SYSTEM
2: OPERATION OF CW & ACW PUMP
3: OPERATION OF AIR COMPRESSOR
4: OPERATION OF DMCCW SYSTEM
5: OPERATION OF ID FAN
6: OPERATION OF HIGH PRESSURE FLUIDIZING SYSTEM
7: OPERATION OF SECONDARY AIR FAN
8: OPERATION OF PRIMARY AIR FAN
9: OPERATION FOR COLD START UP OF BOILER
10: OPERATION OF SOOT BLOWER
11: OPERATION OF OIL SYSTEM OF TURBINE
12: OPERATION OF EH OIL SYSTEM
13: OPERATION OF CONDENSATE EXTRACTION PUMP
14: OPERATION OF CONDENSATE WATER SYSTEM
15: OPERATION OF VACUUM PUMP
16: OPERATION OF BOILER FEED PUMP
17: OPERATION OF FEED WATER SYSTEM
18: OPERATION OF CT FANS
Prepared by: DM & SM
Issued by: MR
Issued by: MR
All work permits related to this system closed after job completion.
Check that all related instrument & fitting are properly mounted
Confirm that L .D.O tank is filled well above the suction level of the pump.
Open the valves of the pump supply lines and headers (coming from F.O tank) so that Inlet header of the
pumps is charged.
5) Check for any leakage in the line joints and instruments.
6) Open the suction & the discharge valve of the F .O Transfer Pumps to be started and check for any
leakage.
7) Partially open all possible venting points in the entire fuel oil line up to boiler to remove air and
arrangements made to avoid any loss of oil. (Only to be done for first time startup)
8) Open Short recirculation bypass valve & its header valve going to LDO tank also open.
9) Discharge header valve full closed for going to boiler.
10) Bearing Cooling water inlet & out valve open and its pressure up to 4 kg/sqcm should be maintained.
START UP
1. Check power supply to the pumps for healthiness.
2. Check the filter vent nozzle by opening it so that oil comes freely without air.
3. Start one pump with discharge valve open and short recirculation throttled condition. After normal start,
open the recirculation valve as per pressure requirement.
4. Oil DP should be maintained
30%-50% (max)
Issued by: MR
START PERMISSIVES
1. Sump level not low.
2. Water path healthy either condenser inlet and outlet valve or recirculation valve is in
open condition.
3. Pump is in remote Position.
4. Discharge valve 100 % close condition and close limit switch is healthy.
5. Motor DE & NDE bearing temperature are not high.
6. Motor winding temperature is not high.
7. Pump breaker is in service position and not fault relays are acted.
8. Discharge valve is in remote position and no fault condition.
Issued by: MR
START UP
1 Give START command to pump and check if discharge valve starts opening. If it
doesnt then instruct field operator to open the valve from field.
2 Check the CW Discharge pressure 2.5 kg/cm2.
3 Check for the bearing temperature, vibration, noise, and any leakages.
4 Select the pump to keep in standby mode selection tile in DCS. Put the valve and
pump in auto start mode.
5 If the recirculation valve is open ensure the condenser valves are open and if
required close the recirculation valve.
CW & ACW STOP
1. Get clearance from CCR to stop the pump.
2. Uncheck selection of stand by pump and put in manual mode.
3. Give close command to discharge valve as soon as it goes below 80% give stop
command to the pump.
4. Put the pump in Auto start mode and select it for standby selection.
5. Press the emergency stop button, if the pump is going for the maintenance activity.
Issued by: MR
5.3
Issued by: MR
Issued by: MR
DMCCW TANKPUMP
Boile
r
Turbin
START:
1. Check on DCS for pump start permissive:
a) NO fault.
b) Pump Remote service position.
2. Give START command to pump.
3. Check the Discharge pressure >4.2 Kg/cm2, and current < 194 amps.
4. Check pump packing temperature is normal, cooling water flow normal
5. Check there is no friction, vibration, noise, motor temperature is normal.
Prepared by: DM & SM
Issued by: MR
6. Check the availability of Stand by DMCCW pump and take the interlock in service.
STOP:
1.
2.
3.
4.
5.
Issued by: MR
START PERMISSIVE:
1. There is no Fault on the DCS.
2. ID Fan is in Remote condition.
3. ID Fan is in Service position (6.6 KV power available).
4. All Bearing Temperature and Vibration Transmitter in service.
5. ID Fan Discharge & suction IGV & Damper have close feedback.
6. NO priority stops on DCS.
START UP
1.
2.
3.
After ID Fan is started, check the time for the speed and current to be stable.
4.
Check I/L Dampers (04 Nos.) & the discharge dampers (02 Nos.) are fully opened automatically.
5.
Issued by: MR
6.
7.
8.
As the ID fan is normal, maintain the Furnace Pressure ( <125 Pa ) by controlling the IGV &
Scoop Position.
STOP
1. To stop the ID Fan, release Auto switch first, & ensure that all the PA Fan , SA Fan & HPFB
are in stopped condition.
2. Reduce the speed of the fan by reducing the Hyd. Coup. Position with respect to the Furnace Pressure.
3. Give STOP command to ID Fan.
4. After Stopping the ID Fan, It should be ensured that the I/L & O/L dampers are fully closed
automatically.
5. The Local Push Button should be pressed.
Issued by: MR
START PERMISSIVE:
1. There is no Fault on the DCS.
2. HPFB is in Remote condition.
3. HPFB is in Service position (6.6 KV Power available).
4. All Bearing Temperature and Vibration Transmitter in service.
5. HPFB Discharge damper & Vent have close & open feedback respectively.
6. HPFB discharge to Seal Pot Dampers should be in fully open condition.
7. NO priority stops on DCS.
Issued by: MR
START UP
1. The start permissive of the HPFB in DCS should be healthy.
2. Any ID Fan Is in Running Condition.
3. Give START command to HPFB.
4.
After HPFB started, check the current to be stable, fully auto open O/L Valve & the vent
to be fully auto closed.
5. Check HPFB Set noise, Bearing temperature and vibration, Discharge Flow are normal.
6. As the HPFB is normal, check the availability of stand by HPFB and put the interlock in service.
STOP
1. To stop the HPFB, release interlock switch first, & ensure that all the PA Fan & SA Fan
are in stopped condition.
2. Give STOP command to HPFB.
3. After Stopping the HPFB, It should be ensured that the O/L Valve is fully auto closed & the vent is fully
auto opened, if not, open/close manually & The Local Push Button should be pressed
Issued by: MR
START PERMISSIVE:
1. There is no Fault on the DCS.
2. SA Fan is in Remote condition.
3. SA Fan is in Service position (6.6 KV power Available).
4. Any HPFB should be in running condition.
5. All Bearing Temperature and Vibration Transmitter in service.
6. SA Fan Discharge damper & IGV has close feedback.
7. NO priority stops on DCS.
Prepared by: DM & SM
Issued by: MR
START UP
1. The start permissive of the SA Fan in DCS should be healthy.
2. Any HPFB should be in running condition.
3. Give START command to SA Fan.
4. After SA Fan started, checks the auto open of O/L damper & current to be stable.
5. Check SA Fan Set noise, Bearing temperature and vibration are normal.
6. As the SA Fan is normal, increase the flow as per requirement by maintaining the Furnace
Pressure.
7. Start the Standby SA Fan as per the requirement of Air Flow.
STOP
1. To stop the SA Fan, ensure that all the PA Fan Are in stopped condition.
2. Give STOP command to SA Fan.
3. After Stopping the SA Fan, It should be ensured that the O/L damper is fully auto closed
if not, close manually.
4. As the SA fan Stops Local Push Button should be pressed.
Issued by: MR
START PERMISSIVE:
1. Any SA Fan is in running condition.
2. There is no Fault on the DCS.
3. PA Fan is in Remote condition.
4. PA Fan is in Service position (6.6 KV power available).
Prepared by: DM & SM
Issued by: MR
START UP
1. The start permissive of the PA Fan in DCS should be healthy.
2. One of the lube oil pumps should be running
3. Give START command to PA Fan.
4. After PA Fan started, check full auto open of O/L damper & the current to be stable.
5. Check PA Fan Set noise, temperature and vibration are normal.
6. As the PA Fan is normal, increase the flow as per requirement maintaining the Furnace Pressure.
7. Start the Standby PA Fan as per the requirement of Air Flow.
STOP
1. Slowly reduce the IGV by maintaining the furnace pressure.
2.
3. After Stopping the PA Fan, It should be ensured that the O/L damper is fully auto closed
if not, close manually.
4. As the PA fan Stops Local Push Button should be pressed.
5. After stopping the PA Fan as the bearing temp. Becomes <50oC, Stop the lube oil pump in the oil station.
Issued by: MR
5.9
Check suction make up v/v opened & the suction pressure to 2.0 Kg/cm 2.
After ensuring all pump start condition, give the START command to DMCCW pump.
Issued by: MR
10. Ensure that hot well Makeup Pump is running, Dm water for DMCCW tank & for makeup purpose is available.
11. Put ESP Insulator Heater in service 8 hrs. Before Boiler Lit-up.
12. Start the LDO Pump & ensure that LDO pressure is available at around 1.80 MPa in DCS
13. Ensure that the Air Compressor is running & Instrument air pressure is available at 0.6 0.7 MPa.
14. Ensure that HP and LP Dosing Pump should be available.
15. The furnace bed height should be normal & free from any foreign material. (Bed Height 760mm)
16. All fire protection system is in operational condition.
17. Hydrostatic plugs or test tags are removed from safety valves.
18. All Pressure & temperature gauges and Transmitters are in service.
19. All Expansion indicators in different area are normal and indicator pin is free from Jam.
20. Check fully opening & closing of the discharge damper of PA, SA, ID fans & High pressure blowers.
21. Opening and closing of ID fan Suction & scoop operation, Also the IGV operation of SA & PA Fan
22. Check operation of all control valves and motorized valves.
23. Ensure boiler and fan-Set safety interlock, Protection and annunciation OK.
24. Ensure the following valves are in closed condition before cold start up.
Feed water station drain valve, economizer drain valve, and economizer recirculation drain valve, all
the attemperation water drain valves and all the drain valves of furnace lower headers,CBD,EBD
should be in closed condition.( i.e. all water side drain valve should be closed and steam side drain
valve should be open)
25. Ensure the boiler main steam stop valve should be in closed condition
25. Ensure opening of Drum, CRH, HRH and SH air vent and start up vent valve.
26. Ensure the opening of SH, CRH, HRH and main steam line drain valve.
27. Take water in drum up to normal (-50 mm to -100 mm) level through cold filling line, Then open economizer
Recirculation valve.
Prepared by: DM & SM
Issued by: MR
35. After Purge complete, put one start-up oil gun into operation at minimum combustion rate. Regulating related
air flow, check if the combustion condition is good. Then put opposite start-up oil gun into operation at the same
Manner, After 30 min. changeover another two opposite oil guns based on the principle of changeover.
36. Boiler heating-up and boosting pressure should be slowly and uniform, must control all the gas side
temperature
(Including bed temperature change rate not more than 135C/hr, also control the saturated temperature rising
Speed 93C/hr and Drum metal temperature change rate 55C/hr, and Drum upper & lower metal temperature
difference 50C/hr.
37. After achieving the drum pressure 0.1 ~ 0.3 MPa, close the drum vent, and purge water level gauge and
check
Water level, also at 0.5 MPa closes the superheater vent.
38. As the drum Pressure reaches 0.5 ~ 1.0 MPa, inform chemical section to test the steam & water quality.
39. According to the drum wall temperature difference, open periodic blow down valve as per requirement, making
Uniform heating up of different part and establish good water circulation.
40. The Expansion reading of the Boiler to be taken periodically as the boiler loading increases.
.
Prepared by: DM & SM
Issued by: MR
41. As the furnace temperature increase, must control the temperature difference between material return device
and
Furnace outlet within 38C, when the temperature at material return device is lower than furnace outlet
temperature
38 C or more, primary air flow must be increased in order to reduce temperature difference .
42. As the drum pressure reaches 1.0 1.2 MPa as well as according to the drum level condition, starts the feed
Water pump, and takes the feed water from (30 %) control valve. (Close economizer recirculation valve).
43. After getting all the permissive for the HP/LP bypass, start the steam dumping and close the start-up vent
valve.
43. As steam pressure increased to 1.8 ~2.0 MPa, superheated steam temperature reaches to 360C & the
temperature difference between superheated steam and reheated steam is not more than 40C, and temperature
difference between right and left side of SH & RH is not bigger than 20C, Also supervise drum upper/down wall
temperature difference 50 C, connect with turbine section for rolling the turbine. Meanwhile, keep on observing
the steam temperature and steam pressure.
44. During turbine rolling, regulate bypass to meet the requirement of steam pressure and temperature for turbine
rolling.
45. After synchronization, unit immediately carries 5% rated load.
46. As the furnace bed temperature reaches above 6000C coal feeding can be proceeded.
47. Start coal feeder at minimum coal feed rate & observe bed temperature and oxygen change and
accordingly
Feed coal continuously.
48. After feeding coal, supervise & regulate, the change of bed DP, bed temperature, flue gas temperature &
wall Temperature.
49. As the furnace temperature increases flow rate of the oil gun can be gradually decreased down to minimum,
and
Then oil gun can be cut off one by one. At the same time, feeding coal can be gradually increased.
50. According to bed DP take Bed material feeding or Bed Ash conveying system into operation.
51. Gradually increase the coal feeding & supervise the Main steam pressure and Temperature with respect to bed
Temperature rising as per the Turbine load requirement.
Prepared by: DM & SM
Issued by: MR
52. According to Loads the main steam and Re heater temperature to be controlled by taking attemperation system in
Service. Also regulate the RH/SH flue gas regulating damper into operation as per requirement.
53. As the ESP I/L temperature reaches to 120C, put ESP field in operation.
54. Gradually increase the load and regulate air flow based on combustion condition (Maintain Oxygen level 3 ~ 4
%).
55. According to start-up curve, gradually increase load to rated value, and inspect the entire boiler from top to
Bottom for any abnormality.
56. Also note down all the parameters of Boiler at the desk and at field as per the normal values.
5.10
1) There are altogether 42 sets retractable soot blowers for this boiler arranged in the
back-pass SH area, RH area, economizer and air pre-heater area. Steam source is
taken from cold end platen SH outlet pipe, before first stage spray water attemperator,
then the steam pressure reduce to design value through pressure reduction station and
transmit to each soot blower.
2) Steam parameters for soot blower are: temperature 260C, pressure 18 MPa.
Issued by: MR
5.11
Issued by: MR
START UP
1. Start oil vapor extraction fan.
2. START AC lube oil pump, check lube oil pressure is >0.088mpa.
3. Check the availability of DC oil pump and put AC/DC lube oil pump interlock switch in service.
4. Check thoroughly lube oil system has no leakage.
5. Check the Lube oil filter DP.
For JOP:1. Open the inlet valves of Both jacking oil pump and confirm pump inlet oil Pressure
>0.039mpa
2. START jacking oil pump.
3. Check outlet pressure in range of 10 to 12 MPA.
4. Confirm shaft journal should be lifted 0.03 to 0.05 mm.
5. Check all bearing return oil is normal and note down individual bearing oil pressures.
6. Check the JOP filter DP.
Issued by: MR
For Turning Gear operation:1. Check the power supply on the Turning gear panel, and all the permissive (Compressed air
availability>0.06 Mpa, Motor cooling fan running condition, JOP pressure available).
2. Before starting the Turning gear turn the Rotor 180 Degree.
3. Turning gear on AUTO Mode: - as it senses ZERO rpm signal, and remote condition, it starts
automatically.
Turning gear on Semi-automatic mode: - when speed reaches zero, push button START initiating this
mode.
Turning gear on Inching mode: - maintenance use, inching button START, shaft turning some angle.
Turning gear on Manual Mode:- when failure of air supply, pull out pin, turning shaft manually.
5.12
Issued by: MR
6. Check all valves of the system are in open condition (Suction & discharge valve of main oil
pump, filter pump and Cooling pump, also to the individual governing valve).
7. Oil Tank temperature> 20 C.
8. Check the power supply available for the EH main oil pump, Cooling pump and Filter pump.
On DCS check
a) EH oil pump NO fault.
b) EH oil level Normal.
START UP
1. Start the EH oil filter pump.
2. Start the EH oil Cooling pump, and check the flow.
3. Start the EH oil Main pump.
4. Check the pressure 140.5 Mpa.
5. Check for any abnormal sound, and for any leakages.
Issued by: MR
START PERMISSIVE:
1. There is no Fault on the DCS.
2. CEP is in Remote condition.
3. CEP is in Service position.
4. Condenser level normal > 650 mm
5. CEP Discharge valve close feedback.
6. CEP Recirculation valve open feedback >95%
7. NO priority stops on DCS.
START UP:
1. Give START command to CEP.
2. After CEP started, check the time for the speed and current to be stable, auto opening of
discharge Valve (Delay 10seconds)
3. Adjust condensate re-circulating valve, keeping outlet pressure normal.
4. Check CEP noise, bearing temperature and vibration are normal, also check the operating
parameters and any abnormality at the field.
Prepared by: DM & SM
Issued by: MR
5. Check the availability of Stand by CEP and put the interlock in service
CEP STOP
1. Interlock to be removed from service before Stop the CEP.
2. When condensate pump flow is<140t/h, check condensate re-circulating Valve is open
3. Give STOP command to condensate pump which is in operation.
4. After the CEP stopped, the Hotwell Make up & the Local Push Button should be pressed.
5. If the Stopped CEP in Standby condition then put the interlock in service.
Issued by: MR
Issued by: MR
LP HEATERS IN OPERATION:
a) Before starting, check LP heater system, all valves and instrument are
good.
b) Check the LP Heater Local Level Gauge glass in service.
c)
Close steam side drain valve, confirm the drain valves upstream and
downstream of extracting check valve had opened.
d) Confirm the operated LP heaters water side drain valve and vent valve
had opened.
e) Open slowly the operated LP heater water side inlet valve filling water,
after water flows out from vent valve, close it, open water side inlet
valve gradually, close condensate bypass valve.
f)
g) Open operated LP heaters steam inlet valve slightly, warm the heater,
2 C/min temperature raise rate, the maximum is 3 C/min.
h) Close related drain valves upstream and downstream of extracting
check valve.
i)
j)
12. Check the Flow and pressure of Condensate system after LP heater to Deaerator
13. After the Turbine load increased > 60 MW start the LP Drip pump and maintain the heater level.
Issued by: MR
START UP
Before starting the Vacuum pump check the permissive of cooling water recirculation pump,
1. Now start the Cooling water recirculation pump and check the make-up solenoid valve auto open
close operation according to the separator level.
2. Now after satisfying the vacuum pulling condition (sealing of the Turbine with gland sealing
Condenser) and closing the vacuum breaker valve, The Vacuum Pump should be started.
3. Give START command to Vacuum Pump.
4. After starting the vacuum pump check the inlet solenoid valve auto open condition.
Prepared by: DM & SM
Issued by: MR
5. Now check for the abnormality in the vacuum pump like vibration, bearing temperature, sound in
the field.
6. Now start the 2nd Vacuum pumps cooling water recirculation pump and put the vacuum pump on
the stand-by condition.
Issued by: MR
START UP
1. The start permissive of the BFP in DCS as below :
a) Deaerator level normal >1950mm
b) Check the Booster pump suction pressure.
c) Recirculation Valve open >95%
d) Discharge MOV fully closed
e) Lube oil Pressure Normal >0.16 MPa ( AOP should be running)
f)
Issued by: MR
2. Start AOP and check the lube oil header pressure (> 0.21 MPA), and the filer DP.
3. Give START command to BFP
4. After BFP started, check the time for the speed and current to be stable, auto open Discharge
Valve (delay 10 seconds) & the Suction Flow should not be less than 100 T/Hr for a time of 60 sec
to avoid tripping.
5. Check thoroughly BFP for noise, bearing temperature, vibration, leakage at field is normal, if any
abnormality found then inform to Control-room and stop the pump if required.
6. After lube oil header pressure >0.25 MPa, auxiliary oil pump should be auto stopped.
7. After AOP stop check lube oil pressure and working oil pressure should be normal.
8. Check that the lube oil and working oil temperature is in normal range.
9. Put the recirculation valve in Auto giving the Low flow set point of >150t/h, so it can adjust the flow
accordingly.
10. BFP Middle Tap MOV should be opened as per the requirement of SH & RH Spray.
11. Put interlock switch in service if the availability of the Standby Start the BFP AOP & check the lube
oil pressure & Filter P, oil level
BFP STOP
1. Check that auxiliary oil pump is healthy & sealing water and cooling water is Normal.
2. Release BFP interlock & start decreasing BFP speed as per the requirement of the system
(maintaining the drum level).
3. When BFP feed water flow is <150 t/h, BFP re-circulating valve will be Opened 100 %
automatically, if not, open it manually.
4. Decrease speed to minimum, scoop position adjusted to 20%.
5. Give
STOP command to BFP & check discharge valve closed & also the local push button
should be pressed.
6. As the BFP is stopped, check that the AOP is auto started. After 30 min, the AOP will be auto
stopped.
7. When lube oil temperature decreased to 40c, close lube oil cooler cooling water valve.
8. When working oil temperature decreased to 50c, close working Oil cooler cooling water valve.
9. In change over condition, the BFP interlock switch, BFP discharge valve, lube oil and working oil
cooler cooling water inlet valve and re-circulating valve of Stand by BFP should be opened.
Prepared by: DM & SM
Issued by: MR
10. If maintenance work will be done after BFP stopping, the auxiliary oil pump will be kept operating
30 min. After BFP stopping to cool the BFP.
11. After pump casing temperature decreased <80c, drain water from casing and stopping cooling
water supply will be permitted.
3.
4.
5.
6.
7.
8.
9.
Issued by: MR
10. Supply steam into station steam header, before supply steam, it will be
12.
13.
14.
15.
16.
17.
HP HEATER IN OPERATION:
1. Confirm HP heater water inlet and outlet valve are in close condition, feed water
2.
3.
4.
5.
6.
7.
flows through bypass piping, filling water valve is close tightly, open water side
vent valve.
Open HP heater filling water valve, and close the vent valve after proper
venting,
When HP heater pressure is equal to the feed water pressure, open HP heater
motor outlet valve first then open motor inlet (3 way) valve, check the bypass
valve is closed and steam side water level is zero to confirm no leakage.
Open HP heater-1 & 2 shell side vent valve and vent to deaerator.
Open extraction 1 & 2 check valves ensuring its upstream and downstream
drain valves open.
Open extraction 1 and 2 MOV slowly (increasing rate is not more than
1.83C/min.i.e.110C/h), keeping pressure 0.05-0.1MPa to warm heaters, close
drain valves upstream and downstream of extraction 1 & 2 check valves.
Close HP heater 1 & 2 shell side vent valve, keep vent to deaerator vent open
condition.
Issued by: MR
8. Pay attention to HP heater water level, when its steam side pressure is 0.3MPa
9.
10.
11.
12.
higher than that of deaerator, close the HP heater-2 to LP heater-4 drip valve
and take the Drip to deaerator in-service and also check HP heater water level is
normal.
Check the Feed water Flow, pressure and temperature after HP Heater.
Check the LP and HP dosing system operation for maintaining the water quality of
Deaerator and Drum.
Take the water to the Drum as per requirement through the feed control station.
When water is not taken through the Feed control station maintain the circulation
through Eco-recirculation valve.
Issued by: MR
Issued by: MR
g) DM Tank level.
4. Check the analysis report of DM water, Hotwell, Lube oil and EH Oil for the acceptable range.
5. Check and Confirm Electrical Power supply is available for all the motors and valves.
6. Check the stand by interlock of all the equipments and the operation of all MOV & CV.
7. Check that Cooling Tower Sump Water Level Is Normal. Start the ACW Pump with proper venting &
maintain O/L header pressure as 5.2 Kg/cm2
8. Start CW (Circulating water) pump supplying water to the condenser, open both side water outlet
valve and vent valves, after proper air venting open both side inlet valve slightly and maintain the O/L
header pressure as 2.5 Kg/cm2
9. Start the Instrument Air Compressor and conform the availability of Stand by Compressor. (01 out of
04 nos.)
10. Open Inlet/Outlet Valves Of Oil Cooler And Filter, Cooling Water Will Be Adjusted According To The
Oil Temperature.
11. The Oil Inlet Valve Of HP Oil Pump And LP AC/DC Oil Pump Will Be Opened.
12. Coordinate with C&I to check DEH, ETS, TSI device are normal. And test the following protection:
Issued by: MR
f)
j)
ii)
iii)
Start AC lube oil pump, filling oil into system and venting air, check no leakage, oil return is normal
iv)
v)
vi)
vii)
Turning gear should be started around 4 hrs. Prior to the turbine rolling, Also check the turning
gear interlock in service.
viii)
ix)
Confirm rotor eccentricity is inacceptable range, and the bearing lube oil temperature before turbine
start is 21-27c.
x)
Ensure that all the drains & vents of the turbine side should be in opened condition. (All
extractions, CRH, HRH, MS, GSC Header, Aux. PRDS header, D/A vent, HP/LP By Pass)
Issued by: MR
xi)
Deaerator Will Be In a Normal Level. Warming Auxiliary Steam Header With Station Back Up Steam
Source, keeping Its Pressure, 0.6 TO 0.7Mpa, Temperature, 150C TO 250C. Open Deaerator
Auxiliary Steam Supply Valve Heating Storage Tank Water To 90C TO100C.
xii)
Ensure the DMCCW pump is running and the DMCCW water valve for Turbine and other equipment are
open condition.
xiii)
Check the level of condenser and the no.6, no.5, no.4 LP heater is normal.
xiv)
Start one CEP, and check there is no leakage in the condensate circuit, and keep stand by pump
interlock in service.
xv)
When the boiler drum pressure reaches 0.7 MPa & MS temperature reaches 300C, the Aux. PRDS
should be charged slowly through Drum to Aux PRDS line with proper drain and vent open,
OR if the other unit is running condition charge the APRDS of start-up unit from the APRDS line of
Running unit with proper drain & vent open condition.
xvi)
After the APRDS temperature & pressure reaches 160 - 180C & 0.6 MPa,Start the GSC Fan &
slowly charge the Gland Steam Header (0.03 MPA & 120 150 C) and check there should be no
leakage and adjust drain valve between multistage U tube type siphon and maintain the gland
steam cooler level.
xvii)
xviii)
Start one Vacuum pump and simultaneously close the vacuum breaker valve and check the
healthiness of the pump and observe the rate of increasing trend of the vacuum, if necessary take
another vacuum pump in service. And keeping vacuum at (>-65 KPA).
xix)
Start EH Oil Pump, EH Oil Cooling & Filter pump, check current is normal and fluid pressure increasing
slowly to specified value. (If fluid temperature is lower than 10C, EH pump start is
Open Bypass stage I & II (HP-Bypass & LP- Bypass) based on requirement, observe the main
Issued by: MR
steam and Re-heat steam temperature, full-fill the requirement by paying attention to condenser
vacuum.
xxi)
When By-pass temperature reaches the value- HP-bypass 360 C & LP-bypass 180 C start spray
water for maintaining temperature and the III-stage spray will auto open based on the LP steam
Exhaust temperature.
14. After pressure established in boiler, based on operation mode, check the
tightness of TV, RSV, GV, IV and HP exhaust check valve, prevent it from casing
metal temperature change due to steam leakage.
15. When Main Steam Pressure 1.5 To1.6mpa. Main Steam Temperature 360C,
Reheat
steam
Temperature >300C, The Difference Between Main Steam And Reheat Steam Temperature Of Both Side
Will Be Not More Than17C, Condenser Vacuum > (-65kpa) (G), Outlet Oil
Temperature
Of
Oil
Cooler Will Be 35 To45 C, Rotor Eccentricity Will Not Be More Than 0.076 Mm, Regulating Oil Pressure
Will Be 1.17mpa, Lube Oil Pressure Will Be 0.147 MPa, All Bearing Return Oil Is Normal value are
Reached Rolling Can Be Started.
16. Push protection reset button first then turn on main protection switch, inform C & I Person to
turn on Hp Expansion difference, Axial displacement, bearing temperature, bearing oil
pressure, over speed protection and bearing vibration protection switches.
17. Finally go through the Prerequisite before turbine rolling if it satisfy then Go to DEH OVERVIEW
display and put DEH-control system to OPERATOR AUTO mode, click LIMIT SET to set VALVE
LIMIT and conform valve position 100 % and click LATCH button, Turbine Latched ,TV & RSV full
open.
18. Starting time period in various conditions:
Issued by: MR
Item
Warm Start
Hot Start
HP Stationary Blade
Main Steam
Temperature
Reheat Steam
RPM
Temperature
500
1100
2950
Maximum Speed
Increasing Rate
Remark
200--320C
45 min
10 min
70-100 R/Min
40- 50 Min
100 rpm/min
200 rpm/min
Same As Hot
Issued by: MR
19. Give the target speed to 500 RPM with the speed rate of 100 RPM/min & click GO button for the rolling.
20. GV, IV Opening gradually, Speed increase gradually, turning gear disengage automatically,
if not then trip the turbine, and check for the reason.
21. After reaching 500 RPM hold up for the primary warm-up period (15 min).
22. In speed-up period check HP Exhaust check valve opening condition, drain of turbine proper and other
related piping will be good, there is no water hammer and vibration existed.
23. Pay attention to main steam and Reheater steam parameter change condition, the deviation with startup curve will not more.
24. Now increase the Target speed to 1100 RPM with a rate of 100 RPM/min. The warm-up time will be
maintained at 1100 RPM for 45 minutes and check all important parameters of turbine,
Rotor eccentricity (<0.076 mm), Rotor vibration, axial displacement ((+/-) 1), casing absolute
expansion,
HP/IP Upper & Lower casing temperature difference (<50C), Bearing Temperature- (Journal <90C,
Thrust <85C), Return oil temperature < 65C.
25. After completion of the warm-up period increase the target speed to 2950 RPM with a rate of 200
RPM/min.
26. Check JOP Auto Stop at 1250 RPM, if not Stop it manually.
27. The turbine critical Bands of turbine are: 1st Band
:-
Issued by: MR
2nd Band
:-
3rd Band
:-
28. Within the critical bands the increasing speed rate will be automatically change to 500 RPM/min.
supervises the Turbine vibration with this critical band. After reaching at 2950 RPM with normal
parameters increase the target speed to 3000 RPM. Within the range of 2950 to 3000 RPM the Rate of
Speed will automatically change to 50 RPM/min.
29. Now unit will be warm up at 3000 RPM, check the system thoroughly (Both on DCS & Field).
30. Check mail oil pump outlet press 1.17 MPa and Inlet Pressure 0.098 MPa, conform lube oil pressure and
oil temperature. After this STOP HP oil pump and put its interlock switch in service.
31. Now Turbine will thoroughly check normal then the Electrical & C&I personnel should be co-ordinate for
synchronization with grid.
32. For synchronization process, go to DEH panel & take AUTO SYNC in service.
START the excitation system & wait for the Excitation voltage & PMG Voltage to be developed to
25 Volts & 330 Volts resp.
33. As the above parameters are satisfied then go to the DEH panel & click on PREPARE FOR AUTO
SYNC if the required permissive are OK.
34. Check the unit synchronization conditions are fulfilled then SYNCHRONIZATION with Grid making
turbine operated with 5 % rated load immediately.
Now check and maintain primary load warm-up period with,
35. Now increase the Turbine loading as per requirement and increase Boiler pressure and temperature
Prepared by: DM & SM
Approved by: HEAD (POWER PLANT)
Issued by: MR
** Coordinate control system (CCS) is a critical one in full power plant automatic control system.
The function of Coordinate Control System is boiler and turbine receive the load command, coordinated together
to satisfy the load requirement of net work and guarantee the power plant safe operating. It consists of master
control system, boiler fuel control system, boiler air flow control system, feed water control system and steam
temperature control system, in turbine aspect DEH system.
Issued by: MR
When some auxiliaries damaged, regardless the outside load requirement, unit load should decreased to a
specified level to guarantee unit operating safely and continuously, the run back rate will be limited according to
the damage condition.
Turbine follow control mode (pressure control by turbine)
At turbine follow control mode, main steam pressure is controlled automatically by turbine control loop, and the
boiler load is control manually by operator.
All equipment and piping and valve of LP DRIP pump have been pre-checked. & should be OK.
START UP
1. Check the discharge Control valve is in close condition.
2. START the Drip pump.
Prepared by: DM & SM
Issued by: MR
3. Now check for the abnormality in the vacuum pump like vibration, bearing temperature, sound in
the field.
4. Open the Control valve as per the requirement looking on to the level of LP Heater-6.
STOP
1. Reduce the Discharge Control valve position looking on to the LP Heater-6 level, and after
reducing loading of pump give the STOP command.
2. Press Emergency Push Button on the field.
3. If no maintenance work will be taken in this pump then put the stand by interlock in service.
Issued by: MR
4. Open GV gradually keeping load 100 MW for 10 to 20 min. Casing temperature should be
checked every 15 min during this period.
5. Reduce the TG load set point, observing the main steam pressure and temperature.
Following regulations should be followed during shut down period:
i) Avoid ETS over speed test.
ii) Maintain differential expansion in the range of +8 to -3mm, if not, inform boiler group
to control parameter stable, pay attention to negative expansion difference.
iii) After process is stable, main steam temperature will be 10C to 20C lower than
regulating stage metal temperature.
iv) In low load condition, pay attention to heaters water level and maintain lube oil
temperature.
v) when load decreased to 30% rated load, open HP/LP bypass system, according
to boiler requirement, pay attention to condenser vacuum and turbine exhaust
temperature.
vi) Stop all coal feeding into furnace while load slide down to 30%, to generate power by
using of residual heat.
vii) When load decreased to 25% rated load, check Gland sealing steam source change
over from extraction-3 or auxiliary steam header from boiler drum or from other unit
and maintain the gland sealing temperature and pressure.
viii) When load decreased to 20% rated load, Stop Drip pump according to No.6 LP
heater water level.
ix) Stop CT fan according to load, observing the vacuum and cooling water I/L & O/L
temp. Of condenser.
x) HP heater-2 drip will be changed from deaerator to LP heater-4 when HP Heater-2
pressure is lower than the deaerator.
xi) All extractions taken out of service according to the load reduction curve.
xii) When main steam parameter decreased to < 3.0 MPa and 470C, boiler
pressure/temperature decreasing period finished, for avoiding negative expansion
difference to make turbine trip.
xiii)Keep on ventilating into furnace after shutdown, pay attention to each part of
refractory temperature fluctuation within regulated range. When bed
temperature slide down to 400C, after purging 30 minutes to Boiler, if boiler
Prepared by: DM & SM
Issued by: MR
not cooling down rapidly, stop primary air fan, secondary air fan, high pressure
fluidized fan and induce draft fan running sequentially.
SHUT DOWN
i) Release boiler main protection and water level protection.
ii) Start AC lube oil pump, release HP start oil pump low oil pressure interlock.
iii) Steps out generator, the operating time in this period will not exceed 15 min., speed
should keep stable.
iv) Report to shift leader, push EMERGENCY SHUT DOWN button, check
TV, GV, RSV, IV, HP extracting check valve and extracting check valves
closed quickly, recording trip time.
v) Regulate HP/LP bypass system as per requirement.
vi) Pay attention to rotor coasting condition, especially the vibration when passed through
the critical speed.
vii) When speed decreased to 1250 rpm, release interlock protection, shut down vacuum
pump, and check auto starting of Jacking Oil pump, if not start it manually.
viii)When speed decreased to 500 rpm, LP hood water spray auto stopped, if not close it
manually.
ix) When speed decreased to 0 rpm,put in turning gear, recording shaft eccentricity,
turning gear motor, rotor coast down time, casing expansion and expansion difference.
x) Close all gland sealing steam supply isolating valve, stop gland sealing fan.
xi) When boiler drum level increased up to +400mm level, stop BFP, close water inlet and
open economizer recirculation valve.
xii) Release condenser and deaerator water level auto control function, shut down
condensate pump as per requirement.
xiii)When slid pressure shut down, turbine metal temperature decreases and temperature
difference will not exceed following limit.
Issued by: MR
xiv) Control lube oil outlet temperature of cooler in 35C to 40C range.
xv) Stop generator air cooler cooling water supply.
xvi) After casing metal temperature decreased to 250C, open main steam,
reheat steam, extraction steam piping drain valve, if its open will influence the
temperature difference between upper and lower casing, it will be kept closed.
xvii) After temperature of regulating stage upper inner wall 150C stop turning gear
and jacking oil pump if required.
xviii) When LP exhaust temperature decreased to lower than 50C and no any steam
Drainage flow into condenser, main circulating pump can be stopped.
xix)When drum pressure slide down to 0.17MPa, open drum air vents.
xx) If boiler cooling is required, open inlet and outlet damper of induce draft fan,
primary air fan, secondary air fan in terms of drum wall temperature deviation,
and maintain furnace negative pressure at -125Pa, cool furnace down by
natural ventilating.
Issued by: MR
10. Gas test is required for Work Permits requiring activities to be performed like hot work and confined space
entry to ascertain the presence of Oxygen, Carbon Monoxide (CO) and LEL of any flammable gas. Gas testing
shall be conducted by authorized person (Jr. Manager & above/ the person who is competent in the gas test
operations and the use of the relevant equipment i.e. Multi gas Detector.
11. Where the oxygen level is below 19.5% or atmospheric contaminants cannot be reduced below relevant
exposure levels, entry may only occur with suitable PPE including SCBA (Self Contained Breathing Apparatus),
supplied air respirator etc.
12. Entry shall not be permitted to a confined space when flammable contaminants are greater than or equal to
5% LEL or where oxygen level exceeds 23.5%.
13. Upon completion of work the Requisitioner shall first ascertain that all men were withdrawn, materials are
removed and the equipment is safe to operate in all respect and return the work permit to the issuer i.e.
authorized issuing authority (Operation).
14. The Requisitioner will sign the Work Permit with Date and time in token of having completed the work and
cleared the equipment for operating and return it to the issuer.
15. The issuer closes the Work Permit after cross-checking the work area and restores the operation. It will be
recorded in work Permit issue register.
16. During shift change over, the outgoing permit issuer shall brief details of all work permits issued during the
shift to the incoming issuing authority before leaving the shift.
Issued by: MR
Issued by: MR
7. Check various reading of parameters (RPM, Lube oil pressure, Lube oil temperature,
water temperature, voltage, current, frequency, KWH, KW, PF.
Issued by: MR
TG DESK ENGINEER:
RESPONSIBILIT
IES
1.
Issued by: MR
Pressure is adequate.
2.
ii)
If still the pump does not start, A.C oil pump should be
started, when supply is restored from DG set.
iii)
3.
4.
5.
6.
Issued by: MR
7.
8.
If DC J.O.P. does not pick up and fails to start from control room,
instruct local operator to start from local.
9.
on it from
case hand
stand still.
turbine by
Ensure Scanner fan takes start on auto. If it fails to start it from DCS
and ensure scanner air supply to Flame Scanners and Igniters. Also
confirm from local operator that scanner fan discharge pressure at
about 10 KPa.
2.
Check that EBD and CBD valves got closed or not. If they fail to
operate on black out signal, close from control room. If they fail
to operate from control room, close them locally with the help of
local boiler operator.
3.
Issued by: MR
4.
1.
2.
3.
Issued by: MR
RESPONSIBILITI
ES
OF SHIFT-INCHARGE
TO BE STATIONED AT MAIN CONTROL ROOM
BE ACCESSIBLE ALWAYS
AND
1.
2.
4.
5.
Coordinate with Desk Engineers of Unit for safe operation in black out.
6.
7.
NORMALISATION OF SUPPLY
RESPONSIBILITI
ES
OF ELECTRICAL ENGINEER.
They should be in constant touch with Shift- in- charge
1.
2.
Check the feeder & motor availability. If tripped, check the description
of protection acted, if healthy reset the system.
3.
In EMCC check source I/C from unit PCC if healthy change over the
source from DG I/C to the main.
Issued by: MR
1.
2.
Normalize ACW, DMCW, LDO Pump, Boiler Fill pump and Hot well
make up pump.
3.
4.
5.
Depending on the start-up power (MW) start one CEP and one
BFP and restore water supply to drum.
6.
7.
Issued by: MR
9.
Open Boiler MSV 10-15% from the local and open HP bypass
around 5% and maintained CRH pressure sufficiently. Charged
aux. steam header pressure about 0.5 to 0.6 Mpa and
temp.around 230DegC. If drum pressure comes down less than
3.0 Mpa charge aux. steam deader through drum itself.
Charge gland steam header and maintained hdr. pressure 0.05
Mpa and temp. in the range of 100- 140 Deg C.
Start both the Vacuum pumps and start vacuum pulling.
10.
Ensure PCC buses are normalized from PCC and DG sets are put
on auto.
12.
13.
Issued by: MR
START:1.
2.
3.
4.
5.
6.
Issued by: MR
2.
3.
4.
5.
6.
6. CUSTOMER FEEDBACK
Customer feedback to be collected once in every year.
7. LIST OF CUSTOMER
1. GRID
2. BARBIL
3. PLATE MILL
4. SMS
5. PROCESS BOILER
6. CAS
7. OXYGEN PLANT
8. DRI
9. CGP
Issued by: MR
Flow Chart
Issued by: MR
Issued by: MR
REC-OPR-1-01-
Title
Form No.
Retention
Location
Responsibility
Period
1
Shift In Charge
Log Book
1 year
Control Room
Shift In charge
Six Month
Control Room
Shift In charge
Six Month
Control Room
Shift In charge
Two week
Control Room
Shift In charge
Perpetual
Control Room
Shift In charge
Perpetual
Control Room
Shift In charge
Perpetual
Control Room
Shift In charge
OPR-1-01-A
Day ahead
schedule file
OPR-1-01-E
Generation sheet
OPR-1-01-F
Energy-meter
Register
OPR-1-01-G
Issued by: MR