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(UNDER COMMISSIONING)
KAWAI 660MW X 2
(UNDER ERECTION)
ACHIEVEMENTS
INDIAS FIRST 66O MW SUPER
CRITICAL UNIT SYNCHRONISED BY
ADANI POWER LTD, MUNDRA IN OCT
2010 IN RECORD TIME OF 36
MONTHS.
COMMISSIONED 4Nos. 660MW UNITS
IN A YEAR.
ADANI IS THE FIRST COMPANY IN
INDIA TO EARN CARBON CREDIT.
WELCOME
TO
PRESENTED BY
B.K.PANDEY
APML, TIRODA
START-UP SEQUENCE
BOP SYSTEM READYNESS
BOILER FLUSHING: COLD/HOT
BOILER LINE UP AND LIGHT UP.
TURBINE LINE UP.
TURBINE ROLLING.
SYNCHRONISATION
PHASE CHANGE OVER
FULL LOAD
START UP MODES
COLD START UP:HP & IP SHAFT METAL
TEMP <204C
WARM START UP: HP & IP METAL TEMP IN
BETWEEN 204 TO 400C
HOT START UP :HP & IP METAL TEMP
>400C
Boiler
Economiser
FCS
11+1
2x
7
HP
T
IPT
3
HPH - 2
HPH - 1
RH
2x
7
LPT A
5
LPT B
7
LPH -7A
LPH -8A
LPH -7B
LPH -8B
Condensor
(HP)
Deaerator
Condensor
(LP)
EXT From
CRH
(MD BFBP
1x35%)
HPH -3
TDBFP 2X50%
CEP
3x50
%
1994 TPH
GSC
CPP
1482 TPH
LPH -5
LPH -6
WHY BCP ?
TO ASSIST CIRCULATION IN BOILER WATER WALL
TO INCREASE THE CIRCULATION VELOCITY
TO AVOID DNB (Departure from Nucleate Boiling) IN LOW LOAD.
TO REDUCE THE OVER HEATING AND UNDUE STRESSES ON
WATER WALL TUBES.
TO AVOID DRY OUT OF WATER WALL TUBES WHEN LOAD IS
REDUCED.
pH >= 6.5
: MAX. 5 L/MIN
Boiler flushing
SP SP
START-UP
LINE
Sampling
Fe+
Below
Above
500ppb
500ppb
MIXER
BCP
WW
ECO
CW
LINE
HOTWELL
Fe
< 500PPB
SiO2 < 100PPB
THEN CPU WILL BE TAKEN IN SERVICE TO REDUCE WATER
LOSS AND IMPROVE QUALITY.
COLD CYCLIC FLUSHING QUALIFIES
Fe < 100PPB
SIO2 < 50PPB
FE
SIO2
> 100PPB
> 50PPB
FE
< 100PPB
SIO2 < 50PPB
FE
< 50PPB
SIO2 < 30PPB
LDO/HFO GUN
Fuel
Light Oil
Fuel Pressure
0.8MPa-2.0MPa
Fuel Flow
500kg/h -3000kg/h
0.6MPa-1.2MPa
100-600kg/h
Ignition Method
Fuel
Heavy Oil
Fuel Pressure
0.8MPa- 2.0MPa
Fuel Flow
1000-4000 kg/h
0.8MPa-1.2MPa
100-400kg/h
Ignition Method
TURBINE LINE UP
ENSURE:
LUBE OIL SYSTEM: IN SERVICE (0.8 MPA)
JACKING OIL SYSTEM:IN SERVICE ( 14 MPA)
TURBINE BARRING GEAR: 3-4 RPM
SEAL OIL SYSTEM: AIR & H2 SIDE. CHARGED
STATOR AND H2 COOLING WATER SYSTEM:CHARGED TEMP CONTROL
IN AUTO)
TURBINE LINE UP
ENSURE TDBFP IN BARRING.
GLAND STEAM CHARGING: ENSURE STEAM TEMP. IS 56C
- 111 C MORE THAN ROTOR TEMP & DEGREE OF SH >
50C.
CHARGE THE GLAND SEAL SYSTEM OF TDBFP.
START THE VACUUM PULLING WITH VACUUM PUMP.
MAINTAIN VACUUM -0.9 KG/CM2.
CHARGE THE HP-LP BYPASS SYSTEM .MAINTAIN THE MS
STEAM PRESSURE AND FIRING RATE FOR ACHIEVING
TURBINE ROLLING PARAMETERS.
HOT ROLLING
MS TEMP
RH TEMP
SPEED
MS FLOW
LOAD
MS PRESS
MS
HPBP
HPT
CRH NRV
RFV
IPT
Ventilator valve
TO CONDENSER
BDV
TO CONDENSER
CRH LINE
TURBINE ROLLING
AS PER REQUIREMENT OF START UP CURVE, FIRING TO BE
INCREASED.
REQUIRED STEAM PARAMETERS BEFORE ROLLING
MS PR: 8.73 MPA, TEMP: 330-380 C
RH PR: 1.1 MPA , TEMP: 330C
- THE DEGREE OF SUPER HEAT > 56C.
AFTER LATCHING THE TURBINE, START IP ROLLING WITH HP VENT
TO CONDENSER IN OPEN CONDITION TO KEEP THE HPT IN VACUUM.
MSV 1&2 AND RSV 1&2 ARE IN OPEN CONDITION.
GIVE THE SPEED SET POINT TO 600 RPM
CHECK THE TURBINE SUPERVISORY INSTRUMENT PARAMETER.
THE ECCENTRICITY SHOULD BE LESS THAN 0.076 MM.
TURBINE ROLLING
SELECT TARGET SPEED 1500 RPM WITH RAMP RATE OF 100
RPM/MIN.
ENSURE ALL HP CVS OPENS TO 12% TO WARM UP THE HP
CASING.
WHEN HP CASING TEMP >320C.CLOSE THE HP CVS.
SOAK THE TURBINE FOR 4 HRS ACCORDING TO THE START UP
CURVE.
CHARGE THE LP HEATER 5 & 6 BEFORE 3000 RPM
SELECT TARGET SPEED TO 3000 RPM WITH RAMP RATE OF 100
RPM/MIN.SOAK IT FOR 30 MIN AS PER S/U CURVE.
AS PER PROCEDURE SYNCHRONISE THE UNIT.
LOADING
AFTER SYNCHRONISATION INITIAL LOAD WILL BE 30 MW.HOLD IT FOR
30 MIN AND CHEK THE VIBRATION, BEARING TEMP, DIFF EXPANSION,
CASING EXPANSION.
CHARGE EXTRACTION STEAM TO DEAERATOR.
TAKE MORE OIL GUNS IN EF/AB ELEVETION.
TAKE PA FANS & SEAL AIR FAN.
AFTER ACHIEVING FURNACE TEMP. MORE THEN 450C. TAKE COAL
MILL-B AT. STEAM T/PR 380C/8.7 MPA.
INCREASE FUEL FLOW MAINTAINING STEAM TEMP.& RAISE LOAD
AT 70 MW IP TO HP CHANGE OVER. CVS WILL START OPENING, CLOSE
THE BDV AND VENTILATING VALVE.
INCREASE THE LOAD AT 3MW/MIN
CLOSE THE HP-LP BYPASS GRADULLY.
660
LOAD
(MW)
350
660 MW
495
330MW
330
198MW
165
60MW
33MW
400
450
500
MINUTES
550
600
650
MILL-B CUT IN
SYNCHRONISE
&CHARGE D/A
LPT A
2nd
LPT B
2nd
5th
5th
6th
6th
5th
4th
4th
5th
6th
6th
LP HEATER 7A
LP HEATER 7B
LP HEATER 8A
LP HEATER 8B
CONDENSER
HP HEATER
LP HEATER
5
5
CONDENSER
HP HEATER
LP HEATER
6
6
TDBFP START UP
TAKE ONE TDBFP IN SERVICE( CHANGE OVER WITH MD BFP) WHILE
DRIVING STEAM IS AVAILABLE. SECOND TD BFP WILL BE TAKEN AT 180
MW.
WARM UP THE TURBINE.
SLOWLY OPEN THE AUX STEAM MOV TO TURBINE.
PARAMETERS FOR ROLLING TDBFP.
HP
IP
1.12 Mpa
378 C
1.3 MPa
350 C
Aux. Steam
Header
To
CRH
Changeover Valve
From
CRH
E
M
4 MPa
315.3 C
TDBFP-B
To
Condenser
Deaerator
TDBFP-A
Booster
pumps
LOADING
TAKE THE MILL-C IN SERVICE AT 100 MW. STEAM T/PR:400C/8.7
MPA.
GRADUALLY WITH DRAW THE OIL SUPPORT AS PER THE FLAME
CONDITION.
INCREASE THE LOAD TO 150 MW AND TAKE THE HPH-3, HPH-2 &
HPH-1 IN SERVICE. MS T/PR 410C/8.7 MPA.
AT 180 MW TAKE SECOND TDBFP IN SERVICE.
MS LINE
HRH LINE
IP EXHAUST
CRH LINE
9th stage
5th stage
TDBFP A
HP HEATER
1
HP HEATER
2
HP
HP HEATER
HEATER
33
DEAERATOR
TDBFP B
LOADING
TAKE MILL-A AT 210 MW.
CUT THE OIL SUPPORT AT 260 MW AS PER THE FLAME CONDITION.
TAKE MILL-D AT 300 MW. MS T/PR 475C/10 MPA.
Parameters
1
Unit
390.37
t/h
Design fuel
2111
t/h
25.4
MPa
569
1749.1
t/h
4.73
MPa
4.49
MPa
324
10
569
Feedwater pressure
28.8
MPa.g
11
Feedwater temperature
280
12
421
153.3
147.2
13
14
Indian coal
87.19% BMCR
TURBINE PARAMETERS
Steam Admission Parameters at Turbine Inlet
HPT
IPT
LPT
Pressure (MPa)
24.2
3.961
1.12
566
566
378
O/L Temp(deg C)
315.3
378
1959.25
1649
No of Control valves
1.12MPa / 378c
RSV
MS LINE
MSV
CV
CV
CV
TO BLR RH
CV
CRH
HPT
IPT
LPT
#1
LPT #2
CRH
RCV
CV
CV
MSV
MS LINE
HRH
CV
CV
RCV
CV
CONDENSOR A
RSV
RSV
CONDENSOR B
GEN
SHUT DOWN
EXCEPT IN AN EMERGENCY, LOAD SHOULD BE REDUCED
GRADUALLY.
CUT THE MILL-F AT 540 MW.
CUT THE MILL-E AT 470MW.
CUT THE MILL-D AT 300 MW.
TAKE OIL SUPPORT FOR FURNACE STABILITY ( AT THE TIME OF 3
MILL OPERATION).
CUT THE MILL-A AT 210 MW.
TAKE THE HPH-1,2,3 OUT OF SERVICE.
WHEN THE LOAD < 30% BOILER COMES IN WET MODE FROM
DRY MODE. START THE BCP AND MAINTAIN THE SEPEARTOR
LEVEL.
SHUT DOWN
WHEN THE LOAD HAS DECREASED TO 20% OF RATED LOAD TRIP THE
TURBINE ON TURBINE PROTECTION. THIS CLOSES THE THROTTLE
VALVES, GOVERNOR VALVES, REHEAT STOP VALVES AND INTERCEPTOR
VALVES
CHECK DRAIN VALVES OPENS IN AUTO.
HP LP BYPASS VALVE OPENS TO MAINTAIN THE FLOW.
REDUCE THE BOILER LOAD GRADULLY.
TRIP THE BOILER.
THE VACUUM BREAKER VALVES SHOULD NOT BE OPENED UNTIL THE
TURBINE UNIT HAS COASTED DOWN.
VACUUM SHOULD BE KILLED BEFORE GLAND SEALING STEAM IS SHUT
OFF.
AUX OIL PUMP STARTS IN AUTO AT 2850 RPM.
JOP START IN AUTO AT 1200 RPM.
SHUT DOWN
WHEN THE VACUUM REACHES ZERO, SHUT OFF THE SEALING STEAM
TO THE GLAND STEAM CONTROL VALVES.
SHUT DOWN THE GLAND STEAM CONDENSER EXHAUSTER. SHUT
DOWN CONDENSATE PUMP.
SHUT DOWN THE VACUUM PUMP.
SHUT OFF THE COOLING WATER SUPPLY TO THE GENERATOR
HYDROGEN COOLERS.
ENSURE THAT BARRING GEAR HAS CUT IN.
THANK YOU