660 MW Supercritical Thermal Power Plant Simulator Manual

Version:2.2 2015

Start up Criteria
a. Cold Start up: Turbine first stage inner casing metal temperature ＜120°C (After long term
stoppage)
b. Warm start up-I: Turbine first stage inner casing metal temp between 120°C to 260°C (For
more than 72 hours boiler stoppage)
c. Warm start up -2: Turbine first stage inner casing metal temp between 260°C to 415°C (Bet.
10 to 72 hrs of boiler Stoppage)
d. Hot start up: Turbine first stage inner casing metal temp between 415°C to 450˚C (Bet 1 to 10
hrs of Boiler stoppage)
e. Extreme hot start up: Turbine first stage inner casing metal temp > = 450°C (Boiler stoppage
< 1 hr)

660MW Simulator Unit Start–up Procedure

1 Common Pre-checks:
a. Ensure that all maintenance of unit is complete & work permits are cancelled.
b. Ensure healthiness of DCS & DEH systems.
c. Ensure that no trip conditions persist & all relays are reset.
d. Ensure that isolation valves to all measuring instruments are open.
e. Ensure that all safety valves are in normal position.
f. Ensure that fire fighting system is healthy.
g. Boiler internal scaffoldings / sky climbers are removed and no man is working
inside.
h. Boiler all manholes / peepholes are properly shut
i. All ESP doors are properly locked.
j. All Oil guns, soot blowers are retracted & properly fitted.
k. Ensure H2 and CO2 cylinders are available at filling points (150 H2 and 30 CO2
cylinders)
l. Ensure DM tank levels and CST level are normal
m. Ensure coal handling system is ready and coal bunkers are filled
n. Ensure all drains and vents are opened from boiler as well as turbine sides

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2 Restore 400 KV power on Bus I & II from Grid

3 Restore 11 KV / 3.3KV / 415 V auxiliary supply:

a. Close UT-1A &UT -1B circuit breaker to charge Unit BUS 1A & 1B
b. Close up stream & downstream breaker of Boiler Service transformer1A & 1B to
charge 415V Boiler PMCC 1A & 1B respectively.
c. Close up stream & downstream breaker of TG Service transformer1A & 1B to
charge 415V TG PMCC 1A & 1B respectively.
d. Close up stream & downstream breaker of Cooling tower transformer 1A, 1B, 1C
& 1D to charge 415V CT MCC.
e. Close up stream & downstream breaker of ESP transformer1A, 1B, 1C & 1D to
charge 415V ESP PMCC.
f. Close up stream & downstream breaker of UAT 1A & 1B to charge 3.3kV Unit
Auxiliary board 1A & 1B respectively.
g. Restore 415 V auxiliary supplies.
4 Auxiliary Steam Header Charging:
a. Ensure all the discharge line to auxiliary header are closed
b. Keep header drain open
c. Charge Aux Header from adjacent unit steam
d. Warm up the header by slowly charging and raise the pressure and temperature to 0
.8 MPa and 300⁰C respectively
e. Line up and charge Auxiliary to HFO tank floor heating, HFO heaters and HFO
and LDO atomizing line
5 Ensure LDO and HFO pumps are available and lined up

6 Ensure bottom ash handling and fly ash handling system is ready. Put bottom ash
handling system in service.
7 Commission CW System:
a. Open 10 to 12 Cooling Tower riser valves.
b. Fill up the fore bay to 7m level from clarifier.
c. Open inlet & outlet valves of Condenser.
d. Open water box air vent and close after removal of air
e. Start one CW pump and ensure CW discharge pressure to 4 kg/cm2.

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f. Open 18 risers before starting another CW pump

g. Start cooling tower fans as required.
h. Line up chlorination dozing system in coordination with chemist.

8 Commission OCCW System:

a. Open motorized filter inlet & outlet valves (motorized filter starts on Auto if filter
∆p is high).
b. Line up the local operation on FOD page & All the FOD’s should be opened
c. Open the inlet valves of both OCCW pump & start any one pump.
d. Ensure the discharge valves of running pump opens on Auto.
e. Ensure that OCCW header pressure is 4.5 kg/cm2
f. Put the 2nd OCCW Pump in Backup & ensure its inlet valve is open.
g. Line up local operations (FOD).

9 Commission CCCW System:

a. Fill up the CCCW expansion tank by opening the manual valve (FOD) from
makeup water system. Open the level controller valve as per requirement.
b. Line up the local operation on FOD page (all the FOD should be opened except
Expansion tank drain).
c. Start any CCCW pump & put other in backup.
d. Charge BCP cooling line from CST
10 Charging of Compressed air system:
a. Charge service air and instrument air compressors.
b. Ensure that the service air and instrument air systems are charged
c. Maintain discharge pressure to 7 kg/cm2
11 Start lube oil pumps of all equipments (fans, pumps, mills, BFP etc)

12 Start turbine lube oil system, Jacking system and put turbine on barring gear

1. Commission turbine lubricating oil System:

a. Start one oil vapours extraction fan, put other in back up.
b. Line up local operations (FOD) digital and analog both.
c. Open suction valves of AC lube oil pump A & B, & DC lube oil pump.
d. Open the oil filter up stream & downstream valves.

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e. Open the oil cooler downstream valves.

f. Start one AC lube oil pump, put 2nd AC lube oil pump & emergency DC lube
oil pump on back up
g. Ensure lube oil pressure is between 0.1 to 0.18MPa and temp between 38°C to
42°C.
2. Commission jacking oil system:
a. Open jacking oil discharge valve.
b. Ensure jacking oil pump inlet pressure is not low.
c. Start AC Jacking oil pump, ensure that discharge pressure is > 16Mpa, put
other pump in backup.
3. Put turbine on barring gear:
Before steam admission, turbine should run for min 4 hrs on barring gear
with shaft eccentricity < 75µm at speed 4 rpm
13 Commission DEH oil system:
a. Line up local operation for EH oil system.
b. Start EH oil cooling pump.
c. Start EH oil filtration pump.
Start one EH oil Pump, put other pump in back up and ensure EH oil pressure >14Mpa

14 Fill up Hotwell and Deaerator

a. Ensure CST tank is filled up.
b. Ensure no PTW is pending related o Hotwell ,Condenser and Deaerator
c. Start fill system and start fill pumps.
d. Line up and fill Hotwell to normal level ( 1000mm )
e. Fill Deaerator using to normal level ( 2600mm )
f. Star auxiliary steam to deaerator from auxiliary ( if available )
15 Boiler Filling:
a. Open drains and vents of economiser, bottom header, superheaters & reheater.
b. Open separator vent,
c. Open MS line, RH line, MSV, GV, RSV&IV drains valve.
d. Recommended fill water temp for cold fill is 40 to 60°C.
e. The rate of water fill-up should be controlled to < 100 TPH.
f. Boiler fill time should be more than two hours.
g. Closely monitor water level in separator water tank

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h. Maintain water level in separator between 7000 mm to 15000 mm

16 Starting Boiler circulation pump ( BCP ):

a. BCP is a submersible pump. Prime motor and pump cavity with boiler fill pump.
b. Line-up BCP cooling water system with CCCW system
c. Start BCP bearing and winding cooling pump
d. While staring the BCP separator level will go down below trip value. So before starting
it, fillup separator to maximum value i.e. > 15 M.

17. Boiler Flushing guidelines:

a. Cold flush the boiler through BFP-> Economiser -> WW -> Separator Tank ->Flash
tank ->CW system until iron content in water has reduced < 500 ppb at separator
outlet.
b. Continue cold flushing the boiler water through BFP-> Economiser -> WW ->
Separator Tank -> Flash tank -> HW, until iron content in water has reduced < 200
ppb at separator outlet.
c. BCP can be started now and boiler can be light up now. Iron content will again
increase on boiler light up.
d. Hot flush the boiler water through BFP-> Economiser-> WW-> Separator Tank ->
BCP -> Flash tank-> HW, until iron content has again reduced< 200 ppb at
separator tank outlet.
e. Stop flushing now.

Note: Upto 30% load from now, maintain total flow through economizer > 700 TPH
( BFP + BCP flow ). Else boiler will trip.

17 Commission Generator seal oil system:

a. Line up all local operation for Air side & H2 side seal oil system.
b. Start one AC Air side seal oil pump & put others pumps on backup.
c. Start one H2 side seal oil pump & put others pumps on backup.
d. Ensure seal oil pressure>6Bar
e. Start vapour extraction fan and put the other fan on backup.

18 H2 filling Procedure (FOD):

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a. Open H2 vent to atmosphere.

b. Fill up CO2 to generator at 0.2 kg/cm2 pressure & expel air to atmosphere until 95%
purity of CO2 in air is achieved.
c. Fill up H2 to generator at 0.2 kg/cm2 pressure & expel CO2 to atmosphere until 98%
purity of H2 in CO2 is achieved.
d. Increase generator H2 pressure to 3.00 kg/cm2 up to 300 MW load
e. After 300 MW load raise H2pressure to 4 kg/cm2.

19 Commission generator stator cooling water system

a. Line up field operations (FOD).

b. Fill up stator cooling water tank to 80%.
c. Open manual discharge valve of both stator water cooling pump and next open
manual inlet valves.
d. Start one stator cooling water pump & put another pump on back up.
e. Ensure water flow of 110T/hr, pressure 0.35Mpa & Gen outlet temp> 47 C.

20 Fuel oil system line-up:

a. Ensure sufficient oil stock in LDO & HFO tanks.

b. Ensure Auxiliary steam header is charged with neighbour / auxiliary boiler.
c. Line-up LDO and HFO system:
a. Open the suction & discharge valve of LDO & HFO pump (FOD).
b. Open the Aux. Steam to HFO heater & condensate drain valve (FOD).
c. Start HFO pumps and put fuel oil in short recirculation, and then in long
circulation
d. Start LDO pumps and put fuel oil in short recirculation &then in long
recirculation up to firing floor (After purge over).
e. Maintain LDO, HFO discharge pressure at 3.0MPa and no leakage is
observed
f. Perform following local operations;
a. Open LDO tank fill up valve
b. Open LDO tank discharge valve
c. Open surge tank FWD RC valve

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d. Open LDO RC valve-1

e. Keep surge tank ULD RC valve closed
f. Open HDO tank fill up valve
g. Open HDO tank discharge valve
h. Open surge tank FWD RC valve
i. Open HDO RC valve-1
j. Keep surge tank ULD RC valve closed

21 Water System Line Up:

a. Ensure supply steam to deaerator. Ensure that Deaerator temp does not
increase >1.5°C / min.
b. Put CEP in recirculation. Keep path clear up to Deaerator.
c. BFP line up:
a. Line up the field operation for M BFP lube oil system.
b. Start the auxiliary oil pump of MBFP.
c. Ensure the scoop position is minimum.
d. Open the booster pump inlet valve.
e. Start BFP in recirculation. Min flow through BFP should be 400 TPH. Keep
path clear up to Separator.

22 Air & Gas Path line up:

a. Fill up Bottom ash hopper with water & fill up sealing trough with water.
b. Open all air & Gas path dampers (Not ID & FD fan inlet &outlet ).
c. Start Air pre heater:
a. Ensure that lube oil tank oil level & temperature are OK.
b. Establish lube oil cooling. (for lubrication of support bearings, gears and
bearings)
c. Start APH electric main motor keep Auxiliary motor on stand by
d. Ensure that it picks up speed smoothly.
e. Ensure that there is no noise from any rotating object.
f. Ensure APH speed 1.5RPM
d. Open all Sec air dampers> 50%
e. Ensure the lube oil system of ID, FD, & PA fan is running.

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f. Start one I.D. fans and regulate furnace draft bet -100 to -150 Pa.
g. Start one F.D. Fans and regulate furnace draft around -30 to -50 Pa.
h. Start second ID fan then FD fan.
i. Regulate Wind box to furnace differential pressure around 450 to 640 Pa
j. Start Scanner air fan and furnace flame TV
k. Maintain air flow > 30% but < 40 % before light up and furnace pressure
stabilized at -50Pa
l. Open LTSH side gas dampers to 70% and PRH side gas dampers to 50%(
Total will be always = 120%). Min possible opening of each is 30%.
m. Put stand by lube oil pumps in interlock
n. Observe ID, FD fans for vibrations, bearing and winding temperatures

23 Line up APH soot blowing line from Aux. Steam header and start APH soot blowing
before boiler light up. Keep it on until oil firing is there.

24 Ensure HP/LP bypass system is normalised

25 Establish lube oil system for TDBFP A & B with stand by lube oil pump in interlock

26 Purging of Boiler:

a. Ensure following primary conditions are satisfied ( If unsatisfied then purge

is required again )
I. No MFT Condition
II. All oil burners oil valves shut
III. Oil Trip valve shut
IV. All mills off
V. All mill discharge valves closed
VI. All coal feeders off
VII. No PA Fan is in service
VIII. No flame / Furnace fire not detected
IX. Any ID/FD fan running
X. Furnace Pressure OK
XI. All Mill inlet hot and Cold air damper closed
XII. Maintain air flow > 30% but < 40 %

b. SADC dampers in purge position ( > 50 % open )

c. Furnace pressure not Hi Hi nor Lo Lo

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d. Both APH running

e. When all above conditions are satisfied purge ready indicator will glow.
f. Press purge start button and wait for 300 sec (5 min).
g. After 5 min, purge over indicator will glow.
h. MFT/ OFT will reset automatically now.

27 Final Checks before Light –Up

a. Boiler cold flushing is completed and Iron content < 200 ppb
b. All protections are checked and functional. All auto loops are functional.
c. Wind box SADC (fuel, aux, air and SOFA) are functional
d. All flame scanners are healthy
e. All drains and vents are in light up position
f. BCP and other auxiliaries are running normal
g. All boiler metal tags are reading

28 Boiler Light up:

Perform LDO, HFO leak test. If leak test is OK, go for light up.

a. Ensure that fuel oil system is in recirculation up to firing floor.

b. Light up boiler with A elevation LDO guns
c. Observe the flame condition locally as well as on surveillance television
d. Do not put ESP in service during oil firing.
e. Put APH soot blowers in continuous operation during oil firing.
f. The firing rate should be controlled slowly enough and water wall temperature
increasing rate is recommended less than 1.5°C/min
g. Put C elevation LDO guns in service
h. At 0.2 MPa separators pressure close separator vents and open MSSVs.
i. At 0.5 MPa separator pressure close super heater drains & vents but keep start up
vent (PCV) open.
j. Mill can be taken in service only when
i. Furnace temp is > 500.C.
ii. AHP outlet air temp is > 250.C
iii. Hot PA temp >150.C
k. HFO burner can be put into service if

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i. Furnace temp. more than 250˚C ( for cold start-up) OR

ii. APH outlet hot air temp is >125˚C ( for hot start-up)
l. Charge Aux steam on unit when MS pressure is > 0.5 Mpa and temp >300.C

29 Turbine gland sealing and vacuum rising:

a. Close the vacuum breaker valve
b. Start vacuum pump; ensure vacuum rises to -43 kpa.
c. Ensure that turbine is on barring gear
d. Ensure Gland steam condenser is taken in service from water side
e. Start gland steam exhaust fan.
f. Charge Aux. steam to Gland steam line
g. Seal the glands of turbine from Aux. steam header
h. Maintain HP IP turbine gland seam pressure to 35Kpa and temperature at 270⁰C and
LP turbine gland steam pressure same with temperature 180⁰C
i. Charge gland steam spray line to control temperature.
j. Ensure vacuum is < -93 kpa after gland steam is supplied.
k. Ensure that gland seal steam temp & turbine shaft temp diff is < 110°C

30 Warm-up operation

Start warm up operation when separator pressure is reached to 1.0 Mpa.

a. Open LP turbine exhaust hood sprays.
b. Ensure that DEH and Bypass oil system is in service and oil pr is adequate ( >
13Mpa)
c. Manually open IP/LP bypass valve by 5% & then open HP bypass valve by 5%
d. Close start-up vent (PCV) of boiler and put it on auto.

31 Turbine bypass / HP,LP bypass operation:

a. Ensure that separator pressure has reached 6.0 MPA

b. Open HP bypass valve so as to maintain MS pressure < 5.6 Mpa.

c. Simultaneously open IP/LP bypass valve so as to maintain HRH pressure

to 1 Mpa

d. Open HP bypass spray valve so as to maintain HRH temp 300°C

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e. Open LP bypass spray valves so as to maintain LP bypass steam temperature is

< 90°C
f. Do bypass operation until IP inlet pressure is > 1Mpa & temp is min 300°C but not
exceeding 430°C (56°C above saturation temp).
g. Continue bypass operation until steam iron content is < 50 ppb and silica content is
< 30 ppb

32 Take more oil gun in service and raise the steam parameters to the desired limit for
Turbine Rolling

33 Ensure Furnace pressure, Air flow, Feed flow are normal, All auxiliaries running and its
parameters must be within controlled limit of operation

34 Turbine rolling:

A. Reset / Latch the turbine

Conditions for turbine latch

a. HP & LP differential expansion, axial displacement, HP & IP & LP up and

down differential temperature, eccentricity, and differential temperature of
inner & outer wall of steam chamber are in limited range.
b. Main steam pressure: 4.0 Mpa, temperature: 340°C
c. Reheat steam pressure: 1.0 Mpa, temperature: 300°C
d. Main and reheat steam must have >56°C superheat degree.
e. Condenser vacuum at HP & LP side < -65KPa
f. Eccentricity < 75 micron
g. Lubrication oil temperature is between 38 to 42°C
h. Lubrication oil pressure: 0.1 to 0.18 Mpa.
i. Turbine turning gear on, speed 4 RPM
j. DEH oil pr. Should be >13 MPa
k. LP cylinder exhaust hood water spraying valve is open / auto , hood temperature
<80⁰C
l. Press ‘LATCH’ button, ensure that GV opens 100% & RSV opens 100%.

B. Roll the turbine with HP & IP turbine both

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a. Rolling is done through HP & IP turbine combined.

b. Initially speed is regulated by MSV ( for HPT ) & IV ( for IP turbine )
c. Open HP exhaust steam to condenser valves by 20%.
d. Control temperature of HP exhaust steam to condenser by 60°C with spray
valves.
e. Press run button
f. Press auto / manual button & put operator auto ON
g. Give turbine target speed as 500 rpm at rate of 100 rpm/min and press
GO.
h. Check for any abnormality, noise or any vibration of turbine
i. Trip the turbine at 500 rpm for friction test ( In case of cold start up only ).
Verify that no abnormal noise from bearings / casing gland seals etc and
observe that MSV, GV, RSV & IV closed perfectly.
j. Latch / Reset the machine and again raise the turbine speed to 500 RPM
k. Raise the speed to 2000 rpm at rate of 150 rpm/min.
l. Soak the turbine at 2000 rpm for 150 min or till turbine supervisory
parameters comes within control.
m. During critical speed carefully observe bearing vibrations. Don’t hold the
acceleration during this speed range. (650 to-850rpm, 1550-to 2150 rpm).
Ensure that speed rise rate during critical speed becomes 300 rpm / min
automatically.
n. Give open command to CRH NRV. It will release the force closing of
valve. NRV will automatically open when HP exhaust pressure is > CRH
pressure.
o. Main steam temperature slowly slide to 380, reheated steam temperature
slowly slide to 335. Main steam temp can increase to 430⁰C, but the
temperature rise rate should not be > 0.99°C/min.
p. Charge LPH 5, 6, 7 & 8
i. Ensure that heaters are charged from water side first.
ii. Then commission drip cascade system.
iii. Open vent to condenser ( FOD )
iv. Charge from steam side.
q. Raise the turbine speed to 2900 rpm at rate of 300 rpm/min

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r. Change over from MSV control to GV control ( for HPT ) at 2900 rpm.
s. Raise speed to 3000 rpm at rate of 30 rpm / min
t. Carefully monitor following parameters

i. Bearing vibrations
ii. Bearing temp
iii. Axial shift
iv. Differential Expansions
v. Condenser Vacuum
C. Ensure MOP discharge pressure is 2.2 Mpa & Suction pressure is 0.26 Mpa,

stop AC lube oil pump, ensure that barring gear motor & jacking oil pump

stops on auto, otherwise stop them manually and put them on interlock.

D. Carry out turbine following protection test.

i. ETS oil pressure low / high {For Emergency Trip System (ETS)}.
ii. DEH oil pressure low
iii. Lube oil pressure low
iv. Vacuum low
v. Oil injection test ( Spray test )/( Mech over speed )

35 Synchronization:

a. Ensure H2 pressure is 0.3Mpa. It will automatically rise with temp /

load. At 660 Mw rise it to 0.4 Mpa.

b. Ensure that H2 purity is > 98%

c. Ensure Speed > 2970 rpm

d. Ensure that GCB isolators are closed and Earthing isolators are open.

e. Ensure supply of AVR panel in ON and Remote/Local selection in

Remote

f. Close FCB from DCS (ECS Menu-synchro permissive)

g. Ensure Excitation is on AUTO in DCS

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h. Start Excitation from DCS

i. Ensure rated Generator terminal voltage ( Uab, Ubc&Uca ) is

achieved ( 19.50 KV to 20.00 KV)

I. Auto synchronization procedure

a. Enable “Permit to DEH” from synchronization page.

b. Press “Auto synchro ON” from DEH control page
c. Press “Start synchro command” from synchronization page.
d. Wait till GCB close.

II. Manual synchronization procedure

a. Put switches 1 in manual mode at synchro scope local panel

b. Enable Permit to DEH from DCS
c. Match the system frequency by raising or lowering TG speed (±0.15 Hz )
d. Match the system voltage by raising or lowering excitation (±5 % )
e. Match Phase Angle ( ±30°). When this condition is match, rotating GREEN
LED will turn into RED colour and another RED LED will glow (pass)at centre
of synchroscope.
f. Push GCB close button at synchro scope panel & Ensure closing of GCB
g. After ensuring closing of GCB (unit synchronized) make both DC supply of
synchro scope panel OFF
On synchronization change feedback to MW loop from DEH>>Feedback>>MW
Loop>>IN

36 Load Raising:

a. Take 33 MW (5%) load immediately to prevent reverse power.

b. Soak for 30 min at 33 MW (5% of rated load). During this period, maintain steam
temperature, pressure stability. Temperature rising rate should not be more than
110°C/hr
c. Check and make sure that vibration, differential expansion, absolute expansion,
axial displacement and metal temperatures of all bearings are normal, lubricating
oil pressure, bearing returning oil temperature and EH oil pressure are normal.

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37 Start first Pulverisers:

a. Ensure that both PA fans are working and hot PA header pressure is adequate
and hot PA air temp is > 150°C
b. Ensure APH outlet hot air temp > 250.C
c. Ensure Furnace temp > 500.C
d. Start seal air fan
e. Supply sealing air to mill & compressed air to mill discharge valves.
f. Start lube oil pump
g. Ensure that all oil burners of mill elevation are in service
h. Open Cold air gate. Open cold air damper by 5-10%
i. Open Hot air gate. Open hot air damper by 5-10%
j. Open 6 mill discharge valve ( MDV )
k. Raise mill discharge temp between 60°C to 80°C
l. Maintain mill air flow ~ 55 to 60 THP
m. Ensure all mill permissive are available.
n. Start mill
o. Open feeder discharge gate
p. Ensure that feeder all permissives are available
q. Start feeder
r. Open bunker discharge gate
s. Maintain mill discharge temp ~ 77.C with CAD
t. At low mill load, maintain mill air flow 2 times of coal flow. At full load of mill,
air flow should be 1.5 times of coal flow. Use HAD for flow control.
38 Roll both TDBFP with aux steam after synchronization.
a. Establish lube oil system for TDBFP A & B
b. Reset the alarm & then the TDBFP on the TDBFP control Page
c. Ensure aux steam pressure > 0.6 MPa
d. Open the booster pump suction valve.
e. Open recirculation valve
f. Close discharge valve.
g. Put the TDBFP operator in Auto mode & initially give a set point 1000 RPM @
150 RPM/ Min
h. After 10 Min soaking increase the speed to 2000 rpm @ 200 rpm/ min
i. Check the discharge pressure at the outlet of TDBFP
j. Increase the speed to 3000 rpm @ 300 rpm/ min
k. Keep running the TDBFP in recirculation till 30% load
l. At load 220 MW ( 30 % ) load, CRH pressure will be sufficient to take load of
TDBFP.
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m. Raise TDBFP speed to @ 5000 rpm and observe discharge pressure.

n. When TDBFP discharge pressure is equal to the running MDBFP, open TDBFP
discharge valve.
o. Raise TDBFP speed as desired.
p. When load is 525 MW (80 %) changeover steam from CRH to 4th extraction.
q. At 80% load start loading 2nd TDBFP and off load MDBFP.
r. Stop MDBFP

39 Monitor and control level of separator throughout the load raising. (As you add fuel the
level will change because of more heat input to boiler. Control the level by appropriate
addition of water through BFP and BCP). This will go on till load increases more than
180MW or 30%. The total feed flow through BFP +BCP must be more than 700TPH.

40 Keep watch on BTG parameters and control as necessary.

41 Observe that HP outer casing top & bottom temp diff < 50°C. HP inner casing top &
bottom temp diff < 35°C

42 Boiler pressure rise rate should not be > 0.1 MPa / min

43 Take 2ndmill in service at load approx. 100MW.

44 When boiler load reaches to 30% BMCR, the operation mode changes from
recirculation mode to once through mode;

a. At above 25% BMCR closely monitor BFP as well as BCP flow

b. BCP flow to be adjusted looking at the separator level while the same flow to be
compensated by BFP. In turn keep total feed water flow through Economizer
constant.
c. The Separator level will go to zero with no water in the separator
d. This will take place when boiler steaming rate becomes equal to feed water flow
rate.
e. Slowly close the BCP discharge regulating valve looking at the separator level
f. Control the fuel firing so that separator temperature doesn’t rise fast.
g. Keep sufficient flow of feed water through BFP around 700 TPH
h. BCP will run in recirculation for some time. During this time ensure fuel flow
doesn’t reduces.
i. BCP will trip on separator level Low Low

45 Increase load further

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46 Take HP heaters in service at load 200MW sequence:

Charge HPH 3 then HPH 2 & then HPH 1

1) First charge from water side

2) Ensure that HPH 3 extraction pressure is higher than Deaerator
pressure
3) Line up from drip side
4) Then open extraction steam.
5) Observe that axial shift is normal

47 Take 3rdmill in service at load approx. 200MW.

48 Take 1st TDBFP on load at 200 MW and reduce load on MDBFP

To put the BFP in Auto mode select the Remote in command & put TDBFP controller in
auto mode from feed water control face plate from the DCS
49 Increase load further@ 3MW/Min, monitor all critical parameters and control
appropriately

50 Withdraw out oil support if load is >60%

51 Take ESP in service if no oil firing is existing and APH discharge temp > 120.C

52 Change over Gland steam to CRH steam

53 Monitor Turbine vibrations, bearing temperatures, TSI parameters, boiler metal

temperatures and note the values. Address any abnormality if found.

54 At 400 MW load, take 5thmill in service. Adjust feed flow and air flow according to fuel

55 Increase load up to 500MW by take 6th mill in service

56 At 80% load change over TDBFP steam from CRH to 4th Extraction

57 Take 2nd TDBFP on load at ( 80 % load ) 525 MW and stop MDBFP. Ensure that feed
flow is equally shared by both TDBFP’s

57 Change Aux. steam source to extraction 4 at Pr>0.7Mpa

58 Monitor Turbine vibrations, bearing temperatures, TSI parameters, boiler metal

temperatures and note the values. Address any abnormality if found.

59 Reach load to 660MW. Stabilize all the parameters as per standard given by the supplier

60 Ensure water quality parameters are in control including SiO2 <=15ppb, Na<=5ppb,
Fe<=10ppb, Cu<=3ppb.

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Safe Shutdown Procedure of 660 MW Unit

The following procedure is for normal shutdown and is based on the assumption that unit is
operating at full load on automatic control. The intention is to reduce the pressure to zero
and cool the boiler completely.

1. Stop coal feeding to bunkers in such a way that top mill bunker get empty first and
lower mill in last ( This is to avoid rat hole and spontaneous combustion in bunkers
in case of long shutdown )
2. Be prepare for auxiliary steam from neighbour boiler.
3. Carry out an overall check of fuel oil system before boiler shutdown. All the oil
burners shall be put into service once to check whether it is normal and in good
standby status. The fuel oil storage quantity shall meet the requirement of boiler
shutdown.
4. Before unit shutdown, carry out trial run of AC / DC lube oil pump, Seal oil pump &
jacking oil pump.
5. Reduce firing rate by cutting the coal flow in top mills and allow the pressure to drop
with the reduction in load.
6. Reducing the load to 660MW~450MW at 12MW/min according to the turbine-boiler
sliding shutdown curves.
7. During load reducing period, pay attention to separator outlet steam temp
8. Steam temperature control, combustion control and feed water control may be left on
automatic mode until the point is reached when better control can be obtained on
manual mode.
9. Continuously watch furnace pressure, sec airflow and oxygen content in the flue gas.
10. Main steam pressure drop variation rate shall not be higher than 0.5 Mpa/min.
11. At 540MW load, watch that if unit changeover from sequential valve mode to single
valve mode.
12. When the unit load is 480MW, Soot blowing of all heating surfaces shall be carried
out once.
13. Reduce coal flow in top mill and ensure ignition permit is available. Start oil firing if
ignition energy not available. Stop coal feeder after it bunker is empty. Close the hot
air and allow the mill temp to drop below 45.C then trip the mill. ( Mills should stop
from top to bottom in order.). Stop secondary air to this mill as per SADC logics.
14. Reducing load from to 450MW to 300MW as per curve.

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15. At 400MW, check if main turbine gland sealing pressure is normal. If 4th ext / CRH
steam pressure is not adequate then charge over to aux. system.
16. At 350MW, Stop one more feeder and then stop the pulveriser after it bunker is
empty.
17. At 330 MW load stop one TDBFP, keep watch on separator outlet temp.
18. At 300MW, ensure main steam temperature is 520℃, reheat steam temperature is
540℃.
19. Reduce load from 300MW to 80MW at the rate 9MW/min
20. At 350MW, start oil firing for flame stability.
21. Stop ESP.
22. The air preheater shall put into continue soot blowing mode.
23. At load 220MW load, gradually increase the feed flow and ensure that water level
start building in separator. Start BCP. Economizer inlet flow should not go <700T/H.
24. Extraction 4 pressure will not be sufficient for Deaerator ( BFP suction ). Supply
cautioning steam to deaerator from aux steam header.
25. Take out HP heaters from service.
26. At 220 MW changeover from TDBFP to MDBFP.
27. Change over from main valve to 30% FCV.
28. Stop one ID and FD fan.
29. During reducing the load, notice that the all HP, LP heaters water level should be
normal.
30. Changeover auxiliary steam from unit to neighbour boiler or auxiliary boiler.
31. At 180MW stop one more pulveriser and ensure that bunkers are empty. Ensure oil
firing is there.
32. At 120MW ensure main steam temperature is 480℃ & HRH temperature is 480℃.
33. Put LP Turbine Exhaust hood spray at 130 MW load. Ensure LP cylinder exhausting
temperature is not higher than 67℃.
34. At 66MW, ensure main steam temperature is 450℃, reheat steam temperature is
450℃.
35. Reduce load from 66MW to 33MW.
36. At 33 MW load, stop last pulveriser and ensure that adequate oil firing is there.
Ensure bunker & pulveriser are empty
37. Ensure air flow does not go below 30%

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38. Start HP, LP bypass operation to maintain MS & HRH pressure & temp.
39. Start AC lube oil pump.
40. Trip the Turbine at 33MW; watch the generator circuit breaker opens on low forward
power relay. Ensure generator field breaker is open.
41. After Generator disconnected, check if auxiliary power 11KV & 3.3 KVC are
normal.
42. Ensure GV, MSV, RSV, IV are fully closed.
43. Ensure all turbine drain valves, MS line strainer drain & CRH drain open on auto.
44. When the rotating speed reaches 1200 RPM, check if jacking oil pump automatically
start, or manually start one of them, check jacking oil main and all bearing jacking
oil pressure is normal.
45. Note the casting down period. It should be >60 min in vacuum condition & > 40 min
in case of no vacuum condition.
46. When turbine speed comes to 0, barring gear starts on auto. Else engage it manually
and start motor.
47. Gradually cut off oil firing from top to bottom elevations
48. Trip Boiler & perform purge by 30% MCR air flow for 5 to 10 min.
49. Ensure no pressurised drain goes to condenser.
50. Seal oil system can be stopped when H2 & CO2 is expelled.
51. During operation of barring gear, lubrication oil temperature should be within
38~42℃.
52. Watch the upper& lower cylinder temperature difference of turbine casing. It should
not be >50°C. If find upper, lower cylinder temperature difference increases rapidly,
should find out the reason of water entering or cold steam entering. Cut off the
source and open drains.
53. When the HP 1st stage inner wall temperature is above 350℃, barring gear cannot be
stopped for more than 3min. If needed stop for 1min and then continue run it for 10
min.
54. When HP cylinder 1st stage inner wall temperature is above 220℃, if needed for
emergency work, stop barring gear and turn it by 180° every 30 min.
55. When the inner wall metal temperature of HP cylinder is lower than 150℃, stop the
barring gear. ( This cooling process may take 6 to 7 days ) When the rotor stops, stop
the jacking oil pump. After 8 hours of stopping the barring gear, we could stop
supplying lubrication oil.
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56. Make a record of boiler expansion values from full load to no load.
57. Make sure that the desuperheater’s isolating and regulating valves, of superheater
and reheater are closed.
58. Make sure that fuel oil trip valve and burner inlet valve are closed.
59. When main steam pressure is reaches 2.0 MPa
a. Stop HP & LP bypass operation.
b. Close boiler stop valve.
c. Open the air vent at FSH, the air vent at LTSH outlet & inlet, and the air vent at
roof superheater and reheater.
60. Kill the vacuum by opening vacuum breaker, stop vacuum pump.
61. Stop CTID fans
62. When vacuum drops below -0.1 kg/cm2, Stop gland seal steam.
63. When LP turbine exhausting temperature is lower than 50℃, stop the last CW pump,
And OCCW pumps
64. When exhaust hood temp is < 45.C and there is no condensate user, stop CEP.
65. Cool down the boiler by operating one set of ID & FD fans
66. At 0.2 Mpa pressure open separator vents.
67. Boiler cools down by absorbing latent heat from water wall tubes and venting the
steam. Keep running BCP. Maintain the separator level with BFP.
68. At 0.1 Mpa pressure hot drain the boiler. BCP will trip on separator level low. We
can stop BFP now.
69. At APH inlet gas temp 120.C, hot wash the APH with service water line. This will
dislodge the deposits inside APH.
70. After the gas temperature at air preheater inlet is reduced to below 120℃, the air
preheater can be stopped.
71. After gas temperature at furnace outlet is reduced to 50℃ or below, the ID fan, FD fan
& flame scanner air fan can be stopped.
72. We may not stop following systems during shutdown.
a. CCCW system - needed for service air compressors.
b. Service air compressors - if required for shutdown job.
c. Stator cooling system ( We maintain generator winding temp @ 50.C to avoid
moisture condensation, if needed start the heater in winter )
d. Generator Seal oil system - if there is no need to expel H2.

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Important parameters of 660MW Unit

Sr. No. Parameter Unit Value @ TMCR

1 MSP MPa 24.2

2 MST °C 566
3 RHP MPa 4.0
4 RHT °C 566
5 MS Flow TPH 1984.3
6 RH Flow TPH 1660.3
7 CRH Pressure MPa 4.04
8 CRH Temp °C 318.7
9 Condenser Vacuum KPa 89.9
10 Hotwell temp °C 46.1
11 CEP Discharge pressure MPa 3.5
12 Deaerator pressure MPa 0.91
13 Deaerator Temp °C 176.1
14 MDBFP discharge pressure MPa 30
15 Economizer inlet temperature °C 280
16 Hotwell level mm 1000
17 Deaerator level mm 2800
18 CW inlet temperature °C 32
19 CW outlet temperature °C 41
22 Air flow TPH 2150
23 Windbox DP KPa 0.8
24 Furnace Pressure Pa -50
25 Total Coal flow TPH @475
26 Mill DP KPa 3.5
27 Mill discharge temperature °C 80
28 Seal air DP KPa >2.5
29 PA Outlet pressure KPa 8
30 Instrument air pressure Kg/cm2 7
31 Service air pressure Kg/cm2 7
32 Lube oil pressure MPa 0.18
33 Jacking oil outlet pressure MPa 14
34 Barring speed RPM 4
35 EH oil pressure MPa 14.4
36 Generator H2 pressure KPa 420
37 Stator water inlet temperature °C 380
38 Seal oil pressure KPa 620
39 Stator water flow TPH 100
41 Flue exhaust temperature °C 120
42 APH Speed RPM 1.5
43 Aux. Header pressure MPa 0.9
44 Aux. Header temperature °C 300
45 HP/IP Gland sealing pressure KPa 70
47 HP/IP gland sealing temperature °C 280
48 LP gland sealing pressure KPa 70

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49 LP gland sealing temperature °C 180

Turbine Cold Start up Turbine Curve

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Boiler Cold start-up curve

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Boiler Warm Start-up Curve

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Heat & Mass balance at 660MW load with 0 % Make up

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Turbine Safe Shutdown Curves

Thank you

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Common Abbreviations
Sr. No. Acronym Description Sr. No. Acronym Description
1 P Power generated 28 Q Reactive power
2 MSP Main Steam Pressure 29 RHP Reheater Pressure
3 MST Main Steam 30 RHT Reheater Temperature
Temperature
4 MSF Main Steam Flow 31 FDF Forced draught fan
5 FWF Feed Water Flow 32 PAF Primary air fan
6 PRDS Pressure Reducing 33 IDF Induced draught fan
De-superheater
7 ESP Electrostatic 34 BCP Boiler circulation
precipitator pump
8 APH Air pre heater 35 OP Open
9 MFT Main fuel trip 36 CL Close
10 OFT Oil fuel trip 37 HAG Hot air gate
11 SAF Seal air fan. 38 CAG Cold air gate
12 MSV Main stop valve 39 TV Throttle valve
13 HP CV High pressure 40 RH CV Reheater control valve
control valve
14 EH Electro-hydraulic 41 RSV Reheater stop valve
15 MD-BFP Motor driven boiler 42 TD-BFP Turbine driven boiler
feed pump feed pump
16 TD-BFPT Turbine booster 43 MIV Motorized isolation
pump valve
17 CWP Circulating water 44 OCCW Open Circuit cooling
pump system
18 CCCW Closed circuit 45 FSSS Furnace safeguard and
cooling water supervisory system
19 TSI Turbine supervisory 46 CBD Continuous blow
Instrumentation down
20 LRSB Long retractable soot 47 IBD Intermediate blow
blowers down
21 LPT Low pressure turbine 48 EOP Emergency oil pump
22 CEP Condensate 49 CPU Condensate polishing
extraction pump unit
23 TOP Turbine oil pump 50 MOP Main oil pump
24 CTP Condensate transfer 51 RC Recirculation valve
pump
25 GSC Gland steam 52 DEH Digital electro
condenser hydraulic system
26 CTF Cooling tower fan 53 PHE Plate heat exchanger
27 HPT High pressure 54 IPT Intermediate pressure
turbine turbine

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