A Presentation On :-

Unit Start-Up Procedure

(Cold, Warm & Hot Start-Up)
600 MW UNIT

By:-
Hemant Durandhar
(Operation 4X600MW)
 Unit Start-Up Condition
1) For The Cold Start-Up condition of the unit when the metal
temperature of the HP turbine Casing inner surface is less than
150C. Normally this condition comes if the unit is under
shutdown for more than Five days.

2) For Warm Start-Up condition the metal temperature of the HP

turbine Casing inner surface between 150C to 350C.

3) For Hot Start-Up condition the metal temperature of the HP

turbine Casing inner surface is greater than 350C.
 Boiler

Economiser

2X10
15 2x 2x
8 8
HP IPT LPT A LPT B
T
5 6 5 6
7 7 7 7
3 8 8 8 8
1 LPH -
RH 1A LPH -1B

Condenser
HPH Condenser
Deaerator
SYTEM

EXT From
CRH
(MD BFBP
1x50%)
FC
S

TDBFP
2X50%

CEP
3x50
1994 TPH
%
GSC

CPU
1482 TPH
LPH -2 LPH -3
 Pre-Checking and Activities in BOP area before Unit Light-Up:

1. Ensure all Required permits to work (PTW) have been returned and take trial all
required equipments.
2. Start at least one ACW Pump.
3. Ensure line up of compressor cooling water supply through running ACW.
4. Ensure at least one instrument compressor and also one service air compressor are
running.
5. Fill-up CW pipe lines and fill-up condenser water box for air release from ACW
water.
6. Start CW pumps as per requirement like as during vacuum pulling.
7. Ensure Emergency DG diesel tank level is adequate and its trial is already taken.
8. Ensure Fire fighting system should be ready.
9. Ensure all ESP fields manhole closed and CERM & EERM are in service.
10. Ensure ESP all hopper heater ON, also support and shaft insulator heater also
should be ON.
11. Ensure DM plant is informed about boiler light up.
12. Ensure LDO tank level is ok (>3000mm) and at least one LDO pump is running for
maintain 12 ksc header pressure and short re circulation CV is in AUTO.
 Unit Cold Start-Up Procedure:
Common Pre-Checking and Activities in BTG Area before Unit Light-
Up
1. All PTWs are returned and all maintenance activities checked also
men & materials are removed from all working area and
clearance from All Maintenance Departments for Unit light-up.
Please ensure that gagging of all safety valves is removed.
2. Availability of all Equipments is ensured and checking of
interlocks & protection of all equipments is completed.
3. Ensure all peep hole and manholes of boiler are closed.
4. Ensure at least one ESP pass available and also line-up all four
ESP pass.
5. Ensure Bottom ash hoppers & fly ash system is ready and lined
up.
6. Ensure Seal turf is filled up and cooling water line is also lined
up.
Common Pre-Checking and Activities in BTG Area before Unit Light-Up:
7. Ensure CST & DMCW O/H tank levels are normal.
8. DMCW 2 pumps (TG side) & one pump (SG side) should be started & ensure that
at least 2 PHE in TG & 1 in SG side are in service.
9. Ensure DMCW (TG side) lines are charged with initial filling & proper venting for
CEP, MDBFP, TDBFPs, GENERATOR, EXCITER, SEAL OIL COOLERS AND TG LUBE
OIL COOLERS.
10. Ensure DMCW (SG side) line charged with initial filling & proper venting for lube
oil coolers of boiler side are charged and start all LOP’s.
11. Ensure generator primary water cooling pump should be started its temp CV is in
AUTO. (Set pt=41°C)
12. Ensure DMCW (SG side) lines are charged of all coolers and respective
equipments.
13. Ensure BCW O/H tank is over flowed and ECW pump lined up.
14. Ensure at least one boiler fill pump and one DM make up pump is running.
15. Ensure APH service air line is charged for air motor.
16. Ensure TG & Boiler both side instrument air lines are charged.
17. Ensure Service air to oil gun charged.
 Common Pre-Checking and Activities in BTG Area before Unit Light-Up:

18. Start Boiler Fill Pump to Take Water in Boiler Drum and Deaerator Storage
Tank.
19. Fill up initially hotwell through DM make up pumps.
20. Boiler drum vents B1,B2,B28 & B29 are in open conditions.
21. Ensure boiler is filled up to adequate level (+100 mm) also checked in
local gauge glass.
22. Ensure started at least one BCWPs is running for correct water circulation
(during BCWPs starting at least two boiler drum vent are closed require.)
23. Ensure another BCWPs Pumps lined up condition.
24. All SH & RH drains and vents are in open conditions.
25. Eco recirculation MOV E15 is in open condition.
26. Ensure CBD and EBD lines all manual valves are in open conditions.
27. Both APH-A & APH-B are in service & Air motor trial is already taken.
Boiler Light-Up Activities
Before Unit Light-Up
 Pre-checks and Activities in BOILER side before Unit Light-Up:

 The line-up of all equipments is completed and are ready for starting.
 Ensure oil gun ready on all elevations.
 Ensure all sample lines are lined up and sample cooler is in service.
 Ensure all spray lines are lined-up condition.
 Ensure AC scanner fan is running and DC scanner fan trial is already taken.
 Ensure Burner Tilts at horizontal condition.
 Ensure Boiler expansion reading is already taken at cold condition.
 Ensure Boiler drum metal temp has been noted down.
 Ensure Furnace temp probe is working condition.
 Ensure all soot blowers are in home position.
 Ensure APH soot blowing initial line-up from air. (If APRDS not charge from
any unit).
 Ensure flue gas path available.
 Ensure All manholes & peep holes are in close condition.
 Ensure Cooling hose pipe of scanner should be connected (C&I checking).
Various Power System Charging :-
 Ensure Station bus supply is available and unit board power supply
should be charged from Tie to Station Bus.
 ALL POWER SUPPLY VIZ. 3.3 KV, 11 KV, 415V, 220V DC, 110 V AC,
AND 24 V DC SUPPLY TO THE RESPECTIVE SYSTEMS SHOULD BE
AVAILABLE.
 220 V / 24 V DC battery systems and UPS system Ok.
 Ensure power supply is available of all required equipments for unit
light up likes as ID fans, FD fans, PA fans, CEPs, MDBFP etc and also
respected LOPs.
 Ensure Excitation system is ready.
 After turbine resetting, reset GRP relays.
Turbine Light-Up Activities
Before Unit Light-Up
Pre-checking and Activities in TURBINE area side before Unit Light-
Up:
GENERATOR H2 & SEAL OIL SYSTEM: -
 Start one Seal Oil Pump.
 Ensure the availability of standby pump.
 Take trial of DC Seal Oil Pump.
 Ensure the power supply of both vacuum pump and start any
one of them.
 Start one BC Exhauster Fan and ensure the availability of
standby fan.
 Start charging Hydrogen and purge CO2 in generator.
 Ensure H2 pressure up to 3.5kg/cm2 and purity > 99% .
 Ensure Seal Oil System maintaining DP from 1.5 to 1.75
Kg/cm2.
 Ensure manual isolation valve of Generator & Exciter cooler
open.
Pre-Checking and Activities in TURBINE area before Unit Light-Up:

TG LUB OIL SYSTEM TESTING :-

1. All PTWs are returned and all maintenance activities checked.
2. Ensure TG side MOT, HPCF, TDBFP-A & B, HPBP, LPBP tank level adequate and
centrifuge in service.
3. Ensure Normalize power supply of all pumps.
4. Check at least one lube oil cooler in service.
5. Stop AC LOP & Check AC-2nd .
6. Stop both AC LOPs & then check DC EOP start now.
7. Drain Lube oil Pr. Switch, Check AC & DC EOP start on low lube oil pressure.
8. Normalize and take Pr. Switch in service.
9. Keep DC JOP SLC "ON" & AC JOP SLC "OFF“.
10. Stop AC JOP then check DC JOP will took start.
11. Keep AC JOP SLC "ON" & DC JOP SLC "OFF" .
12. Keep all SLC "ON" .
 Pre-Checking and Activities in TURBINE area before Unit Light-Up:-

LINE-UP OF BARRING GEAR :-

1. Start DC EOP & check the oil circuit for any oil leakage .
2. Start one AOP & Pump Disc. pr. >7.5Kg/cm2 & Lube oil header pr. >2.5
Kg/cm2.
3. Ensure SLC AOPs & EOP, "ON".
4. Start AC JOP , Lift oil pressure >155kg/cm2 .
5. Ensure SLC JOP "ON" .
6. Start one OVEF fan. Ensure the availability of standby fan.
7. Put TG Set on barring gear by opening barring gear solenoid.
LINE-UP HPCF Pumps :-
8. Start HPCF pump and SLC should be in ON condition.
9. HPCF temp. control valve should be in AUTO with set point of 52 °C.
 Pre-checking and Activities in TURBINE area side before Unit Light-
Up (CEP, MDBFP, TDBFPs etc)
 Ensure all lube oil system in healthy condition (all equipments).
 Ensure one CEP is running and maintain DEAERATOR level
(upto100 mm).
 Ensure MDBFP & another CEP lined up condition.
 Both TDBFPs lube oil pumps are running and their respective EOPs
trial taken.
 TDBFP-”A “ & “B” put on barring.
 MDBFP is ready to start.
 Ensure all drains are opened for MS, CRH, HRH, HPBP, LPBP, Gland
Steam, Extractions etc.
 Ensure all MAL drain should be open as per SLC logic.
 Ensure all OIL temp. control valves are healthy and are in AUTO.
 Ensure all chemical dosing systems are ready.
SIMULATOR
 To Start Boiler Light-Up Activities:-

 Ensure Before Boiler light-up TG rotor on Barring (check TG

list)
 Start both APHs from air motor after that electric motor.
 Start 1st ID Fan and ensure furnace pressure within limit (-5
to -6 mmwc)
 Start 1st FD Fan and ensure furnace pressure within limit (-5
to -6 mmwc)
 Maintain air flow up to 30% to 40% ( air flow between 750
to 770 ton/Hrs, Total air 2352 ton/hrs)
 Ensure SADC in manual and all dampers 100% open.
 Check all purge permissive are satisfied.
 PURGE the boiler ( 540 sec).
 After PURGE Complete Put Auxiliary damper control in Auto
Mode and check DP maintain according boiler load graph.
 BOILER PURGING:-
• FOLLOWING PURGE PERMISSIVES SHOULD BE SATISFIED BEFORE
PURGING.
 NO BOILER TRIP
 HOTV CLOSED
 LOTV CLOSED
 ALL HONV CLOSED
 ALL LONV CLOSED
 ALL PA FANS OFF
 ALL FEEDERS OFF
 ALL HOT AIR GATE CLOSED
 ALL AUX. DAMP MODULATING
 AIR FLOW>30% & <40%.
 ALL SCAN NO FLAME.
 MFT DPU not Frozen.
 BOILER
LIGHT-UP
 Boiler Light-Up Activities:-
1. Ensure all oil guns are cleaned before light-up.
2. Ensure ESP all hoppers insulator Heaters are ON.
3. Check oil gun should be in remote mode.
4. Ensure isolation valves of LONV and HONV should be open.
5. Check atomizing air valve in open position and maintain air pressure 7 kg/cm2
6. Open LOTV and maintain LDO pressure around 8 ksc.
7. Light up the boiler with 2 LDO guns in AB Elev.
8. After 30min take another 2 LDO guns in AB elev.
9. Check temp. of FG is raising, also checking BCWP cavity temp & Drum metal
temp starting increasing.
10. Control the firing so that drum metal difference for TOP & Bottom should not
exceed more than 50 °C.
11. Ensure temp. rise in metal temp of SH/RH is not more than 2 °C per minute
also Main Steam Temp rise not more than 5 °C per minute.
12. At drum pressure reaches >2 kg/cm2 then close all drum vents.
13. Start MDBFP and maintain drum level -50 mm if water level going high due to
water swelling, open CBD or EBD.
 Boiler Light-Up Activities:-
14. Ensure APH soot blowing initially done by air in every by half hour.
15. Take oil gun on CD elevation if temp raising is normal.
16. If drum pressure reaches >5 Kg/cm2 closed all the SH vent and ensure all
boiler side & TG side drains as well as start-up vent in open condition.
17. Charge the MS line Bypass valve by opening MSV-3, MSV-4, MSV-5 & MSV-
6.
18. Charge MS line MSSV by opening MSV-1 & MSV-2.
CHARGING APRDS SYSTEM:-
 If APRDS is not available then open MS to APRDS drain ASV-164 at APRDS
floor and Ensure drain is open to IBD tank.
 Charge LT PRDS header also and maintain its pressure 16 kg/cm2 and temp
as 210°C.
 Maintain the APRDS pr/temp around 16ksc/320°C.
 After APRDS charging APH soot blowing line charged from APRDS and
ensure at least APH soot blowing done in every one hour.
 Boiler Light-Up Activities:-
VACUUM PULLING & STEAM DUMPING:-
1. Start one CEP and establish flow through R/C.
2. Ensure Gland Steam supply control valve I/L Manual Isolation Valve closed.
3. Ensure Gland Steam supply control valve bypass motorized valve closed.
4. Ensure Gland Steam drain valves AS 139 open to Atm F/T.
5. Ensure Mal-81 Gland steam header drain open.
7. Open ASV-20 at APRDS gradually for heating.
8. Ensure Gland steam temperature before Gland steam supply CV > 180 deg.c
9. Ensure to Sealing water to vacuum breaker established.
10. Ensure to Vacuum breaker valve closed.
11. Ensure to Seal water level & flow in vacuum pump established.
12. Start vacuum pulling by starting all vacuum pumps (in cold rolling condition & hot rolling
condition First gland steam charge after that vacuum pulling.)
13. Maintain Vacuum > -0.4kg/cm2 . Close atmospheric drain of gland steam and divert those
to flash tank.
14. Start one Gland steam exhaust fan.
15. Open manual valve before gland steam supply CV & Ensure gland steam supply bypass
MOV valve should be closed.
16. Open Gland steam supply control valve gradually till gland steam header pressure reaches
to 350 mmwc .
17. Put the gland steam control in Auto mode with set point 450 mmwc.
 HP/LP Bypass Oil System Starting Procedure:-
1. Start HP bypass skid oil pump-1.
2. Check for HP bypass oil pressure rising.
3. Check for any abnormality in the pump.
4. If found and abnormality then stop the pump and inform TMD.
5. Start HP bypass recirculation pump and start its cooling fan.
6. Check for any oil leakage in the system.
7. Start LPBP Pump-1 & select Pump-2 as stand by.
8. Check for LP bypass oil pressure rising.
9. Check for any abnormality in the pump.
10. If found and abnormality then stop the pump and inform TMD.
11. Start LP bypass recirculation pump and start its cooling fan.
12. Start LP bypass skid regeneration pump.
13. Check for any oil leakage in the system.
 HP/LP Bypass Steam Charging Procedure :-

1. Open HP bypass warm-up line atmospheric line drains.

2. Open HP bypass warm-up line valves BPV - 3 & 4.
3. Open LP bypass warm up lines Drain valves HRHV 113 & HRHV 114.
4. LPBP Trip reset at vacuum > -0.7 kg/cm2.
5. HPBP Trip reset at vacuum > -0.7 kg/cm2.
6. HPBP warm-up completed (T>200 °C, Downstream temp of HPBP).
7. Check CRH pot drain manual isolation & its MOV valve in open
condition.
8. Ensure all MAL valves and their MOVs are in open condition.
9. Ensure SLC of MAL valves are in ON condition.
10. Now Open HP bypass and LP bypass slowly.
11. Check turbine speed, It should not raise.
12. Regulate HP/LP bypass manual or auto mode. (Final position: HP
bypass 50% & LP bypass full open).
13. Close start up vent & boiler stop valve drains MS 101 and MS 102.
 Protection OF HPBP/LPBP :-
HPBP Pr CV BPV-1 & BPV-2 will priority close if :-
 Condenser vacuum is < -0.7 kg/cm2.
 Turbine axial shift very high.
 TG Lube oil pr very low ( < 0.8 kg/cm2 )
 Downstream temp. of CV is >380°C
 TG shaft vibration very high.
LPBP will trip if :-
 Condenser vacuum <0.6 bar, or
 Condenser wall temp is > 90 deg.C , or
 HPSU emergency off or
 CF pump-1&2 protection off & position set pt. LPBP>-40 %.
 Water injection operated.
 Unit Light-Up Other Checking Activities:-
 HPBP temp control valves BPE-1 & BPE-2 with set point 330 °C put in auto and
observe that BD valve is opened when BPE-1 & BPE-2 opening >2%.

 Put LP Bypass CVs & Spray CVs in Auto mode.

 Close HPBP warm-up and LPBP warm up motorize valves.
 Charge Dearator pegging steam slowly-slowly from APRDS.
 Raise MS pressure up to 50 Kg/cm2 and MS temp as 350°C.
 Ensure at least APH soot blowing done in every one hour.
 Ensure Recirculation valve of ECO- bottom Ring Header is closed after drum

pressure reaching 40 kg/cm2.

 Again Ensure bottom Ash Hopper & Seal Trough is over
 Turbine Rolling Activities:

1. Wait to Fulfill the criteria X1 & X2 for opening ESV during HP/LP Bypass
system running.
2. Reset the Turbine protections in turbine protections graphics page and
ensure no ‘fault’ or ‘trip’ is being displayed on that page.
3. Reset generator Protection GRP relay.
4. Select the turbine in “EHG” mode from EHTC graphics page and check
“EHG selected” is being displayed.
5. Bring starting device to zero position this will cause generation of trip
oil, check trip oil pressure around 8 bar.
6. Bring Speeder gear to min position.
7. Raise the Starting device position to 42% and check HP turbine Stop
valve (ESV) is full opened.
8. Raise further Starting device position to 56% and check IP turbine IV is
full opened.
9. Further raise the starting device up to 100%.
10. Raise the Speeder gear up to 100%. This is will bring EHG in effect.
 Turbine Rolling Activities:

11. Maintain MS pressure=50 Kg/cm2 (Corresponding Saturation Temp=264°C), MS

Temp= 350°C.
12. Also maintain HRH pressure=12 kg/cm2, HRH Temp= 330°C.
13. Wait to Fulfill the criteria X3, X4 and X5.
14. Checking chemical parameters of MS and drum like as Silica, Phosphate,
Conductivity etc.
15. Ensure lube oil temp and control oil temp controlling systems are in AUTO and set
point is 41°C and 50°C respectively.
STARTING OF MILLS:-
16. Ensure Complete vacuum pulling before taking coal mill.
17. Ensure HP Bypass & LP Bypass system in service.
18. Start One PA Fan & establish PA header pressure >850 mmwc and at least two
mills CAG, & CAD should be opened to establish PA flow.
19. Coal available in bunkers.
20. Secondary air temp. should be above 180 °C.
21. Ensure furnace temp. Should be above 500 °C also MS temp. > 350 °C.
22. Line up for one mill (in cold light-up on AB elv. & hot light-up CD or Top elv.)
23. Check all mill conditions and keep other mills ready for start.
 STARTING OF MILLS:-
9. Ensure at least one seal air fan running and maintain seal header
pressure >1200 mmwc. Check all seal air systems are charged and Open
Mill cold air gate.
10. Check Tank Lube oil level is normal & LOP suction, discharge valves are
open.
[Link] lube oil pump (A or B). Ensure pressure & flow normal (Pr>3.5 Kg &
Flow >120 LPM).
12. Lineup cooling water to lube oil coolers.( DMCW supply, return valves are
open).
13. Open Tramp iron spout valve.
14. Check Mill Main Motor Breaker in service and in remote and Motor
protection relay is healthy.
15. Ensure burner inlet gate at all corners & pulverizer (Mill) discharge
dampers are in open condition.
16. Ensure all Permissive of mill are available and Start mill.
17. Open hot air gate. Open HAD & CAD to establish mill air flow 60-70 ton/hr
and adjust mill outlet temp 70 °C.
 Mill Starting & Other Activities :-
18. Ensure Feeder module is ON and Feeder selection is in Remote
(From feeder panel).
19. Open Bunker out let gate and Feeder inlet/outlet gates also open.
20. Start coal feeder.
21. Check Clean Out Conveyor is in ON position (on feeder panel &
Local).
22. Start second set of ID,FD & PA as per requirement.
23. Ensure Recirculation valve of ECO- bottom Ring Header is closed
after drum pressure reaching 40 kg/cm2.
24. Regulate HPBP to control MS pressure.
25. Take other mills in service as per requirement.
26. After establishing steam flow the drum level control transfer to 3-
element control.
27. ESP charge after APH O/L temp. reaches to 110 °C.
 Raising the speed up to 360 rpm (Soaking Speed):

1. Inform all concern persons about TG rolling (EMD/TMD/C&I).

2. Ensure HP turbine evacuation valve to condenser is closed.
3. HP evacuation v/v will be open at only turbine tripping and that time if trip
turbine speed reach below 2000 rpm or condenser pr. Drop upto 0.6
kg/cm2 ). HP evacuation Valve is used to dumping steam from HP turbine
to condenser at the time of turbine tripping for HP turbine preventing any
damage.
4. Put “360” rpm in Rpm ref in EHTC page and check that turbine speed is
rising.
5. Check that TG barring gear is stopped at 240 rpm otherwise stop it
manually.
6. Observe MOT oil level is rise after barring gear stopped.
7. Check all bearing vibration, temp. & other turbovisory parameters are
within permissible range. If not trip the turbine and search the cause.
8. Check the TSE margin is > 30k
9. Check again all MAL drains are open as per SLC logic. (TG check list)
 Raising the Turbine speed up to 3000 rpm:
1. Wait to Fulfill the criteria X6 .
2. Checking Before going to 3000 RPM Generator Primary Water cooler, H2
Cooler and Exciter cooler should be charged condition
3. Ensure Hydrogen purity should be maintained more than 98% .
4. Hydrogen drier is kept ready.
5. Start rolling the turbine by giving speed reference to ‘3000 rpm’ and check
turbine speed is rising.
6. Check for HP (Ti - Tm) should be < 10 or equal deg C.
7. Observe JOP is cut off at 540 rpm.
8. Observe AOP is cut off at 2850 rpm
9. MOP will take over after cut off AOP. Also observed MOP discharge
pressure.
10. Check all bearing vibration & other turbovisory parameters are within
permissible range. If parameters are not in range than trip the turbine and search
the cause. Also Observe vibration at every bearing at critical speeds.
11. Check turbine oil system, seal oil system, Generator Hydrogen Pr. and Generator
Primary Water System for any abnormality.
12. If everything ok, Start the running mill feeder and keep running mill on min
loading.
 Synchronization of the unit/loading of the unit:

1. Check the X7 criteria are satisfied.

2. Take clearance from Electrical department for Synchronization.
3. Inform the switch yard and SLDC.
4. Close generator isolator.
5. Close all the isolator for GEN main breaker and TIE breaker.
6. Close the Field Breaker from “Gen & 400KV” graphics page.
7. Select the excitation channel to be kept in AUTO (channel-1 or
Channel-2).
8. Switch ‘ON’ the Excitation system and check voltage building
across the generator terminal up to 18.5KV.
9. Increase the terminal voltage up to 21KV manually.
10. Select GT breaker to be Synchronization.
Synchronization of the unit/loading of the unit:-
11. Now insert the key for synchronization in GCP & switch ‘ON’ the
synchroscope.
12. The speed of the needle in synchroscope will indicate the “FAST” or
“SLOW” speed of generator. So, increase or decrease the TG speed
accordingly so that rotation of needle becomes as per requirement.
13. Close GCB manually to synchronize the unit.
14. Observe that unit load is reached up to 30 MW.
15. Switch “OFF” the synchroscope.
16. Switch “ON” load controller by selecting “LOAD CONTROL ON” from EHTC
page and ensure “LOAD CONTROL ON” is being displayed in EHTC page.
17. Enter Load Gradient 10 MW/min and Min load set point as 30 MW.
18. Increase the load reference to increase the load.
19. After establishing steam flow the drum level control transfer to 3-
element control.
THANK
YOU