Adani Power Limited

Power Business Goal - 20,000 MW

ADANI POWER AT A GLANCE

Power Business Goal - 20,000 MW BY 2020

MUNDRA 330MW X 4 + 660MW X 5

TIRODA 660MW X 5 (UNDER COMMISSIONING)

KAWAI 660MW X 2 (UNDER ERECTION)

BITTA 40MW BIGGEST SOLAR IN INDIA
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.



PRESENTED BY
B.K.PANDEY
APML, TIRODA
WELCOME
TO
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
HPT IPT LPT A LPT B
CPP
GSC
Condensor
(HP)
Condensor
(LP)
H
P
H

-

1

H
P
H

-

2

H
P
H

-
3

EXT From
CRH
LPH -5
LPH -6
LPH -7A
LPH -7B
LPH -8A
LPH -8B
3
Deaerator
Boiler
CEP
3x50%
F
C
S

5 5
6
6
Economiser
1482 TPH
1994 TPH
(MD BFBP 1x35%)
7
8
7
8 8
7 7
8
11+1 8 2x7
2x7
RH
1
TDBFP 2X50%
PRE STARTUP READYNESS

HT/LT POWER SUPPLY READINESS

WATER SYSTEM: FIRE WATER,SERVICE WATER,DMP,CW &
ACW.

CCCW SYSTEM

COMPRESSOR SYSTEM

AUXILIARY STEAM. (S/B UNIT OR AUX BOILER).

START CEP AND MDBFP.

CHECK THE BCP SYSTEM IS READY.

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.
BCP FILLING ,PURGING & FLUSHING
PURPOSE-
- TO FILL THE MOTOR CAVITY.

RECOMMENDED MOTOR FILLING WATER QUALITY
- CONDUCTIVITY <1 s/cm
- BOILER FEED WATER
- TEMP.<
=
45
O
C
- CL
-
<
=
50 PPM
- pH >
=
6.5
- SUSPENDED SOLIDS <
=
5 PPM

FILLING,PURGING & FLUSHING WATER REQUIREMENT

- MOTOR INITIAL FILLING FLOW RATE : MAX. 5 L/MIN

PRE BOILER FLUSHING
START CEP.

FILL & DRAIN FROM DEAERATOR UNTIL
REQUIRED WATER QUALITY IS ACHIEVED.
( Fe<500 Ppb.)

START MDBFP.

START THE BOILER COLD/HOT FLUSHING
TO REDUCE THE Fe & SiO2 CONTENT IN
FEED WATER.

Sampling Fe
+

Above
500ppb
Below
500ppb MIXER
Boiler flushing
HOTWELL
CW
LINE
BCP
START-UP
LINE
ECO
WW
SP SP
BOILER COLD FLUSHING
COLD FLUSHING

WATER WALL TEMP REQUIRED 105-120 DEG.C
(TEMP MAINTAINED BY DEAERATOR PEGGING
STEAM)

COLD OPEN FLUSHING QUALIFIES 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


(ALL ANALYSIS FROM SEPARATOR DRAIN)


BOILER HOT FLUSHING
HOT FLUSHING

WATER WALL TEMP REQUIRED 150-190 DEG.C (TAKE
OIL GUNS OF BC ELEVATION)

HOT OPEN FLUSHING START UP CRITERIA FE > 100PPB
SIO2 > 50PPB

IF HOT CYCLIC FLUSHING CRITERIA IF FE < 100PPB
SIO2 < 50PPB

HOT CYCLIC FLUSHING QUALIFIES IF FE < 50PPB
SIO2 < 30PPB


AFTER COLD FLUSHING START BCP WITH MINIMUM 30%
FEED FLOW & THROTTLE FRS VALVE.

BOILER LINE UP AND LIGHT UP
FUEL OIL SYSTEM: LDO/HFO PUMPS

ESP HEATERS & RAPPERS

AIR FLUE GAS SYSTEM: APH,IDF, FDF &
SCANNER FAN.

MAINTAIN AIR FLOW : 30% - 40%.

FURNACE PURGE: 300 Sec.

LIGHT UP BOILER WITH OIL GUNS AT BC (LDO)
ELEVETION.

CONTINUE HOT FLUSHING UNTIL REQD.WATER
QUALITY IS ACHIEVED


THEN TAKE CD ELEVETION GUNS. IF REQUIRED
TAKE 2 NO. GUNS IN AB ELEVETION.


BOILER LINE UP AND LIGHT UP


CONTINUOUS APH SOOT BLOWING TO BE DONE AT THE
TIME OF OIL FIRING.

PR RISING RATE- 0.05 MPA/MIN. BETWEEN 0-1 MPA
PR RISING RATE 0.1 MPA/MIN. BETWEEN 1 2 MPA
PR RISING RATE 0.2 MPA/MIN. ABOVE 2 MPA

FURNACE EXIT GAS TEMP MUST BE BELOW 538C FOR
REHEATER PROTECTION (UNTIL HP-LPBP IS CHARGED).

CLOSE SH DRAINS AND VENTS AFTER ACHIEVING DEGREE
OF SH 50 C ( CLOSE IT AFTER CHARGING HP-LP BYPASS).





LDO/HFO GUN
Fuel Light Oil
Fuel Pressure 0.8MPa-2.0MPa
Fuel Flow 500kg/h -3000kg/h
Atomizing Air Pressure 0.6MPa-1.2MPa
Atomizing Air Flow 100-600kg/h
Ignition Method HESI (20 joules/spark)
Fuel Heavy Oil
Fuel Pressure 0.8MPa- 2.0MPa
Fuel Flow 1000-4000 kg/h
Atomizing Steam Pressure 0.8MPa-1.2MPa
Atomizing Steam Flow 100-400kg/h
Ignition Method HESI (20 joules/spark)
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)

H2 FILLED IN GENERATOR AND MAINTAIN PR 0.35 MPA.

EH OIL SYSTEM: IN SERVICE (14 MPA)



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.

COLD START UP CURVE
HOT ROLLING
MS TEMP
RH TEMP
SPEED
MS FLOW
LOAD
MS PRESS
PRE HEATING OF HP CASING.

PREHEATING OF HPT REQUIRED WHEN INNER METAL TEMP <150C.

CRH PR 0.5-0.7 MPA/220-380C.

OPEN PRE HEATING VALVE (REVERSE FLOW VALVE) GRADUALLY.

OPEN BDV VALVE FULLY.

OPEN CRH DRAIN BEFORE NRV AND HPT-IPT CASING DRAINS.

HEATING RATE SHOULD NOT BE MORE THAN 50C PER HR.

HP CASING TOP-BOTTOM & INNER-OUTER WALL METAL TEMP
DIFFRENCE SHOULD BE WITHIN 50C.

AFTER ATTAINING THE CASING TEMP > 150C CLOSE THE RFV
VALVE AND OPEN HP CYLINDER VENTILATION VALVE TO
CONDENSOR.

TURBINE WARM UP OPERATION



TURBINE STARUP PROCEDURE
RFV
CRH NRV
HPT
HPBP
CRH LINE
Ventilator valve
TO CONDENSER
IPT
BDV
TO CONDENSER
MS
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.

350 400 450 500 550 600 650
MINUTES
LOAD
(MW)
165
330
495
660
33MW
60MW
198MW
330MW
S
Y
N
C
H
R
O
N
I
S
E

&
C
H
A
R
G
E

D
/
A

M
I
L
L
-
B

C
U
T

I
N

I
P

T
O

H
P

C
H
A
N
G
E

O
V
E
R

(
7
0
M
W
)

M
I
L
L
-
C

C
U
T

I
N

A
T

1
0
0
M
W

H
P
H

C
H
A
R
G
E
D
(
1
5
0

M
W
)

2
N
D

T
D
B
F
P

C
U
T

I
N
(
1
8
0
M
W
)

W
E
T

T
O

D
R
Y

C
H
A
N
G
E

O
V
E
R

M
I
L
L
-
A

C
U
T

I
N
(
2
1
0
M
W
)

O
I
L

G
U
N

C
U
T

O
U
T

(
2
6
0
M
W
)

M
I
L
L
-
D

C
I
T

I
N

(
3
0
0
M
W
)

M
I
L
L
-
E

C
U
T

I
N

(
4
3
0
M
W
)

M
I
L
L
-
F

C
U
T

I
N

(
5
4
0
M
W
)

660 MW
CONDENSER
LP HEATER 7A
LP HEATER 8A
CONDENSER
LP HEATER 7B
LP HEATER 8B
LPT A LPT B
HP HEATER
5
HP HEATER
6
LP HEATER 5
LP HEATER 6
2
nd
2
nd

4
th

4
th

5
th
5
th
5
th
5
th

6
th

6
th
6
th

6
th

FROM IPT EXHAUST
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.

STEAM PRESSURE: 0.61.3MPA, STEAM TEMP: 50 DEG C MORE THAN
CASING TEMP.

ROLL THE TDBFP AS PER PROCEDURE.

GIVE THE TARGET SPEED 500 RPM AND THAN TO 1000 HOLD FOR 40
MIN.CHECK THE TSI PARAMETER

WHEN SPEED REACHES 2840 RPM, GIVE REQUEST COMMAND FROM
FW MENU. THEN SELECT CCS CONTROL IN FROM MEH MENU.

IP
TDBFP-A
TDBFP-B
Aux. Steam
Header
To
CRH
HP
From
CRH
M
M M M
Deaerator
Booster
pumps
6/10/2014
M M
M

E
E
To
Condenser
Aux. Steam
Header
M

M
M
M M
M M
E
E
Deaerator
1.3 MPa
350 C
1.12 Mpa
378 C
4 MPa
315.3 C
Changeover Valve
TDBFP STEAM SOURCES
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.




HP HEATER
3
DEAERATOR
HP HEATER
2
HP HEATER
1
CRH LINE
TDBFP A TDBFP B
MS LINE
9
th
stage
5th stage
HP HEATER
1
HP HEATER
2
HP HEATER
3
HRH LINE
DEAERATOR
IP EXHAUST
PHASE CHANGE FROM WET TO DRY MODE
DURING LOAD RAISING >25% BMCR, THE BCP FLOW AND FEED
WATER FLOW TO BE MONITORED CLOSELY.

THE BCP FLOW NEED TO BE ADJUSTED W.R.T SEPERATOR TANK
LEVEL AND THE SAME FLOW TO BE ADJUSTED IN FEED WATER FLOW
TO MAINTAIN TOTAL FEED WATER FLOW TO ECONOMISER
CONSTANT.

WHEN BOILER STEAMING RATE RISES TO >30% BMCR, W.R.T FUEL
FIRING, THE SEPERATOR LEVEL REDUCES .

ONCE THE CONDITION FULFILLS THE BCP STOPS AND FEED FLOW
CONTROL CHANGES OVER FRS.

AFTER STOPPING BCP IT ACTS AS SUB-CRITICAL ONCE THROUGH.


WHEN THE STEAM PR REACHES 22.1 MPA IT IS IN SUPERCRITICAL
ZONE



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.

TAKE MILL-E AT 430 MW. MS T/PR 566C/17 MPA.

TAKE MILL-F AT 540 MW. MS T/PR 566C/24.1 MPA.

INCREASE THE LOAD TO FULL LOAD 660 MW GRADUALLY.

Boiler Design Parameters
NO. Parameters Unit
1
100% BMCR Coal consumption (Design)

390.37

t/h
2 Design fuel Indian coal
3 Superheated steam flow 2111 t/h
4 Superheater outlet pressure 25.4 MPa
5 Superheater outlet temperature 569
6 Reheated steam flow 1749.1 t/h
7 Reheater inlet pressure 4.73 MPa
8 Reheater outlet pressure 4.49 MPa
9 Reheater inlet temperature 324
10 Reheater outlet temperature 569
Feedwater pressure 28.8 MPa.g
11 Feedwater temperature 280
12 Separators steam temperature 421
13
Air preheaters outlet air temperature, uncorrected
After correcting
153.3
147.2
14 Calculating thermal efficiency of boiler 87.19%BMCR
TURBINE PARAMETERS
HPT IPT LPT
Pressure (MPa) 24.2 3.961 1.12
I/L Temp (Deg C) 566 566 378
O/L Temp(deg C) 315.3 378
Steam Flow (tph) 1959.25 1649
TURBINE HEAT RATE( KCL/KWH) 1885
No of Stop valves 2 2
No of Control valves 4 4
Steam Admission Parameters at Turbine Inlet
TURBINE AT FULL LOAD
HPT IPT
RSV
LPT
LPT #2 GEN
CRH
CRH
HRH
MS LINE
HRH
MS LINE
3.96MPa / 566c
24.2MPa/566C
TO BLR RH
RCV
MSV
RCV RCV RCV CV CV CV
RSV
CV CV
CV CV
RSV
CV CV MSV
CV CV
LPT
LPT #2 LPT GEN #2 LPT
LPT #1
MSV CV CV MSV CV MSV CV MSV CV CV MSV CV MSV CV MSV CV CV MSV
MSV CV MSV CV CV MSV
RSV
CV CV
RSV
CV
RSV
CV
RSV
CV CV
RSV
1.12MPa / 378c
CONDENSOR A CONDENSOR B
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
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.




SHUT DOWN CURVE

COOL DOWN CURVE


THANK YOU