660 MW WARM STARTUP PROCEDURES

WARM START UP AFTER 36 HRS SHUTDOWN AND HPC

TEMPERATURE 340 C AND IPC 320 C WITH BOILER PR 1 TO
30 KSC
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ACTIVITY SEQUENCE
All HT, LT SWGR ,Battery chargers are charged
Raw water pump in service & Clarified water treatment plant in service.- Pr. 2.5 ksc
SACW pump in Service- Pr. 4.5 ksc
Instrument and Service Air Compressors in service- Pr. 7 ksc
Service water pump in service -Pr. 6 ksc
CW pumps in service- Pr. 2 ksc, All Condenser pass charged., CT fan in service
TG-ECW , SG-ECW & ACW pumps in service Pr.7, 10 & 4 ksc
Generator PSW System in service- Tank level>500mm, disch pr. 7.5 KSC. Stator water
flow 110 -120 T/hr.Winding DP is 1.4 to 2.2 KSC. Conductivity 2.5-5 micro siemens/cm.
Gen Filling with Air & Gen Seal Oil system charging Pp Disch Pr 10 KSC, Seal oil to
Hydrogen DP is 0.6 to 0.9 KSC
TG Lub Oil pump,& JOP in sevice- Lub Oil pr 1.2 ksc, JOP pr 80 ksc, Lub oil Temp 4042 0C,DP across plate filter (150 to 300 mm) & Duplex filter are normal
Baring Gear in service- Barring Gear motor current 35 to 40 Amps.
Shaft eccentricity is 0.04 mm. Turbine speed: 1.1 RPM
Control Fluid pump in service- Pr 50 ksc , temp 48-50 0C,
Aux PRDS hdr Charging- Pr.16 ksc, Temp HT-310 0C, LT-210 0C
Gen CO2 & H2 Filling- H2 pr.in Gen. is 3.8-4.0 ksc , purity > 99%
Hot Well filling & CEP in service- Hotwell level 400 mm, disch Pr 30 ksc, Dea level
Control station &LP heater water side lineup, CPU in service
Dea. Filling & FST heating , level 2000 mm, Temp 105 0C
MDBFP in service - Scoop 15-18 % & R/C open, ,Chemical Dozing system in service
,FRS & HPH water side lineup
Condenser Vacuum pulling & Turbine seal steam charging- Vacuum Pumps (02) are in
service and Third pump is in stand by mode, Seal steam Pr. 1.05 to 1.25 KSC. Seal steam
temp 160 to 180 C in cold header. Spray system is lined up for desuperheater. Aux steam
HT header pressure is 16 KSC and temp is 310 C. Drain valves of Hot and Cold headers
of seal steam are open (05 nos.) Cond Vacu < 0.28 ksc, LP turbine exhaust hood spray line
up
Boiler Filling- Open all vents of Boiler & close Eco,WW & intermediate Header drains,
Open Start up system all isolating valves, Put WR &ZR valve in auto. The warming
system for the boiler start-up system is isolated
Start Filling the Boiler with DM Water Initially maintain flow rate 220 T/Hr ( 10 % of
TMCR), When WR opens > 30 % increase the feed water flow to 660 T/ Hr ( 30 % of
TMCR), Boiler is filled when WR Full open and ZR 15 % open for 2 minute and separator
level is stable Maintain again flow rate 220 T/Hr ( 10 % of TMCR) Close the ECO vents
Water Recirculation via Boiler for Clean-up-Water flows through the economizer and
evaporator, and discharges the boiler through the WR valve to the flash tank and via
connecting pipe to the condenser. From the condenser, the water flows through the CPU &
remove impurities, then returns to the FST Measure the chemical property of water

( Ph 9, Silica < 20 ppb, conductivity <0.2 MicroS/cm

LDO Pump & HFO Pump Stating- Pressure in LDO Station at Boiler 15 Ksc Charge
HFO Heater and maintain temperature at O/L of Heater is 120C, Maintain Pressure of
HFO at Boiler End 15 Ksc, Charge Heat Tracing panels ( 6 Nos) Charge Atomizing Steam
Line from LTPRDS
Starting BRP- Set UG valve to 18 % position, Ensure ECO I/L Flow > 110 T / Hr,
Ensures the CW flow through pump heat exchanger, Start BRP & put UG valve in auto
with flow 600 T/Hr as a set points and DP 17 - 18 Ksc
Starting APH/ ID /FD- Run all APH, Fill Seal Trough and Bottom ASH Hopper, Line up
3 pass of ESP & Start one set of ID / FD, Ensure Both PAPH are isolated from FG side.
Maintain the Air Flow to 30 % TMCR (750 T/Hr), Put Furnace Draft in auto - 10 mmwc
SADC maintain a programmed set point differential pressure of 102mmwg. between the
wind box and furnace, Start scanner air fan, Charge SCAPH
Boiler Light Up Ensure Furness draft, air flow, Feed water control (
BFP Scoop, R/C, FRS), Start up system (BCP & UG valve), Separator level
control(WR, ZRvalves) ,BRP stop are in auto. Min 600T/Hr Min Eco Flow &110
T/Hr FW flow are maintained
Furnace Purging Ensure all permissive are available & start purging Time 10 min,
After completion of Purging open, LOTV, HOTV & HORV & put Oil pr control in auto
LDO Pr. 14 ksc HFO pr. 9.3 ksc

Boiler firing sequence as per startup curve (Doosan)

Both MS stop valves made open & HPBP 12 % open & LPBP closed. All MS, HPBP,
CRH, HRH, LPBP drains to Atm Flash Tank should be Opened.
Start AB Elevation with LDO 3 % of TMCR firing (One oil gun = 1.5 % firing at 9.3
ksc) & Stabilized
Start CD Elevation 3 % firing & stabilized
Change LDO to HFO in AB & Maintain firing at 10 % of TMCR
- Steaming start
Close start up vent at 3.5 Ksc & all other vents at 5 Ksc
Continue oil AB & CD firing at 10% firing , Raise separator pr to 8 ksc Ramp rare
should be 0-10 ksc = 0.5 ksc/min, 0-20= 1 ksc/min, >20 =2 ksc/minOpen
At HPBP stm pr. 12 ksc put HP Bypass in Pressure ramp mode( 4ksc/min) will ramp pr
up to 90 ksc & LP bypass set point to 10 ksc. In parallel close all atm flash drains.
Put FW system (scoop,FRS ) in auto.
Start EF Elevation Increase firing at rate 0.5 % & Continue oil firing at 15%- At 100 Ksc
pr HP bypass is release to Pressure control mode will maintain constant pr. during rolling
& initial loading. Adjust firing rate to achive require steam parameters MS flow 510 T/hr,
MS 442C,Rh 407C, Maintain

Take Expansion reading of Boiler. Check Boiler water & Steam

condition.
Steam temp should be control by adjusting firing rate & air
flow prior to synchronizing.
Turbine side Activities
(i) Ensure drain valves of M S, CRH & HRH pipelines are open to Flash tank.
(ii) Ensure drain valves of all Extraction steam upstream of NRVs are open

(iii) Ensure drain valves of HP CV & cross over pipes to HPT are open
(iv) Ensure drain valves of IP CV & cross over pipes to IPT are open
(v) Ensure drain valves of IP -LP cross over pipes are open
(vi) Ensure LP Bypass warm up & drain valves are open
(vii) Ensure drain valves of M S, CRH & HRH pipelines are open to Flash tank.
ENSURE GATE VALVES ON STEAM EXTRACTIONS FROM TURBINE ARE
CLOSED
ENSURE CRH NRVS BYPASS VALVES ARE CLOSED.
ENSURE HPC & IPC FLANGE HEATING VALVES ARE CLOSED
ENSURE ALL TURBO-SUPERVISORY READINGS ARE WITHIN LIMIT
Raise HPC & crossover pipe temp. upto 340 deg C
Preheating of Stop & Control Valves
At MS temp of 4420C and HRH temp of 400-4200C
Latch the turbine & ensure HP & IP stop valves are open
Start preheating of HP SV & HPCV , IPSV & IPCV
Ensure turbine speed should not exceed 600 rpm during heating.
Ensure Shaft eccentricity at HPC front
0.07 MM (when barring gear is ON)
0.10 MM (when RPM < 1150 ), 0.25 MM (when RPM > 1150 )
Heating is complete if metal temperature of HP/IP SV, HP & IP CrossHP Casing temperature is >350 0C

Turbine rolling up to 500 RPM

Ensure Cold rolling parameters
MS press. & temp - 100, 442 deg C.
HRH press & temp - 16 KSC, 420 deg C
MS Flow- 510 T/hr
Raise speed to 500 rpm with acceleration of 300.
Ensure barring gear EM & JOP are ON
Check the following & Keep watch up to 660 MW loading
A)
absolute bearing housing vibration ( 4.5 mm/s)
relative rotor vibration ( 165 micron/s)
absolute rotor vibration ( 200 micron/s)
B) seizing in turbine end side seals
C) abnormal noise in Turbine cylinders
D) thermal and mechanical conditions of turbine
E) Rotor deflection (< 0.10 MM )
F) temp diff in top and bottom of HPC and IPC in steam
admission Zones (+/- 50 0C)
G) Rotor axial displacement (towards Front brg 1.2 mm and
towards Generator 2.0mm)
H) Maximum limits for relative position of turbine rotors
:
(HPC :
-3.0 to 5.5 mm)
(IPC :
-2.0 to 5.0 mm)
(LPC1 :
-2.0 to 40 mm)
(LPC2:
-2.0 to 47 mm)
I) oil temp of bearing I/L (42 to 44 0C) and O/L (<65 0C)
Continue oil firing with Oil Gun in AB CD EF GH & JK if required
MS press. & temp - 100ksc, 442 deg C.

over pipes &

HRH press & temp - 16 KSC,400 deg C

MS Flow- 510T/hr
Raise speed to 1900 rpm (Soak for approx. 40 min)
Ensure barring gear EM and JOP are OFF at speed >1500 rpm
Condenser pressure shall not be > 0.08 KSC
IP Casing inlet temperature shall be > 325 0C(as per PM instructions)
MS press. & temp - 100ksc, 442 deg C.
HRH press & temp - 16 KSC, 400 deg C
MS Flow- 510 T/hr
Raise speed to 3000 rpm gradually and continuously without interruption at intermittent
speed of rotation to avoid turbine operation at critical RPM while increasing the RPM
check the following.
a) shaft eccentricity
b) bearing and rotor vibration
c) bearing babbit temp (for support and for thrust bearing < 95 0C)
d) diff expansions
Close MS, CRH and HRH line drains
Increase MS Flow to 600 T/hr
Put LPH I/S before synchronization
Synchronize the machine and gain load of 40-50 MW .
Take JK oil gun inservice
Increase load to 135 MW
Close Turbine Drains
Close LP Bypass valves
Start IPC flange heating
Put LP Heaters in service
Keep the load for achieving steady thermal conditions & expansions of IPT
Ensure Deaerator line up & readiness & Make ready TDBFP A in warm up condition
Put TDBFP A I/S before 1st Mill I/S.
Start PA fan & seal air fans. PA header pressure control in auto with
800 mmwc.
Mill B I/S after closer of LP bypass AFTER THE SECONDARY AIR TEMP IS
ABOVE 175 C
Put SH sprays into Auto and vary its set point manually.
Start HPC flange heating.

HPC takes load at 12 % TMCR (80MW)

Ensure Auto Close gate valve & CV of CRH NRV bypass, crossover pipes drains
remain open for putting HPC under vacuum
Ensure HPCV-1 & 2 open ( Pressure in control oil >19.5 KSC)
Gate valve 10MAX 14AA101 on power oil CRH NRV gets opened
HPC inlet pipes drain valves get closed
CRH NRVs get opened
Close HPBP valves
Immediately raise the load to 100 MW. Put turbine controller in constant pr
mode .
Ensure HP exhaust steam temperature is < 380 0C

Mill C I/S after closer of HP bypass increase total firing up to 30 % equalized feeder
rating after second mill is proven & increase load
Raise the load to 150 MW
Steam pr. at IP I/L 16 KSC and at HP I/L100 KSC up to 25 % load
In 15 min and then soaking for 40 min.
Gradually increase MS & RH temp to 450 & 470 C at 30 % load (195MW)

Firing Rate should never exceed the rate necessary to match total steam
generation. Watch WW tube metal temp. Increase load up to 30 % 195MW at
Turbine loading rate 0.5 MW/min
MS Flow 600 T/Hr, MS & RH temp to 415 &410 0C
For further Turbine loading up to 530 MW, loading rate shall be
3 MW/min
at permanent HP CV opening, i.e. sliding pressure mode
Operation
The speed of temperature increase for live steam and reheat upstream of turbine
shall not exceed 0,7/min

Before Change over Put controller into Sliding Pressure Mode .

CHANGE FROM WET TO DRY MODE
Load 30% 195-200 Mw
Steam pr. at IP I/L : 13 KSC and at HP I/L :100KSC
M S temperature: 415 0C, HRH temp. 410 0C
MS Flow 700 T/hr
Before change over separator level set point to be reduced.
Ensure
1. Feed water O/L temp. - Eco inlet temp. < 2 C
2. Separator O/L Temp > 20 C above its saturation temp.
3. MS flow > 600 t/hr.
4. Ensure BRP in auto stop & warm up system put into service
5.Start Up System Circulation Valve Closes, UG Valve Full Open WR / ZR
Valve isolation valve close
6.Give Set point 3000 mm to wet leg level control valve ( 10HAG15AA151) in
warm up line
7. Closely watch metal temp. and stabilize
After C/O remove AB elevation oil guns.
Measure the chemical property of water ( Ph 9, Silica < 20 ppb, conductivity <0.2
MicroS/cm
Put Steam Temp & Combustion in Auto
Start second set of boiler auxiliaries in service ( APH-B,ID-B,FD-B,PA-B)
RAISE LOAD UPTO 250MW with loading rate 3MW/min.
Steam pr. at IP I/L : 18 KSC and at HP I/L :120 KSC
M S temperature: 430 0C, HRH temp. 440 0C
MS Flow 900 T/hr

After reaching 30 TMCR load Reduce oil firing maintaining total firing rate same by
taking another mill i/S
HPH charging : Charge just after Change over
LOAD RAISING TO 660 MW
Start 4th. mill A at 300 MW (temp. 480/480, pr.150/20)
Charge extraction steam to deaerator from IPC 6th Stage
Connect HPH, close drains on steam extraction pipelines to HPH
Cut-in second TDBFP from auxiliary header.
RAISE LOAD TO 330 MW & CHANGEOVER TDBFP SOURCE to IP
extraction
Steam pr. at IP I/L : 24 KSC and at HP I/L :150 KSC
M S temperature: 450 0C, HRH temp. 455 0C
Start 5th mill E at 400 MW
(MS/HRH temp. 510/300C, MS/HRH pr. 180/30 KSC,
MS flow 1320T/hr)
RAISE LOAD TO 450 MW (MS/HRH temp. 470/4850C;
MS/HRH pr. 215/37KSC, MS Flow 1500 T/hr)
Stop HPC & IPC flange heating
Start 6th mill at 530MW
MS/HRH temp. 510/5100C;
MS/HRH pr 240/40 KSC , MS flow: 1680T/hr) and switch to constant
press mode
RAISE LOAD TO 660 MW (MS Flow to 2024 T/hr )in constant press
mode
Take 7th mill if required.
Steam pr. at IP I/L : 48 KSC and at HP I/L :247 KSC
M S temperature: 538 0C, HRH temp. 565 0C
Change the pressure controller mode to Load controller at rated M S & HRH
temperature