START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT

AEn OPERATION SUPPORT

START UP AND SYNCHRONIZING PROCESS

Primary conditions:-
 Auxiliary steam is not available (All units of the station tripped more than
72 hours).
 Any one LFO pump start (from LFO pump house).
 All guns of elevation AB are installed.
CA & Electrical Side:-
 Ensure all of condenser vents i.e. (6 six) and cooler vents in MOT Room (1
Two) in open position.
For start First ACW conditions are:-
 Fore bay level around 6.4 meter.
 Ensure supply and no one any relay at Breaker in Switch gear Room. DC
supply ON and breaker in remote condition. And LPB (Local push button)
released.
 Ensure discharge and suction valve of ACW pump in opened condition.
 ACW starts and discharge pressure rising up to 3.2 kg/cm2.
For First DMCW pump start:-
 DMCW tank level should be normal.
 Turbine, Boiler and Compressor cooling line valve should be in open
condition.
 After starting one DMCW pump, start another DMCW pump also and put
third DMCW pump in auto mode, maintaining pressure up to 4.5 kg/cm2 by
adjusting recirculation valve from site.
For starting of instruments and service air compressors:-
 Ensure DMCW cooling line valves are in open condition and moisture drains
in open condition.
 For instruments air ADP should be in service for dry air.
 One turbine side and one boiler side instruments and service line drains
open and ensure condense water drain completely. Put that drains crack
open conditions.
For start first CW pump:-
 Ensure proper venting through all condenser and MOT cooler vents.
 Fore bay level around 6.4 meter.

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 START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT
AEn OPERATION SUPPORT

 First open discharge valve 5% or 10 %, when YES check back is shown, than
start CW pump and ensure opening of discharge valve continuously up to
full open position. Pressure of line would be near by 2-2.5 kg/cm2.
 Spring lock of condenser would later on be release by turbine mtc wing.
IF Boiler Drum in Empty condition:-
 Initial filling will start from boiler fill pump.
 CMU level maintain near 6000-7000 mmwcl.
 Initial filling valve of dearator and CST are in closed condition.
 Line up from SH/ECO/WATER VALVES drains as according to requirement.
After annual shut down or any work carried out in boiler (like Boiler Tube
Leakage) we will be filling through SH drains line. Otherwise we can fill
through ECO or any water valve drains header also.
 When drum level is normal, maintain from 50 mmwcl to 100 mmwcl.
Any other activities:-
 Both APH (A&B), air motor ON from control room if it is not ON then ON it
by opening by pass valve of solenoid from local site.
 Ensure the pressure of service air will be adequate (3.5 to 4.5 kg/cm2).
 After 2-3 min of running of air motor of APH we will start main motor
/Aux. motor of APH.
 After checking permissives of ID fan, start one ID fan and maintain draft (-
5mmwcl to 10 mmwcl), put it on auto mode & open IGV near 50 %.
 Start any one FD fan and raise secondary air flow up to 300 T/Hr (270 T/Hr
to 360 T/Hr)
 Start Scanner Air Fan.
 Check Boiler purge permissives.
 HOTV –CLOSED
 LOTV- CLOSED
 AIR FLOW- 30%-40%
 DRUM LEVEL NORMAL
 ALL MILL OUTLET GATE CLOSED
 PURGE READY FOR START AFTER 5 MIN PURGING OF BOILER COMPLETED.
FROM BOILER SIDE:-
 After purge is completed select LFO at AB elevation and take guns in pair (1,
3) or (2, 4).

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 START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT
AEn OPERATION SUPPORT

 Charge SCAPH after light up of boiler. To charge SCAPH first open bypass air
damper and reduce main air damper position up to 50% and then open
SCAPH steam line up to 20 to 30% initially.
 After 30 min change the pair of oil guns for further 30 mins & open E-10.
 After one hour take all LFO guns in service or when drum metal
temperature reached to nearby 1000C.
 At light up, all drum vents, SH, RH vents should be in open condition as well
as SH drain at 17.5 meters.
 When drum pressure rises up to 2-3 kg/cm2, close all vents. Total no. of
vents are 11 (4 SH, 4 RH, 2 DRUM, 1 ECO LEFT SIDE).
 Open startup vents (S28, S29).
 Now if temperature of flue gas before APH reaches about 120-1250C,
changeover of oil guns can be done, i.e. LSHS oil guns at CD elevation may
be taken in service.
 When oil guns at CD elevation are stable, take out LFO guns at AB elevation
from out of service. After scavenging of guns at AB elevation is completed,
change selection of oil from LO to LSHS and take LSHS oil guns at AB
elevation.
 When guns at AB elevation are stable, take oil guns at CD elevation out
from service.
 After drum pressure reaches 8-10 kg/cm2, close SH drains (4 nos.) at 17.5 m
elevation.
 After closing of all drains from site, drum pressure rises very fast so take
one BFP in service to maintain the drum level.

TURBINE SIDE:-
 Turbine on baring gear speed.
 Open drains connected to HP/LP flash tank & close drains connected to
atmosphere. i.e. open MS-105,106 ,109 and HRH-101,102,103,104.
Now for starting first CEP following steps should be followed:-
1. Hotwell level should be normal.
2. LPH vents should be opened.
3. Open CEP sealing valve coming from CST (situated at turbine floor and CST floor).
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 START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT
AEn OPERATION SUPPORT

4. Minimum recirculation valve CD-25 should be 100% open.

5. All valves of water charging side should be ensured to be in open condition.
6. Start any one of the three CEP’S & after its normal current, open discharge valve.
Observe its discharge pressure 20-22 kg/cm2. After some time (2 min) its vent
valve closes automatically.
Sealing steam charging & vacuum pulling:-
1. Ensure APRDS header pressure near 10 kg/cm2 & temperature above 2800C.
2. Open drains of the sealing steam line up to control valve i.e. manual drain at
8.5 mtr, MAW-10 & MAL-81.
3. Check temperature achieved near 2500C up to control valve after opening
seal steam valve at PRDS header.
FOR VACUUM PULLING FOLLOW THESE STEPS:-
1. Normal quantity of water in separator tank and all the permissive of vacuum
pump are met out.
2. Close vacuum breaker.
3. Start re-circulation pump of any one CVP.
4. Start CVP.
5. Open air-isolating valve/solenoid of the CVP.
6. Follow above steps for another CVP to be taken in service.
7. Start any one of the GSC fan after ensuring its path is through.
8. Open isolating valves of seal steam header to raise its temperature.
9. When temperature reaches above 2000C and vacuum is above -0.1kg/cm2,
increase seal steam control valve position above 50% to extend seal steam up
to the turbine glands.
10.Maintain seal steam pressure above 0.02kg/cm2. (Initially bypass valve may
also be opened to achieve sealing purpose).
11.Simultaneously observe vacuum to be building up in the system.
12.Open remaining all drains i.e. CRH-101, all MAL drains and drains of heaters.

 When drum pressure reaches above 30 kg/cm2 & MS temperature above

2400C, open the Bypass of MS-1, MS-2 and then MS1 & MS2 may be
opened (also LP & HP bypass can be charged). Close startup vents S28, S29
simultaneously.

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 START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT
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 Before opening MS-1 & MS-2 v/v, ensure that drum level is on negative side
around (-80 mmwcl ).

 Also before charging of LP & HP bypass, from site ensure opening of CRH
atmospheric drain and closing of BD isolating v/v. Also check that no trace
of water or vapor is issuing out from CRH atmospheric drain i.e.at zero
meters.

LP Bypass charging
1) Start second CEP (if not in service).
2) Raise LP bypass controller so that first LP water injection valves of both sides open.
3) Further raise LP bypass controller up to 35% so that LPBP valves are open and
hence LPBP are charged.
HP Bypass charging
1) Check boiler drum pressure around 35-40Kg/cm2 and main steam temperature
around 3000C.
2) Check HPBP temp. set point to be 2800C.
3) HPBP valves 1 and 2 and HPBP spray valves 1 & 2 should be in manual position.
4) Now lower HPBP pressure setpoint slightly less than running MS pressure. For
example if MS pressure is 37 kg/cm2 than put HPBP set point to be 35kg/cm2.
5) Charge HPBP one by one. For charging put HPBP 1 on auto mode so that it opens
gradually to lower MS pressure up to set point. As soon as HPBP 1 opens greater
than 2% (or when facia of HPBP 1 greater than 2% get reset) switch HPBP to
manual mode.
6) Also ensure that BD valve gets opened and spray valves BPE 1 comes to auto
mode.
7) Similarly charge HPBP 2 as above.
8) After charging of HPBP, raise set point of HPBP again to 165kg/cm2.

Following points should be considered surely when charging HPBP.

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 START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT
AEn OPERATION SUPPORT

1) Ensure that there is no hammering in system especially in CRH line. If hammering

is observed, close HPBP and thoroughly check that there is no water in CRH line or
passing in spray system.
2) Drum level should also to be maintained as drum level will go up when bypass is
charged.
Stop valve opening condition in Hydraulic Mode (or x1/x2 criteria fulfilled).
1. Reset all the generator protection relay on panel (total 8 nos. relays in U#5 and 6
nos. relays in U#6)
2. System is on hydraulic control mode starting device and speeder gear is 0 %.
3.Slightly raise starting device position upto 25% and closely monitor any dip in trip
oil pressure. As soon as there is dip in trip oil pressure (or when close status of HP
stop valve is gone) hold starting device at that position so that stop valves are
opened through oil pressure.
4. Again slightly raise starting device upto 37% and monitor the dip in trip oil
pressure for opening of IP stop valves.
5. When speed is raised upto 450 rpm/600 rpm ,increase staring device nearby 50%-
60%.
6. Check criteria X4/X5 for soaking.
7. After soaking, continuously raise the starting device upto 100% to rise the turbine
speed to 2800 rpm.
8 After that turbine speed increase by speeder gear up to 3000 rpm.
9. For synchronization, at the instant when breaker is closed raise the speeder gear
to increase the rpm so that extra speed converts into stock load.
10. Raise speeder gear slowly upto 100% according to the rate of rise in pressure.
This will achieve load of around 120-125 MW as HP control valves are fully
opened.
11. For further raising of load, increase the MS pressure as control valve of HP/IP are
in wide open condition.

Stop valve opening condition in EHC Mode (or X1/X2 criteria fulfilled).
1. Reset all the generator protection relay on panel (total 8 nos. relays in U#5 and 6
nos. relays in U#6)
2. System is on EHC control mode so position of starting device and speeder gear is
100 %.

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 START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT
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3. To reset the turbine in EHC mode, check that speeder gear is fully opened now
lower starting device to 0%, check that trip oil pressure to built up in oil system up
to 6 to 6.2kg/cm2.

** Turbine is now reset

4. For opening stop valves, check X1, X2 criteria’s are fulfilled.

5. Test valve from site are in open position by turbine mtc wing.
6. Slightly raise starting device position upto 25% & closely monitor any dip in trip oil
pressure. As soon as there is dip in trip oil pressure (or when close status of HP
stop valve is gone) hold starting device at that position so that stop valves are
opened through oil pressure.
7. Wait up to status of HP stop valve open is open showing on BUP.
8. Wait for few seconds to built up the trip oil pressure again up to desired value of 6
to 6.2 kg/cm2.
9. Again slightly raise starting device upto 37% and monitor the dip in trip oil
pressure for opening of IP stop valves.
10. As soon as IP stop valves status on BUP shows open position and trip oil pressure
is built up, raise starting device upto 100%.

Criteria X3 or HP casing temp at 50% depth are 100-1200C ,turbine rolling may be
done to speed 450 rpm or 600 rpm for soaking & to reach temperature of HP
casing at 50% depth to 2000C.

Criteria X4/X5 are for soaking.

At 2000C HP casing 50% depth temp. , we can roll the turbine to 3000 rpm and go
for synchronization.
Criteria X6 is for 3000 rpm and criteria X7 is for synchronization.
Before rolling turbine to 3000 rpm, we should take a mill in service for maintaining
MS pressure.

Mill taking procedure:-

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 START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT
AEn OPERATION SUPPORT

 First check lubrication system i.e. start one LP, one HP, one B&S pump and
one reducer pump, after that start Grease pump. Grease sequence will be
reset.
 Check minimum three oil guns are in service before taking mill on that
elevation (i.e. AB, CD or EF).
 Maximum 4 oil guns or ON status of any one out of 4 guns that is not in
service can be done so that if any one oil gun trips (for any reason), boiler
will be safe and will not trip.
 Now give the command to elevation “A” of Mill –AB.
 First 60 sec purging of coal pipe after classifier would be done. Then after
steam inerting for 240 sec will be done at both classifier and hot air box
side (A and B).
 First Seal air fan comes in service, than GG seal air fan comes & after that
classifier outlet gates will open (all four). Now after opening of seal air fan
discharge damper, open control damper 15%-20% to adequate the seal air
DP (80mmwcl -100 mmwcl). Mill main motor will be ON when Seal Air DP
will be adequate.
 Now increase DP upto 200 mmwcl and put control valve in auto.
 After opening of PA general inlet gate, increase hot air (20%- 30%) and
maintain bypass air flow (13 to 16) t/hr of respective elevation.
 When classifier temp are adequate (450C-500C), give command to elevation
for taking RC Feeder in service. First feeder outlet gate will open then
feeder will come in service.
 After taking feeder in service, open the PAD damper of respective side and
maintain hot air flow >36 t/hr, then afterwards give command to another
elevation.

Procedure for synchronization at panel and turbine desk for synchronization

1. Check that all lockout relays (8 nos. in Unit#5 and 6 nos. in Unit#6) are reset
and no facia is coming.
2. C-isolator is in closed condition.
3. MVAR is in auto mode.
4. On the field breaker from panel (Marker-1).
5. On the excitation from panel (Marker-2).
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START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT
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6. As soon as the excitation is ON incoming voltage starts increasing.

7. Compare the incoming voltage and frequency with running voltage and
frequency.
i) First match the incoming frequency (unit) with the running frequency
(grid) by raising or lowering the turbine rpm from turbine panel.
If the incoming frequency is less than the running frequency, than
increase the rpm very slow from panel. If it is high, than lower the
rpm to match both the frequencies.
ii) Also match the incoming voltage and running voltage by adjusting
MVAR (Marker-3). If incoming voltage is less than the running voltage
than slightly raise the MVAR from panel to match both the voltages.
Cross check that voltage needles are showing same value on BUP.
8. Turn the knob Marker-4 to check position for synchronizing permissive.
Check that both the yellow LED’s are glowing.
9. Turn the synchronizer to ON position (Marker-5).
10. Check the synchronization needle taking rotation. If incoming frequency is
slightly high than that of the running frequency than it will turn clockwise
otherwise it will rotate anticlockwise. We should always go for the
clockwise rotation.
11. Keep the incoming frequency slightly high (2-3 rpm or 0.01 Hz) to that of
the running frequency to rotate the needle a full clockwise circle.
12. Checks the synchronization needle comes to 12’0 clock position and as
soon as the blue LED glows, close the field breaker (Marker-6) from the
panel to synchronize the unit with grid.
Also closely observe the MVAR which will increase abruptly.
13. When breaker is closed and machine is synchronized than it will take a
stock load of 45-50 MW and unit is on speed control mode. Raise the
turbine speed 10-15 rpm to convert the extra speed into load. Check that
load reference is about 55-60 MW and load controller is ON.
14. Continue on this mode for a while and observe that load reference
percentage changes from negative to positive on EHC at HMI and when it
overlaps speed reference percentage or when it goes higher to that speed
reference percentage, than machine switches over to load control mode.
15. At this instant raise the load from load reference from panel to about 65-70
MW and simultaneously lower the speed reference from panel below 3000
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 START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT
AEn OPERATION SUPPORT

rpm so that it may not become higher to that of load reference percentage
and machine does not switches over to speed control mode again.
16. Switch off the synchronizer (marker-5) and permissive (marker-4).

 After the machine is synchronized and stable condition is maintained on

load control mode by raising the load reference & holding the pressure.
 Now gradually close LPBP and HPBP in co ordination with drum level
control

 When 50 to 60 MW is achieved close all drains i.e. MS 105,106,109, CRH-

101, HRH- 101,102,103,104 on CRT, from site close CRH atmospheric drain,
BD isolating valve.

 Charge LPH1(open ext. 17, ext. 18), LPH2(open ext. 09), LPH3(open ext. 10)
from CRT, put DR-19,DR-22,DR-25,DR-28 on auto from panel and close MAL
54,MAL 55,EXT. 125,126,127,128 from CRT.
 Also close MAL 11, 12,26,27,31,32,66,81. Close MAL 22 after HP casing 50%
depth temp. reaches around 3200C.
 Raise load according to pressure keeping temperature margins in range
(should not be less than 300C), simultaneously by increasing firing rate in
Mill.
 SH outlet temperatures should such be maintained that it is not above
4400C, or it should not be greater than 1500C in addition to the 50% HP
casing temperature (for eg. If HP casing temperature is 2500C than SH
outlet temperature must be around 2500C+1500C=4000C).

When around 125MW load is achieved, start preparation for charging HPH-5.
i) For this open site drain of deaerator drip of HPH-5 in addition to Ex-
104,106 and MAL-51. DR-16 should be in fully open condition.
ii) Give Ex-12 a small inching open command, so that extraction line is
warmed up. Wait for few time to see the temperature of deaerator drip
is increasing or not. DR-13 may be opened 8-10% for this purpose.
iii) When after some time by giving inching command to Ex-12,
temperature of deaerator drip starts increasing and becomes equal to
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START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT
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drain temperature than we can deduce that heater is charging. Slowly

open extraction valve by inching and open it fully.
iv) Observe for any hammering in line. When Ex-12 is fully opened, close its
drain, i.e. close Ex-104, MAL-47 and deaerotor drip from site.
v) By maintaining heater level, put DR-13, DR-16 on auto mode.
vi) On the solenoids of NRV’s of heater A2,A3,A5.

Also start procedure for charging deaerotor pegging through Ex-11 at low
MS pressure so that hammering is avoided.
i) Open drain of Ex-11 valve from site so that all condensate is issued out.
ii) After ensuring there is no condensate remained, Give Ex-11 valve a
small inching open command, wait for a few time and check if pressure
and temperature of deaerator is increasing.
iii) Slowly and steadily give open command to Ex-11 valve till it is fully
opened.
iv) After pegging is fully charged, close site drain of Ex-11 valve and turn on
the solenoids A4.1 and A4.2. Also close MAL-51 drain.

 Continue raising the load as according to firing rate in running

Mill and considering temperature margins.
 When 170-180 MW load is achieved preparations for charging
HPH-6 can be started. HPH-6 should be charged from site only by
operating Ex-13 valve from site by putting it on local mode from
MCC. Procedure for charging would be same as that of HPH-5
except that of valve operation.
i) First open drain of deaerator drip from site and open Ex-132,133.
ii) Charge the heater from site slowly (as HPH-5).
iii) After charging, close deaerator drip from site, close Ex-132,133.
iv) By maintaining level, put DR-2, DR-6 and DR-9 on auto mode.

 Procedure of second mill to be taken in service can be started

simultaneously when it is observed that HPH-6 has begun to
charge. It can be ensured by temperature at outlet of feed
water from HPH-6 which will be rising.

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 START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT
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 When second Mill is taken fully in service and stable load

condition is achieved of 190-200 MW all oil guns may be taken
out from service.

Unit tripping and Boxed Up activity

Boiler Side:-
 Unit is running on 250MW or 200MW without oil support.
 Gradually decrease the load by decreasing the firing in boiler through Mill
i.e. reduce fuel master and hot air and open cold air damper 100%.
 If APRDS is not self charged than first charge it from parallel unit so that
after unit is boxed up PRDS pressure is maintained for turbine gland sealing
purpose.
 If PRDS is already self charged than minimize the pressure control valve but
not close it completely and inform parallel unit to charge the PRDS so that
temperature doesn’t go down suddenly. Practice should be such that
temperature doesn’t go down beyond 1950C as gland sealing valve closed
forcibly at 1800C and it further causes problem in turbine barring gear
which can be seized.
 Watch flame intensity at running elevations and then trip that Mill on
which intensity is in poor condition.
 Continue reducing the load as according to MS Pressure.
 Do not take any oil guns in service up to 30% boiler load as unit will not trip
on flame failure.
 According to scheduling of load as per ABT decrease the load and trip
second mill so that boiler trips on loss of all fuel in the time slot when unit
has to be boxed up.
 Now maintain the drum level and trip one BFP. After 15-20 min. when
boiler drum will be completely filled by second BFP, trip second BFP also.
 Trip one set of ID/FD fan after unloading and maintain secondary air flow
near about 200t/hr by taking second FD fan on manual mode.
 Reduce loading of second ID fan by reducing IGV up to 50% so that scoop
remains at 5-10% and it should be on auto mode for maintaining furnace
draft.
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 START UP AND SYNCHRONISING PROCESS PREPARED BY ASHISH SHARMA & NS SHEKHAWAT
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 Remove SCAPH if it is charged.

 Trip another set of ID/FD fan after flue gas temperature before APH
reaches near about 2500C.

Turbine/ CA and Electrical Side

 When firing rate is decreased from boiler side gradually reduce the load as
per ABT scheduling from turbine panel and take out HPH-6 from service at
load 170-180MW simply by closing the steam extraction valve Ex-13.
 Continue decreasing the load from desk and at 140-150MW take HPH-5 out
from service by closing the valve Ex-12.
 Continue decreasing the load from panel and when unit trips, maintain
Hotwell level and gland sealing pressure by opening seal steam
main/bypass valve.
 Open all the drains viz. CRH-101, HRH-101,102,103,104, LPH, HPH
extraction drains. Do not open MS-105,106 and 109. Also open all MAL
drains.
 Keep an eye on turbine rpm. At near about 2800 rpm, AOP will start (if not,
then start it). At 500-510 rpm, JOP will start. Wait for barring gear to
engage. The barring speed will be in between 60-70 rpm and it will take to
anywhere between 45-60 min to achieve barring speed after unit tripping
of unit.
 When barring speed is reached, stop one CEP and one CWP. Switch off SLC
of water injection and open water injection valve to lower the LPT Exhaust
hood temperature.
 Switch off all the CT fans and ESP below flue gas outlet temperature after
APH is 1000C.
 After 3-4 hrs and when LPT Exhaust hood temperature is below 550C,
vacuum may be killed and sealing may be cut. Procedure will be as follows:-
1. Close all extraction drains and MAL drains.
2. Switch off CVP. First close its air isolating valve and then stop CVP.
3. Close seal steam main/bypass valve so that sealing pressure becomes zero.

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4. When vacuum reaches -0.15kg/cm2 ask operator to cut the sealing by

closing the sealing isolating valves at site.

 Check the rate of LPT exhaust hood temperature rise. If its rate is normal or
slow, stop second CWP.
 Wait for another 10-15mins to check LPT exhaust hood temperature. If it is
normal than stop second CEP.
 Close isolating valve of DM-2, DM-4 and CD-58, sealing valve of CEP and
CVP below CST.
 When second set of ID-FD fan are stopped, stop 1 out of 2 running DMCWP
so that only cooling of compressors remains.
 Stop DMCWP and compressor afterwards as when required.
 Change the cooler of MOT from ACWP to service water provision when
casing temperature at 50% depth is less than 4400C.
 Stop ACWP when condenser springs are locked by turbine maintenance
wing.

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