Line up Condenser Circulation Water System

1. Check that sea water filteration system is in service. 2. Line up seal water injection system to CW pumps and establish seal water flow to CW pump (@100lpm). 3. Check that Travelling water screen is clean and the cleaning system is available for operation. 4. Remove bulk head at pump suction pit. 5. Close CW pipe line drain near jetty and all drains in the system. Open vents. 6. Open isolating valves of vacuum breakers. 7. Check that the following valves are closed. a) Screen wash pump water inlet. b) Sea water booster pump suction. c) Sea water heat exchanger inlet. d) Ash water sump water inlet. e) Sea water inlet to chlorination system. 8. Close condenser water box drain and open the vents. 9. Establish 415V supply to condenser inlet, outlet and backwashvalves.Check that the backwash valve is in normal position.

CONDENSER

SWBP

SCS

PHE

Charging and Taking Circulating water System in Service

1. Check that circulating water system is lined up. 2. Establish 415 V supply to CW pump discharge valves. 3. Check that condenser backwash valve is in normal position and inlet/outlet valves are open. 4. Rack in 6.6 KV breaker of CW pump. 5. Start CW pump on manual mode. Check that motor current and discharge pressure is ok. Gradually open the CW pump discharge valve and maintain a pressure of 1.2 bar.(When CW pump is started on manual mode, the discharge valve opens only on manual command from UCB. 6. After the system is filled up gradually throttle the condenser out let valves to complete priming of the condenser water box. The water box pressure should not exceed 0.85 bar during the throttling. Check condenser manholes for leakages.

Charging and Taking Circulating water System in Service

7. Close water box vents water flows continuously from the vents. 8. Line up and take into service water box priming system. 9. Line up and start the second CW pump and open the condenser outlet valves to maintain water box pressure within the limit. 10. Close line vents. 11. Line up and take chlorination plant in service. *Circulating water system is in service*

Once through cooling system (sea water)

Once through system - CW Pump House Layout

CW Motor PG Discharge Valve Traveling Water Screen

CW Pump

Nylon net

Traveling Water Screen

Condenser Sub System Back Wash Valve

In unit 5 back wash valves are used for removal of the debris by reversing the flow.

Condenser
CW Inlet
Back Wash valve

CW Outlet

Line up and taking Auxiliary Cooling Water System in service

1. Check that service water tank levels are ok.Sevice water tanks can be filled by running service water pumps. 2. Fill the ACW tank to normal level through ACW tank level controller. 3. Open head tank outlet valve and charge the system by opening the inlet and outlet valves of : a) primary water cooler, b) seal oil cooler, c) exciter air cooler. 4. Vent the header of ACW through the following vent connections: a) exciter air cooler at 10.8 m, b) hydrogen cooler at 18.3 m and RAPH lube oil cooler at 21.8 m.(these are the vents at the highest points in the system) 5. Line up ACW pumps and open pump discharge valves. 6. Line up and take into service ACW side of plate exchanger . 7. Line up sea water booster pump. Open pump discharge valves. 8. Crack open self cleaning strainer inlet valve and slowly for 5 minutes. After thorough venting of strainer open the inlet and outlet valves. The maximum filling rate of 50 cm/hr should not be exceeded.

Taking Auxiliary Cooling Water System in service

9. Line up and take into service sea water side sea-water side of plate heat exchanger. 10. Establish sea water flow by opening the sea water outlet header valve to seal well. 11. After thorough filling of ACW system on salt water and city water side close discharge valves of ACW and sea water booster pump. Start ACW and sea water booster pump. 12. Take ACW flow controller into service by opening the isolating valves. 13. Establish ACW supply to various system as required. *ACW System in service*

Line up and filling of hotwell

1. Check that hotwell drains are closed. 2. Check that DM water storage tank level is normal. 3. Line up condensate storage tanks for filling with DM water. Line up and start DM transfer pump. Fill condensate storage tank. 4. Close isolating valves of all auxiliary sources taking supply from Hotwell Makeup Pump (HMP) discharge header. (a. CEP sealing, b. Primary Water make up, c.Sampling) 5. Line up and start HMP on recirculation and open discharge valve. 6. Open bypass valve of the hotwell make up control valves. 7. Build up hotwell slowly to normal. 8. Close make up control valves bypass and take the hotwell control valves in service by opening isolating valves. * Hotwell is filled up*

1. Check that ACW of CEP is in service 2. Check that the hotwell level is normal and that hotwell make system is in service. 3. Establish sealing to CEP by opening sealing valve on HMP sealing line to CEP. 4. Open continuous vent(casing vent)valves of the pump. 5. Open discharge line vent valves. 6. Open suction valve of the pump. 7. Close isolating valves of all the sources taking supply from CEP discharge header. 8. Open isolating valve of gland steam condenser. 9. Open excess condensate return lines isolating valves. 10. Open isolating valves of CEP recirculation control valves. 11. Close isolating valves of 25% and 75% Deaerator level controllers. 12. Rack in 6.6 KV breaker of the pump motor and start the pump on recirculation. 13. Close discharge line vent. 14. Open isolating valves on sealing line from CEP discharge header and establish sealing * CEP is in service*

Line up and starting Condensate Pump in service

Filling Of Deaerator
1. Check that CEP is in service. 2. Check that deaerator drains are closed. Check that deaerator overflow control valve is in service and in minimum position. Check that deaerator recirculation valve is closed. Check deaerator vents are open. 3. Take LP heaters 123 heaters are in service on water side. i.e. heater inlet and outlet valves are open and bypass valves are closed. 4. Check that 25% and 75% deaerator level controllers are in manual mode and in minimum position . 5. Open isolating valves of deaerator level controllers. 6. Crack open 25% deaerator level control valve and fill up deaerator to normal level. *Deaerator filled up*

Lining up of Boiler Feed Pumps

1. Check that BFP lube oil system is in service. 2. Check that the main pump is disengaged and the turbine is on turning gear.(In case of steam turbine driven boiler feed pump). 3. Check that dearator level is OK, CEP is in service and deaerator level control is on Auto mode. 4. Check that deaerator is pegged with pegging steam. 5. Open isolating valves of minimum recirculation valve at the pump and also at deaerator. 6. Close the drain valves on the line recirculation line. 7. Open isolating valves of the balance drum leak off. 8. Establish seal water supply to the pump through duplex filter. In case seal water from CEP is not available then Emergency seal water pump can be used. 9. Take seal water control valves on manual and open control vales on sealing line full.

BFP Installation

Lining up of Boiler Feed Pumps

10. Crack open drains of strainer, vent valves of the pump and discharge lines . Open vent valves after suction valve of the pump. 11. Establish ACW flow through Booster pump bearing jacket cooling. 12. Take into manual mode and close warm up valve and its isolating valves. 13. Throttle the seal water return to condensate sump and start filling the pump. 14. Close the drains of the strainers when water flows continuously. 15. Vent the pump, discharge line and super heater spray line thoroughly and close the vents. 16. Close vents after suction when water flows continuously. 17. Check that feed control valves are isolated and 100% valves of STBFP are closed. 18. In case of MBFP a) Prime the main oil pump,b) Vent and take into service Motor air cooler. AOP should be in service.

Lining up of Boiler Feed Pumps

19. Normalize the sealing before starting the pump. Note : 1) MBFP/STBFP should be started on recirculation after opening the suction valve 2) Loading of the pump is permitted when delta T between casing and deaerator is less than 40 deg C 3) When pump is cold and deaerator is hot pump to be warmed up through warm up line *BFP lined up*

Starting of STBFP
1. Check that all releases are cleared 2. Check that vacuum is built up in the condenser 3. Check that steam is available for starting STBFP Steam pressure > 3 bar is required for resetting the turbine. Initially steam is taken through Auxiliary Control Valve tapped from CRH line. Hence HPLP bypass should be in service. 4. Open isolating valve for Auxiliary Control Valve. 5. Check that deaerator level is ok. 6. Check that lube oil and governing system is lined up. 7. Start one AOP and put the other on auto standby. 8. Check the availability of DC EOP. 9. Check that the pump is lined for taking in service. 10. Engage quick disconnect coupling. Coupling can be engaged or disengaged only at zero speed.

Starting of STBFP
11. Start one jacking oil pump. 12. Open turning gear valve. Check that STBFP rpm picks up. 13. Open gland steam isolating valve and apply sealing to the glands. 14. Open turbine exhaust valve. 15. Open turbine casing drains and stop valve manual drain valve. Drains are connected to surge expander. 16. Close starting device (anticlockwise close). 17. Bring speeder gear to minimum(speeder gear range is from 50% to 110 %). 18. Ensure that speed reference is at minimum. Reset the turbine lockout(speed controller (EHC) range is from 20% to 110%. 19. Open starting device slowly. 20. Warm up the turbine at 500 rpm. 21. Close turning gear valve and put on auto. When turbine trips, the turning valve opens on Auto if JOP pressure is adequate(> 70 bar).

Starting of STBFP
22. Stop JOP. 23. Ensure that DC JOP is on Auto. 24. Open starting device further and roll the turbine. ( At 1200 rpm EHC comes into action). 25. Open starting device full. 26. Take control on EHC and increase speed to 3000 rpm. Close all the drains. While rolling monitor exhaust hood temperature, bearing temperatures, vibrations and expansions. 27. Put tracking on. (Speeder gear tracks EHC) 28. Open isolating valves for 25% control valve and use it initially. 29. If any other BFP is running open 100% discharge valve with STBFP discharge pressure lower than the BFP header pressure. 30. Slowly increase STBFP speed till the feed flow is equally shared between the two pumps. 31. Put STBFP speed control on Auto after ensuring that the control deviation is near zero. *STBFP is in service*

Line up and taking Turbine lube oil system in service

1. Check that hydraulic turning gear shut off valve is closed. 2. Establish 415 V supply and start the vapour extraction fan. 3. Check that the oil level in the lube oil tank is ok.Lube oil can be topped up by running clean oil pump preferably through browser. 4. Line up lube oil cooler as per standard procedure. 5. Line up thrust bearing filter. 6. Transfer lube oil temperature controller on manual mode and open the control valve. 7. Check that lube oil cooler bypass line vent is open. 8. Check the lube oil supply valves to turbine bearings are open. These valves are normally adjusted during commissioning. 9. Check that MOP suction injector priming valves are open. 10. Establish 415 V supply and start the Auxiliary oil pump. 11. Check auto start of standby AOP and EBOP. 12. Transfer lube oil temperature controller to auto mode *Main Turbine Oil System is in service.*

Line up and taking jacking oil system in service

1. Check that main turbine lube oil system is in service. 2. Check that fine control valves supplying high pressure oil for lifting devices are open. These valves normally adjusted at the time of commissioning. 3. Check that pressure limiting device is properly set and the bypass valve is closed. 4. Establish 415 V supply and start jacking oil pump. Check operating conditions are normal. 5. Establish 415 V supply to standby JOP and DC jacking oil pump. Transfer the SLC mode to Auto. 6. Check Auto start of standby JOP and emergency JOP. * Jacking oil pump in service*

Taking Turbine on Turning Gear

1. Check that main turbine lube oil system is in service. Oil temperature to be maintained at 45 Deg C. 2. Check that the jacking oil system of main turbine is in service. 3. Check that oil supply system SGC and lube oil and jacking oil pumps SLC is on Auto mode. 4. Open turning gear shut off valve and check the speed of the rotor. Note : Oil system and Turning gear to be in service at least 6 hrs before Turbine start. *Turbine on Turning Gear*

Line up and taking Control Fluid System in service

1. Check that the level in control fluid tank is ok. 2. Check that all drains in system are closed. 3. Check that high pressure and low pressure discharge valves of the pumps are open. 4. Line up duplex filters provided along the high pressure and low pressure supply to various sources. 5. Line up control fluid coolers. 6. Open high pressure accumulators isolating valves provided at various high pressure service points. 7. Establish 415 V supply and start the control fluid pump. Check Auto start of standby pump. 8. Establish control fluid supply to various services. *Control fluid system in service*

Check out of TG system

1. Check that main turbine lube oil tank level is normal. 2. Check that main turbine oil conditioner is in service. 3. Check that all power supplies are made available to AOPs, EOP, Oil vapour extractors, turning gear oil valve, JOPs, Primary water pumps, Seal oil pumps, Generator bearing extractors. 4. Check that turbine lube oil coolers are in service. 5. Start one oil vapour extractor. 6. Start one AOP and check that the oil pressure is adequate. Pr>5bar. 7. Put PLCs of AOPs and EOP on Auto. 8. Put oil temperature controller on Auto. Oil system is taken in service 6 hrs in advance. Temp. 45 Deg C. 9. Check that control fluid tank level is normal. 10. Check that CF system including conditioning system is lined up. 11. Start one CF circulation pump.CF temperature >20 deg C. 12. Start one CF pump and check pressure. Pr > 28 bar.

Check out of TG system

13. Put SLCs on Auto for CF pumps and heaters. 14. Put temperature controller on Auto. Temperature 55 deg C 15. Check that Generator primary water system is in service. 16. Check that Generator Seal Oil system is in service and Hydrogen purity and pressure are OK. Purity > 99 % and Pressure > 3 bar. 17. Establish seal steam to turbine and put the control on Auto. 18. Check that at least one half of the condenser is in service on sea water side. 19. Check that vacuum breaker is closed. 20. Start one vacuum pump and build up vacuum in the condenser. 21. Start one JOP and observe that jacking oil pressure is adequate. Put SLCs of JOP on Auto. 22. Open the Turning Gear gate valve and put its SLC on Auto and watch turbine speed going up. 120 RPM with full vacuum. Initially turbine has to be rolled by hand barring to overcome the inertia to overcome the inertia then hydraulic gear takes over.

Line up and taking Gland Sealing System in service

1. Check that the machine is on turning gear. 2. Check that main condenser in service. 3. Check that CEP is in service. Line up and take Gland Steam Condenser (GSC) in service on water side. 4. Open leak - off to GSC.Check that atmospheric leak off is closed. 5. Close Gland Steam Isolating valve to STBFP. 6. Open GSC vapour extraction fan inlet. Establish 415 V supply and start the fan. 7. Check that gland steam leak off isolating valve from individual glands are open. These valves are set at the time of commissioning. 8. Crack open gland steam leak off bypass valve to condenser. 9. Open drain and open Auxiliary steam isolating valve to Gland steam header. Aux. steam temperature should be @ 330 deg C.

Line up and taking Gland Sealing System in service

10. Check that gland steam pressure is set at 60 mmwg. 11. When the system is adequately warmed open the second isolating valve of auxiliary steam controller and crack open the first isolating valve. 12. Slowly charge the system and open the first isolating valve. Close the drain. 13. Take gland steam leak off control valve in service by opening the isolating valves. Close leak off bypass valve. 14. Establish Gland steam supply to STBFPs as required.

*Gland Steam System in service*

Lining up and taking in service Elmo Air Evacuation System

1. Close drains and fill the Air/Water separator tank of ELMO pump by condensate quality water. Make up is from HMP discharge. 2. Line up tank level controller by open isolating valve. 3. Charge, vent and take into service the condensate cooler. 4. Open air side isolating valve, Bypass valve and close solenoid valve i.e. put the pump on Hogging mode. Pump should always be started in Hogging mode to avoid cavitation. 5. Check that gland steam in service. 6. Start the pump and check vacuum. Note : For building vacuum in condenser all the possible paths should be blocked. i.e. turbine glands, HRH vents and drains, Vacuum breaker valve, Atmospheric lines coming to Auxiliary Flash Boxes and KWU flash box. *Elmo Air Evacuation System is lined up and taken in service*

Condenser Evacuation System

Vacuum Breaker

To Atmosphere

To Atmosphere Holding valve Ejector Separator tank Hogging valve Vacuum Pump 2 x 100 %

Inlet valve Ejector Steam Jet Air Ejector

Holding valve

Inlet valve Separator tank

Hogging valve Vacuum Pump 2 x 100 %

Steam Valve

To atmosphere

Separator tank heat exchanger

Separator tank heat exchanger

Charging and taking feed water heaters in service

1. After the unit is synchronized the feed water heaters may be taken in service 2. Before charging the steam side condensate path should be taken in service. The following procedure for LP heater (no.2) is a typical procedure for taking a heater in service 1. Take the heater standpipe in service by closing drain valve and opening valves on level switches, level gauges and level transmitters on both the ends of the heater 2. Close the water box drains 3. Open water box vents 4. Crack open the heater inlet valve bypass valve 5. When water starts coming out of the vents close the vents 6. Open inlet and out valve and close bypass valve on condensate line Now the water side is in service

Feed Water Heater

Charging and taking feed water heaters in service

7. Close atmospheric vents and drains. Keep drain valves on heater drain lines closed. Open drain control valve isolating valves. Open vent to atmosphere. 8. Energize extraction NRV solenoids from control room. Crack open extraction steam isolating valve. Note : In the case of HP heaters, it is important to warm up the shell and drain lines. This is achieved by keeping the shell vents and drain line drains crack open for some time. But in case of LP heaters since they are under vacuum at low loads atmospheric vents and drains should not be opened. 9. After the heater is warmed up for about half an hour , open extraction isolating valve. 10. After LP heaters are in service take LP drain receiver in service. 11. After building up drain receiver tank level, take LP heater drain pump in service. *LP Heater is in service*