SEPC POWER PRIVATE LIMITED

1 X 525 MW THERMAL POWER PLANT, TUTICORIN; TAMILNADU

UNIT COLD START-UP CHECK LIST
Doc. No: SEPC/CHK/BTG/OPN/096 R0 Rev Date:24-01-2023
DATE: SHIFT: GROUP:
** Criteria: Turbine Metal Temp. <150°C (Shut Down > 72 Hours)

HP shaft HP Turbine differential expansion

HP casing IP Diff Expansion

IP shaft Over all expansion HP/LP

IP Casing LPT 1 diff Expansion

AOP running HPT Shaft expansion

JOP running IPT shaft Expansion

Lube oil header pr and temp After cooler Axial shift

JOP header pressure Seal oil DP

S No. Description Time/ Status Remarks

Boiler side check list before light up

1 NO PTW is pending & clearance obtained from all departments

2 Ensure that all required electrical system available and charged properly.

3 Ensure all peep hole & manholes of boiler are closed & manholes cooling water opened.

Ensure before MSSV drain valve MSV 101/102 are opened, and Take Open/Close trial of
4
MSV-1 and MSV-2 kept Closed Position.

5 Ensure BCP cooling Emergency overhead tank level is Full (2100 mm).

Ensure HP & LP heater vent line is isolated and Normal and emergency drip line MIV
6
opened and lined up condition.

7 Maintain normal drum level (-50 mm).

8 Ensure at least 2 BCP's are running and other pump in standby

9 Boiler drum vents B1, B2, B3, B4, B25, B26 B28 & B29 are in open condition.

10 All SH & RH drains and vents are in open condition.

11 Eco recirculation MOV E17 is in open condition

12 Ensure CBD and EBD lines all manual valves are in open conditions.

13 Both APH-A & APH-B are in service & Air motor trial taken.

14 Ensure all the 4 passes of ESP are lined up as per requirement.

15 All ESP hopper heaters, CERM and EERM are running in auto mode.

16 Ensure Bottom ash hoppers & fly ash system is ready and lined up.

Ensure Seal trough, bottom ash SCC are filled up and refractory cooling water line is also
17
lined up.

18 All ID Fans, FD Fans & PA Fans & its LOPs are lined up and PCD operation checked

19 Ensure VFD room AC system, reactor air washer units are in service.

20 Ensure SCAPH bypass opened or SCAPH is through and drains are lined up to IBD tank.

21 Ensure all SH and RH and APRDS spray lines are lined-up condition.

22 Ensure AC scanner fan is running and DC scanner fan trial taken.

23 Ensure all soot blowers & LRSB are in home position

24 Ensure APH soot blower are line up with Service air.

Ensure APH oil carry probe is working and is in inserted condition and cooling water is
25
charged.

26 Ensure all sample lines MIVs are opened and sample cooler is charged from SGDMCW.

27 Ensure ERV’s (SV-9,10) are lined up and power supply is ON.

28 Ensure all Expansion indicators of boiler are in position, & record their initial values.

29 Ensure burner tilt should be horizontal.

 BOP side check list before light up

30 Ensure at least One CW & 09 cells riser valves is open.

31 Ensure one ACW pump is running.

32 Ensure SGDMCW & TGDMCW pumps are in service and PHE lined up.

33 Ensure both DM storage tanks & CST having sufficient quantity of water.

Ensure CT make up line is charged either through gravity or at least one CT make up pump
34
is running for Hotwell makeup.

35 Ensure Emergency DG tank level is adequate and its trial is taken.

36 Ensure either fire hydrant system in service and movable fire tender is available at site.

Ensure CHP, AHP, DM plant and Fire & safety department is duly informed about boiler
37
light up.
Ensure LDO &HFO tank level is ok and one LDO pump is running in recirculation with
38
sufficient pressure (15 kg/cm2).
Ensure electric heat tracing coil at FOPH (circuit no P1 to P4) and tracing coil at Boiler
39
(circuit no 1 to 17) are ON condition.
Ensure instrument air compressor with respective drier and one service air compressor
40 should be running and line should be charged in TG side & Boiler side with pressure more
than 6.5 kg/cm2
Turbine side check list before Boiler light up
Ensure MOT, TDBFPA&B , Seal Oil Vacuum tank, HPCF, HPBP, LPBP oil tank levels are
41
normal.

42 Ensure Seal steam supply line, Codensate system, feedwater system, vaccum system lined up

Ensure Turbine is on barring gear and DC EOP and DC JOP trial taken and its temp CV is in
43
auto. (Set pt. 45˚C)

44 Ensure one HPCF oil pump is running.

45 Ensure oil system all SLC is on.

Ensure one CEP is running and ensure line up for PRDS, LP exhaust hood spray, LPBP &
46
Turbine flash tank.

47 Ensure Primary water pump is running and its temp CV is in Auto.

48 Ensure Seal oil pump is running and DC seal oil pump trial is already taken.

Ensure hydrogen is filled, its purity (99%) and pressure (4 kg/cm2) and its temp CV is in
49
Auto. (Set point 40˚C)
Both TDBFPs lube oil pumps are running and their respective EOPs trails taken. Ensure
50
both TDBFPS are in barring.
Ensure all drains are opened for MS, CRH, HRH, HPBP, LPBP, MAL, Gland Steam
51
&Extractions.

52 Ensure MAL drains are in auto and their manual isolating valve is in open condition.

Ensure all spray lines are lined-up condition. All temp control valves are healthy and are in
53
Auto.
Ensure chemical dosing system is ready.( Ensure chemicals are available, mixing tanks are
54 filled, power supply for local panel and pumps, agitator motors are available, dozing line
valves for D/A, condensate and drum are open.)

55 Ensure Excitation system is ready and all GRP relays are reset.

56 Ensure IPBD air pressurisation unit is in service.

57 Ensure SWAS is in lined up.

58 Ensure deaerator level is normal (+400mm) and its drain to flash tank is in close condition.

Boiler Light up activity

Start one ID and FD fan as per SOP and maintain furnace draft (-10 mmwc). Similarly start
59
another set of ID & FD Fan by maintaining draft

60 Establish air flow between 30 to 40% (630TPH to 840TPH)

61 Ensure Purge permit available.

After purge, put aux damper control in auto and set point for wind box to furnace DP is
62
40mmwc.

63 Open LOTV, LOCV and maintain LDO pressure after LOCV as 13 kg/cm²

64 Light up the boiler with 2 LDO guns in AB Elev and maintain oil pressure around 10 kg/cm2

After 15 min take another 2 LDO guns in AB elevation and maintain oil pressure around 9
65
kg/cm2.

66 Check temp in FG, Drum metal is raising

At drum pressure reaches 2 kg/cm2 than close all drum vents after ensuring sufficient steam
67
flow from local.

68 Ensure both APH soot blower is running

 At drum pressure 5 kg/cm2, close all the SH vents and close all SH drains at 8 kg/cm2
69
except start-up vent.
Warm up the MS line by opening MSV-3, MSV-4, and MSV-5 & MSV-6 at MS Pressure of
70
5 kg /cm2 , Ensure condensate removed in MS strainer drain.

71 Charge MS line by opening MSV-1 & MSV-2 by ensuring both sides pressures equal.

72 Charge APRDS from MS line and maintain header pressure 12 kg/cm2

Charge APH sootblowing, Mill Inerting, Main turbine & TDBFP Gland sealing, HFO tracing
73
steam, atomising steam from APRDS.

74 Start vacuum pulling by starting all vacuum pumps. Close Reheater vents & drains.

Charge Gland steam system (Steam temperature before CV > 220˚C and header pressure
75
350mmwc).
Start HFO Forwarding pump as per SOP and put HFO in long recirculation by charging
76 heaters. Open HOTV, HOCV to attain the HFO Firing parameters. (temp > 120 degC,
pressure around 10 kg/cm2)
Open LP and HP bypass around 10%. Ensure HP bypass warm-up lines are already open.
77
Ensure the CRH and HRH drains open from local

78 Close start-up vent full after charging HP/LP bypass.

79 Close HPBP warm-up MOV.

Raise MS pressure and temp as 40 kg/cm2/350˚C and HRH temperature and pressure to 330
80
deg C and 6 kg/cm2.

81 Ensure steam parameters are satisfied before rolling and get approval from chemist

82 Note down Boiler expansion readings and ensure no fouling in boiler area.

Turbine Rolling Activities

83 Ensure Temp curves X1 & X2 are satisfied for opening ESV and EHG is enable

Bring starting device to zero position this will cause generation of trip oil, check trip oil
84
pressure and Start up Oil pressure.

85 Ensure Speeder gear open position (100%).

86 Close CRH QCNRV MIV.

Raise the Starting device position to approx 27-30% & ensure start up oil pressure zero and
87
check HP/IP turbine Stop valve is fully opened in DCS and local.

88 Further raise the starting device up to 100%.

Raising the speed up to 360 rpm (Soaking Speed):

89 Ensure temp curves X3, X4 and X5 are satisfied.

90 Drum level should be -50 mm.& Ensure GT cooling fan's switched ON

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

92 Ensure HP turbine evacuation valve to condenser is in closed condition.

93 Put “360” rpm in rpm ref in EHTC page and check that turbine speed is rising. DN/DT is ok.

94 Check that TG barring gear MOV is closed at 240 rpm otherwise close it manually.

95 Observe MOT oil level is rise after barring gear stopped.

Check all bearing vibration & other turbovisory parameters are within permissible range. If
96
not, trip the turbine and search the cause.

97 Check the TSE margin is > 30k

98 Check drains are operating as per SLC logic. Temp. is in increasing trend.

Raising the speed up to 3000 rpm:

After APH Secondary air temperature is >180˚C, Start one PA Fan and check Seal air fan
99 start in auto, Maintain PA header pressure around 800 mmWC and seal air pressure 1200
mmWC.
Line up for one mill (Lowest Elev possible).Start one mill & keep it in warm-up condition
100
and check other mills to ready for start

101 Ensure Temp curves X6 criteria are satisfied.

Raise the turbine speed by giving speed reference to ‘3000 rpm’ and check turbine speed is
102 rising,Observe JOP is cut off at 540 rpm and AOP is cut off at 2850 rpm otherwise stop it
manually.

103 Monitor turbine vibration readings at critical speed.

Check turbine oil system, seal oil system, Hydrogen and primary water system for any
104
abnormality.

105 If everything ok, Start the running mill feeder and keep running mill on min loading.
 Synchronization of the unit/loading of the unit:

106 Load mill around 20 to 30 TPH.

107 In EHTC page load ref. 50 -60 MW.

108 In EHTC page Pr. max 60-80 MW

109 Check the X7 criteria are satisfied.

110 Take clearance from Elect dept for Syncronisation and inform switch yard, SLDC

111 Synchrnoize the unit as per SOP

112 Observe that unit load is reached up to 50-60 MW.

113 Switch “OFF” the synchroscope.

114 Ensure “LOAD CONTROL ON” is being changed & displayed in EHTC page.

115 Enter load gradient value up to 10 MW.

116 Increase the load reference to increase the load.

117 After Unit synchronisation close slowly HP and LP Bypass and close all line drain valves.

118 Start Coal Mill B and load as per requirement.

119 Charge all LP heater Extraction on load above 80 MW.

120 Charge Deareator from Extraction @ 120MW.

121 Charge all HPH extraction on 200 MW.

122 Start rolling of any one TDBFP as per SOP and observe parameters

123 Changeover APRDS steam supply from MS to CRH line.

Start Coal Mill C and increase load upto 270 MW. Remove oil guns after ensuring intensity
124
and charge ESP
Take TDBFP A & B in service and put drum level control in auto. Stop MDBFP if TDBFP
125
parameters are satisfied. Keep MDBFP in standby.
Take Coal mill D & E in service @ 350 MW and 450 MW respectively and load the unit
126
upto 525 MW
Major Issues faced (if any):

Reason for delay (if any):

Boiler Desk Engr: Name & Sign TG Desk Engr: Name & Sign

UCE: Name & Sign SCE: Name & Sign

UCE: Name & Sign SCE: Name & Sign
 SEPC POWER PRIVATE LIMITED
1 X 525 MW THERMAL POWER PLANT, TUTICORIN; TAMILNADU
UNIT HOT START-UP CHECK LIST
Doc. No: SEPC/CHK/BTG/OPN/097 R0 Rev Date:24-01-2023

DATE: SHIFT: GROUP:

** Criteria: Turbine Metal Temp. >350°C
HP shaft HP Turbine differential expansion

HP casing IP Diff Expansion

IP shaft Over all expansion HP/LP

IP Casing LPT 1 diff Expansion

AOP running HPT Shaft expansion

JOP running IPT shaft Expansion

Lube oil header pr and temp After cooler Axial shift

JOP header pressure Seal oil DP

Condenser vacuum

S No. DESCRIPTION STATUS REMARKS

1 All PTW from BOP, BTG and Electrical are closed

2 Clearance given by all concern departments.

3 One or both CW pump and Atleast 09 IDCT fans are running.

Two TGDMCW,One SGDMCW & One ACW pump are running and discharge pressure and
4
temperature are healthy.
One IAC & SAC are running and header pressure is above 6 kg/cm², Turbine and boiler side
5
lines are charged.

6 LDO & HFO Forwarding pumps are running & available for light up.

7 Two BCW pumps are running.

8 Minimum One CEP pump is running.

9 MDBFP running on recirculation.

10 Main Turbine and Both TDBFP are on barring.

11 Seal Oil,Primary water,HPCF,HPBP,LPBP oil systems are in service

12 One stream of Draught System are in service.

13 AC or DC scanner air fan in service.

S No. DESCRIPTION Time REMARKS

Ensure that Lube oil,HPCF,Seal oil & Primary Water System SLC is ON and power supply
1
is healthy.

2 Ensure that all temperature control valves are on auto, check set points

Establish 30% to 40% of rated air flow (630-840 TpH) by operating FD fan blade
3
pitch.

4 Adjust ID Fan VFD to maintain furnace pressure to -5 to -10 mmWC, put it in auto.

Check the purge permissive is satisfied; if ok initiate purging of boiler. After 9 min
5
purging will over & Master fuel trip (MFT) relay will reset .

6 Set furnace to wind box DP to 40 mmwc by putting auxiliary air damper in auto.

7 Light-up the boiler with LDO/HFO in AB or CD elevation.

8 Before charging MS lines ensure corresponding MS and CRH line drains are opened.

9 After charging main steam lines open the PRDS drains & charge PRDS.

After achieving adequate temperature(>280°C) at Gland Steam inlet line,Charge

10
Gland Steam for Main Turbine & Both TDBFP.Parallely,Start Vacuum Pulling.

11 Charge HP/LP bypass system.

12 Start one PA fan & seal air fan.Maintain PA header pressure 800 mmwc

13 Take Mill B in service if HP turbine casing temperature is <400˚C.

 Take coal mill B&C in service if HP turbine casing temperature is >450˚C &feeder
14
up to 50-60% load as per requirement.
15 Maintain HRH pressure 6 kg/cm²
Bring the MS & HRH steam temperature as per requirement with the help of HP
16
bypass system.
Ensure Temp curves X1 & X2 are satisfied for opening ESV during HP/LP Bypass
17
running
Bring starting device to zero position this will generate trip oil, check trip oil pressure
18
around 8 kg/cm2.
Raise the Starting device position to 27-30% (start up oil pressure zero) and check
19
HPSV/IPSV is full opened.
20 Ensure temp curves X3, X4 and X5 are satisfied for Turbine Rolling.
Put “360” rpm in rpm ref in EHTC page and check that turbine speed is rising and
21
DN/DT is ok.
22 Ensure GT cooling fan's switched ON.
23 Check that TG barring gear is stopped at 240 rpm otherwise stop it manually.
24 Ensure Temp curves X6 criteria are satisfied for 3000 rpm.
Ensure Lube oil TCV, HPCF TCV, Primary water TCV & H2 cooler TCV are in
25
auto, Primary water cooler, H 2 cooler & Exciter cooler are charged.
Start rolling the turbine by giving speed reference to ‘3000 rpm’ and check turbine
26
speed is rising.Ensure CRH NRV is opened while speed rising.
27 Observe JOP is cut off at 540 rpm
28 AOP to be cut off after adequate Lube oil header pr.> 2 ksc at 2850 Rpm.
29 Check all bearing temperatures are within permissible range.
Check all bearing vibration & other turbovisory parameters are within permissible
30
range.
31 Start 2nd set of ID & FD Fan.
32 Check whether all synchronization criteria are satisfied.
33 Take clearance from Elect dept for Synchronisation and inform switch yard, SLDC
34 Synchrnoize the unit as per SOP
After Synchronization, Increase the load on turbine by observing TSC margin
35
accordingly.
36 Charge all LP heater Extraction on load above 80 MW.

37 Charge Deareator from Extraction @ 120MW.

Start Coal Mill C and load as per requirement.Remove oil guns after ensuring intensity and
38
charge ESP.Increase load upto 250 MW.

39 Charge all HPH extraction on 200 MW.

40 Start rolling of any one TDBFP as per SOP and observe parameters

41 Start Coal Mill A and increase load upto 350 MW.

Take TDBFP A & B in service and put drum level control in auto. Stop MDBFP if TDBFP
42
parameters are satisfied.

43 Take Coal mill E in service @ 450 MW and load the unit upto 525 MW
Major Issues faced (if any):

Reason for delay (if any):

Boiler Desk Engr: Name & Sign TG Desk Engr: Name & Sign
Boiler Desk Engr: Name & Sign TG Desk Engr: Name & Sign

UCE: Name & Sign SCE: Name & Sign