Boiler Startup
DEPENDS ON HP TURBINE SHAFT
TEMPERATURE
COLD STARTUP - <150 DEG C
WARM STARTUP - 150-350 DEG C
HOT STARTUP - >350 DEG C
LIGHTUP PRE-CHECKS
AND
READINESS FOR
LIGHTUP.
Lightup Pre-
checks
CHECK ALL PTW RETURNED.
TAKE ELECTRICAL DEPT. ,C&I DEPT. ,BMD DEPT. & TMD
DEPT. CLEARANCE PRIOR TO LIGHTUP.
ALL POWER SUPPLY VIZ. 11 KV, 3.3KV,415V, 220V DC, 110 V
AC, AND 24 V DC SUPPLY TO THE RESPECTIVE SYSTEMS
SHOULD BE AVAILABLE.
INFORM TO DM PLANT PRIOR TO LIGHTUP SO THAT THEY
CAN START CHEMICAL DOSING SYSTEM AS REQUIRED.
Lightup Pre-
checks cont.
INFORM TO SWITCHYARD ABOUT LIGHTUP.
LINEUP AND START 1 NO. ACW PUMP AND 1 NO. CW PUMP.(Condenser
back charging and DMCW PHE charging)
ENSURE RUNNING OF COMPRESSOR OTHERWISE START ONE
COMPRESSOR. TAKE ONE AIR DRYER IN SERVICE FOR INSTRUMENT
AIR.
CHECK AIR SUPPLY ESTABLISED AT ALL POINTS IA INSTRUMENT AIR
FOR ALL CONTROL VALVES AND SERVICE AIR FOR OIL ATOMISING.
CHECK ADEQUATE CST LEVEL AND AVAILABILITY OF BOILER FILL PUMP
AND HOTWELL MAKEUP PUMP(CT PUMP)
CHARGE HTPRDS FROM OTHER UNIT(IF AVAILBALE)
Lightup Pre-
checks cont.
CHECK ALL SOOT BLOWERS TO BE RETRACTED POSITION.
APH SOOT BLOWING START WITH AIR OR STEAM
ENSURE ALL 4 PASSES OF ESP LINEUP AS PER REQUIREMENT.
ENSURE ALL SPRAY LINES ARE LINED-UP CONDITION
CHECK ALL GAGS FROM THE SAFETY VALVES ARE REMOVED.
INFORM TO CHP AND CONFIRM COALS ARE AVAILABLE IN COAL BUNKERS.
OPEN DRUM VENTS, SH VENTS, AND MS LINE VENTS AND TURBINE SIDE DRAINS.
BEFORE DRAIN VALVE OF MSSSV (MSV-101 & MSV-102 OPENED)
OPEN FULLY THE STARTUP VENT
OPEN ALL MIV OF CBD VALVE (EBD AND CBD LINEUP)
Lightup Pre-
checks cont.
OPEN ECONOMISER RECIRCULATION VALVE(E-15).
START 1No.SGDMCW PUMPS AND 1No.TGDMCW
ENSURE DMCW LINES IN LUBE OIL COOLERS OF BOILER SIDE ARE CHARGED
AND START ALL EQUIPMENT LOP’S.
ENSURE THE DMCW LINES ARE CHARGED IN TG SIDE FOR
CEP,BFP,GENERATOR ,EXCITER, SEAL OIL COOLERS AND TG LUBE OIL
COOLERS.
ALL SAMPLE LINES ARE LINED UP AND SAMPLE COOLER IS IN SERVICE
START LDO PUMP IN RECIRCULATION MODE.
ALL MIV OPENED BEFORE LONV, AAONV AND IGNITERS COOLING LINE ARE
OPENED
Lightup Pre-
checks cont.
FILL THE BOILER DRUM THROUGH BOILER FILL PUMP UPTO -100
MMWC.
START 1 NO. OF CT PUMP AND FILL THE HOTWELL UPTO 00
MMWC.
START 1 NO. OF CEP AND FILL THE DEAERATOR UPTO 100 MMWC.
START 1 NO. OF BFP{MDBEP/TDBFP(If APRDS available.)} IN
RECIRCULATION MODE.
START ATLEAST 02 No BCW PUMP
CHARGE DEAREATOR PEGGING FROM APRDS
Lightup Pre-
checks cont.
START BOTH APH BY AIR MOTOR FIRST AND THEN BY
AC MOTOR.
START 1 NO. OF ID AND FD FAN AND MAINTAIN AIR
FLOW BETWEEN 30% TO 40% APPROX. (670 to 750TPH)
AND FURNACE DRAFT BETWEEN -5 TO -10 MMWC.
PUT SADC IN AUTO TO MAINTAIN FURNACE TO WIND
BOX DP.
START AC SCANNER AIR FAN AND CHECK DC SCANNER
AIR FAN IS COMING IN AUTO IF AC FAN TRIPS.
BOILER PURGING
Boiler Purging
FOLLOWING PURGE PERMISSIVES SHOULD BE
SATISFIED BEFORE PURGING.
NO BOILER TRIP
LOTV CLOSED
ALL LONV CLOSED
ALL PA FANS OFF
ALL FEEDERS OFF
ALL HOT AIR GATE CLOSED
ALL AUX. DAMP MODULATING
AIR FLOW>30% & <40%.
ALL SCAN NO FLAME.
Boiler Purging
cont.
START PURGING.
WAIT UNTIL PURGE IS COMPLETED.(BOILER PURGING
TIME IS 540 SEC.)
DURING PURGING SEE AL L SADC DAMPERS ARE FULL
OPEN POSITION AND AFTER PURGING WAIT UNTIL IT
COMES TO MODULATING POSITION.
BOILER IS READY FOR LIGHTUP.
BOILER
LIGHT-UP
Boiler Light-up
ENSURE ALL OIL GUNS ARE CLEANED BEFORE
LIGHTUP.
CHECK OIL ELEVATION SHOULD BE READY FOR TAKING
IN SERVICE FROM LOCAL AND REMOTE.
CHECK OIL GUN SHOULD BE IN REMOTE MODE AND
ALL ISOLATION VALVES OF LONV SHOULD BE OPEN.
CHECK ATOMISING AIR VALVE IN OPEN POSITION AND
MAITAIN AIR PRESSURE 7 KG/CM2
Boiler Light-up
cont.
OPEN LOTV VALVE AND LOFCV AND MAINTAIN
PRESSURE UPTO 10 KG/CM2
LIGHT-UP THE BOILER BY GIVING COMMAND TO AB/CD
ELEVATION LDO CORNER 1 & 3 OR 2&4
MAINTAIN OIL PRESSURE AGAIN UPTO 10 KG/CM2 FOR
TAKING NEXT TWO OIL GUNS.
TAKE OIL PAIR FOR AB ELEVATION CORNER 2 & 4.
MAINTAIN OIL PRESSURE AT 7 KG/CM2.
Boiler Light-up
cont.
CONTROL THE FIRING RATE BY OIL PRESSURE SO THAT THE BOILER
STARTS STEAMING AFTER 45 MINUTES.
SEE THE TEMPERATURE RISE OF DRUM METAL (1.5 DEG/MIN.)
ENSURE THE FURNACE FLUE GAS EXIT TEMPERATURE SHOULD NOT
INCREASE 500 DEG C . THIS IS TO PROTECT THE REHEATER TUBES
BEFORE THE FLOW IS ESTABLISED.(FURNACE TEMPERATURE PROBE
IS PROVIDED TO MEASURE THE FURNACE TEMPERATUE).
CONTROL THE FIRING SO THAT DRUM METAL DIFFERENCE TOP &
BOTTOM SHOULD NOT BE EXCEED MORE THAN 50 DEG. C.
WAIT FOR RAISE IN DRUM PRESSURE AND TEMP MEANWHILE START
THE TURBINE SIDE ACTIVITIES.
Boiler Light-up
cont.
ENSURE TURBINE SIDE MS, CRH, HRH DRAINS AND MAL VALVES
SHOULD BE OPEN POSITION.
UPTO THIS TIME THE TURBINE SHOULD BE TAKEN IN BARRING GEAR.
START HPCF PUMP AND OPENED GAUGE OF ALL CV.
GENERATOR HYDROGEN SHOULD BE 4.5 KSC.
START ALL VACUUM PUMP STARTED.
CHARGE THE SEAL STEAM FROM APRDS TO TURBINE GLANDS. ALSO
START GLAND SEAL EXHAUST FAN.
START VACUUM PULLING AND TURBINE SEALING IN TG MAINTAINING
APPROX 0.13 KG/CM2 abs.
Boiler Light-up
cont.
CLOSE THE DRUM AND SH VENTS AT 2-3 KG/CM2 DRUM
PRESSURE. CLOSE THE SH DRAINS AT 5 KG/CM2.
OPEN BYPASS VALVE OF MS STOP VALVE FOR WARM UP
THE LINE AT 5-6 KG/CM2 PRESSURE AND 225 DEG C SH
TEMP AND THEN CHARGE THE MAIN STEAM LINE.
THROTTLE THE STARTUP VENT
RAISE THE DRUM PRESSURE/MS PRESSURE UPTO 15
KG/CM2
Boiler Light-up
cont.
OPEN HPBP AND LPBP VALVES WHEN STEAM
PRESSURE REACHES UPTO 15 KSC AND STEAM TEMP
UPTO 250 DEG C.
TAKE CD ELEVATION IN SERVICE TO INCREASE STEAM
DUMPING.
CLOSE THE STARTUP VENT.
WAIT FOR TURBINE ROLLING CRITERIA (SEE THE
CRITERIA X1, X2,X3 TO BE FULFILLED)
Boiler Light-up
cont.
RESET THE TURBINE PROTECTION GRAPHICS PAGE AND
ENSURE NO FAULT OR TRIP IS DISPLAYED IN PAGE.
BRING STARTING DEVICE TO ZERO POSITION THIS WILL
CAUSE GENERATION OF TRIP OIL ,TRIP OIL PR. SHOULD BE
>8KSC.
BRING SPEEDER GEAR TO MIN. POSITION
AT STARTING DEVICE POSITION 27% HPSV FULL OPENED.
AT STARTING DEVICE POSITION 45% IPCV IS FULL OPENED
FURTHER RISE AT 100% POSITION.
RAISE THE SPEEDER GEAR UPTO 100%. THIS WILL BRING
EHG IN EFFECT.
Boiler Light-up
cont.
AT 25-30 KSC STEAM PRESSURE AND STEAM TEMP 300-325 DEG C TURBINE STOP
VALVES IS OPENED.
WAIT UNTIL CRITERIA X4 & X5 FULLFILLED
TG BARRING GEAR IS STOPPED AT 240 RPM OTHERWISW STOP IT MANUALLY.
ROLL THE TURBINE TO 360 RPM.
CHARGE MOT ,EXICTER AND PW COOLER
START ONE PAF
BOTH SEAL AIR FAN STARTS IN AUTO WITH STARTING OF PA FAN. STOP ONE FAN.
KEEP PA HEADER PR. >760 MMWC
START ONE MILL (LOWEST MILL)
Boiler Light-up cont.
ROLL THE TURBINE TO 3000 RPM. ( WAIT
CRITERIA X6 IS SATISFIED).
OBSERVE THE TURBINE VIBRATIONS DURING
ROLLING TO 3000 RPM.
OBSERVE JOP IS CUT OFF AT 540 RPM.
OBSERVE AOP IS CUT OFF AT 2850 RPM.
CHECK THE X7 CRITERIA ARE SATISFIED
Boiler Light-up
cont.
INFORM THE SWITCHYARD THAT THE TURBINE IS GOING TO
BE SYNCHRONISED.
PUT LOAD REFERENCE AT 60 MW AND LOAD GRADIENT AND
LOAD CONTROL IN ‘ON’ POSITION.
MATCH THE GENERATOR VOLTAGE WITH THE INCOMING
VOLTAGE WITH THE HELP OF EXCITATION SYSTEM.
MATCH THE FREQUENCY OF THE GENERATOR WITH THE
GRID FREQUENCY BY CHANGING THE SPEED REFERENCE.
SYNCHRONISE THE MACHINE.
Boiler Light-up
cont.
INCREASE THE SPEED REFERENCE TO INCREASE THE
LOAD
THE TURBINE WILL GO FROM SPEED CONTROL TO LOAD
CONTROL WHEN LOAD CONTROLLER OUTPUT WILL
BECOME MORE THAT SPEED CONTROLER OUTPUT. THEN
LOAD IS CHANGED BY CHANGING THE LOAD SET POINT.
CLOSE ALL DRAINS.
CLOSE HPBP AND LPBP VALVES.
CLOSE MAL DRAIN VALVES.
Boiler Light-up
cont.
CLOSE ECO. REC. VALVE E-15
INCREASE FIRING TO INCREASE LOAD
START 2ND IDF,FDF & PA FAN,INCREASE THE PA HEADER PRESSURE UP TO 800 MMWC.
(BALANCE ALL THE FANS)
START 2ND NO. OF CEP AND TGDMCW(OTHER PUMP TAKEN IN S/B)
ROLL 2ND TDBFP AND TAKEN IN SERVICE(BALANCE THE LOAD ON BOTH BFP).TAKE
MDBFP IN S/B.
START 2ND MILL AND INCREASE THE LOAD.
CHARGE LPH-1,2,3.(>120 MW)
START 3rd MILL AND INCREASE THE LOAD.
CHARGE HPH-5 AND 6(>240 MW)
DEAREATOR PEGGING TAKEN IN SERVICE FROM IP EXTRACTION AND ISOLATE FROM
APRDS
Boiler Light-up
cont.
GRADUALLY INCREASE THE CAOL FEEDEING, MS
PRESSURE, MS & HRH TEMPERATUE BELOW 540 DEG C.
TAKE MILL-D IN SERVICE.
TAKE OUT ALL OIL GUNS AT BOILER LOAD >60%
TAKE MILL-E AND MILL-F
SLOWLY INCREASE THE LOAD UPTO 600 MW.
HARIOM
THANK
YOU
BIRBAL KUMAR
