BRIEF INTRODUCTION
OF
Warm startup of Boiler & Turbine rolling and loading
procedure
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PRESENTED BY:
Mahendra singh
Boiler Startup
DEPENDS ON TURBINE HP 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.
 M/C ON BARRING, AND LUB OIL TEMP IS >550C
 TAKE ELECTRICAL .BMD,AHP,TMD AND C & I DEPARTEMENT
CLEARANCE PRIOR TO LIGHTUP.
 ALL POWER SUPPLY VIZ. 6.6 KV, 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. CW PUMP AND 1 NO. ACW PUMP.
 ENSURE RUNNING OF COMPRESSOR OTHERWISE START ONE
COMPRESSOR. TAKE ONE AIR DRYER IN SERVICE FOR INSTRUMENT
AIR.
 CHECK AIR SUPPLY ESTABLISED AT ALL POINTS i,e 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
Lightup Pre-checks cont.
 CHECK ALL SOOT BLOWERS TO BE RETRACTED POSITION.
 CHECK ALL GAGS FROM THE SAFETY VALVES ARE REMOVED.
 INFORM TO CHP AND CONFIRM COALS ARE AVAILABLE IN COAL
BUNKERS.
 OPEN DRUM, SH , AND ECONOMISER VENTS. SH AND STEAM
COOL WALL DRAINS AND TURBINE SIDE DRAINS TO BE OPENED.
 OPEN FULLY THE STARTUP VENT AND CBD VALVE SHOULD BE
LINE UP.
Lightup Pre-checks cont.
 OPEN ECONOMISER RECIRCULATION VALVE.
 ENSURE DMCW LINES IN LUBE OIL COOLERS OF BOILER SIDE
ARE CHARGED AND START ALL LOP’S.
 ENSURE THE DMCW LINES ARE CHARGED IN TG SIDE FOR
CEP,BFP,GENERATOR ,EXCITER, SEAL OIL COOLERS AND TG LUBE
OIL COOLERS.
 START ACW, DMCW , AND DMCW BOOSTER PUMPS
 START LDO PUMP IN RECIRCULATION MODE.
Lightup Pre-checks cont.
 FILL THE BOILER DRUM THROUGH BOILER FILL PUMP OR
THROUGH BFP UPTO -80 MMWC.
 START 1 NO. OF DM MAKE-UP PUMP AND FILL THE HOTWELL
UPTO 1200 MMWC.
 START 1 NO. OF CEP AND FILL THE DEAERATOR UPTO
350CMMWC.
 START 1 NO. OF BFP IN RECIRCULATION MODE.
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. 350 tons/hour AND FURNACE
DRAFT BETWEEN -10 TO -12 MMWC.
 START FURNACE PURGING.
 PUT SADC IN AUTO TO MAINTAIN FURNACE TO WIND BOX DP
AFTER MODULATION.
 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
 HOTV CLOSED
 LOTV CLOSED
 ALL HONV 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 5
MINUTES.)
 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.
 ESP: ALL HOPPER,INSULATORS HEATERS ARE ON.
 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 AND HONV SHOULD BE OPEN.
 CHECK ATOMISING AIR VALVE IN OPEN POSITION AND MAITAIN
AIR PRESSURE 7 KG/CM2
 APH SOOT BLOWING SHOULD BE CONTINUE
TILL OIL SUPPORT WITHDRAWN.
 ENSURE BOTTOM ASH HOPPER & SEAL TROUGH
IS OVERFLOWING.
 FIREMEN SHOULD BE PROVIDED AT FIRING
FLOOR AND TG FLOOR
Boiler Light-up cont.
 OPEN LOTV VALVE AND LOFCV AND MAINTAIN PRESSURE UPTO 10
KG/CM2.
 ENSURE THE OIL SELECTION SHOULD BE IN LDO.
 LIGHT-UP THE BOILER BY GIVING COMMAND TO AB ELEVATION
LDO CORNER 1 & 3.
 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 6 KG/CM2.
OIL PRESSURE VERSUS OIL FLOW
HFO PRESSURE VS FLOW
OIL PR.
OIL FLOW PER GUN
(KG/CM2)
(KG/HR.)
4.6
750
5
815
5.5
6
6.5
7
7.5
8
8.5
9
9.5
9.7
895
976
1057
1137
1218
1299
1379
1460
1541
1573
LDO PRESSURE VS FLOW
OIL PR.
OIL FLOW PER
(KG/CM2)
GUN (KG/HR.)
3.5
750
4
849
4.5
5
5.5
6
6.5
7
7.5
948
1047
1145
1244
1343
1442
1541
Boiler Light-up cont.
 CONTROL THE FIRING RATE BY OIL PRESSURE SO THAT THE
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BOILER STARTS STEAMING AFTER 45 MINUTES.
SEE THE TEMPERATURE RISE OF DRUM METAL (110 DEG/HR)
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).
WAIT FOR RAISE IN DRUM PRESSURE AND TEMP MEANWHILE
START THE TURBINE SIDE ACTIVITIES.
TAKE CD ELEVATION OIL GUNS IN SERVICE TO INCREASE STEAM
GENERATION IN CONTROL WAY
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.
 GENERATOR SEAL OIL SYSTEM STARTED.
 GENERATOR HYDROGEN SHOULD BE CHARGED.
 VACUUM PUMP STARTED.
 VACUUM IN TG MAINTAINING APPROX -.910 KG/CM2.
Boiler Light-up cont.
Boiler Light-up cont.
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.
 BEFORE CHARGING MS LINE COND. SHOULD HAVE PROPER
VACCUM i.e. -.91
 OPEN BYPASS VALVE OF MS STOP VALVE FOR WARM UP THE LINE
AT 8--10 KG/CM2 PRESSURE THEN CHARGE THE MAIN STEAM
LINE.
 THROTTLE THE STARTUP VENT
 RAISE THE DRUM PRESSURE/MS PRESSURE UPTO 10 KG/CM2
Boiler Light-up cont.
 OPEN HPBP AND LPBP VALVES WHEN STEAM PRESSURE
REACHES UPTO 08 KSC AND STEAM TEMP UPTO 160-180 DEG C.
 CLOSE THE STARTUP VENT.
 AS WE ARE FOCUSING IN WARM LIGHT UP TODAY REQUIRED
MAXIMUN STEAM TEMP SHOULD BE +30 DEGREE ABOVE SHAFT
TEMP.
 RAISE THE PRESSURE & TEMP UP TO DESIRED VALUE
 RESET ALL THE RELAYS AT GRP AND LINE UP OF GT
 AS PER REQUIREMENT START ONE PA FAN TO
RAISE THE STEAM TEMP. & PRESSURE
 START ADJECENT MILL B OR MILL C AS BOTH
ELEVATION HAVE 3 OR MORE GUNS
 AFTER TAKING MILLS KEEP CLOSE WATCH ON
STEAM TEMP. & PR. & REGULATE FUEL IN MILLS
ACCORDING TO REQUIRED TEMP.
 BOTH SEAL AIR FAN STARTS IN AUTO WITH
STARTING OF PA FAN. STOP ONE FAN
 X1
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=
X1A =
X2 =
X3 =
X41 =
X42 =
X5 =
X61 =
X61 =
X62 =
X62 =
X7 =
FOR OPENING MAIN STOP VALVE
FOR OPENING MAIN STOP VALVE
FOR OPENING MAIN STOP VALVE
FOR OPENING MAIN STOP VALVE
HP SHAFT FOR 600 RPM
HP CYLIMDER 600 RPM
FOR 600 RPM
CONSTANT PRESSURE FOR 3000RPM
SLIDING PRESSURE FOR 3000RPM
CONSTANT PRESSURE FOR 3000RPM
SLIDING PRESSURE FOR 3000RPM
FOR LOADING
Boiler Light-up cont.
 * BEFORE STEAM ADMISSION ENSURE STEAM QUALITY
 AT 25 KSC STEAM PRESSURE AND STEAM TEMP ABOVE SHAFT TEMP DEG C
TURBINE STOP VALVES IS OPENED.
 WAIT UNTIL CRITERIA X41/HPS, X42/HPC, X5, is fulfilled)
 CHANGE LUB OIL TEMP SET POINT
 ROLL THE TURBINE TO 600 RPM. SOAK THE TURBINE UNTIL PARAMETER COME
UNDER CONTROL LIKE VIBRATION ,DIFFERENTIAL EXPANSION, TOP- BOTTOM
TEMP , TSE UPPER MARGIN, SUFFICIENT STEAM FLOW etc.
 . JOP IS CUT OFF AT 540 RPM.
 ( WAIT UNTIL CRITERIA X6 IS SATISFIED). OBSERVE THE TURBINE VIBRATIONS
DURING ROLLING TO 2980 RPM.
 STOP AOP AFTER 2850 RPM ,AND SUFFICIENT LUB OIL PR.
 BEFORE SYNCHRONISING TAKE CLEANCE FROM DM PLANT REGARDING THE
SILICA CONTENT OF THE BOILER DRUM AND MS STEAM.
 MAINTAIN DRUM PRESSURE WITHIN THE PERMISSIBLE LIMITS AT OPERATING
PRESSURE.
Boiler Light-up cont.
Boiler Light-up cont.
Boiler Light-up cont.
 INFORM THE SWITCHYARD and WRLDC THAT THE MACHINE IS
GOING TO BE SYNCHRONISED.
 PUT LOAD REFERENCE AT 30 MW AND LOAD GRADIENT AND LOAD
CONTROL IN ‘ON’ POSITION. LOAD GRADIENT TO BE PUT TO
10MW/MIN.
 ABOVE 2850RPM ON EXCITER BKR. AND MAINTAIN VOLTAGE
 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 TO
AVOID TRIPPING ON REVERSE POWER.
 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.
 LOAD CONTROL MADE ON AFTER 25MW
 MAINTAIN GEN VOLTAGE TO EXPORT VAR(LAGGING)
 CLOSE ALL DRAINS.
 CLOSE MAL DRAIN VALVES.
Boiler Light-up cont.
 CLOSE ECO. REC. VALVE E024
 INCREASE FIRING TO REACH 40 MW AT 35 KSC.
 START OTHER PA FAN AND INCREASE THE PA HEADER PRESSURE
UP TO 800 MMWC. AND BALANCE THEM
 START MILL A AND INCREASE THE LOAD.
 CHARGE LPH-1,2,3.
Boiler Light-up cont.
 START SECOND SET OF ID FAN, FD FAN, CEP AND BFP.
 AFTER 50 MW CHARGE DEARATOR EXTRACTION LINE..
 AFTER 75 MW CHARGE HPH-5 . AND 6 PUT IN FLUSHING/
WARMUP.
Boiler Light-up cont.
Boiler Light-up cont.
 GRADUALLY INCREASE THE CAOL FEEDEING, MS PRESSURE, MS & HRH
TEMPERATUE BELOW 540 DEG C.
 AT LOAD 90MW
 TAKE UAT TRANSFER.
 UNIT TRANSFORMER PUT IN LOAD
 SLOWLY INCREASE THE LOAD TO 150 MW
 TAKE OUT ALL OIL GUNS.
 TAKE MILL-D IN SERVICE.
 SLOWLY INCREASE THE LOAD UPTO
250 MW.