• Power Business Goal - 20,000 MW BY 2020
• MUNDRA– 330MW X 4 + 660MW X 5
• TIRODA– 660MW X 5
(UNDER COMMISSIONING)
• KAWAI– 660MW X 2 (UNDER ERECTION)
• BITTA– 40MW BIGGEST SOLAR IN INDIA

• INDIA’S FIRST 66O MW SUPER
CRITICAL UNIT SYNCHRONISED BY
ADANI POWER LTD, MUNDRA IN OCT
2010 IN RECORD TIME OF 36
MONTHS.
• COMMISSIONED 4Nos. 660MW UNITS
IN A YEAR.
• ADANI IS THE FIRST COMPANY IN
INDIA TO EARN CARBON CREDIT.

TO
PRESENTED BY
B.K.PANDEY
APML, TIRODA

• BOP SYSTEM READYNESS
• BOILER FLUSHING: COLD/HOT
• BOILER LINE UP AND LIGHT UP.
• TURBINE LINE UP.
• TURBINE ROLLING.
• SYNCHRONISATION
• PHASE CHANGE OVER
• FULL LOAD

• COLD START UP:HP & IP SHAFT METAL
TEMP <204 ° C
• WARM START UP: HP & IP METAL TEMP IN
BETWEEN 204 TO 400 ° C
• HOT START UP :HP & IP METAL TEMP
>400 ° C

Boiler
Economiser
RH
11+1
HPT
1
3
8
IPT
Deaerator
EXT From
CRH
(MD BFBP 1x35%)
TDBFP 2X50%
2x7
LPT A
8
7
LPH -7A
LPH -8A
5
6
7
8
Condensor
(HP)
2x7
LPT B
8
7
5 6
7
8
LPH -7B
LPH -8B
Condensor
(LP)
1994 TPH
GSC
CEP
3x50%
CPP
1482 TPH
LPH -5 LPH -6

• HT/LT POWER SUPPLY READINESS
• WATER SYSTEM: FIRE WATER,SERVICE WATER,DMP,CW &
ACW.
• CCCW SYSTEM
• COMPRESSOR SYSTEM
• AUXILIARY STEAM. (S/B UNIT OR AUX BOILER).
• START CEP AND MDBFP.
• CHECK THE BCP SYSTEM IS READY.

• TO ASSIST CIRCULATION IN BOILER WATER WALL
• TO INCREASE THE CIRCULATION VELOCITY
• TO AVOID DNB (Departure from Nucleate Boiling) IN LOW LOAD.
• TO REDUCE THE OVER HEATING AND UNDUE STRESSES ON
WATER WALL TUBES.
• TO AVOID DRY OUT OF WATER WALL TUBES WHEN LOAD IS
REDUCED.

BCP FILLING ,PURGING & FLUSHING
• PURPOSE-
- TO FILL THE MOTOR CAVITY.
-
-
• RECOMMENDED MOTOR FILLING WATER QUALITY
CONDUCTIVITY <1 µs/cm
- BOILER FEED WATER
-
-
TEMP.<
=
CL <
=
45 O
50 PPM
C pH >
=
6.5
SUSPENDED SOLIDS <
=
5 PPM
• FILLING,PURGING & FLUSHING WATER REQUIREMENT
- MOTOR INITIAL FILLING FLOW RATE : MAX. 5 L/MIN

• START CEP.
• FILL & DRAIN FROM DEAERATOR UNTIL
REQUIRED WATER QUALITY IS ACHIEVED.
( Fe<500 Ppb.)
• START MDBFP.
• START THE BOILER COLD/HOT FLUSHING
TO REDUCE THE Fe & SiO2 CONTENT IN
FEED WATER.

SP SP
WW
ECO
MIXER
BCP
Boiler flushing
START-UP
LINE
Sampling Fe +
CW
LINE
HOTWELL

BOILER COLD FLUSHING
COLD FLUSHING
• WATER WALL TEMP REQUIRED 105-120 DEG.C
(TEMP MAINTAINED BY DEAERATOR PEGGING
STEAM)
• COLD OPEN FLUSHING QUALIFIES Fe < 500PPB
SiO2 < 100PPB
• THEN CPU WILL BE TAKEN IN SERVICE TO REDUCE WATER
LOSS AND IMPROVE QUALITY.
• COLD CYCLIC FLUSHING QUALIFIES Fe < 100PPB
SIO2 < 50PPB
(ALL ANALYSIS FROM SEPARATOR DRAIN)

BOILER HOT FLUSHING
HOT FLUSHING
• WATER WALL TEMP REQUIRED 150-190 DEG.C (TAKE
OIL GUNS OF BC ELEVATION)
• HOT OPEN FLUSHING START UP CRITERIA FE > 100PPB
SIO2 > 50PPB
• IF HOT CYCLIC FLUSHING CRITERIA IF FE < 100PPB
SIO2 < 50PPB
• HOT CYCLIC FLUSHING QUALIFIES IF FE < 50PPB
SIO2 < 30PPB
• AFTER COLD FLUSHING START BCP WITH MINIMUM 30%
FEED FLOW & THROTTLE FRS VALVE.

BOILER LINE UP AND LIGHT UP
• FUEL OIL SYSTEM: LDO/HFO PUMPS
• ESP HEATERS & RAPPERS
• AIR FLUE GAS SYSTEM: APH,IDF, FDF &
SCANNER FAN.
• MAINTAIN AIR FLOW : 30% - 40%.
• FURNACE PURGE: 300 Sec.
• LIGHT UP BOILER WITH OIL GUNS AT BC (LDO)
ELEVETION.
• CONTINUE HOT FLUSHING UNTIL REQD.WATER
QUALITY IS ACHIEVED
• THEN TAKE CD ELEVETION GUNS. IF REQUIRED
TAKE 2 NO. GUNS IN AB ELEVETION.

• CONTINUOUS APH SOOT BLOWING TO BE DONE AT THE
TIME OF OIL FIRING.
• PR RISING RATE- 0.05 MPA/MIN. BETWEEN 0-1 MPA
• PR RISING RATE 0.1 MPA/MIN. BETWEEN 1 – 2 MPA
• PR RISING RATE 0.2 MPA/MIN. ABOVE 2 MPA
• FURNACE EXIT GAS TEMP MUST BE BELOW 538 ° C FOR
REHEATER PROTECTION (UNTIL HP-LPBP IS CHARGED).
• CLOSE SH DRAINS AND VENTS AFTER ACHIEVING DEGREE
OF SH 50 ° C ( CLOSE IT AFTER CHARGING HP-LP BYPASS).

LDO/HFO GUN
Fuel
Fuel Pressure
Fuel Flow
Atomizing Air Pressure
Atomizing Air Flow
Ignition Method
Fuel
Fuel Pressure
Fuel Flow
Atomizing Steam Pressure
Atomizing Steam Flow
Ignition Method
Light Oil
0.8MPa-2.0MPa
500kg/h -3000kg/h
0.6MPa-1.2MPa
100-600kg/h
HESI (20 joules/spark)
Heavy Oil
0.8MPa- 2.0MPa
1000-4000 kg/h
0.8MPa-1.2MPa
100-400kg/h
HESI (20 joules/spark)

• ENSURE:
• LUBE OIL SYSTEM: IN SERVICE (0.8 MPA)
• JACKING OIL SYSTEM:IN SERVICE ( 14 MPA)
• TURBINE BARRING GEAR: 3-4 RPM
• SEAL OIL SYSTEM: AIR & H2 SIDE. CHARGED
• STATOR AND H2 COOLING WATER SYSTEM:CHARGED TEMP CONTROL
IN AUTO)
• H2 FILLED IN GENERATOR AND MAINTAIN PR 0.35 MPA.
• EH OIL SYSTEM: IN SERVICE (14 MPA)

• ENSURE TDBFP IN BARRING.
• GLAND STEAM CHARGING: ENSURE STEAM TEMP. IS 56 ° C
- 111 ° C MORE THAN ROTOR TEMP & DEGREE OF SH >
50 ° C.
• CHARGE THE GLAND SEAL SYSTEM OF TDBFP.
• START THE VACUUM PULLING WITH VACUUM PUMP.
MAINTAIN VACUUM -0.9 KG/CM2.
• CHARGE THE HP-LP BYPASS SYSTEM .MAINTAIN THE MS
STEAM PRESSURE AND FIRING RATE FOR ACHIEVING
TURBINE ROLLING PARAMETERS.

MS TEMP
RH TEMP
SPEED
MS FLOW
LOAD
MS PRESS

• PREHEATING OF HPT REQUIRED WHEN INNER METAL TEMP <150 ° C.
• CRH PR 0.5-0.7 MPA/220-380 ° C.
• OPEN PRE HEATING VALVE (REVERSE FLOW VALVE) GRADUALLY.
• OPEN BDV VALVE FULLY.
• OPEN CRH DRAIN BEFORE NRV AND HPT-IPT CASING DRAINS.
• HEATING RATE SHOULD NOT BE MORE THAN 50 ° C PER HR.
• HP CASING TOP-BOTTOM & INNER-OUTER WALL METAL TEMP
DIFFRENCE SHOULD BE WITHIN 50 ° C.
• AFTER ATTAINING THE CASING TEMP > 150 ° C CLOSE THE RFV
VALVE AND OPEN HP CYLINDER VENTILATION VALVE TO
CONDENSOR.

TURBINE WARM UP OPERATION
MS
CRH LINE
HPBP
HPT IPT
RFV
CRH NRV
BDV
TO CONDENSER
Ventilator valve
TO CONDENSER
TURBINE STARUP PROCEDURE

• AS PER REQUIREMENT OF START UP CURVE, FIRING TO BE
INCREASED.
• REQUIRED STEAM PARAMETERS BEFORE ROLLING
– MS PR: 8.73 MPA, TEMP: 330-380 ° C
– RH PR: 1.1 MPA , TEMP: 330 ° C
- THE DEGREE OF SUPER HEAT > 56 ° C.
• AFTER LATCHING THE TURBINE, START IP ROLLING WITH HP VENT
TO CONDENSER IN OPEN CONDITION TO KEEP THE HPT IN
VACUUM.
• MSV 1&2 AND RSV 1&2 ARE IN OPEN CONDITION.
• GIVE THE SPEED SET POINT TO 600 RPM
• CHECK THE TURBINE SUPERVISORY INSTRUMENT PARAMETER.
• THE ECCENTRICITY SHOULD BE LESS THAN 0.076 MM.

TURBINE ROLLING
• SELECT TARGET SPEED 1500 RPM WITH RAMP RATE OF 100
RPM/MIN.
• ENSURE ALL HP CV’S OPENS TO 12% TO WARM UP THE HP
CASING.
• WHEN HP CASING TEMP >320 ° C.CLOSE THE HP CV’S.
• SOAK THE TURBINE FOR 4 HRS ACCORDING TO THE START UP
CURVE.
• CHARGE THE LP HEATER 5 & 6 BEFORE 3000 RPM
• SELECT TARGET SPEED TO 3000 RPM WITH RAMP RATE OF 100
RPM/MIN.SOAK IT FOR 30 MIN AS PER S/U CURVE.
• AS PER PROCEDURE SYNCHRONISE THE UNIT.

LOADING
• AFTER SYNCHRONISATION INITIAL LOAD WILL BE 30 MW.HOLD IT
FOR 30 MIN AND CHEK THE VIBRATION, BEARING TEMP, DIFF
EXPANSION, CASING EXPANSION.
• CHARGE EXTRACTION STEAM TO DEAERATOR.
• TAKE MORE OIL GUNS IN EF/AB ELEVETION.
• TAKE PA FANS & SEAL AIR FAN.
• AFTER ACHIEVING FURNACE TEMP. MORE THEN 450 ° C. TAKE COAL
MILL-B AT. STEAM T/PR 380 ° C/8.7 MPA.
• INCREASE FUEL FLOW MAINTAINING STEAM TEMP.& RAISE LOAD
• AT 70 MW IP TO HP CHANGE OVER. CV’S WILL START OPENING,
CLOSE THE BDV AND VENTILATING VALVE.
• INCREASE THE LOAD AT 3MW/MIN
• CLOSE THE HP-LP BYPASS GRADULLY.

660
660 MW
495
LOAD
(MW)
330
330MW
198MW
165
60MW
350
33MW
400 450 500
MINUTES
550 600 650

LPT A
FROM IPT EXHAUST
LPT B
6 th
5 th
2 nd 2 nd
5 th
6 th
LP HEATER 7A
LP HEATER 8A
CONDENSER
6 th
5 th
4 th
4 th
5 th
6 th
LP HEATER 7B
LP HEATER 8B
CONDENSER
HP HEATER
LP HEATER 6

TDBFP START UP
• TAKE ONE TDBFP IN SERVICE( CHANGE OVER WITH MD BFP) WHILE
DRIVING STEAM IS AVAILABLE. SECOND TD BFP WILL BE TAKEN AT
180 MW.
• WARM UP THE TURBINE.
• SLOWLY OPEN THE AUX STEAM MOV TO TURBINE.
• PARAMETERS FOR ROLLING TDBFP.
STEAM PRESSURE: 0.6
～ 1.3MPA, STEAM TEMP: 50 DEG C MORE THAN
CASING TEMP.
• ROLL THE TDBFP AS PER PROCEDURE.
• GIVE THE TARGET SPEED 500 RPM AND THAN TO 1000 HOLD FOR 40
MIN.CHECK THE TSI PARAMETER
• WHEN SPEED REACHES 2840 RPM, GIVE REQUEST COMMAND FROM
FW MENU. THEN SELECT CCS CONTROL IN FROM MEH MENU.

TDBFP STEAM SOURCES
To
CRH
HP IP
1.12 Mpa
378 ºC
To
Condenser
4/17/2020
TDBFP-A
TDBFP-B
1.3 MPa
350 ºC
Aux. Steam
Header
Changeover Valve
From
CRH
4 MPa
315.3 ºC
Booster pumps

LOADING
• TAKE THE MILL-C IN SERVICE AT 100 MW. STEAM T/PR:400 ° C/8.7
MPA.
• GRADUALLY WITH DRAW THE OIL SUPPORT AS PER THE FLAME
CONDITION.
• INCREASE THE LOAD TO 150 MW AND TAKE THE HPH-3, HPH-2 &
HPH-1 IN SERVICE. MS T/PR 410 ° C/8.7 MPA.
• AT 180 MW TAKE SECOND TDBFP IN SERVICE.

CRH LINE
MS LINE
9 th stage
5th stage
IP EXHAUST
HRH LINE
TDBFP A TDBFP B
HP HEATER
1
HP HEATER
2
HP HEATER
3

PHASE CHANGE FROM WET TO DRY MODE
• DURING LOAD RAISING >25% BMCR, THE BCP FLOW AND FEED
WATER FLOW TO BE MONITORED CLOSELY.
• THE BCP FLOW NEED TO BE ADJUSTED W.R.T SEPERATOR TANK
LEVEL AND THE SAME FLOW TO BE ADJUSTED IN FEED WATER FLOW
TO MAINTAIN TOTAL FEED WATER FLOW TO ECONOMISER
CONSTANT.
• WHEN BOILER STEAMING RATE RISES TO >30% BMCR, W.R.T FUEL
FIRING, THE SEPERATOR LEVEL REDUCES .
• ONCE THE CONDITION FULFILLS THE BCP STOPS AND FEED FLOW
CONTROL CHANGES OVER FRS.
• AFTER STOPPING BCP IT ACTS AS SUB-CRITICAL ONCE THROUGH“.
• WHEN THE STEAM PR REACHES 22.1 MPA IT IS IN “SUPERCRITICAL
ZONE”

LOADING
• TAKE MILL-A AT 210 MW.
• CUT THE OIL SUPPORT AT 260 MW AS PER THE FLAME CONDITION.
• TAKE MILL-D AT 300 MW. MS T/PR 475 ° C/10 MPA.
• TAKE MILL-E AT 430 MW. MS T/PR 566 ° C/17 MPA.
• TAKE MILL-F AT 540 MW. MS T/PR 566 ° C/24.1 MPA.
• INCREASE THE LOAD TO “ FULL LOAD 660 MW ” GRADUALLY.

NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
100% BMCR Coal consumption (Design)
Design fuel
Superheated steam flow
Superheater outlet pressure
Superheater outlet temperature
Reheated steam flow
Reheater inlet pressure
Reheater outlet pressure
Reheater inlet temperature
Reheater outlet temperature
Feedwater pressure
Feedwater temperature
Separator’s steam temperature
Air preheater’s outlet air temperature, uncorrected
After correcting
Calculating thermal efficiency of boiler
Parameters
390.37
Unit t/h
Indian coal
2111
25.4
569
1749.1
4.73
t/h
MPa
℃ t/h
MPa
4.49
324
569
28.8
280
421
153.3
147.2
87.19% （ BMCR ）
MPa
℃
℃
MPa.g
℃
℃
℃
℃

Steam Admission Parameters at Turbine Inlet
Pressure (MPa)
I/L Temp (Deg C)
HPT
24.2
566
IPT
3.961
566
O/L Temp(deg C) 315.3 378
Steam Flow (tph) 1959.25 1649
TURBINE HEAT RATE( KCL/KWH) 1885
No of Stop valves 2
No of Control valves 4
2
4
LPT
1.12
378

3.96MPa / 566 °c
24.2MPa/566ºC
HRH
MS LINE
TO BLR RH
CRH
HPT
CRH
MS LINE
HRH
CV CV
TURBINE AT FULL LOAD
CV
IPT
1.12MPa / 378 °c
LPT #1
CONDENSOR A CONDENSOR B

• EXCEPT IN AN EMERGENCY, LOAD SHOULD BE REDUCED
GRADUALLY.
• CUT THE MILL-F AT 540 MW.
• CUT THE MILL-E AT 470MW.
• CUT THE MILL-D AT 300 MW.
• TAKE OIL SUPPORT FOR FURNACE STABILITY ( AT THE TIME OF 3
MILL OPERATION).
• CUT THE MILL-A AT 210 MW.
• TAKE THE HPH-1,2,3 OUT OF SERVICE.
• WHEN THE LOAD < 30% BOILER COMES IN WET MODE FROM
DRY MODE. START THE BCP AND MAINTAIN THE SEPEARTOR
LEVEL.

• WHEN THE LOAD HAS DECREASED TO 20% OF RATED LOAD TRIP
THE TURBINE ON TURBINE PROTECTION. THIS CLOSES THE
THROTTLE VALVES, GOVERNOR VALVES, REHEAT STOP VALVES AND
INTERCEPTOR VALVES
• CHECK DRAIN VALVES OPENS IN AUTO.
• HP LP BYPASS VALVE OPENS TO MAINTAIN THE FLOW.
• REDUCE THE BOILER LOAD GRADULLY.
• TRIP THE BOILER.
• THE VACUUM BREAKER VALVES SHOULD NOT BE OPENED UNTIL THE
TURBINE UNIT HAS COASTED DOWN.
• VACUUM SHOULD BE KILLED BEFORE GLAND SEALING STEAM IS
SHUT OFF.
• AUX OIL PUMP STARTS IN AUTO AT 2850 RPM.
• JOP START IN AUTO AT 1200 RPM.

• WHEN THE VACUUM REACHES ZERO, SHUT OFF THE SEALING STEAM
TO THE GLAND STEAM CONTROL VALVES.
• SHUT DOWN THE GLAND STEAM CONDENSER EXHAUSTER. SHUT
DOWN CONDENSATE PUMP.
• SHUT DOWN THE VACUUM PUMP.
• SHUT OFF THE COOLING WATER SUPPLY TO THE GENERATOR
HYDROGEN COOLERS.
• ENSURE THAT BARRING GEAR HAS CUT IN.

SHUT DOWN CURVE