Cold Start up
Cold Start up Check List
Applicable when HP shaft temperature is less than 250oc
| Sl. NO | ACTIVITY | CHECK | TIME * / REMARKS |
| 1 | Ensure 6.6KV, 415V, 220V DC, UPS & emergency power supply are available & buses are charged. | ||
| 2 | Reset under voltage relays on 6.6 kV bus, BTS panel & 415V buses. | ||
| 3 | Ensure islanding switch is in “OUT” condition (if this unit is selected for islanding) | ||
| 4 | Ensure all soot blowers are in retracted condition. | ||
| 5 | Ensure air compressor is running, instrument air & service air systems are charged and backup N2 system is charged. | ||
| 6 | Shift LPG, H2 & CO2 cylinders (min. 5 LPG, 50 H2 & 20 CO2 cyl.) | ||
| 7 | Ensure coal-handling system is ready & coal is filled in the bunkers | ||
| 8 | Ensure ash-handling system is ready. | ||
| 9 | Ensure fire system is ready & pumps are in auto. Jackey pump is running. | ||
| 10 | Ensure all PTW related to corex system returned & Start N2 purging for corex system as per procedures and check for O2 percentage at both C headers and before trip valve | ||
| 11 | If O2 before FGTV is less than 0.5 %,open the unit goggle valve after equalizing the pressure before & after the goggle valve. | ||
| 12 | Boiler drum filling (If drained) | ||
| (a) Ensure DMST levels are normal (> 3.5 mt.). | |||
| (b) Ensure PTWs related to boiler water / steam touched parts up to MS stop valves & boiler filling system are returned. | |||
| (c) Ensure steam / water sampling system is lined up & charged. | |||
| (d) Open Boiler SH, RH, ECO vents & start up vents. | |||
| (e) Open ECO recirculation valve (E-20). | |||
| (f) Open low point header drains. Close the main isolation valve to IBD tank. Close SH filling line also. | |||
| (g) Open SH drains at 22 Mt. | |||
| (h) Ensure DM – 34 of both units are closed. | |||
| (i) Open the chemical dosing valve to boiler filling line. Line up Amine skid to boiler, for chemical dozing. Ensure m/u water to dosing system | |||
| (j) Line up and start Boiler fill pump. Start Amine skid pump(s). | |||
| (k) Fill drum level upto (-) 100mm. | |||
| (l) Close the low point drain header drains (both isolation valves). | |||
| 13 | Raise fore bay level up to + 100mm. | ||
| 14 | Starting CW & ACW system | ||
| (a) Ensure PTWs related to CW & ACW system are closed. | |||
| (b) Ensure forebay level is above normal (+100mm) | |||
| (c) Line up CW system. Open condenser water box vents & air vents on CW supply line. | |||
| (d) Ensure that CW hot tunnel & cold tunnel is filled through ACW return lines of adjacent unit (when water falls down to CT basin through risers) | |||
| (e) Start CW pump & close the vents after venting. | |||
| (f) Ensure standby CW & ACW pumps are available. | |||
| (g) Open supply valve to ACW suction header (from this unit). | |||
| (h) Charge ACW system slowly, by opening the unit supply valve. | |||
| 15 | After ensuring that no PTWs are pending on boiler bottom hopper & DCC, start filling the DCC using CW blow down pump. | ||
| 16 | (a) Ensure PTWs related to feed water system & Deaerator are closed. | ||
| (b) Start Deaerator filling using Boiler fill pump. | |||
| (c) Line up BFPs & feed water line. [At least one BFP suction & discharge valves and HP heaters I/L, O/L & bypass valves should be kept open]. | |||
| (d) Keep feed control station valves in open condition and vent through eco. inlet vent. | |||
| 17 | Ensure PTWs related to condenser & hot well makeup systems are closed. | ||
| Fill hotwell using DM makeup pump, up to + 100mm. | |||
| 18 | Starting of LFO & HFO system | ||
| (a) Ensure PTWs related to LFO & HFO system are closed. | |||
| (b) Line up and start LFO transfer pump with 12ksc set point for the recirculation valve. | |||
| (c) Switch on HFO heat tracing at P&H area and at boiler 18mt. | |||
| (d) Line up and start HFO transfer pump. Keep pump recirculation pressure control valve in auto (SP 12ksc). | |||
| (e) Line up & charge one HFO heater from oil as well as steam side (Temp. set point shall be kept as 1100C). | |||
| (f) Open HO – 48 & keep HFO system in short recirculation. | |||
| (g) Ensure standby LFO & HFO transfer pumps are available. | |||
| (h) Line up LPG system & maintain header pressure of 3 ksc. | |||
| 19 | Starting of flue gas & air system | ||
| (a) Ensure PTWs related to APH, ESP, Flue gas, Secondary air & main boiler are closed. Ensure that manholes & peepholes are closed. | |||
| (b) Ensure DCC has been filled & Seal established. | |||
| (c) Line up and start both air pre-heater. Check operation of air motors once. | |||
| (d) Line up secondary air system, flue gas path, and ID & FD fans. | |||
| (e) Line up ESP fields & rapping systems. | |||
| (f) Ensure all stand by LOPs of ID, FD & APH are in standby. | |||
| (g) Start AC scanner air fan after ensuring that emergency air damper is open | |||
| (h) Start one stream of ID & FD fans. Put furnace pressure control in auto (SP -10mmwc).. | |||
| (i) Start Ignitor fan & put damper control in auto (SP 85mmwc) | |||
| 20 | Purge & Light up | ||
| (a) Ensure that all I&C permits related BMS are returned. Switch ON the power supply for flame scanners. | |||
| (b) Ensure >190 t/hr airflow and Purge the boiler. | |||
| (c) Open IGTV & LOTV and ensure that ignitor pr. after IGTV >0.8 ksc, LFO pr. after trip LOTV >8ksc & atomizing air pr. > 6 ksc. | |||
| (d) Keep the ESP rapping motors ON. Ensure that ESP fields are not charged. | |||
| (e) Ensure MS – 1, 2, 3 & 4are closed. | |||
| (f) Light up boiler with 2 LFO guns at AX1. | |||
| 21 | Start atleast 4 CT fans | ||
| 22 | Open HFO return trip valve & HOTV and keep in long recirculation. Close the short recirculation valve (HO 48). | ||
| 23 | Start H2 /CO2 filling
( refer Gen. Gas purging/ filling procedure OP/DC/20/XX) |
||
| 24 | Starting of Seal, Lube & Lift oil system | ||
| (a) Ensure PTWs related to turbine & their oil systems are returned. | |||
| (b) Ensure MOT & SOT levels are normal. [If SOT is empty, fill up the system by running lub oil system] | |||
| (c) Start OVEF & Generator brg. Exhaust fan. Keep standby fans in auto. | |||
| (d) Line up seal oil system [Ensure that SOST to SOT valve is open and seal oil pump disc. to MOT is closed]. | |||
| (e) Start seal oil pump and keep other pumps in auto. Start SO vacuum pump. | |||
| (f) Line up lube oil system and start lube oil pump and ensure other pumps availability & are in auto. Keep lube oil cooler ACW O/L valve closed to maintain 450C oil temp. | |||
| (g) Start lift oil pump and put turbine on barring gear. | |||
| 25 | (a) Ensure PTWs related to condensate system are returned. | ||
| (b) Line up CEP & condensate line, through LP heaters. | |||
| 26 | At drum pressure 2 ksc, Close drum, SH, RH & ECO air vents. Start phosphate dozing pump at 2ksc-drum pressure. Open CBD around 30%& bypass to IBD tank | ||
| 27 | Start CEP in recirculation. | ||
| (a) Ensure valve gland-sealing header is charged & establish sealing for suction valve of both CEPs. | |||
| (b) Keep pump discharge valves close and dearator level control valve in closed condition & LPH-1 &2 I/L & O/L valves are open & bypass is open . | |||
| (c) Ensure CEP header vent, recirculation valve are open & in auto. | |||
| (d) Ensure PRDS spray valves are closed. | |||
| (e) Ensure turbine exhaust hood spray valve in auto. | |||
| (f) Start the CEP and keep the other CEP in standby. | |||
| 28 | Start BFP in recirculation. | ||
| (a) Start lube oil pump & keep in auto. | |||
| (b) Keep BFP discharge valve closed and start booster pump. | |||
| (c) Ensure min. scoop, R/C valve full open and start BFP. Ensure that LOP stops when lube oil pr is >2.8ksc. | |||
| (d) Close warm-up manual isolation valve. | |||
| (e) Keep another BFP in standby with warm up valve open. | |||
| 29 | (a) At drum pressure 5 ksc; Close SH header drains and throttle start up vents to 15%. | ||
| (b) Give blow down from low point header drains around 3 times & collect the sample. | |||
| 30 | (a) Ensure PTWs related to control oil HSU are closed. | ||
| (b) Line up Control oil system and start pump. | |||
| (c) Line up & start control oil-circulating pump. | |||
| 31 | (a) Ensure PTWs related to HP bypass HSU are closed. | ||
| (b) Line up and start HPBP oil pump | |||
| 32 | Charge PRDS | ||
| (a) Ensure PTWs related to PRDS, MS lines, GS are returned. | |||
| (b) Ensure Deaerator pegging from APRDS is closed. | |||
| (c) Ensure PRDS drains are open. | |||
| (d) Ensure PRDS sprays MIVs are open. | |||
| (e) If external steam is available, | |||
| (f) Slowly open AS-34 to charge unit header from station header | |||
| (g) Maintain PRDS temperature. | |||
| If external steam is not available,( follow after MS line charging) | |||
| (a) Ensure AS-34 inter connection to other unit APRDS is closed. | |||
| (b) Open MOVs AS-31 &AS-21& their MIVs | |||
| (c) Charge slowly APRDS low capacity Line by opening the CV. | |||
| (d) Put PRDS pressure & temperature controls in auto with SP -9 ksc. | |||
| 33 | Vacuum pulling | ||
| (a) Ensure PTWs related to vacuum system are returned. | |||
| (b) Ensure turbine on barring gear. | |||
| (c) Ensure hotwell level is normal & CEP is running | |||
| (d) Ensure for valve sealing (LPH-1 normal & emerg. Drain valve, LPH-2 emergency drain valve, LPH-3 emerg. drain valve, vacuum pump suction valves) | |||
| (e) Close Vacuum breaker valve, keep in auto & establish water seal. | |||
| (f) Ensure RH vents & EX-12 are closed. | |||
| (g) Switch ‘ON’ GSC Ex. Fan. | |||
| (h) Line up & Start Vacuum pumps. | |||
| 34 | Gland steam header charging | ||
| (a) Open Gland steam header drain to atmosphere & also open MAL 81. | |||
| (b) | |||
| (c) Open partially GS header inlet MIV (full open, If charged from the same unit). | |||
| (d) Open AS-9 fully & its MIV partially (full open, If charged from the same unit). | |||
| (e) Charge gland seal when vacuum is >- 0.3 ksc. | |||
| (f) Control temperature at GS inlet as per curve by throttling AS-9 MIV (if steam is taken from adjacent unit). | |||
| (g) Open GS drain to condenser when vacuum is greater than-0.4 ksc, close atmospheric drain. | |||
| (h) Close CRH pot drain to atoms. & Open CRH-101& keep MAL-81 in auto. | |||
| 35 | MS line Charging at drum pressure 10 ksc | ||
| (a) Ensure PTWs on turbine stop valves, MS, CRH, HRH& HP/LP & PRDS (if PRDS is charged from same unit) are returned. | |||
| (b) Open MS-101 & MS-102 & it’s before MIVs. | |||
| (c) Open MS strainer drains (MS-105, 106 and before & after MIVs). | |||
| (d) Open drain before APRDS (AS-116). | |||
| (e) Ensure APRDS isolation valves closed. | |||
| (f) Ensure HP bypass is closed. | |||
| (g) Open MIVs of MS-3 & MS-4. | |||
| (h) Charge line by Slowly opening MS-3 & MS-4. | |||
| (i) Close MS-101 & MS-102 & it’s before MIVs. | |||
| (j) Open boiler stop valves MS 1&2 when upstream and downstream pressures are equal. | |||
| (k) Close AS-116. | |||
| (l) Close MS-3, MS-4 & their MIVs. | |||
| 36 | Ensure CBD is diverted to IBD tank. | ||
| 37 | Charge Deaerator pegging slowly from PRDS. | ||
| 38 | Close Economiser recirculation E-20 valve When feedwater flow is continuous. (may be made auto on feed flow) | ||
| 39 | Keep Deaerator & hotwell level controls in auto. | ||
| 40 | HP-LP bypass charging | ||
| (a) Ensure HRH strainer drain (HRH 101,102 & their MIV) are open. | |||
| (b) Ensure CRH drain (CRH 127 & CRH 101) & their MIVs are open. | |||
| (c) Ensure HRH 113, 114, 103, 104 & their MIVs are open. | |||
| (d) Ensure CRH pot drain to atmosphere & RH vent is closed. | |||
| (e) Ensure that all MAL drains are open in auto. | |||
| (f) Ensure condenser vacuum is > – 0.9 ksc. | |||
| (g) Open LPBP spray valve around 40%. | |||
| (h) Trip reset LPBP trip. | |||
| (i) Open LPBP valve 5%. | |||
| (j) Open HP bypass slowly (around 3%) | |||
| (k) Open HPBP spray MIV (after watching the raising trend in temp). | |||
| (l) Close start up vents. | |||
| (m) Put HP-LP bypass in auto & keep set point 35 ksc & 8 ksc respectively | |||
| (n) Prove second stream of fans. | |||
| 41 | Do APH soot blowing through SCAPH line. | ||
| 42 | If corex clearance is available,
(a) Ensure corex N2 purging is in progress & O2 in corex sample through vent less than 0.5%. |
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| Take one pair of BC guns and change over AX1 to HFO | |||
| 43 | Ensure that boiler water temp. rise is within 110°c/hr | ||
| 44 | Refer Rolling & Synchronization check list OP/F/11/XX) | ||
| 45 | Put drum level controls in auto. | ||
| 46 | (a) Line up Primary air system & start one PA fan. | ||
| (b) Ensure seal air fan starts in auto on starting of PA fan | |||
| 47 | Give Deaerator pegging from CRH. | ||
| 48 | Ensure SH & RH sprays MIVs are open. | ||
| 49 | Charge gen. H2 cooler & lube oil cooler. | ||
| 50 | Start remaining CT fans. | ||
| 51 | Ensure SADC are in auto. | ||
| 52 | If corex is available ,take one pair in X1 elevation otherwise | ||
| Line up Mill & Start Mill-A. | |||
| Charge ESP fields at minimum. | |||
| Cut in feeder-A & put temp and airflow control in auto. | |||
| 53 | Close HP bypass and put auto/manual station in auto | ||
| 54 | Close MS, HRH & CRH drain. Keep CRH pot drain CRH-101 in auto & HRH-103 &104 bypass MIV partially open. | ||
| 55 | Keep the all the turbine drain MAL-11,12,15,16,26,27,31,32 valves (close MIV ‘s if passing) & MAL 81,65 closed & in auto. SLC ON | ||
| 56 | Increase the load by watching MS-HRH Vs Casing temp. curve | ||
| 57 | If corex is taken, cut-in second pair in X1 elevation. | ||
| 58 | Line up & start second stream of ID, FD & PA fans. | ||
| 59 | Ensure all standby LOPs of ID, FD & PA are in standby. | ||
| 60 | Match the currents of FD & ID fans & put ampere bias control in auto. Also keep ID fan draft control in auto (-10mm). | ||
| 61 | Ensure LPH-1 & 2 are charged & level controls & waterside valves in auto. | ||
| 62 | Charge LPH 3 at 25 MW. | ||
| (a) Ensure PTW related to LPH-3 is returned. | |||
| (b) Ensure heater is charged from waterside (I/L & O/L valves are open & bypass valve is closed). | |||
| (c) Extraction line drains (EX-125, MAL-54 &126) are open. | |||
| (d) Ensure operating vent is open & shell vent to atmosphere is close | |||
| (e) Open emergency drain & close normal drain. | |||
| (f) Open slowly EX-9 by seeing the heater level & shell pressure. | |||
| (g) After fully opening EX-9 & put it in auto & close EX-125, MAL-54 & 126 & put them in auto. | |||
| (h) Put normal & emergency drains valves in auto (SP-0 & 20 mmwc). | |||
| 63 | Start second BFP at 25 MW & ensure third BFP in standby mode. | ||
| 64 | At 25MW changeover UAT from station. | ||
| 65 | Put MS temperature controls on auto. | ||
| 66 | Charge Deaerator from CRH. | ||
| 67 | If corex is taken, cut-in one pair in X2 elevation, otherwise | ||
| Start second PA fan. | |||
| (a) Ensure fan discharge damper is closed. | |||
| (b) Raise scoop & damper to 30-35% | |||
| (c) Match discharge pressure with running fan discharge pressure. | |||
| (d) Open discharge damper. | |||
| (e) Equally load the fans & put PA header pressure & ampere bias controls in auto. | |||
| Start mill-B & Cut in feeder-B. Put temp and airflow control in auto. | |||
| Ensure DCC is running. | |||
| 68 | Line up & Charge HPH – 5 at 50 MW | ||
| (a) Ensure PTW related to HPH-5 are closed. | |||
| (b) Ensure heater is charged from waterside (I/L &O/L valves are open & bypass valve is closed). | |||
| (c) Open extraction line drains (EX-104, MAL-47 & 106) & ensure operating vent is open & atmosphere vent is close. | |||
| (d) Open fully emergency drain control valve & Keep normal drain control valve in close condition. | |||
| (e) Open slowly block valve EX-11 by seeing the level & shell pressure. | |||
| (f) After fully opening the EX-11 & put in auto & also close drains & keep in auto. | |||
| (g) Put HP heater -5 level (normal & emergency) controls in auto. (SP-0 & 20 mm resp.) | |||
| (h) Ensure heater waterside I/L, O/L & bypass valves are in auto. | |||
| 69 | Line up & Charge HPH 6 at 60 MW. | ||
| (a) Ensure PTW related to HPH-6 are closed. | |||
| (b) Ensure heater is charged from waterside (I/L &O/L valves are open & bypass valve is closed). | |||
| (c) Open EX-128 & its MIV (drain before EX-12) & open operating vent & close atmosphere vent. | |||
| (d) Open emergency drain control valve. | |||
| (e) Ensure control valves of normal & alternate drains are close. | |||
| (f) Open slowly EX-12 from local by seeing the heater level & shell pressure. | |||
| (g) After fully opening the EX-12, put it in remote. Close EX-128 & put in auto. | |||
| (h) Put HP heater -6 level (normal, alternate & emergency) controls, EX-128 in auto. (SP-0, 20& 40 mm resp.). | |||
| (i) Ensure heater waterside I/L, O/L & bypass valves are in auto. | |||
| 70 | Deaerator charging from Extraction-4 at 80MW | ||
| (a) Open drain traps & its bypass valves before & after EX-4 NRV ‘s & ensure MAL-51 is open | |||
| (b) Slowly Open EX-10 from DCS. | |||
| (c) After matching upstream & down stream pressure, fully open EX-10 & keep in auto & also close its bypass of traps of the drains. Dea. Pressure operator SP – 3ksc | |||
| 71 | If corex is taken, Cut-in second pair of X2 elevation. | ||
| 72 | Stop second vacuum pump , select the running pump & keep in auto | ||
| 73 | Ensure SH temperature Controls in auto. | ||
| 74 | Ensure HP turbine exhaust temperature is < 365 oC. | ||
| 75 | If corex is taken, Cut-in one pair of X3 elevation otherwise | ||
(a) Start mill-C & cut in feeder-C |
|||
| (b) Cut in feeder-C & put temp and airflow control in auto. | |||
| (c) Ensure feeder A & B >50% & scanner intensity > 50 | |||
| (d) Remove oil in BC elevation. (If only coal in service). | |||
| 76 | Raise the load as per TSE margins available to 120 MW. | ||
| 77 | Keep MS temperature control SP as 537 oC. | ||
| 78 | If corex is taken, Cut-in second pair of X3 elevation. | ||
| 79 | Put islanding switch in “IN”, if load is more than JVSL complex load. (if applicable) | ||
| 80 | Gradually raise the load to 130MW based on drum water silica | ||
| 81 | Ensure CBD tank is taken into service based on silica. | ||
| 82 | Ensure ESP fields are in maximum if full coal firing otherwise 1st & 5th fields. | ||
| 83 | Ensure H2 pressure > 2.8 ksc & purity > 98%. | ||
| 84 | Put unit in CMC after matching the parameters. CMC Ref. of load should track actual load |
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