SUPERCRITICAL UNIT STARTUP

AND SHUTDOWN

INTRODUCTION

INDIAS 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.

START-UP SEQUENCE

BOP SYSTEM READYNESS

BOILER FLUSHING: COLD/HOT

BOILER LINE UP AND LIGHT UP.

TURBINE LINE UP.

TURBINE ROLLING.

SYNCHRONISATION

PHASE CHANGE OVER

FULL LOAD

START UP MODES

COLD START UP:HP & IP SHAFT

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

Boiler
Economiser
FCS

11+1

2x
7

HP
T

IPT
3

HPH - 2

HPH - 1

RH

2x
7

LPT A
5

LPT B
7

LPH -7A
LPH -8A

LPH -7B
LPH -8B

Condensor
(HP)

Deaerator

Condensor
(LP)

EXT From
CRH

(MD BFBP
1x35%)
HPH -3

TDBFP 2X50%

CEP
3x50
%

1994 TPH

GSC
CPP

1482 TPH
LPH -5

LPH -6

PRE STARTUP READYNESS

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.

WHY BCP ?

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 s/cm

BOILER FEED WATER

TEMP.<= 45 OC

CL- <= 50 PPM

pH >= 6.5

SUSPENDED SOLIDS <= 5 PPM

FILLING,PURGING & FLUSHING WATER REQUIREMENT

MOTOR INITIAL FILLING FLOW RATE

: MAX. 5 L/MIN

PRE BOILER FLUSHING

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.

Boiler flushing

SP SP

START-UP
LINE

Sampling
Fe+

Below
Above
500ppb
500ppb

MIXER

BCP
WW
ECO
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

SIO2 > 50PPB

IF HOT CYCLIC FLUSHING CRITERIA IF

FE
SIO2 < 50PPB

> 100PPB

< 100PPB

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.

BOILER LINE UP AND LIGHT UP

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 538C 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

Light Oil

Fuel Pressure

0.8MPa-2.0MPa

Fuel Flow

500kg/h -3000kg/h

Atomizing Air Pressure

0.6MPa-1.2MPa

Atomizing Air Flow

100-600kg/h

Ignition Method

HESI (20 joules/spark)

Fuel

Heavy Oil

Fuel Pressure

0.8MPa- 2.0MPa

Fuel Flow

1000-4000 kg/h

Atomizing Steam Pressure

0.8MPa-1.2MPa

Atomizing Steam Flow

100-400kg/h

Ignition Method

HESI (20 joules/spark)

TURBINE LINE UP

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)

TURBINE LINE UP
ENSURE TDBFP IN BARRING.
GLAND STEAM CHARGING: ENSURE STEAM TEMP. IS 56C 111 C MORE THAN ROTOR TEMP & DEGREE OF SH > 50C.
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.

COLD START UP CURVE

HOT ROLLING

MS TEMP
RH TEMP
SPEED
MS FLOW
LOAD
MS PRESS

PRE HEATING OF HP CASING.

PREHEATING OF HPT REQUIRED WHEN INNER METAL TEMP <150C.

CRH PR 0.5-0.7 MPA/220-380C.

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 50C PER HR.

HP CASING TOP-BOTTOM & INNER-OUTER WALL METAL TEMP DIFFRENCE

SHOULD BE WITHIN 50C.

AFTER ATTAINING THE CASING TEMP > 150C CLOSE THE RFV VALVE AND
OPEN HP CYLINDER VENTILATION VALVE TO CONDENSOR.

TURBINE WARM UP OPERATION

MS
HPBP

HPT

CRH NRV

RFV

IPT

Ventilator valve
TO CONDENSER

BDV

TO CONDENSER

CRH LINE

TURBINE STARUP PROCEDUR

TURBINE ROLLING

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: 330C
- THE DEGREE OF SUPER HEAT > 56C.

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 CVS OPENS TO 12% TO WARM UP THE HP

CASING.

WHEN HP CASING TEMP >320C.CLOSE THE HP CVS.

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 450C. TAKE COAL MILL-B AT.
STEAM T/PR 380C/8.7 MPA.

INCREASE FUEL FLOW MAINTAINING STEAM TEMP.& RAISE LOAD

AT 70 MW IP TO HP CHANGE OVER. CVS WILL START OPENING, CLOSE THE BDV

AND VENTILATING VALVE.

INCREASE THE LOAD AT 3MW/MIN

CLOSE THE HP-LP BYPASS GRADULLY.

660

LOAD
(MW)

350
660 MW

495

330MW

330

198MW

165
60MW

33MW

400
450
500
MINUTES
550
600
650

MILL-F CUT IN (540MW)

MILL-E CUT IN (430MW)

MILL-D CIT IN (300MW)

OIL GUN CUT OUT (260MW)

MILL-A CUT IN(210MW)

WET TO DRY CHANGE OVER

2ND TDBFP CUT IN(180MW)

HPH CHARGED(150 MW)

MILL-C CUT IN AT 100MW

IP TO HP CHANGE OVER (70MW

MILL-B CUT IN

SYNCHRONISE
&CHARGE D/A

LPT A

2nd

LPT B

FROM IPT EXHAUST

2nd

5th

5th

6th

6th

5th

4th

4th

5th
6th

6th

LP HEATER 7A

LP HEATER 7B

LP HEATER 8A

LP HEATER 8B

CONDENSER

HP HEATER
LP HEATER
5
5

CONDENSER

HP HEATER
LP HEATER
6
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

HP

IP
1.12 Mpa
378 C

1.3 MPa
350 C

Aux. Steam
Header

To
CRH

Changeover Valve

From
CRH

E
M

4 MPa
315.3 C

TDBFP-B
To
Condenser
Deaerato
r

TDBFP-A

Booster
pumps

LOADING

TAKE THE MILL-C IN SERVICE AT 100 MW. STEAM T/PR:400C/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 410C/8.7 MPA.

AT 180 MW TAKE SECOND TDBFP IN SERVICE.

MS LINE

HRH LINE

IP EXHAUST
CRH LINE

9th stage

5th stage

TDBFP A

HP HEATER
1

HP HEATER
2

HP
HP HEATER
HEATER
33

DEAERATOR

TDBFP B

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 475C/10 MPA.

TAKE MILL-E AT 430 MW. MS T/PR 566C/17 MPA.

TAKE MILL-F AT 540 MW. MS T/PR 566C/24.1 MPA.

INCREASE THE LOAD TO FULL LOAD 660 MW GRADUALLY.

Boiler Design Parameters

NO.

Parameters
1

100% BMCR Coal consumption (Design)

Unit

390.37

t/h

Design fuel

Superheated steam flow

2111

t/h

Superheater outlet pressure

25.4

MPa

Superheater outlet temperature

569

Reheated steam flow

1749.1

t/h

Reheater inlet pressure

4.73

MPa

Reheater outlet pressure

4.49

MPa

Reheater inlet temperature

324

10

Reheater outlet temperature

569

Feedwater pressure

28.8

MPa.g

11

Feedwater temperature

280

12

Separators steam temperature

421

153.3

147.2

13
14

Air preheaters outlet air temperature, uncorrected

After correcting
Calculating thermal efficiency of boiler

Indian coal

87.19% BMCR

TURBINE PARAMETERS
Steam Admission Parameters at Turbine Inlet
HPT

IPT

LPT

Pressure (MPa)

24.2

3.961

1.12

I/L Temp (Deg C)

566

566

378

O/L Temp(deg C)

315.3

378

Steam Flow (tph)

1959.25

1649

TURBINE HEAT RATE( KCL/KWH) 1885

No of Stop valves

No of Control valves

TURBINE AT FULL LOAD

3.96MPa / 566c
HRH
24.2MPa/566C

1.12MPa / 378c

RSV

MS LINE

MSV

CV

CV
CV

TO BLR RH

CV

CRH

HPT

IPT

LPT

#1

LPT #2

CRH
RCV
CV
CV
MSV
MS LINE

HRH

CV

CV

RCV
CV
CONDENSOR A

RSV
RSV

CONDENSOR B

GEN

SHUT DOWN

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.

SHUT DOWN

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.

SHUT DOWN

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

COOL DOWN CURVE

THANK YOU