UNIT START UP SEQUENCE ACTIVITIES

1. All permits at boiler area, turbine area and at least one set of all equipments should
be returned.
2. Any equipment may be run by taking all necessary lineup and without bypassing
any protections /interlocks.
3. Water line will be charged after proper venting and any steam line will be charged
after proper draining.
4. Start ACW pump. Line up firing floor and open HORV.
5. Start DMCW(T), charge water up to CEP, BFP, Compressor
6. Start one SA & IA compressor.
7. Line up the boiler. Keep start up vent, SH vents, RH vents, HP drains open. LP
Drain, Master Drain, IBD, EBD, CBD closed. MS 101,102,105,106 kept open. MS-
1, 2 close.
8. Check availability of Chemical dosing p/ps (NH 3, N2H4, HP)
9. Initially boiler water filling may be done by running CTP with Chemical at CTP
disch. (in case of empty) or by BFP with chemical.
10. Ask DM plant regarding light up chemical.
11. Start DMCW (B) and charge water up to ID, APH, FD, Mill, PA
12. Start both APH by electric motor and check availability of air motor. LOP s of
APH - MCC ON normal.
13. Start AC scanner air fan and check DC scanner air fan.
14. Check Seal oil system OK, DC SOP –availability. Check Generator hydrogen
gas pressure ~2.0 Kg/cm²
15. Start AC EOP, AC JOP, AOP of turbine and put AC EOP, DC EOP and DC JOP
in Auto.
16. Turbine should be put in burring gear.
17. Check SADC position ---all dampers will remain in full open.
18. Charge condenser through ACW. Start one CW pump.
19. Start one CEP in recirculation, check hood spray, LP bypass spray line.
20. Start ID fan. Then start FD fan.
21. Maintain air flow >30 %< 40% i.e 280-310 TPH and draft -5.
22. Start LDO pump and establish oil pressure ~15 Kg/cm² at firing floor.
23. Trough seal & bottom ash hopper water to be established.
24. Make drum level normal. Operate EBD as per requirement.
25. Furnace purging to be done.
26. Start one BFP if boiler was filled by CTP otherwise one BFP will be run
continuously from boiler filling.
27. Light up at AB elevation with one pair oil gun. Firing rate: saturated steam temp
rise <110°C per hour (pressure rise @ 30 kg/cm 2/hr) or the furnace exit gas
temperature(<540°C)
28. Drum Pr. 2.5-3 Kg/cm². Close all vent valves except RH vent and start up vent.
Close high point drain valves.
29. Line up of TAS, Gland Steam system, Vacuum Pulling
 Open all drain valves (U/S & Downstream of TAS HC Controller).
 Open GSC Controller Upstream drain valve, manual isolating valve.
 Close GSC Controller downstream manual isolating valve.
 Open all drain valves before & after AS-9 and gland stm line at o meter.
 Open CRH-105 open to atmosphere bypass valve.
 All drain valves connected to Condenser must be kept closed.
 Open CRH drain (manual) CRH103,104 open to atmosphere at 0 mt.
  Close TAS attemperation root valve at CEP Discharge.
 Open Ejector Controller isolating valves, drain valves.
 Open drain valve of starting ejector steam/exhaust line.
30. Drum Pr ~ 20 Kg/cm², Open MS 3,4,5,6 for heating of MS line. Heating of MS
line should continue for one hour.
31. Open TAS HC line, partially open TAS HC Controller, Open Ejector Controller
and AS-9 for warm up of all lines.
32. Drum Pr ~ 25 Kg/cm²; fully open MS 1, 2 gradually to charge MS line.
33. TAS Charging :
 Open ejector controller 100 % and starting ejector steam valve.
 Maintain TAS Pressure ~ 9.0 Kg/cm², Temperature ~250ºC.
 Ejector Steam Pr ~ 8.0 Kg/cm². Increase gland steam temp> 210 ºC.
 Start D/A pegging by AS-2 from TAS to increase consumption.
34. Vacuum Pulling : Before vacuum pulling please check the following.
 Vacuum breaker must be open. Air supply valve open.
 Both main ejector loop filling to be completed
 Close RH vent. Close CRH -101 open to atmosphere at zero meter
 Gland steam temperature > 210 ºC
 GSC Controller Downstream manual isolating valve open.
35. Start vacuum Pulling
 Start Gland Steam Exhauster -1 no and keep other in auto.
 Open air valve of starting ejector. Ejector steam pr ~ 7.5 Kg/cm²
 When vacuum reaches 15 mm of Hg then open GSC controller and put into auto.
Check Gland steam pr set point as 0.067 Kg/cm².
 When Gland stm pr >0.02 Kg/cm² (vacuum ~50 mm of Hg close vacuum breaker.
 When vacuum reaches 650 mm of Hg. One main ejector will be put into service and
starting ejector may be withdrawn.
 Open all drain valves connected to HP Flash tank. Open CRH 105 to HP flash tank
and close CRH 105 open to atmosphere bypass.
 Partially close all atmospheric drain valves (TAS, Gland Steam).
36. HPLP Bypass Line up & Charging
 Ensure oil pumps of OSUs are running, Check auto cut in/cut out
 Open condensate dump line. Close LPH3 I/L, O/L bypass valve.
 Check LP bypass spray manual isolating valves and kept open.
 Open BP 101,103(warm up drain valves connected to UFT)
 Open drain valves of HPBP spray lines.
 Vacuum more than 650; open all drain valves connected to condenser (CRH 101,
HRH 101, 102, 103, 104, 115, and 116).
 When vacuum >680 mm of Hg open LPBP warm up valves (HRH 109, 110) . Then
open HPBP warm up valves (BP 3,4) partially. Gradually open BP 3, 4 fully and
continue HPBP and LPBP warm up.
 Check HRH pressure set point 3 Kg/cm².
 Open LPBP control valve partially (>2%) LPBP stop valves will open automatically.
Put LPBP control and spray control valves into auto.
 Increase drums Pr. above 40 Kg/cm².
 Ensure warm up of HP.LP bypass was done above 30 minutes, closely observe
drum level.
 Open HPBPCV 1,2 around 2~3 % .HPBP spray control valves put into auto.
Check LP Bypass .
 Check CRH line, if any hammering is coming close HPBP.
 Set HPBP down stream temperature as 250 0C for cold machine, and 300 0C for
hot/very hot boiler.
 Open manual isolation of BD valves of HPBP D/S temp ~200 0C .
 Gradually increase opening of HPBP control valve and check LPBP control valve is
responding accordingly. Check HRH pressure as 3 Kg/cm² and % opening of LPCV.
 Don’t open HPCV more than 5% at a time.
 Increase drum Pr. by increasing firing rate and gradually open HP bypass. Check
opening of LPCV. Open HPBP control valves to some extent such that LPCV open
25% at 3 Kg/cm². Then more opening of HPBP control valves HRH PR set point will
increase gradually up to 11 Kg/cm² keeping LP bypass CV at 25% opening.
 From the beginning HPBP may put in AUTO. It will open as per logic
 Check all turbine and condenser parameters.
 Ask DM plant regarding rolling chemicals.
 In cold start up mode turbine rolling and synchronisation will be done with out
taking any mill., i.e oil synchronisation, otherwise temperature parameters will not
be maintained.
 For Warm/Hot/ Very Hot Rolling, depending on temperature upper mills may be
taken after opening of HP, LP Bypass .
37. Turbine Rolling conditions
Mode of rolling as classified below depending on HP casing 50% metal temperature.
A. Cold rolling < 250 ºC, B. Warm Rolling >250ºC <410ºC, C.Hot Rolling <410ºC
<460ºC D.Very Hot Rolling >460ºC
Checking before Turbine Rolling
 Check turbine all rolling parameters OK, as per (*) in Graph.
 Check drum Pr.>70 Kg/cm² and Drum Level Normal (-30).
 Minimum HP bypass opening should be such that LP bypass CV will open at least
25 % with 11 Kg/cm2 HRH pressure. If all oil guns are not available then keep HRH
pressure at 11 Kg/cm2
 Inform GCR regarding readiness of rolling.
 Rolling may be done by ATRS or manually.
 Please check bearing vibration at all points are below 10 µ and shaft vibration at all
points below 20 µ
Automatic Turbine Rolling System (ATRS)
 Check turbine drain valves (MAL drains) are in open condition and kept in AUTO.
 Open ATS/ASD page. Select turbine sequence ‘ON.
 Select semi or full auto mode of ATRS
 Click on start up permissive, if permissive is available then select
cold/warm/hot/very hot depending on turbine HP casing 50% metal temperature. If
permissive is not available then go through causes and try to satisfy.
 Click on start up. Then click on ‘EX’ for sequence steps of ATRS.
 Follow ATRS steps one by one. If all conditions satisfy then ATRS will go to next
step by pressing advance. If all conditions do not satisfy then try to satisfy the
conditions and go for next step by pressing advance.
 In full auto mode ATRS will go next step automatically if all conditions satisfy in
each step.
 Do not skip any condition of ATRS without clearance of competent authority and
that should have to be written in bypass register.
 After achieving last step, press “Speed raise ON”, if drum level is normal.
 Turbine speed will increase either in 200 rpm /min or in 500 rpm/min depending on
cold or other mode of rolling.
 Check turning oil supply valve will close at 400 rpm and AC JOP will stop at 500
rpm.
 In cold rolling, after achieving soaking speed (1080rpm), soaking time count
starts. After 30 minute go for rated speed(3000 rpm) at 500 rpm /min. Wait for 5
min in 3000 rpm before synchronization.
 In all other mode of rolling(warm, hot, very hot), go for rated speed(3000 rpm)
at 500 rpm/minute without soaking.
Manual Rolling
 Check turbine drain valves are in open condition and kept in AUTO.
 Reset all tripping relays of all GRP panel (1,2,3,4) before turbine reset.
 Confirm governor selection in ‘EGH) & in MAN mode.
 Confirm 65 M --- 100%, Confirm Power setter (65P) – 0%
 Confirm Speed setter (65 F) – 0%
 Turbine reset (77M ----- 0%)
 Turbine reset by pressing reset button at Back Panel/CRT.
 77M 0% -- 42%, Check MSV, RSV open.
 MAL 11, 12 open from 25 % to 100 %
 Then Mal 11, 12---- 100% to 25%
Check the condition for steam admission
 Check the MSV(L) casing metal diff temp < 30 oC
 Check the HPT casing metal diff temp < 30 oC
 Check the HPT rotor metal diff temp < 30 oC
 Check the IPT rotor metal diff temp < 30 oC
 Check the differential temp of turbine casing between up & down HP casing < 55 oC
& IP casing < 65 oC
 Check the shaft eccentricity : < 75 m
Cold rolling
 Set 77M : 100%
 Set the EHG speed setter(65F) : 1080 rpm
 Kept TSE ‘ON’, Select – Speed Rate ‘SLOW’ i.e 200 RPM/min
 Now start turbine rolling in Cold start up mode by selecting Heat Soak ‘ON’
 Check MCV1,2 and IPCV1,2 are opening slowly and turbine speed increases from
burring to 1080 RPM.
 Check Turbine oil valve closes at > 400, ACJOP stops at >500 RPM.
 Keep at 1080 RPM for 30 minutes for soaking.
Check following during soaking
 Differential Expansion within limit
 Bearing Metal Temperature < 90 or 100 or 105 oC
 HP Turbine exhaust steam temperature : < 480 oC
 Turbine exhaust steam temperature : < 90 oC
 Bearing and shaft vibration within limit.
 Confirm the condition for turbine speed up
 Set speed setter 65F : 3000 rpm, speed rise rate : 500 rpm/min
 Select ‘Rated Speed’ push button and make ‘ON’. Speed rise rate is automatically
selected as ‘FAST’ i.e 500 RPM/min
 Turbine speed will increase to 3000 RPM. AOP cut out at 2950 RPM.
 Always monitor turbine supervisory parameters during rolling and take maximum
vibrations at diff points and corresponding speed.
Warm/Hot/ Very Hot Rolling
 Kept TSE ‘ON’, Select – Speed Rate ‘FAST’ i.e 500 RPM/min
 Now start turbine rolling in Warm/Hot/ Very Hot mode by selecting Heat Soak ‘ON’
 Keep at 1080 RPM for 2~5 minutes for checking all turbine supervisory parameters
and then proceed.
 Select ‘Rated Speed’ push button and make ‘ON’. Speed rise rate is automatically
selected as ‘FAST’ i.e 500 RPM/min
 Turbine speed will increase to 3000 RPM.
 Check all parameters and drives auto cut out same as cold startup.
38. Synchronisation
 Check Turbine speed is 3000 RPM and keep drum level Normal (-50). Allow 5
minute in 3000 rpm before synchronization.
Holding time at rated speed : cold mode- 5 min, warm mode – 2 min, Hot &Very
hot mode – 0 min
 Check all tripping relays of all Generator Relay Panel (1,2,3,4) have already been
reset.
 Ask GCR to switch ON respective isolators (29 C line side and respective BUS side
isolator)
 Field Circuit Breaker ON from Generator Panel or CRT
 Excitation ON from Generator Panel and select in AUTO.
 Check Auto/manual balance voltage at Zero(0) position
 Ensure excitation voltage near about 15.75 KV
 Ask GCR to switch ON Synchronizing Switch.
Synchronisation may be done by Auto Synchronisation or manual i.e Check
Synchronisation.
Auto Synchronisation
 Put Synchronizing selector switch in position 2 (AUTO) at GCP.
 Switch ON- Synchroscope ON switch.
 Within one minute m/c will automatically synchronized with auto synchronizer.
 Switch OFF Synchroscope switch and keep Synchronizing selector switch in
position ‘1’.
 Inform GCR and note down the actual time of Synchronisation.
Check Synchronisation (Manual)
 Put Synchronizing selector switch in position 3 (MAN) at GCP
 Switch ON- Synchroscope ON switch.
 Check the rotation of Synchroscope in clock wise and then adjust the speed of
turbine nearer to Grid frequency and observe the LED (25C operated) indication
and switch ON the GCB control switch when the Synchroscope niddle is near to
12’O’ Clock and blowing of LED (25C operated). So M/c is synchronized in manual
or Check Synchro mode.
 Switch OFF Synchroscope switch and Synchronizing selector switch in position ‘1’.
 Inform GCR and note down the actual time of Synchronisation.
39. Load raising
 After synchronisation open Generator, exciter cooler water valves.
 After synchr close all drain valves and MS105,106, BP101, 103.
 Inform DM plant regarding synchr and ask for any recommendation.
During cold start up load may be increased in following rate
 Keep Load at ~ 10.5 MW for one hour.
 After one hour at 10 MW, load will be increased upto 60 MW at 1 MW/min rate.
 Then load will be increased upto full load at 02 MW/min
 So during cold startup full load will be achieved after 195 min of synchronization.
 Increase MS pressure upto 149 Kg/cm 2 gradually by increasing firing rate and
closing HPLP bypass.
During warm start up load may be increased in following rate Keep Load at ~
10.5 MW for 10 minute.
 After that, load will be increased upto 50 MW at 04 MW/min.
 Then load will be increased upto full load (210MW) at 02 MW/min
 So during warm startup full load will be achieved after 100 min of synchronization.
During hot start up load may be increased in following rate
 Keep Load at ~ 10.5 MW for 01 minute.
 After that, load will be increased upto 40 MW at 05 MW/min rate.
 Then load will be increased upto 70 MW at 02 MW/min rate.
 Then load will be increased upto full load (210MW) at 03 MW/min
 So during hot startup full load will be achieved after 68 min of synchronization.
During Very hot start up load may be increased in following rate Keep Load at ~
10.5 MW for 01 minute.
 Then load will be increased upto full load at 4.2 MW/min
 So during very hot startup full load will be achieved after 48 min of synchronization.
Common steps to be followed after synchronization in all start up.
 Cut in lower most mill for Cold start up. In case of other mode of rolling and
depending on temperature, upper mills may be taken before turbine rolling.
 Increase firing rate gradually by taking mills. Air flow should be increased
accordingly.
 Check SADC. Put in AUTO.
 Opening of HP Bypass CV may be reduced gradually but must be kept open at
least ~10% upto 70 MW load. HP bypass may be closed fully above 70 MW load.
 Check all turbine drain valves. All drain valves will close automatically at 20% load
(42 MW)
 At 50 MW BTS change over will be done, i.e UAT will be in service.
 At 60 MW all LP Heaters will be taken in service sequentially 1, 2, 3 one after
another and observe on temperature rise .
 At 90 MW load HP heaters will be taken in service sequentially 5, 6 one after
another.
 During taking heater in service always monitor vacuum. If vacuum starts falling
withdraw last operation and find out the actual cause.
 At 100 MW load EX -4 will be charged to Deaerator.
 Load may be increased upto 210 MW.