Boiler & Turbine Cold / Warm Startup checklist

ACTIVITY BEFORE LIGHT UP 1. All ESP fields made OFF and CERM & EERM are in service. 2. ESP all hopper heater ON, also support and shaft insulator heater ON. 3. All Required permits to work (PTW) have been received. 4. At least one CW pump & one condenser pass in service. 5. ACW pumps in service. 6. DMW ST, CST, Deaerator levels are normal. 7. DMCW pumps & heat exchangers are in service 8. DMCW Booster pump in service 9. Scaffold & Access doors DMCW water flow established 10. Seal trough and bottom ash hopper over flow optimized . 11. All oil guns are cleaned and engaged. 12. Ignitor cooling valve should be open. 13. Atomising ring header drain open. 14. Bottom ash hopper should be filled with water. 15. Bottom ash handling system ready and available 16. At least one ESP pass available 17. Boiler drum level normal (-100 mmwc) 18. Boiler drum vents, SH vents are in open condition(Cold startup) 19. Drain before Main Stop Valve (MS101 & 104) is open and manual valve also opened condition. 20. S/H drains are open & header drain also open 21. Eco-bottom ring header recirculation valve open (E024) 22. Furnace probe available 23. All soot blowers are in home position 24. Burner Tilts at horizontal condition 25. flue gas path available 26. All manholes & peep holes are in close condition 27. Cooling hose of scanner should connected. 28. Drum level normal & check with local gauge glass 29. All lub oil system in healthy condition (all equipments). ACTIVITY FOR BOILER LIGHT UP (WITH AB ELEVATION GUN) Before lit up ensure TG rotor on Barring (TG check list)

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2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 1. 2. 3. 1. 2. 3. 4. 5. 6. 7. 8.

AC scanner fan in service & DC Scanner fan is healthy Start Air Pre-Heater & check availability of Air Motor One ID Fan in service One FD fans in service Establish air flow between 340 to 380ton/Hrs and draft -5 to -10mmWC Purge permissive satisfied Purge start Purge completed LDO Pump Discharge Pressure control on manual & recirculation valve is >50% open Start one LDO pump & put pump dis. Pressure control in auto with set point of 18 kg/cm2. Open LOTV after >1 Minute of Purge completion to reset SADC Maintain LDO pressure as required >14Kg/cm2 after LOFCV Take guns in service as required Establish oil guns and regulate LDO pressure around 7Kg/cm2 Regulate startup vent as required to raise steam pressure Close drum vent at Drum Pr > 2 kg/cm2 Close SH drain and vents at drum Pr > 5Kg/cm2 Open Main Steam Strainer Drain (MS105,106,109) Raise drum pressure up to 15 kg/cm2 MAIN STEAM LINE CHARGING Open S110, 111, 120, 121 Valves for MS line heating Slowly open S109, 119 after heating. After equilisation SH O/L & turbine I/L temp. Close drain (MS101 & 104) before Main Steam Stop Valve. Also close respective manual valve. APRDS CHARGING Open all drains in APRDS line Ensure sealing steam line valve (AS 09) at APRDS is close Ensure manual isolation valve before gland steam supply valve is close Ensure bypass valve of gland steam supply valve is close Ensure spray control valve is lined up and in auto with set point 320 deg. C Open APRDS motorized valve. Open APRDS pressure control valve gradually Put APRDS pressure control valve in auto with set point of 8 kg/cm2 TAKING CD ELEVATION GUN

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Ensure HFO Tank heating in service through other unit Ensure / charge the steam tracing line. Open long recirculation valve (HORV) Line up one HFO heater from HFO side. Start one HFO Pump & put pump dis. Pressure control in auto with set point of 18 kg/cm2. Charge steam to HFO Heater & put steam control valve in auto with HFO temp.set point 110 deg.c Ensure HFO temp. at firing floor is 100 deg.c Charge steam automising line & maintain header pressure 7.0 kg/cm2 Close HORV before taking gun in service. Take gun in CD elevation as per requirement APH soot blowing started. STARTING OF MILLS

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Complete vacuum pulling. Take HP/LP BP in service. Start One PA Fan & establish PA header pressure >850mmWC Ensure at least one seal air fan is in service Coal available in bunkers Ensure all per missives of mill is available and start mill Open hot air gate & coal air gate Open HAD & CAD to establish mill air flow 60 ton/hr and mill outlet temp. 70 deg.c Start coal feeder. Close Recirculation valve of ECO- bottom Ring Header Regulate HPBP to control MS pressure Take other mills in service as required After establishing steam flow the drum level control transfer to 3-element control ESP charge after APH O/L temp. reaches to 1000C.

Turbine Startup checklist

Normalisation of TG lub oil system
1. 2. 3. 4. 5. 6. 7. 8. Ensure all permit returned Normalise power supply of all pumps. Check at least one lube oil cooler in service Start DC EOP & check the oil circuit for any oil leakage Start one AOP & Pump Disc. pr. >7.5Kg/cm2 & Lub oil header pr. >3.5 Kg/cm2 Make SLC AOP, EOP, OIL TEMP. CONTROL "ON" Start AC JOP , Lift oil pressure >155kg/cm2

Make SLC JOP "ON" TG Lub oil System Testing & Barring Gear 1. 2. 3. 4. 5. 6. 7. 8. 9. Stop AC LOP & Check AC & DC LOP start Stop Ac LOP & then DC LOP Drain Lub oil Pr. Switch, Check AC & DC EOP start on low lub oil pressure Normalise and take Pr. Switch in service Stop AC & DC EOP Keep DC JOP SLC "ON" & AC JOP SLC "OFF" Stop AC JOP. DC JOP will took start. Keep AC JOP SLC "ON" & DC JOP SLC "OFF" Stop DC JOP. AC JOP will took start.

10. Keep all SLC "ON" 11. Start OVEF. Ensure the availability of standby fan 12. Put TG Set on barring gear by opening barring gear solenoid. 1. 2. 3. 4. 5. 6. 7. 8. Vacuum Pulling & Steam Dumping 1. 2. 3. 4. GS supply control control valve I/L man. Isol. Valve closed GS supply control control valve bypass motorised valve closed Ensure Gland steam drain valves AS 139 open to Atm F/T Ensure bypass line of AS139 through orifice is open

Generator H2 & Seal Oil System

Start one Seal Oil Pump. Ensure the availability of standby pump Take trial of DC Seal Oil Pump Ensure the power supply of both vacuum pump and start any one of them. Start one BC Exhauster Fan and ensure the availability of standby fan Ensure H2 pressure up to 3.0kg/cm2 and purity > 99% Ensure Seal Oil System maintaining DP 1.75 Kg/cm2 Ensure manual isolation valve of Generator & Excitor cooler open

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Ensure Mal-81 Gland steam header drain open Open AS-20 at APRDS gradually for heating Ensure Gland steam temperature before CV > 180 deg.c Seal water to vacuum braker eastablished Seal water to LP Valves eastablished

10. Vacuum braker valve closed 11. Seal water level & flow in vacuum pump eastablished 12. Start both vacuum pump. 13. Vacuum > -0.4kg/cm2 14. Start one Gland steam exaust fan 15. Open manual valve before gland steam supply CV 16. Open Gland steam supply control valve gradually till gland steam header pressure reaches to 350 mmwc

17. Put the gland steam control in Auto mode with set point 200 mmwc 18. Ensure Vacuum >-0.9 Kg/cm2 19. Open HPBP warm up line drain (Open BP-5,6,7,8) 20. Open LPBP drains (Open HRH- 103 & 104) 21. LPBP Trip reset at vacuum > -0.6 kg/cm2 22. HPBP Trip reset at vacuum > -0.6 kg/cm2 23. Check CRH pot drain manual isolation for open 24. Check CRH pot Motorised drains for open 25. MAL-11 Drain before HPCV-1 open for warm-up 26. MAL-12 Drain before HPCV-2 open for warm-up 27. MAL-22 HP Casing drain open for warm-up 28. MAL-26 Drain before INPT CV-1 open for warm-up 29. MAL-27 Drain before INPT CV-2 open for warm-up 30. MAL-31 Drain after INPT CV-1 open for warm-up 31. MAL-32 Drain after INPT CV-2 open for warm-up 32. MAL-66 drain before CRH NRV open 33. MAL-47 Drain of Extraction A5 34. MAL-51 Drain of Extraction A4 35. MAL-54 Drain of Extraction A3

36. MAL-55 Drain of Extraction A2 37. Open HPBP warm-up valve manual & Motorised valve (BP-3,9,4,10) 38. HPBP warm-up completed (T>200Deg.C) 39. LP Bypass CVs & Spray CVs in Auto mode 40. LPBP Fixed set point 6Kg/cm2 41. HPBP Pressure set point 25Kg/cm2 42. HPBP open by 2% & BD opened in auto mode 43. Keep Temp. control BPE in auto with set point 330 Deg.C for hot start up. 44. Gradually open HPBP & closed startup vent.

45. Keep MS & HRH temp < 370 deg C (Cold start up only) 1. 2. 3. 4. 5. 6. 7. 8. 9.

Rolling of Turbine with EHC control

MS Temp & Turbine Criteria achieved RH Temperature & Turbine criteria fulfilled Take the mill as per requirement of Temperature Put drains in auto mode Check local position of all drains Turbine Stress Evaluator Influence ACTIVE. Frequency influence OFF Co-Ordinated control OFF HP Exaust pressure control on auto

10. HP & IP CV Limiter set as per requirement Increase firing so as to achieve steam dumping at least 100MT/Hr and hold MS & HRH 11. Temp <375degreeC for COLD START UP and MS & HRH Temp <500 degreeC for HOT START UP 12. Close MS line drain to IBD tank 13. Check Criteria fulfilled 14. Ensure Speed Reference & Load Reference '0'. PR Max.250 MW and trimming device should be ON.

Wait toFulFill the criteria X1 to X3 Made starting device ZERO for turbine resetting. ( before that generator must be reset) 15. Open stop valves by raising the starting device. Speeder gear made full open. Wait toFulFill the criteria X4 and X5

16. Raise the speed refeance to 600RPM and observe the vib. and temp. of all bearings. 17. JOP will stop at 540 RPM 18. Wait toFulFill the criteria X6 . Raise the speed refeance to 3000RPM and observe the vib. and temp. of all bearings Check for HP (Ti - Tm) = or < 10 deg C

For rolling full speed raise the speed referance to 3000 rpm.Check all turbine and Generator vib. in range. Observe vibration at every bearing at critical speeds.(1255, 19. 2418) MOP will take over & AOP will stop after 3000 rpm. After checking MOP discharge press.

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Synchronisation of Unit 1. 2. 3. 4. 5. 6. 7. 8. 9. Check Generator gas press, excitor air cooler DMCW line , Hydrogen Cooler DMCW line charged by opening temp. control valve before that venting should be done. Wait toFulFill the criteria X7 Close generator field braker & Excitation ON Match speed and voltage manually and switch on Auto-synchroniser As soon as unit synchronised give pulse commond to speed referance to raise load up to 25 MW. Trim device made off. Make Load Gradient & Load Control ON. Load Gradient 10 MW/min. Increase the Load refeance 5 MW above the actual load. 'Load control O/P' will become more than 'Speed control O/P' and Load control will tranfer from 'Speed control' to 'Load control' Close strainer drains (MS & HRH) Gradually Increase the load. Hence Load is minimum 1.25 times of MS PR.

Close all the Line Drains & MAL Drains. Increase the Load Set Point According to TSE MARGIN AVAILABLE. 10. Beside that Boiler MS & HRH Temp should not be increased more than 537 Deg.C.So, accordingly COAL FLOW to be maintained bywatching MS PR & Steam Flow.

Loading of Turbine

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Raise the load above 60MW close HPBP / LPBP Fully Check all the drains close Check SLC Drain on Auto Take LPH-1,2 & 3 in service at 50 MW load Check MAL 54 Extraction drain closed after LPH-2 cutin Check MAL 55 Extraction drain closed after LPH-3 cutin Withdraw any deaerator auxiliary pegging and Charge Ext-4 to deaerator Check for self gland sealing if load is 90MW

Transfer HPBP CV in auto mode & pressure set point in sliding mode Ensure followings -HPBP pressure set point shell be greater than the actual pressure by 10Kg/cm2 -Auto influence in LPBP shall be kept OFF unless specified 10. According to Load ( 100 MW ) 2nd set of Fan & BFP taken in service. After 125 MW Load Any one ELV. Gun taken out of service as per Boiler Flame Intensity. Take HPH-5 & 6 in service after 150 MW load 11. After 150 MW Load 2nd ELV. Gun taken out of service as per Boiler Flame Intensity. 12. Ensure MAL-47 & 51Ext-drain close after taking HPH-5 & 6 in service 13. Raised the Load gradually as per availability of TSE margin.