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SHREE SINGAJI THERMAL POWER PROJECT Doc. No.

: 92200-2024
STAGE-II (2×660 MW)
Rev. No.: 1
STEAM GENERATOR & AUXILLARIES
L&T-MHPS Boilers Pvt. Ltd. PACKAGE Date: 02/04/2018
Boiler start up procedure without Page: 2 of 8
BCP Job No.: 51005

Revision History:

Rev No. Description Date

0 First Issue 22/12/2016

1 Revised as per LII/MPPGCL comments 02/04/2018


SHREE SINGAJI THERMAL POWER PROJECT Doc. No.: 92200-2024
STAGE-II (2×660 MW)
Rev. No.: 1
STEAM GENERATOR & AUXILLARIES
L&T-MHPS Boilers Pvt. Ltd. PACKAGE Date: 02/04/2018
Boiler start up procedure without Page: 3 of 8
BCP Job No.: 51005

Index

1. Preamble
2. Purpose
3. Pre-requisite
4. Procedure
SHREE SINGAJI THERMAL POWER PROJECT Doc. No.: 92200-2024
STAGE-II (2×660 MW)
Rev. No.: 1
STEAM GENERATOR & AUXILLARIES
L&T-MHPS Boilers Pvt. Ltd. PACKAGE Date: 02/04/2018
Boiler start up procedure without Page: 4 of 8
BCP Job No.: 51005

1. Preamble:

During boiler start up and wet mode operation the flow through the economizer and water
wall is maintained at about 25% TMCR flow with the help of BFP and BCP.
In this period the WSDT (water separator drain tank) level is maintained by both BR valve
1 (03HAG03AA700) and WDC valves (03HAG03AA701/702). BCP and BR valve
(03HAG03AA700) is used to recirculate the water through economizer and water walls and
the WDC valve (03HAG03AA701/702) drains the excess water to condenser, thus maintaining
WDC level within acceptable range. During wet mode operation, the boiler operation is
similar to sub critical drum type boiler.

To maintain the required flow at eco inlet in absence of BCP, the BFP flow is to be increased
to maintain Feed Water flow around 438TPH (90% of 25% TMCR Flow).

When the Boiler is to be operated in wet mode without BCP, to maintain WSDT level, the
water is recovered through condenser via WDC Valve (03HAG03AA701/702) instead of BCP.
Therefore, to maintain WSDT level, the WDC valve (03HAG03AA701/702) is to be modulated
as per “without BCP” operation logic, and the WDC Valve control loop needs to be in auto.

2. Purpose:

This procedure aims to establish the guidelines of starting up the boiler without the help of
boiler circulating pump.

3. Pre-requisite:
i. Implement modified WDC valve logic for No BCP operation and check its
function.
ii. All other system, equipment, and auxiliaries are available and are in service as
mentioned in normal start up procedure.

4. Procedure:
A. Boiler water filling:
After completion of pre-boiler clean up, fill the boiler using BFP as per normal
operation procedure.

B. Boiler cold clean up blow:


This process will be same as followed during normal operation condition.

C. Boiler cold clean up recirculation:


After completion of Boiler cold clean up blow, Boiler cold clean up recirculation can
be started by opening WDC valve. Boiler water will be channelled in condenser from
where it will go back to feed water circuit through condensate polisher. The flow has
SHREE SINGAJI THERMAL POWER PROJECT Doc. No.: 92200-2024
STAGE-II (2×660 MW)
Rev. No.: 1
STEAM GENERATOR & AUXILLARIES
L&T-MHPS Boilers Pvt. Ltd. PACKAGE Date: 02/04/2018
Boiler start up procedure without Page: 5 of 8
BCP Job No.: 51005

to be replenished by BFP to boiler. ECO inlet feed water flow need to be increased
up to 45% from 25% TMCR flow in steps of 5% as well as to maintain WSDT level
around 8.5 m (minimum).

D. Boiler light up and hot clean up:


Follow normal boiler light up procedure with the following exceptions:
1. BCP is not available for operation.
2. BR valve (03HAG03AA700) is to be kept closed.
3. Boiler feed water flow at Eco inlet is maintained around 438 TPH.
1
4. Confirm “BCP OFF” mode is selected and WDC valves control loop is in auto.
5. Please ensure to charge SCAPH before light up.
• Note: There may be swelling of WSDT level occasionally during boiler firing rate
change. This has to be taken care of by prudent operation action. One of the
WDC valve (03HAG03AA701/702) may be taken in manual mode to control
WSDT level, in case WSDT level fluctuates heavily.

E. Boiler pressuring for synchronization:


Boiler pressure has to be raised slowly maintaining WDST level by WDC control valve
(03HAG03AA701/702). Following operation changes has to be done in case of
operation without BCP.
1 i. Increase Eco inlet Feed water temperature as much as possible by injecting more
steam in DA.
Required temperature: 110 deg. C at in ECO inlet.
ii. Required min. Feed water flow: approx. 438 TPH.
* Strict vigil has to be kept in heating profile inside furnace. Boiler metal
temperature and temperature unbalance at intermediate header, furnace O/l
header, roof O/L header, Superheater & Reheater has to be monitored and
maintained below maximum allowable temperature.
iii. Fuel input is expected to be 10% more than the normal operating condition. As
heat is not recovered by forced recirculation with BCP, fuel input has to be more
than that of normal operation until wet stage is over.
iv. Control of furnace outlet temperature:
Since fuel injection will be more, it may so happen that furnace exit gas
temperature will be increased. To control this temperature, following measures
may be taken:
Increase AA damper opening set point: This will cool the furnace as higher
amount of air will be supplied in furnace.
Required setting: normal+30%
* Keep an eye on furnace to windbox DP. It has to be maintained as per normal
setting.
SHREE SINGAJI THERMAL POWER PROJECT Doc. No.: 92200-2024
STAGE-II (2×660 MW)
Rev. No.: 1
STEAM GENERATOR & AUXILLARIES
L&T-MHPS Boilers Pvt. Ltd. PACKAGE Date: 02/04/2018
Boiler start up procedure without Page: 6 of 8
BCP Job No.: 51005

v. As higher rate of fuel will be burnt along with higher cooling air requirement at
AA port, total air flow set-point will also be higher.
Required set-point: Normal+10%
When pressure and temperature is achieved for steam admission into turbine, admit steam
to turbine and synchronize as per turbine manufacturer procedure.
Note:
- Aux steam should be supplied by auxiliary boilers or auxiliary steam from other running
unit.
- Ensure drain valve opening during pressurizing stage, especially on MS drain valve.

Attachment- A: Control logic for WSDT level control

B: Start Up System P&I Diagram (97000-2111-2)


1


    

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16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

P P

WATER WATER
SEPARATOR SEPARATOR

1813 P10-0600-1
O O

TO BOILER P&ID
WATER
SEPARATOR
DRAIN
TANK

| 370.0 °C
SA-106C 150NB x XXS
03HAG03BR023

28.30 MPa(g)
LP TURBINE A LP TURBINE B
03HAG03 03HAG03
REFER TO DWG. NO. P10-0600-1 CP404 CP405
N BOILER P&I DIAGRAM N
PP PP
P10-0600-1 1942

03HAG03
BCP WARMING WATER
BOILER CIRCULATION &

FLO

AA706
DISCHARGE CONTROL
SPRAY WATER SEQ

03HAG03

03HAG03
25NB

AA831

25NB
DCS

AA829
DCS

03HAG03BR815

03HAG03BR814
150NB

03HAG03
03HAG03

AA009
M
CT501

TG

03HAG03

03HAG03
AA830
25NB

25NB

AA828
03HAG03BR022 03HAG03BR021 100NB 100NB 100NB
SA-106C 150NB x XXS SA-106C 100NB x XXS
M M

03HAG03BR926
28.30 MPa(g) | 370.0 °C 28.30 MPa(g) | 370.0 °C 03HAG03

| 370.0 °C

03HAG03BR020

03HAG03BR924
03HAG03 AA705 03HAG03
03HAG03 AA007 AA005

03HAG03
150NB
CT004

BP005
TE

03HAG03

28.30 MPa(g)
M/A

03HAG03
AA704
FO
25NB

25NB

03HAG03
AA922

25NB
DCS

AA019

03HAG03
25NB
BOILER CIRCULATION & 03HAG03BR928

AA920
03HAG03
SPRAY WATER SEQ AA008

03HAG03
25NB

AA923
03HAG03
150NB
DCS

AA004
03HAG03
25NB

03HAG03BR927

03HAG03
AA924

25NB
03HAG03BR035

AA921
SA-312TP316H 25NB x XXS

SA-106C 25NB x S160


03QUA01
25NB

97000-2115-1 1849
AA401
03QUA01BR401

| 320.0 °C

03HAG03BR925
L TO BCP PURGE WATER 31.50 MPa(g) L

03HAG03
COOLER

25NB

AA925
25NB 03HAG03BR811 25NB 03HAG03
PP

03HAG03BR929
CP402
M/A 03HAG03 03HAG03
03QUA01

AA822 AA823
25NB

AA402

DCS BOILER CIRCULATION & 03HAG03

03HAG03
CF101
SPRAY WATER SEQ

BP004
FT
DCS
SA-106C 500NB x 63.00 mm

| 370.0 °C

25NB
03HAG03BR810 25NB PP 03HAG03 03HAG03
03HAG03BR401

LMB 03HAG03 03HAG03 03HAG03 03HAG03 CP401 CF102


CP102 CP502 03HAG03 03HAG03
28.30 MPa(g)

CP501 CP101 FT
AA820 AA821
TO SWAS PG PT PT PG

03HAG03

03HAG03

03HAG03
SA-106C 150NB x XXS

03HAG03
25NB 03HAG03BR804 25NB

25NB 03HAG03BR802 25NB

25NB 03HAG03BR803 25NB

25NB 03HAG03BR805 25NB


BOILER CIRCULATION &

AA809

AA805

AA807
BCP MINIMUM FLOW
03HAG03BR018

AA811
K K
03HAG03

03HAG03

03HAG03
03HAG03

LTP
SPRAY WATER SEQ
25NB 03HAG03BR800 25NB

25NB 03HAG03BR801 25NB

25NB 03HAG03BR855 25NB


25NB 03HAG03BR854 25NB

AA855

AA803

AA857
AA801

DCS
CONNECTIONS 03HAG03 03HAG03 03HAG03
PRIMARY FOR CHEMICAL CONNECTIONS
CT005 CT006 CT502
COOLER FOR CHEMICAL

03HAG03
03HAG03
CLEANING (150A)

03HAG03

03HAG03
FOR CLEANING (150A) TE TE TG

AA806
AA808

AA804

AA810
03HAG03

03HAG03

SAMPLING BR
03HAG03
03HAG03

500NB 400NB
AA854

AA856
AA802
AA800

M M
03HAG03BR402
SA-106C 400NB x 52.00 mm

LMB | 370.0 °C 03HAG03


| 370.0 °C

28.30 MPa(g) 03HAG03 03HAG03


03HAG03 03HAG03 03HAG03 AA700 CF002
AA402

SA-106C 25NB x S160


SA-106C 50NB x XXS

AT400 AA401 AP101


LTP BCP
03HAG03BR027

03HAG03BR900
28.30 MPa(g)

SA-106C 50NB x XXS


STRAIGHT LENGTH

03HAG03
J (1 X 100%) J

03HAG03
25NB

03HAG03BR902
50NB
AA900

AA902
NOTE 8

03HAG03
50NB
03HAG03

AA903
03HAG03
50NB

25NB
AA014

AA901

03HAG03BR903
03HAG03BR934
03HAG03
50NB

| 370.0 °C
SA-106C 400NB x 57.00 mm

| 320.0 °C
AA013

SA-106C 100NB x XXS


03HAG03BR901
03HAG03
25NB

03HAG03BR019
AA912

03HAG03BR404
6.21 MPa(g) | 280.0 °C
I I

31.50 MPa(g)

31.50 MPa(g)
03HAG03
25NB

AA913
UNLESS OTHERWISE STATED ALL DIMENSIONS ARE
IN MILLIMETRES. DO NOT SCALE. IF IN DOUBT, ASK.

97000-2113-1 1657
03HAG03BR935

SA-106C 25NB x S80


03HAG03BR931

03HAG03
AA927
25NB
BOILER CIRCULATION & CONDENSER

SA-106C 25NB x S160


LTP M/A

03HAG03BR930
50NB SPRAY WATER SEQ
03HAG03BR028 DCS
H SA-106C 50NB x XXS
H
WDC VALVE WARMING PIPE DCS
03HAG03 31.50 MPa(g) | 370.0 °C 03HAG03BR908

03HAG03
AA015 03HAG03 03HAG03 SA-106B 300NB x S80

AA926
03HAG03BR026 TP-03 CP103 CP503 TP-03 TP-03
50NB

25NB
SA-106C 50NB x XXS
| 280.0 °C

BOILER RECIRCULATION LINE


LMB BE-608 PT PG BE-617a 300NB BE-617b 6.21 MPa(g)
LMB LMB TP-03 LMB LMB LMB
| 370.0 °C M

03HAG03BR029
31.50 MPa(g) 03HAG03 EB-640 300NB
AA012 TP-03 TP-03
03HAG03
03HAG03

03HAG03 03HAG03 LATER


25NB

EB-635
25NB

EB-634

03HAG03BR039
AA837
AA813

CT003 CT503
M/A 03HAG03 03HAG03 ATMOSPHERIC FLASH
TE TG TP-03 AA905
03HAG03BR806

03HAG03BR818

AA904 TANK.
BE-609a DCS LMB
LMB
TP-03 TP-03
TP-03 TP-03 03HAG03

03HAG03
CP105 BE-618a BE-618b

25NB
EB-637

AA016
EB-636 LMB LMB PT
03HAG03

03HAG03

LMB
LMB LMB
25NB
25NB

LMB
AA812

SA-106C 300NB x 40.00 mm


SA-106C 300NB x 40.00 mm
AA836

G TP-03 G

SA-106C 25NB x S160

BCP SUB COOLING LINE


03HAG03BR001 TP-03 WSDT LEVEL CONTROL EB-638

03HAG03
03HAG03BR905
03HAG03BR030

03HAG03BR904
SA-106C 500NB x 62.00 mm

AA815
BE-609b

25NB
DCS BOILER CIRCULATION &

03HAG03BR807
28.30 MPa(g) | 370.0 °C WDC(A)
TP-03
SPRAY WATER SEQ
BE-611a LMB DCS
03HAG03BR002 FC
SA-106C 300NB x 40.00 mm

03HAG03
03HAG03
BCP WARMING LINE

AA814
AA701

25NB
28.30 MPa(g) | 370.0 °C LTP
LMB
TP-03
300NB
TP-03
03HAG03BR008
SA-312TP304 300NB x S40
TP-03 BE-613a BE-163b LMB
M
03HAG03BR006 03HAG03BR007
BE-610a TP-03 LTP SA-106C 300NB x 40.00 mm
SA-106C 300NB x 40.00 mm
03HAG03 BE-611b
| 370.0 °C | 370.0 °C
25NB

03HAG03
AA017
LMB LMB 28.30 MPa(g) 03HAG03 28.30 MPa(g)
CP151 AA001 03HAG03
F PT BP001 03HAG03BR009 F
M/A LMB LMB
LMB TP-03 TP-03 A-240GR304 550NB x 15.00 mm
SA-106C 25NB x S160

TP-03 TP-03 LMB


NOT BE REPRODUCED, USED, DISCLOSED OR TRANSMITTED IN WHOLE OR IN PART UNLESS AUTHORISED IN WRITING BY L&T-MHPS BOILERS PRIVATE LIMITED"

DCS BE-615a BE-615b


03HAG03BR032

BE-610b xxx MPa(g) xxx °C

03HAG03
EB-639

AA817
25NB
NOTE 10

03HAG03BR808
TP-03 WDC(B) BOILER CIRCULATION &
c "THIS DRAWING IS THE PROPERTY OF AND CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF L&T-MHPS BOILERS PRIVATE LIMITED AND SHALL

BE-612a SPRAY WATER SEQ


LMB
03HAG03BR004
SA-106C 300NB x 40.00 mm FC DCS
03HAG03

03HAG03
1812 P10-0600-1

| 370.0 °C TP-03 03HAG03BR012

AA816
AA702 TP-03

25NB
28.30 MPa(g) LTP
LMB BE-614a 300NB SA-312TP304 300NB x S40
FEED WATER LOW LOW TRIP BE-614b
LMB
M
03HAG03BR010 03HAG03BR011
LTP
03LAB24 TP-03 SA-106C 300NB x 40.00 mm SA-106C 300NB x 40.00 mm
BPS
CF111 BE-612b NOTES:
E FT
28.30 MPa(g) | 370.0 °C 03HAG03 28.30 MPa(g) | 370.0 °C 03HAG03 E
AA002 BP002 03HAG03BR013
FEED WATER FLOW 03LAB24 A-240GR304 550NB x 15.00 mm 1. MOTORISED AND CONTROL VALVE ON THE WARMING LINE TO
LMB TP-03 TP-03
CF112 LMB 2RY DESH SHALL BE LOCATED CLOSE TO EACH OTHER.
CONTROL LOOP BE-616a BE-616b xxx MPa(g) xxx °C
FT
NOTE 10 2. LMB - L&T MHPS BOILERS PVT LTD
DCS
M/A 03LAB24 3. LTP - L&T POWER LIMITED.
CF110
FT TP-03 TP-03 TP-03 4. ALL TAGS WILL BE PREFIXED WITH 04 FOR UNIT #4.
DCS LMB
LMB EB-620a EB-620b EB-620c M/A
03LAB24 03LAB24 M/A 5. SPOOL PIECE IS CONSIDERED TO PREVENT THE LEAKAGE OF HP FEED WATER
ECONOMIZER OUTLET HEADER CP125 DCS
03LAB23

03LAB23

03LAB23

03LAB23

03LAB23

03LAB23
25NB
25NB

25NB

25NB

25NB

25NB

CP525 IN TO THE FILLING LINE DURING NORMAL OPERATION.


AA326

AA322

AA318

AA316

AA820

AA324

PT PG LTP LTP DCS


LMB TP-03
TP-03 LMB LMB LMB 03LAB24 03LAB24 03LAB24 03LAB24 03LAB24
TP-03 6. INDICATED DESIGN PARAMETERS ARE PRELIMINARY AS PER LTP INFORMATION
03LAB23BR313

03LAB23BR311

EB-630a CT502 CP124 CP524 CP424


03LAB23BR309

03LAB23BR308

03LAB23BR310

EB-630 CT029
03LAB23BR312

EB-624 AND THE SAME WILL BE CONFIRMED AFTER LTP CONFIRMATION.


25NB

03LAB24
03LAB24

TE TG PT PG PP
25NB

AA312
AA314

LMB TP-03 TP-03


D LMB 7. THIS P&ID IS PREPARED BASED ON DRY MODE OPERATION D
EB-623 EB-622
03LAB24BR306
03LAB24BR307

03LAB23

03LAB23

03LAB23

8. STRAIGHT LENGTH WILL BE CONFIRMED AFTER VENDOR FINALIZATION.


03LAB23

03LAB23

03LAB23
25NB

25NB

25NB

25NB

25NB
AA315

AA319

AA323
25NB

03LAB24
AA325

AA321

AA317

03LAB24

03LAB24
ECONOMIZER INT. HEADER 03LAB24

AA306
03LAB24 03LAB24 03LAB24 03LAB24
AA310

AA308
25NB

25NB
25NB
03LAB24BR305

03LAB24BR303
9. * PRELIMINARY INFORMATION. TO BE CONFIRMED BY LTP.

03LAB24BR304
CT426 CT032 CT031 CT030 CT527
TW TE TE TE TG 10. LTP TO CONFIRM THE DESIGN TEMPERATURE AND DESIGN PRESSURE .

03LAB24

03LAB24
03LAB24
25NB

25NB

25NB
03LAB24

03LAB24

AA307

AA305
AA309
25NB
AA313
25NB

AA311

LMB LMB TP-03 LMB TP-03 LMB TP-03 TP-03 LMB


TP-03 TP-03 TP-03 TP-03 TP-03 TP-03 LMB LMB TP-03
EB-633 EB-632c EB-631 BE-604b 600NB BE-604a LTP LTP 600NB x 80.00 mm* BE-602 EB-626 EB-625
EB-632b EB-632a EB-621
SA-106C
ECONOMIZER INLET HEADER P10-0600-1 1939 L797000-XG02-03-LA-110006
TP-03 03LAB51 TP-03 03LAB24 TP-03 FROM HP FEEDWATER
TP-03 TP-03
03LAB51BR001

HEATERS OUTLET
REFER TO DWG. NO. P10-0600-1 LMB AA225 LMB CF010 EB-627
EB-628 LMB BE-605 LMB BE-603b BE-603a

SA-106C 200NB x 26.00 mm


BOILER P&I DIAGRAM LMB LMB LMB LMB
C
03LAB51
80NB

AA926

SA-312TP316H 15NB x XXS

03GHC01BR071
03QUA01

03LAB51BR929
15NB

C
AA026
03QUA01BR021

SA-106C 80NB x XXS


03LAB51
25NB

SHREE SINGAJI THERMAL POWER PROJECT


AA001

PROJECT
STRAIGHT LENGTH NOTE 5 STAGE-II ( 2 X 660 MW )
03LAB51
80NB

AA927

NOTE 8 200NB 200NB 03GHC01BR028 200NB MADHYA PRADESH POWER GENERATING CO. LTD.
03LAB51

CUSTOMER
03QUA01

SA-106B 200NB x S40


25NB

AA002

15NB

L797000-XG02-00-GHC-110003 JABALPUR - INDIA.


AA027

FROM BOILER FILL PUMP


03GHC01 03GHC01 03GHC01 DISCHARGE HEADER
CUSTOMER'S
AA039 AA038 AA037 LAHMEYER INTERNATIONAL (INDIA) PVT. LTD.
CONSULTANT
50NB 03GHC01BR913
50NB
SA-106B 50NB x S80 JOB
LMB EPC CONTRACTOR LARSEN & TOUBRO LIMITED -
No. MALWA-II
TO SWAS 03GHC01 03GHC01
HYDROSTATIC TESTING AA907 AA954 B
B EPC CONTRACTOR'S JOB
03LAB51BR930 L&T-S&L L & T - SARGENT & LUNDY LTD No. L797000
SA-106B 80NB x S80
LTP CONSULTANT
97000-2113-1 1658
JOB
TO BOILER FLASH TANK 6.21 MPa(g) | 280.0 °C BOILER CONTRACTOR L&T L & T - MHPS BOILERS PVT. LTD. No.
51005
-
PRIMARY (FORMERLY KNOWN AS L&T-MHI BOILERS PRIVATE LIMITED)
COOLER
FOR SPEC.TITLE:
SAMPLING
SG & AUXILIARIES
TITLE START UP SYSTEM P&I DIAGRAM SPEC.No.: -
WBS :
L&T-MHPS DATE UNIT
A SIZE A0 SCALE - 03- A
1 REVISED AS PER MPPGCL/LI COMMENTS & LMB ENGINEERING PROGRESS MS PDR RK 21-02-15 PPD MS 24-10-14 NTS DESIGNATION
PDR
REV
No.
ZONE DESCRIPTION PPD CHD APPD DATE
CHD
APPD RK
24-10-14