START-UPs CONDITIONS (Boiler) CONDITIONS (Turbine)

COLD 1. shutdown > 72 HOURS 1. metal temp < 170 °C

2. BOILER PR. < 1ksc

WARM 1. shutdown < 36 HOURS 1. HPC ~ 340 °C, IPC ~ 320 °C

2. BOILER PR. >= 1Ksc & < 30 ksc

HOT 1. shutdown < 8 HOURS 1. HPC ~ 430 °C, IPC ~ 470 °C

2. BOILER PR. >= 30Ksc & < 120 ksc

START-UPs Activities Time, min Total time

Light-up – Rolling 0-250 4 hr, 10 min
COLD Rolling – Synchronisation 250-290 40 min 9 hrs
Synchronisation – Full load 290-540 4 hr, 10 min
Light-up – Rolling 0-90 1 hr, 30 min
WARM Rolling – Synchronisation 90-110 20 min 4 hrs, 40
Synchronisation – Full load 120-280 2 hr, 40 min min
Light-up – Rolling 0-120 2 hr
HOT Rolling – Synchronisation 120-140 20 min 3 hrs, 40
Synchronisation – Full load 140-220 1 hr, 20 min min

 BMCR (Boiler Maximum Continuous Rating) = 109.94% of TMCR

 TMCR (Turbine Maximum Continuous Rating) = Turbine’s max. guaranteed rating
 EMCR (Economic Maximum Continuous Rating) @ generator o/p terminals.
Sl.No Procedures Status Remarks
1. All HT, LT SWGR ,Battery chargers are charged
2. SACW pump in Service A/B/C Pr. 4.5 ksc
3. IA Compressors I/S 1/2/3/4 Pr.7-8 ksc
PA Compressors I/S 1/2/3 Pr.7-8 ksc
5. Service Water pumps in service A / B / C Pr.6-7.5 ksc
6. CW pumps in service 1/2/3/4/5/6 Pr. 2 ksc,
All Condenser passes charged
7. CT fans in service (A / B) /16 /16 / 36
8. TG-ECW pumps I/S A/B/C Pr.: 8 ksc
SG-ECW pumps I/S A/B Pr.: 8 ksc
ACW pumps I/S A/B/C Pr.: 4 ksc
11. Pumps A/B
Generator PW System Tank level >500mm
Discharge pr. 7.5-8.5 KSC
Stator water flow 110 -120 T/hr
Winding DP 1.4 to 2.2 ksc
Conductivity 2.5-5 µs/cm
17. MOPs A / B // EOP A / B
TG Lub Oil pump I/S MOT (150 to 300 mm)
Lub Oil pr 1.2 ksc
Lub oil Temp 42-440C
Duplex filter/ DP
JOP in sevice AC Pump / pr 120 ksc
DC Pump / pr 80 ksc
Seal Oil (SO) System AC Pump / pr 12 ksc
DC Pump / pr 12 ksc
SO to H2 DP 0.6-0.9 ksc
Generator H2 gas Pr. 3.8 – 4.0
Purity >98%
29. Baring Gear(BG) in service BG motor current 35 to 40 Amps
Shaft eccentricity ≤ 0.04 mm
Turbine speed 1.1 RPM
32. Control Fluid(CF) pumps in Pumps A/B
service Pr / filter DP 50 ksc /
Temp 48-50 0C
35. Aux PRDS hdr Charging HT Pr. / Temp 16 ksc 3100C
LT Pr. / Temp 16 ksc 2100C
37. Hot Well filling & CEP in service- Hotwell level 620 mm, disch Pr 30 ksc, Dea level
Control station &LP heater water side lineup, CPU in service
38. Dea. Filling & FST heating , level 2000 mm, Temp 105 0C ,
Seal steam line heating.(pr. 13ksc & temp. 300ºC)
39. MDBFP in service - Scoop 15-18 % & R/C open, ,Chemical Dozing system in
service ,FRS & HPH water side lineup
40. a) Charge AuxPRDS (for FST/ a) Feedwater and boiler metal diff.
deaerator,atomosing steam, APHs Temp. (DT) should be < 111°C.
Sootblower & turbine sealing.) b) Ensure Fans’ LO system & blade
pitch position/SADC
b) Charge Seal steam line & start FST position/Burner Tilt horizontal/
heating (FW is deaerated water @ Fuel air dampers modulation/
105°C, to avoid oxygen corrosion in Overfire air damper close position
the boiler) and scanner air/seal air fans/ Two
ESP passes min.
c) Ensure availability of CEPs, CPUs c) Close Economizer and furnace
,hotwell & dea. levels,& MDBFPs. wall drains.
d) Open Economizer o/l Vents.
d) Ensure seal steam system temp.& pr. e) Open SH and RH drain valves .
f) Open SH and RH vents.
e) Start vacuum pulling on condenser to g) Close warming system for start-
accept water from start-up FT. up.(water-leg level)
 Provide seal steam immediately. h) Ensure availability of WR & ZR
Parameters Units Value status
f) Start MDBFP on R/C. s
pH 9.0
g) Drain valves on MS,CRH & HRH Silica ppb <30
lines are open.(after vacuum pulling) Conductivi µs/cm <0.5
ty
(after
h) Fill boiler with flow rate 10% TMCR
cation)
(202 t/hr).Water recirculation to be Dis.O2 ppb <100
continued until the water quality Iron ppb <20
within limits.(Through FST, sodium ppb <10
economizer, evaporator, WR& ZR Turbidity NTU <5
valves, FT, condenser ,CPU then FST valves, BCP and its HP cooling.
) i) Ensure seal trough filling and
Bottom Ash Hopper filling.
i) Ensure water quality and seperator
level

j) Start BCP with UG v/v min opening Chemistry parameters for light-
(15%-18%) for 30% TMCR water flow up(Feedwater):
(600t/hr).

1. Continue oil AB & CD firing at 10% firing -Close all SH, RH vent & drain except 75-180 Min
start up vent at 3.5 ksc , Raise separator pr to 8 ksc Ramp rare should be 0 t0-10
ksc = 0.5 ksc/min, 0-20= 1 ksc/min, >20 =2 ksc/minOpen
MS line & HP-LP bypass Charging- All MS, HPBP, CRH, HRH, LPBP drains to
Atm Flash Tank Open MSV IBV at Boiler Pressure 10 Ksc Monitor The Pressure
and Temperature of MS Line &Open MSV After stabilizing the MS Line. Open HP /
LP Bypass valve. At HP bypass stm pr. 12 ksc put HP Bypass in Pressure ramp
mode will ramp pr up to 90 ksc & LP bypass set point to 10 ksc. In parallel close
all atm flash drains. FW flow should increase as steam flow increase in auto
2. Start EF Elevation Increase firing at rate 0.5 % & Continue oil firing at 15%- At 90 180-240
Ksc pr HP bypass is release to Pressure control mode will maintain constant pr.
during rolling & initial loading. Adjust firing rate to achive require steam parameters
MS flow 220 T/hr, MS 340 0C,Rh 320 0C, Maintain
FG Exit Temperature < 538 C
Take Expansion reading of Boiler. Check Boiler water & Steam condition.
Steam temp should be control by adjusting firing rate & air flow prior to
synchronizing.
3. Turbine side Activities

4. (i) Ensure drain valves of M S, CRH & HRH pipelines are open to Flash tank. 30-240min

5. (ii) Ensure drain valves of all Extraction steam upstream of NRV’s are open

6. (iii) Ensure drain valves of HP CV & cross over pipes to HPT are open

7. (iv) Ensure drain valves of IP CV & cross over pipes to IPT are open

8. (v) Ensure drain valves of IP -LP cross over pipes are open

9. (vi) Ensure LP Bypass warm up & drain valves are open

10. (vii) Ensure drain valves of M S, CRH & HRH pipelines are open to Flash tank.

11. ENSURE GATE VALVES ON STEAM EXTRACTIONS FROM TURBINE ARE

CLOSED
12. ENSURE CRH NRV’S BYPASS VALVES ARE CLOSED.

13. ENSURE HPC & IPC FLANGE HEATING VALVES ARE CLOSED

14. ENSURE ALL TURBO-SUPERVISORY READINGS ARE WITHIN LIMIT

15. Start preheating of HP turbine when CRH pressure is 2-4 ksc.
Open Drains in crossover pipes of HP CV to HP cylinder
Open Motorised valves in bypass of CRH NRV’s
Open Control valves in bypass of CRH NRV’s to raise pressure in HP turbine at
0.1 ksc/min upto 10-12 ksc.
Raise HPC & crossover pipe temp. upto 170-180 deg C
16. Preheating of Stop & Control Valves
At MS temp of 250-300 0C and HRH temp of 200-250 0C
Latch the turbine & ensure HP & IP stop valves are open
Start preheating of HP SV & HPCV , IPSV & IPCV
Ensure turbine speed should not exceed 600 rpm during heating.
Ensure Shaft eccentricity at HPC front
≤ 0.07 MM (when barring gear is ON)
≤ 0.10 MM (when RPM < 1150 ), ≤ 0.25 MM (when RPM > 1150 )
Heating is complete if metal temperature of HP/IP SV, HP & IP Cross-
over pipes & HP Casing temperature is >170 0C
17. Turbine rolling up to 500 RPM 240-250
 Ensure Cold rolling parameters
MS press. & temp - 90ksc, 350 deg C.
HRH press & temp - 10-12 KSC, 320 deg C
MS Flow- 220 T/hr
Take 2 guns in EF if required
 Raise speed to 500 rpm (5..10min) with acceleration of 300.
Ensure barring gear EM & JOP are ON
 Check the following & Keep watch up to 660 MW loading
A) absolute bearing housing vibration (≤ 4.5 mm/s)
relative rotor vibration (≤ 165 micron/s)
absolute rotor vibration (≤ 200 micron/s)
B) seizing in turbine end side seals
C) abnormal noise in Turbine cylinders
D) thermal and mechanical conditions of turbine
E) Rotor deflection (< 0.10 MM )
F) temp diff in top and bottom of HPC and IPC in steam
admission Zones (+/- 50 0C)
G) Rotor axial displacement (towards Front brg 1.2 mm and
towards Generator 2.0mm)
H) Maximum limits for relative position of turbine rotors :
(HPC : -3.0 to 5.5 mm)
(IPC : -2.0 to 5.0 mm)
(LPC1 : -2.0 to 40 mm)
(LPC2: -2.0 to 47 mm)
I) oil temp of bearing I/L (42 to 44 0C) and O/L (<65 0C)
J) steam temp at HPC exhaust < 380 0C
18. Continue oil firing at 15% with Oil Gun in AB CD&EF 250-280 min
MS press. & temp - 90ksc, 350 deg C.
HRH press & temp - 10-12 KSC, 320 deg C
MS Flow- 300T/hr
Raise speed to 1900 rpm (Soak for approx. 40 min)
Ensure barring gear EM and JOP are OFF at speed >1500 rpm
Condenser pressure shall not be > 0.08 KSC
IP Casing inlet temperature shall be > 120 0C
19. Start GH Elevation Increase firing at rate 0.5 % & Continue oil firing at 25% 280-290
Take 2 guns in GH (Total 14 guns)
MS press. & temp - 90ksc, 350 deg C.
HRH press & temp - 10-12 KSC, 320 deg C
MS Flow- 400T/hr
Raise speed to 3000 rpm gradually and continuously without interruption at
intermittent speed of rotation to avoid turbine operation at critical RPM while
increasing the RPM check the following.
a) shaft eccentricity
b) bearing and rotor vibration
c) bearing babbit temp (for support and for thrust bearing < 95 0C)
d) diff expansions
e)
 Close MS, CRH and HRH line drains
Increase MS Flow to 400 T/hr
20. Synchronize the machine and gain load of 40-50 MW & hold for 40-60 Min 300-340
Close Turbine Drains
Close LP Bypass valves
Start IPC flange heating
Put LP Heaters in service
Keep the load for achieving steady thermal conditions & expansions of IPT
Ensure Deaerator line up & readiness & Make ready TDBFP A in warm up
condition
21. Start PA fan & seal air fans. PA header pressure control in auto with 340-360
800 mmwc.
Mill A I/S after closer of LP bypass MS Flow 450 t/Hr MS 340 0C,Rh 320
0C,MS/HRH pr 90/12 Ksc

HPC takes load at 12 % TMCR (80MW)

Close gate valve & CV of CRH NRV bypass, crossover pipes drains
remain open for putting HPC under vacuum
Ensure HPCV-1 & 2 open ( Pressure in control oil >19.5 KSC)
Gate valve 10MAX 14AA101 on power oil CRH NRV gets opened
HPC inlet pipes drain valves get closed
CRH NRV’s get opened
Close HPBP valves
Immediately raise the load to 110 MW
Ensure HP exhaust steam temperature is < 380 0C
Start HPC flange heating.
Ensure seal steam valve 10MAW12AA101 is closed and 10MAW11AA101 is
open
22. Mill B I/S after closer of HP bypass increase total firing up to 30 % equalized 360-420
feeder rating after second mill is proven & increase load
Raise the load to 150 MW
Steam pr. at IP I/L 12 KSC and at HP I/L 90 KSC up to 25 % load
Turbine loading rate 0.5 MW/min
Gradually increase MS & RH temp to 415 &410 0C at 30 % load (195MW)

23. Mill C I/S after steam flow reaches 25-30 % (550T/hr) Increase total firing up to 420-470
35 % Firing Rate should never exceed the rate necessary to match total
steam generation. Watch WW tube metal temp. Increase load up to 30 %
195MW at Turbine loading rate 0.5 MW/min MS Flow 600 T/Hr, MS & RH temp
to 415 &410 0C
At 200 MW take LPH in service
For further Turbine loading up to 530 MW, loading rate shall be 3
MW/min at permanent HP CV opening, i.e. sliding pressure mode
Operation
The speed of temperature increase for live steam and reheat upstream of turbine
shall not exceed 0,7ºС/min
24. CHANGE FROM WET TO DRY MODE
Load 30% 195-200 Mw
Steam pr. at IP I/L : 13 KSC and at HP I/L :100KSC
M S temperature: 415 0C, HRH temp. 410 0C
MS Flow 700 T/hr
Before change over separator level set point to be reduced.
Ensure
1. Feed water O/L temp. = Eco inlet temp.
2. Separator O/L Temp > 20 C above its saturation temp.
3. MS flow > 600 t/hr.
4. Ensure BRP in auto stop & warm up system put into service
5.Start Up System Circulation Valve Closes, UG Valve Full Open WR /
ZR Valve isolation valve close
6.Give Set point 3000 mm to wet leg level control valve
( 10HAG15AA151) in warm up line
5. If require; raise load
6. Closely watch metal temp. and stabilize
25. Measure the chemical property of water ( Ph 9, Silica < 20 ppb, conductivity
<0.2 MicroS/cm
Put Steam Temp & Combustion in Auto
 Start second set of boiler auxiliaries in service ( APH-B,ID-B,FD-B,PA-B)
26. RAISE LOAD UPTO 250MW with loading rate 3MW/min. & Take
TDBFP- A into service
Steam pr. at IP I/L : 18 KSC and at HP I/L :120 KSC
M S temperature: 430 0C, HRH temp. 440 0C
MS Flow 900 T/hr
After reaching 30 TMCR load Reduce oil firing maintaining total firing rate
same by taking another mill i/S
27.

28. LOAD RAISING TO 660 MW 470-490

Start 4th. mill D at 300 MW (temp. 435/445, pr.120/20)
Charge extraction steam to deaerator from IPC 6 th Stage
Connect HPH, close drains on steam extraction pipelines to HPH
Cut-in second TDBFP from auxiliary header.
RAISE LOAD TO 330 MW & CHANGEOVER TDBFP SOURCE to IP
extraction
Steam pr. at IP I/L : 24 KSC and at HP I/L :150 KSC
M S temperature: 450 0C, HRH temp. 455 0C

29. Start 5th mill E at 400 MW 490-520

(MS/HRH temp. 460/4700C, MS/HRH pr. 180/30 KSC,
MS flow 1320T/hr)
RAISE LOAD TO 450 MW (MS/HRH temp. 470/4850C;
MS/HRH pr. 215/37KSC, MS Flow 1500 T/hr)
Stop HPC & IPC flange heating

30. Start 6th mill at 530MW 520-540

MS/HRH temp. 490/5100C;
MS/HRH pr 240/40 KSC , MS flow: 1680T/hr) and switch to constant
press mode
RAISE LOAD TO 660 MW (MS Flow to 2024 T/hr )in constant press
mode
Take 7th mill if required.
Steam pr. at IP I/L : 48 KSC and at HP I/L :247 KSC
M S temperature: 538 0C, HRH temp. 565 0C
Change the pressure controller mode to Load controller at rated M S & HRH
temperature