SYNCHRONIZATION TIME AND TARGET

ACHIEVEMENT ISSUE OF WHRPP

 SOP for Cold Startup of
Turbine
KILN Feed Boiler Temperature Turbine Synchronization

6.5 hrs 2.3 hrs

1. Auxiliary oil pump and turning gear must be in operation 03
hours before starting the turbine.
2. Turbine stop valve & Turbine main steam line must be
opened before startup.
3. Start Turbine Auxiliary including cooling tower, condensate
pump and water ejection pumps.
4. When HP header temperature & pressure reaches 200°C &
1.0 MPa , adjust the gland steam pressure at 0.05 MPa to
make vacuum.
5. When condenser vacuum reaches -85 kPa, slowly take
PRD line in service & adjust the boilers AQC & SP steam
drum pressure between 1.2 ~ 1.4 MPa.
6. Close all the drains of HP header and main steam line.
7. When temperature of main steam reaches 270+°C, open
turbine main steam valve.
8. Make sure that all the safeties & interlocking are at their
normal position.
9. Give first startup command from 505 turbine control of 600

rpm for 40 minutes (turning motor/gear should shutdown

automatically when speed passes 200 rpm).

10. Check all bearing temperatures & vibrations

11. Give 2nd set point of 1200 rpm for 70 minutes.

12. Give 3rd set point of 2500 rpm for 15 minutes.

13. Give 4th set point of 3000 rpm for 5 minutes.

 Note: Before giving any set point check the temperature &
vibration of turbine. Lower and Upper casing temperature
difference should be less than 50°C, if it is higher, then allow
the turbine to operate at that set point for more time.
 At the critical speed (1840~2410 rpm) check the
temperature and vibrations.
 Check at 2900 rpm HP oil pump should automatically
shutdown.
 If all the parameters are normal then synchronize the
generator.
 After synchronization, for 10~15 minutes allow the generator
to take load of 2 MW only.
1. Auxiliary oil pump should be taken in service.

2. Turbine stop valve & Turbine main steam line must be

opened before startup.

3. Start Turbine Auxiliary including cooling tower, condensate

pump and water ejection pumps.

4. Condenser vacuum should be -85 kPa.

5. When temperature of main steam reaches 270+°C, open

turbine main steam valve.

6. Make sure that all the safeties & interlocking are at their

normal position.
 Note: Before giving any set point check the temperature &
vibration of turbine. Lower and Upper casing temperature
difference should be less than 50°C, if it is higher, then allow
the turbine to operate at that set point for more time.
 At the critical speed (1840~2410 rpm) check the
temperature and vibrations.
 Check at 2900 rpm HP oil pump should automatically
shutdown.
12. If all the parameters are normal then synchronize the
generator.
13. After synchronization, for 10~15 minutes allow the
generator to take load of 2 MW only.
7. Give first startup command from 505 turbine control of 600
rpm for 15 minutes (turning motor/gear should shutdown
automatically when speed passes 200 rpm).
8. Check all bearing temperatures & vibrations
9. Give 2nd set point of 1200 rpm for 15 minutes.
10. Give 3rd set point of 2500 rpm for 10 minutes.
11. Give 4th set point of 3000 rpm for 10 minutes.
1. Auxiliary oil pump should be taken in service.

2. Turbine stop valve & Turbine main steam line must be

opened before startup.

3. Start Turbine Auxiliary including cooling tower, condensate

pump and water ejection pumps.

4. Condenser vacuum should be -85 kPa.

5. When temperature of main steam reaches 270+°C, open

turbine main steam valve.

6. Make sure that all the safeties & interlocking are at their

normal position.
7. Give first startup command from 505 turbine control of 600
rpm for 10 minutes (turning motor/gear should shutdown
automatically when speed passes 200 rpm).
8. Check all bearing temperatures & vibrations
9. Give 2nd set point of 1200 rpm for 10 minutes.
10. Give 3rd set point of 2500 rpm for 5 minutes.
11. Give 4th set point of 3000 rpm for 5 minutes.
 Note: Before giving any set point check the temperature &
vibration of turbine. Lower and Upper casing temperature
difference should be less than 50°C, if it is higher, then allow
the turbine to operate at that set point for more time.
 At the critical speed (1840~2410 rpm) check the
temperature and vibrations.
 Check at 2900 rpm HP oil pump should automatically
shutdown.
12. If all the parameters are normal then synchronize the
generator.
13. After synchronization, for 10~15 minutes allow the
generator to take load of 2 MW only.
 For Example:
 Following are the details of the cold startup after kiln planned
shutdown on 16-02-2018
 Kiln feed start time = 1430 hrs.
 Boilers temperature achieved = 1750 hrs. 6.3
hrs 09
 Turbine first set point = 2050 hrs. hrs
 Synchronized with WAPDA = 2300 hrs.
 Power at 7.2 MWh = 2339 hrs.
 Total time from kiln startup to 7.2MWh = 09 hrs.
 As the cold startup time of turbine is 2.30 hours
therefore after synchronization the turbine load is
increased gradually due to following reasons:

1. Upper and lower casing temperature of Turbine.

2. Turbine thermal and differential expansion.
3. Axial Displacement of turbine.
4. In addition to this sudden increase in load can cause
vibration which can cause severe damage to turbine.
 Generation time should start when the load is at 75% of
gross power i.e.
75% of Gross Power=(9.6*0.75)
75% of Gross Power =7.2MWh.
 Therefore Generation time should be counted from 7.2
MWh and onwards.
 Generation time will be provided by Head of Department
to Plant control.