Npti Training Manual

Piyush Kr.Singh, Dy.
Director, NPTI Nangal

Simulator Training Manual for 500 MW
Nangal Dam, Ropar, Punjab, 140124
Piyush Kr.Singh, Dy.Director, NPTI Nangal
I. COLD START UP PROCEDURE
STEP-1 COOLING WATER SYSTEM
SU0101 Starting CWP1
Go to Cooling Water System screen from BOP Menu
Open the Cond.CW inlet BFV-L CW13
Open the Cond. CW inlet BFV-R CW18
Open the Cond.CW outlet BFV-L CW19
Open the Cond.CW outlet BFV-R CW24
Switch On the CWP-1 Pump
Open CWP-1 Disch. Valve CW-1
Observe that Common header pressure reaches 5.0 Kg/ cm2
Starting CWP2
Ensure that discharge valve is closed
Switch On the CW Pump-2
Open CWP-2Disch. Valve CW-2
Cooling Water system to BOP & TG Auxiliaries
SU0103 Starting ACWP-A
Go to ACW Sys screen from BOP Menu
Switch On ACW Pump-A
Ensure that discharge valve ACW-4 opens in Auto
SU0104 Starting ACWP-B
Switch On ACW pump-B
Ensure the discharge valve ACW-8 opens in Auto
Observe that ACW Disch header pressure reaches 5.0 Kg/ cm2
SU0105 Starting ACWPump-A Booster Pump
Ensure that the suction and discharge valves of ACW-
A Booster Pump in opencondition
Switch On ACW Pump-A Booster Pump
SU0106 Starting ACWPump-B Booster Pump optional
Ensure that the suction and discharge valves of ACW-
B Booster Pump in opencondition
Switch On ACW Pump-B Booster Pump
SU0107 Starting CW-HC & CW-PC valves
Open CW-HC valve to Hydrogen coolers
Open CW-PC valve to Primarywater coolers
Open MDBFP-C AUX CLR valve
SU02 PLANT START-UP PREPARATION
SU0201 Ensuring normal level in Condenser Hot well
Goto HOTWELL LVL CNTRL screen from BOP-SLD menu
Set the Hot well Normal level Set Point to 0 mm
Set the Normal level controller in Auto (DM38)
Set the Emergency level controller in Auto (DM63)
Set the Cond Excess dump controller in Auto (CD43)
HOTWELL NORMAL 0 mm
Permissives from Remote Station for CT Pump A
1 Ensure DM42 Open
2 Line up CT PMP-A SUC VLV
SU0202 Starting CT PMP-A
Go to CONDENSATE TR SYS screen from BOP Menu
Ensure Cond Storage Tank level Normal
Open the discharge valve DMV-15
SU020203 Start the CT pump-A motor
CT PMP-B starting optional
Permissives from Remote Station for CT Pump B
1 Ensure DM42 Open
2 Line up CT PMP-B SUC VLV
SU0202 Starting CT PMP-B
Open the discharge valve DMV-18
Start the CT pump-B motor
Generate snapshot as CWSYSTEM
SU0211 Deaerator Initial Filling & Boiler filling
Go to CONDENSATE TR SYS screen from BOP Menu (DOUBT)
Line up BOILER FILL PUMP A
Start Boiler Fill Pump A
Rate of Filling can be increased by selecting Fast mode
Start Boiler Fill Pump B
Permissives from Remote Station for Boiler Fill Pump A
1 Boiler Fill Pump A
2 DM41
SU0212 Starting Boiler Fill PMP-A
Ensure BFLP-A Disch VLV Open
Ensure BFLP-A Suc VLV Open
Start the Boiler Fill pump-A motor
Permissives from Remote Station for Boiler Fill Pump B
1 Boiler Fill Pump B
2 DM41
Starting Boiler Fill PMP-B
Ensure BFLP-B Disch VLV Open
Ensure BFLP-B Suc VLV Open
Start the Boiler Fill pump-B motor
OBSERVE DEAERATOR LEVEL REACHES 0 mm
OBSERVE DRUM LEVEL REACHES - 52 mm
Generate snapshot as DRUMINTFILL
DOUBT : SU0213 Charging LT / HT Auxiliary Steam Header from station
Auxiliary Steam Header
Go to AUX PRDS SYSTEM screen from BOP Menu
Line up Auxilary PRDS
Ensure HT PRDS Pressure >12 ata and Temp >320
deg.c
Open ASV-35
Open CDV-89 valve
Regulate CDV-90 valve
Observe that LT Aux. Stm Header Pressure >12 ata
Observe that LT Aux. Stm Tempearature >220deg.c
Open ASV-67 to allow steam to Turbine Gland seals
SU0214 CEP System Starting CEP-A
Go to COND.EXT.PUMPS screen from BOP Menu
Line up CEP-A
Ensure the suc vlv opens
Open the CEP-A Rec Valve CD-10 to 100%
Ensure CEP-A dis.vent vlv. VAV7 in Open position
Ensure CEP-A dis. Vlv. CD4 in Close position
Ensure CEP-A dis. Byp vlv. CD7 in Close position
Switch On CEP-A Pump
Ensure CEP-A Vent vlv. VA7 Closes
Ensure CEP-A Dis. Byp valve CD7 Opens in Auto
Ensure CEP-A Dis. valve CD4 Opens in Auto
Ensure CEP-A Dis. Byp valve CD7 Closes
Goto SLD CEP-A RCV CTRL Page
Set CEP-A MREC Flow SP to 500 TPH
Set CEP-A Rec. vlv. CD10 to Auto
Goto SLD GSC MIN FLOW CTRL Page
Set GSC MIN Flow SP to 500 TPH
Set GSC Rec. vlv. CD39 to Auto
Set Cond. Excess vlv. CD43 to Auto
Permissives from Remote Station for CEP-A
1 LINE-UP CEP-A SYS
OBSERVE CEP DISCH. HEADER PRESS AROUND 30 kg/cm2
SU0215 Condensate Path Opened
Go to LPH&DRN CLRS screen from BOP Menu
Open LPH-1 I/L AND O/L VALVES
SU0216 Deaerator Charging
Go to DEAERATOR & HOTWELL screen from BOP Menu
Open Deaerator level cv-1 inlet isolation valve CD21
Goto SLD DEA LVL CTRL Page
Set Deaerator level SP to 0 mmwc.
Set CEP Disch Hdr Press to 32 kg
Set Deaerator level CV-1 controller, CD22, to Auto
Open Deaerator Start up vent SM22
Goto SLD DEA PRESS CTRL Page
set Deaerator Steam pressure SP to 1.5KG/CM
2
Set Auxiliary Steam Deaerator pressure CV AS-8 in Auto
Close Deaerator Start up vent valve SM22
ENSURE DEAERATOR OUTLET WATER
TEMPERATURE >100
0
C
ENSURE DEAERATOR OUTLET WATER Pressure
=1.5 KG/ CM
2
SU0217 Drum level controller in Auto
Go to DRUM,FEED CTRL STATION screen from BOP Menu
Open Economiser inlet IBV-1 E003
Open Economiser inlet IBV-2 E002
Open Economiser inlet Valve E0212
Open Low Load FCV FD14 (>20%)
Ensure the FCS inlet FD13 IBV opens in Auto
Ensure the FCS inlet FD13 opens in Auto
Goto SLD DRUM LEVEL CTRL Page
Set Drum Level SP to 50MMWC
Keep LOW LOAD FCV FDV14 in AUTO
Goto FEED WATER CYCLE screen from BOP
Menu
Open HPH FW 100% Byp Valve FD11
Open HPH FW 100% Valve FD11
SU0218 Boiler Drum IBD Valves
Go to DRUMS & DRAINS screen from BOP Menu
Close Emgency Drum Drain valve B-096 & B098
Close Emgency Drum Drain valve B-097 & B099 (0 %)
Close Drum CBD Valves B-091 & B094 (0%)
SU0219 Starting MD BFP-C
Go to MTR DRVN BFP-C screen from BOP Menu
Line up MD BFP-C Systems
Switch On BFP-C AOP
Ensure the MD BFP-C Disch Byp Valve FD6B closes
Start the MD BFP-C AOP
Open BFP-C Recirculation valve FC-5
Start the MD BFP-C Motor
Ensure the MD BFP-C Disch Byp Valve FD6B Opens
in Auto
Ensure the MD BFP-C Disch Valve FD6 Opens in
Auto
Ensure the MD BFP-C Disch Byp Valve FD6B closes
in Auto
Ensure the Feedline path availability (BFP disch. to
Drum)
Set Low Load FCV FD14 Into Auto
Permissives from Remote Station for MD BFP C
1 MD BFP Suction vlv open
2 MD BFP Rack-in/Rack-out
BFP DISCHARGE HEADER PRESS >58 Kg/cm
2
DRUM LEVEL SHOULD BE -50 mmwc
FCS LOWLOAD CV IN OPERATION
SU0220 Starting BCW Pumps
Go to BCW PUMP screen from BOP Menu
Line up BCW A System
Ensure the Diff Temp.Between BCW Pump-A casing &
Suction Manifold <38
0
C.
Close B001
Close B002
Start the BCWP-A Motor
Ensure the Diff Temp.Between BCW Pump-B casing &
Suction Manifold <38
0
C.
Start the BCWP-B Motor
BCW Pumps A AND B On & DP > 25 psi
SU03 BOILER DRAFT SYSTEM
SU0301 Preparation of Air & Flue Gas Path
Go to AIR&FG SYSTEM screen from BOP Menu
Ensure that FDF-A o/l damper is in Full open position
Ensure that FDF-A blade pitch is in maximum position
Open EP-A Inlet Gate1
Open EP-A Inlet Gate2
Open EP-A Outlet Gate1
Open EP-A Outlet Gate2
Open all EP-B,EP-C,EP-D I/L and O/L Gates
Go to AIRHTRS screen from BOP Menu
Switch On AH-A ElectricMotor
Open AH-A SA SCAPH-A I/L AND O/L ISO damper
Open AH-A SA air o/l damper
Open AH-A flue gas i/l damper GD-1A
Open AH-A flue gas o/l damper GD-2A
Open AH-A PA I/L damper PAD-3A
Open AH-A PA air o/l damper PAD-4A
Switch On AH-B ElectricMotor
Open AH-B SA SCAPH-A I/L AND O/L ISO damper
Open AH-B SA air o/l damper
Open AH-B flue gas i/l damper GD-1A
Open AH-B flue gas o/l damper GD-2A
Open AH-B PA I/L damper PAD-3B
Open AH-B PA air o/l damper PAD-4B
FLUE GAS PATH AVAILABLE
SU0302 IDF-A Start Sequence
Go to ID FANS screen from BOP Menu
SU030201 Start IDF-A LOP-A On
Close the inlet gate 1&2
Close the outlet gate 1&2
Set IDF-A control damper to minimum
Set the IDF-A ch1 SRC Breaker On
Set the IDF-A ch2 SRC Breaker On
Set the IDF-A VFD ch1 On
Set the IDF-A VFD ch2 On
Observe that the ID Fan-A Motor On indicator appears
Observe the inlet and outlet gates are fully opened on
interlock.
Set ID Fan-A Control Damper to 100%
Set ID Fan-A VFD Drive to 15%
SU0303 FDF-A Start Sequence
Go to FD FANS screen from BOP Menu
Set The FD Fan-A Control Damper Position To
Minimum [0%]
Start FD Fan-A Lop-A or Lop-B
Close FD Fan-A Outlet Gate
Ensure the Permissive Available
Start the FD Fan-A
Observe FD Fan-A motor On indication appears.
Ensure FD Fan-A Outlet Gate opens after 20 seconds
delayIN Auto
Adjust the FD Fan-A Control Damper so that the
Secondary Airflow is greater than 650TPH.
SU0304
SU0305 Furnace Pressure Control in Auto
Go to SLD FURNACE PRESSURE CTRL screen from BOP-SLD Menu
Set the Furnace Pressure SP to 10 mmwc
Set the ID Fan-A I/L Control to Auto mode
Set the ID Fan-A VFD Drive Control to Auto mode
Set the FUR PRESS MASTER to Auto mode when the
Furnace Pressure reaches the SP
AIR fl ow >540 TPH
Furnace Pressure = -10mmwc
SU0306 Stator water coolinq system
Go to GENERATOR PRIMARY WATER SYSTEM screen from TG Menu
Start the PW Pump 1
Observe that Primary water flow Generator phases T,
S , R main bush is >1.5 m
3
/hr
Observe that Primary water flow at stator winding
outlet shows >54 m
3
/hr
Set the PW temp controller to auto mode
Select the TGV and set to 40 degc and press confirm
SU0307 Gen Seal Oil System
Go to GENERATOR SEAL OIL SYSTEM screen from TG Menu
Line up the Seal oil system
Start AC SOP-1 & AC SOP-4
Start B.C EX FAN-1
Observe Hydrogen side seal oil pump started and Oil
pressure >7kg/cm2
The seal oil to hydrogen differential pressure starts
showing at the indicator both at TE & EE
Observe in the GENERATOR GAS SYSTEM
H2 PRESS IN GEN CASING >3.5 KG/CM2
H2 PURITY IN AIR >95%
SU0308 SGC Turbine Oil System
Go to TURBINE OIL SYSTEM screen from TG Menu
Start AOP1
Start J OP1
Start Oil vapour extractor FAN1
SET Oil temperature controller to auto
Ensure Lub oil discharge hdr pressure goes above 4.8
kg/cm2
Ensure J acking oil header pressure >135 kg/cm2
Open Gate valve grng
Turbine speed comes to approx 120 rpm with vacuum
otherwise 80 rpm
Go to TURBINE HPCF SYSTEM screen from TG
Menu
Start HP control fluid pump 1
Start anyone of the HP control fluid vapour EXTR-1 FAN
Start anyone of the HPCF recirculation pump
HP control fluid pressure comes over 32 kg/cm2
Switch on Control fluid heater l
SET HPCF Oil temperature controller to auto
SU0309 Vacuum Building
Go to CONDENSATE & EVACUATION SYSTEM screen from TG Menu
Ensure that atleast One CEP is on
LINE UP open Air Header IV from local operatons
Go to SEAL STEAM SYSTEM screen from TG
Menu
Switch on Seal Steam Cond Exh 1
Switch on Seal Steam Vap Exh 1 isol valve
Open Seal Steam Cond seal valve
Close Seal Cond safety valve 1
Open SSIV valve
Close Vacuum breaker
Ensure the gland steam control valve close
Observe the temp 320 deg c and press >300 mmwc
Go to CONDENSATE & EVACUATION SYSTEM
screen from TG Menu
Switch on Vacuum pump 1
Open Solenoid valve IV 1
Switch on Vacuum pump 2
Open Solenoid valve IV 2
Switch on Recirculation Pump 1
Switch on Recirculation Pump 2
Condenser vac. begins to increase
Gland steal stm press cntrler is switched on to auto mode
Observe gland stm pressure is maintained at the set value
Observe Condenser vacuum comes to -0.9 kg/cm2
CONDENSER PRESS < - 0.85kg/cm
2
AP526 PS332
TURBINE LUBE OIL PRESS >4.8 KG/CM2 AP511 PS209
TURBINE SPEED >80 RPM AP278 PS209
TRIP FLUID PRESS >30 KG/CM2
SU04 PURGE
Go to CAUSE OF MFT&PURGE screen from SG Menu
Ensure all the Purge Permits are available
Start a Purge cycle on the furnace by pressing the "Push
to Purge switch
During purging, Purging lamp comes on. After 9 minutes
"purging" lamp and "Push to Purge" goes out and "purge
complete" lamp comes on
Set the Aux. Air (SADC) in Auto
Observe that WB-Furnace DP is maintained at 40 mmwc
FURNANCE PURGE COMPLETED
SU05 DRAINS AND VENTS
Opening Final Super Heater Outlet Header Air Vents
Go to SH STM & VENTS screen from BOP Menu
Open S036
Open S037 to 100%
Open S034
Open S035 to 100%
SU0501 Boiler Drum Air Vents
Open B98
Open B99
Open B100
Open B101
Open B104
Open B105
Open B102
Open B103
SU0502 Div.Panel Super Heater Air Vents
Open S68
Open S69
Open S70
Open S71
Opening Final Super Heater Outlet Header Air Vents
Open S79 CE 658 PS342
Opening Roof Super Heater Air Vents
Open S12 to 60% CE 638 PS342
Open S14 to 60% CE 640 PS342
SU0503 Super Heater Header Drains
Open S25 to 60% CE 645 PS342
Open S26 to 60% CE 647 PS342
Open S22 to 60% CE 642 PS342
Open S84 to 60% CE 660 PS342
Open S83 to 60% CE 657 PS342
Open S19 to 60% CE 636 PS342
Open S74 to 60% CE 653 PS342
Open S75 to 60% CE 654 PS342
Open S77 to 60% CE 655 PS342
SU0504 Economiser / Water wall drains
Close E17 CE 682 PS340
Close B115 CE 683 PS340
Close B118 CE 683 PS340
Open E21 CE 624 PS339
SU0505 CRH / HRH Drains
Open HRH125 CE 1290 PS345
SU0506 RH Vents
Open R75 CE 663 PS204
SU0507 MS Drains
Open MS101 CE 1125 PS343
MS/HRH DRAINS AND RH Vents
SU0508 HRH / MS LINE STNR DRAIN TO UFT
SU0509 HRH/MS LINE STNR DRN TO SDFT Open
SU06 AB- LIGHT OIL STARTUP:
AB Elevation Light oil Lined up
Start one LDO pump-A / B
Select L ight Oil
Ensure opening of Manual isolating valves for atomizing
air, Light Oil lines at each corner
Ensure Oil guns are engaged properly and are in retract
position
Ensure Atomising air pressure is 8.00 kg/cm2
Open LOTV L030
Open LFO IV L024
Set LOFCV L023 to 85%
Start pair 1&3
Observe that LONV 1 is open after some time
Observe that LONV 3 opens after time delay
Start pair 2&4
Observe that LONV 2 is open after some time
Observe that LONV 4 opens after time delay
Permissives from Remote Station for AB Elevation Light Oil
1 AB LO Man Isol Vlv 1 RO:001 PS-101
5 At Air Man Isol Vlv AB 1 RO:045 PS-101
9 Oil Gun Engd AB 1 RO:049 PS-101,102
13 Scavenge Vlv AB 1 pos RO:069 PS-101,102
17 SA 1 RO:208 PS-376,377
18 SA 54 RO:209 PS-376
19 IA 70 RO:210 PS-377
SU06 AB- HEAVY OIL STARTUP:
Go to OIL-AB HFO screen from SG Menu
Line up AB Elevation Heavyoil
Select Heavy OIL
Open HORV
Go to HFO system screen from BOP Menu
Press mode selector to Auto
Start HFO Pump and Open HO11A to 20%
Go to SLD HFO HTR-A O/L TEMP page
Keep the SP to 110 degc
Set the HFO TEMP AT HTRA O/LController into
Auto
Go to SLD HFO Press CTRL page
Set the HFO pump O/L Press Controller into Auto
Keep HFO pump o/l Press SP to 35 kg
Go to SLD HFO Flow CTRL page
Set the HO33 Controller into Auto
Keep HFO Hdr Press SP to 10 kg
Go to SLD ATOM STM PR CTRL page
Set the OS33 Controller into Auto
Keep ATOM STM Press SP to 12 kg
Open HOTV
Ensure opening of Manual isolating valves for atomizing
air, HeavyOil lines at each corner
Ensure Oil guns are engaged properly and are in retract
position
Ensure Atomising air pressure is 10.00 kg/cm2
Start pair 1&3
Observe that HONV 1 is open after some time
Observe that HONV 3 opens after time delay
Start pair 2&4
Observe that HONV 2 is open after some time
Observe that HONV 4 opens after time delay
Permissives from Remote Station for AB Elevation Heavy Oil
1 AB HO Man Isol Vlv 1
5 At Air Man Isol Vlv AB 1
9 Oil Gun Engd AB 1
10 Oil Gun Engd AB 2
13 Scavenge Vlv AB 1 pos
17 SA 1
18 SA 54
19 IA 70
Observe that Drum level starts raisng when steaming takes place in the Drum due to
swelling.
Observe that Boiler Drum Pressure starts increasing. When Drum Pressure crosses 2.0
Kg/sq.cm close drum vents and all the drains
Gradually close Start Up Vents S83 & S84 after charging HP/LP bypass
After pressure reaches 5kgs start Main steam path
SU07 MAIN STEAM LINE CHARGING
SU00701 Main Steam Valves
GOTO MAIN STM screen from BOP Menu
Open MSSV(R) IBV1 MS4
Open MSSV(R) IBV2 MS6 >2%
Observe MS pressure and Temp. rise
Open MSSV(L) MS1 after warming up MS line
Open MSSV(L) MS2 after warming up MS line
Observe that MSSV(L) IBV1 MS3 closes on Auto
OBSERVE MS PRESSURE EXCEEDING 8 KG/CM
2
SU0702 MS Drains
Close MS101 CE 1125 PS343
SU0703 HRH / MS LINE STNR DRAIN TO UFT
SU0704 HRH/MS LINE STNR DRN TO SDFT Close
Boiling will start after 2 pairs of Heavy oil and it will take 8 minutes to Boiling
complete. Observe the Drum Pressure starts building.
When Main Steam Pressure crosses 8.0 Kg/sq.cm charge HP & LP Bypass
SU09 PRESSURE AND TEMPERATURE CONTROL
SU0901 HP Bypass Charging
Go to HP BYPASS screen from SG Menu
Open Warm Up Drain Valve BP 101
Open Warm Up Drain Valve BP 102
Open HPBP(L) Warmup Line Isov BP3
Open HPBP (R ) Warmup Line Isov BP4
Close Warm Up Drain Valve BP 101
Close Warm Up Drain Valve BP 102
Set HP Temp set point 320 Deg.
Open Block valve BD
Set HPBP-1 Valve >2%
Set HPBP-2 Valve >2%
Observe that BPE-1 & BPE-2 valves switch over to Auto
SU0902 CRH / HRH Drains
Close HRH125
Close HRH101
Close HRH102
Close HRH127
Close HRH105
Close HRH106
Close HRH109
Close HRH110
Close HRH113
Close HRH114
SU0903 LP Bypass charging
Go to LP BYPASS screen from TG Menu
Set Fixed setpoint at 2.0 kg/sqcm
Switch on Auto Control Interface
Put LPBP Controller in Auto
Observe that Injection valve 1 & 3 Open
Observe that Stop valve 1 & 2 Opens
Observe that LPBP Valve-1 opens
Observe that LPBP Valve-2 opens
Set point is to be raised gradually to 6.0 kg/sqcm at the
time of rolling
After pressure reaches 25kgs start CD Heavy OIL
SU08 CD- HEAVY OIL START-UP:
Go to OIL-CD HFO screen from SG Menu
Open heavy oil return valve HORV
Open HOTV
Switch On pair 1&3
Observe that CD HOnV 1 is open after some time
Observe that CD HOnV 3 opens after time delay
Start pair 2&4
Observe that CD HOnV 2 is open after some time
Observe that CD HOnV 4 opens after time delay
Switch On pair 2&4
Set the Heavy Oil Pressure Controller to Auto
Set the Atomising Steam Pressure Controller to Auto
Permissives from Remote Station for CD Elevation Heavy Oil
1 HO Man Isol Vlv CD 1
5 At St Man Isol Vlv CD 1
9 Oil Gun Engd CD 1
10 Oil Gun Engd CD 2
13 Scavenge Vlv CD 1 pos
Keep on opening HP Bypass valves 1&2 till the following Rolling parameters are
reached
Drum Pressure >50 KG/CM
2
MS flow > 200TPH
MAIN STEAM Pressure >40 KG/CM
2
MAIN STEAM TEMPERATURE >350
0
C
RH STEAM TEMPERATURE >320
0
C
Keep the Press SP to 40 kgs and put the HP Bypass valves to Auto
SU10 TURBINE START-UP
SU1001 SGC TURBINE STARTUP
Go to MAIN TURBINE SGCS screen from TG Menu
GotoTURBINE EHTC screen from TG Menu
Select the Press. CTR Mode to LP mode
Set the PRMAX set point to 525 MW
GotoTURBINE DRAINS SYSTEMscreen from TG
Menu
Open drain before HPCV1&HPCV2 to 100%
Set TSC On Lined up
Switch On the Load controller
Select TSC mode to Normal
Observe the X1Criteria fulfillness
Plunger coil On Line up
Goto MAIN TURBINE SGCS screen from TG
Menu
Select SGC Turbine
Select Auto mode( 3
rd
sel in the small pop up)
Select Start
Observe ESVs opening at Step 6
Observe IVs opening at Step 9
Observe Turbine Speed crossing 300 rpm at step 13
Observe Turbine Speed crossing 2950rpm at step 17
Observe Generator Field breaker is on at step 18
Observe Synchroniser switches on & closes the
Generator breaker at step 21
Observe Generator Load crosses 50 MW and EHTC
switches over to Load Control mode at step 23
If the load doesnot cross 50 MW raise speed ref
Close HP Bypass valves
Set HP Bypass Pressure SP to 175 KG/CM
2
Set HP Bypass Pressure Controller to Auto
Observe that LP Bypass valves Closed
Close Start Up Vents
Steps bypass
1. Bypass step 102 : press semi and press Advance.
Press auto to go further
2. Bypass step 107
3. Bypass step 110
4. Bypass step 111 : GEN CNDNS FLFLLED
5. Bypass step 114
6. Bypass step 118 : DVR Exciitation
7. Bypass step 119
8.
UNIT SYNCHRONISED AND LOAD >50 MW
Close Economiser recirculation valve E21.
After synchronisation further loading will be done by bringing in additional mills
and establishing suitable main steam process parameters (pressure and
temperature)
SU11 MILLS IN SERVICE
SU1102 PAF-A Start
Go to PA FANS screen from BOP Menu
Switch On PA Fan-A LOP-A or LOP-B
Set the PA Fan-A control damper position to 0%
Start the PA Fan-A
Observe PA Fan-A Outlet Gate opens after 20 seconds
delay
Raise the control damper PA Fan-A till the PA Header
pressure reaches 800 mmwc
Observe that PA Header pressure starts raising
Set the PA Header Press,Setpoint to 850 mmwc
Set the control damper PA Fan-A to Auto
Set the PA Master to Auto
SU1103 First Coal Elevation Lightup
Go to COAL-A screen from SG Menu
Mill-A lined up
Switch On the Pulv. lub oil pump
Open Pulv-A disch Valve
Open Cold air Gate A
Switch On Pulveriser motor A
Open Hot air Gate A
Open CAD to 25% cold air damper Mill-A
Open HAD to 75% Hotair damper Mill-A
Ensure Mill outlet temp. reaches >50degc
Open the FDR O/L Gate
Set the Mill O/L temp. setpoint to 85
0
C
Switch On the Feeder A
Set the HAD & CAD into Auto mode
Increase the loading on the pulveriser by increasing the
feeder speed
Repeat the above steps to take other Pulverisers into
service
Permissives from Remote Station for Mill A
1 RCF Inlet Gate A
2 Tr.Iron Hop Vlv A
3 Bunkr O/L Gate A
4 Bunkr Isolation Gate A
5 Feeder SA valve A
6 Mill-A MOTOR Rack-in/Rack-out
Raising the Load
GotoTURBINE EHTC screen from TG Menu
1 Observe that Turbine is in Load control mode
2 Observe that Pressure control mode is Limit Pr mode
3 Set the Load rate SP to 25 MW/Min
4 Raise the load SP to the desired load
5 Observe that load gradually raises to the SP
6 Increase the Fuel input when the Main steam pressure
falls
7 Observe gradual rising of flue gas temperature
8 Observe gradual rising of main steam temperature
9 Observe gradual rising of total fuel flow
10 Observe gradual rising of steam flow
When Load crosses 150 MW Open FD-16. Take MD BFP C Scoop controller in Auto
and Feed Water Master controller in Auto
SU1104 Charging LP Heaters ( when load=200MW)
LPH-1 Charging (LPH-1 is to be taken into service before steam admission into
condenser)
Goto LPH&DRN CLRS screen from BOP Menu
Open LPH-1 inlet isolation valve CD28 IBV
Open LPH-1 inlet isolation valve CD28
Open LPH-1 outlet isolation valve CD29
Close LPH-1 inlet isolation valve CD28 IBV
Close LPH-1 bypass valve CD30
LPH-2 Charging
Open LPH2 inlet isolation valve CD31 IBV
Open Ext LPH2 drain valve EX119
Open LPH2 inlet isolation valve CD31
Open LPH2 outlet isolation valve CD32
Close LPH2 inlet isolation valve CD31 IBV
Close Condenser bypass valve CD33 (0%)
Open Ext LPH2 valve EX11
Close Ext LPH2 drain valve EX119
Set the NWL set point to -25mm
Set the HWL set point to 18mm
Set the LPH2 drain CV DR34 to Auto
LPH-3 Charging
Open LPH3 inlet isolation valve CD34 IBV
Open Ext LPH3 drain valve EX118
Open LPH3 inlet isolation valve CD34
Open LPH3 outlet isolation valve CD35
Close LPH3 inlet isolation valve CD34 IBV
Close Condenser bypass valve CD36 (0%)
Open LPH2 EXT valve EX12
Close EXT LPH2 DRN valve EX118
Set the NWL set point to -25mm
Set the HWL set point to 18mm
Open Deaerator extraction valve Ex13.
When Load crosses 200 MW second set of auxiliaries to be started
SU12 STARTING SECOND SET OF AUXILIARIES
SU1202 AH-B Start Sequence
Goto AIR HETERS screen from BOP menu
Switch On the AH-B ElectricMotor
Open the AH-B FG I/L Damper -1 &2
Open the AH-B FG O/L Damper
Open the SCAPH-B I/L SAD-3B & SAD-4B O/L
dampers
Open the SAD-6B SA O/L damper
Open the PA I/L Damper PAD-3B
Open the PA O/L Damper PAD-4B
SU1203 IDF-B Start Sequence
Goto ID FANS screen from BOP menu
Line up IDF-B System
Set IDF-B LOP-A or LOP-B On
Set the IDF-B ch1 SRC Breaker On
Set the IDF-B ch2 SRC Breaker On
Set the IDF-B VFD ch1 On
Set the IDF-B VFD ch2 On
Ensure the ID Fan-B Motor On indicator appear
Permissives from Remote Station for IDF-B
1 IDF-B CH-1 Rack-in/Rack-out
2 IDF-B CH-2 Rack-in/Rack-out
SU1204 FDF-B Start Sequence
Goto FD FANS screen from BOP menu
Set The FD Fan-B Control Damper Position To Min
Start FD Fan-B Lop-A or Lop-B
Close FD Fan-B Outlet Gate
Ensure the Permissive Available
Start the FD Fan-B
Observe the pump is On, red light appears.
Ensure FD Fan-B Outlet Gate opens after 20 seconds
delay
Permissives from Remote Station for FDF-B
1 FDF-B Rack-in/Rack-out
SU13 UNIT LOAD RAISING TO FULL LOAD
SU1302 PAF-B Start
Goto PA FANS screen from BOP menu
Line Up PAF-B System
Switch On PA Fan-B Lop-A or Lop-B
Ensure the PA Fan-B control damper position to
minimum
Start the PA Fan-B
Ensure PA Fan-B Outlet Gate opens after 20 seconds
delay
Set the PA Header Press,Setpoint to 800 mmwc
Set the control damper PA Fan-B to25%and set to auto
Raise the PA Header Master position to control damper
position of PAF-B
Set the PA Master to Auto
Permissives from Remote Station for PAF-B
1 PAF-B Rack-in/Rack-out
SU1303 TD BFP-A Oil System
Goto BFPDT-A LUBE/JACK OIL SHEME screen from TG menu
Start TD BFP-A Main Aux oil(LOP) pump A/B
Observe theBFPT-A lub oil header pressure increases
to >3.0 Kg/ cm
2
Change the TDBFP-A EOP Auto to On status
Start TDBFP-A J OP
Strat oil vap ex-fan 1
Open the Gate Valve Gearing
SU1304 TD BFP-A Start
Goto BFPDT-A CONTROL SHEME screen from TG menu
Line up TD BFP-A
Ensure Deaerator level around 0 mmwcl
Ensure Condenser press <-0.85 kg/cm
2
Ensure Suction valve for BFP A opened
Open steam drain valve before ESV of BFPT-A
Open drain vlv D/S of TDBFP-A aux CV
Open IP/LP common drain vlv Ex 109
Open Aux stm to TDBFP-A
Open CRH stm to BFPT-A block valve CRH1
Open BFPT-A vent valve U/S of ESV
Open TDBFP-A exhaust vlv to condenser EX27
Open TDBFP-A warmup Aux CV
Open TDBFP-A casing drain vlv
Open TDBFP-A casing cross drain vlv
Set Gland steam Ref to 180mmwc
Set TDBFP-A Gland steam Controller to Auto(control
action should be Reverse)
Observe that Gland steam pressure raises to 180 mmwcl
Open IP bleed stm common block vlv
Open TDBFP-A recirculation valve
Ensure TDBFP-A control valve closed
BFPDT-A Trip reset On
Ensure all start permissives are met
Open TDBFP-A ESV
Observe the Oil pressure below piston rises to 8.0 kg/cm
2
Observe the Oil pressure above piston rises to 8.0 kg/cm
2
Observe the Oil pressure below piston falls to 0.0 kg/cm
2
Observe the Full opening of ESV
Raise the speed set point of TDBFP-A slowly to match
the speed of MDBFP and then put it in Auto when both
the speeds are matching
Open TDBFP-A discharge bypass valve
Open TDBFP-A discharge valve
Permissives from Remote Station for TD BFP A
1 TD BFP A SUC VLV
2 TD BFPA TANK LEVEL OK
SU1305 TD BFP-B Oil System
Goto BFPDT-B LUBE/JACK OIL SHEME screen from TG menu
Start TD BFP-B Main Aux oil pump A/B
Observe theBFPT-B lub oil header pressure increases
to >3.0 Kg/ cm
2
Change the TDBFP-B EOP Auto to On status
Start TDBFP-B J OP
Open the Gate Valve Gearing
TDBFP-B speed reaches >400 rpm
SU1306 TD BFP-B Start
Goto BFPDT-B CONTROL SHEME screen from TG menu
Line up TD BFP-B & put on turning gear
Ensure Deaerator level Normal
Ensure Condenser press <-0.85 kg/cm
2
Ensure Suction valve for BFP A opened
Open steam drain valve before ESV of BFPT-B
Open drain vlv D/S of TDBFP-B aux CV
Open IP/LP common drain vlv Ex 109
Open Aux stm to TDBFP-B drain vlv
Open CRH stm to BFPT-B block valve CRH1
Open BFPT-B vent valve U/S of ESV
Open TDBFP-B exhaust vlv to condenser EX27
Open TDBFP-B warmup Aux CV
Open TDBFP-B casing drain vlv
Open TDBFP-B casing cross drain vlv
Set Gland steam Ref to 180mmwc
Set TDBFP-B Gland steam Controller to Auto
Observe that Gland steam pressure raises to 180 mmwcl
Open IP bleed stm common block vlv
Open TDBFP-B recirculation valve
Ensure TDBFP-B control valve closed
BFPDT-B Trip reset On
Ensure all start permissives are met
Open TDBFP-B ESV
Observe the Oil pressure below piston rises to 8.0 kg/cm
2
Observe the Oil pressure above piston rises to 8.0 kg/cm
2
Observe the Oil pressure below piston falls to 0.0 kg/cm
2
Observe the Full opening of ESV
Raise the speed set point of TDBFP-B slowly to match
the speed of MDBFP and then put it in Auto when both
the speeds are matching
Open TDBFP-B discharge bypass valve
Open TDBFP-B discharge valve
Permissives from Remote Station for TD BFP B
1 TD BFP B SUC VLV
2 TD BFPB TANK LEVEL OK
SU1307 Starting CEP-B
Goto COND.EXT.PUMPS SCHEME screen from BOP menu
Line up CEP-B
Open the CEP-B Rec Valve CD-12
Ensure CEP-B dis.vent vlv. VA8 in Open position
Ensure CEP-B dis. Vlv. CD5 in Close position
Ensure CEP-B dis. Byp vlv. CD8 in Close position
Switch On CEP-B Pump
Ensure CEP-B Vent vlv. VA8 Closes
Ensure CEP-B Dis. Byp valve CD8 Opens
Ensure CEP-B Dis. valve CD5 Opens
Ensure CEP-B Dis. Byp valve CD8 Closes
Set CEP-B Flow SP to 500 TPH
Set CEP-B Rec. vlv. CD12 to Auto
Keep CEP-C in standby
Permissives from Remote Station for CEP-B
1 CEP-B Rack-in/Rack-out
2 CEP-B Suction VLV
SU1308 CEP-C in Stand by
Line up CEP-C
Set CEP-C Flow SP to 500 TPH
Set CEP-C Rec. vlv. CD14 to Auto
Set CEP C in Stand by mode
Observe CEP-C dis. Vlv. CD6 in Close position
Observe CEP-C dis. Byp vlv. CD9 in Close position
Permissives from Remote Station for CEP-C
1 CEP-C Rack-in/Rack-out
2 CEP-C Suction VLV
SU1309 HPH Charge (When Load crosses 300 MW)
HPH-5A and 6A Charging
Goto HP HEATERS scheme screen from BOP menu
Open HPH-5A inlet isolation valve IBV FD7 IBV
Open HPH-6A outlet isolation valve IBV FD8 IBV
Open HPH-5A/5B EXT STM DRN valve EX147
Open HPH-6A EXT STM DRN valve EX101
Open HPH-5A inlet isolation valve FD7
Open HPH-6A outlet isolation valve FD8
Close HPH-5A inlet isolation valve IBV FD7 IBV
Close HPH-6A outlet isolation valve IBV FD8 IBV
Close HPH FW 50% Byp valve FD12
Open HPH FW 50% Byp valve FD12 IBV
Open HPH FW 50% Byp valve FD12
Close HPH FW 50% Byp valve FD12 IBV
Close HPH FW 100% Byp valve FD11
Open HPH-5A EXT STM inlet valve EX21
Close HPH-5A/5B EXT STM DRN valve EX147
Close HPH-6A EXT STM DRN valve EX101
Set the HPH 5A NWL set point to -90mm
Set the HPH 5A HWL set point to -15mm
Set the HPH 5A drain CV DR15 to Auto
Set the HPH 6A NWL set point to -90mm
Set the HPH 6A HWL set point to -15mm
HPH-5B and 6B Charging
Open HPH-5B inlet isolation valve IBV FD9 IBV
Open HPH-6B outlet isolation valve IBV FD10 IBV
Open HPH-6B EXT STM DRN valve EX102
Open HPH-5B inlet isolation valve FD9
Open HPH-6B outlet isolation valve FD10
Close HPH-5B inlet isolation valve IBV FD9 IBV
Close HPH-6B outlet isolation valve IBV FD10 IBV
Open HPH-5B EXT STM inlet valve EX22
Close HPH-6B EXT STM DRN valve EX102
Set the HPH 5B NWL set point to -90mm
Set the HPH 5B HWL set point to -15mm
Set the HPH 5B drain CV DR22 to Auto
Set the HPH 5B drain CV DR25 to Auto
Set the HPH 6B NWL set point to -90mm
SU130945 Set the HPH 6B HWL set point to -15mm
SU130946 Set the HPH 6B drain CV DR8 to Auto
SU130947 Set the HPH 6B drain CV DR11 to Auto
SU1310 Selection of CMC mode:
Goto CMC scheme screen from BOP-SLD menu
SU130101 Set the min. load SP to 350 MW
SU130102 Set the max. load SP to 525 MW
SU130103 Set the load rate SP to 25 MW/Min
SU130104 Set the Fuel master to Auto
SU130105 Set the Air Flow control to Auto
SU130106 Ensure Feedwater master is in Auto
SU130106 Set the Boiler master to Auto
SU130107 Select the Mode as CMC
SU130108 Set the CMC Mode On
Permissives from Remote Station for AB Elevation Heavy Oil:
1 HO Man Isol Vlv AB 1
5 At St Man Isol Vlv AB 1
9 Oil Gun Engd AB 1
13 LCL MAINT.SW AB1 REM
Permissives from Remote Station for CD Elevation Heavy Oil:
3 HO Man Isol Vlv CD3
5 At St Man Isol Vlv CD1
9 Oil Gun Engd CD 1
13 LCL MAINT.SW CD1 REM
Permissives from Remote Station for EF Elevation Heavy Oil
1 HO Man Isol Vlv EF 1
5 At St Man Isol Vlv EF 1
9 Oil Gun Engd EF 1
10 Oil Gun Engd EF 2
13 LCL MAINT.SW EF1 REM
Permissives from Remote Station for GH Elevation Heavy Oil
1 HO Man Isol Vlv GH 1
5 At St Man Isol Vlv GH 1
9 Oil Gun Engd GH 1
10 Oil Gun Engd GH 2
13 LCL MAINT.SW GH1 REM
Permissives from Remote Station for Mill B
1 RCF Inlet Gate B
2 Tr.Iron Hop Vlv B
3 Bunkr O/L Gate B
4 Bunkr Isolation Gate B
5 Feeder SA valve B
6 Mill-B MOTOR Rack-in/Rack-out
Permissives from Remote Station for Mill C
1 RCF Inlet Gate C
2 Tr.Iron Hop Vlv C
3 Bunkr O/L Gate C
4 Bunkr Isolation Gate C
5 Feeder SA valve C
3 Mill-C MOTOR Rack-in/Rack-out
Permissives from Remote Station for Mill D
1 RCF Inlet Gate D
2 Tr.Iron Hop Vlv D
3 Bunkr O/L Gate D
4 Bunkr Isolation Gate D
5 Feeder SA valve D
6 Mill-D MOTOR Rack-in/Rack-out
Permissives from Remote Station for Mill E
1 RCF Inlet Gate E
2 Tr.Iron Hop Vlv E
3 Bunkr O/L Gate E
4 Bunkr Isolation Gate E
5 Feeder SA valve E
3 Mill-E MOTOR Rack-in/Rack-out
Permissives from Remote Station for Mill F
1 RCF Inlet Gate F
2 Tr.Iron Hop Vlv F
3 Bunkr O/L Gate F
4 Bunkr Isolation Gate F
5 Feeder SA valve F
6 Mill-F MOTOR Rack-in/Rack-out
Permissives from Remote Station for Mill G
1 RCF Inlet Gate G
2 Tr.Iron Hop Vlv G
3 Bunkr O/L Gate G
4 Bunkr Isolation Gate G
5 Feeder SA valve G
3 Mill-G MOTOR Rack-in/Rack-out
Permissives from Remote Station for Mill H
1 RCF Inlet Gate H
2 Tr.Iron Hop Vlv H
3 Bunkr O/L Gate H
4 Bunkr Isolation Gate H
5 Feeder SA valve H
3 Mill-H MOTOR Rack-in/Rack-out
Permissives from Remote Station for ACW-C
1 ACW-C Suction VLV
2 ACW-C Rack-in/Rack-out
Permissives from Remote Station for DMCW-C
1 DMCW-C Suction VLV
2 DMCW-C Rack-in/Rack-out
Permissives from Remote Station for BCW-C
1 BCW Pump-C Rack-in/Rack-out
2 BCWP C DISCH VALVE
Permissives from Remote Station for CWP-3
Permissives from Remote Station for Service Air
1 SA 1
2 SA 54
Permissives from Remote Station for INSTRUMENT AIR COMPRESSOR
1 IA COMP-1 Rack-in/Rack-out
Permissives from Remote Station for PLANT AIR COMPRESSOR
1 PA COMP-1 Rack-in/Rack-out
2 PA COMP-2 Rack-in/Rack-out
Permissives from Remote Station for ISOLATORS
1 ISO 9-89
2 ISO 9-89A
3 ISO 89-GT1
4 ISO 8-89A
5 ISO 8-89B
6 ISO 7-89
7 HVCB 7-52
8 ISO 7-89A
9 ISO 89-ST1

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What are the steps involved in the cold start up procedure?

What are the steps to charge the LT/HT auxiliary steam header?

Piyush Kr.Singh, Dy.

Director, NPTI Nangal

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