Hot Startup Checklist1

Hot startup checklist
Page 1 of 6
JINDAL THERMAL POWER CO. LTD.

Rec. No:
Date:
Page:
Check List No
HOT START-UP CHECK LIST
OP/ F/ 07/ 05
08/08/2005
Page 1 of 6
..
Applicable when HP shaft temperature > 3800C

Unit:
Trip Description:
Date:
Coasting down time:
Step. No
I
Shift:
Trip time & date: ..
Synchronization time:
ACTIVITY
Ensure immediately after trip:

1 Immediate checks after Turbo-Generator tripping.
(a) Change the Islanding switch to "OUT" condition immediately after trip (Only if the
tripped unit is selected for islanding) and change the islanding selection to other
unit, if running above required load and change isolators to required configuration.
(b) Take islanding switch to IN position after above step (if applicable)
(c) Ensure Generator bkr, field bkr & unit incoming feeder breakers have opened &
turbine is coasting down.
2 Take the following actions to avoid boiler tripping if the boiler has not tripped on any
protection, otherwise go to 4 of Step I .
(a) Ensure HP & LP bypass has opened & maintaining the MS & RH pressure.
(b) Start the HFO transfer pump for the unit if it is not running.
(c) Reduce firing
If corex in service, reduce firing to four corex burners.
If corex not in service, cut-in oil elevation & reduce firing to 30%.
(d) While cutting out fuel, maintain normal drum level with HP bypass & drum level control.
3 Go to step no. II if boiler sustains on HP LP bypass, other wise continue.
4 Immediate checks if boiler also trips along with Turbo-Generator. Step No. 4
(a) Ensure N2 trip valve opens in auto on FGTV closure.
(b) Ensure closure of SH & RH spray Block valves.
(c) Close MIV before RH spray block valve.
(d) Ensure all the fuel trip valves & fuel nozzle valves are closed.
(e) Close HP Bypass valve & spray valve to hold boiler pressure.
II Ensure after TG trip (Either Boiler tripped or survived)
(a) Close all extraction block valves & open all extraction line drains.
(b) Ensure Lift oil pump starts at 510 rpm & turbine comes to barring speed.
(c) Ensure Deaerator pressure is maintaining from PRDS or CRH .
(d) Start DM makeup pump to maintain the hot well.
(e) Ensure gland steam temp. is maintained; by Opening PRDS drain traps bypass valves.
(f) Open MS strainer drain 105, 106 & before MIVs.
CHECK
TIME * /
REMARKS
Step. No
Page 2 of 6
ACTIVITY
III Ensure following during Hot startup

1 Check the following for turbine startup.
(a) Ensure second vacuum pump is also running & vacuum is more than -0.8ksc.
(b) Ensure CW pump is running & ACW system is charged.
(c) Open MIV before MAL valves (if closed)& MAL valves.
(d) Ensure control oil pump & HPBP oil pumps are running & Header Pr. are
adequate.(Around 160 Ksc & 100 Ksc respectively).
(e) Ensure DC, emergency power supplies are available.
(f) Ensure air compressor is running, instrument & service air is charged & N2 back up is
lined up.
(g) Change over the turbine lube oil pump if it is first trip of the month.
(h) Ensure all CT fans are running.
(i) Open HRH 101, HRH 102, HRH 113, HRH114, HRH 103, HRH 104 & their MIVs.
(j) Open CRH pot drain CRH - 101,CRH -127 & their MIVs.
2 If boiler has sustained on HP LP bypass, other wise continue.
3 Checks, if Boiler also tripped along with turbine.
(a) All 6.6kv, 415v buses are charged.
(b) Under voltage relays on 6.6KV buses are reset.
(c) Ensure Soot blower MOV S-81 for close & all blowers are out.
(d) Check the operation flue gas inlet dampers of both APH, if it is first trip of the month.
(e) Ensure blocking is reset on BTS panel, ready to transfer indication is "on".(if fast
change over has failed.)
Ensure at least one stream of ID & FD fans are running & furnace draft control in auto and
4
airflow more than 200 T/ hr.
5 Open economizer re circulation (E-20) valve & ensure at local also.
6 Ensure that one BFP is running & one pump in standby. Bring up the drum lvl to normal.
Charge PRDS from other unit if MS Stop valves are to be closed or light up has been
delayed more than 1 hour or drum pr has dropped less than 60 ksc.
Due to any reason
7
1. If PRDS temp. is not maintaining then charge from other unit.
2. If PRDS is already charged from other unit & stable, do not changeover the PRDS steam
supply.
Ensure HFO pump is running in short re circulation (SP-12 Ksc) & other pump in standby.
8
Interconnection valve is in close condition.
9 Ensure CEP is running in recirculation, Deaerator & hot well level controls are in auto.
10 Divert CBD to IBD tank.
11 Purging
(a) Ensure scanner air fan is in service.
(b) Ensure ignitor air fan is in service & ignitor air to furnace dp is at 85mm in auto.
(c) Ensure all purge permissive are satisfied.
(d) Purge the boiler.
(e) Open the IGTV & ensure ignitor gas pressure is more than 0.9 ksc.
(f) Take HFO on long recirculation & close short recirculation (HO-48) after purge is over.
12 MS line Charging (if Boiler stop valves are closed as per step no 7)
CHECK
TIME * /
REMARKS
Step. No
Page 3 of 6
ACTIVITY
(a) Ensure all MAL & its MIV are open.
(b) Open MS-101 & MS-102 & it's before MIVs.
(c) Ensure MS strainer drains (MS-105, 106 and its MIVs) are open.
(d) Open drain before APRDS (AS-116).
(e) Ensure APRDS isolation valves closed.
(f) Ensure HP bypass is closed.
(g) Ensure no PTW on turbine valve & HP/LP bypass valve
(h) Open MIVs of MS-3 & MS-4.
(i) Charge line by Slowly opening MS-3 & MS-4.
(j) Close MS-101 & MS-102 & it's before MIVs.
(k) Open boiler stop valves MS 1& 2 when upstream and downstream pressures are
equal.
(l) Keep AS-116 throttled.
(m) Close MS-3, MS-4 & their MIVs.
(n) Open HRH 101, HRH 102, HRH 113, HRH114, HRH 103, HRH 104 & their MIVs.
(o) Open CRH pot drain CRH - 101,CRH -127 & their MIVs.
13 Light-up
If corex clearance is available,
(a) Ensure SADC in auto
(b) Light up the boiler with 2 HFO guns at AX1.
(c) Charge HP-LP bypass.
1. Open LPBP spray control valves around 50%. Reset LPBP trip & open LPBP
around 10%.
2. Open HPBP slowly to 5% & Keep HPBP spray on auto with set point 350 oC.
(d) Take other pair of oil guns at AX1 elevation.
(e) After C header purging as per procedure TS/WI/02/XX., check O2 % less than 0.5%
in corex vent, take one pair corex in X1 elevation & ensure N2 trip valve closes in auto
(f) Cut-in second pair of burners in X1 elevation. Ensure X1 cor-2 & 4 Auto/Manual
selection in Auto
(g) Take at least one PA fan into service
If corex clearance is not available,
(a) Ensure SADC in auto
(b) Light up the boiler with 2 HFO guns at BC elevation
(c) Charge HP-LP bypass.
1. Open LPBP spray control valves around 50%. Reset LPBP trip & open LPBP
around 10%.
2. Open HPBP slowly to 5% & Keep HPBP spray on auto with set point 350 oC
(d) Take other pair of oil guns at BC elevation.
(e) Start both PA fans. Put PA header pressure & ampere bias controls in auto.
(f) Start mill-B, put temp. and air flow control in auto (temp SP-75 oC).
(g) Cut in feeder-B.
(h) Ensure ESP fields are charged & rapping motors are ON.
Keep four oil burner in service till corex is not taken in service or all three mills are proven /
14
stabilised.
CHECK
TIME * /
REMARKS
Step. No
Page 4 of 6
ACTIVITY
Open CBD around 25 to 30 %. Start phosphate dosing pump & maintain conductivity
around 25-30 micro mho. Step No. 15
Start second BFP if not in service & ensure third BFP is in standby with booster pump
16
running.
17 Start second pair of ID & FD if only one pair is in service.
15
18 Line up the SH & RH spray control station.

Ensure HPBP auto / manual station in manual. Put HP-LP bypass in auto after matching
19
MS/HRH pressure with set point (MS-75ksc & HRH- 8ksc).
20 Maintain the temperatures of RH & SH >480OC by burner tilt & airflow.
21 Ensure LPH1 & 2 inlet & outlet valves are open & bypass is closed and all in auto
After achieving the parameters Roll the turbine & synchronize as per turbine rolling &
22
synchronization checklist OP/F/11/XX.
Close MS, HRH & CRH drain. Keep CRH pot drain CRH-101 in auto & HRH-103 &104
23
bypass MIV partially open.
Keep all the turbine drain MAL-11, 12,15,16,26,27,31,32 valves (close MIV 's if passing) &
24
MAL 81,65 closed & in auto. Keep SLC ON
Gradually rise HP bypass set point & make HP LP bypass to close in auto. Close LP
25
bypass spray valve & put in auto after closing of LP bypass.
Ensure that LPH 1& 2 are charged & heater level controls are in auto. Ensure CD-29, 30,
26
31 in auto
27 Close economiser recirculation valve
Take corex pair if corex is available (keep AX1 guns if X1 burners to be taken), otherwise
28
take mill into service. (Start second PA fan if second mill is to be taken)
29 Increase the load and maintain steam pressure & temperature as defined in attachment -1.
30 Charge LPH 3 at 25 MW.
(a) Ensure PTW related to LPH-3 is returned.
(b) Ensure heater is charged from waterside (I/L & O/L valves are open & bypass valve is
closed).
(c) Extraction line drains (EX-125& 126, MAL-54) are open.
(d) Ensure operating vent is open & shell vent to atmosphere is close
(e) Open emergency drip control valve & close normal drip control valve.
(f) Open slowly EX-9 by seeing the heater level & shell pressure.
(g) After fully opening EX-9 & put it in auto & close EX-125, MAL-54 & 126 & put them in
auto.
(h) Put normal & emergency drains valves in auto (SP-0 & 20 mmwc).
31 At 25MW changeover 6.6 kV supply from station to UAT.
32 Put the bus transfer scheme of unit buses in to service after changeover of 6.6 kV supply
Take corex pair if corex is available (keep AX1 guns if X1 burners to be taken), otherwise
33
take mill into service. (Start second PA fan if second mill is to be taken)
34 Ensure DCC is running if two mills are in service.
35 Line up & Charge HPH - 5 at 50 MW
(a) Ensure PTW related to HPH-5 are closed.
(b) Ensure heater is charged from waterside (I/L &O/L valves are open & bypass valve is
closed).
(c) Ensure extraction line drains (EX-104 & 106, MAL-47) are open & operating vent is
open & atmosphere vent is close.
(d) Open fully emergency drip control valve & Keep normal drip control valve in close
condition.
(e) Open slowly block valve EX-11 by seeing the level & shell pressure.
CHECK
TIME * /
REMARKS
Step. No
Page 5 of 6
ACTIVITY
CHECK
TIME * /
REMARKS
(f) After fully opening the EX-11 & put in auto & also close drains & keep in auto.
(g) Put HP heater -5 level (normal & emergency) controls in auto. (SP-0 & 20 mm resp.)
(h) Ensure heater waterside I/L, O/L & bypass valves are in auto.
36 Line up & Charge HPH 6 at 60 MW.
(a) Ensure PTW related to HPH-6 are closed.
(b) Ensure heater is charged from waterside (I/L &O/L valves are open & bypass valve is
closed).
(c) Ensure EX-128 & its MIV (drain before EX-12) are open & operating vent is open &
atmosphere vent is close.
(d) Open emergency drip control valve.
(e) Ensure control valves of normal & alternate drips are close.
(f) Open slowly EX-12 from local by seeing the heater level & shell pressure.
(g) After fully opening the EX-12, put it in remote. Close EX-128 & put in auto.
(h) Put HP heater -6 level (normal, alternate & emergency) controls, EX-128 in auto. (SP0, 20& 40 mm resp.).
(i) Ensure heater waterside I/L, O/L & bypass valves are in auto.
37 Deaerator charging from Extraction-4 at 80MW
(a) Open drain trap bypass valve before & after EX-4 NRV 's & ensure MAL-51 is also
open.
(b) Slowly Open EX-10 from DCS.
(c) After matching upstream & down stream pressure, fully open EX-10 & keep in auto &
also close the drain trap bypass (keep drain trap in service).
38 Stop second vacuum pump and keep pump & suction valve in auto.
Take corex pairs if corex is available (keep AX1 guns if X1 burners to be taken), otherwise
39
take mill into service. ( start second PA fan if second mill is to be taken)
40 Raise the load as per TSE margins & Drum silica to 120 MW.
41 Put HPBP auto / manual set point station in auto.
42 Gradually raise the load to 130MW based on drum water silica
43 Ensure CBD tank is taken into service based on silica.
44 Ensure ESP fields are charged based on the SPM level
45 Ensure H2 pressure > 2.9 ksc & purity > 97%.
46 Check load gradient value is 3.5 mw
47 Ensure the CMC load reference - EHTC (in EHTC-1 screen) is tracking actual load.
48 Put unit in CMC after matching the parameters.
Charge PRDS from same unit Open AS-116 and other PRDS drains before charging
49
APRDS. The drain valves shall be closed after charging
50 Do APH soot blowing if unit was started with coal on oil support.
Control room shift operator
1
Signature .
2
Signature .
For major / critical activities, starting & ending times may be mentioned.
The Shift - in - charge engineer shall verify atleast 10 important / critical steps, at random.
Approved by:
** R
CONTROL STATUS
R Pilai
HOD - OPERATION
** This document is computer generated hence dose not require signature.
Issued & Controlled by:
** Anoop Vaish
OPERATION SUPPORT ENGINEER
Page 6 of 6
Attachment 1
Steam Parameters & rate of rise of load to be maintained for different startups
For Hot Startup :
ACTIVITY
Time (min)
Pressure (KSC)
Temperature (o C)
Synchronisation
80
480
25 MW
90
480
50 MW
105
490
80 MW
10
110
500
130 MW**
35
125
537
**Drum water Silica should be with in permissible limit before

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JINDAL THERMAL POWER CO. LTD.