SINGARENI THERMAL POWER PLANT

2X 600 MW POWER PLANT

SOP FOR COLD START UP

STANDARD OPERATING PROCEDURE

FOR
COLD START UP
[STPP/600/SOP/02]

Approved By
Rev No. & Date Change Pages Prepared By Controlled By
STPP STEAG
Suresh
Rev 0, 10.02.2017

STPP 2X600 MW SOP Page 1

 SINGARENI THERMAL POWER PLANT
2X 600 MW POWER PLANT
SOP FOR COLD START UP

Amendment Record
Amendment Amendment Date Description Acknowledge by
Reviewer
Rev No. Page No.

STPP 2X600 MW SOP Page 2

 SINGARENI THERMAL POWER PLANT
2X 600 MW POWER PLANT
SOP FOR COLD START UP

PURPOSE: This procedure is used as work instruction for Unit Cold Start up.

SCOPE: This procedure is applicable to Unit Cold Start Up in STPP 2X600 MW.

RESPONSIBILITY: All operator, Desk/Field Engineer, Unit control engineer and Shift In charge.

Cold start-up procedure:

Turbine Metal Temp. <1500C (Shut Down > 72 Hours)

Pre checks and Activities in Boiler side before BLU:

1) NO PTW is pending & clearance given by all departments.

2) Ensure Station bus supply is available and unit board power supply is in charge condition.
3) Ensure power supply is available to the aux system required for boiler light up.
4) Ensure all peep hole and manholes of boiler are closed & manholes (55 m floor & 9 m floor) cooling line
opened.
5) Ensure boiler is filled up to adequate level (-50 mm) and at least 2 BCWPs are running.
6) Boiler drum vents B1, B2, B28 & B29 are in open condition.
7) All SH & RH drains and vents are in open condition.
8) Ensure before MSSV drain valve MSV 101/102 are opened.
9) Eco recirculation MOV E15 is in open condition.
10) Ensure CBD and EBD lines all manual valves are in open conditions.
11) Both APH-A & APH-B are in service & Air motor trial is already taken.
12) Ensure all the 4 passes of ESP are lined up as per requirement.
13) Ensure Bottom ash hoppers & fly ash system is ready and lined up.
14) Ensure Seal trough is filled up and refractory cooling water line is also lined up.
15) All ID Fans, FD Fans & PA Fans & its LOPs are lined up and ready to start.
16) Ensure all spray lines are lined-up condition.
17) Ensure AC scanner fan is running and DC scanner fan trial is already taken.
18) Ensure Boiler drum metal temp has been noted down.
19) Ensure all soot blowers & LRSB are in home position.
20) Ensure APH soot blowing is running (with Air or Steam)
21) Ensure oil carry probe is working and is in inserted condition.
22) Ensure all sample lines are lined up and sample cooler is in service.
23) Ensure igniters cooling line MIV are opened.
24) Ensure Air & Flue Gas path available.

Pre checks and activity in BOP side before Boiler light up:

1) No PTW is pending.
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 SINGARENI THERMAL POWER PLANT
2X 600 MW POWER PLANT
SOP FOR COLD START UP

2) Ensure at least one CW and ACW pumps are running.

3) Ensure CST level is >5 mtr.
4) Ensure at least one CT make up pump is running.
5) Ensure Emergency DG diesel tank level is adequate and its trial is already taken.
6) Ensure either fire water pump running or movable fire tender is available at site.
7) Ensure DM plant is duly informed about boiler light up.
8) Ensure LDO &HFO tank level is ok and at least one LDO/HFO pump is running for maintain 20-25 kg/cm 2
header pressure and short re circulation CV is in Auto.
9) Ensure power supply for pumps are healthy.

Pre checks and Activities in Turbine side before Boiler light up:

1) NO PTW is pending.
2) Ensure at least one SA Comp. & IA Comp. is running & air line charged. ( IA and SA pressure)
3) Ensure at least 1 TG ECW is running and at least 2 PHE is charged with ACW system.
4) Ensure at least 1 SG ECW is running and at least 1 PHE is charged with ACW system.
5) Ensure Turbine is on barring gear and DC EOP trial is already taken and its temp CV is in auto. (Set pt. 50 0C)
6) Ensure one HPCF oil pump is running.
7) Ensure one CEP is running.
8) Ensure Primary water pump is running and its temp CV is in Auto (Set pt.45 0C)
9) Ensure Seal oil pump is running and DC seal oil pump trial is already taken. Ensure its temp CV is in Auto
(temp CV set pt. 450C).
10) Ensure hydrogen is filled, its purity(99%) and pressure(>4.5kg/cm2) is OK and its temp CV is in Auto (Set pt.
450C)
11) Both TDBFPs lube oil pumps are running and their respective EOPs trails is already taken.
12) MDBFP is ready to start.
13) Ensure all drains are opened for MS, CRH, HRH, HPBP, LPBP, MAL, Gland Steam &Extractions.
14) Ensure all temp control valves are healthy and are in Auto.
15) Ensure all spray lines are lined-up condition.
16) Ensure chemical dosing system is ready.
17) Ensure Excitation system is ready and all GRP relays are reset.
18) HFO to be taken on short recirculation and HFO temperature to be increased to 120 ‘C
19) Note down Boiler expansion readings.
20) If Second unit is in service, charge the Aux.PRDS from the other unit. Start vacuum pulling and charge the
turbine seal steam of turbine. Whilecharging seal steam turbine barring gear to be monitored carefully.
Dearator pegging to be done while boiler filling. Charge Atomising steam pressure.

Boiler Light Up activities:

1) Start 1st ID Fan and ensure furnace pressure within limit (-10 mmwc)
2) Start 1st FD Fan and ensure furnace pressure within limit (-10 mmwc)
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 SINGARENI THERMAL POWER PLANT
2X 600 MW POWER PLANT
SOP FOR COLD START UP

3) Maintain air flow up to 30% to 40% // Mention air flow//

4) Ensure all aux damper are open 100%.
5) Check all purge permissive are satisfied.
6) PURGE the boiler (540 sec).
7) Put aux damper control in auto and set point for wind box to furnace DP is 40mmwc.
8) Open LOTV/HOTV and maintain LDO/HFO pressure around 10-15 kg/cm2.
9) Light up the boiler with 2 LDO guns in AB Elev.
10) Maintain oil pressure up to 6-8 kg/cm2 to prevent unborn.
11) After 30 min take another 2 LDO guns in AB elevation.
12) Check temp in FG is raising, BCWP cavity temp & Drum metal temp starting increasing.
13) Control the firing so that drum metal difference for TOP & Bottom should not exceed more than 500C
14) Ensure temp rise in metal temp of SH/RH is not more than 100C per min.
15) At drum pressure reaches 2 kg/cm2 than close all drum vents.// after ensuring complete venting//
16) Start MDBFP and maintain drum level -50mm if water level going high due to water swelling, open CBD or
EBD.// MDBFP to be taken in service before purging of the boiler//
17) Check the oil carry probe & view glass for the condition of APH. // APH soot blowing to be ensured
continuously as long as oil guns are in service//
18) Take CD elevation if temp raising is normal
19) Once drum pressure reaches 5 kg/cm2, close all the SH vents and drains except start-up vent.
20) Charge the MS line by opening MSV-3, MSV-4, MSV-5 & MSV-6 at MS Pressure of 5-10 kg/cm2.
21) Charge MS line by opening MSV-1 & MSV-2 by ensuring both sides pressures equal.
22) If APRDS is not available then open MS to APRDS drain ASV-164 at APRDS floor and Ensure drain is open to
IBD tank.
23) Charge LT PRDS header also and maintain its prss. and temp as 12 kg/cm 2/2100C
24) Maintain the APRDS pr/temp around 12 kg/cm2/320-3400C.
25) Charge atomising steam for HFO guns.
26) HFO guns taken in CD elevation
27) Charge Deaerator pegging steam from APRDS.
28) Start vacuum pulling by starting all vacuum pumps.
29) Charge Gland steam system (header pressure 400mmwc).
30) Maintain vacuum around 0.13abs.
31) Open LP and HP bypass around 10% Ensure their respective warm-up line are already open. //Ensure the
CRH and HRH drains open from local//
32) Close start-up vent full after charging HP/LP bypass.
33) Put LP interface ( ACI) in On & LP bypass in AUTO. Observe fixed set point is set at 12 kg/cm2.
34) Close HPBP warm-up and LPBP warm up MOV.
35) Raise MS pressure and temp as 40 kg/cm2/3500C

Turbine Rolling Activities:

1) Ensure all lube oil cooler are in service.

2) Ensure Temp curves X1 & X2 are satisfied for opening ESV during HP/LP Bypass running.

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2X 600 MW POWER PLANT
SOP FOR COLD START UP

3) Reset the Turbine protections in turbine protections graphics page and ensure no ‘fault’ or ‘trip’ is
being displayed on that page.
4) Select the turbine in “EHG” mode from EHTC graphics page and check “EHG selected” is being
displayed.
5) Bring starting device to zero position this will cause generation of trip oil, check trip oil pressure
and Start up Oil pressure around 8 kg/cm2..
6) Bring Speeder gear open position(100%).
7) Raise the Starting device position to aprox 27-30% & ensure start up oil pressure zero and check
HP/IP turbine Stop valve is full opened.// Same ensure from local//
8) Further raise the starting device up to 100%.

Checks before TG set Rolling:

1) MS pressure 40 kg/cm2, MS temp= 3500C

2) HRH pressure=6 kg/cm2, HRH Temp= 3300C.
3) Ensure chemical parameters for MS(silica <20 ppb) and drum are ok. // Silica , 50 ppb//
4) Ensure lube oil temp and control oil temp controls are in AUTO and set point is 45 0C .
5) Ensure temp curves X3, X4 and X5 are satisfied.
6) Ensure all SLC drains is ON.
7) Ensure exhaust hood spray line up.
8) Ensure DG is available.

Raising the speed up to 360 rpm (Soaking Speed):

1) Drum level should be -100 mm.
2) Ensure all SLC & pump selection are in ‘ON’ condition.
3) Inform all concern persons about TG rolling (EMD/TMD/C&I).
4) Ensure turbine evacuation valve to condenser is in closed condition.
5) Put “360” rpm in rpm ref in EHTC page and check that turbine speed is rising. DN/DT is ok.
6) Check that TG barring gear is stopped at 240 rpm otherwise stop it manually.
7) Observe MOT oil level is rise after barring gear stopped.
8) Check all bearing vibration & other turbovisory parameters are within permissible range. If not trip the
turbine and search the cause.
9) Check the TSE margin is > 30k
10) Check drains are operating as per SLC logic. Temp. is in increasing trend.

Raising the speed up to 3000 rpm:

1) Ensure Primary water cooler, H2 cooler & Exciter cooler are charged.
2) Start 2nd set of ID & FD Fan.
3) Start one PA fan.
4) Start one seal air Fan.
5) Keep PA header pressure > 750mmwc. // around 800 mmwcl//

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 SINGARENI THERMAL POWER PLANT
2X 600 MW POWER PLANT
SOP FOR COLD START UP

6) Line up for one mill (Lowest Elev possible)

7) Start one mill & keep it in warm-up condition
8) Check all mill conditions and keep other mills ready for start.
9) Ensure Temp curves X6 criteria is satisfied.
10) Start rolling the turbine by giving speed reference to ‘3000 rpm’ and check turbine speed is rising.
11) Observe JOP is cut off at 540 rpm.
12) Observe AOP is cut off at 2850 rpm otherwise stop it manually.
13) Check all bearing vibration& other turbovisory parameters are within permissible range. If not trip the
turbine and search the cause.
14) Check turbine oil system, seal oil system, Hydrogen and primary water system for any abnormality.
15) If everything ok, Start the running mill feeder and keep running mill on min loading.

Synchronization of the unit/loading of the unit:

1) In EHTC page load ref. 50 -60 MW.

2) In EHTC page Pr. max 80-100 MW.
3) In EHTC page starting/speeder gear 100%.
4) In EHTC page HP/IP trimming device is trimmed. // Trimming device in OFF position//
5) Check the X7 criteria are satisfied.
6) Take clearance from Elect dept for Sync.
7) Inform the switch yard and SLDC.
8) Close all the isolator for GEN main breaker and TIE breaker.
9) Close the field breaker from “Gen & 400KV“ graphics page
10) Select the excitation channel to be kept in AUTO (channel-1 or Channel-2).
11) Switch ‘ON’ the Excitation system and check voltage building across the generator terminal up to 21KV.
12) Select GT breaker to be sync.
13) Switch ‘ON’ the synchroscope.
14) The speed of the needle in synchroscope will indicate the “FAST” or “SLOW” speed of generator. So,
increase or decrease the TG speed accordingly so that rotation of needle becomes slow.
15) Close GCB manually to synchronize the unit. // Auto Synchroniser//
16) Observe that unit load is reached up to 50-60 MW.
17) Switch “OFF” the synchroscope.
18) Ensure “LOAD CONTROL ON” is being displayed in EHTC page.
19) Enter load gradient value up to 10 MW.
20) Increase the load reference to increase the load.

CROSS REFERENCE: All Manual

RECORDS: The records are maintained in field log book and in CCR log book .

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