DB POWER LIMITED, RAIGARH
2 X 600 MW Power Plant
DB / SOP / WS
SOP FOR WARM START-UP
Issue Date: Revision Date:
Issue No: Revision: 00 File no: Page 1 of 6
06/12/2013
WORK INSTRUCTIONS
FOR
WARM STARTUP
[DB / SOP / WS]
Reviewed by: Approved by:
Prepared by: Signature: Signature:
FEEDBACK POWER O&M Name: P. K. SAHA Name:
Designation: HOD Operations, DBPL Designation:
DB POWER LIMITED, RAIGARH
2 X 600 MW Power Plant
DB / SOP / WS
SOP FOR WARM START-UP
Issue Date: Revision Date:
Issue No: Revision: 00 File no: Page 2 of 6
06/12/2013
Amendment Record
Amendment Amendment Nature of Change ACK No.
Date
Rev Page
No. No.
Reviewed by: Approved by:
Prepared by: Signature: Signature:
FEEDBACK POWER O&M Name: P. K. SAHA Name:
Designation: HOD Operations, DBPL Designation:
DB POWER LIMITED, RAIGARH
2 X 600 MW Power Plant
DB / SOP / WS
SOP FOR WARM START-UP
Issue Date: Revision Date:
Issue No: Revision: 00 File no: Page 3 of 6
06/12/2013
1.0 Purpose:
This Procedure is intended to provide guidance for Warm Startup.
2.0 Responsibility:
1. All the personnel involved in carrying out /supervising the above activities are required to ensure
implementation of this procedure.
2. In the event of any changes required in the procedure such changes may be requested with Site
in charge, who would take appropriate action with approval from respective departmental heads
Warm Startup:
When the Turbine metal temp is more than 150⁰C and less than 350⁰C., the boiler light up is so
adjusted that the main steam temperature is at least 50⁰C more than the metal temperature.
Accordingly the boiler firing is to be adjusted and the required mills are taken into service. In this
case also as in hot start up the drains are opened just before the rolling is begun.
The procedure in line with cold start-up up to synchronisation is to be followed. The only difference
is that the boiler is boxed up at certain pressure and temperature based on time completed after
boxing up.
From the noted pressure and temperature the parameters of boiler are raised to meet the turbine
condition following the procedure described in cold start up and activities are continued till
synchronisation.
Since the load is to be raised immediately after synchronization, the mill readiness should be
confirmed before rolling. During loading and subsequent rising of the load, the turbovisory
parameters should be closely monitored.
4) SAFETY CHECKS:
1. All Work permits have been cancelled & Men and Materials have been cleared.
2. CO2 system for firefighting is ready at suitable places.
3. Firefighting system (deluge etc.) is ready for the, transformer and Main lube oil tank.
4. All air pre-heaters fire water is charged up to the last valve.
5. PPE should be worn in local area during Boiler light up.
6. All the steam turbine And Boiler auto protections are in service, as they take care for
men & machine (e.g. over speed protection).
Reviewed by: Approved by:
Prepared by: Signature: Signature:
FEEDBACK POWER O&M Name: P. K. SAHA Name:
Designation: HOD Operations, DBPL Designation:
DB POWER LIMITED, RAIGARH
2 X 600 MW Power Plant
DB / SOP / WS
SOP FOR WARM START-UP
Issue Date: Revision Date:
Issue No: Revision: 00 File no: Page 4 of 6
06/12/2013
5) WARM START-UP CHECK LIST:
1. All ducts cleared and manholes closed.
2. All works on pressure parts completed & boxed up.
3. Unit Switch gear, station Switch gear and Auxillary Switch gear should be in charged condition
and all drives power supply should be normal.
4. All equipment checklist should be filled by field Engineers and signed by Desk Engineer/Unit
Controller
5. All available oil guns are flushed checked for any leakage cleaned and clamped
6. All LRSBs are retracted fully.
7. All instruments related to APHs and boiler and all auxiliaries is working.
8. All protections & interlocks of boiler (Furnace Safeguard Supervisory System FSSS) are checked &
kept in service.
9. All alarms set as per the design, tested and kept in service.
10. APH soot blowers are cleared for operation.
11. Bottom ash hopper and seal trough are filled.
START-UP:
1. Start the air pre-heaters of both the passes one by one and keep the associated dampers
open. (Check interlock for AC/ DC APH starting) and put DC APH as auto standby.
2. Boiler is filled up to the normal level and Keep the two CC Pumps in service.
3. Start the scanner fan (Check Interlock for other fan starting) and keep it in service. Keep the
other fan as auto standby. Ensure that the scanner air pressure is normal.
4. Start the ID and FD Fan and maintain 30% air flow in furnace to get permissive for purging.
5. LOTV of supply and return line should be in closed condition
6. Ensure burner tilt is in horizontal position (in all corners).
7. Maintain furnace pressure in the range of normal value.
8. Drum level should be maintained normal level.
9. Ensure SADC dampers are 100% open and all purge permissive fulfilled.
10. Check CW Pumps in service & line up to NDCT is normal.
11. Check 2 ACW pumps are in service other pump available as standby on Auto.
12. Ensure Two TG DMCW PHE & One SG DMCW PHE are in service.
13. Ensure Two TG DMCW pumps are in-service and other Pump is available as standby on Auto.
14. Ensure One SG DMCW pump in service and other Pump is available as standby on Auto
15. Ensure AC Seal Oil Pump is in service and maintain the H2 pressure > 4.0 KSC with purity
>98%.
16. Ensure TG is on barring with AOP, JOP and OVEF in service Check Lube oil temp. Control
valve in auto & temp is maintained at 45 0C. Ensure Lub oil /Jacking Oil filters are clean.
Reviewed by: Approved by:
Prepared by: Signature: Signature:
FEEDBACK POWER O&M Name: P. K. SAHA Name:
Designation: HOD Operations, DBPL Designation:
DB POWER LIMITED, RAIGARH
2 X 600 MW Power Plant
DB / SOP / WS
SOP FOR WARM START-UP
Issue Date: Revision Date:
Issue No: Revision: 00 File no: Page 5 of 6
06/12/2013
17. One CEP is in service and kept in recirculation after filling the Deaerator.
18. MD BFP is in service and kept in recirculation after filling drum level to the normal level.
19. Both TD BFP’s are on turning gear.
20. Keep SH/RH attemperation block valves closed & lined up from all 3 BFP 's
21. Turbine side all drains manual valves are open , All UFT drains are open initially to flush
the lines outside & then take them into Condenser.
22. Ensure all atmospheric drains connected to vacuum system are closed. Lines to condenser are
lined up.
23. Ensure all coolers are in charged condition, Lub oil, CF Cooler, TDBFP A/B Cooler, H2 coolers,
Seal oil coolers, PW coolers.
24. HP bypass OSU are healthy. Warm up line valves are open. Spray lined Up from BFP
Discharge Header.
25. LP bypass warm up valves are open, Spray lined up.
26. Check LP Dosing chemical dosing system available.
27. Ensure Primary Water system and its parameters are normal, Alkalyser Unit in service.
BOILER LIGHT-UP:
1. Start the furnace purging cycle of 300 secs.
2. On completion of purge (‘PURGE COMPLETE’), MFT gets reset.
3. Open the LOTV of both supply and return line to ensure Recirculation in service.
4. Adjust opening of SADC damper to maintain furnace to wind box DP.
5. Maintain the LDO header pressure.
6. During warm start-up (AB) elevation LDO burners is to be taken in to service. take any two
corner (1-3,2-4) gun pair in service
7. Ensure the auxiliary air dampers of the respective LDO burners are in service
8. Give start command to the selected burner. It is preferable to start one burner at a time, by
monitoring its performance at local. Check and ensure the flame of burner and in case of
poor flame or a leak, take out the burner immediately. Identify the cause and attend it.
9. After boiler light up informed DM plant to maintain water chemistry
10. Rotate the LDO burners of each corners to ensure uniform Boiler heating and expansion.
11. Check the chimney exit. If excessive black smoke is observed, adjust air flow.
12. Start Air pre heater soot blowers keep continuous soot blowing of APH till guns are in service
13. Check bottom ash hopper overflow for any trace of oil.
14. Maintain drum level within normal limits. Keep Economiser recirculation Valve open till
continuous FW flow is established through the Economiser to Boiler Drum.
15. At a drum pressure of 2 kg/cm2 close all vents except Start up vent and at 5 kg/cm2 close all
drains except drain after Final super heater (it will be close after MSSV has opened).
Reviewed by: Approved by:
Prepared by: Signature: Signature:
FEEDBACK POWER O&M Name: P. K. SAHA Name:
Designation: HOD Operations, DBPL Designation:
DB POWER LIMITED, RAIGARH
2 X 600 MW Power Plant
DB / SOP / WS
SOP FOR WARM START-UP
Issue Date: Revision Date:
Issue No: Revision: 00 File no: Page 6 of 6
06/12/2013
16. Informed DM plant to maintain water chemistry and take clearance for TG rolling
17. At Boiler pressure 7-8 kg/cm2 Start 3rd CC pump if not in service earlier, take additional
guns in CD elevation and slowly charge the MS line.
MAIN STEAM LINE CHARGING:
1. MS line header turbine side atmospheric drains are already in open condition.
2. Ensure PRDS and Gland Steam header line drains are in open condition.
3. Slowly Open the Boiler Stop valve and Charge the PRDS line.
4. Through the PRDS line maintain the Gland steam header pressure 250mmwc and
Temperature >200 deg C.
5. MS, CRH, HRH, lines get warm up , close the atmospheric drains after sufficient warm up is
experienced.
6. Once the Pressure Builds up in MS line, Open MS stop valves and Check MS Pressure &
temperature.
7. Before Vacuum pulling ensure that RH vents are closed.
8. Start GSC fan, Close Vacuum breaker with ensuring proper water sealing.
9. Start the both Vacuum Pump and when the Vacuum reaches to -0.2 KSC charge the Gland
steam to turbines.
10. If Gland sealing pressure is not sufficient with Auxiliary header then charge sealing from MS
to Gland sealing header.
11. When the Vacuum reaches to -0.82KSC, Ensure HP Bypass line drains are open and its
manual valves are open.
12. Start CF Oil pump and keep standby pump in auto mode. Start CF oil circulation pump.
13. Ensure exhaust hood spray manual isolation valve in open condition.
14. Ensure that Attemperation CV and SOV open and open third Attemperation MOV and SOV
Open LP bypass valves >12 %
15. Ensure drain after and before HPBP is in open condition. Attemperation line for HPBP control
v/v is charged. open HPBP to 5 %
16. Open MSSV bypass valve and after sufficient warming up open MSSV and close its bypass
valve, and regulate HP LP Bypass Valves to control the pressure and temperature.( Maintain
LPBP temp. Below 120Deg C and HPBP below 360 Deg.C Temp. to avoid fast closing LPBP
and HPBP).
17. Close Start up vent of super heater and reheater.
The procedure in line with cold start-up upto synchronisation is to be followed.
Reviewed by: Approved by:
Prepared by: Signature: Signature:
FEEDBACK POWER O&M Name: P. K. SAHA Name:
Designation: HOD Operations, DBPL Designation:
