STG-II 660 MW COLD/WARM/HOT START UP CHECKLIST

UNIT- DATE: ______________

SLNO Description Status

1 Clearance received from all Maintenance Department
2 Ensure all PTW’s closed, ,
3 All peepholes and manholes are closed condition
4 Ensure all necessary clearance recorded for BLU
5 Fire tender informed & ensured its presence at BOILER/TG 0m

TYPE OF ROLLING FOR BOILER FOR TURBINE MS /HRH MS /HRH

(SHAFT TEMP) PR(Ksc) TEMPERATURE
( C)
0
(0C)
COLD START UP Separator metal Temperature<1000C HPS metal temp 110/12-15 390/390 or as per TSE
& <150,IPS metal
Separator Pressure~0ksc temp<80

WARM START UP Separator metal Temperature > HPS metal temp~150 110/12-15 450/430 or as per TSE
(48Hrs) 1000C to 380
& IPS metal
Separator Pressure < 28ksc temp~80to265

HOT START UP (8Hrs) Seperator metal Temperature≥3160C HPS metal temp~380 110/15-17 540/530 or as per TSE
& to 505
Seperator Pressure≥84 ksc IPS metal temp~265
to 410
HOT START UP (2Hrs) Seperator metal Temperature≥3160C HPS metal temp~530 110/15-17 540/530 or as per TSE
& IPS metal temp~500
Seperator Pressure≥84ksc

TYPE GUNS RATE OF RATE OF PR.RISE LOAD RAMP LIMITS

OF SEQUENCE SEPERATOR PER MIN.
START TEMP RISE
COLD AB,BC,DE.. <3.7°C/MIN up Up to UP TO
to 232°C 50KSC<1.5ksc/min, 66MW~3.3MW/MIN,66MW
Above TO
<5.5°C/MIN AT 50KSC<2.5KSc/mi 265MW~6.6MW/MIN,265MW
MORE THAN n TO 660MW~13MW/MIN
232°C
WARM BC,DE <3.7 Up to UP TO 66MW~3.3MW/MIN.
DEGC/MIN 50KSC<2ksc/min, 66MW TO
Above 265MW~6.6MW/MIN,
50KSC<3KSc/min 265MW TO
660MW~13MW/MIN
HOT FG,HJ.. <5.5DEGC/MIN Up to UP TO 66MW~3.3MW/MIN,
50KSC<3ksc/min, 66MW TO
NAME SIGN.Above 265MW~6.6MW/MIN,
SHIFT
50KSC<4KSc/min 265MW TO
660MW~25MW/MIN
*For cold/warm start up, Feeder to be taken in service after synch

BOILER START UP CHECK LIST

SL.
NO.
ACTIVITIES STATUS

(1) Checking of HWL-1,HWL-2 & MEFCV/FTDT pump

a) Ensure oil level in HWL oil unit. Ensure p/p in oil unit running
b) Ensure operation of HWL-1,HWL-2 & MEFCV
c) Ensure operation of FTDT pump & its discharge v/v& recirculation valve
d) Ensure service water line up & v/v operation of spray to FTDT
(2) Opening of Vents/drain
a) Ensure SST, Evaporator O/L & Eco vents are open.
b) Ensure all SH/RH vents and drains are open. (RH drain may be kept
closed as per vacuum, to be opened before charging HP/LPBP)
c) Close bottom ring header drain, intermediate header drain ECO drain(*In
case of shut down>48hrs, clean up cycle to be done as per SOP)
(3) Charging of Aux PRDS
Charge Aux PRDS HT/LT header from other unit. Ensure other Unit
PRDS charged from MS to get desire temp~300-350°C
(4) Filling of separator level and flushing

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 a) If Boiler is drained, & shut down>48hrs, boiler clean up cycle & boiler filling to be
done as per SOP
b) Boiler filling & further activities to be done with TDBFP as per PRDS
availability
(6) Line up of Hoppers and other auxiliaries
a) Ensure all ECO hoppers & BAH are empty(Check along with AHM)
b) Fill the bottom ash hopper and hopper seal trough & ensure overflow
c) Ensure closing of Economizer hopper outlet manual gate
d) ESP hoppers' heaters, Shaft-Insulators' heaters and support insulators’
heaters are switched on 24 hours prior to light-up.
e) Ensure instrument air and Service air headers for boiler area are charged.
Maintain Service air pr. and instrument air pr. around 6.0 kg/Cm2
f) Check megger value of all fans, BRP,BFP,CEP (If equipment stopped for
>15 days & no trial run done)
g) Ensure all WB’s & LRSB’s are in retracted condition
(7) Line up of Flue Gas, Air Path
a) Open Secondary SCAPHs and Primary SCAPHs air inlet & outlet
dampers (put in local),close scaph bypass damper by 50%
b) If SCAPH not available, open SCAPH bypass damper
c) Ensure opening of all PAPH &SAPH air outlet dampers.
d) Ensure operation of all ESP pass i/l and o/l gates & Charge 3 passes.
e) Open SAPH-A&B Gas inlet gate, flue gas outlet damper
f) Close PAPH-A,B flue gas inlet/outlet damper
g) Check operation of ID-A&B I/L gate1, 2, 3, 4 & O/L gate 1, 2.
h) Open AC & DC Scanner air fan inlet dampers.
i) Open Seal air fan-A&B suction IGV.
j) Close following dampers :-
(a) CCOFA dampers, SOFA dampers
(b) All dampers of mills.
k) Ensure Secondary air dampers are open
(8) Phase-II flushing with BRP
Starting of BRP(after chemistry clearance)
a) Ensure BRP pump cavity is filled. Open Suction and discharge valve.
b) Ensure cooling water charged for BRP, note SGECW pr. at BRP inlet
c) Ensure BRP Emergency tank level is full(~1400mm) & booster p/p
available. Ensure SD-021,SD-022 operative
d) Keep MEFCV at 30%, start BRP
e) Ensure MEFCV working in auto. Note BRP current(~100A), DP~7,
Cavity temperature~38°C, Eco I/L flow~850TPH.
(9) Starting of FTDT pump(after chemistry clearance)
a) After chemistry clearance, Start FTDT and line up to condenser
b) Flushing to be continued till light up clearance from Chemistry
(10)
Starting of APH
a) Ensure fire water charged up to individual v/v of APH
b)
Ensure all APH Guide/Support Brg. & Gear box lub oil level are normal
c) Ensure lub oil coolers charged from ECW. Start guide/support brg LOP’s.

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 d) Start air motor first, then electrical motor. Observe currents are normal.
Stop air motor
e) Ensure availability of APH soot blower(elec.supply&line up from PRDS)
f) Ensure ECW charged to oil carry over probe & insert it
(12) Checking of oil levels & fans blade pitch
a) Ensure All Mills & fans lub oil tank level are normal, lub oil coolers
charged from oil & water side, take trial of Mills & fan LOP’S
b) Check blade pitch of fans, Ensure running of LOP’s during checking.
Check operation of fan gates.
(13) Checking of boiler stop v/v operation & opening of drain
a) Check Operation of Boiler stop valve and its IBV
b) Ensure the closing of Main steam Stop and bypass valves after checking
c) Ensure the opening of drains valves before Boiler Stop Valves.
(14) LDO/HFO Line Up
a) For start up with HFO p/p’s:
a)Check HFO p/p’s Recirculation valve operation INITIAL
(b) Ensure manual valve before recirculation is open HFO
(c ) Isolate LDO v/v and open HFO v/v at oil station. TANK
(d) Open HFO p/p’s r/c v/v full and take two HFO p/p’s in service. LEVEL-
(e) Gradually increase pr.~10ksc at Oil station.
b) For start up with LDO p/p’s: INITIAL
a)Check LDO p/p’s Recirculation valve operation LDO
TANK
(b) Ensure manual valve before recirculation is open LEVEL-
(c ) Isolate HFO v/v and open LDO v/v at oil station.
(d) Open LDO p/p’s r/c v/v full and take one LDO p/p in service.
(e) Gradually increase pr.~10ksc at Oil station.
c) Open manual valves on atomizing air supply line and fuel oil supply line
valve to each burner.
d) Scavenge all oil guns & check for leakages (if any)
(15) Line up all available Milling System and Ensure operation along with
C&I
1. CAG open
2. BIG and MDV open
3. Feeder inlet gate and bunker outlet gate open
4. Check Coal on belt permissive is available
5. Lub oil level normal. Take trial of Lub oil pump’s and keep one
LOP i/s
6. Check CAD and HAD ,HAG, Feeder outlate gate, seal air valve
of mill & feeder
7. Mill reject area clean & Reject gate operation normal
(16) Other Line up
a) Open feed water, boiler water, saturated steam and SH steam sample lines
isolation valves.
b) Ensure SH and RH spray water supply block valves and control valves are
closed. (both at Boiler & BFP end)
c) Ensure isolating valves of all ERVs open and ERV in auto
(17) Chemistry parameter for boiler light up
a) Take clearance from chemistry for boiler light up

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 (18) Preparation for Light up
a) Ensure RH PROTECTION NOT ARMED
b) Start AC Scanner air fan. Take trial of DC scanner air fan & stop
c) Start one ID & FD fan. Keep air flow 900-950T/Hr. Draft-10 mmwcl put
furnace pr in auto.
d) Ensure permissive and Push to purge
e) Reset and open HOTV . Open Control Valve. Maintain pr ~10 ksc at
firing floor
f) Check wind box DP 40 mmwcl (Close SOFA/COFA & put SADC in
auto)
g) Take Sec.SCAPH (from steam side)in service

TURBINE START UP CHECK LIST

(TO BE CHECKED ALONG WITH BOILER)

SL. ACTIVITIES STATUS

NO.
(1) Switchyard side checklist
a) No earth switch should be connected
b) Isolator closed
c) All switch gear charged from normal incomer
d) Ensure Main breaker Trip is reset from SCADA PC
(2) CW pass charging/ACW/ TGECW /SGECW system/PHE availability
a) Open vents (CW pass outlet vent, PHE vent, Vacuum pump ACW line
vent, SCS vent).Charge by crack open ICV. Ensure CT fans riser valves
open. After proper venting, Start CW pump
b) Start one ACW pump. Check availability of other ACW pump. Keep SCS
in auto
c) Ensure SG & TG tank levels normal, tank make up v/v operation available
d) One number TGECW p/p in service. PR. ok.Check other pump availability
e) One number SGECW p/p in service. PR. ok.Check other pump availability
f) 2 number TGPHE,one SGPHE in service

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 Turbine side oil system checklist
a) Ensure Turbine in barring, Barring speed~ RPM
b) Lub oil pr~4ksc, LOP running
c) If MOT filter chocked. Change over filter. Clean it
d) Jacking oil pressure>130 ksc
e) MOT level adequate (920 to 930mm) at turbine barring, note down level
f) MOT cooler charged, Lub oil temperature controller in auto and operation
checked.
g) All Turbine oil pumps SLC ON
h) MOT & Gen.brg. Vapour. Extractor running
i) Standby LOP,DC EOP, DCJOP,DCSOP available
(3) CF system readiness
a) CF level~(300 mm).check from local also
b) CF tank cooler charged, oil temperature controller in auto and operation
checked.
c) Check CF Pr.~160Ksc.,CF recirculation pump running
d) Ensure standby CF pump available
(4) AUX PRDS /Seal steam v/v checking
a) Operation check Aux PRDS & Seal steam line v/vAS-19,AS-20,AS-
45,AS-47,AS-38,AS-85,ASV-1,ASV-2 (After checking ensure closing of
v/v)
b) Check Seal steam station motorized & control v/v.After checking ensure
closing of v/v
(5) MDBFP/Condensate cycle/Feed water cycle normalization
a) Ensure Deaerator, Hot well level normal. Ensure line up of HW to CST &
keep excess spill CV in auto with set point ~200mm
b) Ensure LPH’s 1, 2, 3 charged from condensate side and ensure level stand
pipe normalized. Drip manual valves in open condition & drains closed
c) Check operation of both Deaerator level control valve, iso. MOV’s and
bypass line MOV. Ensure Deaerator overflow lined up
d) Charge condensate system with one CEP and ensure availability of other
CEP’s by taking trial
e) Check Megger value of MDBFP(if started after 15 days) Take trial of
MDBFP on R/C.
f) Charge HPH’s from feed water side with proper venting and ensure level
stand pipe normalized. Drip manual valves in open condition & drains
closed
g) Ensure line up & operation of low & high range FRS valves
(6) Opening Of drains
a) All Turbine drains manual & motorized Isolating valves are open.
(Extraction line drain, MAL drain, MS, CRH/HRH line drains to UFT/FT.)
Open UFT spray (from service water) line manual valve upto 50%.
b) Open LPBP line drain and LPBP warm up drain, HPBP warm up line drain
c) Operation checking to be done for HPBP warm up line-motorized valve,
After checking ensure opening of manual valve and closing of MOV
d) Open CRH drain manual v/v to atmosphere(in case of cold/warm rolling)
e) Open Seal steam drain at 8.5 mtr
f) Ensure closing HPBP spray manual vv, SH/RH spray manual v/v/’s
(7) Vacuum pulling

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 a) Check line up of Vacuum pumps
a) separator tank level adequate
b) Cooler ACW v/v open
c) Vacuum p/p suction manual v/v open
d)Ensure water level in Vacuum p/p casing body
b) Start Vacuum pump and close Vacuum breaker. Charge seal steam at
vacuum~0.7ksc.Start GSC fan.
c) To improve vacuum, close HRH vents.To be opened just after charging
HPBP
(8) TDBFP normalization
a) TDBFP-A,B in barring .(normalized from Feed water side)
b) TDBFP-A&B Tank levels ok, Coolers charged, Lub oil temp.CV in auto
and operation checked
c) TDBFP-A,B exhaust v/v is in open and put in local mode
d) TDBFP IP extraction manual valve open
(9) Generator system normalization
a) Primary water : tank level / N2 pr. / Conductivity
( >260mm / 0.3ksc / Approx. 2 μmho/cm )
b) Cold Gas cooler, Exciter, PW cooler, Seal oil cooling water manual
isolating valves in open condition.
c) Primary water Winding & Bushing flow normal
d) P.W. & H2 Gas cooler temperature. controller operative and in Auto.
(operation checking to be done)
e) H2 pr. in generator adequate (4.8ksc),Purity>98%
f) One PW Pump running, SLC ON, standby PW pump available
g) One SOP running, SLC ON, Gen. brg. Vapour. Extractor & Seal oil
vacuum pump are running & vacuum is normal, Ensure DCSOP available
h) Ensure Seal oil pressure / DP normal, seal oil & IOT level normal,seal oil
temp. normal
i) G.T. fans supply is available from both sources.
j) H2 drier supply normalized. Open gas inlet/outlet valve. (However drier
will take start after synchronization)
k) Generator 400KV breaker isolators closed, earth switch open
l) Ensure Main breaker Trip is reset from SCADA PC
(1) BOILER LIGHT UP
a) Start APH soot blowing with steam form Aux PRDS
b) Take AB elevation guns. Keep 4 guns in service up to 1.5Ksc of separator
pressure.
c) Close separator vent after steaming (~1.5ksc). Take BC elevation 2guns.
d) During Boiler cold start up MS ERV blowing at 10ksc for 2min. to be done
before opening MS stop vv(both ERV at a time)
e) After ERV blowing open Boiler stop valve IBV’s & HPBP warm up vv’s
f) Wait for Turbine inlet Pr. to come near Boiler outlet Pr. Then Open MS
stop vv’s , open HPBP vv’s gradually to 15%
g) Ensure opening of HRH vents & CRH atmospheric drain
h) If ERV blowing not there, Open Boiler stop valve IBV at 2 Ksc & HPBP
warm up vv’s & Boiler stop valve at 3-5 ksc. Observe rise in MS line drain
temperatures
i) Close Drain v/v’s after MS stop v/v(MS-401,402)

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 j) Close all SH vents at 12ksc separator pressure except Startup vents &
drains
k) Ensure CRH NRV closed. At MS pr~5 to 7ksc, Gradually open
HPBP~15% and watch increase in down stream temp. Maintain HPBP at
this position till MS pr.15ksc. Ensure CRH atmospheric drain open.
l) Check no speed rise of TG and 5st stage Pr. after charging HPbypass,
which may be a indication of passing of CRH NRV. Ensure closing of
HPBP warmup v/v
m) Start 2nd CEP,Open LPBP stop v/v and keep CV’s at 0% till HRH pr~5ksc.
Then open 8% and maintain till HRH pr~8ksc.Then increased manually
and regulate CV till 12ksc, then keep in auto. Ensure Water injection of
LPBP always in auto
n) Close CRH atmospheric drain v/v after steaming
o) After HP/LPBP charging, take BC elevation 2 more guns.
p) After ensuring adequate flow through HPLP bypass, (HP/LPBP~10%),
Close SH/RH start up vents& drains (except back pass lower front & rear
header drains, To be closed gradually after all SH/RH metal
temp>saturation temp.)
q) At MS pr.~20ksc, Close MS line drain 624L/R, BPV 101/102 and close its
manual valve. HRH line drain 624L/R to be closed at HRH pr.~8ksc
r) Slowly increase HRH pr. up to 18ksc with ramp rate <2ksc/min & LPBP
range 10% to 30%.Maintain HRH pr~18ksc(LPBP range 30% to 40%)
s) Keep close watch on all SH & RH MTMs. Rate of rise<3.7°C/min.
t) Control the firing rate to keep the maximum furnace exit gas temperature
below 593°C (FSH inlet FG inlet temperature) until adequate flow
(BLI~10%MCR) through HP/LP bypass stablished
u) At MS Pr~20ksc, take DE elevation 2guns and observe rate of pr. and
temp. rise within limits(1.5ksc/min, 3.7°C/min.)
v) Open HPBP spray manual v/v at downstream temp~290°C
w) Regulate HPBP from 15% to 45% till 108ksc within ramp rate 1.5ksc/min.
Maintain 108ksc with HPBP 45% to 60% range.
x) In case of Cold start up,At MS pr 60ksc,Blow MS ERV & HRH
ERV(@HRH12ksc)for 5min.each.3 cycles to be done.
y) Gradually take oil guns in FG & HJ elevation for further requirement for
Pr.&Temp.
z) Ensure LPBP in auto with CV opening around 20% to cater the
disturbance in HRH pressure during HPBP sudden opening to 100%
Zi) In case of Cold start up, 3 cycles of HPBP sudden opening to 100% at MS
pr.80ksc to be done
Zii) Ensure Separator level control in auto with setpoint 4.5m to cater level
disturbance during HPBP sudden opening cycle
Ziii) Ensure HPBP opening~50%. Open both HPBP to 100% and bring down to
55% again. Repeat the cycle for two more times.
Ziv) After Overhaul, while the unit is heating up, frequent checks should be
made of the boiler expansion movements in all elevation.
Zv) Keep checking OCP’s of AHP’s every hour, if any oil deposition adjust air
flow/SADC
(2) Readiness of Mills(Activity Start@MS~70ksc)
a) Open two mills Cold air damper .Start PA fan & charge Primary SCAPH.

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 b) Ensure opening of PAPH flue gas inlet gate in auto. Open PAPH Flue gas
outlet damper gradually (keep watch on PAPH current)
c) Following Mills to be taken (after synch.in case of cold/warm start up):-
For cold start up Mill-B or A to be taken.
-For warm start up Mill-C or D to be taken
-For Hot start up Mill-H or J
(3) TURBINE STOP VALVE OPENING & ROLLING
a) Take clearance from chemistry before Turbine stop valve opening
b) Ensure all class-A protections reset in GRP
c) All temperature criterions (X-criterion) must be satisfied before for
opening SV. MS temperature greater than 50°C of HP shaft temperature &
separator pressure~75ksc
d) Ensure BOP ready healthy
a) MS saturated & superheated with pr.-temp curve (50°C superheat>5min)
b) HRH saturated & superheated with pr. temp curve (50°C
superheat>5min)
c) Boiler MS stop valve-L&R open
d) HP&LP bypass ready for operation
e) Drain/warmup valves open- MS-426&427, BPV-101&102, HRH-624
L&R
e) Ensure Circulation & closed cooling water system OK healthy
a) 2 TGECW pumps running with discharge valve open
b) 2 ACW pump running with discharge valve open
f) Ensure SLC Drains & SLC Extraction ON
g) Ensure Generator casing H2 pr.>4.70ksc
h) X5 criteria forcing (‘0’ value) to be done by C&I to avoid rolling of
turbine after opening of Stop v/v’s.
i) Ensure Load output mode is in Load controller (2) instead of speed
controller(1) in Turbine controller page
j) SGC Turbine mode selection to be done as “Auto” and not “Semi Auto”.
k) All SGC’s/ SLC has to be ensure to be “ON” prior to start of SGC rolling
l) Ensure ATT mode selected for the Valves before start of SGC rolling
m) During rolling, All steps/feedbacks to be monitored in MAXDNA for
quick identification if fault occur in any step.
n) Prior to Step-8 SGC oil pumps check, DCEOP to be started once and
stopped to avoid delay in “ON” feedback during oil pumps check
o) Ensure in step-8, SGC oil check pumps is normal. Steam purity to be
provided at SGC turbine step no.11
p) After stop v/v open status came, close MS/HRH line warm up line MOV’s-
426/427,606/607 & its manual valve.
q) Ensure Class-B relays reset in GRP & 400kv Main breaker Trip is reset
from SCADA PC after Stop v/v’s opening
r) Note down if any raise in Speed after opening of SV’s
(4) ROLLING TO 860 RPM
a) Increase Boiler parameters to meet TG rolling criterion separator pressure:
~110ksc and MS temperature at HPT inlet as per the TG shaft temperature
criterion. Ensure BLI 10%.
b) Ensure HPBP in auto with setpoint also in auto in MAX & tracking from
ALSTOM pressure set point

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 c) ESV’s & IV’s opening confirmed from local before speed raising.
d) After X5 criteria available, it shall be unforced for rolling up-to 860rpm
e) Ensure closing of Barring solenoid v/v at 180rpm, Stopping of JOP at
540RPM. After stopping JOP, ensure barring solenoid opens again
f) At 860 rpm, change load set point in Siemens PC to 70MW and Maximum
Load set point to 200MW
g) Hold for 30min at 860rpm or as per the TG margin (should be greater than
>30deg)
h) All turbo visiory parameter to be observed & recorded
(5) ROLLING TO 3000 RPM
a) Ensure RGMO Off. & frequency influence band to be increase to 50.30Hz
from existing 50.03Hz & to 49.60Hz from 49.85Hz to avoid unwanted
machine unloading/loading after synchronizing
b) When all X curve permissive available release nominal speed 3000RPM
(Ensure BLI~15%)
c) TSI parameters are within limit during critical speed of turbine
d) Turbine drainage system operated as per interlocks
e) Lub oil, seal oil, C.F. temperatures are within limit
f) P.W., Cold gas, Exciter air temperature. are within limit
g) P.W., Cold gas, lub oil & C.F. temperature controllers are in auto
h) MOT level adequate at 3000 rpm
i) Confirm MOT filter % choke and do change over
j) Turbine brg. Temperature are normal and steady after rolling
k) All turbovisiory parameter to be observed & recorded
(6) JUST BEFORE SYNCHRONIZATION
(a) Ensure atleast 2 Mills/Feeders are ready to be kept in service after synch.
(for cold & warm start ups)
(b) Ensure operator entered Unit capability>capability as per auxiliaries
(c ) Start 2nd CW pump also and open ICV and keep 5th CW pump common
stand by
(d) Ensure Line and bus isolators closed.
(e) Generator 400KV breaker isolators closed, earth switch open
(f) Ensure 400kv Main breaker Trip is reset from SCADA PC
(g) Give release for Excitation system, it will ON in auto through SGC
(h) Ensure Field breaker ON and excitation ON. Note down Generator
voltage, Field current, Excitation current & voltage & MVAR
(i) Excitation both channels are healthy and changeover is taking place by
actually changing over the channels before synchronization(every 3
months of last such check)
(j) G.T. fans and oil pumps are running to be ensured from local. Ensure no
alarm of cooler trouble is coming.
(k) Select Main breaker & Keep auto synchronizer On
(l) Unit will synchronize with block load. Close Tie breaker.
(7) JUST AFTER SYNCHRONIZATION
a) Ensure Block load is taken by Turbine and value available on facia in LVS
b) As soon as machine is synchronized take adequate load and if fault during
synchronization is observed- press “master Setpoint Release”
c) If block load not coming, check for HP/IPCV’s and Machine shall be in
Limit pressure mode

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 d) If machine came in initial Pr. mode, ensure Throttle Pressure set
point<Actual throttle pressure to release the valves
e) Keep watching HP wet steam monitoring alarm, it may restrict load set
point if HP exhaust steam temp is near saturation temp
f) Before closing of HP/LPBP, Check RH protection normal .HP/LP bypass
will close gradually in auto (keep watch on HP pressure ratio).
g) As soon as HPBP closed, Machine will come to initial pr. mode. Ensure
throttle pressure set point is near actual pressure. Ensure SGC start up at
step 35 & made it off after confirmation from C&I
h) Ensure HPBP & LPBP in Auto
i) Ensure closing of all TG side drains as per SLC.
j) Once after Synch., ensure Auto Synch Release is Deselected
k) Charge LPH, D/A extraction(Close deaerator pegging slowly) and TDBFP
extraction valve.
l) Watch all alarms & Turbine & generator parameters are normal
m) At 120 MW changeover to be done from Station to UT
n) Ensure no drop in MS pr./Temp. during load raising. Check TSE margins
and monitor for no alarm of HP/IP wet steam.
o) Ensure H2 drier came into service. No oil in LLD (ensure from local)
l) MDBFP rated flow is 813 TPH. As feed water flow increases, another BFP
shall be loaded and put in auto.

(8) LOAD RAISING UP TO 40% AND CHANGE OVER TO DRY

MODE
a) Keep CT fans in service gradually (CW inlet temp should be<33C°)
b) Charge HPH’s at around 150-200MW.
c) Gradually increase firing rate by taking more feeders in service. Strict
monitoring of fuel to feed water ratio especially up to 42% BMCR feed
water flow at HPH outlet(0.8 to 1.2)
d) Monitor all max. MTMs. Firing rate shall be reduce in case of increase in
MTM.
e) Mode of operation should be initial pressure control from Block load to
40% load.
f) Degree of Super heat at separator outlet should not exceed 20°C prior to
change over from wet to dry mode
g) At BLI 40 % auto open command is issued to FDV16A/FDV16B. Keep
one valve (FDV16 or16B) in maintenance. FRS changeover shall be done
in auto. After opening of one 50% valve, ensuring no disturbance in feed
water flow and second 50% valve shall be opened.
h) Charge SH spray line by monitoring MS temperature & gradually increase
MS temperature as per TSE margins of main turbine.
i) Between 50% and 100% load, MS and RH temperature deviations should
be within +- 50°C from working temperature

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 j) Maximum limit for FW demand from separator level control is 848tph. As
feed water demand reaches 848tph, ensure changeover of FW demand
from separator level control to Boiler Master control. In case of delay in
changeover, fuel to be added only by strict monitoring of MTMs. (Note:
FW bias is effective only if bias flow+FW demand from Boiler
master>demand from separator level control)
k) Gradually take more Mills, increase load observing margin, MS/HRH
temp. & Metal temp.
l) After Unit c/o to dry mode, Throttle pr set point will start coming from
sliding set point. Manually increase pr. set point near actual pr before
keeping it in auto.
m) At BLI>45%& separator level<3m, it is expected other requisites for dry
mode will be satisfied and changeover to dry mode happens
n) To reduce separator level, wet keg CV to be open & keep in auto
o) At unit load >40% second TDBFP shall be rolled and put in auto (after
soaking)
p) Ensure line up of spray from TDBFP’s before unloading MDBFP
q) Ensure closing of TDBFP’s exhaust hood spray bypass v/v’s if opened
earlier
(9) JUST BEFORE OIL SUPPORT IS WITHDRAWN (>55 % OF THE
LOAD)
a) Check all the flame scanners sensing flame. Slowly withdraw the guns
b) Stop APH Soot blowing .Ensure removal of OCP’s from all APH
c) Charge ESP fields after ensuring APH FG o/l temp.>110°C
d) Keep SCAPH i/s as per load and Mill o/l temp or else open scaph bypass
e) Mill rejects removal is in progress and bottom ashing is normal. Ensure
eco hoppers gates open.
f) Check all the level controllers like Hotwell/ Deaerator,PW,CF , L.O,Cold
Gas temp. are on auto
g) All the HP heaters are in service ,PW,Cold gas, Seal oil temp.normal
h) All Mills,APH, fans Lube oil pressures are O.K.
i) Both TDBFPs are in service and on auto above 300MW
j) Check all protections in service
k) Gradually increase unit load and MS pressure to put machine in CMC after
dry mode achieved.
l) Between 50% and 100% load, MS and RH temperature deviations should
be within +- 50°C from working temperature
m) Take local round & check for any oil leakages, passing through high
energy drains & vents,safety valves etc
n) Supply to be made off as per identified list of critical valves

NAME SIGN. SHIFT

 START UP TIMINGS
Timing of Different activities
Activity Time Remarks/Defects
PRDS charging
Vacuum Pulling
Boiler filling start&
end
Boiler hot flushing
start & end
Chemistry clearance
for BRP running
BRP Start Time
Chemistry clearance
for Boiler light up
Starting of Fans
Boiler purging start
& end
Boiler Light-up
MS line Charging
HP-LPBP Charging
Oil guns timing

NAME SIGN. SHIFT

 Mills timing

Chemistry clearance
for TG Rolling
Opening of HP&IP
Stop valves
Rolling to 860RPM
Soaking time at
860RPM
Rolling to 3000 RPM
Soaking time at
3000RPM
Unit Synchronization
Unit Wet to Dry c/o
Unit at Techmin load
Oil guns withdrawn

START UP PARAMETERS
PARAMETERS UNIT Before Before At At After At At
S.N
light up rolling 860RPM 3000RPM Synch. 350MW 660MW
1. Separator Pressure Ksc
2. Separator level mm
3. SH Metal temp. (max.) 0
C
4. RH Metal temp. (max.) 0
C
5. Main Steam Pressure Ksc
6. Main Steam Temp. 0
C
7. CRH pressure Ksc
8. CRH Temperature 0
C
9. HRH Steam Pr. Ksc
10. HRH Steam Temp. 0
C
11. Condenser Vacuum mmHg
12. Barring Speed RPM
13. Boiler Water pH -----
14. Boiler Water Silica ppb
15. Boiler Water Fe ppb
16. Boiler water conductivity µmho
17. MS pH ppb
18. MS Si ppb
19. MS ACC µmho
20. MS sodium ppb
21. CPU in service / Flow m3/hr
22. Turbine Axial shift mm

NAME SIGN. SHIFT

 23. HPT Diff Expansion mm
LP Turbine Diff mm
24.
Expansion
HPT top/bottom 0
C
25.
differential temp
IPT top/bottom differential 0
C
26.
temp.
27. HP pressure ratio -
28. MSV Ti/Tm 0
C
29. MCV Ti/Tm 0
C
30. HPT Shaft Temp.( Ti/Tm) 0
C
31. IPT shaft Temp. (Ti/Tm) 0
C
32. HPT exhaust temp 0
C
33. LPT exhaust temp 0
C
34. Gland seal steam press mbar
35. Gland seal steam temp 0
C
36. MOT level mm
37. Lub oil temp after cooler 0
C
38. Lub oil pr. bar
39. Cold gas temp./CV auto 0
C
40. Seal oil temp. 0
C
41. CF Pressure bar
42. CF temp. 0
C
43. Hydrogen Pressure ksc
44. Hydrogen purity %
45. Stator water conductivity µmho
46. Stator wtr flow wdg/bush. M3/hr
Stator water temp 0
C
47.
(in/out)/CV auto
TG brg Temp.(1,2, 3,4 ) 0
C
48.

TG Thrust bearing temp 0

C
49.

TG bearing Temp. ( 5,6,7 ) 0

C
50.

TG bearing Vibration mm/s

(1,2,3,4,5,6,7)
51.

TG Shaft Vibration mic.

( 1,2,3,4,5,6,7 )
52.

53. Gen.End Wdg vibrations mic.

54. Gen volt/current / MVAR Kv
55. Exc current / Voltage A/V
56. Gen.Field current A
57. GT wind. Temp( R,Y,B ) 0
C

NAME SIGN. SHIFT

 660MW SHUTDOWN CHECKLIST (STAGE-II)
UNIT- DATE&TIME:

Reason of Shut down-

Sl.No DESCRIPTION STATUS

1 Open seal steam manual drain at 8.5 mtr
2 Maintain seal steam temperature >300°C.If required charge PRDS from Unit MS if
available or charge from other Units
3 Ensure all mal drains & strainer drains manual isolating valves are open.
4 Keep COLTCS in collection(if in injection mode)
5 Gradually reduce load to 400MW. Maintain MS/HRH steam temperature.
6 Take machine out of CMC when load reaches 400MW& take oil gun in one elevation
(where feeder is running)
7 Take 5th feeder out of service. ensure all running feeder coal flow >50%
8 Check both TDBFP barring gear valve supply is in normalized condition
9 At 400MW load Take one MDBFP, put in auto & unload one TDBFP.
10 Put 2nd standby MDBFP in manual.
11 Trip unloaded TDBFP and close its CRH block v/v. Ensure it came on barring with JOP
i/s. After tripping of TDBFP put standby MDBFP in auto.
12 Gradually reduce coal feeding & Do UT to ST change over at ~350MW.
13 Start BRP & ensure its parameters are normal.
14 ATT of the v/v’s to be done if last done date is>1month

NAME SIGN. SHIFT

 15 Gradually stop 4th&3rd Mill. Reduce load to 275 MW (Ensure Eco flow.normal)
16 Inform chemistry for taking out Unit from OT
17. Keep COLTCS in collection
18 At around 275MW with 2 Mills & oil gun in one elevation-open HP&LP bypass manually.
Gradually stop Mills one by one after ensuring its emptiness. Bring the Sep.Pr.110KSc and
Unit load 100MW & hand trip the Boiler.
19 After Boiler Trip ensure following-All Mills & Feeders trip, HOTV and all HONVs close,
No scanner sensing flame, all Mills HAG close, Both PA fans and seal air fan trips
20 Open Safe shut down status mimic and observe all drives are tripped as per procedure and
parameters are normal
21 Ensure closing of PAPH FG i/l gates on PA fan tripping, otherwise close manually or
close FG o/l dampers
22 Stop one set of ID/FD and ensure air flow 800 TPH with other set of fans & Purge boiler
23 Keep only 3 ESP passes in service during running duration of ID/FD fans
24 Close HP & LP bypass after depressurization of Reheater.
25 Blow MS ERVs at MS Pr.~60ksc & HRH ERV at 10-15ksc for 5min.
26 Operate WWSB/LRSB as per boiler cooling procedure in case of BTL
27 Close LDO station manual isolating v/v, all elevations oil manual v/v’s and Boiler side
SH/RH spray manual v/v’s
28 Keep BRP running till casing temperature/water wall temp. ~93°C(or as per dry
preservation SOP) and maintain separator level>2m with intermittent running of BFP. If
BRP trips, before start ensure its casing temp. is less than saturation temp.
29 Follow boiler cooling procedure in case of BTL otherwise stop equipment’s as per
sequence if shut down more than 1day
30 Open all SH vents and drains, MS o/l drains (MS401&402) at 10ksc sep.Pr. Open
Separator vents at 5ksc(RH vents & drains to be opened immediately after vacuum killing)
31 ESP field to be made off after all fans is stopped. Watch Opacity, if high, again made
fields on for 1st two passes
32 After complete evacuation of ESP hoppers, heaters and rappers has to be taken out of
service.
33 Ensure bottom ashing once in shift till ash coming from Eco hoppers.After ensuring no
ash from Eco hoppers, close its gates.
34 Close suction& discharge valve of BRP if Boiler to be drained
35 Ensure emptying of the Mills (if any got trip while S/D)
AFTER SHUT DOWN TURBINE SIDE CHECK LIST
1 After Boiler trip ensure Turbine trip on MFT, generator trip on low forward power relay
2 Ensure Main TG all HPSV&HPCV close, all extraction block v./v close, CRH NRV close,
Opening of Generator Main breaker, Tie breaker and field breaker. Ensure stopping of GT
fans.
3 Open Safe shut down status mimic and observe all drives are tripped as per procedure and
parameters are normal
4 Ensure one TG LOP is running.
5 If running TG LOP trips ,ensure stand by LOP start in auto,If other LOP also fail to start,
Ensure EOP start in auto or start manually.
6 Ensure HPT evacuation valve opens after turbine tripped (provided condenser vacuum is
better than -0.4ksc) and closes at 2000RPM.
7 Ensure TG lub oil temp. ~50°C
8 During Turbine coasting down, observe seal steam pr. and temp. Continuously. Ensure
Seal steam Pr~35mbar and temp~280°C to 300°C
9 Ensure stopping of 2nd TDBFP. Ensure that TDBFP came into barring. Close its Normal
ext block v/v & CRH ext.block v/v.
10 Ensure JOP cut in at 510RPM or start it manually(check for leakages in MOT room & TG Time taken from
bearing area).Barring solenoid will close with JOP start and again open at 120rpm. 3000 to 510RPM-
11 Observe MOT level Drop after JOP start. (From __ to __ )
12 If DCJOP has started, ensure healthiness of DCDB(Load should be on charger & not on
Battery).Again change over to be done to ACJOP by watching disch pr.
13 Maintain Hotwell & D/A at normal level. Ensure D/A overflow v/v not opens while TG
coasting down.

NAME SIGN. SHIFT

 14 Close HPBP spray line manual isolating valve. Ensure closing of LPBP spray injection
v/v. Close all BFP’s RH spray manual v/v’s.
15 Ensure turbine barring gear solenoid open at 120RPM.Observe MOT level . (From __ Time taken from
to __ ) & drop inJOP disch. header pr.( From __ to __ ) 3000to120RPM-
16 Monitor barring speed & see it stabilizes at 60RPM with vacuum.
17 Ensure SLC-drains are on and all drain v/v operate on interlock .Ensure opening of manual
v/v of all Mal drain /MS&HRH strainer drain/Extraction drain v/v/HPLP Bypass line drain
18 Ensure Cold gas/PW temp CV maintain temp. in auto. Close Cold gas temp CV as per
requirement to maintain H2 temp~40degc & thus drop in H2 pr.
19 Monitor HPS/IPS/HPC/IPC Top/Bottom & Howell level & seal steam temperature.
20 Ensure that Generator bearing chamber and TG vapour exhauster fans are running
21 Check TG area for any oil leakage/ fire hazards
22 Fill post shut down hourly log sheet
23 Inform chemistry to cut out CPU after stopping CEP
VACUUM KILLING(IF SHUT DOWN FOR MORE THAN 1 DAY)
1 When barring speed stabilizes at 60RPM, start killing vacuum. Before killing vacuum,
ensure no sheet in vacuum breaker exhaust pipe
2 Put SLC evacuation in manual . open vacuum breaker &Stop vacuum p/p
3 At ~0.7 ksc isolate seal steam to main TG & TDBFP by closing MOV’s in PRDS
4 Stop GSC vapour exhauster
5 Isolate manual valve of seal steam line at 8.5 mtr
6 After killing vacuum, leak off steam control v/v to be kept open~10% so that any
accidental entry of condensate/moisture will drain through it
7 Close Boiler stop valve
 FOLLOW BOILER COOLING PROCEDURE IN CASE OF BTL & FILL BOILER COOLING DATA.
 FILL POST SHUT DOWN HOURLY LOG SHEET

 FOLLOW APC REDUCTION CHECKLIST FOR STOPPING OF EQUIPMENT IF SHUTDOWN >1DAY

 DO CONDENSER BOTH PASSES BACK FLUSHING IF DP WAS HIGH DURING UNIT RUNNING

 FOLLOW BOILER PRESERVATION CHECKLIST IF PRESERVATION IS PLANNED

 DO OPPORTUNITY CHANGE OVERS OF EQUIPMENTS & ENTER IN OPPORTUNITY

CHANGEOVER LOG IN ONLINE REGISTER (PW,HPCF,TG LOP,BFP LOP’S)
STG-II SHUTDOWN LOGSHEET
HOURLY PARAMETERS AFTER UNIT SHUT DOWN
UNIT- DATE-

Time------------>
Parameter
Seperator level
Dearator level
Hotwell level
Seperator pressure
MS pressure
CRH/HRH Pressure
Throttle pr.
Turbine Speed
TG Lub Oil pr.
TG Jacking oil pr.
TG Lub Oil Temp
MOT level
Generator seal oil
DP
Generator casing H2
Pr.
CF Tank level

NAME SIGN. SHIFT

Condenser vacuum
Main TG seal steam
temp
Main TG seal steam
pr.
HP casing
TOP/Bottom temp.
HP shaft temp.
IP casing Top/Bottom
temp(Front)
IP casing Top/Bottom
temp(Rear)
IP shaft temp.
HP/IP/LP rotor
expansion
HP/IP Diff.expansion
Axial shift
HP exhaust temp.
LP exhaust temp.
Max TG brg temp.
HPBP downstream
temp.
CRH temp
HPH’s Drip level
LPH’s drip level
GSC lvl switch status

STG-II BOILER COOLING DATA

UNIT- DATE-

1. MAX. RATE OF FLUID TEMP. DROP IN SUPERCRITICAL UNIT 1.7°C/MIN

2. MAX. RATE OF METAL TEMP. DROP OF SH/RH 2.7°C/MIN
RH FINISH
PLATEN SH RH-IMTM RH-IIMTM MTM
SEP. TEMP WW.METAL MTM SH-I MTM SH-II MTM (RATE < (RATE < (RATE <
<51°C/30 TEMP (RATE<75°C/ 30 (RATE<75°C/ (RATE<75°C/ 75°C/30 75°C/30 75°C/30
TIME MIN <51°C/30 MIN MIN) 30 MIN) 30 MIN) MIN) MIN) MIN)

NAME SIGN. SHIFT

 STG-II EQUIPMENT STOPPAGE SEQUENCE AFTER UNIT STOPPAGE

Unit: Date: Unit stoppage Time:

UNIT AUXILIARY TIME REMARKS/CRITERIA
TO BE STOPPED
Target Time Duration
One ID fan 15min
One FD fan 15 min
One ACW p/p 15 min Stopping based on ambient temp.&
Auxiliaries temp
One TGECW p/p 15 min Stopping based on ambient temp.&
Auxiliaries temp
One CEP 15min Monitor Hotwell level
CT fan 30 min All fans/alternate fans to be stopped as per
ambient temp.
DM make up pump 1hr Run based on DM make up requirement of
other unit
MDBFP C/D 1hr Intermittent start req. for BRP/Separator
level/Eco flow
Vacuum P/P 2hrs(Approx.) Vacuum killing after Main TG barring
stable
2nd CEP 3hrs After seal steam isolation. Observe LPT
exhaust hood temperature before CEP
stopping. CEP to be started as per water

NAME SIGN. SHIFT

 requirement in D/A. Inform chemistry to
bypass CPU
One IAC/PAC 4 hrs To be stopped based on other Unit
req./Observe I.A. pr.
2nd ID fan 5hrs(Approx.) When flue gas temperature before APH
<205°C
2nd FD fan 5hrs(Approx.) When flue gas temperature before APH
<205°C
All ESP fields 5hr(Approx.) After stopping of 2nd set ID/FD fans
1st CW pump 6hrs After 4hrs of vacuum killing. Close ICV
before stopping 1st CW pp. Ensure
COLTCS already in collection.Do
condenser both pass backflushing as per
SOP
Boiler Side LOP 6hrs After 1 hr of Fan/APH/Mill stopping.
2nd ACW p/p 8Hrs May be stopped earlier based on ambient
temp. & auxiliaries temp
BRP 14hrs (Approx.) After Evaporator/WW temp reached
~93°C.(or as per Dry preservation SOP)
2nd CW p/p 48hrs/HP casing Condenser CW inlet one side valve closed
325°C(whicheve & other side condenser inlet valve 20%
r is later) open (ensure ICV crack open & Condenser
outlet valve open).Ensure stable barring
speed & Vacuum of other running unit
ESP Rapping/heaters 24hrs(approx.) After ensuring complete evacuation of
hoppers
AC scanner air fan 24hrs(approx.) When furnace temperature <149 °C.
Ensure DC scanner fan supply off
SGECW p/p 30hrs(approx.) When BRP suction manifold temp <65°C.
Before stopping ensure BRP v/v’s from
OHT(supply&return) are tagged out

NAME SIGN. SHIFT