Unit Lightup Synchronisation & Shutdown

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Adani Power Limited Power Business Goal - 20,000 MW

ADANI POWER AT A GLANCEADANI POWER AT A GLANCE

• Power Business Goal - 20,000 MW BY 2020

• MUNDRA– 330MW X 4 + 660MW X 5

• TIRODA– 660MW X 5 (UNDER COMMISSIONING)

• KAWAI– 660MW X 2 (UNDER ERECTION)

• BITTA– 40MW BIGGEST SOLAR IN INDIA

ACHIEVEMENTSACHIEVEMENTS

• INDIA’S FIRST 66O MW SUPER CRITICAL UNIT SYNCHRONISED BY ADANI POWER LTD, MUNDRA IN OCT 2010 IN RECORD TIME OF 36 MONTHS.

• COMMISSIONED 4Nos. 660MW UNITS IN A YEAR.

• ADANI IS THE FIRST COMPANY IN INDIA TO EARN CARBON CREDIT.

PRESENTED BYB.K.PANDEYAPML, TIRODA

WELCOME TO

START-UP SEQUENCESTART-UP SEQUENCE• BOP SYSTEM READYNESS• BOILER FLUSHING: COLD/HOT• BOILER LINE UP AND LIGHT UP.• TURBINE LINE UP.• TURBINE ROLLING.• SYNCHRONISATION• PHASE CHANGE OVER• FULL LOAD

START UP MODESSTART UP MODES

• COLD START UP:HP & IP SHAFT METAL TEMP <204°C

• WARM START UP: HP & IP METAL TEMP IN BETWEEN 204 TO 400°C

• HOT START UP :HP & IP METAL TEMP >400°C

IPT LPT A LPT B

Condensor (HP) Condensor

EXT From CRH

LPH -5 LPH -6

LPH -7ALPH -7B

LPH -8ALPH -8B

Deaerator

Boiler

CEP3x50%

5 56 6

Economiser

1482 TPH

1994 TPH

(MD BFBP 1x35%)

11+1 8 2x7

TDBFP 2X50%

PRE STARTUP READYNESSPRE STARTUP READYNESS

• HT/LT POWER SUPPLY READINESS

• WATER SYSTEM: FIRE WATER,SERVICE WATER,DMP,CW & ACW.

• CCCW SYSTEM

• COMPRESSOR SYSTEM

• AUXILIARY STEAM. (S/B UNIT OR AUX BOILER).

• START CEP AND MDBFP.

• CHECK THE BCP SYSTEM IS READY.

WHY BCP ?WHY BCP ?

• TO ASSIST CIRCULATION IN BOILER WATER WALL

• TO INCREASE THE CIRCULATION VELOCITY

• TO AVOID DNB (Departure from Nucleate Boiling) IN LOW LOAD.

• TO REDUCE THE OVER HEATING AND UNDUE STRESSES ON WATER WALL TUBES.

• TO AVOID DRY OUT OF WATER WALL TUBES WHEN LOAD IS REDUCED.

BCP FILLING ,PURGING & FLUSHINGBCP FILLING ,PURGING & FLUSHING

• PURPOSE-- TO FILL THE MOTOR CAVITY.

• RECOMMENDED MOTOR FILLING WATER QUALITY- CONDUCTIVITY <1 µs/cm- BOILER FEED WATER

- TEMP.<= 45 OC

- CL- <= 50 PPM

- pH >= 6.5

- SUSPENDED SOLIDS <= 5 PPM

• FILLING,PURGING & FLUSHING WATER REQUIREMENT

- MOTOR INITIAL FILLING FLOW RATE : MAX. 5 L/MIN

PRE BOILER FLUSHINGPRE BOILER FLUSHING

• START CEP.

• FILL & DRAIN FROM DEAERATOR UNTIL REQUIRED WATER QUALITY IS ACHIEVED. ( Fe<500 Ppb.)

• START MDBFP.

• START THE BOILER COLD/HOT FLUSHING TO REDUCE THE Fe & SiO2 CONTENT IN FEED WATER.

Sampling Fe+

Above 500ppb Below

500ppb MIXER

Boiler flushing

HOTWELLCW LINE

START-UP LINE

BOILER COLD FLUSHINGBOILER COLD FLUSHINGCOLD FLUSHING

• WATER WALL TEMP REQUIRED 105-120 DEG.C (TEMP MAINTAINED BY DEAERATOR PEGGING STEAM)

• COLD OPEN FLUSHING QUALIFIES Fe < 500PPB SiO2 < 100PPB

• THEN CPU WILL BE TAKEN IN SERVICE TO REDUCE WATER LOSS AND IMPROVE QUALITY.

• COLD CYCLIC FLUSHING QUALIFIES Fe < 100PPB SIO2 < 50PPB

(ALL ANALYSIS FROM SEPARATOR DRAIN)

BOILER HOT FLUSHINGBOILER HOT FLUSHINGHOT FLUSHING

• WATER WALL TEMP REQUIRED 150-190 DEG.C (TAKE OIL GUNS OF BC ELEVATION)

• HOT OPEN FLUSHING START UP CRITERIA FE > 100PPB SIO2 > 50PPB

• IF HOT CYCLIC FLUSHING CRITERIA IF FE < 100PPB SIO2 < 50PPB

• HOT CYCLIC FLUSHING QUALIFIES IF FE < 50PPB

SIO2 < 30PPB

• AFTER COLD FLUSHING START BCP WITH MINIMUM 30% FEED FLOW & THROTTLE FRS VALVE.

BOILER LINE UP AND LIGHT UPBOILER LINE UP AND LIGHT UP• FUEL OIL SYSTEM: LDO/HFO PUMPS

• ESP HEATERS & RAPPERS

• AIR FLUE GAS SYSTEM: APH,IDF, FDF & SCANNER FAN.

• MAINTAIN AIR FLOW : 30% - 40%.

• FURNACE PURGE: 300 Sec.

• LIGHT UP BOILER WITH OIL GUNS AT BC (LDO) ELEVETION.

• CONTINUE HOT FLUSHING UNTIL REQD.WATER QUALITY IS ACHIEVED

• THEN TAKE CD ELEVETION GUNS. IF REQUIRED TAKE 2 NO. GUNS IN AB ELEVETION.

BOILER LINE UP AND LIGHT UPBOILER LINE UP AND LIGHT UP

• CONTINUOUS APH SOOT BLOWING TO BE DONE AT THE TIME OF OIL FIRING.

• PR RISING RATE- 0.05 MPA/MIN. BETWEEN 0-1 MPA • PR RISING RATE 0.1 MPA/MIN. BETWEEN 1 – 2 MPA • PR RISING RATE 0.2 MPA/MIN. ABOVE 2 MPA

• FURNACE EXIT GAS TEMP MUST BE BELOW 538°C FOR REHEATER PROTECTION (UNTIL HP-LPBP IS CHARGED).

• CLOSE SH DRAINS AND VENTS AFTER ACHIEVING DEGREE OF SH 50 °C ( CLOSE IT AFTER CHARGING HP-LP BYPASS).

LDO/HFO GUN

Fuel Light Oil

Fuel Pressure 0.8MPa-2.0MPa

Fuel Flow 500kg/h -3000kg/h

Atomizing Air Pressure 0.6MPa-1.2MPa

Atomizing Air Flow 100-600kg/h

Ignition Method HESI (20 joules/spark)

Fuel Heavy Oil

Fuel Pressure 0.8MPa- 2.0MPa

Fuel Flow 1000-4000 kg/h

Atomizing Steam Pressure 0.8MPa-1.2MPa

Atomizing Steam Flow 100-400kg/h

Ignition Method HESI (20 joules/spark)

TURBINE LINE UPTURBINE LINE UP• ENSURE:

• LUBE OIL SYSTEM: IN SERVICE (0.8 MPA)

• JACKING OIL SYSTEM:IN SERVICE ( 14 MPA)

• TURBINE BARRING GEAR: 3-4 RPM

• SEAL OIL SYSTEM: AIR & H2 SIDE. CHARGED

• STATOR AND H2 COOLING WATER SYSTEM:CHARGED TEMP CONTROL IN AUTO)

• H2 FILLED IN GENERATOR AND MAINTAIN PR 0.35 MPA.

• EH OIL SYSTEM: IN SERVICE (14 MPA)

TURBINE LINE UPTURBINE LINE UP• ENSURE TDBFP IN BARRING.

• GLAND STEAM CHARGING: ENSURE STEAM TEMP. IS 56°C - 111 °C MORE THAN ROTOR TEMP & DEGREE OF SH > 50°C.

• CHARGE THE GLAND SEAL SYSTEM OF TDBFP.

• START THE VACUUM PULLING WITH VACUUM PUMP. MAINTAIN VACUUM -0.9 KG/CM2.

• CHARGE THE HP-LP BYPASS SYSTEM .MAINTAIN THE MS STEAM PRESSURE AND FIRING RATE FOR ACHIEVING TURBINE ROLLING PARAMETERS.

COLD START UP CURVECOLD START UP CURVE

HOT ROLLINGHOT ROLLING

MS TEMPRH TEMPSPEEDMS FLOWLOADMS PRESS

PRE HEATING OF HP CASING.PRE HEATING OF HP CASING.• PREHEATING OF HPT REQUIRED WHEN INNER METAL TEMP <150°C.

• CRH PR 0.5-0.7 MPA/220-380°C.

• OPEN PRE HEATING VALVE (REVERSE FLOW VALVE) GRADUALLY.

• OPEN BDV VALVE FULLY.

• OPEN CRH DRAIN BEFORE NRV AND HPT-IPT CASING DRAINS.

• HEATING RATE SHOULD NOT BE MORE THAN 50°C PER HR.

• HP CASING TOP-BOTTOM & INNER-OUTER WALL METAL TEMP DIFFRENCE SHOULD BE WITHIN 50°C.

• AFTER ATTAINING THE CASING TEMP > 150°C CLOSE THE RFV VALVE AND OPEN HP CYLINDER VENTILATION VALVE TO CONDENSOR.

TURBINE WARM UP OPERATION

TURBINE STARUP PROCEDURE

RFV CRH NRV

CRH LINE

Ventilator valve

TO CONDENSER

TURBINE ROLLINGTURBINE ROLLING• AS PER REQUIREMENT OF START UP CURVE, FIRING TO BE

INCREASED.

• REQUIRED STEAM PARAMETERS BEFORE ROLLING– MS PR: 8.73 MPA, TEMP: 330-380 °C– RH PR: 1.1 MPA , TEMP: 330°C

- THE DEGREE OF SUPER HEAT > 56°C.

• AFTER LATCHING THE TURBINE, START IP ROLLING WITH HP VENT TO CONDENSER IN OPEN CONDITION TO KEEP THE HPT IN VACUUM.

• MSV 1&2 AND RSV 1&2 ARE IN OPEN CONDITION.

• GIVE THE SPEED SET POINT TO 600 RPM

• CHECK THE TURBINE SUPERVISORY INSTRUMENT PARAMETER.

• THE ECCENTRICITY SHOULD BE LESS THAN 0.076 MM.

TURBINE ROLLINGTURBINE ROLLING

• SELECT TARGET SPEED 1500 RPM WITH RAMP RATE OF 100 RPM/MIN.

• ENSURE ALL HP CV’S OPENS TO 12% TO WARM UP THE HP CASING.

• WHEN HP CASING TEMP >320°C.CLOSE THE HP CV’S.• SOAK THE TURBINE FOR 4 HRS ACCORDING TO THE START UP

CURVE.• CHARGE THE LP HEATER 5 & 6 BEFORE 3000 RPM

• SELECT TARGET SPEED TO 3000 RPM WITH RAMP RATE OF 100 RPM/MIN.SOAK IT FOR 30 MIN AS PER S/U CURVE.

• AS PER PROCEDURE SYNCHRONISE THE UNIT.

LOADINGLOADING• AFTER SYNCHRONISATION INITIAL LOAD WILL BE 30 MW.HOLD IT FOR

30 MIN AND CHEK THE VIBRATION, BEARING TEMP, DIFF EXPANSION, CASING EXPANSION.

• CHARGE EXTRACTION STEAM TO DEAERATOR.

• TAKE MORE OIL GUNS IN EF/AB ELEVETION.

• TAKE PA FANS & SEAL AIR FAN.

• AFTER ACHIEVING FURNACE TEMP. MORE THEN 450°C. TAKE COAL MILL-B AT. STEAM T/PR 380°C/8.7 MPA.

• INCREASE FUEL FLOW MAINTAINING STEAM TEMP.& RAISE LOAD

• AT 70 MW IP TO HP CHANGE OVER. CV’S WILL START OPENING, CLOSE THE BDV AND VENTILATING VALVE.

• INCREASE THE LOAD AT 3MW/MIN

• CLOSE THE HP-LP BYPASS GRADULLY.

350 400 450 500 550 600 650MINUTES

LOAD (MW)

660 MW

CONDENSER

LP HEATER 7A

LP HEATER 8A

CONDENSER

LP HEATER 7B

LP HEATER 8B

LPT A LPT B

HP HEATER 5 HP HEATER

6LP HEATER 5

LP HEATER 6

2nd 2nd 4th 4th

5th 5th 5th 5th

6th 6th 6th

FROM IPT EXHAUST

TDBFP START UPTDBFP START UP• TAKE ONE TDBFP IN SERVICE( CHANGE OVER WITH MD BFP) WHILE

DRIVING STEAM IS AVAILABLE. SECOND TD BFP WILL BE TAKEN AT 180 MW.

• WARM UP THE TURBINE.

• SLOWLY OPEN THE AUX STEAM MOV TO TURBINE.

• PARAMETERS FOR ROLLING TDBFP.

STEAM PRESSURE: 0.6 ～ 1.3MPA, STEAM TEMP: 50 DEG C MORE THAN CASING TEMP.

• ROLL THE TDBFP AS PER PROCEDURE.

• GIVE THE TARGET SPEED 500 RPM AND THAN TO 1000 HOLD FOR 40 MIN.CHECK THE TSI PARAMETER

• WHEN SPEED REACHES 2840 RPM, GIVE REQUEST COMMAND FROM FW MENU. THEN SELECT CCS CONTROL IN FROM MEH MENU.

TDBFP-A

TDBFP-B

Aux. Steam Header

To CRH

FromCRH

Deaerator

Booster pumps

04/19/23

To Condenser

Aux. Steam Header

Deaerator

1.3 MPa350 ºC

1.12 Mpa378 ºC

4 MPa315.3 ºC

Changeover Valve

TDBFP STEAM SOURCESTDBFP STEAM SOURCES

LOADINGLOADING

• TAKE THE MILL-C IN SERVICE AT 100 MW. STEAM T/PR:400°C/8.7 MPA.

• GRADUALLY WITH DRAW THE OIL SUPPORT AS PER THE FLAME CONDITION.

• INCREASE THE LOAD TO 150 MW AND TAKE THE HPH-3, HPH-2 & HPH-1 IN SERVICE. MS T/PR 410°C/8.7 MPA.

• AT 180 MW TAKE SECOND TDBFP IN SERVICE.

HP HEATER 3

DEAERATOR

HP HEATER 2

HP HEATER 1

CRH LINE

TDBFP A TDBFP B

MS LINE

9th stage 5th stage

HP HEATER 1

HP HEATER 2

HP HEATER 3

HRH LINE

DEAERATOR

IP EXHAUST

PHASE CHANGE FROM WET TO DRY MODEPHASE CHANGE FROM WET TO DRY MODE• DURING LOAD RAISING >25% BMCR, THE BCP FLOW AND FEED

WATER FLOW TO BE MONITORED CLOSELY.

• THE BCP FLOW NEED TO BE ADJUSTED W.R.T SEPERATOR TANK LEVEL AND THE SAME FLOW TO BE ADJUSTED IN FEED WATER FLOW TO MAINTAIN TOTAL FEED WATER FLOW TO ECONOMISER CONSTANT.

• WHEN BOILER STEAMING RATE RISES TO >30% BMCR, W.R.T FUEL FIRING, THE SEPERATOR LEVEL REDUCES .

• ONCE THE CONDITION FULFILLS THE BCP STOPS AND FEED FLOW CONTROL CHANGES OVER FRS.

• AFTER STOPPING BCP IT ACTS AS SUB-CRITICAL ONCE THROUGH“.

• WHEN THE STEAM PR REACHES 22.1 MPA IT IS IN “SUPERCRITICAL ZONE”

LOADINGLOADING

• TAKE MILL-A AT 210 MW.

• CUT THE OIL SUPPORT AT 260 MW AS PER THE FLAME CONDITION.

• TAKE MILL-D AT 300 MW. MS T/PR 475°C/10 MPA.

• TAKE MILL-E AT 430 MW. MS T/PR 566°C/17 MPA.

• TAKE MILL-F AT 540 MW. MS T/PR 566°C/24.1 MPA.

• INCREASE THE LOAD TO “FULL LOAD 660 MW” GRADUALLY.

Boiler Design ParametersBoiler Design ParametersNO.NO. ParametersParameters UnitUnit

11100% BMCR Coal consumption (Design)100% BMCR Coal consumption (Design) 390.37390.37

t/ht/h

22 Design fuelDesign fuel Indian coalIndian coal

33 Superheated steam flowSuperheated steam flow 21112111 t/ht/h

44 Superheater outlet pressure Superheater outlet pressure 25.425.4 MPaMPa

55 Superheater outlet temperatureSuperheater outlet temperature 569569 ℃℃

66 Reheated steam flowReheated steam flow 1749.11749.1 t/ht/h

77 Reheater inlet pressureReheater inlet pressure 4.734.73 MPaMPa

88 Reheater outlet pressureReheater outlet pressure 4.494.49 MPaMPa

99 Reheater inlet temperatureReheater inlet temperature 324324 ℃℃

1010 Reheater outlet temperatureReheater outlet temperature 569569 ℃℃

Feedwater pressureFeedwater pressure 28.828.8 MPa.gMPa.g

1111 Feedwater temperatureFeedwater temperature 280280 ℃℃

1212 Separator’s steam temperature Separator’s steam temperature 421421 ℃℃

1313 Air preheater’s outlet air temperature, uncorrectedAir preheater’s outlet air temperature, uncorrectedAfter correctingAfter correcting

153.3153.3 ℃℃

147.2147.2 ℃℃

1414 Calculating thermal efficiency of boilerCalculating thermal efficiency of boiler 87.19%87.19% （（ BMCRBMCR ））

TURBINE PARAMETERSTURBINE PARAMETERS

HPT IPT LPT

Pressure (MPa) 24.2 3.961 1.12

I/L Temp (Deg C) 566 566 378

O/L Temp(deg C) 315.3 378

Steam Flow (tph) 1959.25 1649

TURBINE HEAT RATE( KCL/KWH) 1885

No of Stop valves 2 2

No of Control valves 4 4

Steam Admission Parameters at Turbine Inlet

TURBINE AT FULL LOADTURBINE AT FULL LOAD

HPT IPT

LPT LPT #2 GEN

MS LINE

3.96MPa / 566°c

24.2MPa/566ºC

TO BLR RH

RCVRCV RCVCV CVCV

CVCVMSV

LPT LPT #2LPT GEN#2LPTLPT #1

MSV CV CVMSV CVMSV CVMSV CVCVMSV CVMSV CVMSV CV CVMSV

MSV CVMSV CVCVMSV

RSV1.12MPa / 378°c

CONDENSOR A CONDENSOR B

• EXCEPT IN AN EMERGENCY, LOAD SHOULD BE REDUCED GRADUALLY.

• CUT THE MILL-F AT 540 MW.

• CUT THE MILL-E AT 470MW.

• CUT THE MILL-D AT 300 MW.

• TAKE OIL SUPPORT FOR FURNACE STABILITY ( AT THE TIME OF 3 MILL OPERATION).

• CUT THE MILL-A AT 210 MW.

• TAKE THE HPH-1,2,3 OUT OF SERVICE.

• WHEN THE LOAD < 30% BOILER COMES IN WET MODE FROM DRY MODE. START THE BCP AND MAINTAIN THE SEPEARTOR LEVEL.

SHUT DOWNSHUT DOWN

• WHEN THE LOAD HAS DECREASED TO 20% OF RATED LOAD TRIP THE TURBINE ON TURBINE PROTECTION. THIS CLOSES THE THROTTLE VALVES, GOVERNOR VALVES, REHEAT STOP VALVES AND INTERCEPTOR VALVES

• CHECK DRAIN VALVES OPENS IN AUTO.

• HP LP BYPASS VALVE OPENS TO MAINTAIN THE FLOW.

• REDUCE THE BOILER LOAD GRADULLY.

• TRIP THE BOILER.• THE VACUUM BREAKER VALVES SHOULD NOT BE OPENED UNTIL THE

TURBINE UNIT HAS COASTED DOWN.

• VACUUM SHOULD BE KILLED BEFORE GLAND SEALING STEAM IS SHUT OFF.

• AUX OIL PUMP STARTS IN AUTO AT 2850 RPM.• JOP START IN AUTO AT 1200 RPM.

SHUT DOWNSHUT DOWN• WHEN THE VACUUM REACHES ZERO, SHUT OFF THE SEALING STEAM

TO THE GLAND STEAM CONTROL VALVES.

• SHUT DOWN THE GLAND STEAM CONDENSER EXHAUSTER. SHUT DOWN CONDENSATE PUMP.

• SHUT DOWN THE VACUUM PUMP.

• SHUT OFF THE COOLING WATER SUPPLY TO THE GENERATOR HYDROGEN COOLERS.

• ENSURE THAT BARRING GEAR HAS CUT IN.

SHUT DOWN CURVESHUT DOWN CURVE

COOL DOWN CURVECOOL DOWN CURVE

THANK YOU

Unit Lightup Synchronisation & Shutdown

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