Bhel Tg Rolling

7/15/2015 TechnicalServices

http://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm 1/26

CONTENTS

SL.NO.DESCRIPTION

01. COLDSTARTUP

02. INTEGRATEDSTARTUPPROCEDURECOLDSTARTUP

03. HOTANDWARMSTARTUPS.

04. INTEGRATEDSTARTUPPROCEDUREWARMSTARTUP

05. INTEGRATEDSTARTUPPROCEDUREHOTSTARTUP.

06. START UP BY CURVES FOR ABSOLUTE COLD START WITH HP/LP BYPASSSYSTEM.

07. START UP CURVES AFTER 48 HOURS SHAT DOWN WITH HP/LP BYPASSSYSTEM.

08. START UP PROCEDURE AFTER 8 HOURS SHUT DOWN WITH HP/LP BYPASSSYSTEM.

09. TECHNICAL DATA LIMIT CURVES FOR TURBINE VALVES WALL OF THECASINGSHAFTS.

10. WARMINGUPANDSTARTINGTHETURBINETEMPERATURECRITERIA.

11. TECHNICALDATAREACTIVECAPACITYCURVEFORTURBOGENERATORS.

COLDSTARTUP

(WithAuxSteamavailable)Acoldstartupisbydefinition,oneofwhichthemaximumofHPcasingandHPshaftislessthan1500C.Thisnormallymeansthattheunitisshutdownfromthemaximumloadformorethanfivedays.Ifmachineisstartedfromambienttemperature(HPC/HPshafttempapprox.400C),heatingupofcastingisrequired.Thisisaccomplishedbysoakingthemachineat360rpmatwarmingupsteamparameters(40kg/cm2,3600C),tilltheTSEmarginaresatisfactory.Therifleconstructionofthewaterwallcombinedwiththeboilercirculatingwaterpumpspermitsveryhighrateofpressurerisingofboiler.Anupperlimitof2000C/hrsaturationtemperaturegradientcanbeallowed,i.e.approximatelytheboilerpressurecanbebroughtto20kg/cm2withinanhourofcoldstartup.ButactualtemperaturegradientislimitedbythethickwalledYpieceprovidedinthemainsteamandHRHlines.Amainsteamlineheatingistobestartedasearlyaspossible(atapprox.4kg/cm2)asmaximumdifferentialtemperatureallowedbetweeninner(98%)andmidwalltemperature(50%)is400C.Soboilerloadingisaccordinglyregulated.ItmaybepreferablytostartonlytwoCCpumpsinordertominimiseflashingindowncomers(andsubsequentvibration)whentheboilerwaterisinrangeof850Cto1250C.Thethirdpumpshouldbestartedbeforedrumpressurereaches7kg/cm2tominimisethetemperaturetransientsexperiencedbythepumpcasing(thisistoavoidfastloadoutbackontheboilerintheeventofanyCCpumptripping).Togettherollingparameters,normallytwoelevationoilgunsaretakenwithapprox.70to80t/hrflowthroughHPLPbypass.AtthattimeM.S.parameterswouldbe40kg/cm2and3600C,HRHparameterswouldbe12kg/cm2and3600C.Assoonastheturbineloadinghasstarted,HP/LPbypassclosesandgetscompletelyclosedastheturbinereachestheboilerload.Firstmillisputintooperationaround10%ofgeneratorload.Secondmillisputintooperationaround25%whilethirdmillisat40%ofgeneratorload.Fourthandfifthmillsareputintooperationat60%and80%ofgeneratorloadrespectively.Sixthmillistakentoreachfullgeneratorload.DuringloadingtheRHoutletsteamtemperaturehastobekeptascloseaspossibletoSHoutletsteamtemperatureBurnertilt,SHspray,RHspraycontrolshastobeadjustedaccordingly.Theturbineloadingrateisdecidedbyaselectioncircuitwhichcomparestheexternalloadgradient,TSEmarginandtimedependantgradient(setinternally)andfrequencyinfluence.



INTEGRATEDSTARTUPPROCEDURE

COLDSTARTUP

(AUXILIARYSTEAMAVAILABLE)

REF.DRGNO.20BPE691

STEP TIME UNITCONDITION OPERATION NOTES

0 .. Boilerpr.0kg/cm2(g)

andAmbienttemperature

ChargeAux.Steamheader16ata,2600C,fromexistingunits.

Chargesteamtofueloilpumphouse,atomisingsteamandtracingsteamdeaeratorwarmingup.

Allthesteamtracinglinesandelectricaltracingsinpumphouse&boilertobecharged.

StarttankheatingofLSHSoil.

StartoneLSHSpumponrecirculationassoonasthesufficientoiltemperatureatinletisachieved.

ChargeLSHStoboilerfrontandkeepitonlongrecirculation,withheaterscontrolsetonAutotomaintain1101290C.

Fillwaterindrumupto+200mm.

EnsurethatthesuctionanddischargevalvesofalltheCCpumpsareopenandthepumpsuctionanddischargelinesarevented.

StartBearingcoolingwatersystempumpsforBoiler,TurbineandTGauxiliaries.

Checkallcircuitshavesufficientflow.Beforestartingthepumps,theemergencycoolingwatertankleveltobecheckedandmadenormal.

StartinstrumentaircompressorandcheckthatallthelinestoBoilerandTGarecharged.

Checkthatallcircuitshavesufficientairpressure.

StartserviceaircompressorandfilltheairreceivertanksofSRAPH&PRAPHarefilled.

EnsurethatpurgeairtoHEAisopeninallcorners.

LineupAirandfluegascircuitsforstartup.Checkdampersandgatesregisterposition.

ESPreadyinallrespects.

Furnacebottomashsystemandsealthroughlinedup.

FSSSpanelreadyinallrespects.

EASTpanelreadyinallrespects.

Excitationpanelreadyinallrespects.



Generatorprotectionpanelreadyinallrespects.

GeneratorH2gaspressureis

4kg/cm2CheckpurityofH2gasisnormal.

Generatorstatorwatersystemreadyinallrespects.Checkpurityofgeneratorstatorwaterisnormal.

H2coolingwatersystemreadyinallrespectswithSLCon.

LP&HPchemicaldozingsystemisready.

CheckforlevelinHydrazine,Ammoniaandphosphatepreparationtanks.

SADCpanelreadiness. Checkforairpressureinallthecornersandelevations.

PowersupplyforallthevalvesanddampersareON.EnsureAux.airdampersandmodulating.

SupplyforallauxiliariesofSG,TurbineandGeneratorisensured.

ReadinessofHPbypasspanelinallrespects.

Ensuretheoilunitisrunningandallthebypassandsprayvalvesareclosed.

StartoneoftheCCpumps.Ensuredrumlevelis+200mm,andthedrumairventsareclosed.

StartthesecondCCpump. Ensuredrumlevelisnormal. Startscannerairfan.

Startboththesecondaryairpreheaters.

Ensurethatalltheinletandoutletairgasdampersareopen.

Startboththeprimaryairpreheaters.Ensurethatthegasdampersareclosed.

StartonesetofIDandFDfans.

Adjust30%airflow,andfurnacedraftminus5to10mmWCL.

ChargesteamcoilpreheaterconcernedwiththerunningFDfans.

InitiateBoilerPurge(duration5minutes).

AfterpurgecompletionBoilertripvalveswillgetreset.

Also,afterpurge,adjustthewindboxdamperstoget3040mmWCL.Windboxdp.

Luboilsystemstopped. Startonevapourextractionfan,keepotherfanstandby. CheckoillevelinMOT.

LineupluboilcoolerandthrustbearingfilterStartoneAOP.

PutonSLCsforotherAOPandEOP.

CheckoutautostartofAOPandEOP.

Putluboiltemperaturecontrolleron.

StartoneJOP. PutonSLCsforotherJOPandDCJOP.

CheckoutautostartofJOP



andDCJOP.

PutoffSLCsJOP1,2&3.StoprunningJOP.

Opengatevalvegearing. SwitchonSLCgatevalvegearing.

StartoneJOPandswitchonSLCsforJOPs.

M/c.comesonbarring.MOTlevel50mmoiltemp.450CJOPheaderpr.140kg/cm2speed80100rpm.

ThesequentialoperationnarratedaboveonLuboilsystemstoppedisachievedbySGCmode.

Iftheprogrammegetsinterrupted,thestepandcriteriatobecheckedandtobefulfilledfortheprogrammetoproceedfurther.

M/conbarring. Startcentrifugewithbothheaters

FRFsysteminstoppedcondition. CheckFRFtanklevel. +200mm.

LineupFRFcoolerandduplexfiltersin32barsystemstartoneCEP.CheckautostartofstandbyCEP.

Establishcontrolfluidsupplytovariousservices. FRFtanklevelO(normal).

StartoneVEF.

StartonerecirculationpumpandincludeoneFiltersearthandultrafine.

SwitchonFRFheaterandkeepSLCONfortemperaturecontrol,andcontrolfluidpumps.

FRFtemperature550C.

SwitchONcontrolfluidSGC.

FRFsystem,SGCison.

ThesequentialoperationnarratedaboveinFRFsystemstoppedconditionisachievedbySGCFRFsystemonstartingprogrammemode.

Iftheprogrammegetsinterruptedthestepandcriteriatobecheckedandfulfilledfortheprogrammetoproceedfurther.

01 ooBoilerreadyforlightupandTurbineonTurninggear.

Start4burnersinABelevationwithLSHS.

CheckthatSH&RHventsareopen.

SH&RHdrainsareopen.

MSVsclosedanddrainsbeforeMSVopen.

Regulateoilpressureto810kg/cm2.

Ensureatomisingsteampressureabout6kg/cm2.

After30minutes,takeadditionalburners,soastoensureadrummetaltemperatureraiseofabout20C/min.

Insertfurnaceprobeandensurethatthetemperatureisbelow5350C.

Checkdrumlevelandgiveblowdown.

KeepopentheEco.



recirculationvalvewhenthereisnofeedingtodrum.

Startmotordrivenfeedpumponrecirculation. Checkdeaeratorlevel.

Chargethefeedlineuptofeedcontrolstation.

ChargeheatingsteamtodeaeratorfromAux.PRDS.

Startcondensatepumpsandfeedtodeaeratorasandwhenrequired.

Checkhotwelllevel.

Starthotwellmakeuppumpsandfeedhotwellasandwhenrequired.

Aux.PRDSsteam15kg/cm2

(g)2600C

CWsystemischarged.

CWboxestoensureventilatingofwaterboxes.

Startoneglandsteamexhausterfan.

LineupvacuumpumpsandstartonebyoneGraduallyadmitglandsteamwhencondenservacuumreaches0.2kg/cm2(g).

Ensureglandsteamadmissiontemperatureisalwaysabove2000C.

VacuumbuildingcanbedonethroughSGCvacuumonstartingprogrammemode,glandsteamexhausterhastobestartedmanually.

Vacuum09kg/cm2(g).Openalldrainsconnectedtoflashtanksandflashboxesconnectedtocondenser.

OpenHPBPwarmupvalves. SwitchonSLCdrains.

02 60' Boilerpressure2kg/cm2 CloseSH&RHheadervents.

CloseSH&RHheaderdrains.

OpenMSVbypasslines. MS,HRH,&CRHlineswillgetwarmedup.

03 100 Boilerpressure5kg/cm2.SwitchonautomaticcontrolinterfaceofLPbypass.

Assoonasthefixedsetpointreaches12kg/cm2,itseizes.

OpenMainsteamvalves.

Automaticcontrolinterfacegetsswitchedoffwhenthehotreheatsteampressurereaches13kg/cm2i.e.aftersynchronisation.

OpenHPbypass.

StartthirdC.C.pumpwhenboilerpressurereaches9kg/cm2.

TakeadditionalgunsinCD&EFelevation.Airheatersootblowingtobecarriedout.



CloseHPBPwarmupvalves.

AROLLINGTHROUGHHYDRAULICGOVERNOR

04 150

Boilerpressure:15kg/cm2

Temperature:1802000C

HRHPressure:812Kg/cm2

OpenHPESVs&IPESVsforwarmingupbyoperatingstartingdevicetoapproximately42%.

Checkandensurethatspeedsetpointiszeroandspeedergearis0%position.

EnsureTSEinfluenceisswitchedonandavailablemarginsaregreaterthan=300K.

05 300

M.S.Pr.50kg/cm2

M.S.temp.3500C

H.R.H.Pr.12kg/cm2

HRHtemp.:3500C

RaisethespeedsetpointofEHCto3200rpm

IftheoilsystemofEHCisisolatedatspeedGov.rack,speedsetpointneednotberaised.

Graduallyraisethestartingdevicetobringthespeedto360rpm

Startingdevicepositionapproximately56%.

TurbinereadyforRolling. Holdthespeedat360rpmforabout35to40mts.

Ensureclosureofgatevalvegearingat240rpm.Monitorbearingvibrations,shaftvibrations,TSEmargins,bearingtemperature&Turbosupervisoryreadingsat360rpm.

06 360M.S.Pr.50kg/cm2/3500C.Turbinerunningat360rpm.

Raisethespeedupto2400rpmthroughstartingdeviceattherateof600rpm.

EnsuretrippingofJOPat540rpm.

Raisefurtherspeedupto3000rpmthroughspeedergear.

Startingdevicewillbeat90%.

Monitoringbearingtemperatureandvibrations,shaftvibrations,TSEmarginsandTurbovisoryreadings,Sealoil,Primarywaterandgastemperatures&Generatorwindingtemperature.

EnsuretrippinfofAOPat2950rpm.

Speedergearpositionwillbeapproximatelyat50to60%.

07 370

MSPr.50kg/cm2.Temperature:3500CTurbinerunningat3000rpm.

PutAVRonAuto.

Closefieldbreaker.

Setmanuallythegeneratorvoltagetogridvoltage.

Synchronisethegeneratorwithgrid.



Pickup50MWloadbyoperatingspeedergear.

IncreaseHPBPsetpoint.EnsureclosureofHPBPsteamvalves&sprayvalves.

Closeotherdrains,M.S.HRH,keepingSLCdrainson.

DrainpotdrainsofMS,CRH&HRHandextractionsteamlineswilloperateaspertheactuationoflevelswitches.

BROLLINGTHROUGHEHC.

04 150'

MSPr.:15kg/cm2.Temperature:1802000CHRHPressure:8to12kg/cm2.

OpenHPESVs&IPESVsforwarmingupbyoperatingstartingdevicetoapproximately42%.

CheckandensurethatTSEinfluencesisswitchedonandavailablemarginsaregreaterthan300K.

Checkandensurethatspeedsetpointiszeroandspeedergearis0%position.

05 300'

MSPressure:50kg/cm2

MSTemperature:3500C

HRHPressure:12kg/cm2

HRHTemperature:3500C.

TurbineReadyforrolling

Raisethestartingdevicetoabout70%.

CheckandensureopeningofvalvesinHP/IPsecondaryfluidlinestoEHCatspeedcontrolrack.

Raisethespeedsetpointto360rpmandwatchtheactualspeed.

IftrackingdeviceisswitchedON,startingdevicepositionwillautomaticallytracktheEHCposition

Raisethespeedergearto100%

Holdthespeedat360rpmforabout35to40mts.Ensureclosureofgatevalvegearingat240rpm.

Monitoringbearingvibrations,bearingtemperatures,shaftvibrations,TSEmarginsandTurbovisoryreadings.

06 360'MSPressure:50kg/cm2

MSTemperature:3500C

Raisethespeedsetpointto3000rpm.

Ensuretrippingofjackingoilpumpat540rpm.

Turbinespeed:360rpm. Therateofaccelerationwillbe600to850rpm.

Monitorbearingvibrationandtemperatures,shaftvibrations,TurbovisoryreadingsandTSEmargins

Monitorandcontrol,SEALoiltemperatures,Primarywatertemp.Hydrogengastemperatureandwindingtemperature.

EnsuretrippingofAOPat2950rpm.



07 370'

MSPressure:50kg/cm2

MSTemperature:3500C

Turbinespeed:3000rpm.

PutAVRonauto,CloseFieldBreaker.

Setmanuallygeneratorvoltagetogridvoltage.


Speedsetpointwillraiseautomaticallyby8rpmandloadwillbepickedupto20MW.

Raisethespeedsetpointandpickuptheloadto50MW.


CloseotherdrainsofMS,CRH,HRH,keepingSLCdrains'ON'.

DrainpotdrainsofMS,CRH,HRHandextractionsteamlineswilloperateaspertheactuationoflevelswitches.

CROLLINGTHROUGHSGCTURBINE.

04 150'

MSPressure:15kg/cm2

MSTemp.:1802000C


SwitchonthestartupprogrammeofSGCTurbine.

EnsureTSEinfluenceisswitchedon.

Iftheprogrammeinterruptstheparticularstepandcriteriatobecheckedandcorrectedfortheprogrammetoproceedfurther.

AlloperationsasexplainedunderEHCrollingwillbecarriedoutbySHCTurbineprogrammesequentially.

05 300'

MSPressure:50kg/cm2

MSTemperature:3500C


HRHTemp.:3500C.


Turbinespeedwillberaisedto360rpmthroughSGCProgramme.

Ensureclosureofgatevalvegearingat240rpm.

Monitorbearingvibration,bearingtemperature,shaftvibration,TSEmarginsandTurbovisoryreadings.

Toachievetheprogrammeasperthestartingcurve,themainsteamtemperatureshouldbemaintainedsteadilytillloadingupto50MW.

06 360'

MSPressure:50kg/cm2

MSTemperature:3500CTurbinespeedwillberaisedupto3000rpmthroughSGCprogramme.




Turbinerunningat360rpm.


Monitorbearingtempandvibrations,shaftvibrations,TSEmarginsandturbovisoryreadingssealoil,primarywater,HydrogengasandGeneratorwindingtemperatures.

07 370'

MSPressure:50kg/cm2

MSTemperature:3500C


SGCprogrammewillswitchONfieldbreaker,putAVRonauto,synchroniseandpickuploadupto20MW.

EnsureSGCstartupprogrammeiscompleted.

Raisethespeedsetpointandpickuptheloadupto50MW.

IncreaseHPBPsetpoint.EnsureclosureofHPBPsteamvalvesandsprayvalves.

CloseotherdrainsofM.S.CRHandHRH,keepingSLCdrainsON.

DrainpotdrainsofMS,CRH,HRHextractionsteamlineswilloperateaspertheactuationoflevelswitches.

08 390'

Load:55MW

M.S.:54kg/cm2/3500C

HRH:12kg/cm2/3400C

StartsealairfanandPAfanandtakefirstmillinservice.

BeforestartingP.A.fan,ensurethatairandgasdampersofPrimaryAirPreheatersareopen.

ChargeESPfields EnsureAshhandlingsystemisready.

StartthesecondsetofID&FDfans.MakereadySH&RHspraysystems.

CutinL.P.heaters2&3. Ensureswitchingonofloadcontrollerabove60MW.

CutoutheatingsteamfromAux.P.R.D.S.toDeaerator.

PegDeaeratorfromCRHsteamgraduallyupto2kg/cm2.

Cutinautocontrollers.

Load:55MW

M.S.:54kg/cm2/3500C

HRH:12kg/cm2/3400C

ChargeAux.PRDSstationfromCRH.Cutinsprayandmaintainatemperatureof2500C.

Ensureenergizingofsolenoidintrimmingdeviceatandabove100MWload.

PegDeaeratorgraduallyto4kg/cm2.

RaisethepressuresetpointofDeaeratorpressurecontrollergradually.

CutinIIndmillandcutinautocontrollers.

Startwithdrawingoilsupportgradually.Ensurefireballscannerhealthiness

Controlmainsteamandreheatsteamtemperaturesbyusingsprayifrequired.



10 440'

Load:160MW

M.S.:90kg/cm2/3800C

HRH:20kg/cm2/3800C

Steamflow:580t/hr.

Increasethewindboxtofurnacedifferentialpressureto100mmW.C.byadjustingSADC.

ChargeH.P.heaters5A,5B,6Aand6B.

Putcontrollersonauto.

StartfirstTDBFP&secondCEP.

ChargeDeareatorpeggingsteamflowCRHtoExtractionaround200MWload.

EnsureDeareatorPressurecontrollerremainsasauto.

11 480'

Load:250MW

M.S.:120kg/cm2/4200C

HRH:26kg/cm2/3400C

Steamflow:820t/hr.

CutinIIIrdmillandcutinautocontrollers.

StartsecondP.A.Fan.BeforestartingP.A.fanensurethatairandgasdampersofPAPHsareopen.

12 510'

Load:320MW

M.S.:125kg/cm2/3500C

HRH:2830kg/cm2/3400C

Steamflow:1040t/hr.

CutinIVthmillandcutinautocontrollers.

Cutofoilsupportcompletely.Ensurehealthinessoffireballscanners.

13 550'

Load:405MW

M.S.:145kg/cm2/4600C

HRH:33kg/cm2/4600C

Steamflow:1310t/hr.

CutinVthmillandcutinautocontrollers.

CutinsecondTDBFPandswitchoffmotordrivenBFP.

14 590'

Load:500MW

M.S.:170kg/cm2/4750C

HRH:40.5kg/cm2/4750C

IffullloadisnotreachedcutinVIthmillalongwithitscontrollers.IncreasethesetpointofSH&RHspraycontrollerssuchthatratedparametesareachievedgradually.

15 670'

Load:405MW

M.S.:145kg/cm2/4600C

HRH:33kg/cm2/4600C

Steamflow:1310t/hr.



WARMANDHOTSTARTUPS

(WithAux.SteamAvailable).

Awarmstartupis,bydefinition,onewhichthemaximumofHPcasing/HPshafttemperatureis

between1500Cand3500C.Thisnormallymeansthattheunitisshutdownfromthemaximumloadforone

to fourdays.Dependingupon theabsolute temperatureofHPcasingandHPshaft, steamparametersare

derived.AhotstartupisbydefinitiononewhichthemaximumofHPcasing/shafttemperatureismorethan

3500C.InthiscasetogettherollingparameterstwomillsaretakenintoservicekeepingHP,LPbypassin

operation. (Again the flowrate is restrictedby the Ypiecesconstraints i.e.,400C). Inboth the cases,

curves are given to derive the rolling parameters. In case when machine is rolled through EAST, curve

generators,calculateandgivepermissiveforrolling.


WARMSTARTUP(AFTER48HOURSSHUTDOWN).

STEP TIMEINMINUTES UNITCONDITION OPERATION NOTES.

OneCCpumpinoperationandscannerfaninoperation.

MotoroperatedBFPisrunasandwhenrequiredtomaintainthedrumlevel.

BothSAPHsandPAPHsinoperation.

TurbineonbearinggearwithAOP,JOPandsealoilpumpsinoperation.

Controlfluidsystemreadyinallrespects.Onecirculatingpumpinoperationwithoneearthfilterandultrafinefilterincircuit.

Generatorgassystem,sealoilsystemandprimarywatersysteminoperation.

Bearingcoolingwatersysteminoperation.

HTandLTauxiliariespowersupplyavailable.

HPbypasssystemreadyinallrespects.

ESPreadyinallrespects.

EASTpanelsreadyinallrespects.

Furnacebottomashsystemandsealtroughlinedup.

Vacuumpumpslinedupandreadyforoperation.

Glandsteamandleaksteamcontrollersarelinedupandreadyforoperation.



Generatorprotectionpanelandexciterpanelsreadyinallrespects.

Boilerdrumpressure=0kg/cm2.SHtemperaturebetween1300Cand1500C.

1.Chargeauxiliarysteamheaderfromexistingunits.Pr.16atatemp.2600C.

2.Chargesteamtofueloilpumphouse,atomisingsteamandtracingsteam.

3.StarttankheatingofLSHSoil.

4.StartoneLSHSpumponrecirculationassoonassufficientoiltemp.atinletisachieved.

StartinstrumentoilcompressorandserviceaircompressorsandcheckthatalllinestoboilerandTGarecharged.

ChargeLSHSpumptoboilerfrontandkeepitonlongrecirculationwithheaterscontrolsetonautotomaintain1200C.

Startcirculatingwaterpumpforcondenseranddeaeratethecondenserwaterboxes.

StartsecondCCPump.EnsurerunningofmotordrivenBFPcontinuouslyformaintainingdrumlevel.

StartonesetofIDandFDfans.

Initiateboilerpurge.

StartoneCEPandkeepthehotwellmakeupinservice.

Startoneofthecontrolfluidpumpsandkeepthesecondasautostandby.

Keepthecontrolfluidtemperaturecontrolonauto.

Lineupmainsteam,CRHandHRHsteamlinesforchargingbyopeningrespectivelinedrains.

LineupFSSSpanelsinallrespects

ChargeheatingsteamlinetoDeaeratorfromAux.PRDS.

01 ooBoilerreadyforlightupandturbineonturninggear.


CheckthatSH&RHventsareopen.

SH&RHdrainsareopen.

MSVsclosedanddrainsbeforeMSVopen.



Ensureatomisingsteampressureofabout6kg/cm2

EnsuremotoroperatedBFPisinservice.

StartGlandsteamExhauster.

Startonebyonevacuumpumps.

Admitglandsteamwhenvacuumreaches0.2kg/cm2.

Ensureglandsteamadmissiontemperatureisalwaysabove2000C.

VacuumbuildingcanbedonethroughSGCvacuumonstartingprogrammemode.Glandsteamexhausterhastobestartedmanually.

Openalldrainsconnectedtoflashtanksandflashboxesconnectedtocondenser.

Ensurecondenservacuumof0.8kg/cm2.

SwitchonSLCdrains.

CloseSH&RHheaderventsanddrains.Ensureboilerpressureis2kg/cm2.

OpenHPBPwarmingupvalves.

OpenMSVbypasslines.

SwitchAutomaticcontrolinterfaceofLPbypass.


Automaticcontrolinterfacegetsswitchedoffwhenthehotreheatsteampressurereaches13kg/cm2(i.e.)aftersynchronisation.

OpenMainsteamstopvalves.EnsureMS,CRH&HRHlinesgetwarmedup.

OpenHPbypassandclosetheHPBPwarmupvalves.EnsureBoilerpressureis5kg/cm2.

StartthirdCCpump. EnsureBoilerpressureis9kg/cm2.

PutHPbypasscontrolleronautoandvarythesetpointaccordingtothegradientofpipelinetemperatures.

EnsureBoilerpressureis10kg/cm2

PutHPbypassspraycontrolonauto.

Takeadditionalgunsaccordingtotherequirement.

Airheatersootblowingtobecarriedout.

AROLLINGTHROUGHHYDRAULICGOVERNOR.

02 180'

MS:50kg/cm2/3650C

HRH:12kg/cm2/3250C

Bypasssteamflow:170t/hr.

OpenHPESVandIPESVforwarmingupbyoperatingstartingdevicetoapprox.42%

Checkandensurethatspeedsetpointiszeroandspeedergearis0%.

EnsureTSEinfluenceis



switchedonandavailablemarginsaregreaterthan300K.

03 210'

MS:60kg/cm2/4000C

HRH:12kg/cm2/3500C


RaisethespeedsetpointofEHCto3200rpm.

IftheoilsystemofEHCisisolatedatspeedGov.rack,speedsetpointneednotberaised.

Graduallyrisethestartingdevicetobringthespeedto360rpm.


Holdthespeedat360rpmforabout5minutes.Ensureclosureofgatevalvegearingat240rpm.

Monitorbearingvibrations,shaftvibrations,TDEmargins,bearingtemp.&Turbovisoryreadingsat360rpm.

04 215' Turbinerunningat360rpm.

Raisethespeedupto2400rpmthroughstartingdeviceattherateof600rpm.




Monitorbearingtemp&vibrations,shaftvibrations,TSEmarginsandTurbovisoryreadings.Sealoil,Primarywaterandgastemperatures&Generatorwindingtemperature.


Speedergearpositionwillbeapprox.at50to60%.

05 220' Turbinerunningat3000rpm PutAVRonauto.

Closefieldbreaker.


Synchronisethegeneratorwithgrid.Pickup50MWloadbyoperatingspeedergear.


Closeotherdrains,M.S.HRH,keepingSLCdrainson.

DrainpotdrainsofMS,CRH,andHRHandextractionsteamlineswilloperateaspertheactuationoflevelswitches.

Furtherloadraisingwillbedonebyoperatingthespeedergearaccordingtothestartupcurve.

BROLLINGTHROUGHEHCMS:50kg/cm2/3650C



02 180'HRH:12kg/cm2/3250C


OpenHPESVsandIPESVsforwarmingupbyoperatingstartingdevicetoapprox.42%.

CheckandensurethatTSEinfluenceisswitchedonandavailablemarginsaregreaterthan300K.

Checkandensurethatspeedsetpointiszeroandspeedergearis0%.

03 210'

MS:60kg/cm2/4000C

HRH:12kg/cm2/3500C


Turbinereadyforrolling.




IftrackingdeviceisswitchedonstartingdevicepositionwillautomaticallytracktheEHCposition

Raisethespeedergearto100%.Ensureclosureofgatevalvegearingat240rpm.

Holdthespeedat360rpmforabout5minutes.

Monitorbearingvibrationsbearingtemperatures,shaftvibrations,TSEmargins&turbovisoryreadings.

04 215' Turbinerunningat360rpm. Raisethespeedsetpointto3000rpm.EnsuretrippingofJackingoilpumpat340rpm.

Monitorbearingvibrationsandtemps,shaftvibration,turbovisoryreadingsandTSEmargins.


05 225' Turbinespeed:3000rpm. PutAVRonautocloseFieldbreaker.

Setmanuallygeneratorvoltagetogridvoltage.


Speedsetpointwillberaiseautomaticallybyabout8rpm&loadwillbepickedupto20MW.

Raisethespeedsetpointandpickuptheloadto50MW.

IncreaseHPBPsetpoints.EnsureclosureofHPBPsteamvalvesandsprayvalves.

CloseotherdrainsofMS,CRH,andHRHkeepingSLCdrainsON.


CROLLINGTHROUGHSGCTURBINE.

02 180'

MS:50kg/cm2/3650C

HRH:12kg/cm2/3250C

Bypasssteamflow:

SwitchonthestartupprogrammeofSGCTurbine.

EnsureTSEinfluenceisswitchedon.



170t/hr.

Iftheprogrammeinterruptstheparticularstepandcriteriatobecheckedandcorrectedfortheprogrammetoproceedfurther.

AlloperationsasexplainedunderEHCrollingwillbecarriedoutbySGCTurbineprogrammesequentially.

03 210'

MS:50kg/cm2/3650C

HRH:12kg/cm2/3250C



Turbinespeedwillberaisedto360rpmthroughSGCProgramme.


Monitorbearingvibration,bearingtemp,shaftvibration,TSEmarginsandTurbovisoryreadings.

Toachievetheprogrammeasperthestartingcurve,themainsteamtemperatureshouldbemaintainedsteadilytillloadingupto50MW.

04 215'

MS:60kg/cm2/4000C

Turbinerunningat360rpm.

Turbinespeedwillberaisedupto3000rpmthroughSGCProgramme.

EnsuretrippingofJOPat540rpm.EnsuretrippingofA.O.P.at2950rpm.

Monitorbearingtemp&vibrations,shaftvibrations,TSEmarginandturbovisoryreadings,sealoil,primarywater,HydrogengasandGeneratorwindingtemperatures.

05 225'

MS:60kg/cm2/4000C


SGCprogrammewillswitchONfieldbreaker,putAVRonauto,synchroniseandpickuploadupto20MW.

EnsureSGCStartupprogrammeiscompleted.

Raisethespeedsetpointandpickuploadupto50MW.

IncreaseHPBPsetpointEnsureclosureofHPBPsteamvalvesandsprayvalves.

CloseotherdrainsofM.S.,CRHandHRH,keepingSLCdrainsON.

DrainpotdrainsofM.S.,CRH,HRHandExtractionsteamlineswilloperateaspertheactuatoroflevelswitches.



06 230'

Load:60MW

MS:60kg/cm2/4100C

HRH:14kg/cm2/3600C

CutinL.P.heaters2and3. Ensureswitchingonofloadcontrollerat60MW.

CutoutheatingsteamfromAux.PRDStoDeaerator.

PegDeaeratorfromCRHsteamgraduallyupto2kg/cm2.

Cutinallautocontrollers.

StartsealairfanandP.A.fan

BeforestartingP.A.fan,ensurethatairandgasdampersofPrimaryAirPreheatersareopen.

Cutinfurtheroilgunsforraisingparameters.

07 245'

Load:110MW

MS:80kg/cm2/4200C

HRH:19kg/cm2/3800C

Mainsteamflow:470t/hr.

TrimmingdeviceisinOFF.

Cutin1stcoalmillandcutinAutocontrollers.

MakereadySH&RHspraysystem.

ChargeESPFields. EnsureAshhandlingsystemisready.


PegDeaeratorgraduallyupto4kg/cm2.

RaisethepressuresetpointofDeaeratorpressurecontrollergradually

CutinH.P.heatersandputthelevelcontrolsonauto.

StartfirstTDBFPandsecondCEParoundaloadof170MW.

Increasethewindboxtofurnacediff.pressureto100mm.W.C.byadjustingSADC.

08 270'

Load:200MW

MS:100kg/cm2/4350C

HRH:19kg/cm2/4000C


CutinIIndmillandcutinautocontrollers.

Startwithdrawingoilsupportgradually.Ensurehealthinessoffireballscanners.

Controlmainsteamandreheatsteamtemperaturebyusingsprayifrequired.

ChangeDeaeratorpeggingsteamfromCRHto EnsureDeaeratorpressure



Extractionsteam. controllerremainsonauto.


StartsecondP.A.fan.

BeforestartingP.A.fanensurethatairandgasdampersofPAPHareopen.

09 300'

Load:320MW

MS:125kg/cm2/4500C

HRH:30kg/cm2/4300C



Cutoffoilsupportcompletely.Ensurehealthinessoffireballscanners.

CutinVthcoalmillandcutinautocontrollers.

StartsecondTDBFPandswitchoffmotordrivenBFP.

CutinVIthcoalmillandcutinautocontrollers.

10 340'

Load:500MW

MS:170kg/cm2/4800C



Checkallparametersatfullloadandensurethemwithinlimits.

IncreasethesetpointofSH&RHspraycontrollerssuchthatratedparametersareachieved.

11 420'

Load:500MW

MS:170kg/cm2/5350C




HOTSTARTUP(AFTER8HOURSSHUTDOWN)

STEP TIMEINMINUTES. UNITCONDITION OPERATION NOTES.

TwoCCpumpsinoperationandscannerfaninoperation.

MotoroperatedBFPisrunasandwhenrequiredtomaintainthedrumlevel.IfnecessaryBFPshouldbekeptrunningcontinuously.

BothSAPHsandPAPHsinoperation.

Turbineonbarringgear



withAOP,JOPandsealoilpumpsinoperation.

Controlfluidpumpinoperation.Onecirculatingpumpinoperationwithoneearthfilterandultrafinefilterincircuit.

Generatorgassystem,sealoilsystemandprimarywatersysteminoperation.

Bearingcoolingwatersysteminoperation.

Condensercirculatingwatersysteminoperation.

Serviceairandinstrumentaircompressorsinoperation.

Onecondensatepumpinoperationandhotwellmakeupinservice.

Aux.steamheaderchargedfromexistingunits(16ata2600C).

LSHSpumpinoperationonlongrecirculationuptoboilerfrontwithheaterscontrolseton

HPbypasssystemreadyinallrespects.

LP&HPandchemicaldosingsystemready.

ESPpanelsreadyinallrespects.

EASTpanelsreadyinallrespects.

Furnacebottomashsystemandsealtroughlinedup.

Vacuumpumpslinedupandreadyforoperation.

Glandsteamandleaksteamcontrollersarelinedupandreadyforoperation.

Generatorprotectionpanelandexciterpanelsreadyinallrespects.

FSSSpanelreadyinallrespects.

BoilerdrumPr.75kg/cm2

SH.Temp.between4150Cand4300C.

Lineupmainsteam,CRHandHRHsteamlinesforchargingbyopeningrespectivelinedrains.

EnsureMSVisclosed.

Startoneglandsteamexhauster.

Startonebyonevacuumpumps.

Admitglandsteamwhenvacuumreaches0.2

Ensureglandsteamadmissiontemperatureis



kg/cm2. alwaysabove2000C.

VacuumbuildingcanbedonethroughSGCvacuumonstartingprogrammemode.Glandsteamexhausterhastobestartedmanually.

Openalldrainsconnectedtoflashtanksandflashboxesconnectedtocondenser.



OpenHPBPwarmingupvalves.

SwitchAutomaticcontrolinterfaceofLPbypass.


Automaticcontrolinterfacegetsswitchedoffwhenthehotreheatsteampressurereaches13kg/cm2(i.e.)aftersynchronisation.

StartthirdCCpump. Ensuredifferentialtemp.iswithinpermissiblelimits.

EnsurerunningofmotordrivenBFPcontinuouslyformaintainingdrumlevel.

StartbothID&FDfans Initiateboilerpurge.

ChargeheatingsteamlinetoDeaeratorfromAux.PRDS.

01 ooBoilerreadyforlightupandturbineonturninggear.


Ensureatomisingsteampressureofabout6kg/cm2.

DrumPr.75kg/cm2

SH.Temp.4150Cand4300C.

EnsuremotoroperatedBFPisinservice.

OpendrainsbeforeMSV. OpenMSVbypasslines.

OpenMainsteamstopvalves.EnsureMS,CRH,HRHlinesgotwarmedup.

OpenHPbypassandclosetheHPBPwarmupvalves.

PutHPbypasscontrollersonautoandvarythesetpointaccordingtothegradientofpipelinetemperatures.

PutHPbypassspraycontrolonauto.

Takeadditionalgunsaccordingtotherequirement.

Airheatersootblowingtobecarriedout.

StartbothP.A.fansandsealairfans.

BeforestartingP.A.FansensurethatairandgasdampersofPrimaryair



preheatersareopen.

Lineupmillingsystemforstarting.

AROLLINGTHROUGHHYDRAULICGOVERNOR

02 40'

MS:85kg/cm2/4850C

HRH:12kg/cm2/4400C


Cutinfirstcoalmill&cutinautocontrollers.

MakereadySHandRHspraysystem.

ChargeESPfields. EnsureAshhandlingsystemisready.

Increasethewindboxtofurnacediff.Pressureto100mmW.C.byadjustingS.A.D.C.

Cutinsecondmillandcutinautocontrollers.

PegthedeaeratorfromCRHgraduallyupto2kg/cm2.

OpenHPESVsandIPESVsforwarmingupbyoperatingstartingdevicetoapproximately42%.

Checkandensurethatspeedsetpointiszeroandspeedergearisat0%.

EnsureTSEinfluenceisswitchedonandavailablemarginsaregreaterthan300K.

03 50'

MSPressure:85kg/cm2

MSTemperature:5000C





RaisethespeedsetpointofEHCto3200rpm.

IftheoilofEHCisisolatedatspeedGov.rack,speedsetpointneednotberaised.

Graduallyraisethestartingdevicetobringthespeedto360rpm



Monitoringbearingvibrations,shaftvibrations,TSEmargins,bearingtemp&Turbovisoryreadingsat360rpm.

04 52' Turbinerunningat360rpm.Raisespeedupto2400rpmthroughstartingdeviceattherateof600rpm.




Monitorbearingtempandvibrations,shaft



vibrations,TSEmarginsandturbovisoryreadings.SealoilPrimarywaterandgastemperaturesandGeneratorwindingtemperature.


Speedergearpositionwillbeapproximatelyat50to60%.

05 56' Turbinerunningat3000rpm PutAVRonauto.

Closefieldbreaker.


SynchronisetheGeneratorwithgrid.Pickup50MWloadbyoperatingspeedergear.


Closeotherdrains,M.S.CRH,HRH,keepingSLCdrainson.

DrainpotdrainsofMS,CRH,andHRHandextractionsteamlineswilloperateaspertheactuationoflevelswitches.

Furtherloadraisingwillbedonebyoperatingthespeedergearaccordingtothestartupcurve.

BROLLINGTHROUGHEHC

02 40'

MSPressure:85kg/cm2

MSTemperature:4850C





MakereadySH&RHspraysystems.




PegthedeareatorfromCRHgraduallyupto2kg/cm2.

OpenHPESVsandIPESVsforwarmingupbyoperatingstartingdevicetoapproximately42%.

Checkandensurethatspeedsetpointiszeroandspeedergearisat0%.

EnsureTSEinfluenceisswitchedonandavailablemarginsaregreaterthan



300K.

03 50'

MSPressure:85kg/cm2

MSTemperature:5000C



TurbineReadyforrolling.Bypasssteamflow:360t/hr.




IftrackingdeviceisswitchedonstartingdevicepositionwillautomaticallytracktheEHCposition.

Raisethespeedergearto100%.Ensureclosureofgatevalvegearingat240rpm.

Holdthespeedat360rpmforabout5minutes.

Monitorbearingvibrations,bearingtemperatures,shaftvibrations,TSEmarginsandturbovisoryreadings.

04 52' Turbinereadingat360rpm.Raisethespeedsetpointto300rpm.

EnsuretrippingofJackingoilpumpat540rpm.

Therateofaccelerationwillbe600to800rpm2.

Monitorbearingvibrationsandtemperatures,shaftvibration,turbovisoryreadingsandTSEmargins.

Monitorandcontrol,sealoiltemperatures,primarywatertemperature.Hydrogengastemperatureandwindingtemperature.


05 56' Turbinespeed:3000rpm. PutAVRonautoClosefieldbreaker.

SetManuallygeneratorvoltagetogridvoltage.


Speedsetpointwillberaisedautomaticallybyabout8rpmandloadwillbepickedupto20MW.


IncreaseHPBPsetpoint.EnsureclosureofHPBPsteamvalvesandsprayvalves.

CloseotherdrainsofMS.CRHandHRH,keepingSLCdrainsON.


CROLLINGTHROUGHSGCTURBINE.MS:85kg/cm2/4850C



02 40' HRH:12kg/cm2.



MakereadySH&RHspraysystems.




PegthedeaeratorfromCRHgraduallyupto2kg/cm2.

SwitchonthestartupprogrammeofSGCTurbine.EnsureTSEinfluenceisswitchedON.

Iftheprogrammeinterrupts,theparticularstepandcriteriatobecheckedandcorrectedfortheprogrammetoproceedfurther.

AlloperationsasexplainedunderEHCrollingwillbecarriedoutbySGCTurbineprogrammesequentially.

03 50'


MS:85kg/cm2/5000C

HRH:12kg/cm2/4500C


Turbinespeedwillberaisedto360rpmthroughSGCprogramme.


Monitorbearingvibration,bearingtemperature,shaftvibration,TSEmarginsandTurbovisoryreadings.

Toachievetheprogrammeasperthestartupcurve,themainsteamtemperatureshouldbemaintainedsteadilytillloadingof50MW.

04 52' Turbinereadingat360rpm.

Turbinespeedwillberaisedupto3000rpmthroughSGCprogramme.



Monitorbearingtemperatureandvibrations,shaftvibrations,TSEmargins,Turbovisoryreadings,sealoil,primarywater,HydrogengasandGeneratorwindingtemperatures.


MS:85kg/cm2/5000C SGCProgrammewillswitch



05 56' HRH:12kg/cm2/4500C


ONfieldbreaker,putAVRonautosynchroniseandpickuploadupto20MW.

EnsureSGCstartupprogrammeiscompleted.

Raisethespeedsetpointandpickuploadupto50MW.


CloseotherdrainsofM.S,CRHandHRH,keepingSLCdrainsON.

DrainpotdrainsofMS,CRH,HRHandExtractionsteamlineswilloperateaspertheactuationoflevelswitches.

06 60'

LOAD:60MW.

MS:85kg/cm2/5000C

HRH:16kg/cm2/4700C

CutinL.P.heaters2and3. Ensureswitchingonofloadcontrollerat60MW.

CutoutheatingsteamfromAux.PRDStoDeaerator.

Raisethegeneratorpressurefrom2kg/cm2to4kg/cm2.

RaisethepressuresetpointofDeaeratorpressurecontroller.

Cutinautocontroller.

Startwithdrawingoilsupportgradually.Ensurehealthinessoffireballscanners.

07 65'

LOAD:150MW.

MS:100kg/cm2/5000C

HRH:20kg/cm2/4800C


TrimmingdeviceisinOFF.


CutinH.P.heatersandputthelevelcontrolsonauto.

StartfirstTDBFPandsecondCEParoundaloadof170MW.

Controlmainsteamandreheatsteamtemperaturebyusingsprayifrequired.

ChangedeaeratorpeggingsteamfromCRHtoExtractionsteam.

EnsureDeaeatorpressurecontrollerremainsonauto.


08 70'

LOAD:230MW.

MS:120kg/cm2/5000C

HRH:20kg/cm2/4950C





Cutoffoilsupportcompletely.

Ensurehealthinessoffireballscanners.

CutinVthcoalmillandcutinautocontrollers.

StartsecondTDBFPandswitchoffmotordrivenBFP.

CutinVIthcoalmillandcutinautocontrollers.

09 86'

LOAD:500MW.

MS:170kg/cm2/5000C



Checkallparametersatfullloadandensurethemwithinlimits.

IncreasethesetpointofSH&RHspraycontrollerssuchthatratedparametersareachieved.

10 135'

LOAD:500MW.

MS:170kg/cm2/5000C



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Date post:	15-Dec-2015
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Bhel Tg Rolling

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