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Unit lightup synchronisation & shutdown

Date post: 07-May-2015
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Adani Power Limited Power Business Goal - 20,000 MW
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  • 1.Adani Power Limited Power Business Goal - 20,000 MW

2. ADANI 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 3. ACHIEVEMENTS INDIAS 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. 4. WELCOME TOPRESENTED BYB.K.PANDEY APML, TIRODA 5. START-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 6. START UP MODES COLD START UP:HP & IP SHAFT METAL TEMP 400C 7. Boiler Economiser 8HP TFCS11+1IPTLPT A3HPH - 2HPH - 1RH2x72x7815767LPT B 88756LPH -7A LPH -8A8LPH -7B LPH -8BCondensor (HP)Deaerator7Condensor (LP)EXT From CRH(MD BFBP 1x35%) HPH -3TDBFP 2X50%CEP3x50%1994 TPHGSC CPP1482 TPH LPH -5LPH -6 8. PRE 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. 9. 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. 10. BCP FILLING ,PURGING & FLUSHING PURPOSE- TO FILL THE MOTOR CAVITY. RECOMMENDED MOTOR FILLING WATER QUALITY CONDUCTIVITY 56C. 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. 25. TURBINE ROLLING SELECT TARGET SPEED 1500 RPM WITH RAMP RATE OF 100 RPM/MIN. ENSURE ALL HP CVS OPENS TO 12% TO WARM UP THE HP CASING. WHEN HP CASING TEMP >320C.CLOSE THE HP CVS. 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. 26. LOADING 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 450C. TAKE COAL MILL-B AT. STEAM T/PR 380C/8.7 MPA. INCREASE FUEL FLOW MAINTAINING STEAM TEMP.& RAISE LOAD AT 70 MW IP TO HP CHANGE OVER. CVS WILL START OPENING, CLOSE THE BDV AND VENTILATING VALVE. INCREASE THE LOAD AT 3MW/MIN CLOSE THE HP-LP BYPASS GRADULLY. 27. 660LOAD (MW)350 660 MW495330MW330198MW165 60MW33MW400 450 500 MINUTES 550 600 650MILL-F CUT IN (540MW)MILL-E CUT IN (430MW)MILL-D CIT IN (300MW)OIL GUN CUT OUT (260MW)MILL-A CUT IN(210MW)WET TO DRY CHANGE OVER2ND TDBFP CUT IN(180MW)HPH CHARGED(150 MW)MILL-C CUT IN AT 100MWIP TO HP CHANGE OVER (70MWMILL-B CUT INSYNCHRONISE &CHARGE D/A 28. FROM IPT EXHAUSTLPT A2ndLPT B2nd5th5th6th6th5th4th4th5th 6th6thLP HEATER 7ALP HEATER 7BLP HEATER 8ALP HEATER 8BCONDENSERCONDENSERHP HEATER LP HEATER 5 5HP HEATER LP HEATER 6 6 29. TDBFP 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. 30. TDBFP STEAM SOURCESHPIP 1.12 Mpa 378 C1.3 MPa 350 CAux. Steam Aux. Steam Header HeaderTo CRHMChangeover ValveE EMMMMFrom CRHE E MM4 MPa 315.3 CTDBFP-B To Condenser Deaerator DeaeratorTDBFP-ABooster pumps 31. LOADING TAKE THE MILL-C IN SERVICE AT 100 MW. STEAM T/PR:400C/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 410C/8.7 MPA. AT 180 MW TAKE SECOND TDBFP IN SERVICE. 32. MS LINEHRH LINEIP EXHAUST CRH LINE9th stage5th stageTDBFP AHP HEATER 1HP HEATER 2HP HEATER HP HEATER 3 3DEAERATORTDBFP B 33. PHASE 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 34. LOADING 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 475C/10 MPA. TAKE MILL-E AT 430 MW. MS T/PR 566C/17 MPA. TAKE MILL-F AT 540 MW. MS T/PR 566C/24.1 MPA. INCREASE THE LOAD TO FULL LOAD 660 MW GRADUALLY. 35. Boiler Design Parameters NO.Parameters 1100% BMCR Coal consumption (Design)Unit390.37t/h2Design fuel3Superheated steam flow2111t/h4Superheater outlet pressure25.4MPa5Superheater outlet temperature5696Reheated steam flow1749.1t/h7Reheater inlet pressure4.73MPa8Reheater outlet pressure4.49MPa9Reheater inlet temperature32410Reheater outlet temperature569Feedwater pressure28.8MPa.g11Feedwater temperature28012Separators steam temperature421153.3147.213 14Air preheaters outlet air temperature, uncorrected After correcting Calculating thermal efficiency of boilerIndian coal87.19% BMCR 36. TURBINE PARAMETERS Steam Admission Parameters at Turbine Inlet HPTIPTLPTPressure (MPa)24.23.9611.12I/L Temp (Deg C)566566378O/L Temp(deg C)315.3378Steam Flow (tph)1959.251649TURBINE HEAT RATE( KCL/KWH) 1885 No of Stop valves22No of Control valves44 37. TURBINE AT FULL LOAD 3.96MPa / 566c HRH 24.2MPa/566C1.12MPa / 378c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