KORADI TPS EXPANSION PROJECT – 3 x 660

LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 3 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

TABLE OF CONTENTS

1.0 INTRODUCTION.............................................................................................................................................. 5

2.0 SCOPE ................................................................................................................................................................ 5

3.0 BOILER & TURBINE START-UP MODE ................................................................................................... 5

4.0 START-UP PREPARATION ........................................................................................................................... 6

4.1. START-UP POWER AVAILABILITY ..................................................................................................................... 6

4.2. BALANCE OF PLANT SYSTEMS START-UP ........................................................................................................ 6

5.0 LP SYSTEM CLEANUP BREAK POINT ................................................................................................... 10

5.1. TURBINE GLAND SEALING & VACUUM PULLING ........................................................................................... 10

5.2. CONDENSATE POLISHING SYSTEM STARTUP ................................................................................................. 11

5.3. DEAERATOR INITIAL HEATING ....................................................................................................................... 11

5.4. MDBFP STARTUP .......................................................................................................................................... 11

6.0 HP SYSTEM CLEANUP BREAK POINT ................................................................................................... 12

7.0 BOILER COLD CLEANUP BREAK POINT ............................................................................................. 12

8.0 BOILER START-UP ....................................................................................................................................... 13

8.1. MAIN STEAM SYSTEM CHARGING ................................................................................................................. 14

8.2. RH STEAM SYSTEM CHARGING ..................................................................................................................... 14

9.0 TURBINE START-UP .................................................................................................................................... 15

9.1. ST ROLLING .................................................................................................................................................... 15

9.2. SYNCHRONIZATION & INITIAL LOAD BP ....................................................................................................... 16

9.3. LOAD UP TO 20% BP ...................................................................................................................................... 16

9.4. LOAD UP TO 30% BP ...................................................................................................................................... 17

10.0 SHUTDOWN PROCEDURE ......................................................................................................................... 19

10.1. COAL MILLS CUT OFF .................................................................................................................................... 19

10.2. ONE TDBFP STOP .......................................................................................................................................... 19

10.3. ONE CEP STOP ............................................................................................................................................... 19

10.4. CHANGEOVER FROM COAL TO OIL FIRING..................................................................................................... 20

10.5. AUXILIARY STEAM SOURCE CHANGEOVER ................................................................................................... 20

10.6. CHANGEOVER FROM TDBFP TO MDBFP...................................................................................................... 20

 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 4 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

10.7. FEED WATER HEATER EXTRACTION CUT OFF ............................................................................................... 20

10.8. START-UP OF BCP .......................................................................................................................................... 20

10.9. ST TRIP AND BYPASS OPERATION ................................................................................................................. 20

10.10. BOILER SHUTDOWN ........................................................................................................................................ 21

11.0 REFERENCE DOCUMENT .......................................................................................................................... 21

12.0 ATTACHMENT : AUTOMATIC PLANT STARTUP FLOW DIAGRAM ............................................ 22

13.0 PLANT SHUTDOWN FLOW DIAGRAM .................................................................................................. 40

14.0 ATTACHMENT : PLANT STARTUP CURVE ..........................................................................................49

 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 5 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

1.0 Introduction

This document contains guidelines for Automatic Plant Startup procedure for Koradi TPS
Expansion Project in Maharashtra. Plant Start-up flow diagram and Startup Curve can also be
referred, along with this document, for graphical sequence of plant start-up programmed in
DCS.

The complete APS will be divided in to various break points. A break Point defines various
sequence of events. Once the break point is started automatically by APS or initiated by
operator, all steps corresponding to that break point will be performed sequentially. Once all
the steps are completed, Break Point is considered to be completed.

2.0 Scope

Scope of this document is to describe the automatic plant start-up procedure for the overall
power plant system. This document is subject to revision based on the further detailed
engineering and vendor/OEM information.

3.0 Boiler & Turbine Start-up Mode

Boiler start-up mode is defined based on separator inlet temperature as per the table given
below:

Sr No Separator Inlet Temperature Mode of Startup

(⁰C)

1 T < 120 Cold Startup

2 120 < T < 260 Warm Startup

3 260 < T < 340 Hot Startup

4 T > 340 Very Hot Startup

 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 6 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

Similarly, steam turbine startup mode is defined based on 1st stage metal temperature as per
the table given below:

Sr No HP Inlet Casing Metal Mode of Startup

Temperature

(⁰C)

1 T < 120 Cold Startup

2 120 < T < 350 Warm Startup

3 T > 350 Hot Startup

At the time of overall plant startup, both boiler and turbine mode of startup will be decided in
respective control systems and the same will be communicated to DCS.

4.0 Start-up Preparation

4.1. Start-up power availability

Auxiliary power required for plant start-up is taken from the grid. Station transformer will be
charged from the grid power (400 kV). Station switch gear buses-A & B (11 kV) are charged
from ST to supply power to the various plant auxiliaries.

4.2. Balance of Plant Systems Start-up

Before initiating plant start-up, following utility systems are considered to be in service.

 DM water system

DM water system will be started manually by operator from DCS. DM transfer pump will
be running to supply water for condensate storage tank.

 Condensate Storage and Transfer System

Once DM water system is running, operator will initiate filling of condensate storage tank.
Boiler Fill Pump (2 X 100%) / Cycle Makeup Pump (3 X 100% + 1 common standby) will
be operated to fulfill initial fill up requirement of various systems as well as hotwell make
up water requirement.

 DMCW system for SG

 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 7 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

DMCW water system for SG auxiliaries will be started manually by operator from DCS.
Initial filling of DMCW tank will be done from CST by operating cycle makeup pump.
One DMCW pump for SG auxiliaries along with PHE will be kept in operation. Cooling
water supply to various coolers will be charged manually by operator as per operational
requirements. The level in the overhead tank will be maintained by tank inlet LCV.

 DMCW system for TG

DMCW water system for TG auxiliaries will be started manually by operator from DCS.
Initial filling of DMCW tank will be done from CST by operating cycle makeup pump. 2
X 50% DMCW pumps for TG auxiliaries along with two PHE will be kept in operation.
Cooling water supply to various coolers will be charged manually by operator as per
operational requirements. The level in the overhead tank will be maintained by tank inlet
LCV.

 CW system

CW system will be started manually by operator from DCS. 2 х 50% circulating water
pumps will be started one after the other by taking water from CW forebay. The
circulating water supply to condenser will be established manually by operator.

CW treatment system (Owner’s scope) shall be taken in line manually by operator.

 ACW system

Operator starts any one of 2 X 100% ACW pump from DCS to supply cooling water to the
DMCW heat exchanger and vacuum pump seal water coolers as per requirements.

 Compressed Air system

As soon as cooling water for air compressor is available from ACW system, operator will
give compressed air system (Owner’s scope) group start command from DCS and charge
instrument air and service air distribution systems as per operational requirements.

 Service Water system

Start-up of service water system includes charging of service water overhead tank from
plant water system and startup of one service water pump. Charging of service water
distribution lines will be done by operator as per operational requirements.

 Fire water system

 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 8 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

Fire water system will be charged and kept in auto to avoid any potential hazard in the
plant.

 Fuel oil forwarding system

Fuel oil system start-up will be done manually by operator from DCS. HFO pressurizing
pump will be started and kept ready for operation.

LDO pressurizing pump will also be started to fulfill the fuel oil requirement during start-
up by operator.

 Chemical Dosing System

Chemical dosing system shall be kept ready for plant startup.

4.2.1 Initial Fill

Condenser hotwell is filled up to the normal water level (850 mm) by opening manual
isolation valves (08GHC27AA112/113) and LCV (08GHC27AA085). The condensate system
piping filling is done from condensate storage tank through boiler fill pump by opening
manual isolation valve 08GHC27AA111. Before starting any CEP, it shall be ensured that
piping downstream of CEP is completely filled with water.

Initial fill water for deaerator is supplied from condensate storage tank through boiler fill
pump by opening MOV (08GHC14AA147).

System high point vent valves are operated during initial filling. Once filling is completed,
vent and drain valves are closed.

4.2.2 Auxiliary Steam System Line up

Auxiliary steam during start-up will be supplied from the other unit operating via unit
auxiliary steam header or from the auxiliary boiler (in case of first unit startup).

Auxiliary steam consumption during start-up includes the following consumers:

 Deaerator initial heating

 Deaerator Pegging Steam

 HFO steam tracing

 Oil drain tank

 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 9 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

 Fuel oil unloading cum storage area

 Day oil tank area

 HFO heating

 HFO line tracing

 Turbine Gland Seal Steam

 BFPT gland seal steam

 BFP Turbine warm up line

 Steam Air Heater (Aux steam lines to SAH will be charged and kept ready for operation)

Once all start permissive required for APS are satisfied, Operator can select “APS IN” from
DCS. This is will execute various steps related to cleanup, boiler startup & turbine startup. At
any point of time if operator selects “APS OUT”, APS sequence will stop advancing and get
terminated. If operator selects “APS HOLD” then sequence will stop at that step and wait for
further operator confirmation.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 10 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

5.0 LP System Cleanup Break Point

LP system cleanup is divided in to following steps which will be performed sequentially:

Step 1 : Condenser Bottom Blow (This step is required to be performed only during
commissioning and after a long shutdown. This step will be performed manually by
operator. )

Step 2 : Condensate Clean up Blow

Step 3 : Condensate Clean up Bypass Blow

Step 4 : Condensate Clean up Recirculation

Step 5 : LP Heater Line Clean up Blow(1/2)

LP Heater Line Clean up Blow (2/2)

Step 6 : LP Heater line Clean up Recirculation (1/2)

Step 7 : LP Heater line Clean up Recirculation (2/2)

Refer to “System Description, Operation & Control for Startup Cleaning – L555-00M- 00929”
for detailed startup cleaning procedure. Completion of each step shall be confirmed by
operator after checking necessary completion criteria. Once Operator confirms a step
completion, the sequence will move further to the next step.

5.1. Turbine Gland sealing & Vacuum Pulling

During LP system cleanup operation, condenser vacuum is built up before Condensate

Cleanup Recirculation (Step: 4) is initiated.

However, for condenser vacuum building, gland seal steam is to be established first. Gland
Seal steam source during this period will be steam supply from operating unit aux. steam
header or aux boiler. Seal steam header will be charged by opening the isolation MOV
(08LBG17AA003). PCV (08MAW01AA701) will maintain the seal steam header pressure
(0.25 kg/cm2).
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 11 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

Once gland seals are established, condenser vacuum pulling can be initiated. During startup
both main and standby vacuum pumps shall be operated for hogging operation. Once
sufficient vacuum (0.3453 kg/cm2) is established, the standby vacuum pump will be stopped.

5.2. Condensate Polishing System Startup

Condensate Polishing Unit will be taken in line during Condensate Cleanup Recirculation.
Start command to CPS shall be given from APS. Once CPS is started and in service,
Condensate Cleanup Recirculation will be initiated from APS.

5.3. Deaerator Initial Heating

During LP heater line cleanup circulation, auxiliary steam supply to deaerator will be charged
and initial heating of deaerator is initiated. MOV (08LBG17AA005) in auxiliary steam supply
line to deaerator will be opened. PCV will maintain deaerator pressure.

5.4. MDBFP Startup

MDBFP will be started during LP cleanup recirculation with LP heaters in line. During this
step MDBFP will be operated in minimum recirculation mode with discharge MOV closed.
This operation will help increasing feedwater temperature faster.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 12 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

6.0 HP System Cleanup Break Point

HP system cleanup break point is divided in to following steps which will be performed
sequentially:
Step 8: HP Heater Cleanup Blow

Step 9: HP Heater Line Recirculation

Refer to “System Description, Operation & Control for Startup Cleaning – L555-00M- 00929”
for detailed startup cleaning procedure. Completion of each step shall be confirmed by
operator after checking necessary completion criteria. Once Operator confirms a step
completion, the sequence will move further to the next step.

7.0 Boiler Cold Cleanup Break Point

Boiler Cold cleanup break point is divided in to following steps which will be performed
sequentially:
Step 10: Boiler Cold Cleanup Blow

Step 11: Boiler Cold Cleanup Recirculation

Refer to “System Description, Operation & Control for Startup Cleaning – L555-00M- 00929”
for detailed startup cleaning procedure. Completion of each step shall be confirmed by
operator after checking necessary completion criteria. Once Operator confirms a step
completion, the sequence will move further to the next step.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 13 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

8.0 Boiler Start-up

Boiler start command will be issued from APS which will initiate a boiler startup sequence.
Following Break Points will be performed under Boiler Startup Sequence till turbine steam
admission.

 Furnace Purge BP

o Boiler Banking Reset

o Air & Gas Draft Group Startup

o SSC Group Start

o Boiler Circulating Water Group Startup

o SAH Group Start

o Fuel Oil Group Startup

o Furnace Purge Start

o Fuel Oil Leak Test Start

o Primary air Group Start

 Boiler Light off BP

o Main & Reheat Steam Drain and Boiler Drain Group ON

o Fuel Oil Burner Light off

o Boiler Hot Cleanup Circulation

o Boiler Pressure & Temperature Rising

 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 14 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

8.1. Main Steam System Charging

HP bypass system is provided to control the main steam pressure. During start-up before boiler
is fired and all permissive for HP bypass system are satisfied HP bypass system will be put in
to service under auto control.

HP bypass will be operated as per LMB’s recommendation from boiler light off till the
parameter (pressure and temperature) required for turbine steam admission are achieved.

Spray water for HP bypass valve is supplied from BFP discharge line. HP bypass temperature
control valve operate in auto mode. TCV will be modulated based on the feedback signal from
HP bypass valve downstream temperature measurement.

Once the main steam pressure reaches to steam admission pressure (91.8 Kg/cm2), HP bypass
controller mode changes to pressure control mode. HP bypass is operated so as to maintain the
main steam pressure constant at steam admission pressure (91.8 Kg/cm2).

As steam flow to turbine will gradually increases, HP bypass will start closing automatically.
Once HP Bypass valve opening is less than 2%, HP Bypass valve will be fully closed. Then
after HP bypass will remain in auto mode (back up mode) to cater to any emergency
conditions.

8.2. RH Steam System Charging

LP bypass system is provided for reheat steam pressure control. LP bypass will be operated as
per LMTG recommendation from boiler light off till the steam parameters required for steam
admission are achieved.

Spray water for LP bypass valve desuperheater is supplied form the CEP discharge line. LP
bypass valve TCV operate in auto mode. Enthalpy based temperature control is realized for LP
bypass downstream temperature control.

As soon as synchronizing pressure is reached, LP bypass valve controller mode changes to

pressure control mode so as to maintain the constant reheat steam pressure.

As steam flow to turbine will gradually increases, LP bypass will start closing automatically.
Once bypass PCV opening is less than 2%, PCV will be fully closed. Then after LP bypass
will remain is auto mode to cater to any emergency conditions.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 15 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

9.0 Turbine Start-up

Turbine start-up is performed by Automatic Turbine Run up System (ATRS) which is a part of
turbine control system.

The Automatic Turbine Run up System provides acceleration, load rates, and hold times
directly to the primary controls or guide messages for the operator.

The ATS function will furnish guidance messages to the operator in which set points should be
selected for proper operation. The operator will follow these guidelines in respect to pre-start
temperature and stress conditions, recommended acceleration rates and whether to implement
speed holds.

9.1. ST rolling

The turbine will be rolled by the ATRS sequence at suitable speed and acceleration rate based
on the thermal stress of HIP rotor.

Rub check will be performed once the speed reaches to 400 RPM.

Turbine is accelerated to high speed hold (2000 RPM). Once speed reaches to 800 RPM,
jacking oil pump will be stopped automatically. Steam Turbine speed will be held constant at
2000 RPM for heat soaking. Holding period for various modes of start-up is as given in the
table below:

Mode of start-up Holding period (min)

Cold start-up 180

Warm start-up 0

Hot start-up 0

Once holding period is completed, turbine accelerates to full speed. Auxiliary oil pump and
turning oil pump stop at 2950 RPM. Field excitation will be applied to the generator excitation
system when close to rated speed. Also, valve changeover form MSV to GV will be
performed.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 16 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

9.2. Synchronization & Initial Load BP

Generator synchronization will be done through Auto Synchronization Sequence (ASS).

Automatic synchronizing consists of automatically speed matching and voltage matching,
checking of phase matching and commanding the generator breaker to close.

Once synchronization is completed, turbine will be loaded to 5% initial load. Load hold will
be applied at initial load depending up on the mode of startup as per the table given below:

Mode of start-up Holding period (min)

Cold start-up 40

Warm start-up 20

Hot start-up 10

Once initial load hold time is completed, 1st pulveriser warming will be initiated.

9.3. Load up to 20% BP

During this break point 1st coal pulveriser light off will be done. Also, warming of 2nd
pulverize will be initiated.

9.3.1. BFPT Warming

Warming of both BFPT will be done simultaneously. Steam supply for BFPT warming will be
done from auxiliary boiler or unit auxiliary header. BFPT warming will be done as per OEM
recommendation.

9.3.2. LP Heater Drain Line Cleanup

Once turbine load increases to 15%, LP heater drain line cleanup will be initiated.

Refer to “System Description, Operation & Control for Startup Cleaning – L555-00M- 00929”
for detailed cleaning procedure. Completion LP heater drain line blow shall be confirmed by
operator after checking necessary completion criteria. Once Operator confirms a step
completion, the heaters 3& 4 will be taken in line from steam side with normal and emergency
drain valve in auto and blow valve in closed condition.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 17 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

9.3.3. HP Heater Drain Line Cleanup

Once turbine load increases to 20%, HP heater drain line cleanup will be initiated.

Refer to “System Description, Operation & Control for Startup Cleaning – L555-00M- 00929”
for detailed cleaning procedure. Completion HP heater drain line blow shall be confirmed by
operator after checking necessary completion criteria. Once Operator confirms a step
completion, the heaters 6, 7 & 8 will be taken in line form steam side with normal and
emergency drain valve in auto and blow valve in closed condition.

9.4. Load up to 30% BP

9.4.1. Boiler Wet- Dry Mode Changeover

As boiler steam production increases, water separator level reduces. Between 20-30% BMCR
load, water separator level will reduce and BCP will stop. Boiler mode of operation changes
over from wet state to dry state. The boiler now operates in once through mode.

9.4.2. MDBFP to TDBFP Changeover

Once CRH steam parameters are sufficient for BFPT operation, 1st TDBFP can be started
between 20-30% load. Once TDBFP is started and taken in service, MDBFP will be taken out
of service. Then after MDBFP can be shutdown and feedwater demand will be fulfilled by
TDBFP.

9.4.3. DA pegging steam source changeover – Aux Steam to CRH

Once CRH parameters are suitable for supply to deaerator, open permissive for DA pegging
steam line MOV (08LBC03AA058) from CRH steam will be available. This MOV can be
opened from DCS. Once CRH steam line MOV is opened, pegging steam line MOV
(08LBC17AA075) in the aux steam line is closed automatically. Hereafter, DA pegging steam
will be supplied from CRH steam.

9.5. Load up to 50% BP

9.5.1. BFPT Steam and Pegging Steam Changeover from CRH to IP Extraction

As soon as turbine load increases so that sufficient IP steam is available for BFPT operation,
changeover from CRH steam to IP steam will be done. Now steam to operate BFPT will be
supplied from IP extraction and CRH steam will be kept as a backup.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 18 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

Isolation MOV (08LBD11AA013) in the IP extraction line to deaerator open and pegging
steam line MOV (08LBC03AA058) from CRH to deaerator closes. Now pegging steam to
deaerator will be supplied from IP extraction and CRH steam will be kept as a backup.

9.5.2. Auxiliary Steam Source Changeover to CRH

As soon as turbine load reaches to 40% CRH steam pressure is sufficient (>19 kg/cm2) to
fulfill aux. steam requirements. MOV (08LBC03AA056) in aux. steam supply from CRH will
be opened. And pressure reducing valve (08LBC03AA083) will maintain the auxiliary steam
requirement (19 kg/cm2g) from CRH steam supply. Temperature control valves
(08LCE13AA097/98) will maintain aux steam LT header temperature (220 ⁰C). Hereafter, all
aux. steam requirements will be fulfilled from CRH steam supply.

9.5.3. Second TDBFP Startup

At around 40% unit load depending upon the operational requirement second TDBFP will be
started to fulfill the increasing feedwater requirement. Once both TDBFP are in service,
feedwater requirement will be shared by both TDBFP equally.

9.5.4. Second CEP Start-up

At around 45% unit load depending upon the operational requirement second CEP will be
started to fulfill increasing condensate requirement.

Once load increases beyond 30%, deaerator 100% LCV starts to control the DA level based on
three element control using deaerator level measured by triple redundant level transmitters
61LAA10CL001/2/3, deaerator output (as measured by feedwater flow), and condensate flow
to the deaerator measured by flow transmitter 61LCA90CF001.

9.6. Load up to 100% BP

9.6.1. Changeover from Oil firing to Coal firing

Start-up is envisaged with fuel oil as a firing fuel. Coal mills will be started sequentially
depending up on the furnace temperature and load requirement. Before taking first mill in to
line, mill reject system will be started and will be kept in auto mode (level probe). As coal
mills start, oil firing is decreased gradually. To light up the coal burner in order to increase the
load, adjacent oil burner should be in operation. Therefore the last oil burner can be taken out
only after 4th coal mill is cut in.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 19 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

10.0 Shutdown Procedure

The normal plant shutdown is considered from the unit operating at full load. At this point
plant is operating at 100% TMCR condition. Four/ Five coal mills are in operation depending
upon the coal being used. Boiler feedwater requirement is being fulfilled by two TDBFP. Two
CEPs are in operation. HP-LP bypass systems are in auto and valves are in closed condition.

Target load to which load reduction is to be done automatically will be selected by operator.
Also, whether shutdown is to be done with condenser vacuum up or not is to be selected by
operator. However, if any of the following condition occurs then vacuum break mode will be
selected automatically:

1. HP Condenser vacuum breaker valve open

2. LP Condenser vacuum breaker valve open

3. Condenser vacuum >(-0.667) barg

Depending up on the selection, shutdown will be performed automatically by executing

various break points.

Steam turbine load will be reduced at a predefined rate of 1.5% /min up to 50% load. Once
load is reduced to 50%, load hold of around 30 min will be initiated. Then load will be
reduced to minimum load condition at a predefined load rate of 1% /min.

10.1. Coal Mills Cut off

As the output starts reducing, the coal burners are turned off sequentially according to the decrease of
the fuel flow rate.

10.2. One TDBFP stop

As load reduces boiler feedwater requirement also reduces and at 50% load the feedwater requirement
reduces to the extent where only one TDBFP can fulfill the feedwater requirement. Once load reduces
below 45%, one BFPT will be shutdown and respective TDBFP will be taken out of service.

10.3. One CEP stop

As load reduces, total condensate flow will also reduce and both CEPs will continue to run on part load.
At 40% load one CEP can be stopped. After that only one CEP along with the standby pump will be
running to supply condensate flow to the deaerator.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 20 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

10.4. Changeover from Coal to Oil Firing

Once all permissive for HFO leak test are satisfied, Steam air heater will be started. Then HFO leak test
will be performed. Once all permissive for HFO burner light off are satisfied, 3rd coal mill is cut off
below 35% load. Electrostatic precipitator shutdown sequence will be initiated. Oil firing will be
introduced to support further shutdown. Remaining two coal mills will be gradually cut off as the load
reduces towards 20%. Once all coal burners are cut off and at least one oil burner is in operation then
fuel changeover is deemed to be completed. Subsequent shutdown will be performed with the help of
oil firing only.

10.5. Auxiliary Steam Source Changeover

Auxiliary steam will be supplied from CRH until the CRH pressure reduces & CRH to aux steam PRV
is full open. After that auxiliary steam source will be changed over to primary superheater for
subsequent requirement. Once primary superheater steam parameters reduce below 91 kg/cm2 & 355⁰C,
auxiliary steam will be taken from unit crosstie.

10.6. Changeover from TDBFP to MDBFP

MDBFP is started once the steam load comes down to 30% during shutdown. Once MDBFP is in
service, TDBFP will be given stop command. The subsequent feedwater requirement to accomplish the
shutdown will be fulfilled via MDBFP. The FCV at feed control station will be operated in order to
control the feedwater flow to the boiler and feed control station MOV is closed.

10.7. Feed Water Heater Extraction Cut off

As steam turbine load reduces towards minimum load condition, feedwater heater extractions get cut off
automatically based on availability of extraction steam. Once load reduces below 16%, HPH extraction
for heater 8, 7 and 6 closes sequentially. All LP heaters will also get cut-off as soon as steam turbine
load reduces below 12 %.

10.8. Start-up of BCP

As steam generation in the boiler reduces, the steam temperature at separator inlet will fall below the
superheated region, and water level will start to develop in the separator. BCP is started now to maintain
the minimum water wall flow and boiler is operated in recirculation mode.

10.9. ST Trip and Bypass Operation

Turbine load will be reduced to minimum load condition. After the minimum shutdown load is reached
(≤ 5%) turbine desynchronization breakpoint is initiated.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 21 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

As soon as turbine is desynchronized, turbine speed decreases at a predefined gradient and once speed
reaches near to zero speed, turning gear is started. HP-LP bypass valve will open to maintain the
upstream pressure at floor pressure (91.8 kg/cm2).

10.10. Boiler Shutdown

Once steam turbine is tripped, boiler shutdown is performed in following steps:

4. Last fuel oil burner shutdown

5. Primary air group shutdown

6. Boiler Circulation Pump shutdown

7. Air & flue gas draft group shutdown

8. Boiler banking ON

9. CPS out of service (bypass mode) (in case of vacuum break mode)

10. CPS shutdown (in case of vacuum break mode)

11. Condensate vacuum group shutdown (in case of vacuum break mode)

12. Chemical injection group shutdown

11.0 Reference Document

 Process & Instrumentation Diagram (P&ID)

 Control Loops and Logic Digram
 Boiler Startup/Shutdown Sequence
 Turbine Startup Procedure
 Startup/shutdown Curve for Steam Turbine
 Startup curve for Boiler
 System Description
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 22 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

12.0 Attachment : Automatic Plant Startup Flow Diagram

LEGENDS - STARTUP FLOW DIAGRAM

START/ END OF FLOW DIAGRAM

DECISION BOX

FLOW STEPS

OFF PAGE REFERENCE

ACTION REQUIRING MANUAL OPERATION

BREAK POINT START/ FINISH

REFERENCE TO RESPECTIVE LOGIC DIAGRAM

SIMULTANEOUS ACTIVITIES (INDICATIVE ONLY)

EXTERNAL SEQUENCE LOGIC

Page 1
 ABBREVIATION

APS: AUTOMATIC PLANT STARTUP

BP: BREAK POINT

B/T: BOILER/ TURBINE

BCP: BOILER CIRCULATION PUMP

BFPT: BOILER FEED PUMP DRIVE TURBINE

CW: CIRCULATING WATER

CCW: CLOSED COOLING WATER

CEP: CONDENSATE EXTRACTION PUMP

CPU: CONDENSATE POLISHING UNIT

IA: INSTRUMENT AIR

MS: MAIN STEAM

MDBFP: MOTOR DRIVEN BOILER FEED PUMP

RH: REHEAT STEAM

SA: SERVICE AIR

ST: STEAM TURBINE

TDBFP: TURBINE DRIVEN BOILER FEED PUMP

Page 2
 START

APS START-UP PERMISSIVE:

1. CW SYSTEM “IN SERVICE”
2. DM STORAGE TANK LEVEL ADEQUATE
3. ANY TWO CST LEVEL ADEQUATE
4. IA SYSTEM “IN SERVICE” APS STARTUP PREPERATION
5. SA SYSTEM “IN SERVICE”
6. GENERATOR SEAL OIL SYSTEM “IN
SERVICE”
7. MAKE UP WATER SYSTEM “IN
SERVICE”

NO START
PERMISSIVE
SATISFIED

YES

UNIT STARTUP
UNIT START-UP PERMISSIVE: PREPARATION
1. B/T CCW SYSTEM “IN SERVICE” BP START
2. TURBINE OIL SUPPLY SYSTEM “IN SERVICE”
3. TURNING GEAR SYSTEM “IN SERVICE”
4. AUXILIARY STEAM SYSTEM AVAILABLE
5. LP EXTRACTION GROUP AUTO
6. HP EXTRACTION GROUP AUTO
7. BFPT A OIL SUB GROUP START UP
UNIT STARTUP
8. BFPT B OIL SUB GROUP START UP
PREPERATION
9. INITIAL FILLING OF CONDENSATE SYSTEM
COMPLETED
10. INITIAL FILLING OF DEAERATOR
COMPLETED
11. INITIAL FILLING OF BOILER INCLUSIVE OF
HP HEATERS COMPLETED
12. BOILER FUEL SYSTEM READY
13. MDBFP AUX OIL PUMP STARTED

NO START
PERMISSIVE
SATISFIED

YES

APS IN SELECTION

APS GO/HOLD SELECTION

UNIT STARTUP
PREPARATION
BP COMPLETE

NOTE:
1. IF OPERATOR SELECTS “APS OUT” MODE THEN
APS SEQUENCE WILL STOP ADVANCING AND GET P-6
TERMINATED
2. IF OPERATOR SELECTS “APS HOLD”
SEQUENCE WILL STOP AT THAT STEP AND WAITS
FOR FURTHER OPERATOR CONFIRMATION Page 3
 P-3

BOILER STARTUP MODE

TURBINE STARTUP MODE
SELECTED BY BOILER
SELECTED IN TCS
CONTROL SYSTEM

1ST CEP STARTUP

LP CLEANUP
BP START

CONDENSER BOTTOM STEP 1

BLOW COMPLETED CONDENSER BOTTOM BLOW
(OPERATOR INTERVENTION) COMPLETED
(REFER NOTE) (REFER NOTE)

CLEAN UP STEP NO
2 REQUIRED

YES

STEP 2
CONDENSER CLEANUP
BLOW START
(REFER NOTE)

STEP COMPLETION
CRITERIA FULFILLED &
(OPERATOR INTERVENTION)

STEP 2
CONDENSER CLEANUP
BLOW AUTO COMPLETED

OR

P-6

NOTE: DURING NORMAL OPERATION STEP 1 WILL NOT BE PERFORMED. CONDENSER BOTTOM BLOW WILL BE DONE
ONLY AFTER A LONG SHUTDOWN. Page 4
 P-6

CLEAN UP STEP NO
3 REQUIRED

YES
STEP 3
LOGIC REFERENCE:
CONDENSER CLEANUP
LATER
BYPASS BLOW AUTO START

STEP COMPLETION
CRITERIA FULFILLED &
(OPERATOR INTERVENTION)

STEP 3
CONDENSER CLEANUP
BYPASS BLOW COMPLETED

OR

CONDENSER VACUUM LOGIC REFERENCE:

GROUP “STARTUP” 601A-15

CONDENSER VACUUM
LOGIC REFERENCE:
P-9

GROUP STARTUP
601A-39
COMPLETED

LOGIC REFERENCE:
ANY CPU AUTO START
959A-25

LOGIC REFERENCE:
ANY CPU IN SERVICE
969A-50

P-6

Page 5
 P-5

CLEAN UP STEP NO
4 REQUIRED

YES
STEP 4
CONDENSATE CLEANUP LOGIC REFERENCE:
RECIRCULATION AUTO 59-10
START

STEP COMPLETION CRITERIA

FULFILLED &
(OPERATOR INTERVENTION)

STEP 4
CONDENSATE CLEANUP
RECIRCULATION
COMPLETED

OR

CLEAN UP STEP NO
5 REQUIRED

YES
STEP 5
LOGIC REFERENCE:
LP HEATER CLEANUP BLOW
301A-17
(½) AUTO START

STEP COMPLETION CRITERIA

FULFILLED &
(OPERATOR INTERVENTION)

STEP 5
LP HEATER CLEANUP BLOW
(½) COMPLETED

STEP 5
LP HEATER CLEANUP BLOW
(2/2) AUTO START

LOGIC REFERENCE:
STEP COMPLETION CRITERIA LATER
FULFILLED &
(OPERATOR INTERVENTION)

STEP 5
LP HEATER CLEANUP BLOW
(2/2) COMPLETED
DEAERATOR INITIAL
HEATING START LOGIC REFERENCE:
LATER
OR

P-7

Page 6
 P-6

CLEAN UP STEP NO
6-7 REQUIRED

YES
STEP 6
LP HEATER LINE CLEANUP
LOGIC REFERENCE:
RECIRCULATION (½) AUTO
302A-17
START

STEP COMPLETION CRITERIA

FULFILLED &
(OPERATOR INTERVENTION)

STEP 6
LP HEATER LINE CLEANUP
RECIRCULATION (½)
COMPLETED

STEP 7
MDBFP STARTUP LP HEATER LINE
CIRCULATION 2 AUTO START

STEP COMPLETION CRITERIA

FULFILLED &
(OPERATOR INTERVENTION)

STEP 7
LP HEATER LINE
CIRCULATION 2 COMPLETED

OR

P-8

Page 7
 P-7

LP CLEANUP
BP COMPLETE

HP CLEANUP
BP START

CLEAN UP STEP NO
8 REQUIRED

YES

STEP 8
LOGIC REFERENCE:
HP HEATER CLEANUP BLOW
801A-21
AUTO START

STEP 8
HP HEATER CLEANUP BLOW
COMPLETED

OR

CLEAN UP STEP NO
9 REQUIRED

YES
STEP 9
HP HEATER CLEANUP LOGIC REFERENCE:
RECIRCULATION AUTO 802A-21
START

STEP COMPLETION CRITERIA

FULFILLED &
(OPERATOR INTERVENTION)

STEP 9
HP HEATER CLEANUP
RECIRCULATION
COMPLETED

OR

P-9
Page 8
 P-8

HP CLEANUP
BP COMPLETE

BOILER COLD
CLEANUP BP
START

STEP 10
LOGIC REFERENCE:
BOILER COLD CLEANUP
904C-2
BLOW AUTO START

STEP COMPLETION CRITERIA

FULFILLED &
(OPERATOR INTERVENTION)

STEP 10
BOILER COLD CLEANUP
BLOW COMPLETED

STEP 11
BOILER COLD CLEANUP
RECIRCULATION AUTO
START

STEP COMPLETION CRITERIA

FULFILLED &
(OPERATOR INTERVENTION)

STEP 11
BOILER COLD CLEANUP
RECIRCULATION
COMPLETED

BOILER COLD
CLEANUP BP
COMPLETE

P-10

Page 9
 P-9

REFERENCE:
MS/RH STEAM DRAIN BOILER STARTUP
GROUP AUTO ON SEQUENCE
COMMAND

HP BYPASS IN AUTO MODE &

FURNACE PURGE BP:

- FDF,IDF CONTROL OIL PUMP &

SEAL AIR FAN START BOILER REFERENCE:
- BOILER BANKING RESET STARTUP BOILER STARTUP
- AIR & GAS DRAFT GROUP START SEQUENCE SEQUENCE
- SSC GROUP START
- BCP GROUP STARTUP
- FUEL OIL GROUP START
- FURNACE PURGE START
- FUEL OIL LEAK TEST START
- PRIMARY AIR GROUP START P-5 & CONDENSATE HEADER PRESSURE OK

BOILER LIGHT OFF BP:

- FUEL OIL BURNER LIGHT OFF

- BOILER HOT CLEANUP
RECIRCULATION LP BYPASS OPERATION
(AS PER LMTG
RECOMMENDATION)

RH PRESSURE INCREASE
TOWARDS Psync.
(XX barg/min)

NO
P = Psync.

YES
P-12

LP BYPASS CONTROLLER IN
FIXED PRESSURE CONTROL
MODE

P-11

Page 10
 P-10

LP BYPASS MODULATES TO
MAINTAIN CONST.
PRESSURE

NO LP BYPASS PCV
OPEN<2%

YES

LP BYPASS CONTROLLER IN
FOLLOW MODE

END

Page 11
 MS PRESSURE = 91.6 KG/CM2
TURBINE STEAM ADMISSION
MS TEMPERATURE (LEFT)= 380°C
CONDITION OK
MS TEMPERATURE (RIGHT)= 380°C

RH TEMPERATURE (LEFT)= T sync

P-10
RH TEMPERATURE (RIGHT)= T sync &
(LMTG INPUT REQUIRED)

TURBINE
STARTUP BP
START

TURBINE
REFERENCE:
STARTUP
TURBINE STARTUP BP: TURBINE STARTUP
ON
- TURBINE RESET SEQUENCE
COMMAND
- RUB CHECK AT 400 RPM
- JACKING OIL PUMP STOP
SPEED HOLD FOR HEAT SOAKING AT
2000 RPM
- AUX OIL PUMP STOP
- TURNING OIL PUMP STOP
- VALVE TRANSFER FROM MSV TO GV
ST SPEED INCREASE TO 3000
RPM

TURBINE
STARTUP BP
COMPLETE

SYNCHRONIZATI
ON AND INITIAL
LOADING BP
START

SYNCHRONIZATION
- AVR AUTO SEQUENCE COMPLETED
- GENERATOR CIRCUIT BREAKER
CLOSED
- 1ST PULVERISER WARMING START

P-13

Page 12
 P-12

ST LOAD SP = 5%
(BLOCK LOAD)

ST INITIAL LOAD HOLD

COLD START: 40 MIN
WARM START: 20 MIN
HOT START: 12 MIN

INITIAL LOAD
NO HOLD TIME
COMPLETED

YES

SYNCHRONIZATI
ON AND INITIAL
LOADING BP
COMPLETE

ST LOAD
INCREASE TO
20% BP START

BOTH BFPT WARMUP

INITIATED

NO
ST LOAD > 14%

YES

LP HEATER DRAIN CLEANUP LOGIC REFERENCE:

AUTO START 303A-17

P-14

Page 13
 P-13

STEP COMPLETION CRITERIA

LP HEATER DRAIN CLEANUP
FULFILLED
COMPLETED
(OPERATOR INTERVENTION)

ST LOAD INCREASE
TOWARDS 20%

NO
ST LOAD > 18%

YES

HP HEATER DRAIN CLEANUP LOGIC REFERENCE:

AUTO START 803A-19

STEP COMPLETION CRITERIA

HP HEATER DRAIN CLEANUP
FULFILLED
COMPLETED
(OPERATOR INTERVENTION)

- 2ND PULVERISER WARMING

LOAD
START
INCREASE TO
- COAL LOAD PROGRAM ON
20% BP
1ST PULVERISER LIGHT OFF
COMPLETE

- DEAERATOR PEGGING STEAM

P-15
CHANGEOVER FROM CRH TO IP
STEAM
- BFPT STEAM SOURCE
CHANGEOVER TO IP STEAM
- AUXILIARY STEAM SOURCE
CHANGEOVER TO CRH STEAM

Page 14
 P-14

LOAD
INCREASE TO
30% BP START

LOGIC REFERENCE:
1ST BFPT IN SERVICE
171E-15

- WET TO DRY MODE

CHANGEOVER
- BCP STOP
MDBFP TO TDBFP TRANSFER
COMPLETED

LOGIC REFERENCE:
MDBFP SHUTDOWN
171J-3

ST LOAD
INCREASE TO
30% BP
COMPLETE

ST LOAD
INCREASE TO
50% BP START

LOAD INCREASE TOWARDS

- 2ND COAL PULVERISER LIGHT 50%
OFF
- FUEL OIL BURNER SHUTDOWN
- ESP START
- 2ND CPU START

NO
ST LOAD ≥ 40%

YES
- 3RD PULVERISER WARMING
START
- 3RD PULVERISER LIGHT OFF
P-16

Page 15
 P-15

LOGIC REFERENCE:
2ND TDBFP START COMMAND
171E-23

2ND TDBFP IN SERVICE

LOGIC REFERENCE:
2ND CEP START COMMAND
LATER

LOGIC REFERENCE:
2ND CEP IN SERVICE
LATER

ST LOAD
INCREASE TO
50% BP
COMPLETE

ST LOAD
INCREASE TO
75% BP START
- 4TH PULVERIER WARMING
START
- 4TH PULVERISER LIGHT OFF

ST LOAD 75%

ST LOAD
INCREASE TO
75% BP
COMPLETE

P-17

Page 16
 P-16

ST LOAD
INCREASE TO
100% BP
START

- 5TH PULVERISER WARMING

START
ST LOAD 100%
- 5TH PULVERISER LIGHT OFF
(NOTE)

ST LOAD
INCREASE TO
100% BP
COMPLETE

END

NOTE: 5TH COAL MILL WILL BE TAKEN IN TO LINE IN CASE OF WORST COAL ONLY. Page 17
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 40 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

13.0 Plant Shutdown Flow Diagram

LEGENDS - STARTUP FLOW DIAGRAM

START/ END OF FLOW DIAGRAM

DECISION BOX

FLOW STEPS

OFF PAGE REFERENCE

ACTION REQUIRING MANUAL OPERATION

BREAK POINT START/ FINISH

REFERENCE TO RESPECTIVE LOGIC DIAGRAM

SIMULTANEOUS ACTIVITIES (INDICATIVE ONLY)

EXTERNAL SEQUENCE LOGIC

Page 1
 ABBREVIATION

APS: AUTOMATIC PLANT STARTUP

BP: BREAK POINT

B/T: BOILER/ TURBINE

BCP: BOILER CIRCULATION PUMP

BFPT: BOILER FEED PUMP DRIVE TURBINE

CW: CIRCULATING WATER

CCW: CLOSED COOLING WATER

CPU: CONDENSATE POLISHING UNIT

MS: MAIN STEAM

MDBFP: MOTOR DRIVEN BOILER FEED PUMP

RH: REHEAT STEAM

ST: STEAM TURBINE

TDBFP: TURBINE DRIVEN BOILER FEED PUMP

T/M: TURBINE/MOTOR

Page 2
 START

APS IN SELECTION

APS GO/HOLD SELECTION

LOAD DOWN
75% BP START

LOGIC REFERENCE:
ST LOAD REDUCTION AT
TURBINE SHUTDOWN
1.5 %/MIN
SEQUENCE
1ST COAL BURNER
SHUTDOWN

NO MW DEMAND
≤ 75%

YES

LOAD DOWN
75% BP
COMPLETE

P-4

Page 3
 P-3

LOAD DOWN
50% BP START

ST LOAD REDUCTION AT
1.5 %/MIN

2ND COAL BURNER

SHUTDOWN
NO
ST LOAD 50%

YES

LOAD DOWN
50% BP
COMPLETE

ST LOAD HOLD FOR 30 MIN

NO LOAD HOLD
PERIOD
COMPLETE

YES

LOAD DOWN
35% BP START

P-5

Page 4
 P-4

ST LOAD REDUCTION AT
1%/MIN

AUX STEAM SOURCE

CHANGEOVER TO PSH
- 1ST CEP SHUTDOWN

NO MW DEMAND
< 45%

YES

LOGIC REFERENCE:
2ND T-BFP SHUTDOWN
- STEAM AIR HEATER GROUP ON
171J-20
- HFO LEAK TEST
- 3RD COAL BURNER SHUTDOWN
- ESP SHUTDOWN
- HFO BURNER LIGHT OFF
LOAD DOWN
35% BP
COMPLETE

T/M
TRANSFER BP
START

- 4TH COAL BURNER SHUTDOWN

ST LOAD REDUCTION AT
1%/MIN

NO MW DEMAND
≤ 30%

YES

LOGIC REFERENCE:
MDBFP START COMMAND
171E-3

P-6

Page 5
 P-5

LOGIC REFERENCE:
MDBFP IN SERVICE
171E-39

TDBFP SHUTDOWN LOGIC REFERENCE:

COMMAND 171J-23

T/M
TRANSFER BP
COMPLETE

FUEL
CHANGEOVER
BP START
FUEL CHANGEOVER BP
- STEAM SYSTEM DRAIN VALVE ON
- MS-RH STEAM DRAIN VALVE ON
- BCP GROUP START
- 5TH COAL BURNER SHUTDOWN
FUEL
CHANGEOVER
BP COMPLETE

MIN LOAD BP
START

- TURBINE DRAIN GROUP ON

GENERATOR LOAD 5%
- MS-RH STEAM DRAIN GROUP ON
COMMAND
- STEAM SYSTEM DRAIN GROUP ON

P-7

Page 6
 P-6

- TURBINE DRAIN GROUP ON

ST LOAD REDUCTION AT
- MS-RH STEAM DRAIN GROUP ON
1%/MIN

NO MW DEMAND
≤ 5%

MIN LOAD BP
COMPLETE

DESYNC. BP
START

- TURBINE OIL SUPPLY GROUP ON

- TURNING GEAR GROUP ON
LOGIC REFERENCE:
TURBINE TRIP COMMAND
LATER

TURBINE TRIP FEEDBACK LOGIC REFERENCE:

(FROM TPS) LATER

DESYNC. BP
COMPLETE

P-8

Page 7
 P-7

BOILER &
TURBINE
SHUTDOWN
BP START

- LAST FUEL OIL BURNER SHUTDOWN

- PRIMARY AIR GROUP SHUTDOWN
- BOILER CW GROUP SHUTDOWN
LOGIC REFERENCE:
- BCP OFF BOILER MFT
LATER
- AIR AND GAS DRAFT GROUP SHUTDOWN
- BOILER BANKING ON

NO VACUUM BREAK
MODE SELECTED

YES

CPS OUT OF SERVICE

(BYPASS OPERATION)

CPS SYSTEM SHUTDOWN

CPS SYSTEM SHUTDOWN LOGIC REFERENCE:

COMPLETED LATER

CONDENSER VACUUM LOGIC REFERENCE:

GROUP SHUTDOWN LATER

OR

BOILER &
TURBINE
SHUTDOWN
BP COMPLETE

END
Page 8
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
Rev.: A
MAIN PLANT PACKAGE WRITEUP ON APS
Date: 21/08/12
L&T Project No. : C10901 Page: 49 of 50
Document No.: L555-00M-01002
L&T-S&L Job No.: L555000

14.0 Attachment : Plant Startup Curve

 ESTIMATED PLANT START-UP CURVE (COLD MODE)
BOILER STARTUP MODE
Pr T < 120 COLD STARTUP
Load Speed Temp (Kg/ Y MAX 120 < T < 260 WARM STARTUP
2
(%) (RPM) (˚C) cm ) 260 < T < 340 HOT STARTUP
600 Y MIN 565˚C T < 340 VERY HOT STARTUP
580 T: WATER SEPARATOR INLET TEMPERATURE
APS PERMISSIVE CONDITIONS: 560
1 CW SYSTEM “IN SERVICE” 540
2
2 CST LEVEL ADEQUATE 520 247 Kg/cm
3 IA SYSTEM “IN SERVICE” 500
4 SA SYSTEM “IN SERVICE” 480
5 MAKE UP WATER SYSTEM “IN SERVICE” 460
440 TURBINE STARTUP MODE
420 T < 120 COLD STARTUP
UNIT START PERMISSIVE: 400 120 < T < 350 WARM STARTUP
1 B/T CCW SYSTEM “IN SERVICE” 380 T > 350 HOT STARTUP
2 TURBINE OIL SUPPLY SYSTEM “IN SERVICE” 360 T: 1ST STAGE OUTLET METAL TEMPERATURE
3 AUX STEAM SYSTEM IN SERVICE 340
4 AUXILIARY STEAM SYSTEM AVAILABLE 320 3000 RPM
5 LP EXTRACTION GROUP AUTO 3000 300
6 HP EXTRACTION GROUP AUTO 2800 280 MODE OF STARTUP INITIAL LOAD LOAD HOLD
7 BFPT A OIL SUB GROUP START UP 2600 260 COLD 5% 40 MIN
8 BFPT B OIL SUB GROUP START UP 2400 240 WARM 5% 20 MIN
9 INITIAL FILLING OF CONDENSATE SYSTEM COMPLETED 2200 220 91.8 Kg/cm2 2000 RPM HOT 5% 10 MIN
10 INITIAL FILLING OF DEAERATOR COMPLETED 100 2000 200 100
11 INITIAL FILLING OF BOILER INCLUSIVE OF HP HEATERS COMPLETED 90 1800 180 90
12 BOILER FUEL SYSTEM READY 80 1600 160 80 MODE OF STARTUP LOADING RATE (5%- 40%) LOADING RATE (40%- 100%)
13 MDBFP AUX OIL PUMP STARTED 70 1400 140 70 1%/MIN COLD 0.5% / MIN 1% / MIN
60 1200 120 60 WARM 0.5% / MIN 1% / MIN
50 1000 100 50 HOT 1%/ MIN 2% / MIN
40 800 80 40
30 600 60 30
20 400 40 20 5% 0.5%/ MIN
10 200 20 10

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Boiler Firing Turbine Rolling Turbine Synchronisation Full Load LEGEND

SYNC & INITIAL LOAD MS Temperature (˚C)

LOAD UP TO 20% MS Pressure (Kg/cm 2)

BREAK POINT LP SYSTEM CLEANUP HP SYSTEM CLEANUP FURNACE PURGE BOILER LIGHT OFF TURBINE STARTUP
LOAD UP TO 30% Speed (RPM)

LOAD UP TO 50% Load (%)

LOAD UP TO 100% BYPASS POSITION (%)

1ST PULVERISER WARMING START

FDF,IDF, CONT. OIL PUMP & SEAL AIR FAN START

Note:
MAIN AND REHEAT STEAM DRAIN AND BOILER DRAIN GROUP ON

BOILER BANKING RESET FUEL OIL BURNER LIGHT OFF 2ND PULVERISER WARMING START This startup curve is provided for reference only.
AIR & GAS DRAFT GROUP START-UP BOILER HOT CLEANUP CIRCULATION COAL LOAD PROGRAM ON

SSC GROUP START BOILER PRESSURE AND TEMPERATURE RISING 1ST PULVERISER LIGHT OFF
Since boiler startup curves are available only till steam admission to turbine, it is assumed that boiler shall be capable to
match the ramp rates shown by turbine.
BOILER CIRCULATING WATER GROUP START-UP 2ND PULVERISER LIGHT OFF

FUEL OIL GROUP START WET TO DRY MODE CHANGEOVER

It is assumed that time shown on startup curve from (-30) min to (0) min is for indication only.
BOILER FURNACE PURGE START BCP STOP

FUEL OIL LEAK TEST START FUEL OIL BURNER SHUTDOWN

PRIMARY AIR GROUP START 3RD PULVERISER WARMING START

3RD PULVERISER LIGHT OFF

4TH PULVERISER WARMING START

FOR APPROVAL
4TH PULVERISER LIGHT OFF

5TH PULVERISER WARMING STRAT

5TH PULVERISER LIGHT OFF

TURBINE RESET AVR AUTO

TURBINE SPEED 400 RPM ASS ON

RUB CHECK REQUEST

JACKING OIL PUMP STOP AT 800 RPM

TURBINE SPEED 2000 RPM

SPEED HOLD FOR HEAT SOAKING

KORADI TPS EXPANSION PROJECT - 3X660 MW
AUXILIARY OIL PUMP STOP AT 2950 RPM

TURBINE TURNING OIL PUMP STOP AT 2950 RPM

TURBINE SPEED 3000 RPM

VALVE TRANSFER FROM MSV TO GV

(UNIT: 8,9 & 10), KORADI, MAHARASHTRA

HP HEATER LINE & BOILER COLD CLEANUP BYPASS

CONDENSER BOTTOM BLOW BLOW HP BYPASS IN AUTO HP BYPASS OPERATES TO INCREASE MAIN STEAM PRESSURE TO SYNCHRONISATION PRESSURE HP BYPASS IN CONSTANT PRESSURE MODE BOTH BFPT WARMING

CONDENSER CLEANUP BLOW HP HEATER & BOILER CLEANUP BLOW LP BYPASS IN AUO LP BYPASS OPERATES TO INCREASE REHEAT STEAM PRESSURE TO SYNCHRONISATION PRESSURE LP BYPASS IN CONSTANT PRESSURE MODE LP HEATER DRAIN CLEANUP

CONDENSER CLEANUP BYPASS BLOW HP HEATER LINE CLEANUP RECIRCULATION LP HEATER IN LINE

CONDENSER VACUUM GROUP STARTUP HP HEATER DRAIN CLEANUP

CPS STARTUP HP HEATER IN LINE

BOP
CONDENSATE CLEANUP RECIRCULATION

LP HEATER CLEANUP (1/2)BLOW

1ST TDBFP IN SERVICE

M-T TRANSFER PLANT COLD STARTUP CURVE

LP HEATER CLEANUP (2/2) BLOW MDBFP SHUTDOWN

LP HEATER CLEANUP RECIRCULATION (1/2) DA PEGGING STEAM CHANGEOVER

DEAERATOR INITIAL HEATING BFPT STEAM SOURCE CHANGEOVER

LP HEATER LINE RECIRCULATION (2/2) AUXILIARY STEAM SOURCE CHANGEOVER

MDBFP STARTUP 2ND TDBFP STARTUP

2ND CEP STARTUP

HP/LP BYPASS CLOSED