BOILER TURBINE / GENERATOR AUXILIARY

THIS OPERATING PROCEDURE SHOWS THE OUTLINE OF

THE STEPS NORMALLY REQUIRED FOR STRATING – UP
THE PLANT FROM A COLD CONDITION SUCH AS THE
PLANT INITIAL START – UP AND AFTER THE OVERHAUL
INSPECTIONS OF THE PLANT AND SHUTTING – DOWN OF
THE PLANT FROM A NORMAL CONDITION.
NATURALLY, THIS IS NOT AN ABSOLUTE RULE. IT CAN
BE VARIED IN VARIOUS MANNERS ACCORDING TO THE
PECULIARITIES OF THE VARIOUS MACHINES, HABITS
FORMED ON THE BASIS OF THE EXPERIENCE OF THE
OPERATERS AND OTHER NECESSITIES AND DESIRES
FROM TIME TO TIME. THERE ARE NO PARTICULAR
OBJECTIONS TO ANY VARIATIONS AS LONG AS THE ARE
REASONABLE AND PRACTICAL.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 1 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

PRELIMINARY CHECK & CONFIRMATION

Before starting the boiler, turbo generator, condensate & feed water system, following preliminary checks & confirmation should be carried out.

1. Check that:

1) Power supplies to all electrical auxiliaries are available from the starting transformer and DEG is also available.
2) Instrument air compressor system is in service and instrument air supply pressure to all instruments and controls which use air are normal.
3) All supervisory instruments are in operation satisfactory.
4) Main and auxiliary cooling water system are operating.
Water treatment system, chlorination plant, ferrous sulfate system and chemical injection system are in service.
5) Lubricating oil for auxiliary equipment is adequate.
6) Fuel tanks are filled up to normal level.
7) All soot blowers are retracted from furnace.
8) Drum level television is available and drum level indicators are normal.
9) All access doors and inspection holes are closed tightly.

2. Check and prepare boiler systems of air, 2. Check and confirm turbine and generator 2. Check and confirm auxiliaries.
fuel gas, water, steam, fuel, etc. for start system.
up. 1) CW. Pump is in service
(See boiler instruction book). 2.1. Check the oil level (MAV01CL03, - P01) in (PAC10/11AP001).
the main 2) Check that water boxes are full and
oil tank, and test the oil level alarm then close the vents.
(MAV01CL01 – S01) and (MAV01CL02 –
S01). The normal oil level is 600 mm
below the upper plate of the main oil tank.
The alarm level is 100 mm from the
normal level.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 2 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

2-1 Water system (start – up BFP & boiler 2-2 Generator 3) Check condensate system from
filling) (Refer to flow diagram No. KUO- demineralized
150-399 & 332). water head tank to the condenser and on
through
1). Confirm that the following main are closed. 1). Stator winding cooling water system is in the system to the deaerator, including related
service. instruments, instruments air, and control
a. Continues blow valves (HAN31AAO1/02). power
b. Drum water level reducing valve a. Cooling water pump A or B is operating as follows:
(HAN30AA02/03). (MKF12AP001 or MKF12AP002).
c. Soot blower steam and auxiliary steam b. Pump discharge pressure (6-9 bar. g) a. Check that the level in the demineralized
supply valves (HCB20AA01, (MKF12CP04 – P01). water head tank is adequate and make up
LBC41AA01/05). c. Generator inlet cooling water (1.8 bar. g) water supply system are ready for operation.
d. Valves on auxiliary steam line (MKF17CP07 – P01). b. Check that condenser hot well level is
(LBG21AA04). d. Stator cooling water conductivity (less than normal for start – up. Usually above normal
e. N2 gas injection valve. 0.5/cm) (MKF17CQ001, MKF22Q001). running level.
f. Drain valves of down – comer and feed e. Generator inlet cooling water flow c. Check that condensate pumps are ready for
water line (9HAN23AA02, (Approximately 740 1/min) service.
HAN21/22AA01, HAN10AA01/02). (MKF17CF01 – P01). d. Check that condensate line to deaerator is
g. Bypass valve of super heater and re-heater f. Deionizer water flow (Approximately set for normal operation through all heat
line. 1.15/1/min) (MKF20CF01 – P01). exchanger with bypasses closed where
g. Generator inlet cooling water temperature provided, line and equipment fall, all line
2). Confirm that the following main valves are less than 46 C (MKF17CT01 – P01). vents and drains are closed, control valves
open. h. Storage tank water level is normal normal with instrument air available and
(MKF19B3001). ready for operation.
a. Boiler feed water stop valves i. Stand – by side pump (COS) is “AUTO” e. Check deaerator for normal water level,
(LAB70AA02). position (MKF12AP001 or MKF12AP002). controls and alarms for proper operation.
b. Main steam boiler stop valve j. Cooling water for cooling water cooler is f. Check that LP heater bypass valves are
(LBA10AA13). available (MKF10BC001, MKF20BC001). closed.
c. Air vent valves (HAO1AA25/26, k. Stator cooling water temperature controller
HAH01AA01/03, HAH23AA01/02, is in service. 4) Check that auxiliary steam control to
LBA10AA01/02, HAJ01AA01/02). deaerator is in service and deaerator is
d. Drain valve for super heater, main steam 2). Shaft sealing oil system is in service. pegged and vent to atmosphere is open.
pipe including hot and cold reheat pipe
(HAN55AA01/02, HAN65AA01/02, a. Seal oil vacuum pump is operating
HAN75AA01/02, HAN85AA01/02, (MKW20AP001).
LBA21AA05/02, LBA22AA05,
JAJ01AA04/05/06/07).
e. Instrument intake valves.
f. Sampling and chemical injection valve.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 3 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

3). Super heater and re heater temperature b. Vacuum of vacuum tank (MKW10CP01 – 5). Check the feed water system from the
control valves are closed. P01). Deaerator to the steam generator, noting
(LAE41/42AA501, Approximately 74 – 76 cmHg. that all lines and equipment are filled, that
LAE11/12AA501, LAF60AA501). c. Vacuum tank oil level is normal water line vents and drains are closed tight,
4). Feed water flow control valves are closed (MKW20BB001). instrument are in service, instrument air
(LAB62/63AA02). d. Main seal oil pump is operating and control power are available and
5). Water filling of boiler: (MKW12AP001). normal.
e. Seal oil pump discharge pressure 7.3 bar. g
a. Open a boiler water filling valve (MKW12CP02 – P01). a. Check that the boiler feed pump are ready
(LAB61AA03). And fill the boiler with f. Seal oil pressure at turbine end collector for start - up as follows.
demineralized water until the boiler water ring end. (See B.F.Pump instruction book).
reaches normal drum water level - 100mm. Generator H2 pressure + 0.34 bar. g Oil level normal
b. Close the boiler water filling valve. (MKW13CP01 – P – 1, MKW14CP01 – Pump inlet valves: OPEN
P01). Pump discharge valves : CLOSED
2-2 Draft system (start – up of fans) g. Seal oil differential pressure approximately. Sealing water supply and returns valves:
(Refer to flow diagram No. KUO – 150 – 0.34 bar. g (MKW10CP – P01). OPEN Minimum flow recirculation line set
409). h. Emergency seal oil pump (COS) is for automatic operation. All instruments,
“AUTO” position (MKW31AP001). controls, instrument air and control power
1). confirm that the manual dumpers position are i. Emergency seal oil vacuum pump (COS) is in normal service.
workable condition. “AUTO” position (MKW10AP002). b. Check feed water system from the BFP to
2). Start one of flame detector fan (ANO1). the outlet of HP No. 06 heater.
3). Put the following items selector station on 3). Hydrogen control system. Note that:
AUTO. All HP heaters full of water on water side
a. Generator hydrogen pressure 3.0 – 3.1barg by checking vents and that all water side
a. Group control A/H (1) and (2). (MKG23CP05 – P011). vents and drains are CLOSED TIGHT. HP
b. FDF (1) and (2) controller. heaters bypass three way valve is set in
c. Group control FDF (1) and (2). 3. Open drains valves as follows: “heater in service” position.
d. FDF inlet main controller. 1). Main stop valve above and below seat 6). Check high pressure and low pressure
e. GRF (1) and (2) controller. drain valves. heater drainage system noting heater
f. Group control GRF (1) and (2). (MAL10AA001, MAL20AA001, levels, proper setting of drain valves,
g. GRF main controller. MAL11AA001, MAL21AA001, instrument air supply, etc.
h. Group control combustion air supply. MAL10AA002, MAL20AA002, 7). Check that all heater vent valves in the
MAL11AA002, MAL21AA002). vent line where orifice.
4). Push ON “group control combustion air 2). Reheat stop valve above and below seat
supply button” with draft equipments with drain
start step by step automatically. valves. (MAL30AA002, MAL40AA002,
MAL32AA002, MAL42AA002).

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 4 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

a. STEP 1: FG A/H (1) and (2) ON 3). Intercept valve below seat drain valves. Plates are used are fully opened.
(HLD1/2AC01) A/H inlet gas and outlet air (MAL50AA002, MAL60AA002). 8) Check that all bled steam stop valves are
Damper open (BLA41/42AB01, closed.
HNA11/12AB01) A/H bypass damper dose 4. Check that drain trap valves are set as 9) Start boiler feed pump as follows:
(HLA33/34AB01) follows: (Refer to B. F. Pump instruction book)
b. STEP 2: All air register open. Inlet and outlet valve: OPEN See part A, item 13.a.
c. STEP 3 &4: FG FDH (1) and (2) on FDF Bypass valve: CLOSED
inlet Vane & outlet damper close a. Check that water level in deaerator storage
(HLB01/02Ab01, HLA11/12AB02 1) No. 1 bled stem drain trap tank is normal.
FDF on HLB1/2AN01). FDF controller 2) No. 2 // // // // b. Start BFP (LAC10/20, 30AP002)
auto. 3) No. 3 // // // // c. Check operation of BFP minimum flow
d. STEP 5: FG GRF on 4) Cold reheat steam line drain trap circulation control valve.
GRF inlet and outlet damper close. 5) Steam jet air ejector steam drain trap (Lab11/21/31AA002)
(HNF21/22AB01, HNF11/12AB01) d. Open discharge valve and
GRF on GLB1/2AN01) 5. Check that condenser vacuum breaker is (LAB10/20/30AA003) required, HP feed
GRF controller auto OPEN. (MAG01AA001). water system and boiler.
GRF outlet damper open and GRF
sealing damper close (HNF21/22AB01, 10) Check the evacuation system.
HLA16AB01/02)
e. Air flow is increased up more than 50% a. Vacuum pump air suction valves are closed
f. STEP 6: Wait for furnace purge 5min b. Steam jet air, ejector.
g. STEP 7: Purge timer over Steam supply valve: closed (LAG30AA002)
h. Air flow is decreased to 15% Air vent valve : closed (MAJ01AA206)
i. STEP 8: Air register close
j. STEP 9: Ignition release ON
2.3 Igniter & diesel oil firing system

1). Igniter system (Refer to flow diagram No.

KU1 – 263 – 665)
Normally igniter is used with natural gas,
but at this mount with LPG.
a. LPG vaporizer is workable condition
b. LPG cylinder should be filled
c. All igniter stop valves are closed (MMG50
– 61AA01/02).

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 5 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

d. Valve principle of ignition gas bottle

system is open (MJG03AA03)
e. Valve principle of ignition gas vent is
opened (HHG08AA01)

2) Diesel oil system (Refer to flow diagram

No. KU1 – 263 – 664)
o Start – up burner is used with diesel
oil in starting up when natural gas is not
available.
a. Diesel oil storage tank level is normal.
b. Diesel oil boiler supply pumps are
workable condition.
c. All diesel burner inlet valves are closed
(HHH70/72/74AA01)
d. Start diesel oil pump (AENIC20 – AP01)
e. Check atomizing air system is workable
condition (HHH10)

3) Natural gas system (Refer to flow diagram

No. KU1 – 263 – 665)

a. Gas reducing station is workable

condition.
b. All gas burner vent valves are opened
(HHG70 – 81AA03)
c. All gas burner header vent valves are
opened (HHG04AA01/03)
d. All gas burner stop valves are closed
(HHG70 – 81AA01/02)

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 6 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

B: PREPARATION OF LIGHTING OFF THE

BOILER

1. After boiler protection is reset, make sure

that the following lighting – on condition is
satisfied.

1) Lamp of boiler protection ON

2) Lighting header pressure is normal (>
0.3 bar)
3) Diesel oil header pressure is normal
(> 0.6 bar)
4) Differential pressure between furnace
and wind box is approximately 150
mm bar
5) Drum water level is NWL – 100 mm
6) GAS/OIL burner station on HFO
BNR or GAS BNR (HHA70 –
81EA121)
7) If fuel oil burner is selected, put HFO
– DIESEL oil selector of start – up
burners on DIESEL OIL (HHF70,
74AA020
8) Lamp of IGNITION RELEASE ON
on module comes on
9) Lamp of purge timer over on module
comes on
10) Close HP bypass valve
(LBC11/12AA501) and LP bypass
valve (LBP10AA02/06)

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 7 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

C: BOILER LIGHT OFF

1. Boiler light – off and boiler pressurization

1) Light on burner (HHA70EA100) and

adjust fuel oil flow control valve to
maintain oil pressure.
After confirming the burner
combustion condition, light off next
burner (HHA72EA100) Burner
interlock diagram are as follows:

a. Step 1: Air register close

Igniter transformer ON
Electrode is inserted
b. Step 2: igniter stop valve 1 & 2 open
c. Step 3: igniter transformer OFF
Electrode is inserted
d. Step 4: Oil burner id inserted
e. Step 5: Atomizing valve open
f. Step 6: Air register open
Burner fuel oil valve open
g. Step 7: Igniter stop valve close

2) After lighting off burner, stop GRF

(HNF11/12AN01)
3) Adjust the firing rate so as to keep the
rate of drum temperature rise less then
30 C/H
4) Take care of sudden rise of drum
water level at about 1 bar drum
pressure. If sudden arise of drum level
occurs, reduce the firing rate and open
continuous blow and down water level
reducing valve to maintain drum
level. (HAN31AA01/02,
HAN30AA02/03).

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 8 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

5) When drum pressure reaches 2 to 3 1. Check to see that the vapour extractor is
bar a, close boiler vent valve fully. running.
(HA01AA25/26, HAH01AA01/03, (Confirm that the vapour extractor start
HAH23AA01/03, LBA10AA01/02) light goes on at *CCR)
2. Oil purifier in service
6) Adjust super heater and main steam
drain valves up to 20% 1) Push the oil separator vent fan
(HAN55AA01/02, HAN65AA01/02, (MAV90AN001) Confirm that the oil
HAN75AA01/02, Han85AA01/02, separator start light goes on
LBA21AA02/05, LBA22AA05) 2) Open the oil separator inlet valve
7) Control PH at economizer outlet at 4.1 (HAV90AA002) and the oil
to 9.4 by injecting hydrazine or separator outlet valve
ammonia in to deaerator down comer (MAV92AA002)
or CP outlet. 3) Push the oil circulating pump
8) Increase the firing rate if necessary (HAV91AA001) start button
Check tail pressure between the
cartridge filter inlet and outlet is less
than 1.5 bar a.
3. Turbine oil system in service.

1) Push the auxiliary oil pump

(MAV04AP001) start button at CCR.
2) Confirm that the auxiliary oil pump
start light goes on at CCR.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 9 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

9) After drum pressure reaches about 5 3) Confirm that the jacking oil pump
bars, super heater and main steam inlet valve (MAV80AA0010 open.
drain valves can be closed.
HP turbine bypass valve open by 4) Push the jacking oil pump
manual and keep the reheat pressure 5 (MAV80Ap001) start button at CCR.
bar a (LBC11/12AA501). 5) Confirm that the jacking oil pump
10) Confirm that the HP Turbine spray start light goes on at CCR.
valves are open and control steam 6) Check to see that the oil level is
temperature at 195 C (LAE60AA01, normal as indicated by the float level
LAE60AA502, LAE61/62AA501). gauge, with the pump running and
11) Start to send steam to auxiliary steam the system filled with oil.
header. 7) Check to see that the bearing oil
Open auxiliary steam stop valve pressure is normal at 1.72 bars (g).
(LBC41AA01) and steam control 8) Check to see that the operating oil
valve (LBG10AA501/502) gradually. pressure is normal at 13.7 bars (g).
12) Put the steam conversion system in 9) Check the oil flow at each bearing
service (Refer to flow diagram No. sight discharge.
KU1 – 249 – 684) 10) The oil to the bearings must not be
less than 27 C or more than 40 C for
turning gear operation.
11) Push the turning gear motor
(MAK10) start button at CCR.
12) Confirm that the turning gear motor
start light goes on at CCR.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 10 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

13) Put the heavy fuel oil system in 13) Push the turning gear engage start
service (Refer to flow diagram No. button at CCR.
KUO – 153 – 547, KUO – 156 – 320, 14) Confirm that the turning gear engage
KUI – 273 – 474) light goes on at CCR.

a. Heavy fuel oil tank level is normal. 4. gland seal system in service
b. Confirm that the following main
valves are open: 1) Check the following conditions:
o All burner inlet valves (HHF70 –
81AA01) a. Auxiliary steam stop valve
o Instrument intake valves (LBG40AA002) is fully open.
c. Confirm that the drain, vent and b. Primary super heater outlet steam
bypass valves are close. stop valve (LBG50AA002) is fully
d. Check the auxiliary steam system: open.
o Atomizing steam line c. Isolating valves of SSR water pot are
o Oil heating steam line fully open (LBW30AA005, 06).
o Steam trace line d. Auxiliary steam bypass valve of SSR
e. Put steam trace line in service is fully closed (LBG40AA003).
f. Start fuel oil pump: e. Primary super heater outlet steam
o Check oil temperature is normal bypass valve (LBG50AA003) is fully
closed.
o Put fuel oil control valve at 0%
f. Mixing steam inlet valve
o Start heavy fuel oil supply pump
(LBW01AA001/002) of gland
(EGD41AP01) exhauster fan is cracked open (15 –
o Start heavy fuel oil boiler pump 20%).
(HHF11AP01) g. Condensate system is in service.
c. Warming up of recirculation line.
o Open fuel flow control valve 2) Push open – button of the steam feed
gradually and carry out the to SSR drain valves
arming up of fuel oil by opening (LBG50AA004/005)
of recirculation valve 3) Confirm that the full – open lights of
o Put in service fuel oil heater the steam feed to SSR drain valves to
(HHF41/51/61BC01) on.
d. Make atomizing steam alive. 4) Push start – button of the gland
o Open atomizing steam supply condenser exhauster fan
valve gradually (LBJ01AN001/002) at CCR
o Confirm that atomizing steam 5) Confirm that start – light of the gland
pressure is controlled at 10.5 bar condenser exhauster fan goes on.
a. (HHM10AP01)

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 11 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

14) Put steam air heater in service (Refer 6) Check to see that the SSR steam feed
to flow diagram No. KUO – 150 – valve (LBG50AA002) and the SSR
312) auxiliary steam feed valve
(LBG40AA002) is automatically
a. Confirm that all valve positions on open.
system are normal.
b. Open the heating steam stop valve 7) After the SSR Steam feed valve
(LBG 32AA05) and heating steam open, check to see that the steam feed
intake valve (LBS32AA502) to SSR drain valves
gradually. (LBG50AA004/055) are
c. Start one of SAH drain pumps after automatically closed.
high level of drain tank ANN comes 8) Confirm that the gland steam
on (LNC10/11AP01) pressure and the gland condenser
d. Put SAH drain pump selector station shell vacuum are normal.
on auto.
Confirm that SAH drain level is *Use SSR steam bypass valve (LBG40/50AA003) 1. Vacuum up
controlled normally. if necessary, to get normal steam seal header
e. Waste the drain to the drain flush pressure and boiler pressure goes up, adjust the 1) Start the vacuum pump
tank. bypass valve as needed. 2) When the vacuum is near normal,
f. Drain quality becomes good, recover one of vacuum pumps stop.
the drain to the deaerator. 5. When the condenser vacuum reaches to
g. After the average temperature of A/H 0.07 bar. g LP bypass stop valves are open
cold end reaches to 130 C, close A/H and LP bypass valve control mode is put
bypass air and gas damper. onto auto position.

15) At starting of vacuum, all air and

drain valves of re-heater should be
closed (HAJAA01/03/04/05/06/07,
LBC20AA13/14, LBC10AA30).
16) When the condenser vacuum is
established, adjust HP bypass valve to
keep the re heat pressure at 8 bar. a
manually.
17) Put the HP turbine bypass valve on
the pressure control (LBC –
1/12AA501). HP turbine bypass spray
valve is controlled at 195 C.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 12 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

18) Start warming of soot blower line and 6. Start turbine pre – warming
then operate A/H soot blower
(HLB20AA01/03). If HP turbine after first stage metal is below
19) Light on heavy oil burner (HH79 – 150 C, HP turbine pre – warming is required
81/AV01) one by one, and adjust the
fuel oil flow control valve to maintain 1) Prior to start HP turbine pre –
oil pressure. warming, check to see that:
20) Cut off diesel oil burner (HA70, a. All turbine drain valves are fully
72/EA100) one by one. open
21) After completing of oil burner change b. The turbine is on turning
from diesel oil to heavy oil, confirm c. The gland steam supply system is in
the following items. service
a. Heavy oil flow is adjusted 10 – d. The condenser vacuum is built up
12m /hour e. 8bar (a) reheat pressure is
b. Air flow is adjusted at 25% established.
c. Combustion condition in the furnace f. The ventilator valves
d. Heavy oil pressure and temperature is (MAA07AA001, MAA08AA001)
normal are fully closed
e. Average temperature of A/H cold end g. The emergency blow down valve
is controlled at 130 C (MAA06AA001) is fully open
f. Feed water temperature is heated up h. The emergency trip valve is tripped
to 110 C. position
i. The turbine control valves are fully
open
j. The drain trap valves of cold reheat
are fully open

2) Start turbine pre – warming

After checking above items, the HP
turbine pre – warming will start in
accordance with as follows:
a. Open the turbine control valves by
pushing the EHG governor increase
button

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 13 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

b. Fully open the pre – warming valve.

(LBC0AA003) by pushing the pre –
warming
valve open button.
c. Regulate the HP turbine pressure by
the main stop valve below seat drain
valves (MAL11/12AA002).
d. After HP turbine after first metal
temperature reach to approx. 150 C.
Keep this condition for 3 hours.
e. After 3 hours, HP turbine pre –
warming is completely.
f. Fully close the pre – warming valve
22) Adjust the main and reheat steam by pushing the pre – warming valve
temperature to meet a turbine metal close button.
condition by super heater spray valve g. Close the turbine control valve by
and HP turbine bypass spray valve. pushing EHG governor decrease 2. Supply auxiliary steam to deaerator.
(LAE41/42AA501, LAE31/32AA501, button.
LAF61/62AA001) h. Check to see that the ventilator
valves automatically open.

7. Control valve chest warming.

1) The following two conditions require

the control valve chest warming
respectively.
a. The control valve chest inner metal
temperature is below 150 C.
b. The chest inner metal temperature
exceeds 83 C higher than outlet metal
temperature.
2) Prior to the control valve chest
warming, check to see that:
a. The emergency trip valve is tripped
position.
b. The main stop valves, the turbine
control valves, the reheat stop valves
and the intercept valves are fully
closed.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 14 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

c. The operating oil pressure for the control

mechanism is established.
d. The main stop valves below seat drain
valves are fully open.

3) After checking above items, the control

valve chest warming will start in
accordance with as follows:

a. Energize both chest warming solenoid by

push the chest warming solenoid
energize button.
b. Reset the turbine.
c. Check that following main stop valves
are fully open.
o MSV (MAA20AA001,
MAA20AA001)
o RSV (MAB10AA001,
MAB20AA001)
5) Check that CV and ICV’s are fully
closed.

o CV & ICBV
o ICV (MAB30AA001,
MAB40AA001)

6) Note.
a. CHECK TO SEE THAT THE BACK –
UP OVERSPEED TRIP IS ITS
NORMAL SETTING POSITION.
b. SET THE INITIAL PRESSURE AND
VACUUM UNLOADER OUT – OF –
ACTION WITH A LOW STEAM
PRESSURE START UP.
c. CHECK THE SUPERVISORY
INSTRUMENT to see that the turbine
rotor is straight.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 15 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

d. CHECK TO SEE THAT 8bar (a) REHEAT

STEAM PRESSURE IS ESTABLISED.
8. Check the following conditions on the
Hitass criteria.
o SUPERVISORY POWER NOT OK
o MAIN STEAM PRESSURE LOW
o MAIN STEAM TEMPERATURE
LOW
o CONDENSER VACUUM NOT OK
o VIBRATION NOT OK
o DIFF. EXPANSION NOT OK
o EXHAUST HOOD TEMPERATURE
HIGH
o GLAND STEAM PRESSURE NOT
OK
o LUB. OIL TANK LEVEL NOT OK
o LUB. OIL PRESSURE LOW
o LUB. OIL TEMPERATURE NOT OK
o TURBINE NOT TURNING
o OPERATE OIL PRESSURE LOW
o TURBINE NOT RESET
o ECCENTRICITY NOT OK
o MISS. MATCH NOT OK
o IP & VAC UNLOADER NOT OK
o EXHAUST HOOD SPRAY NOT OK
o DRAIN VALVE NOT OPEN
o BEARING DRAIN TEMPERATURE
HIGH
o THRUST METAL TEMPERATURE
HIGH
o MSV NOT OPEN
o RSV & ICE NOT OPEN
o LLM NOT CLOSE
o MSV-R CHEST TEMPERATURE
DIFF. NOT OK
o MSV-L CHEST TEMPERATURE
DIFF. NOT OK

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 16 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

o STEAM CHEST TEMPERATURE

DIFF. NOT OK
o ICBV CHEST TEMPERATURE
DIFF. NOT OK
o H2 SYSTEM NOT OK
o STATOR COOLING SYSTEM NOT
OK (U# 1,2)
o GENERATOR PROTECTION
RELAY NOT OK

TURBINE ROLLING

1. Turbine rub check:

a. Set the acceleration rate (120 1. LP & HP heaters are in service.

rpm/min.) and target speed (200 rpm) All extraction stop valves are opened.
and set EHG all valve closes after the (LBS20AA001, LBS30AA001,
turbine speed reached to 200 rpm. LBS40AA002)
And during this operation, listen to (LBS40AA004, LBQ10AA001,
the rub of turbine. LBQ20AA001)
b. Check the stop of the rub of turbine.

2. Acceleration and 1000 rpm heat soak:

Set target speed 1000 rpm and maintain
1000 rpm.
3. Acceleration:

a. Set target speed (3000 rpm.)

b. When the speed reaches 500 rpm,
stop the jacking oil pump.
4. Maintain the 3000 rpm, for the heat soak.
Emergency governor testing before
exitation by oil tripping only if.
a. The emergency governor was tested
by over – speeding when last shut
down, or

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 17 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

b. Emergency governor over speed test

is not required by “Periodic
Operational Test Summary”. See
turbine instruction manual.
c. Emergency governor has not been
adjusted or worked on.

5. Stop the auxiliary oil pump.

6. Excitation

o Close the excitation breaker.

o Select the AVR in the auto position.

7. Check the following condition before the

synchronization.
o SUPERVISORY POWER NOT OK
o MAIN STEAM PRESSURE LOW
o MAIN STEAM TEMPERATURE
LOW
o CONDENSER VACUUM NOT OK
o VIBRATION NOT OK
o DIFF. EXPANSION NOT OK
o EXHAUST HOOD TEMPERATURE
HIGH
o GLAND STEAM PRESSURE NOT
OK
o LUB. OIL TANK LEVEL NOT OK
o LUB. OIL PRESSURE LOW
o LUB. OIL TEMPERATURE NOT OK
o TURBINE NOT TURNING
o OPERATE OIL PRESSURE LOW
o TURBINE NOT RESET
o ECCENTRICITY NOT OK
o MISS. MATCH NOT OK
o IP & VAC UNLOADER NOT OK
o EXHAUST HOOD SPRAY NOT OK

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 18 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

1. If turbine metal matching condition is ready, o DRAIN VALVE NOT OPEN

start the steaming to the turbine and roll it. o BEARING DRAIN TEMPERATURE
2. Increase main steam pressure from 25 bar. a HIGH
to 70 bar. a gradually. o THRUST METAL TEMPERATURE
3. Control main and reheat steam temperature HIGH
to meet the turbine requirement by adjusting o MSV NOT OPEN
firing rate and spray valves. o RSV & ICV NOT OPEN
4. When drum pressure reaches to 70 bar. a o LLM NOT CLOSE
check drum water quality. o MSV-R CHEST TEMPERATURE
DIFF. NOT OK
o MSV-L CHEST TEMPERATURE
DIFF. NOT OK
o STEAM CHEST TEMPERATURE
DIFF. NOT OK
o ICBV CHEST TEMPERATURE
DIFF. NOT OK
o H2 SYSTEM NOT OK
o STATOR COOLING SYSTEM NOT
OK (U# 1,2)
o GENERATOR PROTECTION
RELAY NOT OK

SYNCHRONIZATION

1. Synchro. And initial loading.

1) Set the load limiter and load setter to

2% load position.
2) Rise/lower the governor position
manually.
3) Generator circuit breaker is closed.
4) Maintain the initial load (2%).
5) Select the loading rate (1%/min.) and
set the load setter to 5%.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 19 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

2. Check the following conditions after

synchronization:

o SUPERVISORY POWER NOT OK

o MAIN STEAM PRESSURE LOW
o MAIN STEAM TEMPERATURE
LOW
o CONDENSER VACUUM NOT OK
o VIBRATION NOT OK
o DIFF. EXPANSION NOT OK
o EXHAUST HOOD TEMPERATURE
HIGH
o GLAND STEAM PRESSURE NOT
OK
o LUB. OIL TANK LEVEL NOT OK
o LUB. OIL PRESSURE LOW
o LUB. OIL TEMPERATURE NOT OK
o TURBINE NOT TURNING
o OPERATING OIL PRESSURE LOW
o TURBINE NOT RESET
o ECCENTRICITY NOT OK
o MISS. MATCH NOT OK
o IP & VAC UNLOADER NOT OK
o EXHAUST HOOD SPRAY NOT OK
o DRAIN VALVE NOT OPEN
o BEARING DRAIN TEMPERATURE
HIGH
o THRUST METAL TEMPERATURE
HIGH
o MSV NOT OPEN
o RSV & ICV NOT OPEN
o LLM NOT CLOSE
o MSV-R CHEST TEMPERATURE
DIFF. NOT OK
o MSV-L CHEST TEMPERATURE
DIFF. NOT OK
o STEAM CHEST TEMPERATURE
DIFF. NOT OK

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 20 of 28
 BOILER TURBINE / GENERATOR AUXILIARY REMARKS

1. Add burner if necessary o H2 SYSTEM NOT OK

o STATOR COOLING SYSTEM NOT
1) During the initial load operation, OK (U# 1,2)
stabilize the boiler operation condition o GENERATOR PROTECTION
as follows: RELAY NOT OK
o FIELD BREAKER NOT CLOSE
a. Main steam pressure: Approx. 70 o AVR NOT IN USE
bar.g. o GENERATOR VOLTAGE NOT OK
b. Main steam temperature: Approx. 360 o DISCON NOT CLOSE
C.
c. Drum water level : NWL +-0mm
3. Loading up (5 to 20%).
2. Confirm that the following selector stations 1. Bus transfer. After all turbine drain
1) Select the loading rate (3%/min.)
are put on auto position. 2. Start the 2nd BFP valves are fully closed
2) Set the load set 20% load.
(LAC10/20/30AP sequentially.
3) Close the all turbine drain valves at
1) FDF inlet vane. 002) CP Group module of
15% load.
2) Feed water control valve (LCB10/20/30AP turbine drain System
3) Fuel oil flow control valve 001) and CBP should be off.
4. Loading up (20 to 50%).
3. HP bypass valve reduce their opening to (LCB10/20/30AP
Set the loading rate (1%/min.) and select
maintain main steam pressure wherein LP 001) at 45% load.
the load set to 50%.
bypass valve control reheat steam pressure to
5. Loading up (50 to 100%).
maintain predetermined set pressure.
Set the loading rate (3%/min.) and select
4. Along with further increase of steam flow to
the load set to 100% load.
turbine, HP % LP bypass valve reduce their
opening to full close position.
5. When HP bypass valve is fully closed, adjust
the boiler master set pressure and put it auto
position after that put the HP turbine bypass
valve put auto position.
6. Increase the boiler master setting gradually
up to 140 bar pressurerize rate is 1.1 bar/min.
7. Add burner according to load up.
8. Start GRF at 25 % load (HNF11/12AN01).
9. Adjust economizer outlet O2 as matching the
furnace.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 21 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

10. Combustion condition

check the water quality for mainly silica
content and adjust the continuous blow valve
of drum. HP control of feed water is at 9.2 to
9.4/
11. Put GRF control on auto position at 50%
load.
12. Carry out all foot blowers.
13. Confirm that the unit is operated under 6. Check all turbines – generator supervisory 3. Check performance of all auxiliary
automatic control condition. instruments and continue routine visual equipment to determine that they are normal
inspections. for the load on turbine.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 22 of 28
 BOILER TURBINE / GENERATOR AUXILIARY
For normal shutdown of short duration the load should be reduced gradually, to avoid excessive rate of change of turbine metal temperature, thus reducing
distortion of hot parts, including valves, shells and rotors. The exact procedure should be modified to give the expected optimum conditions of temperatures and
pressures to be expected at the time of the restarting of the unit. (See turbine instruction book “Operating Instructions”

Prior to the unit shutdown, it is very important to 1. Take vacuum unloading and initial pressure 1. When the total auxiliary power being used
carry out one cycle operation of all soot blowers. unloading device. is within the rating of the starting
1. Load down. 2. Reduce load transformer, transfer auxiliary power to the
starting transformer.
1) Steam temperature control is change o Temperature differentials between 2. As load is reduced, check drainage of all
to manual operation at 40 – 60% load. inner and outer surface should be feed water heaters.
2) At around 40% load, stop one of minimized and held below that 3. One of BFP stop at 40% load.
boiler feed water pump. recommended by “Allowable 4. One of main condensate pump and
3) If necessary cutting out the burners in Differences”. Careful boiler operation condensate booster pump at 40% load.
accordance with the load, take into is required for temperature control.
consideration of cutting out the burner o Watch metal temperature, differential
when the fuel oil pressure reaches to expansion, steam pressure and
minimum one. temperature, exhaust hood
4) During load operation, control main temperature, etc., to be sure safe limits
and reheat steam temperatures to meet are not exceeded.
the turbine requirements. o In the event extended operation at light
5) Load down further to around 25% loads (below transfer point) is not
load and stop GRF. planned and the unit is to be tripped
6) Load down to around 15% loads from out promptly upon reduction of load, it
25% load. Change the boiler master to is permissible to SHUT THE
manual and HP turbine bypass valve TURBINE DOWN as a procedure
are changes to pressure control. simplification.
In case of boiler forced cooling after
shut down the unit, reduce the main Proceed as follows:
steam pressure by changing of set
point of HP turbine bypass valve up to 1) Gradually reduce load to
50 bars. approximately 15% rated.
7) During 15% load operation, level only 2) When the unit load reaches about
two burners. At that time it is better to 15% rated, note that the water sprays
leave two burners to get uniform to the turbine exhaust hoods are put
absorption heat. in service.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 23 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

8) Put all selectors on manual position. 3. Turbine trip

9) Extinguish burners one by one.
10) After boiler shut down, carry out the 1) Actuate the oil trip
furnace purge for final burner purge.
11) After the burner purge is completed, o When the unit trips out, the auxiliary
put the boiler on either hot banking oil pump should start automatically
condition, natural cooling down or under either of two conditions.
forced cooling down operation in Immediately upon tripping due to a dip
accordance with the unit in hydraulic oil pressure as the valves
requirements. close quickly.
o Upon decrease in speed where main
shaft pump pressure decreases to the
cut – in pressure of the auxiliary oil
pump pressure switch.
See that the auxiliary oil pump starts
automatically at an operating oil
pressure, as specified on the “Diagram
of turbine control mechanism”.

a. Main stop valves close.

b. The reheat stop valves close
c. The extraction relay dump valve
operates to close all power – operated
extraction check valves.
d. Generator circuit breaker open.

2) Check to see that the ventilator

valves are open.

Note: Alternate methods of removing

the unit from the line are described
under “Load removal” of “Starting
and loading instructions” and may be
used, where applicable.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 24 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

AUXILIARY STOP

1. When the turbine reduces speed to about

2000 rpm, open vacuum breaker valve and
shut down vacuum pump in case of long
period plant shut down.
The steam seal system must remain in
operation as long as vacuum exists in the
turbine so as to prevent cold air from being
pulled in along the shaft.
2. Check to see that the all turbine admission
valves are closed.
3. As speed decreases, the bearing oil
temperature should be reduced so that a
temperature of 27 – 40 C is obtained by the
time the unit stops rolling for turning gear
operation.
4. When the speed drops 2000 rpm, start the
jacking oil pump.
5. Open all turbine drains, close the shut – off
valves of both reheat stop valves.
6. Adjust the hydrogen purity indicator valves
for shut down (standstill) operation. Refer
to “Generator instruction”.
7. Shut down the steam seal system when the
vacuum reaches zero.
Remove the steam seal regulator from
service. Stop the gland condenser exhaust
fan.
8. Start the turning gear motor, when the
turbine reduces to approx. 2 rpm.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 25 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

9. Engage the turning gear as soon as the rotor

stops rolling.
Never allow a hot rotor to stand without
rolling. Operators should be trained to stand
at the turning gear as the rotor rolls to a
stop, so that the pinion can be immediately
engaged.
In case of emergency, where the shaft
cannot immediately be rolled by turning
gear operation, every effort should be made
to get the unit on turning gear as soon as
possible. Is it is found that turning gear will
not turn the shaft, never admit steam to the
turbine to try to turn it.

10. Stop and lock out the auxiliary oil pump

and see that the turning oil pump starts
automatically.
11. Check the turning oil pump to see that it is
running satisfactorily.
12. Stop the turning oil pump and see that the
emergency bearing oil pump starts
automatically. It is possible that the turning
gear may stop due to a bearing oil pressure
dip sensed by the turning gear interlock
when transferring from one pump to the
other. Check to see if the turbine shaft is
still rotating. If the turning gear has stopped,
proceed to step 13 and restart and engage
the turning gear. The turning gear cannot
start below 0.7 bar (g) bearing oil pressure
and can start above 1.03 bar (g) by means of
interlock of the pressure switch.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 26 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

13. Check the emergency bearing oil pump to

see that it is running satisfactorily.
14. Restart the turning oil pump.
15. See that the emergency bearing oil pump is
stopped.
16. When the turbine is completely cold:

1) Load out the emergency oil pump.

2) Stop the turning gear motor.
3) Stop and lock out the auxiliary oil
pump. Care must be taken to see that 1. Shut – down boiler feed water pump.
no steam or water can enter the turbine 2. Shut – down main condensate pump and
while it is idle. condensate booster pump.
3. Remove oil purifier from service.
4. Remove condenser cooling water system
from service.
5. When hydrogen gas is in the generator, the
shaft seal oil system and the vapour
extractor of turbine oil reservoir must be
kept in service. During the unit
is shut – down check the hydrogen purity.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 27 of 28
 BOILER TURBINE / GENERATOR AUXILIARY

GENERAL OPERATING CAUTION

During normal operation of the entire unit, it is necessary to
make routine periodic tests of safety features, controls,
interlocks, alarms, and the various emergency operating devices.
Operation of all of this equipment is necessary to insure it will
operate correctly when needed, and that the operators remain
familiar with operating procedures. Only a few of the checks and
tests encountered during routine start – up and shut down are
mentioned in these instructions.

_________________________________________________________________________________________________________________________________________________________________________________________
/conversion/tmp/activity_task_scratch/749598701.doc Rehabilitate by: Farooq Sharif & Zafar Ali Sabir Page 28 of 28