P CHANDANKHEDE Dy.

Supdt, Operation

TG ROLLING PREPARATION
1. VACUUM PULLING & SEAL STEAM CHARGING 2. MS LINE WARMING & CHARGING 3. HP BYPASS CHARGING 4. LPBYPASS CHARGING

VACUUM PULLING
ENSURE DRAIN BEFORE CRH NRV TO SDFT CRHV 101 , MS/HRH STRAINER DRAINS (to remove impurities) TO SDFT(MSV109,110 & HRHV 105,106) ARE OPEN. STATRT VACUUM P/P 1 RECIRCULATION P/P & OBSERVE THAT SEAL WATER FLOW (remember the water ring around impeller!) IS ADEQUATE,START VACUUM P/P 1. AIR IV V/V OPENS ON INTERLOCK & VAC STARTS BUILDINGUP. START 2ND VAC P/P FOR HOGGING OPERATION FOLLOWING THE SAME

SEAL STEAM CHARGING

ENSURE OPENING OF SEAL STEAM HEADER DRAIN MAL 81 & WARM UP DRAIN V/V BEFORE SUPPLY HEADER. ENSURE SEAL STEAM SUPPLY HEADER IS ISOLATED. CRACK CHARGE SEAL STEAM MANUAL ISOL V/V AT 8.5 M & PRDS SOURCE MOTORIZED V/V ASV-67 AT 17. OBSERVE THAT STEAM TEMP STARTS RISING & As AUX STEAM TEMP BEFORE SUPPLY HEADER INCREASES > 190 0 C , GRADUALLY FULL OPEN THE MAN & MOT V/Vs & CHARGE HEADER UPTO WARM UP DRAIN V/V.

SEAL STEAM CHARGING

CRACK OPEN SUPPLY HEADER BYPASS V/V, SEAL STEAM HEADER PRESS STARTS BUILDING OPEN GSC SAFETY V/V TO ATMOSPHERE. START ONE GSC VAPOUR EXTRACTOR & ENSURE OPENING OF ITS I/L TO GSC. OPEN SEAL STEAM SUPPLY V/V TO GSC, SEAL STEAM SAFETY V/V CLOSES ON INTERLOCK. OPEN SUPPLY & LEAK OFF HEADER MAIN LINE V/VS. PUT SEAL STEAM HEADER PRESS CONTROL ON AUTO & MAINTAIN HEADER 200 MMWCL.

Stage 2 or 3

MS LINE WARM UP & CHARGING

AT BOILER DRUM PRESS APPROX 2 to 3 Ksc, ENSURE DRUM VENTS & SH VENTS ARE CLOSED. AT APPROX 8 TO 10 Ksc ENSURE SH DRAINS ARE CLOSED. CONDENSER VAC IS PULLED. ENSURE MS DRAINS TO IBD TANK BEFORE BOILER STOP V/Vs (MSV 101 & MSV 102) ARE OPEN.

MS LINE WARM UP & CHARGING

ENSURE MS STRAINER DRAIN V/Vs MSV105 & MSV106 TO UFT (TILL BYPASS IS NOT CHARGED) & HPBP DRAINS BEFORE BP V/Vs ( BPV 101 & BPV 102) TO UFT ARE OPEN. OPEN STOP V/VS EQUALIZING LI NE MOT V/Vs MSV3 & MSV4 & THEN CRACK CHARGE INCHING V/Vs MSV5 & MSV6 & OBSERVE MS TEMP BEFORE ESV IS RISING, GRADUALLY INCREASE INCHING V/Vs OPENING TO FULL & THEN OPEN MSV1 & MSV2. AFTRE MSV1 & MSV2 ARE FULL

HP BYPASS CHARGING
Drain v/vs BPV 101 & BPV 102 to UFT of BP1 & BP2 warm up line are open & also ensure opening of bypass spray block v/v(BD v/v) man isolating v/v. Open BP1 & BP2 line warm up v/vs BPV3,BPV-4 & close their drains to UFT. Open BP1 & BP2 5% manually & check HPBP D/S temp is rising & also temp is maintained by spray control v/vs BPE1 & BPE2. Raise boiler firing by increasing HFO pr. & close SH start up vents.

LP BYPASS CHARGING
Open LPT exh hood spray isolation v/v & charge LPBP warm up line drains. LPBP spray from CEP is lined up. LPBP both temp dependent solenoid v/vs are reset. Keep LPBP controller in manual mode & give command to controller until water injection v/v 1 & 3 open, then both bypass stop v/vs & control v/vs open in sequence. Regulate CVs opening & maintain HRH pr approx 4-6 ksc. IF LPBP D/S flow increases > 45%, check & ensure opening of second stage water injection v/vs. LPBP operation with ACI: it automatically opens LPBP CVs to 25% & holds it until HRH pr. reaches 12 Ksc, then ACI switches off.

TYPES OF TG ROLLING
1. Cold Start up If HPC metal Tempr<1500C. 2. Warm start up If HPC metal tempr betwn 150 to 3500C. 3.Hot start up If HPC metal temp > 3500C.

PRE-REQUISITES FOR TG ROLLING

Turbo-Generator on Barring gear with all Turbo supervisory parameters are normal. Boiler is lighted up condition with one /two oil elevations are I/s. VACUUM PULLED(S. STEAM PR./TEMP 0.02 KSC/>220 DEG C) & GLAND STEAM PR CONTROL ON AUTO. HP-LP Bypass is in charged condition. Boiler load index is 95 to 100 T/Hr. Steam parameter are ready for rolling. M.S. Pr. 35-40 Ksc. HRH Pr. 6-12 Ksc. M.S. and HRH Temp. 320 to 3500C

START UP CONSIDERATIONS
During the startup the Turbine is subjected to Non-Steady state operation. This covers the operating condn where Speed, steam Pressure and temperature change with time. Under these condn turbine components which are exposed to temperature changes subjected to thermal stress and expansion. For turbine life point of view, it is very much necessary to limit the extent of these temperature changes. To take care of the above factor the operator has to follow the recommendations from Turbine Stress Evaluator and start the Rolling procedure by

TURBINE STRESS EVALUATOR

The Turbine is equipped with the TSE which provides adequate guidance to the operator by indicating temp margins and Load margins. These Margins have been derived on the basis of Actual Thermal Stress and Material Fatigue. Frequent and substantial departures from criteria curves and TSE Indication can result
a. Reduction in total life of Turbine

RESETTING THE TURBINE WHY?

BEFORE STARTING ROLLING WITH ATRS TURBINE NEEDS TO BE RESETTED AS DURING TURBINE TRIP DUE TO ELECTRICAL/ MECHANICAL PROTECTION TRIP OIL DRAINS When the Turbine trips due to Electrical or Mechanical Protection Trip oil drains quickly. In the absence of the Trip oil Turbine Stop and Control valves closes quickly. So the Trip oil is basically required for keeping the ESVs and IVs in open condition and getting required Secondary oil pressure for opening the HPCVs and IPCVs. The Trip oil again can be generated again by resetting the Turbine.

KWU 500 MW TURBINE GOVERNING

RESETTING THE TURBINE

Reset the Unit Or Master Trip Relay. Bring the Starting Device to Zero. Unit or Master Trip Relay can be reset By 1.Resetting Boiler Master Fuel Trip Relays.

2.All Generator Trip Relays Reset.

3.Turbine Electrical Protections to be Reset. The Zero position of starting device generates a. Start up oil and b. Aux start up oil. Aux start up oil is required to reset Trip gear. Start up oil is required for resetting ESVs and IVs. It also ensures that the control valves opening are prevented till ESVs and IVs are opened.

RELEASE FOR SGC TURBINE 1. STARTING DEVICE ATSTART-UP ZERO POSITION OR

ANY ONE HP ESV OPEN AND ANY ONE INTCPT ESV OPEN 2. TURBINE CONTROLLER POSITION SET POINT < O% OR STARTING DEVICE > 42 % AND STARTING DEVICE > 56 % 3. GENERATOR BREAKER OFF AND FIELD BREAKER OFF OR TURBINE SPEED > 2850 RPM 4. DRAINS BEFORE HPCVs 1 & 2 (MAL 11, MAL 12) : NOT CLOSED OR (ANY ONE HP ESV OPEN AND ANY ONE INTCPT ESV OPEN) OR (TURBINE SPEED > 300 RPM)

5. LIMIT PRESSURE MODE: ON

6. POWER/LOAD CONTROL: ON 7. TG LUB OIL PRESS > 4.8 Ksc 8. SYNCHRONIZER: OFF 9. PROTECTION SHUTDOWN NOT INITIATED

SEQUENCE STEP 1 SGC Turbine startup sequence on COMMAND SLC DRAINS: ON SEQUENCE STEP 2
1. 2. 3. SLC DRAINS: ON All HP & IP ESVs :CLOSED OR STARTING DEVICE > 42% AND ESVs: OPEN ALL HPCVs & ALL IPCVs: CLOSED AND CRH NRV: CLOSED OR STARTING DEVICE >56% AND TURBINE POSITION CONTROLLER SET POINT > 0%

4. ALL EXTRAXTION NRVs (A2, A3, A4.1, A4.2, A5) POSITION < 5 % OR GENERATOR LOAD > 10%

COMMANDMS STRAINER DRAIN1: MS STRAINER DRAIN2: HRH STRAINER DRAIN1 : HRH STRAINER DRAIN2 : MONITORING TIME: 2 Secs

OPEN OPEN OPEN OPEN

SEQUENCE STEP - 3
1. CONDENSER PRESSURE < -0.5 Ksc 2. TRIP FLUID PRESSURE > 5 Ksc 3. CEP DISCHARGE HEDER PRESSURE > 19 Ksc 4. SLC DRAINS: NO FAULT 5. TURBINE SPEED > 15 RPM 6. HPC MID TOP/BOTTOM DT > -550K AND < 550 K 7. IPC FRONT TOP/BOTTOM DT > -300K AND < 300 K 8. IPC REAR TOP/BOTTOM DT > -300K AND < 300 K 9. MS STAINER 1,2 & HRH STRAINER 1,2 DRAINS: NOT CLOSED OR TURBINE SPEED > 300 RPM

SEQUENCE STEP - 4
1. DRAINS BEFORE HPCV 1,2 (MAL 11, MAL 12): CLOSED OR ESVs: OPEN

COMMAND

:NIL

SEQUENCE STEP 5
1. FLAME IN BOILER: ON 2. HP CF TEMP > 500C 3. STEAM TEMP BEFORE HPBP (BP1,BP2) SUPERHEAT > 300 K AND STEAM TEMP BEFORE LPBP 1,2 SUPERHEAT > 300 K OR

5. DT (WET STEAM BEFORE HPBP 1,2 HPCV 1,2 MIDWALL TEMP ) < X2 6. LUB OIL TEMP AFTER OIL COOLER > 350 C

COMMAND : raise

Starting device

NOTE: CRITERION X1 & X2 SHOULD BE FULFILLED BEFORE OPENING THE HP ESVs CRITERIA X3 (PRESSURE CRITERIA ) IS ALSO REQUIRED WHILE OPENING THE ESVs. MAX MS PRESS BEFORE ESVs, pMS = f ( TMCV50% ) IF TMCV50% > TSAT , PRESSURE CRITERIA IS NOT OBSERVED TMCV50% = MIDWALL TEMP OF MCV1,2 TSAT = SAT STEAM TEMP BELONGING TO MS

X1 CURVE
600

MID WALL TEMPERATURE HPCV-1 & 2

500 400 300 200 100

STEAM TEMPERATURE BEFORE HPBP-1 & 2

10 0

20 0

300

400 500

600

1.

ANY ONE ESVs: NOT CLOSED

OR STARTING DEVICE > 42 %

SEQUENCE STEP 6

COMMANDNIL MONITORING TIME: 30 Secs

SEQUENCE STEP 7
1. BOTH HP ESVs: OPEN NO COMMAND MONITORING TIME: 60 Secs

SEQUENCE STEP 8
1. MS FLOW > 15 %

OR TURBINE SPEED > 2850 rpm 2. STEAM TEMP BEFORE HPBP 1,2 SUPERHEAT >300 K

COMMAND : Drain before HPCV in auto SEQUENCE STEP 9

1. DRAIN BEFORE HPCV1,2: AUTO OR TURBINE SPEED > 540 rpm OR GENERATOR BREAKER: ON COMMAND TRACKING DEVICE: ON MONITORING TIME: 20 Secs

SEQUENCE STEP 10
1. TRACKING DEVICE: ON 2. BOTH INTCPT ESVs: OPEN COMMAND : Speeder gear raise ( Condition : Turbine speed <2800 rpm AND Speeder gear <100% )

SEQUENCE STEP 11
1. 2. 3. 4. 5. 6. DRAINS: NO FAULT GLAND STEAM PRESS CONTROL: AUTO SPEEDER GEAR > 100% LUB OIL TEMP CONTROL: AUTO GENERATOR CONDITIONS: FULFILLED ANY ONE VAPOUR EXTRACTOR: ON

COMMAND : Power set point raise

GENERATOR CONDITIONS FULFILLED
1. 2. 3. 4. 5. 6. 7. COLD GAS TEMP CONTROL: AUTO H2 PURITY IN AIR > 94 % H2 CASING PRESS > 3 Ksc SEAL OIL DPAIR(TE)-H2 SIDE > 0.9 Ksc SEAL OIL DPAIR(EE)-H2 SIDE > 0.9 Ksc SEAL OIL PRESS BEHIND PUMP H2 SIDE > 7 Ksc SEAL OIL PRE-CHAMBER TE LEVEL < MAX

GENERATOR CONDITIONS CONTINUED

8. SEAL OIL PRE-CHAMBER EE LEVEL < MAX 9. LIQUID IN GENERATOR TE < MAX 10. LIQUID IN GENERATOR CENTRE< MAX 11. LIQUID IN GENERATOR LEAD BOTTOM 1 &2 < MAX 12. ANY ONE AIR SIDE AC SEAL OIL PUMP: ON 13. H2 SEAL OIL PUMP: ON 14. AIR SIDE DC SEAL OIL PUMP VOLTAGE: PRESENT 15. PW TEMP CONTROL: AUTO 16. PW CONDUCTIVITY <1 mho 17. ANY ONE GENERATOR BEARING

SEQUENCE STEP 12
1. GENERATOR CONDITIONS FULFILLED 2. STEAM PRESS BEFORE HP ESVs SUPERHEAT > X3 3. DT (STEAM TEMP BEFORE HP ESV 1,2 -HP 5. CASING) > STEAM TEMP BEFORE LPBP MEAN DT (HRH X4 TEMP IP CASING T > 15 rpm 4. TURBINE SPEEDIPT50%)> X5 AND RH STEAM TEMP BEFORE LPBP > 4800C OR TURBINE SPEED > 2850 RPM 6. DRAIN BEFORE HPCV 1 & 2: NOT CLOSED OR TURBINE SPEED > 2850 RPM 7. POWER SET POINT > 10% 8. CONDENSER PRESSURE < -0.8 Ksc COMMANDTURBINE SPEED SET POINT : RAISE

SEQUENCE STEP 13
1. TURBINE SPEED SET POINT > 360 RPM OR GENERTOR BREAKER: ON COMMAND :NIL

SEQUENCE STEP 14
TURBINE SPEED > 300 RPM

COMMAND : MS strainer 1 drain close MS strainer 2 drain close HRH strainer 1 drain close HRH strainer 2 drain close

SEQUENCE STEP 15
1. TSE TEST PROGRAMME: BLOCKED AND SGC TURBINE STEP 14 ON DELAYED: 180 Secs OR WALL TEMP HP CASING > 2500 C TSE MARGIN > 300 K OR TURBINE SPEED > 2850 RPM DT (MS TEMP BEFORE HPBP 1 & 2 MIDWALL TEMP HP CASING) < X6 MS STRAINER DRAINS 1 & 2: CLOSE HRH STRAINER DRAINS 1 & 2: CLOSE

2.

3. 4. 5.

COMMAND : Drains HPCV in manual

NOTE:
1. AFTER STEP 14 TSE MARGIN IS NOT CHECKED FURTHER IN ATRS, AS IF STEAM TEMP IS MAINTAINED MARGINS WILL NOT DECREASE. 2. HOWEVER, TSE MARGIN EFFECT WILL BE PRESENT THROUGH EHC IF TSE INFLUENCE IS ON. 3. IF TSE INFLUENCE IS MADE OFF, SGC TURBIN BECOMES OFF THROUGH PROTECTION CIRCUIT. 4. IN CASE OF TSE FAULT SGC TURBINE WILL NOT BE OFF & LAST MARGINS ARE FROZEN UNTIL SPEED REACHES 2850 RPM.

dn/dt PROTECTION
BRINGS DOWN TURBINE SPEED TO SOAKING SPEED (360 RPM)

1.IF ATRS PROGRAMME IS MADE OFF BEFORE NR > 2850 RPM 2.IF TSE MARGIN RESTRICTS TURBINE ACCELERATION < 108 RPM/MIN THROUGH EHC.

SEQUENCE STEP - 16
DRAINS BEFORE HPCV 1 & 2: MANUAL

COMMAND :Turbine Speed set point raise Drain before HPCV 1 close Drain before HPCV 2 close

SEQUENCE STEP 17
1. TURBINE SPEED SET POINT > 3036 RPM OR GENERATOR BREAKER : ON COMMAND NIL

SEQUENCE STEP 18
1. TURBINE SPEED SET POINT < 2950 RPM OR GENERATOR BREAKER : ON

COMMAND:AVR in auto

SEQUENCE STEP 19
1. AVR: AUTO OR GENERATOR BREAKER: ON 2. FIELD BREAKER: ON COMMAND DRAIN BEFORE HPCV 1 & 2 : CLOSE

SEQUENCE STEP 20
1. BOTH AOPs OFF TD10s 2. DT (RH STEAM TEMP BEFORE LPBP MEAN TEMP IP SHAFT) < X7 3. H2 CASING PRESS > 3 Ksc 4. CG TEMP AFTER H2 COOLER A & B < 450 C 5. CG TEMP AFTER H2 COOLER C & D < 450 C 6. DRAIN BEFORE HPCV 1 & 2: CLOSE

7. ANY ONE AIR SIDE AC SEAL OIL PUPMP: ON

8. BOTH AIR SIDE AC SEAL OIL PUPMP : AVAILABLE 9. PW TEMP < 500 C 10. PW FLOW THROUGH STATOR WINDING & BUSHING: NOT LOW 11. DT (PW - H2) > 10 K TD15 MIN 12. CONDUCTIVITY AFTER MAIN FILTER < 2.5 mho 13. EXCITER COLD AIR TEMP < 450 C COMMAND AVR: AUTO MONITORING TIME BLOCKED

SEQUENCE STEP 21
1. 2. 3. SGC TURBINE STEP 20 COMMAND DELAYED: 15 Secs AVR on AUTO GENERATOR VOLTAGE > 95 % OR GENERATOR BREAKER ON AND GENERATOR LOAD > 10 %

SEQUENCE STEP - 22
1. GENERATOR BREAKER: ON COMMAND Speed set point raise

SEQUENCE STEP - 23
1. WAITING TIME: 2 Secs OR GENERATOR LOAD >10%

SEQUENCE STEP - 24
1. GENERATOR BREAKER: ON 2. TURBINE SPEED > 2850 RPM

END OF PROGRAMME

SYNCHRONIZATION
Generator breaker will close once permissive are matched. Immediately raise speed reference to pick up the load on the machine to avoid reverse power trip or low forward power trip. Increase the load as per TSE margin and close HP/LP bypass valves. Close all the drains which were opened during rolling. Turn off the synchroscope switch to de energize synchroscope. Ensure that load reference set point is higher than the actual load value. Observed that changeover from speed controller to load controller takes place once output of load

SYNCHRONIZATION
The load controller active light glows on Turbine desk. Ensure tracking device is on. Increase the load limiter value to about 150MW. Check the Generator winding, exciter air, cold gas temp., generator stator core temp. & all TSI parameter are normal. Raise the HP bypass pressure set point to 10KSC more than throttle steam pr and temp. Set point to about 340C to avoid HP by pass opening on auto. Ensure that LP bypass stop valves and spray valves are closed.

LP HEATER CHARGING
Check that LPH-1 inlet/outlet valves are in open condition and bypass valve in closed condition. Ensure all LP heater shell vents to condenser are in open condition. Charge both LP heaters 2 and 3 from condensate side by opening I/L valves and O/L valve and closing their bypass valve respectively. Charge LP heater-2 by opening its extraction valve. Note there is increase in level. Put its cascading drip to LP heater-1 and emergency drip to auto when the normal level is reached. Before putting to auto ensures that level set point of emergency drip is greater than normal drip set point. Repeat above for LP heater-3.

TO TAKE PULVERIZER INTO SERVICE

Starting of PA FAN Can be started if flue gas outlet temperature at Platen outlet is>300C Check all the permissive is satisfied. Any PRAPH is running. Give command check Discharge damper will open on auto. PAPH FG & air side in/out let opens on auto. *PA FAN IN SERVICE*

Starting Mill
Line-up from local and check all the per missives. Start Coal mill A(bottom most available Mill) open HAG/CAG & dampers to achieve air flow > 80T/Hr & temp>65C Start feeder and ensure flame gets stabilized. If pressure rises, Then increase load. Control MS & HRH temp to get sufficient margin. Maintain 100C more MS & HRH temp than HPS/HPC/IPS/HPSV/HPCV.

 Maintain MST & HRH temp by BT & spray. Take another mill into service. Pr 90 KSC & load 200MW. Take another Mill into service. Pr 110 ksc & load 250MW. Take another mill into service. Pr 120 Ksc & load 300MW. Remove oil support. Take another Mill and raise the load. Pr 130KSC & load 400MW Take 6th Mill in to service & raise the load.Pr 170 & load 500MW. Maintain O2 3.5%. CO less than 40.

Charge ESP when flue gas temperature at outlet of APH reaches above 100C Steam Temperature Control
To line-up &charge super heater attemperation system. To line-up & charge reheater attemperation system.

Charging Of Unit Transformer

To charge unit Transformer put

 Close the breaker when in-synchronism light glows and hold it for 2sec. Note that the incomer breaker from SA/SB bus, is tripped.

LOAD RAISING OPERATION

If unit is in EHTC and in load control mode, load increase command can be given from the desk (by increasing load reference) Pressure variation should be minimum to set throttle pressure. If throttle pressure is decreasing after giving certain load set point, increase boiler firing (by PA header pressure or by opening control damper or

 At load around 150-200 MW take feed water Hi-range in service. Now varying the BFP speed will control drum level. If the speed is put to auto , FW master will give the command to BFP speed. FW master may be put in auto if normal level is achieved. It is advisable to put primary air pressure control in auto to facilitate good control over firing.

Taking Second Set Of Auxiliaries

STARTING OF TDBFP Lube oil system Jacking Oil system Turbine on Barring Gear Steam charging and rolling TO LINE UP AND TAKE HP HEATER IN SERVICE RAISE THE LOAD TO RATED VALUE