Stage 3: Unit Shutdown Checklist

Date : __________ Time : ___________ Reason of Tripping: __________________________________________________________ __________________________________________________________ __________________________________________________________ 1. Unit Just Tripped / Stopped First Up acted --- Turbine: !oiler :

!oiler Side
S."o #cti$it% to be &onitored Both PA Fans stopped 1.
2. 3. 4. &. '. ,. -. /. 12. 11. 12. 13. 14.

'e&arks

All Mills Tripped All Feeders Tripped ! spra" #al#es $losed on a%to R! spra" #al#es $losed on a%to All $anners sho( )* + Flame !F* Tri p #al#e is $losed .D* trip #al#e is $losed !F*0.D* )o11le #al#es in $losed $ondition All !ot air gates are in $losed $ondition 3lose Boiler top #al#es B%rner Tilt 4e$ame hori1ontal 3lose the #al#es if the Boiler is not going to 4e lighted %p immediatel" P%t the $ontrol in man%al and $lose P%t the $ontrol in man%al and $lose

1&.

Turbine Side
S."o 1(. 1). #cti$it% to be &onitored
Both the 4%ses %ppl" $hange o#er to station Both the 42256 4rea7ers are open .%4e oil press%re 9

'e&arks

1-. A*P $ame on a%to 8 2-&2 RPM

1/. 22. 21. 22. 23. 24. 2&. 2'. 2,. 2-.

All T%r4ine stop and $ontrol #al#es $losed 3he$7 !P e#a$%ation #al#e open T%r4ine speed is $oasting do(n 3ondenser #a$%%m is )ormal 0 7illed All e:tra$tion #al#es $losed .P! 1;2;3 0 !P! &A ; &B ; 'A ; 'B 0 D0A BFP 3 to 4e 7ept in ser#i$e for maintaining Dr%m .e#el <i#e Trip $ommand to TDBFPs 3he$7 TDBFPs $ame on 4arring speed !P B"pass #al#es in $losed $ondition 3lose the man%al #al#e in !P B"pass spra" line R! press%re sho%ld 4e less than 12 5s$ 3he$7 all the MA. drains are open in$l%ding !P 3asing drain 3he$7 Motorised drain in 3R! line is in open $ondition @*P started at &12 RPM <ate #al#e gearing open at 212 RPM 2 3lose from lo$al =f re>%ired R! $an 4e de ? press%ri1ed

2/.
32. 31. 32. 33.

Time ta7en for T< $ome on 4arring speed from 3222 RPM to 1. Time ta7en to rea$h &42 RPM :
34.

_______________ min%tes _______________ min%tes _______________ min%tes _______________ min%tes

2. Time ta7en to rea$h 212 RPM : 3. Time ta7en to rea$h 122 RPM : 4. Time ta7en to rea$h -& RPM A 6a$%%m 5illed B :

3&. 3'. 3,.

3ontin%o%sl" monitor !ot(el le#el 3he$7 Dearator le#el 3lose !P B"pass spra" man%al #al#e

3losing of ma7e %p #al#e ma" 4e re>%ired to $ontain the rise in le#el

#cti$ities a*ter T+ ca&e on barring

S."o #cti$it% to be &onitored
3he$7 !ot(ell le#el team enters the s"stem thro%gh

'e&arks
!ot(el le#el has the tenden$" to rise indefinitel" ? monitor the le#el $ontin%o%sl". a. $lose TDBFPs + a%: steam #al#es 4. $lose !ot(el ma7e %p isolating #al#e

3-.

a. A%: steam to TDBFPs drain 4. eal steam drain

3/. 42. 41. 42. 43. 44. 4&.

top one 3C P%mp top all the 3T Fans (it$h off all D P fields after 22 !rs of Boiler trip =f re>%ired #a$%%m $an 4e 7illed 3he$7 for an" oil lea7ages or fire or smo7e at T%r4ine 4earings 0 !P B"pass 0 eal steam #al#es Monitor the T%r4ine speed 3lose all the man%al isolating #al#es at *il ele#ations D P e#a$%ation sho%ld $ontin%e for 2- hrs of Boiler Trip 3omplete ash handling s"stem $an 4e stopped after 2- !rs of Boiler Trip 3

4'.

=t (as e:perien$ed that small >%antit" of ash left in the hoppers $ho7e the mo%th and gets hardened and $reate f%rther pro4lems in ne:t light %p

4,.

4-. 4/. &2. &1. &2.

M%lsifier s"stem on Transformers $an 4e $he$7ed after $ons%ltation (ith DMD 0 *FF site Mt$ 0 safet" 0 fire (ing *pen the isolators if the %nit (ill 4e sh%t do(n for more than 22 hrs 3hangeo#er PC F 3ontrol Fl%id P%mps

<T 0 EATs $an 4e $he$7ed

Remar7s : _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ ____

Stage 3: Unit Start , Up Checklist

-ate: Ti&e:

.. Just !e*ore &aintenance gi$e clearance *or boiler light up !oiler Side
S."o #cti$it% to be &onitored &3. 3he$7 all the PTC pending
&4.

'e&arks

*ff sites + Fire (ater 0 ash handling s"stem 0 D P all passes 0 et$ + a#aila4le 0 in ser#i$e

&&.

< A one p%mp B 0 T< D3C A t(o p%mpsB are in ser#i$e 3ooling (ater is 3harged for all the a%:iliaries li7e =D ; FD ; PA ; Mills ;

&'.

&,.

.%4e oil s"stem for =D ; FD ; PA ; Mills a%:iliaries is in ser#i$e and filters are $lean 4

&-. &/. '2.

3he$7 AP!s for a$t%al rotation from lo$al F air motor is in normali1ed $ondition $anner air fan is r%nning and header Pr. )ormal ? G 2&2 mm B%rner Tilt !ori1ontal Boiler e:pansion indi$ating rods are in position

'1.

'2. '3. '4. '&. ''. ',.

=nstr%ment F er#i$e air press%res are ade>%ate $raper $on#e"or and $lin7er grinder are a#aila4le for ser#i$e tro%gh seal o#er flo( is *5 D$o hoppers + spool pie$es are repla$ed and normali1ed. Dns%re all the manholes and peep holes of the Boiler are $losed A#aila4le mills are 7ept normali1ed ele$tri$all" and me$hani$all"

&

S."o (/.
'/.

#cti$it% to be &onitored
tart !F* heating and raise the !F* temG1222 3 Dns%re Tra$ing 0 atomi1ing steam in normali1ed $ondition and lines at oil ele#ations are hot. ! ; R! spra" #al#es normali1ed Dns%re !P B"pass spra" man%al #al#e is 7ept $losed Dns%re Pre?$leaned g%ns are p%t in 4oiler ele#ations M ; 3BD ; ! sampling points are normalised 3BD man%al #al#es at Dr%m and DF ele#ation are 7ept open Boiler $orners fire prote$tion s"stem is in ser#i$e 5eep Dr%m le#el man%al #ents and ! header drains open %ffi$ient $hemi$als in the dosing tan7s H .P F !P dosing p%mps are a#aila4le Boiler is lined %p for filling thro%gh fill p%mp All DR6s motori1ed isolating #al#es are in open $ondition Cet?la" p%mp lined %p to 4e r%n along (ith 4oiler fill?p%mp AP! soot 4lo(ing is in lined %p $ondition AP! + oil $arr"o#er pro4e is 7ept after $leaning 0 .ights are glo(ing in $old end side 3AP! isolating #al#es are 7ept open Atomi1ing steam line 0 tra$ing steam are in $harged $ondition tat%s of Prote$tions li7e Dr%m le#el ; Reheater All .R B F (all Blo(ers in retra$ted $ondition + $he$7ed from lo$al

'e&arks

,2. ,1. ,2. ,3. ,4. ,&. ,'. ,,. ,-. ,/. -2. -1. -2. -3. -4. -&. -'. -,. --.

'

T+ Side
S."o 1.
2. 3. 4. &. '. ,. -. /. 12. 11. 12. 13. 14. 1&. 1'. 1,. 1-. 1/. 22. 21.

#cti$it% to be &onitored
T< on 4arring and T%r4ine l%4e oil press%re is *.5. =f ne$essar" .%4e oil filter 3hange o#er and stand 4" got $leaned < 0 T< D3C and AR3C p%mps are in ser#i$e (ith P!D. Boiler 0 T< D3C tan7 le#els + *5 M*T 0 FRF 0 BFPs + oil le#els are *5 All $oolers li7e M*T ; 3.F. ; BFPs ; <as ; D:$iter ; Primar" (ater ; eal oil in $harged $ondition Primar" (ater al7al"ser is in ser#i$e F $ond%$ti#it" normal Both The 3C passes are in $harged $ondition T(o 3C p%mps are in ser#i$e All the a#aila4le 3T Fans are p%t in ser#i$e <o#erning ra$7 is in normali1ed $ondition (ith D!3 isolating #al#es in open $ondition *n D!3 $onsole + Pl%nger $oil s%ppl" *) 0 .oad $ontroller *) 3he$7 all the man%al isolating #al#es pro#ided in the t%r4ine side drains are in open $ondition A#aila4le BFPs are 7ept normali1ed T%r4ine top and $ontrol #al#es + gagging is in remo#ed $ondition A 3.F. #al#es are normali1ed B M*T 0 TDBFP A 0 B H 3ontrol Fl%id H * T #apor e:ha%sters are in ser#i$e 3he$7 all the T< 4earings ret%rn oil flo( 0 #a$%%m *.5. All DM Ma7e %p p%mps a#aila4le in$l%ding 3 T p%mps Both 3PEs are in ser#i$e Darth (it$hes +<T ; EATs are in open $ondition <T ; EAT $oolers are on a%to

'e&arks
..* Pr 9

S."o ...
23. 24. 2&. 2'. 2,. 2-. 2/. 32. 31. 32. 33.

#cti$it% to be &onitored
%ppl" to all the B%ses !T 0 .T is a#aila4le .P dosing p%mps read" to 4e r%n along (ith BFP %ffi$ient 3*2 3"linders are $onne$ted to manifold <enerator 3asing !"drogen press%re is ade>%ate + 3.2 5s$ Fire prote$tion s"stems for transformers and $a4le galleries is in ser#i$e .ist of Prote$tions 7ept 4"passed Critten $learan$e from PP 0 RM 0 3F= 0 TM 0 A!M 0 DM in $omm%ni$ation register Boiler 0 T< PF= $he$7s as per .M= $ompleted 3he$7 M*T 0 FRF Tan7 .e#els

'e&arks

3. !oiler light Up to S%nchroni0ation

S."o #cti$it% To be 1onitored 1. AP! oot 4lo(ing is in progress
2. 3. 4. &. '.

'e&arks

3AP! is 7ept in ser#i$e Air and Fl%e gas o%t let temperat%res of AP!s are normal D$o re$ir$%lation 6al#es *pen 3he$7 for oil falling in slag 4ath Dr%m metal temperat%res Top 0 Bottom Dearator Pegging steam $harged + after an" BFP is 7ept in ser#i$e F Press%re and Temperat%res are *5 +3.& 5s$ F G122Deg 3he$7 T%r4ine speed (hile $harging !P 0 .P B"?pass 3he$7 ? .oad referen$e sho%ld 4e at '3 MC as per logi$ on a%to (hile rolling thro%gh ATR 5eep PRMa: A load limiter B at G 2&2MC 3BD is 7ept open 3he$7 !ot(ell ; Dearator ;Dr%m le#els ; !F* 0 ! D press%res !P 0 .P dosing done as per re>%irement Rate of rise of parameters M T 0 !R! (ith in limits + 2& 0 12 Deg 3 per min. Both the #a$%%m p%mps are in ser#i$e 3he$7 for an" oil lea7ages or fire or smo7e at T%r4ine 4earings 0 !P B"pass 0 eal steam #al#es *pen !P B"pass spra" man%al #al#e A at Dr%m press%re G 12 5s$ B 0 4efore I%st ta7ing mill in ser#i$e eal air fan too7 tart along (ith PA Fan and dis$harge Press%re ade>%ate D P fields are p%t in ser#i$e after =st mill is p%t in ser#i$e <RP ?? all rela"s are a#aila4le H D3 s%ppl" *5 <RP + generator prote$tions normali1ed H <RP rela"s reset /

,.

-. /. 12. 11. 12. 13. 14. 1&. 1'.

1,.

1-. 1/. 22. 21.

22. 23. 24. 2&.

)ote do(n D0A ; !ot(el le#els )ote do(n $ondenser 6a$%%m 5eep all the T%r4ine side drains open 4efore starting T%r4ine rolling Roll one TDBFP and 7eep it r%nning in re$ir$%lation

12

S."o #cti$it% To be 1onitored .(. Both =D F FD Fans in ser#i$e

2,. 2-. 2/. 32. 31. 32. 33. 34. 3&. 3'. 3,.

'e&arks

<ate #al#e gearing sho%ld $lose at T%r4ine speed G 242 RPM All @*Ps sho%ld stop at T%r4ine speed G &42RPM !P e#a$%ation #al#e sho%ld $lose at T%r4ine speed G 2-&2 RPM Critten $learan$e from 3hemist for T%r4ine rolling Both sets of fans to 4e in ser#i$e 4efore s"n$hronisation 3he$7 seal air fan too7 start on a%to along (ith PA Fan and dis$harge header press%re G 12&2mm 3he$7 !P B"pass 0 seal steam area for an" oil spillage 0 Fire 3he$7 seal air fan too7 start along (ith PA fan and dis$harge press%re ade>%ate

D3 @*P has to 4e stopped man%all" at T%r4ine speed G &42 RPM

Press%re 9

11

2. Unit Just S%nchronised S."o 1.

2. 3. 4. &. '. ,. -. /. 12. 11. 12. 13. 14. 1&.

#cti$it% To be 1onitored
<T Fans are r%nning + $he$7 lo$all" and see for an" $ooler tro%4le alarm in <enerator alarm .6 D:$itation is on AET* and at Enit" Po(er Fa$tor =n$rease load set point A if re>%ired B 3lose all MA. drains 3lose the se$ond 42256 4rea7er. Carn a4o%t the do%4tf%l mills (hi$h ma" in$rease the temperat%res rapidl" All the heaters .P! 2 ; 3 ; D0A and e:tra$tion #al#e to TDBFPs are $harged )ote do(n D0A ; !ot(el le#els )ote do(n $ondenser 6a$%%m 5eep the 3R! header drain open for some more time. All the T%r4ine side drains are $losed 6entilation #al#e $losed on a%to + Dlse $lose it man%all" 3lose !P 0 .P 4"pass after $he$7ing R! prote$tion in the s$heme.

'e&arks

3. Checklist be*ore crossing .45 o* the 6oad

S."o 1.
2. 3. 4. &. '. ,. -. /. 12. 11.

#cti$it% To be 1onitored

'e&arks

!P T%r4ine top 0 Bottom temperat%re differen$e 8 12Deg =P Front 0 Rear ??top 0 4ottom temp differen$e less than 12 Deg eal steam and lea7 off $ontrollers on a%to All .P!s are in $harged $ondition tart se$ond TDBFP rolling and p%t in ser#i$e 3he$7 Margins G 12Deg al(a"s 3he$7 !P D:ha%st temperat%re 3he$7 R! press%re 3orresponding (ith the load %ppl" $hange o#er from station to EATs. Bet(een 1&2MC to 2&2 MC 3harge !P! at load G 142 MC 12

12. 13. 14.

(. Just !e*ore 7il Support is 8ithdrawn 9: (4 5 o* the 6oad;

S."o #cti$it% To be 1onitored All the flame s$anners sensing flame 1.
2. 3. 4. &. '. ,. -. /. 12. 11. 12. 13. 14. 1&. 1'. 1,.

'e&arks

D P is $harged and in ser#i$e AP! oot 4lo(ing stopped 3AP! is isolated Mill reIe$ts $leaning is in progress Bottom ash is normal 3BD sili$a 0 DPR are monitored 3he$7 all the le#el $ontrollers li7e Dr%m ; !*TCD. 0 Dearator ; PC ; 3F ; ..* ; <as temp are on a%to All the !P heaters are in ser#i$e Mills and =D fan .%4e oil press%res are *.5. Both TDBFPs are in ser#i$e and on a%to a4o#e 2&2 MC
Fill )ormal .og sheet after oil s%pport (ithdra(n

Cater (all soot Blo(ing G ,&J load 3he$7 Margins G 2&Deg al(a"s 3he$7 all prote$tions are p%t in ser#i$e

Remar7s: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____

<ara&eters to be sub&itted *or 7'T 'eport

13

.)o Parameter 1. 2. 3. 4. &. '. ,. -. /. 12. 11. 12. 13. 14. 1&. 1'. 1,. 1-. 1/. 22. 21. 22. 23. 24. 2&. 2'. 2,. Dr%m Press%re M press%re Dr%m metal temperat%re M T 0 !R! !R! steam press%re ! spra" R! spra" Total air flo( *il g%ns in ser#i$e Mills 0 3oal flo( Boiler ili$a 3ondenser 6a$%%m T< 4arring peed T%r4ine A:ial shift !PT DD =PT DD .PT DD !PT AD =PT AD !PT $asing temp Top 0 Bottom =PT Front $asing Temp T0B =PT rear $asing Temp T0B !PT rotor temp =PT rotor temp Ma: T< 4earing temp Ma: T< shaft 6i4ration Ma: T< Bearing 6i4

Before Boiler .ight Ep

After 3harging !P 0 .P B"pass

At oa7ing peed of 3'2 RPM

At 322RPM or @%st After s"n$hr.

Timings of Different A$ti#ities A An" dela" (ith reasons to 4e mentionedB

.)o 1 2 A$ti#it" Boiler .ight Ep *il <%n pro4lems AB 1 AB 2
14

Timing 0 remar7s

AB 3 AB 4 3D 1 3D 2 3D 3 3D 4 3oal Mills A B 3 3 D D F 4 & ' , / 12 11 !P 0 .P B"pass 3garging oa7ing at 3'2 RPM oa7ing at 3222 RPM "n$hronisation *il s%pport Cith? dra(n All prote$tions normalised ; if 4"passed 4efore F%ll .oad 3BD 3losed

!oiler Filling = >%drotest Checklist

9 <rechecks be*ore >%drotest ;

Date : __________ Time : ___________

S."o
1. 2.

#cti$it% to be &onitored
3learan$e a#aila4le from BMD? PP All persons are remo#ed from inside the 1&

'e&arks

3. 4. &. '. ,. -. /. 12. 11. 12. 13. 14. 1&.

Boiler A 1st and 2nd passesB All persons are remo#ed from Bottom ash0D$o hopper area Boiler fill p%mp a#aila4le Dr%m and Bottom Ring header manhole doors 4o:ed %p !"drastep 0 Dr%m le#el transmitters are in normali1ed $ondition. T< on 4arring + prefera4l" .o$al 4ig dial press%re ga%ges are fitted at Dr%m le#el A .! 0 R! B E3B dr%m press%re 0 M press%re indi$ations are a#aila4le Boiler sh%toff #al#es and their =B6s $losed ! DR6 man%al #al#es $losed. ! DR6 $ontrol s(it$hes in E3B are 7ept in *ff position 3BD #al#es at $ontrol station A'&M. B in $losed $ondition. DBD #al#es $losed <C3 p%mps Motor $a#it" fl%shing and filling done M 03R! 0 !R! header drains open on t%r4ine side. 3 T le#elG &m

1'

S."o
1'. 1,. 1-.

#cti$it% to be &onitored
BFP ? ! spra" man%al #al#es $losed BFP ? R! spra" man%al #al#es $losed !P 4"pass spra" man%al #al#e $losed 3C $harged; D3C and AR3C s"stem in ser#i$e. At least one 3DP in ser#i$e or A3 seal (ater p%mp in ser#i$e for pro#iding seal (ater to BFP main p%mps Boiler feed p%mp a#aila4le + prefera4l" MDBFP .P dosing s"stem a#aila4le and p%t in ser#i$e as soon as starting of MDBFP. Feed (ater s"stem $harged %pto FR De aerator filled and le#el normal Cet la" p%mp a#aila4le BFP 3 re$ir$%lation #al#e air #al#e to 4e

'e&arks

1/.

.ine %p D3C for BFP .%4 oil; (or7ing oil; BP me$h. seal and MDBFP motor $oolers

22.

21. 22. 23. 24. 2&.

3harged from feed (ater side and seal (ater line %p for main p%mp.

2'.

7ept $losed. This (ill ens%re re$ir$%lation #al#e to remain in open $ondition thro%gh o%t the test.

1,

!oiler Filling = >%dro test 9>%dro Test <rocedure;

S."o 1. ..
3. 4. &. '. ,. -. /. 12. 11. 12.

#cti$it% to be &onitored
3lose Boiler master drain to =BD tan7 *pen ! fill0drain header indi#id%al #al#es in 3D ele#ation 3lose ! fill0drain header final drain #al#e to =BD tan7. .ine %p BR!; D3* and ! filling #al#es R! filling #al#e al(a"s remain in $losed $ondition + remain it in $lose $ondition. Dr%m #ents open ! man%al #ent #al#es; start %p #ents open. tart 4oiler fill p%mp and $lose re$ir$%lation 3lose Dr%m #ents after thoro%gh #enting 3lose ! man%al #ents after thoro%gh #enting 3lose ! start %p #ents after thoro%gh #enting Afrom E3BB top 4oiler fill p%mp and $lose 4oiler fill #al#e. tart MDBFP and Press%ri1e 4oiler slo(l" K & 5s$ per min%te AMa:B Press%ri1e 4oiler %pto re>%ired test press%re A 2125s$B slo(l" Red%$e BFP dis$harge press%re to 122 5s$ 0 Trip MDBFP ?? as per re>%irement + and note do(n press%re drop

'e&arks

Dns%re 3%rrent is 82-2 Amps 4" throttling dis$harge #al#e. )ormall" ta7es 42 Min to 1 hr.

Allo( 4oiler press%ri1ation %pto , 5 3.

13.

14.

1&.

5eep R03 #al#e f%ll open !old at 122 ? 142 5 3 dr%m press%re till BMD?PP gags all Dr%m and ! safet" #al#es. !old at this press%re for the time d%ration as per re>%irement A generall" 2 min%tesB After 1 min:_______________ After 2 min:_______________ After 3 min:_______________ After 4 min:_______________ After & min:_______________ After 12 min:_______________

1'.

Boiler $an 4e de ? press%ri1ed 4" opening drains in sampling station.

1-

Defe$ts d%ring ATR Rolling tep 1. 2. 3. 4. &. '. ,. -. /. 12. 11. 12. 13. 14. 1&. 1'. 1,. 1-. 1/. 22. 21. 22. 23. 24. 3riteria )%m4ers Remar7s

Ma: haft and Bearing Pedestal 6i4rations d%ring Rolling

haft 0 Bearing Pedestal Ma: rea$hed T%r4ine peed

1/

*4ser#ations 0 Defe$ts 0 $ope for impro#ement d%ring tart %p till f%ll load
_____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ ___ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ ___ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ ___ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ ___

F%ll .oad =mportant Parameters for *RT .)o 1. Time F date 22 Parameter Design 6al%e A$t%al

2. 3. 4. &. '. ,. -. /. 12. 11. 12. 13. 14. 1&. 1'. 1,. 1-. 1/. 22. 21.

.oad M6AR Dr%m Press%re Throttle team Press%re =st tage Press%re 3ondenser #a$%%m 0 Ba$7 Press%re M T !R! Feed Cater *0. temp at !P! *0. F D$o =0. M Flo( FC Flo( ! pra" R! pra" Fl%e <as temperat%re =0. F *0. of AP! A F B Fl%e <as temperat%re =0. F *0. of PAP! A F B 3C =nlet 3C o%tlet <enerator tator 3%rrent

&22 MC 2 1-- 5s$ 1,2 5s$ 1&1.,2 5s$ ,' MM &3, 23 &3, 23 2&3., 23 1&42.2 1&42.2 2 2 133 23 133 23 32.2 23 42.-' 23 1'.2 5A

21