ADHUNIK POWER & NATURAL RESOURCES LIMITED

2 X 270 MW, PADAMPUR

WORK INSTRUCTIONS
DOC REF NO CI/WI/001 REV 0 DATE OF ISSUE 15.05.13
RESPONSIBILITY MECHANICAL-OPERATION
PURPOSE PAGE 03
COLD STARTUP PROCEDURE (CEP)

1. GT should be Back Charged & 6.6 KV Electrical Supply system should be made healthy.
2. Check that all the PTWs are returned.
3. Before going to Start-up, ensure that the generator is filled with the hydrogen having
required pressure & purity. Also ensure that the Seal Oil system is healthy with
availability of both AC SOPs & one DC SOP.
4. Check the availability of DM water from DM plant & normalize the level of CST & CT
basin by running DM transfer & CT makeup.
5. Start ACW water pumps (2 pumps for 1 unit).
 Before starting ACW pumps, sump level should be normal (Above 6mtrs).
 All the Vents & ARVs should be kept open.
 Inlet & Outlet valves of PHE should be kept open.
 Riser valves should be in open condition.
 After starting ACW pump, remove all entrapped air through vents & close them
after the removal of air. Check discharge Pressure & Current.
6. Start Main Plant Air Compressors (2 compressors for both units).
 Cooling water supply pressure should be normal (4 kg/cm²).
 Check Gear Box oil temp (>32°C) & Lub Oil Pressure (>0.9kg/cm²).
 Butterfly valve in discharge should be kept open.
 Start Inst. Air dryer.
 Start Air compressor & Open Service air & Inst. Air valves.
 Check for Current, Loading & Unloading of Compressors.
 Though 1 compressor can cater single unit but for redundancy start another
compressor.
7. Charge DMCW system.
 Ensure that the level of DMCW Overhead tank is normal (>1500mm).
 Check the suction pressure of DMCW pump to be normal (2 kg/cm²).
 Open vents in DMCW discharge line.
 Start 2 nos DMCW pumps. Check that the discharge valves are opening in DCS as
well as in local.
 After the valve opens fully & a discharge pressure of 5kg/cm² is reached, start 1
DMCW Booster pump. Check the discharge pressure of the pump.
 Close all vents after the removal of air.
8. Filling of Boiler Drum & Waterwalls.
 Open all Drum vents, SH vents, RH vents & Eco vents on both LHS & RHS of Boiler.

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  Open Eco recirculation valve (E-23).
 Open Bottom ring hdr drain valves & Initial filling line valves.
 Close the Master Drain valve to IBDT. Also ensure that CBD, EBD & IBD valves are
tightened manually.
 Close the Initial filling line for to another Unit.
 After checking level in CST, start Boiler fill pump. Adjust the recirculation valve so
that a discharge pressure of 12kg/cm² is obtained.
 Fill boiler upto 3 ports (-25mmwc). Close the filling valve locally.
 Stop boiler fill pump.
9. Start AC Scanner Fan.
 Before starting check that the atmospheric suction damper is open locally.
 Take trail of DC scanner fan before starting AC Scanner Fan.
 After finding DC scanner fan normal, start AC Scanner Fan & check its discharge
pressure (>250 mmwc). If discharge pressure is not normal, check the Auto-
change over damper.
 Take auto pick-up trail by stopping AC Scanner fan.
10. Starting of Air Pre-heater (APH-1A & 1B).
 Before starting, check that all the manholes are in closed position. Also the Flue
gas inlet, flue gas outlet, PA inlet, PA outlet, Sec Air inlet & Sec Air outlet dampers
should be in open condition.
 Check the oil level in gear box to be normal. Check the level of oil in Support
Bearing & in Guide Bearing.
 Check the level of oil in Air lubricator and drain moisture trap if there is entrapped
water droplets.
 Check the air pressure and air motor. Check the air path from Inst air header to air
motor. No valves should be in closed condition except bypass valve of solenoid
valve.
 Start both APH-1A & 1B.
11. Start ID fan (any 1 IDF-1A/1B initially).
 Check the level oil to be normal in oil tank (should be between MAX & MIN
markings on level gauge glass.)
 Start both the LOPs one by one & check its discharge pressure & flow.
 Check the oil level in Hydraulic coupling.
 Check the DMCW inlet & outlet pressure to Lub oil & WO coolers.
 Check the Lub Oil DP & change filter if necessary.
 IGV & Scoop should be in minimum position.
 FG path should be available. (If not check that all the dampers starting from FD fan
discharge upto ESP outlet should be open.)
 ID fan inlet & outlet gate should be closed.
 Start ID fan & check that its inlet & outlet gates are opening in AUTO. Also check
for its current & abnormal sound.
12. Start FD fan.
 Close the discharge damper. Check the pressure of DMCW inlet & outlet.
 Check LUB oil tank level & auto change-over of LOPs & there discharge pressure &
flow.
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  Blade Pitch Control should be kept MIN.
 Start FD fan & look for the current & opening of disch damper in AUTO.
 Check that the scanner air fan suction through atmosphere closes in AUTO.

13. Establishing 30% to 40% Air Flow.

 30% air flow accounts to (1030*0.3=309T/Hr).
 Blade Pitch of FD fan should be increased according to achieve the Sec air flow of
309T/Hr, while maintaining Furnace draft in between -5 to -10mmwc by
operating IGV & Scoop of ID fan.
 Air flow should not be increased beyond 40% which accounts to
(1030*0.4=412T/hr).
14. Purging of Boiler.
 Purging is the process to remove any residual unburnt fuel inside the Boiler
furnace which can cause explosion at the time of Light-up. Following are the Purge
permissive:
 NO Boiler Trip.
 All LONVs CLOSED.
 LOTV CLOSED.
 All scanners show NO flame.
 PA fan should be OFF.
 All HAD should be CLOSED.
 Air flow 30% to 40%.
 All feeders should be proven OFF.
 Aux Dampers modulating.
 Give Purge start command after getting all the above permissive.
 The Purge timer is set at 300secs i.e. 5 mins.
15. Starting of LDO pumps & charging of LDO system.
 Ensure that the level of LDO tank is normal (>300mm)
 Ensure that the suction valves & discharge valves are in open condition.
 Open the short recirculation valve 100%.
 Start both LDO transfer pumps one by one and check for abnormal sound and
leakages.
 Slowly close the short recirculation valve so that the LDO line pressure rises to
32kg/cm².
 Put the valve in AUTO & insert a Set point (SP) of 32.
16. Filling of Feed Storage Tank (FST).
 Open D/A vent valve before filling
 Line-up Boiler fill pump for filling FST.
 Start Boiler Fill Pump after checking CST level. Fill D/A upto a level of 100mm.
 During filling, keep a close eye on CST level.
17. Boiler Light-Up with AB elevation.
 After the Purge has got competed, check that MFT has been reset. Open LOTV &
close LORV.
 Open LOCV so that to maintain oil pressure of 10 kg/cm². Also ensure that the
bypass line of LOCV & LDO totalizer is in closed position.
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  Ensure adequate pressure of Service air for atomization (air pressure should be
greater than LDO pressure after LOCV).
 Check that all the permissive for taking gun in service at each corner is available.
 Give start command to AB-1&3 or AB-2&4 oil guns.
 Check the sequence of firing. Also maintain the pressure of LDO & Furnace draft.
 After every half an hour change over of oil gun pairs may be made for uniform
heating of furnace. Flue gas temperature will start raising gradually and drum
metal temperature increases. Change over of oil guns are made till drum metal
temperature reaches 100°C. Drum pressure will start increasing after 100°C take
another oil guns pair in service and keep both pairs of AB elevation oil guns in
service. If flue gas temperature at furnace outlet is greater than 540°C, FTP will
come out automatically. Then adjust firing rate to control the flue gas temperature
at furnace outlet by reducing the LDO pressure.
 Maintain drum level, flue gas temperature, furnace draft & total air flow
meanwhile.
 OPEN CBD isolation valve so as to maintain drum level.
 Monitor the rate of rise of SH outlet temperature & ensure that it is within the
limits (5°C per min). Rate of rise to metal temperatures of SH, RH & Drum should
not go beyond (2°C per min for Drum metal temperature).
 Start chemical dozing pump & do dozing as per directed by the Chemist.
18. Charging of CW system (2 pumps for each unit & 1 common standby)
 Check that CT Basin level (>7000mm) & CW pump bearing oil level is normal
 Riser valves should be kept open.
 Run atleast 5 CT fans after checking Gear Box oil level.
 OPEN Water Box Vents, CW line vents & ARVs.
 Check that the discharge valve of CW pump should be in CLOSED condition.
 Start CW pump after checking availability of all permissive.
 Check for motor current & any abnormal sound. Close all vents except ARVs after
releasing entrapped air.
19. Start of Condensate Extraction Pump (Any 1).
 Fill hotwell by starting Hotwell makeup pump and open Normal Makeup line
control valve DM-20. Keep an eye on CST level to avoid tripping of pump due to
low level.
 Raise the level of Hotwell upto 50mmwc and put Normal makeup (DM-20) &
Emergency makeup (DM-15) in AUTO.
 To establish condensate circuit, check the Main Discharge Valve of CEP (CD-3 for
CEP-1A & CD-4 for CEP-1B) to be CLOSED. Ensure that the inlet & outlet valves of
LPH 1, 2 & 3 are in OPEN condition and their bypass is in CLOSED condition.
 Check that the DMCW supply to the Thrust Bearing is established. Check the oil
level of Thrust Bearing.
 Open MIN Recirculation Valve CD-25 at about 75% and close the D/A level control
valve CD-14 fully.
 Open vent valves of each LPHs.

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  Start CEP. Check motor current. Open Main discharge valve (CD-3 for CEP-1A &
CD-4 for CEP-1B). Put CD-25 & CD-14 in AUTO with a SP of 350T/hr & 50mmwc
respectively.
 Close all the vents after removing air from the circuit.
20. Establishing Feed Water Circuit.
 Check that the oil level of Hydraulic coupling is NORMAL. Check that the cooler
inlet valves to Mechanical seal cooler, Lub oil cooler, working oil cooler & BFP
motor cooler is OPEN. Ensure that the scoop of BFP is in MIN position.
 Ensure that the D/A level is NORMAL.
 BFP suction valve should be open, recirculation valve (both at 0mtr & 21mtrs)
should be open. Close the discharge valve & its IBV.
 Start BFP by checking all its permissive. Open Discharge IBV & then its Main
Discharge Valve.
21. Closing Vents & Drains & Charging of MS Bypass.
 When drum pressure reaches 2 kg/cm² close all the Drum vents, SH vents, RH
vents.
 SH Master Drain to be closed when drum pressure reaches 5kg/cm².
 Open all MS strainer drains (MS-105 & MS-106), HRH strainer drain (HRH-101 &
HRH-102), Drain before Main Stem Stop Valves (MS-101 & MS-102)Turbine drains
& CRH drains (CRH-101)along with their manual isolations.
 Gradually open MS Bypass valves MS-3, MS-4, MS-5 & MS-6.
 Open Start-up Vent to rise MS temperature.
 When the difference between the temperatures before & after MS stop valve is not
more than 50°C, open MS-1 & MS-2 gradually.
22. Taking TG Lube oil System & Turning Gear in Service.
 Ensure that the Level of Oil is normal in MOT (>250mm)
 Check the availability of EOP & AOP.
 Check the Inlet & Outlet valves of Oil cooler in OPEN condition.
 Start EOP to fill the oil lines. After the lines has filled, start AOP and check its
discharge pressure, current & filter Dp. Start any one OVEF after checking its
suction valves in OPEN condition.
 Start AC-JOP. Check that its header pressure rises upto 160kg/cm². Open turning
gear solenoid valve. Open the manual isolation gradually before solenoid. Turbine
will start rolling. Adjust manual isolation valve so that the speed will not rise
beyond 50rpm.
 Ensure that the SLC of both AOPs, EOP, AC-JOP, DC-JOP & Oil TCV is ON.
 During turbine on turning gear, keep a close watch on the Bearing metal
temperatures of Turbine.
23. Charging of PRDS.
 Ensure PRDS header drains are open locally.
 Open AS-9A & AS-9. Then open PRDS pressure control valve AS-10 so as to obtain
a pressure of 5-6kg/cm². Put AS-10 in AUTO with a SP of 7.
 Open D/A initial heating line gradually so as to give a flow of around 3 T/Hr in
PRDS. Check that temperature of PRDS is rising.

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  Open Gland Steam manual valve from PRDS station & ensure that the atmospheric
drain of Gland Steam Station is in OPEN condition.
 Check the rise of temperature before Gland Steam Supply Valve. Wait for the
temperature to raise upto 280°C.
 Check that the manual spray isolation valve should be in OPEN condition. Put the
Spray control valve CD-65 in AUTO with a SP of 380°C.
24. Charging of Gland Steam.
 Before opening Gland Steam Supply valve ensure that the temperature before
valve should be >280°C. Also ensure that the Reheater vents are CLOSED.
 Start GSC Exhauster fan after ensuring its suction valve in OPEN condition.
 Open the Gland Steam Supply valve gradually to obtain a pressure of 300mmwc in
Gland Steam Supply Header.
 Put GSPC controller in AUTO with a SP of 300mmwc. Also ensure that the
atmospheric drain of GSC should be open.
25. Vacuum Pulling.
 Check that the Separator level is normal and suction isolation valves (SM-8 & SM-
9) is OPEN.
 Start vacuum pump. Check that its recirculation pump starts in AUTO. Open its
suction valve. Procedure should be repeated for another Vacuum Pump.
 Close Vacuum Breaker.
 Check that the vacuum is raising gradually upto -0.91kg/cm².
26. Charging of HPBP & LPBP system
 Open HPBP warm-up line BP-3 & BP-4 along with their manual isolation valves.
Also open BP-6 & BP-8 (warm-up drain to UFT).
 Put HPBP spray valve in AUTO with a SP of 300°C.
 Switch on the Oil supply unit for HPBP system & LPBP system.
 Put LPBP CV in AUTO with a Fixed SP of 2 kg/cm². Also ensure that the water
injection valve (WIV) is in AUTO.
 When the temperature before and after HPBP valves equalizes, open HPBP valves
(BP-1 & BP-2) so that a minimum flow is obtained through HPBP system.
Simultaneously close the Start-up Vent maintaining MS pressure.
 Wait for the parameters to satisfy the criteria for Turbine Rolling.
 Take another pair of gun at CD elevation for criteria to arrive in less time.
27. Rolling of Turbine
 Start another pair of FD & ID fans and put furnace draft in auto with SP of -5
mmwc.
 Observe that TSE upper margin shows >30°C.
 Observe the EHC position shows zero.
 Set Load Limit at 28MW (Block Load).
 Switch ON Turbine MAL drains SLC.
 For Rolling of Turbine criteria X1, X2, X3, X41, X42 & X5 should be satisfied.
 If criteria are satisfied, increase TSLLE gradually from 0 to 100%.
 At 12% Pilot valves switches ON, at 42% HPSV OPENS. Gradually increase TSLLE
to 100%.
 Enter 651rpm in Speed Ref Block & confirm.
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  The speed of Turbine will gradually increase. At 240 rpm the Turbine Turning
Gear Solenoid Valve closes & at 540 rpm JOP-1 trips.
 Keep turbine in soaking until the criteria for speeding upto 3000rpm (criteria X61
S & X62 S) satisfies.
28. Increasing Turbine Speed to 3000rpm
 After the above said criteria are achieved, increase the Speed Ref to 3001 rpm and
confirm. Turbine will gradually speed upto 3000rpm at the rate of 600 rpm/min
if TSE margin is >30°C.
 Observe at critical speeds turbine bearing vibrations will go high and will
normalize after passing through critical speeds.
 AOP will trip at 2850rpm and MOP will supply Lub oil. Check its discharge oil
pressure to be 9.5 kg/cm².
29. Soaking of Turbine at 3000 rpm
 At 3000rpm turbine is to be soaked for about half an hour till X7 criteria is
satisfied.
 During rolling keep a close watch on: Differential Expansion, Overall expansion,
Axial shift, Turbine bearing & shaft vibrations, Turbine lube oil header
temperature.
30. Line-up for Synchronization of Generator with Grid
 Ensure that the DMCW cooling valve for Hydrogen gas cooler in kept in AUTO.
 When X-7criteria is satisfied, then synchronization of Generator with Grid to be
performed.
 Frequency of generation can be matched with that of the Grid my changing
gradually the speed of Turbine.
 At the time of synchronization, close HPBP to maintain MS pressure. Control drum
level manually through 30% control valve.
 After synchronization close all the drain valves (MS drain valves, HRH drain
valves, Turbine drain valves along with their manual isolation valves).
31. Start PA fan (any one initially).
 Check the oil level in Oil tank. Check the operation of each LOPs along with its
discharge pressure & flow.
 Ensure the Blade Pitch should be in MIN position & its discharge gate in CLOSED
condition. Also ensure that the discharge path is available upto HAG.
 If all permissive are available, start PA fan & check that its discharge gate is
opening in AUTO along with motor current.
 Increase Blade Pitch so as to get a Header pressure of 780mmwc.
 Check that the Seal Air fan has started in AUTO.
32. Taking Pulverizer-1A in Service.
 Check the cooling water inlet & outlet valves. Check the operation of both LOPs
along with its discharge pressure & flow. Check Dp of oil filter.
 Open Seal valve for respective Mill. Also ensure that Knife Gate valves & Mill MDVs
are OPEN.
 Start Mill after checking permissive. Look for motor current & abnormal sound.
 Ensure that the CAG is in OPEN condition.

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  Open HAG & then HAD by keeping an eye on PA HDR pressure. Maintain a air flow
of 70 TPH from Mill.
 When the mill outlet temperature reaches to 60°C, open feeder outlet gate.
 Check that feeder is not showing ‘No Coal on Belt’ and its seal air valve is in OPEN
condition. Feeder should be kept at minimum Feeder Demand.
 Start respective Feeder if all permissive are available.
 See for the change in current of due to its loading.
 Slowly load the Mill by increasing Feeder demand keeping focus on Mill outlet
temperature.
33. Increasing load & charging of LPH & HPH.
 As the pressure develops, increase load accordingly.
 Charge LPH 1, 2 & 3 at about 40MW.
 Before charging open drain line isolation & control valves.
 Open extraction line drain valves. Open the Extraction line main valve (EX1, EX2,
EX3 for LPH1, LPH2 & LPH3 respectively). Open extraction line NRV solenoids.
 Put drip level control valves of LPHs on AUTO.
 Start another BFP. Take 100% line of FCS in service if BLI increases beyond
260TPH.
 When the load reaches about 100MW, start taking HPH in service by following the
same procedure as followed for LPHs.
34. Increasing load beyond 100MW
 Increase firing rate by taking more mills in service (at max 4 for full load i.e.
270MW). Subsequently remove oil guns from service one by one from local.
 Start another PA fan for taking 4th Mill in service & another Seal Air Fan for taking
5th Mill.
 As the pressure increases, increase the load & go for full loading.
 Put Drum level control; SH spray control, Mill Air Flow Control & Mill Outlet temp
control in AUTO.

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