PTPS, HPGCL, PANIPAT WORK INSTRUCTION TITLE : Turbo-Generator and auxiliaries operation, Responsibility: A.E. Desk Operation. Sr.No.

Parameter Range Frequency 1. H2 Pressure 3.3-3.7 bar Continuous

Doc Page : 1 of 3 Issue : Date: Corrective Action If, low, charge generator with H2 Cylinders, if repeatedly drops then ask TG maintenance to check for leakages. As per result of sample by testing lab if low, maintain by purging H2 from generator and charging with H2 Cylinders. If low, changeover the filter in coordination with TG maintenance .Also Emergency Oil Pump during filter changeover.. If low, take standby ejector into service. Also maintain PRDS to Ejector line Pr.>10 kg/cm2 Maintain adequate water level in stator water tank by adjusting recirculation valve at site. If high, take the demineraliser in service at local site. Also drain expansion tank gradually to enter fresh DM for restoring normal conductivity. If deviations are high, adjust Dearator level control valve by manual intervention, if low, open bypass valve of control valve. If deviation are high, adjust load set valve Adjust Generator Voltage On deviation, adjust by raising/lowering excitation. Reviewed & Approved By :

2.

H2 Purity

>98%

Every Shift through sampling Continuous

3.

Lub Oil Pressure

1-1.2 bar

5. 6. 7.

Condenser Vacuum Station Water Pressure Stator water conductivity

.80 - .90 bar 3.5-5.5 bar <1.5uS

Continuous Continuous Hourly

Dearator Level

900-1400 mm

Continuous

9. 10. 11.

Load MVAR Generator Voltage

210MW As per requirement 14.7-16.1KV

Continuous Hourly Hourly

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Note: The record /data related to the observation on above parameters are mentioned in log sheets/ DCS

PTPS, HPGCL, PANIPAT WORK INSTRUCTION TITLE: Activities for start of Turbine. Responsibility : 1 a)

Doc Page : 1 of 4 Issue : Date:

Availability of sufficient DM water in DM storage tank. If not so, ensure as under : Ensure sufficient clarified water in suction chamber (sump) of clarified (misc.) water pump house. If not so, run raw water pump after ensuring raw water level in the raw water reservoir. Open Cooling Tower (CT) make up valve installed at Misc. pump house for filling CW forebay (basin) up to the level of 5 M and above. Start two no. Bearing Cooling water pump installed in CW pump house and establish clarified cooling water flow for various Auxiliaries such as plate Heat Exchanger for DM cooling water, instrument air compressors, Ash Handling vacuum pumps and Ash Handling air compressor etc. Open condenser vents and start one CW pump. Close condenser vents when proper water flow through established. Start instrument and service air compressor/compressors. Check if sufficient DM water is available in DM storage tank. If not, start DM feed pump installed in Misc. Pump House for DM water generation. Start CTP/BFP for filling boiler drum to maintain normal level in the drum (about-50 mm level). Start one o CTP and maintain hot well & expansion tank level. Start any one CEP after ensuring normal Hot well level for filling and in Dearator up to normal level (about 900 mm level). maintain water

b) 2

3.
4. 5. 6. 7. 8.

9. Start filling carbon dioxide in the stator and maintain purity more than 95%. Then start filling Hydrogen and maintain Hydrogen purity about 98%, then start increasing hydrogen pressure to 3.5 kg/cm2 in stator and maintain differential pressure between hydrogen and seal oil as >1.0 kg/cm2 . 10. Engage Barring Gear from DCS or manually form local site. 11 Start one of the BFP for maintaining normal level in Boiler Drum. 12. On attaining steam pressure about 20 kg/cm2 charge (APRDS) Auxiliary Reducing Station. 13. Also Take Heating steam for Dearator from APRDS for pegging . Pressure

14. Start vacuum pulling in the condenser by taking starting ejector, main ejector in service. 15. Take gland steam condenser exhaust fan in to service and supply steam from APRDS to gland sealing system & maintain 0.01 kg/cm2 in the header.

16. Confirm opening of turbine Drains, Main steam drains, HRH drains, CRH drains,Turbine casing drain,Governing valve drains etc.Put SLC drain on auto. 17. Charge HP & LP by-pass system and maintain the steam pressure more than 40 kg/cm2 and temperature about 350oc. Ensure the total steam flow is >15 % of MCR flow. 18. Check all turbine protections. 19. Start ATRS program. 20. Check that JOP (AC) stop at Turbine speed 540 RPM (approximately). 21 Start raising the speed of turbine to 600 rpm and soak the turbine till HP casing Temp. > 200 C and HPT/IPT overall expansion increase to optimum level. 22 Raise turbine steed t o 3000 rpm and soak the turbine till IP shaft temperature > 200 deg C 23. Start building excitation to 15.75 kv and switch on Auto synchronizer/ synchroscope. 24. Now auto synchronizer will adjust Governor Voltage and Turbine speed automatically to synchronize the machine with grid and on synchronization of Machine with grid, block load of about 30 to 40 MW will appear on the screen. 25. Auto synchronizer now is to be switched off. 26. Excitation is to be adjusted as per load condition. 27. Close all Turbine side drains after achieving load more than 40 MW. 28 Charge LP heaters 1, 2 & 3 after achieving about 50 MW load. 29. 30. Take Unit Auxiliary Transformers UAT-1A & UAT-1B both in to service Now charge Turbine extraction-4 line for Dearator pegging at 120 MW. Also take 2nd BFP, CEP, and CW pump in to service as per requirement to maintain various Parameters. Charge HP Heater 6 & 5 after achieving at 80 & 120 MW load. Increase the load gradually up to 210MW according to steam Pressure.

31.
32.

33.

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Reviewed & Approved By :

Note: The record /data related to the observation on above parameters are mentioned in log sheets/ DCS

PTPS, HPGCL, PANIPAT WORK INSTRUCTION TITLE : BFP A/B/C. Responsibility : BFP A/B/C Before Start Up :-

Doc Page : 1 of 10 Issue : Date:

1. D/A level normal. 2. BFP Inlet suction valve open. 3. BFP lube oil pressure normal. 4. BFP Inlet filters ok. 5. Minimum recirculation valve open and minimum flow should be >95 t/hr. 6. BFP Outlet valve is closed before startup & open in auto after startup. 7. Motor shaft direction is clock wise. 8. Lube oil level in the tank is ok. 9. Lube oil pressure is ok (2.5 kg). 10. DM cooling water flow is ok; Inlet/Outlet valves are open in condition. 11. Check Auxiliary oil pump in service. 12. Ensure the PTW on equipment is cancelled. 13. One no. BCW should be in service. 14. One no. CTP should be in service. 15. All the Inlet/outlet valves to PHEs for DM secondary system should be in open condition. 16. Booster pump suction temperature should be less than 169 c. 17. The vent valves installed on the Inlet / Outlet lines for suction & discharge of BFP should be open. 18. All the HPH heaters feed water line in service & the by pass valves in closed condition. After Start Up :1. 2. 3. 4. 5. 6. 7. Check oil pressure is normal. Check DM water pressure & temperature is normal. Check any leakage of water & oil in system. Check any vibration/abnormal sound. Check the bearing temperature (<75 c). All the vents are closed after startup. Change the Duplex oil filter of BFPs when the lube oil pressure DP goes to 0.6 kg/cm.

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Reviewed & Approved By :

Note: The record /data related to the observation on above parameters are mentioned in log sheets/ DCS

PTPS, HPGCL, PANIPAT

CEP A/B Before Start Up :1. Ensure the PTW on equipment is cancelled. 2. Condenser hot well level in normal 250mm. 3. CEP outlet motorized valve should be closed condition before startup & same will be opened on auto after startly up of CEPs. 4. Lube oil level is ok. 5. Check the cooling water supply is ok. 6. CEP valve is open & DP across suction strainers should be less than 0.5 kg/cm. 7. Motor Shaft direction is ok. 8. Isolating valve of recirculation valve for CEPs should be in open condition & all the vents of CEP discharge should open condition & closed after startup. 9. D/A level control valves, isolating valve should be open. 10. All the LPH feed water line are in service and the by pass valve are in closed condition. After Start Up :1. 2. 3. 4. Check any leakage of water & oil in system. Check any vibration / abnormal sound. Check the bearing & winding temperature. Check the discharge pressure of the pump (20 kg/cm). JOP A/B Before Start Up :1. JOP I/L pressure is normal. 2. JOP O/L & I/L valve is in open condition. 3. Ensure the PTW is cancelled on the system. After Start Up :1. Oil pressure should be > 120 Kg/cm2. 2. Check any oil leakage on the system. 3. Check the vibration/abnormal sound in the system. AUXILIARY LUB OIL PUMP A/B Before Start Up :1. Ensure the PTW is cancelled on the system.

2. 3. 4. 5. 6. 7.

Check the power supply of the motor. Ensure the Outlet valve is open. Check the level of the MOT is normal. Vapour Exhaust fan installed on MOT should be in service. The lube oil temperature should be more then 30 c before starting if lube oil pump. The Inlet/Outlet valve of lube oil cooler fan water & oil side is open in condition.

After Start Up :1. 2. 3. 4. Check the discharge pressure of the pump. Check the any leakage on the system. Check the abnormal sound/vibration on the system. Maintain the lube oil temperature Outlet of lube oil coolness b/w 40 c.

STATOR WATER PUMP A/B Before Start Up :1. 2. 3. 4. 5. Ensure the PTW is cancelled on the system. Ensure the power supply is on. Ensure the Inlet/Outlet valve is open. Ensure the tank level is normal. Check the oil level in the Gear box of the pump is ok.

After Start Up :1. Check the discharge pressure & flow is normal. 2. Check the any leakage from the system. 3. Check the abnormal sound/vibration on the system. SEAL OIL PUMP A/DC SOP Before Start Up :1. 2. 3. 4. Ensure the PTW is cancelled on the system. Ensure the power supply is on. Ensure the Inlet/Outlet valve is open. Check the tank level is normal.

After Start Up :1. 2. 3. 4. Ensure the discharge pressure is ok. Ensure the any leakage from the system. Check the any abnormal sound/vibration on the system. Monitor seal oil DP. It should be >= 1.0 Kg/cm2.

DM SECONDARY PUMP A/B Before Start Up :1. Ensure the PTW is cancelled on the system. 2. Ensure the power supply is on. 3. Ensure the Inlet & Outlet valve is open. 4. Check the DM tank level. After Start Up :1. Ensure the discharge pressure is ok. 2. Ensure the any leakage from the system. 3. Check the any abnormal sound/vibration on the system.

CW PUMP A/B/C Before Start Up : 1. 2. 3. 4. 5. 6. 7. 8. 9. Ensure the PTW is cancelled on the system. Check the power supply. Check all the vents are open. Check the Outlet valves are should be closed condition & should be open in auto after starting of pump. Check the level of CW sump. Check the oil level in the pump. Check the Inlet/Outlet valve of the condenser is open. Check all the drains in the condenser pit of the CW line are closed. Check the cooling water Inlet/Outlet valves are open.

After Start Up :1. 2. 3. 4. 5. Check the vibration & abnormal sound in the system. Check the discharge pressure is normal (2 to 2.2 kg/cm). Check the bearing temperature is normal. Check the any leakage from the system. Close condenser vent and line valves.

BCW PUMP A/B Before Start Up :1. 2. 3. 4. 5. 6. Ensure the PTW on the system is cancelled. Ensure the power supply is on. Check all the vents are open. Check the Outlet valves are before startup is closed & open in auto after pump startup. Check the CW sump level normal Check the oil level in the pump.

After Start Up :-

1. 2. 3. 4. 5.

Check the vibration/abnormal sound in the system. Check the discharge pressure is normal (3.5 kg/cm). Check the bearing temperature is normal. Check the any leakage from the system. Check all the vents in the system are closed.

STARTING EJECTOR/MAIN EJECTOR A&B Before Start Up :1. Ensure the PTW on the system is cancelled. 2. Ensure the power supply is on. 3. Ensure the steam & air valve of starting ejector closed. 4. Ensure the steam valve of main ejector A & B closed & air valve open. 5. Ensure the vacuum breaker valve closed. 6. Check the cooling / sealing water supply on. 7. One no. CEP in running conditions. 8. Ensure the PRDS pressure > 10 kg/cm2. After Start Up :1. Check the vibration /abnormal sound in the system. 2. Check the any steam leakage from the system. 3. Check ejector gauge glass level normal.

SEAL OIL SYSTEM Before Start Up :1. 2. 3. 4. 5. Ensure that all the PTWs are cancelled. Proper oil level in SOT tank. Check the power supply of seal oil pumps. Ensure the Inlet & Outlet valve of pumps are in open condition. Ensure cooling system is charged.

After Start Up :1. Ensure running of one seal oil pump DP across the seal oil & H2 should be > 1.0 kg/cm. 2. Ensure the auto selection of D.C seal oil pump. 3. Ensure that one no seal oil Exhaust fan is running & its Inlet & Outlet valve are in open condition. 4. Check DP across seal oil filters of air/H2 side & rotate these condition filters at least once in a shift. 5. Any abnormal sound & vibration in the system. 6. Check the any leakage from the system.

RAW WATER PUMPS A/B/C Before Start Up :Ensure that all the PTWs are cancelled. Ensure proper level in RAW water pond Check the power supply of raw water pumps. Open air vent. Ensure the Inlet & Outlet valve of pumps are in open condition. After Start Up :1. 2. 3. 4. Any abnormal sound & vibration in the system. Check the any leakage from the system. Check pump discharge pressure. Closed air vent

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Reviewed & Approved By :

The record /data related to the observation on above parameters are mentioned in log sheets/ DCS

CLARIFIER/SERVICE WATER PUMPS A/B/C Before Start Up :1. 2. 3. 4. 5. Ensure that all the PTWs are cancelled. Ensure proper level in clear well Check the power supply of pumps. Open air vent. Ensure the Inlet & Outlet valve of pumps are in open condition.

After Start Up :1. 2. 3. 4. Any abnormal sound & vibration in the system. Check the any leakage from the system. Check pump discharge pressure. Closed air vent

AIR COMPRESSOR A/B/C Before Start-up 1. Ensure that all the PTWs are cancelled. 2. Ensure power supply of compressor. 3. Ensure the discharge valve of compressor open condition. 4. Ensure cooling system is charged. 5. Ensure proper oil level in crank case. 6. Check Lubricator. After start-up

1. Ensure proper running of compressor and observe amperage. 2. Ensure oil pressure>1.5 kg/cm2 (for proper lubrication of bearings).
3. Any abnormal sound & vibration in the system. 4. Check the any air/oil leakage from the system

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Reviewed & Approved By :

Note: The record /data related to the observation on above parameters are mentioned in log sheets/ DCS

Centrifuge System Before Start Up :1. Ensure that all the PTWs are cancelled. 2. Ensure proper level in MOT 3. Check the power supply of pump. 4. Ensure the Inlet & Outlet valve of pump are in open condition. After Start Up :-

1. 2. 3.

Any abnormal sound & vibration in the system. Check the any oil/water leakage from the system. Check pump discharge pressure>1.5kg/cm2 Observe centrifuge outlet temperature for proper working of heaters.

Prepared By :

Reviewed & Approved By :

The record /data related to the observation on above parameters are mentioned in log sheets/ DCS