sop 01-turbine cold startup

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MB POWER (MP) LIMITED,ANUPPURDocument No. Issue No/Date Revision No/ Date

MBPMPL/OPN-SOP/TG/01 01/02.02.2015 00/02.02.2015

Title: TURBINE COLD STARTUP

1

MB POWER (MP) LIMITED

2×600 MW Thermal Power Project,

ANUPPUR

Standard Operating Procedure

For

TURBINE COLD START-UP


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Sl.NO. Index Page No.

1.0 Purpose 4

2.0 Scope 4

3.0Responsibility

4

4.0 System Description 4

4.1 Pre Start-up checks 6

4.2 Start-up 7

5.0 References 12

6.0 Records 12


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Revision status Record:

Revision

No.

Date Page no. Details of Changes Reason for changes

Document Approval sheet:

Prepared by Signature

Checked by Signature

Reviewed by

(HOD)

Signature

Approved by

(Head-O&M)

Signature


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1.0

Purpose:

This Procedure is intended to provide guidance and instructions for carrying out the startup procedures

of turbine.

2.0

Scope:

a) This Procedure is applicable to turbine start-up process during cold start-up, warm start-up, hot

start-up & very hot start-up in plant.

3.0 Responsibility:

a) All the personnel involved in carrying out /supervising the above activities are required to ensure

implementation of this procedure and may consult any other relevant documents indicated under

Reference section below.

b) In the event of any changes required in the procedure such changes may be requested with

operation head, who would take appropriate action with approval from respective departmental

heads.

4.0 System Description:

(Start-up conditions are determined by the First Stage metal temperature of HP turbine)1. Cold start-up: the first stage metal temp 120 , (for start-up after long time shutdown)

2. Warm start-up I : the first stage metal temp >120 & 260 , (for start-up after shutdown of

> 72 hours)

Steps as per Curve:

0-600 rpm @150 r/m (5 minutes)

Soak for 5 minutes at 600 rpm

600 - 2400 rpm @150 r/m (12 minutes)

Soak for 90 minutes at 2400 rpm

2400 - 3000 rpm @300 r/m (2 minutes)

[Change from TV to GV at 2900 rpm and raise speed up to 3000 rpm]

[Total time from 0 to 3000 rpm = 114 minutes]


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5. Very Hot start-up: the first stage metal temp >450 , (for start-up after shutdown of less than

1 hour.)

Steps as per Curve:

0-3000 rpm @ 300 r/m (10 minutes)

[Total time from 0 to 3000 rpm = 10 minutes)

Load Rising Rate:

Synchronisation+5% Load – after 15 minutes

5% Load Holding -1 Minutes

Load Raising: 5% to 30% -@18MW/Min, 30% to100%-@30MW/Min

4.1 Pre Start-up Checks:

Fire Fighting System

CW System

ACW System

CCCW System & ensure Expansion tank level normal

Instrument Air Compressor

EH Oil System

Lube Oil System (Maintain Pr at bearings > 0.083MPa & temp at bearing outlet 60-70°C)

Seal Oil System

Generator Stator Water System

Hydrogen circulating Blower

Air Pre Heater

Flame Scanner Air Fan

MDBFP with its lube oil system/ running in re-circulation

Boiler drum level /Dearator level /Hot well level is normal

( if required start Boiler fill pump/hot well make up pump)

CEP running in re-circulation


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All heaters charged through water side.

Vacuum pump & its system

Boiler Circulation Pump

ESP hopper heating system

LDO system /HFO System is running & charged up-to boiler in long recirculation.

4.1 Start-up:

Ensure to open all drains of turbine proper and HP&IP system. ( should be opened till 20% load)

Put LP cylinder spray system in auto to maintain temp 70° and keep vacuum normal.

Start Jacking oil pump. Check & sure jacking oil pr at header/ bearing are normal. ( Pr=11.76-14.7

MPa)

Put Turning gear into operation and check no any abrasion sound.

Charge auxiliary steam from another unit, which will be used to heat feed water tank, and put into

shaft gland, when temperature and pressure reach, to create vacuum.

Set inclination of burner to be horizontal position.

Start Induced draft fan & maintained furnace draft -100 Pa.

Start Forced draft fan system & maintained furnace draft -50 Pa.

Adjust air flow (30~40%) & purge the boiler.

Lit-up the boiler.

Start one gland sealing cooling fan and Open gland sealing regulating valve (keep gland sealing pr

7-21 KPa & temp 120-180° C) and establish condenser vacuum.

Get required parameter of drum pressure.

Open HP Bypass valve to maintain MS pr


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Charge LPH 1, 2, 3 &4 from steam side as well as drip system.

At 2900 rpm click ‘TV/GV Change’ button: GV will close slowly and TV will open slowly.

After TV/GV changeover raise turbine speed up to 3000 rpm.

Carefully watch all critical parameters such as bearing vibration& temp/axial shift/differential

expansion/condenser vacuum.

Ensure MOP suction/discharge pr is ok. Stop AOP ,seal oil standby pump and put them in auto

mode.

Ensure Barring gear motor & JOP stops on auto, otherwise stop them manually.

Close Main steam & RH steam line drain & vents.

Charge the excitation system.

Synchronize the unit.

After the unit synchronizes, it is controlled by control valve and takes on an initial load of 5%.Hold

the 5% load as per warm/hot start up curves. In this process, the temperature rise rate of main

steam temperature shall be controlled at no more than 83℃/h. When the temperature rise rate of

steam temperature drops to 14℃/10min, it indicates that main steam temperature has been

stable, and loading up rate can be raised to 10–20%.

Put Coal mill in service as per pr/temp requirement.

Close economiser recirculation valve.

Regulate steam temperature and load to reduce the metal temperature

Maintain the initial load until the LP cylinder exhausting outlet has been cooled down below 52℃.

Close the MSV valve upper seat and lower seat drain valves.

Cylinder transferring : On the turbine control interface, click “Increase load”, check if the IP

regulating valve opened gradually until fully opened, HP regulating valve begin to open, V.V valve

closed, HP exhausting check valve opened. HP bypass valve turns down automatically and keep

the turbine main pressure at 5MPa. When HP bypass are all closed, check both side LP bypass

valve closed. (When the unit load is higher than 120MW or HP bypass all closed, cylinder

transferring ends.)


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When turbine cylinder transferring ends, turbine main control put in auto mode: check if the

turbine main steam pressure is 5MPa, click “require remote control” on the unit main control

interface, click “auto” to put in, check if the unit control mode is “TF”.

When the load is higher than 60MW, check turbine proper HP side drain link closed, when the unit

load is higher than 120MW, check turbine LP side drain link closed, or close it manually.

Put other mill in service.

At 90 MW load ensure turbine exhaust hood spray valve closed.

Close all drains at 20% load.

Changeover power supply from station service to main transformer.

Put TDBFP for steam heating.

When the load is within 160~180MW, parallel the first TDBFP with MDBFP.

Change dearator steam & TDBFP steam source from auxiliary to 4th extraction.

Put #3, #2，#1 HP heater in service by sequence.

At 200 MW load put third mill in service.

At 240 MW load withdraw oil support of running mill whose load is >60%.

At 240 Mw load put other TDBFP in heating.

Above 300 MW load put 4th mill in service and take out all guns.

Put other TDBFP in service & stop MDBFP.

At 360 MW load Burner Tilt operation may put in auto to maintain RH temp.

Above 400 MW load put 5th mill in service

Above 500 MW load put 6th mill in service

Raise load up-to 600 MW

Put all control loops/ all master controller in auto mode.


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Warm start-up I Curve

Warm start-up II Curve


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Hot start-up Curve

Very Hot start-up Curve


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Cold start-up Curve

5.0 References:

1. Operation and Maintenance Manual for Steam Turbine Document No.: LITL-020-MEV-202-W-30334,

2. Start Up Curve: LITL-020-MEV-202-T-30251(R1)

6.0 Records:

Turbine desk logbook.

sop 01-turbine cold startup

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