Cold Start Check List Ccp1!10!10-08

8/6/2019 Cold Start Check List Ccp1!10!10-08

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JSWSL CPP-1x100MW

COLD START-UP CHECK LISTRec. No:Date:Page: 1 of 8

Applicable when casing temperature is less than 220 o C Date: 12-10-2008Reason for shutdown:

Date & time of S/D: Synchronization time:

Sl.NO ACTIVITY CHECK

REMARK S

1

Ensure 6.6KV, 415V (PMCCA, PMCCB, NE, CWPH, BVDC,

TVDC), 220V DC, UPS are available and charged&emergency power supply by taking DG SET trial.

Reset under voltage relays on, 6.6 kV bus, 415V buses.Ensure islanding mode-1 condition selected .Ensure fire system is ready & pumps are in auto. Jockeypump is running.Ensure all PTW related CW,ACW,Compressed airsystem,and any all PTWs including corex and BF systemreturned & Start N2 purging for corex andBFsystems as per procedures and check for O2percentage at both C headers and before trip valve. Corexand BF seal pots are filled and over flow is ensured. Allgas line drains to seal pots are open.

If O2 before TV is less than 0.5 %, pressurize before TVheader up to 400 mmwc with Nitrogen and close N2 ventbefore TV. Drain U seal and open the goggle valve of Corex and BFG.

9 Boiler drum filling (If drained)(a)Ensure CST 1& 2 levels are normal (> 7 mt.).If not start

DM tank filling from JSWEL(b)Ensure PTWs related to boiler water / steam touched

parts up to MS stop valves & boiler filling systems arereturned. Ensure Boiler safety valve gags are removed

(c) Ensure steam / water sampling system (SWAS)is linedup & charged.

(d)Open Boiler PSH, De SH, Drum, ECO vents & start upvents.


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Cold start-up check list Page 2 of 11Sl.NO ACTIVITY CHECK

REMARK S

(e)Check low point header drains are open. Close theheader isolation valves to IBD tank.

(f) Open De SH, SSH drain, PSH drain & MS line drains.(g)Ensure MS - 1, 2, 3 & 4are closed. Drains in MS line are

open(h)Isolate one CST and add chemicals as per chemist

instruction. Run boiler fill pump on recirculation. Lineup HP dosing to boiler, for chemical dozing.

(i) Close boiler fill pump line to de-aerator and ACW o/htank .Line up and start Boiler fill pump in re-circulationto bottom header through LPD for economizer andboiler filling. Maintain fill pump flow such that thepump current is normal.

(j) Fill drum level upto (-)75 mm.(k) Close all the low point header drains (both isolation

valves) and stop fill pump.Starting CW & ACW system

(a)Ensure PTWs related to CW & ACW system are closed.(b) Ensure fore bay level is above normal (- 250mm)(c) Line up CW system. Open condenser water box inlet

outlet both sides and its vents & air vents on CW pumpdischarge. Open 4 cells of CT raisers till the marking onvalve (40%)

(d)Ensure that CW hot tunnel & cold tunnel is filledthrough service water back charge line. (when waterfalls down to CT basin through risers close service

water filling).(e)Permissive for starting the pump to be checked.(f) Start CW pump & close the vent after opening of

discharge valve and condenser vents also to be closed after air venting.

(g)Ensure standby CW pumps are available. Start chlorineand acid dosing system and SSF.Charge two PHEs fromCW side.

(h)Fill ACW over head tank from fill pump and addchemicals as per chemist instruction. Charge ACWsystem slowly, by opening the overhead tank outletand vent all coolers in boiler side, turbine side,compressor and generator. Vent ACW system at SWASroom. All 3 pumps inlet outlet open and vent out air.Start two pumps one by one and maintain headerpressure. Charge PHEfrom ACW side

27 Starting compressed air system


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REMARK S

Start one compressor. Ensure instrument air & serviceair systems are charged

and backup N2 system is charged. Other compressoris selected auto s/b.(a)Ensure PTWs related to feed water system & Deaerator

is closed.(b)Start Deaerator filling using Boiler fill pump. (Ensure

boiler and ACW filling valve is closed).(c) Line up BFPs & feed water line. [At least one BFP

suction & discharge valves and HP heaters I/L, O/L &bypass valves should be kept open]. Ensure Standby

pump is available(d) Keep feed control station valves in open condition and

vent through eco. Inlet vent. Vent air through all thevents in BFD. Close vents after completing the venting.

(e)Check operation of FCV 30 and 100% CV.Starting condensate system

(a)Ensure PTWs related to condenser & hot well makeupsystems are closed.

(b) Fill hot well using H/W makeup pump, up to +1300mm.Put hot well make up pumps in auto

(c) Open re-circulation control valve fully and ensurecondensate line up

(a) Keep pump discharge valves are closed and de-aeratorlevel control valve in closed condition. LPH-1 & 2 I/L,O/L valves & bypass valves are open.

(b)Ensure CEP header vent, re-circulation valve are open.(c) Ensure HP bypass spray valves are closed.(d)Check pump local line up. Canister vent, discharge sol

vent and its bypass MIV in open condition.(e) Start one CEP. charge the discharge header . Do

venting properly in the condensate line. Closevents after evacuating air .Keep the other CEP instandby

(f) Charge LP Economiser condensate side slowly and after venting take in service .

(g)Starting of LDO system.

(a)Ensure PTWs related to LDO system are closed.(b) Line up and start LDO forwarding pump with 10ksc set

point for the re-circulation valve.(c) Ensure standby LDO transfer pump is available.

Starting of Fans(a)Ensure PTWs related to Flue gas system, LP eco,

Chimney, Secondary air & main boiler are closed.Ensure that manholes & peepholes are closed.


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REMARK S

(b)Ensure SADC are in auto.(c) Line up secondary air system, flue gas path, LP

economizer and ID & FD fans.(d)LP economizer is isolated in flue gas side with bypass

damper full open and close inlet damperEnsure that DC scanner is available by taking its trial andits discharge dampers are operating.Start AC scanner air fan. Ensure header pressure is

normal. Select DC fan and its discharge valve in auto.(e) Start one stream of ID & FD fans after ensuring local

line up. Put furnace pressure control in auto (SP-7mmwc).

43

Purge & LDO system line up(a)Ensure that all I&C permits related firing system is

returned. All oil guns ,igniters and scanners and itsfeedbacks are ok

(b)Ensure >140 t/hr airflow and Purge the boiler.(c) Open LOTV and ensure that pr. after LOTV >10ksc &

atomizing air pr. > 6 ksc.Starting of Lube & Jacking oil system

(a)Ensure PTWs related to turbine & their oil systems arereturned.

(b)Ensure MOT level is normal.(> 640 mm)(c) Start one OVEF and open suction and discharge (mot

vac>100 mm hg). Keep other fan in standby. Oil coolerACW side is charged

(d)Line up lube oil system with cooler and filter and startone lube oil pump. Ensure other pumps availability.Running AOP is in auto and other AOP is selectedstandby. EOP selected in auto. Ensure OHT level isbuilding up.

(e)Start AC Jacking oil pump and put turbine on barringgear. Ensure DC JOP is standby AC JOP in auto andbarring selected auto. Trial run of DC AOP, DC JOP andstandby AOP is to be taken.

51

Boiler Light up(a)Light up boiler with 2 LDO guns at A elevation. Burnerschange over to be done after 1 hr. Ensure startup vent isopen.(b) Check Furnace condition, Expansion measurements,and oil leaks if any.

55 (

56 (e) Monitor Hydrastep and all three drum level Tx.crosscheck with drum local gauge .57 Start CEP in re-circulation.


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REMARK S

(a)Keep pump discharge valves are closed and de-aratorlevel control valve in closed condition. LPH-1 & 2 I/L, O/Lvalves & bypass valves are open.(b)Ensure CEP header vent, re-circulation valve are open.Pump discharge sol. Valve and its bypass MIV in openconditionEnsure HP bypass spray MIV at 4MTR in open andSpray block valves are closed.(d)Start one CEP. Slowly charge the discharge header .Doventing properly in the condensate line. Close vents afterevacuating air. Keep the other CEP in standby with bypassMIV in open condition.(e)Start LP dosing system.

64

Start BFP in recirculation.(a) Ensure all BFP and BFD related permits closed. Start

lube oil pumps of all pumps & keep in auto. Line upBFPs and HPHeaters. All HP Heaters inlet outlet andbypass open.

(b) Ensure min. scoop, R/C valve MIVs for all BFPs atdeaerator are open. ACW is charged. BFP dischargevalve is closed and start BFP. Open the discharge valveIBV and then discharge valve .Slowly charge the line.Ensure that LOP stops when lube oil pr is normal.

(c) Keep another BFP in standby .Take 30% FCS intoservice to maintain the drum level.

(a) At drum pressure 3 ksc; Close SH, Drum, Eco vents

and throttle start up vents to 20%. Close SH headerdrains at 5 KSC(b)Give blow down at approx 20KSC from low point

header drains around 3 times & collect the sample.(c) As per chemist start LP and HP dosing systems with

required stroke.(d)Start second pair of oil guns in A elevation.

71

Control oil system and HP bypass oil system(a)Ensure PTWs related to control oil system are closed.(b)Line up Control oil system and start pump. Running

pump selected auto and other pump is selected instandby

(c) Line up & start control oil-circulating pump.(d)Ensure PTWs related to HP bypass system are closed.(e)Line up and start HPBP oil pump. Panel switches are

selected auto77 MS line Charging at drum pressure 10 Ksc.


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REMARK S

(a)Ensure PTWs on turbine stop valves, MS, HP/BP arereturned. MS drains at turbine side are open. EnsureMS vents at turbine end and seat drain are open.Ensure Turbine is on barring

(b)Ensure PRDS isolation valves closed.(c) Ensure HP bypass is closed.(d)Charge line by slowly opening MS-3 & MS-4. Equalize

pr across MSSV(e)Open boiler stop valves MS 1&2 when upstream and

downstream pressures are equal.(f) Close MS-3, MS-4 throttle start up vent opening to limit

rate of pressure and temp

83 (g) Close MS drains bef ore MS stop valve. Ensure MSspray MIV s open.

84 (h)

85

If corex & BF clearance is available,(a) Ensure corex and BF N2 purging is in progress & O 2 in

corex and BF- C header sample through vent less than0.5%.

(a)Check corex C header O2 is less than 0.5%(b) Open corex trip valve. Maintain C header pr .Take

corex burners in A elevation. Ensure corex flame inlocal and remove oil burners. Maintain the firing to getthe pr rise of (15-20)ksc/hr apprx.

(c) Take LP eco in service and bypass damper is kept 25%

openLine up & start second stream of ID, FD fans.Match the currents of FD & ID fans. Check ID fan draftcontrol in auto (-7mm).

92

Charge PRDS at 15 ksc(a)Ensure PTWs related to PRDS, MS lines, Gland Steam

are returned.(b)Ensure De-aerator pegging line and initial heating lines

from PRDS are closed.(c)(d)Ensure PRDS drains and sprays MIVs are open. Gland

steam and ejector MIVs are closed condition(e)Slowly open Low capacity control valve to charge

header. Slowly raise the header pressure.(f) Maintain PRDS temperature. Charge slowly APRDS hi

capacity Line by opening the CV.(g)Put PRDS pressure & temperature controls in auto with

SP -9 ksc. Hi cap PRDS is in service. Throttle the drainsto min position


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REMARK S

99

Gland steam header charging and Vacuumpulling

(a)Open Gland steam header drains & vents toatmosphere

(b)Open GS header inlet MIV at PRDS and slowly chargeGS line

(c) Ensure PTWs related to vacuum system are returned.

(d)Ensure turbine on barring gear.(e)Ensure hot well level is normal & CEP is running(f) Close Vacuum breaker valve, keep in auto & establish

water seal.(g)Start 4 CT fans for which raisers are open(h) Charge gland seal. Control temperature of GS as per

required condition. Select FG seal steam in auto. Autoselected GSC fan starts and other fan is standby. Sealsteam upstream header Pr 12 KSC, Degree of SH >50,temp not less than casing by 200 deg C. PRDS temp. -250 C

(i) Charge ejector steam. Line up and start startingejector with drain after starting ejector in crack opencondition

(j) Open GS drain to condenser when vacuum is greaterthan -0.4 ksc , close atmospheric drain.

Change over to main ejector and remove starting ejectorat 0.15 bar A.

Charge Dea-erator pegging slowly from PRDS.Close de-aerator start up vent valve .Keep Deaerator & hotwell level controls in auto.

114Cl

HP bypass charging(a) Ensure condenser vacuum is < 0.4 bar a.(b)(c) Ensure spray block valve, control valve and bypass

valve in auto and downstream MOV open. Spray MIV inthe condensate line is open

(d)Open HPBP valve 5% slowly.(e) Open HPBP spray to maintain the downstream

temperature(f) Close start up vents if HPBP CV >10%.(g)Start second CW pump .Open all CT raisers to the

required opening. Start remaining CT fans. CW pumpstandby is selected on auto

Ensure that boiler water temp. raise is within 55.5c/hrand expansions are normal. Raise boiler pr to 40 Ksc


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REMARK S

Check Generator relay panel is resetted. AVR is ready.GT-1 and 2 are ready. Reset turbine trip. Reset hydraulic trip.Check other conditions are satisfiedOpen ESV. (Minimum parameters 32 bara, 290 deg C andmaximum parameters 70 bara and 420 deg C at turbineinlet). Minimum degree of SH required is 50 deg C andsteam temperature to be more than casing temp- 50degC

Check JOP stops at 900 rpm. Lube oil temp min 32deg at30% speed, 40deg at 70% speed Monitor turbineparameters, mainly vibrations.Field bkr. Closes at 95 % speed & excitation control inauto. 3000 rpm is reached within 70 min. SelectFrequency controller in autoMatch Gen. Frequency & voltage. Switch onsynchronoscope .Take clearance from MSDS and JSWELSynchronize generator to grid by closing GT-1 and Gt-1breakers. Load gradually rises to up 13.6 MW. Put Loadcontroller on auto and raise load.Monitor boiler drum, hot well and de-aerator levels andput in auto.Now check for turbine vibrations ,axial shift and generalcheckup for all equipments parametersClose HP bypass and put auto/manual station in auto.Close MS/PRDS drains .

Increase the load by watching load. curveIncrease corex firing and air flow .135

Charge LPH 1&2 at 15 MW.(a)Ensure PTW related to LPH-1&2 are returned.(b)Ensure heaters are charged from waterside (I/L & O/L

valves are open & bypass valve is closed for bothheaters).

(c) Extraction line drains are open.(d)Ensure service vent is open & shell vent to atmosphere

is close for both heaters(e)Line up cascading drains of both heaters. Control

valves are open 50%.(f) Open slowly LPH-1 extraction by seeing the heater

level & shell pressure.(g)After the level is build up, level control in auto (sp 110

&130 mmwcl), Ensure extraction MOVs, Heater inlet/outlet MOVs, Heater bypass MOVs and drain MOVs areselected remote


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REMARK S

(h)Open slowly LPH-2 extraction by seeing the heaterlevel & shell pressure Put normal & emergency drainsvalves in auto (SP110 & 130mmwc). Ensure extractionMOVs, Heater inlet /outlet MOVs, Heater bypass MOVsand drain MOVs are selected remote

Start second BFP & ensure third BFP in auto standbymode.Increase firing and raise load as per the load curve.

Steam chemical parameters are controlled with CBD anddosing.Monitor Diff. Expansion and vibrations.

Deaerator charging at 20MW

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(a)Open drain traps & its bypass valves before & afterextraction line NRV 's & ensure drains are open

(b) Slowly Open De-aerator extraction.

(c) After matching upstream & downstream pressure, fullyopen the valve Close bypass of traps of the drains. Auxsteam line from pegging to be stopped.

Change over to Low capacity PRDS (set pt 11 ksc and 260deg C). Hi cap PRDS set point(9 ksc)Cut in second elevation corex burners in C elevation (If steam flow >117tph)Changeovers drum level control to 100 % FCV in service.Ensure standby FWCV and line is through.

145

Line up & Charge HPH - 1 at 30 MW(a)Ensure PTW related to HPH-1 are closed.

(b)Ensure heater is charged from waterside (I/L &O/Lvalves are open & bypass valve is closed).

(c) Open extraction line drains & ensures service vent &atmosphere vent is close.

(d)Line up emergency drain control valve & normal draincontrol valve.

(e)Open slowly block valve by seeing the level & shellpressure.

(f) Fully open the valve. Drains are kept in auto after levelis build up. Ensure extraction MOVs, Heater inlet /outletMOVs, Heater bypass MOVs and drain MOVs areselected remote

149

Line up & Charge HPH 2 at 40 MW.(a)Ensure PTW related to HPH-2 are closed.(b)Ensure heater is charged from waterside (I/L &O/L

valves are open & bypass valve is closed).(c) Open extraction drains & service vent & close

atmosphere vent.(d)Line up drains.


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REMARK S

(e)Open slowly extraction from local by seeing the heaterlevel & shell pr.

(f) Put HP heater 2 level (normal, alternate & emergency)controls in auto after level is build up. Ensureextraction MOVs, Heater inlet /outlet MOVs, Heaterbypass MOVs and drain MOVs are selected remote

Increase load and firing to 55 MW

Starting BF firing at 55 MW (BF clearance isavailable)

(a) Check BF C header O2 % < 0.5% .Open BF trip valve

153

c

(b) Cut in BF B elevation one by one. Maintain MS temp byspray control.

(c) IF BF clearance is not available take E elevation corexand raise the load

(d) caution While cutting in BF burners allow sufficient time, till temperature stabilization.

(e) Adjust LP Economiser damper as per fuel type and combination.

Islanding mode 2 selected if conditions ok.Check GT fans started on auto.Chemistry of Boiler parameters and CW parameters to bemonitored.

Check SWAS system values and sample lines to Lab are

through.Check level of EOT of turbine /Generator.Check ups load and relays in GRP panelCut in second elevation BF and Gradually raise the load to104MW based on drum water silica. Maintain excess air.O2 %1.8.Ensure HP bypass pressure set point 90KSC andpressure/spray system in auto.Standby auxiliaries (BFP, CWP, CEP, Compressor, ACW,lube oil system) to be kept ready. Aux system like firesystem, AC ventilation and SSF are in service. EnsureEMRV isolation valves are open and EMRV selected auto.

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Cold start-up check list Page 11 of 11Approved by: CONTROL STATUS Issued & Controlled by:

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Cold Start Check List Ccp1!10!10-08