Npti Training Manual

Piyush Kr.Singh, Dy.Director, NPTI Nangal

Simulator Training Manual for 500 MW

Nangal Dam, Ropar, Punjab, 140124


I. COLD START UP PROCEDURE


STEP-1 COOLING WATER SYSTEMSU0101 Starting CWP1

Go to Cooling Water System screen from BOP Menu

Open the Cond.CW inlet BFV-L CW13

Open the Cond. CW inlet BFV-R CW18

Open the Cond.CW outlet BFV-L CW19

Open the Cond.CW outlet BFV-R CW24

Switch On the CWP-1 Pump

Open CWP-1 Disch. Valve CW-1

Observe that Common header pressure reaches 5.0 Kg/ cm2

Starting CWP2Ensure that discharge valve is closedSwitch On the CW Pump-2Open CWP-2 Disch. Valve CW-2

Cooling Water system to BOP & TG Auxiliaries

SU0103 Starting ACWP-AGo to ACW Sys screen from BOP Menu

Switch On ACW Pump-A

Ensure that discharge valve ACW-4 opens in Auto

SU0104 Starting ACWP-B

Switch On ACW pump-B

Ensure the discharge valve ACW-8 opens in Auto

Observe that ACW Disch header pressure reaches 5.0 Kg/ cm2


SU0105 Starting ACW Pump-A Booster Pump

Ensure that the suction and discharge valves of ACW-

A Booster Pump in open condition

Switch On ACW Pump-A Booster Pump

SU0106 Starting ACW Pump-B Booster Pump optional

Ensure that the suction and discharge valves of ACW-

B Booster Pump in open condition

Switch On ACW Pump-B Booster Pump

SU0107 Starting CW-HC & CW-PC valvesOpen CW-HC valve to Hydrogen coolers

Open CW-PC valve to Primary water coolers

Open MDBFP-C AUX CLR valve

SU02 PLANT START-UP PREPARATION

SU0201 Ensuring normal level in Condenser Hot wellGoto HOTWELL LVL CNTRL screen from BOP-SLD menu

Set the Hot well Normal level Set Point to 0 mmSet the Normal level controller in Auto (DM38)Set the Emergency level controller in Auto (DM63)Set the Cond Excess dump controller in Auto (CD43)

HOTWELL NORMAL 0 mm

Permissives from Remote Station for CT Pump A1 Ensure DM42 Open2 Line up CT PMP-A SUC VLV


SU0202 Starting CT PMP-AGo to CONDENSATE TR SYS screen from BOP Menu

Ensure Cond Storage Tank level Normal

Open the discharge valve DMV-15

SU020203 Start the CT pump-A motor

CT PMP-B starting optionalPermissives from Remote Station for CT Pump B

1 Ensure DM42 Open2 Line up CT PMP-B SUC VLV

SU0202 Starting CT PMP-B

Ensure Cond Storage Tank level Normal

Open the discharge valve DMV-18

Start the CT pump-B motor

Generate snapshot as CWSYSTEM

SU0211 Deaerator Initial Filling & Boiler fillingGo to CONDENSATE TR SYS screen from BOP Menu (DOUBT)

Line up BOILER FILL PUMP AStart Boiler Fill Pump A Rate of Filling can be increased by selecting Fast modeStart Boiler Fill Pump B

Permissives from Remote Station for Boiler Fill Pump A1 Boiler Fill Pump A2 DM41

SU0212 Starting Boiler Fill PMP-AEnsure Cond Storage Tank level Normal

Ensure BFLP-A Disch VLV Open


Ensure BFLP-A Suc VLV Open

Start the Boiler Fill pump-A motor

Permissives from Remote Station for Boiler Fill Pump B1 Boiler Fill Pump B2 DM41

Starting Boiler Fill PMP-BEnsure Cond Storage Tank level Normal

Ensure BFLP-B Disch VLV Open

Ensure BFLP-B Suc VLV Open

Start the Boiler Fill pump-B motor

OBSERVE DEAERATOR LEVEL REACHES 0 mm

OBSERVE DRUM LEVEL REACHES - 52 mm

Generate snapshot as DRUMINTFILL

DOUBT : SU0213 Charging LT / HT Auxiliary Steam Header from station Auxiliary Steam Header

Go to AUX PRDS SYSTEM screen from BOP Menu

Line up Auxilary PRDSEnsure HT PRDS Pressure >12 ata and Temp >320deg.cOpen ASV-35Open CDV-89 valveRegulate CDV-90 valveObserve that LT Aux. Stm Header Pressure >12 ataObserve that LT Aux. Stm Tempearature >220 deg.cOpen ASV-67 to allow steam to Turbine Gland seals

SU0214 CEP System Starting CEP-AGo to COND.EXT.PUMPS screen from BOP Menu

Line up CEP-AEnsure the suc vlv opensOpen the CEP-A Rec Valve CD-10 to 100%Ensure CEP-A dis.vent vlv. VAV7 in Open positionEnsure CEP-A dis. Vlv. CD4 in Close position


Ensure CEP-A dis. Byp vlv. CD7 in Close positionSwitch On CEP-A Pump Ensure CEP-A Vent vlv. VA7 ClosesEnsure CEP-A Dis. Byp valve CD7 Opens in AutoEnsure CEP-A Dis. valve CD4 Opens in AutoEnsure CEP-A Dis. Byp valve CD7 ClosesGoto SLD CEP-A RCV CTRL PageSet CEP-A MREC Flow SP to 500 TPHSet CEP-A Rec. vlv. CD10 to AutoGoto SLD GSC MIN FLOW CTRL PageSet GSC MIN Flow SP to 500 TPHSet GSC Rec. vlv. CD39 to AutoSet Cond. Excess vlv. CD43 to Auto

Permissives from Remote Station for CEP-A 1 LINE-UP CEP-A SYS

OBSERVE CEP DISCH. HEADER PRESS AROUND 30 kg/cm2

SU0215 Condensate Path OpenedGo to LPH&DRN CLRS screen from BOP Menu

Open LPH-1 I/L AND O/L VALVESOpen LPH-2 I/L AND O/L VALVESOpen LPH-3 I/L AND O/L VALVES

SU0216 Deaerator ChargingGo to DEAERATOR & HOTWELL screen from BOP Menu

Open Deaerator level cv-1 inlet isolation valve CD21 Goto SLD DEA LVL CTRL PageSet Deaerator level SP to 0 mmwc.Set CEP Disch Hdr Press to 32 kgSet Deaerator level CV-1 controller, CD22, to AutoOpen Deaerator Start up vent SM22 Goto SLD DEA PRESS CTRL Pageset Deaerator Steam pressure SP to 1.5KG/CM2

Set Auxiliary Steam Deaerator pressure CV AS-8 in AutoClose Deaerator Start up vent valve SM22


ENSURE DEAERATOR OUTLET WATER TEMPERATURE >1000CENSURE DEAERATOR OUTLET WATER Pressure =1.5 KG/ CM2

SU0217 Drum level controller in AutoGo to DRUM,FEED CTRL STATION screen from BOP Menu

Open Economiser inlet IBV-1 E003Open Economiser inlet IBV-2 E002Open Economiser inlet Valve E0212Open Low Load FCV FD14 (>20%)Ensure the FCS inlet FD13 IBV opens in AutoEnsure the FCS inlet FD13 opens in AutoGoto SLD DRUM LEVEL CTRL PageSet Drum Level SP to 50MMWCKeep LOW LOAD FCV FDV14 in AUTOGoto FEED WATER CYCLE screen from BOP MenuOpen HPH FW 100% Byp Valve FD11Open HPH FW 100% Valve FD11

SU0218 Boiler Drum IBD ValvesGo to DRUMS & DRAINS screen from BOP Menu

Close Emgency Drum Drain valve B-096 & B098Close Emgency Drum Drain valve B-097 & B099 (0 %)Close Drum CBD Valves B-091 & B094 (0%)

SU0219 Starting MD BFP-C Go to MTR DRVN BFP-C screen from BOP Menu

Line up MD BFP-C SystemsSwitch On BFP-C AOPEnsure the MD BFP-C Disch Byp Valve FD6B closesStart the MD BFP-C AOPOpen BFP-C Recirculation valve FC-5Start the MD BFP-C MotorEnsure the MD BFP-C Disch Byp Valve FD6B Opensin AutoEnsure the MD BFP-C Disch Valve FD6 Opens in AutoEnsure the MD BFP-C Disch Byp Valve FD6B closesin AutoEnsure the Feedline path availability (BFP disch. to


Drum)Set Low Load FCV FD14 Into Auto

Permissives from Remote Station for MD BFP C1 MD BFP Suction vlv open2 MD BFP Rack-in/Rack-out

BFP DISCHARGE HEADER PRESS >58 Kg/cm2

DRUM LEVEL SHOULD BE -50 mmwcFCS LOWLOAD CV IN OPERATION

SU0220 Starting BCW PumpsGo to BCW PUMP screen from BOP Menu

Line up BCW A SystemEnsure the Diff Temp.Between BCW Pump-A casing & Suction Manifold


Open AH-A PA air o/l damper PAD-4ASwitch On AH-B ElectricMotorOpen AH-B SA SCAPH-A I/L AND O/L ISO damperOpen AH-B SA air o/l damperOpen AH-B flue gas i/l damper GD-1AOpen AH-B flue gas o/l damper GD-2AOpen AH-B PA I/L damper PAD-3BOpen AH-B PA air o/l damper PAD-4B

FLUE GAS PATH AVAILABLE

SU0302 IDF-A Start SequenceGo to ID FANS screen from BOP Menu

SU030201 Start IDF-A LOP-A OnClose the inlet gate 1&2Close the outlet gate 1&2Set IDF-A control damper to minimumSet the IDF-A ch1 SRC Breaker OnSet the IDF-A ch2 SRC Breaker OnSet the IDF-A VFD ch1 OnSet the IDF-A VFD ch2 OnObserve that the ID Fan-A Motor On indicator appearsObserve the inlet and outlet gates are fully opened on interlock.Set ID Fan-A Control Damper to 100%Set ID Fan-A VFD Drive to 15%

SU0303 FDF-A Start SequenceGo to FD FANS screen from BOP Menu

Set The FD Fan-A Control Damper Position To Minimum [0%]Start FD Fan-A Lop-A or Lop-B Close FD Fan-A Outlet GateEnsure the Permissive AvailableStart the FD Fan-AObserve FD Fan-A motor On indication appears.Ensure FD Fan-A Outlet Gate opens after 20 seconds delay IN AutoAdjust the FD Fan-A Control Damper so that the Secondary Airflow is greater than 650 TPH.


SU0304

SU0305 Furnace Pressure Control in AutoGo to SLD FURNACE PRESSURE CTRL screen from BOP-SLD Menu

Set the Furnace Pressure SP to 10 mmwcSet the ID Fan-A I/L Control to Auto modeSet the ID Fan-A VFD Drive Control to Auto modeSet the FUR PRESS MASTER to Auto mode when the Furnace Pressure reaches the SP

AIR flow >540 TPHFurnace Pressure = -10mmwc

SU0306 Stator water coolinq systemGo to GENERATOR PRIMARY WATER SYSTEM screen from TG Menu

Start the PW Pump 1Observe that Primary water flow Generator phases T, S , R main bush is > 1.5 m3/hrObserve that Primary water flow at stator winding outlet shows > 54 m3/hrSet the PW temp controller to auto mode Select the TGV and set to 40 degc and press confirm

SU0307 Gen Seal Oil System Go to GENERATOR SEAL OIL SYSTEM screen from TG Menu

Line up the Seal oil systemStart AC SOP-1 & AC SOP-4Start B.C EX FAN-1Observe Hydrogen side seal oil pump started and Oil pressure > 7kg/cm2The seal oil to hydrogen differential pressure starts showing at the indicator both at TE & EE

Observe in the GENERATOR GAS SYSTEM

H2 PRESS IN GEN CASING >3.5 KG/CM2H2 PURITY IN AIR >95%


SU0308 SGC Turbine Oil SystemGo to TURBINE OIL SYSTEM screen from TG Menu

Start AOP1Start JOP1Start Oil vapour extractor FAN1 SET Oil temperature controller to autoSelect the TGV and set to 45 degc and press confirmEnsure Lub oil discharge hdr pressure goes above 4.8 kg/cm2Ensure Jacking oil header pressure > 135 kg/cm2Open Gate valve grngTurbine speed comes to approx 120 rpm with vacuum otherwise 80 rpmGo to TURBINE HPCF SYSTEM screen from TG MenuStart HP control fluid pump 1Start anyone of the HP control fluid vapour EXTR-1 FANStart anyone of the HPCF recirculation pumpHP control fluid pressure comes over 32 kg/cm2Switch on Control fluid heater l SET HPCF Oil temperature controller to autoSelect the TGV and set to 45 degc and press confirm

SU0309 Vacuum BuildingGo to CONDENSATE & EVACUATION SYSTEM screen from TG Menu

Ensure that atleast One CEP is onLINE UP open Air Header IV from local operatonsGo to SEAL STEAM SYSTEM screen from TG MenuSwitch on Seal Steam Cond Exh 1 Switch on Seal Steam Vap Exh 1 isol valve Open Seal Steam Cond seal valve Close Seal Cond safety valve 1Open SSIV valveClose Vacuum breakerEnsure the gland steam control valve closeObserve the temp 320 deg c and press >300 mmwcGo to CONDENSATE & EVACUATION SYSTEM screen from TG MenuSwitch on Vacuum pump 1 Open Solenoid valve IV 1Switch on Vacuum pump 2


Open Solenoid valve IV 2Switch on Recirculation Pump 1 Switch on Recirculation Pump 2Condenser vac. begins to increase Gland steal stm press cntrler is switched on to auto mode Observe gland stm pressure is maintained at the set valueObserve Condenser vacuum comes to -0.9 kg/cm2

CONDENSER PRESS < - 0.85kg/cm2 AP526 PS332TURBINE LUBE OIL PRESS >4.8 KG/CM2 AP511 PS209TURBINE SPEED >80 RPM AP278 PS209TRIP FLUID PRESS >30 KG/CM2

SU04 PURGE Go to CAUSE OF MFT&PURGE screen from SG Menu

Ensure all the Purge Permits are availableStart a Purge cycle on the furnace by pressing the "Push to Purge switchDuring purging, Purging lamp comes on. After 9 minutes "purging" lamp and "Push to Purge" goes out and "purge complete" lamp comes on Set the Aux. Air (SADC) in AutoObserve that WB-Furnace DP is maintained at 40 mmwc

FURNANCE PURGE COMPLETED

SU05 DRAINS AND VENTS

Opening Final Super Heater Outlet Header Air VentsGo to SH STM & VENTS screen from BOP Menu

Open S036Open S037 to 100%Open S034Open S035 to 100%


SU0501 Boiler Drum Air VentsOpen B98Open B99Open B100Open B101Open B104Open B105Open B102Open B103

SU0502 Div.Panel Super Heater Air VentsOpen S68Open S69Open S70Open S71

Opening Final Super Heater Outlet Header Air VentsOpen S79 CE 658 PS342Open S80 CE 659 PS342

Opening Roof Super Heater Air VentsOpen S11 CE 637 PS342Open S12 to 60% CE 638 PS342Open S13 CE 639 PS342Open S14 to 60% CE 640 PS342

SU0503 Super Heater Header DrainsOpen S25 to 60% CE 645 PS342Open S26 to 60% CE 647 PS342Open S23 CE 644 PS342Open S24 CE 646 PS342Open S21 CE 641 PS342Open S22 to 60% CE 642 PS342Open S82 CE 660 PS342Open S84 to 60% CE 660 PS342Open S81 CE 656 PS342Open S83 to 60% CE 657 PS342Open S19 to 60% CE 636 PS342Open S74 to 60% CE 653 PS342Open S75 to 60% CE 654 PS342Open S77 to 60% CE 655 PS342

SU0504 Economiser / Water wall drainsClose E17 CE 682 PS340Close E16 CE 681 PS340


Close B115 CE 683 PS340Close E19 CE 682 PS340Close E18 CE 681 PS340Close B118 CE 683 PS340Open E21 CE 624 PS339

SU0505 CRH / HRH Drains Open HRH125 CE 1290 PS345Open HRH101 CE 1288 PS345Open HRH102 CE 1289 PS345Open HRH127 CE 1294 PS345Open HRH105 CE 1292 PS345Open HRH106 CE 1293 PS345Open HRH109 CE 1295 PS204Open HRH110 CE 1296 PS204Open HRH113 CE 1297 PS204Open HRH114 CE 1298 PS204

SU0506 RH VentsOpen R75 CE 663 PS204Open R74 CE 662 PS204Open R7 CE 665 PS204Open R6 CE 664 PS204Open R10 CE 666 PS344

SU0507 MS DrainsOpen MS101 CE 1125 PS343Open MS102 CE 1142 PS343

MS/HRH DRAINS AND RH Vents

SU0508 HRH / MS LINE STNR DRAIN TO UFT Open MS117 CE 1287 PS343Open MS105 CE 1285 PS343Open MS106 CE 1286 PS343

SU0509 HRH/MS LINE STNR DRN TO SDFT Open Open MS119 CE 1301 PS343Open MS109 CE 1299 PS343Open MS110 CE 1300 PS343

SU06 AB- LIGHT OIL STARTUP:AB Elevation Light oil Lined upStart one LDO pump-A / B


Select L ight OilEnsure opening of Manual isolating valves for atomizing air, Light Oil lines at each corner Ensure Oil guns are engaged properly and are in retract positionEnsure Atomising air pressure is 8.00 kg/cm2Open LOTV L030 Open LFO IV L024Set LOFCV L023 to 85%Start pair 1&3Observe that LONV 1 is open after some timeObserve that LONV 3 opens after time delayStart pair 2&4Observe that LONV 2 is open after some timeObserve that LONV 4 opens after time delay

Permissives from Remote Station for AB Elevation Light Oil 1 AB LO Man Isol Vlv 1 RO:001 PS-1012 AB LO Man Isol Vlv 2 RO:002 PS-1013 AB LO Man Isol Vlv 3 RO:003 PS-1014 AB LO Man Isol Vlv 4 RO:004 PS-1015 At Air Man Isol Vlv AB 1 RO:045 PS-1016 At Air Man Isol Vlv AB 2 RO:046 PS-1017 At Air Man Isol Vlv AB 3 RO:047 PS-1018 At Air Man Isol Vlv AB 4 RO:048 PS-1019 Oil Gun Engd AB 1 RO:049 PS-101,10210 Oil Gun Engd AB 2 RO:054 PS-101,10211 Oil Gun Engd AB 3 RO:059 PS-101,10212 Oil Gun Engd AB 4 RO:064 PS-101,10213 Scavenge Vlv AB 1 pos RO:069 PS-101,10214 Scavenge Vlv AB 2 pos RO:074 PS-101,10215 Scavenge Vlv AB 3 pos RO:079 PS-101,10216 Scavenge Vlv AB 3 pos RO:084 PS-101,10217 SA 1 RO:208 PS-376,37718 SA 54 RO:209 PS-37619 IA 70 RO:210 PS-377

SU06 AB- HEAVY OIL STARTUP:Go to OIL-AB HFO screen from SG Menu

Line up AB Elevation Heavy oil Select Heavy OILOpen HORV


Go to HFO system screen from BOP MenuPress mode selector to AutoStart HFO Pump and Open HO11A to 20%Go to SLD HFO HTR-A O/L TEMP pageKeep the SP to 110 degc Set the HFO TEMP AT HTRA O/LController into AutoGo to SLD HFO Press CTRL pageSet the HFO pump O/L Press Controller into AutoKeep HFO pump o/l Press SP to 35 kg

Go to SLD HFO Flow CTRL pageSet the HO33 Controller into AutoKeep HFO Hdr Press SP to 10 kgGo to SLD ATOM STM PR CTRL pageSet the OS33 Controller into AutoKeep ATOM STM Press SP to 12 kgOpen HOTVGo to OIL-AB HFO screen from SG MenuEnsure opening of Manual isolating valves for atomizing air, Heavy Oil lines at each corner Ensure Oil guns are engaged properly and are in retract positionEnsure Atomising air pressure is 10.00 kg/cm2Go to OIL-AB HFO screen from SG MenuStart pair 1&3Observe that HONV 1 is open after some timeObserve that HONV 3 opens after time delayStart pair 2&4Observe that HONV 2 is open after some timeObserve that HONV 4 opens after time delay

Permissives from Remote Station for AB Elevation Heavy Oil 1 AB HO Man Isol Vlv 12 AB HO Man Isol Vlv 23 AB HO Man Isol Vlv 34 AB HO Man Isol Vlv 4 5 At Air Man Isol Vlv AB 16 At Air Man Isol Vlv AB 27 At Air Man Isol Vlv AB 38 At Air Man Isol Vlv AB 49 Oil Gun Engd AB 110 Oil Gun Engd AB 211 Oil Gun Engd AB 312 Oil Gun Engd AB 4


13 Scavenge Vlv AB 1 pos14 Scavenge Vlv AB 2 pos15 Scavenge Vlv AB 3 pos16 Scavenge Vlv AB 3 pos17 SA 118 SA 5419 IA 70

Observe that Drum level starts raisng when steaming takes place in the Drum due to swelling.Observe that Boiler Drum Pressure starts increasing. When Drum Pressure crosses 2.0 Kg/sq.cm close drum vents and all the drains

Gradually close Start Up Vents S83 & S84 after charging HP/LP bypass

After pressure reaches 5kgs start Main steam path

SU07 MAIN STEAM LINE CHARGING

SU00701 Main Steam Valves GOTO MAIN STM screen from BOP Menu

Open MSSV(R) IBV1 MS4Open MSSV(R) IBV2 MS6 >2%Observe MS pressure and Temp. riseOpen MSSV(L) MS1 after warming up MS lineOpen MSSV(L) MS2 after warming up MS lineObserve that MSSV(L) IBV1 MS3 closes on AutoObserve that MSSV(L) IBV2 MS5 closes on AutoObserve that MSSV(L) IBV1 MS4 closes on AutoObserve that MSSV(L) IBV2 MS6 closes on Auto

OBSERVE MS PRESSURE EXCEEDING 8 KG/CM2

SU0702 MS DrainsClose MS101 CE 1125 PS343Close MS102 CE 1142 PS343

SU0703 HRH / MS LINE STNR DRAIN TO UFT Close MS117 CE 1287 PS343Close MS105 CE 1285 PS343Close MS106 CE 1286 PS343

SU0704 HRH/MS LINE STNR DRN TO SDFT Close


Close MS119 CE 1301 PS343Close MS109 CE 1299 PS343Close MS110 CE 1300 PS343

Boiling will start after 2 pairs of Heavy oil and it will take 8 minutes to Boiling complete. Observe the Drum Pressure starts building.

When Main Steam Pressure crosses 8.0 Kg/sq.cm charge HP & LP Bypass

SU09 PRESSURE AND TEMPERATURE CONTROL

SU0901 HP Bypass ChargingGo to HP BYPASS screen from SG Menu

Open Warm Up Drain Valve BP 101Open Warm Up Drain Valve BP 102Open HPBP(L) Warmup Line Isov BP3Open HPBP (R ) Warmup Line Isov BP4Close Warm Up Drain Valve BP 101Close Warm Up Drain Valve BP 102Set HP Temp set point 320 Deg.Open Block valve BDSet HPBP-1 Valve >2%Set HPBP-2 Valve >2%Observe that BPE-1 & BPE-2 valves switch over to Auto

SU0902 CRH / HRH Drains Close HRH125Close HRH101Close HRH102Close HRH127Close HRH105Close HRH106Close HRH109Close HRH110 Close HRH113Close HRH114

SU0903 LP Bypass chargingGo to LP BYPASS screen from TG Menu


Set Fixed setpoint at 2.0 kg/sqcmSwitch on Auto Control InterfacePut LPBP Controller in AutoObserve that Injection valve 1 & 3 OpenObserve that Stop valve 1 & 2 OpensObserve that LPBP Valve-1 opensObserve that LPBP Valve-2 opensSet point is to be raised gradually to 6.0 kg/sqcm at the time of rolling

After pressure reaches 25kgs start CD Heavy OIL

SU08 CD- HEAVY OIL START-UP:Go to OIL-CD HFO screen from SG Menu

Open heavy oil return valve HORVOpen HOTV Switch On pair 1&3Observe that CD HOnV 1 is open after some timeObserve that CD HOnV 3 opens after time delayStart pair 2&4Observe that CD HOnV 2 is open after some timeObserve that CD HOnV 4 opens after time delaySwitch On pair 2&4Set the Heavy Oil Pressure Controller to AutoSet the Atomising Steam Pressure Controller to Auto

Permissives from Remote Station for CD Elevation Heavy Oil1 HO Man Isol Vlv CD 12 HO Man Isol Vlv CD 23 HO Man Isol Vlv CD 34 HO Man Isol Vlv CD 45 At St Man Isol Vlv CD 16 At St Man Isol Vlv CD 27 At St Man Isol Vlv CD 38 At St Man Isol Vlv CD 49 Oil Gun Engd CD 110 Oil Gun Engd CD 211 Oil Gun Engd CD 312 Oil Gun Engd CD 413 Scavenge Vlv CD 1 pos14 Scavenge Vlv CD 2 pos15 Scavenge Vlv CD 3 pos


16 Scavenge Vlv CD 4 pos

Keep on opening HP Bypass valves 1&2 till the following Rolling parameters are reached

Drum Pressure >50 KG/CM2

MS flow > 200TPHMAIN STEAM Pressure >40 KG/CM2

MAIN STEAM TEMPERATURE >3500C

RH STEAM TEMPERATURE >3200C

Keep the Press SP to 40 kgs and put the HP Bypass valves to Auto

SU10 TURBINE START-UP

SU1001 SGC TURBINE STARTUPGo to MAIN TURBINE SGCS screen from TG Menu

GotoTURBINE EHTC screen from TG MenuSelect the Press. CTR Mode to LP modeSet the PRMAX set point to 525 MWGotoTURBINE DRAINS SYSTEM screen from TG MenuOpen drain before HPCV1&HPCV2 to 100%Set TSC On Lined upSwitch On the Load controller Select TSC mode to NormalObserve the X1 Criteria fulfillnessPlunger coil On Line upGoto MAIN TURBINE SGCS screen from TG MenuSelect SGC TurbineSelect Auto mode( 3rd sel in the small pop up)Select Start Observe ESVs opening at Step 6Observe IVs opening at Step 9Observe Turbine Speed crossing 300 rpm at step 13Observe Turbine Speed crossing 2950rpm at step 17Observe Generator Field breaker is on at step 18Observe Synchroniser switches on & closes the Generator breaker at step 21Observe Generator Load crosses 50 MW and EHTC switches over to Load Control mode at step 23If the load doesnot cross 50 MW raise speed ref


Close HP Bypass valves Set HP Bypass Pressure SP to 175 KG/CM2

Set HP Bypass Pressure Controller to AutoObserve that LP Bypass valves ClosedClose Start Up Vents

Steps bypass1. Bypass step 102 : press semi and press Advance. Press auto to go further2. Bypass step 1073. Bypass step 1104. Bypass step 111 : GEN CNDNS FLFLLED5. Bypass step 1146. Bypass step 118 : DVR Exciitation7. Bypass step 1198.

UNIT SYNCHRONISED AND LOAD >50 MW

Close Economiser recirculation valve E21.After synchronisation further loading will be done by bringing in additional mills and establishing suitable main steam process parameters (pressure and temperature)

SU11 MILLS IN SERVICE

SU1102 PAF-A StartGo to PA FANS screen from BOP Menu

Switch On PA Fan-A LOP-A or LOP-BSet the PA Fan-A control damper position to 0%Start the PA Fan-AObserve PA Fan-A Outlet Gate opens after 20 seconds delayRaise the control damper PA Fan-A till the PA Header pressure reaches 800 mmwcObserve that PA Header pressure starts raisingSet the PA Header Press,Setpoint to 850 mmwcSet the control damper PA Fan-A to Auto


Set the PA Master to Auto

SU1103 First Coal Elevation Lightup Go to COAL-A screen from SG Menu

Mill-A lined up Switch On the Pulv. lub oil pump Open Pulv-A disch ValveOpen Cold air Gate ASwitch On Pulveriser motor AOpen Hot air Gate AOpen CAD to 25% cold air damper Mill-AOpen HAD to 75% Hotair damper Mill-AEnsure Mill outlet temp. reaches >50degcOpen the FDR O/L GateSet the Mill O/L temp. setpoint to 850 C Switch On the Feeder A Set the HAD & CAD into Auto modeIncrease the loading on the pulveriser by increasing the feeder speedRepeat the above steps to take other Pulverisers into service

Permissives from Remote Station for Mill A1 RCF Inlet Gate A2 Tr.Iron Hop Vlv A3 Bunkr O/L Gate A

4 Bunkr Isolation Gate A5 Feeder SA valve A6 Mill-A MOTOR Rack-in/Rack-out

Raising the LoadGotoTURBINE EHTC screen from TG Menu

1 Observe that Turbine is in Load control mode2 Observe that Pressure control mode is Limit Pr mode3 Set the Load rate SP to 25 MW/Min4 Raise the load SP to the desired load5 Observe that load gradually raises to the SP6 Increase the Fuel input when the Main steam pressure

falls7 Observe gradual rising of flue gas temperature8 Observe gradual rising of main steam temperature9 Observe gradual rising of total fuel flow


10 Observe gradual rising of steam flow

When Load crosses 150 MW Open FD-16. Take MD BFP C Scoop controller in Auto and Feed Water Master controller in Auto

SU1104 Charging LP Heaters ( when load=200MW)

LPH-1 Charging (LPH-1 is to be taken into service before steam admission into condenser)Goto LPH&DRN CLRS screen from BOP Menu

Open LPH-1 inlet isolation valve CD28 IBV Open LPH-1 inlet isolation valve CD28Open LPH-1 outlet isolation valve CD29Close LPH-1 inlet isolation valve CD28 IBV Close LPH-1 bypass valve CD30

LPH-2 Charging Open LPH2 inlet isolation valve CD31 IBV Open Ext LPH2 drain valve EX119 Open LPH2 inlet isolation valve CD31Open LPH2 outlet isolation valve CD32Close LPH2 inlet isolation valve CD31 IBV Close Condenser bypass valve CD33 (0%)Open Ext LPH2 valve EX11Close Ext LPH2 drain valve EX119 Set the NWL set point to -25mmSet the HWL set point to 18mmSet the LPH2 drain CV DR34 to AutoSet the LPH2 drain CV DR37 to Auto

LPH-3 Charging Open LPH3 inlet isolation valve CD34 IBV Open Ext LPH3 drain valve EX118Open LPH3 inlet isolation valve CD34Open LPH3 outlet isolation valve CD35Close LPH3 inlet isolation valve CD34 IBV Close Condenser bypass valve CD36 (0%)Open LPH2 EXT valve EX12Close EXT LPH2 DRN valve EX118Set the NWL set point to -25mmSet the HWL set point to 18mm


Set the LPH3 drain CV DR28 to AutoSet the LPH3 drain CV DR31 to Auto

Open Deaerator extraction valve Ex13.

When Load crosses 200 MW second set of auxiliaries to be started

SU12 STARTING SECOND SET OF AUXILIARIES

SU1202 AH-B Start SequenceGoto AIR HETERS screen from BOP menu

Switch On the AH-B ElectricMotorOpen the AH-B FG I/L Damper -1 &2Open the AH-B FG O/L DamperOpen the SCAPH-B I/L SAD-3B & SAD-4B O/L dampers Open the SAD-6B SA O/L damperOpen the PA I/L Damper PAD-3BOpen the PA O/L Damper PAD-4B

SU1203 IDF-B Start SequenceGoto ID FANS screen from BOP menu

Line up IDF-B System Set IDF-B LOP-A or LOP-B OnSet the IDF-B ch1 SRC Breaker OnSet the IDF-B ch2 SRC Breaker OnSet the IDF-B VFD ch1 OnSet the IDF-B VFD ch2 OnEnsure the ID Fan-B Motor On indicator appear

Permissives from Remote Station for IDF-B1 IDF-B CH-1 Rack-in/Rack-out2 IDF-B CH-2 Rack-in/Rack-out

SU1204 FDF-B Start SequenceGoto FD FANS screen from BOP menu

Set The FD Fan-B Control Damper Position To Min Start FD Fan-B Lop-A or Lop-B Close FD Fan-B Outlet GateEnsure the Permissive AvailableStart the FD Fan-BObserve the pump is On, red light appears.Ensure FD Fan-B Outlet Gate opens after 20 seconds delay

Permissives from Remote Station for FDF-B


1 FDF-B Rack-in/Rack-out

SU13 UNIT LOAD RAISING TO FULL LOAD

SU1302 PAF-B StartGoto PA FANS screen from BOP menu

Line Up PAF-B System Switch On PA Fan-B Lop-A or Lop-B Ensure the PA Fan-B control damper position to minimumStart the PA Fan-BEnsure PA Fan-B Outlet Gate opens after 20 seconds delaySet the PA Header Press,Setpoint to 800 mmwcSet the control damper PA Fan-B to25%and set to autoRaise the PA Header Master position to control damper position of PAF-BSet the PA Master to Auto

Permissives from Remote Station for PAF-B1 PAF-B Rack-in/Rack-out

SU1303 TD BFP-A Oil SystemGoto BFPDT-A LUBE/JACK OIL SHEME screen from TG menu

Start TD BFP-A Main Aux oil(LOP) pump A/BObserve theBFPT-A lub oil header pressure increases to > 3.0 Kg/ cm2

Change the TDBFP-A EOP Auto to On statusStart TDBFP-A JOP Strat oil vap ex-fan 1Open the Gate Valve Gearing

SU1304 TD BFP-A StartGoto BFPDT-A CONTROL SHEME screen from TG menu

Line up TD BFP-A Ensure Deaerator level around 0 mmwcl Ensure Condenser press < -0.85 kg/cm2

Ensure Suction valve for BFP A openedOpen steam drain valve before ESV of BFPT-A Open drain vlv D/S of TDBFP-A aux CV Open IP/LP common drain vlv Ex 109 Open Aux stm to TDBFP-A Open CRH stm to BFPT-A block valve CRH1 Open BFPT-A vent valve U/S of ESV


Open TDBFP-A exhaust vlv to condenser EX27 Open TDBFP-A warmup Aux CV Open TDBFP-A casing drain vlv Open TDBFP-A casing cross drain vlv Set Gland steam Ref to 180mmwcSet TDBFP-A Gland steam Controller to Auto(control action should be Reverse)Observe that Gland steam pressure raises to 180 mmwclOpen IP bleed stm common block vlv Open TDBFP-A recirculation valve Ensure TDBFP-A control valve closedBFPDT-A Trip reset OnEnsure all start permissives are met Open TDBFP-A ESV Observe the Oil pressure below piston rises to 8.0 kg/cm2

Observe the Oil pressure above piston rises to 8.0 kg/cm2

Observe the Oil pressure below piston falls to 0.0 kg/cm2

Observe the Full opening of ESVRaise the speed set point of TDBFP-A slowly to match the speed of MDBFP and then put it in Auto when both the speeds are matchingOpen TDBFP-A discharge bypass valve Open TDBFP-A discharge valve

Permissives from Remote Station for TD BFP A1 TD BFP A SUC VLV2 TD BFPA TANK LEVEL OK

SU1305 TD BFP-B Oil SystemGoto BFPDT-B LUBE/JACK OIL SHEME screen from TG menu

Start TD BFP-B Main Aux oil pump A/BObserve theBFPT-B lub oil header pressure increases to > 3.0 Kg/ cm2

Change the TDBFP-B EOP Auto to On statusStart TDBFP-B JOP Open the Gate Valve Gearing

TDBFP-B speed reaches >400 rpm

SU1306 TD BFP-B StartGoto BFPDT-B CONTROL SHEME screen from TG menu

Line up TD BFP-B & put on turning gearEnsure Deaerator level Normal


Ensure Condenser press < -0.85 kg/cm2

Ensure Suction valve for BFP A openedOpen steam drain valve before ESV of BFPT-B Open drain vlv D/S of TDBFP-B aux CV Open IP/LP common drain vlv Ex 109 Open Aux stm to TDBFP-B drain vlv Open CRH stm to BFPT-B block valve CRH1 Open BFPT-B vent valve U/S of ESV Open TDBFP-B exhaust vlv to condenser EX27 Open TDBFP-B warmup Aux CV Open TDBFP-B casing drain vlv Open TDBFP-B casing cross drain vlv Set Gland steam Ref to 180mmwcSet TDBFP-B Gland steam Controller to AutoObserve that Gland steam pressure raises to 180 mmwclOpen IP bleed stm common block vlv Open TDBFP-B recirculation valve Ensure TDBFP-B control valve closedBFPDT-B Trip reset OnEnsure all start permissives are met Open TDBFP-B ESV Observe the Oil pressure below piston rises to 8.0 kg/cm2

Observe the Oil pressure above piston rises to 8.0 kg/cm2

Observe the Oil pressure below piston falls to 0.0 kg/cm2

Observe the Full opening of ESVRaise the speed set point of TDBFP-B slowly to match the speed of MDBFP and then put it in Auto when both the speeds are matchingOpen TDBFP-B discharge bypass valve Open TDBFP-B discharge valve

Permissives from Remote Station for TD BFP B1 TD BFP B SUC VLV2 TD BFPB TANK LEVEL OK

SU1307 Starting CEP-BGoto COND.EXT.PUMPS SCHEME screen from BOP menu

Line up CEP-BOpen the CEP-B Rec Valve CD-12Ensure CEP-B dis.vent vlv. VA8 in Open positionEnsure CEP-B dis. Vlv. CD5 in Close positionEnsure CEP-B dis. Byp vlv. CD8 in Close position


Switch On CEP-B Pump Ensure CEP-B Vent vlv. VA8 ClosesEnsure CEP-B Dis. Byp valve CD8 OpensEnsure CEP-B Dis. valve CD5 OpensEnsure CEP-B Dis. Byp valve CD8 ClosesSet CEP-B Flow SP to 500 TPHSet CEP-B Rec. vlv. CD12 to AutoKeep CEP-C in standby

Permissives from Remote Station for CEP-B 1 CEP-B Rack-in/Rack-out2 CEP-B Suction VLV

SU1308 CEP-C in Stand byLine up CEP-CSet CEP-C Flow SP to 500 TPHSet CEP-C Rec. vlv. CD14 to AutoSet CEP C in Stand by modeObserve CEP-C dis. Vlv. CD6 in Close positionObserve CEP-C dis. Byp vlv. CD9 in Close position

Permissives from Remote Station for CEP-C1 CEP-C Rack-in/Rack-out2 CEP-C Suction VLV

SU1309 HPH Charge (When Load crosses 300 MW)

HPH-5A and 6A ChargingGoto HP HEATERS scheme screen from BOP menu

Open HPH-5A inlet isolation valve IBV FD7 IBVOpen HPH-6A outlet isolation valve IBV FD8 IBV Open HPH-5A/5B EXT STM DRN valve EX147Open HPH-6A EXT STM DRN valve EX101Open HPH-5A inlet isolation valve FD7Open HPH-6A outlet isolation valve FD8Close HPH-5A inlet isolation valve IBV FD7 IBVClose HPH-6A outlet isolation valve IBV FD8 IBV Close HPH FW 50% Byp valve FD12Open HPH FW 50% Byp valve FD12 IBVOpen HPH FW 50% Byp valve FD12Close HPH FW 50% Byp valve FD12 IBVClose HPH FW 100% Byp valve FD11Close HPH FW 100% Byp valve FD11 IBVOpen HPH-5A EXT STM inlet valve EX21


Open HPH-6A EXT STM inlet valve EX23Open HPH-6A EXT STM inlet valve EX24Close HPH-5A/5B EXT STM DRN valve EX147Close HPH-6A EXT STM DRN valve EX101Set the HPH 5A NWL set point to -90mmSet the HPH 5A HWL set point to -15mmSet the HPH 5A drain CV DR15 to AutoSet the HPH 5A drain CV DR18 to AutoSet the HPH 6A NWL set point to -90mmSet the HPH 6A HWL set point to -15mmSet the HPH 6A drain CV DR2 to AutoSet the HPH 6A drain CV DR5 to Auto

HPH-5B and 6B ChargingOpen HPH-5B inlet isolation valve IBV FD9 IBVOpen HPH-6B outlet isolation valve IBV FD10 IBV Open HPH-6B EXT STM DRN valve EX102Open HPH-5B inlet isolation valve FD9Open HPH-6B outlet isolation valve FD10Close HPH-5B inlet isolation valve IBV FD9 IBVClose HPH-6B outlet isolation valve IBV FD10 IBV Close HPH FW 50% Byp valve FD12 IBVOpen HPH-5B EXT STM inlet valve EX22Open HPH-6B EXT STM inlet valve EX25Open HPH-6B EXT STM inlet valve EX26Close HPH-6B EXT STM DRN valve EX102Set the HPH 5B NWL set point to -90mmSet the HPH 5B HWL set point to -15mmSet the HPH 5B drain CV DR22 to AutoSet the HPH 5B drain CV DR25 to AutoSet the HPH 6B NWL set point to -90mm

SU130945 Set the HPH 6B HWL set point to -15mmSU130946 Set the HPH 6B drain CV DR8 to AutoSU130947 Set the HPH 6B drain CV DR11 to Auto

SU1310 Selection of CMC mode:Goto CMC scheme screen from BOP-SLD menuSU130101 Set the min. load SP to 350 MWSU130102 Set the max. load SP to 525 MWSU130103 Set the load rate SP to 25 MW/Min SU130104 Set the Fuel master to AutoSU130105 Set the Air Flow control to AutoSU130106 Ensure Feedwater master is in Auto


SU130106 Set the Boiler master to AutoSU130107 Select the Mode as CMCSU130108 Set the CMC Mode On

Permissives from Remote Station for AB Elevation Heavy Oil:1 HO Man Isol Vlv AB 12 HO Man Isol Vlv AB 23 HO Man Isol Vlv AB 34 HO Man Isol Vlv AB 45 At St Man Isol Vlv AB 16 At St Man Isol Vlv AB 27 At St Man Isol Vlv AB 38 At St Man Isol Vlv AB 49 Oil Gun Engd AB 110 Oil Gun Engd AB 211 Oil Gun Engd AB 312 Oil Gun Engd AB 413 LCL MAINT.SW AB1 REM14 LCL MAINT.SW AB2 REM15 LCL MAINT.SW AB3 REM16 LCL MAINT.SW AB4 REM

Permissives from Remote Station for CD Elevation Heavy Oil:1 HO Man Isol Vlv CD 12 HO Man Isol Vlv CD 23 HO Man Isol Vlv CD 34 HO Man Isol Vlv CD 45 At St Man Isol Vlv CD 16 At St Man Isol Vlv CD 27 At St Man Isol Vlv CD 38 At St Man Isol Vlv CD 49 Oil Gun Engd CD 110 Oil Gun Engd CD 211 Oil Gun Engd CD 312 Oil Gun Engd CD 413 LCL MAINT.SW CD1 REM14 LCL MAINT.SW CD2 REM15 LCL MAINT.SW CD3 REM16 LCL MAINT.SW CD4 REM

Permissives from Remote Station for EF Elevation Heavy Oil1 HO Man Isol Vlv EF 12 HO Man Isol Vlv EF 2


3 HO Man Isol Vlv EF 34 HO Man Isol Vlv EF 45 At St Man Isol Vlv EF 16 At St Man Isol Vlv EF 27 At St Man Isol Vlv EF 38 At St Man Isol Vlv EF 49 Oil Gun Engd EF 110 Oil Gun Engd EF 211 Oil Gun Engd EF 312 Oil Gun Engd EF 413 LCL MAINT.SW EF1 REM14 LCL MAINT.SW EF2 REM15 LCL MAINT.SW EF3 REM16 LCL MAINT.SW EF4 REM

Permissives from Remote Station for GH Elevation Heavy Oil1 HO Man Isol Vlv GH 12 HO Man Isol Vlv GH 23 HO Man Isol Vlv GH 34 HO Man Isol Vlv GH 45 At St Man Isol Vlv GH 16 At St Man Isol Vlv GH 27 At St Man Isol Vlv GH 38 At St Man Isol Vlv GH 49 Oil Gun Engd GH 110 Oil Gun Engd GH 211 Oil Gun Engd GH 312 Oil Gun Engd GH 413 LCL MAINT.SW GH1 REM14 LCL MAINT.SW GH2 REM15 LCL MAINT.SW GH3 REM16 LCL MAINT.SW GH4 REM

Permissives from Remote Station for Mill B1 RCF Inlet Gate B2 Tr.Iron Hop Vlv B3 Bunkr O/L Gate B4 Bunkr Isolation Gate B5 Feeder SA valve B6 Mill-B MOTOR Rack-in/Rack-out

Permissives from Remote Station for Mill C1 RCF Inlet Gate C2 Tr.Iron Hop Vlv C


3 Bunkr O/L Gate C4 Bunkr Isolation Gate C5 Feeder SA valve C3 Mill-C MOTOR Rack-in/Rack-out

Permissives from Remote Station for Mill D1 RCF Inlet Gate D2 Tr.Iron Hop Vlv D3 Bunkr O/L Gate D4 Bunkr Isolation Gate D5 Feeder SA valve D6 Mill-D MOTOR Rack-in/Rack-out

Permissives from Remote Station for Mill E1 RCF Inlet Gate E2 Tr.Iron Hop Vlv E3 Bunkr O/L Gate E4 Bunkr Isolation Gate E5 Feeder SA valve E3 Mill-E MOTOR Rack-in/Rack-out

Permissives from Remote Station for Mill F1 RCF Inlet Gate F2 Tr.Iron Hop Vlv F3 Bunkr O/L Gate F4 Bunkr Isolation Gate F5 Feeder SA valve F6 Mill-F MOTOR Rack-in/Rack-out

Permissives from Remote Station for Mill G1 RCF Inlet Gate G2 Tr.Iron Hop Vlv G3 Bunkr O/L Gate G4 Bunkr Isolation Gate G5 Feeder SA valve G3 Mill-G MOTOR Rack-in/Rack-out

Permissives from Remote Station for Mill H1 RCF Inlet Gate H2 Tr.Iron Hop Vlv H3 Bunkr O/L Gate H


4 Bunkr Isolation Gate H5 Feeder SA valve H3 Mill-H MOTOR Rack-in/Rack-out

Permissives from Remote Station for ACW-C1 ACW-C Suction VLV2 ACW-C Rack-in/Rack-out

Permissives from Remote Station for DMCW-C 1 DMCW-C Suction VLV2 DMCW-C Rack-in/Rack-out

Permissives from Remote Station for BCW-C1 BCW Pump-C Rack-in/Rack-out2 BCWP C DISCH VALVE

Permissives from Remote Station for CWP-3

Permissives from Remote Station for Service Air 1 SA 12 SA 54

Permissives from Remote Station for INSTRUMENT AIR COMPRESSOR1 IA COMP-1 Rack-in/Rack-out2 IA COMP-2 Rack-in/Rack-out3 IA COMP-3 Rack-in/Rack-out

Permissives from Remote Station for PLANT AIR COMPRESSOR1 PA COMP-1 Rack-in/Rack-out2 PA COMP-2 Rack-in/Rack-out

Permissives from Remote Station for ISOLATORS1 ISO 9-89 2 ISO 9-89A3 ISO 89-GT14 ISO 8-89A5 ISO 8-89B6 ISO 7-897 HVCB 7-528 ISO 7-89A9 ISO 89-ST1

Npti Training Manual

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