Organization:

Raj West Power Limited

Project:

8 x 135 MW
LIGNITE BASED THERMAL POWER PLANT, BHADRESH

Doc. Title:

Unit Cold start up Check list

Doc No:
RWPL/OPR/CL_001
Issue Date: No of Sheets:
21/02/2014
(including cover sheet)

6
Revision Record:

1 R0 - First Release nil

S. Revision Date of Prepared by Nature of Revision Remarks
No No. Revision

Approved by: Control status Issued & Controlled by:

CVR REDDY S.C TOTLA
DGM (Operation) AGM (Operation)
** As the document is computer generated, hence there is no need for signature
 Raj West Power Limited
Doc. NO. RWPL/OPR/CL_001
Unit Cold start up Check List
Date: 21/02/2014
Page: Page 2 of 6

Sr. Verification /
Activity Check
No Remarks
1 Ensure all PTW returned, man, material & temporary structure removed from area.
2 HT/LT side on 6.6 KV/415 V supply charged, DC voltage, UPS, Battery chargers are
healthy & in service.
3 Ensure all monitoring & testing instrument are put in service & are normal
4 Ensure there is not restriction for boiler expansion.
5 Ensure all air nozzles of bed cleaned.
6 Ensure all man holes of furnace, APH, U Seal planem & ESP are closed.
7 Ensure all coal feeders outlet gate is closed.
8 Ensure bed material in furnace is filled up to 700 mm height & there is no clinker &
oversize material in furnace bed.
9 Ensure boiler vents are open including drum & start up.
10 Ensure SH & RH drains are open.
11 Ensure CW System is started (refer doc. no. RWPL/OPR/SOP_007) & maintain CW
header pressure 0.20Mpa to 0.23Mpa.
12 Ensure ACW System is started (refer doc. no. RWPL/OPR/SOP_005) & maintain CW
header pressure > 0.40Mpa.
13 Ensure CCCW System is started (refer doc no. RWPL/OPR/SOP_006) & maintain
CCCW header pressure > 0.30Mpa.
14 Ensure PAC/IAC with dryer is started (refer doc no. RWPL/OPR/SOP_002) & header
pressure > 0.65Mpa.
15 Ensure all PTW related to Boiler should be closed.
16 Ensure all boiler vents are open
17 Ensure that down comer, water wall & economizer drain are closed.
18 Ensure local drum gauge glass & hydra step in service.
19 Ensure boiler fill pump is lined up & started (refer doc. No. RWPL/OPR/SOP_022) to fill
drum up -100mm to - 150mm level (also start Hydrazine dozing by consulting to
Chemist).
20 Ensure oil gun cleaning is done & atomization test completed.
21 Ensure LDO line flushing up to oil gun completed & oil strainer cleaned.
22 Ensure LDO pump is lined up & started (refer doc. no. RWPL/OPR/SOP_004) & put in
long recirculation with discharge pressure 2.5Mpa.
23 After drum filling, start dearetor filling (by using Boiler fill pump/condensate make up
pump).
24 Ensure U valve blower, ID fan, SA fan, PA fan lined up and air path through.

Approved by: Control status Issued & Controlled by:

CVR REDDY S.C TOTLA
DGM (Operation) AGM (Operation)
** As the document is computer generated, hence there is no need for signature
 Raj West Power Limited
Doc. NO. RWPL/OPR/CL_001
Unit Cold start up Check List
Date: 21/02/2014
Page: Page 3 of 6

Sr. Verification /
Activity Check
No Remarks
25 Ensure two U valve blower are started (refer doc. No. RWPL/OPR/SOP_043) & ensure
proper air flow to both U seal. Put third one on link mode (CV of U seal header to PA
header should be closed & in AUTO mode). Maintain discharge pressure 47KPa
26 Ensure both ID fans are started (refer doc. No. RWPL/OPR/SOP_010) & furnace draft is
between – 50 Pa to + 50 Pa.
27 Ensure both SA fans are started (refer doc. No. RWPL/OPR/SOP_011).
28 Ensure both PA fans are started (refer doc. No. RWPL/OPR/SOP_009).
Ensure loading of PA fan is increased (upto 90,000 Nm³/hr) for proper fluidization of bed
29
material & check for fluidization through view glass.
30 Ensure loading of SA fan is increased (upto 60,000 Nm³/hr).
Ensure RH side gas damper is closed & maintain 30% to 40% of rated air flow (Air flow
31
should be > 138,000 Nm³/hr).
32 Ensure economizer recirculation valve is open.

33 Ensure boiler purging is started.

34 Ensure purging completed & LDO in longest recirculation.

35 Ensure MOT level should be > 1520mm.

Ensure AC Lube oil pump is running & discharge header pressure should be 0.3Mpa
36
(±0.05Mpa).
37 Ensure AC JOP is running & discharge header pressure should be 15Mpa (±1.5Mpa).

38 Ensure that turbine is on barring gear.

Ensure two ignition duct oil guns (one in left side & other in right side) of boiler are in
39 service to lit up boiler. Maintain duct outlet temperature below 550˚C (rate of rise of
temperature should not increase greater than 85˚C/hr).
Ensure rate of rise of cyclone inlet temperature should be less than 80˚C/hr & metal
40
temperature difference of top & bottom of drum less than 50˚C.
41 Ensure outer metal temperature of ignition duct & u-seal is normal at all locations.
Ensure hot well make up system is lined up to maintain normal hot well level (650mm to
42
750mm).
43 Ensure CEP & condensate system is lined up (refer doc. No. RWPL/OPR/SOP_008).

44 Ensure BFPs are lined up (refer doc. No. RWPL/OPR/SOP_012).

Sr. Verification /
Activity Check
No Remarks
Approved by: Control status Issued & Controlled by:
CVR REDDY S.C TOTLA
DGM (Operation) AGM (Operation)
** As the document is computer generated, hence there is no need for signature
 Raj West Power Limited
Doc. NO. RWPL/OPR/CL_001
Unit Cold start up Check List
Date: 21/02/2014
Page: Page 4 of 6

Ensure other pair of ignition duct oil gun are in service to increase the average bed
45
temperature upto 400˚C. Ignition duct outlet temperature should be less than 800˚C.
At 0.2 Mpa drum pressure, close drum & SH vents. Also close SH drain (except high
46
temp SH & platen SH outlet header drain).
Ensure DM transfer pumps are running & hot well level is normal, then start CEP
47
(refer doc.no. RWPL/OPR/SOP_008).
48 Ensure BFP is started (refer doc.no. RWPL/OPR/SOP_012).
Ensure phosphate dozing is started with consultation of DM plant
49
(refer doc.no RWPL/OPR/SOP_037)
50 Ensure at 0.3Mpa drum pressure high temperature SH outlet header drains are closed .

51 Ensure that MS line drains & vent are open.

52 Ensure MS line is charged at 0.6 Mpa (refer doc.no. RWPL/OPR/SOP_054)

53 Ensure that PRDS, Gland sealing header drains are open.

Ensure the PRDS header & Gland sealing line from PRDS or MS (refer doc.no.
54
RWPL/OPR/SOP_054) upto gland sealing header control valve is charged.
Ensure GS header is charged (maintain header pressure 20KPa & temperature 120˚C to
55
180˚C).
Ensure coal feeders are lined up & intermittent coal feeding is started at 325˚C of
56
average bed temperature (refer doc.no. RWPL/OPR/SOP_041).
Gradually increase average bed temperature to 540˚C & then take coal feeders in service
57
simultaneously (as per requirement).
58 Gradually reduce the oil.
Ensure that inlet gas temperature & PRH metal temperature doesn’t exceed 580˚C &
59
550˚ simultaneously till HP bypass is not charged.
Ensure vacuum breaker valve is closed & vacuum extraction pump is started (refer
60
doc.no. RWPL/OPR/SOP_047)& start vacuum pulling.
Ensure CT fans are lined up & started (refer doc.no. RWPL/OPR/SOP_031) to maintain
61
CW inlet temperature between 30˚C to 34˚C.
62 Ensure HRH & CRH line drains are open.

63 Ensure HP/LP bypass oil pump lined up & started (refer doc.no. RWPL/OPR/SOP_034).

64 Ensure that all MAL & EXT drains are open.

65 Ensure that HP/LP bypass system is charged at > 88Kpa vacuum.

Sr. Verification /
Activity Check
No Remarks
66 PRDS & GS drains can be throttled to minimum at appropriate header temperature

Approved by: Control status Issued & Controlled by:

CVR REDDY S.C TOTLA
DGM (Operation) AGM (Operation)
** As the document is computer generated, hence there is no need for signature
 Raj West Power Limited
Doc. NO. RWPL/OPR/CL_001
Unit Cold start up Check List
Date: 21/02/2014
Page: Page 5 of 6

Ensure that the opening of HP/LP bypass is increased to achieve the MS temperature
67
280˚C at 1.0Mpa pressure & RH steam temperature 220˚C at 0.2Mpa pressure
68 Ensure all RH drains are closed.
69 Check that EH oil pump is lined up & then start it (refer doc.no. RWPL/OPR/SOP_035).

70 Check that turbine trip at back up panel is reset.

71 Check that master trip relay is reset at SCADA/switchyard.

Ensure that turbine stop valve is opened from DCS & rolling of turbine is started (refer
72 doc.no. RWPL/OPR/SOP_055)& ensure barring gear is automatically unhitched after
starting of rolling.
73 Keep watch on vibration & bearing temperature during rolling.

75 Ensure that turbine speed is raised to 500 (@100rpm per minute).

76 Ensure that overall checking of turbine is done at 500rpm within 5minutes.

Ensure that the rotating speed is raised to 1100 rpm (@100rpm per minute) & warm up
77
for 10 minutes.
Ensure that the rotating speed is raised to 2300 rpm (@100-150rpm per minute) & warm
78
up for 10 minutes (At turbine speed 1200 rpm, JOP should AUTO shut down).
Ensure that the rotating speed is raised to 3000 rpm constant speed (@100-150rpm per
79
minute) & warm up for 30 minutes.
80 Ensure AOP is stopped at 3000 rpm,

81 Ensure all isolator of GT bay is closed corresponding to main bus ½.

Ensure auto/manual selector switch is in ‘AUTO’ & generator breaker selection is
82
‘CLOSE’ in generator panel.
83 Ensure the field breaker is closed.

84 Make excitation ‘ON’.

85 Ensure CB11/CB12 is selected.

86 Match the generator voltage & frequency with grid.

87 Make synchronization on ‘AUTO’ in DEH.

88 Select engage AUTO SYNCHRONISATION in DEH.

Sr. Verification /
Activity Check
No Remarks
89 Start synchronization & synchronize the unit (refer doc.no. RWPL/OPR/SOP_055).

Approved by: Control status Issued & Controlled by:

CVR REDDY S.C TOTLA
DGM (Operation) AGM (Operation)
** As the document is computer generated, hence there is no need for signature
 Raj West Power Limited
Doc. NO. RWPL/OPR/CL_001
Unit Cold start up Check List
Date: 21/02/2014
Page: Page 6 of 6

After synchronization, ensure that load is raised to 10MW (@1MW/min) & warm up for 60
90
minutes.
91 Ensure economizer valve is closed at 10MW load.
Ensure that ESP is ready for charging & charge ESP when all oil gun is removed & ESP
92
inlet flue gas temperature Is greater than 110˚C.
After that ensure that load is raised to 40MW (@1MW/min) & warm up for 60 minutes (all
93
MAL drains should be closed at 30MW load).
94 Ensure that UAT is taken in service at 18MW load.

95 Ensure that all LP heaters are taken in service at 20MW load.

96 Ensure that turbine casing drains & MS line drains closed at 34MW load.

97 Ensure that the drum level is put in 3 elements.

98 Ensure that LP drip pump is started to regulate the excess air < 7%.
Ensure MS temperature & pressure is increased as per cold start up curve & increase
99
loading of ID/SA/PA fan as per requirement.
Ensure with continuously rising temperature & pressure, load is added to rated load
100
(135 MW) @ 1MW/min.
101 Ensure that the HP heaters are charged at 50MW load.

Approved by: Control status Issued & Controlled by:

CVR REDDY S.C TOTLA
DGM (Operation) AGM (Operation)
** As the document is computer generated, hence there is no need for signature