C 14/10/03 Jp Ch Bad Reviewed further to Client’s letter n°3407(17.09.

03) FUS
B 08/07/03 Jp Mo Bad Reviewed further to Client’s letter n°1886(21.05.03) FUS
A 21/03/03 Jp Ch Bad First issue PRE
REV DATE AUTH. CHECK. APPR. BY MODIFICATIONS STATUS
BY

TEAS
TÜRKIYE ELEKTRIK ÜRETIM - ILETIM A. S.
SANTRALLAR PROJE VE TESIS DAIRESI BASKANLIGI
TURKISH ELECTRICITY GENERATION - TRANSMISSION Co.

2 x 160 MW ÇAN THERMAL POWER PLANT

ALSTOM Power Centrales – ALSTOM Power Boiler GmbH. – ALSTOM Enerji-Nakil A.S. – TEKNOTES Ltd. Sti.

CONSORTIUM

PROJECT DWG. N° :

DESIGN SUBCONT.

DRAWING OVERALL OPERATING INSTRUCTIONS

TITLE
UNIT WARM START-UP

TÜRKIYE ELEKTRIK ÜRETIM - ILETIM A. S.

ÇAN THERMAL POWER PLANT

SCALE : - Rev. No
Drawing N° CNK 1 2 M - - - OV EO I 11 2
SIZE : C

ALSTOM Power
ALL RIGHT PERTAINING TO THE REPRODUCTION, TRANSFORMATION AND USE OF THIS DOCUMENT
IN ANY FORM OR MANNER REMAIN THE EXCLUSIVE PROPERTY OF ALSTOM POWER
abcd
Power
Plant Segment
Engineering

ÇAN THERMAL POWER PLANT

2 x 160 MW

OVERALL OPERATING INSTRUCTIONS

UNIT WARM START UP

SUMMARY

_____

1 PURPOSE

2 SCOPE OF THE PROCEDURE

3 INITIAL STATE

4 UNIT START-UP

Reference documents :

- Boiler and steam turbine start-up curve CNK 00 M --- --- SC 020
- General system design manual CNK 00 M OVE --- DM 001
- Master block control CNK 01 M KCA --- DM 001

CNK 12 M OVE --- OI 112 C October 2003

1 PURPOSE

This document is a general guidance for experienced and authorised operators. It lists the main
operations to be carried out for the warm start-up of the unit, with auxiliary-steam not available from
the other unit.

To start the different equipment, the operator refers to the system operating instructions of the
relevant systems.

This procedure is arranged to use with DCS in an specific page preview. When will notified in the
Operating Instructions form to start or to put or to select or to adjust or to open or to close or to check
any plant or system or equipment the operator would perform as following :

- check the permissive before to do any action,

- display the page,
- select the group,
- select the equipment from where the action would be acted,
- follow the sequence will be performed,
- check that the result of the action have been performed,
- check that the other equipment attached are in good order and correctly disposed,
- check that the group is “ON”.

Future conditions may dictate the requirement to implement changes to this document.

All the unit load figures indicated in the loading up phase are for guidance only. Specific figures will
be determined under actual operating conditions.

2 SCOPE OF THE PROCEDURE

The unit warm start-up is applied if one or until all of the following conditions exist :

- when the unit has been shutdown for more than 8 hours up to less 40 hours,
- when the lower bed boiler temperature is between 100 and 650 °C.

The boiler will be started according the warm start-up curve.

The turbine is run up and synchronised using steam flow through the IP and LP turbines only, with
the HP turbine isolated, bypassed and under vacuum. HP steam flow is established at nominally
24 MW load.

If need, the HP turbine and valve chests are pre-warmed by pressuring with cold reheat steam
towards a value of 20 to 22 bar a. to reduce thermal stresses when normal steam flow is introduced
to the HP turbine. Turbine speed is limited to 1000 rpm until pre-warming is completed.

Run up rates are automatically limited with IP governing valves controlling the steam admission
depending on initial the IP cylinder metal reference temperature. If need, run-up rates are limited to :

- 500 rpm/min, if IP cylinder temperature will be greater than 190 °C,

- when passing through critical speed bands the run up rate is automatically selected to
1000 rpm/min.

The operator may set a lower rate if required.

The operator, depending on the HP cylinder metal reference temperature sets loading rates.

The turbine then operates in a conventional manner with steam admission being controlled by the
HP governing valves.

If need, the turbine load is held at block load nominally 24 MW to allow the IP turbine thermal stress
to decay before the loading is resumed.

CNK 12 M OVE --- OI 112 C 3/17

3 INITIAL STATE

The entire auxiliaries, boiler, turbine, balance of plant systems have been pre-start checked as
indicated in the documents :
- CNK 12 M OVE OI 101
- CNK 12 M OVE OI 104
- CNK 12 M OVE OI 105
- CNK 12 M OVE OI 106
and are ready to operate or in operation.

4 UNIT START-UP

STEP ACTIONS OBSERVATIONS DISPLAY

0 GENERAL WARM START-UP PREPARATION
0.01 Check as follows :
- that the entire auxiliaries systems have been
pre-start and checked,
- that the heaters of the electrostatic precipitator
are running,
- that the Regenerative Air Heater is running,
- that the feedwater circuits are ready to operate
(normal and emergency),
- the demineralised water make-up systems are
ready to operate,
- the alarm screen for permissive.
0.02 Check and adjust the level and needs as
follows :
- the water level and the needs of the boiler,
condenser, feedwater tank, closed circuit
cooling water tank, lub oil tank, chemical
conditioning tank, ash cooler,
0.03 Cooling water system starting-up as follows :
- start one pump of the cooling water circulating
pump,
- start one closed cooling water pump PGC 11
AP 001 or PGC 12 AP 001 is in normal
operation and ensures the circulation of the
cooling water of the auxiliary cooling towers to
the different equipment to be cooled,
- the different double speed motors fans of the
six auxiliary cooling cells PGC 91/92/93/94/95
and 96 AN 010 are controlled automatically by
a temperature ON/OFF control chain or
individually by the operator.

CNK 12 M OVE --- OI 112 C 4/17

 STEP ACTIONS OBSERVATIONS DISPLAY
0.04 Condenser extraction pumps system starting-
up as follows :
- ensure that the ash coolers bypass hand
isolating valves are closed,
- ensure that the feedwater tank level is normal, 2500 mm
- ensure that the condenser normal make-up
isolating valves are opened,
- ensure that the forward flow valves are closed
and in auto,
- ensure that the condensate circuit is primed,
- start extracting pump (ensure that the
discharge valve and recirculation valve open
fully, establish the flow through the circuits).
0.05 Feedwater pumps system start-up as follows :
- ensure that the pre-start checks have been
carried out including priming of pump and
opening of the suction valves,
- select the feedwater duty pump,
- ensure that the scoop control is at minimum
and on manual,
- start the feedwater pump :
. check the parameters as the pump runs up,
. when the pressure 50 bars is reached the
relevant motorised discharge valve is open
and when the full opening is obtained, the by-
pass motorised valve re-closes automatically,
. increase the scoop position to increase the
speed (this will clear the anti-cavitation
protection),
. check that the pump flow is satisfactory,
0.06 Boiler to be started-up :
- check that the main steam, cold reheat steam
and hot reheat steam isolating valves on VVP
system are correctly set (isolating valves are
opened on the boiler starting-up side),
0.07 Boiler ventilation starting-up:
- make sure that there is a natural draft through
the air flue gas circuit (when the whole
ventilation is shut down, the dampers on
secondary air circuit (air inlet) and (upper
secondary air level) are open),
- start the induced draft fan after ID start,
- put in automatic control the boiler negative - 1.5 mbar
pressure, after that the ID started (set point at
measurement at the top of rear pass),
- start the 2 fluidising air fans for double loop
seals,

CNK 12 M OVE --- OI 112 C 5/17

 STEP ACTIONS OBSERVATIONS DISPLAY
- check the opening of the hand trimm valves,
Ash cooler fans starting-up :
. put in automatic control the inlet damper,
. start the ash cooler fans,
. check the air flow to the ash cooler empty 1.1 kg/s
chamber,
. check the air flow to the ash cooler cooled 1.6 + 2.7 kg/s
chamber,
Secondary air fan 1 starting-up :
. open inlet damper and close RAH outlet
isolating damper,
. put in manual and at the minimum, the total
air flow control station,
. start the secondary air fan (the vent damper
closes),
. check that the secondary air pressure set 80 mbar
point,
. open RAH outlet isolating damper,
. put in automatic control the vane guide.
Secondary air fan 2 starting-up see fan 1
Primary air fan starting-up :
. open inlet damper and close RAH outlet
isolating damper,
. put in manual and at the minimum, the
primary air flow control station,
. start the primary air fan (the vent damper
closes),
. check the primary air flow according to set
point diagram,
. open RAH outlet isolating damper,
. put primary air flow control in automatic.
Primary air fan 2 starting-up see fan 1

CNK 12 M OVE --- OI 112 C 6/17

 STEP ACTIONS OBSERVATIONS DISPLAY
0.08 Boiler purge
The boiler purge is performed prior to burner start.
- If shutdown more of 8 hours.
0.09 Turbine Pre-start checks :
- lubricating oil temperature must be higher than
30°C,
- the turbine must have been turned by the 65 rpm
electric turning gear for at least 6 hours, all
rotor eccentricities must have settled and
should be less than 50 µm.
- control fluid temperature must be higher than
20°C,
- turbine supervisory and control systems must
be healthy.
1 BOILER FIRING START-UP
1.01 Check as follows :
- check that the total air flow is established,
- HFO will be used with a combustion air
temperature of at least 120 °C,
- check that the fluidising air pressure, is at the
adequate value,
1.02 Start-up burner until 40% GCC
- light oil operation shall be pre-selected,
- oil supply must be started,
- put in automatic the air control valve,
- check that the starting position will be
automatically controlled to its minimum,
- if oil lance is empty, safety time is running for
12 seconds,
- if oil lance is not empty (filled lance), safety
time is running for 5 seconds,
- put fuel oil flow control in auto,
- check bed temperature increase < 100 K/h,
- for the normal start time, a minimum of 3 fail
starts is allowed.

CNK 12 M OVE --- OI 112 C 7/17

 STEP ACTIONS OBSERVATIONS DISPLAY
1.03 Rise in combustor temperature
- increase gradually start-up burner power,
- put to its minimum flow rate the secondary air, 50 kg/s
to avoid cooling the combustor,
- do not decrease this minimum flow (because
ashes may come backwards into secondary air
ducts),
- during the rise in combustor temperature, 100 K/h
- maintain the HP bypass at a constant opening,
- open reheat LP vent valve,
- warm up the main steam pipes to turbine,
- check that all the automatic drains on super-
heaters and reheaters open,
2 BED LANCES START-UP (8) Until 15% GCC
- ignition of bed lances possible with at least
(HFO/500°C), (LFO/550°C) bed temperature,
- bed lances are used for heating up of the bed
material in the furnace until the release of coal
feeding is reached,
- maximum out flow 5.1 t/h.(total),
- close the scavenging air valve,
- open the lance position valve,
- start the lances,
- if the lance is the first to be started :
. open the general oil shut off valve,
. put under control loop the oil inlet pressure
control valve,
. comeback to 1.02.
3 BOILER RISING
3.01 Adjust the steam rising
Adjust at a constant value the steam pressure (the 70 bar a
steam flow increases according to the firing rate)
(when the steam pressure reaches 70 bar a, the
HP bypass control switches from minimum opening
to pressure control).
3.02 Vacuum rising
- when the turbine gland steam sealing system is
in operation start the vacuum plant as follows :
. select hogging group level,

CNK 12 M OVE --- OI 112 C 8/17

 STEP ACTIONS OBSERVATIONS DISPLAY
. the Hogging ejector system starts
automatically (first step sequence automatic
action will close the vacuum breaker valve.
Open the main steam isolating valve. Open
the desuperheating isolating valve ; second
step sequence automatic action : open
hogging vacuum valve ; third step sequence
automatic action : check that the hogging
vacuum valve is open. Check that correct
vacuum value for holding ejectors start),
. select the holding group,
. the holding ejector system starts
automatically,
. check that the pressure is obtained,
. check that the both ejector sets are started
simultaneously,
. check that hogging ejector shutdown.
3.03 Rising
- stop the start-up burner (when the combustor
temperature have reached), 660 °C
- increase the PA flow according to set point
diagram (this is mandatory to have a correct
fluidisation of the bottom of the furnace and to
avoid ash coming back to the wind-box. Having
a bad furnace fluidisation can lead to disparities
in ashes temperatures and local bad
combustion),
- start the coal injection lines (when the
combustor temperature is reached) (at the At about 650 °C
minimum speed) from 30% GCC up to max,
- waiting time until coal ignition (coal ignition is
recognised by fast increasing of bed
temperature,
- reduce the oil flow to lances to maintain the bed
temperature,
- increase of coal firing rate, synchronous
reduction of oil firing rate and firing turn-off,
4 STEAM TURBINE STARTING
Acting as follows:
- check the main steam pressure, 70 bar a
- check the main steam temperature (MST), See appendix 2
- adjust the furnace temperature by changing
the coal flow (between 650 °C and 850 °C to
maintain MST),
- check that LP bypass regulate the reheat 15 bar a
steam pressure at:
(22 bar a for HP back warming)
- check the reheat steam temperature (RST), See appendix 1

CNK 12 M OVE --- OI 112 C 9/17

 STEP ACTIONS OBSERVATIONS DISPLAY
- acting on the cold steam temperature set point
(50°C margin with the saturated steam
temperature)
- put ST run-up rate, 500 rpm/min
Close progressively the LP reheater vent valve.
5 FEEDWATER TANK AND DEAERATOR
5.01 Check that the vent valve LAA 15 200 M to Below 250 mbar
atmosphere close automatically.
5.02 Check that the vent valve LAA 15 AA 100 M to Below 250 mbar
condenser open automatically.
6 TURBINE CHECKS ON BARRING
6.01 Check the turbine speed.
6.02 Check the turbine eccentricities,
- Rotor eccentricity should be less than 50 µm.
6.03 Check the generator eccentricities (eccentricities
should be less than 50 µm).
6.04 Check HP turbine casing metal top to bottom
differential temperature during cooling, these will
tend to increase and may exceed the positive
alarm values but must not exceed the following :
- HP mid-length : + 50 °C,
- HP exhaust end : + 65 °C.
6.05 Check IP turbine casing metal top to bottom
differential temperature during cooling, these will
tend to increase and may exceed the positive
alarm values but must not exceed the following :
- IP extraction 6 : + 50 °C,
- IP extraction 5 : + 50 °C.
7 TURBINE RUN-UP TO SPEED
7.01 Check that turbine governing is permitted.
7.02 Check ST run-up rate is at : 500 rpm/min
7.03 Set loading rate according to HP inner casing See appendix 3
flange metal temperature (unless plant or external
conditions are such that a lesser rate is
necessary).
7.04 Set Master load control system maximum and
minimum loads (if plant or external conditions are
such that these should be other than the default
values).
7.05 Set target load (as required).
7.06 Check that stress control is selected ON (stress
control of loading rate is not enabled until HP
cylinder steam flow has been established)
7.07 Initiate turbine governing "ON" order.

CNK 12 M OVE --- OI 112 C 10/17

 STEP ACTIONS OBSERVATIONS DISPLAY
7.08 Check that HP cylinder evacuation valve open (HP 950 rpm
cylinder is evacuated).LCM30AA100M.
7.09 Check that turbine speed increase. 500 rpm/m
7.10 Check that the turbine HP stop valves close. 1020 rpm
7.11 Check that the LP exhaust cooling valve opens. 2000 rpm
MAL85AA360S.
7.12 Check excitation field circuit breaker closes. 2700 rpm
7.13 Check that the electrical turning gear and jacking 2900 rpm
oil pump stop.
7.14 Check and confirm that trends of HP and IP
cylinder metal top to bottom differential
temperatures are towards the “on load” normal
values, during speed increase.
7.15 Check when the speed has settled: 3000 rpm
- lubricating oil system pressures.
- lubricating oil system temperatures.
- the bearing temperatures.
7.16 Check the reheat pressure is not greater than 15
bar a.
8 TURBINE SYNCHRONISATION
8.01 Put speed dead-band in service.
8.02 Check that excitation is on automatic regulation
control.
8.03 Adjust set point voltage (by using lower, raise
buttons).
8.04 Check that the pre-synchronising criteria are
satisfied.
8.05 Place keys in auto synchro position and automatic,
(for the circuit breaker to be closed) (incoming and
running voltage).
8.06 - Press start synchronising push button.
- Check synchroscope is rotating.
- After synchronisation check AC lubricating oil
pump has shut down.
8.07 Block load of approximately 8 MW is automatically
applied over a period of nominally 1 minute.
8.08 Check main steam conditions temperatures and
pressures are within limits, the regulation being
done by the block load control.
8.09 Ensure available HP steam flow (HP bypass flow). 75.6 t/h

CNK 12 M OVE --- OI 112 C 11/17

 STEP ACTIONS OBSERVATIONS DISPLAY
8.10 Check that the LP heater drain pump is started-up
automatically (when level into LP heater 3 is not
low any more)
8.11 Check that heating is carried on the feedwater tank
from bleeding 5 IP casing steam.
8.12 Increase the coal feeders flow. With a rate of load
change 2-3 %/min
8.13 Put HP heater 6 in service (slowly open bled steam
valve until fully open).
8.14 Confirm cylinder metal top/bottom differential
temperature (once HP turbine steam flow has been
than established) (reduce to less than + 35 °C).
8.15 Check that heating is carried on the HP 7 heater
from bleeding 7 cold reheat steam when main
steam flow is greater than : 150 t/h
8.16 Check that heating is proceeding correctly. Heating
is done automatically.
8.17 Ensure the bled steam drain valves close
automatically.
8.18 Check when the relation ship of HP and IP steam
pressure and flow is satisfactory, the HP turbine
At about 24 MW
steam flow is introduced automatically.
Note : if conditions for HP turbine steam flow
introduction are not satisfied, load will be
automatically limited until conditions are satisfied.
8.19 Observe that the HP cylinder evacuation valve
closes LCM30AA100M.
8.20 Observe HP stop valves open.
8.21 Observe turbine HP governing valves partially
open (in full admission mode) to control HP turbine
steam flow.
8.22 Ensure HP steam chest, loop pipe and turbine At 32 MW
drains valves close.
8.23 Ensure IP steam chest and loop pipe drains At 32 MW
valves have close.
8.24 Ensure LP spray cooling valve has closed. At 36 MW
MAL85AA360S.
8.25 Reduce the oil lances flow.

CNK 12 M OVE --- OI 112 C 12/17

 STEP ACTIONS OBSERVATIONS DISPLAY
9 BOILER LOAD RISE
9.01 During the steam turbine low power step :
- Put primary air flow the auto-manual station in
automatic,
- Put secondary air flow control station in
automatic,
- Put in automatic control the ash extraction
valve at the furnace bottom,
- Gradually put at the same flow the coal lines,
- Adjust the boiler load control station to the
existing value,
- Put in automatic control the coal feeders,
- Start the limestone injection lines (at the
minimum flow).
9.02 During the steam turbine load rise:
- Increase the coal flow,
- Put in automatic control the 4 ash extracting
valves,
- Put in automatic control the boiler load,
- Put in automatic control the desuperheaters of
superheaters,
- Put in automatic control the desuperheaters of
the reheaters,
- Put in automatic control the limestone injection.
- observe when steam conditions are satisfied
and IP stress margin shows a steadily
improving trend,
- re-initiate loading (by DCS GRE Load 30 %
reference Hold OFF command) from block 48 MW
load,
- continue to monitor IP stress margin,
- if necessary, reduce the loading rate or re-
impose GRE Load reference Hold (automatic
stress control of loading rate is not enabled
until HP turbine steam flow has been
introduced),
- check that the LP bypass is closed.

CNK 12 M OVE --- OI 112 C 13/17

 STEP ACTIONS OBSERVATIONS DISPLAY
9.03 - Monitor all unit parameters :
. boiler steam and metal temperatures,
. combustor temperatures and air flow,
. water quality,
. condenser vacuum,
. turbine expansion,
. TG vibrations,
. condensate level in HP/LP heaters.
9.04 Stop progressively the oil lances.
10 Load following
10.01 Check that the automatic load follows the needs.
When load has reached : 48 MW
- observe that GRE load control changes from
DIRECT to AUTO MODE,
- observe that DCS GL turbine operation start-
up sequence completes,
- observe that the load now holds until the target
load is reset and the hold released by the
operator,
- observe when the turbine GRE valve opening 60 %
reference signal reaches that the HP governing
valves control will automatically change from
FULL ADMISSION TO PARTIAL.
10.02 Check all majors unit parameters.

CNK 12 M OVE --- OI 112 C 14/17

 550

500
REHEATER OUTLET TEMPERATURE°C

450

MAXIMUM STEAM TEMPERATURE

AT REHEATER OUTLET
400

350

300
MINIMUM STEAM TEMPERATURE
AT REHEATER OUTLET
250

200
0 50 100 150 200 250 300 350 400 450 500 550

IP INNER CASING REFERENCE TEMPERATURE BEFORE START UP °C FROM AVERAGE OF MAB30CT605XV1 & MAB30CT610XV1

FIG 1 REHEATER OUTLET STEAM TEMPERATURE FOR TURBINE START UP

CNK 12 M OVE --- OI 112 C Appendix 1 1/1

 550

SUPERHEATER OUTLET TEMPERATURE °C

500

450
MAXIMUM STEAM TEMPERATURE
AT SUPERHEATER OUTLET

400

350 MINIMUM STEAM TEMPERATURE

AT SUPERHEATER OUTLET

300

250
0 50 100 150 200 250 300 350 400 450 500 550

HP CASING REFERENCE TEMPERATURE BEFORE HP CYLINDER INTRODUCTION °C FROM AVERAGE OF MAA30CT605XV1 & MAA30CT610 XV1

FIG 2 SUPERHEATER OUTLET STEAM TEMPERATURE FOR HP CYLINDER INTRODUCTION

CNK 12 M OVE --- OI 112 C Appendix 2 1/1

 ignition

stop
t/h bar °C %

oil

oil
600

100
200
500

ST-load

Synchronisatio
Turbine start

Coal feeding
550
180
450

90

n
+
500
160
400

80
450
SH-Temp.
140
350

70
5,3 bar/min
400

Steam-flow
120
300

60
350
Steam-pressure

2°C/min
Temperature
Steam-flow

RH-Temp.
300
100
250

50

SH-Pressure
250
200

80

40
200

3000 rpm
150

60

30
150

ST-speed
100

40

HP bypass
20
100

Fuel-rate
20
50

RH-Pressure
10
50

LP bypass
0

0
0

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220
Time (min)
CAN - 2 x 160 MW Appr. Bdj
COAL FIRED THERMAL PLANT Check Pm
Power WARM START-UP CURVE ( 08 to 40h shutdown ) Author Sb
Steam Power Plant N° CNK 00 M --- SC 020 D 04/03/02