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Doc. No.

: CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 1 of 14

START DATE/TIME: END DATE/TIME:

UNIT NO: I/II

(This checklist is applicable when turbine first stage metal temp is < 120 oC.)

Checked By
S.
ACTIVITY CHECKS/STEPS
No SCE/UI DE FE

Confirm no any permit to work (PTW) is pending on BTG and BOP


1
system or equipment.

Ensure that oil levels in MOT, both TDBFP & MDBFP oil tanks, EH oil,
2 HP & LP bypass skid, all fan & coal mill lube oil tanks normal from the
field.
Ensure that oil levels normal in all auxiliary equipment bearing
3
housing.
Ensure that all required electrical system available and charged
4
properly.

5 Take trial of DG sets and ensure that its working normally.

Ensure availability of power supply to all the MOVs in boiler & turbine
6
area.
All the MOV, dampers, Control valves, SOVs and servo valves testing
7
should be done from remote as well as local.
Confirm from C&I that all the control room and local control panels
8
and cabinets power supply is on and indications normal.
9 Ensure all logic testing such as (MFT, ETS) completed.
Ensure all protections and interlocks are in service and no trip alarm
10
is coming.

11 Inform electrical to take Megger of required motors.

Ensure that firefighting system is in operation and all Diesel driven


12
fire pumps trial taken and are available.

inform CHP in advance and ensure that coal levels in all bunker
13
normal
Doc. No. : CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 2 of 14

Inform ash handling plant in advance to keep both bottom & fly ash
14
handling system ready and confirm.

Ensure from chemist the availability of fore bay make up water, Desal
15
water and service water from refinery.

Ensure that water levels in Forebay, Desal tank, DMFT, DMST and CST
16
normal.

17 As Per SOP Start Potable water pump for HVAC IDCT.

As Per SOP Start CW cooling water pump & Lubrication water pump,
18
CW pump & CCCW pump.
As Per SOP Start plant air compressor system and maintain its
19
pressure.
Pre-Start up Checks Boiler Side
Ensure sufficient level in LDO & HFO tank. Also ensure that its
20
forwarding system is available.
Ensure normal oil level in all coal mills lube oil tanks, all fan lube oil
21
tanks, APH gearbox and other auxiliaries.
22 All manholes & peep holes are in close condition
Ensure that air and flue gas path inspection and manhole doors are
23
closed.
24 Furnace probe and flame TV available
Ensure that sootblower system is available and all the sootblowers
25
are in retrated position.
Drum level indicating local gauges and hydrasteps available but
26
isolated.
27 Ensure that Burner Tilts of all four corners at horizontal position.
28 Ensure that all LDO & HFO Oil guns are clean.
29 Ensure that all Scanner & Oil gun cooling hose are connected.
Ensure availability of left & right side cameras for drum level and
30
furnace flame.
Check open & close operation of boiler MSSV and feed water station
31
100% MOV.
Pre-Start up Checks TURBINE Side
Ensure normal oil levels in MOT, both TDBFP & MDBFP oil tanks, EH
32
oil and HP & LP bypass skid.
Doc. No. : CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 3 of 14

Ensure that rotor eccentricity does not exceed 0.075mm and all TSI
33
parameters are normal.
Ensure that no differential expansion or axial displacement of turbine
34
HP, IP or LP cylinder exceeds limitation.
Ensure that temperature difference between HP outer cylinder top
35
and bottom is < 50 oC.
Ensure that temperature difference between HP inner cylinder top
36
and bottom is < 35 oC.
Ensure that HP & LP bypass system is available and take spray line
37
block valve trial of both HP & LP bypass valves.
38 Ensure normal water level in Stator cooling water tank
Turbine Auxiliaries Start-up/checks Sequence before Light up.

39 Ensure proper line up of condenser cooling water system


40 As Per SOP Start one of the circulating water (CW) pumps.
41 Start OCCW pump and line up required PHE and auxiliaries.
As Per SOP Start CCCW pump and line up required PHE and
42
auxiliaries.

43 Start CTP pump and take normal hotwell level.

Ensure that CPU is in bypass and its I/L and O/L isolation valves are
44
closed.

45 Charge CEP header with CTP.

Start one CEP in RC and then maintain normal Deaerator level (400
46
mm)

47 Inform chemist to start LP dosing system.

Start main turbine lube oil system and ensure that lube oil discharge
48
header pressure > 0.130- 0.163 Mpa.

49 Check inter lock of AC LOP and DC EOP

Maintain instrument air pressure inside generator up to 0.3 to 0.5


50
kg/cm2.
51 Start Generator Seal Oil System.
52 Start H2 filling as per SOP.
53 Start Jacking oil system & Engage TG on Barring gear.
Doc. No. : CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 4 of 14

Boiler Auxiliaries start-up/checks Before Light up

54 Fill seal trough and ensure that BAH over flow is there and optimized.

55 Ensure that ESP is available and start its heater

56 Start lube oil system of both ID, both FD & both PA Fans.

57 Start lubes oil system of all six coal mills.

58 Charge HFO atomizing and HFO heating steam line

59 Start one HFO pump and put it in to short recirculation cycle.

60 Start LDO pump and put it in to short recirculation cycle.


Ensure that boiler drum and SH vents are in open condition
61
(Cold start up)
62 Ensure that back pass drains and vents are open

63 Ensure that SH drains are open & header drain also open
Ensure that RH drain and vents open (17 meter RH drain open) and
64
the same should be closed before vacuum pulling.
65 Open Economiser recirculation valve.
Take drum level up to 300 mm and ensure the level with hydra step &
66
local gauge glass also.

IF boiler stop for long time then start Internal Cavity flushing of BCP
67
with CTP line and take magger of BCP motor

68 As per SOP Start MDBFP and fill Boiler upto Normal level (-50 mm)

69 Ensure BCP cooling water flow (9-12 TPH)

70 As Per SOP start two BCP pumps One by one (first start middle one)
Start AC scanner air fan and put DC scanner fan in to back up and
71
ensure standby DC scanner operation
72 Start both air pre heater (APH) one by one

73 Put SCAPH in line


Doc. No. : CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 5 of 14

Boiler Light Up

74 Before light up ensure TG rotor on Barring.

75 As Per SOP Start One ID Fan and maintain furnace draft -50 to -100 Pa
As Per SOP Start One FD Fan and maintain furnace draft -50 to -100
76
Pa
77 Similarly start Second ID and FD Fan.

78 Establish air flow between 30 to 40% and draft -50 to -100 Pa

79 Ensure all purge permissive satisfied & Start Boiler purging.


Charge APH soot blower line from service airline. If one unit is
80 running charge from Auxiliary Header

When Purge completed set SADC such that Furnace DP between


81
0.38 KPa to 0.45 KPa
82 Bypass LDO & HFO Leak test, open LDO supply & Return Trip valve.
Put HFO on long circulation for increasing temperature above 100 C.(
83
Firing permissives-100 Deg C )

84 Set LDO pressure 3- 3.4 MPa & take AB elevation LDO Gun in service

Take 1st LDO gun in service and ensure flame healthiness from local as
85
well as DCS.
Take second gun in service and monitor Drum metal temperature
86
rate of rise.
As soon as boiler is light up open continuous blowdown valve to
87
100%.
Rotate the oil gun one hour once. Monitor the Metal temperature
88
difference. (Left & Right)
89 Close drum vent at Drum Pr > 0.2 Mpa
Close SH & RH drains and back pass drain at drum Pr > 5Kg/cm2 &
90
150 Deg C.
91 Charge Aux header from MS line at 0.5Mpa.

92 Charge FOPH steam line from aux header.

93 Raise HFO temp >100C at forwarding heater outlet by recirculation.


Doc. No. : CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 6 of 14

94 Take HFO in long recirculation and raise temp.


95 Take HFO gun of BC layer when hot secondary air temperature 150 C.
Maintain HFO pressure 1.3 -1.5 MPa and adjust SADC (Flame intensity
96
90 %)
Take other BC elevation guns according to temperature rise
97
requirement as per start up curve.
Take SCAPH out of service when cold end flue gas temp reach to 120
98 o
C.
Charge Deaerator pegging line and increase Deaerator water
99 temperature slowly (ensure that boiler is filled with cold water 40-60
C before Deaerator water temp raised).
As Per SOP start Vacuum pulling. When Vacuum reaches - 75Kpa
100
Charge HP & LP Bypass line.
Ensure that required permissive for HP LP bypass operation
101
established like MDBFP & CEP running.
102 Open charging valve of LP bypass after resetting

Gradually seeing drum pressure and level open HP bypass up to 30-


40% in accordance with the MS & RH steam pressure and
103 temperature requirement.

Open LP bypass valve looking at RH pressure before LP bypass.


104
Ensure that this pressure remains < 0.1 MPa.
Open HP bypass spray only when downstream steam temp of HP
105
bypass is > 320 oC.
Open LP bypass spray looking at the steam temperature on
106
downstream of bypass valve.
107 1st Coal Mill Start (when hot secondary air temp > 177 oC)

Ensure PA fan air path to boiler is through (open CAD, CAG and all
108
four MDVs of min 2 coal mills)
109 Open seal air MOVs of at least two coal mills

As per SOP Start both PA fans one by one and maintain its header
110
pressure

111 Start seal air fan one by one and maintain its header pressure
Doc. No. : CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 7 of 14

When hot secondary air temp rises to 177 oC start either of coal mill A
112
and start coal feeding at rate max 25 TPH.
Once coal feeding started based on temp & Pr rise requirement
113
optimise no of LDO & HFO guns
Raise MS/RH temperature up to 340/300 oC respectively and MS/RH
114
pressure up to 5.9/1.0 MPa respectively for TG rolling.

Take 2nd coal mill after generator synchronisation. Adjust both mill
115
coal flow and optimise no of LDO & HFO guns according to load.

116 Take 3rd coal mill at 180 MW load

Remove all oil guns from service at appx. 200 MW load once three
117
coal mills are running.
118 Further according to load requirement take 4th and 5th coal mills.

Regulate the boiler continuous blow down valve according to chemist


requirement based on silica content in boiler water. Maintain drum
119
pressure vs silica according to below table.

120 Start Stator cooling water system. Ensure H2 pressure 200 Kpa
121 Start turbine EH oil system
TG Rolling
Ensure that all turbine auxiliary equipment runs normally and their
122
parameters are normal.
123 Ensure that TSI parameters are normal
124 Ensure required steam parameters for TG rolling achieved.
125 Start HP start up oil pump.
Ensure that all MSV, GV, RSV, IV, CRH QCNRV and all extraction
126
QCNRV are close.

127 Ensure that turbine valve control is in Single Mode


Reset turbine from local or DCS ETS page and ensure that turbine
128
tripped signal is removed and all alarms are reset in ETS page.
Ensure that RSV opened fully and Enable roll green light is on after
129
turbine reset.
Doc. No. : CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 8 of 14

130 Select Automation in control mode on DEH page.

131 Set Valve limit 120 %


Give speed target 600 rpm at ramp rate of 100 rpm and click on ACK
132
& GO button.
Ensure that turbine starts rolling and its MSV and IV are in control
133
mode during rolling while RSV and GV are fully open.
Open HP exhaust control valves by maintaining HP exhaust
134
temperature (<426 oC).
Ensure that turning gear disengages in auto and stop turning gear
135
motor manually at 200 RPM.
Throughout turbine rolling keep watching all TSI parameters, HP
136 exhaust ratio and temp and other turbine parameters. Ensure that
they are normal.
Throughout rolling ensure that no abnormal sound, vibrations and
137
leakages from the field.
Throughput rolling and subsequent operation maintain lube oil temp
138
40-45 oC.
139 Give open command to CRH QCNRV. If not opened in Auto.

140 One by one put all LP heaters in service at 2000RPM.

141 Once turbine reaches 2000 RPM soak turbine for 150 Mins.

142 Latch One TDBFP and start rolling as per SOP


143 Put TDBFP in warm up condition with Aux. header

After 150 min soaking give next speed target 2900 RPM at the ramp
144
rate of 150 rpm
Ensure that JOP stops at 2600 RPM in auto and put it on standby
145
mode.
Ensure Degree of superheat between MS temperature & Control
146
valve first metal stage temperature
At 2900 RPM valve changeover from MSV to GV is permitted. Click on
147 MSV/GV transfer button in DEH, slowly MSV will open full while GV
will slowly set to required controlling position.

148 Now raise speed up to 3000 at the ramp rate of 50 rpm/min.


Doc. No. : CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 9 of 14

149 Ensure all CCCW control valves in Auto Mode

Generator Synchronisation
Ensure that following conditions are met before turbine
synchronisation
- turbine runs with speed of 3000r/min and is stable; DEH
device is normal
150
- All control indications are normal when turbine runs with no
load; auxiliary equipment are normal
- If required tests under 3000r/min for unit are completed
- Main steam temperature and steam pressure are stable

Before Starting Synchronization, Check Whether Generator


Relay Panel A & B Lockout Relay Should Be Reseted.

To Reset Lockout Relay, Press B12 & B13 Push Button In Relay
Panel A And Press B22 & B23 Push Button In Relay Panel B.

If Turbine Speed Reaches 3000 Rpm, Close Fcb By Close And


Ack Button.

Then Open Excitation Menu And Click Excitation Start & Ack
151 Button.

The Voltage Will Build Upto 19.98kv. Check The Grid Voltage
Level, Accordingly Raise Excitation.

Then Open Auto Sync Menu In Generator System Window

Check Auto Sync Selected Or Not, If Not, Change The


Selector Switch In Generator Control Panel Into Dcs.

Click Automatic Sel Switch Reset &Ack Button (One After


The Other Within 2 Sec)
Doc. No. : CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 10 of 14

Then Click Select Gcb & Ack Button (One after the Other
within 2 Sec).

Check Any Alarm (Fault) From Auto Synchronizer Panel In


Auto Sync Menu

Then Select Auto Sync Control In DEH Menu.

Then Wait For Auto Sync Permit From DEH In Auto Synch
Menu. If Auto Sync Permit From Deh Came, Press Start
Sync And Ack Button.

Auto Synchronization Will Start After Press Start Sync Button


And Ack Button.

Wait For Breaker Close Status.

If Any Abnormalities, Press Stop & Ack Button

If Gcb Closed, It Will Be Displayed As Synch Success

152 Once above confirmed synchronize the machine with the grid

153 After Synchronisation Block load of 30 MW shift to turbine

Slowly close HP exhaust control valve looking at the HP temperature


154
(<426 C).

155 Close HP and LP bypass gradually by observing Drum level

Ensure that main oil pump outlet pressure is 2.0-2.3 MPa and inlet oil
156
pressure is 0.12-0.14 MPa.
Stop running AC AOP and HP back up pump and put both on standby
157
mode.

158 Regulate lube oil temp between 38-42 C.


Doc. No. : CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 11 of 14

Watch Winding temperature, H2 temperature (40-45 C), PF and


159
Voltage of Generator.

160 After synchronisation put required control loops in auto.

After synchronization heat up the machine at 5% rated load (30


MW) for 30 minutes, during this period maintain steam temperature
161
& pressure, ensure that temperature rising rate is not more than 83
o
C/hr.
Ensure all TSI parameters, EH oil pressure and temp difference
162
between top & bottom cylinder normal.
Refer turbine cold start up curve for load and MS & RH pressure and
163
temperature raising rate.
From 30 MW 180 MW (max 3 mw/min)
Looking at the LP cylinder steam exhaust temp (<50 C) gradually close
164
the hood spray valves.

165 Start 2nd Coal Mill as per SOP.

166 Raise the load to 120 MW and do the following (steps 3-6)
At 120 MW load check whether all turbine steam pipe drains close in
167
auto.
Charge all three HP heaters keeping feedwater outlet temp rise < 1.5
168 o
C/min.

169 Start 2nd TDBFP rolling as per SOP

When 4th extraction steam pressure is > 0.165 MPa, Deaerator steam
170
source is switched over to 4th extraction steam.

171 Gland steam source can be changed to CRH from aux steam.

172 Start 3rd Coal Mill at 120MW and raise the load.

173 At 180 MW change FRS 30% to 100% valve.


At 180MW load put running TDBFP in parallel with MDBFP and
174
maintain the drum level.
From 180 MW 300 MW (max 6 mw/min)

175 Start 4th Coal Mill at 180 Mw


Doc. No. : CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 12 of 14

Raise the load to 240 MW and do the feedwater valve changeover


176
from 30% CV to 100% MOV.
At 240 MW load change Aux. header from MS to CRH and close
177
interconnection. Put MS source in back up.

178 At 280 MW Cut out all Oil elevation & take ESP in service.

From 300 MW 600 MW (max 12 mw/min)


At 300 MW load Put 2nd running TDBFP in parallel with already
179
running feed pumps. Unload MDBFP and put both TDBFP in auto.
180 Take CPU in to service.

At 360 MW load put the unit under CCS mode after fulfilling required
181
permissive.

182 At 360 MW Change extraction source for both TDBFP from Aux to 4th.

183 Stop MDBFP and put it in to standby.

184 Raise the load further based on start-up curve and SLDC requirement.

185 Start the 5th Coal Mill

186 Raise the Load upto 460 MW

Take turbine governing control from single to sequential control after


187
all turbine expansions are normal and expanded properly.
Self-sealing of Turbine achieved. Maintain Header pressure between
188
18- 24 kpa, by opening the dump control valve to flash vessel.

189 Start 6th Coal Mill

190 Raise the Load up to 600 MW.


Doc. No. : CEPL/OPN/CL/002
2x600MW Mutiara Thermal power Rev. Date : 20/05/2016
Plant
CHECKLIST FOR UNIT COLD START UP
Revision : 00
Page 13 of 14

Total duration for startup:

Delay time for startup:

Oil consumption LDO/HFO:

Reason for the delay:

Major problems faced:

Name Shift Date Sign


Field
Engineer
Desk
Engineer
Unit in
charge
Shift in
charge