NTPC LIMITED CORPORATE OPERATION SERVICES (BOILER) Re 16/BLR/CC/BTL Date: 18.04.2014 Sub: Review of Boiler Start Up procedure on account of boiler tube failure occurred during boiler startup. Since, some of the boiler tube failures in water wall, SH & RH took place during boiler start-up in various NTPC stations, it was decided in ROPR of ER -ll held at TTPS on 16.08.2013, to constitute 2 committee to review boiler startup procedure. A committee having members from Sipat(WR Il), Ramagundam (SR), TSTPS(ER I!) Rihand (NR), Dadri (NCR), CC-Operation and CC-Boiler was constituted con 02.09.2013 by the competent authority vide note sheet dated 26.08.2013 (copy enclosed). First meeting of the committee was held on 10.09.2013 at EOC Noida.The Committee discussed in detail the boiler startup procedure given by manufacturer for Cold, Warm and Hot startup in 1st generation 500 MW boilers and present boilers. Current practice of boiler startup during safety valve floating was also discussed and it was observed that there is no boiler startup procedure existing for safety valve floating elther in manufacturer's manual or in NTPC guidelines. It was decided to make a procedure for the same. Some of the stations are using primary fuel (fuel oil) only during safety valve floating since unit commissioning. Hence, these stations advocated use of fuel oll during safety valve floating. However, other members had apprehension regarding the rate of rise of pressure, accomplishment of the required pressure and consumptionaf time for actual floating of safety valves using fuel ol. Therefore, it was decided to demonstrate it in one or two stations before inclusion of the same in start up procedure. ‘Adjustment of set pressure of safety Valves both by trevi and actual floating as well as blow down adjustment was done at following stations by firing fuel oll only. 4. Adjustment of set pressure of safety valves with trevi followed by actual floating and adiustment of blow down was done in 210 MW Unit #3 Dadri on 06.10.2013 with 4 HFO oll guns having 116 tips. ‘Approximate time taken from boiler lit up to last safety valve floating was 09 hrs, Rate of pressure rise at the time of actual safety valve floating was 3-4 Ksc. Also there was no difficulty in accomplishing the required pressure. 2. Adjustment of set pressure of safety valves with trevi followed by actual floating and adjustment of blow down was done in 500 MW Unit #3 Rihand on 12.10.2013 with OBHFO ofl guns (124 Tips) in service, 9! gun was taken in service during floating of highest pressure drum safety valve. [Approximate time taken from bolle lit up to last safety valve floating was 09 hrs excluding the u specific problems. Also there was no difficuty in accomplishing the required pressure.3, Adjustment of set pressure of safety valves with trevi followed by actual floating and adjustment of blow down was done in 500 MW Unit #2 Simhadri on 04.12.2013 with 08 HFO oil guns (J24 Tips) in service. 9" gun was taken in service during floating of highest pressure drum safety valve. ‘Approximate time taken from boiler lit up to last safety valve floating was 09 hrs excluding the unit specific problems. Also there was no difficulty in accomplishing the required pressure. Salient features of above demonstration are as follows: 1. Pressure of 160 Ksc were achieved within 3hrs 2. Due to precise control of pressure within one Ksc,trevi and actual floating were done quite accurately. 3. Drum level remained quite stable during the process. 4, Time taken from boiler start up to hand popping, trevi of all valves and actual floating of MS, Drum and RH valves was approximately 09 hrs excluding the unit specific problems. Next meeting of the committee was held on 16.12.2013 at EOC Noida to deliberate and finalise the boiler start-up procedure for safety valve floating. After detailed deliberationboiler start up procedure during safety valve floating was finalised for drum type boilers. Boiler start up procedure after BTL when Boiler is cold but turbine is Warm/Hot, was also deliberated in detail as no standard guidelines exits even in this case either in manufacturer's manual or NTPC guidelines andit was further observed that current practices are varying from station to station and are not consistent. Therefore a procedure was made for boiler start up after BTL. However one of the members suggested to demonstrate this procedure in one or two stations before finalizing the same. Demonstration of the draft start up procedure after BTL was done at the following stations: 1. 500 MW Dadri Unit #6 was done on 22.12.2013. 2.500 MW Simhadri Unit #1. was done on 06.01.2014 3.500 MW Simhadri Unit #2 was done on 07.01.2014 Salient features of above demonstration are as follows: © Pressure up to 60-80 Ksc was raised by fuel oil only, in approximately 150 minutes with 08 HFO oil guns in service. ‘© 1 lowermost Mill cut in after achieving rolling pressure to raise steam temperature as per TSE * Mill loading kept at minimum (20-25 t/hr.) to control rise in metal temperature. * After achieving the required steam temperature, turbine was rolled and unit was synchronized in approximately 03 hrs. ¢ No SH and RH spray were given before synchronization.Third meeting of the committee was held on 11.02.2014. The Committee discussed in detail all the above demonstrations and finalized the procedure for boiler start up after BTL. Thus boiler start procedure during safety valve floating followed by rolling, synchronization and full load have been finalized for drum type boilers. Boiler start up procedure after BTL which is similar to warm start up has also been finialised. Both the procedures are enclosed here with. Start Up curves for above procedures for old & new 500 MW boilers are also enclosed here with. Boiler start up procedure for hot start up will remain same as per manufacture’s start up procedure. Put up for kind perusal please. aber oh=0a (VinodChoudhary) GM COS-Boiler ED (ds) yo 7 Cee tt as Ment! La ee Ron Scere ; ks ST) conmedsgt O85 io 7 Deb ea ferent D Evy Wate en be . alos) 214u Ghat" @ OS-ST; Start up wise comments are as follows; A. Cold start up after overhauling; Pl. include : ‘Step__| Time Unit condition [ Operation Notes OL 00 Line up main steam, CRH and HRH steam lines for charging by ‘opening respective line drains and ensuring manual isolating valves are open. 2 1150 ‘Start second TDBFP with steam supply from extraction steam. ‘After cutting in second TOBFP, wait for stabilization and then switch off MDBFP. B. WARM start up (HP shaft temperature 300-400°C: Step | Time Unit condition | Operation Notes 02 60 ‘While seal steam charging into turbine glands, ensure that auxiliary seal steam temperature upstream of gland steam supply valve is more than 240°C and for New generation 500 MW fleet i.e. \VSTPS St. 2 onwards, charge PRDS through CRH steam, isolate CRH ‘Spray and maintain PRDS header ‘temperature such as to get 285°C+ at 8.5 meter, TG area, upstream of seal steam station. 06 190 ‘Start TDBFP after ensuring thorough draining of steam supply line. 10 290 ‘Start second TDBFP with steam ‘supply from extraction steam. Wait for stabilization and then switch off MDBFP.Sheet “A” Cold start up after Overhauling 1. Steam dumping takes lot of time (10 to 12 hrs). During this time after reduction of steam parameters subsequent to safety valve floating, bottom most mill may be taken in service with minimum feeder speed. 2. Once steam purity is achieved the turbine warm up may be started while condensate is to be dumped outside. Make up is to be given in deareator. 3. Attthis stage CPU is to be kept in service with 50% flow to obtain condensate quality. Once condensate quality is achieved, it can be put in closed circuit operation. 4, Rolling and electrical testing may be done with bottom mill with feeder running at minimum speed. 5. During 100% oil firing APH soot blowing needs to be done continuously. Oil carry over probe have to be inspected every 4 hrs. for any collection of oil. All APH temperatures should be recorded every half an hour. Light up after boiler tube leakage 1, There is no need to take mill into service during light up after boiler tube leakage. 2. Mill can be kept spinning (Turbine speed at 3000 rpm) to start coal firing immediately after synchronization. 19.8 Ny ee (08 ~ fom)SI.No. BOIER START-UP PROCEDURE CONTENTS DESCRIPTION BOILER START UP PROCEDURE:SAFETY VALVE FLOATING FOLLOWED BY UNIT SYNCHRONISATION AND RAMP UP UPTO FULL LOAD. (500 MW Drum Type Boiler- COLD START UP)). BOILER START-UP PROCEDURE AFTER BTL: BOILER COLD AND TURBINE WARM/HOT ( 500 MW Drum Type Boiler- WARM START UP)BOILER COLD START-UP (Preparations) (600 MW Drum Type Boiler) A Cold Start Up is by definition, one which the maximum of HP casing and HP shaft is less than 150°C. ‘STEP | TIME | UNIT CONDITION OPERATION NOTES 0 Boiler Pressure ‘0 Ksc| Charge Aux. Steam header from and Temperature: | existing units. Pr. & Temp. as per Ambient design. Charge steam to fuel oil pump house, atomizing steam and tracing steam Charge Deaerator warming up line Start tank heating of HFO oll Start one HFO pump on recirculation ‘as soon as the sufficient oil temp at inlet is achieved Charge HFO to boiler front and keep it on long recirculation, with heaters control set on ‘Auto’ to. maintain 120°C. Fill water in drum upto + 200 mm. Start service air compressor and fill the air receiver tanks of SAPH & PAPH are filled. Ensure that purge air to HEA is open in all comers. Line up Air and flue gas circuits for start up. All the steam tracing lines ‘and. electrical tracings in pump house & boiler to be charged, Check dampers and gates and register position. Fumace bottom ash system and seal through lined up. LP & HP chemical dozing systems are ready,SADC panel readiness. Check for air pressure in all the comers and elevations. Ensure Aux. Air dampers are modulating, Power supply for all the valves and dampers are ON. Ensure the oil unit is running Readiness of HP bypass pane! in | and all the bypass and spray all respects. valves are closed. Ensure drum level is + 200 mm, and the drum air vents Start one of the CC pumps. aBOILER COLD START UP AND SAFETY VALVE FLOATING PROCEDURE (600 MW Drum Type Boiler) ‘STEP | TIME | UNIT CONDITION OPERATION NOTES 01 00" | Boller ready forlight | Start 4 burners in “AB” elevation | Check that SH & RH up and Turbine on | with LDO. vents are open. Turing gear. ‘SH & RH drains are open. MSV's closed & drains before MSV open. ‘After 30 minutes, take additional burners and limit drum metal temp. raise of < 2°C/minute. Regulate oil pr. To 8-10 Kglem? Ensure atomizing steam pr. About 6 Kg/cm? Change over AB elevation to HFO Charge SCAPH Charge APH soot blowing (Pr 10-12 Ksc) Airheater soot blowing to be carried out regularly Charge oil carry over probe Ensure availability of IRDS Ensure Cold end basket view glass light Keep open the Eco. Recirculation valve Till 30% BLI Charge heating steam to Deaerator from Aux. PRDS.‘Open HPEP warm up valves. 02 | 60" | Boiler Drum pressure | Close SH & RH header vents 2 kglom? ‘Open MSV by pass lines MS, HRH & CRH lines will get warmed up. 03 | 400° | Boiler Drum pressure | Open Main steam valves. 5 kglom? ‘Open HP by pass 8-10 %. Close SH & RH drain at 14 Ksc Drum Pr. Close HPBP warm up valves. 04 | 165" | Boiler Drum Pressure | 08 HFO guns in service with oil | Positive pressure to be 60 kgfom? pressure 9-10 Ksc ( Gun Tip J24) | maintained in RH CKT throughout Safety Valve floating operation 05 | 190" | Boiler Drum Pr. 120 |ERV checking by manual kglom? ‘command from UCB 06 | 200" | Boller Drum Pr.160 [Hand Popping Approx60 min kglem? activity 07 | 260" Boller Drum Pr. 175 | Trevi setting 2 hours ( 8 valves - kglem? ‘MS+Drum) 08 | 380" | Boiler Drum Pr 185- | Actual Valve floating (Drum + Main | Ensure drum level 210 Steam) within limits {{frequired take 09" gun in service) 08 | 440" | Boiler Drum Pré0 | Trevi of CRH & HRH ( lowest | Cutoffoil gun at EF and Ksc pressure set valves) CD to reduce firing and ‘maintain Pressure. HRH PR 40 KSC 40 | 480" | Boiler Drum : 60 ‘Actual floating of CRH & HRH kglom? HRH:40-50 kgiom? Safety Valves7 [540 Safely Valve Floating Activity completed 72 | 660° | Reduce MS Prto50_| Do Steam dumping & get clearance Ksc of chemical parameters 73 [660° | MS Pressure: 50 kg’ | Turbine speed will be raised to 360|To achieve the com? rpm through SGC-Programme programme as per the starting curve, the main MS Temp: 350°C. steam temperature should be maintained en Sod odin ut 50 MW. HRH Temp: 350°C Turbine ready for rolling 74 [720° | MS Pr. 50 kglem®, | Turbine speed will be raised upto | Control firing to maintain 350°C Turbine 3000 rpm — through SGC- | Pressure & Temp. running at 360 rpm. | programme. 75 | 960 | MS Press: 50 kg/cm? | Electrical Testing, Oil Injection tests MS Temp.: 350°C Turbine speed: 3000 pm 76 [970 | MS Press: 60 kgicm? | SGC programme will switch ON Ensure SGC startup field breaker, put AVR. on auto, | programme is MS Temp.: 350°C synchronise completed. Turbine speed: 3000 rpm Raise the speed set point and pick up the load upto 50 MW. Increase HPBP set point Ensure closure of HPBP steam valves & spray valves. Close other drains of M'S.CRH and | Drain pot drains of MS, HRH, keeping SLC drains ‘ON. | CRH, HRH_ extraction steam lines will operate ‘as per the actuation of level switches. 7 [990 | toad: 55 MW Start seal air fan and PA fan and | Before starting P.A. fan,MS. 54 kglom?/350°C HRH: 12 Kg/om?/340°C My $- Floor 7200 Thy take first mill in service. ‘ensure that air and gas | dampers of Primary Air Preheaters are open. ‘Start the second set of ID & FD fan. Make ready SH & RH spray systems. Cutin L P.heaters 2 and 3, Ensure switching on of load controller above 60 Mw. Cut out heating steam from Aux. P.RDS. to Deaerator. Peg. Deaerator from CRH steam gradually upto 2 kg/cm? Cutin all auto Controllers. MS: 90kg/om?/380°C. HRH:20kg/om?/380°C Steam Flow: 580t/hr. dif. Pressure to 100 mm W.C.by adjusting SADC. 78 0/1020 | Load: 170 MW ‘Charge Aux. PRDS station from | Ensure energizing of RH. Cut in spray and maintain a | solenoid in trimming MS: 70 kglem/370°C | temperature of 250°C. device at and above ry 4100 MW load, kglom?/360°C Peg Deaerator gradually to 4 | Raise the pressure set kglom point of | Deaerator pressure controller gradually. Cut in lind Mill and cut in auto | Rate of increase of controllers. coal firing to be less than 1.5 T/Min 79 | 1050 | Load: 160 MW Tnorease the wind box to furnace Charge HP. heaters 5A, 5B, 6A and 6B, Put controllers on auto. ‘Start first TDBFP & second CEP.Charge Deaerator pegging steam from CRH to Extraction around 200 MW load, Cut in Ilird mill and cut in auto controllers. Ensure Deaerator Pressure controller remains as auto, 20 [7080 | Load: 250 MW Sart second PA Fan ms: Cut in IVth mill and cut in auto 120kglem2/410°C —_| controllers. HRH: 26kglem2/400°C Steam Flow: 820vhr. Before starting P.AFan ensure that air and gas dampers of PAPHs are open. 27 | 4150 | MS:125kg/eme/420°C | Cut off oll support completely HRH: 28- 30kgiomer420°C a Cut in second TD BFP and'Suitch Load: 320 MW off motor driven BFP. S Ensure healthiness of ‘Steam flow: 1040vhr. | Cut in Vth mill and cut in auto | fire ball scanners. controllers. Load: 405 MW Steam flow: 1310¢hr. 2 [7230 | MS: 170 Cut in Vith mil along with is kglom2/475%C controllers. Increase the set point of SH & RH spray controllers such HRH that rated parameters are achieved 40.5kgiom"475°C | gradually Load: 500 MW 3 [1320] MS: 170 kolem/535%° HRH: 40.8 kglom2/5359C Load: 500 MW Steam flow: 1570Uhr.Boiler Start Up after BTL (Warm Start Up) (600 MW Drum Type Boiler) ‘Above start up is, by definition, one which the maximum of HP casing/ HP shaft temp. is between 300°C and 400°C. This normally means that the unit is shut down from the maximum load for one to two days. Depending upon the absolute temperature of HP casing and HP shaft, steam parameter are derived. Boiler is in cold condition Warm Start up Preparation: ‘STEP | TIME | UNIT CONDITION OPERATION NOTES 0 0 Boiler drum pr = 0 | Charge auxiliary steam header from kg/cm? existing units. Pressure & Temp as per design. Charge steam to fuel oil pump house, atomizing steam and tracing steam. f Charge Deaerator warming up line Start tank heating of HFO oil ‘Start one HFO pump on recirculation as soon as sufficient oil temperature at inlet is achieved. Charge HFO pump to boiler front and keep it on long recirculation with heaters control set on auto to maintain 120°C, ‘Start ID & FD fans. Charge Steam Coil Airpreheater concerned with the running FD fan. Initiate boiler purge. Line up main steam, CRH and HRH steam lines for charging by opening respective line drains, Line up FSSS panels in all respects.STEP | TIME | UNIT CONDITION ‘OPERATION NOTES 01 | 00" | Boiler ready for light | Start 4 bumers in ‘AB’ elevation | Check that SH & RH up and turbine on | with LDOMFO. vents are open, turing gear. Guns to be taken only after ensuring availability of APH soot blowing. APH soot blowing to be done regularly. Ensure availabilty of IRDS Ensure Cold end basket View glass light Charge Oil carry over probe. Boiler drum pressure Ensure atomizing steam = 0 kglom? SHIRH pressure of about 6 Header Temperature kglome. between 150°C and 300%. ‘Take additional burners, limit drum | APH soot _ blowing ‘metal temperature raise of < | Pressure 10-12 Ksc. 2Ciminute. Regulate oil pressure to 8-10 Kglom? 02 [60° | Boller Drum Pr. 2Ksc | Close SH & RH header vents. ‘Open HPEP warming up valves. ‘Open MSV by pass lines. 03 | 100" | Boiler Drum Pr5Ksc | Open Main steam stop valves. Ensure MS, CRH & HRH lines get warmed up. ‘Open HP by pass 8-10 % and close the HPBP warm up valves, Close SH & RH header drains at 14 ksc Drum Pressure. in case of fit up after hydro - Take special ‘are of draining,Put HP by pass spray control on auto. Start one P-A fan and seal air Fan Before starting PA Fan ensure that air and gas dampers are open. (04 | 165" | MS: 80-100 Ksc ( as | Take EF elevation US and Float Mill per rolling curve | Awhen MS flow > 200T/Hr) requirement) ‘Temp - 3658C HRH:12kg/cm?/325°C 05 | 190" | MS Pr: 60-100 Kse (| Cut in First lower most Mill and | No SHIRH spray Is to ‘as per rolling curve | maintain min coal flow ) be given. requirement) Secondary Air temp MS Temp :As per >175°C TSE Reduce firing HRH Pr: 12 Ksc accordingly to control, Temp. rise < (Make HRH Temp As per ready SH & RH spray TSE system) 06 | 200" | Turbine running at | Synchronise the Generator with grid. 3000 rpm, Pick up 50 MW load by operating speeder gear. Increase HPBP set point. Ensure closure of HPBP steam valves & Float 2nd mill spray valves. Increase Mil A firing Firing to be regulated ( Rate of increase of Charge ESP Fields. Coal Fans tet bs limited to <1.5 Timin upto 50% TMCR load) to limit any abrupt spray requirement. 07 | 220" J Load: 60 MW Cutin LP heaters 2 and 3 Ensure switching on of load controller at 60 MS: 60 Ksc Mw. MS Temp :As_perrequirement. 07 | 220° | Load: 60 mw Cutin LPheaters 2 and 3 Ensure switching on of load controller at 60 MW. MS: 60 Ksc MS Temp :As per TSE Cut out heating steam from Aux PRDS to Deaerator. Change Deaerator pegging steam es from CRH to Extraction steam. Catin all auto controllers. Cut in 2nd mill and cut in auto controllers. 08 238° | Load: 110 MW ‘Charge Aux. PRDS station from | CRH. Cut in spray and maintain a MS:80 kg/cm? temperature of 250°C. MS Temp :As per TSE Cut in H.P.heaters and put the level controls on auto. Cut in 3rd mill and cut in auto controllers. 08 | 260" | Load :150 Mw Start Second Pa Fan Before starting PA Fan ensure that air and gas MS: 100 Ksc/435 °C dampers are open. Controt_main steam and reheat steam temperature by using spray if required Cut in 4th mill and cut in auto | Ensure healthiness of fre controllers. ball scanners Start withdrawing oll _support‘gradually. 70 [290° | Load: 250 mW ‘Cut in Sth coal mill and cut in auto controllers. 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