of 134

Simulator Generic

Published on December 2016 | Categories: Documents | Downloads: 11 | Comments: 0
66 views

Generic Simulator

Comments

Content

OPERATING MANUAL
670 MW Coal Fired Power Plant Training Simulator

Steag Power Plant Learning Centre
Steag Energy Services India Pvt. Ltd.
A-30, Sector -16, Noida, (U.P.) - 201301

GENERIC TPP SIMULATOR STARTUP PROCEDURE
INITIAL CONDITION
This exercise begins with the unit ordered to startup following an extended unit outage. The student performs preliminary
checks and lineups; if necessary, fills the hotwell, deaerator, and boiler; starts the boiler; warms, rolls and synchronizes the
turbine, and increases load.
The exercise is normally initialized at a condition representing deaerator, hotwell and boiler drained and no power to the
unit buses.


LP01A Cold SU: Vessels Empty / No Plant Power

However, if desired, the simulator can be initialized with vessels filled to their normal operating levels and /or unit buses
energized.




LP01B Cold SU: Vessels Empty / Plant Power
LP01C Cold SU: Vessels Filled / No Plant Power
LP01D Cold SU: Vessels Filled / Plant Power

The exercise is complete when the unit is stable in Coordinated Control Mode (the Boiler Master in auto and the Turbine
Master in auto) at a load of ~300 GMW with boiler firing on coal and fuel oil shutdown.
STARTUP PROCEDURE SUMMARY
Following are the major steps involved in this exercise:
1. Line up the plant electrical system and provide power through the Startup Transformer to all switchgear, load centers
and motor control centers required for a startup to full load.
2. Place the Compressed Air System in service and line up the Instrument Air and Compressed Air Systems.
3. Line up and place in service the Closed Cooling Water system with one closed cooling water pump in service and
establish closed cooling water flow through various equipment coolers.
4. Line up and place the Vacuum Priming System and Circulating Water System in service with three circulating water
pumps in operation and establish flow through the main condenser and to the closed cooling water heat exchangers.
5. Line up the Condensate Storage System and fill the Condenser Hotwell to 65% (±5%).
6. Line up and place the Condensate System in service and fill the Deaerator:
- Place Condensate Pump A in operation and establish condensate recirculation flow through the GSC back to the
condenser
- Place Condensate Pumps B and C in Standby
- Fill the Deaerator to 65% (±5%) and begin Condensate circulation from Condenser to Deaerator and back
- Line up and start ammonia injection to the Condensate Water at the Drain Coolers Inlet
- Maintain Condensate circulation and ammonia injection until the Condensate water quality is satisfied (~9.3 pH)
7. Lineup the Feedwater System. Line up valving to fill the boiler through the Boiler Fill Valve and fill the boiler until
the drum level is 200mm (±50mm).
8. Line up and fill the Seawater Scrubber Absorbers and FGD Emergency Cooling Water Tank.
9. Line up and place in operation the Main Turbine Lube Oil and EHC Systems.
10. Line up and place in service the lube oil systems for BFPT A and BFPT B. Place both BFPT's on turning gear.
11. Place the Main Turbine Turning Gear system in service.
12. Lineup and place the Stator Cooling Water system in service.
13. Lineup and place the Fuel Oil System in service with one Fuel Oil Pump running and the other two in auto.
14. Fill the boiler and lineup and start the Boiler Circulating Water Pumps with two pumps in operation.
15. Lineup and place the Bottom Ash Handling system and Bottom Ash Seal Water System in service. Lineup and place
the Combustion Air and Gas System in service and establish 35% airflow while maintaining a furnace pressure of 0.13kPag with two Induced Draft (ID) and two Forced Draft (FD) fans in service.
16. Conduct the specified Draft Plant Interlock Tests to insure the MFT interlocks function correctly.
17. Complete final checks in preparation for light off.
18. Place Elevation AB Oil Guns in service and control the boiler firing rate to limit the rate of saturation temperature
change to 222°C/hr and the furnace exit gas temperature to < 538°C. Place the Air Heater Sootblowers in service.
Place Deaerator pegging steam in service with a setpoint of 40kPag.
19. After the drum pressure > 1000kPag, place the Seal Steam System in service using either Main or Auxiliary Steam
Jharsuguda Generic Startup Procedure
Rev. 04

1-1

GENERIC TPP SIMULATOR STARTUP PROCEDURE

20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

30.
31.
32.

33.
34.
35.

36.
37.
38.
39.
40.
41.
42.
43.

with a Seal Steam Header Pressure of 0.3barg (±0.05bar).
Lineup and place the Condenser Vacuum System in service and evacuate the condenser. After evacuating the
Condenser, configure the Condenser Vacuum System for normal operation.
Before the drum pressure increases above 3000kPag, start the MDBFP. Use the MDBFP to control drum level during
boiler pressurization and place in auto when steam flow from the drum is sufficiently high and stable.
Lineup and start the Turbine Bypass System. Increase firing and Main Steam Pressure to ~130bar to allow for boiler
silica boil out. Once boiler silica requirements are satisfied reduce firing and shutdown the Turbine Bypass System.
Reset the Main Turbine. Lineup the LP Feedwater Heaters for operation.
Lineup and initiate Main Turbine Rotor Warming. Warm the turbine rotor above the specified temperature limits and
then stop the rotor warming.
Lineup and reset BFPT A and BFPT B in order to initiate warming of the BFPT CV Casings.
Lineup and place in service PA Fans A and B. Start the Flyash Handling System.
Lineup and initiate warming for Pulverizer B.
Start BFPT A and place in service in auto providing feedwater to the drum. Stop the MDBFP.
Lineup and initiate Main Turbine Chest Warming. Warm the Control Valve Chest until the CV Inner to Outer Metal
Temperature Differential and the Main Steam to Control Valve Outer Metal Temperature Differential are within the
allowed limits. Stop Chest Warming.
Prepare for and roll the Main Steam Turbine to 3000 rpm using either Automatic or Semi-Auto modes. As the turbine
accelerates monitor turbine stress and other critical parameters.
Synchronize the unit to the grid and load up to the initial load ~20 GMW.
Ramp the Unit Load to the Minimum Load point of ~80 GMW. Match the following conditions at this load:
- Main Steam Pressure 100bar (±5barg)
- Main Steam Temperature 380°C (±50°C)
- Pulverizer B in service
- Feedwater controls in Auto
- Boiler Master in Manual Mode
- Turbine Master in Manual Mode
At ~70 GMW, initiate Coal Firing on Pulverizer B. Adjust Pulverizer B Feeder demand and Warmup Oil Header
Pressure to control Main Steam Pressure. Start Warming Pulverizer C. Startup Electrostatic Precipitators.
At ~80 GMW, lineup and begin warming the HP Feedwater Heaters and Deaerator Extraction Lines. After sufficiently
warmed, open the extraction steam valves to place the HP Feedwater Heaters and Deaerator extraction in service.
Ramp the Unit Load to ~300 GMW. Match the following conditions at this load:
- Main Steam Pressure 115-130barg
- Main Steam Temperature 425°C (±25°C)
- Pulverizers B, C and D in service
- Oil Guns out of service
- Feedwater controls in Auto
- Turbine Master in Auto
- Boiler Master in Auto
- Unit in Coordinated Control Mode
At ~120 GMW, transfer House Load Supply from the Startup Transformer to the Auxiliary Transformer.
At ~130 GMW, lineup and place Superheater and Reheater Desuperheaters in service.
At ~130 GMW, start BFPT B and place in service in auto in parallel operation with BFPT A.
At ~150 GMW, initiate Coal Firing on Pulverizer C. Adjust Pulverizers B and C Feeder demands and Warmup Oil
Header Pressure to control Main Steam Pressure. Start warming Pulverizers D.
At ~200 GMW, start a second Condensate Pump.
At ~250 GMW, initiate Coal Firing on Pulverizer D. Adjust Pulverizers B, C and D Feeder demands and Warmup Oil
Header Pressure to control Main Steam Pressure.
At ~300 GMW, shutdown Oil Gun Elevations AB and CD. Maintain stable control of Main Steam Pressure.
Ramp the unit from 300 GMW to full load (685 GMW) at a high and steady loading rate within the maximum
allowable rate determined using operating procedures and maintain the following critical system parameters with the
specified limits:

Jharsuguda Generic Startup Procedure
Rev. 04

1-2

GENERIC TPP SIMULATOR STARTUP PROCEDURE
Main steam pressure 110 ~ 166bar
Main steam temperature 380 ~ 538oC
Reheat steam temperature 360 ~ 538oC
Steam drum water level -100 ~ +100mm
Furnace pressure -0.15kPag (±0.1kPag)
44. Given the unit operating during a load increase from ~300 GMW to full load, start auxiliary equipment as follows:
Warm and start additional pulverizers at appropriate time to insure smooth loading and operation of "in service"
feeders at >50%.
45. Given the load ramp complete with the unit at full load, stabilize the unit at the following conditions:
Main steam pressure at 166bar (±1bar)
Main steam temperature at 538oC (±5oC)
Reheat steam temperature at 538oC (±5oC)
Steam drum water level at 0mm (± 100mm)
Five pulverizers in service without warm-up guns
Boiler O2 at 3.5% (±0.5%)

Jharsuguda Generic Startup Procedure
Rev. 04

1-3

GENERIC TPP SIMULATOR STARTUP PROCEDURE
LOCAL OPERATIONS
This exercise includes some local operations performed outside of the control room by the local equipment Auxiliary
Operator (AO). The local operations are integrated into the exercise because they are critical to unit operations and they
motivate the student by creating an environment that closely resembles actual unit operation.
When requested, the instructor will play the AO role and perform local operations from either the Instructor Station Local
Operation Screens (LOS) or the Command Window.

Local operations that are NOT modeled and DO NOT affect control room indications should be verbally simulated by the
instructor. In other words, upon completion of each action, make the appropriate verbal report to the student on the status
of actions taken.
It is the student's responsibility to ensure the readiness of a system by verifying that all local operations have been
performed and the system components are ready for operation.
At a minimum, the student must perform the following for all local operations:


Dispatch the AO to perform the applicable lineups, system starts, etc.

Verify that all local operations have been completed before starting any equipment
[]

Option: If the student fails to verify the completion of local operations, the instructor may wish to close
manually operated local valves, dampers etc. This would cause operational problems once a system is placed in
service. For example, close the suction valve of the pump to be started.

OVERVIEW
Initial Plant Condition
Describe the initial conditions of the unit:
Boiler, turbine, and auxiliaries at ambient conditions
Hotwell, deaerator, and boiler drained or filled (depending upon the initial condition)
All motor control centers and electrical busses energized or not (depending upon the initial condition)
All "Permits to Work" released and cleared
All Pre-Start Check Sheets completed
Compressed Air System out of service
Generator Seal Oil System out of service with generator hydrogen pressure low
All coal silos are full
Fuel oil tanks are full
Condensate storage tanks are full
Unit 2 at full load
All transmitters in service from DCS
Exercise Description
Describe the startup exercise:
The student is to return the unit to service following an extended outage:
Energize various buses and MCC's
Fill the hotwell, start the Condensate System
Fill the deaerator
Fill the boiler and start the BCWP's
Start the Combustion Air and Gas System, purge and light off the boiler
Jharsuguda Generic Startup Procedure
Rev. 04

1-4

GENERIC TPP SIMULATOR STARTUP PROCEDURE





Warm the boiler without exceeding the maximum temperature ramp rate (222oC/hr or 56oC/15 minutes saturation
temperature change)
Warm the turbine rotor and valve steam chest
Roll and load the turbine according to GE Starting and Loading Instructions
Increase the unit load to ~300 GMW with all conditions normal:
- Main steam pressure 11500-13000kPag
- Main steam temperature 425oC (±25oC)
- All controls in auto

COLD UNIT STARTUP CONCERNS
Discuss the following concerns during cold unit startup:













Maintaining furnace exit gas temperature < 538oC
Limiting the boiler saturation temperature ramp rate to <222oC/hr (56 oC/15 minutes)
Controlling steam drum level swell
Limiting drum pressure until silica is <10 ppb
Ensuring adequate flow through the superheater and reheater
Obtaining at least 50oC of superheat prior to turbine roll
Minimizing turbine thermal stress
- For a cold startup the steam temperature will be hotter than turbine metal temperature
- Follow the GE Starting and Loading Instructions to roll and load the turbine
Minimizing turbine vibration through critical speeds
Maintaining turbine lube oil temperature at 32oC while on the turning gear and at >40oC at speeds > 2500rpm (the
temperature setpoint is automatically calculated based on turbine speed)
Firing with Pulverizers and maintaining stable combustion
Manually controlling oil flow, feeder demand and turbine demand while increasing load

Jharsuguda Generic Startup Procedure
Rev. 04

1-5

GENERIC TPP SIMULATOR STARTUP PROCEDURE
LOAD PLANT CONDITION
1.

Select and load one of the following conditions:
- LP01A Cold SU, Vessels Empty / No Plant Power
- LP01B Cold SU, Vessels Empty / Plant Power
- LP01C Cold SU, Vessels Filled / No Plant Power
- LP01D Cold SU, Vessels Filled / Plant Power

SHIFT TURNOVER
Conduct a shift turnover.
Discuss the following plant status:
Note: The plant status is dependent upon the initial condition that was loaded. All initial conditions are identical except
where noted.


Conditions that apply to all initial conditions:
- Returning the unit to service following an outage
- All clearances released and cleared
- Boiler, turbine, and auxiliaries shutdown and at ambient conditions
- Miscellaneous locally operated valves isolated
- All coal silos are full
- Fuel oil tanks are full
- Condensate storage tanks are full
- Compressed Air System in service with one air compressor supply Unit 2
- Generator Seal Oil System out of service with generator casing CO2 gas pressure low
- All transmitters in service from DCS
Conditions that apply to the LP01A Cold SU: Vessels Empty / No Plant Power initial condition only:
- Hotwell, deaerator, and boiler empty
- Electrical Buses and MCC's not energized.
Conditions that apply to the LP01B Cold SU: Vessels Empty / Plant Power initial condition only:
- Hotwell, deaerator, and boiler empty
- Electrical Buses and MCC's energized
Conditions that apply to the LP01C Cold SU: Vessels Filled / No Plant Power initial condition only:
- Hotwell level at 55%
- Deaerator level at 65%
- Steam drum level at +200mm
- Electrical Buses and MCC's not energized
Conditions that apply to the LP01D Cold SU: Vessels Filled / Plant Power initial condition only:
- Hotwell level at 55%
- Deaerator level at 65%
- Steam drum level at +200mm
- Electrical Buses and MCC's energized









Inform the student that he has responsibility as the Control Room Operator (CRO) position from this point forward.
DETERMINE THE TYPE OF STARTUP
Discuss the criteria for Hot, Warm and Cold Startups:


For this unit, a turbine is considered Hot if:
- the unit has been shutdown for no more than 2 continuous hours with the boiler unfired and not drained, or
- the unit has been shutdown for more than 2 but less than 8 continuous hours with the boiler continuously fired at

Jharsuguda Generic Startup Procedure
Rev. 04

1-6

GENERIC TPP SIMULATOR STARTUP PROCEDURE





15% MCR
- Startup Time Limitation: from startup to synchronous speed in 1 hour
For this unit, a turbine is considered Warm if:
- the unit has been shutdown for more than 8 but less than 32 continuous hours with the boiler unfired and not
drained, or
- the unit has been shutdown for more than 32 but less than 150 continuous hours with the boiler continuously fired
at 15% MCR
- Startup Time Limitation: from startup to synchronous speed in 2 hours
For this unit, a turbine is considered Cold if:
- the unit has been shutdown for more than 32 continuous hours with the boiler unfired and not drained, or
- the unit has been shutdown for more than 150 continuous hours with the boiler continuously fired at 15% MCR
- Startup Time Limitation: from startup to synchronous speed in 7 hours

Jharsuguda Generic Startup Procedure
Rev. 04

1-7

GENERIC TPP SIMULATOR STARTUP PROCEDURE
BEGIN SIMULATOR TRAINING
1. Have the student take his station at the simulator.
2. Assign roles.
3. RUN the simulator.

Jharsuguda Generic Startup Procedure
Rev. 04

1-8

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS01: STATION POWER SUPPLY
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. When energizing station power, the below guidelines should be
followed:
a. Verify the PT and bus protection is in service before the bus feed
breaker is closed.
b. Parallel supply to a bus is not permitted. Thus two bus feed
breakers and tiebreakers may not be closed at the same time.
c. Verify all load breakers are in the open position before closing the
bus feed breaker when energize electrical system.
2. To use the Synchronization Check Switch (SCS) key on the emulated
Electrical Control Panel:
a. The key must be available and appear in the lower left-hand corner
of the ECP screen. If it is not available, this means the key is in an
SCS somewhere on the ECP.
b. If the key is available, click on SCS where you want to place the
key. The key will disappear from the lower left-hand corner of the
ECP screen and reappear in the SCS.
c. To turn the key to the On position, clock on the "ON" text on the
SCS. The key will turn to the On position.
d. To turn the key to the Off position, clock on the "OFF" text on the
SCS. The key will turn to the Off position.
e. The key can be removed from the SCS and made available by
clicking on the key. The key will then disappear from the SCS and
reappear in the lower left-hand corner of the ECP screen.
3. Prior to closing the Startup Transformer Breaker (CS-52SUT7) place all
13.8kV breakers in the Pull-to-Lock position.
^


Questions:

1.

Lineup 150kV Power Supply:
a.

Place 13.8kV SWGR A MAIN BKR 1AM (CS-1AM) in PULL TO
LOCK position

ECP05

b.

Place 13.8kV SWGR A STARTUP BKR 1AT (CS-1AT) in PULL
TO LOCK position

ECP05

c.

Place UNITS 1&2 13.8kV BUS TIE BKR 1AT8A (CS-1AT8A) in
PULL TO LOCK position

ECP05

d.

Place 13.8kV SWGR B MAIN BKR 1BM (CS-1BM) in PULL TO
LOCK position

ECP08

e.

Place 13.8kV SWGR B STARTUP BKR 1BT (CS-1BT) in PULL
TO LOCK position

ECP11

Jharsuguda Generic Startup Procedure
Rev. 04

1-9

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS01: STATION POWER SUPPLY
Instructor Activity / Operating Procedure

2.

3.

Student
Response

Screen or LOS
Reference

f.

Place UNITS 1&2 13.8kV BUS TIE BKR 1BT8B (CS-1BT8B) in
PULL TO LOCK position

ECP11

g.

Place 13.8kV SWGR C MAIN BKR 1CM (CS-1CM) in PULL TO
LOCK position

ECP14

h.

Place 13.8kV SWGR C STARTUP BKR 1CT (CS-1CT) in PULL
TO LOCK position

ECP14

i.

Place UNITS 1&2 13.8kV BUS TIE BKR 1CT8C (CS-1CT8C) in
PULL TO LOCK position

ECP14

j.

Close START-UP XFMR BKR (CS-52SU1)

ECP16

k.

Place the Startup Transformer Tap Changer SU LTC AUTO/MAN
SELECTOR SWITCH in auto

ECP17

Lineup 13.8kV Bus A:
a.

Put BKR 1AT SYNC CHECK SWITCH (SCS-1AT) in the ON
position by using SCS key

ECP05

b.

Close 13.8kV SWGR A STARTUP BKR (CS-1AT)

ECP05

c.

Place TRANSFER SELECTOR SWITCH (43-1A) in the 1AT1AT8A position

ECP05

d.

Place the TRANSFER ENABLE/DISABLE SWITCH 1AM (691AM) in the ENABLE position

ECP05

e.

Place the TRANSFER ENABLE/DISABLE SWITCH 1AT (691AT) in the ENABLE position

ECP05

f.

Place the TRANSFER ENABLE/DISABLE SWITCH 1AT8A (691AT8A) in the ENABLE position

ECP08

Lineup 13.8kV Bus B:
a.

Put BKR 1BT SYNC CHECK SWITCH (SCS-1BT) in the ON
position by using SCS key

ECP11

b.

Close 13.8kV SWGR B STARTUP BKR (CS-1BT)

ECP11

c.

Place TRANSFER SELECTOR SWITCH (43-1B) in the 1BT1BT8B position

ECP08

d.

Place the TRANSFER ENABLE/DISABLE SWITCH 1BM (691BM) in the ENABLE position

ECP11

e.

Place the TRANSFER ENABLE/DISABLE SWITCH 1BT (691BT) in the ENABLE position

ECP11

f.

Place the TRANSFER ENABLE/DISABLE SWITCH 1BT8B (691BT8B) in the ENABLE position

ECP11

Jharsuguda Generic Startup Procedure
Rev. 04

1-10

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS01: STATION POWER SUPPLY
Instructor Activity / Operating Procedure
4.

Screen or LOS
Reference

Lineup 13.8kV Bus C:
a.

Put BKR 1CT SYNC CHECK SWITCH (SCS-1CT) in the ON
position by using SCS key

ECP14

b.

Close 13.8kV SWGR C STARTUP BKR (CS-1CT)

ECP14

c.

Place TRANSFER SELECTOR SWITCH (43-1C) in the 1CT1CT8C position

ECP14

d.

Place the TRANSFER ENABLE/DISABLE SWITCH 1CM (691CM) in the ENABLE position

ECP14

e.

Place the TRANSFER ENABLE/DISABLE SWITCH 1CT (691CT) in the ENABLE position

ECP14

f.

Place the TRANSFER ENABLE/DISABLE SWITCH 1CT8C (691CT8C) in the ENABLE position

ECP17

5.

Lineup 13.8kV to 6.9kV and 416V Bus A:
a.

Close 13.8kV FEEDER BKR (CS-1A2)

ECP05

b.

Close 13.8kV FEEDER BKR (CS-1A3)

ECP05

c.

Close 13.8kV FEEDER BKR (CS-1A4)

ECP05

d.

Close 13.8kV FEEDER BKR (CS-1A5)

ECP08

e.

Close 13.8kV FEEDER BKR (CS-1A6)

ECP08

f.

Close 13.8kV FEEDER BKR (CS-1A1)

ECP05

6.

7.

Student
Response

Lineup 13.8kV to 6.9kV and 416V Bus B:
a.

Close 13.8kV FEEDER BKR (CS-1B2)

ECP11

b.

Close 13.8kV FEEDER BKR (CS-1B3)

ECP11

c.

Close 13.8kV FEEDER BKR (CS-1B4)

ECP11

d.

Close 13.8kV FEEDER BKR (CS-1B5)

ECP11

e.

Close 13.8kV FEEDER BKR (CS-1B6)

ECP11

f.

Close 13.8kV FEEDER BKR (CS-1B1)

ECP08

Lineup 13.8kV to 6.9kV Bus C:
a.

Close 13.8kV FEEDER BKR (CS-1C1)

ECP14

b.

Put BKR 1C1M SYNC CHECK SWITCH (SCS-1C1M) in the ON
position by using SCS key

ECP15

c.

Close 6.9kV SWGR C1 MAIN BKR (CS-1C1M)

ECP15

Jharsuguda Generic Startup Procedure
Rev. 04

1-11

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS01: STATION POWER SUPPLY
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

d.

Place the TRANSFER ENABLE/DISABLE SWITCH-1C1M (691C1M) in the ENABLE position

ECP15

e.

Place the TRANSFER SELECTOR SWITCH-1C1 (43-1C1) in the
1C1-1A1 position

ECP15

8.

Lineup 6.9kV Bus A1:
a.

Put BKR 1A1M SYNC CHECK SWITCH (SCS-1A1M) in the ON
position by using SCS key

ECP06

b.

Close 6.9kV SWGR A1 MAIN BKR (CS-1A1M)

ECP06

c.

Place the TRANSFER ENABLE/DISABLE switch (69-1A1M) in
the ENABLE position

ECP06

d.

Close 6.9kV FEEDER BKR (CS-1A1A)

ECP06

9.

Lineup 6.9kV Bus B1:
a.

Put BKR 1B1M SYNC CHECK SWITCH (SCS-1B1M) in the ON
position by using SCS key

ECP09

b.

Close 6.9kV SWGR B1 MAIN BKR (CS-1B1M)

ECP09

c.

Place the TRANSFER ENABLE/DISABLE switch (69-1B1M) in
the ENABLE position

ECP09

d.

Close 6.9kV FEEDER BKR (CS-1B1A)

ECP09

e.

Close 6.9kV FEEDER BKR PRECIPITATOR LC (CS-1B11)

ECP09

10. Lineup 6.9kV Bus C1:
a.

Close 6.9kV FEEDER BKR PRECIPITATOR LC (CS-1C11)

ECP15

b.

Close 6.9kV FEEDER BKR SODIUM HYPO SYST (CS-1CSH)

ECP15

11. Lineup 416 V Bus A2:
a.

Close TURBINE LC A2 MAIN BKR (CS-1A2M)

ECP06

b.

Request AO to close 416V MCC FEED from LC A2 (A21)

LOS13

c.

Request AO to close 416V MCC FEED from LC A2 (A22)

LOS13

d.

Request AO to close 416V MCC FEED from LC A2 (A23)

LOS13

e.

Request AO to close 416V MCC FEED from LC A2 (A24)

LOS13

12. Lineup 416V Bus B2:
a.

Close TURBINE LC B2 MAIN BKR (CS-1B2M)

ECP12

b.

Request AO to close 416V MCC FEED from LC B2 (B21)

LOS14

Jharsuguda Generic Startup Procedure
Rev. 04

1-12

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS01: STATION POWER SUPPLY
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

c.

Request AO to close 416V MCC FEED from LC B2 (B22)

LOS14

d.

Request AO to close 416V MCC FEED from LC B2 (B24)

LOS14

13. Lineup 416 V Bus A3:
a.

Close TURBINE LC A3 MAIN BKR (CS-1A3M)

ECP06

b.

Request AO to close 416V MCC FEED from LC A3 (A31)

LOS13

c.

Request AO to close 416V MCC FEED from LC A3 (A32)

LOS13

d.

Request AO to close 416V MCC FEED from LC A3 (A33)

LOS13

14. Lineup 416V Bus B3:
a.

Close TURBINE LC B3 MAIN BKR (CS-1B3M)

ECP12

b.

Request AO to close 416V MCC FEED from LC B3 (B31)

LOS14

c.

Request AO to close 416V MCC FEED from LC B3 (B32)

LOS14

d.

Request AO to close 416V MCC FEED from LC B3 (B33)

LOS14

e.

Request AO to close 416V MCC A23 ALT FEED from LC B3 (B35)

LOS14

15. Lineup 416 V Bus A4:
a.
b.

Close WTR TREATMENT/SEAWTR R.O. LC A4 MAIN BKR
(CS-1A4M)
Request AO to close 416V MCC FEED from LC A4 (A41)

ECP06
LOS13

16. Lineup 416V Bus B4:
a.

Close WARE HOUSE LC B4 MAIN BKR (CS-CB4M)

ECP12

b.

Request AO to close 416V MCC FEED from LC B4 (B41)

LOS14

c.

Request AO to close 416V MCC FEED from LC B4 (B42)

LOS14

d.

Request AO to close 416V MCC FEED from LC B4 (B43)

LOS14

17. Lineup 416 V Bus A5:
a.

Close ADMIN. BLDG LC A5 MAIN BKR (CS-1A5M)

ECP09

b.

Request AO to close 416V MCC FEED from LC A5 (A51)

LOS13

c.

Request AO to close 416V MCC FEED from LC A5 (A52)

LOS13

d.

Request AO to close 416V MCC FEED from LC A5 (A53)

LOS13

18. Lineup 416V Bus A6:

Jharsuguda Generic Startup Procedure
Rev. 04

1-13

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS01: STATION POWER SUPPLY
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

a.

Close PRECIPITATOR LC A6 MAIN BKR (CS-1A6M)

ECP09

b.

Request AO to close 416V MCC FEED from LC A6 (A61)

LOS13

c.

Request AO to close 416V MCC FEED from LC A6 (AB61)

LOS13

d.

Request AO to close 416V MCC FEED from LC A6 (AB62)

LOS13

19. Lineup 416V Bus B6:
a.

Close PRECIPITATOR LC B6 MAIN BKR (CS-1B6M)

ECP12

b.

Request AO to close 416V MCC FEED from LC B6 (B61)

LOS14

c.

Request AO to verify open 416V MCC FEED from LC B6 (AB61B)
to prevent parallel power supply to one bus

LOS14

d.

Request AO to verify open 416V MCC FEED from LC B6 (AB62B)
to prevent parallel power supply to one bus

LOS14

20. Lineup 416 V Misc. Area
a.

Request AO to close Main Break ESP Load Center
B11(EP_LC_B11)

LOS13

b.

Request AO to close Main Break ESP Load Center
C11(EPLCC11)

LOS13

c.

Request AO to close CH Area Bus A1A1 Feed From 1A1A/or
2A 1A(EP_LC_A 1A1)

LOS13

d.

Request AO to close SB Area Bus B1A1 Feed From 2B1A/or
2B1A(EP_LC_B1A 1)

LOS13

21. Lineup Diesel Generator supply:
a.

Put DIESEL GEN MODE SELECTOR SWITCH in AUTO

ECP17

22. Lineup Continuous 250V DC supply:
a.

Request AO to close breaker to bus 250VDC (EB-BYC-250)

CS01 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-14

LOS14

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS02: COMPRESSED AIR SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. The power supply distribution for each of the Air Compressors A
through E:
a. Air Compressor A (CCA-CMP-100A) power supply taken from
(Unit 2) 2EN-SWGR-A1.
b. Air Compressor B (CCA-CMP-100B) power supply taken from
(Unit 2) 2EN-SWGR-B1.
c. Air Compressor C (CCA-CMP-100C) power supply taken from
(Unit 1) 1EN-SWGR-A1.
d. Air Compressor D (CCA-CMP-100D) power supply taken from
(Unit 1) 1EN-SWGR-B1.
e. Air Compressor E (CCA-CMP-100E) power supply taken from
(Unit 1) 1EN-SWGR-C1.
Notes:
1. Air Compressor A supplied from Unit 2 and supplying compressed air
to Unit 2 should already be in service. Valve CCA-PY-110 should be
open to allow air from Air Compressor A to flow to Unit 2 Compressed
Air System.

7•

Questions:

1.

Complete the Compressed Air System pre-start check sheet

2.

Request AO to place air compressors A ON (CCA-CMP-100A)

LOS12

3.

Verify Air Compressor A (CCA-CMP-100A) is in service in manual

CAOV

4.

Request AO to place other air compressors B through E in auto:
a.

Place Air Compressor B (CCA-CMP-100B) in auto

LOS12

b.

Place Air Compressor C (CCA-CMP-100C) in auto

LOS12

c.

Place Air Compressor D (CCA-CMP-100D) in auto

LOS12

d.

Place Air Compressor E (CCA-CMP-100E) in auto

LOS12

5.

Request AO to open AIR COMP C DISCH VALVE TO UNIT 1 (CCAISV-100)

LOS12

6.

Open Service Air Supply Valve to Unit 1 (1CA-PY-110)

CAOV

CS02 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-15

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS03: CLOSED COOLING WATER (CCW) SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. Closed Cooling System makeup can be taken from different sources:
a. During normal operation (Condensate System in service) makeup is
taken from the Condensate System.
b. If makeup cannot be taken from the Condensate System, makeup
can be taken from the Condensate Storage System for either Unit 1
or 2 via Emergency Pump (CC-P-500)
Notes:
1.

The CCW pumps will trip if CCW expansion tank level < 25%.

^


Questions:
1. Why should the discharge valve be throttled open before starting
the first Closed Cooling Water Pump?
Answer: to allow sufficient flow to avoid damaging the pump while still
limiting the flow to avoid water hammer effects in the closed cooling
system lines.

1.

Complete the CCW System Pre-Start Check Sheet

2.

Request AO to lineup the CCW system and report the status of the local
operations when complete.
a.

Open CCW Heat Exchanger A Inlet Valve (CC-ISV-107A)

LOS10

b.

Open CCW from SCW Clr A Outlet Valve (CC-ISV-238A)

LOS10

c.

Open CCW to STG LO Cooler A Inlet Valve (CC-ISV-153A)

LOS10

d.

Open 75% CCW from BCWP A Cooler Out Valve (CC-ISV-766A)

LOS10

e.

Open 75% CCW from BCWP B Cooler Out Valve (CC-ISV-766B)

LOS10

f.

Open 75%CCW from BCWP C Cooler Out Valve (CC-ISV-766C)

LOS10

g.

Open STG LO TCVIsolation Valve (CC-ISV-156)

LOS10

h.

Open STG LO After TCV Isolation Valve (CC-ISV-157)

LOS11

i.

Select STG LO Cooler Inlet 3-Way Valve to Cooler A (LT-V-105)

LOS11

j.

Select BFPTA LO Filter Inlet 3-Way Valve to Filter A (LT-FV510A)

LOS11

k.

Select BFPTB LO Filter Inlet 3-Way Valve to Filter A (LT-FV510B)

LOS11

l.

Open Gen Stator Cooler A Inlet Valve (SC-ISV-104A)

LOS11

Jharsuguda Generic Startup Procedure
Rev. 04

1-16

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS03: CLOSED COOLING WATER (CCW) SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

3.

Ask Chemist Technician if the CCW water quality is satisfactory
(Nitride content > 600 ppm)

Not Modeled

4.

Verify CCW expansion tank level (CCLIC800) is OK (80-85%) for the
filling the CCW system piping, if the level is not high enough:

CCWOV

a.

Open unit 1 CST discharge valve (CS-MOV-402)

CONDSTG

b.

Request AO to open CC Emer Makeup Pump discharge valve (CCISV-502)

LOS09

c.

Request AO open CC Exp Tank Makeup Bypass Valve (CC-ISV120)

LOS10

d.

Request AO start CC Emergency Makeup Pump (CC-P-500)

LOS09

e.

When the level close to 65%, request AO to close CC Exp Tank
Makeup Bypass Valve (CC-ISV-120)

LOS10

f.

Verify CCW expansion level control valve (CCLIC800) setpoint at
65%

CCWOV

g.

Put CCW expansion level control valve (CCLIC800) in AUTO

CCWOV

h.

Request AO to stop CC Emergency Makeup Pump (CC-P-500)

LOS09

i.

Request AO to close CC Emer Makeup Pump discharge valve (CCISV-502)

LOS09

5.

Request AO to throttle open CCW pump discharge valve (CC-ISV102A/B)

LOS10

6.

Request AO to open CCW pump venting to release air

Not Modeled

7.

For initial start up, request AO to open venting valve of CCW line at
high level location (air heater guide bearing)

Not Modeled

8.

Request AO to full open CCW pump suction valve (CCISV100A/B)

Not Modeled

9.

Request AO to open minimum flow bypass valve (CC-ISV-106) to 50%

LOS10

10. Before startup CCW pump, to verify that BCWP emergency cooling
lineup is correct and will not allow CCW to drain to BCWP Emergency
Cooling System:

BCWPEC

a.

Close the BCWP Emergency Cooling Supply Valve (CC-FY-327)

BCWPEC

b.

Close the BCWP Emergency Cooling Return Valve (CC-FY-202)

BCWPEC

c.

Open the BCWP Normal Cooling Return Valve (CC-FY-201)

BCWPEC

11. Verify the CCW Pump Minimum Flow Control station (CCPDIC804) is
tracking in manual and setpoint is 400kPa

CCWOV

12. Start CCW Pump A (CC-P-100A)

CCWOV

Jharsuguda Generic Startup Procedure
Rev. 04

1-17

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS03: CLOSED COOLING WATER (CCW) SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

13. Verify the CCW Pump Minimum Flow Control station (CCPDIC804)
changed to Auto with current dP as setpoint

CCWOV

14. Request AO to fully open CCW Pump Discharge Valves (CC-ISV102A/B)

LOS10

15. Request AO to close Min Flow Bypass Valve (CC-ISV-106)

LOS10

16. Prepare the standby CCW Pump for auto operation:

CCWOV

a.

Request AO to verify CCW Pump Discharge valves (CC-ISV102A/B) are fully open

LOS10

b.

Place standby CCW Pump B (CC-P-100B) in auto

CCWOV

17. Put the Generator Hydrogen Temperature Control station (GHTIC152)
in auto:

CCWOV

a.

Set Generator Hydrogen Temperature Control station (GHTIC152)
setpoint to 38oC

CCWOV

b.

Place Generator Hydrogen Temperature Control station
(GHTIC152) in Auto

CCWOV

18. Put BFPT A Lube Oil Temperature Control station (CCTIC838) in
auto:

CCWOV

a.

Set BFPT A Lube Oil Temperature Control station (CCTIC838)
setpoint to 42oC

CCWOV

b.

Place BFPT A Lube Oil Temperature Control station (CCTIC838)
in Auto

CCWOV

19. Put BFPT B Lube Oil Temperature Control station (CCTIC822) in auto:

CCWOV

a.

Set BFPT B Lube Oil Temperature Control station (CCTIC822)
setpoint to 42oC

CCWOV

b.

Place BFPT B Lube Oil Temperature Control station (CCTIC822)
in Auto

CCWOV

20. Put the Main Turbine Lube Oil Temperature Control station
(LTTIC106B) in auto:

CCWOV

a.

Verify Lube Oil Temperature Control station (LTTIC106B)
setpoint is 32oC. Note: this setpoint value is calculated by the
controls.

CCWOV

b.

Place Lube Oil Temperature Control station (LTTIC106B) in Auto

CCWOV

CS03 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-18

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS04: CIRCULATING WATER (CW) SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. The condenser should be filled with water and any air pockets in the
circulating water pump discharge piping minimized, or if possible,
eliminated prior to starting a pump. If a circulating water pump is
started with air pockets in the system, pressure pulsations will occur
that can cause rupture and serious damage to the condenser and entire
circulating water piping system.
2. Use of only two Circulating Water Pumps (CWP) will reduce plant
efficiency at any load. In addition, the life of the pump motors and the
discharge valve gear boxes will be reduced if they are to be started too
frequently. Therefore, three pumps should be in service at all loads
provided that they are available. In the case where only two pumps are
available, the unit will still be able to produce 100% load but with lower
efficiency.
Notes:
1. Before startup of the CW system, the Closed Cooling Water, CW Intake
canal system, and at least one condenser loop should be in service.
2. CW Pump discharge valve will open to 37% if only one pump is in
service and will open 100% if two or three pumps are in service.
3. Condenser Fill status will automatically change to inactive if condenser
water box B level > 85% and will automatically open CW-ISV-170A/B
and close CW-VTV-157A/B.

7

Questions:
1. Why is it important to vent air from the condenser water box?

a

Answer: Air left in the water box can create an insulating blanket of
air in the condenser tubes and result in a reduction of heat transfer to
the circulating water.

1.

Complete the Circulating Water System Pre-start Check Sheet

2.

Request AO to place the Drum Screens in service

LOS12

3.

Request AO to open the CCW Heat Exchanger A inlet valve (CW-ISV200A)

LOS09

4.

Open the LP Condenser Inlet Isolation Valves (CW-ISV-120A/B)

CWOV

5.

Line up the condenser waterboxes for venting and filling

CWOV

a.

Put Condenser Waterbox Vent Valves (CW-VTV-157A/B) in auto

CWOV

b.

Set Condenser Fill to active

CWOV

c.

Verify Condenser Waterbox Vent Valves (CW-VTV- 157A/B) open

CWOV

Jharsuguda Generic Startup Procedure
Rev. 04

1-19

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS04: CIRCULATING WATER (CW) SYSTEM STARTUP
Instructor Activity / Operating Procedure
d.

Open the HP Condenser Outlet Isolation Valves (CWISV170A/B)
and verify it open and stop at a intermediate position.

6.

Request AO to start Waterbox Priming Pumps (CP-P-400A/B)

7.

Start Circulating Water Pump A (CW-P-100A):

Screen or LOS
Reference
CWOV
LOS09

a.

Use the CWP Sequence Start to start Circulating Water Pump A
(CW-P-100A)

CWOV

b.

For one CW pump in operation, verify the Circ Water Pump
Discharge Valve (CW-MOV-703A) is forced to auto and opens to
16%, and opens to 36% after two minutes of CWP operation

CWOV

8.

9.

Student
Response

Start Circulating Water Pump B (CW-P-100B):
a.

Use the CWP Sequence Start to start Circulating Water Pump B
(CW-P-100B)

CWOV

b.

Verify the Circ Water Pump Discharge Valve (CW-MOV-703B) is
forced to auto and opens to 16%

CWOV

c.

With two CWP running, verify the Circ Water Pump Discharge
Valves (CW-MOV-703A/B) of the running pumps travel to 100%
open after at least two minutes of pump operation

CWOV

When condenser waterbox level (CWLI732A) > 85%, Condenser fill is
completed:

CWOV

a.

Request AO to verify that condenser water box fill is sufficient
(water comes out from vent valve)

Not Modeled

b.

Verify vent valve (CW-VTV-157A/B) auto close

CWOV

c.

Verify HP Condenser Outlet Isolation Valves (CWISV170A/B)
automatically travel to full open

CWOV

d.

Verify Condenser Fill status automatically returns to INACTIVE

CWOV

10. Start Circulating Water Pump C (CW-P-100C):
a.

Use the CWP Sequence Start to start Circulating Water Pump C
(CW-P-100C)

CWOV

b.

Verify the Circ Water Pump Discharge Valve (CW-MOV-703C) is
forced to auto and opens to 16%

CWOV

c.

Verify the Circ Water Pump Discharge Valves (CW-MOV-703C)
travels to 100% open after two minutes of pump operation

CWOV

11. Ask Chemist Technician if chlorine injection to intake area is required;
coordinate with chemist for chlorine injection flow rate.

Not Modeled

12. Request AO to start Sodium Hypochlorite Generator A (CCL-RECT100A)

LOS12

Jharsuguda Generic Startup Procedure
Rev. 04

1-20

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS04: CIRCULATING WATER (CW) SYSTEM STARTUP
Instructor Activity / Operating Procedure
13. Open Sodium Hypochlorite Supply Valve to Unit 1 Intake Structure
(CL-MOV-218)

Student
Response

Screen or LOS
Reference
SODHYPO

14. Make the Dilution Water Pumps ready for service:
a.

Place the Dilution Water Pump Discharge Valves (ID-MOV792A/B) in auto

IDSYSOV

b.

Close Pump A/B Bubbler (SA-FSV-516A/B), 5 mins later, Dilution
water Pumps are ready to run.

IDSYSOV

CS04 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-21

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS05: CONDENSATE STORAGE SYSTEM STARTUP AND CONDENSER FILLING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. The Condensate Storage Tank level may be controlled at a constant
level by the CST Level Setpoint on LOS02.
^

Questions:

M

1.

Complete Condensate Storage System Pre-start Check Sheet

2.

If Condensate Storage Tank level is low, request AO to open Makeup
Demin to Unit 1 CST Valve (CS-ISV-516)

LOS09

3.

Request AO to open Condensate Makeup Bypass Valve (CS-HV-481) in
order to fill condenser faster

LOS09

4.

Start Condensate Transfer Pump (CS-P-100)

CONDSTG

5.

Put the Hotwell Level Control station (CMLIC481) in manual and
increase output to 100%:
a.

Set Hotwell Level Control station (CMLIC481) setpoint to 65%

COND1

b.

Increase Hotwell Level Control station (CMLIC481) output to
100%

COND1

6.

Request AO to close Condensate Makeup Bypass Valve (CS-HV-481)
as the condenser level approaches 65%

7.

Decrease the Hotwell Level Control station (CMLIC481) output to 0%
and place in auto:

LOS09

a.

Decrease Hotwell Level Control station (CMLIC481) output to 0%
after the condenser level has reached 65%

COND1

b.

Place the Hotwell Level Control station (CMLIC481) in Auto

COND1

CS05 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-22

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS06: CONDENSATE SYSTEM STARTUP AND DEAERATOR FILLING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. Before starting the Condensate System, the Closed Cooling Water
System should be in service and the Condensate Drain Pumps should be
available.
2. The lineup of the Condensate System requires the opening of the low
pressure (LP) feedwater heater motor operated valves (MOV's) and
manual operated valves used in heater isolation. Observe that the
student completes the opening of the valves either on the OIS or
through the local equipment AO.
3. The Condensate Pumps will trip if the hotwell level < 10%.
4. The Condensate Drain Tank Level limit switch settings:
a. High-High Level = 70%
b. High Level = 50%
c. Low Level = 25%
d. Low-Low Level = 10%

0
2.

Questions:

1. What is the purpose of the Condensate Minimum Flow Control
Valve?
Answer: The re-circulation valve maintains minimum flow through the
condensate pump to prevent over-heating during low load conditions.
Why is the condensate Minimum Flow Control Valve located
downstream of the gland steam condenser?
Answer: The location ensures that sufficient cooling flow is maintained
through the gland steam condenser during startup.

1.

Complete Condensate System Pre-start Check Sheets
a.

Prepare Main Condenser A & B for start up

b.

Prepare Condensate Pump A for startup

c.

Prepare Condensate Pump B for startup

d.

Prepare Condensate Pump C for startup

e.

Prepare Condensate System for startup - From Extraction Pumps
Discharge to Inlet of Feedwater Heaters 1A & 1B

f.

Prepare Condensate System for startup-Feedwater Heaters 1A &
1B Outlet to Outlet of Feedwater Heater 4

2.

Line up the condensate flow path to the Deaerator:
a.

Open Condensate Polisher Bypass Valve (CM-MOV-417)

COND1

b.

Open FWH 1A/B Inlet Valve (CM-MOV-427)

LPFWHOV

Jharsuguda Generic Startup Procedure
Rev. 04

1-23

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS06: CONDENSATE SYSTEM STARTUP AND DEAERATOR FILLING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

c.

Open FWH 1A/B Outlet Valve (CM-MOV-437)

LPFWHOV

d.

Close FWH 1A/B Bypass Valve (CM-MOV-438)

LPFWHOV

e.

Request AO to open Feedwater Heater 2 Inlet Valve (CM-ISV-340)

LOS08

f.

Request AO to open Feedwater Heater 2 Outlet Valve (CM-ISV345)

LOS08

g.

Request AO to close Feedwater Heater 2 Bypass Valve (CM-ISV343)

LOS08

h.

Request AO to open Feedwater Heater 3 Inlet Valve (CM-ISV-350)

LOS08

i.

Request AO to open Feedwater Heater 3 Outlet Valve (CM-ISV355)

LOS08

j.

Request AO to close Feedwater Heater 3 Bypass Valve (CM-ISV353)

LOS08

k.

Request AO to open Feedwater Heater 4 Inlet Valve (CM-ISV-360)

LOS08

l.

Request AO to open Feedwater Heater 4 Outlet Valve (CM-ISV365)

LOS08

m.

Request AO to close Feedwater Heater 4 Bypass Valve (CM-ISV363)

LOS08

n.

Close Condensate Polisher Inlet Valve (CM-MOV-414)

COND1

o.

Close Condensate Polisher Outlet Valve (CM-MOV-416)

COND1

3.

Verify the Deaerator Level Control Valve (CMLIC455) is in manual
and closed

COND1

4.

Verify the DA Makeup Valve (CM-MOV-455) is in manual and closed

COND1

5.

Set the Condensate Minimum Flow Valve control station (CMFIC426)
to auto. Note: the setpoint is automatically generated in the controls.

COND1

6.

Request AO to verify Deaerator Venting Valve (HV-VTV-500) is open

GSPROC!BOP

7.

Request AO to verify Condensate Chemical Dosing equipment is
available and the solution tank level is normal

Not Modeled

8.

Setup and Start Condensate Pump A (CM-P-100A):
a.

Request AO to full open Condensate Pump A Inlet Valve (CM-ISV100A)

LOS07

b.

Request AO to throttle open (10%) Condensate Pump A Outlet
Valve (CM-ISV-110A)

LOS07

c.

Start Condensate Pump A (CM-P-100A)

COND1

Jharsuguda Generic Startup Procedure
Rev. 04

1-24

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS06: CONDENSATE SYSTEM STARTUP AND DEAERATOR FILLING
Instructor Activity / Operating Procedure
d.
9.

Request AO to gradually open to full open Condensate Pump A
Outlet Valve (CM-ISV-110A)

Verify Condensate Minimum Flow Control Valve (CM-FV-426) opens
and controls condensate flow to setpoint

Student
Response

Screen or LOS
Reference
LOS07
COND1

10. Setup Condensate Pump B (CM-P-100B) for standby operation:
a.

Request AO to open Condensate Pump B Inlet Valve (CM-ISV100B)

LOS07

b.

Request AO to open Condensate Pump B Outlet Valve (CM-ISV110B)

LOS07

c.

Place Condensate Pump B (CM-P-100B) in auto

COND1

11. Setup Condensate Pump C (CM-P-100C) for standby operation:
a.

Request AO to open Condensate Pump C Inlet Valve (CM-ISV100C)

LOS07

b.

Request AO to open Condensate Pump C Outlet Valve (CM-ISV110C)

LOS07

c.

Place Condensate Pump C (CM-P-100C) in auto

COND1

12. Line up Condensate Drain Pumps and Condensate Drain Tank
Discharge Flow control valve:
a.

Set the Cond Drain Tank Discharge Flow control station
(CMFIC500) setpoint to 19.0 T/h

CDRAIN

b.

Place the Cond Drain Tank Discharge Flow control station
(CMFIC500) in Auto

CDRAIN

c.

Place Condensate Drain Pump A (CMP300A) in Auto

CDRAIN

d.

Place Condensate Drain Pump B (CMP300B) in Auto

CDRAIN

13. Request Chemist Technician to check condenser water quality:
condensate water quality should be: pH (9.2~9.6), Conductivity (< 0.3
is/cm), TSS (< 100). If TSS is above the acceptable limit, dump and fill
if necessary in co-ordination with Chemist Technician until water
quality is within acceptable limits.

Not Modeled

14. Place the DA Normal Level Controller (CMLIC455) in manual and
gradually open to establish condensate flow and fill the Deaerator:
a.

Place DA Normal Level Controller (CMLIC455)in Manual

COND1

b.

Gradually open DA Normal Level Controller (CMLIC455) to 10%

COND1

c.

Fill the Deaerator until the level is 55%

COND1

Jharsuguda Generic Startup Procedure
Rev. 04

1-25

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS06: CONDENSATE SYSTEM STARTUP AND DEAERATOR FILLING
Instructor Activity / Operating Procedure
15. Open DA Emergency Level Controller (HDLIC680) to 50% ~ 75% and
continue filling Deaerator to a level of ~65%

Student
Response

Screen or LOS
Reference
DEAOV

16. Line up Chemical Treatment System for ammonia injection to the Drain
Cooler Inlet:
a.

Open Ammonia to Condenser Block Valve (CT-FY-719) to dose
ammonia to the Drain Cooler Inlet

CTOV

b.

Request AO to verify flow path for ammonia injection to the drain
cooler inlet is available

Not Modeled

c.

Start Ammonia Feed Pump A (CT-P-400A)

CTOV

d.

Discuss with Chemist Technician and Set the Ammonia Feed Pump
A Control station (CTFZ400A) output to 20%

CTFP1

17. Once the Deaerator level has reached 65% and water has begun
draining from the DA Emergency Level Control Valve balance
Condensate and DA Emergency Drain flows and continue circulation
until water quality is satisfied:

DEAOV

a.

Adjust Condensate Flow in order to maintain the Deaerator level at
~65% by adjusting the output of the DA Normal Level Controller
(CMLIC455)

COND1

b.

Verify Deaerator and Condenser level are stable

COND1

c.

Continue injecting ammonia and maintain condensate circulation
until the condensate water quality is satisfied (pH ~ 9.3)

CTOV
COND1

d.

When condensate water quality is satisfied, reduce ammonia dosing
(ammonia dosing can later be increased when filling the boiler and
additional water is being made up to the Condenser)

CTOV

18. Stop the Unit 1 Condensate Transfer Pump (CSP100) until additional
makeup is required for the Condenser
CS06 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-26

COND1

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS07: FEEDWATER SYSTEM LINE UP AND INITIAL BOILER FILLING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1.

Boiler water volume and expected time required for filling.

Notes:
1. While waiting for Boiler filling to be completed proceed to steps CS08
through CS12:
- CS08: Main Turbine Lube Oil and EHC Startup
- CS09: BFPT Lube Oil System Startup
- CS10: Main Turbine Turning Gear Startup
- CS11: Stator Cooling Water System Startup
- CS12: Fuel Oil System Startup
^

Questions:

M

1.

Line-up HP feed water system (open normal flow path):
a.

Open FWH 6A Inlet Valve (FW-MOV-342A)

HPFWHA

b.

Open FWH 6A Outlet Valve (FW-MOV-347A)

HPFWHA

c.

Open FWH 6B Inlet Valve (FW-MOV-342B)

HPFWHB

d.

Open FWH 6B Outlet Valve (FW-MOV-347B)

HPFWHB

e.

Close FWH 6A/6B Bypass Valve (FW-MOV-341) and place in
Auto

HPFWHB

f.

Open FWH 7A Inlet Valve (FW-MOV-350A)

HPFWHA

g.

Open FWH 7A Outlet Valve (FW-MOV-354A)

HPFWHA

h.

Open FWH 7B Inlet Valve (FW-MOV-350B)

HPFWHB

i.

Open FWH 7B Outlet Valve (FW-MOV-354B)

HPFWHB

j.

Close FWH 7A/7B Bypass Valve (FW-MOV-348) and place in
Auto

HPFWHB

k.

Open FWH 8A Inlet Valve (FW-MOV-357A)

HPFWHA

l.

Open FWH 8A Outlet Valve (FW-MOV-362A)

HPFWHA

m. Open FWH 8B Inlet Valve (FW-MOV-357B)

HPFWHB

n.

Open FWH 8B Outlet Valve (FW-MOV-362B)

HPFWHB

o.

Close FWH 8A/8B Bypass Valve (FW-MOV-355) and place in
Auto

HPFWHB

Jharsuguda Generic Startup Procedure
Rev. 04

1-27

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS07: FEEDWATER SYSTEM LINE UP AND INITIAL BOILER FILLING
Instructor Activity / Operating Procedure
p.
2.

Request AO to Open Economizer Inlet Valve (FW-SHV-100)

Student
Response

Screen or LOS
Reference
LOS06

Verify various boiler drains are closed:
a.

Verify Lower Drum Drain Valve (FW-MOV-118) is closed

BLRCIRC

b.

Verify Economizer Drain Valve (FW-MOV-110) is closed

BLRCIRC

3.

Open Boiler Drum Vent Valves:
a.

Boiler Drum Vent Valve #1 (BS-MOV-200B)

DRUMBD

b.

Boiler Drum Vent Valve #2 (BS-MOV-201B)

DRUMBD

c.

Boiler Drum Vent Valve #3 (BS-MOV-205)

DRUMBD

d.

Boiler Drum Vent Valve #4 (BS-MOV-210)

DRUMBD

4.

Open Superheater Vent Valves:
a.

Intermediate SH Desuperheater A Vent Valve (BS-MOV-230A)

SHVENTS

b.

Intermediate SH Desuperheater B Vent Valve (BS-MOV-230B)

SHVENTS

c.

SH Crossover Vent Valve #1 (BS-MOV-240)

SHVENTS

d.

SH Crossover Vent Valve #2 (BS-MOV-276)

SHVENTS

e.

Final SH Desuperheater A Vent Valve (BS-MOV-250A)

SHVENTS

f.

Final SH Desuperheater B Vent Valve (BS-MOV-250B)

SHVENTS

g.

Final SH Vent Valve #1 (BS-MOV-104A)

SHVENTS

h.

Final SH Vent Valve #2 (BS-MOV-104B)

SHVENTS

5.

Open Reheater Vent Valves:
a.

RH Outlet A Vent Valve (BS-MOV-146A)

RHVENTS

b.

RH Outlet B Vent Valve (BS-MOV-146B)

RHVENTS

c.

Reheater Vent Valve (BS-MOV-300)

RHVENTS

6.

Request Chemist Technician to verify Condensate water quality: pH at
9.2~9.6, conductivity < 0.3js/cm, TSS < 100ppb

Not Modeled

7.

Verify Feedwater to Boiler differential temperature < 111°C

BLRCIRC

8.

Open Economizer Recirculate Valve (FW-MOV-114)

BLRCIRC

9.

Line up the Boiler Blowdown System:
a.

When Int. Blowdown Tank level higher than 35%, Place
Blowdown Recovery Pump A (BBP200A) in Auto

Jharsuguda Generic Startup Procedure
Rev. 04

1-28

BBOV

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS07: FEEDWATER SYSTEM LINE UP AND INITIAL BOILER FILLING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

b.

When Int. Blowdown Tank level higher than 35%, Place
Blowdown Recovery Pump B (BBP200B) in Auto

BBOV

c.

Set Blowdown Tank Level Control (BBLIC300) setpoint to 50%

BBOV

d.

Place Blowdown Tank Level Control (BBLIC300) in Auto

BBOV

10. Request AO to close the following valves:
a.

Boiler Intermittent Blowdown Valve (FW-BDV-120)

LOS06

b.

Boiler Continuous Blowdown Valve (BB-HV-100)

LOS06

c.

Continuous Blowdown Tank Bleed Valve (BB-ISV-100)

LOS06

11. Request AO to throttle open Condensate to Boiler Fill Valve (FW-CKV561) to provide ~100T/H offeedwater flow

LOS06

12. Verify Feedwater Flow (FWFI364) ~ 100T/H

BLRCIRC

CS07 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-29

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS08: FILL FGD SYSTEM
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. Do not operate the Absorber Pumps with the discharge vents closed.
2. Do not operate the Absorber Pumps without flooded suction or motor
cooling.
3. Do not operate Absorber Pump at the shutoff head for an extended
period.
4. Do not start Absorber Pump with the discharge valve fully open
^
Questions:

1.

Complete FGD System Pre-start Check Sheet

2.

Open Absorber FGD Sea Water Supply Valves, and set to auto :
a.

FGD A Seawater Supply Valve (FCMOV104)

FCEC

b.

FGD B Seawater Supply Valve (FCMOV204)

FCEC

3.

Place ECW Pump Discharge Valve (CFCISV300) in auto

FCEC

4.

Place Emergency Cooling Water Pump A (CFCP301A) in auto

FCEC

5.

Verify that Emergency Cooling Water Pump A (CFCP301A) auto starts

FCEC

6.

Verify that ECW Pump Discharge Valve (CFCISV300) auto opens

FCEC

7.

Place Emergency Cooling Water Pump B (CFCP301B) in auto

FCEC

8.

Verify that Emergency Cooling Water Pump B (CFCP301B) auto starts

FCEC

9.

The Emergency Cooling Water Pumps will continue in operation until
the Emergency Cooling Water Tank level (FCLI301) > 75.6%

FCEC

CS08 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-30

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS09: MAIN TURBINE LUBE OIL AND EHC STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. The main turbine lube oil system supplies oil to the following:
a. Turbine bearings
b. Generator bearings
c. Thrust bearing wear detector
d. Hydrogen seal oil system backup
Notes:
1. Before starting the Turbine Lube Oil System, the Closed Cooling Water
System should be in service and the Generator Casing Pressure should
be at minimum 5 psig.
2. Turbine will trip when the bearing lube oil header pressure < 0.41bar
3. EHC System will alarm when the EHC pump header pressure < 91bar,
the Turbine will trip when the EHC pump header pressure < 77. 4bar
4. EHC cooling pump will auto start when EHC oil temperature > 49oC
and auto stop when the temperature < 43oC
^


Questions:
1. If the Lube Oil System normal operating temperature is between
110 ~ 115°F (43.3 ~ 46.1°C), why is the temperature maintained at 90°F
(32.2oC) during startup?
Answer: During turning gear or low speed operation the turbine
journal can climb the walls off of the bearing then suddenly drop,
causing vibration in the low pressure turbine blades. With the oil
temperature at a lower temperature, the oil is more viscous, thus
supporting the weight of the journal better.

Turbine Lube Oil System Startup
1.

Complete Lube Oil System Pre-start Check Sheet

2.

Verify that the Main Oil Tank level (LTLI100) is within the normal
range (~72%)

3.

Request AO to line up the Lube Oil System:

LUBEOIL

a.

Open STG Lube Oil TCV Isolation Valve (CC-ISV-156)

LOS10

b.

Close STG Lube Oil TCV Bypass Valve (CC-ISV-158)

LOS10

c.

Open CCW to STG Lube Oil Cooler A Inlet Valve (CC-ISV-153A)

LOS10

d.

Open STG Lube Oil Cooler Inlet 3-way Valve (LT-V-105) to use
Cooler A

LOS11

e.

Open CCW STG after TCV Isolation Valve (CC-ISV-157)

LOS11

Jharsuguda Generic Startup Procedure
Rev. 04

1-31

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS09: MAIN TURBINE LUBE OIL AND EHC STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

4.

Start Main Oil Tank Vapor Extractor (LT-VX-100)

LUBEOIL

5.

Start Turbine Lube Oil Pump A (LT-P-100A)

LUBEOIL

6.

Verify the following conditions are satisfied:
a.

Lube oil pressure increases to ~ 3 bar

LUBEOIL

b.

Seal oil differential pressure increases to ~0.8 bar

LUBEOIL

c.

Lube Oil System Status indication changes to "In Service"

LUBEOIL

7.

Place Turbine Lube Oil Pump B (LT-P-100B) in auto

LUBEOIL

8.

Place Turbine Emergency Bearing Oil Pump (LT-P-300) in auto

LUBEOIL

9.

Place Turbine Emergency Seal Oil Pump (GS-P-200) in auto

LUBEOIL

10. Verify Lube Oil Temperature Control station (LTTIC106B) is in auto

LUBEOIL

11. Request AO to closely check and verify adequate lube oil flow to all
Turbine and Generator bearings

Not Modeled

12. Perform routine Turbine Lube Oil test according to RPT-LT-01 and
RPT-LT-02

Not Modeled

Charge Generator with Hydrogen
13. Request AO to lineup generator gas system and charge with Hydrogen
(AP-H2), Until Hydrogen casing pressure ~4.5bar, Purity about 96%.

LOS12
GENOV

EHC System Startup
14. Complete EHC System Pre-start Check Sheet
15. Verify that the EHC Tank level (LTLI201) is within the normal range
(~ 80%)

HPU

16. Request AO to open EHC Bypass Valve (LT-FV-400)

LOS11

17. Request AO to pen EHC Cooler Inlet 3-way Valve (LT-V-200) to use
Cooler A

LOS11

18. Start EHC Pump A (LT-P-400A)

HPU

19. Request AO to close bypass valve (LT-FV-400)

LOS11

20. Verify that EHC oil pressure increases to normal pressure ~105kg/cm2
and EHC Pump current is ~35A

HPU

21. Place EHC Pump B (LT-P-400B) in auto

HPU

22. Place EHC Cooling Pump in auto (LT-P-430)

HPU

Jharsuguda Generic Startup Procedure
Rev. 04

1-32

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS09: MAIN TURBINE LUBE OIL AND EHC STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

23. Set EHC oil tank cooler fan A (LTFAN200A) on AUTO

HPU

24. Perform EHC routine test according to RPT-LT-03

Not Modeled

CS09 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-33

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS10: BFPT LUBE OIL SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. While on turning gear, BFPT Lube Oil Temperature control setpoint
should be 42°C. This should be changed to 52°C after startup.
^


Questions:

BFPT A Lube Oil System Startup
1.

Start BFPT A Lube Oil Tank Vapor Extractor A (LT-VX-500A)

FWPALO

2.

Start BFPT A Lube Oil Pump A (LT-P-200A)

FWPALO

3.

Verify that the BFPT A bearing lube oil pressure increases to about 1.41
~ 1.55kg/cm2

TDBFWPAD

4.

Request AO to verify control oil pressure about 12.7 ~ 14.8kg/cm2

Not Modeled

5.

Place BFPT A Lube Oil Pump B (LT-P-210A) in auto

FWPALO

6.

Put BFPT A Emergency Lube Oil Pump (LT-P-250A) in auto

FWPALO

7.

Verify BFPT A Lube Oil Temperature Control station (CCTIC838) is in
auto with a setpoint of 42oC

FWPALO
FWPA

8.

Request AO to start BFPT A Turning Gear (FW-TGR-100A)

LOS07

9.

Verify BFPT A Turning Gear status indicates "running"

FWPA

10. Perform BFPT Lube Oil routine test according to RPT-LT-04

Not Modeled

BFPT B Lube Oil System Startup
11. Start BFPT B Lube Oil Tank Vapor Extractor A (LT-VX-500B)

FWPBLO

12. Start BFPT B Lube Oil Pump A (LT-P-200B)

FWPBLO

13. Verify that the BFPT B bearing lube oil pressure increases to about 1.41
~ 1.55kg/cm2

TDBFWPBD

14. Request AO to verify control oil pressure about 12.7 ~ 14.8kg/cm2

Not Modeled

15. Place BFPT B Lube Oil Pump B (LT-P-210B) in auto

FWPBLO

16. Put BFPT B Emergency Lube Oil Pump (LT-P-250B) in auto

FWPBLO

17. Verify BFPT B Lube Oil Temperature Control station (CCTIC838) is in
auto with a setpoint of 42oC

FWPBLO
FWPB

Jharsuguda Generic Startup Procedure
Rev. 04

1-34

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS10: BFPT LUBE OIL SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

18. Request AO to start BFPT B Turning Gear (FW-TGR-100B)

LOS07

19. Verify BFPT B Turning Gear status indicates "running"

FWPB

20. Perform BFPT Lube Oil routine test according to RPT-LT-04

Not Modeled

CS10 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-35

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS11: MAIN TURBINE TURNING GEAR STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. The primary function of the Main Turbine Turning Gear is to rotate the
turbine generator shaft slowly and continuously, when the turbine is
shutdown and the shaft is still warm, to prevent bowing of the turbine
rotors.
2. Time requirements for having the turbine on turning gear.
3. The Main Turbine Turning Gear will engage and disengage
automatically when in AUTO.
4. Eccentricity should be < 0.03mm prior to a turbine roll.
Notes:
1. Before starting the turning gear, the following systems should be in
service: Closed Cooling Water, Circulating Water, and Main Turbine
Lube Oil.
2. For Cold Start conditions the Main Turbine Turning Gear should be put
in service at least 4 hours prior to rolling the turbine.
3. For Hot and Warm Start conditions, the turbine should continue on
turning gear following turbine shut down.
4. During Unit Shutdown, the turning gear can be stopped if absolutely
necessary after all shell metal temperature drop below 260oC.
^

Questions:

1.

Complete Main Turbine Pre-start Check Sheet

2.

Request AO to verify that lube oil flow and pressure are normal for all
turbine and generator bearings

Not Modeled

3.

Request AO to check Main Turbine Turning Gear is engaged

Not Modeled

4.

Start Main Turbine Turning Gear (TG-TGR-200PB)

TGEAR

5.

Verify the following conditions are satisfied:

TGEAR

a.

The Piggy Back Turning Gear Motor starts

TGEAR

b.

After a 5 seconds the Main Turning Gear Motor should start and
the Piggy Back Motor will stop

TGEAR

c.

Check Main Turbine speed increases to ~4 rpm

TGEAR

6.

Place Main Turbine Turning Gear in auto

TGEAR

7.

Verify that Main Turbine Eccentricity decreases to within the normal
range (0 ~ 0.3 mm)

TDATA1
RTRWARM

CS11 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-36

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS12: STATOR COOLING WATER SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. Before the Stator Cooling System startup, the Closed Cooling Water
System should be in service.
2. The Generator Hydrogen should be charged prior to placing the Stator
Cooling Water System in service. When the Generator Hydrogen is not
charged, the Stator Cooling Water System should be shutdown.
3. Stator Cooling Water System Runback/Trip setpoints are:
a. Stator inlet water flow < 1098Lpm
b. Stator inlet water pressure < 211kPag
c. Stator discharge water temperature > 83.4°C
^

Questions:

M

1.

Complete Stator Cooling Water System Pre-start Check Sheet

2.

Request AO to verify Stator Cooling Water Tank level is normal (above
the marking on the level gauge)

Not Modeled

3.

Request AO to Open Stator Cooler A Inlet Valve (SC-ISV-104A)

LOS11

4.

Verify Stator Cooling Pressure Control Valve (SCPIC370) is in Auto
with a setpoint of 530 kPa

SWCOOL

5.

Put Stator Cooling Temperature Control Valve (SCTIC355) in Auto:
a.

Set control station (SCTIC355) setpoint to 42°C

SWCOOL

b.

Place control station (SCTIC355) in Auto

SWCOOL

6.

Start Stator Cooling Water Pump A (SC-P-100A)

SWCOOL

7.

Place Stator Cooling Water Pump B (SC-P-100B) in Auto

SWCOOL

8.

Verify Stator Cooling Water System operating parameters (Pressure,
Temperature and conductivity) are within normal operating ranges

SWCOOL
SCTRENDS
STATSLOT

CS12 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-37

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS13: FUEL OIL SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. The Fuel Oil Main Storage Tank level may be controlled at a constant
level by the Fuel Oil Storage Tank Level Setpoint on LOS02.
^

Questions:

M

1.

Complete Fuel Oil System Pre-start Check Sheet

2.

Verify Ignition Oil Storage Tank level (FOLI407) is adequate (> 70%).
If not, take the following actions to fill the tank:

FUELOIL

a.

FUELOIL

b.

Verify Fuel Oil Storage Tank level (CFO-LI-407) is adequate (>
70%)
Request AO Start Fuel Oil Transfer Pump A (CFO-P-610A)

LOS02

3.

Verify that the Fire Fighting System is available

Not Modeled

4.

Request AO to confirm that all oil guns are in the off position (FOOGN-800A~L)

LOS03

5.

Place Ignitor Fuel Oil Header Pressure Control (FOPIC412)in auto:
a.

Set Ignitor Fuel Oil Header Pressure Control station (FOPIC412)
setpoint to 1500kPa

FUELOIL

b.

Place Ignitor Fuel Oil Header Pressure Control station (FOPIC412)
in auto

FUELOIL

6.

Start Fuel Oil Pump A (FO-P-700A)

FUELOIL

7.

Verify the Ignitor Fuel Oil Header Pressure Control (FOPIC412) is
controlling the header pressure at the setpoint

FUELOIL

8.

Using Fuel Oil Pump Standby Selector (FOHS410E) select Fuel Oil
Pump B as the standby pump

FUELOIL

9.

Place Fuel Oil Pump C (FO-P-700C) in auto

FUELOIL

10. Alternatively, the Fuel Oil Pump Sequence Control (FOHS410D) may
be used:
a.

Place all three fuel oil pumps in auto

FUELOIL

b.

Using Fuel Oil Pump Standby Selector (FOHS410E) select Fuel
Oil Pump B as the standby pump

FUELOIL

Jharsuguda Generic Startup Procedure
Rev. 04

1-38

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS13: FUEL OIL SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

c.

Select ON from the Fuel Oil Pump Sequence Control (FOHS410D)

FUELOIL

d.

Verify that Fuel Oil Pumps C and A auto start

FUELOIL

e.

After the Fuel Oil Header Pressure has stabilized at the setpoint
(~1500kPa), shutdown Fuel Oil Pump C and place in Auto

FUELOIL

11. Request AO to Stop Fuel Oil Transfer Pump A (CFO-P-610A) when
Fuel Oil Tank level is sufficient

LOS02

12. Request AO to check locally to make sure there are no fuel oil leaks

Not Modeled

CS13 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-39

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS14: BOILER FILL AND CLEAN UP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. Boiler water volume:
a. Boiler Drum (to NWL) = 25.946 tons
b. Furnace Water Walls = 190.673 tons
c. Economizer = 136 tons
Notes:
1. Before starting the Boiler Circulating Water Pumps, Condensate and
Feedwater Systems should be available and the Closed Cooling Water
should be in service.
2. All BCW Pumps must be filled and purged completely prior to filling
the boiler. Never open the BCWP motor drain valve while filling the
boiler.
3. Fill and drain the boiler until the boiler water quality is satisfactory:
TSS < 200ppb and pH is 9.0~9.5. If boiler water TSS is too high (>
500ppb), completely drain boiler water and refill.
4. After the boiler water quality is acceptable, put one Condensate polisher
in service.
5. Close water side Drum Vents (BS-MOV-200B and BS-MOV-201B)
prior to starting the first BCWP.
6. Verify that no Drum Level transmitters are bypassed (DLSELECT.)
7. Verify that no Drum Pressure transmitters are bypassed (DLSELECT.)
8. Verify that no Economizer Outlet Temperature transmitters are
bypassed (ECONBFPS.)
^


Questions:

BCWP A Startup
1.

Complete Pre-start Check Sheets:
a.

To Prepare the BCP Pump A for Service

b.

To Prepare the BCP Pump B for Service

c.

To Prepare the BCP Pump C for Service

2.

Request AO to complete BCWP Fill and Purge Sequence following
Plant Operating Instruction

3.

After drum level reaches 200-250 mm above normal water level,
request AO to close the Condensate to Boiler Fill Valve (FW-CKV-561)

4.

Close water side drum vent valves:
a.

Rev. 04

DRUMBD

Boiler Drum Vent Valve #1 (BS-MOV-200B)

Jharsuguda Generic Startup Procedure

DRUMLVL
LOS06

1-40

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS14: BOILER FILL AND CLEAN UP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

b.

Boiler Drum Vent Valve #2 (BS-MOV-201B)

DRUMBD

c.

Economizer Vent Valve (FW-MOV-113)

DRUMBD

5.

Request AO to open BCWP discharge valves:
a.

BCWPump A Discharge Valve 1 (FW-CKV-700A)

LOS06

b.

BCW Pump A Discharge Valve 2 (FW-CKV-701A)

LOS06

c.

BCW Pump B Discharge Valve 1 (FW-CKV-700B)

LOS06

d.

BCW Pump B Discharge Valve 2 (FW-CKV-701B)

LOS06

e.

BCW Pump C Discharge Valve 1 (FW-CKV-700C)

LOS06

f.

BCW Pump C Discharge Valve 2 (FW-CKV-701C)

LOS06

6.

Start BCWP A (FW-P-300A) and maintain operation to establish water
circulation

7.

The drum level will decrease, fill the drum again if necessary:

BLRCIRC

a.

Request AO to throttle open the Condensate to Boiler Fill Valve
(FW-CKV-561) to ~ 20%

LOS06

b.

After drum level reaches 150mm above normal water level, request
AO to close the Condensate to Boiler Fill Valve (FW-CKV-561)

DRUMLVL
LOS06

8.

Ask Chemist Technician to check boiler water quality after 1/2 hour of
circulation

Not Modeled

9.

If boiler water TSS > 200ppb, drain and fill the boiler until TSS is <
200ppb

Not Modeled

CS14 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-41

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS15: DRAFT PLANT STARTUP
Instructor Activity / Operating Procedure
Instructor Information
Discuss:
1. The danger of fire in the AH during startup
2. Why the air AH sootblowers are operated continuously during startup
when fuel oil is used as the startup fuel
3. The required permissives to initiate a boiler purge:
a. No Boiler Trip Command
b. Air Heaters Running
c. Both Primary Air Fans Off
d. No Flames Detected
e. Furnace Air Flow > 30%
f. Nozzle Tilts Horizontal
g. Furnace Air Flow < 40%
h. All Auxiliary Air Dampers Modulating
i. All SOFA Dampers Closed
j. Drum Level Satisfactory
k. All Warm Up Nozzle Valves Closed
l. All Pulverizers Off
m. All Hot Air Gates Closed
n. All Feeders Off
Notes:
1. In preparation for ESP start up, verify that:
a. Hopper Heaters and Insulator Heaters shall be turned on at least 6
hours prior to starting ESP.
b. Flue gas temperature from air heaters outlet shall be greater than
100°C for at least one hour prior to starting ESP.
2. ESP does not need to be running during fuel oil only firing in the
Boiler.
3. For FD Fan Startup, the meaning of "ID Fan in Service":
a. ID Fan is running
b. The running ID Fan's inlet damper is open
c. The running ID Fan's blade pitch control is in auto
4. In order to put ID Fan blade pitch control in auto, the Furnace Pressure
transmitters must be in service (FPCNTL)
5. For the FGD Hydraulic skids the A-pump is always the duty pump, the
B-pump is a "fail safe" pump and will only be in service when there is a
system malfunction.
6. If the ID Fan Inlet Damper does not open within 20 seconds of the fan
start, the fan will trip
Questions:
1. Before a fan starts, why must the inlet or outlet dampers and
blade pitch be closed?
Answer: With the dampers open, large furnace pressure surges are
possible and motor starting current can be excessive
Jharsuguda Generic Startup Procedure
Rev. 04

1-42

Student
Response

Screen or LOS
Reference

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS15: DRAFT PLANT STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Pulverizer Lube Oil Startup
1.

2.

Start Pulverizer Lube Oil Heaters:
a.

Pulverizer A Lube Oil Heater (BF-HTR-700A)

PULVA

b.

Pulverizer B Lube Oil Heater (BF-HTR-700B)

PULVB

c.

Pulverizer C Lube Oil Heater (BF-HTR-700C)

PULVC

d.

Pulverizer D Lube Oil Heater (BF-HTR-700D)

PULVD

e.

Pulverizer E Lube Oil Heater (BF-HTR-700E)

PULVE

f.

Pulverizer F Lube Oil Heater (BF-HTR-700F)

PULVF

After Pulverizer Lube Oil Temperature > 32°C, start Pulverizer Lube
Oil Pumps:
a.

Start Pulverizer A Lube Oil Pump (BF-P-700A)

PULVA

b.

Start Pulverizer B Lube Oil Pump (BF-P-700B)

PULVB

c.

Start Pulverizer C Lube Oil Pump (BF-P-700C)

PULVC

d.

Start Pulverizer D Lube Oil Pump (BF-P-700D)

PULVD

e.

Start Pulverizer E Lube Oil Pump (BF-P-700E)

PULVE

f.

Start Pulverizer F Lube Oil Pump (BF-P-700F)

PULVF

Draft Start Preparation
3.

Complete all fan group Pre-start Check Sheets:
a.

To Prepare the Secondary Air Heater A for service

b.

To Prepare the Secondary Air Heater B for service

c.

To Prepare the Primary Air Heater for service

d.

To Prepare the Forced Draft Fan A for service

e.

To Prepare the Forced Draft Fan B for service

f.

To Prepare the Induced Draft Fan A for service

g.

To Prepare the Induced Draft Fan B for service

h.

To Prepare the Primary Air Fan A for service

i.

To Prepare the Primary Air Fan B for service

Jharsuguda Generic Startup Procedure
Rev. 04

1-43

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS15: DRAFT PLANT STARTUP
Instructor Activity / Operating Procedure
4.

Student
Response

Screen or LOS
Reference

Request AO to do the following:
a.

Open Bottom Ash Hopper Seal Water Valve (BA-SHV-110) greater
than 50%

LOS05

b.

Check Bottom Ash Conveyor

LOS05

c.

Start Bottom Ash Handling PLC

LOS05

d.

Start Fly Ash Control

LOS05

e.

Place ESP Operating Mode (BG-PCP-800A) in remote

LOS05

f.

Start ESP Hopper and Insulation Heaters(BG-HTR-800)

LOS05

g.

Ensure all boiler manholes are closed

Not Modeled

h.

Verify status ESP Local Control panel: Hopper Vibro Motor
Control and Rapper Motor Control in auto

Not Modeled

5.

Start the FGD Hydraulic System:
a.

Place Absorber A Outlet Damper Hydraulic Pumps A and B (FC-P102A/B) in Auto

FGDHYD

b.

Start FGD A Outlet Damper Hydraulic System (FCP102A/B)

FGDHYD

c.

Verify Absorber A Outlet Damper Hydraulic Pump A (FC-P-102A)
is the duty pump and Pump B (FC-P-102B) is in standby

FGDHYD

d.

Place Absorber A Inlet Damper Hydraulic Pump A and B (FC-P101A/B) in Auto

FGDHYD

e.

Start FGD A Inlet Damper Hydraulic System (FCP101A/B)

FGDHYD

f.

Verify Absorber A Inlet Damper Hydraulic Pump A (FC-P-101A)
is the duty pump and Pump B (FC-P-101B) is in standby

FGDHYD

g.

Place Absorber B Outlet Damper Hydraulic Pumps A and B (FC-P202A/B) in Auto

FGDHYD

h.

Start FGD B Outlet Damper Hydraulic System (FCP202A/B)

FGDHYD

i.

Verify Absorber B Outlet Damper Hydraulic Pump A (FC-P-202A)
is the duty pump and Pump B (FC-P-202B) is in standby

FGDHYD

j.

Place Absorber B Inlet Damper Hydraulic Pumps A and B (FC-P201A/B) in Auto

FGDHYD

k.

Start FGD B Inlet Damper Hydraulic System (FCP201A/B)

FGDHYD

l.

Verify Absorber A Inlet Damper Hydraulic Pump A (FC-P-201A)
is the duty pump and Pump B (FC-P-201B) is in standby

FGDHYD

m. Place Absorber Bypass Damper Hydraulic Pumps A and B (FC-P301A/B) in Auto

FGDHYD

Jharsuguda Generic Startup Procedure
Rev. 04

1-44

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS15: DRAFT PLANT STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

n.

Start Bypass Damper Hydraulic System (FCP301A/B)

FGDHYD

o.

Verify Absorber Bypass Damper Hydraulic Pump A (FC-P-301A)
is the duty pump and Pump B (FC-P-301B) is in standby

FGDHYD

6.

Open the FGD Bypass Damper (FC-GSV-301) and the FGD Bypass
Damper Lower Section (FC-GSV-302)

7.

Verify closed all FGD inlet and outlet damper:

IDFANS
FCOV1

a.

FGD A Inlet Damper (FC-GSV-101)

IDFANS

b.

FGD A Outlet Damper (FC-GSV-102)

IDFANS

c.

FGD B Inlet Damper (FC-GSV-201)

IDFANS

d.

FGD B Outlet Damper (FC-GSV-202)

IDFANS

8.

Open ID Fan A and B Inlet Dampers (BG-ISD-811A/B)

IDFANS

9.

Open FD Fan A and B Outlet Dampers (BG-DMP-513A/B)

FDFANS

10. Close PA Fan A and B Inlet and Outlet Dampers:
a.

Close PA Fan A Inlet Damper (BF-FAN-600A)

PAFANS

b.

Close PA Fan B Inlet Damper (BF-FAN-600B)

PAFANS

c.

Close PA Fan A Outlet Damper (BF-PY-602A)

PAFANS

d.

Close PA Fan B Outlet Damper (BF-PY-602B)

PAFANS

11. Request AO to put Primary Air Heater Guide Bearing Oil Pump (BFHS-210) in auto

LOS05

12. Request AO to put Primary Air Heater Support Bearing Oil Pump (BFHS-230) in auto

LOS05

13. Request AO to put Secondary Air Heater A and B Guide Bearing Oil
Pumps (BG-HS-310A/B) in auto

LOS05

14. Request AO to put Secondary Air Heater A and B Support Bearing Oil
Pump (BG-HS-330A/B) in auto

LOS05

15. Start PA Fan A Lube Oil System:
a.

Start PA Fan A Lube Oil Pump # 1 (BF-P-100A)

PAFANA

b.

Place PA Fan A Lube Oil Pump #2 (BF-P-101A) in auto

PAFANA

c.

Start PA Fan A Lube Oil Fan #1 (BF-FAN-110A)

PAFANA

d.

Place PA Fan A Lube Oil Fan #2 (BF-FAN-111A) in auto

PAFANA

e.

Perform PA Fan A Lube Oil Pump Auto Standby Start Test

PAFANA

Jharsuguda Generic Startup Procedure
Rev. 04

1-45

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS15: DRAFT PLANT STARTUP
Instructor Activity / Operating Procedure
f.

Perform PA Fan A Lube Oil Fan Auto Standby Start Test

Student
Response

Screen or LOS
Reference
PAFANA

16. Start PA Fan B Lube Oil System:
a.

Start PA Fan B Lube Oil Pump # 1 (BF-P-100B)

PAFANB

b.

Place PA Fan B Lube Oil Pump #2 (BF-P-101B) in auto

PAFANB

c.

Start PA Fan B Lube Oil Fan #1 (BF-FAN-110B)

PAFANB

d.

Place PA Fan B Lube Oil Fan #2 (BF-FAN-111B) in auto

PAFANB

e.

Perform PA Fan B Lube Oil Pump Auto Standby Start Test

PAFANB

f.

Perform PA Fan B Lube Oil Fan Auto Standby Start Test

PAFANB

17. Start FD Fan A Lube Oil System:
a.

Start FD Fan A Lube Oil Pump #1 (BG-P-100A)

FDFANA

b.

Place FD Fan A Lube Oil Pump #2 (BG-P-101A) in auto

FDFANA

c.

Start FD Fan A Lube Oil Fan #1 (BG-FAN-110A)

FDFANA

d.

Place FD Fan A Lube Oil Fan #2 (BG-FAN-111A) in auto

FDFANA

e.

Start FD Fan A Hydraulic Oil Pump #1 (BG-P-200A)

FDFANA

f.

Place FD Fan A Hydraulic Oil Pump #2 (BG-P-201A) in auto

FDFANA

g.

Start FD Fan A Hydraulic Oil Fan #1 (BG-FAN-213A)

FDFANA

h.

Place FD Fan A Hydraulic Oil Fan #2 (B G-FAN-214A) in auto

FDFANA

i.

Perform FD Fan A Lube Oil Pump Auto Standby Start Test

FDFANA

j.

Perform FD Fan A Lube Oil Fan Auto Standby Start Test

FDFANA

k.

Perform FD Fan A Hydraulic Oil Pump Auto Standby Start Test

FDFANA

l.

Perform FD Fan A Hydraulic Oil Fan Auto Standby Start Test

FDFANA

18. Start FD Fan B Lube Oil System:
a.

Start FD Fan B Lube Oil Pump #1 (BG-P-100B)

FDFANB

b.

Place FD Fan B Lube Oil Pump #2 (BG-P-101B) in auto

FDFANB

c.

Start FD Fan B Lube Oil Fan #1 (BG-FAN-110B)

FDFANB

d.

Place FD Fan B Lube Oil Fan #2 (BG-FAN-111B) in auto

FDFANB

e.

Start FD Fan B Hydraulic Oil Pump #1 (BG-P-200B)

FDFANB

f.

Place FD Fan B Hydraulic Oil Pump #2 (BG-P-201B) in auto

FDFANB

Jharsuguda Generic Startup Procedure
Rev. 04

1-46

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS15: DRAFT PLANT STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

g.

Start FD Fan B Hydraulic Oil Fan #1 (BG-FAN-213B)

FDFANB

h.

Place FD Fan B Hydraulic Oil Fan #2 (B G-FAN-214B) in auto

FDFANB

i.

Perform FD Fan B Lube Oil Pump Auto Standby Start Test

FDFANB

j.

Perform FD Fan B Lube Oil Fan Auto Standby Start Test

FDFANB

k.

Perform FD Fan B Hydraulic Oil Pump Auto Standby Start Test

FDFANB

l.

Perform FD Fan B Hydraulic Oil Fan Auto Standby Start Test

FDFANB

19. Start ID Fan A Lube Oil/Hydraulic Oil System:
a.

Start ID Fan A LO/HO Pump #1 (BG-P-850A)

IDFANA

b.

Place ID Fan A LO/HO Pump #2 (BG-P-851A) in auto

IDFANA

c.

Start ID Fan A LO/HO Fan #1 (BG-FAN-860A)

IDFANA

d.

Place ID Fan A LO/HO Fan #2 (BG-FAN-861A) in auto

IDFANA

e.

Start ID Fan A Seal Air Fan #1 (BG-FAN-907A)

IDFANA

f.

Place ID Fan A Seal Air Fan #2 (BG-FAN-908A)in auto

IDFANA

g.

Place ID Fan A LO/HO Heater (BG-HTR-850A) in auto

IDFANA

h.

Perform ID Fan A LO/HO Pump Auto Standby Start Test

IDFANA

i.

Perform ID Fan A LO/HO Fan Auto Standby Start Test

IDFANA

20. Start ID Fan B Lube Oil/Hydraulic Oil System:
a.

Start ID Fan B LO/HO Pump #1 (BG-P-850B)

IDFANB

b.

Place ID Fan B LO/HO Pump #2 (BG-P-851B) in auto

IDFANB

c.

Start ID Fan B LO/HO Fan #1 (BG-FAN-860B)

IDFANB

d.

Place ID Fan B LO/HO Fan #2 (BG-FAN-861B) in auto

IDFANB

e.

Start ID Fan B Seal Air Fan #1 (BG-FAN-907B)

IDFANB

f.

Place ID Fan B Seal Air Fan #2 (BG-FAN-908B)in auto

IDFANB

g.

Place ID Fan B LO/HO Heater (BG-HTR-850B) in auto

IDFANB

h.

Perform ID Fan B LO/HO Pump Auto Standby Start Test

IDFANB

i.

Perform ID Fan B LO/HO Fan Auto Standby Start Test

IDFANB

21. Open the Primary Air Heater Gas Outlet Temperature Control Damper
(BGTIC609)

Jharsuguda Generic Startup Procedure
Rev. 04

1-47

PAHTR

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS15: DRAFT PLANT STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

22. Fully open the Secondary Air Heater A Gas Outlet Temperature Control
Damper (BGTIC507A)

SAHTR

23. Fully open the Secondary Air Heater B Gas Outlet Temperature Control
Damper (BGTIC507B)

SAHTR

24. Open the Cold Secondary Air Cross Over Damper (BF-PY-605)

PAFANS

25. Open the Hot Secondary Air Cross Over Damper (BF-PY-606)

PAFANS

26. Start the Primary Air Heater:
a.

Request AO to put Primary Air Heater Air Drive (BF-HS-600) in
auto

LOS05

b.

After the Primary Air Heater indicates "turning" on the OIS screen,
start the Primary Air Heater electric motor (BF-HTR-600)

PAHTR

27. Start Secondary Air Heater A:
a.

Request AO to put Secondary Air Heater A Air Drive (BG-HS510A) in auto

LOS05

b.

After the Secondary Air Heater A indicates "turning" on the OIS
screen, start the Secondary Air Heater A electric motor (BG-HTR510A)

SAHTR

28. Start Secondary Air Heater B:
a.

Request AO to put Secondary Air Heater B Air Drive (BG-HS510B) in auto

LOS05

b.

After the Secondary Air Heater A indicates "turning" on the OIS
screen, start the Secondary Air Heater A electric motor (BG-HTR510B)

SAHTR

29. Verify that no Primary Air Heater Temperature transmitters (BGHS609,
BGHS610, BGHS611) are bypassed

PASAHTRS

30. Verify that no Secondary Air Heater A Gas Outlet Temperature
transmitters (BGHS586A, BGHS587A, BGHS588A) are bypassed

PASAHTRS

31. Verify that no Secondary Air Heater A Gas Outlet Temperature
transmitters (BGHS586B, BGHS587B, BGHS588B) are bypassed

PASAHTRS

32. Verify all Auxiliary Air Dampers are full open

WBOXOV

33. Verify the Windbox Nozzle Tilt Control (BFTIC729A) is in manual and
the position is horizontal (50%)

WBOXOV

34. Verify that the SOFA Nozzle Tilt Control (BFHS730) is in manual and
the position is horizontal (38%)

WBOXOV

35. Verify at least one BCW pump in service

BLRCIRC

Jharsuguda Generic Startup Procedure
Rev. 04

1-48

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS15: DRAFT PLANT STARTUP
Instructor Activity / Operating Procedure
36. Verify that no Furnace Pressure Transmitters (BGHS548/697/699) are
bypassed

Student
Response

Screen or LOS
Reference
FPCNTL

Manual Draft Startup
37. Set Furnace Pressure Set Point (BGFPSETPT) to -0.15 kPag

FPCNTL

38. Close ID Fan A Inlet Damper (BG-ISD-811A)

IDFANS

39. Close FD Fan A Outlet Damper (BG-DMP-513A)

FDFANS

40. Ensure FD Fan B Outlet Damper is open in order to get ID Fan A Start
permissive (BG-DMP-513B)

FDFANS

41. Start ID Fan A (BG-FAN-500A), the ID Fan A Inlet Damper (BG-ISD811A) will automatically open after 5 seconds.

IDFANA

42. Place ID Fan A Blade Pitch Demand (BGIDFANA) in auto

IDFANA

43. Start FD Fan A (BG-FAN-510A)

FDFANA

44. Open FD Fan A Outlet Damper (B G-DMP-513 A)

FDFANA

45. Place FD Fan A Blade Pitch Demand (BGFDFANA) in auto

FDFANA

46. Close ID Fan B Inlet Damper (BG-ISD-811B)

IDFANS

47. Close FD Fan B Outlet Damper (BG-DMP-513B)

FDFANS

48. Wait for the air flow to increase above 20% and for the furnace pressure
to stabilize

FDFANS

49. Start ID Fan B (BG-FAN-500B), the ID Fan B Inlet Damper (BG-ISD811B) will automatically open after 5 seconds

IDFANB

50. Place ID Fan B Blade Pitch Demand (BGIDFANB) in auto

IDFANB

51. Start FD Fan B (BG-FAN-510B)

FDFANB

52. Open FD Fan B Outlet Damper (BG-DMP-513B)

FDFANB

53. Place FD Fan B Blade Pitch Demand (BGFDFANB) in auto

FDFANB

54. Adjust the balance between ID Fans A and B by adjusting the bias of
the ID Fan Blade Pitch Demand stations (BGIDFANA/B) appropriately

AIRMSTR

55. Adjust the balance between FD Fans A and B by adjusting the bias of
the ID Fan Blade Pitch Demand stations (BGFDFANA/B) appropriately

AIRMSTR

56. Verify that the initial airflow is automatically established at 35%

FPCNTL

57. Place the Auxiliary Air Damper Demand station (BGPDIC546/7) in
auto.

WBOXOV

Jharsuguda Generic Startup Procedure
Rev. 04

1-49

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS15: DRAFT PLANT STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Automatic Sequence Draft Startup
58. Verify ID Fan A Inlet Damper (BG-ISD-811A) is closed

IDFANA

59. Verify FD Fan A Outlet Damper (BG-DMP-513A) is closed

FDFANA

60. Verify FD Fan B Outlet Damper (BG-DMP-513B) is open

FDFANS

61. Verify ID Fan A Start Permissives are satisfied

HIDA

62. Start ID Fan A Start Sequence (BGIDASEQSTART), verify the
following sequence occurs:

IDFANSSA

a.

ID Fan A (BG-FAN-500A) starts

IDFANSSA

b.

ID Fan A Inlet Damper (BG-ISD-811A) opens

IDFANSSA

c.

ID Fan A Blade Pitch Demand (BGIDFANA) goes to its minimum
and then to auto

IDFANSSA

63. Start FD fan A Start Sequence (BGFDASEQSTART), verify the
following sequence occurs:

FDFANSSA

a.

FD Fan A Blade Pitch Demand (BGFDFANA) goes to minimum

FDFANSSA

b.

FD Fan A (BG-FAN-510A) starts

FDFANSSA

c.

FD Fan A Outlet Damper (BG-DMP-513A) opens

FDFANSSA

d.

FD Fan A Blade Pitch Demand (BGFDFANA) goes to auto

FDFANSSA

64. Close FD Fan B Outlet Damper (BG-DMP-513B)

FDFANS

65. Verify that the air flow is automatically increasing. Wait for the air
flow to increase above 20% and for the furnace pressure to stabilize

FDFANS

66. Start ID Fan B Start Sequence (BGIDBSEQSTART), verify the
following sequence occurs:

IDFANSSB

a.

ID Fan B (BG-FAN-500B) starts

IDFANSSB

b.

ID Fan B Inlet Damper (BG-ISD-811B) opens

IDFANSSB

c.

ID Fan B Blade Pitch Demand (BGIDFANB) goes to minimum
and then to auto

IDFANSSB

67. Start FD fan B Start Sequence (BGFDBSEQSTART), verify the
following sequence occurs:

FDFANSSB

a.

FD Fan B Blade Pitch Demand (BGFDFANB) goes to minimum

FDFANSSB

b.

FD Fan B (BG-FAN-510B) starts

FDFANSSB

c.

FD Fan B Outlet Damper (BG-DMP-513B) opens

FDFANSSB

Jharsuguda Generic Startup Procedure
Rev. 04

1-50

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS15: DRAFT PLANT STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

FD Fan B Blade Pitch Demand (BGFDFANB) goes to auto

FDFANSSB

68. Adjust the balance between ID Fans A and B by adjusting the bias of
the ID Fan Blade Pitch Demand stations (BGIDFANA/B) appropriately

AIRMSTR

69. Adjust the balance between FD Fans A and B by adjusting the bias of
the FD Fan Blade Pitch Demand stations (BGFDFANA/B)
appropriately

AIRMSTR

70. Verify that the initial airflow is automatically established at 35%

FPCNTL

71. Set the Windbox/Furnace dP Bias (BGPDIC546-BIAS) to 0

WBOXOV

72. Place the Auxiliary Air Damper Demand station (BGPDIC546/7) in
auto.

WBOXOV

d.

73. After MFT be cleared, usually after Purge, Place SOFA Dampers in
Auto:
a.

Set SOFA A Dampers Demand station (BFFIC713) Bias to 0%

WBOXOV

b.

Place SOFA A Dampers Demand station (BFFIC713) in Auto

WBOXOV

c.

Set SOFA B Dampers Demand station (BFFIC712) Bias to 0%

WBOXOV

d.

Place SOFA B Dampers Demand station (BFFIC712) in Auto

WBOXOV

e.

Set SOFA C Dampers Demand station (BFFIC711) Bias to 0%

WBOXOV

f.

Place SOFA C Dampers Demand station (BFFIC711) in Auto

WBOXOV

g.

Set SOFA D Dampers Demand station (BFFIC710) Bias to 0%

WBOXOV

h.

Place SOFA D Dampers Demand station (BFFIC710) in Auto

WBOXOV

CS15 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-51

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS16: DRAFT PLANT INTERLOCK TEST
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information:
Discuss:
1. During tests avoid excessive maximum or minimum values and do not
hold at high furnace pressure or draft.
2. Make sure all boiler air/gas path inspection doors are closed.
3. Be sure to inform operations staff and personnel at boiler that draft
plant test will be performed.
Notes:
1. Normal Furnace Pressure Block Increase occurs at a furnace pressure of
+1.3kPa. Normal Furnace Draft Block Increase occurs at a furnace
pressure of -1.5kPa.
2. In order to perform "I&C Temporary Modification" on the simulator,
place BG-FURN-REL switch (LOS05) in the following positions:
a. DRAFT to force High Draft Block
b. POSITIVE to force High Furnace Pressure Block
c. NO to release the force logic
3. Tests should be conducted at an air flow of 35% MCR
4. Test should be conducted with a furnace pressure setpoint -0.15kPag
5. Boiler alarm/trip condition:
a. Boiler Low Air Flow Alarm will occur when air flow < 30%
b. Boiler Low Air Flow Trip MFT will occur when air flow < 25%
c. Furnace Pressure Low Alarm will occur when < -1.0kPag
d. Furnace Pressure Low Trip MFT will occur when < -1.75kPag
e. Furnace Pressure High Alarm will occur when > +0.75kPag
f. Furnace Pressure High Trip MFT and fan trip will occur when >
+1.5kPag
6. Save a temporary AV (Boiler Purge Complete) after the boiler purge is
completed to use as the basis for the Draft Plant Interlock Tests.
7. Reload the Boiler Purge Complete AV prior to successive interlock
tests in place of the last two steps of each test.
8. Verify that the Bottom Ash Seal Water Valve is open > 50% to avoid
air in leakage into the boiler (LOS05.)

7•

Questions:

Draft Test Preparation
1.

Verify that Auxiliary Air Dampers are modulating and that the
Auxiliary Air Damper Demand control station (BGPDIC546/7) is in
AUTO mode

AUXAIR

2.

Verify ID Fan Blade Pitch Demand control (BGIDFANA/B) and FD
Fan Blade Pitch Demand control (BGFDFANA/B) are in auto

IDFANS
FDFANS

3.

Verify that the Purge Permissive "Purge Ready" has been established

PURGE

Jharsuguda Generic Startup Procedure
Rev. 04

1-52

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS16: DRAFT PLANT INTERLOCK TEST
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

4.

Place Secondary Air Heater A Gas Outlet Damper control station
(BGTIC507A) in auto

SAHTR

5.

Place Secondary Air Heater B Gas Outlet Damper control station
(BGTIC507B) in auto

SAHTR

6.

Place Primary Air Heater Gas Outlet Damper control station
(BGTIC609) in auto

PAHTR

7.

Initiate Boiler Purge (BF-BLR-PURGE)

PURGE

8.

Verify that the MFT is reset when the purge is completed

PURGE

Test 1: DCS MFT Push Button
9.

Initiate a Boiler Emergency Trip (BF-BLR-TRIP) from the OIS

PURGE

10. Verify that an MFT occurs and the boiler trips

PURGE

11. Acknowledge and clear any alarms

ALARMS

12. Re-initiate Boiler Purge (BF-BLR-PURGE)

PURGE

13. Verify that the MFT is reset when the purge is completed

PURGE

Test 2: DCS MFT Push Button
14. Initiate a Boiler Emergency Trip (BOILER TRIP) from the HPE

DRUMLVL

15. Verify that an MFT occurs and the boiler trips

PURGE

16. Acknowledge and clear any alarms

ALARMS

17. Re-initiate Boiler Purge (BF-BLR-PURGE)

PURGE

18. Verify that the MFT is reset when the purge is completed

PURGE

Test 3: Low Air Flow MFT
19. Place both ID Fan Blade Pitch Demand control stations
(BGIDFANA/B) in auto

IDFANS

20. Place both FD Fan Blade Pitch Demand control stations
(BGFDFANA/B) in manual

FDFANS

21. Gradually decrease the FD Fan Blade Pitch Demand (BGFDFANA/B)
to reduce the air flow

FDFANS

22. Verify the occurrence of the "Low Air Flow" alarm when air flow
decreases below 30% MCR

ALARMS

23. Verify that an MFT occurs and the boiler trips when air flow decreases
below 25%

PURGE

Jharsuguda Generic Startup Procedure
Rev. 04

1-53

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS16: DRAFT PLANT INTERLOCK TEST
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

24. Verify MFT/First Out indicates the "Air Flow < 25%" trip

PURGE

25. Return both FD Fan Blade Pitch Demand control stations
(BGFDFANA/B)to auto

FDFANS

26. Acknowledge and clear any alarms

ALARMS

27. Re-initiate Boiler Purge (BF-BLR-PURGE)

PURGE

28. Verify that the MFT is reset when the purge is completed

PURGE

Test 4: Furnace Draft High Alarms and MFT
29. Place both ID Fan Blade Pitch Demand control stations
(BGIDFANA/B) in manual

IDFANS

30. Gradually increase the ID Fan Blade Pitch Demand (BGIDFANA/B) to
reduce the furnace pressure

IDFANS

31. Verify the occurrence of the "Low Furnace Pressure" alarm when the
furnace pressure decreases below -1.0kPag

ALARMS

32. Verify that a Furnace Pressure Low Block occurs when the furnace
pressure drops below -1.55 kPag

ALARMS

33. Request I&C personnel to conduct "I&C Temporary Modification " to
control logic to disable High Draft (DRAFT) block

LOS05

34. Verify that an MFT occurs and the boiler trips when the furnace
pressure decreases below -1.75kPag

PURGE

35. Verify that the fan groups trip when the furnace pressure decreases
below -2.25kPa

IDFANS
FDFANS

36. Verify MFT/First Out indicates the "High Furnace Draft" trip

PURGE

37. Acknowledge and clear any alarms

ALARMS

38. Restart the ID and FD Fans
39. Re-initiate Boiler Purge (BF-BLR-PURGE)

PURGE

40. Verify that the MFT is reset when the purge is completed

PURGE

Test 5: Furnace Pressure High Alarms and MFT
41. Place both ID Fan Blade Pitch Demand control stations
(BGIDFANA/B) in manual

IDFANS

42. Verify both FD Fan Blade Pitch Demand control stations
(BGFDFANA/B) have automatically switched to manual

FDFANS

43. Gradually decrease the ID Fan Blade Pitch Demand (BGIDFANA/B) to
increase the furnace pressure

IDFANS

Jharsuguda Generic Startup Procedure
Rev. 04

1-54

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS16: DRAFT PLANT INTERLOCK TEST
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

44. Maintain airflow at 35% by increasing FD Fan Blade Pitch Demand

FDFANS

45. Verify the occurrence of the "High Furnace Pressure" alarm when the
furnace pressure increases above +0.75kPag

ALARMS

46. Verify that a Furnace Pressure High Block occurs when the furnace
pressure drops below +1.3 kPag

ALARMS

47. Request I&C personnel to conduct "I&C Temporary Modification " to
control logic to disable High Pressure (POSITIVE) block

LOS05

48. Verify that an MFT occurs and the boiler trips when the furnace
pressure increases above +1.5kPag

PURGE

49. Verify that the fan groups trip when the furnace pressure increases
above +1.5kPag

IDFANS
FDFANS

50. Verify MFT/First Out indicates the "High Furnace Pressure" trip

PURGE

51. Acknowledge and clear any alarms

ALARMS

52. Restart the ID and FD Fans
Test Completion
53. Request AO to verify Bottom Ash Water Seal still established.

LOS05

54. Verify ID Fan Blade Pitch Demand control stations (BGIDFANA/B)
have been returned to auto

IDFANS

55. Verify FD Fan Blade Pitch Demand control stations (BGFDFANA/B)
have been returned to auto

FDFANS

56. Verify furnace pressure is stable at -0.15kPag

IDFANS

57. Verify air flow is stable at ~35% MCR

FDFANS

CS16 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-55

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS17: FINAL CHECKS FOR LIGHT OFF
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. Before startup, remind CRO to verify that various transmitters have
been placed in service:
a. Furnace Press Transmitters (FPCNTL)
b. Drum Level Transmitters (DLSELECT)
c. Drum Pressure Transmitters (DLSELECT)
d. Air and Gas Temperature Transmitters (PASAHTRS)
e. Main Steam Press Transmitters (MSPRESS)
f. Economizer Outlet Temperature Transmitters (ECONBFPS)
Notes:
^


Questions:

Boiler Side Checks
1.

Verify that the Purge Permissive "Purge Ready" has been established.
If Drum Level Satisfactory not OK, maybe it's because of Drum level
Transmitter in Bypass, Place the level transmitter include please.

PURGE
DLSELECT

2.

Initiate Boiler Purge (BF-BLR-PURGE)

PURGE

3.

Verify that the MFT is reset when the purge is completed

PURGE

4.

Verify Fuel Oil Pump A (FO-P-700A) is in service

FUELOIL

5.

Verify drum level is approximately -200mm to allow for drum swell on
firing

DRUMLVL

6.

Verify the Windbox Nozzle Tilt Control (BFTIC729A) is in manual and
the position is horizontal (50%)

WBOXOV

7.

Verify that the SOFA Nozzle Tilt Control (BFHS730) is auto tracking

WBOXOV

8.

Ask Chemist Technician to verify boiler water quality is satisfactory
(TSS < 150ppb, pH= 9.0 ~ 9.6)

Not Modeled

9.

Request AO to select Air Heater Soot Blower Media as air

LOS12

10. Request AO to set Air Heater Soot Blower Drain Temperature Setpoint
(BS-TC-720) to 0°F when using air as the blowing media

LOS12

11. Request AO to set air heater soot blower drain temperature (BS-TC730) at 0°F when using air as the blowing media

LOS12

12. Verify Air Heater Soot Blowers are ready to operate

GSSBS-22

13. Open Economizer Recirculation Valve (FW-MOV-114)

BLRCIRC

Jharsuguda Generic Startup Procedure
Rev. 04

1-56

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS17: FINAL CHECKS FOR LIGHT OFF
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

14. Start Scanner Air Fan A (BF-SAFA)

SAFANS

15. Place Scanner Air Fan B (BF-SAFB) in auto

SAFANS

16. Put Furnace Thermal Probes in service and fully extended into furnace

GSSBS-07

17. Verify Primary Air Heater Temperature Transmitters
(BGHS609/610/611) are in service

PASAHTRS

18. Verify Secondary Air Heater A Gas Outlet Temperature Transmitters
(BGHS586A/587A/588A) are in service

PASAHTRS

19. Verify Secondary Air Heater B Gas Outlet Temperature Transmitters
(BGHS586B/587B/588B) are in service

PASAHTRS

20. Place Secondary Air Heater A Gas Outlet Temperature Control Damper
(BGTIC507A) in auto

SAHTR

21. Place Secondary Air Heater B Gas Outlet Temperature Control Damper
(BGTIC507B) in auto

SAHTR

22. Place Primary Air Heater Gas Outlet Temperature Control Damper
(BGTIC609) in auto

PAHTR

23. Verify Auxiliary Air Damper Demand station (BGPDIC546/7) is in
auto

WBOXOV

24. Place SOFA Dampers in auto:

WBOXOV

a.

SOFA D Dampers (BFFIC710)

WBOXOV

b.

SOFA C Dampers (BFFIC711)

WBOXOV

c.

SOFA B Dampers (BFFIC712)

WBOXOV

d.

SOFA A Dampers (BFFIC713)

WBOXOV

25. Put CCOFA Dampers in auto

WBOXOV

a.

CCOFA B Dampers (BFFIC714)

WBOXOV

b.

CCOFA A Dampers (BFFIC715)

WBOXOV

26. Verify that there is sufficient coal in the coal silos

PULVA-F

27. Request AO to open Coal Silo Gates for Silos A-F

LOS03

28. Request AO to start Coal Silo Vibrators for Silos A-F

LOS03

29. Ensure all Longstroke Sootblowers and Wall sootblowers are retracted

GSSBS

30. Verify the following transmitters are in service:
a.

Jharsuguda Generic Startup Procedure
Rev. 04

FPCNTL

Furnace Pressure Transmitters
1-57

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS17: FINAL CHECKS FOR LIGHT OFF
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

b.

Drum Level Transmitters

DLSELECT

c.

Air and Gas Temperature Transmitters

PASAHTRS

d.

Main Steam Press Transmitters

MSPRESST

e.

Economizer Outlet Temperature Transmitters

ECONBFPS

Turbine Side Checks
31. Verify Main Turbine Lube Oil is in service

LUBEOIL

32. Verify Main Turbine Hydraulic Oil Systems is in service

HPU

33. Verify Stator Cooling Water System is in service

SWCOOL

34.

Not Modeled

Verify Generator Core Monitor and Digital Fault Recorder are in
service

35. Verify Main Turbine is on Turning Gear

TGEAR

36. Verify that the generator is charged with hydrogen with a pressure of
~4.5 bar and a minimum hydrogen purity of 96%
If not, request AO to lineup generator gas system and charge with
Hydrogen(AP-H2), Until Hydrogen casing pressure ~4.5bar, Purity about
96%

GENOV
LOS12

37. Verify Group A Turbine Drains are open
a.

HP Turbine Stop Valve 1 Inlet Drain (BS-MOV-120A)

BSDRAINS

b.

HP Turbine Stop Valve 2 Inlet Drain (BS-MOV-120B)

BSDRAINS

c.

Stop Valve 1 Above Seat Drain (TG-FY-310A)

RTRWRMV1

d.

Stop Valve 2 Above Seat Drain (TG-FY-310B)

RTRWRMV1

e.

Stop Valve 1 Below Seat Drain (TG-FY-311A)

RTRWRMV1

f.

Stop Valve 2 Below Seat Drain (TG-FY-311B)

RTRWRMV1

g.

Combined Reheat Valve 1 After Seat Drain (TG-FY-400A)

RTRWRMV2

h.

Combined Reheat Valve 2 After Seat Drain (TG-FY-400B)

RTRWRMV2

38. Verify Group B Turbine Drains are open
a.

Cold Reheat A Drain Pot 1 (BS-MOV-134A)

RTRWRMV1

b.

Cold Reheat B Drain Pot 1 (BS-MOV-134B)

RTRWRMV1

c.

Cold Reheat A Drain Pot 2 (BS-MOV-135A)

RTRWRMV1

d.

Cold Reheat B Drain Pot 2 (BS-MOV-135B)

RTRWRMV1

Jharsuguda Generic Startup Procedure
Rev. 04

1-58

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS17: FINAL CHECKS FOR LIGHT OFF
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

e.

Hot Reheat A Drain Valve (BS-MOV-154A)

RTRWRMV2

f.

Hot Reheat B Drain Valve (BS-MOV-154B)

RTRWRMV2

g.

HP Shell Drain Valve 1 (TG-FY-200)

RTRWRMV1

h.

HP Shell Drain Valve 2 (TG-FY-210)

RTRWRMV1

i.

HP Shell Drain Valve 3 (TG-FY-220)

RTRWRMV1

j.

HP Shell Drain Valve 4 (TG-FY-230)

RTRWRMV1

k.

CV Common Drain Valve (TG-MOV-340)

RTRWRMV1

39. Verify Main Turbine Valves are closed:

STMVALVE

a.

HP Main Stop Valve 1 (MSV1)

STMVALVE

b.

HP Main Stop Valve 2 (MSV2)

STMVALVE

c.

HP Control Valve 1 (CV1)

STMVALVE

d.

HP Control Valve 2 (CV2)

STMVALVE

e.

HP Control Valve 3 (CV3)

STMVALVE

f.

HP Control Valve 4 (CV4)

STMVALVE

g.

Reheat Intercept Valve 1 (IV1)

STMVALVE

h.

Reheat Intercept Valve 2 (IV2)

STMVALVE

i.

Reheat Stop Valve 1 (RSV1)

STMVALVE

j.

Reheat Stop Valve 2 (RSV2)

STMVALVE

40. Place MKV to DCS Control Selection (TG-MKV-DCS) on DCS

HPBYPASS

41. Verify Backpass Superheater header drains are open:
a.

Backpass Roof Drain Valve (BS-MOV-220)

SHDRAINS

b.

Backpass Front Header Drain Valve (BS-MOV-221)

SHDRAINS

c.

Backpass Rear Header Drain Valve #1 (BSMOV222)

SHDRAINS

d.

Backpass Rear Header Drain Valve #2 (BSMOV223)

SHDRAINS

e.

Backpass Rear Header Drain Valve #3 (BSMOV224)

SHDRAINS

42. Verify all drum and superheater vents are open until steam is flow
established and indicated by increasing temperatures during boiler lightoff
a.

Boiler Drum Vent Valve #3 (BS-MOV-205)

Jharsuguda Generic Startup Procedure
Rev. 04

SHVENTS

SHVENTS
1-59

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS17: FINAL CHECKS FOR LIGHT OFF
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

b.

Boiler Drum Vent Valve #4 (BS-MOV-210)

SHVENTS

c.

Intermediate SH Desuperheater A Vent Valve (BS-MOV-230A)

SHVENTS

d.

Intermediate SH Desuperheater B Vent Valve (BS-MOV-230B)

SHVENTS

e.

SH Crossover Vent Valve #1 (BS-MOV-240)

SHVENTS

f.

SH Crossover Vent Valve #2 (BS-MOV-276)

SHVENTS

g.

Final SH Desuperheater A Vent Valve (BS-MOV-250A)

SHVENTS

h.

Final SH Desuperheater B Vent Valve (BS-MOV-250B)

SHVENTS

i.

Final SH Vent Valve #1 (BS-MOV-104A)

SHVENTS

j.

Final SH Vent Valve #2 (BS-MOV-104B)

SHVENTS

43. Request AO to verify superheater and reheater attemperator spray
isolation valves are closed
a.

RH Desuperheater Isolation Valve (FWISV325A)

LOS07

b.

RH Desuperheater Isolation Valve (FWISV325B)

LOS07

c.

Final SH Desuperheater Isolation Valve (FW-ISV-338B)

LOS07

d.

Final SH Desuperheater Isolation Valve (FW-ISV-338D)

LOS07

44. Request AO to verify Auxiliary Steam to Deaerator Isolation Valve is
open (AS-ISV-150)

LOS06

45. Verify Deaerator Auxiliary Steam Pressure Control station (ASPIC110)
is in manual and closed

AUXSTM

46. Verify Gland Steam Blower A or B (TL-BLO-550A/B) in service

STMSEAL

47. Open Unit 1/2 SH Division Panel Cross Tie (AS-MOV-104) to allow
use of Unit 2 steam supply to auxiliary steam during startup

AUXSTM

48. Prepare the Auxiliary Steam line from Unit2 by flushing for at least one
hour

Not Modeled

49. Request AO to place all Oil Gun Local switches in REMOTE

LOS03

50. Request AO to open Main Steam to BFPT Isolating Valve (BS-SHV105)

LOS07

51. Request AO to open IP Steam to BFPT A Isolating Valve (TG-ISV260A)

LOS07

52. Request AO to open IP Steam to BFPT B Isolating Valve (TG-ISV260B)

LOS07

CS17 FINISHED
Jharsuguda Generic Startup Procedure
Rev. 04

1-60

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS18: LIGHT OFF AND INCREASING PRESSURE
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. Before light off, ensure BP.4 Final Check for Light off has been
completed.
2. Boiler Light off Notes:
a. For a cold start put AB elevation oil guns in first.
b. Boiler temperature ramp rate should be < 222°C/hr
(56°C/15minutes)
c. Furnace exit gas temperature should be < 538°C
d. For a cold start, the startup from light off to synchronous speed
shall require < 7.0 hours
e. Ensure 2-4 Superheater Back Pass Drains, all Superheater Drains
and Vents, and all Reheater Vents are open.
f. Place only one BCWP in service while boiler water temperature
(suction manifold temperature) is between 93-121°C.
g. Perform change over of BCWP' s during rising boiler temperature
and pressure in order to keep BCWP differential temperature
(between suction manifold and casing) <55°C and thus maintain
the start permissive.
3. BCWP Trip Conditions:
a. Motor Cavity Temperature > 60°C
b. Pump Differential Pressure < 41.37kPag for > 5 sec (when three
BCW pumps are in service)
c. Cooling Water Flow < 242.3 l/min
4. Keep one or tow backpass drains open until the turbine is rolling. Do
not close all backpass drains before the turbine begins rolling.
1 ^ 1 Questions:
1 • 1 1. Why are the drum vents closed at 200kPag?
Answer: The drum vents are used to vent oxygen and dissolved gases
from the boiler so they do not react with the boiler tubes to cause
corrosion. At 200kPag, the drum is considered free of air and the
venting process in complete.
1.

Complete the Deaerator Pre-start Check Sheet

2.

Verify Atomizing Air Pressure status indicates "ready" on OIS screen
and Atomizing Air Pressure (FOPI910) is OK

ELEVAB

3.

Verify Fuel Oil Pressure status indicates "ready" on OIS screen and
Fuel Oil Pressure (FOPI825) is OK

ELEVAB

4.

Verify Thermal Probes are in service and fully extended

GSSBS-07

5.

Open Warm Up Oil Trip Valve (BF-WUOTV)

FUELOIL

6.

Put Warm Up Oil Control station (FOFIC800) in service:

FUELOIL

Jharsuguda Generic Startup Procedure
Rev. 04

1-61

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS18: LIGHT OFF AND INCREASING PRESSURE
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

a.

Set Warm Up Oil Control (FOFIC800) pressure setpoint to
900kPag

FUELOIL

b.

In manual, gradually open Warm Up Oil Control Valve
(FOFIC800) until Lockout status is released

FUELOIL

c.

Place Warm Up Oil Control (FOFIC800) in auto

FUELOIL

7.

Request AO to verify Elevation AB Oil Guns are in Remote position at
the local panel

LOS03

8.

Start Elevation AB Oil (BF-ELEV-AB), wait for elevation start
sequence to complete (all corners fired)

ELEVAB

9.

Reset and Restart if any oil nozzle (corner) is not proven

ELEVAB

10. Adjust Warm Up Oil Control (FOFIC800) pressure setpoint as required
to maintain desired warmup rate

ELEVAB

11. Request AO to verify selected Sootblower Media is Air/MS and
Sootblower Drain Temperature Setpoints (BS-TC-720/730) are set to
0°F

LOS12

12. Start Air Heater Soot Blowers in Continuous Mode using Service Air.

GSSBS-07

13. When Steam Flow > 10% request AO to change Sootblower Drain
Temperature Setpoints (BS-TC-720/730) to 204 °C

LOS12

14. Verify that Air Heater Sootblower automatically changeover to Main
Steam when Steam Flow > 10%

GSSBS-07

15. Verify Unit 1/2 SH Division Panel Cross Tie (AS-MOV-104) is open

AUXSTM

16. After Auxiliary Steam line from Unit 2 is ready, place Deaerator
Auxiliary Steam Pressure Control in service:
a.

Gradually warm the Deaerator by manual opening the Deaerator
Auxiliary Steam Pressure Control Valve (ASPIC110)

AUXSTM

b.

When the Deaerator is warmed and pressurized to ~35kPag, set the
Deaerator Auxiliary Steam Pressure Control (ASPIC110) setpoint
to 40kPag

AUXSTM

c.

Place the Deaerator Auxiliary Steam Pressure Control (ASPIC110)
in auto

AUXSTM

17. Waiting for the Main Steam Pressure and Temperature to increase

STMTEMP

18. Closely monitor drum level and economizer temperature, prevent
economizer from steaming, verify maximum feed water to boiler
temperature differential < 111°C (feedwater temp - steam drum temp)

FWOV

19. If the Drum Level increases above +150mm, lower drum level:
a.

Request AO to open Intermittent Blow Down Valve (FW-DRV-120)

Jharsuguda Generic Startup Procedure
Rev. 04

1-62

LOS06

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS18: LIGHT OFF AND INCREASING PRESSURE
Instructor Activity / Operating Procedure
b.

Open Lower Drum Drain Valve (FW-MOV-118)

Student
Response

Screen or LOS
Reference
BLRCIRC

20. If the Drum Level drops, request AO to open the Condensate to Boiler
Fill Valve (FW-CKV-561)

LOS06

21. Closely monitor B CWP's difference between the Casing Temperature
(FW-TI-762A/B/C) and the Suction Manifold Differential Temperature
(FW-TI-763A/B/C) for the standby pumps

BCWPA/B/C

a.

Make sure the differential temperature does not exceed 55°C

BCWPA/B/C

b.

Change over the pumps if the differential temperature reaches
~25°C

BLRCIRC

c.

Start the second BCWP (two in service) after the drum water
temperature > 121°C

H2OMENU

22. After the Main Steam Pressure > 150kPa or Steam Temperature >
120°C (whichever comes first), close the drum vents:
a.

Boiler Drum Vent Valve #3 (BS-MOV-205)

DRUMBD

b.

Boiler Drum Vent Valve #4 (BS-MOV-210)

DRUMBD

23. After the Main Steam Pressure > 150kPa, close the superheater vents:
a.

Intermediate SH Desuperheater A Vent Valve (BS-MOV-230A)

SHVENTS

b.

Intermediate SH Desuperheater B Vent Valve (BS-MOV-230B)

SHVENTS

c.

SH Crossover Vent Valve #1 (BS-MOV-240)

SHVENTS

d.

SH Crossover Vent Valve #2 (BS-MOV-276)

SHVENTS

e.

Final SH Desuperheater A Vent Valve (BS-MOV-250A)

SHVENTS

f.

Final SH Desuperheater B Vent Valve (BS-MOV-250B)

SHVENTS

g.

Final SH Vent Valve #1 (BS-MOV-104A)

SHVENTS

h.

Final SH Vent Valve #2 (BS-MOV-104B)

SHVENTS

24. The Reheater Vents (BSMOV146A/B and BSMOV300) can be closed
at the same time as the superheater vents, however, they must be closed
prior to starting the Condenser Vacuum System

RHVENTS

25. Keep all Main Steam Drains and Reheat Drains Open

MSDRAIN
RHDRAINS

26. Coordinating with Chemist Technician to check Boiler water quality.

Not Modeled

CS18 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-63

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS19: STEAM SEAL SYSTEM START UP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. Steam Seal can be put in service using steam from the Main Steam
System or the Auxiliary Steam System
a. Using Main Steam: when the Main Steam Pressure is > 1000kPag
and the Main Steam Temperature is > 200°C.
b. Using Auxiliary Steam: When Unit 2 must has sufficient steam
quality and Unit 1/2 SH Division Panel Cross Tie (AS-MOV-104)
is open.
Notes:
1. Steam Seal Temperature must be maintained above 150°C and below
399°C.
^

Questions:

Steam Seal System Preparation
1.

Start Gland Steam Condenser Blower A (TL-BLO-550A)

STMSEAL

2.

Verify GSC Blower Suction Pressure is negative (about -10inH2O).

STMSEAL

3.

Set Steam Seal Header Pressure setpoint (AP_SSH_CMD) to 0.30barg

STMSEAL

4.

Verify MKV to DCS Control Select (TG-MKV-DCS) is set to DCS

STMSEAL

5.

Request AO to put Steam Seal Mode to A UTO at Mark V <I>

LOS06

Steam Seal System Startup Using Auxiliary Steam
6.

Manually open the Auxiliary Steam Seal Header Drain Valve (TL-LY291)

7.

Put the Auxiliary Steam Temperature Control station (TLTIC290) in
service

STMSEAL

a.

Place the Steam Seal Desuperheater Block Valve (CM-FY-192) in
auto

STMSEAL

b.

Set Auxiliary Steam Temperature Control station (TLTIC290)
setpoint to 310°C

STMSEAL

c.

Place the Auxiliary Steam Temperature Control station
(TLTIC290) in auto

STMSEAL

8.

Put the Auxiliary Steam Pressure Control station (TLPIC290) in auto
a.

Set Auxiliary Steam Pressure Control station (TLPIC290) setpoint
to 600kPag

Jharsuguda Generic Startup Procedure
Rev. 04

1-64

STMSEAL

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS19: STEAM SEAL SYSTEM START UP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

b.

Place the Auxiliary Steam Pressure Control station (TLPIC290) in
auto

STMSEAL

c.

Allow the Auxiliary Steam Header Pressure to stabilize at the
setpoint

STMSEAL

d.

Place the Auxiliary Steam Seal Header Drain Valve (TL-LY-291)
in Auto

STMSEAL

9.

Start the Steam Seal System Control (LSSON_CMD)

STMSEAL

10. Gradually open Auxiliary Steam Seal Block Valve (TL-MOV-295)

STMSEAL

11. Verify the Steam Seal Header Pressure (AP SSH) stabilizes between
0.30 ~ 0.32barg

STMSEAL

12. From the Steam Seal Header Divert (SSHDR-AD) select yes. The Auto
Dump Enable will indicate "Active."

STMSEAL

Steam Seal System Startup Using Main Steam
13. Request AO to open Main Steam to Seal Steam Isolation Valve (BS-ISV108)

Not Modeled

14. Verify the Steam Seal System Control (LSSON_CMD) is ON

STMSEAL

15. Gradually open Steam Seal Admission Block Valve (TL-MOV-250)
until full open

STMSEAL

16. Verify that Steam Seal Pressure Control Valve (TLFV270) is
controlling and that the Steam Seal Header Pressure (AP_SSH)
increases and stabilizes at 0.3~0.32 barg

STMSEAL

17. From the Steam Seal Header Divert (SSHDR-AD) select yes. The Auto
Dump Enable will indicate "Active."

STMSEAL

Condensate Polisher A Startup
18. After the boiler water quality becomes acceptable, confirm with
Chemist Technician and place Condensate Polisher A in service:
a.

Open Condensate Polisher Inlet Valve (CM-MOV-414)

COND1

b.

Open Condensate Polisher Outlet Valve (CM-MOV-416)

COND1

c.

Close Condensate Polisher Bypass Valve (CM-MOV-417)

COND1

CS19 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-65

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS20: CONDENSER VACUUM SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. During start up put all three Vacuum Pumps in service: Vacuum Pump
A to Condenser A, Vacuum Pump to Condenser B, and Vacuum Pump
C to Both Condensers A and B.
2. After the unit has reached the load target and the condenser vacuum is
normal, shutdown Vacuum Pump C and close both inlet valves.
3. Condenser A and B Vacuum Breaker Seal Water Valves (CM-FV525A/B) on LOS08 should be opened > 50%.
|?|

1.

Questions:

Complete all vacuum pump groups Pre Start Check Sheet
a.

Prepare Condenser Vacuum Pump A for start up

b.

Prepare Condenser Vacuum Pump B for start up

c.

Prepare Condenser Vacuum Pump C for start up

2.

Close the Reheater Vent Valves:
a.

RH Outlet A Vent Valve (BS-MOV-146A)

RHVENTS

b.

RH Outlet A Vent Valve (BS-MOV-146B)

RHVENTS

c.

Reheater Vent Valve (BS-MOV-300)

RHVENTS

3.

Request AO to open Condenser A to Vacuum Pump A Isolation Valve
(CV-ISV-200)

LOS08

4.

Request AO to open Condenser A to Vacuum Pump C Isolation Valve
(CV-ISV-220)

LOS08

5.

Request AO to open Condenser B to Vacuum Pump B Isolation Valve
(CV-ISV-215)

LOS08

6.

Request AO to open Condenser B to Vacuum Pump C Isolation Valve
(CV-ISV-225)

LOS08

7.

Close Condenser A Vacuum Breaker (CMMOV525A)

CONDVAC

8.

Close Condenser B Vacuum Breaker (CMMOV525B)

CONDVAC

9.

Request AO to open Condenser A Vacuum Breaker Seal Water Valve
(CM-FV-525A)

LOS08

Jharsuguda Generic Startup Procedure
Rev. 04

1-66

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS20: CONDENSER VACUUM SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

10. Request AO to open Condenser B Vacuum Breaker Seal Water Valve
(CM-FV-525B)

LOS08

11. Start three Condenser Vacuum Pumps (CV-P-100A/B/C) one by one

CONDVAC

12. Monitor the Condenser Pressure as it decreases. The Condenser
evacuation process will take ~2 hours.

CONDVAC

13. After the load target is reached and the Condenser Pressure drops below
60mmHg, stop Vacuum Pump C:

CONDVAC

a.

Stop Condenser Vacuum Pump C (CVP100C)

CONDVAC

b.

Request AO to close Condenser A to Vacuum Pump C Isolation
Valve (CV-ISV-220)

LOS08

c.

Request AO to close Condenser B to Vacuum Pump C Isolation
Valve (CV-ISV-225)

LOS08

14. Two Vacuum Pumps will remain in service

CONDVAC

CS20 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-67

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS21: MOTOR DRIVEN BFP STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. At low steam flow, drum level control in auto is usually unstable. Drum
level control may placed in auto after higher and more stable steam
flow has been established.
Notes:
1. MDBFP Trip Conditions:
a. Lubrication Oil Trip Set Points:
Bearing Oil Header Pressure < 50kPag
Bearing Oil Header Temperature > 60°C
Working Oil After Cooler Temperature > 120°C
b. Fluid Coupling Side Trip Set Points:
Bearing Temperature > 90°C
Input & Intermediate Vibration > 150^m
Output Vibration > 120^m
c. Motor Side Trip Set Points:
Outboard & Inboard Bearing Vibration > 70^m
d. Pump Side Trip Set Points:
CP & A.CP Bearing Temperature > 85°C
CP & A.CP Side Mechanical Flushing Temperature > 100°C
Thrust Bearing Temperature > 75°C
Outboard & Inboard Bearing Vibration > 100^m
2. The Condensate Pumps are only capable of providing feedwater to the
boiler for drum pressures up to 4000kPag.

[21 Questions:
1.

Complete MDBFP Pump Pre-start Check Sheet

2.

Request AO to open MDBFP Minimum Flow Isolating Valve (FW-ISV210)

LOS07

3.

Start MDBFP Auxiliary Lube Oil Pump (FW-P-252)

MDFWP

4.

Place MDBFP Suction Flow control station (FWFIC309C) in auto

MDFWP

5.

Verify all MDBFP Start Permissive indicate Ready

HMDFWP

6.

Before Drum Pressure increases above 3000kPag, start the MDBFP
(FW-P-200.) Observe the following

MDFWP

a.

The MDBFP starts and speed increases to 500rpm

MDFWP

b.

The MDBFP Suction Flow Control Valve (FWFIC309C) remains
full open to allow minimum flow through the pump

MDFWP

Jharsuguda Generic Startup Procedure
Rev. 04

1-68

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS21: MOTOR DRIVEN BFP STARTUP
Instructor Activity / Operating Procedure
c.

The MDBFP Discharge Check Valve (FW-FY-318C) auto opens

Student
Response

Screen or LOS
Reference
MDFWP

7.

When ready, open MDBFP Discharge Valve (FW-MOV-318F) to feed
drum

MDFWP

8.

Gradually increase MDBFP Demand (FWSIC242) to increase pump
speed and pump discharge pressure to match with boiler pressure

MDFWP

9.

Adjust feed water flow to maintain normal drum level (FWSIC242)

MDFWP

10. Once steam flow (and thus feedwater demand) have stabilized at a
sufficient level place the Drum Level Control (FWLIC370) in auto:
a.

Set Drum Level Control (FWLIC370) setpoint to -50mm

MDFWP

b.

Place MDBFP Demand (FWSIC242) in auto

MDFWP

c.

Place Drum Level Control (FWLIC370) in auto

MDFWP

d.

Verify Drum Level control is stable, if not place Drum Level
Control (FWLIC370) in manual and control manually

MDFWP

CS21 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-69

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS22: TURBINE BYPASS SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. After a unit outage, boiler steam silica needs to be boiled out before
sending steam to the turbine. This is done by firing the boiler and
establishing steam flow through the Turbine Bypass System. The
bypass will be controlled at a target condition of 130 bar until the
Chemist Technician confirms the silica boil out is complete. After
boiler steam silica requirements are satisfied, the Turbine Bypass
System can be shutdown.
Notes:
1. The HP Bypass if one of the following conditions occurs:
a. Condenser vacuum > 259mmHg
b. HP Bypass line temperature < 121°C
c. Feedwater to Reheater differential pressure < 10bar
2. When steam flow > 20%, the "Loss of Reheat Protection" will be
armed. The protection will only be disarmed when an MFT occurs.
Thus, in order to prevent arming, the steam flow should be maintained
below 20% during operation of the Turbine Bypass System.

a

1.

Questions:

Verify conditions are satisfactory for starting the Turbine Bypass
System:
a.

Firing the Boiler with one Oil Gun Elevation in service

FLMDMP

b.

Main Steam Pressure ~6000kPag

HPBYPASS

c.

Condenser Vacuum is established (vacuum < 90 mmHg)

COND1

d.

One TDBFP or MDBFP is in service

FWOV

2.

Reset the Turbine Bypass System (L43BYP_TRP)

HPBYPASS

3.

Setup and verify the following conditions for the Turbine Bypass
System:
a.

HP Bypass Steam Control Mode (L83HPSV_MNPS) is in auto

HPBYPASS

b.

HP Bypass Water Control Mode (L83HPW_MNPS) is in auto

HPBYPASS

c.

HP Bypass Control Mode (L83HPW_AU) is in auto

HPBYPASS

d.

LP Bypass Steam Control Mode (L83LPS_MNPS) is in auto

HPBYPASS

e.

LP Bypass Water Control Mode (L83LPW_MNPS) is in auto

HPBYPASS

f.

LP Bypass Control Mode (L83HPS_AU) is in auto

HPBYPASS

Jharsuguda Generic Startup Procedure
Rev. 04

1-70

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS22: TURBINE BYPASS SYSTEM STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

g.

Set the HP Bypass Pressure Setpoint (HPSV_PR_CMD) to 5 bar
above the current pressure

HPBYPASS

h.

Set the LP Bypass Pressure Setpoint (LPS_SP) to 12 bar

HPBYPASS

4.

Start the Bypass System (L43M_BYPR) by selecting ON

HPBYPASS

5.

Gradually reduce the HP Bypass Pressure Setpoint (HPSV_PR_CMD)
in 2 bar increments until the HP Bypass Valves start opening and the LP
Bypass Pressure starts increasing

HPBYPASS

6.

Increase the firing rate to increase Main Steam Pressure and steam flow
by increasing the Warm Up Oil Control (FOFIC800) setpoint

WUHDR

7.

Close all Backpass Drain Valves:
a.

Backpass Roof Drain Valve (BSMOV220)

SHDRAINS

b.

Backpass Front Header Drain Valve (BSMOV221)

SHDRAINS

c.

Backpass Rear Header Drain Valve #1 (BSMOV222)

SHDRAINS

d.

Backpass Rear Header Drain Valve #2 (BSMOV223)

SHDRAINS

8.

Increase the HP Bypass Pressure Setpoint (HPSV_PR_CMD) as the
firing rate increases

HPBYPASS

9.

Continue adjusting the firing rate and the HP Bypass pressure setpoint
until the Main Steam Pressure is ~130 bar and the steam flow > 10%

HPBYPASS
WUHDR

10. Hold this condition until the Chemist Technician confirms that the
boiler silica condition is satisfied

Not Modeled

11. Once the boiler silica condition is satisfied, shutdown the Turbine
Bypass System:
a.

Decrease the firing rate by decreasing the Warm Up Oil Control
(FOFIC800) setpoint

WUHDR

b.

As the firing rate decreases decrease the HP Bypass Pressure
Setpoint (HPSV_PR_CMD) until the setpoint is 100 bar

HPBYPASS

c.

Continue decreasing the firing rate until the HP Bypass Valves are
closed

WUHDR
HPBYPASS

d.

Stop the Bypass System (L43M_BYPC) by selecting OFF

HPBYPASS

CS22 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-71

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS23: RESET THE MAIN TURBINE
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
?

Questions:

1.

Check all extraction steam valves and clear any "Command Disagree"
(CMDDSG) alarm indications on the valve faceplates

2.

Verify that the Turbine Valves are in the appropriate "tripped" position

LPFWHOV
HPFWHOV

a.

Main Stop Valve 1 (MSV1) is closed

STMVALVE

b.

Main Stop Valve 2 (MSV2) is closed

STMVALVE

c.

Control Valve 1 (CV1) is closed

STMVALVE

d.

Control Valve 2 (CV2) is closed

STMVALVE

e.

Control Valve 3 (CV3) is closed

STMVALVE

f.

Control Valve 4 (CV4) is closed

STMVALVE

g.

Intercept Valve 1 (IV1) is closed

STMVALVE

h.

Intercept Valve 2 (IV2) is closed

STMVALVE

i.

Reheat Stop Valve 1 (RSV1) is closed

STMVALVE

j.

Reheat Stop Valve 2 (RSV2) is closed

STMVALVE

k.

Ventilator Valve (VV) is open

STMVALVE

3.

Verify all Lock Out Relays are reset

LORELAY

4.

Reset the Main Turbine (L86MR1_CPB)

MKVMRST

5.

Verify that the Master Reset button text turns to green and there are no
Active Turbine Trips

MKVMRST

6.

Verify that the LP Feedwater Heater Extraction Isolation Valves open:
a.

FWH 2 A Steam Isolation Valve (HB-MOV-295A)

LPFWHOV

b.

FWH 2 B Steam Isolation Valve (HB-MOV-295B)

LPFWHOV

c.

FWH 3 Steam Isolation Valve (HB-MOV-283)

LPFWHOV

d.

FWH 4 Steam Isolation Valve (HB-MOV-271)

LPFWHOV

Jharsuguda Generic Startup Procedure
Rev. 04

1-72

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS23: RESET THE MAIN TURBINE
Instructor Activity / Operating Procedure
7.

Student
Response

Screen or LOS
Reference

Verify that the LP Feedwater Heater Extraction Check Valves
faceplates indicate an OPEN command, but the valve position feedback
indicates closed:
a.

FWH 2 Extraction Check Valve A (HB-SY-296A)

LPFWHOV

b.

FWH 2 Extraction Check Valve B (HB-SY-296B)

LPFWHOV

c.

FWH 3 Extraction Check Valve (HB-SY-284)

LPFWHOV

d.

FWH 4 Extraction Check Valve (HB-SY-272)

LPFWHOV

e.

Deaerator Extraction Check Valve #1 (HB-SY-245)

DEAOV

f.

Deaerator Extraction Check Valve #2 (HB-SY-249)

DEAOV

8.

Verify HP Feedwater Heater Extraction Steam Check Valves are open:
a.

FWH 6A Extraction Steam Check Valve (HB-SY-232A)

HPFWHA

b.

FWH 7A Extraction Steam Check Valve (HB-SY-219A)

HPFWHA

c.

FWH 8A Extraction Steam Check Valve (HB-SY-206A)

HPFWHA

d.

FWH 6B Extraction Steam Check Valve (HB-SY-232B)

HPFWHB

e.

FWH 7B Extraction Steam Check Valve (HB-SY-219B)

HPFWHB

f.

FWH 8B Extraction Steam Check Valve (HB-SY-206B)

HPFWHB

9.

Place the LP Feedwater Heater Level Control stations in auto:
a.

FWH 2 Normal Level Control (HDLIC644)

LPFWHOV

b.

FWH 2 Emergency Level Control (HDLIC645)

LPFWHOV

c.

FWH 3 Normal Level Control (HDLIC636)

LPFWHOV

d.

FWH 3 Emergency Level Control (HDLIC637)

LPFWHOV

e.

FWH 4 Normal Level Control (HDLIC628)

LPFWHOV

f.

FWH 4 Emergency Level Control (HDLIC629)

LPFWHOV

CS23 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-73

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS24: MAIN TURBINE ROTOR WARMING
Instructor Activity / Operating Procedure
Instructor Information
Discuss:
1. Rotor Warming should take 4-6 hours depending on the starting rotor
temperatures and the warming rate.
2. During turbine rotor warming the CRO should proceed to warm the
BFPT's, prepare the PA Fans for startup and lineup and fill the FGD sea
water system.
Notes:
1. Main Turbine Rotor Pre-Warming Requirements:
a. HP Rotor Bore Temperature > 176°C
b. RHT Inlet Rotor Bore Temperature > 54.4°C
c. RHT Exhaust Rotor Bore Temperature > 54.4°C
2. Main Turbine Rotor Warming Operating Parameter Limits:
a. Maximum Turbine Speed = 23rpm.
b. Maximum Warming Rate = 38°C/hr
c. Maximum MSV2 opening = 2.95%
d. Chest pressure = ~12bar
3. Main Turbine Rotor Warming Operating Parameter Limits:

^

Questions:
' 1. List the Main Turbine Wanning valves and give the purpose of
each?
Answer:
-

Main Stop Valve Bypass Valve - The MSV Bypass valve provides
main steam flow to the control valve chest during rotor warming
and chest warming.

-

Reverse Flow Valve (RFV) - The Reverse Flow Valve provides
warming flow through the HP turbine from the reheater during
operation in Reverse Flow.

-

Heating Steam Feed Valve (HSFV) - This valve admits packing
steam from the steam seal header to the midspan of the double
flow reheat turbine section to pre-warm the intermediate pressure

Jharsuguda Generic Startup Procedure
Rev. 04

1-74

Student
Response

Screen or LOS
Reference

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS24: MAIN TURBINE ROTOR WARMING
Instructor Activity / Operating Procedure

-

Student
Response

Screen or LOS
Reference

rotor.
Heating Steam Block Valve (HSBV) - This valve will admit steam
leak-off from the HP Turbine to the Deaerator. The valve will
open when the IV's open > 20%.

1.

Verify that the Main Steam temperature is within the recommended
range for rotor warming

2.

Close the following Drain and Vent Valves between the CV's and the
IV's by first placing the valve in manual and then closing the valve:

LOADCR

a.

Stop Valve 1 Below Seat Drain (TG-FY-311A)

RTRWRMV1

b.

Stop Valve 2 Below Seat Drain (TG-FY-311B)

RTRWRMV1

c.

Cold Reheat A Drain Pot 1 (BS-MOV-134A)

RTRWRMV1

d.

Cold Reheat B Drain Pot 1 (BS-MOV-134B)

RTRWRMV1

e.

Cold Reheat A Drain Pot 2 (BS-MOV-135A)

RTRWRMV1

f.

Cold Reheat B Drain Pot 2 (BS-MOV-135B)

RTRWRMV1

g.

HP Shell Drain Valve 1 (TG-FY-200)

RTRWRMV1

h.

HP Shell Drain Valve 2 (TG-FY-210)

RTRWRMV1

i.

HP Shell Drain Valve 3 (TG-FY-220)

RTRWRMV1

j.

HP Shell Drain Valve 4 (TG-FY-230)

RTRWRMV1

k.

CV Common Drain Valve (TG-MOV-340)

RTRWRMV1

l.

HP Bypass A Outlet Drain Valve (BS-MOV- 116A)

RTRWRMV1

m. HP Bypass B Outlet Drain Valve (BS-MOV-116B)

RTRWRMV1

n.

Reheat Desuperheater A Outlet Valve (BS-MOV-290A)

RTRWRMV2

o.

Reheat Desuperheater B Outlet Valve (BS-MOV-290B)

RTRWRMV2

p.

Hot Reheat A Drain Valve (BS-MOV-154A)

RTRWRMV2

q.

Hot Reheat B Drain Valve (BS-MOV-154B)

RTRWRMV2

r.

Combined Reheat Valve 1 After Seat Drain (TG-FY-400A)

RTRWRMV2

s.

Combined Reheat Valve 2 After Seat Drain (TG-FY-400B)

RTRWRMV2

t.

RH Outlet A Vent Valve (BS-MOV-146A)

RTRWRMV2

u.

RH Outlet B Vent Valve (BS-MOV-146B)

RTRWRMV2

v.

Reheater Vent Valve (BS-MOV-300)

RTRWRMV2

Jharsuguda Generic Startup Procedure
Rev. 04

1-75

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS24: MAIN TURBINE ROTOR WARMING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

3.

Confirm with the Chemist Technician that steam quality is satisfactory
for turbine rotor warming: Silica: <10ppb, Sodium: < 3ppb, cation
conductivity: < 0.2ps/cm

Not Modeled

4.

Verify the Main Turbine is Reset (L86MR1_CPB)

MKVMRST

5.

Initiate the Rotor Warming Request command (L43RWR)

RTRWARM

6.

Verify that all Main Turbine CV's fully open

STMVALVE

7.

Verify that the HSFV is open

STMVALVE

8.

Close FWH 8A/8B Before Isolation Drain Valves (HB-FY-204A/B) by
placing in manual and then closing the valves

RTRWRMV1

9.

Gradually open Main Stop Valve #2 Bypass Valve (SVR_BS2) in 0.2%
increments

RTRWARM

10. As the Main Stop Valve #2 Bypass valve is opened, the chest pressure
(CP_CHST) and HP Exhaust Pressure (TP_HPE_DPY) will increase
and the turbine may lift off the turning gear. The MSV2 Bypass valve
should be positioned:

RTRWARM

a.

Limit Main Turbine Speed to ~20 rpm

RTRWARM

b.

Limit Chest Pressure to ~12 barg

RTRWARM

11. Record first stage shell metal temperature before rotor warming and
determine rotor warming hold time based the curve in note 3, above.
12. After the HP turbine shell is pressurized, open the HP Shell Drain
Valves one-by-one for a few second to release any condensation inside
the turbine:

RTRWRMV1

a.

HP Shell Drain Valve 1 (TG-FY-200)

RTRWRMV1

b.

HP Shell Drain Valve 2 (TG-FY-210)

RTRWRMV1

c.

HP Shell Drain Valve 3 (TG-FY-220)

RTRWRMV1

d.

HP Shell Drain Valve 4 (TG-FY-230)

RTRWRMV1

13. Rotor Warming is complete when the Rotor Bore Temperatures are
above the target values and when the Rotor Warming Required status
indicates "NO"

RTRWARM

14. After Rotor Warming is complete, initiate the Rotor Warming Cancel
command (L43RWC)

RTRWARM

15. Verify that all Main Turbine CV's close

STMVALVE

16. Verify that the HSFV closes

STMVALVE

17. Put the following Drain and Vent Valves between the CV's and the
IV's in auto:
Jharsuguda Generic Startup Procedure
Rev. 04

1-76

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS24: MAIN TURBINE ROTOR WARMING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

a.

Cold Reheat A Drain Pot 1 (BS-MOV-134A)

RTRWRMV1

b.

Cold Reheat B Drain Pot 1 (BS-MOV-134B)

RTRWRMV1

c.

Cold Reheat A Drain Pot 2 (BS-MOV-135A)

RTRWRMV1

d.

Cold Reheat B Drain Pot 2 (BS-MOV-135B)

RTRWRMV1

e.

HP Shell Drain Valve 1 (TG-ISV-200)

RTRWRMV1

f.

HP Shell Drain Valve 2 (TG-ISV-210)

RTRWRMV1

g.

HP Shell Drain Valve 3 (TG-ISV-220)

RTRWRMV1

h.

HP Shell Drain Valve 4 (TG-ISV-230)

RTRWRMV1

i.

CV Common Drain Valve (TG-MOV-340)

RTRWRMV1

j.

HP Bypass A Outlet Drain Valve (BS-MOV- 116A)

RTRWRMV1

k.

HP Bypass B Outlet Drain Valve (BS-MOV-116B)

RTRWRMV1

l.

FWH 8A Before Isolation Drain Valves (HB-FY-204A)

RTRWRMV1

m. FWH 8B Before Isolation Drain Valves (HB-FY-204B)

RTRWRMV1

n.

Reheat Desuperheater A Outlet Valve (BS-MOV-290A)

RTRWRMV2

o.

Reheat Desuperheater B Outlet Valve (BS-MOV-290B)

RTRWRMV2

p.

Hot Reheat A Drain Valve (BS-MOV-154A)

RTRWRMV2

q.

Hot Reheat B Drain Valve (BS-MOV-154B)

RTRWRMV2

r.

Combined Reheat Valve 1 After Seat Drain (TG-ISV-400A)

RTRWRMV2

s.

Combined Reheat Valve 2 After Seat Drain (TG-ISV-400B)

RTRWRMV2

t.

RH Outlet A Vent Valve (BS-MOV-146A), and Close

RTRWRMV2

u.

RH Outlet A Vent Valve (BS-MOV-146A) , and Close

RTRWRMV2

v.

Reheater Vent Valve (BS-MOV-300) , and Close

RTRWRMV2

18. Verify that the Main Turbine coasts back on turning gear
CS24 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-77

TGEAR

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS25: BFPT WARMING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. In order to save time during the startup, the first BFPT may be warmed
during the rotor warming period.
Notes:
Questions:

BFPT A Warming
1.

Complete TDBFP A Pre-start Check Sheet

2.

Request AO to open TDBFP A Min Flow Isolation Valve (FW-ISV-150)

LOS07

3.

Request AO to verify Main Steam to BFPT Isolation Valve (BS-SHV105) is open

LOS07

4.

Request AO to verify IP Steam to BFPT A Isolation valve (TG-ISV260A) is open

LOS07

5.

Request AO to place BFPT A Turning Gear (FW-TGR-100A) in auto

LOS07

6.

Request AO to open BFPT A Exhaust Valve (HB-FY-266A)

LOS07

7.

Open the following BFPT A Steam Drains and place in auto:
a.

BFPT A Steam Supply Drain Valve (BS-MOV-114A)

FWPA

b.

BFPT A HP Stop Valve Drain #1 (TG-MOV-113A)

FWPA

c.

BFPT A HP Stop Valve Drain #2 (TG-MOV-114A)

FWPA

d.

BFPT A LP Stop Valve Drain #1 (TG-MOV-111A)

FWPA

e.

BFPT A LP Stop Valve Drain #2 (TG-MOV-112A)

FWPA

f.

BFPT A First Stage Drain (TG-MOV-115A)

FWPA

8.

Check Turbine Driven Feed Pump A Start Permissives display and
verify BFPT A is ready

HFWPA

9.

Reset TD BFP A (TGTRB100A) and verify the following events occur

FWPA

a.

Verify that the TD BFP A (TGTRB100A) faceplate display
indicates Reset

FWPA

b.

Verify that the BFPT A HP and LP Stop Valves open

FWPA

c.

Verify that BFPT A Control Valves remain closed

FWPA

Jharsuguda Generic Startup Procedure
Rev. 04

1-78

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS25: BFPT WARMING
Instructor Activity / Operating Procedure
10. Warming will be complete when the temperature difference between the
Inlet Steam Temperature and the BFPT A CV Casing Metal
Temperature is less than 80°C (Casing Metal Temperature Not Low
indicates Ready)

Student
Response

Screen or LOS
Reference
HFWPA

BFPT B Warming
11. Complete TDBFP B Pre-start Check Sheet
12. Request AO to open TDBFP A Min Flow Isolation Valve (FW-ISV-160)

LOS07

13. Request AO to verify IP Steam to BFPT B Isolation valve (TG-ISV260B) is open

LOS07

14. Request AO to place BFPT B Turning Gear (FW-TGR-100B) in auto

LOS07

15. Request AO to open BFPT B Exhaust Valve (HB-FY-266B)

LOS07

16. Open the following BFPT B Steam Drains and place in auto:
a.

BFPT B Steam Supply Drain Valve (BS-MOV-114B)

FWPB

b.

BFPT B HP Stop Valve Drain #1 (TG-MOV-113B)

FWPB

c.

BFPT B HP Stop Valve Drain #2 (TG-MOV-114B)

FWPB

d.

BFPT B LP Stop Valve Drain #1 (TG-MOV- 111B)

FWPB

e.

BFPT B LP Stop Valve Drain #2 (TG-MOV-112B)

FWPB

f.

BFPT B First Stage Drain (TG-MOV-115B)

FWPB

17. Check Turbine Driven Feed Pump B Start Permissives display and
verify BFPT B is ready

HFWPB

18. Reset TD BFP B (TGTRB100B) and verify the following events occur:

FWPB

a.

Verify that the TD BFP B (TGTRB100A) faceplate display
indicates Reset

FWPB

b.

Verify that the BFPT B HP and LP Stop Valves open

FWPB

c.

Verify that BFPT B Control Valves remain closed

FWPB

19. Warming will be complete when the temperature difference between the
Inlet Steam Temperature and the BFPT B CV Casing Metal
Temperature is less than 80°C (Casing Metal Temperature Not Low
indicates Ready)
CS25 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-79

HFWPB

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS26: PRIMARY AIR FAN STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. The Primary Air Fans can be prepared during turbine rotor warming and
started after rotor warming is complete.
2. Before placing PA Fan Bias Station in auto, confirm bias is < 50%. If >
50%, manually increase the output to reduce below 50%.
"t|

Questions:

PA Fan Preparation
1

Verify the PA Fan Lube Oil Systems are in service:

PAFANA

a.

PA Fan A Lube Oil Pump #1 (BF-P-100A) is running

PAFANA

b.

PA Fan A Lube Oil Pump #2 (BF-P-101A) is in auto

PAFANA

c.

PA Fan A Lube Oil Fan # 1 (BF-FAN-110A) is running

PAFANA

d.

PA Fan A Lube Oil Fan #2 (BF-FAN-111A) is in auto

PAFANA

e.

PA Fan B Lube Oil Pump #1 (BF-P-100B) is running

PAFANB

f.

PA Fan B Lube Oil Pump #2 (BF-P-101B) is in auto

PAFANB

g.

PA Fan B Lube Oil Fan # 1 (BF-FAN-110B) is running

PAFANB

h.

PA Fan B Lube Oil Fan #2 (BF-FAN-111B) is in auto

PAFANB

2

Verify PA Fan Start Permissives are satisfied

HPA

3

Verify Hot and Cold Secondary Air Crossover Dampers (BF-PY605A/606A) are open

PAFANS

4

Issue a PA Fan Request to Start (BF PA FAN RTS) and verify the
following events:

PAFANS

a.

PAFANA/B/C/D/E/F

All Pulverizer Cold Air Dampers (BFFIC666A through F) are
closed to 5%
PA Fan Manual Start

5

Verify PA Fan A Bias Station is in manual and the PA Fan A Inlet
Dampers (BF-FCD-600A/601A) are closed

PAFANA

6

Verify PA Fan A Outlet Damper (BF-PY-602A) is closed

PAFANA

7

Start PA Fan A (BF-FAN-600A)

PAFANA

Jharsuguda Generic Startup Procedure
Rev. 04

1-80

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS26: PRIMARY AIR FAN STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

8.

Verify Seal Air Booster Fan A (BF-SABFA) auto starts

SAFANS

9.

Open the Cold Air Gate for at least one pulverizer: Pulverizer A
(BFPY664A)

PULVA

10. Open PA Fan A Outlet Damper (BF-PY-602A)

PAFANS

11. Verify Cold Secondary Air Crossover Damper (BF-PY-605A)
automatically closes

PAFANS

12. Verify Hot Secondary Air Crossover Damper (BF-PY-606A)
automatically closes

PAFANS

13. Increase PA Fan A Bias Station demand until PA Fan to Furnace DP
(BF-PDI-683/4) is ~7.5kPag

PAFANS

14. Place PA Fan A Bias Station in auto

PAFANA

15. Open remaining Pulverizer Cold Air Gates (if any):
a.

Pulverizer A Cold Air Gate (BF-PY-664A)

PULVA

b.

Pulverizer B Cold Air Gate (BF-PY-664B)

PULVB

c.

Pulverizer C Cold Air Gate (BF-PY-664C)

PULVC

d.

Pulverizer D Cold Air Gate (BF-PY-664D)

PULVD

e.

Pulverizer E Cold Air Gate (BF-PY-664E)

PULVE

f.

Pulverizer F Cold Air Gate (BF-PY-664F)

PULVF

16. Verify PA Fan B Bias Station is in manual and the PA Fan B Inlet
Dampers (BF-FCD-600B/601B) are closed

PAFANB

17. Verify PA Fan B Outlet Damper (BF-PY-602B) is closed

PAFANB

18. Start PA Fan B (BF-FAN-600B)

PAFANB

19. Open PA Fan B Outlet Damper (BF-PY-602B)

PAFANB

20. Place PA Fan B Bias Station in auto

PAFANB

21. Adjust the balance between PA Fans A and B by adjusting the bias of
the PA Fan B Bias Stations appropriately

AIRMSTR

PA Fan Automatic Sequence Startup
22. Verify PA Fan A Start Permissives are satisfied

HPA

23. Verify PA Fan A Outlet Damper (BF-PY-602A) is closed

PAFANA

24. Start PA Fan A Start Sequence (BGPAASEQSTART), verify the
following sequence occurs:

PAFANSSA

Jharsuguda Generic Startup Procedure
Rev. 04

1-81

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS26: PRIMARY AIR FAN STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

a.

PA Fan A (BF-FAN-600A) starts

PAFANSSA

b.

PA Fan A Outlet Damper (BF-PY-602A) open

PAFANSSA

c.

PA Fan A Bias Station lock is released and Inlet Dampers remain
closed

PAFANSSA

25. Place PA Fan A Bias Station in auto, the Inlet Dampers will
automatically open to control PA to Furnace dP to the setpoint

PAFANS

26. Verify Seal Air Booster Fan A (BF-SABFA) auto starts

SAFANS

27. Verify Cold Secondary Air Crossover Damper (BF-PY-605A)
automatically closes

PAFANS

28. Verify Hot Secondary Air Crossover Damper (BF-PY-606A)
automatically closes

PAFANS

29. Open Pulverizer Cold Air Gates:
a.

Pulverizer A Cold Air Gate (BF-PY-664A)

PULVA

b.

Pulverizer B Cold Air Gate (BF-PY-664B)

PULVB

c.

Pulverizer C Cold Air Gate (BF-PY-664C)

PULVC

d.

Pulverizer D Cold Air Gate (BF-PY-664D)

PULVD

e.

Pulverizer E Cold Air Gate (BF-PY-664E)

PULVE

f.

Pulverizer F Cold Air Gate (BF-PY-664F)

PULVF

30. Verify PA Fan B Outlet Damper (BF-PY-602B) is in auto

PAFANB

31. Start PA Fan B Start Sequence (BGPABSEQSTART), verify the
following sequence occurs:

PAFANSSB

a.

PA Fan B (BF-FAN-600B) starts

PAFANSSB

b.

PA Fan B Outlet Damper (BF-PY-602B) opens

PAFANSSB

c.

PA Fan B Bias Station goes to manual and PA Fan Inlet Dampers
close

PAFANSSB

32. Place PA Fan B Bias Station in auto

PAFANS

33. Adjust the balance between PA Fans A and B by adjusting the bias of
the PA Fan B Bias Stations appropriately

AIRMSTR

Flyash Handling Startup
34. Request AO to Start Flyash Handling System

LOS05

CS26 FINISHED
Jharsuguda Generic Startup Procedure
Rev. 04

1-82

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS27: PULVERIZER WARMING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. Each pulverizer needs to be warmed before coal is fed into the
pulverizer. Adequate warming requires that the outlet temperature of
the pulverizer be maintained at >60°C for at least 15 minutes.
2. At low loads (low Hot Primary Air Temperature) only one pulverizer
can be warmed at a time. Warming for the next pulverizer can be
initiated once the first pulverizer is placed in service with a feeder
demand > 30%. After two pulverizers are in service, it is possible to
warm two pulverizers at a time.
3. Pulverizers should be warmed in the sequence in which they will be put
in service. The typical sequence for placing Pulverizers in operation
during a Cold Start is as follows:
a. Pulverizer B
b. Pulverizer C
c. Pulverizer D
d. Pulverizer A
e. Pulverizer E
Notes:
1—|
| • | Questions:

1.

Complete Pulverizers Pre-start Check Sheets:
a.

To prepare Pulverizer A for service

b.

To prepare Pulverizer B for service

c.

To prepare Pulverizer C for service

d.

To prepare Pulverizer D for service

e.

To prepare Pulverizer E for service

f.

To prepare Pulverizer F for service
Pulverizer B Warming

2.

Verify Pulverizer B Lube Oil System is in service and Lube Oil
Temperature > 35°C

HPULVBR1

3.

Request AO to open Seal Air to Coal Feeder Valve (BF-ISV-515B)

LOS04

4.

Verify Pulverizer B Seal Air Valve (BF-PULVB-SAV) faceplate
command indicates Open

PULVB

5.

Request AO to Put Coal Feeder B OP Mode to REMOTE(BF-FDR500B)

LOS04

Jharsuguda Generic Startup Procedure
Rev. 04

1-83

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS27: PULVERIZER WARMING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

6.

Request AO to Open Inerting steam Block Valve B(BS-FV-210B)

LOS06

7.

Open Pulverizer B Discharge Valves (BFFY509B)

PULVB

8.

Verify Pulverizer B Start permissive is satisfied

HPULVBR1

9.

Start Pulverizer B (BF-PVR-500B)

PULVB

10. Verify Pulverizer B Seal Air Valve (BF-PULVB-SAV) auto opens

PULVB

11. Verify Pulverizer B PA Flow Control station (BFFIC666B) opens and
wait for air flow to increase to the setpoint

PULVB

12. Open Pulverizer B Hot Air Gate (BF-PY-662B)

PULVB

13. Place Pulverizer B PA Flow Control station (BFTIC666B) in auto

PULVB

14. Place Pulverizer B Temperature Control station (BFTIC586B) in auto:
a.

Set Pulverizer B Temperature Control station (BFTIC586B)
setpoint to 72°C

PULVB

b.

Place Pulverizer B Temperature Control station (BFTIC586B) in
auto

PULVB

15. Pulverizer Warming will be complete when the Pulverizer Outlet
Temperature (BFTIC586B) has been maintained at >66°C for at least
15 minutes

PULVB

CS27 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-84

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS28: BFPT A STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. BFPT startup notes:
a. Do not attempt to start or operate the turbine under any
circumstances without the Emergency Oil Pump in the "ready"
position. Serious equipment damage and consequential personal
injury may result due to loss of oil pressure.
b. Do not operate the turbine boiler feed pump with oil reservoir
temperature below 37.8°C to assure proper suction condition for
the emergency oil pump.
c. At low steam flow, AUTO drum level control usually not
controlling properly. Drum level control may put on AUTO later
after higher and more stable steam flow
d. Prior to put BFPT in service, warming is required to reduce
differential temperature between BFPT steam inlet and BFPT
casing metal. The differential temperature shall less than 80°C.
2. BFP Pump-side trip setpoints:
a. Outboard & inboard bearing high vibration > 120^m
b. CP & A.CP bearing high temp > 85°C
c. Thrust bearing high temp > 75°C
d. CP & A.CP side mechanical flushing high temp > 100°C
3. BFP Turbine-side trip setpoints:
a. HP bearing high vibration > 152^m
b. LP bearing high vibration > 152^m
c. Rotor Axial position > +0.81 or < -0.81
d. Exhaust Steam press > 295 ~ 320mmHg
e. Exhaust steam high temp > 204.4°C
4. The BFPT Speed Pickups do not work correctly at speeds less than
500rpm. Prior to reaching that speed the speed indication on the OIS
screen will indicate 0.

[7]

Questions:

1.

Verify BFPT A Warming is complete

FWPA

2.

Check Turbine Driven Feed Pump A Start Permissives display and
verify BFPT A is ready to start

HFWPA

3.

Verify BFPT A Lube Oil Temperature Control (CCTIC838) is in auto
and Lube Oil Temperature is above 37.8°C

FWPA

4.

Place TD BFP A Suction Flow Control station (FWFIC309A) in auto

FWPA

5.

Place BFPT A Discharge Check Valve (FWFY318A) in auto (FW-FY318A)

FWPA

Jharsuguda Generic Startup Procedure
Rev. 04

1-85

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS28: BFPT A STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

6.

Verify BFPT A Emergency Lube Oil Pump (LT-P-250A) is on standby

FWPA

7.

Start TD BFP A (TGTRB100A)

FWPA

8.

After starting, the BFPT A Control Valves will open and bring the
BFPT Speed to the minimum speed of 500rpm

FWPA

9.

After starting the BFPT A observe the following events occur:

FWPA

a.

BFPT A starts and after a delay speed signal indicates ~500rpm

FWPA

b.

The TD BFP A Suction Flow Control Valve (FWFIC309A)
remains full open to allow minimum flow through the pump

FWPA

10. Open the BFPT A Discharge Check Valve (FW-FY-318A), if cannot
open, set auto and set to manual again, then open it.

FWPA

11. Change BFPT A Lube Oil Temperature Control (CCTIC838) setpoint
to 50°C

FWPA

12. Open the BFPT A Discharge Valve (FW-MOV-318D)

FWPA

13. Gradually increase TD BFP A Demand (TGSIC100A) to increase pump
speed and pump discharge pressure to match with the current MDBFP
outlet pressure

DRUMLVL

14. Verify all BFPT A Drains is close automatically when BFPT Speed >
1200rpm:

FWPA

a.

BFPT A Steam Supply Drain Valve (BS-MOV-114A)

FWPA

b.

BFPT A HP Stop Valve Drain #1 (TG-MOV-113A)

FWPA

c.

BFPT A HP Stop Valve Drain #2 (TG-MOV-114A)

FWPA

d.

BFPT A LP Stop Valve Drain #1 (TG-MOV-111A)

FWPA

e.

BFPT A LP Stop Valve Drain #2 (TG-MOV-115A)

FWPA

f.

BFPT A First Stage Drain (TG-MOV-113A)

FWPA

15. After TD BFP A speed has increased sufficiently to provide feedwater
to the drum, adjust TD BFP A Demand (TGSIC100A) to maintain
normal drum level

DRUMLVL

16. Verify MDBFP gradually withdraws as BFPT A maintains drum level
stable

DRUMLVL

17. Place TD BFP A Demand (TGSIC100A) in auto

DRUMLVL

18. Place MD BFP Demand (TGSIC242) in manual

DRUMLVL

19. Gradually reduce MD BFP Demand (TGSIC242) to 0%

DRUMLVL

20. Stop the MD Boiler Feed Pump (FW-P-200)

MDFWP

Jharsuguda Generic Startup Procedure
Rev. 04

1-86

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS28: BFPT A STARTUP
Instructor Activity / Operating Procedure
CS28 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-87

Student
Response

Screen or LOS
Reference

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS29: MAIN TURBINE CHEST WARMING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. Turbine Chest Warming metal temperature:
a. Chest warming is required to reduce CV inner to outer metal
differential temperature and main steam to CV outer metal
differential temperature.
b. During chest warming the heat soak is effective if the pressure ratio
(Chest pressure/Main steam pressure) > 85%.
c. Main turbine should be on turning gear during chest warming
d. Maximum differential temperature between CV Inner and Outer
Metal temperatures = 168°C
e. Maximum differential temperature between Main Steam and CV
Outer Metal temperatures = 185°C
pyj

Questions:

1.

Check if Chest Warming is required. If required, initiate the next step.
If not required, CS29 may be skipped.

CHSTWARM

2.

Initiate the Chest Warming Request command (L43CWR)

CHSTWARM

3.

Verify that the Main Stop Valve Above and Below Seat Drains are
closed:
a.

Stop Valve 1 Above Seat Drain (TG-FY-310A)

RTRWRMV1

b.

Stop Valve 2 Above Seat Drain (TG-FY-310B)

RTRWRMV1

c.

Stop Valve 1 Below Seat Drain (TG-FY-311A)

RTRWRMV1

d.

Stop Valve 2 Below Seat Drain (TG-FY-311B)

RTRWRMV1

4.

Gradually open Main Stop Valve #2 Bypass Valve (SVR_BS2) in 0.2%
increments

CHSTWARM

5.

As the Main Stop Valve #2 Bypass valve is opened, the chest pressure
(CP_CHST) will increase. Continue to open the Main Stop Valve #2
Bypass Valve until the Chest Pressure Ratio (CHST_MSP_PCT) is
greater than 85%

CHSTWARM

6.

Chest warming is complete when:

CHSTWARM

a.

Control Valve Metal Inner to Outer Differential Temperature
(VT_MCV_DIFF) is less than the allowable (VT_CV_ALLOW)

CHSTWARM

b.

Main Steam to Control Valve Metal Outer Differential
Temperature (MST OUTR DIFF) is less than the allowable
(MSOTR_DIFTAR)

CHSTWARM

Jharsuguda Generic Startup Procedure
Rev. 04

1

88

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS29: MAIN TURBINE CHEST WARMING
Instructor Activity / Operating Procedure
c.

The Rotor Warming Required status indicates "NO"

7.

After Chest Warming is complete, initiate the Chest Warming Cancel
command (L43CWC)

8.

Open the Main Stop Valve Above and Below Seat Drains:

Student
Response

Screen or LOS
Reference
CHSTWARM
CHSTWARM

a.

Stop Valve 1 Above Seat Drain (TG-FY-310A)

RTRWRMV1

b.

Stop Valve 2 Above Seat Drain (TG-FY-310B)

RTRWRMV1

c.

Stop Valve 1 Below Seat Drain (TG-FY-311A)

RTRWRMV1

d.

Stop Valve 2 Below Seat Drain (TG-FY-311B)

RTRWRMV1

CS29 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-89

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS30: START MAIN TURBINE IN FORWARD FLOW
Instructor Activity / Operating Procedure
Instructor Information
Discuss:
1. At approximately 2500rpm the GE Mark V controls will initiate the
"Wobbulator" operation which will vary speed by ±84rpm. This speed
variation is done to avoid holding the turbine at or near a critical speed.
Notes:
1. Main Turbine Trip Conditions:
a. Main Oil Tank Level < 8 inch below normal level
b.
c.
d.

2.

3.

Turbine Bearing Lube Oil Header Pressure < 0.41barg
Hydraulic Fluid Pump Header Pressure < 77.4barg
Rotor High Vibration:

- Speed < 661rpm
Vibration > 101.6 |m
- 661 < Speed < 1665rpm
Vibration > 228.6|im
- Speed > 1665rpm
Vibration > 228.6|im
e. Trust Bearing Wear:
Wear > +889 |im
Wear < -889|im
f. LP A&B Hood Steam Temperature:
- > 79°C for 15 minutes
>107°C
g. Bearing Metal Temperature:
- > 115°C alarm or
> 121°C tripped
h. L-1 Stage Hood Steam Temperature:
- > 204°C for 15 minutes
> 232°C
i. HP Exhaust Temperature Trip:
- > 427°C for 15 minutes
> 454°C
Main Turbine Acceleration Rate:
a. In Semi-Automatic Mode: Speed Target shall be selected by
operator and proper Acceleration rate and Hold recommendations
shall be provided by ATS. Operator shall follow MKV ATS
recommendations and GE Starting and Loading Instructions.
b. Below 200 rpm and under negative stress conditions, the Fast
Acceleration rate is always selected. For stress above 50%, the
Slow Acceleration rate will be selected, otherwise Medium
Acceleration rate will be selected.
For Main Turbine Roll: Automatic mode should be normally selected.

LU

Questions:
1. List the turbine auxiliary valves and give the purpose of each?

Answer:
-

Ventilator Valve (VV) - The Ventilator Valve Opens on load

Jharsuguda Generic Startup Procedure
Rev. 04

1-90

Student
Response

Screen or LOS
Reference

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS30: START MAIN TURBINE IN FORWARD FLOW
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

rejection or turbine trip and is used to provide cooling flow
through the HP turbine from the reheater.
-

2.

Equalizer Valves - The equalizer valves opens on a turbine trip
when the closed end position switch indicates that all reheat stop
and intercept valves are closed. The valve vents the intercept
valve balance chamber to the condenser, and reduces pressure to
allow reopening of the reheat stop valves.
Why don't the rotor and the shell expand or contract at the same rate?
Answer: The rotor expands and contracts faster than the shell because
it is less massive and has more surface area exposed to steam flow.

3.

After the main turbine has been on turning gear for 4 hours, what is the
maximum eccentricity limit, prior to a turbine roll?
Answer: 0.03mm

Preparation for Turbine Startup in Forward Flow
1.

Verify that the Main Steam Temperature is within the Recommended
temperature range (between Min Temp and Max Temp)

ROLLOFF

2.

Verify all Active Trip signals have been cleared

MKVMRST

3.

Verify Main Steam conditions are satisfied:
a.

Main Steam Press (FP_MSP_PSI) > 6500kPag

ROLLOFF

b.

Main Steam Temperature (FT_MSP) is within recommend limits

ROLLOFF

c.

Superheater Outlet Silica (CTAI281) < 10ppb

CTFP2

d.

Superheater Outlet Sodium (CTAI283) < 3ppb

CTFP2

e.

Superheater Outlet Cation conductivity (CTAI285) < 0.3^s/cm

CTFP2

4.

Prepare for enough steam flow by increasing fuel flow on WARM UP
OIL CONTROL (increasing fuel oil press setpoint)

WUHDR

5.

Verify Main Turbine is reset (L86MR1CPB)

MKVMRST

6.

Verify that the Eccentricity (ECCENT) < 0.03mm for more than one
hour

TDATA1

7.

Verify Main Turbine Bearing Metal Temperature (TGTI201-210) are
normal at 27~32°C

TGEAR

8.

Verify Steam Seal Pressure (AP_SSH) is normal at 0.30~0.32barg

STMSEAL

9.

Verify Condenser Pressures (CMPI905A/B) are normal at: < 85mmHG

CONDVAC

10. Verify Turbine Lube Oil System is normal:
a.

Turbine Lube Oil Pump A (LT-P-100A) is running

Jharsuguda Generic Startup Procedure
Rev. 04

1-91

LUBEOIL

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS30: START MAIN TURBINE IN FORWARD FLOW
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

b.

Turbine Lube Oil Pump B (LT-P-100B) is in auto

LUBEOIL

c.

Turbine EBOP (LT-P-300) is in auto

LUBEOIL

d.

Emergency Seal Oil Pump (GS-P-200) is in auto

LUBEOIL

e.

Lube Oil Pressure > 1.2barg

LUBEOIL

f.

Lube Oil Temperature is between 27~32°C

LUBEOIL

11. Verify turbine EHC system normal:
a.

Turbine EHC Pump A (LT-P-400A) is running

HPU

b.

Turbine EHC Pump B (LT-P-400B) is in auto

HPU

c.

EHC Oil Pressure is between 105.5~119.5barg

HPU

d.

EHC Oil Temperature is between 38~49°C

HPU

12. Verify Generator Casing Hydrogen Pressure > 4.5barg and Hydrogen
Purity > 96%

GENOV

13. Set Turbine Valve Position Limiter setpoint (CVR-VPL CMD) to
120%

TURBLIM

14. Verify Turbine Rotor Warming is not required

RTRWARM

15. Verify Turbine Chest Warming is not required

CHSTRARM

16. Verify Group A Turbine Drains are open
a.

HP Turbine Stop Valve 1 Inlet Drain (BS-MOV-120A)

BSDRAINS

b.

HP Turbine Stop Valve 2 Inlet Drain (BS-MOV-120B)

BSDRAINS

c.

Stop Valve 1 Above Seat Drain (TG-FY-310A)

RTRWRMV1

d.

Stop Valve 2 Above Seat Drain (TG-FY-310B)

RTRWRMV1

e.

Stop Valve 1 Below Seat Drain (TG-FY-311A)

RTRWRMV1

f.

Stop Valve 2 Below Seat Drain (TG-FY-311B)

RTRWRMV1

g.

Combined Reheat Valve 1 After Seat Drain (TG-FY-400A)

RTRWRMV2

h.

Combined Reheat Valve 2 After Seat Drain (TG-FY-400B)

RTRWRMV2

17. Verify Group B Turbine Drains are auto
a.

Cold Reheat A Drain Pot 1 (BS-MOV-134A)

RTRWRMV1

b.

Cold Reheat B Drain Pot 1 (BS-MOV-134B)

RTRWRMV1

c.

Cold Reheat A Drain Pot 2 (BS-MOV-135A)

RTRWRMV1

Jharsuguda Generic Startup Procedure
Rev. 04

1-92

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS30: START MAIN TURBINE IN FORWARD FLOW
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

d.

Cold Reheat B Drain Pot 2 (BS-MOV-135B)

RTRWRMV1

e.

Hot Reheat A Drain Valve (BS-MOV-154A)

RTRWRMV2

f.

Hot Reheat B Drain Valve (BS-MOV-154B)

RTRWRMV2

g.

HP Shell Drain Valve 1 (TG-FY-200)

RTRWRMV1

h.

HP Shell Drain Valve 2 (TG-FY-210)

RTRWRMV1

i.

HP Shell Drain Valve 3 (TG-FY-220)

RTRWRMV1

j.

HP Shell Drain Valve 4 (TG-FY-230)

RTRWRMV1

k.

CV Common Drain Valve (TG-MOV-340)

RTRWRMV1

18. Verify at least one BFP is in service (TDBFP preferred)

FWOV

19. Verify the Stator Cooling Water System is in service:

SWCOOL

a.

Stator Cooling Water Pump A (SC-P-100A) is running

SWCOOL

b.

Stator Cooling Water Pump B (SC-P-100B) is in auto

SWCOOL

c.

Stator Cooler Temperature Control station (SCTIC355) is in auto

SWCOOL

d.

Stator Cooling Pressure Control station (SCPIC370) is in auto

SWCOOL

20. Perform lube oil pump auto cut in test and ETD1, 2 & ETSV test (RPTLT-01 and RPT -TG-09)

Not modeled

21. Verify the Turbine Turning Gear (TGTGR200PB) is in auto

TGEAR

22. Verify all alarms have been cleared, acknowledged and reset

ALARMS

23. To protect the turbine, the HP and RH Turbine Temperature Ramp
Rates should be controlled to a low level. It is recommended that these
rates be no higher than 4.0 °C/min, otherwise a startup hold will be
required because of a high rotor stress.
24. Allowable Acceleration rate and Medium, High and Rated Speed Hold
times can be calculated based on the First Stage Steam to Metal
Temperature Mismatch. MKV ATS will give a recommendation for
acceleration rate. And for a cold startup, Medium and Rated Speed
Hold times are recommended to both be 30 minutes; High Speed Hold
time should be 60 minutes.
25. Option: Prior to the turbine being rolled up to synchronous speed
insert the Exhaust Hood Spray Valve Fails Closed Malfunction.
Main Turbine Roll Off in Semi-Automatic
26. Select Semi-Auto Turbine Mode by issuing an Automatic Mode Cancel
command (L43M_AUC)

Jharsuguda Generic Startup Procedure
Rev. 04

1-93

TSPEED

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS30: START MAIN TURBINE IN FORWARD FLOW
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

27. Select Acceleration based on ATS Recommended Acceleration,
normally this would be a High Acceleration Rate Request (L43A_HIR)

TSPEED

28. Initiate turbine rolling with the selection of the 800rpm Speed Target by
issuing a Medium Speed Request (L43N_MER)

TSPEED

29. Verify that the Main Turbine rolls off and that the speed is increasing

TSPEED

30. Verify that the Turbine Turning Gear (TGTGR200PB) auto stops

TGEAR

31. Selection of Acceleration Rate and Speed Targets should follow ATS
recommendations and the turbine vendor specifications

TSPEED

32. When turbine speed has increased above 200rpm, the Turbine Mode
may be changed to Automatic if no Holds exist.

TSPEED

33. During Roll Off and increasing speed closely monitor turbine operating
parameter:
a.

Turbine Surface, Bore and Look Ahead Stresses

RSTRESS

b.

Turbine Bearing Vibrations

TSPEED

c.

Lube Oil temperature

TSPEED

d.

Turbine Bearing Metal Temperatures

TGEAR

e.

Mark V Alarms display

MKVALM

34. Request AO to check for abnormal noise, vibration and leaks

Not Modeled

35. Adjust boiler firing to gradually increase or maintain Main Steam
Pressure

FUELOIL

36. The Medium Speed Hold time can be calculated based on the First
Stage Steam to Metal Temperature Mismatch and cross over metal
temperature. For a cold startup, a hold time of 30 minutes is
recommended.
37. After the Turbine Speed reaches 800rpm and the Medium Speed Hold is
completed, and if no turbine alarm and no hold conditions exist,
continue to increase speed to 2500rpm by issuing a High Speed Request
(L43N_HIR)

TSPEED

38. The High Speed Hold time can be calculated based on the First Stage
Steam to Metal Temperature Mismatch and cross over metal
temperature. For a cold startup, a hold time of 60 minutes is
recommended.
39. Before increasing speed above 2500rpm the following conditions
should be satisfied:
a.

Lube Oil Temperature > 40.6°C

TSPEED

b.

Crossover Metal Temperature > 177°C for 60 minutes

XOVERTMP

Jharsuguda Generic Startup Procedure
Rev. 04

1-94

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS30: START MAIN TURBINE IN FORWARD FLOW
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

40. At 2500rpm a HOLD condition may appear, check the hold list and
monitor the hold reason. Wait for the hold to pass.

TSPEED
HOLDLIST

41. Increase the Turbine Speed to 3000rpm by issuing a Rated Speed
Request (L43N_RTR)

TSPEED

42. Verify the Exciter starts at 2940rpm

EX2000

43. Check the Excitation IOS on the ECP

ECP01

44. Request AO to verify that the Air Conditioning Unit at the Excitation
Cabinet is in service.

Not Modeled

45. Verify Turbine Speed reaches 3000rpm

TSPEED

46. The Rated Speed Hold time can be calculated based on the First Stage
Steam to Metal Temperature Mismatch and cross over metal
temperature. For a cold startup, a hold time of 30 minutes is
recommended.
Main Turbine Roll Off in Automatic
47. Select Semi-Auto Turbine Mode by issuing an Automatic Mode Cancel
command (L43M_AUC)

TSPEED

48. Check the hold status and verify that no hold conditions exist

HOLDLIST

49. Select Auto Rolloff Start by issuing an Auto Roll Request
(L43N_ROLL.PB)

TSPEED

50. Select Auto Turbine Mode by issuing an Automatic Mode Request
command (L43M_AUR)

TSPEED

51. Verify that the Main Turbine automatically rolls off and the speed
increases

TSPEED

52. Verify that the Turbine Turning Gear (TGTGR200PB) auto stops

TGEAR

53. Note: in Auto mode the Speed Target, Acceleration Rate and Hold
Status will automatically determined by the ATS

TSPEED

54. During Roll Off and increasing speed closely monitor turbine operating
parameter:
a.

Turbine Surface, Bore and Look Ahead Stresses

RSTRESS

b.

Turbine Bearing Vibrations

TSPEED

c.

Lube Oil temperature

TSPEED

d.

Turbine Bearing Metal Temperatures

TGEAR

e.

Mark V Alarms display

MKVALM

55. Request AO to check for abnormal noise, vibration and leaks
Jharsuguda Generic Startup Procedure
Rev. 04

1-95

Not Modeled

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS30: START MAIN TURBINE IN FORWARD FLOW
Instructor Activity / Operating Procedure
56. Adjust boiler firing to gradually increase or maintain Main Steam
Pressure

Student
Response

Screen or LOS
Reference
FUELOIL

57. The High Speed Hold time can be calculated based on the First Stage
Steam to Metal Temperature Mismatch and cross over metal
temperature. For a cold startup, a hold time of 60 minutes is
recommended.
58. Before increasing speed above 2500rpm the ATS will wait until the
following conditions should are satisfied:
a.

Lube Oil Temperature > 40.6°C

LUBEOIL

b.

Crossover Metal Temperature > 177°C for 60 minutes

RSTRESS

59. At 2500rpm a hold may appear, check the hold list and monitor the hold
reason. Typically, a hold occurs because the lube oil temperature is not
satisfied. Waiting for the hold to pass.

TSPEED
HOLDLIST

60. Verify the Exciter starts at 2940rpm

EX2000

61. Check the Excitation IOS on the ECP

ECP01

62. Request AO to verify that the Air Conditioning Unit at the Excitation
Cabinet is in service.

Not Modeled

63. Verify Turbine Speed reaches 3000rpm

TSPEED

64. The Rated Speed Hold time can be calculated based on the First Stage
Steam to Metal Temperature Mismatch and cross over metal
temperature. For a cold startup, a hold time of 30 minutes is
recommended.
CS30 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-96

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS31: UNIT SYNCHRONIZATION AND INITIAL LOAD
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. Generator Synchronization Notes:
a. Automatic Synchronization (automatic closing of the Generator
CB) is normally selected to synchronize the unit. If Automatic
Synchronization is not available, Manual Synchronization may be
selected.
b. The generator should be operated within the generator capabilities
curves furnished by GE.
c. Do not overload the generator beyond maximum stator current
rating of 21,242amps.
d. Manual Synchronization means that the Generator Breaker is
manually closed from the ECP (using hand switch CS 52G7) while
the turbine speed matching and excitation controls are in auto.
Manual Synchronization is only used when Auto Synchronization
is not available.
e. Caution must be used not to close the generator breaker when the
generator is more than 10o out of phase with the grid. Such closure
is likely to result in damage to the generator.

71

Questions:
1. Why is hydrogen used to cool the generator?

Answer: Hydrogen is better at removing heat than most other gasses.
Also because it is lighter than all other gasses, it requires less energy to
circulate and produces reduced windage losses.

2.

If the voltage of the generator is too low when the generator breaker is
closed, will the generator be over or under excited?
Answer: Under excited. When under excited, the generator is drawing
Vars from the system in order to bring voltage up to the voltage of the
bus. If grossly under excited the generator may slip a pole which can
cause damage to the rotors

Elevation CD Oil Guns in Service
1.

Request AO to verify Elevation CD Oil Guns are in Remote position at
the local panel

LOS03

2.

Start Elevation CD Oil (BF-ELEV-CD), wait for elevation start
sequence to complete (all corners fired)

ELEVCD

3.

Reset and Restart if any oil nozzle (corner) is not proven

ELEVCD

4.

Adjust Warm Up Oil Control (FOFIC800) pressure setpoint as required
to maintain desired Main Steam Pressure

ELEVCD

Generator Synchronization in Manual
Jharsuguda Generic Startup Procedure
Rev. 04

1-97

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS31: UNIT SYNCHRONIZATION AND INITIAL LOAD
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

5.

Select Generator Sync Monitor On by issuing a Synch Monitor Request
(L43S_MTRR)

GENSYNC

6.

Place Speed Matching in auto by issuing a Speed Match Auto Request
(L43NM_AUR)

GENSYNC

7.

Set Auto Speed Match Slip (TN_NMSLP_CMD) to 3rpm

GENSYNC

8.

Verify all Protective Lockout Relays have been reset

LORELAY

9.

Verify Turbine Hold Status is Normal

GENSYNC

10. Place Gen Bkr Auto/Manual Sync Selector Switch in Manual

ECP03

11. Verify the Generator CB Control Switch (CS- 52G7) is in the release
position

ECP03

12. Insert the SCS Key in Generator Breaker Synchronizing Switch (SS52G7) and place in the ON position

ECP03

13. Verify that the Synchroscope is on and rotating to indicate the phase
difference between the Generator and the Grid. The synch-check lights
will be out (minimum brightness) when the Synchroscope is at the 0o
position and will be at maximum brightness when the Synchroscope is
at the 180o position.

ECP10

14. Verify the Generator Voltage Error and Frequency Error are within
acceptable ranges:

GENSYNC

a.

Generator Voltage Error (DV_ERR) between 0 to 3%

GENSYNC

b.

Generator Frequency Error (SFDIFF1) between 0.01 to 0.25%.

GENSYNC

15. If Generator Voltage Error is outside the acceptable range, adjust the
Generator Voltage:
a.

Increase/Decrease Generator Voltage using the GSU Transformer
Tap Changer Control Switch (CS-GSULTC)

ECP04

b.

Raise/Lower KV/VAR (L43DVLT_R/L) on OIS

EX2000

16. Verify all Sync Help conditions indicate Ready

GENSYNC

17. Select Generator Sync Monitor Off by issuing a Synch Monitor Cancel
(L43S_MTRC)

GENSYNC

18. Use the Generator Breaker 52G7 Control Switch (CS-52G7) to
Synchronize the Generator (close the 52G7 Circuit Breaker) when the
phase difference (as indicated by the Synchroscope) is between -10o to
+10o

ECP03
ECP10

Generator Synchronization in Auto
19. Select Auto Turbine Mode by issuing an Automatic Mode Request
command (L43M_AUR)
Jharsuguda Generic Startup Procedure
Rev. 04

1-98

GENSYNC

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS31: UNIT SYNCHRONIZATION AND INITIAL LOAD
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

20. Select Generator Sync Monitor On by issuing a Synch Monitor Request
(L43S_MTRR)

GENSYNC

21. Place Speed Matching in auto by issuing a Speed Match Auto Request
(L43NM_AUR)

GENSYNC

22. Set Auto Speed Match Slip (TN_NMSLP_CMD) to 3rpm

GENSYNC

23. Verify all Protective Lockout Relays have been reset

LORELAY

24. Verify Turbine Hold Status is Normal

GENSYNC

25. Place Gen Bkr Auto/ Manual Sync Selector Switch in Auto

ECP03

26. Verify the Generator CB Control Switch (CS- 52G7) is in the release
position

ECP03

27. Insert the SCS Key in Generator Breaker Synchronizing Switch (SS52G7) and place in the ON position

ECP03

28. Verify that the Synchroscope is on and rotating to indicate the phase
difference between the Generator and the Grid. The synch-check lights
will be out (minimum brightness) when the Synchroscope is at the 0o
position and will be at maximum brightness when the Synchroscope is
at the 180o position.

ECP10

29. Verify the Generator Voltage Error and Frequency Error are within
acceptable ranges:

GENSYNC

a.

Generator Voltage Error (DV_ERR) between 0 to 3%

GENSYNC

b.

Generator Frequency Error (SFDIFF1) between 0.01 to 0.25%.

GENSYNC

30. If Generator Voltage Error is outside the acceptable range, adjust the
Generator Voltage:
a.

Increase/Decrease Generator Voltage using the GSU Transformer
Tap Changer Control Switch (CS-GSULTC)

ECP04

b.

Raise/Lower KV/VAR (L43DVLT_R/L) on OIS

EX2000

31. Verify all Sync Help conditions indicate Ready

GENSYNC

32. Select Generator Sync Monitor Off by issuing a Synch Monitor Cancel
(L43S_MTRC)

GENSYNC

33. The Generator will automatically synchronize (the 52G7 Circuit
Breaker will close) when the phase difference (as indicated by SSDIFF1
or by the Synchroscope) is between -10o to +10o

GENSYNC
ECP03

Initial Load and Post-Synchronization Checks
34. After Generator Synchronization, verify the Unit Load increase to an
initial load of about 3% (~20 GMW)
Jharsuguda Generic Startup Procedure
Rev. 04

1-99

GENSYNC

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS31: UNIT SYNCHRONIZATION AND INITIAL LOAD
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

35. Verify the Group A Drains have closed:
a.

HP Turbine Stop Valve 1 Inlet Drain (BS-MOV-120A)

BSDRAINS

b.

HP Turbine Stop Valve 2 Inlet Drain (BS-MOV-120B)

BSDRAINS

c.

Stop Valve 1 Above Seat Drain (TG-FY-310A)

RTRWRMV1

d.

Stop Valve 2 Above Seat Drain (TG-FY-310B)

RTRWRMV1

e.

Stop Valve 1 Below Seat Drain (TG-FY-311A)

RTRWRMV1

f.

Stop Valve 2 Below Seat Drain (TG-FY-311B)

RTRWRMV1

g.

Combined Reheat Valve 1 After Seat Drain (TG-FY-400A)

RTRWRMV2

h.

Combined Reheat Valve 2 After Seat Drain (TG-FY-400B)

RTRWRMV2

36. Place the Generator Breaker Synchronizing Switch (SS-52G7) and
place in the OFF position and remove the SCS Key

ECP03

37. Maintain the unit at the Initial Load until the maximum rotor stress
decreases to a normal level, <50%. This Initial Load hold typically
takes ~90 minutes.

RSTRESS

CS31 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-100

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS32: UNIT LOAD RAMP TO MINIMUM LOAD
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. The Minimum Load point is ~80 GMW and is the point where the ATS
examines turbine stress to determine if a load hold is required.
2. Load Increase Notes:
a. Closely monitor Main Turbine operating parameters such as
Turbine Stress, Vibration, Bearing temperature, etc during load
increases.
b. At low loads (with one or two pulverizer already in service), flame
voting must be observed carefully before startup or shutdown of an
oil elevation. Verify that the flame voting indications are healthy
on the OIS Flame & Damper (FLMDMP) screen.
c. It is better to put oil guns in service for an elevation above the
existing coal firing elevation rather than below.
d. Ensure warm up oil pressure is greater than 900kPag.
3. Main Steam Pressure should be gradually increased as load is increased.
The control point for the Main Steam Pressure is controlled by the CRO
based on the curve below:
Throttle Press--Gen Power Relation
(for cold startup)

tn
m

£
Ql

v

175
150
125
100
75
50
25
0

-153
•100"

0

110

30

-166- -166-

166

'124

50

80

90

100

105

Gen. Power Percent

Notes:
1. Permissive for MKV Remote Control:
a. ATS Forward Flow
b. Not at Load Ceiling
c. Generator On Line
d. No Load Runback Active
e. Main Steam Pressure Limiter Not Active
f. Turbine Not Tripped
g. Valve Limiter Not Active
h. IV Reference > 30% and Armature Current > 20%

a
1.
2.

Questions:

Place GE MKV Mode (MKV MODE) in Remote
GE MKVATS will calculate the maximum allowable loading rate.

Jharsuguda Generic Startup Procedure
Rev. 04

UNITMSTR

1-101

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS32: UNIT LOAD RAMP TO MINIMUM LOAD
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

3.

Adjust Boiler Firing to maintain/increase Main Steam Pressure

FUELOIL

4.

Increase Unit Load by gradually increasing Turbine Master (Turbine
Master) output

UNITMSTR

5.

Verify that the Admission Mode automatically transfer to Partial Arc
Mode at a load of ~10%

ADMMODE

6.

Continue increasing load to ~80 GMW

UNITMSTR

7.

As load increases monitor the First Stage Shell Metal and Reheat Bowl
Metal Temperatures and control loading

RSTRESS

8.

At ~70 GMW place Pulverizer B in Service (see CS33)

9.

At ~80 GMW begin warming HP Feedwater Heaters (see CS34)

10. At Main Steam Flow > 10%, verify that AH Sootblower media has
changed to steam
CS32 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-102

GSSBS-07

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS33: PULVERIZER B COAL FIRING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. Coal Firing notes:
a. Pulverizer must be warmed up so that the mill outlet temperature is
at the setpoint of 72°C for a minimum of 15 minutes before coal
feeding. After coal feeder has been placed in service, gradually
reduce temperature setpoint to 66°C.
b. If a pulverizer trips at load, pulverizer inerting and steam transport
shall be carried out. (Refer to POI-BF-05).
c. Put additional (adjacent) feeder in service when existing feeder
demand is greater than 70%
d. Do not leave pulverizer in low load (< 40%) operation for extended
periods of time (> 20 minutes.) Bring pulverizer load above 40%
as soon as practical.
2. Mill trip conditions:
a. Mill outlet temp > 120°C
b. PA Flow < 52%
c. Pulverizer to furnace DP < 0.4kPag
3. If pulverizer bowl DP > 3.6kPag, feeder will run down to minimum
25%
pyj

Questions:

Pulverizer B Coal Firing
1.

Verify Pulverizer B (BF-PVR-500B) is running

PULVB

2.

Verify Pulverizer B has been sufficiently warmed and the Pulverizer
Outlet Temperature (BFTIC586B) has been >66°C for at least 15
minutes

PULVB

3.

Verify Hot Primary Air Temperature (BFTI656) out of the Primary Air
Heater is > 220°C

PAHTR

4.

Verify Electro-Static Precipitator is ready for operation

ESPOV

5.

Request AO to put Feeder B Operating Mode (BF-FDR-500B) in Local

LOS04

6.

Request AO to Jog Feeder B (BF-FDR-500B). Jog should be
maintained for several seconds until "Coal On Belt" is indicated

LOS04
PULVB

7.

Request AO to put Feeder B Operating Mode (BF-FDR-500B) in
Remote

LOS04

8.

Verify Ignition Permit requirements are satisfied

HPULVBR1

Jharsuguda Generic Startup Procedure
Rev. 04

1-103

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS33: PULVERIZER B COAL FIRING
Instructor Activity / Operating Procedure
9.

Start Coal Feeder B (BFFDR500B-SS)

Student
Response

Screen or LOS
Reference
PULVB

10. Increase Feeder B Bias Station (BFFDR500B) output above 30% to
ensure a stable coal flame

PULVOV

11. Verify Ignition Permit is available for at least 3 minutes after the Feeder
started running

PULVB

12. Adjust Warmup Oil Control station (FOFIC800) pressure setpoint
accordingly to control Main Steam Pressure increase

WUHDR

Pulverizer C Warming
13. Verify Pulverizer C Lube Oil System is in service and Lube Oil
Temperature > 35°C

HPULVCR1

14. Request AO to open Seal Air to Coal Feeder Valve (BF-ISV-515C)

LOS04

15. Verify Pulverizer C Seal Air Valve (BF-PULVC-SAV) faceplate
command indicates Open

PULVC

16. Request AO to Put Coal Feeder C OP Mode to REMOTE(BF-FDR500C)

LOS04

17. Request AO to Open Inerting steam Block Valve C(BS-FV-210C)

LOS06

18. Open Pulverizer C Discharge Valves (BFFY509C)

PULVC

19. Verify Pulverizer C Start permissive is satisfied

HPULVCR1

20. Start Pulverizer C (BF-PVR-500C)

PULVC

21. Verify Pulverizer C Seal Air Valve (BF-PULVC-SAV) auto opens

PULVC

22. Verify Pulverizer C PA Flow Control station (BFFIC666C) opens and
wait for air flow to increase to the setpoint

PULVC

23. Open Pulverizer C Hot Air Gate (BF-PY-662C)

PULVC

24. Place Pulverizer C PA Flow Control station (BFTIC666C) in auto

PULVC

25. Place Pulverizer C Temperature Control station (BFTIC586C) in auto:
a.

Set Pulverizer C Temperature Control station (BFTIC586C)
setpoint to 72°C

PULVC

b.

Place Pulverizer C Temperature Control station (BFTIC586C) in
auto

PULVC

26. Pulverizer Warming will be complete when the Pulverizer Outlet
Temperature (BFTIC586C) has been maintained at >66°C for at least
15 minutes

PULVC

27. Option: As the Pulverizer C Warming is completed, insert the Loss of
Coal Flow on Feeder B Malfunction.
Jharsuguda Generic Startup Procedure
Rev. 04

1-104

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS33: PULVERIZER B COAL FIRING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

ESP Startup
28. Verify Pulverizer B Feeder Demand is > 40%

PULVOV

29. Verify the Flue Gas Temperature into the Electrostatic Precipitator is >
120°C

ESPOV

30. Request AO to verify ESP Operating Mode (BG-PCP-800A) is in
Remote

LOS05

31. Verify ESP Heater Status indicates "ON"

ESPOV

32. Start the Electrostatic Precipitators (BGESP)

ESPOV

33. ESP rectifiers will start one-by-one and will take approximately 20
minutes for 14 out of 16 rectifiers to be energized

ESPOV

FGD Startup
34. After at least 14 of 16 ESP rectifiers have started, start the FGD System
35. Verify the Emergency Cooling Water Tank Level (FCLI301) > 75.6%

FCEC

36. Verify FGD Absorber are bypassed

FCOV1

37. Verify FGD Absorber Inlet, Outlet and Bypass Damper Hydraulic
Systems are in service

FGDHYD

38. Place all FGD inlet, outlet, and bypass dampers in auto:
a.

FGD A Inlet Damper (FCGSV101)

FCOV1

b.

FGD B Inlet Damper (FCGSV201)

FCOV1

c.

FGD A Outlet Damper (FCGSV102)

FCOV1

d.

FGD B Outlet Damper (FCGSV202)

FCOV1

e.

FGD Bypass Damper (FCGSV301)

FCOV1

f.

FGD Bypass Damper Lower Section (FCGSV302)

FCOV1

39. Request AO to verify Absorber Purge Fan is off and the outlet damper
is supplied with service air

Not Modeled

40. Start Seawater Scrubber Absorber A (FGD-A)

FCOV1

41. Verify the following events occur:
a.

FGD A Outlet Damper (FCGSV102) opens

FCOV1

b.

FGD Outlet Damper A Seal Fan (FCFAN102) stops

FCOV1

c.

FGD A Inlet Damper (FCGSV101) opens

FCOV1

Jharsuguda Generic Startup Procedure
Rev. 04

1-105

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS33: PULVERIZER B COAL FIRING
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

d.

FGD Inlet Damper A Seal Fan (FCFAN101) stops

FCOV1

e.

FGD Bypass Damper (FCGSV301) closes

FCOV1

f.

FGD Bypass Damper Lower Section (FCGSV302) closes

FCOV1

42. Wait for flue gas temperature and flow to stabilize
43. Start Seawater Scrubber Absorber B (FGD-B)

FCOV1

44. Verify the following events occur:
a.

FGD B Outlet Damper (FCGSV202) opens

FCOV1

b.

FGD Outlet Damper B Seal Fan (FCFAN202) stops

FCOV1

c.

FGD B Inlet Damper (FCGSV201) opens

FCOV1

d.

FGD Inlet Damper B Seal Fan (FCFAN201) stops

FCOV1

45. Wait for flue gas temperature and flow to stabilize
CS33 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-106

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS34: HP FWH WARMUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. Prior to reaching a Unit Load of 90 GMW, the HP Feedwater Heater
Steam Isolation Valves should be cracked open to allow for warming of
the heaters and to satisfy the necessary conditions for the automatic
closure of the extraction lines drains at Unit Load >90 GMW.
Notes:
Questions:

1.

Complete Heaters Pre Start Check Sheet
a.

To Prepare the Heater 6A for service

b.

To Prepare the Heater 6B for service

c.

To Prepare the Heater 7A for service

d.

To Prepare the Heater 7B for service

e.

To Prepare the Heater 8A for service

f.

To Prepare the Heater 8B for service

2.

Place HP Feedwater Heater Level Control Stations in auto:
a.

FWH 6A Normal Level Control station (HDLIC620A)

HPFWHA

b.

FWH 6A Emergency Level Control station (HDLIC621 A)

HPFWHA

c.

FWH 7A Normal Level Control station (HDLIC612A)

HPFWHA

d.

FWH 7A Emergency Level Control station (HDLIC613 A)

HPFWHA

e.

FWH 8A Normal Level Control station (HDLIC603A)

HPFWHA

f.

FWH 8A Emergency Level Control station (HDLIC604A)

HPFWHA

g.

FWH 6B Normal Level Control station (HDLIC620B)

HPFWHB

h.

FWH 6B Emergency Level Control station (HDLIC621B)

HPFWHB

i.

FWH 7B Normal Level Control station (HDLIC612B)

HPFWHB

j.

FWH 7B Emergency Level Control station (HDLIC613B)

HPFWHB

k.

FWH 8B Normal Level Control station (HDLIC603B)

HPFWHB

l.

FWH 8B Emergency Level Control station (HDLIC604B)

HPFWHB

Jharsuguda Generic Startup Procedure
Rev. 04

1-107

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS34: HP FWH WARMUP
Instructor Activity / Operating Procedure
3.

Student
Response

Screen or LOS
Reference

Verify HP Feedwater Heater Extraction Steam Check Valves are open:
a.

FWH 6A Extraction Steam Check Valve (HB-SY-232A)

HPFWHA

b.

FWH 7A Extraction Steam Check Valve (HB-SY-219A)

HPFWHA

c.

FWH 8A Extraction Steam Check Valve (HB-SY-206A)

HPFWHA

d.

FWH 6B Extraction Steam Check Valve (HB-SY-232B)

HPFWHB

e.

FWH 7B Extraction Steam Check Valve (HB-SY-219B)

HPFWHB

f.

FWH 8B Extraction Steam Check Valve (HB-SY-206B)

HPFWHB

4.

Verify Deaerator Extraction Steam Check Valves are auto:
a.

DA Extraction Check Valve #1 (HB-SY-245)

TDBFPEXT

b.

DA Extraction Check Valve #2 (HB-SY-249)

TDBFPEXT

5.

Crack open HP Feedwater Heater Steam Isolation Valves:
a.

FWH 6A Steam Isolation Valve (HB-MOV-231A)

HPFWHA

b.

FWH 7A Steam Isolation Valve (HB- MOV -218A)

HPFWHA

c.

FWH 8A Steam Isolation Valve (HB- MOV -205A)

HPFWHA

d.

FWH 6B Steam Isolation Valve (HB- MOV -231B)

HPFWHB

e.

FWH 7B Steam Isolation Valve (HB- MOV -218B)

HPFWHB

f.

FWH 8B Steam Isolation Valve (HB- MOV -205B)

HPFWHB

6.

Verify HP Feedwater Heater Pressures are increasing

HPFWHOV

7.

Verify HP Feedwater Heater Level Control Valves control properly

HPFWHOV

8.

Crack open Deaerator Extraction Steam Valves (HB-MOV-244)

TDBFPEXT

9.

Verify that the HP Feedwater Heater Extraction Drain Valves auto close
when the Unit Load >90 GMW, if not close manually, and set to auto.
a.

FWH 6A Before Isolation Drain Valve (HB-FY-230A)

HPFWHA

b.

FWH 6A After Check Drain Valve (HB-FY-233A)

HPFWHA

c.

FWH 7A After Check Drain Valve (HB-FY-220A)

HPFWHA

d.

FWH 8A Before Isolation Drain Valve (HB-FY-204A)

HPFWHA

e.

FWH 8A After Check Drain Valve (HB-FY-207A)

HPFWHA

f.

FWH 6B Before Isolation Drain Valve (HB-FY-230B)

HPFWHB

Jharsuguda Generic Startup Procedure
Rev. 04

1-108

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS34: HP FWH WARMUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

g.

FWH 6B After Check Drain Valve (HB-FY-233B)

HPFWHB

h.

FWH 7B After Check Drain Valve (HB-FY-220B)

HPFWHB

i.

FWH 8B Before Isolation Drain Valve (HB-FY-204B)

HPFWHB

j.

FWH 8B After Check Drain Valve (HB-FY-207B)

HPFWHB

10. After the extraction lines and feedwater heaters have been sufficiently
warmed (Unit Load ~130 GMW), continue opening HP Feedwater
Heater Steam Isolation Valves and Deaerator Extraction Steam Valve

HPFWHA
HPFWHB

11. Open BFPT IP Steam Check Valve (HB-SY-255)

TDBFPEXT

12. Close BFPT Before Check Drain Valve (HB-FY-267)

TDBFPEXT

13. Close BFPT After Check Drain Valve (HB-FY-268)

TDBFPEXT

CS34 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-109

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS35: UNIT LOAD RAMP TO 300 GMW
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. While increasing load adjust the throttle pressure setpoint manually
based on the curve below.

Throttle Press-Gen Power Relation
(for cold startup)
175
150
125
100
75
50
25
0

(fl
(fl
£

q[

v

-153

-166- -166-

166

AV124

-100"

0

110

30

50

80

90

100

105

Gen. Power Percent

Notes:

a

Questions:

1.

Verify that no Hold conditions exist

UNITMSTR

2.

Adjust Boiler Firing to maintain/increase Main Steam Pressure

FUELOIL

3.

Increase Unit Load by gradually increasing Turbine Master (Turbine
Master) output

UNITMSTR

4.

Continue increasing load to ~300 GMW

UNITMSTR

5.

As load increases monitor the First Stage Shell Metal and Reheat Bowl
Metal Temperatures and control loading

RSTRESS

6.

At ~120 GMW transfer house load supply from Startup Transformer to
Auxiliary Transformer (see CS36)

7.

At ~130 GMW place Desuperheaters in service (see CS37)

8.

At ~130 GMW startup BFPT B (see CS38)

9.

At ~150 GMW place Turbine Master in auto

UNITMSTR

10. At ~150 GMW startup Pulverizer C (see CS39)
11. At ~200 GMW startup Condensate Pump B (see CS40)
12. At ~250 GMW or when Pulverizer B and C Feeder Demands have both
increased > 55%, startup Pulverizer D (see CS41)
Jharsuguda Generic Startup Procedure
Rev. 04

1-110

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS35: UNIT LOAD RAMP TO 300 GMW
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

13. At ~300 GMW take Oil Guns out of Service (see CS42)
14. After the Oil Guns are out of service, place the Unit in Coordinated
Control Mode:
a.

Place Feeder B Bias Station (BFFDR500B) in Auto

PULVOV

b.

Place Feeder C Bias Station (BFFDR500C) in Auto

PULVOV

c.

Place Feeder D Bias Station (BFFDR500D) in Auto

PULVOV

d.

Place Fuel Master (FUEL MASTER) in Auto

PULVOV

e.

Place Boiler Master (BOILER MASTER) in Auto

PULVOV

f.

Verify Unit is in Coordinated Control Mode

PULVOV

CS35 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-111

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS36: TRANSFER HOUSE LOAD
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. House Load Transfer notes:
a. Automatic transfer operation is not available when transferring
from the standby source to the normal source.
b. To prevent loss of supply on 13.8kV buses during transfer, use of
the synchronism check relay (ECP13) is recommended. Manual
initiation of transfer by using High Speed Transfer Relay (HSTR)
should be used in emergency situations only.
c. The generator must be stable and at a steady state and ready to
accept plant auxiliaries load (about > 150MW) prior to transferring
house load.
|~7~| Questions:

1.

Verify that 13.8kV Switchgear Transfer Enabled lamps on ECP are lit:
a.

13.8kV Switchgear A (EM-SWGR-A) Transfer Enabled lamp

ECP08

b.

13.8kV Switchgear B (EM-SWGR-B) Transfer Enabled lamp

ECP11

c.

13.8kV Switchgear C (EM-SWGR-C) Transfer Enabled lamp

ECP17

2.

Request AO to verify that no Lock Out Status exists on High Speed Fast
Transfer Relay panel

3.

Transfer to the 13.8kV Switch Gear A Main Breaker 1AM:

Not Modeled

a.

Put the Breaker 1AM Sync Check Switch (SCS-1AM) in the ON
position by using SCS key

ECP05

b.

Confirm that the Incoming Voltage meter and Running Voltage
meter indicate similar voltages (~120VAC)

ECP10

c.

Close the 13.8kV Switch Gear A Main Breaker 1AM (CS-1AM)

ECP05

d.

Confirm that the 13.8kV Switch Gear A Startup Breaker1AT
automatically opens after closing of the 1AM breaker

ECP05

e.

Place the 13.8kV Bus A Transfer Selector switch (43-1A) in the
1AM-1AT position

ECP05

f.

Verify that Transfer Enable/Disable Switches 1AM (69-1AM),
1AT (69-1AT) and 1AT8A (69-1AT8A) are in the ENABLE
position

ECP05
ECP08

4.

Transfer to the 13.8kV Switch Gear B Main Breaker 1BM:

Jharsuguda Generic Startup Procedure
Rev. 04

1-112

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS36: TRANSFER HOUSE LOAD
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

a.

Put the Breaker 1BM Sync Check Switch (SCS-1BM) in the ON
position by using SCS key

ECP11

b.

Confirm that the Incoming Voltage meter and Running Voltage
meter indicate similar voltages (~120VAC)

ECP10

c.

Close the 13.8kV Switch Gear B Main Breaker 1BM (CS-1BM)

ECP08

d.

Confirm that the 13.8kV Switch Gear B Startup Breaker 1BT
automatically opens after closing of the 1BM breaker

ECP11

e.

Place the 13.8kV Bus B Transfer Selector switch (43-1B) in the
1BM-1BT position

ECP08

f.

Verify that Transfer Enable/Disable Switches 1BM (69-1BM), 1BT
(69-1BT) and 7BT8B (69-1BT8B) are in the ENABLE position

ECP11

5.

Transfer to the 13.8kV Switch Gear C Main Breaker 1CM:
a.

Put the Breaker 1 CM Sync Check Switch (SCS-1 CM) in the ON
position by using SCS key

ECP14

b.

Confirm that the Incoming Voltage meter and Running Voltage
meter indicate similar voltages (~120VAC)

ECP10

c.

Close the 13.8kV Switch Gear C Main Breaker 7BM (CS-1CM)

ECP14

d.

Confirm that the 13.8kV Switch Gear C Startup Breaker 1CT
automatically opens after closing of the 1CM breaker

ECP14

e.

Place the 13.8kV Bus C Transfer Selector switch (43-1C) in the
1CM-1CT position

ECP14

f.

Verify that Transfer Enable/Disable Switches 7CM (69- 1CM), 7CT
(69-1CT) and 7CT8C (69-1CT8C) are in the ENABLE position

ECP14
ECP17

6.

Verify that 13.8kV Switchgear Transfer Enabled lamps on ECP are lit:
a.

13.8kV Switchgear A (EM-SWGR-A) Transfer Enabled lamp

ECP08

b.

13.8kV Switchgear B (EM-SWGR-B) Transfer Enabled lamp

ECP11

c.

13.8kV Switchgear C (EM-SWGR-C) Transfer Enabled lamp

ECP17

7.

Request AO to verify that no Lock Out Status exists on High Speed Fast
Transfer Relay panel

CS36 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-113

Not Modeled

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS37: DESUPERHEATERS IN SERVICE
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
^

Questions:

1.

Request AO to verify Final SH Desuperheater Isolation Valve B (FWISV-338B) is open

LOS07

2.

Request AO to verify Final SH Desuperheater Isolation Valve D (FWISV-338D) is open

LOS07

3.

Request AO to verify RH Desuperheater Isolation Valve A (FW-ISV325A) is open

LOS07

4.

Request AO to verify RH Desuperheater Isolation Valve B (FW-ISV325B) is open

LOS07

5.

Place 1ST S/H Spray Block Valve (FW-FY-337A) in auto

STMTEMP

6.

Place Final S/H Spray Block Valve (FW-FY-337B) in auto

STMTEMP

7.

Place Final R/S Superheater Temperature Control station (BSTIC338B)
in auto

STMTEMP

8.

Place Final L/S Superheater Temperature Control station (BSTIC338D)
in auto

STMTEMP

9.

Place 1ST L/S Superheater Temperature Control station (BSTIC338A)
in auto

STMTEMP

10. Place 1ST R/S Superheater Temperature Control station (BSTIC338C)
in auto

STMTEMP

11. Verify Intermediate S/H Spray Drain Valve (FW-MOV-3 38A) auto
closes

STMTEMP

12. Verify Final S/H Spray Drain Valve (FW-MOV-338B) auto closes

STMTEMP

13. Verify S/H Sprays Drain Valve (FW-MOV-338C) auto closes

STMTEMP

14. Place Reheat Spray Block Valve (FW-FY-324) in auto

RHTEMP

15. Place Final A Reheat Temperature Control station (BSTIC325A) in
auto

RHTEMP

16. Place Final B Reheat Temperature Control station (BSTIC325B) in auto

RHTEMP

17. Put reheat spray block valve (FWFY324) in AUTO

RHTEMP

Jharsuguda Generic Startup Procedure
Rev. 04

1-114

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS37: DESUPERHEATERS IN SERVICE
Instructor Activity / Operating Procedure
18. Verify Cold Reheat Spray Drain Valve (FW-MOV-325) auto closes
CS37 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-115

Student
Response

Screen or LOS
Reference
STMTEMP

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS38: BFPT B STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1. The BFPT Speed Pickups do not work correctly at speeds less than
500rpm. Prior to reaching that speed the speed indication on the OIS
screen will indicate 0.
^

Questions:

1.

Verify BFPT B Warming is complete

FWPB

2.

Check Turbine Driven Feed Pump B Start Permissives display and
verify BFPT B is ready to start

HFWPB

3.

Verify BFPT B Lube Oil Temperature Control (CCTIC822) is in auto
and Lube Oil Temperature is above 37.8°C

FWPB

4.

Place TD BFP B Suction Flow Control station (FWFIC309B) in auto

FWPB

5.

Verify BFPT B Emergency Lube Oil Pump (LT-P-250B) is on standby

FWPB

6.

Start TD BFP B (TGTRB100B)

FWPB

7.

After starting, the BFPT B Control Valves will open and bring the
BFPT Speed to the minimum speed of 500rpm

FWPB

8.

After starting the BFPT B Observe the following events occur:

FWPB

a.

BFPT B starts and after a delay speed signal indicates ~500rpm

FWPB

b.

The TD BFP B Suction Flow Control Valve (FWFIC309B)
remains full open to allow minimum flow through the pump

FWPB

9.

Open the BFPT B Discharge Check Valve (FW-FY-318B)

FWPB

10. Change BFPT B Lube Oil Temperature Control (CCTIC822) setpoint to
50°C

FWPB

11. Open the BFPT B Discharge Valve (FW-MOV-318E)

FWPB

12. Gradually increase TD BFP B Demand (TGSIC100B) to increase pump
speed and pump discharge pressure to match with the current BFPT A
outlet pressure

DRUMLVL

13. Verify all BFPT B Drains is close automatically when BFPT Speed >
1200rpm:

FWPB

a.

BFPT B Steam Supply Drain Valve (BS-MOV-114B)

Jharsuguda Generic Startup Procedure
Rev. 04

1-116

FWPB

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS38: BFPT B STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

b.

BFPT B HP Stop Valve Drain #1 (TG-MOV-113B)

FWPB

c.

BFPT B HP Stop Valve Drain #2 (TG-MOV-114B)

FWPB

d.

BFPT B LP Stop Valve Drain #1 (TG-MOV- 111B)

FWPB

e.

BFPT B LP Stop Valve Drain #2 (TG-MOV-115B)

FWPB

f.

BFPT B First Stage Drain (TG-MOV-113B)

FWPB

14. After TD BFP B speed has increased sufficiently to provide feedwater
to the drum, adjust TD BFP B Demand (TGSIC100A) to maintain
normal drum level

DRUMLVL

15. Place TD BFP B Demand (TGSIC100B) in auto

FWPA

16. Adjust balance between BFPT A and BFPT B by adjusting TD BFP
Demand station (TGSIC100A/B) bias appropriately

DRUMLVL

CS38 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-117

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS39: PULVERIZER C STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. In general, it is important to keep the individual pulverizer feeder
demand at > 50%. This helps ensure stable combustion. Coal firing on
each pulverizer should be initiated in anticipation of loading and
maintaining feeder speeds at > 50%.
2. Each feeder delivers approximately 89TPH of coal at a demand of
100%. One TPH of coal will deliver approximately 2.3MW. Thus, two
pulverizers with feeder demand of 50% will deliver about 205MW.
Notes:
pyj

Questions:

Pulverizer C Coal Firing
1.

Verify Pulverizer C (BF-PVR-500C) is running

PULVC

2.

Verify Pulverizer C has been sufficiently warmed and the Pulverizer
Outlet Temperature (BFTIC586C) has been >66°C for at least 15
minutes

PULVC

3.

Request AO to put Feeder C Operating Mode (BF-FDR-500C) in Local

LOS04

4.

Request AO to Jog Feeder C (BF-FDR-500C). Jog should be
maintained for several seconds until "Coal On Belt" is indicated.

LOS04
PULVC

5.

Request AO to put Feeder C Operating Mode (BF-FDR-500C) in
Remote

LOS04

6.

Verify Ignition Permit requirements are satisfied

HPULVCR1

7.

Start Coal Feeder C (BFFDR500C-SS)

PULVC

8.

Increase Feeder C Bias Station (BFFDR500C) output above 30% to
ensure a stable coal flame

PULVOV

9.

Verify Ignition Permit is available for at least 3 minutes after the Feeder
started running

PULVC

10. Adjust total fuel flow accordingly to control Main Steam Pressure
increase
a.

Adjust Warmup Oil Control station (FOFIC800) pressure setpoint

WUHDR

b.

Adjust Feeder B Bias Station Demand (BFFDR500B). Demand
should be > 50%.

PULVOV

c.

Gradually increase Feeder C Bias Station Demand (BFFDR500C).
Increase demand towards 50%

PULVOV

Jharsuguda Generic Startup Procedure
Rev. 04

1-118

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS39: PULVERIZER C STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Pulverizer D Warming
11. Verify Pulverizer D Lube Oil System is in service and Lube Oil
Temperature > 35°C

HPULVDR1

12. Request AO to open Seal Air to Coal Feeder Valve (BF-ISV-515D)

LOS04

13. Verify Pulverizer D Seal Air Valve (BF-PULVD-SAV) faceplate
command indicates Open

PULVD

14. Request AO to Put Coal Feeder D OP Mode to REMOTE(BF-FDR500D)

LOS04

15. Request AO to Open Inerting steam Block Valve D(BS-FV-210D)

LOS06

16. Open Pulverizer D Discharge Valves (BFFY509D)

PULVD

17. Verify Pulverizer D Start permissive is satisfied

HPULVDR1

18. Start Pulverizer D (BF-PVR-500D)

PULVD

19. Verify Pulverizer D Seal Air Valve (BF-PULVD-SAV) auto opens

PULVD

20. Verify Pulverizer D PA Flow Control station (BFFIC666D) opens and
wait for air flow to increase to the setpoint

PULVD

21. Open Pulverizer D Hot Air Gate (BF-PY-662D)

PULVD

22. Place Pulverizer D PA Flow Control station (BFTIC666D) in auto

PULVD

23. Place Pulverizer D Temperature Control station (BFTIC586D) in auto:
a.

Set Pulverizer D Temperature Control station (BFTIC586D)
setpoint to 72°C

PULVD

b.

Place Pulverizer D Temperature Control station (BFTIC586D) in
auto

PULVD

24. Pulverizer Warming will be complete when the Pulverizer Outlet
Temperature (BFTIC586D) has been maintained at >66°C for at least
15 minutes

PULVD

CS39 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-119

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS40: CONDENSATE PUMP B STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. Prior to starting a second Condensate Pump, a second polisher should
be placed in service in order to avoid high differential pressure
associated with excessive flow through one polisher.
Notes:
^

Questions:

Condensate Polisher B Startup
1.

Prior to starting a second Condensate Pump, place Condensate Polisher
B in service:
a.

Request AO to clear any alarms from the local Condensate
Polisher Console

LOS09

b.

Verify Condensate Polisher Inlet Valve (CM-MOV-414) is open

COND1

c.

Verify Condensate Polisher Outlet Valve (CM-MOV-416) is open

COND1

d.

Close Condensate Polisher Bypass Valve (CM-MOV-417)

COND1

Condensate Pump B Startup
2.

Request AO to verify Condensate Pump B Inlet Valve (CM-ISV-100B) is
open

LOS07

3.

Request AO to verify Condensate Pump B Outlet Valve (CM-ISV-110B)
is open

LOS07

4.

Start Condensate Pump B (CM-P-100B)

COND1

5.

Setup Condensate Pump C (CM-P-100C) for standby operation:
a.

Request AO to verify Condensate Pump C Inlet Valve (CM-ISV100C) is open

LOS07

b.

Request AO to verify Condensate Pump C Outlet Valve (CM-ISV110C) is open

LOS07

c.

Verify Condensate Pump C (CM-P-100C) in auto

COND1

CS40 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-120

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS41: PULVERIZER D STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. In general, it is important to keep the individual pulverizer feeder
demand at > 50%. This helps ensure stable combustion. Coal firing on
each pulverizer should be initiated in anticipation of loading and
maintaining feeder speeds at > 50%.
2. Each feeder delivers approximately 89TPH of coal at a demand of
100%. One TPH of coal will deliver approximately 2.3MW. Thus,
three pulverizers with feeder demand of 50% will deliver about 300
GMW.
Notes:
|~?j Questions:

Pulverizer D Coal Firing
1.

Verify Pulverizer D (BF-PVR-500D) is running

PULVD

2.

Verify Pulverizer D has been sufficiently warmed and the Pulverizer
Outlet Temperature (BFTIC586D) has been >66°C for at least 15
minutes

PULVD

3.

Request AO to put Feeder D Operating Mode (BF-FDR-500D) in Local

LOS04

4.

Request AO to Jog Feeder D (BF-FDR-500D). Jog should be
maintained for several seconds until "Coal On Belt" is indicated.

LOS04
PULVD

5.

Request AO to put Feeder D Operating Mode (BF-FDR-500D) in
Remote

LOS04

6.

Verify Ignition Permit requirements are satisfied

HPULVDR1

7.

Start Coal Feeder D (BFFDR500D-SS)

PULVD

8.

Increase Feeder D Bias Station (BFFDR500D) output above 30% to
ensure a stable coal flame

PULVOV

9.

Verify Ignition Permit is available for at least 3 minutes after the Feeder
started running

PULVD

10. Adjust total fuel flow accordingly to control Main Steam Pressure
increase
a.

Adjust Warmup Oil Control station (FOFIC800) pressure setpoint

WUHDR

b.

Adjust Feeder B Bias Station Demand (BFFDR500B). Demand
should be > 50%.

PULVOV

Jharsuguda Generic Startup Procedure
Rev. 04

1-121

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS41: PULVERIZER D STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

c.

Adjust Feeder C Bias Station Demand (BFFDR500C). Demand
should be > 50%.

PULVOV

d.

Gradually increase Feeder D Bias Station Demand (BFFDR500D).
Increase demand towards 50%

PULVOV

CS41 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-122

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS42: OIL ELEVATION SHUTDOWN
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. After the unit has stabilized on coal firing (steam flow > 35% and coal
feeder demand > 50%), the oil guns may be taken out of service.
Notes:
Questions:

Elevation AB Shutdown
1.

Verify Steam Flow (SFPCT) > 35%

UNITMSTR

2.

Verify the Pulverizer B Feeder Demand (BFFDR500B) > 50%

UNITMSTR

3.

Verify the Pulverizer C Feeder Demand (BFFDR500C) > 50%

UNITMSTR

4.

Stop Elevation A/B Oil (BF-ELEV-AB)

ELEVAB

5.

Verify Elevation AB shuts down successfully

ELEVAB

6.

Adjust total fuel flow accordingly to control Main Steam Pressure:
a.

Adjust Warmup Oil Control station (FOFIC800) pressure setpoint

WUHDR

b.

Adjust Feeder B Bias Station Demand (BFFDR500B). Demand
should be > 50%.

PULVOV

c.

Adjust Feeder C Bias Station Demand (BFFDR500C). Demand
should be > 50%.

PULVOV

Elevation CD Shutdown
7.

Verify Steam Flow (SFPCT) > 35%

UNITMSTR

8.

Verify the Pulverizer B Feeder Demand (BFFDR500B) > 50%

UNITMSTR

9.

Verify the Pulverizer C Feeder Demand (BFFDR500C) > 50%

UNITMSTR

10. Verify the Pulverizer D Feeder Demand (BFFDR500D) > 25%

UNITMSTR

11. Stop Elevation C/D Oil (BF-ELEV-CD)

ELEVCD

12. Verify Elevation CD shuts down successfully

ELEVCD

13. Adjust total fuel flow accordingly to control Main Steam Pressure:
a.

Adjust Feeder B Bias Station Demand (BFFDR500B). Demand
should be > 50%.

Jharsuguda Generic Startup Procedure
Rev. 04

1-123

PULVOV

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS42: OIL ELEVATION SHUTDOWN
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

b.

Adjust Feeder C Bias Station Demand (BFFDR500C). Demand
should be > 50%.

PULVOV

c.

Adjust Feeder D Bias Station Demand (BFFDR500D). Demand
should be ~ 50%.

PULVOV

CS42 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-124

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS43: UNIT LOAD RAMP TO FULL LOAD
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
1. While increasing load adjust the throttle pressure setpoint manually
based on the curve below.
Throttle Press-Gen Power Relation
(for cold startup)
175
150
125
100
75
50
25
0

(fl
(fl

£

q[

v

-153
-100-

0

-166- -166-

166

AV124

110

30

50

80

90

100

105

Gen. Power Percent

2.

Sequence of starting auxiliaries:
a. Except for pulverizers and feeders all required auxiliaries are
already in service.
b. Pulverizers A and E should be warmed in preparation for being
placed in service at higher loads.
c. After completing warming a, Pulverizer and Feeder A should be
started at the appropriate load point.
d. After completing warming and at the appropriate load point,
Pulverizer and Feeder E will be the last pulverizer required to reach
full load.

Notes:

E

y

iJ

Questions:
1. What indicators does an operator have to determine when it is
time to place additional equipment in service?
Answer: Equipment demand (on M/A stations) and the current vs.
target load. Additional equipment is started as the demand on
operating equipment approaches 70%. Also, additional equipment is
started if the capacity of currently operating equipment is not enough
for the target load.

1.

Verify that no hold conditions exist

UNITMSTR

2.

Verify that the both the Boiler Master (Boiler Master) and the Turbine
Master (Turbine Master) are in Auto and the control mode indicates
Coordinated Mode

UNITMSTR

3.

Set the MW Rate of Change Limit (MW-ROC) to the maximum rate as
determined by operating procedures, usually set to 3MW/min.

UNITMSTR

4.

Continue increasing load to ~685 GMW by setting the Unit Master
Load Setpoint (Unit Master) to 685 MW

UNITMSTR

Jharsuguda Generic Startup Procedure
Rev. 04

1-125

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS43: UNIT LOAD RAMP TO FULL LOAD
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

5.

As load increases periodically adjust the Main Steam Pressure Setpoint
(STM PRESS SP) in line with the sliding pressure curve designated in
operating procedures

UNITMSTR

6.

As load increases monitor the First Stage Shell Metal and Reheat Bowl
Metal Temperatures and control loading

RSTRESS

7.

At ~400MW startup Pulverizer A (see CS44)

8.

At ~500MW startup Pulverizer E (see CS44)

9.

Option: As the Unit Load is increasing from 550 GMW to 685GMW
insert the BFP Turbine A Trip malfunction.

10. Stabilize the unit at full load (see CS45)
CS43 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-126

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS44: REMAINING PULVERIZER STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

Instructor Information
Discuss:
Notes:
1.

2.

3.

4.

5.

In general, it is important to keep the individual pulverizer feeder
demand at > 50%. This helps ensure stable combustion. Coal firing on
each pulverizer should be initiated in anticipation of loading and
maintaining feeder speeds at > 50%.
Each feeder delivers approximately 89TPH of coal at a demand of
100%. One TPH of coal will deliver approximately 2.3MW. Thus,
each pulverizer with a feeder demand of 50% will deliver about
100MW.
Coal Firing notes:
a. Pulverizer must be warmed up so that the mill outlet temperature is
at the setpoint of 72°C for a minimum of 15 minutes before coal
feeding. After coal feeder has been placed in service, gradually
reduce temperature setpoint to 66°C.
b. If a pulverizer trips at load, pulverizer inerting and steam transport
shall be carried out. (Refer to POI-BF-05).
c. Put additional (adjacent) feeder in service when existing feeder
demand is greater than 70%
d. Do not leave pulverizer in low load (< 40%) operation for extended
periods of time (> 20 minutes.) Bring pulverizer load above 40%
as soon as practical.
Mill trip conditions:
a. Mill outlet temp > 120°C
b. PA Flow < 52%
c. Pulverizer to furnace DP < 0.4kPag
If pulverizer bowl DP > 3.6kPag, feeder will run down to minimum
25%

7

Questions:

a

Pulverizer A Warming
1.

Verify Pulverizer A Lube Oil System is in service and Lube Oil
Temperature > 35°C

HPULVAR1

2.

Request AO to open Seal Air to Coal Feeder Valve (BF-ISV-515A)

LOS04

3.

Verify Pulverizer A Seal Air Valve (BF-PULVA-SAV) faceplate
command indicates Open

PULVA

4.

Request AO to Put Coal Feeder A OP Mode to REMOTE(BF-FDR500A)

LOS04

5.

Request AO to Open Inerting steam Block Valve A(BS-FV-210A)

LOS06

Jharsuguda Generic Startup Procedure
Rev. 04

1-127

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS44: REMAINING PULVERIZER STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

6.

Open Pulverizer A Discharge Valves (BFFY509A)

PULVA

7.

Verify Pulverizer A Start permissive is satisfied

HPULVAR1

8.

Start Pulverizer A (BF-PVR-500A)

PULVA

9.

Verify Pulverizer A Seal Air Valve (BF-PULVA-SAV) auto opens

PULVA

10. Verify Pulverizer A PA Flow Control station (BFFIC666A) opens and
wait for air flow to increase to the setpoint

PULVA

11. Open Pulverizer A Hot Air Gate (BF-PY-662A)

PULVA

12. Place Pulverizer A PA Flow Control station (BFTIC666A) in auto

PULVA

13. Place Pulverizer A Temperature Control station (BFTIC586A) in auto:
a.

Set Pulverizer A Temperature Control station (BFTIC586A)
setpoint to 72°C

PULVA

b.

Place Pulverizer A Temperature Control station (BFTIC586A) in
auto

PULVA

14. Pulverizer Warming will be complete when the Pulverizer Outlet
Temperature (BFTIC586A) has been maintained at >66°C for at least
15 minutes

PULVA

Pulverizer E Warming
15. Verify Pulverizer E Lube Oil System is in service and Lube Oil
Temperature > 35°C

HPULVER1

16. Request AO to open Seal Air to Coal Feeder Valve (BF-ISV-515E)

LOS04

17. Verify Pulverizer E Seal Air Valve (BF-PULVE-SAV) faceplate
command indicates Open

PULVE

18. Request AO to Put Coal Feeder E OP Mode to REMOTE(BF-FDR500E)

LOS04

19. Request AO to Open Inerting steam Block Valve E(BS-FV-210E)

LOS06

20. Open Pulverizer E Discharge Valves (BFFY509E)

PULVE

21. Verify Pulverizer E Start permissive is satisfied

HPULVER1

22. Start Pulverizer E (BF-PVR-500E)

PULVE

23. Verify Pulverizer E Seal Air Valve (BF-PULVE-SAV) auto opens

PULVE

24. Verify Pulverizer E PA Flow Control station (BFFIC666E) opens and
wait for air flow to increase to the setpoint

PULVE

25. Open Pulverizer E Hot Air Gate (BF-PY-662E)

PULVE

Jharsuguda Generic Startup Procedure
Rev. 04

1-128

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS44: REMAINING PULVERIZER STARTUP
Instructor Activity / Operating Procedure
26. Place Pulverizer E PA Flow Control station (BFTIC666E) in auto

Student
Response

Screen or LOS
Reference
PULVE

27. Place Pulverizer E Temperature Control station (BFTIC586E) in auto:
a.

Set Pulverizer E Temperature Control station (BFTIC586E)
setpoint to 72°C

PULVE

b.

Place Pulverizer E Temperature Control station (BFTIC586E) in
auto

PULVE

28. Pulverizer Warming will be complete when the Pulverizer Outlet
Temperature (BFTIC586E) has been maintained at >66°C for at least
15 minutes

PULVE

Pulverizer A Coal Firing
29. Verify Pulverizer A (BF-PVR-500A) is running

PULVA

30. Verify Pulverizer A has been sufficiently warmed and the Pulverizer
Outlet Temperature (BFTIC586A) has been >66°C for at least 15
minutes

PULVA

31. Request AO to put Feeder A Operating Mode (BF-FDR-500A) in Local

LOS04

32. Request AO to Jog Feeder A (BF-FDR-500A). Jog should be
maintained for several seconds until "Coal On Belt" is indicated.

LOS04
PULVA

33. Request AO to put Feeder A Operating Mode (BF-FDR-500A) in
Remote

LOS04

34. Verify Ignition Permit requirements are satisfied

HPULVAR1

35. Start Coal Feeder A (BFFDR500A-SS)

PULVA

36. Increase Feeder A Bias Station (BFFDR500A) output above 30% to
ensure a stable coal flame

PULVOV

37. Verify Ignition Permit is available for at least 3 minutes after the Feeder
started running

PULVA

38. Adjust total fuel flow accordingly to control Main Steam Pressure
increase
a.

Place Feeder A Bias Station Demand (BFFDR500A) in auto

PULVOV

b.

Gradually increase Feeder A Bias Station Demand (BFFDR500A)
bias towards 0%

PULVOV

Pulverizer E Coal Firing
39. Verify Pulverizer E (BF-PVR-500E) is running

Jharsuguda Generic Startup Procedure
Rev. 04

PULVE

1-129

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS44: REMAINING PULVERIZER STARTUP
Instructor Activity / Operating Procedure

Student
Response

Screen or LOS
Reference

40. Verify Pulverizer E has been sufficiently warmed and the Pulverizer
Outlet Temperature (BFTIC586E) has been >66°C for at least 15
minutes

PULVE

41. Request AO to put Feeder E Operating Mode (BF-FDR-500E) in Local

LOS04

42. Request AO to Jog Feeder E (BF-FDR-500E). Jog should be
maintained for several seconds until "Coal On Belt" is indicated.

LOS04
PULVE

43. Request AO to put Feeder E Operating Mode (BF-FDR-500E) in
Remote

LOS04

44. Verify Ignition Permit requirements are satisfied

HPULVER1

45. Start Coal Feeder E (BFFDR500E-SS)

PULVE

46. Increase Feeder E Bias Station (BFFDR500E) output above 30% to
ensure a stable coal flame

PULVOV

47. Verify Ignition Permit is available for at least 3 minutes after the Feeder
started running

PULVE

48. Adjust total fuel flow accordingly to control Main Steam Pressure
increase
a.

Place Feeder E Bias Station Demand (BFFDR500E) in auto

PULVOV

b.

Gradually increase Feeder E Bias Station Demand (BFFDR500E)
bias towards 0%

PULVOV

CS44 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-130

GENERIC TPP SIMULATOR STARTUP PROCEDURE
CS45: STABILIZE AT FULL LOAD
Instructor Activity / Operating Procedure
Instructor Information
Discuss:
Notes:
^

Questions:

M

1.

Stabilize the unit at full load and verify that all equipment is functioning
normally

2.

Option: As the unit is being stabilized at full load (~685 GMW) insert
the Secondary Air Heater A Trip malfunction.

CS45 FINISHED

Jharsuguda Generic Startup Procedure
Rev. 04

1-131

Student
Response

Screen or LOS
Reference

GENERIC TPP SIMULATOR STARTUP PROCEDURE
EXERCISE CONCLUSION
FREEZE the simulator and end the exercise when the unit is stable with the
following conditions:



Unit Load ~685 GMW
Main Steam Pressure 166barg (±1bar)









Main Steam Temperature 538°C (±5°C)
Five pulverizers in service
Oil Guns out of service
Feedwater controls in Auto
Turbine Master in Auto
Boiler Master in Auto
Unit in Coordinated Control Mode

END EXERCISE

Jharsuguda Generic Startup Procedure
Rev. 04

1

1 32

Sponsor Documents

Or use your account on DocShare.tips

Hide

Forgot your password?

Or register your new account on DocShare.tips

Hide

Lost your password? Please enter your email address. You will receive a link to create a new password.

Back to log-in

Close