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However, if desired, the simulator can be initialized with vessels filled to their normal operating levels and /or unit buses
energized.
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 222C/hr and the furnace exit gas temperature to < 538C. 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
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
1-2
1-3
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:
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
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
1-5
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.
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:
1-6
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
1-7
1-8
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.
ECP05
b.
ECP05
c.
ECP05
d.
ECP08
e.
ECP11
1-9
2.
3.
Student
Response
Screen or LOS
Reference
f.
ECP11
g.
ECP14
h.
ECP14
i.
ECP14
j.
ECP16
k.
ECP17
ECP05
b.
ECP05
c.
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
ECP11
b.
ECP11
c.
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
1-10
Screen or LOS
Reference
ECP14
b.
ECP14
c.
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.
ECP05
b.
ECP05
c.
ECP05
d.
ECP08
e.
ECP08
f.
ECP05
6.
7.
Student
Response
ECP11
b.
ECP11
c.
ECP11
d.
ECP11
e.
ECP11
f.
ECP08
ECP14
b.
ECP15
c.
ECP15
1-11
Student
Response
Screen or LOS
Reference
d.
ECP15
e.
ECP15
8.
ECP06
b.
ECP06
c.
ECP06
d.
ECP06
9.
ECP09
b.
ECP09
c.
ECP09
d.
ECP09
e.
ECP09
ECP15
b.
ECP15
ECP06
b.
LOS13
c.
LOS13
d.
LOS13
e.
LOS13
ECP12
b.
LOS14
1-12
Student
Response
Screen or LOS
Reference
c.
LOS14
d.
LOS14
ECP06
b.
LOS13
c.
LOS13
d.
LOS13
ECP12
b.
LOS14
c.
LOS14
d.
LOS14
e.
LOS14
ECP06
LOS13
ECP12
b.
LOS14
c.
LOS14
d.
LOS14
ECP09
b.
LOS13
c.
LOS13
d.
LOS13
1-13
Student
Response
Screen or LOS
Reference
a.
ECP09
b.
LOS13
c.
LOS13
d.
LOS13
ECP12
b.
LOS14
c.
LOS14
d.
LOS14
LOS13
b.
LOS13
c.
LOS13
d.
LOS13
ECP17
CS01 FINISHED
1-14
LOS14
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.
Questions:
1.
2.
LOS12
3.
CAOV
4.
LOS12
b.
LOS12
c.
LOS12
d.
LOS12
5.
LOS12
6.
CAOV
CS02 FINISHED
1-15
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.
2.
Request AO to lineup the CCW system and report the status of the local
operations when complete.
a.
LOS10
b.
LOS10
c.
LOS10
d.
LOS10
e.
LOS10
f.
LOS10
g.
LOS10
h.
LOS11
i.
LOS11
j.
LOS11
k.
LOS11
l.
LOS11
1-16
Student
Response
Screen or LOS
Reference
3.
Not Modeled
4.
CCWOV
a.
CONDSTG
b.
LOS09
c.
LOS10
d.
LOS09
e.
LOS10
f.
CCWOV
g.
CCWOV
h.
LOS09
i.
LOS09
5.
LOS10
6.
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.
Not Modeled
9.
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.
BCWPEC
b.
BCWPEC
c.
BCWPEC
11. Verify the CCW Pump Minimum Flow Control station (CCPDIC804) is
tracking in manual and setpoint is 400kPa
CCWOV
CCWOV
1-17
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
LOS10
LOS10
CCWOV
a.
Request AO to verify CCW Pump Discharge valves (CC-ISV102A/B) are fully open
LOS10
b.
CCWOV
CCWOV
a.
CCWOV
b.
CCWOV
CCWOV
a.
CCWOV
b.
CCWOV
19. Put BFPT B Lube Oil Temperature Control station (CCTIC822) in auto:
CCWOV
a.
CCWOV
b.
CCWOV
20. Put the Main Turbine Lube Oil Temperature Control station
(LTTIC106B) in auto:
CCWOV
a.
CCWOV
b.
CCWOV
CS03 FINISHED
1-18
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.
Questions:
1. Why is it important to vent air from the condenser water box?
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.
2.
LOS12
3.
LOS09
4.
CWOV
5.
CWOV
a.
CWOV
b.
CWOV
c.
CWOV
1-19
6.
7.
Screen or LOS
Reference
CWOV
LOS09
a.
CWOV
b.
CWOV
8.
9.
Student
Response
CWOV
b.
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
CWOV
a.
Not Modeled
b.
CWOV
c.
CWOV
d.
CWOV
CWOV
b.
CWOV
c.
CWOV
Not Modeled
LOS12
1-20
Student
Response
Screen or LOS
Reference
SODHYPO
IDSYSOV
b.
IDSYSOV
CS04 FINISHED
1-21
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:
1.
2.
LOS09
3.
LOS09
4.
CONDSTG
5.
COND1
b.
COND1
6.
7.
LOS09
a.
COND1
b.
COND1
CS05 FINISHED
1-22
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.
b.
c.
d.
e.
f.
2.
COND1
b.
LPFWHOV
1-23
Student
Response
Screen or LOS
Reference
c.
LPFWHOV
d.
LPFWHOV
e.
LOS08
f.
LOS08
g.
LOS08
h.
LOS08
i.
LOS08
j.
LOS08
k.
LOS08
l.
LOS08
m.
LOS08
n.
COND1
o.
COND1
3.
COND1
4.
COND1
5.
COND1
6.
GSPROC!BOP
7.
Not Modeled
8.
LOS07
b.
LOS07
c.
COND1
1-24
Student
Response
Screen or LOS
Reference
LOS07
COND1
LOS07
b.
LOS07
c.
COND1
LOS07
b.
LOS07
c.
COND1
CDRAIN
b.
CDRAIN
c.
CDRAIN
d.
CDRAIN
Not Modeled
COND1
b.
COND1
c.
COND1
1-25
Student
Response
Screen or LOS
Reference
DEAOV
16. Line up Chemical Treatment System for ammonia injection to the Drain
Cooler Inlet:
a.
CTOV
b.
Not Modeled
c.
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.
COND1
b.
COND1
c.
CTOV
COND1
d.
CTOV
18. Stop the Unit 1 Condensate Transfer Pump (CSP100) until additional
makeup is required for the Condenser
CS06 FINISHED
1-26
COND1
Student
Response
Screen or LOS
Reference
Instructor Information
Discuss:
1.
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:
1.
HPFWHA
b.
HPFWHA
c.
HPFWHB
d.
HPFWHB
e.
HPFWHB
f.
HPFWHA
g.
HPFWHA
h.
HPFWHB
i.
HPFWHB
j.
HPFWHB
k.
HPFWHA
l.
HPFWHA
HPFWHB
n.
HPFWHB
o.
HPFWHB
1-27
Student
Response
Screen or LOS
Reference
LOS06
BLRCIRC
b.
BLRCIRC
3.
DRUMBD
b.
DRUMBD
c.
DRUMBD
d.
DRUMBD
4.
SHVENTS
b.
SHVENTS
c.
SHVENTS
d.
SHVENTS
e.
SHVENTS
f.
SHVENTS
g.
SHVENTS
h.
SHVENTS
5.
RHVENTS
b.
RHVENTS
c.
RHVENTS
6.
Not Modeled
7.
BLRCIRC
8.
BLRCIRC
9.
1-28
BBOV
Student
Response
Screen or LOS
Reference
b.
BBOV
c.
BBOV
d.
BBOV
LOS06
b.
LOS06
c.
LOS06
11. Request AO to throttle open Condensate to Boiler Fill Valve (FW-CKV561) to provide ~100T/H offeedwater flow
LOS06
BLRCIRC
CS07 FINISHED
1-29
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.
2.
Open Absorber FGD Sea Water Supply Valves, and set to auto :
a.
FCEC
b.
FCEC
3.
FCEC
4.
FCEC
5.
FCEC
6.
FCEC
7.
FCEC
8.
FCEC
9.
FCEC
CS08 FINISHED
1-30
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 ~ 115F (43.3 ~ 46.1C), why is the temperature maintained at 90F
(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.
2.
Verify that the Main Oil Tank level (LTLI100) is within the normal
range (~72%)
3.
LUBEOIL
a.
LOS10
b.
LOS10
c.
LOS10
d.
Open STG Lube Oil Cooler Inlet 3-way Valve (LT-V-105) to use
Cooler A
LOS11
e.
LOS11
1-31
Student
Response
Screen or LOS
Reference
4.
LUBEOIL
5.
LUBEOIL
6.
LUBEOIL
b.
LUBEOIL
c.
LUBEOIL
7.
LUBEOIL
8.
LUBEOIL
9.
LUBEOIL
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
LOS12
GENOV
HPU
LOS11
17. Request AO to pen EHC Cooler Inlet 3-way Valve (LT-V-200) to use
Cooler A
LOS11
HPU
LOS11
20. Verify that EHC oil pressure increases to normal pressure ~105kg/cm2
and EHC Pump current is ~35A
HPU
HPU
HPU
1-32
Student
Response
Screen or LOS
Reference
HPU
Not Modeled
CS09 FINISHED
1-33
Student
Response
Screen or LOS
Reference
Instructor Information
Discuss:
Notes:
1. While on turning gear, BFPT Lube Oil Temperature control setpoint
should be 42C. This should be changed to 52C after startup.
^
Questions:
FWPALO
2.
FWPALO
3.
Verify that the BFPT A bearing lube oil pressure increases to about 1.41
~ 1.55kg/cm2
TDBFWPAD
4.
Not Modeled
5.
FWPALO
6.
FWPALO
7.
FWPALO
FWPA
8.
LOS07
9.
FWPA
Not Modeled
FWPBLO
FWPBLO
13. Verify that the BFPT B bearing lube oil pressure increases to about 1.41
~ 1.55kg/cm2
TDBFWPBD
Not Modeled
FWPBLO
FWPBLO
FWPBLO
FWPB
1-34
Student
Response
Screen or LOS
Reference
LOS07
FWPB
Not Modeled
CS10 FINISHED
1-35
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.
2.
Request AO to verify that lube oil flow and pressure are normal for all
turbine and generator bearings
Not Modeled
3.
Not Modeled
4.
TGEAR
5.
TGEAR
a.
TGEAR
b.
After a 5 seconds the Main Turning Gear Motor should start and
the Piggy Back Motor will stop
TGEAR
c.
TGEAR
6.
TGEAR
7.
TDATA1
RTRWARM
CS11 FINISHED
1-36
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 > 83.4C
^
Questions:
1.
2.
Not Modeled
3.
LOS11
4.
SWCOOL
5.
SWCOOL
b.
SWCOOL
6.
SWCOOL
7.
SWCOOL
8.
SWCOOL
SCTRENDS
STATSLOT
CS12 FINISHED
1-37
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:
1.
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.
LOS02
3.
Not Modeled
4.
Request AO to confirm that all oil guns are in the off position (FOOGN-800A~L)
LOS03
5.
FUELOIL
b.
FUELOIL
6.
FUELOIL
7.
FUELOIL
8.
Using Fuel Oil Pump Standby Selector (FOHS410E) select Fuel Oil
Pump B as the standby pump
FUELOIL
9.
FUELOIL
10. Alternatively, the Fuel Oil Pump Sequence Control (FOHS410D) may
be used:
a.
FUELOIL
b.
FUELOIL
1-38
Student
Response
Screen or LOS
Reference
c.
FUELOIL
d.
FUELOIL
e.
After the Fuel Oil Header Pressure has stabilized at the setpoint
(~1500kPa), shutdown Fuel Oil Pump C and place in Auto
FUELOIL
LOS02
12. Request AO to check locally to make sure there are no fuel oil leaks
Not Modeled
CS13 FINISHED
1-39
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.
b.
c.
2.
3.
4.
Rev. 04
DRUMBD
DRUMLVL
LOS06
1-40
Student
Response
Screen or LOS
Reference
b.
DRUMBD
c.
DRUMBD
5.
LOS06
b.
LOS06
c.
LOS06
d.
LOS06
e.
LOS06
f.
LOS06
6.
7.
The drum level will decrease, fill the drum again if necessary:
BLRCIRC
a.
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
1-41
1-42
Student
Response
Screen or LOS
Reference
Student
Response
Screen or LOS
Reference
2.
PULVA
b.
PULVB
c.
PULVC
d.
PULVD
e.
PULVE
f.
PULVF
After Pulverizer Lube Oil Temperature > 32C, start Pulverizer Lube
Oil Pumps:
a.
PULVA
b.
PULVB
c.
PULVC
d.
PULVD
e.
PULVE
f.
PULVF
b.
c.
d.
e.
f.
g.
h.
i.
1-43
Student
Response
Screen or LOS
Reference
LOS05
b.
LOS05
c.
LOS05
d.
LOS05
e.
LOS05
f.
LOS05
g.
Not Modeled
h.
Not Modeled
5.
FGDHYD
b.
FGDHYD
c.
FGDHYD
d.
FGDHYD
e.
FGDHYD
f.
FGDHYD
g.
FGDHYD
h.
FGDHYD
i.
FGDHYD
j.
FGDHYD
k.
FGDHYD
l.
FGDHYD
FGDHYD
1-44
Student
Response
Screen or LOS
Reference
n.
FGDHYD
o.
FGDHYD
6.
Open the FGD Bypass Damper (FC-GSV-301) and the FGD Bypass
Damper Lower Section (FC-GSV-302)
7.
IDFANS
FCOV1
a.
IDFANS
b.
IDFANS
c.
IDFANS
d.
IDFANS
8.
IDFANS
9.
FDFANS
PAFANS
b.
PAFANS
c.
PAFANS
d.
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
PAFANA
b.
PAFANA
c.
PAFANA
d.
PAFANA
e.
PAFANA
1-45
Student
Response
Screen or LOS
Reference
PAFANA
PAFANB
b.
PAFANB
c.
PAFANB
d.
PAFANB
e.
PAFANB
f.
PAFANB
FDFANA
b.
FDFANA
c.
FDFANA
d.
FDFANA
e.
FDFANA
f.
FDFANA
g.
FDFANA
h.
FDFANA
i.
FDFANA
j.
FDFANA
k.
FDFANA
l.
FDFANA
FDFANB
b.
FDFANB
c.
FDFANB
d.
FDFANB
e.
FDFANB
f.
FDFANB
1-46
Student
Response
Screen or LOS
Reference
g.
FDFANB
h.
FDFANB
i.
FDFANB
j.
FDFANB
k.
FDFANB
l.
FDFANB
IDFANA
b.
IDFANA
c.
IDFANA
d.
IDFANA
e.
IDFANA
f.
IDFANA
g.
IDFANA
h.
IDFANA
i.
IDFANA
IDFANB
b.
IDFANB
c.
IDFANB
d.
IDFANB
e.
IDFANB
f.
IDFANB
g.
IDFANB
h.
IDFANB
i.
IDFANB
21. Open the Primary Air Heater Gas Outlet Temperature Control Damper
(BGTIC609)
1-47
PAHTR
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
LOS05
b.
After the Primary Air Heater indicates "turning" on the OIS screen,
start the Primary Air Heater electric motor (BF-HTR-600)
PAHTR
LOS05
b.
SAHTR
LOS05
b.
SAHTR
PASAHTRS
PASAHTRS
PASAHTRS
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
BLRCIRC
1-48
Student
Response
Screen or LOS
Reference
FPCNTL
FPCNTL
IDFANS
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
IDFANA
FDFANA
FDFANA
FDFANA
IDFANS
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
IDFANB
FDFANB
FDFANB
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
FPCNTL
WBOXOV
1-49
Student
Response
Screen or LOS
Reference
IDFANA
FDFANA
FDFANS
HIDA
IDFANSSA
a.
IDFANSSA
b.
IDFANSSA
c.
IDFANSSA
FDFANSSA
a.
FDFANSSA
b.
FDFANSSA
c.
FDFANSSA
d.
FDFANSSA
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
IDFANSSB
a.
IDFANSSB
b.
IDFANSSB
c.
IDFANSSB
FDFANSSB
a.
FDFANSSB
b.
FDFANSSB
c.
FDFANSSB
1-50
Student
Response
Screen or LOS
Reference
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
FPCNTL
WBOXOV
WBOXOV
d.
73. After MFT be cleared, usually after Purge, Place SOFA Dampers in
Auto:
a.
WBOXOV
b.
WBOXOV
c.
WBOXOV
d.
WBOXOV
e.
WBOXOV
f.
WBOXOV
g.
WBOXOV
h.
WBOXOV
CS15 FINISHED
1-51
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.)
Questions:
Verify that Auxiliary Air Dampers are modulating and that the
Auxiliary Air Damper Demand control station (BGPDIC546/7) is in
AUTO mode
AUXAIR
2.
IDFANS
FDFANS
3.
Verify that the Purge Permissive "Purge Ready" has been established
PURGE
1-52
Student
Response
Screen or LOS
Reference
4.
SAHTR
5.
SAHTR
6.
PAHTR
7.
PURGE
8.
PURGE
PURGE
PURGE
ALARMS
PURGE
13. Verify that the MFT is reset when the purge is completed
PURGE
DRUMLVL
PURGE
ALARMS
PURGE
18. Verify that the MFT is reset when the purge is completed
PURGE
IDFANS
FDFANS
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
1-53
Student
Response
Screen or LOS
Reference
24. Verify MFT/First Out indicates the "Air Flow < 25%" trip
PURGE
FDFANS
ALARMS
PURGE
28. Verify that the MFT is reset when the purge is completed
PURGE
IDFANS
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
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
ALARMS
PURGE
40. Verify that the MFT is reset when the purge is completed
PURGE
IDFANS
FDFANS
IDFANS
1-54
Student
Response
Screen or LOS
Reference
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
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
ALARMS
LOS05
IDFANS
FDFANS
IDFANS
FDFANS
CS16 FINISHED
1-55
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:
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.
PURGE
3.
PURGE
4.
FUELOIL
5.
DRUMLVL
6.
WBOXOV
7.
Verify that the SOFA Nozzle Tilt Control (BFHS730) is auto tracking
WBOXOV
8.
Not Modeled
9.
LOS12
10. Request AO to set Air Heater Soot Blower Drain Temperature Setpoint
(BS-TC-720) to 0F when using air as the blowing media
LOS12
11. Request AO to set air heater soot blower drain temperature (BS-TC730) at 0F when using air as the blowing media
LOS12
GSSBS-22
BLRCIRC
1-56
Student
Response
Screen or LOS
Reference
SAFANS
SAFANS
16. Put Furnace Thermal Probes in service and fully extended into furnace
GSSBS-07
PASAHTRS
PASAHTRS
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
WBOXOV
WBOXOV
a.
WBOXOV
b.
WBOXOV
c.
WBOXOV
d.
WBOXOV
WBOXOV
a.
WBOXOV
b.
WBOXOV
PULVA-F
LOS03
LOS03
29. Ensure all Longstroke Sootblowers and Wall sootblowers are retracted
GSSBS
FPCNTL
Student
Response
Screen or LOS
Reference
b.
DLSELECT
c.
PASAHTRS
d.
MSPRESST
e.
ECONBFPS
LUBEOIL
HPU
SWCOOL
34.
Not Modeled
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
BSDRAINS
b.
BSDRAINS
c.
RTRWRMV1
d.
RTRWRMV1
e.
RTRWRMV1
f.
RTRWRMV1
g.
RTRWRMV2
h.
RTRWRMV2
RTRWRMV1
b.
RTRWRMV1
c.
RTRWRMV1
d.
RTRWRMV1
1-58
Student
Response
Screen or LOS
Reference
e.
RTRWRMV2
f.
RTRWRMV2
g.
RTRWRMV1
h.
RTRWRMV1
i.
RTRWRMV1
j.
RTRWRMV1
k.
RTRWRMV1
STMVALVE
a.
STMVALVE
b.
STMVALVE
c.
STMVALVE
d.
STMVALVE
e.
STMVALVE
f.
STMVALVE
g.
STMVALVE
h.
STMVALVE
i.
STMVALVE
j.
STMVALVE
HPBYPASS
SHDRAINS
b.
SHDRAINS
c.
SHDRAINS
d.
SHDRAINS
e.
SHDRAINS
42. Verify all drum and superheater vents are open until steam is flow
established and indicated by increasing temperatures during boiler lightoff
a.
SHVENTS
SHVENTS
1-59
Student
Response
Screen or LOS
Reference
b.
SHVENTS
c.
SHVENTS
d.
SHVENTS
e.
SHVENTS
f.
SHVENTS
g.
SHVENTS
h.
SHVENTS
i.
SHVENTS
j.
SHVENTS
LOS07
b.
LOS07
c.
LOS07
d.
LOS07
LOS06
AUXSTM
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
LOS03
LOS07
LOS07
LOS07
CS17 FINISHED
Jharsuguda Generic Startup Procedure
Rev. 04
1-60
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 < 222C/hr
(56C/15minutes)
c. Furnace exit gas temperature should be < 538C
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 93-121C.
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) <55C and thus maintain
the start permissive.
3. BCWP Trip Conditions:
a. Motor Cavity Temperature > 60C
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.
2.
ELEVAB
3.
Verify Fuel Oil Pressure status indicates "ready" on OIS screen and
Fuel Oil Pressure (FOPI825) is OK
ELEVAB
4.
GSSBS-07
5.
FUELOIL
6.
FUELOIL
1-61
Student
Response
Screen or LOS
Reference
a.
FUELOIL
b.
FUELOIL
c.
FUELOIL
7.
LOS03
8.
ELEVAB
9.
ELEVAB
ELEVAB
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
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.
AUXSTM
b.
AUXSTM
c.
AUXSTM
17. Waiting for the Main Steam Pressure and Temperature to increase
STMTEMP
FWOV
19. If the Drum Level increases above +150mm, lower drum level:
a.
1-62
LOS06
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
BCWPA/B/C
a.
BCWPA/B/C
b.
BLRCIRC
c.
Start the second BCWP (two in service) after the drum water
temperature > 121C
H2OMENU
22. After the Main Steam Pressure > 150kPa or Steam Temperature >
120C (whichever comes first), close the drum vents:
a.
DRUMBD
b.
DRUMBD
23. After the Main Steam Pressure > 150kPa, close the superheater vents:
a.
SHVENTS
b.
SHVENTS
c.
SHVENTS
d.
SHVENTS
e.
SHVENTS
f.
SHVENTS
g.
SHVENTS
h.
SHVENTS
RHVENTS
25. Keep all Main Steam Drains and Reheat Drains Open
MSDRAIN
RHDRAINS
Not Modeled
CS18 FINISHED
1-63
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 > 200C.
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 150C and below
399C.
^
Questions:
STMSEAL
2.
STMSEAL
3.
STMSEAL
4.
STMSEAL
5.
LOS06
Manually open the Auxiliary Steam Seal Header Drain Valve (TL-LY291)
7.
STMSEAL
a.
STMSEAL
b.
STMSEAL
c.
STMSEAL
8.
1-64
STMSEAL
Student
Response
Screen or LOS
Reference
b.
STMSEAL
c.
STMSEAL
d.
STMSEAL
9.
STMSEAL
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
Not Modeled
STMSEAL
STMSEAL
STMSEAL
17. From the Steam Seal Header Divert (SSHDR-AD) select yes. The Auto
Dump Enable will indicate "Active."
STMSEAL
COND1
b.
COND1
c.
COND1
CS19 FINISHED
1-65
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:
b.
c.
2.
RHVENTS
b.
RHVENTS
c.
RHVENTS
3.
LOS08
4.
LOS08
5.
LOS08
6.
LOS08
7.
CONDVAC
8.
CONDVAC
9.
LOS08
1-66
Student
Response
Screen or LOS
Reference
LOS08
CONDVAC
CONDVAC
13. After the load target is reached and the Condenser Pressure drops below
60mmHg, stop Vacuum Pump C:
CONDVAC
a.
CONDVAC
b.
LOS08
c.
LOS08
CONDVAC
CS20 FINISHED
1-67
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 > 60C
Working Oil After Cooler Temperature > 120C
b. Fluid Coupling Side Trip Set Points:
Bearing Temperature > 90C
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 > 85C
CP & A.CP Side Mechanical Flushing Temperature > 100C
Thrust Bearing Temperature > 75C
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.
2.
LOS07
3.
MDFWP
4.
MDFWP
5.
HMDFWP
6.
MDFWP
a.
MDFWP
b.
MDFWP
1-68
Student
Response
Screen or LOS
Reference
MDFWP
7.
MDFWP
8.
MDFWP
9.
MDFWP
10. Once steam flow (and thus feedwater demand) have stabilized at a
sufficient level place the Drum Level Control (FWLIC370) in auto:
a.
MDFWP
b.
MDFWP
c.
MDFWP
d.
MDFWP
CS21 FINISHED
1-69
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 < 121C
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.
1.
Questions:
FLMDMP
b.
HPBYPASS
c.
COND1
d.
FWOV
2.
HPBYPASS
3.
Setup and verify the following conditions for the Turbine Bypass
System:
a.
HPBYPASS
b.
HPBYPASS
c.
HPBYPASS
d.
HPBYPASS
e.
HPBYPASS
f.
HPBYPASS
1-70
Student
Response
Screen or LOS
Reference
g.
HPBYPASS
h.
HPBYPASS
4.
HPBYPASS
5.
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.
SHDRAINS
b.
SHDRAINS
c.
SHDRAINS
d.
SHDRAINS
8.
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.
WUHDR
b.
HPBYPASS
c.
Continue decreasing the firing rate until the HP Bypass Valves are
closed
WUHDR
HPBYPASS
d.
HPBYPASS
CS22 FINISHED
1-71
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.
STMVALVE
b.
STMVALVE
c.
STMVALVE
d.
STMVALVE
e.
STMVALVE
f.
STMVALVE
g.
STMVALVE
h.
STMVALVE
i.
STMVALVE
j.
STMVALVE
k.
STMVALVE
3.
LORELAY
4.
MKVMRST
5.
Verify that the Master Reset button text turns to green and there are no
Active Turbine Trips
MKVMRST
6.
LPFWHOV
b.
LPFWHOV
c.
LPFWHOV
d.
LPFWHOV
1-72
Student
Response
Screen or LOS
Reference
LPFWHOV
b.
LPFWHOV
c.
LPFWHOV
d.
LPFWHOV
e.
DEAOV
f.
DEAOV
8.
HPFWHA
b.
HPFWHA
c.
HPFWHA
d.
HPFWHB
e.
HPFWHB
f.
HPFWHB
9.
LPFWHOV
b.
LPFWHOV
c.
LPFWHOV
d.
LPFWHOV
e.
LPFWHOV
f.
LPFWHOV
CS23 FINISHED
1-73
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.
1-74
Student
Response
Screen or LOS
Reference
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.
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.
RTRWRMV1
b.
RTRWRMV1
c.
RTRWRMV1
d.
RTRWRMV1
e.
RTRWRMV1
f.
RTRWRMV1
g.
RTRWRMV1
h.
RTRWRMV1
i.
RTRWRMV1
j.
RTRWRMV1
k.
RTRWRMV1
l.
RTRWRMV1
RTRWRMV1
n.
RTRWRMV2
o.
RTRWRMV2
p.
RTRWRMV2
q.
RTRWRMV2
r.
RTRWRMV2
s.
RTRWRMV2
t.
RTRWRMV2
u.
RTRWRMV2
v.
RTRWRMV2
1-75
Student
Response
Screen or LOS
Reference
3.
Not Modeled
4.
MKVMRST
5.
RTRWARM
6.
STMVALVE
7.
STMVALVE
8.
RTRWRMV1
9.
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.
RTRWARM
b.
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.
RTRWRMV1
b.
RTRWRMV1
c.
RTRWRMV1
d.
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
STMVALVE
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
Student
Response
Screen or LOS
Reference
a.
RTRWRMV1
b.
RTRWRMV1
c.
RTRWRMV1
d.
RTRWRMV1
e.
RTRWRMV1
f.
RTRWRMV1
g.
RTRWRMV1
h.
RTRWRMV1
i.
RTRWRMV1
j.
RTRWRMV1
k.
RTRWRMV1
l.
RTRWRMV1
RTRWRMV1
n.
RTRWRMV2
o.
RTRWRMV2
p.
RTRWRMV2
q.
RTRWRMV2
r.
RTRWRMV2
s.
RTRWRMV2
t.
RTRWRMV2
u.
RTRWRMV2
v.
RTRWRMV2
18. Verify that the Main Turbine coasts back on turning gear
CS24 FINISHED
1-77
TGEAR
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.
2.
LOS07
3.
LOS07
4.
LOS07
5.
LOS07
6.
LOS07
7.
FWPA
b.
FWPA
c.
FWPA
d.
FWPA
e.
FWPA
f.
FWPA
8.
HFWPA
9.
FWPA
a.
FWPA
b.
FWPA
c.
FWPA
1-78
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
LOS07
LOS07
LOS07
16. Open the following BFPT B Steam Drains and place in auto:
a.
FWPB
b.
FWPB
c.
FWPB
d.
FWPB
e.
FWPB
f.
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.
FWPB
b.
FWPB
c.
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 80C (Casing Metal Temperature Not Low
indicates Ready)
CS25 FINISHED
1-79
HFWPB
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
PAFANA
a.
PAFANA
b.
PAFANA
c.
PAFANA
d.
PAFANA
e.
PAFANB
f.
PAFANB
g.
PAFANB
h.
PAFANB
HPA
Verify Hot and Cold Secondary Air Crossover Dampers (BF-PY605A/606A) are open
PAFANS
Issue a PA Fan Request to Start (BF PA FAN RTS) and verify the
following events:
PAFANS
a.
PAFANA/B/C/D/E/F
PAFANA
PAFANA
PAFANA
1-80
Student
Response
Screen or LOS
Reference
8.
SAFANS
9.
Open the Cold Air Gate for at least one pulverizer: Pulverizer A
(BFPY664A)
PULVA
PAFANS
PAFANS
PAFANS
PAFANS
PAFANA
PULVA
b.
PULVB
c.
PULVC
d.
PULVD
e.
PULVE
f.
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
PAFANB
PAFANB
PAFANB
PAFANB
21. Adjust the balance between PA Fans A and B by adjusting the bias of
the PA Fan B Bias Stations appropriately
AIRMSTR
HPA
PAFANA
PAFANSSA
1-81
Student
Response
Screen or LOS
Reference
a.
PAFANSSA
b.
PAFANSSA
c.
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
SAFANS
PAFANS
PAFANS
PULVA
b.
PULVB
c.
PULVC
d.
PULVD
e.
PULVE
f.
PULVF
PAFANB
PAFANSSB
a.
PAFANSSB
b.
PAFANSSB
c.
PAFANSSB
PAFANS
33. Adjust the balance between PA Fans A and B by adjusting the bias of
the PA Fan B Bias Stations appropriately
AIRMSTR
LOS05
CS26 FINISHED
Jharsuguda Generic Startup Procedure
Rev. 04
1-82
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 >60C 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.
b.
c.
d.
e.
f.
2.
HPULVBR1
3.
LOS04
4.
PULVB
5.
LOS04
1-83
Student
Response
Screen or LOS
Reference
6.
LOS06
7.
PULVB
8.
HPULVBR1
9.
PULVB
PULVB
PULVB
PULVB
PULVB
PULVB
b.
PULVB
PULVB
CS27 FINISHED
1-84
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 37.8C 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 80C.
2. BFP Pump-side trip setpoints:
a. Outboard & inboard bearing high vibration > 120^m
b. CP & A.CP bearing high temp > 85C
c. Thrust bearing high temp > 75C
d. CP & A.CP side mechanical flushing high temp > 100C
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 > 204.4C
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.
FWPA
2.
HFWPA
3.
FWPA
4.
FWPA
5.
FWPA
1-85
Student
Response
Screen or LOS
Reference
6.
FWPA
7.
FWPA
8.
After starting, the BFPT A Control Valves will open and bring the
BFPT Speed to the minimum speed of 500rpm
FWPA
9.
FWPA
a.
FWPA
b.
FWPA
FWPA
FWPA
FWPA
DRUMLVL
14. Verify all BFPT A Drains is close automatically when BFPT Speed >
1200rpm:
FWPA
a.
FWPA
b.
FWPA
c.
FWPA
d.
FWPA
e.
FWPA
f.
FWPA
DRUMLVL
DRUMLVL
DRUMLVL
DRUMLVL
DRUMLVL
MDFWP
1-86
1-87
Student
Response
Screen or LOS
Reference
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 = 168C
e. Maximum differential temperature between Main Steam and CV
Outer Metal temperatures = 185C
pyj
Questions:
1.
CHSTWARM
2.
CHSTWARM
3.
Verify that the Main Stop Valve Above and Below Seat Drains are
closed:
a.
RTRWRMV1
b.
RTRWRMV1
c.
RTRWRMV1
d.
RTRWRMV1
4.
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.
CHSTWARM
a.
CHSTWARM
b.
CHSTWARM
88
7.
8.
Open the Main Stop Valve Above and Below Seat Drains:
Student
Response
Screen or LOS
Reference
CHSTWARM
CHSTWARM
a.
RTRWRMV1
b.
RTRWRMV1
c.
RTRWRMV1
d.
RTRWRMV1
CS29 FINISHED
1-89
2.
3.
LU
Questions:
1. List the turbine auxiliary valves and give the purpose of each?
Answer:
-
1-90
Student
Response
Screen or LOS
Reference
Student
Response
Screen or LOS
Reference
2.
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
ROLLOFF
2.
MKVMRST
3.
ROLLOFF
b.
ROLLOFF
c.
CTFP2
d.
CTFP2
e.
CTFP2
4.
WUHDR
5.
MKVMRST
6.
Verify that the Eccentricity (ECCENT) < 0.03mm for more than one
hour
TDATA1
7.
TGEAR
8.
STMSEAL
9.
CONDVAC
1-91
LUBEOIL
Student
Response
Screen or LOS
Reference
b.
LUBEOIL
c.
LUBEOIL
d.
LUBEOIL
e.
LUBEOIL
f.
LUBEOIL
HPU
b.
HPU
c.
HPU
d.
HPU
12. Verify Generator Casing Hydrogen Pressure > 4.5barg and Hydrogen
Purity > 96%
GENOV
TURBLIM
RTRWARM
CHSTRARM
BSDRAINS
b.
BSDRAINS
c.
RTRWRMV1
d.
RTRWRMV1
e.
RTRWRMV1
f.
RTRWRMV1
g.
RTRWRMV2
h.
RTRWRMV2
RTRWRMV1
b.
RTRWRMV1
c.
RTRWRMV1
1-92
Student
Response
Screen or LOS
Reference
d.
RTRWRMV1
e.
RTRWRMV2
f.
RTRWRMV2
g.
RTRWRMV1
h.
RTRWRMV1
i.
RTRWRMV1
j.
RTRWRMV1
k.
RTRWRMV1
FWOV
SWCOOL
a.
SWCOOL
b.
SWCOOL
c.
SWCOOL
d.
SWCOOL
20. Perform lube oil pump auto cut in test and ETD1, 2 & ETSV test (RPTLT-01 and RPT -TG-09)
Not modeled
TGEAR
22. Verify all alarms have been cleared, acknowledged and reset
ALARMS
1-93
TSPEED
Student
Response
Screen or LOS
Reference
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.
RSTRESS
b.
TSPEED
c.
TSPEED
d.
TGEAR
e.
MKVALM
Not Modeled
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.
TSPEED
b.
XOVERTMP
1-94
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
TSPEED
EX2000
ECP01
44. Request AO to verify that the Air Conditioning Unit at the Excitation
Cabinet is in service.
Not Modeled
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
TSPEED
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.
RSTRESS
b.
TSPEED
c.
TSPEED
d.
TGEAR
e.
MKVALM
1-95
Not Modeled
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.
LUBEOIL
b.
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
EX2000
ECP01
62. Request AO to verify that the Air Conditioning Unit at the Excitation
Cabinet is in service.
Not Modeled
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
1-96
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?
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
LOS03
2.
ELEVCD
3.
ELEVCD
4.
ELEVCD
1-97
Student
Response
Screen or LOS
Reference
5.
GENSYNC
6.
GENSYNC
7.
GENSYNC
8.
LORELAY
9.
GENSYNC
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.
GENSYNC
b.
GENSYNC
15. If Generator Voltage Error is outside the acceptable range, adjust the
Generator Voltage:
a.
ECP04
b.
EX2000
GENSYNC
17. Select Generator Sync Monitor Off by issuing a Synch Monitor Cancel
(L43S_MTRC)
GENSYNC
ECP03
ECP10
1-98
GENSYNC
Student
Response
Screen or LOS
Reference
GENSYNC
21. Place Speed Matching in auto by issuing a Speed Match Auto Request
(L43NM_AUR)
GENSYNC
GENSYNC
LORELAY
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.
GENSYNC
b.
GENSYNC
30. If Generator Voltage Error is outside the acceptable range, adjust the
Generator Voltage:
a.
ECP04
b.
EX2000
GENSYNC
32. Select Generator Sync Monitor Off by issuing a Synch Monitor Cancel
(L43S_MTRC)
GENSYNC
GENSYNC
ECP03
1-99
GENSYNC
Student
Response
Screen or LOS
Reference
BSDRAINS
b.
BSDRAINS
c.
RTRWRMV1
d.
RTRWRMV1
e.
RTRWRMV1
f.
RTRWRMV1
g.
RTRWRMV2
h.
RTRWRMV2
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
1-100
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
175
150
125
100
75
50
25
0
-153
100"
110
30
-166- -166-
166
'124
50
80
90
100
105
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:
UNITMSTR
1-101
Student
Response
Screen or LOS
Reference
3.
FUELOIL
4.
UNITMSTR
5.
ADMMODE
6.
UNITMSTR
7.
As load increases monitor the First Stage Shell Metal and Reheat Bowl
Metal Temperatures and control loading
RSTRESS
8.
9.
10. At Main Steam Flow > 10%, verify that AH Sootblower media has
changed to steam
CS32 FINISHED
1-102
GSSBS-07
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 72C for a minimum of 15 minutes before coal
feeding. After coal feeder has been placed in service, gradually
reduce temperature setpoint to 66C.
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 > 120C
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:
PULVB
2.
PULVB
3.
Verify Hot Primary Air Temperature (BFTI656) out of the Primary Air
Heater is > 220C
PAHTR
4.
ESPOV
5.
LOS04
6.
LOS04
PULVB
7.
LOS04
8.
HPULVBR1
1-103
Student
Response
Screen or LOS
Reference
PULVB
PULVOV
11. Verify Ignition Permit is available for at least 3 minutes after the Feeder
started running
PULVB
WUHDR
Pulverizer C Warming
13. Verify Pulverizer C Lube Oil System is in service and Lube Oil
Temperature > 35C
HPULVCR1
LOS04
PULVC
LOS04
LOS06
PULVC
HPULVCR1
PULVC
PULVC
PULVC
PULVC
PULVC
PULVC
b.
PULVC
PULVC
1-104
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 >
120C
ESPOV
LOS05
ESPOV
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
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.
FCOV1
b.
FCOV1
c.
FCOV1
d.
FCOV1
e.
FCOV1
f.
FCOV1
39. Request AO to verify Absorber Purge Fan is off and the outlet damper
is supplied with service air
Not Modeled
FCOV1
FCOV1
b.
FCOV1
c.
FCOV1
1-105
Student
Response
Screen or LOS
Reference
d.
FCOV1
e.
FCOV1
f.
FCOV1
FCOV1
FCOV1
b.
FCOV1
c.
FCOV1
d.
FCOV1
1-106
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.
b.
c.
d.
e.
f.
2.
HPFWHA
b.
HPFWHA
c.
HPFWHA
d.
HPFWHA
e.
HPFWHA
f.
HPFWHA
g.
HPFWHB
h.
HPFWHB
i.
HPFWHB
j.
HPFWHB
k.
HPFWHB
l.
HPFWHB
1-107
Student
Response
Screen or LOS
Reference
HPFWHA
b.
HPFWHA
c.
HPFWHA
d.
HPFWHB
e.
HPFWHB
f.
HPFWHB
4.
TDBFPEXT
b.
TDBFPEXT
5.
HPFWHA
b.
HPFWHA
c.
HPFWHA
d.
HPFWHB
e.
HPFWHB
f.
HPFWHB
6.
HPFWHOV
7.
HPFWHOV
8.
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.
HPFWHA
b.
HPFWHA
c.
HPFWHA
d.
HPFWHA
e.
HPFWHA
f.
HPFWHB
1-108
Student
Response
Screen or LOS
Reference
g.
HPFWHB
h.
HPFWHB
i.
HPFWHB
j.
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
TDBFPEXT
TDBFPEXT
TDBFPEXT
CS34 FINISHED
1-109
Student
Response
Screen or LOS
Reference
Instructor Information
Discuss:
1. While increasing load adjust the throttle pressure setpoint manually
based on the curve below.
(fl
(fl
q[
-153
-166- -166-
166
AV124
-100"
110
30
50
80
90
100
105
Notes:
Questions:
1.
UNITMSTR
2.
FUELOIL
3.
UNITMSTR
4.
UNITMSTR
5.
As load increases monitor the First Stage Shell Metal and Reheat Bowl
Metal Temperatures and control loading
RSTRESS
6.
7.
8.
9.
UNITMSTR
1-110
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.
PULVOV
b.
PULVOV
c.
PULVOV
d.
PULVOV
e.
PULVOV
f.
PULVOV
CS35 FINISHED
1-111
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.
ECP08
b.
ECP11
c.
ECP17
2.
Request AO to verify that no Lock Out Status exists on High Speed Fast
Transfer Relay panel
3.
Not Modeled
a.
ECP05
b.
ECP10
c.
ECP05
d.
ECP05
e.
ECP05
f.
ECP05
ECP08
4.
1-112
Student
Response
Screen or LOS
Reference
a.
ECP11
b.
ECP10
c.
ECP08
d.
ECP11
e.
ECP08
f.
ECP11
5.
ECP14
b.
ECP10
c.
ECP14
d.
ECP14
e.
ECP14
f.
ECP14
ECP17
6.
Verify that 13.8kV Switchgear Transfer Enabled lamps on ECP are lit:
a.
ECP08
b.
ECP11
c.
ECP17
7.
Request AO to verify that no Lock Out Status exists on High Speed Fast
Transfer Relay panel
CS36 FINISHED
1-113
Not Modeled
Student
Response
Screen or LOS
Reference
Instructor Information
Discuss:
Notes:
^
Questions:
1.
LOS07
2.
LOS07
3.
LOS07
4.
LOS07
5.
STMTEMP
6.
STMTEMP
7.
STMTEMP
8.
STMTEMP
9.
STMTEMP
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
STMTEMP
RHTEMP
RHTEMP
RHTEMP
RHTEMP
1-114
1-115
Student
Response
Screen or LOS
Reference
STMTEMP
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.
FWPB
2.
HFWPB
3.
FWPB
4.
FWPB
5.
FWPB
6.
FWPB
7.
After starting, the BFPT B Control Valves will open and bring the
BFPT Speed to the minimum speed of 500rpm
FWPB
8.
FWPB
a.
FWPB
b.
FWPB
9.
FWPB
FWPB
FWPB
DRUMLVL
13. Verify all BFPT B Drains is close automatically when BFPT Speed >
1200rpm:
FWPB
a.
1-116
FWPB
Student
Response
Screen or LOS
Reference
b.
FWPB
c.
FWPB
d.
FWPB
e.
FWPB
f.
FWPB
DRUMLVL
FWPA
DRUMLVL
CS38 FINISHED
1-117
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:
PULVC
2.
PULVC
3.
LOS04
4.
LOS04
PULVC
5.
LOS04
6.
HPULVCR1
7.
PULVC
8.
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.
WUHDR
b.
PULVOV
c.
PULVOV
1-118
Student
Response
Screen or LOS
Reference
Pulverizer D Warming
11. Verify Pulverizer D Lube Oil System is in service and Lube Oil
Temperature > 35C
HPULVDR1
LOS04
PULVD
LOS04
LOS06
PULVD
HPULVDR1
PULVD
PULVD
PULVD
PULVD
PULVD
PULVD
b.
PULVD
PULVD
CS39 FINISHED
1-119
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:
LOS09
b.
COND1
c.
COND1
d.
COND1
LOS07
3.
LOS07
4.
COND1
5.
LOS07
b.
LOS07
c.
COND1
CS40 FINISHED
1-120
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:
PULVD
2.
PULVD
3.
LOS04
4.
LOS04
PULVD
5.
LOS04
6.
HPULVDR1
7.
PULVD
8.
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.
WUHDR
b.
PULVOV
1-121
Student
Response
Screen or LOS
Reference
c.
PULVOV
d.
PULVOV
CS41 FINISHED
1-122
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.
UNITMSTR
2.
UNITMSTR
3.
UNITMSTR
4.
ELEVAB
5.
ELEVAB
6.
WUHDR
b.
PULVOV
c.
PULVOV
Elevation CD Shutdown
7.
UNITMSTR
8.
UNITMSTR
9.
UNITMSTR
UNITMSTR
ELEVCD
ELEVCD
13. Adjust total fuel flow accordingly to control Main Steam Pressure:
a.
1-123
PULVOV
Student
Response
Screen or LOS
Reference
b.
PULVOV
c.
PULVOV
CS42 FINISHED
1-124
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[
-153
-100-
-166- -166-
166
AV124
110
30
50
80
90
100
105
2.
Notes:
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.
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.
UNITMSTR
4.
UNITMSTR
1-125
Student
Response
Screen or LOS
Reference
5.
UNITMSTR
6.
As load increases monitor the First Stage Shell Metal and Reheat Bowl
Metal Temperatures and control loading
RSTRESS
7.
8.
9.
1-126
Student
Response
Screen or LOS
Reference
Instructor Information
Discuss:
Notes:
1.
2.
3.
4.
5.
Questions:
Pulverizer A Warming
1.
HPULVAR1
2.
LOS04
3.
PULVA
4.
LOS04
5.
LOS06
1-127
Student
Response
Screen or LOS
Reference
6.
PULVA
7.
HPULVAR1
8.
PULVA
9.
PULVA
PULVA
PULVA
PULVA
PULVA
b.
PULVA
PULVA
Pulverizer E Warming
15. Verify Pulverizer E Lube Oil System is in service and Lube Oil
Temperature > 35C
HPULVER1
LOS04
PULVE
LOS04
LOS06
PULVE
HPULVER1
PULVE
PULVE
PULVE
PULVE
1-128
Student
Response
Screen or LOS
Reference
PULVE
PULVE
b.
PULVE
PULVE
PULVA
30. Verify Pulverizer A has been sufficiently warmed and the Pulverizer
Outlet Temperature (BFTIC586A) has been >66C for at least 15
minutes
PULVA
LOS04
LOS04
PULVA
LOS04
HPULVAR1
PULVA
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.
PULVOV
b.
PULVOV
PULVE
1-129
Student
Response
Screen or LOS
Reference
40. Verify Pulverizer E has been sufficiently warmed and the Pulverizer
Outlet Temperature (BFTIC586E) has been >66C for at least 15
minutes
PULVE
LOS04
LOS04
PULVE
LOS04
HPULVER1
PULVE
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.
PULVOV
b.
PULVOV
CS44 FINISHED
1-130
Questions:
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
1-131
Student
Response
Screen or LOS
Reference
END EXERCISE
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