The document provides instructions for various operations at a thermal power plant, including: 1) Charging the PRDS system and opening associated valves. 2) Opening valves in the cooling water system and starting the cooling water pump. 3) Heating the deaerator and establishing feedwater flow to the boiler by regulating valves. 4) Starting the boiler feed pumps and monitoring associated parameters. 5) Charging the main steam lines and monitoring drum level and flue gas temperatures. 6) Building condenser vacuum by opening air vents and valves, starting the ejectors, and admitting gland sealing steam.

1. THERMAL POWER PLANT
OPERATIONS
Simulator Part 3- Day2
MANOHAR TATWAWADI
Director, tops
A2-806, PALLADION, BALEWADI, PUNE 411045
Mob: 9372167165, Email:-mtatwawadi@gmail.com
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2. PRDS CHARGING
• Charge 16 ata header from other unit :
• Open Aux PRDS Drains 10% from Field.
• Put "PRDS CHARGE FROM OTHER UNIT" to 100 from field.
• Observe pressure in 16 ata header on Boiler Feed Pump &
PRDS' Panel.
• Observe temp. in 16 ata header on 'Condensate Panel‘.
• Same parameters also on Mimic page “Aux. PRDS System”.
• Open auxiliary steam valve by putting "AUX PRDS TO EJS AS-
1" to ON position from Field page.
• Open valve FW-83, FW-82, FW-77 (PRDS Spray) and AS-
51(PRDS Iso.) from Panel "Boiler feed pump and PRDS station"
• Open AS-81 (Steam to Ejector) and AS-79 (Gland Steam
Cooler)& GC-1 from Panel "Turbine Control/Lube oil Pump“.
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3. PRDS…… MIMIC
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4. CW SYSTEM
• Open CW-1, CW-2,CW-3,CW-4,CW-5,CW-6,CW-7 and
CW-8 from field page.
• CW Pump-A Local/Remote/Panel on remote, Start the
CW Pump A by switch on 'Condensate Panel‘
• Check Motor Current Graphics page 'Cooling Water
system'.
• NOTE: 1) If the pump is in local mode then, operate
the pump from Field page.
2) Corresponding valves for CWP-B are also on
same pages as CWP-A.
• Start C.T lift pump from field page.
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5. COOLING WATER SYSTEM
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6. Deaerator Heating
• Open Isolating Valves of AS-66,67,68 & 69 from Field page.
• Open Isolating Valves of AS-72 & AS-73 from Field Page.
• Open AS-72 to 30% from Panel and bring up the temperature
of feed water in deaerator to around 85-90 degree C. (Watch
Temp on Panel)
• Open manually to 30% AS-57 (bypass of AS-58) & AS-65 from
Panel. (16 ata auxiliary steam supply valve to deaerator.)
• Put Both Valves on Auto with SP on 6 Kg/sqcm.
• Start deaerating the incoming main condensate water into
deaerator by opening deaerator steam pressure regulating
valve.
• Start feed water heating in deaerator by regulating steam
valve AS-58 and bring up the temperature of feed water in
deaerator to around 85-90 degree C.
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7. FEED WATER SYSTEM
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8. BOILER FEED PUMPS
• For starting the boiler feed pump:
• Put L/R/P switch to Remote for both Aux. Oil Pump &
Boiler Feed Pump.
• Ensure Feed pump auto control in Manual mode & Feed
pump selection on DP mode from Panel-4
• Recirculation of Aux oil Pump and Warm up valve of BFP
should be open.
• BFP Scoop Position on Minimum. (30%)
• BFP 1P/2P on 1 Pump. And BFP A/B/C/ selection on
Manual
• Give “ON” command to BFP A
• Observe that the normalized current for BFP-A is 218
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9. BFP Panel
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10. BOILER FEED PUMPS
Observe the following :
• Warm up-line valve and AOP closes on interlock.
• Observe boiler feed pump suction flow (about 120t/hr) on trend
page “Desk 4 – BFP Parameters” .
• Observe that the boiler feed pump suction pressure is more than
about 5.8 Kg/cm2 on panel-5.
• Boiler feed pump discharge header pressure on panel-4
• The discharge valve indication on graphics "Feed Water System".
• If ELP is running then put it OFF from field page 4.
• Note the motor bearing temperatures along with oil pressure on
IMV page no. 1
• Observe pressure at inlet of feed regulating station on panel-5 and
open discharge valve FW-40 of BFP-A.
• Start feeding water to boiler drum by opening low load regulating
valve FW-26 in "manual mode" and increasing scoop tube position
such that a flow of about 50 t/hr at minimum feed pump discharge
pressure.
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11. Establishing FEED WATER FLOW
For establishing feed water flow to boiler
• Again observe the following:
• -BFP discharge header pressure
• -Deaerator level
• -Condenser hot well level
• -FW26 control from panel-4
• -Control Master & pump scoop from panel-4.
• -Observe feed water temperature and pressures.
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12. Establishing FEED WATER FLOW…
• -Keep a close watch a deaerator level and maintain at
3/4th of instrument scale by regulating DM make up
valves DM-24 or DM-25.
• -Keep a close watch on condenser hotwell and maintain at
3500 mm by regulating hot well level control valve MC-36
manually.
• -Maintain deaerator water temperature around 90 degree
C by deaerator feed tank heating valve AS-58.
• -Observe drum level on panel-4 or "Feed Water System "
graphics.
• -Bring down pump scoop tube position such that feed
pump discharge pressure is minimum (at least 5 Kg/cm2
more than low discharge pressure trip setting).
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13. Establishing FEED WATER FLOW…
• Keep on slowly raising deaerator temperature and pressure by
deaerator steam regulating valve AS-58 and gradually observe the rise in
pressure. Maintain the deaerator pressure at 6 kg/cm2 (7 ata).
• Put Drum level control, scoop in Auto mode.
• Make sure (3E,del p) switch position on del P position and (1E/3E) switch
position on 1E position.
• Make sure valve selection switch into Main position.
• Put BFP A scoop & BFP B scoop controller into manual mode of operation.
• Master scoop controller setpoint is on 50% settings.(CD-4) and in manual
mode.
• Increase output of master scoop controller till BFP a scoop setpoint
matches with its measured variable.
• Once the error becomes zero of BFP A scoop A then put BFP A scoop
controller into Auto mode.
• Adjust the master controller setpoint to match its measured variable and
put into auto mode from CD-4.
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14. CHARGING OF MAIN STEAM LINES
• Main steam line to be charged by opening MS-11 & M-12 from field
page no.11.
• Check : Put interlock selector switch of boiler drum emergency drain
valve in interlock mode from CD-4.OR Put Inching valve B-39 to 50%.
• Open the following drain valves from Field page no. 11
• -MS line drain to 10%
• -HPBP & LPBP line drains to 5%.
• -HPT casing & rotor drains to 5%.
• -IPT casing & rotor drains to 5%.
• Continuous blow down is on Imf page No.10.
• Keep a very close watch on boiler drum level and maintain it a
normal value (0 mm of scale) if so required, by low load feed
regulating valve FW-26.
• -drum level on panel-4.
• -Drum steam temp. on "Water & steam cycle" graphics.
• -Drum metal temp. on bargraph group=3, page=7, variable=3.
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15. Watching Drum Level & Flue Gas Temps.
• Observe the gradual rise in flue gas temperatures at exit, at
platen SH exit, at airheater exit, at economizer inlet, at
airheaters inlet and at airheaters exit. (Mimic Page No.1)
• Observe these parameters on trend page“Desk1–Flue gas
Temperatures”.
• Observe the gradual rise in air temperatures at air heaters
exit on trend page “Desk 1 - Flue Gas Temperatures”.
• Observe steam temperature on trend page “Desk4 – Drum
Parameters”.
• At about 2 kg/cm2 boiler drum pressure, close boiler drum
vents from field page no.13 and superheater vents and at
about 5 kg/cm2 of boiler drum pressure, throttle superheater
drains.
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16. Watching Drum Level & Flue Gas Temps
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17. CONDENSER VACUUM BUILDUP
• Check that non-return valves in CRH lines and their bypass valves (CR-3,
CR-4) are closed from Panel
• Close EV-1 & EV-2 from CD-5.
• Open airvent to condensors CA1 & CA2 from field page no.14.
• Open syphon filling valve MC-56 from field page no.9.
• Close vacuum breaker valve from panel-7
• Observe turbine rotor’s differential expansions on panel or trend page
no “Desk 7 – Turbine Expansions” .
• Open the ejector drain valve from field page no.12.Put gland seal steam
pressure controller valve(AS-81) with setpoint of .2kg into auto mode
from Panel 7. from field page no.14 to charge the gland sealing system
from panel-6.
• Open the valve on air line to starting ejector CA-5 from panel-6 & observe
graphics "Vacuum raising".
• Start starting ejector by opening its steam supply valve AS-4 to 50%
(Panel 7) .
• Observe the condenser vacuum on panel 6. It will take approx.3 to 5min
for vacuum to start.05/10/2019 Manohar Tatwawadi 17

18. CR1, CR2, CR3 & CR4 NRVs
MS & CRH
NRVs
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19. VACUUM RAISING
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20. Vacuum Raising
• Vacuum pulling has now started.
• When the vacuum is around 30-35 mm of Hg.cl (about 0.04
kg/cm2) take gland cooler No. 1 steam ejector in service by
opening steam supply valve to glands (AS-9,AS-10,AS-11,AS-
12,AS-13 & AS-14) from Field page no.14 such that, vacuum
of about 450-500 mm is available at GC-1 ejector.
• Close drains of Steam lines to starting ejector and to main
ejectors and GSC-1 from Field page no. 12
• When the vacuum is around 50-60 mm of Hg.cl. (about .07
kg/cm2) admit steam to turbine gland seals by opening
gland seal pressure regulating valve such that a pressure of
about 0.15 kg/cm2 to 0.20 kg/cm2 is available in seal steam
header.
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21. GLANDS SEALING
• Check that gland steam temperature is between 130-1500 C.
• Put the control of turbine gland sealing steam pressure
regulating valve AS-05 on `Auto‘ from Control Panel 7.
• The rate of vacuum pulling would become faster when gland
sealing steam is admitted.
• Start both main ejectors by opening their steam supply valve
(AS-2, AS-3) from Panel 7 to speed up the vacuum pulling rate.
• Open CA-3 and CA-4 from field page no.14.
• Open DM48,DM46,DM49,DM47 from field page no.12 on IC.
• Observe Mimic "Air Ejection System"
• When the vacuum in condenser is around 580 mm of Hg (about
0.76 kgcm-2) stop starting ejector first by closing its air line
valve CA-5 and then closing its steam Supply valve AS-4. Vacuum
continues to rise.
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