The presentation is for the simulator for the operation of Thermal Power Plant from starting. It describes the Electrical Charging and Water Cycle Establishment. The simultaneous operations on Turbine sides are also described for the First Part.

1. THERMAL POWER PLANT
OPERATIONS
Simulator Part 1- Day1
MANOHAR TATWAWADI
Director, tops
9372167165, mtatwawadi@gmail.com

2. ELECTRICAL CHARGING
• The first step is to establish power supply for
the auxiliaries at least for cooling water /GS
water pumps
• The power supply will be required for the
Instrument Air and Service air compressors.
• For Station Lighting , other station auxiliaries
and in the Water Treatment Plant.
• The power supply may be taken from the
440/220KV GRID by Station Transformers

3. Care to be Taken
• Get the clearance from Switchyard for charging the
400kv/220kv breakers of the station transformers.
• Check that all CTs & PTs in the switchyard are in order
• Before charging breaker, check the isolators.
• Generally always charge the HV side breaker of the
transformers first
• Mostly all 11kv, 6.6kv, 415V boards are charged from
both sides with their respective Bus Couplers in OFF
position
• Before charging check all the transformer protections
are in service.

4. STATION TRANSFORMER
• All the Electrical Supply required for the station is from
the Station Transformer (generally a (220/400)/6.6KV).
The station transformer capacity is approximately 20%
of the generating capacity. The supply may be changed
over to Unit Auxiliary Transformer, after the unit is
synchronized.
• The 6.6 KV station boards are charged by charging the
station transformer from the HV side (220/400KV side)
of the transformer first. The isolators of the 400kv side
breaker are closed and then the breaker is made ON.
• The incomers to the station boards are made ON to
charge the bus bars in the Board.

5. CHARGING OF STATION BOARDS

6. CHARGNG OF UNIT BOARDS 6.6 KV (UAT A & UAT B)
UNIT TRANSFORMER
16.5KV /6.6KV 20/25MVA
UNIT TRANSFORMER
16.5KV /6.6KV 20/25MVA

7. Charging of LT 6.6kv/440V Boards
• Charge Boiler Boards
• Charge Turbine Boards
• Station Service Boards
• Standby Board
• New Emergency Board
• Emergency Board and
• Main Lighting Distribution Board

8. CHARGING OF GS AND DM WATER
• The River water Pumps, pump water for the whole
requirement of water to the TPS. This water pumped
by the RWP is sent to the WT Plant where it is treated
& stored and then made available as G.S. water.
• The General water service pumps for all auxiliaries
cooling systems are started and all cooling water
systems are charged. The overhead GS water tanks are
also filled up. The tanks are provided so as to act as
buffer in case the pumps trip or not available for some
time.

9. Water Cycle Establishment
• General Water System will be charged first so that it
caters the need of cooling water to all auxiliaries.
• Two GS Pumps will be started for the purpose.
• Instrument Air and Service Air Compressors will be
started when cooling water is available
• The WT Plant will be started and DM water from the
WT Plant will be made available
• DM Intermediate Tank will be filled to its full capacity.
• DM Makeup will be started for filling DM Overhead
tanks.

10. CHARGING OF GS WATER
The General water service pumps for all auxiliaries cooling systems are started and all cooling water systems are
charged. The overhead GS water tanks are also filled up. The tanks are provided so as to act as buffer in case the
pumps trip or not available for some time.

11. Charging of DM and GS Water
• After the cooling water is available for Instrument and
service air compressors, the compressors can be
started and Instrument and Service air is made
available for the operation of valves, Atomisation etc.
• From the WT Plant, the DM water will be available
now. The Intermediate DM Tank is filled up by opening
valves DM4 and DM5 and DM Makeup pumps can be
started after the Intermediate Tank Level reaches more
than 2M.
• There are two Emergency DM tanks provided in case
of failure of DM Pumps. These tanks are filled by DM
Makeup Pumps by opening the respective valves.

12. TYPICAL DM MAKEUP SYSTEM

13. DM MAKEUP AND COND CYCLE
• The Unit Drain Tank and Condenser may be filled up
with the help of DM Make up pumps by opening the
respective valves. (UDT level 2M & Condenser Level
3M).
• The Condensate Cycle can be taken into service at this
time. There are Three No of CEPs. Two are running and
one standby. The First CEP to be started is started with
its Discharge Bypass valve 10% open, so that it
develops some header pressure. (More than
14kg/cm2, otherwise the started CEP will trip on “CEP
Discharge Header Pressure Low”.) Once a pressure of
20kg/cm2 is reached, the discharge valve of the CEP is
opened.

14. DM MAKEUP AND COND CYCLE
• Before the CEP is started the condensate line
upto the deaerator is made through (All Heaters
Inlet / Outlet Valves open & Bypass Valves
Closed). The main Condenser level control valve
is also kept closed. (MC36 Valve closed).
• After starting the CEP and opening the discharge
valve, Main Condenser level Control Valve (MC36)
can be opened and the flow to Deaerator can be
observed.

15. CONDENSATE CYCLE CHARGING
The Deaerator can now be filled up by opening the Main Condensate Control Valve MC36
slightly. (About 5%). The Condenser Hotwell Level in the process will come down. The
Condensate Level has to be maintained by the Condensate makeup valve CV6 or CV7. Once
the Deaerator level reaches to about 4M close the Main Condensate Control Valve MC36 and
stop the make up to condenser

16. BOILER DRUM FILLING & Feed water system
• The Vents of the boiler drum shall be opened for boiler drum
filling. Also the Economiser Recirculation Valve must be
opened before starting the boiler drum filling. By starting
Boiler Filling Pump and making the circuit through for boiler
filling through the Boiler Drain header, the Boiler Drum can
now be filled up to NORMAL Level. (0.6 M).
• Boiler Drum can also be filled by opening the Feed Control
Station Low Load Line valves, the economizer inlet valve and
the boiler filling pump discharge line to FCS valve.
• After the drum Filling is done up to the normal Level , the
boiler filling valve can now be closed. The Economiser vent
valves shall also be closed as water comes out from
Economoser Vents.
• The Drum Vents and the Economiser Recirculation will be
kept open, till there is pressure in the boiler drum.

17. FEED WATER SYSTEM & BOILER DRUM FILLING

18. Feed water system

19. Turbine Side Activities
• Start AC LOP, AC Seal Oil Pump
• After filling the oil lines fully, start Starting Oil Pump,
observe Relay Oil Pressure 18kg/cm2.
• Lubricating Oil Pressure 4kg/cm2 before oil coolers and
1kg/cm2 after coolers
• Take trials of DC LOP and DC Seal Oil Pumps by tripping the
respective AC Pumps.
• Stop AC Lub oil and AC Seal oil Pumps. Start JOP
• Check the lub oil and seal oil pressures, if OK
• Start Barring Gear motor and check the speed of the
turbine rotor.
• Start the Hydrogen Filling in the Generator. Observe the
pressure and Purity of Hydrogen in the Generator

20. TURBINE OIL SYSTEM 270 MW

21. Seal Oil System 210 MW

22. Hydrogen Filling in Generator

23. We have Achieved
• Whole Thermal Power Plant has been electrified
• GS water made available to all auxiliaries for cooling.
Overhead GS Tank Levels 3.5M
• Cooling Towers taken in service
• Instrument Air/ Service Air Pressure 6.5kg/cm2
• Unit Drain Tank, Emergency DM Tank, Condenser,
Deaerator and boiler drum filled with DM water.
• Condensate cycle charged with DM water
• Starting Oil Pump for Turbine Lub Oil, Seal Oil and relay oil
started.
• Turbine Rotor put on barring
• Hydrogen filling in Generator started.

24. We have Achieved
• Instrument air/service air pressure 6.5kg/cm2
• DM Intermediate Tank Level 4.5M
• Unit Drain Tank Full to its capacity
• Condenser Hotwell Level 3M
• Deaerator Level 4M
• Boiler Drum Level 0.6M
• SOP running, AC Lub oil & Seal oil Pumps OFF
Governing Oil Pres. 18kg/cm2,
• H2/seal oil Differential Pressure 0.9 to 1 kg/cm2
• Lub oil pres. 4kg/cm2, 1kg/cm2 before, after cooler.
• Barring gear ON Turbine rotor speed 3 to 4 RPM

25. Operational Tests
• Condenser level low, Deaerator level low,
Boiler Drum level low, UDT level low and DM
intertank level low reset.
• Starting of DC Lub oil and Seal oil Pumps on
Turbine lub oil pr low, seal oil pr low.
• Airheater AC motor tripping and DC / Air
motor starting
• All aux are getting cooling water