1. Adani Power Limited Power Business Goal - 20,000 MW

2. ADANI POWER AT A GLANCE Power Business Goal - 20,000 MW BY 2020
MUNDRA– 330MW X MW X 5
TIRODA– 660MW X 5 (UNDER COMMISSIONING)
KAWAI– 660MW X 2 (UNDER ERECTION)
BITTA– 40MW BIGGEST SOLAR IN INDIA

3. ACHIEVEMENTS
INDIA’S FIRST 66O MW SUPER CRITICAL UNIT SYNCHRONISED BY ADANI POWER LTD, MUNDRA IN OCT 2010 IN RECORD TIME OF 36 MONTHS.
COMMISSIONED 4Nos. 660MW UNITS IN A YEAR.
ADANI IS THE FIRST COMPANY IN INDIA TO EARN CARBON CREDIT.

4. PRESENTATION ON UNIT LIGHTUP,
WELCOME TO
PRESENTATION ON UNIT LIGHTUP,
SYNCHRONISATION
&
SHUTDOWN
PRESENTED BY
B.K.PANDEY
APML, TIRODA

5. START-UP SEQUENCE BOP SYSTEM READYNESS BOILER FLUSHING: COLD/HOT
BOILER LINE UP AND LIGHT UP.
TURBINE LINE UP.
TURBINE ROLLING.
SYNCHRONISATION
PHASE CHANGE OVER
FULL LOAD

6. START UP MODES COLD START UP:HP & IP SHAFT METAL TEMP <204°C
WARM START UP: HP & IP METAL TEMP IN BETWEEN 204 TO 400°C
HOT START UP :HP & IP METAL TEMP >400°C

7. HPT IPT LPT A LPT B RH 1 CEP GSC (MD BFBP 1x35%) TDBFP 2X50% 3x50%
Boiler
Economiser
FCS
11+1 8
2x7
2x7
HPT
IPT
LPT A
LPT B 5 6 5 6 7 7 7 7 3 8 8 8 8 RH 1
LPH -7A
LPH -7B
HPH - 1
LPH -8A
LPH -8B
Condensor (HP)
Condensor
(LP)
Deaerator
HPH - 2
EXT From CRH
(MD BFBP 1x35%)
TDBFP 2X50%
HPH -3
CEP
3x50%
1994 TPH
GSC
CPP
1482 TPH
LPH -5
LPH -6

8. PRE STARTUP READYNESS HT/LT POWER SUPPLY READINESS
WATER SYSTEM: FIRE WATER,SERVICE WATER,DMP,CW & ACW.
CCCW SYSTEM
COMPRESSOR SYSTEM
AUXILIARY STEAM. (S/B UNIT OR AUX BOILER).
START CEP AND MDBFP.
CHECK THE BCP SYSTEM IS READY.

9. WHY BCP ? TO ASSIST CIRCULATION IN BOILER WATER WALL
TO INCREASE THE CIRCULATION VELOCITY
TO AVOID DNB (Departure from Nucleate Boiling) IN LOW LOAD.
TO REDUCE THE OVER HEATING AND UNDUE STRESSES ON WATER WALL TUBES.
TO AVOID DRY OUT OF WATER WALL TUBES WHEN LOAD IS REDUCED.

10. BCP FILLING ,PURGING & FLUSHING
PURPOSE-
- TO FILL THE MOTOR CAVITY.
RECOMMENDED MOTOR FILLING WATER QUALITY
CONDUCTIVITY <1 µs/cm
BOILER FEED WATER
TEMP.<= 45 OC
CL- <= 50 PPM
pH >= 6.5
SUSPENDED SOLIDS <= 5 PPM
FILLING,PURGING & FLUSHING WATER REQUIREMENT
MOTOR INITIAL FILLING FLOW RATE : MAX. 5 L/MIN

11. PRE BOILER FLUSHING START CEP.
FILL & DRAIN FROM DEAERATOR UNTIL REQUIRED WATER QUALITY IS ACHIEVED. ( Fe<500 Ppb.)
START MDBFP.
START THE BOILER COLD/HOT FLUSHING TO REDUCE THE Fe & SiO2 CONTENT IN FEED WATER.

12. Boiler flushing SP SP BCP WW ECO MIXER START-UP LINE Below 500ppb
Sampling Fe+
Below
500ppb
Above
500ppb
MIXER
BCP WW
ECO
CW LINE
HOTWELL 12 12

13. BOILER COLD FLUSHING COLD FLUSHING
WATER WALL TEMP REQUIRED DEG.C (TEMP MAINTAINED BY DEAERATOR PEGGING STEAM)
COLD OPEN FLUSHING QUALIFIES Fe < 500PPB
SiO2 < 100PPB
THEN CPU WILL BE TAKEN IN SERVICE TO REDUCE WATER LOSS AND IMPROVE QUALITY.
COLD CYCLIC FLUSHING QUALIFIES Fe < 100PPB
SIO2 < 50PPB
(ALL ANALYSIS FROM SEPARATOR DRAIN)

14. BOILER HOT FLUSHING HOT FLUSHING
WATER WALL TEMP REQUIRED DEG.C (TAKE OIL GUNS OF BC ELEVATION)
HOT OPEN FLUSHING START UP CRITERIA FE > 100PPB
SIO2 > 50PPB
IF HOT CYCLIC FLUSHING CRITERIA IF FE < 100PPB
SIO2 < 50PPB
HOT CYCLIC FLUSHING QUALIFIES IF FE < 50PPB
SIO2 < 30PPB
AFTER COLD FLUSHING START BCP WITH MINIMUM 30% FEED FLOW & THROTTLE FRS VALVE.

15. BOILER LINE UP AND LIGHT UP
FUEL OIL SYSTEM: LDO/HFO PUMPS
ESP HEATERS & RAPPERS
AIR FLUE GAS SYSTEM: APH,IDF, FDF & SCANNER FAN.
MAINTAIN AIR FLOW : 30% - 40%.
FURNACE PURGE: 300 Sec.
LIGHT UP BOILER WITH OIL GUNS AT BC (LDO) ELEVETION.
CONTINUE HOT FLUSHING UNTIL REQD.WATER QUALITY IS ACHIEVED
THEN TAKE CD ELEVETION GUNS. IF REQUIRED TAKE 2 NO. GUNS IN AB ELEVETION.

16. BOILER LINE UP AND LIGHT UP
CONTINUOUS APH SOOT BLOWING TO BE DONE AT THE TIME OF OIL FIRING.
PR RISING RATE MPA/MIN. BETWEEN 0-1 MPA
PR RISING RATE 0.1 MPA/MIN. BETWEEN 1 – 2 MPA
PR RISING RATE 0.2 MPA/MIN. ABOVE 2 MPA
FURNACE EXIT GAS TEMP MUST BE BELOW 538°C FOR REHEATER PROTECTION (UNTIL HP-LPBP IS CHARGED).
CLOSE SH DRAINS AND VENTS AFTER ACHIEVING DEGREE OF SH 50 °C ( CLOSE IT AFTER CHARGING HP-LP BYPASS).

17. LDO/HFO GUN Fuel Light Oil Fuel Pressure 0.8MPa-2.0MPa Fuel Flow
500kg/h -3000kg/h
Atomizing Air Pressure
0.6MPa-1.2MPa
Atomizing Air Flow
kg/h
Ignition Method
HESI (20 joules/spark)
Fuel
Heavy Oil
Fuel Pressure
0.8MPa- 2.0MPa
Fuel Flow
kg/h
Atomizing Steam Pressure
0.8MPa-1.2MPa
Atomizing Steam Flow
kg/h
Ignition Method
HESI (20 joules/spark)

18. TURBINE LINE UP ENSURE: LUBE OIL SYSTEM: IN SERVICE (0.8 MPA)
JACKING OIL SYSTEM:IN SERVICE ( 14 MPA)
TURBINE BARRING GEAR: 3-4 RPM
SEAL OIL SYSTEM: AIR & H2 SIDE. CHARGED
STATOR AND H2 COOLING WATER SYSTEM:CHARGED TEMP CONTROL IN AUTO)
H2 FILLED IN GENERATOR AND MAINTAIN PR 0.35 MPA.
EH OIL SYSTEM: IN SERVICE (14 MPA)

19. TURBINE LINE UP ENSURE TDBFP IN BARRING.
GLAND STEAM CHARGING: ENSURE STEAM TEMP. IS 56°C °C MORE THAN ROTOR TEMP & DEGREE OF SH > 50°C.
CHARGE THE GLAND SEAL SYSTEM OF TDBFP.
START THE VACUUM PULLING WITH VACUUM PUMP.
MAINTAIN VACUUM -0.9 KG/CM2.
CHARGE THE HP-LP BYPASS SYSTEM .MAINTAIN THE MS STEAM PRESSURE AND FIRING RATE FOR ACHIEVING TURBINE ROLLING PARAMETERS.

20. COLD START UP CURVE

21. HOT ROLLING
MS TEMP
RH TEMP
SPEED
MS FLOW
LOAD
MS PRESS

22. PRE HEATING OF HP CASING.
PREHEATING OF HPT REQUIRED WHEN INNER METAL TEMP <150°C.
CRH PR MPA/ °C.
OPEN PRE HEATING VALVE (REVERSE FLOW VALVE) GRADUALLY.
OPEN BDV VALVE FULLY.
OPEN CRH DRAIN BEFORE NRV AND HPT-IPT CASING DRAINS.
HEATING RATE SHOULD NOT BE MORE THAN 50°C PER HR.
HP CASING TOP-BOTTOM & INNER-OUTER WALL METAL TEMP DIFFRENCE SHOULD BE WITHIN 50°C.
AFTER ATTAINING THE CASING TEMP > 150°C CLOSE THE RFV VALVE AND OPEN HP CYLINDER VENTILATION VALVE TO CONDENSOR.

23. TURBINE WARM UP OPERATIONMS
HPBP
IPT
HPT
Ventilator valve
CRH NRV
TO CONDENSER
BDV
RFV
TO CONDENSER
CRH LINE
TURBINE STARUP PROCEDURE

24. TURBINE ROLLING
AS PER REQUIREMENT OF START UP CURVE, FIRING TO BE INCREASED.
REQUIRED STEAM PARAMETERS BEFORE ROLLING
MS PR: 8.73 MPA, TEMP: °C
RH PR: 1.1 MPA , TEMP: 330°C
- THE DEGREE OF SUPER HEAT > 56°C.
AFTER LATCHING THE TURBINE, START IP ROLLING WITH HP VENT TO CONDENSER IN OPEN CONDITION TO KEEP THE HPT IN VACUUM.
MSV 1&2 AND RSV 1&2 ARE IN OPEN CONDITION.
GIVE THE SPEED SET POINT TO 600 RPM
CHECK THE TURBINE SUPERVISORY INSTRUMENT PARAMETER.
THE ECCENTRICITY SHOULD BE LESS THAN MM.

25. TURBINE ROLLING
SELECT TARGET SPEED 1500 RPM WITH RAMP RATE OF 100 RPM/MIN.
ENSURE ALL HP CV’S OPENS TO 12% TO WARM UP THE HP CASING.
WHEN HP CASING TEMP >320°C.CLOSE THE HP CV’S.
SOAK THE TURBINE FOR 4 HRS ACCORDING TO THE START UP CURVE.
CHARGE THE LP HEATER 5 & 6 BEFORE 3000 RPM
SELECT TARGET SPEED TO 3000 RPM WITH RAMP RATE OF 100 RPM/MIN.SOAK IT FOR 30 MIN AS PER S/U CURVE.
AS PER PROCEDURE SYNCHRONISE THE UNIT.

26. LOADING
AFTER SYNCHRONISATION INITIAL LOAD WILL BE 30 MW.HOLD IT FOR 30 MIN AND CHEK THE VIBRATION, BEARING TEMP, DIFF EXPANSION, CASING EXPANSION.
CHARGE EXTRACTION STEAM TO DEAERATOR.
TAKE MORE OIL GUNS IN EF/AB ELEVETION.
TAKE PA FANS & SEAL AIR FAN.
AFTER ACHIEVING FURNACE TEMP. MORE THEN 450°C. TAKE COAL MILL-B AT. STEAM T/PR 380°C/8.7 MPA.
INCREASE FUEL FLOW MAINTAINING STEAM TEMP.& RAISE LOAD
AT 70 MW IP TO HP CHANGE OVER. CV’S WILL START OPENING, CLOSE THE BDV AND VENTILATING VALVE.
INCREASE THE LOAD AT 3MW/MIN
CLOSE THE HP-LP BYPASS GRADULLY.

27. LOADING CURVE
WET TO DRY CHANGE OVER
IP TO HP CHANGE OVER (70MW)
OIL GUN CUT OUT (260MW)
MILL-C CUT IN AT 100MW
2ND TDBFP CUT IN(180MW)
HPH CHARGED(150 MW)
MILL-D CIT IN (300MW)
MILL-E CUT IN (430MW)
MILL-F CUT IN (540MW)
MILL-A CUT IN(210MW)
SYNCHRONISE &CHARGE D/A
MILL-B CUT IN
660
660 MW
495
330MW
LOAD (MW)
330
198MW
165
60MW
33MW
350
400
450
500
550
600
650
MINUTES

28. LP HEATER 7A LP HEATER 7B LP HEATER 8A LP HEATER 8B CONDENSER
LPT A
FROM IPT EXHAUST
LPT B
2nd
2nd
4th
4th
5th
5th
5th
5th
6th
6th
6th
6th
LP HEATER 7A
LP HEATER 7B
LP HEATER 8A
LP HEATER 8B
CONDENSER
CONDENSER
LP HEATER 5
HP HEATER 5
HP HEATER 6
LP HEATER 6

29. TDBFP START UP
TAKE ONE TDBFP IN SERVICE( CHANGE OVER WITH MD BFP) WHILE DRIVING STEAM IS AVAILABLE. SECOND TD BFP WILL BE TAKEN AT 180 MW.
WARM UP THE TURBINE.
SLOWLY OPEN THE AUX STEAM MOV TO TURBINE.
PARAMETERS FOR ROLLING TDBFP.
STEAM PRESSURE: 0.6～1.3MPA, STEAM TEMP: 50 DEG C MORE THAN CASING TEMP.
ROLL THE TDBFP AS PER PROCEDURE.
GIVE THE TARGET SPEED 500 RPM AND THAN TO 1000 HOLD FOR 40 MIN.CHECK THE TSI PARAMETER
WHEN SPEED REACHES 2840 RPM, GIVE REQUEST COMMAND FROM FW MENU. THEN SELECT CCS CONTROL IN FROM MEH MENU.

30. TDBFP STEAM SOURCES HP IP To CRH Aux. Steam Header Aux. Steam Header E
1.12 Mpa
378 ºC
1.3 MPa
350 ºC
To CRH M M
Aux. Steam Header
Aux. Steam Header M M E E M M
Changeover Valve M M E E
From
CRH M M
4 MPa
315.3 ºC
TDBFP-B
To Condenser
TDBFP-A
Booster
pumps
Deaerator
Deaerator
4/19/2017 30

31. LOADING
TAKE THE MILL-C IN SERVICE AT 100 MW. STEAM T/PR:400°C/8.7 MPA.
GRADUALLY WITH DRAW THE OIL SUPPORT AS PER THE FLAME CONDITION.
INCREASE THE LOAD TO 150 MW AND TAKE THE HPH-3, HPH-2 &
HPH-1 IN SERVICE. MS T/PR 410°C/8.7 MPA.
AT 180 MW TAKE SECOND TDBFP IN SERVICE.

32. DEAERATOR DEAERATOR HP TURBINE IP TURBINE MS LINE HRH LINE IP EXHAUST
CRH LINE
HP TURBINE
IP TURBINE
5th stage
9th stage
TDBFP A
TDBFP B
HP HEATER 1
HP HEATER 1
HP HEATER 3
HP HEATER 3
HP HEATER 2
HP HEATER 2
DEAERATOR
DEAERATOR

33. PHASE CHANGE FROM WET TO DRY MODE
DURING LOAD RAISING >25% BMCR, THE BCP FLOW AND FEED WATER FLOW TO BE MONITORED CLOSELY.
THE BCP FLOW NEED TO BE ADJUSTED W.R.T SEPERATOR TANK LEVEL AND THE SAME FLOW TO BE ADJUSTED IN FEED WATER FLOW TO MAINTAIN TOTAL FEED WATER FLOW TO ECONOMISER CONSTANT.
WHEN BOILER STEAMING RATE RISES TO >30% BMCR, W.R.T FUEL FIRING, THE SEPERATOR LEVEL REDUCES .
ONCE THE CONDITION FULFILLS THE BCP STOPS AND FEED FLOW CONTROL CHANGES OVER FRS.
AFTER STOPPING BCP IT ACTS AS SUB-CRITICAL ONCE THROUGH“.
WHEN THE STEAM PR REACHES 22.1 MPA IT IS IN “SUPERCRITICAL ZONE”

34. LOADING TAKE MILL-A AT 210 MW.
CUT THE OIL SUPPORT AT 260 MW AS PER THE FLAME CONDITION.
TAKE MILL-D AT 300 MW. MS T/PR 475°C/10 MPA.
TAKE MILL-E AT 430 MW. MS T/PR 566°C/17 MPA.
TAKE MILL-F AT 540 MW. MS T/PR 566°C/24.1 MPA.
INCREASE THE LOAD TO “FULL LOAD 660 MW” GRADUALLY.

35. Boiler Design Parameters
NO.
Parameters
Unit 1
100% BMCR Coal consumption (Design)
390.37
t/h 2
Design fuel
Indian coal 3
Superheated steam flow
2111 4
Superheater outlet pressure
25.4
MPa 5
Superheater outlet temperature
569 ℃ 6
Reheated steam flow
1749.1 7
Reheater inlet pressure
4.73 8
Reheater outlet pressure
4.49 9
Reheater inlet temperature
324 10
Reheater outlet temperature
Feedwater pressure
28.8
MPa.g 11
Feedwater temperature
280 12
Separator’s steam temperature
421 13
Air preheater’s outlet air temperature, uncorrected
After correcting
153.3
147.2 14
Calculating thermal efficiency of boiler
87.19%（BMCR）

36. Steam Admission Parameters at Turbine Inlet
TURBINE PARAMETERS
Steam Admission Parameters at Turbine Inlet
HPT IPT LPT
Pressure (MPa)
I/L Temp (Deg C)
O/L Temp(deg C)
Steam Flow (tph)
TURBINE HEAT RATE( KCL/KWH) 1885
No of Stop valves 2 2
No of Control valves 4 4

37. TURBINE AT FULL LOAD HPT IPT LPT #1 LPT LPT LPT LPT #2 #2 #2 GEN GEN
3.96MPa / 566°c
HRH
24.2MPa/566ºC
1.12MPa / 378°c CV
RSV
RSV
RSV
RSV
MS LINE
MSV
MSV
MSV CV
MSV CV CV CV CV
HPT CV CV
IPT CV
TO BLR RH
CRH
LPT #1
LPT
LPT
LPT
LPT #2 #2 #2
GEN
GEN
LPT
LPT
CRH CV CV
RCV
RSV CV
RCV CV CV CV
RCV CV
RCV CV
CONDENSOR A
CONDENSOR B
MSV
MSV
MSV CV
MSV
MSV
MSV
MSV
MSV
MSV CV CV CV CV CV CV CV CV CV CV CV
RSV
RSV
RSV
MS LINE
HRH

38. SHUT DOWN EXCEPT IN AN EMERGENCY, LOAD SHOULD BE REDUCED GRADUALLY.
CUT THE MILL-F AT 540 MW.
CUT THE MILL-E AT 470MW.
CUT THE MILL-D AT 300 MW.
TAKE OIL SUPPORT FOR FURNACE STABILITY ( AT THE TIME OF 3 MILL OPERATION).
CUT THE MILL-A AT 210 MW.
TAKE THE HPH-1,2,3 OUT OF SERVICE.
WHEN THE LOAD < 30% BOILER COMES IN WET MODE FROM DRY MODE. START THE BCP AND MAINTAIN THE SEPEARTOR LEVEL.

39. SHUT DOWN
WHEN THE LOAD HAS DECREASED TO 20% OF RATED LOAD TRIP THE TURBINE ON TURBINE PROTECTION. THIS CLOSES THE THROTTLE VALVES, GOVERNOR VALVES, REHEAT STOP VALVES AND INTERCEPTOR VALVES
CHECK DRAIN VALVES OPENS IN AUTO.
HP LP BYPASS VALVE OPENS TO MAINTAIN THE FLOW.
REDUCE THE BOILER LOAD GRADULLY.
TRIP THE BOILER.
THE VACUUM BREAKER VALVES SHOULD NOT BE OPENED UNTIL THE TURBINE UNIT HAS COASTED DOWN.
VACUUM SHOULD BE KILLED BEFORE GLAND SEALING STEAM IS SHUT OFF.
AUX OIL PUMP STARTS IN AUTO AT 2850 RPM.
JOP START IN AUTO AT 1200 RPM.

40. SHUT DOWN
WHEN THE VACUUM REACHES ZERO, SHUT OFF THE SEALING STEAM TO THE GLAND STEAM CONTROL VALVES.
SHUT DOWN THE GLAND STEAM CONDENSER EXHAUSTER. SHUT DOWN CONDENSATE PUMP.
SHUT DOWN THE VACUUM PUMP.
SHUT OFF THE COOLING WATER SUPPLY TO THE GENERATOR HYDROGEN COOLERS.
ENSURE THAT BARRING GEAR HAS CUT IN.

41. SHUT DOWN CURVE

42. COOL DOWN CURVE

43. THANK YOU