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SH1-DHI-P0100-GE-M01-PRO-5304 - Plant Startup Shutdown Procedure - Rev.6
SH1-DHI-P0100-GE-M01-PRO-5304 - Plant Startup Shutdown Procedure - Rev.6
PROJECT TITLE
VIETNAM OIL AND GAS GROUP (PVN) FICHTNER GmbH & Co. KG PV ENGINEERING
CONTENTS
1. INTRODUCTION................................................................................................................ 5
2. SCOPE .................................................................................................................................. 5
3. PLANT START-UP AND SHUTDOWN DURATION .................................................... 5
4. START-UP PREPARATION ............................................................................................. 5
4.1. START-UP POWER AVAILABILITY ............................................................................. 5
4.2. BALANCE OF PLANT SYSTEMS START-UP .............................................................. 6
4.2.1. INITIAL FILL ..................................................................................................................... 7
4.2.2. LOW PRESSURE SYSTEM START-UP.......................................................................... 8
4.2.3. HIGH PRESSURE SYSTEM START-UP ........................................................................ 8
4.2.4. AUXILIARY STEAM SYSTEM LINE UP ....................................................................... 9
4.2.5. GLAND SEALING AND VACUUM PULLING ............................................................ 10
4.3. CONTINUOUS EMISSION MONITORING SYSTEM ................................................ 10
5. BOILER START-UP ......................................................................................................... 10
5.1. DRAUGHT PLANT START AND BOILER PRE-LIGHT OFF SEQUENCE ........... 11
5.2. ESP SYSTEM START UP ................................................................................................ 12
5.3. LIGHT-OFF BOILER....................................................................................................... 13
5.4. FGD SYSTEM START UP ............................................................................................... 14
5.5. MAIN STEAM SYSTEM CHARGING .......................................................................... 14
5.6. RH STEAM SYSTEM CHARGING................................................................................ 15
6. TURBINE START-UP ...................................................................................................... 15
6.1. ROTOR PREWARMING ................................................................................................. 16
6.2. CHEST WARMING .......................................................................................................... 16
6.3. FINAL PREPARATION FOR ROLLOFF ..................................................................... 17
6.4. TEMPERATURE MATCHING ....................................................................................... 18
6.5. ST ROLLING ..................................................................................................................... 19
6.6. SYNCHRONIZATION ..................................................................................................... 20
6.7. DA PEGGING STEAM SOURCE CHANGEOVER ..................................................... 21
6.8. LOADING UP AFTER INITIAL LOAD ........................................................................ 21
6.9. EXTRACTION STEAM SYSTEM START-UP ............................................................. 21
6.9.1. EXTRACTION STEAM SYSTEM FOR LP HEATERS .............................................. 21
6.9.2. EXTRACTION STEAM SYSTEM FOR HP HEATERS .............................................. 22
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ABBREVIATIONS
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SA Secondary Air
SAH Steam Air Heater
SB Standby
SCAH Steam Coil Air Heater
SCR Selective Catalytic Reduction
SDCC Submerged Drag Chain Conveyor
SSDV Steam Seal Dump Valve
STG Steam Turbine Generator
SVBV Main Stop Valve Bypass Valve
SW Sea Water
T-BFP Turbine driven-Boiler Feedwater Pump
TBN Turbine
TCS Turbine Control System
TMCR Turbine Maximum Continuous Rating
TRCP Transformer Control Panel
UMC Unit Master Control
VV Ventilator Valve
VWO Valve Wide Open
W Working
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1. Introduction
This document contains guidelines for plant startup and shutdown procedure for Song Hau 1 Thermal
Power Plant. Plant Start-up & Shutdown Sequence Diagram can also be referred, along with this
document, for graphical sequence of plant start-up programmed in DCS.
2. Scope
Scope of this document is to describe the start-up and shutdown procedure for the complete power
plant system. The start up scenario in this document is based on normal start up condition (i.e. one
unit start up while neighboring unit already in operation). However also initial start up (i.e. first unit
start up from both unit shut down status) is also applicable, where the only difference is ‘auxiliary
steam supply from Auxiliary boiler’ for initial start up which is mentioned in clause 4.2.4 in this
document..
Mode of Duration HP turbine 1st stage Mode of start-up time Start-up time
start-up of shell metal From Boiler Ignition to from Push Button
shutdown temperature (deg.C) Full Load (min) Activation to Full
(hr) Load(min)
Cold >48 hr 550 920
T < 265
start-up
Warm <48 hr but 380 530
265 < T < 442
start-up >8 hr
Hot start- <8 hr 200 315
T > 442
up
Note: The start-up mode will be automatically selected by DCS based on turbine metal temperature
indicated in above table.
4. Start-up Preparation
4.1. Start-up power availability
Auxiliary power required for plant start-up is taken from the grid. Unit auxiliary transformers are
charged from the grid power (500 kV). Unit switch gear bus-A & B (11 kV) are charged from UAT to
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supply power to the various plant auxiliaries. (See document ‘ELECTRICAL SYSTEM DESIGN
CRITERIA’ SH1-DHI-P0ZEN-E-M01-CRT-5601)
BOP system electricity during start-up is supplied from external grid. Operator must obtain permission
from EVN informing them of the time of start-up, synchronization, load-up to scheduled load.
4.2. Balance of Plant Systems Start-up
Before initiating plant start-up, following utility systems are considered to be commissioned and in
service.
(For detailed group level start of each system, see system description which reference is listed in 8.1
of this document.)
• CW system
CW water system will be started manually by operator from DCS. Circulating water pumps will be
started. The circulating water supply to condenser will be established manually by operator.
• ACW system
When circulating water system is started and water is available up to ACW pump (P1PCB09AP001,
P1PCB10AP001) suction, operator starts any one of 2 X 100% (1W+1SB) ACW pump
(P1PCB09AP001, P1PCB10AP001) from DCS to supply cooling water to the CCW heat exchanger
(P1PGB05AC001, P1PGB06AC001, P1PGB07AC001), vacuum pump seal water coolers
(P1PCB31AC001, P1PCB32AC001, P1PCB33AC001) and SDCC cooling system as per requirements.
• CCW system
CCW water system will be started manually by operator from DCS. 2х100% CCW pump
(P1PGB02AP001, P1PGB03AP001) along with three CCW heat exchangers (P1PGB05AC001,
P1PGB06AC001, P1PGB07AC001) will be kept in operation. Cooling water supply to various coolers
will be charged manually by operator. The level in the overhead tank (P1PGB80BB001) will be
maintained by tank inlet LV (P1GHC77AA081).
• Compressed Air system
As soon as cooling water for air compressor is available from CCW system, operator will give
compressed air system group start command from DCS. Start-up includes start-up of 3 х 50 % air
compressors (2W+1SB) (P0SCA01AN001, P0SCA02AN001, P0SCA03AN001), 2 х 100 % air dryer
plant (1W+1SB) (P0SCA30AT001, P0SCA30AT002), air receivers and charging of instrument air
and service air.
• DM water system
DM water system will be group started manually by operator. DM water storage tank will be filled by
DM water supply pump. DM water storage tank level is maintained by opening/closing MOV at tank
inlet. 2х 100% (1W+1SB) (P0GHC11AA001, P0GHC11AA002) DM water supply pump will be
running to supply water for condensate storage tank (P0GHC50BB001, P0GHC50BB002).
• Condensate Storage and Transfer System
Once DM water system is running, operator will initiate filling of condensate storage tank. Operator
will start one of 2 X 100% (1W+1SB) condensate transfer pump (P0GHC61AP001, P0GHC62AP001)
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from DCS to fulfill initial fill up requirement of various systems as well as hotwell make up water
requirement. The various sytems are as below
- Condensate System
- Condensate System(For Stator Cooling System)
- Boiler
- Deaerator
• Service Water & Fire fighting system
Service & Fire Fighting Water Storage Tank (P0GHD02BB001, P0GHD03BB001) will be filled by
tap water. Start-up of service water system includes charging of service water storage
tank(P0GHD02BB001, P0GHD03BB001), start-up of one of 2 X 100% (1W+1SB) service water.
Charging of service water distribution lines will be done by operator.
Once service water storage tank in filled, entire fire fighting water system is charged and kept in auto
to avoid any potential hazard in the plant.
• Diesel oil forwarding system
Diesel oil system start-up will be done manually by operator from DCS. Any one of 3 х 50 %
(2W+1SB) diesel oil forwarding pump will be started to fulfill the diesel oil requirement during start-
up. Diesel oil storage tank level will be made up by running the diesel oil from diesel oil unloading
pump (in the ship).
• Water treatment system
Water treatment system will be group started by operator.
• Chemical dosing system
Chemical dosing system shall be group started by operator.
• Sampling system
Sampling system shall be group started by operator.
• ESP system
Preheating (Insulation / Hopper) for ESP system shall be completed.
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ammonia shall be injected which injection piping (P1QCA01BR001) is connected to feedwater filling
piping (P1GHC78BR001).
System low point drain valves and vent valves are operated during initial filling. Once filling is
completed, vent and drain valves are closed.
Once initial filling is done, low pressure system is started-up which contains start-up of condensate
system.
Until Deaerator level is decreased due to feedwater supply to boiler after firing, condensate is
recirculated via minimum recirculation line to condenser.
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High pressure system start-up includes start-up of feedwater system and charging the circuit up to
economiser inlet FCV. Once the following start-up permissives are fulfilled, operator will initiate
feedwater system group start sequence from DCS.
Feedwater group start-up permissive:
Start-up M-BFP (P1LAC10AP001) ready to start
FW system drives/ CV in auto
Recirculation FCV (P1CA41AA081) set to Auto.
Feedwater system group start includes start-up of start-up M-BFP (P1LAC10AP001) and HP heater 6,
7 and 8.
During start-up M-BFP (P1LAC10AP001) will be operated to fulfill the feedwater requirement of
boiler. Feed control valve (P1LAB60AA081) at economizer inlet will control the feedwater flow to
the economizer during start-up up to 30% load.
During start-up except above case, the auxiliary steam will be initially provided from another unit at
15 bar(g) and 300°C. As the CRH steam pressure increases beyond the requirement of unit auxiliary
steam header pressure, Aux steam will provide from CRH by opening MOV (P1LBC32AA001).
Normally as plant load increases, auxiliary steam consumption is reduced. And if auxiliary steam
consumption is less than 6 tons per hour, CRH Secondary PRDS will operate in place of CRH Primary
PRDS.
Auxiliary steam consumption during start-up includes the following consumers:
Feed water storage tank initial heating
Deaerator pegging
Steam coil air heater
Turbine pre-warming and gland sealing
BFP Turbines
FGD damper sealing
Soot blower for GAH
BFPT will be started by cold reheat steam. So quality of steam source is already secured because
generation of cold reheat steam means steam admission to turbine. and at 25% load, steam source will
be changed to IP turbine extraction steam. generation of IP turbine extraction steam also means steam
quality is secured. And main steam is used for the steam source of BFPT for transient condition like
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load rejection, this codition also means steam quality is secured because steam had admitted into
turbine.
5. Boiler Start-up
Boiler start-up is envisaged in following three modes based on separator metal temperature, and it will
follow criteria of turbine start up mode selection (turbine metal temperature).
1. Cold Start
2. Warm Start
3. Hot Start
For initial start up or start up after overhaul, boiler internal piping and B.O.P piping initial filling is
required. For initial filling, filling line connected at feedwater system which is from condensate
transfer system is utilized. However, in case start up after normal shut down, water level in boiler
separator could be drained / lowered by gravity, and only small portion of filling is required. In this
case, M-BFP and boiler recirculation pump is used to estabilish required level in boiler separator.
After feedwater system start-up, boiler filling is started. A level is established within the storage
vessel in preparation for start-up of the boiler recirculation pump. Drains and vents should be opened
or closed to the light off position.
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After Furnace Purge, The MFT Relays are reset. And then Diesel oil Leak Test is completed. The
Master Diesel oil Safety Shutoff Valves are opened and The Diesel oil control valve is put to auto.
Initiate light-up of diesel oil burners and Atomising air & diesel oil control loops on auto.
16) Release the atomizing air control valves and atomizing air control valves to AUTO control
setpoint.
17) Insert the furnace temperature thermo-probes.
18) Initiate GAH sootblowing; Aux. steam must be available.
19) Open the diesel oil header main trip valves when the following are completed.
• Furnace purge is completed.
• The MFT relay has been reset.
• Oil Leak Tests are completed
20) Boiler now ready for light off
If light off has not been achieved within 30 minutes of MFT Reset then a new Furnace Purge
will be required.
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1) DCS will send start up signal to ESP System and Transformer will be energized as per its group
sequence. Initially, ESP is set to Primary Charge Mode, and once fuel change (from oil to coal)
is initialted, it is set to Normal Charge Mode.
2) After start up of ESP, start up permissive signal will be sent to Ash Handling System.
5.3. Light-off Boiler
1) Operator will monitor firing permissive if all available, gives the Light Off command to start.
2) All dampers should be the light off position (as at end of purge).
3) Put Hot secondary air pressure control into auto.
4) Put superheater and reheater temperature controls on auto.
5) Oil firing is established for initial pressure raising and to provide support for coal introduced on
the first and all subsequent mills. Progressively add additional oil burners to achieve desired
pressure raising rate.
6) Start the 1st (Mill C), 2nd (Mill E), 3rd (Mill B), 4th (Mill A) Mill Group oil burners as required,
refer to table below. The respective burners should be operated at full rating prior to coal ignition
on that burner row as per NFPA 85 requirements to stable flame. Firing rate is adjusted to
achieve the pressure/temperature raising rate required per the start up curves.
Control rate of firing to satisfy the following conditions. If necessary, reduce the number of
burners in service.
Burner identification notation
Burner Front Wall, Top Burner Row
Row D
Burner Front Wall, Middle Burner Burner Rear Wall, Middle Burner
Row B Row Row A Row
Burner Front Wall, Bottom Burner Burner Rear Wall, Bottom Burner
Row C Row Row E Row
Note:
• Gas temperature at primary superheater inlet must not exceed 540 ºC until an adequate
flow of steam is established through the reheater.
• The steam pressure should be increased slowly during the initial start of a new steam
generator. This allows sufficient time for checking expansion movements and permits the
operators to become familiar with the characteristics of the steam generator and auxiliary
equipment.
• During start-up a minimum feedwater flow through the circuit is maintained by running
boiler recirculation pump (BRP (P1HAG31AP001)) to prevent water wall tube overheating.
7) As sepator pressure increases, progressively close the superheater steam line drains in use
according to predetermined sequence.
8) After light off of oil minimum air flow of 35%TMCR is maintained. (Note MFT occurs if purge
flow falls below 25%TMCR air flow).
9) PF can only be fed to a burner row once the associated oil burners are firing.
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Note : The number and position of burners will be determined by the type of start-up and
commissioning experience, but typically would be as follows:
10) Start seal air fan, followed by first PA fan (note, seal air fan suction is from PA fan discharge) ,
then start second PA fan as required for mill warming. Mill outlet temperature may be put into
auto during mill warming.
5.4. FGD System Start Up
After 30 min. of Boiler Light-off, DCS will set FGD system to AUTO.
Initial position of FGD damper is bypass mode (i.e. FGD inlet / outlet damper closed, FGD bypass
damper open).
As soon coal firing is initiated, FGD damper will be changed to FGD mode (i.e. FGD inlet / outlet
damper open, FGD bypass damper closed).
5.5. Main Steam System Charging
HP bypass valves(P1LBH10/20AA081, capacity is 60 % of HP steam at BMCR condition) are
provided to control the main steam pressure. During start-up once boiler is fired and all permissives
for HP bypass system are satisfied HP bypass system will be put into service under auto control. HP
bypass valve opens to the minimum opening condition Ymin (10%).
Spray water for HP bypass valve is supplied from BFP discharge line. Once bypass valve opens more
than 2%, spray water line shut off valves (P1LAE53AA051/52) open and the HP bypass temperature
control valves (P1LAE53AA081/82) operate in auto mode. TCVs will be modulated based on the
feedback signal from HP bypass valve downstream temperature measurement (P1LBH11CT001/002
& P1LBH21CT001/002).
When main steam pressure increases beyond Pmin (99.6 barg) HP bypass controller mode changes to
minimum pressure control mode. HP bypass valve will open to maintain the main steam pressure
constant. The bypass valve opening set point is set to Ymax (25%). Main steam temperature keeps on
increasing at a predefined gradient. As soon as bypass valves opening reaches to Ymax (25%), HP
bypass controller mode changes to pressure rise mode.
In pressure rise mode, set point for HP bypass valve is set to synchronization pressure Psync (49 barg).
As boiler firing and steam production increases, main steam pressure increases at a predefined
gradient depending up on the cold, warm or hot mode of start-up. HP bypass valves will be modulated
to control the pressure gradient till main steam pressure reaches to synchronizing pressure. Once the
main steam pressure reaches to synchronizing pressure, HP bypass controller mode changes to fixed
pressure control mode.
During fixed pressure control mode, HP bypass is operated so as to maintain the main steam pressure
constant at synchronizing pressure.
During warm or hot start-up, the minimum opening mode and the minimum pressure control mode is
skipped since initial main steam pressure is high enough to operate in pressure rise mode.
When steam generation meets with load on the curve, bypass valve starts to close. And after this point
it will be converted into monitoring mode by DCS.
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6. Turbine Start-up
Turbine start-up is envisaged in following three modes based on thermal condition of turbine rotor.
1. Cold Start
2. Warm Start
3. Hot Start
HP turbine 1st stage shell metal temperature is communicated from turbine control system to DCS
based on which operator may select the mode of start-up.
Turbine start-up is performed by automatic turbine start-up (ATS) sequence which is a part of turbine
control system.
The Automatic Turbine Start-up (ATS) function of the control system provides acceleration, load rates,
and hold times directly to the primary controls or guide messages for the operator.
The ATS function will furnish guidance messages to the operator in which set points should be
selected for proper operation. The operator will follow these guidelines in respect to pre-start
temperature and stress conditions, recommended acceleration rates and whether to implement speed
holds.
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Normal starting and operation would be in control system’s automatic mode of operation, because it
provides for the most time-efficient operation. The control system’s manual mode will be used if the
operator wants to have more influence over set point selection using guide messages on the control
system CRT.
Following turbine auxiliary systems need to be in operation before turbine startup:
• Turbine lube oil system
• Turning gear system (min. four hours before turbine rolling)
• Steam seal system
• Hydraulic fluid system
• Seal oil system
• Hydrogen gas system
All the turbine drain valves will be opened at the time of turbine start-up.
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1) Control Valve Chest Pressurization — Open the SVBV by selecting MSV position set point and
slowly pressurize the CV chest in compliance with messages given. Hold chest warming if
requested. A request for slow pressurization indicates the need for a low set point as follow;
a. TSAT – CVO > CVALLOW
TSAT: Saturation Temperature of Main Steam
CVO : CV Outer Temperature
CVALLOW : CV Allowable temperature.
b. Main Steam Temp - CV Outer Temp < Allowable Temperature diff. * 1.2
c. CV Inner Temp. – CV Outer Temp < Allowable Temperature diff. * 0.4
2) Control Valve Chest Heat Soaking — Heat soaking begins after the chest pressure has reached
85% of main steam pressure. The differences between chest wall temperatures (inner–outer) and
between main steam and chest wall outer temperatures (main steam– CV outer) must be less than
the heat soak targets (allow) for the CV chest to be ready for rolloff.
Once chest warming is completed, turbine control system will issue the message “Chest warming
completed” to DCS.
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In Reverse Flow, turbine control system is designed to affect the temperature in the highpressure
turbine, including the first stage, by operation of the Reverse Flow Valve (RFV(P1LBC10AA081))
and Ventilator Valve (P1MAL10AA051) to admit steam to the HP turbine exhaust. Therefore, the 6
primary consideration before rolling the turbine should be to match reheat steam temperature to the
reheat bowl inner surface metal temperature by adjusting the steam generator accordingly.
Steam admission temperature matching condition for each start up mode is as follows :
HP Turbine Admission IP Turbine Admission
Mode of start-
Temperature Pressure Temperature Pressure
up
(Deg.C) (Barg) (Deg.C) (Barg)
Cold start-up 400 49 390 11
6.5. ST rolling
The turbine will be rolled by the ATS sequence at suitable speed and acceleration rate based on the
thermal stress of HIP rotor. Generally, recommended turbine acceleration rate during various modes
of start-up is given in table below:
In automatic mode, turbine will be started in reverse flow mode. In reverse flow, speed/load control is
conducted with the intercept valves, with transfer to forward flow at low loads. During this phase, CV
will remain closed and steam to the turbine will flow only through the IP and LP turbines. LP bypass
valve starts closing as IV(P1MAB10/11AA053)s are opening.
VV(P1MAL10AA051) will be opened at roll-off and will keep the HP turbine at near vacuum during
6
most of the acceleration. When the speed reaches approximately 2200 RPM, the
RFV(P1LBC10AA081) will be opened in a programmed manner to provide suitable reverse flow,
from the RFV(P1LBC10AA081) and out through the VV(P1MAL10AA051) to prevent overheating
of the HP turbine.
Turbine is accelerated to high speed hold (2500 RPM). It is recommended that the holding period at
high speed be maintained for heat soaking and lube oil heating. Holding period for various modes of
start-up is as given in the table below:
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(* Even though above holding time is met, holding will not be released unless turbine stress value is within 6
acceptable range.)
Once holding period is completed, turbine accelerates to full speed. Field excitation will be applied to
the generator excitation system when close to rated speed.
During acceleration speed holds will be implemented by the ATS, if:
1) Lookahead stresses are calculated to be greater than allowable limits.
(Lookahead stresses are stresses predicted for the next higher speed target considering current and
allowable stresses and current mismatch between steam and metal temperatures.)
2) At 2500 rpm, the rotor bores are found to be not heated sufficiently, the generator field is prewarmed
insufficiently, or the bearing oil cooler outlet temperature is less than 38° C.
3) A high vibration alarm is present.
4) A manual hold has been selected by the operator.
5) Oil trip test malfunction occurred before reaching rated speed.
Once turbine full speed is reached, the following checks will be performed by the turbine control system:
1. Bearing Header Pressure –1.03 barg minimum
2. Operating Bearing Header Pressure – 1.72±0.20 barg
3. Inlet Lube Oil Temperature - 43–49° C
6) High speed heat soak
Cold Start Mode: High speed heat soaking during 20 min.
Warm/Hot Start Mode: High speed heat soaking during 10 min.
6.6. Synchronization
Generator synchronization will be done from turbine control system in automatic mode. Automatic
synchronizing consists of automatically speed matching, voltage matching, phase matching and
commanding the generator breaker to close within the predefined band of positive slips.
Since the facility of synchronization is provided for both Generator Circuit Breaker (GCB) and High
Voltage Circuit Breaker (HVCB) proper selection of the synchronizing breaker will be necessary
through selector switch external to turbine control system. However during normal hot, warm or cold
start-up condition always GCB will be closed since HVCB is already in closed condition. turbine
control system will receive inputs and issue a synchronizing command to a respective breaker as per
the selection made externally at synchronizing panel. After synchronization, block load (5%) will be
obtained. Thereafter, operator shall select a target load and a loading rate limit. Then loading will
continue at a calculated loading rate which will be equal to or less than the selected limit. A loading
rate is calculated based on actual rotor stress and change of stress and steam temperatures.
Synchronization Permissive Condition :
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Operator permissive (This permissive shall be manually given by the operator after ensuring that LP
heaters 2(P1LCC20AC001), 3(P1LCC30AC001) and 4(P1LCC40AC001) are in line (condensate
charged).
Group start sequence for LP heater includes sequential start-up of steam extraction to LP heater
2(P1LCC20AC001), 3(P1LCC30AC001) & 4(P1LCC40AC001). The start-up vent MOV for each LP
heater will be closed once turbine is synchronized and respective heater level is not low. The LP
heater extraction steam group sequence is considered to be complete when LP heater 4 pneumatically
actuated NRV (P1LBS40AA051) and motor operated isolation valve is fully opened.
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Beyond 40 % RO and up to 100 % RO load CC (Coordinate Control) mode is activated. Boiler follow
mode shall only be activated if the following permissives are fulfilled:
At least one mill master is released to auto
One CID fan is released to auto
One FD fan released to auto
During turbine follow mode, boiler fuel firing control remains under “pressure control”. Turbine
governor valve shall be increased open rate by increasing flow. The governor valves shall remain in
the same position (wide open) unless there is frequency correction is required. From 40 % RO to
100 % RO load range the load demand will be given to both Boiler fuel firing control loop as well
turbine governor demand control loop.
Turbine governor demand from UMC will be under “load control” mode. The governor valve will be
modulated for any change in load.
Constant Pressure Mode will be operated from 0 % TMCR to 40 % TMCR load range and Sliding
Pressure Mode will be operated from 40 % TMCR to 100 % TMCR load.
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eco inlet MOV (P1LAB21AA001), T-BFP (P1LAC20/30AP001) on speed control mode is enabled
and eco inlet FCV (P1LAB60AA081) is closed.
At 40% RO load, secondary T-BFP (P1LAC20/30AP001) will be started to meet the overall
feedwater requirement.
Note) Benson load is 35% TMCR to ensure the furnace tubes are adequately cooled whilst operating
at start up and at loads up.
6.12. T-BFP (P1LAC20/30AP001) steam and Pegging steam changeover from CRH to IP extraction
As soon as turbine load reaches to 25%, isolation MOV (P1LBQ70AA001) and NRV
(P1LBQ50AA051) in the line from IP extraction to T-BFP open. Now steam to operate T-BFP will be
supplied from IP extraction.
Isolation MOV (P1LBQ60AA001) and NRV (P1LBQ60AA051) in the IP extraction line to deaerator
(P1LAA10AC001) open and pegging steam line MOV (P1LBC33AA001) from CRH to deaerator
(P1LAA10AC001) closes. Now pegging steam to deaerator (P1LAA10AC001) will be supplied from
IP extraction.
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SONG HAU 1 THERMAL POWER PLANT PROJECT
Start-up is envisaged with Diesel oil as a firing fuel. Coal mills will be started depending up on the
furnace temperature and load requirement. As coal mills start, oil firing is decreased gradually.
During startup oil firing can be stopped once boiler load is above 40%. But to light up the coal burner
in order to increase the load, adjacent oil burner should be in operation. Therefore the last oil burner
can be taken out only after 4th coal mill is cut in. The oil support is completely cut off beyond 70-
75% load.
1) Start Ash Handling system (Ash Handling System should be in service prior to Mill operation).
2) All the light-up oil burners associated with the coal mill end(s) to be put into service must be in
operation during the coal mill start-up sequence before mill PA and classifier outlet valves are
opened for mill warming.
3) The first mill will be required to be brought into service after synchronizing Turbine Generator
Note: For warm and hot starts the sequence of introducing mills will be brought into service
prior to steam turbine rolling.
4) Start up of the 1st mill at minimum turndown can then proceed as required by boiler loading.
5) Put 1st mill outlet temperature control to auto.
Note: a warming sequence will be required per manufacturer’s instructions.
6) SA to BNRs of 1st mill will already be in auto.
7) Put PA to 1st mill on auto.
8) Put feeder to 1st mill on auto.
9) Put Mill Master on auto.
10) Start SCAH system (P1HLC51AH001, P1HLC52AH001) when 1st coal feeder is operated.
Start steam air heater after PF burner is lit and set to control the gas air heater inlet air
temperature to 68 ºC
11) Start up of the 2nd Mill can proceed at any time after the 2nd Mill Group oil burners are firing
and as required by boiler loading. Proceed to Mill Master for the 2nd mill.
12) Select O2 trim to auto. O2 trim will be allowed to operate above boiler load 40%.
13) The unit may be placed on Boiler Master Control when operating conditions dictate. It is
recommended that a minimum of two mills are in service and mill load is shared equally.
14) Increase boiler load and start up of the 3rd, 4th (and 5th as required with worst coal) can then
proceed in a similar way at any time as required by boiler loading having first started as
associated oil burners.
15) Before these subsequent mills are put onto Boiler Master Control it is recommended that the load
on each mill is raised on Mill Master to equalize the load with the existing mills to ensure a
bumpless transfer.
16) Reduce number of oil burners in service commensurate with mill start requirements and boiler
heat input requirements.(set during commissioning)
17) Throughout any start the operator should monitor:
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SONG HAU 1 THERMAL POWER PLANT PROJECT
Combustion, pressure raising rate, lower furnace spiral wall tube temperatures, furnace outlet
metal temperatures, furnace outlet steam temperatures, storage vessel temperature differentials,
thermoprobe temperatures, dead space metal temperatures of the superheater and reheater
18) As the load increases, the superheat and reheater temperature approaches its target of 569C.
Check that the attemperators limit the final steam temperature to 569C.
19) Increase load steadily to 100% TMCR or at a load specified by the Grid Controller.
7. Plant Shutdown
The normal plant shutdown is considered from the unit operating at full load. At this point plant is
operating at 100% RO condition. Four coal mills are in operation. Boiler feedwater requirement is
being fulfilled by two T-BFP (P1LAC20/30AP001). CEP (P1LCB21/22/23AP001) are in operation.
Both HP and LP bypass systems are available and valves are in closed condition.
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SONG HAU 1 THERMAL POWER PLANT PROJECT
At 40% load CEP (P1LCB21/22/23AP001) can be stopped automatically. First any one CEP
(P1LCB21/22/23AP001) will be stopped. After that only one CEP (P1LCB21/22/23AP001) will be
running to supply condensate flow to the deaerator (P1LAA10AC001).
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SONG HAU 1 THERMAL POWER PLANT PROJECT
Turbine is envisaged to be shutdown with vacuum maintained which requires continuous seal steam
supply till turbine reaches to zero speed. When condenser vacuum reaches to atmospheric pressure
gland sealing is stopped.
Once seal steam system is stopped, vacuum pump will be stopped. M-BFP (P1LAC10AP001) and
running CEP (P1LCB21/22/23AP001) will be stopped by the operator.
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SONG HAU 1 THERMAL POWER PLANT PROJECT
8. Reference Documents
- PID’s
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SONG HAU 1 THERMAL POWER PLANT PROJECT
46 SH1-DHI-P0QFB-M-M01-PID-5202
Instrument Air System
47 SH1-DHI-P0QFB-M-M01-PID-5203
48 SH1-DHI-P0QH-M-M01-PID-5201 Aux Boiler
49 SH1-DHI-P0QJA-M-M01-PID-5333 N2 Gas System
50 SH1-DHI-P0SCA-M-M01-PID-5201 Compressed Air System
51 SH1-DHI-P1LAB-M-M01-PID-3187
52 SH1-DHI-P1LAB-M-M01-PID-3188
53 SH1-DHI-P1LAB-M-M01-PID-3189
54 SH1-DHI-P1LAB-M-M01-PID-3190
55 SH1-DHI-P1LAB-M-M01-PID-3191 BFP
56 SH1-DHI-P1LAB-M-M01-PID-3192
57 SH1-DHI-P1LAB-M-M01-PID-5201
58 SH1-DHI-P1LAB-M-M01-PID-5202
59 SH1-DHI-P1LAB-M-M01-PID-5203
60 SH1-DHI-P1LCH-M-M01-PID-5321
FeedWater Heater Drain System
61 SH1-DHI-P1LCJ-M-M01-PID-5322
62 SH1-DHI-P1PAB-M-M01-PID-5324 Circulating Water System
63 SH1-DHI-P1PCB-M-M01-PID-5325 Aux. Cooling Water System
64 SH1-DHI-P1PGB-M-M01-PID-5327
65 SH1-DHI-P1PGB-M-M01-PID-5328
Closed Cooling Water System
66 SH1-DHI-P1PGB-M-M01-PID-5329
67 SH1-DHI-P1PGB-M-M01-PID-5330
- System Description / Operation Philophy of System:
Sr. No. Document No. Description
No. Document No. Description
1 SH1-DHI-P1LBA-M-M01-PHL-5307 Main & Reheat Steam System
3 SH1-DHI-P1LBG-M-M01-PHL-5308 Auxiliary Steam System
4 SH1-DHI-P1LCA-M-M01-PHL-5305 Condensate System
5 SH1-DHI-P1LAB-M-M01-PHL-5306 Feedwater System
FeedWater Heater Extraction Steam
6 SH1-DHI-P1LBD-M-M01-PHL-5309
System
FeedWater Heater Drain & Vent
7 SH1-DHI-P1LBD-M-M01-PHL-5310
System
8 SH1-DHI-P0EGA-M-M01-PHL-5201 Diesel oil System
9 SH1-DHI-P0GA-M-M01-PHL-5201 Raw Water System
Demineralized Water Storage &
10 SH1-DHI-P0GHC-M-M01-PHL-5313
Transfer System
11 SH1-DHI-P0GHC-M-M01-PHL-5314 Condensate Storage & Transfer System
12 SH1-DHI-P0GHD-M-M01-PHL-5201 Raw Water Supply System
13 SH1-DHI-P0GKB-M-M01-PHL-5201 Potable Water System
14 SH1-DHI-P0LD-M-M01-PHL-5401 Condensate Polishing Plant
15 SH1-DHI-P0MAV-M-M01-PHL-5201 Clena and Dirty Lube Oil System
16 SH1-DHI-P0QH-M-M01-PHL-5201 Aux Boielr
17 SH1-DHI-P0SCA-M-M01-PHL-5201 Compressed Air System
18 SH1-DHI-P1MAA-M-M01-PHL-3137 Steam Turbine and Auxiliaries
Gen Stator Winding Liquid Cooling
19 SH1-DHI-P1MKF-M-M01-PHL-3172
System
20 SH1-DHI-P1MKG-M-M01-PHL-3173 Generator Gas Control System
SH1-DHI-P1MKW-M-M01-PHL-
21 Generator Hydrogen Seal Oil System
3171
22 SH1-DHI-P1PCB-M-M01-PHL-5311 Aux. Cooling Water System
23 SH1-DHI-P1PGB-M-M01-PHL-5312 Closed Cooling Water System
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PLANT COLD START-UP CURVE
Temp. Steam
Press. (deg.C) /Oil/Coal
(bara) Speed Flow(%)
(Shut Down Hour : > 48HR, Assumed HP turbine Metal Temp : Prewarming Target Temperature)
(x10rpm) Load(%)
[°C]
[%]
300 600
Main Steam Temp.
200 400
Reheater Temp.
ST Speed
150 300
Coal Flow
Load
Steam
50 100 50 Flow
Oil Flow
Feedwater Flow
HRH Pr
0 0 0
-600 -550 -500 -450 -400 -350 -300 -250 -200 -150 -100 -50 0 50 100 150 200 250 300 350 400 450 500 550 560
Time[min.]
BOP
TBN
FICHTNER
Gmbh & Co.KG
ENGINEERING
(PVN)
VIETNAM MACHINERY
TOKYO ELECTRIC POWER SERVICES
INSTALLATION CORPORATION
COMPANY LIMITED - TEPSCO
(LILAMA)
NOTE :
1. In case of 1st stage shell inner metal temp of steam turbine < 150 °C, pre-warming of steam turbine is necessary after condenser vacuum is established
2. Load change Rate and Temperature variation shall be satisfied except for the condition of start-up or shut-down of mills according to RFQ 1.1.4.11.
3. A dead band time due to the combustion system must be excluded to the load change rate evaluation.
4. This start-up curve is typical drawing, actual trend can be adjusted according to actual site condition.
However, start-up time will be complied as specified in the contract.
PLANT WARM START-UP CURVE
Temp. Steam
Press. (deg.C) /Oil/Coal
(bara) Speed Flow(%)
(Shut Down Hour : >8HR and < 48HR)
(x10rpm) Load(%)
[°C]
[%]
300 600
MS Pr
200 400
Reheater Temp.
ST Speed
150 300
Load
Coal Flow
100 200 100
50 100 50 Steam
Oil Flow Flow
Feedwater Flow HRH Pr
0 0 0
-650 -600 -550 -500 -450 -400 -350 -300 -250 -200 -150 -100 -50 0 50 100 150 200 250 300 350 400
Time [min.]
BOP
TBN
FICHTNER
Gmbh & Co.KG
BLR FICHTNER GmbH & Co. KG
ENGINEERING
PV ENGINEERING
VIETNAM OIL AND GAS GROUP
(PVN)
VIETNAM MACHINERY
TOKYO ELECTRIC POWER SERVICES
INSTALLATION CORPORATION
COMPANY LIMITED - TEPSCO
(LILAMA)
NOTE :
1. Load change Rate and Temperature variation shall be satisfied except for the condition of start-up or shut-down of mills according to RFQ 1.1.4.11.
2. A dead band time due to the combustion system must be excluded to the load change rate evaluation.
3. This start-up curve is typical drawing, actual trend can be adjusted according to actual site condition.
However, start-up time will be complied as specified in the contract.
PLANT HOT START-UP CURVE
Temp. Steam
Press. (deg.C) /Oil/Coal
(bara) Speed Flow(%)
(Shut Down Hour : <8HR)
(x10rpm) Load(%)
[°C]
[%]
300 600
Reheater Temp.
200 400
ST Speed
150 300
Coal Flow
Steam
50 100 50 Flow
Oil Flow
Feedwater Flow HRH Pr
0 0 0
-350 -325 -300 -275 -250 -225 -200 -175 -150 -125 -100 -75 -50 -25 0 25 50 75 100 125 150 175 200 225
Time
[min.]
BOP
TBN
FICHTNER
Gmbh & Co.KG
ENGINEERING
VIETNAM MACHINERY
TOKYO ELECTRIC POWER SERVICES
INSTALLATION CORPORATION
COMPANY LIMITED - TEPSCO
(LILAMA)
NOTE :
1. Very Hot Start means Shut Down Hour : < 2 hr
2. Very Hot Start sequence is same to above Hot Start up curve except above Note 1.
3. Load change Rate and Temperature variation shall be satisfied except for the condition of start-up or shut-down of mills according to RFQ 1.1.4.11.
4. A dead band time due to the combustion system must be excluded to the load change rate evaluation.
5. This start-up curve is typical drawing, actual trend can be adjusted according to actual site condition.
However, start-up time will be complied as specified in the contract.
PLANT SHUT DOWN CURVE
Temp. Steam
Press. (deg.C) /Oil/Coal
(bara) Speed Flow(%)
(x10rpm) Load(%)
[°C]
[%]
300 600
250 500
Reheater Temp.
200 400
ST Speed
150 300
Main Steam Press.
STG LOAD
0 0 0
-50 -25 0 25 50 75 100 125 150 175 200 225 250 270
Time[min.]
De-Synchronization
BOP
(IF MAIN STM FLOW ≤ 519t/hr MAIN STM PR ≥ 90bara AND UNIT IS ON SHUT DOWN MODE -> HP BYPASS SET VALUE : 90bara )
(IF REHEAT PR ≥ 8.8 bara AND HP BYPASS IS ON SHUT DOWN MODE -> LP BYPASS SET VALUE : 8.8 bara)
TBN
FICHTNER
Gmbh & Co.KG
ENGINEERING
(PVN)
VIETNAM MACHINERY
TOKYO ELECTRIC POWER SERVICES
INSTALLATION CORPORATION
COMPANY LIMITED - TEPSCO
(LILAMA)
NOTE :
1. Load change Rate and Temperature variation shall be satisfied except for the condition of start-up or shut-down of mills according to RFQ 1.1.4.11.
2. A dead band time due to the combustion system must be excluded to the load change rate evaluation.
SONG HAU 1 THERMAL POWER PLANT PROJECT
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1. Definition of Minimum stable load
<Contract Description>
2.2 PLANT DESIGN AND OPERATING DUTIES
The Facility shall be capable to operate on sliding pressure, typically, between 40% and 90% TMCR while the pressure will remain constant above 90% and
below 40% TMCR. The minimum stable load achievable without oil firing shall be 40% TMCR or below.
A minimum stable load defines that the load could be sustained with main fuel only without any
Definition of auxiliary fuel.
Minimum Stable This minimum stable load can be determined at steady condition, not transient conditions such as
Load boiler start-up or shut-down.
The combustion system is designed to satisfy the safe operation and the availability.
Basic Concept
Operating
In any case of lighting-off, the fuels must be in service of its igniters using auxiliary fuels for main fuel
Concept burning equipment so as to support the ignition energy.
It must be in service of oil burners as an igniters for lighting-off the main fuel in order to keep safe
and steady for furnace condition, when any pulverizer has to be shut-down or start-up during the
boiler load-down or load-up.
0
2. Oil support according to NFPA 85 code
6.8.5.1.1.5 Burner shall not be lighted using a previously lighted burner or from the hot refractory.
1
SONG HAU 1 THERMAL POWER PLANT PROJECT
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SONG HAU 1 THERMAL POWER PLANT PROJECT
Cold Start Up
Activity Check
WATER TREATMENT SYSTEM NORMAL
CONDENSATE STORAGE & TRANSFER SYSTEM NORMAL
TWO(2) CWP, CTCS AND DEBRIS FILTER ARE IN SERVICE
CLOSED COOLING WATER SYSTEM NORMAL
AIR COMPRESSOR SYSTEM NORMAL
AUX. COOLING WATER SYSTEM IN SERVICE
DM WATER STORAGE & TRANSFER SYSTEM IN SERVICE
AUXILIARY STEAM SYSTEM NORMAL (14BAR HDR)
HP/LP BYPASS HYDRAULIC SYSTEM NORMAL
ALL MANUAL VALVES IN ALL SYSTEM PROPERLY POSITIONED
ALL EQUIPMENTS (TRAIN GROUP, PUMPS) PRESELECTED
BLR FILL UP COMPLETED
WTR LEVEL IN DEAERATOR STORAGE TK AND STG CONDENSER
ARE NORMAL
CLEAN UP OF CONDENSATE SYSTEM COMPLETED
TWS AND CHLORIDE INJECTION IS IN SERVICE
LDO FORWARDING SYSTEM IN OPERATION
COND. WATER BOX (CW SIDE) VACUUM IN SERVICE
BLR FLUSHING COMPLETED
SERVICE WATER & FIRE FIGHTING SYSTEM IN SERVICE
CONDENSATE AND CIRCULATING WATER SYSTEM IN SEREVICE
CEMS NORMAL
CPP IN SERVICE
SCANNER COOLING AIR FAN IN SERVICE
OPERATOR VERIFY FLOW PATH FWH #1,2,3,4
ESP HEATING COMPLETED
BFPT LUBE OIL, TURNING GEAR IN SERVICE
SAMPLING SYSTEM NORMAL
TBN LUBE OIL SYSTEM NORMAL
GENERATOR SEAL OIL SYSTEM NORMAL
H2 GAS FILL UP COMPLETED IN THE GENERATOR
STG TURNING GEAR IN SERVICE
STG HYDRAULIC SYSTEM IN SERVICE
GEN STATOR COOLING SYSTEM NORMAL
TBN STEAM SEAL SYSTEM AVAILABLE
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Warm Start Up
Activity Check
WATER TREATMENT SYSTEM NORMAL
CONDENSATE STORAGE & TRANSFER SYSTEM NORMAL
TWO(2) CWP, CTCS AND DEBRIS FILTER ARE IN SERVICE
CLOSED COOLING WATER SYSTEM NORMAL
AIR COMPRESSOR SYSTEM NORMAL
AUX. COOLING WATER SYSTEM IN SERVICE
DM WATER STORAGE & TRANSFER SYSTEM IN SERVICE
AUXILIARY STEAM SYSTEM NORMAL (14BAR HDR)
HP/LP BYPASS HYDRAULIC SYSTEM NORMAL
ALL MANUAL VALVES IN ALL SYSTEM PROPERLY POSITIONED
ALL EQUIPMENTS (TRAIN GROUP, PUMPS) PRESELECTED
BLR FILL UP COMPLETED
WTR LEVEL IN DEAERATOR STORAGE TK AND STG CONDENSER
ARE NORMAL
CLEAN UP OF CONDENSATE SYSTEM COMPLETED
TWS AND CHLORIDE INJECTION IS IN SERVICE
LDO FORWARDING SYSTEM IN OPERATION
COND. WATER BOX (CW SIDE) VACUUM IN SERVICE
BLR FLUSHING COMPLETED
SERVICE WATER & FIRE FIGHTING SYSTEM IN SERVICE
CONDENSATE AND CIRCULATING WATER SYSTEM IN SEREVICE
CEMS NORMAL
CPP IN SERVICE
SCANNER COOLING AIR FAN IN SERVICE
OPERATOR VERIFY FLOW PATH FWH #1,2,3,4
ESP HEATING COMPLETED
BFPT LUBE OIL, TURNING GEAR IN SERVICE
SAMPLING SYSTEM NORMAL
TBN LUBE OIL SYSTEM NORMAL
GENERATOR SEAL OIL SYSTEM NORMAL
H2 GAS FILL UP COMPLETED IN THE GENERATOR
STG TURNING GEAR IN SERVICE
STG HYDRAULIC SYSTEM IN SERVICE
GEN STATOR COOLING SYSTEM NORMAL
TBN STEAM SEAL SYSTEM AVAILABLE
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SONG HAU 1 THERMAL POWER PLANT PROJECT
Hot Start Up
Activity Check
WATER TREATMENT SYSTEM NORMAL
CONDENSATE STORAGE & TRANSFER SYSTEM NORMAL
TWO(2) CWP, CTCS AND DEBRIS FILTER ARE IN SERVICE
CLOSED COOLING WATER SYSTEM NORMAL
AIR COMPRESSOR SYSTEM NORMAL
AUX. COOLING WATER SYSTEM IN SERVICE
DM WATER STORAGE & TRANSFER SYSTEM IN SERVICE
AUXILIARY STEAM SYSTEM NORMAL (14BAR HDR)
HP/LP BYPASS HYDRAULIC SYSTEM NORMAL
ALL MANUAL VALVES IN ALL SYSTEM PROPERLY POSITIONED
ALL EQUIPMENTS (TRAIN GROUP, PUMPS) PRESELECTED
BLR FILL UP COMPLETED
WTR LEVEL IN DEAERATOR STORAGE TK AND STG CONDENSER
ARE NORMAL
CLEAN UP OF CONDENSATE SYSTEM COMPLETED
TWS AND CHLORIDE INJECTION IS IN SERVICE
LDO FORWARDING SYSTEM IN OPERATION
COND. WATER BOX (CW SIDE) VACUUM IN SERVICE
BLR FLUSHING COMPLETED
SERVICE WATER & FIRE FIGHTING SYSTEM IN SERVICE
CONDENSATE AND CIRCULATING WATER SYSTEM IN SEREVICE
CEMS NORMAL
CPP IN SERVICE
SCANNER COOLING AIR FAN IN SERVICE
MS PR MAINTAINED MORE THAN 40 BARG
OPERATOR VERIFY FLOW PATH FWH #1,2,3,4
ESP HEATING COMPLETED
BFPT LUBE OIL, TURNING GEAR IN SERVICE
SAMPLING SYSTEM NORMAL
CONDENSER VACUUM IS AVAILABLE
TBN LUBE OIL SYSTEM NORMAL
GENERATOR SEAL OIL SYSTEM NORMAL
H2 GAS FILL UP COMPLETED IN THE GENERATOR
STG TURNING GEAR IN SERVICE
STG HYDRAULIC SYSTEM IN SERVICE
GEN STATOR COOLING SYSTEM NORMAL
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