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DOCUMENT SUBMISSION STATUS: FOR CONSTRUCTION

6 28.02.2020 FOR CONSTRUCTION S.H.JUNG H.W.NAM J.H.PARK

5 02.01.2020 FOR CONSTRUCTION S.H.JUNG H.W.NAM J.H.PARK

4 09.08.2019 FOR CONSTRUCTION S.H.JUNG H.W.NAM J.H.PARK

3 07.12.2018 FOR CONSTRUCTION J.M.SHIN H.W.NAM J.H.PARK

2 26.07.2018 FOR CONSTRUCTION J.M.SHIN H.W.NAM K.H.KIM

1 18.07.2017 FOR CONSTRUCTION J.M.SHIN H.W.NAM K.H.KIM


REV DATE DESCRIPTION PREPARED CHECKED APPROVED

PROJECT TITLE

SONG HAU 1 THERMAL POWER PLANT (2x600MW)

OWNER OWNER’S CONSULTANT

VIETNAM OIL AND GAS GROUP (PVN) FICHTNER GmbH & Co. KG PV ENGINEERING

EPC CONTRACTOR EPC CONTRACTOR’S CONSULTANT

VIETNAM MACHINERY INSTALLATION TOKYO ELECTRIC POWER SERVICES


CORPORATION (LILAMA) COMPANY LIMITED - TEPSCO
SUB-CONTRACTOR

DATE NAME SIGN DOCUMENT TITLE

PREPARED 28.02.2020 S.H.JUNG

CHECKED 28.02.2020 H.W.NAM Plant Startup & Shutdown Procedure

APPROVED 28.02.2020 J.H.PARK

DOCUMENT NO. REV.


SH1-DHI-P0100-GE-M01-PRO-5304 6
SONG HAU 1 THERMAL POWER PLANT PROJECT

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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6.9.3. UNIT MASTER CONTROL ............................................................................................ 22


6.10. T-BFP (P1LAC20/30AP001) START-UP ........................................................................ 23
6.11. BOILER WET- DRY STATE CHANGEOVER............................................................. 24
6.12. T-BFP (P1LAC20/30AP001) STEAM AND PEGGING STEAM CHANGEOVER
FROM CRH TO IP EXTRACTION .................................................................................................. 24
6.13. AUX. STEAM SUPPLY .................................................................................................... 24
6.14. ST GLAND SELF SEALING ........................................................................................... 24
6.15. CHANGEOVER FROM OIL FIRING TO COAL FIRING ......................................... 24
7. PLANT SHUTDOWN ....................................................................................................... 26
7.1. LOAD REDUCTION......................................................................................................... 26
7.2. COAL TO OIL FUEL CHANGEOVER ......................................................................... 26
7.3. FIRST T-BFP (P1LAC20/30AP001) STOP ..................................................................... 26
7.4. AUX. STEAM REQUIREMENT DURING SHUTDOWN ........................................... 26
7.5. ONE CEP STOP (P1LCB21/22/23AP001) ....................................................................... 26
7.6. START UP OF BRP (P1HAG31AP001) .......................................................................... 27
7.7. CHANGEOVER FROM T-BFP (P1LAC20/30AP001) TO M-BFP (P1LAC10AP001)27
7.8. HEATER EXTRACTION SYSTEM ............................................................................... 27
7.9. ST TRIP AND BYPASS OPERATION ........................................................................... 27
7.10. BOILER SHUTDOWN ..................................................................................................... 28
7.12. AUX. SYSTEMS SHUTDOWN........................................................................................ 28
ATTACHMENT I START UP AND SHUTDOWN CURVE .......................................................... 32
ATTACHMENT 2 OIL IGNITION FOR PULVERIZER STARTUP & SHUTDOWN .............. 33
ATTACHMENT 3 CHECK LIST FOR PREREQUISITE CONDITIONS................................... 34

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ABBREVIATIONS

APC Automatic Plant Control


APS Automatic Plant startup & shutdown Sys.
BFP Boiler Feedwater Pump
BLR Boiler
BNR Burner
BMCR Boiler Maximum Continuous Rating
BOP Balance of Plant
BRP Boiler Recirculation Pump
CC Coordinated Control
EMS Continuous Emission Monitoring System
CEP Condensate Extraction Pump
CID fan Combined Induced Draft fan
CPP Condensate Polishing Plant
CRH Cold Reheat
CRV Combined Reheat Valve
CW Circulating Water
CWP Circulating Water Pump
DA Deaerator
DCS Distributed Control System
DOLT Start the Diesel oil Leak Test (DOLT)
DHI Doosan Heavy Industry
ESP Electro Static Precipitator
EVN Vietnam Electricity
FCV Flow Control Valve
FD fan Forced Draft fan
FGD Flue Gas Desulfurization System
FW Feed Water
GAH Gas Air Heater
GCB Generator Circuit Breaker
GR fan Gas Recirculation fan
H/W Hot Well
HDR Header
HFO Heavy Fuel oil
HIP High-Intermediate Pressure
HP High Pressure
HRH Hot Reheat
HSPV Heating Steam Pressureizing Valve
HTR Heater
HVCB High Voltage Circuit Breaker
ID fan Induced Draft fan
IP Intermediate Pressure
IV Intercept Valve
LDO Light Diesel Oil
LP Low Pressure
M-BFP Motor driven-Boiler Feedwater Pump
MCV Main Control Valve
MFT Master Fuel Trip
Misc. Miscellaneous
MOV Motor Operated Valve
NRV Non Return Valve
O&M manuals Operating & Maintenance manuals
OFA Over Fire Air
P&I diagrams Piping & Instruments diagrams
PA fan Primary Air fan
PRDS Pressure Reducing and Desuperheating station
RFV Reverse Flow Valve
RPM Revolution Per Minute
RO Rated Output

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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..

3. Plant Start-up and Shutdown Duration


Plant start-up is envisaged in following three modes based on boiler and turbine thermal condition.
1. Cold Start
2. Warm Start
3. Hot Start
Start-up time is considered from the time the first oil ignition. The start-up time for various modes is
as given in the table below:

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.

4.2.1. Initial Fill


Before initiating condensate/ feedwater system fill up, auxiliary systems including DM water system
and condensate storage and transfer system must be in operation. One DM water supply pump
(P0GHC31/32AP001) will be running to maintain the condensate storage tank water level. One
condensate transfer pump (P0GHC61/62AP001) will be running to supply water to condensate
distribution system for initial filling of system.
Condenser hotwell is filled up to the normal water level by opening bypass line MOV
(P1GHC80AA105). The condensate system piping will be filled by opening (P1GHC75AA101).
Initial fill water for deaerator (P1LAA10AC001) is supplied from condensate transfer pump by
opening MOV (P1GHC74AA001).
Feedwater/boiler piping filling is done from condensate transfer pump (P0GHC61AP001,
P0GHC62AP001) via piping P1GHC78BR001. During feedwater/boiler piping initial filling,

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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.

4.2.2. Low Pressure System Start-up


Low pressure system startup includes start-up of condensate system and charging the circuit up to
deaerator LCV (P1LCA90AA081). Once the following start-up permissives are fulfilled, operator will
initiate condensate system group start sequence from DCS.
Condensate group start-up permissive:
 CEP A/B/C (P1LCB21/22/23AP001) ready to start
 CPP ready
 Condensate clean-up LCV (P1LCA92AA081) closed
 Condenser to Waste Water Treatment LCV (P1LCA93AA081) closed
 Recirculation FCV (P1LCA41AA081) set to Auto.
 Operator permissive (This permissive shall be manually given by the operator after ensuring the
status of all manual valves in condensate system, through field check)
 Condensate system drives and CV, to be operated in auto, are in auto mode.
Condensate system group start includes sequential start-up of LP heater 1 (P1LCC11/12AC001) &
drain cooler(P1LCC11/12AC002), primary CEP (P1LCB21/22/23AP001), Condensate Polishing
Plant. Start-up of LP heater 2(P1LCC20AC001), 3(P1LCC30AC001), 4(P1LCC40AC001) and Gland
Steam Condenser(P1MAW60AC001) will be done manually by operator.

Until Deaerator level is decreased due to feedwater supply to boiler after firing, condensate is
recirculated via minimum recirculation line to condenser.

DA level will be controlled by controlling condensate flow from LP heater 4 to deaerator


(P1LAA10AC001) by modulating deaerator 30% start up LCV (P1LCA90AA081) based on single
element level control based on DA level measured by triple redundant level transmitters
P1LAA10CL001/2/3.
When condensate system start-up is completed, operator will further proceed with the high pressure
system start-up which contains start-up of feedwater system.

4.2.3. High Pressure System Start-up

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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.

4.2.4. Auxiliary Steam System Line up


In case of initial start-up (i.e. first unit start up from both unit shut down status), Auxiliary Boiler shall
be started in order to provide auxiliary steam for start up at the initial stage of start up. Isolation MOV
(P0LBG01AA001/002) shall be opened for this steam supply. When the Main steam pressure is above
35 bar(a) (preliminary, to be verified), steam supply will change over to main steam line.

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.

4.2.5. Gland sealing and vacuum pulling


Once condensate systems are running, turbine gland sealing can be initiated. Auxiliary steam source
during this period will be steam supply from neighboring unit or auxiliary boiler. Once turbine gland
seals are established(Required Steam Seal Header Pressure : 0.28 barg), condenser vacuum pulling
will be started. During start-up, vacuum pumps will be running in hogging mode.
Once condenser initial hogging is completed (254 mmHga = 33.864 Kpa), one vacuum pump will be
stopped in holding mode.

4.3. Continuous Emission Monitoring System


CEMS will be kept in operation before boiler light up. During normal operation guaranteed emission
values are as given in the table below. All the emission values are based on the reference condition of
6% O2-dry at 25°C and 1 atmosphere.

Guaranteed Emission Values Concentration

NOx 450 mg/Nm3


SOx 300 mg/Nm3
Particulates 116 mg/Nm3

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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5.1. Draught Plant Start and Boiler Pre-Light off Sequence


Boiler air and flue gas path will be established once feedwater system start-up is completed. Both
draught plant streams are taken into service, i.e. starting in sequence, first Air Preheater, first CID fan
group start (P1HNC10AN001, P1HNC20AN001) and Furnace Pressure Control Auto, then first FD
fan group start and Air Flow control Auto. Then the second Air Preheater/CID/FD fan group start. For
starting CID/FD fans, the outlet dampers shall be in close position and inlet blade pitch is in the
minimum position.

1) Operator initiates Boiler Start sequence.


2) Start-up feed water supply pump. The boiler is filled and a stable level is obtained in the storage
vessel. Thereafter the circulating pump is started automatically.
Note: The circulating water quality must be monitored constantly and appropriate action taken to
rectify any failure to meet the specified quality.
3) Start Diesel oil pumps (if not already running).
4) Put in service Gas air heater/ID/FD fan and coal mills lube and hydraulic oil systems.
5) Start the scanner cooling air fan and purge air fan.
6) Set the boiler drains and vents to boiler start up positions.
7) The furnace purge sequence will set the Air & Gas dampers to purge position.
8) Start gas air heaters A and B rotating.
9) Start ID fan A against closed dampers.
Closes discharge damper and blade pitch then ID fan a run-ups and open discharge damper and
release blade pitch to AUTO furnace pressure control. Furnace pressure setpoint is minus
10mmH2O.
10) Start FD fan A against closed dampers.
Closes discharge damper and blade pitch then FD fan A run-ups and open discharge damper,
blade pitch gradually then release to AUTO flow control (min flow control set point is 30% of
BMCR flow = furnace purge rate).
11) Start ID fan B against closed dampers (similar to ID Fan A above).
12) Start FD fan B against closed dampers (similar to FD Fan A above).
13) Open ID Fan blade pitch and set to Auto Furnace pressure control.
14) Start Furnace Purge Sequence timer of 15 minutes when the following permissive are present:
In order to remove accumulated combustible gases or combustible dust in any part of the boiler,
boiler purging is performed during start-up. Purging will be performed in accordance with NFPA
85 requirements. Once all purge permissives are fulfilled purge sequence is initiated either
automatically or by operator which continues for 15 minutes (5 furnace volume changes).
• Any ID fan running
• Any FD fan running
• Diesel oil ignition and burner header main and return trip valves closed
• All individual burner oil valves closed

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• No boiler trip condition present


• Any gas air heaters running
• Air flow at 35% of TMCR flow
This step purges the furnace,GAH A/B, EP A/B(supplied by others). If any furnace purges
permissive fails during purge timing, the fault must be rectified and the furnace purge restarted.
The total airflow for the Furnace Purge condition is 35% of TMCR load volumetric flow and
should be maintained through purge and light off of the first oil burners.
This flow will effectively remove gaseous combustibles and replace with air. Start the Diesel oil
Leak Test (DOLT).
15) Start the diesel oil leak test. Following satisfactory completion of Stage 2 oil leak test open
MFSSOV (Master Fuel Safety Shut-off valve,P1EGD50AA051) to establish oil flow to burner
rails and return line.
Diesel oil forwarding system should be in service prior to leak test.
Note for leak test:
• Stage 1- pressurizes the system and tests for any pressure decay which would indicate
leaks in the burner valves or return valve.
• Stage 2- releases the system pressure by opening the return valve. The return valve is then
closed and the system checks for a rise in pressure which would indicate a leak on the
MFSSOV.

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.

5.2. ESP System Start Up


ESP System will be started once boiler initial firing is initiated :

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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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5.6. RH Steam System Charging


LP bypass valves(P1LBH31/41AA081) are provided for reheat steam pressure control. LP bypass
valves will be kept closed until the minimum reheat pressure is reached. Once reheat steam pressure
reaches to Pmin (18 barg), LP bypass valves controller changes to minimum pressure control mode.
LP bypass valve opening set points is set to Ymax (45%) depending up on the reheater flow.
Spray water for LP bypass valve desuperheater is supplied form the CEP (P1LCB21/22/23AP001)
discharge line. Once LP bypass PCV opens more than 2%, respective LP bypass valve TCV
(P1LCE41AA081/42AA081) operate in auto mode. Enthalpy based temperature control is realized for
LP bypass downstream temperature control.
Once LP bypass valve opens to Ymax (45%) respective LP bypass controller mode changes to pressure
rise mode. During pressure rise mode set point for LP bypass controller is set to synchronizing
pressure Psync (14 barg). Reheat steam pressure increases towards synchronizing pressure at a
predefined gradient depending up on the cold, warm or hot mode of start-up.
As soon as synchronizing pressure is reached, LP bypass valve controller mode changes to fixed
pressure control mode so as to maintain the constant reheat steam pressure.

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.

HP turbine 1st stage shell metal Approx. Duration of


Mode of Start-up
temperature (deg.C) Shutdown (hr)
T < 265 > 48hr Cold
265 < T < 442 < 48hr but > 8hr Warm
T > 442 < 8 hr Hot

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.

6.1. Rotor prewarming


Turbine rotor prewarming needs to be done if the high pressure rotor bore temperature is less than
149°C and the reheater bowl and reheat exhaust temperatures are less than 54°C.
The steam supply should be limited to an enthalpy range of 662.2~714.9 Kcal/kg (1192~1287
BTU/lb) to raise the HP shell (and rotor) surface temperature to 149°C or more when pressurized to
3.79~4.82 barg. Simultaneous with pressurization, the reheat section should be prewarmed to 54.4°C
by maintaining allowable condenser back pressure with the steam seals in operation. The time
required for the reheat section to reach 54.4°C may exceed the time to prewarm the high pressure to
149°C.
The reheat section is considered to be prewarmed when all the metal temperature thermocouples in
this section read 54.4°C or higher. The turbine may be reset or tripped. If sufficient steam conditions
are available at auxiliary steam header, steam can be admitted to the HP turbine and the reheat pipes
via the HSPV.
In Automatic mode, the turbine control system will pressurize HP turbine and reheat pipes in a
controlled manner. The pressure setpoint will be ramped at approximately 0.39 barg/min until 18.24
bar(g) is reached, with the provision that the error between setpoint and actual pressure does not
exceed a certain limit.
HSPV Inlet Pressure Limiter will begin to close the HSPV if the auxiliary header pressure decreases
below 18.24 bar(g). Regulation is 10%, and the HSPV will be closed at 16.37 bar(g).

6.2. Chest warming


Control valve chest warming sequence needs to be entered if the turbine control system issues a
message that chest prewarming is required. This is the case if the difference between main steam
temperature and control valve chest outer surface temperature is greater than the allowable
temperature difference across the valve wall.
Chest warming consists of two phases:

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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.

6.3. Final Preparation for rolloff


The turbine control system will continuously monitor turbine auxiliary systems, turbine temperatures
and several generator parameters as a preparation for rolloff.
Following checks need to be performed before turbine rolloff:
1) All trip inputs to the turbine control system should be reset.
The Valve Position Limit shall be set at 120% maximum.
No problems should be indicated on TCS alarm lists.
2) All data on displays should be in acceptable ranges, and no alarms present on displays.
3) Condenser pressure should be -0.85 bar (g) maximum. (- 637.55 mmHg (g))
4) Steam seal header pressure should be 0.17 to 0.31 barg. An alarm will be given for a pressure
outside a 0.13 to 0.41 barg range and operate valves in automatic mode.
5) All turbine drain valves should be open.
6) Hydraulic fluid pressure should be 131 to 165.4 barg. Hydraulic fluid temperature should be 29.4
to 49° C. Turbine control system will alarm below 131 barg, below 18° C and above 65.6° C.
7) Auxiliary Bearing Oil Pump should be running, the Emergency Bearing Oil Pump should be off
and its control switch should be in the AUTO position.
8) Bearing lube oil temperature should be between 27 and 32° C. Bearing header pressure should be
greater than 1.03 barg. An alarm will be given below 1.03 barg and outside a 10 to 32° C range.
9) Start-up BFP shall be in service.
The main cooling water shall be in service.
The auxiliary cooling water shall be in service.
LP bypass flows shall be ready for turbine roll.
Main turbine shall have normal eccentricity and bearing metal temperatures.

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10) Generator Ready Checks:


A hold will be issued if the generator’s hydrogen and stator coolant systems indicate problems.
An event message will be provided if generator field prewarming is required at 3000 rpm, as
indicated by the hydrogen cooler gas inlet temperature being less than 20° C.
11) Required steam purity:

12) Rub check (for initial start-up)


a. Select turbine speed rate : 100rpm/min
b. Check turning gear disengage
c. Close valve or master trip after turbine speed reaches in 200rpm
- Confirm there is not any abnormal noise at each gland sealGenerator Ready Checks:

6.4. Temperature matching


Matching of steam temperature to turbine inlet metal temperature is very critical step before steam
admission to turbine. Optimal steam to metal temperature matching delivers the best start-up times.
HP turbine 1st stage temperature signal is used for main steam temperature matching. IP turbine bowl
temperature signal is used for IP steam temperature matching.
ATS provides values for maximum and minimum recommended steam temperatures which are
calculated from current steam pressure, current stresses and metal temperatures.
Additionally, although the selected steam temperature is above the minimum, the steam temperature
should be more than 41.7°C (75°F) above saturation temperature.

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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

Warm start-up 470 89 460 11

Hot start-up 490 89 480 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:

Mode of start-up Acceleration rate (RPM/minute)

Cold start-up 100


Warm start-up 150
Hot start-up 300

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:

Mode of start-up Holding period (min) Purpose


6
Cold start-up 20 min IP turbine Heat Soaking

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Warm start-up 10 min Lube oil Heating

Hot start-up 10 min. Lube oil Heating

(* 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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*block load: obtained power right after synchronization

6.7. DA pegging steam source changeover


When CRH pressure reaches to 10 barg, DA pegging steam line MOV (P1LBC31AA001) from CRH
steam is opened automatically (or by operator) from DCS. Once CRH steam line MOV is opened,
pegging steam line MOV (P1LBG31AA001) in the aux steam line is closed automatically (or by
operator).
Hereafter DA pegging steam will be supplied from CRH steam.

6.8. Loading Up after Initial Load


After reaching the initial load or completion of initial load holding, steam turbine controller follows
the operator’s or plant DCS’s instruction to increase the load and operate at the target load. The ramp
rate (load up rate) should be determined in accordance with the Start-up Curves.
First mill will be started as per the sequence (on a cold start superheater temperature control may
require coal to be put on the first mill after the turbine has been synchronised). The subsequent mills
will be started as the load increase.
Duty mill seal air fan and PA Fans shall be in service before mill start. PA fan controls Hot PA duct
pressure.

6.9. Extraction Steam System Start-up


All HP and LP heaters are charged from feedwater and condensate side during the start-up of
feedwater and condensate systems.
Extraction line drain valves will be operated automatically.
Heaters are included in group start sequence, so they are started automatically.

6.9.1. Extraction Steam System for LP Heaters


As soon as HIP turbine starts rolling LP heater extraction steam group command can be manually
issued by operator to initiate LP heater extraction steam group sequence. It comprises of all
drives/systems of the extraction steam system and heater drain and vent system to achieve automated
sequential charging of complete LP heaters from steam side. Startup vent MOV for all LP heaters will
be opened when hogging pressure is reached in the condenser.
The LP heater extraction steam group command can be issued only when all the following permissive
are fulfilled
 All participating drives and control valves of extraction steam system and heater drain and vent
system are in auto mode of operation.
 LP heater 1 (P1LCC11/12AC001) in-line (condensate charged)
 All LP heaters extraction steam NRV and MOV open permissives satisfied
 Steam turbine rolls.

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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.

6.9.2. Extraction Steam System for HP Heaters


The HP heater extraction steam group command can be manually issued by operator to initiate HP
heater extraction steam group sequence. The HP heater extraction steam group comprises of all
drives/systems of the extraction steam system and heater drain and vent system to achieve automated
sequential charging of complete HP heaters from steam side. Start-up vent MOV for all HP heaters
will be opened once deaerator (P1LAA10AC001) atmospheric vent is opened.
The HP heater extraction steam group command can be issued only when all the following
permissives are fulfilled
 All participating drives and control valves of extraction steam system and heater drain and vent
system, in auto mode of operation.
 All HP heaters in-line (feedwater charged)
 HP heater (6,8)’s extraction steam NRV (P1LBQ30AA051, P1LBQ10AA051) and HP heaters
(6,7,8)’s MOV (P1LBQ30AA001, P1LBQ20AA001, P1LBQ10AA001) open permissives
satisfied.
Group start sequence for HP heater includes sequential start-up of steam extraction to HP heater 6, 7,
8 and deaerator (P1LAA10AC001)/ T-BFP (P1LAC20/30AP001). Extraction to heater 7
(P1LAD20AC001) is initiated once CRH pressure reaches to 10 barg. Once 20% load is achieved
extraction for HP heater 6 (P1LAD10AC001) is commenced. Once heater 6 is in line extraction for
heater 8 is started. IP steam extraction for deaerator (P1LAA10AC001) at 30% load and for BFPT is
started at 30% load. The start-up vent MOV for each HP heater will be closed once respective heater
extraction starts and respective extraction NRV is opened for more than 10 sec. The HP heater
extraction steam group sequence is considered to be complete when deaerator pneumatically actuated
NRV and motor operated isolation valve is fully opened.

6.9.3. Unit Master Control


During start-up once load increases beyond 10 % and UMC is permitted from TCS, operator enables
Unit Master Controller from DCS.
Once following conditions are true then turbine follow mode shall be enabled in UMC:
 Unit is synchronized
 Block load is applied

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 No turbine limiting conditions are present


 UMC mode is permitted from turbine control system
 HP/LP Bypass PCVs are closed.
From 15 % to 40 % RO Turbine follow mode is operated. Boiler fuel firing will be under “load
control”. Setpoint for load controller shall be from UMC with loading rate as per pre-defined start-up
mode. Turbine governor valve control shall be under pressure control from UMC. These governor
valves shall be modulated to control turbine inlet pressure at pre-define setpoint.

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.

6.10. T-BFP (P1LAC20/30AP001) start-up


At around 25% RO load load primary T-BFP (P1LAC20/30AP001) will be started in recirculation
mode.
As soon as following permissives are fulfilled, “Primary T-BFP (P1LAC20/30AP001) auto run-up
command” is issued from DCS:
 Primary T-BFP (P1LAC20/30AP001) change over command issued
 FW system in auto mode
 Primary T-BFP (P1LAC20/30AP001) ready for auto run-up
Primary T-BFP (P1LAC20/30AP001) is kept in pressure sync mode first. Once primary T-BFP
(P1LAC20/30AP001) discharge pressure difference is within limit, T- BFP discharge MOV
(P1LAB22/23AA001) opens and then start-up M-BFP discharge MOV (P1LAB21AA001) close
command is issued. As soon as T-BFP discharge MOV (P1LAB22/23AA001) is opened and M-BFP
discharge MOV (P1LAB21AA001) is closed, economiser inlet MOV (P1LAB50AA006) open
command is issued. After MOV close for M-BFP, M-BFP will be stopped. With the close feedback of

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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.

6.11. Boiler Wet- Dry state changeover


As boiler steam production increases, water separator level reduces. At around 35% TMCR load
(about 210 MW), water separator level eventually disappears. Boiler mode of operation changes over
from wet state to dry state. The boiler now operates in once through mode and boiler recirculation
pump (P1HAG31AP001) will shutdown at 40 TMCR load (5 percentage points above Benson load).

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.

6.13. Aux. steam supply


As soon as Main steam pressure reaches to 34 barg, Aux. steam supply from Main steam line by
opening MOV (P1LBA30AA001) and Aux. steam supply from auxiliary boiler is cut off completely
by closing MOV (P0LBG11AA001/002).
Aux steam will supply from CRH steam at 230 MW by opening MOV (P1LBC32AA001) and close
MOV (P1LBA30AA001) which placed in CRH supply line.
Hereafter all aux. steam requirements will be fulfilled from CRH steam supply.

6.14. ST gland self sealing


Turbine gland system is in self sealing mode once load reaches to 70% RO load (about 420 MW). So,
during start-up seal steam supply from aux. steam header gets gradually reduced by closing the seal
steam line control valve(P1LBC11AA081) as the turbine load increases. During self sealing operation
seal steam line control valve(P1LBC11AA081) will be kept in auto mode to maintain the seal steam
header pressure in case it reduces below the pre-set value.

6.15. Changeover from Oil firing to Coal firing

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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:

SH1-DHI-P0100-GE-M01-PRO-5304 25 of 38
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 569C.
Check that the attemperators limit the final steam temperature to 569C.
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.

7.1. Load Reduction


From 100% RO condition turbine load is reduced to 90% in constant pressure mode. After that
turbine load will be reduced in a sliding pressure mode at a predefined gradient (as per shutdown
curve) by reducing boiler firing.
Turbine seal steam supply is started from auxiliary steam header once turbine load reduces below
70% load.

7.2. Coal to Oil fuel changeover


When the output starts reducing, the coal burners are turned off in order according to the decrease of
the fuel flow rate. The subsequent shutdown is completed with the support of oil firing. Once all the
coal mills are stopped, PA fans will be stopped.

7.3. First T-BFP (P1LAC20/30AP001) stop


As load reduces boiler feedwater requirement also reduces and at 40% load the feedwater requirement
reduces to the extent where only one T-BFP (P1LAC20/30AP001) can fulfill the feedwater
requirement. At this point pre-selelcted T-BFP (P1LAC20/30AP001) will be stopped with operator
verification button.

7.4. Aux. Steam requirement during shutdown


Steam turbine shutdown is envisaged with vacuum maintained in the condenser as per turbine OEM’s
recommendation. Aux. steam supply for gland sealing and pulverizer inerting (if required) during
shutdown will be supplied from CRH steam or main steam line.

7.5. One CEP stop (P1LCB21/22/23AP001)

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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).

7.6. Start up of BRP (P1HAG31AP001)


At 35% steam load, the steam temperature at separator inlet will fall below the superheated region,
and water level will start to develop in the separator. BRP (P1HAG31AP001) is started to provide the
minimum flow and boiler is operated in recirculation mode.

7.7. Changeover from T-BFP (P1LAC20/30AP001) to M-BFP (P1LAC10AP001)


Normal shutdown can be performed by T-BFP (P1LAC20/30AP001) itself. M-BFP
(P1LAC10AP001) may be (on operators discretion) manually started by operator once the steam load
comes down to 30% and floor pressure is reached during shutdown. Once M-BFP (P1LAC10AP001)
is on load, T-BFP (P1LAC20/30AP001) can be stopped by operator. The subsequent feedwater
requirement to accomplish the shutdown will be fulfilled via M-BFP (P1LAC10AP001). The FCV
(P1LAB60AA081) at feed control station will be operated in order to control the feedwater flow to
the boiler and feed control station MOV (P1LAB50AA006) is closed.
When M-BFP is not available(P1LAC10AP001) for shutdown, T-BFP(P1LAC20/30AP001) will be
operated by auxiliary steam and it is same procedure for shutdown by T-BFP(P1LAC20/30AP001).

7.8. Heater Extraction System


As steam turbine load reduces feedwater heater extractions get cut off automatically based on
availability of extraction steam. Below 20% load, IP extraction for DA pegging and T-BFP
(P1LAC20/30AP001) gets cut-off and CRH steam cuts-in. once load reduces below 20%, HPH
extraction for heater 8 and 6 closes sequentially.
Extraction for HPH 7 will continue until BLR trips. All LP heaters will also get cut-off as soon as
steam turbine is tripped.

7.9. ST Trip and Bypass Operation


After the minimum shutdown load is reached (LOAD AT TARGET) and this load is above 5%, it is
recommended that the remaining load be dropped quickly with the RAPID UNLOAD feature ON,
and the unit tripped without delay at, or below 5–10% load.
As soon as turbine is tripped, HP-LP bypass valve(P1LBH10/20AA081, P1LBH31/41AA081) will
open to maintain the upstream pressure. After desynchronization steam turbine speed decreases at a
predefined gradient and once speed reaches to zero speed, turning gear is started.
Turbine is kept on turning gear until maximum temperature of the inner surface metal of the casing,
corresponding to the rotor system shell surface metal temperature is less than 250° C.

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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.

7.10. Boiler Shutdown


Once steam turbine is tripped, boiler shutdown is performed. Diesel oil flow is decreased and
gradually all oil burners are turned off as per burner stop sequence. Once boiler is fired out, boiler
recirculation pump is stopped. Boiler is converted into MFT Condition when all burner flame is off.
When final oil burner is turned off, the furnace purge with min.air flow is performed. After
completion of furnace purging, FD fans (P1HLB10AN001, P1HLB20AN001) and CID fans
(P1HNC10AN001, P1HNC20AN001) will be stopped.

7.11. ESP Stop


Once boiler MFT, ESP will be stopped (transformer de-energized) in 10 minutes and heaters (insulation
/ hopper) will be remained power-on.

7.12. Aux. Systems shutdown


After completion of main plant shutdown, the plant auxiliary systems may be shutdown manually by
the operator depending on the reason of unit shutdown.

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SONG HAU 1 THERMAL POWER PLANT PROJECT

8. Reference Documents
- PID’s

No. Document No. Description


1 SH1-DHI-P1LBA-M-M01-PID-5314
2 SH1-DHI-P1LBC-M-M01-PID-5315 Main & Reheat Steam System
3 SH1-DHI-P1LBB-M-M01-PID-5316
4 SH1-DHI-P1LAB-M-M01-PID-5311
5 SH1-DHI-P1LAB-M-M01-PID-5312 Feedwater System
6 SH1-DHI-P1LAB-M-M01-PID-5313
7 SH1-DHI-P1LBD-M-M01-PID-5317
8 SH1-DHI-P1LBD-M-M01-PID-5318 FeedWater Heater Extraction Steam
9 SH1-DHI-P1LBD-M-M01-PID-5319 System
10 SH1-DHI-P1LBD-M-M01-PID-5320
11 SH1-DHI-P1LBG-M-M01-PID-5326 Auxiliary Steam System
12 SH1-DHI-P1LCA-M-M01-PID-5304
13 SH1-DHI-P1LCA-M-M01-PID-5305
14 SH1-DHI-P1LCA-M-M01-PID-5306
15 SH1-DHI-P1LCA-M-M01-PID-5307 Condensate System
16 SH1-DHI-P1LCA-M-M01-PID-5308
17 SH1-DHI-P1LCA-M-M01-PID-5309
18 SH1-DHI-P1LCA-M-M01-PID-5310
19 SH1-DHI-P1MAA-M-M01-PID-3129 Turbine
20 SH1-DHI-P1HAH-M-M01-PID-1005
21 SH1-DHI-P1HAH-M-M01-PID-1006
22 SH1-DHI-P1HAH-M-M01-PID-1007
23 SH1-DHI-P1HAH-M-M01-PID-1008
24 SH1-DHI-P1HAH-M-M01-PID-1009 Boiler
25 SH1-DHI-P1HAH-M-M01-PID-1010
26 SH1-DHI-P1HAH-M-M01-PID-1011
27 SH1-DHI-P1HAH-M-M01-PID-1012
28 SH1-DHI-P1HAH-M-M01-PID-1013
29 SH1-DHI-P0EGA-M-M01-PID-5201
Diesel oil System
30 SH1-DHI-P0EGA-M-M01-PID-5202
31 SH1-DHI-P0ETA-M-M01-PID-1001 Bottom Ash Handling System
32 SH1-DHI-P0GA-M-M01-PID-5201 Raw Water Supply System
33 SH1-DHI-P0GHC-M-M01-PID-5331 Demineralized Water System
SH1-DHI-P0GHC-M-M01-PID-5332 Condensate Storage and Transfer
34
System
35 SH1-DHI-P0GHD-M-M01-PID-5201
Service Water System
36 SH1-DHI-P0GHD-M-M01-PID-5202
37 SH1-DHI-P0GKB-M-M01-PID-5201 Potable Water System
38 SH1-DHI-P0GCF-M-M01-PID-5401 Water Treatment Plant
39 SH1-DHI-P0GM-M-M01-PID-5201
40 SH1-DHI-P0GM-M-M01-PID-5202
Waste Water Transfer System
41 SH1-DHI-P0GM-M-M01-PID-5203
42 SH1-DHI-P0GM-M-M01-PID-5205
43 SH1-DHI-P0LCB-M-M01-PID-5201 Condensate Pump
44 SH1-DHI-P0LD-M-M01-PID-5401 Condensate Polishing Plant
45 SH1-DHI-P0MAV-M-M01-PID-5201 Clean and Dirty Oil System

SH1-DHI-P0100-GE-M01-PRO-5304 29 of 38
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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SONG HAU 1 THERMAL POWER PLANT PROJECT

24 SH1-HRC-P0HDE-E-M06-PHL-0002 Operation Philosophy Of ESP


25 SH1-DHI-P0QC-M-M01-PHL-5401 Chemical Dosing System
26 SH1-DHI-P0QU-M-M01-PHL-5401 Sampling System
27 SH1-HEG-P0100-M-M05-PHL-0001 Process Description of FGD
28 SH1-DHI-P0100-GE-M01-PHL-5301 Plant Operation Philosophy
SH1-DHI-P0CJD-I-M01-DLG- Plant Start-up & Shutdown Sequence
29
5502~5505 Diagram
30 SH1-DHI-P0QH-M-M01-PHL-5201 AUX. BOILER_System description
Electrical Operation & Switching
31 SH1-DHI-P0ZEN-E-M01-MAN-5601
Procedure
32 SH1-DHI-P0GCF-M-M01-PHL-5401 Water Treatment Plant

SH1-DHI-P0100-GE-M01-PRO-5304 31 of 38
SONG HAU 1 THERMAL POWER PLANT PROJECT

ATTACHMENT I START UP AND SHUTDOWN CURVE

SH1-DHI-P0100-GE-M01-PRO-5304 32 of 38
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.

Main Steam Press.


250 500

200 400
Reheater Temp.
ST Speed

150 300

Coal Flow

100 200 100

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.]

Boiler Fire On TBN Synchronization Full Load


START

BOP

TBN

FICHTNER
Gmbh & Co.KG
ENGINEERING

BLR VIETNAM OIL AND GAS GROUP


FICHTNER GmbH & Co. KG PV ENGINEERING

(PVN)

VIETNAM MACHINERY
TOKYO ELECTRIC POWER SERVICES
INSTALLATION CORPORATION
COMPANY LIMITED - TEPSCO
(LILAMA)

SONG HAU 1 THERMAL POWER PLANT


2 x 600MW

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

Main Steam Temp.


250 500

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.]

Boiler Fire On TBN Synchronization Full Load


START

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)

SONG HAU 1 THERMAL POWER PLANT


2 x 600MW

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

Main Steam Temp.


Main Steam Press.
250 500

Reheater Temp.

200 400

ST Speed

150 300

Coal Flow

100 200 100


Load

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.]

TBN Synchronization Full Load


START

BOP

TBN

FICHTNER
Gmbh & Co.KG
ENGINEERING

BLR VIETNAM OIL AND GAS GROUP


(PVN)
FICHTNER GmbH & Co. KG PV ENGINEERING

VIETNAM MACHINERY
TOKYO ELECTRIC POWER SERVICES
INSTALLATION CORPORATION
COMPANY LIMITED - TEPSCO
(LILAMA)

SONG HAU 1 THERMAL POWER PLANT


2 x 600MW

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

Main Steam Temp.

250 500
Reheater Temp.

200 400

ST Speed

150 300
Main Steam Press.

100 200 100

HRH Pr BLR LOAD


50 100 50

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

BLR VIETNAM OIL AND GAS GROUP


FICHTNER GmbH & Co. KG PV ENGINEERING

(PVN)

VIETNAM MACHINERY
TOKYO ELECTRIC POWER SERVICES
INSTALLATION CORPORATION
COMPANY LIMITED - TEPSCO
(LILAMA)

SONG HAU 1 THERMAL POWER PLANT


2 x 600MW

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

ATTACHMENT 2 OIL IGNITION FOR PULVERIZER STARTUP & SHUTDOWN

SH1-DHI-P0100-GE-M01-PRO-5304 33 of 38
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.

3.1 STEAM GENERATOR AND ACCESSORIES


3.1.1.3. Performance design parameters
The unit and all auxiliary equipment shall be capable of safe, stable and continuous operation without overstressing or damaging any components over the
following ranges of operating parameters and conditions:
- All loads above 40% on the worst coal without using auxiliary fuel.

 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.

Transient condition(ex. during load-up)


The igniters shall be used for lighting-off the main fuel.

Steady condition(ex. Full load)


Ignition source is not required to support the main fuel.

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

<NFPA 85 Code >


 6.8.5.1.1.4 The igniter for the burner shall always be used.

 6.8.5.1.1.5 Burner shall not be lighted using a previously lighted burner or from the hot refractory.

 6.7.5.2.3.6 Each burner shall be shut down in the following sequence:


(1) The igniter shall be placed in to service on the particular burner to be shut down.

 6.8.5.1.5.6 Burner Operation


(C) The pulverizer loading and primary air flow shall be permitted to be used as a guide in maintaining the necessary fuel flow for
each burner and shall be maintained within the prescribed limits as follows:
(4) The associated igniter shall be placed in service prior to admitting coal to any burner.
(5) When the burner(s) and furnace fuel input are within the predetermined prescribed limits necessary to maintain stable flame
without the aid of igniters (as determined by test), the igniters shall be permitted to be removed from service.

A basis of burner operating in accordance with NFPA 85 is that ;


NFPA Code
Requirement  The igniters for the associated main burners shall be used always, in particular, it is not allow
to be ignited by previous lighted adjacent burner or hot refractory.
 Igniters should be in service enough time until main fuel flame is stable without ignition energy.

DHI complies with NFPA 85 requirement.


NFPA
Application  Whenever, the main coal burners shall be lighted-off by the associated oil burners as an igniter
during start-up & shutdown of pulverizer.
 If oil burners are not in service, the coal burner could not be start-up and/or shut-down logically.

1
SONG HAU 1 THERMAL POWER PLANT PROJECT

ATTACHMENT 3 CHECK LIST FOR PREREQUISITE CONDITIONS

SH1-DHI-P0100-GE-M01-PRO-5304 34 of 38
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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SONG HAU 1 THERMAL POWER PLANT PROJECT

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

SH1-DHI-P0100-GE-M01-PRO-5304 36 of 38
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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SONG HAU 1 THERMAL POWER PLANT PROJECT

TBN STEAM SEAL SYSTEM AVAILABLE

SH1-DHI-P0100-GE-M01-PRO-5304 38 of 38

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