Coldstart Final

Gulf Coast Plant Unit Cold Start-Up
IRI Units 1 & 2

IRI UNITS 1 AND 2
UNIT COLD START-UP PROCEDURE
TABLE OF CONTENTS

I. Purpose.................................................................................................................................. 2
II. Prerequisites.......................................................................................................................... 2
General Operational Guidelines ............................................................................................ 4
III. Procedure.............................................................................................................................. 5
Boiler Firing............................................................................................................................ 5
Turbine Warm-up and Roll up.............................................................................................. 24
Generator Synchronization and Increasing Load to Full Load............................................ 29
IV. Valve Lists............................................................................................................................ 35
Boiler Firing Valve Preparation (Startup)............................................................................. 35
Steam Coil Air Heater Startup............................................................................................. 36
Condensate and Feedwater Pumps.................................................................................... 37
Turbine Valve Positions....................................................................................................... 38
V. Access Doors....................................................................................................................... 40
Boiler Doors ......................................................................................................................... 40
Boiler Air Heater Doors........................................................................................................ 45
Baghouse Doors.................................................................................................................. 47
INTREX Inner Doors............................................................................................................ 49

Revision 0 (Date) Page
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IRI Units 1 & 2

IRI UNIT COLD START-UP PROCEDURE - UNITS 1 AND 2
I. Purpose
This procedure provides information and guidance for the correct and safe startup of the Unit (1
or 2) from a cold start.

II. Prerequisites
A. Ensure all personnel are aware of equipment start-up and are clear of any eminent
dangers present during equipment start-up.
B. All 4160 and 2400 volt motors, that do not have Megalerts, should be Meggered within 24
hours prior to initiating unit startup.
C. Verify that Instrument Air is available for instrumentation and control.
D. Verify DCS Graphic designations for instrumentation and control are functional and
operating.
E. Verify the operational availability/readiness (lubrication levels, cooling water, control
power) for startup of equipment and associated controls for the following:
At least one (1) Circulating Water Pump,
One (1) Condensate Pump,
One (1) Boiler Feed Pump,
Condensate Recirc Pump, (Controls for the Condensate Recirc Pump are in the old
Control Room.)
One (1) ID Fan,
One (1) PA Fan,
One (1) SA Fan,
Three (3) INTREX Blowers,
Three (3) J -Valve Blowers
F. Verify that the boiler hydrostatic test (if performed) was acceptable and no other
problems are apparent, that safety valve gags have been removed, steam lines drained,
and drum level is at minus one (1) on the drum sightglass or Yarway.
G. Verify that the Boiler Pins have been removed from the hangers at the top of the Heat
Recovery Area (HRA) and the (INTREX). Refer to section 1, step 5.
H. Notify Lab and other units that are charged with responsibility for the Demineralized
water/Demineralizer that IRI is starting up and will be using a large volume of water
I. Verify that the Demineralized Water Storage Tank is filled to adequate level (between 12
and 17 feet).
J . Verify Cooling Tower level to be adequate, between Hi and Low level alarms.

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IRI Units 1 & 2

K. Verify Hotwell level indication (Tygon tubing) is lined up and Hotwell level is adequate
[between 8 and 10 feet for unit startup.
L. Verify the Deaerator (DA) and the Feedwater Heaters are lined up (valved in) and ready
for service.
M. Verify Deaerator level is adequate between 65 and 75 inches for unit startup.
N. Verify all Heater levels are visible in sight glass for unit startup.
O. Verify the Stripper Cooler spray block valves are double blocked and vented.
P. Stroke Turbine Governor Valves to ensure ease of operation and movement.
Verify Turbine Auxiliary Oil Pump is running
RESET Turbine Relay 95X (Turbine Auxiliary Trip) in Relay Room
RESET the Vacuum Trip button located on the Turbine Front Standard
PUSH IN and hold the Turbine Reset Knob. While holding the knob, verify that
the Relay Oil Pressure (upper gauge) increases to 140 psi.
As Relay Oil Pressure increases, Hot Reheat Stops and Intercepts fully OPEN.
Verify Reheat Stops and Intercepts are in the Full OPEN position.
Have COS check DCS Turbine Valve graphic. Reheat Stops and Intercept
Valves, when fully open, will show red limits as illustrated on Figure 1.
Verify Turbine Stop Valves are CLOSED.
Verify that the six (6) Governor Valves are completely CLOSED.
Position the Load Limiter to the fully OPEN position (located on the Turbine Front
Standard). The Load Limiter is illustrated on Figure 2.
Verify the (6) Governor valves stroke 100 percent open and then back closed
using the Governor Control Switch in the old control room.
Have the Control Operator Supervisor (COS) TRIP the Turbine from the IRI
Control Room, and visually check that all the Turbine Valves moved to FULLY
CLOSED position.
After the Turbine valves are verified as being CLOSED, run the Load Limiter
back down to the fully closed position.
Report any deficiencies to the COS.
Q. Verify that Bearing Cooling Water/Component Cooling Water is aligned and in service.
R. Verify Turbine Lube Oil Tank level is established and that Vapor Extractor is in service.
S. Verify Lube Oil Conditioner (Bowser) is in service.
T. Verify Turning Gear Oil Pump is in service.
U. Verify Turbine is on Turning Gear with Turning Gear Motor operating and clutch engaged.
V. Verify that all Clearances are released as required for equipment startup and that
equipment is in a safe condition for startup operation.

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IRI Units 1 & 2

W. Review Permit Confined Space Log to ensure all spaces required for startup are signed
off and hatches/manways closed.
X. Ensure all Boiler Doors are closed and secured. Ensure that a properly completed Boiler
Doors Closure List (Section V of this procedure) has been provided to Control Operator
Supervisor (COS).
Y. Turn off Drum Level Trips for unit startup.
Z. Turn off 86TX relay for unit startup.
AA. Call LA Ash dispatcher to confirm amount and approximate time of ash delivery. If all
bed material was removed, 150 tons will be required. If only J -Valve and INTREX bed
material was removed, approximately 50 tons will be required.

General Operational Guidelines
In the event that major changes in Unit control setpoints are made, equipment is started or shut
down, or unstable operations exist just prior to or at shift change, the off-going shift Control
Operator Supervisor (COS) and appropriate Operators shall stay and work with the oncoming
shift, until the initiated changes are well in hand, Unit operation has totally stabilized, and the on-
coming shift is fully aware of all aspects of changes and/or root causes.

Maintain Electronic Log and Turnover Log for oncoming shift as record of changes/unstable
conditions.

A hard copy of this Startup Procedure is to be printed out and maintained on the console at all
times during unit cold startup.

As each prerequisite and numbered startup step is verified appropriate Control Operator
Supervisor (COS) shall confirm action by initial and time. Mark-up any missing, incomplete or
erroneous startup instructions. Completed procedure shall, at conclusion of startup, be routed to
Production Superintendent and IRI Operations Manager for information and/or review.

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IRI Units 1 & 2

III. Procedure
Boiler Firing
____1. Align Condensate Pump and Condensate Recirc. Pump for startup.
____2. Drain/fill the boiler to firing level.
a. OPEN V-58 HRA Partition Wall Inlet Header Vent Valve (Elevation 15.5)
b. OPEN V-60 PSH Outlet Header Vent Valve (Elevation 15.5)
c. OPEN V-27 Drum Vents (2) (Elevation 14.5)
d. OPEN V-51 Cyclone Cooling Steam Vent Valve (Elevation 14)
e. OPEN the Mass Blowdown Root Valve (Edwards Valve) at the Drum (Elevation 14)
f. OPEN Chemical Feed Valve at the Drum (Elevation 14)
g. OPEN V-63 ISH Outlet Header Vent Valve (Elevation 5)
h. OPEN V-67 FSH Outlet Header Vent Valve (Elevation 5)
i. OPEN 2 rounds V-52 Cyclone Lower Ring Header Drain Valve (Elevation 5)
j. OPEN 2 rounds V-54 HRA Partition Wall Outlet Header Drain Valve (Elevation 5)
k. OPEN 2 rounds V-55 HRA Left Side Wall Inlet Drain Valve (Elevation 5)
l. OPEN 2 rounds V-56 HRA Right Side Wall Inlet Header Drain Valve (Elevation 5)
m. OPEN 2 rounds V-57 HRA Front Wall Inlet Header Drain Valve (Elevation 5)
n. OPEN 2 rounds V-59 Rear Wall Outlet/PSH Inlet Header Drain Valve (Elevation 5)
o. OPEN 2 rounds V-82/83 Reheater Inlet Header Drain Valves (Elevation 5)
p. OPEN 2 rounds V-69 FSH Outlet Header Drain Valve (Elevation 4)
q. OPEN 2 rounds V-62 ISH Inlet Header Drain Valve (Elevation 1)
r. CLOSE V-80 HRA Outlet Header Vent (verify closed) (Elevation 15.5)
s. CLOSE V-75 Economizer Inlet Header Drain Valve (Elevation 5)
t. OPEN Economizer Recirc Valves (DCS)
u. CLOSE FSH Outlet Tell-Tale Drain Valve (Elevation 4)
NOTE: The Intermediate Superheater (ISH), Finishing Superheater (FSH), and Reheat (RH)
Spray Block Valves should remain closed until the unit comes on line or sprays are
required. These valves have the potential to leak by and will cool the turbine steam,
resulting in water hammer.
v. CLOSE Finishing Superheater Spray Block Valves (Elevation 4)
w. CLOSE Intermediate Superheater Spray Block Valves (Elevation 2)
x. CLOSE Reheat Spray Block Valves (Elevation 1 platform)
y. CLOSE each Stripper Cooler Spray Block Valves double block and bleed
(Elevation 1)

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IRI Units 1 & 2

_____3. Verify that all eight (8) Downcomer Drains have flow. This ensures that they are
not plugged and that the Downcomers have water in them. Report any plugged
or partially plugged Downcomer drains to Process/Maintenance
Superintendents.
a. Individually check each Downcomer Drain for flow.
b. OPEN each of the drain valves several rounds, observe flow from the Quenching
Pot Sewer Hub.
c. CLOSE the associated drain valve.
d. Downcomer Drain Valves are as follows: V-46 A&B, V-47 A&B, V-84 A&B, V-85
A&B, V-86 A&B.
____4. Verify that all Boiler Doors are CLOSED. (Refer to the Boiler Doors List found in
section V).
a. Two (2) IRI and IMC individuals perform this step separately.
b. Starting at the 15
th
floor, verify all doors CLOSED and secured. Walk down the
Boiler all the way to the ground floor, including the Air Heater section.
c. Individually check and initial each door as closed on the Boiler Door List. Give
completed form to Control Operator Supervisor (COS).
____5. Verify the HRA and INTREX hanger pins have been removed after the HRA and
INTREX are drained.
a. Verify that pins are removed from the 26 hangers on top of the HRA.
b. Verify that pins are removed from the five (5) INTREX hangers (top) on Unit 1 and
the six (6) INTREX hangers (top) on Unit 2.
____6. Establish Boiler Air and Flue Gas flow path.
a. Refer to the DCS Open Path Graphic (RA02) to ensure that open path permissives
are satisfied.
b. Position associated dampers so that the red (OPEN) indication is displayed for
each component. Refer to the Air and Flue Gas Graphic (BA05) to identify the
specific damper / limit switch that is not in the correct position.
____7. START one (1) Induced Draft (ID) Fan.
a. Ensure a fan ready light is indicated on DCS
b. Line up cooling water to fan bearings on the fan to be started.
c. From the DCS, SELECT the ID Fan to be placed in service, and then select
START and ENTER. The DCS Boiler Air and Flue Gas Graphic is illustrated on
Figure 4.
d. After fan roll-up (approximately 60 seconds) and Outlet Damper comes open,
OPEN the inlet vanes to re-establish open path. (The ID Fan Inlet Damper should
be approximately 30 percent open after the fan starts, and then close back to

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IRI Units 1 & 2

barely open while maintaining a NOT CLOSED damper indication. Ensure
Furnace Pressure is negative)
e. Inspect bearing oil level and slinger ring rotation.
f. Monitor fan bearing vibrations and temperatures until they stabilize.
____8. START two (2) INTREX Blowers.
Permissives are as follows.
Inlet/bypass channel tall nozzles NOT CLOSED.
ISH and FSH dampers CLOSED.
ISH and FSH dampers stay closed until you are ready to place the INTREX in
service (between 25 and 35 MW.)
INTREX blower inlet damper CLOSED
Line up all Intrex flow and level transmitter purge air supplies and adjust to proper
flow
a. Select the INTREX blower to be placed in service.
b. Ensure a blower ready light is indicated on DCS
c. Select the START Target and ENTER.
d. OPEN the inlet damper.
e. Select the second INTREX Blower to be placed in service.
f. Select the START Target and ENTER.
g. OPEN the inlet damper.
h. Monitor the blower bearing temperatures and lubrication levels until they stabilize.
i. Set the setpoint to 9kpph flow on the tall nozzles.
j. Place the Controllers in AUTO.
k. Set the setpoint to 0kpph flow on the short nozzles and place in manual.
l. Place the INTREX pressure controller in AUTO with a setpoint of 140 IN WC if
there is no bed and a setpoint of 160 IN WC if there is bed in the furnace.
m. Monitor motor current on the running blowers - should remain between 20 and 30
amps.
n. Ensure all blower dampers are in cascade.
o. Place the third blower in auto standby.
____9. Place all (3) J-Valve Blowers in Service.
Permissives are as follows:
At least one (1) INTREX Blower must be running.
INTREX inlet/bypass dampers for tall nozzles are NOT CLOSED
Operate all J -Valve dampers so that no closed damper limits are made.
Line up all J -Valve flow and level transmitter purge air supplies and adjust to proper
flow.

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IRI Units 1 & 2

a. Select the J -Valve blower to be started. Ensure a blower ready light is indicated on
DCS.
b. Select the START Target.
c. Select ENTER.
d. Repeat previous steps to start the remaining blowers.
e. Put the J -Valve controllers in AUTO with the following setpoints:
E downleg at 110 IN WC
I downleg at 220 IN WC
A downleg at 500 IN WC
B upleg at 1000 IN WC
UI upleg at 335 IN WC
f. Place the J -valve Pressure Controller in AUTO, with a setpoint of 220 IN WC.
g. Verify that the J -Valve air to the Stripper Cooler transition duct is CLOSED.
h. Verify that all J -Valve air tap block valves are lined up and that all flow meters have
flow.
____10. Place all Induced Draft (ID) Fan inlet vanes in AUTO.
a. SELECT the furnace pressure controller.
b. OPERATE the controller manually to obtain a furnace pressure of (-2 IN WC).
c. Set the furnace pressure controller setpoint to (-2 IN WC)
d. Place the furnace pressure controller in AUTO.
____11. Place Primary Air (PA) and Secondary Air (SA) fan lube oil systems in service.
OPEN the cooling water inlet and outlet valves.
a. Verify that lube oil reservoir level is adequate.
b. START one (1) lube oil pump on each PA/SA Fan.
c. Set the standby oil pump to AUTO.
d. Verify lube oil pressure is adequate (approximately 40 to 60 psi downstream of the
pressure regulator.)
e. Adjust oil flow to bearings to maintain bearing temperatures at a value of less than
170 degrees Fahrenheit.
f. Verify block valve in oil tubing to each bearing is open and oil flow visible in sight
glass.
____12. Place one (1) Primary Air (PA) Fan in service.
a. SET the PA Furnace Plenum Air Damper controller to an output of 25 percent.
Visually verify both dampers are 25 percent open.
b. SELECT the PA fan to be placed in service. Select START, and ENTER.
c. After fan roll-up, (approximately 60 seconds) and outlet damper comes open.
SELECT the PA Duct Pressure controller and increase the pressure, in order to

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IRI Units 1 & 2

attain 25 percent airflow (180 kpph on each duct), as a permissive for the boiler
purge to start.
d. SET the INTREX Return Channel Air Flow Controller to a set point of 30 kpph and
when permissives are made place in AUTO.
e. Verify the Coke Sweep Air is indicating flow. These should be set at 15 kpph for
each feeder.
f. Set the Coke Feeder Variable Air Flow to 10 kpph for each feeder.
g. Set the Stripper Cooler Air Flow Controller for the Stripper compartment at 6 ft/sec
and the Cooler side at 16 kpph. When permissives are made place controllers in
AUTO.
h. Total Plenum airflow should be maximum 400 kpph (and no more) for Induct
Burners to light off.
i. Equalize PA Duct Plenums flow. The duct flows should be 180 to 200 kpph.
____13. Start one (1) Secondary Air (SA) Fan.
a. Verify Upper Overfire Air Damper is 25 percent open and Lower Overfire Air
Damper is 50 percent open.
b. Ensure a fan ready light is indicated on DCS.
c. SELECT the SA Fan to be placed in service, select START and ENTER. The Inlet
and Outlet Dampers will drive closed; fan will start.
d. After fan roll-up (approximately 60 seconds), and outlet damper comes open.
SELECT the SA Fan flow controller and SLOWLY OPEN the Inlet Vanes on the
running fan to re-establish open path. The Inlet Damper needs to be off the
CLOSED limit.
e. Continue slowly opening the SA Fan Inlet Damper to attain 25 percent air flow (225
kpph). This is a permissive for the boiler purge. Monitor furnace pressure.
f. Place SA Fan Flow Controller in AUTO with a set point of 225 kpph.
g. Verify Boiler Purge Timer started.
____14. Place the second ID Fan in service.
a. Line up cooling water to fan bearings on the fan to be placed in service.
b. SELECT the DCS Air/Flue gas graphic.
c. SELECT the Furnace Pressure Controller and SLOWLY INCREASE the setpoint to
+2 or +3 INWC.
d. SELECT the Inlet Damper of the fan to be place in service and place in MANUAL
MODE with an output of zero (0).
e. SELECT the ID Fan to be placed in service. Select START and ENTER.
f. After fan roll-up (approximately 60 seconds), and outlet damper comes open.
Balance fan motor amps by opening the Inlet Damper to match other fan.

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g. Once Furnace Pressure and dampers controls have stabilized put damper controls
in AUTO.
h. Observe fan bearing vibration and temperatures.
i. Slowly decrease the Furnace Pressure Controller setpoint to -2 INWC.
____15. Place the second PA Fan in service.
a. SELECT the DCS Air/Flue gas graphic
b. SELECT the Furnace Pressure Controller and SLOWLY DECREASE the set point
to -5 or -6 INWC.
c. SELECT the PA Fan Pressure Control Detail graphic.
d. SELECT the PA Fan Inlet Damper of the fan to be placed in service and place in
MANUAL MODE with an output of zero (0).
e. SELECT the PA Fan to be placed in service. Select START and ENTER
f. After fan roll-up (approximately 60 seconds), and outlet damper comes open.
Balance fan motor amps by opening the Inlet Dampers to match other fan.
g. Once PA pressure, flow and damper controls have stabilized place damper
controls in AUTO.
h. Monitor fan bearing vibration and temperatures.
i. Slowly decrease Furnace Pressure Controller setpoint to -2 INWC.
____16. Place the second SA Fan in service
a. SELECT the DCS Air/Flue Gas graphic.
b. SELECT the SA Fan Pressure Control Detail graphic.
c. SELECT the SA Fan Inlet Damper of the fan to be placed in service and place in
MANUAL MODE with an output of zero (0).
d. SELECT the SA Fan to be placed in service. Select START and ENTER.
e. After fan roll-up (approximately 60 seconds), and outlet damper comes open.
Balance fan motor amps by opening the Inlet Damper to match the other fan.
f. Once SA pressure, flow, and damper controls have stabilized place the damper
controller in AUTO.
____17. INTREX Return Channel Fluidization.
a. Observe the Plenum Air Flow Dampers to remain in the lower to middle operating
range (50-60 percent) and the INTREX Return Channel to remain fluidized with 30-
kpph airflow.
____18. Add Bed Material - Adding Bottom Ash through Limestone (L/S) Feeder Blowers
(If all bed material was removed during outage, 150 tons will need to be added)
(If only J -Valve and Intrex bed material was removed, 50 tons will need to be added.
a. With blowers OFF, OPEN the tie-in valves. (These are the blue valves on the 4th
elevation.)

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b. Have the truck driver hook into piping on the ground floor.
c. Put L/S Blowers in LOCAL and turn ON.
d. Make sure both Furnace gates come OPEN.
e. Do not put Rotary Air Locks (RAL's) on. This will help keep the blower safeties
from lifting.
f. Have truck driver START his blower and slowly start feeding bed ash into the line.
g. If Blower safeties start lifting, have truck driver throttle back on his valve.
____19. Check all Boiler doors in the pressurized section of the furnace and INTREX.
a. Inspect all INTREX and lower furnace doors to be sealed with no leaks.
____20. Initiate a Boiler Purge.
a. SELECT the DCS Boiler Purge Graphic
b. All listed permissives should have a red box to the left indicating that each has
been attained.
c. Once all permissives have been met, the 5-minute boiler purge should start
automatically.
____21. Reset Boiler Master Fuel Trip (MFT)
a. SELECT the DCS Burner Management Graphic
b. The Purge Complete green target should be lit.
c. SELECT the MFT Reset and hit ENTER.
d. The Purge Complete Target will turn red, and on the Burner Management page
(RA01), the First Outs will turn green.
____22. Place Steam Coil Air Heaters in service
a. OPEN the low point trap before the auxiliary steam pressure regulator (Elevation
9).
b. OPEN the low point drain before the Primary and Secondary Steam Coil
temperature controllers. The Set point should be at 175 degrees Fahrenheit. (This
is for the Average Cold-end Temperature at the Air Heater Gas outlet.)
c. OPEN the Auxiliary Steam Connection Root Valve V-94 (Elevation 15.5).
d. OPEN the Crossover Valve at Unit No. 1 Pressure Regulator (Elevation 9).
e. SELECT the DCS Condensate Collection Graphic (FB01) and SLOWLY OPEN the
Auxiliary Steam Pressure Regulator.
f. Slowly increase the pressure to 125 psi. Then place the controller in AUTO.
____23. Place Hotwell Make-up pump in service.
a. Open inlet and outlet valves.
b. Open the Recric. valve 25 percent.
c. Line up Hotwell make-up block valve to bottom of hotwell and closed to sprays,
(only during startup.)

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d. Start pump and if need to adjust recric valve so pump has sufficient flow.
____24. Start Condensate Recirculation Pump.
a. Verify Suction and Discharge valves are OPEN.
b. Place the Condensate Recirculation Pump Control switch in the START position.
____25. Start a Condensate Pump. Condensate Pumps are illustrated on the Feedwater
System Graphic shown on Figure 8.
a. Check the Megalert to be in a safe range.
b. Verify the Suction, Balance, Recirc, and packing water block valves are OPEN on
the pump to be started.
c. Verify Condensate recirculation regulator is lined up for service.
d. CLOSE both Condensate pump discharge valves.
e. Close Feedwater main regulator and Feedwater Startup regulator.
f. SELECT the Condensate Pump to be started. Select the START Command, and
hit ENTER.
g. After the pump starts throttle pump discharge valve to maintain no more than 200
psig at Pump discharge.
h. Monitor DA level, manually, maintaining between 65 and 75 inches.
i. Monitor motor amp load and bearing temperature as flow to the boiler is
established.
j. Verify Turbine Hood Sprays to be open.
____26. Place Methoxypropyl-amine (MPA), Phosphate, and Nalco Elimin-Ox (Oxygen
scavenger) Pumps in service.
a. Verify tanks have adequate chemical level.
b. Verify that suction and discharge valves are OPEN.
c. Manually start chemical pumps.
d. One (1) Phosphate pump should be started at continuous feed. (Stroke will be
whatever the setting was at Shut Down.)
e. The MPA and Elimin-Ox stroke should be set at 70 percent.
f. A Condensate Pump should be in service at all times while feeding chemicals.
g. Verify the Chemical Injection Block Valves on the Condensate Discharge Header
are lined up.
h. Verify that the Mixing Water Valves at the Boiler Feed Booster Pump (BFBP)
Recirc. (Deaerator tank) are in the OPEN position.
i. Verify Phosphate injection valve at the boiler drum is in open position.

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____27. Line up Fuel Gas to Induct Burners
a. Ensure the Fuel Gas Supply Valve is CLOSED.
b. OPEN vent valve on fuel gas supply line.
c. Thoroughly clean out the flange area, disk, and the blank before opening valve.
(This ensures that no trash enters the line and helps keep the gas regulators and
Induct Burner tips clean.)
d. OPEN the valve, PULL OUT the blank, SWAP it over and INSTALL the disk in the
open position.
e. CLOSE the vent valves.
f. SLOWLY OPEN the Main Gas Supply Valve.
g. Check the gas spacer for leaks. If a leak is found:
CLOSE the Main Gas Supply valve
OPEN the vent valve
PULL the disk
CLEAN it off
REPOSITION the disk
PULL UP on the valve
PRESSURIZE it once again.
h. OPEN the two (2) valves going to the A and B sides of the Gas Skid.
i. Verify the gas pressure upstream of the regulator is approximately 150 psi, and the
gas pressure downstream of the regulator is 70 psi - at the Pilot Regulator.
____28. Purge Induct Burners
a. SELECT the DCS Induct Burner Graphic (illustrated on Figure 9).
b. Select RESET the "A" Burner
c. Select PURGE on the "A" Burner (5 minutes)
d. After 5 minutes Purge Complete target will turn red indicating purge complete.
e. Repeat steps "B" and "C" for the "B" Burner.
____29. Place Induct Burner in service (after burner purge is completed)
a. SELECT the Induct Burner Graphic.
b. SELECT the Pilot on one (1) of the burners. Select the START target and ENTER.
When the Pilot lights off, the green indication for the regulator will change to red.
The vent valve indication will change to green. (If the pilot does not light off, you
will have to reset and go through the purge process again.)
c. After the Pilot lights off, SELECT the burner target, hit START and ENTER.
d. Selected Burner target will turn red indicating burner in service.
e. Repeat steps "B" and "C" for the second burner to be put in service.

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f. Enter a setpoint of 200 degrees Fahrenheit for A and B Induct Burner Temperature
Control Valves and place in AUTO. (It should take about 10 minutes to reach 200
degrees Fahrenheit).
g. Hold 200 degrees Fahrenheit for 15 minutes. Then raise set point to 300 degrees
Fahrenheit.
h. Raise the temperature at a rate of 100 degrees every 30 minutes, until you reach
600 degrees Fahrenheit. [This should take about two (2) hours].
i. After reaching 600 degrees Fahrenheit, raise temperature at a rate of 100 degrees
per hour until you reach 1600 degrees Fahrenheit.
____30. Line up Cold Reheat (CRH) Start-up Tanks
Note: Unit 1 has one (1) startup tank and Unit 2 has two (2) startup tanks.
a. Open SUV-04 and SUV-02
b. Before raising vacuum on the Turbine, drain the Drip Pot on the Cold Reheat Line
using drain SUD-01 to the floor.
c. After tank is drained CLOSE SUV-02.
d. Unlock and CLOSE the block valve SUD-02 before the CRH drain valve.
e. Verify CRH startup valve (SUV-01) is CLOSED
f. CLOSE drain valve SUD-01
g. Verify the atmospheric vent (SUV-03) is CLOSED.
h. Re OPEN CRH Drip pot startup tank vent valves (SUV-02 and SUV-04).

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Hi Level
Switch
HI HI Level
Switch
SUV-04
SUV-02
SUV-03
Drip Pot
SUD-01
SUV-01
Quenching Pot
Well
Water
Supply
CRH Drain
Vv
CRH Drip Pot
Startup Tank
Flex Hose
Drain Vent
Cold Reheat Line
SUD-02
Floor
Drain
Cold Reheat Drip Pot Startup Tank

____31. Line up Superheat and Reheat Pass Dampers for startup
a. Use the Hydraulic Ram to close off the Reheat Damper to zero (0) percent.
b. OPEN the Superheat Damper to 100 percent. (Damper positioners are located on
the 10th elevation). (There is no steam flow in the Reheat Tubes at this time so
flue gas/ash flow over the tubes would cause overheating and possible failure.)
____32. PA/SA Air Heater Gas Inlet Damper
a. Put the PA/SA Gas Inlet Damper Controller in AUTO, with a setpoint of 0.

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IRI Units 1 & 2

____33. Check doors on pressurized sections of the Boiler.
a. Verify (8) INTREX Door Seals do not leak
b. Verify Furnace and Furnace Plenum doors do not leak.
c. Verify INTREX Drains to floor do not leak.
____34. Adjust Stripper Cooler (S/C) Air Flows.
a. Verify the cooling water block valves on the ground floor are closed, double block
and bleed line.
b. Verify the Stripper Air Flow Controller is in AUTO with a setpoint of 6 ft/sec.
c. Verify the Cooler Air Flow Controller is in Auto with a setpoint of 16 kpph
d. Remember keep S/C Rotary Air Locks (RAL's) off until needed.
____35. Place the Baghouse in service.
a. When the Baghouse inlet temperature reaches 200 degrees Fahrenheit, the
baghouse should go into service automatically.
b. The Reverse Air Fan inlet damper needs to be in closed position.
c. START one Reverse Air Fan and OPEN the inlet damper to 100 percent open.
d. Verify that all the baghouse dampers (Inlets, Outlets, Reverse, and Bypass) are in
the normal operating mode.
____36. Place Pegging Steam on the Deaerator from an alternate Unit.
a. Ensure that the auxiliary steam Edwards valves on the running unit are open.
b. OPEN the telltale drain to floor a couple of rounds to get water out.
c. SLOWLY OPEN the chain valve off the Auxiliary Steam Header located on the
Deaerator floor.
d. OPEN inlet and outlet block valves on the pressure control valve.
e. OPEN the vent bypass valve.
f. SELECT the DCS Aux/Export Steam Graphic.
g. SELECT the Auxiliary Steam Pressure Controller to the Deaerator and CRACK
OPEN the valve manually.
h. CLOSE the telltale-drain after all water is out.
i. Manually adjust pressure control to obtain 7psig. Once pressure is stable, place
controller in Auto mode with 7psig set point..
____37. Line up drains around the Main Steam Lead MOV to Blowdown Tank.
a. OPEN the Main Steam Lead upper bypass valve.
b. OPEN the drain around the Main Steam Lead to the Blowdown Tank wide open.
c. Keep the bottom drain valve that goes to Main Stop Valves closed.

16
IRI Units 1 & 2

____38. Line up the Turbine.
a. Make sure by physical verification, that the Turbine is on TURNING GEAR
b. Verify that the Load Limit is fully lowered
c. Verify that the green light on the Turbine Governor is energized. (Indicates valves
are closed.)
d. Verify that Turbine is tripped.
e. Verify hood sprays are lined up.
f. CLOSE the Gland Steam supply and bypass valves
g. TURN all five (5) Cuno filters:
Handwheel on the Turbine Front Standard for the Relay Oil
Cuno filter down under the grating at #5 Turbine Generator Bearing
Cuno filter in the Generator Doghouse at #6 Turbine Generator Bearing
Cuno filter for the East Reheat Stop and Intercept Valves
Cuno filter for the West Reheat Stop and Intercept Valves.
____39. Line up Turbine Drains before pulling vacuum.
a. Gland Steam trap bypass valve to Condenser - OPEN 2 rounds
b. Gland Steam trap drain to floor - OPEN 2 rounds.
c. Cold Reheat trap bypass valve to Condenser - OPEN 2 rounds.
d. Cold Reheat trap drain to floor - WIDE OPEN.
e. Hot Reheat Steam Lead strainer drain valve - OPEN to the Hot Reheat trap.
f. Hot Reheat trap bypass valve to Condenser - OPEN 2 rounds.
g. Hot Reheat trap drain to floor - WIDE OPEN.
h. Four (4) Hot Reheat after seat drains to Condenser WIDE OPEN.
i. Two (2) Hot Reheat before seat drain valves to floor - OPEN 2 rounds.
j. Verify two (2) Cold Reheat header drain valves are OPEN to Cold Reheat trap.
k. Diaphragm Unloading and Balanced Piston drain valves OPEN 2 rounds
l. Verify air supply to Diaphragm Unloading and Balanced Piston drain valves are
OPEN.
m. Three (3) Second Point Extraction drain valves - WIDE OPEN.
n. Three (3) Third Point Extraction drain valves - WIDE OPEN.
o. Three (3) Fourth Point Extraction drain valves wide open.
p. Two (2) Fifth Point Extraction drain valves - WIDE OPEN.
q. Before Main Stops drains to floor - OPEN one (1) round.
r. Inlet Bend Manifold drain block valve - OPEN two (2) rounds.
s. Steam Chest drain block valve - OPEN two (2) rounds.
t. Inner Cylinder drain block valve - OPEN two (2) rounds.

17
IRI Units 1 & 2

____40. Vent the Boiler Feed Booster Pump (BFBP) Seals.
It is recommended that while using low temperature condensate water during startup,
that the Boiler Feed Booster Pump (BFBP) Seals be vented. This is to prevent them
from being air bound during low flow.
a. CRACK OPEN vent lines on feedwater side of seal cooler only long enough to get
a steady flow of water with no air.
b. Continue periodic venting of all seals in this manner until after a continuous flow of
feed water is established in the startup.
c. Vent the cooling waterside in the same manner to ensure that the coolers do not
become air bound.
____41 Upon reaching Boiler Drum Pressure of 25 psi:
Close each of the following:
a. V-58 HRA Partition Wall Inlet Header Vent Valve (Elevation 15.5)
b. V-60 PSH Outlet Header Vent (Elevation 15.5)
c. V-27 (2) Boiler DRUM VENTS (Elevation 14.5)
d. V-51 Cyclone Cooling Steam Vent Valve (Elevation 14)
e. V-52 Cyclone Lower Ring Header Drain Valve (Elevation 5)
f. V-54 HRA Partition Wall Outlet Header Drain Valve (Elevation 5)
g. V-55 HRA Left Side Wall Inlet Header Drain Valve (Elevation 5)
h. V-56 HRA Right Side Wall Inlet Header Drain Valve (Elevation 5)
i. V-57 HRA Front Wall Inlet Header Drain Valve (Elevation 5)
j. V-59 Rear Wall Outlet/PSH Inlet Header Drain Valve (Elevation 5)
k. V-82/83 Reheater Inlet Header Drain Valves (Elevation 5)
l. V-63 ISH Outlet Header Vent Valve (Elevation 5)
m. V-67 FSH Outlet Header Vent Valve (Elevation 5)
n. V-69 FSH Outlet Header Drain Valve (Elevation 4)
o. V-65 FSH Inlet Header Drain Valve (Elevation 1)
p. V-62 ISH Inlet Header Drain Valve (Elevation 1)
Note: Monitor Drum Level and manually control level using the Startup regulator or main
feed-water regulator.
____42 Place Circulating Water Pump in service.
a. Verify the meg-alert is in a safe range.
b. OPEN Condenser Water Box outlets and inlet valves.
c. VENT Condenser Water Boxes and confirm vents to flow water and be void of air.
d. Confirm that an adequate level is in the Cooling Tower Basin and the Sabine River
Authority (SRA) make-up is lined up for service.
e. Verify the packing cooling water is lined up.

18
IRI Units 1 & 2

f. SELECT the DCS Circulating Water pump graphic

Circulating Water Pumps Graphic

g. SELECT the Circulating Water Pump to be placed in service, select the START
target and ENTER.
h. Monitor the discharge valve position (comes OPEN as pump comes up to speed),
and monitor the bearing temperatures and motor current until pump is stabilized.
i. After pump is in service, OPEN all condenser vent valves on the water boxes,
Turbine Oil coolers and H2 coolers to confirm full of water and void of air then
close.
j. Continue periodic venting of water boxes and coolers during startup.
k. Start 2 groups of cooling tower fans.
____43. Verify that Feedwater Heaters are lined up for service.
a. Verify inlet and outlet valves are OPEN. Bypass valve should be CLOSED.
b. Verify all Normal Drip Block Valves are open and regulators lined up.
c. Verify the 5th Point Heater Recirc (Drip) Pump is line up properly.
d. Manually rotate shaft of 5
th
point heater Recirc. pump and inspect for leaks.
e. Verify the Deaerator Level Controller is lined up for service.

19
IRI Units 1 & 2

f. If the heater level goes high, OPEN the drain on the Drip Line and the bypass to
atmosphere. CLOSE off when drained, or pulling vacuum.
____44. Line up Boiler Feed Pump for service.
a. Verify the Megalert is in a safe range.
b. Verify the Suction valve is OPEN.
c. Verify the Discharge MOV valve is CLOSED.
d. Verify the Discharge bypass valve is CLOSED.
e. Verify the balance line to the Deaerator Storage Tank is OPEN (sleeve in place).
f. Verify the pump drains are CLOSED.
g. Verify that recirculation valve block valves are OPEN and air supply to Recirc.
valve is OPEN.
h. Select the Recirc controller on DCS and put to OPEN. This will keep the Recirc.
valve OPEN until adequate feed water is established (around 35 MW's).
i. Verify that packing gland water supply is OPEN.
j. Verify that oil cooler cooling water inlet and outlet valves are OPEN.
k. Verify that oil reservoir level is adequate. Rotate Cuno oil filter.
l. Put Auxiliary Oil Pump local switch in AUTO. It will start. Oil pressure should be
between 12 to 20 psi).
____45. Start the Boiler Feed pump.
a. Set the Recirc. Controller in the OPEN position, this will help keep drum level from
swinging.
b. SELECT the Boiler feed pump to be started, select START and ENTER.
c. Monitor pump amp loading and bearing temperatures until current and
temperatures stabilize.
d. Manually adjust Deaerator level to 72-inches, make sure controller is lined up and
in service.
e. Manually adjust startup regulator to maintain steam drum level.
f. Monitor all heater levels as the Boiler is pressurized.
____46. Warm the Cold Reheat line
Make sure the turbine is still on Turning Gear.
a. Verify Turbine is on Turning Gear. (again)
b. Turn all Turbine Cuno filters. (again)
c. Check all IRI Export Steam (NISV) isolation block valves to be OPEN.
d. OPEN all lower drip pot drains on Export Line to the floor.
e. Verify that the Condenser vacuum breaker is OPEN. If it is not OPEN it.
f. Verify all turbine drains are OPEN.

20
IRI Units 1 & 2

g. SLOWLY OPEN the warm-up globe valve (Export steam from opposing unit) to 1/4
round open. This is the valve between the Unit 1 and 2 export lines, located on the
Mezzanine floor above old control room.
h. Monitor the Following:
Cold Reheat temperature at the Reheat spray nozzle to achieve 200 degrees
Fahrenheit.
Turbine Hood temperatures to get 140 degrees Fahrenheit.
Check the Vacuum Breaker periodically to verify that no steam is escaping.
DO NOT PRESSURIZE THE LP TURBINE.
i. Continue to increase flow on the warm-up line at the rate of 1/4 round ever hour
until 200 degrees Fahrenheit Cold Reheat temperature at the Reheat spray nozzle
has been established.
j. Maintain temperature on the Cold Reheat (CRH) and Hot Reheat (HRH) Lines at
200 degrees Fahrenheit.
k. CLOSE WARM-UP LINE BEFORE ROLLING TURBINE
____47. Warm the Main Steam Lead (400 psi on boiler Drum).
a. Verify the Turbine is on Turning Gear. Visually verify that the Governor valves are
CLOSED.
b. OPEN the Hogger steam supply drain valve two (2) rounds.
c. SLOWLY OPEN Auxiliary steam supply valve above the Main Steam Lead (This is
the Hogger Steam supply.)
d. CLOSE steam drain valves before the Main Stop valves to 1/4 round open.
e. SLOWLY OPEN the lower rear Main Steam Lead MOV Bypass Valve.
f. After pressure is equalized across the Main Steam Lead, let the line heat up for
about 30 minutes
Note: Make sure turbine is still on Turning Gear.
g. Open the Main Steam Lead MOV to about 10% using the local pushbutton. Wait
about 5 minutes open MOV to 20%, wait 5 more minutes and open to 30%. After
30% and no problems with noise or leaks, MOV can be opened 100%.
h. After the main steam lead MOV is fully open, CLOSE BACK on the lower rear valve
(valve to blow down tank) to two (2) rounds open.
____48. Line up the Electromatic Relief Valve (ERV) at 500 psi on the FSH Outlet.
a. Place Control room switch for the ERV in the OFF position (Controls are illustrated
on Figure 18.
b. SLOWLY OPEN the block valve at the ERV, (Elevation 5)
c. Verify the ERV is not leaking through.
d. Place the ERV controller in AUTO.

21
IRI Units 1 & 2

____49. At 550 psi and 550 degrees Fahrenheit, send FSH Outlet Steam to Export Steam
header. (This will help to obtain 100 degrees Fahrenheit superheat steam
temperature).
a. Notify SASOL of change in steam quality, of higher temperature.
b. Verify the Auxiliary Steam Orifice Drains at the Mezzanine Floor and the ground
floor are OPEN.
c. Verify MOV 3 (Auxiliary Steam Block to the export supply) is OPEN.
d. Verify that Auxiliary Steam Pressure Regulator PCV-3 is CLOSED.
e. SLOWLY OPEN the two (2) Edwards Hammer Supply Valves. (These are the root
valves to PCV-3.)
f. Increase the Auxiliary Steam Header Pressure to 550 psi using the local pressure
controller.
g. SELECT the Auxiliary/Export Steam Header Pressure Controller, on the
Aux/Export Steam Graphic, and SLOWLY OPEN to allow a maximum of 50 kpph
flow at SASOL, not to exceed 525 psi at PCV-4.
h. The pressure will have to be monitored as it changes, and adjusted at the local
pressure controller.
i. After Drum pressure is above 600 psig and the steam flow is adequate, place the
drum Feedwater Controller in the normal mode.
j. When the Drum Pressure reaches 800 psi, notify the Lab Personnel so that they
can perform lab sample analysis.
____50. Warm and pressurize the steam chest, at 550 psi and 550 degrees Fahrenheit at
the FSH Outlet.
a. Verify the Turbine is on Turning Gear and turn all Cuno Filters (again).
b. SELECT the DCS Turbine Lube Graphic.
c. SELECT and START the Auxiliary Oil pump and check system for adequate
pressure (at or above 150 psi) and no leaks.
d. SELECT the Turbine Emergency Bearing oil pump and the Emergency Seal oil
pump and place these pumps in stand-by (not locked out).
e. RESET the turbine trip relay 95X in the Relay Room on the first floor.
Note: The Stop valve that has the by-pass will remain closed. Once warming is complete, the
bypass will have to be manually cranked down and then back open. This will allow the
Stop Valve to come open.
f. Check Turbine to be tripped, load limit at zero (0) position and the Governor to be
closed, as indicated by the green light being illuminated on the control board.
g. Physically verify that the Governor valves are CLOSED.
h. PUSH IN the Vacuum Reset Button on Turbine Front Pedestal.

22
IRI Units 1 & 2

i. PUSH IN and HOLD the Turbine Reset device until Relay and Intermediate oil
pressure increases above 150 psi.
j. CLOSE BACK on the three (3) Steam Chest Drain Valves to 1/2 round OPEN.
k. Visually confirm the Diaphragm Unloading Dump valve and the Balance Piston
Dump valve to be FULLY CLOSED and no air is leaking from Pilot Valve vents.
l. Verify that the Gland Steam, Cold Reheat, and Hot Reheat trap drain valves to the
floor are OPEN.
m. Visually confirm Reheat Stops and Intercept valves to be FULLY OPEN.
n. Heat and pressurize Steam Chest by opening and closing the Main Stop valve [the
one (1) without the bypass valve] alternately, five (5) second cycles for five (5)
minutes and then 10 second cycles for 10 minutes. Monitor that the Turbine does
not roll off of Turning Gear.
Make sure Turbine is still on TURNING GEAR.
o. After the 10-minute sequence, leave the Main Stop valve OPEN.
p. Physically crank the bypass valve on the other Main Stop valve, down to reach a
closed limit. Then crank it back up to get the open limit on the Main Stop valve.
q. Control Lube Oil temperature to 110 degrees Fahrenheit by throttling circulating
water out of the coolers.
____51. Operate the INTREX Protection Vent Valves to attain 100 degrees Superheat
Steam temperature.
a. Ensure that export steam via auxiliary steam system is at maximum. Call SASOL
as required to increase steam take.
b. SELECT the DCS Steam and Water Graphic.
c. As Main Steam Pressure increases to approximately 1200 psi, the INTREX
protection vent valves can be opened to achieve the desired 100 degrees
superheat temperature. (Refer to Etapro point ID #513)
d. INTREX protection vent valves can also be used to control pressure as required.
____52. Line up the Finishing Superheater (FSH) and Intermediate Superheater (ISH)
sprays.
a. At 900 psi Drum Pressure, OPEN the block valves before and after the spray
regulators.
b. FSH sprays are on the 4th Floor.
c. ISH sprays are on the 2nd floor.
____53. Verify that Warm-up steam to the Cold Reheat Line is CLOSED.

23
IRI Units 1 & 2

Turbine Warm-up and Roll up
Initial Conditions
A. Turbine must be on Turning Gear and eccentricity should be less than 3 mils.
B. Generator should have Hydrogen pressure of at least 10 psi and the Hydrogen Seal Oil
system in service.
C. All Turbine Oil Systems and Turbine Oil Pumps should be test run for availability for
service.
D. Turbine Bearing Oil temperature should be maintained at 90 degrees Fahrenheit
minimum while on Turning Gear and increased to minimum of 110 degrees Fahrenheit
prior to roll-off.
E. All Clearances are cleared on required equipment and the equipment is in a safe mode to
operate.
F. Refer to the Turbine metal temperature graphic to determine turbine minimum HP/IP
inner cylinder casing temperature. Select lowest of points 7, 8, 13, or 14 on the DCS
Turbine Graphic
G. Refer to Siemens Startup Curves (page 75) to determined minimum hold times at 1000
and 3600 rpms.

____1. Prepare for and pull vacuum. (Ensure that Boiler Pressure is at or greater than
1000 psi.)
a. Verify the Turbine is on Turning Gear.
b. CLOSE both atmospheric Hot Reheat Drains before the stop valves.
c. CLOSE Hot and Cold Reheat atmospheric drains.
d. Line up the Cold Reheat Start-up Tanks for vacuum (Note: Unit 1 has one startup
tank and Unit 2 has two startup tanks). Refer to figure on page 22.
Drain CRH line to floor then close SUD-02.
Close block valve before the CRH Quenching Pot.
Verify CRH Startup valve SUV-01 to be closed.
Close CRH Startup Tank drain valve SUD-01.
Verify atmospheric vent on top of Startup tank SUV-03 is closed.
Open CRH drip post start-up tank vent valves SUV-02 and SUV-04.
e. CLOSE the Main Steam drain valves before stop valves.
f. OPEN Gland Steam supply valve and Gland Steam Bypass valve.
g. OPEN cooling water to Gland Steam Cooler one (1) round.
h. START the Gland Steam Exhauster
i. START the 5th Point Heater Drip Pump

24
IRI Units 1 & 2

j. Verify that the idle Condensate Pump has adequate packing water.
k. Valve out the Tygon tubing at the Hotwell
l. CLOSE the Vacuum Breaker to a cracked open position.
m. OPEN the Hogger jet steam supply valve, regulate to 300 psi.
n. OPEN the air valve.
o. CLOSE the Hogger steam supply drain and establish condenser vacuum,
approximately 24-inches or greater.
p. Verify that the Turbine does not roll off Turning Gear.
____2. Put both Air Ejectors in service. Placing Air Ejectors in service:
1.) Verify that the Secondary Drain Trap is lined up for service
2.) Verify that the Primary Drain Valve is open
3.) Verify that the Secondary Drain Valve is open
4.) Verify that the Vacuum Breaker is cracked open
5.) OPEN the Secondary Steam Valve
6.) OPEN the Secondary Air Valve
7.) Verify that the Primary J et Discharge Valve is open
8.) OPEN the Primary Steam Valve
9.) Function Test the Air Ejector
10.) OPEN the Primary Air Valve
11.) Repeat steps 3 through 10 for the second Air Ejector.

25
IRI Units 1 & 2

26

b. Blocking in a Faulty Air Ejector

Primary Secondary
Vent
Primary Steam
Secondary Steam
Air Suction (Secondary)
Air Suction (Condenser
Air Ejector Test
Connection
(Normally
Plugged
Primary J et
Discharge Valve
Secondary Drain
Valve (West)
Primary Drain
Valve (East)
To Condenser
To Atmosphere
Secondary Drain Trap
Primary Loop Seal Drain
NO
NC
NC
NO
NO
Secondary Air Valve
Cutaway View of Single Air Ejector
Primary Air
Valve
IRI Units 1 & 2

1.) CLOSE the Primary Air Valve
2.) CLOSE the Primary Steam Valve
3.) CLOSE the Secondary Air Valve
4.) CLOSE the Secondary Steam Valve
c. Adjust inlet steam pressure to 375 psi.
d. Close drain valve.
e. Periodically check and adjust inlet steam pressure, it will change as boiler
conditions change.
f. Function test air ejectors for proper operation and performance.
1.) Remove bull plug and hook-up manometer to test connection.
2.) Close Air valve to function test of air ejector.
3.) Document vacuum, should read approximately 26 to 27 WC.
4.) Reinstall bull plug in test connection.
5.) Repeat with other of air ejector.
6.) Report vacuum readings to Production Supt. and IRI Operations Mgr.
g. Verify that the turbine does not roll off turning gear.
____3. Upon reaching 800 psi Drum pressure Contact Lab personnel for sample
analysis.
____4. Warm-up the Turbine
a. Verify the Turbine is on Turning Gear.
b. All Turbine valves (Main Stops, Reheat Stops and Intercepts) should be open and
showing a red open limit on the DCS.
c. Verify the Turbine Gland Steam regulator is in service, open supply block valve and
by-pass at the Northeast corner of the Turbine, this will start the Turbine warming.
d. Allow Turbine to warm until the LP Hood temperature is about 140 to 150 degrees
Fahrenheit on the Turbine Exhaust end.
e. At this point if Steam pressure and temperature has 100 degrees Superheat, the
Turbine is ready to roll.
f. If the steam does not have 100 degrees Superheat, notify SASOL and increase the
Auxiliary Steam flow to a maximum of 80 kpph. If this is still not enough, OPEN the
INTREX Protection Vent Valves.
____5. Place the coke feeders in service.
a. Conditions to Start feeding coke:
Bed level of +15 inches
Bed temperature greater than 1000 degrees Fahrenheit
Induct burners temperature greater than 1600 degrees Fahrenheit
b. SELECT the coke feeder hand switches, select the START target and ENTER.

27
IRI Units 1 & 2

c. SELECT the coke feeder flow controllers and place them in NORMAL.
d. SELECT the Fuel Master and start feeding coke, attempting to establish a flow of
0.5 kpph on each feeder.
e. Place the Variable Air Damper Controller in AUTO, with a setpoint of 10 kpph per
feeder, for a total of 100 kpph.
f. As Bed temperature increases above 1200 degrees Fahrenheit, start reducing
Induct Burners by 50 degrees Fahrenheit per hour on each induct burner.
g. When Bed temperature starts to decrease, add coke, at about 0.5 percent more
output on the Fuel Master controller.
h. When Bed temperature gets to 1300 degrees Fahrenheit, start-removing gas at a
rate of 100 degrees Fahrenheit per hour on each induct burner.
i. Continue adding coke (but be careful not to add too much) and lowering Induct
temperatures.
j. When Bed temperature reaches 1350 to 1450 degrees Fahrenheit, Induct setpoints
should be about 1000 degrees Fahrenheit.
Note: Limestone should not be added until Bed Temperature is greater than or equal to 1500
degrees Fahrenheit and SOx is greater than or equal to 350 ppm. After SOx is back in
range, decrease Limestone flow.
____6. Roll-up the Turbine - Check Steam Turbine Start up curves.
a. Maintain 1000 to 1200 psig on the FSH outlet by operating the INTREX protection
vent valves.
b. Ensure the Turbine Control Valves are closed and the Load Limiter knob on the
turbine front standard is in the closed position.
c. LOWER the Governor Control switch (Old Control Room) until the green light is
illuminated on the bench board.
d. CLOSE the vacuum breaker.
e. INCREASE the Hogger steam pressure to 500 psi to pull as much vacuum as
possible.
f. Maintain air ejector steam pressure at 350 psig.
g. Verify Turbine Drains are positioned in required positions per the Turbine Drain
Arrangement found in appendix.
h. Turbine roll up should be performed in compliance with the SIEMENS start up
curves, page 75. (Recommendation is to use the Load Limiter up to the speed of
approximately 3400 RPM's.) After the Load Limiter is fully open, use the Turbine
Governor Control Switch (Old Control Room) to run up to 3600 rpm's.
Note: A minimum of 100 to 150 degrees Superheat is required to start the Turbine Roll. With
a Main Steam pressure of 1000 psi and a temperature of 700 degrees Fahrenheit,

28
IRI Units 1 & 2

there are 155 degrees of superheat. Refer to the Steam Tables or to the Etapro to
determine the degrees of superheat contained in the Main Steam for the given
pressure and temperature.
i. Monitor Turbine vibration and bearing temperatures in either the IRI or Old Control
Room.
j. Close the Main Exciter ACB just after the turbine rolls off Turning Gear, switch is on
the bench board in the Old Control Room. This will start the Main Transformer
Fans and Oil Pumps,
k. Verify all Transformer Fans are selected to run continuously.
l. Manually start the Collector Ring Blower and verify it is running.
m. Inspect Main Transformer Oil Pumps and Fans and verify they are running.
____7. Place Hydrogen Coolers in service.
a. Shut off Generator Shutdown heater.
b. Shut off the Recirculation Pump.
c. CLOSE the make-up water supply water.
d. OPEN the cooler inlet and outlet valves and vent until the cooler is void of air then
close the vents.

Generator Synchronization and Increasing Load to Full Load
Initial Conditions
A. Turbine warm-up has been completed in compliance with SIEMENS recommendations.
B. At least one (1) Generator Air Circuit Breaker (ACB) is available for service and its
associated disconnects are CLOSED.
C. Generator Hydrogen pressure is at least 10 psi and the Hydrogen Seal Oil System in
service. (Normal Hydrogen Pressure is 30 psig.)
D. All Turbine Oil System and Turbine Oil pumps have been test run for determination of
availability.
E. Turbine Bearing Oil temperature is maintained at minimum of 90 degrees Fahrenheit
while on Turning Gear and increased to a minimum of 110 degrees Fahrenheit prior to
roll-off.
F. DC Emergency Oil Pumps are in the stand-by mode, (not locked out).
G. The Static Exciter System is available for service.
H. All Clearances are cleared on required equipment and the equipment is in a safe
condition to operate.

29
IRI Units 1 & 2

____1. Prepare for and Synchronize the Generator to the Transmission Grid.
Note: Contact EMO that the unit is coming on line
a. After the Load Limiter is increased to 100 percent (approximately 3400 RPM's)
raise Turbine speed to 3600 RPM's using the Governor Control Switch on the
existing control room bench board.
b. At 3600 RPM's STOP the Auxiliary Oil Pump and observe the operating pressure
to ensure the Shaft Driven Oil Pump is maintaining adequate pressure.
c. At 3600 RPMs, STOP the Turning Gear and Main Seal Oil Pumps.
d. As Turbine approaches rated speed, verify that the Exciter Voltage Regulator is in
the MANUAL MODE on the DCS.
e. Verify that the target light is not illuminated on the Pride Relay. (If it is lit, RESET
with target reset button).
f. From the DCS, CLOSE the Exciter Field Breaker.
g. At 3600 RPM's INSERT the synchroscope switch and SELECT the Generator ACB
to be closed.
h. ADJ UST turbine speed so the synchroscope is turning slowly in the fast direction.
i. SELECT the volts mode on the Volts/Hertz meter on the south wall of the existing
control room.
j. INCREASE the exciter voltage using the Exciter Manual control hand switch on the
DCS until the Voltage reads 117-118 volts on the Volts/Hertz meter.
k. Place the Exciter voltage control in AUTO.
l. With the synchroscope turning slowly in the fast direction, CLOSE the selected
generator ACB when the scope reaches the 12 O'clock position.
m. YOU ARE NOW ON LINE. Record the time in the logbook.
n. CLOSE the INTREX Vent protection valves. Take Auxiliary Steam out of Export
line and block in at hammer valves.
o. ADJ UST voltage to obtain approximately five (5) MVARS, place VAR control in
automatic with set point of 5 MVARS, and INCREASE LOAD to 5 to 10 MWs. Hold
this load until HP and IP metal temperatures have decreased their rate of change
to less than 100 degrees Fahrenheit per hour.
p. Remove the Hogger from service.
Slowly CLOSE the air valve while monitoring system vacuum
CLOSE the steam block valve.
CLOSE the drain valve
q. Contact the COS to verify vacuum is stable.
r. Periodically check Air Ejector steam pressure, it will change with Boiler changes.

30
IRI Units 1 & 2

____2. Monitor and Control the Reheat Temperatures.
a. After the generator is placed on line RH temperature will significantly increase.
Sprays may be required to control temperatures.
b. OPEN the Reheat Spray Block Valves and verify valves are not leaking through..
c. Manually adjust spray control valve as required to maintain RH temperature.
____3. Remove the Steam Coil Air Heater (SCAH) from service.
a. Isolate the Steam Coil heaters from service.
____4. At 10 MWs perform each of the following steps:
a. CLOSE the second Generator breaker (ACB).
b. CLOSE the gland steam bypass valve as gland steam pressure permits.
c. OPEN the Gland steam dump by-pass valve as needed.
d. RACK IN and then CLOSE the Normal Station Service (NSS) 2400V breaker.
e. OPEN the Reserve Station Service (RSS) 2400V breaker after verifying the NSS
breaker is paralleled.
____5. DCS Governor Control and Export Steam capability.
a. Reset Relay 86TX
b. TEST the governor controls from the DCS.
c. Return Boiler Level Drum trips to service.
d. Line up export steam valves and use as needed. Normal export will not be
available from cold reheat system until approximately 90MW.
____6. Increase Coke feed rate and decrease Fuel Gas flow.
a. Continue to gradually increase the coke feed rate and decrease the fuel gas flow to
the furnace until the bed temperature is greater than 1500 degrees Fahrenheit and
the excess 0
2
is stable (greater than 4.5 percent).
b. All coke feeders should be in service before fuel gas flow is reduced to zero.
c. Induct Burners should be on until reaching about 40 to 50 MWs.
d. Place limestone feeders in service when bed temperature is greater than 1500
degrees Fahrenheit and SO2 at or approaching 350 ppm.
____7. At 20 MW's
a. Start rest of cooling tower fans, have someone visually verify all fans running.
b. Position turbine drain valves as directed by Turbine Drains List found in Section IV
of this procedure - 20 MW load
c. CLOSE the Exhaust Hood Sprays block valves.
d. CLOSE both Economizer Recirculation Valves (from the Steam and Water
Graphic).
e. Verify the drum level controller is controlling level and is in NORMAL mode..

31
IRI Units 1 & 2

f. Place the Boiler Feed Pump recirculation valve controller in AUTO. (The Recirc.
Valve should close).
g. CLOSE the Deaerator vent bypass valve.
NOTE: Assuming no major equipment problems, ramp boiler and turbine at a rate of 5 mws per
hour until to reach full load, should take approximately 24 hours.
____8. Increase Primary and Secondary Airflow and Coke Feed Rate.
a. Increase PA, SA flow, and the coke feed rate to establish a bed temperature of
1600 degrees Fahrenheit and excess O
2
to 5.3 percent.
____9. Place the Soot Blowers in service. The Soot Blower Control Panel is illustrated on
Figure 39.
a. OPEN the Soot Blower Steam Supply Valve.
b. SELECT the Warming Mode on the soot blower control panel
c. Check the Thermal Drains to be lined up and operating.
d. Bypass valves should be cracked open to warm the header.
e. Put Soot Blower sequences in service, in CR (1-4 groups)
____10. At 30 to 40 MWs, place INTEX in service
Mointor bed temperatures, should be betwee 1500 and 1600 degrees Fahrenheit.
Start the third INTREX blower.
Manually adjust Intrex Blowers pressure to 160 IN WC. Once stablized put controller in Auto with
setpoint of 160 IN WC.
a. Manually open ISH air controller while monitoring bed temperature.
b. Continue to open controller until ISH airflow is about 18 to 20 kpph. This should
take about 30 minutes to complete.
c. Once bed temperature is stabilizes place the ISH air controller in Auto with a set
point of 20 kpph.
d. Monitor the bed temperature and if stable prepare to place FSH air controller in
service.
e. Manually open FSH air controller while monitoring bed temperature. Continue to
open controller until FSH airflow is about 18 to 20 kpph. This should take about 30
minutes to complete.
f. Once bed temperature is stabilized place the FSH air controller in Auto with a set
point of 20 kpph.
g. Bed temperature may momentarily decrease. You will have to add coke to get bed
temperature under control.
h. Take Induct Burners out of service at about 40 to 50 MWs and line up for back up.
i. Reset Inducts and Purge.

32
IRI Units 1 & 2

____11. After INTEX is placed in service, place hot well make-up pump in service and line
up to condenser sprays
____12. At approximately 60 MWs place second Circulating Water Pump in service
a. Verify megalert in safe range
b. Verify cooling tower at adequate level
c. START pump
d. Verify discharge valve opened
____13. At approximately 60 to 80 MWs place Boiler Feed Booster Pump (BFBP) in
service.
a. START the BFBP Auxiliary lube oil pump. (It should already be running).
b. Verify motor meggared and in safe range.
c. Following valves should be lined up:
d. Pump Suction - OPEN
e. Pump Discharge MOV - OPEN
f. Warm-up valve Three (3) rounds OPEN
g. Recirculation Block Valves - OPEN
h. Verify pump drains are closed.
i. Verify oil reservoir has adequate level.
j. Verify cooling water lined up to seals and oil coolers.
k. Line up the air supply to the Recirculation Flow Controller valve. Make sure the
Recirc. Valve has a closed indication and is not leaking through.
l. The BFBP should already be warmed.
m. Select BFBP to be placed in service
n. Select START target and enter
o. Monitor motor amps and vibration until pump is stabilized
p. The Auxiliary lube oil pump will shut down if oil pressure is adequate.
q. Place stand-by BFBP in remote AUTO.
____14. RH/SH pass dampers
e. Put SH pass damper to 100 percent open
f. Slowly open RH pass damper to 50 percent open. Manually adjust reheat sprays
as required to maintain temperature below 1008 degrees Fahrenheit.
g. Automate RH and SH sprays when temperatures reach 950 degrees Fahrenheit
with set points of 1008 degrees.
h. Adjust ISH and FSH splits so that ISH has 70 percent of the SH flow and FSH has
approximately 30 percent of the flow.

33
IRI Units 1 & 2

____15. At approximately 100 to 110 MWs, individually inspect all six (6) governor valves
and verify 100 percent open. Communicate if any valves not 100 percent open
and ensure a work request is written.
____16. Place Sand Feeder in service and resume scheduled sand injection schedule.
____17. Place Stripper Coolers in Service. Test run both RALs for proper operation.
____18. Put Export Steam in service.
a. Hot Reheat pressure at 500 psiq.
b. Check all associated block valves in export steam to be lined up.
c. Open MOV and adjust so both units are sharing export steam.
____19. Perform a detailed walkdown of the old side and new side to verify all
appropriate drain /blowdown valves are properly blocked and not leaking
through. Ensure a work request is written for any leaking valves.
____20. Check the DCS for Disabled and Inactive Alarms.
Note: It is very important to check the DCS for Disabled and Inactive Alarms.
a. Return all alarms to normal conditions.
b. Write Work Requests for all alarms not working, stating associated problem(s).

34
IRI Units 1 & 2

IV. Valve Lists
Boiler Firing Valve Preparation (Startup)
Valve Description Position at
Startup
Drum
Pressure @
25 psi
Valve
Location
V-58 HRA Partition Wall Inlet Header Vent
Valve
OPEN CLOSED Elevation
15.5
V-60 PSH Outlet Header Vent Valve OPEN CLOSED Elevation
15.5
V-27 Drum Vents (2) OPEN CLOSED Elevation
14.5
V-51 Cyclone Cooling Steam Vent Valve OPEN CLOSED Elevation 14
Mass Blowdown Root Valve (Edwards Valve)
at the Drum
OPEN OPEN Elevation 14
Chemical Feed Valve at the Drum OPEN OPEN Elevation 14
V-63 ISH Outlet Header Vent Valve OPEN CLOSED Elevation 5
V-67 FSH Outlet Header Vent Valve OPEN CLOSED Elevation 5
V-58 HRA Partition Inlet Vent OPEN 2
rounds
CLOSED Elevation 5
V-52 Cyclone Lower Ring Header Drain Valve OPEN 2
rounds
CLOSED Elevation 5
V-54 HRA Partition Wall Outlet Header Drain
Valve
OPEN 2
rounds
CLOSED Elevation 5
V-55 HRA Left Side Wall Inlet Drain Valve OPEN 2
rounds
CLOSED Elevation 5
V-56 HRA Right Side Wall Inlet Header Drain
Valve
OPEN 2
rounds
CLOSED Elevation 5
V-57 HRA Front Wall Inlet Header Drain Valve OPEN 2
rounds
CLOSED Elevation 5
V-59 Rear Wall Outlet/PSH Inlet Header Drain
Valve
OPEN 2
rounds
CLOSED Elevation 5
V-82/83 Reheater Inlet Header Drain Valves OPEN 2
rounds
CLOSED Elevation 5
V-69 FSH Outlet Header Drain Valve OPEN 2
rounds
CLOSED Elevation 4

35
IRI Units 1 & 2

Startup
Drum
Pressure @
25 psi
Valve
Location
V-62 ISH Inlet Header Drain Valve OPEN 2
rounds
CLOSED Elevation 1
V-80 HRH Outlet Header Vent (verify closed) CLOSED CLOSED Elevation
15.5
V-75 Economizer Inlet Header Drain Valve CLOSED CLOSED Elevation 5
FSH Outlet Tell-Tale Drain Valve Drain Valve CLOSED CLOSED Elevation 4
Finishing Superheater Spray Block Valves CLOSED CLOSED Elevation 4
Intermediate Superheater Spray Block Valves CLOSED CLOSED Elevation 2
Reheat Spray Block Valves CLOSED CLOSED Elevation 1
platform
Stripper Cooler Spray Block Valves CLOSED CLOSED Elevation 1

NOTE: The Intermediate Superheater (ISH), Finishing Superheater (FSH), and Reheat (RH)
Spray Block Valves should remain closed until the unit comes on line or sprays are
required. These valves have the potential to leak by and will cool the turbine steam,
resulting in water hammer.

Steam Coil Air Heater Startup
Startup
Valve Location
Low point trap before the Auxiliary Steam
pressure regulator
OPEN (Elevation 9).
Low point drain before the Primary and
Secondary Steam Coil temperature controllers.
OPEN (Elevation 3)
Auxiliary Steam Connection Root Valve V-94 OPEN (Elevation 15.5).
Crossover Valve at Unit No. 1 Pressure
Regulator
OPEN (Elevation 9).

36
IRI Units 1 & 2

Condensate and Feedwater Pumps
Valve Description Position at Startup
Condensate Recirc Pump Reach Rod OPEN
Condensate Recirc Pump Suction Valve OPEN
Condensate Recirc Pump Discharge valves OPEN
Condensate Pump Suction Block Valves OPEN
Condensate Pump Recirc Block Valves OPEN
Condensate Pump Seal Water Block Valves OPEN
Condensate Pump Discharge Valve CLOSE
Boiler Feed Pump Discharge MOV Valve CLOSED
Boiler Feed Pump Discharge Bypass Valve CLOSED
Boiler Feed Pump Balance Line To The Deaerator Storage Tank OPEN (sleeve in
place)
Boiler Feed Pump Drains CLOSED
Boiler Feed Pump Recirculation Valve Block Valves OPEN
Boiler Feed Pump Air Supply To Recirc. Valve OPEN
Boiler Feed Pump Packing Gland Water Supply OPEN
Boiler Feed Pump Oil Cooler Cooling Water Inlet And Outlet Valves OPEN
Mixing Water Valves At The Boiler Feed Booster Pump (BFBP)
Recirc. (Deaerator Tank)
OPEN
Boiler Feed Booster Pump Suction Valve OPEN
Boiler Feed Booster Pump Discharge Valve OPEN
Boiler Feed Booster Pump Warm-up Valves Three (3) rounds
OPEN
Boiler Feed Booster Pump Recirculation Block Valves OPEN
Air supply to the Boiler Feed Booster Pump Recirculation Flow
Controller valve
OPEN
Boiler Feed Booster Pump Recirc. Valve CLOSED

37
IRI Units 1 & 2

Turbine Valve Positions
Turbine Drains Valve Description Position
before
pulling
vacuum
Position
when full
vacuum is
being
pulled
Position at
20 MW
Gland Steam trap bypass valve to condenser 2 rounds
Open
Closed Closed
Gland Steam trap drain to floor 2 rounds
Open
Closed Closed
Cold Reheat trap bypass valve to Condenser 2 rounds
Open
2 rounds
Open
Closed
Cold Reheat trap drain to floor Wide Open Closed Closed
Hot Reheat Steam Lead strainer drain valve
to the Hot Reheat trap
Wide Open Wide Open Wide Open
Hot Reheat Trap bypass valve to Condenser 2 rounds
Open
2 rounds
Open
Closed
Hot Reheat trap drain to floor Wide Open Closed Closed
Hot Reheat after seat drains to Condenser
(4)
2 rounds
Open
2 rounds
Open
Closed
Hot Reheat before seat drain valves to the
floor (2)
2 rounds
Open
Closed Closed
Cold Reheat header drain valves to Cold
Reheat Trap (2)
Wide Open Open Open
Diaphragm Unloading and Balanced Piston
drain valves
2 rounds
Open
1 round
Open
Closed
Air supply to Diaphragm and Balanced Piston
drain valves
Wide Open Wide Open Wide Open
2
nd
Point Extraction drain valves (3) Wide Open 2 rounds
Open
Closed
3
rd
Open
Closed
4
th
Open
Closed
5
th
Open
Closed
Before Main Stops drains to floor 1 round Open Closed Closed

38
IRI Units 1 & 2

Turbine Drains Valve Description Position
before
pulling
vacuum
Position
when full
vacuum is
being
pulled
Position at
20 MW
Inlet Bend Manifold drain block valve 2 rounds
Open
2 rounds
Open
Closed
Steam Chest drain block valve Open 2
rounds
2 rounds
Open
Closed
Inner Cylinder drain block valve 2 rounds
Open
2 rounds
Open
Closed
(6) Steam Chest individual Valves Open at all
times
Open at all
times
Open at all
times

39
IRI Units 1 & 2

V. Access Doors
Boiler Doors
NOTE: SHADED CELLS ARE DOORS TO BE OPEN FOR UNIT COOL DOWN

Location/Description
Floor
Level

Label

Order:

Opened By:

Closed By:
HRA Penthouse 15 A 2
HRA Penthouse 15 B 2
HRA Penthouse 15 C 2

Furnace Penthouse 14 A 3
Cyclone Outlet 14 B 3
Reheat and Primary Superheat
(HRA)
14 C 3
(HRA)
14 D 3

Top of Cyclone 13 A 4
Top of Cyclone 13 B 4
Top of Cyclone 13 C 4
(HRA)
13 D 4
(HRA)
13 E 4

Furnace to Cyclone Crossover 12 A 5
Furnace to Cyclone Crossover 12 B 5
Furnace to Cyclone Crossover 12 C 5
(HRA)
12 D 5

40
IRI Units 1 & 2

Floor
Level

Label

Order:

Opened By:

Closed By:
(HRA)
12 E 5

(HRA)
10 A 6
(HRA)
10 B 6
(HRA)
10 C 6

Economizer Area 9 A
Economizer Area 9 B

Economizer Area 8 A

Bottom of Cyclone 7 A
Bottom of Cyclone 7 B
Bottom of Cyclone 7 C

Secondary Air Damper 6 A
Secondary Air Damper 6 B
Secondary Air Damper 6 C
Economizer Hopper 6 D
Economizer Hopper 1A-7 (East
Side)
6 E
Primary Air Duct 5 A

Secondary Air Duct 4 A
A J -Valve 4 B

41
IRI Units 1 & 2

Floor
Level

Label

Order:

Opened By:

Closed By:
INTREX Penthouse 4 C 7
B J -Valve 4 D
INTREX Penthouse 4 E 7
C J -Valve 4 F
INTREX Intermediate Superheat 4 G 7
A J -Valve UI Side 4 H
A J -Valve I Side 4 I
B J -Valve UI Side 4 J
B J -Valve I Side 4 K
C J -Valve UI Side 4 L
C J -Valve I Side 4 M
Furnace Floor 3 A
Finishing Superheat Unit 2
Intermediate Superheat
3 B
Intermediate Superheat Unit 2
Finishing Superheat
3 C
Intermediate Superheat Unit 2
Finishing Superheat
3 D

Stripper Cooler 2 A
Stripper Cooler Plenum 2 B
Stripper Cooler 2 C
Stripper Cooler Plenum 2 D
Furnace Plenum 2 E
Return Channel 2 F
INTREX (See note at bottom of
table) **
2 G
INTREX Plenum 2 H
Stripper Cooler 2 I

42
IRI Units 1 & 2

Floor
Level

Label

Order:

Opened By:

Closed By:
Stripper Cooler Plenum 2 J
Stripper Cooler Plenum 2 K
Stripper Cooler Plenum 2 L
Furnace Plenum 2 M
Return Channel 2 N
INTREX (See note at bottom of
table) **
2 O
INTREX Plenum 2 P

**Before closing INTREX doors be sure the INTREX drain stand pipes have been filled with Sand.**
Primary Air Duct 1 A
Primary Air Duct 1 B
Primary Air Duct 1 C
Secondary Air Fan Duct 1 D
Secondary Air Fan Duct 1 E
Secondary Air Fan Duct 1 F
Secondary Air Fan Duct 1 G
Secondary Air Fan Duct 1 H
Secondary Air Fan Duct 1 I
Primary Air Fan Duct 1 J
Primary Air Fan Duct 1 K
Primary Air Fan Duct 1 L
Primary Air Fan Duct 1 M

UNIT ONE ONLY
Return Channel Duct flange
(East Side Unit 1)
1 N
(East Side Unit 1)
1 O

43
IRI Units 1 & 2

Floor
Level

Label

Order:

Opened By:

Closed By:
(West Side Unit 1)
1 P
(West Side Unit 1)
1 Q

UNIT TWO ONLY
(East Side Unit 2)
1 N
(East Side Unit 2)
1 O
(West Side Unit 2)
1 P
(West Side Unit 2)
1 Q

44
IRI Units 1 & 2

Boiler Air Heater Doors

NOTE: SHADED CELLS ARE DOORS TO BE OPEN FOR UNIT COOL DOWN

Floor
Level

Label

Order:

Opened By:

Closed By:
Air Heater AH-6 A 1
Air Heater AH-6 B 1
Air Heater AH-6 C

Air Heater AH-5 A
Air Heater AH-5 B 1
Air Heater AH-5 C 1
Air Heater AH-5 D
Air Heater AH-5 E 1
Air Heater AH-5 F
Air Heater AH-5 G

Air Heater AH-4 A
Air Heater AH-4 B 1
Air Heater AH-4 C
Air Heater AH-4 D 1
Air Heater AH-4 E
Air Heater AH-4 F
Air Heater AH-4 G
Air Heater AH-4 H

Air Heater AH-3 A
Air Heater AH-3 B
Air Heater AH-3 C

45
IRI Units 1 & 2

Floor
Level

Label

Order:

Opened By:

Closed By:
Air Heater AH-3 D
Air Heater AH-3 E
Air Heater AH-3 F

Air Heater AH-2 A
Air Heater AH-2 B
Air Heater AH-2 C
Air Heater AH-2 D
Air Heater AH-2 E
Air Heater AH-2 F
Air Heater AH-2 G
Air Heater AH-3 H
Air Heater AH-3 I

46
IRI Units 1 & 2

Baghouse Doors
Location/Description Cell Label Order: Opened By: Closed By:
Cell Hopper Door A 1
Lower Cell Door North A 2N
Lower Cell Door South A 2S
Upper Cell Door North A 3N
Upper Cell Door South A 3S
Compartment Inlet A 4
Cell Hopper Door B 1
Lower Cell Door North B 2N
Lower Cell Door South B 2S
Upper Cell Door North B 3N
Upper Cell Door South B 3S
Cell Hopper Door C 1
Lower Cell Door North C 2N
Lower Cell Door South C 2S
Upper Cell Door North C 3N
Upper Cell Door South C 3S
Cell Hopper Door D 1
Lower Cell Door North D 2N
Lower Cell Door South D 2S
Upper Cell Door North D 3N
Upper Cell Door South D 3S
Cell Hopper Door E 1
Lower Cell Door North E 2N
Lower Cell Door South E 2S
Upper Cell Door North E 3N
Upper Cell Door South E 3S
Cell Hopper Door F 1
Lower Cell Door North F 2N

47
IRI Units 1 & 2

Location/Description Cell Label Order: Opened By: Closed By:
Lower Cell Door South F 2S
Upper Cell Door North F 3N
Upper Cell Door South F 3S
Cell Hopper Door G 1
Lower Cell Door North G 2N
Lower Cell Door South G 2S
Upper Cell Door North G 3N
Upper Cell Door South G 3S
Cell Hopper Door H 1
Lower Cell Door North H 2N
Lower Cell Door South H 2S
Upper Cell Door North H 3N
Upper Cell Door South H 3S

Cell Hopper Door I 1
Lower Cell Door North I 2N
Lower Cell Door South I 2S
Upper Cell Door North I 3N
Upper Cell Door South I 3S
Cell Hopper Door J 1
Lower Cell Door North J 2N
Lower Cell Door South J 2S
Upper Cell Door North J 3N
Upper Cell Door South J 3S
Baghouse Outlet Duct K 2
Inlet to Outlet Duct Access Door
(Inside Outlet Duct)
L 2
Top Door to Reverse Air Duct M 1

48
IRI Units 1 & 2

INTREX Inner Doors

Location/Description Door Opened By: Verified Closed By:
A Bypass Channel/FSH Wall 1
FSH/B Bypass Channel Wall 2
B Bypass Channel/ISH Wall 3
ISH/C Bypass Channel Wall 4

A
Bypass
Channel
4 1
C
Bypass
Channel
ISH
B
Bypass
Channel
FSH
2 3

2H 2P
Figure 40 - INTREX Plenum Doors
Note: This view is looking South

49
IRI Units 1 & 2

Steam Turbine Startup Curves

50

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Gulf Coast Plant Unit Cold Start-Up

IRI Units 1 & 2

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