Supercritical unit lightup and shutdown procedure

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SUPERCRITICAL UNIT STARTUP AND SHUTDOWN
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INTRODUCTION

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

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UNIT LIGHTUP, SYNCHRONISATION SHUTDOWN

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START-UP SEQUENCE

• BOP SYSTEM READYNESS
• BOILER FLUSHING COLD/HOT
• BOILER LINE UP AND LIGHT UP.
• TURBINE LINE UP.
• TURBINE ROLLING.
• SYNCHRONISATION
• PHASE CHANGE OVER
• FULL LOAD

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START UP MODES

• COLD START UPHP IP SHAFT METAL TEMP lt204C
• WARM START UP HP IP METAL TEMP IN BETWEEN 204
  TO 400C
• HOT START UP HP IP METAL TEMP gt400C

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Boiler
Economiser
2x7
FCS
111
8
2x7
LPT A
HPT
IPT
LPT B
5
5
6
6
7
7
7
7
3
8
8
8
8
RH
1
LPH -7A
LPH -7B
LPH -8A
HPH - 1
LPH -8B
Condensor (HP)
Condensor (LP)
Deaerator
HPH - 2
EXT From CRH
(MD BFBP 1x35)
TDBFP 2X50
HPH -3
CEP
3x50
1994 TPH
CPP
1482 TPH
LPH -6
LPH -5
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PRE STARTUP READYNESS

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

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WHY BCP ?

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

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BCP FILLING ,PURGING FLUSHING

• PURPOSE-
• - TO FILL THE MOTOR CAVITY.
• RECOMMENDED MOTOR FILLING WATER QUALITY
• CONDUCTIVITY lt1
  µs/cm
• BOILER FEED WATER
• TEMP.lt 45 OC
• CL- lt 50 PPM
• pH gt 6.5
• SUSPENDED
  SOLIDS lt 5 PPM
• FILLING,PURGING FLUSHING WATER REQUIREMENT
• MOTOR INITIAL FILLING FLOW RATE
  MAX. 5 L/MIN

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PRE BOILER FLUSHING

• START CEP.
• FILL DRAIN FROM DEAERATOR UNTIL REQUIRED WATER
  QUALITY IS ACHIEVED. ( Felt500 Ppb.)
• START MDBFP.
• START THE BOILER COLD/HOT FLUSHING TO REDUCE THE
  Fe SiO2 CONTENT IN FEED WATER.

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Boiler flushing
SP
SP
START-UP LINE
Sampling Fe
Above 500ppb
Below 500ppb
MIXER
BCP
WW
ECO
CW LINE
HOTWELL
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BOILER COLD FLUSHING

• COLD FLUSHING
• WATER WALL TEMP REQUIRED 105-120 DEG.C (TEMP
  MAINTAINED BY DEAERATOR PEGGING STEAM)
• COLD OPEN FLUSHING QUALIFIES Fe
  lt 500PPB
• 
  SiO2 lt 100PPB
• THEN CPU WILL BE TAKEN IN SERVICE TO REDUCE WATER
  LOSS AND IMPROVE QUALITY.
• COLD CYCLIC FLUSHING QUALIFIES Fe
  lt 100PPB
• 
  SIO2 lt 50PPB
• (ALL ANALYSIS FROM SEPARATOR DRAIN)

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BOILER HOT FLUSHING

• HOT FLUSHING
• WATER WALL TEMP REQUIRED 150-190 DEG.C (TAKE
  OIL GUNS OF BC ELEVATION)
• HOT OPEN FLUSHING START UP CRITERIA FE gt 100PPB
• 
  SIO2 gt 50PPB
• IF HOT CYCLIC FLUSHING CRITERIA IF FE lt
  100PPB
• 
  SIO2 lt 50PPB
• HOT CYCLIC FLUSHING QUALIFIES IF FE lt
  50PPB
• 
  SIO2 lt 30PPB
• AFTER COLD FLUSHING START BCP WITH MINIMUM 30
  FEED FLOW THROTTLE FRS VALVE.

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BOILER LINE UP AND LIGHT UP

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

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BOILER LINE UP AND LIGHT UP

• CONTINUOUS APH SOOT BLOWING TO BE DONE AT THE
  TIME OF OIL FIRING.
• PR RISING RATE- 0.05 MPA/MIN. BETWEEN 0-1 MPA
• PR RISING RATE 0.1 MPA/MIN. BETWEEN 1 2 MPA
• PR RISING RATE 0.2 MPA/MIN. ABOVE 2 MPA
• FURNACE EXIT GAS TEMP MUST BE BELOW 538C FOR
  REHEATER PROTECTION (UNTIL HP-LPBP IS CHARGED).
• CLOSE SH DRAINS AND VENTS AFTER ACHIEVING DEGREE
  OF SH 50 C ( CLOSE IT AFTER CHARGING HP-LP
  BYPASS).

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LDO/HFO GUN
Fuel Light Oil
Fuel Pressure 0.8MPa-2.0MPa
Fuel Flow 500kg/h -3000kg/h
Atomizing Air Pressure 0.6MPa-1.2MPa
Atomizing Air Flow 100-600kg/h
Ignition Method HESI (20 joules/spark)
Fuel Heavy Oil
Fuel Pressure 0.8MPa- 2.0MPa
Fuel Flow 1000-4000 kg/h
Atomizing Steam Pressure 0.8MPa-1.2MPa
Atomizing Steam Flow 100-400kg/h
Ignition Method HESI (20 joules/spark)
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TURBINE LINE UP

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

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TURBINE LINE UP

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

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COLD START UP CURVE
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HOT ROLLING
MS TEMP
RH TEMP
SPEED
MS FLOW
LOAD
MS PRESS
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PRE HEATING OF HP CASING.

• PREHEATING OF HPT REQUIRED WHEN INNER METAL TEMP
  lt150C.
• CRH PR 0.5-0.7 MPA/220-380C.
• OPEN PRE HEATING VALVE (REVERSE FLOW VALVE)
  GRADUALLY.
• OPEN BDV VALVE FULLY.
• OPEN CRH DRAIN BEFORE NRV AND HPT-IPT CASING
  DRAINS.
• HEATING RATE SHOULD NOT BE MORE THAN 50C PER HR.
• HP CASING TOP-BOTTOM INNER-OUTER WALL METAL
  TEMP DIFFRENCE SHOULD BE WITHIN 50C.
• AFTER ATTAINING THE CASING TEMP gt 150C CLOSE THE
  RFV VALVE AND OPEN HP CYLINDER VENTILATION VALVE
  TO CONDENSOR.

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TURBINE WARM UP OPERATION

MS
HPBP
IPT
HPT
Ventilator valve
CRH NRV
TO CONDENSER
BDV
RFV
TO CONDENSER
CRH LINE
TURBINE STARUP PROCEDURE
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TURBINE ROLLING

• AS PER REQUIREMENT OF START UP CURVE, FIRING TO
  BE INCREASED.
• REQUIRED STEAM PARAMETERS BEFORE ROLLING
• MS PR 8.73 MPA, TEMP 330-380 C
• RH PR 1.1 MPA , TEMP 330C
• - THE DEGREE OF SUPER HEAT gt 56C.
• AFTER LATCHING THE TURBINE, START IP ROLLING WITH
  HP VENT TO CONDENSER IN OPEN CONDITION TO KEEP
  THE HPT IN VACUUM.
• MSV 12 AND RSV 12 ARE IN OPEN CONDITION.
• GIVE THE SPEED SET POINT TO 600 RPM
• CHECK THE TURBINE SUPERVISORY INSTRUMENT
  PARAMETER.
• THE ECCENTRICITY SHOULD BE LESS THAN 0.076 MM.

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TURBINE ROLLING

• SELECT TARGET SPEED 1500 RPM WITH RAMP RATE OF
  100 RPM/MIN.
• ENSURE ALL HP CVS OPENS TO 12 TO WARM UP THE HP
  CASING.
• WHEN HP CASING TEMP gt320C.CLOSE THE HP CVS.
• SOAK THE TURBINE FOR 4 HRS ACCORDING TO THE
  START UP CURVE.
• CHARGE THE LP HEATER 5 6 BEFORE 3000 RPM
• SELECT TARGET SPEED TO 3000 RPM WITH RAMP RATE OF
  100 RPM/MIN.SOAK IT FOR 30 MIN AS PER S/U CURVE.
• AS PER PROCEDURE SYNCHRONISE THE UNIT.

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LOADING

• AFTER SYNCHRONISATION INITIAL LOAD WILL BE 30
  MW.HOLD IT FOR 30 MIN AND CHEK THE VIBRATION,
  BEARING TEMP, DIFF EXPANSION, CASING EXPANSION.
• CHARGE EXTRACTION STEAM TO DEAERATOR.
• TAKE MORE OIL GUNS IN EF/AB ELEVETION.
• TAKE PA FANS SEAL AIR FAN.
• AFTER ACHIEVING FURNACE TEMP. MORE THEN 450C.
  TAKE COAL MILL-B AT. STEAM T/PR 380C/8.7 MPA.
• INCREASE FUEL FLOW MAINTAINING STEAM TEMP. RAISE
  LOAD
• AT 70 MW IP TO HP CHANGE OVER. CVS WILL START
  OPENING, CLOSE THE BDV AND VENTILATING VALVE.
• INCREASE THE LOAD AT 3MW/MIN
• CLOSE THE HP-LP BYPASS GRADULLY.

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LOADING CURVE
WET TO DRY CHANGE OVER
IP TO HP CHANGE OVER (70MW)
OIL GUN CUT OUT (260MW)
2ND TDBFP CUT IN(180MW)
MILL-C CUT IN AT 100MW
MILL-D CIT IN (300MW)
HPH CHARGED(150 MW)
MILL-E CUT IN (430MW)
MILL-F CUT IN (540MW)
MILL-A CUT IN(210MW)
SYNCHRONISE CHARGE D/A
MILL-B CUT IN
660
660 MW
495
330MW
LOAD (MW)
330
198MW
165
60MW
33MW
350
400
450
500
550
600
650
MINUTES
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LPT A
LPT B
FROM IPT EXHAUST
2nd
2nd
4th
4th
5th
5th
5th
5th
6th
6th
6th
6th
LP HEATER 7A
LP HEATER 7B
LP HEATER 8B
LP HEATER 8A
CONDENSER
CONDENSER
HP HEATER 5
LP HEATER 5
HP HEATER 6
LP HEATER 6
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TDBFP START UP

• TAKE ONE TDBFP IN SERVICE( CHANGE OVER WITH MD
  BFP) WHILE DRIVING STEAM IS AVAILABLE. SECOND TD
  BFP WILL BE TAKEN AT 180 MW.
• WARM UP THE TURBINE.
• SLOWLY OPEN THE AUX STEAM MOV TO TURBINE.
• PARAMETERS FOR ROLLING TDBFP.
• STEAM PRESSURE 0.61.3MPA, STEAM TEMP 50
  DEG C MORE THAN CASING TEMP.
• ROLL THE TDBFP AS PER PROCEDURE.
• GIVE THE TARGET SPEED 500 RPM AND THAN TO 1000
  HOLD FOR 40 MIN.CHECK THE TSI PARAMETER
• WHEN SPEED REACHES 2840 RPM, GIVE REQUEST COMMAND
  FROM FW MENU. THEN SELECT CCS CONTROL IN FROM
  MEH MENU.

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TDBFP STEAM SOURCES
IP
HP
1.3 MPa 350 ºC
1.12 Mpa 378 ºC
Aux. Steam Header
Aux. Steam Header
Changeover Valve
From CRH
4 MPa 315.3 ºC
TDBFP-B
To Condenser
TDBFP-A
Booster pumps
Deaerator
Deaerator
2/8/2019
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LOADING

• TAKE THE MILL-C IN SERVICE AT 100 MW. STEAM
  T/PR400C/8.7 MPA.
• GRADUALLY WITH DRAW THE OIL SUPPORT AS PER THE
  FLAME CONDITION.
• INCREASE THE LOAD TO 150 MW AND TAKE THE HPH-3,
  HPH-2
• HPH-1 IN SERVICE. MS T/PR 410C/8.7 MPA.
• AT 180 MW TAKE SECOND TDBFP IN SERVICE.

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MS LINE
HRH LINE
IP EXHAUST
CRH LINE
HP TURBINE
IP TURBINE
5th stage
9th stage
TDBFP A
TDBFP B
HP HEATER 3
HP HEATER 1
HP HEATER 1
HP HEATER 3
HP HEATER 2
HP HEATER 2
DEAERATOR
DEAERATOR
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PHASE CHANGE FROM WET TO DRY MODE

• DURING LOAD RAISING gt25 BMCR, THE BCP FLOW AND
  FEED WATER FLOW TO BE MONITORED CLOSELY.
• THE BCP FLOW NEED TO BE ADJUSTED W.R.T SEPERATOR
  TANK LEVEL AND THE SAME FLOW TO BE ADJUSTED IN
  FEED WATER FLOW TO MAINTAIN TOTAL FEED WATER FLOW
  TO ECONOMISER CONSTANT.
• WHEN BOILER STEAMING RATE RISES TO gt30 BMCR,
  W.R.T FUEL FIRING, THE SEPERATOR LEVEL REDUCES .
• ONCE THE CONDITION FULFILLS THE BCP STOPS AND
  FEED FLOW CONTROL CHANGES OVER FRS.
• AFTER STOPPING BCP IT ACTS AS SUB-CRITICAL ONCE
  THROUGH.
• WHEN THE STEAM PR REACHES 22.1 MPA IT IS IN
  SUPERCRITICAL ZONE

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LOADING

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

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Boiler Design Parameters
NO. Parameters Unit
1 100 BMCR Coal consumption (Design) 390.37 t/h
2 Design fuel Indian coal Indian coal
3 Superheated steam flow 2111 t/h
4 Superheater outlet pressure 25.4 MPa
5 Superheater outlet temperature 569 ?
6 Reheated steam flow 1749.1 t/h
7 Reheater inlet pressure 4.73 MPa
8 Reheater outlet pressure 4.49 MPa
9 Reheater inlet temperature 324 ?
10 Reheater outlet temperature 569 ?
Feedwater pressure 28.8 MPa.g
11 Feedwater temperature 280 ?
12 Separators steam temperature 421 ?
13 Air preheaters outlet air temperature, uncorrected After correcting 153.3 ?
13 Air preheaters outlet air temperature, uncorrected After correcting 147.2 ?
14 Calculating thermal efficiency of boiler 87.19(BMCR) 87.19(BMCR)
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TURBINE PARAMETERS
Steam Admission Parameters at Turbine Inlet
HPT IPT LPT Pressure (MPa) 24.2 3.961 1.12
I/L Temp (Deg C) 566 566 378 O/L Temp(deg C)
315.3 378 Steam Flow
(tph) 1959.25 1649 TURBINE HEAT RATE(
KCL/KWH) 1885 No of Stop valves 2 2 No of
Control valves 4 4
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TURBINE AT FULL LOAD
3.96MPa / 566c
HRH
24.2MPa/566ºC
1.12MPa / 378c
RSV
RSV
RSV
MS LINE
CV
CV
MSV
MSV
CV
MSV
CV
IPT
CV
CV
CV
HPT
TO BLR RH
CRH
GEN
GEN
LPT
2
LPT
2
LPT
2
LPT
1
LPT
LPT
LPT
CRH
RCV
RCV
RCV
RCV
CV
CV
CV
CV
CV
CV
CV
CONDENSOR A
CONDENSOR B
MSV
CV
CV
MSV
CV
CV
MSV
CV
MSV
CV
MSV
CV
CV
MSV
CV
MSV
CV
MSV
CV
RSV
RSV
RSV
MS LINE
HRH
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SHUT DOWN

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

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SHUT DOWN

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

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SHUT DOWN

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

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SHUT DOWN CURVE
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COOL DOWN CURVE
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THANK YOU