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KUMAf?

o NA TI0NAL P0 WER TRAINING INSTITUTE


NAGPUR

O 210 MW POWER PLANT SIMULATOR


o
c
o
0 OPERATING INSTRUCTIONS MANUAL
O.

NATIONAL POWER TRAINING INSTITUTE


SOUTH AMBAZARI ROAD
XJ
. GOPAL NAGAR
O NAGPUR 22
m
o
o

C 0 N 1 E N
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Si . Top ic: Page
0 No,, No.

o
1. COLD START UP OF U N I T 1
o
2. PLANNED SHUT DOWN OF UNIT 64
o
3. SHUT DOWN TO HOT STAND-BY OF UNIT 81
o
4. HOT RESTART OF UNIT 88
o
5. AUTOMATIC TURBINE RUN-UP SYSTEM AND 95
O SGC OIL LOGICS
Q 6. INTERLOCKS AND PROTECTIONS OF UNIT 116
0 7. CRITERIA CURVES FOR ROLLING THE TURBINE 145
AND SYNCHRONISING THE GENERATOR
o
8. THERMAL SCHEMATIC DIAGRAMS 152

O
o
n
o PROCEDURE FOR STARTUP OF THE UNIT FROM COLD CONDITION

o yC-l CHARGING OF 6_^ KV ELECTRICAL SUPPLY SYSTEM


E-l Ensure that ;220 KV Grid is charged.-- Ref.Tag

Station Transformer 220 KV Breaker key is in "ON1 MCL2


o position at MCL-2. All BTSP (BTPS-1,BTPS-2,BTPS-3,
BTPS-4) are out. Station Transformer-2 is in
charged condition. , .J,
:
E-2 Through local operation close isolator from grid to :

station transformer-1. (Bus-1 or Bus-2 side) (RFED05)


%^ E-3 Through local operation close station transformer-1
6.6 KV side isolator. (RFED-08)
o E-4 Through local operation close station transformer-1
220 KV breaker. ( RFED-12)

E-5 Through local operation close station boards OCC


O C D ' s a l l 6.6 K V o u t g o i n g f e e d e r s . (RFED) f ":>'-'

CHARGING OF 6_^6 KV SWITCH BOARD

E-6 Close STN BD OCA INCOMER BREAKER Stn. board QCA MCL2
o volt meter will show 6.6 KV.

E'-7 Close STN BOARD OCB INCOMER BREAKER Stn.Board OCB "
o
Voltmeter will show 6.6 KV. .'.

E-8 TIE BREAKER BETWEEN STN BUS OCD & OCB. /,


G E-9 TIE BREAKER BETWEEN STN BUS OCC & OCA. "

E-10 Close TIE BREAKER BETWEEN UNIT BD ICA & STN BD OCA. MCL1

Unit Board ICA voltmeter will show 6.6 KV. ' -r ^.^ ........ , ~ ,.

E -11 Close TIE BREAKER BETWEEN UNIT BD ICB & STN BDS OCB. "
tJ
Unit Board ICB voltmeter wil] show S.S KV.'
E-12 Close all 6.6 KV outgoing feeders at ICA & ICB. MCL1
E-13 Close incomer-1 and incomer-2 Bkr. to Board IDA. "
E-14 Close all 6 . 6 KV outgoing feeders at OCA & OCB. MCL2
E-.15 Close incomer-1 and incomer-2 Breaker to Bus ODA. MCL2

E-16 Through local operation (Case_ rf_ ups_ close)

charge UPS-l,UPS-2; 220 V charger-1 & charger-2.

C-2 STARTING OF G S WATER PUMPS \0 ' r


J
Before starting G S Water pump check following:
1. Electrical supply is available to GSW Pumps.
2. Sump level is normal.
3. Over head tank outlet valves GSW-132 & GSW-133 are open.

4. G S over head tank incoming valves GSW-115 and GSW-114


are open.

5. Breakers are racked in and DC control supply is"ON 1 .


Start G S water pump-A, check motor current of 30 A.

$f Open GSW recirculation valve CW-44 (RFCW001) by 20%


locally. Open Discharge Valve DV-39 .f cw-3=0

GSW OVER HEAD TANK LEVEL will increase slowly and

wait till GSW OVER HEAD TANK LEVEL HIGH alarm appears.

C-3 STARTING OF SERVICE AIR AND INSTRUMENT AIR COMPRESSORS !?->

Before starting service air and instrument air compressors

check following:

l.GS water supply is available to the compressors.

2.I/L, O/L valves of all air receivers are open.

(IA07,IA10,IA8,IA11,IA09,IA12,IA01,IA04,IA02,IA05 IA03,IA06)

3.IA-15 valve is initially closed.


/"I

o
o
Start SAC-A & SAC-B and establish service air header pressure

at 7 to 8 kg/cm2. Check that service air compressor trouble

^ indication resets and air pressure low indication resets.

,f^ Start instrument air compressors A & B and establish 7 to 8

fh Kg/cm2 instrument air header pressure.

#| Indication of instrument^ air header pressure will reset.


O Ensure that the inter-connecting valve between IAC and SAC -is

Q> closed and can be opened if required during emergency.


ID C-4 CHARGING OF CW SYSTEM AND STARTING CW PUMPS
<rs Before charging CW System check following:
f>\ 1. CW sump level is normal.
fr, 2. Cooling water 0/L valves from condenser to cooling towers
g\ , >'"' are in open position.
I7 '
r>) 3. Electrical supply to CW pumps is available.

f~) 4. Check Condenser water box vents are open initially and

f*, close locally after charging.

O Open COND CW I/L Valve CW-48 & Valve CW-49.


Q Open COND CW 0/L Valve CW-55 & Valve CW-56.
P Start CW PUMP-1 from CWA-15 desk.
Q Discharge valve will open (20%) initially and then later-
Q on opens fully.
Q Ammeter reading of CW PUMP-1 will show 140 amps.
Q CW PR COND A I/L pressure will show 2 to 2.2 kg/cm2.
Q Start CW pump-2 from CWA-15 desk.
DISCHARGE VALVE CW-16 will open by 20% initially and

after time delay will open completely.

CW PUMP-2 will show 14 0 amps.

CW PR COND B I/L pressure will show 2 to 2.2 kg/cm2

and DP 0.3 5 kg/cm 2. ( ' 3V

j6-S OPENING BOILER SIDE VENTS AND DRAINS

Before filling Boiler drum open locally Boiler drum

vent valve B-5, startup vent valves S-32, S-33, SH vent


i"f- jV- ' f 15.
valves S-40, S-21, S-25, S-30. ^J
x ^
Open RH vent valves R-l and R-4.
Open SH drains S-15, S-17, S-19.

't-' Open B-95 ring header drain valve.


1
U- Ensure that all the water side drain valves are closed.

' Open economiser recirculation valve E-12V.

C-6 ,/ CHARGING OF DM MAKE UP SYSTEM, il

Ensure DM water storage tank outlet valves DM-2,DM make-up -

pump suction valves DM-3 and DM-4,DM make-up discharge valvt;

DM-7 and DM-8 are open.

Open valve DM I/L Valve DM-01 to STG TANK on CWA-15 desk. A

Close DM-01 ' valve when DM storage tank reaches normal


(
(7600 mm) . *

Ensure that DM overhead tank inlet outlet valves are open.


Select DM transfer pump-1 on CWA-15 desk.

Put DM PUMP SEQUENCE on auto.

Press VON' push button of DM PUMP SEQUENCE to start.

DM transfer pump-1 will start and shows 40 A.


m

Observe tripping of DM transfer pump on interlock when

level reaches 3350 mm.


Condensate surge tank can be filled directly bypassing

DM O/H tank if required.


DM-12 will respond based on CST level to maintain CST
level.

DM overhead tank level low indication resets at >1050 mm.

Annunciation window OH COND SURGE TANK LVL LOW resets at

/2050 mm and when level reaches at 2500 mm DM-12 will close.

^ FILLING OF BOILER DRUM

r?s Ensure that all the water wall drains, header drains are
<p closed and ECO recirculation is open.
r*i Open locally water wall header drain valve B-95 and ini-

tial filling valve E-10. Initially boiler drum is to be


Q filled from bottom ring header.


Q, Start Boiler fill pump. Water level in boiler drum will
r% start raising. Fill the drum upto 3 ports (-25 mmwc) and
p, then close filling valve E-10 locally.
Q C-8 / FILLING OF FEED STORAGE TANK
v> y
G Open initial filling valve DM-50 (RFFW08).

Q y^ Deaerator level gradually increases and "DEAERATOR

Q h ,M LEVEL LOW" annunciation window resets at 2385 mm.

Q . ;)r Wait till DEAERATOR level reaches normal (2785 mm) .


-, .0'
0 "? Stop Boiler fill pump and close DM-50 locally.
r^ Ensure that isolating valves of over flow valve DR-33
O are open.
^ CjJ) FILLING OF HOT WELL

Open following local valves for filling hot well.

Open DM-34 and DM-36 (RFDM-04).

Open DM-31 and DM-33 (RFDM-03).

Open valve DM-32 on CWA-15 desk for filling hot well.

Hotwell level will increase gradually.

" Hotwell very low" indication resets at 350 mm level

and hotwell level low indication resets at 650 mm level.

Close DM-32 valve when level reaches 850 mm.

C-10 STARTING OF AIR PRE-HEATER-A AND B r . <~> ">

Before starting APH-A ensure following valves are open:

\<y' 1. The discharge valve of guide bearing lub.oil pump.

*j!_ j;.:-'''''" 2. The discharge valve of support bearing lub oil pump.

3. Air heater-A support bearing Cooler-I inlet valve

GSW-171.

4. Air heater-A support bearing cooler-2 inlet valve

GSW-172.

5. Air heater-A guide bearing inlet valves GSW-165 and

GSW-166.

- START PERMISSIVES OF AIR HEATER A/B

Check following on DAS CRT and observe missing

criterias for start-up sequence of APH-A.

ANY ESP I/L. O/L DAMPER OPENED

AH-A SUPPORT BEARING TEMPERATURE NHIGH

AH-A GUIDE BEARING TEMPERATURE NHIGH

AH-A MAIN DRIVE OFF

AH-A S/S POSITION REMOTE.


o
AH-A FG I/L DAMPER CLOSED
0
AH-A FG O/L DAMPER . CLOSED
AH-A SA I/L DAMPER CLOSED
AH-A SA 0/ts.DAMPER CLOSED
^ -STARTING OF AIR PRE-HEATER-A
APH-A can be started manually or in group sequence.
Procedure for starting APH-A in group sequence.
o
Ensure that guide and support bearings lub.oil sequence

is on auto and select any one pump and ensure that APH-A
DC motor is running.
o
^ Keep AIR.HEATER-A GROUP SEQUENCE on auto mode .
Press "ON' push button of group sequence to start APH-A.
G
STEP INDICATOR wil indicate step number zero to eight one
after the other.
Observe that APH-A MAIN MOTOR starts and Aux.motor trips.
SA I/L DAMPER SAD-3A, SA 0/L DAMPER SAD-4A, FG I/L DAMPER
0
GD-1A, FG 0/L DAMPER GD-2A will open.
u
~, PROCEDUREgroup
FOR STARTING
^ Observe sequence AIR HEATER-A
steps on DAS ON MANUAL
CRT.
^ Keep Air heater-A Group sequence on manual mode.
*->

^ Press "ON' bush button, of AIR HEATER-A MAIN MOTOR. c*

^ AIR HEATER-A main motor(AC) will start and Aux.motor trips

p> Open SA I/L DAMPER SAD-3A, SA 0/L DAMPER SAD-4A, FG I/L.

^ DAMPER GD-1A, FG 0/L DAMPER GD-2A .

<r^ Selected lub.oil pump will pick up when guide bearing


rA . temperature >40 deg.C and support bearing temperature >35
r> deg.C. respectively.
ApfJ

- , - - ( - < i " . : * -

W JL C-

AUTO PICK UP TRIAL OF AIR HEATER-A AUXILIARY MOTOR

Press "OFF' push button of AIR HEATER-A MAIN motor.

AIR HEATER-A motor will trip .

AIR Heater-A AUX. motor will pick up and shows 3 amps.

Press "ON'push button of AIR HEATER-A MAIN MOTOR.

AIR Heater-A AUXILIARY MOTOR will trip.

Similarly Air Pre-heater-B can be taken into service

on manual or in group sequence mode.

Observe support and guide bearing temperatures of both

Air heaters (on CRT).

Ensure that bearing oil coolers are charged from water

side .

t-11 STARTING OF ID FAN-A

PERMISSIVES TO START ID FAN-A .

IDF-A S/S POSITION . REMOTE '

AH- A/B ON

v
IDF-A MOTOR & FAN BEARING TEMPERATURE NOT HI

IDF-A CB POSITION IN SER v


IDF-A CB SPRING CHARGED ./

IDF-A OFF

AH-A/B FG I/L & 0/L DAMPER OPEN

ID FAN-A INLET GATE CLOSED

ID FAN-A OUTLET GATE CLOSED

ID FAN-A REGULATING GUIDE VANES(IG-V) MINIMUM

- ID Fan-A can be started in group sequence or in manual

mode.
-.

O PROCEDURE FOR STARTING ID FAN-A IN GROUP SEQUENCE

O Put ID FAN-A GROUP SEQUENCE on auto mode.

Observe on DAS, group sequence programme(missing criteria)

Make "ON1 ID FAN-A GROUP SEQUENCE to start ID FAN-A in

^ group sequence.

STEP INDICATOR will indicate step numberv zero to seven _..

^ one after the other. Observe following operations on desk.

Seal air blower will be "ON1.

^ OUTLET DAMPER GD-7B & inlet damper GD-5B will close on

interlock (if the dampers are not closed).


GD-6B position will come to minimum (if position is not
o
minimum). ID FAN-A will start.
o
No load current of ID FAN-A will show 40 amps.
GD-7A and GD-5A will open after time delay of 45 seconds.
PROCEDURE FOR STARTING ID FAN-A ON MANUAL
o
Ensure that1 all start permissives of ID fAN-A are

satisfied.

Ensure that bearing coolers of ID fan are charced


o
from water side.
Keep ID FAN-A GROUP SEQUENCE on manual mode and start seal
Q'
air blower.
o
Open
Start DAMPERS
ID FAN-AGD-5B and GD-7B closes on interlock.
motor.
o GD- 6B position will come to minimum.
o Open GD-5A and GD-7A manually from the desk CWA-11 and
load the fan by GD-6A IGV.
C-12 STARTING OF FD FAN-A ' > '

FD Fan-A can be started manually or in group sequence.

Ensure that following valves are open for starting LOPS

of FD Fan-A.

1. Suction valve FDL - 0A01 of LOP-A (FD fan-A) open.

2. Discharge valve FDL-0A02 of LOP-A (FD Fan-A) open.

3. LOP-A (FD Fan-A) cooler water valves are open.

4. LOP-A (FD fan-A) filter-1 is in service.

5. Suction valve FDL-OAO4 of LOP-B (FD fan-A) open.

6. Discharge valve FDL-OAO5 of LOP-B (FD Fan-A) open.

7. Cooling water valves of LOP-S are open.

Start LOP-A and adjust recirculation valve FDL-0A07

(RFAGO2) for 8 kg per sq.cm2 control oil pressure and

valve FDL-O12 for proper bearing lub.oil pressure.

Both indications of lub oil pressure low and control oil

pressure low will reset onJTWA-11 desk.

Observe lub.oil pressure and temperature of bearings of

FD Fan-A on DAS CRT.

z AUTO PICK UP TRIAL OF LOPS OF FD FAN-A

Select PUMP-A for FD FAN-A..

Put sub group sequence of LOPS of FD FAN-A on auto and

make it "ON'.

Selected pump-A will pick up.

Stop LOP-A, LOP-B will pick-up on interlock.

Stop LOP-B, LOP-A will pick-up on interlock.

FD Fan-A lub oil pressure low and'control oil

pressure low indications reset.

10
^ -START PERMISSIVES FOR FD FAN -A
o
^ - Start permissives of FD Fan-A can be observed on DAS CRT
\y

f% FDF-A FAN/ MOTOR TEMP.BEARING TEMPERATURE NOTHI

Q, FDF-A Circuit Breaker INSERVICE'

Q FDF-A BREAKER SPRING CHARGED

O FDF-A OFF

O FDF-A S/S POSITION REMOTE

IDF-A or B ON & FDF-A SELECTED . AVAILABLE

0 FDF-A DISCHARGE DAMPER CLOSED

O FDF-A VANES MIN POSITION

0 LUB OIL PUMP-A or B .ON

0 CTRL OIL PRESSURE >8 kg per sq. cm

G z. STARTING PROCEDURE OF FD FAN-A IN GROUP SEQUENCE

Q Put FD. FAN-A GROUP SEQUENCE on auto mode.

0 Ensure LOP sub group sequence on auto & PUMP-A is selected

O Press"ON'push button of FD FAN-A GROUP SEQUENCE to start

O FD FAN-A in group sequence.

0 STEP INDICATOR indicates step number zero to seven one

0 after the other.

O Selected LO pump-A will pick up. FD fan-A motor will start

^ FD FAN-A ammeter will show no load current of 20 amps.

G DISCHARGE DAMPER SAD-2A will open.

O DISCHARGE DAMPER SAD-2B will close on interlock.


{">.

^ SAD-1A will get enable to open command.


<3 SAD-IB POSITION will come to zero position.
<J Scanner Air Fan atmospheric suction damper SCAD-1 will
w close on interlock .
o xl
PROCEDURE TO START FD FAN-A ON MANUAL MODE

Ensure that all the permissives are satisfied and FDF-A

group sequence is on manual.

Ensure that SAD-iA is closed and minimum.

Discharge damper SAD-2A is closed and LOP sub group

sequence is on auto and "ON1.

Selected pump-A will pick-up.

Start FD Fan-A motor manually.

FD FAN-A ammeter will show no load current of 2 0 amps.

DISCHARGE DAMPER SAD-2B will close if it is open.

Open DISCHARGE DAMPER SAD-2A.

Load the fan by opening regulating damper SAD-IA

(Blade pitch control).

C-13 TO PUT FURNACE PRESSURE CONTROL ON AUTO

Adopt following procedure to put furnace pressure

control on auto.

Bring furnace pressure set point to -10mm we.


FURNACE PRESSURE SET will indicate -10 mm we.

Open DAMPER GD-6A until actual FURNACE PRESSURE comes

to -10 mm we.

Observe the furnace pressure on recorder (furnace Pressure


narrow range and wide range on back pannel).
Press middle push button of DAMPER GD-6A to keep it on

auto,if the deviation between set and actual valve is zero.

12
O /<->Y> : KSTAP.LTSHTMC; ;>,Q% TO 1.0% A I R FLOW

O Open DAML'Kk MAD-IA till actual total air flow comes to 2130

. T/hr on TOTAL AIR FLOW ACT meter (30% to 40% air flow) .

^ ^AIR FLOW LOW TRIP'alarm will reset.


ft)
^ TOTAL AIR FLOW ACT indicator will show 250 T/hr.

ID FAN guide vanes GD-6A will open accordingly to adjust

furnace draft.
ffj)
/C-15 - CHARGING OF PRDS FROM OTHER UNIT ,<:?>
Ensure that PRDS header drains are open. f'-"
o
Open slowly the interconnecting valve locally between
o^ other PRDS and charge the PRDS header.
Observe that PRDS pressure comes to 12 kg sq.cm and
o temperature 200 deg.C on CWA-13 pannel close PRDS header
drain valves.
G
y
-":-16 - CHARGING OF SCAPH (STEAM COIL AIR PRE-HEATER)
G Ensure that the drain valve of SCAPH are open.
Open auxiliary steam valve AS-320 , AS-325, AS-3.26 of
O SCAPH locally.
o ^,?
Open steam valve AS-323 from CWA-15 pannel.

Secondary Air temperature will start raising. V


o
Observe air temperature in DAS CRT.

STARTING AC SCANNER FAN

Ensure that DC Scanner Fan-B is running.

/atmospheric suction damper is open, if FD fan is off

and it v/ill close when FD fan is started.

Q
"{ <' r n f L

Start AC scanner Fan-A, observe discharge pressure and

furnace to scanner DP on CWA-11 pannel.

Observe parameters on DAS. Stop DC Scanner Fan-B.

Take auto pick-up trial by stopping Fan-A , DC Fan-B will

pick-up and vice-versa.

_-18 - STARTING LDO PUMPS AND CHARGING LDQ SYSTEM f-^'7 'f

Ensure that the following valves are in open condition

before starting LDO pumps. These valves are to be operated

locally in oil handling plant.

Valve LOV-l before filter-1, Valve LOV-2 after filter-1,

Valve LOV-7 suction of Pump-1, Valve LOV-8 discharge of


Pump-I, Valve LOV-3 before filter-2, Valve LOV-4 after

filter-2, Valve LOV-9 suction of pump -2, Valve LOV-10

discharge of pump-2, Valve LOV-5 before filter-3, Valve

LCV-S after filter-3, Valve LOV-11 suction of pump-3,Valve


x
LOV-12 discharge of pump-3.

Open slightly LDO pressure control valve LO-11 (20%)-.

Set LO pressure to 06 kg/cm2 in LO pressure set indicator.

Start LDO Pump-1 from oil handling plant( RFFS 07)locally.

LO pressure gradually increases and maintain it to 6

kg/cm2 by LO-11 valves.

If the deviation between set pressure and actual pressure

is zero, put LO-11 on auto. Select LO from HO/LO SELECTION.

Open locally AT-20 atomising Air valve (RFFS12).

Bar indicator shows atomising air pressure of 7 to 8

kg/cm2.

LO PRESSURE ACT will be maintained at 6 kg/cm2 on auto.

14
XJ

r. !CJ PURGING OF MO! \ ,\-\li


o
insure LI1..1L. I he bulbs oJ. Llie iol lowing puryc permissivo.s

** are glowing.

^ LO TRIP VALVE CLOSED, HO TRIP VALVE CLOSED, ALL LO NVS

^ y CLOSED, ALL HO NVS CLOSED, ALL PA FANS OFF, NO BOILER

Q TRIP, ALL FEEDERS OFF, ALL HOT AIR GATES CLOSED, ALL

*% SCANNERS SHOW NO FLAME.

Q Ensure that "READY1 and "START' lamp of PURGE CYCLE is

f% glowing.

Q Press the push button of PURGE CYCLE to start the PURGE.


ff, "Purging' lamp will glow, Wait till 5 minutes.

Q "PURGE OVER1 bulb of PURGE CYCLE will come.

O Boiler MFR will reset and secondary air dampers will close

r% on auto.

Q Ensure that Burner tilt is kept horizontal (50% position).

Q C-20 - TO PUT FURNACE/WIND BOX DP CONTROL DAMPERS ON AUTO

/T>, Following operation may be made to put furnace / wind

Q box DP control on auto.

O Turn PROG SELECTION switch to position-1 or 2.

O Set the FURN/WB DP SET at (40) mmwc.

O Bring auxiliary air dampers on elevations AB,BC,CD,DE,EF

0 and FF to 40% by pressing lower push button and put all

O dampers on auto.

Q Put master DP control station on auto to maintain DP as

Q per set point.

Q Furnace to W/B DP will show 40 mm on recorder on CWA-11

O panne1.

o
G is
C-21 z LIGHTUP OF BOILER WITH AB ELEVATION PAIR
1-3 OR 2^_ WITH LDO

Ensure that LO is selected and all oil Nozzle Valves are


closed. /;'v'

Open LO TRIP VALVE- LO-19.Insert furnace temperature probe


Press "START' push button of AB elevation pair 1-3 or 2-4.
"START 1 bulb will blink slowly. HEA IGNITORS correspond-
ing to pair 1-3 or 2-4 of elevation AB will advance.
LIGHT OIL NOZZLE VALVES of 1-3 or 2-4 pair will open.
DISC SCANNER red lamp will show presence of flame.
HEA IGNITORS will be get retracted.
START bulb of AB elevation pair 1-3 or 2-4 becomes steady.
Boiler is lighted with AB elevation pair 1-3 or 2-4 oil
guns with LDO.

After every 1/2 hour change over of oil gun pairs may be
made for uniform heating of furnace.

Flue gas temperature v/ill start raising gradually and drum


metal temperature increases.
Change over of oil guns is made till drum metal tempera-
ture reaches 100 deg.C. drum pressure will start increas-
ing after 100 deg.C. drum metal temperature.
When drum metal temperature is greater than 100 deg.C.,
keep both pairs of A3 elevation oil guns in service.
If the flue gas temperature at furnace outlet is greater
than 540 deg.C., furnace temperature probe will come out
;J4' automatically. Then adjust firing rate to control the
C'

v>sJ'_f, flue gas temperature at furnace outlet.


m
o
y
^ C:22 - DEAIjiUA'l.'OR IIKATING AN1J PUGGING ' ' :. ' ' L . ' '' -

Open doaorator vent valve SM-18 from CWA--15 desk.


O
f Open auxi.li.ary steam supply valve AS-365. ^e^jZ**^?*1^*' "^

0 Open FST heat i nq valve? AS-370.

(Q) Temperature of feed water will start raising .

0 When feed water temperature reaches 100 deg.C.stop heating

0 Close vent valve SM-18.

ty Close valve AS-370.

0 Open CR-306 to supply deaerator pegging steam.

Adjust deaerator pressure set point to 3.5 kg/cm2.


0> Put CR-306 on auto to maintain deaerator pressure as per

O set value.

Deaerator pressure will start raising gradually.

<Q MANUAL BFP START-UP

G Check that following points are fulfilled.

o
O / C-23 STARTING HFO PUMP AND HFO HEATING f 'r C
'l''
Ensure that following valves are open locally.

O
^ Suction filter valves HOV-1, HOV-3.

^ HFO Pump suction valves HOV-2,HOV-4.

"^ HFO pumps discharge valves HOV-5,HOV-6.

' Steam coil heaters isolating valves HOV-25, HOV-27,

O HOV-26, HOV-28,, HFO Filters isolating valves HOV-21,

0 HOV-22, HOV-23, HOV-24. ' . / < , /


--0: '/ ');C ' '.", C'i >y\ linn ' A ' - w

v> Ensure that recirculation valve HO-'35 is open.


^ ' Open HO Trip valve HO-29. Start HFO Pump-A.
w
' Open Auxiliary steam valve HOV-50 for HFO heating.

17
Temperature of HFO will start raising and reaches about
120 deq.C. after 1 hour.

13
^ C-21 fri'AiriTNC; OK TUK'BINR TilJR.OII, SYS'l'KM
*"* ' E n s u r e t h a t MOT l e v e l is n o r m a l . S e l e c t C o o l e r N o . 1 .
0
Cruirqi.: i,.'oo.l <.,: r No. .1. from w a t e r s i d e ; by l o c a l l y o p e n i n g
o v,iivc;i GSW I1. <: G S W - 1 7 .
o
Start oil vapour extractor Fan-1 from CWA-16 desk.
O
Start Auxiliary oil pump-1.

Ammeter of AOP-1 will show 110 amps.

\y AOP discharge pressure will show 7.5 kg/cm2 (DAS) .


\
Oil pressure before oil cooler will show 5.4 kg/cm2 (DAS) . .
h
O 0
Oil pressure after oil cooler will show 4.8 kg/cm2 on back
0
pannel.
o Lub.oil header pressure will show 3.7 kg/cm2.
O ^~
- AUTO START TRIAL OF TURBINE AOP-2
O '
Make SLC AUX OIL PUMP-2"ON'. Ensure SLC AOP-1 is "OFF1.
o
Trip AUX OIL PUMP-1 . AOP-2 will pick up at lub.oil

' discharge
AOP-2 pressure of 4.6 kg/cm2.
o E n s u r e t h a t take
SLC auto
A u x i lstart
i a r y o trial
i l pump-1 1
is "ONby and SLC
o Similarly of AOP-1 making

r ~> auxiliary oil Pump-2 is "OFF1 .

Q z AUTO PICKUP TRIAL OF TURBINE EOP(Emergency OIL PUMP)

r^, Ensure SLC AOP-1 and AOP-2 are "OFF1.

^ , . .. Make SLC EMERGENCY OIL PUMP "ON1. Trip AUX OIL PUMP-1.

c -> AOP discharge pressure will drop below 4.5 kg/cm2 .

-^ Emergency oil pump will pick up when discharge pressure

r^ drops below 1.3 kg/cm2.

o
19
EOP ammeter will show 40 amps on CWA-16 desk.

Make SLC of AOP-1 and AOP-2 "ON"

Start AOP-1 and then trip EOP manually.

Make SLC lub.oil temperature control "ON' to maintain

lub.oil temperature to 44 deg.C on auto from CWA-16 desk.

C-25 TAKING GENERATOR SEAL OI_L SYSTEM IN SERVICE

Check following before charging generator seal oil .system

1. Tank levels IOT, SOT and SOST are normal.

2. AOP-1 is running.

3. Start seal o.-. .1 ::;::nk vacuum pump from CWA-.I7 desk.

Seal oil tank is under vacuum of 200 mm.

i . Generator seal o.i ] cooler-A is in service

-CHARGING GEN.SEAL OIL SYSTEM

ES-1 Through Local operation, close oil cooler bypass valve

V-63 (RFEG06).

. ES-2 Through Local operation, close inlet valve to turbine oil

tank, valve V-18 (RFEG07).

ES-3 Through Local operation, close bypass valve V-I7 of:

DPRV -E (RFEG0 8) .

ES-4 Through local opera;:, ion, select seal oil cooler-A (RFEG.13)

and its inlet outlet cooling water valves are open.

ES-5 Through local oporai: .ion, close generator seal oil cooler '.'

outlet valve GSW-35 (RFEG03;.

LS-G Through local operation, seJect seal oil filter No. .'I

(RFHG09).
O - ESTABLISHING GENERATOR SEAL OIIi : SYSTEM
REF TAG
0 ES-7 Keep g e n e r a t o r s e a l o i l pumps A a n d B on manual CWA-17
ff mode.

ES-8 Select D.C. SOP on manual.

ES-9 Press"ON'push button of GENERATOR SEAL OIL PUMP-A [I

^ - TAKING TffTAT.S OF AUTO PICK-UP OF S.O,P.s

^ ES-10 Select position-1 of A/M selector/;:switch of II

A.C. SOP to keep Pump-A on manual", ;&. pump-B on auto.'

ES-11 . Press "OFF1 push button of S.O:-P.A^ Check that SOP-B n

O ' i '^' j
. w i l l p i c k up on a u t o . -.;,../;:;..-'.:.._ .
""" E S - 1 2 " S e l e c t p o s i t i o n - 3 of A / M - s e l e c t b i p ^ W i t c h of A . C . S . O . P "
G .-:;::: " ' : - ^ ^ ^ : \ -

to keep pump-B on manual & pump^A!#:pn. :auto.


o .:."%::>

ES-13 ..Press "OFF1 push button of S.OiLP-rB^ Check that SOP-A "
y
o . '?; : - :W:
will pick up on auto. ;.:.'-.:-
o . "V .'
ES-14 Select D.C. S.O.P A/M selector ^switch position on auto."
o
ES-15 Select position-2 of A/M selector switch of A.C. S.O.P "

to keep both pumps on "manual1.-


O
^ ES-16 Press "OFF1 push button of S.O.P.B (running S.O.P). "

f^ Check that D.C. S.O.P. pick up on auto.

Q ES-17 Repeat step ES-9 to start S.O.P.- A.

Q ES-18 Select position-1 of A/M selector switch of "


:'"> ES-15 Select. 7).?.. B.C.?. selector switch position Manual
Q A.C.S.O.P".
0 & t : r i p 0 . ; . S.O.P.

21
C-26 CHARGING GENERATOR WITH HYDROGEN

Ensure that carbon dioxide is filled in generator Casing.

EH-1 Through Local Operation open Hydrogen feeding inlet

valve H-34 and vent valve.

EH-2 When Hydrogen pressure reaches 3.5 kg/cm2, through

local operation close hydrogen feeding inlet valve H-34.

Che"ck purity of hydrogen > 98% on the back pannel CWF--04.

Close Hydrogen vent valve.

C-27 TO PUT TURBINE ON TURNING GEAR

Ensure to keep SLC JACK OIL PUMP^-1 in "OFF1 mode.

Start JOP-1.

Ammeter of JOP-1 will show 50 amps.

JOP header pressure will show 120 kg/cm2.

Jacking oil pressure low indication resets.

Take auto-pick-up trial of JOP-2.

Make SLC JACK OIL PUMP-2 "ON1 and Trip JOP-1.

JOP header pressure drops from 120 kgs/cm2 .

JOP pressure low indication comes at < 100 kg/cm2.

JOP-2 v/ill pick up when JOP header pressure is less than

100 kg/cm2'.

Ammeter of JOP-2 willtshow 50 amps.

JOP header pressure will show 120 kgs/cm2.

. JOP pressure low indication resets.

Similarly JOP-1 auto pick-up trial can be taken.

Make' SLC JOP-1 and JOP-2 on "ON1 .

Press "ON1 push button of GATE VALVE GEARING to open it.

22
^ Turbine speed will increase slowly and will come to

^ 120 rpm.

g% Make SLC TURNING GEAR "ON'.

Complete oil system can be taken in service by putting


O
^ SGC oil on auto.

d> C-28 STARTING OF CEP-A OR B AND CHARGING CONDENSATE CYCLE

|J Before starting any CEP check following , ,

0 Condensate pump-A discharge valve closed.

f*i Condensate pump-B discharge valve closed.

|j) Ensure that the following valves are in open condition:

Q 1./u CS-1, CS-2, CD-18, CD-20, CD-22, CD-24 and C D - 3 5 i W - = i w

rj CST level normal.1"" DM tank level normal.

0 DM-32 and DM-35 make-up valves are on manual and

3& t h e i r i s o l a t i n g ..valves a r e op"en. .,,...... ~ <,.-?. "'>7f~

Q GSW-28, GSW-30, GSW-29 & GSW-31 are open (Bearing cooler

0 valves) . ' ,..''' :

O Following local operations are to be performed-

f3 Open main ejector-A & B inlet and outlet valves CD-5,CD-6,

O -CD-7 and CD-8.

O Close GSC bypass valve CD-12. Open CD-'lO and CD-11.

'O Close main ejector by pass valve CD-9.

Q Open isolating valves CD-13 & CD-15 of CD-14 hot well

O level control valve. , >\\ ,

O - Put SLC COND pumps ^ON' and open valve CD-19 to 2 0%.

Q Open VALVE DM-32 to fill hotwell till level reaches

O 8 50 mm.

23
Select condensate Pump-A
Press ^ON1 push button of CONDENSATE PUMP-A to start
condensate pump-A.
Discharge Valve-A opens on auto.

Condensate discharge pressure will raise to 24 kg/cm2.


Vent valves VA-1 and VA-2 will open on auto and closes
after venting (60 seconds).
CEP-A ammeter shows 3 0 amps.
Open valve CD-19 gradually.

Check thrust bearing temperatures < 6 0 deg. C.


Close DM-32 when hotwell level is 850 mm.

Hot well level is to be maintained normal by DM-32/DM-35,


if required. .. .

Ensure to keep COND PUMP A/B PRE-SELECTION in position-2

to keep CEP-B in standby mode and its discharge valve will

open. .

C-29 CHARGING OF LP HEATERS FROM WATER SIDE

Open heater 1,2,3 vent valves before charging and

close vent valves after charging.

Close CD-27 locally and open CD-25 & CD-26.

Close CD-30 locally and open CD-28 & CD-29.

Close CD-33 locally and open CD-31 & CD-32.


Keep valve CD-23 on manual mode and closed.

Open CD-14 manually to 10% and observe that hotwell

level is maintained.

24
J

O C-30 PUT DEAERATOR LEVEL CONTROL ON AUTO

<Q) By pressing raise push buttons of DEA NWL SET

fj bring the set point to zero mm we on DEA NWL SET.

fl Press middle push button of VALVE-DM 32 to keep it on

li> auto.

^ Press middle push button of VALVE DM-35 to keep it on

O auto.

O> 3y pressing raise push buttons of DEA HWL SET bring the

& set point to zero mm we on DEA HWL SET(High water level 2600).

"-^ Press middle push button of VALVE CD-23 to keep it on

-^ auto.

^ C-31 PUT HOTWELL LEVEL CONTROL ON AUTO

** By pressing raise push buttons of HOT 'WELL LEVEL SET

*^ bring the hot well level set point to zero mm we.

*-* Press middle push button of VALVE CD-14 to keep it on

^ auto.

-p Press middle push button of CD-19 to keep it on auto.

O C-32 STARTING OF BOILER FEED PUMP-A (FIRST BFP)


y
Before s t a r t i n g BFP-A check following-
3 1.Mechanical Seal Cooler of BPF-A is charged from

water side.-

2 . The follcv-.'ir.g valves are to be opened locally


a (Booster pump bearing oil cooler).
^ GSW-39, GSW-40 - Mechanical Seal Cooler.
^ GSW-41, GSW-42 - Lub.Oii Cooler ,.-.
O
GSW-44, GSW-45 - Working oil cooler
!
GSW-46, GSW-47 - Radiator cooler f,oM

25
m

3.Hydraulic c o u p l i n g oil level is n o r m a l . ^

4.Minimum r e c i r c u l a t i o n v a l v e F C - 3 0 2 is open initially.


r
5 . D e a e r a t o r level is n o r m a l . J

Open locally BFP-A bearing & stuffing box cooler valve p


X GSW-4 0. *

Open locally BFP-A working oil cooler valve GSW-45.


Open locally suction valve FS-301, FS-302, FS-303 of C

BFP-A,B,C. Z

BFP "A1 AOP is running on interlock. '1

PERMISSIVES OF BFP-A. :

BFP-A Off

Circuit breaker In service

Breaker spring Charged v

Deaerator level Normal v* V

BFP-A Suction Valve opened ^j 1

Aux.oil pump ON

Lub.oil pr.at HYD.coupl >2.5 kg/cm2 H -

C-33 STARTING BFP-A .':

Starting of .BFP-A in group sequence.

Put discharge valves of BFP-A,B,C Sub-group sequence

on auto.
Put BFP-A group sequence on auto mode.

Put BFP group control on auto. ^-

Ensure that BFP B,C AOPs are running and recirculation

valves of BFPs are open.

Select one pump operation.

26
'v >'


J -V
Select BFP-A from CWA-13 desk. cf - v ^''
[x r-r-
Make BFP Group Control 'ON1 . ,,c'r * W~'
^ BFP-A will start and stay at s t e p - 0 9 /

BFP B &. (.' w.i ! 1. come to stand by mode: and stays at step-03

Observe various BFP parameters on desk.

(JW v a l v e w i l l o p e n on i n t e r l o c k , f/<* n// ">""'- '"-''

DISCHARGE Valve FD-304 will open.

MANUAL BFP START-UP

Check that Lollowing points are iuliillod.

1. Suction valve open jT/

2 . Recirculation valve open ' .. **


... /.' .

3. Discharge vlave closed

4. Motor cooling water valve closed C ^ ''''


O
5. Scofe on manual & in minimum position
Q . ' 6 . A O P running .

0 7. Lub oil & mechanical seal cooler cooling water

<0 valves open.

Q PROCEDURE FOR START-UP

O 1. Start BFP by pressing "ON' push button

O 2. Open motor cooling valves

O 3. After the motor current become normal,open discharge

O valve

G 4. Raise the scoop position as required

G 5. Check that motor, BFP & Hyd. coupling bearing tempera

O ture are normal


f

27
C-34 FEED CONTROL STATION IN OPERATION (LOW LOAD LINE)

30% LOAD CONTROL VALVE IN SERVICE

Ensure that all spray valves before feed regulating

station are closed.

Ensure that drain valves of feed lines are open & closed

after charging.

Press "OP1 push button of LC FCV O/L ISO VALVE FD-325.

Press "OP1 push button of LC FCV I/L ISO VALVE FD-324.'

Set the drum level at zero mm we and observe that, drum

level set point comes to zero mm we.

Put ECO I/L ISO VALVE-E2 sub group sequence on auto and
make it on.

ECO I/L bypass valve will open and then main valve-E2

will open. Then bypass valve closes.

C-35 CLOSING DRUM VENTS,SUPERHEATER VENTS AND DRAINS


AND REHEATER VENTS
When drum pressure reaches 3 kg/cm2 close drum vent B-5
superheater vent valves S-21,S-25,S-30,S-40, Superheater
drains S-19,S-17,S-15,Reheater vent valves R-l and R-4 can
be closed before pulling the condensate vacuum.

<

28
V >'

m
hi

C
~36 GIVING BOILER BLOW DOWN AT 10kg/cm2 DRUM PRESSURE V.p . ( \,y

C Press emergency push buttons to hand trip the boiler.

^* "Boiler MFR TRIP" annunciation will come MFT-1 & MFT-2

^ green lamp will glow and MFR "RESET1 lamp will vanish.

AB elevation oil guns will withdraw and LOTV and HOTV

will close.
o
Secondary air and fumace/windbox DP dampers will open
O
full on interlock, ICJO1'.
0
All purge permissive lamps will glow and "PURGE" ready

bulb will glow.


^ Ensure FD-20 is in closed position <
open IBD ISO Valve B-97 .from desk CWA-13.
Open IBD ISO Valve B-98 from desk CWA-13 and reduce drum
level to -100 mm then close IBD Valve B-97 and B-98.
o
Increase the drum level to normal level by opening
G
low load line valve FD-20 and BFP scoop.
After drum level is restored to normal put FD-20 on auto.
C-37 RELIGHT UP THE BOILER WITH HFO
Before light up the boiler start purging of boiler.
o
After 5 minutes purge over signal will come and MFR
o
will reset.
Secondary air dampers at 6 fuel elevations will close.
W
Set furnace to windbox DP to 4 0% and bring all auxiliary
G
air dampers to about 40%. Put all dampers on auto and
o
Q then put master DP control station on auto.
n 29
Close locally atomising air valve AT-20 and open locally

interconnecting valves for HFO and atomising steam for AB

elevation.

Now select HO at AB elevatiton from CWA-11 desk.

Set HFO pressure of 6 kg/cm2 and atomising steam pressure

of 8kg/cm2 by HO-11 and OS-27 valves.

When actual pressure and set pressure is same put HO-11

and OS-27 on auto.

Start pair 1-3 and 2-4 oil guns of AB elevation to

light up the boiler.

Drum pressure, flue gas temperatures and SH temperature

will start increasing. * _ r^~

C-38 WARMING OF MAIN STEAM LINES

Before warming up of main steam lines open following drain

.valves from CWA-16 desk.

Open HR STRAINER DRAIN HR-206.

Open HR STRAINER DRAIN HR-208.


Open LPBP WARM UP LINE ISO HR-311.

Open LPBP WARM UP LINE ISO HR-312.

Open LPBP LINE DR HR-233.

Open LPBP WARM UP LINE DRAIN HR-234.

Open LPBP LINE DRAIN HR-230.

Open LPBP LINE DRAIN HR-232.

Open DRAIN BFR IV SEAT HR-214.

Open DRAIN BFR IV.SEAT HR-216.

30
I >

m
o

o
Open (M IDIUVIM ^; r ^ ^ s s v MS.-202.
;
^r^ MS5? M.s-212.

o
3FR TCV MS-226.
:
.Ai:\[R DRN MS-224 .

N BFR TCV MS-228.

:RK AFT HPBP CR-206-.

:RN AFT HPBP CR-206.


,,,_,, i!R -TRAINER DRN HR-206.
kee-o MS stoo valves Grouo sequence en manual .
Ifitw ocen :-'.SL VALVE IB MS-301A & 302A.
O '
. :;.'c.v throttle start-up vent S-33 main steam lines and

m a w steam stop valves'temperature will increase when


temperature of ESV body reaches 100 deg.C. .
Then 0.9en main steam line.valves MS-301 and MS-302.

. Then close integral bypass. yal.ves MS-301A and MS-302A


%j . ' : -;;.'':-' 1 ' " [ ' ' ' ; ^ t - - 1
; - ' "

_ . r:rom d e s k C W A - 1 3 . ':';' ' ' ''

PULLING AND GLAND SEALING

r e h e a t e r vents are closed before coniensaSje


o
o
. ^]c\Yi<A &]r<L^A c o o l e r e x t r a c t i c r . -f<^f. from CWA-15 desk.
G
and AS-376 locally.

O f ( \^ ' 1 ^- t^y t^f *- ^v V *--"* ^ -~jf -Vrf Y v _^\ 1 %-v. .-

l f
- ^ ; - . - ^ \ / ; - "

IP
Open AS-373 valve and adjust ejector steam pressure set

to 6 kg/cm2.

If the deviation between set value and actual value is

zero, put AS-378 valve on auto to maintain ejector steam

pressure to 6 kg/cm2.

Open starting ejector steam valve AS-2 and air valve SM-16

Wait till vacuum reaches 0.2 kg/cm2.

Open locally AS-368 valve to supply gland seal steam.

Put seal steam control on auto from CWA-16 desk.

Gland seal steam drain valve MAL-81 closes when gland

steam header temperature reaches 150 deg.C.

When condenser vacuum reaches beyond 0.7 kg/cm2 take

main ejector-A in service by opening its steam valve

AS-3 from desk and air valve SM-14 locally.

When condenser vacuum reaches 0.75 kg/cm2 withdraw

starting ejector by closing its steam valve and air valve.

Condenser pressure high alarm resets at -0.75 kg/cm2


vacuum will increase and reaches 0.95 kg/cm2.

Condenser vacuum can be pulled through SGC condensate and

evacuation by putting it on auto and make SGC "ON1.

C-40 CHARGING OF HP/LP BYPASS SYSTEM

Open locally HPBP valve MS-311 .& MS-312 (warm up valves) .

Before opening HPBP main valves observe that the

upstream and down stream temperature differential is

not more than 25 deg.C.

32
Put LPBP control on ciuLc; ar1/.: make LPBP automatic
o control interface ""ON1 .

Set HPBP down steam temp, to 230 deg.C and open valves

BPE-1 and BPE-2 by opening it by 5% to 10%.


o
Close HPBP warm up valves MS-311 and MS-312 locally.

Open HPP-P valves gradually :o increase main steam

Clow, oressure and ten;Do:r;:;U;!:e.


o
When MS oressure reaches 3 5 kg/cm2 set HPBP pressure set
0
point to 35 kg/cm2 and put the valves on auto.
o
Close start up vent valves S-33 and S-32.
In order to raise the steam parameters of 35 kg/cm2,
G
3 50 deg.C and 9 5 T/hr steam required for rolling the

turbine, take CD and EF oil elevations in service.


C-41 CHARGING OF PRDS OF OWN UNIT
o
Ensure that the following valves are in open condition:

^ AS-306, AS-309, AS-310, FD-34 0 and FD-339 (PRDS. valves) .


Open isolating valve FD-332 locally.
Ensure that PRDS-1 and PRDS-2 both pressure and tempera-
o
ture control are on manual.
o
^ Ensure to open first the spray control valve and then
pressure control valve .
O ' -

Press raise push button of TEMPERATURE SET till indicator


U
of PRDS-1 TEMPERATURE SET shows 2 00 Deg.C.
'w' Open FD-342 PRDS spray control isolating valve and
^> open FD-343 from desk.

o
Press middle push button of PRDSE-1 (FD-343) to keep
it on auto.
PRDS-1 TEMPERATURE ACT v/ill show 2 00 deg. C.
Adjust PRDS pressure set point at 12 kg/cm2.

Open PRDS-1 isolating valve AS-307.

Press middle push button of PRDS-1 (AS-308) to keep it

on auto.

PRDS PRESSURE ACT will show 12 kg/cm2 on CWA-13 desk.

Gradually close auxiliary steam interconnecting valve

AS-500 from local.


C-42 CHARGING OF STATOR WATER SYSTEM

Ensure, that expansion tank ejector is in service.

Stator water cooler inlet valves GSW-10 and GSW-11

are open locally.

Close expansion tank drain valve Y-19 locally.

Check the following valves are open:

Y-l, Y-2, Y-3, Y-6, Y-7, Y-18, Y-6.2 and Y-21

Expansion Tank level is normal.

z OPERATIONS IN STATOR WATER CIRCUIT

SW-1 Through local operation open stator water cooler-A

outlet valve GSW-12.

SW-2 Through local operation close stator water cooler-B

outlet valve GSW-13.

SW-3 Through local operation close water cooler bypass

valve Y-B.

SW-4 Through local operation select stator water cooler-A.

34
f) SW-5 Through local operation open the inlet valve Y-23
fji to polishing unit.. . .-

SW-6 . Through local operation close the stator water bypass

9 operation valve Y-17.

SW-7 ': Turn the selector, switch of GENERATOR CW PUMP A/M S/S to

: ..position number-2 to make generator CW pumps A & B manual.

^ SW-8 Press "ON'push button of GENERATOR STATOR CW PUMP-A'.

SW-9 Through local operation adjust valve Y-17 till stator

i water recorder shows 27 cubic meters per hour flow .


o i i
SW-1'0 i Turn the selector switch of GENERATOR CW PUMP-A/M S/S to

position number-1 to keep CW pump-B in on auto.

^ SW-11 Press -OFF' push button of GENERATOR STATOR CW PUMP-A.

^ Check that GEN STATOR CW PUMP-B will pick up on auto.

SW-12 Turn the selector switch of GENERATOR CW PUMP-A/M S/S to


G
position number-3 to make generator CW pump-A on auto.
^ .SW-13-.\ Press -OFF1 push button of GENERATOR STATOR CW PUMP-B.
o
Check that GEN. STATOR CW PUMP-A will pick up on auto.

SW-14 Turn the selector switch of GENERATOR CW PUMP-A/M S/S to


o
position number-1 to make generator CW pump-B on auto.

C-43 ROLLING OF TURBINE


o ,
Before rolling the turbine ensure that all the
^_ parameters listed below are built up to. the values as
w
indicated below.
o
Main steam pressure 35 kg./cm2.'
o
Main steam ;::en\peratur e around 3 5 0 Deg . C .
' Main steam f,lcw about 96. T / h r .
^ .PA
o
35
Press "0Nr push button of LOAD CONTROL from CWA-16 desk.
Press "ON'push button of LOAD Gradient.

Raise LOAD REF till indicator on LOAD REF shows 20 MW.


Observe that the bulbs of following indications are

glowing:
CR/H NRV LHS CLOSED.
CR/H NRV RHS CLOSED.
HP STOP VALVE-1 CLOSED.
HP STOP VALVE-2 CLOSED.
INTERCEPTOR VALVE-1 CLOSED.
INTERCEPTOR VALVE-2 CLOSED.
Press "GM: push button of KP/IP TRIM DEVICE.
Ensure that tracking device i's "OFF1 .
Ensure co keep following SLCs are in "ON' postion:

SLC AUXILIARY OIL PUMP-1

SLC AUXILIARY OIL PUMP-2


SLC EMERGENCY OIL PUMP
SLC JACKING OIL PUMP-1
SLC'JACKING OIL PUMP-2
SLC TURNING GEAR
SLC CONDENSATE PUMPS

SLC LP WATER INJECTION v""


SLC DRAINS L/.

Press middle push button of SGC OIL SUPPLY


to keep it on auto.

36
m

O /' Observe that red light is glowing on TTS SUPPLY-1

<" and TTS SUPPLY-2.

Observe that TSE upper margin shows 3 0 Deg. C.


- - ,

Observe that EHC position shows zero.


^ Bring STARTING DEVICE position to zero.
O
Raise SPEEDER GEAR till indicator of SPEEDER GEAR
o'
shows 100%.

Set LOAD LIMIT at 50 MW.
o
Set LOAD GRADIENT at 20
o
Ensure that STOP REF LIMITER light is ^OFF1. ^
o
Ensure that GATE Valves V-l and V-2 are open.
Ensure that SPD/PWR SET Point Blocked light is "ON1.
o
Make SYNCHRONISER "OFF1. ^
Ensure that TURBINE TRIPPED indication is
A persisting.
o
Put M.S. pressure controller on limit pressure mode.

Before proceeding to next step ensure the- fulfilment

of temperature criterias for opening the ESV and ISV


o
as per CURVE Number X-l, X-2, X-3, X-4 and X-5 on CRT.
Select TSE on admission mode PB (ADM).

Raise STARTING DEVICE till its indication comes to 42%.

on STARTING DEVICE POSITION to open HP stop valves (ESVS).

^ Before starting device is raised to 56%, wait till the

temperatures of the following valves increases gradually

and stabilize.

c^ The temperature of these valves should raise gradually.


Q
Q
w
37
Warmup can be concluded when the temperatures stablises

VALVE NUMBER POIONT NUMBER IN WALL STRESS


RECORDER

ViMSVMS f) 3

VMSVMS \c ? 4

ViMCVMC 5

VMCVMC 6

ViMSVMS 3

Raise STARTING DEVICE till its indicator T, -H--- ^


j in-
comes to 56% on STARTING DEVICE POSITION to open IV-1 AND
IV-2. IV 1 & IV-2 will open.

Make "ON 1 TRACKING DEVICE.

Raise SPEED REF till reference RPM shows 600 to increase

the turbine speed to 600 rpm.

Observe GATE VALVE gearing indicates barring gear


disengaged at 240 rpm.(Gate valve gearing c l o s e s ) .

Observe bearing vibrations are < 35 microns.

JOP-1 trips at turbine speed of 54 0 rpm.

Observe the bearing vibrations and shaft vibrations.

C-44 TURBINE TRIP SOLENOID TESTING / 1 ' n -A#-'W


To check healthiness of Turbine trip solenoid press push

button of TURBINE TRIP to trip turbine manually.

"TURBINE TRIP" annunciation will come.

HP stop valves and IP stop valves will close.


0 JOP-1 will pickup on auto when turbine speed is at 510 rpm

0 Bring STARTING DEVICE to zero position to reset

0> turbine trip indication .

C-45 REROLL THE TURBINE TO 6C> RPM AND SOAKING OF TURBINE

^ Follow the same procedure given in step-43 to reroll


o
the turbine to 60 0 rpm.

Soak the turbine for about one hour to satisfy X-6

'' criteria (HP shaft mid metal temperature) .

Observe that following MAL valves will close.


O
Down stream of HPCV drain MAL-15.
O
^ Down stream of HPCV drain MAL-16.
c
Drain ahead of swing check NRV MAL-65.
O
Drain ahead of swing check NRV MAL-66.

Drain before IPCV MAL-31. Drain before IPCV MAL-32.


w
Drain before IV MAL-26.
w
Drain before IV MAL-27.
O
Observe the turbovisory parameters.
Turbine bearing vibrations < 12 microns.
o
Turbine shaft vibrations at HPT,IPT,LPT <120 microns.
Bearing metal temperature < 90 Deg.C
o

Bearing drain oil temperature < 60 Deg.C


HPT top/bottorn temperature 160/150 Deg.C
. Inlet HP casing temperature 270 Deg.C
o
HPT exhaust temperature 2 00 Deg.C
o
O IPT top/bottom temperature
39 90 Deg.C

Observe that the criteria X-6 is satisfied.


C-46 INCREASING TURBINE SPEED TO 3000 RPM

Press raise button of SPEED REFERENCE till indicator

shows 3 000 rpm.

Turbine speed will gradually increases to 3000

rpm at the rate of 60 0 rpm/min.

Observe at critical speeds, turbine bearing vibrations

will go high and will normalize after passing through

critical speeds. ! '. ' c A (. I '-"> ''"' o -^

, , When secondary oil pressure reaches 3.0 Kg /Cm2,

I--' r hydraulically operated extraction swing check valves

\ ,
N-
,"''"' " (except A-4) open.

^J"'""\ AOP-1 will trip at about 2800 rpm.

v i^ '^MOP discharge pressure will be 9.5 kg/cm2.

Turbine lub oil pressure after cooler will show

5.5 kg/cm2.

When'-turbine speed reaches 3000 rpm observe HP/LP bypass/

opening reduces.

C-47 SOAKING. OF TURBINE AT 3000 RPM TO SATISFY X-7 CRITERIA

At 3000 rpm turbine is to be soaked for about half an hour

till X-7 criteria is satisfied (IP shaft mid metal

temperature).

Observe Following Parameters:

HPT differential expansion -4.0 to +5.5mm

IPT differential expansion -3.2 to +7.2mm

LPT differential expansion -7.0 to 30.0mm

HPT overall expansion < 2 6mm

40
J
IPT overall expansion < 13mm
Axial shift -1.0 tomm +1.0mm
^ Turbine bearing vibrations 12 microns
^ Turbine lub oil Temperature 44 Deg C
<Q Turbine shaft vibrations at HPT,IPT,LPT < 120 microns.
<Q Turbine can also be rolled through ATRS provided all
f>\ . release conditions are satisfied.
r*\ Put SGC turbine on auto and make it "ON1 .

o
ly, ATRS programme will run and follow various steps in
O, sequence (refer ATRS logic) .
Q C-48 LINE UP FOR SYNCHRONISATION OF GENERATOR WITH GRID
Q .... SY-1 Select the bus to which Generator is to be
0 connected and through local operation close
Q ' isolator (Grid side) 29-AE or 29-BE (REFD-01).
Q SY-2 Through local operation close isolator 29-AE
(GT side) (REFD-04).
Ensure that"Field breaker circuit healthy1 CWA17
0 indication is available.
O .'

SY-3 Select"REMj selection for Exciation Control


SY-4 Select "Auto' Channel for Excitation
o
SY-5 Press"ON' push button of FIELD BREAKER CONTROL
u
to close the generator field breaker
Check that field voltage & field current rises
to 90 V & 900 amps, and generator voltage rises
to 15.75 KV approximateley.

41
z MANUAL SYNCHRONISATION OF GENERATOR
SY-6 Ensure that "Gen. ckt. Bkr. spring charged1 CWA17
indication is available.
r[
SY-7 Select "check'position of "Syn SS-1 for -n^- CWA17
:ftfr*
(&> main breaker1 key switch. a^ "

SY-8 Adjust raise/low push button of auto balance so CWA17

that running voltage & incoming .voltage are equal.

SY-9 Insert key in "synchroscope SS' & turn it to "

, **" position-2 to make it "ON1. Check that "Bright ,,


/} ^ V r K
'-3 "'' '""
A * f ' On Syn. 'LED lits up.
3 r
^ i\

* SY-10 Adjust "Speed Reference1 so that synchroscope CWA16

needle takes a slow, clockwise rotation.

SY-11 When synchroscope needle posititon is 12 O'clock CWA17

and check syn. relay operated "LED lits up 1 ,

Close main CB control switch 52-E..

SY-12 Adjust speed reference to pick 10-15 MW Load. CWA16


SY-13 Turn the "Synchroscope SS' to position "I 1 CWA17

to make it "OFF' ..

SY-14 Turn key in "Syn SS-1 of Main Bkr'to position"2'(OFF) "

^ AUTO SYNCHRONISATION OF GENERATOR AFTER STEP SY-5

SY-6A Insert key in "Syn SS-1 for main breaker1 and turn "

it to position "3' to select "Auto1.

SY-7A Press "ON' push button of synchroniser. CWA16


SY-8A Check main breaker gets closed,& 10-15 MW load
is picked up.

42
SY-9A :Turn the "Synchroscope SS' to position "1 ' CWA17

^ " " to m a k e it "OFF1 .

"^ SY-10A Turn key in "Syn SS-1 for main breaker'

to position S 2 ' (OFF).

After Synchronisation check that GTR Wdg.temp.is normal -/&


o GTR cooling pump has started.
o. ^
C-49 OBSERVE IMPORTANT PARAMETERS OF TURBO GENERATOR
<5

AFTER SYNCHRONISATION

(Range of various parameters)


o
GTR HV temperature < 90 Deg.C
GTR LV temperature < 90 Deg.C
GTR Oil temperature < 90 Deg.C
O HPT middle top/bottom temp, difference < 30 Deg.C
o IPT front top/bottom temp, difference < 30 Deg.C
4> ^
fU r\ (,\ IPT rear top/bottom temp, difference < 30 Deg.C
O ' A \) -A
Condenser vacuum 0.9 Kg/Cm2
ESV body temperature . 32 0 - 3 50
G V ,\
\0
* ISV body temperature 320 - 350

i HP casing mid metal temp. 280 -300

\^ CRH temperature 230 - 250

AIV '' ' p> Ensure closing of all MAL drains on auto after
, \i c y.n* synchronization.

t. HPT differential expansion -2.00 to +5 mm

^M v ^ IPT differential expansion -2.0 to + 5.5mm

;>XJ'\ ^ LPT. differential expansion -7.0 to 25.0 mm

'V , i': HP overall expansion 26 mm


IP overall expansion 13 mm

43
Axial shift . -1.0 to +1.0 mm

Turbine bearing vibrations < 12 microns

Turbine shaft vibrations < 120 microns

at HPT,IPT,LPT

TSE margins (Load margins) >3 0 K

Turbine lub oil temperature 44 Deg.c

Note that all differential expansions should move

towards positive side.

Bearing metal temperature << 90


90 Deg .C
Bearing drain oil temp. < 65 Deg .C

HPT top/bottom temp 160/150 Deg .C

Inlet HP casing temp . 270 Deg .C

HPT exhaust temp. 200 Deg .C


IPT top/bottom temp. 90 Deg .C

HPCV position(approx). 20 %

IPCV position minimum

Generator slot temp. < 75 Deg .C

Generator core temp. < 75 Deg .C

LPT exhaust temp. 45 Deg .C

C-50 CLOSING OF VARIOUS TURBINE SIDE DRAINS

Following turbine side drain valves are to be closed

after synchronization/

Close valves from CWA-16 desk-

HR-206, HR-208, HR-311, HR-312, HR-233, HR-234, HR-230,

HR-232, HR-214, HR-216, MS-204, MS-214, MS-202, MS-212,

MS-222, MS-226, MS-224, MS-228, CR-206, CR-208.

44
C-51 CHARGING OF HYDROGEN COOLING SYSTEM

1. Hydrogen coolers outlet valves GSW-24, GSW-25

GSW-26, and GSW-2 7 are open.

2. Hydrogen cooler-A outlet valve GSW-20 is open.


o H-1 Open hydrogen cooler-B inlet valve GSW-2(RFCW09)locally.
o H-2 Open hydrogen cooler-C inlet valve GSW-22(RFCW-10)locally.
0 H-3 Open hydrogen cooler-D inlet valve GSW-23(RFCW-11)locally.

^ GT-1 Open locally GSW-500 generator transformer cooler(RFCW006)

"^ Ensure that generator HT and LT winding temperature are

"^ within limits.

^ Ensure that station transfomer winding temperature is

within limit.

^ C-52 WITHDRAWAL OF STEAM TO SCAPH

When flue gas outlet temperature is greater than

^ 110-115 d e g . C , close auxiliary steam supply to SCAPH


O
^ by closing the valve AS-323 from desk CWA-15.
C-53 TAKING PULVERISER-A IN SERVICE (1st PULVERISER) '

'"*' In order to increase the load on turbogenerator coal


O
firing is to be initiated with lower most pulveriser.
o
It is assumed that ESP is in service.
o
Select pulveriser-A manual mode from CWA-12 desk.
O
Start lub. oil pump-A on desk CWA-12.
Ensure that lub.oil cooler is in service.

o
45
STARTING PA FAN-A

Start seal air blower of PA FAN-A.

Put all the primary air dampers on manual mode.

Cold air damper PAD-4A is full open.

Before starting PA fan-A,Open PA fan-A bearing cooler

inlet valve GSW-210 and outlet valve GSW-202 locally.

Open PAD-3A cold air gate by 5% locally .

Start seal air Fan-A from CWA-11 desk.

Check permissives of PA fan-A are satisfied except seal

air bowl DP.

j The permissives are -

SA bowl DP OK

NO MFR Trip

Pulveriser ignition permit

Hot air gate closed.

Inlet damper in minimum position.

CAD is less than 5% open.

Give command to start PA Fan-A.

Auto command will be given to close PAD-4A cold air damper

to close <5% and seal air valve for mill-A to open..

Seal air DP will build up and seal air bowl DP O.K. and

fan ready indication will come.

Then PA fan-A will start. Check Fan Current.

Then open pulveriser discharge valve.


0 ,
O
-STARTING PULVERISER-A
0
^ Ensure that mill-A is on manual.
o . - Check auto pick up of lub oil pumps.
lP
fj
. - Trip lub oil pump-1,LOP-2 will pick up and trip
O
f ' LOP- 2, LOP-1 will pick up.
% Check mill bearing temperatures are normal.
f^ Check all pulveriser permissives are satisfied as given
^v below:
1. Pulveriser start permit
2. Primary air permit
O It -
^ 3 . Lub
4. Buriner
oil gates
OK open
- \

J
' 5. Pulveriser discharge valve open
o
6. Tempering .air valve open
O
7. Bunker gate open
o
^ 8. Cold air gate open
o
9. Pulveriser outlet temperature < 94 Deg. C.
o
10. Pulveriser ignition permit
11. No auto pulveriser start command
o 12. Pulveriser OFF'
o
13. Seal air header/bowl DP OK
o
14. No pulveriser trip
15. Pulveriser ready
w
Ensure that bunker gates CD-1A, CD-2A, CD-3A are open
O '
locally.
Ensure Mill-A oil cooler inlet valve open locally.
o
GSW-217 and outlet valve GSW-219 open locally.

o
Ensure lub.oil pump-1 A & 2A suction and discharge ^

valves are open locally. ^

Ensure lub.oil pump recirculation valve is open locally ^

and adjust lub.oil pressure more than 1.2 kg/cm2.

Start pulveriser-A and observe mill current of 20A. .^

Open hot air gate PAD1-A from desk. r-

Set mill coal air temperature(mill outlet temperature) ^

to 77 deg. C to maintain actual mill outlet temperature /--

on auto. . ^

Set PA flow of 55 T/hr on PA flow set to maintain actual ,-


flow, of 55 T/hr on auto. ,-~

Open PAD-2A , PAD-4A and PAD-5A. :r>

Open the dampers to an such extent that actual mill outlet '-

temperature is 77 deg. C and actual PA flow is 55 T/hr. ^

Put PAD-2A and PAD-4A on auto to maintain mill outlet temp. <~

and put PAD-5A on auto to maintain flow through.the mill.

Check the mill current is normal (20A) . r--

Start feeder-A. Check current. After one minute, f-

feeder speed can be increased. _

Increase the feeder speed slowly steaming rate of the f_

boiler will increase. Steam flow, MS temp, MS pressure C

will increase slowly.

Increase the load on turbine according to M S pressure. C

Ensure that 02 is about 7-8 % at APH inlet.

Put pulveriser-A fuel air dampers on auto. ;'

48
o
o
-START UP OF PULVERISER
: ON AUTO
o
~ Coal Mill-A can be started on "Auto mode1 by putting

O elevation on auto.
f^ Open PA fan discharge valve and give "ON'command to
f% pulveriser.
,..%, PA Fan-A,Coal mill-A and coal feeder-A will start on auto
f* Hot air gate also opens on auto.
f^ Ensure to keep 02 TRIM SET on manual mode.
.r& C-54 - TO PUT AIR FLOW CONTROL ON AUTO

if> Raise 02 TRIM SET to raise 02 TRIM SET point to 7%.


r\ Increase 02 Trim to increase air flow set on Auto to
*v get SAD-1A of FD fan-A. Control vane deviation zero.
jl Then put SAD-1A - FD fan-A control vane on auto.
p> By adjusting "02 Trim 1 bring 02 deviation zero.
o> Then press middle push button of 02 TRIM to keep
c--s it on auto.
(--%, Air flow will vary to adjust 02 % to 7%.
Q) ID fan control vanes will vary to control furnace draft.
O C-55 LOAD RAISING UPTO 5_0. MW
^ Increase the feeder-A speed to 60% to 70%.
0 MILL-A FLOW ACT will increase.
<p; Main steam pressure and temp, will increase gradually.

0 Feeder-A speed comes to 600 rpm.

Q Press "RAISE1 push button of LOAD REF on CWA-16 upto 50

Q MW for increasing the load to 50 MW. Load raising should

Q be done keeping in view the TSE margins.

49
o
C-56 CARRY OUT AUXILIARY SUPPLY CHAANGE OVER FROM STATION
TOUNTTBUS-1CA
Ensure that breakers 1-CA and l-CB are in service and DC control supply is

W .
AS -1 BTSP-I is 'IN' and selection is on "MAN FAST'.

Ensure that Bus transfer system ready for Fast Transfer & Bus transfer system

is <W indications are available at BTPS-1.

CHANGE OVER TO AUXILIARY SUPPLY BUS 1 CA


1

AS-2 Press the'TEST4 push button on the back panel (BTPS 01).

TC BKR CB1 CLOSE test mode' window, TIE BKR CB-2 open 'test mode1

window on FACIA WINDOW FW-1 will glow. Pressthe "IESTRESET

BUTTON: All the above indications will disappear "READY FOR TRFR"

green lamp will glow.

AS - 3 Pre ss 'READY FOR TRFR% push button. *VC BKR CB-1 CLOSE window,

& "TIE BKR CB-2 OPEN' window on FACIA WINDOW FW-1 will glow

"READY FOR TRFR" lamp will disappear and will glow again.

UNIT BD1CA INCOMER BKR' & "TIE BKR. BET. 1CA & OCA'

discrepancy switches will flicker on MCL-1.

AS - 4 Turn the 'TRANSFER SELECTOR4 to 'AUTO* mode on BTPS-01.

AS - 5 Turn the discrepancy switch of ICA I/C BKR to 'ON' and discrepancy

switch of TIE BKR to ICA to 'OFF'.

C-57 CARRYING OUR AUXILIARY SUPPLY CHANGE OVER FROM

STATION TO UNIT BUS ICB

AS - 6 BTSP-2 is 'IN' and selection is on 'MAN FAST'.

Ensure that 'Bus transfer system ready for Fast Transfer & Bus Transfer

System IN' indications are available or BTSP-2.


AS-7 Press the "TEST' push button on the back panels (BTPS-02)
a
"I/C BKR CB1 CLOSE test mode' window, & "TIE BKR CB-2 OPEN

test mode'window on FACIA WINDOW FW1 will glow on BTPS-02.

^ AS-8 Press the "TEST RESET1 button. All the above indications

,f| will disappear. "READY FOR TRFR" lamp will glow.

Q AS-9 Press "READY FOR TRFR1 push button "I/C BKR CB-1 CLOSE1

rt window Sc "TIE BKR CB2 OPEN1 window on FACIA WINDOW FW1 will

,<QN . glow "READY FOR TRFR1 lamp will disappear and will glow

f^ ' again. "UNIT BD ICB INCOMER BKR'& 'TIE BKR. BET.ICB & OCB'
f% discrepancy switches will flicker on MCL-1.

o AS-11 Turn the "TRANSFER SELECTOR1.to "AUTO1 mode on BTPS-02.

( ^S AS-12 Turn the discrepancy switch of ICB I/C Bkr. to "ON1

r\ Sc discrepancy switch of TIE BKR to ICB to"OFF'.

iQ C-58 CHARGING OF LP HEATERS FROM STEAM SIDE AT ABOUT 5_0 MW LOAD

r^. Open drain valves DR-15, DR-17 and DR-18 locally.

O Open LP heaters shell vents from local before charging

("-) from steam side. After charging close shell vents,

<f| open DR-23 and DR-32 locally.

Q Open locally extraction-1 pipeline drain valve EX-113.

\J Open locally isolating valves of DR-21 i.e. valves

P DR-20 and DR-22.

Q Open LPH-1 EXT STM ISO EX-9 to charge LPH-1 from steam

<Q side.

Q Level will start raising in LPH1 after some time EXTRA-

Q A2-UP STREAM and DOWN STREAM will gradually increase as

O flow increases (CWA-16).

51
Press^OP' push button of LPH-2.EXT STM ISO EX-10 to charge

LPH-2 with steam.

Level will start raising in LPH-2 after some time.

Close LPH-2 EXT DRN EX-101.

Note:

When load exceeds 2 0 MW and EX-A2, A3 opening is greater

than 15% & SLC drains is "ON1 MAL valves-55, 54 will close.

Close locally extraction-1 pipe line drain valve EX-113.

Put LPH-2 level control on auto. First set NWL and HWL

to zero on level set indicator.

Then open DR-21 and DR-24 manually and maintain LPH-2

level.

If the deviation in valves is zero put DR-21 and DR-24 on

auto.

Open LPH-3 EXT STM ISO EX-11 to charge LPH-3 from steam

side. LPH-3 drip level will rise gradually.

Close LPH-3 EXT DRN EX-103


Observe increase in Condensate temperature after

LP heaters.

Observe LPH-3 level in the indicator LPH-3 drip level LCD

meter shows 200 mm.

Put level Control at LPH-3 on auto.

Bring LPH-3 NWL SET point to zero mm we.

Bring LPH-3 HWL SET point to zero mm we.

Put DR-16 and DR-19 valves on auto.

Whenever EXTN NRV (A3) opens more,observe that DR-16 also

opens more to maintain LPH-3 drip level.

52
_ C-5 9 TAKING FEED CONTROL STATION FULL LOAD LINE INTO OPERATION
t'S ' ~ '"" " "" """ ~ "
^ This is to be done at a load oJ: about 50 MW.
O

~ Select ^3 ELEMENT CONTROL'of CONTROL SELECTOR to keep drum

f% level control on three element control.

0 Keep BFP-A SCOOP on auto.

|3 Open isolating valves FD-320 and FD-321 of full load


<Q' control valve FD-21. Put FD-20 valve on manual.
0 Gradually open FD-21 and close FD-20 completely.
Q) FD-22 control valve which is bypass to FD-21 can be taken
^ in service by closing FD-21 and maintain drum level to normal
-Q DP across Feed Regulating Station is to be maintained at
0, around 6 kg/cm2 by manually operating the valve FD-21.
|j C-60- FOR FURTHER INCREASING THE LOAD INCREASE THE PRESSURE
fv SET POINT OF HP B Y P A S S TO KKD k g / c m 2 .
0 C-61 TAKING PULVERISER-"B1IN SERVICE
0 Ensure that L O P - 1 is running and L O P - 2 is s t a n d b y .
O Select m a n u a l m o d e of p u l v e r i s e r .
O Start seal air b l o w e r of P A N - B . Set Mill O u t l e t
Q t e m p e r a t u r e to 77 D e g . C and PA flow to 55 T/hr.
'J> Check permissives of PAN-B. If all permissive lamps are
v) glowing then start PA fan-B.
*-* Open pulveriser discharge valve.
0 Check mill permissives are available to start mill-B.
O Start pulveriser-B manually. Open hot air gate.
D Then open PAD-5B, PAD-2B and PAD-4B and get 55 T/hr
Q of PA flow and mill outlet temperature to 77 Deg.C.

53
Put all the above dampers on auto.
Start coal feeder-B manually.

After one minute feeder speed can be increased.

Increase feeder speed.

Flue gas temperature, MS, HRH temperature will increase.

Maintain 02 % at APH inlet to about 6% by increasing

secondary air. Increase the feeder speed gradually.

C-62 INCREASING -LOAD TO KKD MW

Increase the load Co 90 MW by load reference.

Reduce oil firing by withdrawing oil support of EF

elevation.

Increase the load to 100 MW by increasing load reference

to 100 ME.' .

Feeder speed of, A & B mill will come to about 60-70%.

C-63 TAKING SECOND BFP IN SERVICE ^

For further increasing the load on turbogenerator start

BFP-B.

Before starting BFP-B check its permissives and line up

BFP-B.

If the feed water flow is more than 240 T/hr, change 1

pump operation to 2 pumps operation of BFP's.

If BFP group control is "on "auto1 then BFP-B will pick-up

beyond feed water flow of 325 T/hr.

Otherwise BFP-B can be started on sub group sequence or

on manual.

Put BFP-C on standby mode so that if any pump trips

standby pump will, pick up.

5.4
o
m

- C-64 CHANGE: 0V1JR OF \JM)lj


O
^ Make change over oJ: PRDS-1 (High capacity PRDS) to

Q PRDS-2 (Low capacity PRDS).

!| Open first isolating valves AS-304 and FD-335.

0 Gradually open PRDS-2 spray control valve and close PRDS-1

O spray control valve.

0 PRDS temperature will be maintained at 205 deg.C.

0 Then gradually open pressure control valve of PRDS-2 and

0 close PRDS-1 pressure control valve.

O PRDS-2 pressure control valve will maintain PRDS pressure

Q to 12 kg/cm2.

0 Then take PRDS-1 on manual and PRDS-2 on auto.

0 C-65 TRAKING SUPERHEATER SPRAY CONTROL VALVES IN SERVICE

0 Open isolating valves in super heater spray control lines

0 S-57, S-59, S-62,S-68,S-69 and S-71.

O Keep SH spray control on manual:

O Open block valve S-52 then open 1/2 isolating valves

0 S-60 and S-66.

<U> With the help of spray control valves S-61 and S-67

'<j maintain actual temp, at SH outlet at around 5.0 0 deg. C.

Q C-66 LINING UP REHEATER SPRAY CONTROL VALVES & BURNER TILT

O Open locally valves R-18,R-20, R 15, R-23 and R-24.

G Ensure to keep of RH STEAM TEMPERATURE SET on manual.

G Ensure to keep TILT MASTER A/M STN on manual.

O Put BTPC-1, BTPC-2, BTPC-3, BTPC-4 on auto.

G Maintain RH STM TEM ACT at around 50 0 Deg C. by

^ manipulating TLT MASTER CONTROLLER.


O
55
C-67 CHARGING OF HP HEATERS 5 & 6_ FROM FEED WATER SIDE
Open HP heaters 5 & 6 water box vents locally before

charging and close it after charging from water side.

Ensure HEATER BP valves FD-9 & FD-12 are open.

Ensure to keep FW I/L ISOL VLV GROUP on manual.

Open FW I/L VLV IB FD-7A.

Ensure to keep FW 0/L ISOL VALVE GROUP on manual.

Open FW O/L VALVE IB FD-8A.

Ensure to keep FW I/L ISOL VALVE GROUP on manual.

Open FW I/L VALVE IB FD-10A.

Ensure to keep FW O/L ISOL VALVE GROUP on manual.

Open FW O/L VALVE IB FD-11A.

Ensure to keep HTR BP VALVE GROUP on manual.

Open locally heater charging valve FD-18.

^OP' bulb of GR BYPASS VALVE FD-17 will glow.

"OPr bulb of GR BYPASS VALVE FD-16 will glow.

Then close valve FD-1S.

Open HP HEATERS inlet/outlet valves FD-7, FD-8, FD-10,

and FD-11.

Close their integral bypass valves FD-7A, FD-8A, FD-10A,

and FD-11A.

Close HEATER BP Valve FD-9 & FD-12.

Now HP heaters are charged from feed water side.

56
C-68 ESTABLISHING SECOND AIR CYCLE
o
Before tciking pulveriser-C in service start another air
o
cycle . Start IDB & FDB.
. .-
Equalize the loading of ID Fan-A & ID Fan-B and FD Fan-A

-. and FD Fan-B.
5
_ Increase HP/LP bypass pressure set point to 125 kg/cm2.
CJ)
^ Ensure that deaerator pegging steam changeover takes place

-^ at 12 kg/cm2 of CRH pressure from PRDS to CRH line.


tp. It maintains D/A pressure of 3.5 kg/cm2 .

~ C-69 ESTABLISHING
: PULVERISER - C
o
r>. Start pulveriser-C and further increase the load by load

g^ reference .
f^ Increase the load to 126 MW by raising load
^ C-70 INCREASING LOAD TO 126 MW
,Q reference. If BFPB is not started on manual it will pick

r^ up on auto at flow of > 325 T/hr.


^ Maintaian SH steam temperature and RH steam temperature

0 release will now be available for taking EXT-4 in service

Q for deaerator pegging.

Q Open valve EX-301.

Q Observe closing of valve CR-306.

Q Observe various parameters at 126 MW.

Q C-71 AIR FLOW CONTROL ON AUTO

0 Bring 02 trim set to 50% to maintain 02 in flue gas at

0 APH outlet at 5% .Put 02 trim set on auto. 02 trim set

O will generate 02 set point according to load.

57
C-72 CHARGING OF HP HEATER _5 FROM STEAM SIDE

Open DR-13 and DR- 8 locally.

Open HPH-5 EXT DRN EX-112.

Open EX-13 to admit extraction steam to HPH-5.

Drain extraction valve- A5 (MAL-47) closes.

Set HPH-5 NWL SET will show to zero mm we.

Set HPH-5 HWL SET to zero mm we.

Put DR-14 on auto.

Put DK-11 on auto.

Close HPH-5 EXT DRN EX-112.

HPH-5 level will increase slowly to 250 mm we.

Feedwater temperature AFTER HPH-5 will rise slowly.


1
HPH-5 LEVEL L O W annunciation will reset.

C-73 CHARGING OF HPH-6 FROM STEAM SIDE

Open DR-1 and DR-3 locally.

Open HPH-6 EXT DRN EX-110.

Open EX-12 to admit extraction steam to HPH-6.

Set HPH-6 NWL SET indicator to zero mm we.

HPH-6 HWL SET indicator to zero mm we.

Put'VALVE DR-2 on auto.

Put VALVE DR-34 to keep on auto.

Put DR-6 on auto.

Close HPH-6 EXT DRN EX-110.

HPH-6 level will increase to 250 mm we.

"HPH-6 LEVEL LOW1 annunciation window will reset.

Feed water temperature will rise slowly.

58
^ Load initially will reduce marginally.
f%
v>
Spray will reduce.
Economiser inlet temperature will increase.
Observe feed water temperature & outlet of HPH-5 & HPH-6.
TO PUT HP HEATERS LEVEL GROUP PROTECTION ON AUTO.
Put FW I/L ISOL VALEV GROUP on auto.
o
Put FW 0/L ISOL VALVE GROUP on auto.
o
Put HEATER-5BP VALVE GROUP on auto.

Put FW I/L ISOL VALVE GROUP on auto.

Put FW O/L ISOL VLV GROUP on auto.

Put HTR-6 BP VALVE GROUP on auto.


o
Put HEATER GROUP BP on auto.
^ C-74 LOAD RAISING UPTQ 150 MW
o
Raise load reference to increase the load 150 MW.

After coal feeder C speed goes beyond 60% withdraw oil


o HP bypass pressure set point is maintained 5 kg/cm2
support
above at pressure.
M.S. CD elevation.
o
"^ While raising steam parameters and load, ensure that
Oo C-7.5 TAKING PULVERISER-D TN SERVICE
Q Take pulveriser-D in service and increase the fuel firing
Q C-76 LOAD RAISING TO _17j5 MW
Q Raise LOAD REF to increase the load upto 175 MW.
Q MW meter will show 175 MW (actual).
r^ Observe all the parameters. M.S.temperature and HRH steam

o temperature to be maintained around 52 0 deg.C.

o
59
C-77 TO WITHDRAW OIL SUPPORT FROM AB ELEVATION

Increase feeder speed of D mill to raise the load.

When MS pressure starts increasing raise load ref. to

190 MW to increase the load.

Put SH steam temperature spray control valves and RH

steam temperature spray control valves and Burner TILT

MASTER on auto.

Put SH steam temperature Set point & HRH steam temperature

set point also on auto.

C-78 LOAD RAISING TO 210 MW

Maintain MS pressure at around 150 kg/cm2 and increase

the load to 210 MW .

C-79 TO PUT UPC' ON AUTO

Ensure RC feeders A,B,C & D speed deviation is zero and

put them on "Auto'.

Raise UDC pressure GRAD set point to 50%.

Raise UDC pressure set point to match actual MS pressure.

Raise START UP FUEL GRAD to 50%.


Observe deviation between UDC pressure set point and

actual MS pressure at the deviation meter provided on

control desk CWA-12.

Put BLR FUEL MASTER on "Auto',when this deviation is zero.

START UP MODE will come into service indicated by START

UP FUEL SET POINT RUN lamp glowing.

60
To take CMC mode in service adjust unit target load GRAD
0
SET POINT to 50% and ensuring zero deviation between UDC
PRESSURE SET POINT & actual MS pressure to make CMC "ON'

from turbine desk button. Now load can be varied from

^ unit target load set point.

Put UDC pressure set point on auto. Put HPBP pressure set

point on auto.

_ Raise UDC PR SP till indicator on UDC PR SP INDICATION



^ comes to 150 kg/cm2.
Wait till pressure deviation comes to nil
^ (Time 15 minutes approx.).

Press "ON1 push button CO-ORD MODE,"ON1 bulb will glow.

Put boiler set POINT on auto.

~ Start-up fuel lamp will be off on CVJA-12.


O

r~-_, MS pressure will be maintained as per set point.


^ Unit load will be maintained as per set point.

c^ C-80 . IMPORTANT PARAMETERS AT 2_10_ MW

,^-S Maintain important parameters as given below:

'> Main steam pressure before ESV 150 kg/Cm2

Q Main steam temperature at boiler outlet 540 Deg. C

-^ Main steam flow 627 T/hr

Flue gas temperature at air heater O/L 14 9 Deg.C

~> Drum pressure 162 Kg/Cm2

Q-x Condensate flow 501 T/hr

Q Condensate header pressure 20 Kg/Cm2

Q Feed water flow 650 T/hr

61
F'eed w;;ii:.r temperature at; economi ser .i.n.lc.-r; 24-1 Deg. C

Total combustion air . 792 .7 T/hr

02 in flue gas at economiser outlet 3 .5 %


.Wind box to furnace DP 100 mmwc

Reheater steam pressure at outlet 34 . 8 Kg/Cm2

CST .lev.: I. 2900 mm

Stator water conductivity <5- mmho/cm


I.-':

instrument air header pressure 6-7 Kg/Cm2


Service air, header pressure 6-7 Kg/Cm2
!

Condenser'' vacuum 0.91 Kg/Cm2 ^ ? ,

Deaerator pressure : 6. 5 Kg/Cm2

EJ'/A level ' '' "'" 2700 mm . : "(*

D/A temperature 160 deg.C

. Hotwell level 850 mm


HPT differential expansion -2 . 00' to + 5 mm
1 PT d i. l I'.: I'enl: ial cxpanuJon :>. .oo to i-5 m m

;.LHT -differential expansion - 7 . 0 0 .,to 25 mm:; .;

HP overall expansions 26 , mm
IP^overa LI expansion;: , 13.. mm '.:.

-1.0 to +1 . 0 mm
Turbine bearing vibrations < 12 microns

^Turbine sha^t:-^ibra:t^G^is^at, HPT, IPT, LPT


P.T. <12.0',.,,. micrpris %
.V'TSEi.margins'(Lbad margins): >3 0 ' K
\ Turbine lub .oil temperature 44 Deg. c

' HPH-6 level : 230 mm


HPH-5 l.-vol '?. 5 0 mm

62
o
LPH-3 level 410 mm
LPH-2 level 350 mm
Ejector steam pressure 7 Kg/cm2

PRDS pressure 12 kg/Cm2

PRDS temperature 200 Deg.C

CRH pressure after attemperator 37 Kg/Cm2

CRH temperature attemperator 370 Deg.C

o HRH Reheater steam temp.at outlet . 540 Deg.C

o HRH Reheater steam flow at outlet 564 .5 T/hr


S H Spray 26 T/hr
T/hr
o RH Spray 0

Burner tilt + 13 deg

GSW tank level 3160 mm


G
Generator volts 15.75 K.Volts
C
o Generator current(R/Y/B) 9000 amps

Generator MVAR lagging 130 MVAR


G
Field current 2(D0 amps

Field voltage volts

o H2 pressure in Gen.casing 3 .5 Kg/cm2

Hydrogen purity 99 % ,

Q HP control valve V-2 position(approx) 60 % .


IP control valve position (approx) 100 % '
EHC position(approx) 70 %
Seal steam pressure 0 . 12 Kg/Cm2

C-81 TAKING STANDBY PULVERISERS E AND F I_N SERVICE

G Standby pulverisers can be taken in service one by one

and withdraw pulverisers A & B one after another.


o
63
"., if

PLANNED SHUTDOWN PROCEDURE FOR UNIT


(SHUTDOWN TO COLD STANDBY)

SC-1 When the planned shutdown/shutdown to cold s/b is to be

started the following procedure is to be followed.

Reduce the load on the T/G machine alongwith reduction

in temperature and pressure of main steam.

SC-2 The unit is running on full load and planned shutdown

is to be started . Observe the important parameters on

full load (210 MW) before reducing the load.

SC-3 LOAD REDUCTION TO l_8_0 MW


/J - > - / ,1
Unit is running on CMC. . Jo-t>di* Y * ' - ^
Press TURB FLG MODS push button to select turbine follow

mode.

Reduce target load gradient to 20% from CWA-16 desk.

Bring target Load Set point (UDC) indicator to 180 MW.

Slowly MW will reduce. Observe various parameters.

SC-4 OBSERVATION OF IMPORTANT RESPONSES '

WHILE REDUCING LOAD TO 180 MW -

Speed & Amps of FEEDER-A reduces.

Speed & Amps of FEEDER-B reduces.

Speed & Amps of FEEDER-C reduces.

Speed & Amps of FEEDER-D reduces.

TOTAL FUEL FLOW will decrease.

Mill-A amperage will reduce.

Mill-B amperage will reduce.

Mill-C amperage will reduce.

64
Mill-D amperage will reduce. TSE will show 180 MW.

Total air flow reduces.

Main steam flow reduces, feed water flow and condensate

flow reduces.
G
SC-5 LOAD REDUCTION TO 165 MW

Brina unit load target set ooint to 165 MW to reduce the
o
load to 165 MW.
o
SC-6 PULVERISER ^D SHUTDOWN
0
_ Put Feeder-D from auto to manual from CWA-12 desk.

. . .. Reduce FEEDER-D speed gradually to minimum. .
^ RC FEEDER-D amperes will slowly reduce.
When current of mill-D is minimum then stop FEEDER-D
G
by making it off manually.
%J>
"No coal flow" annunciation corresponding to Mill-D
O
^ will glow.

Bowl DP will reduce slowly. Close Hot air gate.

^ Press ^OFF1 push button of PULVERISER-D to stop

^ pulveriser-D.

r-N Put all the PA dampers of pulveriser-D on manual.

o Ensure that mill outlet temperature is <4 5 Deg.C.

r-\. Close all the primary air dampers .

,"-, Close pulveriser discharge valves.

o, Then stop PA Fan-D.

r\ No coal flow annunciation will come after stopping

(5 RC Feeder-D.

ry, Pulveriser
* -Xo e..ef D djalso
(? can be 65
shutdown on auto mode.

n V,
2_ PROCEDURE TO SHUTDOWN PULVERISER-D ON AUTO MODE

Put pulveriser-D en auto mode. Press "OFF' push button of

pulveriser-D to make it "OFF1 in auto mode.

First command goes to CD elevation oil support(oil guns)

Feeder speed will slowly come to minimum.

Hot air gate closes and hot air damper closes.

Cold air damper opens to reducee pulveriser outlet

temperature. Then pulveriser will be "OFF1.

At last PA Fan will be "OFF'.

Cose pulveriser discharge valves on manual. Then if

required, oil support at CD elevation can be withdrawn.

SC-7 ISOLATING HP-6 FROM STEAM SIDE

Close valve EX-12 to cut off steam to HPH-6 (Extraction

steam of HPH-6). DR-2 valve will close slowly.

Open EX-110 drain valve before EX-12 valve.

Feed water temperature will reduce.

Put DR-2,DR-34,DR-6 on manual after they close on auto.

SC-8 ISOLATING HP-5 FROM STEAM SIDE

Close EX-13 valve to cut off steam to HPH-5.

DR-11 valve will close slowly.

Open EX-112 drain valve (Extraction line drain valve).

EXTRACTI0N-A5 closes oh auto.

Valve MAL-4 7 will open on auto.

Put DR-11 valve on manual.

Put VALVE DR-14 on manual.

Feed water temperature will reduce .

66
SC-9 CUT OFF HP HEATERS FROM WATER SIDE

Open HPH 5,6 bypass valves FD-9 and FD-12.


o
Close FD-7,FD-8, FD-10 and FD-11 to bypass, HP heaters
0-
from water side.

In order to take main heater bypass line in service open

-CL1 bulb
FD-130 and of
FD-131.
GR BYPASS VALVE FD-16 will glow.
V
^ . CL' bulb of GR BYPASS VALVE FD-17 will glow .
o
~. Open dump valve FD-125 from desk.

^ After some time FD-125 can be closed.

__ Close FD-130 and FD-131.


%J
Heaters can be isolated from steam side and
water side on auto with the help of heater group

_ SC-10 bypass from CWA-13


LOAD REDUCTION TO desk.
140 MW
o
~ Reduce target LOAD SET POINT (UDC) till INDICATOR on
SET POINT meter comes to 140 MW.
o
^ Load will gradually reduce to 140 MW.
p, ~ OBSERVATION OF IMPORTANT RESPONSES WHILE REDUCING
LOAD TO 140 MW
Q
Speed & Amps of FEEDER-A reduces.
Q
Speed & Amps of FEEDER-B reduces.
o
Speed & Amps of FEEDER-C reduces.

^ Indicator of TOTAL FUEL FLOW will decrease.


Mill-A amperes will reduce. Mill-B amperes will reduce.
O
^ . Mill-C amperes will reduce. TSE will show 140 MW.
o
Steam flow will reduce.
o
o
O 67
o
o
SC-11 TAKING HO GUNS INTO SERVICE AT
(AB) ELEVATION (PAIR 1-3 & 2-4)
Ensure that HO trip valve is open (HO-29) and observe HO

and atomising steam pressure of 6 kg/cm2 and 8 kg/cm2

respectively.

Press -START1 push button of AB elevation pair 1-3.

"START1 bulb will blink slowly..

HEA IGNITORS corresponding to pair 1-3 of elevation

AB red light will lit to indicate advancement of

HEA IGNITORS.

DISC SCANER light will come corresponding to pair 1-3.

HEA IGNITORS "G1 bulb will glow to indicate IGNITORS

RETRACTED.

START bulb of AB elevation PAIR 1-3 becomes steady.

HO short recirculation valve HO-11 will close.

After 40 seconds command will go to pair 2-4 to start

and pair 2-4 will prove after 90 seconds time.

SC-12 CHANGEOVER OF CMC FROM AUTO TO MANUAL MODE.

At 140 MW load make CMC ~OFF' from CWA-16 desk.

Bring MS pressure set point to manual.

Boiler fuel master will be on auto.

Start up mode will come'in service.

Put Boiler fuel master on manual.

Unit will come to "base mode' operation.

Take UDC pressure set point to manual.

68
SC-13 LOAD REDUCTION TO ll_0 MW

^ Bring load reference to 110 MW from CWA-16 desk.

Load will gradually reduce.

HPT and IPT control valves opening will reduce.


f%
Put RC feeder speed on manual to reduce further fuel
firing rate.
0
Reduce speed of RC Feeder-C to maintain steam flow
o
and MS pressure.
0
UDC pressure set point may be reduced equal to MS
o
pressure so that the difference between actual
''s pressure and set point. may not be more than 10 kg/cm2,
^ so that unit will not go to "pressure control1 mode.
SC-14 Release
OBSERVATION
lamp OF
of RESPONSE
extraction-4
AFTER (A4)
110 will
MW LOAD
be'OFF' and MAL-51
O will open.
o Close EX-301 and open EX-108 valves.
o
CR-306 valve will open to maintain deaerator pressure.
^ SC-15 PULVERISER -C SHUTDOWN
o
Remove Pulveriser-C as per procedure mentioned in step

^ SC-6.

MS temperature >4 8 0 deg.C by RC feeders of A & B.


o
SC-16 SHUT DOWN OF SEAL AIR FAN-B
When A & B pulveriser are in service then stop seal
Q
air Fan-B.
Seal air Fan-A will be running.
o
o
O 69
SC-17 SHUT DOWN OF 3FP z B

Put standby 3?P on manual. Take SCOOP-B on manual.

Reduce SC00P-3 till indicator on SCOOP-B position

comes to minimum.

MIN RCV FC-306 will open at 60 T/hr flow.

SCOCP-A of BFPA will increase to adjust feed water flow.

Amperes of BFP-B will reduce and BFP-A will increase.

Press OFF push button of BFP-B to make it OFF from CWA-13

desk. AOP of BFP-B will pick up on auto.

Cooling water valve of BFP-B. will close on auto.

If one pump operation is selected and if flow- is less

than 290 T/hr BFP-B will trip on auto.

SHUT DOWN OF FD FAN-B AND ID FAN-B AT l_00 MW

Reduce load on FD Fan by taking SAD-1 on manual and

close it fully.

Then stop FD fan motor from CWA-11 desk.

Close discharge damper.

LOP sub group sequence can be put on manual and then

stop running LOP A/B.

FD Fan can be shutdown in group sequence.

Reduce load or. ID Fan-3 by taking QD-SB on manual and

close IGV manually.

Stop ID Fan motor.

. Close inlet outlet dampers.

Stop ID fan seal air blower.'

ID fan can be shutdown in qrouo seui.'once.

70
m

O SC-19 REDUCTION OF LOAD TO 50 MW

O Reduce load inference to 50 MW to reduce load to 50MW.

Load will reduce to 50 MW. Adjust feeder speeds of running

^ pulverisers A & B so that MS pressure will not increase.


o
TSE will show 50 MW load. Gland steam supply valve will

open and leak off valve will close.


o
SC-20 PULVERISER-B SHUT DOWN
o
Follow the same procedures given in Step SC-6.
^ SC-21 CHANGE OVER TO LOW LOAD LINE AT 5_0 MW LOAD
FROM FULL LOAD LINE(Feed Regulating station)
Open VALVE FD-20 slowly and close valve FD-21 so that
drum level is maintained to normal.
,,r\
^ Close VALVE FD-21 till indicator of FD-21 position
c
comes to zero.

^ Put valve FD-2 0 on auto and scoop of BFP-"A' on manual.


^ SC-22 CARRYING OUT AUXILIARY SUPPLY CHANGE OVER FROM UNIT
Q TO STATION BUS OCA
0 Ensure that breakers OCA and OCB are in service and DC
O control supply is "ON".
Q AS-1 BTSP-1 is "IN1 and selection is on "MAN FAST 1 .
vj/ Ensure that "Bus transfer system ready for Fast Transfer1
Q & "Bus transfer System IN' indications are available at
O BTSP-1.
O AS-2 Press the "TEST' push button on the back panel(BTPS 01)
O and proceed further when"READY FOR TRFR' bulb on the back
w panel glows.
U

71
"I/C BKR CB-1 0?3Nr Test mode window on FACIA WINDOW FW-1

will glow.

"TIE BKR CB-2 CLOSE' Test mode window on FACIA WINDOW

FW-1 v/ill glow. Press the TEST RESET button.

All the above indications will -disappear.

"READY FOR TRFR" green lamp will glow.

AS-3 Press "READY FOR TRFR1 push button."I/C BKR CB1 OPEN'

window on FACIA WINDOW FW-1 will glow."TIE BKR CB-2

CLOSE'window on FACIA WINDOW FW-1 will glow."READY FOR

TRFR" lamp will disappear and will glow again."UNIT BD

1CA INCOMER BKR1 & "TIE BKR between ICA & OCA'discrepancy

switch will flicker on MCL-01.

AS-4 Turn the discrepancy switch of ICA I/C BKR to "OFF1.

AS-5 Turn the discrepancy switch of TIE BKR to ICA to 'ON'.

CARRYING OUr AUXILIARY SUPPLY CHANGE OVER

FROM UNIT TO STATION BUS OCB

AS-6 BTSP-2 is"IN'and selection is on "MAN FAST'. Ensure that

Bus transfer system ready for Fast Transfer & Bus Transfer
System IN indications are available on BTSP-2.

AS-7 Press the "TEST1 push button on the back panels (BTPS-02)

and proceed further when"READY FOR TRFR'bulb on the back

panel glows.

"I/C BKR CB-1 1 "OPEN test mode1 window on FACIA

WINDOW FW-1 will glow.

"TIE BKR CB-2 CLOSE test mode1 window on FACIA

WINDOW FW-1 will glow.

72
AS-8 Press the "TMST RESET1 button. All the above

indications will disappear."READY FOR TRFR"

green lamp w.i.1.1 glow.

^ AS-9 Press "READY FOR TRFR 1 push button"I/C BKR CB1 OPEN 1

r*, window on FACIA WINDOW.

r "TIE BKR CB2 CLOSE 1 window on FACIA WINDOW FW1 will glow.

^ "READY FOR TRFR'lamp will disappear and will glow again.

r% ""UNIT BD 1CB INCOMER BKR'&'TIE BKR between ICB & OCB'

f* discrepancy sv/itch will flicker on MCL-02.

^ AS-10 Turn the discrepancy switch of ICB I/C Bkr to "OFF1.

f* Turn the discrepancy switch of TIE BKR to ICB to "ON'.

^. SC-23 CHANGE OVER OF PROS-2 TO PRDS-1(PRESSURE & TEMP.CONTROL)


*> Ensure to ke^.; PRDS-1 (AS-308) on manual.

iO) Slowly open A.^-3 08 of PRDS-1 and A3-305 closes ON AUTO.

,f> When AS-305 closes completely put: PRDS-2 (AS305) on manual

f^ Put PRDS-2 :AS-308) on auto.

f% Valve AS-308 v.'ill open to maintain pressure of 12 kg/cm2 .

Q Open HCPRV I/L ISO FD-342.

Q Slowly open FD-347 of PRDSE-1 (FD-347 ) on auto.

Q FD-346 will close gradually on auto so that PRDS

Q temperature will be maintained at 2 00 Deg.C.

^-> Put PRDS-2 on manual and PRDS-1 on auto.

Q Close isolating valves of PRDS-II after change over.

O SC-24 ISOLATING LP HEATERS FROM STEAM SIDE(LPH-3,2,1)

Q CLOSE EXT STKi ISO VALVE EX-9 to cut off steam to LPH-1.

O Open locally EX-113 drain of extraction line.

Q Close EXT ST:>\ ISO VALVE EX-10 to cut off steam to LPH-2.

L) 73
Open EX-101 extraction line drain valve locally.

EXTRACTION- A2 release to NRV will be "OFF'.

MAL- 55 will open on auto.

Open EX-102 extraction line drain.

Close EXT STM ISO VALVE EX-11 to cut off steam to LPH-3.

Open EX-103 extraction line drain.

EXTRACTION-A3 release to NRV will be "OFF1.

MAL-54 will open on auto.

All the Drip valves DR-21,DR-16,DR-24,DR-21,DR-16,DR-19

will close on auto. Drip valves may be put on manual.


SC-25 LOAD REDUCTION TO 30 MW

Reduce load reference to 3 0 MW to reduce actual LOAD TO

3 0 MW.

TSE will show 3 0 MW gradually.

Steam flow will decrease.

Observe on DAS various parameters.

SC-26 PULVERISER-A SHUTDOWN

Follow the same procedure to shut down pulveriser-A as

given in Step SC-6.

Stop seal air Fan-A from CWA-11 desk.

SC-27 SHUT DOWN THE TURBINE

Note the presen: value of steam pressure and set HPBP

more than actual pressure so that HP3P will not open.

Press the TURBINE TRIP push button to trip the turbine

"MANUAL TURBINE TRIP" alarm will come.

MAIN CB CONTROL SWITCH-52 will open.

"OFF1 bulb of FIELD BKR will glow.

74
"OFF1 bulb of EXCITATION OFF will glow.
^ Field current will become zero.
,K Field volts will become zero.
O
1^ AUTO POT MIN bulb will lit.

p . GEN BKR OPEN bulb will lit.

#% EXCITATION TRIP bulb will glow.

(J MW meter will show zero.

0 TURBINE TRIPPED bulb will lit.


<Q HP STOP V-l CLOSED bulb will glow.
C3 HP STOP V-2 CLOSED bulb will glow.
0 INTCPT V-l CLOSED bulb will glow.
Q> INTCPT V-2 CLOSED bulb will glow.
0 CRH NRV LH CLOSED bulb will glow.
0 CRH NRV RH CLOSED bulb will lit.
0 HPT CVS,IPT CVS will close.
J Turbine speed reduces gradually.
/ When turbine speed is at 2800 rpm AOP-I will pickup on
O auto.
O When turbine speed is at 510 rpm JOP-I will pickup on auto
0 When turbine speed is at 240 rpm "ON 1 bulb of GATE VALVE
O GEARING will lit and barring gear will engage to put turbine
vJ on barring. Turbine speed would be 150 rpm on turning gear.
^ Boiler will trip on Turbine trip to boiler trip
%j protection (R H Protection)

75
Turbine can also be shutdown through ATRS (SGC Turbine) at'

210 MW load.

Make CMC "OFF' and ensure SGC turbine is on auto.

Adjust load gradient to 3 to 5 MW per minute.

Start shutdown sequence by making SGC turbine "OFF1.

Adjust Fuel Fire rate as per the reduction in load.

SC-28 SHUTDOWN OF GENERATOR STATOR CW PUMP

Turn the GEN CW PUMP A/M S/S switch to position number-2

to make generator stator CW pumps on manual.

Stop GEN STATOR CW PUMP-A(running pump) stator water flow

comes to zero and flow low indication flashes on the desk

CWA-17.
SC-29 SHUTDOWN OF BOILER

When boiler trips after tripping turbine observe following

"BOILER MFR TRIP" annunciation will'come.

MFT-1 and MFT-2 lamps will glow and MFR "RESET'lamp will

be OFF.

All oil guns will be OFF. HO trip valve will close on auto

Short circulation valve of HO-35 will open on auto.

Scavenging of guns at AB and CD elevations will start

and after 5 minutes automatically scanenge valves close.

Fuel air and Auxiliary' air dampers will open full.

Bypass turbine trip to boiler trip protection.

All purge permissives will be satisfied.

Purge the boiler.

After 5 minutes purge over signal will come.

76
& SC-30 KILL CONDENSER VACUUM

Close main ejector A/B steam valve.

^* Open vacuum breaker to kill condenser vacuum. Vacuum will


fall slowly. Observe on CWA-16 desk and DAS.

SC-31 SHUT DOWN OF TURBINE GLAND SEAL SYSTEM


Put seal steam control on manual.
*-* Close seal steam isolating valve AS-368 locally .

Gland seal steam header drain valve MAL-81 will open on


^ interlock.
When temperature of header drops below 12 0 deg. C. stop
%
* GSC evacuation Pump 1/2 from CWA-16 desk.
u
' SC-32 SHUT DOWN OF PRDS

^ Put PRDS pressure and temperature control on manual and

close control valves.

*" Then close isolating valves for pressure and


"~" temperature control .
W
SC-33 BOILER FILLING ABOVE NORMAL DRUM LEVEL
^ Put FD-20 on manual and open the valve.
^ Fill boiler drum above normal level so that level will be
visible when drum pressure drops and level drops when drum
O
level pressure drops.
Restore drum level with BFP and feed control valve from

^ CWA-13 desk.
Ky
SC-34 CLOSING OF BOILER OUTLET VALVES
O
Close boiler outlet valves MS-301 & 302 from CWA-13 desk.

77
SC-35 SHUTDOWN OF BFP-A
Press "OFF'push button of BFP-A motor.
AOP will pickup on auto.
BFP-A cooling water valve will close on auto.
Close Discharge valve from CWA-13 desk.
BFP-A suction flow will become minimum.
BFP-A suction pressure reduces.
BFP-A can be shut down in group sequence also.
SC-36 SHUTDOWN OF SECOND AIR CYCLE(ID FAN A & FD FAN A)

When flue gas temperature at APH inlet is less than 200

deg.C. second air cycle can be stopped.

SC-37 SHUTDOWN OF AIR HEATER-A


Before stopping the Air Heaters, wait untill FG
temperature at APH inlet reaches < 10 0 Deg.C.
Press middle push button of AIR HEATER-A GROUP SEQUENCE
to keep group sequence on Auto.
Press "OFF' push button of group sequence to make APH-A
main drive off.
APH- A will be off and ammeter of AIR HEATER-A will show
zero amps. APH-A DC motor will pick up on auto.

Dampers GD-1A, SAD-4A,GD-2A and SAD-3A will close on

interlock.

Support and guide bearing LOP's will be off if bearing

temperature < 35 deg.C and 4 0 deg.C.

LOP group sequence can be put on manual.


APH-A can be shut down manually.

78
5 SC-41 OPENING OF BOILER SIDE VENTS
*k When drum pressure reaches 3 kg/cm2 open drum Vent valve
f% B-5 locally.
Q Open locally super heater vent valves S-40, S-21,
9 - S-25, S-30 and drain valves S-15, S-16, S-17.
Q> Open RH vent valves R-l and R-4.

O SC-42 SHUTDOWN OF CW PUMPS

Stop CW PUMP-1 and CW Pump-2.

Ammeter reading of CW PUMP-2 will show zero amps.


i

G Close COND CW I/L valve CW-48 & CW-49, COND CW O/L valve
CW-55 Sc CW-56.

O SC-43 SHUT DOWN OF GSW PUMPS


O Stop GENERAL SER PUMP-A.
i
O Ammeter of GENERAL SER PUMP-A will show zero amps.
i

0 Close GEN SER PUMP-A Discharge Valve DV-39.

G GS 0/H tank level will fall.

O SC-44 SHUT DOWN OF AC SEAL OIL PUMP

O When Hydrogen is purged out and C02 is filled and purged


^ out with compressed air, AC seal oil pump can be stopped.
;
o
Ir> xxxxxxxxxxxxxxx

o
Q

G
Q

80
C-38 SHUTDOWN THE AIR HEATER-B

Press middle push button of AIR HEATER-B GROUP SEQUENCE.

Press "OFF1 push button of AIR HEATER-B group sequence to

keep APH- B "OFF1 .

APH-B will be off and Ammeter of AIR HEATER-B will show

zero amps. DC motor will pick-up on interlock.

All the dampers in flue gas path and air path will open

on interlock. Response will be same as step No.SC-37.

SC-3 9 SHUTDOWN OF CEP A/B (RUNNING)

Shutdown the CEP when LP exhaust temperature ' reaches

less than 45 Deg.C.

Make SLC COND Pumps OFF.

Press "OFF1 push button of CEP-A to make it off.

Ammeter of CEP-A will show zero amps.

CEP-A discharge valve closes on interlock.

Take DM-32 & DM-35 on manual and close them.

SC-40 SHUTDOWN OF TURBINE LUB OIL SYSTEM


Take SGC oil supply on manual.

Make SLCs of JOP-1, JOP-2, AOP-1, AOP-2, EOP OFF.

When turbine casing temperature reaches<100 Deg.C,then

stop GATE VALVE GEARING from CWA-16 desk.

Turbine speed will gradually reduce and turbine

will come to standstill.

Stop JACKING OIL PUMP-1.

Stop AUX OIL PUMP-1 .

Make SLC lub.oil temperature control OFF.

79
PROCEDURE FOR SHUT DOWN OF UNIT FOR HOT STANDBY
o
When unit trips' from full load (210 MW) on any protec-
Q tion or load through off or is to be tripped manually
for any abnormal condition,follow the procedure as
Q) mentioned below.
O HS-2 TRIPPING THE TURBINE MANUALLY

O Press TURBINE TRIP push button to trip the turbine .

0 manually from CWA-16 desk. "MANUAL TURBINE TRIP" alarm


/
will come. TSE will shift to admission side to indicate
0 turbine speed.
O MAIN CB CONTROL SWITCH 52-E will open y

0 FIELD BKR will be "OFF1/ . ..


0 . CO-ORD mode lamp will go "OFF1, and boiler startup mode
0 . lamp will glow,
EXCITATION will be "OFF.1
O Field current will become zero.
O Field volts will become zero,
O AUTO POT MIN bulb will lit . \
O GEN BKR OPEN bulb will lit.
Q EXCITATION TRIP bulb will glowt
^ . HP BYPASS will OPEN to adjust main steam pressure.
o
'yJ LPBP opens to adjust HRH pressure.
^ TURBINE TRIPPED bulb will glow,
^ HP stop and control valves V-l & V-2,IP stop and
O control valves,CRH NRVS will close fully.
O Observe various indications of valves on control
O desk CWA-16.

81
Turbine speed reduces gradually,
EXTRACTION NRVS A-2,'A-3,A-4 and A-5 will close
Drain extraction valves MAL-47, MAL-51, MAL-54 and
MAL-55 will open
After closure of Extractiton valves, the following
drain valves will open

Ex-101,Ex-102,Ex-103,Ex-108,Ex-112 ,Ex-110.

When turbine speed reaches at 2 80 0 rpm AUX OIL PUMP-1

will pick up.


j
When turbine speed reaches at 510 rpm JACKING OIL
PUMP-1 will pick up
When turbine speed is at 24 0 rpm. GATE VALVE
GEARING will engage (Barring gear)_

RC FEEDER-A,RC FEEDER-B ,RC FEEDER-C, RC FEEDER-D speed


will reduce
ID FAN-A/B amperes will reduce
FD FAN-A/B amperes will reduce
Feed water flow will reduce

(V) Gland steam Leak off valve will close and supply valve

will open
EX-301 extraction valve will close and CR-306 will
open to maintain D/A pressure.
Condensate flow to D/A will reduce.
BFP-A scoop position & amps will reduce,
BFP-B scoop position & amps will reduce,
GT oil pump will become OFF on interlock.

82
I-IS-2 ^'L^IM 2Z hR HEATERS EXTRACTION STEAM VALVES
s* Close LPH-1 EXT STM ISO EX-9^

Q . Close LPH-2 EXT STM ISO EX-10 v

Q Close LPH-3 EXT STM ISO EX-11^


Q Open Extraction line drain valves .

Q HS-3 CLOSING HP HEATERS EXTRACTION STEAM VALVES

0 'Close EX-13 HPH-5 extraction steam valve.


Q Close EX-12 HPH-6 extraction steam drain valve.
0 Open extraction line drain valves.
Q HS-4 BOILER MASTER ON MANUAL
Q Put BOILER MASTER on manual

Q Then Boiler base mode lamp will glow

HS-5
Q Take oil support at AB elevation HFO pressure 6 kg/cm2
0 and atomising steam pressure of 8 kg/cm2.

O HS-6 PULVERISER-D SHUTDOWN


Q Reduce FEEDER-D speed, when it comes to minimum

Q Stop FEEDER-D

O "No coal flow " annunciation corresponding

O to MILL-D will come

G MILL-D ampers will slowly reduce and will show 22 amps


r
O PAD-2D position will reduce

O PAD-4D will close

O PAD-5D position will reduce

Q Close hot air gate

o
O 33
Stop PA Fan-D

Stop PULVERISER-D

After withdrawing Mill D, maintain MS temperature &

pressure at 530 deg.C. and 130 kg/cm2 respectively.

Observe various turbine and boiler paramerters.

HS-7 . 7 SHUTDOWN OF BFP-B(MANUAL)

Put BFP group sequence control on manual

Put BFP C o n manual. and change BFP-"2 pump'operation

to "1 pump1 operation.

Put SCOOP-B on manual

Reduce SCOOP-B till indicator on SCOOP-B POSITION

comes to minimum

^OP1 bulb of MIN RCV FC-306 will lit at flow of 60 T/hr

approximately.

SCOOP-B POSITION will come to minimum

SCOOP-A POSITION will increase

. Ampers of BFP-B will reduce

Ampers of BFP-A will increase

Press "OFF1 push button of BFP-B to stop it manuallay

AOP corresponding to BFP-B will pick up on auto

Wait for some time after switching off the BFP-B

Cooling water valve of BFP-B will close

Discharge valve will close

BFP-B SUCTION flow will be zero

Put BFP-B on auto standby,if required.

BFP-B can be shut down in group sequence also.

34
O HS-8 ADJUST THE HP BYPASS SET VALUE TO 130 kq/cm2

O By pressing"+' and"-'push buttons of HPBP PRESSURE

. SET the HPBP PRESSURE SET at 130 kg/cm2 (operating

^ pressure 135- bias pressure 5)


w
, ^ HP PR SET will show 130 kg/cm2
o *

BP-1 VALVE will open further

BP-2 VALVE will open further

BD valve will open


BPE-1 VALVE will open
o
BPE-2 VALVE will open
o
LP BY PASS Control valve will remain open
o
VI and V3 of LP by pass spray will remain open
G
V2 and V4 of LP is
by more
pass than
spray will open if the opening
of LPBP valves 50%

HS-9 STATUS OF THE PLANT


o
Status of plant will be as follows (running
o
auxiliaries)
- HO guns in service at AB elevation
o
- Mill-A in service with about 40 % load & on manual
- Mill-B in service with about 40 % load & on manual
o
- Mill-C in service with about 4 0 % load & on manual
- BFP-A in service
\^'
- ID Fan-A in service
- ID Fan-B in service
G
- FD Fan-A in service
- FD Fan-B in service
O . pa

85
- CEP-A in service

- CW pump-1 in service

- CW pump-2 in service

- Turbine on barring gear

- Main Ejector-A in service

- HP/LP bypass in service

- Stator water pump-A in service

- Seal oil Pump-A is running.

- S/H & RH spray on auto

HS-10 IMPORTANT PARAMETERS AFTER TRIPPING THE TURBINE

FOR HOT STANDBY


Main steam pressure at superheater outlet 130 Kg/Cm2

Main steam temperature at boiler outlet 530 Deg. C

HP casing temperature 500 Deg.C

Main steam flow 200 T/hr

Flue gas temperature after air heater 141 Deg.C

Drum pressure 13 8 Kg/Cm2

Condensate flow 2 00 T/hr

Condensate header pressure 2 3 Kg/Cm2

Feed water flow 220 T/hr

Total combustion air 350 to 400 T/hr

Hydrogen pressure ' 3.5 Kg/Cm2

Hydrogen purity 99.5 %

Reheater steam pressure at outlet 2 7 Kg/Cm2

CST level 2 90 0 mm

Condensor vacuum . 0.91 Kg/Cm2

Deaerator pressure 6.5 Kg/Cm2

86
D/A level 2700 mm
O
^ D/A temperature 160 Deg.
^ Hotwell level 850 . mm
0 HP overall expansion < 2 6 mm
Q IP overall expansion < 13 mm
0) ... Turbine bearing vibrations * < 12 microns
0 Turbine shaft vibrations at HPT,IPT,LPT < 120 microns
iQ Turbine lub oil temperature 44 Deg.C
0 Ejector steam pressure 7 Kg/cm2
Q PRDS pressure 12 Kg/Cm2
Q PRDS temperature 2 00 Deg.C
Q CRH pressure after attemperator 2 9 Kg/Cm2
Q CRH temperature attemperator 3 70 Deg.C
0 HRH Reheater steam temperature 53 0 Deg.C
Q Stator water flow 27 M3/hr
(3 LP exhaust temperature 4 7 Deg.C
Q Burner tilt +13 deg
Q GSW tank level 3160 mm
O Seal steam pressure 0.15 Kg/Cm2(gauge)
G xxxxxxxxx
G
o

o
87
HOT RESTART OF THE UNIT AFTER SHORT SHUTDOWN

HRS-lEnsure that the boiler is on load with mill A,B & C

and FD fans running. Hp/LP bypass is open and turbine

is on barring generator seal oil pump and stator water

pumps is running. Note the following important parame-

ters:

1. Main steam pressure 130 kg/cm2

2. Main steam temperature 53 0 deg.C

3. Main steam flow 200 T/hr

4. HPT outer casing temp, top/bottom 500 deg.C

HRS-2 ROLLING OF TURBINE

Press "ON1 push button of load control increase load

reference to 20 MW(House load).Ensure that load gradi-

ent is"ON'. Speed control active lamp is glowing.Ensure

that CMC is "OFF1. Observe that HP & IP stop valves are

closed, and CRH NRVs are closed. Make "ON1 HP/IP TRIM

DEVICE. Make Tracking device "OFF1. Ensure that SLCs

of all oil pumps are "ON1, SLC condensate pumps

"ON1,SLC turning gear ."ON1, SLC LP water injection is

"ON1, SLC Drains "ON1. Put SGC oil supply on auto.

Observe that TTS-1 and TTS-2 supply is ON.Observe' that


TSE margins are greater than 3 0 K. Observe that EHC

position shows zero. Bring starting device to zero

position. Turbine trip indication will reset. Bring

speeder gear to 100% position.


m

Ensure that MW load limit indicator is at 210 MW. Keep

UDC pressure set point on manual. Ensure that load

gradient is on and show 20 MM. Ensure that "stop refer-

ence is OFF 1 , limit pressure reached light is OFF,gate

valves V-l and V-2 tripped light is ON. Ensure that


OFF
SPD /PWR set point light is ON and synchronization
f% blocked light is QN. Raise starting device to 42 % and

g% observe that HP stop Valves V-l and V-2 are open. Then

Q raise starting device further to 56% and observe that


/>. IV-1 and IV-2 are open. Then raise starting device to

Q 80%. Make tracking device "ON r . Increase speed refer-

0 ence to 3000 rpm. Now turbine rolling will start and

0 turbine speed will gradually increase at the rate of

Q 600 rpm/ minute. Observe the various criteria curves

Q X-2, X-3,X-4,X-5,X-6 are satisfied.Observe that gate

0 valve gearing trips at 240 rpm. Observe that bearing

Q and pedestal vibrations are within limit. Observe

O vibrations at critical speeds of turbine shaft(1545 &

O 2136 rpm).At 540 rpm JOP-1 will stop. Turbine speed

O will gradually increase to 3000 rpm.At 2850 rpm observe

O that AOP-1 trips and MOP discharge pressure will show

O 9-6 kg/cm2 . Observe that turbine lub oil pressure

O after oil cooler will be 5.5 kg/cm2. Adjust RC feeder

O A,B and C speed to maintain Steam temperature,pres-

O sure and flow. Observe that rolling criterias are

O satisfied (X-6, X-7) .

89
HRS-3 OBSERVATION OF TURBOVISORY PARAMETERS

Before proceeding further observe turbovisory parainet-

mere i.e. differential expansions, overall expansions

att4.;*Xial: Shift-;'; '"; ''':- '''"[s: t'il-:" ;;:o ' ' !"

HPT- HiMXe top/Bottom ti*mp:.difference :' < 30 deg . C..

IPT' 'front fcbpvfbot'&otn teftpld'iffererice' " : <3 0 deg.C.

' IPT/'re'ar top/bottom temp\"difference : <30 deg.C.

T S B M a r g i n s ' - .--?.. . : > 3 0 K


c
.. :.;: ;. - r - v '^' i - ' :: .f = ? i ! :'-^-"'
HRS-4 SYNOHRONISATION OF" GENERATOR WITH GRID
;
: . . . 1 r . . J . :-: -i :.
Close generator field breaker and observe that follow

ing lamps (LED) are glowing. Field breaker circuit.


healthy. Excitation "ON1. Spring charged. GeneraLor
breaker open . Put excitation on "auto1 . Generator.
: :
. , ,. , - - r i - M \ : o v . ': : . o . : . J .- <<'- -

voltage raises gradually to 5 KV and suffencly reaches

to full scale and comes baak to 14. KV. observe field

of 700 atnps, Observe that, field flash becomes


f : :
. . : :::-, -;:(> -iv:r: ^ - ^ "3 - ^ ^ - '

ON .and kAuto pot any Position*1; bulb.glows. Raise auto

pot position. 'Generator1 voltage. Increases, gradually to

15.75. KV. Obserye filjs$. yoltS:,,of 9,0 ;,.^.olts. Observe


: j ;
' . ' " . ...'; "..' .'. 'x.i'^ 'P- ^ " " > - '- - ' :

filed current of 900 amps... Now. make synchrozscope ON.

Put main circuit breaker on auto synchronisation posi

tion(SYN SS-1) i.e. position No. 3 . Synchroscope need!'.

will start rotating. If synchroscope needle is moving

in anticlockwise direction and speed is slow. when

synchrosaope needle , comes to 11'0 clock position in

clockwise direction,auto synchronizing LED

90
Q) and main CB control switch 52 AE closes. Observe mini-

Q) mum phase currents on (R,Y,B) all oil pump will pick

0 up on auto. OFF bulb of synchronizer on CWA-16 indica-

O -tion will glow. Grid voltage frequency and generator

O ' voltage frequency will be zero on CWA-17 panel. Now

^ make synchroscope OFF (position-1).

0 HRS-5 BRINGING HOUSE LOAD OF 20 MW ON UNIT

Now increase speed reference (CWA-16 Panel) till

actual MW meter shows 20 MW (House load). Speed control

01 active bulb will be off and load control active bulb

G will glow.Observe that at 5 to 10 MW TSE will come to

O turbine mode from admission mode. TSE will start

O showing load margins(Upper and lower) .Ensure that

CJ upper load margin is available to increase the load.

O Observe various generator parameters like field current


t y
- and voltage, generator current and voltage, MVAR and

^ power factor.

O HRS-6 TO PUT "BOILER FUEL MASTER'ON AUTO.

"-^ Put RS feeder A & B speed control on auto. Then put


w
"Boiler Fuel Master 'on auto. Keep HP bypass pressure

^ set point on 150 kg/cm2 and observe that MS pressure


w
is maintained at 150 kg/cm2 (CWA-15). Slowly HPBP-1,

^ HPBP-2 and BPE-1, BPE-2 closes on auto. BD valve will

^ close after full closer of BPE-1 and BPE-2. As LP

^ bypass control is auto, it will close LP bypass control

^ valves and spray valves.

91
HRS-7 INCREASING LOAD UPTO 100 MW.

Increase Load reference set point to 100 MW. Load will

gradually increase to 100 MW.With the help of boiler

fuel master increase fuel to adjust MS pressure and

flow. Observe upper TSE load margin is

available. .Observe various turbine metal

temperatures.Observe that all the turbovisory parame-

ters are normal.

HRS-8 CHARGING OF LP HEATERS FROM STEAM SIDE

Open LP-1 . extractiton steam isolating valve EX-9 to

charge LPH-1 from steam side. Extraction NRVA-2 will

open on auto. Extraction line drain valve MAL-55

closes. Now open LPH-2 extraction steam isolating valve

EX-10 and close extraction line drain valve EX-101 and

EX-102 (CWA-15). Close locally drain valve of LPH-1,

EX-113. Open LPH-3 extraction line steam isolating

valve EX-11. Extraction NRV A3 will open and drain

valve MAL- 54 closes on auto. Close extraction line

drain valve EX-103 for LPH-3. Put LPH-1,2,3 level

controls on auto, one after another (CWA-15).

HRS-9 CARRYOUT AT l_00 MW AUXILIARY SUPPLY CHANGE OVER

From station bus to unit auxiliary bus and turn trans-

fer bus selector on auto mode so that when unit trips

auto changeover takes place from UAT to station trans-

former.

92
&

O HRS-10 STARTING BOILER FEED PUMPVB' ON GROUP SEQUENCE OR MANUAL.

O Start BFP manually or in group sequence and make equal

loading of both the BFPs. Check feed water flow and

^ maintain drum level to normal.

^ HRS-11 LOAD RAISING TO L50 MW


o
Line-up Plveriser- C for increasing further load
O ' '
start pulveriser- C and load RC feeder to 60-70%.
o
MS pressure, load temperature will increase. Increase
O '
load reference to 150 MW . Load will gradually increase
to 150 MW as per the load gradient. Ensure that TSE
Hi
margins are available for increasing load. Check turbo-
o
visory parameters. . Observe all the important parame-
G
t e r s at 150 MW.
o
HRS-12 CHARGING OF HP HEATERS FROM.STEAM SIDE
Ensure that heaters are charged from water side. Open
o HPH-5 extraction drain valve EX-112 and HPH-6 extrac-
ts
tion 'line drain Valve EX110 . Open extraction valve
o.
EX-13 for HPH-5 and EX-12 for HPH-6. Open drip control
o ^
valves to maintain NWL of 250 mmwc in the heaters. Put
*
. drip control on auto for both the heaters. Then close
r^ extraction line drain valves EX-112 and EX-110. Put HP

^ heaters group protection on auto and level controls on

auto.
Q

93
HRS-13 WITHDRAW HO GUNS FROM AB ELEVATION.

Withdraw oil firing from AB elevation by giving stop

commands to pair 1-3,2-4.

HRS-14 TAKING PULVERI5ER-D IN SERVICE

For further increase in load, take pulveriser D in

service. Increase RC feeder-D speed to 60%.

HRS-15 INCREASING LOAD TO 21J3 MW

Increase load reference to 210 MW . Load gradually

increases to 210 MW at the rate as per the gradient

set. Observe various important parameters.

HRS-16 TO PUT UDC ON AUTO

Bring UDC pressure set point to 150 kg/cm2. Wait till

pressure deviation on boiler desk (CWA-12) comes to

zero. Press "ON1 push button of co-ordinated mode to

make it "ON1. Put boiler set point on auto. Put fuel

factor on auto.Put MS pressure set point on auto. MS

pressure will be maintained . Any deviation in the load

is to be made by varying unit load target set point

(ULDSP).

HRS-17

' Note various important parameters at 210 MW load from

control desk and back panels.

xxxxxxx

94
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It is apparent that each functional group continues to

function automatically all the times demanding "Enabling

Criteria1 from other functional groups. In case the red

"Enabling Criteria' is not available from neighbouring

"Functitonal Group Control, the system would automatically

- act in such a manner as to ensure the safety of the main

turbine. This method avoids a major difficulty generally

encountered in laying down priority and correct sequence of

the various steps in single logical chain of events.

MODE- OF OPERATION

Each functional group is divided into logical steps arranged


in a proper sequence.Prior to the commencement of any step,

it is necessary that certain conditions regarding status of

plant get fulfilled and the relevant parameters acquire the

desired value. All these pre-conditions are meticulously

planned for each step and demanded from the system as

"Enabling Criteria1 for next step.

ATRS- STRUCTURE AND GENERAL FEATURES

Automatic Turbine Run-up system is essentially organised in

two subgroup controls namely Turbine Run-up(SGC Turbine) and

Oil System (SGC Oil). These groups in conjunction with TSE

and electro-hydraulic governing system accomplish the ' var-

ious functions. A sub-group control essentially executes a

set of steps in a proper sequence. Sub-group control at

times envisages a sub-loop control which essentially exe-

cutes commands based on the availability of "Enabling Crite-

ria1 .

96
m

f% Sub-group control for the turbine run-up acts directly on:


^ a) Sub-loop controls (SLC) for the drains
0 . b) Electro-hydraulic governing system
c) Auto Synchroniser
0 . Sub-group control for the oil directly actuates:
C5 a) SLC for the DC lub.oil pump
O b) SLC for lub.oil system
^ c) SLC for turning gear operation and
d) Interface devices for selected few pumps.
^ According to pre-determined sequence, SGC & SLC ensure
t> various requirements of control oil, lub.oil hydraulic
^> turning,etc. under run-up shut-down and trip conditions.
O The sub-loop controllers get switched ON and OFF accord-
^ ing to the pre-defined sequence logic built in the SGC.
O The sub-loop controls can be operated independently of
w
SGC. However the actual execution of command of a SLC
^ takes place only if the enabling criteria for the ful-
^ filment of a particular command are completely satisfied.
^ It is possible to intervene manually at any level namely
interface sub-loop control or sub-group control.
o
The enabling criteria at the various levels of heirarchy are
O
of different nature. For instance, the enabling criteria at
w
the "interface level1 envisaged is based on the equipment

^ protection point of view rather than the process considera-

^ tion.

97
It is also possible to manually start the plant upto any

level/status then ask the sub-group control to perform the

remaining functions. To facilitate such modes of operations,

the sequential logic has been developed in such a manner

. that sub-group control shall quickly skip to the proceeding

step done manually and accomplish the steps automatically in

the desired logical manner. The SGC Turbine logics (ATRS)

incorporating various steps and criteria required to execute

each steps are given below:

ATRS START-UP PROGRAMME

Operation Release

1. Starting device 0%

2. Position set point of turbine control <0%

3. Generator field breakerVOFF'

4. Generator breaker "OFF1

5. Drain BEF HP control valve-I not closed '>>^'iJ " .<-.,<

6. Drain BEF HP control valve-2 not closed >^'"~'

7. Limit pressure operation "ON'

8. Load Control "ON'

9. Synchronizer "OFF'

10. f$^s Oil pressure>4.8 kg/Sq.Cm.

Step-1

Switch on SLC drains-MON time 2 seconds.

Criteria for Step-2

1. SLC drains "ON1

2. All ESVs closed

3. HP control valve-1 closed

98
o
_ 4. HP control valve -2 closed

0 5. INTCPT Valve-1 closed

0 6. INTCPT Valve-2 closed

0 7. NRV CRH LH closed


<Q 8. NRV CRH RH closed
0 9. EXTR Valve A5 <5%
0 10. EXTR valve A4 <5%
|3 11. EXTR valve A3 <5%
j 12. EXTR valve A2 <5%
0 Step-2
(Q No command issued - MONS time 100 seconds
Q Criteria for Step 3^

Q 1. Trip fluid pressure > 5kg/Cq.Cm.

Q 2. Turbine speed >15 rpm


o 3
One Condensate Pump "ON1
o 4
SLC drains not faulted
o 5
DT HP CAS SEN TOP - BOT > minus 40 K
w . .6
DT HP CAS SEN TOP - BOT < plus 40 K

O 7. DT IP CAS FR TOP - BOT < plus 40 K

O 8. DT IP CAS FR TOP - BOT > minus 40 K

O 9. DP IP CAS RE TOP - BOT < plus 40 K

O 10. DP IP CAS RE TOP - BPT > minus 40 K

O Step:3

Q Close drain BEP HP CONTROL Valve-1

Q . Close drain BEF HP CONTROL Valve-2

O Switch SLC warm-up CONTROL "OFF1

99
Criteria for Step-4

1. Drain BEF HP CONTROL valve-1 closed

2. Drain BEF HP CONTROL valve-2 closed

3. SLC warm-up CONTROL ^OFF'

4. Waiting time 60 seconds.

Step:4

No command issued - MON time blocked

Criteria for Step-5

1. Boiler fire v0N'

2. Steam BEF HP BYP 1>3OK superheat


3. Steam BEF HP BYP 2>3 0K superheat

4. Steam BEF LP BYP 1>3OK superheat

5. Steam BEF LP BYP 2>3 0K superheat

6. DT (HP BYP-1-CONTROL valve mid) GT X-l-1

7. DT (HP BYP-2-CONTROL valve mid) GTX-1-2

8. Total boiler steam flow GT 15%

9. DT (wet steam 1-CONTROL valve) LT X-2.1

10. DT (wet steam 2-CONTROL valve) LT X-2.2

11. DT (HP BYP-1 CONTROL valve) LT X-3

OR BLR steam temperature BEF HP BYP-1 < 4 00 deg.C

12. DRN BEF HP ESV-1 Not closed

13. DRN BEF HP ESV-2 Not closed

14. DRN BEF INTCPT ESV-1 not closed

15. DRN BEF INTCPT ESV-2 not closed

16. Oil temperature after cooler >35 deg.C

100
G . . Step-5:

C? Starting device raise-MON time 60 seconds.

*53" Criteria for Step-6

'^ 1. Starting device >34 %

2. HP ESV-1 not closed


^ 3. HP ESV-2 not closed
Step-6:
^ No command issued-MON time 60 seconds.
Criteria for Step-7
1, HP ESV-1 open
^ 2. HP ESV-2 open
KjJ
Step-7:
^ No command issued - MON time blocked
Criteria for Step-8
1. Total steam flow >15%
'^ 2. Steam BEF HP BYP-l>30 K superheat
W
3. Steam BEF HP BYP-l>3 0 K superheat
^ 4. Steam BEF LP BYP-l>30 K superheat
^ 5. Steam BEF LP BYP-2>30 K superheat
6. Boiler fire "ON'
7. DT (HP BYP-1 CONTROL valve) > XI.1
8. DT(HP BYP-2 CONTROL valve) > XI.2
9. Condensate pressure < 0.5 kg/sq.cm.
"^ Step-8:
^ SLC warmup CONTROL ON-MON time 2 seconds pa

101
Criteria for Step-9

1. SLC warm-up CONTROL ~0N'

Step-9:-

Starting device r'aise-MON time 40 seconds.

.Criteria for Step-10

1. Starting device >70%

2. INTCPT ESV-1 open

3. INTCPT ESV-2 open .

Step-10:

Speeder gear raise - MON time 500 seconds.

Criteria for Step-11

1. Drains no fault

2. Speeder gear 100%

3. Gland steam pressure CONTROL "ON1

4. SLC oil temperature CONTROL "ON1

' 5. Any oil vapour- extraction "ON1

6.' HYD purity 97%

7. Generator gas pressure>3.4 kg/sq.cm.

8.- Generator seal oil gas DP >0.9 kg/sq.cm.

9. Generator seal oil turbine side pressure>3.8 kg/sq.cm.

10. Generator seal oil EXC side pressure >3.8 kg/sq.cm.

11.. Level in pre-chamber-l&2 <Max.

12. GENERATOR CW FLOW >21 cub. mtr./hr.

13. GENERATOR Stator CW pressure >2.4 kg

14. Stator CW inlet temperature <44 deg.C.

102
V /

0
15. HYD cooler CW pressure >2.5 kg/sq.cm.pa
o
16. Liquid in GEN not present
0
~ 17. Generator SW CONDUCTIVITY <5 MHO
Q
> Step-ll

i^ . No command issued-MON time blocked.

<f% Criteria for step-12


O l. All criteria for STEP-11

0 2. Steam BEF HP ESV-1 SUPER HEATER > X-4.1

Q 3. Steam BEF HP ESV-2 Super Heater >X-4.2


0 4. DT (HP ESV-1 HP case) > x 5.1

O 5. DT (HP ESV-2 HP shaft)> x 5.2

<f> 6. Turbine speed >15 rpm

rsj 7. DT (LP BYP-l-IP CAS) >30 K

0 8. DT (LP BYP-2-IP CAS) >30K

"0 9. Steam temperature BEF LP BYP-1 > 480 deg.C


10
Steam temperature BEF LP BYP-2 > 480 deg.C
11.

r\ Drain BEF HP CONTROL valve-1 not closed


12 .
Drain BEF HP CONTROL valve-2 not closed
'-^ 13.
Power set point >10%

O 14. CONDENSATE pressure <0..2 kg/sq.cm

O 15. R E L EXP CAS-1 front <plus 8 mm

Q 16. REL EXP DAS-2 rear <minus2 mm

Q 17. REL EXP CAS-2 rear <plus 8 mm

O 18. REL EXP CAS-2 rear <minus2 mm

Q 19. REL EXP CAS-3 rear <plus 8 mm

O 20. REL EXP CAS-3 rear <minus 2mm

103
frOT

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>
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suoaoxui sc> quojj
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auiT3 NOW- p a n s s t pueuituoo OH

spuooss 00C suitq BuT^teM 'Z

ujda: 0S9 ^urod ^as pasdg

spuooss o^ sujxq NOW- SSTEJI ^utod ^as peeds


?* '.a

,*>. 16.RAD bear 1 CAS front LH top temp. <MAX

tf| 17. RAD bear 1 CAS front RH BOT temp. <MAX

Q 18.RAD bear 1 CAS front LH BOT temp. <MAX

0 19.RAD bear 1 CAS front RH BOT temp. <MAX

0 2 0.RAD bear 1 CAS rear LH top temp. <MAX

0 21.RAD bear 1 CAS rear RH top temp. <MAX

0 22.RAD bear 1 CAS front LH BOT temp. <MAX

O 23.RAD bear 1 CAS front RH BOT temp. <MAX

O 24.AX bear 1 CAS R/F LH temp. <MAX

25.AX bear 1 CAS R/F RH temp. <MAX

O 26.AX bear 1 CAS R/R LH temp. <MAX

O 27.AX bear 1 CAS R/R RH temp. <MAX

O 28.RAD bear 2 CAS rear temp. <MAX

O 29.RAD bear 2 CAS R/RHB temp. <MAX

C5 3 0.RAD bear 2 CAS R/F RHB temp. <MAX

O 31.RAD bear 2 CAS R/R RHB temp. <MAX


"J? 3 2.REL EXP <MAX
O 33.GEN Bear front temp. <90 deg.C

^ 34.Gen bear front temp. <90 deg.C


xi
Step-15

*"' SLC warm-up CTRL OFF MON TIME 10 Seconds.

"-v Criteria for Step-16


^ 1. SLC warm-up control "OFF 1
w
Step-16:
^ Turbine speed set point raised-MON time 200 seconds
^ DRN BEF HP CONTROL valve-1 closed
w
DRN BEF HP CONTROL valve-2 closed
o
105
Criteria for Step-17

1. Speed setpoint 3000 rpm.

Step-17

No command issued - MON time blocked

Criteria for Step-18

1. Turbine speed >2950 rpm

2. Bear VIB CAS GEN < MAX

3. Shaft VIB < MAX

4. Bearing temp. < MAX

Step-18

DRN BEF HP CONTROL V-l closed. MON time 4 0 seconds

Criteria for Step-20

1. Both AOP "O?'Fr

2. DT (LP BYP-l-IP shaft)< X 7

3. Gen. conditions fulfilled

4. Field flash supply "ON'

5. AVR control supply "ON1

6. AVR PROT supply "ON1

Ster-20

"-en. filed BRKR ON

C : : .'ria for stiep 7 i.

1. Wait time 15 seconds.

2. Generator field BRKR ON

3. Generator Voltage 15 KV

Step-21

Synchroniser ON- MON t: i me 6 0 seconds.


:3' Criteria for step-22

1. GENERATOR BREAKER ON

^ Step-22

Starting device raised-MON time 100 seconds.

.* Criteria for step-23

""" 1. Gen. load >10%

Step-23
o No command issued-MON time 2 seconds.
i f *
Criteria for Step-24
1. Wait time 2 seconds.

Step-24 .
<r "*
Starting device raised- MON time 60 seconds.

c Criteria for Step-25


1. Starting device 100%
^ Step-25
e
No command issued- MON time blocked

"" ATRS SHUT- DOWN PROGRAMME

Step-51

1. SLC drain ON- MON time 2 seconds.

Criteria for Step-52

1. SLC drains ON

Step-52

Power set point lower-MON time blocked

Criteria for step-53

1. Speed CONTROL in action


2. Power set point 0% or Gen. BRKR OFF

107
V

Step-53

Turbine.'speed set point lower Mon time 60 seconds

after a delay of 100 seconds. i

Criteria for step-54

1. Elec. turbine trip CH-1 trip

2. Elec. turbine trip CH-2. trip- MON time 2 seconds.

3. Synchro."-" ser OFF

Criteria for Step-55

1. SYNCHRONISER OFF

2. Trip fli.^o pressure < 5 kg/sq.cm

:? . GENERATOR field breaker OFF.

1 . ALL ESVs ,...osed ?

Step-5S:

Starting device lower

1. Drain before HP CONTROL V-l open-MON time 120 seconds

2. Drain be. re HP CONTROL V-2 open

/3 . SLC warm-up control OFF

Criteria for step-56

1. Drain before HF .iONTROL V-l open

2. Drain Before K? "DNTROL V-2 open

3. Smarting devi< :* '

4. Drains no fault ' .

5. SLC warm up CONTROL OFF

Step-56 '

No command issued-MON time blocked.

108
o

o
f% ATRS SGC OIL LOGICS-Shut down programme:
f| ' 1- Temp. HP casing top 50% <100 deg.C.
Q 2. Temp. HP casing bottom 50% <100 deg.C.
Q Step-51
0 SLC turbing gear OFF - MON time 60 seconds. Gate valve
O gearing closed.
0 Criteria for Step-52
0 1. SLC turning gear OFF
O 2. Gate valve gearing closed
O Step: S2_:
0 No command issued Mon time blocked
G Criteria for Step-53
0 1. Turbine speed <10 rpm
Step-53
O No command issued - MON time blocked
O Criteria for Step-54
O 1. Waiting time 1000 seconds.
O Step-54
Q SLC JOP-1 OFF- MON time 4 seconds. SLC JOP-2 OFF
^ SLC oil temp. CONTROL OFF, JOP-1 OFF
^ Criteria for Step-55
O 1. SLC JOP-1 OFF
O 2. SLC JOP-2 OFF
O 3. SLC oil temperature CONTROL OFF
G 4. JOP-1 OFF
<Kj
5. JOP-2 OFF
O

109

/'>
SLC AOP-X OFF
SLC AOP-2 OFF
SLC BOP OFF
AOP-1 OFF
AOP-2 OFF
Oil temperature CONTROL valve closed.
Criteria for step-56 . :

1. SLC AOP-1 OFF


'A . SLC AOP-2 OFF
3. SLC EOP OFF
4. AOP-1 OFF
5. AOP-2 OFF
6. Oil temp. CONTROL valve closed
7. EOP.OFF
Step-56
No command issued- MON time blocked
Fire Protection-l

] fire protection-l is pushed or main oil tank level I:..;

low, command is given to trip turbine and to trip th;

gate valves.
After generator breaker opens command is given for 3 second:;
to open vacuum breaker if trip oil pressure does not I:"a 1 1 bo i ,w
5 kg/sq.cm and emergency stop valve does not close wii hiii 10
seconds annunciation" FIRE PROTECTION NOT COMPLETE' a y>\ ", r ::.

110
o

!'' -I
F u e f r o I eel:, i o n 2. w h e n p].';!:e<] r cciii IK . .1 i

R o o m ,-u'Vr. on f.iic pn'M'i-; ; . a no .jivey us.-. ... ur-c- c>.

F u r t h e r It g i v e s thi.

-,. SGCOI.J#> SUPPLY OF:-1

.*^:* SLC AOP-1 '0^?

^ , SLC A0P-2vv'-:-.

0 SLC -EOP^ON v <


k.

^ SLC JOP-1 QFf'

0 SLC J6?y2- OFF


^> . SLC turning gear OFF
Q ' AOP-1 PRO'T 'OFF

Q A0P T 2 PROT O F F '

Q J O P - 1 PROT/OFF '- -

Q J O P - 2 P R O T O F F (, '- * ' " *

0 A check i^ m^de whether a l l above comrtiands are^ fulf i-lled

Q alongwith cb^lapsEeyof t r i p o i l p r e s s u r e . If -hpt, a n n u n c i a t io;i


O ^FIRE PRF0TECTIGN.-2 FAULT'. a p p e a l s ; ; ' .
O Sub-Group C o n t r o l Oil Logics

0 ' Operation R e l e a s e s : . . .

O> 1 . o i l v a p o u r e x t r a c t o r (1) o r (2) ON


O ' 2 . Oil- tank level adequate
O Step:1

O. No command issued-MON time-blocked


O Step:2

O Switch on auxiliary oil pump (1) monitoring time 2 seconds.

111
CriJteria for step- 3-
.1 . . Auxiliary oil pump (1) ON
2. Pressure-oil pressure > 4.8 kg/Sq.cm.

Step-3

Switch on SLC oil temperature controller monitoring time 2


seconds.
Criteria for step-4
1. SLC oil temperature controller ON

2. Gen.seal oil gas D P ^ O . 8. kg. sq.cm

3. Gen. seal oil turbine side pressure >3.8 kg/cq.cm

'1 . Gen. seal oil excitor pressure >3.8 kg/sq.cm


5. Hydrogen purity >97%

6. Generator gas pressure >3.4 Kg/sq.cm

7. Liquid in generator not present

Switch SLC turning gear ON Monitoring time 60 seconds.


Criteria for Step-5 - /
1. Gate Valve- gearing Open
2 . S.LC t u r n i n g g e a r O N '.''

S t e p - , 5 ' ' "" . p., ,' ..

Switch SLC auxiliary oil pump-1 ON


.-Switch SLC auxiliary oil pump-2 ON
Switch SLC emergency oil pump ON

Monitoring time 200 seconds.

Switch SLC jacking oil pump-1 ON

Switch SLC jacking oil pump-2 ON

112
o
Criteria for Step-6
Fulfilment of all the above commands

Turbine speed > 15 rpm



Step-6
O\
No command issued. Monitoring time 200 seconds.
Criteria for step:7
0
Turbine speed >54 0 rpm

Step-7
o
No command issued - Monitoring time 200 seconds

Criteria for step -8

1. Jacking oil pump-1 OFF

2. Jacking oil pump-2 OFF


3. Gate valve gearing closed
Step-8

No command issued-Monitoring time blocked.

Criteria for step-9

1. Turbine speed > 2950 rpm

^ ' 2. Pressure-oil pressure >7kg/sq.cm.

,^ 3. Switch auxiliary oil pump-1 OFF

o 4. Switch auxiliary oil pump-2 OFF

^ Monitoring time 0.5 seconds.

Crirteria for step-10

o Waiting time 0.5 seconds.

r^ Step-10

No. command issued-Monitoring time 10 seconds.

113
T-dOr
.I9-4B9JG st. psadf-; r9u-cq:tn^ gi

M H
'-l '-13 AT 6 3T

Wdtf. 0rS esa.x si posds; ^i.ij.

NO ST. 1-dOr OTS


;
I-dOr iczquoo aoox-qns
dO3. u o qoq.TA\s o q U S A T B SX p u e u w o o

i.uo-bs/6>( T1.---X ut*qq ss.9X s\ s j t n f s s e a d X'io a r r r J.J

I TO Aouobasuia oa-io^quoo aooT-qns

XT 'xnv uo tptl.TMS qq USAIB ST pu^iuiuoo

5.td T.TO-HO

I-dOV

NO. ST. Z- dOV DrlS

3~-'d.u;ric[ x~f'o X3cT2TXTxnV ~ T ^ ^ ^ U " 5 ' 5 " cIoox

XT "'1-V u o
T-P^TMS 03 QSAIB ST

ST s.xasssad '[TO HO
sd-c.zq e-a

NO ST I- ,-lOV D'lS U3MH

q-qns

,i.3O diu:id [ t o Ao

.LJO' ?; - du.!ad X T O Aae.'TXT^"^' ' 1

3dO T.-dumd [TO A.iirT 7/1 >:ny "c

s p u o o s c 01 ^LiiT ra fiurri T'S

'ii'oj ^
Sub-loop Control-Jack Oil Pump-2
o
When SLC JOP-2 is ON
o
If JOP-1 trips
OR if jack oil pressure is <120 kg/sq.cm.
o

^ When turbine speed is <510 rpm with a delay of 5 seconds

O Command is given
1. To switch ON JOP-2
_ 2. To switch OFF JOP-1

_ 3. To switch OFF SLC JOP-1


G
Sub-Loop Control-Turning Gear
O

g^ When SLC turning gear is ON


g~\ If turbine speed is less than 200 RPM
p, Command is given to open the gate valve gearing
r> If turbine speed is greater than 250 RPM
f^ Command is given to close gate valve gearing

xxxxx

115
210MW UNIT AUXILIARIES INTERLOCKS & PROTECTIONS

A^ BOILER & IJTS AUXILIARIES INTERLOCKS & PROTECTIONS

1.0 ID FAN INTERLOCKS

1.1 Conditions existing when the unit is shut down and

prior to starting of ID fans

ID Fan-A and ID Fan-B off

Regulating dampers of Fans A & B fully open

inlet gates of Fans A &"B open

Outlet gates of Fans A & B open

The regulating dampers will be on manual control during

shutdown, and impulse from furnace draft control to

regulating, dampers of ID fans disconnected.

1 .2 Starting ID Fan "A' (ID Fan 'B' 'off')

(a) ID fan-A shall be prohibited from starting till the

following conditions are satisfied (start permissive

conditions)

1. Regulating damper of Fan-A (GD-6A) in close position -

2. Outlet damper of Fan-A closed v

'3. Inlet damper of Fan-A closed >

4. Fan/Fan motor bearing temperatures not high <85/60 deg. C

5. One of the Air preheaters is running.

(b) When ID fan-A is started (ID fan-B is off) impulse shall

be given for-

1. Opening the inlet damper and outlet damper of Fan-A

2. Connecting the regulating damper of Fan-A to the auto

control (enable to operate)

116
li

o
^ 3. ID Fan-B bringing the regulating damper to close
o
^ position
4. Permission to start either FD fan-A or FD fan-B
o
1.3 Starting ID fan-B (ID fan-A is off)

Interlocks similar to those at clause 1.2 shall hold good

for this condition.

1.4 Tripping of LD Fan-A (ID fan-B is off)

(a) ID fan-A shall trip automatically under the following


. -
conditions.
1. ID fan-A bearing temperature too high >90 deg.C (prior
o
to this, ID Fan-A bearing temperature high shall be
G
deg.C (prior in
annunciated to UCB)
this, ID fan A motor bearing temperature
o
2. ID Fan-A motor bearing temperature too high >70
high shall be annunciated in UCB)

3. "Post purge FAN Trip1 from FSSS (one contact will be

provided to trip all the ID & FD fans). Command is


o
o
initiated when furnace pressure is very high or very

low +352/-250 mmwc.


o
4. ID fan-A motor protection acted.

(b) When ID fan-A trips(ID fan- B is off) impulse shall be

given for:
1. Opening the outlet damper of ID fan-B
2. Opening the inlet damper of ID fan-B
G
3. Opening the regulating damper of ID Fan-B to wide open
position.

117
4. Disconnecting the regulators impulse from acting

on regulating damper of ID fan-A

5. Opening the regulating damper of ID fan-A to wide

open position

6. Tripping the running FD fans

7. Boiler tripping-through FSSS (Initiated MFT)

8. To keep the inlet gate and outlet gate of ID fan-A open.

1.5 Tripping of ID fan-B (ID fan-A is off)

Iterlocks similar to those at clause 1.4 shall hold

good for this condition.

1.6 Starting of ID fan-B (ID fan-A _is ON)

(a) ID fan-A shall be prohibited from starting till the

following conditions are satisfied (start permissive

conditions).

1. Outlet damper of Fan-B is closed

2. Inlet damper of Fan B-is closed

3. Regulating damper of Fan-B is in minimum position

4. Fan/Fan motor bearing temperatures not high <60/85

deg.C.

5. One of the Air preheaters is running.

(b) When ID fan-B is started impulse shall be given for

1. Opening the inlet damper and outlet damper of Fan-B

2. Connecting the regulating damper of Fan-B to the

auto control (enable to operate)

3. Permission to start the other FD fan

118
o

^ 1_J_ Starting of LD fan-A (ID f a n - B ^ s ON)

T n t ' . r i f l o t );;; similar to those- at rl anno 1.6 shall hold


o
good i'di Uris condition.

1.8 T r J P P i n i l P J - L D F a n - B (ID F a n - A i s ON)


o " "" ~ " "
;<;) II.} fa:r-i;, sh<\ 1.1 trip a u t o m a t i c a l l y under the follow-
o
inq conditions.
o
1. Fan bearing temperature too high (prior to this,
0
fan bearing temperture high shall bo: annunciated in
^ UCB) 7 0 deg.C.
o
^ .': . Fan !iio;..or bearing temperature too high (prior to this,
fan motor bearing temperature high shall be annunciated

/r> in UCB >90 deg.C.

3. ^Post purge FAN Trip1 from FSSS

~ 4. ID fan-A motor protection acted.

^ (b) When ID fan-B trips (ID fan-A is ON) impulse shall be


O
^ given for:

f% 1. Disconnecting the regulator from acting on the regulat-

fi ing damper of FAN-B

Q 2. Bringing the regulating damper of Fan-B to close

Q) posi t: ior. .

Q 3. Closing che inlet damper of fan-B

Q 4. Closing the outlet damper of fan-B

O 5. Tripping the FD fan-B provided FD fan-A is on.

Q 6. Energisation of partial load relay (50% Run back)

Q 1.9 Tripping of ID fan-A (ID fan-B is open)

Q Interlocks similar to those clause 1.8 sahll hold

Q for this condition.


Q
G 119
2.0 FD FAN INTERLOCKS

2.1 Conditions prior to starting FD fans

FD Fan-A and FD fan-B off

FD Fan-A & B impellers are full open

Outlet dampers are fully open

FD Fan-A & B impeller regulators disconnected (Forced.

open)

2.2 Starting FD fan-A (FD fan-B _is off)

(a) FD fan-A shall be prohibited from starting until

the following conditions are satisfied:

(Start Permissive conditions)

1. ID Fan-A or ID Fan-B is on

2. FD Fan .Control Oil pressure adequate (8 kg sq.cm)

(control oil pressure adequate lamp indication provided

on the control desk)

3. FD fan-A impeller in minimum position

4. Outlet damper of Fan-A in closed position

5. FD fan/motor bearing temperature not high <95/85 deg.C

(b) When FD Fan-A is started (FD Fan-B off) impulse shall

be given for:

1. Outlet damper of FD Fan-A to open

2. The outlet damper of FD Fan-B to close & impeller blades


of Fan-B to be driven to minimum position.

3. Connecting the impeller of Fan-A control drive to auto

control.

: 120
o

0 2^3_ Starting of FD fan-B (FD fan-A is off)

O Iterlocks similar to those at 2.2 shall hold good for this

^ condition.

^ ' 2 .4 Tripping of FD fan-A (FD fan-B jLs off)

. (a) FD fan-A shall trip under the following conditions-


d
1. FD Fan-A bearing temperature too high (prior to FD fan-A
1
bearing temperture high shall be annunciated in UCB >105 dec
to this, FD fan-A motor bearing temperature high shall be
o FD Fan-A Fan motor bearjjig_tejTiperature too high (pjrior
annunciated in UCB >90 deg.C.
3. Both ID fans trip
G
4. "Post purge FAN Trip1 from FSSS
5. FD fan-A motor protection acted.
G
b) When FD fan-A trips(FD fan-B is off) impulse shall be
o .
given for:
o
1. Disconnecting the impeller control drive from the regu-
o
lator of FD FAN-A
2. Bringing the impeller of FD Fan-A to the wide open
o
position.

3. Bringing the impeller of FD Fan-B to the maximum

position.
Q
4. Opening of outlet damper of FD fan-B
o 5. To open the emergency scanner air damper
6. Boiler tripping
7. The outlet damper of FD fan-A shall remain open.

o
o

o
2.5 Tripping of FD fan-B X?J2 fan-A is off)
Interlocks similar to those of 2.4 shall hold for this

condition. . .

2 .6 Starting FD Fan-B iFD fan-A i_s on)

(a) FD fan-B (FD Fan-A is ON) shall be prohibited from

starting until the following conditions are satisfied:

1. Both ID fans are ON

2. FD fan-B Control Oil- pressure adequate (8kg sq.cm)

(control oil pressure adequate lamp indication

provided on the control desk)

3. FD fan-B impeller in minimum position

4. Outlet damper of FD Fan B in the closed position

5. FD fan-B / Fan motor bearing temperature not high

95/85 deg.C.

(b) When FD Fan-B is started (FD Fan-A is ON) impulse

shall be given for:

1 . Outlet damper of FD Fan-B to .open

2. Connecting the impeller control drive of FD Fan-B

to auto control (enable to operate) .

2. 7 Starting of FD fan-A (FD fan-B i_s ON)

Iterlocka similar to those at 2.6 shall hold good for

this condition.

28 Tripping of FD fan-B (FD fan-A i_s ON)

(a) FD fan-B shall trip (when FD fan-A is ON) under the

following conditions

122
1. FD Fan-B trips (provided FD Fan-A is in service)
o 2. FD Fan-13 motor bearing temperature too high >90 deg. C
o
^ (prior to this, FD fan-B motor bearing temperature high
0
_ shall be annunciated in UCB)
O
,f% 2. FD Fan-B bearing temperature too high >105 deg. C

r% (prior to this, FD fan-B bearing temperature high shall

U be annunciated in UCB .

0 3. "Post purge FAN Trip 1 from FSSS

(H) -4. FD fan-A motor protection acted.

Q 5. FD fan-B oil pressure low shall be annunciated at

,r>, UCB <0.4 kg/ctn2 .


2
G 9 Tripping of FD Fan-A (FD Fan-B is ON)

Q Interlocks similar to those at 2.8 shall hold good for

0 this condition.

0 3 .0 AIR r_THEATERS INTERLOCKS

O 3 .1 Conditions before start-up of APH

O a) Both AHS are OFF (Both AC AH motors are OFF and

O DC AH motors are ON)

> b) The inlet dampers and the outlet dampers in the gas path

^ and. secondary air path, are in full open conditions.

Q 3^ ^Starting AH _^AJ_ _(AH "B1 o^s OFF)


'-'' a) AH "A' electric motor is started, if the temperature
^ of the bearings is less than 60 deg.C.
^ b) Whenever AH "A1 electric motor trips, impulse shall be
G given for starting AH "A1 DC motor provided the tempera-
"~g ture of support/guide bearing of AH is less than 60

' deg.C.
o
12 3
c) Impulse shall be given for closing of the inlet and

outlet dampers of AH "B' which is OFF.

3.3 Tripping of AIT A1 (AH "B1 is OFF)

(a) DC motor shall trip automatically when AH "A'

electric motor starts.

.3 .4 Starting of AH ^BJ. (AH^A1 _is OFF)

a) The interlocks said above for AH "A1 starting(AHB OFF)

is applicable .

3 .5 Tripping o_f AH S B' (AH"A' JLS OFF)

a) The interlocks said above for tripping of AH V A' (AH"B'

is OFF) is applicable .

3.6 Both AHs are working when AH^A' trips & AH^B' continue _to

run.

The gas inlet damper, the secondary air inlet damper of

the tripped AH "A1 shall automatically closed. The gas

outlet damper the secondary air outlet damper of the

tripped AH V A' need not be closed.However if the operator

wants to manually close these outlet dampers,they can be

closed.

124
,f> 3 -7 Both AHs are working when AH"B' trips and AH 'A1 continue

f% t_o run

@ a) The interlocking conditions said above under 3.6 is

0 applicable .

3 .8 One AH ijs working and the other AH i^s OFF

^> a) If the working AH trips, the operator shall try for re-

B starting the AH. If the restarting is not within 5

^ Minutes, the boiler shall be tripped manually.

^ 39 Both AHs are working

a) If both AHs A & B trip, the operator may try for re-

^ starting the AHs. Ifany one of the AH is not started


Kj/
within 5 minutes, the operator shall manually trip

the boiler.
0
3.10 Interlocks for lub oil pumps of support bearing
^ 2 x 100% lub oil pumps has been provided for the support
o
bearing. Any of the two lub oil pumps can be preselected

as main pump and the other as standby. Following inter-

locks shall be provided for the lub oil pump.

^ 1) Whenever the temperpature of support bearing of air

^ . heater is high (35 deg.C), impulse shall be given to

o start the selected oil pump.

2) The standby oil pump shall start when the main oil pump

^ fails to start or trips.

r^ 3) The main oil pump/standby oil pump shall trip when the

r-\ temperature of the support bearing falls below a preset

Q value(30 deg.C)
o
125
3.11 Interlocks for lube oil pumps of guide bearing

2 x 100% lub oil pump has been provided for the guide

bearing. Any of the two lub oil pumps can be preselected

as main pump and the other as standby.The interlocks for

these pumps shall be similar to that of support bearing as

envisaged in clause 3.10 except starting the pump at 40

deg.C second and tripping the pump at 3 5 deg.C.

4.0 BLOW DOWN VALVES

1. When drum water level rises to +125 mm above normal

water level, an annunciation "drum level high'shall

be given in UCB and the blow down valves shall open

simultaneously.

2. Blow down valves to be closed manually when the water

level falls down to NWL.

5.0 FD FAN-B LUB OIL/CONTROL OIL SYSTEM (FD LUB OIL PUMPS)

(a) 1. Pump-A will start automatically if pump-B trips

provided A/M switch is in auto position and sequence

is "ON 1 . Pump-A is selected.

2. Pump-A will start automatically with a time delay of

60 seconds if oil pressure falls below a set value

and the pump-B is working provided A/M switch is in

auto position and sequence is "ON 1 .

(b) 1. Pump-B will start automatically if pump-A trips/ has

not started, provided A/M switch is in auto position.

126

2. Pump-B will start automatically with a time delay of
60 seconds if oil pressure falls below a set value
0
- and the pump-A is working provided A/M switch is in

~ auto position.

^v (c) Pump-A or Pump-B can be started/tripped by pressing the

ff_ respective push button only when A/M switch is on

n manual position.

<S**K (d) FD fan-A shall be prohibited from starting until the

f% control oil pressure is adequate( 8 kg sq.cm)

g% 6.0 FURNACE TEMPERATURE PROBE


^ 1. Furnace temperature probe can be advanced/retracted

,o, using the push buttons provided in UCB as well as at

O local.

r*t 2. Furnace temperature probe shall be prohibited from

r^y being advanced further into the furnace if furnace

C\ temperature sensed by it is more than 540 deg.C.

;H) 3. If furnace temperature probe is inside the furnace

O and the temperature exceeds 54-5 deg.C it will be

Q retracted back automatically.

7.0 Air blower for ID Fan outlet gate/ dampers

a) Whenever any ID fan is started the air blower motor

will be started and shall run continuously irrespective

of whether the ID fan outlet gate/damper is in closed

or in open position.

b) The blower motors shall be tripped manually after both


r>
ID fans are tripped.
U .pa

127
c) With lockable remote/local selector switch, start/stop

facility may be provided remote and local. Local may be

provided with deinterlock facility.

7.1. INTERLOCKS FOR MOTOR OPERATED VALVES WITH INTEGRATED

BYPASS VALVES

1. First open the bypass valves fully

2. A f t e r bypass valve is fully opened, o p e n the main

valve

3. After main valve is fully opened, bypass valve may

may be closed.

4. Main valve can be closed wherever required. The bypass

valve, if not already closed, can also be closed along

with main valve.

7.2 INTERLOCK FOR MOTOR OPERATED ISOLATION V A L V E S IN SERIES


WITH MOTOR OPERATED REGULATING V A L V E .

1. While opening, the isolating v a l v e has to be opened

fully first and then the regulating v a l v e has to be

opened.

>. While closing, the regulating v a l v e , has to be closed

fully first and then the isolating valve has to be

closed.

This is to prevent erosion of the seat of isolating

valve which has to maintain its tight shut off

characteristics.

PA FAN INTERLOCKS

a) PA Fan start permissives

1. No MFR trip

12 8
11

^ 2. Pulveriser ignition permit available

^ 3. Hot air'gate is closed

0 4. Seal air pulveriser bowl DP O.K.

0 5. Inlet damper in mini position (closed)

<y? 6. CAD < 5% open.

Q b) PA fan tripping

0 l.PA fan off push button pressed

0 2.MFR trip

Q 3.PA fan auto stop command

G 9^ SEAL AIR FAN INTERLOCKS

0 a) 3 seal air fans are provided s/b fan picks up when seal

O air pressure is low for more than 10 seconds.

0 If fan-A gets a start command but does not start, after

0 5 seconds Fan-B gets start command.

O If fan-B gets a start command but does not start, after

O 5 seconds Fa.n-C gets start command.

O If fan-C gets a start command but does not start, after

O 5 seconds Fan-A gets start command.

^!' b) If any one of the two seal air fans trips or seal air

'^-; header pressure is low the third fan will start.

'** And if 3rd fan does not start the mills will get trip
x
--' command from top downwards .

^J Manual trip is possible only if the pressure is not low


^j and
^ i) 2 or 3 seal air fans on & less tan 4 mills in
f^
w
service
^ ii) 1 seal air fan on & no mill in service

^ 12 9
c) Each seal air fan has an associated outlet damper.

Whenever any seal air fan is started, the outlet damper

gets a close command. After 10 seconds it gets an open comma

d) Whenever a seal air fan is stopped the associated

outlet damper gets a close command.

e) Seal air valve will get close command when all

the following conditions are present.

1. Hot air gate closed

2. PA fan inlet damper closed

3. CAD less than 5% open

4. Pulveriser Off

5. Hot air damper closed

6. PA fan off.

11. PULVERISER ,

a) Ignition permissive

Prior to startup of any pulveriser the ignition

permissive must be adequate to support coal firing.

This is accomplished by either minimum of 3 of the

4 heavy oil guns in service on the adjacent elevation

or boiler loading is greater than 3 0 % and pulveriser

load should be greater than 5 0 % on the adjacent

elevation.

b) Lub oil pumps for mills

Both the pumps will be tripped if any one of the

following conditions is preset:

1. When push botton is pressed when pulveriser is in

manual mode and off.

130
2. When there is an auto stop order when pulveriser

is in auto mode
o 3. Oil level in main oil tank is very low.
c) Pulveriser permissives

1. Pulveriser/feeder start permit

2. Primary air permit

3. Burner gates open


Q
4. Lub oil pressure OK
5. Pulveriser discharge valve open.

6. Tramp iron hopper valve open

7. Bunker gate open


G
8. Cold air gate open
9. Pulveriser outlet temp.<94 deg.C.
10. Pulveriser ignition permissive O.K.

11. Pulveriser OFF

13. Seal air header bowl dp greater than 200 mmwc

14. No pulveriser trip command.


d) Pulveriser tripping conditions
a) Pulveriser discharge valve not open or any bunker
gate not open
b) Loss of unit critical power(+24V)
c) Pulveriser ignition permissive i.e. support
ignition energy is removed within 3 minutes from
starting of associated coal feeder.
d) MFT operated
e) PA fan trips
.pa

131
f) Seal air DP low < 115 mmwc

g) Loss of elevation DC (+24V)

h) Lub oil prpessure low < 0.4 kg sg.c.

e) Feeder speed comes to minimum when

1. Pulveriser bowl dififerential pressure high >3 00 mmwc

2. Pulveriser motor current (40A) above max set point


reaches

f) Loss of coal flow and low pulvleriser motor current

(22A) will trip the feeder and closes hot air gate

g) High pulvleriser outlet temperature >95 deg.C will

close hot air gate and will open cold air damper.

h) When one FD fan trips & four or more pulverisers

are in service, trip command will be given, starting

from the pulveriser serving top most elevation,until

the pulverisers remaining in service reduced to three.

12. MASTER FUEL TRIP

MFT command will initiate following

1. All-pulverisers, feeders trip

2. Both the trip valves closes(HO & LO)

3. All oil guns will trip

4. All the PA fans trip

5. All pulverisers cold air dampers are open to

100% position after time delay of 5 minutes.

6. All auxiliary air and fuel air dampers are

opened to 100 % after time delay of 2 seconds.

132
^ Following conditions will initiate MFT
&
Boiler will trip on any of the following conditions:
1. Both ID fans off
Q>
2. Both FD fans off
3. Emergency trip button operated(initiated by operator)
4. Furnace pressure very low - 250 mmce

5. Furnace pressure very high + 325 mmwc

6. Rehater protectiton trip

7. Drum level very high +225 mmwc

8. Drum lelvele very low - 225 mmwc


o
9. Loss of unit 220 V DC power for more than 2 seconds
c 10. Low.air flow < 30 % (<240 T/hr)
0
11. Unit flame failure

_^ Scanner Fans

1. S/b scanner fan will pick up when scanner duct to

furance differential pressure is below 112 mm we

After 10 seconds an alarm is annunciated

^ 2. The scanner fan emergency damper will open when both

^A the FD fans are off

^ 3. An operator can. trip the fan provided scanner to furnace

,,.. DP is not low 150 mmwc.

& TURNINE AND ITS AUXILIARIES INTERLOCKS & PROTECTIONS

O 2.0 BOILER Feed Pump

^-J 2.1 BFP start permissives conditions-

^ Boiler feed pump will start when following conditions

are satisfied-

133
1. Deaerator level normal

2. BFP suction valve open

3. Aux.Oil pump "ON'and lub.oil pressure > 2.5 kg sq.cm

4. Discharge valve closed,recirculation valve is open

5. Working oil temperature not high < 13 0 deg.c.

6. Differential temperpature across feed pump suction &

discharge not high < ' 12 deg.C

2.1.1 Tripping conditions

Boiler feed pump will trip automatically on any of the

following conditions

-+. 1. Differential temperature across feed-pump suction

i^ and discharge is high 12 deg.C

L 2. Working oil temperpature high 13 0 deg.c.


M
3. Lub.oil pressure less than 1.0 kg sq.cm
D
4. Motor protections acted~ (motor winding temp. > 95
deg.C and over load)

5. Deaerator level less than 700 mmwc

2.1.2 Automatic starting of standby BFP

1. In case of running BFP trips standby BFP picks up and

when 2 pump operation is selected and flow greater than

325 T/hr

2.1.3 BFP recirculation valve will open when corresponding

boiler feed pump is "ON' and feed water flow is less

than 100 T/hr or if differential temperature is greater

than 12 deg.C.

2.1.4 BFP recirculation valve will close when feed water

discharge flow is greater than 220 T/hr

134
0 2.2 Condensate Extraction Pumps
0 2.2.1 Start permissive conditions-
0 Hot well level not low >3 00 mmwc

2.2.2 Tripping conditions- Running CEP will trip automatically

When any of the following conditions exist:


o 1. CEP discharge pressure is less than 14 kg cq.cm.
2. Motor protection acted
3. Hot well level is very low <300 mmwc
0 2 .2.2 Standby CEP will pick up on auto when SLC is "ON1 and
0 running pump trips on protection or discharge pressure
is less than 14 kg sq.cm.
O 2 .3 Turning gear (gate valve gearing)
When turbine rolling is started gated valve gearing
(turning gear trips) will be OFF at turbine speed at
O 240 rpm. When turbine trips and speed drops from 3000
rpm, turning gear will engage at 210 rpm..
O 2 .4 Interlocks for Turbine Oil Pumps

2 .4.1 AOP-1
o When SLC AOP-1 is ON and AOP-2 trips or oil pressuure is
^ less than 4.8 kg sq.cm. AOP-1 will pickup. When turbine
w
trips and turbine speed comes to 2850 rpm AOP-1 will pick

up. If fire protection-1 acts AOP-1 SLC will be OFF.


w
AOP-2
O
^ When SLC AOP-2 is ON and if lub oil pressure is less
^ than 4.5 kg sq.cm,AOP-2 will pick-up.

135
2.4.2 DC EMERGENCY OIL PUMP

When SLC EOP is ON and if lub oil pressure is less than

1.1 kg sq.cm EOP will pick-up.

2.4.3 JACKING OIL PUMP-1

When SLC JOP-1 is ON, and if turbrine speed is less than

510 rpm, command is given to switch on JOP-1. If the

turbine speed is greater than 540 rpm command is given

to switch OFF JOP-1.

2.4.4 JACKING OIL PUMP-2

When SLC is ON if JOP-11 trips or if jacking oil press-

ure is less than 12 0 kg sq.cm and when turbine speed is


less than 510 rpm command is given to

1. To switch ON JOP-2

2. To switch OFF JOP-1

3. To switch OFF SLC JOP-1

2.5 DM OVERHEAD TANK LEVEL CONTROL

Selected DM transfer pump will be ON if overhead DM

tank level is lVs<,< 12 00 agggfc mmwc and selected pump

trips if overhead DM tank level reaches 3 3 50 mmwc

If DM storage tank level low <4000 mm DM transfer pump

will trip.

2.6 CONDENSATE SURGEE TANK LEVEL CONTROL(CST LELVEL)

Make up valve DM-12 will open if CST lelvel falls below

2500 mm and valve closes when level reaches 3200 mm.

Whenever surge tank level is low command is given to

close valves DM-32 and DM-35.

136
O

Tripping conditions of: turbine.


Turbine will trip on any of the following conditions-


I . l-.'.Lectr ic I:, rip vacuum low : 0.3 kg s q. cm
2. l-'ire Protection I &. 1.1 operated
O 9oLL
3. Main Oil tank level low 700 mm
'
4. M S temperature < 480 deg.C
- -

5. Turbine trip push button pressed


o
6. From ATRS -- through shut down logic

7. Generator Protection acted


o 8. Boiler MFT
. .

9. Drum level very high +225 mm


o
10. Low forward t r i p relay operated
U
1.1 . Ax.i oi I. s i n . I: i\ : 0 . ' nun

o
I ? . >>(: i -.;; i .1 .(:?( I 1 1 % i, !::'*. o l . r a t e d 3 p e e d

G
.1.3. l i u b . o i .1 h e a d e r p r e s s u r e l o w < 1 . 2 kg s q . c m .

oG L P HEATER LEVEL CONTROL


o
LPH-2 Valve DR-211 will maintain normal level of LPH-2. .
Valve DR-24 will open if LP heater-2^ level goes high

greater than 60.0 mm.

^ LPH-3 Valve DR-16 will maintain normal level. Valve DR-19


HCn;will LEVEL
WELJJopen if CONT_ROL
LP- heater-3 level goes high greater than
Vdlve CD-14 will' maintain hot well level to 850mm.
6 00 mm.

O
o
137
DEAERATOR LEVEL CONTROL

Valves DM-32 & DM-35 will maintain normal level of

Deaerator. Valve CD-23 will open if deaerator level

goes high and dump the excess condensate to

condensate surge tank. DM-32 & DM-35 valves closes

on interlock when CST level goes low i.e. less than

2000 mm. Deaerator overflow valve DR-3'3 will open


if deaerator level goes very high i.e. greater than

2760mm

HPH-5 LEVEL CONTROL

Valve DR-11 will maintain normal level of HPH-5

Valves DR-14 will open if HPH-5 level goes high i.e.

greater than 3 60 mm.

HPH-6 LEVEL CONTROL

Valves DR-2 will open to maintain normal lelvel of

HPH-6 by cascading HPH-6 drip to HPH-5. DR-2 will

close if HPH-5 level is high i.e. greater than 360 mm

Valve DR-6 will maintain normal level of HPH-6 by

cascading HPH-6 drip to deaerator. FR-6 opening

can be adjusted by bias provided on control panel.

Valve DR-34 will open if HPH-6 level goes high greater

than 360 mm taking the HPH-6 drip to hot well.

138
o
o
o
HP HEATER GROUP BYPASS PROTECTION
It will operate if any one of the HPH's level goes
very high . It will isolate both the heaters from
steam side and affected heater from water side .
o
Valvess FD-130 & FD-131 will open to close valves
o
FD-16 & FD-17. Drip valve FD-125 will also open.

O
G
O
O
o
o
o
o
o

139
C. GENERATOR PROTECTIONS & INTERLOCKS
1.0 FAULT SETTING CAUSE EFFECT
_. ____.___.-_.-

1. STATOR E/F Short circuit in slot between Insulation


64G core & wdg.(Interturn)s/c damage
Mech.or Thermal damage to
corona preventive paint.

Action: Gen.will trip.

2. ROTOR E/F Abnormal Mech. or thermal -do-


64 R stresses due to vibrations,
overcurrent,overheating.
Action: Gen.may be run after balancing 1st E/F.

3. INTERTURN Interturn S/C -do-


FAULT 95 G

Action: Gen.will trip.

4. 0/V PROTN Sudden loss of load at full -do-


59 G " load & rated P.F. & AVR fails
or C/0 to manual & gen.overspeeds.
Action: Monitor & control through Excitation control.

5. L.|F. P. 3 7G Upon on electrical tripping. Overspeed-


(Low For- Prime mover fails to trip. ing
ward power

Action: Trip the Turbine manually.

6. 0.FREQ.14A/ Sudden loss of load.C.B.open Overspeed

Action: Monitor & reduce Generation accordingly.

7. U/F 14B/81L Inc.in load Over fluxing

(less speed) Aux.speed falls

Action: Monitor & increase Generation, if possible.

8. OVERFLUXING Malfunctioning of AVR Load Overheating of


59F throws-off with excn. on stator iron and
manual.U/F operation. transformer iron
Action: Monitor Frequency.
9. GEN.LOSS of 1. Unintentional opening of F.B. Induction gen.
EXCN.40G 2.An o/c or s/c in field wdg. Asynchronous opn.
3.Fault in AVR Oveheating of rot
&statorendzone.

140
o

n
O

o
G

:j i:
10.NEGATIVE Unbalance loading Excessive rotoi
pH.SEQ.4 6G heating C

Action: Reduce Generation, Inform L.D.Centre. C

11.GEN.MIN.21G Phase to phase s/c in stator C


(IMPEDENCE wdg. on gen. bus in UAT.LV ^
MHO BACKUP) side of GTR. -=

Action: Generator will trip. ^-;

12.GEN.DIFF.P . Internal fault "

87G

Action: Gen.will trip. .,_

13.RPP 32 G Re- Failure of Prime Mover Motoring (is ska


verse power as reverse power"
Protection) also damage to r-
meant for turb. turbine blades."
protection)
Action: Gen. will trip. ,~
14.0/L PROTN 51G Overloading in terms of Temperature rise-
(Over load) current or MVA. Failure of stator winding ""
coolant flow or temperature ^
Action: Maintain the parameters within rated values. ^
15.LBB 50Z PROTN GCB fails to trip.(Gen.circuit External sources-
(Local Brkr. breaker) LBB gives command for feeding the
backup) "Bus-bars protection'.Bus bar
will get isolated.

Action: Busbar prot.will operate.

2.0 INTERLOCKS FOR GENERATOR AUXILIARIES

1. While closing, isolators are to be closed before Circuit

Breakers.

2. While opening circuit breakers are to be opened before

isolators.
o

O 3. Changeover of Aux. supply from unit supply to station supply

0 is automatic, in the event of generator tripping provided

BTSPs are in service & mode of selection is on "Auto1 & UAT


d . . .
VJ
^ is in service.
0
4. After synchronisation , changeover of Aux. supply from statio
0
5. DG set will start automatically if incomers to Bus IDD & Bu
supply to unit supply is to be done manually.
ODJ (Unit emergency Bd. & station emergency Bd respective
o
fails & mode of selection for D.G. set is on Auto 1 .
o
6. Changeover of excitation system from "Auto Channel' to "man
channel' is Automatic. To change excitation system from"m
O
channel' to "Auto channel1, "A/M Balance' Voltmeter should
o
brought to "Null' & changeover is to be carried out manually
G
7. If one stator 'water pump trips or made off, other S.W. pump w

pick up automatically, if an Auto.


9.
8. If
If one
bothA.C. seal
stator oil pump
water pump trips,
trips or made off.,
generator will other
trip. will pic
o automatically , if on Auto. If both A.C. seal oil pump trip
o made OFF, D C seal, oil pump will pick up whether on Auco
o
manual.
o
10. Field breaker cannot be tripped manually if GCB is on.
o

Q 11. Operation of Generator on laod with Air as a medium is not

O permitted.

143
3. EMERGENCIES ON CWA-17 .

1. Excitation Auto Channel Fail: Change over to Manual.

Control Excitation manually.

2. Aux.Thyristor fail,(N-l): No problem. Gen. can be taken u

full Generation.

3. Stator water flow low: Check pump ammeter. Check filter.

4. Stator water temp.high: Check cooler.

5. Hydrogen purity low: Purge hydrogen.

6. Hydrogen pressure low: Fill up hydrogen.

7. Seal oil / H2 DP low: Check H2 pr. Check seal oil filter.

8. do high: do . Check DPR.

9. Liquid in generator casing : Drain the oil.

10. GTR.wdg.temp.high: Check wdg.temp. Start standby pump,

if not started on auto.

xxxxx

744
sin

K W

to CO
o o o
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X / / \ to
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:
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1

H3

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/ / ' // / / // / / / Xx If
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X 8

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o
/ / / / X t 1
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CO
CRITERIA X 2 OPENING OF HP STOP VALVES y i'
TEMP SATURATED > MID WALL TEMP HP CONTROL VALVE + X2

(OC)

V \ \ \ \\ \ V7
\
\ \
500

3 MMEmm

\\ A y \
\
, y> 7
400 V \\ \
\ \ \
\ \
y
/
V N\ \ \\ \ /
Y/
ON

v
^ /
300
TEMP
xN
vy
SATURATED STEAM
Y\
RE( ffiNL )ED
200
/
V
100
/
o
/
0 100 200 300 400 500 (OC)
MID WALL TEMP HP CONTROL VALVE

r
) i ) (
O p P c -Q- o -a o -o-p- o -o-o- o o-o- o o C:>
X 3 - OPEHXHG HP STOP VALVES
MS TEMP BEF HP BYPASS < MIDWALL TEMP HP CONTROL VALVE + X3

(OC)

V\ \ \ \ V y \
y
500

y y y

V \\ \ \y y \
400

\\
v
\\ \x
y
y
MS TEMP
300
y yy1
BEF HP BYPASS
y y REi fflNL1ED
200 -X3

/
/
100
/
0 / 100 200 300 400 500 (0C)
MID MALL TEMP HP CONTROL VALVE
CRXTEEUA K 4-TURBINE ROLLING ON STEAM BEF RAISING SPEED TO 600 RPM
MS TEMP BEF HP STOP VALVES > MS TEMP SATURATED + X4

(OC)

500
/
x \
A

/ \x
400
XX \

XI \\
00

RE'COMMEN DED \ \
MS TEMP 3 0 0
BEF HP STOP
XX \ \

AX\ \ \
VALVES

200
\ \

100 A x\
/ r\ \
NO:V RE:COM'MENDED

\
\
\
i \

X \
\\
\ \

n X\ \
0 100 200
\
300
\ \
400
\ \

500 (OC)
MAIN STEAM TEMP SATURATED

(fe
C) ( ) ( ) C) ( > ('')
o cc o oo o o a o o n
CRITERIA X 5- TURBINE ROLLING ON STEAM BEF RAISING SPEED TO 600RPM
o oo mo
TEMP BEF HP STOP VALVE 1 > MIDWALL TEMP (EVALUATED) HP SHAFT + X5
TEMP BEF HP STOP VALE 2 >MIDWALL TEMP HP CASING + X5
(OC)

500

400

RECOMMENDED
MS TEMP 300
BEF HP STOP
VALVES

200 \ 1\ l\ K I\
\X5 NOT RECOMMENDED

100

100 200 300 400 500 (0C)


MID WALL TEMP (EVALUATED) HP SHAFT
MID WALL TEMP HP CASING
CRITERIA X 6 TURBINE RAISE TO RATED SPEED
MS TEMP BEF HP BYPASS < MIDWALL, TEMP (evaluated) HP SHAFT +x6

(OC)

500 ?
\ ^

\s
\ \
iECtmd WJE
\ \ \
\
\ \
y
/
A
y
- * -v
1

A\ \ \ \ /
400
VA\ \ V y
A
in
o

MS TEMP
300
v
V
\]
y,y n A /
BEF HP BYPASS

200 y -xe Y J
l
RE(70MbZENL

100
j K ft""

o /
0 100 200 300 400 500 (OC)
MID WALL TEMP (EVALUATED)HP SHAFT

() v V) o o f) o n
()
( p p p. r G
-' w
w v.y v. ___ a O W OO
X 7 CONDITION BEF SYNCHRONISATION

STEAM TEMP BEF LP BYPASS < MIDWALL TEMP (evaluated) IP SHAFT +X7

(OC)

V\ \ \ \ \
\ \ v
v> A
y /

/
500

400 V \ \
\1\\\ W X
\
\

/
HRH-: TEMP
BEF LP BYPASS
300
\\ >> /
/

RECZOMb1ENL>ED
200 -x 7 /

100
/ / /

i'

/ 100 200 300 400 500 (OC)


MID WALL TEMP (EVALUATED) IP SHAFT
r o o oo o oo o o o O O Q
PLANT OVERVIEW
AG - AIR SYSTEM
FROM ATMOS

SCAF-A SCAD2A

TO SCANNER
AIR COOLING
DUCT
(BLADE PITCH
CONTROL)
SAD1A

TO COLD PA HEADER FROM


TO HOT PA HEADER
ATMOS
m

(BLADE PITCH
CONTROL)
SAD IB

FROM
ATMOS

TO HOT PA HEADER TO COLD PA HEADER

210 Mff SIMULATOR


HPTI HAGPUR
! REF:0-97-238-00212
AIR SYSTEM FOR BOILEF
zTtrf In
c c c o c c c o o o o o o o o o. o o o O O O O Q a o a o"
FLUEGAS PATH

CHIMNEY

b r O 4 )FRQM FURNACE

FG SIDE
IDF-A
Q
H

GDI A A GD2A GD3A GD4Ai GD5A W J f GD7A

-0 GD 6 A
(IGV)

IDF-B

GD1B
-> s;
GD2B GD3B "-B; GD4B
-i-
GD7B
FG SIDE

(IGV)

210MW SIMULATOR
NPTI HAGPUR
AG02 Flue Gas flow
REF:97-288-00212
>aqOl> PAD5A
PAD1A
FROM HOT PA RHS
LINE PAD2A
PAF-A
PAD IB
PAD2B PAD5B ^ ^ PAF-B
PAD1C
-J2- PAD2C PAD5C TO PULVARISERS
PAF-C
PAD ID a,
PAD2D
PAD5D PAF-D
en PAD IE
FROM HOT PA LHS PAD2E PAD5E
LIHE PAD IF
>ag01 >
PAD2F PAD5F
>ag01 > PAF-F
COLD PA RHS
PAD3A PAD 4 A

PAD3B PAD4B

PAD3C PAD4C

PAD3D PAD4D

COLD PA LHS PAD3E PAD4E

PAD3F 210MW SIMULATOR


PAD4F
NPTI NAGPUR
AG03 PA FAHS
Ref:0-97-291-00602

O <]) o
r '!
coccco ooo o 5_ a o j O O Q 4 O
CONTROL OIL RETURN

LEAKAGE OIL RETURN

FDF-A OIL TO
CONTROL VANE

FDF-A OIL TO
BEARINGS
'FDFL-2A FDLOA12

LUB OIL RETURN

CONTROL OIL RETURN

FDF-B OIL TO
S7 NZ CONTROL VANE

FDF-B OIL TO
BEARINGS

LUB OIL RETURN 210MW SIMULATOR


NPTI HAGPUR
AG04 FD Fan Lub Oil
SLD8A
A C

SLD8B
B SAF-A FLT-A
en
SLD8C
C C fsO3> FROM
* SLD7B Atinos
SAF-B FLT-B
TO SEAL
AIR VALVES
OF MILLS SLD8D

SLD7C

E C fsO5">

SLD8F

210 Mw SIMULATOR
NPTI HAGPUR
AG05 Seal Air Fans
Ref:0-97-291-00602
l' '\ f "\ f )
r^t r(>-a >
c; a;.) c O O O O G O O O 0 oO Q o Q a ma
TO SH INLET h d r E22
ECO OUTLET TO BLR DRUM

SVB1
Drum Vent B5
phosphate
B41 dosing
DRUM

vi w B69
a a
D c t 1
oo e 1 CBD
W M
N E r s
R EBD
S
B99 GXD B100

I
RING HEADER B
ECO REC
D
T
EH 3

B9 5
INITIAL B97

ft
IBD EN 2A I I EN 2B
FILLING LINE B98

E10
FROM BLR B9 6 L EH 1
E2A
FEED NATER FROM
FILL PUMP FEED REGULATING
STATION
I E9
B
D
T _
ILIE2
ECO INLET VALVE 210MW SIMULATOR
DRAIN NPTI NAGPUR
EEF:0-00-047-41236 BR01 Drum & E c o
." JStart 1^1 verity
X 0 S3 3>- C sa f e t y WS301

S H H 14
FSH
NS202
S H H 13
KS214

S H H 12
IBDT PSH IBDT
BLOWING
S H H 11
STEAM

DESH S77
-t
01 S H H 10
70
SH vent
S H H 9

S H H 7
SHH3Ai t FROM FRS

t t TJEXTN
s w eM
T
SHH8 S59
,H S71
<H
S61'
S67 0
SHH5 S58 S70
S60
, S21 S57 S66
SHH2
S69

SHH1 spray control stm S52


S19 S15
210MW SIMULATOR
SH dm hdr NPTI NAGPUR
C \oIBDTank 0 FROM BLR DRUM BR02 Super Heaters
REF : 0-00-047-41236

-) o O o r^ ::^ ri> o c^ () a
cocc 1OOGOO o o o o

TO IPTurbine TO IPTurbine
msO3

KH SPBAY
CONTROL STN FROM HPT
FROM HPT EXHAUST
EXHAUST

BH SPRAY
BLOCK VALVE
210MW SIMULATOR
NPTI NAGPUR

REF: 0-00-047-41236 BR03 R e h e a t e r s


00 00 00

00 0QC00OOO0O0O
00 00 00 00 00 00 00

I I I I I I I I I
I I i i i i i i i to r o r o r o t o r o r o to ro
k i} J:L i?_PLL G P J^Q. Q J5= o

I CD-7

2 Z

21OMW SIMULATOR
spray HPTI HAGPUR
CSO1 Condenser System
REF:PE-0-09 0^100-004
TO DEAERATOR
CD-3 5 X

CD-32
EXT STEAM FROM
-H msO4 LPT 3rd STAGE

CD-33 A LP HEATER-3
CD-31 />
S- *fi
M 1 P

Op-
-H- EXT STEAM FROM
LPT 5th STAGE
0
CD-29
CD-30J LP HEATER-2

-H- EXT STEAM FROM


CD-28 mS
< 4 ) LPT 7 t h STAGE
-H
CD-2 6 n?
CD-27 T LP HEATER-1

-H
CD-25
GD-16
DRAIN COOLER
CD-:
CONDENSATE FROM
GSC
-M -4-<cs01<
CD-60 CD15 CD_14 CD-13
EXCESS FLOW
TO CST
dmOl y -M- 210MW SIMULATOR
CD 24
~ CD-23 HPTI NAGPUR
REF:PE-0-090-100-004 CS02 LP H e a t e r s

a ^ o '{'y ('
^ C)
c c ooo
O 9 < O
^j Q Q t Cj
cwO2<
cwO3 <
OUTLET cw O7J> OUTLET FROM
COOLERS COOLERS TO
(Hot vater) CH SUMP
-, CH SUMP
1
c w O9>- cwO5 < (Hot vater)
Cff cwQ6
CW SUMP
". TOWERS:

I 1
CW-55 / ) /-) CW-56 , , v ..

O *

CW-3 CW-l^B GSW-A GSW-B

! !

COHD-A&B CW-40(?
CW-3 9
CW-12 CW-16 CW-14

CW-42
CW-48 (M> / CW-49
CW-44

To GS 0/H tank

210MW SIMULATOR
cwO2 HPTI HAGPUR
CW to GT,stator vater CW01 C i r W a t e r s y s t e m
and turbine lub o i l coolers
cooling water
from cw system
< cw01<
cooling water
from GS svstera

GSW501
GSW500 ][ T GSW10 I GSW15 ][ GSW16

GSW12 Jk jLGSW13 GSW17 GSW18

GENERATOR STATOR TURBINE


TRANSFORMER WATER OIL
COOLERS COOLERS COOLERS

TO CW SUMP

., 210MW SIMULATOR

HPTI NAGPUR
CW02 Cir Water System
cc c
c o o o . o o o o o o o o o o oo o #o

From GS pumps

GS OVER HEAD GS OVER HEM>


TANK

GSW 28 JL GSW 29 iGSW 33 I GSW 20 A GSW 21 A

To coolers

GSW 3 0

GEH SEMi OIL ffifDROGEH HYDROGEN


COHDENSATE
EXTRATION COOLERS COOLERS COOLERS
PUMP
BEARINGS
210 Mff SIMULATOR
M
(HOT WATER) HPTI NAGPUR
CW03 GS w a t e r S y s t e m
VI GS WATER FROM
c OH GS TANK
V
0

CN43

GSW 3 9 GSW 41 GSW 46


GSW 3 7 GSW 44

MECH SEAL MECH SEAL


DM WATER DM WATER

BFP-A BFP-A BFP-A BFP-A


BFP-A BEARING BFP-A MOTOR
BOOSTER SEAL LUB OIL WORKING
PUMP AND OIL COOLER
COOLER COOLER

(Hot water)

T
GSW 38 GSN 40
STUFFING
BOX
COOLER
i
GSW 42 GSW 45. *
COOLER

GSW 47

w s
u
M 210MW SIMULATOR
P
HPTI NAGPUR
CW04 G S Water System

() f
< ) C) ( )
c C c c
C O O O O O O O O O O O 0 Q Q Q Q o Q
CW - General Service Water System CW05
From GS cooling
vater HDR

CW57

GSW 49 GSPI 51 GSW 53 GSW 55 GSW 58

MECH SEfiL MECH SEAL BFP-B


DM WATER DM WATER MOTOR
COOLER

BFP-B BFP-B
BFP-B BFP-B BFP-B
BEARIHG WORKING
BOOSTER SEAL LUB OIL
PUMP COOLER AND COOLER OIL
STUFFIHG COOLER
BOX
GSH 50 GSW 52 COOLER GSW 54 GSW 56 GSW 59

To CW SUMP

(Hot Water)

210 MW SIMULATOR
HPTI HAGPUR
CW05 G S Water System
VI
c From GS cooling
w water header
0

CW69

GSW 6 1 GSW 63 GSW 65 GSW 68 GSW 70

00

MECH SEAL MECH SEAL BFP-C


DM WATER DM WATER MOTOR
COOLERS

BFP-C BFP-C BFP-C


BFP-C BEARING LUB OIL WORKING
SEAL AND COOLER OIL
COOLER STUFFING COOLER
GSW 62 BOX
COOLER
GSW 64 GSW 66 GSW 69 GSW 7 1
To CW SUMP
CXJ01
BFP-C
BOOSTER (HOT WATER)
PUMP

210MW SIMULATOR
HPTI NAGPUR
CW06 G S W a t e r S y s t e m

o r n () m ,)
o oo o oo o O O Q O Q O O d> O

FROM GS COOLING
WATER HEADER

CSV 201 ]' GSW 203 ][ GSW 205X GSW 207 Y GSW 209^^ GSW 21l][cSW 24O] [ GSW 242T GSW 213 A GSW 222T GSW 2lT GSW 218T

B D B la

L
GSW 202 A GSW 204T GSW 206 A GSW 208 A GSW 210 A L GSW 212>kGSW 241A GSW 243IA GSW 214 AA GSW 224 A G S W ^^ GSW 220A
GSW 214

pa PA FaN ID FaN FD FaN FD FaN


BEBJRING BEaRING BEARING BEARING BEaRING
COOLERS COOLERS COOLERS COOLERS COOLERS

T o CW
SUMP 210MW SIMULATOR
HPTI NAGPUR
CW07 G S Water System
<S From GS cooling
CY/03
-^ water Header

GSW 221 225


GSW 217 X A GSW 229 Y GSW 233 ][ GSW 23 6 JL

GSW 219 I GSW 223 J GSW 227 GSW 231 ][ GSW 23 5 j GSW 238

cwO3
MILL OIL MILL OIL TO CW SUMP
COOLERS COOLERS (HOT WATER)

210MW SIMULATOR
HPTI HAGPUR
CW08 G S Water System

(') () (>
c cc c c c o c c o o o o o o o o o Q <& O
CW - General Service Water System CW09
cwO3 <C From GS cooling
water header

GSW 174 V GSW 173,, GSW 178 .p GSW 177 ,, GSW 167 GSW 168 v GSW 163,, GSW 164,,

IB 2A

GSW 172 GSW 171 GSW 17 6 GSN 17 5 GSW 165 GSW 166 GSW 179 GSW 180

AIR HEATER AIR HEATER AIR HEATER AIR HEATER


SUPPORT SUPPORT GUIDE GUIDE
BEARINGS BEARINGS BEARINGS BEARINGS

210MW SIMULATOR

TO CW SUMP HPTI NAGPUR


(HOT WATER) CW09 G S Water System
DM-11 CONDENSATE EXCESS
FLOW RETURN FROM
-M CD-23(dea l e v e l )

T
DM 1R S T A T R WATER
DM-18 SYSTEM
- M i K eg Oil
DM
lDM-15
OVERHEAD
TANK
DM-12

DM-14
-M DM-32
Bypass valve DM-3 3 DM-31
DR-37 J C S T
{ cs01>
DM MAKEUP TO -M- - -M
CONDENSER DM-36 DM-35 DM-34

From DM
DR-38 J
f BLR FILL
PUMP

DM-1(UM MAKEUP)

DM PUMP1 ..
DM WATER DM-2 DM-3 DM-7
STORAGE TANK TO BLR INITIAL
INITIAL FILLING FILLING

DR-3 6 X DM-8
DM-4 DM-6
drn
"^ DM PUMP2 210 Mtf SIMULATOR
NPTI NAGPUR
Ref:PE-0-090-100-021 DM01 DM makeup System

Tfc
o o n n n
C C C C C o o o c o o o o o o o o o Q Q Q O O d> O I

DRAINS/DRIP
DR-304 TO HOTWELL

DR-11 1 LPH # 3 LPH #2 LPH # 1


DR-312
-M-

6
TO DEA

DR-6 DFB-3

DR-3 2

HPH # 6 DR-20 DR-22


DR-16

DR-15 DR-21 DC

DR-18 i t
DR-17 -M-
DR-23 DR-24 DFB-1
DR-19 <
DR-3 5
MAIN EJECTORS

B
DR-14

HPH # 5 -w- TO HOTWELL


DFB-2
&

DR-3 4^
210MW SIMULATOR
DR-13 HPTI HAGPUR
-M DR01 Htr Drains
-M- REF:0-090-100-003
DR-08
main b u s - 1
main b u s - 2
transfer bus

29BE 29BG
29AE 2 9 AC
29AG
gcb 52E 29BC TR b u s
29CE s t n - 2 CB Breaker
s t n - 1 CB |\?l 52C 52B
29DE 29CC 29CG
29DG
29DC

GT
Stn Stn
Xmer1 Xmer-2

GENERATOR < edO4>


to bus occ t o bus ocd
uat
to bus oca to bus ocb

<edO2 < - ^ edO2> 210MW SIMULATOR


to bus lea to bus leb
NPTI NAGPUR
ED01 220KV BUS SYSTEM

( ) C') (') (
a
SCI

o
o a
o
o o
H1
o a
o
Hl
o
oo
o Cd O
o

sGD-o i-1 O
h1
r+
0
o n
cr cr
o CO

0
0
P)

NJ O
<S>
Vi
0 O
o

o
to
<$>
WOHWOP
to

a h
Vi o

oa
o
oHoa

0
from Stn-ltr from Stn-1 tr

edO4>
CS20 to bus ocf

to bus ocd

210MW SIMULATOR
HPTI NAGPUR
ed5j>to bus odj ED03 6.6KV-415V
SUPPLY SYSTEM

o n a ^ ('"" <' } {^ ilk


c c c o c o c c O O O O O O O O O O O O O O O Q O ooo o

from oca
from stn-2
e
from ocb from stn-2 d
0

SEMI 8 SEMI 6 SEM17


SEMI 9
bus ocd
bus occ

SEM22 SEM23 Nil SEM20 SEM21K2I SEM24 SEM2 6 SEM27

I/T
ODDT02 WTR iSPARE
SPARE T/F
ODCT02 ODGT02

ODDT02 SPARE
load ODCT02 ODGT02 I T WTR SPARE
t/f load
load load t/f load t / f load

bus oce bus ocf

edO3 edO3>
>
from oca from ocb

210MW SIMULATOR
HPTI NAGPUR
ED04 6 . 6 K V - 4 1 5 V
SUPPLY SYSTEM
V
from bus Ida2 from bus odal e
d from bus oda2
0

CS30 CS33 CS3 5

bus ldd bus odj

31AA 31AB 31AC


30AA 30flB 30AC 30AD 30AE CS34 CS3 6
CS32
^ \ \

co

To UPS1 2 2 2
4 4 2
To UPS2 V V 0 t o bus
C C V odk
H H D to
R R C ups
G G (sby)
R R /^N
T DG SET
to 220v t o -24v to T
Chgrl chgr i t o -24v chgr2 t o 220v
(main) chgr2 chgr(sby)
to +24v
chgri

210MW SIMULATOR
HPTI NAGPUR
ED05 DG s e t System

( )
O C)
c
/ " ^ ,''"'-'

c o c c c o o o o o o o o o o o o o o o o o o o o o ^ o o o Q

STATOR COOLING WATER SYSTEM

GENERATOR
EXPN TANK MAGNETIC FILTER

-M
Y62
STATOR Y15 J Y16
HINDGINGS
mech i
fltrs!
Y17

DRAIN Y23 Y13 I Y14 I


-M-
POLISHING UNIT

STATOR WATER
PUMPS Y8

YS COOLERS
DM MAKEUP
-M-
-M- Y9 Yll
Y7

c c
EJECTOR w w Y10 Y12
w
210MW SIMULATOR
DRAIN HPTI NAGPUR
EG01 STATOR WATER SYSTEM
GEN SEAL OIL SYSTEM TURB EXE
END END

TO
ATMOS

V_l
OIL VAPOUR LsSfc?8
FANS
OIL DRAIN
FROM GEN BRGS
D
PC-2
VS5
-M-
TO ATKOS J1
OVERFLOW seal oil
TO LUB OIL
SYSTEM
storage
tank Vll
0
o
SEAL OIL OIL FROM
TANK
Gtoverning system

I SOP-2

SOP-l
0 DC SOP
V63

I V6 TV9 6 1 V7 SEAL OIL


COOLERS

-M-
V18
v62

210MW SIMULATOR
HPTI NAGPUR
EG02 SEAL OIL SYSTEM

n o n n n> n
n
c c c c c c c
o o o O O O O O O O O O O Q O O O O O ^ O O Q O Q

VENT

H35

TUR END GEN END

H2 HEADER

H2 c o o l e r from GS
c
w
Ii2 FULING
LINE 1 to CW
sump
cooling
water
header
H34
C02 FILLING
B
LLD LINE
H2 DRIERS

? AAA
DRAIN 210 Mw SIMULATOR
NPTI NAGPUR
H2 Cylinders CO2 Cylinders TVENT
ATMOS
TO EG03 H2 Cooling
VENT TO system
ATKOS
GEN-T/F
EXCITATION
TRANSFORMER

0
PT

-oo- AVR AUTO THYRIS-


TOR
CONVER-
TOR
CT MANUAL

FIELD
BREAKER
CONTROL

FIELD FLASHING
NPTI NAGPUR
210Mw SIMULATOR
EG04 Excitation System

\ I. I { I
<) O
ccccc o o o oooooooooo o o Q Q Q 3

COAL BUNKER

TO COAL BURNERS CD-1A DUPLEX


OIL
(E| 1b COOLER
r r r r } CD-2A
0 0 0
4J w <4f
0

CD-3A Bunker Ga.t& V


\
CD2
CD4 i u! GDI RC FEEDER A
PULVARISER
DISCHARGE VALVES
0

MILL - A -M-
RETURN OIL
SUMP

FLTR 1&

FROM
P A FAN

FROM SEAL
AIR FAN
FLTR 2A
210MW SIMULATOR
HPTI NAGPUR
REF:1-97-291-00602 MILLING SYSTEM FOR MILLS A/B/C/D/E/F FS01 Mill-A System
LFO SUCTION
LOT
RETH

LGV1 LGV3 J LGV5

Filter 1 ]Filter 2 Filter 3

LGV6
LGV2 J LGV4

LGV7 LGV9

PUMP1 l i p 1 IPUMP2 PUMP 3

00 n'- NKVl NKV3

^ 1GV8 LGV10
Jk. LGV12

-a
LO p r CV

L019 J - D LOTV.' i^*r


(interconnecting
valves for LO/HO)
HGV7
LDO HDR ~v-" ^ OIL From
' f s 0 8 < H O System
-M-
AT20 J HDIHD
CV ! HGV8
ffl-I f
b
H
h
2101OT SIMULATOR
r NPTI NAGPUR
ATOMISING ELV-Ai OIL GUNS 0
AIR 4 FS07 LDO SYSTEM
o o c o p o) P
c o o o o o o o p. o o o o o o. o o .o
FS - Fuel Oil(HFO) FSOo
RETURN TO HFO
TANK

HFO SUCTION

HGVl ] L HGV23 HGI^l

FOJITR
on on
SRAXNER1 STRAINER2

Heater-2
HGV2

HGV28
^ HCT-22
PUMP 1 ]LHGV24
00

<ur HGVSO Y:?A


TO AB *"Temp cv HO29
ELEVATION f o r FO HOTV

s
AUX STEAK
s 0
FROM PRDS HO3 5 "
0
(Long rec vlv)"1
7
FO HDR

f
1 mi ::HD mi L
Q HD *-i '&) mi ^ mi HD B
OS27/I
cv
G3
i-B- LX
TO AB
ELEVATION
m|
r b
1
t
>^>
r
b b b r
r r r r
r 0
0 0 0 0 0
ATOM STEAM 0 4
4 4
V4y V4>
f r o m PRDS w

ELEV-CD ELEV-EF
( o i l guns) 210 Mw SIMULATOR
( o i l guns)
NPTI NAGPUR
FSogHFO SYSTEM
Cond from
FEED WATER SYSTEM LP H t r s
VENT -c J
CR309 - x INITIAL FILLING LINE
CR308 DM50 j[ . Iron B o i l e r f i l l pump
SM18 fift
M
Aux stam FC312
from PRDS < M- M FC308
& CRH l i n e CR305 CR307 Aux steam from
FC304 DEflERaTORJ. PRDS for FST
CR306 AS 3 70 ^ h e a t i n g
msO4 *)- I 1
i..-
"7Peg sbm
*Y from Ext4 FEED STORAGE TANK 1 -( drOl)
Fc3io TFC302 FD19
y Drip from HP
Heaters
(Rec Valve) I FC30|fi
DR313
\
CO DR315i[

(Dis Valve)
IFD304 FD1
chemical
dosing J DR314

-M-
FS301
IBDT
,, FD304A
C\ FD305
-M-
TO HP FS302
HEATERS BFP-B it
FD305A
FD3
0 FD306

BFP BOOSTER FS303 210MW SIMULATOR


BFP-C " PUMP
HPTI NAGPUR
FD306A
FW01 D e a e r a t o r & BFP
REF:0-90-100-005

n o : n () O C) Ife
c c c c
<n o o o o o o o o o o o o o o o Q O G 3 O

{ b r O l " ) p^r T0 ECONOMISER I/L

FD32 5

brO2 } control stn Extraction steam


FW to KH from CRH line
control stn 0

-4

Extraction steam
from IPT

FW TO PRDS spray

FW TO HP Bypass spray
Feed water from BFP
<fw01<

210 Mff SIMULATOR


NPTI HAGPUR
REF:0-90-100-005 FW02 HP HEATERS & FRS
Service Air AIR
Comprssors RECEIVERS

ATOMISING AIR
TO LO GUNS

Co
(70

IAC-C BLR side inst air


Inst Air
Compressors
TURB side inst air

210MW SIMULATOR
HPT I NAGPim
IA01 Inst S Service
Air System

o a o v)
o a o IB
r,
c o c c o
^,-s ^ ^

W v.
C O O O O O Q O O O 0 O
O 0 O O CD CG

v
- LEflKOFF STERM
T0 G S C lVo
MAW80AASD1 ^

2 t 2 I

V ^ '
IPT LPT
HPT

Vf ^

"^ LEAKDFF
GLAND SEAL STEAM HDR
STEAM to c a n d
QsOl}
csOl )
DRAIN TO COND
AIK STEAM
TO GLAND ST WJR

"SmsOb
210MW SIMULATOR
MAW10AA501 MAWIOAAOOI(CV) HPTI HAGPUR
MS01 S e a l Steam System
REF:01310015121
HP BYPASS SYSTEM KS311
(HPBP Warmup
REF:0-090-100-002 valve)

HPBP-1
TO REHEATER CRH L i n e
br03
CRH NRV
65

FROM SH
brO2
MS l i n e

DEA PEG
STEAM

o
Ext steam
to HPH6

A Aux Steam f
To PKDS
CR
208 T
brO2
MS l i n e DRAINS TO
FROM SH COND

CRH MRV
_brO3>
TO REHEATER CRH l i n e

WS224
66 I*)

CKH LINE
DRN TO COND
i 210MW SIMULATOR
FD331
J-IQ J-ffJ HPTI NAGPUR
BPE2
MS02 HP Bypass system
TV SPRAY BDvalve

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r-
V. /
o Vv XL G Kjy a 0- Q O
Drn to cand SVl
L P BYPASS SYSTEM IHR233
Atmos

HR311Y-V '

fl]LPBP-1
HBH LINE
FROM BLR

LPBP DJJ WATER


VALVES

SV3

LERP SPRAY FROM


CEP D i s c h a r g e

LPBP INJ WATER


VALVES

210MW SIMULATOR
Atmos HPTI KAGPUR
HR232 Dm to cond
REF:0-090-100-002 MS03 LP B y p a s s S y s t e m
I")EX301
IP TURBINE LP TURBINE
LBS40 LBS40 J
AP001 AAOO1 ^

210MW SIMULATOR
0-090-100-002 HPTI HAGPUR
MS04 Extractions from
Turbines

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f
vy oooooo Q m Q O ^ O
P R D S SYSTEM
AS370
TO FST HEATING
FROM CRH LINE
Y T0 DEA pEGGrNG

AUJ; steam from I


other unit

CR301 X w I AS365 i0
M AUX STEAM HDR

AS 376
y * -m +m*\S-l-l

TO GLAND AS368
m
STEAM HDR s AS320
0 AS375 j t EJECTOR STEAM HDR
scflPH-a HEATING
1

CaqOl ) M-
AS326
-+k-
AS323
STEAM TO HFO
AS2 y^Aj AS3 ,,: AS4T
AS 10

C agOl)M- -M- V Ejector steam Steam to M Ejectors .^O^- To


starting
AS325 AS324 i HDR ddrain
rai p Ejector
Ejector
SCflPH-B FD347 r n)342 , . )

f sO8 ) - -M- AS304 FD343


ATOMISING ST TO KFO AS361 AS308 ' , '

'V FD332
>msO2> DSH $4
AS307 'f" AS309 ra346
FD336 m335
FROM F W LINE
FROM M S LINE

>^- M-
FD339
AS310 AS311(\L'" FD340 FD338

210MW SIMULATOR
AS308-Hig^i capacity Pr CV AS305-Lov capacity Pr CV HPTI HAGPUR
REF:0-090-100-002 &
0-00-301-30259 FD343-Hicjh capacity temp CV FD336-Lov capacity temp CV MS05 Aux Steam & PRDS
TB - Lub Oil System
JACKING OIL HEADER

V?

M
Oil vapour
Ext FAN
2 2 i GOVERNING OIL
FOR SEALING
(egO2)
J*3 ,
I TEMP CONTROL
VALVE TO SOST

J0P1 JOP2
LUB O H
COOLERS

AOPl AOP2 EOP w cooling


water
v V
0

cooling
water 210MW SIMULATOR
HPTI NAGPUR
TB01 Turbine Lub oil
REF:11310015101 System
) [ft
C C O O C; O O "0 O O Q o G O ^ f? 0 O G

HRH Line l e f t

MS l i n e l e f t

CRH l i n e ( L ) -

ESV-1
iv-l

Gen front Gen rear


brg brg
HPT IPT LPT GEH

HPT front combind LPT rear


Thrust brg ,
bearing brg
bearing

Vf-2 1
i
IPCV-2
HPCV-2
-* TO CONDENSER
CRH l i n e ( R ) - ESV-2

HRH Line right


MS l i n e r i g h t

210 Mff SIMULATOR


HPTI HAGPUR
TB03 T u r b i n e L i n e s
STEAM i MSV MSV
ADMISSION m MSV A 01 MSV
AREA <2>i MCV TSE A MCV
0m MCV .
A6i MCV
- HPS
i HPS .
FUNGTON
0m MPS -
9- HPS
GENERATIONS IPS
TURBINE
AREA
0i IPS
@m IPS io* IPS
0i HPC HPC
HPC
0m HPC
nact Apu A pi
pact nact/pact
RJECOBDER
EH72C020
RECORDER
EH72CO23
HARMING UP
i MSV CONTROLLER
STEAM m MSV TSE LEGEND
ADMISSION 0i MCV pi - Instantaneous Load
AUTO CONTRL
AREA 0m MCV SYSTEM ni - Instantaneous Speed
Qi HPS 0i - Surface Temp
FUNCTON TURBINE O Mean Temp
m HPS GENERATIONS GOVERJIOR Upper Temp Margin
<Si IPS A 1 - Lower Temp Margin
m IPS
TURBINE Qi LIVE STM RH
AREA ^ MODULING CNTRL MSV Main Stop Valve
MCV Main Control Valve
nact HPS High Pressure Shaft
pact UNIT
IPS Intermediate Press Shaft
COORDINATOR
High Pressure Casing
A p - Upper Load Margin
Lower Load Margin

210 MW SIMULATOR
NPTI NAGPUR
TSE INDICATOR TB04 TSE

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o c c c c c: c o CD , o o o o o o o o o o o o O O- Q 0 O

Nact
MANUAL
ATRS SPEED REF LIH SPEED VALVE ELECTRO HYDRAULIC
AUTO REF Nref "CONTROLER POSITION HYDRAULIC MIH
SYNC Hr dn/dt CNTRL CONVERTER

Track-
SPEEDER GEAR
TSE IMFL Track M
MAX
Fact
MIH N HPCV & IPCV

TSE I1TFL Fref- O


MANUAL
ATRS REF LIM M LOflD/FREQ
AUTO
LOAD KEF

Pr
Prlim
H
-o- CONTROLER
SYNC

Track- Pact
dp/dt Track
LOAD MANUAL
GRAD f Fact LOAD
PRESSURE
COHTROLER
TURB Hact

FREQ LIMIT
INFL
Fref- Pact
dp

'PRsetpt

PRact

210 MW SIMULATOR
NPTI HAGPUR
TC01 EHC
LEAK OFF
VLV POS
MANUAL/AUTO MANUAL/AUTO

Leakoff
PID valve
MANUAL
SET MAW50AA001
POINT hact
MAW50CG001
SEAL
SEAL s t e a m STEAM
VLV POS HEADER
CONTRL

CO
SET PI
V VALVE
SET PT
PID steam
POINT valve
DEVTN
MAW10AA001
Pact
MAW10CP001

2 1 0 Mtf SIMULATOR
HPTI NAGPUR
TC02 Seal Steam Control

k
n O ( ' (:
>
n n n
C r" r c 0 0^ oo^
o o o o O O Q 0 0 O

OIL AFTER COOLER!?

SLC TEMP CONTROL

MAV42 O
CT011

1 OIL TEMP CV
I I
O O
MRV41 CONTROLLER
ftAOOl Ji

AS 11

Luto o i l MCC
coolers

210 Mtf SIMULATOR


HPTI NAGPUR
OIL BEFORE COOLERS TC03 Luboil temp c o n t r o l
DRN VLV BEF HPCV-1 DRW VLV BEF HPCV-2 SLC NARMUP CONTROL

MS L I N E o

MflAlOAAOOl
MAA10AA002
i MaLllAAOll

AS12 CONTROLLER
g
o TSE INFL
HPT
L- MCC AS12 CONTROLLER

MCC

MAA20AA002 *
MflA20AA001 A
HAL12AA011

MS LIKE
210 MW SIMULATOR
HPTI HAGPUR
TC04 HPCV WARMUP CNTRL

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KAV21AP001
Test o i l TRIP OIL
MAIH
TRIP STOP VALVES
VALVE
KAX51AA001 ?.tAXSlAA002

MAIN REMOTE REMOTE tbOl ")


TRIP TRIP TRIP
VALVE VALVE VM.VE CONTROL OIL

MAV21AP001
AUX. TRIP OH

SOL FOR
LS RELAY
MAV21KP001

MAIH
o OIL SEC OIL
PVMP TO IPCV

CONTROL OIL SEC O H


TO HPCV
AUX. NAX47BY001
CONTROL OIL
STARTUI JWX45BY011 HAX4SBY001
OIL STARTING S
LOAD LIM DEV HYDRAULIC ELECTRO SOL FOR
FOLLOW UP tTMBRRULIC
FOLLOW UP HP/IP
AMPLIFIER PISTONS COHVERT0R PISTONS TRIM DEV

HYDRAULIC
STARTUP
Gffi'ERNOR tfAX46AAUll
OIL TO
STOP
VALVES SOL FOR HP/IP
HP/IP
TRIM
PRD.V1RY IS RELAY TRIM
DEVICE DEVICE
OH

TRIP OIL

210 MW SIMULATOR
REF:0-100-00-40013 HPTI HAGPUR
TC08 Governing System
... OVER SPEED TRIP
THRUST BRG TRIP

CONTROL OH
FILTER RTV MTV
r -- LOW VACCUM TRIP
~AUX STARTUP On TO
RESET PROTECTIONS
CONTROL OH -CONTROL OIL
LOAD
CHANGE STARTING SHEDDING
FttTER R1T OVER AND LOAD RELAY
VALVE LIMITING SPEED
CONTROL OIL CHANGER
DEVICE

ELECTRO
HYDRAULIC HYDRAULIC TRIP
GOVERNOR
AMPLIFIER CONVERTOR on
8-
IV
MAIN 11 STARTUP On
on TO RESET IPCV
ESV & ISV
CONTROL On TO DRAIN
LORD
SHEDDING Load
RELAY

IPT LPT
CONTROL OIL

210 MW SIMULATOR
NPTI NAGPUR
TC09 Governing System

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