Power Plant Operation

First Edition

SYNERGEM
Center of Excellence in Power Plant Engineering
(Central Electricity Authority Recognized, Under Ministry of Power, Govt. of India)
 CHAPTER A

POWER PLANT OPERATIONS

INTRODUCTION
The procedures outlined in this section are intended to serve as a guide during different stages
of operation. The procedures include precautions which should be observed and the proper
operating sequences of the unit, the fuel firing equipment and auxiliaries. Sequential
procedures do not include detailed reference to other equipment like feed pumps, condensate
pumps, turbine etc.

Reference should be made to the Burner Management System (Furnace Safeguard Supervisory
System), Steam Temperature and Secondary Air Damper Control System and other control sub
loop instructions for further operating details.

The unit operation discussed in general is for a natural circulation, single drum, radiant reheat,
balanced draft boiler with tilting tangential burners. Firing equipment consists of remotely
controllable HEA Igniters, air cooled oil guns and coal nozzles. The elevations of coal nozzles are
supplied with pulverized coal from Bowl Mills.

There are 3 major circuits in the Steam Generation system viz., water & steam circuit, air & flue
gas circuit and fuel firing system.

Following are the associated control systems for the above.

a) Unit monitoring, b) Alarm & annunciation, c) Interlocks, Protections & d) Auto control

Control equipment includes Furnace Safeguard Supervisory System to protect the pressure
parts and flue gas system under extreme emergency conditions from severe damages, Soot
Blower Control System, Secondary Air Damper Control System, Electromatic Relief Valve
Control and other local pneumatic controls.

The various auxiliaries include two numbers rotary regenerative air preheaters, six numbers
Bowl Mills arranged at the REAR SIDE of the boiler, two numbers axial reaction FD Fans, two
numbers Axial reaction PA Fans, two numbers radial ID Fans, two numbers Seal Air Fans and
two numbers Electrostatic Precipitators.

The Boiler is designed for control load operation from 60% TMCR to 100% BMCR. Accordingly
the SH / RH surface areas are designed to achieve the rated steam parameters in the control
range.

The steam output of the Boiler is termed as Boiler Load Index (BLI) and it is the cumulative
addition of flow in steam turbine, HP by pass lines and auxiliary PRDS lines.
GENERAL PRINCIPLES OF OPERATION
1. Operations must be carried out with certain goals / milestones (Hydraulic Test, Acid
Cleaning, loading, Cold Rolling, Hot Rolling etc.) decided before doing the actual
operations.

2. The operations to be done serially and / or parallel must be decided as per the goals /
milestones set for the operation.

3. As the fuel consumed during startup before synchronization increases the HEAT RATE,
set the priorities for the starting and stopping of the systems. See figure 1.

Figure 1

4. Before the operation is carried out, think about the parameters, that may prove the
operation, e.g. in case of starting a pump, check the ampere meter, bearing temp, pump
pressure, suction level, pump flow etc.

5. After the starting of pumps, fans etc, check the starting kick in the ampere meter. In case
of big auxiliaries such as BFP, keep a watch on station load and inform other control
rooms / units.

6. For charging steam / water/ fluid lines open the drains and vents of the line / header.
Then open the isolating valves and charge the line with steam / water / fluid. When
 continuous steam / water / fluid comes out from the drains, close the drains. This
procedure will eliminate the hammering in lines / headers causing damage.

(If there is water in the header and if the steam valve inlet to the header is opened, the
steam going into the header gets condensed forming a vacuum in the header and causes
severe hammering in the header.)

7. Close the vents also when the steam / water / fluid comes out from the vents in a
continuous manner. This procedure eliminates the possibility of air entrapment in the
header / vessel/ pipeline.

8. While starting a fan, it must be started on no load and hence its discharge damper must
be kept closed, the vanes also must be at minimum.

9. The lubricating oil pumps must be developing the requisite oil pressure for the bearing
lubrication as well as for the control oil. The standby oil pump must start in the event of
any problem in the running pump. The trials must be taken to ensure this.

10. While starting any pump, keep always the discharge valve closed except for operation of
some pumps where minimum discharge pressure is required. (In case of CEP). Also the
auxiliary oil pumps for lubrication and control must be running and developing requisite
oil pressure.

11. All pump / fan motors and Lubricating oil systems must be charged from the GS cooling
System for cooling of Motors and Lubricating / Control Oil.

12. All starting / tripping interlocks for the equipment must not be bypassed but put in
service before starting the equipment / auxiliary.

13. For charging an electrical board, the HV side should be charged first.

14. All electrical operations, such as racking in of breakers etc. must be done with all safety
precautions.

15. All the instruments viz pressure indicators, temp indicators etc related to the system
must be calibrated well before charging the system.

16. The control supply must be Uninterrupted Power Supply.

17. Check that all work permits related to the system being operated are cancelled and all
the staff and laborers are in a safe zone before charging the system.
COMMISSIONING OPERATIONS
GENERAL SEQUENCE OF OPERATIONS

ELECTRICAL CHARGING
COOLING / GS WATER SYSTEM
COMP. AIR SYST
DM WATER

SYST
FILLING OF BOILER DRUM, DEAERATOR & CONDENSER
BOILER LIGHTUP.

1. CHARGING OF STATION BOARDS

All the Electrical Supply required for the station is from the Station Transformer (generally a
400/6.6KV). The station transformer capacity is approximately 20% of the generating capacity.
The supply may be changed over to Unit Auxiliary Transformer, after the unit is synchronized.

FIGURE -2

The 6.6 KV station boards are charged by charging the station transformer from the HV side
(400KV side) of the transformer first. The isolators of the 400kv side breaker are closed and
then the breaker is made ON.

The incomers to the station boards are made ON to charge the bus bars in the Board.
All the outgoing breakers on the Station Board are made ready and 6.6KV supply is extended to
CHP, AHP and CW Systems. The supply is also extended to UAT A and UAT B. (Unit Boards 6.6
KV). See figure 2.

Low Voltage Station Service Boards receive supply through Station Service Transformers (6.6 KV
to 415 V 3 Ph) from the Station Boards. See Figure 2 STATION BOARDS.

2. CHARGNG OF UNIT BOARDS 6.6 KV (UAT A & UAT B)

UNIT TRANSFORMER
UNIT TRANSFORMER
16.5KV /6.6KV 20/25MVA 16.5KV
KV /6.6KV 20/25MVA

Figure -3 Unit Boards

Both the Unit boards have two incomers each 1. Tie From station and 2. From UAT 16KV /6.6KV
20/25MVA. (Marked Red). Rest of the board supply power to unit auxiliaries HV and
an LV.

All the LV Boards (Boiler Board, Turbine Board, and Emergency Board) are also charged.
3. COOLING & GS WATER CYCLE ESTABLISHMENT

This depends on the systems provided at site. Typical system operations are described here.

I) GS/Cooling and DM Water System at KTPS Koradi and

II) Cooling Water System and DM makeup system at EPL Bela (270 MW).

GS & DM WATER SYSTEMS AT KTPS, KORADI

a) The River water Pumps, pump water for the whole requirement of water to the TPS.
This water pumped by the RWP is sent to the WT Plant where it is treated & stored and
then made available as G.S. water.
b) The General water service pumps for all auxiliaries cooling systems are started and all
cooling water systems are charged. The overhead GS water tanks are also filled up. The
tanks are provided so as to act as buffer in case the pumps trip or not available for some
time. (Figure 4.)
 Figure -4 TYPICAL GS WATER SCHEME AT KTPS KORADI

c) After the cooling water is available for Instrument and service air compressors, the
compressors can be started and Instrument and Service air is made available for the
operation of valves, Atomization etc.
d) From the WT Plant, the DM water will be available now. The Intermediate DM Tank is
filled up by opening valves DM4 and DM5 and DM Makeup pumps can be started after
the Intermediate Tank Level reaches more than 2M. There are two Emergency DM
tanks provided in case of failure of DM Pumps. These tanks are filled by DM Makeup
Pumps by opening the respective valves. (Figure 5)

Figure -5 TYPICAL DM MAKEUP SYSTEM FOR 210 MW LMW UNIT

e) The Unit Drain Tank and Condenser may be filled up with the help of DM Make up
pumps by opening the respective valves. (UDT level 2M & Condenser Level 3M).
f) The Condensate Cycle can be taken into service at this time. There are Three No of
CEPs. Two are running and one standby. The First CEP to be started is started with its
Discharge Bypass valve 10% open, so that it develops some header pressure. (More
than 14kg/cm2, otherwise the started CEP will trip on “CEP Discharge Header Pressure
Low”.) Once a pressure of 20kg/cm2 is reached, the discharge valve of the CEP is
opened.

Before the CEP is started the condensate line up to the deaerator is made through (All
Heaters Inlet / Outlet Valves open & Bypass Valves Closed). The main Condenser level
control valve is also kept closed. (MC36 Valve closed).

After starting the CEP and opening the discharge valve, Main Condenser level Control
Valve (MC36) can be opened and the flow to Deaerator can be observed. (Figure 6).

Valves Closed

Note:- Valve MC36 to be opened only after starting CEP.

Figure – 6 CONDENSATE SYSTEM of 210 MW LMW UNIT at KTPS, KORADI

The Deaerator can now be filled up by opening the Main Condensate Control Valve
MC36 slightly. (About 5%). The Condenser Hotwell Level in the process will come down.
 The Condensate Level has to be maintained by the Condensate makeup valve CV6 or
CV7. Once the Deaerator level reaches to about 4M close the Main Condensate Control
Valve MC36 and stop the make up to condenser.

COOLING WATER SYSTEM & DM MAKE UP SYSTEM AT IEPL BELA (For 270 X 2 MW )

Here the CW water comes to the CW Forebay through a CW makeup Valve. The opening of
this valve is monitored for make up in the CW system. All the cooling water required for
Turbine Exhaust Steam Cooling and other Auxiliary cooling is taken from the CW Forebay.

There are two CW Pumps and three Auxiliary Cooling water pumps. The CW Pumps
discharge water to the Cooling water Header. The Auxiliary cooling water pumps discharge
water to the Low pressure Auxiliary Coolng water Header.

Both Headers are interconnected with an isolating valve and a pressure reducer.

The Cooling water header discharges water into the condenser and the condenser outlet
goes to the CW return header. (Figure 7)

The low pressure Auxiliary cooling water header discharges the CW to the Plate Heat
Exchangers (2 Nos) through the self cleaning strainer. After the plate heat exchangers the
CW water goes to the CW return line.

This water is also made available for the Vacuum Pumps for creating Vacuum in the
condenser. The vacuum Pump discharge also goes to the CW return line. (Figure 8)

For Auxiliaries Cooling, DM Water is used and the hot DM water is cooled in the plate heat
exchangers and recycled.

The DM water used for the cooling system is taken from the DM Transfer pump into the
DWCW Overhead Tank. There are three DMCW Pumps, which discharge water into the
Plate Heat Exchanger, where DM water is cooled and then supplied to the turbine /
generator and Boiler auxiliaries.

As the Boiler auxiliaries are generally away, a pump is also provided for boiler auxiliaries.
The Pumps are started as per the requirement. (Figure 9).

The DM Water from the WT Plant is taken to the Condensate Storage Tank and from there
through the makeup valve it is given to the condenser. Figure 10.
So the condenser can be filled by Starting the DM Transfer Pump, Filling the CST and then
opening the condenser makeup valve.

Initially the Deaerator can be filled up by Boiler filling line as shown in the Figure – 10.

Figure – 7 Cooling Water Scheme at IEPL Bela (2X270MW)

Figure – 8 Auxiliary Cooling Water System at IEPL, Bela (2X270 MW)

Figure – 9 DM CW System (2X270 MW)

Figure – 10 Condensate & Deaerator Filling (2X270 MW)
4. BOILER DRUM FILLING
 Figure - 11 Valves to be opened for Boiler Filling through Boiler Drain Header.

The Vents of the boiler drum shall be opened for boiler drum filling. Also the Economizer
Recirculation Valve must be opened before starting the boiler drum filling. By starting Boiler
Filling Pump and making the circuit through for boiler filling through the Boiler Drain header,
the Boiler Drum can now be filled up to NORMAL Level. (0.6 M). Refer Figure 11.

The Boiler Drum can also be filled by opening the Feed Control Station Low Load Line valves,
the economizer inlet valve and the boiler filling pump discharge line to FCS valve. Figure 12.

Figure 12 Boiler Drum Filling through FCS and Economizer (210 MW)

After the drum filling is done up to the normal Level, the boiler filling valve can now be closed.
The Economizer vent valves shall also be closed as water comes out from Economizer Vents.

The Drum Vents and the Economizer Recirculation will be kept open, till there is pressure in
the boiler drum.
PREPARATION FOR COLD LIGHTUP
1. CHECK AND REMOVE ANY FOREIGN MATERIAL FROM BOILER. ENSURE ALL MANHOLES, ACCESS
DOORS AND OPENINGS IN THE BOILER AND DUCTING ALL SECURELY CLOSED.
2. REMOVE ANY RESTRICTION OBSTRUCTING THE BOILER EXPANSION.
3. ENSURE FURNACE HOPPER WATER SEALING
4. ENSURE AVAILABILITY OF COMPRESSED AIR, POWER, CHEMICALS, COOLING WATER ETC.,
5. CHECK UP AND KEEP READY THE OIL PUMPING AND FIRING EQUIPMENT AND SYSTEMS.
6. ENSURE CORRECT FUNCTIONING OF ALL INTERLOCKS AND PROTECTIONS OF AUXILIARIES,
DAMPERS AND VALYES.
7. ENSURE ALL EQUIPMENT ARE PROPERLY LUBRICATED AND KEPT READY FOR START UP AS PER
THEIR OPERATING INSTRUCTIONS.
8. ENSURE FULL CLOSING OF ALL DESUPERHEATING SPRAY CONTROL VALVES.

A) PRE OPERATIONAL PROCEDURES

1. CLEAN UP

Before initial firing and prior to each subsequent cold start-up, after maintenance has been
done on the unit, the furnace should be inspected and cleaned both internally and externally.
All foreign materials should be removed from the pressure parts. Any grating, pipe lines,
electric conduit, etc., that might restrict normal expansion of the unit should be cleared. All
personnel should be clear and access doors closed.

A complete check list should be prepared by the Operating Department.

2. CHEMICAL CLEANING

For procedures for boiling out and acid cleaning refer to "Acid Cleaning and Steam Blowing.
"Firing procedures are outlined under Section 2.3. Lighting off, should be used as a guide when
operating the fuel burning equipment.

3. BLOWING OF STEAM LINES

Prior to starting up a new unit or after major pressure parts repairs on an older unit, the main
steam lines and the reheated steam lines should be blown out to remove scale and foreign
matter thereby preventing damage to the turbine. This should be done after acid cleaning and
prior to setting drum and superheater safety valves. Consideration should be given to setting
the reheater safety valves before removing the temporary blowout piping.

Refer to manufacturer’s instruction on 'Acid Cleaning and Steam Blowing' for recommended
operating procedures and precautions.
 4. SETTING SAFETY VALVES

Setting of the safety valves on the drum and super heater should be done prior to turbine
rolling.

Refer to the safety valves manufacturer's instructions for setting procedures. A conservative
firing rate should be maintained limiting the furnace exit gas temperature to a maximum of 540
deg.C.

If the reheater safety valves were not set during the steam line blowing procedure, they may be
set while the turbine is carrying a light load, by closing down the intercept valves until a reheat
steam pressure is reached high enough to lift the reheater safety valves. (Consult the turbine
manufacturer's instructions for allowable procedures). Popping pressure and blow-downs
should be adjusted to conform with design values.

B) COLD START UP

It is assumed that at this time the following preparatory work has been completed:

1. The unit has been chemically cleaned, that the steam lines have been blown, that the
safety valves have been set and that the unit has been filled to slightly above the normal
operating level with properly treated feed water.
2. The feed water tank should have been filled with water.
3. All instrumentation and associated mechanical equipment have been checked and are
available for service.
4. Check all safety interlock system prior to startup to ensure proper functioning.
5. The oil firing equipment has been checked out to assure proper functioning Recheck items
such as:
• Oil guns inserted and properly coupled. (Check gaskets between unions).
• All manual valves open.
• All control valves closed.

6. The pulverizers and feeders have been checked and are available for service. "Refer Mill
starting sequence" under FSSS.

7. The feed water system, instrumentation and equipment, have been checked and are
available for operation. It is recommended that during start ups the feed water is
controlled remote-manually, until a continuous flow is established. See Section 2.3
"Lighting Off'. To avoid possibility of oxygen corrosion in the boiler, the use of undeaerated
feedwater temperature less than 100 deg.C is not recommended.
8. All air handling equipment have been checked and are available for service. All air and gas
duct dampers should be in the startup position. Refer to Notes and caution below.
below

a. I.D. Fan outlet shut off gate closed. Inlet regulating vanes/dampers are in closed position
during starting.

b. Keep the F.D. Fan outlet shut

shut-off dampers closed.
ed. Keep the F.D. Fan regulating
Vanes/Blades in the minimum position.

C) PREPARATIONS FOR LIGHTING UP

It is assumed that the unit will be started with both F.D.Fans and I.D.Fans. If the unit is started
with only one set of fans and air heaters, the corresponding dampers associated with the
equipment to be kept open. Dampers associated with idle equipment should be closed.

Dampers Open

Figure 13

Flue gas Path ID Fans

VFD
Minimum

Dampers Open

Dampers Closed

Figure 14
Refer Figures 13 & 14 above

The ID Fans are capable of developing drafts in excess of the furnace design pressure. Therefore,
the operator must take care to establish and maintain an air flow path through the unit prior to
starting the I.D. Fan and prior to opening the I.D.Fan inlet damper by ensuring that other
dampers in the system are in the start up positions indicated above.

The I.D. Fan inlet damper must be kept closed until after the fan is started. This procedure will
minimize the possibility of developing excessive negative pressure in the unit during the starting
procedure.

The operator must take care to maintain the furnace draft within safe limit at all times. He must
be especially careful when draft and air low controls are in the "Manual mode. He must be alert
at all times for possible malfunctions of automatic control equipment resulting in abnormal
excursions in furnace pressure either negative or positive.

9. Check that the air heaters have been cleaned and prepared for service, than an adequate
means of extinguishing air heater fires is available and ready for use.

10. Place the gas temperature probe intermittently for monitoring the Furnace Outlet
Temperature. It shall be less than 5400C till Reheater is charged and accordingly the firing
rate shall be limited.

11. The soot blowing equipment has been checked for proper operation and the system is in
the startup condition. (All blowers retracted, main steam supply valve open).

12. Boiler Drum along with Economizer is filled with DM water up to the Normal Level by the
boiler filling pump. The Drum vents are open. All the drains of Boiler drum and Economizer
are closed.

13. All Soot Blowers / Deslagers are in OUT Position.

14. All Boilers, Superheater and Reheater drain and vent valves are in open / the start up
position. Refer Figure 15.

15. The turbine generator is available for service and has been prepared for service as
described in the manufacturer's instructions.
 Valves Open

Valves Closed

Eco Rec
Valve

Figure – 15 Start up Position For Drain and Vent Valves

D) Initial Firing Precautions

To ensure a maximum safety margin during start

start-ups.
ups. It is mandatory that at least 30% of full
load air flow be maintained in order to produce the following conditions:

I. An air-rich
rich furnace atmosphere. This precludes the possibility of an accumulation of explosive
mixtures in the event of poor or delayed ignition after fuel is introduced in to the furnace.

II. High excess air through the air heater. This mi

minimises
nimises the dilution of combustion air by inerts,
carried over by the air heater rotor.

Air flow should be increased when the boiler reaches a load where additional air is required to
maintain the rated operating excess air. Refer air flow vs. load curve.

During start-ups,
ups, lighting off is done with the lower igniters and warm up oil guns. Warming up
can be accomplished with either the warm warm-upup oil guns or fuel oil firing. In either case, the
required firing rate must permit operation of an entire elevation o off fuel nozzles without
exceeding the furnace exit gas temperature limitation as described in the following paragraph.
NOTE: To minimize the possibility of adverse visible stack emission it is desirable to use the
warm-up oil guns till attained to at least 35 Kg/cm2 (g) drum pressure and 177 deg.C secondary
air temperatures before firing pulverized coal.

When bringing the unit up to pressure and temperature, the saturated (steam temperature rise
must be limited to 110 deg. C per hour (See Note). The stat-up curve (curve 1) shows the
corresponding rate of drum pressure increase. The capacity variation curve (curve 2) shows the
capacity pressure relationship required for proper water wall circulation. At reduced drum
pressure the steam flow must not exceed the corresponding maximum allowable capacity (%
design capacity) shown on the curve.

During all start-ups the firing rate should be controlled to keep the maximum furnace exit gas
temperature below 540 deg.C (as measured by the furnace outlet gas temperature probe) until
adequate flow is established through RH by cutting in the HP/LP Bypass. After rolling the
turbine, the steam temperature and pressure rise at the turbine throttle should at all times be
in accordance with the limits prescribed by the turbine manufacturer.

NOTE: It is recommended that during initial start of a new unit a relatively slow rate of pressure
increase be followed, in order to allow sufficient time for checking expansion movements and to
permit the operators to become familiar with the characteristics of the unit and its auxiliaries.
Once these characteristics have been established, subsequent startups may be made at the
fastest rate consistent with maintaining the furnace exist gas temperature limitation of 540
deg.C until the HP/LP Bypass is cut - in.

E) Starting of Air and Flue Gas Cycle: - Refer Figure 13 & 14.

ESTABLISHING AIR CYCLE

a)Taking Into Service APHs

• The lub. Oil pumps of support and guide bearings can be started from control room
but preferably from Local for the first time.
• Start any one of the pump locally and see that there is no oil leakage.
• Check the lub oil pressure.
• Stop the pump and start the other pump and see that the flow and pressure is
normal, and that there is no oil leakage.
Note: All the 8 Nos. pumps shall be started locally and checked before giving clearance
for remote operation. The stop push buttons shall be kept in released condition.

• Now open the air valve for starting the air motor of APH A or B as the case may be. As
the main drives are not in service, the solenoid will supply air to air motor.
• Check the operation of APH for any abnormal sound or abnormal seal rubbing.
• If the performance is normal, the main drive can be started locally or from remote.
• Check the performance of APH on main drive-the load current and abnormal sound and
vibrations are to be watched.
• On starting the main drive, the Air motor shall stop. This can be verified in control
room by the indication given from the service air pressure switch, provided in the line.
• Now stop the main drive from Control room and check that the Air motor comes on
Auto.
• The air preheater soot blowers are to operated at regular intervals, after lighting up of
the boiler.
• The DP across Air preheaters has to be watched closely to see that the APHs are free
from choking.
• The oxygen and carbon dioxide levels in flue gas, before and after APH have to be
measured once in a shift to see the performance of the boiler as well as APH. Abnormal
drop in carbon dioxide level after APH shall indicate poor performance of the APH seals.
Normal Drop: 2%

b) ID fan pre-start checks:

Ensure that there is no pending permit in respect of ID fans, ESP, furnace and APH.

 Ensure the manholes are closed.

 Check the availability of instruments to measure flow, pressure, temperature etc. of
the ID fan and drive motor.
 Check the closing and the opening of the suction and discharge gates. Keep them
closed before starting the ID fan.
 Check healthiness of all the protections and interlocks for their functioning.
 Ensure the local push button is in the released position.
 Check that the discharge dampers of blower motors are open and the modules are
kept ON for supply.
 Check that the flue gas path is made through
♦ APH inlet flue gas dampers are open.
♦ ESP inlet gates are open.
♦ ESP outlet gates are open.
 Check that the seal trough is filled with water and overflow is maintained.
 Start the ID fan after ensuring the healthiness of protections whenever the fan is to
be started after long shutdown.
Starting Permissives for Induced draft Fan:

Check that the final start permissive is available. The final start permissive will get available if
the following conditions are satisfied,

 ID fan stopped.
 Cooling water to the coolers adequate.
 Suction gate closed.
 Discharge gate closed.
 Ensure VFD for minimum speed.
 ID fan tripped indication should not exist.
 Ensure 220 V DC control supply for the breaker of other ID fans is available.

Now the first ID fan can be started

Post Start Checks:

 Check the opening of gates on interlock, after 10 secs.

 Check the performance of the motor.
 Check adequate lub. oil pressure.
 Check the starting of both the discharge gate blower motors on interlock. If not,
start manually.
 Maintain the furnace vacuum at -12 mmWC by suitable loading of the fan.

c) FD FANS STARTING:

Please refer Fan panel control diagram provided in the boiler control and instrumentation
manual. Protection interlocks for drive motor shall be as recommended by the respective
supplier.

PRE START CHECKS:

 Ensure No Permit is pending.

 Ensure the electric supply to the drives and equipments are available.
 Ensure the Air Heater flue gas inlet dampers the gas gates before and after ESP are kept
open.
 Ensure the secondary air dampers of Air Heaters A & B are kept open. At least one
pair should be kept open for starting the first FD fan.
 Ensure the Secondary air dampers in wind boxes are in open position as per FSSS logic.
 Check healthiness of all the protections and interlocks for their functioning.
  The suction and discharge dampers of the FD fan should be checked for its operation
and kept closed before starting the fan.
 Ensure at least one ID fan is in service to start the first FD fan. Both ID fan should be in
service to start second FD fan.
 Ensure bottom ash hopper seal water trough is filled with water and maintain overflow.

FD Fan Start Permissives:

 Blade pitch control servomotor is in minimum position.

 FD fans discharge dampers are in closed position.
 ID Fan is running.
 Bearing temperature of motor are within permissible limit.

START SEQUENCE OF THE FAN:

a) Tank oil level > 50%

b) Tank oil temp > 25 deg C

c) Control oil pressure > 20 bar

d) Lub oil pressure > 4 bar

e) Bearing temp < 95 deg C

f) Control blade adjustment : Manual

g) Impeller blades position : Close

h) Discharge damper/gate : Close

i) Fan Motor : ON

When any FD fan is started impulses shall be given for:

 Opening the outlet damper of the corresponding FD fan after the motor reaches
its rated speed. (After 10 secs.)
 Connecting the blade pitch control drive of the fan to auto control, if
Auto/Manual station is selected on Auto.
 Closing the atmospheric suction damper of scanner fan if they are running with
suction from the atmosphere.
 d) ALARM & TRIP VALUES

When the fan is kept under service, the following values may be applied as reference
limit and in case the values are found exceeding, suitable corrective actions may be
carried out to maintain the following values below alarm limit.

DESCRIPTION ALARM TRIP

Fan Bearing Temperature >= 95 deg C >= 105 deg C
Fan Bearing Vibration (Vel -rms) For Fans erected >= 4.5 mm/s >= 9.0 mm/s
on Solid Concrete foundation.
Fan Bearing Vibration (Vel - rms) For Fans erected >= 7.0 mm/S >= 14 mm/s
on Spring Isolator
Differential Pressure across oil filter >= 5 bar ****
Lub Oil Pressure low <= 4 bar ****
Control Oil Pressure low <=14 bar ****
Oil Level In The Tank low < 50 % ****
Refer Logic Diagram for Additional interlocks.

e) STARTING OF FAN & MOTOR FOR TRIALS:

• Ensure that all protections and interlocks are functioning properly.

• Start the motor. Check for correct direction of rotation of motor. This fan should rotate in
Anti-clockwise while viewing from motor.
• Test runs the motor for 8 hours. If found satisfactory, couple the fan with motor.
• Operate the impeller blades to minimum position (Full close).
• Keep the delivery damper in full close position.
• Start the Fan and note starting time.
• Ensure that the discharge damper/ gate starts open simultaneously with the start of fan
motor.
• Measure static pressure at Fan discharge with blades in minimum position. Ensure at
least + 20 mmwc. If not, readjust minimum blade setting for this value.
• Measure the vibration and temperature of the bearing. Record the vibration and bearing
temperature every 15 minutes for first half an hour of run and every 30 minutes for the
subsequent 2 hours of run and every hour till trial run completion.
• Check for any abnormal noise in the Fan.
• Check and record the motor current, voltage, and blade opening position.
• Test run for 8 hours.

Caution: Fan should be trial run in the normal operating condition. Loading the fan with
few man hole doors opened discharge blocked condition is not permissible.
f) CHECKS DURING NORMAL OPERATION OF THE FAN

During continuous operation of the Fan the following information may be logged at fixed
convenient intervals.

Vibration level, Oil level in the tank, Leakages in lub and control oil line and Differential
pressure indication of oil filter.

NOTE: Although it is sufficient to operate one set of fans until the turbines carry a light load, it
may be desirable to light off with both sets of fans in order to avoid unbalancing of the air flow
when load is being carried.

• When the fans are started, the secondary air damper control should adjust the auxiliary
air dampers to obtain approximately 37mm wc ahg wind box to furnace differential
pressure. Check that all other purge permissive are satisfied.
• Initiate a furnace purge. Upon completion' of purge cycle, check that all firing
prerequisites are satisfied and place the temperature probe in service.

Note: - During warming up period keep open the economizer recirculating line valve.

g) F.S.S.S. :

i) Control supply for F.S.S.S. must be available.

ii) Purge ready signal will appear only when the following conditions are full filled.

• Boiler drums level normal.

• At least one air cycle in service.
• Air flow at least 30% or more than 30%
• Trip valves of igniter, LDO + FO be proven closed.
• All warm up & heavy oil nozzle valves proven closed.
• All auxiliary air dampers modulating.
• All coal mills, coal feeders off and hot air gates closed. Cold air damper 5 % open.
• All flame scanners show no flame.
• No boiler trip command exists.

Further the boiler can be loaded as per FSSS discussed in separate booklet.

All Procedures described in the booklet FSSS.

BOILER OPERATION
IMPORTANT INSTRUCTIONS –

BOILER OPERATING PROCEDURES DO’s

A. PREPARATIONS FOR LIGHTING UP

1. CHECK AND REMOVE ANY FOREIGN MATERIAL FROM BOILER. ENSURE ALL MANHOLES, ACCESS
DOORS AND OPENINGS IN THE BOILER AND DUCTING ALL SECURELY CLOSED.
2. REMOVE ANY RESTRICTION OBSTRUCTING THE BOILER EXPANSION.
3. ENSURE FURNACE HOPPER WATER SEALING.
4. ENSURE AVAILABILITY OF COMPRESSED AIR, POWER, CHEMICALS, COOLING WATER ETC.,
5. KEEP ALL VENTS AND DRAINS AS PER VALVE OPERATING DIAGRAM.
6. ENSURE BURNER TILTING IS HORIZONTAL.
7. CHECK UP AND KEEP READY THE OIL PUMPING AND FIRING EQUIPMENT AND SYSTEMS.
8. ENSURE CORRECT FUNCTIONING OF ALL INTERLOCKS AND PROTECTIONS OF AUXILIARIES,
DAMPERS AND VALVES.
9. CHECK UP THE WINDBOX FOR PROPER DAMPER POSITIONING.
10. CHECK UP CORRECT FUNCTIOINING OF ALL INSTRUMENTS.
11. KEEP ALL DAMPERS IN AIR AND GAS SYSTEM IN START UP CONDITIONS.
12. CHECK AND ENSURE CORRECT FUNCTIOING OF PROBE.
13. ENSURE ALL EQUIPMENT ARE PROPERLY LUBRICATED AND KEPT READY FOR START UP AS PER
THEIR OPERATING INSTRUCTIONS.
14. FILL UP THE BOILER UPTO NORMAL LEVEL.
15. ENSURE FULL CLOSING OF ALL DE SUPERHEATING SPRAY CONTROL VALVES.
16. CHECK UP AND ENSURE THAT ALL INSTRUMENTATION AND ASSOCIATED MECHANICAL EQUIPMENT
ARE AVAILABLE FOR SERVICE.

B. INITIAL FIRING

1. CHECK THAT NO BOILER TRIP CONDITION EXISTS.

2. ENSURE 30% AIR FLOW THROUGH BOILER.
3. COMPLETE THOROUGH PURGING OF FURNACE.
4. ENSURE ENOUGH OIL AND AIR PRESSURES ARE OBTAINED.
5. CHECK UP THAT ALL THE LIGHTED UP BURNERS ARE BURNING WELL, FREE OF SMOKE, PROPER
ATOMISATION ETC.,
6. CHECK UP FOR GOOD FURNACE CONDITION.
7. IF THE FURNACE IS FOUND SMOKY ADJUST THE SECONDARY AIR AROUND BURNER OR INCREASE
THE TOTAL AIR FLOW IF REQUIRED.
8. SELECT THE BURNERS IN ROTATION TO HAVE UNIFORM HEATING.
9. CHECK FOR FREE EXPANSION OF FURNACE AND RECORD.
10. CHECK AND CONTROL FIRING RATE AS PER START UP CURVE.
11. CHECK AND MAINTAIN DRUM LEVEL ALWAYS NEAR NORMAL.
12. CHECK AND CONTROL BOILER WATER, FEED WATER AND STEAM CONDITIONS AS RECOMMENDED.
13. KEEP THE CONTROL DAMPER IN APH BY PASS LINE OPEN AND CLOSE THE DAMPER IN MAIN LINE
TO SECONDARY APH DURING FUEL OIL FIRING / STARTUP.
14. DO FREQUENT SOOT BLOWING OF AIR PREHEATER DURING INITIAL LIGHT UP AND START UP
PERIOD.

C. NORMAL LOADING

1. INCREASE THE BOILER LOAD ONLY AS PER STARTUP CURVES.

2. START COAL FIRING ONLY WHEN SUFFICIENT IGNITION ENERGY IS AVAILABLE.
3. COMMISSION ALL AUTOMATICS AS EARLY AND PRACTICABLE AS POSSIBLE.
4. CHECK AND RECORD SUPERHEATER AND REHEATER METAL TEMPERATURES.
5. CHECK AND MAINTAIN EQUAL WINDBOX PRESSURE ON ALL SIDES.
6. CHECK AND MAINTAIN THE FOLLOWING WITHIN LIMITS BY PERIODIC ANALYSIS.
a. FLUE GAS ANALYSIS.
b. QUALITY OF FEED WATER, BOILER WATER/STEAM.
c. PULVERIZED COAL FINENESS.
7. DO FREQUENT SOOT BLOWING OF REGENERATIVE AIR PREHEATER ESPECIALLY ON LOW LOAD TO
AVOID AIRHEATER FIRE.
8. KEEP APH SECONDARY AIR BY PASS LINE IN SERVICE TILL THE RECOMMENDED COLD END
TEMPERATURE OF REGENERATIVE AIRHEA TER IS REACHED.

D. NORMAL REDUCTION OF LOAD

1. REDUCE THE LOAD AS PER THE RECOMMENDED RATE.

2. CHECK AND ADJUST THE DESUPERHEATER SPRAY TO GET THE DESIRED STEAM TEMPERATURES.
3. CHECK AND TAKE OUT THE CONTROLS ON MANUAL AT A POINT WHERE BETTER CONTROL CAN
BE OBTAINED MANUALLY.

E. NORMAL SHUT DOWN TO COLD

1. REDUCE THE LOAD AS GRADUALLY AS POSSIBLE.

2. CHECK THAT NORMAL DRUM LEVEL IS MAINTAINED.
3. ENSURE ENOUGH PURGING OF FURNACE AFTER TRIPPING THE FUEL.
4. FILL UPTO + 150 MM ABOVE NORMAL LEVEL IN DRUM DURING BOXING UP OF BOILER.
5. CHECK AND MAINTAIN DRUM LEVEL PERIODICALLY TILL IT COOLS SUFFICIENTLY.
6. NOTE DOWN ALL MINOR MAINTENANCE WORKS LIKE VALVE LEAKAGE, GLAND LEAKAGE ETC.,
AND ATTEND DURING SHUTDOWN.
7. RUN THE ID & FD FANS AND REGENERATIVE AIR PREHEATER TILL THE INLET FLUE GAS
TEMPERATURE DROPS DOWN TO 200DEG.C.
DON'Ts

A. INITIAL FIRING

1. DO NOT CONTINUE FIRING IF THE DRUM WATER LEVEL IS DANGEROUSLY LOW.

2. NEVER INCREASE THE FIRING RATE SO AS TO CAUSE FURNACE OUTLET TEMPERATURE MORE
THAN 540 DEG C, IF THERE IS NO FLOW IN REHEATER.
3. DO NOT INCREASE THE RATE OF STEAM PRESSURE AND TEMPERATURE RISE HIGHER THAN THE
RECOMMENDED VALUES.
4. NEVER LIGHT UP OR CONTINUE FIRING IF REGENERATIVE AIR PREHEATER IS NOT RUNNING.
5. DO NOT KEEP FURNACE PROBE INSIDE THE FURNACE IF FLUE GAS TEMPERATURE EXCEEDS 540
DEGC.

B. NORMAL LOADING

1. DO NOT INCREASE OR DECREASE THE RATE OF LOADING BEYOND RECOMMENDED VALUES.

2. NEVER PUT THE MILL WITHOUT ESTABLISHING SUFFICIENT IGNITION ENERGY.
3. NEVER OPERATE AT HIGHER STEAM TEMPERATURE THAN RECOMMENDED IN THE START UP
CURVES AS IT MAY HARM THE SUPERHEATER AND REHEATER METALS.
PROCEDURE OF BOILER LIGHT UP & BOILER LOADING:
1. COLD START UP
1.1 Preparations for Lighting Off
It is assumed that at this time the following preparatory work has been completed:
I. The unit has been chemically cleaned, that the steam lines have been blown, that the
safety valves have been set and that the unit has been filled to slightly above the
normal operating level with properly treated feed water. The feed water tank should
have been filed with water.
II. All control systems have been checked and are available for service.
III. All instrumentation and associated mechanical equipment have been checked and are
available for service. Check all safety interlock system prior to start-up to ensure proper
functioning.
IV. The oil firing equipment has been checked out to assure proper functioning.
V. Recheck items such as:
 Oil guns inserted and properly coupled. (Check gaskets between unions).
 All manual valves open.
 All control valves closed.
VI. The pulverisers and feeders have been checked and are available for service. "Refer Mill
starting sequence" under Mill Operating Procedure.
VII. The wind boxes have been checked for proper damper positioning, tilts at horizontal,
etc.
VIII. The feed water system, instrumentation and equipment, have been checked and are
available for operation. It is recommended that during start ups the feed water is
controlled remote-manually, until a continuous flow is established. To avoid possibility
of oxygen corrosion in the boiler, the use of undeaerated feed water temperature less
than 100 deg.C is not recommended.
IX. All air handling equipment have been checked and are available for service. All air and
gas duct dampers should be in the start up position. Refer to Notes and caution below;
 I.D. Fan outlet shut off gate closed. Inlet regulating vanes/dampers are in closed
position during starting.
 Keep the FD. Fan outlet shut-off dampers closed. Keep the F.D. Fan regulating
X. Vanes/Blades in the minimum position.
 Primary air fan outlet shut off gate and inlet control dampers are closed.
 Wind box (secondary) auxiliary air dampers open.
 Scanner emergency air damper closed.
 Pulveriser seal air fan shut off dampers open.
 Air and gas dampers around air heater open.
 Notes:
 Refer to the Fan Manufacturers instructions for operating details.
 It is assumed that the unit will be started with both F.D.Fans and I.D. Fans. If the unit
is started with only one set of fans and air heaters, the corresponding dampers
associated with the equipment to be kept open. Dampers associated with idle
equipment should be closed.
Caution:
The ID Fans are capable of developing drafts in excess of the furnace design
pressure. Therefore, the operator must take care to establish and maintain an air flow
path through the unit prior to starting the ID. Fan and prior to opening the ID.Fan inlet
damper by ensuring that other dampers in the system are in the start up positions
indicated above.
XI. The ID. Fan inlet damper must be kept closed until after the fan is started. This
procedure will minimize the possibility of developing excessive negative pressure in the
unit during the starting procedure. The operator must take care to maintain the furnace
draft within safe limit at all times. He must be especially careful when draft and air low
controls are in the "Manual mode. He must be alert at all times for possible
malfunctions of automatic control equipment resulting in abnormal excursions in
furnace pressure either negative or positive .
XII. Check that the air heaters have been prepared for service, than an adequate means of
extinguishing air heater fires is available and ready for use. Refer to Air Preheater
instructions for details.
XIII. The soot blowing equipment has been checked for proper operation and the system is
in the start up condition. (All blowers retracted, main steam supply valve open).
XIV. All Desuperheater Spray Water Control Valves and block valves are closed.
XV. All Boilers, Superheater and Reheater drain and vent valves are in the start up position.
Refer to the Valve Operating Diagram.
XVI. The furnace gas temperature probe is in working order and available for service.
XVII. The turbine generator is available for service and has been prepared for service as
described in the manufacturer's instructions.
XVIII. Cooling water and compressed air service is available.

1.2 Initial Firing Precautions

To ensure a maximum safety margin during start-ups. It is mandatory that at least 30% of full
load air flow be maintained in order to produce the following conditions:
i. An air-rich furnace atmosphere. This precludes the possibility of an accumulation of
 explosive mixtures in the event of poor or delayed ignition after fuel is introduced in to
the furnace.
ii. High excess air through the air heater. This minimises the dilution of combustion air by
inerts, carried over by the air heater rotor.
iii. Air flow should be increased when the boiler reaches a load where additional air is
required to maintain the rated operating excess air.
iv. During start-ups, lighting off is done with the lower ignitors and warm up oil guns.
Warming up can be accomplished with either the warm-up oil guns or fuel oil firing. In
either case, the required firing rate must permit operation of an entire elevation of fuel
nozzles without exceeding the furnace exit gas temperature limitation as described in the
following paragraph.
NOTE: To minimize the possibility of adverse visible stack emission it is desirable to use the
warm-up oil guns till attained to at/east 35 Kg/cm 2 (g) drum pressure and 177 deg. C
secondary air temperatures before firing pulverised coal.
v. When bringing the unit up to pressure and temperature, the saturated (steam
temperature rise must be limited to 110 deg. C per hour (See Note). The stat-up curve
(curve 1) shows the corresponding rate of drum pressure increase. The capacity variation
curve (curve 2) shows the capacity pressure relationship required for proper water wall
circulation. At reduced drum pressure the steam flow must not exceed the
corresponding maximum allowable capacity (% design capacity) shown on the curve.
vi. During all start-ups the firing rate should be controlled to keep the maximum furnace exit
gas temperature below 540 deg.C (as measured by the furnace outlet gas temperature
probe) until adequate flow is established through RH by cutting in the HP/LP Bypass.
After rolling the turbine, the steam temperature and pressure rise at the turbine throttle
should at all times be in accordance with the limits prescribed by the turbine
manufacturer.
NOTE: It is recommended that during initial start of a new unit a relatively slow rate of
pressure increase be followed, in order to allow sufficient time for checking expansion
movements and to permit the operators to become familiar with the characteristics of the unit
and its auxiliaries. Once these characteristics have been established, subsequent startups may
be made at the fastest rate consistent with maintaining the furnace exist gas temperature
limitation of 540 deg. C until the HP/LP Bypass is cut - in.

1.3 Lighting off

i. Start both air preheaters. Then start two 1.D. Fans and both F.D. Fans. After starting the
F.D. Fan, open the shut - off dampers for minimum. 30% air flow by variable pitch
control (See Note below and "Caution" under Section "Preparation for Lighting up").
NOTE: Although it is sufficient to operate one set of fans until the turbines, carry a light load, it
may be desirable to light off with both sets of fans in order to avoid unbalancing of the air
flow when load is being carried.
ii. Open the air preheater air bypass duct.
iii. Start the scanner and seal air fans.
iv. Adjust the fan and wind box dampers to permit a purge air flow of at least 30% of total
air
flow and a furnace draft of approximately 12.7mm wg.
v. When the fans are started, the secondary air damper control should adjust the auxiliary
air dampers to obtain approximately 37mm wg wind box to furnace differential pressure.
vi. Check that all other purge permissives are satisfied.
vii. Initiate a furnace purge. Upon completion of purge cycle, check that all firing
prerequisites are satisfied.
viii. Place the temperature probe in service
ix. Initiate a light off sequence of the lower elevation of igniters and warm-up oil guns.
Refer to the "Furnace Safeguard Supervisory System". "Igniters" and Air cooled Oil Gun"
Instructions for details.
x. During warming up period keep open the economiser recirculating line valve.
xi. Blow down the unit as required to maintain the drum water level in sight in the gauge
glass.
xii. The firing rate should be controlled to keep the furnace exit gas temperature below 540
deg. C until steam flow through Reheater is established. Establish a slight flow through
superheater by opening its start-up vent. More superheater drains/vents may be
opened, if necessary, for increasing the steam temperature to match turbine conditions.
NOTE: HP-LP By pass Station helps the unit to be quickly synchronised.
xiii. Increase the firing rate as required within permissible limit of 110 deg.C hr. to raise the
pressure, if necessary with fuel oil.
xiv. While the unit is heating up, frequent checks should be made of the boiler expansion
movements. Special attention should be given to expansion of the lower part of the
boiler relative to building steel. Expansion movements should be recorded for
comparison with future start-ups. Refer to the expansion movements diagrams.
xv. Maintain drum water level at normal and check boiler water concentrations and
constituents as frequently as required to maintain proper boiler water conditions.
xvi. Close the economiser recirculation valve when continuous feed water flow is
established.
xvii. Before raising a vacuum in the condenser, make sure that all reheater vents or drains
that open to the atmosphere are closed. Leave drains or vents connected to HP drain
flash tank open until the turbine is carrying a light load.
xviii. As drum pressure increases, progressively throttle the final Superheater Outlet Header
 vent (Start-up Vent) and other start-up drains used (main steam line drain, turbine
drains, etc.,).
a) Sufficient steam flow must be maintained at all times to assure clearing the
superheater elements of condensate. Increase the firing rate as necessary,
without exceeding the furnace exit gas temperature limitation.
b) Do not close start-up vent completely until steam flow through the turbine is
established.
c) Start rolling the turbine as soon as the minimum permissible start-up pressure
and temperature, specified by the turbine manufacturer, are reached. Refer to
turbine manufacturer's instructions.
xix. When bringing the turbine up to speed, the firing rate should be controlled to prevent
the furnace exit gas temperature from exceeding 540 deg. C. When the turbine is up to
speed, it may be synchronized. At this point the gas temperature probe may be
withdrawn and the firing rate increased as required. In no case should the firing rate
exceed than what is necessary to satisfy steam demand.
NOTE: If the unit is put on the line before design operating pressure is reached, further
increase of firing rate should be in accordance with the start-up rate. The steam flow must
not exceed the maximum allowable capacity.
xx. If the unit was started with one set of fans then start the second set of fans.
xxi. Place additional level of oil guns in service as the load demands replace the warm-up oil
guns with load carrying guns after the first level of main oil guns are in service and fire is
stable.
xxii. If coal was not fired previously (See Note) the pulveriser serving the lowest elevation of
coal nozzle (adjacent to the warm up oil guns) should be prepared for operation so that
it can readily be started at this time. Refer to Section 'Furnace Safeguard Supervisory
System" for startup sequence and controls. Prior to placing pulveriser in service, ensure
that one of the P.A. fans developing adequate header pressure is in service.
xxiii. Refer to the Furnace Safeguard Supervisory System instructions. The coal fuel-air
dampers should remain closed until ignition is established. Check to see that the nozzle
tilts are horizontal. Place the second Primary Air Fan in service, if not done previously."
NOTE: If a pulveriser was started during the warming up period increasing load requirements
can be met by increasing fuel flow through this pulveriser. When pulveriser is put into service
ensure that the corresponding seal air fan is also in service.
xxiv. When placing the first Coal mill in service, check that the pulveriser start permissives
(ignition energy, etc.,) are satisfied. (Check and Refer FSSS)
xxv. If ignition does not take place immediately after coal appears at the coal nozzles, stop
the feeder. Determine the cause of the ignition failure before attempting to restart the
feeder.
 xxvi. Maintain proper coal/air temperature leaving the pulverisers. Regulate the hot and cold
air damper to hold between 66 deg.C and 90 deg.C at the pulveriser outlet. At no time
should this temperature exceed 95 deg.C. If it should exceed 95 deg. C the hot air
damper must be closed.
NOTE: Pulverizer start-up will cause a sudden and sharp increase of steam pressure. This will
level out rapidly as load is placed on the turbine.
xxvii. Take the second coal mill in service in a similar manner when the coal feeding of the first
mill has reached 90% of its maximum. (Refer FSSS)
xxviii. Refer FSSS for loading, unloading, shutting off of Mills and Furnace oil and Light oil
burners.
xxix. The Furnace Safeguard Supervisory System and Secondary Air Damper Controls should
close the auxiliary air dampers serving compartments adjacent to coal nozzles which are
out of service. When the boiler reaches 20% of full load increase the wind box to furnace
differential pressure to approximately 100 mmwc.
xxx. It is essential that the air flow to the furnace is sufficient for the firing rate at all times,
Automatic control equipment is normally arranged to maintain such a balanced
condition. The Oxygen measuring devices which are often tied in with the air flow
control should be checked periodically to assure continuous and dependable operation.
xxxi. Place additional pulverisers in service as the unit loading demands.
xxxii. Place the Steam Temperature Controls and Combustion Controls on 'Auto' when firing
conditions are stable and the temperature and pressure control set points have been
reached. Refer to the control manufacturer's instructions for specific procedures.
xxxiii. Adjust the feed water supply to the boiler as necessary to maintain normal water level,
as per drum level operating curve. Feed water control should be placed on automatic as
soon as possible and practicable when continuous feed water flow is established.
xxxiv. When the unit firing conditions are stabilised, all warm-up oil guns and igniters may be
taken out of service.

2. NORMAL OPERATION - UNIT LOAD CHANGES

During normal operation, with the unit on the line, changes in pulveriser loading and/or the
number of pulverisers in service may be required to accommodate unit load changes. A wide
range of load control can be achieved with the pulverisers on automatic control.

2.1 Decreasing Load

If the unit load decreases, the feeder speed can be reduced so as to reduce the load. The
feeder speed can be reduced up to 50% below which further reduction may affect the ignition
energy of the adjoining coal mill. (Refer to FSSS).
To remove the pulveriser from service, refer mill normal shutdown procedure.
 Additional pulverisers can be taken out of service in a similar manner if required.
Every effort should be made to keep adjacent ends in service. If, due to maintenance a
pulveriser is not available, skipping the coal elevation served by that pulveriser is permissible.
Skipping of two coal elevations is not recommended and is only permissible with the use of
auxiliary supporting fuel oil (associated warm-up guns and igniters).

NOTE: Auxiliary supporting fuel should be used at any time and under any conditions in which,
in the operators 'judgment in stabilization of ignition is necessary.

2.2 Increasing Load.

If it is required to increase the load, the feeder speeds of all the coal feeders can be increased in
equal manner after a load decrease when pulveriser has been taken out of service.
If the unit load is to be increased further by taking a pulveriser in service. (Refer FSSS).

3. NORMAL SHUTDOWN TO COLD

The following procedures for normal shutdown are based on the assumption that the unit is
operating at full load on automatic control and that it is the intention to reduce the pressure to
zero and cool the boiler completely.
i. Gradually reduce load on the unit; reduce the firing rate in line with the decreasing
steam flow. Allow the pressure to drop with the reduction in load to accelerate cooling.
A) Reduce the steam temperature at the rate prescribed by the turbine
manufacturers.
B) Steam temperature control, combustion control and feed water control may be left
on automatic mode until the point is reached when better control can be obtained
on manual mode.
ii. Refer to FSSS for shutting down.
iii. As pulverisers are taken out of service the secondary air damper control system should
close the associate wind box dampers and throttle other dampers as required to
compensate for the reduction in firing rate.
NOTE: It is recommended that the above consecutive elevation shutdown sequence be
followed. Firing coal at separated coal nozzle elevations without auxiliary supporting fuel is
not permitted.
iv. Operate all soot blowers. Refer to manufacturer's instructions.
v. Reduce the air flow in line with fuel reduction until 30% of maximum air flow is
reached. Do not reduce the air flow below this rating until all fires are out and the unit
is off the line. See curve 3. To avoid firing instability during this period of high relative
air flow, the auxiliary air dampers at all elevations should d open and reduce the wind
box to furnace differential pressure to its lower setting.
vi. Check the expansion movement of the unit as load is being reduced.
 vii. Close the desuperheater isolating valves.
viii. After the last pulveriser end has been shut down, remove the warm-up guns and the
igniters from service. Shut off the cooling water to the pulverisers. All fires should be
removed when the unit is off the line.
ix. Immediately after closing the turbine stop valves, open wide the superheater outlet
vents and drains and all reheater vents and drains. Open other drains in the super
heater system as required for further pressure reduction. Open steam line and turbine
drains as described by the turbine manufacturer.
x. Open the economiser recirculating valves.
xi. During the shutdown period if it is not required to enter the unit immediately a slow
rate of pressure and temperature decay may be desirable. This can be accomplished as
follows:
• Purge the unit by running the induced draft and forced draft fans for atleast five
minutes (at 30% air flow) after the fires are extinguished.
• Reduce the air flow through the unit to a minimum. Keep the fans and airheaters in
service until the unit has cooled to the desired temperature.
• After stopping the fans stop the airheater.
• Keep the water level near normal in the gauge glass, add make up as required.
NOTE: Fans and Air heater should not be taken out of service until the air heater gas inlet
temperature has dropped to below 200 deg. C.
xii. Open the drum vents when the unit pressure has decayed to 2 kg/cm2 (g).
xiii. If it is desirable to accelerate the cooling process in order to permit entry into the unit
for maintenance, proceed as follows:
• Purge the unit by running the induced draft and forced draft fans for atleast five
minutes (at a minimum of 30% air flow) after the fires are extinguished.
• Continue running the fans to cool the unit at the desired rate. The airheaters may be
shutdown when the gas temperature at air heater inlet has dropped to below 200
deg.C.
• Maintain the water level near normal in the gauge glass.
• Open the drum vents when the unit pressure has been reduced 2 kg/cm2 (g).
xiv. The boiler water temperature should be reduced to atleast 93 deg.C before draining.

4. NORMAL SHUTDOWN TO HOT STANDBY

It is assumed that the boiler will be shut down for a relatively short period of time and existing
pressure and temperature condition will be substantially maintained. A procedure similar to
that for normal shutdown should be followed except:
a. Do not reduce drum pressure in line with unit load reduction. The rate of pressure drop
should be much less than the rate followed during normal shutdown. When the desired
 pressure at which the boiler is to be held is reached after the turbine is off the line, the
boiler may be bottled up closing all super-heater drains and vents. Reheater drains and
vents are kept open.
NOTE: If it is expected that the Unit will be restarted in a very short period of time in which the
turbine metal temperatures will not decrease appreciably, it may be desirable to cool the
turbine metal to below 425 deg.C by reducing the steam temperature and pressure, while the
unit load is being reduced. This will reduce the steam/turbine metal differential temperature
upon restart.
b. It is recommended that after all fires are extinguished (See Caution below) the I.D. and F.D.
Fans are kept running until the airheater gas inlet temperature has dropped to below 200
deg.C (See Warning below). Close all gas duct, secondary air duct and windbox dampers
after the fans are shut down.
CAUTION: If it is known or suspected that combustible deposits are present in the air heater
elements, the airheater gas inlet temperature must be reduced to 200 deg.C before shutting
down the F.D. Fans, 1.0. Fans and airheaters. The airheaters must be thoroughly cleaned to
remove any combustible products before it is shut down.
WARNING: If it is decided to shut down the fans with the airheater gas inlet temperature above
200 deg.C the airheaters MUST be kept rotating. However running an air heater with the gas
inlet temperature above 200 deg. C and no air flow through it will result in seal damage and
subsequent excessive leakage during operation (Refer to airheater instructions). The decision to
bottle up the unit above 200 deg.C must be made with this in mind.
c. Keep the water level in sight in the gauge glass. As the unit cools and the water shrinks,
make up should be added intermittently to prevent the water from dropping out of sight in
the gauge glass.
NOTE: The operator should observe the gauge glass periodically so that he is always aware of
the actual drum level and can take the appropriate action to re-establish water level when the
unit is being restarted.

5. HOT RESTART
Assuming the boiler has been down for a comparatively short period of time and
considerable drum pressure was maintained, the following procedures should be used
in restarting the unit.
i Make a general inspection of the boiler and check the points as mentioned under normal
start-up.
ii. If the airheater and fans were shutdown at reduced temperatures (See 5 Step (ii) Normal
Shutdown to Hot Standby), start the AH and fans as outlined under Sec 2.1 'Cold Start-
up. If the unit was bottled up hot with the air heaters still running, start the fans in the
normal sequence.
 iii.
Initiate a furnace purge and normal light off sequence of the warm-up oil guns.
iv.
Open wide all super heater drains to allow complete draining of super heater headers
And/or elements. After draining, close all drains, except the super heater steam cooled
rear outlet header and side steam cooled wall outlet header drains and the start-up
drain vent (Main Steam Line Vents and drains). Keep the steam cooled wall header
drains slightly cracked open until steam is admitted to the turbine. Keep the startup
vent, drains open. Reheater drains and vents are open. Open the desuperheater
isolating valves. Desuperheater control valves must be closed.
v. Close all reheater vents and atmospheric drains before pulling a vacuum in the condenser.
Reheater condenser drains may be left open until the turbine is under light load. They
may be closed soon after HPLP Bypass has been cut into operation.

vi. When steam is admitted to the turbine for rolling, it is desirable to have a minimum
steam/turbine metal temperature differential. This can be achieved by firing at a
maximum rate within the furnace exit gas temperature limitation of 540 deg.C until HP-
LP bypass is cut in. In order to reach the exit gas temperature limit it may be desirable to
put more oil guns to start a pulveriser at this time. Stabilize the firing conditions to
maintain the maximum furnace exit gas temperature without exceeding it.
vii. Proceed as during normal start-up from cold.
viii. During a hot restart the turbine metal temperature will normally require a rapid
reloading of the unit and this is achieved by closing the bypass as the turbine valve
opens.

BOILER PROTECTIONS

The following boiler protections are incorporated,

Sr.No. Description
01 All FD Fans OFF
02 All ID Fans OFF
03 Reheater Protection Trip
04 220 VDC Fail for > 2 seconds
05 Furnace pressure High
06 Furnace Pressure Low
07 Drum Level Very Low
08 Drum Level Very High
 09 < fire ball & loss of AC
10 Flame failure trip
11 Loss of Fuel Trip
12 Low air flow < 30 %
13 24 VDC Failed Or MFT O/PS Freezed
14 MFT Net Work Failed
15 Emergency Trip

Purge Permissives:

No Boiler Trip
All PA Fans are OFF
Heavy Oil Trip Valve closed
Light Oil Trip Valve Close
All Light oil Nozzle valves Close
All Heavy oil Nozzle valves Close
All Mills are OFF
All Mills O/L Gates closed
All Scanners Show ‘No Flame’
Air Flow > 30 % & < 40 %
All Aux. dampers modulating
AUXILIARY STEAM SYSTEM (PRDS) & HPLP BP CHARGING

Figure 16 AUXILIARY STEAM SYSTEMS FOR 270 MW UNITS (IEPL)

At at about 16 kg/cm2 drum pressure charge self PRDS from M.S. line. Open the valves
supplying steam for FO Heating from the Low Temp Aux Steam Header and increase FO
temp up to 1200C by keeping recirculation valve of FO open. (Figure 16)

Note:- While charging the PRDS open the drain valve of the PRDS first and let the
condensate in header come out from the drain. Open the isolating valve slowly so that the
steam goes into the header and forces out the condensate through the drain. When steam
comes out from the drain the drain can now be throttled/closed.

a) After this flue gas temp after air heater shall increase and attend the temperature up to
1000C and at this time take one pair of oil gun of C.D. elevation in service.
b) Take FO in AB elevation and increase the firing rate by taking second pair of oil gun of
C.D. elevation.
c) Close vents of Reheater.
d) Start vacuum pulling in condenser by Vacuum Pumps / starting ejector. Give Gland
sealing steam for glands and then increase vacuum further by taking main ejector in
service. Increase condenser vacuum upto 680 mm Hg.
e) Charge HP/LP bypass system. (Figure 13) and raise the steam parameters.
f) If ELP can maintain drum level up to 18 to 20 kg/cm2 drum pressure else start Boiler
feed pump and maintain drum level.
g) After charging of HP/LP bypass, start up vent can be closed or throttled.

Figure 13 HPLP Bypass for 270MW TURBOGENERATOR

*******
TURBINE OPERATION (270 MW KWU Units)
1. When Putting M/c on Baring

1. AC AOP 1 & 2 / DC EOP / Oil vapor Extractor Fans / AC SOP/ DC SOP supply modules as well as
the DCJOP/ AC JOP/ Vacuum pump/ Bearing chamber exhauster fan Modulus are ON
2. MOT level Normal.
3. All drains in Duplex filler / oil cooler in closed condition.
4. Start A C AOP-1.
5. Note the discharge press/header pressure /MOT level.
6. See the oil from return line.
7. Ensure that SOST Valve to Seal oil in open condition.
8. Start AC AOP -2 and stop AC AOP -1
9. Stop AC AOP-1/2 and auto pick up of DCEOP to be checked.
10. Start AC JOP - 170 to 180 Kg/cm2. JOP is screw pump.
11. Note the pressure
12. Stop AC JOP and check the auto pick up of DCJOP
13. Start OVEF-1
14. Start AC S O P
15. Note the discharge pressure of seal oil.
16. AC SOP-1 OFF AC SOP-2 ON.
17. AC SOP 1 & 2 OFF DC EOP auto picks up to be checked.

Check when DC JOP running and note the values:

(1) Discharge press

(2) Current
-- Now the turbine can be put on barring.

2. STARTING STEPS FOR ROLLING

1. ACW pump in service ----1 No

2. CW pumps in service ----1 No. /02 Nos.
3. ACW booster pumps in service ---- 1 No. --- 3 / 4 kg/cm2
4. Hot well level Normal.
5. All drains connected.
6. Start CEP in minimum recirculation.
7. Charging of MS line.
• Open the drain of MS line.
8. Boiler light up press 25 kg/cm2/300oC
9. PRDS charge [ required for turbine glands sealing ]
--- Turbine MUST BE on Barring before giving gland sealing.

10. Vacuum pump ----- seal water circulating pumps are started.
11. Vacuum pumps ---- start (-0.2kg/cm2)
• [Ensure Vacuum Breaker is closed]
12. Charge the gland sealing.
13. Ensure Gland steam condenser exhauster fan is in service.
14. Gland steam condenser inlet / outlet valves in open condition & drain /drip to condenser.
15. Achieve full vacuum. Within15 to 20 min (-0.9 kg/cm2) Vacuum is achieved.
16. Ensure the following;
• Drum level Normal.
• Boiler steaming with 2kg/cm2
• Boiler fill pumps I/S

For BFP normalizing

A. Ensure that Oil level in Hydraulic coupling is Normal.

B. Start AOP of BFP.

C. FST level normal.

D. Ensure that inlet outlet valves of lub. Oil cooler /working oil cooler /Mech. Seal line of
BFP Main & Booster pump are charged.

E. Ensure that suction valve and Recirculation valves are open.

F. Ensure that Discharge Valve is close.

G. Note the bearing pressure of all brgs.

H. Cheek the brg. Return oil.

I. Isolating valves of Feed control station & HPH5 & 6 are opened & the bypass valves of
heaters are close.

17. Start BFP

• Ensure that ACW-34 valve providing water for Motor & Working oil cooler opens.
• Ensure cooling of motor i.e. Flow meter for adequate flow.
• Integral Valve (By pass of discharge valve) open.
18. Start Vacuum pump of seal oil system.
19. Start Brg. Chamber Exhauster Fan.

• Note the shaft vibration ,Brg. Vibrations

• Inspect of any abnormal sound at local
Please ensure that all required drains of steam lines & turbine casings are full opened
 20. Crack open HPBP valve

21. Charge the line of CRH.

22. Charge the line of HRH.

23. Crack open LPBP Valve.

24. Please ensure HP-LP Bypass is in-service & steam dumping is in progress.

25. Now steam parameters at turbine inlet

• MS Press 40 Kg/cm2
• MSTemp 350oc
• HRH pressure (during steam dumping=4.5 kg/cm2)

26. Obtain Steam sample from Boiler drum & Ms Line at Turbine Inlet

• Silica MS Line 0.02 ppm &

• PH 9 to 10

There are rolling charts or start-up- diagrams which are designated as X1 / X2/ X3/ X4/X5/X6 & X7
which can be referred to in the BHEL Turbine manual. These diagrams also known as criteria for
rolling.

Cold / Warm / Hot rolling

• Criteria : X1 & X2 fulfilled : Turbine stop valves of HP & IP can be opened. ( 04 nos. of valves)
• Criteria : X3 & X4 fulfilled : Speed to 600 rpm .Soaking speed 600 rpm.
• Criteria :X5 & X6 fulfilled : speed to 3000 rpm
• Criteria : X7 fulfilled : Loading (synchronize)

Note:

1. All rollings of 270 MW KWU turbine is through HPT under all condition.

Critical Zone: Turbine 1800 to 2200 rpm

Generator 1200 rpm.

2. HP LP Bypass System remains in operation during all types of rollings.

3. After synchronizing, the HP / LP Bypass system is to closed gradually.

4. Turbine Stress Controller (TSC) Generated the above criteria. X1 to X7.

TURBINE PROTECTION SYSTEM (270 MW Units)
1. Function

It is the function of the turbine protection system to put the turbine out of operation by closing the
turbine emergency stop and control valves as soon as operating conditions occur that can no longer
be maintained within the admissible limits by the protective equipment and thus endanger the plant.
In this way, it should free the operating personnel from the necessity of making speedy decisions in a
critical situation and convert the plant to a safe state.

2. Structure

The steam supply to the turbine is interrupted when the turbine emergency stop and control valves
are closed. The turbine trip is initiated hydraulically by reducing the pressure of the trip fluid. The
pressure of the trip fluid can be reduced either directly by means of the mechanical protective
equipment or by means of the electrical protective equipment via solenoid valves. Two solenoid
valves are provided for this purpose and the transfer of the electrical initiation signals to the hydraulic
tripping circuit takes place via these valves through two independent protection channels. The
response of one of the two solenoid valves is adequate to initiate the turbine trip.

The turbine protection system can be tested during operation. A device to initiate Turbine Trip during
protective device testing is provided with the automatic turbine testing system so that the turbine is
protected continuously during the period the protective devices are being tested.

3. Protective Equipment

3.1 Over-speed Trip

The turbine is fitted with two over-speed trips which trip the turbine, when its speed exceeds rated
speed by a certain value which can be adjusted between 10 to 12%. Each over-speed trip consists of
an eccentric bolt fitted in the shaft with its centre of gravity displaced from axis of rotation and held
in position against centrifugal force by a spring. At the adjusted value of overspeed, centrifugal force
overcomes the spring force and eccentric bolt fly out suddenly to extended positions, strike the lever
catch and releases pilot valve of releasing device. The auxiliary trip fluid circuit is connected to drain,
thereby the trip fluid circuit collapses in valve, which results in turbine trip.

3.2 Condenser Pressure Too High (Hydraulic and electrical)

In the event of deteriorating vacuum, the turbine trip is initiated to protect the condenser from over
pressure. In this way, the steam supply through the turbine to the condenser is interrupted. The
electrical trip signal is initiated by three pressure transmitters in 2 out of 3 logic.

3.3 Axial Shaft Displacement Too High (Electrical)

When axial shaft displacement of the rotor is too high, which can occur as a result of impermissible
wear of the axial bearing pads, the turbine is put out of operation in order to preclude damage (e.g.,
rubbing between the rotating and stationary components). Turbine trip is initiated by three proximity
sensors in 2 out of 3 with cyclic testing.

3.4 Lubricating Oil Pressure Too Low (Low bearing oil pressure trip)

The supply of oil to the bearings is endangered when the lubricating oil pressure sinks. The
emergency stop valves and control valves are closed when the oil pressure sinks. The control oil
circuit is connected to the lubrication oil circuit. Therefore, the turbine is ensured when the
lubrication oil pressure sinks. The trip is initiated by three pressure switches in 2 out of 3 logics.

3.5 Fire Protection

Amongst other reasons, turbine trip is initiated within the framework of the fire protection measures
to stop delivery of the main oil pump (which is driven by the turbine shaft) as quickly as possible. The
fire protection measures can be initiated either manually by means of the fire protection push
buttons provided specially for the turbine or automatically by means of the "Low oil tank level" signal.

3.6 Oil Tank Level Too Low

A leakage must be assumed in the event of an non-admissible drop in the level in the oil tank. There is
then a risk that the oil will ignite. As the oil supply system is fed by the main oil pump that is driven by
the turbine, turbine trip is initiated via the fire protection logic section.

3.7 Boiler Protection

When the "boiler protection" signal is annunciated, turbine trip is initiated to protect the steam
generator by preventing an inadmissible drop in steam pressure. Without trip initiation, the steam
conditions, which alter quickly, otherwise, would represent an unnecessary risk to the steam
generator and the turbine.

4. Electrical Generator Protection System

Turbine trip is initiated together with the response of the electrical generator protection system and
parallel to generator shut-down in order to preclude damage by removing turbine torque.

5. Manual Trip Initiation

From the logging desk/CRT and mechanical initiation on the turbine)

This initiation device enables the operating personnel both during operational shut-down and in the
event of detection of failures to carry out turbine trip either electrically from the control room
(remote trip initiation) or mechanically on the spot.

6. Remote Solenoid Trip

Remote solenoid trip of main and reheat stop valves is provided by two solenoid valves. These can be
energized from the control room by means of push/control buttons, the electric low vacuum and any
other station requirements.

7. Solenoid Valve for Load Shedding Relay

One solenoid valve has been incorporated in the secondary fluid line of IP control valves and one in
Auxiliary Secondary fluid line in order to prevent the turbine reaching trip speed in the event of the
turbine suddenly loosing load. These valves are operated by a load shedding relay when the rate of
change of load exceeds a certain value. The solenoid valves drain the IP secondary fluid and Auxiliary
Secondary fluid circuits directly. Direct draining of IP secondary fluid circuit causes the reheat valve to
close without any significant delay.

After an adjustable time, the solenoid valve is re-closed and IP secondary fluid pressure
corresponding to reduced load builds up.

Solenoid valve provided in the Auxiliary Secondary fluid line ensures the closing of both HP and IP
control valves under the above conditions.

8. HP Exhaust Temperature High

The HP exhaust steam temperature protection circuit protects the exhaust sections of the
turbine, the blading of extraction points against overheating. The temperature is measured by
means of three thermocouples and protection criteria are derived in 2 out of 3 logic.

*******
TURBINE OPERATION 210 MW LMW Units.
Cold Rolling: - All Metal Temperatures are lower than 150 Deg C.

Boiler Lighted up, MS Pressure 25 kg/cm2, Temp 280 Deg C, HP/LP Bypass Charged.

a) At this time transfer pipes of HP & IP turbine can be put on heating and watch the
parameters.
b) Before rolling of the T/A set following should be the temperature of respective pipe
lines.
• Main steam line - 1500C
• H.P. transfer pipe line - 1500C
• Cold Re-heat line - 1000C
• I.P. transfer pipe line - 1000C
• H.P. casing temperature > 1500C
a. Boiler drum pressure is kept at about 25 kg/cm2 and above parameters are
achieved.
b. H.P. L.P. bypass system is now withdrawn and T.A. set is rolled and synchronized.
c. About 10 – 15 MW load is picked up and preparation of coal firing is started.
d. Start both the P.A. fans A & B and keep lower elevation coal mill on heating.
e. Charge ESP, close economizer re-circulation valve.
f. Load the T. G set by taking 30-35 MW load and for this increase the firing rate. To
increase the firing rate start coal mill of lower elevation.
g. Keep watch on turbine as well as boiler parameters, while cut-in of coal mill, check
furnace draft and keep it under permissible value. Rate of increase of drum
temperature should not be more than 1000C min in one hour.
h. Before starting of second mill, super heat spray line can be charged. In this way take
one by one mill and increase the load.
i. Oil support can be withdrawn at the boiler load more than 60%. At about 40% of
boiler load start second BFP.
j. CBD is to be kept open according to the advice of chemist and boiler blow down may
be taken in service at about 20 kg/cm2 of drum pressure and that too as per the
advice of chemist.
k. Continue firing and increase the firing rate to achieve the following parameters:
 Drum pressure / MS Pressure 145 kg/cm2 / 138kg/cm2
 Hot R/H pressure / Temp - 24 kg/cm2 / 5400C
 F.W. temp at economizer inlet - 2450C
 M.S. flow - 650 T/hr.
1. PREPARATION FOR START UP OF TURBINE

GENERAL INSTRUCTIONS FOR STARTING OF TURBINE

The turbine is considered to be cold if the temperature of lower part of H.P.T. casing is 1500C.
From the moment, auxiliary equipment is put into operation; regularly note the readings on all
the important measuring instruments in the turbovisory.

Eccentricity: Before supplying steam to turbine, when the rotor is on barring gear, check shaft
eccentricity by means of the separate dial indicator provided with long arm. Increase in rotor
speed is prohibited if eccentricity is more than 0.07 mm. If the eccentricity exceeds more than
0.20 mm, the turbine should be shut down immediately and put on barring.

Vibrations: If during rolling bearing vibrations approach 40 microns, stop the turbine and the
rotor should be put on barring gear. Restarting is permitted only after finding out and removing
the cause of vibration.

Critical speed: Critical speeds of turbine shaft system are 1585, 1881,2017,2489,4500 RPM.
While increasing the rotor speed, the critical speeds should be passed as fast as possible to
avoid appearance of rotor vibration. In case there is a sudden increase in vibration while
increasing the speed, trip the turbine through ESV and break vacuum to decrease the speed
quickly.

Metal Temperatures: While heating the casing of ESV, HPT & IPT and also while increasing
speed and loading turbine, metal temperature should be raised gradually avoiding sudden
sharp rises.
Cylinder Expansion: The thermal expansion of the casing should be symmetrical. While
increasing the speed and loading of turbine, it is recommended to check clearances between
pins mounted on the bearings and casing supports.

Differential Expansion: It is prohibited to raise the speed of the turbine rotor if relative
expansion on contraction of the rotor reaches maximum permissible values given below;

• For Rotor of HPT + 4.0 mm or -1.2 mm.

• For Rotor of IPT + 3.0 mm or -2.5 mm.
• For Rotor of LPT + 4.5 mm or -2.5 mm.

(‘+ ve’ sign indicates that rotor is longer than cylinder and vice versa for ‘- ve’ sign.)

Oil Temperature: Lub oil temperature should not be less than be 40°C and should be within
40+/-5 Deg. C. Temp. of oil at the exit of bearing should not exceed 65°C.

Checks: During heating, speeding and loading of turbine, carefully watch following readings-

1. Shaft eccentricity.

2. Vibrations of bearings.

3. Axial shift of rotors.

4. Differential expansion of all the three rotors.

5. Metal temperature of upper and lower halves of HPT.

6. Oil temperature of the inlet & outlet of bearings.

7. Babbitt temperature of thrust bearing.

8. Pressure and temperature of steam of control points.

9. Vacuum.

2. OPERATION OF TURBINE AND AUXILIARIES:

Following is the brief description of the major steps / actions to be taken for starting, loading
and shutting down the 210 MW LMW steam turbine. Before the actual rolling of the turbine,
the following auxiliary equipments and systems are to be established.

a) Ensure C.W.System is running normal :

1) Ensure that raw water pumps are in service.

2) Maintain the basin level at cooling tower pumps and as well as CW pump sump level. Check
that the CT fans are running normal.

3) Ensure whether all the permits from maintenance division are cleared.

4) Keep the 6.6 KV electrical breaker of CW pump ready after carrying out protection and
interlock tests, if on long shut down. Then start the CW pump by opening CW discharge valve
20-30 %. After normalising the pump, the discharge valve should be opened fully from unit
control board.

5) Observe the ampere of the pump motor

6) Then give the prestart checks to Cooling Water (CW) Booster pump.

7) After getting the clearance of prestart checks, at least one hydrogen cooler suction and
discharge valve to be kept open, otherwise pump can be run on recirculation. Now start the
CW booster pump. Ensure from the operator that the post start checks are complete and
healthy.

8) After 5 min. run of the booster pump, the pump is to be stopped and to be started again
when turbine speed comes to 1100 rpm.

9) CW system is running normal.

b) Ensure Condensate system is running normal:

1) Start the DM make up pumps after checking DM tank level and lineup of connected lines.

2) Open both the isolating valves for hot well make up.

3) Maintain hot well level more than 3/4th of the gauge glass. Check the hot well level high/low
level alarm is working alright.

4) After normalizing the electrical breaker and clearance from operator, start the condensate
extraction pump.

5) Chemist to check the quality of condensate to ensure that there is no condenser tube
leakage.

6) Keep other two available pumps as stand-by, putting interlock switch to ‘ON’ position.

7) Take water to deaerator after charging LP heaters from water side.

8) Condensate system is running healthy.

c) Ensure feed system is running normal:

1) Maintain the deaerator level normal by running Condensate Extraction Pump. Maintain the
pressure and temp. in deaerator at 2 kg/cm2 and 90°c by auxiliary steam.

2) Ensure that all permits are cleared from maint. division for BFP and HP heaters.

3) After line up of the pump, ensure that protections and interlocks are healthy.

4) Inform the operator to restore power to the pump. line up HP heaters after checking the
interlocks.

5) After getting clearance from BFP operator, start the boiler feed pump.

6) If there is delay in opening recirculation valve by more than 2 sec. then open the valve
remotely from UCB, otherwise trip the pump. Watch and note down ampere of pump motor.

7) After about 15 min. when the bearing temp. gets stabilised open the discharge valve.

8) Inform turbine operator to charge the HP heaters on water side.

9) Check the other two BFP for their availability.

10) Keep the other BFP pumps available on interlock by putting the interlock switch on ‘P’

11) Feed water system is running healthy.

d) Ensure generator seal oil & hydrogen cooling systems are normal :

1) Ensure the main oil tank (MOT) level is normal and quality of oil is OK.

2) Run the Centrifugal and MOT vapour fans at least 6 hrs. before taking seal oil system in
service.

3) Start the AC seal oil pump.

4) Check availability of DC seal oil system. Protection and interlocks for the pumps should be
tested.

5) Hydrogen pressure in generator casing should be maintained at 3.5 kg/cm2. Sufficient nos. of
H2 cylinders should be available.

6) Seal oil and H2 cooling system running normal.

e) Ensure turbine lub oil system is running normal :

1) A.C. standby lub. Oil pump should be running. Maintain tub oil pressure 1.0 to 1.1 kg/cm2 at
bearing header and also check the availability DC lub oil pump.

2) Lub oil pump interlocks should be ‘ON’.

3) Maintain the oil temp. around 40°c. If it is’ more, charge the oil cooler from water side also.

4) Check protection and interlocks of lub oil system.

f) Ensure turbine rotor is on barring gear and normal:

1) Check the protection of barring gear. Barring gear should not start when lub oil pressure falls
to 0.3 kg/cm2.

2) Ensure that turbine rotor is at stand still position and lub oil system is running.

3) Engage the barring gear lever and start the barring gear motor. Note down the ampere of the
motor.

4) Check barring gear protection and again restart barring gear. Barring gear should trip at 0.3
kg/cm2 lub. oil pressure.

5) Keep a constant watch on lub oil pressure (1.1 kg/cm2) and temp. (40Oc).

6) Barring gear is normal and healthy.

g) Ensure auxiliary steam line is charged:

1) Inform boiler operator to charge auxiliary steam line (16 ATA header) from running unit or
from MS line of its own unit.

2) Keep the drain valve near the gland steam cooler open and charge the steam line for ejector,
gland steam cooler and steam seals by opening the valve. Before charging, check that system
inlet valves are closed.

3) After the line is heated up (for 15 to 20 min.) throttle the drain valve near gland steam cooler
to avoid wastage of steam.

h) Vacuum pulling:

1) Ensure CW pumps are in service

2) Ensure Condensate system in service and main ejectors both and LP heaters (all) are charged
from water side. All valves subjected to vacuum should be sealed by condensate water.
3) Ensure that turbine is on barring gear.

4) Ensure that aux. steam is charged from 16 ATA header to turbine seal and ejector header.

5) Close the vacuum breaker valves near main ejector and fill the funnel with DM water for
sealing. And open valves at condenser outlets.

6) Prior to start the starting ejector open the drain valves (after steam valves) and the isolating
valves. Then open inlet valves for putting starting ejector in service and close the drain
valves. Open air valves. See the condenser Vacuum rises to 100 to 150 mm of Hg.

7) Start gland steam cooler ejector. Open inlet valves and adjust pressure at 3 kg/cm2 and see
that vacuum at GSC rises to 40 to 60 mm of Hg column.

8) Admit steam to seals. Steaming from faces of end sealing is not permitted.

9) Open the drain valves to the condenser from the first stage of the ejector. Ensure that drain
valve from stage III to UDT is open.

10) Open the steam to main ejector through motorised valves when vacuum in condenser is
400 mm. See the steam pressure to main ejector is 6 kg/cm2 and see that vacuum is
steadily rising in the condenser.

11) Stop the starting ejector by vent valve first and steam valve afterwards.

12) At about 600 mm of Hg check the vacuum protection.

3. COLD START UP OF TURBINE

Preparation for Turbine Rolling

1) Check that all present requirements are over.

2. Operation of HP/LP bypass station :

a) Before HP/LP bypass stations are brought into operation, check -

I. ESV, IV are closed.

II. Oil system of bypass station is put into operation by switching on its motor.

III. Vacuum in the condenser is deeper than 540 mm of Hg. (about 600)

IV. Condensate flow to steam throw off device in the condenser is established by opening
motor operated valves MC-39 and MC 57.
b) Ensure that the valves of bypass system are fully closed by reading the respective position
indicators.

c) Set the temperature set point of HP bypass station at 200 °C with the help of push button.

d) Put the pressure controllers and slave positioners of each HP bypass valves on ‘Manual’
mode with the help of push button.

e) Put LP bypass valves on ‘Auto’ mode, set the temperature set point of LP bypass station at
2000C. Switch over the temperature control loop of LP bypass valve on ‘Auto’ mode with the
help of push button.

f) Put the control of LP bypass valve on ‘Auto’ mode with pressure loop in circuit with the help
of selector switch by making the contact in ‘R’ position. Set the pressure set point at a 6.0 ata
with the help of push button. Check that HPT evacuating valves and bypass valves across cold
reheat NRV’s are tightly closed.

2. After internal superheater flow has been established through start up vent, open drain valves
before and after bypass. Open drain valves of MS, CR & HR lines and open after LP bypass
drain valves.

3. Open fully the MS valves for HP bypass and then open the outlet MS valves. Check that
temperature control loop is functioning normal. The steam flow thus established shall assist
in the heating of main steam, cold & hot reheat lines and also increasing the parameters of
the steam. Watch the rise of metal temp. of MS,CR & HR Lines.

4. After 50°C superheat is available at super heater outlet, open bypass valves of MSV for
heating pipelines upto turbine.

5. Open the ESV to CV (HPT transfer pipe line) drain valves. And open ESV by about 10-20 mm
as per scale and heat the steam admission pipe up to control valves to a temperature of
1500C. Rise in metal temp. should not be more than 4°C per min. While opening the ESV care
should be taken so that the CV’s of HP turbine should remain tightly closed.

6. Open bypass valves across the NRV’s in the cold reheat lines and heat H.P. turbine upto
150°C. Rise in metal temp. should not be more than 4°C per min.

7. Check the steam pressure in hot reheat line, which should be less than 1 kg/cm2 (gauge)
before starting the heating of steam admission pipe up to control valves of IPT. If the
pressure in this line is more than 1 kg/cm2 (gauge) adjusts the set value at 1 kg/cm2 with the
help of push button. If it still exceeds close a little the HP bypass valves.
8. Open IV to CV (IPT transfer pipe line) drain valves. And open IV’s by 10-15 mm as per the
scale and heat the steam admission pipelines up to control valves to a temperature of 100°C.
Care should be taken that CV’s of IPT remain closed completely during the operation.

9. Close bypass valves of MSV and cold reheat NRV’s when steam parameters before MSV are
20 -25 kg/cm2 and 280 - 300 DC and steam admission pipe of HPT and IPT are heated upto
1500C and 100 DC respectively. Rise in metal temp. should not be more than 40C per min.

10. Close ESV and IV.

11. Bring the control of LP bypass valve on ‘Manual’ mode’.

12. Manually close the HP bypass valve with the help of push button. When the pressure in the
reheat line comes to condenser pressure, manually close the LP bypass valve with the help
of push button.

13. After having accomplished the heating, check and note down the following readings in the
log-sheet before rolling the set.

a) Metal temp. Of pipes before MSV and also before ESV.

b) Metal temp. Of steam admission pipes.

c) Metal temp. of hot reheat lines.

d) Metal temp. Of IV’s.

e) Metal temp. Of HPT & IPT top/bottom.

f) Steam parameters before MSV.

g) Differential expansions of HP,IP and LP rotors.

h) Axial shift, total expansion of HPT/IPT and Condo Vacuum.

i) Eccentricity of turbine rotor on barring gear.

14. Open the drain valves of HPT, IPT, HP and LP extraction valves.

15. Open ESV, IV, and CV’s of HPT & IPT completely with help of control gear (Full Arc Admission
Method).

Turbine Rolling:
16. Slowly open the bypass valves of MSV’s, thereby allowing the steam to roll the turbine. As
soon as speed rises above 3.4 rpm, check that barring gear gets disengaged and its motor
gets switched off automatically. Increase in rotor speed is prohibited if the turbine rotor
eccentricity is more than 0.07 mm. During the process of raising the speed bearing vibration
should not exceed 40 microns.

17. Raise the speed to 500 rpm. For good listening of the turbine for rubbing at 500 rpm, it is
recommended to stop the steam supply to the turbine by closing the bypass valves MSV
and if any abnormality is found, stop further rolling of the turbine.

18. Being certain that turbine is in healthy condition again raise the speed to 500 rpm by
opening bypass valve of MSV, and soak the set for 5-10 min. at this speed. It is prohibited to
raise the speed of turbine if the diff. expansion of the turbine rotor reached the max.
Permissible values.

19. Smoothly raise he speed to 1200 rpm and soak the set for about 20 min. Note that the
control valves of HPT tend to close with rise in speed .To keep them completely open, the
control gear should be turned in the direction of ‘increase’.

20. Raise the speed smoothly to 3000 rpm from 1200 rpm in 5 min. without any pause. The
critical speeds (1585, 1881, 2017 & 2489) of the machine should be passed as fast as
possible to avoid the appearances of rotor vibration.

21. Hold the turbine at 3000 rpm for about 20-25 min with a view to carryout inspection,
listening and soaking of the turbine. Perform the checking of protection and governing
system and tightness test of ESV and CV’s of HPT.

22. While raising the speed, observe the temp. of oil entering the bearings. Maintain temp at
about 40+/-5 °c. Stop the SOP and keep it ready.

23. After attaining the rated speed and before synchronizing rated parameters of the steam
should be as follows:

• Main steam pressure : 22 - 25 Kg/cm2

• Main steam temp. : 290-310 Deg. C
• Steam temp. before IPT : 240 - 260 Deg. C

24. At the speeds 500, 1200, 3000 rpm record the following readings.

1. Shaft eccentricity.

2. Vibration of bearings.
 3. Axial shift of rotors.

4. Differential expansion of all the three rotors.

5. Metal temperature of upper and lower halves of HPT.

6. Oil temperature of the inlet & outlet of bearings.

7. Babbit temperature of thrust bearing.

8. Pressure and temperature of steam of control points.

9. Vacuum.

25. Speeding, loading and increasing of parameters should be carried out in conformity with the
enclosed drawing. Curves for cold start up of turbine 210 MW units.

26. Now synchronize the machine with the grid.

4. LOADING THE TURBINE

1. After synchronising the machine with the grid, take a load of 10 to 15 MW. Hold the machine
at this load for 30 min. to carry out soaking and listen for rubbing. After soaking close all the
drain valves on steam lines, steam admission pipes, HP & IP drain collectors.

2. The steam parameters by this time are expected to be as bellow:

• Pressure of steam before ESV : 30 Kg/cm2

• Temp. of main steam : 3500C
• Pressure of steam before IV : 3200C
• HPT overall expansion : 10 mm

3. During the heating of turbine under load, constantly monitor the relative expansion of the
rotor and in no case it should be permitted to exceed the permissible limits. Ensure that the
metal temp. diff. between outer & inner surfaces of the wall of HPT and IPT casing at
regulating stage does not exceed 350C.

4. Charge the LP heaters from water and steam side.

5. Start the flange & stud heating, if the diff. expansion comes to + 2.5 mm.

6. After ensuing the satisfactory and healthy operation of turbine at the load of 10- / 5 MW,
increase the load to 30 MW in a period of 70 min. Hold the set at this load for 20 min. for
 soaking of the turbine. Steam parameters should be continuously raised to attain following
values at the end of this soaking period.

• Pressure of steam before ESV : 65 Kg/cm2

• Temp. of main steam : 4300C
• Pressure of steam before IV : 4200C
• HPT overall expansion : 20mm

7. At the load of 30 MW close all the drain valves in LP heater extraction. Note the thermal
expansion of the turbine and all other readings. Charge deaerator by opening 2 nd extraction
steam valves.

8. Put the drip pump in service.

9. Stop flange and stud heating system. The diff. of temp. across the width of the flange should
be within 20-30 Deg. C.

10. Increase the load to 60-70 MW in a period of 50 min. and put HP heaters in service. Charge
HP heaters from water and steam side. Close HP extraction drain valves.

11. After soaking the turbine for 30 min. at 70 MW, the parameters of the steam should be as
follows:

• Pressure of steam before ESV : 105 Kg/cm2

• Temp. of main steam before ESV : 4900C
• Pressure of steam before IV :4800C
• HPT overall expn. :28 mm

12. As the pressure in deaerator stabilises at 7.0 Kg/cm2 abs., change over the steam supply for
ejectors and glands from auxiliary source to deaerator (2nd extraction).

13. At about 80 MW start second condensate extraction pump and boiler feed pump and keep
third as standby.

14. At about 150 MW, check that the supply of steam to deaerator gets switched over from 2nd
to 3rd extraction. When pressure in HP heater 5 reaches the preset value, check that the
drip automatically cascades from HP heater 5 to deaerator. When the condensate flow
increases to 300 T/H, partly open the bypass valves on main ejectors, gland system cooler
and LPH-1.
15. Smoothly and gradually increase the load to 210 MW in a period of 70 min. and
simultaneously raise the steam parameters to the rated value. On reaching the rated load,
steam parameters should be as follow:

• Pressure of steam before ESV : 130 Kg/cm2

• Temp. of main steam before ESV : 5350C
• Pressure of steam before IV : 5350c
• HPT overall expn. : 35mm

16. Set point of HP bypass valves pressure control loop at 140 ata and temp. set point at 3800C.
Change manual mode of pressure control loop of HP bypass valves to ‘Auto’ with the help of
push button. Set the LP bypass valve pressure set point to 6.0 Kg/cm2 and temp. set point to
2000C . Changeover LP bypass operation from ‘manual’ mode to ‘Auto’ mode with pressure
control loop in circuit.
5. WARM START UP OF TURBINE

This type of start is chosen when metal temperature of H.P.T. casing in the zone of regulating
stage is between 150 to 350°C.

1. Before warm / hot restart, the auxiliary equipment should be started in the same manner
and order as in the case of “cold start”.

2. Before warm / hot restart the starting oil pump should have been working and supplying oil
to bearings, the shaft is rolling on barring gear and one of the condensate extraction pumps
is operative. Check oil pressure in lubrication and governing system and see draining of oil
from bearings.

3. Check that all the control and measuring instruments are switched ON and they are working
satisfactorily.

4. Supply steam to end sealing and check that pressure in the header should be 1.15 to 1.20
kg/cm2.

5. Put starting ejector and main ejectors into operation to create vacuum in condensers.

6. Before starting heating of steam lines, vacuum in condenser should be 600 mm. MSV, ESV,
CV’s of HPT & IPT should be tightly closed.

7. Heating of live steam lines, body of ESV, reheat pipe lines, body of IV may be done in case the
temperature of these elements is 80 - 100°C less than the temperature of the lower half of
HPT casing in the zone of regulating stage and in the zone of steam admission, in case of
I.P.T. respectively by opening the drain of relevant portion.

8. Main steam pipes, body of ESV and steam admission pipes should be heated upto the
temperature existing in the zone of regulating stage of HPT. Heating of reheat lines is
accomplished by allowing fresh steam through H.P. bypass station. The temperature of
steam entering the cold reheat line should be about 50°C higher than the metal temperature
of cold reheat line but not more than 380°C.

9. By using the “temperature-matching chart” as shown below determine the desired steam
temperature and pressure for rolling the turbine. However, the steam temperature should,
be more by at least 25°C than the hottest metal temperature of ESV and steam admission
pipes of H.P.T.
10. Select the operational mode of H.P. bypass valve on ‘Manual’ and of L.P. bypass valve on
‘Auto’. The LP. bypass valve be selected for pressure mode of operation. Set the set point of
LP. bypass station of 6.0 ata.

11. Select the temperature control loop of H.P. bypass station on ‘Auto’ and set the
temperature as per the requirement on the down steam side of HP bypass station.
Temp.control loop of LP. bypass station temperature should be on ‘Auto’ and temp. be set
at 200°C.

12. Ensure that evacuating valves and valves across NRV’S in cold reheat lines are tightly closed.

13. Open H.P. bypass valve and raise the steam parameters of boiler to desired value and
simultaneously heat the main steam, cold reheat and hot reheat lines if required. During
this operation have a check that the flue gas temperature is within 540°C.
14. Open bypass valves of MSV and ESV by about 15-20 mm and heat steam admission pipes up
to control valves.

15. Check steam pressure in hot reheat lines which should be less than 1 Kg/cm2 (gauge). If
required manually close a little the HP bypass valve before heating of steam admission pipe
of LP.T. If the pressure is more, adjust with the help of LP bypass valves or closing a little
H.P. bypass valves.

16. Open LV. servomotor by about 10-15 mm and heat steam admission pipes up to control
valves of LP.T. control valve of IPT should remain tightly closed during this process.

During the process of heating the seam pipe lines, check the draining system is all right.

17. Having accomplished the heating, check and note down the various metal temp. viz. of
steam pipes, ESV,IV,IP casing and HPC at the regulating stage. Ensure that the desired
matching steam temp. is available at ESV.

18. Bring control of LP. bypass valves on ‘Manual’ mode’.

19. Manually close H.P. bypass valves and open LP. bypass valves when pressure in reheat line
comes to condenser vacuum, close LP. bypass valves.

20. Check that eccentricity and diffn expansion are within limit.

21. With the help of speeder gear, fully open ESV, IV and CV’s of H.P. & LP. turbines.

22. Slowly open the bypass valves of MSV and roll the turbine. Raise the speed to 500 RPM
within 5 minutes by further opening bypass valves of MSV. Hold the turbine speed for 5
minutes for checking differential expansion, bearing vibration etc.

23. Raise the speed from 500 to 1200 rpm. within 5 min. and hold the turbine 3 min.
forchecking differential expansion, bearing vibration etc.

24. Raise the speed from 1200 to 3000 RPM within 3 min. without any pause. Hold the turbine
at 3000 RPM for 5 minutes for inspection, listening and soaking of turbine.

25. Ensure that M.O.P. takes over at 2800 R.P.M. and then stop S.O.P. and keep it standby.

26. Synchronize the set with the grid and load the set to 20-30 MW. All the drains must be
closed after some load has been taken on turbine. Raising of steam parameters and loading
is carried out as per curve and guidelines of loading for the warm start.

27. After loading the unit, HP/LP bypass stations be set as follows:
i) HP bypass station -

• Pressure control loop -’Auto’ mode with set point at 140 ata
• Temp. control loop 380 °C ‘Auto’ mode.

ii) LP bypass station -

• Operational mode - Pressure control

• Pressure control loop - ‘Auto’ with set point of 6 kg/cm2 (abs)
• Temp. control loop -200 °C ‘Auto’ mode.

28. The 2nd condensate extraction pump, boiler feed pump & HP heaters etc. should be cut in
depending upon the load conditions as described in “Loading the turbine” (Page 7/16).

6. HOT START UP OF TURBINE

This type is selected when metal temperature of H.P.T. casing at regulating stage is more than
350°C. With the help of “temperature matching chart” as shown in the drawing no.2 desired
steam temperature and pressure are determined. Steam temperature before E.S.V. at the time
of rolling must be more by at least 25°C than the hottest element mentioned below.

• Body of ESV.
• Steam admission pipes of HPT& IPT.
• HPT in the zone of regulating stage.
• Steam admission chamber of LP.T.
• Body of IV.

1. Parameters are raised with the help of H.P/L.P. bypass station. After attaining desired steam
temperature and pressure, suitable for rolling, hold firing rate of boiler.

2. Ensure that all the prestart conditions such as oil system is in operation, vacuum in
condenser is more than 540 mm of Hg, flow of condensate in steam throw device is OK.

3. Set the HP bypass valves on ‘AUTO’ mode and set the pressure setting at 5-8 % higher than
the actual pressure available in the main steam lines. Set the LP bypass station also on
‘AUTO’ with pressure control mode with set point at 6.0 Kg/cm2.

4. Put the temperature control loop of HP bypass valves on ‘AUTO’ mode and set the
temperature set point at 50°C higher than the cold reheat pipe metal temperature. The set
point of temperature would have also to be slided upwards to meet the boiler temperature
and ensuring the allowed heating rate of cold reheat pipe lines and reheater.
 The temp. set point should not exceed 380°c. The temperature set point of LP bypass
station to be set at 200°C with ‘AUTO’ mode.

5. Ensure that the bypass valves across NRV’s in cold reheat lines are closed. Open the
evacuating line valves CR-5 & CR-6 to release the entrapped.

6. Supply fresh steam to front sealing of HPT & IPT in case the contraction of HPT rotor has
reached 0.8 mm and that of LP. rotor 1.5 mm.

7. Before supplying fresh steam to front seals of HPT & IPT, the concerned pipelines should be
adequately heated up and blown out by opening valves. For supplying steam to HPT front
sealing, open valve AS-42 / 43 and check that valve AS-47 gets closed under interlock action.
For supplying steam to LP.T. front sealing, open valve AS-42 and AS-44 and check that AS-48
gets closed under interlock action. Check readiness of entire equipment of the turbo set for
hot start.

8. Heat transfer pipes between IV & CV of IPT by opening IV by 5-10 mm. Valves in the drains of
these pipes should be kept full open prior to opening of IV. After heating, close IV fully.

9. Open fully both M.S.V.’s and valves in drain lines of transfer pipes.

10. Completely open ESV & IV with the help of control gear. Turbine will start rolling through
LP.T.

11. As soon as speed rises above 3 .4 rpm ensure that barring gear lever has disengaged and its
motor cuts out automatically. Ensure that the valves CR-5 & CR-6 in the evacuating lines of
HPT get closed.

12. Start opening of CV’s of IPT. Raise speed to 3000 RPM without pause.

13. Ensure that MOP takes over at 2800 RPM and stop SOP and keep it standby.

14. Synchronize the set and pick up 20 MW load. Close all drains.

15. Load the turbine at the rate of 5 MW per minute until the HP bypass gets closed under the
pressure impulses and the entire steam is swallowed by the turbine. Hold the set at this
load.

16. As soon as the steam starts flowing through H.P. turbine, ensure that H.P. bypass valves
start closing.
17. Further loading of the set is done as per the curves for hot start of turbine by increasing
boiler-firing rate. The time for loading the set during hot restarts depends on the thermal
condition of H.P.T. & I.P.T.

18. While loading the turbine, ensure that metal temp. diff. between inner and outer surfaces
of the wall of HPT casing not exceed 350C. In case this requirement is not fulfilled, stop
further loading till it is met.

19. Stop fresh steam supply to front sealing of HPT & IPT when differential expansion of HPT &
IPT rotors has reduced and has got stabilized as per the differential expansion indicator.

For this close valves AS- 42, 43 & 44 and check that AS 47 & 48 get opened under interlock
action.

20. At 60-70 MW load bring H.P. heaters in service.

21 Check that drip pump cuts in under interlock action of 70 MW.

22. At 90-100 MW check that supply of steam to deaerator gets switched over from auxiliary
source to second extraction under interlock action.

23. As the pressure in deaerator stabilises at 7.0 kg/cm2 abs, change over the steam supply
from auxiliary source to deaerator for ejectors and glands.

24. At 100 MW start second condensate extraction pump.

25. Start second boiler feed pump at 100-110 MW.

26. At 150 MW check that supply of steam to deaerator gets switched over from Extraction II to
Extraction III.

27. When pressure in HP heater no. 5 has reached preset value, check that the condensate of
heating steam automatically cascades from heater no.6 into heater no.5 and from heater
no.5 to deaerator.

28. Set the set point of HP bypass valve pressure control loop at 140 ata and temperature set
point at 3800C. Changeover the ‘Manual’ mode of pressure control to ‘Auto’.

29. Set the LP bypass operation to ‘Auto’ mode with pressure control loop in circuit. Set the
pressure set point to 6 kg/cm2 and temp. set point at 2000C.
7.PLANNED SHUT DOWN OF TURBINE

1. Inform the boiler house that the turbine would be soon shut down.

2. Check the SOP and also availability to AC & DC lub. Oil pumps.

3. Reduce the load at a rate of 3 MW per min. at rated parameters by operating control gear
motor.

4. Watch the axial shift and diff. expansion of the rotor and cylinder.

5. After reducing load to 160 MW switch off the HP heaters on steam side and drain heating
steam condensate by opening the drain valves.
6. At 90-100 MW switch off one of the CEP and at 70 MW load check the drip pump gets
switched off under automatic controller action and also ensure that aux. power supply is
changed from unit to reserve.

7. Maintain deaerator & condenser hot-well level normal.

8. At load 10 -12 MW, open bypass valve of MS before ESV and close valve on main steam line.

9. Reduce the load to about 5 MW slowly. Trip the unit through any protection.

10. Check the ESV and control valves get closed. Isolate lub oil cooler from cooling water side
one by one to maintain lub oil temp. at 45°C.

11. Ensure that generator is isolated through low forward power relay and the time for
stopping the steam supply to turbine and isolation of generator should not be more than 4
min.

12. After closure of the control valves immediately close the main steam outlet and check that
bypass of main steam valves are also closed.

13. Stop the other Boiler Feed Pump depending upon the level of the boiler drum.

14. At 2800 rpm. start AC lub oil pump and AC seal oil pump, check the lub oil pressure and AC
seal oil pressure is normal.

15. When rotor comes to stop, start the barring gear and roll the rotor continuously on barring
gear till temp. of lower part of HP casing at regulating temp. stage drops to 1700C, engage
the barring gear lever at a stand still condition of rotor and then start the barring gear
motor and make sure that rotor RPM is 3.4 when put on barring gear.

16. Break the vacuum by opening vacuum braking valve and cut off the steam supply to main
ejector, gland steam cooler and steam to seals and closing the respective valves.

17. When max. Turbine metal temp. comes down below 200°C ,open cylinder, transfer line and
main steam line valves.

18. Barring gear and lub oil pumps can be stopped if necessary.

19. Condensate and CW pumps can be stopped when LP exhaust temperature comes below
40°C.
GENERATOR SYNCHRONISATION
Synchronisation of a generator with the bus bar of the grid involves systematic operation of the
system. In this process mainly three parameters of generator and busbar are matched by
controlling the speed of generator, by excitation system and other switchgear. Magnitude of
voltage, Frequency and phase sequence of the generator and bus bar is matched and then only
the circuit breaker of the generator is closed. the steps involved in this process are as per the
following.

A) Switch Yard :

1) Select the bus to which the generator is to be connected.

2) Check the circuit breaker. No-load, “Make-break” trial may be taken.

3) Close related insulators’. Check contacts for proper closing.

4) Check protection relay settings and fuses if any. Check “Trip ckt. Healthy” indication.

5) Check C. B. control fuse.

B) Generator Transformer & Unit Aux. Transformer :

1) Check general cleanliness and bushings

2) Ensure that cooling system is available.

(Circulating oil pumps – fans – supply must be available).

3) Check transformer tap position.

4) Check oil level and silica-gel in breathers

5) Check that all protections are available.

C) Generator :

1) Check protections.

2) Hydrogen and stator water cooling system should be available. Check tank levels,
prime the pumps, prime the coolers by properly venting.

3) Check Hydrogen and seal oil pressure.

4) Check supply to all pumps.

 5) Check field breaker and AVR.

D) Turbine :

1) Near 3000 R.P.M. Governor should take over control.

2) Stop valves should be fully open.

3) Speed control should be by speeder gear.

4) Over speed trip test may be taken.

E) Boiler :

1) Boiler may be steaming with about 4 oil burners only. Additional oil burners should
be ready. Check and test igniters.

2) In case of Hot Rolling with HP/LP by-pass systems, one coal mill may be already in
service. In this case boiler is already on load as far as steam flow is concerned. After
synchronization, the steam flow will be gradually diverted through the turbine till
HP/LP by-pass valves are fully closed.

3) Check drums level. It must be normal or slightly below normal level. It must not be
high at the time of synchronization.

4) Ensure that all isolating valves, in feed line are fully open.

Synchronising : Matching of Voltage Magnitude Frequency & Phase Sequence.

1) Give the Field Flashing Supply.

2) Close field breaker and gradually build up excitation by Manual Potentiometer.

3) Generator Transformer terminal voltage should be slightly less than rated value.
Check the voltage set point and put in service.

4) Now match the turbine speed to grid frequency, by speeder gear.

5) Finally adjust Generator Transformer Terminal voltage to Grid voltage. (by adjusting
excitation Manual Potentiometer)

6) Switch on the synchroscope. The indicator should be rotating slowly clock-wise.

Anti-clockwise rotation means that the turbine (Generator) frequency is less than
the grid frequency.
 7) The speeder gear should be used to raise or lower the speed .

8) If difference in frequencies is very high, the synchroscope indicator may become

stationary at any position. Frequencies should be matched by observing the
frequency indicator.

9) When the indicator starts slow clock-wise rotation and reaches the 12’ O clock
position, the C. B. should be closed, and about 5% load should be picked up.

10) The speeder gear operation now controls the load. Changes in excitation will
control the RMVA.

11) Match the AVR Voltage difference to Zero and change over Excitation from Manual
to Auto.

12) Put cooling systems in service, i.e.

a) Stator water cooling system

b) Hydrogen cooling system

c) Step-up Transformer cooling system.

Note:- During rolling of the T. G. Set, the generator gas temperatures/ winding temp. should be
watched and if necessary, the Hydrogen cooling and stator water system may be switched on
even before synchronization.

13) In this way the generator is synchronized with the grid system and further activities
of revising of load and sharing or absorbing of RMVA are carried out.

14) The sharing of RMVA to be done within the capability curve of the Generator at all
loads.
CAPABLITY CURVE OF 270 MW TURBOGENERATOR
 CHAPTER B

FURNACE SAFEGUARD SUPERVISORY SYSTEM

 1. Meaning of Logical Statements
The logic sequences are represented in English as statements, which are to be executed
in certain order of precedence as described below.

The logical gates are represented in Upper case Letters, preceded and followed by “dots”.

e.g. .AND, .OR.

The logical function combining two statements in the same line to be executed first.

eg. Xxxxxxxxxx .AND. xxxxxxxxxxxxxxx

The logical function in the right most position is to be executed next and so on.

E.g. xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

.AND. Xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

The logical function at the left most position is executed last. eg.
Xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

.OR. Xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

Both logical operators .AND.,.OR. have equal precedence between them. For better
understanding the following example with mixed logical expressions is marked with the order
of execution.

eg. Xxxxxxxxxxxxx .OR.5 xxxxxxxxxxxxx

.AND.4

xxxxxxxxxxxxxxxxxxxxxxxxxx .OR.1 xxxxxxxxxxxxxxxxxxxx

.AND.2

Xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx .OR.3

Xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

NB: xxxxxxxxxxx represent logical statements.

2. INTRODUCTION:-

The F u r n a c e Safeguard Supervisory System (FSSS) is designed to ensure the execution of a

safe, orderly operating sequence i n the start up and shutdown of fuel firing equipment and
to prevent errors of omission and commission in following such a safe operating procedure.

The system provides protection, should there be a malfunction of fuel firing equipment
and associated air systems. The safety features of the system are designed for protection in
most common emergency situations.

In some phases of operation, the Furnace Safeguard Supervisory System provides permissive
interlocks, only to ensure safe start up sequence of equipment. Once the equipment is in
service, the operator must use normally acceptable safe operating practices.

It is essential that all parts of the Furnace Safeguard Supervisory System are in service at all
times if the system is to provide protection for which it is designed.

This instruction section of the system gives a complete description of the Furnace Safeguard
supervisory System furnished for 270 MW BHEL Corner fired boiler unit as it is related
to the various operating phases and operation of the fuel firing equipment and associated air
systems.

Basically the system is designed to perform the following functions:

• Prevent any fuel firing unless a satisfactory furnace purge sequence has first been
completed.

• Prevent start-up of individual fuel firing equipment un l e ss certain permissive interlocks

have first been satisfied.

• Monitor and control the proper component sequence (Manual or Automatic) during
start-up and shut-down of fuel firing equipment.

• Make continued operation of fuel firing equipment subject to certain safety interlocks
remaining satisfied.

• Providecomponent status feedback to the operator and in some cases, to the unit
control system.

• Provide flame supervision when fuel firing equipment is in service and affect a fuel trip
upon certain adverse operating conditions.

• Initiate a fuel trip when certain abnormal operating conditions exist.

Furnace safeguard supervisory system (FSSS) discussed here is designed for a natural
circulation, Heavy Oil (HO) fired boiler with coal as the primary fuel and Light Oil (LO) as the start-
up fuel and Heavy Oil as the fuel for warm up and stabilization. This system provides for the
remote / manual operation of three elevations of high energy arc (HEA) igniters, three
elevations of oil guns with provision for firing Light oil in elevation AB only, Heavy oil in
elevation AB, CD & EF and six pulverizers, serving six elevations of 24 coal nozzles from a
remote, console mounted control panel in addition to operation through CRT. (Refer Figure-1)

Figure – 1

From the console insert; Heavy oil trip valve, Light oil trip valve & HO Recirculation Valve can
be opened/closed, Purge cycle can be started, Scanner Fans & Seal Air Fans can be
started/stopped & Hot Air Gate can be opened / closed, Pulveriser & Feeder can be started /
stopped. Indicating lamps on the console insert shows the operating status of v a r i o u s field
equipments connected to FSSS.

The following operational functions are included in FSSS.

• Furnace purge supervision.

• Secondary air damper modulation, on/off control and supervision.

• Light oil on-off control and supervision.

• Heavy oil on-off control and supervision.

• Pulveriser and feeder on-off control and supervision.

• Flame scanner intelligence and checking.

• Overall boiler flame failure protection.

• Boiler trip protection.

The Furnace Safeguard Supervisory System has been designed for Energize to Open & Energize
to Close philosophy. This means any on/off device or equipment has to get an impulse/command
to change its present state and has to get again another impulse/command to regain to the
original state.

3. HEAVY OIL RECIRCULATION VALVE CONTROL (Refer Figure-2) :-

Before any main fuel can be fired the heavy oil must be brought to proper temperature. This is
accomplished by recirculating H.O. through the oil recirculation system by means of the
HOTV and HO Recirculation valves (HO Return Trip Valve).

FSSS permits the opening of HOTV for oil recirculation purpose following a boiler trip and prior to
starting a furnace purge cycle as follows:

i) Depressing the "HO Recirculation valve (HORV) open Push Button" will open the
Recirculation valve (long), provided all the H.O. nozzle valves are f u l l y closed.
ii) When t h e H.O.R.V. is fully open as i n d i c a t e d b y the "H.O.R.V. open" light
(red) being on, depress the "H.O.T.V. open Push Button". This will start the H.O.
recirculation.
iii) Before furnace purge cycle is started H.O.T.V. must be proven closed. To close this,
depress the associated close Push Button. When the trip valve is fully closed,” H.O.T.V.
Closed" (green) light comes on.
iv) To re-establish the oil recirculation after the furnace purge cycle has been completed,
open H.O.T.V. as described in the respective section under trip valve operation.
v) The H.O.R.V. remains open until the first nozzle valve opens at which time, the
recirculation valve closes automatically.

Figure – 2

4. FURNACE PURGE:-

Before any fuel firing can take place, (initially or after a boiler trip) a successful furnace purge
cycle must be completed.

To start a furnace purge cycle proceeds as follows:

a. Establish AC & DC power to FSSS and the related equipment.

b. Establish proper drum water level.

c. Place at least one ID and one FD fan in service.

d. Establish airflow between 30% and 40% MCR through the furnace.

“Purge Ready” and “Push to Purge” Light will be on after condition (a) to (d) are satisfied. When
both these lights are on it indicates that all the purge requirements are satisfied.
 (See Note 1 below).

Now, depress the purge start Push Button.

This will start the furnace purge if all the requirements are satisfied, as indicated by the Yellow
“Purge ready “light.

Note 1:- If the “ Purge ready” light does not come ON, after conditions (a) through (d) above
have been completed, check to see that:

• The light oil trip valve is proven closed.

• All the light oil nozzle valves are proven closed.
• The heavy oil trip valve is proven closed.
• All the heavy oil nozzle valves are fully closed.
• All PA Fans are off.
• All feeders are off.
• All hot air gates are fully closed.
• All the flame scanners show "No Flame" (Both fire ball and discriminating scanners).
• No boiler trip command is present (See boiler trip section for specifics).
• Air flow > 30% and < 40 % MCR
• All auxiliary dampers are modulating.
• Each of the above conditions is indicated by a lamp on Unit console.
The furnace purge cycle can be started after all the purge requirements are satisfied and the
“PURGE READY” and “PUSH TO PURGE” lights are on. The furnace purge cycle is started by
depressing the PUSH TO PURGE Push Button. This will start a five minutes purge timer and the
“PURGING” light will come on. See Note 2 below.

Note 2:- Loss of purge permissive at any time during the five minutes purging period will reset
the purge timer. When this happens, the purge requirements must be re-established
(PURGE READY) and another furnace purge cycle has to be started by depressing the “PUSH TO
PURGE” Push Button.

At the end of 5 minutes furnace purge cycle, provided the purge permissive remain satisfied, the
boiler trip is reset.

This is indicated by the “MFT TRIP” light going off , the “PURGING” and “PUSH TO PURGE”
lights going off. A “No MFT Trip” condition is now established and the “CAUSE OF TRIP”
memories are reset.

The operator may open the various trip valves as described in the following sections.

5. SELECTION OF LIGHT OIL/HEAVY OIL FIRING:-

Either Light Oil or Heavy Oil can be fired at elevation AB, when selected by the operator.

Depressing the “Select LIGHT OIL” Push Button will select light oil, provided all the HO
nozzle valves and LO nozzle valves are fully closed and both pairs have been stopped.

When the above conditions are satisfied, the “El. AB LIGHT OIL SELECTED” light comes on.

Depressing the “Select HEAVY OIL” Push Button will select Heavy oil, provided all the HO
nozzle valves and LO nozzle valves are fully closed and both pairs have been stopped.

When the above conditions are satisfied, the “El. AB HEAVY OIL SELECTED” light comes on.

6. LIGHT OIL TRIP VALVE CONTROL (Refer Fig. 3): -

Figure - 3
 Once the boiler trip circuit is reset and all the light oil nozzle valves are proven closed, pressing
the light oil trip valve “ Open" Push Button, will open light oil trip valve provided the
following conditions are satisfied.

• Light oil header pressure is adequate

• Elevation AB all the light oil nozzle valves remain closed.

When the Light oil trip valve is moved from the fully closed position, the (Green) light oil trip
valve "closed” light goes out. When the trip valve reaches the fully open position, the (Red)
light oil trip valve "open" light comes on.

Pressing the light oil trip valve "Close" Push Button will close the valve. The light oil trip valve also
closes automatically under following conditions:

Master fuel trip .OR. Any light oil nozzle valve not closed

.AND.

Light oil header pressure very low (From 2/3 logic)

.OR.

Atomising air pressure very l o w (From 2/3 logic).

.AND.

No light oil elevations in start or stop.

.AND.

Any Light oil nozzle valve not closed.

The LOTV is commanded to close on Loss of unit +24V DC.

7. LIGHT OIL ELEVATION START (Elevation AB – PAIR MODE) :-

Light oil can be fired at elevation AB only and in pair basis.

Corners 1 and 3 make one pair, while corners 2 and 4 make the other pair. The corners making
up a pair are diagonally opposite.
To place the light oil guns in service proceed as follows:

• Select light oil firing.

• Establish light oil elevation start p e r m i t b y the following conditions being satisfied.

a) No master fuel trip.

b) Light oil trip valve proven fully open.

c) Pulverizer / Feeder start permit is available.

8. PULVERIZER / FEEDER START PERMIT

Pulveriser / Feeder start permissive is as below;

Nozzle Tilt Horizontal . AND. Air flow is between 30% and 40% MCR

.OR. Any oil Elevation is in service .OR. Any feeder on .AND. NO MFT

Pressing the associated pair start (1-3 or 2-4) PB, provided the above conditions are satisfied,
will initiate a 70 seconds start time to place the associated pair of light oil guns in service.
Refer to Heavy oil elevation start for the sequence of introduction of oil gun in service, which
is similar.

Light oil elevation trip occurs under any of the following Conditions:

• Master fuel trip.

• Light oil trip valve not open.

9. HEAVY OIL TRIP VALVE CONTROL (Refer Figure-2) :-

Depressing “HOTV OPEN” PB, will open the HOTV provided either of the following conditions are
satisfied.

HO recirculation valve is fully open .AND. HO trip valve close command is not present. All heavy
oil nozzle valves are close. .AND. Heavy oil supply pressure is adequate .AND.

Heavy oil supply temperature is adequate .AND. No MFT condition is present.

When HOTV is moved from the fully closed position, the (Green) “HOTV CLOSED” light goes
out. When the trip valve reaches the fully open position, the (Red) “HOTV OPEN” light comes
on.
Pressing the “HOTV CLOSE” Push Button will close the HOTV provided the valve is not already
closed.

The HOTV also closes automatically under any one of the following circumstances provided the
valve is not closed.

Master-fuel trip .AND. HO Long recirculation valve not open .OR. If any of the following
conditions exist for more than 5 seconds.

Any heavy oil nozzle valve not closed .AND. Atomising steam pressure very low (2 / 3 logic)
.AND. No HO start of stop in any elevation .OR. Heavy oil Header pressure very low (2 / 3 logic)
.AND. HOTV Not closed .OR. Any heavy oil nozzle valve not closed .AND. Heavy oil header
temperature very low (2 / 3 logic) .AND. HOTV Not closed

The HOTV is commanded to close on Loss of unit +24V DC

10. HEAVY OIL ELEVATION START (Pair Mode)

(Elevation AB, CD & EF - PAIR MODE) (Refer Figure- 4):- Heavy oil can be fired at Elevations AB
and / or CD and / or EF either independently or in combination.

Pair mode is selected automatically when any one of the following conditions exist.
Both coal elevations A and B are not in service .AND. All feeders are off .AND. Pulveriser in
manual mode.

Both coal elevations A and B are not in service .AND. Elevation AB back up trip exists

Corners 1 and 3 make one pair, while the corners 2 & 4 make the other pair. Corners making up
a pair are diagonally opposite. To place the heavy oil guns in service at any elevation in
pair mode, proceed as follows:

• Select heavy oil firing.

• Establish heavy oil elevation start permit by the following conditions being satisfied.

a) No master fuel trip.

b) Heavy oil trip valve proven fully open.

c) Pulverizer / Feeder start permit available

Pressing the associated “PAIR START” push button, (for corners 1 and 3 or for corners 2 and 4)
when the above conditions are satisfied will initiate a 70 sec. start time to place the associated
pair of heavy oil guns in service as follows:

a) A start command is sent to oil corner 1 (when corners 1 and 3 have been started) or to oil
corner 2 (when 2 and 4 have been started).

b) Fifteen seconds later, a start command is sent to oil corner 3 (when corners 1 and 3 have
been started) or to oil corner 4 (when corners 2 and 4 have been started).

When an individual oil corner receives a start command, it is placed in service in the following
sequence.

When the oil gun is properly positioned in firing position, the oil gun engaged indicating lamp
(Red) will come on. The local oil gun maintenance switch shall be put in the “REMOTE”
position.

The steam nozzle valve will open up on receiving the open command provided scavenge nozzle
valve is closed .

When the atomising steam nozzle valve (air nozzle valve in the case of light oil) is proven open,
HEA Ignitor gets command for advancing. When HEA rod is advanced HO nozzle valve gets open
command provided the following conditions are satisfied.

• The corner is not in scavenge

 • Atomising nozzle valve (Air / Steam) is proven open

• None of the corner trip condition is present

• Light oil nozzle valve and Heavy oil nozzle valve not open or Discriminating scanner
shows no flame.

When the oil nozzle valve is in Not closed condition, HEA ignitor gets command for sparking. 15
seconds later, HEA advance and spark command are removed.

If the flame is established (indicated by the “DISCRIMINATING SCANNER FLAME” light on) within
the above 15 sec. then the oil gun is said to have been successfully placed in service and will
continue to operate.

When the 15 seconds counting period expires, corner-3 oil gun start command is established and
will be placed in service in the same manner as previously described for corner 1.

When the seventy second counting period expires (for corner 1 & 3), the 15 second timer for
corner 3 is reset and oil gun at corner 1 or 3 will be shut down if the associated oil nozzle valve
is not fully open.

Corner N o . 2 a n d N o . 4 are p l a c e d i n s e r v i c e by the associated “PAIR 2-4 START” Push

Button. The following events will occur:

The “PAIR 2-4 START” light is illuminated and the associated “PAIR 2-4 STOP” light goes off

The 70 second elevation pair (for corners 2 and 4) counting period is reset.

When the Push Button is released, the 70 seconds counting period is started. The “Start”
command for corner 2 is established and a 15 second counting period, to establish a “Start”
command for corner 4 is started.

After the “Start” command is established, the associated corner oil guns (LO/HO) are placed in
service in the same manner as previously described for corner 1.

When at least three of the four oil (LO/HO) nozzle valves are fully open, the warm-up oil
elevation (LO/HO) is in service. This is indicated by the “IGNITION PERMIT” light coming on
the Coal Console insert f o r the pulveriser associated with the warm-up oil elevation. The
“Ignition permit” is now satisfied and the associated mill can be placed in service after other
permissives are satisfied.

When the 70 second counting period (for corners 2 & 4) expires, the 15 seconds timer for
corner 4 is reset and the oil gun 2 or 4 will be shut down if the associated oil nozzle valve is not
fully open.

11. HEAVY OIL ELEVATION START (Corner Mode)

(Elevation AB, CD & EF – ELEVATION MODE):- The elevation mode of operation is selected
automatically when the following conditions exist:

Either adjacent feeder associated with the HO elevation is proven on (feeder on for more than
fifty seconds) or the associated oil elevation start auto is established.

When the elevation mode is selected, the HO elevation is in service as follows provided the “OIL
ELEVATION START PERMIT” remains established.

When pair 1-3 start or pair 2-4 start Push Button is depressed, an “Elevation Start” command is
established for corner 1 & 3.

After the “ elevation start” command is established, a 40 second counting period is started to
establish a n “elevation start” command for corners 2 and 4.

Corners 1 and 3 are now placed in service in the same manner as described in the “PAIR MODE
OPERATION” section.

After the 40 second counting period expires, corners 2 and 4 are placed in operation in the same
manner as described in the “PAIR MODE OPERATION” section.

When a t l e a s t three of the four warm-up (LO/HO) nozzle valves are fully open, the warm-up
(LO/HO) elevation is “proven in service”.

An “Elevation Unsuccessful Start” condition is established when both 70 second counting

periods expire and if less than three oil (LO/HO) nozzle valves are in service.

When an “Elevation Unsuccessful Start” signal is established, two seconds later, corner 1
and 3 receive “Stop” command and a 40 second counting period is started. 40 seconds later
corners 2 and 4 receive “Stop” commands.

An “Elevation Unsuccessful Start” condition initiates an alarm. All four corners are shut down
(see “oil elevation shutdown” section for specifics).

12. PULVERIZER IGNITION PERMIT:-

Prior to start any feeder, the pulveriser ignition energy must be adequate to support coal firing.
This is accomplished as follows:
PULVERIZER "A"

A minimum of 3 of the 4 elevation “AB “oil nozzle valves proven open. . OR. Boiler loading is
greater than 30% .AND. feeder “B” is in service at greater than 50% loading.

PULVERIZER "B"

A minimum of 3 of the 4 elevation "AB" oil nozzle valves proven open. .OR. Boiler loading is
greater than 30% .AND. feeder "A” .OR. "C" is in service at greater than 50% loading.

PULVERIZER "C"

A minimum of 3 of the 4 elevation "CD" heavy oil nozzle valves proven open. .OR. Boiler loading is
greater than 30% . AND. feeder “ B" .OR. "D" is in service at greater than 50% loading. .OR. A
minimum of 3 of the 4 elevation “ AB" heavy o i l nozzle valves proven open .AND. Feeder "B"
is in service at greater than 50% loading.

PULVERIZER "D"

A minimum of 3 of the 4 elevation "CD" oil nozzle valves proven open. .OR. Boiler loading is
greater than 30% .AND. feeder "C" .OR. "E" is in service at greater than 50% loading.

PULVERIZER "E"

A minimum of 3 of the 4 elevation "EF" oil nozzle valves proven open. .OR. Boiler loading is greater
than 30% .AND. feeder "D" .OR. "F" is in service at greater than 50% loading. .OR. A minimum
of 3 of the 4 elevation "CD" heavy oil nozzle valves proven open. .AND.
Feeder "D" is in service at greater than 50% loading.

PULVERIZER "F"

A minimum of 3 of the 4 elevation "EF" heavy oil nozzle valves are proven open .OR.
Boiler loading is >30% .AND. Feeder "E" is in service at greater than 50% loading.
13. PULVERIZER READY (Refer Figure-8):-

Figure 8a Coal Mill System

Prior to starting a pulverizer, a pulverizer start permit condition for the respective pulverizer
must be established by confirming the following conditions being satisfied:

Each condition is indicated by a yellow light on the console.

a. Pulverizer discharge valve open. b. Pulverizer outlet temp. not high.

c. Cold air gate open. d. Pulverizer/Feeder start permit.

e. Tramp iron hopper valve open. f. Bunker outlet gate open & feeder inlet gate open.

g. Primary air permit or pulverizer on. h. No auto pulverizer unsuccessful start.

i. Lub oil system permit j. All burner manual isolation valves open

When all the above conditions are satisfied for the respective pulverizer, its associated
pulverizer ready condition is satisfied.
14. PULVERIZER START :-

Pulverizer and the associated equipment

equipments can be started either automatically
automaticall or manually.

Auto/Manual mode of pulverizer start can be selected by means of selector pushbuttons

pushbutton provided
on coal Elevation n. Console insert.

14.1 PULVERIZER START (MANUAL MODE):-

By establishing Ignition energy available and pulverizer ready conditions forr the respective
pulverizer, it may be placed in servic
service as follows:

Ensure pulverizer ready conditio

condition and ignition energy available condition are e present. Start
pulverizer by pressing its associate
associated "START” Push Button. First, seal air valve opens,
opens after seal air
to bowl DP adequate is established
established, pulverizer will start.

When the pulverizer is proven o

on as indicated by the (Red) pulverizer "ON" light,
light open the hot
air gate by pressing its "OPEN
"OPEN" button and allow the pulverizer to come com up to the
temperature.

When the pulverizer comes up p to temperature, (approximately more than 49 deg. C- say
around 70 deg. C) start the feede
feeder by pressing its associated "START” Push Button.
Button Coal flow must
be proven either by the coal flo
flow detector or satisfactory pulverizer current within
withi 5 seconds,
after the feeder is started.

Fifteen seconds after the feeder is started, the feeder output is released to the include feeder
in the totalising circuit.

When the feeder is ON for 50 secs. the feeder speed is released to auto control and the fuel air
dampers are opened to modulate as a function of feeder speed.

When a minimum of two feeders are established at greater than 50% loading, the associated oil
elevations may be shut down provided the feeder has been ON for a minimum of 3 minutes.

OPERATOR’S NOTE:-A single feeder in service for fifty seconds at its minimum speed setting
will establish a `fireball' in the furnace (a single fireball is established when a coal elevation is
placed in service. When additional coal elevations are placed in service, this single fireball is
merely enlarged). If the support ignition energy is removed, the fireball will be monitored by
the associated elevation flame scanners. However, good operator procedure dictates that an
adjacent feeder must be placed in service and both feeder speeds be increased to 50% before
removing the support of the fireball. When removing feeders from service, the inverse procedure
should be followed and support ignition energy should be reinstated when only two feeders
remain in service at 50% feeder speed.

14.2 PULVERIZER START (AUTO MODE) :-

The selected pulverizer can be placed in operation automatically if all the following conditions are
satisfied:

The associated “Pulverizer Ready “condition remains satisfied.

The " AUTO” mode is selected for the associated pulverizer.

The pulverizer is started by momentarily depressing the pulverizer "start" Push Button. The
following events will occur:

a) A 180 second counting period is started to prove the associated pulverizer / feeder in
service.

b) If the pulverizer ignition energy permissive is not satisfied an "auto start support ignition”
command is established and the associated HFO elevation is automatically placed in
operation. (Refer to " Elevation Mode of Operation" section for details).

c) When the associated support ignition elevation start time has expired (both seventy second "
Pair start” counting periods have expired) and the pulverizer ignition permissive is satisfied, the
“Auto start pulverizer " and "Open hot air gate" commands are established simultaneously.
d) A pulverizer “Start " command is established and the pulverizer is started in the same
manner as previously described in pulverizer manual mode.

e) When the pulverizer is proven ON the following events occur:

i) The hot air gate is opened, provided the pulverizer outlet temperature is less
than 940 C.

ii) A sixty second counting period is started to establish an "Auto start feeder" Command.

f) When the sixty second counting period expires, an "auto start feeder" command is established
for five seconds. A "start feeder " command is now established, provided the hot air gate is
open. The feeder is put into service in the same manner as previously described. After the 180
second "elevation start" counting period expires and the pulverizer is on and the feeder is
off, the unsuccessful elevation start is established. When the feeder is off for more than three
minutes, the pulverizer receives an "auto stop pulverizer" command and is shutdown.

15. PULVERIZER IN SERVICE (Refer Figure-8):-

With the pulverizer / feeder in service, several operational parameters are continuously
monitored. However, it is left to the operator’s discretion to investigate and take further
corrective action.

An operating pulverizer and feeder are subject to the following operational checks:

The feeder speed will be run back to minimum if the pulverizer bowl differential pressure is high.

If the pulverizer outlet temperature is high ( greater than 94 Degree C), then the following events
occur:

i) Pulverizer air and temperature control is released from auto mode. The hot air dampers close
and the cold air dampers open to 100% pulverizer air flow position.

ii) The hot air gate is closed after a thirty second time delay to allow the associated dampers
to react.

Any of the following conditions will give signal to run the feeder speed to minimum until the
initiating condition is corrected.

a) Pulverizer bowl differential pressure high. b) Feeder is off.

Loss of coal flow and low pulverizer current will trip the feeder and close hot air damper. The
operator should take appropriate corrective action, then reopen the hot air damper and restart
the feeder.
High pulverizer outlet temperature (above 94 deg. C) will open cold air damper and close the hot
air damper. It will close Hot Air Gate after 30 sec delay.

16. PULVERIZER TRIP :-

The following conditions will initiate a pulverizer trip command.

a) Any Pulverizer discharge valve not open.

b) Loss of unit critical power (24V DC).

c) Pulverizer ignition permit is not available .AND. support ignition required.

d) MFT (See boiler trip section for details).

e) Loss of primary air

f) Seal air header to pulverizer differential pressure low (125 mm WC) .AND. Pulverizer on for
more than 60 secs.

g) Any coal burner of that elevation Manual Isolation Valve not open.

h) Pulverizer Failed to start >10 secs.

i) Pulverizer Lub oil system failed.

When the primary air duct pressure falls below the low set point (for more than 5 secs.) all
pulverizers in service a receive stop command.

When both PA fans stop or the primary air duct pressure goes very low, all the pulverizers are
tripped instantaneously.

When one PA fan or one FD fan trips and three or more pulverizers are in service, each pulverizer
with a 2 sec time delay a trip command will be given starting from the pulverizer serving top most
coal elevation, until the number of pulverizers remaining in service is reduced to three.

17. PULVERIZER SHUT DOWN:-

17.1 PULVERIZER SHUT DOWN (MANUAL MODE) :-

When manual pulverizer control mode is selected, manual shut down of a pulverizer is
accomplished as follows:
 • Start the associated oil elevation, if it is not in service. Reduce the feeder speed to
minimum.

• Close the hot air gate by depressing its "CLOSE" Push Button.

• When the pulverizer outlet temperature is reduced to below 49.5 deg C, then shut down
the feeder by pressing its "OFF" Push Button.

• Allow the pulverizer to run for about 2 minutes to ensure that it is completely empty of
coal, then shut down the pulverizer by pressing its "OFF" Push Button.

17.2 PULVERIZER SHUTDOWN (AUTO MODE) :-

In the auto mode of operation, the pulverizer is shutdown as described below.

a) The operator initiates a pulverizer auto shutdown sequence by momentarily depressing the
associated "Stop” pushbutton. The following events will occur.

i) The "auto stop memory" signal is established and the "Auto start memory" is reset.

ii) If the associated pulverizer ignition permissive is not satisfied, an "auto start support
ignition energy" command is established.

iii) A ten minutes "Elevation stop" counting period is started.

b) When the support ignition time has expired (both seventy second H.O pair starting
Periods have expired) and the pulverizer ignition permissive is satisfied, then the following
commands are established simultaneously.

i) Run the feeder speed to minimum. The feeder speed will be reduced through auto
control.

ii) Close hot air gate in auto mode. The associated hot air gate is closed in the manner
previously described (see PULVERISER MANUAL SHUT DOWN section).

c) When the hot air gate is closed and the pulverizer outlet temperature has been reduced
below 49 deg. C(120 deg.F), the associated feeder will receive an "Auto stop" Pulverizer
command. The feeder will now be shut down.

d) When t h e feeder is off for three minutes, the associated pulveriser will receive an "auto
stop" pulveriser command. The pulveriser will now be shut down.
 e) If the pulveriser is to remain on "Stand by" then the discharge valve should remain open to
allow air to flow through the pulveriser. If required, the discharge valve is closed by
depressing the associated “Close” Push Button (provided the pulveriser is off).

f) The associated H.O elevation can be shut down when the furnace and boiler Conditions have
been estabilised.

When the ten minutes "elevation stop” count period expires, an "Unsuccessful elevation shut
down” signal will be sent to the alarm if any of the following conditions exist at the associated
coal elevation:

i) The pulveriser is on.

ii) The feeder is on.

iii) The hot air gate is not closed.

17.3 FEEDER OUTLET GATE CONTROL :-

Depressing “OPEN” Push Button for RC Feeder Outlet Gate will open the gate provided
the following conditions are fulfilled.

Pulveriser on.

Close RC Feeder Outlet Gate command is not present. RC Feeder Outlet Gate not open.

Start Feeder - Auto command will automatically open the gate.

“Red” lamp will indicate open state of the gate.

Similarly by depressing “CLOSE” Push Button for RC Feeder Outlet Gate will close the gate
provided RC Feeder Outlet Gate is not closed and the following conditions are fulfilled.

Feeder off .AND. RC Feeder Outlet Gate close command present.

.OR.

Pulveriser trip

.OR.

Feeder off .AND. Stop feeder - auto.

“Green” lamp will indicate close state of the gate.

17.4 HOT AIR GATE CONTROL :-

Depressing Hot Air Gate “OPEN” Push Button on, will open the gate if following conditions are
present.

Pulveriser on .AND. Pulveriser auto start .OR. Pulveriser manual mode

.AND. Close Hot air gate command is not available.

“Red” lamp will indicate open state of the gate.

Hot Air Gate will close automatically if following conditions are present.

Close Hot Air Gate command present for more than 30 seconds.

.OR. MFT .OR. pulveriser off

Loss of unit 24V DC will also close the Hot Air Gate. This is indicated by “Green” lamp.

18. OIL ELEVATION SHUTDOWN (Elevation AB, CD & EF - PAIR MODE) :-

When adjacent coal elevations are not in service and elevation back up trip exists .OR. when all
feeders are off, the associated warm-up (LO / HO) elevations are automatically selected to the
“Pair operation Mode” and t h e warm-up (LO / HO) elevation can be shut down, pair-wise.

Under “pair operation mode” the oil elevation is removed from service in the following manner.
Either pair (1-3) or (2-4) can be initially shutdown. Each pair of oil guns are shutdown in the
following manners.

Depressing “PAIR (1-3 or 2-4) STOP” PB momentarily will establish a stop signal for that pair.
This will cause the following events to occur:

A 375 second elevation “pair stop” counting period is started.

The associated Elevation “PAIR (1-3 or 2-4) STOP” light comes on.

A “stop” command for corner 1 (or corner 2) is established, and a 15 sec. counting period
is started to establish a “stop” command for corner 3 (or corner 4).

The corner oil (LO/HO) nozzle valve will receive a “CLOSE” command.

(When the corner oil nozzle valve is moved to the fully closed position, the oil
valves “CLOSED” light comes ON and the associated “DISC. SCANNERS NO FLAME” light comes on.)

After the warm-up (LO / HO) nozzle valve is closed, the scavenge nozzle valve receives “open”
command. Also the spark rod of HEA is advanced and gives spark for a period of 15 seconds.
After the scavenge valve is fully open, a 300 seconds counting period is started.
After the 300 seconds scavenge trial time expires, the scavenge valve receives “close”
command. When the scavenge valve is moved from the fully open position, the five
minute counting period is reset.

When the scavenge valve is closed, the associated atomising (air/steam) nozzle valve receives a
“close” command.

When the 15 seconds counting period expires, a “stop” command is established for corner 3 (or
corner 4) which is removed from service in the same manner as previously described
for corner 1 (or corner 2).

After the pair stop time expires, the scavenge valve memory is reset. The other pair (1-3 or 2-4)
is stopped similarly by depressing the “PAIR STOP” Push Button (see Note 3 below).

Note 3 :- Simultaneously, a 360 second counting period is started to establish a “warm-up”

elevation back up trip after the first pair (1-3 or 2-4) of oil guns have been shut down and the
“stop” command for the first oil gun of the second pair (1-3 or 2-4) is established.

The associated pair of oil guns are shut down in the same manner as previously described for
the other pair of oil guns (1-3 or 2-4).

When the 360 second counting period expires, a “warm-up elevation back up trip” condition
is established. This pair “back up trip” establishes a redundant “stop” command to ensure that
the oil guns are shut down.

The signal to “position the warm-up oil elevation dampers for oil firing” is removed. After the
“warm-up oil elevation back up trip” is established, an “Unsuccessful warm-up oil elevation
shut down” condition is established when both 375 second counting period expire and any
warm-up (LO / HO) nozzle valve is not closed or any HEA IGNITOR is not retracted in the
associated elevation. This initiates “oil elevation unsuccessful shut down” alarm.

A warm-up oil (LO/HO) gun may also be shut down and scavenged individually by placing its
local oil gun maintenance switch in the “SCAVENGE” position. The warm-up oil gun will be shut
down and scavenged as described above.

To return the warm-up oil gun to service, return the local maintenance control switch to
“REMOTE” position and depress the associated warm-up oil elevation “PAIR START” Push
Button.

Any one of the conditions listed below will trip an individual warm-up oil corner by issuing a
corner trip signal.
 • Associated local maintenance control switch turned to “OFF” position.

• Warm-up oil gun not engaged.

• Atomising (air/steam) Manual isolating valve not open.

• Corner not in scavenge .AND. Corner start time expired .AND. Warm-up oil nozzle valve
not open .OR. Atomising steam nozzle valve not open .OR. Discriminating scanner no flame

• Elevation back up trip.

• LO (HO) selected when HO ( LO) is fired.

19. OIL ELEVATION SHUTDOWN (Elevation AB, CD & EF - ELEVATION MODE) :-

When either of the coal elevation associated with the warm-up oil elevation, is in service, the
warm up oil elevation can be shut down under this elevation mode. The subject elevation can
be shut down as described in the following section.

Under Elevation mode, the oil elevation is removed from service in the following manner.
Depressing the “PAIR STOP” Push Button (1-3.OR. 2-4) will establish a corner “STOP” command
(see Note 4 below).

Note 4 :- The “PAIR STOP” command will establish a corner “STOP” command provided
both coal elevations associated with the warm-up elevation have been ON for at least three
minutes or both associated coal elevations are not in service.

The corner “STOP” command will cause the following events to occur:

• A 375 second elevation pair counting period is started for corner 1 and 3.

• A 40 second counting period is started to establish a “STOP” command for corner 2 and 4.

• The Elevation “PAIR 1-3 STOP” light comes on. A “STOP” command for corner 1 is
established and a 15 second counting period is started to establish a “STOP” command for
corner 3.

• After the “STOP” command is established, the oil gun at corner 1 is removed from
service in the same manner as previously described.

• When the 15 second counting period expires, the “STOP” command for corner 3 is
established and is removed from service in the same manner as corner 1. When the
40 second counting period expires, the “STOP” command is established causing the
following events to occur. A
 • 375 second elevation pair counting period is started for corners 2 and 4. The Elevation
“PAIR 2- 4 STOP” light comes on.

• Corner 2 stop command is established and a 15 second counting period is started to

establish a stop command for corner 4.

The oil gun at corner 2 is removed from service in the same manner as previously described.
When 15 second counting period expires the “STOP” command for corner 4 is established
and is removed from service in the same manner as corner 2. All other interlocks i.e., Backup
trip, elevation unsuccessful shutdown etc. are same as described earlier.

UNIT PROTECTION (TRIPLE REDUNDANT) :

For unit protection, triple redundant fashion has been implemented for the following signals
(three contacts each). All the three contacts are distributed to the three Channels/subsystems for
2 out of 3 voting.

• Furnace pressure very high.

• Furnace pressure very low.

• Drum level very high.

• Drum level very low.

• Both FD fans off.

• Both ID fans off.

• Air Flow < 30 %.

• Loss of Reheater Protection. Spare trip.

• Loss of Unit 220 V DC.

All the above conditions are processed in 3 independent sub systems and 2 out of 3 voting are
done in individual processor.

In addition to the above, the internally generated trip signals like

• Loss of all fuel trip.

• Flame failure trip.

• Less than Fire ball and loss of AC at any elevation in service.

are processed in the above three processors for 2 out of 3 voting for formalising the MFT
condition.

20. BOILER TRIP CONDITIONS :-

20.1 MASTER FUEL TRIP :-

Master Fuel Trip is initiated by any one of the following conditions :

• Drum water level very low for more than 5 seconds.

• Drum water level very high for more than 10 seconds.

• Both FD Fans off.

• Both ID Fans off.

• Unit air flow is less than 30%

• Furnace pressure very low.

• Furnace pressure very high.

• Spare trip (See Note 5).

• Less than fire ball and loss of AC at any elevation in service (See the Note 6).

• Loss of all fuel trip (See the Note 7)

• Unit flame failure trip (See the Note 8)

• Both emergency trip PB pressed (Operator initiated boiler trip)

• Loss of reheater protection.

• Loss of 220V DC for more than 2 sec.

Note 5: - A spare channel for boiler tripping is provided for use at a later date if required.
Otherwise it should be left unconnected.

MFT command will initiate the following actions.

All fuel inputs are stopped by tripping all the pulverisers, all the feeders, closing all hot air
gates, closing all the nozzle valves (LO/HO) and trip valves (LO/HO).
In addition to the above,

• The HO elevations revert to “pair operation” mode.

• The upper (elevations F,E&D) and lower (elevations C,B&A) fuel air dampers are
opened and transfer to manual.

• Transfer the auxiliary air control to manual and open all auxiliary air dampers.

• After 5 secconds and the “loss of fuel trip arming” memory is reset and the “loss of fuel trip
arming” signal is removed

• The furnace pressure recorder speed is changed for 30 seconds when the furnace
pressure is not high and not low after 30 seconds the recorder reverts to its original speed.

• After a “Master fuel trip” occurs, a “feed forward to furnace draft control” signal is
established for 30 seconds. After 30 seconds this signal is removed.

Note 6 :- “Less than fire ball and loss of AC in any elevation in service” condition occurs,
when all the feeders are not in service and there is a loss of power supply (110V AC) at any
of the elevation in service. Under this condition as ignition energy will not be proper (no fire ball),
the HO elevation (Oil)cannot be allowed to run without control (as there is no power supply).
Hence the boiler has to be tripped to shut down the elevation.

Note 7 :- Loss of All Fuel Trip circuit is armed as soon as oil firing is introduced into the
furnace, through any one of the following conditions. i.e. if any oil burner comes into service.
This condition also indicates that the “Boiler is on”.

Elevation AB any LO nozzle valve NOT closed

Elevation AB any HO nozzle valve NOT closed

Elevation CD any HO nozzle valve NOT closed

Elevation EF any HO nozzle valve NOT closed

20.2 Loss of All Fuel Trip :-

“Loss of All Fuel Trip” condition is generated if all the following conditions exist along with
“Loss of all fuel trip arming” condition.

All feeders are off

.AND.

Elevation AB Backup trip .OR. All LO valves are closed

.OR.

LO trip valve is not open

.AND.

Elevation AB back up trip .OR. All HO valves are closed

.AND.

Elevation CD back up trip .OR. All HO valves are closed

.AND.

Elevation EF back up trip .OR. All HO valves are closed

.OR.

HO trip valve not open.

Loss of all fuel trip arming memory is reset 5 seconds after MFT trip occurs.

20.3 UNIT FLAME FAILURE :- “Unit Flame Failure Trip” occurs if all the 6 elevations vote for
“No flame” along with the arming signal.

Conditions for the generation of No Flame voting elevation wise is given below :

ELEVATION “A”

Feeder “A” is not proven.

.OR.

Elevation AB 3 out of 4 Fireball scanners show no flame .AND. HO/LO 2 out of 4 nozzle valves
not open .

.OR.

Elevation AB started and loss of power.

ELEVATION “B”

Feeder “B” is not proven

.OR.

Elevation AB 3 out of 4 Fireball scanners show no flame .AND. HO/LO 2 out of 4 nozzle valves

not open .

.OR.

Elevation AB started and loss of power.

.AND.

Elevation “BC” 3 out of 4 fire ball scanners show no Flame

ELEVATION “C”

Feeders C not proven .

.OR.

Elevation CD 3 out of 4 Fireball scanners show no flame .AND. HO 2 out of 4 nozzle valves not
open .

.OR.

Elevation CD started and loss of power.

.AND.

Elevation “BC” 3 out of 4 fire ball scanners show no flame

ELEVATION “D”

Feeder D not proven.

.OR.

Elevation CD 3 out of 4 Fireball scanners show no flame .AND. HO 2 out of 4 nozzle valves not
open .

.OR.

Elevation CD started and loss of power.

.AND.

Elevation “DE” 3 out of 4 fire ball scanners show no flame

ELEVATION “E”

Feeder E not proven.

.OR.

Elevation EF 3 out of 4 Fireball scanners show no flame .AND. HO 2 out of 4 nozzle valves not
open .

.OR.

Elevation EF started and loss of power.

.AND.

Elevation “DE” 3 out of 4 fire ball scanners show no flame

ELEVATION “F”

Feeder F not proven.

.OR.

Elevation EF 3 out of 4 Fireball scanners show no flame .AND. HO 2 out of 4 nozzle valves not
open.

.OR.

Elevation EF started and loss of power.

Note 8 :- Unit Flame failure Trip circuit is armed 2 sec. after any coal elevation is put into
service. (i.e. any feeder proven condition).

20.4 FIRST OUT TRIP SYSTEM :-

A First Out Trip System provided allows the operator to determine the cause of a boiler trip by
observing the indication lamps located on the Unit Console insert under First Cause of Trip.

When an event that causes occurrence of boiler trip, the associated “Cause Of Trip” memory is set,
and the indicating lamp for trip command, responsible for the boiler trip is illuminated and the
successive trip commands to the other indications are blocked.

When the event that caused the boiler trip is corrected & boiler purging is completed the “Cause
Of Trip” memory is reset.

This indicates that a “No Boiler Trip Command” is established. The memories are reset
automatically after a successful 5 minute furnace purge cycle has been completed. The FIRST
CAUSE OF TRIP light that caused the boiler trip will go off.

20.5 POST PURGE EXCURSION PROTECTION :-

Post purge excursion protection circuit has been designed in the Furnace Safeguard Supervisory
System. It operates as described below:

When all the following conditions are satisfied, a 5-minute counting period is started.

Light oil trip valve closed.

Elevation AB all LO nozzle valves closed.

Heavy oil trip valve closed.

All elevation all HO nozzle valves closed.

All Feeders off.

Air flow > 30 % MCR and <40 % MCR.

All scanners show “no flame”. All Hot air gates closed.

All aux. air dampers modulating

All PA fans off.

After 5 minute counting period expires, the “Post Purge Fan Trip” memory is set, if very high or
very low furnace pressure exists, the post purge fan trip command is issued (for tripping FD&ID
fans). When any HO / LO valve is open, this is reset.

20.6 FEED FORWARD COMMAND TO FURNACE DRAFT CONTROL :-

A 30 seconds Feed Forward command to Furnace draft control is given if either of the conditions
listed below exists.

Loss of unit +24V DC power

Occurrence of Master Fuel Trip, when the boiler is on (i.e., Loss of all fuel trip arming is
present).

20.7 FURNACE PRESSURE RECORDER SPEED CHANGE :-

This contact has been provided to switch the Furnace Pressure Recorder to the alternate speed (if
Dual speed recorder is provided) under the conditions mentioned below, to observe Furnace
Draft fluctuations.

1. MFT

2. Loss of unit +24V DC power

3. Furnace Pressure High or Low

For condition 1 mentioned above, the Recorder speed is reverted back to original value after 30
seconds. For condition 3, the Recorder is set to original value 30 seconds after condition 3 is
removed.

21. SCANNER AIR FAN CONTROL (Refer Figure-6) :-

Two scanner air fans (1 AC main + 1 DC stand-by) are provided for the unit. Either scanner air
fan can be placed in service in the following manner.

Start command to any of the scanner fan can be given from the Console.

After a Purge complete and No MFT, a start command is also established automatically for
scanner air fan ‘A’ (AC operated), if the scanner duct to furnace differential pressure is “low”
for more than 5 seconds. If this low condition exists for more than 10 sec., the same is
annunciated as “Scanner Duct To Furnace DP Low” for more than 10 seconds.

A start command is also established for the stand-by scanner air fan (ie. DC) if the first fan fails
to start within 5 seconds after receiving the start command or if it trips.

Loss of unit 24 V DC establishes start command for both scanner air fans.

The scanner air fan can be stopped by momentarily depressing the “STOP” Push Button, provided
the scanner duct of furnace differential pressure is not low. When both the scanner fans fail to
start within 10 seconds from getting auto start command, an alarm is generated as “Both Scanner
fans failed to start” and this will reset start memory of both scanner fans, to avoid
toggling between Fan-A and Fan-B.

The status of Scanner air Fans is displayed on the Console.

The scanner emergency damper is opened when all FD fans are off .OR. Unit +24V DC power is
lost. If both these conditions are not present, the scanner emergency damper will be closed.

22. SEAL AIR FAN CONTROL (Refer Figure-7) :-

There are two seal air fans that serve this unit, one working and one standby.

Any seal air fan can be started manually by depressing its “START PB”. This action gives start
command to the motor.

The seal air fan which is not in service, is started on Auto command if, Any PA fan is on .AND.
Seal air header to cold PA header DP is low for > 10 secs.

The seal air fan “A” will start automatically 5 sec. after the seal air fan “B” trips or fails to start on
receiving start command (SA fan “B” starts automatically if SA fan “A” fails to start).

Any seal air fan can be stopped by depressing its “STOP PB”, provided the following conditions
are satisfied.

Seal Air Header / Cold Air duct DP not low

.AND.
Both Seal Air fans on

Both Seal Air Fans are tripped once Both PA Fans are off > 15 Secs.

23. SECONDARY AIR DAMPER CONTROL :-

For a complete description of the Secondary Air Damper Control, refer the write up on
SADC system. Operation of the secondary air damper control as effected by the FSSS is
described here.

23.1 AUXILIARY AIR DAMPER CONTROL :-

All elevations of the aux. air dampers will be automatically switched to “Manual” control and then
commanded to open 100%, if any one of the following conditions exist.

• All FD fans are off

• All ID fans are off

• Master fuel trip exists (for more than 2 seconds PULSE)

• Loss of Unit +24 V DC power

When the auxiliary air control is placed in the “Auto” mode of operation, the auxiliary
air dampers modulate to control wind box to furnace differential pressure at a predetermined
set point.

During the furnace purge cycle, all auxiliary air dampers modulate to maintain wind box to
furnace differential pressure at a predetermined set point.

When the unit load exceeds 30% of MCR, the following events occurs :

The wind box to furnace differential set point is gradually increased as the unit load is increased.
Conversely, the differential pressure set point is gradually decreased as unit load is decreased. The
rate of increase (or decrease) is controlled by the auxiliary damper controller.

When the Unit Load is increased above 30% MCR, the Auxiliary air dampers on elevation AB, BC,
CD, DE, EF& FF are closed in a timed sequence (10 seconds interval) provided the associated
coal elevations are not in service and the associated oil elevations are not in service. The
auxiliary air dampers are closed, starting from the top elevation, progressing towards the lowest
elevation.

When the unit load is reduced below 30% of MCR, the following events occur:

The wind-box to furnace differential pressure set point reverts to its original value.

The auxiliary air dampers associated with the coal and LO/HO elevations not in service are
opened in a timed sequence (10 sec. interval) starting at the lowest elevation, progressing
towards the top.

When a LO/HO Elevation is started (i.e. when the associated “elevation back-up” trip is
removed) the associated auxiliary air dampers in that elevation are set to preset position for
LO/HO firing.

When the “Post Trip Purge Time Expired” command is established and all FD / ID fans are not off
and a Master fuel trip” command doesn’t exist, then a 35 seconds counting period is started.
After it expires, the “Open All Auxiliary Air Dampers” command is removed from memory.

23.2 FUEL (COAL) AIR DAMPER CONTROL :-

All elevations of fuel air dampers are commanded to open 100% when any one of the following
conditions exist.

• All FD fans are off

• All ID fans are off

• Master fuel trip exists (for more than 2 seconds PULSE)

• Loss of Unit +24V DC power

When a coal elevation is in service, the associated fuel air dampers modulate as a function of
feeder speed as indicated by the associated coal elevation “MODULATING” light coming on.
When the coal elevation is shut down, the associated fuel air dampers are closed, as indicated by a
“CLOSED” light.

When the “Post Trip Purge Time Expired” command is established and all FD and ID fans are
not off and a “Master fuel trip” command does not exist, the “Open upper fuel air dampers
(elevation F, E & D)” command is removed from memory. Thirty seconds later, the “Open
lower fuel air dampers (elevation C, B & A )” command is removed from memory.
 CHAPTER C

HANDLING OF TURBINE DURING EMERGENCY

210 MW Units
EMERGENCIES IN TURBINE AND AUXILIARIES:

In day to day power plant operations there can be any number of emergencies in Turbine
operation. Thrust is given on representative emergencies. Following are the representative
emergency operations and they are discussed one by one.

1) Partial load throw off (due to high

frequency).

2) Partial load throw off due to Aux.

Failure.

3) Sudden increase of load from full

load

4) Vibration
high

5) Differential Expansion
high/low

6) Axial shift
high

7) Loss of
vacuum

8) High level in
condenser

9) Loss of barring gear or barring gear fails to start

Following is the description of probable causes and remedial operation at the time of occurrence
of such emergencies.

1) Partial load throw off (due to high frequency).

Probable Reasons and Action to be taken:-

1. The steam pressure at ESV will increase: FSSS operator shall control the boiler pressure.

2. Governor will control the load. If it fails, then throttle the control valves suitably and
maintain pressure to normal till the frequency comes down.

3. The turbine load will decrease: There should be a constant watch on the supervisory
 instruments.

4. Disturbance in differential expansion, vibration, axial shift, eccentricity:

keep a close watch on Turbovisory Parameters.

5. Disturbance in condenser level : Adjust and maintain the hot well level

6. Disturbance in vacuum :Check and adjust ejector steam pressure and gland steam
pressure to normal

7. Turbine lub oil temp will change: Adjust the lub oil coolers water flow as necessary.

8. Disturbance in Deaerator pressure : IfDeaerator pressure tends to fall, maintain it through

extraction or 16 ata header.

2) Partial load throw off due to Aux. Failure.

Probable Reasons and Action to be taken:-

There is a provision for initial load throw off by help of a relay without time delay which
reduces turbine load to 100 MW in case of tripping of following equipment’s .

• One C.W. pump in case both are running: *

• One BFP in case two are running and standby does not come on auto remote
/not available. : *

• One condensate pump in case two are running and standby does not come on auto/
remote not available: *

• And also due to tripping of any one of I.D. fan, F.D. fan P.A.fan.: *

* If the partial load relay fails / not in circuit reduce the turbine load and inform the
boiler operator to control steam parameter in case one C.W. pump or one condensate
pump trip. Careful watch may be kept on vacuum. Inform the local operator to check
the cause of tripping. Maintain the deaerator and hot well level.

• In case of full load throw off (due to opening generator breaker): Unit trip on protection.

• The turbine may trip due to over speeding : Close the control gear hand wheel.

• If closing control valve can control the speed: Check that ESV and control valves are
closed. immediately otherwise trip the Turbine by emergency trip button
 : Close the valves in the M.S. line. Close the Extr. steam valves.

3) Sudden increase of load from full load

Probable Reasons and Action to be taken:-

• Low frequency: Since the turbine is on governor control the load will increase due to
fall in speed. Reduce the load by the control gear and bring the boiler parameter and
load to normal.

• Due to sudden rise of boiler drum pressure.: Bring back the load /governing wheel
pressure to normal by control gear and inform the boiler operator.

4) Vibration high

Probable Reasons and Action to be taken:-

• Normally the vibration in bearings should be within 40 microns. If it exceeds the limit,
turbine should be shut down: Check the turbine cylinder drain should not be cold (if
necessary open the drain valve for few minutes if turbine is on load).

: Check bearing oil press flow and temp. to be normal .

: Check for any rubbing sound etc.

• Turbine bearing oil press low: Reduce the load /speed. Check the main line pressure and
maintain it.

• Bearing oil inlet temp. High: Check the cooling water valves are open in oil coolers and
vent the coolers. Put the standby cooler in service, ensure C.W.P. is running normal.
Check bearing oil outlet temp. (less then 65° c ).

5) Differential Expansion high/low

Probable Reasons and Action to be taken:-

• Normally the rotor gets long during running and gets short during s h u t down. The
expansion is to be controlled by admitting steam or shutting off supply to flange and
stud heating, chamber heating accordingly. In case if it goes beyond control, the
machine to be tripped: Check the steam temp. reduce load / speed. Check the valve for
flange heating is in open condition if rotor is long or close dlf rotor is short. Check and
adjust gland steam temp.
 • Check the vacuum to be normal

6) Axial shift high

Probable Reasons and Action to be taken:-

• In case of excessive shift the turbine will trip through the

protection.

• Sudden change in load: Control the load and maintain the steam parameter.

• Abrupt change of steam parameter: Control the load and maintain the steam
parameter

• Sudden closure of FCNRV of heater (HP/LP) : Control the load and maintain the
governing pressure, if heaters are healthy open FCNRV.

• Variation in lub. Oil temp .pressure and quality : Maintain lub. Oil pressure and temp.
for quality get the oil tested from laboratory and if necessary oil is to be changed.

• Difference of oil temp . from thrust bearing front & rear outlet should not be more than
3°c.

7) Loss of vacuum

If there be any loss of vacuum, start the standby ejector at the earliest. Still if it does not
improve start starting ejector. With no further improvement of vacuum, reduce the load as
required to maintain the vacuum at 700 MM. Meanwhile try to detect the specific reason
which may be as follows

: Steam ejector not properly functioning : Check that steam pressure in 6 kg/ cm².

8) High level in condenser

Probable Reasons and Action to be taken:-

• Malfunctioning of condensate pump or valve: Check the normal running of the condensate
pump, start standby.

• Check the operation of valve from UCB by taking it to manual; if not all right control the hot
well level bypass valve.

• Malfunctioning of DM make up valve : Close valve from UCB and watch that hot well
level falls.
• Condenser tube leakage: If the above operation fails to control the hot well level, get the
condensate water tested by laboratory to confirm the leakage .if the tube leakage is very
high, it may not be possible to pump out the condensate from the condenser when the
condensate level will gradually increase. Ultimately if the water level rises up to the air
suction space of condenser, water will be sucked in to air suction pipe line of the ejector.
When the same well be supercooled and ejector will not function. Shut down the turbine
at the earliest to get the leakage attend.

• CW pump failure: If one pump is tripped, reduce the load. Meanwhile determine the
cause of CWP failure and rectify the defects. Of course if both the CW pumps fail, there is
no way out other than to trip the unit.

• Malfunctioning of DM make up valve: Check the valve, reduce load and try to maintain
levels tell normalization.

• Air leak into system: Check scaling water pressure to valves under vacuum is normal.
Check starting ejector air vale and vacuum break valve are tightly closed. Measure the
amount of air leakage At air removal equipment outlet and investigate the source of leak.

• Condenser tube choking: Check the CW inlet and outlet temperature.

9) Loss of barring gear or barring gear fails to start

Probable Reasons and Action to be taken:-

• For loss of electrical supply D.G. set will come automatically Otherwise start. : If not
possible to start the DG set, attempt to turn the shaft by slings with the help of over head
crane by 180 Degrees at regular intervals of 15 minutes after cutting in the D.C.
emergency lub oil pump.

• Smoke from turbine seals. : Check differential expansions are normal

• Reduce seal steam temperature, if high.

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