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NA TI0NAL P0 WER TRAINING INSTITUTE

NAGPUR 210 MW POWER PLANT SIMULATOR

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OPERATING INSTRUCTIONS MANUAL

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NATIONAL POWER TRAINING INSTITUTE SOUTH AMBAZARI ROAD GOPAL NAGAR NAGPUR 22

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C 0 N 1 E N

Page

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1.

COLD START UP OF U N I T

2. 3. 4. 5.

PLANNED SHUT DOWN OF UNIT SHUT DOWN TO HOT STAND-BY OF UNIT HOT RESTART OF UNIT AUTOMATIC TURBINE RUN-UP SYSTEM AND SGC OIL LOGICS INTERLOCKS AND PROTECTIONS OF UNIT CRITERIA CURVES FOR ROLLING THE TURBINE AND SYNCHRONISING THE GENERATOR THERMAL SCHEMATIC DIAGRAMS

64 81 88 95 116 145

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6. 7.

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152

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PROCEDURE FOR STARTUP OF THE UNIT FROM COLD CONDITION CHARGING OF 6_^ KV ELECTRICAL SUPPLY SYSTEM Ref.Tag MCL2

Ensure that ;220 KV Grid is charged.-Station Transformer 220 KV Breaker key is in "ON1 position at MCL-2. All BTSP (BTPS-1,BTPS-2,BTPS-3, BTPS-4) are out. Station , Transformer-2 is in

charged condition. E-2

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Through local operation close isolator from grid to station transformer-1. (Bus-1 or Bus-2 side) (RFED05)

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E-3

Through local operation close station transformer-1 6.6 KV side isolator. (RFED-08)

E-4

Through local operation close station transformer-1 220 KV breaker. local ( RFED-12) operation close station boards OCC
f ":>'-'

E-5

Through

O C D ' s a l l 6.6 K V o u t g o i n g

f e e d e r s . (RFED)

CHARGING OF 6 _ ^ 6 KV SWITCH BOARD

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E-6

Close STN BD OCA INCOMER BREAKER Stn. board QCA volt meter will show 6.6 KV.

MCL2

E'-7

Close STN BOARD OCB INCOMER BREAKER Stn.Board OCB Voltmeter will show 6.6 KV. . ' .

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E-8 E-9 E-10

TIE BREAKER BETWEEN STN BUS OCD

& OCB. /, " MCL1

TIE BREAKER BETWEEN STN BUS OCC & OCA. Close TIE BREAKER BETWEEN UNIT BD ICA & STN BD OCA.

Unit Board ICA voltmeter will show 6.6 KV. ' -r ^.^ ........ , ~ ,. E -11
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Close TIE BREAKER BETWEEN UNIT BD ICB & STN BDS OCB. Unit Board ICB voltmeter wil] show S.S KV.'

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E-12 E-13 E-14 E-.15 E-16

Close all 6.6 KV outgoing feeders at ICA &

ICB.

MCL1 " MCL2 MCL2

Close incomer-1 and incomer-2 Bkr. to Board IDA. Close all 6 . 6 KV outgoing feeders at OCA & OCB.

Close incomer-1 and incomer-2 Breaker to Bus ODA. Through local operation (Case_ rf_ ups_ close)

charge UPS-l,UPS-2; 220 V charger-1 & charger-2. C-2 STARTING OF G S WATER PUMPS \0 ' r

Before starting G S Water pump check following: 1. Electrical supply is available to GSW Pumps. 2. Sump level is normal. 3. Over head tank outlet valves GSW-132 & GSW-133 are open. 4. G S over head tank incoming valves GSW-115 and GSW-114 are open. in and DC control supply is"ON 1 . check motor current of 30 A.

5. Breakers are racked

Start G S water pump-A,

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Open

GSW

recirculation

valve CW-44 (RFCW001) by 20%

locally. Open Discharge Valve DV-39 .f cw-3=0 GSW OVER HEAD TANK LEVEL will increase slowly and

wait till GSW OVER HEAD TANK LEVEL HIGH alarm appears. C-3 STARTING OF SERVICE AIR AND INSTRUMENT AIR COMPRESSORS !?-> Before starting service air and instrument air compressors check following: l.GS water supply is available to the compressors. 2.I/L, O/L valves of all air receivers are open. (IA07,IA10,IA8,IA11,IA09,IA12,IA01,IA04,IA02,IA05 3.IA-15 valve is initially closed. IA03,IA06)

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Start SAC-A & SAC-B and establish service air header pressure ^ ,f^ fh #| at 7 to 8 kg/cm2. indication resets Check that service air compressor and air pressure trouble low indication resets.

Start instrument

air compressors

A & B and establish 7 to 8

Kg/cm2 instrument air header pressure. Indication of instrument^ air header pressure will reset. Ensure that the inter-connecting valve between IAC and SAC -is closed and can be opened if required during emergency. C-4 CHARGING OF CW SYSTEM AND STARTING CW PUMPS Before charging CW System check following: 1. CW sump level is normal.

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2. Cooling water 0/L valves from condenser to cooling towers are in open position. 3. Electrical supply to CW pumps is available. 4. Check Condenser water box vents are open initially and

close locally after charging. Open COND CW I/L Valve CW-48 & Valve CW-49. Open COND CW 0/L Valve CW-55 & Valve CW-56. Start CW PUMP-1 from CWA-15 desk. Discharge valve will open (20%) initially and then lateron opens fully. Ammeter reading of CW PUMP-1 will show 140 amps. CW PR COND A I/L pressure will show 2 to Start CW pump-2 from CWA-15 desk. 2.2 kg/cm2.

DISCHARGE VALVE CW-16 will open by 20% initially after time delay will open completely.

and

CW PUMP-2 will

show 14 0 amps. pressure will show 2 to 2.2 kg/cm2

CW PR COND B I/L and j6-S

DP 0.3 5 kg/cm 2.

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OPENING BOILER SIDE VENTS AND DRAINS Before filling Boiler drum open locally Boiler drum

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

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15.

valves S-40, S-21, S-25, S-30. Open RH vent valves R-l and R-4. Open SH drains S-15, S-17, S-19. ' t '
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Open B-95 ring header drain Ensure that

valve.

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all the water side drain valves are closed.

Open economiser recirculation valve E-12V. CHARGING OF DM MAKE UP SYSTEM, il

C-6 ,/

Ensure DM water storage tank outlet valves DM-2,DM make-up pump suction valves DM-3 and DM-4,DM make-up discharge valvt; DM-7 and DM-8 are open. A

Open valve DM I/L Valve DM-01 to STG TANK on CWA-15 desk. Close DM-01 ' valve when DM storage tank reaches normal
(

(7600 mm) . Ensure that DM overhead tank inlet outlet valves are open. Select DM transfer pump-1 on CWA-15 desk. Put DM PUMP SEQUENCE on auto. Press VON' push button of DM PUMP SEQUENCE to start. DM transfer pump-1 will start and shows 40 A.

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Observe tripping of DM transfer pump on interlock level reaches 3350 mm. Condensate surge tank can be filled directly bypassing when

DM O/H tank if required. DM-12 level. DM overhead tank level low indication resets at >1050 mm. Annunciation window OH COND SURGE TANK LVL LOW resets at reaches at 2500 mm DM-12 will close. will respond based on CST level to maintain CST

/2050 mm and when level ^ r?s <p r*i FILLING OF BOILER DRUM Ensure that

all the water wall drains, header drains are

closed and ECO recirculation is open. Open locally water wall header drain valve tial filling valve E-10.

B-95 and

ini-

Q Q, r% p, Q C-8

Initially boiler drum is to be

filled from bottom ring header. Start start Boiler fill pump. raising. Water level in boiler drum will

Fill the drum upto 3 ports (-25 mmwc) and

then close

filling valve E-10 locally.

/ FILLING OF FEED STORAGE TANK

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initial filling valve DM-50 (RFFW08). Deaerator level gradually increases and "DEAERATOR LEVEL LOW" annunciation window resets at 2385 mm.

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Wait till DEAERATOR level reaches normal (2785 mm) . Stop Boiler fill pump and close DM-50 locally. Ensure that isolating valves of over flow valve DR-33 are open.

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FILLING OF HOT WELL Open following local valves for filling hot well. Open DM-34 and DM-36 (RFDM-04). Open Open DM-31 and DM-33 (RFDM-03). valve DM-32 on CWA-15 desk for filling hot well.

Hotwell level will increase gradually. " Hotwell very low" indication resets at 350 mm level

and hotwell level low indication resets at 650 mm level. Close DM-32 valve when level reaches 850 mm. C-10 STARTING OF AIR PRE-HEATER-A AND B r . <~> "> Before starting APH-A ensure \<y' *j!_ j ; . : ' ' ' ' ' " following valves are open:

1. The discharge valve of guide bearing lub.oil pump. 2. The discharge valve of support bearing lub oil pump.

3. Air heater-A support bearing Cooler-I inlet valve GSW-171. 4. Air heater-A support bearing cooler-2 inlet valve GSW-172. 5. Air heater-A guide bearing inlet valves GSW-165 and GSW-166. START PERMISSIVES following on OF AIR HEATER DAS CRT A/B observe missing

Check

and

criterias for start-up sequence of APH-A. ANY ESP I/L. O/L DAMPER AH-A SUPPORT BEARING TEMPERATURE AH-A GUIDE BEARING TEMPERATURE AH-A MAIN DRIVE AH-A S/S POSITION OPENED NHIGH NHIGH OFF REMOTE.

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AH-A FG I/L DAMPER CLOSED CLOSED CLOSED CLOSED

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AH-A FG O/L DAMPER . AH-A SA I/L DAMPER AH-A SA 0/ts.DAMPER ^ -STARTING OF AIR PRE-HEATER-A APH-A can be started manually or in group sequence.

Procedure for starting APH-A in group sequence. Ensure that guide and support bearings lub.oil sequence is on auto and select any one pump and ensure that APH-A

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DC

motor is running.

Keep AIR.HEATER-A GROUP SEQUENCE on auto mode . Press "ON' push button of group sequence to start APH-A.

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STEP INDICATOR wil indicate step number after the other. Observe that APH-A MAIN MOTOR starts and Aux.motor trips. SA I/L DAMPER SAD-3A, SA 0/L DAMPER SAD-4A, FG I/L DAMPER zero to eight one

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GD-1A, FG 0/L DAMPER GD-2A will open. PROCEDURE FOR STARTING HEATER-A MANUAL Observe group sequence AIR steps on DAS ON CRT. Keep Air heater-A Group sequence on manual mode.

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

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AIR HEATER-A main motor(AC) will start and Aux.motor trips Open SA I/L DAMPER SAD-3A, SA 0/L DAMPER SAD-4A, FG I/L. DAMPER GD-1A, FG 0/L DAMPER GD-2A . Selected lub.oil pump will pick up when guide bearing temperature >40 deg.C and support bearing temperature >35 deg.C. respectively.

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AUTO PICK UP TRIAL OF AIR HEATER-A AUXILIARY MOTOR Press "OFF' push button of AIR HEATER-A MAIN motor. AIR HEATER-A motor will trip . AIR Heater-A AUX. motor will pick up and shows 3 amps. Press "ON'push button of AIR HEATER-A MAIN MOTOR. AIR Heater-A AUXILIARY MOTOR will trip. Similarly Air Pre-heater-B can be taken into service

on manual or in group sequence mode. Observe support and guide bearing temperatures of both Air heaters (on CRT). Ensure that side . t-11 STARTING OF ID FAN-A PERMISSIVES TO START ID FAN-A . IDF-A S/S POSITION . AH- A/B IDF-A MOTOR & FAN BEARING TEMPERATURE IDF-A CB POSITION IDF-A CB SPRING IDF-A AH-A/B FG I/L & 0/L DAMPER ID FAN-A INLET GATE ID FAN-A OUTLET GATE ID FAN-A REGULATING GUIDE VANES(IG-V) REMOTE '
ON

bearing oil coolers are charged from water

NOT HI

IN SER v CHARGED . / OFF OPEN CLOSED CLOSED MINIMUM

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

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O O ^ PROCEDURE FOR STARTING ID FAN-A IN GROUP SEQUENCE Put ID FAN-A GROUP SEQUENCE on auto mode.

Observe on DAS, group sequence programme(missing criteria) Make "ON1 ID FAN-A group sequence. STEP INDICATOR will indicate step numberv zero to seven _ . . GROUP SEQUENCE to start ID FAN-A in

one after the other. Observe following operations on desk. Seal air blower will be "ON1.

OUTLET DAMPER GD-7B & inlet damper GD-5B will close on interlock (if the dampers are not closed). GD-6B position will come to minimum (if position is not

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minimum).

ID FAN-A will start.

No load current of ID FAN-A will show 40 amps. GD-7A and GD-5A will open after time delay of 45 seconds.

PROCEDURE FOR STARTING ID FAN-A ON MANUAL Ensure that1 all start permissives of ID fAN-A are satisfied.

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Ensure that bearing coolers of ID fan are charced from water side. Keep ID FAN-A GROUP SEQUENCE on manual mode and start seal air blower. Open and GD-7B closes on interlock. Start DAMPERS ID FAN-AGD-5B motor. GD- 6B position will come to minimum. Open GD-5A and GD-7A manually from the desk CWA-11 and load the fan by GD-6A IGV.

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C-12

STARTING OF FD FAN-A

' > ' or in group sequence.

FD Fan-A can be started manually

Ensure that following valves are open for starting LOPS of FD Fan-A. 1. Suction valve FDL - 0A01 of LOP-A (FD fan-A) open. 2. Discharge valve FDL-0A02 of LOP-A (FD Fan-A) open. 3. LOP-A (FD Fan-A) cooler water valves are open.

4. LOP-A (FD fan-A) filter-1 is in service. 5. Suction valve FDL-OAO4 of LOP-B (FD fan-A) open. 6. Discharge valve FDL-OAO5 of LOP-B (FD Fan-A) open. 7. Cooling water valves of LOP-S are open. Start LOP-A and adjust recirculation valve FDL-0A07 (RFAGO2) for 8 kg per sq.cm2 control oil pressure and valve FDL-O12 for proper bearing lub.oil pressure. Both indications of lub oil pressure low and control oil

pressure low will reset onJTWA-11 desk. Observe lub.oil pressure and temperature of bearings of FD Fan-A on DAS CRT.
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AUTO PICK UP TRIAL

OF LOPS OF FD FAN-A

Select PUMP-A for FD FAN-A.. Put sub group sequence of LOPS of FD FAN-A on auto and make it "ON'. Selected pump-A will pick up. Stop LOP-A, LOP-B will pick-up on interlock. Stop LOP-B, LOP-A will pick-up on interlock. FD Fan-A lub oil pressure low and'control oil

pressure low indications reset.

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-START PERMISSIVES FOR FD FAN -A - Start permissives of FD Fan-A can be observed on DAS CRT FDF-A FAN/ MOTOR TEMP.BEARING TEMPERATURE FDF-A Circuit Breaker FDF-A BREAKER SPRING FDF-A FDF-A S/S POSITION IDF-A or B ON & FDF-A SELECTED FDF-A DISCHARGE DAMPER FDF-A VANES LUB OIL PUMP-A or B CTRL OIL PRESSURE . NOTHI INSERVICE' CHARGED OFF REMOTE AVAILABLE CLOSED MIN POSITION .ON >8 kg per sq. cm

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z. STARTING PROCEDURE OF FD FAN-A IN GROUP SEQUENCE Put FD. FAN-A GROUP SEQUENCE on auto mode. Ensure LOP sub group sequence on auto & PUMP-A is selected Press"ON'push button of FD FAN-A GROUP SEQUENCE to start FD FAN-A in group sequence. STEP INDICATOR indicates step number zero to seven one

after the other. Selected LO pump-A will pick up. FD fan-A motor will start FD FAN-A ammeter will show no load DISCHARGE DAMPER SAD-2A will open. DISCHARGE DAMPER SAD-2B will close on interlock. current of 20 amps.

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SAD-1A will get enable to open command. SAD-IB POSITION will come to zero position. Scanner Air Fan atmospheric suction damper SCAD-1 will close on interlock .

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PROCEDURE TO START FD FAN-A ON MANUAL MODE Ensure that all the permissives are satisfied and FDF-A group sequence is on manual. Ensure that SAD-iA is closed and minimum. Discharge damper SAD-2A is closed and LOP sub group

sequence is on auto and "ON1. Selected pump-A will pick-up. Start FD Fan-A motor manually. FD FAN-A ammeter will show no load current of 2 0 amps.

DISCHARGE DAMPER SAD-2B will close if it is open. Open DISCHARGE DAMPER SAD-2A. Load the fan by opening regulating damper SAD-IA

(Blade pitch control). C-13 TO PUT FURNACE PRESSURE CONTROL ON AUTO Adopt following procedure to put furnace pressure

control on auto. Bring furnace pressure set point to -10mm we.

FURNACE PRESSURE SET will indicate -10 mm we. Open DAMPER GD-6A until actual FURNACE PRESSURE comes to -10 mm we. Observe the furnace pressure on recorder (furnace Pressure narrow range and wide range on back pannel).

Press middle push button of DAMPER GD-6A to keep it on auto,if the deviation between set and actual valve is zero.

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KSTAP.LTSHTMC;

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TO

1.0%

A I R FLOW

Open DAML'Kk MAD-IA till actual total air flow comes to 2130 . T/hr on TOTAL AIR FLOW ACT meter (30% to 40% air flow) . ^AIR FLOW LOW TRIP'alarm will reset.

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^ TOTAL AIR FLOW ACT indicator will show 250 T/hr. ID FAN guide vanes GD-6A furnace draft.
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will open accordingly to adjust

/C-15

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CHARGING OF PRDS FROM OTHER UNIT Ensure that PRDS header drains are open.

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Open slowly

the interconnecting valve locally between

other PRDS and charge the PRDS header. Observe that PRDS pressure comes to 12 kg sq.cm and temperature 200 deg.C on CWA-13 pannel close PRDS header drain valves.

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- CHARGING OF SCAPH (STEAM COIL AIR PRE-HEATER) Ensure that the drain valve of SCAPH are open. Open auxiliary steam valve AS-320 , AS-325, AS-3.26 of

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SCAPH locally. Open steam valve AS-323 from CWA-15 pannel. raising. V

Secondary Air temperature will start Observe air temperature in DAS CRT. STARTING AC SCANNER FAN

Ensure that DC Scanner Fan-B is running. /atmospheric suction damper is open, if FD fan is off and it v/ill close when FD fan is started.

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Start AC scanner Fan-A, observe discharge pressure and furnace to scanner DP on CWA-11 pannel. Observe parameters on DAS. Stop DC Scanner Fan-B. Take auto pick-up trial by stopping Fan-A , DC Fan-B will pick-up and vice-versa. _-18 - STARTING LDO PUMPS AND CHARGING LDQ SYSTEM f-^'7 'f

Ensure that the following valves are in open condition before starting LDO pumps. These valves are to be operated locally in oil handling plant. Valve LOV-l before filter-1, Valve LOV-2 after filter-1, Valve LOV-7 suction of Pump-1, Valve LOV-8 discharge of Pump-I, Valve LOV-3 before filter-2, Valve LOV-4 after filter-2, Valve LOV-9 suction of pump -2, Valve LOV-10 discharge of pump-2, Valve LOV-5 before filter-3, Valve LCV-S after filter-3, Valve LOV-11 suction of pump-3,Valve LOV-12 discharge of pump-3. Open slightly LDO pressure control valve LO-11 (20%)-.
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Set LO pressure to 06 kg/cm2 in LO pressure set indicator. Start LDO Pump-1 from oil handling plant( RFFS 07)locally. LO pressure gradually increases and maintain it to 6 kg/cm2 by LO-11 valves. If the deviation between set pressure and actual pressure is zero, put LO-11 on auto. Select LO from HO/LO SELECTION. Open locally AT-20 atomising Air valve (RFFS12). Bar indicator shows atomising air pressure of 7 to 8

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

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r. !CJ PURGING OF MO! \ ,\-\li insure L I 1 . . 1 L . I he bulbs oJ. Llie iol lowing puryc permissivo.s are glowing. LO TRIP VALVE CLOSED, HO TRIP VALVE CLOSED, ALL LO NVS CLOSED, TRIP, ALL HO NVS CLOSED, ALL PA FANS OFF, NO BOILER ALL HOT AIR GATES CLOSED, ALL

ALL FEEDERS OFF,

SCANNERS SHOW NO FLAME. Ensure that "READY1 and "START' lamp of PURGE CYCLE is glowing. Press the push button of PURGE CYCLE to start the PURGE. "Purging' lamp will glow, Wait till 5 minutes.

"PURGE OVER1 bulb of PURGE CYCLE will come. Boiler MFR will reset and secondary air dampers will close on auto. Ensure that Burner tilt is kept horizontal (50% position). C-20 - TO PUT FURNACE/WIND BOX DP CONTROL DAMPERS ON AUTO Following operation may be made to put furnace / wind box DP control on auto. Turn PROG SELECTION switch to position-1 or 2.

Set the FURN/WB DP SET at (40) mmwc. Bring auxiliary air dampers on elevations AB,BC,CD,DE,EF and FF to 40% by pressing lower push button and put all

dampers on auto. Put master DP control station on auto to maintain DP as per set point. Furnace to W/B DP will show 40 mm on recorder on CWA-11 panne1.

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C-21

LIGHTUP OF BOILER WITH AB ELEVATION PAIR 1-3 OR 2^_ WITH LDO

Ensure that LO is selected and all oil closed. /;'v'

Nozzle Valves are

Open LO TRIP VALVE- LO-19.Insert furnace temperature probe Press "START' push button of AB elevation pair 1-3 or 2-4. "START 1 bulb will blink slowly. HEA IGNITORS correspondwill advance.

ing to pair 1-3 or 2-4 of elevation AB

LIGHT OIL NOZZLE VALVES of 1-3 or 2-4 pair will open. DISC SCANNER red lamp will show presence of flame. HEA IGNITORS will be get retracted.

START bulb of AB elevation pair 1-3 or 2-4 becomes steady. Boiler is lighted with AB elevation pair 1-3 or 2-4 oil guns with LDO. After every 1/2 hour change over of oil gun pairs may be made for uniform heating of furnace. Flue gas temperature v/ill start raising gradually and drum metal temperature increases. Change over of oil guns is made till drum metal temperaincreas-

ture reaches 100 deg.C. drum pressure will start ing after 100 deg.C. drum metal temperature.

When drum metal temperature is greater than 100 deg.C., keep both pairs of A3 elevation oil guns in service. If the flue gas temperature at furnace outlet is greater probe will come out to control the

than 540 deg.C., furnace ;J4'

C'

temperature firing

automatically. Then

adjust

rate

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flue gas temperature at furnace outlet.

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C:22

- DEAIjiUA'l.'OR IIKATING AN1J

PUGGING

' ' :. ' ' L . ' '' -

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Open doaorator vent valve SM-18 from CWA--15 desk. Open auxi.li.ary steam supply valve AS-365. Open FST heat i nq valve? AS-370. ^e^jZ**^?*1^*' "^

(Q) 0 0 ty 0 0> O <Q G

Temperature of feed

water will start raising .

When feed water temperature reaches 100 deg.C.stop heating Close vent valve SM-18. Close valve AS-370. Open CR-306 to supply deaerator pegging steam. Adjust deaerator pressure Put CR-306 set value. Deaerator pressure will start raising gradually. MANUAL BFP START-UP Check that following points are fulfilled. set point to 3.5 kg/cm2. per

on auto to maintain deaerator pressure as

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O / C-23 STARTING HFO PUMP AND HFO HEATING f 'r
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Ensure that following valves are open locally. ^ O ^ " ^ ' O 0 v> ^
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Suction filter valves HOV-1, HOV-3. HFO Pump suction valves HOV-2,HOV-4. HFO pumps discharge valves HOV-5,HOV-6. Steam HOV-26, coil heaters isolating valves HOV-25, HOV-27, HOV-21,

HOV-28,, HFO Filters isolating valves

HOV-22, HOV-23, HOV-24. Ensure that recirculation valve ' '

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

HO-'35 is open.

Open HO Trip valve HO-29. Start HFO Pump-A. Open Auxiliary steam valve HOV-50 for HFO heating. 17

Temperature of HFO will start raising 120 deq.C. after 1 hour.

and reaches about

13

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C-21

fri'AiriTNC; OK TUK'BINR TilJR.OII, SYS'l'KM E n s u r e t h a t MOT l e v e l is n o r m a l . S e l e c t C o o l e r N o . 1 .

Cruirqi.: i,.'oo.l <.,: r No. .1.
v,iivc;i GSW

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from w a t e r

s i d e ; by l o c a l l y o p e n i n g

I1. < : GSW-17.

Start

oil vapour extractor Fan-1 from CWA-16 desk.

Start Auxiliary oil pump-1. Ammeter of AOP-1 will show 110 amps. \ y AOP discharge pressure will show 7.5 kg/cm2 (DAS) . \ Oil pressure before oil cooler will show 5.4 kg/cm2 (DAS) . .

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Oil pressure after oil cooler will show 4.8 kg/cm2 on back pannel. Lub.oil header pressure will show 3.7 kg/cm2.

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- AUTO START TRIAL OF TURBINE AOP-2 Make SLC AUX OIL PUMP-2"ON'. Ensure SLC AOP-1 is "OFF1. Trip AUX OIL PUMP-1 . AOP-2 will pick up at lub.oil

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'

discharge AOP-2

pressure of 4.6 kg/cm2.

1 E n s u r e t h a t take SLC auto A u x i lstart i a r y o trial i l pump-1 is "ON SLC Similarly of AOP-1 by and making

auxiliary oil Pump-2 is "OFF1 .

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AUTO PICKUP TRIAL OF TURBINE EOP(Emergency OIL PUMP) "OFF1. Trip AUX OIL PUMP-1.

Ensure SLC AOP-1 and AOP-2 are , . ..

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Make SLC EMERGENCY OIL PUMP "ON1.

AOP discharge pressure will drop below 4.5 kg/cm2 . Emergency oil pump will pick up when discharge pressure drops below 1.3 kg/cm2.

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EOP ammeter will show 40 amps on CWA-16 desk. Make SLC of AOP-1 and AOP-2 "ON" Start AOP-1 and then trip EOP manually.

Make SLC lub.oil temperature control "ON' to maintain lub.oil temperature to 44 deg.C on auto from C-25 TAKING GENERATOR SEAL OI_L SYSTEM IN SERVICE CWA-16 desk.

Check following before charging generator seal oil .system 1. Tank levels IOT, SOT and SOST are normal. 2. AOP-1 is running.
: 3. Start seal o . . .1 : : ; : n k vacuum pump from CWA-.I7 desk.

Seal oil tank is under vacuum of 200 mm. i . Generator seal o . i ] cooler-A is in service -CHARGING GEN.SEAL OIL SYSTEM ES-1 Through Local operation, close oil cooler bypass valve V-63 . ES-2 (RFEG06).

Through Local operation, close inlet valve to turbine oil tank, valve V-18 (RFEG07).

ES-3

Through Local operation, close DPRV -E (RFEG0 8) .

bypass

valve V-I7 of:

ES-4

Through local opera;:, ion, select seal oil cooler-A (RFEG.13) and its inlet outlet cooling water valves are open.

ES-5

Through local oporai: .ion, close generator seal oil cooler '.' outlet valve GSW-35 (RFEG03;.

LS-G

Through local operation, seJect seal oil filter No. . ' I (RFHG09).

O 0 ff ^ ^ ES-10 ES-8 ES-9 ES-7

- ESTABLISHING GENERATOR SEAL OIIi : SYSTEM Keep g e n e r a t o r s e a l o i l pumps A a n d B on manual mode. Select D.C. SOP on manual. Press"ON'push button of GENERATOR SEAL OIL PUMP-A - TAKING TffTAT.S OF AUTO PICK-UP OF S.O,P.s Select position-1 of A/M selector/;:switch of
I I [ I

REF TAG CWA-17

A.C. SOP to keep Pump-A on manual", ;&. pump-B on auto.' ES-11 . Press "OFF1 push button of S.O:-P.A^ Check that SOP-B
O ' i
'^'
n

. w i l l p i c k up on a u t o . """
G

-.;,../;:;..-'.:.._

. "

E S - 1 2 " S e l e c t p o s i t i o n - 3 of A / M - s e l e c t b i p ^ W i t c h of A . C . S . O . P
.-:;::: " ' : ^ ^ ^ : \ -

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

o .:."%::>

o o o

ES-13 ..Press "OFF1 push button of S.OiLP-rB^ Check that SOP-A " y '?; : :W: will pick up on auto. ; . : . ' . : . "V . ' ES-14 Select D.C. S.O.P A/M selector ^switch position on auto." ES-15 Select position-2 of A/M selector switch of A.C. S.O.P " to keep both pumps on "manual1.-

O
^ f^ Q Q Q 0
: ' " >

ES-16

Press "OFF1 push button of S.O.P.B (running S.O.P). Check that D.C. S.O.P. pick up on auto.

"

ES-17
ES-15

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

Select. 7).?.. B.C.?. selector switch position

ES-18

Select position-1 of A/M selector switch of

Manual

"

A.C.S.O.P". & t : r i p 0 . ; . S.O.P.

21

C-26

CHARGING GENERATOR WITH HYDROGEN Ensure that carbon dioxide is filled in generator Casing.

EH-1

Through Local Operation open Hydrogen feeding inlet valve H-34 and vent valve.

EH-2

When Hydrogen pressure reaches 3.5 kg/cm2, through local operation close hydrogen feeding inlet valve H-34. Che"ck purity of hydrogen > 98% on the back pannel CWF--04. Close Hydrogen vent valve.

C-27

TO PUT TURBINE ON TURNING GEAR Ensure to keep SLC JACK OIL PUMP^-1 in "OFF1 mode. Start JOP-1. Ammeter of JOP-1 will show 50 amps. JOP header pressure will show 120 kg/cm2. Jacking oil pressure low indication Take auto-pick-up trial of JOP-2. Make SLC JACK OIL PUMP-2 "ON1 and Trip JOP-1. resets.

JOP header pressure drops from 120 kgs/cm2 . JOP pressure low indication comes at < 100 kg/cm2. JOP-2 v/ill pick up when JOP header pressure is less than 100 kg/cm2'. Ammeter of JOP-2 willtshow 50 amps. JOP header pressure will show 120 kgs/cm2. . JOP pressure low indication resets. Similarly JOP-1 auto pick-up trial can be taken. Make' SLC JOP-1 and JOP-2 on "ON1 . Press "ON1 push button of GATE VALVE GEARING to open it.

22

^ ^ g%

Turbine 120 rpm. Make

speed

will

increase slowly

and

will

come

to

SLC TURNING GEAR "ON'. oil system can be taken in service by putting

O
^ d> |J 0 f*i |j) Q rj 0 3& Q 0 O f3 O O 'O Q O O Q O C-28

Complete

SGC oil on auto. STARTING OF CEP-A OR B AND CHARGING CONDENSATE CYCLE Before starting any CEP check following Condensate pump-A discharge Condensate pump-B discharge valve closed. valve closed. are in open condition: , ,

Ensure that the following valves

1./u CS-1, CS-2, CD-18, CD-20, CD-22, CD-24 and C D - 3 5 i W - = i w CST level normal.1"" DM tank level normal. DM-32 and DM-35 make-up valves are on manual and t h e i r i s o l a t i n g ..valves a r e op"en. . , , . . . . . . ~ <,.-?. "'>7f~ GSW-28, GSW-30, GSW-29 & GSW-31 are open (Bearing cooler valves) . ' ,..''' :

Following local operations are to be performedOpen main ejector-A & B inlet and outlet valves CD-5,CD-6, -CD-7 and CD-8. Close GSC bypass valve CD-12. Open CD-'lO and CD-11.

Close main ejector by pass valve CD-9. Open isolating valves CD-13 & CD-15 of CD-14 hot well level control valve. , > \ \ ,

- Put SLC COND pumps ^ON' and open valve CD-19 to 2 0%. Open VALVE DM-32 to fill hotwell till level reaches

8 50 mm.

23

Select condensate Pump-A Press ^ON1 push button of CONDENSATE PUMP-A to start

condensate pump-A. Discharge Valve-A opens on auto.

Condensate discharge pressure will raise to 24 kg/cm2. Vent valves VA-1 and VA-2 will open on auto and closes after venting (60 seconds). CEP-A ammeter shows 3 0 amps. Open valve CD-19 gradually. Check thrust bearing temperatures < 6 0 deg. C. Close DM-32 when hotwell level is 850 mm. Hot well level is to be maintained normal by DM-32/DM-35, if required. Ensure to .. .

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

to keep CEP-B in standby mode and its discharge valve will open. C-29 CHARGING OF LP HEATERS FROM WATER SIDE Open heater 1,2,3 vent valves before charging and close vent valves after charging. Close CD-27 locally and open CD-25 & CD-26. Close CD-30 locally and open CD-28 & CD-29. Close CD-33 locally and open CD-31 & CD-32. Keep valve CD-23 on manual mode and closed. Open CD-14 manually to 10% and observe that hotwell level is maintained. .

24

O <Q) fj fl li> ^ O O> & "-^ -^ ^ ** *^ * * ^ -p O

C-30

PUT DEAERATOR LEVEL CONTROL ON AUTO By pressing raise push buttons of DEA NWL SET

bring the set point to zero mm we on DEA NWL SET. Press middle push button of VALVE-DM 32 to keep it on auto. Press middle push button of VALVE DM-35 to keep it on auto. 3y pressing raise push buttons of DEA HWL SET bring the

set point to zero mm we on DEA HWL SET(High water level 2600). Press middle push button of VALVE CD-23 to keep it on auto. C-31 PUT HOTWELL LEVEL CONTROL ON AUTO By pressing raise push buttons of HOT 'WELL LEVEL SET bring the hot well level set point to zero mm we.

Press middle push button of VALVE CD-14 to keep it on auto. Press middle push button of CD-19 to keep it on auto. C-32
y

STARTING OF BOILER FEED PUMP-A (FIRST BFP) Before s t a r t i n g BFP-A check following1.Mechanical Seal Cooler of BPF-A is charged from water side.2 . The follcv-.'ir.g valves are to be opened locally

a
^ ^

(Booster pump GSW-39, GSW-40 GSW-41, GSW-42

bearing oil cooler). - Mechanical Seal Cooler.

- Lub.Oii Cooler , . .

O
GSW-44, GSW-45 GSW-46, GSW-47 - Working oil cooler - Radiator cooler f,oM 25
!

3.Hydraulic c o u p l i n g oil level is n o r m a l . 4.Minimum r e c i r c u l a t i o n v a l v e F C - 3 0 2 5 . D e a e r a t o r level is n o r m a l . is open initially.

r

Open locally BFP-A bearing & stuffing box cooler valve X GSW-4 0. Open locally BFP-A working oil cooler valve GSW-45. Open locally suction valve FS-301, FS-302, FS-303 of BFP-A,B,C. BFP "A1 AOP is running on interlock. PERMISSIVES OF BFP-A. BFP-A Circuit breaker Breaker spring Deaerator level BFP-A Suction Valve Aux.oil pump Off In service Charged v Normal v* opened ^j 1 ON

p *

C Z '1 :

Lub.oil pr.at HYD.coupl >2.5 kg/cm2 H C-33 STARTING BFP-A Starting of .BFP-A in group sequence. Put discharge valves of BFP-A,B,C Sub-group sequence on auto. Put BFP-A group sequence on auto mode.

. ' :

Put BFP group control on auto. Ensure that BFP B,C AOPs are running and recirculation valves of BFPs are open. Select one pump operation.

^-

26

' v >'

J Make BFP Group Control 'ON1 . ^ BFP-A will start and stay at s t e p - 0 9 / BFP B &. ( . ' w . i ! 1. come to stand by mode: and stays at step-03 Observe various BFP parameters on desk. Select BFP-A from CWA-13 desk. -V f ^'' c v [x r-r,,c'r * W~'

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

DISCHARGE Valve FD-304 MANUAL BFP START-UP Check that Lollowing

will open.

points are iuliillod. jT/ '

... /.'

1. Suction valve open 2 . Recirculation valve open ..

.

**

3. Discharge vlave closed 4. Motor cooling water valve closed C ^ ' ' ' ' O 5. Scofe on manual & in minimum position
Q 0 <0 Q . ' 6 . A O P running . 7. Lub oil & mechanical seal cooler cooling water valves open. PROCEDURE FOR START-UP

O O O O G G O
f

1. Start BFP by pressing "ON' push button 2. Open motor cooling valves 3. After the motor current become normal,open discharge valve 4. Raise the scoop position as required 5. Check that motor, BFP & Hyd. coupling bearing tempera ture are normal

27

C-34

FEED CONTROL STATION IN OPERATION (LOW LOAD LINE) 30% LOAD CONTROL VALVE IN SERVICE Ensure that all spray valves station are closed. Ensure that drain valves of feed lines are open & closed after charging. Press "OP1 push button of LC FCV O/L ISO VALVE FD-325. Press "OP1 push button of LC FCV I/L ISO VALVE FD-324.' Set the drum level at zero mm we and observe that, drum level set point comes to zero mm we. Put ECO I/L ISO VALVE-E2 sub group sequence on auto and make it on. ECO I/L bypass valve will open and then main valve-E2 before feed regulating

will open. C-35

Then bypass valve closes.

CLOSING DRUM VENTS,SUPERHEATER VENTS AND DRAINS AND REHEATER VENTS When drum pressure reaches 3 kg/cm2 close drum vent B-5

superheater vent valves S-21,S-25,S-30,S-40, Superheater drains S-19,S-17,S-15,Reheater vent valves R-l and R-4 can be closed before pulling the condensate vacuum.

<

28

V> '

m
hi

C ^* ^

~36

GIVING BOILER BLOW DOWN Press

AT 10kg/cm2 DRUM PRESSURE V.p . ( \ , y

emergency push buttons to hand trip the boiler.

"Boiler MFR TRIP" annunciation will come MFT-1 & MFT-2 green AB lamp will glow and MFR "RESET1 lamp will vanish. oil guns will withdraw and LOTV and HOTV

elevation

will close.

o
Secondary air and fumace/windbox DP dampers will open

O
full on interlock, ICJO1'.

0
All

purge permissive lamps will glow and "PURGE" ready will glow.

bulb ^

Ensure FD-20 is in closed position < open IBD ISO Valve B-97 .from desk CWA-13. Open IBD ISO Valve B-98 from desk CWA-13 and reduce drum level to -100 mm then close IBD Valve B-97 and B-98. Increase the drum level to normal level by opening

o
G

low load line valve FD-20 and BFP scoop. After drum level is restored to normal put FD-20 on auto. C-37 RELIGHT UP THE BOILER WITH HFO Before light up the boiler start purging of boiler. After 5 minutes purge over signal will come and MFR will reset. Secondary air dampers at
W

o o

6 fuel elevations

will close.

Set air

furnace dampers

to windbox DP to 4 0% and bring all auxiliary to about 40%. Put all dampers on auto and

o
Q
n

then put master DP control station on auto. 29

Close locally

atomising air valve AT-20 and

open locally for AB

interconnecting valves for HFO and atomising steam elevation. Now select HO at AB elevatiton from CWA-11 desk. Set HFO pressure of 6 kg/cm2 and atomising steam of When 8kg/cm2 by actual HO-11 and OS-27 valves.

pressure

pressure

and set pressure is same put HO-11

and OS-27 on auto. Start light Drum pair up the 1-3 and 2-4 oil guns of AB elevation to

boiler. SH temperature

pressure, flue gas temperatures and

will start increasing. C-38 WARMING OF MAIN STEAM LINES

* _ r^~

Before warming up of main steam lines open following drain .valves from CWA-16 desk. Open Open Open Open Open Open Open Open Open Open HR STRAINER DRAIN HR-206. HR STRAINER DRAIN HR-208. LPBP WARM UP LINE ISO HR-311. LPBP WARM UP LINE ISO HR-312. LPBP LINE DR HR-233.

LPBP WARM UP LINE DRAIN HR-234. LPBP LPBP LINE DRAIN HR-230. LINE DRAIN HR-232. HR-214. HR-216.

DRAIN BFR IV SEAT DRAIN BFR IV.SEAT

30

I >

m
o o
Open (M
IDIUVIM

^; r ^ ^ s s v
;

MS.-202.
M.s-212.

^r^

MS5?

o
3FR TCV
:

MS-226. MS-224 . MS-228. CR-206-.

.Ai:\[R DRN

N BFR TCV :RK AFT HPBP

:RN AFT HPBP CR-206. ,,,_,, i ! R -TRAINER DRN HR-206.

kee-o MS stoo valves Grouo sequence en manual . I f i t w ocen : ' . S L VALVE IB MS-301A & 302A.
O '

; : . ' c . v throttle

start-up vent S-33 main steam lines and

m a w steam stop valves'temperature will increase when temperature of ESV body reaches 100 deg.C. . Then 0.9en main steam line.valves MS-301 and MS-302. .
%j . '

Then
.

close

integral
:

bypass. yal.ves MS-301A and MS-302A

1 ' " [ ' ' ' ; ^ t - 1

-;;.'':-'

; - '

"

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

':';'

'

'

''

PULLING AND GLAND SEALING

o o
G

r e h e a t e r vents are closed

before coniensaSje

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

and AS-376 locally.

\^

'

^-

t^y

t^f

*-

^v

*--"*

-~jf

V r f

_^\

%-v.

.-

"

IP

Open AS-373 valve and adjust ejector steam pressure set to 6 kg/cm2. If the deviation between set value and actual value is

zero, put AS-378 valve on auto to maintain ejector steam pressure to 6 kg/cm2. Open starting ejector steam valve AS-2 and air valve SM-16 Wait till vacuum reaches 0.2 kg/cm2.

Open locally AS-368 valve to supply gland seal steam. Put seal steam control on auto from CWA-16 desk. Gland seal steam drain valve MAL-81 closes when gland steam header temperature reaches 150 deg.C. When condenser vacuum reaches beyond 0.7 kg/cm2 take main ejector-A in service by opening its steam valve AS-3 from desk and air valve SM-14 locally.

When condenser vacuum reaches 0.75 kg/cm2 withdraw starting ejector by closing its steam valve and air valve. Condenser pressure high alarm resets at -0.75 kg/cm2 vacuum will increase and reaches 0.95 kg/cm2. Condenser vacuum can be pulled through SGC condensate and evacuation by putting it on auto and make SGC "ON1. C-40 CHARGING OF HP/LP BYPASS SYSTEM Open locally HPBP valve MS-311 .& MS-312 (warm up valves) . Before opening HPBP main valves observe that the upstream and down stream temperature differential is not more than 25 deg.C.

32

o o o
0

Put

1 LPBP control on ciuLc; a r / . : make LPBP automatic

control interface ""ON1 . Set HPBP down steam temp, BPE-1 to 230 deg.C and open valves

and BPE-2 by opening it by 5% to 10%. MS-311 and MS-312 locally. increase main steam

Close HPBP warm up valves Open HPP-P valves

gradually :o

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

When MS oressure reaches point to 35 kg/cm2 and

3 5 kg/cm2 set HPBP pressure set put the valves on auto.

o
G

Close start up vent valves S-33 and S-32. In order to raise the steam parameters of 35 kg/cm2, 3 50 deg.C and 9 5 T/hr steam required for rolling the

o
^

C-41

turbine, take CD and EF oil elevations in service. CHARGING OF PRDS OF OWN UNIT Ensure that the following valves are in open condition: AS-306, AS-309, AS-310, FD-34 0 and FD-339 (PRDS. valves) . Open isolating valve FD-332 locally. Ensure that PRDS-1 and PRDS-2 both pressure and temperature control are on manual. Ensure to open first the spray control valve and then pressure control valve .
'

o o
^
O

Press raise
U

push button of TEMPERATURE SET till indicator

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

'w' ^>

Press middle push it on auto.

button of PRDSE-1 (FD-343) to keep

PRDS-1 TEMPERATURE ACT v/ill show

2 00 deg. C.

Adjust PRDS pressure set point at 12 kg/cm2. Open PRDS-1 isolating valve AS-307. Press middle push on auto. PRDS PRESSURE ACT will show 12 kg/cm2 on CWA-13 desk. button of PRDS-1 (AS-308) to keep it

Gradually close auxiliary steam interconnecting valve AS-500 C-42 from local.

CHARGING OF STATOR WATER SYSTEM Ensure, that expansion tank ejector is in service.

Stator water cooler inlet valves GSW-10 and GSW-11 are open locally. Close expansion tank drain valve Y-19 locally. Check the following valves are open: Y-l, Y-2, Y-3, Y-6, Y-7, Y-18, Y-6.2 and Y-21 Expansion Tank level is normal.
z

OPERATIONS IN STATOR WATER CIRCUIT

SW-1

Through local operation open stator water cooler-A outlet valve GSW-12.

SW-2

Through local operation close stator water cooler-B outlet valve GSW-13.

SW-3

Through local operation close water cooler bypass valve Y-B.

SW-4

Through local operation select stator water cooler-A.

34

f) fji 9

SW-5

Through local operation open the inlet valve Y-23 to polishing unit.. . .-

SW-6 .

Through local operation close the stator water bypass operation valve Y-17.

SW-7 ':

Turn the selector, switch of GENERATOR CW PUMP A/M S/S to

: ..position number-2 to make generator CW pumps A & B manual. Press "ON'push button of GENERATOR STATOR CW PUMP-A'. Through local operation adjust valve Y-17 till stator water recorder shows 27 cubic meters per hour flow .

SW-8 SW-9 i

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

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

^ ^

SW-11

Press -OFF' push button of GENERATOR STATOR CW PUMP-A. Check that GEN STATOR CW PUMP-B will pick up on auto.

SW-12

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

G
position number-3 to make generator CW pump-A on auto. ^ .SW-13-.\ Press -OFF1 push button of GENERATOR STATOR CW PUMP-B.

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

o o
^_ w

SW-14

Turn the selector switch of GENERATOR CW PUMP-A/M S/S to position number-1 to make generator CW pump-B on auto.

C-43

ROLLING OF TURBINE

,
Before rolling the turbine ensure that all the parameters listed below are built up to. the values as indicated below. Main steam pressure 35 kg./cm2.'
Main steam ;::en\peratur e around 3 5 0 Deg . C . ' Main steam f,lcw about 96. T / h r . .PA
35

o
o
^

Press "0Nr push button of LOAD CONTROL from CWA-16 desk. Press "ON'push button of LOAD Gradient. Raise LOAD REF till indicator on LOAD REF shows 20 MW. Observe that the bulbs of following indications are glowing: CR/H NRV LHS CLOSED. CR/H NRV RHS CLOSED. HP STOP VALVE-1 CLOSED. HP STOP VALVE-2 CLOSED. INTERCEPTOR INTERCEPTOR VALVE-1 CLOSED. VALVE-2 CLOSED. of KP/IP TRIM DEVICE.

Press "GM: push button Ensure that

tracking device i ' s "OFF1 .

Ensure co keep following SLCs are in "ON' postion: SLC AUXILIARY OIL PUMP-1 SLC AUXILIARY OIL PUMP-2 SLC EMERGENCY OIL PUMP SLC JACKING OIL PUMP-1 SLC'JACKING OIL PUMP-2 SLC TURNING GEAR SLC CONDENSATE PUMPS SLC LP WATER INJECTION v " " SLC DRAINS . L / of SGC OIL SUPPLY

Press middle push button to keep it on auto.

36

O <"

/'

Observe that red light is glowing on TTS SUPPLY-1 and TTS SUPPLY-2. Observe that TSE upper margin shows 3 0 Deg. C.

Observe that EHC position shows zero. ^ Bring STARTING DEVICE position to zero. Raise SPEEDER GEAR till indicator of SPEEDER GEAR

o'

shows 100%. Set LOAD LIMIT at 50 MW. Set LOAD GRADIENT at 20

o o

o o
o

Ensure that STOP REF LIMITER light is ^OFF1. ^

Ensure that GATE Valves V-l and V-2 are open. Ensure that SPD/PWR SET Point Blocked light is "ON1. Make SYNCHRONISER "OFF1. ^ Ensure that TURBINE TRIPPED indication is persisting. A Put M.S. pressure Before controller on limit pressure mode. the- fulfilment

proceeding to next step ensure

of temperature criterias for opening the ESV and ISV as per CURVE Number X-l, X-2, X-3, X-4 and X-5 on CRT.

Select TSE on admission mode PB (ADM). Raise STARTING DEVICE till its indication comes to 42%.

on STARTING DEVICE POSITION to open HP stop valves (ESVS). ^ Before starting device is raised to 56%, wait till the

temperatures of the following valves increases gradually and stabilize.

c^

The temperature of these valves should

raise

gradually.

Q Q
w

37

Warmup can be concluded when VALVE NUMBER

the temperatures stablises

POIONT NUMBER IN WALL STRESS RECORDER f) \c ? 3 4 5 6 3

ViMSVMS VMSVMS ViMCVMC VMCVMC ViMSVMS

Raise

STARTING DEVICE till its indicator

T,

H -^

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

Make "ON 1 TRACKING DEVICE. Raise SPEED REF till reference RPM shows 600 to increase

the turbine speed to 600 rpm. Observe GATE VALVE gearing indicates barring gear disengaged at 240 rpm.(Gate valve gearing c l o s e s ) . Observe bearing vibrations are < 35 microns. JOP-1 trips at turbine speed of 54 0 rpm. Observe the bearing vibrations C-44 and shaft vibrations.

TURBINE TRIP SOLENOID TESTING / 1 ' n -A#-'W To check healthiness of Turbine trip solenoid press push button of TURBINE TRIP to trip turbine manually.

"TURBINE TRIP" annunciation

will come.

HP stop valves and IP stop valves will close.

0 0 0> ^ C-45

JOP-1 will pickup on auto when turbine speed is at 510 rpm Bring STARTING DEVICE to zero position to reset

turbine trip indication . REROLL THE TURBINE TO 6C> RPM AND SOAKING OF TURBINE Follow the same procedure given in step-43 to reroll

o
the turbine to 60 0 rpm. Soak the turbine for about one hour to satisfy X-6 '' criteria (HP shaft mid metal temperature) . following MAL valves will close. drain MAL-15.

Observe that

O
Down stream of HPCV

O
^
c

Down stream of HPCV drain MAL-16. Drain ahead of swing check NRV MAL-65.

O
Drain ahead of swing check NRV MAL-66. Drain before IPCV
w w

MAL-31. Drain before IPCV MAL-26.

MAL-32.

Drain before IV Drain before IV

MAL-27.

o
o

Observe the turbovisory parameters. Turbine bearing vibrations < 12 microns. Turbine shaft vibrations at HPT,IPT,LPT <120 microns. Bearing metal temperature < 90 Deg.C < 60 Deg.C

Bearing drain oil temperature HPT top/bottorn temperature

160/150 Deg.C 270 2 00 90 Deg.C Deg.C Deg.C

o o
O

. Inlet HP casing temperature HPT exhaust temperature

39 IPT top/bottom temperature

Observe that the criteria X-6 is satisfied.

C-46

INCREASING TURBINE SPEED TO 3000 RPM Press raise button shows 3 000 rpm. Turbine rpm at speed the will gradually increases to 3000 of SPEED REFERENCE till indicator

rate

of 60 0

rpm/min. turbine bearing vibrations

Observe at critical speeds,

will go high and will normalize after passing through critical speeds. ! '. ' c A (. I ' " >' ' " ' o -^ , , When I ' r secondary oil pressure reaches 3.0 Kg /Cm2,

hydraulically operated extraction swing check valves

\ , , " ' ' " ' " (except A-4) open. N ^J"'""\ v AOP-1 will trip at about 2800 rpm. 9.5 kg/cm2. cooler will show

i^ '^MOP discharge pressure will be Turbine lub oil

pressure after

5.5 kg/cm2. When'-turbine speed reaches opening reduces. C-47 SOAKING. OF TURBINE AT 3000 RPM TO SATISFY X-7 CRITERIA At 3000 rpm turbine is to be soaked for about half an hour till X-7 criteria is satisfied (IP shaft mid metal temperature). Observe Following Parameters: HPT differential expansion IPT differential expansion LPT differential expansion HPT overall expansion -4.0 to +5.5mm -3.2 to +7.2mm -7.0 to 30.0mm < 2 6mm 3000 rpm observe HP/LP bypass/

40

IPT overall expansion Axial shift Turbine bearing

< 13mm -1.0 tomm +1.0mm

^ ^ <Q <Q f>\ r*\ .

vibrations 12 microns 44 Deg C

Turbine lub oil Temperature

Turbine shaft vibrations at HPT,IPT,LPT < 120 microns. Turbine can also be rolled through ATRS provided all release conditions are satisfied. Put SGC turbine on auto and make it "ON1 . ATRS programme will run and follow various steps in sequence (refer ATRS logic) . C-48 .... LINE UP FOR SYNCHRONISATION OF GENERATOR WITH GRID SY-1 Select the bus to which Generator is to connected and through local ' be

o
Q Q 0 Q Q

ly, O,

operation close

isolator (Grid side) 29-AE or 29-BE (REFD-01).

SY-2 Through local operation close isolator 29-AE (GT side) (REFD-04). Ensure that"Field breaker circuit healthy1 CWA17

0
O

indication is available.
.'

SY-3 Select"REMj selection for Exciation Control

o
u

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

41

MANUAL SYNCHRONISATION OF GENERATOR CWA17 r[ -n^-

SY-6

Ensure that "Gen. ckt. Bkr. spring charged1 indication is available.

SY-7

Select "check'position of "Syn SS-1 for main breaker1 key switch.

CWA17

:ftfr*
(&> SY-8 a^ " CWA17 Adjust raise/low push button of auto balance so that running voltage & incoming .voltage are equal. SY-9 Insert key in "synchroscope SS' & turn it to position-2 to make it "ON1. Check that "Bright " ,,

/} ^ V
A *
^
3

, **"
r K

3 ' " ' ' '""

'

On Syn. 'LED lits up.

i\

SY-10

Adjust "Speed

Reference1 so that synchroscope

CWA16

needle takes a slow, clockwise rotation. SY-11 When synchroscope needle posititon is 12 O'clock and check syn. relay operated "LED lits up 1 , Close main CB control switch 52-E.. SY-12 SY-13 Adjust speed reference to pick 10-15 MW Load. CWA16 CWA17 CWA17

Turn the "Synchroscope SS' to position "I 1 to make it "OFF' ..

SY-14

Turn key in "Syn SS-1 of Main Bkr'to position"2'(OFF) ^ AUTO SYNCHRONISATION OF GENERATOR AFTER STEP SY-5

"

SY-6A

Insert key in

"Syn SS-1 for main breaker1 and turn

"

it to position "3' to select "Auto1. SY-7A SY-8A Press "ON' push button of synchroniser. Check main breaker gets closed,& 10-15 MW load is picked up. CWA16

42

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

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

CWA17

"^

SY-10A Turn key in "Syn SS-1 for main breaker' to position S 2 ' (OFF).

o
o.
C-49
<5

After Synchronisation check that GTR Wdg.temp.is normal / & GTR cooling pump has started. OBSERVE IMPORTANT PARAMETERS OF TURBO GENERATOR AFTER SYNCHRONISATION

o
O

(Range of various parameters) GTR HV temperature GTR LV temperature GTR Oil temperature < 90 Deg.C < 90 Deg.C < 90 Deg.C < 30 Deg.C < 30 Deg.C < 30 Deg.C 0.9 Kg/Cm2 32 0 - 3 50 320 - 350 280 -300 230 - 250 MAL drains on auto after

o 4> ^
O ' A \) -A
G V
i

HPT middle top/bottom temp, difference IPT front top/bottom temp, difference IPT rear top/bottom temp, difference Condenser vacuum ESV body temperature ISV body temperature HP casing mid metal temp. \^ AIV , '' \i
c

fU

r\

(,\

\0 , \
*

CRH temperature ' p> Ensure y . n * . t closing of all

synchronization. HPT differential expansion -2.00 to +5 mm

^M v ^ ; > X J ' \ ^ 'V , i ' :

IPT differential expansion -2.0 to + 5.5mm LPT. differential expansion -7.0 to 25.0 mm HP overall expansion IP overall expansion 26 13 mm mm

43

Axial shift

-1.0 to +1.0 mm microns microns

Turbine bearing vibrations < 12 Turbine shaft vibrations at HPT,IPT,LPT TSE margins (Load margins) >3 0 Turbine lub oil temperature 44 < 120

K Deg.c

Note that all differential expansions should move towards positive side. Bearing metal temperature Bearing drain oil temp. HPT top/bottom temp Inlet HP casing temp . HPT exhaust temp. < < 90 90 < 65 160/150 270 200 90 20 minimum < 75 < 75 45 Deg .C Deg .C Deg .C Deg .C Deg .C Deg .C Deg .C Deg .C Deg .C %

IPT top/bottom temp. HPCV position(approx).

IPCV position Generator slot temp. Generator core temp. LPT exhaust temp. C-50

CLOSING OF VARIOUS TURBINE SIDE DRAINS Following after turbine side drain valves are to be closed

synchronization/

Close valves from CWA-16 deskHR-206, HR-208, HR-311, HR-312, HR-233, HR-234, HR-230, HR-232, HR-214, HR-216, MS-204, MS-214, MS-202, MS-212, MS-222, MS-226, MS-224, MS-228, CR-206, CR-208.

44

C-51 1.

CHARGING OF HYDROGEN COOLING SYSTEM Hydrogen coolers outlet valves GSW-24, GSW-25

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

2.

Hydrogen cooler-A outlet

valve GSW-20 is open.

o o
0
^ "^ "^ ^

H-1 H-2 H-3

Open hydrogen cooler-B inlet valve GSW-2(RFCW09)locally. Open hydrogen cooler-C inlet valve GSW-22(RFCW-10)locally. Open hydrogen cooler-D inlet valve GSW-23(RFCW-11)locally. Open locally GSW-500 generator transformer cooler(RFCW006) Ensure that generator HT and LT winding temperature are within limits. Ensure that station transfomer within limit. winding temperature is

GT-1

C-52

WITHDRAWAL OF STEAM TO SCAPH When flue gas outlet temperature is greater than

^ O ^ C-53 ' " * '

110-115 d e g . C , close by closing the

auxiliary steam supply to SCAPH CWA-15.

valve AS-323 from desk

TAKING PULVERISER-A IN SERVICE (1st PULVERISER) ' In order to increase the load on turbogenerator coal

o o
O

firing is to be initiated with lower most pulveriser. It is assumed that ESP is in service. Select pulveriser-A manual mode from CWA-12 desk.

Start lub. oil pump-A on desk CWA-12. Ensure that lub.oil cooler is in service.

o
45

STARTING PA FAN-A Start seal air blower of PA FAN-A. Put all the primary air dampers on manual mode.

Cold air damper PAD-4A is full open. Before starting PA fan-A,Open PA fan-A bearing cooler

inlet valve GSW-210 and outlet valve GSW-202 locally. Open PAD-3A cold air gate by 5% locally . Start seal air Fan-A from CWA-11 desk. Check permissives of PA fan-A are satisfied air j bowl DP. except seal

The permissives are SA bowl DP OK NO MFR Trip Pulveriser ignition permit Hot air gate closed. Inlet damper in minimum position. CAD is less than 5% open. Give command to start PA Fan-A. Auto command will be given to close PAD-4A cold air damper to close <5% and seal air valve for mill-A to open.. Seal air DP will build up and seal air bowl DP O.K. and fan ready indication will come. Then PA fan-A will start. Check Fan Current.

Then open pulveriser discharge valve.

0 O 0
^ o .
lP

-STARTING PULVERISER-A Ensure that mill-A is on manual. - Check auto pick up of lub oil pumps. - Trip lub oil pump-1,LOP-2 will pick up and trip

fj .

O
f % f^
^v

'

LOP- 2, LOP-1 will pick up. Check mill bearing temperatures are normal. Check
below:

all pulveriser permissives are satisfied 1. Pulveriser start permit 2. Primary air permit

as

given

O
^
\

It
3 . Lub Buriner open 4. oil gates OK '

open

5. Pulveriser discharge valve 6. Tempering .air valve open

o
O

o ^ o o

7. Bunker gate open 8. Cold air gate open 9. Pulveriser outlet temperature < 94 Deg. C.

o
o
o
w
Ensure
O '

10. Pulveriser ignition permit 11. No auto pulveriser start command 12. Pulveriser OFF'

13. Seal air header/bowl DP OK 14. No pulveriser trip 15. Pulveriser ready that bunker gates CD-1A, CD-2A, CD-3A are open

o o

locally. Ensure Mill-A oil cooler inlet valve

open locally.

GSW-217 and outlet valve GSW-219 open locally.

Ensure

lub.oil pump-1 A & 2A suction and

discharge

^ ^ ^

valves are open locally. Ensure lub.oil pump recirculation valve is open locally lub.oil pressure more than 1.2 kg/cm2.

and adjust

Start pulveriser-A and observe mill current of 20A. Open hot air gate PAD1-A from desk. Set mill coal air temperature(mill outlet temperature) actual mill outlet temperature . maintain actual

.^ r^ /-^ ,, ~
:r>

to 77 deg. C to maintain on auto.

Set PA flow of 55 T/hr on PA flow set to flow, of 55 T/hr on auto. Open PAD-2A , PAD-4A and PAD-5A.

Open the dampers to an such extent that actual mill outlet temperature is 77 deg. C and actual PA flow is 55 T/hr.

'- ^ <~

Put PAD-2A and PAD-4A on auto to maintain mill outlet temp. and put PAD-5A on auto to maintain flow Check the mill current is normal (20A) . Start feeder-A. Check current. After one minute, feeder speed can be increased. Increase boiler the feeder speed slowly steaming rate increase. Steam flow, MS temp, MS of the through.the mill.

r f_ f_ C

will

pressure

will increase slowly. Increase the load on turbine according to M S pressure. Ensure that 02 is about 7-8 % at APH inlet. Put pulveriser-A fuel air dampers on auto. ;' C

48

o o
~

-START UP OF PULVERISER ON AUTO : Coal Mill-A can be started on "Auto mode1 by putting elevation on auto.

O
f^ f% ,..%, f* f^ . r &
if>

Open PA fan discharge valve and give "ON'command to pulveriser. PA Fan-A,Coal mill-A and coal feeder-A will start on auto Hot air gate also opens on auto. Ensure to keep 02 TRIM SET on manual mode. C-54 - TO PUT AIR FLOW CONTROL ON AUTO Raise 02 TRIM SET to raise 02 TRIM SET point to 7%. Increase 02 Trim to increase air flow set on Auto to get SAD-1A of FD fan-A. Control vane deviation zero. Then put SAD-1A - FD fan-A control vane on auto. By adjusting "02 Trim 1 bring 02 deviation zero. Then press middle push button of 02 TRIM it on auto. Air flow will vary to adjust 02 % to 7%. ID fan control vanes will vary to control furnace C-55 LOAD RAISING UPTO 5 _ 0 . MW Increase the feeder-A speed to 60% to 70%. MILL-A FLOW ACT will increase. draft. to keep

r\ *v jl p> o> c--s (--%, Q) O ^ 0 <p; 0 Q Q Q

Main steam pressure and temp, will increase gradually. Feeder-A speed comes to 600 rpm. LOAD REF on CWA-16 upto 50

Press "RAISE1 push button of MW be

for increasing the load to 50 MW. Load raising done keeping in view the TSE margins.

should

49

C-56 CARRY OUT AUXILIARY SUPPLY CHAANGE OVER FROM STATION TOUNTTBUS-1CA Ensure that breakers 1-CA and l-CB are in service and DC control supply is W . AS -1 BTSP-I is 'IN' and selection is on "MAN FAST'. Ensure that Bus transfer system ready for Fast Transfer & Bus transfer system is <W indications are available at BTPS-1. CHANGE OVER TO AUXILIARY SUPPLY BUS 1 CA
1

AS-2

Press the'TEST4 push button on the back panel (BTPS 01). TC BKR CB1 CLOSE test mode' window, TIE BKR CB-2 open 'test mode1 window on FACIA WINDOW FW-1 will glow. Pressthe "IESTRESET BUTTON: All the above indications will disappear "READY FOR TRFR" green lamp will glow.

AS - 3 Pre ss 'READY FOR TRFR% push button. *VC BKR CB-1 CLOSE window, & "TIE BKR CB-2 OPEN' window on FACIA WINDOW FW-1 will glow "READY FOR TRFR" lamp will disappear and will glow again. UNIT BD1CA INCOMER BKR' & "TIE BKR. BET. 1CA & OCA' discrepancy switches will flicker on MCL-1. AS - 4 Turn the 'TRANSFER SELECTOR4 to 'AUTO* mode on BTPS-01. AS - 5 Turn the discrepancy switch of ICA I/C BKR to 'ON' and discrepancy switch of TIE BKR to ICA to 'OFF'. C-57 CARRYING OUR AUXILIARY SUPPLY CHANGE OVER FROM STATION TO UNIT BUS ICB AS - 6 BTSP-2 is 'IN' and selection is on 'MAN FAST'. Ensure that 'Bus transfer system ready for Fast Transfer & Bus Transfer System IN' indications are available or BTSP-2.

a
^ ,f| Q

AS-7

Press the "TEST' push button on the back panels (BTPS-02) "I/C BKR CB1 CLOSE test mode' window, & "TIE BKR CB-2 OPEN test mode'window on FACIA WINDOW FW1 will glow on BTPS-02.

AS-8

Press the "TEST RESET1 button.

All the above

indications

will disappear. "READY FOR TRFR" lamp will glow. AS-9 Sc . ' Press "READY FOR TRFR1 push button "I/C BKR CB-1 CLOSE1 "TIE glow BKR CB2 OPEN1 window on FACIA WINDOW FW1 will glow

rt window ,<QN f^ f%
o ( ^S

"READY FOR TRFR1 lamp

will disappear and will

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

AS-11 AS-12

Turn the "TRANSFER SELECTOR1.to "AUTO1 mode

on BTPS-02.

Turn the discrepancy switch of ICB I/C Bkr. to "ON1 Sc discrepancy switch of TIE BKR to ICB to"OFF'.

r\ iQ r^. O ( " ) <f| Q \J P Q <Q Q Q O C-58

CHARGING OF LP HEATERS FROM STEAM SIDE AT ABOUT 5 _ 0 MW LOAD Open drain valves DR-15, DR-17 and DR-18 locally. Open LP heaters shell vents from local before charging from steam side. After charging close shell vents,

open DR-23 and DR-32 locally. Open locally extraction-1 pipeline drain valve EX-113. Open locally isolating valves of DR-21 i.e. valves DR-20 and DR-22. Open LPH-1 EXT STM ISO EX-9 side. Level will start raising in LPH1 after some time EXTRAto charge LPH-1 from steam

A2-UP STREAM and

DOWN STREAM will gradually increase as

flow increases (CWA-16).

51

Press^OP' push button of LPH-2.EXT STM ISO EX-10 to charge LPH-2 with steam. Level will start raising in LPH-2 after some time. Close Note: When load exceeds 2 0 MW and EX-A2, A3 opening is greater than 15% & SLC drains is "ON1 MAL valves-55, 54 will close. Close locally extraction-1 pipe line drain valve EX-113. on auto. First set NWL and HWL LPH-2 EXT DRN EX-101.

Put LPH-2 level control

to zero on level set indicator. Then open DR-21 and DR-24 manually and maintain LPH-2 level. If the deviation in valves is zero put DR-21 and DR-24 on auto. Open LPH-3 EXT STM ISO EX-11 to charge LPH-3 from steam side. LPH-3 drip level will rise gradually.

Close LPH-3 EXT DRN EX-103 Observe increase in Condensate temperature after

LP heaters. Observe LPH-3 level in the indicator LPH-3 drip level LCD

meter shows 200 mm. Put level Control at LPH-3 on auto. Bring LPH-3 NWL SET point to zero mm we. Bring LPH-3 HWL SET point to zero mm we. Put DR-16 and DR-19 valves on auto. also

Whenever EXTN NRV (A3) opens more,observe that DR-16 opens more to maintain LPH-3 drip level.

52

_
t'S

C-5 9
'

TAKING FEED CONTROL STATION FULL LOAD LINE INTO OPERATION

~
'""

"

""

"""

"

^
O

This is to be done at a load oJ: about 50 MW. Select ^3 ELEMENT CONTROL'of CONTROL SELECTOR to keep drum level control on three element control. Keep BFP-A SCOOP on auto. FD-320 and FD-321 of full load

~ f% 0 |3 <Q' 0 Q) ^ -Q 0, |j fv 0 0 O O Q 'J> v) * * 0 O D Q C-61

Open isolating valves

control valve FD-21. Put FD-20 valve on manual. Gradually open FD-21 and close FD-20 completely. FD-22 control valve which is bypass to FD-21 can be taken in service by closing FD-21 and maintain drum level to normal DP across Feed Regulating Station is to be maintained at around 6 kg/cm2 by manually operating the valve FD-21. C-60- FOR FURTHER INCREASING THE LOAD INCREASE THE PRESSURE

SET POINT OF HP B Y P A S S TO KKD k g / c m 2 . TAKING PULVERISER-"B1IN SERVICE Ensure that L O P - 1 is running and L O P - 2 is s t a n d b y .

Select m a n u a l m o d e of p u l v e r i s e r . Start seal air b l o w e r of P A N - B . Set Mill O u t l e t t e m p e r a t u r e to 77 D e g . C and PA flow to 55 T/hr. Check permissives of PAN-B. glowing then If all permissive lamps are

start PA fan-B.

Open pulveriser discharge valve. Check mill permissives are available to start mill-B. Start pulveriser-B manually. Open hot air gate.

Then open PAD-5B, PAD-2B and PAD-4B and get 55 T/hr of PA flow and mill outlet temperature to 77 Deg.C.

53

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

After one minute feeder speed can be increased. Increase feeder speed. Flue gas temperature, MS, HRH temperature will increase. Maintain 02 % at APH inlet to about 6% by increasing

secondary air. Increase the feeder speed gradually. C-62 INCREASING -LOAD TO KKD MW Increase the load Co 90 MW by load reference.

Reduce oil firing by withdrawing oil support of EF elevation. Increase the load to 100 MW by increasing load . 60-70%. reference

to 100 ME.'

Feeder speed of, A & B mill will come to about C-63 TAKING SECOND BFP IN SERVICE ^

For further increasing the load on turbogenerator start BFP-B. Before starting BFP-B check its permissives and line up BFP-B. If the feed water flow is more than 240 T/hr, change 1 pump operation to 2 pumps operation of BFP's. If BFP group control is "on "auto1 then BFP-B will pick-up beyond feed water flow of 325 T/hr. Otherwise on manual. on standby mode so that if any pump trips BFP-B can be started on sub group sequence or

Put BFP-C

standby pump will, pick up.

5 . 4

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

O
^ Q !| 0 O 0 0 0 O Q 0 0 0 0 O O 0 <U> '<j Q O G G O G ^ O C-66 C-65 Make change over oJ: PRDS-1 (High capacity PRDS) to PRDS-2 (Low capacity PRDS). and FD-335.

Open first isolating valves AS-304

Gradually open PRDS-2 spray control valve and close PRDS-1 spray control valve. PRDS temperature will be maintained at 205 deg.C. Then gradually open pressure control valve of PRDS-2 and

close PRDS-1 pressure control valve. PRDS-2 pressure control valve will maintain PRDS pressure to 12 kg/cm2. Then take PRDS-1 on manual and PRDS-2 on auto. TRAKING SUPERHEATER SPRAY CONTROL VALVES IN SERVICE Open isolating valves in super heater spray control S-57, S-59, S-62,S-68,S-69 and S-71. Keep SH spray control on manual: Open block valve S-52 then open 1/2 isolating valves lines

S-60 and S-66. With the help of spray control valves S-61 and S-67 deg. C.

maintain actual temp, at SH outlet at around 5 . 00

LINING UP REHEATER SPRAY CONTROL VALVES & BURNER TILT Open locally valves R-18,R-20, R 15, R-23 and R-24.

Ensure to keep of RH STEAM TEMPERATURE SET on manual. Ensure to keep TILT MASTER A/M STN on manual.

Put BTPC-1, BTPC-2, BTPC-3, BTPC-4 on auto. Maintain RH STM TEM ACT at around 50 0 Deg C. by

manipulating TLT MASTER CONTROLLER.

55

C-67

CHARGING OF HP HEATERS 5 & 6_ FROM FEED WATER SIDE Open HP heaters 5 & 6 water box vents locally before charging and close it after charging from water side.

Ensure HEATER BP valves FD-9 & FD-12 are open. Ensure to keep FW I/L ISOL VLV GROUP on manual. Open FW I/L VLV IB FD-7A. Ensure to keep FW 0/L ISOL VALVE GROUP on manual. Open FW O/L VALVE IB FD-8A. Ensure to keep FW I/L ISOL VALVE GROUP on manual. Open FW I/L VALVE IB FD-10A. Ensure to keep FW O/L ISOL VALVE GROUP on manual.

Open FW O/L VALVE IB FD-11A. Ensure to keep HTR BP VALVE GROUP on manual.

Open locally heater charging valve FD-18. ^OP' bulb of GR BYPASS VALVE FD-17 will glow. "OPr bulb of GR BYPASS VALVE FD-16 will glow. Then close valve FD-1S. Open HP HEATERS inlet/outlet valves FD-7, FD-8, FD-10, and FD-11. Close their integral bypass valves FD-7A, FD-8A, FD-10A, and FD-11A. Close HEATER BP Valve FD-9 & FD-12. Now HP heaters are charged from feed water side.

56

o o
.

C-68

ESTABLISHING SECOND

AIR CYCLE

Before tciking pulveriser-C in service start another air cycle .

. -

Start IDB & FDB.

Equalize the loading of ID Fan-A & ID Fan-B and FD Fan-A -. and FD Fan-B. Increase HP/LP bypass pressure set point to 125 kg/cm2.

5
_ CJ) ^ -^ tp.

Ensure that deaerator pegging steam changeover takes place at 12 kg/cm2 of CRH pressure from PRDS to CRH line. It maintains D/A pressure of 3.5 kg/cm2 . C-69

o
r>. g^ f^ ^ ,Q r^ ^ 0 Q Q Q Q Q 0 0 O

ESTABLISHING : PULVERISER - C Start pulveriser-C and further increase the load by load reference . Increase the load to 126 MW by raising load INCREASING LOAD TO 126 MW reference. If BFPB is not started on manual it will pick up on auto at flow of > 325 T/hr. Maintaian SH steam temperature and RH steam temperature release will now be for deaerator available for taking EXT-4 in service

C-70

pegging.

Open valve EX-301. Observe closing of valve CR-306. Observe various parameters at 126 MW. C-71 AIR FLOW CONTROL ON AUTO Bring 02 trim set to 50% to maintain 02 in APH flue gas at

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

will generate 02 set point according to load.

Q
57

C-72

CHARGING OF HP HEATER _5 FROM STEAM SIDE Open DR-13 and DR- 8 locally. Open HPH-5 EXT DRN EX-112. Open EX-13 to admit extraction steam to HPH-5. Drain extraction valve- A5 (MAL-47) closes. Set HPH-5 NWL SET will show to zero mm we. Set HPH-5 HWL SET Put DR-14 on auto. Put DK-11 on auto. Close HPH-5 EXT DRN EX-112. HPH-5 level will increase slowly to 250 mm we. Feedwater temperature AFTER HPH-5 will rise slowly.
1

to zero mm we.

HPH-5 LEVEL L O W annunciation will reset.

C-73

CHARGING OF HPH-6 FROM STEAM SIDE Open DR-1 and DR-3 locally.

Open HPH-6 EXT DRN EX-110. Open EX-12 to admit extraction steam to HPH-6. Set HPH-6 NWL SET indicator to zero mm we. HPH-6 HWL SET indicator to Put'VALVE DR-2 on auto. Put VALVE DR-34 to keep Put DR-6 on auto. Close HPH-6 EXT DRN EX-110. HPH-6 level will increase to 250 mm we. will reset. on auto. zero mm we.

"HPH-6 LEVEL LOW1 annunciation window

Feed water temperature will rise slowly.

58

Load initially will reduce

marginally.

f%
v>

Spray will reduce. Economiser inlet temperature will increase. Observe feed water temperature & outlet of HPH-5 & HPH-6. TO PUT HP HEATERS LEVEL GROUP PROTECTION ON AUTO. Put FW I/L ISOL VALEV GROUP on auto. Put FW 0/L ISOL VALVE GROUP on auto. Put HEATER-5BP VALVE GROUP on auto. Put FW I/L ISOL VALVE GROUP on auto. Put FW O/L ISOL VLV GROUP on auto.

o o

o o

^ C-74

Put HTR-6 BP VALVE GROUP on auto. Put HEATER GROUP BP on auto.

LOAD RAISING UPTQ 150 MW Raise load reference to increase the load 150 MW.

o
o "^ o O
Q Q Q Q r^ C-76 C-7.5

After coal feeder C speed goes beyond 60% withdraw oil HP bypass pressure set point is maintained 5 kg/cm2 support at pressure. CD elevation. above M.S. While raising steam parameters and load, ensure that TAKING PULVERISER-D TN SERVICE Take pulveriser-D in service and increase the fuel firing LOAD RAISING TO _ 1 7 j 5 MW

Raise LOAD REF to increase the load upto 175 MW. MW meter will show 175 MW (actual). Observe all the parameters. M.S.temperature and HRH steam temperature to be maintained around 52 0 deg.C.

o
59

C-77

TO WITHDRAW OIL SUPPORT FROM AB ELEVATION Increase feeder speed of D mill When MS pressure to raise the load. ref. to

starts increasing

raise load

190 MW to increase the load. Put SH steam temperature spray control valves and RH

steam temperature spray control valves and Burner TILT MASTER on auto. Put SH steam temperature Set point & HRH steam temperature set point C-78 also on auto.

LOAD RAISING TO 210 MW Maintain MS pressure at around 150 kg/cm2 and increase

the load to 210 MW . C-79 TO PUT UPC' ON AUTO Ensure RC feeders A,B,C & D speed deviation is zero and put them on "Auto'. Raise UDC pressure GRAD set point to 50%. Raise UDC pressure set point to match actual MS pressure. Raise START UP FUEL GRAD to 50%. Observe deviation between UDC pressure set point and actual MS pressure at control desk CWA-12. Put BLR FUEL MASTER on "Auto',when this deviation is zero. START UP MODE will come into service indicated by START UP FUEL SET POINT RUN lamp glowing. the deviation meter provided on

60

To take CMC mode in service adjust unit target load GRAD

0
SET POINT to 50% and ensuring zero deviation between UDC PRESSURE SET POINT & actual MS pressure to make CMC "ON' from turbine desk button. Now load ^ unit target load set point. Put UDC pressure set point on auto. point on auto. _ Raise UDC PR SP till indicator on UDC PR SP INDICATION Put HPBP pressure set can be varied from

^ comes to 150 kg/cm2. Wait till pressure ^ (Time deviation comes to nil

15 minutes approx.).

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

O

Put boiler set POINT

on auto.

Start-up fuel lamp will be off on CVJA-12. MS pressure will be maintained as per set point.

r~-_, ^ c^ , ^ S '> Q -^ C-80

Unit load will be maintained as per set point. . IMPORTANT PARAMETERS AT 2 _ 1 0 _ MW Maintain important parameters as given below: Main steam pressure before ESV Main steam temperature at boiler outlet Main steam flow Flue gas temperature at air heater O/L 150 540 627 14 9 162 501 20 650 61 kg/Cm2 Deg. C T/hr Deg.C Kg/Cm2 T/hr Kg/Cm2 T/hr

~> -x Q

Drum pressure Condensate flow Condensate header pressure Feed water flow

Q Q

F'eed w;;ii:.r temperature at; economi ser . i . n . l c . r ; 24-1 Deg. C Total combustion air . 02 in flue gas at economiser outlet .Wind box to furnace DP Reheater steam pressure at outlet CST .lev.: I. Stator water conductivity instrument air header pressure Service air, header pressure Condenser'' vacuum Deaerator pressure EJ'/A level ' ' ' : 792 .7 3 .5 100 34 . 8
2900

T/hr

%
mmwc Kg/Cm2 mm mmho/cm
I.-':

<56-7

Kg/Cm2 Kg/Cm2 Kg/Cm2 ^ Kg/Cm2

! ? ,

6-7 0.91 6. 5 2700 160 850

"'"

mm .
deg.C

"(*

D/A temperature . Hotwell level HPT differential expansion 1 PT d i. l I ' . : I'enl: ial cxpanuJon ;.LHT -differential expansion HP overall expansions IP^overa LI expansion;: ,

mm

-2 . 00' to + 5 mm :>. .oo to - 7 . 0 0 .,to

26 ,
i 5 mm
25 mm:;

. ;

mm

mm

13..

'.:.

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

^Turbine sha^t:-^ibra:t^G^is^at, HPT, IPT, LPT P.T. <12.0',.,,. micrpris .V'TSEi.margins'(Lbad margins): \ Turbine lub .oil temperature ' HPH-6 level : HPH-5 l.-vol >3 0 ' 44 230
'?. 5 0

K
Deg. c

mm
mm

62

o
LPH-3 level LPH-2 level Ejector steam pressure PRDS pressure PRDS temperature CRH pressure after attemperator CRH temperature attemperator
410 350 7 12 200 37 370 . 540 564 .5 26 0 + 13 3160 15.75 9000 130 2(D0

mm mm
Kg/cm2 kg/Cm2 Deg.C Kg/Cm2 Deg.C Deg.C

o o o
G C

HRH Reheater steam temp.at outlet HRH Reheater steam flow at outlet S H Spray RH Spray Burner tilt GSW tank level Generator volts Generator current(R/Y/B) Generator MVAR lagging Field current Field voltage

T/hr
T/hr

T/hr
deg

mm
K.Volts amps MVAR amps volts

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G

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Q

H2 pressure in Gen.casing Hydrogen purity HP control valve V-2 position(approx) IP control valve position (approx) EHC position(approx) Seal steam pressure C-81

3 .5 99 60 100 70 0 . 12

Kg/cm2 % , % . % ' % Kg/Cm2

TAKING STANDBY PULVERISERS E AND F I _ N SERVICE Standby pulverisers can be taken in service one by one and withdraw pulverisers A & B one after another.

o
63

"., if

PLANNED SHUTDOWN PROCEDURE FOR UNIT (SHUTDOWN TO COLD STANDBY) SC-1 When the planned shutdown/shutdown to cold s/b is to be started the following procedure is to be followed.

Reduce the load on the T/G machine alongwith reduction in temperature SC-2 and pressure of main steam. planned shutdown

The unit is running on full load and

is to be started . Observe the important parameters on full load (210 MW) before reducing the load. SC-3 LOAD REDUCTION TO l _ 8 _ 0 MW
/J - > / ,1

Unit is running on CMC. . Press TURB FLG MODS push button mode. Reduce target load gradient

Jo-t>di*

Y * ' - ^ follow

to select turbine

to 20% from CWA-16 desk.

Bring target Load Set point (UDC) indicator to 180 MW. Slowly MW will reduce. Observe various parameters. SC-4 OBSERVATION OF IMPORTANT RESPONSES WHILE REDUCING LOAD TO 180 MW Speed & Amps of FEEDER-A reduces. Speed & Amps of FEEDER-B reduces. Speed & Amps of FEEDER-C reduces. Speed & Amps of FEEDER-D reduces. TOTAL FUEL FLOW will decrease. '

Mill-A amperage will reduce. Mill-B amperage will reduce. Mill-C amperage will reduce.

64

Mill-D amperage will reduce. Total air flow reduces.

TSE will show 180 MW.

Main steam flow reduces, feed water flow flow reduces.

and condensate

G
SC-5 LOAD REDUCTION TO 165 MW Brina unit load target set ooint to 165 MW to reduce the load to 165 MW. SC-6 PULVERISER ^D SHUTDOWN Put Feeder-D from auto to manual from CWA-12 desk.

o o
0
_

. . .. ^ Reduce FEEDER-D speed gradually to minimum. . RC FEEDER-D amperes will slowly reduce. When current of mill-D is minimum then stop FEEDER-D

G
by making it off manually.

%J>
"No coal flow" annunciation corresponding to Mill-D

O
^ will glow. Bowl DP will reduce slowly. Close Hot air gate. ^ ^ r-N o r-\. , " , o, r\ (5 ry, Press ^OFF1 push button of PULVERISER-D pulveriser-D. Put all the PA dampers of pulveriser-D on manual. Ensure that mill outlet temperature is <4 5 Close all the primary air dampers . Close pulveriser discharge valves. Then stop PA Fan-D. No coal flow annunciation will come after stopping RC Feeder-D. Pulveriser also shutdown on auto mode. * -Xo e..ef D dj (? can be 65 Deg.C. to stop

n V,

2_

PROCEDURE TO SHUTDOWN PULVERISER-D ON AUTO MODE Put pulveriser-D en auto mode. Press "OFF' push button of pulveriser-D to make it "OFF1 in auto mode. First command goes to CD elevation oil support(oil guns)

Feeder speed will slowly come to minimum. Hot air gate closes and hot air damper closes. Cold air damper opens to reducee pulveriser outlet temperature. Then pulveriser will be "OFF1.

At last PA Fan will be "OFF'. Cose pulveriser discharge valves on manual. Then if

required, oil support at CD elevation can be withdrawn. SC-7 ISOLATING HP-6 FROM STEAM SIDE Close valve EX-12 to cut off steam to HPH-6 (Extraction steam of HPH-6). Open DR-2 valve will close slowly.

EX-110 drain valve before EX-12 valve. will reduce.

Feed water temperature

Put DR-2,DR-34,DR-6 on manual after they close on auto. SC-8 ISOLATING HP-5 FROM STEAM SIDE Close EX-13 DR-11 Open valve to cut off steam to HPH-5. close slowly.

valve will

EX-112 drain valve (Extraction line drain valve). closes oh auto. will on open on auto. manual.

EXTRACTI0N-A5 Valve MAL-4 7

Put DR-11 valve Put VALVE DR-14

on manual.

Feed water temperature will reduce .

66

SC-9

CUT OFF HP HEATERS FROM WATER SIDE Open HPH 5,6 bypass valves FD-9 and FD-12. to bypass, HP heaters

o
0-

Close FD-7,FD-8, FD-10 and FD-11

from water side. In order to take main heater bypass line in service open

FD-130 and of FD-131. -CL1 bulb GR BYPASS VALVE FD-16 will glow. .
V

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~. ^ __ %J

CL' bulb of GR BYPASS VALVE FD-17 will glow . Open dump valve FD-125 from desk.

After some time FD-125 can be closed. Close FD-130 and FD-131. Heaters can be isolated from steam side and

water side on auto with the help of heater group

o
~

SC-10

bypass from CWA-13 LOAD REDUCTION TO desk. 140 MW Reduce target LOAD SET POINT (UDC) till INDICATOR on

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^ p,

SET POINT meter comes to 140 MW. Load will gradually reduce to 140 MW. ~ OBSERVATION OF IMPORTANT RESPONSES WHILE REDUCING LOAD TO 140 MW Speed & Amps of FEEDER-A reduces.

Q Q
Speed & Amps of FEEDER-B reduces. Speed & Amps of FEEDER-C reduces. ^ Indicator of TOTAL FUEL FLOW will decrease. Mill-A amperes will reduce. Mill-B amperes will reduce. . Mill-C amperes will reduce. Steam flow will reduce. TSE will show 140 MW.

o
O
67

o o

SC-11

TAKING HO GUNS INTO SERVICE AT (AB) ELEVATION (PAIR 1-3 & 2-4) Ensure that HO trip valve is open (HO-29) and observe HO and atomising steam pressure of 6 kg/cm2 and respectively. Press -START1 push button of AB elevation pair 1-3. 8 kg/cm2

"START1 bulb will blink slowly.. HEA IGNITORS corresponding to pair 1-3 of elevation

AB red light will lit to indicate advancement of HEA IGNITORS. DISC SCANER light will come corresponding to pair 1-3. HEA IGNITORS "G1 bulb will glow to indicate IGNITORS RETRACTED. START bulb of AB elevation PAIR 1-3 becomes steady. HO short recirculation valve HO-11 will close. After 40 seconds command will go to pair 2-4 to start and pair 2-4 will prove after 90 seconds time. SC-12 CHANGEOVER OF CMC FROM AUTO TO MANUAL MODE. At 140 MW load make CMC ~OFF' from CWA-16 desk. Bring MS pressure set point to manual. Boiler fuel master will be on auto.

Start up mode will come'in service. Put Boiler fuel master on manual. operation.

Unit will come to "base mode' Take UDC

pressure set point to manual.

68

SC-13

LOAD REDUCTION TO ll_0 MW Bring Load load reference to 110 MW from CWA-16 desk. will gradually reduce.

HPT and IPT control valves opening will reduce. f% Put RC feeder speed on manual to reduce further fuel firing rate.

o
0

Reduce speed of RC Feeder-C to maintain steam flow and MS pressure. UDC pressure set point may be reduced equal to MS pressure so that the difference between actual than 10 kg/cm2,

o
''s ^

pressure and set point.

may not be more

so that unit will not go to "pressure control1 mode. SC-14 Release OBSERVATION lamp OF of RESPONSE extraction-4 AFTER (A4) 110 will MW LOAD be'OFF' and MAL-51 will open. Close EX-301 and open EX-108 valves. CR-306 valve will open to maintain deaerator pressure.

o
o
^ SC-15

o
^

PULVERISER -C SHUTDOWN Remove Pulveriser-C as per procedure mentioned in step SC-6. MS temperature >4 8 0 deg.C by RC feeders of A & B.

o
SC-16

SHUT DOWN OF SEAL AIR FAN-B When A & B pulveriser are in service then stop seal air Fan-B. Seal air Fan-A

Q
will be running.

o o
O
69

SC-17

SHUT DOWN OF 3FP

Put standby 3?P on manual. Take SCOOP-B on manual. Reduce SC00P-3 comes to till indicator on SCOOP-B position

minimum. 60 T/hr flow.

MIN RCV FC-306 will open at SCOCP-A

of BFPA will increase to adjust feed water flow.

Amperes of BFP-B will reduce and BFP-A will increase. Press OFF push button of BFP-B to make it OFF from CWA-13 desk. AOP of BFP-B will pick up on auto. Cooling water valve of BFP-B. will close on auto. selected and if flow- is less

If one pump operation is than 290 T/hr BFP-B SHUT DOWN OF

will trip on auto.

FD FAN-B AND ID FAN-B AT l_00 MW

Reduce load on FD Fan by taking SAD-1 on manual and close it fully. Then stop FD fan motor from CWA-11 desk. Close discharge damper. LOP sub group sequence can be put on manual and then stop running LOP A/B. FD Fan can be shutdown in group sequence. Reduce load or. ID Fan-3 by taking QD-SB on manual and close IGV manually. Stop ID Fan motor. . Close inlet outlet dampers. Stop ID fan seal air blower.'

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

70

O O ^ SC-19 REDUCTION OF LOAD TO 50 MW Reduce load inference to 50 MW to reduce load to 50MW. Load will reduce to 50 MW. Adjust feeder speeds of running pulverisers A & B so that MS pressure will not increase.

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

open and leak off valve will close. SC-20 PULVERISER-B SHUT DOWN Follow the same procedures given in Step SC-6. 5 _ 0 MW LOAD

o
^

SC-21

CHANGE OVER TO LOW LOAD LINE AT

FROM FULL LOAD LINE(Feed Regulating station) Open VALVE FD-20 slowly and close valve FD-21 so that drum level is maintained to normal. ,,r\ ^

c
^ ^ Q 0 O Q

Close

VALVE

FD-21 till indicator of

FD-21

position

comes to zero. Put valve FD-2 0 on auto and scoop of BFP-"A' on manual. SC-22 CARRYING OUT AUXILIARY SUPPLY CHANGE OVER FROM UNIT TO STATION BUS OCA Ensure that breakers OCA and OCB are in service and DC control supply is "ON". AS-1 BTSP-1 is "IN1 and selection is on "MAN FAST 1 .

vj/ Q O O O w U AS-2

Ensure that "Bus transfer system ready for Fast Transfer1 & "Bus transfer System IN' indications are available at BTSP-1. Press the "TEST' push button on the back panel(BTPS 01) back

and proceed further when"READY FOR TRFR' bulb on the panel glows.

71

"I/C BKR CB-1 0?3Nr Test mode window on FACIA WINDOW FW-1 will glow. "TIE BKR CB-2 CLOSE' Test mode window FW-1 v/ill glow. on FACIA WINDOW

Press the TEST RESET button.

All the above indications will -disappear. "READY FOR TRFR" green AS-3 lamp will glow.

Press "READY FOR TRFR1 push button."I/C BKR CB1 OPEN' window on FACIA WINDOW FW-1 will glow."TIE BKR CB-2 CLOSE'window on FACIA WINDOW FW-1 will glow."READY FOR TRFR" lamp will disappear and will glow again."UNIT BD

1CA INCOMER BKR1 & "TIE BKR between ICA & OCA'discrepancy switch will flicker on MCL-01. AS-4 AS-5 Turn the discrepancy switch of ICA I/C BKR to "OFF1. Turn the discrepancy switch of TIE BKR to ICA to 'ON'.

CARRYING OUr AUXILIARY SUPPLY CHANGE OVER FROM UNIT TO STATION BUS OCB AS-6 BTSP-2 is"IN'and selection is on "MAN FAST'. Ensure that Bus transfer system ready for Fast Transfer & Bus Transfer System IN indications are available on AS-7 BTSP-2.

Press the "TEST1 push button on the back panels (BTPS-02) and proceed further when"READY FOR TRFR'bulb on the back

panel glows. "I/C BKR CB-1 1 "OPEN test mode1 window WINDOW FW-1 will glow. "TIE BKR CB-2 CLOSE test mode1 window WINDOW FW-1 will glow. on FACIA on FACIA

72

AS-8

Press the "TMST RESET1 button.

All the above

indications will disappear."READY FOR TRFR" green lamp w . i . 1 . 1 glow. ^ r*,

r

AS-9

Press "READY FOR TRFR 1 push button"I/C BKR CB1 OPEN 1 window on FACIA WINDOW.

"TIE BKR CB2 CLOSE 1 window on FACIA WINDOW FW1 will glow. "READY FOR TRFR'lamp will disappear and will glow again.

^ r% f* ^
f*

""UNIT BD 1CB INCOMER BKR'&'TIE BKR between ICB & OCB' discrepancy sv/itch will flicker on MCL-02. AS-10 Turn the discrepancy switch of ICB I/C Bkr to "OFF1. to "ON'.

Turn the discrepancy switch of TIE BKR to ICB SC-23

^. *>
iO)

CHANGE OVER OF PROS-2 TO PRDS-1(PRESSURE & TEMP.CONTROL) Ensure to ke^.; PRDS-1 (AS-308) on manual. Slowly open A.^-3 08 of PRDS-1 and A3-305 closes ON AUTO. When AS-305 closes completely put: PRDS-2 (AS305) on manual Put PRDS-2 :AS-308) on auto. pressure of 12 kg/cm2 .

,f> f^ f% Q Q Q Q ^-> Q O Q O Q SC-24

Valve AS-308 v.'ill open to maintain Open HCPRV I/L ISO FD-342. Slowly open FD-347

of PRDSE-1 (FD-347 ) on auto.

FD-346 will close gradually on auto so that PRDS temperature will be maintained at 2 00 Deg.C. Put PRDS-2 on manual and PRDS-1 on auto.

Close isolating valves of PRDS-II after change over. ISOLATING LP HEATERS FROM STEAM SIDE(LPH-3,2,1) CLOSE EXT STKi ISO VALVE EX-9 to cut off steam to LPH-1. Open locally EX-113 drain of extraction line. Close EXT ST:>\ ISO VALVE EX-10 to cut off steam to LPH-2.

L)

73

Open

EX-101 extraction

line drain valve locally.

EXTRACTION- A2 MAL55

release to NRV will be "OFF'.

will open on auto.

Open EX-102 extraction line drain. Close EXT STM ISO VALVE EX-11 to cut off steam to LPH-3. Open EX-103 extraction line drain. to NRV will be "OFF1.

EXTRACTION-A3 release MAL-54 will open

on auto.

All the Drip valves DR-21,DR-16,DR-24,DR-21,DR-16,DR-19 will close on auto. SC-25 LOAD REDUCTION Reduce 3 0 MW. TSE will show 3 0 MW gradually. Steam flow will decrease. Observe on DAS various parameters. SC-26 PULVERISER-A SHUTDOWN Follow the same procedure to shut down pulveriser-A as given in Step SC-6. Stop seal air Fan-A from CWA-11 desk. SC-27 SHUT DOWN THE TURBINE Note the presen: value of steam pressure and set HPBP more than actual pressure so that HP3P will not open. Press the TURBINE TRIP push button to trip the turbine Drip valves may be put on manual.

TO 30 MW to 3 0 MW to reduce actual LOAD TO

load reference

"MANUAL TURBINE TRIP" alarm will come. MAIN CB CONTROL SWITCH-52 will open. "OFF1 bulb of FIELD BKR will glow.

74

"OFF1 bulb of EXCITATION OFF will glow. ^ ,K Field current will become zero. Field volts will become zero.
AUTO POT MIN bulb will lit. . GEN BKR OPEN bulb will lit.

O
1^ p #% (J 0 <Q C3 0 Q> 0 0 0 J / O O 0 O vJ ^ %j

EXCITATION TRIP bulb will glow. MW meter will show zero. TURBINE TRIPPED bulb will lit. HP STOP V-l CLOSED bulb will glow. HP STOP V-2 CLOSED bulb will glow. INTCPT V-l CLOSED bulb will glow. INTCPT V-2 CLOSED bulb will glow. CRH NRV LH CLOSED bulb will glow. CRH NRV RH CLOSED bulb will lit. HPT CVS,IPT CVS will close. Turbine speed reduces gradually. When turbine speed is at 2800 rpm AOP-I will pickup on auto. When turbine speed is at 510 rpm JOP-I will pickup on auto When turbine speed is at 240 rpm "ON 1 bulb of GATE VALVE GEARING will lit and barring gear will engage to put turbine on barring. Turbine speed would be 150 rpm on turning gear. Boiler will trip on Turbine trip to boiler trip

protection (R H Protection)

75

Turbine can also be shutdown through ATRS (SGC Turbine) at' 210 MW load. ensure SGC turbine is on auto.

Make CMC "OFF' and Adjust Start

load gradient to 3 to 5 MW per minute. shutdown sequence by making SGC turbine "OFF1.

Adjust Fuel Fire rate as per the reduction in load. SC-28 SHUTDOWN OF GENERATOR STATOR CW PUMP Turn the GEN CW PUMP A/M S/S switch to position number-2 to make generator stator CW pumps on manual. Stop GEN STATOR CW PUMP-A(running pump) stator water comes to zero and flow CWA-17. SC-29 SHUTDOWN OF BOILER When boiler trips after tripping turbine observe following "BOILER MFR TRIP" annunciation will'come. MFT-1 and MFT-2 be OFF. All oil guns will be OFF. HO trip valve will close on auto Short circulation valve of HO-35 will open on auto. lamps will glow and MFR "RESET'lamp will flow

low indication flashes on the desk

Scavenging of guns at AB and CD elevations will start and after 5 minutes automatically scanenge valves close. Auxiliary' air dampers will open full.

Fuel air and

Bypass turbine trip to boiler trip protection. All purge permissives will be satisfied. Purge the boiler. After 5 minutes purge over signal will come.

76

& ^*

SC-30 KILL CONDENSER VACUUM Close main ejector A/B steam valve. Open vacuum breaker to kill condenser vacuum. Vacuum will fall slowly. Observe on CWA-16 desk and DAS. SC-31 SHUT DOWN OF TURBINE GLAND SEAL SYSTEM Put seal steam control on manual.

* *

Close seal steam isolating valve AS-368 locally . Gland seal steam header drain valve MAL-81 will open on

interlock. When temperature of header drops below 12 0 deg. C. stop

% u

* SC-32

GSC evacuation Pump 1/2 SHUT DOWN OF PRDS

from CWA-16 desk.

'

Put PRDS pressure and temperature control on manual and close control valves.

* " " ~ "

W

Then close isolating valves for pressure and temperature control . SC-33 BOILER FILLING ABOVE NORMAL DRUM LEVEL Put FD-20 on manual and open the valve. Fill boiler drum above normal level so that level will be when drum

^ ^

visible when drum pressure drops and level drops

O
level pressure drops. Restore drum level with BFP and feed control valve from ^
Ky

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

77

SC-35

SHUTDOWN OF BFP-A Press "OFF'push button of BFP-A motor. AOP will pickup on auto. BFP-A cooling water valve will close on auto. Close Discharge valve from CWA-13 desk. BFP-A suction flow BFP-A suction will become minimum.

pressure reduces.

BFP-A can be shut down in group sequence also. SC-36 SHUTDOWN OF SECOND AIR CYCLE(ID FAN A & FD FAN A) When flue gas temperature at APH inlet is less than 200 deg.C. second air cycle can be stopped. SC-37 SHUTDOWN OF AIR HEATER-A Before stopping the Air Heaters, wait untill FG

temperature at APH inlet reaches < 10 0 Deg.C. Press middle push button of AIR HEATER-A GROUP SEQUENCE to keep group sequence on Auto.

Press "OFF' push button of group sequence to make APH-A main drive off. APH- A will be off and ammeter of AIR HEATER-A will show zero amps. APH-A DC motor will pick up on auto.

Dampers GD-1A, SAD-4A,GD-2A and SAD-3A will close on interlock. Support and guide bearing LOP's will be off if bearing temperature < 35 deg.C and 4 0 deg.C. LOP group sequence can be put on manual. APH-A can be shut down manually.

78

5 *k f% Q 9 Q> O
i

SC-41

OPENING OF

BOILER SIDE VENTS

When drum pressure reaches 3 kg/cm2 open drum Vent valve B-5 locally. Open locally super heater vent valves S-40, S-21,

S-25, S-30 and drain valves S-15, S-16, S-17. Open RH vent valves R-l and R-4.

SC-42

SHUTDOWN OF CW PUMPS Stop CW PUMP-1 and CW Pump-2. Ammeter reading of CW PUMP-2 will show zero amps.

G O O
i

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

SC-43

SHUT DOWN OF GSW PUMPS Stop GENERAL SER PUMP-A. Ammeter of GENERAL SER PUMP-A will show zero amps. Close GEN SER PUMP-A Discharge Valve DV-39.

O
i

0 G O O ^ SC-44

GS 0/H tank level will fall. SHUT DOWN OF AC SEAL OIL PUMP

When Hydrogen is purged out and C02 is filled and purged out with compressed air, AC seal oil pump can be stopped. xxxxxxxxxxxxxxx

Ir>

o
Q

G
Q
80

C-38

SHUTDOWN THE AIR HEATER-B Press middle push button of AIR HEATER-B GROUP SEQUENCE. Press "OFF1 push button of AIR HEATER-B group sequence to keep APH- B "OFF1 . APH-B will be off and Ammeter of AIR HEATER-B will show zero amps. DC motor will pick-up on interlock. All the dampers in flue gas path and air path will open on interlock. Response will be same as step No.SC-37.

SC-3 9

SHUTDOWN OF Shutdown

CEP A/B (RUNNING)

the CEP when LP exhaust temperature ' reaches

less than 45 Deg.C. Make SLC COND Pumps OFF. Press "OFF1 push button of Ammeter of CEP-A will show CEP-A to make it off. zero amps.

CEP-A discharge valve closes on interlock. Take DM-32 & DM-35 on manual and close them. SC-40 SHUTDOWN OF TURBINE LUB OIL SYSTEM Take SGC oil supply on manual. Make SLCs of JOP-1, JOP-2, AOP-1, AOP-2, EOP OFF. When turbine casing temperature reaches<100 Deg.C,then

stop GATE VALVE GEARING from CWA-16 desk. Turbine speed will gradually will come Stop to standstill. reduce and turbine

JACKING OIL PUMP-1. PUMP-1 .

Stop AUX OIL

Make SLC lub.oil temperature control OFF.

79

PROCEDURE FOR SHUT DOWN OF UNIT FOR HOT STANDBY

o
Q Q) O O 0 HS-2 When unit trips' from full load (210 MW) on any protection or load through off or is to be tripped manually for any abnormal condition,follow the procedure as mentioned below. TRIPPING THE TURBINE MANUALLY Press TURBINE TRIP push button to trip the turbine .

manually from CWA-16 desk.

/

"MANUAL TURBINE TRIP" alarm

0 O 0 0 0 O O O O Q ^ o
'yJ ^ ^ O O O

will come. TSE will shift to admission side to indicate turbine speed. MAIN CB CONTROL SWITCH 52-E FIELD BKR will be "OFF1/ . . . will open
y

..

CO-ORD mode lamp will go "OFF1, and boiler startup mode lamp will glow, EXCITATION will be "OFF.1 zero.

Field current will become

Field volts will become zero, AUTO POT MIN bulb will lit . \ GEN BKR OPEN bulb will lit. EXCITATION TRIP bulb will glowt . HP BYPASS will OPEN to adjust main steam pressure.

LPBP opens to adjust HRH pressure. TURBINE TRIPPED bulb will glow, HP stop and control valves V-l & V-2,IP stop and

control valves,CRH NRVS will close fully. Observe various indications of valves on control desk CWA-16.

81

Turbine speed EXTRACTION NRVS

reduces gradually, A-2,'A-3,A-4 and A-5 will close MAL-47, MAL-51, MAL-54 and

Drain extraction valves MAL-55 will open

After closure of Extractiton valves, the following drain valves will open Ex-101,Ex-102,Ex-103,Ex-108,Ex-112 ,Ex-110. When turbine speed reaches will pick up. When turbine speed reaches at 510 rpm JACKING OIL PUMP-1 will pick up When turbine speed is at 24 0 rpm. GATE VALVE
j

at 2 80 0 rpm AUX OIL PUMP-1

GEARING will engage (Barring gear)_ RC FEEDER-A,RC FEEDER-B ,RC FEEDER-C, RC FEEDER-D speed will reduce ID FAN-A/B amperes will reduce

FD FAN-A/B amperes will reduce Feed water flow will reduce (V) Gland steam Leak off valve will close and supply valve will open EX-301 extraction valve will close and CR-306 will

open to maintain D/A pressure. Condensate flow to D/A will reduce. will reduce,

BFP-A scoop position & amps

BFP-B scoop position & amps will reduce, GT oil pump will become OFF on interlock.

82

I I S 2
s* Q Q Q Q 0 Q 0 Q Q Q Q 0 O Q Q O O G
r O

^'L^IM 2Z hR HEATERS EXTRACTION STEAM VALVES

Close LPH-1 EXT STM ISO EX-9^

Close LPH-2 EXT STM ISO EX-10 v Close LPH-3 EXT STM ISO EX-11^ Open Extraction line drain valves . HS-3 CLOSING HP HEATERS EXTRACTION STEAM VALVES 'Close EX-13 HPH-5 extraction steam valve. Close EX-12 HPH-6 extraction steam drain Open extraction line drain valves. HS-4 BOILER MASTER ON MANUAL Put BOILER MASTER on manual Then Boiler base mode lamp will glow HS-5 Take oil support at AB elevation HFO pressure 6 kg/cm2 and atomising steam pressure of 8 kg/cm2. HS-6 PULVERISER-D SHUTDOWN Reduce FEEDER-D speed, when it comes to minimum valve.

Stop FEEDER-D "No coal flow " annunciation corresponding

to MILL-D will come MILL-D ampers will slowly reduce and will show 22 amps PAD-2D position will reduce PAD-4D will close PAD-5D position will reduce Close hot air gate

O O Q

o
O 33

Stop PA Fan-D Stop PULVERISER-D After withdrawing Mill D, maintain MS temperature & pressure at 530 deg.C. and 130 kg/cm2 respectively.

Observe various turbine and boiler paramerters. HS-7 . 7 SHUTDOWN OF BFP-B(MANUAL)

Put BFP group sequence control on manual Put BFP C o n manual. and change BFP-"2 pump'operation to "1 pump1 operation. Put SCOOP-B Reduce on manual

SCOOP-B till indicator on SCOOP-B POSITION

comes to minimum ^OP1 bulb of MIN RCV FC-306 will lit at flow of 60 T/hr approximately. SCOOP-B POSITION will come to minimum SCOOP-A POSITION will increase . Ampers of BFP-B will reduce Ampers of BFP-A will increase Press "OFF1 push button of BFP-B to stop it manuallay AOP corresponding to BFP-B will pick up on auto Wait for some time after switching off the BFP-B Cooling water valve of BFP-B will close

Discharge valve will close BFP-B SUCTION flow will be zero

Put BFP-B on auto standby,if required. BFP-B can be shut down in group sequence also.

34

O O ^
w

HS-8

ADJUST THE HP BYPASS SET VALUE TO 130 kq/cm2 By pressing"+' and"-'push buttons of HPBP PRESSURE

SET the HPBP PRESSURE SET at

130 kg/cm2 (operating

pressure 135- bias pressure 5) ,

^
*

HP PR SET will show 130 kg/cm2

BP-1 VALVE will open further BP-2 VALVE will open further BD valve will open BPE-1 VALVE will open

o o o
G

BPE-2 VALVE will open LP BY PASS Control valve will remain open VI and V3 of LP by pass spray will remain open

V2 and V4 of LP is by more pass than spray will open if the opening of LPBP valves 50% HS-9 STATUS OF THE PLANT Status of plant will be as follows (running

o o o o
\^'

auxiliaries) - HO guns in service at AB elevation - Mill-A in service with about 40 % load & on manual - Mill-B in service with about 40 % load - Mill-C in service with about 4 0 % load - BFP-A in service - ID Fan-A in service - ID Fan-B in service & on manual & on manual

G
- FD Fan-A in service - FD Fan-B in service

. pa

85

- CEP-A in service - CW pump-1 - CW pump-2 in service in service

- Turbine on barring gear - Main Ejector-A in service - HP/LP bypass in service - Stator water pump-A in service - Seal oil Pump-A is running. - S/H & RH spray on auto HS-10 IMPORTANT PARAMETERS AFTER TRIPPING THE TURBINE FOR HOT STANDBY Main steam pressure at superheater outlet Main steam temperature at boiler outlet HP casing temperature Main steam flow Flue gas temperature after air heater Drum pressure Condensate flow Condensate header pressure Feed water flow Total combustion air Hydrogen pressure Hydrogen purity Reheater steam pressure CST level Condensor vacuum Deaerator pressure . at outlet ' 130 Kg/Cm2 530 Deg. C 500 Deg.C 200 T/hr 141 Deg.C 13 8 Kg/Cm2 2 00 T/hr 2 3 Kg/Cm2 220 T/hr 350 to 400 T/hr 3.5 Kg/Cm2 99.5 % 2 7 Kg/Cm2 2 90 0 mm 0.91 Kg/Cm2 6.5 Kg/Cm2

86

D/A level

2700 mm

O
^ ^ 0 Q 0) 0 iQ 0 Q Q Q Q 0 Q (3 Q Q O G ... D/A temperature Hotwell level HP overall expansion IP overall expansion Turbine bearing vibrations * 160 850 Deg. . mm

< 2 6 mm < 13 mm < 12 microns

Turbine shaft vibrations at HPT,IPT,LPT < 120 microns Turbine lub oil temperature 44 Deg.C 7 Kg/cm2 12 Kg/Cm2 2 00 Deg.C 2 9 Kg/Cm2 3 70 Deg.C 53 0 Deg.C 27 M3/hr 4 7 Deg.C +13 deg 3160 mm 0.15 Kg/Cm2(gauge)

Ejector steam pressure PRDS pressure PRDS temperature CRH pressure after attemperator CRH temperature attemperator HRH Reheater steam temperature Stator water flow LP exhaust temperature Burner tilt GSW tank level Seal steam pressure

xxxxxxxxx

o
87

HOT RESTART OF THE UNIT AFTER SHORT SHUTDOWN HRS-lEnsure that the boiler is on load with mill A,B & C

and FD fans running. Hp/LP bypass is open and turbine is on barring generator seal oil pump and stator water pumps is running. Note the following important parameters: 1. Main steam pressure 2. Main steam temperature 3. Main steam flow 4. HPT outer casing temp, top/bottom HRS-2 ROLLING OF TURBINE Press "ON1 push button of load control increase load reference to 20 MW(House load).Ensure that load gradi130 kg/cm2 53 0 deg.C 200 T/hr 500 deg.C

ent is"ON'. Speed control active lamp is glowing.Ensure that CMC is "OFF1. Observe that HP & IP stop valves are closed, and CRH NRVs are closed. Make "ON1 HP/IP DEVICE. Make Tracking device "OFF1. Ensure that of all oil pumps are "ON1, SLC condensate TRIM SLCs pumps is

"ON1,SLC "ON1,

turning gear ."ON1, SLC LP water injection Drains "ON1. Put SGC oil supply on

SLC

auto. that EHC zero Bring

Observe that TTS-1 and TTS-2 supply is ON.Observe' TSE margins are greater than 3 0 K. Observe zero. Bring starting device that to

position position.

shows

Turbine

trip indication will position.

reset.

speeder gear to 100%

Ensure that MW load limit indicator is at 210 UDC pressure set point on manual. Ensure

MW. Keep that load

gradient is on and show 20 MM. Ensure that "stop reference is OFF 1 , limit pressure reached valves SPD f% g% Q />. Q 0 0 Q Q 0 Q O O O O O O O O O light is OFF,gate Ensure that

V-l and V-2 tripped light is ON.

OFF

/PWR

set point

light is ON

and

synchronization and Then that to

blocked light is QN. Raise starting device to 42 % observe that HP stop Valves V-l and V-2 are open. raise starting device further to 56% and IV-1 80%. ence observe device

and IV-2 are open. Then raise starting

Make tracking device "ON r . Increase speed to 3000 rpm. Now

referand of

turbine rolling will start rate

turbine

speed will gradually increase at the Observe the various criteria

600 rpm/ minute. X-2, valve and

curves gate

X-3,X-4,X-5,X-6 are satisfied.Observe gearing trips at 240 rpm. Observe pedestal vibrations are within

that

that

bearing Observe &

limit.

vibrations 2136

at critical speeds of turbine shaft(1545 540 rpm JOP-1 will stop. Turbine

rpm).At

speed

will gradually increase to 3000 rpm.At 2850 rpm observe that 9-6 AOP-1 trips and MOP discharge pressure will kg/cm2 . Observe that turbine lub oil show

pressure feeder

after

oil cooler will be 5.5 kg/cm2. Adjust RC speed to maintain Steam flow. Observe that .

A,B and C sure and

temperature,prescriterias are

rolling

satisfied (X-6, X-7)

89

HRS-3

OBSERVATION OF TURBOVISORY PARAMETERS Before proceeding further observe turbovisory parainetmere i.e. differential expansions, overall expansions

: att4.;*Xial: Shift-;'; ' " ;' ' ' - '''"[s: t'il-:" ;;:o ' ' !"

HPT- HiMXe top/Bottom ti*mp:.difference

:' < 30 deg . C..

IPT' 'front fcbpvfbot'&otn teftpld'iffererice' " : <3 0 deg.C. ' IPT/'re'ar top/bottom temp\"difference
T S B M a r g i n s ' -
.. : . ; :

: <30 deg.C.
: > 3 0 K

.--?..

.
c

; . - r - v '^' i - ' :: .f = ?

i ! :'-^-"'

HRS-4

SYNOHRONISATION OF" GENERATOR WITH GRID

: . . . 1 r . . J . : : -i
;

:.

Close generator field breaker ing lamps (LED) are glowing.

and observe that follow Field breaker circuit.

healthy.

Excitation "ON1.

Spring charged. GeneraLor Generator.

breaker open .
. , , . , r

Put excitation on "auto1 .

i :

':

. : . J

.-

<<'-

voltage raises gradually to 5 KV and suffencly reaches to full scale and comes baak to 14. KV. of
. . :

observe flash

field becomes auto to

700 atnps, Observe that, field

-;:(> -iv:r: ^ ^ " 3
f

:::-,

^ - '

ON .and kAuto pot any Position*1; bulb.glows. Raise

pot position. 'Generator1 voltage. Increases, gradually 15.75. KV.

' . ' " .

Obserye filjs$. yoltS:,,of

...'; "..' .'. 'x.i'^ 'P^ " " >
:

9 , 0 ;,.^.olts.
j ;

Observe ON.

'-

- ' :

filed

current of 900 amps... Now. make synchrozscope

Put main circuit breaker on auto synchronisation tion(SYN SS-1) i.e. position No. 3 . Synchroscope will start rotating. If in anticlockwise synchroscope needle is slow.

posi need!'. moving when in

direction and speed is

synchrosaope

needle , comes to 11'0 clock

position LED

clockwise direction,auto synchronizing

90

Q) Q) 0 O O ^ 0 01 G O O CJ O
t y

and main CB control switch 52 AE closes. Observe mum phase currents on (R,Y,B) all oil pump will

minipick

up on auto. -tion '

OFF bulb of synchronizer on CWA-16 indicaand generator Now

will glow. Grid voltage frequency frequency will be zero on CWA-17 (position-1). ON UNIT (CWA-16

voltage

panel.

make synchroscope OFF HRS-5 BRINGING Now

HOUSE LOAD OF 20 MW speed reference

increase

Panel)

till

actual MW meter shows 20 MW active

(House load).

Speed control active bulb to start that load.

bulb will be off and load control

will glow.Observe that at 5 to 10 MW TSE will come turbine showing upper mode load from admission mode. TSE will .Ensure the

margins(Upper and

lower)

load margin is available to increase

Observe various generator parameters like field current and voltage, generator current and voltage, MVAR and

^ O " ^
w

power factor. HRS-6 TO PUT "BOILER FUEL MASTER'ON AUTO. Put RS feeder A & B speed control on auto. Then put

"Boiler Fuel Master 'on auto. set point on 150 kg/cm2 and

Keep HP bypass pressure observe that MS pressure (CWA-15). Slowly HPBP-1,

^
w

is maintained at 150 kg/cm2

^ ^ ^ ^

HPBP-2 and BPE-1, BPE-2 closes on auto. BD valve will close after full closer of BPE-1 and BPE-2. As LP

bypass control is auto,

it will close LP bypass control

valves and spray valves.

91

HRS-7

INCREASING LOAD UPTO 100 MW. Increase Load reference set point to 100 MW. Load gradually fuel flow. increase to 100 MW.With the help increase fuel to adjust MS upper TSE various load of will

boiler and is metal parame-

master

pressure margin

Observe

available.

.Observe

turbine

temperatures.Observe ters are normal. HRS-8

that all the turbovisory

CHARGING OF LP HEATERS FROM STEAM SIDE Open LP-1 . extractiton steam isolating valve LPH-1 from steam side. Extraction on auto. Extraction line drain EX-9 to

charge open

NRVA-2 valve

will MAL-55

closes. Now open LPH-2 extraction steam isolating valve EX-10 and close extraction line drain valve EX-101 EX-102 EX-113. valve valve drain (CWA-15). Close locally drain valve Open EX-11. MALvalve LPH-3 extraction line steam of and

LPH-1,

isolating and drain line level

Extraction NRV A3 will open

54 closes on auto. Close EX-103 for LPH-3. Put

extraction LPH-1,2,3

controls on auto, one after another (CWA-15). HRS-9 CARRYOUT AT l_00 MW AUXILIARY SUPPLY CHANGE OVER transtrips trans-

From station bus to unit auxiliary bus and turn fer bus selector on auto mode so that when unit

auto changeover takes place from UAT to station former.

92

&

O O ^ ^

HRS-10

STARTING BOILER FEED PUMPVB' ON GROUP SEQUENCE OR MANUAL. Start BFP manually or in group sequence and make equal loading of both the BFPs. Check feed water flow and maintain drum level to normal.

HRS-11

LOAD RAISING TO L50 MW Line-up Plveriser- C for increasing RC further to load

o
O ' '
start pulveriser- C MS and load feeder 60-70%. Increase pressure, load temperature will increase.

o
O
Hi

'
load reference to 150 MW . Load will gradually increase to 150 MW as per the load gradient. Ensure that TSE margins are available for increasing load. Check turbo-

o
G

visory

parameters. . Observe all the important

parame-

t e r s at 150 MW.

o
HRS-12

o
ts

CHARGING OF HP HEATERS FROM.STEAM SIDE Ensure that heaters are charged from water side. HPH-5 extraction drain valve EX-112 and HPH-6 drain Valve EX110 . Open

Open

extracvalve

o.
o ^

tion 'line

extraction

EX-13 for HPH-5 and EX-12 for HPH-6. Open drip * .

r^

control Put close HP on

valves to maintain NWL of 250 mmwc in the heaters. drip control on auto for both the heaters. Then

extraction line drain valves EX-112 and EX-110. Put heaters group protection on auto and level controls auto.

93

HRS-13

WITHDRAW HO GUNS FROM AB ELEVATION. Withdraw oil firing from AB elevation by giving stop

commands to pair 1-3,2-4. HRS-14 TAKING PULVERI5ER-D IN SERVICE For further increase in load, take pulveriser D in

service. Increase RC feeder-D speed to 60%. HRS-15 INCREASING LOAD TO 21J3 MW Increase increases load to reference to 210 MW . Load the gradually gradient

210 MW at the rate as per

set. Observe various important parameters. HRS-16 TO PUT UDC ON AUTO Bring UDC pressure set point to 150 kg/cm2. Wait deviation on boiler desk (CWA-12) comes mode Put auto. till to to fuel MS

pressure zero. make

Press "ON1 push button of co-ordinated it "ON1. Put boiler set point on auto. on auto.Put MS pressure set point on

factor

pressure will be maintained . Any deviation in the load is to be made by varying unit load target set point

(ULDSP). HRS-17 ' Note various important parameters at 210 MW load and back panels. xxxxxxx from

control desk

94

S6

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) , Ajddns I T O suxqanj^ puB , XOJ^UOO auxqjnj,^ s^

qons sx dnoaB

suox^oss x^T u t t o s : l P9UT3?P Ax^^ax0 O^UT papxAxp uxeui aq^ ^Bt[^ paseq sueaui qoxq/A Aqdosoxxqd , dn-unj 01SYS Z uxeui s t p 50 aoueuiaojasd sx u o p u a ; ^ aax^ua sqq snq^ snoiJEA BuxAaAans ux SUXAXOAUX ^ S B ^ dn-unn ox^euio^nv uox^en^xs aq^ go ^uauiaBpnC pup

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ue

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It

is

apparent that each functional automatically from all the times

group

continues

to

function Criteria1 "Enabling

demanding case

"Enabling the red

other functional groups. In is not available

Criteria'

from

neighbouring automatically the main

"Functitonal Group Control, the system would - act in

such a manner as to ensure the safety of This method avoids a major difficulty

turbine.

generally of

encountered in laying down priority and correct sequence the various steps in single logical chain of events. MODE- OF OPERATION

Each functional group is divided into logical steps arranged in a proper sequence.Prior to the commencement of any step, of the

it is necessary that certain conditions regarding status plant get fulfilled and the relevant parameters acquire desired planned value. for All these pre-conditions step and demanded from are the

meticulously system as

each

"Enabling Criteria1 for next step. ATRS- STRUCTURE AND GENERAL FEATURES in

Automatic Turbine Run-up system is essentially organised

two subgroup controls namely Turbine Run-up(SGC Turbine) and Oil and ious set times System (SGC Oil). These groups in conjunction with TSE

electro-hydraulic governing system accomplish the ' varfunctions. A sub-group control essentially executes of steps in a proper sequence. Sub-group envisages a sub-loop control which control a at exe-

essentially

cutes commands based on the availability of "Enabling Criteria1 .

96

m
f% ^ 0 0 C5 O ^ ^ t> ^> O ^ O
w

Sub-group control for the turbine run-up acts directly on: a) Sub-loop controls (SLC) for the drains . b) Electro-hydraulic governing system c) Auto Synchroniser . Sub-group control for the oil directly actuates: a) SLC for the DC lub.oil pump b) SLC for lub.oil system c) SLC for turning gear operation and d) Interface devices for selected few pumps. According to pre-determined sequence, SGC & SLC ensure various requirements of control oil, lub.oil hydraulic turning,etc. under run-up shut-down and trip conditions. The sub-loop controllers get switched ON and OFF according to the pre-defined sequence logic The sub-loop controls SGC. built in the SGC.

can be operated independently of SLC

However the actual execution of command of a

^ ^ ^

takes place only if the enabling

criteria for the ful-

filment of a particular command are completely satisfied. It is possible to intervene manually at any level namely interface sub-loop control or sub-group control.

o
O

The enabling criteria at the various levels of heirarchy are of different nature. For
w

instance, the enabling criteria at the equipment considera-

the

"interface level1 envisaged is based on

^ ^

protection point of view rather than the process tion.

97

It

is also possible to manually start the

plant

upto

any the

level/status

then ask the sub-group control to perform

remaining functions. To facilitate such modes of operations, the sequential logic has been developed in such a manner

. that sub-group control shall quickly skip to the

proceeding

step done manually and accomplish the steps automatically in the desired logical manner. The SGC Turbine logics (ATRS)

incorporating various steps and criteria required to execute each steps are given below: ATRS START-UP PROGRAMME Operation Release 1. Starting device 0% 2. Position set point of turbine control <0% 3. Generator field breakerVOFF' 4. Generator breaker "OFF1 5. Drain BEF HP control valve-I not closed '>>^'iJ " . < . , <

6. Drain BEF HP control valve-2 not closed >^'"~' 7. Limit pressure operation "ON' 8. Load Control "ON' 9. Synchronizer "OFF' 10. f$^s Oil pressure>4.8 kg/Sq.Cm. Step-1 Switch on S L C drains-MON time 2 seconds. Criteria for Step-2 1. 2. 3. SLC drains "ON1 All ESVs closed HP control valve-1 closed

98

o
_ 0 0 0 <Q 0 0 |3 j 0 (Q Q Q Q 4. 5. 6. 7. 8. 9. 10. 11. 12. HP control valve -2 closed INTCPT Valve-1 closed INTCPT Valve-2 closed NRV CRH LH closed NRV CRH RH closed EXTR Valve A5 <5% EXTR valve A4 <5% EXTR valve A3 <5% EXTR valve A2 <5%

Step-2 No command issued - MONS time 100 seconds Criteria for Step 3^ 1. 2.
3 4

Trip fluid pressure > 5kg/Cq.Cm. Turbine speed >15 rpm One Condensate Pump "ON1

o o o
w

SLC drains not faulted DT HP CAS SEN TOP - BOT > minus 40 K DT HP CAS SEN TOP - BOT < plus DT IP CAS FR DT IP CAS FR DP IP CAS RE DP IP CAS RE Step:3 Close drain BEP HP CONTROL Valve-1 TOP - BOT < plus 40 K 40 K

. .6 7. 8. 9. 10.

O O O O O Q Q O

TOP - BOT > minus 40 K TOP - BOT < plus 40 K

TOP - BPT > minus 40 K

Close drain BEF HP CONTROL Valve-2 Switch SLC warm-up CONTROL "OFF1

99

Criteria

for Step-4

1. Drain BEF HP CONTROL valve-1 closed 2. Drain BEF HP CONTROL valve-2 closed 3. SLC warm-up CONTROL ^OFF' 4. Waiting time 60 seconds. Step:4 No command issued - MON time blocked Criteria for Step-5 1. Boiler fire v0N' 2. Steam BEF HP BYP 1>3OK superheat 3. Steam BEF HP BYP 2>3 0K superheat 4. Steam BEF LP BYP 1>3OK superheat 5. Steam BEF LP BYP 2>3 0K superheat 6. DT (HP BYP-1-CONTROL valve mid) GT X-l-1 7. DT (HP BYP-2-CONTROL valve mid) GTX-1-2 8. Total boiler steam flow GT 15%

9. DT (wet steam 1-CONTROL valve) LT X-2.1 10. DT (wet steam 2-CONTROL valve) LT X-2.2 11. DT (HP BYP-1 CONTROL valve) LT X-3 OR BLR steam temperature BEF HP BYP-1 < 4 00 deg.C 12. DRN BEF HP ESV-1 Not closed 13. DRN BEF HP ESV-2 Not closed 14. DRN BEF INTCPT ESV-1 not closed 15. DRN BEF INTCPT ESV-2 not closed 16. Oil temperature after cooler >35 deg.C

100

G C?
5 3 * "

. Step-5: Starting device raise-MON time 60 seconds. Criteria for Step-6 1. Starting device >34 %

'^

2. HP ESV-1 not closed ^ 3. HP ESV-2 not closed Step-6: ^ No command issued-MON time 60 seconds. Criteria for Step-7 1, HP ESV-1 open ^
KjJ

2. HP ESV-2 open Step-7: No command issued - MON time blocked Criteria for Step-8 1. Total steam flow >15%

'^
W

2. Steam BEF HP BYP-l>30 K superheat 3. Steam BEF HP BYP-l>3 0 K superheat 4. Steam BEF LP BYP-l>30 K superheat 5. Steam BEF LP BYP-2>30 K superheat 6. Boiler fire "ON' 7. DT (HP BYP-1 CONTROL valve) 8. DT(HP BYP-2 CONTROL valve) > XI.1 > XI.2

^ ^

9. Condensate pressure < 0.5 kg/sq.cm. "^ ^ Step-8: SLC warmup CONTROL ON-MON time 2 seconds pa

101

Criteria for Step-9 1. SLC warm-up CONTROL ~0N' Step-9:Starting device r'aise-MON time 40 seconds. .Criteria for Step-10 1. Starting device >70% 2. INTCPT ESV-1 open 3. INTCPT ESV-2 open Step-10: Speeder gear raise - MON time 500 seconds. Criteria for Step-11 1. Drains no fault 2. Speeder gear 100% 3. Gland steam pressure CONTROL "ON1 4. SLC oil temperature CONTROL "ON1 ' 5. Any oil vapour- extraction "ON1 6.' HYD purity 97% 7. Generator gas pressure>3.4 kg/sq.cm. 8 . - Generator seal oil gas DP >0.9 kg/sq.cm. 9. Generator seal oil turbine side pressure>3.8 kg/sq.cm. 10. Generator seal oil EXC side pressure >3.8 kg/sq.cm. 11.. Level in pre-chamber-l&2 <Max. 12. GENERATOR CW FLOW >21 cub. mtr./hr. 13. GENERATOR Stator 14. Stator CW inlet CW pressure >2.4 kg .

temperature <44 deg.C.

102

V /

o
0
Q
> i^ <f% ~

15. HYD cooler CW 16. Liquid

pressure >2.5 kg/sq.cm.pa

in GEN not present

17. Generator SW CONDUCTIVITY <5 MHO Step-ll . No command issued-MON time blocked. Criteria for step-12 l. 2. 3. 4. 5. 6. 7. 8.
10

O
0 Q 0 O < f > r s j 0 "0

All criteria

for STEP-11 > X-4.1

Steam BEF HP ESV-1 SUPER HEATER

Steam BEF HP ESV-2 Super Heater >X-4.2 DT (HP ESV-1 HP case) > x 5.1 DT (HP ESV-2 HP shaft)> x 5.2 Turbine speed >15 rpm

DT (LP BYP-l-IP CAS) >30 K DT (LP BYP-2-IP CAS) >30K Steam temperature BEF LP BYP-1 > 480 deg.C Steam temperature BEF LP BYP-2 > 480 deg.C Drain BEF HP CONTROL valve-1 not closed Drain BEF HP CONTROL valve-2 not closed Power set point >10%

9.

11.

r\

12 .
13.

'-^
O O Q Q O Q O

14. 15. 16. 17. 18. 19. 20.

CONDENSATE pressure <0..2 kg/sq.cm R E L EXP CAS-1 front <plus 8 mm REL EXP DAS-2 rear REL EXP CAS-2 rear REL EXP CAS-2 rear REL EXP CAS-3 rear REL EXP CAS-3 rear <minus2 mm <plus 8 mm <minus2 mm <plus 8 mm <minus 2mm

103

frOT

XYW> XYW > XYW> XYW>

XTSBX

I j e q s dT aiA'ST ^?eqs dH HIA"*T IJ^S dH SIA'ET

V JOJCJ 1JVVIS dH aiA'ST

sucaoxw os> suoaoxtu os>

SUCaOXlU 0 S SUOJTDXUl
>

-IHSJ -reaa
^UC ^O

N3D aiA JBafl'TT N30 aiA JBsg-OT

>^J N30 aiA ^ e a a '6 '^J N30 aiA JBaa 8 2 SYD aiA J e e a z. 2 SYO aiA J ^ a a '9 T SYD aiA J e a a "S T SYD aiA -iBapT *

0S>
>

suoaoxui ge

Jeaj:

suoaoxiu sc> quojj

SUOJ:OXIII

s>

JB3J

suoaoxui sc> quojj

9-x> <dW3I, J.JYHS dH-dAa dH)

ia 'Z

08T suix^ ^THM "T

DOHd qse^ ,ss8J^s

UICLJ:

009 p s s d s euyqanj,

auiT3 NOW- p a n s s t pueuituoo OH

spuooss 00C suitq BuT^teM ujda: 0S9 ^urod ^as pasdg

'Z

spuooss o^ sujxq N O W - SSTEJI ^utod ^as peeds

?* ' . a

, * > .
tf|

16.RAD bear 1 CAS front LH top temp. <MAX 17. RAD bear 1 CAS front RH BOT temp. <MAX 18.RAD bear 1 CAS front LH BOT temp. <MAX 19.RAD bear 1 CAS front RH BOT temp. <MAX 2 0.RAD bear 1 CAS rear 21.RAD bear 1 CAS rear LH top temp. <MAX RH top temp. <MAX

Q 0 0 0 0 O O O O O O C5 O

22.RAD bear 1 CAS front LH BOT temp. <MAX 23.RAD bear 1 CAS front RH BOT temp. <MAX 24.AX bear 1 CAS R/F LH temp. 25.AX bear 1 CAS R/F RH temp. 26.AX bear 1 CAS R/R LH temp. 27.AX bear 1 CAS R/R RH temp. 28.RAD bear 29.RAD bear 3 0.RAD bear 31.RAD bear 3 2.REL EXP 33.GEN Bear front temp. 34.Gen bear front temp. Step-15 SLC warm-up CTRL OFF MON TIME 10 Seconds. Criteria for Step-16 1. SLC warm-up control "OFF 1 Step-16: Turbine speed set point raised-MON time 200 seconds DRN BEF HP CONTROL valve-1 closed DRN BEF HP CONTROL valve-2 closed 2 CAS rear temp. 2 CAS R/RHB temp. 2 CAS R/F RHB temp. 2 CAS R/R RHB temp. <MAX <MAX <MAX <MAX <MAX <MAX <MAX <MAX <MAX <90 deg.C <90 deg.C

" J ?
O ^
xi

* " '
v " -

^
w

^ ^
w

o
105

Criteria for Step-17 1. Speed setpoint 3000 rpm. Step-17

No command issued - MON time blocked Criteria for Step-18 1. Turbine speed >2950 rpm

2. Bear VIB CAS GEN < MAX 3. Shaft VIB < MAX 4. Bearing temp. < MAX Step-18 DRN BEF HP CONTROL V-l closed. MON time 4 0 seconds Criteria for Step-20 1. Both AOP "O?'Fr 2. DT (LP BYP-l-IP shaft)< X 7 3. Gen. conditions fulfilled 4. Field flash supply "ON' 5. AVR control supply "ON1 6. AVR PROT supply "ON1 Ster-20 "-en. filed BRKR ON
C : : .'ria for stiep 7 i.

1. Wait time 15 seconds. 2. Generator field BRKR ON 3. Generator Voltage 15 KV Step-21 Synchroniser ON- MON t: i me 6 0 seconds.

:3' ^

Criteria for step-22 1. GENERATOR Step-22 Starting device raised-MON time . * Criteria for step-23 1. Gen. load >10% Step-23 No command issued-MON time 2 seconds. 100 seconds. BREAKER ON

" " "

o
if *

Criteria for Step-24 1. Wait time 2 seconds. Step-24 <r " * Starting device raised- MON time 60 seconds. .

c e
"" ^

Criteria for

Step-25 100%

1. Starting device Step-25

No command issued- MON time blocked ATRS SHUT- DOWN PROGRAMME Step-51 1. SLC drain ON- MON time 2 seconds. Criteria for Step-52 1. SLC drains ON Step-52 Power set point lower-MON time blocked Criteria for step-53 1. Speed CONTROL in action 2. Power set point 0% or Gen. BRKR OFF

107

V
Step-53 Mon time 60 seconds i Turbine.'speed set point lower after a delay of 100 seconds. Criteria for step-54 1. Elec. turbine trip CH-1 trip 2. Elec. turbine trip CH-2. trip- MON time 2 seconds. 3. Synchro."-" ser OFF Criteria for Step-55 1. SYNCHRONISER OFF 2. Trip fli.^o pressure < 5 kg/sq.cm

: ? . GENERATOR field breaker OFF. 1 . ALL ESVs ,...osed Step-5S: Starting device lower 1. Drain before HP CONTROL V-l open-MON time 120 seconds 2. Drain be. re HP CONTROL V-2 open /3 . SLC warm-up control OFF Criteria for step-56 1. Drain before HF .iONTROL V-l open 2. Drain Before K? "DNTROL V-2 open 3. Smarting devi<
4. Drains no fault

:* '
' .

5. SLC warm up CONTROL OFF Step-56 ' No command issued-MON time blocked.

108

o o
f% f| Q Q 0 O 0 0 O O 0 G 0 O O O O Q ^ ^ O O O G
<Kj

ATRS SGC OIL LOGICS-Shut down programme: ' 1- Temp. HP casing top 50% <100 deg.C. 2. Temp. HP casing Step-51 SLC turbing gear OFF - MON time 60 seconds. gearing closed. Criteria for Step-52 1. SLC turning gear OFF 2. Gate valve gearing closed Step: S2_: No command issued Mon time blocked Criteria for Step-53 1. Turbine speed <10 rpm Step-53 No command issued - MON time blocked Criteria for Step-54 1. Waiting time 1000 seconds. Step-54 SLC JOP-1 OFF- MON time 4 seconds. SLC JOP-2 OFF SLC oil temp. CONTROL OFF, Criteria for Step-55 1. SLC JOP-1 OFF 2. SLC JOP-2 OFF 3. SLC oil temperature CONTROL OFF 4. JOP-1 OFF
5. JOP-2 OFF

bottom 50% <100 deg.C.

Gate valve

JOP-1 OFF

O
109

/'>

SLC AOP-X OFF SLC AOP-2 OFF SLC BOP OFF

AOP-1 OFF AOP-2 OFF Oil temperature CONTROL valve closed. Criteria for step-56 1. SLC AOP-1 OFF .
:

'A . SLC AOP-2 OFF 3. 4. 5. 6. 7. SLC EOP OFF AOP-1 OFF AOP-2 OFF Oil temp. CONTROL valve closed EOP.OFF

Step-56 No command issued- MON time Fire Protection-l ] fire protection-l is pushed or main oil tank level I : . . ; to trip th; blocked

low, command is given to trip turbine and gate valves.

After generator

breaker opens command is given for 3 second:;

to open vacuum breaker if trip oil pressure does not I : " a 1 1 bo i ,w 5 kg/sq.cm and emergency stop valve does not close wii hiii 10 seconds annunciation" FIRE PROTECTION NOT COMPLETE' a y>\ ", r ::.

110

o
F u e f r o I eel:, i o n 2.
!'' -I

w h e n p].';!:e<]

r cciii IK .

.1 i

R o o m ,-u'Vr. on f.iic pn'M'i-; ; F u r t h e r It g i v e s thi. , . .*^:* ^ 0 , SGCOI.J#> SUPPLY OF:-1 SLC AOP-1 '0^? SLC A0P-2vv'-:-. SLC -EOP^ON v
k.

. a no .jivey us.-. . . . ur-c- c>.

<

SLC JOP-1 QFf'

0 ^>
Q Q Q
Q

SLC J6?y2- OFF . SLC turning gear OFF

' AOP-1 PRO'T 'OFF A0P T 2 PROT O F F J O P - 1 PROT/OFF
J O P - 2 P R O T O F F

' '(,

* ' " *

'-

0 Q O O 0 O> O O O. O '

A check i^ m^de whether a l l above comrtiands are^ fulf i-lled alongwith cb^lapsEeyof t r i p o i l p r e s s u r e . If -hpt, a n n u n c i a t io;i ^FIRE PRF0TECTIGN.-2 FAULT'. a p p e a l s ; ; ' . Sub-Group C o n t r o l Oil Logics Operation R e l e a s e s : 1 . o i l v a p o u r e x t r a c t o r (1) o r (2) ' 2 . Oil- tank level adequate Step:1 No command issued-MON time-blocked Step:2 Switch on auxiliary oil pump (1) monitoring time 2 seconds. . . ON .

111

CriJteria for step- 3.1 . . Auxiliary oil pump (1) ON 2. Pressure-oil pressure > 4.8 kg/Sq.cm.

Step-3 Switch on SLC oil temperature controller seconds. Criteria for step-4 1. SLC oil temperature controller ON 2. Gen.seal oil gas D P ^ O . 8. kg. sq.cm 3. Gen. seal oil turbine side pressure >3.8 kg/cq.cm '1 . Gen. seal oil excitor pressure >3.8 kg/sq.cm 5. Hydrogen purity >97% 6. Generator gas pressure >3.4 Kg/sq.cm 7. Liquid in generator not present monitoring time 2

Switch SLC turning gear ON Criteria for Step-5 1. Gate Valve- gearing Open
2 .

Monitoring time 60 seconds. /

S.LC t u r n i n g g e a r O N
Step-,5 ' ' "" . p.,

'.''
,' . .

Switch SLC auxiliary oil pump-1 ON .-Switch SLC auxiliary oil pump-2 ON Switch SLC emergency oil pump ON Monitoring time 200 seconds.

Switch SLC jacking oil pump-1 ON Switch SLC jacking oil pump-2 ON

112

o
Criteria for Step-6 Fulfilment of all the above commands Turbine speed > 15 rpm

Step-6
O\

No command issued. Monitoring time 200 seconds. Criteria for step:7

0

Turbine speed >54 0 rpm

Step-7 No command issued - Monitoring time 200 seconds Criteria for step -8 1. Jacking oil pump-1 OFF 2. Jacking oil pump-2 OFF 3. Gate valve gearing closed Step-8 No command issued-Monitoring time blocked. Criteria for step-9 1. Turbine speed > 2950 rpm

^ ,^
o

'

2. Pressure-oil pressure >7kg/sq.cm. 3. Switch auxiliary oil pump-1 OFF 4. Switch auxiliary oil pump-2 OFF Monitoring time 0.5 seconds. Crirteria for step-10

o r^

Waiting time 0.5 seconds. Step-10 No. command issued-Monitoring time 10 seconds.

113

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.I9-4B9JG st. psadf-; r9u-cq:tn^ gi
M H

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Wdtf.

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esa.x si posds; ^ i . i j .

NO ST. 1-dOr OTS

;

I-dOr iczquoo aoox-qns

dO3. u o qoq.TA\s o q U S A T B SX p u e u w o o

i.uo-bs/6>( T1.---X ut*qq ss.9X s\

s j t n f s s e a d X'io a r r r

J.J

I TO Aouobasuia oa-io^quoo aooT-qns XT 'xnv uo tptl.TMS qq USAIB ST pu^iuiuoo

5.td T.TO-HO

I-dOV NO. ST. ZdOV DrlS

3~-'d.u;ric[ x~f'o X3cT2TXTxnV ~ T ^ ^ ^ U " 5 ' 5 " cIoox

XT "'1-V
u o

T-P^TMS

03

QSAIB

ST

ST s.xasssad '[TO HO
sd-c.zq
NO ST I-

e-a
U3MH

,-lOV D'lS

q-qns

,i.3O

diu:id

[ t o Ao

.LJO' ?; - du.!ad X T O Aae.'TXT^"^' ' 1 3dO T.-dumd [TO A.iirT 7/1 >:ny "c

s p u o o s c 01 ^LiiT ra fiurri T'S

'ii'oj ^

o o
o

Sub-loop Control-Jack Oil Pump-2 When SLC JOP-2 is ON If JOP-1 trips OR if jack oil pressure is <120 kg/sq.cm.

When turbine speed is <510 rpm with a delay of 5 seconds Command is given 1. To switch ON JOP-2 To switch OFF JOP-1 To switch OFF SLC JOP-1

O
_

2. 3.

O
g^ g~\ p, r> f^

Sub-Loop Control-Turning Gear

When SLC turning gear is ON If turbine speed is less than 200 RPM Command is given to open the gate valve gearing If turbine speed is greater than 250 RPM Command is given to close gate valve gearing xxxxx

115

210MW A^ 1.0 1.1

UNIT

AUXILIARIES

INTERLOCKS & PROTECTIONS

BOILER & IJTS AUXILIARIES INTERLOCKS & PROTECTIONS ID FAN INTERLOCKS Conditions existing when the unit is shut down and prior to starting of ID fans ID Fan-A and ID Fan-B off Regulating dampers of Fans A & B fully open inlet gates of Fans A &"B open

Outlet gates of Fans A & B open The regulating dampers will be on manual control during shutdown, and impulse from furnace draft control to

regulating, dampers of ID fans disconnected. 1 .2 Starting ID Fan "A' (ID Fan 'B' 'off') (a) ID fan-A shall be prohibited from starting till the (start permissive

following conditions are satisfied conditions) 1. 2.

Regulating damper of Fan-A (GD-6A) in close position Outlet damper of Fan-A closed v

'3. Inlet damper of Fan-A closed > 4. 5. (b) Fan/Fan motor bearing temperatures not high <85/60 deg. C One of the Air preheaters is running.

When ID fan-A is started (ID fan-B is off) impulse shall be given for-

1. 2.

Opening the inlet damper and outlet damper of Fan-A Connecting the regulating damper of Fan-A to the auto control (enable to operate)

116

li

o
^ 3. ID Fan-B bringing the regulating damper to close

o
^ 4. position Permission to start either FD fan-A or FD fan-B

o
1.3 Starting ID fan-B (ID fan-A is off)

Interlocks similar to those at clause 1.2 shall hold for this condition. 1.4 Tripping of LD Fan-A (ID fan-B is off) (a) ID fan-A shall trip automatically under the following good

.
1.

conditions. ID fan-A bearing temperature too high >90 deg.C (prior to this, ID Fan-A bearing temperature high shall be

o
G

o
2. 3.

deg.C (prior in to UCB) this, ID fan A annunciated

motor bearing temperature

ID Fan-A motor bearing temperature too high >70 high shall be annunciated in UCB) "Post purge FAN Trip1 from FSSS provided initiated to trip all the ID (one contact will be

o o o
4.

& FD fans). Command is is very high or very

when

furnace

pressure

low +352/-250 mmwc. ID fan-A motor protection acted. ID fan-A trips(ID fan- B is off) impulse shall be

(b) When 1. 2.

given for: Opening the outlet damper of ID fan-B Opening the inlet damper of ID fan-B Opening the regulating damper of ID Fan-B to position. wide open

G
3.

Q
117

4.

Disconnecting the regulators impulse from acting on regulating damper of ID fan-A

5.

Opening the regulating damper of ID fan-A to wide open position

6. 7.

Tripping

the running FD fans

Boiler tripping-through FSSS (Initiated MFT)

8. To keep the inlet gate and outlet gate of ID fan-A open. 1.5 Tripping of ID fan-B (ID fan-A is off) Iterlocks similar to those at clause 1.4 shall hold good for this condition. 1.6 Starting of ID fan-B (ID fan-A _is ON) (a) ID fan-A shall be prohibited from starting till the (start permissive

following conditions are satisfied conditions). 1. Outlet damper of Fan-B is closed 2. Inlet damper of Fan B-is closed

3. Regulating damper of Fan-B is in minimum position 4. Fan/Fan motor bearing temperatures not high <60/85 deg.C. 5. One of the Air preheaters is running. (b) When ID fan-B is started impulse shall be given 1. 2. Opening the inlet damper and outlet Connecting the regulating damper for

damper of Fan-B of Fan-B to the

auto control (enable to operate) 3. Permission to start the other FD fan

118

1_J_

Starting

of

LD

fan-A

(ID

f a n - B ^ s ON) to those- at rl anno 1.6 shall hold

T n t ' . r i f l o t );;;

similar

o
good i'di Uris condition.

o o o
0

"

1.8

T r J P P i n i l P J - L D F a n - B (ID F a n - A i s ON)

;<;) II.} fa:r-i;, sh<\ 1 . 1 trip a u t o m a t i c a l l y under the inq conditions. 1. Fan fan UCB) . ' :. Fan fan bearing temperature too high

" " ~ "

"

follow-

(prior to this,

o
^

bearing temperture high shall bo: annunciated in 7 0 deg.C. ! i i o ; . . o r bearing temperature too high (prior to this, motor bearing temperature high shall be annunciated

/r>

in UCB >90 deg.C. 3. ^Post purge FAN Trip1 from FSSS 4. ID fan-A motor protection acted.

~ ^

(b) When ID fan-B trips (ID fan-A is ON) impulse shall be

O
^ f% fi Q Q) Q Q O Q Q Q Q 1.9 3. 4. 5. 6. 2. 1. given for: Disconnecting the regulator from acting on the regulating damper of FAN-B Bringing posi t: ior. . Closing che inlet damper of fan-B Closing the outlet damper of fan-B Tripping the FD fan-B provided FD fan-A is on. Energisation of partial load relay (50% Run back) the regulating damper of Fan-B to close

Tripping of ID fan-A (ID fan-B is open) Interlocks similar to those clause 1.8 sahll hold for this condition. 119

Q
G

2.0 2.1

FD FAN INTERLOCKS Conditions prior to starting FD fans FD Fan-A and FD fan-B off FD Fan-A & B impellers are full open Outlet dampers are fully open FD Fan-A & B impeller regulators disconnected (Forced. open)

2.2

Starting FD fan-A (FD fan-B _is off) (a) FD fan-A shall be prohibited from starting until

the following conditions are satisfied: (Start Permissive conditions) 1. 2. ID Fan-A or ID Fan-B is on FD Fan .Control Oil pressure adequate (8 kg sq.cm)

(control oil pressure adequate lamp indication provided on the control desk) 3. 4. 5. FD fan-A impeller in minimum position Outlet damper of Fan-A in closed position FD fan/motor bearing temperature not high <95/85 deg.C FD Fan-A is started (FD Fan-B off) impulse shall

(b) When

be given for: 1. Outlet damper of FD Fan-A to open 2. The outlet damper of FD Fan-B to close & impeller blades of Fan-B to be driven to minimum position.

3. Connecting the impeller of Fan-A control drive to auto control.

: 120

0 O ^ ^ ' .

2^3_

Starting of FD fan-B (FD fan-A is off) Iterlocks similar to those at 2.2 shall hold good for this condition.

2 .4

Tripping of FD fan-A (FD fan-B jLs off) (a) FD fan-A shall trip under the following conditions1. FD Fan-A bearing temperature too high (prior to FD fan-A

d
1

o
3.

bearing temperture high shall be annunciated in UCB >105 dec to this, FD fan-A motor bearing temperature high shall be FD Fan-A Fan motor bearjjig_tejTiperature too high (pjrior annunciated in UCB >90 deg.C. Both ID fans trip "Post purge FAN Trip1 from FSSS FD fan-A motor protection acted. When FD fan-A trips(FD fan-B is off) impulse shall be

G
4. 5.

o o o o

b)

given for: 1. Disconnecting the impeller control drive from the lator of FD FAN-A Bringing the impeller of FD Fan-A to the wide open position. 3. Bringing the impeller of FD Fan-B to the maximum position. regu-

2.

o
o o o

4. 5. 6. 7.

Opening of outlet damper of FD fan-B To open the emergency scanner air damper Boiler tripping The outlet damper of FD fan-A shall remain open.

2.5

Tripping of FD fan-B X?J2 fan-A is off)

Interlocks similar to those of 2.4 shall hold for this condition. . FD Fan-B iFD fan-A i _ s on) .

2 .6

Starting

(a) FD fan-B (FD Fan-A is ON) shall be prohibited from starting until 1. 2. the following conditions are satisfied:

Both ID fans are ON FD fan-B Control Oil- pressure adequate (8kg sq.cm) (control oil pressure adequate lamp indication provided on the control desk)

3. 4. 5.

FD fan-B impeller in minimum position Outlet damper of FD Fan B in the closed position FD fan-B / Fan motor bearing temperature not high 95/85 deg.C.

(b)

When

FD Fan-B is started (FD Fan-A is ON) impulse

shall be given for: 1 . Outlet damper of FD Fan-B to .open 2. Connecting the impeller control drive of FD Fan-B to auto control (enable to operate) . 2. 7 Starting of FD fan-A (FD fan-B i _ s ON) Iterlocka similar to those at 2.6 shall hold good for this condition. 28 Tripping of FD fan-B (FD fan-A i _ s ON) (a) FD fan-B shall trip (when FD fan-A is ON) under the following conditions

122

o o ^
0
_

1. 2.

FD Fan-B trips (provided

FD Fan-A is in service)

FD Fan-13 motor bearing temperature too high >90 deg. C (prior to this, FD fan-B motor bearing temperature high shall be annunciated in UCB)

O
,f% r% U 0 (H) Q ,r>, G Q 0 0 O O O > ^ b) 3 .0 3 .1
2

2.

FD Fan-B bearing temperature too high >105 deg. C (prior to this, FD fan-B bearing temperature high shall be annunciated in UCB .

3. -4. 5.

"Post purge FAN Trip 1

from FSSS

FD fan-A motor protection acted. FD fan-B oil pressure low shall be UCB <0.4 kg/ctn2 . annunciated at

Tripping of FD Fan-A (FD Fan-B is ON) Interlocks similar to those at 2.8 shall hold good for this condition. AIR r_THEATERS INTERLOCKS Conditions before start-up of APH a) Both AHS are OFF (Both AC AH motors are OFF and DC AH motors are ON) The inlet dampers and the outlet dampers in the gas path and. secondary air path, are in full open conditions.

Q 3^ ^Starting AH _ ^ A J _ _(AH "B1 o ^ s OFF) ' ' ' a) AH "A' electric motor is started, if the temperature ^ ^ G
g " ~

of the bearings is less than 60 deg.C. b) Whenever AH "A1 electric motor trips, impulse shall be given for starting AH "A1 DC motor provided the temperature of support/guide bearing of AH is less than 60 deg.C.

'

o
12 3

c)

Impulse shall be given for closing of the inlet and outlet dampers of AH "B' which is OFF.

3.3 Tripping of AIT A1 (AH "B1 is OFF) (a) DC motor shall trip automatically when AH "A' electric motor starts. .3 .4 Starting of AH ^BJ. (AH^A1 _is OFF) a) The interlocks said above for AH "A1 starting(AHB OFF) is applicable .

3 .5 Tripping o _ f AH S B' (AH"A' JLS OFF) a) The interlocks said above for tripping of AH V A' (AH"B' is 3.6 OFF) is applicable .

Both AHs are working when AH^A' trips & AH^B' continue _to run. The gas inlet damper, the secondary air inlet damper of the tripped AH "A1 shall automatically closed. The gas outlet damper the secondary air outlet damper of the tripped AH V A' need not be closed.However if the operator wants to manually close these outlet dampers,they can be closed.

124

,f> f% @ 0 ^> B ^ ^

3 -7

Both AHs are working when AH"B' trips and AH 'A1 continue t _ o run a) The interlocking conditions said above under 3.6 is applicable .

3 .8

One AH i j s working and the other AH i ^ s OFF a) If the working AH trips, the operator shall try for restarting the AH. If the restarting is not within 5 Minutes, the boiler shall be tripped manually.

39

Both AHs are working a) If both AHs A & B trip, the operator may try for restarting the AHs. Ifany one of the AH is not started within 5 minutes, the operator shall manually trip

^
Kj/

the boiler.

3.10 Interlocks for lub oil pumps of support bearing 2 x 100% lub oil pumps has been provided for the support bearing. Any of the two lub oil pumps can be preselected as main pump and the other as standby. Following locks shall be provided for the lub oil pump. inter-

^ ^
o

1) .

Whenever the temperpature of support bearing of air heater is high (35 deg.C), impulse shall be start the selected oil pump. given to

2) ^
r^

The standby oil pump shall start when the main oil pump fails to start or trips.

3)

The main oil pump/standby oil pump shall trip when the temperature of the support bearing falls below a preset value(30 deg.C)

r-\

125

3.11 Interlocks for lube oil pumps of guide bearing 2 x 100% lub oil pump has been provided for the guide

bearing. Any of the two lub oil pumps can be preselected as main pump and the other as standby.The interlocks for these pumps shall be similar to that of support bearing as envisaged in clause 3.10 except starting deg.C second and tripping the 4.0 BLOW DOWN VALVES 1. When drum water level rises to +125 mm above normal water level, an annunciation "drum level high'shall be given in UCB and the blow down valves shall open simultaneously. 2. Blow down valves to be closed manually when level falls down to NWL. 5.0 FD FAN-B LUB OIL/CONTROL OIL SYSTEM (FD LUB OIL PUMPS) (a) 1. Pump-A will start automatically if pump-B trips sequence the water the pump at 40

pump at 3 5 deg.C.

provided A/M switch is in auto position and is "ON 1 . Pump-A is selected.

2. Pump-A will start automatically with a time delay of 60 seconds if oil pressure falls below a set value is working provided A/M switch is in

and the pump-B

auto position and sequence is "ON 1 . (b) 1. Pump-B will start automatically if pump-A trips/ has not started, provided A/M switch is in auto position.

126

 0
~ ^v ff_ n
<S**K

2. Pump-B will start automatically with a time delay of 60 seconds if oil pressure falls below a set value and the pump-A auto position. is working provided A/M switch is in

(c) Pump-A or Pump-B can be started/tripped by pressing the respective push button only when A/M switch is manual position. on

(d) FD fan-A shall be prohibited from starting until the control 6.0 oil pressure is adequate( 8 kg sq.cm)

f% g% ^ ,o, O r*t r^y C\ ;H) O Q 7.0 3. 2.

FURNACE TEMPERATURE PROBE 1. Furnace temperature probe can be advanced/retracted using the push buttons provided in UCB as well as at local. Furnace temperature probe shall be prohibited from being advanced further into the furnace if furnace temperature sensed by it is more than 540 deg.C. If furnace temperature probe is inside the furnace

and the temperature exceeds 54-5 deg.C it will be retracted back automatically. Air blower for ID Fan outlet gate/ dampers a) Whenever any ID fan is started the air blower motor will be started and shall run continuously irrespective of whether the ID fan outlet gate/damper is in closed

or in open position. b)
r>

The blower motors shall be tripped manually after both ID fans are tripped.

.pa
127

c)

With lockable remote/local selector switch, start/stop facility may be provided remote and local. Local may be provided with deinterlock facility.

7.1.

INTERLOCKS FOR MOTOR OPERATED VALVES WITH INTEGRATED BYPASS VALVES 1. 2. First open the bypass valves fully A f t e r bypass valve is fully opened, o p e n the valve 3. After main valve is fully opened, bypass valve may may 4. be closed. main

Main valve can be closed wherever required. The bypass valve, if not already closed, can also be closed along

with main valve. 7.2 INTERLOCK FOR MOTOR OPERATED ISOLATION V A L V E S IN SERIES WITH MOTOR OPERATED REGULATING V A L V E . 1. While opening, the isolating v a l v e has to be opened be

fully first and then the regulating v a l v e has to opened. >. While closing, the regulating

v a l v e , has to be closed be

fully first and then the isolating valve has to closed.

This is to prevent erosion of the seat of isolating valve which has to characteristics. PA FAN INTERLOCKS a) 1. PA Fan start permissives No MFR trip maintain its tight shut off

12 8

11

^ ^ 0 0 <y? Q 0 0 Q G 0 O 0 0 O O O O ^!'
; ' ^ -

2. 3. 4. 5. 6. b)

Pulveriser ignition permit available Hot air'gate is closed Seal air pulveriser bowl DP O.K. Inlet damper in mini position (closed) CAD < 5% open. PA fan tripping

l.PA fan off push button pressed 2.MFR trip 3.PA fan auto stop command 9^ SEAL AIR FAN INTERLOCKS a) 3 seal air fans are provided s/b fan picks up when seal air pressure is low for more than 10 seconds. If fan-A gets a start command but does not start, after 5 seconds Fan-B gets start command. If fan-B gets a start command but does not start, after 5 seconds Fa.n-C gets start command. If fan-C gets a start command but does not start, after 5 seconds Fan-A gets start command. b) If any one of the two seal air fans trips or seal air header pressure is low the third fan will start. And if 3rd fan does not start the mills will get trip command from top downwards . Manual trip is possible only if the pressure is not low and i) 2 or 3 service ii) 1 seal air fan on & no mill in service seal air fans on & less tan 4 mills in

' * *
x

'

^J ^j ^
f^ w

12 9

c)

Each seal air fan has an

associated outlet damper. the outlet damper it gets an open comma

Whenever any seal air fan is started, gets a close command. After 10 seconds d)

Whenever a seal air fan is stopped the associated outlet damper gets a close command.

e)

Seal air valve will get close command when all the following conditions are present. 1. Hot air gate closed 2. PA fan inlet damper closed 3. CAD less than 5% open 4. Pulveriser Off 5. Hot air damper closed 6. PA fan off.

11.

PULVERISER , a) Ignition permissive Prior to startup of any pulveriser the ignition permissive must be adequate to support coal firing.

This is accomplished by either minimum of 3 of the 4 heavy oil guns in service on the adjacent elevation or boiler loading is greater than 3 0 % and pulveriser greater than 5 0 % on the adjacent

load should be elevation. b)

Lub oil pumps for mills Both the pumps will be tripped if any one of the

following conditions is preset: 1. When push botton is manual mode and off. pressed when pulveriser is in

130

2.

When there is an auto stop order when pulveriser is in auto mode

3. c)

Oil level in main oil tank Pulveriser permissives

is very low.

1. Pulveriser/feeder start permit 2. Primary air permit

3. Burner gates open 4. Lub oil pressure OK

5. Pulveriser discharge valve open. valve open

6. Tramp iron hopper

7. Bunker gate open

8. Cold air gate open 9. Pulveriser outlet temp.<94 deg.C. 10. Pulveriser ignition permissive O.K. 11. Pulveriser OFF

13. Seal air header bowl dp greater than 200 mmwc 14. No pulveriser trip command. d) Pulveriser tripping conditions a) Pulveriser discharge valve not open or any bunker gate not open b) c) Loss of unit critical power(+24V)

Pulveriser ignition permissive i.e. support ignition energy is removed within 3 minutes from starting of associated coal feeder.

d) e) .pa

MFT operated PA fan trips

131

f) Seal air DP low < 115 mmwc g) Loss of elevation DC (+24V) h) Lub oil prpessure low < 0.4 kg sg.c. e) Feeder speed comes to minimum when 1. 2. Pulveriser bowl dififerential pressure high >3 00 mmwc Pulveriser motor current reaches (40A) above max set point

f) Loss of coal flow and low pulvleriser motor current (22A) will trip the feeder and closes hot air gate

g) High pulvleriser outlet temperature >95 deg.C will close hot air gate and will open cold air damper. h) When one FD fan trips & four or more pulverisers

are in service, trip command will be given, starting from the pulveriser serving top most elevation,until the pulverisers remaining in service reduced to three. 12. MASTER FUEL TRIP MFT command will initiate following 1. All-pulverisers, feeders trip 2. Both the trip valves closes(HO & LO)

3. All oil guns will trip 4. All the PA fans trip 5. All pulverisers cold air dampers are open to

100% position after time delay of 5 minutes. 6. All auxiliary air and fuel air dampers are

opened to 100 % after time delay of 2 seconds.

132

^ &

Following conditions will initiate MFT Boiler will trip on any of the following conditions:

1. Both ID fans off

Q>
2. Both FD fans off 3. Emergency trip button operated(initiated by operator) 4. Furnace pressure very low - 250 mmce 5. Furnace pressure very high + 325 mmwc 6. Rehater protectiton trip 7. Drum level very high +225 mmwc

8. Drum lelvele very low - 225 mmwc 9. Loss of unit 220 V DC power for more than 2 seconds 10. Low.air flow < 30 % (<240 T/hr)

c
0

11. Unit flame failure _^ Scanner Fans 1. S/b scanner fan will pick up when scanner duct to below 112 mm we

furance differential pressure is

After 10 seconds an alarm is annunciated ^ ^A ^ , , . . & O ^-J ^ 3. 2. The scanner fan emergency damper will open when both the FD fans are off An operator can. trip the fan provided scanner to furnace DP is not low 150 mmwc.

TURNINE AND ITS AUXILIARIES INTERLOCKS & PROTECTIONS 2.0 BOILER Feed Pump 2.1 BFP start permissives conditionsBoiler feed pump will start when following conditions are satisfied133

1. Deaerator level normal 2. BFP suction valve open 3. Aux.Oil pump "ON'and lub.oil pressure > 2.5 kg sq.cm 4. Discharge valve closed,recirculation valve is open 5. Working oil temperature not high < 13 0 deg.c. 6. Differential temperpature across feed pump suction & discharge not high < ' 12 deg.C 2.1.1 Tripping conditions Boiler feed pump will trip automatically on any of the following conditions + . i^ L 1. Differential temperature across feed-pump suction and discharge is high 12 deg.C 2. Working oil temperpature high 13 0 deg.c. 3. Lub.oil pressure less than 1.0 kg sq.cm 4. Motor protections acted~ (motor deg.C and over load) 5. Deaerator level less than 700 mmwc 2.1.2 Automatic starting of standby BFP 1. In case of running BFP trips standby BFP picks up and when 2 pump operation is selected and flow greater than 325 T/hr 2.1.3 BFP recirculation valve will open when corresponding boiler feed pump is "ON' and feed water flow is less winding temp. > 95

M
D

than 100 T/hr or if differential temperature is greater than 12 deg.C. 2.1.4 BFP recirculation valve will close when feed water

discharge flow is greater than 220 T/hr

134

0 0 0

2.2 2.2.1

Condensate Extraction Pumps Start permissive conditionsHot well level not low >3 00 mmwc

2.2.2

Tripping conditions- Running CEP will trip automatically When any of the following conditions exist:

o
0 0 O O O
2 .4 2 .4.1 2 .2.2

1. CEP discharge pressure is less than 14 kg cq.cm. 2. Motor protection acted level is very low <300 mmwc is "ON1 and

3. Hot well

Standby CEP will pick up on auto when SLC

running pump trips on protection or discharge pressure is less than 14 kg sq.cm.

2 .3

Turning gear (gate valve gearing) When turbine rolling is started gated valve gearing (turning gear trips) will be OFF at turbine speed at 240 rpm. When turbine trips and speed drops from 3000 210 rpm..

rpm, turning gear will engage at Interlocks for Turbine Oil Pumps AOP-1

o
^
w

When SLC AOP-1 is ON and AOP-2 trips or oil pressuure is less than 4.8 kg sq.cm. AOP-1 will pickup. When turbine trips and turbine up. speed comes to 2850 rpm AOP-1 will pick acts AOP-1 SLC will be OFF.

If fire protection-1

AOP-2 When SLC AOP-2 is ON and if lub oil pressure is less than 4.5 kg sq.cm,AOP-2 will pick-up.

O ^ ^

135

2.4.2

DC EMERGENCY OIL PUMP When SLC EOP is ON and if lub oil pressure is less than 1.1 kg sq.cm EOP will pick-up.

2.4.3

JACKING OIL PUMP-1 When SLC JOP-1 is ON, and if turbrine speed is less than 510 rpm, command is given to switch on JOP-1. If the

turbine speed is greater than 540 rpm command is given to switch OFF JOP-1. 2.4.4 JACKING OIL PUMP-2 When SLC is ON if JOP-11 trips or if jacking oil pressure is less than 12 0 kg sq.cm and when turbine speed is less than 510 rpm command is given to 1. To switch ON JOP-2 2. To switch OFF JOP-1 3. To switch OFF SLC JOP-1 2.5 DM OVERHEAD TANK LEVEL CONTROL Selected DM transfer pump will be ON if overhead DM tank level is l V s < , < 12 00 a g g g f c mmwc and selected pump trips if overhead DM tank level reaches 3 3 50 mmwc

If DM storage tank level low <4000 mm DM transfer pump will trip. 2.6 CONDENSATE SURGEE TANK LEVEL CONTROL(CST LELVEL) Make up valve DM-12 will open if CST lelvel falls below 2500 mm and valve closes when level reaches 3200 mm. Whenever surge tank level is low command is given to close valves DM-32 and DM-35.

136

Tripping conditions of:

turbine.

Turbine will trip on any of the following conditions

I . l . ' . L e c t r ic I : , rip vacuum low : 0.3 kg s q. cm 2. l ' i r e Protection I &. 1 . 1 operated 3. Main Oil tank level low 700 mm

9oLL

'
4. M S temperature < 480 deg.C 5. Turbine trip push button pressed 6. From ATRS -- through shut down logic 7. Generator Protection acted 8. Boiler MFT

o
U

9. Drum level very high +225 mm

10.
1.1 .

L o w forward t r i p relay operated

Ax.i oi I. s i n . I: i\ : 0 . ' nun

o
I ? . >>(: i . ; ; i . 1 .(:?( I 1 1 % i, ! : : ' * . ol. r a t e d 3 p e e d

G
.1.3. l i u b . o i .1 h e a d e r p r e s s u r e l o w < 1 . 2 kg s q . c m .

G o o

L P HEATER LEVEL CONTROL LPH-2 Valve DR-211 will maintain normal level of LPH-2. . Valve DR-24 will open if LP heater-2^ level goes high greater than 60.0 mm.

LPH-3

Valve DR-16 will maintain normal level.

Valve DR-19

HCn; WELJJ LEVEL will open if CONT_ROL LP- heater-3 level goes high greater than Vdlve CD-14 will' maintain hot well level to 850mm. 6 00 mm.

o
137

DEAERATOR LEVEL CONTROL Valves DM-32 & DM-35 will maintain normal level of Deaerator. Valve CD-23 will open if deaerator level goes high and dump the excess condensate to DM-32 & DM-35 valves closes

condensate surge tank.

on interlock when CST level goes low i.e. less than 2000 mm. Deaerator overflow valve DR-3'3 will open if deaerator level goes very high i.e. greater than 2760mm HPH-5 LEVEL CONTROL Valve DR-11 will maintain normal level of HPH-5 Valves DR-14 will open if HPH-5 level goes high i.e. greater than 3 60 mm. HPH-6 LEVEL CONTROL Valves DR-2 will open to maintain normal lelvel of HPH-6 by cascading HPH-6 drip to HPH-5. DR-2 will close if HPH-5 level is high i.e. greater than 360 mm Valve DR-6 will maintain normal level of HPH-6 by cascading HPH-6 drip to deaerator. can be adjusted by bias provided on FR-6 opening control panel.

Valve DR-34 will open if HPH-6 level goes high greater than 360 mm taking the HPH-6 drip to hot well.

138

o
o
HP HEATER GROUP BYPASS PROTECTION It will operate if any one of the HPH's level goes both the heaters from very high . It will isolate

o o

steam side and affected heater from water side . Valvess FD-130 & FD-131 will open to close valves

FD-16 & FD-17. Drip valve FD-125 will also open.

O G O O

o o o o o

139

C. GENERATOR PROTECTIONS 1.0 FAULT SETTING CAUSE

_. ____.___.-_.-

& INTERLOCKS EFFECT Insulation damage

1. STATOR E/F 64G

Short circuit in slot between core & wdg.(Interturn)s/c Mech.or Thermal damage to corona preventive paint. Gen.will trip. Abnormal Mech. or thermal stresses due to vibrations, overcurrent,overheating.

Action: 2. ROTOR E/F 64 R Action: 3. INTERTURN FAULT 95 G Action: 4. 0/V PROTN 59 G Action: 5. L.|F. P. 3 7G (Low Forward power Action: 6. 0.FREQ.14A/ Action: 7. U/F 14B/81L (less speed) Action: 8. OVERFLUXING 59F Action: 9. GEN.LOSS of EXCN.40G "

-do-

Gen.may be run after balancing 1st E/F. Interturn S/C Gen.will trip. Sudden loss of load at full load & rated P.F. & AVR fails or C/0 to manual & gen.overspeeds. -do-do-

Monitor & control through Excitation control. Upon on electrical tripping. Prime mover fails to trip. Trip the Turbine manually. Sudden loss of load.C.B.open Overspeed Overspeeding

Monitor & reduce Generation accordingly. Inc.in load Over fluxing Aux.speed falls Monitor & increase Generation, if possible. Malfunctioning of AVR Load throws-off with excn. on manual.U/F operation. Monitor Frequency. 1. Unintentional opening of F.B. 2.An o/c or s/c in field wdg. 3.Fault in AVR Overheating of stator iron and transformer iron Induction gen. Asynchronous opn. Oveheating of rot &statorendzone.

140

o
n
O

o
G

:j i:

10.NEGATIVE pH.SEQ.4 6G Action: 11.GEN.MIN.21G (IMPEDENCE MHO BACKUP) Action: 12.GEN.DIFF.P . 87G Action:

Unbalance loading

Excessive heating

rotoi C C C ^ -=
; ^ -

Reduce Generation, Inform L.D.Centre. Phase to phase s/c in stator wdg. on gen. bus in UAT.LV side of GTR. Generator will trip. Internal fault

"

Gen.will trip.

. , _

13.RPP 32 G ReFailure of Prime Mover Motoring (is ska verse power as reverse power" Protection) also damage to rmeant for turb. turbine blades." protection) Action: Gen. will trip. ,~ 14.0/L PROTN 51G Overloading in terms of Temperature rise(Over load) current or MVA. Failure of stator winding "" coolant flow or temperature ^ Action: Maintain the parameters within rated values. ^ 15.LBB 50Z PROTN (Local Brkr. backup) GCB fails breaker) "Bus-bars will get to trip.(Gen.circuit LBB gives command for protection'.Bus bar isolated. External sourcesfeeding the

Action: 2.0 1.

Busbar prot.will operate. INTERLOCKS FOR GENERATOR AUXILIARIES While closing, isolators are to be closed before Circuit Breakers.

2.

While opening circuit breakers are to be opened before isolators.

O 0

3.

Changeover of Aux. supply from unit supply to station supply is automatic, in the event of generator tripping provided

BTSPs are in service & mode of selection is on "Auto1 & UAT

d
VJ

^ 4.

is in service. After synchronisation , changeover of Aux. supply from statio DG set will start automatically if incomers to Bus IDD & Bu supply to unit supply is to be done manually. ODJ (Unit emergency Bd. & station emergency Bd respective fails 6. & mode of selection for D.G. set is on Auto 1 .

0 0
5.

o o
O

Changeover of excitation system from "Auto Channel' to "man channel' is Automatic. To change excitation system from"m channel' to "Auto channel1, "A/M Balance' Voltmeter brought should

o
G
7.

to "Null' & changeover is to be carried out manually

If one stator 'water pump trips or made off, other S.W. pump w pick up automatically, if an Auto.

o o o o
o

9. 8.

If seal oil pump pump trips, trips or made off., If one bothA.C. stator water generator will other trip. will pic automatically , if on Auto. made If both A.C. seal oil pump trip up whether on Auco

OFF, D C seal, oil pump will pick

manual. 10.

Field breaker cannot be tripped manually if GCB is on. Operation of Generator on laod with Air as a medium is not permitted.

Q
O

11.

143

3. 1.

EMERGENCIES ON CWA-17 Excitation Auto

. over to Manual.

Channel Fail: Change

Control Excitation manually. 2. Aux.Thyristor fail,(N-l): No problem. Gen. can be taken u full 3. 4. 5. 6. 7. 8. 9. 10. Generation.

Stator water flow low: Check pump ammeter. Check filter. Stator water temp.high: Check cooler. Hydrogen purity low: Purge hydrogen. Hydrogen pressure low: Fill up hydrogen. Seal oil / H2 DP low: Check H2 pr. Check seal oil filter. do high: do . Check DPR.

Liquid in generator casing : Drain the oil. GTR.wdg.temp.high: Check if not started on auto. xxxxx wdg.temp. Start standby pump,

744

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TEMP SATURATED > MID WALL TEMP HP CONTROL VALVE + X2

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400

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CRXTEEUA K 4-TURBINE ROLLING ON STEAM BEF RAISING SPEED TO 600 RPM

MS TEMP BEF HP STOP VALVES > MS TEMP SATURATED + X4

(OC)

/
500 / 400
00

\x
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RE'COMMEN DED
MS TEMP 3 0 0 BEF HP STOP VALVES 200

100

A x\ \ X X\ \
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CRITERIA X 5- TURBINE ROLLING ON STEAM BEF RAISING SPEED TO 600RPM TEMP BEF HP STOP VALVE 1 > MIDWALL TEMP (EVALUATED) HP SHAFT + X5 TEMP BEF HP STOP VALE 2 >MIDWALL TEMP HP CASING + X5 (OC)

o oo mo

500

400

RECOMMENDED
MS TEMP 300 BEF HP STOP VALVES 200 \X5
\ 1 \ l \ K I \

NOT RECOMMENDED

100

100 200 300 400 500 MID WALL TEMP (EVALUATED) HP SHAFT MID WALL TEMP HP CASING

(0C)

CRITERIA X 6 TURBINE RAISE TO RATED SPEED

MS TEMP BEF HP BYPASS < MIDWALL, TEMP (evaluated) HP SHAFT +x6

(OC) \ ^ 500
\

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STEAM TEMP BEF LP BYPASS < MIDWALL TEMP (evaluated) IP SHAFT +X7 (OC)

500

400

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300 HRH-: TEMP BEF LP BYPASS 200

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100 200 300 400 500 MID WALL TEMP (EVALUATED) IP SHAFT

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PLANT OVERVIEW

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AG - AIR SYSTEM
FROM ATMOS SCAF-A SCAD2A

TO SCANNER AIR COOLING DUCT

(BLADE PITCH CONTROL) SAD1A TO COLD PA HEADER FROM ATMOS

TO HOT PA HEADER
m

(BLADE PITCH CONTROL) SAD IB FROM ATMOS

TO HOT PA HEADER

TO COLD PA HEADER 210 Mff SIMULATOR HPTI HAGPUR AIR SYSTEM FOR BOILEF

! REF:0-97-238-00212

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H GDI A A GD2A

GD3A

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GD7A

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GD2B GD3B "-B; GD4B

i GD7B

FG SIDE

(IGV)

210MW SIMULATOR NPTI HAGPUR AG02 Flue Gas flow

REF:97-288-00212

>aqOl> FROM HOT PA RHS LINE PAD1A PAD2A PAD IB PAD2B PAD1C

PAD5A PAF-A

PAD5B

^ ^ PAF-B TO PULVARISERS

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PAD2C
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PAD5C

PAF-C

PAD ID

PAD2D

PAD5D

en
FROM HOT PA LHS LIHE >ag01 >

PAD IE PAD2E PAD IF PAD2F >ag01 > COLD PA RHS PAD5F PAD5E

PAF-D

PAF-F PAD3A
PAD3B PAD3C PAD3D PAD 4 A PAD4B

PAD4C PAD4D PAD4E

COLD PA LHS

PAD3E

PAD3F

PAD4F

Ref:0-97-291-00602

210MW SIMULATOR NPTI NAGPUR AG03 PA FAHS

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CONTROL OIL RETURN

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LEAKAGE OIL RETURN

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FDF-A OIL TO CONTROL VANE FDF-A OIL TO BEARINGS 'FDFL-2A FDLOA12

LUB OIL RETURN

CONTROL OIL RETURN

S7

NZ

FDF-B OIL TO CONTROL VANE FDF-B OIL TO BEARINGS

LUB OIL RETURN

210MW SIMULATOR NPTI HAGPUR AG04 FD Fan Lub Oil

SLD8A

A C
SLD8B

SAF-A SLD8C
*

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C C fsO3>
TO SEAL AIR VALVES OF MILLS SLD7B SLD8D SLD7C SAF-B FLT-B FROM Atinos

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SLD8F

210 Mw SIMULATOR NPTI HAGPUR AG05 Seal Air Fans Ref:0-97-291-00602 r^t r(>-a >
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SVB1

Drum Vent

B5
B41
DRUM

phosphate dosing

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B69
CBD EBD

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B99 GXD B100

I B D T

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RING HEADER

EH 3

INITIAL FILLING LINE

B97 B98

B9 5 IBD

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I B D T

B9 6

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E9

EN 2A I I EN 2B

EH 1

E2A

FEED NATER FROM FEED REGULATING STATION

_ DRAIN

ILIE2
ECO INLET VALVE

EEF:0-00-047-41236

210MW SIMULATOR NPTI NAGPUR BR01 Drum & E c o

." JStart 1 ^ 1 verity

X 0 S3 3>- C
S H H 14 FSH
KS214

sa f e t y

WS301

S H H 13 S H H 12

NS202

IBDT
S H H 11

PSH

IBDT
BLOWING STEAM

DESH
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S77

01
70

S H H 10 SH vent S H H 9 S H H 7 SHH3Ai t
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SHH8
,H

S59

S71
S58
S57

SHH5
, S21

S61' S60

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S67

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SHH2 SHH1
S19
S H dm hdr

S66 S69
spray control stm S52

S15

C \oIBDTank REF : 0-00-047-41236

FROM BLR DRUM

210MW SIMULATOR NPTI NAGPUR BR02 Super Heaters

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TO IPTurbine msO3

KH SPBAY CONTROL STN

FROM HPT EXHAUST

FROM HPT EXHAUST

BH SPRAY BLOCK VALVE

210MW SIMULATOR NPTI NAGPUR BR03 R e h e a t e r s

REF: 0-00-047-41236

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to r o r o r o t o r o r o to ro

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I CD-7

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21OMW SIMULATOR HPTI HAGPUR CSO1 Condenser System

spray REF:PE-0-09 0^100-004

TO DEAERATOR

CD-3 5 X

CD-32

-H
CD-33 S- *fi
A

msO4 LP HEATER-3

EXT STEAM FROM LPT 3rd STAGE

CD-31

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CD-2 6

CD-28

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CD-27 T -H
CD-25 DRAIN COOLER
CD-:

LP HEATER-1

GD-16 CONDENSATE FROM GSC

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CD-60 EXCESS FLOW TO CST

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CD_14

CD15

CD-13

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24

210MW SIMULATOR HPTI NAGPUR CS02 LP H e a t e r s

CD-23

REF:PE-0-090-100-004

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OUTLET COOLERS (Hot vater)

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CW-l^B

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GSW-B

COHD-A&B CW-12 CW-16

CW-40(? CW-14 CW-3 9

CW-42
CW-48 (M>

CW-49 CW-44

To GS 0/H tank

cwO2
CW to GT,stator vater and turbine lub o i l coolers

210MW SIMULATOR HPTI HAGPUR CW01 C i r W a t e r s y s t e m

cooling water from cw system < cw01< cooling water from GS svstera

GSW501 GSW500 ][

GSW10 I

GSW15 ][

GSW16

GSW12 Jk GENERATOR TRANSFORMER COOLERS STATOR WATER COOLERS

jLGSW13

GSW17 TURBINE OIL COOLERS

GSW18

TO CW SUMP

., 210MW SIMULATOR HPTI NAGPUR CW02 Cir Water System

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GS OVER HEAD

GS OVER HEM> TANK

GSW 28

JL GSW

29

iGSW 33

I GSW 20

A GSW 21

To coolers

GSW 3 0

COHDENSATE EXTRATION PUMP BEARINGS

M

GEH SEMi OIL COOLERS

ffifDROGEH COOLERS

HYDROGEN COOLERS

(HOT WATER)

210 Mff SIMULATOR HPTI NAGPUR CW03 GS w a t e r S y s t e m

VI
V

GS WATER FROM

c OH GS TANK 0 CN43

GSW 3 7

GSW 3 9

GSW 41

GSW 44

GSW 46

MECH SEAL DM WATER

MECH SEAL DM WATER

BFP-A BOOSTER PUMP (Hot water)

BFP-A SEAL COOLER

GSW 38

GSN 40

BFP-A BEARING AND STUFFING BOX COOLER

GSW 42

BFP-A LUB OIL COOLER .* GSW 45

BFP-A WORKING OIL COOLER GSW 47

BFP-A MOTOR COOLER

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210MW SIMULATOR HPTI NAGPUR CW04 G S Water System

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C O O O

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CW - General Service Water System

From GS cooling vater HDR

CW57

GSW 49

GSPI 51

GSW 53

GSW 55

GSW 58

MECH SEfiL DM WATER

MECH SEAL DM WATER

BFP-B MOTOR COOLER BFP-B LUB OIL COOLER BFP-B WORKING OIL COOLER
GSW 59

BFP-B BOOSTER PUMP

GSH 50

BFP-B SEAL COOLER GSW 52

BFP-B BEARIHG AND STUFFIHG BOX COOLER

GSW 54

GSW 56

To CW SUMP (Hot Water)

210 MW SIMULATOR HPTI HAGPUR CW05 G S Water System

VI
c w 0 From GS cooling water header

CW69

GSW 6 1

GSW 63

GSW 65

GSW 68

GSW 70

00

MECH SEAL DM WATER

MECH SEAL DM WATER BFP-C WORKING OIL COOLER GSW 69

GSW 7 1

BFP-C MOTOR COOLERS BFP-C LUB OIL COOLER

BFP-C SEAL COOLER GSW 62 GSW 64

BFP-C BEARING AND STUFFING BOX COOLER

GSW 66

To CW SUMP
CXJ01

BFP-C BOOSTER PUMP

(HOT WATER)

210MW SIMULATOR HPTI NAGPUR CW06 G S W a t e r S y s t e m

o r

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m ,)

o oo o oo o

O O Q O

Q O O d > O

FROM GS COOLING WATER HEADER

CSV 201 ]' GSW 203 ][ GSW 205X GSW 207 Y GSW 209^^ GSW 21l][cSW 24O] [ GSW 242T GSW 213 A GSW 222T GSW 2lT GSW 218T

GSW 202 A GSW 204T GSW 206 A GSW 208 A GSW 210 A L GSW 212>kGSW 241A GSW 243 IA GSW GSW 214 214 A A GSW 224 A G S W ^^ GSW 220A

la

pa
BEBJRING COOLERS

PA FaN BEaRING COOLERS

BEARING COOLERS

ID FaN

FD FaN BEARING COOLERS

FD FaN

BEaRING COOLERS

T o CW SUMP

210MW SIMULATOR HPTI NAGPUR CW07 G S Water System

CY/03

<S From GS cooling -^ water Header

GSW 217 X

GSW 221

225

GSW 229 Y

GSW 233 ][

GSW 23 6

JL

B
GSW 219 I GSW 223 J
GSW 227 GSW 231 ][

GSW 23 5 j

GSW 238

cwO3 MILL OIL COOLERS MILL OIL COOLERS

TO CW SUMP

(HOT WATER)

210MW SIMULATOR HPTI HAGPUR CW08 G S Water System

( ' ) ()

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c cc c c c o c c o o o o o o o o
CW - General Service Water System cwO3 <C From GS cooling water header

o
CW09

Q <& O

GSW 174 V

GSW 173,,

GSW 178 .p

GSW 177 , ,

GSW 167

GSW 168 v

GSW 163,,

GSW 164,,

IB

2A

GSW 172

GSW 171

GSW 17 6

GSN 17 5

GSW 165

GSW 166

GSW 179

GSW 180

AIR HEATER SUPPORT BEARINGS

AIR HEATER SUPPORT BEARINGS

AIR HEATER GUIDE BEARINGS

AIR HEATER GUIDE BEARINGS

210MW SIMULATOR TO CW SUMP (HOT WATER) HPTI NAGPUR CW09 G S Water System

DM-11

-M
T DM 1R S T A T R WATER DM-18 SYSTEM - M i K eg Oil

CONDENSATE EXCESS FLOW RETURN FROM CD-23(dea l e v e l )

DM OVERHEAD TANK

lDM-15

DM-12
DM-14 Bypass valve

-M

DM-32
DM-3 3

DM-31 C S T

DR-37 J { cs01>
DM MAKEUP TO CONDENSER

-MDM-36

-M
DM-34 DR-38 J

DM-35

BLR FILL PUMP

From DM

DM-1(UM MAKEUP)

DM WATER STORAGE TANK

DM PUMP1 .. DM-2 DM-3 DM-7

INITIAL FILLING TO BLR INITIAL FILLING

DR-3 6 X

drn

DM-4 DM-6 "^ DM PUMP2

DM-8 210 Mtf SIMULATOR NPTI NAGPUR DM01 DM makeup System

Ref:PE-0-090-100-021

o o n

n n

T f c

C C C C C

o o o c o o o o o o o o

Q Q
DRAINS/DRIP TO HOTWELL

O O d > O I

DR-304

DR-11 1 DR-312

LPH # 3

LPH #2

LPH # 1

-M6 TO DEA

DR-6

DFB-3 DR-3 2 HPH # 6

DR-16

DR-20

DR-22

DR-15 DR-18
i t

DR-21 DR-17

DC
DR-24

-MDR-23

DR-3 5

DR-19 < MAIN EJECTORS B

DFB-1

DR-14 HPH # 5
&

-wDR-3 4^ DR-13

TO HOTWELL

DFB-2

-M -MDR-08 REF:0-090-100-003

210MW SIMULATOR HPTI HAGPUR DR01 Htr Drains

main b u s - 1 main b u s - 2 transfer bus 29AE 29BE 52E 29CE 29DE s t n - 1 CB |\?l 52C 29DC 29CC 29DG 29BG 2 9 AC 29BC s t n - 2 CB 29AG TR b u s Breaker 29CG 52B

gcb

GT

Stn
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Stn Xmer-2

GENERATOR

< to bus occ

edO4> t o bus

ocd

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to <edO2 < to bus lea ^ edO2> to bus leb bus oca to bus ocb

210MW SIMULATOR NPTI NAGPUR ED01 220KV BUS SYSTEM

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from Stn-1 tr

edO4> CS20
to bus ocf

to bus ocd

ed5j>to bus odj

210MW SIMULATOR HPTI NAGPUR ED03 6.6KV-415V SUPPLY SYSTEM

n a ^( ' " " < ' } {^

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c c c o c o c c

O O O O O O O O O O O O O O

O Q O

ooo

from oca from stn-2 from ocb from stn-2

e d 0

SEMI 8

SEMI 6

SEMI 9

SEM17

bus ocd

bus occ
SEM23

SEM22

Nil SEM20

SEM21K2I

SEM24

SEM2 6

SEM27

I/T
ODDT02 SPARE ODCT02 ODGT02
WTR

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T/F

ODDT02 load

SPARE

t/f

load bus ocf

ODCT02 load

ODGT02 load

I T WTR

t/f

load

SPARE t / f load

bus oce edO3 from oca edO3> > from ocb

210MW SIMULATOR HPTI NAGPUR ED04 6 . 6 K V - 4 1 5 V SUPPLY SYSTEM

from bus Ida2

V from bus odal e

d 0

from bus oda2

CS30

CS33

CS3 5

bus ldd
30AA 30flB
30AC

bus odj
31AA

30AD

30AE

31AB
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31AC

CS34

CS3 6

CS32
^

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To UPS1 To UPS2

T
to 220v t o -24v Chgrl chgr i (main) to +24v chgri

2 4 V C H R G R

2 4 V C H R G R

2 2 0 V D C

t o bus odk ups (sby) DG SET

to

/^N
T

to t o -24v chgr2 chgr2

t o 220v chgr(sby)

210MW SIMULATOR HPTI NAGPUR ED05 DG s e t System

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c o c c c o o o o o o o o o o o o o o o o o o o o o ^ o o o
STATOR COOLING WATER SYSTEM GENERATOR
EXPN TANK

MAGNETIC FILTER

M
Y62 STATOR HINDGINGS Y17 DRAIN Y23

Y15 J Y16
mech i fltrs!

Y13 I Y14 I

M POLISHING UNIT STATOR WATER PUMPS

Y8

DM MAKEUP

YS

COOLERS

M Y7

-MY9 Yll

c EJECTOR w DRAIN

Y10

Y12 210MW SIMULATOR HPTI NAGPUR EG01 STATOR WATER SYSTEM

GEN SEAL OIL SYSTEM

TO ATMOS

TURB END

EXE
END

V_l
OIL VAPOUR FANS
OIL DRAIN FROM GEN BRGS

LsSfc?8

D
PC-2

VS5

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seal oil storage tank

TO ATKOS J1

Vll
SEAL OIL TANK

OIL FROM Gtoverning system

I
SOP-l

SOP-2

DC SOP

V63
SEAL OIL COOLERS

I V6 TV9 6 1 V7

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v62

210MW SIMULATOR HPTI NAGPUR EG02 SEAL OIL SYSTEM

n o n n

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o o o O O O O O O O O O O Q O O O O O ^ O O Q O

VENT H35 TUR END

H2 HEADER

GEN END

c w

H2 c o o l e r
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1
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to CW sump

from GS cooling water header

H34 LLD
C02 FILLING LINE

H2 DRIERS

DRAIN

? AAA
H2 Cylinders
VENT TO ATKOS TO CO2 Cylinders TVENT ATMOS

210 Mw SIMULATOR NPTI NAGPUR EG03 H2 Cooling system

GEN-T/F EXCITATION TRANSFORMER

-ooCT

PT

AVR

AUTO

THYRISTOR CONVERTOR

MANUAL

FIELD BREAKER CONTROL FIELD FLASHING NPTI NAGPUR 210Mw SIMULATOR EG04 Excitation System

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COAL BUNKER

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TO COAL BURNERS

CD-1A

r 0

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CD2

r 0

r
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DUPLEX OIL COOLER

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CD4

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GDI

PULVARISER DISCHARGE VALVES

MILL - A
SUMP

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FLTR 1&

FROM P A FAN

FROM SEAL AIR FAN

FLTR 2A 210MW SIMULATOR HPTI NAGPUR FS01 Mill-A System

REF:1-97-291-00602

MILLING SYSTEM FOR MILLS A/B/C/D/E/F

LFO SUCTION

LOT
RETH
LGV1

LGV3 J

LGV5

Filter 1

]Filter 2

Filter 3

LGV2

LGV4

LGV6

LGV7

LGV9

PUMP1 l i p 1
00
n'-

IPUMP2

PUMP 3

NKVl

NKV3

1GV8

LGV10

Jk. LGV12

LO p r CV

-a
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(interconnecting valves for LO/HO)

LDO HDR

HGV7 ~v-"

M AT20 J
CV !

^ OIL From ' f s 0 8 < H O System

HDIHD ffl-I f
b

HGV8

H h
ELV-Ai
OIL GUNS

2101OT SIMULATOR NPTI NAGPUR FS07 LDO SYSTEM

ATOMISING AIR

r 0 4

o o c
FS Fuel

o p
Oil(HFO)

o c o o o o o o o p. o o o o )P
RETURN TO HFO TANK

o o.

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HFO SUCTION

HGVl ] L

HGV23

HGI^l

FOJITR

on
SRAXNER1 Heater-2 HGV2 HGV28 PUMP 1 00 <ur HGVSO Y:?A *"Temp cv f o r FO AUX STEAK FROM PRDS s 0 ]LHGV24

on STRAINER2

HCT-22

TO AB ELEVATION

HO29 HOTV

s 0 7

HO3 5 " (Long rec vlv)"1 FO HDR

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mi ::HD mi

Q
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w

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LX
r 0 4

TO AB ELEVATION ATOM STEAM f r o m PRDS r 0 4

b r 0 V4y ELEV-CD ( o i l guns)

b r 0 V4>

ELEV-EF ( o i l guns) 210 Mw SIMULATOR NPTI NAGPUR FSogHFO SYSTEM

FEED WATER SYSTEM

VENT

Cond from LP H t r s
CR309
- x DM50 j[ .

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CR308

Aux stam from PRDS & CRH l i n e

M
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CR305 CR306
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SM18 fift

INITIAL FILLING LINE Iron B o i l e r f i l l pump

MCR307

FC312

FC308

FC304 msO4 *)"7Peg sbm *Y from Ext4

DEflERaTORJ.

Aux steam from PRDS for FST AS 3 70 ^ h e a t i n g

FEED STORAGE TANK

FD19

Fc3io (Rec Valve) I

CO

TFC302
FC30|fi

y
\

1
DR315i[

-( drOl)
Drip from HP Heaters DR313

(Dis Valve) IFD304

chemical dosing
FD1

DR314

-MFS301 ,, FD304A C\ FD305

IBDT

-MTO HP HEATERS

BFP-B FD305A 0 FD306

FS302
it

FD3

FD306A REF:0-90-100-005

BFP-C "

BFP BOOSTER PUMP

FS303

210MW SIMULATOR HPTI NAGPUR FW01 D e a e r a t o r & BFP

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FD32 5

FW to KH control stn

brO2 } control stn

Extraction steam from CRH line

-4

Extraction steam from IPT

FW TO PRDS spray

FW TO HP Bypass spray
Feed water from BFP

<fw01< 210 Mff SIMULATOR NPTI HAGPUR FW02 HP HEATERS & FRS

REF:0-90-100-005

Service Air Comprssors

AIR RECEIVERS
ATOMISING AIR TO LO GUNS

Co
(70

IAC-C Inst Air Compressors

BLR side inst air TURB side inst air

210MW SIMULATOR HPT I NAGPim IA01 Inst S Service Air System

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MAW80AASD1

2 t

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HPT

IPT

LPT

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LEAKDFF STEAM to c a n d

GLAND SEAL STEAM HDR

csOl ) 210MW SIMULATOR HPTI HAGPUR MS01 S e a l Steam System

MAW10AA501

MAWIOAAOOI(CV)

REF:01310015121

HP BYPASS SYSTEM REF:0-090-100-002

KS311 (HPBP Warmup valve)

HPBP-1

TO REHEATER br03

CRH L i n e
CRH NRV

65

FROM SH brO2
MS l i n e
DEA PEG STEAM

Ext steam
to HPH6

A Aux Steam f To PKDS

brO2

CR

208 MS l i n e

T
DRAINS TO COND

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CRH MRV

_brO3>
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CRH l i n e 66 I*)
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CKH LINE DRN TO COND

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BDvalve
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FD331
TV SPRAY

J-IQ J-ffJ
BPE2

210MW SIMULATOR HPTI NAGPUR MS02 HP Bypass system

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Q O

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HR311Y-V '

fl]LPBP-1
HBH LINE FROM BLR

LPBP DJJ WATER VALVES

SV3

LERP SPRAY FROM CEP D i s c h a r g e

LPBP INJ WATER VALVES

HR232 REF:0-090-100-002

Dm to cond

Atmos

210MW SIMULATOR HPTI KAGPUR MS03 LP B y p a s s S y s t e m

I")EX301
LBS40 AP001 LBS40 J AAOO1 ^

IP TURBINE

LP TURBINE

0-090-100-002

210MW SIMULATOR HPTI HAGPUR MS04 Extractions from Turbines

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AS370 TO FST HEATING

Q m Q O ^ O

P R D S SYSTEM

FROM CRH LINE

Y
AUJ; steam from other unit

T0

DEA

pEGGrNG

I
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CR301

AS 376
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TO GLAND STEAM HDR

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AS368
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t

+m*\S-l-l

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MAS326

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AS 10

AS2 y^Aj AS3 , , :

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V
AS304 AS308
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Steam to M Ejectors .^O^p r FD347 n)342 FD343

To starting Ejector Ejector

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ATOMISING ST TO KFO

'V
DSH

FD332
m335

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AS307
FROM M S LINE

$4
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AS309

FD336

FROM F W LINE

>^-

AS310

AS311(\L'" AS305-Lov capacity Pr CV FD336-Lov capacity temp CV

FD340

FD338

MFD339

AS308-Hig^i capacity Pr CV

REF:0-090-100-002 & 0-00-301-30259

FD343-Hicjh capacity temp CV

210MW SIMULATOR HPTI HAGPUR MS05 Aux Steam & PRDS

TB - Lub Oil System

JACKING OIL HEADER

V?

Oil vapour Ext FAN

M
J0P1 JOP2

2 2

i
EOP

GOVERNING OIL FOR SEALING (egO2)

I TEMP CONTROL VALVE

TO SOST

J*3 ,

LUB O H COOLERS

AOPl

AOP2

w
v 0
V

cooling water

cooling water REF:11310015101

210MW SIMULATOR HPTI NAGPUR TB01 Turbine Lub oil System

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C C O O C; O O

" 0 O O

o G O ^ f? 0 O

H R H Line l e f t MS l i n e l e f t

CRH l i n e ( L ) ESV-1

iv-l

Gen front brg HPT H P T front bearing Thrust bearing i

IPCV-2
HPCV-2

Gen rear brg

GEH

IPT
combind brg ,

LPT LPT rear brg

Vf-2 1

CRH l i n e ( R ) -

-* TO CONDENSER

ESV-2

MS l i n e r i g h t

H R H Line right

210 M f f SIMULATOR HPTI HAGPUR TB03 T u r b i n e L i n e s

i MSV STEAM ADMISSION m MSV <2>i MCV AREA 0m MCV

.

MSV

TSE
. -

TURBINE AREA

i HPS 0m MPS 0i IPS @m IPS 0i HPC 0m HPC

nact pact

A 01 MSV A MCV A6i MCV HPS

FUNGTON GENERATIONS

9-

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HPS IPS IPS HPC HPC A pi nact/pact

RJECOBDER EH72C020

RECORDER EH72CO23 STEAM ADMISSION AREA i m 0i 0m MSV

MSV MCV

HARMING UP CONTROLLER

TSE
AUTO CONTRL SYSTEM pi ni 0i O

LEGEND Instantaneous Load Instantaneous Speed Surface Temp Mean Temp Upper Temp Margin A 1 - Lower Temp Margin MSV MCV HPS IPS Main Stop Valve Main Control Valve High Pressure Shaft Intermediate Press Shaft High Pressure Casing Lower Load Margin

MCV

TURBINE AREA

Qi HPS m HPS <Si IPS m IPS

Qi

FUNCTON GENERATIONS

TURBINE GOVERJIOR LIVE STM RH MODULING CNTRL UNIT COORDINATOR

^ nact pact

A p - Upper Load Margin

TSE INDICATOR

210 MW SIMULATOR NPTI NAGPUR TB04 TSE

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O O- Q 0 O

MANUAL ATRS AUTO SYNC Track-

SPEED REF Hr

REF LIH Nref dn/dt

SPEED "CONTROLER

VALVE POSITION CNTRL

ELECTRO HYDRAULIC CONVERTER

HYDRAULIC MIH

TSE IMFL

SPEEDER GEAR Track Fact MIH N HPCV & IPCV

MAX

TSE I1TFL
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LOAD KEF

Fref-

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REF LIM Prlim

Pr

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LOflD/FREQ

Trackdp/dt
LOAD GRAD

Track
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Fact FREQ INFL

LOAD LIMIT

PRESSURE COHTROLER

TURB

Hact

Fref-

Pact dp 'PRsetpt

PRact

210 MW SIMULATOR NPTI HAGPUR TC01 EHC

LEAK OFF VLV POS MANUAL/AUTO MANUAL/AUTO Leakoff valve

MAW50AA001

PID MANUAL SET POINT

hact
MAW50CG001 SEAL s t e a m VLV POS CONTRL

SEAL STEAM HEADER

CO
SET POINT PI

VALVE SET PT DEVTN

PID

steam valve MAW10AA001

Pact MAW10CP001

2 1 0 Mtf SIMULATOR HPTI NAGPUR TC02 Seal Steam Control

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O O Q 0 0

OIL AFTER COOLER!?

SLC TEMP CONTROL

MAV42 CT011

1
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OIL TEMP CV

O O
CONTROLLER

MRV41 ftAOOl Ji

AS 11

Luto o i l coolers

MCC

OIL BEFORE COOLERS

210 Mtf SIMULATOR HPTI NAGPUR TC03 Luboil temp c o n t r o l

DRN VLV BEF HPCV-1 MS L I N E

DRW VLV BEF HPCV-2

SLC NARMUP CONTROL

o
MaLllAAOll

MflAlOAAOOl MAA10AA002

i
HPT

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LMCC

AS12

CONTROLLER TSE INFL

AS12

CONTROLLER

MCC

MAA20AA002

* HAL12AA011

MflA20AA001 A

MS LIKE
210 MW SIMULATOR

HPTI HAGPUR TC04 HPCV WARMUP CNTRL

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KAV21AP001
MAIH TRIP VALVE Test o i l TRIP OIL STOP VALVES KAX51AA001 MAIN TRIP VALVE MAV21AP001 AUX. TRIP OH
REMOTE TRIP VALVE

oq >o

?.tAXSlAA002
REMOTE TRIP VM.VE

tbOl ")
CONTROL OIL

MAV21KP001

SOL FOR LS RELAY

MAIH OIL PVMP

SEC OIL TO IPCV SEC O H TO HPCV JWX45BY011 HAX4SBY001 FOLLOW UP PISTONS

ELECTRO tTMBRRULIC COHVERT0R

CONTROL OIL AUX. STARTUI NAX47BY001 STARTING S LOAD LIM DEV

CONTROL OIL
SOL FOR HP/IP TRIM DEV

OIL

HYDRAULIC AMPLIFIER

FOLLOW UP PISTONS

STARTUP OIL TO STOP VALVES

HYDRAULIC Gffi'ERNOR

tfAX46AAUll SOL FOR IS RELAY

HP/IP TRIM DEVICE

PRD.V1RY OH

HP/IP TRIM DEVICE

TRIP OIL

REF:0-100-00-40013

210 MW SIMULATOR HPTI HAGPUR TC08 Governing System

... OVER SPEED TRIP CONTROL OH FILTER RTV THRUST BRG TRIP

MTV

r
-CONTROL OIL
STARTING AND LOAD LIMITING DEVICE

-- LOW VACCUM TRIP ~AUX STARTUP On TO RESET PROTECTIONS LOAD SHEDDING RELAY

CONTROL OH FttTER CONTROL OIL R1T CHANGE OVER VALVE

SPEED CHANGER

GOVERNOR

HYDRAULIC AMPLIFIER

8IV
MAIN 11 STARTUP On on TO RESET ESV & ISV

ELECTRO HYDRAULIC CONVERTOR

TRIP

on

IPCV
CONTROL On TO DRAIN

LORD SHEDDING RELAY

Load

CONTROL OIL

IPT

LPT

210 MW SIMULATOR NPTI NAGPUR TC09 Governing System

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