Steam Turbine Interlocks

F.S.S.S.
CHARECTERISTICS OBSERVATION REMARKS

1.A) Initial conditions :-
a) M.F.R. is in no trip condition.
b). I.D. Fans- A & B bkrs. are in test position.
c) Both I.D.& F.D.Fans A & B are made ON

B) Operations performed:-
a) I.D.Fan - A / B OFF P.B. pressed.

b) I.D. Fans- A & B both OFF P.Bs. pressed.

a) MFR does not trip.

b) i) MFR trips.
ii)All ID fans off indication
lamp appears in First Cause
of Trip panel.
iii)All ID fans off annunciation
appears.

a) F.D.Fan- A / B
does not trip.

b) Both F.D.Fans trip
& annunciations
appear.
2. A) Initial conditions:-
b) I.D. Fans A & B bkrs are in test
positions.
c) I.D.& F.D.Fans- A / B is made ON.

Either I.D. Fan - A / B (whichever is
running) Off P.B. pressed.

i) M.F.R. trips.
ii) All I.D. Fans OFF indication
lamp appears in First Cause of
Trip panel
iii) All I.D. Fans off annunciation
appears

Running F.D.Fans
trip and
annunciations appear.
3. A) Initial conditions:-
b) F.D. Fans-A & B bkrs. are in test mode.
c) Both I.D.& F.D.Fans-A & B are made ON

a) F.D. Fan A / B off P.B. pressed.

b) Both F.D.Fans off P.Bs. pressed.

a) M.F.R. does not trip.

b) i) M.F.R trips.
ii) All F.D.Fans off indication
Trip panel
iii) All F.D.Fans off annunciation
appears

a) I.D. Fan A / B
does not trip.
b) Both I.D.Fans do
not trip.
4. A) Initial Conditions:-
b) F.D.Fans-A & B bkrs. are in test mode.
c) F.D.Fan-A / B is made on.

Either F.D.Fan-A / B
(whichever is running) Off P.B. pressed.

i) M.F.R. trips.
ii) Both F.D.Fans off indication
Trip panel.
iii) All F.D.Fans off annunciation
appears.

CHARACTERISTICS OBSERVATION REMARKS
5.A) Initial Condition:-
M.F.R. is in no tripcondition.

a) Emergency P.B.-1 / 2 is only pressed.
b) Both emergency P.Bs.-1& 2 are pressed
simultaneously

a) M.F.R. does not trip.
b) i) M.F.R trips.
ii) Emergency Trip indication
Trip panel.
iii) Emergency Trip annunciation
appears

6.A) Initial Conditions:-
b) Drum level is normal.

B) Operations Performed:-
a) Drum level is increased to > + 125 mmwcl.

b) Drum level is increased to > + 225 mmwcl.

c) Drum level is decreased to < - 125 mmwcl.

d) Drum level is decreased to < - 225 mmwcl.

a) Drum level high annunciation
appears.
b) i) M.F.R. trips with a time delay of
10 secs.
ii) Drum level very high
indication lamp appears in
First Cause of Trip panel.
iii) Drum level very high
annunciation appears.
c) Drum level low annunciation
appears.
d) i) M.F.R. trips with a time delay of
5 secs.
ii) Drum level very low
iii) Drum level very low

b) Drum level very
high annunciation
resets at +200 mm
wcl.

d) Drum level very
low annunciation
resets at 200 mm
wcl.
b) Furnace draft is normal.
c) All I.D. & F.D.Fan bkrs. are in test mode.

B) Operation Performed: -
Total air flow is decreased to < 252 T/hr.

i) M.F.R. trips.
ii) Air flow <30 % M.C.R.
indication lamp appears in First
Cause of Trip panel.
iii) Air flow < 30 % M.C.R.

a) M.F.R.is in no trip condition.
b) Total air flow is > 30% ( 264.4 T/hr).

a) Furnace press. is increased to > + 150 mm.

b) Furnace press.is decreased to < -175 mm.

a) i) M.F.R. trips.
ii)Furnace press. very high
iii)Furnace press. very high
b) i) M.F.R. trips.
ii)Furnace press. very low
iii)Furnace press. very low

.CC

9.A) Initial Condition:-
M.F.R.is in no trip condition.

a) Unit 220V DC supply is not available.

b) 24V DC supply is not available at :
i) MFT panel (By hardware tripping).
ii) Oil / Coal panel(By individual equipment
hardware tripping).

c) Unit flame failure occurs when :
Coal elevation is without oil support &
corresponding elevation scanners 2 out of
4 F.B.s are not present.
d) R/H protection operated when :
[Any HPBP / LPBP v/v opening < 2% +
Feeder on > 50 secs. + GCB open] OR
[( Feeder on > 50 secs.) + {(HPBP &
HPCVs closed) / (LPBP & IPCVs closed)}]
with a time delay of 10 secs.
e) Loss of all fuel occur when :
No oil gun & coal feeder are in service.

a) i) M.F.R. trips with a time delay of
2 secs.
ii) Loss of unit 220V DC >2secs.
iii) Loss of unit 220V DC >2secs.'
b) i) M.F.R. trips.
ii)24V DC loss indication lamp
appears in First Cause of Trip
panel.
iii)24V DC loss annunciation
appears.
c) i) M.F.R. trips.
ii)Unit flame failure trip
d) i) M.F.R. trips.
ii)R/H protection trip indication
Trip panel.

e) i) M.F.R. trips.
ii)Loss of all fuel trip indication
Trip panel.

a) All H.O.& L.O. nozzle v/v-s are closed.
b) H.O.T.V. & L.O.T.V. are closed.
c) All P.A.Fans are off & H.A.Gs. are closed
d) All feeders are off.
e) No boiler trip is persisting.
f) All scanners are showing no flame.
g) Air flow is > 30% & < 40%.

B) Operation Performed:-
Push to Purge P.B. is pressed.

A)
i) If anyone of these is not present,
the two lamps mentioned first will
get off.
ii) No boiler trip lamp will not glow
if any cause of M.F.T. presents.
iii) When all conditions are satisfied,
Purge Ready & Push to Purge
lamps will glow.
B)
i) Purging lamp will glow for 300
secs.
ii) After 300 secs.,Purge Complete
lamp will glow& previous lamps
will get off.
iii) If any cause of M.F.T.occurs
during the purging lamp glowing
period, all the other lamps will
get off.

b) T.L.R. is reset.
c) Generator ckt.bkr. is closed.

a) M.F.T. is operated.

b) Generator class-A, group-1 is operated.

a) i) Turbine trips.
ii) Generator low forward power
relay 37G operates.
iii) Generator class-B, group-2
operates.
iv) Generator class-C, group-1
operates.
v) Boiler S/H attemperation block
v/v-s will close & indication
lamps appear.
b) i) M.F.R. trips.
ii) Turbine trips.
iii) Spare Trip indication lamp
appears in First Cause of Trip
panel.

b)AC 110V is available in all fuel elevations.
c) All coal feeders are in off condition.
d) L.O.T.V. & H.O.T.V. are open.
e) One pair of nozzle v/v-s are open.

B) Operation Performed:-
Simulate such that
AC 110V is not available for the
corresponding mill & nozzle v/vs.

i) M.F.R. trips with a time delay of 4
secs.
ii) After M.F.R. trips, all running
feeders get off and L.O.T.V. &
H.O.T.V. get closed.
iii) <F.B.& loss of ACindication
Trip panel.
iv) <F.B.& loss of AC at any
elevation in servicealarm appears

TURBINE INTERLOCKS & PROTECTIONS

Annunciation Characteristics
Alarm Value Trip Value
Process Remarks

1.
1.1) Control oil press low.
1.2) Control oil press.very low.

1.3) Control oil press. > 8 kg/cm
2
&
turbine speed 2950 rpm.
1.4) Trip oil press.low.

1.1) 5 kg/cm
2
.

1.2) 2 kg/cm
2

Control oil press.
low trip alarm.

1.4) 3 kg/cm
2

Trip oil press.low
alarm at CRT.

By draining
press.switch
line.

1.1) AC A.O.P. auto cut-in.
1.2) Turbine trip
(T.L.R.= 86T
1
-T
2
& 86TX
1
-TX
2

operated).
1.3) AC A.O.P. auto cut-off.

1.4) Turbine trip
(T.L.R.= 86T
1
-T
2
& 86TX
1
-TX
2

operated).
2.
2.1) AC A.O.P. trips / L.O.press.low.
2.2) AC power failure / AC E.O.P. trips / AC EOP
fails to develop L.O.press.>1.1kg/cm
2

2.1) 1 kg/cm
2
.
2.2)DC EOP auto
startalarm.

By
simulation.

2.1) AC E.O.P. auto start.
2.2) DC E.O.P. auto start
3.
3.1) Turbine speed = 500 rpm.

3.2) Turbine speed = 400 rpm.

3.3) AC power failure during AC J.O.P.running.

3.4) Jacking oil filter dp high.
3.5) Jacking oil press. low.

3.3)DC JOP auto
startalarm.
3.4) 1 kg/cm
2

3.5) 150 kg/cm
2

J.O.press.low
alarm.

~DO~

3.1) AC J.O.P.auto cut-off during
turbine speed raising.
3.2) AC J.O.P.auto start during
turbine speed lowering.
3.3) DC J.O.P.auto start.
4. Turbine L.O.press.very low.

0.8 kg/cm
2

L.O.press.low trip
alarm.
~DO~

Turbine trip & vacuum breaker open
(T.L.R.= 86T
1
-T
2
& 86TX
1
-TX
2

operated).
5.
5.1) Turbine speed = 403 rpm during speed rising.
5.2) Turbine speed = 302 rpm during speed
decreasing.

5.1) Turing oil supply valve closes.
5.2) Turning oil supply valve opens.
6. T.P.R. system heavy fault

6. Turbine trip alarm.

6. By
making
point
contact.
6. Turbine trips
(T.L.R.= 86T
1
-T
2
& 86TX
1
-TX
2

operated).

Annunciations Characteristics
Process Remarks
7.
7.1) Turbine trip from back-up panel.

7.2) Turbine trip by emergency trip device at
governing rack.

7.1)Emergency turbine
trip on P.B.alarm.

7.2) Turbine trip &
Emergency hand
trip device
operated alarms.

7.1) By
pressing
P.B.at
back-up
panel.
7.2) By
pressing
lever.

7.1) Turbine trips, MSVs.& RSVs.
close
(T.L.R.= 86T
1
-T
2
&86TX
1
- TX
2

operated).

7.2) ~DO~
8.
8.1) Axial thrust high (mechanical).

8.2) Axial thrust high (electrical).
8.3) Axial thrust very high ( mechanical).

8.4) Axial thrust very high (electrical).

8.1) + 0.51 mm.
- 0.53 mm.
8.2) + 0.49 mm.
- 0.53 mm.

8.3) + 0.98 mm.
- 1.03 mm.
Thrust failure
protection device
operated &
Condenser vacuum
breaker openalarms

8.4) + 1.00 mm.
- 1.01 mm.
Electrical thrust
failure trip &
Condenser vacuum
breaker openalarms

8.3) By
operating
lever for
thrust
failure
device
near brg.
no.- 2.
8.4) By
simulation.

8.3) Turbine trips& vacuum breaker
opens
(T.L.R.= 86T
1
-T
2
& 86TX
1
-TX
2

operated).

8.4) ~DO~

9.
9.1) Turbine overspeed (mechanical).

9.2) Turbine overspeed (electrical).

9.1) 111% O.S. i.e.
3260 rpm.
Emergency
governor 1/ 2
operated at 111%
O.S.alarm.
9.2) 112 % O.S. i.e.
3360 rpm.
Elect.O.S.tripalarm.

9.1) By
operating
1st & then
2
nd
lever of
emergency
governor.
9.2) By
simulation.

9.1) Turbine trips
(T.L.R.= 86T
1
-T
2
& 86TX
1
-TX
2

operated ).

9.2) ~DO~

Process Remarks
10.
10.1) Shaft vibration high.
10.2) Shaft vibration very high.

10.1) 125 micron.

10.2) 250 micron
Shaft vibration
high trip alarm.

10.2) By
simulating
high signal
to any brg.
& very high
signal to its
consecutive
brg.

10.2) Turbine trips & vacuum
breaker opens
(T.L.R.= 86T
1
-T
2
& 86TX
1
-TX
2

operated).

11.
11.1) Brg. pedestal vibration high.

11.2) Brg. pedestal vibration very high.

11.1) 62 micron
Brg.pedestal
vibration
highalarm.

11.2) 125 micron
Brg. pedestal
vibration very
high tripalarm.

11.2) By
simulation.

12. Turbine eccentricity high. 12. 75 micron
Turbine
eccentricity
highalarm.

13.
13.1) Condenser vacuum low.

13.2) Condenser vacuum very low.

13.1) 608 mmHg
Condenser
vacuum low
alarm.

13.2) 532mmHg.
Condenser
vacuum very low
trip alarm.

13.1) By
simulation.

13.2) By
actual.

13.2) Turbine trips
(T.L.R.= 86T
1
-T
2
& 86TX
1
-TX
2

operated).

14.
14.1) Seal oil temp.after duplex filter high.

14.2) Seal oil temp.after duplex filter very high.

14.1) 50
0
C.
Seal oil temp.
after duplex
filter high
alarm.

14.2) 55
0
C.
Seal oil temp.after
duplex filter very
high& Turbine
tripalarms.

14.2) By
simulation

14.2) Turbine trips
(T.L.R.= 86T
1
-T
2
& 86TX
1
-TX
2

operated ).
Generator mechanical protection
relay operated.

Process Remarks
15.
15.1) Differential expansion high:
a) H.P.T.

b) I.P.T.

c) L.P.T.

15.2) Differential expansion very high:
a) H.P.T.

b) I.P.T.

c) L.P.T.

15.3) Turbine casing expansion high.

15.1)
a) + 4.75 mm.
- 3.02 mm.
b) + 7.6 mm.
- 2.0 mm.
c) + 18.5 mm.
- 3.0 mm.
Differential
expansion high
alarm.

15.3) 36 mm.
Turbine casing
expansion high
alarm.

15.2)
a) + 5.69 mm.
- 3.96 mm.
b) + 8.4 mm.
- 2.9 mm.
c) +19.2 mm.
- 3.8 mm.
Differential expansion
very high trip alarm.

15.2) By
simulation.

15.2) Turbine trips
(T.L.R.=86T
1
-T
2
& 86TX
1
-TX
2

operated)
16. Liquid in generator terminal bushing. 16. Liquid in generator
high & Turbine
tripalarms.
16. By
making
point
contact.
16. Turbine trips
(T.L.R. = 86 T
1
- T
2
& 86TX
1
-TX
2

operated).
Generator mechanical protection
relay operated.
17.
17.1) H.P.T. I/L steam press. low.

17.2) H.P.T. I/L steam press. very low.

17.1) 63.5 kg/cm
2

H.P.T. I/L steam
press. low alarm.

17.2) 60 kg/cm
2

H.P.T. I/L steam press.
very low tripalarm.

17.2) By
simulation.

17.2) Turbine trips when turbine
load > 40 %
(T.L.R.= 86 T
1
- T
2
& 86TX
1
-TX
2

operated).

Process Remarks
18.
18.1) H.P.T. I/L temp. low.

18.2) H.P.T. I/L temp.very low.

18.3) H.P.T. I/L temp. high.

18.4) H.P.T. I/L temp.very high.

18.5) L.P.T.exhaust steam temp.high.

18.6) L.P.T.exhaust steam temp.very high

18.7) H.P.T./ I.P.T.casing I/L differential temp.high.

18.1) 450
0
C
H.P.T. I/L temp.
lowalarm.

18.3) 545
0
C
H.P.T. I/L temp.
highalarm.

18.5) T.E.= 90.6
0
C
G.E.= 90.8
0
C
L.P.T.exhaust
steam temp.
highalarm.

18.7) 30
0
C
H.P.T./ I.P.T.casing
I/L differential temp.
highalarm.

18.2) 430
0
C
H.P.T. I/L
temp.very low
tripalarm.

18.4) 565
0
C
H.P.T. I/L
temp.very
high trip
alarm.

18.6) T.E.=110
0
C
G.E.=111
0
C
L.P.T.exhaust
steam temp.
very high trip
alarm.

18.2) By simulation.

18.4) ~DO~


18.2) Turbine trip
(T.L.R.=86T
1
-T
2
& 86TX
1
-TX
2

operated).

18.4) ~DO~

18.5) L.P.T.exhaust spray v/v opens.

18.5) Turbine trip
(T.L.R=86T
1
-T
2
& 86TX
1
-TX
2

operated).

19.
19.1) T.O.cooler O/L oil temp.high.

19.2) Brg. L.O drain temp. high.

19.3) Brg. metal temp. high.

19.4) Brg. metal temp.very high.

19.1) 55
0
C
Oil cooler O/L oil temp.
high alarm.
19.2) 75
0
C
Brg. L.O. drain temp.high
alarm.
19.3) Brg.no.-1 = 100
0
C
Brg.no.-2 = 90
0
C
Brg.no.-3 & 4=105
0
C
Brg.metal temp.highalarm

19.4) 120
0
C.
Brg. metal temp.very
high. trip alarm.


20. U-ring broken (MCV:1-4 drain temp.high) 20. 100
0
C
U-ring broken (MCV:1-4
drain temp.high)alarm.

TILPARA INTAKE PUMP
1.Annunciations: -
1.1) Sump level high = 62.39 M.
1.2) Sump level low = 60.20 M.
1.3) Sump level very low = 59.70 M.
1.4) Pump discharge header press.low = 7 kg/cm
2
.
1.5) Pump discharge header press.high = 11 kg/cm
2
.
1.6) Motor brg.( D.E. / N.D.E.) temp.high = 70
0
C.
1.7) Motor brg.( D.E. / N.D.E.) temp.very high = 80
0
C.
1.8) Motor winding temp.high = 100
0
C.
1.9) Motor winding temp.very high = 110
0
C.
2. Start Permissives: -
2.1) Sump level not low.
2.2) Motor brg. & winding temps.not high.
2.3) Discharge butterfly v/v fully closed.
2.4) No auto stand-by selection.
2.5) No switchgear disturbance persisting.
2.6) L.O.S. released, bkr.in service & D.C.P. selector switch innormalposition.
2.7) Bus under-voltage relay(86M) not operated.
2.8) Lock out relay(86A) not operated.
2.9) Interlock AC supply not failed at DCP.
2.10) Trip ckt.relay(95C) in reset condition, i.e. DC control on.
3. Interlocks & Protection Trips:-
3.1) Sump level very low.
3.2) Motor brg. temp.very high.
3.3) Motor winding temp.very high.
3.4) Bus under-voltage relay(86M) operated.
3.5) Lock out relay(86A) operated.
3.6) Off-command from local / DCP.
3.7) Discharge butterfly v/v will close after pump trips / made off.
3.8) Auto stand-by pump starts if running pump trips.
3.9) Auto stand-by pump does not start if running pump is tripped manually from D.C.P.
3.10) Pump does not start if discharge butterfly v/v is not fully closed.
3.11) If all the three pumps in pipeline no.-1 are started, then preferential tripping of pump no.-3 will occur. Also,if all the three pumps in
pipeline no.-2 are started,then preferential tripping of pump no.-6 will occur.
3.12) In running conditions of pumps,if power-pack v/v of any pipeline gets closed; then all the pumps in that line will trip.

Bakreswar Intake Pump

1. Status Indications & Audio Visual Indications At Drive Control Panel (D.C.P.):
1.1) On / Off / Trip indication lamp of each pump.
1.2) Pump failure audiovisual indication.
1.3) Pump discharge header press.low ( 1kg. /cm.
2
) audiovisual indication.
1.4) Pump discharge header press.high ( 3kg. /cm.
2
) audiovisual indication.
1.5) Motor winding temp.high(100
0
C.) audiovisual indication.
1.6) Motor winding temp.very high(110
0
1.7) Motor brg.temp.high(70
0
1.8) Motor brg.temp.very high(80
0
1.9) Full closing / opening of discharge v/v audiovisual indication.
1.10) Pump suction press.low( 0.3 kg /cm.
2
70.5 M) audiovisual indication.

2. Start Permissives:
2.1) Suction press.not low.
2.2) Pump discharge v/v fully closed.
2.3) Motor brg.& winding temps.not high.
2.4) L.O.S.released,bkr.in service & D.C.P.selector switch inman./ normalmode.
2.7) Trip ckt.relay(95C) in reset condition, i.e. DC control on.
2.8) Lockout relay(86A) not operated.

3. Interlocks & Protection Trips:
3.2) Motor brg.temp.very high (scanner / heat gauge).
3.3) Motor protection relay operated.
3.4) Motor trip through L.O.S. / from DCP.
3.5) Lockout relay(86A) operated.
3.7) Discharge v/v will close automatically after pump trips.

Raw Water Pump

1.1) R.W. sump level not low(> 67.25 M).
1.2) Brg.temp.not high(< 70
0
C).
1.3) Motor winding temp.not high(< 110
0
C).
1.4) Discharge v/v fully closed.
1.5) No electrical trip persisting.
1.6) L.O.S.released,bkr.in service & D.C.P.selector switch inman/automode.
1.9) 95C trip ckt.relay in reset condition, i.e. DC control on.
1.11) Lockout relay(86A) not operated.

2. Annunciations:
2.1) R.W. sump level high = 75 M.
2.2) R.W. sump level low = 67.25 M.
2.3) R.W. sump level very low = 67 M.
2.4) R.W. discharge header press.high = 4.55 kg /cm.
2

2.5) R.W. discharge header press.low = 2 kg /cm.
2

2.6) Motor brg.temp.high = 70
0
C.
2.7) Motor brg.temp.very high = 80
0
C.
2.8) Motor winding temp.high = 110
0
C.
2.9) Motor winding temp.very high = 120
0
C.

3.1) R.W. sump level very low.
3.2) Motor brg.temp.very high.
3.4) Lock out relay(86) operated.
3.6) Off- command from local / DCP.
3.7) Discharge butterfly v/v will close if pump trips / made off.
3.8) In auto,stand-by pump will take start if running pump trips.
3.9) In auto,stand-by pump does not take start if running pump is tripped manually from D.C.P.

C.T.Make-Up Pump, A.H.P.Make-Up Pump & Service Water Pump


1.1) Sump level not very low (> 72 M).
1.2) Discharge v/v fully closed.
1.3) No electrical trip persisting.
1.4) L.O.S.released,bkr.in service & D.C.P. selector switch inman/ normal mode.

2. Annunciations:

2.1) Clear water sump level high = 77.25 M.
2.2) Clear water sump level low = 72.25 M.
2.3) Clear water sump level very low = 72 M.
2.4) C.T.M.U.Pump discharge header press.high = 5 kg /cm.
2

2.5) C.T.M.U.Pump discharge header press.low = 2 kg /cm.
2

2.6) A.H.PM.U.Pump discharge header press.high = 6.3 kg /cm.
2

2.7) A.H.PM.U.Pump discharge header press.low = 3 kg /cm.
2

2.8) S.W. Pump discharge header press.high = 16 kg /cm.
2

2.9) S.W. Pump discharge header press.low = 10 kg /cm.
2


3.1) Sump level very low.
3.2) In auto, stand-by pump will take start if running pump trips.
3.3) In auto, stand-by pump does not take start if running pump is tripped manually from D.C.P.

A.C.W.Pump


1.1) Bkr.is in service & selector switch is innormalmode.
1.2) L.O.S.of pump & its discharge v/v are in released condition.
1.3) Motor protection relay not operated & no trip command existing.
1.4) At local control panel(L.C.P.),selector switch is inman/automode.
1.5) Motor winding temp.not high(<120
0
C).
1.6) Motor brg.temp.not high(<70
0
C).
1.7) Sump level not low(>72.75M).

2.Alarms & Annunciations:

2.1) Sump level high(74.5M).
2.2) Sump level low(72.75M).
2.3) Sump level very low (72.3 M).
0
C).
0
C).
2.6) Pump/Motor brg.vibration high(150microns).
2.7) Pump/Motor brg.vibration very high(200microns).
2.8) Pump thrust brg.temp.high(70
0
C).
2.9) Pump thrust brg.temp.very high(80
0
C).
2.10) Common discharge header press.low(2.8 kg/cm
2
).
2.11) Motor protection operated (indication lamp only).
2.12) Pump trip.
2.13) Discharge v/v 90% opening failure.
2.14) Discharge v/v 90% closing failure.
2.15) A.C.W.dp across discharge basket strainer high (0.8 kg/cm
2
).

3. Protection Trips:

0
C).
0
C).
3.3) Pump/Motor brg.vibration very high(200microns).
3.4) Motor electrical protection operated.
3.5) Discharge v/v fails to open 30% with a time of 10 secs.
3.6) Sump level very low(71.1 M).

4. Auto Operation & Interlocks:

4.1) In auto, stand-by pump will take start (provided start permissives are fulfilled) at the following conditions:-
a] Running pump trips.
b] Common discharge header press.low(2.8 kg/cm
2
).
4.2) After pump starts,discharge v/v will open 30% automatically.
4.3) Discharge v/v will fully open when discharge header press.becomes adequate(>2 kg/cm
2
).
4.4) On issuestopcommand to pump other than trip,discharge v/v will close first & after full closing of the v/v,the pump will stop.
4.5) Due to 30% opening failure of discharge v/v,when a pump trips or when a pump trips for another reason,further start of the said
pump & operation of its discharge v/v are protected unless reset is done by closing the L.O.S.of the pump & its discharge v/v.

5. Remote Feedback At U.C.R.:

5.1) Current of both pumps.
5.2) On,Off&Tripindications.
5.3) Discharge v/vopen&closeindications.
5.4) Discharge header press.lowalarm.
5.5) Alarm as group trouble of both pumps.

C.W.Pump

1. Start Permissive:

1.1) Bkr.is in service & no switchgear disturbance is persisting.
1.2) Motor protection relay not operated & no trip command existing.
1.3) At L.C.P.,selector switch is inman/automode.
1.4) Motor winding temp.not high(< 100
0
C).
1.5) Pump / Motor brg.temp.not high(< 70
0
C).
1.6) Pump thrust brg.temp.not high(< 70
0
C).
1.7) Sump level not low.
1.8) L.O.S.of pump & its discharge v/v are in released conditions.

2.Alarms & Annunciations:

2.1) Sump level high.
2.2) Sump level low.
2.3) Sump level very low(71.1 M)
0
C).
0
C).
2.6) Pump/Motor brg.vibration high(6.3mm/sec).
2.7) Pump/Motor brg.vibration very high(13mm/sec).
2.8) Pump/Motor brg.temp.high(70
0
C).
2.9) Pump/Motor brg.temp.very high(80
0
C).
2.10) Pump thrust brg.temp.high(70
0
C).
0
C).
*2.12) Common discharge header press.low(1.3 kg/cm
2
for #1 and 1.4 kg/cm
2
for #2 & #3). Alarm reset value = 1.5 kg/cm
2
for #1 and 1.6 kg/cm
2
for
#2 & #3.
2.13) Motor protection operated (indication lamp only).
2.14) Pump trip.
2.15) Discharge butterfly v/v 10
0
opening failure.
0
opening failure.
0
closing failure.
2.18) C.W.dp.across condenser (L/R) high(0.6 kg/cm
2
).


3.1) Motor electrical protection operated (earth fault, short ckt.,stalling,-ve phase sequence & overcurrent).
3.2) Motor winding temp.very high (130
0
C).
3.3) Bus under voltage (86M).
3.4) BTS trip command.
3.5) Lock out relay(86) operated (multiplier at DCP).
3.6) Trip command from LCP.
3.7) Off- command from LCP / local.
3.8) Pump/Motor brg.temp.very high(80
0
C).
3.9) Pump/Motor brg.vibration very high.
3.10) Pump thrust brg.oil temp.very high(80
0
C).
3.11) Discharge v/v fails to open 10
0
with a time delay of 12 secs.
3.12) Sump level very low(71.1 M).

4. Auto Operation & Interlocks:~

4.1) In auto,stand-by pump will take start (provided start permissives are fulfilled) at the following conditions:
a] Any other pump trips.
b] Common discharge header press.low(1.2 kg/cm
2
).
4.2) After pump starts,discharge v/v will open 10
0
automatically.
4.3) Discharge v/v will fully open when discharge header press.becomes adequate(>1.1 kg/cm
2
).
4.4) Discharge v/v closes fully with pump off / trip.
4.5) Due to 10
0
opening failure of discharge v/v,when a pump trips or when a pump trips for another reason,further start of the said
pump & operation of its discharge v/v are protected unless reset is done by closing the L.O.S.of the pump & its discharge v/v.

5. Remote Feedback At U.C.R.:

5.1) Current of both pumps.
5.2) On, Off&Tripindications.On feedbacks of C.W.P
P
s. which were earlier from aux.contactor at C.W.local panel are modified
& presently taken from individual pump breaker to avoid tripping problem originating from panel.
5.3) Discharge v/vopen&closeindications.
5.4) Discharge header press.lowalarm.
5.5) Alarm as group trouble of all pumps.

C.W.Chlorination System

1. Annunciations:
1.1) Expansion tank I/L press.high(2.5 kg/cm
2
).
1.2) Liquid CL
2
press.low(1.5 kg/cm
2
).
1.3) Liquid CL
2
press.high(18 kg/cm
2
).
1.4) Safety relief v/v I/L press.high(>1.5-2.5 kg/cm
2
).
1.5) Evaporator gas line press.high(>15 kg/cm
2
).
1.6) Press. regulating v/v d/s press.high(3.5 kg/cm
2
).
1.7) Evaporator water level high.
1.8) Booster pump discharge header press.high(9.6 kg/cm
2
).
1.9) Booster pump discharge header press.low(3.5 kg/cm
2
).
1.10) Booster pump overloaded.
1.11) Evaporator water temp.low(<70
0
C).
1.12) Evaporator water temp.high(>90
0
C).
1.13) Vacuum in chlorinator high(>25of WC).
1.14) Vacuum in chlorinator low(<5of WC).
1.15) Gas filter differential press.high(0.8 kg/cm
2
).
1.16) Caustic solution level low.
1.17) CL
2
leak high LD-1(>1ppm)
1.18) CL
2
leak high LD-2(>1ppm)
1.19) Booster pump suction press.low(1.2 kg/cm
2
).

2 Interlocks & Protections:
2.1) Gas CL
2
v/v(CL-34) opens when vacuum is normal(between 5&25of WC).
2.2) CL-34 v/v closes when vacuum is high(>25of WC)or low(<5of WC).
2.3) CL-34 v/v openes when evaporator water temp.>70
0
C.
2.4) CL-34 v/v closes when evaporator water temp.<70
0
C.
2.5) Heater will cut-off automatically at evaporator water temp.>85
0
C.
2.6) Heater will cut-in automatically at evaporator water temp.<77
0
C.
2.7) CL
2
gas shut-off v/v closes when booster pump discharge header press.becomes low(<3.5 kg/cm
2
).
2.8) CL
2
gas shut-off v/v opens when booster pump discharge header press.becomes high(>9.6 kg/cm
2
).
2.9) When evaporator tank water level falls down due to continuous evaporation & if automatic water filling v/v fails to maintain the water
level,water level lowannunciation will appear in D.C.P.& at the same time heater will cut-off automatically initiated by the water
level low switch.

C.T.Fan


1.1) Gearbox oil level is normal.
1.2) Nooverload trip&vibration high tripis persisting.
1.3) Control fuse O.K. & L.O.S. released.
1.4) D.C.P. control supply,control transformer-A/B & 415v 1PC bus-A/B normal.

2. Power Source:

2.1) In general:~
a] Control transformer-A415v 1PC bus-AGroup-A C.T.fans (Fan nos.-1 to 5).
b] Control transformer-B415v 1PC bus-BGroup-B C.T.fans (Fan nos.-6 to 10).
2.2) In case of shut-down / emergency:~
Control transformer-A / B 415v 1PC bus-A & B or 415v 1PC bus-A / B Group-A & B C.T.Fans.

3. Indications, Annunciations & Protection Trips:

3.1) On&Offindications of each C.T.fan in C.R.T.
3.2) Any C.T.fan tripannunciation at U.C.P.
3.3) Any C.T.fan tripannunciation at U.C.P.will appear for the following protection trips:~
a] If anyone or more running C.T.fans in Gr.-A / B trip because of overload/control fuse blown/vibration high/oil level low.
b] If all the running C.T.fans in Gr.-A / B trip because of 415v 1PC bus-A / B dead/control transformer-A /B fail.
c] If all the running C.T.fans in Gr.-A & B trip because of 415v 1PC bus-A & B dead/control supply of D.C.P.fail.

Compressor
1.1) L.O.S.normal.
1.2) Bkr.is in service.
1.3) Cooling flow adequate(>300 lit/min).
1.4) L.O.press.O.K.(>2.5 kg/cm
2
).
1.5) H.P.cylinder jacket cooling water temp.normal(< 47
0
C).
1.6) L.O.temp.normal(< 60
0
C).
1.7) L.P.cylinder O/L air temp.normal(< 165
0
C).
1.8) H.P.cylinder O/L air temp.normal(< 175
0
C).
2. Alarms & Interlocks:
2.1) Auto start of compressor at low common header press.through PS-3 press.switch < 7.2 kg/cm.
2

2.2) H.P.cylinder discharge air press.lowalarm through PS-4 press.switch 7.8 kg/cm
2
.
2.3) H.P.cylinder discharge air press.highalarm through PS-5 press.switch 8.4 kg/cm
2
.
2.4) After cooler O/L air press.highalarm through PS-6 press.switch 7.3 kg/cm
2
.
2.5) Receiver air press.lowalarm through PS-7 press.switch 6.8 kg/cm
2
.
2.6) Receiver air press.highalarm through PS-8 press.switch 8.3 kg/cm
2
.
2.7) Cooling water header press.lowalarm through PS-11 press.switch 2 kg/cm
2
.
2.8) L.O.press.lowalarm through PS-12 press.switch 2.5 kg/cm
2
.
2.9) L.O.press.very lowalarm & compressor trip through PS-13 press.switch 2 kg/cm
2
.
2.10) L.P.cylinder O/L air temp.very highalarm & compressor trip through TS-1 temp.switch > 165
0
C.
2.11) H.P.cylinder suction air temp.highalarm through TS-2 temp.switch > 50
0
C.
2.12) H.P.cylinder O/L air temp.very highalarm & compressor trip through TS-3 temp.switch > 175
0
C.
2.13) Aftercooler O/L air temp.highalarm through TS-4 temp.switch > 50
0
C.
2.14) L.O.temp.highalarm through TS-5 temp.switch 60
0
C.
2.15) L.O.temp.very highalarm & compressor trip through TS-6 temp.switch 65
0
C.
2.16) H.P.cylinder jacket cooling water temp.highalarm through TS-7 temp.switch 47
0
C.
2.17) H.P.cylinder jacket cooling water temp.very highalarm & compressor trip through TS-8 temp.switch 50
0
C.
2.18) Compressor trip due to overloadalarm.
2.19) Cooling water flow lowalarm through FS-2 flow switch = 300 lit/min 2.5 kg/cm
2
.
2.20) Cooling water flow very lowalarm & compressor trip through FS-1 flow switch = 270 lit/min 1.8 kg/cm
2
.
2.21) 100% 50% loading unloading through PS-1 press.switch = 7.8 7.5 kg/cm.
2

2.22) 100% 0% loading unloading through PS-2 press.switch = 8.1 kg/cm.
2
2.23) Atomising air press.at operating floor lowalarm = 5 kg/cm.
2

2.24) Atomising air press.at operating floor very lowalarm = 4.5 kg/cm.
2

3. Compressor panel & its drier panel control power supplies which were initially from 240v AC control power,have been changed &
presently taken from UPS & 24v DCDB respectively to avoid tripping of all compressors due to power supply failure.

Fuel Oil Pumps

1. L.D.O. & H.F.O. Pumps:~
1.1) Start Permissives:
a] L.D.O./H.F.O. storage tank level not very low ( 0.8 M).
b] M.C.C. selected normal,power isolator on & L.O.S. released.
c] L.C.P. selected in manual mode.
1.2) Auto-start Interlocks:
In auto,stand-by pump will take start at the following conditions:
a] Any running pump trips or fails to start.
b] F.O.header press.becomes low( 13 kg/cm
2
for L.D.O./H.F.O.) at a definite time delay.
1.3) Indications & Remote Operations:
At L.C.P. & U.C.R. pumpon,off,M.C.C.disturbance,normal power supply&alternate power
supply healthyindications should be found O.K.
Remote operation of H.F.O.pump no.-1 from U.C.R.-1,H.F.O.pump no.-2 from U.C.R-
2,H.F.O.pump no.-3 from U.C.R.-3,H.F.O.pump no.-4 from all U.C.Rs. & L.D.O.pumps from L.C.P.should be checked & found O.K.
L.D.O. / H.F.O. tank I/L or O/L v/vopenindications,L.D.O./ H.F.O.tank level high / low,H.F.O.tank oil temp.high /
low,H.F.O. tank stage heater temp.low,D.O.T. level high / low&H.F.O. / L.D.O. pump suction strainer dp highannunciations are
to be found O K.
After H.F.O.C.V.-HO33A1,H.F.O.press.lowalarm = 3.5 kg/cm
2
.
After H.F.O.C.V.-HO33A1,H.F.O.temp.lowalarm = 115
0
C.
DP across H.F.O.discharge strainer highalarm 0.7 kg/cm
2
.
H.O.T.V./L.O.T.V. trip at very low oil press. 3 kg/cm
2
.
2. L.D.O. & H.F.O. Unloading Pumps:~
a] Either L.D.O. tank-1 / 2 & H.F.O. tank-1 / 2 levels are normal.
b] Either I/L v/vs of L.D.O. tank-1 / 2 & H.F.O. tank-1 / 2 are open.
2.2) Protection Trippings:
a] Either L.D.O. tank-1 / 2 level becomes high = 9.35 M.
b] Either H.F.O. tank-1 / 2 level becomes high = 10.45 M.
3. Drain Oil Pump, Oil Recovery Pump, Oil / Water Separator Pump & Sump Pump:~
For D.O.pump & O.R.pump,selector switches are to be put in1for starting of pump no.-1 & vice versa. Nothing is
provided for O / W.S.pump.
3.2) Protection Tripping: Tank level low.

C.S.T.-D.M.S.W.Pump-C.T.P.

1. Alarms, Annunciations & Feedback Indications:~

1.1) L.C.P. alarms & annunciations:
a] C.S.T. level high = 8.15 M.
b] C.S.T. level low = 1.15 M.
c] C.S.T. level very low = 0.65 M.
d] D.M. make-up tank level high.
e] D.M. make-up tank level low.
f] D.M.S.W.pump discharge press.lowalarm appear = 3 kg/cm
2
.
g] D.M.S.W.pump discharge press.lowalarm reset = 3.5kg/cm
2
.
h] Suction dp highof D.M.S.W.pump & C.T.P. 0.6 kg/cm
2
.
I] D.M.S.W.pump & C.T.P.trip.
j] Stand-by D.M.S.W.pump & C.T.P.start.

1.2) U.C.R. alarms & annunciations:
a] C.S.T. level high,low & very low.
b] D.M.S.W.pump trip.

1.3) U.C.R. feedback indications:
a] On,Off,Trip&Remoteindications of D.M.S.W.pumps & C.T.Ps.
b] Operation of D.M.S.W.pump from back-up panel.

2. Start Permissives For C.T.P.& D.M.S.W.Pump:~

2.1) C.S.T.level not very low.
2.2) M.C.C.selected for L.C.P.,L.O.S. released,module switch on,no M.C.C.disturbance or trip exists.
2.3) L.C.P.selected local/U.C.B.for L.C.P./U.C.B.operation respectively.

3. Auto-start Interlocks:~

3.1) D.M.S.W.Pump:
a] C.S.T. level not very low.
b] Pump selected auto at L.C.P. & not running,discharge press.low and any of the other two running pumps tripped.
3.2) C.T.P.:
a] C.S.T. level not very low.
b] Pump selected auto at L.C.P.& not running and if the other running pump trips.

4. Protection Trip:~
C.S.T. level very low.

5. Local & Auto Operation Of The Following V/vs:~

Valves Manual Auto Closing Auto Opening Status
5.1) D.M.- 4 / 5 5.1) O.K. 5.1) C.S.T. level high. 5.1) C.S.T. level low / very low. 5.1) O.K.
5.2) D.M. 6 / 7 5.2) O.K. 5.2) C.S.T. level very low. 5.2) C.S.T. level not low. 5.2) O.K.
5.3) D.M. 63 / 64 5.3) O.K. 5.3) C.S.T. level very low. 5.3) C.S.T. level not low. 5.3) O.K.
5.4) D.M.C.W. 40 5.4) O.K. 5.4) D.M. make-up tank level high 5.4) D.M. make-up tank level low. 5.4) O.K.

D.M.C.W.( Boiler ) & D.M.C.W.( Turbine ) Pumps

1. Suction press.lowalarm 1.5 kg/cm
2
.

2. Suction press.lowalarm reset & pump start permissive 1.8 kg/cm
2
.

3. Discharge header press.lowalarm 3.5 kg/cm
2
.[D.M.C.W.(B)] / 3.2 kg/cm
2
.[D.M.C.W.(T)].

4. Discharge header press.lowalarm reset 4.4 kg/cm
2
.[D.M.C.W.(B)] / 4.5kg/cm
2
.[D.M.C.W.(T)].

5.Stand-by pump auto-start interlock checking procedure:
5.1) Pump M.C.C.power & position = Normal.
5.2) Pump L.O.S.condition = Released.
5.3) Pump selector switch condition = Auto.
5.4) Pumpsuction press.lowalarm = Reset.
5.5) After satisfying point nos.- 5.1 to 5.4,the stand-by pump should take start in auto when discharge header press.of the running pump
becomes low[ 3.5 kg/cm
2
.{D.M.C.W.(B)}/3.2 kg/cm
2
.{D.M.C.W.(T)}]or get tripped electrically.
For D.M.C.W.(T) system,this auto-
start interlock logic is applicable for the third stand-by pump when two pumps are already in running condition as well as for the first
pump when the remaining two pumps areoff.

6. All annunciation & indication lamps at L.C.P.,U.C.R.& C.R.T.should be found O.K.Onfeedbacks of D.M.C.W.(T)P
P
s.which were
earlier from aux.contactor at local panel,are modified & presently taken from individual pump MCC to avoid tripping of all DMCW(T)P
P
s
& thereby C.E.P
P
s.due to power supply failure at local panel.

C.E.Pump

1.Start Permissives:~
1.1) Suction v/v = Open.
1.2) Recirculation v/v open 80%.
1.3) Vent v/v = Open.
1.4) Discharge v/v = Close.
1.5) Hotwell level = Adequate ( 0 mm).

2. Alarms & Interlocks:~
2.1) Hotwell level very lowalarm & pump trip with alarm = - 800 mm.
2.2) Hotwell level lowalarm = - 400 mm.
2.3) Hotwell level + 150mm.alarm = 150 mm.
2.4) Hotwell level highalarm = 260 mm.
2.5) Hotwell level very highalarm = 300 mm.
2.6) DP across suction strainer highalarm 0.05 kg./cm
2
.
2.7) Discharge press.lowalarm 16 kg/cm
2
.
2.8) Discharge press. very lowalarm & pump trip with alarm with a time delay of 20 secs.14 kg/cm
2
.
2.9) After first pump starts,discharge v/v will open when discharge press.18 kg/cm
2
. In case of S.G.C.,discharge v/v of stand-by pump
will open if common discharge header press.16 kg/cm
2
.
2.10) Discharge v/v will close after pump off.
2.11) Pumps will trip if all DMCW(T)Ps.off feedback comes.
2.12) Vent v/v will close after 2 mins.of pumpon.
2.13) Vent v/v will open after pump stop / trip.
2.14) Motor winding temp.highalarm 125
0
C.
2.15) Motor winding temp.very highalarm at C.R.T.130
0
C.
2.16) Pump thrust pad temp.highalarm at C.R.T.85
0
C.
2.17) Pump journal brg.temp.highalarm at C.R.T.85
0
C.

3. S.L.C. Auto-start Permissives:~
Out of three pumps,one no.,selected asmain(say pump-A),is started & between the remaining two pumps-B & C;anyone,say pump-C is
kept in stand-by mode and thereafter SLC is madeon.In this condition,the logics are as follows:
3.1) If mainpump-A runs single, pump-B will start inautowhen m/c load is > 50%.
3.2) If single running mainpump-A trips or its discharge header press.becomes < 16.5 kg/cm
2
when m/c load is > 50%, then pump-B
will start in auto.If m/c load is < 50%,then stand-by pump-C will start in auto instead of pump-B when discharge header press.
becomes < 16.5 kg./cm
2
.Stand-by pump-C will also take start in autowhen common discharge header press.becomes < 16.5kg/cm
2

in case both pumps-A & B are running.
3.3) Discharge v/v of stand-bypump-C will open when common discharge header press. 16 kg/cm
2
.
3.4) If M.S.flow & L.P.B.P.CV position are > 60% each,then one or two pumps which are not running, all will take start.
3.5) If mainpump-A or pump-B trips & the reason for tripping is withdrawn then the tripped pump will start instantaneously
irrespective of stand-by pump-C is running or not.

Boiler Feed Pump

1.1) Suction & recirculation v/vs open.
1.2) Deaerator level adequate(> 0 mm).
1.3) Deaerator level not very low(> -1835 mmwc).
1.4) Motor winding temp.not high(<125
0
C).
1.5) Motor brg.temp.not high(< 85
0
C).
1.6) L.O.common header press.normal(> 2 kg./cm
2
.).
1.7) No electrical trip.
1.8) Bkr.in service & selector switch innormalcondition.

2. Alarms:
2.1) L.O.press.low(1.2 kg/cm
2
).
2.2) Motor brg.temp.high( 85
0
C).
0
C).
2.4) Pump brg.temp.high(90
0
C).
2.5) Working oil cooler oil I/L temp.high(110
0
C).
2.6) L.O.cooler oil I/L temp.high(65
0
C)at LCP.
2.7) L.O.cooler oil O/L temp.high(55
0
C)at LCP.
2.8) L.O.suction strainer dp high at LCP.
2.9) Pump discharge press.low(50 kg/cm
2
).
2.10) Common discharge header press.low(75 kg/cm
2
).
2.11) Suction strainer dp high(0.6 kg/cm
2
).
2.12) Deaerator level low(-500 mm).
2.13) Deaerator level high(150 mm).
2.14) Deaerator level high +100(250 mm).
2.15) Deaerator level very high(465 mm).

3. Protection Trips With Alarms:
3.1) Motor brg.temp.very high(90
0
C).
0
C).
3.3) Working oil cooler oil I/L temp.very high(130
0
C).
3.4) L.O.common header press.very low (1 kg/cm
2
).
3.5) Suction v/v close with a time delay of 1.5secs. The previous instantaneous tripping logic has been modified & a time delay is
introduced to avoid pump tripping & thereby system instability causing from momentary malfunctioning of limit switch.
3.6) Deaerator level very low(-1835mmwc).

4. Interlocks:
4.1) Pumpongives auto open command to D.M.C.W.- 63 v/v.
4.2) Pumpoffgives auto close command to D.M.C.W.- 63 v/v.
4.3) Pumpoff& L.O.press.< 1.5 kg/cm
2
= A.O.P. cut-in.
4.4) Pumpon& L.O.press. > 2.8 kg/cm
2
for 30 secs = A.O.P. cut-out.
4.5) When either one/two pumps are running & the selected pump is put into stand-by mode,the discharge v/v of the stand-by pump will
open in auto after 30 secs.
4.6) DT across pump discharge / suction very high (15
0
C) = Manual action to be taken.

4.7) Recirculation v/v of a running pump will close in auto when its flow is >220T/hr & open at <110T/hr. Inmanmode,the recirculation
v/v may be opened / closed in the pump flow range between 110T/hr. & 220T/hr.

5. Auto Start-up Sequences:
5.1) Step-01 = Pump start permissives.
5.2) Step-02 = a] Selected stand-by pumps lamp indication appears.
b] A.O.P.takes start & L.O.press.> 2 kg/cm
2
.
c] Pumps discharge v/v alongwith its I.B.V.close.
d] Recirculation v/v opens.
e] Scoop position becomes minimum.
5.3) Step-03 = a] Pump takes start.
b] D.M.C.W. I/L v/v opens.
5.4) Step-04 = a] Pump scoop changes over frommantoautomode.
b] Scoop position matches as per demand.

6. Auto Shut-down Sequences:
6.1) Step-51 = Shut-down-selected pump stop command.
6.2) Step-52 = a] A.O.P.takes start.
b] D.M.C.W. I/L v/v closes.
c] Recirculation v/v opens.
6.3) Step-53 = I.B.V.of discharge v/v alongwith the discharge v/v get closed.

I.D.Fan
1. L.O.press.adequate & fan start permissive 0.8 ata.
2. L.O.press.lowalarm & L.O.pump auto change-over when fan is on 0.6 ata.
3. L.O.press.very low alarm & fan trip with a time delay of 10 secs 0.4 ata.
4. DP.across L.O.filter highalarm 0.6 ata.
5. Hydraulic Coupling troublealarm for the followings:
5.1) Before cooler W.O.temp.highalarm 100
0
C.
5.2) Before cooler W.O.temp.very highalarm & fan trip 110
0
C.
5.3) After cooler W.O.temp.highalarm 80
0
C.
5.4) After cooler W.O.temp.very highalarm & fan trip 90
0
C.
5.5) H.C. DP across L.O.filter highalarm 0.4 bar.
5.6) H.C. DP across L.O.filter very highalarm & fan trip with a time delay of 20 secs 0.6 ata.
5.7) H.C. L.O. I/L press.> 0.8 bar within 20 secs.after fan starts,otherwise fan will trip.
5.8) H.C. L.O. I/L press.lowalarm 0.8 bar.
5.9) H.C. L.O. I/L press. very lowalarm & fan trip 0.6 ata.with a time delay of 20 secs.
6. Fan DE/NDE brg.temp.highalarm 77
0
C.
7. Fan DE/NDE brg.temp.very highalarm & fan trip 82
0
C.
8. Motor DE/NDE brg. temp.highalarm 85
0
C.
9. Motor DE/NDE brg. temp. very highalarm & motor trip 90
0
C.
10. Motor winding temp.highalarm 125
0
C.
11. Motor winding temp. very highalarm & motor trip 130
0
C.
12. All I.D.Fan offannunciation at U.C.P.
13. Fan brg.vibration highalarm 9 mm/sec.
14. Fan brg.vibration very highalarm & fan trip with a time delay of 5 secs 18 mm/sec.
15. S.G.C. Start-up:
15.1) Permissive (Release for step 01):~
a] Fan A / B motor brg./ winding temp. = Not high.
b] Any F.D.Fanon& I.D.Fanon/off = True.
c] I.D.Fan A / B status = Off & not tripped.
d] I.D.Fan A / B selector switch = Normal.
e] I.D.Fan A / B bkr. = Spring charged & DC on.
15.3) Step 01 = I.D.Fan A / B L.O.P
P
. SLC on& discharge gate bloweronif inauto.
15.4) Release for step 02 = I.D.Fan A / B any L.O.P
P
.on& L.O.press.> 0.8 ata.
15.5) Step 02 = I.D.Fan A / B I/L gate(GD-5A/5B) & O/L gate(GD-7A/7B) close & scoop position minimum.
15.6) Release for step 03 = Step 02.
15.7) Step 03 = I.D.Fan A / B start.
15.9) Step 04 = I.D.Fan A / B I/L gate(GD-5A/5B) & O/L gate(GD-7A/7B) opens.
15.11) Step 05 (I.D.Fan-A status on) = Monitoring status upto Step - 04
15.13) Step 06 = Monitor I.D.Fan B on/If I.D.Fan B drive statusoff,then I.D.Fan B I/L & O/L gates(GD-5B & 7B) close &
scoop position minimum.
15.14) Step 07 = I.D.Fan A scoop controlauto.

F.D.Fan

1.Start Permissives:
1.1) L.O.press.O.K.( 0.8 ata).
1.2) Control oil press.O.K.( 8 ata).
1.3) Fan brg.temp.not high( 95
0
C).
1.4) Motor brg.temp.not high( 85
0
C).
1.5) Motor winding temp.not high(125
0
C).
1.6) I.D.Fanon.
1.7) Pitch control damper position min.(<5%).

2.1) Fan DE/NDE brg.temp.very high( 105
0
C).
2.2) Motor DE/NDE brg.temp.very high(105
0
C).
0
C).
2.4) I.D.Fan trip.
2.5) Both F.D.Fansoff= M.F.T.operates.
2.6) Both I.D.Fansoff = Both F.D.Fansoff= M.F.T.operates.
2.7) Fan brg.vibr.very high(18 mm/sec) & fan trips with a time delay of 5 secs.

3. Alarms:
3.1) Fan DE/NDE brg.temp.high( 95
0
C).
3.2) Motor DE/NDE brg. temp.high(85
0
C).
0
C).
3.4) Control oil press.low( 6 ata).
3.5) DP across L.O.filter high( 0.6 ata).
3.6) F.D.Fan trip.
3.7) Both F.D.Fans off.
3.8) L.O.press.very low( 0.4 ata).
3.9) F.D.Fan brg.vibration high ( 9 mm/sec).

4. L.O.System:
4.1) Starting of stand-by L.O.pump from tripping of running L.O.pump.
4.2) Starting of stand-by L.O.pump if running L.O.pump develops control oil press.< 5 ata.
4.3) F.D.Fan pitch control position becomes minimum when control oil press.becomes very low(< 5 ata).

T.A.S. & B.A.S.

Controls & Interlocks:~

1.Auxiliary steam header press.is sensed by press.transmitters-LBG10,CP101&CP102(for T.A.S.) & LBG20,CP101&CP102(for B.A.S.) in
1 out 2logic & HC-PRV(AS-22 for T.A.S. & AS-46 for B.A.S.) or LC-PRV(AS-32 for T.A.S. & AS-56 for B.A.S.)[depending upon the
v/v selected for operation] is modulated to maintain constant press.of 11kg/cm
2
in the auxiliary steam header.
If both HC-PRV & LC-PRV
are in operation,HC-PRV is modulated to maintain constant header press.

2. Auxiliary steam header temp.is sensed by temp.elements- LBG10,CT101 & CT102(for T.A.S.) & LBG20,CT101 & CT102 (for B.A.S.) in
1 out 2logic & HC-PRV(CD-65 for T.A.S. & CD-77 for B.A.S.) or LC-PRV(CD-71 for T.A.S. & CD-83 for B.A.S.) is modulated.
If both HC-PRV & LC-PRV
are in operation,spray water temp.control v/v of HC-PRV is modulated to maintain constant temp.LC stream spray water temp.control v/v
remains open corresponding to LC-PRV position.

3. When HC-PRV(AS-22 for T.A.S. & AS-46 for B.A.S.) opens > 2%,the following actions will be initiated:
3.1] The u/s M/O isolating v/v(AS-21 for T.A.S. & AS-45 for B.A.S.) will open automatically.
3.2] Spray water control v/v(CD-65 for T.A.S. & CD-77 for B.A.S.) is to be in operation automatically.
3.3] The M/O isolating v/v(CD-64 for T.A.S. & CD-76 for B.A.S.) in spray water line will open automatically.
3.4] AS-32/AS-56 will changeover fromautotoman.

4. When HC-PRV opening is < 2%,the following interlocks will be initiated:
4.1) AS-21/AS-45 v/v will close.
4.2) CD-65/CD-77 v/v will close.
4.4) AS-32/AS-56 will open.

5. When HC-PRV opening is < 2% & M.S.flow is 5T/hr,the following actions will be initiated:
AS-22/AS-46 will changeover fromautotoman.

6.When LC-PRV(AS-32 for T.A.S. & AS-56 for B.A.S.) opens > 2%,the following actions will be initiated:
6.1) AS-31/AS-55 will open automatically.
6.2) CD-71/CD-83 is to be in operation automatically.
6.3) CD-70/CD-82 will open automatically.

7. When LC-PRV(AS-32 for T.A.S. & AS-56 for B.A.S.) opening is < 2%,the following interlocks will be
initiated:
7.1) AS-31/AS-55 v/v will close.

8. Auto-changeover from LC-PRV to HC-PRV:
8.1) When aux.steam header press.comes down to 10 kg /cm
2
.
8.2) Continues to be 10 kg/cm
2
for 0 10 secs.
8.3) When LC-PRV opening is > 95% or M.S.flow is > 5T/hr.

9. Forced-closing of both LC-PRV & HC-PRV:
9.1) AS-22 & 32 will close when TPRDS temp.becomes very high(300
0
C).
9.2) AS-46 & 56 will close when BPRDS temp.becomes very high (240
0
C).

10. Alarms:
10.1) TAS temp.lowalarm is 220
0
C.
10.2) TAS temp.highalarm is 280
0
C.
10.3) BAS temp.lowalarm is 210
0
C.
10.4) BAS temp.highalarm is 225
0
C.
10.5) TAS/BAS header press.lowalarm is

When HC-PRV opens automatically,controls will be transferred to HC-PRV,both on steam as well as spray water side. LC stream spray
temp.control v/v remains open corresponding to LC-PRV position.To avoid undesirable prolonged & repeated operation of control v/vs
at very low opening,LC-PRV is to be closed manually when HC-PRV is operating at low lift condition.

Air Evacuation System

1. Auto Sequential Vacuum Pulling:

1.1) Step-00 = S.G.C.of condensate & air evacuation system is madeon.
1.2) Step-01= S.L.C.of C.E.P
P
.is madeon.
1.3) Step-02 = a] Turbine drain v/v master is put intoauto.
b] Gland steam exhauster A/B is madeon.
1.4) Step-03 = a] L.P.exhaust hood spray v/v is put intoauto.
b] Gland steam press.controller is inmanmode.
c] Condensate header press.is > 18 kg/cm
2
.
d] Gland steam CV-1 is closed.
e] Gland steam supply header press.> 5.5 kg/cm
2
.
1.5) Step-04 = Starting ejector steam I/L v/v opens.
1.6) Step-05 = a] Starting ejector air I/L v/v opens.
b] After 2 mins,vacuum bkr.is put intoauto& it becomes closed.
1.7) Step-06 = a] As per selection,main ejector A/B steam I/L v/v opens.
b] Main ejector A/B air I/L v/v opens.
c] Second main ejector steam I/L v/v opens.
d] Second main ejector air I/L v/v opens.
1.8) Step-07 = a] Turbine speed > 15 rpm.
b] Condenser vacuum > 133 mm of Hg or Condenser press.< 0.85kg/cm
2
.
1.9) Step-08 = a] Gland steam press.controller is inauto.
b] Gland steam press.< 200 mmwc.
c] Gland steam press.> 1900 mmwc.
d] As per selection,gland steam exhauster A/B takes start.
1.10) Step-09 = Condenser vacuum > 568 mm of Hg or Condenser press.< 0.26 kg/cm
2
.
1.11) Step-10 = Starting ejector air I/L v/v closes.
1.12) Step-11 = Starting ejector steam I/L v/v closes.
1.13) Step-12 = a] Condenser vacuum > 672 mm of Hg or Condenser press.< 0.12 kg/cm
2
.
b] Generator load > 5%.
1.14) Step-13 =As per selection of main ejector,the stand-by ejectors steam I/L & then air I/L v/vs get closed.

2. Auto Sequential Vacuum Breaking:

2.1) Step-00 = S.G.C.condensate & evacuation shut-down is madeon.
2.2) Step-01 = a] Main ejector-A steam I/L v/v closes.
b] Main ejector-A air I/L v/v closes.
c] Main ejector-B steam I/L v/v closes.
d] Main ejector-B air I/L v/v closes.
2.3) Step-02 = a] Vacuum bkr.opens.
b] Starting ejector air I/L v/v closes.
2.4) Step-03 = a] Turbine drain v/v master is inauto.
b] Gland steam press.controller is inmanmode.
c] Gland steam supply controller closes.
2.5) Step-04= Gland steam exhauster A & Boff.

3. Vacuum Breaker :-

3.1) Auto open logic :
(a) When gen.ckt.bkr.not close.
(b) T.G.in tripped condition.
+

(a) Axial shift very high
[1(M)/1.1(E)mm]
(b) Turbine L.O. press.low(0.8kg/cm
2
)
(c) Shaft vibration very high(250)
Or

(a) Turbine speed < 200 rpm
(b) Boiler is in tripped condition
(c) H.P.B.P. & L.P.B.P.are closed

3.2) Auto close logic :
During open command / feedback of Starting Ejector air v/v with a time delay of 2mins.

4. Auxiliary steam press. to main ejector low alarm = 7.5 kg/cm
2
.

Steam Extraction Check Valves

1. Steam Extraction Check Valve No.-2:
Under the following satisfied conditions,this will open otherwise it will trip or not open: ~
1.1) L.P.H.-2 drip level not very high(< 300 mmwc).
1.2) Secondary oil press.is not low(> 2.8 kg/cm
2
).
1.3) I.P.T.steam I/L press.> 2.73 kg/cm
2
.
1.4) Turbine not tripped.

2.1) L.P.H.-3 drip level not very high(< 260 mmwc).
2
).
2
.

3.1) Deaerator level not very high(< 465 mmwc).
3.2) Secondary oil press.is not low (> 2.8 kg/cm
2
).
3.3) Check v/v dp high(> 60% i.e. 6 kg/cm
2
) with a time delay of 2 mins.
2
.

4. Steam Extraction Check Valve Nos.- 5 & 6:
4.1) H.P.H.-5/6 drip level not very high(< 400 mmwc).
2
& > 1.8 kg/cm
2
for steam extraction check v/v nos.- 5 & 6 respectively).
2
for steam extraction check v/v no.- 5 & H.P.T.chamber I/L press.> 23 kg/cm
2
for steam extraction
check v/v no.- 6.

5. Reheater Check Valve:
2
).
5.3) H.P.turbine steam I/L press.< 23.6 kg/cm
2
.

L.P.Heater

1. L.P.H. 1:
1.1) Drip level very high alarm appear = 300 mmwc.
1.2) Drip level very high alarm reset = 250 mmwc.
1.3) Drip level high alarm appear = 150 mmwc.
1.4) Drip level high alarm reset = 110 mmwc.
At drip level very high:
a] Auto close command = EX-17,CD-29 & 30 and DR-25.
b] Auto open command = CD-31.
2. L.P.H. 2:
2.5) Drip level low alarm appear = - 50 mmwc.
2.6) Drip level low alarm reset > - 50 mmwc.
a] Auto close command = EX-9,CD-32 & 33 and DR-19.
b] Auto open command = CD-34,EX-128 & 133.
c] Protection open command = DR-28.
3. L.P.H. 3:
3.5) Drip level low alarm appear = - 50 mmwc.
3.6) Drip level low alarm reset > - 50 mmwc.
a] Auto close command = EX-10,CD-35 & 36.
b] Auto open command = CD-37,EX-126 & 132.
c] Protection open command = DR-22.
4.
4.1) Protection open command of EX-126,128,132 & 133 during turbine trip.
4.2) Protection close command of EX-17 during turbine trip or close signal of CD-29 / 30.
4.3) Protection close command of EX-9 during turbine trip or close signal of CD-32 / 33
4.4) Protection close command of EX-10 during turbine trip or close signal of CD-35 / 36.

H.P.Heaters

1. Alarms:

1.1) H.P.H. 5 / 6 drip level low alarm = - 200 mmwc.
1.2) H.P.H. 5 / 6 drip level high alarm = 200 mmwc.
1.3) H.P.H. 5 / 6 drip level very high alarm = 400 mmwc.

2. Protection Interlocks:

2.1) At H.P.H. 5 drip level very high: ~
a] Auto close command = FD-7,7A,9,9A; EX-12 & DR-2.
b] Auto open command = FD-8A, EX-104 & DR-16.
c] Protection open command = FD-8.
2.2) At H.P.H. 6 drip level very high: ~
a] Auto close command = FD-10,10A,12,12A; EX-13 & DR-2.
b] Auto open command = FD-11A, EX-131 & DR-9.
c] Protection open command = FD-11
2.3) At deaerator level very high (465 mmwc):
Auto close command = DR-6 & 13.
2.4)
(a) At turbine trip / close signal of FD7 / 9 = Protection close command of EX-12.
(b) At turbine trip / close signal of EX12 = Protection open command of EX-104.
(c) At turbine trip / close signal of FD10 / 12 = Protection close command of EX-13.
(d) At turbine trip / close signal of EX-13 = Protection open command of EX-131.

P.A.Fan

1. Start Permissives:~
1.1) No M.F.T.
1.2) P.A.fan general shut off damper closed.
1.3) C.A.D.< 5% open.
1.4) P.A.fan discharge damper in minimum position.
1.5) P.A.fan L.O.system healthy(L.O.press.> 0.8 kg/cm
2
)
1.6) P.A.fan bkr.in service & no switchgear disturbance persisting.
1.7) P.A.fan ready permissive (one F.D.fan must run for three P.A.fans only).
1.8) Seal air system healthy [S.A.fanon,seal air dampers open & seal air to hot P.A.dp O.K.(> 100mm)].
1.9) Followingno pulveriser tripconditions:
(a) H.A.G. & C.A.G. open.
(b) Feeder I/L & O/L gates open.
(c) Mill discharge v/vs open.
(d) Mill O/L temp. not high(< 110
0
C).
(e) Mill L.O.(L.O.press.> 0.9kg/cm
2
& L.O.flow > 40lit/min) and gas (N
2
-gas press. > 41kg/cm
2
) systems healthy.
(f) Burner manual isolating v/vs open.
2. Protection Trippings:~
2.1) M.F.T.
2.2) F.D.fan trip (when one out of two running F.D.fans trips,the topmost 4
th
P.A.fan will trip).
2.3) L.O.system failure[L.O.press.very low ( 0.4 kg./cm
2
) or *tripping of both L.O.P
P
s.] with a time delay of 60 secs.
*2.4) Discharge press. very low( 500mmwc).
2.5) P.A.fan brg.vibration very high( 10 mm/sec) with a time delay of 60secs.
2.6) P.A.fan motor winding temp.very high(130
0
C).
2.7) P.A.fan / fan motor brg.temp.very high(90
0
C).
2.8) Followingpulveriser tripconditions:
(a) *Burner manual isolating v/vs closed.
(b) Ignition permit not available within 3mins.from feederontoofforofftoonstatus.
(c) HAG,CAG,feeder I/L & O/L gates closed.
(d) Anyone mill discharge v/v closed with a time delay of 3secs.
(e) Mill O/L temp.high(110
0
C).
(f) Mill gas press.very low( 22 kg./cm
2
).
(g) Mill L.O.press. very low( 0.6 kg./cm
2
) with a time delay of 3secs. & L.O.flow very low( 40lit/min) with a time delay of 5secs.
(h) Millon& seal air system failed [seal air to hot PA dp low(100mm) with a time delay of 70secs. & S.A.fan off with a time delay of 60secs].
3. Alarms:~
3.1) P.A.fan brg.temp.high = 85
0
C.
3.2) P.A.fan motor winding temp.high = 125
0
C.
3.3) P.A.fan brg.vibration high = 8 mm/sec.
*3.4) P.A.fan discharge press.low = 350 mmwc.
4. L.O.P
P
. Auto Changeover:~
Stand-by L.O.P
P
.(MCC & L.O.S.being normal) will take start in auto if L.O.press. becomes low (0.6 kg/cm
2
)
or running L.O.P
P
.is made off / trips when P.A.fan is on.

Pulveriser
1.1) Seal air system healthy[S.A.fanon,seal air dampers open & seal air to hot P.A.dp O.K.(>100mm)].
1.2) P.A.fan on >20 secs.
1.3) P.A.fan general shut off damper open.
1.4) Mill L.O.S.released,bkr.in service & no switchgear disturbance is persisting.
1.5) Mill L.O.(L.O.press.>1.1 kg/cm
2
& L.O.flow > 40 lit/min) and gas (N
2
-gas press.> 41kg/cm
2
) systems healthy.
1.6) Mill O/L temp.not low(> 65
0
C).
1.7) Pulveriser / Feeder start permissive (burner-tilt position horizontal & total airflow < 40% MCR in case of 1
st
mill / feeder).
1.8) Pulveriser ignition permit available.
1.9) Nopulveriser tripcondition persisting.
2. Protection Trippings:
2.1) M.F.T.
2.2) No burner isolating v/v.is open.
2.3) S.A.fan off > 60 secs.
2.4) Seal air to hot P.A.dp low(<100 mmwc) >70 secs.
2.5) P.A.fan off.
2.6) H.A.G. & C.A.G. closed.
*2.7) Mill gearbox brg.vibration very high( 4.5 mm/sec).
2.8) Mill gearbox brg.temp.very high(90
0
C).
2.9) Mill motor winding temp.very high(130
0
C).
2.10) Mill motor brg.temp.very high(90
0
C).
2.11) Mill L.O.press.very low( 0.6 kg./cm
2
) > 3secs.
2.12) Mill L.O.flow low(< 40lit/min) > 5secs.
2.13) Mill loading gas press.very low( 22 kg./cm
2
).
2.14) Any mill-discharge-gatenot openfeedback > 3secs.
*2.15) Feeder I/L & O/L gates closed.
2.16) (a) With feederon,if mill O/L temp.becomes high(110
0
C). After mill tripping,H.A.G.will close with a time delay of 30secs;if high mill O/L temp.does not reset within that period.
(b) With feederoff,if mill O/L temp.becomes high(110
0
C),H.A.G.will close first with a time delay of 30secs.& then the mill trips.
2.17) If ignition permit is not available within 3mins.from feeder on to off or off to on status.
3. L.O.P
P
. Auto Changeover:
Stand-by L.O.P
P
.(MCC & L.O.S.being normal) will take start in auto if L.O.press. becomes low(0.9 kg/cm
2
) or running L.O.P
P
.is made off / trips when pulveriser is on.
4. Auto Start-up Sequence Of Mill Group:
4.1) Step-1= Oil elevation starts provided ignition permit is available.
4.2) Step-2= a] Seal air fan starts.
b] S.A.fan O/L damper opens with a time delay of 40 secs.
c] Seal air to pulveriser I/L damper opens.
d] Seal air to hot P.A.dp becomes O.K.
4.3) Step-3= Mill L.O.P
P
.-Astarts. If not,L.O.P
P
.-B will start with a time delay of 5secs. Mill L.O.press. & L.O.flow to mill become O.K.
4.4) Step-4=Pulveriser discharge v/vs. open.
4.5) Step-5= a] P.A.fan starts.
b] P.A.fan general shut off damper opens.
4.6) Step-6=Pulveriser starts if P.A.D.minimum signal is not present.
4.7) Step-7=Coal feeder starts with minimum feeding with a time delay of 60 secs.
5. Auto Shut-down Sequence Of Mill Group:
5.1) Step-1= Oil elevation starts provided ignition permit is available.
5.2) Step-2= Running feeder speed becomes minimum.
5.3) Step-3= Coal feeder becomes off.
5.4) Step-4= Pulveriser becomes off.
5.5) Step-5= P.A.Fan becomes off.
5.6) Step-6= P.A.fan general shut off damper closes.
5.7) Step-7= S.A.Fan becomes off & its discharge damper closes.

Seal Oil System

Characteristics Observation
1. Auto start of stand-by A.C.S.O.P.(provided, pump L.O.S.released,
M.C.C.power available,seletor switch in normal& pump is in
auto mode)
1.a) Running A.C.S.O.P.trips.
b) Running A.C.S.O.P.fails to develop discharge press.>8.5 kg/cm
2

c) A.C.S.O.P.auto on annunciation appears.
2. Auto start of D.C.S.O.P.(fulfilling start permissives). 2.a) Running A.C.S.O.P.- 1 / 2 trips & stand-by A.C.S.O.P.fails to
start / develop discharge press.>8.5 kg/cm
2
.
b) A.C.power failure.
c) When both A.C.S.O.Ps fail to develop discharge press.> 8.5
kg/cm
2
.
d) D.C.S.O.P.auto on annunciation appears.
3. Remote operation of A.C.S.O.P.- 1 / 2 (fulfilling start permissives) 3.a) On& Offindication lamps appear as per command.
b) Locally pump normal discharge press.= 9.5 kg/cm
2
.

4. Seal oil tank level high.

4.a) Vacuum tank oil level high annunciation appears.
b) Running seal oil vacuum pump trips.
5. Seal oil tank level low.

5.a) Vacuum tank oil level low annunciation appears.
b) Running A.C.S.O.P.trips & D.C.S.O.P.takes auto start.
6.a) Seal oil temp.after duplex filter high alarm.
b) Seal oil temp.after duplex filter very high alarm.
6.a) 50
0
C.
b) 55
0
C. & turbine trips.
7.a) Seal oil to H
2
differential press. low / high alarms.
b) Seal oil press. to seals low alarm.
7.a) 0.9 / 1.7 kg/cm
2
.
b) 2 kg/cm
2
.
8. Brg.chamber extraction blower vacuum low alarm. 8. > 0.3 bar.
9. CO
2
flash evaporator temp.high alarm. 9. 150
0
C.
10. Temp.of air side to H
2
side seal oil drain temp.high alarm. 10. 70
0
C.
11. H
2
purity in generator casing low alarm. 11. 95%.
12. H
2
press. in generator casing low / high alarms. 12. 1.8 / 2.2 kg/cm
2
.
13. Brg.chamber extraction blower overload alarm. 13. Blower trips.
14.a) Liquid in generator casing(T.E.) high alarm.
b) Liquid in generator casing(G.E.) high alarm.
c) Liquid in generator casing(E.E.) high alarm.
d) Liquid in terminal bushing(both ends) high alarm.
e) Oil level in prechamber(E.E.) high alarm.
14. Liquid in generator high group alarm.
15. I.O.T. level low alarm.

H.P.Bypass System

A. Interlocks:-
1. Remote(from C.R.T.& back-up panel) open& closeoperation of BP
1
& BP
2
v/vs. 1. Operation as well as feed back positions are to be found accurate.
2. BP
1
& BP
2
v/vs 2% open. 2.a) BPE
1
& BPE
2
change from man to auto mode.
b) BD v/v opens.
3. BP
1
& BP
2
v/vs < 2% open or closing of BP
1
& BP
2
v/vs. 3.a) BPE
1
& BPE
2
close & remain in auto.
b) BD v/v. closes.
4. Oil press. of oil unit very low(90 kg/cm
2
). 4. BP
1
& BP
2
stuck-up position.
5. O.S.U.- 1 / 2 auto start. 5. At oil press.110 kg/cm
2
& 115 kg/cm
2
respectively.
6. O.S.U.- 1 / 2 auto stop. 6. At oil press.145 kg/cm
2
& 155 kg/cm
2
respectively.
7.a) Condenser vacuum low ( 308 mm.of Hg.)

b) Downstream temp.very high (380
0
C.)
c) Turbine L.O.press.very low (0.8 kg/cm
2
.).
d) Axial shift very high ( 1 mm.) or thrust failure trip.
e) Shaft vibration very high ( 249 micron)
7.a) H.P.bypass trip. BP
1
,BP
2
& BDv/vs.close.BPE
1
& BPE
2

also close & change fromautotoman.
b) Downstream temp.very highalarm appears at 380
0
C.

B. Operating Conditions:-
1. H.P.B.P.spray temp.should be at least 140
0
C.for M.S.temp.> 460
0
C.For this,the deaerator should be pegged well at 3.5 kg/cm
2
press.
either from T.A.S.header or from C.R.H.
2. H.P.B.P. M/O warm-up regulating glove v/vs should always be opened & regulated to have a H.P.B.P.v/v u/s temp.of 450
0
C during
normal operation.
3. H.P.B.P. d/s set point should be maintained to around 330
0
C during normal operation of unit.This set point should be manipulated
during house-load operation to keep C.R.H.temp.within limits.During start-up,it should be manipulated to get required R/H O/L temp.
4. Condenser press.should be < 0.6 ata before H.P.B.P.is opened.
5. H.P.B.P.warm-up line drain v/vs are to be kept opened till H.P.B.P.v/vs are taken into service.
6. H.P.B.P. set-point:
6.1)Fixed set-point:
a] When m/c is running on C.M.C.,H.P.B.P.set-point = Set-point from C.M.C.+ x% where x = parameter set.
b] When m/c is not running on C.M.C.,the set-point will follow the following logics:
i) As soon as boiler fire is on,set-point = 24 kg/cm
2
.It can be increased manually (keeping set-point in auto mode only) upto 120 kg/cm
2
@ 50 kg/min.
ii) After M.S.press.crosses this set-point,H.P.B.P.v/vs start opening.
iii) After H.P.B.P.v/vs are 10% open,set-point tracks actual press.Thus H.P.B.P.position does not change till M.S.press.is 70 kg/cm
2
.
iv) Once M.S.press.> 70 kg/cm
2
,set-point is fixed at 70 kg/cm
2
.After this,it can be increased manually upto 120 kg/cm
2
@ 50 kg/min.
6.2) Variable set-point:
a] Once m/c.load > 70 MW & H.R.H.press.> 11 kg/cm
2
,the variable set-point circuit allows the M.S.press.to rise @ 2kg/cm
2
max.with set-point as = M.S.press.+ 2 kg/cm
2
.
b] If after that,any of the above conditions(i.e.>70 MW or.>11kg/cm
2
) does not hold true,then set-point (M.S.press + 2 kg/cm
2
) remains at last value.
c] If turbine trips,set-point remains at last value.However,if M.S.press.decreases,set-point also decreases.

7. H.P.B.P.opening limitations:

7.1) 0 MW = 100%.
7.2) 110 MW = 67%.
7.3) 130 MW = 54%.
7.4) 150 MW = 40%.
7.5) 170 MW = 40%.
7.6) 190 MW = 15%.
7.7) 210 MW = 5%.
H.P.B.P.max.set-point = 153 kg/cm
2
.
8. Once m/c.load > 70 MW & H.R.H.press.> 11 kg/cm
2
is achieved & afterthat if any condition disappears,then minimum opening = 10%.
9. When both H.P.B.P.v/vs are in auto,the position of both the v/vs will try to be very close to each other (tracking of position of other v/v by way of changing effective set-point).

C. Valve Fast Opening Command:-
During large load rejections,H.P.B.P.v/vs shall open in about 3 secs.after initiation of no priority closingsignals from the followings:
i)Generator bkr.open, ii)Turbine trip & iii)Turbine load shedding relay operate.
Rapid opening of H.P.B.P.v/vs under the above conditions is achieved by activating a fast opening device which is incorporated in the bypass v/v actuators.
a] In case of fast opening,both BPE
1
& BPE
2
positions will track BP
1
& BP
2
positions respectively for 10 secs.& then switch over to auto.
b] If M.S.press.< 130 kg/cm
2
& m/c load < 50 MW or M.F.T.operated,then no fast opening occurs;only H.P.B.P.v/vs are forced to auto.
c] Fast opening time varies depending on the load & press.at the point of initiation of fast open.
Load (0 to 120 MW) = Fast opening time (0.3 to 3 secs).
M.S.press.(130 to 140 kg/cm
2
) = Fast opening time is (80 to 100%) the average mean time being derived from load.
d] Whenever fast open & H.P.B.P.system is forced to auto,the H.P.B.P.press.set-point is matched momentarily to actual M.S.press.

L.P.Bypass System

A. Operation Procedure:
1) Step-1 = Put L.P.B.P.spray controller on auto.
2) Step-2 = Check initial set-point of L.P.B.P.to be at 3 kg.
3) Step-3 = Open L.P.B.P.CV manually to around 5%.
4) Step-4 = Open H.P.B.P.
5) Step-5 = Check H.R.H.press.When H.R.H.press.is > 4 kg., put L.P.B.P.CV on auto.

B. Controller Logic:
At the first step,L.P.B.P.controller set-point is fixed at 3 kg. As H.R.H.press.increases,L.P.B.P.CV opens. When L.P.B.P.
CV opens 25%,the CV is fixed at 25% & the set-point tracks the H.R.H.press.upto 11 kg. Then the L.P.B.P.CV maintains constant 11 kg.
press.in the H.R.H.line. At this condition,the turbine is rolled & the H.P.chamber press.increases. At certain load,the H.P.chamber press.
becomes > 11 kg.& at that time the max.selector in the control circuit selects the H.P.chamber press.as its set-point. As this set-point is
more than H.R.H.press.,the CV starts closing & under normal operation the CV remains closed. The H.P.chamber press.set-point is limited
to 41 kg. So H.R.H.press.cannot go beyond 41 kg. Emergency open of L.P.B.P.CV occurs when load shedding relay operates.

C. L.P.B.P.CV Opening Condition:
No emergency close command is existing.

D. L.P.B.P. Stop V/v. Emergency Auto Open Condition:
1)Load shedding relay operated for 2secs.
+
2) L.P.B.P.spray flow > 17%. Or (L.P.B.P.CV > 1% open).
+
3) Emergency stop command not existing.

E. L.P.B.P. Stop V/v. Emergency Close Conditions:
1) Hotwell level high ( 260 mm). An annunciation of hotwell level = + 150mm is introduced to get an early alarm of level tending to higher value
for taking precautionary measure to avoid tripping of LPBP through high hotwell level,occasionally occurring during unit start-up.
2) Condenser vacuum very low ( 308 mm.of Hg.).
3) Condenser temp.very high ( 90
0
C.).
4) L.P.B.P.spray flow deviation very high (> 13.3%).
5) No C.W.pump is running.
6) Turbine thrust failure trip.

F. Protection & Interlocks:
Test Item Condition Action Confirmation
1. Output signal for CV.

2. Stop v/v operation command ( Open Close ).

3.L.P.B.P.CV operation command (Open Close).

4. FCV auto operation command.

5. Attemperation spray flow
EMG close.

6. Condenser level high ( 260mm)
EMG close.

7. Condenser vacuum low(304mmof Hg.)
EMG close.

8. Condenser temp.high ( 90
0
C).
EMG close.

Simulate the condition as follows:
a) Cable short:
MAG11CT001A &
MAG11CT002A
b) Cable lift:
MAG11CP205
c) Make contact C.W.pump run
d) Spray flow > 20%.
TCP manual mode.
e) Simulate the H.R.H.press.50%.

C.E.P
P.
running.

C.E.P
P.
running.

1.a) Output signal = 0,25,50,75& 100%.
b) ~DO~
c) ~DO~
d) ~DO~

2.a) Stop v/v open P.B.on.
b) Stop v/v close P.B.on.

3.a) L.P.B.P.CV manual operation (open).
b) L.P.B.P.CV manual operation (close).
c) L.P.B.P.CV auto operation (open / close).

4. FCV auto operation (open).

5.a) A & B Spray flows simulated to 0%.

5.b) A & B - Spray flows simulated to 22%
keeping L.P.B.P.CVs.in auto.

5.c) Simulate A & B spray control deviation > 10%

5.d) Simulate A & B spray control deviation to 0%
keeping L.P.B.P.CVs in auto.

6.a) Make the contact of condenser level very high
switch at local.

6.b) Return the contact of level switch to normal

7.a) Make the contact of condenser vacuum low
press. switch at local.

7.b) Return the contact of level switch to normal

8.a) Make the contact of condenser temp.high
switch at local.

8.b) Return the contact of temp.switch to normal

1.a) A-CV position indicator 0 to 100%.
b) B-CV position indicator 0 to 100%.
c) A-FCV position indicator 0 to 100%
d) B-FCV position indicator 0 to 100%

2.a) A & B Stop v/v open lamp on.
b) A & B Stop v/v close lamp on.

3.a) A & B Stop v/vs open lamp on.
b) A & B Stop v/vs close lamp on.
c) A & B Stop v/vs open /close lamp on.

4.a) A & B L.P.B.P.CV 100%
b) A & B FCV 100%.

5.a).i] A & B Stop v/vs close lamps on.
ii] A & B L.P.B.P.CVs.0%.
iii] A & B FCVs.x% where x% = any %
depending on control demand.
L.P.B.P.CVs. press. controls force to manual.
5.b).i] A & B Stop v/vs open lamps on.
iii] A & B FCVs. x%.
5.c).i] A & B Stop v/vs close lamps on.
ii] A & B L.P.B.P.CVs. 0%.
(After 5 secs.from deviation low)
5.d).i] A & B Stop v/vs open lamps on.

iii] A & B FCVs. x% .



Test Item Condition Action Confirmation
9. C.W.P
P
. stop.
EMG close.

10. EMG open.

10.Simulate the condition as follows:
a) Cable short: MAG11CT001A&MAG11CT002A
b) Cable lift: MAG11CP205
c) Make contact: C.W.pump run
d) Spray flow > 20%.
e) Simulate H.R.H.press. to 0%.

9.a) Make the contact of C.W.P
P
.stopat M.C.C.

9.b) Return the contact of C.W.P
P
.run keeping
L.P.B.P.CVs.in auto.

10.a) Make contact load shedding relay by EHG.

10.b) After 6 secs.from load shedding relay on.

10.c) Simulate the spray water flow to 0%. Make
contact the load shedding relay by EHG.

10.a).i] A & B Stop v/vs open lamps on.
(EMG open command is 6 secs.on by DCS).
b).i] A & B Stop v/vs open lamps on.
iii] A & B FCVs. 0%.
c).i] A & B Stop v/vs close lamps on
iii] A & B FCVs.100%.

G. Oil Supply Unit:
O.S.U.P
P
.no.- 1 or 2 will always remain in opn.as per pump selection if the control is in auto,no fault is present and both pumps
power supply & LOS are on.Normal system press.will remain between120 kg/cm
2
&160 kg/cm
2
.
Filter pump will also start in auto as soon as any O.S.U.P
P
.gets start.Filter pump can only be made off from MCC, if reqd.
Cooling fan takes start when oil temp.becomes high(50
0
C) & vice versa.
During initial starting,i.e.,at zero press.condition,both O.S.U.P
P
s.will take start throughoil press.lowalarm(<110 kg/cm
2
).If this alarm gets reset
within 2 mins.,then the stand-by pump becomes off otherwise both pumps become off &oil press.very lowalarm(<120 kg/cm
2
) appears.Both
O.S.U.P
P
s.become off at the following conditions:
a) Oil temp.very high( 60
0
C).
b) Oil tank level very low(approx.165lits.or 70mm from min.level).
c) If oil press.lowalarm does not reset within 2 mins.when both O.S.U.P
P
s.are in service.
Auto changeover of the running O.S.U.P
P
.to the stand-by one will happen at the following cases:
a)At low oil flow,b)If MCC of running O.S.U.P
P
.
is made off,c)When oil press.becomes high(190kg/cm
2
) the running O.S.U.P
P
.gets off & the 2
nd
pump takes start only whenoil press.highalarm
gets reset.This may occur if relief v/v setting(160kg/cm
2
) malfunctions and d)When one O.S.U.P
P
.is running & oil press.lowalarm(110kg/cm
2
)
appears,then 2
nd
pump gets start & if the alarm gets reset within 1min.,the 2
nd
pump becomes off. O.S.U.P
P
.auto changeover will occur if oil
press.lowalarm appears twice within 15mins.Even after the start of 2
nd
pump if oil press.lowalarm does not reset within 2mins.,then both pumps
become off &oil press.very lowalarm(<120 kg/cm
2
) appears.

Generator-Turbine-Boiler Alarms-Interlocks-Protections

Characteristics Annunciations Process Remarks
1.a) Cold gas temp.after H
2
-
coolers high.
b) Cold gas temp.after H
2
-
coolers very high.

c) Hot gas temp before H
2
-
coolers high.
d) Cold gas temp. controller
1.a) 50
0
C.

b) 55
0
C.
Cold gas temp.after H
2
-
coolers very high trip &
Turbine trip.
c) 75
0
C.
1.a) By simulation.

b) ~DO~

c) ~DO~

d) By power failure

1.b) Turbine trips, T.L.R.= 86 T
1
-
T
2
& TX
1
-TX
2
operated and
Generator mech.protection
relay operated.

1.d) V/v will open during power
failure. The old, v/v close
logic is changed to avoid
manual opening opn. delay
during panel power failure
for eliminating unit tripping
2.a) Cold air temp.to main
excitor high.
b) Hot air temp.after rectifier
wheel high.
c) Hot air temp.after main
excitor high.
d) Hot air temp.after main
excitor very high.
2.a) 45
0
C. [ ]
[ Air temp.of ]
b) 65
0
C. [ excitor / rectifier]
[ wheel high ]
c) 70
0
C. [ ]

d) 80
0
C.
Turbine trip& Air temp.of
excitor / rectifier wheel high
2.a) By simulation.

b) ~DO~

c) ~DO~

d) ~DO~

2.d) Turbine trips, T.L.R.= 86 T
1
-
T
2
& TX
1
-TX
2
operated and
Generator mech. protection
relay operated.
3.a) Stator winding temp.high.
b) Stator core temp.high.
3.a) 105
0
C.
b) 100
0
C.
3.a) By simulation.
b) ~DO~

4. Rotor temp.high. 4. 110
0
C. 4. By simulation.
5.a) Generator brg.temp.high.
b) Gen.brg.temp.very high.
5.a) 90
0
C.
b) 120
0
C.
5.a) By simulation.
b) ~DO~

6.a) Gen. brg. vibration high.
b) Gen. brg. vibr.very high.
6.a) 250 micron.
b) 400 micron.
6. By simulation.
7. Load shedding relay operates.

7. Gland steam press.abnormal.

7. By simulating gland steam temp
>235
0
C & then operating the
load shedding relay.
7. Gland steam supply controller opens fully.Gland
steam exhaust controller closes. Gland steam set
press.tracks actual gland steam press.& then I/L
controller position changes as per actual.

Characteristics Annunciations Process Remarks
8.Generator casing H
2
-gas press. 8.a) Low alarm = 1.8 kg./ cm
2
.
b) High alarm = 2.2 kg./ cm
2
.

9.Generator casing H
2
-gas purity 9. Low alarm = 95%.
10. Boiler M.F.R. trip. 10.M.F.R.trip,Turbine trip,
T.L.R.=86T
1
-T
2
& 86TX
1
-TX
2

operated,Low forward power
relay operated,Gen.class-B,
Gr.-1,86B
11
B
12
B
13
operated&
Gen.class-C,Gr.-1,86C
11
C
13

operated.
10.By pressing M.F.R.trip P.B. 10.M.F.R.,turbine & generator
trip,main ckt.bkr.opens & gen
field bkr.becomes off.
11.a) Gen.class-A,Gr.-1 operated.

b) Gen.class-A,Gr.-2 operated.

11.a)M.F.R.trip,Turbine trip,
T.L.R.=86T
1
-T
2
& 86TX
1
-
TX
2
operated,&Gen.class-A
Gr.-1,86A
11
A
12
A
13
operated.
b)M.F.R.trip,Turbine trip,
T.L.R.= 86T
1
-T
2
& 86TX
1
-
TX
2
operated,Gen.class-A,
Gr.-2,86A
21
A
22
A
23
operated
& alarm of the simulated
relay appear.

11.a) By pressing emergency P.B

b) By simulation.

11.a)M.F.R., turbine & generator
trip,main ckt.bkr.opens & gen
field bkr.becomes off.

b) ~DO~
12.Gen.class-B,Gr.-1 operated.

12.Turbine trip,T.L.R.= 86T
1
-T
2
& 86TX
1
- TX
2
operated,Gen.
class-B,Gr.-1,86B
11
B
12
B
13

operated& alarm of the
simulated relay appear.
12. By simulation. 12. No M.F.R.trip.Only turbine
trips, main ckt. bkr.opens &
generator field bkr.becomes
off.
13.a) Gen.class-C,Gr.-1 operated.

b) Gen.class-C,Gr.-2 operated
13.a)Gen.class-C,Gr.- 1,86C
11
C
13


b)Gen.class-C,Gr.- 2,86C
21
C
23


13.a) By simulation.

b) ~DO~
13.a) No M.F.R.& turbine trip.
Only gen.ckt.bkr.opens.
In running condition, m/c
will go back to house load.
b) ~DO~

Important Annunciations

1. Condensate Cycle:~
Gland steam cooler condensate level high = 110 mm.

2. Boiler:~
2.1) Atomizing steam press.very low = 5 kg/cm
2
.
2.2) Horizontal S/H metal temp. high = 475
0
C.
2.3) Platen S/H metal temp. high = 565
0
C.
2.4) Final S/H metal temp. high = 587
0
C.
2.5) R/H metal temp. high = 610
0
C.

3. SWAS System:~
3.1) Deaerator O/L or economizer I/L dissolved O
2
high 7 ppb.
3.2) C.E.P
p
.discharge header dissolved O
2
high 30 ppb.
3.3) Economizer I/L conductivity high 10 mho/cm.
3.4) Hotwell conductivity high 2 mho/cm.
3.5) S/H steam conductivity high 0.2 mho/cm.
3.6) C.E.P
p
.discharge header Si. high 0.02 ppm.
3.7) Economizer I/L or C.E.P
p
.discharge header or DMCW(T) / (B) after P.H.E., PH high 9.2.

4. Scanner Air Fan:~
4.1) DP across scanner air fan suction filter low = 4 mmwc.
4.2) DP across scanner air fan suction filter high = 15 mmwc.
4.3) Scanner air duct to furnace dp low = 150 mmwc.

5. Turbine Gland Steam Supply:~
5.1) Gland steam press.abnormal.
5.2) Gland steam temp.abnormal.

Raw Coal Feeder

1. Start Permissives:~
a) Feeder in remote.
b) Coal on belt.
c) Feeder O/L gate open & discharge pipe not plugged.
d) Feeder speed demand minimum.
e) Pulveriser / Feeder start permissive available.
f) Pulveriser status on & ignition permit available.
g) H.A.G. open.

2. Protection Trippings:~
a) No coal on belt.
b) Discharge pipe plugged. At back-up panel, a common annunciation of Feeder Shear Pin Failure & at CRT
Event Log, individual annunciations are introduced for elimination of coal jamming inside feeder.
c) Pulveriser off / trip condition.
d) Pulveriser O/L temp.very high ( 110
0
C).
e) Pulveriser ignition permit not available within 3mins.from feeder on to off or off to on status.

Miscellaneous Valve Interlocks

1. The following v/vs have integral M/O bypass v/vs :~
1.1) CRH- 1 = Isolating v/v before control v/v in CRH pegging line.
1.2) FD-13,16&19 = Isolating v/vs before feed control regulating v/vs.
1.3) FD-7&9 = Isolating v/vs before & after H.P.H.-5 in the feed water line.
1.4) FD-10&12 = Isolating v/vs before & after H.P.H.-6 in the feed water line.
1.5) FD-8&11 = Isolating v/vs on bypass of feed water of H.P.H.-5 & 6 respectively.
1.6) FD-4,5&6 = Isolating v/vs in B.F.P
P
s individual discharge line.
1.7) MS-1&2 = Isolating v/vs on main steam line at S/H O/L.
The above main v/vs shall not open unless their M/O integral bypass v/vs are in fully open position.This interlock is not applicable for v/vs FD-8&11
For them, the main as well as the integral bypass v/v. shall open simultaneously at very high level in the respective H.P.H.
When the main v/v is fully
open,its IBV shall be closed.The M/O integral bypass v/vs shall close simultaneously when its main v/v is closed.

2. C.R.H. Line Drain Pot Control :~
A drain pot has been provided at the lowest point in the CRH line. Drains are led to HP drain flash tank through
upstream locked open manual v/v CRH-102 & downstream m/o v/v CRH-101. Drain v/v CRH-101 is opened automatically on high water level in
the drain pot. Remote manual facility to open/close the v/v from UCR is also provided. However, auto command (high level control) will override
the manual closed position. Position indication of the v/v is also provided in UCR. CRH-101 will close in auto when m/c load becomes > 20%. It
will also close after 10 secs.if drain pot level is not high.

3. Boiler S/H. Attemperation Block V/vs(SD- 2 & 7): ~
These v/vs should close when the respective control v/v opening is < 2% or M.F.R.trips.

4. Deaerator Press.Control V/v From C.R.H. Line(CRH2):~
This will get permissive for opening when CRH press.exceeds 8 kg/cm
2
& no protection
closing logic is persisting. Press.control will then automatically transfer frommantoauto. If CRH press. falls below 8 kg/cm
2
or deaerator level
becomes very high(465mm) or turbine trips, protection closing of CRH-2 will occur.

5. 4
th
Steam Extraction V/v(EX-11): ~
a) At deaerator press.> 2.5 kg/cm
2
= Opening permissive of EX-11.
b) At deaerator level very high(465mm) = Auto closing of EX-11.
c) If turbine trips = Protection closing of EX-11.

6. Deaerator Overflow V/v(DR-38):~
a) At deaerator level very high(465mm) or deaerator level high + 100(250mm) = Auto open of DR-38.
b) At deaerator level high-100(50mm) = Auto close of DR-38.

7. TAS To Deaerator Pegging Supply V/v(AS-2):~
At deaerator level very high(465mm) = Protection closing of AS-2.

8. Gland Steam Supply V/v From C.R.H. Line(CRH-7):~
Gland steam temp.198
0
C = Auto open of CRH-7.

9. Gland Steam Supply Control V/v From T.A.S.:~
a) Gland steam temp.198
0
C = Auto close of control v/v.
b) Gland steam temp.220
0
C = Auto open of control v/v.

10. Condensate Recirculation Controller(CD-19) & All Solenoid-Operated Controllers At Feed Control Station:~
Air lock relays & fail-freeze solenoids
are introduced for which all controllers remain in stay-put condition during failure of air supply or 24v power supply.

11. Feed Control Station M/O V/vs (FD-16,16A,13,13A,19&19A):~
The above m/o isolating v/vs position remain unchanged irrespective of their
control v/vs(FD-17,14 & 20) position.

12. Condenser Vacuum Breaker,CD-41,FD-14,17 & 20:~
At I.A. supply failure condition, the position of the above v/vs will remain unchanged.

Turbine Auto Trip Tests

The following turbine trip tests can be executed at turbine on-load condition & during testing no influence occurs to the running condition :~
i) Emergency Governor Test (Oil Trip Test)
ii) Solenoid Trip Device Test
iii) Thrust Failure Protection Device Test
iv) Condenser Vacuum Trip Test Vacuum CH1 / Vacuum CH2

Operation Method :~
i) The button of the trip test to be performed is selected. Then the lamp of the selected trip test is turned on.
ii) Check Permission lamp turn-on.
iii) Test PB on operation. Then Permission lamp turns off.
iv) Test lamp turns on automatically i.e. selected trip test starts.
v) OK lamp flickers automatically.
vi) Reset PB on operation. Then OK lamp flickers off & Reset lamp turns on automatically.
vii) Again OK lamp flickers automatically.
viii) Off PB on operation. Then OK lamp flickers off and Test & Reset lamps turn off.
ix) End of trip test.

Trip Tests :~
i) Emergency Governor Test (Oil Trip Test) :
20 secs 1 Bypass SV (41.1) Energise 20BYPSTX MAX09AA001
a) Control oil press. 6 kg/cm
2

Skip Reset PB On
20 secs 2 Bypass SV (41.1) De-Energise 20BYPSTX MAX09AA001
2

Skip Reset PB On
2

Skip Reset PB On
20 secs 4 SV (41.2) For Change-over V/v Energise 20CHGTX MAX08AA006
a) Change-over v/v test position
b) Aux. Start-up oil press. 2 kg/cm
2

c) Trip oil press. 6 kg/cm
2

d) Aux.Trip oil press. > 2 kg/cm
2

Skip Reset PB On

480 secs 5 Oil Trip Test Device Open R052A MAX55CG001
a) Test oil press. > 0.5 kg/cm
2
(For oil trip test)
b) Emergency governor (1) trip position
c) Emergency governor (2) trip position
d) Trip oil press. 2 kg/cm
2

e) Aux.trip oil press. 2 kg/cm
2

f) Emergency trip device trip position
Skip Reset PB On
0 6 Emergency Governor Test Reset Start Push The Reset PB
Skip Reset PB On
480 secs 7 Oil Trip Test Device Close R045A MAX55CG001
a) Oil trip test device position close
b) Test oil press. 0.5 kg/cm
2
(For oil trip test)
20secs 8 Test Reset SV (41.4) Energize 20RSTTX MAX56AA001
a) Emergency trip device not trip position
b) Emergency governor (1) not trip position
c) Emergency governor (2) not trip position
d) Thrust failure protection device not trip position
e) Aux.trip oil press. not 2 kg/cm
2

f) Trip oil press. 6 kg/cm
2

g) Aux. Start-up oil press. not 2 kg/cm
2

Skip Turbine Trip
20secs 9 Test Reset SV (41.4) De-Energize 20RSTTX MAX56AA001
a) Aux. Start-up oil press. 2 kg/cm
2

20secs 10 SV (41.2) For Change-over V/v De-Energise 20CHGTX MAX08AA006
a) Change-over v/v normal position
20secs 11 Bypass SV (41.1) De-Energise 20BYPSTX MAX09AA001
a)Control oil press. 2 kg/cm
2

0 12 Emergency Governor Test Reset End Push The Off PB
a) Test off PB
Emergency Governor Test Ends

ii) Solenoid Trip Device Test :
20secs 1 Bypass SV (41.1) Energise 20BYPSTX MAX09AA001
2

Skip Reset PB On
2

Skip Reset PB On
2

Skip Reset PB On
2

2

2

Skip Reset PB On
20 secs 5 Solenoid Trip Device (2) (41.3.2) Energize 20TRIP2TX MAX08AA005
2

b) Trip oil press. 2 kg/cm
2

c) Aux. trip oil press. 2 kg/cm
2

d) Emergency trip device trip position
Skip Reset PB On
20 secs 6 Solenoid Trip Device (1) (41.3.1) Energize 20TRIP1TX MAX08AA004
2

Skip Reset PB On
0 7 Solenoid Trip Device Test Reset Start Push The Reset PB
Skip Trip Test Reset PB
20 secs 8 Solenoid Trip Device (1) (41.3.1) De-Energize 20TRIP1TX MAX08AA004
2

Skip Reset PB On
20 secs 9 Solenoid Trip Device (2) (41.3.2) De-Energize 20TRIP2TX MAX08AA005
a) Control oil press. not 2 kg/cm
2

Skip Reset PB On
20 secs 10 Test Reset SV (41.4) Energize 20RSTTX MAX56AA001

2

2

2

Skip Turbine Trip
20 secs 11 Test Reset SV (41.4) De-Energize 20RSTTX MAX56AA001
2

20 secs 12 SV (41.2) For Change-over V/v De-Energise 20CHGTX MAX08AA006
2
0 14 Solenoid Trip Device Test Reset End Push The Off PB
Test Off PB
Solenoid Trip Device Test Ends

iii) Thrust Failure Protection Device Test :~
20secs 1 Bypass SV (41.1) Energise 20BYPSTX MAX09AA001
2

Skip Reset PB On
2

Skip Reset PB On
2

Skip Reset PB On
2

2

2

Skip Reset PB On
20 secs 5 Test SV (41.6) For Thrust Failure Protection Device Energize 20THRUTX MAX58AA001

a) Thrust failure protection device trip position
b) Trip oil press. 2 kg/cm
2

c) Aux.trip oil press. 2 kg/cm
2

d) Emergency trip device trip position
e) Test oil press. not 2 kg/cm
2

Skip Reset PB On
0 6 Thrust Failure Protection Device Test Reset Start Push The Reset PB
Skip Reset PB On
20 secs 7 Test SV (41.6) For Thrust Failure Protection Device De-Energize 20THRUTX MAX58AA001
a) Test oil press. 2 kg/cm
2

20 secs 8 Test Reset SV (41.4) Energize 20RSTTX MAX56AA001
2

2

2

Skip Turbine Trip
20 secs 9 Test Reset SV (41.4) De-Energize 20RSTTX MAX56AA001
2

20 secs 10 SV (41.2) For Change-over V/v De-Energise 20CHGTX MAX08AA006
2
0 12 Thrust Failure Protection Device Test Reset End Push The Off PB
Test Off PB
Thrust Failure Protection Device Test Ends

iv)(a) Condenser Vacuum Trip Test Vacuum CH1 :~
11secs 1 Test SV For CH-1 (40.2.1) Energize 20CH1TX MAW91AA503
a) Condenser Vacuum CH-1 (A) Operated
b) Condenser Vacuum CH-1 (B) Operated
Skip Reset PB On
0 2 Condenser Vacuum CH-1 Test Reset Start Push The Reset PB

Skip Reset PB On
5secs 3 Test SV For CH-1 (40.2.1) De-Energize 20CH1TX MAW91AA503
a) Condenser Vacuum CH-1 (A) Not Operated
b) Condenser Vacuum CH-1 (B) Not Operated
Skip Reset PB On
0 4 Condenser Vacuum CH-1 Test End Push The Off PB
Test Off PB
Condenser Vacuum CH-1 Trip Test Ends

iv)(b) Condenser Vacuum Trip Test Vacuum CH2 :~
11secs 1 Test SV For CH-2 (40.2.2) Energize 20CH2TX MAW91AA504
a) Condenser Vacuum CH-2 (A) Operated
b) Condenser Vacuum CH-2 (B) Operated
Skip Reset PB On
0 2 Condenser Vacuum CH-2 Test Reset Start Push The Reset PB
Skip Reset PB On
5secs 3 Test SV For CH-2 (40.2.2) De-Energize 20CH2TX MAW91AA504
a) Condenser Vacuum CH-2 (A) Not Operated
b) Condenser Vacuum CH-2 (B) Not Operated
Skip Reset PB On
0 4 Condenser Vacuum CH-2 Test End Push The Off PB
Test Off PB
Condenser Vacuum CH-2 Trip Test Ends

Turbine Auto Valve Test

The following turbine AVTs can be performed at 40 80% on-load condition & during testing no influence occurs to running condition :~
i) MSV(L)
ii) MSV(R)
iii) RSV(L)
iv) RSV(R)

Test Conditions :~
i) ALFC on
ii) Governor Free off
iii) Hold Function on
iv) Limit Press. Control off
v) EHG available condition
vi) CMC mode
vii) ATT not operating
viii) Load 40 80%
ix) MSVs & RSVs full open

Operation Methods :~
i) The button of the v/v test to be performed is selected. Then the lamp of the selected v/v test is turned on.
ii) Check Permission lamp turn-on.
iii) Test PB on operation. Then Permission lamp turns off.
iv) Test lamp turns on automatically i.e. v/v test starts.
v) OK lamp flickers automatically.
vi) Off PB on operation. Then OK lamp flickers off & Test lamp turns off.
vii) Test ends.

1. AVT Of MSV(L / R) :~
240secs 1 MCV(3/4) Close
a) MCV(3/4) close
Skip Reset PB on
Skip Turbine Trip
240secs 2 MCV(1/2) Close
a) MCV(1/2) close
Skip Reset PB on
Skip Turbine Trip

3secs 3 MSV(L/R) Test SV(1) Energize
a) Trip oil press. for MSV(L/R) piston lower room 2kg/cm
2
.
Skip Reset PB on
Skip Turbine Trip
3secs 4 Wait
a) MSV(L/R) close
Skip Reset PB on
Skip Turbine Trip
25secs 5 MSV(L/R) Test SV(2) Energize
a) Trip oil press. for MSV(L/R) plunger upper room 6kg/cm
2
.
Skip MSV(L/R) open
Skip Turbine Trip
10secs 6 MSV(L/R) Test SV(1) De-Energize
a) Trip oil press. for MSV(L/R) test v/v front line 6kg/cm
2
.
b) MSV(L/R) close
Skip MSV(L/R) open
Skip Turbine Trip
70secs 7 MSV(L/R) Test SV(2) De-Energize
a) MSV(L/R) open
Skip Turbine Trip
240secs 8 MCV(1/2) Open
a) MCV(1/2) test device upper limit
240secs 9 MCV(3/4) Open
a) MCV(3/4) test device upper limit
0 10 V/v Test Ends
Test off PB
MSV(L/R) Valve Test End

2. AVT Of RSV(L / R) :~
240secs 1 ICV(L/R) Close
a) ICV(L/R) Close
Skip Reset PB on
Skip Turbine Trip
3secs 2 RSV(L/R) Test SV(1) Energize
a) Trip oil press. for RSV(L/R) piston lower room 2kg/cm
2

Skip Reset PB on

Skip Turbine Trip
3secs 3 Wait
a) RSV(L/R) Close
Skip Reset PB on
Skip Turbine Trip
25secs 4 RSV(L/R) Test SV(2) Energize
a) Trip oil press. for RSV(L/R) plunger upper room 6kg/cm
2

Skip RSV(L/R) open
Skip Turbine Trip
10secs 5 RSV(L/R) Test SV(1) De-Energize
a) Trip oil press. for RSV(L/R) test v/v front line 6kg/cm
2

b) RSV(L/R) open
Skip RSV(L/R) close
Skip Turbine Trip
70secs 6 RSV(L/R) Test SV(2) De-Energize
a) RSV(L/R) open
Skip Turbine Trip
240secs 7 ICV(L/R) Open
a) ICV(L/R) test device upper limit
0 8 V/v Test Ends
Test off PB
RSV(L/R) Valve Test End

Diesel Generator Set

D.G.set will keep on running under any of the following abnormal conditions:~
1. Non-trip Local Alarms :
i) Master trip relay circuit unhealthy
ii) Generator brg. temp.high ( 95
0
C)
iii) Generator brg. temp. very high ( 100
0
C)
iv) Generator PT fuse-failure relay operated
v) Generator neutral displacement relay operated
vi) Generator under voltage relay operated
vii) Generator over voltage relay operated
viii) Generator under frequency relay operated
ix) Generator master trip relay operated
x) Generator negative phase sequence relay operated
xi) Generator breaker auto tripped
xii) Generator winding temp. high ( 125
0
C)
xiii) Engine tripped
xiv) Engine L.O.press. low ( 20 psi)
xv) Fuel oil day tank level low ( 200 mm from bottom of the tank)
xvi) Engine jacket water temp. high ( 200
0
F)
xvii) Battery earth fault
xviii) Battery charger-A failure
xix) Battery charger-B failure
2. Remote Alarms :
i) Engine running
ii) Engine trouble ( Batch alarm = Low L.O.press. + High jacket water temp.)
iii) Engine tripped
iv) D.G.set fails to start in auto mode
v) 86G relay operated
vi) Local breaker open

D.G.set will trip through 86G under any of the following conditions:~
i) Engine overspeed ( 1810 rpm)
ii) Engine L.O.press. very low ( 14 psi)
iii) Engine jacket water press.very low ( 14 psi)
iv) Engine jacket water temp.very high ( 207
0
F)
v) Generator differential protection relay operated
vi) Generator over-current relay operated
vii) Generator winding temp.very high ( 130
0
C)
viii) D.G.set failed to start in auto mode (after 3 attempts)
ix) When D.G.set is tripped by operating Generator Master Trip Relay 86G, the following alarms will appear:
a) Generator Master Trip Relay operated
b) Engine tripped
c) Generator breaker auto tripped

Secondary Air Damper

A. SADC Logic:~

1. Both I.D.Fans trip or both F.D.Fans trip or MFR operated. 1. All auxiliary air damperscontrol get changed to manual & become 100% open.
2. MFR reset. 2.i) Furnace to windbox dp = 40 mmwc.
ii) All coal dampers = Close.
iii) All auxiliary air dampers = Modulating.
3. Furnace to windbox dp 240 mmwc. 3. All auxiliary air damperscontrol get changed to manual & become 100% open.
4. Boiler load = 0 to 30%. 4.i) Furnace to windbox dp = 40 mmwc.
ii) All auxiliary air dampers = Modulating.
5. Boiler load = 45%. 5.i) Furnace to windbox dp = 60 mmwc.
6. Boiler load 60%. 6.i) Furnace to windbox dp = 100 mmwc.
7. Both dp transmitters malfunction or DPT deviation + 20 mmwc. 7. All auxiliary air damperscontrol get changed to manual & become 100% open.

B. Logic For Over Fire Auxiliary Dampers(Lower & Upper):~

1. Boiler load = 50%. 1. OFA-L damper starts opening & aux. dampers start modulating.
2. Boiler load = 60%. 2. OFA-L damper = 40% open & aux. dampers start modulating.
3. Boiler load = 75%. 3. OFA-L damper = 100% open, OFA-U damper starts opening & aux.dampers start modulating.
4. Boiler load = 90%. 4. OFA-L damper = 100% open, OFA-U damper = 60% open & aux.dampers start modulating.
5. Boiler load = 100%. 5. OFA-L & U dampers = 100% open & aux.dampers start modulating.

C. Logic For Oil Dampers:~

Any elevation oil gun in
service.
i) Particular elevation aux. damper = 70% open.
ii) Rest aux. dampers = Modulating.

D. Logic For Coal Dampers:~

l. Coal rate feedback = 0 to 25%. 1. Coal damper opening = 20%.
2. Coal rate feedback = 40%. 1. Coal damper opening = 37%.
3. Coal rate feedback = 60 to 100%. 1. Coal damper opening = 60%.

CONDENSER ON LOAD TUBE CLEANING (COLTC) SYSTEM

1. Advantages of OLTC system :-
a) Increase in heat transfer rate.
b) Optimum turbine back pressure.
c) Increased generation efficiency.
d) Avoidance of corrosion in tubes.
e) Avoidance of shutdown for manual cleaning.
f) Reduction of chemical costs for water treatment.
g) Reduction in fuel costs.

2. Operation procedure of OLTC system :-
a) Pre-requisite or charging of cleaning balls:
(i) DP Flushing Pumps(F32) dp transmitter line CW isolating ball v/vs(N21 & N22), dp switch line CW
isolating ball v/vs(N23 & N24) & pumps suction v/v(N25); Ball injection v/vs(N31 & N32), Ball
extraction v/vs(N41 & N42) and Ball Vessel vent v/v(N91) are to be kept open.
(ii) M/O 3-way reversing v/v(M01) of DP flushing system is to be kept closed.
(iii) Ball Recirculation Pump(F01) & DP Flushing Pump(F32) are to be kept off.
(iv) Ball Vessel I/L(N01) & O/L(N02) M/O v/vs and manual bypass v/v(N05) are to be kept closed.
(v) 50% Ball Vessel water level is to be maintained by operating its drain v/v(N92).
(vi) Cleaning balls are to be charged through Ball Vessel(G01) hand hole.
(vii) Ball Vessel is to be slowly filled with water through its bypass v/v(N05).
(viii) Ball Vessel vent v/v(N91) is to be closed when water comes out of it & then Ball Vessel bypass
v/v(N05) is to be opened fully.
b) Manual operation procedure of COLTC system:
(i) Control Panel is to be kept energized with no fail indication persisting & Selector Switch is to be kept in man mode.
(ii) Ball Separators(A01) are to be kept in operation position.
(iii) Ball Recirculation Pump(F01) is to be started & Ball Vessel I/L v/v(N01) is to be opened.
(iv) In Ball Vessel, circulation of cleaning balls is to be observed.
(v) After 5mins. running of Ball Recirculation Pump, Ball Vessel O/L v/v(N02) is to be opened.
(vi) Ball Oversize Cum Recirculating Monitor is to be started for counting the effective & total no.of balls in circulation.
(vii) Ball Oversize Cum Recirculating Monitor is to be stopped after checking the DP across the Ball Separator Screens in DP
Indicating Controller.
(viii) After one hr. manual opn., Ball Vessel O/L v/v(N02) is to be closed.
(ix) Ball Vessel I/L v/v(N01) is to be closed 30mins. later & then Ball Recirculation Pump(F01) is to be made off.

c) Manual operation procedure of DP Flushing system:
(i) DP Flushing Pump(F32) is to be started manually when DP Measuring System shows dp exceeding the set limits(30mbar & 50
mbar respectively) through lamp indications for Backwash & Emergency Backwash.
(ii) Keeping the M/O 3-way reversing v/v(M01) open for a certain time, DP Flushing Pump(F32) is to be stopped finally.
d) Auto operation procedure of COLTC system:
(i) Pre-start checks:-
* Check the Ball Separator(A01) Screens are in Backwash position & balls are available in Ball Vessel.
* Check Ball Vessel vent v/v(N91) & drain v/v(N92) are fully closed and bypass v/v(N05) is fully opened.
* Set the timer of ball collection time(T
b
:ball collection time = 1hr) & flushing opn. time(T
f
:flushing time=30mins).
Operation time of tube cleaning = 1 hr.
* Turn the control cabinet mode of operation function Selector Switch to auto.
* Check Ready To Start lamp is on.
* Start the system by pressing Automatic Start PB.
(ii) Observation of the following auto operation steps:-
* Ball Separator Screens turn to operation position.
* Ball Recirculating Pump(F01) starts.
* Ball Vessel I/L v/v(N01) opens & cleaning balls circulate in Ball Vessel.
* Ball Vessel O/L v/v(N02) opens after 5 mins. & on completion of opn. time(1hr), it closes.
* After completion of ball collection time(30 mins), Ball Vessel I/L v/v(N01) closes.
* Ball Recirculating Pump(F01) stops.
(iii) Auto operation procedure by DP Controller when dp across Ball Separator Screens is >30mbar & <50mbar:-
* Indication lamp of Screen Backwash is on.
* Ball Vessel O/L v/v(N02) closes & cleaning balls are being collected in Ball Vessel.
* After completion of ball collection time(30 mins), Ball Vessel I/L v/v(N01) closes.
* Ball Recirculation Pump(F01) stops.
* Ball Separator Screens turn to Backwash position. Screens are backwashed & cleaned for 30 mins.
* DP will display 0 mbar, DP Flushing operation become on & DP Flushing Pump(F32) starts.
* 3-way reversing v/v(M01) opens & thereafter closes.
* DP Flushing Pump(F32) stops.
* After completion of backwashing (30 mins), Ball Separator Screens turn to Operation position.
* Ball Recirculation Pump(F01) starts.
* Ball vessel I/L v/v(N01) opens & cleaning balls circulate in Ball Vessel.
* After 5 mins., Ball Vessel O/L v/v(N02) opens & cleaning balls distribute themselves through the system.
Now unit is again in operation.

(iv) Auto operation procedure by DP Controller when dp across Ball Separator Screens is >50mbar:-
* DP indicator on control panel displays Failure indication & lamp of Emergency Backwash is on with alarm.
* Ball Separator Screens turn to Backwash position.
* Ball Vessel I/L v/v(N01) & O/L v/v(N02) close.
* Ball Recirculation Pump(F01) stops.
* Ball Oversize Cum Recirculating Monitor becomes off.
* Screens are in Backwash position for 30 mins.
* DP flushing becomes on & DP Flushing Pump(F32) starts.
* 3-way reversing v/v(M01) opens & thereafter closes.
* DP Flushing Pump(F32) stops.
After flushing is over, DP value comes down & then the following operations are to be carried out:
* Turn the function Selector Switch from auto to manual.
* Press fault accept & reset PB.
* Turn the function Selector Switch from manual to auto.
* Press the Automatic Start PB for starting the COLTC operation with auto mode.
After each Emergency Backwash opn., cleaning balls are to be counted & the no. of balls lost are to be replaced with new
cleaning balls to maintain the basic charge.
e) Auto shutdown procedure of COLTC for charging of cleaning balls:
For charging of new cleaning balls during auto mode opn. of COLTC,
the control cabinet illuminated Automatic Stop PB is to be pressed when the following operations will take place automatically :-
(i) Ball Vessel O/L v/v(N02) closes. Cleaning balls are being collected in Ball Vessel.
(ii) 30 minutes later(adjusted by timer) Ball Vessel I/L v/v(N01) closes.
(iii) Ball Recirculation Pump(F01) stops.
(iv) Automatic Stop PB glows steadily i.e. OFF program is comple.
(v) Turn the function Selector Switch to manual.
After completion of the above automatic opn., the procedure for charging of cleaning balls is followed.

Debris Filter Cleaning System

(A) Manual operation of debris filter cleaning system :
i) Check cooling water system is completely vented through Debris Filter Vent v/v(N32).
ii) Check all the isolation v/vs(N21, N22, N23, N24, N25, N61 & N71) are open.
iii) Turn the Selector Switch to manual mode.
iv) Start the Debris Flushing Pump(F31).
v) Open the Debris Discharge v/v(M31).
vi) Start the Geared Motor Drive(B21/T21) of Rotary Spray Water Arm.
vii) After completion of flushing the debris(5mins), stop the Geared Motor Drive.
viii) Close the Debris Discharge v/v(M31).
ix) Stop the Debris Flushing Pump.
(B) Manual operation of dp transmitter flushing system :
i) Start the DP Transmitter Flushing Pump(F32).
ii) Open the 3-way reversing v/v(M01) & after a negligible time delay close the same.
iii) Stop the DP Transmitter Flushing Pump.
(C) Auto operation of debris filter cleaning system :
i) Set Flushing Time = 5mins. & Operation Cycle Time = 1hr.
ii) Turn the Selector Switch to auto mode.
iii) Check that Ready To Start indication appears.
iv) Start the system by pressing the Automatic Start PB.
The following operations will take place step by step automatically :-
i) Debris Filter Flushing Pump(F31) starts.
ii) Debris O/L v/v(M31) opens.
iii) Geared Motor Drive of Rotary Water Spray Arm(B21/T21) starts to rotate after the debris discharge v/v is fully opened.
iv) The flushing timer picks up. When the timing is elapsed, the Geared Motor Drive of Rotary Water Spray Arm stops.
v) Debris discharge v/v(M31) closes & Debris Filter Flushing Pump(F31) stops.
vi) System is ready to start.
(D) Auto operation of debris filter cleaning system through dp transmitter(when dp>100mbar):
i) Debris Filter Flushing Pump(F31) starts & debris O/L v/v(M31) opens.
ii) Geared Motor Drive of Rotary Spray Arm(B21) starts to rotate.
iii) After completion of cycle time (duration of flushing) Geared Motor Drive stops.
iv) Debris O/L v/v(M31) closes & Debris Filter Flushing Pump(F31) stops.
v) DP transmitter impulse line Flushing Pump(F32) starts.
vi) 3-way reversing v/v(M01) opens & thereafter closes.
vii) DP transmitter impulse line Flushing Pump(F32) stops.

Compressor Air Drying Plant System

The basic objective of Air Drying Plant is to ensure the supply of totally moisture and oil free compressed air to the system requirements.
For this purpose two nos. of ADP are provided for each unit :- one for I.A. compressors and other for S.A. compressors. The main elements
of Air Drying Plant = Pre-filters, After-filters, Heater, Adsorber towers , Blowers & Control panel.
The blower reactivated drier comprises of 2 nos. pre-filters (1W + 1S), 2 nos. after-filters (1W + 1S), 2 nos. of blowers (1W + 1S), one
heater and two mild carbon steel towers. Each adsorber tower contains a measured quantity of desiccant (815 kg). The towers are designed
to work at 8 kg/cm
2
press. & are hydrostatically tested up to 15 kg/cm
2
. The ADP is designed for 8 hrs. cycle out of which 480 mins. & 270
mins. are required for Drying and Regeneration cycle respectively.
The towers are provided with an I/L & O/L diffusers. They prevent direct impingement of air on desiccant & uniformly distributes air I/L
flow. The towers are also provided with a temp. gauge, safety relief v/v, insulation of adequate thickness, a sight glass for viewing and
desiccant filling & drain port. The compressed air through the tower is controlled by two 4-way pneumatically operated v/vs(SOV21 &
SOV22).
A double stage blower (1W+1S) driven with an electric motor is connected to the adsorber towers through a regeneration heater. The blower
discharge air is heated in the heater which increases the temp.to the set temp.of TIC( temperature indicator & controller). Air is then passed
through one of the two towers for reactivation. It leaves the tower through 4-3 port of the bottom 4-way v/v & is purged into atmosphere
through SV21 & silencer. The depressurization v/v SV22 (DPV) serves to adjust flow rate of purged air.
A temp. indicator controller controls the heater temp. The operation of pneumatic actuator is controlled by solenoid mounted on the
actuators. The air for the actuator is taken from dry air O/L line. Solenoid v/vs are operated by PLC unit mounted in control panel. The PLC
is programmed and relay signals are biased on from inbuilt programme.

i) Pre-start checks before ADP operation :
a) The re-pressurization(SV23) & de-pressurization(SV22) v/vs should be in open conditions.
b) The blower damper should be in 3/4th open condition.
c) Out of two, one no. each prefilter & afterfilter are to be kept in service(max. dp = 0.4 kg/cm
2
).
d) The needle v/vs at DPG at pre-filter and after-filter are to be closed before charging of air to the drier. After confirming air coming
through O/L of drier, the v/vs at DPG are to be opened simultaneously.
e) The blower to be put into service & the mode(auto/manual) of operation are to be selected.

ii) Auto mode operation :
a) Turn the switches of heater & blowers to auto mode.
b) Turn the tower switch to that tower position which is to be dried.
c) Turn the blower (PLC) selection switch to the service blower.
d) Switch on main switch & press the Cycle Start PB. Before that all manual switches should be in off condition, otherwise on
supply of power panel shows fault changeover.
e) Press the PLC Start PB to start the cycle.

During auto mode the following operations will take place sequencially on time cycle :-

Time Tower No.1 Tower No.2 Observation

0 min. Drying De-pressurization SV22 opens & SV23 closes.
+ 7 mins. Drying De-pressurization SV21 opens.
+ 10 mins. Drying De-pressurization Blower starts.
+ 12 mins. Drying Regeneration start(4.5 hrs.) Heater ON (timer start).
+ 282 mins. Drying Cooling start(3.2 hrs.) Heater OFF.
+ 474 mins. Drying Re-pressurization start(6mins.) SV21, SV22 close & SV23 opens.
+ 480 mins. De-pressurization Drying Tower changeover

iii) Manual mode operation :
a) Turn all switches to manual mode & switch on the main switch.
b) Press the Cycle Start PB.
c) Turn the changeover & De-pressurization switches to on positions.
d) When press. in regeneration line will fall to 5 kg/cm
2
, turn the exhaust switch to on position.
e) After 2 to 3 mins., press Blower Start PB & blower lamp will glow.
f) Then press the Heater Start PB for dryer regeneration having 4.5 hrs.time period, otherwise confirm from sight glass whether
regeneration is over or not (color of silica gel at sight glass may turn brown to bluish color).
g) After regeneration, cooling will be done by stopping of heater. Stop the blower when tower bed temp. falls < 60-65
0
C.
h) Re-pressurization will be done by closing SV21 & SV22. Continue this process till the tower press. rises to 8 kg/cm
2
.
i) Then turn the changeover switch to dry.
Regeneration of 2
nd
tower will take place at the same procedure.

Generator H
2
-Gas Dryer System

H
2
-gas used for cooling purpose of generator stator and rotor windings must be moisture free to prevent condensation occurring in the
coldest components of generator. For this, H
2
-gas dryer is used. Differential press. is used to circulate a flow of H
2
continuously through the
dryer, typically of twin tower type using activated desiccant.
In the Blower Reactivated Type H
2
Dryer, an air blower is used to regenerate the saturated desiccant bed. The desiccant adsorbs the
moisture or oil from the H
2
stream by adsorption phenomenon. In the duplex towers, one of the tower is under adsorption and the other
during adsorption cycle is regenerated and kept ready for the next cycle.
To regenerate the adsorption bed (tower) which has completed the cycle, air is blown from the centrifugal type air blower via the heater
chamber to the saturated desiccant bed in counter flow direction. The moisture loaded air from the bed under regeneration is then exhausted
into the atmosphere.
The major components of H
2
gas dryer unit = Adsorber, Air blower with motor, Regeneration air flow control v/v, Regeneration electrical
heater, 3-way double changeover v/vs, Dew point sampling v/v, Press.& Temp.gauges and Local panel.

i) Dryer safety interlocks :-
a) Limit switches are provided on the two sets of 3-way v/vs for actuating the air blower. These limit switches ensure that the air blower &
the electrical heater will be switched on only when the 3-way v/vs are in the position to facilitate flow off regeneration air from the
blower to atmosphere through the desiccant bed.
b) A safety thermostat is provided on the electrical heater which will switch off the heater in case the temp. reaches 180
0
C.
c) The electrical heater is switched on after a few mins. of time lag so that all H
2
present in the tower is expelled before hot air starts
entering the adsorber.
d) The limit switches & other instruments will all be suitable for a control voltage of 6V.

ii) Dryer operation logic :-
a) Step one = LS -1, LS -2 / 3 & LS-4 should be closed during regeneration cycle. Start the panel by pressing startPB. Make sure that
one duplex gas dryer tower is in service(drying mode) & other is in regeneration mode. In this condition, 3-way v/v handle
will always be in diagonally opposite position.
b) Step two = Wait for blower to start after 60 secs(PLC output No. 0 & 2). Wait for heater to start after another 180 secs[PLC output
no.1). In this condition heater as well as blower will keep running automatically by PLC. Here regeneration of silica gels
of selected gas dryer tower will start. DTC No.1 will measure exhaust gas temp. Once exhaust gas temp. reaches 45
0
C
(setting can be changed as per requirement), DTC No.1 will send one input to PLC. From this time, PLC will keep the
heater & blower running for 2hrs. Afterthat, PLC will switch off the heater automatically but blower continues to run.
c) Step three = Even after switching off the heater from PLC, the temp.of selected duplex gas dryer tower bed will continue to rise. This
rising trend of temp.will continue for 1 to 2.5 hrs. Blower keeps on running for this entire period.

d) Step four = After completion of step three, temp. starts falling down. Still blower continues to run. DTC no.2 is assigned to
measure temp. of selected duplex gas dryer tower bed. When the temp.of tower bed falls down to set value of DTC no.2
(55 - 58
0
C, which can be changed as per requirement), DTC no.2 will send signal to PLC & PLC puts off the blower
automatically. Now heater & blower both are in off condition and regeneration cycle is complete.
e) Step five = When dryer is changed from A to B / B to A , above-mentioned cycle from step one to four is repeated automatically.

iii) Dryer operation procedure :-
a) Ensure that H
2
dryer I/L & O/L v/vs are open.
b) Switch on the panel main switch & control supply power. Ensure main supply voltage is showing at the bottom of the panel &
Control Supply ON lamp is glowing at the top of the panel.
c) Turn on the heater & blower switches.
d) Turn the 3-way double changeover v/v handle at the proper position. Ensure the required limit switch lamp(LS-3 / 4) is glowing at the
top of the panel.
e) Turn the PLC reset switch from 1 to 0 position and then back from 0 to 1 position.
f) Press the cycle start PB.
g) The sequence starts & automatic operation of blower & heater will take place as per dryer logic.

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