Emergency Procedure Final-1

1.
Drum level dropping fast

Likely causes
One of the running BFP might have tripped

Sudden tripping of one or more Mills/feeder.
FW control valve/scoop might have closed/stuck.
Malfunction of auto control/scoop regulation.
BFP recirculation valve suddenly opened or valve passing
Sudden reduction of load.
Tube failure in water walls.
HPBP in open position for long time under full load condition
Inadvertent opening of EBD & low point drains.
Drum pressure very high
Drum level transmitters faulty.
Plant response
Drum level LOW alarm appears.

BFP's scoop rises to maximum.
FCV opens to 100%
Boiler will trip if drum level becomes very low
Parameters of concern / Adverse Effects
Drum level very low may affect natural circulation in water wall panel and if drum is empty tubes will melt in no time
Deaerator level
Hot well level
Feed water flow
Steam flow
SH/RH temp
Immediate expected or desirable operator action.
See that standby BFP starts on tripping of running BFP or else

Manually start standby BFP when level drops to -100 mm & load the pump immediately.
Check for any malfunction of auto control like scoop/FCV not raising or recirculation open in auto, take control in to manual &
regulate it
Close CBD if it is open.
Close BFP RC valve MIV if heavy passing is noticed
Close HPBP slowly if it is open.
Reduce boiler firing when level is about -100 mm
Final Corrective Activity.
2.
Check drum level is getting stabilised.

Ensure drum level controls are in auto.
Check feed water flows matches with steam flow for full load, if deviation is more then check for any leak in boiler area.
Ensure for the availability of standby BFP as early as possible.
Check for local level gauge & transmitters.
Check boiler low point drains & EBD.
Check for scoop controls for any linkage failures.
Drum level shooting up fast
Likely causes
Malfunction of feed control valve or BFP scoop.

Scoop /Flow control valve might have stuck.
Sudden increase of load
Drum level transmitters may be faulty.
Sudden increase of firing rate.
Sudden opening of HPBP.
Plant response
Drum level high alarm will appear.

If drum level reaches very high level boiler will trip
BFP scoop & FCV position reduces
BFP RC valves may open
Parameters of concern / Adverse Effects

Drum level very high may cause priming foaming & carry over. If Water is discharged to super heater header hammering may occur
& wet steam may enter MS line
Deaerator level
Hot well level
Feed water flow
Steam flow
SH/RH temp
Open emergency blow down EBD-valve
Reduce HPBP valve position if it is open
Reduce boiler firing
If drum level is approaching trip value take drum level control on manual & regulate
Reduce load for a momentso as to control the water level (if water level is due to upward load surge).
Final correction activity
Check feed water flow matches with steam flow.
Check for stuck of feed control valves & scoop.
3.
Check the level at local, hydrostep and transmitters are matching.
Rapid Boiler steam pressure rise

Likely causes
Corex calorific value increased drastically.

Sudden loading of mill.
High firing rate.
Feeder hunting.
Malfunction of CMC.
Sudden dropping of generator load & HPBP not opened
Plant response
Throttle pressure high alarm will come

HP/LP bypass opens on auto.
APH FG I/L O2 low alarm will appears
Boiler safety valve may float.
Drum level will vary.
Parameters of concern/Adverse effects.

Drum pressure sudden raise may cause safety valve lifting
Tube leak may start
Unit load
MS /RH temperature
Drum level
APH inlet O2
HP/LP bypass
Immediate expected or desirable operator action

Take the fuel control into manual mode if it is in CMC & reduce the fuel firing.
Trip the malfunctioning feeder/mill & reduce PA airflow through that mill.
Check for pressure drop & if it is not holding remove the corex burners.
Start standby BFP if drum level is dropping
Check for reseating of safety valve
As soon as the pressure starts dropping, restore the correct fuel input.
Stop the third running BFP and keep it in standby.
Ensure drum level got stabilised.
Check for closure of HP bypass.
Ensure pressure is stable.
4.
Rapid Boiler steam pressure decrease

Likely causes
Sudden drop in corex pressure or Calorific value

Tripping of mill or feeder or oil elevation
Mill getting unloaded
HPBP got opened
Sudden rise in load.
Boiler tube leakage
Safety valve not closing after floating
Plant response
O2 at APH inlet high alarm

MS pressure will drop.
Generator load will come down.
Drum level will drop.
Parameters of concern/Adverse effects
Drum level
generator load
MS pressure
MS/RH temperatures
APH FG inlet O2
If rate of pressure drop is more than the given saturation temp. curve boiler drum will subjected to severe thermal shock
Check for any mill unloading/ tripping

Reduce load set point to hold the MS pressure around 110 kg/cm2.
Close HPBP if it is opened

Check for safety valve floating
Raise boiler firing in case of mill tripping. Take oil elevation in to service if required
Check boiler flame
Monitor drums levels during this disturbance, if it is dropping very fast, start standby BFP.
Final correction activity.
5.
Ensure drum level is stable.

If mill is unloaded stop the mill & take other mill into service.
Increase to full load based on the fuel.
Remove oil if it is introduced if furnace conditions are good or bright.
EMRV floating and resetting in succession

Likely causes
Improper blow down setting for EMRV/ pressure switch malfunction

Fuel in put to boiler varying continuously.
Turbine control valve/HPBP valve hunting
MS pressure fluctuation
Plant response

EMRV open/close indication in Control room
Drum pressure fluctuation
Ms temp and RH temp variation.
Turbine control valve may hunt due to varying throttle pressure

Drum level
MS pressure.
Ms temp and RH temp
Shock to boiler component
Valve may get damaged.
Reduce the fuel firing if pressure is really high.
If MS pressure is less, still EMRV is operating, keep selection switch to "OFF" so that the EMRV will not operate.
Even by putting "off ", valve is still in open condition, its manual isolation valve can be closed.
Ensure for proper re-seating of the valve & put back in auto.
6.
RH SV floating and resetting in succession

Likely causes
HP bypass opened & valve hunting

LP bypass opened & valve hunting
HPBP opened & LPBP not opened
Improper blow down setting of Safety valve
Plant response
HRH steam pressure high alarm will appear.

MS and RH temp variation
HRH/MS pressure variation
Generator load may vary due to turbine control valve hunting
Drum level
MS and RH pressure
HRH temp
Shock to boiler component

If LP bypass not opened even with pressure more than sliding setpoint, reset LPBP trip & see LPBP is opened
Take HP/LP bypass valve on manual if it is hunting in auto
Reduce MS pressure, if actually high, so that HP bypass will close in auto.
Reduce the turbine load until the valve resets
If Blowdown adjustment is required do it in the nearest available opportunity
If any control is malfunctioning attend to it
7.
MS temperature rising fast
Likely causes
Inadequate spray due to malfunctioning of spray control valves.

Excess airflow.
Burner tilt stuck in up position
Leakage in the spray line.
Low feed water temperature.
Boiler firing raised in top elevation
Heavy furnace slagging
Spray isolation valve in close condition
Plant response
MS temperature high alarm will appear.

Spray control valves will go for further opening.
If temperature is very high, turbine will trip.
MS/RH temperatures
MS temp at turbine inlet
HP exhaust temperature.
Spray quantity/ FCV differential pressure.
Tilt position
Metal temp. raise above design value will reduce tube life drastically
Make burner tilt fully down
Take MS spray control to manual & raise spray quantity (stage -1 o/l temp should be around 450C & stage -2 o/l temp around
505C)
Reduce firing in top elevation
If rate of pressure rise is more, then pick up load if margin is there.
Reduce airflow based on the O2 percentage.
Check spray station is properly lined up
8.
Start soot blowing, if slagging is more

Restore back the temp controls in auto if it has been taken in manual
Check for any malfunction of spray control valves & isolate such type of valve.
Burner tilt can be kept horizontal.
RH temperature rising fast
Likely causes
Inadequate spray due to malfunctioning of spray control valves.

Excess airflow.
Burner tilt stuck in up position

Boiler firing raised in top elevation
HP exhaust temp is high
Spray isolation valve in close condition
Plant response
RH temperature high alarm will appear.

Amount of spray will rise.
Turbine will trip if RH temp reaches very high
RH temperatures
RH temp at turbine inlet
HP exhaust temperature.
Spray quantity/ FCV differential pressure.
Tilt position
Metal temp raise above design value will reduce tube life drastically
Make burner tilt fully down

Take RH spray control to manual & raise spray quantity
Reduce firing in top elevation
Check spray station is properly lined up
Check HP exhaust temp is normal
9.
Start soot blowing if furnace slagging is there.

Keep the burner tilt in horizontal condition.
Restore back the control in auto if it has been taken in manual.
MS temperature falling fast
Likely causes
Tripping of mill
Sudden boiler pressure drop
Malfunctioning of spray control valves.
Spray station passing
Less air flow
Burner tilt fully down
High feed water temperature
Soot deposits on SH tubes
Plant response
MS temperature low alarm will appear.

Turbine will trip if MS temp goes very low.
Ms temp
Spray quantity
Burner tilt
Close the spray control valves by taking it into manual.

Make burner tilt upward.
Check airflow &Rise if necessary.
Increase firing in top elevation
Reduce turbine load if pressure is dropping
Close spray station Block valve/ isolation valve if control valve is passing.
Start LRSB operation

Observe for improvement in temperature.
Restore back the controls in auto (spray control)
Check for any malfunction of control valve & isolate it.
10.
RH temperature falling fast

Likely causes
Tripping of mill
Sudden boiler pressure drop
Spray station passing
Less air flow
Burner tilt fully down
Soot deposits on RH tubes
Plant response
RH temperature low alarm will appear.

Turbine will trip if RH temp goes very low 450C
RH temp
Spray quantity
Burner tilt
Load
Close the spray control valves by taking it into manual

Make burner tilt upward
Check airflow &Rise if necessary
Increase firing in top elevation
Reduce turbine load if pressure is dropping
Close spray station Block valve/ isolation valve if control valve is passing.
Start LRSB operation

11.
COREX VENT VALVE FAIL TO CLOSE.

(A) INDIVIDUAL CORNER VENT NOT CLOSING
LIKELY CAUSES
Inadequate Air supply to the valves

Command from DCS to field not extended
Feedback problems in nozzle valves
PLANT RESPONSE
Down stream pressure will come down as compared with the corresponding valve position.
PARAMETERS OF CONCERN
Corex header pressure.

CO ppm in the atmosphere.
OPERATOR ACTION
Check the valve position at local.

Take out pair of corresponding burners.
FINAL CORRECTIVE ACTION
Remove pair of corresponding burner & rectify the problem with help of C&I.
(B) COREX C- HEADER VENT VALVE OPENED

LIKELY CAUSES
Inadequate air supply to the valves

Command from DCS to field not extended
PLANT RESPONSE
Corex pressure will come down at faster rate

Corex leak alarm may come
Corex header pressure.

CO ppm in the atmosphere.
OPERATOR ACTION
Take out burners in pairs.

Close trip valve
Find out the root cause & rectify the problem with help of maintenance.
12.
COREX TRIP VALVE FAILS TO CLOSE.

LIKELY CAUSES
Inst. air supply failure

Mechanical failure.
Command from DCS to field not extended.
PLANT RESPONSE
If the trip valve has failed to close during boiler trip, the corex will vent
out from the C hdr vents & chances of increase in CO
PPM will be there.
Corex may also enter in the boiler if there is passing in any of the corner nozzle valves.
PARAMETER OF CONCERN
CO ppm in atmosphere.
Furnace draft. (If the corex trip valve has failed to close during boiler trip accompanied with the failure of closing of any corner
nozzle valves).
MS pressure. (If the corex trip valve has failed to close during boiler trip accompanied with the failure of closing of any corner nozzle
valves).
Furnace flame. (If the corex trip valve has failed to close during boiler trip accompanied with the failure of closing of any corner
nozzle valves).
OPERATOR ACTION
Close UNIT supply goggle valve &

Ensure that the C header pressure reduces to atmospheric pressure.
Ensure the furnace purge cycle completion.
Find out the root cause & rectify the problem with help of maintenance.
13.
HEAVY ASH BUILD UP IN ONE OF THE HOPPERS.

LIKELY CAUSES
Failure to carry out ash evacuation in time.

Problems with electronic controller and transformer rectifier of the fields in service.
Under voltage tripping of the fields in service.
Transformer protection acted of the fields in service.
Choked ash lines preventing hopper from being evacuated
Moist ash. Rat hole in hopper
Struck up of foreign material in the conveying system

Failure of heating element-ash may stick to the hopper
Insufficient vacuum developed by blower.
Problem with air intake valve
Insufficient loading of succeeding fields.
PLANT RESPONSE
EP fields trip on low voltage.

Build up to high tension emitting system, causing short circuit
Buckling of collecting electrode/Dislocation
Ash level high alarm will come, will trip the field
Dust carry over from chimney.
CEMS will indicate high SPM.
OPERATOR ACTION
Check ash-handling system.

Switch off the field
Try to charge possible fields as early as possible
Switch over to corex fuel. (If it is going to take longer period to rectify the problem). Reduce coal firing.
Manual poking of hopper to be done (ensure that particular field is off)
If vacuum is not developing change the blower.
Switch on heaters.
Check rapping frequency
The ash evacuation should be continued due to gravity settlement
Stack emission.
Tripping of field
Arrange for ash evacuation.

After evacuation charge the field.
14.
OIL LEVEL LOSS IN APH BEARINGS
LIKELY CAUSES
Leakage in piping
Leakage in drain plug, instruments, connections
Leakage in threaded joints
Leakage through filter vent plug
Oil seal damage
PLANT RESPONSE
Rapid rise in oil temperature

Noise may come if bearing is damaged
Bearing temp will raise.
If leakage is there near the hot end, may cause fire break-out.
OPERATOR ACTION
Find out the leakage point.

Stop the oil pump to avoid further loss of oil.
Make up the oil level in the bearing housing.
Run the stand by oil pump only if the leakage point is not from the common piping.
In case of any fire, extinguish it with the help of proper extinguisher at the earliest possible.
Oil level
Oil temperature
Bearing temperature.
Add oil through the dip stick hole until max oil level mark .
Leakage to be arrested.
Put the oil system back in to service.
15.
AIR-PREHEATER MOTOR TRIPS/ AIR MOTOR DOES NOT START
A. ONE APH MOTOR TRIPS/AIR MOTOR DOES NOT START.

LIKELY CAUSES
Motor may trip on overload.

Power supply to the motor failed.
Air motor failure or solenoid failure
No compressed air available.
Lube oil system fail.
Some foreign material fallen on the APH & got stuck.

Seal of the APH has got disturbed.
PLANT RESPONSE
Rapid fall of hot air temperature on one side.

Rapid rise of gas temperature of stopped APH.
Possibility of deformation of APH.
Alarm at ECP/ DCS electrical motor stop- appears.
Furnace draft will fluctuate due to ingress of cold FD air.
Mill temp will drop as a result of drop in hot PA temperature.
OPERATOR ACTIONS
Reduce boiler/generator load to 60% MCR gradually.

Attempt for starting the electric motor, if the power has resumed or after resetting the over load.
If the air motor has not started because of air solenoid problem open the bypass valve of the solenoid.
Isolate affected air heater on the gas side first if all the attempts of starting the air motor or electric motor has failed. (Keep watch on
draft)
Isolate the affected APH at airside (keep watch on total airflow)
Try to rotate air heater manually.
Maintain generator load depending upon the parameters of the running AH.
Watch hot air temperatures to mills
Cut in oil burners, when load is reduced.
Reduce corex to minimum.
Checks lube oil system & restore lubrication.
Flue gas temp at APH I/L & O/L.

Furnace draft.
Mill o/l temp / hot PA temperature

Secondary air temperature.
B.
After rectifying the problem of electric motor / air motor, start air / electric motor before normalizing the dampers on air/gas side.
If the problem is due to stucking of foreign material, then outage may be required to remove the same.
WHEN BOTH APH MOTOR TRIP/AIR MOTORS DO NOT START
LIKELY CAUSES
Power supply failure/ motor failure.

Compressed air failure
PLANT RESPONSE
Rapid fall of hot air temperature

Rapid increase in flue gas temperature
Possible distortion in air heater rotor
Air heaters A/B electrical motor stop & APH rotor stop alarm at ECP/DCS.
OPERATOR ACTION
Reduce the fuel firing drastically as early as possible.

Parallel attempts to be made for electric/air motor
If failed to restore APH rotation within ten minutes, shut down the boiler.
Manually rotate APH till alternate arrangement is made.
Flue gas temp at APH I/L & O/L.

Furnace draft.
Mill o/l temp / hot PA ,SA temperatures.
Secondary air temperature
16.
After rectifying the problem of electric motor / air motor, start air / electric motor before normalizing the dampers on air/gas side.
SUDDEN INCREASE IN STEAM SILICA
LIKELY CAUSES
DM make water silica may be high.

Condenser tube leakage.
System taken into service after major over haul & maintenance.
OPERATOR ACTION
Ask chemist to confirm panel instrument readings of silica by actual analysis.

Increase the drum blow down.
Reduce drum pressure as per the curve silica in boiler water/boiler pressure" taking into account solubility of silica in steam at
elevated pressures.
Maintain phosphate concentration in Drum around 5ppm.
If the steam quality is affected by the process within the system, shutdown the turbine & start dumping through bypass to improve
the steam quality before rolling the turbine.
If steam quality cannot be improved because of the make up water faulty/ condenser tube leakage, shutdown the unit.
Silica concentration in drum, steam.

Phosphate concentration.
Drum pressure.
PLANT RESPONSE
Drum silica & steam silica high alarms will appear.

Silica carry over in steam>0.02ppm leads to deposits on turbine blades.
17.
Check &Correct DM make up quality.

If condenser tube leakage is there after attending only, boiler to be lighted up.
Hot blowdown is to be given to displace impure water & level to be made up with fresh DM water.
After restart of the boiler, don't take condensate into the system into service until quality of condensate is satisfactory.
BOILER WATER pH IS FALLING FAST
LIKELY CAUSE
Improper phosphate dosing

make up water faulty
Due to continuous passing in IBD/CBD.
PLANT RESPONSE
pH low alarm will appear
Leads to accelerated corrosion of boiler tubes and consequent tube failure

conductivity of boiler drum also comes down
pH of the drum water

pH of condensate.
Conductivity
OPERATOR ACTIONS
Increase phosphate dosing.

Check for passing in CBD/IBD.
Consult the chemist. Check whole regime of the system.
Find the root cause of the problem; if it is due to faulty dosing then check concentration of the dose. If it is due to passing get it
arrested. ask chemist to check DM water quality.
18.
REPEATED TRIPPING OF COLLECTING RAPPING MOTORS OF ESP
LIKELY CAUSE
High ash level in hoppers.

Improper setting of motor overload relay
PLANT RESPONSE
Inefficient ash collection in ESP.

Stack SPM may increase
Ash level, field current,SPM
OPERATOR ACTIONS
Switch off the motor supply

Switch off the fields if tripping on ash level high and empty the hopper.
Switch on available /stand by field in the same pass.
Switch on the field and take rapping motor into service

Get over load setting checked rectify the problem.
19.
AC Scanner fan tripped & DC failed to pickup
Likely causes
DC fan fails to start after AC fan trip
Both fan getting over load/electrical fault
Plant response
Scanner air to furnace DP low alarm
Scanner air fan tripped alarm
Inadequate cooling of scanners may cause damage to scanner sensing element
Scanner air to furnace DP low
Flame scanner cooling is not taking place
Operator action
Try to start fan by resetting overload relay
Increase FD fan discharge pressure so that some air will always available for scanner
If not happening reduce load to minimum & get the fan started at the earliest.
If Scanner air fan could not be restarted even after reasonable time delay trip the boiler
19.
ID/FD trip
Probable Causes
ID trip
Motor protection acted.
Lub oil pressure v.lo 0.2ksc
H.C oil pressure v.lo 0.6ksc
H.C oil tank temp high 110oc
H.C oil cooler o/l temp 90oc
Winding temp v.hi 120oc
Bearing temp (fan/motor) v.hi (75oc/95oc)
FD trip
Motor protection acted.
Fan/motor bearing temp v.hi 95oc
Winding temp v.hi 120oc
Plant response
On ID trip, corresponding stream FD fan will trip.
Running ID/FD fans will get loaded to maintain draft and airflow.
When in CMC, runback will act and reduce load SP to 90/100MW @ 20MW/min
Mill-C will trip (On FD fan trip), if 3 mills are in service.
Parameters to watch
Furnace draft, drum level, airflow, ID & FD currents, mill loading, TG load, MS pressure & temperature, RH temperature, WB to furnace
DP, O2 at APH i/l.
Operator action
Case1: 3 mills in service without corex

Mill-C will trip on FD fan trip. After 1-min timer, cut-in oil guns.
Mill-A & B is to be increased to max. Hold pressure at 110ksc by reducing load.
Cut-in corex if available & restore load, keeping a watch on ID/FD fan current.
Start the tripped ID/FD fan after investigation and raise the load to full.
Case2: 1 mill with corex at 3 elevations
1. Remove corex on X3 elevation. Hold pressure at 110ksc by reducing load.
2. Start another mill and restore load keeping a watch on ID/FD fan current.
3. Start the tripped ID/FD fan after investigation and raise the load to full.
20.
APH fire
Likely causes
Defective oil burner, leading to deposition of un burnt oil particles on APH heating elements.
Soot deposit on APH heating element
In effective APH soot blowing.
Guide bearing oil leakage in to APH.
Plant response
Flue gas/ secondary air temp high alarm should come(presently not commissioned)
Flue gas temp after Air heater rises sharply

Sec air and primary air temp after APH rises sharply.
At worst case APH may get damaged
Parameters of concern.
Flue gas temp after Air heater
Sec air and primary air temp after APH
Damage to APH
Reduce boiler load
Close Flue gas inlet damper
Close PA &Secondary air side inlet & outlet dampers
Open APH hopper drain plug
Open cold end side & hot end side hydrant valve and quench fire
Stop the oil guns with smoky flame if they are in service.
Isolate APH and open for inspection if fire is extensive
21.
FIRE NEAR MILL AREA
LIKELY CAUSES
High mill outlet temp.
Running mill with less air flow for long time can cause coal accumulation in mill discharge pipe & cause fire
High % of volatile mater in coal
If mill rejects are more & not removed regularly may cause fire in rejects chamber.
Tramp Iron Gate stuck in close position, causing fire in rejects chamber.
Coal accumulation in hot air duct
Fire conveyed from bunker coal
PLANT RESPONSE :
Mill out let temp. high alarm
Mill DP & air flow , current variation.
Fire coming from reject hopper
Red hot mill body/ reject chamber
Parameters of concern
Mill puffing
Mill o/l temp.
Air i/l temp.
Mill airflow.
Mill DP
Mill rejects.
Immediate /expected or desirable operator action

Reduce hot air flow to mill & continue to run with more coal.
Mill rejects hopper to be cleared
If fire is not reduced stop feeder & open Mill inheriting steam valve & Hydrant water valve
Stop Mill & release for clearing after fire is quenched
Inspect mill internals and feeder for healthiness.
22.
LRSB NOT RETRACTED
LIKELY CAUSES
Forward/Reverse motor trip
Lance jammed after advancing
LRSB clutch de coupled after advancing
Electrical supply failure during operation
Chain broken.
PLANT RESPONSE
Soot blower not retracted alarm
Soot blower overload acted alarm
Steam jet hitting boiler tubes
LRSB getting damaged
Reset the module & give retract command from local push button. If it fails to retract even after module is reset, switch-off the
module.
Reduce soot blower header pressure to 3- 4Ksc.
Disengage the clutch and try to retract manually from handle. If it is retracting do not release handle in the middle ( If handle is to be
released in the middle, first engage the clutch & then only release) .
Inform maintenance if it is not retracting manually also.
Try retracting with additional assistance for max. one hour.
If it could not be retracted within 1hour, reduce pressure to 0 ksc & try again.
Still if it is not retracting ask maintenance to insert dummy in steam supply line flange so that other blower operation can be carried
out.
23.
If the lance is deformed change with new one
FIRE IN ESP
LIKELY CAUSES
OIL/soot deposit on ESP fields
Very high un burnt in fly ash & hopper heating element Not switching off
ESP transformer fire
PLANT RESPONSE
ESP transformer trip.
Furnace Draft variation
ESP O/L temperature
ID fan loading
Furnace Draft
Damage to ESP
Trip ESP field
Isolate the power supply of all related ESP pass/field.
If fire is outside ESP, use extinguisher & douse the fire.
If it is inside ESP reduce unit load & close ESP inlet & outlet gate.
Inform fire man
Open ESP man holes
Open ESP ash hopper drain plugs/man hole
Quench the fire with fire hydrant water
Identify the reason and rectify it.
26. ONE OF THE TURBINE CONTROL VALVE FAIL TO CLOSE

A. Symptom /parameter effected
While reducing load, it will not reduce below certain MW even if load set point is less.
Stuck Valve position feed back will show open position control room whereas other valve will go for close.
High speed control acting.
B. Likely cause
Valve mechanically stuck.
Trip mechanism not working.
Oil not getting drained from actuator.
C. Operator action
Immediate action
Reduce turbine load to 100MW if unit is in service.
If turbine has tripped. close MS1.2.3 &4 & depressurise MS & RH line.
Open corresponding MAL drain before & after control valve(Partially).
Subsequent action
If valve has stuck. Reduce boiler pressure & shut down the unit for attending the problem.
Final corrective action
Start turbine only after valve problem is attended.
27. ONE PHASE OF THE GT POLES FAIL TO OPEN AFTER UNIT TRIP
Pole Discrepancy alarm will come.
LBB protection will trip all the breaker connected to that bus.
TG speed does not drop after trip.
TG draws current from grid (reverse power).
Negative sequence current in Generator.
LP exhaust temperature may shoot up.
B. Likely cause
Breaker contact mechanically stuck.
C. Operator action
Immediate action
Trip all the 220 kV breaker connected to the particular bus including bus coupler.(If LBB not acted).
Trip field breaker manually. If it did not opened.
Open isolators of GT breaker.
Subsequent action
Normalise supply by charging Lines .STs and Bus coupler.
Attend GT breaker before restarting Turbine.
28. SCANNER FAN TRIPPED & DC FAN FAIL TO START

Scanner air to furnace DP low alarm.

Scanner air fans tripped alarm.
B. Likely cause
Dc fan fails to start after AC fan trips.

Both fan getting over load/electrical fault.
C. Operator action
Immediate action
Trip the boiler
+
Subsequent action
Try to start fan by resetting overload relay.

Increase FD fan discharge pressure so that some air will always available for scanner.
If not happening reduce load to minimum & get the fan started at the earliest.
If Scanner air fan could not be restarted even after reasonable time delay trip the boiler.
Lightup boiler only after starting scanner air fan.
29. HIGH DIFFERENTIAL EXPANSION IN TURBINE

Difference between shaft & casing expansion more than normal.

Change in axial shift.
High turbine vibration.
B. Likely cause
Positive differential expansion.
More than rated steam pressure & temp. for rolling.
Inadequate soaking during rolling.
Too fast load pickup of load.
Sudden raise in MS/RH temp.
Casing not moving freely over its slide/ restriction for casing expansion.
High gland steam temperature.
Improper drain operation.
Negative differential expansion
Less than rated steam pressure & temperature for rolling.
Sudden drop in MS /RH temperature.
Improper drain operation.
Wet steam entry in to turbine.
C. Operator action
Immediate action
Positive differential expansion
Reduce steam temp if it is more.
Bring machine to soaking speed if it is during rolling.
Reduce turbine loading if it is after synchronisation.
Check and control gland steam temperature.
Check MAL drains are operating properly.
Negative differential expansion

Increase steam temperature if it is less.
increase turbine load if it is after synchronisation.
Check MAL drains are working properly.
Check gland steam temperature.
Check MAL drains are operating properly.
Subsequent action
Maintain steam temperature steady.
30. TURBINE BEARING TEMPERATURE RAISING FAST

Turbine/generator bearing temp. high alarm.
Lub oil return line oil temp. gauge showing more than normal.
Turbine oil cooler inlet/outlet temp. more than normal.
Change in turbine vibration pattern.
B. Likely cause
ACW pump tripped or ACW to lub oil cooler not charged after synchronisation.
High lube oil inlet temperature.
Bearing failure.
Thermostatic valve failure.
Inadequate lub oil flow or pressure.
Excessive bearing vibration.
High axial thrust.
Lub oil cooler not vented properly.
C. Operator action
Immediate action
Trip the turbine if bearing temp reaches 120 0C(atleast 2 indications in metal temp overview screen).
If temp is with in 1200C then try the Subsequent action.
Subsequent action
Check lube oil flow & pressure to bearing.
Check Lub oil cooler is charged on ACW side & ACW flow is adequate.
Check return oil temp from each bearing.
Verify babit temperature by other means (to rule out faulty measurement)
If thrust bearing temperature is increasing check for axial shift.
Start Standby AOP if oil pressure is low.
Vent lub oil cooler properly.
Find out reason for bearing temp raise.
31. TURBINE VIBRATION SHOOTS UP

Turbine bearing/shaft vibration high alarm.
Turbine will trip if shaft vibration reaches trip value.
B. Likely cause
Turbine bearing damage.
Rotor eccentricity high/ Shaft distortion.
Turbine blade damage.
Turbine glands rubbing.
Sudden change in steam inlet temperature.
Lube oil temperature too low.
Uneven cylinder expansion/restriction for expansion.
Foundation bolts loose.
Alignment/centering problems.
Change in axial shift.
Sudden MVAR load change.
Improper drain Operation
High grid frequency
Machine coasting down rate too slow after trip.
C. Operator action
Immediate action
Reduce turbine load by load limiter and trip the machine if bearing vibration is >11mm/sec(for Brg No. 6 >18mm/sec.
Subsequent action.
Check locally whether vibration is actually high.
Listen to bearing sounds using a vibration sensing stick.
Maintain steam parameters normal.
Check lube oil pressure and after cooler temperature.
Check any sudden MVR change is there.
Wait for frequency change.
Trip the machine if it does not trip on high vibration.
32. TURBINE STARTS ROLLING ON ESV OPENING
Turbine speed may rise without giving command for rolling.
B. Likely cause
Control valve passing.
Control valve stuck in open position.
C. Operator action
Immediate action
Close ESV by tripping turbine.
Check whether control valves are fully closed (in DCS as well as local).
Check for the EHTC output (has to be zero).
Subsequent action
If all rolling criteria are ok and if only minor passing only is there and speed is reaching to say 800rpm roll to 3000rpm if it is a
hot startup.
Attend valve problem in nearest shut down.
33. HPBP OIL LINE LEAK

Oil leak noticed by personnel.

HPBP oil pump continuously running.
HPBP oil pressure low alarm.
HPBP valve creep opening without open signal.
B. Likely cause
Oil leaking from ferules.
Servo valves leaking.

Flexible hoses bursting out.
C. Operator action
Immediate action
Isolate leaking oil line/valve.
Switch off HPBP oil pump supply.
Isolate spray line MIV if leak is in spray line.
Subsequent action
If main valve creeping is started due to loss of oil pressure then reduce turbine load slowly to 60 MW.
Bring down boiler pressure to 85Ksc. and get the leak attended.
Trip boiler if HPBP downstream steam temp. could not be maintained.
Close MS-1.2.3 & 4 and depressurise MS line in that case.
If leak is attended charge the line slowly and raise the load
If leak could not be attended trip the boiler after reducing load.
34. CONTROL OIL LINE LEAK

Oil leak noticed by personnel.

Control oil tank level low alarm.
Control oil pressure dip.
Oil leak detected from LPBP/IPSV tray switch.
Oil leak detected from Control oil skid tray switch.
B. Likely cause
Oil leaking due to O ring failure.

Servo valves leaking.
Joint leak/welding failure.
Excessive control oil pressure.
C. Operator action
Immediate action
Close isolation valve (at control oil skid) of leaking line if leak is in individual lines.
Reduce turbine load to 100MW.if any turbine valve has closed.
Open corresponding MAL valve partially.
Change over to standby pump if leak is in pumping unit.
If leak is in common block & leak does not stop after change over, reduce turbine load & trip Control oil Pumps immediately.
Subsequent action
Inform fireman and keep fire extinguisher ready if oil is spilled over valve body or steam line.
After attending leaky point charge line very slowly.
Arrange to clean leaked out oil.
35. WATER/OIL DETECTED IN GENERATOR CASING.

Liquid in Generator casing alarm.

TG trip on LLD sensing level in Generator bushing top.
B. Likely cause
H2 cooler leakage.
DPRV malfunctioning and maintaining higher DP.
Defective seals component and oil entering generator casing.
C. Operator action
Immediate action
Open LLD drains after isolation and empty it. See whether oil or water is coming.
After draining, normalise and wait for further liquid level sensing.
If water is coming reduce generator load & isolate one hydrogen cooler & find out leaky cooler .
If oil is coming see seal oil to H2 DP is normal.
Subsequent action
If liquid from drain is continuos plan for unit shut down.

If liquid is because of DPR malfunctioning get it attended.
Find out reason for liquid entry in casing and rectify it.
36. WATER HAMMER IN PIPELINE

B. Symptom /parameter effected
Abnormal / intermittent sound in pipe line.

Pipeline. Hanger or supporting structure damages.
To & pro movement of pipeline.
B. Likely cause
Proper charging procedure not followed.
Sudden entry of steam into water lines.
Sudden entry of steam into improperly drained pipelines.
Improper warm up during charging steam lines.
Faulty drain traps or ill designed drain valves.
Sudden opening of high pressure valves.
C. Operator action
Immediate action
Cut off steam supply to the line in which hammering is occurring.
Subsequent action
Open drains & trap bypass valves of that line.
Wait for full draining/proper warm up.
Slowly open valve and allow steam to come out of drains.
Allow system pressure to build up.
Close drains & put trap in to service.
If it is a water line ensure no steam is entering pipe line.
Follow proper charging procedure.
37. COREX GAS LEAK

Symptom /parameter effected
Alarm at local / DCS will come depending upon location of leak.( 08 static CO detector in blower area, 8 CO detector & 8 H 2 detector
in different elevation on both the boiler & 01 detector in control room AC duct are connected to DCS system in Control room).
Lamp indication with hooter near DM plant water tanks

For > 50 ppm
For > 100 ppm
- orange
- red
In addition Siren will be activated from control room for corex leak emergency.
B. Likely cause
Corex leak due to seal pot water seal breaking
Flange. valve gland leakage.
Passing of valves.
Explosion in pipe line.
Leakage from adjacent steel plant process
Major leakage can occur in the unlikely event of natural calamities such as earthquake etc.
C. Operator action
Check CO concentration with portable detectors and confirm with that of control room indications.
If the CO-detected by permanent / portable detectors is reading 200ppm and above, effect local area evacuation and parallel
start reduction of corex in the corresponding unit (if the leakage is sensed in blower area reduction to be done in both the
units). If greater than 400ppm for 15 min, stop A/C plant and remove corex elevation of the corresponding unit. (if the
leakage is sensed in blower area remove the corex completely in both the unit & close the bypass goggle valve and JVSL
double gate valve). And if greater than 500ppm for 30 min, declare emergency by actuating siren for totally evacuation of the
personnel.
Inform safety officer / fire control room in any of the above case.
Check for leakage, all the source of ignition should be kept away, Self-contained breathing apparatus (SCBA) to be used
while checking and attending leak.
In case fire takes place during leak, first the pressure in the supply line should be reduced to shorten the flame & then the fire
should be extinguished. Only after the fire is extinguished, the main gas should be closed completely. Never close the main
valve, when the fire is still there and the pressure in the gas main should not be reduced below 100mmwc.
In case anyone notices an emergency type situation, shift-in-charge should immediately reach the location of emergency with
necessary safety gadgets and assess the situation. He will declare the emergency by informing control room to send coded
siren (15 seconds on & off for 3 minutes). At the same time he will decide about the emergency shut down of the plant
Perform the head count at the assembly point (Old admin. Bldg).
All clear signals (2 min- continuous) siren to be raised if the declarer of emergency clears the emergency after attending the
leakage.
Subsequent action
Purge the corex system with nitrogen & achieve the co ppm less than allowable range of 50 ppm
Find out the exact location of the leakage.
Arrest the leakage point & check for leakage
Take corex in to service only after clearance from safety dept.
38. COREX VENT VALVE FAIL TO CLOSE

Valve fail to close alarm

Corex leak alarm
Valve close indication not coming in DCS
B. Likely cause
No or inadequate air supply to the valve actuator.
Valve mechanically stuck in open condition.
C. Operator action
Immediate action
If C- header vent valve fails to close. then remove corex totally from that unit.
Ensure Nitrogen purge valve is open.
If it is corner vent valve. remove that corex pair from service.
Subsequent action
Check instrument air supply is normal to valve actuator.
Arrange to get vent valve closed from maintenance.
Take corex in to service only after the satisfactory valve stroking
39. COREX TRIP VALVE FAILS TO CLOSE.

Valve fail to close alarm.

Corex leak alarm.
Valve close indication not coming in DCS.
B. Likely cause
Valve Mechanically stuck.
C. Operator action
Immediate action
Ensure all corner nozzle valves are closed.
Close corex control valve.
Close UNIT supply goggle valve and purge supply line & C header with N 2.
Subsequent action
Take corex in to service only after the valve is made operational.
Emergency Procedure
1. APH FIRE
Symptoms / parameter
effected
1. Flue gas temp. at APH
outlet goes above
3500C suddenly from
normal value
2. Secondary air temp. at
APH outlet goes above
Immediate Operator
Action
1. Reduce unit load to 65
Likely cause
MW
2. Close Flue gas inlet
deposit on APH.
damper of particular
APH.
3. Close ESP inlet damper
Heavy unburnt
Poor combustion of
Subsequent operator
action
1. Open APH hopper drain
plug.
2. If the fire is confirmed
fuel oil.
open cold end side & hot
Not doing APH soot
end side hydrant valve
blowing regularly
and quench fire
3500C suddenly from
of the corresponding
especially during oil
normal value
APH.
elevation was in
with air motor/electrical
service
Motor if possible.
3. APH fire sensing
4. Close PA &Secondary
thermocouple gives
air side outlet & inlet
alarm (presently not
dampers of that APH.
hooked up)
3. Continue running APH
Final corrective
action
Isolate APH and
release for
inspection.
Do APH soot
blowing every shift if
oil is in service
2. AIR-PREHEATER MOTOR TRIPS/ AIR MOTOR DOES NOT START
A. ONE APH MOTOR TRIPS/AIR MOTOR DOES NOT START.

Immediate Operator
effected
Action
1. APH Electrical motor 1. Reduce unit load to 65
trip alarm.
Subsequent operator
action
Motor tripped on 1. If the air motor has not
Likely cause
overload.
started because of air
Power supply to
solenoid problem open
the motor failed.
the bypass valve of the
Air motor failure
solenoid and air motor
temperature of tripped 3. Close PA &Secondary
or
will start, If it does not
APH outlet(>3000C)
air side outlet & inlet
failure
4. Rapid fall in secondary
dampers of that APH.
2. APH
rotor
MW
stopped 2. Close Flue gas inlet
alarm.
3. Rapid rise in flue gas
& primary air temp at

APH outlet.(<1000C)
damper of particular
APH.
No
solenoid
compressed
air available after

power failure.
start then
2. Attempt for starting the
electric
motor
if
the
power has resumed, or
foreign
after resetting the over
material fallen on
load. If neither air motor
the APH & got
nor
stuck.
came in to service then
Some
electrical
motor
try to rotate by putting

handle on motor shaft.
(Module to be switched
off before trying this)
B. WHEN BOTH APH MOTOR TRIP/AIR MOTORS DO NOT START

Immediate Operator
effected
Action
1. APH Electrical motor 1. Confirm from DCS
trip alarm.
2. APH
rotor
stopped
alarm.
Likely cause
alarm that both APHs
tripped
are tripped
overload.
solenoid problem open
Power supply to
the bypass valve of the
both
solenoid and air motor
2. Manually Trip the boiler
3. Rapid rise in flue gas

temperature of tripped
APH outlet(>3000C)
Both
Subsequent operator
action
Motor 1. If the air motor has not
on
motors
started because of air
failed.
will start, If it does not
Both air motor
start then
4. Rapid fall in secondary
failure
& primary air temp at
APH outlet.
or 2. Attempt for starting the
solenoid failure
electric
No
compressed
power has resumed, or
air available after
after resetting the over
power failure.
load. If neither air motor
Some
nor
foreign
motor
electrical
if
the
motor
material fallen on
came in to service then
the APH & got
try to rotate by putting
stuck.
handle on motor shaft.

(Module to be switched
off before trying this)
3. TG barring gear does not established after turbine trip

Immediate Operator
Subsequent operator
Likely cause
effected
Action
action
1. Turbine speed <10 rpm 1. Start manual hand Lift oil pressure not 1. Change over lift oil filter
alarm.
barring when TG shaft
sufficient/filter
becomes standstill.
choked
Stand by pump NRV
if it is choked
2. Close
standby
pump
discharge valve if NRV

is passing
passing
3. If
Turning
gear
solenoid
disconnect
is
solenoid
solenoid problem
connection near front
Lift oil line pressure
bearing pedestal
regulator problem or 4. Close regulator

valve if it is open
test valve open
oil
Lift oil pump relief

valve problem
Leakage in lift oil

line
Bearing lift improper
Turbine
internals
rubbing
test
pump 5. Open pump discharge

valve if it is close
discharge valves in
Lift
closed condition
faulty
Hydro motor
problem
4.Both JOPS fails during coasting down

Immediate Operator
effected
Action
1. Turbine speed <510 1. Start JOP manually
rpm and JOP not in

service alarm
2. Turbine speed <10 rpm
alarm.
Subsequent operator
action
JOPs not in AUTO 1. Check module fuse
Likely cause
and or SLC not on
2. Reset module
AC/DC power failure
3. Ensure Lub oil pump is
Fuses blown out
Pump
module
problem
Module tripping on
overload
Pump
damage
mechanical
in service.
5.Boiler flue gas temperature shoots up

Immediate Operator
effected
Action
1. Flue gas temp at APH 3. Reduce boiler load to
outlet >3000C
2. Secondary air temp at
APH outlet >3000C
Likely cause
APH Fire
bring down flue gas
More Air Flow
temp within limits
Loss of seal trough

water
Inadvertent closure
of any of the APH
inlet/outlet damper.
Improper
Subsequent operator
action
1. Refer
APH
fire
procedure
4. Reduce Air flow if it is
more
5. Make up seal trough
water if it is broken
6. Check all APH dampers
and open if any damper
is closed.
operation of
7. Set SADC correctly
SADC
8. Refer boiler tube leak
Boiler tube leakage
Heavy soot deposit in
procedure
9. Do soot blowing.
boiler
6. Condenser pressure raises on vacuum loss

Immediate Operator
Likely cause
effected
Action
1. Condenser vacuum low 1. Open vacuum breaker Vacuum breaker
alarm
valve manually if
valve close.
2. LP exhaust hood temp
vacuum is less than - Any Drains to
high alarm
0.2Ksc
condenser open.
3. Condenser
pressure 2. Open LP exhaust
CW pump not
Transmitter
showing
hood spray main/
running.
+ve value
bypass valve if
exhaust hot temp is
Seal steam supply

not cut off.
Subsequent operator
action
Close all drain MIV

connected to
condenser.
Close seal steam

supply valve from
PRDS
Depressurise
MS
&
HRH lines by opening
If LPT diaphragm is
ruptured replace it
>900C
LPBP valve drift
MS drain to atmosphere
open.
& HRH vent
7. Emergency DG not starting after Blackout

Immediate Operator
effected
Action
1. DG
trouble/tripped 1. Ensure DC EOP.JOP.
alarm
Seal oil pump.
2. KB bus under voltage
alarm
E-Stop pressed
Subsequent operator
action
1. Release E-stop
DG not in auto
2. Start DG manually
Scanner air fan are
Over crank shutdown
started
Over speed
2. Close DG switch gear

bus coupler if other
Likely cause
shutdown
3. Charge KB bus by
manually closing 415 V
breaker if it is not
closed on auto.
Find out cause for

DG trouble and
rectify it
DG is running
Started & tripped on
4. Start the AC motors
Low oil pressure
where DC motors are
running and stop DC
Low water tank level
motors
5. Close MS-1 & 2, AS-9,
High water
CRH-105 manually if
temperature
DG supply is not
available
6. All other activities of
black out to be
performed.
8. Boiler Tube leakage
Immediate Operator
effected
Action
1. Acoustic leak detector 1. Start reducing unit
alarm
load
2. Drum level fluctuation

3. Furnace
draft
Fluctuation
4. Sound
Likely cause
from
2. Confirm tube leakage

by observing sound &
boiler parameters.
5. Not able to maintain

hotwell level even with
makeup valve full open
stuck in advanced
normal & if required
condition for long
start Standby BFP
time.
inside
boiler
Wall blower / LRSB
Sustained high metal

Erosion of tubes due
4. Drain boiler after
Erosion on tube due

coal.
Blocked tubes
Scale
formation/corrosion
inside tubes
reducing load
3. Box up boiler
to high ash content in
2. Shut down the unit after
temperature.
to soot blowing
Subsequent operator
action
1. Maintain drum level
Operating boiler with

faulty drum level
transmitter.
depressurisation and
isolate it
Replace leaky tubes
Bursting of tube due

to pressure
fluctuation.
Improper setting of
safety valve.
9. Fire near MOT/Control oil system
Immediate Operator
effected
Action
1. Fire
noticed
by 1. If fire is isolated one
personnel.
2. Fire alarm. if actuated
in local by any persons
after observing fire
3. Burning smell
quench with
appropriate
extinguisher
Trip the unit.

4. Operate
corresponding deluge
valve.
5. Stop control oil
system
near MOT
of affected area if
Welding on oil lines
required.
with
2. Inform firemen.
3. If it is big in nature.
Subsequent operator
action
Electrical short circuit 1. Isolate electrical supply
Likely cause
out
precaution
safety 2. Isolate oil lines if

possible
Oil leakage Catching

fire oil spillage on
high temperature
steam line
3. Use hydrant system for

fire fighting.
Replace MOT/control
oil if contaminated
10. Fire in Coal mill

Immediate Operator
effected
Action
1. Mill outlet temp. high 1. Close hot air gate &
alarm
2. Mill outlet temp going
out of range.
continue to run mill

with more coal without
overloading.
3. Mill body & coal pipe 2. Open mill inheriting

paint peeling off
steam valve to cool
Likely cause
Excessive mill
temperature.
Excessive
Subsequent operator
action
1. Wait for mill outlet
temp to drop below
500C.
accumulation of pyrites
2. Stop feeder.
or coal in scrapper
3. Purge mill completely.
chamber
4. Stop mill for
Clear mill internals

Change gear box oil
if carbonising is
noticed
4. Mill outlet temp. not

coming
down
after 3. Mill rejects hopper to
closing hot air damper

5. Fire
coming
the mill
out
be cleared
in
rejects hopper*.
Foreign material such

as rags. Wood. Paper
*Note: Normally fire in
collecting in mill.
reject hopper will not
Running mill with less
contribute to above bowl
air flow for long time
fire. Clearing the hopper
can cause coal
will suffice in such cases.
accumulation in mill
discharge pipe &
cause fire
Coal accumulation in
hot air duct
Fire conveyed from
bunker coal
11. Fire in transformers
inspection.
effected
1. Fire alarm in fire
Immediate Operator
Action
1. If transformer has not
monitor system
tripped, trip it
console.
manually & isolate it.
2. Spray system deluge

valve operated alarm
3. Fire noticed from
personnel.
Likely cause
Transformer Internal
faults causing fire
Fire from external
source carried to
transformer
Subsequent operator
action
1. If Spray system not
operated Open by
pass valve of deluge
valve
2. Inform fireman.
3. Drain transformer oil
to burnt oil pit
4. Prevent fire from
spreading to other
equipment by fire
fighting measures
Release transformer
for inspection
12. Fire in cable gallery

effected
monitor system
console.
valve operated alarm.
personnel.
Immediate Operator
Action
1. Trip the unit.
Likely cause
Short circuit.
Cable insulation failure
due to over loading
Fire from external
source
Subsequent operator
action
1. Isolate AC supply as
per the condition and
if required trip the
station transformer.
2. If hydrant system not
operated Open deluge
valve bypass
3. Inform fireman
Isolate faulty cables

& recharge electrical
system.
13. Fire in coal conveyer

effected
monitor system
console.
valve operated alarm.
personnel
Immediate Operator
Likely cause
Action
1. Switches off Conveyer Burning coal loaded on
supply modules.
2. Inform fireman.
the conveyer.
Electrical short-circuits.
Fire in the spilled coal
around conveyer.
Subsequent operator
action
1. If hydrant deluge
valve not opened
open bypass valve
2. Use the nearest
hydrant point for
additional spray
Remove burnt coal

from conveyer.
Repair damaged
component
14. Fire in coal bunker

effected
1. Smoke coming out of
bunker opening.
2. Paint peeling off on
bunker surface.
Immediate Operator
Action
1. Stop feeding to that
bunker.
Likely cause
Spontaneous ignition
Subsequent operator
action
1. If possible run the mill
due stagnant coal in
& empty that bunker
bunker
at the earliest or
Coal coming from stock 2. Empty the bunker by

other means
itself having fire
3. Use minimum water
(only if flames are
Use nitrogen blanket

in bunker for storing
coal for longer
duration
visible)
15. Fire in ESP

effected
1. Flue gas temp at ESP
Immediate Operator
Action
1. Reduce unit load to
outlet is much higher
65MW if fire is inside
than ESP inlet temp.
ESP
Likely cause
Oil/soot deposit on
ESP fields
Very high unburnt in fly
Subsequent operator
action
1. If fire is outside ESP,
use extinguisher &
douse the fire.
2. Outside fire noticed by

personnel
3. ESP insulation showing
signs of internal fire
2. Trip ESP field
ash & hopper heating
2. Inform fire man
3. Isolate the power
element Not switching
3. Open ESP man holes
off
4. Open ESP ash
supply of particular
pass/field.
ESP transformer fire
hopper drain
4. Close particular ESP
plugs/man hole
inlet & outlet gate
5. Quench the fire with

fire hydrant water
16. Fire in fuel oil storage
Immediate Operator
effected
Action
1. Fire
noticed
by 1. Stop HFO /LFO
personnel.
pumps
2. Fire alarm. if actuated 2. Isolate electrical

in local by any persons
supply for all related
after observing fire
equipments.
Electrical short circuit
Subsequent operator
action
1. Inform fireman
Very high Oil
2. Put hydrant system
Likely cause
temperature.
External fire conveyed
to oil tank
3. Burning smell
Improper earthling
with foam into service

& quench fire
3. If it is local fire douse
with extinguisher.
causing spark due to

static current
Emergency Procedure
17. Fuel oil leakage
effected
1. Oil leak noticed by
personnel
2. Oil pressure low alarm
Immediate Operator Action

1. Stop
corresponding
Likely cause
oil Fuel oil pipe
Subsequent operator
Final corrective
action
1. Isolate leaking point
action
Attend leaking
pump. If leak is in pump
puncture by any
2. Inform fireman
discharge line.
means.
3. Arrange to clean
point
Any control valve,

isolation valve,
pump gland/flange
leak
Gun leak due to
washer damaged.
18. Generator winding temp raising fast
leaked oil
effected
1. Generator winding
temp. high alarm.
2. Generator hot gas
temp>600C.
Likely cause
1. Reduce generator MVAR

loading to zero.
2. Reduce
generator
load
gradually till winding temp.

Raising trend reverses.
High MVAR loading
Final corrective
action
1. Check ACW pressure
action
Overloading of
at Hydrogen cooler. If
generator
required start standby
ACW flow to
ACW pump.
hydrogen cooler
low
Subsequent operator
Hydrogen cooler air
2. Vent hydrogen cooler.

3. Fill hydrogen if
pressure is low.
locked
19. Flash over
effected
1. Observed by personnel
2. Fire alarm
1. Trip the switch gear in

which
flash
occurred
over
Subsequent operator
Final corrective
action
Loose contacts
action
If flashover is observed in
Short-circuits
an equipment, then isolate
Likely cause
has
Over load
Insulation failure
Switching/lightning
voltage surges
that equipment electrically
20. Heater level going high

effected
1. Heater level high alarm
Likely cause
1. If heater is not bypassed in
auto, bypass it on feed

water/condensate side.
2. Take heater level controls

in to manual and open it
fully
Drip control valve
Subsequent operator
Final corrective
action
1. Check level locally and
action
If tube leak is
failure.
confirm level
confirmed
Failure of drip auto
transmitter is reading
isolate heater
control due to
correct.
totally and
wrong level sensing 2. Open feed water side

IBV /condensate side
Heater Tube
leakage/failure
valve partially to
confirm whether
heater tube is leaking
release for
maintenance.
21. High axial shift

effected
1. Axial shift high alarm
2. Turbine will trip at axial

1. Reduce
load
to
reduce
axial shift
uniformly open
pads & thrust bearing

/return oil temp raise
action
Abrupt change in 1. Maintain
of 2. If turbine has tripped

check vacuum breaker
steam temperature
Sudden
drop
Sudden closure of
extraction valves
Too fast pick up of

load
Turbine overload
has opened
3. Check
vibrations
during coasting down

4. Note
Final corrective
action
steam
parameter steady
load
shift very high limit of 2. Check all stop valves /

0.5mm
governing
valves
are
3. Overloading of thrust
Subsequent operator
Likely cause
coasting
down
time
5. If salting is suspected
Silica deposits on
arrange for early steam
turbine blades
washing of turbine or
Turbine
other methods of
internal
damaged
cleaning
GSC fan not

functioning
22. Hydrogen leak from generator

effected
1. H2 pressure in
generator casing low

1.
If hydrogen pressure
reaches <1 ksc trip
Likely cause
Seal oil running

pump trips &
Subsequent operator
Final corrective
action
Try to establish seal oil
2.
action
pressure by starting
alarm
2. Seal oil system fault
generator & purge
standby AC & DC
stand by pump or by
generator with CO2
pump fails to start
closing DPRV inlet MIV
Seal oil pressure to
alarm
3. If seal oil pressure is
if seal oil pressure is

low.
seal is low
low standby oil pump
DPR malfunction
will start.
Hydrogen leakage
4. Winding temperature
developed in
may increase
3.
If leaking point is
identified, try to isolate
it. If not possible,
generator system
5. Hot Gas temperature
may increase
Seal oil leakage

from
piping/valve/flanges
23. LRSB not retracting

effected
Likely cause
Subsequent operator action
Final
corrective
action
1. LRSB not retracted
alarm
2. Observed from local
1. Reset the module & give
Forward motor trip
retract command from
after advancing
local push button. If it
Lance jammed after
fails to retract even after

module is reset, switchoff the module.
advancing
1. Reduce soot blower
If LRSB could
header pressure to 3-
not retracted,
4Ksc.
ask
2. Disengage the clutch and
maintenance to
LRSB clutch de
try to retract manually from
insert dummy
coupled after
handle. If it is retracting do
in steam supply
advancing
not release handle in the
line flange so
middle ( If handle is to be
that other
released in the middle, first
blower
engage the clutch & then
operation can
only release) .
be carried out.
Electrical supply
failure during
operation
Chain broken.
3. Inform maintenance if it is
not retracting manually
also.
4. Try retracting with
additional assistance for
max. one hour.
5. If it could not be retracted
within one hour, reduce
pressure to zero ksc & try

again.
24. Lube oil leak/MOT level going low

effected
1. MOT level low alarm
2. Oil pressure low alarm
if oil leak is from oil
supply line to bearing.
3. Oil leak observed from
local
4. Oil collected in drain oil
tank/CEP pit
Likely cause
1. If leak is more and could

not be isolated, reduce
load & trip the unit.
2. If
leak
is
less
and
MOT
drain
Subsequent operator
Final corrective
action
action
is 1. Check any drain in Stop turbine
opened
MOT area is open, if
lube oil pump
Lube oil cooler tube
open close it
after turbine
2. If leakage is before
leakage
comes to
confinable. Top up MOT

and inform firemen.
Lube oil line/ flange
lube oil pump NRV
barring gear
/filter leakage
change over the pump
and arrange
Leakage from TG
(change
for attending
Seal oil system oil

leakage/seal
will
happen in auto on lube
bearings
over
oil
oil pressure low)

3. Check centrifuge for
leak.
Clean oil
leaked out to
cooler tube leakage
seal
Charging
draining out
of
standby oil cooler
break
and
oil
avoid fire
hazard
4. Check oil channel
entering 5. Check lube oil cooler

water side drain/vent
generator
casing
for presence of oil
from seals
Oil
Oil draining out

through centrifuge.
6. Check seal oil cooler

water side drain/vent
for presence of oil
7. If any cooler leak is
noticed change over
that cooler.
25. Oil spill noticed in bottom ash hopper

effected
1. Oil traces noticed in
Likely cause
1. If any burner is in service
Burner in service
Subsequent operator
Final corrective
action
1. Check for the passing
action
bottom ash hopper from
without flame, trip that
local
corner immediately
without flame
2. Oil burner flame not

visible from peep hole
Oil nozzle valve
2. Check for atomising
passing
steam / air pressure
Atomising steam/air
and adjust it
pressure very low
oil gun & isolate it
Oil specification
different from
designed one.
26. One of the turbine control valve fail to close

effected
1. While reducing load, it
Likely cause
1. Reduce turbine load to
will not reduce below
100MW(if unit is in
certain MW even if load
service). If turbine has
set point is less
tripped. close MS1.2.3 &4
2. Stuck Valve position
& depressurise MS & RH
feed back will show

open position control
line
2. Open corresponding MAL
room whereas other
drain before & after control
valve will go for close.
valve(Partially)
3. High speed control will

act
Valve mechanically
Final corrective
action
1. If valve has stuck.
action
stuck
Reduce boiler pressure
Trip mechanism not
& shut down unit.
working
Subsequent operator
Oil not getting

drained from
actuator
27. One phase of the GT poles fail to open after unit trip
effected
1. Pole Discrepancy alarm
will come
2. LBB protection will trip
all the breaker
connected to that bus
3. TG speed does not
drop after trip
4. TG draws current from
grid (reverse power)
5. Negative sequence
current in Generator
6. LP exhaust temperature
going high
Likely cause
1. Trip all the 220 kV breaker
connected to the particular

bus including bus coupler.
(If LBB not acted)
2. Trip field breaker manually.
if it did not opened.
3. Open isolators of GT
breaker
Breaker contact
mechanically stuck
Subsequent operator
Final corrective
action
1. Normalise supply by
action
Attend GT
charging Line .ST and
breaker before
Bus coupler.
restarting
Turbine
28. scanner fan tripped & DC fan fail to start

effected
Scanner air to furnace
DP low alarm
Scanner air fans tripped
alarm
Likely cause
1. Trip the boiler
Dc fan fails to start

after AC fan trips
Both fan getting
over load/electrical
fault
Subsequent operator
Final corrective
action
action
1. Try to start fan by
Lightup boiler
resetting overload
only after
relay
2. Increase FD fan
starting
discharge pressure so
scanner air
that some air will
always available for
fam
scanner
3. If not happening
reduce load to
minimum & get the fan
started at the earliest.
4. If Scanner air fan could
not be restarted even
after reasonable time
delay trip the boiler
29. seal oil pressure going low

effected
Likely cause
Subsequent operator
Final corrective
action
action
1
a
c
d
Drum level dropping fast

Likely causes
One of the running BFP might have tripped
Sudden tripping of one or more Mills.
Feeder might have tripped.
FW control valve might have closed/stucked.
Malfunction of auto control/scoop regulation.
BFP recirculation might have opened of the running pump.
Sudden reduction of load because of malfunction of EHTC.
Sudden tube failure in water walls.
HPBP might have opened.
Inadvertent opening of EBD & low point drains.
Drum pressure may be high.
Plant response
Drum level LOW alarm appears.
BFP's scoop rises to meet the demand if it is in auto.
Boiler will trip on drum level very low.
In extreme case, if water level falls below visible range of gauge glass, may affect the
flow through downcomers & may lead to tube failure.
Main steam /reheater temperatures ,drum level,dearator level
See that standby BFP starts on tripping of running BFP or manually start when level
2
a
b
c
d
drops to -100 mmwc & load the pump to the running pumps scoop.
Check for any malfunction of auto control like scoop not raising or recirculation open
in auto, take control into manual & make up drum level.
Close CBD if it is open.
Close HPBP if it is open.
Remove corex burners (when level is above (-100 mmwc)).
Caution: Do not do any major removal of fuel at drum level (-100 mm & above., like
mill tripping, burner removal)
Check feedwater flows matches with steam flow for full load, if deviation is more then
check for any leak in boiler area.
Ensure for the availability of standby BFP as early as possible.
Check for local level gauge & transmitters.
Check boiler low point drains & EBD.
Check for scoop controls for any linkage failures.
Drum level shooting up fast
Likely causes
Malfunction of feed controls.
Sudden increase of load (due to malfunction of EHTC)
Sudden increase of firing rate.
Scoop /control valves might have stucked.
Sudden opening of HPBP.
Plant response
Drum level high alarm will appears.
On drum level high high, boiler will trip.
SH/RH temperatures drum level.
Check the hydrostep level, if it is high take drum level control to manual & match
3
a
c
d
feedwater flow with steam flow.

Open emergency drain/CBD drain.
Open MS strainer drains.
Try to reduce the load so as to control the water level (if water level is due to upward
load surge).
Check feedwater flow matches with steam flow.
Check for stuck of feed control valves & scoop.
Check the level at local, hydrostep and transmitters are matching.
Rapid Boiler steam pressure rise
Likely causes
Corex calorific value might have changed drastically.
Sudden loading of mill.
High firing rate.
Feeder hunting.
Malfunction of CMC.
Sudden dropping of generator load.
Plant response
HPBP will open if it is in auto.
Reheater safety valve will popup first & then on high steam pressure, reaching in
stages may blow EMRV & superheater SV & drum safety valves.
Throttle pressure high alarm will appears
APH FG I/L O2 low alarm will appears
Generator will get more loaded because of pressure correction of EHTC.
MS /RH temperature, Drum level, APH inlet O2, HP/LP bypass,
Take the unit into manual mode if it is in CMC & reduce the fuel firing.
For momentary action additional load can be taken
4
a
c
d
Trip the malbehaving feeder/mill & reduce PA airflow through that mill.
Check for pressure drop & if it is not holding remove the corex burners.
Caution:Donot reduce the fuel when the drum level is around -100mm
Start standby BFP when drum level reaches -100mm & rise the scoop to running BFP
scoop.
Check for reseating of safety valve
As soon as the pressure starts dropping, restore the correct fuel input.
Stop the third running BFP and keep it in standby.
Ensure drum level got stabilised.
Check for closure of HP bypass.
Ensure pressure is stable.
Bring back the unit load to normal.
EMRV floating and reseating in succession
Likely causes
Maloperation of valve.
High fuel firing rate.
MS pressure fluctuation.
Maloperation of turbine control valve.
Plant response
Generator load will vary.
Hp bypass will open if it is in auto & may hunt.
Ms temp and RH temp variation.
Drum level, Ms temp and RH temp, MS pressure.
Reduce the fuel firing if pressure is really high.
If MS pressure is less, still EMRV is operating, keep selection switch to "OFF" so that
the EMRV will not operate.
Even by putting "off ", valve is still in open condition, its manual isolation valve can
be closed.

Ensure for proper re-seating of the valve & put back in auto.
5
a
RH SV floating and reseating in succession

Likely causes
HP bypass might have opened in auto & LP bypass has not opened.
Maloperation of valve.
Opening /hunting of HP bypass.
Plant response
HRH steam pressure high alarm will appear.
MS and RH temp variation
Generator load will rise.
Drum level, MS and RH temperature
If LP bypass not opened, trip reset & open the valve by around 10% & put back in
auto.
Reduce the MS pressure, if it is actually high, so that HP bypass will close in auto.
Reduce the load until the valve re-seat
Check for proper seating of the valve.
Inform to maintenance isf & it is not re-seating at lower pressure also.
c
d
6
a
b
Corex CV decrease
Likely causes
Malfunction of COREX process.
Variation in corex constituents %.
Plant response
Ms pressure will drop fast
Generator Load will drop.
O2 at APH FG inlet will rise & high alarm may appears.
c
d
7
a
c
d
MS pressure, load, APH flue gas inlet oxygen.
Reduce load set point inorder to hold the boiler pressure
Enquire EMD Dept about CV variation & if corex is stable then raise the feeding on
running mills.
Ensure O2 at APH i/t is normal
Restore the fuel input to boiler once the CV of corex stabilises.
Rapid Boiler steam pressure decrease
Likely causes
Sudden drop in Calorific value or pressure of corex.
Tripping of mill or feeder.
Sudden rise in load.
Disturbed combustion conditions in furnace.
Mill might have got unloaded.
Plant response
MS pressure will drop.
Generator load will come down.
Drum level will drop.
O2 at APH FG inlet will rise.
Drum level, generator load, MS/RH temperatures, APH FG inlet O2.
Check for any mill unloading.
Reduce load set point to hold the MS pressure around 110 kg/cm2.
Check boiler flame, take oil elevation into service.(don't take oil when combustion
conditions are very poor)
Monitor drum levels during this disturbance, if it is dropping very fast, start standby
BFP & load the scoop equal to running pump scoops.
Ensure drum level is stable.

If mill is unloaded stop the mill & take other mill into service.
Increase load set point to full load based on the fuel.
Remove oil if it is introduced if furnace conditions are good or bright.
8
a
c
d
MS temperature rising fast

Likely causes
Inadequate spray due to malfunctions of spray control valves.
Excess airflow.
Instrument air pressure may not be adequate.
Burner tilt Maloperation.
Ms pressure may be high.
Plant response
MS/RH temperature high alarm will appear.
Spray control valves will go for further opening.
Load will rise for the same pressure.
If temperature is very high ,turbine will trip.
"Positive" turbine expansion
MS/RH temperatures, feedwater flow, drum level, HP exhaust temperature.
Tilt burner down.
Control the spray flow in manual so that stage -1 o/l temp will be around 450 deg.C &
stage -2 o/l temp around 505 deg.C, if temp control response is poor in auto
Reduce firing rate (preferably top elevation).
Introduce soot blowing if MS/RH temperatures are still maintaining high & spray
quantity is more..
Restore back the temp controls in auto if it has been taken in manual
Check for any malfunction of spray control valves & isolate such type of valve.
Burner tilt can be kept horizontal.
9
a
c
d
RH temperature rising fast

Likely causes
Inadequate spray due to malfunctions of spray control valves.
Cutting in of Top mill into service.
Cutting in corex in quick succession.
Excess airflow.
MS temperature may be high.
MS pressure may be high.
Heavy furnace slagging.
Burner tilt Maloperation.
Plant response
RH temperature high alarm will appear.
RH metal temperatures high alarm will appear.
Amount of spray will rise.
Load will rise for the same pressure.
"Positive" turbine expansion.
RH temp, drum level, feed water flow, feedwater differential pressure.
Control the spray flow manually at RH inlet around 250 deg.C, if temp control
response is poor in auto.
Tilt burner down.
Check for MIV's open before & after spray control valves
Reduce air flow if its more.
10
a
c
d
Reduce firing rate.

Introduce soot blowing if temperature is maintaining high & spray is high.
Keep the burner tilt in horizontal condition.
Restore back the control in auto if it has been taken in manual.
MS temperature falling fast
Likely causes
Tripping of top elevation mill
Less air flow
Low burner tilt
More spray
Plant response
MS temperature low alarm will appear.
Unit may trip on MS temp very low.
Turbine expansion may become Negative.
Ms temp, drum level, feed water flow.
Close the spray control valves by taking into manual.
Tilt burner upward.
Check airflow &Rise if necessary.
Top elevation mill can be taken into service /firing can be raised
Check for MIV open before & after control valves.
Initiate LRSB soot blowing if temperatures are maintaining still less.
11
a
c
d
12
a
RH temperature falling fast

Likely causes
Less air flow
Tripping of top elevation mill
Low burner tilt.
More spray.
Plant response
RH temperature low alarm will appear.
Negative expansion of turbine
Unit may trip on RH temp very low.
MS/RH temp, drum level, feed water flow.
Close the spray control valves by taking in manual.
Tilt burner upward.
Rise the Airflow.
Top elevation mill can be taken into service /firing can be raised.
Initiate LRSB soot blowing if temperatures are maintaining still less.
One of the Turbine control valve fails to close
Likely causes
Trip SOV may be problem.
Trip coil faulty
Choking in servo valve ports
Problem in control valve linkage.
c
d
e
13
a
b
c
d
e
14
Airlock in control oil system

Mechanical problem
Plant response
Load hunting
Load cannot be varied as per requirement
EHTC controller O/P will reduce very much to maintain same load .
Speed fluctuation will occur during synchronising time.
Speeds, Load, pressure, control oil pressure, and drum level, HP exhaust temperature.
Inform immediately to Maintenance dept.
Trip the unit ,if there is no any ready solution
Check control oil pressure.
Ensure proper functioning of control valves
Control oil circulation pump failed
Likely causes
Pump may be tripped on any electrical protections
Plant response
Control oil tank temperature will rise.
Control oil pressure may drop because of viscosity reduction.
HSU Tank temperature high alarm will appear.
Control oil temperature, HSU header pressure,
Check pump module along with electrical maintenance.
Try to restart the pump as early as possible.
Ensure continuous running of the pump.
Control oil leakage
c
d
Likely causes
Damage in pipe line/pin hole puncture.
N2 accumulator diaphragm might have punctured.
Control oil pressure may be very high.
Plant response
Standby pump will pick up on header pressure low
Because of low pressure ,control valves may go for close
MS pressure may rise.
LP bypass malfunction.
Unit may trip.
Unit load ,pressure, HSU pressure.
If leakage is heavy, turbine to be tripped on fire protection channel.
If leakage is heavy personal safety to be ensured and fire fighting dept to be informed.
15
a
Locate point of leakage.

Stop S/B pump
Ensure leakage has been arrested fully
Ensure all the parameters are restored back
Ensure control oil pressure is normal.
One of the Turbine control valve closes
Likely causes
Trip drain SOV may be problem.
Trip coil faulty
Problem in control valve linkage.
Mechanical problem.
Airlock in control oil system
Choking in servo valve ports.
Plant response
First stage pressure will rise than the normal value, if at all problem is there with IP
c
d
control valve.
HP exhaust temperature will rise.
RH pressure will rise than the normal.
RH Safety valves may pop.
Thrust loading/axial shift may vary
Load hunting
Load cannot be varied as per requirement
Speed fluctuation will occur during synchronising time
Load, pressure, control oil pressure, drum level, HP exhaust temperature, axial shift.
Maintenance dept., to be informed immediately
Check for control oil pressure
Keep standby pump running in manual mode.
If possible reduces load and pressure.
Control boiler firing.
Control SH & RH temperature.
Ensure proper functioning of control valves.
Restore back all the parameters.

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1.

Drum level dropping fast

One of the running BFP might have tripped

Drum level LOW alarm appears.

Parameters of concern / Adverse Effects

Immediate expected or desirable operator action.

See that standby BFP starts on tripping of running BFP or else

Final Corrective Activity.

Check drum level is getting stabilised.

Malfunction of feed control valve or BFP scoop.

Drum level high alarm will appear.

Parameters of concern / Adverse Effects

Check the level at local, hydrostep and transmitters are matching.

Rapid Boiler steam pressure rise

Corex calorific value increased drastically.

Throttle pressure high alarm will come

Parameters of concern/Adverse effects.

Immediate expected or desirable operator action

Rapid Boiler steam pressure decrease

Sudden drop in corex pressure or Calorific value

O2 at APH inlet high alarm

Parameters of concern/Adverse effects

Immediate expected or desirable operator action.

Check for any mill unloading/ tripping

Close HPBP if it is opened

Final correction activity.

Ensure drum level is stable.

EMRV floating and resetting in succession

Improper blow down setting for EMRV/ pressure switch malfunction

Drum level will vary.

Parameters of concern/Adverse effects

RH SV floating and resetting in succession

HP bypass opened & valve hunting

HRH steam pressure high alarm will appear.

Parameters of concern/Adverse effects

Immediate expected or desirable operator action

MS temperature rising fast

Inadequate spray due to malfunctioning of spray control valves.

MS temperature high alarm will appear.

Parameters of concern/Adverse effects

Immediate expected or desirable operator action

Make burner tilt fully down

Final correction activity

Start soot blowing, if slagging is more

RH temperature rising fast

Inadequate spray due to malfunctioning of spray control valves.

Leakage in the spray line.

RH temperature high alarm will appear.

Parameters of concern/Adverse effects

Immediate expected or desirable operator action

Make burner tilt fully down

Final correction activity

Start soot blowing if furnace slagging is there.

MS temperature falling fast

MS temperature low alarm will appear.

Parameters of concern/Adverse effects

Immediate expected or desirable operator action

Close the spray control valves by taking it into manual.

Final correction activity

Start LRSB operation

RH temperature falling fast

RH temperature low alarm will appear.

Parameters of concern/Adverse effects

Immediate expected or desirable operator action