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KORBA SIMULATOR 2
FOREWORD
Power is the most vital necessity for industrial and economical growth of any nation.
Electricity can bring sea changes in quality of life of its society members. NTPC in its
endeavour for becoming most significant entity once again after 30 years of untiring and
relentless efforts, reaffirm its commitment towards making India a self-reliant nation in
the field of power generation. Having proven excellence in Operation & Maintenance of
200 and 500MW units; for the first time we are going ahead with the commissioning of
660MW units at our Sipat Project. This is a major step towards technological
advancement in power generation.
In the present time, efficient and economical power generation is the only answer to
realise our ambitious plan. It is the need of the hour that available human resources who
are the at the whelm of the affairs managing the large thermal power plants having
sophisticated technology and complex controls, is to be properly channelised and trained.
NTPC management firmly believes that skill and expertise up-gradation is a continuous
process. Therefore, training gets utmost priority in our company.
Power Plant Simulators are the most effective tools ever created. This has computer based
response, creation incorporating mathematical models to provide real time environment,
improves retentivity and confidence level to an optimum level in a risk-free, cost and time
effective way.To supplement the hands-on training on panel and make the training more
effective an operation manual in two volumes has been brought out.
The operation manual on 500MW plant provide the information comprehensively covering
all the aspects of Power Plant Operation which can be useful for fresh as well as
experienced engineers. It provides a direct appreciation of basics of thermal power plant
operation and enables them to take on such responsibility far more sincerely and
effectively.
I am pleased to dedicate these manuals (volume- I & II), prepared by CSTI members which
is a pioneer institute covering more than 7000 participants till date, to the fraternity of
engineers engaged in their services to power plant. The volume-I deals with the Plant &
system description and II covers the operating instruction in a lucid way. I sincerely hope
that readers will find these manuals very useful and the best learning aid to them.
I believe that in spite of all sincere efforts and care of faculty members & staff, some
area of improvement might have remained unnoticed. Hence, your valuable
suggestions and comments will always be well received and acted upon.
( A. CHAUDHURI )
GENERAL MANAGER
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CONTENTS
CHAPTER
TOPIC PAGE NO
NO.
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COLD START-UP PROCEDURE
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CHARGING OF ELECTRICAL SYSTEM
1. Ensure electrical supply to C.W. Pumps and other associated auxiliaries are
available.
2. Charge Station Transformer TOC or TOD and respective station buses SE/SF.
3. Ensure that all the electrical breakers are racked IN and OFF Service mode.
6. Charge Unit Service Switch Gear, Emergency Bus through normal Breaker.
7. Ensure that supply is available to various MCCs, (Turbine MCC, Boiler MCC,
TVDC, BVDC, Lub oil MCC).
8. Charge ESP and Ash Handling Transformers.
10. Check Unit Bus Voltage, Voltage can be adjusted by changing the tap position
of Station Transformer.
11. Normalise MDBFP Breaker through Station Bus SF.
1. Check the D.G.Set physically for fuel level, oil, cooling water.
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CHARGING OF AUXILIARY STEAM HEADER
OBJECTIVE
1. Work permit on 16 ata header, auxiliary PRDS and associated system such as
SCAPH, atomising steam, HFO heater, etc., cancelled and men, material
removed from these areas.
2. All drains and manholes are closed and the equipment and system are in
service worthy condition.
3. All level gauges, indicating instruments, pressure and flow switches and other
Protective devices are lined up for services.
4. 415 V supply available to valve actuators.
5. 220 V DC supply available.
6. Control panel supply available
10. Ensure the output of primary and secondary RAPH A/B cold end temperature
control valves are closed.
11. Ensure the Dearator pressure control by auxiliary steam control valve is closed.
12. Auxiliary steam header pressure and temperature controller are closed.
13. Open the auxiliary steam header drain valve from local.
14. Ensure all the manual isolating valves to fuel oil tank heating, burner
atomising, SCAPHs, etc. are close.
15. Ensure the motorised steam isolation valves to BFP and deaerator (ASL-004
and ASL-006) are closed.
16. Ensure the gland sealing steam valve ASH-006 is in closed condition.
17. Ensure the existing 200 MW unit auxiliary steam is available and inform UCB
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personnel.
18. Ensure the cold reheat to auxiliary steam block valve ASH - 001 is closed if not
OPERATIONAL STEPS
1. Open the auxiliary steam interconnection form existing 200 MW unit 16 ata
2. Check the pressure and temperature of the 16 ata header comes to normal.
3. Open the primary and secondary SCAPH A or B inlet and outlet isolating
valves.
4. Open the deaerator pegging motorised valve ASL - 006.
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AUXILIARY STEAM SYSTEM
12
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CHARGING OF RAW COOLING WATER (ARCW) SYSTEM.
OBJECTIVE
1. Work permit on circulating water duct, auxiliary cooling water pump, plate
type heat exchanger and associated system cancelled.
2. All level gauges, indicating instruments, pressure and flow switches and other
3. All filters and coolers are cleaned and necessary lubrication of equipment’s are
done.
6. 6.6KV switch gear charged and breakers are kept in service mode.
1. Ensure that suction valve for all three pumps are open from local.
2. Check that the gland sealing is in service (i.e.sealing water valves are open),
3. Close the pump drain and open the vent to ensure no air is coming.
5. Ensure that isolating valves for the plate type heat (PHE) exchangers are open
to CW discharge seal pit.
7. Ensure the motorised discharge valves for all three pumps are closed from
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CSSAEP.
8. Ensure that the EPB (Emergency push button) is released from local.
OPERATIONAL STEPS
2. Start ARCW pump Amotor by turning the hand switch position to on and
release it.
3. Check the starting current and discharge pressure.
4. The pump discharge valve will start opening and red light will come indicating
5. Close the recirculation valve from local once the discharge valve is fully
opened.
6. Check the return flow of the raw cooling water in the CW discharge seal pit.
8. Ask local operator to check for any abnormal sound from the motor or pump
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KORBA SIMULATOR
AUXILIARY RAW COOLING WATER SYSTEM
16
CHARGING OF EQUIPMENT COOLING WATER (ECW) SYSTEM
OBJECTIVE
7. Ensure that 6.6 KV switch gear is charged and the breakers are kept in service
mode.
1. Ensure that suction valve for all three pump is open from local.
4. Open the inlet valve to the suction header from the over head DM water
cooling tank.
5. Close the pump drain and open vent to ensure no air is coming.
6. Ensure that isolating valves are open for the plate type heat exchanger which
is already charged from the auxiliary raw cooling water side.
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7. Ensure the motorised discharge valves for all the three pumps are closed from
CSSAEP.
OPERATIONAL STEPS
2. Start ECW pump A motor by turning the hand switch position to on.
4. The pump discharge valve to be opened and red light will come indicating
5. Maintain the level in the DM water cooling tank by taking additional make up
6. Charge the ECW to various auxiliary coolers and check the differential
pressure is maintained by the control valve, PCV-1145 for Boiler. package,
PCV 1146 for BFP coolers ,PCV - 1144 for CEP, etc.
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19
EQUIPMENT COOLING WATER SYSTEM
START UP OF CONDENSATE SYSTEM
OBJECTIVE
deaerator.
2. Work permit on various LP heaters, drip system, drain cooler, etc., cancelled
and men, material removed from these areas.
7. Ensure that 6.6 KV switch gear is charged and breakers are kept in the service
mode.
8. Ensure that EPB is released from LOCAL.
2. Open ECW inlet and outlet valves to CEP bearing oil cooler.
6. Ensure that condensate spill valve bypass and condensate fill valves are closed.
7. Open the suction valve for all three CEPS from LOCAL
9. Rack in the CEP breakers from Switch gear in service remote position.
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10. Open the sealing line valve from common discharge from local .
11. Ensure the common isolation valve for exhaust hood spray and drain manifold
is closed from local .
12. Open the manual isolating valves for Deaerator level controller (CO16, CO17)
from local .
13. Line up the hot well high level controller from local .
14. Ensure the line up of the LP heaters from water side is through upto the
16. Ensure that all the recirculation valves are full open and are in manual mode.
OPERATION STEPS
1. Change the emergency make - up pump A status from manual to auto mode
from UCB.
4. Open the hot well make up emergency control valves to fill the hot well.
5. Observe the steady rise in the condensate make - up flow and hot well level.
7. Close both the controllers when hot well level comes to about +50 mm.
8. Check the hot well level adequate permissive appears on all the three CEP start
permissive indication.
9. Check that all permissive lamps are on to start CEP.
10. Start the CEP-A by turning the hand switch to close position and release it.
11. Check that discharge valve opens and discharge pressure gradually builds up.
12. Check that the pump is running OK and no abnormal noise at local.
13. Keep the lead / lag switch of pump B and C to lead and lag mode respectively.
14. Open the block valve of the Deaerator level control valve CO-014 .
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15. Open the deaerator level control valve to about 20%.
18. Open the emergency make- up control valve to make - up hot well level to
normal value.
19. Close the Deaerator level controller once the Deaerator level has come above
normal level.
20. Close the emergency make-up controller as the condensate pump is running on
recirculation only.
22. Keep the block valve of Deaerator level controller B station (CO -17) also in open
state.
*CEP in service *
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CONDENSATE SYSTEM
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MOTOR DRIVEN BOILER FEED PUMP ( BFP - C )
OBJECTIVE
2. Work permit on various HP heaters, drip system, deaerator, etc. cancelled and
men, material removed from these areas.
5. Check that deaerator over flow valve and drain valves are closed.
1. Establish the ECW flow to the working oil and lub oil coolers.
3. Ensure that seal quench valve is open and seal quench pressure is more than
15 Kg/cm2.
4. Line up the BFP system from local (Lub oil coolers,working oil coolers etc).
5. Open the recirculation valve isolating valve for all the three pumps from local
6. Check that AOP of BFP is taking start from UCB and recirculation valve
controller,scoop controller is operative from UCB
10. Line up the emergency seal quench water pump from local .
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11. Line up the LP dosing and HP dosing system from local .
12. Ensure that HP heaters are bypassed (valve FW-14 should be opened). Check
the analog indication in UCB.
13. Start the auxiliary oil pump of BFP-C
14. Ensure that all the permissive lamps are ON in the UCB for boiler feed pump
C.
OPERATIONAL STEPS
1. Check once more the scoop tube controller is minimum and recirculation valve is
full open.
2. Start BFP by turning the hand switch to breaker close position and release it.
4. Check the BFP discharge pressure and motor current from UCB
5. Ensure that motor cooling water valve has opened on interlock and red lamp is on.
6. Raise the scoop tube position by about 10% to raise the discharge pressure
7. Check the bearing temperature and vibrations from the UCB indicators.
* MD BFP-C is in service. *
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FEED WATER SYSTEM
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BOILER FILLING
OBJECTIVE
• To line up to fill the water wall, down comers, drum & economiser by
boiler feed pump.
PRE - REQUISITES & STATE OF PLANT
1. Boiler water circulating pumps motor cavity is properly filled and vented.
3. Hot well make-up pump available for chemical mixing and diluting.
4. Local drum gauge glass charged. Hydrastep and drum level recorder available
in UCB.
5. Unit ECW system in service.
7. Hot well make-up system lined up from hot well make-up pump.
11. Sufficient quantity of Ammonia and Hydrazine put in mixing tank and diluted
with DM water.
PRE - START CHECKS AND LINE UP
1. Close boiler low point drain valve to IBD tank. Close economiser inlet
2. Header drain and inlet lead drain valves at low point drain station.
3. Ensure that emergency blow down regulating valves is closed from UCB.
4. Ensure that all the three SGCW pump casing drains are closed.
5. Check SH and RH fill valve at low point drain station are closed.
6. Open all three SGCW pump suction spool vent valves from local.
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DRUM FILLING
SGCW PUMPS
OBJECTIVE
• To fill the boiler water wall, downcomers, drum and economiser by boiler
feed pump.
1. Open the economiser inlet valve E-2 and Economiser recirculation valves from
the UCB.
2. Open the low range feed control station isolating valves, close high range
isolating and control valves. Check low range control valve operation.
3. Check HP heaters feed water bypass valve full open (FW - 14).
1. Gradually open the low range feed control valve and control the flow to boiler as
per rate of make up to deaerator.
2. Close the recirculation valve of the BFP if sufficient feed flow is established.
3. Close the SGCW pump suction spool vents once air free water comes out of
them.
4. Check for level rise in local gauge glass, hydrastep and recorders.
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5. Close the low range feed control valve and open the recirculation valve once the
level comes to about 300 mm.
6. Stop chemical dosing pump and isolate the dosing line.
7. Ensure the pump discharge valve are fully open, permissive lamp 1 and 2 are
ON.
11. Start the SGCW pump -A by turning the hand switch to close position.
12. Ensure the pump draws about 60 amps if current drawn is less stop the pump
13. Check that drum level is adequate, if not open the low range feed control valve
to make it up.
14. Repeat the procedure for SGCW pump B also.
a) Motor current
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START UP AND WARM UP OF THE FUEL OIL SYSTEM.
OBJECTIVE
• To warm up the fuel oil to required temperature for boiler light up.
1. Adequate oil level in the HFO storage tank for pump operation.
1. Open the suction valve and discharge valve of any one pump.
2. Charge the steam tracing system and heat sufficiently before the pump is taken
in service.
5. Since the discharge line is empty crack open the oil valve inlet to the heater,
6. Ensure that H.O. short recirculation valve HO27is closed and operative from
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UCB
7. Ensure that H.O. delivery valve (HO18) and inlet to the firing floor (HO25)
valves
are fully open.
8. Open the riser vent at GH elevation (HO44) initially.
OPERATIONAL STEPS
2. Check the pressure of fuel oil at the boiler front starts increasing gradually as
indicated.
3. Once the header is pressurised open the inlet valve to the heater fully.
4. Open the vent of the HFO heater before charging the steam.
6. Close the drain and vent once the heater is thoroughly vented.
8. Take the temperature controller of the HFO heater in service to maintain the fuel
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LINE UP OF FLUE GAS PATH & APHs
OBJECTIVE
1. Work permit on various boiler areas such as furnace, APH, ID, fans, ESP, ducts,
dampers, etc., cancelled and men, material removed from these areas.
2. Instrument air charged in boiler side pneumatic valves & dampers.
9. Boiler slag bath, trough seal, economiser hopper, APH hoppers & ESP flushing
Apparatus are filled with water and over flowing. HP-LP & service water pump
in Service (ASH).
10. Local pressure, temperature, flow, level gauges and transmitters charged.
1. Check oil level in guide bearing and support bearing by dip stick and if
necessary top up with the correct oil to bring the level normal.
2. Establish ECW supply through guide bearing oil coolers.
3. Open the suction valve of the lub oil pump for APHs.
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4. Open the inlet/outlet dampers for all the four ESP pass from GD11 to GD 18.
5. Open the equaliser dampers GD9 and GD10 before ESP from local .
6. Ensure that flue gas inlet damper and outlet damper to secondary RAPH A,
GD 3 and GD 7 are closed.
7. Ensure that secondary air inlet and out let dampers SAD3 & SAD5 for
secondary RAPH A are closed.
8. Ensure that primary RAPH A gas inlet/outlet dampers GD1 & GD 2 and GD5,
9. Ensure that all the dampers for secondary RAPH B are closed.
10. Line up the boiler bottom ash hopper system from local .
11. Switch on any of the three ash slurry pump from local .
OPERATIONAL STEPS
1. Turn the secondary RAPH - A LOP A for guide bearing to lead mode.
2. Turn the secondary RAPH -A LOP B for guide bearing to lag mode.
3. Repeat the above two steps for the support bearing LOPs also
4. Repeat the above three steps for the secondary RAPH-B also
6. Line up air motor and start RAPH-A on air motor and ensure smooth running
of RAPH from local .
7. With the same sequence take secondary RAPH -B also in service on air motor.
8. Establish 415V supply and start RAPH electric motor by turning the hand
switch to close position.
9. Ensure that air motor cuts out on interlock.
10. Open the secondary air out let damper SAD5 followed by the inlet damper SAD
11. Open the flue gas out let damper GD7 followed by the inlet damper GD3.
* RAPH in service *
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START UP AND LINE UP OF ONE ID FAN
OBJECTIVE
1. Work permit on various boiler areas such as furnace, APH, ID, FD fans, ESP,
ducts, damper, etc., cancelled and men material removed from these areas.
5. Boiler slag bath trough seal, economiser hopper, air preheater hoppers and
ESP flushing apparatus are filled with water and over flowing .
6. Instrument air is charged to various actuators and dampers, etc.
7. Boiler man holes, peep holes are in closed condition cooling water charged in
1. Check that adequate oil level is in the tank, if necessary top up with the correct
2. Charge the hydraulic coupling cooler and one lub oil cooler with Equipment
Cooling Water.
3. Open the suction and discharge valve for the lub oil pump.
4. Ensure the line up of lub oil through cooler and filter upto the bearing from
local.
5. Ensure that inlet vane position controller is minimum and operative.
6. Rack in the 6.6 KV motor breaker for ID fan A from switch gear.
8. Ensure that hydraulic scoop position is minimum and permissive lamp is on.
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OPERATIONAL STEPS
1. Give ID fan A breaker a start command and check the hydraulic oil pump A
takes start, red lamp comes on.
2. Ensure that inlet/Outlet dampers starts closing on interlock green lamp comes
on.
3. Hydraulic coupling oil pressure adequate permissive lamp comes on.
4. The moment inlet/outlet dampers get fully closed the fan will take start. Check
the starting and no load current.
5. Check that inlet/outlet dampers for the ID fan A opens after a time delay and
inlet/outlet dampers for the other fans close on interlock GD 20,21 and GD23
to GD 25
6. Check the bearing temperature and vibration from the UCB and are normal.
Also motor winding temperature is normal.
7. The hydraulic oil pump for the non running fans may be put in service after
line up.
8. Increase the inlet vane position to load the fan by raising the controller.
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FLUE GAS SYSTEM
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START UP AND LINE UP OF ONE FD FAN
OBJECTIVE
1. Work permit on various boiler areas such as furnace, APH, ID, FD fans,
SCAPHS, wind box, burner tilts, etc., cancelled and men, material removed
from these areas.
2. Atleast one secondary air preheater is running.
1. Check that adequate oil level is in the tank, if necessary top up with correct oil
to bring the level to normal.
2. Establish the ECW supply through fan lub oil coolers from local.
3. Ensure the line up of the lub oil through cooler and filter upto the bearing.
6. Start the lub oil pump B in auto mode once lub oil pressure is adequate.
7. Keep the lub oil pump B in auto mode once lub oil pressure is adequate.
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OPERATIONAL STEPS
1. Give FD fan a start command
2. Ensure that outlet damper SAD - 1 starts closing and permissive lamp comes
on.
3. All the permissive will be available the moment discharge damper is closed the
fan will take start. Check its starting and no load current and also the motor
winding temperature.
4. Check that outlet damper for FD fan A reopens after a time delay and discharge
5. Check the bearing temperatures and vibrations from the UCB are normal.
7. Check the FD fan discharge pressure and wind box pressure should show
same value.
8. Increase the blade pitch of FD fan A to load the fan and observe that air flow
should increase.
9. Open the scanner air fan inlet dampers SID - 1/2 from local.
* FD fan in service *
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LINE UP, CHARGING AND TAKING SCAPHS INTO SERVICE
OBJECTIVE
3. Ensure that drain valve down stream of SCAPH line supply header is open.
1. Open all the four inlet and outlet valves for Secondary air SCAPHs.
2. Ensure that secondary RAPH - A/B cold end temperature controllers are in
closed condition in UCB
3. Ensure the power supply is available to the motorised SCAPH valves.
OPERATIONAL STEPS
1. Open the Secondary SCAPH A/B steam inlet valve from local.
2. Open the motorised valves upstream and downstream of SCAPH control valve
3. Crack open the Secondary air cold end temperature controller to warm up all
the lines.
4. Throttle drain valves when steam comes out of them.
5. After sufficient warm up, control valve can be opened more to achieve the
required cold end temperature.
6. Close all the drain valves downstream of the SCAPH
7. If required, adjust the temperature setter of the cold end temperature controller
and transfer the controller in auto mode.
* SCAPHS ARE CHARGED *
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LINE UP FOR BOILER LIGHT UP
OBJECTIVE
1. Work permit on various boiler areas such as furnace, APH, ID, FD fans, ESP,
ducts, damper, etc., cancelled and men, material removed from these areas.
2. Instrument air charged in boiler side for pneumatic valves and damper
operation, oil guns, etc.
3. Service air charged in boiler side for air heater, air motor ignitor cooling air,
etc.
4. Ensure 16 ata steam header is charged
10. Secondary air damper control system (SADC) checked for remote operation.
11. Boiler manholes, peep holes are in closed condition. cooling water charged in
access doors.
12. DC/AC scanner air fan should be in service and interlocks should be checked.
13. All the wall blowers and LRSB are in retracted condition.
14. Boiler spring loaded safety valve gags are in removed condition (if light up is
being done after safety valve floating activity).
15. Bottom ash equipment such as scrapper conveyer, clinker grinder, hydraulic
oil pump, blowers, etc. available for taking into service.
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16. Boiler slag bath, trough seal, economiser hopper, APH hoppers and ESP
hoppers, flushing apparatus are filled with water and overflowing.
17. Following boiler side equipment’s are available for taking in service with their
interlocks and protections checked.
• At least two numbers of CC pumps.
18. Following equipment should also be made ready for requirements at later stage.
20. Ensure S/H spray and R/H spray station block valves and control valves are
closed.
21. Open the S/H drain header drain valve to IBD full.
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4. Open S-H steam, saturated steam, CBD water and feed water sampling
isolating valves.
5. Open all S/H header drains full for draining any where in S/H and leave them
crack open.
9. Ensure that main steam stop valve (boiler side)is closed along with bypass
valves.
10. Open the motorised RH outlet header vent
11. Ensure sufficient cold end temperature of the Sec. RAPHs before light up.
12. Change the status of local oil gun station from local to remote for all four
corners and all four elevations.
14. Ensure that heavy oil pumps are running and warmed up.
15. Check that atomising steam is charged upto the firing floor. Also all the steam
tracing lines should be charged.
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BOILER LIGHT UP
OIL FIRING SYSTEM
OBJECTIVE
2. Ensure that all the operational steps mentioned before are carried out before
the boiler is ready for a purge cycle.
OPERATIONAL STEPS
1. Adjust the ID fan and FD fan blade pitch to maintain air flow above 30 % but
below 40 %.
2. Adjust the burner tilt position to horizontal with burner tilt controller
3. Keep the furnace pressure to about -10 mmwcl with ID inlet valve control.
• Mode permit (Nozzle tilt horizontal and air flow less than 40 %).
• PA fans off.
• Drum level satisfactory.
• Air flow > 30%
• All feeders off.
• All nozzle valves closed
• Wind box/furnace DP satisfactory.
• No boiler trip command.
• Aux. air dampers modulating.
• All hot air gates closed.
• All scanners sensing no flame.
• All pulverisers off.
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• H.O. Trip valve closed.
5. If wind box/furnace DP permissive is not available wait for all the fuel air
dampers to close from top, once air flow is between 30 to 40 % pre-purge
damper reset timer will take 5 min.
6. Ensure that ‘PURGE READY’ & ‘PURGE START’ lamps are glowing at FSSS
panel.
7. Push “Purge start” push button and see ‘purging ‘ lamp comes on the panel.
After purging time of 5 min. is over see purge complete lamp glows.
8. Ensure that master fuel trip relays MFR A and MFR B relay reset and green
lamp comes on.
9. Open H.O. trip valve. Valve opens, if not, open the long recirculation valve and
then open the H.O. trip valve.
10. Increase the H.F.O. pressure controller output.
11. Adjust the set point of the controller to about 10 - 12 Kg/cm2 and transfer the
controller to auto mode.
12. Wait till HFO temperature at boiler front comes to about 110 o C.
13. In between once again ensure that superheater vents etc. are fully open and
also drains are opened.
14. Close on oil recirculation valve, green lamp comes on and HFO supply pressure
momentarily increases
15. Insert the furnace probe LHS/RHS till it advances to about 80 to 100 %. Push
park button
16. Depress the ‘Pair 1-3 START’ push button on AB elevation. corner No. 1 is
placed in service initially and following occures.
• AB-1 oil gun advances.
• The spark rod advance yellow lamp comes on.
• The spark rod lamp comes for 15 sec.
• Heavy fuel oil nozzle valve start opening.
• Discriminating scanners starts sensing the flame.
• HEA ignitor spark signal is removed HEA ignitor is retracted
• Heavy oil nozzle valve open fully red open lamp comes on
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• AB-3 gun will advance after 30 sec delay and same seq. as above will follow
17. Depress the pair 2-4 START push button on AB elevation. AB-2 is placed in
service similarly to AB-3 mentioned above.
18. The furnace pressure goes up slightly, increase the ID fan loading to maintain
the value to about -10 mmwc.
19. Increase the heavy oil controller output to maintain the H.O. supply pressure
23. Maintain the drum level with low range feed control valve.
24. Maintain rate of rise of drum metal temp. less than 2 degree per minute and
that of main steam temp. less than 50C by controlling oil firing.
25. At drum pressure of 2 Kg/ cm2 close the boiler drum vents
26. Close all the superheater header manual vents and drains once pressure
28. Check the furnace temperature by the furnace probes should not exceed
5400C.
29. Open emergency blow down valves if drum level is swelling to higher level.
30. Check the drum top bottom metal temperatures should not exceed 50oC.
** Boiler lighted up **
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CONDENSER CHARGING
OBJECTIVE
6. Check that travelling water screen is clear and cleaning system is available for
operation.
PRE - START CHECKS AND LINE UP
4. Ensure that discharge valves for all the three pumps are in closed position.
OPERATIONAL STEPS
4. After the system is filled up gradually open the condenser inlet valve to ensure
complete priming of the condenser water box.
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5. Close duct outlet vents when water flows continuously from the vents.
7. Line up and start the second CW pump and open the condenser inlet valve to
maintain the condenser water box pressure within limits .
8. After sometime switch off the condenser water box priming pump.
* Condenser charged *
KORBA SIMULATOR 53
KORBA SIMULATOR
CONDENSER COOLING WATER SYSTEM
54
LINE UP AND CHARGING OF TURBINE LUB OIL/SEAL OIL
SYSTEM
LUB OIL / SEAL OIL SYSTEM
OBJECTIVE
system, main oil tank, turbine lub oil coolers, vapour extractors, injectors,
main oil pump and associated pipe line thrust bearing filter etc., cancelled
1. Check that gate valve gearing closed with its SLC off.
2. Line up the lub oil cooler as per the standard practice (thorough venting of
3. Line up the thrust bearing lub oil filter and that ensure standby filter is
available.
KORBA SIMULATOR 55
5. Check the lub oil supply valves to turbine and generator bearings are open.
OPERATIONAL STEPS
4. Check the lub oil pressure and AOP current are normal.
5. Switch on the SLC for the AOP2 and EOP from the control insert
9. Line up and take in service seal oil coolers and oil filters .
11. Ensure that air is purged out & generator is filled with CO2
13. Check the hydrogen pressure once the pressure reaches 4 Kg/cm2 then close
the valve.
14. Check the hydrogen purity from indicator in UCB and, get the measurement of
moisture in H2 is done
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KORBA SIMULATOR 57
KORBA SIMULATOR 58
TO TAKE HYDRAULIC BARRING GEAR IN SERVICE
OBJECTIVE
1. Work permit on various turbine oil system as main oil tank turbine lub oil
1. Check the fine control valve supplying high pressure jacking oil for open.
2. Check that pressure relief valve is properly set and the bypass valve is closed.
OPERATIONAL STEPS
1. Start jacking oil pump. Check that jacking oil press. is normal.
2. Standby and DC jacking oil pumps available for service. Check winding
temperature locally.
3. Transfer the SLC mode of all the jacking oil pumps to auto.
5. Turn on the SLC turning gear. The gate valve gearing starts opening and
KORBA SIMULATOR 59
6. The speed should come up to approximately 80 RPM without vacuum, check
the lub oil temperature controller maintains the set lub oil temperature.
7. Check that bearing vibrations and bearing temperature are normal and lub oil
KORBA SIMULATOR 60
KORBA SIMULATOR 61
LINE UP AND START UP OF CONTROL FLUID PUMPS
OBJECTIVE
1. Work permit on various turbine control oil system such as control fluid tank,
governing rack, coolers, accumulator, LP bypass valve’s actuators, pumps and
various interconnecting pipe - lines.
1. Check the line up of the duplex filters provided in the high pressure and low
pressure control system.
OPERATIONAL STEPS
2. Start control fluid pump, and check the discharge pressure and motor amps.
3. Keep the SLC of both the pumps to auto mode from console.
KORBA SIMULATOR 62
CONTROL FLUID SYSTEM WITH REGENERATION PLANT
KORBA SIMULATOR 63
VACUUM PULLING
OBJECTIVE
• To line up and start the vacuum pump for establishing the vacuum.
7. All the possible air paths are blocked, i.e., turbine glands, hot reheat vents and
drains vacuum breaker valve, atmospheric lines coming to auxiliary flash box.
1. Close drains and fill the air/water separator tank of ELMO vacuum pump.
OPERATIONAL STEPS
1. Open air isolating valve, bypass valve and close the air ejector valve to put the
pump in hogging mode.
2. Open the drain valve of the gland steam supply from console
3. Open the aux steam block valve ASH-006 to to gland seal system.
4. Increase the opening of the steam seal supply valve to warm-up the header and
watch the gland steam temp.
KORBA SIMULATOR 64
5. Switch on the seal steam condenser exhauster from insert
6. Slowly increase the output of the seal steam pressure controller to maintain
12. Close the air ejector 1 bypass valve and open the air ejector valve 1 to keep the
vacuum pump in hold mode.
13. Close the gland seal steam drain valve after gland steam temperature reaches
140 to 150 0 C
KORBA SIMULATOR 65
KORBA SIMULATOR
66
VACUUM PUMP FLOW DIAGRAM
MAIN STEAM LINE WARMING AND CHARGING
OBJECTIVE
• To warm-up and charge the main steam line up to Emergency stop valves
1. Work permit on various boiler areas such as main steam stop valve, safety
valves, main steam strainer, various lines etc., cancelled and men, material are
removed from these areas.
2. Boiler is in lighted up condition and boiler drum pressure is about 6 to 8
Kg/cm2.
3. Condenser vacuum is pulled.
1. Ensure that main steam header drain valve MSD-050 valve is open.
2. Open the main steam strainer drain valve MSD - 054 to MSD - 060
3. Open the hot reheat strainer drain valve MSD - 034 to MSD - 040
4. Check that SLC drain is kept on auto and drains are open as per the logic.
OPERATIONAL STEPS
1. Turn the main steam stop valve’s MS-001 equaliser isolating valve to open position
and wait till it is fully open. Repeat the above step for MS - 002 valve also.
2. Crack open the regulating valve by holding the switch to open position for MS-
001 and MS - 002.
3. Wait for sometime; observe the main steam temperature rises before ESV.
5. Open the main steam stop valve 1 and 2 after opening the bypass valve fully.
6. Check that bypass equaliser valves should close once the main steam stop
valves are full open.
* Main steam line warmed and charged. *
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HP BYPASS CHARGING
OBJECTIVE
1. Work permit on various HP bypass oil unit, valves, desuperheater, lines, etc.,
cancelled and men, material removed from the area.
3. Both HP bypass pumps auto start and stop with oil pressure < 110 Kg/cm2
4. All the five numbers hydraulic operated valves, i.e. BP1/2, BD, BPE1/2 oil line
valves are operative.
6. All the five numbers of hydraulic operated valves open and close operation
checked from local and control room in manual mode.
7. ECW system running and bypass valves BP1 and BP2 gland cooling water inlet
and outlet valves are in open condition.
8. Any one of the BFP is running and common feed discharge line is charged to
supply HP bypass spray water.
10. R/H start up vents electrical supply available. Also LP bypasses system lined
up and available to take care of RH steam flow and pressure.
11. Main steam line in charged condition with line drain open to flash tank - 6 and
HP strainer drain open to HP/LP Flash tank.
KORBA SIMULATOR 68
PRE - START CHECKS AND LINE UP
2. Close HP bypass spray water line manual drain valves after BD, BPE-1 and
BPE-2 valves.
3. Ensure that spray water line hydraulic valves BD, BPE1 and BPE2 are in fully
closed condition.
4. Open the HP bypass spray water line manual isolating valve.
OPERATIONAL STEPS
2. Adjust the temperature set point of BPE-1 and BPE-2 to about 220oC.
3. Adjust the LP bypass fixed set point to about 4 Kg/cm 2 and ensure that LP
bypass is kept on auto.
5. Open the BP1 and BP2 valve manually to about 5 % from the console. Check
that BD valves and both BPE valves get transferred to auto mode.
7. Raise the boiler firing by raising the heavy oil pressure to increase the steam
pressure.
8. Ensure that LP bypass has opened and hot reheat pressure is maintained as
per fixed set point.
9. Bypass valves can be put in auto mode with main steam pressure matching the
HP bypass pressure setter to have bumpless transfer after adequate boiler firing
is achieved.
10. Close the superheater header vents and start up vents.
11. The downstream temperature set point can be varied depending on the final
(280oC to 340oC)
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12. Close the reheater outlet header vents once the LP bypass valves are
Kg/cm2 to bring the main steam parameters for rolling the turbine.
Note 1
HP bypass valves will force close / not open under following condition.
In case by pass valve closes fully, the corresponding spray valve should be closed
immediately to prevent water entry. The downstream temperature should be allowed to
come down naturally before opening the bypass valve again. The start up vents should
be opened to avoid stagnation of steam in superheater.
Note 2
Once unit is synchronised the main steam pressure and down stream temperature set
point of HP bypass system should be increased to more than operating full load
parameter but less than minimum MS safety valve setting. The valves can be 175
Kg/cm 2 and 340 o C. This is to be done to prevent unwanted opening of bypass and
spray water valves if controllers are kept in auto.
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HP BYPASS SYSTEM
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LP BYPASS CHARGING
OBJECTIVE
condenser, etc., cancelled and men, material removed from these areas.
2. Control fluid pump is running, 32 bars and 8 bar control oil available.
3. Turbine lub oil and jacking oil system in service with turbine on barring gear.
1. Open the manual isolation valves for exhaust hood spray and drain manifold.
4. Ensure that all the 8 bar control fluid line and various valves are open and
KORBA SIMULATOR 72
temperature dependent solenoid valves, injection water pressure switch,
5. Check that individual injection water manual bypass valves are closed.
6. Check that isolating valves downstream of duplex filter in 32 bar control fluid
8. Check the main isolating valve in the injection water line from CEP discharge
header is open.
OPERATIONAL STEPS
1. Set the hot reheat pressure set point reference to 4 Kg/cm2 in LP bypass
console.
2. Check that both temperature dependent solenoid valves are in reset condition
3. Charge the main steam line and open the HP bypass valves upto 5 %.
controller gradually till the injection water valves 1 and 3 opens full and then
both the bypass stop valves opens full as indicated in the console.
5. Increase the controller further till both the bypass control valves open about 25
%.
6. As HP and LP Bypass in service, the boiler start up vents, hot reheat vents can
be closed.
7. As HP Bypass valves open more (either in manual or auto), hot reheat pressure
will gradually approaches 12 Kg/cm2, raise the LP bypass fixed set point to 12
Kg/cm2.
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8. Check the control error deviation in the console. When it becomes zero the LP
bypass controller can be switched to auto with automatic control interface (ACI)
off.
injection water valves open automatically and will be indicated on the console.
Note -1
LP bypass operation can be done with automatic interface kept ‘ON’. It will
automatically open the bypass control valve to 25 % and will hold it till the actual Hot
Note – 2
ii) Injection water pressure after injection valves is less than set
value(18Kg/Cm2).
iii) Either of the stop and control valve will close if the corresponding
Note – 3
When turbine is on load, the LP bypass pressure set point (sliding set point) is a
function of HP turbine first stage pressure. The maximum of fixed and sliding set
point will be the operating set point and LP bypass will open if in auto mode, when
actual reheat pressure is more than this set point.
KORBA SIMULATOR 74
LP BYPASS SYSTEM
KORBA SIMULATOR 75
LINE UP FOR TURBINE ROLLING
OBJECTIVE
1. Work permits on various turbine side equipments like main oil pump’
HP/IP/LP turbine, generator, extraction system, drains, reheat steam lines,
extraction NRVs, etc., are cancelled and men material removed from these
areas.
2. The turbine lub oil system and jacking oil system charged and turbine is on
barring gear.
3. Atleast one control fluid pump is in running condition and 32 bar and 8 bar
fluid charged to various parts of governing system.
4. The boiler is lit up condition with HP/LP bypass in operation and main steam
pressure/temperature to about 40 Kg /cm 2with 350 OC.
5. Adequate water level in the primary water tank and nitrogen charging system
available.
6. The control power supply to the governing panels/insert available.
PRE - START CHECKS AND LINE UP
5. Line up the primary water system by opening the suction and discharge vlv and
6. Open the stator water cooling system manual inlet isolating valve from local.
KORBA SIMULATOR 76
1. Ensure that SLC drain is ON.
2. Check the TSE indicator and recorders are healthy and showing the correct
values.
3. Check the main steam pressure about 40 Kg/cm2 and temperature < 3500C
with hot reheat pressure about 12 Kg/cm 2 and temperature around 3600C.
OPERATIONAL STEPS
3. Check the primary water flow & temperature from the UCB.
4. Ensure that unit is on the limit pressure mode with deviation positive on
console.
6. Reduce the starting device to zero value. Check that trip oil pressure is built
and auxiliary start up oil pressure should come up to more than 5 Kg/cm2.
KORBA SIMULATOR 77
TURBINE ROLLING SYNCHRONISATION
OBJECTIVE
1. Work permit on various generator side equipments such as exciter, AVR, field
3. The switchyard 400 KV buses are charged with bus coupler close.
5. All the lockout relays in the generator protection panel are reset.
8. Hydrogen pressure is adequate( 4.0 Kg/cm2 ) and spare bottles are available.
1. Check the excitation not blocked, signal is available in the control panel.
3. Check that hot reheat and cold reheat drain valves are open
6. Close the 400 KV generator - 6 bay’ main bus -2 line isolator (SEM - 6004) from
switch yard .
7. Ensure the Earthing switch ( SEM - 6008 ) is in open condition from switch
yard .
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8. Close the 400 KV generator -6 bay’ breaker, incoming isolator (SEM-6006).
11. Switch on the generator transformer control supply for all the three phases
from local Ensure that exciter air cooler isolating, hydrogen cooler isolating,
12. Switch on the control supply for both the unit auxiliary transformers by
15. Ensure that turbine is kept on turbine follow mode with the minimum load
16. Ensure that trip oil pressure and start up oil pressure values are normal
OPERATIONAL STEPS
2. Ensure that start up oil pressure has decreased and at about 42 % of the
3. Further raise the starting device position to open the hot reheat stop valves.
4. Checks the temperature of the turbine stop valves at 50 % depth and control
5. Keep the warm-up controllers in auto mode. The output of the controller will
6. Raise the starting device position to about 80 % and check that secondary oil
KORBA SIMULATOR 79
8. Ensure the pressure controller deviation is on positive side.
9. Ensure that drum level is on lower side to avoid sudden swing which may cause
10. Raise the speed reference to about 360 RPM from UCB.
11. Check the uniform opening of control valves and turbine acceleration rate.
12. Ensure that gate valve gearing has closed when turbine speed exceeds 240
RPM.
13. Check that ‘Jacking oil pump’ has switch off at speed of about 540 RPM
14. Check all the bearing temperature rise and bearing vibrations to be normal.
15. Check the thrust bearing temperature and the differential expansions.
16. Soak the turbine at the soaking speed till the HP shaft temperature at 50 %
depth (Calculated) reaches to about 1800C with respect to existing main steam
17. Check the TSE margin for various channels. First it will reduce and then
gradually will increase once the difference between surface and mean
temperature reduces.
19. The turbine speed starts increasing opening of IP control valves can be seen at
this stage.
20. At speed of about 2960 RPM the AOP should be switched off as main oil pump
takes over (ensure that SLC for all the oil pumps are on).
21. Soak the turbine at 3000 RPM till IP shaft mean temperature (50 % depth) with
22. Check that a minimum of about 30 K margin should be available before unit is
to be synchronised.
KORBA SIMULATOR 80
23. Close the generator field breaker from AVR console.
24. Raise the AVR set point to build the Generator voltage to about 21.5 KV
25. Match the auto and manual set point of the AVR and transfer the AVR to auto
mode.
26. Ensure that load controller is on with load gradient kept at 20 MW/min.
27. Turn on the synchroscope switch to check mode. All the meters showing
incoming and running voltage and frequency energises. The synchroscope rate
28. Adjust the voltage so that incoming and running voltage values are same.
29. Adjust the turbine speed so that synchroscope is slowly rotating in clockwise
30. Check the breaker closing permissive green lamp glows once synchroscope is
31. Close the generator breaker when Gen. breaker closing permissive green lamp
32. Immediately raise speed reference to pick up the load on the machine to avoid
33. Increase the load as per the TSE margin and at the earliest close HP/LP bypass
valves.
34. Ensure that warm-up controllers have closed, otherwise close them manually.
35. Close all the drains which were opened during rolling.
37. Check that Prlim value slowly increase. Also ensure that load reference set
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38. Observed that change over from speed controller to load controller takes place
once output of load controller is greater than that of speed controller. The load
39. Raise the starting device position to 100 %. Check the increase in auxiliary
secondary oil pressure. Also ensure that tracking device is switched on.
40. Increase the load limiter value to about 150 MW from insert
41. Check the generator slot,core, exciter air and hydrogen cold gas temperatures
42. Check from the multipoint selector switches, generator stator core temperature.
43. Raise the HP bypass pressure set point to about 160 Kg/cm2 and temperature
44. Ensure that LP bypass stop valves and spray valves have closed fully.
KORBA SIMULATOR 82
LP HEATER CHARGING
OBJECTIVE
1. Work permit on various LP heaters, drip valves, level gauges, water side valves,
NRVs, etc., cancelled and men, material removed from these areas.
3. The instrument air is charged to various drip valves and valves are checked for
4. All the pressure gauges, local level gauges, root valves and various instrument
2. Ensure all the shell side heater vents are in open condition represented
3. Check that all the isolating valves of the LP heater level controllers are full open
4. Charge the local level gauges for all the three heaters.
OPERATIONAL STEPS
1. For LPH1 put the normal drain valve control switch to control mode from section.
2. Check that LPH-2 condensate inlet/outlet valves are in open condition and
KORBA SIMULATOR 83
3. Open the extraction steam isolating valve to LPH2.
4. De-energise the extraction NRV solenoid from ATRS console by pressing the left
side push button. The NRV position starts increasing as the steam goes to LPH2.
5. Put the normal drain valve control switch to control mode. The valve starts
6. Check the condensate inlet / Outlet valves for the LPH3 are open and bypass
valve closed.
8. Put the normal drain valve control switch to control mode. The valve starts
10. Check the condensate temperature after LPH-1,2,3. The temperature should
* LP heaters charged *
KORBA SIMULATOR 84
TO TAKE PULVERISER INTO SERVICE
OBJECTIVE
1. Work permit on various pulveriser side equipment such as seal air fans and valves,
pulveriser discharge valves, cold air damper, hot air gate and dampers, feeder, coal
bunker mill reject system etc., cancelled and men, material are removed from these
areas.
2. The equipment cooling water system is charged and all the coolers are in charged
condition.
3. Atleast one set of ID fan and FD fan are running with furnace purging carried out.
5. Instrument air is charged to all cold and hot air damper actuators.
6. Primary air preheater is in service with air / gas dampers in open condition.
2. Take any one primary RAPH in service and ensure the dampers are open.
3. Establish the equipment cooling water supply through the lub oil coolers for PA
fan .
5. Rack in the 6.6 KV breaker for PA fan A.The green lamp in UCB glows.
KORBA SIMULATOR 85
6. Switch on the lub oil pump A for PA fan A and keep the selector switch of B in
12. Open the cold air gate for all the pulverisers.
15. Check the lub oil pressure satisfactory permissive appears on the FSSS console.
16. Ensure that both the hot air damper and cold air dampers are operable from
UCB.
17. Ensure the feeder inlet gate is open and corresponding permissive lamp is
OPERATIONAL STEPS
4. All the permissive will be available the moment discharge damper is closed the
fan will take start. Check its starting and no load current.
5. Check that outlet damper for PA fan A reopens after a time delay and discharge
6. Check the bearing temperature and vibration from UCB are normal.
KORBA SIMULATOR 86
7. Ensure that lub oil pump for PA fan B is running with standby pump in lead
8. Increase the blade pitch of PA fan A, and observe that PA fan A discharge
pressure increases.
9. Bring the PA header pressure to about 800 mmwcl by raising blade pitch
further.
11. Ensure that 2 nos. of seal air fan are running, otherwise standby fan will get
12. Open the pulveriser discharge valve by pressing the open push button.
14. Check that ignition permit is available for the pulveriser to be taken into
15. Ensure that the following pulveriser start permissives are satisfied.
• Start permit (nozzle tilts horizontal and air flow less than 40 %).
• Ignition permit.
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• Feeder inlet gate open.
16. Momentarily press the pulveriser start push button. The following events will
occur.
• The pulveriser seal air valve opens and red open light comes
• Once seal air header to pulveriser under bowl differential pressure is more than
• All the permissive on the console appear and pulveriser ready lamp glows.
• Pulveriser ammeter pegs out to draw the starting current and comes down to no
load value.
• Pulveriser cold air damper opens 100 % and primary air flow to mill comes to 95
T/hr.
17. Maintain the furnace pressure by raising the ID fan inlet guide vanes.
18. Open the hot air gate by pressing the ‘Open ‘ push button. Hot air gate opens
19. Open the hot air damper and simultaneously decrease the primary air flow
20. Check the pulveriser outlet temperature increases gradually since hot primary
21. Start the feeder by depressing the start push button. The feeder starts and
22. Increase the loading on the mill by raising the feeder speed and maintain the
23. Check the furnace pressure and maintain it to about - 15 mmwcl by loading
the ID fan.
24. Increase the opening of the fuel air damper as per the feeder speed.
KORBA SIMULATOR 88
Start the feeder B
25. Check that the fire ball scanners should start sensing flame and flame failure
26. Check the pulveriser bowl differential pressure and mill motor current and
27. The drum level and other parameters are to be maintained during this
operation.
28. Electro Static Precipitator can be put in service, when coal firing has stabilised
considerably in 3 to 4 mills.
KORBA SIMULATOR 89
STEAM TEMPERATURE CONTROL
OBJECTIVE
2. Minimum one BFP is running with feed water charged upto the feed control
5. The boiler load (steam flow) is more than 30 % with drum pressure around 80
Kg/cm2
3. Check the trend of the main steam and reheat temperature rise during the load
raising operation.
OPERATIONAL STEPS
2. Open the SH outlet temperature controller LHS isolating block valve S - 83.
The pressure equalising valve opens first and then main valve opens fully.
similarly.
KORBA SIMULATOR 90
4. Increase the controller output to about 10 % manually. Check the valve
6. Increase the controller output for the RHS also. Check the valve position
8. Open the isolating valves for each left and right hand side reheater
9. Reduce the burner tilt first by the controller, if the HRH temperature is rising
rapidly.
10. Increase the RH spray on LHS and RHS to maintain the HRH outlet steam
temperature.
11. Check the temperature variation in the recorders, which is a positive indication
of spray flow.
12. Check that rate of increase of SH and RH temperature should slow down,
otherwise further raise the attemperation control valves to increase the flow
rate.
Note 1 To control RH temperature, first the burner tilts should be used. The
KORBA SIMULATOR 91
SUPERHEATER SPRAY CONTROL STATION
KORBA SIMULATOR 92
CHARGING OF UNIT AUXILIARY TRANSFORMERS
OBJECTIVE
1. Turn the 6.6 KV Unit Swgr No. A, UAT-A incomer Syn. hand switch to check
mode. The synchroscope indicator locks up at 12 O’ clock position and
voltages for incoming and running are shown.
2. Adjust the voltage of the incoming by changing the excitation set point from
AVR console to match the running station supply voltage
3. Check the breaker closing permissive green lamp glows as soon as the voltage
is matched (Keep the incoming slightly on higher side).
4. Close the 6.6 KV unit Swgr 6A, UAT-A incomer breaker. The breaker closes
and ammeter starts showing the current drawn.
5. Open the 6.6 KV tie breaker.
6. Switch off the synchroscope by turning it to off position.
7. Check the UAT A winding temperature & oil temperature.
8. Repeat the above procedure Sl.No. 1 to charge the Unit Auxiliary Transformer B
also.
9. Check the UAT- B winding temperature & oil temp..
KORBA SIMULATOR 93
LOAD RAISING OPERATION
OBJECTIVE
• To remove oil support once coal firing is established.
• To raise the unit load upto 50 %.
PRE - REQUISITES & STATE OF PLANT
1. The unit load is about 75 MW with Unit Auxiliary Transformers charged.
2. Three to four pulverisers are ready with all associated equipments.
3. The superheater and reheater attemperation is lined up.
4. Check that sufficient margin is available on TSE to raise the load.
5. Raise the load limit on both EHG and CCS consoles to about 300 MW.
OPERATIONAL STEPS
1. Checks that the upper load margin in the TSE indicator and IPS temperature
margin in TSE recorder are adequate to load the turbine further.
2. Take two more pulverisers in service as per the standard procedure mentioned
earlier.
3. Increase the loading on all the three pulverisers equally and check for better
combustion condition in the furnace.
4. If oil elevations at AB/CD/EF are in service, then oil guns at EF elevation can
be removed for economic operation.
5. Depress the PAIR 1-3 stop’ push button on’ oil console at EF elevation.
6. Check that the oil nozzle valve closes and associated ‘closed’ light comes on, spark
rod of ignitor advances and sparks for 15 secs then retracts back.
7. Ensure that oil gun at corner 1 and 3 retracts back once the 5 min scavenge
operation of oil gun is complete.
8. Repeat the same for the pair 2-4 also, check till both the oil guns retracts back.
9. Reduce the heavy oil pressure.
10. Increase the feeder speed for all the three feeders beyond 60 % and check the
flame intensity at AB as well as BC should improve
11. Raise the load reference on EHG control insert to pickup the load as the drum
pressure increases.
12. Maintain the SH and RH outlet temperatures by increasing the opening of the
attemperation control valves or reducing the burner tilts.
KORBA SIMULATOR 94
13. Change the set point of mill A outlet temperature and PA flow by turning the
knob till it comes to 770C and 95 T/ hr respectively.
14. Check the error deviation of the controllers to be zero and transfer the
controller in auto mode by pressing the middle A/M push button.
15. Repeat the above operation for other pulverisers, watch the outlet temperature
and bowl differential pressure.
16. Keep the bias setter for all the three pulverisers at 1 .
17. Raise the output of the fuel master till the error deviation in each feeder speed
comes to zero. (Adjust the bias setter if loading is unequal.)
18. Transfer all the feeders to auto mode and raise the fuel master output. All the
three feeders will get loaded simultaneously.
19. Keep on increasing the load set point as the parameters are building.
20. Maintain the air flow / furnace pressure / wind box pressure as the firing is
changing by adjusting the respective controls in UCB.
21. Check the loading of the auxiliaries as the load approaches 50 %
approximately.
* Unit load is brought to 50 % *
KORBA SIMULATOR 95
TAKING SECOND SET OF AUXILIARIES
OBJECTIVE
1. Work permit on the second set of auxiliaries second stream of flue gas /
secondary air and primary air ducts, etc., cancelled and men, material are
2. The unit load is about 50 % .Cold reheat pressure is more than 12 Kg / cm2 to
start TD BFP.
OPERATIONAL STEPS
2. Ensure the suction valve and recirculation valve of CEP- B are full open.
3. Start the condensate pump B and observe that motor current is normal.
5. Adjust the set point of the recirculation controller and transfer the controller to
auto mode.
11. Open the cold reheat steam to BFPT-A block valve Ex-20.
KORBA SIMULATOR 96
12. Raise the starting device position to about 60 % to open the stop valve and
13. Raise the speed reference to increase the BFP discharge pressure. Check that
14. Stop the motor driven boiler feed pump once the TD BFP is taken in service.
15. Similarly line up and start the TD BFP B for load raising operation.
16. Line up and start the ID fanB and balance the loading of both the fans.
17. Line up and start the FD fan B and balance the loading of both the fans.
18. Increase theoutput of fuel flow control master manually to increase the firing.
19. Check that all the coal feeder loading has increased and pulveriser amps have
increased.
20. Adjust the output of the boiler master so that deviation on the fuel master and
21. Transfer the FD controller in auto for a smooth change over and check that the
22. The boiler master can be used now to increase or decrease the load on the
boiler. The unit may be kept in Boiler Follow mode with limit pressure mode in
operation (after having kept first Fuel Master on Auto and then Boiler Master
on Auto).
24. Take pulveriser D in service and load the feeder. The coal flow in all three
25. Increase the Boiler Master output slowly to raise the firing if Boiler Master is
kept manual.
KORBA SIMULATOR 97
26. The boiler temperature, pressure rapidly increases as a result of increased coal
firing.
27. Raise the load set point Pref. check that opening of the HP control valve
increases.
29. Increase the maximum load limit set point on the CMC console as well on the
30. Adjust the furnace pressure set point to about -15 mmwcl and keep the bias
32. Check that both the PA fans are equally loaded. Raise the set point for PA
header pressure to about 800 mmwcl and set the bias setter to 1.0 by turning
the knob. Transfer both the controller to auto mode after ensuring the control
deviation is zero.
33. Repeat the above step for FD fans; note that FD set point is generated by the
Boiler Master.
KORBA SIMULATOR 98
TDBFP SYSTEM
KORBA SIMULATOR 99
LOAD RAISING OPERATION WITH CCS.
OBJECTIVE
1. Work permit on the HP heaters, drains, control valves, associated piping, etc.,
OPERATIONAL STEPS
1. Ensure that HPH both the streams are charged through water side i.e. HPH
3. Open the extraction steam to heater 5A and 5B by opening EX-005 and EX-006
respectively.
5. Turn the control switch of HP heater 5A and 5B drip to deaerator valve LCV-
6. Check that the heater levels are normal and controller modulates to maintain
level.
7. Close the Extraction steam line drain valve after NRV, MSD-063
10. In the same manner charge HPH 6A and 6B also. Check that drip control valve
14. Match the load demand signal to actual load by raising the unit master output
15. Ensure the load gradient to about 5 MW/min for better result.
16. Increase gradually the throttle pressure set point above the actual pressure
value by 2 to 3 Kg/cm2.
17. Transfer the boiler master to auto mode. Check the output of the boiler master
18. Ensure the minimum load and maximum load set point are 50 and 500 MW
respectively.
19. Place the unit in coordinated mode. The Unit control mode Coordinate facia
20. Raise the Unit Master set point to about 350 MW.
21. Watch all the unit critical parameters carefully and check that they are not
22. Check that the generator reactive power is within limits as per the generator
capability curve.
23. Raise the throttle pressure set point gradully and check that the boiler firing
24. Increase the Unit Master set point to 450 MW and check that sufficient upper
26. Adjust the set point of the Reheater and Main steam temperature set points to
27. Watch the trend of main steam and reheat temperature, it may come down
28. Check the unit load limiter on both console is beyond 500 MW. Raise the unit
29. Check that the control valve opening increases, load comes to 500 MW.
600 Cut In 6-th 170 475 40.5 475 3000 1600 500
Mill
And
Reach Full
Load
086 Reach Full 170 500 40.5 500 3000 1610 500
Load
Check the following conditions exist immediately after the Unit Tripping.
UAT’s Supply to Unit Buses are tripped and Station Supply takes over
automatically.
Turbine trip oil , Aux Sec oil & Secondary oil pressure became Zero.
All the Feed Water Heaters Extraction Block valves are closed automatically.
Verify
Turbine Gate valve gearing is opened automatically at 210 rpm(if SLC is on).
SH/RH attemperation Block valves are closed if spray control valves are less
than 5% open.
Drum level may sink.
Stop one set of ID/FD fans to avoid forced cooling of the boiler.Stablise &
BOILER PURGE:
Ensure all purge permissives are available & do furnace purging for 5 minutes.
The first cause of unit tripping gets reset along with the MFR reset.
Deaerator:
Ensure Deaerator pressure is maintained at 3.5 Kg/cm2 & auxiliary steam pressure is
14 Kg/cm2
Condenser:
Kg/cm2(approximately).
Light up the boiler with the upper elevation oil guns and a mill or two is put in
service if
9. HP casing drain.
Open HP Bypass valves so as to establish 15% flow through them,taking care to see
Ensure LP Bypass system is functioning normally on Auto.Adjust the fixed set point to
8 Kg/cm2.
Steam flow thus established shall assist in heating Main Steam, Cold Reheat and Hot
Reheat lines.
Turbine can be rolled to rated speed either by ATRS rolling or manual rolling through
than 300C.
H.P.Control Valves.
2) Verify that drains before HP Control valves are in Auto and these valves have
opened.
Differential pressure between Seal oil Air side and Hydrogen side (both turbiine
and Exciter end is more than 0.7 Kg/cm2)
a) The degree of Superheat of Main steam before turbine is more than 50°c.
temperature of IP Shaft.
During the warm up and hot start up of the turbine, observe the following parameters.
• Differential Expansions.
• Axial Shift
• Steam parameters.
Turbine Rolling
Raise the speed set point so as to admit steam to steam to the turbine & Start rolling.
Close all the drains valves as mentioned earlier for warm up of steam lines.
While admitting steam to the turbine, ensure that permissible wall temperature of
Close the drains after HPCV if differential temperature between HPCV & Saturated
Raise the speed to 3000 rpm provided the following parameters are with in the limits.
b. The differential temperature between the top & bottom of the casing less than +
450C.
c. Bearing temperature and vibration are less than 900C and 45 microns
respectively.
AT 3000 rpm
temperature.
7) Differential temperature between primary water & Hydrogen is more than 10C.
c) Switch on the Synchroniser & synchronise the Generator with Grid when
incoming Frequency, Voltage and Phase sequence match with the running
system.
d) Raise the Starting device and take a block load of 10% by raising Nref from
e) Close HP Bypass and check LP Bypass closes on Auto, when sliding set point is
f) Charge Unit Auxiliary Transformer to change over 6.6 KV supplies from Station
to UAT.
g) Raise the Turbine inlet Main Steam Pressure at the rate of 0.8 Kg/cm2 per
minute up to Kg/cm2 at 25 % load and after wards at 1.65 Kg/cm2 per minute
h) Raise turbine inlet Main steam temperature at the rate of 1.60C /minute upto
than 3000C.
j) Verify that drains before HP Turbine exhaust NRVs have closed with the
opening of NRVs.Close the drains before and after IPCVs when difference
Main steam temperature can be raised at the rate 1.60C up to 4850C and at the
Verify that drain before LPH 2&3 closed when opening of respective extraction
Verify that drain before Deaerator extraction line NRV closes when opening
extraction NRV is more than 15% & differential pressure across NRV is more
Put Hot well level control and deaerator level control on auto.
Above 20% Boiler Load Index, drum level three element control can be put on
auto.
AT 27% Turbine load, cut in the first mill and at 43% turbine cut in the second
mill.
AT 40% Turbine load, combustion controls can be put on auto. HP Heaters 5 &
Around 50 % Turbine load, cut in the second set of Boiler and Turbine
IIIrd 50%
IVth 60%
Vth 70%
Between 50% and 75% load,maintain turbine inlet main steam temperature at 4850C.
From 97% to 100% turbine load, raise the turbine inlet temperature at the rate of
OBJECTIVE
OPERATIONAL STEPS
1. Ensure that unit is on coordinated mode with limit pressure mode in service
and boiler master in auto mode.
2. Check the load gradient is set at 5 MW/min on both the consoles.
3. Reduce the unit master set point (load demand) to 400 MW.
4. Take the attemperation control in manual mode and slightly raise the
controller output to bring down the main steam and reheat temperature.
5. Check that the load reference set point comes down and boiler master reduces
its output to reduce firing.
6. Reduce the AVR set point by pressing the lower button on AVR insert.
8. Check that all HP control valve opening reduces and load come down to 400
MW.
9. Gradually reduce the throttle pressure set point to about 130 Kg/cm2.
10. Turn the burner tilts to lower side by decreasing the controller output.
11. Check that fuel flow starts coming down followed by the air flow and steam
flow.
12. Check that the main steam pressure and cold reheat pressure also starts
dropping.
13. The ESV surface temperature starts dropping followed by the mean
temperature, same is the case for the control valve also.
14. Further drop the main steam and reheat temperature to cool the turbine. The
points shown by the TSE 12 point recorder shows the decreasing trend.
16. Stop the topmost pulveriser to reduce the firing. Reduce the output of fuel
master manually.
17. Close the extraction block valves to HP heater 6B and 5B from steam side. The
valve starts closing, the drain control valve also starts closing since there is no
18. The boiler pressure increases momentarily then drops down as the feed water
19. Further reduce the output of the fuel master to reduce the firing and steam
temperatures. Ensure that the unit is in turbine follow mode with initial
20. The load will drop automatically in turbine follow mode to maintain the
21. Stop one more pulveriser to reduce the firing. Reduce the out put of fuel
master manually.
22. Maintain the furnace pressure, boiler drum level and primary air header
23. Check that HP casing temperature and HP shaft temperature (calculated) drops
24. Check the flame intensity at elevation corresponding to running feeders and
OPERATIONAL STEPS
2. Take the feeder speed control in the manual mode and reduce the loading of
the feeder to minimum.
3. Close the hot air gate from the FSSS console. Cold air damper opens 100 %
and hot air damper closes fully.
4. Check that mill outlet temperature drops rapidly and Mill current also comes
down.
5. Stop the feeder by depressing the feeder stop button. The coal flow drop to
zero. The loading in other pulverisers will increase to compensate the lost coal
supply.
6. Wait till the pulveriser grinding current comes to no load current. Check that
mill outlet temperature and bowl differential pressure comes down.
7. Decrease the fuel air damper opening to almost close condition.
8. Check that feeder voted light (no flame)comes once the feeder is stopped.
9. Open the tramp iron gate to remove any rejects accumulated in pulveriser.
10. Stop the pulveriser by depressing pulveriser stop push button. Check that the
cold air damper closes full and mill air flow drops down.
14. Close the pulveriser discharge valves by depressing the close push button from
FSSS console.
OPERATIONAL STEPS
1. This step is in continuation with the operating instructions given earlier where
2. Check that the turbine pressure controller is active and unit is in turbine follow
4. Check the overall flame stability within furnace and the analog output of the
6. Reduce the main steam temperature and hot reheat steam temperature by
7. Reduce the throttle steam pressure set point gradually by lowering the S/P on
8. Transfer the furnace pressure controller to manual mode and reduce the
9. Transfer the FD blade pitch control to manual mode and unload the FD fan
10. Maintain the furnace pressure and air flow during above operation.
11. Stop one ID fan and one PA fan by giving a stop command from UCB control
desk hand switch. The breaker opens, green off indication lamp comes.
support. Three feeders with loading above 75 % may not need the oil
support.
13. Check that the inlet/outlet dampers of ID fan and discharge damper of the FD
14. Adjust the HP bypass pressure set point to match existing throttle pressure.
15. Transfer the initial pressure mode to limit pressure mode and reduce the
16. Reduce the target load set (load reference) value from the governing console i.e.,
pr ref. & pr lim comes down at a rate set by the load gradient.
17. Ensure that LP bypass controller is kept on auto with fix set point slightly
18. As the throttle pressure increases on reduction of load the HP bypass valves
will open on auto causing the cold reheat pressure to go up. Once this
pressure exceeds the sliding set point, LP bypass valves will also open.
19. Further reduce the load set point from governing console. Check that the
attemperation valves.
20. Change over from unit supply to station supply for 6.6 KV A and B buses using
synchroscope.
21. Cut in oil support at AB elevation with minimum oil pressure to stabilise the
flame.
22. Transfer all the three running feeders to manual mode by pressing the middle
24. Close the extraction steam block valves to LPH1, 2 & 3 once load has come
below 20 %. Check that the drain control valve closes. Open the drains of the
extraction line.
25. Transfer the low load feed regulating station to auto mode and take the three
26. Stop one CEP also by giving a stop command from the UCB hand switch after
27. Cut in one more oil elevation and maintain the oil pressure & temp.
28. Change over the 16 ata header from existing unit by opening the tie valve.
29. reduce the attemperation if the main steam temperature has come to around
3800C.
30. Maintain the hot well, deaerator level during this transient operation.
OPERATIONAL STEPS
1. At about 540 RPM ensure that jacking oil pump takes start and jacking oil
2. At about 210 RPM check that the barring gear valve starts opening and turbine
3. Open the HP casing drain manually after switching off the SLC.
4. Open all the four drains upstream interceptor valve at valve seat.
8. Check the differential expansions of all the three casing within limits.
9. Check the bearing temperature for all the bearing should start coming down.
11. Check that the seal steam pressure is maintained and condenser vacuum
satisfactory.
12. Reduce the fixed set point of LP bypass to maintain flow through reheaters. The
OPERATIONAL STEPS
2. Take the HP/LP bypass valves in manual mode and reduce the opening of HP /
LP bypass.
4. Check that all the fuel air dampers close from top to bottom.
6. Check that start permit is available, burner tilt horizontal and air flow less
than 40 %.
buttons.
8. Check that 5 min. scavenging operation is complete and gun retracts back.
10. The moment oil nozzle valve for 4th corner closes, the boiler will trip and loss of
11. MFR tripped alarm comes. Both the MFR A/B relays trip red lamp comes.
12. Check that HOTV closes and green lamp comes on.
13. Bring the air flow to less than 40 % by FD fan blade pitch.
14. Check that all the purge permissives are satisfied and purge ready lamp comes.
15. Close the HP/LP bypass manually and increase the set pressure higher than
16. Push the ‘Push to purge’ switch from FSSS console. The purging light glows
and stays for 5 mins. and purge complete light comes once purging is over.
17. Wait till the fuel air damper starts closing from top. Maintain the air flow in
between 30 to 40 %.
18. Raise the BFP discharge pressure by raising the speed of BFP turbine.
19. Open the low range feed control valve to start the drum filling . Check that the
20. Stop the drum filling once all the ports of the hydrastep are indicating water
(green lamps on). Ensure that blow down valves are closed including
that the EHC position drops to zero and control valve closes.
26. Close the manual isolating valve to HP bypass desuperheating valve from local.
27. Check that BFP discharge pressure and flow drops to zero.
* Turbine on barring gear with boiler in tripped condition, drum filled upto
the top *
OBJECTIVE
OPERATIONAL STEPS
1. Check the plant status with boiler in tripped condition and purging carried out.
2. In manual mode reduce the FD fan blade pitch to 0 %. Check that the air flow
3. Check that first cause of trip red flags comes on FSSS console as air flow is less
than 30 %. Both the MFR trip and red lamp comes on.
5. Check that the fan current drops down to zero and discharge pressure starts
dropping down.
9. Check that the fan amps drops down to zero and inlet/outlet pressure
decreases.
10. Ensure that the dampers for all three fans GD-20 to GD-25 opens fully on
interlock .
11. Keep the lub oil pumps of all the fan running till the bearing temp. of the fans
come down.
12. Check that the flue gas temp. entering the air heater goes less than 120oC.
Stop sec. RAPH A and B motor from UCB manually. [ Note that air motor will
14. Keep open all the flue gas inlet/outlet dampers on air side as well as flue gas
15. Check and close all air preheater cold end temp. controllers.
16. Close the steam inlet valves to primary and secondary RAPH A and B.
17. Stop the ash slurry pumps and bottom ash transport pumps.
19. Stop the DC scanner air fan from FSSS console, once the furnace is sufficiently
cooled.
OPERATIONAL STEPS
2. Ensure that turbine is on barring gear with circulating water system in service.
JOP should also be in service.
3. Transfer the SLC drain to auto mode and check the drain valves are
4. Stop the vacuum pump No. 1 from the oil console insert.
5. Close the air isolation valve and hold the command till the valve is fully closed.
6. Open the vacuum breaker from the insert. Check that vacuum falls rapidly.
7. Take the gland seal steam controller to manual mode and close it fully. Open
8. Close the block valve for seal steam supply to glands ASD-006.
12. Stop the control fluid pump.Check that the pump current drops down to zero.
13. Switch off the HP control fluid heater No. 1 from the console insert.
14. Isolate the control fluid cooler from water side by closing the inlet outlet valves
15. Isolate the high pressure accumulator by closing the isolating valves.
17. Check that turbine side temperatures (e.g. HP shaft, HP casing, IP shaft etc.)
18. Check that the differential expansions for all the three casing are within limit.
19. Ensure from DAS and local also that turbine metal temperatures are below
75oC.
21. Close the gate valve gearing by pressing the left side push button.
23. Once the turbine is stand still the jacking oil pump can be stopped.
25. Switch off the jacking oil pump N0. 1 by pressing the left side push button.
26. Purge the hydrogen from the generator and fill with the carbon di-oxide.
27. Ensure that Hydrogen is removed before stopping the barring gear.
28. Ensure that CO2 occupies the generator space. This can be checked from the
CO2/O2 purity meter.
29. De-pressurise the generator by removing the carbon dioxide. Ensure that no
hydrogen cylinder is connected at gas filling header.
lamp comes.
36. Check from the local (exciter end) that turbine has come to stand still.
37. Switch off the auxiliary oil pump. Check that the current drops down to zero.
39. Check that EOP and AOP-2 do not take start as their SLCs are off.
40. Isolate the turbine lube oil coolers from water side.
41. Switch off the oil vapour extractor by pressing left side push button.
42. Take the oil temperature controller in manual and close it.
* The condenser vacuum killed. Turbine / Control oil and lube oil system taken
out of service. *
OBJECTIVE
OPERATIONAL STEPS
1. Check that the plant status is safe, with turbine side equipments stopped.
2. Ensure that the Dea. Level controller is in closed condition and in manual
mode.
3. Close the block valve of the Dea. Level controller station CO-14 CO-17.
recirculation only.
5. Keep the selector switch of the CEP - B and C in normal position to prevent
6. Stop the CEP- A by turning the switch to stop position. The CEP stops and
8. Ensure that discharge valves of all the three CEP should close.
9. Check that vent valve on turbine oil system opens on auto as all the CEPs are
off.
10. Check that hotwell level is in steady state, if increasing then check the make
11. Ensure that all the recirculation controllers are full open and are in manual
mode .
12. Close the sealing line valve from common discharge from local .
13. Ensure that condenser spill valve bypass and condensate fill valves are closed
15. Close the suction valve for all three CEPs from local .
16. Close the ECW inlet and outlet valve of the CEP bearing oil coolers
17. Close the GSC minimum flow isolating valve from local .
18. Ensure that all the make up control valves along with there by-pass valves are in
19. Change the emergency make up pump control status from auto to manual .
OBJECTIVE
OPERATIONAL STEPS
4. Stop any one of the CW pumps. Both pumps should not be stopped as ARCW
pumps are still running and the suction is taken from CW inlet duct.
5. Check that the discharge valve of CW pump which is taken out of service closes.
Note : Both the CW pumps should not be taken out of service till the ARCW pumps
are in service.
OBJECTIVE
OPERATIONAL STEPS
1. Close the oil temperature control valve to reduce the steam supply to HFO
heaters.
5. Close the discharge valve of the HFO pump to isolate the HFO heater.
8. Close the HFO delivery valve (HO - 18) and inlet to the firing floor (HO - 25)
valves.
9. Isolate the suction valves to both the pumps and drain the pump.
10. Isolated the steam lines going to pump jacket and strainers.
11. Stop the HFO tank heating if long shut down is expected.
12. Isolate the auxiliary steam supply to the HFO pump house and open the
OBJECTIVE
OPERATIONAL STEPS
1. Check that the plant status is safe and no major auxiliaries running.
3. Isolate the cooling water inlet valve to FD fan A/B/C lub oil systems from local.
4. Isolate the various auxiliary cooler and isolate the differential pressure
6. Stop one DMCW pump by turning the hand switch to off position.
7. Check that the motor current drops down to zero and discharge pressure drops
slightly.
10. Check that the discharge pressure & the motor current drops down to zero.
12. Keep the selector switch to off position for ARCW pump from CSSAEP
14. Check that the current drops down to zero and main CW pressure at heat
15. Stop ARCW pump B also by turning the switch to off position.
16. Close the discharge valves of ARCW pump A & B, both valve close and green
17. Unit - 6 ARCW pump discharge header pressure low alarm comes in.
18. Isolate the plate type heat exchanger by closing the inlet and outlet valves.
19. Open the pump drain and vent valve to drain the pump.
21. Switch off the electrical power to the ARCW pump since the suction valve is
closed.
OBJECTIVE
OPERATIONAL STEPS
1. Check that the plant status is safe with boiler in tripped condition and turbine
2. Close the primary SCAPH A / B steam inlet valves if not done earlier.
ensure that pressurisation of D/A due to aux. steam does not take place any
further.
Note : Since the auxiliary steam header can be charged either from cold reheat line
6. Ensure that motorised isolating valves to TDBFP, ASL-004 and gland steam
9. Check that the auxiliary steam pressure shown by UCB indicator comes down
to zero.
10. Open various steam traps and drains for the atomising line and steam tracing
11. Ensure that gland steam line drains from auxiliary steam are opened.
INTRODUCTION
The Furnace Safeguard Supervisory System (FSSS) is designed to ensure the execution
of a safe, orderly operating sequence in the start-up and shutdown of fuel firing
equipment and to prevent errors of omission or commission in the following such as
safe operating procedure.
The system provides protection against malfunction of fuel firing equipment and
associated air systems. The safety features of the system are designed for protection
in most common emergency situations; however, the system cannot supplant the
intelligent and reasonable judgement of the operator in all situations.
It is important that the operator is familiar with the overall operation of the unit and
the operation of individual equipment, as outlined in the section “Unit Operating
Procedures” and the various individual equipment sections in this manual.
It is essential that all parts of the Furnace Safeguard Supervisory System are operable
and in service at all times if the system is to provide the protection for which it is
designed. Adequate maintenance and periodic inspection of the system and
associated hardware is essential for its continued proper operation.
This instruction section of the manual gives a complete description of the Furnace
Safeguard Supervisory System furnished for this Unit as it relates to the various unit
operating phases and the operation of the fuel firing equipment and associated air
systems.
a. Prevent any fuel firing unless a satisfactory furnace purge sequence has first
been completed.
c. Monitor and control proper component sequencing during start-up and shut
down of fuel firing equipment.
e. Provide component status feedback to the operator and, in some cases to the unit
control system and/or data logger.
g. Effect a Master Fuel Trip upon certain adverse Unit operating conditions.
The method of accomplishing the logic in this unit is with C - E / Sulzer solid state
logic system.
3. Each of the four oil elevation (AB,CD,EF and GH) has a section for the oil
elevation and associated Safe Scan equipment.
4. There are separate sections for each coal elevation (“A” thru “H”).
There is also a Unit Simulator panel assembly located on a swing panel in the Unit
section.
There are also four Oil Elevation Simulator panel assemblies. Each Simulator is
located on a swing panel located in the associated oil elevation section.
Each of the eight coal elevation sections has a Coal Elevation Simulator which is
located on a swing panel in the associated coal elevation section. The Unit contains
four (4) elevations of HEA ignitors, four (4) warm-up elevations and eight (8) coal
elevations. Flame monitoring is accomplished with four (4) elevation of “Safe Scan”
equipment and five (5) elevations of “Fireball” (Series 510) flame scanners.
The “Safe Scan” equipment is used as discriminating flame scanner. This equipment
is the Safe Scan 1-”Rear Access” model.
OIL RECIRCULATION
When all heavy oil nozzle valves are closed (PURGE PERMITS (White)”NOZL VALVS
CLOSED” light is on), the heavy oil recirculation valve can be opened to head the
heavy oil to obtain the proper viscosity for efficient combustion.
This is accomplished by depressing the H.O. RECIRC. VLV “OPEN” push button.
When the heavy fuel oil recirculation valve is moved from the closed position, the
associated (red) “OPEN” push button is illuminated. The recirculation valve is proven
The heavy oil recirculation valve can be closed by depressing the H.O. RECIRC. VLV
“CLOSE” push button. The heavy oil recirculation valve is closed automatically when
any heavy oil nozzle valve is not closed (PURGE PERMITS (WHITE) “ NOZL VALVES
CLOSED” light goes off).
UNIT START-UP
FURNACE PURGE
Before any fuel firing can take place (initially or following a boiler trip), a satisfactory
purge cycle must be completed. All of the conditions listed below must be satisfied.
To start a furnace purge cycle, proceed as follows:
1. The A.C. and D.C. power requirements are satisfied when the following conditions
are satisfied :
A. Loss of ACS power for more than two seconds does not exit. The “LOSS OF ACS
POWER” signal at the Data Logger is removed.
B. Loss of customer 220 VDC Battery power for more than two seconds does not
exist. The “LOSS OF 220 VDV> 2 SEC” signal at the Data Logger is removed.
C. Loss of customer 220 VDC Battery power for more than two seconds does not
exist.
The “LOSS OF UNIT CRITICAL POWER” signal at the Data Logger is removed.
2. The “Mode Permit” signal is proven established when the PURGE PERMITS
(white) “MODE PERMIT “ light is on.
3. A “ Simulator Trip” signal does not exist. The “SIMULATOR TRIP” signal at the
Data Logger is removed.
4. Both “Drum level high” signals from the Acs or the HYDRA STEP do not exist for
more than ten seconds. The “DRUM LEVEL LOW” signal at the Data logger is
removed (See Note 1).
5. Both “drum level low” signals from the Acs or the HYDRA STEP do not exist for
more than ten seconds. The “DRUM LEVEL LOW” signal at the Data logger is
removed (See Note 1).
When items 4 and 5 above are simultaneously satisfied, the PURGE PERMITS (White)
“DRUM LVL. SATIS.” light comes on.
6. When at least one boiler feed pump is not off, the “BOILER FEED PUMPS
TRIPPED” signal at the Data Logger is removed.
7. The “inadequate waterwall circulation” signal does not exit. The “INADEQUATE
W.W. CIRCULATION” signal at the Data Logger is removed.
8. Both P.A. (primary air) fans are proven off when the PURGE PERMITS (White)
“P.A. FANS OFF” light is on.
9. When at least one of the three (Induced Draft) fans are proven not off, the “All I.D.
FANS OFF” signal at the Data Logger is removed.
10. When at least one of the two F.D. (Forced Draft) fan is proven not off, the “BOTH
F.D. FANS OFF” signal at the Data Logger is removed.
11. When the air flow is greater than 30%, the “AIR FLOW < 30% TRIP” signal at the
Data logger is removed and the PURGE PERMITS (White) “AIR FLOW > 30 %”
light comes on.
12. The auxiliary air dampers are proven modulating on all nine elevations when the
PURGE PERMITS (White) “AUX AIR DMPRS MOD” light comes on (See “Post
Purge Excursion Protection” section for specifics.
13 The windbox to furnace differential pressure is proven satisfied when the PURGE
PERMITS (White)”W/B FURN P SATIS” light comes on.
14 The Deaerator Level is “not low-low” when the “LOW/LOW DEAERATOR LEVEL”
signal at the Data Logger is removed.
15 When all of the purge requirements are proven satisfied, the PURGE CYCLE
(White) “PURGE READY” light comes on (See Note 2).
NOTE 2
If the light does not come on after items 1 thru 14 mentioned above have been
satisfactorily completed, check to ensure that all of the following conditions are
satisfied.
A. A “furnace pressure high trip” signal does not exist. The “FURN PRESS HIGH”
signal at the Data Logger is removed.
C. The heavy fuel oil (H.F.O) trip valve is proven closed when PURGE PERMITS
(White) “TRIP VLV CLOSED” light is on.
D. The H.F.O nozzle valves on all four oil elevation are proven closed when the
PURGE PERMITS (White) “NOZL VALVES CLOSED” light is on.
E. The pulverizers on all eight coal elevations are proven off when the PURGE
PERMITS (White) “PULVS OFF” light is on.
G. All hot air gates are proven closed when the PURGE PERMITS (white) “HOT AIR
GATES CL.” light is on.
H. The flame scanners on all nine elevations indicate “no flame” when the PURGE
PERMITS (white) “SCANRS NO FLAME” light is on
I A “no boiler trip command” exists. This is indicated by the PURGE PERMITS
(white) “ NO B.T.” light being on.
When items 2,11,15c,15d,15e,15f and 15h mentioned above are satisfied, a five
minute counting period is started (see “ Post Purge Excursion Protection” section for
specifics).
After the “PURGE READY” light comes on, the furnace purge cycle can be started.
The PURGE CYCLE (green) “ PUSH TO PURGE” light will also be on because a master
fuel trip memory signal exists at MFT “ A” and/or MFT “B” (the (red))” MFT A TRIP”
and /or “MFT A TRIP” and / or “MFT B TRIP” lights are on).
The furnace purge cycle is started when the “PUSH TO PURGE” illuminated push
button is momentarily depressed. This action will turn on the PURGE CYCLE (amber)
“PURGING” light and start a five minute counting period. The “PURGING” light
remains on during the entire counting period (see Note 3)
NOTE 3
If the “PURGING” light goes off before the five minute counting period expires, this
indicates that at least one purge permissive is no longer satisfied (item 1 thru 15
above). The purge permissive must be re-established (“PURGE READY” light is on)
and another furnace purge cycle started by momentarily depressing the “ PUSH TO
PURGE “ push button.
When the five minute counting period expires (and the “PURGING” light remained on),
a successful furnace purge cycle has been completed and the following events will now
occur:
18 Two separate “no master fuel trip” memory signals are established, causing the
following events to occur:
A. The (green) “MFT A RESET” and “MFT B RESET” lights come on.
F. The “MFT A TRIPPED” and “MFT B TRIPPED” signals at the Data Logger are
removed.
G. The pulverizer’s and feeder’s can now be placed in the AUTO mode of operation,
when it is deemed necessary
H. The pulverizer’s and feeder’s can now be placed in service after other permissives
are satisfied.
I. The “trip primary air fans” signal is removed. The “TRIP P.A. FANS” signal at the
Data Logger is removed.
J. A five minute counting period is reset which allows the primary air (P.A.) fans to
be started.
K. A five second counting period is reset which will allow the “loss of fuel trip
arming” memory signal to be established when other permissives are satisfied
(see “Oil Elevation Start” section for specifics).
M. The heavy oil trip valve can now be opened (see “Heavy Oil Trip Valve Operation”
section for specifics).
The heavy oil trip valve must be opened to heat the heavy oil before a furnace purge
cycle is started and a “master fuel trip” exists (both (red) “MFT A TRIP and “ MFT B
TRIP” light are on). This is accomplished by initially opening the heavy oil
The heavy oil trip valve is energised to “open” when the H.O. TRIP VLV “ OPEN” push
button is depressed. When the trip valve is moved from “closed” position, the (red)
“OPEN” push button is illuminated. The trip valve is proven fully when the associated
(green) “CLOSE” light goes off.
The heavy oil is reciruclated so that the heavy fuel oil header temperature is satisfied.
The heavy fuel oil supply pressure must also be satisfied. When these two conditions
are satisfied, the heavy oil trip valve must be closed before a Furnace Purge can be
started (see “Furnace purge” section, item 15c).
When a “no master fuel trip” signal is established (both (green) “MFT A RESET” and
“MFT B RESET” lights are on), the heavy oil trip valve can now be reopened if all of the
following conditions are satisfied:
1. All heavy oil nozzle valves remain closed (PURGE PERMITS (White)”NOZL VALVS
CLOSED” light is on).
The heavy oil trip valve is energised to “Open” when the H.O. TRIP VALV “OPEN” push
button is depressed. when the trip valve is moved from “closed” position, the (red)
“OPEN” push button is illuminated and the (white) “PURGE READY” light goes off.
The “elevation trip” signal at all four oil elevations (AB,CD,EF and GH) is removed and
the “elevation start permit” is now “ armed”.
The heavy fuel oil trip valve can be closed by depressing the H.O. TRIP VALVE
“CLOSE” push button.
The heavy fuel oil trip valve will be closed automatically if any of the following
conditions exist :
4. Any heavy oil nozzle is not closed and a “master fuel trip” signal is established.
5. After any heavy fuel oil nozzle valve is not closed and any of the following
conditions exist for more than two seconds.
A. The heavy fuel oil pressure is “low”, data logger receives a signal.
- OR -
C. The heavy fuel oil header temperature is “low-low”, data logger receives a signal.
HEAVY OIL ELEVATION “AB” START (Typical for Elevations CD,EF & GH)
All heavy oil elevations (AB,CD,EF & GH) are placed in service in the same manner.
The “oil elevation start permit” must initially be established. The permit was “armed”
when a “no master fuel trip” signal was established and the heavy fuel oil trip valve
was proven fully open. The “oil elevation start permit” will now be established when
the following condition is satisfied (see Note 4):
- AND -
NOTE 4
When any feeder is “proven” (feeder is on for more than fifty seconds). item 1 above is
no longer required to satisfy the “oil elevation start permit”.
When the “oil elevation start permit” is established, the oil elevation can be placed in
service in the “pairs” or “elevation” firing mode. The firing mode that is selected is
automatically determined by the status of the feeders.
The “pairs” firing mode is selected when all feeders are off for more than two seconds.
The “elevation” firing mode is selected when any feeder is proven or an “auto start
support ignition signal is established (see “Pulverizer Auto Start” section for specifics).
The following sections describe the operation of these two different firing modes.
The “pairs” firing mode is automatically selected when all feeders are off for more than
two seconds. Corners No. 1 and No. 3 are placed in service as one pairs. Corner No. 1
After the “oil elevation start permit” signal is established, the “corner Pair” can be
placed in service in the following manner:
1. Depress the PAIR 1-3 “START” push button (held depressed), the following events
occur:
A. The pair 1-3 “start memory” signal is proven established when the (red) “START”
push button is illuminated and the associated (green)”STOP” light goes off.
B. The “start corner No. 1” signal is established and the “start corner No. 3” signal is
“armed”.
C. The auxiliary air dampers in the associated oil elevation are closed.
2. When the “START” push button is released, the following events occur:
Each of the four oil elevation corners are placed in service in the same manner after
“start corner” signal is established.
The corner no. 1 oil gun is placed in service after the “start corner No. 1” signal is
established (see item 1.B. above), if all of the following conditions are satisfied:
5 The heavy fuel oil isolation valve is proven open-and- the atomising steam
isolation valve is open and the local control station the selector switch is proven
in the REMOTE position when the LOCAL CONTROL STATION-COR. 1 (red)
“REMOTE” light is on.
6 The associated high energy arc (HEA) ignitor “advance spark rod” signal is
established if the associated corner discriminating flame scanner proved “no
flame” (DISC FLAME SCANNER COR 1 (GREEN) “NO FLAME” light is on and the
associated (red) “FLAME” light is off). When the HEA ignitor is moved from the
“retracted’ position, the HEA IGNITOR - COR 1 (yellow) “ADVD” light comes on.
The HEA ignitor is proven advanced when the associated (green) “RETRD” light
goes off. The steam atomising valves “open” command is now “armed”.
8 When the oil gun is moved from the retracted position, the following events occur:
9. The oil gun is proven “advanced” when the OIL GUN COR 1 (green) “RETRO” light
goes off. The following events will also occur :
B. The “corner trip” signal is removed, removing the heavy fuel oil nozzle valves
“close” command.
C. The associated steam atomising valve’s “open” command is now established and
the “close” command is removed. The heavy fuel oil nozzle valve’s “open”
command is now “armed”.
10. When the steam atomising valve is moved from the closed position, redundant
signals are established to ensure that the “retract oil gun” signal and “corner
shutdown” signals remain removed.
11. When the steam atomising valve is opened, the following events will occur :
A. The HEA ignitor “spark” signal is proven established when the HEA IGNITOR
COR 1 (red) “SPARK” light comes and (see item 9. A. above).
B. The heavy fuel oil nozzle valve’s “open” command is now established (see item
9.C. above)
12. When the heavy fuel oil nozzle valve is moved from the “closed” position, the
following events occur:
13. The heavy fuel oil nozzle valve is proven fully open when the OIL VALVE COR 1
(green) “CLSD” light goes off.
14. The corner oil gun proves flame when the DISC FLAME SCANNER COR 1 (red)
“FLAME” light comes on and the associated (green) “NO FLAME” light goes off.
When the twenty five second counting period expires (see item 12.C above), the
HEA ignitors “spark” signal is removed and the HEA ignitor is retracted.
15. If the corner oil gun does not prove flame when the twenty five second counting
period expires, the HEA ignitor’s “spark” signal is removed and the HEA ignitors
“spark” signal is removed and the HEA ignitor is retracted and the heavy fuel oil
nozzle valve is closed.
16. When the “heavy fuel oil flow satisfactory” signal is established and the heavy oil
nozzle valve remains fully open, the associated corner No. 1 oil gun is proven “in-
service”.
When the thirty second counting period expires (see item 2.A. above), the “start corner
No. 3” signal is established and the oil gun at corner No. 3 is placed in service in the
same manner as the oil gun at corner No. 1 (starting with item 3 above).
When the seventy second counting period expires (see item 2.B. above), a “corner trip’
signal is established if any of the following condition exist at the associated corner.
19. The heavy fuel oil nozzle valve is not fully open.
Corner pair 2-4 are placed in service in the same manner as corner pair 1-3.
When at least three of the four oil guns are “in-service” (heavy fuel oil nozzle valve is
fully open a fuel flow is adequate at the associated oil nozzle valve), a “H.F.O. elevation
in service” signal established. This is proven when the PULV START PERMITS (white)
“IGNITION PERMIT” lights comes on at both adjacent coal elevations.
When the seventy second counting period expires for either corner pair (1-3 or 2-4),
the Data Logger’s “UNSUCCESSFUL SPARK ROD RETRACTION” signal is established
if any HEA ignitor spark rod is not retracted on the associated oil elevations.
The auxiliary air dampers “close” command is removed and the auxiliary air dampers
on the associated oil elevation are positioned for “oil firing” when any of the following
conditions occur:
AND
The “ elevation start” memory signal does not exist for both pairs (1-3 and 2-4).
OR
The seventy second counting period expires for both pairs (1-3 and 2-4).
OR
At least three of the four oil nozzle valves are proven fully open and fuel flow is
adequate the associated oil nozzle valve.
The “elevation” firing mode operation is automatically selected when any feeder is
“proven” or “auto start support ignition” signal is established (see “Pulverizer Auto
Start” section for specifics).
After the “oil elevation start permit” signal is established, the associated oil elevation is
placed in service when the PAIR 1-3 or the PAIR 2-4 “START” push button is
depressed and then released. The oil corner pair 1-3 are placed in service in the same
manner as previously described in the “Pair Firing Mode Operation” starting with item
1 thru item 16.
When the thirty second counting period expires, the “start corner No. 3” signal is
established and the oil gun at corner No. 3 is placed in service in the same manner as
the oil gun at corner No. 1.
When the “start corner No. 3” signal is established, a thirty second counting period is
started. Thirty seconds later, the pair 2-4 “ started “ memory signal is established.
This is indicated by the PAIR 4 (red) “START” light coming on and the associated
(green) “STOP” light going off. The second pair (2-4) are now placed in service in the
same manner as pair 1-3. Corner No. 2 will be placed in service and then corner No. 4
will be placed in service after a delay of thirty seconds.
When both seventy second “elevation pair” counting periods expire, the Data Logger
will received “UNSUCCESSFUL START” signal for the associated oil elevation if a “HFO
elevation in service” signal is not established for more than two seconds. A “ HFO
elevation in service” signal does not exist when less than three of the four oil nozzle
valves or the associated oil nozzle valve indicating “inadequate” fuel flow.
All coal elevation ( A thru H) are placed in service in the same manner. The
pulverizers can be placed in service manually or automatically. Both procedures are
described in the following sections.
Prior to starting any pulverizer, the pulverizer ignition energy must be adequate to
light off coal. The Pulverizer ignition energy is adequate (to support coal firing) for the
coal elevation that is selected when the conditions listed below are satisfied.
Pulverize “A” :
NOTE 5
A “ HFO elevation in service” signal is established when at least three of the four oil
nozzle valves are proven fully open and fuel flow is adequate at the associated oil
nozzle valve.
OR
2. Elevation B feeder is “proven” (feeder is on for more than fifty seconds) and the
associated feeder speed is operating at greater than 50 % and the boiler load is
greater than 30 %.
Pulverizer “B” :
OR
Pulverizer “C” :
OR
Pulverizer “D” :
OR
Pulverizer “E” :
OR
OR
Pulverizer “F” :
OR
Pulverizer “G” :
OR
OR
Pulverizer “H” :
OR
The “pulverizer ignition permit” is proven established when the PULV START PERMITS
(white) “IGNITION PERMIT” light comes on. The pulverizer on the associated coal
elevation can now be placed in service after other permissives are satisfied.
Pulverizer Ready
Prior to starting a pulverizer, a “Pulverizer Ready” signal for the selected pulverizer
must be established. This signal is established when all of the following conditions are
satisfied:
C. A “no master fuel trip” memory signal remains established. The pulverizer start
permit” signal is proven established when the PULV START PERMITS (white)
“START PERMIT” light is on.
After any feeder is proven, items A & B above are no longer required to satisfy the
“pulverizer start permit”.
2. The “primary air permit” signal is satisfied. There are two separate “pulverizer
primary air permit” signals. One signal is used for pulverizers A,B,C and D. The other
signal is used for pulverizers E,F,G and H. The “primary air permit” signal (for
pulverizers A,B,C and D) is established when the following conditions are satisfied :
OR
At least one F.D. fan is on and at least one P.A fan is on and less than four pulverizers
are on
B. The hot primary air duct pressure (for pulverizers A,B, C,D) is “not low”
C. The hot primary air duct pressure (for pulverizers A,B,C,D) is “not low-low”.
The “primary air permit” signal (for pulverizers E,F,G,H) is established when the
following conditions are satisfied:
AND
E. The hot primary air duct pressure (for pulverizers E,F,G,H) is “not low”
AND
F. The hot primary air duct pressure (for pulverizers E,F,G,H) is “not low-low”.
The “primary air permit” signal is proven established when the ‘PULV START
PERMITS (white) “P.A. PERMIT” light comes on. After the associated pulverizer is
on, the “primary air permit” is no longer required at pulverizer that is on.
4. The pulverizer outlet temperature is proven less than 2000 F when the PULV start
permits (white) “ OUTLET < 2000 F light comes on.
5. At the pulverizer hydraulic journal system, the hydraulic pump control is placed
in the REMOTE and AUTO positions. When this condition is satisfied, the
PULV START PERMITS (white) “ JRNL CTRL PERMIT” light comes on.
6. The feeder controller is proven in the REMOTE position when the PULV START
PERMITS (white) “FDR IN REMOTE “ light is on.
7. The cold air gate is proven open when the PULV START PERMITS (white) “COLD
AIR GATE OP” light is on.
8 The tramp iron hopper valve is proven open when the PULV START PERMITS
(white) “TRAMP IRON VLV OP” light is on.
9. The feeder inlet gate is proven open when the PULV START PERMITS (white)
“FDR INLET GATE OP” light is on.
12. The PULV START PERMITS (white) “SATIS LUB LVL & TEMP” light comes on
when the lube oil sump level is adequate and the lube oil temperature is greater
than 320C. After the pulverizer is on, this permissive is not required to keep the
“pulverizer ready” signal established at the pulverizer that is on.
13. A “pulverizer trip” signal does not exist when PULV START PERMITS (white) “NO
PULV TRIP” light is on (see “Pulverizer in Service” section for specifics).
After item’s 1 thru 13 above are satisfied, the PULV START PERMITS (white) “PULV
READY” light comes on. This indicates that the pulverizer an now be placed in service
if the “pulverizer ignition permit” remains satisfied (PULV START PERMITS (white)
“IGNITION PERMIT” light is on).
MANUAL START
The associated pulverizer can be placed in service manually after the PULV START
PERMITS (white) “IGNITION PERMIT” and “PULV. READY” light are on. The pulverizer
is placed in the manual mode of operation by depressing the PULV MODE “MANUAL”
push button momentarily. The “manual mode” memory signal is proven established
when the (green) “MANUAL” push button is illuminated and the associated (red)
“AUTO” light is off.
The pulverizer can now be placed in service manually in the following manner:
Note 6
A “pulverizer start” memory signal is also established if a “auto start pulverizer” signal
is established“ .
B. The pulverizer seal air valve’s “close” command is removed and the “open
command is established. The seal air valve is proven open when the SEAL AIR
VLV (red) “OPENED” light is on and the associated (green) “CLOSED” light is off.
2. After the pulverizer seal air valve is opened and the seal air header to pulverizer
underbowl differential pressure is proven greater than 8 inches w.c., the PULV
START PERMITS (white) “SEAL AIR PRESS SAT.” light comes on. When this
light comes on, the “pulverizer start” signal is established (see item 1.A. above).
3. When the pulverizer is on, it establishes a “pulverizer on” memory signal. The
following events will now occur.
A. The PULV (red) “START” push button is now illuminated and the associated
(green) “STOP” light goes off.
B. The ten second counting period is reset (see item 1.D. above). If the pulverizer is
not on when this ten second counting period expires, the pulverizer is tripped.
H. The cold air dampers are opened to the “100% pulverizer air flow position” and
the “run cold air dampers to < 5% open” signal is removed.
J. If the pulverizer lube oil pump is off, the Data Logger receives a “PULV LUBE OIL
PRESS. LOW” signal. If this signal remains for more than ten seconds, the
pulverizer is tripped.
L. The pulverizer hydraulic journal system is now affected in the following manner.
a. The Data Logger receives a “PULV JOURNAL HYDRAULIC LEVEL LOW” signal, if
the hydraulic fluid level is low.
d. When the journal hydraulic pressure is satisfactory, the associated feeder can be
started.
e. When the 120 second counting period expires, the Data Logger receives a “PULV.
JOURNAL HYDRAULIC PRESSURE LOW” signal if the pressure is low. The
associated feeder cannot be placed in service. Corrective action must be taken.
4. After the pulverizer is proven on, the hot air gate should now be opened to
establish the desired coal/air temperature at the pulverizer outlet.
The hot air gate will receive an “open” command after the HOT AIR GATE “OPEN” push
button is depressed (see Note 7 ).
NOTE 7
The hot air gate will also receive an “open” command automatically (after the
pulverizer is on), if a “auto open hot air gate” signal is established. See Pulverizer
Operation Auto Start” section.
A. When the hot air gate is moved from the closed position, the (red) “OPEN” push
button is illuminated. The “ open cold air damper to 100 % pulverizer air flow
position” signal is now removed.
B. The hot air gate is proven open when the associated (green) “CLOSE” light goes
off. The pulverizer temperature control will now receive a “release air and
temperature control to AUTO” signal.
5. It should be noted that the feeder can be placed in service in the MANUAL MODE
of operation without opening the hot air gate.
6. The feeder can now be placed in service, if the following conditions remain
satisfied:
G. The “feeder speed demand at minimum” signal is established because the feeder
is off.
7. The feeder is now placed in service when the FEEDER “START” push button is
held depressed. The following events will occur.
A. The one hundred eighty “ignition permit required” counting period is reset.
C. If the feeder discharge chute is not plugged, the feeder “start” signal is
established. The feeder is proven on when the (red) “START” push button is
illuminated and the associated (green) “STOP” light goes off. The “feeder seal in “
signal is now established and the “START” push button can be released (after it is
illuminated). When the push button is realised the 180 second counting period
is started (see item A above).
8. When the five second counting period expires (see item 7.B. above), the following
events can occur :
A. The Data Logger receives a “NO COAL FLOW” signal if the “coal on belt” signal
does not exist.
AND
10. If the feeder goes off after it was on, the five second counting period is started (see
item 9.C.c. above). The following events will occur which will minimize the
possibility of a pulverizer fire, if the hot air gate is not closed.
B. The cold air dampers are opened to the “ 100% pulverizer air flow” position.
C. The pulverizer temperature control’s air and temperature control is removed from
AUTO.
D. A thirty second counting period is started. Thirty seconds later, the hot air gate
is closed.
E. When the hot air gate is closed, the hot air dampers “close” signal is removed if
the pulverizer outlet temperature remains less than 2000F. The cold air dampers
will remain in the “100 % pulverizer air flow “position.
11. When the fifteen second counting period expires (see item 9.A. above), the
“include feeder in totalizing circuit” signal is established.
12. When the fifty second counting period expires (see item 9.B. above), a “feeder
proven” memory signal is established and the following events occur:
A. The “release feeder speed to auto” signal is now established because the “run
feeder speed demand to minimum” signal was previously removed (see item
9.C.a. above).
B. If at least two of the four scanner indicate flame on the associated flame scanner
elevation, the FIREBALL FLAME SCANNERS (red) “ELEV FLAME” light is on and
the associated (green) “ELEV NO FLAME “ light is off.
When the 180 second counting period expires (see item 7.C. above), this indicates that
the feeder is established and the furnace flame has stabilized. The “Pulverizer ignition
energy” that was initially required to support coal firing is no longer required (see
“Pulverizer Ignition Permissives” section for specifics) and can now be removed.
OPERATOR NOTE
A signal feeder in service for more than fifty seconds at its minimum speed on
approximately 25 % constitutes a “Fireball Established”. A signal “Fireball” results
when an elevation is in service. Additional elevations placed in service merely enlarges
this single “Fireball”. The established “Fireball” is monitored by the associated flame
scanners.
Only in an emergency situation would an operator select and start an elevation remote
from one that is already in service. In this case, good operator procedure dictates that
the second feeder be placed in service and “pulverizer ignition energy” be maintain
unit both feeders are loaded to greater than 50 % before ignition energy is removed.
When removing feeders from service, the inverse procedure should be followed. The
“pulverizer ignition energy” should be reinstated when only two feeders are in service
and operating at less than 50 % loading.
Auto Start
The associated pulverizer can be placed in service automatically after the PULV START
PERMITS (white) “IGNITION PERMIT” and “PULV READY” lights are on.
The pulverizer is placed in the automatic mode of operation by depressing the PULV
MODE “AUTO” push button momentarily. The “auto mode” memory signal is proven
established when the (red) “AUTO” push button is illuminated and the associated
(green) “MANUAL” light is off.
The pulverizer can now be placed in service automatically in the following manner :
1. Momentarily depress the PULV “START” push button, the following events will
occur:
A. A 210 second” elevation start” counting period is reset and then started.
3. The “auto start pulverizer” signal will now place the pulverizer in service in the
same manner as previously described in the “Pulverizer Operation Manual Start”
section starting with item 1 (see Note 6).
4. After the pulverizer is proven on, the “auto open hot air gate” signal will open the
hot air gate in the same manner as previously described in the “Pulverizer
Operation Manual Start’ section, starting with item 4 (see Note 7)
5. When the Pulverizer is on, the sixty second counting period is now started (see
item 2 above when the sixty second counting period expires, an “auto start
feeder’ signal is established for five seconds.
6. After the hot air gate is proven open (HOT AIR GATE (green) “CLOSE” light is off)
AND the “auto start feeder” signal is established, the following events will occur :
A. The one hundred eighty “ignition permit required” counting period is reset.
C. If the feeder discharge chute is not plugged, the feeder “start” signal is
established. The feeder is proven on when the FEEDER (red) “START” light is on
and the associated (green) “STOP” light is off. The “feeder seal in” signal is now
established. If the “feeder seal in signal is not established when the “auto start
feeder” signal is removed (after five seconds), the feeder is tripped.
7. The feeder is placed in service in the same manner as previously described in the
“Pulverizer operation - Manual Start” section, starting with item 8.
10. The cold air dampers are opened to the “100 % pulverizer air flow” position.
11. The hot air gate is closed after a delay of thirty seconds.
12. When the feeder is off for more than three minutes, the associated pulverizer is
stopped.
Pulverizer in Service
During normal operation as the unit load increases and decreases, the individual
pulverizers share the load. When the average loading with pulverizers in service
exceeds 80 %, an additional pulverizer should be placed in service. When the average
loading with the pulverizers in service is reduced to less than 40 %, a pulverizer
should be taken out of service.
When pulverizer and associated feeder are in service, they are subject to the following
operational checks :
1. Any of the following conditions will run the feeder speed to minimum until the
initiating condition is corrected:
2. Five seconds after the “feeder start” command is established, “no coal on belt”
and “pulverizer power less than min. “will trip the feeder. The Operator should
take appropriate corrective action, then restart the feeder. If the hydraulic oil
pressure is inadequate, the feeder will be tripped.
3. A high pulverizer outlet temperature (above 200 F) will close the hot air gates and
open the cold air dampers to the “100 % pulverizer air flow” position after the air
and temp. control are released form auto control.
The high temperature signal will then close the hot air gate after a time delay of
thirty seconds. (see Caution Note).
CAUTION
A. Elevation power or Unit power is lost for more than two seconds.
D. Pulverizer lube oil pressure is not on and associated pulverizer is on for more
than ten seconds.
E. Pulverizer lube oil pressure is “not adequate” and pulverizer is on for more than
ten seconds.
F. Pulverizer ignition energy not available when support ignition is required (before
expiration of the three minute ignition time period).
NOTE 8
A “primary air trip” exists when the following conditions exists at the elevations listed
below:
Elevations A,B,C,D:
1. Any pulverizer is on
AND
All F.D. fans are off or all P.A. fans are off
OR
2. For Pulverizer A,B,C,D, the hot primary air duct pressure is “Low - Low”
OR
3. For Pulverizer A, B, C, D, the hot primary air duct pressure is “low” for more than
five seconds.
Elevations E,F,G,H:
OR
5. For Pulverizer E,F,G,H, the hot primary air duct pressure is “Low - Low”
OR
If at least five pulverizers are on and less than two F.D. fans are on or less than
two P.A. fans are on, the following events occur:
7. Pulverizer “H” is tripped immediately, then at two second intervals pulverizer G,F
and E are tripped. After pulverizer “H” is tripped, the pulverizers will only be
tripped until four pulverizers remain in service. The “primary air trip” signal is
then removed. More than four pulverizers can only be placed in service when
both F.D. and both P.A. fans are on.
A “pulverizer trip” signal is proven established when the PULV START PERMITS
(white) “NO PULV TRIP” light goes off.
UNIT SHUTDOWN
When the unit is shutdown, the pulverizers should be removed from service and then
the oil elevation are shutdown.
PULVERIZER SHUTDOWN
The pulverizers can be removed from service in the “manual” or “automatic” mode of
operation. The loading should be reduced and then the pulverizer is shutdown. All
coal elevations (“A” thru “H”) are removed from service in the same manner.
Manual Shutdown
When the pulverizer is in the auto mode of operation (PULV MODE (green)”MANUAL”
light is on and the associated (red) “AUTO” light is off), the pulverizer on the associated
coal elevation is removed from service in the following manner:
1. If the associated oil elevation is not in service, start the oil elevation.
2. Reduce the feeder speed to minimum. This will automatically remove the feeder
speed from AUTO control.
3. Close the hot air gate by depressing the associated HOT AIR GATE “CLOSE” push
button. The hot air dampers are closed, the air and temperature control is
removed from AUTO control and cold air dampers are opened to the “100 %
pulverizer air flow” position. Thirty seconds later, the hot air gate “close”
command is established.
When the hot air gate is moved from the fully open position the HOT AIR GATE
(green) “CLOSE” light comes on. The hot air gate is proven closed when the
associated (red) “OPEN” light goes off.
A. The “start feeder” signal is removed and two seconds later the “feeder seal in”
signal is removed.
B. The feeder is proven off when the (green) “STOP’ push button is illuminated and
the associated (red) “START” light is off.
C. The “feeder off” memory signal is established and the “feeder proven” memory
signal is removed.
D. The fifteen second counting period is reset which removes the “include feeder in
totalizing circuit” signal.
F. A fifty second counting period is started. Fifty seconds later, the associated
elevation of fuel air dampers are closed.
5. Allow the pulverizer to run until it is completely empty of coal, then shut down
the pulverizer by depressing the associated PULV “STOP” push button. The
pulverizer is proven off when the associated (green) “STOP” push button is
illuminated and the associated (red) “START” light is off. The pulverizer seal air
valve is closed, the pulverizer hydraulic journal system’s hydraulic pump is
shutdown and the pulverizer discharge valve can now be closed, if it is deemed
necessary.
6. The pulverizer discharge valve should be left open to allow air flow to exist
through the pulverizer when it is not in operation.
7. The associated oil elevation is shutdown once furnace conditions have stabilized
(see “Oil Elevation Shutdown” section for specifics).
Auto Shutdown
When the pulverizer is in the auto mode of operation (PULV MODE (red) “AUTO” light
is on and the associated (green) “MANUAL” light is off), the pulverizer on the
associated coal elevation is removed from service in the following manner:
1. Depressing the PULV “STOP” push button momentarily will cause the following
events to occur simultaneously:
C. A ten minute “elevation stop” counting period is reset and then started.
D. An “auto start support ignition” signal is established and the associated oil
elevation is placed in service in the “elevation firing mode”.
2. When the “pulverizer ignition permit” signal for the associated coal elevation is
established (PULV START PERMITS (white) “IGNITION PERMIT” light is on) AND
both seventy second counting periods have expired, the following events occur:
B. A “auto close hot air gate” signal is established, causing the following events to
occur:
b. The air and temperature control are released from AUTO control.
c. The cold air dampers are opened to the “100 % pulverizer air flow” position.
d. A thirty second counting period is started. Thirty seconds later, the hot air gate
is closed.
3. When the hot air gate is proven closed (HOT AIR GATE (red) “OPEN” light is off)
AND the pulverizer outlet temperature is less than 130 F , an “ auto stop feeder
signal is established.
4. The feeder is now shutdown in the same manner as previously described in the
“Manual shutdown” section , item 4.
5. When the feeder is off, a three minute counting period is started. Three minutes
later, a “auto stop pulverizer” signal is established.
7. When the ten minute counting period expires (see item 1.C. above). The Data
Logger will receive a “UNSUCCESSFUL AUTO PULVE SHUTDOWN” signal if the
following conditions are satisfied.
OR
OR
8. The pulverizer discharge valve can now be closed, if it is deemed necessary. The
pulverizer discharge valve should be left open to allow air flow to exist through
the pulverizer when it is not in operation.
9. The associated oil elevation is shutdown once furnace conditions have stabilized.
All oil elevation (AB, CD,EF,GH) are shutdown in the same manner.
The oil elevations can only be shutdown manually. The oil elevation can be shutdown
if the “elevation” firing mode exists or if the “pair” firing mode exists. The shutdown
procedure for both firing modes is described in the following sections.
If all feeders are off for more than two seconds, the “pairs firing mode is automatically
selected.
When “pairs” firing mode is selected, either pair (1-3 or 2-4) can be initially removed
from services. Both pairs are shutdown in the same manner.
Initially, it is assumed that pair 1-3 will be shutdown. This pair is shutdown in the
following manner:
1. Momentarily depress the PAIR 1-3 “STOP” push button, the following events will
occur simultaneously:
A. The “pair stop” memory signal is proven established when the (green) “STOP”
push button is illuminated and the associated (red) “START” light is off.
2. Corner No. 1 is shutdown in the following manner after “stop corner No. 1” signal
is established.
A. The heavy fuel oil nozzle valve at corner No. 1 receives “close: command.
3. When the oil nozzle valve is proven closed, the steam scavenge valve receives an
“open” command and the steam automizing valve receives a redundant “open”
command (atomizing valve is open). The HEA ignitor “spark rod” receives an
“advance” signal for fifteen seconds.
4. When the HEA spark rod is moved from the retracted position, the HEA IGNITOR
COR 1 (yellow) “ADVD” light comes on. The HEA spark rod is proven advanced
when the associated (green) “RETRO” light goes off. The spark rod is now
energized. When the fifteen second counting period expires, the “spark” is
extinguished and the spark rod is retracted.
5. The steam scavenge valve is proven fully open when the OIL VALVE COR 1
(white) “SCAV” light comes on. A five minute counting period is now started.
6. When the five minute counting period expires, a “scavenge complete” memory
signal is established. This signal causes the following events to occur:
A. The (white) “SCAV” light goes off and the steam scavenge valve is closed.
7. The “corner trip” signal sends redundant “close” signals to the heavy fuel oil
nozzle valve and the steam scavenge valve to reinsure that they are closed. A
“close” command is now established at the steam atomizing valve.
8. When the steam atomizing valve is closed, the oil gun receives a “retract” signal.
9. When the oil gun is moved from the advanced position, the OIL GUN COR 1
(green) “RETRD” light comes on and a redundant “ corner trip” signal is
established to ensure that the fuel oil, steam atomizing and scavenge valves are
closed.
10. The oil gun is proven retracted when the associated (red) “ADVD” light goes off.
The “scavenge incomplete” memory signal is now reestablished and a “corner
shutdown” signal is now established for corner No. 1.
The oil gun at corner no. 1 is now successfully shutdown. When the thirty
second counting period expires (see item 1.B. above) , the “stop corner No. 3”
signal is now established which was previously “armed” (see item 1. E. above).
Corner No. 3 oil gun is now shutdown in the same manner as previously
described for the oil gun at corner No. 1 starting with item 2 above.
The second corner pair (2-4) are removed from service in the same manner as
corner pair (1-3) when the PAIR 2-4 “STOP” push button is momentarily
depressed. The oil gun at corner No 2 is removed from service and thirty seconds
later corner No, 4 is removed from service in the same manner as previously
described for corner No. 1.
When the 340 seconds counting period for corners 2-4 is also expired, the
“elevation stopped and time expired” signal that was previously “armed” is now
established.
11. The Data logger receives a “UNSUCCESSFUL FUEL OIL ELEV. SHUTDOWN”
signal if the corner shutdown” signal was not established at any of the four
corners (see item 10 above).
12. The Data Logger receives a “UNSUCCESSFUL SPARK ROD RETRACTION” signal
if any of the four corner HEA ignitor spark rods were not retracted (HEA IGNITOR
COR (yellow) “ADVD” light is on).
13. An “elevation back up trip” memory signal is now established which establishes
redundant “corner trip” signals at all four corners on the associated oil elevation.
The auxiliary air dampers on the associated oil elevation can now be closed if
other permissives are satisfied.
If any feeder is “proven” the “elevation” firing mode is automatically selected. If any
feeder remains “proven” when the oil elevation is removed from service, the associated
oil elevation is removed form service in the following manner:
1. Depressing the pair 1-3 or the PAIR 2-4 “STOP” push button momentarily will
cause the following events to occur:
A. Corner pair 1-3 are removed from service in the same manner as previously
described in the “Pair. Firing Mode Shutdown” section, starting with item 1 and
through item 10.
B. When the “stop corner no. 3” signal is established, corner no. 3 is removed from
service and simultaneously a thirty second counting period is started.
All four corners are removed from service in the same manner as previously
described in the “Pair Firing Mode Shutdown” section.
CORNER SHUTDOWN
Any corner oil gun can be removed from service at the corner local control station.
IF the associated corner atomizing steam isolation valve remains open, a “stop corner”
signal can be established when the selector switch at the local control station is placed
in the “SCAVENGE” position. This is indicated by the LOCAL CONTROL STATION
COR (white) “SCAV” light coming on.
The “stop corner” signal is now established and the associated corner oil gun is
removed from service in the same manner as previously described in the “Pair Firing
Mode Shutdown” section starting with item 2.
If the local control station selector switch is placed in the “OFF” position, the LOCAL
CONTROL STATION COR (green) “OFF” light comes on. A “corner trip” signal is
established and the oil gun is shutdown without scavenging. The oil gun must then
be retracted by another procedure.
BOILER TRIP
A “boiler trip’ command stops all fuel inputs by tripping all of the pulverizers and
feeders and closing all heavy oil nozzle valves on all elevations.
There are two separate “boiler trip” commands in this unit. Both “no boiler trip”
command signals must be established before a furnace purge cycle can be initiated.
A “boiler trip” command will establish a “master fuel trip” memory signal. This is
indicated by the (red) “ MFT TRIP” light being on and the (green) “MFT RESET” light
being off.
When a “master fuel trip” memory signals established (red, “MFT TRIP” light is on), the
following events occur:
1. The (red) “MFT A TRIP” and MFT B TRIP” lights come on and the associated
(green) “MFTA RESET” and “MFT B RESET” lights go off.
2. The Data Logger receives a “MFT A TRIPPED” AND MFT B TRIPPED” SIGNALS.
When the “master fuel trip” memory signal is established (red, “MFT A TRIP” or
MFT B TRIP” LIGHT IS ON), the following events occur:
5. The PULV MODE (green) “MANUAL” light comes on, if it was off.
6. All pulverizers are tripped as indicated by the PULV START PERMITS (white) “NO
PULV TRIP” lights going off.
7. A five minute counting period is started. Five minutes latter, all cold air dampers
are opened to the “100 % pulverizer air flow position”.
9. The “oil elevation trip” memory signal is established at all oil elevations.
10. If all heavy fuel oil nozzle valves are not closed, the heavy fuel oil trip valve is
closed. The heavy fuel oil trip valve can then be reopened after all heavy fuel oil
nozzle valves are closed and the heavy fuel oil recirculation valve is opened.
11. A five second counting period is started. Five seconds later, the “loss of fuel trip
arming” signal is removed.
14. The upper and lower fuel air dampers are opened.
15. The auxiliary air control is transferred to MANUAL control and all auxiliary air
dampers are opened.
17. The “feed forward to furnace draft control” signal is established for thirty seconds
if the following conditions are satisfied:
A. The unit critical power is available for more than six seconds
AND
When this signal is established, item “B” is no longer required to keep this signal
established.
Thirty seconds later, the “feed forward to furnace draft control” signal is removed.
18. The furnace pressure recorder changes to a higher speed for thirty seconds.
20 Loss of customer’s 220 VDC Battery power for more than 2 ) seconds.
21. Loss of unit critical power for more than two seconds.
23. The water drum level is “low” for more than ten seconds.
24. The water drum level is high” for more than ten seconds.
29. The air flow is less than 30 % before the boiler load exceeds 30 %.
31. At least two of the three pressure switches indicate a “high furnace pressure trip”
condition.
32. At least two of the three pressure switches indicate a “low furnace pressure trip”
condition.
33. Both BOILER TRIP (emergency) push buttons are depressed simultaneously.
34. All feeders are off and loss of power exists at the elevation that is in service.
The “loss of fuel trip” signal becomes “armed” when the first oil elevation that is placed
in service has at least three of the four heavy oil nozzle valves proven fully open (OIL
VALVE COR (green) “CLOSED” lights are off). After the “loss of fuel trip” signal is
“armed”, a “loss of fuel trip” signal will be established if all of the following conditions
occur simultaneously:
A. At all coal elevation, the feeder is off or loss of elevation power exists. This
condition exists for more than two seconds
AND
At all four oil elevations all oil nozzle valves are closed or an “elevation trip” signal
is established at the associated oil elevation.
The “loss of fuel trip” signal is proven established when the Data Logger
receives a “LOSS OF ALL FUEL TRIP” signal.
B. At all coal elevations, the feeder is off or loss of elevation power exists. This
condition exists for more than two seconds.
AND
AND
At all four oil elevations, all oil nozzle valves are closed.
When the “master fuel trip” memory signal exists for more than five seconds
the “loss of fuel trip arming” memory signal is removed.
The Data Logger’s “LOSS OF ALL FUEL TRIP” signal will remain established if
item B above is satisfied. When the heavy oil trip valve is proven fully open (for
oil recalculation), this signal is removed.
NOTE 10
During light off and before any feeder is “proven” for more than two seconds, the
“fireball” flame scanners do not take part in the overall flame failure protection
systems. When any feeder is “proven” for more than two seconds, the system
automatically changes from flame failure protection of an individual fuel nozzle to a
After any feeder is “proven” for more than two seconds, the UNIT FLAME FAILURE
(amber) “ARMED” light comes on. After this light is on, a “unit flame failure “signal is
established when all five UNIT FLAME FAILURE (amber) “GH” and “FG” and “DF” and
“BC” and “AB” lights are all on simultaneously.
This is indicated when the Data Logger receives a “FLAME FAILURE TRIP” signal. This
signal causes a “master fuel trip” memory signal to be established (both (red) “BOILER
TRIP” lights come on).
When each fireball flame scanner elevation votes “no flame”, the associated UNIT
FLAME FAILURE (amber) light comes on at the associated fireball flame scanner
elevation. Listed below are the conditions that will cause this (amber)light to be
illuminated for the various fireball flame scanner elevations.
Elevation “AB”:
1. Feeder A is off or loss of elevation A power and Feeder B is off or loss of elevation
B power. This condition exists for more than two seconds.
OR
2. At elevation AB, less than three of the four heavy fuel oil nozzle valves are fully
open or fuel flow is not adequate at the associated oil nozzle valve or elevation AB
power is not available for more than two seconds and less than two of the four
“fireball” flame scanners indicate flame on elevation “AB”
OR
3. At elevation AB, less than three of the four heavy fuel oil nozzle valves are fully
open or fuel flow is not adequate at the associated oil nozzle valve or elevation AB
power is not available for more than two seconds and any elevation AB heavy fuel
oil nozzle valve is not closed or elevation AB power is not available for more than
2 seconds.
Elevation “BC”:
1. Feeder B is off or loss of elevation B power and Feeder C is off or loss of elevation
C power. This condition exists for more than two seconds.
2. Less than two of the four “fireball” flame scanners indicate flame on elevation
“BC”.
1. Feeder D is off or loss of elevation D power and Feeder E is off or loss of elevation
E power. This condition exists for more than two seconds.
2. Less than two of the four “fireball” flame scanners indicate flame on elevation
“DE”.
Elevation “FG”:
1. Feeder F is off or loss of elevation F power and Feeder G is off or loss of elevation
G power. This condition exists for more than two seconds.
2. Less than two of the four “fireball” flame scanners indicate flame on elevation
“FG”.
3. One elevation GH, any heavy fuel oil nozzle valve is not closed or elevation GH
power is not available for more than two seconds.
Elevation “GH”:
1. Feeder G is off or loss of elevation G power and Feeder H is off or loss of elevation
H power. This condition exists for more than two seconds.
OR
2. At elevation GH, less than three of the four heavy fuel oil nozzle valves are fully
open or fuel flow is not adequate at the associated oil nozzle valve or elevation GH
power is not available for more than two seconds and less than two of the four
“fireball” flame scanners indicate flame on elevation “GH”
OR
3. At elevation GH, less than three of the four heavy fuel oil nozzle valves are fully
open or fuel flow is not adequate at the associated oil nozzle valve or elevation GH
power is not available for more than two seconds and any elevation GH heavy fuel
oil nozzle valve is not closed or elevation GH power is not available for more than
2 seconds.
A “Cause of Trip” system has been incorporated which allows the Operator to
determine the cause of a master fuel trip which was initiated by a boiler trip
command.
The first boiler trip command that causes a master fuel trip (both (red) “BOILER TRIP”
lights come on), will illuminate the appropriate indicator in the CAUSE OF TRIP
section on the console insert. The Data Logger will also receive a corresponding
signal.
Any successive boiler trip commands to the other indicators are blocked. There will be
only one indicator that is illuminated.
When the furnace purge cycle is successfully completed (PURGE CYCLE (yellow)
“PURGE COMPLETE” light is on) and a “ no master fuel trip” memory signal is
established (both (red) “BOILER TRIP” lights are off), all CAUSE OF TRIP memories are
reset and there are no illuminated indicators.
A post purge excursion circuit has been designed into the Furnace Safeguard
Supervisory System. It operates as described below:
1. During the Furnace Purge Cycle, the following conditions are satisfied:
2. When all of these conditions are satisfied simultaneously, a five minute counting
period is started. After the five minute counting period expires, the following
events will occur:
A. A “post purge time expired” memory signal is established and a “post purge fan
trip” signal is established if a “high or low furnace pressure trip” signal is
established.
This is indicated when the Data Logger receives a “FURNACE PRESSURE HIGH”
or a “FURNACE PRESSURE LOW” signal.
B. The “open upper fuel air dampers” memory signal is removed, closing the upper
fuel air dampers. Simultaneously, a thirty second counting period is started.
When the thirty second counting period expires, the “open lower fuel air
dampers” memory signal is removed, closing the lower fuel air dampers.
Simultaneously, a five second counting period is started.
When the five second counting period expires, the auxiliary air dampers are now
released from manual to the auxiliary air control system and the “open auxiliary
air dampers” signal is removed. When all auxiliary air dampers are modulating,
item 12 in the “Furnace Purge” section is satisfied.
When any heavy fuel oil elevation has at least three of the four oil nozzle valves
fully open, the “post purge time expired” memory signal is removed which will
now prevent the “post purge fan trip” signal from being established. When the
heavy oil trip valve is moved form the closed position (for oil recalculation), the
five minute counting period is reset.
The operation of the various air fan control systems are described in the following
sections.
There are two primary air fans serving the unit. The primary air fans are used
primarily to transport the pulverized coal to the respective coal nozzles at each coal
elevation.
When a “master fuel trip” memory signal is established, the primary air fans are
tripped. When the “master fuel trip” signal exists for more than five minutes, all cold
air dampers are opened to the “ 100% pulverizer air flow position”.
When the furnace purge cycle is successfully completed and a “no master fuel trip’
signal is established (both (red) “BOILER TRIP” lights are off), the primary air fans can
be placed in service.
This is accomplished when the customer supplies a “any primary air fan start
command”. When this signal is established, the “open cold air dampers to 100%
pulverizer airflow position” memory signal is removed and all cold air dampers on all
coal elevations (“A” thru “H”) are positioned to “less than 5 % open” because the
associated pulverizers are off.
When all elevation coal air dampers are positioned to “less than 5 % open”, the “permit
to start P.A. fans” signal is established.
The second primary air fan can now be placed in service, when it is required.
There are two separate “pulverizer primary air permit” signals. One signal is used for
pulverizers A, B, C, D. The other signal is used for pulverizers E,F,G,H. The “primary
air permit” signal (for pulverizers A,B,C and D) is established when the following
conditions are satisfied:
OR
At least one F.D. fan is on and at least one P.A. fan is on and less than four
pulverizers are on
AND
2. The hot primary air duct pressure (for pulverizers A,B,C,D) is “not low”
AND
3. The hot primary air duct pressure (for pulverizers A,B,C,D) is “not Low-Low”
The “primary air permit” signal (for pulverizers E,F,G,H) is established when the
following conditions are satisfied:
AND
5. The hot primary air duct pressure (for pulverizers E,F,G,H) is “not low”
AND
6. The hot primary air duct pressure (for pulverizers E,F,G,H)is “not Low- Low”
The “primary air permit” signal is proven established when the PULV START
PERMITS (white) “P.A. PERMIT” light comes on. After the associated pulverizer is
A “primary air trip” signal will trip any pulverizer that is in service (PULV START
PERMITS (White) “NO PULV TRIP” light goes off). A “primary air trip” signal is
established at pulverizers A,B,C and D when the following condition exists:
7. Any purlveriser is on
AND
All P.A. fans are off or all F.D. fans are off
OR
The hot primary air duct pressure is “low” for more than five seconds or the hot
primary air duct pressure is “low-low”.
A “primary air trip” signal is established at pulverizers E,F,G AND H when the
following conditions exists:
OR
The hot primary air duct pressure is “low” for more than five seconds or the hot
primary air duct pressure is “low-low”.
11. If at least five pulverizers are on and less than two F.D. fans are on or less than
two P.A. fans are on, the following events will occur:
B. After pulverizer “H” is tripped, the pulverizers will only be tripped until four
remain in service. The “primary air trip” signal for pulverizers E,F,G,H is now
removed.
The Data Logger will receive signals when any of the following conditions exist:
14. Both P.A. fans are off and any pulverizer is on.
The are two (2) scanner air fans service the unit. The scanner air fans can be placed
in service manually or automatically. Both procedures are described in the following
sections.
When both F.D. fans are off, the scanner air emergency dampers are opened. The
dampers are proven open when the SCANNER AIR (red) “EMERG DAMPR OP” light is
on and the assocaited (green) “EMERG DMPR CL” light is off. When a least one F.D.
fan is not off (“on”), the scanner air emergency dampers are closed.
Manual Operation
Either scanner air fan can be placed in service manually in the following manner:
2. A “scanner start” memory signal is established. The associated scanner air fan
recieves a “start” command. Simultaneously, a two second counting period is
started if both scanner fans are off.
3. The associated scanner air fan motor is started. The scanner air fan is proven on
when the SCANNER FAN (red) “START FAN” push button is illuminated. The
associate (green) “STOP FAN” light goes off. The following events will also occur:
A. The associated scanner air fan outlet damper receives an “open” command. The
scanner fan outlet damper is proven open when the (red) “FAN OUTLET DAMPER
OPEN” light comes on.
B. A five second counting period is started if the other scanner air fan is off. Five
seconds later, the associated scanner air fan’s outlet damper receives a “close”
command and is closed. The outlet damper is proven closed when the
associated (red) “FAN OUTLET DAMPER OPEN” light goes off.
4. If bothscanner air fans remain off when the two second counting period expires
(see item 2 above), the “LOSS OF EITHER SCANNER FAN” signal at the Data
Either scanner air fan can be removed from service manually if the scanner
duct to furnace differential pressure is greater than 6 inches w.g. This is
accomplished in the following manner.
5. Momentarily depress the SCANNER FAN “STOP FAN” push button. The following
events will occur:
A. The “scanner start” memory signal is removed. This removes the scanner air fans
“start” command.
B. The scanner air fan is proven off when the (green) “STOP FAN” push button is
illuminated and the associated (red) “START FAN” light is off.
C. If the other scanner air fan is on, the scanner air fan outlet damper at the
scanner air fan that stopped will be closed after a delay of five seconds.
D. If the other scanner air fan is off, the scanner air fan outlet damper at the
scanner air fan that was stopped will remain open even though the “open”
command was removed.
Automatic Operation
The scanner air fans will be placed in service automatically if the scanner duct to
furnace differential pressure is less than six inches w.g. (see note 11).
NOTE 11
If the scanner duct to furnace differential pressure remains at less than six inches
w.g. for more than ten seconds, the Data Logger receives a “LOSS OF SCANNER
COOLING AIR “ signal.
The scanner air fans are placed in service in the following manner:
1. Scanner air fan “A” “scanner start” memory signal is established and scanner air
fan “A” is placed in serivice in the same manner as previously described in the
“Manual Operation “section, starting with item 2. Simultaneously, a five second
counting period is started.
2. When the five second counting period expires, scanner air fan “B” is placed in the
same manner as previously described in the “Manual Operation” section, starting
with item 2.
If loss of unit critical power exists for more than two seconds, both scanner air
fans ( A and B) are started and both scanner air fan outlet dampers are opened
simultaneously.
3. The “scanner start” memory signal at scanner for “B” is removed and a ten
second counting period is started.
4. “Scanner air fan “B” is removed from service in the same manner as previously
described in the “Manual Operation” section, starting with item 5.
5. When the ten second counting period expires (see item 3 above) the “scanner
start” memory signal at scanner fan “A” is removed if the scanner duct to furnace
differential pressure remains greater than 24 inches w.g. Scanner air fan “ A” is
removed from service in the same manner as previously described in the “Manual
Operation” section, starting with item 5.
There are four seal air fans that serve the unit. Two seal air fans are used for
pulverizers A,B,C,D and the other two seal air fans are used for pulverizers E,F,G,H.
Both pair of seal air fans are placed in service and removed from service in the same
manner.
Seal air fans No. 1 and No. 2 are used with pulverizers A,B,C,D. Seal Air fans No. 3
and No. 4 are used with pulverizers E,F,G,H. The air fans can be placed in service and
removed from service manually or automatically. Both procedures are described in
the following sections.
The operation of seal air fans No. 1 and No. 2 will only be described. Seal air fans No.
3 and No. 4 operation is indentical.
Manual Operation
Either seal air fan can be placed in service manually in the following manner:
1. Momentarily depress the SEAL AIR FAN No.1 or the SEAL AIR FAN No. 2 push
button. The following events occur:
2. A “seal start” memory segnal is established. The associated seal air fan receives
a “start” command. Simultaneously, a two second counting period is started if
both seal air fans (No. 1 and No. 2) are off.
A. The associated seal air fan discharge damper receives an “open” command. The
seal air fan discharge damper is proven open when the associated (green) “FAN
OUTLET DMPR CL” . light is off. The associated (red) “FAN OUTLET DMPR OP”
light came on when the discharge damper was not closed.
4. If both seal air fans remain off when the two second counting period expires (see
item 2 above), the “SEAL AIR FAN 1 & 2 OFF > 2 SEC” signal at Data logger is
established. If this signal is established, both seal air fans (No. 1 and No. 2)
receive “start” commands and are placed in service simultaneously.
If both seal air fans are on (No. 1 and No. 2) , only one of the seal air fans can
be stopped. This is accomplished in the following amnner:
5. Momentarily depress the SEAL AIR FAN NO. “STOP FAN” push button. The
following events will occur:
A. The “seal start” memory signal is removed and the “seal stop” memory signal is
established.
B. The seal air fan is proven off when the (green) “STOP FAN” push button is
illuminated and the associated (red) “START FAN” light goes off.
Automatic Operation
The seal air fans will be placed in service automatically in the following amnner:
1. When either P.A. fan is on, a two “start” command is established and a “seal
start” memory signal is established at seal air fan No. 1 and seal air fan No. 1 is
placed in service in the same manner as previously described in the “Manual
Operation” section, starting with item 2.
2. When either P.A. fan is on and if the seal air header to cold air duct differential
pressure is less than four inches w.g. (pulverizers A,B,C,D) for more than ten
seconds, the Data logger recieves a “SEAL AIR HEADER/COLD AIR DUCT P LOW
> 10 SEC (PULV’S A,B,C,D)” signal and a “seal start” memory signal is
established at seal air fan No. 2.
Seal air fan No. 2 is then placed in service in the same manner as previously
described in the “Manual Operation” section. starting with item 2.
Each coal elevation’s pulverizer has an associated lube oil pump system.
The pulverizer lube oil pump must be operating properly before the associated
pulverizer can be placed in service.
Initially, the lube oil tempreture must be greater than 32 C and the lube oil sump level
must be adequate. When this condition is satisfied, the PULV START PERMITS (white)
“STATIS LUBE LVL & TEMP” light comes on (See “Pulverizer Ready “section, item 12).
If the lube oil sump level is not adequate for more then ten secondsm the date Logger
receives a “PULV LUBE OIL LELVEL LOW > 10 SEC.” signal. If the lube oil
temperature is “low”, the Data Logger receives a “PULV LUBE OIL TEMP. LOW” signal.
The lube oil pump is proven on when the LUBE PUMP (red) “ON” light is on and the
associated (green) “OFF” light is off. When the lube oil pressure is “not low” for more
than five minutes, the PULV START PERMITS (white) “LUBE PRESS SATIS” light
comes on (See “Pulverizer Ready” section, item 11).
After other permissive are also satisfied, the pulverizer can be placed in service. When
the pulverizer is on, the “lube oil temperature greater than 32 C” and “lube oil sump
level adequate” requirements are no longer required to satisfy the “pulverizer ready”
permissive. When the pulverizer is on, the pulverizer will be tripped after a delay of
ten seconds if the lube oil pump is off, When the pulverizer lube oil pump is on and
the lube oil pressure is “low” the Data Logger recieves a “PULV LUBE OIL PRESS LOW”
signal. If this signal exists for more than ten seconds, the pulverizer is tripped.
For a complete and detailed description of the secondary air damper controls, refer to
the manufacturer’s instructions. Operation of auxiliary and fuel air dampers as
affectedby the Furnance Safeguard Supervisory System are described below.
All elevations of auxiliary air dampers are transferred to manual control and are
opened when any of the following events occur:
When the five minute “post purge” counting period expires (see “Post Purge
Excursion Protection” section for specifics), a thirty second counting period is
started. When the thirty second counting period expires, a five second counting
period is started. Five seconds later, the auxiliary air control is removed from
“MANUAL” operation and the “open auxiliary air dampers” command is removed.
The auxiliary air control can now be placed in “AUTO” conrol.
After the auxiliary air control is in “AUTO” contol and at least one I.D. fans is on
and at least one F.D. fan is on, all elevation of auxiliary air dampers modulate to
maintain a pre-determined set point differential pressure between the windbox
and furnace. This is indicated by the DAMPERS MODE (red) lights coming on.
When all nine elevations are modulating, the PURGE PERMITS (white) “AUX AIR
DMPRS MOD” light comes on. this condition exists during the furnace purge
cycle and initial operation of the unit up to 30 % loading.
The auxiliary air dampers on a heavy fuel oil elevation are closed for a high
energy arc (HEA) oil start when the following conditions are satisfied:
AND
The auxiliary air dampers on a heavy fuel oil elevation are positioned to the
“warm up firing” position when the following conditions are satisfied:
3. At least one corner oil nozzle valve on the associated oil elevation is not closed
AND
4. At least three of the four oil nozzle valves are fully open and oil flow is adequate
at the associated oil nozzle valve or both seventy second “elevation pair” counting
periods have expired.
When the unit loading exceeds 30 %, the differential set point is gradually
increased to a higher set point as the boiler loading is increased. The rate of
When the until load is reduced below 30 %, the auxiliary air dampers open in a
timed sequence (ten second intervals), starting with the lowest elevation of
auxiliary air dampers. Simultaneously, the differntial set point reverts to its
lower setting.
3. Loss of unit critical power for more than two seconds exists.
When the five minute “post purge” counting period expires (see “Post Purge
Excursion Protection” section for specifics), the upper fuel air dampers “open”
command is removed which closes the upper fuel air dampers. Simultaneously,
a thirty second counting period is started. Thirty seconds later, the lower fuel air
dampers “Open” command is removed which closes the lower fuel air dampers.
When the feeder is “proven” (feeder is on for more than 50 seconds), the feeder
speed is released AUTO control and the fuel air dampers modulates as a function
of feeder speed. This is indicated by the DAMPERS MODE (red) light coming on
at the associated coal elevation. The associated CL (green) light will be off.
When a feeder is off for more than fifty seconds, the associated elevation of fuel
air dampers are closed.
ID FANS INTERLOCKS
ID FAN - A
START PERMISSIVES
4. Hyd. coupling oil Pump ON and pr. adequate. > 1.2 Kg / cm2
2. TRIP CONDITION
6. Discharge dampers / gate does not open fully within specified time. 3 min after
the fan start
ID FAN - B (BUS - B)
START PERMISSIVES
TRIP CONDITIONS
1. Same as ID - A for 1 to 7
2. ID Fan B (BUS-B) trips when both FD fans are running and FD Fan B trips.
ID FAN - B (BUS-A)
START PERMISSIVES :
TRIP CONDITIONS
ID FAN - C :
START PERMISSIVES
TRIP CONDITIONS
1. When the ID fan start command is given the pump starts and runs for 40 secs.
2. The pump starts if the oil pr. is less than specified limit < 1.8 Kg/cm2
3. The pump starts and runs for 25 mins after the ID fan stops
1. Stops after 40 Secs of ID fan start command and oil pr. reaches the specified
limit. > 2.2 Kg / cm2
[NB The pump selected to lag starts when lead pump fails to start.]
FD FAN-A
START PERMISSIVE
- OR -
TRIP CONDITIONS
1. No ID fan is running
3. Discharge damper does not open fully within specified time after 2 min
starting fan
FD FAN - B
START PERMISSIVES
1. Same as FD - A
TRIP CONDITIONS
1. Same as ID - A for 1 to 7
When the selector switch is in Auto, the oil pump starts under the following
conditions.
3. When the LEAD pump trips, LAG pump starts within 1 sec.
PA FAN - A
START PERMISSIVES :
1. F.D. fan A or B running but PA fan B not running or both FD fan A & B running.
5. Start permit from FSSS (Purge cycle complete & MFR reset.
TRIP CONDITIONS
6. Emergency PB pressed
PA FAN - B
START PERMISSIVES :
1. F.D. fan A or B running but PA fan A not running or both FD fan A & B running.
TRIP CONDITIONS
When the selector switch is in Auto the oil pump starts under the following
conditions.
1. Pump selected to LEAD pump starts when fan start command is given.
2. Stand by ( LAG ) pump starts when fan is running and control <6 Kg/cm2 oil
pressure is low.
3. LAG pump starts when fan is running and LEAD pump trips.
START PERMISSIVES:
TRIP CONDITIONS
AUTO START
2. Boiler load > 60 % & only 1 pump is effective (i.e. second pumps not running &
DP low ( < 10 Psi )
AIR HEATERS ELECTRIC / AIR MOTOR DRIVE INTERLOCK (PAPH & SAPHS)
STARTS WHEN :
2. Lag pump starts if the lead pump is OFF and Oil temp > 550C
3. Running Oil pump will stop when oil temp. falls below 450C
(Unit critical power consists of unit logic Voltage and unit critical interrogate
scan Voltage, which scans All MFT I / P Contracts)
3. A ‘Simulator Trip’ signal exists (All oil & coal elevations OR Unit not in operate
mode)
( i.e. if Boiler Load is > 60 % and atleast two B.C.W. Pumps are ineffective (Pump
is ‘ON & its DP between suction & discharge is < 10 psi 5 Sec OR Pump is OFF)
OR
Boiler load is < 60 % AND (No B.C.W. Pump is ON OR Pump ON AND DP is low)
10. Air flow is less than 30 % of rated air flow, before the Boiler load exceeds 30 % <
624 T / hr
11. The deaerator level is Lo-Lo (2/3 logic, Two from< - 2134 mm
14. Manual emergency Trip (Both the push buttons are pressed )
15. All feeders OFF AND LOSS of Power exists at any oil elevation that is in sevice.
a) Boiler working but all HP ESVs OR all IP ESVs are closed AND (both the HPBP
valves closes or both the LPBP valves closes)
- OR -
b) Boiler working AND (Generator ckt. br. opened or turbine tripped) AND (Both
HPBP valves are closed (open < 2 %) or both LPBP valves are closed (Open < 2 %).
17. “A loss of fuel trip “Signal is established (This signal is established under the
following condition)
After loss of fuel trip signal is “armed” (i.e. when any oil elevation that is placed in
services has atleast 3 / 4 HONVS proven open for > 2 Secs.) this signal will be
established if.
A) All feeders OFF or Loss of elevation. Power in all coal elevation > 2 Secs AND (All
HONVS closed at all four oil elevations or any elevation trip signal is established
at the elevation in services.
AND
AND
18. A “Unit flame failure “ siganl is established (This trip is “armed” only if a feeder is
proven for > 2 Secs. This trip is established when unit flame failure is armed AND All
elevations scanner Vote ‘NO FLAME’ simultaneously)
MILL INTERLOCKS :
Mill starts after the ‘ON’ push button is pressed if following conditions are fulfilled
d) Pulv. start permit (if Nozzle tilt Horizontal & air flow < 40 % ) OR ( Any feeder
proven and NO MFT )
i) Lub oil pressure not low for more than 300 sec
(i) Hot P.A. duct Pressure. not low ( > 625 mm wc)
(ii) P.A. duct pr. not lo-lo ( > 500 mmWc AND
(iii) Both FD s ON and both PA fans ‘ON’ or (Any PA fan ON and any FD Fan
‘ON’ and > 4 mills not ON)
AND
For Mill A:
OR
For Mill B:
a) AB elevation proven
OR
For Mill C:
a) CD elevation proven
OR
OR
a) CD elevation proven
OR
b) Pulv. start command given & not ‘ON’ for > 2 Secs.
OR
OR
d) Pulv ‘ON’ & seal air / under DP Low < 5” wc for more than 1 minute.
OR
f) Pulv ‘ON’ and lub oil pr. low > 10 secs. < 1.76 Kg/cm2
g) Ignition permit required (> 180 secs) & ignition permit lost (i.e. with -in 180 sec of
feeder start)
OR
OR
j) MFT
OR
OR
b) Pulv. is ON
a) Pulv. is OFF
a) Pulv is ‘ON’
AND
AND
OR
OR
OR
OR
VI. No MFT
OR
OR
d) Pulv. OFF
OR
OR
f) No coal on belt
OR
g) discharge plugged
c) HAG is open
b) Pulv ‘ON’ and HAG Close command or HAG closed on inter locks.
D) CLOSE HAD
a) Pulv. off OR
OR
d) Feeder OFF
INTERLOCKS FOR Heavy oil Trip Valve ( HOTV) & Heavy Oil Recirculation Valve
(HORTV)
1. HORV :
(A) This can be opened by pressing the Push button (PB) from Console if All the
HONV s are closed.
(B) HORV closes automatically when any HONV is not closed OR by pressing close
PB.
2. HOTV :
Permissives
SET I :
1. No. Boiler Trip persisting
0
2. HFO Header temperature satisfactory >93 C
6. Open PB depressed
OR
SET II :
3. HORTV open
4. Open PB depressed
0
c) HFO Header Temperature Lo-Lo for > 2 secs. < 95 C
‘AB’ ELEVATION :
a) Feeder A is OFF or LOSS of elevation ‘A’ Power > 2 sec and Feeder B is OFF or
LOSS of elevation B Power > 2 Secs.
OR
b) Elevation AB 2 out of 4 nozzle valves not proven or loss of power for >2 sec.
AND
OR
c) Elevation AB 2 out of 4 nozzle valves not proven or loss of power for >2 secs
AND
Elevation AB any nozzle valve not closed or elevation started and power loss
for 2 secs.
a) Feeder ‘B’ off or loss of elevation power for >2 secs andFeeder ‘C’ off or loss of
elevation Powerfor >2 secs
OR
GH is same as AB elevation.
1. No fan running for 2 secs. A.C. Fan starts and if A.C. fan fails to start, D.C. Fan
starts
2. A.C. Fan running and Scanner Duct / furnace DP low (< 6" WC)
DISCHARGE DAMPERS
1. A.C. Fan running and D.C. fan off A.C. Fan discharge damper opens and D.C. fan
damper closed.
2. D.C. Fan ON and A.C. FAN OFF - D.C. fan’s discharge damper opens and A.C.
fans damper closes.
TURBINE TRIPS
TRIP REASON
b) Push Buttons
1. At UCB console
2. AT MCT room
3. Near HP turbine
4. AT LPBP rack
f) Primary water flow at Main Bushing Phase U lo-lo <0.37 dm3 /S (1.3 T/Hr)
B. MECHANICAL TRIPS
0
4. Diff. Temp. Across Top & Bottom Of Pump > 15 C
Barrel Normal
7. No Turbine Trip
C.E.P. PROTECTION
HP BYPASS INTERLOCKS
For BP Valves :
2. If HPBP downstream steam temp. goes beyond 3800C , BP1 & BP2 will close on
temperature protection.
3. In case of Hydraulic oil pr. low, BP valves control changes to manual and it will
become inoperative (it will remain stay put)
5. Manual Trip command will initiate incase of CRH pot level High alarm.
1. HP Bypass valves opening less than 2 % will automatically close the spray valves.
2. If opening of either of the bypass valves goes to 2%, BP1 & BP2 , valves will
switch over to Auto.
3. If hydraulic oil pressure is low BPE valves control will go to Manual and remain
stayput.
4. In case of fast opening of BP valves irrespective to temp. BPE valves will open by
20 % till fast open command is persisting.
4. Depressing Fast Open push button (Fast open pulse will persist for 5 Sec.)
BD Valve :
* Actual Pr. & Set Pr. deviation +20 Kg/cm2 will initiate “HPBP Pr. Limit exceeded
alarm”.
Boiler will trip when any one or more of the following conditions occur :
1. Turbine Tripped or Gen CB open and HP or LP Bypass valves opening < 2% then
after 5 sec of Time delay.
2. Turbine working (control valves >2 %) and Load shedding relay actuated and if
HP or LP Bypass opening is < 2 % Reheat protection will act after 10 sec. delay.
3. If Turbine not working (HP or IP control valves < 2%) and boiler working (No.
contact of loss all fuel arming relay from FSSS) and HP or LP Bypass valves < 2 %
with a time delay of 5 Sec. Reheat Proctection will act.
Arming of Reheat Protection - Once HP & LP Bypass are open 2 % and steam
flow increases beyond 200T/hr Reheater protection will be armed .
In power plant industries, the four basic variables namely Pressure, Temperature,
Level, and Flow of the process media needed to be continuously controlled for
maintaining them within desired /required limits .Solid state electronics based Analog
control system is provided in the plant for controlling various process variables (e.g.
main steam pressure ,temp, flow drum level, air flow etc.)at desired value. In this type
of control system analoge electrical signals (4 -20mA) are generated to represent the
value of process variables using primary elements /transducers. These signals are
conditioned and transmitted to electronic control system for further processing.
Output of this system is used to activate the final control element e.g. control valves,
dampers, guide vanes etc. so as to maintain the process variables at desired set point.
This system is called Analog Control System because throughout the control starting
from monitoring to conditioning ,to processing and till operating the final control
element there exists a definite analogy between the input and output of various
subsystems (i.e. transducer, transmitter etc.).Here the signals being processed /used
for control are nothing but physical quantities current ,voltage etc. which are similar
to the process variables being controlled. It is totally different from digital system
wherein ,instead of physical quantities, discrete numbers are used for processing. It is
necessary that all the parameters should have optimum values throughout the range
of unit operation. For having control on parameters of various subsystem several
control loops are in service with specific objectives. Description of following important
control loops is covered here under : -
5. SH temperature control
6. Draft control
Acs has got two operating channels which are simultaneously active i.e.
Teleperm - M & Teleperm - C
Teleperm C - is the control system which is purely hardware based electronic wherein
controls all the related logics & computation are done through electronic
cards/modules only.
Teleperm M - This the control which uses software in addition to hardware electronic
cards. Wherein part of the computation logics are performed through software. During
Condenser hotwell level shall be controlled by regulating the make up water flow to the
condenser. The make up to condenser is primarily provided through the make up line
from demineralisation plant. If the condenser make up demand exceeds the flow in
DM water make up line ,the additional requirement of make up water shall be
supplied from condensate storage tank. Accordingly ,the low level in hotwell shall be
controlled by modulating:
Hotwell level control system is provided with three separate controllers termed as
Hotwell high level controller, Hotwell normal level controller and Hotwell low level
controller. For high level and normal or low level there are two separate level
transmitters. In all the three controllers actual Hotwell level is measured through
level transmitters, Output of which is inturn converted into corresponding current
signal and then voltage signal through two converters .The available voltage signal is
compared with Hotwell level set value in terms of voltage. Net available voltage is fed to
a PI controller and output of this used for opening or closing of respective pneumatic
control valves provided for Normal, Emergency or spill control thereby controlling the
makeup flow as per the demand. Actual position feed back of the valve is available in
the UCB. Control circuit is provided with hard hold memory card which retains the
last available value and provides smooth change over to manual whenever auto control
fails.
Auto control fails giving a flashing lamp on the controller module when actual level
goes beyond the level transmitter range.
This control loop is used for controlling of drum level. Depending on the feed water
flow path two separate control loops are used.
Namely, single element control & three element control.
Single element control :- This control system gets selected when BLI(Boiler load
index)is below < 20 % and feed water flow is controlled through low range line. In this
control system actual level of drum, after pressure correction, is compared with the set
point and available net voltage is processed through a PID controller. Output of this
controller is used for generation of pneumatic pressure for actuation of low range feed
water control valve. Actual valve position is displayed in UCB. If running BFP
scoop/speed is kept on auto it will slowly bring the speed to a constant value which is
already preset in the control system and the feed flow will be controlled through
pneumatic control valves.
Actual drum level and set point difference, after taking into account input of BLI, is
compared with sum of feed water flow & SH spray flow signal . The net resultant
output is fed to a PI controller and subsequently the output of feed master controller
sets the speed demand for TDBFP and MDBFP.
It is needed to maintain sufficient primary air pressure under all condition as this is
essential for carrying coal from pulveriser to furnace. Under this control system
actual pressure developed by PA fans is converted into voltage and is compared with
the set voltage (in terms of PA header pressure)then the net available output is
separately processed through two PI controllers meant for individual control loop, the
output of these controllers is used to set the demand position of blade pitch of each
fans. Actual position of blade pitch is available in UCB. Moreover biasing is provided
for adjusting the loading between two fans. Control loop includes following interlocks
1. Control system is released for auto operation only after outlet damper has opened
fully.
Reheater temperature control is achieved through burner tilt and spray. In the
process of reheat temperature control, it is ensured that burner tilt operates first for
bringing down the temperature and after certain time spray comes in service, likewise
when reheat temperature is going down then first spray is cut-off and thereafter
burner tilt is operated.
Reheat temperature Control system consists of two Thermocouples one each for left
and right reheat temperature measurement. For generating temp. demand set point
,output of a function generator, based on BLI and output of a manual setter on the
control desk, are fed to a minimum selector. Minimum of these two signals is used as
final temp. set point for burner tilt. The set point for spray control can be given with a
bias from the panel itself in the range from 0 to 50c. Biasing between left and right
spray valve is also provided which can be set from panel.
Spray block valve will close if control valve opening becomes less than 5 %. In the
control system actual reheat temp is compared with set value for temp and output is
SH temperature Control
In this control system SH steam outlet temp. is maintained at set point which is equal
to the minimum of
(2) Set point derived through a function generator based on BLI (Boiler Load Index).
Thus derived temp. set point is compared with signal corresponding to actual main
steam temp. measured through thermocouple at SH outlet. Separate comparison is
done for SH left and right streams . Error signals thus developed are further
influenced by feedforward signals from burner tilt position and BLI.
These corrected error signals are now compared with respective error signals derived
by desuperheater control loop and the final error signals are given as input to two
separated PID controllers ,one each for left and right streams, for finally controlling
the superheater spray through pneumatically operated control valves. The controler
output is displayed in UCB. An interlock is provided for closing the inlet block valve
below 5% opening of control valves..
In absence of storage capacity for electrical energy it is a must for a modern power
plant to have adequate control system to respond to rapid load changes and at the
same time control the process/the equipments so that no part of the plant runs into a
dangerous operating state i.e. the pressure, temperature and other process
parameters must not cross the designed/safe limits of a particular equipment ,
otherwise, the availability and required safety of the man and machine will be
reduced / endangered.
In order to achieve best efficiency and best availability with requisite safety, it is
necessary that operation of both the main plant equipments ( i.e. Boiler and Turbine)
is co-ordinated using suitable control system and there should be a possibility of
decoupling them during disturbances by means of bypass system.
Boiler and Turbine have a number of equipments which must be able to follow their
demands during unit start-up / shutdown and load variations. As a result, the power
plant process has a hierarchial structure and in order to match with the process best
The above hierarchial control concept is implemented through Teleperm ‘C’ &
Teleperm ‘M’ series of Siemens AG, WG make control system in case of Singrauli
500MW units. As the 500MW Simulator is designed as replica of Singrauli’s 500MW
unit, the control system of the same is taken as base for discussion here. However, the
general philosophy is similar to hierarchial control systems of other projects.
The basic task of achieving balance between energy generated (supply) and its
instantaneous consumption (demand) calls for generating a load set point depending
upon instantaneous grid demand and permissible/allowable limits/conditions of the
various plant equipments at that moment. This is called Target Load Set Point. This
set point is used as guidance signal for monitoring/controlling various plant
equipments/process parameters to accomplish the desired task of energy balance.
The process of generating this target load set point guidance signal is discussed in
following section along with four modes of unit co-ordination . Working philosophy of
some of the important individual control loops of the hierarchial control system is
already covered under Analog Control System above.
Load Demand is the MW set point signal for boiler combustion control and turbine
(EHC). This signal is generated as follows:
Target Load (MW set point) for the unit is set either by UCB operator or in auto mode
from load despatch centre. Digital display is provided for target load. This target load
is subject to MIN & MAX Limits, set by the UCB operator. After this limiting, target
load is subjected to a rate control which various the MW set point signal at the rate set
by the UCB operator or as permitted by the TSE whichever is lower. In CMC both
turbine and Boiler Master (BM) are on auto hence the input to the rate controller
(Known as SPCM) will be the target load set point. To this rate controlled set point a
frequency influence correction signal is added and Load Demand signal is formed.
The function of the boiler master auto / manual station in CMC Console is to provide
a set point for fuel and air flow i.e. fuel demand and air demand signals. In Co-
ordinated mode, it is equal to sum of boiler load set point and master controller (PID)
output. In this mode Boiler master controller acts on DP error. The fuel demand as
generated is compared with actual air flow and a minimum of the two is selected as
the fuel set point.
The air demand as generated is compared with fuel flow & 30 % of air flow and
maximum is selected as air set point. This MIN/MAX selection ensures an air rich
furnace. When fuel/air demand increases the MAX gate first increases the air set
point and when fuel demand decreases the MAX gate permits reduction of air flow only
after fuel has decreased.
Oil flow to burners and feeders speed (which is the measure of coal flow) along with
Calorific Value(C.V) corrections added to get total fuel flow. Cabinet adjustments are
provided to take care of individual calorific values to obtain total fuel flow as fuel oil
equivalent (FOE). The total fuel flow (FOE) is compared with fuel set point to
generated fuel control error. This control error is fed through (Pl) controller (Master
Fuel Controller) to all feeders in auto and Each feeder is provided with a bias and an
auto /manual station.
At SSTPS secondary air flow is measured by aerofoil near the windbox (left & right) by
two transmitters, sum of the two transmitters give the secondary air flow. Primary air
flow is added to this to give total air flow which is used for combustion control, purge
logic & SADC (Secondary Air Damper Control). This actual air flow is compared with
the air set point and then modified by O2 trim to generate the air flow control error.
This signal is doubled in case only one, out of two running fans available for automatic
control. An equalising and biasing signal is added to equalise and bias the individual
fan air flows. Control signal thus formed operates on the individual controller (for
O2 TRIM
A selection station and a setter for oxygen set point are provided to achieve the desired
excess air. If variable O2 set point (SP) is selected, set point is generated by a function
generator which is a function of MAX (air flow SP and total air flow). In other mode SP
is set from UCB. O2 in flue gas is compared with this SP and error is fed to PI
controller, output of which is limited between 0.8 and 1.2 times of total air flow. O2 PI
controller output is now multiplied by total air flow and the resultant O / P signal is
given to makes the FD fans blade pitch controllers for achieving desired air flow. O2
probes are provided at the outlet of economiser for measurement and control of the
flue gas O2. These probes are zirconium oxide probes working on the principle of
partial pressure of oxygen.Thus the input signal to FD Fan blade pitch controllers is
trimmed by O2 signal to get desired Excess air / O2 set point
The pressure set point compared with actual throttle steam pressure to obtain the
control error signal DP. Three pressure transmitters are provided for redundancy
along with deviation monitoring and middle of the three is selected as actual pressure.
In case of two transmitters fault, the control is put to manual. The pressure set point
generated in this circuit is also sent to HP Bypass Control. Actual MW signal (middle
value of O/P of 3 transducer) is sent from turbine control panel to CMC console where
DMW signal is formed as the difference between load demand and actual MW.
Selection of CMC
1. Put Air Master on Auto i.e. atleast one FD fan blade pitch controller on auto.
2. Put feeders speed control on auto after varying Fuel Master (FM) output and
making feeder speed controller error zero.
3. Vary Boiler Master Output so that FM error becomes zero. Then put FM on auto.
4. Make throttle pre. set point and actual pr. difference zero .
5. Put BM on auto
6. Increase / decrease unit master output so that it becomes equal to actual load.
(wait until load set value and load actual value matches as shown in the CMC
console digital indicator)
8. Press co-ordinated push button along with manual release on CMC desk.
In this mode turbine is in manual and the load is set at the turbine desk. The boiler
in auto follows the turbine and fires to maintain the throttle pressure. It means boiler
master has to be on Auto. If for any reason or other,the load demand set point signal
is not available the turbine load has to be set manually and the system can be
switched to boiler follow mode. In Boiler follow mode, set point = sum of boiler load
index and Master controller output (PID) acting on DP.
In Boiler Follow Mode as turbine is on manual so input to SPCM will be turbine load
set point. .
Note : While putting any controller on auto ensure corresponding error signal
is zero.
If the unit is in co-ordinated mode automatic change over to Boiler Follow Mode occurs
under following conditions
OR
b) (PrCMC - Pr lim) > 60 MW [i.e. when difference between set point guidance signal
and load set point for EHC is more than 60 MW ]
It means turbine control has to be on Auto. On turbine follow mode the unit load is
controlled through boiler, acting on the firing rate in the same manner as the steam
pressure control described in CMC mode. The pressure is controlled by Pr.controller
of EHC utilising the pressure deviation formed in the boiler master control system. In
turbine follow mode turbine operates in initial pressure mode.
In TFM set point = Sum of boiler load set point and master controller output (acting
on DMW Error)
5) Now load set point can be changed by varying the boiler master manually.
Runback Mode
Under runback condition the firing rate for the boiler must be reduced to pre-set
values, as close as possible to the tolerable limits. Therefore the swings of firing rate
caused by the action of the PID controller must be avoided. As consequence of this
condition the system has to be switched to pure feed forward control, where the firing
rate set point is directly proportional to the load capability signal. To avoid any
mismatch between steam production of the boiler and the turbine load, the turbine
has to be switched to initial pressure control, as with TFM.
Runback Resetting
2) Reduce load set point from the turbine desk to a value slightly less than Unit
capability so that 1 0 “Runback in Operation” resets.
The sub groups (SGC) can be started in any sequence but it is suggested to switch on
the four SGCs one after other, i.e. the SGC control fluid system first, SGC oil system
there after SGC vacuum system, and then SGC Turbine.
After checking that all the release criteria are fulfilled, simultaneously press the
manual push button of start up or shutdown in the SGC title and push button for
manual release. The lamp start up or shut down shall start flickering. the programme
would come to first step. The lamp for first step shall continue to glow so long as the
programme stays in that step. Along with this, the lamps for unfulfilled criteria shall
also glow until the same gets fulfilled as desired by the process. If the criteria do not
get fulfilled within the specified monitoring time of that particular step, an alarm “SGC
Monitoring Time Exceeded” will appear.
In case the criteria of a particular step get fulfilled after the elapse of the monitoring
time, the programme shall go ahead automatically but it will leave behind the lamp of
the ‘step’ & ‘criteria’ glowing as a trace of Tell-tale story.
Once the monitoring time exceeds for any step, then following shall be observed:
By once pressing the push button ON/OFF (without pressing the manual
release
push button) these lamps can be put off, after the criteria have been achieved.
iv) An alarm is given in case the running time of any step is exceeded.
In this mode of operation, the function group control does not have any automatic
command to the control interfaces, nevertheless the logic programme is followed since
sub group control receives data from the plant and control sections, but the command
output is blocked. The commands to the control interface are to be given manually at
the control interface tiles.
For operating the unit under this mode, a lockable stay - push type switch ‘Operated
Guide Mode’ has been provided on the control console. It should be turned On with
the help of its key. Then start up or shutdown push button on SGC tile alongwith
the manual release push button are to be pressed to bring the operation to first step
of start-up/shutdown programme. Then the commands of the first step are given
manually at control interface level. The programme will seek the checkback criteria
and when they are fulfilled, shall just go to second step. Then again the commands
for that steps are to be given at control interface level, and so on. Thus although the
commands at each step are given manually, the operators strictly follow the
programme and can closely watch the sequences, which otherwise in automatic mode
runs through.
Due to obvious reasons, in this operation mode, the alarm for “Monitoring Time
exceeded” is blocked.
STEP BYPASS
This mode of operation suggested only in very special cases for simulating the missing
criteria for any particular step. When some criteria are missing due to some fault in
transmitter etc., while the plant is in healthy state and actually the criteria have been
fulfilled, a deliberate decision can be taken to electrically simulate the missing criteria.
For this purpose a lockable spring return switch ‘step by step mode’ has been provided
on the control console.
When the programme is stuck up at any step, the switch ‘step by step mode’ is to be
turned with the help of its key. Simultaneously once press the push button start up
or shutdown of SGC tile, without pressing the manual release push button. This will
electrically simulate the criteria for that particular step where the programme got
stuck up and thereby programme shall proceed forward.
Before simulating the criteria, the healthiness of plant and actual fulfilment of all the
criteria must be ascertained. Automatic Runup of Turbine with ATRS should only be
tried after the unit has been successfully run with manual methods and all auxiliaries,
auto controls etc., have undergone successful reliable operation.
OPERATION RELEASE:
1. Starting device 0%
2. Position set point turbine controller < 0%
3. Field breaker OFF.
4. Generator breaker OFF.
5. Drain HP control valve1 not closed.
6. Drain HP control valve2 not closed.
7. Drain HP control valve3 not closed.
8. Drain HP control valve4 not closed.
9. Limit pressure operation ON.
10. Load controller is ON.
11. Synchroniser is OFF.
STEP 1
Commands :
2. HP ESV1 closed.
3. HP ESV2 closed.
4. HP ESV3 closed.
5. HP ESV4 closed.
No command is issued.
4. Drains no fault.
STEP 3
Commands:
STEP 4
Commands:
No command is issued.
or
(Bypass criteria for 2 to 5)
or
DT (HP BP1 - HPCV1 /TM) < X3
STEP 5
Commands :
Or
STEP 6
Commands:
No command is issused.
1. HP ESV1 is open.
2. HP ESV2 is open.
3. HP ESV3 is open.
4. HP ESV4 is open.
STEP 7
Commands:
No Command is issued.
or
or
STEP 9
Commands :
STEP 10
Commands :
No command is issued.
14. Pressure seal oil behind pump Hydrogen side > 3 Kg/cm2
STEP 11
Commands:
No command is issued..
or
or
STEP 12
Commands :
or
STEP 13
No Command is issued.
STEP 14
Commands:
or
or
STEP 15
Commands :
STEP 16
Commands :
STEP 17
Commands :
No Command issued.
Monitoring time is Blocked.
or
STEP 18
Commands :
or
STEP 19
Commands :
STEP 20
Commands :
Generator breaker is on and Gen load >10% (Bypass criteria for 1,2,&3)
STEP 21
Commands :
1. Synchroniser ON.
STEP 22
Commands :
or
STEP 23
Commands:
No command is issued.
END OF PROGRAMME
STEP 51
Commands :
STEP 52
Commands :
STEP 53
Commands :
Commands :
3. Synchroniser OFF.
1. Synchroniser is OFF.
2. HP ESV1 closed.
3. HP ESV2 closed.
4. HP ESV3 closed.
5. HP ESV4 closed.
6. INCPTESV1 closed.
7. INCPTESV2 closed.
8. INCPTESV3 closed.
9. INCPTESV4 closed.
or
Starting device 0%
STEP 55
Commands:
3. Drains no fault.
STEP 56:
No command issued.
OPERATION RELEASE:
STEP 1:
Commands:
No command is issued.
STEP 2:
Commands:
STEP 3
Commands:
2. DP seal oil (Air - H2) Turbine end > 0.7 Kg/ cm2
STEP 4
Commands :
STEP 5
Commands :
STEP 6
Commands:
No command is issued.
STEP 7
Commands :
1. JOP1 OFF.
2. JOP2 OFF.
3. JOP3 OFF.
Commands:
No command is issued.
STEP 9
Commands :
STEP 10
Commands :
No command is issued.
4. EOP is off.
STEP 11:
Commands :
No command is issued.
RELEASE CRITERIA
STEP 51
Commands :
STEP 52
Commands :
No Command is issued.
STEP 53
Commands :
d. AOP1 is off.
e. AOP2 is off
STEP 54
Commands :
2. JOP1 off.
3. JOP2 off.
2. JOP1 off.
3. JOP2 off.
6. JOP3 OFF.
STEP 55
Commands :
4. AOP1 off.
5. AOP2 off.
4. AOP1 is off.
5. AOP2 is off.
7. EOP is off.
STEP 56
Commands:
No command is issued.
Monitoring time - Blocked.
END OF PROGRAMME
RELEASE
STEP 1
Commands :
Or
STEP 2
Commands :
Commands:
STEP4
Commands :
No command is issued.
STEP 5
Commands :
STEP 6
Commands :
No command is issued.
STEP 7
Commands :
Or
STEP 8
Commands:
No command is issued.
STEP 9
Commands:
Commands:
No command is issued.
Monitoring blocked.
STEP 51
Commands :
STEP 52
Commands :
STEP 53
Commands :
STEP 54:
Commands :
1. No command is issued.
STEP1
Commands :
STEP 2
Commands :
STEP 1
Commands:
Heating:
If SLC Exciter dryer is on & the speed of turbine is <210 rpm and exciter top casing
temp is below 450C, Exciter Shut down Heating is switched on and when turbine
speed > 240 rpm and top casing temp >500C Heating is switched off. Also if dryers are
off, Heating is switched off on interlock. If the heating is switched on, it shall also,
automatically close exciter dome flap and flaps 1 & 2 on frame.
Excitor flap(Dome):
Exciter flap is closed automatically if exciter heating is On or drying is on. The release
for closing is, frame flaps 1 and 2 must be closed. The manual P.B. command for
closing can close the exciter flap (dome) if release is available.
Release:-
If exciter flap(dome) is open and cold air temperature is >450C, frame flaps 1 & 2 are
opened on protection or through manual push button commands flaps can be opened.
Alarms:
When turbine speed is 210 rpm and exciter top casing temperature is <450C, if exciter
drying or heating is off , this alarm is initiated.
This alarm is initiated if turbine speed is >240 rpm and drying or heating is on
AUTO SYNCHRONISER:
The synchorniser is switched ON if any of the following conditions are not present
• AVR fault
6. Loss of excitation
7. Pole slipping
8. Over voltage
9. Over fluxing
a) Buchholtz operation
DIFFERENTIAL PROTECTION
GENERATOR DIFFERENTIAL
A direct short circuit between different phases with or without ground fault of the
winding causes a severe fault current to flow inside the affected machine and cause
highly extensive damage. As a result there is a distinct difference between the current
at the neutral and terminal ends of the particular winding. This difference is detected
by the differential relay.
The current entering and leaving the protected object is determined by current
transformers and compared by relays by means of a differential circuits.
A fault inside the protected zone is fed from either one side or both sides depending
upon the current sources present, thus producing a difference current in the
differential circuit. If this differential current exceeds a set percentage of the current
flowing in the protected object, the relay picks up.
The relays used is designated 87GR, 87GY, 87GB type CAG34. It is set to operate
current which corresponds to 1000 Amp fault current . 5% of 5 amp with stabilising
resistors. Rstab = 400 ohm.
UATS DIFFERENTIAL
Since UATs are connected directly to the stator windings, so it has been provided with
a biased differential protection in a similar circulating current scheme. The relay are
designated 87 UTA and 87 UTB are DTH 31 type.
The 400 KV bushings of the generator transformer are connected to the switchyard by
double moose conductor overhead line. Any fault occurring on these lines is detected
by overhead line differential protection.
The relay designated 87 HVR, 87HVY, 87HVB CAG 34 type 0.1 amp with stabilising
resistor of 685 ohm. It picks up at 100 Amp. fault current.
The H.V. winding of the generator transformer is star connected and the neutral is
solidly earthed. The protection is meant for complete protection of H.V. winding of
generator transformer. The delta side of the generator transformer is considered as a
part of the generator and its earth fault would cause the earth fault current to flow
towards the generator neutral and be detected as generator earth fault.
Biased setting of 30% is used to prevent the relay operation in case of a through fault
when the current transformer may saturate and produce an erroneous secondary
current.
The generator neutral is earthed through the primary winding of neutral grounding
transformer of the rating 60 KVA, 18/.24 KV ratio. The secondary winding of the
transformer is shorted through loading resistance of 0.410 ohms.
For an earth fault in the generator the E/F current flows in the primary of the neutral
grounding transformer. As a result a voltage across the resistor is developed which
activates stator E/F sensing relay.
The reason for this kind of protection is due to the mechanical damages resulting from
the insulation fatigue creepage of the conductor bases, vibration of the conductors or
other fittings of the cooling systems.
The earth fault relay designated is VDG 14 type 64 G 1. The relay has a inverse
definite minimum time characteristics.
The relay is connected across an open delta of the generator PT secondary windings.
When there is no E/F the sum of the phase voltages of the generator and hence the
voltage across the relay is zero. The voltage across the point A & B will assume a
positive value when one phase voltage of the generator drops because of earth fault on
that phase.
Ground leakage in the rotor circuit of a generator does not adversely affect operation,
if it occurs only at one point. Danger arises if a second fault occurs causing the
current to be diverted in part at least, from the intervening turns which can burn the
conductor causing severe damage to rotor. If a large portion of winding is shorted the
field flux pattern may change causing the flux concentration at one pole and wide
dispensation at the other. The attractive forces which are proportional to the square of
the flux density will be stronger at one pole than the other which will cause high
vibration and may damage the bearings and may sufficiently displace rotor thereby
fouling the stator.
When leakage occurs between the turns in the same phase of a winding the induced
voltage is reduced and there will be a voltage difference between the centre of the
terminal voltage triangle and the neutral of the machine.
For generators having several parallel windings per phase, the neutral ends are
connected together to form as many neutrals as there are parallel windings per phase.
These neutrals are then joined through current transformer to current relays, or
through voltage transformer to voltage relay. If an inter-turn fault occurs in the
machine, the current transformer carries a transient current or alternatively voltage
transformer produces a voltage thereby picking up the relay and tripping the
generator.
The relay is designated 95G, is a VDG 14 type 5 amp attracted armature voltage
operated IDMT (Inverse Definite Minimum Time) type .
A three phase balanced load produces a reaction field which is constant and rotates
synchronously with the rotor field system. Any unbalanced condition could be resolved
into positive, negative and zero sequence components. The positive sequence
component is similar to the balanced load. The zero sequence components does not
produce armature reaction. The negative sequence component is similar to that of
positive sequence but the resulting reaction field rotates in the opposite direction.
Hence the flux produced by the negative phase sequence current cuts the rotor at
For any current conditions in the three phases the amount of unbalance can be
determined from the values of the negative sequence components I2 of current by the
method of symmetrical components.
The degree of unbalance is taken to be the value of the negative sequence current
component expressed as percentage of rated current. The losses in the rotor are
proportional to the square of the degree of unbalance. This generator has I22.t =8
characteristics indicating that within the generator is capable of withstanding but
beyond it there is time delay of 5 sec.
The time delay has to be matched to the machine negative sequence current withstand
capability.
The relay used is designated 46GA, 46GT and is of solid state design & CTNM+VTT11
type with fixed resistors.
A three phase zone impedance relay is provided for the back-up protection of generator
against external three phase and phase to phase fault in 400 KV system. The zone of
impedance relay should be extended beyond 400KV switchyard and it should be
connected to trip the generator after a time delay of 2 seconds so that the generator is
tripped only when 400KV protection has not cleared the fault even in the second zone.
FIELD FAILURE.
Failure of the field system leads to losing of synchronism and resulting in running
above synchronous speed. It acts as an induction generator, the main flux being
produced by wattless stator current drawn from the system. Operation as an
induction generator necessitates the flow of slip frequency current in the rotor,
damper winding, slot wedges, excitation under these conditions requires a large
reactive component which approaches the value of rated output of the machine. Since
rotor would get overheated due to slip frequency current, the machine should not run
more than a few seconds without excitation. Also it could overload the grid which may
not be able to supply the required excitation MVAR.
When loss of excitation is accompanied by under voltage it will initiate class A trip.
Otherwise class B trip if the grid is able to sustain the voltage dip.
The asynchronous operation of the machine while the excitation is still intact unlike
loss of excitation, causes severe shock both to machine and grid due to violent
oscillations both active and reactive power. Because of it the machine may fall out of
step or usually known as pole slipping trip.
The oscillation may disappear in a few seconds in which case it is not desirable to trip
the machine. If however the angular displacement of the rotor exceeds the stability
limit the rotor will slip a pole pitch. If this disturbance has been sufficiently reduced
by the time this has occurred, the machine may regain synchronism, but if it does not,
it must be isolated from the system.
The swing curves can be detected by an impedance relay. The relay has measuring
elements set at two values near the impedance as seen by the relay. As the impedance
seen by the relay changes it comes in the operating zone of the two relays one after the
other. The sequential operation is observed by auxiliary relays. Since the system faults
would suddenly change the system impedance both the relays shall operate within 55
cms. However, during pole slipping the two elements would operate sequentially and a
trip command is given when both have operated.
The relay can be set to be in operation for swings up plus minus 90 deg.
Corresponding to the stability limit of the generator.
The relay used is designated 98G and is of solid state design of ZTO11 + YTGM14.
In order to discriminate against swings on the grid the tripping is through impedance,
relay (98 GY) set with a reach upto the 400KV yard. Current setting is 90% of 5 amp.
OVER VOLTAGE
The generator winding is rated for 21 KV terminal voltage sustained over voltage would
unduly stress the winding insulation and may lead to failure after some time.
To protect the machine against over voltage the protection relay senses the voltage at
the secondary of the bus duct Pts. The relay is set to operate at 105% rise in the
terminal voltage. A time delay of 3 seconds is provided to take care of transient over
voltage arising from line charging, switching capacitive faults etc. The relay used is
designated 59G & is VTU 21 type 110V A.C.
The iron core of the generator transformer carries the flux to produce required emf. If
the flux increase unduly the magnetic circuits of the generator, generator transformer
become over saturated resulting in high magnetising current. This in turn leads to
higher iron losses which will increase the winding temp. of the transformer. Since core
can be damaged because of the overheating, protection has to be provided against it.
The flux is dependent on ratio of voltage & frequency.
The relay used is designated 99GT and GTT21 + VTT11 type which senses v/f ratio at
the secondary of the bus duct P.T. and gives alarm and trip signals at different time
delay. The adopted setting for relay is v/f = 1.18 P.U. i.e. 20% higher than rated v/f
ratio.
Alarm is set at .5sec and trip at 2 sec.. This v/f relay also generates a AVR ‘ Raise’
block.
When a generator, synchronised with grid, loses its driving force the generator
remains in synchronism. The generator should be isolated from the grid after the
steam flow ceases and the flow of power to grid reduces to minimum i.e. the point
when the generator starts drawing power from the grid and acts as motor.
When the load on generator drops to less than 0.5 percent, generator low forward
power relay gets energised and with turbine tripped or stop valves closed, trips the
generator with a time delay of 2 seconds.
This is a protection to trip generator other than electrical faults. Also this protection is
used for a few electrical faults where generator trip can be delayed.
However, provision for time lag unit is there to prevent undesired operation from
transient power reversal.
The power relay used is designated 37GA, GB and is a WCD13+VTT11. acts as a final
back-up to both L.P.F. protection.
This is a protection against the main generator breaker failure which may occur due to
-
i) Mechanical failure
ii) Trip circuits not healthy
Hence, this protection acts as a back-up to the main generator by tripping all the
breakers connected to that particular bus.
i) D.C. to the relay extended through the trip command (either 86G or 286 G or
B/B protection trip)
ii) Over current element senses that generator breaker that generator breaker
contacts have failed to open.
When both above conditions satisfied LBB protection acts with a timer ( 0.2 secs.) to
trip all other breakers connected to that bus.
The LBB protection initiates bus bar protection. (Refer to the bus bar protection
scheme).
Any internal fault in generator transformer the winding temperature increase rapidly
resulting in vaporisation of oil dissociation of oil accompanied by generation of gas.
The generator gas is utilised for relay operation.,
The relay is a gas operated device arranged in the pipe line between the transformer
tank and separate oil conservator. In the fig. The vessel is full of oil. It contains two
floats B1 and B2 which are to be hinged and to be passed by their buoyancy against
two stops. If gas bubbles are generated in the transformer due to fault, they will rise
and get trapped in the upper part of the relay chamber thereby displacing the oil and
lowering the float B1. This sinks and eventually closes an external contact which
operates as an alarm.
If the rate of generation of gas is small the lower float B2 is unaffected. When the fault
is dangerous and gas production is violent the sudden displacement of oil along with
the pipe tips the float B2 and causes a second contact to be closed and making the
trip circuit and operating the main switches on both HV & LV side.
Gas is not produced until temperature exceeds about 150 deg.c., so momentary
overload of transformer does not affect the relay unless the transformer is really hot.
Also insufficient oil level in Buchholz relay could lead to inadvertent operation of the
same.
Vapour pressure thermometers or resistance temperature detectors are used for this
purpose. The transformer winding temperature and oil temperature are continuously
monitored; when the temperature reaches a certain value it will give indication. Then
the load on the transformer is to be reduced. If the temperature rises still further
tripping will take place.
Sprinkler system is used to protect the transformer from fire hazards. Sprinkler
installation comprising a system of interconnected pipes into which sprinkler heads
are fitted on a definite basis of distribution, according to the network design. Sprinkler
heads are so constructed that the heat arising from fire will cause them to rupture.
Generally the sprinkler system consists of a compressed air line and a water line.
Sprinkler heads are provided in the compressed air line.
The compressed air line will always be in changed condition and prevents the
contractor from entering the water line. When the sprinkler heads then the pressure in
the water header will open to send the water into the water header, from water will be
sprinkled on to the transformer.
282
KORBA SIMULATOR
GENERATOR PROTECTION
283
KORBA SIMULATOR
GENERATOR PROTECTION
284
POWER PLANT CHEMISTRY
INTRODUCTION:
In a modern Thermal Power Plant, the life expectancy of equipment is about 30-40
years. The plant utilizes the best material and technology in designing the critical
plant items such as boiler, turbine generator etc. The control of chemical parameters
is an important task to achieve the goal set for the life of a power plant. The control is
being done at various stages in operation of the plant. The objectives of water
Chemistry control are:
Besides above Power Plant Chemistry covers a vide area of service which affect the
station availability and efficiency as well as Operation, Maintenance and Safety. to
achieve the objectives the control are divided into following headings:
1. Water Treatment
WATER TREATMENT :
DESIGN
The design & operation of W.T. Plant depends upon the feed & boiler water
requirement. In Korba Super Thermal Power Station the design parameter for the W.T.
Plant are as follows:
(for 3 x 500MW units)
A) PRE-TREATMENT
B) DE-MINERALIZATION
a) Pre-Treatment:- The river water contains suspended and organic impurities. The
removal of these impurities is done by the process of coagulation/flocculation in a
Clarifier. The chemicals like Alum & Lime are added to catalyse the process. Chlorine
is also added to disinfect the water.
The general schemes for pre-treatment and demineralisation of water are follows:
The demineralised water produced in W.T. Plant is utilised for steam generation. The
main objective is to prevent or minimise the corrosion, deposition or scale forming on
various system.
A part from this condensate purification plant is also provided in Water/Steam chain.
This plant purifies the condensate thus eliminating the deposition of oxides and other
corrosion product in feed, boiler and steam circuits. To monitor the chemical
parameters, On line instrumentation is provided. The lists of various instruments are
as below:
INSTRUMENT LOCATION
pH meter Condensate
Boiler
Steam
The various design parameters of Water/Steam cycle are as below: (for 3x500 MW
units)
The generator winding is cooled by D.M. Water. The chemical control for the system is
done in two ways:
In first case for degassification high purity nitrogen is used. The corrosion product or
other ionic species are removed from the circuit with the help of a polishing unit.
In second case stator water is made alkaline by addition of caustic soda. This help in
minimising the corrosion of copper and steel.
pH 8.5-9.0
:
Conductivity ms/cm 1.5-2.2
:
Dissolved oxygen ppm <0.03
:
Copper ppm <0.02
:
Iron, ppm <0.02
:
2. HYDROGEN:-
The generator is also cooled by pure hydrogen. The purity of hydrogen and moisture
contents are determined in laboratory for corrective action. The limiting parameters
are as below:
The lubricants & control fluids used in power plant deteriorate on time by oxidation
and by ingress of foreign matter. The quality of lubricant to be monitor in a fixed
interval for:
a) Viscosity
b) Acidity
c) Foaming characteristics
d) De emulsification Nos.
e) Moisture contents
KSTPS get coal and oil from outside. The payment is done on the basis of grade and
calorific value of fuels. The sampling done jointly with Coal Company and the grade is
being determined. Similarly for oil the samples are being drawn on receipt of the oil
rack for determination of Calorific value.
A) LOSSES:
In combustion process coal is burnt in boiler the losses occurred with carry-over of
unburnt carbon along with ash. The quantity of unburnt is direct measure of fuel loss
in system. The monitoring is regularly done and corrective action suggested controlling
the losses to permissible limit.
B) EFFICIENCY:
C) ENVIRONMENT
Thermal Power Plant uses coal and oil as fuel. On combustion various constituents
are produced causes degradation of environment. Therefore, it is very essential to
monitor and control these constituents at the source. The table below give various
constituents monitored and their limits:
S.S.ppm 100
pH 5.5-9.0
Oil, ppm 10
BOD, ppm 30
5. ABS shaft vibration BRG1 casing front & BRG 1/2 rear increases
5. Turbine Trips
4. If DMCW pump A trips: DMCW pump - A motor current decreases to zero DMCW
pump A motor status become trip DMCW pump A motor trip
5. If DMCW pumps B trips: DMCW pump - B motor current decreases to zero DMCW
pump B motor status becomes trip DMCW pumps B motor trip
6. If DMCW pump C trips: DMCW pump - C motor current goes to zero DMCW pump
C motor status become trip DMCW pumps C motor trip
8. All bearing temperatures will rise, Hydrogen gas, PW , exciter hot air temperatures
increases. Unit may trip on any of the above temperature high protection.
20. Scanner air fan outlet damper and emergency dampers will remain stay put.
21. In ATRS panel DC AOP & DC JOP will have fault lamps glowing; if they were in
service they will stop with red fault lamp.
23. Load shedding relay will lose supply (this relay has 220 v d.c supply but load
Shedding solenoid is having 24 v supply)
Emergency 7 : FAILURE OF + 24 V DC
CAUSE : REASON NOT KNOWN
Identification :
Consequences :
5. TSE fails
7. Lub oil temperature, HPCF temp., PW temp., coal gas temp., MAL 11, 12, 13, 14
temp. Controllers will remain stay put.
8. DC EOP will take start if the SLCs ON and lub oil pressure is less than 1.1
Kg/cm2.
10. Excitation system pulse cards will be blocked and excitation collapses.
2. All turbine protection and extended turbine protection will remain healthy.
6. Lub oil temp., PW temp., cold gas temp., MAL-11, 12, 13, 14 and HPCF temp.
Controllers will remain stay put.
9. Burner tilt will be stay put, feedback indication will show zero as power to ACS is
not available.
1. DP across FD fan A/B lube oil filter becomes HI (> 1.2 kg/cm2) with a short delay
2. Annunciation "FD fan cont/lube oil press low" comes in (< 0.8 kg/cm2)
7. "FD fan A/B Motor/fan brg temperature high" annuncitation comes in (> 85/95oC)
8. "FD fan Motor /fan brg temperature high high "comes in (> 90/105oC)
1. The ctrl oil pr drops below 1.8 Kg/sq cm. This causes the lead pump to take auto
start red ON lamp comes, green OFF lamp goes off
2. ID fan control/lub oil pr continues to drop, the permissive lamp hydraulic coupling
oil pr adequate goes off at pr less than 1.2 Kg/cm2)
3. ID fan vibration high alarm also comes
6. ID fan trips on hydraulic oil pr low protection bkr trip white lamp appears
(< 0.5 kg/cm2)
7. '
ID fan tripped/start failure'annunciation appears
8. '
ID fan amps drop down to zero'
9. '
ID fan inlet vane and hydraulic coupling control is forced to manual yellow LED
glows
10. 'ID fan A inlet outlet damper GD 19, 22 starts closing and closed green lamp comes
11. Inlet/outlet damper full close permissive lamp glows
13. FD fan blade pitch control is forced to manual and auto release lamps starts
flickering as ID fan A ctrl is not on Auto
14. '
FD fan tripped/start failure'annunciation appears
15. FD fan discharge damper closes on auto Tripping of FD fan causes PA fan A to trip,
white trip light comes.
16. '
PA fan tripped/start failure'annunciation appears
18. Co-ordinated control system (CCS) transfers to run back mode and initial pr mode.
Run back in operation facia glows
19. SPCM comes down to approx 60% and unit capability drops down
21. '
Unit run back in operation'annunciation appears
NOTE : Loss of both ID fans at full load will cause a boiler trip.
5. RH Steam temperature control will reduce attemperation and/or raise burner tilt
to compensate for falling temp
11. ID fan control will go wide open and ID fan motor overload alarm appears
13. The flue gas differential pr across reheater decreases to normal value
15. Flue gas press. at economiser inlet gradually increases to normal value
16. Flue gas pressure at RAPH inlet gradually decreases to normal value