KUMAf?

o

o NA TI0NAL P0 WER TRAINING INSTITUTE

NAGPUR

O 210 MW POWER PLANT SIMULATORoc

o0 OPERATING INSTRUCTIONS MANUALO .

NATIONAL POWER TRAINING INSTITUTESOUTH AMBAZARI ROAD

XJ. GOPAL NAGAR

O NAGPUR 22

moo

C 0 N 1 E No

Si . Top ic: Page0 No,, No.

o1. COLD START UP OF UNIT 1

o2. PLANNED SHUT DOWN OF UNIT 64

o3. SHUT DOWN TO HOT STAND-BY OF UNIT 81

o4. HOT RESTART OF UNIT 88

o5. AUTOMATIC TURBINE RUN-UP SYSTEM AND 95

O SGC OIL LOGICSQ 6. INTERLOCKS AND PROTECTIONS OF UNIT 1160 7. CRITERIA CURVES FOR ROLLING THE TURBINE 145

AND SYNCHRONISING THE GENERATORo

8. THERMAL SCHEMATIC DIAGRAMS 152

Oo

noo y

PROCEDURE FOR STARTUP OF THE UNIT FROM COLD CONDITION

o

%^

o

o

o

G

C-l CHARGING OF 6_^ KV ELECTRICAL SUPPLY SYSTEM

E-l Ensure that ;220 KV Grid is charged.-- Ref.Tag

Station Transformer 220 KV Breaker key is in "ON1 MCL2

position at MCL-2. All BTSP (BTPS-1,BTPS-2,BTPS-3,

BTPS-4) are out. Station Transformer-2 is in

charged condition. , .J,

E-2 Through local operation close isolator from grid to ::

station transformer-1. (Bus-1 or Bus-2 side) (RFED05)

E-3 Through local operation close station transformer-1

6.6 KV side isolator. (RFED-08)

E-4 Through local operation close station transformer-1

220 KV breaker. ( RFED-12)

E-5

tJ

E-6

E'-7

E-8

E-9

E-10

E -11

Through local operation close station boards OCC

OCD's all 6.6 KV out g o i n g feeders. (RFED) f ":>'-'

CHARGING OF 6_^6 KV SWITCH BOARD

Close STN BD OCA INCOMER BREAKER Stn. board QCA MCL2

volt meter will show 6.6 KV.

Close STN BOARD OCB INCOMER BREAKER Stn.Board OCB "

Voltmeter will show 6.6 KV. .'.

TIE BREAKER BETWEEN STN BUS OCD & OCB. /,

TIE BREAKER BETWEEN STN BUS OCC & OCA. "

Close TIE BREAKER BETWEEN UNIT BD ICA & STN BD OCA. MCL1

Unit Board ICA voltmeter will show 6.6 KV. ' -r ^ .^ ........ , ~ ,.

Close TIE BREAKER BETWEEN UNIT BD ICB & STN BDS OCB. "

Unit Board ICB voltmeter wil] show S.S KV.'

JE-12 Close all 6.6 KV outgoing feeders at ICA & ICB.

E-13 Close incomer-1 and incomer-2 Bkr. to Board IDA.

E-14 Close all 6 . 6 KV outgoing feeders at OCA & OCB.

E-.15 Close incomer-1 and incomer-2 Breaker to Bus ODA.

E-16 Through local operation (Case_ rf_ ups_ close)

charge UPS-l,UPS-2; 220 V charger-1 & charger-2.

C-2 STARTING OF G S WATER PUMPS \0 ' r

MCL1

"

MCL2

MCL2

$f

Before starting G S Water pump check following:

1. Electrical supply is available to GSW Pumps.

2. Sump level is normal.

3. Over head tank outlet valves GSW-132 & GSW-133 are open.

4. G S over head tank incoming valves GSW-115 and GSW-114

are open.

5. Breakers are racked in and DC control supply is"ON1.

Start G S water pump-A, check motor current of 30 A.

Open GSW recirculation valve CW-44 (RFCW001) by 20%

locally. Open Discharge Valve DV-39 .f cw-3=0

GSW OVER HEAD TANK LEVEL will increase slowly and

wait till GSW OVER HEAD TANK LEVEL HIGH alarm appears.

C-3 STARTING OF SERVICE AIR AND INSTRUMENT AIR COMPRESSORS !?->

Before starting service air and instrument air compressors

check following:

l.GS water supply is available to the compressors.

2.I/L, O/L valves of all air receivers are open.

(IA07,IA10,IA8,IA11,IA09,IA12,IA01,IA04,IA02,IA05 IA03,IA06)

3.IA-15 valve is initially closed.

/"I

oo

Start SAC-A & SAC-B and establish service air header pressure

at 7 to 8 kg/cm2. Check that service air compressor trouble

^ indication resets and air pressure low indication resets.

,f^ Start instrument air compressors A & B and establish 7 to 8

fh Kg/cm2 instrument air header pressure.

#| Indication of instrument^ air header pressure will reset.O Ensure that the inter-connecting valve between IAC and SAC is-Q> closed and can be opened if required during emergency.

ID C-4 CHARGING OF CW SYSTEM AND STARTING CW PUMPS

\ 1. CW sump level is normal.

fr, 2. Cooling water 0/L valves from condenser to cooling towers

g\ , >'"' are in open position.I7 '

r>) 3. Electrical supply to CW pumps is available.

f~) 4. Check Condenser water box vents are open initially and

f*, close locally after charging.

O Open COND CW I/L Valve CW-48 & Valve CW-49.

Q Open COND CW 0/L Valve CW-55 & Valve CW-56.

P Start CW PUMP-1 from CWA-15 desk.

Q Discharge valve will open (20%) initially and then later-

Q on opens fully.

Q Ammeter reading of CW PUMP-1 will show 140 amps.

Q CW PR COND A I/L pressure will show 2 to 2.2 kg/cm2.

Q Start CW pump-2 from CWA-15 desk.

DISCHARGE VALVE CW-16 will open by 20% initially and

after time delay will open completely.

CW PUMP-2 will show 14 0 amps.

CW PR COND B I/L pressure will show 2 to 2.2 kg/cm2

and DP 0.3 5 kg/cm 2. ( ' 3 V

j6-S OPENING BOILER SIDE VENTS AND DRAINSBefore filling Boiler drum open locally Boiler drum

vent valve B-5, startup vent valves S-32, S-33, SH venti"f- jV- ' f 15.

valves S-40, S-21, S-25, S-30. ^Jx ^

Open RH vent valves R-l and R-4.

Open SH drains S-15, S-17, S-19.

't-' Open B-95 ring header drain valve.1U- Ensure that all the water side drain valves are closed.

' Open economiser recirculation valve E-12V.

C-6 ,/ CHARGING OF DM MAKE UP SYSTEM, il

Ensure DM water storage tank outlet valves DM-2,DM make-up -

pump suction valves DM-3 and DM-4,DM make-up discharge valvt;

DM-7 and DM-8 are open.

Open valve DM I/L Valve DM-01 to STG TANK on CWA-15 desk. A

Close DM-01 ' valve when DM storage tank reaches normal

(7600 mm) . ( *

Ensure that DM overhead tank inlet outlet valves are open.

Select DM transfer pump-1 on CWA-15 desk.

Put DM PUMP SEQUENCE on auto.

Press VON' push button of DM PUMP SEQUENCE to start.

DM transfer pump-1 will start and shows 40 A.

mObserve tripping of DM transfer pump on interlock when

level reaches 3350 mm.

Condensate surge tank can be filled directly bypassing

DM O/H tank if required.

DM-12 will respond based on CST level to maintain CST

level.

DM overhead tank level low indication resets at >1050 mm.

Annunciation window OH COND SURGE TANK LVL LOW resets at

/2050 mm and when level reaches at 2500 mm DM-12 will close.

^ FILLING OF BOILER DRUM

r?s Ensure that all the water wall drains, header drains are

y G Open initial filling valve DM-50 (RFFW08).

Q y^ Deaerator level gradually increases and "DEAERATOR

Q h,M LEVEL LOW" annunciation window resets at 2385 mm.

Q . ; ) r Wait till DEAERATOR level reaches normal (2785 mm) .-, .0'

0 "? Stop Boiler fill pump and close DM-50 locally.r^ Ensure that isolating valves of over flow valve DR-33O are open.

^ CjJ) FILLING OF HOT WELLOpen following local valves for filling hot well.

Open DM-34 and DM-36 (RFDM-04).

Open DM-31 and DM-33 (RFDM-03).

Open valve DM-32 on CWA-15 desk for filling hot well.

Hotwell level will increase gradually.

" Hotwell very low" indication resets at 350 mm level

and hotwell level low indication resets at 650 mm level.

Close DM-32 valve when level reaches 850 mm.

C-10 STARTING OF AIR PRE-HEATER-A AND B r . ">

Before starting APH-A ensure following valves are open:

\

oAH-A FG I/L DAMPER CLOSED

0AH-A FG O/L DAMPER . CLOSEDAH-A SA I/L DAMPER CLOSED

AH-A SA 0/ts.DAMPER CLOSED

^ -STARTING OF AIR PRE-HEATER-A

APH-A can be started manually or in group sequence.

Procedure for starting APH-A in group sequence.o

Ensure that guide and support bearings lub.oil sequence

is on auto and select any one pump and ensure that APH-A

DC motor is running.o^ Keep AIR.HEATER-A GROUP SEQUENCE on auto mode .

Press "ON' push button of group sequence to start APH-A.G

STEP INDICATOR wil indicate step number zero to eight one

after the other.

Observe that APH-A MAIN MOTOR starts and Aux.motor trips.

SA I/L DAMPER SAD-3A, SA 0/L DAMPER SAD-4A, FG I/L DAMPER0

GD-1A, FG 0/L DAMPER GD-2A will open.u^ Observe group sequence steps on DAS CRT.~, PROCEDURE FOR STARTING AIR HEATER-A ON MANUAL

^ Keep Air heater-A Group sequence on manual mode.* - >

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

^ AIR HEATER-A main motor(AC) will start and Aux.motor trips

p> Open SA I/L DAMPER SAD-3A, SA 0/L DAMPER SAD-4A, FG I/L.

^ DAMPER GD-1A, FG 0/L DAMPER GD-2A .

40 deg.C and support bearing temperature >35

r> deg.C. respectively.

ApfJ

W JL C- - , - - ( - < i " . : * -

t-11

AUTO PICK UP TRIAL OF AIR HEATER-A AUXILIARY MOTOR

Press "OFF' push button of AIR HEATER-A MAIN motor.

AIR HEATER-A motor will trip .

AIR Heater-A AUX. motor will pick up and shows 3 amps.

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

AIR Heater-A AUXILIARY MOTOR will trip.

Similarly Air Pre-heater-B can be taken into service

on manual or in group sequence mode.

Observe support and guide bearing temperatures of both

Air heaters (on CRT).

Ensure that bearing oil coolers are charged from water

side .

STARTING OF ID FAN-A

PERMISSIVES TO START ID FAN-A .

IDF-A S/S POSITION .

AH- A/B

IDF-A MOTOR & FAN BEARING TEMPERATURE

IDF-A CB POSITION

IDF-A CB SPRING

IDF-A

AH-A/B FG I/L & 0/L DAMPER

ID FAN-A INLET GATE

ID FAN-A OUTLET GATE

ID FAN-A REGULATING GUIDE VANES(IG-V)

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

mode.

REMOTE '

O N

NOT HI v

IN SER v

CHARGED ./

OFF

OPEN

CLOSED

CLOSED

MINIMUM

oo

-.

O PROCEDURE FOR STARTING ID FAN-A IN GROUP SEQUENCE

O Put ID FAN-A GROUP SEQUENCE on auto mode.

Observe on DAS, group sequence programme(missing criteria)

Make "ON1 ID FAN-A GROUP SEQUENCE to start ID FAN-A in

^ group sequence.

STEP INDICATOR will indicate step numberv zero to seven _..

^ one after the other. Observe following operations on desk.

Seal air blower will be "ON1.

^ OUTLET DAMPER GD-7B & inlet damper GD-5B will close on

interlock (if the dampers are not closed).GD-6B position will come to minimum (if position is not

ominimum). ID FAN-A will start.

oNo load current of ID FAN-A will show 40 amps.

GD-7A and GD-5A will open after time delay of 45 seconds.

PROCEDURE FOR STARTING ID FAN-A ON MANUALo

Ensure that1 all start permissives of ID fAN-A are

satisfied.

Ensure that bearing coolers of ID fan are charcedo

from water side.Keep ID FAN-A GROUP SEQUENCE on manual mode and start seal

Q'air blower.

o

Start ID FAN-A motor.Open DAMPERS GD-5B and GD-7B closes on interlock.

GD- 6B position will come to minimum.

Open GD-5A and GD-7A manually from the desk CWA-11 and

load the fan by GD-6A IGV.

C-12 STARTING OF FD FAN-A ' > '

FD Fan-A can be started manually or in group sequence.

Ensure that following valves are open for starting LOPS

of FD Fan-A.

1. Suction valve FDL - 0A01 of LOP-A (FD fan-A) open.

2. Discharge valve FDL-0A02 of LOP-A (FD Fan-A) open.

3. LOP-A (FD Fan-A) cooler water valves are open.

4. LOP-A (FD fan-A) filter-1 is in service.

5. Suction valve FDL-OAO4 of LOP-B (FD fan-A) open.

6. Discharge valve FDL-OAO5 of LOP-B (FD Fan-A) open.

7. Cooling water valves of LOP-S are open.

Start LOP-A and adjust recirculation valve FDL-0A07(RFAGO2) for 8 kg per sq.cm2 control oil pressure and

valve FDL-O12 for proper bearing lub.oil pressure.

Both indications of lub oil pressure low and control oil

pressure low will reset onJTWA-11 desk.

Observe lub.oil pressure and temperature of bearings of

FD Fan-A on DAS CRT.

z AUTO PICK UP TRIAL OF LOPS OF FD FAN-A

Select PUMP-A for FD FAN-A..

Put sub group sequence of LOPS of FD FAN-A on auto and

make it "ON'.

Selected pump-A will pick up.

Stop LOP-A, LOP-B will pick-up on interlock.

Stop LOP-B, LOP-A will pick-up on interlock.

FD Fan-A lub oil pressure low and'control oil

pressure low indications reset.

10

^ -START PERMISSIVES FOR FD FAN -A

o^ - Start permissives of FD Fan-A can be observed on DAS CRT\y

f% FDF-A FAN/ MOTOR TEMP.BEARING TEMPERATURE NOTHI

Q, FDF-A Circuit Breaker INSERVICE'

Q FDF-A BREAKER SPRING CHARGED

O FDF-A OFF

O FDF-A S/S POSITION REMOTE

IDF-A or B ON & FDF-A SELECTED . AVAILABLE

0 FDF-A DISCHARGE DAMPER CLOSED

O FDF-A VANES MIN POSITION

0 LUB OIL PUMP-A or B .ON

0 CTRL OIL PRESSURE >8 kg per sq. cm

G z. STARTING PROCEDURE OF FD FAN-A IN GROUP SEQUENCE

Q Put FD. FAN-A GROUP SEQUENCE on auto mode.

0 Ensure LOP sub group sequence on auto & PUMP-A is selected

O Press"ON'push button of FD FAN-A GROUP SEQUENCE to start

O FD FAN-A in group sequence.

0 STEP INDICATOR indicates step number zero to seven one

0 after the other.

O Selected LO pump-A will pick up. FD fan-A motor will start

^ FD FAN-A ammeter will show no load current of 20 amps.

G DISCHARGE DAMPER SAD-2A will open.

O DISCHARGE DAMPER SAD-2B will close on interlock.{">.

^ SAD-1A will get enable to open command.

PROCEDURE TO START FD FAN-A ON MANUAL MODE

Ensure that all the permissives are satisfied and FDF-A

group sequence is on manual.

Ensure that SAD-iA is closed and minimum.

Discharge damper SAD-2A is closed and LOP sub group

sequence is on auto and "ON1.

Selected pump-A will pick-up.

Start FD Fan-A motor manually.

FD FAN-A ammeter will show no load current of 2 0 amps.

DISCHARGE DAMPER SAD-2B will close if it is open.

Open DISCHARGE DAMPER SAD-2A.

Load the fan by opening regulating damper SAD-IA

(Blade pitch control).

C-13 TO PUT FURNACE PRESSURE CONTROL ON AUTO

Adopt following procedure to put furnace pressure

control on auto.

Bring furnace pressure set point to -10mm we.

FURNACE PRESSURE SET will indicate -10 mm we.

Open DAMPER GD-6A until actual FURNACE PRESSURE comes

to -10 mm we.

Observe the furnace pressure on recorder (furnace Pressure

narrow range and wide range on back pannel).

Press middle push button of DAMPER GD-6A to keep it on

auto,if the deviation between set and actual valve is zero.

12

O /Y> : K S T A P . L T S H T M C ; ;>,Q% T O 1.0% A I R F L O WO Open DAML'Kk MAD-IA till actual total air flow comes to 2130

. T/hr on TOTAL AIR FLOW ACT meter (30% to 40% air flow) .

^ ^AIR FLOW LOW TRIP'alarm will reset.ft)^ TOTAL AIR FLOW ACT indicator will show 250 T/hr.

ID FAN guide vanes GD-6A will open accordingly to adjustfurnace draft.

ffj)/C-15 - CHARGING OF PRDS FROM OTHER UNIT ,

Ensure that PRDS header drains are open. f'-"o

Open slowly the interconnecting valve locally between

^ other PRDS and charge the PRDS header.

o

G

O

oObserve that PRDS pressure comes to 12 kg sq.cm andtemperature 200 deg.C on CWA-13 pannel close PRDS header

drain valves.G

y-":-16 - CHARGING OF SCAPH (STEAM COIL AIR PRE-HEATER)

Ensure that the drain valve of SCAPH are open.

Open auxiliary steam valve AS-320 , AS-325, AS-3.26 of

SCAPH locally.o ^,?

Open steam valve AS-323 from CWA-15 pannel.

Secondary Air temperature will start raising. Vo

Observe air temperature in DAS CRT.

STARTING AC SCANNER FAN

Ensure that DC Scanner Fan-B is running.

/atmospheric suction damper is open, if FD fan is off

and it v/ill close when FD fan is started.

Q

"{

XJ

or. ! CJ PURGING OF MO! \ ,\-\li

insure LI1..1L. I he bulbs oJ. Llie iol lowing puryc permissivo.s

** are glowing.

^ LO TRIP VALVE CLOSED, HO TRIP VALVE CLOSED, ALL LO NVS

^ y CLOSED, ALL HO NVS CLOSED, ALL PA FANS OFF, NO BOILER

Q TRIP, ALL FEEDERS OFF, ALL HOT AIR GATES CLOSED, ALL

*% SCANNERS SHOW NO FLAME.

Q Ensure that "READY1 and "START' lamp of PURGE CYCLE is

f% glowing.

Q Press the push button of PURGE CYCLE to start the PURGE.

ff, "Purging' lamp will glow, Wait till 5 minutes.

Q "PURGE OVER1 bulb of PURGE CYCLE will come.

O Boiler MFR will reset and secondary air dampers will close

r% on auto.

Q Ensure that Burner tilt is kept horizontal (50% position).

Q C-20 - TO PUT FURNACE/WIND BOX DP CONTROL DAMPERS ON AUTO

/T>, Following operation may be made to put furnace / wind

Q box DP control on auto.

O Turn PROG SELECTION switch to position-1 or 2.

O Set the FURN/WB DP SET at (40) mmwc.

O Bring auxiliary air dampers on elevations AB,BC,CD,DE,EF

0 and FF to 40% by pressing lower push button and put all

O dampers on auto.

Q Put master DP control station on auto to maintain DP as

Q per set point.

Q Furnace to W/B DP will show 40 mm on recorder on CWA-11

O panne1.

oG is

C-21 z LIGHTUP OF BOILER WITH AB ELEVATION PAIR

1-3 OR 2^_ WITH LDO

Ensure that LO is selected and all oil Nozzle Valves are

closed. /;'v'

Open LO TRIP VALVE- LO-19.Insert furnace temperature probe

Press "START' push button of AB elevation pair 1-3 or 2-4.

"START1 bulb will blink slowly. HEA IGNITORS correspond-

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

LIGHT OIL NOZZLE VALVES of 1-3 or 2-4 pair will open.

DISC SCANNER red lamp will show presence of flame.

HEA IGNITORS will be get retracted.

START bulb of AB elevation pair 1-3 or 2-4 becomes steady.

Boiler is lighted with AB elevation pair 1-3 or 2-4 oil

guns with LDO.

After every 1/2 hour change over of oil gun pairs may be

made for uniform heating of furnace.

Flue gas temperature v/ill start raising gradually and drum

metal temperature increases.

Change over of oil guns is made till drum metal tempera-

ture reaches 100 deg.C. drum pressure will start increas-

ing after 100 deg.C. drum metal temperature.

When drum metal temperature is greater than 100 deg.C.,

keep both pairs of A3 elevation oil guns in service.

If the flue gas temperature at furnace outlet is greater

than 540 deg.C., furnace temperature probe will come out

;J4' automatically. Then adjust firing rate to control theC'

v>sJ'_f, flue gas temperature at furnace outlet.

Omo

^ yC:22 - DEAIjiUA'l.'OR IIKATING AN1J PUGGING ' ' :. ' ' L . ' '' -

O Open doaorator vent valve SM-18 from CWA--15 desk.f Open auxi.li.ary steam supply valve AS-365. ^e^jZ**^?*1^*' "^

0 Open FST heat i nq valve? AS-370.

(Q) Temperature of feed water will start raising .

0 When feed water temperature reaches 100 deg.C.stop heating

0 Close vent valve SM-18.

ty Close valve AS-370.

0 Open CR-306 to supply deaerator pegging steam.

Adjust deaerator pressure set point to 3.5 kg/cm2.0> Put CR-306 on auto to maintain deaerator pressure as per

O set value.

Deaerator pressure will start raising gradually.

Temperature of HFO will start raising and reaches about

120 deq.C. after 1 hour.

13

^ C-21 fri'AiriTNC; OK TUK'BINR TilJR.OII, SYS'l'KM

*"* ' Ensu re t h a t MOT l e v e l is no rma l . S e l e c t C o o l e r N o . 1 .0

Cruirqi.: i,.'oo.l auxiliary oil Pump-2 is "OFF1 .

Q z AUTO PICKUP TRIAL OF TURBINE EOP(Emergency OIL PUMP)

r^, Ensure SLC AOP-1 and AOP-2 are "OFF1.

^ , . .. Make SLC EMERGENCY OIL PUMP "ON1. Trip AUX OIL PUMP-1.

c-> AOP discharge pressure will drop below 4.5 kg/cm2 .

-^ Emergency oil pump will pick up when discharge pressure

r^ drops below 1.3 kg/cm2.

o19

EOP ammeter will show 40 amps on CWA-16 desk.

Make SLC of AOP-1 and AOP-2 "ON"

Start AOP-1 and then trip EOP manually.

Make SLC lub.oil temperature control "ON' to maintain

lub.oil temperature to 44 deg.C on auto from CWA-16 desk.

C-25 TAKING GENERATOR SEAL OI_L SYSTEM IN SERVICE

Check following before charging generator seal oil .system

1. Tank levels IOT, SOT and SOST are normal.

2. AOP-1 is running.

3. Start seal o.-. .1 ::;::nk vacuum pump from CWA-.I7 desk.

Seal oil tank is under vacuum of 200 mm.

i . Generator seal o.i ] cooler-A is in service

-CHARGING GEN.SEAL OIL SYSTEM

ES-1 Through Local operation, close oil cooler bypass valve

V-63 (RFEG06).

. ES-2 Through Local operation, close inlet valve to turbine oil

tank, valve V-18 (RFEG07).

ES-3 Through Local operation, close bypass valve V-I7 of:

DPRV -E (RFEG0 8) .

ES-4 Through local opera;:, ion, select seal oil cooler-A (RFEG.13)

and its inlet outlet cooling water valves are open.

ES-5 Through local oporai: .ion, close generator seal oil cooler '.'

outlet valve GSW-35 (RFEG03;.

LS-G Through local operation, seJect seal oil filter No. .'I

(RFHG09).

[I

II

O - ESTABLISHING GENERATOR SEAL OIIi : SYSTEMREF TAG

0 ES-7 Keep g e n e r a t o r s e a l o i l pumps A a n d B on manual CWA-17

ff mode.

ES-8 Select D.C. SOP on manual.

ES-9 Press"ON'push button of GENERATOR SEAL OIL PUMP-A

^ - TAKING TffTAT.S OF AUTO PICK-UP OF S.O,P.s

^ ES-10 Select position-1 of A/M selector/;:switch of

A.C. SOP to keep Pump-A on manual", ;&. pump-B on auto.'

ES-11 . Press "OFF1 push button of S.O:-P.A^ Check that SOP-B n

O ' i ' ^ ' j . w i l l p i c k up on a u t o . -.;,../;:;..-'.:.._ .

""" ES-12" S e l e c t p o s i t i o n - 3 of A / M - s e l e c t b i p ^ W i t c h of A.C.S .O.P "G . - : ; : : : " ' : - ^ ^ ^ : \ -

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

ES-13 ..Press "OFF1 push button of S.OiLP-rB^ Check that SOP-A "o . '?; : - :W:y

will pick up on auto. ;.:.'-.:-o . "V .'

ES-14 Select D.C. S.O.P A/M selector ^switch position on auto."o

ES-15 Select position-2 of A/M selector switch of A.C. S.O.P "

to keep both pumps on "manual1.-

O^ ES-16 Press "OFF1 push button of S.O.P.B (running S.O.P). "

f^ Check that D.C. S.O.P. pick up on auto.

Q ES-17 Repeat step ES-9 to start S.O.P.- A.

Q ES-18 Select position-1 of A/M selector switch of "

Q A.C.S.O.P".:'"> ES-15 Select. 7).?.. B.C.?. selector switch position

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

Manual

21

C-26 CHARGING GENERATOR WITH HYDROGEN

Ensure that carbon dioxide is filled in generator Casing.

EH-1 Through Local Operation open Hydrogen feeding inlet

valve H-34 and vent valve.

EH-2 When Hydrogen pressure reaches 3.5 kg/cm2, through

local operation close hydrogen feeding inlet valve H-34.

Che"ck purity of hydrogen > 98% on the back pannel CWF--04.

Close Hydrogen vent valve.

C-27 TO PUT TURBINE ON TURNING GEAR

Ensure to keep SLC JACK OIL PUMP^-1 in "OFF1 mode.

Start JOP-1.

Ammeter of JOP-1 will show 50 amps.

JOP header pressure will show 120 kg/cm2.

Jacking oil pressure low indication resets.

Take auto-pick-up trial of JOP-2.

Make SLC JACK OIL PUMP-2 "ON1 and Trip JOP-1.

JOP header pressure drops from 120 kgs/cm2 .

JOP pressure low indication comes at < 100 kg/cm2.

JOP-2 v/ill pick up when JOP header pressure is less than

100 kg/cm2'.

Ammeter of JOP-2 willtshow 50 amps.

JOP header pressure will show 120 kgs/cm2.

. JOP pressure low indication resets.

Similarly JOP-1 auto pick-up trial can be taken.

Make' SLC JOP-1 and JOP-2 on "ON1 .

Press "ON1 push button of GATE VALVE GEARING to open it.

22

^ Turbine speed will increase slowly and will come to

^ 120 rpm.

g% Make SLC TURNING GEAR "ON'.

O Complete oil system can be taken in service by putting^ SGC oil on auto.

d> C-28 STARTING OF CEP-A OR B AND CHARGING CONDENSATE CYCLE

|J Before starting any CEP check following , ,0 Condensate pump-A discharge valve closed.

f*i Condensate pump-B discharge valve closed.

|j) Ensure that the following valves are in open condition:Q 1./u CS-1, CS-2, CD-18, CD-20, CD-22, CD-24 and C D - 3 5 i W - = i w

rj CST level normal.1"" DM tank level normal.0 DM-32 and DM-35 make-up valves are on manual and

3& thei r i s o l a t i n g ..valves are op"en. .,,...... ~

Select condensate Pump-A

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

condensate pump-A.

Discharge Valve-A opens on auto.

Condensate discharge pressure will raise to 24 kg/cm2.

Vent valves VA-1 and VA-2 will open on auto and closes

after venting (60 seconds).

CEP-A ammeter shows 3 0 amps.

Open valve CD-19 gradually.

Check thrust bearing temperatures < 6 0 deg. C.

Close DM-32 when hotwell level is 850 mm.

Hot well level is to be maintained normal by DM-32/DM-35,

if required. . . .

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

to keep CEP-B in standby mode and its discharge valve will

open. .

C-29 CHARGING OF LP HEATERS FROM WATER SIDE

Open heater 1,2,3 vent valves before charging and

close vent valves after charging.

Close CD-27 locally and open CD-25 & CD-26.

Close CD-30 locally and open CD-28 & CD-29.

Close CD-33 locally and open CD-31 & CD-32.

Keep valve CD-23 on manual mode and closed.

Open CD-14 manually to 10% and observe that hotwell

level is maintained.

24

J

m

O C-30 PUT DEAERATOR LEVEL CONTROL ON AUTO

auto.

^ Press middle push button of VALVE DM-35 to keep it on

O auto.

O> 3y pressing raise push buttons of DEA HWL SET bring the

& set point to zero mm we on DEA HWL SET(High water level 2600).

"-^ Press middle push button of VALVE CD-23 to keep it on

-^ auto.

^ C-31 PUT HOTWELL LEVEL CONTROL ON AUTO

** By pressing raise push buttons of HOT 'WELL LEVEL SET

*^ bring the hot well level set point to zero mm we.

*-* Press middle push button of VALVE CD-14 to keep it on

^ auto.

-

p Press middle push button of CD-19 to keep it on auto.

O C-32 STARTING OF BOILER FEED PUMP-A (FIRST BFP)

3

a

y Before starting BFP-A check following-

1.Mechanical Seal Cooler of BPF-A is charged from

water side.-

2 . The follcv-.'ir.g valves are to be opened locally

(Booster pump bearing oil cooler).

^ GSW-39, GSW-40 - Mechanical Seal Cooler.

^ GSW-41, GSW-42 - Lub.Oii Cooler ,.-.O

GSW-44, GSW-45 - Working oil cooler

GSW-46, GSW-47 - Radiator cooler f,oM !

25

m3.Hydraulic coupling oil level is normal. ^

4.Minimum recirculation valve FC-302 is open initially.

5.Deaerator level is normal. rJ

Open locally BFP-A bearing & stuffing box cooler valve p

X GSW-4 0. *

Open locally BFP-A working oil cooler valve GSW-45.

Open locally suction valve FS-301, FS-302, FS-303 of C

BFP-A,B,C. Z

BFP "A1 AOP is running on interlock. '1

PERMISSIVES OF BFP-A. :

BFP-A Off

Circuit breaker In service

Breaker spring Charged v

Deaerator level Normal v* V

BFP-A Suction Valve opened ^ j1

Aux.oil pump ON

Lub.oil pr.at HYD.coupl >2.5 kg/cm2 H -

C-33 STARTING BFP-A .':

Starting of .BFP-A in group sequence.

Put discharge valves of BFP-A,B,C Sub-group sequence

on auto.

Put BFP-A group sequence on auto mode.

Put BFP group control on auto. ^-

Ensure that BFP B,C AOPs are running and recirculation

valves of BFPs are open.

Select one pump operation.

26

'v >'

J -V

Select BFP-A from CWA-13 desk. cf -v^''

[x r-r-Make BFP Group Control 'ON1 . ,,c'r * W~'

^ BFP-A will start and stay at step-09/

BFP B &. (.' w.i ! 1. come to stand by mode: and stays at step-03

Observe various BFP parameters on desk.

(JW v a l v e will open on interlock, f/

C-34 FEED CONTROL STATION IN OPERATION (LOW LOAD LINE)

30% LOAD CONTROL VALVE IN SERVICE

Ensure that all spray valves before feed regulating

station are closed.

Ensure that drain valves of feed lines are open & closed

after charging.

Press "OP1 push button of LC FCV O/L ISO VALVE FD-325.

Press "OP1 push button of LC FCV I/L ISO VALVE FD-324.'

Set the drum level at zero mm we and observe that, drum

level set point comes to zero mm we.

Put ECO I/L ISO VALVE-E2 sub group sequence on auto and

make it on.

ECO I/L bypass valve will open and then main valve-E2

will open. Then bypass valve closes.

C-35 CLOSING DRUM VENTS,SUPERHEATER VENTS AND DRAINSAND REHEATER VENTS

When drum pressure reaches 3 kg/cm2 close drum vent B-5

superheater vent valves S-21,S-25,S-30,S-40, Superheater

drains S-19,S-17,S-15,Reheater vent valves R-l and R-4 can

be closed before pulling the condensate vacuum.

'

m

C~ 3 6 GIVING BOILER BLOW DOWN AT 10kg/cm2 DRUM PRESSURE V.p . ( \,y

C Press emergency push buttons to hand trip the boiler.

^* "Boiler MFR TRIP" annunciation will come MFT-1 & MFT-2

^ green lamp will glow and MFR "RESET1 lamp will vanish.

AB elevation oil guns will withdraw and LOTV and HOTV

will close.o

Secondary air and fumace/windbox DP dampers will openO

full on interlock, ICJO1'.0

All purge permissive lamps will glow and "PURGE" ready

bulb will glow.

^ Ensure FD-20 is in closed position

mo

o

ooG

Open (M IDIUVIM ^;r^ ^ s s v MS.-202.;^

r^ M S 5 ? M . s - 2 1 2 .

o3FR TCV MS-226.

:.Ai:\[R DRN MS-224 .

N BFR TCV MS-228.

:RK AFT HPBP CR-206-.

:RN AFT HPBP CR-206.

,,,_,, i!R -TRAINER DRN HR-206.

kee-o MS stoo valves Grouo sequence en manual .Ifitw ocen :-'.SL VALVE IB MS-301A & 302A.

O ' . :

;.'c.v throttle start-up vent S-33 main steam lines and

m a w steam stop valves'temperature will increase when

temperature of ESV body reaches 100 deg.C. .

Then 0.9en main steam line.valves MS-301 and MS-302.

. Then close integral bypass. yal.ves MS-301A and MS-302A%j . ' : -;;.'':-' 1 ' " [ ' ' ' ; ^ t - - 1 ; - ' "

_ . r : r o m d e s k C W A - 1 3 . ':';' ' ' ''

PULLING AND GLAND SEALING

reheater vents are closed before coniensaSje

. ^]c\Yi

Open AS-373 valve and adjust ejector steam pressure setto 6 kg/cm2.

If the deviation between set value and actual value is

zero, put AS-378 valve on auto to maintain ejector steampressure to 6 kg/cm2.

Open starting ejector steam valve AS-2 and air valve SM-16Wait till vacuum reaches 0.2 kg/cm2.

Open locally AS-368 valve to supply gland seal steam.

Put seal steam control on auto from CWA-16 desk.

Gland seal steam drain valve MAL-81 closes when gland

steam header temperature reaches 150 deg.C.

When condenser vacuum reaches beyond 0.7 kg/cm2 take

main ejector-A in service by opening its steam valveAS-3 from desk and air valve SM-14 locally.

When condenser vacuum reaches 0.75 kg/cm2 withdraw

starting ejector by closing its steam valve and air valve.Condenser pressure high alarm resets at -0.75 kg/cm2

vacuum will increase and reaches 0.95 kg/cm2.

Condenser vacuum can be pulled through SGC condensate and

evacuation by putting it on auto and make SGC "ON1.

C-40 CHARGING OF HP/LP BYPASS SYSTEM

Open locally HPBP valve MS-311 .& MS-312 (warm up valves) .

Before opening HPBP main valves observe that the

upstream and down stream temperature differential is

not more than 25 deg.C.

32

oo

Put LPBP control on ciuLc; ar1/.: make LPBP automatic

control interface ""ON1 .

Set HPBP down steam temp, to 230 deg.C and open valves

BPE-1 and BPE-2 by opening it by 5% to 10%.

Close HPBP warm up valves MS-311 and MS-312 locally.

Open HPP-P valves gradually :o increase main steam

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

When MS oressure reaches 3 5 kg/cm2 set HPBP pressure set0

point to 35 kg/cm2 and put the valves on auto.o

Close start up vent valves S-33 and S-32.In order to raise the steam parameters of 35 kg/cm2,

G3 50 deg.C and 9 5 T/hr steam required for rolling the

turbine, take CD and EF oil elevations in service.

C-41 CHARGING OF PRDS OF OWN UNITo

Ensure that the following valves are in open condition:

^ AS-306, AS-309, AS-310, FD-34 0 and FD-339 (PRDS. valves) .Open isolating valve FD-332 locally.Ensure that PRDS-1 and PRDS-2 both pressure and tempera-

oture control are on manual.

o^ Ensure to open first the spray control valve and then

pressure control valve .O ' -

Press raise push button of TEMPERATURE SET till indicatorU of PRDS-1 TEMPERATURE SET shows 2 00 Deg.C.

'w' Open FD-342 PRDS spray control isolating valve and

^> open FD-343 from desk.

o

Press middle push button of PRDSE-1 (FD-343) to keep

it on auto.

PRDS-1 TEMPERATURE ACT v/ill show 2 00 deg. C.

Adjust PRDS pressure set point at 12 kg/cm2.

Open PRDS-1 isolating valve AS-307.

Press middle push button of PRDS-1 (AS-308) to keep it

on auto.

PRDS PRESSURE ACT will show 12 kg/cm2 on CWA-13 desk.

Gradually close auxiliary steam interconnecting valve

AS-500 from local.

C-42 CHARGING OF STATOR WATER SYSTEM

Ensure, that expansion tank ejector is in service.Stator water cooler inlet valves GSW-10 and GSW-11

are open locally.

Close expansion tank drain valve Y-19 locally.

Check the following valves are open:

Y-l, Y-2, Y-3, Y-6, Y-7, Y-18, Y-6.2 and Y-21

Expansion Tank level is normal.

z OPERATIONS IN STATOR WATER CIRCUIT

SW-1 Through local operation open stator water cooler-A

outlet valve GSW-12.

SW-2 Through local operation close stator water cooler-B

outlet valve GSW-13.

SW-3 Through local operation close water cooler bypass

valve Y-B.

SW-4 Through local operation select stator water cooler-A.

3 4

f) SW-5 Through local operation open the inlet valve Y-23

fji to polishing unit.. . .-

SW-6 . Through local operation close the stator water bypass

9 operation valve Y-17.

SW-7 ': Turn the selector, switch of GENERATOR CW PUMP A/M S/S to

: ..position number-2 to make generator CW pumps A & B manual.

^ SW-8 Press "ON'push button of GENERATOR STATOR CW PUMP-A'.

SW-9 Through local operation adjust valve Y-17 till statori water recorder shows 27 cubic meters per hour flow .

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

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

^ SW-11 Press -OFF' push button of GENERATOR STATOR CW PUMP-A.

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

SW-12 Turn the selector switch of GENERATOR CW PUMP-A/M S/S toG

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

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

SW-14 Turn the selector switch of GENERATOR CW PUMP-A/M S/S too

position number-1 to make generator CW pump-B on auto.

C-43 ROLLING OF TURBINEo ,

Before rolling the turbine ensure that all the^_ parameters listed below are built up to. the values asw

indicated below.o

Main steam pressure 35 kg./cm2.'o

Main steam ;::en\peratur e around 3 5 0 Deg . C .' Main steam f,lcw about 96. T/hr.

^ .PAo

3 5

Press "0Nr push button of LOAD CONTROL from CWA-16 desk.

Press "ON'push button of LOAD Gradient.

Raise LOAD REF till indicator on LOAD REF shows 20 MW.

Observe that the bulbs of following indications are

glowing:

CR/H NRV LHS CLOSED.

CR/H NRV RHS CLOSED.

HP STOP VALVE-1 CLOSED.

HP STOP VALVE-2 CLOSED.

INTERCEPTOR VALVE-1 CLOSED.

INTERCEPTOR VALVE-2 CLOSED.

Press "GM: push button of KP/IP TRIM DEVICE.

Ensure that tracking device i's "OFF1 .

Ensure co keep following SLCs are in "ON' postion:

SLC AUXILIARY OIL PUMP-1

SLC AUXILIARY OIL PUMP-2

SLC EMERGENCY OIL PUMP

SLC JACKING OIL PUMP-1

SLC'JACKING OIL PUMP-2

SLC TURNING GEAR

SLC CONDENSATE PUMPS

SLC LP WATER INJECTION v""

SLC DRAINS L/.

Press middle push button of SGC OIL SUPPLY

to keep it on auto.

3 6

mO /' Observe that red light is glowing on TTS SUPPLY-1

Warmup can be concluded when the temperatures stablises

VALVE NUMBER POIONT NUMBER IN WALL STRESSRECORDER

ViMSVMS f ) 3

VMSVMS \c ? 4

ViMCVMC 5

VMCVMC 6

ViMSVMS 3

Raise STARTING DEVICE till its indicator T, -H--- ^

j in-comes to 56% on STARTING DEVICE POSITION to open IV-1 AND

IV-2. IV 1 & IV-2 will open.

Make "ON1 TRACKING DEVICE.

Raise SPEED REF till reference RPM shows 600 to increase

the turbine speed to 600 rpm.

Observe GATE VALVE gearing indicates barring gear

disengaged at 240 rpm.(Gate valve gearing closes).

Observe bearing vibrations are < 35 microns.

JOP-1 trips at turbine speed of 54 0 rpm.

Observe the bearing vibrations and shaft vibrations.

C-44 TURBINE TRIP SOLENOID TESTING / 1 ' n -A#-'WTo check healthiness of Turbine trip solenoid press push

button of TURBINE TRIP to trip turbine manually.

"TURBINE TRIP" annunciation will come.

HP stop valves and IP stop valves will close.

0 JOP-1 will pickup on auto when turbine speed is at 510 rpm

0 Bring STARTING DEVICE to zero position to reset

0> turbine trip indication .

C-45 REROLL THE TURBINE TO 6C> RPM AND SOAKING OF TURBINE

^ Follow the same procedure given in step-43 to rerollo

the turbine to 60 0 rpm.

Soak the turbine for about one hour to satisfy X-6

'' criteria (HP shaft mid metal temperature) .

Observe that following MAL valves will close.

ODown stream of HPCV drain MAL-15.

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

Drain ahead of swing check NRV MAL-66.

Drain before IPCV MAL-31. Drain before IPCV MAL-32.w Drain before IV MAL-26.

w Drain before IV MAL-27.

OObserve the turbovisory parameters.Turbine bearing vibrations < 12 microns.

oTurbine shaft vibrations at HPT,IPT,LPT

C-46 INCREASING TURBINE SPEED TO 3000 RPM

Press raise button of SPEED REFERENCE till indicator

shows 3 000 rpm.

Turbine speed will gradually increases to 3000

rpm at the rate of 60 0 rpm/min.

Observe at critical speeds, turbine bearing vibrations

will go high and will normalize after passing through

critical speeds. ! '. ' c A (. I '-"> ''"' o -^

, , When secondary oil pressure reaches 3.0 Kg /Cm2,

I--' r hydraulically operated extraction swing check valves

\ N,-,"''"' " (except A-4) open.

^J"'""\ AOP-1 will trip at about 2800 rpm.

v i^ '^MOP discharge pressure will be 9.5 kg/cm2.

Turbine lub oil pressure after cooler will show

5.5 kg/cm2.

When'-turbine speed reaches 3000 rpm observe HP/LP bypass/

opening reduces.

C-47 SOAKING. OF TURBINE AT 3000 RPM TO SATISFY X-7 CRITERIA

At 3000 rpm turbine is to be soaked for about half an hour

till X-7 criteria is satisfied (IP shaft mid metal

temperature).

Observe Following Parameters:

HPT differential expansion -4.0 to +5.5mm

IPT differential expansion -3.2 to +7.2mm

LPT differential expansion -7.0 to 30.0mm

HPT overall expansion < 2 6mm

40

J IPT overall expansion < 13mm

Axial shift -1.0 tomm +1.0mm

^ Turbine bearing vibrations 12 microns

^ Turbine lub oil Temperature 44 Deg C

z MANUAL SYNCHRONISATION OF GENERATOR

SY-6 Ensure that "Gen. ckt. Bkr. spring charged1 CWA17

indication is available.r[

SY-7 Select "check'position of "Syn SS-1 for -n^- CWA17:ftfr*

(&> main breaker1 key switch. a^ "

SY-8 Adjust raise/low push button of auto balance so CWA17that running voltage & incoming .voltage are equal.

SY-9 Insert key in "synchroscope SS' & turn it to "

, **" position-2 to make it "ON1. Check that "Bright ,,/} ^ V '-3 "'' '""A *

f r'K On Syn. 'LED lits up.

^3

ri\

* SY-10 Adjust "Speed Reference1 so that synchroscope CWA16needle takes a slow, clockwise rotation.

SY-11 When synchroscope needle posititon is 12 O'clock CWA17

and check syn. relay operated "LED lits up1,

Close main CB control switch 52-E..

SY-12 Adjust speed reference to pick 10-15 MW Load. CWA16SY-13 Turn the "Synchroscope SS' to position "I1 CWA17

to make it "OFF' ..

SY-14 Turn key in "Syn SS-1 of Main Bkr'to position"2'(OFF) "

^ AUTO SYNCHRONISATION OF GENERATOR AFTER STEP SY-5

SY-6A Insert key in "Syn SS-1 for main breaker1 and turn "

it to position "3' to select "Auto1.

SY-7A Press "ON' push button of synchroniser. CWA16SY-8A Check main breaker gets closed,& 10-15 MW load

is picked up.

42

Oo

SY-9A :Turn the "Synchroscope SS' to position "1 ' CWA17

^ " " to m a k e it "OFF 1 .

"^ SY-10A Turn key in "Syn SS-1 for main breaker'

to position S2' (OFF).

After Synchronisation check that GTR Wdg.temp.is normal -/&o

GTR cooling pump has started.o. ^

C-49 OBSERVE IMPORTANT PARAMETERS OF TURBO GENERATOR< 5

AFTER SYNCHRONISATION

(Range of various parameters)o

GTR HV temperature < 90 Deg.CGTR LV temperature < 90 Deg.CGTR Oil temperature < 90 Deg.C

HPT middle top/bottom temp, difference < 30 Deg.C

IPT front top/bottom temp, difference < 30 Deg.C4> ^

fU r\ (,\ IPT rear top/bottom temp, difference < 30 Deg.CO ' A \) -A

Condenser vacuum 0.9 Kg/Cm2ESV body temperature . 32 0 - 3 50\0

* ISV body temperature 320 - 350G V ,\

\^ CRH temperature 230 - 250

i HP casing mid metal temp. 280 -300

AIV '' ' p> Ensure closing of all MAL drains on auto after

, \i c y.n* synchronization.

t. HPT differential expansion -2.00 to +5 mm

^M v ^ IPT differential expansion -2.0 to + 5.5mm

;>XJ'\ ^ LPT. differential expansion -7.0 to 25.0 mm

'V , i': HP overall expansion 26 mm

IP overall expansion 13 mm

43

Axial shift . -1.0 to +1.0 mm

Turbine bearing vibrations < 12 microns

Turbine shaft vibrations < 120 microns

at HPT,IPT,LPT

TSE margins (Load margins) >3 0 K

Turbine lub oil temperature 44 Deg.c

Note that all differential expansions should move

towards positive side.

Bearing metal temperature < 90

Bearing drain oil temp.

HPT top/bottom temp

Inlet HP casing temp .

HPT exhaust temp.

IPT top/bottom temp.

HPCV position(approx).

IPCV position

Generator slot temp.

Generator core temp.

LPT exhaust temp.

C-50 CLOSING OF VARIOUS TURBINE SIDE DRAINS

Following turbine side drain valves are to be closed

after synchronization/

Close valves from CWA-16 desk-

HR-206, HR-208, HR-311, HR-312, HR-233, HR-234, HR-230,

HR-232, HR-214, HR-216, MS-204, MS-214, MS-202, MS-212,

MS-222, MS-226, MS-224, MS-228, CR-206, CR-208.

< 90

< 65

160/150

270

200

90

20

minimum

< 75

< 75

45

Deg

Deg

Deg

Deg

Deg

Deg

%

Deg

Deg

Deg

.C

.C

.C

.C

.C

.C

.C

.C

.C

44

oo0

2 .

H-1

H-2

H-3

C-51 CHARGING OF HYDROGEN COOLING SYSTEM

1. Hydrogen coolers outlet valves GSW-24, GSW-25

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

Hydrogen cooler-A outlet valve GSW-20 is open.

Open hydrogen cooler-B inlet valve GSW-2(RFCW09)locally.

Open hydrogen cooler-C inlet valve GSW-22(RFCW-10)locally.

Open hydrogen cooler-D inlet valve GSW-23(RFCW-11)locally.

^ GT-1 Open locally GSW-500 generator transformer cooler(RFCW006)

"^ Ensure that generator HT and LT winding temperature are

"^ within limits.

^ Ensure that station transfomer winding temperature is

within limit.

^ C-52 WITHDRAWAL OF STEAM TO SCAPH

When flue gas outlet temperature is greater than

^ 110-115 deg.C, close auxiliary steam supply to SCAPHO^ by closing the valve AS-323 from desk CWA-15.

C-53 TAKING PULVERISER-A IN SERVICE (1st PULVERISER) '

'"*' In order to increase the load on turbogenerator coal

Ofiring is to be initiated with lower most pulveriser.

oIt is assumed that ESP is in service.

oSelect pulveriser-A manual mode from CWA-12 desk.

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

o45

STARTING PA FAN-A

Start seal air blower of PA FAN-A.

Put all the primary air dampers on manual mode.

Cold air damper PAD-4A is full open.

Before starting PA fan-A,Open PA fan-A bearing cooler

inlet valve GSW-210 and outlet valve GSW-202 locally.

Open PAD-3A cold air gate by 5% locally .

Start seal air Fan-A from CWA-11 desk.

Check permissives of PA fan-A are satisfied except seal

air bowl DP.

j The permissives are -SA bowl DP OK

NO MFR Trip

Pulveriser ignition permit

Hot air gate closed.

Inlet damper in minimum position.

CAD is less than 5% open.

Give command to start PA Fan-A.

Auto command will be given to close PAD-4A cold air damper

to close

0 , O

-STARTING PULVERISER-A0^ Ensure that mill-A is on manual.olP. - Check auto pick up of lub oil pumps.fj. - Trip lub oil pump-1,LOP-2 will pick up and tripO

f ' LOP- 2, LOP-1 will pick up.

% Check mill bearing temperatures are normal.

f^ Check all pulveriser permissives are satisfied as given

^v below:1. Pulveriser start permit2. Primary air permit

O It -3 . Buriner gates open^ 4. Lub oil OK

- \

J ' 5. Pulveriser discharge valve openo

6. Tempering .air valve openO

7. Bunker gate openo^ 8. Cold air gate openo

9. Pulveriser outlet temperature < 94 Deg. C.o

10. Pulveriser ignition permit11. No auto pulveriser start command

o12. Pulveriser OFF'

o13. Seal air header/bowl DP OK

o14. No pulveriser trip15. Pulveriser ready

wEnsure that bunker gates CD-1A, CD-2A, CD-3A are open

O ' locally.Ensure Mill-A oil cooler inlet valve open locally.

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

o

Ensure lub.oil pump-1 A & 2A suction and discharge ^

valves are open locally. ^

Ensure lub.oil pump recirculation valve is open locally ^

and adjust lub.oil pressure more than 1.2 kg/cm2.Start pulveriser-A and observe mill current of 20A. .^

Open hot air gate PAD1-A from desk. r-

Set mill coal air temperature(mill outlet temperature) ^

to 77 deg. C to maintain actual mill outlet temperature /--

on auto. . ^

Set PA flow of 55 T/hr on PA flow set to maintain actual ,-

flow, of 55 T/hr on auto. ,-~

Open PAD-2A , PAD-4A and PAD-5A. :r>

Open the dampers to an such extent that actual mill outlet '-

temperature is 77 deg. C and actual PA flow is 55 T/hr. ^

Put PAD-2A and PAD-4A on auto to maintain mill outlet temp.

oo

-START UP OF PULVERISER ON AUTOo :~ Coal Mill-A can be started on "Auto mode1 by putting

O elevation on auto.f^ Open PA fan discharge valve and give "ON'command to

f% pulveriser.

,..%, PA Fan-A,Coal mill-A and coal feeder-A will start on auto

f* Hot air gate also opens on auto.

f^ Ensure to keep 02 TRIM SET on manual mode.

.r& C-54 - TO PUT AIR FLOW CONTROL ON AUTO

if> Raise 02 TRIM SET to raise 02 TRIM SET point to 7%.

r\ Increase 02 Trim to increase air flow set on Auto to

*v get SAD-1A of FD fan-A. Control vane deviation zero.

jl Then put SAD-1A - FD fan-A control vane on auto.p> By adjusting "02 Trim1 bring 02 deviation zero.o> Then press middle push button of 02 TRIM to keep

c--s it on auto.

(--%, Air flow will vary to adjust 02 % to 7%.Q) ID fan control vanes will vary to control furnace draft.

O C-55 LOAD RAISING UPTO 5_0. MW

^ Increase the feeder-A speed to 60% to 70%.

0 MILL-A FLOW ACT will increase.

C-56 CARRY OUT AUXILIARY SUPPLY CHAANGE OVER FROM STATIONTOUNTTBUS-1CA

Ensure that breakers 1-CA and l-CB are in service and DC control supply is

W .AS -1 BTSP-I is 'IN' and selection is on "MAN FAST'.

Ensure that Bus transfer system ready for Fast Transfer & Bus transfer system

is

AS-7 Press the "TEST' push button on the back panels (BTPS-02)a

"I/C BKR CB1 CLOSE test mode' window, & "TIE BKR CB-2 OPEN

test mode'window on FACIA WINDOW FW1 will glow on BTPS-02.

^ AS-8 Press the "TEST RESET1 button. All the above indications

,f| will disappear. "READY FOR TRFR" lamp will glow.Q AS-9 Press "READY FOR TRFR1 push button "I/C BKR CB-1 CLOSE1

rt window Sc "TIE BKR CB2 OPEN1 window on FACIA WINDOW FW1 will

,

Press^OP' push button of LPH-2.EXT STM ISO EX-10 to charge

LPH-2 with steam.

Level will start raising in LPH-2 after some time.

Close LPH-2 EXT DRN EX-101.

Note:

When load exceeds 2 0 MW and EX-A2, A3 opening is greater

than 15% & SLC drains is "ON1 MAL valves-55, 54 will close.

Close locally extraction-1 pipe line drain valve EX-113.

Put LPH-2 level control on auto. First set NWL and HWL

to zero on level set indicator.

Then open DR-21 and DR-24 manually and maintain LPH-2

level.

If the deviation in valves is zero put DR-21 and DR-24 on

auto.

Open LPH-3 EXT STM ISO EX-11 to charge LPH-3 from steam

side. LPH-3 drip level will rise gradually.

Close LPH-3 EXT DRN EX-103

Observe increase in Condensate temperature after

LP heaters.

Observe LPH-3 level in the indicator LPH-3 drip level LCD

meter shows 200 mm.

Put level Control at LPH-3 on auto.

Bring LPH-3 NWL SET point to zero mm we.

Bring LPH-3 HWL SET point to zero mm we.

Put DR-16 and DR-19 valves on auto.

Whenever EXTN NRV (A3) opens more,observe that DR-16 also

opens more to maintain LPH-3 drip level.

52

_ C-5 9 TAKING FEED CONTROL STATION FULL LOAD LINE INTO OPERATIONt'S ' ~ '"" " "" """ ~ "

^ This is to be done at a load oJ: about 50 MW.O

~ Select ^3 ELEMENT CONTROL'of CONTROL SELECTOR to keep drum

f% level control on three element control.

0 Keep BFP-A SCOOP on auto.

|3 Open isolating valves FD-320 and FD-321 of full load Check permissives of PAN-B. If all permissive lamps are

v) glowing then start PA fan-B.

*-* Open pulveriser discharge valve.

0 Check mill permissives are available to start mill-B.

O Start pulveriser-B manually. Open hot air gate.

D Then open PAD-5B, PAD-2B and PAD-4B and get 55 T/hr

Q of PA flow and mill outlet temperature to 77 Deg.C.

53

Put all the above dampers on auto.

Start coal feeder-B manually.

After one minute feeder speed can be increased.

Increase feeder speed.

Flue gas temperature, MS, HRH temperature will increase.

Maintain 02 % at APH inlet to about 6% by increasing

secondary air. Increase the feeder speed gradually.

C-62 INCREASING -LOAD TO KKD MW

Increase the load Co 90 MW by load reference.

Reduce oil firing by withdrawing oil support of EF

elevation.

Increase the load to 100 MW by increasing load reference

to 100 ME.' .

Feeder speed of, A & B mill will come to about 60-70%.

C-63 TAKING SECOND BFP IN SERVICE ^

For further increasing the load on turbogenerator start

BFP-B.

Before starting BFP-B check its permissives and line up

BFP-B.

If the feed water flow is more than 240 T/hr, change 1

pump operation to 2 pumps operation of BFP's.

If BFP group control is "on "auto1 then BFP-B will pick-up

beyond feed water flow of 325 T/hr.

Otherwise BFP-B can be started on sub group sequence or

on manual.

Put BFP-C on standby mode so that if any pump trips

standby pump will, pick up.

5.4

om

- C-64 CHANGE: 0V1JR OF \JM)ljO

^ Make change over oJ: PRDS-1 (High capacity PRDS) to

Q PRDS-2 (Low capacity PRDS).

!| Open first isolating valves AS-304 and FD-335.0 Gradually open PRDS-2 spray control valve and close PRDS-1

O spray control valve.

0 PRDS temperature will be maintained at 205 deg.C.

0 Then gradually open pressure control valve of PRDS-2 and

0 close PRDS-1 pressure control valve.

O PRDS-2 pressure control valve will maintain PRDS pressure

Q to 12 kg/cm2.

0 Then take PRDS-1 on manual and PRDS-2 on auto.

0 C-65 TRAKING SUPERHEATER SPRAY CONTROL VALVES IN SERVICE

0 Open isolating valves in super heater spray control lines

0 S-57, S-59, S-62,S-68,S-69 and S-71.

O Keep SH spray control on manual:

O Open block valve S-52 then open 1/2 isolating valves

0 S-60 and S-66.

With the help of spray control valves S-61 and S-67

'

C-67 CHARGING OF HP HEATERS 5 & 6_ FROM FEED WATER SIDE

Open HP heaters 5 & 6 water box vents locally before

charging and close it after charging from water side.

Ensure HEATER BP valves FD-9 & FD-12 are open.

Ensure to keep FW I/L ISOL VLV GROUP on manual.

Open FW I/L VLV IB FD-7A.

Ensure to keep FW 0/L ISOL VALVE GROUP on manual.

Open FW O/L VALVE IB FD-8A.

Ensure to keep FW I/L ISOL VALVE GROUP on manual.

Open FW I/L VALVE IB FD-10A.

Ensure to keep FW O/L ISOL VALVE GROUP on manual.

Open FW O/L VALVE IB FD-11A.

Ensure to keep HTR BP VALVE GROUP on manual.

Open locally heater charging valve FD-18.

^OP' bulb of GR BYPASS VALVE FD-17 will glow.

"OPr bulb of GR BYPASS VALVE FD-16 will glow.

Then close valve FD-1S.

Open HP HEATERS inlet/outlet valves FD-7, FD-8, FD-10,

and FD-11.

Close their integral bypass valves FD-7A, FD-8A, FD-10A,

and FD-11A.

Close HEATER BP Valve FD-9 & FD-12.

Now HP heaters are charged from feed water side.

56

C-68 ESTABLISHING SECOND AIR CYCLEo

Before tciking pulveriser-C in service start another airo

cycle . Start IDB & FDB. . .-

Equalize the loading of ID Fan-A & ID Fan-B and FD Fan-A

-. and FD Fan-B.5_ Increase HP/LP bypass pressure set point to 125 kg/cm2.CJ)

^ Ensure that deaerator pegging steam changeover takes place

-^ at 12 kg/cm2 of CRH pressure from PRDS to CRH line.

tp. It maintains D/A pressure of 3.5 kg/cm2 .

~ C-69 ESTABLISHING PULVERISER - Co :

r>. Start pulveriser-C and further increase the load by load

g^ reference .

^ C-70 INCREASING LOAD TO 126 MWf^ Increase the load to 126 MW by raising load

,Q reference. If BFPB is not started on manual it will pick

r^ up on auto at flow of > 325 T/hr.

^ Maintaian SH steam temperature and RH steam temperature

0 release will now be available for taking EXT-4 in service

Q for deaerator pegging.

Q Open valve EX-301.

Q Observe closing of valve CR-306.

Q Observe various parameters at 126 MW.

Q C-71 AIR FLOW CONTROL ON AUTO

0 Bring 02 trim set to 50% to maintain 02 in flue gas at

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

O will generate 02 set point according to load.

Q

57

C-72 CHARGING OF HP HEATER _5 FROM STEAM SIDE

Open DR-13 and DR- 8 locally.

Open HPH-5 EXT DRN EX-112.

Open EX-13 to admit extraction steam to HPH-5.

Drain extraction valve- A5 (MAL-47) closes.

Set HPH-5 NWL SET will show to zero mm we.

Set HPH-5 HWL SET to zero mm we.

Put DR-14 on auto.

Put DK-11 on auto.

Close HPH-5 EXT DRN EX-112.

HPH-5 level will increase slowly to 250 mm we.

Feedwater temperature AFTER HPH-5 will rise slowly.1HPH-5 LEVEL LOW annunciation will reset.

C-73 CHARGING OF HPH-6 FROM STEAM SIDE

Open DR-1 and DR-3 locally.

Open HPH-6 EXT DRN EX-110.

Open EX-12 to admit extraction steam to HPH-6.

Set HPH-6 NWL SET indicator to zero mm we.

HPH-6 HWL SET indicator to zero mm we.

Put'VALVE DR-2 on auto.

Put VALVE DR-34 to keep on auto.

Put DR-6 on auto.

Close HPH-6 EXT DRN EX-110.

HPH-6 level will increase to 250 mm we.

"HPH-6 LEVEL LOW1 annunciation window will reset.

Feed water temperature will rise slowly.

58

^ Load initially will reduce marginally.f%v> Spray will reduce.

Economiser inlet temperature will increase.

Observe feed water temperature & outlet of HPH-5 & HPH-6.

TO PUT HP HEATERS LEVEL GROUP PROTECTION ON AUTO.Put FW I/L ISOL VALEV GROUP on auto.

oPut FW 0/L ISOL VALVE GROUP on auto.

oPut HEATER-5BP VALVE GROUP on auto.

Put FW I/L ISOL VALVE GROUP on auto.

Put FW O/L ISOL VLV GROUP on auto.

Put HTR-6 BP VALVE GROUP on auto.o

Put HEATER GROUP BP on auto.

^ C-74 LOAD RAISING UPTQ 150 MWo

Raise load reference to increase the load 150 MW.

After coal feeder C speed goes beyond 60% withdraw oilo

support at CD elevation.

"^ While raising steam parameters and load, ensure thatoo

o

HP bypass pressure set point is maintained 5 kg/cm2

above M.S. pressure.

O C-7.5 TAKING PULVERISER-D TN SERVICE

Q Take pulveriser-D in service and increase the fuel firing

Q C-76 LOAD RAISING TO _17j5 MWQ Raise LOAD REF to increase the load upto 175 MW.

Q MW meter will show 175 MW (actual).

r^ Observe all the parameters. M.S.temperature and HRH steam

temperature to be maintained around 52 0 deg.C.

o59

C-77 TO WITHDRAW OIL SUPPORT FROM AB ELEVATION

Increase feeder speed of D mill to raise the load.

When MS pressure starts increasing raise load ref. to

190 MW to increase the load.

Put SH steam temperature spray control valves and RH

steam temperature spray control valves and Burner TILT

MASTER on auto.

Put SH steam temperature Set point & HRH steam temperature

set point also on auto.

C-78 LOAD RAISING TO 210 MW

Maintain MS pressure at around 150 kg/cm2 and increase

the load to 210 MW .

C-79 TO PUT UPC' ON AUTO

Ensure RC feeders A,B,C & D speed deviation is zero and

put them on "Auto'.

Raise UDC pressure GRAD set point to 50%.

Raise UDC pressure set point to match actual MS pressure.

Raise START UP FUEL GRAD to 50%.

Observe deviation between UDC pressure set point and

actual MS pressure at the deviation meter provided on

control desk CWA-12.

Put BLR FUEL MASTER on "Auto',when this deviation is zero.

START UP MODE will come into service indicated by START

UP FUEL SET POINT RUN lamp glowing.

60

To take CMC mode in service adjust unit target load GRAD0

SET POINT to 50% and ensuring zero deviation between UDCPRESSURE SET POINT & actual MS pressure to make CMC "ON'

from turbine desk button. Now load can be varied from

^ unit target load set point.

Put UDC pressure set point on auto. Put HPBP pressure set

point on auto.

_ Raise UDC PR SP till indicator on UDC PR SP INDICATION^ comes to 150 kg/cm2.

Wait till pressure deviation comes to nil

^ (Time 15 minutes approx.).

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

Put boiler set POINT on auto.

~ Start-up fuel lamp will be off on CVJA-12.O

r~-_, MS pressure will be maintained as per set point.

^ Unit load will be maintained as per set point.

c^ C-80 . IMPORTANT PARAMETERS AT 2_10_ MW

,^-S Maintain important parameters as given below:

'> Main steam pressure before ESV 150 kg/Cm2

Q Main steam temperature at boiler outlet 540 Deg. C

-^ Main steam flow 627 T/hr

Flue gas temperature at air heater O/L 14 9 Deg.C

~> Drum pressure 162 Kg/Cm2

-x Condensate flow 501 T/hr

Condensate header pressure 20 Kg/Cm2

Feed water flow 650 T/hr

QQQ

61

F'eed w;;ii:.r temperature at; economi ser .i.n.lc.-r; 24-1 Deg. C

Total combustion air .

02 in flue gas at economiser outlet

.Wind box to furnace DP

Reheater steam pressure at outlet

CST .lev.: I.

Stator water conductivity

instrument air header pressure

Service air, header pressure

Condenser'' vacuum

Deaerator pressure :

EJ'/A level ' '' "'"

D/A temperature

. Hotwell level

HPT differential expansion

1 PT d i. l I'.: I'enl: ial cxpanuJon

;.LHT -differential expansion

HP overall expansions

IP^overa LI expansion;: ,

Turbine bearing vibrations

^Turbine sha^t:-^ibra:t^G^is^at, HPT, IPT, LPT

.V'TSEi.margins'(Lbad margins):

\ Turbine lub .oil temperature

' HPH-6 level :

HPH-5 l.-vol

792 .7

3 .5

100

34 . 8

2900

3 0'

44

230

'?. 5 0

T/hr

%

mmwc

Kg/Cm2

mm

mmho/cm

Kg/Cm2

Kg/Cm2

Kg/Cm2 ^

Kg/Cm2

mm . :

deg.C

mm

+ 5 mm

i-5 mm

25 m m : ; .;

mm

m m '.:.

. 0 mm

microns

micrpris %

K

Deg. c

mm

mm

I.-':

!

? ,

"(*

62

ooo

o

GCoG

o

Q

C-81

G

o

LPH-3 level

LPH-2 level

Ejector steam pressurePRDS pressure

PRDS temperature

CRH pressure after attemperator

CRH temperature attemperator

HRH Reheater steam temp.at outlet

HRH Reheater steam flow at outlet

S H Spray

RH Spray

Burner tilt

GSW tank level

Generator volts

Generator current(R/Y/B)

Generator MVAR lagging

Field current

Field voltage

H2 pressure in Gen.casing

Hydrogen purity

HP control valve V-2 position(approx)

IP control valve position (approx)

EHC position(approx)

Seal steam pressure

TAKING STANDBY PULVERISERS E AND F I_N SERVICE

Standby pulverisers can be taken in service one by one

and withdraw pulverisers A & B one after another.

410

350

7

12

200

37

370

. 540

564 .5

26

0

+ 13

3160

15.75

9000

130

2(D0

3 .5

99

60

100

70

0 . 12

SERVICE

mm

mm

Kg/cm2

kg/Cm2

Deg.C

Kg/Cm2

Deg.C

Deg.C

T/hr

T/hr

T/hr

deg

mm

K.Volts

amps

MVAR

amps

volts

Kg/cm2

% ,

% .

% '

%

Kg/Cm2

63

"., if

PLANNED SHUTDOWN PROCEDURE FOR UNIT(SHUTDOWN TO COLD STANDBY)

SC-1 When the planned shutdown/shutdown to cold s/b is to be

started the following procedure is to be followed.

Reduce the load on the T/G machine alongwith reduction

in temperature and pressure of main steam.

SC-2 The unit is running on full load and planned shutdown

is to be started . Observe the important parameters on

full load (210 MW) before reducing the load.

SC-3 LOAD REDUCTION TO l_8_0 MW/J - > - / ,1

Unit is running on CMC. . Jo-t>di* Y * ' - ^

Press TURB FLG MODS push button to select turbine follow

mode.

Reduce target load gradient to 20% from CWA-16 desk.

Bring target Load Set point (UDC) indicator to 180 MW.

Slowly MW will reduce. Observe various parameters.

SC-4 OBSERVATION OF IMPORTANT RESPONSES '

WHILE REDUCING LOAD TO 180 MW -

Speed & Amps of FEEDER-A reduces.

Speed & Amps of FEEDER-B reduces.

Speed & Amps of FEEDER-C reduces.

Speed & Amps of FEEDER-D reduces.

TOTAL FUEL FLOW will decrease.

Mill-A amperage will reduce.

Mill-B amperage will reduce.

Mill-C amperage will reduce.

64

Mill-D amperage will reduce. TSE will show 180 MW.

Total air flow reduces.

Main steam flow reduces, feed water flow and condensate

flow reduces.

GSC-5 LOAD REDUCTION TO 165 MW

Brina unit load target set ooint to 165 MW to reduce the

oload to 165 MW.

oSC-6 PULVERISER ^D SHUTDOWN

0_ Put Feeder-D from auto to manual from CWA-12 desk.

. . .. Reduce FEEDER-D speed gradually to minimum. .

^ RC FEEDER-D amperes will slowly reduce.

When current of mill-D is minimum then stop FEEDER-DG

by making it off manually.%J>

"No coal flow" annunciation corresponding to Mill-DO^ will glow.

Bowl DP will reduce slowly. Close Hot air gate.

^ Press ^OFF1 push button of PULVERISER-D to stop

^ pulveriser-D.

r-N Put all the PA dampers of pulveriser-D on manual.

o Ensure that mill outlet temperature is

2_ PROCEDURE TO SHUTDOWN PULVERISER-D ON AUTO MODE

Put pulveriser-D en auto mode. Press "OFF' push button of

pulveriser-D to make it "OFF1 in auto mode.

First command goes to CD elevation oil support(oil guns)

Feeder speed will slowly come to minimum.

Hot air gate closes and hot air damper closes.

Cold air damper opens to reducee pulveriser outlet

temperature. Then pulveriser will be "OFF1.

At last PA Fan will be "OFF'.

Cose pulveriser discharge valves on manual. Then if

required, oil support at CD elevation can be withdrawn.

SC-7 ISOLATING HP-6 FROM STEAM SIDE

Close valve EX-12 to cut off steam to HPH-6 (Extraction

steam of HPH-6). DR-2 valve will close slowly.

Open EX-110 drain valve before EX-12 valve.

Feed water temperature will reduce.

Put DR-2,DR-34,DR-6 on manual after they close on auto.

SC-8 ISOLATING HP-5 FROM STEAM SIDE

Close EX-13 valve to cut off steam to HPH-5.

DR-11 valve will close slowly.

Open EX-112 drain valve (Extraction line drain valve).

EXTRACTI0N-A5 closes oh auto.

Valve MAL-4 7 will open on auto.

Put DR-11 valve on manual.

Put VALVE DR-14 on manual.

Feed water temperature will reduce .

66

SC-9 CUT OFF HP HEATERS FROM WATER SIDE

Open HPH 5,6 bypass valves FD-9 and FD-12.o

Close FD-7,FD-8, FD-10 and FD-11 to bypass, HP heaters0 -

from water side.

In order to take main heater bypass line in service open

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

^ .

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

^ After some time FD-125 can be closed.

__ Close FD-130 and FD-131.%J

Heaters can be isolated from steam side and

water side on auto with the help of heater group

bypass from CWA-13 desk._ SC-10 LOAD REDUCTION TO 140 MWo~ Reduce target LOAD SET POINT (UDC) till INDICATOR on SET POINT meter comes to 140 MW.o^ Load will gradually reduce to 140 MW.

p, ~ OBSERVATION OF IMPORTANT RESPONSES WHILE REDUCINGLOAD TO 140 MW

QSpeed & Amps of FEEDER-A reduces.

QSpeed & Amps of FEEDER-B reduces.

oSpeed & Amps of FEEDER-C reduces.

^ Indicator of TOTAL FUEL FLOW will decrease.Mill-A amperes will reduce. Mill-B amperes will reduce.

O^ . Mill-C amperes will reduce. TSE will show 140 MW.o

Steam flow will reduce.

ooO 67

oo

SC-11 TAKING HO GUNS INTO SERVICE AT(AB) ELEVATION (PAIR 1-3 & 2-4)

Ensure that HO trip valve is open (HO-29) and observe HO

and atomising steam pressure of 6 kg/cm2 and 8 kg/cm2

respectively.

Press -START1 push button of AB elevation pair 1-3.

"START1 bulb will blink slowly..

HEA IGNITORS corresponding to pair 1-3 of elevation

AB red light will lit to indicate advancement of

HEA IGNITORS.

DISC SCANER light will come corresponding to pair 1-3.

HEA IGNITORS "G1 bulb will glow to indicate IGNITORS

RETRACTED.

START bulb of AB elevation PAIR 1-3 becomes steady.

HO short recirculation valve HO-11 will close.

After 40 seconds command will go to pair 2-4 to start

and pair 2-4 will prove after 90 seconds time.

SC-12 CHANGEOVER OF CMC FROM AUTO TO MANUAL MODE.

At 140 MW load make CMC ~OFF' from CWA-16 desk.

Bring MS pressure set point to manual.

Boiler fuel master will be on auto.

Start up mode will come'in service.

Put Boiler fuel master on manual.

Unit will come to "base mode' operation.

Take UDC pressure set point to manual.

68

SC-13 LOAD REDUCTION TO ll_0 MW

^ Bring load reference to 110 MW from CWA-16 desk.

Load will gradually reduce.

HPT and IPT control valves opening will reduce.f%

Put RC feeder speed on manual to reduce further fuel

firing rate.0

Reduce speed of RC Feeder-C to maintain steam flowo

and MS pressure.

0UDC pressure set point may be reduced equal to MS

opressure so that the difference between actual

''s pressure and set point. may not be more than 10 kg/cm2,

^ so that unit will not go to "pressure control1 mode.SC-14 OBSERVATION OF RESPONSE AFTER 110 MW LOAD

ORelease lamp of extraction-4 (A4) will be'OFF' and MAL-51

will open.o

Close EX-301 and open EX-108 valves.o

CR-306 valve will open to maintain deaerator pressure.

^ SC-15 PULVERISER -C SHUTDOWNo

Remove Pulveriser-C as per procedure mentioned in step

^ SC-6.

MS temperature >4 8 0 deg.C by RC feeders of A & B.o

SC-16 SHUT DOWN OF SEAL AIR FAN-BWhen A & B pulveriser are in service then stop seal

Qair Fan-B.Seal air Fan-A will be running.

ooO 69

SC-17 SHUT DOWN OF 3FP z B

Put standby 3?P on manual. Take SCOOP-B on manual.

Reduce SC00P-3 till indicator on SCOOP-B position

comes to minimum.

MIN RCV FC-306 will open at 60 T/hr flow.

SCOCP-A of BFPA will increase to adjust feed water flow.Amperes of BFP-B will reduce and BFP-A will increase.

Press OFF push button of BFP-B to make it OFF from CWA-13

desk. AOP of BFP-B will pick up on auto.

Cooling water valve of BFP-B. will close on auto.

If one pump operation is selected and if flow- is less

than 290 T/hr BFP-B will trip on auto.

SHUT DOWN OF FD FAN-B AND ID FAN-B AT l_00 MW

Reduce load on FD Fan by taking SAD-1 on manual and

close it fully.

Then stop FD fan motor from CWA-11 desk.

Close discharge damper.

LOP sub group sequence can be put on manual and then

stop running LOP A/B.

FD Fan can be shutdown in group sequence.

Reduce load or. ID Fan-3 by taking QD-SB on manual and

close IGV manually.

Stop ID Fan motor.

. Close inlet outlet dampers.

Stop ID fan seal air blower.'

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

70

mO SC-19 REDUCTION OF LOAD TO 50 MW

O Reduce load inference to 50 MW to reduce load to 50MW.

Load will reduce to 50 MW. Adjust feeder speeds of running

^ pulverisers A & B so that MS pressure will not increase.o

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

open and leak off valve will close.o

SC-20 PULVERISER-B SHUT DOWNo

Follow the same procedures given in Step SC-6.

^ SC-21 CHANGE OVER TO LOW LOAD LINE AT 5_0 MW LOAD

FROM FULL LOAD LINE(Feed Regulating station)

Open VALVE FD-20 slowly and close valve FD-21 so that

drum level is maintained to normal.,,r\^ Close VALVE FD-21 till indicator of FD-21 positionc

comes to zero.

^ Put valve FD-2 0 on auto and scoop of BFP-"A' on manual.^ SC-22 CARRYING OUT AUXILIARY SUPPLY CHANGE OVER FROM UNITQ TO STATION BUS OCA0 Ensure that breakers OCA and OCB are in service and DC

O control supply is "ON".

Q AS-1 BTSP-1 is "IN1 and selection is on "MAN FAST1.

vj/ Ensure that "Bus transfer system ready for Fast Transfer1

Q & "Bus transfer System IN' indications are available at

O BTSP-1.

O AS-2 Press the "TEST' push button on the back panel(BTPS 01)

O and proceed further when"READY FOR TRFR' bulb on the back

w panel glows.U

71

"I/C BKR CB-1 0?3Nr Test mode window on FACIA WINDOW FW-1

will glow.

"TIE BKR CB-2 CLOSE' Test mode window on FACIA WINDOW

FW-1 v/ill glow. Press the TEST RESET button.

All the above indications will -disappear.

"READY FOR TRFR" green lamp will glow.

AS-3 Press "READY FOR TRFR1 push button."I/C BKR CB1 OPEN'

window on FACIA WINDOW FW-1 will glow."TIE BKR CB-2

CLOSE'window on FACIA WINDOW FW-1 will glow."READY FOR

TRFR" lamp will disappear and will glow again."UNIT BD

1CA INCOMER BKR1 & "TIE BKR between ICA & OCA'discrepancy

switch will flicker on MCL-01.

AS-4 Turn the discrepancy switch of ICA I/C BKR to "OFF1.

AS-5 Turn the discrepancy switch of TIE BKR to ICA to 'ON'.

CARRYING OUr AUXILIARY SUPPLY CHANGE OVER

FROM UNIT TO STATION BUS OCB

AS-6 BTSP-2 is"IN'and selection is on "MAN FAST'. Ensure that

Bus transfer system ready for Fast Transfer & Bus Transfer

System IN indications are available on BTSP-2.

AS-7 Press the "TEST1 push button on the back panels (BTPS-02)

and proceed further when"READY FOR TRFR'bulb on the back

panel glows.

"I/C BKR CB-11 "OPEN test mode1 window on FACIA

WINDOW FW-1 will glow.

"TIE BKR CB-2 CLOSE test mode1 window on FACIA

WINDOW FW-1 will glow.

72

AS-8 Press the "TMST RESET1 button. All the above

indications will disappear."READY FOR TRFR"

green lamp w.i.1.1 glow.

^ AS-9 Press "READY FOR TRFR1 push button"I/C BKR CB1 OPEN1

r*, window on FACIA WINDOW.

r "TIE BKR CB2 CLOSE1 window on FACIA WINDOW FW1 will glow.

^ "READY FOR TRFR'lamp will disappear and will glow again.

r% ""UNIT BD 1CB INCOMER BKR'&'TIE BKR between ICB & OCB'

f* discrepancy sv/itch will flicker on MCL-02.

^ AS-10 Turn the discrepancy switch of ICB I/C Bkr to "OFF1.

f* Turn the discrepancy switch of TIE BKR to ICB to "ON'.

^. SC-23 CHANGE OVER OF PROS-2 TO PRDS-1(PRESSURE & TEMP.CONTROL)

*> Ensure to ke^.; PRDS-1 (AS-308) on manual.

iO) Slowly open A.^ -3 08 of PRDS-1 and A3-305 closes ON AUTO.

,f> When AS-305 closes completely put: PRDS-2 (AS305) on manual

f^ Put PRDS-2 :AS-308) on auto.

f% Valve AS-308 v.'ill open to maintain pressure of 12 kg/cm2 .

Q Open HCPRV I/L ISO FD-342.

Q Slowly open FD-347 of PRDSE-1 (FD-347 ) on auto.

Q FD-346 will close gradually on auto so that PRDS

Q temperature will be maintained at 2 00 Deg.C.

^-> Put PRDS-2 on manual and PRDS-1 on auto.

Q Close isolating valves of PRDS-II after change over.

O SC-24 ISOLATING LP HEATERS FROM STEAM SIDE(LPH-3,2,1)

Q CLOSE EXT STKi ISO VALVE EX-9 to cut off steam to LPH-1.

O Open locally EX-113 drain of extraction line.

Q Close EXT ST:>\ ISO VALVE EX-10 to cut off steam to LPH-2.

L) 73

Open EX-101 extraction line drain valve locally.

EXTRACTION- A2 release to NRV will be "OFF'.

MAL- 55 will open on auto.

Open EX-102 extraction line drain.

Close EXT STM ISO VALVE EX-11 to cut off steam to LPH-3.

Open EX-103 extraction line drain.

EXTRACTION-A3 release to NRV will be "OFF1.

MAL-54 will open on auto.

All the Drip valves DR-21,DR-16,DR-24,DR-21,DR-16,DR-19

will close on auto. Drip valves may be put on manual.

SC-25 LOAD REDUCTION TO 30 MW

Reduce load reference to 3 0 MW to reduce actual LOAD TO

3 0 MW.

TSE will show 3 0 MW gradually.

Steam flow will decrease.

Observe on DAS various parameters.

SC-26 PULVERISER-A SHUTDOWN

Follow the same procedure to shut down pulveriser-A as

given in Step SC-6.

Stop seal air Fan-A from CWA-11 desk.

SC-27 SHUT DOWN THE TURBINE

Note the presen: value of steam pressure and set HPBP

more than actual pressure so that HP3P will not open.

Press the TURBINE TRIP push button to trip the turbine

"MANUAL TURBINE TRIP" alarm will come.

MAIN CB CONTROL SWITCH-52 will open.

"OFF1 bulb of FIELD BKR will glow.

74

"OFF1 bulb of EXCITATION OFF will glow.

^ Field current will become zero.

,K Field volts will become zero.O

1^ AUTO POT MIN bulb will lit.

p . GEN BKR OPEN bulb will lit.

#% EXCITATION TRIP bulb will glow.

(J MW meter will show zero.

0 TURBINE TRIPPED bulb will lit.

INTCPT V-2 CLOSED bulb will glow.

0 CRH NRV LH CLOSED bulb will glow.

0 CRH NRV RH CLOSED bulb will lit.

0 HPT CVS,IPT CVS will close.

J Turbine speed reduces gradually.

/ When turbine speed is at 2800 rpm AOP-I will pickup on

O auto.

O When turbine speed is at 510 rpm JOP-I will pickup on auto

0 When turbine speed is at 240 rpm "ON1 bulb of GATE VALVE

O GEARING will lit and barring gear will engage to put turbine

vJ on barring. Turbine speed would be 150 rpm on turning gear.

^ Boiler will trip on Turbine trip to boiler trip

%j protection (R H Protection)

75

Turbine can also be shutdown through ATRS (SGC Turbine) at'

210 MW load.

Make CMC "OFF' and ensure SGC turbine is on auto.

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

Adjust Fuel Fire rate as per the reduction in load.SC-28 SHUTDOWN OF GENERATOR STATOR CW PUMP

Turn the GEN CW PUMP A/M S/S switch to position number-2

to make generator stator CW pumps on manual.

Stop GEN STATOR CW PUMP-A(running pump) stator water flow

comes to zero and flow low indication flashes on the desk

CWA-17.

SC-29 SHUTDOWN OF BOILER

When boiler trips after tripping turbine observe following

"BOILER MFR TRIP" annunciation will'come.

MFT-1 and MFT-2 lamps will glow and MFR "RESET'lamp will

be OFF.

All oil guns will be OFF. HO trip valve will close on auto

Short circulation valve of HO-35 will open on auto.

Scavenging of guns at AB and CD elevations will start

and after 5 minutes automatically scanenge valves close.

Fuel air and Auxiliary' air dampers will open full.

Bypass turbine trip to boiler trip protection.

All purge permissives will be satisfied.

Purge the boiler.

After 5 minutes purge over signal will come.

76

& SC-30 KILL CONDENSER VACUUM

Close main ejector A/B steam valve.

^* Open vacuum breaker to kill condenser vacuum. Vacuum will

fall slowly. Observe on CWA-16 desk and DAS.

SC-31 SHUT DOWN OF TURBINE GLAND SEAL SYSTEM

Put seal steam control on manual.

*-* Close seal steam isolating valve AS-368 locally .

Gland seal steam header drain valve MAL-81 will open on

^ interlock.

When temperature of header drops below 12 0 deg. C. stop%* GSC evacuation Pump 1/2 from CWA-16 desk.

u' SC-32 SHUT DOWN OF PRDS

^ Put PRDS pressure and temperature control on manual and

close control valves.

*" Then close isolating valves for pressure and

"~" temperature control .W SC-33 BOILER FILLING ABOVE NORMAL DRUM LEVEL

^ Put FD-20 on manual and open the valve.

^ Fill boiler drum above normal level so that level will be

visible when drum pressure drops and level drops when drumO

level pressure drops.

Restore drum level with BFP and feed control valve from

^ CWA-13 desk.Ky SC-34 CLOSING OF BOILER OUTLET VALVES

OClose boiler outlet valves MS-301 & 302 from CWA-13 desk.

77

SC-35 SHUTDOWN OF BFP-A

Press "OFF'push button of BFP-A motor.

AOP will pickup on auto.

BFP-A cooling water valve will close on auto.

Close Discharge valve from CWA-13 desk.

BFP-A suction flow will become minimum.

BFP-A suction pressure reduces.

BFP-A can be shut down in group sequence also.

SC-36 SHUTDOWN OF SECOND AIR CYCLE(ID FAN A & FD FAN A)

When flue gas temperature at APH inlet is less than 200

deg.C. second air cycle can be stopped.

SC-37 SHUTDOWN OF AIR HEATER-A

Before stopping the Air Heaters, wait untill FG

temperature at APH inlet reaches < 10 0 Deg.C.

Press middle push button of AIR HEATER-A GROUP SEQUENCE

to keep group sequence on Auto.

Press "OFF' push button of group sequence to make APH-A

main drive off.

APH- A will be off and ammeter of AIR HEATER-A will show

zero amps. APH-A DC motor will pick up on auto.

Dampers GD-1A, SAD-4A,GD-2A and SAD-3A will close on

interlock.

Support and guide bearing LOP's will be off if bearing

temperature < 35 deg.C and 4 0 deg.C.

LOP group sequence can be put on manual.

APH-A can be shut down manually.

78

5 SC-41 OPENING OF BOILER SIDE VENTS

*k When drum pressure reaches 3 kg/cm2 open drum Vent valve

f% B-5 locally.

Q Open locally super heater vent valves S-40, S-21,

9 - S-25, S-30 and drain valves S-15, S-16, S-17.

Q> Open RH vent valves R-l and R-4.

O SC-42 SHUTDOWN OF CW PUMPS

Stop CW PUMP-1 and CW Pump-2.

Ammeter reading of CW PUMP-2 will show zero amps.i

G Close COND CW I/L valve CW-48 & CW-49, COND CW O/L valve

CW-55 Sc CW-56.

O SC-43 SHUT DOWN OF GSW PUMPSO Stop GENERAL SER PUMP-A.

i

O Ammeter of GENERAL SER PUMP-A will show zero amps.i

0 Close GEN SER PUMP-A Discharge Valve DV-39.

G GS 0/H tank level will fall.

O SC-44 SHUT DOWN OF AC SEAL OIL PUMP

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

oQ

GQ

80

C-38 SHUTDOWN THE AIR HEATER-B

Press middle push button of AIR HEATER-B GROUP SEQUENCE.

Press "OFF1 push button of AIR HEATER-B group sequence to

keep APH- B "OFF1 .

APH-B will be off and Ammeter of AIR HEATER-B will show

zero amps. DC motor will pick-up on interlock.

All the dampers in flue gas path and air path will open

on interlock. Response will be same as step No.SC-37.

SC-3 9 SHUTDOWN OF CEP A/B (RUNNING)

Shutdown the CEP when LP exhaust temperature ' reaches

less than 45 Deg.C.

Make SLC COND Pumps OFF.

Press "OFF1 push button of CEP-A to make it off.

Ammeter of CEP-A will show zero amps.

CEP-A discharge valve closes on interlock.

Take DM-32 & DM-35 on manual and close them.

SC-40 SHUTDOWN OF TURBINE LUB OIL SYSTEM

Take SGC oil supply on manual.

Make SLCs of JOP-1, JOP-2, AOP-1, AOP-2, EOP OFF.

When turbine casing temperature reaches

PROCEDURE FOR SHUT DOWN OF UNIT FOR HOT STANDBYo

When unit trips' from full load (210 MW) on any protec-Q tion or load through off or is to be tripped manually

for any abnormal condition,follow the procedure asQ) mentioned below.O HS-2 TRIPPING THE TURBINE MANUALLY

O Press TURBINE TRIP push button to trip the turbine .

0 manually from CWA-16 desk. "MANUAL TURBINE TRIP" alarm

/ will come. TSE will shift to admission side to indicate

0 turbine speed.

O MAIN CB CONTROL SWITCH 52-E will open y

0 FIELD BKR will be "OFF1/ . ..

0 . CO-ORD mode lamp will go "OFF1, and boiler startup mode

0 . lamp will glow,

EXCITATION will be "OFF.1

O Field current will become zero.

O Field volts will become zero,

O AUTO POT MIN bulb will lit . \

O GEN BKR OPEN bulb will lit.

Q EXCITATION TRIP bulb will glowt^ . HP BYPASS will OPEN to adjust main steam pressure.o

'yJ LPBP opens to adjust HRH pressure.

^ TURBINE TRIPPED bulb will glow,

^ HP stop and control valves V-l & V-2,IP stop and

O control valves,CRH NRVS will close fully.

O Observe various indications of valves on control

O desk CWA-16.

81

Turbine speed reduces gradually,

EXTRACTION NRVS A-2,'A-3,A-4 and A-5 will close

Drain extraction valves MAL-47, MAL-51, MAL-54 and

MAL-55 will open

After closure of Extractiton valves, the following

drain valves will open

Ex-101,Ex-102,Ex-103,Ex-108,Ex-112 ,Ex-110.

When turbine speed reaches at 2 80 0 rpm AUX OIL PUMP-1

will pick up.j

When turbine speed reaches at 510 rpm JACKING OIL

PUMP-1 will pick up

When turbine speed is at 24 0 rpm. GATE VALVE

GEARING will engage (Barring gear)_

RC FEEDER-A,RC FEEDER-B ,RC FEEDER-C, RC FEEDER-D speed

will reduce

ID FAN-A/B amperes will reduce

FD FAN-A/B amperes will reduce

Feed water flow will reduce

(V) Gland steam Leak off valve will close and supply valve

will open

EX-301 extraction valve will close and CR-306 will

open to maintain D/A pressure.

Condensate flow to D/A will reduce.

BFP-A scoop position & amps will reduce,

BFP-B scoop position & amps will reduce,

GT oil pump will become OFF on interlock.

82

I-IS-2 ^'L^IM 2Z hR HEATERS EXTRACTION STEAM VALVES

s* Close LPH-1 EXT STM ISO EX-9^

Q . Close LPH-2 EXT STM ISO EX-10 v

Q Close LPH-3 EXT STM ISO EX-11^

Q Open Extraction line drain valves .

Q HS-3 CLOSING HP HEATERS EXTRACTION STEAM VALVES

0 'Close EX-13 HPH-5 extraction steam valve.

Q Close EX-12 HPH-6 extraction steam drain valve.

0 Open extraction line drain valves.

Q HS-4 BOILER MASTER ON MANUAL

Q Put BOILER MASTER on manual

Q Then Boiler base mode lamp will glow

HS-5

Q Take oil support at AB elevation HFO pressure 6 kg/cm2

0 and atomising steam pressure of 8 kg/cm2.

O HS-6 PULVERISER-D SHUTDOWN

Q Reduce FEEDER-D speed, when it comes to minimum

Q Stop FEEDER-D

O "No coal flow " annunciation corresponding

O to MILL-D will come

G MILL-D ampers will slowly reduce and will show 22 amps

O PAD-2D position will reduce

O PAD-4D will close

O PAD-5D position will reduce

Q Close hot air gate

r

oO 33

Stop PA Fan-D

Stop PULVERISER-D

After withdrawing Mill D, maintain MS temperature