Power Plant Operation - (GF-4)

Contents

1.0 GENERAL PRINCIPLES OF POWER PLANT OPERATION 1-20

1.1 Introduction 1
1.2 Safety 1
1.3 Role of operation engineers 3
1.4 Unit operation 4
1.5 Some general operating instructions 14
1.6 Shift routine 18
2.0 OPERATION OF BOILER & AUXILIARIES. 21 -75
2.1 Line-up Boiler feed water system. 21
2.2 Line-up boiler water and steam system. 22
2.3 Boiler filling. 23
2.4 Draft system. 26
2.5 Fuel firing system 28
2.6 Boiler purging & lighting up 40
2.7 Boiler loading 45
2.8 Normal shut-down to cold 55
2.9 Auxiliary steam system 64
2.10 Routine checks 67
2.11 Emergency operations 69
3.0 OPERATION OF LMW TURBINE & AUXILIARIES. 77-106
3.1 Line up. 77
3.2 Starting of turbine from cold state 81
3.3 Rolling instructions 84
3.4 Loading the turbine 88
3.5 Warm and Hot start 91
3.6 Hot start 95
3.7 Planned shut down 99
3.8 Important instructions during turbine running 100
3.9 Do's and Don'ts during turbine running 102
3.10 Emergencies in turbine and auxiliaries. 103
4.0 OPERATION OF KWU TURBINE & AUXILIARIES 107-128
4.1 Line-up 107
4.2 Cold start up. 110
4.3 Loading the turbine. 117
4.4 Start up after 48 hours shut-down. 123
4.5 Start up after 8 hours shut-down. 124
4.6 Normal shut-down of turbine. 124
4.7 Emergency shut-down. 125
4.8 Do's & Don'ts for turbine operation. 126
5.0 OPERATION OF GENERATOR & AUXILIARIES 129-148
5.1 Lining up the system 129
5.2 Pre-synchronising checks 132
5.3 Steps for generator synchronising 133
5.4 Routine operation and periodic checks 137
5.5 Operational limits of 210 MW Generator 142
5.6 Emergency operation 145

Note:
For schemes of various systems, whose operating procedures are described in this chapter,
please refer "Thermal Schematic Diagrams (210 MW)" published by Power Engineers Training
Society.
 GENERAL PRINCIPLES OF
POWER PLANT OPERATION
 1. GENERAL PRINCIPLES OF
POWER PLANT OPERATION
1.1 INTRODUCTION

Operating procedures vary with unit size, design, system requirement etc. This volume
describes operating procedure of thermal units, having BHEL Boiler and210 MW BHEL-LMW/500MW
BHEL-KWU turbo-generator. However, certain steps or procedures are common with almost every type
of boiler, turbine and generator. They, with the logics behind them, have been explained in the beginning
of this volume before proceeding to the operating details of 210 MW/ 500 MW units. But this volume is
meant for training only and hence should never be considered as on Operation Manual for 210 MW
/500 MW units.

1.2 SAFETY
Operation Engineers should
Ensure safe working condition.
Use himself and provide other necessary protective equipment to operating staff.
Assign employees the jobs which they are capable of doing safely.
Study and understand the safety procedures mentioned in operation manual and other relevant
documents.
Take immediate steps to correct any violation of safety rules.
Investigate every accident and report to the concerned authorities.
Be familiar with relevant safety regulations like Factories Act, Boilers Act etc.
Ensure the provision of first aid box in the work place and should themselves know how to give
first aid.
Permit to work system
Operation of thermal power plants involve dealing with vessels and pipes carrying Quids of high
temperature and pressure, hazardous chemicals, electricity of different voltage levels, rotating equip-
ments etc. Therefore, a well planned permit to work (PTW) system must be followed strictly to ensure safety
during work on any equipment or system (A typical PTW form has been reproduced in page 2)
It must be noted that
All equipments, in service or available, are under the custody of operation section.
Maintenance section has to request in writing the operation section for clearance to work on any
equipment or system.
Operation section must isolate the equipment and place proper tags so that the workmen are
not exposed to any hazard.
 A Typical PTW
Thermal Power Station
....Thermal Power Station BREAK DOWN INTIMATION SLIP
Expected time
Book No. of return Hrs. Day Book No Permit No
Permit No.

Unit No. I II III rv V s

Unit No. II III IV Type of Maintenance B. D. P.M. OPP.

I hereby declare that all men
and materials under my charge
have cleared the site, equipment/
pipe line and men have been
warned that it is no longer safe to
work on the equipment specified
, on this card.
I hereby declare that the following equipments are isolated
and safe to work. Caution notice have been affixed to all
Controlling valves or Electrical switches. Name of the equipment
Equipment
Type of defect.
Isolations Made

Nature of defect notice

to Equipment Date Time
Stopped
Name Desig Date Time Sign

Details of work done Issued by

Vltc Section incharge
Issued to
BLR TUR MISC C&I EDI E.D.D
Cancelled by

Trial Run Yes No Date Time Time.

Time Carried
Date )ate

Name Representative of Maintenance Representative of Operation fame

Name ... Name „ ignature of Controoler
Designation
Designation Signature of
Signature hift Charge Engineer ..
Signature Controller
 It is the responsibility of the operation section to deliver the equipment to the maintenance
section in such a condition that no hazard is faced by the work men during work.
Before issuing any PTW the operation engineer should ensure that the persons collecting/
requesting PTW are fully familiar with the job and understand the associated systems, if any.
All PTWs must be issued in writing in prescribed forms and all copies of PTW must be signed both
at receipt and at clearance.
PTWs should be issued between specified hour only.
Before receiving back any PTW, the operation engineer must ensure personally that the job has
been carried out as schedule and there is no danger in charging the equipment/system.
Fire Protection
The operation engineer must be familiar that the fire prevention and protection systems
provided in the plant.
Should know his responsibility clearly if a fire breaks out.
Should be able to lead the other operating staff in fire fighting operation till the fire brigade or
others concerned take over.
House Keeping

Operating engineers should :

Be Aware of the importance of cleanliness and proper house keeping inside the plant
Ensure all floors, steps, stairs, passages are kept free from any obstruction and foreign
substances likely to cause a person to slip.
Ensure that no combustible or hazardous material is lying unattended in the plant.
Ensure that the fire fighting equipment and emergency exits are conspicuously marked and are
not obstructed by anything.

Ensure that adequate lighting has been provided in the work areas.

1.3 ROLE OP OPERATION ENGINEER IN THERMAL POWER STATION

The operation engineer is meant to ensure :
Safety of equipment and personnel
Reliability of supply, and
Generation of energy at economic cost.
His responsibility is to :
Start up the equipment in a safe and systematic manner.
Connect the unit to the transmission network in a proper manner so that the consumer can draw
power.
Watch the equipment to ensure its run under safe working conditions.
 Adjust the different control inputs, like fuel, air, water makeup to match the electrical output
of the unit.
Maintain proper cooling of the different teeajing surfaces, by assuring lubrication and heat
dissipation by cooling.
Maintain salient levels in the different subsystems.
Maintain the specified pressure and temperature and levels at various points. Normally,
automatic devices are provided but the operation engineers should be able to intervene and
modulate the control to maintain the parameters within the specified limits.
Maintain proper chemical conditions and concentrations.
Watch the mechanical behaviors of all moving equipment-noise, vibration, bearing lubrication,
cooling, control valves and dampers etc.

1.4 UNIT OPERATION

Unit system is the trend of the day. An unit consists of a boiler, a turbine (single or multicylinder)
and a generator coupled with turbine along with their auxiliaries and subsystems. The unit is, infact, a
self contained power station in its own right, and on load producesthepoweito drive its own auxiliaries
via its unit transformed.
The main functions of unit operation are :
i) Starting and loading
ii) On load activity
iii) Off loading and shut down.
Operating procedures vary from unit to unit due to differences in unit si?es, design criteria,
auxiliary systems, manufacturer etc. Still there are some common basic steps which are to be followed
systematically to ensure smooth operation of any unit.
1.4.1 Unit Start Up and Loading
STAGE-1 : Preparation (Pre-start checks, ensuring availability of fuel and
other essential services)
STAGE-2 : Pressure raising on boiler
STAGE-3 : Putting turbine on barring gear
STAGE-4 : Steam admission to turbine and running it to speed
STAGE-5 : Synchronising and loading.
14.1.1 STAGE-1
Preparation for unit operation involve the following :
i) Checking supplies
ii) Checking availability of services,
iii) Investigation of Permit to work (PTW) system.
The supplies include :
Fuel (coal & Oil)
Cooling water
Service water
DM water
Chemicals for water treatment plant
Lubricating oils and greases
CO2, Hydrogen
The Services include :

Electric supply availability

Water treatment plant availability
Compressed air (or Instrument air) availability
Ash and dust disposal system availability
Fire Fighting system availability
Coal Handling Plant availability.
Investigation of PTW involves :

Investigation of permits issued and returned

Identifying the plants and systems disturbed during maintenance,this will enable the operation
staff to exercise special care when recommissioning such items.
1.4.1.2 STAGE-2
Pressure raising on boilers CAchJevf™ .?iri\iog steam |j»*an>QW*? 35-»5ovw-

Pressure raising on boiler involves the following activities in boiler and turbine sides. Before engaging into
the activities mentioned below it is necessary that pre-start inspection and check has been carried out
in each equipment and system. For example :
Sensors, gauges, recorders correctly set up for monitoring
All boiler access and inspection doors shut C fosznWdet \x> be.'&uibad.)
All soot blowers fully retracted
Ash hoppers door shut, ash hopper seal full
No obstruction to free boiler expansion
£6>Precipitator inspected and ready
Draft system (ID, FD fans, dampers) thoroughly checked
Pre-start checks carried out for ID, FD fans, feed pumps, chemical dosing, pumps, mills, air
heater etc. ^
Boiler Activities
Fill boiler and obtain drum level indication
Charge boiler ring main. 2 comer burners" cracked on recirculation
Start both APH (air pre-heaters)
Start ID fan
Start FD fan with 30% air flow
Complete PURGING of the boiler
Light the boiler with oil burners and establish circulation.
(Recently, in some boilers arrangement has been made for direct firing of coal. In these boilers
oil burners have been replaced by special coal-ignition burners)
Regulate firing, drains and vents for metal temperature control and raise pressure
IF HP/LP Bypass is available take it into system. This will ease reheater metal temperature
control. At high pressure main p.f. burner may also taken into service.
Monitor water/steam quality and act according to chemists'instructions
Turbine Activities
Establish CW flow though condenser.
Fill hot well, start extraction pump
Fill Peaerator
Prime and start standby feed pump
Prime HP feed system
It may be noted that the some activities mentioned above can be performed simultaneously
(parallel), some one after another. Fig. 1.1 shows the PERT Network of pressure raising activities.
1.4.1.3 STAGE-3
Putting Turbine on Barring Gear
i) Turbine oil system
ii) Aux CW system
iii) Generator system
Turbine Oil System
Turbine main oil tank has enough oil and high and low level alarms are working
Commission oil purifier, check oil flow through sight glasses
Check pump automatic start-up sequence
FIG 1.1 STAGE 2 RAISING BOILER PRESSURE
PERT NETWORK
 Start jacking oil pump and AC flushing pump
Start the exhauster fans
Auxiliaries CW System
Aux. CW pump run up
Priming aux CW system
(This system includes cooling water for pumps' bearings oils and other coolers)
Generator Systems
Commissioning seal oil system
Run AC seal oil pump. Control seal oil pressure manually.
Inspect seal oil return sight glasses. Excessive or very low oil flow shows seal malfunctioning.
Wait till turbine is put on barring gear for some time allowing the seals to re-align.
Gassing up
Replace air with CO2
Admit Hj till 25% purity is obtained
Raise gas pressure to designed value %
Gassing up operation take long hours (5-6 hours). So may also be done after putting the turbine
on barring gear
Observe safety regulation strictly during Gassing /Degassing procedure.
Commissioning stator water system
Run stator water pump intermittently and vent after each run. The system thus is primed and
pressurised
Check leakages in the system and monitor pressure differential across stator inlet and outlet
Monitor water quality (mainly conductivity)
Putting turbine on barring gear
Lubrication oil pressure should be satisfactory
Jacking oil pressure should be satisfactory
Engage barring gear with the main turbine shaft
Start barring motor/Admit pressurised oil to gear turning mechanism
Fig. 1.2 shows the PERT network for commissioning barring gear.
1.4.1.4 STAGE-4
Steam admission to turbine and running it to rated speed.
Ensure that pre-start check has been carried out on :-
Turbine valves and lines for steam admission.
Gland packing and vacuum system
Exhausthood spray and flange heating sperm •
8
 Cooling water culvera check __ / ^ ) Am ..cooling system check
Cooling witw pumps priming check i

Aux. cootiiig « « » pump chock Slan aux. cooling pump Pnme aux. cooling system — Prime condenser; _,->

Stator coolani system check

Seal oil system in service y^. Gas-up Pnme stator cooling system _^ Stator coolant system

Turt>m* lubricating oil system check OI pumps stan A auto operation check ^^-^urbme lub oil system in s Turbo-alternator tuming gea/ 1-5
pit punfier m service O
FIG. 1.2 STAGE 3 UNIT RUN-UP COMMISSIONING TURNING GEAR
PERT-NETWORK
Hydrogen cooling system and stator cooling system can be commissioned with turbine on or off turning gear.

The hydrogen cooling system must be commissioned prior to commissioning stator water system.

Condenser priming is not mandatory prior to tuming gear operation. It is desirable in many cases in order to check deflection.

Seal oil must be applied to seals for lubrication purposes prior to commissioning turning gear.
 L.P. feed system
Turbine protection devices

ACTIVITIES ARE AS FOLLOWS ;

Testing of Steam Valves

Emergency stop valves (ESV) of HP and IPT cylinders are to be open and their closure should be
checked by hand trip. This is most important for protection of plant and personnel.
Drainage regulation
On many modern installations main and reheater drains are thermostatically controlled and
close automatically when the desired temperature is achieved. In manual operation usually the
drains are not shut until a substantial flow is passing through the associated pipe work.
Substantial quantities of valuable water and heat will be lost due to prolonged drainage. General
procedure is to close the leg drains when temperature in legs is 50°C above saturatiqn
temperature at that pressure. Note that reheat steam drain must be routed to condenser flash
box if vacuum raising process has already been started.
Vacuum raising and gland steam system
Methods of applying gland steam and raising vacuum vary according to size, manufacturer etc.
Sequences could be :
Seal glands and then raise vacuum, or
Raise vacuum to a certain value and then apply gland steam, or
Apply gland steam and commission vacuum raising equipment simultaneously.
Warming
The turbine is to be warmed before it can be run up to rated speed. Warming is done by admitting
steam in the turbine. The quality and quantity of steam depends on the size of the machine and
on temperature difference between the machine metals and the steam. The mass of metal in
turbine rotor is less that of stator (or cylinder as commonly called). So, when steam is admitted
in the turbine the rotor absorbs heat faster and expands^faster than the cylinder. The difference
in expansion between rotor and cylinder is termed as differential (expansion) and should be near
zero to maintain axial clearance of blades and glands.
To achieve this the turbine is heated slowly and uniformly. Apart from limiting differential ex-
pansion it also reduces chance of high stress and distortion.
In order to heat the machine uniformly the temperature and quantity of steam must be raised
uniformly at a rate suggested by the manufacturer.
Also to reduce the amount of differential expansion and the stresses imposed on bolts and
flanges, the flange heating system is provided. The methods of applying flange heating steam
may vary to suit individual design. On some machines, flange heating is used as a precise form
of control, more or less steam is being admitted to the flange as required. In others, manufac-
turers recommend that the flange heating steam Is to be applied at the commencement of the
run-up and remains on until the turbine has been carrying a substantial load for some time.
Rolling
Of various methods of turbine rolling, the two common methods are as following :

10
Soaking method
In this method, the machine is given a soaking time just before the critical speeds. In a typical
example, the turbine is rolled to 5Q0 rpga. and held at this speed for 15 minutes. Again at 2000
rpm. the machine is held for 45 minuets and then at 3000 rpm. a soaking time of 30jninutes
is given.
Constant acceleration method
The machine is rolled and speed is increased at a constant rate (i.e. constant acceleration) from
0 to 3000 rpm. The acceleration rate should be as per manufacturers guidance.
With modern throttled governed turbines a combination of above two methods are also used.
During the entire rolling period the turbovisory equipments should be carefully monitored.
Turbovisory equipments are :
1 < Diffential expansion detector
I, Eccentricity recorder
j . Total expansion recorder
/ft Tachometer
r Vibration recorder.
Overspeed Bolt Testing
Before synchornising the unit it is necessary to prove that overspeed bolts operates, if :
The bolts have been adjusted
The u,nit was under prolonged shut down
The legal period between testings has elapsed.
The start up activities so far described is cold start-up. The other type of starts are warm start up and hot
start up. This catagorisation depends on the metal temperature of HP Turbine casing in the regulating
zone.
Metal temperature above 350°G . - Hot start
Metal temperature between 150-350°C - Warm start
Metal temperature below 150°C - Cold start
Warm or hot start of the machine is required when the unit is stopped for few hours. But with the advent
of two shifting operations hot start up of the machine may become a routine affair. Most important thing
in_vvarm/hot start up is to match the steamtemperature with that of H.P. cylinder before steam admission
to turbine.
Loading
Loading of turbo-generator (TG) from zero to full load during cold start up involves many operations and
keeping constant watch on the supervisory conditions like :
/ • Differential expansions of all cylinders
I. Axial shift

11
 3. Metal temperature
4- • Vibration
$ Electrical parameters etc.
The TG should be loaded as prescribed by the manufacturer, For a 210 MW set (LMW - Soviet design) it
takes around 6 hours to attain full load.
The major operations during loading are :
f Charging LP and HP heaters
<r" Commissioning of mills and cutting in PF burners as per requirement.
£ Cutting off oil burners as per requirement
f Starting second BFP
a" Operating the excitation system etc.
Loading operation during Warm and Hot start up is more or less similar. Only the time required to attain
full load is reduced to around 2^ hours. Fig 1.3 shows PERT Network for unit start-up and Loading of a
500 MW unit
1.4.2 On Load Activities
Basic activity of operating personnel when the machine is on load are : mA^*P
^ Adjust or ensure (in case of automatic control) that various control Inputs, like fuel, air, water
etc. match the need for generating required electrical output
<f~ Maintain or ensure (in case of automatic control) that specified pressure, temperature, level,
chemical composition, concentration etc. are maintained at various points .
*" Record various parameters regularly and study them
<^ Attended and rectify various faults, trippings and emergencies.
1.4.3 Off Loading & Shut Down
Shut downs are primarily of two types—planned and emergency.
1.4.3.1 PLANNED SHUT DOWN
In planned shut down load is reduced gradually (3MW per minute in case of 210 MW-LMW Unit)
as per manufacturers instructions. Accordingly firing rate is reduced. Reduction of steam temperature
and pressure is mainly decided by turbine limitations. With reduction of load gradually HP heaters, LP
heaters, one BFP etc. are switched off. Control system is generally taken on "manual" mode.
At a very low load (about 5 MW for 2._10 MW units) the unit is tripped through any protection.
Turbine will start loosing its speed. At around ^0% of rated speed AC_oil pumps should cut in-
Barring gear willengage at 250/500 r.p.m..for 50Qi2Ifl_MW_KWXLsets while for 2l^Js^W_LJ^IW-unitsJLt
has to be engaged just after the rotation of TG has come to stand still. Supply of steam for gland_sealing
and ejectors are to be stopped.
Turbine drains are to be opened when metal temperature goes belowj00°C and_barring gearand
lub oil pumps may also be stopped. ~

12
 After the unit has been tripped SH start/up vent is to_t>e_Qpengd.. Vents of SH and Drum is to
be opened when pressure is very low (around 2 kg/cm2). Boiler must be purgedjor at 5 minutes with 30%
air flow. Afterwards ID and FP fans may be stopped and dampers closed. Drum level should be
maintained. If the shut down is for a longer period boiler may be emptied of water and proper action for
preservation must be taken.
1.4.3.2 EMERGENCY SHUT DOWN
Emergency shut down can be of various types due to different reasons. A healthy unit may be
instantenously out of the grid due to system trouble, or it may be due to some serious problem of some
equipment of the unit itself. Depending on the nature of emergency the shutting down procedure of the
unit is to be decided. This will be discussed in details in later chapters.

1.5 SOME GENERAL OPERATING INSTRUCTIONS

Operating engineer and his team have to be fully familar with the details of the system, the design
limits, the sequence of operation, the interdependance of equipments, unsafe conditions of operation and
seriousness of each malfunction. One must know WHY he is carrying out certain operations and its
implication on the system as a whole; Following are some important operations and the logics behind
them.
1.5.1 Air Vents

Air vents are provided to boiler, heating surfaces, heat exchangers, main steam lines etc. The
proper operation of these vents is essential to prevent any emergency situation later on. For example,
precaution must be taken to expel all the air from boiler tubes while boilerfilling. For this purpose all the
air vents are kept open and boiler filling rate is kept slow. If the air pockets are left in the system then it
can cause hindrance to fluid flow, and overheating of boiler tube causing their failure. Care also must be
taken while depressurising. The air vents must be opened as the pressure approaches atmospheric air.
1.5.2 Charging and Pilling

The operations of charging and filling are much the same regardless of the application. The
procedure normally followed is :
Open the air vents
Open the drain valves
Start the pump (if the pumps is already is service, open the filling/charging line valve as follows):
Crack open pumps discharge or filling valve until a satisfactory charging flow is obtained (this
is usually detected by the sound of the flow through the partially opened valve)
Check that the drain is free from any obstruction and close it
Expell the air and close the air vent after a steady flow of water has been obtained from it
While charging, care should be taken to avoid any water hammer
The air must be expelled gradually and completely. To ensure this the rate of charging should
be slow, this will also avoid overloading of fill pump. The slow charging is also essential to avoid
thermal stress where there are temperature differences between the water and the item being
filled.

14
1.5.3 Warming

Warming differs from charging is that the admission of warm steam results in the production of
large quantities of condensate arising from the warming process. This condensate must be drained away
before the lower portion of the pipe can be warmed. Precaution also must be taken to carry out this
operation slowly to prevent large thermal stresses.
1.5.4 Drain Valve Operation

Due to the tremendous amount of damage which can be caused by maloperation, it is important
to know the correct sequence in which drain valves must be operated. Almost invariably drain valves are
fitted in pairs, two valves in series on the same drain line. The upstream valve (valve nearest to source of
pressure) is isolating valve and its companion is the regulating valve. Drain lines should be warmed up
judiciously, avoiding sudden admission of steam or hot fluids which could result in large temperature
gradients in the drain lines and possible 'hammer' or thermal shock.
To avoid this, charging up should be slow, throttling the flow of steam or fluid by restricting valve
opening. This introduces another problem; as the passage of steam or fluid through the restricted valve
opening creates a phenomenon known as 'wire, the valve becomes damaged. To prevent this, the valve
operation sequence must be as follows : (Refer fig. 1.4).

SOURCE OF PRESSURE Regulating ""**

v
Isolating valve Valve

-&« &*
iii N £n C H A R G E D c L
0 D LINE
y?»Q$ uirvv WHICH IS TO BE
FIRST VALVE WARMED SLOWLY
FIG. 1 +

To charge drain line :

Crack open isolating valve. The small length of drain line between the two valves will be
pressurised almost immediately. Wire drawing is virtually nil.
Open isolating valve fully
Crack open regulating valve. This valve is subject to wire drawing. Charge drain line
slowly. Regulate as required using regulating valve only.
To shut off drainage :
Close the regulating valve. Wire drawing takes place as the regulating valve throttles the
flow.
Close the isolating valve. Flow is already zero. So on wire drawing takes place.
Crack open the regulating valve to release the pressure trapped between the valves.

15
 As mentioned, the damage due to wire drawing is inevitable but, at least, by using correct
operation techniques we can restrict the damage to regulating valve only. This means that we can
reasonably expect the isolating valve to give tight isolation when closed, thus preventing losses via
passing drains.
1.5.5 Drum Metal Differential
The boiler drums are filled with
water in the bottom and steam in the top due
to which the cooling and heating rates vary
between the top and the bottom. This re-
sults in temperature differences between
the top and the bottom. Stress analyses
show that the principal criterion for reliable
rates of heating and cooling should be based
on the relationship between the tempera-
ture differential through the drum wall and
the temperature differential between the top
and the bottom of the drum, both measured
is same circumferential plan. Stress analy-
sis also shows that the allowable tempera-
ture differentials are based on tensile
strength, drum diameter, wall thickness,
and pressure; therefore, each steam drum
has its own allowable temperature differen-
tial curves, one set for cooling and one set for
heating. To keep the thermal stress values
within the limit, operation engineer must
ensure that under all operating conditions 70 Ho J»o " f
actual temperature differential is below the
i . ». DRUM PRESSURE KO/Cm*/
allowable temperature differential. Normally
the temperature differential should not exceed
50°C (see fig. 1.5). FIG. 1.5 DRUM TEMP. DIFFERENTAL LIMITS

1.5.6 Drum Gauge Glasses

Normally two gauge glasses (sometimes three) are1 provided to boiler drum. It must be ensured
prior to light up that gauge glasses are available for service and are in charged condition - especially,
during cold start. The remote indication is availablejibove JLO_kg/cm?_drum. pressure. During light up
operation there are large drum level fluctuations. At about 5^ to 10 kg/cm 2 thejgauge
j g g g g l ^^ ^^
J side
id to
t clear
l offffany; dirt
d blocking
b l k i the
h port. As per IBFLboiler must riot be
operated with all the gauge glasses provided out of servipe.
1.5.7 SCAPH - Operation
While lighting up the boiler from cold state, since most of the furnace is relatively cool, large
amount of heat is absorbed in the furnace. This reduces the temperature of flue gas leaving the boiler. The
fuel oil which is fired for light up has 1.5 to 3.5% sulphur depending upon the quality. This sulphur forms
SO 2 /S0 3 after combustion and combines with HjO to form highly corrosive sulfuric acid when tempera-
ture of flue gas is low during lighting up the boiler from cold state. Due to large percentage of sulphur in

16
oil, special care must be taken when oil is being fired. The sulfur ic acid thus formed corrodes air heater
and sometimes economiser tubes also. To prevent this cold ^Lnd corrosion, heat transfer in air heater is
minimized by raising the temperature of air going to air heater. This is done by putting Steam Coil Air Pre
Heater (SCPAH) at thedischarge of F. D. Fan. Steam is passed through SCAPH when heavy oil is being fired
which raises the temperature of airgoing to air heater and flue gas temperature in air heater remain high.
When boiler gets sufficiently warm up, the flue gas temperature the exit of air heater starts increasing,
then gradually steam supply to SCAPH is cut off keeping watch on air heater gas exit temperature.
1.5.8 Boiler Expansion Measurement
Normally for all utility boilers (i.e. power station boilers) the entire boiler, casing and insulation
are suspended from top. The provision for free expansion for all parts of the boiler is important but in the
case of furnace tubes it is vital. Since the boiler is suspended from the boiler house steel work, the
expansion is mostly in downward direction. On a typical 500 MW boiler, the total expansion from cold to
lull load can be as high as 340 mm. Expansions, in other directions are also significant of the order of 70 .
to 80 mm. The boiler must be allowed to expand freely in all directions. Scales are provided at different
elevations to measure the expansions. Readings must be taken and free expansion must be ensured. This
is very important especially when the boiler is being taken into service after major shut down because it
is likely that during shut down some temporary piping, scaffolingwere welded with the boiler structure.
1.5.9 Economiser Recirculation Valve
During pressure raising period, very little amount of water passes through the economiser and
there is a danger of the economiser overheating, and in extreme cases, vapour locking. To prevent this
condition the economiser recalculation valve is kept open during the pressure raising period. The
recalculation in economiser takes place in similar manner as in water wall tubes. Once a steady flow is
established to the drum, economies recirculation valve can be closed.
1.5.10 Barring Gear
When shutting down hot machine or before turbine start up, the turbine must be on barring
gear. When a turbine is shut down, due to its heavy weight, high temperature and uneven cooling the
turbine rotor will have permanent deformation (hogging/bending). So the main function of the barring
gear is to promote even cooling of the rotors, and cylinders when turbine is shut down. The barring gear
is engaged immediately after turbine becomes stand still or at 250/500 r.p.m. for 500/210 MW KWU sets.
The barring speed is usually low.(3 to 4 r.p.iru) for LMW sets but high speed barring gear (about 200 r.p.m.)
are provided in KWU_set&, The provisions of high speed barring gear enables to bring the turbine off
barring gear with minimum steam admission while rolling the turbine.
1.5.11 Soaking of Turbine
Depending upon the type of the start up (cold, warm, hot), turbine is soaked at some particular
rpm. for predetermined time interval. During soaking period turbine speed is held constant and steam
parameters kept steady. Care should be taken to see that soaking speed is not near critical speed (Turbine
manufacturer's recommendations to be followed). Soaking helps in bringing differential expansions
within limits, also the operator gets sufficient time to check up other turbovisory parameters like turbine
expansion, turbine vibrations, bearing drain oil temp, drain oil flow etc. After satisfying himself of
healthiness of turbine he can proceed for further rolling of turbine. The soaking time is more for cold start
compared to warm and hot start.
1.5.12 Critical Speed
When shaft or rotor, revolving in bearings, speeds up to where centrifugal force tending to whip
17
it sideways just balances the elastic stiffness tending to keep it straight, the slightest mechanical
unbalance builds up a whirling motion whicrftnay be of destiUctive amplitude. The rotor then is revolving
at critical speed. This phenomenon is due *© the resonance frequency when the rotation speed
corresponds to the natural frequencies of lateral vibration of the rotor. It is inadvisable to run any rotor
at or near critical speed for any length of time regardless of perfection of balance. The operation engineer
must be well aware of exact critical speeds of the turbine. Care must be taken NOT to hold the turbine
speed nearby critical speed value and the speed rise should be kept uniform without any interruption.
1.5.13 Use of Common Auxiliaries
In a power station consisting of number of units, there are many auxiliaries common to all the
units. So for the operation engineer it is essential to know how the adjacent units will be affected by his
operation. For example, aux. steam supply, fuel oil supply, compressed air supply, cooling water supply,
reserve power supply etc. are common for all the units. Now if a unit is to be started, before charging, say,
aux. steam header from adjacent unit they should be informed about this so that in case of any problem
it can be immediately sorted out without creating any emergency. If not given prior notice, the unit
controller of adjacent unit will have less time to correct the fault developed and this can endanger the
operation of his unit. To prevent such mishaps proper communication must be maintained between the
units especially while using common auxiliaries.
1.5.14 Proper Use of Instruments
As the unit sizes are going on increasing, more and more operation is carried out from remote.
For an operator in UCB, therefore it is very important to have correct knowledge of system parameters.
For this purpose there are large numbers of meters, graphs and other instruments provided in UCB.
For one parameter there could be more than one instruments available in UCB (e.g. drum level,
steam temp, furnace draft etc.) The operator should see that the readings in such instruments are
matching within reasonable limits. In case of any discrepancy^the operator should not take convenient
correct reading for granted, instead should believe the worst reading as correct one and investigate the
matter. If the result of such investigation proves that there is fault in the instrument, then it should be
rectified from maintenance department immediately. For other parameters also (where only one
instrument is provided in UCB for indication) in case of any deviation from standard value, the matter
must be investigated and instrument fault must be attended.

1.6 SHIFT ROUTINE

1.6.1 Major observations

Following are some major observations/checks to be made at intervals within each shift and at
the commencement of each shift.
1.6.1.1 MAIN A.C. CIRCUITS :
Note the position of:
220 KV/400 KV bus bar distribution, distribution of feeders, generator and station
transformers etc.
ii) Auxiliary supply position. The position of interconnectors of H.T. and L.T. supply,
iii) Note whether the unit is on station or unit supply for HT and LT systems.

18
1.6.1.2 BOILER FEED SYSTEM
Note the feed pumps on load and If the standby pumps are available. Observe whether they are
selected to auto or manual.
i) Drum level control - is it on auto or manual,
ii) Which feed line is charged and the position of standby feed line
iii) Note the availability and condition of standby condensate extraction pump.
1.6.1.3. TANK LEVELS :
i) Inspect all tank levels. C P **~v,, nemj&e&, Oe*\*S^uki>*-w*M-;
ii) Check also the levels for F.O. tanks, D.M. make up water tanks etc.
1.6.1.4 MILLS :
Examine mill system :
i) Check which mill systems are on load and the position of standby milling systems.
ii) Note mill temperature and see whether controls are on auto or manual.
iii) Examine P.A. fan differentials and see whether they are on auto or manual.
iv) Check R.C. feeder controllers - see whether on auto or manual.
1.6.1.5 COMBUSTION CONTROL
i) Check whether furnace draft is on auto or manual,
ii) Check whether oxygen control is on auto or manual,
iii) Check furnace draft reading.
1.6.1.6 TURBOGENERATOR
Note :
i) Which ejector/air pumps is in service and the position of standby pumps,
ii) Extraction pump on load and position of standby.
iii) Lub. Oil System.
a) Auxiliary oil pump )
b) D.C. Emergency oil pump. ) Auto or manual selection.
c) Turning gear oil pump (if provided) )
iv) Availability of A.C. and D.C. seal oil pump and auto manual selection,
v) Stator water pump in service and position of standby pump.
vi) Generator transformer oil pump and intercooler water pump on load and whether
standby available and auto/manual selection.
The reason why any plant Is not on auto should be determined.
1.6.1.7 EFFICIENCY CONTROL
Particular attention should be given to following items to monitor efficiency.

19
 i) Ensure that all parameters are at their specified values. Load in particular must not be
lower than suggested by grid control.
ii) Examine milling and combustion. Ensure that they are in good order.
ill) Examine D.M. water consumption.
iv) Check total auxiliary power consumption.
v) Check condenser vacuum.
1.6.1.8 STATUTORY REQUIREMENTS:
i) Check static condition for grit emission and smoke density. (Where these are continu-
ously monitored and each fitted with alarms, this problem is eased).
ii) Check C.W. conditions to ensure that statutory limits are being observed.
1.6.1.9 MISCELLANEOUS:
i) Check all bearing and glands for any of abnormality.
ii) Check oil level of bearing. See whether oil is clean; if in doubt change
iii) Inspect for fresh oil leaks. This will be easy if the plant is clean and almost impossible
if it is dirty.
iv) Check transformer oil levels.
v) Check fire fighting equipments.
vi) Check state of charge of station batteries (quick/trickle)
vii) Check state of lighting - particularly emergency lighting.
viii) Attend to steam, water and coal leaks wherever possible.
1.6.2 Shift Change Over :
It is observed that large number of mishaps in power station operation take place at the time of
shift change over. This shift change over period is such that operator tends to take things easy
after days work-out or he is busy in writing log book. So, there are chances that he may overlook
certain operational parameter going"astray. Similarly when some operator takes over the charge,
then~~he is busy~ln~reading tne logboolTof previous shift. He also may ovejjcok__thejaulty
parameter. Under such_circumstances emergency situation can arise. It is important for
operattorTstaff, therefore, to take care for avoiding such situation. The logging of each event
£hould be done immediately after it occurs with all the details including the remedial action
taken. The logging should be systematic. At the time of charge hand over, the incoming operator
should be briefed about various important operations in the shift, especially if any abnormal
situations had been handled. The problem areas that can endanger unit working or can cause
load reduction must be briefed to incoming operator. The status of standby auxiliaries must be
mentioned in the logbook. This systematic approach taken while shift change over can,
therefore, help in performing safely.
At the same time during the shift also the operator has to be vigilant, so that the unit generation
is kept at optimum level. Here, also, the systematic approach can be very productive.

20
OPERATION OF BOILER & AUXILIARIES
 2. OPERATION OF BOILER & AUXILIARIES

2.1 LINE-UP BOILER FEED WATER SYSTEM

Close Boiler Feed Pumps discharge Close R.H. Attemperat-ior control valves'
valves inlet isolating valves

Close Boiler feed pumps, discharge Open feed line vent valve
valves bypass valves

Close Main Feed Control valve

Close B.F. Pumps discharge header
drain valve 1
Close isolating valves
f

Close feed water isolating valves

Close Standby Feed Control valve and
i isolating valves
Open feed line vent valve

1 Close bypass valves of Standby Con-

Open feed line drain valves trol valves' isolating valves

Close H.P. heater F.W. inlet valve Close Low Load Control valve and
isolating valves
t

Close H.P. heaters F.W. outlet valve

Close bypass valves of isolating valves
f
of low load control valves
Open H.P. heater F.W. bypass valve

1" Open Feed Control station drain valves

Open F.W. line drain valves

f
Close boiler filling isolating valves from
Close S.H. & R.H. Attemperator header Boiler Fill pumps
isolating valve
% f
Close Hydrazine sampling valves' be-
Close R.H. spray block isolating valve fore economiser.

i
Close S.H. Attemperator Control valves Close economiser drain valve to water
inlet isolating valves wall header

21
2.2 LINE-UP BOILER WATER & STEAM SYSTEM

2.2.1 Economlser Close remote level indicator gauge glass

drain valves
Open economiser inlet valve & close
its bypass valve
Open saturated steam sampling branch
i line valves
Open economiser recirculation valves
\ t
Check that Drum safety valves are in
Close economiser drain valves service condition.
i 2.2.3 W.W. Drain Header
Open economiser outlet lines vent
valves
I Close filling valve from Boiler fill pumps
Close economiser outlet lines drain
valves Open S.H. headers & link vent valves
2.2.2 Drum l
Open startup vent valves isolating
valves
Open Drum vent valves
t Open startup vent regulating valves
Close C.B.D. Isolating valve
t Open impulse safety valve isolating
Close Phosphate dosing isolating valves valve
i
Check I.B.D. valves are closed. Establish electric supply to impulse
safety valve.
r

Open Drum level gauge glass (Left and

right) isolating valves quick closing Check that final S.H. header safety
valves. valves are in service
1
Close Drum level gauge glass drain Close M.S. shut-off valves & their bypass
valves. valves

'
Open isolating valves for local pres- Open M.S. drain valves to before boiler
sure gauge, level & pressure transduc- Stop valves
ers.
sr Close Scot Blower steam isolating valves
Open isolating valves for remote drum Open isolating valves of local pressure
level-indicator. gauges, pressure transducers etc.
22
2.2.4 Reheater Close the isolating valves tank level
control standby valve

Open Reheater headers vent valves r

Close standby C.B.D. tank level Con-
trol valve
Open H.R.S. header motorised vent
valves r

PutC B.D. level Control valve for auto

mode of operation.
Close Sampling line valve

2.3 BOILER FILLING

Check that R.H. header safety valve
are in service. 2.3.1 Boiler Filling Using B.F.P.

Open R.H. desuperheater left & Right Fill the Deaerator with D.M. water using
drain valves boiler fill pump

Close R.H. spray line drain valve &

after spray control valves. Prepare Hydrazine & Ammonia solu-
tion in the L.P. Dozing mixing tank

2.2.5 C.B.D. Tank

Take water in L.P. dosing metering
tank
Open isolating valves of main C.B.D.
control valve
r
Open Hydrazine dosing valve in B.F.
suction line & run Hydrazine dosing
Close C.B.D. control valve pump.
f

Close isolating and control valves of Turn on feed water Maintain deaerator
standby line heating steam & O pr. just above
heat up the feed • atmospheric = 0.2
<t water gradually to to kg/cm2 (g)
Open C.B.D. tank atmospheric vent 80 to 85°C.
valve

Run Boiler Feed Pump on recircula-

Check C.B.D. tank safety valve is in tion
service

A.
Close C.B.D. tank vent valve to deaera-
Continue to run B.F.P. on recircula-
tion with Hydrazine amonia dosing
tor

Open the isolating valves, Flash tank

level control valve
23
Check water condition Ammonia content Close economiser vent valves when
before filling: should be should be 0.2 to water starts coming through it
pH 8.5 to 9.5 at 25°C. 0.3 ppm.
Dissolved O2 0.005
ppm. Temperature 80 Feed water lines
to 85°C. Hydrazine in charged
F.W. 0.05 to 0.1 ppm
r

Open BFP discharge valve & close its

Check F.W. system is Refer feed water bypass valve
lined up system line up
r

Maintain moderate Add make up to

Crack open BFP discharge valve by- feeding about deaerator as
pass valve and slowly charge the FW 40 t/hr, for easy -\p the FST level
lines purging ofair & goes down
gradual heating of
drum & W.W. tubes.
Throttle vent valves, as the air is being
released t

Continuously monitor Drum metal

drum level when temperature rise
Close Feed line drain valves water is just visible * rate should be
in gauge glass less than 110°C/hr.

Close F.W. line drain valves after H.P. V

heater after flushing for few minutes. Close BFP discharge Ensure that BFP
valve when drum . recirculation valve
level approaches opens when flow
Close the feed line vent valves before - 120 reading reduces to 100 t/hr.
H.P. heaters when water starts coming
through vent \ t

Boiler is filled up.

Close the feed line vent valves before

feed station when water starts coming
through vent

Open bypass valves of feed control

valves isolating valves.

Open low load feed control valves and

charge the line upto economisef .

Open isolating valves of low load con-

trol valves.

24
2.3.2 Boiler Filling Using Boiler Fill Pump
This method of filling shall be used when cold filling of Boiler is required viz. hydro-static testing.

Check Boiler steam Refer Boiler steam Close S.H. filling valve
and water system & water system
lined-up line up V

Open economiser inlet valve &

Close it bypass valve
Boiler filling solution is prepared in
C.S.T.
Close isolating valves & its bypass
valves of Feed control valves down
Open fill pump suction header inlet stream side.
valve from C.S.T.
•< r
Check the level of water in C.S.T.
Open Boiler fill pump 'A' or 'B' suction
valves 4
Establish electric supply to Boiler fill
pump A & B
Close fill pump discharge valves
r
Start Boiler fill pump
Prime Boiler fill pump
r
Open Boiler fill pump discharge valve
Open isolating valves of pump dis- when it attains full shut-off pressure,
charge control valve check pump discharge pressure.
t
Open fill pump discharge bypass con- Regulate filling rate by opening fill
trol valve isolating valves. pump discharge control valve
r
Close fill pump discharge bypass con- Water is filled up through economiser
trol valve

When drum level comes to 'O' reading

Close fill pump discharge control valve close the fill pump discharge control
valve. Stop boiler fill pump.
Close filling line isolating valve to sec- i
ond unit Close the economiser filling line isolat-
ing valve
Close deaerator filling water isolating
valve Boiler is filled up.

Open economiser filling water valve &

after feed control station & before
econmiser inlet valve

25
2.4 DRAFT SYSTEM
Draft System consists of Induced Draft Fans (2/3 Nos.), Forced Draft Fans (2 Nos.), Air Pre-
heaters (2 Nos.), Steam Coil Air Pre-heaters (2 Nos.), Ignitor Air Fans (2 Nos) and Scanner Air Fans (2 Nos).
This system provided the air required for combustion of fuel and pushes out the combustion products and
maintain a balanced draft in the furnace. This system also supplies air for cooling flame scanners.
2.4.1 ID Fan Operation
1. Starting Pennissives
i) Regulating vane in minimum
ii) Outlet damper closed
ill) Lub oil pr. adequate
iv) Fan/Motor bearing temp, not high
2. Flow chart for typical ID Fan operation

Check No PTWs are pending Check that bottom ash hopper is filled
up/filling line is open
r
t
Flue gas path lined up
Ensure cooling \vater supply

Check ID Fan motor selected for low f

speed if two speed motor provided START ID FAN

A
Ensure that all permissives are OK Open discharge Damper
i
Check Air Heater in service Load the fan by IGV

3. Checks immediately after starting

i) Discharge damper should open automatically after 0-60 seconds,
ii) Check ID Fan Motor current
ill) Other ID Fan suction and guide vanes should get close command and remains closed.
2.4.2 F.D. Fan Operation
1. Starting Permissives
i) ID Fan selected in combination is started,
ii) Control oil pr. is adequate (8 Kg/Cm?)
iii) Fan impeller blades are in minimum position
iv) Outer damper is closed
v) Fan/Motor bearing temp, not high
26
2. Flow chart for typical FD Fan operation

Check that concerned FD fan air path START FD Fan motor

is lined up
Increase Fan Loading by increasing
Ensure all permissives impeller blade pitch

Check cooling water supply Maintain 30% air flow and -20 mm WC
furnace draft

3. Checks immediately after starting

i) Discharge damper should open after 0-60 secondg.
ii) .Other FD Fan discharge damper and blade position should get close command and
should remain closed.
iii) Check that furnace is not getting pressurised.

2.4.3. Starting Air Preheater Check A.P.H. Interconnecting

interconnecting •»•
damper operation
Check that air preheater guide bearing
circulating oil system is lined up
damper opens if
one APH is on/
closes when both
the APH's 'ON*.

Check that air preheater support bear- Check operation of Trip electric
ing circulating oil system is lined up fat
air motor motor-air motor
should start
Check that air flow path is lined up r
Run air preheater electric motor, keep
air motor on xAuto' standby
Check that gas flow path is lined up
r

Check that support Check that pump

Check that A.P.H. water washing top/ bearing oil pump develops correct
bottom valves are closed starts when oil pressure
temperature exceeds
30°C.
Check that station air supply is avail-
able for the air motor 7

Check that guide bearing oil pump

starts when oil temperature exceeds
Establish electric supply to A.P.H. 30°C.
motor. Take out the charging push
button of electric motor. V

Open cooler inlet outlet water valve/

maintain oil temp, at about 40°C.
Start A.P.H. Electric motor.
27
2.4.4 Draft System Starting Start ignitor air Fan

Line up ID Fans/Motors lub oil system Start Scanner air Fan

I
Line up FD Fans/Motors lub oil
r
Light up and load boiler upto 50 MW
system
f

Start Second ID Fan

Line up APHs guide bearing and sup-
port bearing oil circulating system
Equalise Loading on Both ID Fans
A. r
Line up flue gas path
Start*second FD Fan

Line up secondary air path

Equalise loading on FD Fans

Take both APH in service

Stablise furnace draft
Start one ID Fan
Put furnace draft control on Auto
Start one FD Fan

2.5 FUEL FIRING SYSTEM

Fuel firing system comprises of three types of fuels and their associated systems for fuel
preparation, handling and firing. They are :
i) Light Oil (L.O) system for warm up (W/U),
ii) Heavy oil (H.O/LSHS/HPS) system for pressurising, and
iii) Pulverised fuel (PF) (i.e. Coal) firing system for taking on load.
In 210 MW BHEL boilers, fuel firing system is operated through a system called FSSS (Furnace
Safeguard Supervisory system). Boilers of other makes and ratings also, now-a-days, have such
automatic firing control mechanism with different trade names likes BMS (Burner Management System)
etc. As FSSS controls the operation of all fuel firing systemsin an integrated fashion, the milling system,
H.O. W.U oil system etc. are not described separately.
Recently BHEL has also developed DIPC (Direct ignition of pulverised coal) system where
pulverised coal is directly fired by special ignitors. Both L.O. and H.O. systems are dispensed with; DIPC
helps in saving precious fuel oil.
2.5.1 Introduction To FSSS
F.S.S.S. facilitates remote manual /automatic control of fuel firing equipment through mechani-
sed systems and suitable interlocks /logics. It is designed to ensure the execution of a safe, orderly

28
operating sequence In start up and shut down of fuel firing equipment and to prevent errors of omission
of commission in following such a safe operating procedure.
The system provides protection against malfunction of fuel firing equipment and associated air
system. The safety features of system are designed for protection in most common emergency situations.
F.S.S.S. comprises of control, indications and logics etc. to carry out the following :
To start complete furnace purge when all technological conditions are fulfilled.
To start, stop and monitor ignitors.
H.O. guns/w.u. oil guns starting stopping and supervision.
Pulverizer and feeder starting, stopping and supervision.
Flame scanner intelligence and checking.
Furnace flame monitoring and overall furnace flarne failure protection.
To trip out all boiler fires when boiler safety is threatened.
To start/stop Ignitor & Scanner air fans.
To effect secondary air damper control with indication of auxiliary and fuel air damper
modulation /close.
To provide boiler trip signal to other equipment such as P.A. fan, turbine, generator etc.
F.S.S.S. Equipment can be grouped under three heads :
1. The operating and indicating console insert on operator's desk :
This consists of all switches for initiating controls and also indications of status of all fuel
firing equipment and their auxiliaries.
2. Relay and Logic Cabinets :
These cabinets of relays, timers, programmers, circuit breakers for AC and DC control
suppliers flame scanner unit, no coal flow units etc. They control the process logic.
3. Field Equipment :
Field equipments are those which help in actual remote" operation of fuel firing
equipment and those which provide the status to the operating console and relay logic
cabinet.
Field equipments include :
Ignitor/W.U. oil/H.O. Trip valves, H.O./W.U. Oil, atomising steam/air, scavenging steam/air
nozzle valves (Hydrometer type), gun advance/retract mechanisms, oil gun assembly ignitors and its
cabinets, flame scanner and ignitor air fans, pressure switches, temperature switches, flow switches and
limit switches.
Mill discharge valves, hot air gates, sealing air valves, tramp iron gate etc.
2.5.2 Furnace Purge
Furnace purge is required after a boiler tripout, before relighting the boiler to expel all unburnt
fuel particles/gases, vapours, etc. from the boiler so that possibilities of explosion are avoided when boiler
is lighted up.

29
 Boiler Purging cycle is of 5-*rtlnute$iwith air flow being more than 30%. Purging can be started
by pressing 'Purge Start' push button provided purge ready conditions are satisfied and 'PURGE READY
signal will come. This is an indication that boiler M.F.R. is reset and now boiler can be lighted up. If any
time during purging any of the "Purge Ready" conditions are violated, Purge Ready signal disappears and
purging cycle is to be started once again after establishing "Purge Ready" conditions.
Once purging of boiler is completed boiler will trip if any of 'Boiler trip' conditions occur.
Purge Ready Conditions :
220 VD.C. & 110 VA.C. supply to F.S.S.S. panglgstablished.
Boiler drum level normal.
Atleast one I.D. and one F.D. fan running.
Ignitor Trip valve proven closed.
Warm-up oil Trip valve proven closed.
Heavy oil Trip valve proven closed.
All ignitor oil/air valves proven closed.
All W.U. & H.O. nozzle Hydrometer valves proven closed
All pulverizers are off.
All R.C. feeders are off.
All mills hot air gates closed and cold air dampers in minimum open position, (Less than 55
degrees).
All auxiliary secondary air dampers modulating to maintain adequate windbox to furnace
differential pressure.
All elevation flame scanners show "no flame".
No boiler trip command persisting.
2.5.3 Starting the Ignitors
2.S.3.1 IGNITOR TRIP VALVE INTERLOCK :
i) Ignitor trip valve will open when Trip valve 'Open'. P.B. is pressed provided all the
following conditions are fulfilled.
a) Ignitor oil supply pressure is adequate (more than 13 kg/cm2).
b) All Ignitor valves are closed.
c) No boiler trip command is persisting.
d) Ignitor oil pressure is more than 9 kg/cm2.
e) When Ignitor trip valve is fully open, 'Open' signal comes on F.S.S.S. Console,
ii) Ignitor trip valve will close under following conditions :
a) "Close" Push button is pressed from console.
or b) Ignitor oil header pressure falls below 9 kg/cm2 for more than 2 sees, and any Ignitor
valve not closed. " ~
30
 or c) Boiler trip command present. When Ignitor trip valve is closed, Valve 'Closed' green
signal comes on.
2.5.3.2 IGNITOR STARTING
There is no separate Ignitor start switch provided for any of the elevation AB, CD or EF ignitors.
Pressing any one pair (L.O. or H.O.) of oil gun 'START' push button gives a starting impulse to all four
ignitors of that elevation. The spark is applied for 10 seconds only for every pressing of ignitor start push
button.
2.5.3.3 IGNITOR STOPPING
All four ignitors of each elevation are provided with one "STOP" Push button for taking out
ignitors from service. Also ignitors get stop command at the end of stop time trial of H.V. elevation or W.U
oil elevation.
When individual ignitor gets stop command its motorised oil/air valve closes thus taking out
ignitor from service.
2.5.4 Warm Up Oil Firing
Light (Warm up) oil can be fired only at AB elevation after selecting L.O. through L.O. Selector
Push Button. Oil guns have been programmed to light up in pair basis diametrically opposite (1,3 and 2,4)
corners from the pairs. Each pair has got a separate start/stop push button. Warm up oil guns can be
lighted up, only if atleast 3 out of 4 ignitors at corresponding elevations are in service. The warm up oil
guns are not self sustaining hence, ignitors corresponding to W.U. oil gun in service must remain on as
long as W.U. oil gun is in service. There is no flame monitoring for warm up except making sure that they
burn with the help of ignitors.
2.5.4.1 LIGHT OIL TRIP VALVE INTERLOCKS
Light oU trip valve can be opened from F.S.S.S. Console 'Open' P.B. provided :
i) Boiler Trip Circuit (M.F.R.) is reset, and,
ii) All the light oil nozzle valves (Hydrometer) are proven closed and,
iii) Light oil supply pressure adequate.
When L.O. Trip valve opens "Valve Open" red light comes on.
Light Oil Trip Value will close if:
i) Light oil header pressure is low (2 sees, time delay) (less than 1.5 kg/cm2).
ii) Light oil to air differential pressure is low 0:3 kg/cm2 for more than 2 seconds.
iii) Boiler trip occurs.
iv) Valve 'Close' Push button on F.S.S.S. Console is depressed.
Light Oil elevation start permlssives
i) D.C. Power, available.
ii) Ignitor Trip valve proven fully open.
iii) Light oil Trip valve proven fully open.
iv) Air flow adjusted between 30% to 40% of full load air flow (This condition is not required
once any feeder is proven on).
31
 v) Fuel air nozzle till placed in horizontal position (This condition is not required once any
feeder is proven on).
vi) No boiler trip command persists.
Pennissives for each Light Oil Comer to be Satisfied for starting that corner gun.
i) The light oil gun is inserted in guide pipe and coupled,
ii) The local maintenance control switch is placed in remote.
ill) The light oil burner manual isolation valve is open,
iv) The light oil atomizing air manual isolation valve is open.
2.5.4.2 LIGHT OIL GUN STARTING SEQUENCE & MONITORING
When light oil pair Start push button is depressed pair of light oil guns are placed in service in
following sequence, (provided L.O. elevation start permissives and corner start permissives are satisfied).
i) In first 10 seconds of pair start time trial the assocjated_elevation ignitors are started.
When ignitors are proven 'ignitor on' signal comes on. If the flame is noTpfovedrspark
will cease and Jamesbury Valve will close after 10 seconds. ~~
- , -
r W<SJ ii) When minimum of 3 out of 4 ignitors at the associated elevation are proven on at the end
^ of 10 seconds, a start command is sent to Light oil Corner 1 pair (When pair 1 aryl 3 is
started) or Corner 2 (When pair 2 and 4 is started).
ill) Twenty five seconds later a start command is sent to corner 3 (When pair 1 and 3 is
started) or corner 4 (when pair 2 and 4 is started).
When an individual light oil corner receives a start command and if its associated ignitor is
proven on, it is placed in service in following sequence.
i) Light oil gun advances to firing position "Gun Retracted" light goes out.
ii) When the gun is fully advanced the atomizing air nozzle valve opens.
iii) When the atomizing air valve is proven fully open the light oil nozzle valve opens placing
light oil gun in service.

Note :

If the light oil gun fails to advance or the atomizing air or light oil valve fails to open, check :
a) Light oil start pennissives have remained satisfied.
b) The associated ignitor is proven on.
c) Power is available.
2.5.4.3 UNSUCCESSFUL CORNER START
At the end of 90 seconds of light oil pair start time trial a light oil corner trip is initiated for any
corner where,
a) Light oil nozzle valve is not proven fully open by 'Red' Light.
b) Associated ignitor is not proven on.

32
2.5.4.4 UNSUCCESSFUL ELEVATION START
At the end of 90 seconds of light off pair start time tried of the second pair of light oil guns at the
elevation a minimum of 3 of the 4 light oil nozzle valves at that elevation must be proven open, or an
"Unsuccessful Elevation Start" alarm is annunciated and all the light all guns at that elevation are shut
down in an orderly fashion.
2.5.4.5 WARM-UP OIL ELEVATION SHUT DOWN
Warm-up oil elevation is removed from service on a pair basis. Depressing the associated
elevation pair stop Push button will initiate a 375 seconds stop time trial to shut down and scavenge the
associated pair of L.O. guns as follows :-
1) During first ten seconds of stop time trial associated elevation of ignitors is started.
(Ignitors associated with L.O. gun not in service will only acknowledge the start signal
since the ignitors are already on at the L.O. gun in service).
2) At the end of ignitor start time a stop command Is sent to corner 1 (when pair 1 & 3 is
stopped or corner 2 (when pair 2 & 4 is stopped).
3) Fifteen seconds later, a stop command is sent to Corner 3 (When pair 1 and 3 is stopped)
or Corner 2 (when pair 2 and 4 is stopped).
When an individual warm up oil gun, that is in service, receives a stop command.
a) A Scavenge command for that corner is initiated and the W.U. oil nozzle valve closes. The
atomizing air valve remains open.
b) When the W.U. oil nozzle valve is proven fully closed and if the associated ignitor is
proven on and the atomizing air valve has remained open, the Scavenge valve opens.
c) When the Scavenge valve is proven fully open, a five minutes scavenge period is started.
d) At the end of 5 minutes scavenge period, the atomizing air and Scavenge valves close.
e) When both the valves are proven fully closed the W.U. oil gun is retracted from firing
position.
Six minutes after remaining (2nd) pair of W.U. oil guns stop is initiated, a back up trip signal is
established which will remove the associated elevation of ignitors from service and initiate a close signal
to all of the W.U. oil nozzle valves, all of the atomizing air valves and all of the scavenge valves at the
elevation to ensure that they are closed.
Fifteen seconds later on "Unsuccessful Elevation Shut Down" alarm is annunciated if:
a) Any W.U. oil gun is not retracted from firing position at that elevation.
b) Any W.U. oil nozzle valve is not closed at the elevation.
2.5.4.6 SCAVENGING OF W.U. OIL GUN
A warm up oil gun that is in service can be scavenged individually by placing its local
maintenance switch to the "SCAVENGE" position. The W.U. oil gun will be shut down, scavenged, and
retracted as described above. The individual W.U. oil gun can only be restarted by initiating another pair
start sequence.
Scavenging using local maintenance switch is possible only if ignitor associated to the gun is
proven on.

33
 Scavenging will not take place during conditions which cause boiler trip or corner trip.
In the event of ignitor trip out during scavenge (using local maintenance switch or during
elevation pair shut down operation) cycle; scavenge and atomizing air valves will close interrupting the
scavenge.
2.5.5 Heavy Oil Firing

Heavy oil can be fired at CD and EF elevation. It can be fired at AB elevation also provided H.O.
is selected through H.O. Selector. Push button (ICRL 170 AB is on). Heavy oil gun have also been
programmed to light up on pair basis, diametrically opposite corners (1,3 and 2,4) from the pair. Each pair
is provided with separate start/stop push button.
H.O. guns can be lighted up only if atleast 3 out of 4 ignitors at corresponding elevations are in
service. H.O. guns are self sustaining only when elevation firing rate is above 30% Hence, ignitors
corresponding to H.O. guns in service can only be removed when H.O. burner header pressure is above
3 kg/cm 2 (g) and at least three H.O. guns at the elevation are in service.
Heavy oil gun flame is monitored by flame sensing scanners only when the following conditions
are fulfilled :
i) H.O. firing rate (elevation load) is above 30%.
ii) 3 or more H.O. guns at the elevation are in service,
iii) Ignition energy is removed.
2.5.5.1 H.O. TRIP VALVE INTERLOCKS :
H.O. trip valve can be opened by pressing 'OPEN' push button provided.
a) Boiler Trip circuit (MFR) is reset, and
b) All H.O. Nozzle valves of AB, CD, EF oil guns are proven fully closed, and
c) H.O. supply pressure is adequate, (more than 7 kg/cm2)
d) H.O. pressure not low (less than 1.5 kg/cm2 for more than 2 sees)
e) When trip valve is full open valve 'Open' red light comes on. (ICRL 275 and 2 CRL 275 are
on).
H.O. Trip valve closes under any of the following conditions :
a) H.O. header pressure is low for more than 2 seconds or
b) Steam or heavy oil differential pressure is low (less than 0.3 kg/cm2) for more than 2
seconds and provided no guns are being started or stopped, or
c) A boiler trip occurs, or
d) H.O. trip valve 'Close, valve 'Closed' green light comes on
2.5.5.2 H.O. RECIRCULATION VALVE INTERLOCK
Opening :
H.O. recirculation valve can be opened following a boiler trip and before starting furnace purge
cycle by pressing valve 'Open' push button. Valve opens provided :
a) All the H.O. nozzle valves (hydromoter) are fully closed, and
b) H.O. trip valve is closed.

34
Closing
H.O. decirculation valve closes automatically when.any one of the H.O. nozzle (hydromotor) is
not closed.
2.5.5.3 HEAVY OIL ELEVATION START PERMISSIVES
a) D.C. Power available.
b) Ignitor Trip valve proven fully open.
c) No boiler trip command persists.
d) H.O. Trip valve proven fully open.
e) Heavy oil temperature above 100°C.
f) Air flow adjusted between 30% and 40% of full load air flow.
g) Burner tilt placed in horizontal position.
* These condition are no longer required once any one feeder is proven on.
2.5.5.4 H.O. CORNER START PERMISSIVES
At each main oil corner to be placed in service following conditions should be satisfied.
a) The main oil gun is inserted in guide pipe and coupled.
b) The local maintenance control switch is placed in remote.
c) H.O. manual isolation valve is open.
d) Atomizing steam manual isolation valve is open.
2.5.5.5 H.O. GUN STARTING SEQUENCE
Same as that for L.O. guns except.
a) H.O. is to be put in place of L.O.
Atomizing steam is to be put in place of Atomizing air
b) H.O. elevation ignitors can be removed by pressing ignitor stop push button when :
3 out of 4 H.O.nozzle valves are proven open, and
Elevation Loading is above 30%.
Minimum 2 out of 4 flame scanners serving that elevation prove flame on.
2.5.5.6 H.O. ELEVATION SHUT DOWN :
Same as that of L.O. elevation shut down except -
Ignitors associated with H.O. giins in service may or may not be on hence when stop
command is given in first 10 seconds elevation ignitors in service receive start command;
H.O. is to be considered in place of L.O.
Steam is to be considered in place of air.
2.5.5.7 SCAVENGING OF H.O. GUN :
Same as "Scavenging of L.O. gun".

35
2.5.6 Pulverizer Operation
2.5.6.1 AVAILABILITY OF IGNITION ENERGY FOR PULVERIZER OPERATION :
Prior to starting any pulverizer, ignition energy must be adequate to support coal firing. This is
accomplished as follows :-
Pulverizer. A
i) A minimum of 3 out of 4 Elevation AB light oil (or heavy oil) nozzle vales proven open, or
11) Boiler loading is greater than 30% and Pulverizer B is in service at greater than 50%
loading.
Pulverizer B
i) A minimum of 3 out of the 4 Elevation AB light oil ( or heavy oil) nozzle valves .prove open,
or
ii) Boiler loading is greater than 30% and Pulverizer A or C is in service at greater than 50%
loading.
Pulverizer C
i) A minimum of 3 out of the 4 Elevation CD heavy oil nozzle valves proven open, or
ii) Boiler loading is greater than 30% and pulverizer B or D is in service at greater than 50%
loading, or
iii) A minimum of 3 out of the 4 Elevation AB light oil (or heavy oil Nozzle valves proven open
and pulverizer B is in service at greater than 50% loading.
Pulverizer D
i) A minimum of 3 out of the 34 election CD heavy oil nozzle valves proven open, or
ii) Boiler loading is greater than 30% and Pulverizer C or E in service at greater than 50%
loading.
Pulverizer E
i) A minimum or 3 out of-the. 4 Elevation EF heavy oil nozzle valves proven open, or
ii) Boiler loading is greater than 30% and Pulverizer D or F in service at greater than 50%
loading, or
iii) A minimum of 3 out of the 4 Elevation CD heavy oil nozzle valves proven open and
pulverizer D is in service at greater than 50% loading.
Pulverizer F
i) A minimum of 3 out of the 4 Elevation EF heavy oil nozzle valves proven open, or
ii) Boiler loading is greater than 30% and Pulverizer E is in service at greater than 50%
loading.
2.5.6.2 PULVERIZER READY:
Prior to starting a pulverizer, a Pulverizer Ready condition for the respective pulverizer must be
established by the following conditions being satisfied :
i) D.C. Power available.
36
 ii) Fuel and air nozzle tilts placed in the HORIZONTAL POSITION (see Note below).
ill) Air flow adjusted between 30 and 40% of full load air flow (see Note below).
Note : Conditions (ii) and (iii) above are no longer required to satisfy a Pulverizer Ready condition when
any feeder is proven on. However, the operator is still restricted to a minimum air flow above 30%
of minimum continuous rating (M.C.R.).
iv) At the respective pulverizer, all of the following conditions are to be satisfied.
Pulverizer discharge valve open. (CRL 263 A is on)
Seal air valve open.
Cold air shut-off gate open.
Pulverizer outlet temperature less than 90°C.
Feeder inlet gate open (operator check only).
Tramp iron hopper valve open.
Primary air adequate
When all of the above conditions are satisfied for the respective pulverizer, its associated
"Pulverizer Ready" (white) light comes on. (CR 48, A,B,C,D,E,F are on).
2.5.6.3 PULVERIZER START :
When both "Ignition Energy Available" and "Pulverizer Ready" condition are established for the
respective pulverizer, it may be placed in service as follows :
i) Start the pulverizer by depressing its associated push button.
ii) When the pulverizer is proven on (ICRL 53, A,B,C,D,E,F are on) as indicated by its (red)
start ("Pulverizer On") light being on, open the hot air gate by depressing its open push
button and allow the pulverizer to come up to temperature.
iii) When the pulverizer is upto temperature (approx.) 60-70°C, start the feeder by depress-
ing its associated START push button (associated elevation of fuel air dampers to be
proven closed for feeder starting).
Coal flow must be proven either by the coal flow detector or satisfactory pulverizer amps within
five seconds after the feeder is started.
Fifteen seconds after the feeder is started, the feeder output is released to automatic control, and
the fuel air dampers are opened to modulate as a function of feeder speed.
When a minimum of two feeders are on for fifty seconds the feeder speed is released to automatic
control, and the fuel air damper are opened to modulate as a function of feeder speed.
When a minimum of two feeders are established at greater than 50% loading, the associated
elevation of oil guns may be shut down provided the feeder has been on for a minimum of three minutes.
2.5.6.4 PULVERIZERS IN SERVICE :
i) Either of the following conditions will run the feeder speed to minimum until the
initiating condition is corrected, at which time the feeder will be returned to control.

37
 a. Pulverizer bowl differential pressure high.
b. Pulverizer amps above maximum set point.
ii) Loss of coal flow and low pulverizer power as confirmed by low pulverizer amps will trip
the feeder, open the cold air damper, and close the hot air gate. The operator should take
appropriate corrective action, then reopen the hot air gas and restart the feeder.
ill) A high pulverizer outlet temperature (above 90°C) will open the cold air damper and close
the hot air gate.
iv) The following conditions will initiate a pulverizer trip command :
a. Pulverizer discharge valve not open.
b. Loss of unit D.C. power (for more than 2 seconds).
c. Pulverizer ignition permit is not satisfied wh&i support ignition is required and less
than 3 out of the 4 associated oil guns in service.
d. Boiler trip
e. Primary air trip (see item v below).
(v) When both primary fans stop the primary air duct pressure falls below the low sejt point
(for more than 5 seconds), all pulverizer in service receive a stop command. When the
primary air duct pressure falls below the very low set point all pulverizers in service are
tripped instantaneously.
When only one primary air fan stops and four or more pulverizers are in service, a trip command
will be given starting from the lowest pulverizer in service until the number of pulverizer remaining in
service is reduced to three.
2.5.6.5 PULVERIZER SHUTDOWN
Shut down of pulverizer is accomplished as follows :
i) If not in service, start the oil elevation associated with the pulverizer to be shut down.
ii) Reduce the feeder speed to.minimum.
iii) Close the hot air gate by depressing the CLOSE push button.
iv) When the pulverizer outlet temperature is reduced to approximately 60°C shut down the
feeder by depressing its stop push button.
v) Allow the pulverizer to run for approximately two minutes to ensure that it is completely
empty of coal, then shut down the pulverizer by depressing its STOP push button.
vi) The associated oil elevation should be shut once furnace condition have stabilized.
Whenever pulverizer or feeder is shut down by the operator there will be steady indication of the
respective off lamps at the console insert.
Whenever a pulverizer or feeder is tripped a flickering indication will come in the respective "off
lamp at the console.

38
2.5.6.6 F.S.S.S. PROTECTS THE BOILER BY TRIPTOIG OUT ALL FUEL INPUT UNDER THE
FOLLOWING CONDITIONS :
Loss of 220V D.C. to F.S.S.S.
Less than fire ball load and loss of A.C. on any elevation in service
Flame failure trip
Loss of fuel trip
When at least one pair of ID & FD fan is not in service
When Boiler load is less than 30% air flow falls below 30%
Furnace Pressure High/Low (+ 200 mm)
Drum level High/Low (+ 200 mm)
Turbine trip
Both Boiler trip buttons on console pressed
Note : Loss of fuel trip occurs only when 3 ignitors have been proven and if one of the proven ignitor
goes off or if trip valves on warm up heavy oil and ignitor closes or if any valve is open and its
corresponding guns (minimum 3) are not in service, when both pairs are pressed. This condition
is applicable when boiler is on oil firing without any coal feeders.
2.5.6.6 FIRE BALL CONDITION :
A Fire Ball condition is established as follows for the main fuel indicated :
a) Coal firing - any feeder established.
b) Main oil firing - a minimum of three of the four heavy oil nozzle valves proven open at an
elevation (AB or CD or EF) and the elevation loading is above 30%.
When the ignition energy is removed the established FIRE BALL will be monitored by the optical
flame scanners. A unit flame failure signal is initiated when there is a NO FIREBALL condition at all
elevations and either any feeder is not working at any elevation (AB or CD or EF) where less than three
of the four associated ignitors are proven on.
An elevation NO FIREBALL condition is as described below for the respective elevations :
Elevation A & B :
i. Elevation AB flame scanner count shows no flame and any of the following :
a) Loss of elevation (AB) A.C. power for more than 2 seconds, or
b) Light oil is selected at elevation AB and less than 3 of the four elevation AB light oil nozzle
valves are proven open, or
c) Heavy oil is selected at Elevation AB arid less than 3 of the 4 elevation AB ignitors are
proven on.
ii) Both feeder A and B are off either :
a) Loss or elevation (AB) A.C. power for more than 2 seconds, or
b) Less than 3 of the 4 elevation AB heavy oil nozzle valves proven open.
39
 c) Elevation AB flame scanner count shows no flame and less than 3 of the 4 elevation AB
igniters are proven on.
Elevation C & D
Same as above except delete condition AB and substitute elevation designation E and F for A and
B respectively.
Elevation E & F
Same as that for elevation A & B except delete condition AB substitute elevation designation C
& D for A & B respectively.

Start one F.D. fan —• Refer F.D. fan

2.6 BOILER PURGING & LIGHTING UP starting instruction
i

Maintain 30% Air Air flow shall

Feed pump is started & Boiler feed line flow and 5 to not be more
charged 10 mm WCL than 40%
furnace-.draft
Boiler steam & Refer Boiler water
water system is steam system line Put secondary air Check fuel air
lined up up. damper control dampers are
system on "Auto" modulating with
-
& check that aux. air dampers.
Boiler is filled up Refer Boiler filling auxiliary air
to working level instruction. dampers are
of gauge glass modulating to
maintain 35-40 mm
WC windbox to
B.F.P. run on recirculation furnace differential
pressure.
1
Boiler air & flue • Refer Drafts system >
gas system is Start E.P. rapping Check that E.P.
lined up. mechanism insulator heaters
r were switched on
24 hrs before
Start Air Preheaters A&B boiler light up.
>r
Take lube oil system of I.D. fans in Start Scanner Air Fan A/B
service

Take oil systems of Refer F.D. fan Start Ignitor Air Fan A/B
F.D. fans in service starting instruction
Select Burner tilt control on manual,
keep burner tilt in horizontal position
Start one I.D. fan. Refer I.D. fan
starting instruction
Ensure that warm up oil^system is in
service, L.O. system is charged
40
CHECK:

i) A.C. & D.C. power supply is es-

tablished to F.S.S.S. related
equipment

ii) Drum level is normal

iii) At least one I.D. fan one F.D. fan

in service

iv) Minimum of 30% air flow is es-

tablished

v) Ignitor.trip valve is proven closed.

vi) The light oil trip valve is proven

closed.

vii) The heavy oil trip valve is proven Purge start permissive
closed.

viii) All the ignitor valves in all eleva-

tions are proven closed.

ix) All the wajrmup and heavy oil

nozzle valves at all elevations
are proven closed.

xii) All feeders are off.

xiii) All hot air shut off gates are fully

closed.

xiv) All cold air dampers are less

than 5° open.

xv) All elevation flame scanners

show no flame.

xvi) No boiler trip command is pres-

ent

41
 Check that atomizing air lines for igni- Select light oil firing from FSSS insert
tors & W.U. Oil guns are line up and control PB for AB elevation.
charged.

Establish light oil Check :

Make ready each W.U. oil corner indi- elevation permit i) D.C. Power
vidually available.
ii) L.O. trip valve
Start furnace purge Purge cycle is of proven fully
by pressing Start 5 minutes open.
Purge iii) Air flow
between 30%
&.4Q%
After 5 minutes This indicates that
check that purge M.F.T. relay iv) Burner tilt
complete light is reset. placed in
comes on horizontal
position.
v) No Boiler trip
Open igniter trip Igniter trip valves command is
valve from F.S.S.S. will open if persisting.
console insert i) M.F.T. relays
OpenPB is reset. vi) Light oil gun
is inserted in
ii) Igniter valves guide pipe &
are proven coupled.
closed.
vii) Local
iii) Igniter oil maintenance
supply control switch
pressure is is placed on
adequate (14 "Remote"
kg/cm2) ^ viii) Light oil
Manual
isolating valve
Open light oil L.O. Trip valve open
trip valve from opens if
FSSS console 1) M.F. trip ix) L.O. Atomising
insert Open PB relay is reset air manual
isolating valve
2) Light oil are open.
nozzle valves
are proven
closed. Start AB elevation Refer L.O.
are pair of L.O. elevation start
3) Light oil guns by up.
pressure is depressing pair
adequate (5 start PB on
kg/cm2). FSSS insert
console.

42
 Check associated AB elevation at least Keep C.B.D. control Open C.B.D.
3 out of 4 lighters are-proven on valves fully open Isolating valve full
during warm up
r
Check that selected Maintain warm
pair of L.O. guns ->
up oil pressure Control flue gas temperature at fur-
are proven on in 4.5 kg/cm2 nace exit below 538°C by controlling
time sequence. through pressure firing rate till adequate flow is estab-
regulating valve. lished through reheater.
Also maintain
oil/ air AP between T
1 to 1-5 kg/ cm2. When boiler starts Warming up should
steaming throttle be slow; steaming
>r S.H. vents & drains should start after
Start second pair of Maintain Warm 45 to 50 minutes
L.O. guns A.B. up pressure 4.5 of lighting up.
elevation by kg/cm2 through See Fig. 2.1.
-
depressing start regulating valve.
PB on r
When drum Refer cold start
pressure reaches curve for rate
Check that at least 3 out of 4 L.O. guns 2 kg/cm2. Close -> of pressure &
are proven on in timed sequence. drum vents and temperature rise.
outlet header vent Fig 2.1
r
Check
Close steam cooled wall extended side
i) Light oil header pressure is outlet header vents
adequate.
ii) Light oil/air differential pressure Close S.H. Desuperheater link vent
is more than 1 kg/cm2 valves
Otherwise L.O. trip valve will close.
Close platen S.H. outlet link vent valves
Check boiler expansion is free
Throttle following: S.H. drain, Radiant
roof S.H. inlet header drain, & side
Check: steam cooled out let header drain, Rear
Header drain, S.H. S.W.W. front roof
Ignitor oil header pressure is inlet header.
adequate (14 kg / cm2.)

Control firing rate Follow the cold Do not close these drain valves fully
during initial start up curve before rolling the turbine.
warming up such while bringing
that boiler starts up pressure &
steaming after 45 temperature. Check that M.S. line drains are opened
minutes. Fig. 2.1 (near turbine).

43
OVOI Y l f t i -

S 8

MOtHM

s c S s • s 3 S s ^ ? •
o
3 s 3 •8 ?
8 s S

s S |5 2 i s.
3 a 2 a s ft
maeu *

44
 Open boiler stop valves L & R. Check H.O. system is in service on
recirculation before H.O. pressure heat-
ers.
Throttle start up vent valves to control
pressure rise; do not close them fully r
until turbine is under light load/or HP Check atomising steam lines are
& LP by pass system is taken into charged.
service.
r

Take SCAPH corresponding to run-

Close reheater vents & Drains before ning F.D. Fan in service & maintain
vacuum raising. average cold end temperature above
acid dew point.
Bring up the Boiler steam parameter w
to 5 kg/cm2, 195°C, ^_ Check auxiliary steam is given to feed
storage tank heating and deaerator
pegging.
2.7 BOILER LOADING

Put H.O. on Refer H.O.

Refer cold startup curve for rate of recirculation recirculation
pressure & temperature rise & steam through F.O. instructions.
flow (fig. 2,1) trip valve Put H.O. heater
F.O. burner pressure and H.O.
headers temperature
Boiler lighted up & main steam pres- control on auto.
sure & temperature are 5 Kg/cm2,
195°C r
Check H.O. temperature at burners
ir r
Prepare for Heavy *~ Before H.O. firing
oil firing check flue gar Proceed to take It is preferred to
temp, at APH H.O. elevation take lower elevation
outlet is above in service in service
90-100°C. (CD elevation)
f r
Check auxiliary Refer auxiliary Establish H.O. elevation start permit.
steam header is p steam system
r
charged through
inter-connection Depress associated Check H.O. pair
elevation pair start —* is placed in service
PB in programmed
sequential order.
Check auxiliary steam line F.O. heat-
ers & tracing steam lines are charged. Ref:H.O.Elevatior
starting.
t
Maintain Heavy oil burner header pressure.
i r Also Maintain oil/steam AP 1 to 1.5 Kg/cm2
45
 Check both corner burners are proven Main steam Pr 6 Ref: H.P. & L.P.
on ATA M.S. temp bypass operating
225°C instruction; ensure
I
Depress start PB Check H.O. pair
steam throw off
device condensate
for 2nd pair start is placed in spray valves are
of same elevation service in open.
programmed
sequence
Close start-up Give clearance to
vent valves start turbine
Maintain H.O. burner header pressure when flow is rolling
above 3 kg/cm a and temp. 110- 130°C established
through
bypass system
Increase H.O. firing Max. H.O. burner
rate through pressure 8 kg/cm2 4
H.O. regulating Throttle Main Get boiler water
valve steam line drain analysed and start
valves phosphate dozing
Take drum level if required
Warm up oil guns At least 3 out of protection in service
can be taken out of 4 H.O. guns
once the boiler at one elevation Warm-up M.S. lines, Boiler parameters
is warmed up should be in C.R.H., H.R.H. line —> are raised to
and heavy oil service. & transfer lines M.S. pressure and
elevation is in temperature
service. Check M.S.
parameters of
E.S.V.
Check that vacuum Refer vacuum
is raised in the raising Check M.S. pipe
condenser by the instruction metal temp, is
time M.S. above 150°C
parameters come and C.R. pipe
to 6 kg/cm 2 metal above 100°C.
and 275°C
H.P. transfer pipe
line metal temp
Take H.P. and Ensure B.F.P. and 150°C and IP
L.P. bypass system condensate pumps transfer pipe metal
in service when are in service temp 100°C
condenser vacuum
is 540 mm Hg I
H.P. and L.P. Close M.S. lines
bypass system is [—t drains and C.R.H.
cut out and line drains to
turbine rolling condenser.
is started

46
After the M/C M.S. pr. 30kg/cm2 With phosphate Check that C.B.D.
is synchronised before E.S.V. dozing control tank water level
and load is M.S. temp. 350°C C.B.D. valve is maintained
taken, check >
before E.S.V. opening to normal. Put drain
furnace probe maintain boiler control value on
is retracted Retract the furnace water T.D.S. auto.
automatically temperature
Probe if flue gas r
temp, reaches Before increasing Refer silica limit
540°C and probe the drum pressure curve for boiler
is not retracted ensure that silica water. Fig. 2.3.
through interlocks. content in boiler
water is within
r permissible limits
Start Scraper Conveyor and slag at operating
crasher. pressure
r •
r
Maintain average Regulate steam Prepare for coal firing
cold end temp supply control
at A.P.H. outlet valves & check
above acid dew air temperature Start one PA Fan.
point by before and after
controlling steam SCAPH, check
flow to SCAPH flue gas temp after Charge Electrostatic precipitators fields.
A.P.H.
«r
Make S.H. Spray Close drain valves.
Check that E.P. control system Open spray
rapping mechanism ready control valves
is in service inlet isolating
I
Inform chemist to Refer
valves.
Open spray
check the quality recommended control valves
of Boiler water chemical isolating valves
and Feed water composition of
as frequently as Boiler Water and Close spray
possible Feed Water in line drain valves
TableJ_&JTable II
Page:49?:50 Open super
heater header inlet
water isolating
Check phosphate Refer coordinated valves bypass
dozing to boiler phosphate
water. Maintain treatment
boiler water curve and boiler >
alkalinity water limiting Check that spray
values in Fig. 2.2

T «r control valves are

closed.

47
 RECOMMENDED CO-ORDENATED PHOSPHATE CURVE
NON-OPERATION ABOVE CURVE WHICH RESULTS IN
FREE HYDROXIDE IS TO BE AVOIDED
10.8
mm
——
10.4 — - *—
--—— i

10.6
B

o A
U)
CM /

LJJ
3 /

1
8.8
<.
A-OPERATION ABOVE 100 kg/cm2
B- OPERATION BELOW 100 kg/cm2
O 8.4

8.0
0 5 10 15 20 25 30 35 40
PPM PO4 FIG 2.2
TO LIMIT SILICA IN STEAM TO 002 PPM

10.0
20.0

10-0

a
I
u s-.o IJ
10
en
111 FIG. 2.3
2-0
g RECOMMENDED MAXIMUM SILICA
a:
10 CONCENTRATIONS IN BOILER WATER AT
BG

0.8 VARIOUS pH(DRUM TYPE BOILERS)

0.5

0.3

O.t
30 £0 ,90 120 ISO 1(0 210
2
OPERATING PRESSURE Kg/Cm

48
 TABLE - I
RECOMMENDED CHEMICAL COMPOSITION OF BOILER WATER

Characteristics Limit Recommended

Drum Pressure Kg/cm2 10 10-20 21-30 31-50 51-75 76-100 101-125 126-150 151 and above
pHat25°C 10 5-11 3.5-10.5 9.5-10.5 8.5-10.3 9.5-10 8.5-9.0

T.D.S. Max ppm 600 500 250 200 175 100 75 50 50

NOT ALLOWED
Chloride Max ppm
15-30 8-15 5-10 5-10 3-5 3.0-5.0
PO 4 lppm 40-70 40-70 40-70
Hydrazine Dozing shall be employed
SO 3 ppm 10.70 10.70 10.70
According to Curve shown
SiO Max ppm

Specific Electrical
conductivity us/cm 400 250 200 150 100 100
Max. 1200 1000 500

49
 TABLE - II
RECOMMENDED CHEMICAL COMPOSITION FEED WATER

Characteristics Limit Recommended

Drum Kg/cm2 10.00 11-20 21-30 31-50 51-75 76-100 101-125 126-150 151 and above
Pressure M Pa 1.00 1.1-2.0 2.1-30 3.1-50 5.1-7.5 7.6-10 10.1-12.5 12.6-15 15.1 & above
Hardn.ess max ppm 1.0 1.0 1.0 Nil Nil Nil Nil Nil Nil

pH at 25°C 8.0 8.5 8.7 8-9 8-9 8.5-75 8.9-9.5 9.5-9.5

Oxygen Max ppm+ 0.5 0.03 0.007 0.007 0.007 0.007 0.005
Iron Max ppm 0.5 0.5 .0.3 0.1 0.03 0.02 0.02 0.02 0.01

Copper Max ppm 0.2 0.2 o:i 0.05 0.01 0.005 0.005 0.005 0.005
Silica Max ppm 2.0 2.0 0.3 0.3 0.1 0.05 0.02 0.02 0.02
Total CO Max 5 5 3 1 0.5 Nil Nil Nil Nil

Permanganate Max 10+ 10++ 5++ 0.5 0.3 0.3 0.3 0.3
ppm
Specific Electrical
Conductivity at 25oC
Max. 3 Nil Nil Nil Nil

OH Max ppm NOT ALLOWED

+ (i) Hyd-rozine dosing shall be employed for scavanging last traces of disolved oxygen
Maximum permissible limit is 0.10 ppm Residual N2H4.
(2) Condensate pH will stabilise in range of 8.5 to 9.5 if 0.06 ppm of N2H4 residual is maintain at Boiler
inlet.
++ Where feed water is used for desuperheating max. conductivity of F.W. shall not exceed 2 us/cm.

50
Make R.H. Close spray Take main feed a. Open bypass
spray control control station. control valve in valves of main
system ready drain valves service and isolate feed regulating
low load valve valve (FRV)
Close spray
water line drain b. Open isolating
valves valves of main
F.R.V.
Open spray
control valves c. Close bypass
inlet isolating valves of main
valves F.R.V. isolating
valves
Open spray
control valves d. Regulate F.R.V.
isolating valves.
Check that Make ignition , Refer mill
reheater spray energy available to —¥> ignition energy
block valve is the lowest mill to instruction
closed. be taken in service
r
Close economis-er recirculation valves Start first mill. Preferably lowest and
when continuous flow is established work it up.
through economiser

Start its R.C. Keep drum level

Close the S.H. header drain, Radiant feeder. Put mill on lower side
roof S.H. inlet header drain, inlet header air temperature —*> just before
drain, and side steam cooled wall out- and flow control starting
let header drain, Steam cooled wall on auto check mill and feeder.
rear header drain, SH.S.WWW. front mill outlet temp
roof inlet header drain and final S.H. around 65-75°C
header drain
>f
Control drum level Drum level and
Increase firing TakeAB/BP and furnace draft —• furnace pressure
rate and pick-up elevation H.O. carefully. are likely to shoot
30MW load. guns in service as up suddenly when
M.S. pressure, per the feeder is started.
temp65Kg/o* 1 "' requirement,
\ t
430°C, preferably
RHS temp 420°C takeAB Monitor furnace flame stability
elevation H.O. V

I guns.
Increase the feeder
speed upto 50%
of rated
Check ash
—» * handling system is
taken in
service. Check
mill differential
1
pressure is less
than 250 mm WC
51
 Switch on E.P. hopper heaters When load on unit M.S. pressure
is 70 MW check at boiler outlet
check H j ^ , -r 105Jtg/cm^
Increase the main At no time boiler heaters are taken T^TSTtempat
steam/R.H. steam - > drum temperature in service boiler outlet
parameter as per increase rate j>OO?C__-
cold start curve should exceed H.R.H. temp,
100°C/hr. at boiler outlet
495-500°C
Maintain S.H. steam temp control by >
spray water control Check heater drip_pumpcutjn auto-
matically at around 70 MW load
Jr
Maintain R.H. R.H. spray f

steam temperature control should be S t a r t ?,nrt T T~> fen ^( Control furnace

by burner tilt. used as a last at load 60^MW draft carefully,
resort for temp check that flue
control. gas interconnecting
dampers open
Increase the load Follow cold start r
in generator as up curves for Equalise loading on both I.D. fans
boiler output raising load
increases and (fig. 2.1) t

maintain boiler Start 2nd F.D. fan ^ Check that air

pressure interconnecting
dampers open
Start second mill Preferably the mill r
when first mill adjacent to first Equalise loading on both F.D. fans
is loaded to 80% mill
r
Maintain necessary Check stack
Start associated mill feeder when mill total air flow and P exhaust colour
is warmed up furnace draft for proper
combustion
r
Increase the feeder Put mill air temp
speed; equalise the and flow control Take SCAPH Check O2,
loading on both on auto. Check corresponding to CO, and CO2
the feeders air temp = second F.D. Fan content in flue gas
75-80°C, mill air in service if necessary
flow = 54T/hr.
Mill differential
pressure about Check that auxiliary At 30% load ,
200 mm WC. air and flue air furnace to
dampers are windbox differentia
modulating and should be 90 mm
necessary windbox
to furnace differential
is maintained
i r
52
Start 2nd P.A. fan Maintain P.A. Put M.S. & R.H. Steam temp control
and equalise Pressure above system on auto
loading on both 600 mm WC
P.A. fans. Put r
P.A. pressure Put B.F.P.'s scoop Check that
control on Auto tube control on -> 5 kg/cm2
auto differential
I Before starting
pressure is
Check that 2nd maintained by
condensate pump standby BFP it scoop tube
and 2nd boiler —P must be warmed position controller.
feed pump are up
started r
Put main feed Check that drum
t
control yalve on level is maintained
Check that Put deaerator auto by the controller
deaerator pressure pressure control
is increased to on auto I r
6 kg/cm2 gauge Put both I.D. Check that 10 mm
Fans and inlet furnace draft is
vane control i.e. maintained.
Inform laboratory to check boiler and Furnace Draft
feed water quality for intermittent control on auto
phosphate dozing if situation demands
r
f :
Put total air Check O2, CO and
Take 3rd pulverizer Ensure that flow control on CO2 content in
and its feeder in - > ignition energy auto. F.D. Fan flue gas at APH
service when is established. impeller vanes inlet. Ensure that
loading on running control on auto sufficient excess
pulverizers exceeds air is maintained
80%
r
When load on Refer "Pulverizer
Equalise loading on - > Select pulveriser running mill is start up
all the 3 pulverizers nearer to the above 80% take instruction"
elevation already 4th mill and its
in service. feeder in service
and equilise
r
loading on all
Increase load on Refer to boiler 4 mills.
the generator and cold start up
simultaneously - > curve. Increase
r
increase boiler total air flow with Flame support HO Check flame
firing rate increase in firing guns can be condition before
rate; check excess removed once boiler and after removing
air. loading is above 60% H.O. support guns
and more than 2 mills Retain H.O. guns
«i r
are in service at in service if
Boiler pressure 120 kg/cm2 50% loading and furnace flame
M.S. Temp 530°C, Load 120_MW at least two adjacent is unstable.
mill are in service
53
SCAPH's can be Cut SC air Check M.S. "M.S. temp
cut out when flue - • preheater out TEMPERATURE protection out"
gas outlet temp, LOW trip • visual annunciatior
increase to or when interlock comes will be reset.
H.O. is removed. in service when Ensure that low
Put thermal load M.S. temperature steam temp,
control on "AUTO" goes above 520°C protection switch
is on.
r
Increase load on Check M.S. & r
generator. Check R. H. steam and Take SPUG in service - > Refer turbine
that thermal -* tube metal if provided operation
load control temperature
maintains boiler
parameters by Take load limiter Refer turbine
controlling firing in service if operation
rate. r provided
Check that total
air flow is
automatically
maintained.
r
Increase load on generator

Check the Boiler Drum pressure

Parameters 145 kg/cm 2
M.S. Pressure 138
kg/cm 2
M.S. Temp. 540 +
5°C
R.H. Steam
Pressure 24 Kg/cm2
R.H. Steam temp
540 + 5°C
Feed water
temperature
r 245°C

54
2.8 NORMAL SHUT DOWN TO COLD
Suitable for shut down of medium duration when Boiler or Turbine inspection is planned.

Unit is operating Final steam Load Reduced Take HP heaters

at 210 MW with conditions at the to 160 MW out of service
Combustion control, time of unit tripping r
Fuel control, Total will be
air control, Feed M.S. Pressure Load reduced to Check that
water control, 90 kg/cm 2 150 MW: deaerator steam
Steam temperature M.S. Temp approximate is changed over
control Furnace, 465°C parameters at from Ext. 3 to
draft and all R.H. Steam turbine inlet are : Ext. 2 through
other controls on Temp. 465°C M.S. Pressure interlocks
"Auto" 120 kg/cm2
M.S. Temp
r 520°C R.H.S. temp
Take "Combustion control" on Manual 520°C
r
While reducing load check that follow-
Take "M.S. Temperature low" trip pro- ing conditions are maintained :
tection out
f

Total air flow is reduced in proportion

Isolate initial steam pressure unloading gear with load upto 30% load.

Check drum level is maintained nor-

Gradually reduce Refer "Boiler mal on Auto
load on the unit shut down curve"
reducing firing pressure change
rate. MS/HRH limits (fig 2.4) Check S.H. & R.H. steam temperatures
steam temperature Rate of load drop are maintained at set points. Furnace draft
and MS pressure may be about is maintained.
w
shall be reduced 2MW/min
at the rates Carefully monitor Check the boiler expansion/ contraction
permitted by the turbine conditions movements as the load is reduced.
turbine but not and adjust the
exceeding the load, temp.,
rate of saturated pressure drop When the load on mills is reduced to
steam temp drop rates such that 40%
HP/IP I\JL*JI
rntnr
nr / ir

differential Prepare to take Check that

expansion.
vibration, upper most mill associated
eccentricity, shell out; reduce the *> elevation fuel
differential feeder speed air dampers are
temperatures, to minimum. modulating/ closed
turbine cylinder as per feeders
top/bottom speed.
metal temps, Check furnace to
Left/Right • windbox
cylinder flange differention is 90
r temp. diff. are r mmWC
within limits.
55
 LU

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ui a • • -
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DJLV gunssaud wnaa X

 I
Ill §1 fill'
U nit* HOT RESTART CURVES AFTER 68HR SHUT-

Mi
»MTS< nun 1 lOli
DOWN FOR 2)0/200 MW BOILERS FOR UNITS
PROVIDED WITH HP t LP flYPASS

NOTES:
1 HP 1UB»HE M E I A l I t M P ASSUMEO AS <S0*C
Ol I u:oto RIHEAI imet IEMU ro SOUER 6M«SACEOASJOO»C
-•I MINIMUM

3 FLUE SAS TEMP. AT FURNACE OUTLET 10 OE MAINtAliei

BELOW S U M T0.1 HP t l P BYPASS STATION IS CUT I N '

FIG 2.5 BOILER HOT START

n n
TIME IN MINUTES
Take upper elevation oil guns in service. Take heavy oil guns associated with
remote elevation mill in service.
r
Simultaneous with this transfer load
on other mills in service. Stop the Prepare to take See that load
upper most feeder. the next upper is transferred
elevation mill on the running
1f
out. Reduce mills.
Take the upper mill out of service after feeder speed
cooling if down to 40°C emptying it out to minimum &
completely. stop feeder.
Stop the mill
ir after cooling
When load on unit Check that down and
is reduced to deaerator steam completely
100 MW supply is evacuating it.
switched over
M.S. Temp 510°C > from 2nd
extraction to Take heavy oil Refer H.O.
M.S. Pr. 112 kg/cm2 auxiliary steam guns at lower firing instructions.
header through elevation in
H.R. H.Steam temp interlocks. Carefully service
510°C monitor turbine
conditions. I
Take out next Check that load
r higher mill from is transferred to
At 90-100 MW Ensure that auto service when running mills
take out one standby B.F.P. loading on mills
boiler feed pump does not start on is reduced to 40%
from service. stopping of
Check that full - > running BFP
load is smoothly through Check that
transferred on interlocks. Auxiliary and Fuel
running B.F.P. air dampers are
before stopping modulating
the pump.
r
Check that
Continue reducing firing rate, steam associated Fuel
temperature and pressure alongwith air dampers are
drop in load. closed.
t

When the load on When adjacent Take M.S. and R.H. steam temp, con-
mills is reduced to mills are not in trol on hand.
40% take next —* service it is
upper elevation advisable to take
oil guns in service in service oil Continue reducing firing rate, steam
remote to other pressure and temp, with reduction in
mill in service load.
before reducing
'r
feeder speed to 40%

58
T
 At load 70 MW : MS temp. 49&°C Firing rate is Check that all
R.H. Steam temp 490°C reduced further elevation H.O
M.S. pressure 105 kg/cm2 and when load guns are
on mill is taken in service
^r reduced to 40%; by now.
Take drum level control on hand & reduce feeder
maintain drum level speed to minimum
& stop the feeder. Check A.H. cold
r Cool down mill end average
Stop one PA Check damper to evacuate it temperature is
fan after operation completely and above acid dew
transferring full shut it down point.
load on running Charge SCAPH
P.A. corresponding to
running F.D. fan
in service if
Stop lube oil pumps of tripped P.A. average cold end ,
Fan motor and fan bearings after oil temp, is below
bearing temperature is reduced acid dew point.

Stop one F.D. Before stopping When load is Open low load
fan; corresponding F.D. fan increase reduced to 40MW control valve
to P.A. fan tripped. load on other Take low load Feed isolating valves;
->
Check furnace F.D. fan and Control Valve (FCV) open low load
draft and reduce load on in service and control valve
air flow. this fan to isolate main F.C.V. gradually &
minimum. simultaneously.

r Gradually close
Stop one I.D. Transfer load from Main F.C.V.
fan corresponding this I.D. fan
to tripped F.D. to other and Close isolating
fan: check furnace completely unload valves of Main
draft. this I.D. fan F.C.V.
before tripping It.
i Switch off supply to field of Electro-
Switch off supply to the electrostatic precipita- static precipitator.
tors associated with tripped I.D. fan.

Unit at 25-30 MW with H.O. firing.

Carry out soot blowing of complete boiler.

Change over auxiliary electrical sup-

Unit load reduced to 30%. Maintain 30% ply from unit auxiliary transformer to
air flow at all loads below 30%. station transformer.

At 30% load. Check that secondary air damp

ers set point is ramped to maintain windbox tc
furnace differential pressure of 35-40 mm WC

59
Stop P.A. Fan * Check that seal Maintain 30% air Check that turbine
air fan trips on flow and purge the .—• coasts down
interlock. Check boiler for at least safely
the P.A. damper five minutes Start S.O.P/AC
operation. Refer oi) pump
P.A. System
Close sealing
air valves to Check that all the Break the vacuum
mills from station feeders and mills —> when turbine
air system are off. speed comes to
zero.
r Put turbine rotor
Reduce load on unit to 5-7 MW on barring gear.
M.S. Pressure Boiler outlet 90 Kg/cm2 Check that F.C.N.R
M.S. Temp Boiler 465°C Vs in extraction
R.H. Steam Temp 465°C lines closed.

Charge auxiliary steam header from

running units through inter connec- Individual burner H.O. M.V. oil, Ato-
tion, isolate auxiliary P.R.D.S. unit. mising air and steam nozzle valves and
Ignitors valves (air/oil) are closed. .
Trip the unit Check that H.P.
through M.F.T. cylinder evacuatior r
pushbuttons valves open Check that Close isolating
Attemperation SH valves of S.H.
on F.S.S. & RH isolating and Reheater
console/or
through Protection valves and its spray control
r bypass valve valves
When boiler is to are closed.
be tripped, trip
it through r
protection. Open S.H. Start-up Rate of pressure
Maintain log of vent isolating valves drop must not
protection used and partially open - » exceed the limits
each time for S.H. start-up vents specified in the
tripping. Use and reduce pressure curve to limit
different protection saturation temp,
each time so drop rate to
that all are less than 83°C/hr
checked. (Fig. 2.4)
r
Check that Boiler Check that all Open Reheater vents and closed CBD
fire is completely the flame scanners valves
out sense no flame &
check boiler
actually from peep Close Boiler Main steam stop valves
holes & ensure and their by-pass valves
that fire is
r
completely out
T
60
Open M.S. line Refer Turbine Following is the procedures if, after shut down:
drains operating
instructions. (i) Fast cooling of (ii) If Boiler is to
Boiler is desired be Natural by
t cooled
Open C.R.H. Refer Turbine
& H.R.H. line operating (iii) Boiler is to be (iv) Boiler is to
Instructions preserved be Boxed up
r
Shutdown H.O. System 2.8.1

Do not stop warm up oil pumps if it is Boiler is to be forced cooled fast after
common for other units shut down
f

Top up the drum level upto +180 mm Keep I.D. fan At any time
and F.D. fan saturated steam
f
in service. temperature drop
Stop Boiler feed Ensure that auto Regulate air shall not exceed
pump starting of auto flow to effect 83°C/hr.
standby B.F.P. desired rate of
is prevented cooling
r Open starting Regulate opening
Stop Hydrazine Keep B.F.P. as vent valves of vent valves,
dozing pumps hot standby match the rate of
cooling but not
exceeding above
Stop phosphate dozing pump if it is in mentioned limit
service.
r
Cut off deaerator Turn on Bring up drum Start boiler feed
pegging steam deaerator F.W. level to+180 mm pump for topping
supply by closing heating steam to when it drops up the level.
valve maintain F.W. to-180 mm Stop boiler feed
temperature pump afterwards

"^r
Do not stop A.P. Heaters till flue gas Open following vents and drains of
temp, at A.P.H. inlet is less than 205°C S.H. at low pressure (2-3 kg/cm2) :
SH Desup.link drains; Steam cooled
Air Flow through Boiler cooling wall header drain. Roof and Rear steam
furnace shall be rates can be cooled wall drain.
controlled to effect controlled by :
the desired cooling 1. Opening
rate S.H.H. vents
2. Air flow through At 1.8 kg/cm2 drum pressure open
boiler drum vents

61
Stop F.D. fan Check that Bring up Drum level to + 180 mm
and I.D. fans A.P.H. do not
when flue gas stop on inter-
temperature lock take Stop Boiler feed Boiler feed pump
at A.P.H. deinterlock pump and keep —> shall be started
inlet is switch is on it in warm when level drops
reduced to "deinterlock" condition to - 180 mm and
below 25°C position before shall be stopped
and boiler is stopping F.D. / after bringing
cooled I.D. fan level to + 180mm.
Gradually feeding
If required Check that should be done.
stop air A.P.H.'s lube
preheaters oil pumps stop >r
otherwise keep on interlock When gas inlet Preferably keep
them rotating when oil temp, temperature at Air Heater rotating
goes below 40°C. A.P.H. inlet is even after this
—*
reduced to below unless they are
When Boiler water temperature goes 205°C Air Heater required to be
below 94°C. Drain the boiler can be stopped. stopped for works.
r

Open economiser vents; open low point drain Stop A. P. Heaters —> Check A.P.H's lube
valves from W.W. low header and downcomers if required oil pumps stop
to W.W. drain header. when oil temp, is
reduced to 40°C.
Open economiser drain valves in feed line aftei t
economiser inlet valve. Cut out deaerator Turn on F.W.
pressuring steam —> heating steam
by closing steam maintain F.S.T.
Open W.W. drain header drain valves isolating valve water temperature
and slight pressure
2.8.2 in deaerator
Natural cooling of Boiler is desired after shut (Approx. 1.5. Ata)
down
r
One I.D. Fan and one F.D. Fan in service Stop hydrazine dosing pump
Bring I.D. inlet Bring Air heater i
vane and F.D. deinterlock switch Close economiser inlet valve its by-
Fan impeller in deinterlock pass valve.
blade pitch to position. Check
r
minimum. Stop that Air heaters
F.D. Fan Stop are starting. At 1.8kg/cm2g Initially k e e p d r u m
ID fan Check that all drum pressure v e n t s throttled &
secondary air open drum —• when pressure
dampers open. vent & S.H.H. drops down open
Check that all vents. them full.
flue gas dampers
open.
Check that all
auxiliary air
f
dampers open
62
2.8.3 Stop B.F.P. & Keep the S/S of
keep it in autostand by
If Boiler is to be preserved. warm condition B.F.P. in working
position before
Drain the boiler Nitrogen blanket stopping running
when Boiler shall be applied B.F.P.
water temperature when drum
is reduced to pressure reduces Cut out deaerator Turn on F.S.T.
than 94°c to 1.4 kg/cm2 pegging steam by heating steam.
closing valve Keep Feed water
hot & maintain
Open economlser Refer Boiler slight pressure
vent valves & lay-up procedure. in deaerator. Open
drain valves valves.

Open low point drain valves. Open

W.W. drain header drain valve Close startup vent valves

Check S.H. outlet header vents and

2.84 drains are tight closed.

Boiler is to be boxed up Close start up vent valves

One I.D. Fan & one F.D. Fan are running WhenA.P.H. inlet A.P.H.'s shall be
flue gas temperature kept rotating
reduces to 205°c unless they are
Reduce flow to minimum A.P.H.'s may be required to be
stopped stopped.
Stop I.D. Fan Keep A.H. deinter-
Stop F.D. Fan locking switch in
"deinterlock" When S.H. steam Pressure drops down
position before to 3kg/cm2 open partially S.H. vents &
stopping I.D. /F.D. open them full when pressure drops
Fan. down to near zero.
Check that Air
Heaters are not
stopped. Open drum vents partially when drum
pressure comes down and open them
full when when pressure drops down
Close all Secondary air dampers, all
flue gas dampers & all auxiliary air
dampers.
A.
Bring drum level to + 180 mm

Close economiser inlet valve and its

bypass valve.

63
2.9 AUXILIARY STEAM SYSTEM

During start ups and normal running of a unit steam at a low pressure (16 ata/11 ata) and
temperature (200°C) is required for various auxiliary purposes. During start ups till boiler is capable of
providing/generating sufficient quantity of steam at required parameters, this auxiliary requirement of
steam is to be met from alternative source, Auxiliary boiler or other running units. During normal running
of boiler this auxiliary steam is tapped of from M.S. lines and pressure and temperature are suitably re-
duced in auxiliary Pressure Reducing & Desuperheating (P.R.D.S.) system. «
Two P.R.D.S., stations are provided-one for normal service and other as standby. Main P.R.D.S.
station is a combined pressure reducing and desuperheating unit. Pressure is being reduced by throttling
the pressure regulating valve and temperature is controlled by feed water spray into desuperheater
through temperature control valve. Pressure and temperature can be controlled remote, manually or
automatically through sliding set point. For effective temperature control feed water pressure is con-
trolled by a pressure control valve before temp, control valve.
In standby unit pressure is controlled by throttling the pressure control valve (remote operated)
and then temperature is controlled by feed water spray through motor operated temperature control valve.
Auxiliary steam is used for following purposes :
In steam coil air preheater (during startup and at low loads).
Deaerator pegging and P.W. heating during (startup and at low loads).
H.O. heating and steam tracing of H.O. lines.
H.O. atomising.
Main and starting ejectors for vacuum raising (during start-up and at low loads).
Turbine seals (during start-up and at low loads).
To L.P. Heater-4 for condensate heating (during start-up and at low loads).
2.9.1 Lining Up P.R.D.S System :

Close PRDS main steam isolating valve
Open PRDS downstream side isolating
valve
Close PRDS by pass isolating valves
Close Main PRDS and bypass pres-
sure control valves
Open steam supply valve to 16ATA
header from PRDS unit.
Open PRDS upstream side drain iso-
lating valve
Open bypass PRDS upstream side line
drain isolating valve
Crack open the drain control valve of
M.S. supply line to PRDS unit.
Open PRDS down stream line drain
isolating valves
Crack open PRDS down stream line
drain control valve

64
 Open bypass PRDS down stream line
drain isolating valve
Crack open bypass PRDS down stream
line drain control valve
Close PRDS feed spray line valve
Close PRDS bypass feed spray line
valves
Close PRDS bypass feed spray line
isolating valve
Open PRDS line drain isolating valve
after NRV
Crack open PRDS line drain control
valve
2.9.2. Line Up Aux. PRDS Header
Open 16-ATA Steam header vent valve
Close auxiliary steam supply valves to:
Deaerator
SCAPH
F.O. heating area
F.O. control station
L.P.H. 4
Close 16 ATA headers interconnecting
valve
Close interconnecting valves 11ATA
header.
Open steam supply isolating valve to
ejectors and gland seals and gland
steam cooler with ejector
I air is completely purged and steam
65
Close steam supply isolating valve to
ejectors and gland seals steam cooler
with ejector from deaerator.
Open drain valve in steam line to ejec-
tors.
Close isolating valves to ejectors
Close steam supply regulating valve to
G.S.C. with ejector
Close steam supply valves to Turbine
gland seals
Close steam supply valve for Deaera-
tor tank heating
Auxiliary steam header is lined up.
2.9.3. Charging Auxiliary Steam
From 11-ATA Header :
Check that Aux. steam system is lined
up.
Get clearance from existing unit for
charging 16ATA header.
Open interconnecting steam control
valve isolating valves
Crack open interconnecting steam
control valve and slowly warm up the
line. Check that condensate comes
out through ejector steam line drain.
Close 16-ata header vent valve when
comes out through it.
 Check that no hammering occurs in
steam lines. If hammering is observed
throttle steam supply valve
When steam lines are warmed up open
gradually steam supply valve and build
up pressure in auxiliary steam header.
2.9.4 Taking Auxiliary PRDS Station in Service
Auxiliary steam header is charged
through bypass line.
Check that M.S. line pressure is above
30 kg/cm2.
Put auxiliary steam temperature con-
trol valve on Auto and Sat 295°C on
controller. Check that aux. steam temp,
control valve remains closed.
Put spray feed water pressure control
valve on auto. Check set point.
Select manual pressure control made
and open the P.C.V. manually. Check
that spray control valve opens as steam
flow through P.C.V. and 215°C tem-
perature is maintained.
Select auto mode on pressure control
valve and set pressure at 16-ata.
Gradually close bypass pressure con-
trol valve, and simultaneously close
DSS spray control valve
66
As the pressure in header increase
throttle Ejector steam line drain valve.
Do not close drain valve full until steam
flow is established through ejectors.
Attain 11ATA header pressure in
Auxiliary steam header.
Check that main PRDS takes the load
and Aux. steam header pressure and
temperature are maintained.
Close the D.S.S. spray valve. Fully
close bypass pressure control valve.
Close isolating valves
1 r
Close bypass D.S.S. spray water iso-
lating valve
Check that feed water supply valve to
PRDS.
Crack open the drain control valve in
auxiliary steam supply line to 16-ATA
header from PRDS unit and open drain
isolating valve
Check that safety valve is in service.
2.9.5 Taking Aux. PRDS Standby Station in Service :

Check that auxiliary steam system is Open further the PRDS bypass valve
lined up.

Gradually fully open PRDS bypass main

Check that main steam pressure is
above 30kg/cm 2
Open bypass D.S.S. Spray water iso-
lating valve
Open gradually PRDS bypass main
steam supply isolating valve
steam supply isolating valve and regu-
late 16-ATA pressure with PRDS by-
pass pr. control valve.
Regulate temperature control valve to
control steam temperature. Regulate
spray water pressure control valve to
contsol water pressure.

Gradually close interconnecting valve

Slightly open PRDS bypass pressure for 11 -ata header as bypass PRDS takes
control valve over. Check that auxiliary steam header
pressure does not drop.
Control opening of spray feed water
pressure control valve and spray water
temperature valve to get auxiliary steam
temperature of 215°C max.

2.10 BOILER & AUXILIARIES ROUTING CHECKS DURING SHIFT

1. A round of the complete boiler and auxiliaries area is to be taken for checking the
following at least once in a shift to ensure the healthiness of the boiler and auxiliaries.
a) Inspect the furnace flame condition and stability.
b) Inspect the complete boiler pressure parts for any leakages.
c) Inspect the flue gas and air paths for any leakage through ducting, manholes etc.
d) Inspect the running auxiliaries like F.D. fan, I.D. fan, P.A. fans, mills A.P.H. etc. for
any abnormal sound, high vibration, high lub oil bearing temperature, lub. oil
pressure etc.
2. Drum gauges glasses may be blown once a day and. compare drum level readings of local
gauge glass, remote level gauge glass and U.C.B. instruments (to be done by charge
hand/ 18m Boiler Operator).
3. Compare local instruments readings with remote U.C.B. mounted instruments once a
day and if any appreciable discrepancy is observed bring it to the notice of C&I Division.
4. Check that a continuous flow of sampling water is maintained through sample cooler.
Also check for sufficient flow of cooling water through sample cooler.
5. Check stack emission visually. A white smoke indicates high excess air and black smoke
indicates insufficient air flow, both should be avoided.
67
6. Check feed water temperature before, and alter economis-er.
7. Check R.H. & S.H. tube metal temperature and ensure that no overheating of tubes is
existing.
8. Check steam temperature at various stages of S.H. & compare with predicted values.
9. Carry out soot blowing operation at regular intervals or as and when found necessary.
10. Carry out soot blowing of A.P.H. elements at least once in a shift.
11. Get ash sample. Bottom / Fly ash analysed once in a day for carbon content. Accordingly
classifier adjustment must be done.
12. Check the fineness of pulverized coal from each mill once a day. Carry out necessary
adjustments.
13. Check individual pulveriser for coal-air temperature, high differential pressure across
bowl, air flow, classifier setting, abnormal sound, high vibration and oil temperature etc.
14. Check raw coal bunker levels are normal while unit is in operation and empty out
bunkers if unit is planned to be shut down for a few days or more.
15. Check the continuous and satisfactory operation of slag scraper conveyor, slag crusher.
16. Cheek for continuous and satisfactory operation of fly ash system
17. Check electrostatic precipitator operation. (Field voltage, current, spark rate).
18. Check good fluidity of fly ash is maintained by hopper heaters.
19. Check rapping mechanism operation.
20. Check that ignitors spark plugs are kept clean for immediate starting whenever required
21. Check that flame scanner show constant "flame on" condition. In case of flickering "flame
on" and "flame off light, check furnace flame condition, take oil support.
22. Check that pulverisers are loaded to 80% capacity with reserve 20% capacity for
handling emergency conditions.
23. Check that loading of parallel running I.D. fans, or F.D. fan or P.A. fans are equal as far
as possible.
24. CheckH.O. temperature, burner header pressure/atomising steam pressure & tempera-
ture are maintained normal.
25. Check W.U. oil headers pressure and atomising air header pressure are maintained
normal.
26. The following Auxiliaries should be changed over to stand-by equipments once in a week:
a) Seal air fan.
b) Ignitor air fan
c) Hydrazine dozing pump.
d) Phosphate dozing pump
e) Coal mills (if gill the mills are available).
f) Lub oil pumps of ID, FD & PA fans.

68
 27. Check that bottom ash hopper sealing is maintained & water overflows through seal
trough.
2.11 EMERGENCY OPERATIONS
Major emergency situations in Boiler & Auxiliary areas and suggested actions :
2.11.1 High Furnace Pressure
Probable Reasons
One I.D. fan tripped
or mal-operation of
control vanes of I.D./F.D./P.A.
fans or closing of damper
Unstable furnace flame condition.
Sudden starting of coal mill. Low
windbox pressure (under normal F.D.
fans loading conditions), improper air
distribution at elevations
Un-equal burner tilts at corners
or Burner tilt in extreme up or Down.
Fouling in Air heater, air
heater tripped.
Furnace water seal broken, E.P..
or flue gas path manhole opened.
Water wall tube rupture/leakage
2.11.2 Furnace Pressure Low
I.D. fan auto control failure
I.D. fan vane control mechanism
failure causing vanes to open wide
Sudden decrease in air input or
tripping of one F.D. fan.
69
Action to be taken
Take running I.D. fans control on manual &
increase for loading. Check the cause of I.D. fan
tripping and try to restart it if everything is normal.
Check gas^dampers indication & draft reading
along flue gas path. If some damper is closed try to
open that damper.
Take F.D./P.A. fan contro} on manual. Check
control damper operation. Adjust air flow. Check
air for correct flow. Check combustion regime,
openings of Auxiliary air and fuel air dampers,
windbox pressure. See cold air and hot air damp-
ers. Watch Furnace flame. Trip Boiler if flame is
very much unstable. Purge out explosive mixture
by maintaining high air flow.
Check Burner tilt at all corners is equal. Adjust
Burner tilt between +10 to -10 and check control
air pressure.
See air-preheaters are rotating. Restart tripped
air preheater and do A.H. soot blowing.
Check Furnace seal, water flow through seal
trough overflow. Re-establish seal.
Stop the boiler in case of tube leakage as soon as
possible.
Take I.D. fans control on manual & reduce load on
I.D. fans.
Check I.D. fan control mechanism for proper
functioning.
Check air flow, correct if necessary. After
checking restart F.D. fan if it had tripped.
 Sudden tripping of one or more
mills or choking of mills/raw coal
feeder pipe
Partial flame failure
Accidental closing of secondary
air path
2.11.3.Drum Level Low
Mai-operation of Feed Auto Control
or Feed Regulator or Scoop auto.
Tripping of one of working feed
pump (standby pump does not start)
Sudden reduction of load
Sudden increase in firing e.g.
starting of mills having
sufficient coal left before previous
stopping.
Tube rupture/puncture
Inadvertent opening of low point
drain valves or Emergency drum
drain valve.
Note :
If drum level goes below gauge glass and low drum level trip protection fails, trip boiler at once.
2.11.4.High Drum Level
Mal-operation of feed water control
Sudden increase in load resulting
in drum pressure drop.
70
Control the furnace pressure by adjusting I.D.
fan vanes. Simultaneously try to start stand by
mill. Remove the chocking of affected mill/raw coal
feed pipe.
Take the oil gun into service to establish flame at
that locations/corner.
See the proper functioning of secondary air path
damper.
Take feed control valve on hand and increase
feeding rate. Take scoop tube control on hand and
increase scoop tube position. Check that feed
water flow through each pump does not exceed }ts
capacity. Check feed water control valve and scoop
tube control linkages.
Start reserve feed pump on tripping of running
feed pump, if auto starting fails.
Try to increase the load if not possible reduced
firing irate accordingly to control drum pressure.
Reduce firing rate by suitably adjusting the feeding
rate of running mills.
Check water flow and compare with previous
feeding rate and steam flow. High feed flow
indicates tube failure. Inspect water wall and econ-
omiser or any tube leakage. If tube leakage is
observed stop the boiler as soon as possible.
Check drum drains and low point drain for tight
closing.
Take feed control valve on manual and reduce the
feeding rate.
Try to decrease the load as far as possible.
 Sudden decrease in firing rate Increase feeding range of running mills.
e.g. tripping of the running mills

B.F.P. scoop tube position suddenly Check differential pressure across feed control
increased valve and maintain 5 Kg/cm2 by adjusting scoop
tube position.

2.11.5 Flame Failure At an Elewation

Closing of trip valves on H.O., : Do not attempt to introduce ignitors or oil guns at
W.U. Oil/Ignitor (Causing loss of elevation where "No flame" condition persist.
ignition support energy) Where F.O.
is being used as support fuel or when
only oil is being used.

Sudden decrease of mill feeder : Trip out the coal mills of feeding elevation where
speeds to minimum "No flame" condition is persisting. Allow sometime
for purging then introduce oil support adjacent to
working mills until furnace flame is stabilised.

Too low or too high windbox Check that secondary air windbox dampers are
pressure causing unstable modulating to maintain about 80mm windbox to
combustion furnace differential pressure.

Water wall tube failure Check furnace for tube failure.

Malfunction of flame scanners due If two elevations scanners show "No flame" trip the
to supply failure or scanner air boiler manually
failure, slag or soot on scanner
lenses etc.

Burner tilt mechanism negative : Check burner tilt keep it between +10°.
extreme due to air failure to
power cylinders.

Rapid load changes without : Check furnace flame condition.

adjusting air flow leading to
improper combustion.

2.11.6.One Fan Trips (Other in Service)

It is presumed that I.D./F.D./P.A. fan de-interlocking switches are on "Interlock" position.

Fan Bearing temperature high : i) Take draft control or manual,

and/or and/or increase the loading on running fan
and maintain furnace draft.

Fan motor Bearing temperature high ii) Check corresponding fan is tripped through
and/or interlock

71
 Lube oil pressure for motor iii) Take secondary air flow controll on manual
bearings low and/or and maintain correct air flow.

Corresponding Air heater tripped iv) Cut in oil burner adjacent to working mills.
(provided de-inter locking switch is
on "Interlock" position) and/or

Motor protection operated v) Check drum level is controlled on auto; if

necessary, take drum level control on
manual and maintain level.
vi) Check pulverizer in excess of 3 are tripped
starting from bottom.
vii) Check>that the load on the generator has
reduced to 100 - 120 MW (partial load relay
energised).
viii) Check that interconnecting dampers on air
and flue gas side open and tripped fans are
correctly isolated through interlocks.
ix) Check windbox pressure left and right is
maintained normal (about 75 mm WC).
x) Maintain steam temperature
xi) Check furnace flame condition

xii) Check that tripped pulverziers are correctly

isolated (hot air gates close, cold air dampers
come to minimum).

xiii) Investigate the cause of trip. Correct it and

restart the tripped fan.

2.11.7.One Feeder Trips

Support energy is removed i) Check that hot air gate closes & cold air
within 3 minutes of feeder damper opens full if pulveriser is running.
and/or

No coal flow alarm comes & ii) Clear the mill of the coal before stopping it.
low current relay picks up
simultaneously. (Feeder chear
pin given way and/or

Mill trips and/or iii) Stop the pulverizer if feeder cannot be

restarted immediately.

Feeder motor supply fails iv) Check that running mills share the load if
thermal load is on auto.
72
 v) Reduce the load on generator and mainain
steam parameters.
vi) If 3 mills at less than 50% feeder speed or 2
mills are left in service, cut in oil gun
adjacent to working mills.

vii) Check furnace draft, air flow and drum level

are normal.
viii) Check flame is table and scanners sense
"Flame on".
ix) Check that associated elevation fuel
air damper close and windbox
pressufe is maintained 70 mm WC.
2.11.8 One Mill Trips

Mill discharge valves are closed i) Check the running mills share the load if
and/or thermal load control of mills are on auto.
Loss of elevation D.C. supply ii) Reduce the generator load if pressure starts
for more than 2 sees, and/or dropping.
Support ignition energy is removed iii) Start reserve mill and take load.
with 3 minutes of feeder starting,
and/or
Motor protection operates and /or iv) Check furnace draft is maintained normal
One P.A. Fan trips (mill in v) Check the correct air flow is maintained.
excess of 3 will trip starting
from bottom). vi) Check that drum level is maintain
normal.

vii) Check that tripped mill is isolated (hot air

gate closed, cold air damper minimum open,
feeder tripped).

2.11.9.Coal Hangup in Mill

Choking of coal at inlet to mill.

High moisture in coal and /or i) Check feeder trip on "No coal flow & low
current" protection.
Too much fines in coal with moisture, ii) Check mill outlet temperature is less than
and/or 85°C.

73
 Foreign material at R.C. feeder inlet
2.11.10. Water Wall Tube Leakage
Starved water walls due to very low
drum level and/or
Sustained flame impingement on
water wall tubes and/or
Blocked tube, scaling of tube.
resulting in overheating of tube
metal, pitting, corrosion of tubes and/or
Soot blower steam impingement
(wet steam impingement or direct
impingement of steam) and/or
Circulation affected due to opening
of low point drains.
iii) Check mill hot air gate closes on mill outlet
temperature high protection. Close hot air
gate and check mill.
Cold air damper opens full.
iv) Check the flame condition at the sick mill ele-
vation.
v) Trip the sick mill after clearing it of coal.
vi) Increase the load on running mills if Thermal
load control is on manual.
vii) Start reserve mill
viii) Maintain steam pressure and temperature
by reducing load,
ix) Check that furnace draft and air flows are
normal.
x) If 3 mills (or less) are in service with feeder
speed below 50% take oil support at elevation
adjacent to running mills in service.
: i) Compare feed water flow and steam flow to
assess the magnitude of tube leakage.
: ii) Maintain drum level by increasing feed water
low.
: iii) Inspect the furnace for tube leakage.
: iv) If the tube leakage is minute then take the
unit out as a planned shutdown to cold.
: v) If tube leakage is heavy and it is likely to
damage other tubes or likely to disturb the
flame stability trip out the unit.
vi) Keep close watch in furnace flame.
vii) As the load is being reduced try to locate the
burst tube(s)
74
 viii) Check economiser hoppers for water leakage,
steam noise etc. every shift.

ix) Check that furnace draft is maintained

normal.

2.11.11. Reheater/Superheater/Economiser Tube Failure

Sustained high metal temperature i) As soon as leakage is detected start load
due to waterwall Slagging or reduction and trip out the boiler at the
forcing boiler at the time of earliest possible time.
hot restart and/or

Erosion on tubes due to high ii) Try to locate leak through manholes before
excess air, high ash content in boiler Is depresurised.
coal, dislocated tubes, soot blowing
and/or
Blocked tubes causing overheating
and/or
Salt deposition due to high
water level in drum, poor
quality of water* and/or

Inadequate flow due to open

superheater, reheater drain
and/or
Fire side corrosion of tubes
and/or
•Economiser tube can fail due to
over heating if concentration of
Fe, Cu is more in Feed water.
Steaming in economiser occurs
causing salt deposition and
harming the tubes.

75
OPERATION OF LMW TURBINE & AUXILIARIES
 3. OPERATION OF TURBINE & AUXILIARIES
Following is the brief description of the major steps/actions to be taken for operating (starting,
loading, shutting down) the 210 MW LMW (Soviet Design) steam turbine.

3.1 LINE UP

Before starting the actual rolling of the turbine, the following auxiliary equipments and systems
are to be commissioned.
3.1.1 Ensure C.W. System is Running Normal

Ensure that raw Clarifier Water Pumps, Start the CW pump See that the
Clarified Pumps and Clarified booster by closing control discharge
pumps are in service. switch valve CW 3/4
has opened fully.
r
Inform the operator to check the basin
level and Cooling Tower pumps and Observe and note down the amp. of the
C.T. fans running normal. pump motor.
ir

Ensure whether all permits from Main- Inform CW pump At least one
tenance Division are cleared. operator hydrogen
to give the cooler suction
r prestart checks and discharge
Inform Electrical Carry out on CW booster valve to be
Controller to protection & pump kept open,
rack in breaker of - > interlock tests otherwise pump
Circulating Water on C.W. pump if can be run on
pump for on long shut recirculation.
availability of power. down.
t Start the CW booster pump by closing
Check the opening Before starting the control switch.
of CW discharge CW pump, close
valve CW 1/2 or the valve CW-5 to
CW 3/4 and check —P lub oil cooler and Ensure from the operator the post start
whether it has openCW 1/2 checks are complete and healthy
opened fully valve.
from UCB.
After 5 minutes run of the booster
After obtaining Refer C.W. p u m p pump, the pump is to be stopped and
clearance from —• instructions for to be started again when turbine speed
operator inform starting. comes to 1100 rpm.
me operator
through the
intercom that CW System is running normal.
CW pump is
being started.
77
3.1.2 Ensure Condensate System is Running Normal

Start the Demineralized Water (D.M.) The motor current Check and
make up pumps, if already not run- should be within —* maintain hotwell
ning after checking D.M. tank level 18-23 amp and not level at 3/4 of
and line up of connected lines. hunting the gauge glass.
r
Open both the isolating valves for hot- Chemist to check Keep any of the
well make up. the quality of other two
condensate to -> available pumps
r ensure that there as stand-by
Maintain hotwell Check the hotwell is no condenser putting interlock
level more than level Hi/Lo alarm tube leakage switch to "ON"
- > is working alright. position.
3/4thofthe
gauge glass.
r
t Take water to deaerator after charging
Line up condensate system L.P^heater from water side
ir
Inform Elect. Operator to restore power Condensate System is running healthy.
to that condensate pump.

After obtaining clearance from con-

densate pump operator, announce
through intercom that the pump is
being started.

3.1.3 Ensure Feed System is Running Normal

Maintain Deaerator Maintain pressure Ensure that protection & interlock are
(D/A) level normal and temp, in healthy. Inform Elect, operator to re-
by running D/A at store power to the pump.
condensate pump 2 kg/em2 90°C
system normal by auxiliary
steam Inform turbine operator to line up HP
heater after checking the interlock
Ensure that all permits are cleared
from Maint. Divisions for BFP and HP After getting clearance from BFP op-
heaters. erator to start announce that the pump
is being started.

Inform BFP operator to line up the

pump.

78
Start the boiler If there is delay in Inform turbine operator to charge HP
—*
feed pump opening heater on water side.
recirculation
valves by more
than 2 sec. then Check the other two BFP for their availa-
open the valve bility.
remotely from
UCB otherwise
trip the pump. Keep the other BFP Pumps available
on interlock by putting the interlock
r switch on 'P'.
Watch and note down the amperage of
pump motor
Feed water system is running healthy.

After about 15 minutes when the bear-

ing temp gets stabilised open the dis-
charge valve

3.1.4 Ensure Generator Seal Oil & Hydrogen Cooling System are Normal

Ensure the Main Run the oil Hydrogen pressure Sufficient No. of
Oil Tank (MOT) Centrifugal and in Generator casing - > H2 bottles should
level normal and —• MOT vapour fans should be be available.
quality of oil to atleast 6 hours maintained at 3.5
be O.K. before taking seal kg/cm2
oil system in
service. »<r
Seal oil system and Hj cooling system
running normal.
A.C. seal oil pump should be running.

Check the Protection & •

availability interlock for the
ofD.C. seal pumps should be
oil system tested.

3.1.5 Ensure Turbine Lum Oil System is Running Normal

A.C. standby oil pump should be run- Oil temperature at If it is more

ning. Lub. oil pressure 1 to 1.1 kg/cm2 bearing should be • charge the oil
at bearing header and also check the around 40°C cooler from water
availability of D.C. oil pump. side also.

r
Lub oil pump interlock switch should Check protection and interlock of lub.
be 'ON1. oil system.

I 79
3.1.6 Ensure Turbine Rotor is on Barring Gear and Normal

Check the Barring gear Note down the amp (61 amps) of the
protection should not start motor.
• of Barring
• when lub.
gear oil pressure falls r
to 0.3 kg/cm2. Check Barring Barring gear
1 gear protection should trip at .
Ensure that Barring gear and again 0.3 kg/cm2 lub
turbine • engage lever is restart Barring oil pressure.
rotor is at stand fully retraced. gear
still position
and lub oil Engage the r
system —-> barring gear Keep a constant watch on lub. oil pres-
running. lever. sure (1.1 kg/cm2) and temp 40°C.
f

Start the Barring gear motor. Barring gear is normal and healthy

3.1.7 Ensure Auxiliary Steam Line is Charged

Inform boiler Refer Aux. steam 3.1.8 Vacuum Pulling

operator - instructions in
to charge the Chapter-2.
aux. steam Ensure CW pumps are in service.
line (16 ata
header) from
running unit Ensure condensate system in service,
or from M.S. line main ejectors (both) and L.P. heaters
of its own unit. (all) are charged from water side. All
valves subjected to vacuum should be
r sealed by condensate water.
Keep the drain Before charging
valve near the check that the
gland steam system inlet Ensure that turbine is on Barring gear.
cooler open valves are closed.
and charge
the steam line Ensure that auxiliary steam is charged
for ejector, from 16 ata. bus to turbine seal and
gland steam ejector header.
cooler and
steam seals
by opening Close the vacuum breaker valves near
the valve. main ejector and fill the funnel with
DM water for sealing and open valves
r on condenser outlet.
After the line is heated up (for 15 min-
utes to 20 minutes) throttle the drain
valve near gland steam cooler to avoid
wastage of steam.

80
Prior to start Open Air valve. Open the Ensure that drain
See that condensei drain valves w valve from stage
the starting W
w vacuum rises to to the condenser III to UDT is open.
ejector open
the drain valve 100-150 mm. from the first
(after AS-4) stage of the
and the ejector.
isolating valve.
r
Then open
inlet valve Open the steam See the steam
for putting to main w
W
pressure to main
starting ejector through ejector is
ejector in motorised 6 kg/cm 2 and
service and isolating valves see that vacuum
close the when vacuum is steadily rising
drain valves. in condenser is in the condenser
400 mrrTbf Hg.
r
Start gland steam Open inlet valve Stop the starting
cooler (GSC) ejecto r. * and adjust ejector by
closing vent valve
pressure2 at first and steam
3 kg/cm and
see that vacuum and steam valve
at GSC rises to afterwards.
40-60 mm. of Hg
column. r
At about 600 mm of Hg check the vac-
r uum protection.
Admit steam Steaming from
to seals. faces of end
sealing is not
1 permitted.

3.2 STARTING OF TURBINE FROM COLD STATE

Check that all prestart requirements Ensure that the valves of the bypass
are over. system are fully closed by reading the
respective position indicators.
Before HP/LP bypass stations are
brought into operation check : r
i) ESV, IV are closed. Set the Do it with the
ii) Oil system of the bypass sta- temperature help of push
tion is put into operation by set point of w button.
switching on its motor.
HP bypass
iii) Vacuum in the condenser is station at
600 mm of Hg.
200°C
iv) Condensate flow to steam throw
off devices in the condenser are
established by opening the
motor operated valves.

81
Put the pressure Do it with the After the internal superheater flow has beer
controllers help of push established through start up vent, open the
and slave button. drain valves before and after bypass. Open the
positioners drain valves of MS, CR & HR lines and alsc
of each HP open after LP by pass drain valves
bypass valve
on manual
mode Open fully the Check the
MS valves for HP temperature
by pass with control loop
the help of is functioning
Put the LP Set the push button normal
bypass valves temperature set and then open the
on 'Auto' point of LP bypass boiler outlet
mode station at 200°C MS valves
with the help of
push button by
reading its value
on the indicator.
If heating rate
of steam lines
Switch over the exceeds prescribed
temperature limits, adjust the
control loop of position of HP
LP bypass valve bypass valve from
on Auto mode the control desk to
with the help of bring down the
push bottom. temperature
within limit.

Put the control Set the pressure

of LP by pass set point as Watch the rise of metal temperature of
valves on 6.0 ata with the MS, CR & HR lines.
'Auto'mode with help of push
pressure loop button.
in circuit with After 50°C superheat is available at the
the help of superheater outlet open the bypass
selector switch valves of MSV for heating the pipe lines
by making the upto turbine.
contact in
'R' position.
Open the ESV to CVS drain valves.

Check that the High Pressure Turbine

(HPT) evacuating valves and by pass
valves across NRV on cold reheat line
are tightly closed.

82
Open ESV Rise of metal Check that
by about temp, should control valve of
10-20 mm not be more IPT remains closed
as per the than 4°C per complet^y
scale and minute. during tne
operation.
heat the f
steam r
admission While opening
pipe upto the ESV, the Close bypass Rise of metal
control control valves of valve of temp, should not
valves to HP turbine should MSV & NRV be more than
a temp, of remain tightly in the cold w 4°C per minute.
150°C closed. reheat lines
1 when steam
parameters
Open the Heat the HP before MSV
bypass valves turbine up to are 20-25
across the — • 150°C kg/cm 2 and
NRVs in the t 280-300°C and
cold reheat Rise of metal steam
line and the temp, should not admission pipe
drain valves be more than of HPT and
of HPT. 4°C per minute. IPT are heated
upto 150°C
& 100°C
Check the If the pressure respectively.
steam pressure exceeds 1 kg/cm 2
in hot reheat (gauge) adjust
line to be the set value at Close ESV & IV.
less* than 1 kg/cm 2 with
1 kg/cm2 the help of push
(gauge) before W button and Bring the control of LP bypass valves
starting the indicator of LP on 'Manual' mode with the help of
heating of bypass push button.
steam station
admission -Or
pipe upto If it still exceeds Manually close When the pressure
control valves of close a little the the HP in the reheat
IPT. HP bypass valves. bypass valves line comes to
with the help condenser
of push button pressure
Open the IV to CVs drain valves manually close the
LP bypass with
1 the help of push
Open the Heat the steam button.
interceptor admission pipes
valve servo- upto control
motor by w valves to a
about 10-15 temp, of 100°C
mm as per
the scale.
X
83
After having While heating the Turbine is ready for rolling.
accomplished main steam and
the heating, reheat steam pipes
check and the difference in 3.3 ROLLING INSTRUCTIONS
note down temp, of pipes
the following should not exceed
readings in 15°C. But when
Slowly open Allow the steam
the log-sheet the turbine is on
the bypass to roll the turbine.
before rolling load, this difference
valves of MSVs
the turbine. should not be more
Check that barring
a) Metal temp, than 10°C.
gear has got
of pipes Chamber heating
disengaged and its
before MSV, should continue
motor gets
and also till temperature
switched off
before ESV. difference between
automatically.
b) Metal temp, the Upper and
of steam Lower halves of
admission HPT and IPT
Increase in rotor
lines. casing goes 50°C
speed is prohibited
c) Metal temp, near the regulatin
if the turbine
of hot reheat stage in the case
rotor eccentricity
line. of HPT and near
is more thai/
d) Metal temp, the zone of steam
0.07 mm.
of interceptor admission in
valve. case of IPT.
e) Metal temp, Continue flange
and stud heating During the
of HPT and
till metal temp, process of
IPT top/bottom.
of flanges and raising the
f) Steam parameter speed bearing
before MSV. studs has
stabilized and vibration
g) Differential should not
expansion of difference of
temp, across the exceed 40
HP. IP and LP microns.
rotor. width of the
flange is
h) Axial, shift. 20-30°C.
At a speed Stop the steam
total expansion
of 500 rpm. supply to the
ofHPT/IPT
turbine by closing
and condenser
the bypass valves
vacuum.
of MSV and
i) Eccentricity of Listen carefully
turbine rotor for any rubbing
on barring gear. sound. If any
abnormality is
found stop the
Open the drain valves of HPT, IPT, HP rolling of the
and LP extraction valves. turbine.

Open ESV, IV, control valves of HPT

and IPT completely with the help of
control gear.

84
 If the turbine Turn the control
is in healthy gear in the
state, again anticlockwise
raise the direction to keep
speed to the control valves
500 rpm by completely open.
opening the
bypass valves •« r
ofMSV 1 &2. At a speed Hold the turbine
oi oOuu rpm ai ouuu rpm ior
about 20-25 mts.
Soak the set for
5-10 mts. r
Carry out
inspection
It is prohibited and soaking
to raise the speed of the turbine.
of turbine if the
differential r
expansion of the Perform the
turbine rotor checking of
reaches the protection and
maximum governing system
permissible values and tightness test
given below : of ESV and control
For HPT rotor valves of HPT.
+ 4.0 mm or
-1.2 mm r «f.
For IPT rotor Raise the Critical speeds,
+ 3mm or speed of |h are 1585, 1881,
- 2.5 mm turbine to W
2017 and 2489 rpm
For LPT rotor 3000 rpm
+ 4.5 mm or from 1200
- 2 mm rpm in
(+ sign indicates 5 mts.
that rotor is without any
longer than pause. The
cylinder and critical speed
vice-versa for - of the m/c
sign.) should be
passed as
1 fast as possible
At a speed Soak the set to avoid the
of 1200 rpm for about 20 mts. appearance of
rotor vibration
i r
Note that the
control valves Observe the Maintain the lub.
of HPT tend to temperature of oil temp at 40°C
I
close with the lUD Oil * by controlling
rise of speed. entering the the cooling water
bearings. supply to the oil
J 1 coole r s .

85
 SYNCHRONISING
t LOADING

00
05

120 180 2 40 300 360

TIME ( MIN)

FIG. 3.1 CURVES FOR COLD START-UP OF TURBINE 210 MW UNIT

 Stop the Refer Turbine
starting oil lub. oil system
pump and instruction.
keep it ready.

NOTE : A. At the speed of 500, 1200 and 3000 rpm note down the following readings in the log book

i) Condenser vacuum,
ii) Axial shift.
iii) Differential expansion of HPT, IPT and LPT.
iv) Overall total expansion of HPT, IPT.
v) Bearing vibration,
vi) Turbine LPT exhaust hood temp,
vii) Steam parameter at MSV.
viii) M.O.P. discharge pressure.
B. Watch that different metal temperatures have tendency to rise and note down the temperatures.
^ ? ! l l u 8 ^ ? ^ ;^ TURBINE ROLLING GUIDE LINES
'In: •• Metal Temp* J» Turbine Metal
ISo* < : li^fc&stiagi* less
*Temji> is nipre
than SSQ^C*
I. Speed from 0-500 rpm Speed 0-500 rpm Speed from 0-1200
= 5 mts. = 5 mts. rpm = 5 mts.
2. Hold at 500 rpm Hold at 500 rpm Hold at 1200 rpm
= 10 mts. = 5 mts. for checking = 5 mts. for checking
differential expansion, differential expansion,
brg. vibration etc. vibration etc.

3. Speed from 500 rpm Raise the speed from From 1200 rpm to
to 1200 rpm @ 50 rpm 500 rpm to 1200 rpm 3000 rpm = 5 mts.
= 14 mts. = 5mts. without any pause.
4. Hold at 1200 rpm Hold for 3 mts. for
(soaking) = 20 mts. checking diff. expansion,
vibration etc.
5. Speed from 1200 rpm Raise the speed from
to 300 rpm = 5 mts. 1200 rpm to 3000 rpm. <
= 3 mts. without any pause.
6. Hold at 3000 rpm Hold the turbine at this
(soaking) = 20 to 25 mts. speed (3000 rpm) for checkings.
Total = 75 minutes. Total 26 mts. Total =15 mts.

87
3.4 LOADING THE TURBINE

Synchronise the machine Take a load of 10 Constantly watch the

with the grid to 15 MW differential expansion,
axial fchift, metal temp,
difference between outer and
inner surface of the wall of
HPTafcd IPT casing (should
not exceed 35°C).
r

Hold the turbine at

this load for 30 mts.
to carry out soaking
and listen for rubbing.
r
After soaking, close all
the drain valves on
steam lines, steam
admission pipes, HP,
IP drain collectors.
r
Charge LP heaters from
water side and steam side.
* f

Start flange and stud

heating if diff. expansion
comes to + 2.5mm.

At the load Close the drain Note the thermal Charge deaerator
of30MW. valves in LP expansion of the by opening 2nd
heater extraction. turbine and all the extraction steam
other readings valves.

Should be around
20 mm as per the
indicator installed at
the front bearing
pedestal

At the load Put the H.P. heaters

of 60 of 70 MW. in service, charge the
HP heaters from water
side and steam side,
close the H.P. extraction
drain valves.

T 88
 Put the drip pump Stop the flange and
in service —*> stud heating.

r
Thermal expansion The difference of
of the turbine would -> temp, across the
be around 28 mm width of the
flange should be
within 20°C-30°C.

At about 80 Start the second

MWload condensate pump &
BFP and keep the
third as standby.

At about 150 Change over steam Change over steam When condensate
MW load. supply to deaerator supply for the flow increases to
from 2nd extraction ejectors and glands 300 tons/hr. partly
to 3rd extraction from 16 ata to open the bypass
deaerator when valves of maijfi
deaerator pressure ejectors, gland
stabilizes at 6 Kg/cm2 system cooler
andLPH-1.

Change over HP
heater #6 drip
from deaerator to
heater #5.

Similarly change ovei

H.P. heater 5 drip
from LP heater
unit 4 to deaerator.

At the load Set the point of Set the L.P.

of210MW. H.P. bypass valves bypass valve pressure
pressure control set point to
loop at 140 ata 6.0 kg/cm2 (ata)
with the help of and temp, set
push button. point to 200°C.
Change over the Change over the L.P.
manual mode of bypass operation from
pressure control manual mode of'Auto'
loops of HP mode with pressure
bypass valves to control loop in circuit.
'Auto' with the help
of push button

89
 oi;ii>f tares
si
No* Metal temp* is Metal Temp* Metal Temp* is more
less

1. Load upto 5 to 7 Load after synchronisation Load after

MW after synchronisation : 20 to 30 MW. synchornisation
20 to 30 MW. After taking
Live steam pressure.: Soaking time : 10 mts. mills (one by one) in
30 kg/cm 2 Steam press : 70 kg/cm2 service load can
Live steam temp. 350°C. Steam temp : 350°C accordingly be raised to
Steam temp, before IPT : 320°C. 210 MW depending upor
Soaking time : 30 mts. other conditions.
2. Load 5 MW to 30 MW @ 3 Load 30 MW to 65 MW
MW/10 mts. in 70 mts. in 35 mts. Soaking : 20 mts.
Steam press : 90 Kg/cm2.
Steam pressure before
ESV: 65 kg/cm 2
Steam temp : 430°C
Temperature of steam
before IV: 420°C.
Soaking time : 20 mts.
(All the drain valves in
extraction lines of LP
heaters to be closed).
3. Raise from 30 MW to Steam temp : 450°C.
70 MW @1 MW/min. Load 60 MW to 210 MW in 45 mts.
: 50 mts. (depending upon the other
conditions).
Steam press, before
ESV : 105 kg/cm2
Temp, of steam before ESV : 490°C.
Temp, of steam before IV : 480°C.
Soaking time : 30 mts.
Raise from 70 MW to 210
MW in 70 mts. @ 2 MW/mt.

Pressure before ESV : 130 kg/cm2.

Temp, of steam before ESV : 535°C.
Temp of steam before IV : 535°C.

90
3.5 WARM AND HOT START
Depending upon the metal temperature of H.P.T. casing in the zone of regulating stage, the type
of start can be chosen.
1. Metal temperature above 350°C : HOT START
2. Metal temperature between 150°C to 350°C : WARM START
3. Metal temperature less than 15O°C : COLD START.
3.5.1 Preliminaries For Warm or Hot Start
(i) Before warm/hot restart, the auxiliary equipment should be started in the same manner
and order as in the case of cold start.
(ii) Before hot or warm start, the starting oil pump should have been working and supplying
oil to bearings, the turbine shaft is rolling on barring gear, and one of the condensate
pump is operative. Check oil pressure in lubrication and governing system and see
draining of oil from bearings. Check that all the control and measuring instruments have
been switched on and are working alright.
(ill) If condenser vacuum had been killed, start vacuum pulling after supplying steam to the
turbine glands.
(iv) Before starting the heating of steam lines, the vacuum in the condenser should be 600
mm of Hg. MSV, ESV, ISV, CVs of HPT and IPT should be tightly closed.
(v) Heating of main steam lines, body of ESV, reheat pipe lines, body of IV may be done in
case the temperature of these elements is 80-100°C less than the temperature of the
lower half of the HPT casing in the zone of regulating stage and in the zone of steam
admission in case of IPT respectively by opening the drains of relevant portion.
3.5.2 Warm Start
Read the actual metal temperature of H.P. casing at the regulating stage and should be within
150°C to 350°C.
By using the temperature matching chart, (fig. 3.2) determine the desired steam temperature
and pressure for rolling the turbine. However, the steam temperature must be more (atleast 25°C) than
the hottest metal temperature of ESV and steam admission pipes of HPT.
3.5.3 Heating and Rolling of Turbine

Select the Set the set point

operational ^- of L.P. bypass
mode of H.P. station at 6 ata
bypass valve by push button.
CM~i *A^fl T"l 1131 *
U l l 1VXCU1UCU

and L.P.
bypass on
'Auto' and
select for
pressure
mode of
operation.
91
 /

JP*

%
y y '/ A 'A1
«0 y y y,SyY t1i
Ill
cc
K /, y i
<*-7(yft
si y t
/ I
'y,A i
yy \
V

ISO 1
y1 y y, 1 1
CD __ UJ
5
to
si y, |lf X
r.

t
ft!
i
a >

«
33
WAX in
E •
• IE
HA: M 1?
no
IE
H*
HO TER
JRBI HE
J* j
y
/ \y y NOTET-

EXA H A
PRI •cm
H
•i
y 1
w
P
tso
/ I IF FIRST S U Q & H E U L LEHPERATURE IS USED TO «E
08U1N HAW %IEAU TEMP ST*C MIST K ADSEO 10
HCTAL TEMP SF FOBE CNTERMC CHART

AX >BL • EC HE
/ V* y /
y 1 OAIUES OH CURVES ARE NUN STEAM PHTTSURE IN
K C / C M 1 ABS
MSI TCK •E4 cot. II Tl 1 EXAMPUs ILIUSTRATEO ON CHART WlTH DASHEOAt
P URS Al y y y IURBINE MEUI. TEUPAT 1ST SUCE AT TIME UNITS
HOLLEO ] > C * C

' MAIN STEA PRESSURE AT TIHE UNIT S

VALUE ON LOWER DIAGONAL LINES A R E
HP TURBINE METAL TEMP. (C ) JUST BEFORE UNIT IS ROLLED aium.

FIG. 3.2 TEMPERATURE MATCHING CHART

Set the Temperature During the process
temperature control loop of of heating of
control loop L.P. bypass the steam pipe
of H.P. bypass stations should be lines check the
station on 'Auto' on 'Auto' and draining system is
and set the temperature alright.
temperature should be set at
set point as 200°C. r
per the Having Ensure that the
requirement accomplished desired matching
on the down the heating, steam temperature
steam side of check and W is available at
H.P. bypass note down the ESV.
station
Ensure that the temperatures r

evacuating valves viz. of steam Bring the control

and bypass valves pipes, ESV. IV of L.P. bypass
ofNRVsinthe IP casing and valves on 'Manual
cold reheat lines HPCatthe mode" with the
are closed. regulating help of push
stage. button.

Open H.P. Heat the main Manually close Open the L.P.
bypass valve steam cold reheat the HP bypass bypass valves with
and raise and hot reheat valves with — * the help of push
the steam lines. the help of button. When the
parameters push button. pressure in the
of boiler to Open the bypass reheat line comes
desired value. valves of MSV to condenser
and ESV by vacuum close the
about 15-20 mm LP bypass valves.
and heat the
steam admission ><r
pipes upto control Check that the eccentricity and differ-
valves. ential expansion of the rotor are within
limit.
Check that the Open the IV servo
steam pressure motor by 10-15mir With the help of the speeder gear fully open IV,
in hot reheat as per scale and ESV, CVs of IPT and HPT.
line should heat the steam
not exceed admission pipes r
1 kg/cm2. If upto control valve Slowly open Checking should
required, of IPT Control the bypass be made during
manually close valves of IPT valves of MSV rolling as in the
ton
a little the should remain and roll the case of cold start
HP bypass valve. tightly closed turbine as up.
during this per guidelines
process. given to the
synchronising
speed.

93
 STEAM TEMP. C
en
s 3 O
o
STEAM PRESSURE (AT A)
in o> xj jo
^O O O O 8 8 g 5
STEAM FLOW ( T / H R )

P
CO
CO
o
30
m

>

c/>
2
C
TJ

LOAD ( M W )
Synchronise Thewaising of After loading the unit, set HP and LP
the set and steam parameters bypass stations as follows :
load the set and loading of i) HP by-pass station pressure
to 20-30 MW. the set is to be control loop : 14 ata, automode.
All the drains carried out as per Temperature control loop :
must be closed the curve and 380°C, automode.
after some load guide lines of ii) LP by-pass stations operational
has been taken loading for the mode-pressure control.
on the turbine. warm start. Pressure control loop : Auto with
set point at 6 Kg/cm2 (abs) Temp.
T control loop : 200°C, automode.

3.6 HOT START

Read the actual metal temperature of the following elements :-

a) Metal temp, of body of ESV.
b) Steam admission pipes of HPT and IPT.
c) HPT in the zone of regulating stage.
d) Steam admission chamber at IPT.
e) Body of IV.
Now with the help of steam matching chart, determine the desired steam temperature and
pressure for rolling the turbine. Steam temperature before ESV at the time of roll must be more (atleast
by 25°C) than the hottest metal temperature of elements mentioned above.
3.6.1 Hot Rolling of Turbine

Ensure that Set the H.P. Heat the transfer The valves in the
all the bypass valves on pipes between IV drains of these
pre-start 'AUTO' mode and and CV of IPT —• pipes should be
conditions set the pressure by opening IV kept full open,
such as oil setting at 5-8% 5-10 mm as prior to the
system in higher than the p"er scale. opening of IV,
operation, actual pressure . After heating these
vacuum in available in the pipes
the condenser main steam lines. corresponding to
is more than Set the L.P. bypass the available
540 mm of station also on steam temperature
Hg. flow of 'AUTO' with Close IV fuUy.
condensate in pressure control
steam thro mode with set r
device is O.K. point at 6 kg/cm2. Open fully MSVS and IV with the help
of control gear.

<r
95
CD
03

10 20 30 40 SO 60 70 80 90 100 110 120

FIG. 3.4 HOT RESTART CURVES AFTER 16 HOURS SHUT-DOWN

 to
2
130 o

FIR ING
.10
120 '600 ID in

JRJBI
z UJ
110 o to
<T <
100 550 X
i
- <r
a
a

UJ

in THROUGH E-SV

a THROUGH. REHEATER

<
01

20

10
300

TIME (MIN)

FIG. 3.5 HOT RESTART CURVES AFTER 8 HOURS SHUT-DOWN

 avcn
« co >, r- o g g o

(HdM Q33

Q
T% \

X
CO
Iv N
2
cc
O Ul
X \

cc
LU •».'•: 3SV3; 3NI *

5 o
in

CD

g
UJ
3W1, )10H

oc

I1
to •V-3
\

\
»

• i

-Vr
» au

O f ) clH31 NV3IS

NIVW

98
Turbine will As soon as ttie 3,7 PLANNED SHUT DOWN
start rolling speed of the
tlirough IPT. rotor rises above
3.4 rpm, check
that barring gear Inform, the boiler house that the tur-
gets disengaged bine would soon be shut down.
and its motor cuts
out automatically.
Check that the Check the starting oil pump and also
valves MS-22 and availability to A.C. & D.C. lub. oil pumps.
MS-23 in the
evacuating lines of
HPT casing are Reduce the load Watch the axial
closed. at a rate of 3 shift & differential
MW per minute at expansion of the
•<r rated parameters rotor and cylinder.
Start opening At 2800 rpm by operating
ofCVsoflPT check that main control gear
and raise the -> oil pump takes over motor After reducing the
turbine speed Stop the starting load to 160
to 300 rpm oil pump. MW switch off the
without pause. H.P. heater on
steam side and
r drain heating
Synchronise the set and take around steam condensate
20 MW load on the unit. Close all by opening the
drains. drain valves

<r At load 90-100

Immediately load Load the set MW switch off
the turbine at the further as per one of the
rate of 5 MW -* ' the curve for hot condensate pumps
per min. As start of turbine. and feed pumps
soon as the and at 70 MW
steam starts load check the
flowing through drip pump gets
H.P. turbine switched off
ensure that under automatic
the H.P. controller action
bypass valves and also ensure
starts closing. that auxiliary powei
supply is
changed from unit
After loading the unit, set the H.P. L.P. to reserve.
bypass station similar to that in case
of warm start (described earlier).
Maintain deaerator & condenser hot-
well level normal.

At load 10 to 12 MW open by pass valve

of MS before ESV and close valve on
r
main steam line.

99
Reduce the load Check the ESV, When the rotor comes to a stop, start
to about 5 MW IV and control the barring gear and roll the rotor
slowly. Trip valves get closed. continuously on barring gear till temp,
the unit of lower part of HP casing at regulating
through any temp, stage drops to 170°C, engage the
protection. Isolate lub oil barring gear lever at stand still condi-
cooler from tion of rotor and then start the barring
cooling water side gear motor and make sure that rotor
one by one to rpm. is 3.4 when put on barring gear.
maintain lub oil
temp at 45°C.
Break the vacuum by opening vac.
Ensure that After closure of breaking valve and cut off the steam
generator is the control valves supply to main ejector, gland" steam
isolated through immediately close cooler and steam to seals and closing
low forward power the main steam the respective valves.
relay and valves near outlet
the time and check that
for stopping bypass of main When maximum turbine metal temp,
the steam steam valves are comes down below 200°C, open cylin-
supply to also closed. der, transfer line and remain steam
turbine and line drains.
isolation of
generator Stop the other
should not BF pump Barring gear and lub. oil pumps can be
be more depending stopped if necessary.
than 4 upon the level
minutes of the boiler
drum. Condensate and C.W. pumps can be
stopped when LP exhaust temp, comes
below 40°C.
At 2800 rpm. start AC lub oil pump
and AC seal oil pump, check the lub oil
press and A.C. seal oil press, is normal

3.8 IMPORTANT INSTRUCTIONS DURING TURBINE RUNNING

ROUTINE CHECK :
1. The turbine is capable of accepting the variations from the rated conditions within the
limits stated below :
Live steam pressure 117-143 Kg/cm2
Live steam temperature 527-543°C
Reheat steam temp. 527-543°C
2. Sharp fluctuation of temperature and/or load on turbine should be avoided as far as
possible. Sharp fluctuations consume the fatigue life of vital components.

100
3. Turbine operation with ihe steam exhaust to atmosphere is forbidden. In case of rapid
drop in vacuum and opening of atmospheric valves, the turbine should be stopped
immediately. The turbine may be restarted only if the exhaust part of the turbine and the
condenser have cooled down to 55°C.
4. The main steam and reheat steam temperature should preferably be equal to or more
than the metal temperature of steam admission elements.
5. When the turbine is tripped due to action of protection or by turbine shut down switch,
check the operation of the equipments mentioned below along with' the closure of emer-
gency stop valves.
a) Main steam stop valves must be closed.
b) NRVs on extraction lines must get closed.
c) Generator circuit breaker should be open.
6. If there are more than one indicators for the same measurement, then the one which is
giving favourable reading should not be assumed to be correct one.
7. If any of the control valves gets closed accidentally the load on the turbine would get
reduced. Trace out the valve by comparing the pressure reading after all control valves.
8. The turbine must be stopped manually independent of the action of relevant protection
under following situations :-
a) Sudden appearance of excessive vibrations
b) Water hammering
c) Oil ignition
d) Emergency governor out of order.
e) Oil temp, rising upto 75°C at the drain from the bearings.
f) Drop of oil level in the tank below the lowest permissible value.
g) Appearance of metallic noise in the turbine steam flow path.
h) Axial shift of the rotor at the thrust bearings reaching limiting value.
i) Accidental vacuum down to 540 mm.
j) Increase of live or reheat steam temperature upto 655°C.
k) Lubrication oil pressure has dropped to 0.5 kg/cm2 gauge and lubrication pump
(emergency) has failed to start.
1) Sharp fall in the main steam temperature from nominal value to 450°C.
m) Increase in speed beyond 336O r.p.m.
n) ESV, IV or control valves have seized.
9. In order to remove salts deposited on the guide and moving blades, the flushing of
turbine flow path should be carried out with saturated steam during next cold start up.
10. Analyse each drum of oil before filling in the oil tank, in case the filling is done from oil
drums.

101
 11. The generator should operate at a network frequency of 50 cps., which correspond to
generator rotor speed of 3000 r.p.m. The net work frequency below 49.0 or over 50.5 cps
is not allowed and immediate measure should be taken for restoring it within 49.0 to 50.5
cps.
12. Turbine operation on load limiter is not recommended for a long time except in
emergency. Such operation hampers control of network frequency.
13. General temperature rise in oil supplied to the bearings at constant pressure and
constant cooling water temperature indicates the choking of oil coolers.
14. Dust off the turbine at least once a shift, special care should be taken while cleaning the
levers and links of governing and steam distribution systems.

3.9 DO's & DON'Ts

3.9.1 Important DO's During Turbine Running

Do every shift.
Close ESV & IV 15 mm by hand wheel by one and reopen back to full.
Check by draining oil from bottom of MOT for checking water/sediment in the oil.
Position of emergency governor- knob selector (both emergency governor should be in service).
Check all vapour exhaust fans are in service.
Check MOT level (280 mm) is normal.
Dust off the turbine.
Check the availability of R, & CO2 bottles.
Check the quality (moisture, acidity, chemical impurities) of oil in Turbine MOT once in a day.
Check the availability of AC & DC lub oil pumps.
Do every week.
Take out oil tank filters one by one for routine check up and clean by blowing dry compressed
air through them.
Operate the standby equipments in rotation and not equipment should be kept idle for more
than one week.
Do every month
Check the operation of servomotors for forced closing non-return valves by operating solenoid
valves at reduced loads.
Check one the full closing of ESV and IV servomotor at reduced load (120 MW).
3.9.2 Important Dont's For Turbine Operation
Don't start the turbine if the control signals and protection system are not in working order.
When turbine is on barring gear if rotor eccentricity exceeds 0.07 mm do not roll the turbine.
Do not start the turbine with oil temperature at bearing inlet less than 40°C
102
 Do not run the turbine on load with control valves servomotor in full open condition.
During shut down do not open the drain on steam adiftissidn pipes and cylinders till the metal
temperature falls below 200°C.
Do not allow the turbine to run in the steamless conditions for more than 4 minutes.
Do not drain the oil, saturated with hydrogen into Main Oil Tank.
Do not allow hot rotor to stand without rolling (Barring gear).
Do not allow to rotate the rotor by hand if there is not at all oil supply to bearings.
Do not try to engage barring gear unless turbine rotor is completely stopped.
Do not supply the steam to turbine and sealings if the machine is not on barring gear.
Do not overlook abnormality in any important reading.
Do not hold the set in the critical speed zone while raising the speed of the turbine.

3.10 EMERGENCIES IN TURBINE AND AUXILIARIES

Partial load throw off (due to high frequency).

The steam pressure at ESV
will increase
The turbine load will decrease
Disturbance in differential
expansion, vibration, axial
shift, eccentricity.
Disturbance in condenser level.
Disturbance in vacuum
Turbine lub. oil temp, will change.
Disturbance in Deaerator pressure
Partial load thow off due to Aux. failure.
: FSSS operator will control the boiler pressure.
: Governor will control the load. If it fails, then
throttle the control valves suitably and maintain
pressure to normal till the frequency comes down.
There should be a constant watch on the
supervisory instruments.
Adjust and maintain the hotwell level
Check and adjust ejector steam pressure and gland
steam pressure Xo normal.
Deaerator pressure tends coolers water flow as
necessary.
Deaerator pressure tends to fell, maintain it through
extraction on 16 ata.

There is a provision for initial load
throw off by help of a relay without
time delay which reduces turbine
load to 100 MW in case of tripping of
following equipments
In case of the tripping of these equipments
operation of partial load relay will reduce the boiler
output suitably in a sequential manner through
FSS Scheme.

103
 One C.W. pump in case both are If the partial load relay fails/not in circuit reduce
running. the turbine load and inform the boiler operator to
control steam parameter in case one CW pump or
one condensate pump trip. Careful watch may be
kept on vacuum. Inform the local operator to check
the cause of tripping. Maintain the deaerator and
hotwell level.

One BFP in case two are

running and standby does not
come on auto remote/not available.

One condensate pump in case

two are running and standby
does not come on auto/remote
not available.
And also due to tripping of
any one of I.D. fan, F.D. fan
P.A. fan.
In case of full load throw Unit trip on protection if it is kept on T".
off (due to opening generator
breaker).
The turbine may trip due to over- Close the control gear handwheel
speeding (if the speed can be
controlled by closing control valve Check that ESV and Control valves are closed.
immediately otherwise trip the
turbine by emergency trip button) Close the valves in the M.S. line. Close the Extr.
steam valves.

Sudden Increase of Load- from Pull Load

Low frequency Since the turbine is on governor control the load
will increase due to fall in speed. Reduce the load
by the control gear and bring the boiler parameter
andload to normal.
Due to sudden rise of boiler drum Bring back the load/governing wheel pressure to
pressure normal by control gear and inform the boiler opera-
tor.
Vibration High

Normally the vibration in bearings
should be within 40 microns. If
it exceeds the limit, turbine should
be shut down
Check the turbine cylinder drain should not be
cold (if necessary open the drain valve for few
minutes if turbine is on load).
Check brg. oil press flow and temp, to be normal.
Check for any rubbing sound'etc.

104
 : Reduce the load/speed.
Turbine Bearing Oil Press Low
Check the main line pressure and maintain it.
Bearing Oil Inlet Temp. High
Check the cooling water valves are open in oil coolers and vent the coolers. Put the standby cooler
in service, ensure CWP is running normal. Check bearing oil outlet temp, (less than 65°C).

Differential Expansion Hi /Low

Normally the rotor gets long Check the steam temp. Reduce load/speed. Check
during running and gets short during the valve for flange heating are in open condition if
shut down. The expansion is to be rotor is long orclosedlf rotor is short. .Check and
controlled by admitting steam or adjust gland steam temp.
shutting off supply to flange and
stud heating, chamber heating Check the vacuum to be normal
accordingly. In case if it goes
beyond control, the machine
to be tripped.

Axial Shift High

In case of excessive shift the
turbine will trip through the
protection.
Sudden change in load
Abrupt change of steam parameter
Sudden closure of FCNRV of heater
(HP/LP)
Variation in lub. oil temp, pressure
and quality
Control the load and maintain the steam parame-
ter.
Control the load and maintain the steam parame-
ter.
Control the load and maintain the governing
pressure, if heaters are healthy open FCNRV.
Maintain lub. oil pressure and temp. For quality
get the oil tested from laboratory and if necessary
oil is to be changed.

Difference of oil temp, from thrust bearing front

and rear outlet should not be more than 3°C.

Loss of Vacuum
If there be any loss of vacuum, start the standby ejector at the earliest. Still if it does not improve,
start starting ejector. With no further improvement of vacuum, reduce the load as required to
maintain the vacuum at 700 mm. Meanwhile try to detect the specific reason which may be as
follows :

105
 Steam ejector not properly functioning : Check that steam pressure in 6 kg/cm2.

High Level In Condenser

Malfunctioning of condensate pump Check the normal running of the condensate pump,
or valve start standby.

Check the operation of valve from UCB by taking it

to manual, if not alright control the hotwell level
bypass valve.

Malfunctioning of DM make up valve Close valve from UCB and watch that hotwell level
falls.

Condenser tube leakage If the above operation fails to control, the hotwell
level, get the condensate water tested by laboratory
to confirm the leakage. If the tube leakage is very
high, it may not be possible to pump out the
condensate from the condenser when the conden-
sate level will gradually increase. Ultimately if the
water level rises up to the air suction space of
condenser, water will be sucked into air s/iction
pipe line of the ejector. When the same will be
supercooled and ejector will not function. Shut-
down the turbine at the earliest to get the leakage
attended.
CW pump failure If one pump is tripped, reduce the load. Meanwhile
determine the cause of CWP failure and rectify the
defects. Of course if both the CW pumps fails, there
is no way out other than to trip the unit.

Air leak into system Check sealing water pressure to valves under
vacuum is normal. Check starting ejector air valve
and vacuum break valve are tightly closed.
Measure the amount of air leakage at air removal
equipment outlet and investigate the source of
leak.

Condenser tube chocking Check the CW inlet and outlet temperature.

Loss of Barring Gear or Barring Gear Falls to Start
For loss of electrical supply D.G. : If not possible to start the DG set, attempt to turn
set will come automatically; the shaft by slings with the help of over head crane
otherwise start. by 180°C at regular intervals of 15 minutes after
cutting in the D.C. emergency lub oil pump.

Smoke from turbine seals. Check differential expansions are normal

Reduce seal steam temperature, if high.

106
OPERATION OF KWU TURBINE & AUXILIARIES
 4. OPERATION OF KWU TURBINE & AUXILIARIES
This sections describes, briefly, operation of 500 MW KWU turbine. The difference in construc-
tion, control and other parameters between LMW (Soviet Design) turbine and KWU turbines have already
been discussed in Power Plant familiarisation (Vol. Ill , Chapter 11 and 13).
4.1 LINE-UP
Following auxiliaries and systems are to be commissioned before starting the turbine :
4.1.1 Condenser Circulating Water Systems
Open CW valves at condenser inlet.
Ensure that condenser CW outlet pipe
seal pit is established.
Start water box priming pump so as to
evacuate air in the condenser water
boxes & CW. piping and establish
initial vacuum in the water boxes to
achieve desired syphon.
Start circulating water pump(s).
Establish cooling water flow through
the condenser.
Place the condenser on-load tube clean-
ing system in service.
4.1.2 Oil System
Ensure turbine main oil tank level.
Check oil tank level annunciation
(High/Low :- 900 mm/- 950 mm from
top of tank).
Start oil vapour extractors and genera-
tor bearing chamber exhaust fans.
Place one turbine oil cooler oil side in
service and both turbine oil cooler water
side in service.
Place oil temperature control valve in
service.
107
Ensure that air side and gas side seal
oil pujnps are running.
Verify that hydrogen purity in genera-
tor in more than 94%.
Start Primary water pumps.
Verify that fire protection channels 1 &
2 are not in operated condition
Prepare the auxiliary oil pumps (AC) &
emergency oil pump (DC) by opening
the suction and discharge valves. Prime
the pumps by opening air vent cocks.
Start one auxiliary oil pump and gradu-
ally fill up the bearing oil system. When
the system is filled, check the follow-
ing :
a) Oil level in the oil tank.
b) Pressure in lub oil system (1.2
kg/cm2g)
c) Sufficient flow through all bear-
ings
d) Oil temperature down stream of
turbine oil coolers is within per-
missible limits (38°-47°C).
Switch off auxiliary oil pump.
Check automatic starting of the sec-
ond auxiliary oil pump and emergency
oil pump.
 d) Repeat steps (a), (b) & (c) for the following protection systems one by one :
i) Turbine over speed
ii) Axial displacement high
iii) Condenser vacuum too low
iv) Bearing Lube oil Press too low
v) Emergency PB operated.
Ensure that all ESVs IVs and CVs are closed
4.1.5 Condenser Bvacuation System

Verify that vacuum breaker is closed. Keep open gland sealing header drain
valve*, till sound of steam is heard
f through this valve. Close the valve.
Verify also that seal steam condenser
level is not high.
Regulate seal steam control bypass
iT valve to maintain seal steam header
Switch on one seal steam condenser pressure, and to supply steam to tur-
exhauster. bine gland seals.
t t
Open warming up drain valve. Open seal water supply valves and
supply seal water to the vacuum pump
system separator. Verify that the level
Open auxiliary steam supply valve to in the separator is maintained by
main turbine gland sealing system. maximum & minimum level control
valves.

Open sealing steam station inlet isola- r

tion valve. Verify that the vacuum pump is also
filled simultaneously, via the heat
exchanger, to seal off the gaps & clear-
Close warming up drain valves when ances.
sound of steam is heard through this
valve. Reopen the valve so as to drain r
any condensed steam. Repeat closing Ensure cooling water supply to the
& opening until line becomes warm heat exchanger.
up.
r
Open condenser air supply valves from
Open gland sealing steam header drain condenser to vacuum pumps.
valve.
1 Close the condenser air inlet valve to
Crack open seal steam control bypass the vacuum pump steam
valve.

Open the bypass valve and close the

t motive air valve.

109
T
When steam comes out through vent
valves close them and plug them.
Ensure that while heating, differential
temperature between parallel steam
lines remains below 28°C.
Open MS shut off valves when pres-
sure has built-up in MS piping.
Gradually open HP bypass valves so as
to establish 15% steam flow through
them fully taking care to see that
temperature control loop is function-
ing normally. Also ensure that L.P.
bypass system is functioning normally.
Steam flow thus established shall assist
in heating main steam, cold reheat
and hot reheat lines.
HP bypass valves can further be opened
to assist in increasing steam parame-
ters.
Put the Automatic Turbine Run-up
System (ATRS) in service.
Verify conditions, as under, are satis-
fied.
a) Turbine on turning gear (Speed
>15 rpm).
b) Condenser pressure is less than
0.5 kg/cm 2 a.
c) At least one condensate extrac-
tion pump is on.
d) Trip fluid pressure is more than
5 kg/cm 2 .
e) Diff. Temp, between HP casing
mid section and top is less than
30°C.
f) Diff. Temp, between IP casing
mid section and top (both from
and rear) is less than 30°c.
g) HP control fluid temp, is more
than 50°C.
T
111
h) Lub. oil temp, after cooler is more
than 35°C (38°C-47°C).
i) Degree of superheat of MS before
HP bypass is more than 50°C
(Also see pages to
j) MS temp, before HP bypass is
less than 400°C.
k) MS temp, before HP bypass is
more than mid-wall temp, of HP
control valves.
1) MS press, before turbine is a
function of mid-wall temp, of HP
control valves.
Raise starting device above 42%. Ver-
ify that all ESVs have opened. Verify
also that drains before HP control valves
are in Auto and these valves have
opened.
r
Raise starting device about 56%. Ver-
ify that all IVs have opened.
f
Place 'Seal steam controller' and "oil
temperature controller' in AUTO.
r
Verify that following generator condi-
tions are fulfilled :
a) One Gen. bearing chamber ex-
haust fan is on.
b) H 2 temp, controller is in AUTO.
c) H 2 purity is more than 94%.
d) H 2 pressure is more than
3 kg/cm 2 .
e) One air side seal oil pump is on.
H 2 side seal oil pump is on.
n
g) Diff. pressure between seal oil air
side and H 2 side (both turbine
end and exciter end) is more than
0.7 kg/cm 2 .
h) Seal oil pre-chamber level (both
turbine end and exciter end) is
low.
i) Generator bushing box liquid level
is low (Less than 90. mm).
 Verify that following conditions are
fulfilled :
a. Both auxiliary oil pumps are off.
b. HR temp, before LP bypass is less
than simulated mid-section temp.
of IP shaft.
c. Cold Hj gas temp, is less then
45°C
d. Main excites air temp, is less than
45°C
e. Cold primary water temp, is less
than 45°C
f. Primary water flow through bush-
ings is more than 0.37 DM3/Sec.
g- Diff temperature between primary
water and Hj is more than 10°C.

4.2.1 Warming-up and Starting the Turbine (Temp. & Pr. Curves and Formulae)
Temperature Criteria
The admission steam temperatures should meet the metal temperatures as shown in the
diagrams below in order to start and load the turbine in shortest possible time.
Note •. The criteria above represent approximate valves, which can be optimized by operation experi-
ence.
Turbines with Functional Group Automatic (FGA) for the start-up must undergo optimizing. The
values obtained are given in the operational data record.
Criteria for the opening of stop valves
When opening the main stop-valves the main steam parameters should meet the following
recommended values.
- Minimum Main Steam Temperature
tfMS > flS + 50°C Fig. 4.1
ifrMS = Main steam at steam generator outlet
OS = Temperature of saturated steam (depending on main steam pressure)
and
tfMS > f (-9MCV 50%) Fig. 4.2 Curve A
-QMS = Main s t e a m t e m p e r a t u r e at steam generator outlet
flMCV 5 0 % = Middle wall t e m p e r a t u r e of m a i n control valve casing.

113
 If the control valve temperatures MCV 50% exceed the temperature of the saturated steam
belonging to the main steam pressure the pressure criteria must not be observed.

kg/cm 1 T _
xo-

W
Not
«
3
I -

S A
a i"
i - -
I
E aoo
i
s i
2 FIG. 4.3 ALLOWABLE MAXIMUM MAIN
c
J ""1 STEAM PRESSURE AHEAD OF
TURBINE WHEN OPENING THE
i MAIN STEAM STOP VALVES
too 1
i

r
~]
I
? I

I *
M MM

1
\ S1 \ •

D 100 AM xb'e
Temperature of nurin control valve body
m 50 % wall -thicknesj »|\^cv 50 %

Starting Criteria
When the main control valves are opened the main steam and reheat temperatures should fulfill
the following criteria :
- Minimum Main Steam - Temperature
•&MS > * S + 50°C Fig. 4.1
OMS = Main steam temperature ahead of the turbine
TQS = Temperature of saturated steam (depending on main Steam Pressure)
and
ftMS > fltfHT 50%) Fig. 4.4

*c _ t
-
wo - - _
.- -
* 1 t • - -

2 • Recommtndec i
•

« 100
i,
3 -

--
<9 -
T TT 1
r-
P"
|^
01
«00

1
^1 1
1 1 /
A
FIG. 4.4 RECOMMENDED MINIMUM
1 V MAIN STEAM TEMPERATURE
w» X0- "i r
AHEAD OF TURBINE BEFORE
c - OPENING THE MAIN STEAM
CONTROL VALVES
I 100
i_

T /
- -
9 - -- -
ISO-
-
- -

T
-
L i

. Not f^ecommenood

c i4o joo wo «o too tto •(

Temperature HP-turbine 5 0 % ' ' H T ^ O ^

115
 MS = Main Steam temperature ahead of the turbine.
= Middle walktemperature of the HP-turbine casing or
simulated middle phase shaft temperature
Loading Criteria
Before the turbine is loaded the reheat temperature ahead of the turbine should fulfill the
following criteria :
tt Reh = f {& IT 50%) fig. 4.7

FIG. 4.7 RECOMMENDED MAXIMUM

RREHEAT TEMPERATURE
BEFORE THE TURBINE IS
LOADED

Li
ill
RcLommendod T I

1
100 MO >J0 <JO MO «o9 «.
Simulated mxJalo phase i mpiidture
IP l

Steam temperature in the hot reheat line

dIT50% Simulated middle phase temperature of the IP-turbine shaft

4.3 LOADING THE TURBINE

Place AVR on Auto and switch on field Raise the starting device and take a
breaker. block load of 10%.

Verify that generator voltage is more Close HP bypass, verify that LP bypass
than 95%. also closes.

Switch on Synchroniser and synchron-
ise the generator with the grid.
Verify that generator breaker is on.
Raise turbine inlet MS press at the rate
of 0.8 Kg/cm2 per minute upto 75 kg/
cm2 at 25% turbine load and turbine
inlet MS temp, at the rate of 1,6°C / min
up to 485°C at 50% turbine load.

T 117
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119
 Pvrmmiblt ttmp«riture ditteitnte Ai> in the IP turbins »h«H

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120
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d0 •• outir Ijyir timperaturt of the ihsft
FIG.4.11 LIMIT CURVE
i)m - lamperature of middia layer in IN thaft (calculated^

121
4.4 START-UP AFTER 48 HOURS SHUT DOWN

Auxiliary equipment and systems shall Put AVR on auto and switch on the
be started in the same manner and Field Breakers. Verify that generator
sequence as in case of cold start-up voltage is more than 95%.
Switch on synchroniser and synchron-
i ise the generator with grid and take a
block load of 10%.
Check all auxiliary equipment and
systems are working satisfactorily.
f

•<[ Close HP bypass system. Verify that LP

Also check the healthiness of all pro- bypass system also closes.
tections and interlocks.
Close-all the drains.
Ensure that the boiler has been lighted-
up and steam flow established through f

2
HP and LP bypass systems. From 60kg/cm gradually raise HPT
inlet. MS press, at the rate of 1.65
4 kg/cm2 per minute such that 170 kg/
Verify that all the conditions regarding cm2 pressure is reached at 55% tur-
MS and RH steam temp are satisfied. bine load.
1
Raise HPT inlet MS press, and temp, to Raise HPT inlet MS - temp, at the rate
60 kg/cm2g and 380°C, respectively of 1.6°C / minutes from 380°C. to 485°C.
prior to steam rolling.
r Maintain MS temp, at 485°C upto tur-
Admit steam to the turbine ensure bine load 485MW. Thereafter raise MS
that permissible wall temp, of limit temp, at the rate of 0.6°C/min, such
curves are not exceeded. that 535°C is reached when the tur-
bine load has reached 500 MW.
r
After holding the set at warming-up r
speed (300-360 rpm) for soaking pur- Gradually load turbine at an average
poses, verify that criteria for MS temp, rate of 4 MW/min upto 475 MW.
is satisfied.
r
At 40% turbine load cut in HP Heaters.
Close all the drains.
r
i Follow Mill cutting-in sequence as
Raise the speed to 3000 rpm. under :
No. of Mill Turbine Load (%)
\ f First : , 20
Verify that criteria for RH steam temp, Second : 33
is satisfied. Third : 45
Fourth : 55
Fifth : 67
Sixth : ' 74
<r

123
 Unload the turbine by gradual closing a. ESVs, IVs and control valves get
of control valves through remote or closed.
manual operation of speeder gear. The b. All extraction steam line valves to
unloading should be carried out at a HPH5, Deaerator, LPH 3 & 2 get
rate governed by the margins shown closed.
on TSE. c. Initiate load run-back in ACS
d. Initiate fast opening of HP bypass
system.
During unloading always keep watch e. Generator is isolated through low
on following parameters, such that forward power relay
they are always within permissible lim- f. Synchronizer is OFF
its as under : g. Field Breaker is OFF
h. Drains before HP control valves
a. Differential expansion are open.
HP casing : < + 5 mm
> - 3 mm
I.P. Casing : < + 8 mm When turbine speed falls below 2790
> - 2 mm rpm, verify the following :
a. One auxiliary oil pump is on
L.P. Casing : < + 30 mm b. Oil temp, control valve is on Auto
> - 3 mm c. Gate valve gearing has opened.

b. Bearing Vibration < 50 jiM

c. Wall temperature of ESV, HP casing, When turbine speed falls below 510
HP & IP turbine shaft rpm. verify that one Jacking oil pump
is on and the machine is running on
d. Differential temperature between par- barring gear.
allel steam lines 28°C.

Operate HP-LP bypass systems to sta-

bilize boiler conditions and maintain
Having unloaded the turbine to no steam flow through reheater till the
load, trip the turbine manually. En- boiler is shut-down.
sure the following.

J Maintain condenser vacuum as long

as firing in boiler in on.
4.7 EMERGENCY SHUTDOWN

A variety of conditions may arise with the boiler and the turbine that can be considered as of
emergency nature necessitating a shut down. This section details the major steps to be taken in the
turbine side during an immediate emergency.

Operate emergency push buttons from Isolated the generator and switch off
either the ATRS control insert or the field breaker and synchronizer.
local turbine front.

j. Break the vacuum.

Ensure that ESVs, IVs and control
valves of both HPT & IPT have closed.

125
 xv) Regularly note readings of all the turbovisory instruments, take measures for abnormali-
ties. At least once in a year check all the turbovisory instruments mounted on the turbo
set.
4.8.2 DON'T s
i) Do not operate the set if the condenser pressure is more than 0.3 kg/cm2a.
ii) Do not start the turbine if the condenser pressure is more than 0.5 kg.cm2a.
iii) Do not run the turbine if the bearing drain oil temperature exceed72°C.
iv) Do not run the set continually at low load or no load. Do not run the turbine for a long
time at no load or low load immediately after if has run for long duration at higher load,
to avoid quenching of the internal parts.
v) Do not allow the turbine to run if the LP exhaust temperature goes beyond 100pC.
vi) Do not drain oil saturated with hydrogen vapours into the oil tank,
vii) Do not rely solely on the lamp indications for the operation of pumps, valves and fans.
Physical check has also to be resorted to.
viii) Do not synchronise the machine with the grid without checking the operation of solenoid
valves for load shedding relay.
ix) Do not start the turbine without ensuring that standby oil pumps are healthy to operate,
x) Do not start the turbine with faulty instruments. Get them rectified before starting.

127
OPERATION OF GENERATOR & AUXILIARIES
 5. OPERATION OF GENERATOR & AUXILIARIES
5.1 LINE UP :
Before executing and synchronising; the generator following system are to commissioned.
5.1.1 Seal Oil System :
Seal oil system commissioning is re-
quired prior to filling of hydrogen in
the generator.
The turbine main oil tank filled upto
the required level with centrifuged oil.
Following services should be made
available :
1) Electric power for A.C. seal, oil
pump motor,
ii) D.C. power for D.C. seal oil pump
motor, controls relays, starting
and signalling panels,
iii) Cooling water supply for seal oil
coolers,
iv) Dry clean compressed air for
filling the generator..
Open the valves for suction and dis-
charge of AC seal oil pump, its coolers
and oil filters. Open the valves leading.
the discharge oil to damper tank.
Close all other valves.
Charge the seal oil line with oil by
gravity from MOT. Vent air from cooler,
filter etc. and close the discharge valves
of A.C. seal oil pump.
Check the venting of pressure gauges
is over.
Start the A.C. seal oil pumps and slowly
open the discharge valve.
129
Wait till damper tank is full and the oil
level in hydraulic seal rises to a point
midway.
Check the oil level in hydraulic seal oil
tank'above lower gauge glass but be-
low upper gauge glass.
Cheek the alarms for high/low level'in
hydraulic seal tank and damper tank
to be working all right by simulating
both the conditions by level switch
with help of C&I personnel.
Charge the cooling water flow to seal
oil cooler.
Check the centrifugal fan in service in
the main oil tank.
Check the suction and discharge pres-
sure of A.C. seal oil pump.
Check oil pressure before and after the
filter.
Apply thrust oil pressure by regulating
inlet and outlet valve of P.O.R. care-
fully to get the required pressure.
Open inlet and outlet valves of DPR.
Open damper tank by-pass valve.
1
 5.1.2.3 PURGING OF R, BY CO,
Stop filling During H, filling,
operation if continuously
theH, analyse the Admit CO2 to Hydrogen is
concentration —• concentration of the bottom of discharged to the
attains a H 2 in gas mixture the casing atmosphere
—»
concentration of inside the through the through hydrogen
98% and H, machine. CO2 feed pipe. feed pipe line.
pressure
attains rated f
value 3.5 kg/cm 2
Stop filling CO2 when CO2 concentra-
tion has reached 98%.

5.1.2.4 PURGING OF COa BY AIR

When CO2 concentration in the CO2

hydrogen mixture reached 98%, air
filling may be started to expel the CO2
before the machine is opened for main-
tenance. For this purpose dry instru-
ment air is used.

5.1.3 Stator Water Cooling System

Keep the pump interlocking switch in
OFF position.
Check up 415 V, 50c/s supply for sta-
tor water cooling pumps.
Ensure that one D.M. make up pump/-
sis running and fill-up the expansion
tank and D.M. water make up tank (if
provided) upto their normal value by
opening respective inlet valves.
Open the stator bypass valve; start the
pump and slowly open the discharge
valve to full
Adjust the cooling water pressure and
flow.
Charge the other cooler from D.M. wa-
ter side and bring the temperature of
D.M. water to 40°C.

Charge the cooling water for secon-

Supply clarified water to the water line dary stator water cooler.
valve to ejector by opening clarified
water line valve to create vacuum and
thus maintain vacuum in the expan- Charge rectifier for exactor (RCU) by
sion tank. opening D.M. water inlet valve and
adjust the flow by the control valve.
Open the D.M. water valves before and
after the stator water pumps, stator
water coolers and mechanical filters.

131
5.3 STEPS FOR GENERATOR SYNCHRONISING

Ensure the availability and complete- Check bearing vibrations and rubbing
ness of all the equipment and circuits. etc. if any, inside the generator during
rolling or any abnormal sound.

Take clearance from electrical division

for synchronising. Check temperature of bearing seal
babbit and drain oil.
r
Ensure that the If the insulation
insulation resistance of the Throttle inlet and outlet valve of H2 gas
resistance of system is low, coolers according to gas temperature,
the system is dry out of Do not allow the gas temperature to
within stator winding and rise above 55°C.
permissible associated bus
limits duct should
especially if be carried out. Ensure that the machine has attained
the generator the rated speed of 3000 r.p.m. Obtain
is being a go forward signal from boiler and
synchronised turbine operator to synchronise the
after a long machine.
time or in
rainy season.
Enquire from the switchyard control
room about synchronising of machine
Check seal oil system for seal oil pres- to the required bus.
sure, flow and temperature.

Close the isolator for bus.

Check Hj cooling system for H2 pres-
sure, purity and gas leakage.
Charge stator winding coolers with
distillate and ensure quality, pressure,
flow and temperature of the distillate.
Ask switchyard control room operator
to close transformer side isolator and
report back to unit controller about
proper closing of the isolators after
physically verifying the same.

Check that If not, open Check that the synchroscope cut off
generator generator breaker switch is 'OFF and synchronising check
breaker and or field breakers relay "SKE" bypass switch is on "IN
generator as the case may CIRCUIT" position. If not, put these
field breaker be. switches in the said positions.
are open

Advice rolling of turbine to rated full

speed (3000 rpm>.

133
Put Ask turbine Keep generator winding & core tem-
synchroscope operators to carry perature, generator transformer wind-
switch to out necessary ing temperature, H 2 gas temperature,
"OFF" position —• operations on generator seal and bearing metal tem-
turbine side perature within limits by adjusting
required for cooling water flow to generator gas
raising coolers and oil coolers. Load the gen-
the load. erator upto 150 MW as per guide lines
available.

ir
At this load If generator wdg/
Put "antimotoring" protection switch check generator core temperature
on "ON1 position after taking some load bearing and is higher adjust
on the machine (say 20 MW). seals temp, distillate flow
generator and cooling water
winding/core flow to gas coolers.
Gen. voltage and P.F. (power factor) temperature,
will be maintained by AVR if the exci- generator trans-
tation mode is on "Auto"; otherwise, former winding If Gen. T/Fwdg.
maintain generator Voltage and PF by temperature, temp, is high,
varying the field rheostat from the gen. H 2 gas check that ail
control desk. If excitation mode is on temperature, the cooling fans
manual then change over to "Auto" performance and pumps of
mode after matching the parameters. of automatic cooler banks are
(Refer Fig. 5.1). voltage regulator in service.
and cooling
r water flow
Slowly raise Now the voltage toR.C.U. If the AVR is not
the load on and power factor functioning
generator upto will be maintained properly take the
80 MW (follow —» by the automatic voltage control on
the guide lines voltage regulator "Man mode".
given for (AVR). However,
loading the
machine).
the level can
be changed by'
1
Check exciter winding temperature & slip ring
varying the sparking. Ensure that the exciter voltage and
rheostat resistance eurrent are within permissible limits.
r
r
Changeover 6.6 KV auxiliary bus from Check H2 Fill more H2 gas
station supply to unit auxiliary supply pressure, gas if pressure
taking both the unit auxiliary trans- purity and and purity are
former into circuit. Check that the unit temperature, low. If the
auxiliary supply incoming breakers are performance —> performance of
racked in service position. Springs are of seal oil seal oil system
changed and "Local/Remote" switches system and is not satisfactory
are on "Remote" position stator water take corrective
cooling system. measures.

135
 Increase load on the generator as per
loading guide lines up to full rated load.
Check generator wdg/core temp. Gen
T/F wdg. temp, and vibrations.
If Gen. wdg/core temp, cannot be con-
trolled by increasing cooling water flow
to gas coolers and distillate to stator
water coolers. Reduce load.
If the vibrations increase beyond lim-
its reduce load and investigate cause.
Check that all the cooler bank fans
and pumps are running, if not, start
them. Even then if the temperature of
T/F wdg. does not come down, reduce
load.

If all parameters are within limits, main-

tain load on the Generator according
to boiler and Turbine parameters and
conditions.

5.4 ROUTINE OPERATION AND PERIODIC CHECKS

5.4.1
It is important that the generator and its auxiliaries be kept under observation during operation.
The annunciation system will give warning of abnormal conditions, but regular observation is needed to
detect any gradual deterioration in the operating conditions and take appropriate corrective action even
before any alarm comes.
All those parameters should be noted by the operator in the log sheets specially maintained.
These are over and above the automatic recording done by instruments. It is recommended that a full
inspection of the generator should be made after it has been in operation for approximately one year after
commissioning.
5.4.2 Hourly Checks :

5.4.2.1 TEMPERATURE:
Hourly checking of temperature of following should be done and any abnormal rise in
temperature should be reported to the concerned personnel without delay. Remedial measures should be
taken.
Stator winding
Stator core
Rotor winding
Cold and Hot gas (Refer Fig. 5.2)
Distillate temperature and inlet and outlet stator winding (refer Fig. 5.3)
Babbit temperature of bearing and seal liner
Inlet and outlet oil temperatures of generator bearings and shaft seals
Inlet and outlet temperatures of cooling water to gas coolers

137
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UNLOADING SCHEDULE DUE TO HIGH STATOR WATER

TEMPERATURE
FIG. 5.3

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139
 Check the settings of all the electrical contact, pressure gauges and other instruments.
Check the conditions of the lamps in tfte signalling system of H2 cooling, seal oil and stator water
system.
Check stator water system for presence of any gas.
Check the leakage rate of H2.
Check the H^ content in oil tank.
Check the insulation of excitation system.
Test run the stand by A.C. seal oil pump and the emergency D.C. Seal oil pump. Run them for
few minutes to check that they supply oil at the correct pressure and also run smoothly. Check
the interlock between two pumps.
5.4.4 Weekly Checks
Examine the conditions of brush gear. Replace if any, short brushes, Check that brushes are
freely sliding in their holders. Adjust pressure on the brushes so that it is uniform on all the
brushes and is about 1.1. to 1.3. kg., on each brush.
Check interlocking between working and standby stator water pump for automatic take over.
Run stand by pump for few minutes to check that it develops correct pressure of water aj»d also
runs smoothly.
Check the operation of automatic D.C. Bridge recorders.
Check the operation and calibration of hydrogen purity indicator.
Check the differential pressure across the filters in the seal oil and stator water system to
ascertain whether they are choked or not. If necessary switch over to stand by and take corrective
action.
Check interlocking between working and stand by H, cooler booster pump. Test run the stand
by booster pump and check flow and pressure.
Check resistivity of distillate by laboratory testing.
Check purity of Hj by laboratory testing.
Check for H^ concentration in bearing chamber.
Check HJJ concentration in bus duct enclosure.
Check the gas sample taken from hydraulic seal for oxygen content.
Check the bearing vibrations by portable and accurate vibration measuring instruments.
5.4.fj Monthly Checks
Chock all accessible bolts for tightness.
Check all the protection and signalling circuits.
Check that all the alarms operates correctly by simulating abnormal conditions wherever
possible or by manually operating the initiating contacts.
Check once in three months the polarity of slip rings in order to have uniform wear of the slip
rings.
141
143
5.6 EMERGENCY OPERATION

5.6.1 Stator water flow low Check expansion tank level is normal and drains
are closed.
Check position of recirculation value.

Check whether running pump has tripped. Re-

serve pump should start on Auto, if not start
manually.

Check differential pressure across the filter is

normal.

5.6.2 Stator water conductivity high Check D.M. water conductivity from the D.M. Plant.
If normal, then purge same water from system. If
D.M. tank Water conductivity is high then close
D.M. make up valve.
Check stator water cooler for leakage.

Regenerate-polishing unit resin beds & take it into

service.

5.6.3 Hydrogen pressure low Charge fresh hydrogen. If consumption is high

then investigate leaking points. If the pressure
persist to drop then reduce load on generator. If the
pressure can't be maintained then trip the set.

5.6.4 Hydrogen purity low Purge some hydrogen from casing and charge fresh
hydrogen.
Check seal performance is normal.

5.6.5 Seal oil differential high/low Check DPR is functioning normally. If not change
to the bypass line and get DPR attended.

Adjust the pressure at injector/ pump discharge.

5.6.6. Liquid in generator Open the low point drain of generator and check
nature and amount of leakage.
Check proper functioning of DPR.
Check thrust oil pressure.
Check stator water pressure.

5.6.7 Generator stator cooling water Check gas trap and analyse the gas from it. In case
leakage stator water leakage is suspected then shut down
the unit and attend the leak.

5.6.8 Damper tank level low Check DPR operation. If required open the bypass
valve and make up the level. If the level approaches
16w unit will trip.
145
References :

1. PETS Training Materials

2. CEGB Training Materials
3. Modern Power Station Practice - CEGB
4. BHEL/NTPC Mannuals
5. , NTPC Training Materials

>^ pvmp

147