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15th July 2015 Power Plant Operation

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

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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 equipments
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.
Book No.
Unit No. II III IV
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.
Nature of defect notice
to
Details of work done

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Time
Date
Name
Designation
Signature
A Typical PTW
....Thermal Power Station
Expected time
of return Hrs. Day Permit No.
Type of Maintenance B. D. P.M. OPP.
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.
Equipment
Isolations Made
Issued by
Issued to
Cancelled by
Name Desig Date Time Sign
Trial Run
Carried
Yes No Date Time
Representative of Maintenance
Name ...
Designation
Signature
Representative of Operation
Name „
Signature of
Controller
Thermal Power Station
BREAK DOWN INTIMATION SLIP
Book No Permit No
Unit No. I II III rv V s
Name of the equipment
Type of defect.
Equipment
Stopped
Vltc Section incharge
Date Time
BLR TUR MISC C&I EDI E.D.D
Time.
)ate
fame
ignature of Controoler
hift Charge Engineer ..
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

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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

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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

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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)

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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
pit punfier m service O OI pumps stan A auto operation check ^^-^urbme lub oil system in s Turbo-alternator tuming gea/ 1-5
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

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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 expansion
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, manufacturers
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

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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

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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
-&« &*
iiiN£nCHARGED c0L D LINE
y?»Q$ uirvv WHICH IS TO BE
FIRST VALVE WARMED SLOWLY
FIG. 1 +
To charge drain line :

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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 results
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 temperature
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 analysis
also shows that the allowable temperature
differentials are based on tensile
strength, drum diameter, wall thickness,
and pressure; therefore, each steam drum
has its own allowable temperature differential
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
actual temperature differential is below the
allowable temperature differential. Normally
the temperature differential should not exceed
50°C (see fig. 1.5).
70 Ho J»o " f
i . ». DRUM PRESSURE KO/Cm*/
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/cm2 thejgauge g l ^ ^
id t l ff d b l k i h

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jggg^^
J side to clear off any; dirt blocking the 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
SO2/S03 after combustion and combines with HjO to form highly corrosive sulfuric acid when temperature
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.

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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-;

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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 continuously
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

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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
valves
Close
valves
Boiler Feed Pumps discharge
Boiler feed pumps, discharge
bypass valves
Close B.F. Pumps discharge header
drain valve
Close
Open
Open
Close
Close
Open
Open
f
feed water isolating valves
i
feed line vent valve
1
feed line drain valves
t
H.P. heater F.W. inlet valve
t
H.P. heaters F.W. outlet valve
f
H.P. heater F.W. bypass valve
1"
F.W. line drain valves
f
Close S.H. & R.H. Attemperator header
isolating valve
Close

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%f
R.H. spray block isolating valve
i
Close S.H. Attemperator Control valves
inlet isolating valves
Close R.H. Attemperat-ior control valves'
inlet isolating valves
Open feed line vent valve
Close Main Feed Control valve
1
Close isolating valves
Close Standby Feed Control valve and
isolating valves
Close bypass valves of Standby Control
valves' isolating valves
Close Low Load Control valve and
isolating valves
Close bypass valves of isolating valves
of low load control valves
Open Feed Control station drain valves
Close boiler filling isolating valves from
Boiler Fill pumps
Close Hydrazine sampling valves' before
economiser.
Close economiser drain valve to water
wall header
21
2.2 LINE-UP BOILER WATER & STEAM SYSTEM
2.2.1 Economlser
Open economiser inlet valve & close
its bypass valve
i
Open economiser recirculation valves
\t
Close economiser drain valves
i
Open economiser outlet lines vent
valves
I
Close economiser outlet lines drain
valves
2.2.2 Drum
Open Drum vent valves
t
Close C.B.D. Isolating valve
t
Close Phosphate dosing isolating valves
i
Check I.B.D. valves are closed.
r
Open Drum level gauge glass (Left and

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right) isolating valves quick closing

valves.
1
Close Drum level gauge glass drain
valves.
'
Open isolating valves for local pressure
gauge, level & pressure transducers.
sr
Open isolating valves for remote drum
level-indicator.
Close remote level indicator gauge glass
drain valves
Open saturated steam sampling branch
line valves
Check that Drum safety valves are in
service condition.
2.2.3 W.W. Drain Header
Close filling valve from Boiler fill pumps
Open S.H. headers & link vent valves
l
Open startup vent valves isolating
valves
Open startup vent regulating valves
Open impulse safety valve isolating
valve
Establish electric supply to impulse
safety valve.
Check that final S.H. header safety
valves are in service
Close M.S. shut-off valves & their bypass
valves
Open M.S. drain valves to before boiler
Stop valves
22
Close Scot Blower steam isolating valves
Open isolating valves of local pressure
gauges, pressure transducers etc.
2.2.4 Reheater
Open Reheater headers vent valves
Open H.R.S. header motorised vent
valves
Close Sampling line valve
Check that R.H. header safety valve
are in service.
Open R.H. desuperheater left & Right
drain valves
Close R.H. spray line drain valve &
after spray control valves.
2.2.5 C.B.D. Tank
A.

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Close C.B.D. tank vent valve to deaerator

Open the isolating valves, Flash tank
level control valve
Open isolating valves of main C.
control valve
r
Close C.B.D. control valve
f
B.D.
Close isolating and control valves of
standby line
<t
Open C.B.D. tank atmospheric
valve
Check C.B.D. tank safety valve
service
vent
is in
Close the isolating valves tank
control standby valve
r
Close standby C.B.D. tank level
trol valve
PutC
mode
r
B.D. level Control valve for
of operation.
level
Conauto
2.3 BOILER FILLING
2.3.1 Boiler Filling Using B.F.P.
Fill the Deaerator with D.M. water using
boiler fill pump
Prepare Hydrazine & Ammonia solution
in the L.P. Dozing mixing tank
Take water in L.P. dosing metering
tank
Open Hydrazine dosing valve in B.F.
suction line & run Hydrazine dosing
pump.
Turn on feed water
heating steam & O
heat up the feed •
water gradually to
80 to 85°C.
Maintain deaerator
pr. just above
atmospheric = 0.2
to kg/cm2 (g)
Run Boiler Feed Pump on recirculation

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Continue to run B.F.P. on recirculation

with Hydrazine amonia dosing
23
Check water condition
before filling: should be
pH 8.5 to 9.5 at 25°C.
Dissolved O2 0.005
ppm. Temperature 80
to 85°C. Hydrazine in
F.W. 0.05 to 0.1 ppm
Ammonia content
should be 0.2 to
0.3 ppm.
Check F.W. system is
lined up
Refer feed water
system line up
Crack open BFP discharge valve bypass
valve and slowly charge the FW
lines
Throttle vent valves, as the air is being
released
Close Feed line drain valves
Close F.W. line drain valves after H.P.
heater after flushing for few minutes.
Close the feed line vent valves before
H.P. heaters when water starts coming
through vent
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 control
valves.
Close economiser vent valves when
water starts coming through it
r
Feed water lines
charged
Open BFP discharge valve & close its
bypass valve
r
Maintain moderate
feeding about
40 t/hr, for easy -\
purging ofair &
gradual heating of
drum & W.W. tubes.

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t
Continuously monitor
drum level when
water is just visible
in gauge glass
Add make up to
deaerator as
p the FST level
goes down
Drum metal
temperature rise
* rate should be
less than 110°C/hr.
V
Close BFP discharge
valve when drum
level approaches
- 120 reading
Ensure that BFP
. recirculation valve
opens when flow
reduces to 100 t/hr.
\t
Boiler is filled up.
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
and water system
lined-up
Refer Boiler steam
& water system
line up
Boiler filling solution is prepared in
C.S.T.
Open fill pump suction header inlet
valve from C.S.T.
Open Boiler fill pump 'A' or 'B' suction
valves
Close fill pump discharge valves
Prime Boiler fill pump
Open isolating valves of pump discharge
control valve
Open fill pump discharge bypass control
valve isolating valves.
Close fill pump discharge bypass control
valve
Close fill pump discharge control valve
Close filling line isolating valve to second
unit
Close deaerator filling water isolating

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valve
Open economiser filling water valve &
after feed control station & before
econmiser inlet valve
Close S.H. filling valve
V
Open economiser inlet valve &
Close it bypass valve
Close isolating valves & its bypass
valves of Feed control valves down
stream side.
•< r
Check the level of water in C.S.T.
4
Establish electric supply to Boiler fill
pump A & B
r
Start Boiler fill pump
r
Open Boiler fill pump discharge valve
when it attains full shut-off pressure,
check pump discharge pressure.
t
Regulate filling rate by opening fill
pump discharge control valve
r
Water is filled up through economiser
When drum level comes to 'O' reading
close the fill pump discharge control
valve. Stop boiler fill pump.
i
Close the economiser filling line isolating
valve
Boiler is filled up.
25
2.4 DRAFT SYSTEM
Draft System consists of Induced Draft Fans (2/3 Nos.), Forced Draft Fans (2 Nos.), Air Preheaters
(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
Flue gas path lined up
Check ID Fan motor selected for low
speed if two speed motor provided

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Ensure that all permissives are OK

Check Air Heater in service
Check that bottom ash hopper is filled
up/filling line is open
Ensure cooling \
START ID FAN
Open discharge
Load the fan by
r
t
vater supply
f
A
Damper
i
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
is lined up
START FD Fan motor
Ensure all permissives
Increase Fan Loading by increasing
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 that air preheater guide bearing
circulating oil system is lined up
Check that air preheater support bearing
circulating oil system is lined up
Check that air flow path is lined up
Check that gas flow path is lined up
Check that A.P.H. water washing top/
bottom valves are closed

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Check that station air supply is available

for the air motor
Establish electric supply to A.P.H.
motor. Take out the charging push
button of electric motor.
Start A.P.H. Electric motor.
Check A.P.H.
interconnecting
damper operation
Check operation of
air motor
r
•»•
fat
Interconnecting
damper opens if
one APH is on/
closes when both
the APH's 'ON*.
Trip electric
motor-air motor
should start
Run air preheater electric motor, keep
air motor on xAuto' standby
r
Check that support
bearing oil pump
starts when oil
temperature exceeds
30°C.
7
Check that pump
develops correct
pressure
Check that guide bearing oil pump
starts when oil temperature exceeds
30°C.
V
Open cooler inlet outlet water valve/
maintain oil temp, at about 40°C.
27
2.4.4 Draft System Starting Start ignitor air Fan
Line up ID Fans/Motors lub oil system I Start Scanner air Fan
Line up FD Fans/Motors lub oil
system
Line up APHs guide bearing and support
bearing oil circulating system
A.
Line up flue gas path
Line up secondary air path
r

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Light up and load boiler

f
Start Second ID Fan
upto
Equalise Loading on Both ID
r
Start*second FD Fan
Equalise loading on FD Fans
50 MW
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 mechanised
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 :

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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.

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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.

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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

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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/cm2 (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

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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)
Pulverizer B

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i)
ii)
Pulverizer C
i)
ii)
iii)
Pulverizer D
i)
ii)
Boiler loading is greater than 30% and Pulverizer B is in service at greater than 50%
loading.
A minimum of 3 out of the 4 Elevation AB light oil ( or heavy oil) nozzle valves .prove open,
or
Boiler loading is greater than 30% and Pulverizer A or C is in service at greater than 50%
loading.
A minimum of 3 out of the 4 Elevation CD heavy oil nozzle valves proven open, or
Boiler loading is greater than 30% and pulverizer B or D is in service at greater than 50%
loading, or
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.
A minimum of 3 out of the 34 election CD heavy oil nozzle valves proven open, or
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)
iii)
Pulverizer F
i)
ii)
Boiler loading is greater than 30% and Pulverizer D or F in service at greater than 50%
loading, or
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.
A minimum of 3 out of the 4 Elevation EF heavy oil nozzle valves proven open, or
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.

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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 depressing
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 :

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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

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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.
2.6 BOILER PURGING & LIGHTING UP
Feed pump is started & Boiler feed line
charged
Boiler steam &
water system is
lined up
Refer Boiler water
steam system line
up.
Boiler is filled up
to working level
of gauge glass
Refer Boiler filling
instruction.
B.F.P. run on recirculation
1
Boiler air & flue
gas system is
lined up.
r
•
Start Air Preheaters
Refer Drafts system
A&B
Take lube oil system of I.D. fans in
service
Take oil systems of
F.D. fans in service
Refer F.D. fan
starting instruction
Start one I.D. fan. Refer I.D. fan
starting instruction
Start one F.D. fan
i
Maintain 30% Air
flow and 5 to
10 mm WCL
furnace-.draft
Put secondary air
damper control
system on "Auto"
& check that
auxiliary air
dampers are

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modulating to
maintain 35-40 mm
WC windbox to
furnace differential
pressure.
>
Start E.P. rapping
mechanism
>r
—•
-
Refer F.D. fan
starting instruction
Air flow shall
not be more
than 40%
Check fuel air
dampers are
modulating with
aux. air dampers.
Check that E.P.
insulator heaters
were switched on
24 hrs before
boiler light up.
Start Scanner Air Fan A/B
Start Ignitor Air Fan A/B
Select Burner tilt control on manual,
keep burner tilt in horizontal position
Ensure that warm up oil^system is in
service, L.O. system is charged
40
CHECK:
i) A.C. & D.C. power supply is established
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 established
v) Ignitor.trip valve is proven closed.
vi) The light oil trip valve is proven
closed.
vii) The heavy oil trip valve is proven
closed.
viii) All the ignitor valves in all elevations
are proven closed.
ix) All the wajrmup and heavy oil
nozzle valves at all elevations
are proven closed.
xii) All feeders are off.

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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 present
Purge start permissive
41
Check that atomizing air lines for ignitors
& W.U. Oil guns are line up and
charged.
Make ready each W.U. oil corner individually
Start furnace purge
by pressing Start
Purge
After 5 minutes
check that purge
complete light
comes on
Open igniter trip
valve from F.S.S.S.
console insert
OpenPB
Open light oil
trip valve from
FSSS console
insert Open PB
Purge cycle is of
5 minutes
This indicates that
M.F.T. relay
is reset.
Igniter trip valves
will open if
i) M.F.T. relays
is reset.
ii) Igniter valves
are proven
closed.
iii) Igniter oil
supply
pressure is
adequate (14
kg/cm2) ^
L.O. Trip valve
opens if
1) M.F. trip
relay is reset
2)
3)

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Light oil
nozzle valves
are proven
closed.
Light oil
pressure is
adequate (5
kg/cm2).
Select light oil firing from FSSS insert
control PB for AB elevation.
Establish light oil
elevation permit
Check :
i) D.C. Power
available.
ii) L.O. trip valve
proven fully
open.
iii) Air flow
between 30%
&.4Q%
iv) Burner tilt
placed in
horizontal
position.
v) No Boiler trip
command is
persisting.
vi) Light oil gun
is inserted in
guide pipe &
coupled.
vii) Local
maintenance
control switch
is placed on
"Remote"
viii) Light oil
Manual
isolating valve
open
ix) L.O. Atomising
air manual
isolating valve
are open.
Start AB elevation
are pair of L.O.
guns by
depressing pair
start PB on
FSSS insert

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console.
Refer L.O.
elevation start
up.
42
Check associated AB elevation at least
3 out of 4 lighters are-proven on
r
Check that selected
pair of L.O. guns
are proven on in
time sequence.
>r
Start second pair of
L.O. guns A.B.
elevation by
depressing start
PB on
->
-
Maintain warm
up oil pressure
4.5 kg/cm2
through pressure
regulating valve.
Also maintain
oil/ air AP between
1 to 1-5 kg/ cm2.
Maintain Warm
up pressure 4.5
kg/cm2 through
regulating valve.
Check that at least 3 out of 4 L.O. guns
are proven on in timed sequence.
Check
i) Light oil header pressure is
adequate.
ii) Light oil/air differential pressure
is more than 1 kg/cm2
Otherwise L.O. trip valve will close.
Check boiler expansion is free
Check:
Ignitor oil header pressure is
adequate (14 kg / cm2.)
Control firing rate
during initial
warming up such
that boiler starts
steaming after 45
minutes.
Follow the cold

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start up curve
while bringing
up pressure &
temperature.
Fig. 2.1
Keep C.B.D. control
valves fully open
during warm up
Open C.B.D.
Isolating valve full
Control flue gas temperature at furnace
exit below 538°C by controlling
firing rate till adequate flow is established
through reheater.
T
When boiler starts
steaming throttle
S.H. vents & drains
r
When drum
pressure reaches
2 kg/cm2. Close
drum vents and
outlet header vent
->
Warming up should
be slow; steaming
should start after
45 to 50 minutes
of lighting up.
See Fig. 2.1.
Refer cold start
curve for rate
of pressure &
temperature rise.
Fig 2.1
r
Close steam cooled wall extended side
outlet header vents
Close S.H. Desuperheater link vent
valves
Close platen S.H. outlet link vent valves
Throttle following: S.H. drain, Radiant
roof S.H. inlet header drain, & side
steam cooled out let header drain, Rear
Header drain, S.H. S.W.W. front roof
inlet header.
Do not close these drain valves fully
before rolling the turbine.
Check that M.S. line drains are opened
(near turbine).

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43
OVOI Y l f t i -
MOtHM
S8
maeu *
s
3
s
c
S|
S
s
52
s
3
i
•8
s.
•
3
s
o
?
a
3S
8
2a
s
s
s
^?•
S
ft
44
Open boiler stop valves L & R.
Throttle start up vent valves to control
pressure rise; do not close them fully
until turbine is under light load/or HP
& LP by pass system is taken into
service.
Close reheater vents & Drains before
vacuum raising.
Bring up the Boiler steam parameter
to 5 kg/cm2, 195°C, ^_
2.7 BOILER LOADING
Refer cold startup curve for rate of
pressure & temperature rise & steam
flow (fig. 2,1)
Boiler lighted up & main steam pressure
& temperature are 5 Kg/cm2,
195°C

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ir
Prepare for Heavy
oil firing
*~ Before H.O. firing
check flue gar
temp, at APH
outlet is above
90-100°C.
f
Check auxiliary
steam header is
charged through
inter-connection
p
Refer auxiliary
steam system
Check auxiliary steam line F.O. heaters
& tracing steam lines are charged.
ir
Check H.O. system is in service on
recirculation before H.O. pressure heaters.
r
Check atomising steam lines are
charged.
r
Take SCAPH corresponding to running
F.D. Fan in service & maintain
average cold end temperature above
acid dew point.
w
Check auxiliary steam is given to feed
storage tank heating and deaerator
pegging.
Put H.O. on
recirculation
through F.O.
trip valve
F.O. burner
headers
r
Refer H.O.
recirculation
instructions.
Put H.O. heater
pressure and H.O.
temperature
control on auto.
Check H.O. temperature at burners
r
Proceed to take
H.O. elevation

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in service
r
It is preferred to
take lower elevation
in service
(CD elevation)
Establish H.O. elevation start permit.
r
Depress associated
elevation pair start
PB
t
—*
Check H.O. pair
is placed in service
in programmed
sequential order.
Ref:H.O.Elevatior
starting.
Maintain Heavy oil burner header pressure.
Also Maintain oil/steam AP 1 to 1.5 Kg/cm2
45
Check both corner burners are proven
on
I Depress start PB
for 2nd pair start
of same elevation
Check H.O. pair
is placed in
service in
programmed
sequence
Maintain H.O. burner header pressure
above 3 kg/cma and temp. 110- 130°C
Increase H.O. firing
rate through
H.O. regulating
valve
Max. H.O. burner
pressure 8 kg/cm2
Warm up oil guns
can be taken out
once the boiler
is warmed up
and heavy oil
elevation is in
service.
At least 3 out of
of 4 H.O. guns
at one elevation
should be in

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service.
Check that vacuum
is raised in the
condenser by the
time M.S.
parameters come
to 6 kg/cm2
and 275°C
Refer vacuum
raising
instruction
Take H.P. and
L.P. bypass system
in service when
condenser vacuum
is 540 mm Hg
Ensure B.F.P. and
condensate pumps
are in service
Main steam Pr 6
ATA M.S. temp
225°C
Ref: H.P. & L.P.
bypass operating
instruction; ensure
steam throw off
device condensate
spray valves are
open.
Close start-up
vent valves
when flow is
established
through
bypass system
Give clearance to
start turbine
rolling
4
Throttle Main
steam line drain
valves
Take drum level
protection in service
Warm-up M.S. lines,
C.R.H., H.R.H. line
& transfer lines
Check M.S.
parameters of
E.S.V.
Check M.S. pipe

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metal temp, is
above 150°C
and C.R. pipe
metal above 100°C.
H.P. transfer pipe
line metal temp
150°C and IP
transfer pipe metal
temp 100°C
Get boiler water
analysed and start
phosphate dozing
if required
—>
Boiler parameters
are raised to
M.S. pressure and
temperature
I
H.P. and L.P.
bypass system is
cut out and
turbine rolling
is started
[—t
Close M.S. lines
drains and C.R.H.
line drains to
condenser.
46
After the M/C
is synchronised
and load is
taken, check
furnace probe
is retracted
automatically
r
>
M.S. pr. 30kg/cm2
before E.S.V.
M.S. temp. 350°C
before E.S.V.
Retract the furnace
temperature
Probe if flue gas
temp, reaches
540°C and probe
is not retracted
through interlocks.
Start Scraper Conveyor and slag

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crasher.
r•
Maintain average
cold end temp
at A.P.H. outlet
above acid dew
point by
controlling steam
flow to SCAPH
«r
Check that E.P.
rapping mechanism
is in service
Regulate steam
supply control
valves & check
air temperature
before and after
SCAPH, check
flue gas temp after
A.P.H.
I
Inform chemist to
check the quality
of Boiler water
and Feed water
as frequently as
possible
Refer
recommended
chemical
composition of
Boiler Water and
Feed Water in
TableJ_&JTable II
Page:49?:50
Check phosphate
dozing to boiler
water. Maintain
boiler water
alkalinityT
Refer coordinated
phosphate
treatment
curve and boiler
water limiting
values in Fig. 2.2
With phosphate
dozing control
C.B.D. valve
opening to

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maintain boiler
water T.D.S.
r
Before increasing
the drum pressure
ensure that silica
content in boiler
water is within
permissible limits
at operating
pressure
r
Check that C.B.D.
tank water level
is maintained
normal. Put drain
control value on
auto.
Refer silica limit
curve for boiler
water. Fig. 2.3.
Prepare for coal firing
Start one PA Fan.
Charge Electrostatic precipitators fields.
Make S.H. Spray
control system
ready
«r
Close drain valves.
Open spray
control valves
inlet isolating
valves.
Open spray
control valves
isolating valves
Close spray
line drain valves
Open super
heater header inlet
water isolating
valves bypass
>
Check that spray
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

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10.4
10.6
o
U)
CM
LJJ
3
8.8
<.
O 8.4
8.0
0 5 10 15 20
PPM PO4
TO LIMIT SILICA IN STEAM TO 002 PPM
25 30 35
FIG 2.2
a
I
u
10.0
20.0
10-0
s-.o
10
en 111
g
a:
BG
2-0
10
0.8
0.5
0.3
O.t
IJ
/
/1
A
B
--——
— -*
A-OPERATION
B- OPERATION
—
——
ABOVE
BELOW
100
100
mm
i

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kg/cm2
kg/cm2
40
FIG. 2.3
RECOMMENDED MAXIMUM SILICA
CONCENTRATIONS IN BOILER WATER AT
VARIOUS pH(DRUM TYPE BOILERS)
30 £0 ,90 120 ISO 1(0 210
OPERATING PRESSURE Kg/Cm2
48
Characteristics
TABLE - I
RECOMMENDED CHEMICAL COMPOSITION OF BOILER WATER
Limit Recommended
Drum Pressure Kg/cm2 10 10-20 21-30
pHat25°C 10 5-11
T.D.S. Max ppm 600 500 250
Chloride Max ppm
PO4lppm 40-70 40-70 40-70
SO3ppm 10.70 10.70 10.70
SiO Max ppm
Specific Electrical
conductivity us/cm
Max. 1200 1000 500
31-50 51-75 76-100 101-125 126-150 151 and above
3.5-10.5 9.5-10.5 8.5-10.3 9.5-10 8.5-9.0
200 175
NOT ALLOWED
100 75
15-30 8-15 5-10 5-10
Hydrazine Dozing shall be employed
According to Curve shown
50
3-5
50
3.0-5.0
400 250 200 150 100 100
49
TABLE - II
RECOMMENDED CHEMICAL COMPOSITION FEED WATER
Characteristics
Drum Kg/cm2
Pressure M Pa
Hardn.ess max ppm
pH at 25°C
Oxygen Max ppm+
Iron Max ppm
Copper Max ppm
Silica Max ppm
Total CO Max
10.00

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1.00
1.0
8.0
0.5
0.2
2.0
5
11-20
1.1-2.0
1.0
8.5
0.5
0.5
0.2
2.0
5
21-30
2.1-30
1.0
.0.3
o:i
0.3
3
Limit Recommended
31-50
3.1-50
Nil
8.7
0.03
0.1
0.05
0.3
1
51-75
5.1-7.5
Nil
8-9
0.007
0.03
0.01
0.1
0.5
76-100
7.6-10
Nil
8-9
0.007
0.02
0.005
0.05
Nil

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101-125
10.1-12.5
Nil
8.5-75
0.007
0.02
0.005
0.02
Nil
126-150
12.6-15
Nil
8.9-9.5
0.007
0.02
0.005
0.02
Nil
151 and above
15.1 & above
Nil
9.5-9.5
0.005
0.01
0.005
0.02
Nil
Permanganate Max 10+
ppm
Specific Electrical
Conductivity at 25oC
Max. 3
10++ 5++ 0.5 0.3
Nil
0.3
Nil
0.3
Nil
0.3
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.
spray control
system ready
Close spray

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control station.
drain valves
Close spray
water line drain
valves
Open spray
control valves
inlet isolating
valves
Open spray
control valves
isolating valves.
Check that
reheater spray
block valve is
closed.
Close economis-er recirculation valves
when continuous flow is established
through economiser
Close the S.H. header drain, Radiant
roof S.H. inlet header drain, inlet header
drain, and side steam cooled wall outlet
header drain, Steam cooled wall
rear header drain, SH.S.WWW. front
roof inlet header drain and final S.H.
header drain
Increase firing
rate and pick-up
30MW load.
M.S. pressure,
temp65Kg/o*1"'
430°C,
RHS temp 420°C
I
TakeAB/BP
elevation H.O.
guns in service as
per the
requirement,
preferably
takeAB
elevation H.O.
guns.
Take main feed
control valve in
service and isolate
low load valve
Make ignition
energy available to
the lowest mill to
be taken in service

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r
—¥>
a. Open bypass
valves of main
feed regulating
valve (FRV)
b. Open isolating
valves of main
F.R.V.
c. Close bypass
valves of main
F.R.V. isolating
valves
d. Regulate F.R.V.
, Refer mill
ignition energy
instruction
Start first mill. Preferably lowest and
work it up.
Start its R.C.
feeder. Put mill
air temperature
and flow control
on auto check
mill outlet temp
around 65-75°C
>f
Control drum level
and furnace draft
carefully.
\t
—*>
—•
Keep drum level
on lower side
just before
starting
mill and feeder.
Drum level and
furnace pressure
are likely to shoot
up suddenly when
feeder is started.
Monitor furnace flame stability
V
Increase the feeder
speed upto 50%
of rated
—»
Check ash
* handling system is

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taken in
service. Check
mill differential
1 pressure is less
than 250 mm WC
51
Switch on E.P. hopper heaters
Increase the main
steam/R.H. steam
parameter as per
cold start curve
->
At no time boiler
drum temperature
increase rate
should exceed
100°C/hr.
Maintain S.H. steam temp control by
spray water control
Jr
Maintain R.H.
steam temperature
by burner tilt.
Increase the load
in generator as
boiler output
increases and
maintain boiler
pressure
R.H. spray
control should be
used as a last
resort for temp
control.
Follow cold start
up curves for
raising load
(fig. 2.1)
Start second mill
when first mill
is loaded to 80%
r
Preferably the mill
adjacent to first
mill
Start associated mill feeder when mill
is warmed up
r
Increase the feeder
speed; equalise the
loading on both

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the feeders
ir
Put mill air temp
and flow control
on auto. Check
air temp =
75-80°C, mill air
flow = 54T/hr.
Mill differential
pressure about
200 mm WC.
When load on unit
is 70 MW check
check Hj^,
heaters are
in service
>
-r
taken
M.S. pressure
at boiler outlet
105Jtg/cm^
T^TSTtempat
boiler outlet
j>OO?C__-
H.R.H. temp,
at boiler outlet
495-500°C
Check heater drip_pumpcutjn automatically
at around 70 MW load
f
Start ?,nrt T T~> fen ^
at load 60^MW
r
( Control furnace
draft carefully,
check that flue
gas interconnecting
dampers open
Equalise loading on both I.D. fans
t
Start 2nd F.D. fan
r
^ Check that air
interconnecting
dampers open
Equalise loading on both F.D. fans
Maintain necessary
total air flow and
furnace draft
Take SCAPH

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corresponding to
second F.D. Fan
in service if necessary
Check stack
P exhaust colour
for proper
combustion
Check O2,
CO, and CO2
content in flue gas
Check that auxiliary
air and flue air
dampers are
modulating and
necessary windbox
to furnace differential
is maintained
At 30% load ,
furnace to
windbox differentia
should be 90 mm
52
Start 2nd P.A. fan
and equalise
loading on both
P.A. fans. Put
P.A. pressure
control on Auto
Maintain P.A.
Pressure above
600 mm WC
I
Check that 2nd
condensate pump
and 2nd boiler
feed pump are
started
t
Check that
deaerator pressure
is increased to
6 kg/cm2 gauge
—P
Before starting
standby BFP it
must be warmed
up
Put deaerator
pressure control
on auto
Inform laboratory to check boiler and

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feed water quality for intermittent

phosphate dozing if situation demands
f:
Take 3rd pulverizer
and its feeder in
service when
loading on running
pulverizers exceeds
80%
->
Ensure that
ignition energy
is established.
Equalise loading on
all the 3 pulverizers
r
Increase load on
the generator and
simultaneously
increase boiler
firing rate
«i r
->
->
Select pulveriser
nearer to the
elevation already
in service.
Refer to boiler
cold start up
curve. Increase
total air flow with
increase in firing
rate; check excess
air.
Boiler pressure 120 kg/cm2
M.S. Temp 530°C, Load 120_MW
Put M.S. & R.H. Steam temp control
system on auto
r
Put B.F.P.'s scoop
tube control on
auto
r
Put main feed
control yalve on
auto
->
Check that
5 kg/cm2
differential

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pressure is
maintained by
scoop tube
position controller.
Check that drum
level is maintained
by the controller
Ir
Put both I.D.
Fans and inlet
vane control i.e.
Furnace Draft
control on auto
r
Put total air
flow control on
auto. F.D. Fan
impeller vanes
control on auto
r
When load on
running mill is
above 80% take
4th mill and its
feeder in service
and equilise
loading on all
4 mills.
r
Flame support HO
guns can be
removed once boiler
loading is above 60%
and more than 2 mills
are in service at
50% loading and
at least two adjacent
mill are in service
Check that 10 mm
furnace draft is
maintained.
Check O2, CO and
CO2 content in
flue gas at APH
inlet. Ensure that
sufficient excess
air is maintained
Refer "Pulverizer
start up
instruction"
Check flame

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condition before
and after removing
H.O. support guns
Retain H.O. guns
in service if
furnace flame
is unstable.
53
SCAPH's can be
cut out when flue
gas outlet temp,
increase to or when
H.O. is removed.
Put thermal load
control on "AUTO"
r
Increase load on
generator. Check
that thermal
load control
maintains boiler
parameters by
controlling firing
rate.
r
-•
-*
Cut SC air
preheater out
Check M.S. &
R. H. steam and
tube metal
temperature
r
Check that total
air flow is
automatically
maintained.
Increase load on generator
Check the Boiler
Parameters
r
Drum pressure
145 kg/cm2
M.S. Pressure 138
kg/cm2
M.S. Temp. 540 +
5°C
R.H. Steam
Pressure 24 Kg/cm2
R.H. Steam temp

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540 + 5°C
Feed water
temperature
245°C
Check M.S.
TEMPERATURE
LOW trip
interlock comes
in service when
M.S. temperature
goes above 520°C
r
Take SPUG in service
if provided
•
"M.S. temp
protection out"
visual annunciatior
will be reset.
Ensure that low
steam temp,
protection switch
is on.
- > Refer turbine
operation
Take load limiter
in service if
provided
Refer turbine
operation
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
at 210 MW with
Combustion control,
Fuel control, Total
air control, Feed
water control,
Steam temperature
control Furnace,
draft and all
other controls on
"Auto"
r
Final steam
conditions at the
time of unit tripping
will be
M.S. Pressure
90 kg/cm2

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M.S. Temp
465°C
R.H. Steam
Temp. 465°C
Take "Combustion control" on Manual
Take "M.S. Temperature low" trip protection
out
Isolate initial steam pressure unloading gear
Gradually reduce
load on the unit
reducing firing
rate. MS/HRH
steam temperature
and MS pressure
shall be reduced
at the rates
permitted by the
turbine but not
exceeding the
rate of saturated
steam temp drop
w
r
Refer "Boiler
shut down curve"
pressure change
limits (fig 2.4)
Rate of load drop
may be about
2MW/min
Carefully monitor
turbine conditions
and adjust the
load, temp.,
pressure drop
rates such that
HP/IP rntnr nr / ir I\JL*JI
differential
expansion.
vibration,
eccentricity, shell
differential
temperatures,
turbine cylinder
top/bottom
metal temps,
Left/Right
cylinder flange
temp. diff. are
within limits.
Load Reduced

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to 160 MW
r
Load reduced to
150 MW:
approximate
parameters at
turbine inlet are :
M.S. Pressure
120 kg/cm2
M.S. Temp
520°C R.H.S. temp
520°C
r
Take HP heaters
out of service
Check that
deaerator steam
is changed over
from Ext. 3 to
Ext. 2 through
interlocks
While reducing load check that following
conditions are maintained :
f
Total air flow is reduced in proportion
with load upto 30% load.
Check drum level is maintained normal
on Auto
Check S.H. & R.H. steam temperatures
are maintained at set points. Furnace draft
is maintained.
Check the boiler expansion/ contraction
movements as the load is reduced.
When the load on mills is reduced to
40%
Prepare to take
upper most mill
out; reduce the
feeder speed
to minimum.
r
*>
Check that
associated
elevation fuel
air dampers are
modulating/ closed
as per feeders
speed.
Check furnace to
• windbox

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differention is 90
mmWC
55
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nn
TIME IN MINUTES
HOT RESTART CURVES AFTER 68HR SHUTDOWN
FOR 2)0/200 MW BOILERS FOR UNITS
PROVIDED WITH HP t LP flYPASS
NOTES:
1 HP 1UB»HE MEIAl ItMP ASSUMEO AS <S0*C
I u:oto RIHEAI imet IEMU ro SOUER 6M«SACEOASJOO»C
MINIMUM
3 FLUE SAS TEMP. AT FURNACE OUTLET 10 OE MAINtAliei
BELOW SUM T0.1 HP t l P BYPASS STATION IS CUT IN'
FIG 2.5 BOILER HOT START
Take upper elevation oil guns in service.
r
Simultaneous with this transfer load
on other mills in service. Stop the
upper most feeder.
1f
Take the upper mill out of service after
cooling if down to 40°C emptying it out
completely.
ir
When load on unit

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is reduced to
100 MW
M.S. Temp 510°C
M.S. Pr. 112 kg/cm2
H.R. H.Steam temp
510°C
r
At 90-100 MW
take out one
boiler feed pump
from service.
Check that full
load is smoothly
transferred on
running B.F.P.
before stopping
the pump.
r
>
->
Check that
deaerator steam
supply is
switched over
from 2nd
extraction to
auxiliary steam
header through
interlocks. Carefully
monitor turbine
conditions.
Ensure that auto
standby B.F.P.
does not start on
stopping of
running BFP
through
interlocks.
Continue reducing firing rate, steam
temperature and pressure alongwith
drop in load.
t
When the load on
mills is reduced to
40% take next
upper elevation
oil guns in service
'r
—*
When adjacent
mills are not in

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service it is
advisable to take
in service oil
remote to other
mill in service
before reducing
feeder speed to 40%
Take heavy oil guns associated with
remote elevation mill in service.
Prepare to take
the next upper
elevation mill
out. Reduce
feeder speed
to minimum &
stop feeder.
Stop the mill
after cooling
down and
completely
evacuating it.
Take heavy oil
guns at lower
elevation in
service
I Take out next
higher mill from
service when
loading on mills
is reduced to 40%
See that load
is transferred
on the running
mills.
Refer H.O.
firing instructions.
Check that load
is transferred to
running mills
Check that
Auxiliary and Fuel
air dampers are
modulating
Check that
associated Fuel
air dampers are
closed.
Take M.S. and R.H. steam temp, control
on hand.
Continue reducing firing rate, steam
pressure and temp, with reduction in

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load. T
58
At load 70 MW : MS temp. 49&°C
R.H. Steam temp 490°C
M.S. pressure 105 kg/cm2
^r
Take drum level control on hand &
maintain drum level
r
Stop one PA
fan after
transferring full
load on running
P.A.
Check damper
operation
Stop lube oil pumps of tripped P.A.
Fan motor and fan bearings after oil
bearing temperature is reduced
Stop one F.D.
fan; corresponding
to P.A. fan tripped.
Check furnace
draft and
air flow.
r
Stop one I.D.
fan corresponding
to tripped F.D.
fan: check furnace
draft.
i
->
Before stopping
F.D. fan increase
load on other
F.D. fan and
reduce load on
this fan to
minimum.
Transfer load from
this I.D. fan
to other and
completely unload
this I.D. fan
before tripping It.
Switch off supply to the electrostatic precipitators
associated with tripped I.D. fan.
Carry out soot blowing of complete boiler.
Unit load reduced to 30%. Maintain 30%
air flow at all loads below 30%.

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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
Firing rate is
reduced further
and when load
on mill is
reduced to 40%;
reduce feeder
speed to minimum
& stop the feeder.
Cool down mill
to evacuate it
completely and
shut it down
When load is
reduced to 40MW
Take low load Feed
Control Valve (FCV)
in service and
isolate main F.C.V.
Check that all
elevation H.O
guns are
taken in service
by now.
Check A.H. cold
end average
temperature is
above acid dew
point.
Charge SCAPH
corresponding to
running F.D. fan
in service if
average cold end ,
temp, is below
acid dew point.
Open low load
control valve
isolating valves;
open low load
control valve
gradually &
simultaneously.
Gradually close
Main F.C.V.
Close isolating
valves of Main
F.C.V.
Switch off supply to field of Electrostatic

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precipitator.
Unit at 25-30 MW with H.O. firing.
Change over auxiliary electrical supply
from unit auxiliary transformer to
station transformer.
59
Stop P.A. Fan
r
* Check that seal
air fan trips on
interlock. Check
the P.A. damper
operation. Refer
P.A. System
Close sealing
air valves to
mills from station
air system
Reduce load on unit to 5-7 MW
M.S. Pressure Boiler outlet 90 Kg/cm2
M.S. Temp Boiler 465°C
R.H. Steam Temp 465°C
Charge auxiliary steam header from
running units through inter connection,
isolate auxiliary P.R.D.S. unit.
Trip the unit
through M.F.T.
pushbuttons
on F.S.S.
console/or
through Protection
Check that Boiler
fire is completely
out
r
Check that H.P.
cylinder evacuatior
valves open
r
When boiler is to
be tripped, trip
it through
protection.
Maintain log of
protection used
each time for
tripping. Use
different protection
each time so
that all are
checked.

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Check that all

the flame scanners
sense no flame &
check boiler
actually from peep
holes & ensure
that fire is
completely out
Maintain 30% air
flow and purge the .
boiler for at least
five minutes
Check that all the
feeders and mills
are off.
—•
—>
Check that turbine
coasts down
safely
Start S.O.P/AC
oi) pump
Break the vacuum
when turbine
speed comes to
zero.
Put turbine rotor
on barring gear.
Check that F.C.N.R
Vs in extraction
lines closed.
Individual burner H.O. M.V. oil, Atomising
air and steam nozzle valves and
Ignitors valves (air/oil) are closed. .
r
Check that
Attemperation SH
& RH isolating
valves and its
bypass valve
are closed.
r
Open S.H. Start-up
vent isolating valves
and partially open
S.H. start-up vents
and reduce pressure
r
-»
Close isolating
valves of S.H.

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and Reheater
spray control
valves
Rate of pressure
drop must not
exceed the limits
specified in the
curve to limit
saturation temp,
drop rate to
less than 83°C/hr
(Fig. 2.4)
Open Reheater vents and closed CBD
valves
Close Boiler Main steam stop valves
and their by-pass valves
T
60
Open M.S. line
drains
t
Open C.R.H.
& H.R.H. line
r
Refer Turbine
operating
instructions.
Refer Turbine
operating
Instructions
Shutdown H.O. System
Following is the procedures if, after shut down:
(i) Fast cooling of
Boiler is desired
(iii) Boiler is to be
preserved
2.8.1
(ii) If Boiler is to
be Natural by
cooled
(iv) Boiler is to
be Boxed up
Do not stop warm up oil pumps if it is
common for other units
f
Top up the drum level upto +180 mm
f
Stop Boiler feed
pump
r
Stop Hydrazine

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dozing pumps
Ensure that auto
starting of auto
standby B.F.P.
is prevented
Keep B.F.P. as
hot standby
Stop phosphate dozing pump if it is in
service.
r
Cut off deaerator
pegging steam
supply by closing
valve
"^r
Turn on
deaerator F.W.
heating steam to
maintain F.W.
temperature
Do not stop A.P. Heaters till flue gas
temp, at A.P.H. inlet is less than 205°C
Air Flow through
furnace shall be
controlled to effect
the desired cooling
rate
Boiler cooling
rates can be
controlled by :
1. Opening
S.H.H. vents
2. Air flow through
boiler
Boiler is to be forced cooled fast after
shut down
Keep I.D. fan
and F.D. fan
in service.
Regulate air
flow to effect
desired rate of
cooling
Open starting
vent valves
Bring up drum
level to+180 mm
when it drops
to-180 mm
At any time
saturated steam

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temperature drop
shall not exceed
83°C/hr.
Regulate opening
of vent valves,
match the rate of
cooling but not
exceeding above
mentioned limit
Start boiler feed
pump for topping
up the level.
Stop boiler feed
pump afterwards
Open following vents and drains of
S.H. at low pressure (2-3 kg/cm2) :
SH Desup.link drains; Steam cooled
wall header drain. Roof and Rear steam
cooled wall drain.
At 1.8 kg/cm2 drum pressure open
drum vents
61
Stop F.D. fan
and I.D. fans
when flue gas
temperature
at A.P.H.
inlet is
reduced to
below 25°C
and boiler is
cooled
Check that
A.P.H. do not
stop on interlock
take
deinterlock
switch is on
"deinterlock"
position before
stopping F.D. /
I.D. fan
If required
stop air
preheaters
otherwise keep
them rotating
Check that
A.P.H.'s lube
oil pumps stop
on interlock

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when oil temp,

goes below 40°C.
When Boiler water temperature goes
below 94°C. Drain the boiler
Open economiser vents; open low point drain
valves from W.W. low header and downcomers
to W.W. drain header.
Open economiser drain valves in feed line aftei
economiser inlet valve.
Open W.W. drain header drain valves
2.8.2
Natural cooling of Boiler is desired after shut
down
One I.D. Fan and one F.D. Fan in service
Bring I.D. inlet
vane and F.D.
Fan impeller
blade pitch to
minimum. Stop
F.D. Fan Stop
ID fan
f
Bring Air heater
deinterlock switch
in deinterlock
position. Check
that Air heaters
are starting.
Check that all
secondary air
dampers open.
Check that all
flue gas dampers
open.
Check that all
auxiliary air
dampers open
Bring up Drum level to + 180 mm
Stop Boiler feed
pump and keep
it in warm
condition
>r
When gas inlet
temperature at
A.P.H. inlet is
reduced to below
205°C Air Heater
can be stopped.
r
Stop A. P. Heaters

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if required
t
Cut out deaerator
pressuring steam
by closing steam
isolating valve
r
—>
—*
—>
—>
Boiler feed pump
shall be started
when level drops
to - 180 mm and
shall be stopped
after bringing
level to + 180mm.
Gradually feeding
should be done.
Preferably keep
Air Heater rotating
even after this
unless they are
required to be
stopped for works.
Check A.P.H's lube
oil pumps stop
when oil temp, is
reduced to 40°C.
Turn on F.W.
heating steam
maintain F.S.T.
water temperature
and slight pressure
in deaerator
(Approx. 1.5. Ata)
Stop hydrazine dosing pump
i
Close economiser inlet valve its bypass
valve.
r
At 1.8kg/cm2g
drum pressure
open drum
vent & S.H.H.
vents.
—•
Initially keep drum
vents throttled &
when pressure

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drops down open

them full.
62
2.8.3
If Boiler is to be preserved.
Drain the boiler
when Boiler
water temperature
is reduced to
than 94°c
Nitrogen blanket
shall be applied
when drum
pressure reduces
to 1.4 kg/cm2
Open economlser
vent valves &
drain valves
Refer Boiler
lay-up procedure.
Open low point drain valves. Open
W.W. drain header drain valve
2.84
Boiler is to be boxed up
One I.D. Fan & one F.D. Fan are running
Reduce flow to minimum
Stop I.D. Fan
Stop F.D. Fan
Keep A.H. deinterlocking
switch in
"deinterlock"
position before
stopping I.D. /F.D.
Fan.
Check that Air
Heaters are not
stopped.
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.
Stop B.F.P. &
keep it in
warm condition
Keep the S/S of
autostand by
B.F.P. in working
position before

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stopping running
B.F.P.
Cut out deaerator
pegging steam by
closing valve
Turn on F.S.T.
heating steam.
Keep Feed water
hot & maintain
slight pressure
in deaerator. Open
valves.
Close startup vent valves
Check S.H. outlet header vents and
drains are tight closed.
Close start up vent valves
WhenA.P.H. inlet
flue gas temperature
reduces to 205°c
A.P.H.'s may be
stopped
A.P.H.'s shall be
kept rotating
unless they are
required to be
stopped.
When S.H. steam Pressure drops down
to 3kg/cm2 open partially S.H. vents &
open them full when pressure drops
down to near zero.
Open drum vents partially when drum
pressure comes down and open them
full when when pressure drops down
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 reduced
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 controlled
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).

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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 pressure
control valves
Open steam supply valve to 16ATA
header from PRDS unit.
Open PRDS upstream side drain isolating
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 steam supply isolating valve to
ejectors and gland seals steam cooler
with ejector from deaerator.
Open drain valve in steam line to ejectors.
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 Deaerator

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tank heating
Auxiliary steam header is lined up.
2.9.3. Charging Auxiliary Steam
From 11-ATA Header :
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
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
air is completely purged and steam
comes out through it.
65
Check that no hammering occurs in
steam lines. If hammering is observed
throttle steam supply valve
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.
When steam lines are warmed up open
gradually steam supply valve and build
up pressure in auxiliary steam header.
Attain 11ATA header pressure
Auxiliary steam header.
in
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 control

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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 temperature
is maintained.
Select auto mode on pressure control
valve and set pressure at 16-ata.
Gradually close bypass pressure control
valve, and simultaneously close
DSS spray control valve
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
1r
Close bypass D.S.S. spray water isolating
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.
66
2.9.5 Taking Aux. PRDS Standby Station in Service :
Check that auxiliary steam system is
lined up.
Check that main steam pressure is
above 30kg/cm2
Open bypass D.S.S. Spray water isolating
valve
Open gradually PRDS bypass main
steam supply isolating valve
Slightly open PRDS bypass pressure
control valve
Control opening of spray feed water
pressure control valve and spray water
temperature valve to get auxiliary steam
temperature of 215°C max.
Open further the PRDS bypass valve
Gradually fully open PRDS bypass main
steam supply isolating valve and regulate
16-ATA pressure with PRDS bypass

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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
for 11 -ata header as bypass PRDS takes
over. Check that auxiliary steam header
pressure does not drop.
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

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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 & temperature
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
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 dampers.
Watch Furnace flame. Trip Boiler if flame is

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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.
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.
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.
69
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
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.
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.

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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 economiser
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.
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.
Take feed control valve on manual and reduce the
feeding rate.
Try to decrease the load as far as possible.
70
Sudden decrease in firing rate
e.g. tripping of the running mills
B.F.P. scoop tube position suddenly
increased
2.11.5 Flame Failure At an Elewation
Closing of trip valves on H.O., :
W.U. Oil/Ignitor (Causing loss of
ignition support energy) Where F.O.
is being used as support fuel or when
only oil is being used.
Sudden decrease of mill feeder :
speeds to minimum
Too low or too high windbox
pressure causing unstable
combustion
Water wall tube failure
Malfunction of flame scanners due
to supply failure or scanner air
failure, slag or soot on scanner
lenses etc.
Increase feeding range of running mills.
Check differential pressure across feed control

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valve and maintain 5 Kg/cm2 by adjusting scoop

tube position.
Do not attempt to introduce ignitors or oil guns at
elevation where "No flame" condition persist.
Trip out the coal mills of feeding elevation where
"No flame" condition is persisting. Allow sometime
for purging then introduce oil support adjacent to
working mills until furnace flame is stabilised.
Check that secondary air windbox dampers are
modulating to maintain about 80mm windbox to
furnace differential pressure.
Check furnace for tube failure.
If two elevations scanners show "No flame" trip the
boiler manually
Burner tilt mechanism negative :
extreme due to air failure to
power cylinders.
Rapid load changes without :
adjusting air flow leading to
improper combustion.
2.11.6.One Fan Trips (Other in Service)
Check burner tilt keep it between +10°.
Check furnace flame condition.
It is presumed that I.D./F.D./P.A. fan de-interlocking switches are on "Interlock" position.
Fan Bearing temperature high : i)
and/or
Take draft control or manual,
and/or increase the loading on running fan
and maintain furnace draft.
Fan motor Bearing temperature high
and/or
ii) Check corresponding fan is tripped through
interlock
71
Lube oil pressure for motor
bearings low and/or
iii) Take secondary air flow controll on manual
and maintain correct air flow.
Corresponding Air heater tripped
(provided de-inter locking switch is
on "Interlock" position) and/or
Motor protection operated
iv) Cut in oil burner adjacent to working mills.
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).

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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
within 3 minutes of feeder
and/or
No coal flow alarm comes &
low current relay picks up
simultaneously. (Feeder chear
pin given way and/or
Mill trips and/or
Feeder motor supply fails
i) Check that hot air gate closes & cold air
damper opens full if pulveriser is running.
ii) Clear the mill of the coal before stopping it.
iii) Stop the pulverizer if feeder cannot be
restarted immediately.
iv) Check that running mills share the load if
thermal load is on auto.
72
2.11.8 One Mill Trips
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.
Mill discharge valves are closed
and/or
Loss of elevation D.C. supply
for more than 2 sees, and/or
Support ignition energy is removed
with 3 minutes of feeder starting,
and/or
Motor protection operates and /or

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One P.A. Fan trips (mill in

excess of 3 will trip starting
from bottom).
i) Check the running mills share the load if
thermal load control of mills are on auto.
ii) Reduce the generator load if pressure starts
dropping.
iii) Start reserve mill and take load.
iv) Check furnace draft is maintained normal
v) Check the correct air flow is maintained.
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
Too much fines in coal with moisture,
and/or
i) Check feeder trip on "No coal flow & low
current" protection.
ii) Check mill outlet temperature is less than
85°C.
73
Foreign material at R.C. feeder inlet 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 elevation.
v) Trip the sick mill after clearing it of coal.
vi) Increase the load on running mills if Thermal
load control is on manual.
2.11.10. Water Wall Tube Leakage
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.
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

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impingement of steam) and/or

Circulation affected due to opening :
of low point drains.
i)
ii)
Compare feed water flow and steam flow to
assess the magnitude of tube leakage.
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
due to waterwall Slagging or
forcing boiler at the time of
hot restart and/or
i) As soon as leakage is detected start load
reduction and trip out the boiler at the
earliest possible time.
Erosion on tubes due to high
excess air, high ash content in
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.

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ii) Try to locate leak through manholes before

boiler Is depresurised.
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,
Clarified Pumps and Clarified booster
pumps are in service.
r
Inform the operator to check the basin
level and Cooling Tower pumps and
C.T. fans running normal.
ir
Ensure whether all permits from Maintenance
Division are cleared.
r
Inform Electrical
Controller to
rack in breaker of
Circulating Water
pump for
availability of power.
t
Check the opening
of CW discharge
valve CW 1/2 or
CW 3/4 and check
whether it has
opened fully
from UCB.
->
—P
Carry out
protection &
interlock tests
on C.W. pump if
on long shut
down.
Before starting
CW pump, close
the valve CW-5 to
lub oil cooler and
openCW 1/2
valve.
After obtaining

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clearance from
operator inform
me operator
through the
intercom that
CW pump is
being started.
—•
Refer C.W. pump
instructions for
starting.
Start the CW pump
by closing control
switch
See that the
discharge
valve CW 3/4
has opened fully.
Observe and note down the amp. of the
pump motor.
Inform CW pump
operator
to give the
prestart checks
on CW booster
pump
At least one
hydrogen
cooler suction
and discharge
valve to be
kept open,
otherwise pump
can be run on
recirculation.
Start the CW booster pump by closing
the control switch.
Ensure from the operator the post start
checks are complete and healthy
After 5 minutes run of the booster
pump, the pump is to be stopped and
to be started again when turbine speed
comes to 1100 rpm.
CW System is running normal.
77
3.1.2 Ensure Condensate System is Running Normal
Start the Demineralized Water (D.M.)
make up pumps, if already not running
after checking D.M. tank level
and line up of connected lines.
Open both the isolating valves for hotwell

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make up.
r
Maintain hotwell
level more than
3/4thofthe
gauge glass.
t
->
Check the hotwell
level Hi/Lo alarm
is working alright.
Line up condensate system
Inform Elect. Operator to restore power
to that condensate pump.
After obtaining clearance from condensate
pump operator, announce
through intercom that the pump is
being started.
The motor current
should be within
18-23 amp and not
hunting
r
Chemist to check
the quality of
condensate to
ensure that there
is no condenser
tube leakage
r
—*
->
Check and
maintain hotwell
level at 3/4 of
the gauge glass.
Keep any of the
other two
available pumps
as stand-by
putting interlock
switch to "ON"
position.
Take water to deaerator after charging
L.P^heater from water side
ir
Condensate System is running healthy.
3.1.3 Ensure Feed System is Running Normal
Maintain Deaerator
(D/A) level normal
by running

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condensate pump
system normal
Maintain pressure
and temp, in
D/A at
2 kg/em2 90°C
by auxiliary
steam
Ensure that all permits are cleared
from Maint. Divisions for BFP and HP
heaters.
Inform BFP operator to line up the
pump.
Ensure that protection & interlock are
healthy. Inform Elect, operator to restore
power to the pump.
Inform turbine operator to line up HP
heater after checking the interlock
After getting clearance from BFP operator
to start announce that the pump
is being started.
78
Start the boiler
feed pump
r
—* If there is delay in
opening
recirculation
valves by more
than 2 sec. then
open the valve
remotely from
UCB otherwise
trip the pump.
Watch and note down the amperage of
pump motor
Inform turbine operator to charge HP
heater on water side.
Check the other two BFP for their availability.
Keep the other BFP Pumps available
on interlock by putting the interlock
switch on 'P'.
Feed water system is running healthy.
After about 15 minutes when the bearing
temp gets stabilised open the discharge
valve
3.1.4 Ensure Generator Seal Oil & Hydrogen Cooling System are Normal
Ensure the Main
Oil Tank (MOT)
level normal and
quality of oil to

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be O.K.
—•
Run the oil
Centrifugal and
MOT vapour fans
atleast 6 hours
before taking seal
oil system in
service.
A.C. seal oil pump should be running.
Hydrogen pressure
in Generator casing
should be
maintained at 3.5
kg/cm2
»<r
->
Sufficient No. of
H2 bottles should
be available.
Seal oil system and Hj cooling system
running normal.
Check the
availability
ofD.C. seal
oil system
Protection & •
interlock for the
pumps should be
tested.
3.1.5 Ensure Turbine Lum Oil System is Running Normal
A.C. standby oil pump should be running.
Lub. oil pressure 1 to 1.1 kg/cm2
at bearing header and also check the
availability of D.C. oil pump.
Lub oil pump interlock switch should
be 'ON1. I
Oil temperature at
bearing should be
around 40°C
r
•
If it is more
charge the oil
cooler from water
side also.
Check protection and interlock of lub.
oil system.
79
3.1.6 Ensure Turbine Rotor is on Barring Gear and Normal
Check the

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protection
• of Barring
gear
1
Ensure that
turbine
rotor is at stand
still position
and lub oil
system
running.
•
•
—->
Barring gear
should not start
when lub.
oil pressure falls
to 0.3 kg/cm2.
Barring gear
engage lever is
fully retraced.
Engage the
barring gear
lever.
Start the Barring gear motor.
Note down the amp (61 amps) of the
motor.
r
Check Barring
gear protection
and again
restart Barring
gear
r
Barring gear
should trip at .
0.3 kg/cm2 lub
oil pressure.
Keep a constant watch on lub. oil pressure
(1.1 kg/cm2) and temp 40°C.
f
Barring gear is normal and healthy
3.1.7 Ensure Auxiliary Steam Line is Charged
Inform boiler
operator
to charge the
aux. steam
line (16 ata
header) from
running unit

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or from M.S. line

of its own unit.
r
Keep the drain
valve near the
gland steam
cooler open
and charge
the steam line
for ejector,
gland steam
cooler and
steam seals
by opening
the valve.
r
-
Refer Aux. steam
instructions in
Chapter-2.
Before charging
check that the
system inlet
valves are closed.
After the line is heated up (for 15 minutes
to 20 minutes) throttle the drain
valve near gland steam cooler to avoid
wastage of steam.
3.1.8 Vacuum Pulling
Ensure CW pumps are in service.
Ensure condensate system in service,
main ejectors (both) and L.P. heaters
(all) are charged from water side. All
valves subjected to vacuum should be
sealed by condensate water.
Ensure that turbine is on Barring gear.
Ensure that auxiliary steam is charged
from 16 ata. bus to turbine seal and
ejector header.
Close the vacuum breaker valves near
main ejector and fill the funnel with
DM water for sealing and open valves
on condenser outlet.
80
Prior to start
the starting
ejector open
the drain valve
(after AS-4)
and the
isolating valve.

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Then open
inlet valve
for putting
starting
ejector in
service and
close the
drain valves.
Start gland steam
cooler (GSC) ejecto
r
Admit steam
to seals.1
w
Open Air valve.
See that condensei
vacuum rises to
100-150 mm.
r. *
Open inlet valve
and adjust
p3 rkesgs/ucmre2 aatnd
see that vacuum
at GSC rises to
40-60 mm. of Hg
column.
Steaming from
faces of end
sealing is not
permitted.
Open the
drain valves
to the condenser
from the first
stage of the
ejector.
r
Open the steam
to main
ejector through
motorised
isolating valves
when vacuum
in condenser is
400 mrrTbf Hg.
r
w
W
w
W
Ensure that drain

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valve from stage

III to UDT is open.
See the steam
pressure to main
ejector is
6 kg/cm2 and
see that vacuum
is steadily rising
in the condenser
r
Stop the starting
ejector by
closing vent valve
first and steam
and steam valve
afterwards.
At about 600 mm of Hg check the vacuum
protection.
3.2 STARTING OF TURBINE FROM COLD STATE
Check that all prestart requirements
are over.
Before HP/LP bypass stations are
brought into operation check :
i) ESV, IV are closed.
ii) Oil system of the bypass station
is put into operation by
switching on its motor.
iii) Vacuum in the condenser is
600 mm of Hg.
iv) Condensate flow to steam throw
off devices in the condenser are
established by opening the
motor operated valves.
Ensure that the valves of the bypass
system are fully closed by reading the
respective position indicators.
r
Set the
temperature
set point of
HP bypass
station at
200°C
w
Do it with the
help of push
button.
81
Put the pressure
controllers
and slave

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positioners
of each HP
bypass valve
on manual
mode
Put the LP
bypass valves
on 'Auto'
mode
Put the control
of LP by pass
valves on
'Auto'mode with
pressure loop
in circuit with
the help of
selector switch
by making the
contact in
'R' position.
Do it with the
help of push
button.
Set the
temperature set
point of LP bypass
station at 200°C
with the help of
push button by
reading its value
on the indicator.
Switch over the
temperature
control loop of
LP bypass valve
on Auto mode
with the help of
push bottom.
Set the pressure
set point as
6.0 ata with the
help of push
button.
Check that the High Pressure Turbine
(HPT) evacuating valves and by pass
valves across NRV on cold reheat line
are tightly closed.
After the internal superheater flow has beer
established through start up vent, open the
drain valves before and after bypass. Open the
drain valves of MS, CR & HR lines and alsc

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open after LP by pass drain valves

Open fully the
MS valves for HP
by pass with
the help of
push button
and then open the
boiler outlet
MS valves
Check the
temperature
control loop
is functioning
normal
If heating rate
of steam lines
exceeds prescribed
limits, adjust the
position of HP
bypass valve from
the control desk to
bring down the
temperature
within limit.
Watch the rise of metal temperature of
MS, CR & HR lines.
After 50°C superheat is available at the
superheater outlet open the bypass
valves of MSV for heating the pipe lines
upto turbine.
Open the ESV to CVS drain valves.
82
Open ESV
by about
10-20 mm
as per the
scale and
heat the
steam
admission
pipe upto
control
valves to
a temp, of
150°C
1
Rise of metal
temp, should
not be more
than 4°C per
minute.

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f
While opening
the ESV, the
control valves of
HP turbine should
remain tightly
closed.
Open the
bypass valves
across the
NRVs in the
cold reheat
line and the
drain valves
of HPT.
—•
Heat the HP
turbine up to
150°C
t
Rise of metal
temp, should not
be more than
4°C per minute.
Check the
steam pressure
in hot reheat
line to be
less* than
1 kg/cm2
(gauge) before
starting the
heating of
steam
admission
pipe upto
control valves of
IPT.
W
If the pressure
exceeds 1 kg/cm2
(gauge) adjust
the set value at
1 kg/cm2 with
the help of push
button and
indicator of LP
bypass
station
-Or
If it still exceeds

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close a little the

HP bypass valves.
Open the IV to CVs drain valves
1
Open the
interceptor
valve servomotor
by
about 10-15
mm as per
the scale.
X
w
Heat the steam
admission pipes
upto control
valves to a
temp, of 100°C
r
Close bypass
valve of
MSV & NRV
in the cold
reheat lines
when steam
parameters
before MSV
are 20-25
kg/cm2 and
280-300°C and
steam
admission pipe
of HPT and
IPT are heated
upto 150°C
& 100°C
respectively.
w
Check that
control valve of
IPT remains closed
complet^y
during tne
operation.
Rise of metal
temp, should not
be more than
4°C per minute.
Close ESV & IV.
Bring the control of LP bypass valves
on 'Manual' mode with the help of

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push button.
Manually close
the HP
bypass valves
with the help
of push button
When the pressure
in the reheat
line comes to
condenser
pressure
manually close the
LP bypass with
the help of push
button.
83
After having
accomplished
the heating,
check and
note down
the following
readings in
the log-sheet
before rolling
the turbine.
a) Metal temp,
of pipes
before MSV,
and also
before ESV.
b) Metal temp,
of steam
admission
lines.
c) Metal temp,
of hot reheat
line.
d) Metal temp,
of interceptor
valve.
e) Metal temp,
of HPT and
IPT top/bottom.
f) Steam parameter
before MSV.
g) Differential
expansion of
HP. IP and LP
rotor.
h) Axial, shift.

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total expansion
ofHPT/IPT
and condenser
vacuum.
i) Eccentricity of
turbine rotor
on barring gear.
While heating the
main steam and
reheat steam pipes
the difference in
temp, of pipes
should not exceed
15°C. But when
the turbine is on
load, this difference
should not be more
than 10°C.
Chamber heating
should continue
till temperature
difference between
the Upper and
Lower halves of
HPT and IPT
casing goes 50°C
near the regulatin
stage in the case
of HPT and near
the zone of steam
admission in
case of IPT.
Continue flange
and stud heating
till metal temp,
of flanges and
studs has
stabilized and
difference of
temp, across the
width of the
flange is
20-30°C.
Turbine is ready for rolling.
Open the drain valves of HPT, IPT, HP
and LP extraction valves.
Open ESV, IV, control valves of HPT
and IPT completely with the help of
control gear.
3.3 ROLLING INSTRUCTIONS
Slowly open

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the bypass
valves of MSVs
Allow the steam
to roll the turbine.
At a speed
of 500 rpm.
Check that barring
gear has got
disengaged and its
motor gets
switched off
automatically.
Increase in rotor
speed is prohibited
if the turbine
rotor eccentricity
is more thai/
0.07 mm.
During the
process of
raising the
speed bearing
vibration
should not
exceed 40
microns.
Stop the steam
supply to the
turbine by closing
the bypass valves
of MSV and
Listen carefully
for any rubbing
sound. If any
abnormality is
found stop the
rolling of the
turbine.
84
If the turbine
is in healthy
state, again
raise the
speed to
500 rpm by
opening the
bypass valves
ofMSV 1 &2.
Soak the set for
5-10 mts.
It is prohibited

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to raise the speed

of turbine if the
differential
expansion of the
turbine rotor
reaches the
maximum
permissible values
given below :
For HPT rotor
+ 4.0 mm or
-1.2 mm
For IPT rotor
+ 3mm or
- 2.5 mm
For LPT rotor
+ 4.5 mm or
- 2 mm
(+ sign indicates
that rotor is
longer than
cylinder and
vice-versa for -
sign.)
At a speed
of 1200 rpm
1
Soak the set
for about 20 mts.
Note that the
control valves
of HPT tend to
close with the
rise of speed.
J
At a speed
oi oOuu rpm
r
Raise the
speed of
turbine to
3000 rpm
from 1200
rpm in
5 mts.
without any
pause. The
critical speed
of the m/c
should be
passed as

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fast as possible
to avoid the
appearance of
rotor vibration
ir
Observe the
temperature of
lUD Oil
entering the
bearings.
1
|hW
Turn the control
gear in the
anticlockwise
direction to keep
the control valves
completely open.
•« r
Hold the turbine
ai ouuu rpm ior
about 20-25 mts.
r
Carry out
inspection
and soaking
of the turbine.
r
Perform the
checking of
protection and
governing system
and tightness test
of ESV and control
valves of HPT.
«f.
Critical speeds,
are 1585, 1881,
2017 and 2489 rpm
I
Maintain the lub.
oil temp at 40°C
* by controlling
the cooling water
supply to the oil
coolers.
85
00
05
SYNCHRONISING
t LOADING

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120 180
TIME ( MIN)
2 40 300 360
FIG. 3.1 CURVES FOR COLD START-UP OF TURBINE 210 MW UNIT
Stop the
starting oil
pump and
keep it ready.
Refer Turbine
lub. oil system
instruction.
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.
'In:
ISo* <
I.
2.
3.
4.
5.
6.
^ ? ! l l u 8 ^ ? ^ ;^ TURBINE ROLLING GUIDE LINES
: li^fc&stiagi* less
Speed from 0-500 rpm
= 5 mts.
Hold at 500 rpm
= 10 mts.
Speed from 500 rpm
to 1200 rpm @ 50 rpm
= 14 mts.
Hold at 1200 rpm
(soaking) = 20 mts.
Speed from 1200 rpm
to 300 rpm = 5 mts.
Hold at 3000 rpm
(soaking) = 20 to 25 mts.
Total = 75 minutes.
•• Metal Temp* J»
Speed 0-500 rpm
= 5 mts.
Hold at 500 rpm
= 5 mts. for checking
differential expansion,

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brg. vibration etc.

Raise the speed from
500 rpm to 1200 rpm
= 5mts.
Hold for 3 mts. for
checking diff. expansion,
vibration etc.
Raise the speed from
1200 rpm to 3000 rpm.
= 3 mts. without any pause.
Hold the turbine at this
speed (3000 rpm) for checkings.
Total 26 mts.
Turbine Metal
*Temji> is nipre
than SSQ^C*
Speed from 0-1200
rpm = 5 mts.
Hold at 1200 rpm
= 5 mts. for checking
differential expansion,
vibration etc.
From 1200 rpm to
3000 rpm = 5 mts.
without any pause.
<
Total =15 mts.
87
3.4 LOADING THE TURBINE
Synchronise the machine
with the grid
At the load
of30MW.
At the load
of 60 of 70 MW.
Take a load of 10
to 15 MW
r
Constantly watch the
differential expansion,
axial fchift, metal temp,
difference between outer and
inner surface of the wall of
HPTafcd IPT casing (should
not exceed 35°C).
Hold the turbine at
this load for 30 mts.
to carry out soaking
and listen for rubbing.
r
After soaking, close all

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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.
Close the drain
valves in LP
heater extraction.
Note the thermal
expansion of the
turbine and all the
other readings
Charge deaerator
by opening 2nd
extraction steam
valves.
Should be around
20 mm as per the
indicator installed at
the front bearing
pedestal
Put the H.P. heaters
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
in service
Thermal expansion
of the turbine would
be around 28 mm
—*>
->
Stop the flange and
stud heating.
r
The difference of
temp, across the
width of the
flange should be
within 20°C-30°C.
At about 80
MWload

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At about 150
MW load.
At the load
of210MW.
Start the second
condensate pump &
BFP and keep the
third as standby.
Change over steam
supply to deaerator
from 2nd extraction
to 3rd extraction
Set the point of
H.P. bypass valves
pressure control
loop at 140 ata
with the help of
push button.
Change over the
manual mode of
pressure control
loops of HP
bypass valves to
'Auto' with the help
of push button
Change over steam
supply for the
ejectors and glands
from 16 ata to
deaerator when
deaerator pressure
stabilizes at 6 Kg/cm2
Change over HP
heater #6 drip
from deaerator to
heater #5.
When condensate
flow increases to
300 tons/hr. partly
open the bypass
valves of maijfi
ejectors, gland
system cooler
andLPH-1.
Similarly change ovei
H.P. heater 5 drip
from LP heater
unit 4 to deaerator.
Set the L.P.
bypass valve pressure
set point to

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6.0 kg/cm2 (ata)

and temp, set
point to 200°C.
Change over the L.P.
bypass operation from
manual mode of'Auto'
mode with pressure
control loop in circuit.
89
oi;ii>f tares
si
No* Metal temp* is
less
Metal Temp* Metal Temp* is more
1. Load upto 5 to 7
MW after synchronisation
Live steam pressure.:
30 kg/cm2
Live steam temp. 350°C.
Steam temp, before IPT : 320°C.
Soaking time : 30 mts.
2. Load 5 MW to 30 MW @ 3
MW/10 mts. in 70 mts.
Steam pressure before
ESV: 65 kg/cm2
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
70 MW @1 MW/min.
: 50 mts.
Load after synchronisation
: 20 to 30 MW.
Soaking time : 10 mts.
Steam press : 70 kg/cm2
Steam temp : 350°C
Load 30 MW to 65 MW
in 35 mts. Soaking : 20 mts.
Steam press : 90 Kg/cm2.
Load after
synchornisation
20 to 30 MW. After taking
mills (one by one) in
service load can
accordingly be raised to
210 MW depending upor
other conditions.

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Steam temp : 450°C.

Load 60 MW to 210 MW in 45 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
operational
mode of H.P.
bypass valve
CM~i *A^fl T"l 1131 *
U l l 1VXCU1UCU
and L.P.

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bypass on
'Auto' and
select for
pressure
mode of
operation.
^-
Set the set point
of L.P. bypass
station at 6 ata
by push button.
91
CD
to
Ill
cc
si
__ UJ
si
33
«0
ISO
no
WAX
IE
H*
EXA
PRI
AX
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P
in
E•
HO
HA
•cm
TCK
URS
• IE
HA:
TER
JRBI
H
>BL
•E4
M
HE
• EC
cot.
Al
HE

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II Tl
y1
/y
y
y,
•i
y
y
y,
/
/
<*-
'y, V
yw
y
yK
7(y
A\
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J*
\y
1V
y
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ft
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JP*
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r.
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t
I
i1
1
5
ft!
«
j
y
/
y
y
y
NOTETI
IF FIRST SUQ&HEUL LEHPERATURE IS USED TO «E
08U1N HAW %IEAU TEMP ST*C MIST K ADSEO 10
HCTAL TEMP SF FOBE CNTERMC CHART
1 OAIUES OH CURVES ARE NUN STEAM PHTTSURE IN
KC/CM1 ABS
1 EXAMPUs ILIUSTRATEO ON CHART WlTH DASHEOAt
IURBINE MEUI. TEUPAT 1ST SUCE AT TIME UNITS
HOLLEO ]>C*C
VALUE ON LOWER DIAGONAL LINES ARE
HP TURBINE METAL TEMP. (C ) JUST BEFORE UNIT IS ROLLED
' MAIN STEA
aium.
PRESSURE AT TIHE UNIT S
FIG. 3.2 TEMPERATURE MATCHING CHART
Set the
temperature
control loop
of H.P. bypass
station on 'Auto'
and set the
temperature
set point as
per the
requirement
on the down
steam side of
H.P. bypass
station
Open H.P.
bypass valve
and raise
the steam
parameters
of boiler to
desired value.
Check that the
steam pressure

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in hot reheat
line should
not exceed
1 kg/cm2. If
required,
manually close
a little the
HP bypass valve.
Temperature
control loop of
L.P. bypass
stations should be
on 'Auto' and
temperature
should be set at
200°C.
Ensure that the
evacuating valves
and bypass valves
ofNRVsinthe
cold reheat lines
are closed.
Heat the main
steam cold reheat
and hot reheat
lines.
Open the bypass
valves of MSV
and ESV by
about 15-20 mm
and heat the
steam admission
pipes upto control
valves.
Open the IV servo
motor by 10-15mir
as per scale and
heat the steam
admission pipes
upto control valve
of IPT Control
valves of IPT
should remain
tightly closed
during this
process.
r
Having
accomplished
the heating,
check and

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note down the

temperatures
viz. of steam
pipes, ESV. IV
IP casing and
HPCatthe
regulating
stage.
W
During the process
of heating of
the steam pipe
lines check the
draining system is
alright.
Ensure that the
desired matching
steam temperature
is available at
ESV.
r
Bring the control
of L.P. bypass
valves on 'Manual
mode" with the
help of push
button.
Manually close
the HP bypass
valves with
the help of
push button.
><r
—*
Open the L.P.
bypass valves with
the help of push
button. When the
pressure in the
reheat line comes
to condenser
vacuum close the
LP bypass valves.
Check that the eccentricity and differential
expansion of the rotor are within
limit.
With the help of the speeder gear fully open IV,
ESV, CVs of IPT and HPT.
r
Slowly open
the bypass

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valves of MSV
and roll the
turbine as
per guidelines
given to the
synchronising
speed.
ton
Checking should
be made during
rolling as in the
case of cold start
up.
93
STEAM TEMP. C
s3
en
Oo
STEAM PRESSURE ( A T A )
in o> xj jo 8 8 g 5
^O O O O
STEAM FLOW (T/HR )
PC
O
CO
o
30
m
O
>
c/>
2
C TJ
LOAD ( MW)
Synchronise
the set and
load the set
to 20-30 MW.
All the drains
must be closed
after some load
has been taken
on the turbine.
Thewaising of
steam parameters
and loading of
the set is to be
carried out as per
the curve and
guide lines of
loading for the

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warm start.
T
After loading the unit, set HP and LP
bypass stations as follows :
i) HP by-pass station pressure
control loop : 14 ata, automode.
Temperature control loop :
380°C, automode.
ii) LP by-pass stations operational
mode-pressure control.
Pressure control loop : Auto with
set point at 6 Kg/cm2 (abs) Temp.
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
all the
pre-start
conditions
such as oil
system in
operation,
vacuum in
the condenser
is more than
540 mm of
Hg. flow of
condensate in
steam thro
device is O.K.
Set the H.P.
bypass valves on
'AUTO' mode and
set the pressure
setting at 5-8%
higher than the
actual pressure
available in the
main steam lines.
Set the L.P. bypass
station also on
'AUTO' with

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pressure control
mode with set
point at 6 kg/cm2.
Heat the transfer
pipes between IV
and CV of IPT
by opening IV
5-10 mm as
p"er scale.
r
—•
The valves in the
drains of these
pipes should be
kept full open,
prior to the
opening of IV,
. After heating these
pipes
corresponding to
the available
steam temperature
Close IV fuUy.
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
a
a
UJ
in
a
<
01
130
120
110
100
'600
550
20
10
ID
JRJBI
i
zo<
T

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X
to2o
.10
in
FIR ING
UJ
t<o
- <r
THROUGH E-SV
THROUGH. REHEATER
300
TIME (MIN)
FIG. 3.5 HOT RESTART CURVES AFTER 8 HOURS SHUT-DOWN
avcn
« co >, r- o g g o
Q
X
CO
cc
OX
cc
LU 5
CD
gU
J
oc
It
o
T%
•».'•:
1•
i
Iv
3W1,
•V-3
» au
3SV3;
)10H
N
3NI *
-Vr
\
\
Of) clH31 NV3IS
\
(HdM Q33
\
»
2
Ul
oi

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n
NIVW
98
Turbine will
start rolling
tlirough IPT.
•<r
Start opening
ofCVsoflPT
and raise the
turbine speed
to 300 rpm
without pause.
r
->
As soon as ttie
speed of the
rotor rises above
3.4 rpm, check
that barring gear
gets disengaged
and its motor cuts
out automatically.
Check that the
valves MS-22 and
MS-23 in the
evacuating lines of
HPT casing are
closed.
At 2800 rpm
check that main
oil pump takes over
Stop the starting
oil pump.
Synchronise the set and take around
20 MW load on the unit. Close all
drains.
<r
Immediately load
the turbine at the
rate of 5 MW
per min. As
soon as the
steam starts
flowing through
H.P. turbine
ensure that
the H.P.
bypass valves
starts closing.
-*

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Load the set

further as per
' the curve for hot
start of turbine.
After loading the unit, set the H.P. L.P.
bypass station similar to that in case
of warm start (described earlier).
r
3,7 PLANNED SHUT DOWN
Inform, the boiler house that the turbine
would soon be shut down.
Check the starting oil pump and also
availability to A.C. & D.C. lub. oil pumps.
Reduce the load
at a rate of 3
MW per minute at
rated parameters
by operating
control gear
motor
Watch the axial
shift & differential
expansion of the
rotor and cylinder.
After reducing the
load to 160
MW switch off the
H.P. heater on
steam side and
drain heating
steam condensate
by opening the
drain valves
At load 90-100
MW switch off
one of the
condensate pumps
and feed pumps
and at 70 MW
load check the
drip pump gets
switched off
under automatic
controller action
and also ensure
that auxiliary powei
supply is
changed from unit
to reserve.
Maintain deaerator & condenser hotwell
level normal.

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At load 10 to 12 MW open by pass valve

of MS before ESV and close valve on
main steam line.
99
Reduce the load
to about 5 MW
slowly. Trip
the unit
through any
protection.
Ensure that
generator is
isolated through
low forward power
relay and
the time
for stopping
the steam
supply to
turbine and
isolation of
generator
should not
be more
than 4
minutes
Check the ESV,
IV and control
valves get closed.
Isolate lub oil
cooler from
cooling water side
one by one to
maintain lub oil
temp at 45°C.
After closure of
the control valves
immediately close
the main steam
valves near outlet
and check that
bypass of main
steam valves are
also closed.
Stop the other
BF pump
depending
upon the level
of the boiler
drum.
At 2800 rpm. start AC lub oil pump

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and AC seal oil pump, check the lub oil

press and A.C. seal oil press, is normal
When the rotor comes to a stop, start
the barring gear and roll the rotor
continuously on barring gear till temp,
of lower part of HP casing at regulating
temp, stage drops to 170°C, engage the
barring gear lever at stand still condition
of rotor and then start the barring
gear motor and make sure that rotor
rpm. is 3.4 when put on barring gear.
Break the vacuum by opening vac.
breaking valve and cut off the steam
supply to main ejector, gland" steam
cooler and steam to seals and closing
the respective valves.
When maximum turbine metal temp,
comes down below 200°C, open cylinder,
transfer line and remain steam
line drains.
Barring gear and lub. oil pumps can be
stopped if necessary.
Condensate and C.W. pumps can be
stopped when LP exhaust temp, comes
below 40°C.
3.8 IMPORTANT INSTRUCTIONS DURING TURBINE RUNNING
ROUTINE CHECK :
1.
2.
The turbine is capable of accepting the variations from the rated conditions within the
limits stated below :
Live steam pressure
Live steam temperature
Reheat steam temp.
117-143 Kg/cm2
527-543°C
527-543°C
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 emergency
stop valves.
a) Main steam stop valves must be closed.
b) NRVs on extraction lines must get closed.

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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

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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.
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
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

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necessary.
Deaerator pressure tends to fell, maintain it through
extraction on 16 ata.
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
running.
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
off (due to opening generator
breaker).
The turbine may trip due to overspeeding
(if the speed can be
controlled by closing control valve
immediately otherwise trip the
turbine by emergency trip button)
Sudden Increase of Load- from Pull Load
Low frequency
Due to sudden rise of boiler drum
pressure
Vibration High
Normally the vibration in bearings
should be within 40 microns. If
it exceeds the limit, turbine should
be shut down
If the partial load relay fails/not in circuit reduce
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.
Unit trip on protection if it is kept on T".
Close the control gear handwheel
Check that ESV and Control valves are closed.
Close the valves in the M.S. line. Close the Extr.
steam valves.
Since the turbine is on governor control the load
will increase due to fall in speed. Reduce the load

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by the control gear and bring the boiler parameter

andload to normal.
Bring back the load/governing wheel pressure to
normal by control gear and inform the boiler operator.
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
during running and gets short during
shut down. The expansion is to be
controlled by admitting steam or
shutting off supply to flange and
stud heating, chamber heating
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
Loss of Vacuum
Check the steam temp. Reduce load/speed. Check
the valve for flange heating are in open condition if
rotor is long orclosedlf rotor is short. .Check and
adjust gland steam temp.
Check the vacuum to be normal
Control the load and maintain the steam parameter.
Control the load and maintain the steam parameter.
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.

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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 :
High Level In Condenser
Malfunctioning of condensate pump
or valve
Malfunctioning of DM make up valve
Condenser tube leakage
CW pump failure
Air leak into system
Condenser tube chocking
Check that steam pressure in 6 kg/cm2.
Check the normal running of the condensate pump,
start standby.
Check the operation of valve from UCB by taking it
to manual, if not alright control the hotwell level
bypass valve.
Close valve from UCB and watch that hotwell level
falls.
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 condensate
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. Shutdown
the turbine at the earliest to get the leakage
attended.
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.
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.
Check the CW inlet and outlet temperature.
Loss of Barring Gear or Barring Gear Falls to Start
For loss of electrical supply D.G. :
set will come automatically;
otherwise start.
Smoke from turbine seals.
If not possible to start the DG set, attempt to turn

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the shaft by slings with the help of over head crane

by 180°C at regular intervals of 15 minutes after
cutting in the D.C. emergency lub oil pump.
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 construction,
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 cleaning
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 generator
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.
Ensure that air side and gas side seal
oil pujnps are running.
Verify that hydrogen purity in generator
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 gradually

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fill up the bearing oil system. When

the system is filled, check the following
:
a) Oil level in the oil tank.
b) Pressure in lub oil system (1.2
kg/cm2g)
c) Sufficient flow through all bearings
d) Oil temperature down stream of
turbine oil coolers is within permissible
limits (38°-47°C).
Switch off auxiliary oil pump.
Check automatic starting of the second
auxiliary oil pump and emergency
oil pump.
107
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
Verify also
level is not
Switch on
exhauster.
vacuum breaker is closed.
f
that seal steam condenser
high.
iT
one seal steam condenser
t
Open warming up drain valve.
Open auxiliary steam supply valve to
main turbine gland sealing system.
Open sealing steam station inlet isolation
valve.
Close warming up drain valves when
sound of steam is heard through this
valve. Reopen the valve so as to drain
any condensed steam. Repeat closing
& opening until line becomes warm
up.
Open gland sealing steam header drain
valve.
Crack
valve.
open seal

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1
steam
t
control bypass
Keep open gland sealing header drain
valve*, till sound of steam is heard
through this valve. Close the valve.
Regulate seal steam control bypass
valve to maintain seal steam header
pressure, and to supply steam to turbine
gland seals.
t
Open seal water supply valves and
supply seal water to the vacuum pump
system separator. Verify that the level
in the separator is maintained by
maximum & minimum level control
valves.
r
Verify that the vacuum pump is also
filled simultaneously, via the heat
exchanger, to seal off the gaps & clearances.
r
Ensure cooling water supply to the
heat exchanger.
r
Open condenser air supply valves from
condenser to vacuum pumps.
Close the condenser air inlet valve to
the vacuum pump steam
Open the bypass valve and close the
motive air valve.
T
109
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 pressure
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 functioning
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

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to assist in increasing steam parameters.

Put the Automatic Turbine Run-up
System (ATRS) in service.
Verify conditions, as under, are satisfied.
a) Turbine on turning gear (Speed
>15 rpm).
b) Condenser pressure is less than
0.5 kg/cm2a.
c) At least one condensate extraction
pump is on.
d) Trip fluid pressure is more than
5 kg/cm2.
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
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%. Verify
that all ESVs have opened. Verify
also that drains before HP control valves
are in Auto and these valves have
opened.
Raise
r
starting device about 56%. Verify
that all IVs have opened.
Place
f
'Seal steam controller' and "oil
temperature controller' in AUTO.
r
Verify that following generator conditions
filled :
One Gen. bearing chamber exhaust

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fan is on.
H2 temp, controller is in AUTO.
H2 purity is more than 94%.
H2 pressure is more than
3 kg/cm2.
One air side seal oil pump is on.
H2 side seal oil pump is on.
Diff. pressure between seal oil air
side and H2 side (both turbine
end and exciter end) is more than
0.7 kg/cm2.
Seal oil pre-chamber level (both
turbine end and exciter end) is
low.
Generator bushing box liquid level
is low (Less than 90. mm).
111
Verify that following conditions are
fulfilled :

Both auxiliary oil pumps are off.

HR temp, before LP bypass is less
than simulated mid-section temp.
of IP shaft.
Cold Hj gas temp, is less then
45°C
Main excites air temp, is less than
45°C
Cold primary water temp, is less
than 45°C
Primary water flow through bushings
is more than 0.37 DM3/Sec.
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 experience.
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 steam temperature at steam generator outlet

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flMCV 50% = Middle wall temperature of main 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/cm1

Temperature of nurin control valve body

m 50 % wall -thicknesj »|\^cv 50 %
FIG. 4.3 ALLOWABLE MAXIMUM MAIN
STEAM PRESSURE AHEAD OF
TURBINE WHEN OPENING THE
MAIN STEAM STOP VALVES
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

FIG. 4.4 RECOMMENDED MINIMUM

MAIN STEAM TEMPERATURE
AHEAD OF TURBINE BEFORE
OPENING THE MAIN STEAM
CONTROL VALVES
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
Li
ill
RcLommendod T I
1
100 MO >J0 <JO MO «o9 «.
Simulated mxJalo phase i mpiidture
IP l
FIG. 4.7 RECOMMENDED MAXIMUM
RREHEAT TEMPERATURE
BEFORE THE TURBINE IS
LOADED
dIT50%
4.3 LOADING THE TURBINE
Steam temperature in the hot reheat line
Simulated middle phase temperature of the IP-turbine shaft
Place AVR on Auto and switch on field
breaker.

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Verify that generator voltage is more

than 95%.
Raise the starting device and take a
block load of 10%.
Close HP bypass, verify that LP bypass
also closes.
Switch on Synchroniser and synchronise
the generator with the grid.
Verify that generator breaker is on.
T
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.
100 200 300 400 i)min°C 500
Ai> • Jo ~ >)fn in l t l e ^P 'urbine -Jult
d0 •• outir Ijyir timperaturt of the ihsft
i ) m - lamperature of middia layer in IN thaft (calculated^
FIG.4.11 LIMIT CURVE
121
4.4 START-UP AFTER 48 HOURS SHUT DOWN
Auxiliary equipment and systems shall
be started in the same manner and
sequence as in case of cold start-up
i
Check all auxiliary equipment and
systems are working satisfactorily.
•<[
Also check the healthiness of all protections
and interlocks.
Put AVR on auto and switch on the
Field Breakers. Verify that generator
voltage is more than 95%.
Switch on synchroniser and synchronise
the generator with grid and take a
block load of 10%.
f
Close HP bypass system. Verify that LP
bypass system also closes.
Ensure that the boiler has been lightedup
and steam flow established through
HP and LP bypass systems.
4
Verify that all the conditions regarding
MS and RH steam temp are satisfied.
1
Raise HPT inlet MS press, and temp, to
60 kg/cm2g and 380°C, respectively
prior to steam rolling.
r

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Admit steam to the turbine ensure

that permissible wall temp, of limit
curves are not exceeded.
r
After holding the set at warming-up
speed (300-360 rpm) for soaking purposes,
verify that criteria for MS temp,
is satisfied.
Close all the drains.
i
Raise the speed to 3000 rpm.
\f
Verify that criteria for RH steam temp,
is satisfied.
<r
Close-all the drains.
f
From 60kg/cm2 gradually raise HPT
inlet. MS press, at the rate of 1.65
kg/cm2 per minute such that 170 kg/
cm2 pressure is reached at 55% turbine
load.
Raise HPT inlet MS - temp, at the rate
of 1.6°C / minutes from 380°C. to 485°C.
Maintain MS temp, at 485°C upto turbine
load 485MW. Thereafter raise MS
temp, at the rate of 0.6°C/min, such
that 535°C is reached when the turbine
load has reached 500 MW.
r
Gradually load turbine at an average
rate of 4 MW/min upto 475 MW.
r
At 40% turbine load cut in HP Heaters.
r
Follow Mill cutting-in sequence as
under :
No. of Mill Turbine Load (%)
First : , 20
Second : 33
Third : 45
Fourth : 55
Fifth : 67
Sixth : ' 74
123
Unload the turbine by gradual closing
of control valves through remote or
manual operation of speeder gear. The
unloading should be carried out at a
rate governed by the margins shown
on TSE.

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During unloading always keep watch

on following parameters, such that
they are always within permissible limits
as under :
a. Differential expansion
HP casing : < + 5 mm
> - 3 mm
I.P. Casing : < + 8 mm
L.P. Casing
> - 2 mm
: < + 30 mm
> - 3 mm
b. Bearing Vibration < 50 jiM
c. Wall temperature of ESV, HP casing,
HP & IP turbine shaft
d. Differential temperature between parallel
steam lines 28°C.
Having unloaded the turbine to no
load, trip the turbine manually. Ensure
the following.J
a. ESVs, IVs and control valves get
closed.
b. All extraction steam line valves to
HPH5, Deaerator, LPH 3 & 2 get
closed.
c. Initiate load run-back in ACS
d. Initiate fast opening of HP bypass
system.
e. Generator is isolated through low
forward power relay
f. Synchronizer is OFF
g. Field Breaker is OFF
h. Drains before HP control valves
are open.
When turbine speed falls below 2790
rpm, verify the following :
a. One auxiliary oil pump is on
b. Oil temp, control valve is on Auto
c. Gate valve gearing has opened.
When turbine speed falls below 510
rpm. verify that one Jacking oil pump
is on and the machine is running on
barring gear.
Operate HP-LP bypass systems to stabilize
boiler conditions and maintain
steam flow through reheater till the
boiler is shut-down.
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

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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
either the ATRS control insert or the
local turbine front.
j.
Ensure that ESVs, IVs and control
valves of both HPT & IPT have closed.
Isolated the generator and switch off
field breaker and synchronizer.
Break the vacuum.
125
xv) Regularly note readings of all the turbovisory instruments, take measures for abnormalities.
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 required
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

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filling the generator..

Open the valves for suction and discharge
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.
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 below
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 pressure
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. carefully
to get the required pressure.
Open inlet and outlet valves of DPR.
Open damper tank by-pass valve. 1
129
Stop filling
operation if
theH,
concentration
attains a
concentration of
98% and H,
pressure
attains rated
value 3.5 kg/cm2
—•
During H, filling,

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continuously
analyse the
concentration of
H2 in gas mixture
inside the
machine.
5.1.2.3 PURGING OF R, BY CO,
Admit CO2 to
the bottom of
the casing
through the
CO2 feed pipe.
f
—»
Hydrogen is
discharged to the
atmosphere
through hydrogen
feed pipe line.
Stop filling CO2 when CO2 concentration
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 maintenance.
For this purpose dry instrument
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 stator
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.
Supply clarified water to the water line
valve to ejector by opening clarified
water line valve to create vacuum and
thus maintain vacuum in the expansion
tank.
Open the D.M. water valves before and
after the stator water pumps, stator
water coolers and mechanical filters.
Open the stator bypass valve; start the
pump and slowly open the discharge
valve to full
Adjust the cooling water pressure and
flow.

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Charge the other cooler from D.M. water

side and bring the temperature of
D.M. water to 40°C.
Charge the cooling water for secondary
stator water cooler.
Charge rectifier for exactor (RCU) by
opening D.M. water inlet valve and
adjust the flow by the control valve.
131
5.3 STEPS FOR GENERATOR SYNCHRONISING
Ensure the availability and completeness
of all the equipment and circuits.
Take clearance from electrical division
for synchronising.
r
Ensure that the
insulation
resistance of
the system is
within
permissible
limits
especially if
the generator
is being
synchronised
after a long
time or in
rainy season.
If the insulation
resistance of the
system is low,
dry out of
stator winding and
associated bus
duct should
be carried out.
Check seal oil system for seal oil pressure,
flow and temperature.
Check Hj cooling system for H2 pressure,
purity and gas leakage.
Charge stator winding coolers with
distillate and ensure quality, pressure,
flow and temperature of the distillate.
Check that
generator
breaker and
generator
field breaker
are open
If not, open

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generator breaker
or field breakers
as the case may
be.
Advice rolling of turbine to rated full
speed (3000 rpm>.
Check bearing vibrations and rubbing
etc. if any, inside the generator during
rolling or any abnormal sound.
Check temperature of bearing seal
babbit and drain oil.
Throttle inlet and outlet valve of H2 gas
coolers according to gas temperature,
Do not allow the gas temperature to
rise above 55°C.
Ensure that the machine has attained
the rated speed of 3000 r.p.m. Obtain
a go forward signal from boiler and
turbine operator to synchronise the
machine.
Enquire from the switchyard control
room about synchronising of machine
to the required bus.
Close the isolator for bus.
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 the synchroscope cut off
switch is 'OFF and synchronising check
relay "SKE" bypass switch is on "IN
CIRCUIT" position. If not, put these
switches in the said positions.
133
Put
synchroscope
switch to
"OFF" position — •
Ask turbine
operators to carry
out necessary
operations on
turbine side
required for
raising
the load.
Put "antimotoring" protection switch
on "ON1 position after taking some load
on the machine (say 20 MW).
Gen. voltage and P.F. (power factor)

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will be maintained by AVR if the excitation

mode is on "Auto"; otherwise,
maintain generator Voltage and PF by
varying the field rheostat from the gen.
control desk. If excitation mode is on
manual then change over to "Auto"
mode after matching the parameters.
(Refer Fig. 5.1).
r
Slowly raise
the load on
generator upto
80 MW (follow
the guide lines
given for
loading the
machine).
r
—»
Now the voltage
and power factor
will be maintained
by the automatic
voltage regulator
(AVR). However,
the level can
be changed by'
varying the
rheostat resistance
Changeover 6.6 KV auxiliary bus from
station supply to unit auxiliary supply
taking both the unit auxiliary transformer
into circuit. Check that the unit
auxiliary supply incoming breakers are
racked in service position. Springs are
changed and "Local/Remote" switches
are on "Remote" position
Keep generator winding & core temperature,
generator transformer winding
temperature, H2 gas temperature,
generator seal and bearing metal temperature
within limits by adjusting
cooling water flow to generator gas
coolers and oil coolers. Load the generator
upto 150 MW as per guide lines
available.
ir
At this load
check generator
bearing and
seals temp,

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generator
winding/core
temperature,
generator transformer
winding
temperature,
H2gas
temperature,
performance
of automatic
voltage regulator
and cooling
water flow
toR.C.U.
If generator wdg/
core temperature
is higher adjust
distillate flow
and cooling water
flow to gas coolers.
If Gen. T/Fwdg.
temp, is high,
check that ail
the cooling fans
and pumps of
cooler banks are
in service.
If the AVR is not
functioning
properly take the
voltage control on
"Man mode".
1
Check exciter winding temperature & slip ring
sparking. Ensure that the exciter voltage and
eurrent are within permissible limits.
r
Check H2
pressure,
purity and
temperature,
performance
of seal oil
system and
stator water
cooling system.
—>
Fill more H2 gas
gas if pressure
and purity are
low. If the

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performance of
seal oil system
is not satisfactory
take corrective
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 the vibrations increase beyond limits
reduce load and investigate cause.
If Gen. wdg/core temp, cannot be controlled
by increasing cooling water flow
to gas coolers and distillate to stator
water coolers. Reduce load.
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, maintain
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
OF DISTILLATE AT INLET. A
UNLOADING SCHEDULE DUE TO HIGH STATOR WATER
•

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-
TEMPERATURE
FIG. 5.3
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
5.6.2 Stator water conductivity high
5.6.3 Hydrogen pressure low
5.6.4 Hydrogen purity low
5.6.5 Seal oil differential high/low
5.6.6. Liquid in generator
5.6.7 Generator stator cooling water

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leakage
5.6.8 Damper tank level low
Check expansion tank level is normal and drains
are closed.
Check position of recirculation value.
Check whether running pump has tripped. Reserve
pump should start on Auto, if not start
manually.
Check differential pressure across the filter is
normal.
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.
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.
Purge some hydrogen from casing and charge fresh
hydrogen.
Check seal performance is normal.
Check DPR is functioning normally. If not change
to the bypass line and get DPR attended.
Adjust the pressure at injector/ pump discharge.
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.
Check gas trap and analyse the gas from it. In case
stator water leakage is suspected then shut down
the unit and attend the leak.
Check DPR operation. If required open the bypass
valve and make up the level. If the level approaches
16w unit will trip.

Posted 15th July 2015 by kishorereddy kattukolu

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