1.

UNIT NORMAL SHUTDOWN TO COLD

1. Unit is running normal at full load with all auto controllers in service
and it is our intention to stop the unit for long or very long shut down.
2. Inform to load dispatch centre, MCR, CHP, WTP and all maintenance
wings.
3. Operate all soot blowers.
4. Keep the 16 ATA header system in parallel with Stage-I or Stage-II or with other
running unit duly informing other unit operators concerned.
5. Record Boiler expansions at various levels.
6. Gradually reduce the load by reducing feeder speeds and firing rate in line
with reduction in MS pressure.
7. At 150MW take HFO guns in the elevation of top mill in service.
(for ex: - if AB,EF are in service take oil guns in DE elevations)
8. Maintain MS Temperature > 5000C by reducing spray and operating burner
tilt. MS Pressure may be maintained at 150 Kg/cm2 till the unit load is about
150MW. MS pressure may be reduced in line with the load to accelerate
cooling.
9. Close Bunker isolation gate of the top most elevation feeder in service
i.e. ‘F’ feeder. The feeder will trip in Auto on “No coal flow” indication
as soon as the chute gets cleared. Stop the elevation ‘F’ by manual
command. Allow the shut down purging sequence of elevation ‘F’ for
5mints.Load may be around 140MW.
Note: When only one elevation of any mill is in service, ensure PA flow of
about 5 to 7 TPH in the elevation which is not in service to avoid
piling up of coal powder in the PA duct beyond PA damper which
may cause fire and explosions.
10. Gradually reduce the feeder speed of 2nd elevation of the top mill (Feeder
E’) Reduce load according to MS Pressure.
11. Take HFO guns in BC elevation (now HFO guns in two elevations are in
service i.e. BC &DE).
12. Close the bunker isolating gate of feeder ‘E’. The feeder ‘E’ will trip on
‘No coal flow’ indication as soon as the chute gets cleared.
13. Stop the elevation ‘E’ after ensuring that Mill EF is completely empty,
by manual command.
14. Mill EF will trip in auto after 10mnts. Mill EF comes on to barring gear.
Purge sequence starts in auto and completes after 5mts if ignition energy is
available. Now load will be around 120MW. Secondary air flow has to be
reduced in line with fuel reduction.
15. Cut off HFO guns in DE elevation. Now Mill AB is in service. Reduce the
feeder speed of RC feeder ‘A’ of Mill AB.
16. At 100 MW load gradually unload one BFP and load the other BFP. Check
Boiler expansions, Metal temperatures and other important parameters and
act accordingly. Maintain MS and RH Temperatures greater than 5000C.
Close spray block valves if necessary. At load 80MW to 90MW hand trip
the unloaded BFP.
17. Close Bunker gate of RCF ‘A’. The feeder Trips on ‘No coal flow’ in auto
after the chute is cleared. Stop elevation‘A’.Elevation‘A’gets purged for
5mts. Now only one elevation ‘B’ is in service. Load is about 70MW.
Unload PAF-B and hand trip it.
18. Now parallel the UATs with Station Bus one by one and hand trip the
UAT’S.
19. Cut Off Extraction steam to HPHs 5 & 6 at 70MW. Ensure opening of
extraction line drains EX-112, EX-110 and close A5, EX-13, EX-12.
20. Give pegging steam to Deaerator from 16 ATA line by opening AS-17
and stop extraction steam (Close Ex-14) to Deaerator, Close A4 Swing
check valve. Maintain pegging steam pressure at 3.5 Kg/cm2
21. Stop CBD steam to Deaerator by closing BDM-78 and open it to
atmosphere by opening BDM -94 & BD-100.
22. Reduce feeder speed B and gradually reduce the load on Unit.
23. At around 30 to 40 MW cut off extraction steam to LPHs 1, 2, 3, by
closing Ex-9, Ex-10, and Ex-11. Ensure opening of drain valves in
 extraction lines to LPH-2 & LPH-3 Nos EX-101, EX-102, EX-103.
Close A2 & A3 Swing check valves.
24. Close the bunker gate of RCF ‘B’. Before closing the Bunker gate please
ensure that all necessary protections are tested on Turbine side i.e. over
speed trip etc. The feeder ‘B’ will trip in auto after the chute gets cleared.
25. At around 30MW open HPBP Valves BP1 & BP2 and LPBP1 & LPBP2
and hand trip the turbine. HPBP Valves open to full (Fast opening) and
after 3 seconds they may close. Keep HPBP1, HPBP2 and LPBP Valves
10% to 20% open to avoid RH Protection trip. Ensure AOP comes into
service otherwise start AOP. Ensure closing of HPSVs, HPCVs, IPSVs, and
IPCVs, CRH NRVs. Ensure opening of GCB & Field Breaker. If not, open
GCB first and then FB. Ensure that JOP comes into service at 510rpm if
not, start it and gate valve gearing opens at 210 rpm. If not, open it
manually. Frequently check the turbine is running steadily at 120 rpm.
26. Maintain Gland steam pressure by closing the leak steam valve and
opening the Seal steam valve, or by opening the Seal steam bypass valve.
Close CD-14 to maintain Hot well level. Open DM-57A & DM-57B too.
27. Ensure that Mill AB is fully empty. Otherwise start ‘B’ feeder now and
then to avoid mill trip, on both feeders off >10mints. Stop the elevation-B.
Mill AB trips in Auto after 10mimts.(Shutdown sequence) Close all spray
valves of SH and RH System.
28. After the completion of 5mts purge of Mill AB hand trip PA fan A.
29. Cut off HFO guns in BC elevation. Boiler will trip on “Loss of all Fuel”.
Close CBD valve B-80.
30. Reduce Drum Pressure to 40Kg/cm2 by operating HPBP &LPBP.
31. Close LPBP after depressurizing CRH and HRH lines.
32. Close Boiler Stop valves & their equalizer valves and CBD valves.
33. Stop one of the two running CEPs.
34. Fill the drum to the top most port of the hydra step and hand trip BFP.
Add make up as and when required by taking BFP.
35. 30Mints, after the turbine came on to barring gear kill the vacuum by
opening vacuum breaker and by stopping MAEs. Stop gland steam at
-0.2Kg/cm2 vacuum. Stop SSCE fan and close its suction valve. Also
close the ejector steam isolation valve at 10mts and gland steam
isolation valve at 5mts. Also close the valves AS -22 & ASSM - 148 on the
16ATA header.
36. Switch OFF the ESP fields. The rapping motors may be continued in service
till the ash is cleared in all the hoppers.
37. During the shutdown period, if it is not required to enter the Boiler
immediately a slow rate of pressure and temperature decay may be
accomplished as follows.
a. Post purge the Boiler by running ID and FD fans at least for 5mts at
30% total air flow ( Secondary air flow = 240 TPH) after the Boiler
is tripped.
b. Reduce the air flow through the Boiler to a minimum.
Keep the fans in service until the Flue Gas temperature at RAH inlet
has dropped to 1500c.
c. When the Drum Pressure has fallen to 2Kg/cm2 open the drum vents
B-18, B-19, SH vents S-15, S-16, S-25, S-26, S-108, S-109 and
RH vents R-1, R-2, R-14, R-15.
d. When the Drum Pressure decays to 0 Kg/cm2 open SH drains S-9,
S-10,S-11, S-12, MSSM-31C, MSSM-37C and RH drains R-12,
R-13.
e. Stop RAHs when FG Temperature at RAH inlet falls to less than
1500C.
38. During the shut down, if it is required to enter the Boiler immediately
for maintenance works the cooling may be accelerated as follows.

a. Purge the Boiler by running ID and FD fans for at least 5mts at a

minimum of 240TPH (30% air flow) after the Boiler is tripped.
 b. Continue running the fans to cool the Boiler at the desired rate.
During any type of shutdown the cooling rate should not exceed 830C
per hour saturated temperature drop.
c. At Drum Pressure 2 Kg/cm2 open Drum vents B-18, B-19, SH vents
S-15, S-16, S-25, S-26, S-108, S-109, RH vents R-1,R-2,R-14,R-15
d. At Drum Pressure 0Kg/cm2 open SH drains S-9, S-10, S-11, S-12
MSSM-31C, MSSM-37C and RH drains R-12, R-13.
e. Stop RAHs when Flue Gas temperature at RAHs inlet drops to less
than 1500C.
f. Drain the Boiler when the Boiler Drum metal temperature on water
side drops to less than 1200C.
39. Stop 2nd CEP after two Hrs of Unit trip.
40. Stop CWPs when LP exhaust hood temperature = 400C.Inform one hour in
advance to DE/S/Stage-I to regulate canal level.
41. Barring gear can be stopped when HP casing inner metal temperature drops
to 1500C to 1200C.
42. AOP can be stopped when HP casing inner metal temperature drop to less
than or equal to 1000C if necessary, otherwise continue. Stop OVE fan.

NOTE:
The total air flows to be maintained for cooling the boiler in effective
manner are given below. This is applicable only when scraper conveyor is in
service.

1st hour  380TPH

2nd hour  450TPH
3rd hour  500TPH
4th hour  600TPH
If scraper conveyor is removed or scraper conveyor gates opened, ID fans
loading has to be changed to limit the cooling rate. The cooling rate should not
exceed 830C per hour.
 2. UNIT NORMAL SHUT DOWN TO HOT STANDBY

1. Unit is running normal at full load with all controllers in auto and it is the
intention to keep the Boiler under Hot Standby to carryout maintenance
works of minor nature and to bring back the Unit into operation as early as
possible.
2. Inform to load dispatch centre, CHP, MCR, WTP and all maintenance wings.
3. Operate all Soot Blowers.
4. Record Boiler expansions at various levels and these are to be monitored
while unloading the Boiler/unit.
5. Keep 16 ATA header in parallel with other Unit or Unit in other Stages duly
informing other ADE/S/UOs and close self PRDS LC and HC valves.
6. Gradually reduce the load to 150MW by reducing the feeder speeds and
firing rate.
7. At 150 MW, take oil support in the elevation of top mill in service
(for ex: - if AB and EF Mills are in service) i.e. cut in DE elevation oil guns.
8. Maintain MS Temperature > 5200C by reducing the spray and using
Burner Tilt. MS Pressure may be maintained at 150kg/cm2 till the unit load is
about 150MW.Later MS Pressure may be reduced in line with load up to 80
Kg/cm2 in this case i.e. Unit shutdown to Hot Standby. Reduce speed of the
top feeder to minimum.
9. Trip the top feeder and after 5mts trip the top elevation.
10. Now three elevations are in service and load will be around 140 MW and
MS Pressure 150 Kg/cm2.
11. Reduce feeder speed of 2nd elevation of top Mill i.e. RC feeder ‘E’ to
minimum. Mill EF need not be emptied.
12. Take HFO guns in the elevation of bottom Mill (Mill AB) i.e. BC elevation.
Reduce secondary air flow in line with fuel reduction.
13. Trip feeder ‘E’, stop elevation ‘E’. Mill EF will trip in auto after 10mts of
feeder trip. Now only two elevations are in service with guns in BC and DE
elevations. Load is around 110 MW.
14. Check and record Boiler expansions at various levels.
15. Cut off oil guns DE 1 to 4.
16. Reduce bottom most feeder speed i.e. feeder ‘A’ to minimum, if Mill AB
is in service. Trip feeder-A. After 3mts, trip elevation-A. Unload one BFP
and hand trip it at 90MW.
17. Cut off HPH-5 and HPH-6 at around 80 MW by closing Ex-12 & Ex-13.
Ensure opening of drain valves Ex-110 & Ex-112 in extraction lines. Also
close Swing Check Valve A5.
18. Now only elevation ‘B’ is in service and load is around 60 MW.
MS Pressure is around 100Kg/cm2.
20. Now parallel UATs with station Bus one by one and trip UATs.
21. Give pegging steam to Deaerator by opening AS-17 on the 16 ATA auxiliary
PRDS header and close Extraction valve Ex-14. Close CBD to deaerator by
closing BDM-78 and let out to atmosphere by opening BDM-94 &BD-100.
Maintain pegging steam pressure at 3.5Kg/cm2
22. Gradually reduce the feeder speed to minimum (i.e. Feeder ‘B’) and
reduce load to 30 MW.
23. At 30MW cut off extraction steam to LPHs Ex-9, Ex-10, Ex-11and open the
drains Ex-101, Ex-102, Ex-103.
24. Open HP & LPBP to 20% and hand trip the turbine.
25. Ensure that AOP comes into service in auto otherwise start AOP at Turbine
speed less than 2850rpm. Ensure closing of ESVs, IVs, CRH NRVs, and
opening of GCB & FB. If not, open GCB first and then FB. Ensure AC JOP
comes into service at 510 rpm if not start manually. Check whether gate valve
gearing opens at 210 rpm and if not, open the same.
26. Stop elevation ‘B’. Mill AB will be tripped in auto after 10mints. (Shut down
sequence)
27. Cut off BC elevation oil guns. Now Boiler will trip on “Loss of all fuel”.
Close CBD valves B-80. Steams quench the mills.
28. Close HPBP. Depressurize CRH and HRH lines by opening LPBP valves
till RH pressure decays to zero and then close LPBP. Trip one CEP.
29. Fill the drum to the top most port of the hydra step and hand trip BFP. Add
make up as and when required by taking BFP.
30. After post purging the Boiler for 5mts stop the ID fans and FD fans one after
the other.
31. Close Boiler stop valves MSSM-30, MSSM-36 and their equalizing valves
MSSM-30B, MSSM- 36B, and all sampling valves. ESP fields are to be
switched off and rapping motors may be continued in service until the ash is
cleared.
32. Close the discharge dampers of ID, FD and PA fans. Now the Boiler is
under hot box up conditions.
33. Kill vacuum 30mts after the Turbine came on to barring gear. The procedure
is given below
a. Open vacuum breaker.
b. Close steam valves of MAEs by AS-2, AS-3 at -0.5 kg/cm2 vacuum.
c. Stop gland seal steam to turbine when vacuum falls to -0.2kg/cm2.
b. Close ejector steam isolation valves near HPH 5 and Gland steam
isolation valves at 5mts.
c. Stop seal steam condensate extraction fan.
34. Fuel oil may be kept on Recirculation.
NOTE:
a. When Turbine trips, all operations for safe shut down of Turbine are
to be carried out.
b. When Boiler trips all operations for safe shut down of Boiler are to
be carried out.
c. MS stop valves have to be closed in every shut down if the start up is
delayed for 2 to 3 hours.
d. Boiler has to be boxed up if the delay in start up is due to problem on
Turbine or Generator side, to minimize pressure loss and heat loss.
Box up means a. Stopping of ID fans
b. Stopping of FD fans
c. Closing of MS stop valves and their equalizer
valves
d. Closing of CBD (B-80)
e. Closing of all sampling valves.
f. Closing of ID fans inlet and outlet dampers and
closing of FD outlet dampers.
 3. PROCEDURE FOR HYDRAULIC TEST OF BOILER

1. Clearance for conducting the hydraulic test from BM division to be

obtained.
2. Ensure that all the required PTWs are returned by maintenance wings.
3. Ensure that all level gauges of Hot well, Deaerator and Drum are in
working condition. Hydra steps are to be isolated.
4. Line up Boiler filling line. Contact Unit operators of other units and ensure
that their boiler filling line valves are in closed position. Also check various
valves on boiler fill line and open them.
5. Filling up of Deaerator can be done either by CEPs or through Boiler fill
pump (Stage -I). The capacity of DM Make up pumps is about 100 TPH
where as that of Boiler fill pump is about 200TPH. Hence it is advisable to fill
up the Deaerator by Boiler fill pump only.
6. Inform Senior chemist for addition of chemicals in feed water storage tank
after it is filled up to just below normal level. Start one Raw water pump and
fill up the clarifier. After ensuring that sump level is adequate BCW pumps
should be taken into service and ensure that BCW header pressure is
4.0 Kg/cm2.
7. Contact FM/Shift/BCWPH/Stage-I and ask him to start Boiler fill pump.
 value, add chemicals to the water in Deaerator. After adding chemicals rise
the level to +500 mm. Start one BFP and keep it under Recirculation. Before
starting BFP ensure that the manual isolation valve of its Recirculation valve
is in open position. Continue the BFP in Recirculation until required
Hydrazine concentration is achieved (20PPM).
8. Note feed water integrator reading.
9. Ensure the opening of Boiler drains and vent valves.
a. Water wall ring header drains B-93 to B-100.
b. Drum emergency drains B-89, B-90.
c. Economiser drains E-15, E-16.
d. Hanger tube inlet header drain S-9, S-10.
e. ITSH drains S-11, S-12.
f. Drum vents B-18, B-19.
g. SHTR vents S-15, S-16.
h. Start up vents S-25, S-26.
i. HTSH vents S-108, S-109.
j. Continuous Blow down valves B-80, BDM-94.
10. Ensure closure of the following valves
a. Spray valves of Desh-I and Desh-II of Super heater system and their
manual isolation valves .i.e. S-40, S-45 to S-48, S-69, S-74 to S-77.
b. Spray valves including manual isolation valves of Desh of Reheater
system R- 20, R-25 to R-28.
c. Spray valves of Aux PRDS (LC and HC) system (both manual as
well as electrical) BFDM-172(HC), BFDM-203(LC).
d. Boiler stop valves and their equalizer valves MSSM-30, MSSM-36
and MSSM-30B, MSSM-36B.Drains before stop valves MSSM-31C,
MSSM-37C.
e. Spray valves of HPBP system and Soot blowing steam header
isolation valves BFDM - 175, S-99, and their manual isolation
valves.
 f. HP heaters inlet and outlet valves FD-7, FD-8, FD-10, FD- 11 and
their equalizing valves. Ensure opening of FD-9 & FD-12, and their
equalizing valves.
g. Manual isolation valve of EMRV.
h. All Sampling valves
i. All drains of CRH and HRH lines CRHM-22A, CRHM- 22B,
HRHM-56A, HRHM-56B to Flash Box-2.
11. Open the following valves to full
a. All SLC drains.
b. MS line strainer and Drain Pot drains MSSM-83A, MSSM-94A,
MSSM-142A and MSSM-142B.
c. HPBP down stream and up stream drains (8No manual valves to IBD
and MSSM-130C, MSSM-130D to flash box.
12. After getting clearance from the chemist start filling the Boiler through
Main/Stand-by Full Load Feed water control valves.
13. After observing the water through Economiser vents E-20, E-21 close them
and close the Economiser drains E-15, E-16. After flushing the water wall
headers for 10mts close the ring header drains (B-93 to B-100), emergency
drum drains (B-89, B-90) and CBD drains (B-80, BDM-94). Always watch
Deaerator level. If it falls, Boiler fill pump has to be kept in service. If we
equal the Boiler fill pump discharge flow and feed flow to the Boiler the
Boiler fill pump can be continued in service till the entire filling is over.
14. After observing the water flow through the Drum vents B-18, B-19, close
them and continue the feeding. Water enters the Super Heater circuit.
15. After flushing the Super Heater circuit for 10mts, close the SH drains. After
observing water through the vents close the valves S-15, S-16, S-25 and
S-26. Before closing the last set of vents i.e. S-108, S-109 bring the BFP
scoop to 0% position, reduce the FL/SBY FWCV position to minimum and
then close the vents. Above procedure has to be followed to avoid sudden
rise in Drum pressure.
16. The feed water requirement is as follows (approx):
 Drum level Full : 37T
Water walls : 126.5T
Economiser : 25T
SH tubes : 95T
Total : 283.5T
17. Note the reading of feed water integrator raise the deaerator level to 600mm
and ask FM/S/Stage-I to stop the Boiler fill pump.
18. Slowly pressurize the Boiler using low load control valve at the rate of
3 kg/cm2 per minute duly informing BM staff to have vigilant watch for any
leakages.
19. During the pressurization of the Boiler see that the Recirculation valve of
running BFP remains in open position.
20. Raise the Boiler drum pressure to 100 Kg/cm2 and wait for 15 to 20mts to
allow the BM staff to gag the boiler safety valves.
21. Raise the Drum pressure from 100 to 190 kg/cm2 at a rate of 2.5Kg/cm2 per
minute and maintain drum pressure at 190 Kg/cm2 for 2 to 3mts and arrange
for inspection of the pressure parts of the boiler by BM wing.
22. Note the feed water integrator reading.
23. After getting clearance from BM wing kill the Drum pressure at the rate of 2
to 3 kg/cm2 per minute up to 40Kg/cm2 by reducing scoop and low load
control valve position. To reduce the Drum pressure from 40Kg/cm2 to
0Kg/cm2, first close the discharge valve of running BFP and then open CBD
manual valve by about one turn. Open the SH drains at 4kg/cm2. Open the
Drum and SH vents at Drum pressure of 2kg/cm2.
24. Drain the boiler drum up to normal level for flashing the Boiler (if hydraulic
test is OK) by using emergency drains and CBD valves and if necessary open
one set of ring header drains Nos B-93 to B-100.
25. Open the isolating valves in DESHs of SH and RH spray systems.
 Procedure to be followed for conducting air leak test of Reheater

To check the healthiness of Reheater coils i.e. to find out the damaged tubes,
air leak test is conducted. For that service air is used. Provisions are made on the
CRH inlet header on both sides at 7th floor to fill and pressurize the RH circuit by
using service air. Clearance for conducting the test should be obtained from BM wing.
Close the following valves on Boiler side and hand tight them.
a. Reheater vents  R-1, R-2, R-14, R-15
b. Reheater drains  R-12, R-13.
Close the following Motor operated valves and hand tight their manual
isolating valves on Turbine side.
a. CRHM-67A, CRHM-67B.
b. HRHM-41A, HRHM-41B.
c. HRHM-32, HRHM-36, HRHM-34, HRHM-38.
d. HRHM-56A, HRHM-56B.
e. CRHM-22A CRHM-22B.

After ensuring the above, fill and pressurize the RH circuit by using service
air. The maximum pressure attained may be around 2 to 4 Kg/cm2. After the test is
over depressurize the circuit by opening RH drains and vents.
Note: a. Don’t open any of the above valves during the test.
b. Don’t open LPBP valves during the test which may break/open
the LPT diaphragms.

4. UNIT COLD START-UP PROCEDURE

Cold start up is carried out when HP casing/HP shaft inner temperature drops below
1500C.
Prerequisites:-
1. Ensure all the line clears are cleared. Ensure all men and materials are
removed from the site.
2. Ensure all soot blowers are retracted and they are in home position.
3. Ensure RAH (Regenerative air pre heater) fire fighting equipment is
available for service.
4. Ensure drum level hydra step is ready. All control and instrumentation
systems are checked and available for service. All interlock tests are
completed.
5. Get clearance from BM wing for flashing the Boiler for start up.
6. Ensure the following:-
i. Seal oil system is in service with one AC SOP, Seal Oil Vacuum
Pump. Ensure AC SOP2 and DC SOP are available for service.
Generator is filled with H2. H2 pressure at 2kg/cm2 with H2 purity
> 98%. Ensure one Bearing Chamber Extraction Blower is in service.
ii. Turbine is on barring gear with one OVE, AC AOP and AC JOP.
SLCs of second AC AOP, DC EOP, and DC JOP are in ON position.
Turbine Barring gear Procedure:
a. Check seal oil system is in service. H2 pressure = 2Kg/cm2.
b. Keep OVE 1 or OVE 2 in service.
c. Ensure MOT level is normal. Maintain Lub Oil temperature
around 400C.
d. Start EOP and observe Lub Oil pressure: 3Kg/cm2 (Approx)
e. After 5 to 10mts, start AOP1 or AOP2 and observe the
discharge pressure to be 6.0Kg/cm2 (approx). Change over
AOPs and check the pressure.
f. Trip EOP
g. Start AC JOP and observe the header pressure to be
150Kg/cm2. Change over JOPs and check the pressures.
 h. Open the gate valve gearing. Turbine starts rotating and picks
up the speed to 120rpm.
i. If Turbine does not pick up speed the following procedure
may be adopted.
a. Switch ON and OFF the second JOP.
Or
b. Open the gate valve gearing and then start JOP.
iii. Lub oil tank levels of various equipment and MOT are normal.
iv. Fly ash handling and Bottom ash handling systems are ready for
service.
v. Scrapper conveyor is filled with water and overflow is established.
vi. Service and instruments air pressures are adequate i.e. more than
6Kg/cm2.
vii. DM water pumps are in service and DM water pressure is normal.
viii. All LT and HT boards are charged.
7. Inform to all maintenance wings, fuel oil pump house, water treatment plant,
MCR, CHP etc.,
8. Charge 16 ATA header duly informing Asst. Divisional Engineer/UO of the
other Unit. Steam pressure should be around 15 to 16 Kg/cm2 and
temperature around 2600C.
9. i. Start Raw water pumps and ensure that clarifier water tank levels are
normal. Sump Level >3.2mts.
ii. Start 2 BCW pumps one after the other and check that the header
pressure is around 4 Kg/cm2. Keep 3rd BCW pump in Auto standby
mode.
iii. Charge the BCW header (Boiler and Turbine sides) slowly without a
dip in the header pressure.
iv. Procedure for starting a BCW Pump:
Permissives:
a. Switch gear availability.
b. sump level adequate.
 d. Discharge valve of the pump should be in closed position.
e. Motor bearing / winding temperature normal.
f. BW - 12A (Header isolation valve) in open condition.
g. BW - 11A (RCV) in open condition.
Start BCW pump and observe the following
a. Motor gets ON.
b. Discharge valve opens in AUTO.
10. Start two seal water pumps at CWPH one after the other. After that start two
No CWPS after informing Divisional Engineer /Shift/ Stage -I for
maintaining Sump levels. Divisional Engineer/Shift/Stage-I should be
intimated at least 1hour before taking the pumps. Keep 3rd CWP in auto
standby mode.
Procedure for starting of CW Pump:
Check the following permissives before starting the pump.
a. Switchgear available.
b. Sump level adequate.
c. Seal / Lub water pressure adequate (4.5Kg/Cm2).
d. Discharge valve close.
e. Pump Mitchell bearing temperature normal.
f. Condensers A & B inlet and outlet valves CWB-8, CWB-9,
CWB-10, and CWB-11 open.
g. Open condenser water box vents at 5mts.

Start CW pump and observe the following:

a. CWP motor gets ON.
b. Discharge valve opens to 100%.
c. After ensuring that water is coming from the vents close the vents
d. Observe the flow to be around 16,000 TPH.
e. Check discharge pressure of the pump and DP across condenser are
normal.
11. Start Debris systems of the condensers.
12. Fill the Deaerator level by Boiler fill pump after making the Boiler fill pump
line ready. Inform the chemist to add chemicals as required. Peg the
Deaerator with Auxiliary steam, duly draining the condensate in the line, at
1.5Kg/cm2 pressure by opening manual valve AS-17.
13. Open DM water make up valves(DM-57A &DM-57B) and seal water valve
and fill the hot well to +450mm.
14. Start one No CEP after opening the vent valve and ejector bypass valve
(CD- 53). After CEP is started open the discharge valve and open the
recirculation valve (CD-19) to 50%. After 5min close the air vent
15. Ensure closing of all bottom ring header drain valves B-93 to B-100.
16. Start one No BFP and keep it under Recirculation. After the required
concentration of Hydrazene and pH are achieved, fill the Boiler by either
LLCV or FWCV up to 2 to 3 ports in hydra step. Start hydrazine dosing
pump and intimate the same to chemist.
17. Open the following valves of Boiler (Drains and vents)
a. Drum vents  B-18, B-19.
b. SH hanger outlet header vents S-15, S-16.
c. HTSH outlet header vents S-108, S-109.
d. SH Start up vents S-25, S-26.
e. SH hanger inlet header drains S-9, S-10.
f. ITSH inlet header drains S-11, S-12.
g. LTRH inlet header vents R-1, R-2.
h. HTRH outlet header vents R-14, R-15.
i. HTRH inlet header drains R-12, R-13.
j. Drains before MS Stop valves MSSM-31C, MSSM-37C.
Also ensure that block valves and control valves of SH and RH spray
systems are in closed condition. All DESH manual isolation valves
are in open condition.
18. Procedure for starting of BFP:
Check the following permissives before starting BFP.
a. Discharge valve is in close position whereas its equalizer valve is
 b. Suction valve fully open.
c. Recirculation valve and its manual isolation valve at feed water
storage tank (19mts elevation) open.
d. AOP is in service and Lub oil pressure adequate (> 1.5 Kg/Cm2).
e. Scoop of the pump at minimum position.
f. Switch gear availability.
g. Deaerator level adequate.
h. Bearing / Winding temperature normal.
Start BFP and observe the following:
a. Motor starts
b. AOP stops when lub oil pressure is adequate.
c. BCW valve for motor cooling opens.
d. Open the discharge valve at discharge pressure of 50 Kg/cm2.
19. Start RAHs A and B and ensure that flue gas path is through up to ID fans
inlet dampers.
Procedure for starting of RAHs:
Permissives:
a. Switch gear is available.
b. Flue gas dampers GD 1 to 12 are open.
c. Secondary dampers SAD-5 to SAD - 8, PA dampers PAD-5 to
PAD-8 are in open position.
d. LOPs of GB and SB are in service. Start air motor of RAH
and keep it running for at least 5mints. After that switch ON
the electrical drive. Observe the lub oil temperatures of the
bearings.
20. Charge Fuel oil atomizing steam station and maintain steam pressure at
12 Kg/cm2.
21. Charge Fuel oil station (HO) and keep it on short recirculation by opening
HO-40 at 16mts boiler. Inform Sub Engr/S/FOPH to raise Fuel Oil
temperature set to 1250C and maintain header pressure by taking extra pump
if necessary. Charge LO station too.
23. Open the following Turbine side drains to atmosphere and open their
manual isolating valves by about 2 turns.
a. MSSM- 31C / 37C  Drains before MS stop valves.
b. MSSM-85 / 96, HRHM-46/51 Seat drains.(HPSV1&2, IPSV1&2)
c. MSSM-142A /142B  MS Drain pot drains (L/R).
d. MSSM-83A/94A  MS Strainer drains(L/R)
e. MSSM-142C / 142D  HPBP drain pot drains.
f. 8No manual valves in the HPBP up stream path.
f. CRHM-67A / 67B  CRH Drain pot drains.
g. HRHM-41A / 41B  HRH Drain pot drains.
h. HRHM-32 /36  HRH Strainer drains.
24. Ensure that the following MAL drains are in open position. Keep SLC
drains in auto or open them.
a. Drains before HPCVs  MAL - 11, MAL -12
b. Drains after HPCVs  MAL - 15, MAL - 16
c. Drains before IPCVs  MAL -26, MAL -27
d. Drains after IPCVs  MAL -31, MAL - 32
e. HP Casing header drain  MAL - 22
f. Drains before CRH NRVs  MAL - 65, MAL - 66
g. Drains before extraction valves  MAL -55, MAL -54,
MAL - 51, MAL -47
h. Drain before gland steam
Control valve  AS - 102
i. Gland steam header drain  MAL - 81
25. Ensure that the following valves of Turbine drains to condenser through
Flash Box and their manual isolation valves are in closed position.
a. CRH line NRV drains  CRHM -86A
b. CRH line drain pot drains  CRHM -22A / 22B
c. CRH line (HPBP) drain pot drains  MSSM -130C, MSSM-130D
d. HRH line drain pot drains  HRHM - 56A/56B
e. HRH line strainer drains  HRHM - 34 / 38
 g. Drains before LPBP valves  HRHM -19A, 40A,
HRHM - 89B / 90B
26. Start Lops of ID fans and FD fans.
27. Start ID Fan - A
Procedure for starting of ID Fan:
Check the following permissives before starting the motor
a. Switchgear is available.
b. Flue gas path available (Corresponding RAH is in service and
FG Dampers in that path are open)GD 1 to 12.
c. Fan inlet and outlet dampers GD -13 and GD -15 are in closed
position.
d. Inlet vane is at minimum position.
e. Lub oil pump is in service. (Lub oil pressure adequate)
f. Scoop or VFD is at minimum.
g. Motor bearing / winding temperature normal.
h. Fan bearing temperature normal.
Start the fan and check the following :
a. ID Fan starts.
b. Inlet and Outlet dampers open. (GD-13, GD-15)
c. Open the inlet vane.
d. Operate Scoop or VFD to maintain draft.
28. Start FD Fan - A
Procedure for starting of FD fan:
Check the following permissives before starting the motor
a. Switch gear is available.
b. Fan outlet damper SAD-3 close.
c. LOP is in service and LO pressure adequate.
d. Blade pitch is at minimum position.
e. Any ID fan is running.
f. Control oil pressure adequate (8Kg/Cm2).
g. Motor bearing / winding temperature normal.
 Start the motor and observe the following:
a. Fan starts
b. Outlet damper opens.
c. Operate the Blade pitch to raise the secondary air
flow/pressure.
29. Start second set of ID and FD fans.
30. Operate the blade pitches of both FD Fans and raise the secondary air flow
to 280 to 300TPH, simultaneously operate the Scoops or VFDs of the ID
Fans and maintain Furnace pressure at -20 mmwcl. Set the wind box to
furnace differential pressure at 40 mmwcl. The above operations must be
done carefully to avoid excessive variations in the draft.
31. Charge the SCAPH by opening ASSM - 101. Open SCAPH CV 118A/118B
or 120A/120B. Close SCAPH bypass damper SAD - 5 and SAD - 6 to allow
the secondary air to pass through SCAPH.
32. Start Ignitor air fan and AC Scanner air fan. Observe Ignitor air fan
discharge pressure is around 220mmwcl and scanner air fan discharge
pressure is around 320mmwcl. Keep DC scanner air fan as auto standby.
Ensure closure of emergency air damper.
33. Switch on Rapping motors of ESP fields in sequential operation.
34. Note down the Boiler expansions at various levels. These are to be watched
periodically to ensure the healthiness of the Boiler.
35. Check all purge permissives are available.
36. Keep the Burner tilt horizontal.
The following are the purge permissives:
i. No Boiler trip.
ii. All HO, Ignitor, LO Trip valves are in close position.
iii. Both PA fans OFF.
iv. All Mills OFF.
v. All PC outlet gates close.
vi. All Oil nozzle valves are in close position.
vii. Flame Scanners of all the elevation show no flame.
 If so, start purging. After 5mts, purge complete indication comes and
Boiler Trip is reset. (MFT resets).
37. Open the Ignitor oil trip valve, heavy oil trip valve, recirculation valve and
LOTV. Raise the HO pressure to 10Kg/cm2. Ensure all guns are in engaged
condition and all manual isolating valves of both oil and steam lines are in
open position. Keep all oil guns under local scavenge for about 10mints
38. After Fuel oil temperature raises to 1000C and secondary air temperatures to
around 800C, Flash the Boiler with one pair i.e. BC 1 & 3 HO guns after
informing AAE/Shift/Boiler. Take other pair of HO guns BC 2 & 4 after
15mints and stop 1st pair of HO guns. The long Recirculation valve closes in
auto when first gun comes into service and vice versa. After ½ hour, keep all
the 4 HO guns in service. If an oil gun does not prove, cut off the gun and
arrange for cleaning. Always maintain fuel oil temperature > 950C to ensure
proper combustion.
39. Check the oil flame through peep holes at close intervals for ensuring proper
combustion. Adjust secondary air flow if necessary.
40. The Oil catch detectors are to be inserted in the air heaters soon after
establishing HO guns. Observe the Oil catch detectors at regular intervals
for unburnt oil traces. The local operator has to check Air pre heater at
regular intervals for any visible fires.
41. At Drum pressure = 2Kg/cm2 or Drum metal temperature on water side at
1200C close the Drum vents B-18, B-19, and SH air vents S-15, S-16,
S-108, S-109.
At Drum pressure = 4Kg/cm2 or Drum metal temperature on
water side 1500C close the SH Drains S-9, S-10, S-11, S-12. Throttle start
up vents S-25, S-26 if necessary.
42. Always watch the Drum metal temperatures (both water and steam sides).
Difference between any two points should not exceed 500C. If the tendency
is to exceed 500C reduce firing rate by cutting off oil guns. Drum metal
temperature should be observed frequently till the temperature difference
stabilizes with in 500C.
43. During the initial pressure raising period water will swell in the Drum.
Water Swells in the Drum when Drum metal temperature on water side
reaches to 90 - 1100C. To control Drum Swelling open the emergency drum
drains B-89, B-90 and if necessary open one set of Ring header drains.
44. Ensure CBD to Deaerator BDM-78 is in closed position. As soon as Boiler is
flashed Open the CBD to Atmosphere by 2Turns (B-80 and its manual
valve).
45. As the Boiler parameters are rising watch the Boiler expansions frequently.
Boiler expansions at any level at all corners should be almost equal.
Special attention should be given to the expansion of lower part of the Boiler
relative to concrete pylons. Also observe furnace exit gas temperature (Not
more than 4800C) and metal temperatures of LTSH, ITSH, HTSH, HTRH
and Drum.
46. Vacuum Pulling:
a. Ensure the opening of ejector line drains to drain the condensate.
b. Charge the ejector line by opening the ASSM - 148 on 16ATA
header. Slowly open the manual isolating valves of ejector steam
pressure control valve ASSP-157. Set the ejector pressure at
9.0Kg/cm2 and ensure that the temperature of the steam should
be >1900C.
c. Ensure the opening of gland steam header drains.
d. Open the Turbine gland steam isolation valve on 16ATA header
(AS-22) and open the manual isolation valves of Gland steam control
valve. Ensure that temperature of the steam should be >1800C.
e. Ensure Hot well level normal > +450mmwcl. Ensure one CEP is
running and is under recirculation.
f. Start one SSCE fan duly opening its discharge valve.
Ensure the opening of MAE -A air isolation valve (SM-16), MAE-B
air isolation valve (SM-17), condenser to air evacuation header
isolation valves (SM-14, SM-15).
g. Close the vacuum beaker to pull the vacuum. Open the Steam
 isolation valve (SM-18). Vacuum starts rising. Alternately vacuum
pump may be taken into service to pull the vacuum.
h. At -0.2 Kg/cm2 vacuum give gland steam to the Turbine Glands.
i. At -0.5 Kg/cm2 vacuum open the steam inlet valve of MAE-A
or MAE-B (Start MAE-A or MAE-B) or both (AS-2 & AS-3).
j. Maintain Vacuum at around -0.90 Kg/cm2. Low vacuum trip is
to be (Both Electrical and Mechanical) tested, while pulling the
vacuum.
47. While bringing boiler to the required parameters, the firing rate should be
controlled to keep the saturated steam temperature rise below 100oC per
hour.
48. Carry out RAH Soot blowing using PRDS steam once in 4 hours as long as
oil guns only are in service.
49. Watch RAH outlet gas temperature and RAH outlet air temperatures at close
intervals. A sudden and abnormal increase in the gas or air outlet
temperature would indicate that a fire has developed in RAHs. In this event
unit has to be shutdown, box up the Boiler and measures shall be taken to
quench the fire.
50. At Boiler Drum Pressure = 5 Kg/cm2 warm up the MS lines by opening
equalizer valves MSSM - 30B and MSSM -36B. After 5mints change the
MS line, by opening the MS Stop valves MSSM-30 and MSSM- 36. Close
drains before MS stop valves MSSM - 31C, MSSM - 37C.
51. Start second CEP and keep 3rd CEP ready.
52. During all types of start ups the firing rate should be controlled to keep the
maximum FG temperature < 4800C until adequate flow is established
through the Reheater by opening HPBP and LPBP.
53. Duly ensuring the opening of 8 Nos manual valves in the up stream and
MSSM-130C, 130D in the down stream drains of HPBP are in open
position, charge the HPBP slowly to 5%.
Ensure the opening of following drains to FB-2: -
HRHM-108, 109 (Warm up lines drains),
 HRHM-19A, 40A (LPBP line drains)
Keep LPBP in auto and switch on Auto Control Interface.
54. Increase the opening of HPBP. Observe LPBP valves start opening. At 2 to
3 Kg/cm2 HRH pressure, close RH vents R-1, R-2, R-14, and R-15
55. Close the start up vents S-25, S-26.
56. At 4 Kg/cm2 HRH pressure, close the RH drains R-12, R-13.
57. Close all the Turbine drains connected to atmosphere and open all the
drains to Flash Box.
Close [MSSM - 83A, 94A( Strainer drains), 142A, 142B(Drain Pot Drains).
CRHM - 67A, 67B(Drain Pot Drains).
HRHM - 41A, 41B(Drain Pot Drains), 32, 36 ( Strainer drains)
MSSM-142C,142D (HPBP Down Stream Drains)
MSSM-31C,31D (Drains before Boiler Stop Valves).]
Open [CRHM -22A, 22B (Drain Pot Drains), 86A (CRH NRV Drain)
HRHM - 56A, 56B (Drain Pot Drains), 34, 38 (Strainer drains)
HRHM-46, 51 (IV Seat Drains)].
NOTE: MS strainer and drain pot drains should be closed at MS pressure < 10 kg/cm2
58. Charge ESP fields when FG temperature after RAH rises to 800C.
59. Gradually raise the Drum Pressure to 30 Kg/cm2. Rise the temperature of the
Boiler at a rate of 1000C per hour. Check Boiler expansions.
60. Start TSP pump at 30Kg/cm2 Drum pressure.
61. Hot blow down of the Boiler has to be carried out at a Drum pressure of
30 Kg/cm2 to flush out the welding butts and small iron pieces etc. For that
hand trip the Boiler and start purging. Open each set of Ring header drains
for 2 mts each. After that close all the drains and bring the Drum level to
normal position and flash the Boiler with BC 1 to 4 and DE 1 to 4 HO guns.
62. Raise the Boiler parameters as follows duly operating HP LP Bypass
MS Pressure : 40Kg/cm2
MS Temperature : 3200C to 3500C
RH Pressure : 12Kg/cm2
RH Temperature : 3200C to 3500C
 Note that LPBP changes to Auto from Auto control Interface at RH
pressure 12Kg/cm2.
63. Check the Criteria as per the curves X1, X3 and X2 on TSE indicator. Keep
SLC drains in “ON” position. Ensure TSE influence ON. Ensure Speeder
gear at 100%. Reset the Generator by acknowledging LOCK OUT relays in
Generator Protection panel. Reset the Turbine Trip by bringing the
starting and load limiting device to 0%.Ensure HP/IP trim device‘ON’and
load controller ‘ON’.

CRITERIA FOR OPENING OF STOP VALVES

600

540 RECOMMENDED
0C

480
MS TEMPERATURE

420

360 SATURATED STEAM +50

300 SATURATED

240

180

NOT RECOMMENDED
120

60

20 40 60 80 100 120 140 160 180 200

Kg/Cm2
MS PRESSURE
Kg/Cm2
ALLOWABLE MAXIMUM MAIN STEAM

200
PRESSURE AHEAD OF TURBINE WHEN
OPENING THE MAIN STEAM STOP VALVES

150
Main Steam pressure PMS

Not Recommended
100

Recommended
50

Temperature at main control valve only

at 50% wall thickness
9 MCV 50%
50 100 150 200 oC 250

Recommended minimum ( curve A) and

maximum (curve B) Main Steam
temperature ahead of Turbine when
opening the main stop valves
MAIN STEAM TEMPERATURE

oC
NOT RECOMMENDED

500
B

400
A
RECOMMENDED
300
NOT RECOMMENDED

200
9 MS

100

0 100 200 300 400 500 o

C
Temperatures of main control body
at 50% wall thickness 9 MSC 50%
 DIFF.TEMP.CRITERIA X1

500

STEAM TEMP.BEFORE H.P

RECOMMENDED ZONE
400

BYPASS
300

200

NOT RECOMMENDED ZONE

100

0
0 100 200 300 400 500
MID.TEMP.OF M.C.V
DIFF.TEMP.CRITRRIA
X1
OPENING OF H.P STOP VALVES
MS Temp. before HP Bypass >Mid wall Temp.HP CTRL Valve +X1

DIFF.TEMP.CRITERIA X2

500

NOT
400 RECOMMENDE
D
SATURATED STEAM

300
TEMP.

200

RECOMMENDED
100

0 100 200 300 400 500

MID.TEMP.OF
M.C.V
DIFF.TEMP.CRITRRI
A X1
OPENING OF H.P STOP VALVES

Temp.saturated >Mid wall Temp.HP CTRL Valve +X2

 DIFF.TEMP.CRITERIA X3

o
C
500
NOT RECOMMENDED
MAIN STEAM TEMP.BEFORE H.P BYPASS
400 OVERRUN
CONDITION
400OC

300

200

RECOMMENDED
100

0
0 100 200 300 400 500
oC
MID.TEMP.OF M.C.V
DIFF.TEMP.CRITERIA X3

OPENING OF H.P STOP VALVES

MS Temp. before HP Bypass >Mid wall Temp.HP CTRL Valve +X3

1. DT (HPBP1-MCV1) > X1
2. DT (HPBP2-MCV2) > X1
3.(SH Stm. Temp.before HPBP1-SST1) >30K
4.(SH Stm. Temp.before HPBP2-SST2) >30K
5.DT(Wet Steam1-MCV1) < X2
6.DT(Wet Steam2-MCV2) < X2
7.(RH Stm. Temp.before LPBP1-SST1) >30K
8.(RH Stm. Temp.before LPBP2-SST2) >30K

64. Open MAL drains MAL-11 and MAL -12. Check that HP stop valve and
control valve body inner and middle temperature reach 1500C and
differential temperature between inner and middle of the body < 300C.
65. Keep isolating levers in the governing rack in such a position that EHG
is in service.
66. Open HP and IP stop valves by operating SLLD to about 40% position.
67. Ensure H2 Dryer is in service. Ensure H2 pressure 2Kg/cm2 and H2 purity >
98.2% and seal oil system is normal.
68. Check the criteria as per curves X4 and X5 on TSE indicator fulfilled. Ensure
SLC oil temperature controller is in auto with set point at 450C after coolers.
 DIFF.TEMP.CRITERIA X4
TURBINE ROLLING ON STEAM
(Before Raising Turbine Speed to 600 rpm)

( 0C )

500

MAIN STEAM TEMPERATURE BEFORE HP

400

STOP VALVES
300 RECOMMENDED

200

NOT
100 RECOMMENDED

0
0 100 200 300 400 500 ( 0C )
MAIN STEAM TEMP.SATURATED
MS Temp.Bef.HP Stop Valves > MS Temp.saturated + X4
1. ( SH STM TEMP.BEF.ESV1-SST1 ) > X4

2. ( SH STM TEMP.BEF.ESV2-SST2 ) > X4

3. STM TEMP.BEFORE LPB1 > 4800C

4. STM TEMP.BEFORE LPB2 > 4800C

5. DT ( HP ESV1-HPS ) >X5

6. DT ( HP ESV2-HPS ) >X5
7. DT (LPBP1-IP Casing ) > 30K

8. DT (LPBP2-IP Casing ) > 30K

 DIFF.TEMP.CRITERIA X5
TURBINE ROLLING ON STEAM
(Before Raising Turbine Speed to 600 rpm)

Temp.bef: HP Stop valves-1 > Mid wall Temp.(evaluated) HP Shaft + X5

Temp.bef: HP Stop valves-2 > Mid wall Temp. HP Casing + X5

( 0C )

500

MAIN STEAM TEMPERATURE BEFORE HP 400

RECOMMENDED
STOP VALVES

300

200 NOT
RECOMMENDED

100

0
0 100 200 300 400 500 ( 0C )

MID WALL TEMP.(EVALUATED) HP SHAFT

MID WALL TEMP. HP CASING

69. Raise the SLLD position to 85%. Set the speed reference set point at
600rpm. The TG set will pick up the speed to 600rpm and maintain 600
rpm.
70. Watch gate valve gearing closes at 240 rpm if not, close it manually. Watch
JOP stops at 540 rpm if not, stop it manually. Then keep their SLCs in ON
position.
71. Check vibrations, temperatures of bearings and expansions of Turbine. Also
check TSE Margins at frequent intervals.
72. Soak the Turbine at 600rpm for about 2 to 3 hours, until the temperature of
HP casing/rotor reaches to 2000C (Mid temperature point).At this
temperature HPT overall expansion is around 5mm where as that of IPT is
about 2.5mm. Close MAL - 11 and MAL -12.
73. Check the criteria as per curve X6 on TSE indicator and check TSE margins.
Open cooling water valves to exciter coolers, H2 coolers and MOT coolers
 DIFF.TEMP.CRITERIA X6
TURBINE RAISING TO RATED SPEED

MS Temp. bef : HP Bypass < Mid wall Temp.( evaluated ) HP Shaft + X6

( 0C )

500
NOT
RECOMMENDED

MAIN STEAM TEMP.BEF.HP BYPASS

400

300

RECOMMENDED
200

100

0
0 100 200 300 400 500 ( 0C )

MID WALL TEMP.(EVALUATED) HP SHAFT

1. DT (HP Bypass 1 - HP Shaft ) < X6

2. WALL TEMP.( HP Casing ) > X6

3. TSE MARGIN > 30 K

. 4.DT ( LP Bypass 1 - IP Shaft ) < X7

DIFFERENTIAL TEMPERATURE CRITERIA X7

(oC)

500
NOT
RECOMMENDED
400

300

200
RECOMMENDED

100

0
0 100 200 300 400 500 (oC)

MID WALL TEMPERATURE (EVALUATED) IP SHAFT

74. Roll the Turbine to 3000 rpm by raising the speed reference setter to 3000
rpm in a continuous manner (not in pulses) so that Turbine crosses the
critical speeds fast. Speed of the Turbine should reach 3000 rpm in 4minutes.
75. While Turbine is speeding up to 3000rpm, watch for speed/power reference
blocked indication and if it appears, immediately reset it. Set the load
reference set point at 20MW (house load).
76. Check the expansions, vibrations and bearing temperatures. Set the speed of
the Turbine corresponding to the frequency of the grid.
77. Keep AVR in Auto. Close the Field beaker. The Generator voltage builds
up to about 14.2KV. Raise the voltage manually to match with the grid
voltage.
78. Keep Synchronizing selector Switch on Generator control board in auto
position and Switch ON the auto synchroniser on Turbine console. If the
time exceeds for synchronization auto Synchroniser blocked indication
appears. Reset and Switch ON the auto synchroniser again.
79. The GCB closes in auto after synchronizing condition is achieved by
control of voltage and speed from the auto synchronizer.
80. Once the Unit is synchronized, raise the speed reference to get a load of
20MW. Raise the load reference so that load controller takes over. Generator
MVAR has to be maintained as per grid requirement.
81. Close the HPBP slowly. LPBP closes in auto.
82. Keep HPBP in Relief mode. Keep HPBP valves and their spray valves in
auto.
83. Close all the drains which are connected to FB AND IBD(Both Boiler side
and Turbine side).
84. To avoid adverse visible stack emission it is desirable to use the L.O/H.O.
guns till Drum pressure reaches to 35Kg/cm2 and secondary air temperature
reaches to 1750C before firing pulverized coal.
85. Line up and Start PA Fan:
Procedure:
Observe the following permissives before starting PA Fan.
a. Lub oil pressure adequate. (LOP in service)(0.8 Kg/Cm2)
b. Inlet vane minimum.
c. Outlet damper close.
 e. Any one FD fan running.
f. Switch gear availability.
g. Bearing / winding temperature normal.
Start PA Fan A or B. Outlet damper PAD 3 / PAD 4 opens in auto. Slowly
raise the inlet vane to get required pressure i.e., 800 mmwcl.

NOTE: 1. Before starting PA fan ensure that supply voltage is at 6.7KV.

2. As soon as the PA fan is started load the fan at the earliest to avoid
vibrations and damage to the bearings.
86. Start ‘B’ Elevation of Mill AB
Procedure:
Observe the following permissives:
a. Mill Lub oil system ok.
b. Any PA fan ON.
c. Ignition energy availability (3 HO Guns in BC elevation).
d. EM brake is not engaged.
e. Seal air fan header pressure > 600 mmwcl.
f. Girth gear seal air fan ON.
g. PA General gate, PC outlet gates and purge dampers close.
h. No MFT Trip.
i. Aux Motor OFF.
Ensure the following conditions:
a. Mill AB is on barring gear.
b. Bunker gates of all RC feeders are open.
c. Instrument air valves to RC isolation gate and
PA general gate are open.
Give the Start command to B- elevation:
The following sequence takes place
a. Purge shut off damper opens and purge air dampers open. After
1minute they close in auto.
 b. Command goes to open the PC outlet gates. After the PC outlet gates
are opened simultaneous commands go to start Mill Main Motor and
open PA general gate.
c. After ensuring the above conditions open the Hot air damper to 70%.
Raise the bypass air damper of the elevation to get 30 TPH bypass
flow.
d. When the classifier outlet temperature reaches to 500C RC isolation
gate opens and RC Feeder starts in auto. Sequence is completed.
Load the Mill slowly. Raise the PA flow through the elevation after
establishing sufficient pulverized coal in the Mill to increase the
firing rate in the Boiler. MS Pressure starts raising. Duly watching
TSE Margins load the Generator according to MS Pressure. If TSE
Margins are not ok, maintain the MS and RH temperatures steadily
and wait till they are OK.
87. Raise the Secondary air flow inline with PA flow to ensure complete
combustion. Remove the Oil catch detectors. Set the wind box to furnace
DP to 50mmwcl.Cut off DE 1 to 4 HO guns.
88. Charge LP Heaters 1, 2, 3 at 30 to 40MW load.
Notes on LP Heaters:
a. To charge the Drain Cooler and LP Heaters with water first open
their vent valves. Charge the heaters and Drain cooler with
condensate. After ensuring water flow through vents, close them.
b. Drip levels in LP Heaters 3 and 2 are controlled by cascading LP
Heater-3 drip to LP Heater-2 by control valve DR-17 and by
cascading LP Heater-2 drip to LP Heater-1 by control valve DR-22
by the normal drip level controllers of LP Heater-3 and LP Heater-2.
c. In case drip levels of LP Heater-3 or LP Heater-2 increases to high
level due to some problem, the heater drain is taken to Flash box no-
1 through control valves DR-20 and DR-25 for LP Heater-3 and LP
Heater -2 by respective high level controllers.
d. In case of high level in LP Heater-2 or 3 the respective heater gets `
 Drain valves in the extraction lines down stream of NRVs also open
from high level switch of respective heater. Normal drip valves close
on priority command.
e. After heater gets isolated on steam side by the closure of Extraction
valve, isolate the heater on condensate side by first opening the
bypass valve and then closing the isolation valves.
f. While bringing the heater in line it should be charged on condensate
side first and then on steam side.
Charging of LP Heaters:
a. Open the following extraction line drains to flash box. There is no
drain for LP heater-1, there are two drains Ex-101, Ex-102 for LP
heater-2 and one drain Ex-103 for LP heater-3.
b. Open the swing check valves A2, A3.
c. Open the extraction valves Ex-9, Ex-10, Ex-11 slowly.
d. After the extraction valves are opened fully close the drains.
Condensate temperature starts rising.
89. Check all parameters are normal
i. Cold gas temperature.
ii. Turbine oil temperature.
iii. Vibrations of TG set.
iv. H2 pressure and purity.
v. Bearing and winding temperature of all running equipment.
vi. Expansions of Turbine and Boiler and axial shift of the
Turbine.
90. Secondary air flow may be increased on par with load as per air flow (Vs)
load curve.
91. At 60 to 70MW charge the deaerator with extraction steam.
Procedure:
a. The extraction line drains Ex-104, Ex-107, Ex-108 are manual
valves and they are always in open position.
b. Open the Swing check valve A4.
 d. After the extraction valve is opened fully close the drain.
e. Stop the pegging steam to Deaerator.
92. Change over control valve from low load to full load control valve or
standby feed water control valve slowly without disturbing the Drum level.
93. Change over Auxiliary load from station to UATs at 70 to 80MW load.
94. Start PA fan ‘B’ after taking LOP. Outlet damper opens in auto. Load
PA fan-B slowly and make it parallel to PA fan-A and maintain header
pressure at 950 mmwcl. Keep the PA fans A&B in auto with set pressure =
950 mmwcl.
95. Start ‘A’ elevation of Mill AB. Raise the parameters slowly to MS Pressure:
100 to 120Kg/cm2, MS Temperature: 5000C. Slowly raise the load to 90MW
to 110MW by observing TSE margins.
96. Start second BFP and load two BFPs equally. Keep 3rd BFP in auto
standby mode.
97. Charge HP heaters 5 and 6 at 80 to 100MW.
Notes on HP Heaters:
a. To charge the HP heaters on water side first open the
vent valves. Slowly open the feed water inlet valve and
then open the outlet valve. After water is coming out
from the vents, close the vents.
b. The normal drip level in the HP Heater 6 and 5 is
controlled by cascading HP Heater6 drip to HP heater-5
through control valve DR-2 and HP heater-5 drip to
Deaerator through control valve DR-12.
c. In case of a problem in HPheater-5 or in the control
valve DR-2, the drip from HP heater-6 is diverted to
Deaerator by DR-6 control valve and the level in the HP
heater-6 is maintained by Normal level controller.
d. In case level reaches high in HP heater-6 and 5 due to
tube leak or other problems Extraction valves get closed
and the drips are diverted to Flash box-2 by operating
 e. In case Heater level reaches high condition the heaters
are to be isolated on both steam as well as water sides
i.e.
1. Extraction valves get closed.
2. FD-9 and FD-12 get opened.
3. FD-7/FD-8 and FD-10/FD-11 get closed.
During the process, spring load group bypass
valve opens automatically and ensures uninterrupted
flow to the Boiler.
f. Whenever any heater is to be charged first charge on
feed water side and then on steam side.
Procedure of charging HP Heaters:
a. Open the extraction drain valves to Flash Box Ex-112,
Ex-110.
b. Open FD-7, FD-8, FD-10 and FD-11 valves.
c. Close FD-9 and FD-12.
d. Open swing check valve A5 for HP heater-5.
e. For HP heater-6 CRH NRVs are swing check valves
which get opened at 600rpm of Turbine.
f. Slowly open extraction valves Ex-12 and Ex-13.
g. Ensure the closing of drains on extraction lines.
98. Start 2nd Mill either CD/EF with elevations ‘C’ or ‘E’.
99. Slowly raise the MS Pressure = 130 to 140 Kg/cm2 and MS Temperature
5200C, Load to 160MW.Keep Boiler Master in Auto. Keep CMC in auto.
100. Watch O2 and raise secondary air flow as per requirement. Keep FD fans in
auto.
101. Start elevation ‘D’ /’F’. Raise the MS Pressure 150Kg/cm2 MS Temperature
5400C, Load: 210MW. Cut off the oil support when the load > 180MW.
5. HOT START-UP OF STEAM TURBINE
A hot start up is Carried Out when the maximum HP casing/shaft temperature is
>3500C. The procedure to be followed for starting and loading of 210MW units of
stage -II is given below.

1. Ensure BCWPs, CWPs, RAHs, one CEP, IACs, SACs and scanner air fan,
seal oil system are in service. Turbine is on barring gear. Auxiliary steam
header (16ATA) is in charged condition. SCAPH system, Ejector line system,
Gland steam system, vacuum pump are lined up. Ensure scrapper conveyor
system and Ash handling systems are in service. And also ensure Heavy
oil is under short recirculation.
2. Parameters:
Drum pressure:  70Kg/cm2,
MS Temperature:  4000C to 4200C.
Line up MS, CRH and HRH lines by opening their drains to atmosphere.
Don’t open MS Strainer & Drain Pot drains at Boiler Pressure >10Kg/cm2.
Ensure that MSSM - 30, MSSM-36 & their equalizer valves are in closed
position.
3. Start ID fans and FD fans and Maintain Total air flow at 280 TPH and
furnace pressure at -20mm wcl. Charge the SCAPH (if required).
4. Start BFP and feed the Drum to normal level. Peg the Deaerator with aux
steam to 3.5 Kg/cm2. Start hydrazine & TSP pumps.
5. Purge the Boiler and open the HOTV, HORCV, Ignitor trip valve.
Start Ignitor air fan.
6. Flash the Boiler with BC 1 to 4 HO guns. Open CBD by 2 turns to
atmosphere. Open start up vents S-25, S-26.
7. Start one SSCE and open its inlet valve. Close the vacuum breaker and start
vacuum pump. At -0.2Kg/cm2 admit gland steam after ensuring gland steam
temperature is more than 1900C before the valve. Take MAEs into service
at -0.5 Kg/cm2.
8. Open drains before MS stop valves MSSM-31C, MSSM-37C and then charge
the MS lines by opening MSSM-30B, MSSM-36B and MSSM-30,
9. Ensure the opening of 8 no.s manual valve drains in the up stream of HPBP
and MSSM-130C, 130D to FB-2.
Ensure the opening of following LPBP drains to FB-2 :
HRHM-108,109 (Warm up lines drains),
HRHM-90A,90B (LPBP line drains),
HRHM-19A,40A (LPBP line drains)
Open HPBP. Keep LPBP in Auto. Close the start up vents S-25, S-26.
Ensure adequate steam flow in RH coils at RH Pressure of 3 to 4 Kg/cm2.
10. Open the drains of MS, CRH, HRH lines to flash box and close the drains to
atmosphere. Open the seat drains, switch SLC drains ‘ON’.
The Drain No’s are given below
CRHM-22A, CRHM-22B, HRHM-56A, HRAHM-56B, HRHM-34,
HRHM-38, CRHM-86A, MSSM-85, MSSM-96, HRHM-46, HRHM-51.
11. Start one PA fan and raise the header pressure to 900mmwcl.
12. Start ‘B’ elevation of Mill AB.
13. Charge ESP fields.
14. Increase the firing rate and raise the MS Pressure and MS Temperatures.
Open the HPBP &LPBP more and obtain the rolling parameters.
15. Rolling Through Hydraulic Governor
Required Parameters:
MS Pressure: 80Kg/cm2
MS Temperature: 4800C
RH Pressure: 12Kg/cm2
RH Temperature: 4500C
Bypass steam flow: 280TPH
a. Isolate EHG at Governing Rack by operating the levers.
b. Ensure that SLLD and speeder gear are at zero.
c. Ensure TSE Influence is ON and available margins are greater than
300C. Open the stop valves by operating SLLD up to 42%.
d. Raise the parameters to the following values
MS Pressure: 80Kg/cm2
 RH Pressure: 12Kg/cm2
RH Temperature: 4800C
HPBP Steam flow: 360TPH
e. Raise the speed of Turbine to 600 rpm by operating SLLD to 56%.
Ensure closing of gate valve gearing at 240 rpm and tripping
of JOP at 540 rpm.
f. Raise the speed to 2400 rpm by operating SLLD at a rate of
600 rpm/minute.
g. Using the speeder gear raise the speed to 3000rpm. Ensure opening
of cooling water valves to H2 coolers, Exciter coolers and MOT
coolers. Set the oil temperature at 450C.Inform MCR that the unit is
about to be synchronized. Monitor vibrations, expansions, bearing
and drain oil temperatures.
h. Keep AVR in auto and close the field breaker. Set the generator
voltage as per the requirement of the grid. Set the speed of the
machine using speeder gear to match with grid frequency.
i. Synchronize the generator with the grid and raise the load to 20MW
using speeder gear.
j. Using speeder gear load can be raised to 210MW while increasing
the firing rate.
k. Soon after attaining the full load and to limit the load variations with
the frequency it is advisable to keep SLLD in operation. For that
slowly raise speeder gear position and reduce SLLD position
simultaneously without change in load till speeder gear position
reaches to 100%. Change the load with SLLD whenever required.
16. Rolling through EHG
Parameters required:
MS Pressure: 80Kg/cm2
MS Temperature: 4800C
RH Pressure: 12Kg/cm2
RH Temperature: 4500C
 a. Check and ensure the position of levers in the Governing rack.
b. Check and ensure that SLLD position is at 0% and speeder gear
position is at 100%.
c. Open ESVs and IVs for warming up by operating SLLD to 42%.
Ensure TSE influence is ON and available margins are greater than
300C.
d. Raise the parameters to the following values
MS Pressure : 80Kg/cm2
MS Temperature : 5000c
RH Pressure : 12Kg/cm2
RH Temperature : 4800c
HPBP Steam flow : 360TPH
e. Raise the SLLD to 80%. Raise the speed reference set point to
600rpm and watch the speed. If tracking device is switched ON,
SLLD position will automatically trace the EHG position.
f. Ensure gate valve gearing closes at 240rpm and tripping of JOP at
540rpm. Hold the speed at 600 rpm for 5 mts.
g. Ensure opening of cooling water valves to H2 coolers, Exciter
coolers, and MOT coolers. Set the oil temperature set point at 450C.
h. Raise the speed set point to 3000rpm in a continuous manner not in
pulses and speed raises at the rate of 600rpm/minute.Monitor
expansions, vibrations, bearing and drain oil temperatures. Using
load reference set the load at 20MW. Inform MCR that the unit is
about to be synchronized.
i. Keep AVR in Auto. Close the FB. Set Generator voltage as per the
requirement of the grid. Set the speed of the machine to match with
the grid frequency.
j. Switch on auto synchronizer. It synchronies the unit with the grid.
Raise the speed reference by 15 rpm to get 21MW.Raise the load
reference set to activate load controller.
17. Rolling through SGC
 MS Pressure : 80Kg/cm2
MS Temperature : 4800C
RH Pressure : 12Kg/cm2
RH Temperature : 4500C
Bypass steam flow: 280TPH
Switch on startup programme of SGC turbine. Ensure TSE
influence is ‘ON’. If the programme gets interrupted the particular
step and criteria are to be checked and corrected for the
programme to proceed further.
b. SLLD will be raised to 42% by the SGC turbine auto start up
programme to open the HPSVs & IPSVs. Ensure their opening to
full.
c. Raise the Boiler parameters by raising the firing rate to get the
following
MS Pressure : 80Kg/cm2
MS Temperature : 5000C
RH Pressure : 12Kg/cm2
RH Temperature : 4800C
HPBP Steam flow : 360 TPH
d. Turbine speed is raised to 600 rpm through SGC programme. Ensure
closing of gate valve gearing at 240 rpm, trip of JOP at 540rpm. To
achieve the programme MS Temperatures & RH Temperatures must
be maintained steadily at around 5000C till the unit gets
synchronized with the grid
e. Turbine speed is raised to 3000rpm through SGC programme.
Ensure opening of cooling water valves to H2 coolers, Exciter
coolers and MOT coolers. See that the turbine lub oil temperature is
maintaining at 450C in auto. Inform MCR that the unit is about to be
synchronized, monitor vibrations, expansions bearing and drain oil
temperatures.
f. Raise the parameters to the following level:
 MS Temperature : 5000C
RH Pressure : 12Kg/cm2
RH Temperature : 4800C
HPBP Steam flow : 360 TPH
Speed : 3000rpm
g. SGC programme switches on the field breaker after changing AVR
to Auto and builds up the generator voltage. The programme
switches on the Auto Synchroniser. It synchronizes the generator
with the grid and picks up a load of about 21MW. SGC start up
programme is completed.
h. Raise the load reference set to activate load controller.
18. Close HPBP. LPBP closes in auto. Keep HPBP in Relief mode. Keep
HPBP valves and their spray valves in auto.
19. Close all the drains in MS, CRH and HRH lines and keep SLC drains in ‘ON’
position.
20. Using speeder gear when Hydraulic Governor is in service and raise the load
to 50MW. If EHG is in service raise the load to 50MW using speed reference
or load reference.
21. Parameters:
Load : 50MW
MS Pressure : 80Kg/cm2
MS Temperature : 5000C
RH Pressure : 14Kg/cm2
RH Temperature : 4800C.
Charge LP heaters 1, 2, 3. at 30MW.
22. Change over Auxiliary loads from station bus to UATs at a load of 60 to
70MW.
23. Take 2nd PA fan into service and load it. After equalising the load on both
PA fans, keep the PA fans A&B vanes in Auto.
24. Cut in ‘A’ elevation of Mill AB. Raise the load according to MS Pressure.
25. Parameters:
 MS Pressure : 100Kg/cm2
MS Temperature : 5000C
RH Pressure : 16Kg/cm2
RH Temperature : 5000C.
Charge the Dearator with extraction steam and close the pegging steam valve
AS-17.
26. Cut in HP heaters at 80MW.
27. Take 2nd BFP into service.
28. Cut in first elevation of 2nd Mill (3rd elevation) and raise the firing rate. Keep
CMC in auto at load >120MW.
Parameters:
Load : 150MW
MS Pressure : 140 Kg/cm2
MS Temperature : 5350C
RH Pressure : 20 Kg/cm2
RH Temperature : 5350C.
29. Cut in 4th elevation. Raise the load to 180MW. Cut off HO support at load >
170MW after ensuring all four coal elevations are established.
Parameters:
Load : 210MW
MS Pressure : 150Kg/cm2
MS Temperature : 5350C
RH Pressure : 36Kg/cm2
RH Temperature : 5350C
MS flow : 630 TPH
 6. WARM STARTUP OF STEAM TURBINE

A warm start up is carried out when the maximum temperature of HP casing

/ HP shaft is in between 1500C to 3500C. This normally means that the Unit has
been under shut down for 1 to 4 days. According to the absolute temperatures of
HP casing / HP shaft, required Steam parameters are derived for the rolling.

Since the maximum temperature in warm start up is 3500C suitable MS

temperature (4000C) can be achieved with Oil guns. Mill need not be taken into
service. First mill can be taken into service after synchronization.

1. Ensure the following

a. Regenerative air heaters are in service and Flue gas path is through.
b. AC scanner air fan is in service.
c. Seal oil system is in service and Generator is filled with H2 gas to
1.8 Kg/cm2 pressure and purity >98%.
d. Turbine is on Barring gear with AC AOP and AC JOP, OVE in service.
e. Raw water pumps, BCWPS & CWPS are in service.
f. Furnace scrapper conveyor is filled with water and over flow is established.
g. SCAPH system, ejector line system and gland steam line system are lined
up with drains in open position to let out the condensate.
h. IACs and SACs are in service.
2. Boiler Drum Pressure is 0Kg/cm2
a. Charge Auxiliary steam header from existing Units and maintain a pressure
of 16Kg/cm2 and temperature at 230oC to 260oC. Ensure opening of
drains in Ejector steam and gland steam lines.
b. Start ID fans A & B and FD fans A & B one after the other and maintain
air flow at 280TPH and furnace pressure at -20mmwcl.
c. Charge the SCAPH.
d. Line up CRH, HRH and MS lines by opening respective line drains.
Switch on SLC drains.
e. Ensure Deaerator level is OK. Ensure that water is chemically dozed and
required concentration is achieved.
f. Charge Deaerator with pegging steam at a pressure of about 1.5Kg/cm2.
g. Start one BFP and fill the Boiler drum up to 2 ports in Hydra step.
h. Ensure hotwell level is OK. Start one CEP and keep it under recirculation.
i. Complete Boiler purging.
j. Ensure opening of Super heater, Drum, Reheater vents and drains.
k. Ensure closure of Boiler stop valves MSSM-30, MSSM-36 and their
equalizer valves MSSM-30B, MSSM-36B and opening of Drains before
stop valves MSSM-31C & MSSM-37C.
l. Flash the Boiler with BC 1 to 4 H.O guns.
m. At Drum pressure 2 kg/cm2 close Superheater and Drum vents except
start up vents. Close Superheater Drains at Drum pressure 4Kg/cm2.
n. Start one Seal steam condensate extraction fan after opening its inlet valve
locally and close the vacuum breaker. Start vacuum pump. At - 0.2Kg/cm2
admit gland steam at a temperature >1900C and maintain gland steam
pressure at 0.01Kg/cm2. At -0.5Kg/cm2 take one MAE into service and
build up condenser vacuum to -0.85Kg/cm2. Ensure ejector steam
temperature to be more than 2000C.
o. At. MS Pressure 5Kg/cm2, open MS Equalizer valves MSSM-30B,
MSSM - 36B and then open Main valves MSSM -30, MSSM-36
slowly.
p. Duly ensuring the opening of HPBP upstream and down stream drains and
LPBP drains, charge HPBP.
q. Switch ON Auto control interface of LPBP. This keeps the LPBP valves in
fixed open position at 25% and as we open HPBP more and more HRH
2
. Auto control interface switches OFF automatically when the HRH pressure
reaches to 12Kg/cm2, and switches on LPBP to Auto mode
maintaining RH pressure at 12Kg/cm2. r. Open MS, CRH and HRH line
Drains to Flash box. Close MS, CRH and HRH line drains to atmosphere.
Open seat drains too.
s. Take DE 1 to 4 H.O guns into service.
t. Open HPBP valves further as per the requirement of steam pressure and
temperature rise.
u. Carry out the air heater soot blowing once in 4 hours as long as oil firing is
in service.
3. Rolling through Hydraulic Governor
a. Raise the parameters to the following values:
MS Pressure : 40Kg/cm2
MS Temperature : 3500C to 3800C
RH Pressure : 12Kg/cm2
RH Temperature : 3500C to 3800C.
Bypass flow : 150TPH
b. Isolate EHG at governing rack by operating the levers.
c. Ensure TSE Influence is switched ON. Ensure speeder gear is at 0% and
SLLD at 0%. Open HP/IP stop valves by operating the SLLD to 42%.
Observe that the margins are > 300C.
d. Slowly raise the parameters
MS Pressure : 40Kg/cm2
MS Temperature : 4000C
RH Pressure : 12Kg/cm2
RH Temperature : 3500C to 3800C
Bypass flow : 180TPH
e. Gradually raise the SLLD to 56%. Turbine picks up the speed to 600rpm.
Ensure the closure of gate valve gearing at 240rpm and tripping of JOP at
540rpm. Soak the Turbine at this speed till the margins are achieved.
f. Raise the speed to 2700 rpm (i.e., 90% of rated speed) using SLLD at a rate
 g. With speeder gear raise the speed to 3000rpm. Hand trip AOP at 2950rpm.
Speeder gear position will be around 50 to 60%.
h. Ensure opening of cooling water valves to MOT coolers, H2 coolers,
Exciter coolers. Monitor bearing and oil temperatures, bearing and shaft
vibrations, expansions and other important parameters.
i. Keep AVR in auto and close the field breaker. The generator voltage raises
to 14.5KV (Approx.).
j. Adjust the speed of the set to match with the grid frequency. Switch ON
Auto synchronizer or close the Generator breaker at 120 clock position of
the synchroscope. Soon after synchronization, raise the load using speeder
gear to 20MW.
k. With speeder gear, we can load the machine up to full load by increasing
the firing rate.
l. At full load HG control can be changed from speeder gear to SLLD for
maintaining load at 210MW to avoid load changes with change in
frequency.
4. Rolling through EHG:
Parameters :
a. MS Pressure : 40Kg/cm2
MS Temperature : 3500C to 3800C
RH Pressure : 12Kg/cm2
RH Temperature : 3500C to 3800C
Bypass flow : 150TPH
b. Ensure speeder gear is at 100%.
c. Ensure TSE Influence is ON, and margins are OK. Open HP/IP stop valves
for warming up by operating SLLD to 42%.
d. Slowly raise the parameters
MS Pressure : 40Kg/cm2
MS Temperature : 4000C
RH Pressure : 12Kg/cm2
RH Temperature : 3800C
e. Raise the SLLD to 85%. Raise the speed reference to 600rpm and watch
the actual speed. Ensure closing of gate valve gearing at 240rpm and
tripping of JOP at 540rpm.
Note: In all start ups, if TSE influence is switched OFF, the following
procedure may be adopted to carry out operations i.e. stop valve
openings, rolling etc. Ensure opening of seat drains and other
important drains.
i. First record 1 to 12 points in the chino recorder.
1  MS Temperature at HPSV
2  RH Temperature at IPSV
3, 4  HP stop valve inner, mid temperatures
5, 6  HP control valve inner, mid temperatures
7, 8  HP shaft inner, mid temperatures
9, 10  HP casing inner, mid temperatures
11, 12 IP shaft inner, mid temperatures
ii. For opening of the HP and IP stop valves the temperature of the Main
Steam at HPSV must be higher than the control valve body
temperature by 200C to 300C. After opening of MAL-11& MAL-12
open the stop valves if we attain the above parameters i.e., MS
Temperature at HPSV > control valve body temperatures.
iii. For opening of the control valves i.e.,to roll the Turbine to 600rpm
the temperature of the Main Steam at HPSV must be higher than HP
Casing & HP Shaft temperatures by 200C to 300C. Duly ensuring the
opening of SLC drains i.e., HP casing and other drains, raise the
speed set point to 600rpm, if we attain the above parameters.
iv. To roll the Turbine to 3000rpm, we have to watch IP shaft
temperatures too. In all the operations on Turbine side, MS and RH
temperatures at HPSV and IPSV must be greater than 3 to 12 points
in Chino recorder by at least 20oCto 30oC.
v. Please note that MS temperatures should be maintained nearer to the
maximum of 3 to10 in chino recorder and RH temperatures should be
 f. If the margins are OK, roll the turbine to 3000rpm duly ensuring the
cooling water to MOT, H2 coolers and exciter coolers. Watch the
expansions, vibrations, bearing and oil temperatures and other important
parameters. The rate of rise of speed will be around 600 rpm/min i.e., the
turbine takes 4mts to reach 3000rpm. Hand trip AOP at 2950rpm.
(Raise the speed set point to 3000rpm in continuous manner but not in
pulses)
g. Set the load reference at 20MW. Keep AVR in auto and close the field
breaker. Generator builds up the voltage to 14.5KV (Approx.).Raise the
Voltage as per the requirement of the grid.
h. Switch on Auto synchronizer. Unit gets synchronized with grid. Raise the
speed reference to get a load of 20MW.
5. Close HP/LP bypass valves. Keep HPBP in relief mode. Close all the drains. See
that SLC drains are in “ON” Position.
6. Take one PA fan and raise the header pressure to 900mmwcl.
7. Take ‘B’ elevation of Mill AB. If margins are not OK don’t raise the load. Wait
till the margins are OK. Stabilize MS and RH temperatures to get the margins.
8. Raise the load to 30MW, with rise of parameters to the following values:
MS Pressure : 50Kg/cm2
MS Temperature : 4200C
RH Pressure : 12Kg/cm2
RH Temperature : 3600C
Open A2, A3 swing check valves. Charge LP heaters 1, 2 and 3. Raise the
load reference to make load control active.
9. Slowly raise the firing rate and MS Pressure and temperatures. At 60 MW
open A4 swing check valve and charge deaerator with extraction steam and cut
off pegging steam.
10. Change the Auxiliary loads from station to UAT’s.
11. Take 2nd PA fan. Load the PA fan and parallel it to the 1st fan.
12. Take 2nd elevation of the first Mill. Raise the parameters and at 80MW
charge the HP heaters duly opening A5 swing check valve.
13. Cut in 2nd Mill at load above100MW and raise the firing rate and raise the load
to 210MW.

7. DRY SATURATED STEAM TABLE

Absolute Pressure Temperature

1 Kg/cm2 99.120C
2 Kg/cm2 119.600C
3 Kg/cm2 132.840C
4 Kg/cm2 142.890C
5 Kg/cm2 151.090C
8 Kg/cm2 169.620C
10 Kg/cm2 179.060C
20 Kg/cm2 211.410C
30 Kg/cm2 232.750C
 60 Kg/cm2 274.250C
70 Kg/cm2 284.460C
80 Kg/cm2 293.610C
90 Kg/cm2 301.930C
100 Kg/cm2 309.560C
120 Kg/cm2 323.190C
140 Kg/cm2 335.130C
150 Kg/cm2 340.590C
160 Kg/cm2 345.760C
172 Kg/cm2 351.620C

8. DRAIN VALVE OPERATING DIAGRAM FOR TURBINE COLD START

S.No Description of valve Valve No. I II III IV
.
1 M.S.Stnr Drains (L/R) to IBD tank MSSM-83A,94A O T T C
2 M.S. POT DRNS (L/R) to IBD tank MSSM-142A,142B O T T C
3 ESV Seat drns (L/R) to IBD tank MSSM-85,96 O O O C
4 MS pot & stnr combd (L/R) to ATM Manual operated O C C C
(T.G.Hall)
5 M.S POT & STNR COMBD (L/R) TO -do- O C C C
ATM (At IBD)
6 MS POT & STNR COMBD(L/R) TO -do- C O O O
IBB Tank(At IBD)
7 ESV SEAT DRNS (L/R) to ATM (At -do- O C C C
IBD)
8 ESV SEAT DRNS (L/R) to IBD tank (At -do- C O O O
IBD Tank)
9 HPBP UP-STREAM (L/R) to IBD (At -do- O T C C
nozzle)
10 HPBP Up – stream (L/R) to ATM (At TG -do- O C C C
Hall)
11 HPBP UP – STREAM (L/R) to ATM(AT -do- O C C C
IBD)
12 HPBP UP – STREAM (L/R) to IBD (At -do- C O O O
IBD)
13 CRH POT DRNS (L/R) to ATM CRHM-67A,67B O C C C
 T.G.Hall)
16 HRH STNR DRNS (L/R) to ATM HRHM-32,36 O C C C
17 HRH POT DRNS (L/R) to ATM HRHM-41A, 41B O C C C
18 HRH POT & STNR COMBD (L/R) to Manual operated O C C C
ATM(At T.G. Hall)
19 HRH STNR DRNS (L/R) to FB-2 HRHM-34,38 C O T C
20 HRH POT DRN(L/R) to FB-2 HRHM-56A,56B C O T C
21 CRH NRV DRNS (L/R) TO FB-2 CRHM-86 C O T C
22 HPBP DOWN STREAM (L/R) to ATM MSSM-142C,142D O C C C
23 HPBP DOWN STREAM (L/R) to FB-2 MSSM-130C,130D C O T C
24 HPBP DOWN STREAM (L/R) to ATM Manual operated O C C C
(At T.G. hall)
25 IV SEAT DRN (L/R) TO FB-2 HRHM-46,51 C O O C
26 LPBP WARM UP VLVS (L/R) HRHM-55A,55B O O O O
27 LPBP WARM UP DRN VLVS (L/R) TO HRHM-108,109 C O C C
FB-2
28 LPBP UP-STREAM LOW POINT HRHM-89B,90B C O T C
DRNS (L/R) TO FB-2
29 LPBP UP-STREAM DRNS BEF LPBP HRHM-19A,40A C C T C
VLVS TO FB-2

Conditions:

I.  MS pressure 0Kg/Cm2 (Before Boiler light up)

II.  MS pressure 5Kg/Cm2 (Vacuum pulled and MS Stop valves opened)
III. MS pressure 10Kg/Cm2 (HP/LPBP charged and RH pressure =
2Kg/Cm2)
V.  Unit synchronized Load = 20MW

O - Open
C - Close
T - Throttle
 9. SINGLE CONDENSER OPERATION FOR ISSUING PTW TO WORK ON
CONDENSER (FOR EXAMPLE CONDENSER-A)

1. Slowly reduce the load on the Unit to 100MW by cutting Off the top Mill and
taking Oil support to the running Mill (lower). The mill need not be made
empty. Steam inert the tripped Mill.
2. Close the air valve No: SM-14 from condenser A to air evacuation line.
3. Stop the Debris system A
4. Stop the CW pump feeding condenser -A duly keeping the standby pump in
manual mode.
5. Close inlet butterfly valve to condenser path - A. Cut off the supply to the
inlet valve CWB-8 and remove the fuses. Open air vents of condenser-A.
6. a. Make inoperative the fast opening of HPBP and keep HPBP in manual
mode.
b. Keep LPBP in manual mode.
c. Drain the water in the cooling water duct of condenser -A.
7. Observe the values of all expansions, vibrations, oil and bearing temperatures of
Turbine, LPT exhaust temperature and vacuum and all other important parameters
and ensure them to be in safe limits.
8. Open discharge valve of CWP feeding condenser-A by 15% to 20% for draining
the CW duct, if there is any passing of water from condenser inlet butterfly valve.
 The following parameters are to be observed during Single Condenser operation.
HPT IPT LPT
a. Differential expansion limits: +5.0 to -2.5 +5.0 to-3.5 +15.0 to-7.0
b. Bearing and shaft vibrations. : All bearings particularly 3rd and 4th
c. Exhaust hood temperature : Not greater than 500C.
d. Vacuum : > -0.87Kg/cm2.
e. CW temperature at
Condenser -B outlet : Not greater than450C.
f. Load, MVAR, PF, MS & RH temperatures, LTSH, ITSH, HTSH
temperatures, CW temperatures at condenser inlet and outlet.

Restoration of Normalcy after PTW on Condenser-A is returned.

1. After the PTW is returned, open the inlet and discharge valves of condenser -A to
full after switching on the supply to CWB-8, CWB-10.
2. Start either CWP -A or CWP -B which feeds the condenser -A and keep other
pump in auto standby mode. Ensure opening of condenser water box air vents.
3. Duly ensuring the water coming out from the water box vents close them.
4. Put Debris system-A into service.
5. Open the air valve no : SM -14 from condenser -A to evacuation line.
6. Start coal elevations of the 2nd mill one after the other and raise the firing rate and
MS Pressure and raise the load to full. Cut off the oil support at load > 170MW
(After establishing all four coal elevations.)
7. Keep HP/LPBP in auto. Restore fast opening feature of HPBP.
8. Observe the important parameters.

*NOTE: Don’t Roll the Turbine when the Unit is under single condenser
Operation, to avoid unbalanced forces on the Turbine Shaft.
 10. INSTRUCTIONS WHEN ALL THE UNITS SIMULTANEOUSLY TRIP DUE
TO GRID FAILURE

Whenever all the units’ trip due to grid / station supply failure, certain steps have
to be taken for safe shut down and the operators have to check and ensure that these
necessary events do take place. The action to be taken by the operators in a calm and
collective manner is detailed below for the purpose of guidance.

A. Existing Condition: All the units at Dr.NTTPS are in service.

B. Occurrence at 00:00hrs: All the Units at Dr.NTTPS tripped and station
supply also failed due to major fault in the Grid.
C. Emergency operations to be carried out at 00:00hrs:

1. Divisional Engineer/SHIFT OR Asst. Divisional Engineer/UO-3 or 4:

Report the grid failure to the CE/O&M/ Dr.NTTPS, Superintending
engineer/O&M-2, all DEs / maintenance, Divisional Engineer/O&M/General,
Divisional Engineer/E&P.
Contact Divisional Engineer/Shift/Stage - I to regulate the gates since the CW
sump level will increase abnormally consequent to the tripping of all CW Pumps .
Observe and record the annunciations and relays and reset the same. Check and
ensure all emergency operations listed here are carried out.
2. AE/Shift/Turbine Panel:
A. i. Ensure trip of TG. Ensure opening of GCB and field breaker. If not, hand
trip the turbine, open GCB first and then field breaker. Check closure of
ESVs (2 Nos), IVs (2 Nos.) and CRH NRVs (2 Nos.) and turbine control
valves, NRVs in all extractions i.e. A2 to A5.
ii. Check for auto start of DC EOP&DC SOP. If they did not come into
service start EOP from BTG or from local panel at 10mts and start DC SOP
 from local. If DCSOP did not start, arrange for emergency purging of H2
from Generator. Inform Divisional Engineer/EM for necessary action.
iii. Kill vacuum by opening vacuum breaker and its manual isolation valve.
Open starting ejector air isolation valve at 5mtrs floor(SM-18).
iv. Close manual Isolation valve of gland steam station, MAA-10 AA501 at
5mtrs level and close AS-22 Valve on 16 ATA header manually.
v. Close manual isolation valve of ejector steam station ASSP-157 near HPH
5 and close ASSM- 148 on 16 ATA. header manually.
vi. Give stop command to all drives HT and LT motors.
vii. Switch off SLCs of AC AOPs, ACSOPs and Gate Valve Gearing.
viii. Arrange for manual closing of S-99 and all extraction valves i.e.,
EX-9 to EX-14. Do not open extraction line drains to Flash Box.
ix. Close manual isolation valve of PRDS drain pot drain to Flash Box at
‘0’mts area at condenser B and open it to atmosphere.
x. Ensure auto start of DC JOP at 510 rpm. If it did not start, start the same at
around 500 rpm from BTG panel. If it did not start from BTG, start the
same from local panel at 10mtrs. Ensure the healthiness of DC JOP from
AE/SHIFT /’0’mtrs.
xi. Do not open Gate Valve Gearing when DC EOP is in service.
xii. Once the turbine comes to stand still, put the turbine on hand barring
continuously for 30 to 45 minutes and later rotate the turbine shaft through
180 degrees at intervals of 5 minutes.
xiii. Depressurize CRH and HRH lines by opening the following motor operated
valves manually along with their manual isolating valves. All the valves
mentioned below are connected to atmosphere.
Nos. CRHM-67A, CRHM-67B, HRHM-41A, HRHM-41B,
HRHM-32, HRHM-36.
After depressuring the CRH and HRH lines close the above valves. Don’t
open the Drains to condenser in this condition.
xiv. Arrange for opening the water box vents (both inlet and outlet) of both the
Condensers.
 B. When supply is available from DG set and after charging of EMC board, the
following operations are to be carried out one by one
1. Start AC AOP-1, AC SOP one after the other and check oil pressures and loads.
After ensuring them to be normal, stop EOP & DC SOP and keep SLC of DC
EOP in Auto (BTG panel).
2. Stop DC JOP and start AC JOP and check jacking oil pressure to be normal i.e.
greater than 120 kg/cm2 and keep SLC of DC JOP in auto.
3. Stop turbine hand barring and lock hand barring lever.
4. Switch on SLC of Gate valve gearing to keep turbine on hydraulic barring.
5. Start oil supply units of HP BYPASS.
C. On Restoration of AC Supply:
1. Restore normalcy of EMC board and hand trip DG set as per the (procedure)
instructions issued.
2. Switch on SLCs of AC AOPs, and start AC AOP. After ensuring the healthiness
of ACAOP, stop DC EOP. After starting AC SOP stop DC SOP.
3. Inform Divisional Engineer/Shift/Stg-I for regulating CWP sump level for starting
CW Pumps.
4. Arrange for starting of two No Raw Water Pumps one after the other and
maintain clarified water sump level at above 3.2 mts
5. Start 2 Nos. BCW pumps one after the other duly contacting the Sub
Engineer/BCWPH and check BCW header pressure to be more than 4 kg/cm2.
6. Arrange starting of IACs and SACs in Compressor House one by one.
7. Arrange for starting of 2 Nos. seal water pumps at CWPH to supply seal water to
CW Pumps.
8. Start 2 nos. of CW Pumps one by one duly contacting AAE/Shift/CWPH after
ensuring sump level to be normal
9. Start 2 nos. of CEPs one by one, after informing AE/Shift/0mtrs duly ensuring hot
well level greater than 500 mmwcl duly opening the header vent valve.
10. Ensure loads on ST3 and ST5 Transformers are within the limits.
11. Now Unit start up operations may be taken up to synchronize the unit with the
grid.
Note: Before hand barring the turbine, coins, metal articles, pens etc should be
removed from shirt pockets so that they will not fall in the hydraulic barring
gear system.
3. AE/Shift/FSSS/UCB:
A 1. Ensure starting of DC Scanner fan in auto. If not start the fan from BTG and even
then if it does not start , start it from the local panel(DC panel in 3AB Board/4BB
Board).
2. Ensure that all guns (HO/LO) if any in service at the time of grid failure are
tripped and no fuel input is there to the boiler i.e., all fuel valves are closed and
also ensure closure of HO/LO trip valves. Also arrange for closing of fuel oil
manual isolation valves i.e., 2 Nos. manual isolation valves of HFO station and
one No. manual isolation valve of LO station at 16mtrs.
3. Give stop command to all drives HT and LT motors.
4. Arrange for manual closing of all Mills PC outlet Gates.
5. Ensure closure of all PA General Shut Off Gates and all RC Feeder Isolation
Gates and purge air dampers of all mills.
B. After EMC Board Is Charged From DG SET:
1. Start AC Scanner Fan and check pressure. If AC scanner fan is OK, stop DC
Scanner Fan and keep it in Auto standby mode.
2. Start Electric motors of RAHs.
C. On Restoration of AC Supply:
1. Duly keeping Lub. oil System in service, keep Mills on barring Gear and steam
quench them with the available 16 ATA header steam
2. Start ID Fan and FD Fans after taking lub. Oil systems into service. Establish
280 TPH air flow and duly maintaining furnace pressure at -20mmwcl. Purge the
Boiler to start up the Unit.
3. Contact Sub engineer/Fuel Oil Pump House, and inform him about the start up
operations and ask him to maintain HFO temperature and pressure.
4. AE/ Shift/ Feed Water Panel /UCB:
A. 1. Give stop command to all HT Drives and LT Drives.
2. Arrange for closing of CBD Valves manually
 3. Arrange for closing of all isolation valves and block valves of SH and RH spray
systems.
4. Arrange for closing of Boiler stop valves and their equalizing valves MSSM-30,
MSSM-36, MSSM-30B, MSSM-36B manually.
B. After EMC Board Is Charged From DG SET:
1. Start AOPs of all BFPs
2. If Boiler Stop valves are not yet closed manually, close all of them
3. Switch on chargers one by one duly monitoring EMC voltage
C. On Restoration of AC Supply:
START one BFP after ensuring D/A level is normal and feed the Boiler to normal
Drum level. Deaerator level may be maintained by CD-14 duly ensuring CEPs in
service.
5. AE/S/SCB & Asst. Divisional Engineer/S/UO:
A i. Check whether DC emergency lights are ‘ON’ in Auto. If not arrange for the
same by contacting AE/S/0 mts.
ii. Arrange for Starting of DG sets of U3 & U4 duly following the procedure laid
down in consultation with AE/S/0mts/U-3 & U-4.
iii. Charge EMCC Boards from DG sets duly following the instructions issued.
iv. Arrange for switching on AC lighting at various locations in consultation with
AE/S/0mtrs and switch off DC emergency lights.
v. Give clearance to AE/S/FSSS, AE/S/FWP, and AE/S/TP to carry out necessary
operations on charging of EMCC board from DG set.
vi. Reduce ST3 & ST5 Transformers taps to minimum position i.e. Tap2.
vii. Contact AE/S/0mts and ensure all outgoing as well as incoming 6.6KV breakers
in different 6.6KV buses are in tripped condition and reset all relays after
recording them.
viii. Ensure all incoming as well as outgoing LT breakers in various LT boards are in
tripped condition.
ix. Request Asst. Divisional Engineer/S/MCR to charge ST3 and ST5 Transformers
immediately after gird supply is restored. After taking all necessary precautions
like ensuring trip of incoming 6.6KV breakers of ST3 and ST5 in SC and SD
 boards and all tie breakers from SC and SD to other boards, close LV breakers of
ST3 and ST5. Now SC and SD boards are charged.
x. Charge SC and SD boards after taking all steps which are given below.
a. Ensure the tripping of all 6.6KV motor feeder breakers, ST3 LV
breaker,ST5 LV breaker UATs incomer Breakers, in station boards
i.e. SC and SD boards
b. Ensure the tripping of unit auxiliary boards otherwise hand trip them.
c. While restarting units after total station supply failure the normal
existing feeding arrangement between Stg 2 and Stg 3 have to be
de-linked from each other and each stage station transformers have to
feed their own 6.6KV boards i.e. SC from ST3 and SD from ST5
respectively.
d. Ensure that the tie breaker to SE board of Stg 3 panel Nos 5 & 7 in
SE board are in tripped condition. If not hand trip these breakers,
before extending supply to SC board from ST3 and SD board from
ST5.
e. Bring the tap position of ST3 or ST5 to minimum i.e. tap 2.
f. Contact Asst. Divisional Engineer/S/MCR and ask him to close HV
breakers of ST3 & ST5 transformers. When HV breakers at MCR are
closed, supply is available up to 6.6KV LV breakers in the boards.
g. Close the 6.6KV breaker of ST-5to SD board incomer (newly erected
breaker in AA bay near SC Board) and close the 6.6KV breaker panel
No: 24 in SC board. By this SC and SD boards are charged. Restore
supply to Auxiliary boards 3A(T), 3A(B), 3B(T), 3B(B), 4A(T),
4A(B), 4B(T), 4B(B)one by one after taking all necessary precautions.
h. Charge CW-C, CW-D CLW-A, CLW-B, AH-C and AH-D boards one
after the other duly taking all precautions.
xi. Restoration of Normal supply conditions in LT boards:
a. After ensuring 6.6KV supply to station and Unit auxiliary Boards,
charge all LT boards, i.e. Boiler, Turbine, SSS, Lighting distribution,
ESP boards etc. duly taking all necessary precautions.
 b. Restore Normalcy to EMCC board from SSS board after stopping/
cutting off supply from DG set as per instructions separately issued.
c. Please ensure that all LT boards are fed from both sources keeping bus
coupler in open condition.
6. AE/Shift/Boiler:
A a. Ensure closure/Trip of all HFO guns and LO guns.
b. Ensure closure/Trip of HFO Trip valve and LO trip valve.
c. Close HFO station isolation valves (2Nos) and one no. LO station
isolation valve manually. Keep HFO on short recirculation.
d. Close AS-22 auxiliary steam to Turbine glands manually.
e. Close ASSM-148 Auxiliary steam to MAEs manually.
f. Close Auxiliary steam to Deaerater Pegging steam manual valve AS-17.
B. On Restoration of AC supply:
a. Ensure closure of PC outlet gates of all Mills. If necessary close them
manually.
b. Check RAHs and if they are found running report that to UCB.
7. Sub-Engr/Shift/Mills:
a. Ensure Trip of all ESP fields. If not, hand trip all ESP fields.
b. Ensure all incoming as well as outgoing LT breakers in ESP switch
gear are in tripped condition. IF not hand Trip them and reset.
c. Inspect all mills and fans and report any abnormalities to
Asst. Divisional Engineer/S/Blr and Asst. DivisionalEngineer/S/UCB.
8. AE/S/ ‘O’Mts:
A. a. Switch on DC emergency lights if they did not come in Auto.
b. Start DG set after ensuring Diesel Oil tank level is normal and
adequate radiator cooling water as per the instructions issued duly
consulting Asst. Divisional Engineer/S/UO and AE/S/SCB. Charge
EMCC board and give clearance to start important drives on EMCC
Board.
c. Ensure that all 6.6KV breakers, UAT incomer breakers and ST3, ST5
LV breakers in station boards (SC and SD) and Unit auxiliary boards
 d. Watch the Diesel oil tank level and radiator cooling waterlevel now
and then.
e. Switch on supplies to all chargers one by one.
f. Check DC SOP and DC EOP come into service in auto and they are
running normal. If DC SOP did not come into service arrange for
emergency purging of H2 from generator.
g. Ensure all incoming breakers of equipment in various LT boards are
in Tripped condition.
i. Check 6.6KV incoming Breaker of equipment in SC Bus and Tie to
SE board are in Tripped condition.
j. Switch on AC emergency lights and switch off DC emergency lights.
k. Check and ensure that the following 6.6KV breakers are in tripped
condition otherwise hand trip them.
i. Tie between SC and SD boards
ii. Tie from SD to US-4B(B)/4A(B) boards.
iii. Tie from SC to 4A(T) 4B(T) boards.
B. On Restoration of AC supply:
a. After charging the HT Boards, duly consulting Asst. Divisional
Engineer/S/UCB, charge LT boards one after the other and change
over EMCC panel supply to station supply from DG Set as per the
instructions issued.
b. Start AC SOP 1 or AC SOP 2 and after ensuring that SOP is running
normal stop DC SOP.
c. Start 3 No IACs one by one, after ensuring Clarified water supply and
maintain instrument air header air pressure at 7.5 kg/cm2.
d. Start 2 or 3 AC compressors one by one, after ensuring clarified water
supply.
e. Open MAEs bypass valve by 50% (Manually) before taking 1st CEP
into service (CD- 53).
9. AAE/Sub.Er/S/CWPH:
A. a. Ensure that all the breakers that are in service have been tripped
manually from UCB and all breakers have opened out and reset all
relays of the breakers after noting details of relays.
b. Close Butterfly valves of the tripped pumps manually.
c. Check and ensure that breakers of HP pumps have opened out, close
their discharge valves manually.
d. Continuously monitor CWP sump level and inform to Divisional
Engineer/Shift/UCB frequently.
e. Check whether 6.6KV incoming breakers in CW-C and CW-D buses
have opened out or not, if not, hand trip them.
B. On Restoration of AC Supply:
a. Charge CW-C and CW-D boards one after the other, after taking
necessary precautions. Charge LT boards too.
b. After ensuring that BCW pumps are in service start 2 Nos seal water
pumps one after the other and charge seal water header. Give
clearance to start CW pumps.
c. Start HP pumps, LP pumps if required. Start one fire hydrant pump.
e. Monitor CWP sump level and inform to Divisional Engineer/Shift
frequently.
Restoration of 6.6KV supply to CW pump house Boards:
Check whether the feeder breakers to CW pump house panel No:22 in SC
board and panel No:7 in SD board are in closed position or not. If not, close these
breakers. By this, 6.6KV supply to CW-C and CW-D boards at CWPH is available.
Close the incomer breakers in panel No:11 of CW-C and panel No: 9 of CW-D
board one after the other. Ensure that tie breaker is in open condition.
10. Sub Engr/S/BCW PH:
A. a. Check whether the breakers of all BCWpumps and 6.6KV
incoming breakers in BCW boards CLW -A and CLW-B have tripped
and opened out. If not, hand trip the breakers.
b. Manually close the discharge valves of all the pumps.
B. On Restoration of AC Supply:
 a. Arrange for charging of CLW-A and CLW-B duly ensuring that
Ash Pump House 6.6KV boards AH-C and AH-D are charged.
Charge the LT boards.
b. Contact AAE/S/CWPH/Stage-I and arrange for starting of 2 No Raw
water pumps one after the other duly consulting AE/S/TP and
Asst. Divisional Engineers/S/UO of both the Units. Check that the
pumps are running normal.
The Procedure of charging CLW-A and CLW-B boards:
a. Check whether feeder breaker to CLW-B board in AH-D board
panel No:3 is in closed condition. If not, close the breaker. Supply to
CLW-B board is available up to its incomer breaker panel No-5 in
CLW-B board. Close the incomer breaker. Now CLW-B board is
charged.
b. Ensure that supply to CLW-A board is available from Stage -I AH-A
board, by contacting AAE/S/Ash pump house, Stg -I. Now close the
incomer breaker in CLW-A board panel No: 3. Ensure that the Tie
breaker between CLW-A and CLW-B is in open condition.
c. Charge the LT boards of BCW pump house from Ash Pump house.
d. Start the BCWPS duly watching load on station transformer and
watching sump level.
11. Sub Engr/S/Ash pump House:
A. a. Give stop commands to all HT and LT Drives.
b. Check and ensure the breakers of 6.6KV motors and incoming
6.6KV breakers in AH-C and AH-D boards have tripped and opened
out Close Discharge valves of ASH slurry pumps if possible.
B. On Restoration of AC Supply:
a. Arrange for charging the 6.6KV AH-C incomer panel no.14 from SD
board and AH-D incomer panel no.18 from SC board in consultation
with AE/S/’O’ meter. After charging of HT boards charge the LT
boards too.
b. Arrange for starting HP pumps if required.
12. Asst. Divisional Engineer/S/CA:
A. Contact all pump houses and see that all the necessary operations are
carried out by the operators.
B. On Restoration of AC Supply:
Contact all pump houses and see that all the necessary operations are
carried out smoothly by the operators and give clearance to UCB to take up
the start up operations.

220KV FF MCC HT/LT SWITCH GEAR 220KV

CW MCC
GT-4

GT-3
CWT-IIA 220KV
220KV

AH MCC ST-5
CWT-IIB

CW-C ST-3
UAT-4A

UAT-3A
UAT-4B

UAT-3B
MB
CW-D

PB
Generator-4 Generator-3

MB
PB
SC 3BT 3AT
4BT 4AT

MB
PB
UST-4AT

UST-3BB

UST-3AT
UST-4BT

UST-3BT
EPT-3B
SST-3

Turbine
LDT-3

Board Turbine board

Misc MCC
ESP MCC TB
EMC

TVC

EPT-3A
SSS

BB
TVC
ESP-Mcc LDS MCC

UST-3AB
`
BVC
EPT-4A

Boiler Board
EPT-4B

SB-MCC
SB MCC
UST-4AB
UST-4BB

BVC
LDT-4
SST-4

MI
PI

SD
4BB 4AB 3BB 3AB
MB

PB

AH-D
SA/SB
(Not in Use)
AH-C CH-A
CLW-B Stage-I
AH-A
AH-MCC CLW-A

CL-MCC
Pg.5-4
INSTRUCTIONS FOR CHARGIING EMC BOARD FROM DG SET SUPPLY
UNDER TOTAL AC FAILURE

A. Before starting the D.G. sets ensure the following.

a. EMC board is dead and incomer breaker-1 (13F) from SSS-3A Board
and incomer breaker-2 (15F) from SSS-3B and bus coupler breaker
(14F) are in open position. Bus coupler local/remote switch is to be
kept in manual mode.
b. Ensure that EMC-MCC Stage-I, source -I (11F) and tie to EMC-MCC
Stage-I, source-2 (17F) breakers are in open condition.
B. Starting of DG set-1 (old) for Unit-3.
a. Start the Diesel Generator set duly ensuring adequate Diesel tank level
and adequate radiator cooling water and ensure that rated voltage is
built up in all three phases.
b. Switch off all the modules on EMC board
1F to 13F on front side
1R to 10R on rear side.
c. Close the outgoing breaker of DG set-1 on its control panel.
d. Close the incomer breaker from DG set-1 to EMC board
(Module N0: 12F) keeping its local /remote switch in local position.
If the breaker does not close electrically, close the breaker manually.
e. Switch on AC-AOP 2 Module and start AC AOP-2.
f. Switch on ACJOP module 7R2 and start ACJOP.
g. Switch on ACSOP-1 module and start ACSOP-1.
h. After ensuring running of AC SOP-1 stop DCSOP. After ensuring
running of ACAOP-2 and ACJOP stop EOP and DC JOP. Open the
Gate valve gearing manually and keep Turbine on barring gear.
 i. Switch on Boiler main steam stop valve modules MSSM-30, (8F3)
MSSM-36 (9F3) and close the valves.

After completion of the above operations if DG set -1 has further loading margin
(Maximum loading 348A) the following operations are to be carried out keenly
observing the load on the DG set after each operation.
a. Switch on AC scanner fan module 6F3 and start the AC scanner fan.
After ensuring the running of AC scanner fan stop DC scanner fan.
b. Switch on AC emergency lighting module 3R2.
c. Switch on Diesel set (Unit -3) supply module 2F5 for battery charging
d. Switch on 220V main float charger source -1 module 8R3.
e. switch on +26V battery charger module 3F1 and -26V battery charger
module 3F4.
f. Switch on UPS charger module 5R1.
Starting of DG Set -2 (NEW) for Unit - 4, for section-2 of EMC -2
a. Ensure that the bus coupler 14F and incomer from DG set-II.i.e.16F
are in off position (EMC Board).Bus coupler local/remote switch is to
be kept in local mode and auto/manual switch to be kept in manual
mode.
b. Start DG set 2 duly ensuring adequate Diesel tank level and
adequate radiator cooling water and observe that rated voltage is built
up in all three phases.
c. Switch off all the modules on section-2 of EMC i.e. 18F2 to 26F6 on
front side and 18R1 to 26R3 on rear side.
d. Ensure the MCB of the DG set in the control panel is in ON position.
e. Push the load ON switch on the control panel.
f. Close the incomer from DGset-2 breaker module No: 16F (EMC
board), keeping the local/remote switch in local position. If the
breaker does not close electrically, close the breaker manually
g. Switch on Turbine AOP-2 module 22R2 and start ACAOP-2.
h. Switch on AC Jacking oil pump (ACJOP) module 21R2 and
 i. Switch on AC SOP-2 module 18F2 and start ACSOP.
j. After ensuring the running of AC SOP, AC AOP-2 and AC JOP
stop DC SOP, EOP and DC JOP. Open the gate valve gearing
manually and keep the Turbine on Barring gear.
k. Switch on Boiler main steam stop valve modules MSSM-30(24R3)
and MSSM-36(20F2) and close the valves.
After completion of the above operations, if DG set-2 has further loading
margin (Max. loading 348A), the following operations are to be carried out keenly
observing the load on the DG set after each operation.
a. Switch on AC Scanner fan module 24F1 and start the AC scanner fan.
After ensuring the running of AC Scanner fan stop DC Scanner fan.
b. Switch on RAH-4A and 4B Main motor modules 21F2 and 19F2 and
start the RAH A and B motors.
c. Switch on compressor-2 for fire fighting system module-19F1.
d. Switch on compressor-1 for fire fighting system module-24F2.
e. Switch on AC emergency lighting module 18R1.
f. Switch on 220V main float charger source-1 module 20R2.
g. Switch on +26V battery charger module 26R2, 26R3 and -26V
modules 25F2, 26F5).
h. Switch on UPS battery charger module 23R1.
Working instructions for resuming Normalcy on EMC -Board after restoration
of Grid supply:
1. Ensure that the Grid supply is stable and normalcy is completely restored on
the 415V station service switch gear of both the Units and SSS boards.
2. Ensure that Normalcy is restored on 415V Turbine boards (USS).
3. Start AOP-2 and Stop AOP-1 of Unit-3.
4. Start AOP-2 and Stop AOP-1 of Unit-4.
5. Start DC JOP of Unit-3 and Stop AC JOP.
6. Start DC JOP and Stop AC JOP of Unit -4.
7. Trip the Circuit breakers of “EMC Incomer from DG sets” and keep them in
Test position (Feeder NO: 12F, 16F)
9. Duly ensuring that EMC incomers from DG sets are in test position,
proceed further as follows
10. Keep incomer feeder 13F in service position and charge EMC section-1 from
SSS-3A
11. Keep incomer feeder 15F in service position and charge EMC section-2 from
SSS-3B.
12. Ensure that both the Bus sections of EMC are healthy.
13. Hand Trip the Bus coupler. Bring the Auto/Manual selector switch on Bus
coupler (14F) into Auto position.
14. Switch on all those loads which have been switched off earlier, to regulate
the loads on DG set.
15. Instruct the compressor house operator to stop the DG sets if Grid Supply
continues to be stable.
16. During the course of operations, it may please be ensured that at any stage
the “DG set supply shall never be parallel with station/Grid Supply”.
17. A check shall be made to ensure that the circuit breakers of EMC incomers
from DG sets are in test position before the daily trial run of DG set.

DG Set-I DG Set-II

EMC
SC Board

SST-4 SST-3
SD Board

SSS

Note: DG Set starts in Auto when station supply fails

 11. ACTION TO BE TAKEN FOLLOWING BOILER TRIP

Boiler trips on the following :

a. Both ID fans OFF.
b. Both FD fans OFF.
c. Both Boiler emergency push buttons on BTG pressed.
d. Furnace pressure very high (2/3 Logic)  +250mmwcl.
e. Furnace pressure very low (2/3 Logic)  -200mmwcl.
f. Drum level very high (2/3 Logic) for >10secs  +167mmwcl.
g. Drum level very low (2/3 Logic) for >5secs  -450mmwcl.
h. Total air flow <30 % & steam flow <30%
i. Flame failure.
j. Loss of all fuel.
k. Loss of 24V DC.
l. Loss of 220V DC.
m. Less than fire ball and loss of AC at any elevation in service.
n. RH protection.
1. Check that Turbine trips and generator trips. If turbine does not trip, hand trip it.
If generator does not trip, trip the generator breaker first and then trip the
field breaker.
2. Close the following:
2.1 Block valves of SH and RH spray systems Nos: S-40, S-69 & R-20 if they
are not closed in auto.
2.2 Spray control valves.
2.3 Motor operated spray isolation valve No’s: S-45, S-48, S-46, S-47, S-74,
S-77, S-75, S-76. R-25, R-26, R-27, R-28.
3. Ensure tripping of Mills and closure of PC outlet gates, PA general gates & RC
isolation gates of all mills. Ensure mills come onto barring gear.
4. Also ensure closure of HFO Trip valve, LO Trip valve and Ignitor trip valve.
Ensure tripping of oil guns if any are in service.
5. Ensure Tripping of both PA fans. Maintain furnace pressure at normal value
i.e., -15 mmwcl.
6. Close CBD valve B-80. Don’t open the CBD valve until Boiler is flashed to
conserve Boiler pressure.
7. Self PRDS may be taken out of service duly closing LC and HC valves.
8. Make 16 ATA header parallel with the other Unit duly informing other Asst.
Divisional Engineers/Shift/Unit operator.
9. Establish purge permissives. Press “Purge Start” push button to purge the Boiler
and make it ready for flashing.
10. Keep HFO on long recirculation by opening HOTV and HORV in service and
maintain HFO temperature and pressure if there is no problem on Boiler side.
11. Maintain drum level at normal value by one BFP. Unload one BFP and keep it
under Recirculation, if Boiler is going to be flashed shortly. If there is delay, trip
second BFP.
12. If there is a delay in flashing the Boiler, box up the Boiler
1. By Tripping ID and FD fans.
2. By closing Boiler Stop valves MSSM-30, MSSM-36, MSSM-30B,
MSSM-36B.
 4. By opening the Short Recirculation valve to maintain HFO temperature.

12. ACTION TO BE TAKEN FOLLOWING TURBINE TRIP

Turbine may trip on
a. Over speed trip (mechanical) 110% i.e.3300rpm.
b. Axial shift (mechanical)  +1mm.
c. Low vacuum trip (mechanical)  -0.62Kg/Cm2
(Electrical) -0.72 Kg/Cm2
d. MOT oil level low (2/3 Logic)  925mm
e. Bearing lub oil pressure low (2/3 Logic)  2.2 Kg/Cm2 at MOT room
(or)
 1.2 Kg/Cm2 at 10mtrs.
f. MS temperature very low (both L & R) < 4800C.
g. Fire protection 1 or 2 (10mtrs or MOT room or UCB).
h. Emergency trip button (UCB).
i. Generator protection.
j. MFT
k. Boiler fire OFF.
l. SGC Turbine shut down sequence.
m. Drum level very high i.e. +167mmwcl.
n. Trip from Function Key Board.
o. Operating main trip levers.
1. Check for tripping of GCB and Field Breaker. If not, open GCB first and then
Field Breaker.
2. Check for closure of HPSVs, IVs and CRH NRVs.
4. Close CD-14 to minimum position, duly opening CEP Recirculation valve,
to maintain Hotwell level. Open DM Make up valves too. Otherwise CEPs trip
on Hotwell level very low.
5. Maintain Gland steam pressure at 0.01Kg/cm2 duly opening seal steam valve or
its By-pass valve to prevent fall of vacuum.
6. Start vacuum pump as a precautionary measure.
7. On Turbine trip, HPBP valves open to full in auto (Fast opening mode) and
remain there for about 3secs. After that HPBP valves close in auto. Keep
HPBP and LPBP valves at 10% to 15% to save the Boiler from “RH protection
trip”. If boiler is not tripped, continue only one coal elevation in service with
oil support.
8. Close all extraction valves Ex-9 to Ex-14 and open extraction line drains Ex-101
to Ex-103, Ex-110, Ex-112.
9. Ensure Swing check valves A2, A3, A4 and A5 close in auto.
10. Check for auto starting of JOP at 510 rpm in auto. If not, start AC JOP manually.
11. Check for opening of gate valve gearing in auto at 210rpm. If not, open the same
manually.
12. Deaerator has to be pegged at 3.5Kg/cm2 by opening the steam valve AS-17.
13. Kill vacuum 30mts after Turbine came on to Barring Gear if the Unit start up is
delayed. Before killing the vacuum, close Boiler stop valves and depressurize
CRH and HRH lines by opening the HP/LP Bypass valves.
14. Stop CBD steam to Deaerator by closing BDM-78 and open BD-100, if Boiler is
in service. If Boiler is tripped, close CBD isolation valve B-80.
15. Trip one BFP. Maintain Drum level. Maintain SH and RH temperatures.
NOTE: For the following emergencies Turbine does not get tripped on
AUTO. The operator has to take proper action to safeguard the
equipment and personnel.
a. High Bearing / shaft vibrations.
b. High exhaust hood temperature.
c. High differential expansions.
d. High bearing temperatures.
13.ACTION TO BE TAKEN FOLLOWING ONE RAH TRIPS/AIR MOTOR DOES
NOT START
The RAH drive motor trips/air motor does not start on the following
1) Motor protection
2) Supply failure
3) Air motor failure or solenoid failure
4) Failure of instrument air/service air
As soon as the FG temp after RAH crosses >200 oC
1. Take HFO Guns in the elevation of bottom running mill
2. Hand trip the top most mill& steam inert it.
3. By pass drum level protection if necessary and monitor drum level
continuously
4. Reduce load slowly to 100MW on par with MS Pressure
5. Maintain SH/RH temperatures by using burner tilt & spray
6. Isolate RAH on FG side by closing GD-1 & 3
7. After the clearance is given by maintenances wings, start air motor
and after 5 minutes start RAH electric motor and observe the
performance
8. Take tripped mill into service after establishing ignition energy and
raise the load.
14.ACTION TO BE TAKEN FOLLOWING BOTH RAH.s TRIP/AIR MOTORS DO
NOT START

The RAH drive motors trip/air motors fail to start on the following :
a) Supply failure
b) Service/instrument air failure
1) If there is no possibility of starting air heater when the FG temperature after
RAHs >200 oC hand trip the unit at the earliest to avoid possible distortion
of RAHs.
2) Try to rotate RAHs manually
3) After starting RAHs unit start up operation may be taken up

15. ACTION TO BE TAKEN ON TRIPPING OF IDFAN

 1. Lub oil pressure very low ( < 0.2 Kg/Cm2).
2. Scoop oil temperature very high( > 1200C).
3. VFD system Trouble.
4. Motor/Fan Bearing temperature very high ( > 1000C).
5. Motor protection.
6. Supply failure.
7. DP across lub oil filter high (> 0.5 Kg/Cm2).
8. Stop command from UCB or local push Button locked.
1. On ID fan trip, Bottom most elevation of the running mills and one FD fan trip in
Auto. Otherwise hand trip the same.
2. Take Heavy oil guns in the elevation of the running mill at top elevation if it is
healthy. For example if AB & EF are in service take oil support in EF elevation
i.e., DE guns 1 to 4.
3. If the furnace pressure can not be controlled, hand trip the bottom most mill &
control the draft.
4. Bypass the Drum level protection and control the Drum level and monitor it
continuously.
5. If there is any problem in the top mill take oil support in the elevation of running
mill at bottom and hand trip the top most Mill. Steam inert the tripped mill.
6. Control the Furnace pressure by reducing Secondary air flow and Primary air
flows of the running mill.
7. Adjust load according to MS Pressure. While reducing the load see that MS
Pressure does not rise above 160Kg/cm2 at which HPBP opens and it results in
fall of MS Temperature. Turbine trips at MS temperature < 4800C
8. Hence maintain MS & RH Temperatures above 5200C by using Burner tilt and by
reducing the spray. If necessary close spray isolation valves and Block valves.
9. Keep watch on gland steam pressure, Hotwell level and deareator level.
10. Stabilize the Unit with one mill and oil guns at 100 to 120Mw.
11. After clearance is given by BM, I&C and EM wings, restart the tripped ID fan.
Load the ID fan and parallel it to the running ID fan. Take Tripped FD fan into
service and load it and parallel it to the running FD fan.
12. Establish ignition energy and take 2nd mill elevations and gradually raise the load.
Cut off heavy oil support at load above 170MW. (Ensure four elevations are in
service).

Note: a. Some times both channels of one ID fan will unload to ‘0’ Amps and ID fan
ON feedback will not come. Then hand trip the corresponding FD fan and
follow above instructions.
b. Some times one channel each in ID fans A&B trips due to some problem.
Even in this case hand trip one FD fan (any one) and a mill and follow the
above instructions.
c. If a channel in ID fan trips on protection, load need not be reduced as
three channels are capable of maintaining the full load. Maintaining
Furnace draft is the criteria. For that keep single channel ID fan VFD in
manual mode and slowly load it up to 85A duly keeping second ID fan in
AUTO.

16. ACTION TO BE TAKEN ON TRIPPING OF FD FAN

FD fan may trip on
1. Lub oil pressure very low (<0.4 Kg/Cm2).
2. ID fan trip.
3. Motor/Fan bearing temperature very high (>1000C).
4. Supply failure.
5. Motor protection.
1. On FD fan trip, bottom most elevation of the running mills trips in auto.
2. Take HFO guns in the bottom mill which is running with one elevation.
3. Load the running FD fan to the Maximum extent and maintain O2, Total air
flow and furnace pressure. (FD fan full load current is ~86A)
4. Adjust the load according to MS pressure. In any case MS pressure should
not rise above 160 Kg/cm2 at which the HP bypass opens and it may
result in drop of MS temperature. Turbine trips at MS temperature <
480oC. Hence maintain MS & RH temperatures well above 500oC by
adjusting Burner tilt and by reducing the sprays. If necessary close the
Block valves and Isolating valves.
5. Bypass Drum protection if necessary. Closely watch Drum level, Gland
steam pressure, hot well level and Deaerator level.
6. Stabilize the unit with either 3 elevations or one mill and oil support.
7. After clearance is given by BM, I&C and EM wings, take the tripped FD
fan into service and load it, parallel it to the running FD fan and maintain
furnace pressure and total air flow.
8. Establish ignition energy and start the tripped elevations and raise the load
to 210MW with rise in MS pressure. Cut off oil support at load >170MW
after ensuring four coal elevations are in service.

NOTE : -
If the tripped FD fan could not be started due to major problem, the
following procedure may be followed to reduce the oil consumption:
a) As soon as FD fan is tripped, the bottom most elevation trips in auto
on interlock.
b) Cut in oil support to the existing elevation of the bottom mill.
c) Stabilise the parameters with running FD fan.
d) Bypass the I&C interlock duly consulting I&C wing (Tripping of the
bottom most elevation on FD fan trip).
e) Take tripped elevation into service.
 f) Maintain load at about 160 to 180MW duly watching the running FD
fan current (Full load current = 86Amp.s) and fan bearing
temperatures.

17. ACTION TO BE TAKEN ON TRIPPING OF ONE PA FAN

PA fan may trip on:

1. MFT.
2. Lub oil pressure very low (<0.2Kg/Cm2).
3. Fan/Motor bearing temperature very high (>1000C).
4. 6.6 KV supply failure.
5. Motor protection.
6. Motor ON and discharge damper closed (5 minutes time delay).
6. Stop command from UCB or local push button locked.

1. On PA fan trip the bottom most elevation of the running mills trip in auto.
 2. Cut in HO guns in support to the bottom most Mill of which only one
elevation is in service and hand trip the top mill.
(Or)
Cut in HO guns in support to the top most Mill of which two elevations are
in service and hand trip the bottom mill. Steam inert the hand tripped mill.
For one running PA fan only one mill or one elevation must be in service.
3. Raise the inlet vane position of the running PA fan to the maximum extent
to maintain PA header pressure duly watching PA fan amperage (PA fan
full load current is 134A). Otherwise both mills trip on PA header pressure
very low.
4. Bypass the Drum level protection if necessary. Monitor and control the
Drum level. Maintain Hotwell level, Deareator level and Gland steam
pressure.
5. Maintain the furnace pressure.
6. Maintain the load as per MS pressure while reducing the load. See that MS
pressure should not rise above 160Kg/cm2 at which HPBP opens in auto
there by causing drop in MS temperature to < 4800 C. Turbine trips at MS
temperatures < 4800C. Maintain SH and RH temperatures by using Burner
tilt and by reducing the spray at 5200C. If necessary close the block valves
or isolating valves.
7. Stabilize the Unit with one mill or one elevation and oil guns at 80MW to
100MW.
8. After the clearance is given by I&C, BM and EM wings, take the tripped PA fan
into service, load it and parallel it to the running PA fan.
9. Establish ignition energy and take 2nd mill elevations and raise the firing rate,
raise the load to 210MW. Cut off oil support at load > 170MW
(Ensure four coal elevations are in service).
 18. ACTION TO BE TAKEN ON TRIPPING OF ONE MILL

Mill may be tripped on

1. Lub oil system trouble.

2. Seal air pressure to mill DP very low (<340mmwcl).
3. Both PA fans trip.
4. Loss of ignition energy.
5. Greasing sequence not correct > 15mts.
6. Trunnion bearing temperature high (NDE/DE) > 650C.
7. MFT.
8. PA header pressure very low (<350mmwcl).
9. Both feeders OFF for > 10mts.
10. EM brake engaged.
11. Both Auxiliary and Main motors ON for > 10Secs.
12. Centrifugal safety device acted.
13. Both Seal Air fans OFF for > 30Secs.
1. Cut in oil support for running Mill. If necessary in the other elevation too.
Oil support is for flame stabilization only.
2. Reduce load slowly to 100MW as per MS Pressure.
3. Maintain SH and RH temperatures by using Burner tilt and spray systems.
4. Load the running Mill to the maximum extent to maintain MS parameters
i.e., pressure and temperatures.
5. Maintain Drum level. Bypass Drum level protection if necessary.
6. Note the cause of Mill trip and refer it to the concerned maintenance
wings. Steam inert the tripped Mill.
7. Keep standby Mill on barring gear. Establish ignition energy. Take one
elevation of the Mill and raise the firing rate and raise the MS pressure.
8. Slowly raise the load to 140Mw.
9. Cut in second elevation of the second Mill.
10. Raise the load to 210Mw.
11. Cut off oil support at load > 170MW. Stabilize the Unit and check all
parameters.
19. ACTION TO BE TAKEN WHEN ONE BFP TRIPS AND STANDBY
PUMP FAILS TO START OR STABILIZE

Causes for tripping of BFP are:

1. ∆T very high (> 120C).
2. Thrust bearing temperature very high (> 950C)
3. Motor protection.
4. Deaerator level very low (-1260mmwcl).
5. Supply failure.
6. Lub oil pressure very low (< 1.5Kg/Cm2).
7. Motor/ main pump bearing temperature very high (> 1000C).
8. Suction strainer DP very high (> 0.5Kg/Cm2).
9. Working Oil temperature very high (> 1200C).
1. Hand trip the top mill after cutting in oil support to the bottom mill.
2. Reduce Unit load as early as possible to < 100MW to maintain Drum level.
During this operation at any cost HP/LP BP should not be opened in auto.
3. To reduce the MS Pressure steeply in order to reduce load on the unit keep
PA damper of the lowest elevation of the running mill at minimum duly
ensuring 3 guns in service in that elevation. The load may be kept at about
80MW.
4. Bypass drum protection and load the running BFP to the extent possible up
to a suction flow of 380 to 400TPH and amperage of 350A.
5. Maintain MS & RH temperatures using Burner Tilt and by reducing the
6. Note the cause of BFP trip and refer the problem to TM, I&C, EM wings.
7. Keep the tripped mill on barring gear and steam inert it.
8. After getting the clearance from maintenance wings start 2nd BFP and
parallel it with the running BFP.
9. Raise the PA flows of the running mill to the extent possible and raise the
load to 100MW.
10. After establishing ignition energy cut in one elevation of the 2nd mill. Raise
the firing rate and raise the load to 140MW.
11. Cut in 2nd elevation of the 2nd mill after establishing the ignition energy and
raise the firing rate. Raise the load to 210MW.
12. Cut off oil support at load > 170MW.
13. Check all parameters. After getting clearance from maintenance wings,
keep 3rd BFP in auto standby mode.
 20. ACTION TO BE TAKEN IF BOTH BCWPS TRIP AND
STAND BY PUMP FAILS TO START

Causes for tripping of BCWP are:

i. Sump level very low.
ii. Motor protection.
iii. Supply failure.
iv. Pump running and discharge valve closed or Close feedback
(instantaneous).
v. Pump ON and discharge valve closed for >60sec.s
vi. Motor bearing temperature very high (>1000C).
vii. Stop command from UCB.
For supplying cooling water to all auxiliaries when two Units are running
four pumps are necessary. Even when one Unit is in service minimum three
pumps are required to supply water to all auxiliaries.

If two pumps are Tripped either on supply failure or on BCW sump level
very low, CW pumps fail on seal / Lub water pressure not adequate < 3.2 Kg/cm2.
It results in Turbine Trip on condenser vacuum low and Boiler Trips on RH
protection.

After starting the BCW pumps Unit start up operations may be taken up.
The possible cause of trip of both CWPs and not starting of Standby CWP is due
to
1. Sump level very low.
2. Failure of 6.6 KV supply.
3. Lub /seal water pressure very low(<3.2Kg/Cm2).
4. Mitchell bearing temperature very high (>650C)
5. Motor ON and discharge valve closed for >60sec.s.
6. Pump running and discharge valve closed (instantaneous).
1. Try to start standby CWP. If we fail to do so condenser vacuum falls
rapidly and Turbine trips at -0.72Kg/cm2 vacuum (Electric trip). If
Turbine does not get tripped hand trip the turbine at -0.72 kg/cm 2 vacuum.
Boiler gets tripped on RH protection.
2. Carry out all the operations that are done during turbine trip except
maintaining gland steam pressure. Stop gland steam at -0.2kg/cm2
vacuum. After vacuum falls to zero, stop seal steam condensate exhauster
and close its manual inlet valve.
3. Open vacuum breaker and air isolation valve of starting ejector (SM-18).
4. Stop MAE.s and close ASSM-148 on 16 ATA header and close manual
isolation valve at HPHs area.
5. Close manual isolation valve of Gland steam header and AS-22 on 16 ATA
header.
6. Close manual isolation valve of PRDS drain pot drain to flash box-2 at
‘0’mts and open manual isolation valve of PRDS drain pot drain to
atmosphere.
7. Depressurize CRH and HRH lines by opening the following motor operated
valves and their manual isolation valves to atmosphere.
Nos : HRHM-32, HRHM-36, HRHM-41A, HRHM-41B,CRHM-67A
CRHM-67B. After depressurization, close the above valves.
8. Close Boiler stop valves MSSM-30, MSSM-36, MSSM-30B, MSSM-36B
Close CBD isolation valve B-80.
 10. After restarting the 2 No CWPs, restart the Unit.
11. To limit the LPT exhaust hood temperature open one pair of water injection
valves of LPBP duly ensuring two CEPs in service with enough hot well
level
OR
Open the LP water inject valve manually.

22. ACTION TO BE TAKEN WHEN ONE CEP TRIPS AND STANDBY CEP
FAILS TO START
The CEP may trip on
1. Hot well level very low(<+130mmwcl).
2. Discharge pressure low(<15Kg/Cm2).
3. Supply failure.
1. Hand trip the top Mill in service duly taking Oil support to the bottom Mill.
2. Maintain the discharge pressure of the running CEP around 18Kg/cm2 by
adjusting the condensate flow to Deareator by operating control valve
CD-14. Otherwise this CEP may also trip.
3. Reduce the load to 100MW as per MS Pressure.
4. Monitor Hotwell level and deareator level.
5. Monitor Drum level. Bypass Drum level protection if necessary.
6. Maintain MS & RH temperatures by adjusting burner tilt and spray
systems. If necessary close block valves and spray isolation valves.
7. Note the cause of tripping of CEP and refer the problem to TM and I&C
wings.
8. Keep the hand tripped mill on barring gear and steam inert it.
9. After getting clearance from the maintenance wings, start the tripped
or standby CEP. Maintain Hotwell level and deareator level.
10. Duly establishing the ignition energy, start one elevation of the tripped
mill, raise the MS pressure and raise the load to 140MW.
11. Cut in second elevation of the second Mill after establishing ignition energy.
12. Raise the MS pressure and raise the load to 210MW.
13. Cut off oil support at load > 170MW.
14. Keep the 3rd CEP in standby mode after getting clearance from maintenance
wings.

23. ACTION TO BE TAKEN FOLLOWING TRIPPING OF BOTH CEPS

CEP may trip on :

a. Hotwell level very low i.e. +130mmwcl.
b. Discharge pressure < 15 Kg/Cm2
c. Electrical protection.
d. Supply failure.
Take standby CEP into service, if the tripping of CEPs is not on Hotwell
level very low. If the standby CEP does not start, carry out the following
 1. Start vacuum pump and stop MAEs.
2. Close EX-9 to EX-11.
3. Close Swing check valves A2 and A3.
4. Stop SSCE.
5. Open GSC bypass valve on steam side to atmosphere.
6. Watch Deaerator level, Hotwell level and condenser vacuum. To
maintain these reduce Boiler firing and load as per the requirement.
7. If the CEPs Trip is on Hotwell level low close CD-14, open DM
make up valves DM-57A and DM-57B and raise Hotwell level. Then
take CEPs into service one after the other.
8. If CEPs could not be started due to Hot well level very low,
Deareator level falls and BFPs trip on Deareator level very low i.e.,
at -1260mm. Boiler trips on drum level very low.

24. LOSS OF CONDENSER VACUUM - ACTION REQUIRED

(May be due to loss of control oil)

1. On loss of vacuum Turbine will Trip at -0.72Kg/cm2. If not hand trip the
Turbine. Boiler Trips on RH protection.
2. Carry out all the operations that are to be done on Turbine Trip except
maintaining of gland steam pressure. Stop MAEs. Close the gland steam
valve at -0.2kg/cm2. When the vacuum falls to zero, stop SSCE and
close its inlet valve.
3. Close Boiler Stop valves.
4. Close gland steam and ejector steam isolating valves and their motor
operated valves on 16ATA header.
5. Close manual isolation valve of PRDS drain pot drain to flashbox-2 at
‘0’mts and open the manual valve of PRDS drain pot drain to atmosphere.
6. Depressurise CRH and HRH lines by opening their drain pot drains to
atmosphere along with their manual isolating valves.
7. Close all drains valves available in extraction lines to condenser and all
MAL valves.
8. Find the cause of Vacuum loss and after rectification, pull the vacuum and
unit start up operations may be taken up.

25. OPERATING INSTRUCTIONS TO PROTECT THE LP TURBINE

DIAPHRAGMS WHEN STATION SUPPLY FAILURE OCCURS

The following procedure may be adopted to save the LP diaphragms during

station supply failure. The same is applicable when CW pumps are failed
a. Due to sump level very low.
b. Due to very low seal/Lub water pressure (<3.2 Kg/Cm2).
1. Open vacuum breaker from control desk and ensure opening of its manual
isolation valve. If vacuum breaker is not opened from BTG, open it from
locally.
2. Open starting ejector air isolation valve at 5mtrs near MAEs.
3. Close gland steam (auxiliary steam to Turbine glands) manual isolating
valve at 5mtrs.
 4. Close manual isolating valve of auxiliary - steam to ejectors at 10mts near
HPHs.
5. Close 16 ATA header manual drain ( ASSM -154 ) connected to flash
box-2 at ‘0’mts and open the drain to atmosphere.

26. STEPS TO BE TAKEN TO PREVENT JAMMING OF TURNING GEAR

1. Required Jack oil lifts and healthiness of Jack oil hoses shall be ensured
during annual overhaul.
2. All the Jack oil pressure gauges shall be calibrated as and when required.
3. Interlocks for the gland steam system drain valves (MAL-81 and
MAW10AA001) shall be checked during overhaul.
4. Auto operation of gate valve gearing, JOPS and AOPS shall be ensured.
5. Always keep the SLC of MAL drains in auto mode.
6. Ensure proper insulation for HP/IP casings during Annual overhaul.
To prevent entry of Wet steam/ air into hot Turbine through glands.
7. Ensure the gland steam temperature before gland steam control valve is
greater than 1950C and the PRDS temperature is above 2100C.
8. Immediately after tripping of the Unit, manual drain of gland steam shall be
kept open (if it is not connected to flash box).
 valve before gland steam control valve shall be closed to avoid passing of wet
steam).
10. Seal steam exhaust fan shall be stopped after killing the vacuum to avoid the
ingress of cold air in to the Turbine glands.
11. After establishing the barring gear, Turbine casing temperatures (Top/bottom)
shall be monitored and the difference maintained within limits.
12. Incase of total AC supply failure to the station, starting of DC AOP (EOP)
and DCJOP shall be ensured and hand barring shall be continued until the
ACAOP comes into service.
13. During hydraulic test, Auto mode of SLC drains and opening of Manual
isolation valves of MAL drains shall be ensured to prevent entry of water into
the Turbine.
Steps to be taken in case of Seizure of Turning gear:
1. In case of fall in barring speed, check the opening of gate valve gearing valve
and the Jack oil header pressure. Opening of gate valve gearing valve shall be
ensured duly taking care of protections (Fire protection-1 and 2). If the jack
oil header pressure is not adequate standby JOP shall also be taken into
service with due intimation to the TM staff.
2. Attempts shall be made by keeping JOP ON and OFF frequently for
restoration of barring gear.
3. Preparation shall be made for hand barring if the barring speed continues to
fall even after carrying out the above steps. Hand barring shall be commenced
only after barring speed comes to zero.
4. If the rotor is found to be hard for hand barring, gland steam shall be admitted
at high temperature (>2300C) for pulling the vacuum. Vacuum shall be
maintained at -0.5Kg/cm2 for half an hour and hand barring shall be tried for
rotation. Even after carrying out the above steps if the hand barring is found
to be hard, Vacuum shall be killed and gland steam shall also be cut off after
30 to 40 minutes.
The process of pulling and killing of vacuum along with gland steam
shall be continued with an interval of 1 hour while trying the hand barring.
 Once the rotor becomes free while hand barring, auto barring can be
established.

27. 24V ELECTRICAL TURBINE TRIP

Possible causes:
1. Failure of charger which is in service.
2. Bad condition of Battery bank.
3. Flash over in DC Distribution board.
4. Battery inter- connection plates opening.

Plant Response:
a. Tripping of All MCBs in FSSS and ATRS.

FSSS:
On the loss of 24V DC the DC monitoring relay drops initiating all
actions of MFT through 220V DC auxiliary supply.
i. Boiler Trips
ii. HOTV & IOTV close.
iii. Mill motors Trip through motor panel DC.
iv. PA Fans motors Trip through motor panel DC.
v. PC outlet gates close through 110V AC Auxiliary supply.
vi. SADC dampers open to full.
Effects on ATRS:

Loss of 24V DC leads to total supply failure to ATRS system and its
logical function is totally lost.
 ii. EHG signal goes to Maximum and the machine changes into
HG mode automatically with HPCVS and IPCVS in full open
condition.
iii. 220V DC HP/IP Trimming device gets de-energized on the
loss of 24V DC resulting in closure of IPCVs by 50%.
Operator action:
i. Since the Turbine trip cannot be initiated from the BTG due to loss of
ATRS functioning, Turbine has to be hand tripped from local by
pulling Main Trip Valve levers at Governing rack.
ii. Since the AOP will not come into service on Turbine Trip and as it
cannot be started from the BTG, start EOP from the panel at 10Mts.
Instruct AE/S/0mts to start AC AOP from the module in EMC board.
After ensuring that AOP is in service, stop EOP.
iii. After Tripping the Turbine, open the GCB and hand trip
the field breaker.
iv. Start DC JOP from panel at 10mts. Start AC JOP from the module in
TVC or EMC and then stop DC JOP.
v. Other HISEC, HIDEC systems function normally.
28. ACTION TO BE TAKEN WHEN EHG POSITION FALLS TO 0%

When EHG position falls to 0% due to fault in the ATRS load drops to Zero.
The operators have to carry out following steps to save the Unit from
tripping.

1. Take gland steam control into manual and raise the Gland steam
pressure to > 0.01kg/cm2.
Or
Open seal steam bypass valve on the BTG to maintain gland steam
pressure to > 0.01Kg/cm2, otherwise condenser vacuum falls
resulting in Turbine trip.

2. Take Deaerator level control valve CD-14 into manual and close it
completely, to maintain Hotwell level otherwise Hotwell level falls
causing tripping of CEPs.

3. Operate levers at governing rack such that HG system takes over the
control and Maintain load.

4. Operate SLLD to maintain load according to MS pressure.

5. In the mean time HP/LPbypass valves open to full to

Maintain Boiler load.
Class C Trip is initiated with the operation of following relays
1. Bus - bar Protection.
2. Pole discrepancy relay.
3. GT Back up over current and earth fault relay.
Whenever Class-C Trip occurs the GCB only opens. If EHG is in service the
speed controller takes over the control and maintains the load at house load i.e. 21MW
and speed at the set speed. If the Governing system is on HG the Turbine may Trip on
over speed. The operators have to carry out the following operations to avoid Unit
tripping.
1. Take gland system control into manual and maintain the pressure
to > 0.01Kg/cm2 by pressing the raise button.
Or
Operate the seal steam bypass valve to maintain gland steam pressure
to avoid Turbine Trip on condenser vacuum low.
2. Take deaerator level control valve CD-14 into manual mode and
close it completely to maintain hotwell level, otherwise CEPs may
trip on Hotwell level low.
3. Take four oil guns into service and hand trip one Mill. After the
furnace pressure is stabilized, hand trip one elevation in the running
Mill i.e. only one coal elevation should be in service with oil support.
4. Unload one BFP and keep it under Recirculation. Maintain MS and
RH temperatures above 5000C.
5. After the clearance is given by the EM wing, synchronise the Unit
with grid using synchroscope.
6. Raise the firing rate and raise the load.

30. OPERATING INSTRUCTIONS TO MAINTAIN FLUE GAS

TEMPERATURE AFTER RAH WHEN PTW IS ISSUED
ON ESP PASS
 When PTW is issued on ESP pass the flue gas temperature after corresponding
RAH drops to less than 120oC (Acid dew point) resulting in the formation of acid
(H2SO4) which damages the ducts etc. To avoid this following procedure may be
adopted. It is advisable to maintain flue gas temperature up to ID fans outlet well
above 120oC.
a. PTW on ESP pass -A (Pass-B)
For issuing PTW on ESP pass the inlet and outlet gates of the pass
have to be closed. Just before closing outlet and inlet gates GD-9 and
GD-5, bias the fans as given below:
i) To increase flue gas quantity in the ESP pass-B, give positive
bias to the ID fan-A
ii) As quantity of flue gas reduces in RAH-A, we have to reduce
primary air flow and secondary air flows through the RAH.
For that negative bias the FD fan-A and PA fan-A. It is
advisable to reduce the blade pitch of FD fan-A manually to
minimum i.e. 0 %
b. PTW on ESP pass-C (Pass-D)
i) Positive bias ID fan-B to draw more flue gas through RAH-B.
ii) Negative bias PA fan-B and FD fan-B to reduce air flows
through RAH-B. It is advisable to reduce the blade pitch of
FD fan-B manually to minimum i.e. 0 %
NOTE: Load need not be reduced if Furnace draft maintains within the
limits during the period of isolation of ESP pass.
**************************************