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HARYANA POWER GENERATION CORPORATION LIMITED PANCHKULA, HARYANA DESEIN PRIVATE LIMITED CONSULTING ENGINEERS NEW DELHI CENTRAL

ELECTRICITY AUTHORITY SEWA BHAWAN, R K PURAM, NEW DELHI 2X600MW THERMAL POWER PLANT HISAR HARYANA-INDIA
Operation Manual for 600MW Unit DOCUMENT No: HISAR-ZT-07

RELIANCE ENERGY LIMITED


H-146/147, Sector-63 Noida (U.P) 201301

DEVELOPMENT CONSULTANTS PRIVATE LIMITED


CONSULTING ENGINEERS 24B PARK STREET, KOLKATA - 700 016, INDIA

SHANGHAI ELECTRIC CORPORATION


No. 8, Xingyi Rd., Shanghai, 200336, China

SHANGHAI ELECTRIC IMP. AND EXP. CORP,


No. 22, Lane 376, YanAn Rd. (West), Shanghai, 200040, China

HTPC

HUNAN PROVINCIALTHERMALPOWER CONSTRUCTION CO. 99 Jianshe Zhonglu,Zhuzhou,China

Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISARHARYANA-INDIA

DOCUMENT CONTROL SHEET

PROJECT CLIENT LIMITED DOCUMENT TITLE:

: :

2X600 MW THERMAL POWER PLANT HISAR HARYANA-INDIA HARYANA POWER GENERATION CORPORATION

Operation Manual for 600MW Unit

DOCUMENT NO. : HISAR-ZT-07

REV. NO. :0

ENDORSEMENTS

0
Rev No

2009-02-20
Date

First Issue
Description Prepared by Sign.( Initials) Reviewed by Sign. (Initials) Approved by Sign.( Initials)

DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

CONTENTS
CHAPTER I BOILER OPERATION REGULATIONS.................................................................. 1 1.1 INTRODUCTION OF BOILER DEVICES .............................................................................. 1 1.2 BOILER MAIN TECHNIQUE REGULATIONS ...................................................................... 1 1.2.1 MAIN PARAMETERS OF BOILER..................................................................................... 1 1.2.2 MAIN PERFORMANCE INDEX OF BOILER ..................................................................... 2 1.2.3 PARAMETER OF SH PRIMARY, SECONDARY WATER SPRAY DESUPERHEATER RH EMERGENCY SPRAY.................................................................................................................. 4 1.2.4 COAL PERFORMANCE ANALYSIS TABLE ..................................................................... 5 1.2.5 SET VALUE OF BOILER SAFETY VALVE ........................................................................ 5 1.2.6 LIMITING VALUE OF HEATING SURFACE ...................................................................... 6 1.2.7 TECHNIQUE REGULATIONS OF BOILER MAIN AUXILIARIES ..................................... 6 1.3 MAIN CONTROL SYSTEM.................................................................................................. 11 1.3.1 SUMMARIZE ..................................................................................................................... 11 1.3.2 INTRODUCTION OF UNIT COORDINATED CONTROL SYSTEM................................. 11 1.3.3 FSSS INTRODUCTION (FURNACE SAFETY SUPERVISION SYSTEM) ...................... 13 1.3.4 BOILER MFT CONDITION ............................................................................................... 14 1.3.5 CONTROL OF SECONDARY AIR DAMPER ................................................................... 15 1.3.6 FUEL CONTROL OF RB ACTION ................................................................................... 19 1.4 TEST BEFORE BOILER START-UP................................................................................... 21 1.4.1 TESTS BEFORE BOILER START-UP ............................................................................. 21 1.4.2 BOILER OVERALL INTERLOCK TEST .......................................................................... 21 1.4.3 FURNACE PRESSURE PROTECTION ........................................................................... 22 1.4.4 OTHER PROTECTION TEST ........................................................................................... 22 1.5 START UP OF BOILER ....................................................................................................... 23 1.5.1 INITIAL STATE BEFORE START-UP (ENTIRE COLD WORKING CONDITION) .......... 23 1.5.2 PREPARATION BEFORE START-UP.............................................................................. 23

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Operation Manual for 600MW Unit

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1.5.3 BOILER BLOWING CONDITIONS................................................................................... 24 1.5.4 INSPECTION OF CONTROL SYSTEM BEFORE START-UP......................................... 26 1.5.5 BOILER IGNITION, TEMPERATURE INCREASE, PRESSURE RAISE......................... 26 1.5.6 INCREASE COMBUSTION RATE.................................................................................... 27 1.5.7 PRECAUTIONS DURING THE COURSE OF BOILER TEMPERATURE INCREASING27 1.5.8 TURBINE TURNING AND SYNCHRONIZATION ............................................................ 28 1.5.9 TURBINE SYNCHRONIZATION WITH MINIMUM LOAD TO 35% OF BMCR (100MW) 28 1.5.10 LOAD FROM 35% OF BMCR TO 100% ........................................................................ 29 1.5.11 PRECAUTION FOR COLD START ................................................................................ 29 1.5.12 HOT START .................................................................................................................... 30 1.6 BOILER OPERATION CONTROL AND ADJUSTMENT .................................................... 30 1.6.1 ADJUSTING WORK OF BOILER OPERATION .............................................................. 30 1.6.2 FEEDWATER ADJUSTMENT........................................................................................... 31 1.6.3 BOILER COMBUSTION ADJUSTMENT.......................................................................... 31 1.6.4 ADJUSTMENT OF BOILER STEAM TEMPERATURE ................................................... 32 1.6.5 LIMITATION VALUE OF BOILER OPERATING PARAMETER....................................... 33 1.7 STOP BOILER TO OPERATION ......................................................................................... 34 1.7.1 STOP OPERATION BY SMOOTH PARAMETER CHANGING ....................................... 34 1.7.2 EMERGENCE STOP......................................................................................................... 36 1.7.3 PRECAUTIONS DURING BOILER SHUT OFF ............................................................... 37 1.8 TYPICAL ACCIDENTS DISPOSAL IN BOILER ................................................................. 38 1.8.1 FULL WATER OF BOILER ............................................................................................... 38 1.8.2 THE BOILER IS SHORT OF WATER............................................................................... 38 1.8.3 PRIMING OF STEAM & WATER ...................................................................................... 39 1.8.4 MFT.................................................................................................................................... 40 1.8.5 RB ...................................................................................................................................... 40 1.8.6 PRESSURE OF MAIN STEAM AND REHEATING STEAM IN INCORRECT SCOPE ... 41 1.8.7 ABNORMAL OF MAIN STEAM TEMPERATURE ........................................................... 42 DOCUMENT NO. : HISAR-ZT-07
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1.8.8 WATER FLOW FOR BOILER IS LOW ............................................................................. 44 1.8.9 ECO DESTROYED ........................................................................................................... 45 1.8.10 DESTROY OF SH ........................................................................................................... 45 1.8.11 LEAKAGE OF REHEATER............................................................................................. 46 1.8.12 REFRAME IN REAR FUME DUCT................................................................................. 47 1.8.13 COKING BOILER............................................................................................................ 48 1.8.14 TEMPERATURE OF SUPERHEATER TUBE AND REHEATER TUBE SURPASS ..... 49 CHAPTER II OPERATION MANUAL FOR BOILER ACCESSORY ......................................... 51 2.1 AIR PREHEATER................................................................................................................. 51 2.1.1 INTERLOCK PROTECTION FOR PREHEATER ............................................................. 51 2.1.2 TRIP CONDITIONS FOR PREHEATER ........................................................................... 51 2.1.3 START PREHEATER ........................................................................................................ 51 2.1.4 STOP PREHEATER .......................................................................................................... 51 2.1.5 HANDLING PREHEATER TROUBLESOME ................................................................... 51 2.2 IDF ........................................................................................................................................ 52 2.2.1 ADMITTED STARTING CONDITIONS ............................................................................. 52 2.2.2 TRIP CONDITIONS ........................................................................................................... 53 2.2.3 INTERLOCK CONDITIONS OF STARTING COOLING FAN: ......................................... 53 2.2.4 START IDF ........................................................................................................................ 53 2.2.5 SHUT-DOWN IDF.............................................................................................................. 54 2.2.6 HANDLING ACCIDENTS OF IDF..................................................................................... 54 2.3 FDF ....................................................................................................................................... 56 2.3.1 ADMITTING START CONDITIONS .................................................................................. 56 2.3.2 TRIP CONDITIONS ........................................................................................................... 56 2.3.3 INTERLOCK OF LUBRICATE OIL PUMP ....................................................................... 56 2.3.4 INTERLOCK OF ELECTRIC HEATER OF LUBRICATE OIL TANK ............................... 56 2.3.5 START FDF ....................................................................................................................... 56 2.3.6 STOP FAN ......................................................................................................................... 57 DOCUMENT NO. : HISAR-ZT-07
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2.3.7 ACCIDENT HANDLING OF FDF ...................................................................................... 57 2.4 PAF ....................................................................................................................................... 58 2.4.1 ADMITTING START CONDITION..................................................................................... 58 2.4.2 TRIP CONDITIONS ........................................................................................................... 58 2.4.3 INTERLOCK OF LUBRICATE OIL PUMP AND HYDRAULIC OIL PUMP...................... 58 2.4.4 INTERLOCK OF MOTOR DRIVEN LUBRICATE OIL PUMP OF PAF. ........................... 59 2.4.5 INTERLOCK OF ELECTRIC HEATER OF LUBRICATE OIL TANK OF PAF. ................ 59 2.4.6 START PAF ....................................................................................................................... 59 2.4.7 STOP OF PAF ................................................................................................................... 59 2.4.8 HANDLING ACCIDENTS OF PAF.................................................................................... 60 2.5 PULVERIZED COAL SYSTEM ............................................................................................ 62 2.5.1 MILL TRIPS....................................................................................................................... 62 2.5.2 COAL FEEDER TRIPS ..................................................................................................... 62 2.5.3 START SEALING AIR FAN............................................................................................... 63 2.5.4 START PULVERIZED COAL SYSTEM ............................................................................ 63 2.5.5 STOP COAL SYSTEM...................................................................................................... 64 2.5.6 PARAMETER OF COAL SYSTEM................................................................................... 64 2.5.7 HANDLING ACCIDENT OF PULVERIZED COAL SYSTEM ........................................... 65 2.6 CCP (BOILER WATER CONTROL CIRCULATING PUMP) ............................................... 68 2.6.1MAIN PARAMETER OF CCP ............................................................................................ 68 2.6.2 ALARMING AND VALUE-FIXING PARAMETERS OF CCP ........................................... 69 2.6.3 STARTING AND TRIPPING CONDITIONS OF CCP ....................................................... 69 2.6.4 PREPARE FOR OPERATION OF CCP............................................................................ 70 2.6.5 CCP WATER FILLING AND AIR EXHAUST .................................................................... 70 2.6.6 PREPARATION TO START CCP ..................................................................................... 71 2.6.7 OPERATING CONDITIONS OF CCP ............................................................................... 71 2.6.8 THE RUNNING OF CCP ................................................................................................... 72 2.6.9 STOP OF CCP................................................................................................................... 72 DOCUMENT NO. : HISAR-ZT-07
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2.6.10 RELEASING WATER OF CCP ....................................................................................... 72 2.6.11 ISOLATION, MAINTENANCE AND REPAIR OF CCP................................................... 73 2.7 FLAME INSPECTION OF COOLING AIR FAN SYSTEM................................................... 73 2.7.1INTERLOCK PROTECTION OF FLAME INSPECTION ................................................... 73 2.7.2 START FLAME INSPECTION .......................................................................................... 73 2.7.3 STOP FLAME INSPECTION SYSTEM ............................................................................ 73 2.8 OPERATION OF ESP .......................................................................................................... 73 2.8.1TEST AND INSPECTION BEFORE COMMISSIONING ................................................... 73 2.8.2 SWITCH ON ESP.............................................................................................................. 74 2.8.3 SWITCHING OFF OF ESP............................................................................................. 75

2.8.4 TYPICAL FAILURE AND ITS ANALYSIS......................................................................... 76 2.9 SOOT BLOWER................................................................................................................. 78 2.9.1 SOOT BLOWING SYSTEM PARAMETERS.................................................................. 78 2.9.2 CONDITIONS AND INSPECTION OF SOOT BLOWING ................................................ 80 2.9.3 OPERATION OF SOOTBLOWER .................................................................................... 80 2.9.4 SOOTBLOWER OPERATION PERIOD ........................................................................... 81 2.9.5 SOOTBLOWING STEAM SOURCE OF THE AIR PREHEATER .................................... 81 2.9.6 SOOTBLOWER MAINTENANCE..................................................................................... 81 2.9.7 SOOTBLOWER FAULT TREATMENT............................................................................. 81 2.9.8 STOP SOOTBLOWING OPERATION IN CASE OF ANY OF THE FOLLOWING SITUATIONS: ............................................................................................................................. 82 2.9.9 TREATMENT TO ABNORMITY OF SOOTBLOWER STEAM PRESSURE.................... 82 2.10 SECONDARY AIR HEATER .............................................................................................. 82 2.11SYNOPSIS OF PRESSURE AND TEMPERATURE UNDER SATURATION .................... 83 2.12 BOILER STARTUP CURVE AND LOGIC DIAGRAM ....................................................... 84 CHAPTER III STEAM TURBINE OPERATION REGULATIONS........................................ 85

3.1 INTRODUCTION OF STEAM TURBINE ............................................................................. 85 3.1.1 MAIN PARAMETERS OF STEAM TURBINE .................................................................. 85 DOCUMENT NO. : HISAR-ZT-07
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3.1.2 MAIN SPECIFICATION OF TURBINE.............................................................................. 86 3.1.3 BRIEF OF MAIN CONTROL SYSTEMS .......................................................................... 87 3.2 INTERLOCK AND TEST OF STEAM TURBINE................................................................. 89 3.2.1 CONTENTS OF INTERLOCK........................................................................................... 89 3.2.2 UNIT INTERLOCK RELATIONSHIP ................................................................................ 90 3.2.3 INTERLOCK TEST ........................................................................................................... 90 3.2.3 CONDENSER VACUUM TIGHTNESS TEST................................................................... 90 3.3 STARTUP OF TURBINE ...................................................................................................... 97 3.3.1 PREPARATION BEFORE TURBINE STARTUP.............................................................. 97 3.3.2 BASIC RULES FOR TURBINE START............................................................................ 97 3.3.3 COLD START.................................................................................................................... 99 3.3.4 HOT STARTUP PRECAUTIONS .................................................................................... 104 3.4 TURBINE NORMAL OPERATION..................................................................................... 104 3.4.1 GENERAL PRINCIPLES ................................................................................................ 104 3.4.2 MAIN PARAMETER AND LIMITATION OF TURBINE NORMAL OPERATION ........... 104 3.5 SHUTDOWN OF TURBINE ............................................................................................... 105 3.5.1 PREPARATION BEFORE SHUTDOWN ........................................................................ 105 3.5.2 WORKS AFTER SPLITTING .......................................................................................... 106 3.5.3 WORKS AFTER ROTOR BEING STILL ........................................................................ 107 3.6 TURBINE ACCIDENT DISPOSAL..................................................................................... 108 3.6.1 PRINCIPLE OF ACCIDENT DISPOSAL ........................................................................ 108 3.6.2 EMERGENCY SHUT DOWN .......................................................................................... 108 3.6.3 FAILURE SHUTDOWN ................................................................................................... 109 3.6.4 DISPOSAL PRINCIPLES FOR TURBINE EMERGENCY STOP .................................. 109 3.6.5 TURBINE TRIP CONDITIONS........................................................................................ 110 3.6.6 TYPICAL TURBINE FAILURE DISPOSAL .....................................................................111 CHAPTER IV TURBINE AUXILIARY EQUIPMENT OPERATION ......................................... 120 4.1 TECHNICAL SPECIFICATIONS OF TURBINE AUXILIARY EQUIPMENT...................... 120 DOCUMENT NO. : HISAR-ZT-07
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4.1.1 CONDENSER.................................................................................................................. 120 4.1.2 MOTOR DRIVEN FEED WATER PUMP GROUP .......................................................... 120 4.1.3 TBFP GROUP ................................................................................................................. 123 4.1.4 DEAERATOR SPECIFICATION ..................................................................................... 124 4.1.5 THE TECHNICAL SPECIFICATION OF CONDENSATE PUMP ................................... 125 4.1.6 MAIN AND BFP OIL PUMP TECHNICAL SPECIFICATION ......................................... 125 4.1.7 HP HEATER .................................................................................................................... 126 4.1.8 LP HEATER, GLAND STEAM CONDENSER................................................................ 126 4.2 TURBINE LUBE AND EH OIL SYSTEM ........................................................................... 127 4.2.1 LUBE OIL SYSTEM OPERATION.................................................................................. 127 4.2.2 STARTUP OF OIL SYSTEM ........................................................................................... 127 4.2.3 OPERATION AND MAINTENANCE ............................................................................... 128 4.2.4 TURBINE JACKING OIL PUMP AND TURNING GEAR ............................................... 128 4.2.5 LUBE OIL SYSTEM SETTING ....................................................................................... 129 4.2.6 TURBINE EH OIL SYSTEM SETTING ........................................................................... 129 4.3 VACUUM AND SHAFT SEAL STEAM SUPPLY SYSTEM............................................... 130 4.3.1 THE PREPARATION BEFORE START WATER SIDE VACUUM PUMP ...................... 130 4.3.2 STARTUP OF WATER COLLAR VACUUM PUMP........................................................ 130 4.3.3 THE STANDARD OPERATION AND MAINTENANCE ................................................. 130 4.3.4 STOP WATER COLLAR VACUUM PUMP ..................................................................... 130 4.3.5 VACUUM PUMP MAIN INTERLOCK PROTECTION .................................................... 131 4.3.6 PRECAUTION OF GLAND STEAM SUPPLY CONTROL ............................................. 131 4.4 CONDENSATE WATER AND WATER-FEED SYSTEM ................................................... 131 4.4.1 START CONDENSATE PUMP ....................................................................................... 131 4.4.2 STOP SYSTEM ............................................................................................................... 131 4.4.3 CONDENSATE SYSTEM PROTECTION....................................................................... 132 4.5 H/LP HEATERS.................................................................................................................. 132 4.5.1 START OR QUIT RULES OF HP/LP HEATERS............................................................ 132 DOCUMENT NO. : HISAR-ZT-07
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4.5.2 HP SLIDE OPERATION .................................................................................................. 133 4.5.3 HP HEATER START DURING UNIT NORMAL OPERATION ....................................... 133 4.5.4 LP HEATER START WITH UNIT LOAD......................................................................... 134 4.5.5 LP HEATER START INDEPENDENTLY ........................................................................ 134 4.5.6 OPERATION AND MAINTENANCE OF HP/LP HEATERS ........................................... 134 4.5.7 HP HEATER STOPS WITH UNIT LOAD ........................................................................ 135 4.5.8 THE SHUTDOWN OF HP HEATER DURING UNIT OPERATING NORMALLY ........... 135 4.5.9 LP HEATER STOPS WITH TURBINE............................................................................ 136 4.5.10 LP HEATER STOPS PARTICULARLY......................................................................... 136 4.5.11 HP HEATER MAIN INTERLOCK PROTECTION ......................................................... 136 4.5.12 LP HEATER AND DRAIN SYSTEM MAIN INTERLOCK PROTECTION .................... 137 4.6 DEAERATOR SYSTEM ..................................................................................................... 137 4.6.1 OPERATION OF DEAERATOR ...................................................................................... 137 4.6.2 SHUT DOWN OF DEAERATOR..................................................................................... 138 4.6.3 CONTROL PARAMETER OF DEAERATOR UNDER NORMAL OPERATION ............ 138 4.6.4 SHUT DOWN OF DEAERATOR..................................................................................... 138 4.6.5 MAIN INTERLOCK PROTECTION FOR DEAERATOR ................................................ 139 4.7 FEED WATER STEAM (MOTOR) PUMP GROUP ............................................................ 140 4.7.1 MOTOR-PUMP GROUP.................................................................................................. 140 4.7.1.4 OPERATION AND MAINTENANCE FOR MBFP GROUP.......................................... 141 4.7.2 TBFP GROUP ................................................................................................................. 142 4.8 OPEN/CLOSE COOLING SYSTEM .................................................................................. 148 4.8.1 SET PROTECTION VALVE FOR OPEN COOLING SYSTEM ...................................... 148 4.8.2 SET PROTECTION VALUE FOR CLOSE COOLING SYSTEM.................................... 148 4.9 GENERATOR OIL SEALING SYSTEM............................................................................. 148 4.9.1 GENERAL REGULATION .............................................................................................. 148 4.9.2 PUT OIL SEALING SYSTEM INTO RUNNING .............................................................. 148 4.9.3 SHUTDOWN SEAL OIL SYSTEM.................................................................................. 149 DOCUMENT NO. : HISAR-ZT-07
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4.9.4 GENERATOR SEAL OIL SYSTEM OPERATION MAINTENANCE .............................. 149 4.9.5 SEALING OIL SOURCE OF AIR SIDE AND HYDROGEN SIDE .................................. 149 4.9.6 I & C INTERLOCK PROTECTION.................................................................................. 150 4.9.7 ACCIDENT DISPOSAL................................................................................................... 150 4.10 STATOR COOLING WATER SYSTEM............................................................................ 151 4.10.1 STATOR COOLING WATER SYSTEM OPERATION RULES ..................................... 151 4.10.2 PUT STATOR COOLING WATER SYSTEM INTO OPERATION ................................ 152 4.10.3 SHUTDOWN STATOR COOLING WATER PUMP....................................................... 152 4.10.4 STATOR COOLING WATER SYSTEM OPERATING MAINTENANCE ...................... 153 4.10.5 MAIN INTERLOCK PROTECTION............................................................................... 153 4.10.6 ACCIDENT DISPOSAL................................................................................................. 153 CHAPTER V ELECTRICAL EQUIPMENT OPERATION REGULATION ............................... 155 5.1 ELECTRICAL EQUIPMENT .............................................................................................. 155 5.1.1 GENERAL INTRODUCTION .......................................................................................... 155 5.1.2 SPECIFICATION ............................................................................................................. 155 5.2 GENERATOR OPERATION REGULATION ...................................................................... 155 5.2.1 START CONDITION........................................................................................................ 155 5.2.2 CHECK BEFORE STARTING GENERATOR................................................................. 156 5.2.3 TEST BEFORE STARTING ............................................................................................ 157 5.2.4 BASIC OPERATION STEP WHEN START GENERATOR-TRANSFORMER .............. 157 5.2.5 INSPECTION AFTER TURNING (1500R/M OR 3000R/M)............................................ 158 5.2.6 CHECK AFTER G SYNCHRONIZING............................................................................ 159 5.2.7 OPERATION REGULATION AFTER G SYNCHRONIZING .......................................... 159 5.2.8 OPERATION WHEN START GENERATOR................................................................... 159 5.2.9 GENERAL REGULATION WHILE UNIT RUNNING ...................................................... 161 5.2.10 GENERATOR CURRENT AND VOLTAGE REGULATION.......................................... 161 5.2.11 EXCITING SYSTEM REGULATION WHILE RUNNING .............................................. 161 5.2.12 RUNNING REGULATION OF STATOR WATER COOLING SYSTEM........................ 162 DOCUMENT NO. : HISAR-ZT-07
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5.2.13 GENERATOR CHECK AND REPAIR ........................................................................... 163 5.2.14 OPERATE STEP OF DE-SYNCHRONIZING TO REPAIR STATUS............................ 164 5.2.15 RUNNING REGULATION OF HYDROGEN SYSTEM ................................................. 165 5.3 TROUBLESOME OF GENERATOR.................................................................................. 166 5.3.1 STOP GENERATOR EMERGENT.................................................................................. 166 5.3.2 ASK DEPUTY MANAGER OR CHIEF ENGINEER TO STOP GENERATOR WHEN ONE OF SITUATION FOLLOWING APPEARS ............................................................................... 167 5.3.3 GENERAL OPERATION RULES WHEN GENERATOR-TRANSFORMER PROTECTION ACTS ........................................................................................................................................ 167 5.3.4 WHEN TROUBLESOME OR SWITCH REFUSE TO ACT AMONG G-T ...................... 167 5.3.5 GENERATOR VOLTAGE DOESNT GO UP WHILE INCREASING VOLTAGE ........... 167 5.3.6 GENERATOR LOSS OF EXCITING ............................................................................... 168 5.3.7 WHEN GENERATOR PARALLEL ASYNCHRONOUSLY ............................................. 168 5.3.8 CHANGE GENERATOR TO MOTOR RUNNING........................................................... 169 5.3.9 GENERATOR VIBRATION HEAVILY ............................................................................. 169 5.3.10 BRUSH OF SLIP RING HEAT HEAVILY OR CATCH A FIRE ..................................... 169 5.3.11 ABNORMAL TEMPERATURE OF GENERATOR........................................................ 169 5.3.12 TROUBLESOME IN INNER COOLING WATER SYSTEM.......................................... 170 5.3.13 STATOR GROUNDING ................................................................................................. 170 5.3.14 VOLTAGE CIRCUIT WIRING BROKEN....................................................................... 171 5.3.15 WHEN STATOR 3 PHASES CURRENT UNBALANCE............................................... 171 5.3.16 WHEN RUNNING ON PHASE OPEN........................................................................... 172 5.3.17. WHEN GENERATOR OVER-EXCITING ..................................................................... 172 5.3.18 WHEN ROTOR WINDING ONE POINT GROUNDING................................................ 172 5.3.19 HYDROGEN LEAKAGE ............................................................................................... 173 5.3.20 WHEN GENERATOR EXPLODES OR CATCHES A FIRE.......................................... 173 5.3.21 WHEN TROUBLESOME IN EXCITING SYSTEM AND REMOVING .......................... 173 5.3.22 RECTIFIER CABINET DEFECT OR ALARM .............................................................. 173 DOCUMENT NO. : HISAR-ZT-07
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5.3.23 OUTLET AIR TEMPERATURE OF RECTIFIER CABINET HIGH AND ALARM ........ 174 5.3.24 WHEN GENERATOR OVER-LOADS BY ACCIDENT ................................................. 174 CHAPTER VI THE FUEL OIL SYSTEM OPERATION REGULATIONS................................. 175 6.1 FUEL SYSTEM................................................................................................................... 175 6.1.1 EQUIPMENT FUNCTION................................................................................................ 175 6.1.2 THE CONFIGURATION AND PUMP OPERATION MODE............................................ 175 6.1.3. TECHNICAL DATA OF FUEL EQUIPMENT ................................................................. 175 6.2 SHIFT AND EQUIPMENT INSPECTION........................................................................... 177 6.2.1 SPELL PROGRAMS ....................................................................................................... 177 6.2.2 EQUIPMENT INSPECTION ............................................................................................ 178 6.3 LIGHT OIL FEED PUMP .................................................................................................... 178 6.3.1 INSPECTION BEFORE FUEL OIL HANDLING SYSTEM START UP.......................... 178 6.3.2 START LIGHT OIL TRANSFER SYSTEM ..................................................................... 179 6.3.3 LIGHT OIL PUMP OPERATION ..................................................................................... 179 6.3.4 STOP LIGHT OIL TRANSFER SYSTEM ....................................................................... 180 6.3.5 OPERATION AND MAINTENANCE ............................................................................... 180 6.4 HEAVY OIL FEED PUMP................................................................................................... 180 6.4.1 THE INSPECTION BEFORE FUEL OIL HANDLING SYSTEM START-UP.................. 180 6.4.2 FUEL OIL HANDLING SYSTEM STARTUP .................................................................. 181 6.4.3 FUEL OIL PUMPS OPERATION .................................................................................... 182 6.4.4 STOP FUEL OIL HANDLING SYSTEM.......................................................................... 182 6.4.5 NORMAL RUNNING ATTENTION.................................................................................. 183 6.5 PRINCIPLE OF ACCIDENT DISPOSAL ........................................................................... 184 6.5.1 THE CONDITIONS OF EMERGENCY STOP PUMP ..................................................... 184 6.5.2 COMMON TROUBLE AND ITS SOLUTION .................................................................. 184 6.5.3 COMMON FAULT OF FEEDING/RETURN OIL LINE.................................................... 187 6.5.4 APS INTERRUPTION ..................................................................................................... 188 6.5.5 LIGHT PUMP VIBRATION .............................................................................................. 188 DOCUMENT NO. : HISAR-ZT-07
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6.5.6 EXPORT PRESSURE OF LIGHT FUEL PUMP ABNORMAL ....................................... 189 6.5.7 HEAVY FUEL PUMP VIBRATION .................................................................................. 189 6.5.8 HEAVY ABNORMAL HYDRAULIC FUEL PUMP EXPORT .......................................... 189 6.5.9 PUMPS FOR VAPORIZATION ....................................................................................... 189 6.5.10 CURRENT SWING ................................................................................................... 190

6.5.11 PRESSURE SWING ...................................................................................................... 190 6.5.12 FEED OIL PUMPS TRIP ............................................................................................... 190 CHAPTER VII CONDENSATE POLISHING OPERATION AND MAINTENANCE REGULATIONS .................................................................................................................................................. 192 7.1 INTRODUCTIONS.............................................................................................................. 192 7.1.1 PURPOSE OF CONDENSATE POLISHING .................................................................. 192 7.1.2 SYSTEM INTRODUCTION ............................................................................................. 192 7.1.3 PROCESS DESCRIPTION ............................................................................................. 193 7.1.4 MAIN EQUIPMENT STANDARD OF FINE TREATMENT ............................................. 194 7.2 OPERATION OF CONDENSATE WATER FINE TREATMENT DEVICE ......................... 196 7.2.1 THE INSPECTION AND PREPARATION OF INITIAL OPERATION............................. 196 7.2.2 PRE-INSPECTION AND PREPARATION OF THE NORMAL OPERATION................. 199 7.2.3 OPERATION OF MIXED BED ........................................................................................ 200 7.2.4 OUTAGE OF MIXED BED .............................................................................................. 201 7.2.5 SYSTEM BYPASSES VALVE MOVEMENT CONDITION ............................................. 201 7.2.6 OPERATION MODE OF MIXED BED ............................................................................ 202 7.2.7 CHARACTERISTICS OF SYSTEM OPERATION.......................................................... 202 7.3 OPERATION OF MIXED BED FINE TREATMENT REGENERATION............................. 203 7.3.1 PREPARATION OF REGENERATION ........................................................................... 203 7.3.2 REGENERATION OPERATION OF FINE TREATMENT ............................................... 203 7.3.3 OPERATION STEP AND INSTRUCTION OF CONDENSATE POLISHING

REGENERATION ..................................................................................................................... 204 7.3.4 CONTROL OF ELECTRIC HEATING WATER TANK OF REGENERATION SYSTEM 221 DOCUMENT NO. : HISAR-ZT-07
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7.3.5 ACID-ALKALI METERING TANK SYSTEM................................................................... 221 7.3.6 COMMON PROBLEMS AND DISPOSAL FOR MIXED BED OPERATION.................. 222 7.3.7 PRECAUTIONS FOR ENSURING MIXED BED AMMONIA OPERATION ................... 223 7.4 TREATMENT FOR ABNORMAL CONDENSATE POLISHING ........................................ 224 7.5 CHEMICAL QUALITY REQUIREMENTS.......................................................................... 228

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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Chapter I Boiler Operation Regulations


1.1 Introduction of boiler devices Boiler model: SG2050/17.47- M918, subcritical, arrangement, pressure controlled circulation boiler, once intermediate reheat, single furnace, corner tangential firing, balanced draft, dry slag, full steel structure, full suspended structure. Positive pressure straight blow system of medium speed milling primary air fan is adopted for boiler coal pulverized sys temperature Furnace, with width 17830mm, height 17830mm, elevation of water wall lower than 9000mm, and center elevation of furnace top at 80000mm. Boiler inside diameter is 1743mm, 6ps big diameter downcomer are installed along furnace, boiler water is connected to the three LP circulating pump at boiler front side after it is collected by collecting header. There are 2nos outlet valve for each circulating pump, and connect the circulating pump with lower half circular header of water wall by the outlet valve, and install throttle at the inlet of circular header inside water wall. Water wall is composed of furnace wall, nose, bottom & both sides of flue extend side. SH is composed of top pipe, rear HRA, horizontal flue side wall, low temperature SH, division SH, rear division and final SH. Reheater is composed of wall RH, platen RH, final RH. Economizer is below rear HRA. 32ps DC burner is located at furnace four corners with 8 layers, pulverized coal and air is forced from four corner and burn at the center. Temperature of SH is adjusted by two grade ejector. Temperature of RH is adjusted by swing burning (use automatic), install emergency ejector at RH inlet. Bottom of rear HRA is furnished with two sets of primary air fan (Junkers trisection storehouse). Elevation of boiler Operation floor is 17m. Expansion center and zero position guarantee system are set on boiler, the roof is sealed by big shell, and roof pipe is protected by full-steel, furnace wall is the outer casing made of ladder type light metal structure, and water chamber is set on both sides of drum. Light metal shell is selected to make the roof. The pressure, temperature, flow and other parameters of boiler main steam and RH should match the parameters of turbine. Boiler nameplate, that is max continuous evaporation discharge (B-MCR), is equal to the steam flow when all the adjusting valves of turbine are full open (1.02 times VWO). 1.2 Boiler main technique regulations 1.2.1 Main parameters of boiler Name SH steam flow Steam pressure on SH outlet Unit t/h MPa(g) 2050 17.47 BMCR 1906 17.33 BECR

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Name Steam temperature on SH outlet RH steam flow Steam pressure on RH inlet Steam pressure on RH outlet Steam temperature on RH inlet Steam temperature on RH outlet Water temperature on economizer inlet t/h MPa(g) MPa(g) Unit 540 1761 3.94 3.73 330 540 280 BMCR

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

BECR 540 1624 3.70 3.51 323 540 276

Notice: boiler max continuous evaporation capacity BMCRis accordance with steam inlet capacity when turbine is on VWO condition. 1.2.2 Main performance index of boiler Load Name 1. turbine load 2. steam flow Economizer inlet SH outlet RH outlet SH primary water ejector SH secondary water ejector RH water ejector 3. steam pressure SH outlet drum Economizer inlet RH inlet RH outlet 4. steam temperature SH outlet RH inlet RH outlet Desuperheater water Feed water Drum 5. boiler design efficiency (calculate as per low heat productivity) t/h t/h t/h t/h t/h t/h MPa.g MPa.g MPa.g MPa.g MPa.g B-MCR Setting pressure 2068 2076 1761 8.80 0.0 0 17.47 18.84 19.24 3.938 3.733 Designed coal variety TMCR 80%ECR Setting sliding pressure pressure 1855 1906 1624 51.10 0.0 0 17.33 18.50 18.86 3.703 3.510 1336 1458 1261 122.10 0.0 0 17.14 18.02 18.35 3.817 3.618 60%ECR sliding pressure 946 1079 948 133.40 0.0 0 16.82 17.20 17.46 2.133 2.020 Checked coal BMCR Setting pressure 2058 2076 1761 18.00 0.0 0 17.47 18.84 19.24 3.938 3.733

Unit

540 330 540 179 280 361 92.77

540 323 540 179 276 360 92.86

540 299 540 169 259 356 92.50

540 281 540 158 242 354 93.23

540 330 540 179 280 361 91.64

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boiler design efficiency (calculate as per high heat productivity) 6. heat loss of mechanical un-combustion 7. actual fuel consumption rate 8. air temperature Primary air of air preheater inlet secondary air of air preheater inlet Primary air of air preheater outlet secondary air of air preheater outlet 9. flue gas temperature Flue gas temperature of furnace rear platen outlet Flue gas of platen bottom Gas exhaust (before revised) Gas exhaust (after revised) 10. air quantity Primary air of air preheater inlet Secondary air of air preheater inlet Primary air of air preheater outlet Secondary air of air preheater outlet Bypass primary air of air preheater Primary air leakage to secondary air Primary air leakage to flue gas Secondary air leakage to flue gas 11. flue gas quantity Air preheater inlet Air preheater outlet 12. excess air number Furnace outlet

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

87.11

87.22

85.61

% t/h

1.05 366.8

1.05 341.2

1.3 275.1

1.3 210.7

1.8 473.9

37 30 309 320

37 30 306 317

37 30 299 306

37 30 277 283

37 30 312 325

1028

1020

985

936

1024

1329 142.5 138.0

1341 141.0 136.5

1351 141.5 136.5

1317 120.5 115.0

1316 148.5 144.5

kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h

687074 1669169 520034 1660529 204696 32040 135000 40680 2724645.6 2900326

660424 1520028 494104 1511748 212976 32040 134280 40320 2534547.6 2709148

574661 1127434 408341 1123474 172800 33480 132840 37440 2076411.6 2246692

513407 1056542 346727 1052222 112608 33120 133560 37440 1712192.4 1883192

821761 1559102 654721 1550822 222696 32400 134640 40680 2782069.2 2957389

1.25

1.25

1.274

1.381

1.25
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Air preheater outlet 1.338 1.344 1.396 1.532 1.337 13. leakage rate furnace % 5 5 5 5 5 Air preheater % 6.45 6.89 8.20 9.99 6.30 14. steam water resistance SH steam water KPa 1373 RH steam water KPa 200 Economizer (include KPa 392 potential difference) 15. burner Single design output kg/h 15283 14217 13754 13166 16925 (coal dust) Devotion quantity PCS 24 24 20 16 28 16. ahs discharge rate Furnace cool hopper % 20 20 20 20 20 Economizer hopper % 5 5 5 5 5 ESP hopper % 85 85 85 85 85 1.2.3 Parameter of SH primary, secondary water spray desuperheater RH emergency spray N O 1 2 3 Boiler load Item Main steam flow Design pressure of Primary desuperheater Design temperature of primary desuperheater pressure of Primary desuperheater water spray point Temperature of primary desuperheatered Flow speed of primary desuperheater water Designed flow speed of primary desuperheater water SH Secondary desuperheater Design pressure of secondary desuperheater Designed temperature of secondary desuperheater water Spray point pressure of secondary desuperheater water Temperature of secondary desuperheater water Flow calculation of unit t/h Mpa
BMCR TMCR HP exclud ed 1651 80% TMCR 1458 60% TMCR 1078.5 40% TMCR 820

2050 19.79 458

1883

Mpa t/h

18.08 181 27.1

17.85 178 55.3

17.56 182 169.7

17.35 169 98.5

14.04 158 101.1

10.64 148 58.6

4 5 6

t/h

206

II 1 2

Mpa

19.79

513

Mpa t/h

17.72 181 0

17.54 178 6

17.32 182 10

17.16 169 20

13.93 158 20

10.58 148 10

4 5

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secondary desuperheater water 6 Designed flow of secondary desuperheater water t/h III Economizer inlet pressure Mpa RH flow speed t/h IV Emergency spray water 1 Design pressure of emergency spray water Mpa 2 Design temperature of emergency spray water 3 Pressure of emergency water spray point Mpa 4 Temperature of spray water 5 Calculation flow of emergency spray water t/h 6 Design flow of emergency t/h spray water 1.2.4 Coal performance analysis table Particulars Units Proximate Analysis Moisture % Ash % Fixed Carbon % Volatile matter % Ultimate Analysis Carbon % Hydrogen % Sulphur % Nitrogen % Oxygen (by difference) % Moisture % Gross calorific value Kcal/kg Grindability Index HGI t1 t2 t3 1.2.5 Set value of boiler safety valve NO 1 2 3 4 5 6 7 8 9 10 Name Drum P(fixed pressure) 19.79 19.99 20.19 20.19 20.38 20.38 18.35 18.35 18.9 18.9 No. A 1 2 3 4 B 1 2 3 4 5 6 7 C D

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

40 19.24 1740.2

18.86 1605.3

18.39 1638.1

18.05 1261.5

14.62 948.3

11.16 728.5

4.35 343 3.882 177 0 82

3.651 174 0

3.820 178 0

2.865 165 0

2.132 154 0

1.617 144 0

Performance Coal 15.0 34.0 21.0 30 41.22 2.81 0.35 0.71 5.90 15.0 4000 50 1100 1300 1400 K(return ratio) 0.04 0.05 0.06 0.06 0.07 0.07 0.03 0.03 0.03 0.03

Worst Coal for ESP & MILL 15.0 46.0 19.73 19.27 31.88 2.13 0.28 0.59 4.12 15.0 3150 50 1100 1250 1400 p(release) 0.7916 0.9995 1.2114 1.2114 1.4266 1.4266 0.5505 0.5505 0.567 0.567 p1=p-p 18.9984 18.9905 18.9786 18.9786 18.9534 18.9534 17.7995 17.7995 18.333 18.333

Drum SH outlet

SH outlet

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11 EBV 12 13 EBV 14 RH inlet 15 16 17 18 19 RH inlet 20 RH inlet 1.2.6 Limiting value of 17.99 18.17 18.17 4.35 4.35 4.41 4.41 4.48 4.48 4.06 heating surface 0.02 0.02 0.02 0.03 0.03 0.03 0.03 0.03 0.03 0.03

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

0.3598 0.3634 0.3634 0.1305 0.1305 0.1323 0.1323 0.1344 0.1344 0.1218

17.6302 17.8066 17.8066 4.2195 4.2195 4.2777 4.2777 4.3456 4.3456 3.9382

No. Name Unit Alarming temperature 1 No 1 pipe outlet of LP SH vertical part 472 2 No 1 pipe outlet of division platen 482 3 No 4 pipe outlet of rear platen SH 566 4 No 1 pipe outlet of final SH 580 5 No 5 pipe outlet of platen RH 571 6 No 5 pipe outlet of final RH 580 *Notice: pipe on vertical part is the first one counting from boiler front to rear. **Other heating surface pipes are counted from outer circle to inside. 1.2.7 Technique regulations of boiler main auxiliaries 1.2.7.1 Air preheater system Air preheater driven motor Type Main motor type Rotation speed Auxiliary motor type 2-32VI 65-82 SMRC Type MZQA225S-4B3 model Rated power 1480 r/min Rated current GM160M double out Rated power shaft 1450r/min Rated current Air preheater (Junkers trisection storehouse) 37KW 11kw

Rotation speed Rotation rate of Main motor 124.92 reducer Reheating rotation speed when main 11.93 r/min motor runs Air motor INGERSOLL-RAND 1.2.7.2 IDF, FDF, PAF No 1 2 3 4 5 6 7 Name Model Model Air flow rate Full pressure Rotation speed Efficiency Adjusting scope QTY and capacity Unit

Reheating rotation speed when main motor 92RB045/VRSM-330T 7.5 HP 103 r/min FDF FAF25-13.3-1 Axial flow type 261.70 4284 985 83.40 30-75 250 PAF PAF20.2-12.5-2 Axial flow type 172.15 15401 1490 86.35 -3025 250
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m3/S pa r/min

IDF SAF38.5-22.4-1 Axial flow type 651.2 5513 745 88.09 -3025 250

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Operation Manual for 600MW Unit


8 9 Bearing lubricate mode Manufacture Lube oil grease

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

745 991 1488 Shanghai Electric Shanghai Electric Shanghai Electric 15 Manufacture Motor Co. Motor Co. Motor Co. 1.2.7.3 Regulation of pulverized coal system devices 1.2.7.3.1 Mill No 1 Item Mill model Mill output Max. outputgrind output Guaranteed outputdry output, consider abrasion Calculated output Guaranteed output grind output, consider abrasion Min. output Mill load rate Mill air rate Max. air rate Calculated air rate Ensure air rate on output condition (dry output) Min. air rate Temperature of dry medium on mill inlet (calculated output) Outlet temperature Moisture of pulverized coal Mill rotation speed Mill ventilation resistance (include pulverized coal classifier) Max. air flow resistance Air flow resistance (guaranteed output) Calculated air flow resistance(BMCR) Mill seal air system Wind capacity of mill airproof Seal air pressure of mill (tolerance of primary air pressure) 7 Mill unit power Guaranteed unit power when output 8 9 Mill unit abrasion rate Lifespan of main components Grind role separator, KPa KPa KPa m3/ min Pa KW h/t KW h/t g/t h 4.5 4.2 3.83 70.75 2000 4.5 4.2 4.13 Unit Designed coal variety HP1103 75.3 60.2 60.76 67.8 18.8 81 130.8 120.7 125.6 91.6 244 77 4.5 30.3 Worst coal variety

10 11 12 13 14

Model Rated power Rated voltage Rated current Rotation speed

KW KV A r/min

Shanghai Fan Co. Shanghai Fan Co. Induced air fan Draft air fan motor motor YKK900-8 YKK630-6 4200 1400 11 11

Shanghai Fan Co. Primary air fan motor YKK630-4 3650 11

t/h t/h t/h t/h t/h % t/h t/h t/h t/h % r/mi n

75.3 60.2 67.34 67.8 18.8 89.4 130.8 125.3 125.6 91.6 255 77 4.5 30.3

4 5

10.3 1.8 12000


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Operation Manual for 600MW Unit


lining plate Carpolite coal quantitynormal, max. Carpolite coal granularity Carpolite coal temperature Permissible dimension & quantity of fine coal h kg/h mm mm, t/h t/h kW

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

10

12000 30.7/61.3 50 250

34/67.9

11 12

No requirement 124.1 590/557 128.7 638/606

Primary air flow rate on mill outletinclude airproof air flow rate 13 Shaft power(BMCR/TMCR 1.2.7.3.2 Mill technique datasheet No Item Model 1 2 3 4 5 6 7 8 9 Separator model Grind role loading mode Foundation model Input dimension of primary air (inner wall) Dimension/ wall thickness of center coal chute Dimension/ wall thickness pulverized coal pipe junction Volume of Carpolite discharge tank fire control steam Temperature/ pressure Weight of single mill coal of ash mmmm mm/ mm mm/ mm m3 t/h t Unit

Static separator model Spring variable load Fixed integral 1020x3068 610x10 724x16(designed powder supply pipe 710x13, weld the groove before leaving factory 0.8 3~4 180

capacity/

1.2.7.3.3 Parameter table sheet of motor mill which matched with mill No. 1 2 Parameter name Manufacture Electromotor type --kW kV A Hz rpm --Unit Value Shanghai Electric Motor Co. squirrel-cage type asynchronous motor YHP560-6 750 3.3 174 50 978 6 IP54

3 4 5 6 7 8 9 10

Electromotor model Rated power Rated voltage Rated current Rated frequency Rated rotation speed Number of pole Protection grade

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No. 11 12 13 14 Parameter name Insulation grade Cooling type Erection place Working type Efficiency Efficiency under rated load Efficiency under 3/4 rated load 15 Efficiency under 1/2 rated load Power factor Power factor under rated load Power factor under 3/4 rated load 16 17 Power factor under 1/2 rated load Max. torque/ locked-rotor torque NM 0.81 0.75 0.65 Unit ----% % % % 93 92 91 Value F IC611 Near mill

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

S1continuous

/rated torque 18 19 20 Multiple of locked-rotor current Permissible locked-rotor time Accelerate time and startup time (under rated load) 21 22 23 Moment of inertia of electromotor Noise Vibration pedestal 24 25 26 27 Shaft vibration speed Stator temperature up Phase temperature measurer element Bearing model Bearing oil trademark Bearing lubricate type 28 29 30 Bearing cooling type Electromotor weight Flow rate of bearing lube oil (m3/s amplitude of bearing

15376/21966/7322 6

s s kg.m2 dB(A) mm mm/s K

2.5 1.5 80 85(1meter) _____ 2.8 80 3 Platinum resistance rolling bearing 3# lithium-base grease Oil grease Self cooling

kg

7000 Grease lubricate


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No. 31 32 33 34 35 36 37 38 39 40 Parameter name CT model ratio/ precision grade Rotation direction Thread pipe junction tank Thread pipe inlet Equivalent heating time Outline drawing, drawing No. Startup torque Min. startup torque Recommended lube oil Model of resistance temperature NM NM 21966 15376 s Unit Value No

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Bidirection Supply afterwards Supply afterwards Supply afterwards

3# lithium-base grease PT100

detector on stator Model of resistance temperature

detector on bearing 41 Efficiency/ voltage of electric heater

PT100 kW/VAC 1(single mill)/415

1.2.7.3.4 Integrated data sheet of other devices matched with mill No. 1 Parameter name Speed reducer (model) Transmission mode Unit Value JLX-61S Second stage stand-up-drive of helical bevel gear operated gear and planetary gear 32.435 special 250 11 0.15~0.35 20 0.5~0.7 6set/p 415 1.7kW/ 1piece V kW 220AC 0.177535.5W/m ISO-VG320/1500L m3/h Pa kW kW 9-26 16D-3 58211 6659 Y355M2-6 185 153.6(BMCR)/TMCR
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1.1

Transmission ratio Lube cooling device(model) oil pump flow rate Electromotor power Normal pressure of oil Cooling water quantity Cooling water pressure Quantity of oil tank electric heater Rated voltage Rated power of oil tank heater Quantity of electric heater on oil return pipe Rated voltage Rated power Lube oil trademark/ quantity required for each mill Sealing air fan (model) Rated air flow Rated upgrade squeeze head Sealing air fan motor (model) Rated power Bearing power (BMCR/TMCR)

l/min kW MPa m3/h MPa V kW

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Parameter name Rated rotation speed Rated voltage Air strainer (model) Chamber number of each set Air quantity of each chamber Resistance Filter ratio(grain5m) 1.3 Main control system 1.3.1 Summarize No. Unit r/min V

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Value 960 3300 60M 14 4245 1370 95%

m3/h Pa

The control system of this unit is DES of CENTUM CS 3000 R3 manufactured by Henghe Electric Co.; the whole system includes 4 subsystems: data acquisition station (DAS), sequence control system (SCS), simulates control systemMCS, furnace safety supervision system FSSS. 1.3.2 Introduction of unit coordinated control system 1.3.2.1 Boiler is adjusted following turbine (BF) Control strategy is that boiler main control is automatic, adjust main steam pressure, turbine main control manually, and adjust unit power. Set value of main steam pressure accepts setting of sliding pressure curve. Boiler main control performs adjustment based on offset between actual main steam pressure and its setting value. 1. BF when meet the following requirements. a) HP bypass pressure adjusting valve is closed. b) Turbine main control is manual. c) Boiler main control is automatic. d) Generator outlet breaker is shut-up. e) There is no RB dictate of the unit. 2. Operations during BF a) On the air and gas system, make A/B static blade of IDF automatic. b) On the air and gas system, make A/B static blade of FDF automatic c) On the air and gas system, make oxygen content main control automatic. d) Make more than one coal feeder rotation speed automatic. e) Make feedwater main control automatic. f) Make fuel main control automatic. g) Make boiler main control automatic. 3. As following instance happens, unit automatically quit BF mode. aBoiler main control is switched to be manual. b) HP bypass valve is open. RB happens. 4. Any condition stated following can satisfy boiler main control switch to be manual. DOCUMENT NO. : HISAR-ZT-07
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a) Big offset is between set value and adjusted quantum. b) Signal of main steam pressure is abnormal. c) MFT action. d) Signal of unit power is abnormal. 1.3.2.2 Turbine is adjusted following boiler (TF)

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Control strategy is turbine main control is automatic; adjust main steam pressure, which accepts setting of unit sliding pressure curve. Boiler main control is manual, adjust unit power. Satisfy following conditions, unit is on TF mode. a) Turbine main control is automatic. Boiler main control, fuel main control or feedwater main control is manual. HP bypass is closed. B) Operations during TF a) On directive set of unit, check indicator light of set pressure. b) Under base modem, make turbine main control automatic on unit control graph. 1.3.2.3 Coordinated control system CCS A) Main functions of CCS a) Control boiler steam temperature, pressure and combustion rate. b) Improve control efficiency of the unit, increase adaptive capability to load variation. c) When main auxiliary machine has faults, carry out RUN BACK. d) When unit operation parameter or offset is beyond limitation, carry out load increase and decrease block, load fleet increase & decrease and track etc. e) Cooperating with BMS, ensure safety operation of burning equipments. B) CCS control mode a. CCS control strategy is the compound of BT and TF, and requires turbine and boiler main control is automatic. According to difference control mode, sort two control strategies. b. Under coordination mode of BF, boiler main control adjusts main steam pressure. Set value of main steam pressure adjusts turbine main control as per sliding pressure curve setting, but the pressure adjusting coefficient is more than pressure adjusting coefficient, that is, takes power adjustment as important and pressure adjustment as accessorial. Target load is manually set by operator. Boiler and turbine main control synchronously receive feedforward signal of target load, and can take part in grid primary FM. Our factory use this TF coordination control mode, the advantage is it can quickly meet load variation requirement, disadvantage is adjustment fluctuation is large and require high requirement of boiler dynamic performance. c. Under coordination mode of TF, boiler main control adjusts power, and target load is manually set by operator. Turbine main control adjusts main steam pressure and power, but its pressure adjusting coefficient is more than power, namely pressure adjustment is master, power adjustment is accessorial. Boiler and turbine main control synchronously receive feedforward DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

signal of target load, and can take part in grid primary FM. Its advantage is that unit operation is stable, pressure fluctuation is small, and disadvantage is that peak load regulation is a little weak. d. When unit is normally operated, try best to adopt coordinated BF coordination control mode. C) The conditions of CCS in service Furnace pressure is automatic controlled. Air pressure of secondary air is automatic controlled. Air pressure of primary air is automatic controlled. Oxygen content revising is automatic controlled. Air rate of secondary air baffle is automatic controlled. Primary air rate of mill is automatic controlled. Rotate speed of coal feeder is automatic controlled. Fuel oil flow is automatic controlled. Fuel oil pressure is automatic controlled. Feedwater main control is automatic controlled. Coal-water ratio is automatic controlled. D) When meet the following conditions, the unit works at CCS mode. Circuit breaker at outlet of generator is closed. HP bypass is closed. Turbine main control is automatic. Boiler main control is automatic. Unit has no RB dictate. E) Under CCS mode, when turbine main control or boiler main control switches to manual operation, quit CCS operation mode. F) The operation of CCS in service On unit control graph, make boiler and turbine main control automatic. On unit control graph, make adjusting mode automatic. 1.3.3 FSSS introduction (Furnace Safety Supervision System) Boiler safety and supervision for normal operation is becoming more complex when the capacity of unit is increased, which makes general operator difficult to treat the abnormal phenomenons endangered to boiler. Finance safety supervision system, short for FSSS, is composed of burner control system and fuel safety system during boiler startup, operation and shut up condition, FSSS can continuously supervise the parameter and condition of burner system, and calculate and estimate logically. It reacts sharply and makes the complex safety interlock process automatically run by the efforts of the inputted process, which can ensure the safety of boiler furnace and burner system so as to increase safety of the boiler. It also has the important role for preventing explosion caused by operation accident and equipment accident. DOCUMENT NO. : HISAR-ZT-07
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The main functions of this system include: (1) Furnace blowing (2) Main fuel trip (MFT) (3) Display trip reason and memory (to DAS) (4) Protection of furnace positive and negative pressure (5) Leakage test

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

(6) Control of burner light-up and flameout (long distance sequence light-up and site light-up) (7) Switching control of burner (8) Return of load (RB) (9) Protection of furnace flameout (10) Flame test (11) Management of cooling air system on flame checking of probe (12) Interlock control of break valve and circle valve (13) Interlock and alarm (14) Control of secondary air damper 1.3.4 Boiler MFT condition 1.3.4.1 When one of the following conditions happens, FSSS immediately shuts off main fuel of boiler, stops unit operation and displays first trip reason. (1) Manually operate MFT (2) IDF trip (3) FDF trip (4) All preheater trip (5) MCS power loss (6) Drum water over max. (7) Boiler light-up failed (8) Drum water below min. (9) Boiler pressure excess max limitation (choose two from the three) (10) Boiler pressure below min limitation (choose two from the three) (11) Whole furnace loses fuel (12) Whole furnace loses flame (13) Loss flame test cooling air (delayed) (choose two from the three) (14) Air flow below min. value (choose two from the three) 15All boiler water recycle pump trip 16Reheater loses protection. 17All water feeder pump trip 18Air flow of economizer inlet is lower than min set value (choose two from the three)

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19Loss FSSS power 20Temperature of SH outlet is too high 21Temperature of RH outlet is too high 1.3.4.2 Give dictate to the following devices when MFT trips (1) Close boiler oil main pipe trip valve. (2) Close all coal feeder (3) Close all mills

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

(4) Induced air fan and draft air fan changed from manual to automatic (5) Close automatic soot blower (6) Open all secondary air dampers (7) Close desuperheater water adjusting valve (8) Close main steam valve (9) ESP trip (10) Give signal to SCS & MCS (11) Close all fast valves (12) Cut high-energy igniter (13) Close primary air fan (14) Give signal to bypass control system 1.3.4.3 MFT condition explanation 1.3.4.3.1 When the following conditions occur, protection of RH is losing. a) A or B of LP reheater is too high b) HP bypass is closed c) Turbine is tripped 1.3.5 Control of secondary air damper For each air chamber of the burning devices, it has its own air dampers and drove by single electromotor actuator, and operates as per the dictate of TB coordination control system (CCS) and furnace supervision, and commonly the 4 group burners on the same floor will run synchronously with air damper. Control principle of burner secondary air damper is shown in following table. Control principle of burner secondary air damper Wind chamber code name CCOFA4 CCOFA3 CCOFA2 Furnace blowing Close Close Close Light-up & single oil filling Mixed burning of coal & oil Feed pulverized coal only

Backup or confirm burning adjustment Backup or confirm burning adjustment The opening increase from 60% MCR and
Page

as as

per per

gradually full open


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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

CCOFA1

HH H floor coal GH floor heavy oil

G floor coal FG floor light oil

F floor coal EF floor heavy oil

E floor coal DE D floor coal CD floor heavy oil

C floor coal BC floor light oil

B floor coal AB floor heavy oil

A floor coal AA Notice:

when it is 85% MCR. The opening increase gradually from 60% MCR and full open when it is 85% MCR. Close when H mill is shut up, otherwise post it Post into P into P control Function of mill rotation speed of the coal feeder with H floor opening Open When boiler load <30% MCR, close when boiler light-up, fix the opening after light-up succeed. When boiler load >30% MCR, post into P control during light-up; load >30% MCR and G/H floor mills are closed, otherwise post into P control Function of mill rotation speed of the coal feeder with G floor opening Open When boiler load <30% MCR, shut when boiler light-up, fix the opening after light-up succeed. When boiler load >30% MCR, post into P control during light-up; load >30% MCR and F/G floor mills are closed, otherwise post into P control Function of mill rotation speed of the coal feeder with F floor opening Open When boiler load <30% MCR, close when boiler light-up, fix the opening after light-up succeed. When boiler load >30% MCR, post into P control during light-up; load >30% MCR and E/F floor mills are closed, otherwise post into P control Function of mill rotation speed of the coal feeder with E floor opening Post into P control Function of mill rotation speed of the coal feeder with D floor opening Open When boiler load <30% MCR, close when boiler light-up, fix the opening after light-up succeed. When boiler load >30% MCR, post into P control during light-up; load >30% MCR and C/D floor mills are closed, otherwise post into P control Function of mill rotation speed of the coal feeder with C floor opening Open When boiler load <30% MCR, shut when boiler light-up, fix the opening after light-up succeed. When boiler load >30% MCR, post into P control during light-up; load >30% MCR and B/C floor mills are closed, otherwise post into P control Function of mill rotation speed of the coal feeder with B floor opening Open When boiler load <30% MCR, shut when boiler light-up, fix the opening after light-up succeed. When boiler load >30% MCR, post into P control during light-up; load >30% MCR and A/B floor mills are closed, otherwise post into P control Function of mill rotation speed of the coal feeder with A floor opening Fully open when mill A runs, otherwise post Post into P control into P control Close

(1) When it is manually operated, each floor can be controlled separately. (2) Startup boiler, when light up oil gun on the first floor, the damper shall be opened after the third corner oil gun is lighted. (3) Perimeter air can be used after 50s of powder feeding, and cut it after 0s of powder off. (4) Fully open all the dampers when it is MFT. 1.3.5.1 Control of fuel air damper 1.3.5.1.1 MFT has no action condition and coal feeder A doesnt put into operation delayed50s. 1.3.5.1.2 MFT has no action condition and coal feeder B doesnt put into operation delayed 50s. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.3.5.1.3 MFT has no action condition and coal feeder C doesnt put into operation delayed 50s. 1.3.5.1.4 MFT has no action condition and coal feeder D doesnt put into operation delayed 50s. 1.3.5.1.5 MFT has no action condition and coal feeder E doesnt put into operation delayed 50s. 1.3.5.1.6 MFT has no action condition and coal feeder F doesnt put into operation delayed 50s. 1.3.5.1.7 MFT has no action condition and coal feeder G doesnt put into operation delayed 50s. 1.3.5.1.8 MFT has no action condition and coal feeder H doesnt put into operation delayed 50s. 1.3.5.2 Control of auxiliary secondary air damp 1.3.5.2.1 When meet the following conditions, put AB secondary air baffle at flame position. a) Boiler load is more than or equal to 30%, and there is one angle oil gun in service at least at AB, moreover delays 75s. 1.3.5.2.2 When meet one of the following conditions, secondary air damper at AB layer shall automatically close. a) Boiler load is less than or equal to 30%, and there is one angle oil gun for light-up at least, moreover isnt in service. b) Boiler load is more than 30%, delaying 50s. Without MFT condition, mill A, B halt, oil guns at AB floor arent in service. 1.3.5.2.3 When meet all the following conditions, secondary air baffle at AA and auxiliary air baffle at AI shall automatically close. a) Boiler load is more than 30%. b) Mill A has been halted. c) No MFT action condition. 1.3.5.2.4 When meet all conditions as follow, auxiliary air baffle at B floor shall automatically close. a) Boiler load is more than 30%. b) Mill B has been halted. c) No MFT action condition. 1.3.5.2.5 When meet all conditions as follow, auxiliary air baffle at BC floor shall automatically close. a) Boiler load is less than or equal to 30%, and there is one angle oil gun for light-up at least, moreover isnt in service. b) Boiler load is more than 30%, delaying 50s. Without MFT condition, mill A, B halt, oil guns at AB floor arent in service. c) Delay 40s when boiler load is over 30%. d) No MFT action. 1.3.5.2.6 When meet all conditions as follow, secondary air baffle at CD floor is on light up position. a) Boiler load is lower than 30% and there is at least one angle oil gun in service for light-up, DOCUMENT NO. : HISAR-ZT-07
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moreover delayed 70s.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.3.5.2.7 When meet one of following conditions, CD secondary air baffles shall automatically close. a) Boiler load is less than 30%, and there is at least one angle oil gun for light-up at CD floor, and out of service. b) Boiler load is more than 30%, delaying 30s. Without MFT condition, mill C, D are halted, oil gun at CD are out of service. 1.3.5.2.8 When meet all conditions as follow, C floor auxiliary air baffle shall automatically close. a) Boiler load is more than 30%. b) Mill C is halted. c) No MFT action. 1.3.5.2.9 When meet all conditions as follow, D floor auxiliary air baffle shall automatically close. a) Boiler load is more than 30%. b) Mill D is halted. c) No MFT action. 1.3.5.2.10 when meet all conditions as follow, DE floor auxiliary air baffle shall automatically close. a) Mill D is halted. b) Mill E is halted. c) Boiler load is over 30% and delayed 20s. d) No MFT action. 1.3.5.2.11 when meet all conditions as follow, set EF floor secondary air baffle at light position. a) Boiler load is less than 30%, and at least there is one angle oil gun in service at EF, moreover delays 75s. 1.3.5.2.12 when meet one of following conditions, close EF secondary air baffle. a) Boiler load is less than 30%, and there is one angle oil gun for light-up at least at EF and not in service. b) Boiler load is more than 30%, delaying 30s. Without MFT condition, mills E, F are halted. Oil guns at EF are out of service. 1.3.5.2.13 when meet all conditions as follow, close EI secondary air baffle. a) Boiler burden is more than 30%. b) Mill E has been halted. c) No MFT action condition. 1.3.5.2.14 when meet all conditions as follow, close FI secondary air baffle. a) Boiler load is more than 30%. DOCUMENT NO. : HISAR-ZT-07
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b) Mill F has been halted. c) No MFT action condition.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.3.5.2.15 when meet all conditions as follow, set FG floor secondary air baffle at firing position. a) Boiler load is less than 30%, and at least there is one angle oil gun in service at EF, moreover delays 75s. 1.3.5.2.16 when meet one of the following conditions, close FG secondary air baffle. a) Boiler load is less than 30%, and there is at least one angle oil gun for light-up at EF floor, and out of service. b) Boiler load is more than 30%, delaying 30s. Without MFT condition, mill F, G are halted, oil guns at EF floor are out of service. 1.3.5.2.17 when meet all the following conditions, close GI floor secondary air baffle. a) Boiler load is more than 30%. b) Mill G has been halted. c) No MFT action condition. 1.3.5.2.18 When meet all the following conditions, set GH secondary aid damper at lighting position. a) Boiler load is less than 30%, and at least there is one angle oil gun in service at GH, moreover delays 75s 1.3.5.2.19 when meet one of the following conditions, close GH floor secondary air baffle. a) Boiler load is less than 30%, and there is at least one angle oil gun for light-up at EF floor, and out of service. b) Boiler load is more than 30%, delaying 30s. Without MFT condition, mill G, H are halted, oil guns at GH floor are out of service. 1.3.5.2.20 when meet all the following conditions, close HI floor secondary air baffle. a) Boiler load is more than 30%. b) Mill H has been halted. c) No MFT action condition. 1.3.5.2.21 when meet all the following conditions, HH floor auxiliary air damper will close automatically. a) Mill H has been halted. b) Boiler load is more than 30% and delayed 20s. c) No MFT action. 1.3.6 Fuel control of RB action When boiler main auxiliaries broken-down during operation and cant work with full load, RB logic will cut some burners immediately as per the principle of operation condition of burners and advantageous to steady of burner flame, and decrease fuel burning quantity on furnace to match the degree of main auxiliaries operation. DOCUMENT NO. : HISAR-ZT-07
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(1) There are dictates for decreasing load: (2) Two FDF are running, shut down one. (3) Two IDF are running, shut down one. (4) Two APH are running, shut down one. (5) Only one water pump is left for running. (6) Two primary air fans are running, shut down one. (7) Only one recycle water pump is left for running.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.3.6.1 Six mills put into operation, RB action program; oil guns at CD are in service, and switch off mill F delaying 2s, and switch off mill A delaying 6s, switch off mill B. 1.3.6.2 Five mills put into operation, RB action 1.3.6.2.1 Mill A, B, C, D, E are put into operation, RB action program; oil guns at CD are in service, switch off mill E, delaying 2s, switch off mill A. 1.3.6.2.2 Mill A, B, C, D, F are put into operation, RB action program; oil guns at CD are in service, switch off mill F, delaying 2s, switch off mill A. 1.3.6.2.3 Mill A, B, D, E, F are put into operation, RB action program; oil guns at EF are in service, switch off mill A, delaying 2s, switch off mill B. 1.3.6.2.4 Mill A, C, D, E, F are put into operation, RB action program; oil guns at EF are in service, switch off mill A, delaying 2s, switch off mill F. 1.3.6.2.5 Mill B, C, D, E, F are put into operation, RB action program; oil guns at CD are in service, switch off mill B, delaying 2s, switch off mill F. 1.3.6.2.6 Mill A, B, C, E, F are put into operation, RB action program; oil guns at EF are in service, switch off mill A, delaying 2s, switch off mill B. 1.3.6.3 Four mills put into operation, RB action. 1.3.6.3.1 Mill A, B, C, D is put into operation, RB action program; oil guns at CD are in service, switching off mill A. 1.3.6.3.2 Mill A, B, C, E is put into operation, RB action program; oil guns at AB are in service, switching off mill E. 1.3.6.3.3 Mill A, B, C, F is put into operation, RB action program; oil guns at AB are in service, switching off mill F. 1.3.6.3.4 Mill A, B, D, E is put into operation, RB action program; oil guns at AB are in service, switching off mill E. 1.3.6.3.5 Mill A, B, D, F is put into operation, RB action program; oil guns at AB are in service, switching off mill F. 1.3.6.3.6 Mill A, B, E, F is put into operation, RB action program; oil guns at EF are in service, switching off mill A. 1.3.6.3.7 Mill A, C, D, E is put into operation, RB action program; oil guns at CD are in service, switching off mill A. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.3.6.3.8 Mill A, C, D, F is put into operation, RB action program; oil guns at CD are in service, switching off mill A. 1.3.6.3.9 Mill A, D, E, F is put into operation, RB action program; oil guns at EF are in service, switching off mill A. 1.3.6.3.10 Mill B, C, D and E are put into operation, RB action program; oil guns at CD are in service, switching off mill B. 1.3.6.3.11 Mill B, C, D and F are put into operation, RB action program; oil guns at CD are in service, switching off mill B. 1.3.6.3.12 Mill B, C, E and F are put into operation, RB action program; oil guns at EF are in service, switching off mill B. 1.3.6.3.13 Mill C, D, E and F are put into operation, RB action program; oil guns at CD are in service, switching off mill F. 1.3.6.3.14 Mill A, C, E, F are put into operation, RB action program; oil guns at EF are in service, switching off mill A. 1.4 Test before boiler start-up 1.4.1 Tests before boiler start-up 1.4.1.1 Test for remote control valve, air and flue baffle. 1.4.1.2 Single logic protection test and emergency push button test for auxiliary. 1.4.1.3 Actuation test of MFT. 1.4.1.4 Fuel oil leakage test. 1.4.1.5 Test for ignition devices. 1.4.1.6 Boiler overall interlocking test. 1.4.1.7 Bypass valve turning on test and interlock closure test. 1.4.2 Boiler overall interlock test 1.4.2.1 Usually after boiler other tests are finished, start up two IDF, two FDF, two primary air fans, any flame checking cooling air fan. 1.4.2.2 Artificially satisfy furnace blowing condition, after 5 minutes blowing, recover MFT. 1.4.2.3 Open oil trip valve and primary air baffle of mill outlet. 1.4.2.4 In simulation potion, program-control starts up 16 heavy oil guns. 1.4.2.5 Start up 8 mills and 8 coal feeders. 1.4.2.6 Artificially satisfy the condition of load 60%, switch off one IDF, shunt trip relevant FDF and PAF, switch off relevant mills, emergency loudspeaker sounds, turn into RB state. 1.4.2.7 Switch off another IDF, shunt trip relevant FDF and PAF, and send MFT. All mills and coal feeder trip, automatically close primary air damper at outlet of mill, close all oil angle quick action valves and oil tripping valve. 1.4.2.8 Eliminate the single of Permission of oil start-up and permission of mill ignition. 1.4.2.9 After tests, resume the equipments. DOCUMENT NO. : HISAR-ZT-07
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1.4.3 Furnace pressure protection

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.4.3.1 keep on adjusting IDF baffle to make furnace pressure reached 996Pa, and give high pressure alarm to make furnace pressure reached 13240Pa and keep for 5s. Give high-high alarm and MFT action. 1.4.3.2 Keep on adjusting fan baffle to make furnace pressure reached -996Pa, and give low pressure alarm. 1.4.3.3 Adjust air fan baffle to make furnace pressure reached -2490Pa, and give low pressure Alarm, after 5s MFT acts. 1.4.4 Other protection test 1.4.4.1 Alarm when pressure difference of mills bowl is over 3.25Kpa and set coal feeder at minimum speed. Mill will trip when pressure difference of sealing air and primary air is less than 1.0Kpa. 1.4.4.2 Alarm when outlet temperature of mill is over 93 and it will trip when it is over 100. 1.4.4.3 When lube oil quantity of mill is less than 121 L/min, give an alarm after 2s. 1.4.4.4 Alarm when pressure difference of mills lubricating strainer is more than 0.2 Mpa. 1.4.4.5 When lube oil pressure of mills gear box is less than 0.09 Mpa, give an alarm, and trip after 2s when it is less than 0.07MPa. 1.4.4.6 Alarm when lubricating oil level in tank is lower than 200mm. 1.4.4.7 When oil temperature at outlet of mill lubricating pump is 60 higher, give an alarm, and trip when it is 65 higher. 1.4.4.8 When temperature of thrusting pad of mill gear box is 75 higher, give an alarm, and trip when it is 80 higher. 1.4.4.9 When bearing temperature of mill motor is 85 higher, give an alarm, and trip when it is 95 higher. 1.4.4.10 When thrusting bearing temperature of IDF is higher than 85 , give an alarm and shunt start spare cooling air fan; when it is more than 100 , shunt trip IDF. 1.4.4.11 When radial bearing temperature of IDF is more 85, give an alarm and shunt start spare cooling air fan; when it is more than 100 , shunt trip IDF. 1.4.4.12 when horizontal and vertical vibration of bearing of IDF is 0.192 mm, give an alarm. 1.4.12.13 when bearing temperature of motor of IDF is 90, give an alarm. 1.4.4.14 when winding temperature of motor of IDF is more than 125, give an alarm, and when it is more than 145 , IDF trips. 1.4.4.15 When surge of IDF is high (inlet pressure is +2000 Pa when damper is fully closed), delaying 15s, fan trips. 1.4.4.16 When librations of IDF at any side reaches 8mm/s give an alarm, and when it reaches11mm/s, IDF trips. 1.4.4.17 when bearing temperature of IDF is more than 90, give an alarm, and when it is DOCUMENT NO. : HISAR-ZT-07
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more than 100, IDF trips.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.4.4.18 when hydraulic oil pressure of IDF is lower than 2.5Mpa, block IDF. 1.4.4.19 when surge of IDF comes to +2000 Pa, IDF trips after 15s delay. 1.4.4.20 When support bearing temperature of PAF is more than or equal to 85 , give an alarm, and trips when it is more than or equal to 100 . 1.4.4.21 When thrust bearing temperature of PAF is more than or equal to 85 , give an alarm, and when it is more than or equal to 100, PAF trips. 1.4.4.22 When bearing temperature of motor of PAF is more than or equal to 85, give an alarm, and when it is more than or equal to 95, PAF trips. 1.4.4.23When bearing vibration of PAF is more than 8mm/s(X/Y coordinates), give an alarm, and when it comes to 11mm/s, PAF trips. 1.4.4.24 when surge of PAF comes to +2000 Pa (inlet pressure when damper is fully closed), delay15s, fan trips. 1.4.4.25 When motor winding temperature of PAF is more than or equal to 110, give an alarm, and when it is more than or equal to 120, PAF trips. 1.5 Start up of boiler 1.5.1 Initial state before start-up (entire cold working condition) 1.5.1.1 When all maintenance work of the unit is finished and working notice is over, it is ready for start-up. 1.5.1.2 Power isnt supplied yet and all equipments are out of service. 1.5.1.3 All pneumatic valves are out of gas, and other gates are closed. 1.5.1.4 No water is injected into boiler. 1.5.2 Preparation before start-up 1.5.2.1 Supply power to electric devices. 1.5.2.2 Inspect DCS operating station and filed operating station and confirm that all valves are in correct position. Inspect air vent valve of SH and RH, drain valve of SH and RH, and confirm drain valve of main steam pipe to turbine is open. Economizer, drain valve of water wall, SH, spray adjusting valve of reheater and electric stop valve are closed. 1.5.2.3 Boiler start-up system backup includes atmospheric flash vessel, header tank, drain return pump etc. Motor isolator valve of boiler start-up system is open. Start pipe warming valve of boiler start-up system for standby. Adjusting valve of boiler start-up system is automatically put into operation. 1.5.2.4 Smoke temperature probe is in service. 1.5.2.5 Feed water into boiler 1.5.2.5.1 Before boiler filled with water, fill water into motors of boiler water pump one by one as per the Operation Regulation of Boiler Water Pump, and make sure the pipe is clean enough for filling. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.5.2.5.2 After water filled into water pump, fill water into drum by condenser pump through boiler upper valve, the water is chemically desalted and used when drum wall temperature is low; also can fill water by electromotor feedwater pump or steam booster pump through bypass control valve, the water is deoxidized and used when temperature of drum wall is high, and guarantee water quality during filling course. Stop filling when water level in drum is over 200mm. Fill water slowly and feedwater valve shall be opened and closed lightly. Water filling speed: winter 50t/h, filling time 4h, other season 100t/h, filling time 2h. Filling water temperature is 21 & 104 and max 50 higher than boiler wall temperature. When temperature tolerance of water and water wall is more 50, filling time shall be prolonged properly. At initial stage of water filling, fill water through boiler shutdown water filling valve and close it after 15min. 1.5.2.5.3 Check if the expansion indicator is on good condition before filling water to boiler. 1.5.2.5.4 First start A or C boiler water circulating pump, fill water to reach normal elevation (if water elevation on drum decreased to -300mm, shut down boiler water circulating pump and check it) when water elevation on drum is drawdown; then start C or A boiler water circulating pump, stop filling water into boiler when water level is -100mm and keep lighting at low water elevation (as so to avoid pressure increasing and water level expansion), and later open economizer recycle valve. When boiler started, again start B boiler water circulating pump. Every boiler water circulating pump should rotate for 5s, then stop for 15s, and later rotate for another 5s, perform this 3 times so as to thoroughly discharge the air in the motor cavity. 1.5.3 Boiler blowing conditions 1.5.3.1 Start up two APH. 1.5.3.2 Start up IDF, FDF. 1.5.3.3 Adjust output of IDF, FDF, keep furnace pressure at about -100Pa, and control air rate between 30%-40% of total air rate. 1.5.3.4 Start up one flame check probe cooling air fan. 1IDF is in service. 2FDF is in service. 3Close all oil angle quick action valves. 4Close fuel trip valve. 5No MFT dictate. 6All coal feeders are out of service. 7All mills are out of service. 8Water elevation on drum is normal. 9No fire is dictated by any flame checking.

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10Air rate is proper. 11Cooling air for flame checking is normal. 12Preheater is in service. 13ESP is out of service. 14Secondary air damper is on adjusting position. 15Oil leakage test is finished. 16Power of FSSS system is normal. 17Power of FMCS system is normal. 18Close SOFA damper. 19Shut down primary air fan. Furnace blowing steps

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

a) Carry out blowing when the conditions are ready. Blowing time is 5 minutes. b) On operating station, set relevant indicator light to indicate above conditions, and according to working condition, respectively show blowing allowance , blowing process , blowing halt and blowing completion c) Blowing for 5 minutes, air rate is between 30%-40%. d) After finishing blowing, confirm MFT relay is reset. e) Check air damper to flame position, keep air flow at 30% of total. 1.5.3.6 Fuel oil leakage test 1.5.3.6.1 Conditions for oil leakage test. a) Blowing is finished b) Fuel angle valves are closed. c) 1.5MPa Oil inlet pressure of fuel header is allowed to be above 1.5Mpa. Procedure of leakage test of boiler front fuel oil system a) Open inlet quick action valve and return valve to perform oil circulation normally. b) Adjust oil pressure of main pipe to be over set value of 1.5Mpa for leakage test. Close return valve, after charging pressure to inlet quick action valve, leakage testing pressure is more than or equal to 1.5Mpa, close oil inlet quick action valve. c) During stated 3 minutes, ensure pressure of inlet quick action valve is higher than 1.45Mpa. d) After opening return valve to relieve pressure to inlet quick action valve, pressure is less than 0.23Mpa pressure switch action, close return valve. e) Check pressure variation inlet quick action valve. During specified 3 minutes, if inlet quick action valve pressure is less than 0.23 Mpa, it means leakage test for tripping valve is accepted. f) If leakage test is aborted, furnace blowing is unsuccessful, and system gives a failure signal. After treatment, restart leakage test.

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1.5.4 Inspection of control system before start-up 1.5.4.1 Furnace pressure is automatically controlled.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.5.4.2 Air flow is automatically controlled and keeps air rate at about 30% of total. 1.5.4.3 Set up HP/LP bypass automatic control for condenser vacuum and make sure HP/LP bypass desuperheated water is normal. 1.5.4.4 Fuel adjusting valve is automatically controlled. 1.5.4.5 Temperature of SH and RH is automatically controlled and set value of superheat temperature is 50 at least. 1.5.5 Boiler ignition, temperature increase, pressure raise 1.5.1.1 After blowing, entirely inspect light-up conditions. Open fuel inlet and oil return quick action valves. Ensure fuel pressure, atomizing steam pressure and temperature is normal. 1.5.5.2 Put boiler front oil system into operation. In order to ensure successfully light-up and combustion, it is required that viscosity of fuel oil is below 3E and temperature is below 8 which are affected by pressure and temperature of control fuel oil. 1.5.5.3Put soot blowing system of air preheater into operation. Start up oil gun at AB layer, check every angle oil gun are orderly put into operation, generally as per order 1, 3, 2, 4 . Conform light-up is normal. After the third oil gun is put into operation, adjust fuel oil recycle valve as per specific condition. Fuel pressure control can switch to flow control, and oil flow is set to 5% of BMCR 1.5.5.5After oil gun at AB layer is working normally, start up PAF by sequence, and check operation of PAF is normal. Primary air/furnace pressure difference is more than 6.0Kpa. Automatically open damper at inlet of primary air of air preheater, interlock of sealing air fan A is normal, sealing air fan B is in service of interlock standby. 1.5.5.6 Inlet steam air preheater of mill A is put into operation (open isolation damper of hot primary air at inlet of mill B, open adjustable damper of hot primary air of mill B, close secondary isolation damper of hot primary air of mill B, open electric damper at inlet of steam air preheater, open electric damper at outlet of steam air preheater, close isolation damper of hot primary air at inlet of mill A, close adjustable damper of hot primary air of mill A). 1.5.5.7 Make sure ion ignition equipment is conform to start up condition. 1.5.5.8 Start condition of mill A is satisfied, and air temperature at inlet of mill A comes to 180. Make start mode of mill A be plasma mode to start mill A. After outlet temperature of mill reaches 70, turn on every angle ion ignition device after 15minutes, and confirm every angle. 1.5.5.9 Shut down oil gun at AB as per combustion condition, smoke temperature probe indicates temperature is less than 538. 1.5.5.10 According to combustion condition, carry out adjustment of fuel oil quantity and oil secondary air rate. 1.5.9.11 Confirm metal wall temperature of water wall, SH and RH is in specified scope. DOCUMENT NO. : HISAR-ZT-07
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1.5.6 Increase combustion rate

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.5.6.1 When superheat temperature of main steam is over 50 , burning ratio will increase. However, before turbine is synchronous or steam flow reaches 10%, temperature of furnace smoke temperature probe shall be controlled below 538 by burning ratio. 1.5.6.2 Slowly increase burning ratio (make sure temperature of the smoke on furnace outlet is below 538) as per start-up curve after mill A has been put into operation for 25minutes, and notice increasing speed of pressure and temperature. 1.5.6.3 Pressure of main steam reaches 8.6MPa and RH reaches 0.8MPa, check pressure control mode of HP/LP bypass. 1.5.6.4 When temperature of air preheater outlet reaches 200, mill A inlet steam air preheater can be out of service, and make sure that the temperature on mill A outlet is normal. 1.5.6.5 When the temperature of main steam is 380 , open secondary chief valve of desuperheated water and fill up secondary desuperheated water, and ensures water supply speed and temperature is set on 360. When RH steam temperature is 340, operate RH temperature automatically with fixed value at 320. When SH outer pressure reaches 8.4 8.9MPa, HP bypass control mode, adjust burning ratio to make steam temperature match with turbines. 1.5.7 Precautions during the course of boiler temperature increasing 1.5.7.1 Make sure desuperheated water of condenser HP/LP drain flash tank put into operation normally, and the pressure and temperature is within limitation. 1.5.7.2 Supervise the wall temperature of drum, water wall, SH, RH and control temperature increasing speed. 1.5.7.3 Control fuel feeding speed, emphasize supervision of separator water level, and make sure the drum will not full of water. 1.5.7.4 Confirm HP/LP bypass system operate properly. 1.5.7.5 Make sure feed water is adjusted properly, and keep water level of condenser, deaerator in normal level. 1.5.7.6 Check if ion ignition devices operate properly or not. 1.5.7.7 Keep blowing for air preheater during boiler start-up, and strengthen supervision of hotspot of air preheater. Go to site immediately once there is an alarm and so as to avoid burning of air preheater. 1.5.7.8 When the temperature of smoke on furnace is over 538, furnace smoke probe will drop out automatically. 1.5.7.9 Temperature and pressure increasing will carried out as per temperature and pressure increasing curve under cold-start, conform to turbine turning requirement, and keep it. 1.5.7.10 Temperature increasing speed of main and reheat steam cant exceed 110/h.

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1.5.8 Turbine turning and synchronization

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.5.8.1 Make sure quality of steam pressure & temperature satisfy the requirement of speed up and warming of turbine during turbine turning. 1.5.8.2 After turbine is synchronized, close all drain, vent valves of SH & RH. 1.5.8.3 Switchover bypass control of main steam pressure to turbine control. Boiler, turbine control mode is BF mode. 1.5.8.4 By adjusting combustion rate and air rate, control temperature of superheated steam and reheat steam to be stable. 1.5.9 Turbine synchronization with minimum load to 35% of BMCR (100MW) 1.5.9.1 In initial period of load warming, increase speed of main steam is controlled within 1.5 2.5 /min, and reheat steams is controlled between 2.53.5 /min. Load is increased as per 3MW/ min. 1.5.9.2 Adjust hot air duct pressure of PAF, set pressure difference control between hot air duct and furnace to be automatic state. 1.5.9.3 As unit load increases, add fuel on time. After coal quantity of mill A comes to 35t/h, put coal feeder into automatic operation. After mill is warmed on time, put the second and third mill into operation. Pay attention that overall fuel quantity shall be reposefully increased after its in service. 1.5.9.4 According to combustion condition, halt oil gun. Check every angle oil gun quit normally. Smoke temperature probe indicates temperature must be less than 538. 1.5.9.5 Adjust speed of all coal feeders which are in service. Load increases to 17% of BMCR. Two turbine driven feedwater pumps are ready for operation. 1.5.9.7 Confirm boiler feedwater, fuel, FDF system are normally automatic operated. Adjusting valves of proportion of fuel and water, primary desuperheated water, secondary desuperheated water, desuperheated water of RH are in automatic standby state. 1.5.9.9 When the load is about 30%, switch motor driven feedwater pump to steam driven pump, and avoid large range fluctuation of flow water and ensure the self-regulation is in good condition. 1.5.9.10 hen boiler load comes to 28% of BMCR and be stable, unit adopts CCS mode. 1.5.9.11 Increase fuel quantity, when output of working mill is more than 60 of coal flow, add mill for service. 1.5.9.12 Under DEH control mode, as load increases, opening of HP valve is bigger than 90 ,change to sliding pressure control mode, slowly increase fuel quantity and load. 1.5.9.13 after coal is fully combusted; electrical precipitator is put into operation. 1.5.9.14 as per the combustion condition, relevant oil gun can be halted (or plasma device). As per mill operating condition, choose oil gun emergency feeding mode

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1.5.9.15 after load reaches 210MW and is stable; power for factory is changed from standby power into working power. Pay attention that every electric current of auxiliary equipment is normal. 1.5.10 Load from 35% of BMCR to 100% 1.5.10.1 et target load 100% of BMCR on DEH graph600MW, lift load as 6MW/ min for unit. 1.5.10.2 After load reaches 300MW and is kept stable, finish warming the second feedwater pump turbine with low speed, then speed rises to 2500rpm. 1.5.10.3 Slowly adjust rotation speed of the second driven turbine pump, pay attention to variation of water flow. When speed of two driven turbine pumps is similar, put rotate speed of the second driven turbine pump into automatic operation. Make sure feedwater automatic adjustment is normal. 1.5.10.4 Start up the fourth, fifth mill. Gradually raise load to 540MW, and check unit change into constant pressure operation mode. 1.5.10.5 Load comes to 600MW; entirely check whether every parameter of unit is normal. 1.5.11 Precaution for cold start 1.5.11.1 In whole start process, intensify supervision for metal temperature of every heating surface (especially water wall), to avoid exceed temperature. 1.5.11.2 In whole cold start process, ignition, pressure raise, flushing, synchronization and operation with load at each stage of unit, should be carried out and controlled as per unit cold start curve. 1.5.11.3 Put oil gun into operation properly and use big diagonal. 1.5.11.4 Mill is reasonably put into operation. 1.5.11.5 When electric feedwater pump is working, pay attention to adjust its rotation speed during lifting pressure, to ensure feedwater flow is normal. 1.5.11.6 Use desuperheated water on time as per steam temperature of superheat and reheat water. 1.5.11.7 When load is low, discreetly use desuperheated water. If its required, warm its drain pipe to prevent steam temperature from falling down. 1.5.11.8 During start process, open all relative drain of SH, RH system, and make steam temperature increased equally to avoid too hot of some parts. 1.5.11.9 After all oil guns are out of service, continuous blowing of air preheater can be stopped. 1.5.11.10 when load is above 300MW, carry out entire blowing for boiler, put gap control system of air preheater into operation. 1.5.11.11 after normal operation of unit, close relevant drain. 1.5.11.12 during load increase process, decide load increasing rate as per turbine expansion. When abnormal status such as vibration etc happens, stabilize load and extend warm time in DOCUMENT NO. : HISAR-ZT-07
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time as per turbine requirement. 1.5.11.13 Check whether action of HP, LP bypass system is normal. 1.5.12 hot start

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.5.12.1 The process of hot start is basically the same as cold start-up. Boiler temperature and pressure increasing process takes boiler minimum pressure as initial point after light-up. 1.5.12.2 According to units state, arrange work at every stage properly and reasonably. 1.5.12.3 In entire hot start process, according to different state of the unit, strictly control temperature, pressure and load increase speed as per unit warm start curve, unit hot start curve. 1.5.12.4 When temperature of main steam is 30 higher than adjusting metals, open the main valve of secondary desuperheated water, and put secondary desuperheated water into operation. When reheat steam is 20 higher than metal temperature at inlet area, put reheat steam temperature into automatic. HP bypass is pressure controlled, adjust burning ratio to make steam temperature match with turbine. 1.5.12.5 Set turbine parameter as per cylinder temperature and start curve supplied by manufacture. Ensure the temperature of main & reheat steam is 50100 higher than that of adjusting grade and carrier metal of IP cylinder, and 56 of superheat temperature is required at least, but it can not be higher than rated temperature. Dismatch between steam and metal temperature cant exceed the range of 56110. 1.5.12.6 Since load increasing rate is very fast during hot start, it is required to warm mill in advance meet load increasing requirement. 1.5.12.7 Check whether HP, LP bypass actions are normal during temperature increasing and pressure raise. 1.5.12.8 Since temperature of turning main steam is high during hot start, during temperature and pressure increasing course, especially pay attention that the wall temperature of water wall, superheater and reheater cant exceed the limitation. Steam temperature of RH inlet is controlled 400, inlet smoke temperature of HP superheater 538 . 1.5.12.9 Sequence of filling warm fuel: AB oil layerplasma ignitorA coal layerB coal layer C coal layerD coal layerE coal layerF coal layerG coal layerH coal layer. 1.6 Boiler operation control and adjustment 1.6.1 Adjusting work of boiler operation 1.6.1.1 Make sure boiler evaporation capacity meet requirement of unit load. 1.6.1.2 Adjust every parameter fluctuating within in allowable scope. 1.6.1.3 Keep working condition of combustion in furnace well, keep optimal air rate to ensure boiler at optimal combustion rate. 1.6.1.4 Adjust boiler working condition on time, improve boiler efficiency. Try best to make sure

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the unit is operated on the condition that every parameter is under the best working condition. 1.6.2 Feedwater adjustment 1.6.2.1 When feedwater flow is low, feedwater adjusting valve is made to adjust feedwater flow, and feedwater pump is made to maintain pressure difference of adjusting valve. When feedwater adjusting valve is opened to be 80, feedwater pump starts to control feedwater flow, and feedwater adjusting valve is fully opened. 1.6.2.2 When speed of turbine driven feedwater pump is above 3000r/min, two steam driven feed water pumps can be put into operation parallelly with flow deviation less than 100t/h.. When one motor driven water pump and steam driven water pump operate parallelly, steam driven feedwater pump is automatically controlled and motor driven feedwater pump is economical output. 1.6.2.3 During the course of adjusting feedwater, keep water flow rate be stable so as to keep balance of boiler negative load and coal-water ratio and avoid large fluctuation of parameter caused by maladjustment of coal-water ratio. 1.6.3 Boiler combustion adjustment 1.6.3.1 Boiler combustion adjustment purpose: ensure combustion stable, improve combustion economy, make heating load in combustion chamber uniformly distributed, reduce heating deviation, prevent boiler from clinkering, clogging etc, and ensure each parameter is normal during boiler operation. 1.6.3.2 When boiler is in service, variety and chemistry analysis of coal, fuel should be known so as to adjust working condition of operation according to fuel property. During normal operation, operating staff should frequently comprehensively inspect combustion system, if any bad combustion is found, adjust it on time. 1.6.3.3 During boiler combustion, color of flame is golden. When fuel oil is burning, flame is white and bright, flame should be equally filled in furnace and doesnt scourer water wall and platen SH. Flame center at the same elevation should be at the same height. Firing point of fuel should be well situated. Short distance will be easy to cause coke around nozzle. Far distance will make flame center moved up and cause coke around the top of furnace, even it will result in unstable combustion. 1.6.3.4 During normal operation, negative pressure of furnace should be kept between -50 -100Pa. No smoke goes out from boiler upside. 1.6.3.5 During boiler normal operation, air leakage should be furthest reduced. Every access door and manhole should be closed. Plug on time wherever there is air leakage. 1.6.3.6 Oxygen content at furnace outlet should be decided by the character of coal variety and load, if oxygen content is manually controlled, adjust it according to the set value, if oxygen is automatically controlled, it is automatically adjusted by changing oxygen set value. When the melting point of fired coal and fuel is low, in order to avoid coking on furnce, the fuel is fired by DOCUMENT NO. : HISAR-ZT-07
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regular triangle and air is filled by inverted triangular.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.6.3.7 In order to ensure boiler economy operation, coal fineness should be maintained reasonable. Regularly sample ash and slag to analyse and compare, and adjust combustion in time. 1.6.3.8 When adjust combustion or increase negative pressure of boiler, ensure the steam temperature and pressure is normal, outlet temperature of water wall also should be in normal range. After burner is put into operation, check whether firing condition is good or not, and adjust air rate on time to avoid black smoke emitting from chimney. 1.6.3.9 When improper combustion of boiler is cause by variety of reasons, oil gun should be put into operation on time to stabilize combustion, and find out reasons to eliminate unstable factors of combustion. If burnout happens, fuel supply should be stopped at once to avoid boiler deflagration. 1.6.3.10 when furnace blowing is carried under less than 60% load, supervise working condition of combustion in furnace. If combustion is stable, stop blowing at once. 1.6.3.11 As carrying out normal supervision and adjustment, simultaneously intensify analysis of operation parameter and metal temperature at heating surface, such as when there is big temperature difference of steam temperature, or beterrn both sides of primary and secondary desuperheated water, or large temperature deviation of each heating surface, analyse and find out reasons on time to solve problems. Check whether operating mode of pulverized coal system is reasonable. Output for operating pulverized coal system should be furthest kept the same, so as to avoid continuously stopping the two intermediate pulverized coal systems. Check whether there is any damage to adjustable damper of burner secondary air and auxiliary air, whether the position of adjustable damper is correct. Check whether the coal for every working mill is consistent with the mill and whether actual coal feeding quantity for mills is equal. Check and analyse whether coking and damage exist on the burner. Check whether oxygen content measurement point is correct, whether oxygen value is adapts to relevant load. Regularly check working condition of the burner, if any coking is found, clean it out on time. Carry out blowing as per the coking stage in boiler. When coking is serious, take measures to clean. 1.6.4 Adjustment of boiler steam temperature 1.6.4.1 When boiler runs normally, the temperature of main steam should be controlled within 5715, temperature of reheat steam should be controlled within 5695, and temperature difference at both sides is less than 10. At the same time medium temperature at each part and wall temperature should be within set value. 1.6.4.2 Temperature adjusting of main steam is based on adjusting burning, and assisting of desuperheated water and normal temperature of main steam. 1.6.4.3 Reheat steam temperature is mainly adjusted by swing angle of burner. If swing angle of DOCUMENT NO. : HISAR-ZT-07
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burner cant adjust temperature very well, reheat desuperheated water can be used for accessorial adjustment. 1.6.4.4 During the operation of boiler, carry out combustion adjustment, load increase and decrease, start-up and close of burner, feedwater, fan, soot blowing, and lancing etc, which all make the temperature of main steam and reheat steam change. At this time, especially intensify supervision and adjustment of steam temperature on time. 1.6.4.5 When HP heater is going to be in service and out of service, feedwater temperature is going to change greatly, and the working temperature also changes correspondingly at every course. Sickly supervise feedwater and economizer outlet temperature. 1.6.5 Limitation value of boiler operating parameter Adjust and monitor boiler operation to ensure each parameter within scope, also to use program control and auto-adjust to maintain operation situation and quality. Main parameter value: Normal value Item Steam pressure on SH outlet Steam temperature on SH outlet Steam pressure on RH outlet Steam temperature on RH outlet Wall temperature of LPSH vertical outlet Wall temperature on division platen outlet Wall temperature on rear platen SH outlet Wall temperature on final SH outlet Wall temperature on platen RH outlet Wall temperature on final RH outlet Furnace negative pressure Pressure of fuel header Temperature on mill outlet Feedwater temperature Exhaust smoke temperature Main pipe pressure of primary air Pa MPa KPa 580 570 580 -50-100 11.8 77 280 134 810 160 6 560 480 Unit MPa MPa range 17.47 540 3.73 540 470 545 472 530 565 Max. value 17.99 545 530 565 Min. value Trip value

482

566 580 571 580 +996 1.8 93 -996 0.3 65 +13240-2490 0.23 100

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1.7 Stop boiler to operation 1.7.1 Stop operation by smooth parameter changing 1.7.1.1 Use this method in follow situation: 1.7.1.1.1 The unit need to repair and short start time;

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.7.1.1.2 Deal with the defects in pipe of boiler proper and turbine proper; 1.7.1.2.1 Prepare to stop boiler 1.7.1.2.1 General regulation a) Chief supervisor should make order and tell aims and mode of boiler halt; b) The special stop should be put forward by operation dept., approved by deputy manager. The chief supervisor should be noticed by paper or oral and the special engineer should come to site to instruct. c) Chief supervisor should give order in advance and contact with chemical, fuel, ash and desulphurization staff to prepare to stop. d) When command is given to every stall, check the whole system, and record every equipment defect. Prepare to remove defects after stopping. e) If stop boiler before maintenance, the fuel in coal feeder and bunker should be exhausted. To maintain flame in stable situation, reduce coal level smoothly; pay more attention to flame when the bunker will be empty. Special engineer should arrange in site to empty the bunker. 1.7.1.3 Prepare to reduce load 1.7.1.3.1 Check plant steam system; 1.7.1.3.2 Soot blow totally when load is more than 300MW; 1.7.1.3.3 Check if there is enough oil in thin oil house, oil circling system is normal, and oil gun can be put into operation normally. 1.7.1.3.4 Check if plasma ignition apparatus is in spare condition. 1.7.1.3.5 HP and LP by-pass warming pipe is in spare condition. 1.7.1.3.6 Ensure all auto adjusting equipments are in good condition. 1.7.1.3.7 Prepare operation notice for unit shut up. 1.7.1.4 Operation 1.7.1.4.1 Reduce load Reduce load according to chief supervisor order and operate unit by coordinate-control before lower load. The speed of load reducing should be within 5MW/min. Reduce negative load from 100% to 80% a) Operation staff reduces load set value from 600MW to 540MW by coordinate-control mode. And the decreasing ratio is 5MW/min, in this condition, dont reduce mill quantity. b) Reduce coal of every mill gradually, in this condition, the load decreasing ratio can be quicker but not excess 10MW/min. From load the decreased to 90%, the unit goes into smooth pressure mode. Ensure opening of adjusting valve is between 88%~90%, and reduce pressure DOCUMENT NO. : HISAR-ZT-07
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of main steam.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

c) When the load is decreased to 500MW, shut down the first mill according to the order. (Generally shut down G or H first in order to keep stable combustion on furnace.) Decrease negative load from 80% to 50% a) Pay attention to the stability of temperature of main steam & reheat steam and water level of HP heater & LP heater in the course of load decreasing. b) Shut down second and third mill during the course of load decreasing. c) Shift the water load to another steam pump and keep the other pump in recycle operation when the load is decreased to 50%. d) Switch water handling to AVT style. (3) Load from 50% to 35% b) While reducing load, assure the condition of ignition energy. Put into plasma ignition when load to 210MW and stop third mill. The coal level should be not lower than 60T/H. c) Pay attention to air control to prevent air flow lower than 25% and MFT because of stopping mill, the manual control is needed. d) Steam resource of feed water pump will switch to cool section of reheat steam automatically during load reducing period. Before switching, switch the first steam-pump after motor pump be checked operated normally. e) Pay more attention to supervision of air flow rate, temperature of intermediate point & main steam. If the automatism is failure, adjust air flow rate and temperature of desuperheated water manually. (3) Load from 35%to 0 a) Put motor driven water pump into operation when load is 180MW, stop second turbine driven feedwater pump, and monitor water flow and water level in drum. b) Check high-pressure by-pass system when steam pressure near to 8.6MPa, switch DEH to power mode, and reduce load by reducing power value of turbine. c) Stop the sixth mill in the right time. Reduce boiler fuel to 15% or a little smaller if opening of HP by-pass valve is too large, and ignite oil gun if needed. d) Check steam resource of deaerator to see if it can switch normally, and deaerator can operate correctly. e) Report chief supervisor when 0 load, now generator-transformer can trip. 1.7.1.5 Operation of boiler after oilier trip 1.7.1.5.1 After trip turbine, stop the final mill, control steam temperature in 5/min, stop primary fans and tight fans. 1.7.1.5.2 After shut down mill, shut off all oil gun and plasma and boiler flame out. 1.7.1.5.3 Maintain IDF and FDF in operation after boiler flame out, adjust air flow to 30%BMCR, maintain negative pressure of boiler in scope of -50Pa~-100Pa, and sootblower boiler for 5 min. DOCUMENT NO. : HISAR-ZT-07
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After sootblowing, shut down FDF and IDF as per requirement, unlock related interlocks and shut off related dampers. 1.7.1.5.4 Shut down all isolating valves after flame out. 1.7.1.5.5 Shut down motor driven feedwater pump. 1.7.1.5.6 After 6h, open all dampers of flue air system to ensure ventilation of boiler. 1.7.1.5.7 Shut down flame checking air cooling fan when boiler temperature is lower than 150. 1.7.1.5.8 Stop air preheated A/B when its inlet temperature is lower than 120 . 1.7.1.5.9 When boiler is required to cool rapidly, start IDF and FDF to maintain air flow in 30%MCR after boiler is shut-off for 18h. 1.7.2 Emergence stop 1.7.2.1 Shut down boiler rapidly in following situations. 1.7.2.1.1 In operation condition, MFT refuse to work in emergence condition. 1.7.2.1.1 There is serious blasting on boiler heating surface, steam pipe and etc. and cant maintain normal operation. 1.7.2.1.2 Boiler rear flue duct is returned and exhaust smoke abnormally and cant maintain normal operation. 1.7.2.1.3 Steam pressure surpasses limited actuation value and all safety valves are refused to work. 1.7.2.1.4 Safety valve could not resume after actuated, steam pressure is decreased and temperature reached to the condition cant operate continuously. 1.7.2.1.5 There is blasting abruptly happened in furnace or flue duct, and destroy the equipment seriously. 1.7.2.1.6 Feed water pipe break or leak heavily and have risk to operation and human safety. 1.7.2.1.7 There is leakage in SH, RH, economizer, and water wall, and make water flow lower heavily. 1.7.2.1.8There is fire in boiler scope and affects operation of boiler directly. 1.7.2.1.9 There are defects in DAS system or power of thermal control gauge is off and could not monitor or regulate operation parameter. 1.7.2.1.10 Plant power is totally or partly cut off and cant maintain normal operation of unit. 1.7.2.2 Ask for shut-off of the boiler from the chief supervisor in following conditions. 1.7.2.2.1 Water quality and steam quality is becoming worse and could not resume. 1.7.2.2.2 There is leakage in pressure part of boiler which will destroy other heating surface or have damage to human safety. 1.7.2.2.3 Cinder and ash is heavily collected in boiler and cant maintain normal operation after process. 1.7.2.2.4 Shortage in PCV valve and safety valve. DOCUMENT NO. : HISAR-ZT-07
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1.7.2.2.5 Temperature of steam and furnace wall surpass largely. 1.7.2.3 Emergency shut off of boiler

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.7.2.3.1 MFT trip, stop boiler by lock function, otherwise, stops locked equipment manually. 1.7.2.3.2 Equipment should be tripped after MFT: 1) All mills, coal feeder trip. 2) Two primary air fans trip. 3) All outlet dampers of mill are closed. 4) Close fuel trip-valve, oil angle quick valve and blowing oil gun. 5) Stop all high energy igniter. 6) Switch secondary air damper to blowing position. 7) For FD and IDF, switch their auto-control mode to MFT. 8) Closedown stop valve of primary, secondary desuperheated water and RH emergency desuperheated water. 9) When boiler is blowing during MFT, close steam blowing and soot blower will exit automatically. 10) Turbine trips. Tow steam driven pumps trip and motor driven pumps interlock. k) ESP trips. 1.7.2.3.3 If FD and IDF not trip after MFT, blow furnace automatically. Air flow should be larger than 30%BMCR on furnace, make all secondary air dampers open. While air flow is smaller than 30%BMCR during MFT, 5min later, all secondary air dampers will on blowing position, and air flow would be adjusted to 30-40%BMCR automatically, and blowing for 5minutes. 1.7.2.3.4 Due to MFT cause by FDF and IDF, or FDF and IDF trip after MFT, open secondary air damper after 1minute, 15m later, check and ensure all mill outlet dampers, fuel closing valves and fuel quick action valves are closed correctly. Ensure there is no flame in furnace by watching TV and checking by fire inspecting probe, open damper of FD and IDF slowly after all interlocked equipment tripped for 5 min at least. Sootblowing as per normal procedure after FDF and IDF resume. 1.7.2.3.5 When SH pressure is reached to 26.7MPa, pressure of PVC valve should be reduced. 1.7.2.3.6 Other operations should be carried according to the normal regulation. 1.7.3 Precautions during boiler shut off 1.7.3.1 Pay more attention to temperature difference of outer and inner wall of outlet header of separator and SH, decrease cooling speed if temperature difference is larger than normal scope. 1.7.3.3 Decrease opening of main feedwater adjusting valve properly if there is not enough desuperheated water supplied for main steam. 1.7.3.4 To prevent steam temperature changing too much, desuperheating water cant be increased or decreased rapidly in low load condition. DOCUMENT NO. : HISAR-ZT-07
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1.7.3.5 Sootblowing preheater continuously blow during all stopping time. 1.7.3.6 Monitor fumes temperature of air preheater after stopping boiler; check overall if there is any troublesome. Ensure there is no flame in furnace. 1.8 Typical accidents disposal in boiler 1.8.1 Full water of boiler 1.8.1.1 Phenomenon 1.8.1.1.1 All water level indicators exceed regular indicated value, gives an alarm when water level in steam drum is high; 1.8.1.1.2 Flow rate of supplied water is larger than that of steam 1.8.1.1.3 When water level height is IIIdelay 2s and MFT 1.8.1.1.4 When the water is too full main steam temperature suddenly drop water hammer may happen in the main steam pipeline and the pipeline vibrates acutely 1.8.1.2 Reasons: 1.8.1.2.1 The feed water automation device is out of order, and pump rises abnormally 1.8.1.2.2 It is manually operated improperly, or misjudged by operator because of incorrect indication of water level & water steam flow rate; 1.8.1.2.3 Water level is not adjusted timely when load and the steam pressure change a lot; 1.8.1.3 Handle: 1.8.1.3.1 When water level height is I: If the automation of feed water is out of order, transfer automation to manually control immediately, and reduce rotation speed of motor driven feedwater pump at the same timeIf the speed adjustor of motor driven feedwater pump is out of orderstop turbine driven feedwater pump immediately and adjust water supply quantity by turning on motor driven pump 1.8.1.3.2 When water level height is IIIdelay 2 seconds and MFTand handle as per related rules after MFT 1.8.1.3.3 During handling processpay attention to the change of steam temperature 1.8.1.3.4 reasons 1.8.1.3.5 It is forbidden to filling water by offset valve. 1.8.2 The boiler is short of water 1.8.2.1 Phenomenon 1.8.2.1.1 All water level indicators exceed regular indicated value, gives an alarm when steam drum water level is low; 1.8.2.1.2 Flow rate of water supply is much smaller than that of steamexclusive of blowup of Fill water to normal level after boiler shut-up, and light again after eliminate the rotation speed of feedwater

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boiler pipeline;

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.8.2.1.3 When it is acute shortage of water, the main steam temperature rises 1.8.2.1.4 Water level is lower than IIIMFT happened and delay 2 seconds 1.8.2.2 Reasons: 1.8.2.2.1 The feed water automation device is out of orderfeedwater pump speed reduces abnormally or feedwater pump break down; 1.8.2.2.2 The operator misjudge due to improper manual operation, incorrect indication of water level & water steam flow rate; 1.8.2.2.3 Water level is not adjusted timely when load and the steam pressure changed a lot; 1.8.2.2.4 Low pressure of feed water, or serious leakage of lower water drum, water wall, economizer; 1.8.2.3 Handle: 1.8.2.3.1 When water level is lower than I: If the feed water automation is out of order, immediately shift atomization into manual mode and at the same time increase rotation speed of feed water pumpIf speed adjustor of motor driven feedwater pump is out of order, turn on motor driven feedwater pump and adjust water level 1.8.2.3.2 Stop periodic blow down flash tank and continuous blow down flash tank; 1.8.2.3.3 When water level height is lower than III, delay 2 seconds and MFT handle as per and related rules after MFT 1.8.2.3.4 When boiler water level does not show in any water gauges more than 10 minutes strictly prohibit to fill water into boiler. If fill water into boilerit should be approved by chief engineer. 1.8.3 Priming of steam & water 1.8.3.1 Phenomenon 1.8.3.1.1 Steam drum water level undulates rapidlywater level indicator inside water level is vague 1.8.3.1.2 The main steam temperature decreasessteam conductivity increaseswater strike in the main steam inside of pipeline. 1.8.3.1.3 Reasons 1.8.3.1.4 Quality of feed water or the boiler water is unqualified 1.8.3.1.5 Boiler load decreases rapidly or steam pressure comes down rapidly 1.8.3.1.6 Oil enters into the steam and water system 1.8.3.2 Handle 1.8.3.2.1 Report to chief supervisor, decrease and steady boiler load; 1.8.3.2.2 Open big continuous blow down flash tankstrengthen periodic blow down flash tank DOCUMENT NO. : HISAR-ZT-07
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and lower steam drum water level to- 50mm

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.8.3.2.3 Close desuperheated wateropen superheater drainage when it is necessaryand keep close watch to the variation of steam temperature 1.8.3.2.4 Notice the chemistry special fieldstop adding medicineand reinforce boiler water chemical examination. 1.8.4 MFT 1.8.4.1 Phenomenon 1) Alarm accident by voice and light, FSSS will display reason. 2) Related equipment and valves trip. 3) Unit load get to 0 4) Flame is extinguished in boiler, no flame on flame monitor. 1.8.4.2 Reason 1) MFT by hand. 2) Main protection equipment trip because of unit or equipment breakdown. 3) Protection equipment trip incorrectly or thermal element failure. 1.8.4.3 Handle 1) Check if all mill and coal feeder, primary air fan and seal fan tripped, fuel closing valve and oil valve shut off, the first and second stage desuperheating water valve shut off, accident desuperheating water valve for reheater shut off, steam sootblow closedown. Sootblower should be exit automatically if sootblowing when MFT, ensure operation by auto or manually. 2) Check auto tracing for furnace negative pressure is normal, unchain auto if the tracing is abnormal. Regulate it manually to avoid trip of ID, FDF caused by excessive negative pressure. 3) When PCV valve is not open and pressure of SH gets to 17.99MPa, PVC relief valve should be opened manually. 4) After sootblowing is finished, resume all tripped equipments. 5) Monitor fumes temperature and hot air temperature; prevent rear heating surface of boiler re-flame. 6) Find out reasons of MFT, and remove shortage, and then prepare to start again. 1.8.5 RB a) Appearance 1) Alarm accidents by voice and light, CRT will display reason. 2) For equipment tripped, monitors flash. 3) Coal powder system trip partly. 4) Load decreases to 300MW rapidly. B Reasons 1) Trip one steam pump, dont put motor pump into operation.

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2) Trip one of the two FDF. 3) Trip one of the two IDF. 4) Trip one of the two PAF. 5) Trip one of the two APH C Handle

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1) Check if auto tracing equipment works normally, dont remove it. On condition that if it works incorrectly, switch it to manual mode and stop some mills, but remain 4 mills operating at least. Adjust coal feeder output to match with 300MW, and regulate water flow to ensure normal temperature of main steam and reheating steam. 2) Increase the operating steam pump output to max if the other one trips. Switch to assistance steam if pressure on the fourth exhaust is not enough. 3) One FDF output will increase to max if the other one trips. Check the tightness of its outlet damper of the tripped FDF. 4) One FDF output will increase to max. if the other one trips. Check the tightness of its inlet and outlet damper of the tripped FDF. 5) Increase the operation primary fan output to max if the other one trips. Check the tightness of the tripped primary air outlet damper and cool air damper. 6) Adjust coal powder, water flow and air flow to ensure the unit operates stable under max output. Find out reasons of RB and resume to normal operation after eliminating the defects. 1.8.6 Pressure of main steam and reheating steam in incorrect scope 1.8.6.1 Appearance 1) Pressure of main steam and reheating steam offset with normal value. 2) Temperature along main steam pipe and reheating steam pipe may be abnormal. 3) Load may be decreased. 4) Some leakage in main steam safety valve, reheating steam safety valve, HP by-pass, LP by-pass, or high temperature of desuperheater and its valve is open. 5) Some leakage is in main steam and reheating steam pipe, and alarm when the four pipes leak. 6) It is abnormal that water supply rate is even larger than main steam flow rate. 1.8.6.2 Reasons 1) Safety valve or PCV valve trip by accident, or leak heavily and cause pressure of main steam and reheating steam lower. 2) Open by-pass valve by accident, or serious leakage which cause pressure of main steam and reheating steam being abnormal. 3) Auto-valve of main steam or regulating valve is opened up or turned down abnormally. 4) Main and reheat steam system leak heavily. 5) Exhaust system is abnormal. DOCUMENT NO. : HISAR-ZT-07
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1.8.6.3 Handle

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1) In case of PCV valve tripped by accident, force it return to position by hand, if failed, ask to stop boiler. 2) In case of safety valve is opened by accident, find out reason. Ask to shut down boiler if it cant close or leak heavily. 3) In case of by-pass valve is opened by accident, close it by hand. Ask to shut down boiler if it cant close or leak heavily. 4) When main steam valve or regulating valve open up or shut down abnormally, contact respective staff to repair. If the steam pressure is still too high to cause safety valve trip under normal load or rated load, ask to shut down boiler. 5) Dispose main steam system refers to SH destroyed when it leaks heavily. 6) Dispose main steam system refers to RH destroyed when it leaks heavily. 7) Dispose steam exhaust system refers to heating failure when it is abnormal. 1.8.7 Abnormal of main steam temperature 1.8.7.1 Appearance 1) Temperature of main steam is higher than 576 or lowers than 566, temperature of reheating steam higher than 574 or lower than 564, the parameter on control panel will turn to red color. 2) It will alarm when main steam & RH steam temperature is too high or too low. 3) Adjusting valve of first and second stage desuperheating water of main steam, or emergence desuperheating water of reheating steam is open or close thoroughly. 1.8.7.2 Reasons 1) There are coordinate defects in system or manual adjusting is not timely, then cause proportion of coal and water is imbalanced. 2) Boiler working condition fluctuates too much, but the tracing quality is not qualified and manual adjusting is not on time. 3) Feedwater system breaks down, and the tracing quality is not qualified and manual adjusting is not on time. 4) Cinder and ash is heavily assembled on furnace. 5) Sootblowing boiler whenever there is hunk cinder and ash in furnace. 6) Coal quality is much worse than designed value. 7) Break down of desuperheating water valve, or desuperheating water could not be adjusted well. 8) There is serious leakage on heating surface and pipe of steam system. 9) Blast nozzle, air throttle destroyed or air proportion in boiler is unreasonable. 1.8.7.3 Handle 1) Remove coordination control if there is troublesome in coordinate system, adjust fuel and DOCUMENT NO. : HISAR-ZT-07
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water quantity according to current load. In order to prevent system fluctuating too much, try not to adjusting coal and water at same time when proportion of coal and water is incorrect. Adjust load after their proportion is comparatively stable. 2) If boiler condition fluctuate largely (like RB or more than one mill system trip), control system under coordination status and main steam in auto-control status, shift staff should pay more attention to coordination and auto control condition. Dont operate manually as much as possible. If they work incorrectly, shift staff should switch them to manual mode immediately. 3) If there is defect in water system (such as one water pump trip, high-pressure heater trip), control system under coordination status and main steam temperature in auto control status, shift staff should pay more attention to coordination and auto control condition, and dont operate them manually. If they work incorrectly, shift staff should switch them to manual immediately. 4) If cinder or ash is heavily assembled in boiler, which cause temperature of main steam abnormal. When sootblower could not put into operation rightly or cinder and ash are still heavily assembled after sootblowing, repair middle point temperature of water system or adjust it manually, ask to shut down boiler in case steam temperature is still high. 5) When sootblowing boiler when there is heavy cinder and ash on furnace, pay more attention to change of water wall temperature and auto tracing system Decrease set value of steam temperature a little if it is required. Switch auto tracing system to manual mode if it works abnormally. 6) Notice shift staff in advance if coal quality changes. Take some measures to make different kinds of coal mixed together to flame and adjust it. 7) If there is defect in desuperheating water valve, switch it to manual mode and decrease main steam temperature properly. Repair middle point temperature of water system or switch it to manual mode. Decrease load changing ratio properly to prevent too high temperature of main steam. Repair desuperheating water valve immediately. 8) Shut down boiler immediately if main steam system heating surface or tube leak heavily. On operation period, if coordination control or auto control for main steam could not work correctly, switch them to manual mode, and decrease temperature of main steam properly. Shut down boiler after adjustment but have no effect when over temperature of main steam and metal heating surface caused by serious leakage of heating surface and pipe. 9) If there is defect on burner swing equipment or emergence desuperheating water valve, switch reheating steam temperature to manual mode and decrease reheating steam temperature properly, decrease load changing ratio to prevent too high temperature of reheating steam, repair the swing equipment and valve on time. 10) If blast nozzle or throttle destroyed, or air proportion is unreasonable, properly decrease RH steam temperature before the defect is removed. Decrease temperature of reheating steam, DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

load change ratio and avoid too high temperature of RH steam temperature. 11) Adjust air proportion if it is unreasonable. 12) Ask to shut down turbine if parameter could not be controlled. 1.8.8 Water flow for boiler is low A phenomenon 1) Water flow decreases in control panel, and water pressure decreases. 2) Unit load decreases or main steam flow decreases. 3) Media temperature of boiler heating surface increases. 4) Alarm when feedwater flow and main steam temperature are beyond limitation, water feed pump trip or failure of adjusting system B Reasons 1) Steam pump trip, tracing system doesnt work properly, or output of operating steam pump cannot satisfy water flow requirement. 2) Feedwater pipe or HP heater leak. 3) There is defect on HP heater, feedwater valve. 4) Auto control for water supply system is out of control. 5) Unit load decrease abruptly, or steam source of steam driven feedwater pump decrease or intermit. . C Handle 1) Feedwater pump trip when load is higher than 60%, pay more attention to auto control system Try the best to not interfere manually, but if the control system works abnormally, switch it to manual mode immediately. Increase output of operating feedwater pump to max., and decrease output of coal system or stop some mills. Start motor driven feedwater pump. Try best to meet requirement of load for grid. When feedwater pump trip under the condition load is lower than 50%, and auto control system work incorrectly, cut off it immediately, increase water supply rate of feed water the same before tripped. 2) If water pipe leak but can still maintain normal operation, decrease load properly, and adjust proportion of water and coal to its normal value, then ask to shut down boiler. For leakage in HP heater, shut it down immediately, decrease water flow according to water temperature. If leakage of feedwater pipe and HP heater may lead to equipment destroy or human safety. Shut down boiler immediately. 3) If there is defect on HP heater or feedwater valve and water flow is larger than tripped value, decrease load matched to water flow, repair them when unit operate stably. If valve could not be repaired in operation condition, ask to shut down boiler. 4) If auto control system of feedwater devices work abnormally, switch it to manual. Adjust rotation speed of feedwater pump and contact thermal control engineer to deal with auto control system after water flow is controlled stable. DOCUMENT NO. : HISAR-ZT-07
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5) If load decrease abruptly, or steam pressure of steam driven feedwater pump is decreased or intermitted, start motor driven feedwater pump to resume steam pressure when water supply rate is lower than protection value, adjust water flow or decrease fuel rapidly to ensure boiler temperature stable. When water flow is lower than protection value or middle point temperature reach to trip value, but protection equipment refuse to trip, or temperature of water wall surpass heavily, MFT by hand. 1.8.9 ECO Destroyed A Phenomenon 1) Four pipes leak, test equipment alarm. 2) Leakage can be heard if inspected on site. Steam and water would emit in heavily. 3) There will be some ash in economizer, air preheater, ESP hoper, bunker pump or ash handling pipe, air preheater and abnormal operation of ESP. 4) Water flow is abnormally larger than steam flow, and unit load decrease. 5) Temperature increase after leak point, and regulating valve of desuperheating water open wider abnormally. B Reasons 1) There is defect on material of economizer pipe, or some damage exists. 2) Friction bar of Eco. is installed incorrectly, or drop off then tube wall thickness decrease, so blow up. 3) Water quality is worse for a long period, material corrosion, so blow up. 4) Re-flame in eco and make tube temperature higher enough to destroy. 5) Sootblower of eco installed incorrectly, there is water in it then destroy tube. C) Handle 1) If leakage of economizer is not so much heavy, and water flow can maintain operation, as well as temperature of water wall material is normal, pay more attention to wall temperature, report and close watch to leakage. 2) Install enclosure around manhole, ash hoper and hang mark plate. 3) If leakage heavy, and media temperature increases abruptly, MFT by hand. 4) Take close watch to work condition of ash system and economizer, inspect and patrol. If there is heavy ash in ash system or preheater, or ESP work incorrectly, ask to shut down boiler. 5) maintain forced and IDF running after boiler shut down, stop them when no steam or water emit out. 1.8.10 Destroy of SH A Phenomenon 1) Leakage inspection equipment alarm. 2) Leakage can be found if inspect on site 3) ESP may work incorrectly; heavily ash is in ash handling system or preheater. DOCUMENT NO. : HISAR-ZT-07
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4Water flow is abnormally larger than steam flow, and unit load decrease. 5) Temperature behind leakage increase and regulating valve for desuperheating water open incorrectly. B reason 1) There is defect remaining in material or damage during manufacture and installation. 2) Friction bar is installed incorrectly, or drop down too many, or no repairing in a long time then tube wore, wall thickness thinner and lead to blow. 3) Steam quality doesnt conform to request, salt accumulated heavily make tube temperature surpass. 4) Mode of coal system is incorrect, so heat load unevenly, mistaken design, or sootblower destroy, ash accumulate heavily on tube, or support to panel or clamp destroy, and superheater partly in excess temperature condition, lead to blow up. 5) Some sundries remain in tube or stagger welding makes flow in tube decreasing, 6) Coordination system or auto tracing system of SH could not trace regularly, or it operates in excess temperature for long time which leads to blow up. 7) Operation incorrectly leads to water entering into SH lead to excess temperature and blow up of pipe. 8) Position of sootblower is incorrect, water remaining in it and blowing tube to destroy. C handle 1) Leakage is not so heavy that normal running can maintain, now pay more attention to leakage and report it on time. Decrease load if needed. In order to prevent leakage destroy other tube or near tube in low flow or excess temperature, stop boiler as early as possible. 2) If SH heater blows up, temperature behind leakage increase abruptly, normal operation could not remain, or near tube in excess temperature, stop boiler. 3) For operation in light leakage, install enclose around manhole, inspection hole and hang mark plate. 4) Pay more attention to ash system and preheater, inspect and patrol. In case of heavy ash in ash system or preheater, or ESP work incorrectly, ask to stop boiler. 5) After stop boiler, remain FDF and IDF running stop them after no steam or water emit out. 1.8.11 Leakage of reheater A Phenomenon 1) Leakage inspection equipment alarm 2) Leakage can be found if inspect in site 3) ESP may work incorrectly, and heavily ash is in ash system or preheater. 4Water flow larger than steam flow, and load decrease. 5) Temperature behind leakage increase. B Reasons DOCUMENT NO. : HISAR-ZT-07
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1) There is defect remaining in material or destroy during manufacture and installation. 2) Friction bar installed incorrectly, or drop down too many, or no repairing in a long time then tube wore, wall thickness thinner and lead to blow. 3) Steam quality doesnt conform to request, salt accumulated heavily make tube temperature surpass. 4) Mode of coal system is incorrect, so heat load unevenly, mistaken design, or sootblower destroy, ash accumulate heavily on tube, or support to panel or clamp destroy, and superheater partly in excess temperature condition, lead to blow up.

5) Some sundries remain in tube or non-conformity welding makes flow in tube decreasing, 6) Coordination system or auto tracing system of superheater could not trace in time, or it operates in excess temperature situation long time, lead to blow up. 7) Water entering into reheater because of false operates emergence desuperheating water or reheater operates in excess temperature condition lead to tube temperature excess and blow up. 8) No water in tube during start boiler, fume temperature surpass designed value to destroy. 9) Sootblower is incorrect position and water remaining in it to destroy tube. C Handle 1) Leakage is not so heavy that normal running can maintain, now pay more attention to leakage and report in time. Decrease load if needed. To prevent leakage destroy other tube or near tube in low flow or excess temperature, stop boiler as early as possible. 2) For tube blow up, temperature behind leakage increase abruptly, normal operation could not remain, or near tube in excess temperature, stop boiler. 3) For operation in light leakage, install enclose around manhole, inspection hole and hang mark plate. 4) Pay more attention to ash system and preheater, inspect and patrol. In case of heavy ash in ash system or preheater, or ESP work incorrectly, ask to stop boiler. 5) After stop boiler, remain FDF and IDF running stop them after no steam or water emit out. 1.8.12 Reframe in rear fume duct A Phenomenon 1) Inlet fumes temperature or outlet temperature of preheater increase abruptly and surpass normal value. 2) Temperature of hot air increases abruptly and surpasses normal value. 3) Heat inspection for preheater alarm and its temperature difference of inlet fume and outlet hot air is lower, even minus. 4) Suction pressure of furnace fluctuates abruptly. 5) Re-flame around eco, outlet water temperature on eco increases abnormally, rear fume temperature increases abnormally. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

6) Hole around re-flame like manhole, inspection hole and sootblow hole are not seal, and gas or fire emit out from them. Fume duct, eco, preheater hoper, preheater outcaste may be burned red, heat radiation heavy around re-flame. B reason 1) Coal powder is too coarse, coal powder is not even, air proportion is not correct, blast nozzle is destroyed, oxygen in boiler is low, block in eco and preheater could not be found in time, take no sootblowing measure for accumulates in rear fume duct. 2)Fuel ignite for too long and pulverization is not so good, air proportion of oil gun is unreasonable, take no sootblowing measure for eco and air preheater for a long time and lead to rear furnace oil waste accumulated heavily. 3) Boiler flame in mixture of oil and coal, gun control valve leaks. 4) Not so seal around manhole, inspection hole of rear fume duct. 5) Take no sootblowing measure before stop boiler. 7) There is air flowing in fume duct because of air door or damper unseal. C Handle 1) Shut down boiler when find flame in rear fume duct, and stop forced and IDF, close all fume dampers. 2) Put sootblower around re-flame into operation to put out fire. 3) If re-flame around eco, start MBFP and make water flow in speed of 150t/h to cool. 4) If re-flame around preheater, but preheater can work normally, lift sector panel by hand and maintain it running. If preheater blocked, and main driven motor or assist-driven motor trip, lift sector plane by hand and start pneumatic motor, if pneumatic motor trip again, driving rotor of preheater by hand, and repair motor immediately. Put sootblower into operation to put out fire, use hydrant if needed. 5) If outlet water temperature of eco is near to inlet water temperature, there is re-flame around eco, and inlet fume temperature, outlet fume temperature, hot air temperature decreases to lower than 80, no fume or fire star emitted out from manhole or inspection hole, stop sootblowing or hydrant. Open manhole and inspection hole to inspect fire put out. Open drainage door to drain water in fume duct and dry it by opening damper. 6) Cool furnace thoroughly, make sure no equipment is destroyed, clear waste on furnace tube and start boiler again. 1.8.13 Coking boiler A Phenomenon 1) There is cinder around water wall, blast nozzle and cooler hoper. 2) Temperature of middle point, superheater outlet or all, reheater outlet or all is incorrect, regulating valve of desuperheater for superheater or reheater open incorrectly. DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

3) Flame would be not stable if block of cinder exist around blast nozzle, heat load distribute unevenly, or metal temperature. Offset designed value a lot. 4) Slag from slag collector increases and its current surpass normal value. 5) Cool hopper may be blocked. B Reason 1) Coal quality change. 2) Boiler runs on ex-output status. 3) Air proportion in boiler is unreasonable or blast nozzle destroyed, so fire comes nearly to wall. 4) Outlet temperature of mill is higher than normal value, primary air flow is too lower, coal power is tiny than ignite early. 5) Coal system run in irrational mode and heat load is excessive. 6) Oxygen in boiler during operation is thin. 7) Sootblower for water wall could not put into use in a long time or its parameter set incorrectly. C Handle 1) Notice shift staff in advance to take some measures before coal quality change. 2) Boiler should be run in rated output. If boiler coking heavily, decrease boiler output when it cant be improved after sootblowing and burning adjusting. 3) Adjust and maintain rational proportion of primary and secondary air to maintain air rigidity. Repair destroyed blast nozzle and coking to prevent fire from going near to wall. 4) Maintain normal outlet temperature of mill, proper coal powder fineness, and primary air quantity. If coding around blast nozzle is heavy, decrease outlet temperature of mill, increase primary air or decrease coal powder fineness properly to delay ignition. 5) Maintain coal system running normally, if it needs to run in abnormal mode, like some mills need to repair and stop, adjust proportion of air and load of each mill. Decrease output of boiler if sootblowing and adjusting could not solve problem. 6) Increase air proportion of blast nozzle if coking heavily in boiler, decrease air-flamed quantity and increase ex-air factor of furnace. 7) Put sootblower for furnace into running correctly, increase sootblowing times if needed. 1.8.14 Temperature of superheater tube and reheater tube surpass A Phenomenon 1) Temperature of tube is higher than normal value. 2) Temperature of tube is different. B reason 1) Coal system run in irrational mode, heat load distribute unevenly, design incorrectly, sootblower destroyed partly, coking in tube unevenly, panel support or clamp destroyed, or coking heavily in furnace, so heat offset of superheater and reheater exist. DOCUMENT NO. : HISAR-ZT-07
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2) Tube temperature is higher than designed value because of deposit heavily. . 3) Blocked by sundries or mistaken welding, so water flow decreased. 4) Auto control or auto tracing system could not trace very well, so temperature of tube wall surpass. C handles 1) Maintain coal system running normally, if it needs to run in abnormal mode, like some mills need to repair and stop, adjust proportion of air and load of each mill to make heat load going to even. By adjusting, metal temperature is still high, decrease steam temperature of main steam and reheating steam. 2) Sootblowing water wall and superheater more times. Repair destroyed sootblower. 3) Monitor chemical dosing more and if boiler maintain running for a long time, so salt accumulate in superheater and reheater, their steam temperature should be decreased. The boiler needs acid cleansing soon. 4) Decrease steam temperature of superheater and reheater to run if their tube temperature surpass. And cut tube to inspect in repairing time. 5) Adjust and set parameter if tracing system work incorrectly, lower load changing speed or switch auto mode too manually before it repaired.

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Chapter II Operation Manual for Boiler Accessory


2.1 Air preheater 2.1.1 Interlock protection for preheater 2.1.1.1 Signal of direct bearing temperature high occurs if bearing temperature higher than 70, and preheater trip when temperature is higher than 85. 2.1.1.2 Signal of pressure difference of filter high occurs if its guide and supporting bearing pressure difference higher than 0.35Mpa. 2.1.1.3 Put preheater interlock switch into use, if main driven motor of preheater trip when start, then interlock starts assist-driven motor, and vice verse. 2.1.1.4 When main motor and assist motor of preheater running, open primary air and secondary air damper respectively. 2.1.1.5 When both main motor and assist motor trip, close primary air and secondary air damper respectively. 2.1.2 Trip conditions for preheater 2.1.2.1 Preheater stall. 2.1.2.2 Main motor trip, but assist motor doesnt start jointly. 2.1.2.3 Temperature of supporting and guide bearing of air preheater is higher than 85. 2.1.3 Start preheater Air preheater may be auto-controlled or manually starts. Steps as follow: 2.1.3.1 Start oil pump of guide and support bearing. 2.1.3.2 Start main motor. 2.1.3.3 Open outlet dampers of secondary air, primary air and fume inlet damper. 2.1.3.4 Put sealing adjusting device automatically when boiler load is larger than 50MCR and running continuously for more than 4 hours. 2.1.4 Stop preheater Preheater can be stopped by auto-control or manually. Steps as follow: 2.1.4.1 Switch sealing adjusting equipment to manual when boiler load decrease to 300MW, and lift section plate to upper-limited position by hand. 2.1.1.2 Close fume inlet damper, primary air and secondary air outlet damper after boiler is flameout and fume inlet temperature of preheater lower than 120. 2.1.4.3 Stop main motor running. 2.1.5 Handling preheater troublesome 2.1.5.1 Failure of running main motor or AC power off A Treatment a) Monitor suction pressure of furnace, temperature change of primary air and secondary air, and flame combustion in boiler. b) Decrease boiler load if needed, and put oil gun into use, increase sootblowing frequency. DOCUMENT NO. : HISAR-ZT-07
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c) Monitor temperature of primary air, secondary air, and fume.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

d) Maintain normal load if assist-motor starts automatically and air leakage system has normal power. When main motor repaired, return to normal running gradually. e) If rotor of preheater stops, assist-motor auto-start fails, or all AC power is off, preheater stops, take measures as follow: 1) Stop respective forced and induced air fan, and boiler runs in half side. And close all dampers of other side. 2) Monitor alarm of fire monitoring system 3) Lift sector plate of air leakage system 4) Jigger when needed. 5) Put preheater into running after power resume and running condition reached, and sootblowing continuously. 2.1.5.2 Preheater trip A Appearance 1) Current of preheater weaken to 0, assist-motor auto start and voice and light signal alarm. 2) When assist-motor could not auto start, stop signal alarm, fume temperature of respective side will increase. B reason 1) Current of preheater weakens to 0, assist-motor automatically start, voice and light signal alarm. 2) Electric protection trip. 3) Assist-motor auto start fails. C Handle 1) If no ex-current appearance exists before trip, connect it once by force. Continue to run if success. 2) If fail to connecting by force, or ex-current exists when start, stop it immediately, and check if assist-motor run normally. 3) If assist-motor running incorrectly, stop preheater, then close outlet and inlet damper respectively, isolate primary and secondary air, decrease load. If trouble could not be solved shortly, boiler would be stopped. When temperature increase to 250, MFT should be by hand. 2.2 IDF 2.2.1 Admitted starting conditions 2.2.1.1 Bearing temperature of fan 85 2.2.1.2 Bearing temperature of motor 75 2.2.1.3 Any bearing cooling fan running. 2.2.1.4 Inlet rotary blade closed. 2.2.1.5 Inlet motor-damper closed. DOCUMENT NO. : HISAR-ZT-07
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2.2.1.6 Outlet motor-damper opening. 2.2.1.7 The other preheater running. 2.2.2 Trip conditions 2.2.2.1 opposite preheater trip. 2.2.2.2 Opposite FDF trip. 2.2.2.3 2preheater trip. 2.2.2.4 Bearing temperature of fan 100. 2.2.2.5 Bearing temperature of motor 85 2.2.2.6 Winding temperature of motor 145 2.2.2.7 Bearing vibration 7.1mm/s.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2.2.2.8 After MFT, furnace pressure lower than -2290Pa, and FSSS issues trip signal. 2.2.2.9 Press site trip button. 2.2.2.10 IDF surges and trips later 15s. 2.2.3 Interlock conditions of starting cooling fan: 2.2.3.1 Put interlock switch into running 2.2.3.2 The other cooling fan trips. 2.2.3.3 Bearing temperature higher than 85 2.2.4 Start IDF Start IDF automatically by sequence control. or start it solely, 2.2.4.1 Start first IDF. 2.2.4.1.1 Insure electric protection, thermal protection put into running. 2.2.4.1.2 Start condition reached. 2.2.4.1.3 Turn on power, check inlet damper closed, inlet stationary blade closed, and outlet damper opened. 2.2.4.1.4 Start one bearing cooling fan. 2.2.4.1.5 Start fan, and monitor current and voltage of 11kV bus bar, and monitor starting current and returning time. 2.2.4.1.6 Check inlet damper opened in 60s after starting fan, if it could not open fully, stop fan. 2.2.4.1.7 If the opposite preheater running, check inlet damper auto-start. 2.2.4.1.8 open outlet rotary blade slowly, monitor and adjust furnace suction pressure in scope of -50-100Pa, switch the inlet stationary blade to auto. 2.2.4.1.9 Check IDF running normally. 2.2.4.2 Start the other one. 2.2.4.2.1 When start the second fan, the other one should be running. 2.2.4.2.2 Open outlet damper, close inlet damper and outlet rotary blade before start the second fan. 2.2.4.2.3 Start first bearing cooling fan. DOCUMENT NO. : HISAR-ZT-07
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2.2.4.2.4 Adjust first fan work condition lower than lowest point of stall line. 2.2.4.2.5 Start second fan, check inlet damper open in 60s, otherwise stop it immediately. 2.2.4.2.6 Monitor furnace suction pressure, open outlet rotary blade of second fan, check outlet rotary blade of first fan close automatically. When the opening of two outlet rotary blades is same, switch second fans to auto. Take notice that two outputs should be balance. 2.2.5 Shut-down IDF Shut down IDF by stopping sequence control. Control of air and gas system, or stop it solely. 2.2.5.1Two IDF run parallel, stop one of them normally. 2.2.5.1.1 Close the outlet rotary blade which prepared to stop to manual when load decrease to 300MW. 2.2.5.1.2 Gradually close the outlet moving blade of the IDF which will be shut down, and check the other ones opening increase automatically and furnace pressure is normal. 2.2.5.1.3 Ensure system is normal when outlet moving blade is closed fully. Shut down the IDF, and ensure its inlet damper is closed automatically. 2.2.5.1.4 Ensure the outlet damper is closed automatically. 2.2.5.1.5 2h later after stopping IDF, stop bearing cooling air fan. 2.2.5.2 Stop one IDF. 2.2.5.2.1 The last IDF can only be stopped when all FDF are stopped. 2.2.5.2.2 Switch outlet moving blade to manual, and close the blade gradually. 2.2.5.2.3 When outlet rotary blade is closed fully, check all system is normal, and shut down this IDF. 2.2.5.2.4 2h later after stopping the IDF, stop bearing cooling air fan. 2.2.6 Handling accidents of IDF 2.2.6.1 Stopping steps of IDF: a) Stop IDF manually or protection action. b) Ensure outlet moving blade of IDF is closed, outlet and inlet damper of IDF are closed automatically delayed. c) 2h later after stopping fan, stop bearing cooling air fan. 2.2.6.2 Stall of IDF A Phenomenon 1) Alarm of IDF stall is shown on control panel. 2) Furnace pressure and air quantity fluctuate a lot, and boiler is burnt unstable. 3) Current of stalled fan change intensively, abnormal voice would be heard in site. B reason 1) Ash accumulated on heating surface and air pre-heater or flue gas damper is closed incorrectly, which cause increasing of resistance and opening of static blade does not match with flue quantity which causes fan enter into stall area. DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2) IDF will enter into stall area when static blade is adjusted too much. 3) The other air fan will enter into stall area when automatic control equipment is broken down. C Handle 1)Get air fan to manual control mode immediately, turn down the moving blade of the normally operated air fan, and properly turn down the moving blade of the stalled one, adjust moving blade at same time, and maintain boiler pressure in allowable scope. 2) If two air fans stall when they operate parallel, stop parallel. 3) If stall is caused by closing system damper and throttle incorrectly, open them immediately, and adjust opening of static blade. If it is caused by defects of damper or throttle, decrease boiler load and repair as soon as possible. 4) After taking above measures, stall is disappeared, and the unit is in stable condition. Gradually increase load after find out further reasons and take some measures. When above measures is invalidity or it is heavily threatened to equipment safety, stop this air fan immediately. 2.2.6.3 IDF trip A Appearance 1) There are alarms of IDF (A or B) trip and RB shown on control panel. 2) Negative pressure changes intensively. 3) Load decreases abruptly. 4) FDF, which is on the respective side of tripped IDF, trips. 5) Current of tripped fan decreases to 0, outlet moving blade is closed automatically, load of running fan increases automatically. 6) RB action, and cut off corresponding mill. B Operation 1) Ensure unit in coordination mode. 2) Ensure boiler load decrease to 50% automatically, in case auto control breaks down or speed is too slow, decrease it to 50% by hand on time. 3) Ensure moving blade opening on the side of operated IDF increases automatically, and avoid overload. 4) Ensure boiler pressure control is in auto mode; otherwise switch it to auto after adjusted. 5) Ensure moving blade opening on the side of FDF increases automatically, air quantity and oxygen quantity is in normal. 6) Notice steam temperature and steam pressure changing during decreasing load, and adjust desuperheated water to maintain steam temperature stable. 2.2.6.4 Dealing with defects of IDF outlet moving motor actuator. a) Switch it to manual, maintain load stable. b) Staff should go to site to check reasons, contact with main control room when operated DOCUMENT NO. : HISAR-ZT-07
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manually, and monitor boiler negative pressure. c) Open and close in correct direction d) Operate slowly.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

e) When abnormal sound is heard or machine is blocked, stop operation. 2.3 FDF 2.3.1 Admitting start conditions 2.3.1.1 Thrust bearing temperature 85. 2.3.1.2 Support bearing temperature 85 2.3.1.3 Motor bearing temperature 85 2.3.1.4 Winding temperature of motor 110 2.3.1.5 Rotary blade closed 2.3.1.6 Motor outlet damper closed 2.3.1.7 Hydraulic liquid pressure >2.5Mpa. 2.3.1.8 One IDF running at least. 2.3.1.9 Lubricate liquid flow of bearing 3L/min 2.3.2 Trip conditions 2.3.2.1 Respective side IDF trip. 2.3.2.2 FSSS order. 2.3.2.3 FDF bearing temperature is higher than 100. 2.3.2.4 Motor bearing of FDF temperature is higher than 100. 2.3.2.5 Motor winding temperature of FDF is higher than 120. 2.3.2.6 Bearing vibration(X or Y) of FDF is larger than 11mm/s. 2.3.2.7 Field trip button. 2.3.2.8 Failure trip of FDF 2.3.2.9 Surging in FDF, 15s delayed. 2.3.3 Interlock of lubricate oil pump 2.3.3.1 Start FDF by sequence control, interlock starts the chose lubricated oil pump. 2.3.3.2 If one lubricated oil pump is in operation and oil pressure is low, interlock start the other one. 2.3.3.3 Lubricate oil pump trip, interlock start the standby oil pump. 2.3.4 Interlock of electric heater of lubricate oil tank 2.3.4.1 Temperature on oil tank is lower than 25, interlock to start another one; while temperature is higher than 35, interlock to stop. 2.3.5 Start FDF 2.3.5.1 Close outlet damper of FDF, as well as moving blade totally. 2.3.5.2 Press FDF start button, and outlet damper is open automatically.

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2.3.5.3 Adjust moving blade to required opening according to current and furnace negative pressure. Press auto if possible. 2.3.6 Stop fan 2.3.6.1 shut down moving blade slowly which fan is stopped; monitor the other blade opening automatically. 2.3.6.2 Close all outlet dampers after moving blades are closed. 2.3.6.3 Check and stop FDF. 2.3.7 Accident handling of FDF 2.3.7.1 Surge A Phenomenon 1) There is alarm FDF surging shown on control panel. 2) Boiler pressure and air flow fluctuate intensively, and fuel in boiler is burnt unstable. 3) Current of surging fan changes intensively, check it on site and find abnormal sound. B reason 1) Ash is heavily accumulated on heating surface and air preheater or flue gas damper is closed incorrectly, which cause resistance increase and moving blade opening cant match with air or fume quantity and fan enter into stall. 2) When operate moving blade violently, fan will stall. 3) Adjusting performance of moving blade is becoming worse, and two paralleled fan in unbalanced status, or auto system is out of control so one of them stall. 4) Start sootblower when boiler is overloaded or forced air flow is too large. C Handle 1) Switch moving blade control to manual, close down the other normal working moving blade and close down the moving blade of the stall one properly, adjust IDF and FDF to maintain boiler pressure within allowable scope. 2) When surging occurs during paralleling, stop parallel, shut down moving blade of stalled fan quickly, find out reason and resolve it then parallel them again. 3) If surging caused by fume damper or incorrectly close of throttle, open them immediately, and adjust moving blade opening. If there are defects, decrease boiler load, and repair them as soon as possible. If it is caused by sootblowing, stop it. 4) Unit will run stably if surging is disappeared by taking above measures, and increase load of fan after reason is found out and resolved. While surging still exists or bring risk to equipment, stop the fan. 2.3.7.2 FDF trip A Appearance 1) There is alarm of FDF (A or B) trip and RB is shown on control panel. 2) Boiler pressure fluctuates intensively. DOCUMENT NO. : HISAR-ZT-07
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3) Load drop intensively. B operation 1) Ensure unit is in coordination mode.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2) Ensure boiler load decrease to 50% automatically, in case auto control is out of control or speed is too slow, decrease it to 50% manually. 3) Ensure boiler negative pressure is in auto control mode; otherwise switch it to auto after adjustment. 4) Ensure output of running side fan increase automatically, air and oxygen is in normal quantity so as to avoid overload of running side air fan. 5) Notice changing of steam temperature and steam pressure during load decreasing, adjust quantity of desuperheated water and maintain steam temperature stable. 2.4 PAF 2.4.1 Admitting start condition 2.4.1.1 Temperature of PAF bearing is85 2.4.1.2 Temperature of PAF motor bearing is85 2.4.1.3 Lubricate oil flow of PAF bearing is larger than 3L/min. 2.4.1.4 Close moving blade of PAF. 2.4.1.5 Motor blade of motor driven damper of PAF outlet is closed. 2.4.1.6 Hydraulic oil pressure of PAF is normal and2.5MPa. 2.4.1.7 The corresponding side IDF is running. 2.4.1.8 Boiler MFT resumes. 2.4.2 Trip conditions 2.4.2.1 MFT. 2.4.2.2 The corresponding side FDF is tripped. 2.4.2.3 Temperature of PAF bearing is100. 2.4.2.4 Temperature of motor driven bearing of PAF is100. 2.4.2.5 Temperature of motor driven winding of PAF is120. 2.4.2.6 PAF is failure tripped. 2.4.2.7 Bearing vibration (X/Y) of PAF is larger than 11mm/s. 2.4.2.8 Surge of PAF is larger than +2000Pa, 15s delayed. 2.4.2.9 Press field trip button. 2.4.3 Interlock of lubricate oil pump and hydraulic oil pump 2.4.3.1 Oil level of tank is normal and the pump is allowed to start. 2.4.3.2 Hydraulic oil pressure under normal condition is 0.8Mpa and start spare oil pumps interlock. 2.4.3.3 Lubricate oil pressure under normal condition is 0.2Mpa and spare oil pumps interlock. 2.4.3.4 The spare oil pumps interlock while the operated oil pump is tripped. DOCUMENT NO. : HISAR-ZT-07
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2.4.4 Interlock of motor driven lubricate oil pump of PAF. 2.4.4.1 Oil level in tank is normal and oil pump is allowed to start.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2.4.4.2 Lubricate oil pressure under normal operation is 0.075pa and spare oil pumps will interlock. 2.4.4.3 Operated oil pump is tripped while spare oil pumps interlock. 2.4.5 Interlock of electric heater of lubricate oil tank of PAF. 2.4.5.1 Temperature on oil tank is lower than 25, put it into operation, while temperature is higher than 35, and stop automatically. 2.4.6 Start PAF 2.4.6.1 Start the first PAF. 2.4.6.1.1 Put hydraulic lube oil station and motor lube oil station into operation. 2.4.6.1.2 Ensure permissive conditions for starting PAF is achieved. 2.4.6.1.3 Stop moving blade and outlet damper of PAF. 2.4.6.1.4 Start PAF, check outlet damper can be opened automatically, and otherwise open it by hand. 2.4.6.1.5 Open moving blade of PAF slowly, adjust primary air pressure to be normal, and put moving blade control of this PAF into auto. 2.4.6.2 Start the second PAF. 2.4.6.2.1 Check outlet damper and moving blade of PAF are closed. 2.4.6.2.2 Put hydraulic lube oil station and motor lube oil station into operation. 2.4.6.2.3start the second PAF, check its outlet damper can be opened automatically, otherwise open it by hand. 2.4.6.2.4 Start moving blade adjusting damper of the second PAF and adjust moving blade of the first FDF, make the moving blade opening of the two PAF be the same, switch moving blade of the second air fan into auto, pay attention that output of the two PAF should probably be the same. 2.4.7 Stop of PAF 2.4.7.1 Two PAF are running on parallel, stop one of them. 2.4.7.1.1 Switch moving blade of PAF be auto which is going to stop. 2.4.7.1.2 Gradually shut down the moving blade of the hauled PAF; check opening other the one is increasing more automatically. 2.4.7.1.3 Close its moving blade fully and outlet damper. 2.4.7.1.4 Stop this PAF, check running side air fan running normally. 2.4.7.1.5 10 minutes after PAF stopped, stop hydraulic lubricate oil pump as per requirement. 2.4.7.2 Stop one of the PAF. 2.4.7.2.1 The last PAF can only be stopped after all mills are stopped. 2.4.7.2.2 Switch the moving blade of PAF to be manual, and shut down its moving blade DOCUMENT NO. : HISAR-ZT-07
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gradually.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2.4.7.2.3 Close air fan moving blade fully and stop this PAF. Check outlet damper of PAF is closed automatically. 2.4.7.2.4 10 minutes later of stopping fan, stop hydraulic lubricate oil pump as per requirement. 2.4.7.3 Failure trip of PAF. 2.4.7.3.1 Stop PAF by hand or by protection. 2.4.7.3.2 Moving blade of PAF is closed automatically. 2.4.7.3.3 Outlet damper of PAF is closed automatically. 2.4.7.3.4 10 minutes after stopping fan, stop hydraulic oil pump as per requirement. 2.4.8 Handling accidents of PAF 2.4.8.1 Bearing vibrates intensively. A Reason 1) Anchor bolt loose or concrete foundation is destroyed. 2) Bearing is broken, bended, or worn. .

3) Coupling loose and its center offset too much. 4) The blade is destroyed or it is grinded with outer case. 5) Air dust is destroyed. B Operation 1) Monitor vibration, temperature, current or air flow occasionally as per fan vibration. 2) Find out reasons for vibration as soon as possible, contact special staff to resolve problems when necessary. 3) Decrease load if air fan properly. It will trip automatically when vibration is larger than 11mm/s, otherwise stop it by hand. 2.4.8.2 High temperature of bearing of PAF A reason 1) Lubricate oil supplied is incorrectly, oil pump is destroyed or filter is blocked. 2) Cooling water for lubricate oil system is stopped or its quantity is not enough and cause inlet oil temperature increase. 3) Lubricate oil quality worsen. 4) Bearing is destroyed. 5) Bearing vibrates intensively. 6) Overload of PAF. B operation 1) Monitor vibration, temperature, current or air flow occasionally as per fan vibration. 2) Check on site whether hydraulic lubricate oil is normal, find out reasons as soon as possible and contact special staff when required. . 3) While bearing temperature increasing, decrease load of PAF on time. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

4) In case bearing temperature increase because of intense vibration, find out reasons as soon as possible and resolve it. 5) When bearing temperature is higher than 100, fan will trip automatically, otherwise stop it by hand. 2.4.8.3 Surging of PAF A Appearance 1) There is alarm of PAF surging shown on control panel. 2) Current of surging fan changes intensively, check abnormal sound on site. 3) Primary air pressure fluctuates intensively. 4) Fan surges heavily, trip fan 15s delay when reach to trip value. B reason 1) Fume damper close incorrectly, so resistance increase and moving blade opening doesnt match to air quantity, make fan to stall. 2) When operating moving blade too quick, fan will stall. 3) Adjusting performance of moving blade becomes worse, make two paralleled fan in unbalanced status, or auto system is out of control and cause one of them stall. C Handle 1) Switch moving blade control to manual, turn down the moving blade of the other air fan, and properly turn down the moving blade of the stalled one. 2) When surging occurs during paralleling, stop it, shut down moving blade of stalled fan quickly, find out reason and resolve it then parallel them. 3) If surging caused by incorrect closing of damper or throttle of PAF, open them immediately, and adjust moving blade opening. If there are defects, decrease boiler load, and adjust mill system and contact engineer for repairing. 4) Unit will run stably if surging is disappeared by taking above measures, and increase load of fan after reason is found out and resolved. While surging is still exist or bring risk to equipment, stop the fan. 2.4.8.4 PAF trip A Phenomenon 1) There is alarm of PAF (A or B trip shown on control panel. 2) RB cut off respective mill. 3) Load is drop down automatically. B operation 1) Ensure unit in coordination mode. 2) Monitor RB, if load are not decrease by auto control, stop respective mill by hand immediately. 3) Try best to maintain primary air pressure. Stop all hot and cold air dampers of stopped mill if DOCUMENT NO. : HISAR-ZT-07
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outlet damper and moving blade of tripped air fans are closed.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

4) According to primary air pressure, put oil gun into stable burning, stop some mills to prevent MFT. 5) Notice steam temperature and air pressure changing and adjust them when load is decreased abruptly. 6) Ensure boiler pressure and air flow normally. 2.5 Pulverized coal system 2.5.1 Mill Trips Mill trips on any of following condition. 2.5.1.1 Lubricate oil pump trip. 2.5.1.2 Lubricate oil pressure is lower than 0.07MPa, 2s delayed. 2.5.1.3 Bearing temperature of mill speed reducer is 80. 2.5.1.4 Supplied lubricate oil temperature for mill is 65. 2.5.1.5 MFT 2.5.1.5 MFT. 2.5.1.6 Primary air pressure is lower than 4KPa, inlet air flow is low, last for 5s or longer, two PAF will both trip. 2.5.1.7 While mill is running, pressure difference of seal and primary air <1.0KPa. (Is it necessary) 2.5.1.8 Outlet damper of mill is closed. 2.5.1.9 Winding temperature of mill motor is145. 2.5.1.12 Bearing temperature of motor is95. 2.5.1.13 Outlet temperature of mill is 100. 2.5.1.14 Order 2.5.1.15 RB 2.5.1.16 While mill is running, fire detector doesnt find flame.Is it necessary) 2.5.1.17 Coal feeder is stopped, 5minutes delayed. Is it necessary) 2.5.2 Coal feeder trips Coal feeder trips on any of following condition. 2.5.2.1 MFT. 2.5.2.2 Mill trips. 2.5.2.3 Inlet and outlet motor of coal feeder is closed. 2.5.2.4 Defect in coal feeder system a) Defect in belt driving motor. b) Defect in cleaning motor. c) Coal is cut off for coal feeder. DOCUMENT NO. : HISAR-ZT-07
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d) Coal is blocked on outlet of coal feeder. e) Coal flow in coal chute is abnormal. f) Temperature of coal feeder is excess. g) Overload of coal feeder motor. 2.5.3 Start sealing air fan 2.5.3.1 Ensure inlet damper of fan is open. 2.5.3.2 Ensure one of the fan has been put into operation. 2.5.3.3 Ensure all 8 dampers at mill sealing air inlet are closed. 2.5.3.4 Inspect if condition is ready. 2.5.3.5 Start sealing air fan and current is shown normal.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2.5.3.6 Adjust pressure difference of sealing air and primary air to be >2kPa, start sealing air auto. 2.5.3.7 Interlock another sealing air fan. 2.5.4 Start pulverized coal system 2.5.4.1start by hand 1) Start mill, check the current is normal. 2) Check sealing air damper is interlocked. 3)Open hot and cool primary air isolating valve, adjust their regulating valve of mill cool and hot primary air, and warm coal in the speed of 3 / min for about 15m, control outlet temperature of mill in scope of 6593 . 4) Set rotation speed of coal feeder at lowest output condition, start coal feeder, inspect it running normally. 5) Notice rotation speed of other feeder. (Switch operated coal feeder to auto) 6) Ensure belt of coal feeder of mill is put into normal operation automatically. 7) Fuel quantity can be increased after outlet temperature of mill reaches set value. 8) After coal feeder and mill are running normally, switch cool and hot air regulating valve of mill into auto. 2.5.4.2 Start coal system by sequence control A Conditions for sequence control 1) Admit ignited by coal. 2) Any of sealing air fan is operating. 3) No trip order of the mill. 4) No sequence control is executed. 5) Put sequence control into operation by hand or by auto. B Procedures of sequence control 1) Start mill lubricate oil pump by sequence control. 2) Start mills sealing air damper and outlet closing valve by sequence control. DOCUMENT NO. : HISAR-ZT-07
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3) Start mills cool primary air closing valve by sequence control. 4) Put mills damper to start position by sequence control. 5) Start mill by sequence control. 6) Start mills hot primary air closing valve sequence control. 7) Put mills air flow, temperature control to auto. 8) Open outlet coal valve of coal feeder by sequence control. 9) Open outlet coal valve of coal hoper by sequence control. 10) Set rotation speed of coal feeder to lowest by sequence control. 11) Start coal feeder by sequence control.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

12) Put coal feeder control to auto by sequence control. (two mill running at least). 13) Resume sequence control. 14) Finish sequence control. 2.5.5 Stop coal system 2.5.5.1 Stop by hand 1) Switch coal feeder control to manual, decrease coal quantity gradually. 2) Maintain normal temperature of mill outlet when decrease coal quantity. 3) Stop coal feeder after coal feeding ratio drop to 0. 4) Maintain mill running for 10min at least under rated air flow after coal feeder is stopped. 5) When mill outlet temperature is lower than 50 and no coal in mill, stop mill. 2.5.5.2 Stop coal feeding by sequence control. 1) Start sequence control of stopping coal feeding. 2) Set coal feeder rotation speed to lowest by sequence control. 3) Stop hot primary air closing valve by sequence control. 4) Stop outlet valve of coal hoper by sequence control. (when outlet temperature of mill is70). 5) Stop coal feeder by sequence control. 6) Stop outlet valve of coal feeder by sequence control. 7) Stop mill by sequence control. 8) Stop mill outlet closing valve and cool primary air closing valve by sequence control. (Stop mill for 5min, outlet temperature of mill is lower than 65 ). 9) Stop mill sealing air valve by sequence control. 10) Resume sequence control. 11) Finish sequence control. 2.5.6 Parameter of coal system 2.5.6.1 Parameter

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item 1 Description Pressure difference of mill grinding bowl is high Pressure difference of seal air and primary air is low unit alarm

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

trip

remarks Adjust coal feeders output to 25%

KPa 3.25

KPa 1.25 93

1.0 100

1.25 alarm and lock to start spare fan

3 Mill output temperature is high 4 Mill lubricate oil flow is low Mill lubricate oil pressure is low

L/min 121 MPa >0.15

5 Pressure difference of lubricate oil filter is high MPa 0.2 6 Lube oil pressure in mill gear box is low 7 Oil level in lubricate oil tank of mill is low 8 temperature of mill lubricate oil is high 9 temperature of thrust pad of gear box is high 10 temperature of motor bearing of mill is high MPa 0.09 mm 200 60 75 85 65 80 95 0.07 Trip mill 2s delayed

2.5.6.2 Maintain fineness of coal power when coal system is running. 2.5.6.3 Control coal feeders rotation speed in scope of 40%~80%. Put another mill into running when average output excess 80%; stop one mill when average output is lower than 40%. 2.5.6.4 Maintenance of lubricate oil station a) When oil temperature of lube oil tank is higher than 15, start lubricate oil pump. b) Oil temperature of tank is lower than 35, put electric heater of tank into running. Stop electric heating when temperature on oil tank is higher than 40. c) Put heating belt of oil return pipe into operation when temperature of oil return is lower than 45; stop it while it is higher than 49. d) Maintain oil temperature behind cooler in scope of 30~40, alarm when higher than 60. e) Lube oil supplied pressure should be in set valve of 0.15MPa, and alarm when it is lower than 0.09MPa, trip mill when it is 0.07MPa 2s delayed. f) Alarm and change lubricate oil filter when its pressure difference is higher than 2.0MPa.

2.5.7 Handling accident of pulverized coal system 2.5.7.1 Stop coal pulverized system when any of following condition occurred. a) Boiler MFT, and trip protection doesnt work. b) Coal system explodes, and it is dangerous to human. c) Mill is on fire and dangerous to equipment. d) Mill vibrates intensively. e) When there are defects on electric equipment, it is required to stop pulverized coal system. f) Load is dropped abruptly because of grid or electric failure. G) RB trip but load doesnt drop down automatically. DOCUMENT NO. : HISAR-ZT-07
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h) Trip condition reached but protection refuses to trip. 2.5.7.2 Lubricate oil pressure is low A reason 1) Lubricate oil system leak. 2) Defects are on oil pump or coupling is disengaged. 3) Lubricate oil filter is blocked. 4) Viscosity of lubricate oil is too high. (Has high viscosity) 5) Lubricate oil temperature is high. B operation

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1) If oil system leak and could not be isolated, or defects are on oil p ump, stop oil pump and report to foreman to repair. 2) If pressure difference of oil filter is high, change filters and contacts to repair and clean it. 3) If viscosity of lubricate oil is too high, check all oil brands. 4) If lube oil temperature is high, check whether cooling water and auto stopping of electric heater of tank starting is normal. 2.5.7.3 Outlet temperature of mill is too high or low A reason 1) Spontaneous combustion occurred in mill. 2) There are defects in regulator of hot or cold air 3) There are defects of temperature controller on mill outlet. 4) Coal is too humid. B operation 1) If outlet temperature of mill increases abnormally because of firing, stop this mill immediately, and put out fire by steam or water. 2) If outlet temperature of mill decrease too much because of humid coal, decrease coal quantity and open up hot air adjusting damper, shut down cold air regulating damper or adjust setting valve of outlet temperature. 3) If abnormal temperature on mill outlet is caused by defects of regulator or controller, repair them. 2.5.7.4 Coal is blocked in mill A reason 1) Control air quantity of mill incorrectly, air quantity is too low and coal quantity is too much. 2) Mill outlet damper is not open widely or closed by mistake. 3) Coal barrel or ball is worn heavily or force regulated unreasonably. 4) Coal hoper hasnt cleaned for a long time and makes air room collect ashy heavily. B operation 1) Clean coal. DOCUMENT NO. : HISAR-ZT-07
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2) Decrease coal feed and increase air flow.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

3) Open outlet damper fully or open the dampers which are closed by mistake. 4) After taking above measures, defects still exist, stop coal feeder and mill. 2.5.7.5 Handling of mill trip 1) Check mill hot air isolating damper and regulating damper are closed. 2) Check mill cold air isolating damper and regulating damper are closed. 3) Check mill sealing air damper is closed. 4) Check mill outlet damper is closed. 5) Find out reasons for trip, and restart mill after resolve problems. 6) In 30minutes after mill stopping, if it is ready for start, open cold air isolating damper, open cold air regulating damper a little, open outlet damper, blow mill. And monitor rotation speed of other coal feeders, main steam temperature and pressure changing. After blowing for some time, start mill, 10minutes later, restart coal feeder. 7)30minutes after stopping mill, it is still not ready for starting mill, repair mill and clear away the left coal. 2.5.7.6 Trip of coal feeder A Phenomenon 1) Alarm and trip of coal feeder. 2) Total coal feed decrease. 3) Steam temperature and pressure decrease. 4) Coal feeder rotation speed decrease to min. and coal feed decrease to 0. B reason 1) Mill trip or stop emergently. 2) MFT. 3) Electric is failure. 4) Coal chute on mill outlet is blocked. C Handle 1)Shift air flow and outlet air temperature regulating device to be manual, check hot air regulating damper is closed, open up cold primary air regulating damper, and maintain stable temperature on mill outlet. 2) Increase other coal feeders rotation speed, try the best to maintain total coal quantity and unit load be stable. 3) Find out reasons for trip, and repair it. 4) After coal feeder is repaired, open hot air isolating damper and regulating damper to warm coal, prepare to restart coal feeder. 5) If coal feeder could not resume in short time, stop respective mill. 2.5.13.7 Firing in mill DOCUMENT NO. : HISAR-ZT-07
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A Phenomenon 1) Outlet temperature of mill increase intensively. 2) Mill or coal chute is burnt or paint skin is disengaged.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

3) There is a sound heard if spontaneous combustion in mill, air pressure of coal system fluctuates a lot, coal power and gas will emit from the unsealed seam. B Reason 1) Outlet temperature is regulated incorrectly which cause outlet temperature too high. 2) Flammable material enters into mill. 3) Many coal power or stone coal is accumulated on mill baseplate or air inlet side, which causes spontaneous combustion. 4) Some coal power is accumulated on grinding bowl. 5) When mill is not stooped on time or blew fully and mill outlet valve is not closed, return fire. C Handle 1) After ensure combustion in mill, switch coal feeder and mill into manual control, stop coal feeder, close coal outlet valve, and close hot and cold air regulating damper and isolating damper. 2) Put out fire by steam. 3) After outlet temperature of mill is decreased, close steam valve after all firing signals are removed. 4) Maintain mill running for several minutes, clean system thoroughly. 5) When mill outlet temperature is50, stop mill, close mill sealing air damper and outlet damper. Take measures to clean mill. 2.6 CCP (Boiler water control circulating pump) 2.6.1Main parameter of CCP 2.6.1.1Parameters of CCP is shown in the following form. Parameters of BCCP No. 1 2 3 4 5 6 7 8 9 10 11 Item model design pressure design temperature suction pressure Suction temperature flow difference of head pressure hydraulic test pressure pump efficiency absorbing power manufactory Unit MPa MPa m3/h M MPa % KW Data single suckdouble discharge 21 359.1 18.9 359 2180 31.1 31.5 82.5 cold conditions 223.5 hot condition 122.7 British HaywoodTaylor Company
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1 2 3 4 5 6 7

model output power rotate speed power factor efficiency overall efficiency winding insulators

motor parameters wet stator - rat's cage - induction kW 210 r / min 1450 0.70 heat load 0.86clod load 0.885 heat load 0.71cold load 0.73 XLP

8 manufactory British HaywoodTaylor Company 2.6.1.2 Feedwater cooler parameters are shown in the following form. No 1 2 3 Item design pressure design temperature test pressure Unit Mpa Mpa High-pressure side 21.0 359.1 31.5 Low-pressure side 1.0 175 1.5

4 running pressure Mpa 5 running flow L / min 6 inlet temperature 7 outlet temperature 8 feedwater flow L / min 9 temperature Remarks: The feeding water must be desalt

20.96 1.0 12 410 175 40 54 43.6 2.0 ) 2.27 40 water or condensate water, PH value of 7 ~ 9, with

the same quality as the water filled into the boiler, and must be filtered with a 100 mesh stainless steel filtering screen. 2.6.2 Alarming and value-fixing parameters of CCP Number 1 2 3 4 Item motor chamber temperature cooler outlet water temperature pressure difference 1/2 between inlet and outlet cooler outlet water temp 60 HH H 55 57 9 9 151kPa 54 4 L

5 current 2.6.3 Starting and tripping conditions of CCP 2.6.3.1: Starting conditions a) Steam drum water level is 200 mm or any CCP of the boiler is running. b) Motor inner temperature is4 and 55. c) Cold water flow of CCP is 8m3 / h. d) Temperature differences between the boiler shell and water entered into pump is28 . e) Outlet valve 1 and 2 are started. 2.6.3.2 Trip in any of the following conditions: a) Any outlet valve of CCP is closed. DOCUMENT NO. : HISAR-ZT-07
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b) Motor inner temperature is65 . c) Pressure difference between inlet and outlet is 60KPa. d) Steam drum water level is390mm. 2.6.4 Prepare for operation of CCP

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2.6.4.1Finish overhauling, finish work ticket procedures or have preliminary operation ticket. 2.6.4.2 Boiler steam and water system work is over. 2.6.4.3 Turn off the cold water, finish maintenance work of water-filled system and water drain system. 2.6.4.4 Closed cold water pipeline of the cooler has finished watering and washing and prepared to use. 2.6.4.5 Motor cooler of the pump has closed cold water. 2.6.4.6 Prepare water-filled water, HP water filling (flow to the main water supply pipeline before HP superheater), and LP water filling (flow to condensate water pipe). 2.6.5 CCP water filling and air exhaust 2.6.5.1 The internal oxide and welding slag and other impurities of all the cooling, filling and cleaning water pipes and pump cooler at HP side must be cleaned before connected with CCP. Rubbish and impurities are strictly prevented entering the pump motor. In order to eliminate any possible pores, operate carefully for filling water into pump so as to exclude the air into the pump. When water filling upward from the bottom of the motor, operate slowly at the speed about 2 liters per minute, and conform to the following steps: a) Check and adjust the correct position of valves by check card. b) Open the inlet and outlet bypass valve and water-discharging bypass valve of CCP. c) Turn off the duplex isolating valve and open the connecting water pipe of condensate water to LP filling valve and LP 1,2 water valve, discharge impurities of the water pipe through the water pipe valve (if necessary firstly clean and discharge impurities of the filters through the filter blow down valves), fill water and exhaust steam after chemical test is checked to be qualified. d) Adjust opening of water regulating valve, measure water flow to make it slightly less than the regulated water flow (2.27 liters per minute), typically 2 liters. e) Open the duplex isolation valve, turn off the sewage valve of water filling pipe. f) Slowly inject condensate water into CCP through the duplex isolation valve. g) The work of water filling for CCP is over when continuous flow of no-air water exhausts from the inlet and outlet bypass trap of boiler water pump. h) Inject water into the boiler only when CCP is filled with water. 2.6.5.2 Precautions of water filling. a) Water temperature is no more than 54 , no less than 4 . b) Changes of filling water pressure. DOCUMENT NO. : HISAR-ZT-07
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c) The inner temperature of the motor is proper, the rate of temperature rising of pump shell is 1 / min. 2.6.6 Preparation to start CCP 2.6.6.1 Pump has been filled with water and excluded air. 2.6.6.2 Make sure that the closed cold water pipe is connected and the LP cold water flow is in line with the value requirements. If the pump is in hot standby mode, open the inlet and outlet bypass valve. 2.6.6.3 Inspect motor outlet temperature alarm value and tripping values are correct. Check whether all instruments is in good condition to ensure the absolute temperature difference between the collecting header and pump shell does not exceed 56 . Check differential pressure transmitter of the pump and the pump control system has been in operation and functioned well. 2.6.6.4 Make sure the electrical insulation satisfies requirements (with a 1000V shake table measuring insulation resistance, the value is greater than 200 M), the voltage is normal. 2.6.6.5 Drum water level is high. 2.6.7 Operating conditions of CCP 2.6.7.1 Carry out comprehensive inspection as required when the pumps and the boiler has been filled with water, and get the motor point rotating for 5 seconds, then stopped for 15 minutes, then transfer to 5 second point-rotating, repeat like this for there times to discharge the accumulate air in the pump body and the cold water LP system, so that the air in boiler spreads and then disappears at the end. Water should be also filled during the three point rotating exhausting period. 2.6.7.2 At the point rotating exhausting period, observe the motor current value and the pump pressure difference value, pressure should immediately increases to 0.27MPa, stop pumps if the pressure does not rise immediately. It may be caused by motor reversal that has to re-wire the motor. 2.6.7.3 The start-up time of pump is about one second. Stop and check if the motor fails to start in 5 seconds, restart 20 minutes later. 2.6.7.4 Three pumps can be started in A,C,B order, generally start pump A, C first, then start pump B since the drum pressure is activated. 2.6.7.5 Stop water filling to the pump and turn off the duplex isolation valve and LP water valve when the drum pressure increases to 0.5MPa. 2.6.7.6 Check the following contents after starting operation for 15 min and the pump current becomes normal: a) Measure vibration and record the readings. Stop running one CCP (generally open pump A, C first, open pump B after there is pressure), if it vibrates. b) Check the sound of pump and the motor is normal. DOCUMENT NO. : HISAR-ZT-07
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c) Check the current is normal. d) Keep record of the temperature rising of the motor until it is stable.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

e) No leaks of the electric coolers, filters, pump body, valves, gland bush, flange, and etc. f) Check the closed cold water flow is not low, the water flow indicator is normal, and the cold water temperature in electric cooler are normal. g) Check the motor in field temperature, pump shell temperature, and the inlet temperature difference and the outlet pressure difference between the pump and the pump shell are normal. h) Treat the unusual circumstances in pre-operation timely. 2.6.8 The running of CCP 2.6.8.1 In normal circumstances, CCP should keep three pumps running. 2.6.8.2 When CCP is running, the pumps vibration, current, motor temperature, pump shell / import temperature, pump shell temperature, import / export pressure differential and closed chilled water systems water pressure, water temperature normal regularly should be checked. 2.6.9 Stop of CCP 2.6.9.1 Meet stopping pump requirements of disable load, and one CCP run-time load must be less than 60% MCR. 2.6.9.2 The pumps inlet temperature must be less than 150 to stop the final CCP. 2.6.9.3 After boiler water is stopped, maintain the closed cold water system in operation, and monitor the various parameters proper, temperature decreasing speed of pump shell more than 1 / min c. 2.6.9.4 After the pump stopped, maintain opening of outlet valve, import bypass valve, heat balance door at the open position, and outlet micro bypass valve of pump for preparation. 2.6.10 Releasing water of CCP 2.6.10.1 Eject water of CCP after the water wall is ejected water in the order of the inlet pipe. Eject water in the order of CCP inlet pipe, pump body, and finally the motor. 2.6.10.2 It is not allowed to release water of pumps and inlet and outlet pipes through the motor body, neither to release water of the boiler through the pumps. 2.6.10.3 Keep running of the closed cold water system and monitoring motor chamber temperature during water releasing. 2.6.10.4 Releasing water operations of the CCP. a) The boiler has been cooled, the water in boiler body has been released, the temperature of motor and pump shell is lower than 65 . b) Check and open the total water-releasing valve. c) Open the water valve, inlet and outlet bypass valve and inlet and outlet bypass water-releasing valve, and water-release the inlet and outlet pipes and pump body. d) Open the double-septum cut-off valve and release the water to motor after the water in pump body is released over. DOCUMENT NO. : HISAR-ZT-07
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e) Turn off the water valve after water is released. 2.6.11 Isolation, maintenance and repair of CCP

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2.6.11.1 Isolation, maintenance and repair of boiler water circulating pump must be carried after ejecting boiler water. 2.6.11.2 Water pumps have been ejected water. 2.6.11.3 Isolate the water-discharging system; turn off the duplex isolation valve, outlet bypass valve and the total water valve. 2.6.11.4 Isolate the water-filled cooler of the pumps; turn off the closed cold water inlet valve. 2.6.11.5 Turn off the closed cold water inlet and outlet valves of the motor cooler of the pumps. 2.6.11.6 Turn off the outlet valves of the CCP. 2.7 Flame inspection of cooling air fan system 2.7.1Interlock protection of flame inspection 2.7.1.1 Main pipe pressure of cooling air is 7.25KPa. 2.7.1.2 Pressure difference of cooling air and furnace is 1.8KPa, alarm and interlock to start spare cooling air fan. 2.7.1.3 Pressure difference of flame inspection cooling air and furnace1.0KPa, boiler MFT 1800s delayed. 2.7.1.4 Alarm when pressure difference of front and rear of flame inspection cooling air fan filter is 0.15KPa. 2.7.2 Start flame inspection 2.7.2.2 Start flame inspection a) Check fire inspection system normal, power is on. b) Start cooling air fans remotely, 1A/1B. c) Main pipe pressure of flame inspection cooling air is normal 7.25KPa d) Put lock switch of spare cooling fan into running e) Put flame inspecting probe into running. 2.7.3 Stop flame inspection system 2.7.3.1 Check furnace wall temperature lower than 90, or fume temperature lower than 70 2.7.3.2 Flame inspecting probe exit. 2.7.3.3 Interlock of cooling air fan exit. 2.7.3.4 Stop cooling fan remotely 2.8 Operation of ESP 2.8.1Test and inspection before commissioning Before ESP is put into use, for the newly-installed or overhauled ESP, test and inspection should be conducted according to related standards and regulations. The inspection mainly includes: (1) Go through all the procedures of the work notice and remove the safety facilities DOCUMENT NO. : HISAR-ZT-07
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concerning the inspection. Guard bars and index plates should remain. (2) The equipment and components are complete and the symbols are clear and correct. Tight contact surfaces, complete insulation and ample lighting. (3) The motors are wired. The earth wire is fixedly connected. The safety hood should be installed and has no collision, as well as contact with the rotation part. (4) Discharging and collecting rapping devices, ash discharging valve, screw dust discharging machine and other rotation equipment work normally. The oil quality of the gear box is qualified and the oil position is normal. Oil should be added to the driving chain so that chains can move flexibly. (5) All the instruments, switches, protection devices, regulation devices, temperature test devices, alarm signals and indicating lamps are intact, complete and normal. (6) The heating device of high voltage insulation bushing room and hopper heating device are intact. (7) The high voltage rectifier device is clean, as well as insulation parts. Theres no oil leakage in the rectifier transformer and resistor. The oil quality is qualified and the oil position is normal. The lead wire of the rectifier device has good contact ability and the damp resistance is intact. The rectifying control cabinet and the automatic regulation device are intact. The adjustment button or knob is complete and the instruction is correct. High voltage isolating disconnecting link should have good contact ability. The operation mechanism is flexible and can be earthed reliably. The disconnecting link is in the earth position. (8) ESP high voltage cable lead-in cabin is clean. Lead-in wires have good contact ability and the damp resistance is complete. (9) All the switches and disconnecting links of the low voltage distributor work normally. All the power insurance and operation insurance are intact. (10) When the silicon controlled plates, heating and rapping devices are confirmed to be switched off, send power to the above equipments. (11) As for the breakdown or failure, generally, we will inspect the rotation part or the failure part. After confirming that it is normal, it can be put into use. 2.8.2 Switch on ESP Before switching on the ESP, we should confirm that theres no person in the ESP, all manholes are closed and theres no person in the high voltage area. High voltage isolating disconnecting link is put in the operation position. Switch on the heating device 4-8 hours in advance. Heat the porcelain through insulator, column insulator and electromagnetic shaft so as to prevent dewing and creeping. Switch on the hopper heating equipment and remove the moisture on the inner wall of the hopper. Switch on the rapping device of the ESP collection electrode and discharging electrode. Remove the dust particle attached on the electrode. Switch on the main blower fan to preheat and dry the electrode system of the field. Switch off the earth device and put DOCUMENT NO. : HISAR-ZT-07
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high-voltage power in. Operation procedure of ESP:

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Operation starts Switch on the power supply distributed panel Switch on the heating power of the insulator

Close the door of the inlet and maintenance hole

Switch on the dust particle discharging and handling device


Switch on the rapping device of the discharging electrode

Switch on the dust collecting electrode rapping device

Switch off the earthing device

Actuate the air blower

Judge whether the treatment of flue gas is normal Switch on ESP Automatic Automatic or manual Transmit DC HV to ESP. And then it can work automatically. Transmit DC voltage to ESP set voltage manually manual( commission)

End 2.8.3 Switching off of ESP

When the main engine is switched off, ESP can temporarily stop and the post HV isolating disconnecting link on the earth position. After the power is cut off on the plant, the heating device and rapping mechanism will continue DOCUMENT NO. : HISAR-ZT-07
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to work until the dust in the field is cleaned.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

The dust in the hopper should be cleared instead of being emptied completely. When ESP is stopped working because of long-term or middle-term overhaul, treat it as temporary machine halting. The rapping device works at least for 4 hours and then the heating system stops working. Empty the dust in the hopper. In the field, the earth rod is added and the site is kept clean. Make records of the machine halting. Refer to drawing 2 for the machine halting procedure Stop operation

The air blower stops working Close the flue damper The rectifier stops working The earthing device is earthed Stop the discharging electrode rapping Halt the collecting electrode rapping Dust discharging device stops Switch off the insulator heating power (After the machine halting is over 24 hours) Close the hopper heating equipment End 2.8.4 Typical failure and its analysis The life of ESP relates to its design and work conditions, the depreciation period generally is over 20 years. The failure type and failure frequency vary because of different work conditions, but the main component failure and its cause are as follows 2.8.4.1 Failure of the discharging electrode (1) Broken discharging wire. Broken discharging wires have multiple causes. For instance, aging causes discharging electrode to have no enough strength, electric corrosion, deficiency in the erection and construction work and too much rapping force are also the culprit. Because there are wrong with the flue gas and dust, the supporting component of the discharging electrode is corroded and then its usage life is shortened. High specific resistance leads to inverse corona. When the rapping is conducted repeatedly and the discharging electrode DOCUMENT NO. : HISAR-ZT-07
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vibrates, the hammer and discharging electrode are running and its contacting position will give rise to electricity corrosion. Broken electric wire means the collection electrode has burrs. The discharging electrode vibrates and shortens the electrode distance, which leads to the local field strength increase. The discharging wire is broken because of the disruptive discharge. Electric corrosion will happen after ESP is operated for years. (2) Thickness of the discharging electrode. Outside dust particle thickness of the discharging wire concerns the property, concentration, vibration force and rapping mechanism of the dust particle. In the field, positive electricity adheres to the discharging wire and a membrane is formed. Because of inefficient rapping dust clearing and accumulated dust, the discharging wire is thick. When collecting high specific resistance dust particle, the corona current will decrease, corona discharge diminishes and disruptive discharge increases Based on the above circumstance, we should adjust the rapping force; readjust the rapping time and rapping period. If the electrodes thickness is caused by the flue gas below the dew temperature or frequent switching on or off the machine, please improve the insulating measures and power supply. Before the flue temperature falls down to the dew point, clear the dust of the continuous electrode rapping. Continuous rapping is conducted within several hours of stopping the machine. 2.8.4.2 Failure of the dust collecting electrode

Failure of the dust collecting electrode mainly includes: (1) Dust is accumulated on the collecting electrode. Just like the thickness of the discharging electrode, local dust accumulation of the collecting electrode will reduce the discharging property and the collection efficiency will be lowered. Local dust accumulation relates to the nature of smoke, dust concentration, as well as rapping conditions. The major cause is no enough rapping force or uneven rapping force distribution. Sometimes, its because of the loosing of the connection bolt on the collection plate or inefficient rapping force transmission. And then we need to enter the field to ascertain the reason. (2) Deformation of the electrode plate. Deformation of electrode plate makes the electrode distance have some changes. The reason is that the flue gas temperature is high; the electrode plate is deformed due to some limitation. Or accumulated high temperature dust cause thermal storage and then deformation occurs; or the flue gas temperature overpasses regulated temperature value; or the breakdown arc inside the electrode plate transforms the electrode plate. If it is due to the redundant polar plate room or erection problem, when the electrode plate is transformed because of the flue gas, its phenomenon is that the voltage can reach the rated value, when smoke appears, voltage will drop with the rise of temperature. When we stop providing flue gas, the voltage will rise little by little. This kind of failure will appear on the ESP DOCUMENT NO. : HISAR-ZT-07
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which is newly put into use. If the local deformation is caused by thermal storage and arc, we need to ascertain the reason and change transformed electrode plates and solve the problem from adjusting the electrode distance or improve the rapping system. 2.8.4.3 Failure of the rapping device Use hammer for rapping for ESP, the transmission part is on the outside of ESP, the rapping hammer is in the field, the failure of the rapping part can be judged according to the change of the secondary voltage or the decrease of the dust removing efficiency. As for the discharging electrode rapping, if theres wrong with the insulation part, the whole field cant work, this situation will immediately be detected, but if an individual hammer fails or breaks down, we cant find it until it is inspected. Major failures of the rapping and transmission devices include the following: (1) Shaft locking. Main causes are: (1) the supporting shaft of the rapping shaft has a serious abrasion. (2) Rapping shaft bearing is not on the same line and it overpasses the compensation ability of coupling and affects the concentricity of the rapping shaft. (2) During the operation, the hammer and rapping anvil is not aligned. Besides the erection problem, most are caused by the heat inflation of the rapping shaft and ensuing rapping hammer dislocation (3) The rapping and transmission porcelain shaft of the discharging electrode is broken. Firstly, its the quality problem of porcelain shaft, before erection, inspect it. If the porcelain shaft has no test certificate, or has cracks on the surface, it shouldnt be used. During the trial operation, timely re-inspect. Secondly, torsion of the rapping shaft is too much, furthermore, there are other factors concerning excessive leakage current or breaking of the uneven heating of porcelain shaft caused by the dust accumulation and dewing. 2.9 Soot blower The soot-blowing system is equipped with 42 IR-3D furnace soot-blowers of 267mm soot lance blowing distance, 48 IK-545 long extension soot blowers (left and right each 24,including HT SH, HT RH, LT SH, LT RH) with 10450 mm soot lance blowing distance,10 IK-525EL of soot lance blowing distance 5300mm and 10300mm depth, left and right (fuel economizer)each 5, 2 IK-AH with 1200 mm soot lance blowing distance, one for each air preheater. The radius of all soot lances is 2200mm, with 360 angles. The soot-blowing system includes soot-blower, a decompression station, soot-blowing pipe and their fixtures and guides and so on. The steam source of the soot-blowers is from the right and left sides of the connecting pipe from the platen SH to the HT SH, The steam pressure is 17.8Mpa and the temperature is 470 under the working condition of BMC. After the reduction of temperature and pressure, the steam pressure falls to 2.5Mpa,the temperature falls to 350 . 2.9.1 Soot blowing system parameters 2.9.1.1 Furnace soot blower parameters DOCUMENT NO. : HISAR-ZT-07
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Number 1 2 3 4 5 6 7 8 9 Model Distance Running speed Unit set working time Unit set soot blowing time Nozzles diameter Effective soot blowing radius Soot blowing medium pressure Soot blowing medium temperature mm m/min min min mm m MPa Kg/min Unit Data Item Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Data IR3D 267 0.31 3 0.43 25.4 2 1.5 350 ~60

10 Steam consumption 2.9.1.2 Flue duct soot blower parameters NO 1 2 3 4 5 6 7 8 9 10 Item Type Distance Running speed Unit set working time Unit set soot blowing time Nozzles diameter Effective soot blowing radius Soot blowing medium pressure Soot blowing medium temperature Steam consumption

IK525 mm M/min min min mm m MPa Kg/min 7160 2.53.5 4.15.7 4.15.7 28.6 2 1.5 350 36~95 25.4 22.22

2.9.1.3 PH soot blower parameters(TYPE:IK-AH500) NO 1 2 3 4 5 6 7 8 9 Item Distance Running speed Unit set working time Unit set soot blowing time Nozzles diameter Effective soot blowing radius Soot blowing medium pressure Soot blowing medium temperature Steam consumption Unit mm m/min min min mm m MPa Kg/min Data 970 0.08 23 23 12.0)16.0 2.0 1.5 degree of superheat150 ~70
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2.9.2 Conditions and inspection of soot blowing 2.9.2.1 Conditions of soot blowing. a) The boiler works normallyburning condition is stable.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

b) The furnace soot blowers and the flue soot blowers are working, boiler load should be 60% MCR, and the first, the secondary steam temperature is stable. The furnace pressure is normal, the operation condition of IDF and FDF is stable, and IDF can still be adjusted. c) Proper sootblower decompression stations and air preheater sootblower decompression stop operate well. 2.9.2.2 Inspect soot blowers before operation a) Inspect that the system meets with the operation conditions, the valves are in their position, and sootblower are complete and available. b) Check that the reducing gear, supporting bearings, gear lubrication are normal. c) Check the body, valves and start-close structure and distance structure of the blowers is complete and well, the driven machine transmission gear and the rack engages normally. d) Check the stem and inner tube filler of sootblower is normal. e) Inspect sootblower are in the position of not operating, the situ control switch is in "ON" position. f) Check the integrity of the electrical wiring and in-situ control box of sootblower. 2.9.3 Operation of sootblower 2.9.3.1 When put into operation, select short blowing and long blowing together, in accordance with the situation of steam temperature. 2.9.3.2 Attention put into sootblower operation a) When sootblower put into operation, special attention should be put into the pressure and steam temperature changes of the furnace. b) When there is a failure in the operation of sootblower, immediately check the sootblower to stop to prevent damage of heating surface. Before sootblower quitting, ensure that there is steam flow, in order to prevent damage to sootblower. c) Soot blowing order: no matter in what manner to soot blowing, first should soot blowing air preheater, and then furnace and flue heating surface, finally soot blowing the air preheater again. d) Furnace sootblowing should be carried out from top to bottom, and firstly blow the front and behind wall on each layer, then blow the wall on both sides. e) Sootblow the flue heating surface according to the flue gas flow. f) Sootblow more in the furnace region easy to fouling of. g) Do not open the inspection hole, people inlet to observe or do manual work in sootblowing process. h) Inspect comprehensively that all sootblower has completely stopped when over. DOCUMENT NO. : HISAR-ZT-07
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2.9.4 Sootblower operation period 2.9.4.1When boiler operates normally, all heating surface

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

should

be

sootblowed

comprehensively every morning, air preheater be sootblowed every working class. 2.9.4.2 Sootblow more when the boiler burns coals with high ash content. 2.9.4.3 The air preheater should be sootblowed continuously when the boiler starts to ignite and shutdown load <30%. 2.9.4.4 All the heating surface should be sootblowed in boiler startup when the load is 60% and is to shutdown.. 2.9.4.5 One can select to sootblow, skipping a maximum of 20 sootblower, and reset sootblower after the step. 2.9.5 Sootblowing steam source of the air preheater 2.9.5.1 When the boiler operates normally, the sootblower steam source of the air preheater are separating screen outlet header. 2.9.5.2 During the startup of the boiler and load is 30%, sootblower steam source of the air preheater should be used the steam source from the auxiliary steam system. 2.9.5.3 When sootblowing air preheater, the two steam sources are strictly prohibited to operate parallelly. 2.9.6 Sootblower maintenance 2.9.6.1 When sootblowing, if the load is <60%, sootblower stop. 2.9.6.2 When the pressure reducing valve of sootblower decompression stations is 1.48 MPa or 3.43 Mpa, the sootblower shutdown. 2.9.6.3 When sootblower are operating, the automatic sootblowing sequence of the furnace and the flue will be interrupted and the operating sootblower will automatically exit.. 2.9.6.4 When flue sootblower exceed a set time in process, the sootblowing sequence will be interrupted and automatically exit.. 2.9.6.5 When flue sootblower are in process, the motor over-current may cause interruption and automatic exit. 2.9.6.6 In flue sootblowing process, when the MFT comes, all the operating sootblower exit automatically and turn off the total sootblower door to end sootblowing. 2.9.7 Sootblower fault treatment 2.9.7.1Sootblowers motor overload When the sootblower rack is not lube, the tube is bending, the track deforms, the gearbox has fault, as well as the inner tube fills too tight can cause overload maintenance, and the sootblower CRT screen will alarm. 2.9.7.2 When sootblower motor overloads, the sootblower will stop and automatically exit. When sootblower should not automatically exit one should get the control switch to "OFF", manually exit with special handle and ask for the maintenance treatment. DOCUMENT NO. : HISAR-ZT-07
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2.9.8 Stop sootblowing operation in case of any of the following situations: 2.9.8.1 Related equipment failure or damage of sootblowing system. 2.9.8.2 Sootblower sequence-controlled device failure. 2.9.8.3 Boiler combustion instability or failure to maintain negative pressure in combustion chamber. 2.9.9 Treatment to abnormity of sootblower steam pressure 2.9.9.1When sootblowing, the pressure-reducing valve failure of the steam source will cause abnormity behind the valve, which results in excessive pressure; security doors leaving from Block or too low pressure. And then sootblower are interrupted and exit, so that the CRT screen of sootblower will alarm. 2.9.9.2 If the safety gates of the decompression stops of body or the air preheater sootblower cant be seated back, one should immediately turn off the main steam valve, and put an end to sootblowing, contact maintenance staff. 2.10 Secondary air heater Main parameters of NFX4-3-4.28 FBZ heater Item air heater intake in MCR work condition inlet calculation of the wind temperature outlet wind temperature heating steam inlet pressure heating steam inlet temperature design pressure design temperature steam consumption heat exchanging area design abundance air heater interface size height of air heater general resistance steam interface (amount/ diameter) drainage interface (amount/ diameter) heat transfer pipe external diameter thickness length amount weight mode of interfacing Kg Steam and drainage mm mm Pa Unit kg/h MPa MPa t/h m2 Value Design coal 1024438 0 40 1.1 320 1.30 380 21.2 791 Check coal 975925 0 40 1.1 320 1.30 380 20.2 791

1.25 1.25 44054005(inner diameter) (air duct 440040005 insert to air heater and weld) 446 250 6/73 3/45 25 mm x2.5 mm x4505 mm x120 3500 welding
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2.11Synopsis of pressure and temperature under saturation PressureMpa 0.05 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 Temperature 81.35 99.63 120.23 133.54 143.62 151.85 158.84 164.96 170.42 175.36 179.88 187.96 195.04 201.37 207.10 212.37 217.24 221.78 226.03 230.04 233.84 237.44 240.88 244.16 247.31 PressureMpa 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Temperature 250.33 257.41 263.92 269.94 275.56 280.83 285.80 290.51 294.96 299.24 303.31 307.22 310.96 318.04 324.64 330.81 336.63 342.12 347.32 352.26 356.96 361.44 365.71 369.79 373.68

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2.12 Boiler startup curve and logic diagram

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Operation Manual for 600MW Unit Chapter III

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Steam Turbine Operation Regulations

3.1 Introduction of steam turbine 3.1.1 Main Parameters of steam turbine The steam turbine model is N600--16.7/538/538, which consists of HP, IP, and LP parts with 48 flow passage stages. HP part mounted in HP cylinder, has one single row governing stage and eleven pressure stages, IP part placing in IP cylinder with eight pressure stages, LP part has 2 X (2 X 7) pressure stages, and placed in LP cylinder. Except that governing stage is impulse stage, all the other stages are reaction ones. There are eight numbers uncontrolled extraction of the turbine. The eighth extraction steam is extracted after the eighth pressure stage of HP cylinder, the seventh one is pulled from cold reheat steam pipe after HP exhaust check valve; the sixth one is extracted from fifth pressure stage of IP cylinder, the fifth one is extracted after eighth pressure stage of IP cylinder; the forth steam extraction is extracted after second pressure stage (regulating valve end) of #1 LP cylinder, the third one is extracted after forth pressure stage (generator end) of #2 LP cylinder; the second steam extraction is extracted after fifth pressure stage of #1 LP cylinder, the first one is extracted after sixth pressure stage of #2 LP cylinder. HIP cylinder is a combined cylinder structure, and LP cylinder is symmetrical split flow type. HIP cylinder is designed as double shell structure, and LP cylinder is symmetrical split double cylinder structure, every LP cylinder consists of one outer casing and two inner casing. HP inner casing and IP inner casing are supported on the horizontal contact surface of HP outer casing, and they are positioned in axial by convex desk of inner casing lower half part and groove of outer casing, and be placed in traverse by dowel pin on top and bottom of outer casing, so as to make inner casing can expand and shrink freely in transverse and axial inside outer casing while the temperature changes. There are four casing lugs of HIP lower half outer cylinder, and are supported on the front bearing box and LP cylinder. Location pins exist inside #1 LP cylinder to ensure expansion. There are two axial key grooves and two transverse key grooves in middle of four sides of outer casing, and intersection point of said four key grooves center is the absolute dead point. Turning gear is located aside the generator end bearing box at #2 LP cylinder, turning speed is 2.38r/min. In order to reduce load of turning gear motor, each bearing of LP cylinder and generator are fed with HP jacking oil. Turbine HIP rotor and LP rotor are connected by rigid coupling. All 8 radial journal bearing are four tilting bearing bushes. Main oil pump and overspend trip device are connected with HP rotor by lengthening shaft. Thrust bearing is tilted type which located in front bearing box. . #7, #8 bearing of generator rotor are elliptical bearing bush on top and tilting bearing bush underneath. Bearing of collector ring rotor has four tilting bearing bushes. HIP rotor has balance piston to balance axial thrust. The arrangement and open sequence of main, reheat stop valve and governing valve refer to DOCUMENT NO. : HISAR-ZT-07
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below sketch map.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

GV 3-1

GV 4-1

3
GV 1-2

4
GV 2-3

1
TV 1

2
TV 2

From governing end to generator Governing valve


GV 4-1

Number of governing valve opens order Actual position number

Cooling type of unit is condenser surface cooling. Feed-water system comprises one 50%B-MC duty motor driven and two 50%B-MC duty BFP. Under normal work condition, two TBFP run and motor pump is standby. Each unit has 60%BMCR high-low pressure tandem connection bypass system, so as to quicken startup speed and protect re-heater during malfunction. Auxiliary steam system supply common steam to the whole plant. Pressure of auxiliary steam headers is 0.8~1.6MPa, and temperature 362. There is connection manifold connecting to auxiliary steam system of another boiler. The source of auxiliary steam system is from main steam or auxiliary steam system of adjacent boiler when unit startup or in low load, and be came from cold reheat under normal operation. Auxiliary steam system supply steam for soot blow of APH start-up, deaerator start-up, start-up and debugging of TBFP turbine, turbine gland, heating and trace heating of oil tank, fire protection blowing of pulverized coal system. 3.1.2 Main specification of turbine 3.1.2.1 Main Parameters No 1 2 3 4 5 6 7 Description Unit Data model N600-16.7/538/538 Type:subcritical, once intermediate reheat, single shaft, three cylinders, four exhaust hoods, condensing Rated power MW 600 Rated pressure/temperature of steam before MPa/ 16.67/538 main steam stop valve Rated pressure/temperature of Reheat steam MPa/ 3.432/538 Main/reheated steam flow with rated power t/h 1883.418/1605.329 Designed back pressure KPa 4.4/5.4
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Operation Manual for 600MW Unit


8 9 10 11 Rated/ average back pressure exhaust flow Temperature of cooling water Feed water temperature KPa Kgh

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

11.8/4.9 1032469 20max 33 279.5 7545/8045Working condition 12 Guarantee heat rate KJ/KWh as data plate 7(3 HP heaters + 4 LP heaters 13 Stages of feed water heater + 1 deaerator) 14 Rated speed r/min 3000 Clockwise(from turbine to 15 Rotation direction generator) DEH- 16 Model of governing system 48.550.5 17 Max. allowable frequency Hz 18 Flow passage stages stage 1+11+8+722 19 Length of last stage blade mm 905 20 Manufacturer Shanghai Turbine Works CO, Ltd 3.1.2.2 Extraction steam parameter of Rated powerTHA work condition No 8 7 6 5 Location of steam extracted Pressure (MPa) After eighth HP stage 5.886 Exhaust steam of HP cylinder 3.97 After fifth IP stage 1.814 After eighth IP stageexhaust 0.9434 steam of IP cylinder Temperatu re() 350.6 300.6 456.8 362.9 Flow(t/h) 103.568 142.067 60.02 78.135/87.0 64 81.828 60.847 35.866 35.866 Load part 7# HP heater 6# HP heater 5# HP heater Deaerator / Boiler feed water pump steam turbine #3 LP heater #2 LP heater #1A LP heater #1B LP heater

After second LP stage 0.3883 After fifth LP stage 0.05767 After sixth LP stage A LP 0.01555 cylinder 1 After sixth LP stage B LP 0.01555 cylinder 3.1.2.3 Critical speed of steam turbo-generator set Rotor name

4 3 2

254.2 84.94 54.75 54.75

First stage critical speedr/min Shaft Shaft section interconnected HIP rotor 1640 1610 LP rotor I 1680 1600 LP rotor 1690 1600 Generator rotor 820 763 3.1.2.4 Parameters of turbine by-pass system

Second-stage critical speedr/min Shaft Shaft section interconnected 4000 4000 4000 4000 4000 4000 2300 2200 Source of desuperheated water Feed-water Condensate water

Name of by-pass Pressure of Temp. of Steam system entrance /exit entrance /exit flow(T/H) HP by-pass system 16.7/2.41(MPa) 538/323() 2*622.8 LP by-pass system 2.21/0.588(MPa) 538/160() 2*500 3.1.3 Brief of main control systems 3.1.3.1 Unit operation control mode 3.1.3.1.1 Basic model (BM)

Basic mode is a relatively low-level control mode, used for unit startup and low load phase, DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

unit feed-water control manual or abnormal state. Under this mode, main control of turbine and boiler are manually by operator. 3.1.3.1.2 Boiler following turbine (BF) a. Boiler main control regulates main steam pressure automatically; while turbine main control adjusts unit power. b. When turbine main control is in manual, unit power shall be adjusted by operator manually or by DEH automatically, that is BF1 mode. c. When turbine main control is in auto, boiler main control received feedback signal of target load synchronously. Unit power is adjusted by turbine, target load is set by operator manually. That is boiler follow turbine mode BF2. 3.1.3.1.3 Turbine following boiler (TF) a. Turbine main control adjusts main steam pressure automatically; boiler main control adjusts unit power. b. when boiler main control is in manual, unit power depends on output load of boiler only. That is TF1 mode. c. when boiler main control is auto, both turbine and boiler main control received feedback signal of target load. Unit power is adjusted by boiler main control. 3.1.3.1.4 Coordinated control system (CCS) a. This mode is actually compound of BF and TF modes. Turbine and boiler main control must set to auto. b. Co-coordinated control based on BF: boiler main control adjusts main steam pressure, setting value of main steam pressure is set by unit sliding pressure curve; turbine main control adjust not only unit power but also main steam pressure, but its power adjustment coefficient is bigger than pressure adjustment coefficient; that is to say power adjustment is main, pressure adjustment is auxiliary. Target load is set by operator manually, boiler and turbine main control receive feedback signal of target load at the same time; and participate in primary frequency modulation of grid. c. Coordinated control based on TF: boiler main control adjust unit power, target load is set by operator manually; turbine main control adjust main steam pressure as well as unit power, but its pressure adjustment coefficient is bigger than power adjustment coefficient, that is to say pressure adjustment is main, power adjustment is auxiliary. Boiler and turbine main control receive feedback signal of target load at the same time; and participate in primary frequency modulation of grid. d. While unit normal running, it is better to adopt coordinated control mode. 3.1.3.2 Digital electro-hydraulic control system (DEH) (1) Main functions of DEHcontrol the opening of HP, IP main steam stop valves and

regulating valve, so that the unit can increase and reduce speed and load to realize all DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

requirements of unit operation. DEH device receive the signal of speed, power and primary steam pressure, closed loop control speed, power and steam flow of unit. Besides, DEH has other functions such as valve management, rotor stress calculation, parameter monitoring, over-speed protection, auto startup and stop control, etc. (2) Operation control mode a. Operator automaticOPER AUTO mode: setting and its change rate are set by operator on DEH operation board. b. Automatic Turbine Control ATC: ATC can complete turbine acceleration, warming, valve switchover, synchronization and take initial load automatically, then turn to OPER AUTO. During unit load changing, ATC can be put into running, and the change rate of its setting will be decided by control software. During normal running, ATC monitors all parameters, show information and stress calculation of unit automatically. c. REMOTE: setting is given by external systems such as CCS. Other operation will be completed by DEH. d. Automatic synchronization AUTO SYNC: adjust settings by receiving rise and decline signal from synchronizer, so as to make turbine generator unit reach synchronized rotate speed, for the convenience of unit synchronization. e. Turbine Manual (TM): control turbine by manual operating the opening buttons of all main steam stop valves and regulating valves. There are primary manual and secondary manual (it is forbidden while unit speed-up). 3.1.3.3 TSITurbine Supervisory Instrumentation The device supervises the axial displacement, differential expansion, absolute expansion, shaft vibration, speed, eccentricity, etc. of turbine rotor; and compares and judges measuring values; give warning signal and trip signal while exceed limit. 3.1.3.4 (ETS) Emergency Trip System When the steam turbine operating parameters exceed the safety limits (such as: vacuum low lube oil pressure low, EH oil pressure low, rotor axial displacement exceed, over-speed and other trip parameters), ETS will release the pressure oil of hydraulic servomotor to quickly turn off the HIP main steam stop valve and regulating valve so as to ensure the unit safety operation. The system uses a dual-channel design, allowing online tests of important signal, it still have protection function when online tests, and the reliability of the system is improved with no malfunction and rejection. 3.2 Interlock and test of steam turbine 3.2.1 Contents of interlock

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No 1 Equipment Name Emergency governor Type Electric (solenoid valve 20AST) Mechanical (1 eccentric rod) Axial displacement checking Pressure switch Pressure switch Solenoid valve 20AST Mechanical Solenoid valve OPC

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Actuated Conditions More than 110% rated speed Displacement 1.00mm Vacuum higher than -68.7KPa Oil pressure lower than 0.06MPa

2 3 4 5 6 7

Thrust bearing protector Low vacuum protector Low lube oil pressure protector remote electric trip button Local manual trip handle Over-speed protection (OPC

Shaft vibration protector 3.2.2 Unit interlock relationship a. Turbine trip Generator trip if unit load 35%, boiler MFT b. Generator trip c. Boiler MFT 3.2.3 Interlock test 3.2.3 Condenser vacuum tightness test turbine trip Turbine trip generator trip

Speed more than 103% rated speed or while IP exhaust pressure higher than 30% rated pressure (unit load higher than 30% rated) and oil switch tripping appear synchronously More than 0.254mm

if unit load 35%, boiler MFT

a. Make sure unit load is more than 80% rated load, unit running is stable, condenser pressure 10KPa. b. Check local, CRT and DEH vacuum values are the same. c. Record data as unit load, condenser exhaust temperature, condensate water temperature, vacuum value, etc. d. Unlock the interlock of HP and LP condenser vacuum pump, stop vacuum pump running (or close inlet hand-operated valve of vacuum pump) e. Record condenser vacuum value every minute. f. Test will last 3~5mins, start up vacuum pump after test. g. Use the average condenser vacuum value of the middle 3mins to analyze condenser tightness: vacuum reduction valueP0.133KPa/min, excellent; P0.266KPa/min, good; P0.399KPa/min, acceptable. h. If condenser vacuum falls to -87KPa or vacuum declining speed 0.67KPa/min or LP cylinder exhaust temperature is higher than 55 during test, test shall be stopped immediately and vacuum pump shall be put into running to maintain normal vacuum. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

i. After test, report to shift supervisor, and analyze and record the test result of vacuum tightness test. 3.2.3.3 Valve action test of HP, IP main steam stop and regulating valve 3.2.3.3.1 Conditions of valve action test a. Get the permission of shift supervisor, contact I&C personnel to site. b. Load up to 60% and keep stable, boiler combustion is stable, and unit running is normal. c. Make sure DEH mode is at OA and single valve, control mode is bypass cutting, power loop is put on. d. Check the position of HP, IP main steam stop valve and governing valve. 3.2.3.3.2 Test method and precautions (1) HP main steam stop valve action test a. Click TV1 window, open sub-page of main start test, TV1 will close slowly. b. When TV1 valve opening is above 60%, press stop test button to maintain main steam stop valve or cancel test button to reopen valve. c. When TV1 valve opening less than 60%, display CONTINUOUS TV TEST (continue test). d. If operator decides to continue test, press CONTINUOUS TV TEST button, GV1, GV3 will close slowly, and GV2, GV4 rise slowly. GV1 and GV2 turn to 0 opening and then 2 seconds delay; TV1 will close rapidly and then fully open at once. Click CANCEL TEST button, GV1, GV3 and GV2, GV4 return to original opening slowly. e. Test method of TV2 is the same as that of TV1. (2) HP regulating valve action test a. Click GV1 to open sub-page b. Click START TEST button, GV1 will close slowly until completely turn off. c. Click STOP TEST button can stop test, and press CONTINUOUS TEST button can continue. d. Click CANCEL TEST button, GV1 valve open. e. Test GV2, GV3, and GV4 by the same method. (3) IP stop valve, IP regulating valve action test a. Open VALVE TEST control sub-page from DEH control menu. b. Press RV1 button on valve control window. c. Click START TEST button, IV1 and IV3 will close slowly, then RV1 close. d. After 2 seconds delay, RV1 open automatically. e. Click CANCEL TEST button, IV1 and IV3 open slowly. f. Test RV2 and IV2, IV4 by the same method. Remarkafter all tests above completed, put on DEH remote control, coordination and AGC. 3.2.3.4 Steam turbine ETS channel test DOCUMENT NO. : HISAR-ZT-07
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steam valve test (TV1 VALVE TEST), then click

Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

3.2.3.4.1 EH oil pressure low (lube oil pressure low, vacuum low, axial displacement, vibration) ETS system channel test a. I&C personnel shall attend when ETS channel test start. b. Check all alarm light on ETS test panel shall be off. c. Press START TEST function button on ETS panel to start test mode, display light of this button on panel shall be turned on. d. Press function buttons which need to be tested (such as EH oil pressure low, lube oil pressure low, vacuum low, panel shall be turned on. e. Press channel 1 or channel 2button corresponds to the testing channel, that corresponding display light on panel shall be turned on. f. Press test confirmation button to start test. g. Make sure lighting corresponding channel is in action (namely alarm light of corresponding channel is on). h. Press reset test button to reset corresponding action channel. i. Make sure testing channel is not in shutoff state any more (namely alarm light of corresponding channel is off), press quit test function button to quit test mode. j. Test completed, start another channel test as above method. 3.2.3.4.2 Electric over-speed function ETS system channel test a. I&C personnel shall attend when ETS channel test start. b. Check all alarm light on ETS test panel shall be off. c. Press START TEST function button on ETS panel to start test mode, display light of this button on panel shall be on. d. Press over-speed 1over-speed channel, over-speed 1channel display light on panel shall be on. e. Press test confirmation button to start test. f. Make sure electric over-speed CH1 channel alarm light shall be light. g. Press reset test button to reset corresponding action channel. h. Make sure electric over-speed CH1channel alarm light is off, press quit test function button to quit test mode. i. over-speed 2 over-speed 3channel tests are the same as above. 3.2.3.5 Lube oil pressure low shutdown protection test (this test shall be done before turbine reset start and rolling up) a. Start turbine A.C. lube-oil pump and HP seal oil stand-by pump. b. Start EH oil pump. c. Contact I & C personnel to relieve vacuum low, MFT, etc. protection signal. d. Make sure no sound & light alarm on ETS panel. DOCUMENT NO. : HISAR-ZT-07
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axial displacement, vibration, etc.), corresponding display light on

Operation Manual for 600MW Unit


e. select unit start up mode with respect to bypass state. f. Latching, check if valve state meets the requirements.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

g. Check and open inlet valve of lube oil pressure low tripping test block. h. Slowly open channel oil drain valves of test block 63-1/LBO and 63-3/LBO. i. When #1, #3channel oil pressure of test block drop to 0.06MPa. j. Lube oil pressure CH1 and Lube oil pressure CH3 alarm light on ETS panel are on. k. Slowly open channel oil drain valves of test block 63-2/LBO and 63-4/LBO. l. When #2, #4 channel oil pressure of test block drop to 0.06MPa, Lube oil pressure CH2 and Lube oil pressureCH4 alarm light on ETS panel are turned on . m. Check AST solenoid valve is de-energized, turbine is tripped. First-out shutoff signal LBO (lubricant oil)alarm light on ETS panel is on. n. Close oil drain valve of test block. o. Check the oil pressure gauge of test block, pressure should be back to normal. p. Check alarm light of Lube oil pressureCH1, Lube oil pressureCH3, Lube oil pressureCH2 and Lube oil pressureCH4on ETS panel are off. q. Check the first-out shutoff signal LBO (lube oil)alarm light on ETS panel is off reset ETS panel. r. Test complete, recover the system to the state before testing. 3.2.3.6 EH oil pressure low shutdown protection test (this test shall be done before turbine reset start and rolling up) a. Start turbine A.C. lube-oil pump, check if system running is normal. b. Start one EH oil pump, check if system running is normal. c. Contact I & C personnel to relieve vacuum low, MFT, etc. protection. d. Decide unit startup mode with respect to bypass state. e. Latching, check if valve state meets the requirements. f. Open inlet valve of EH oil pressure low tripping test block. g. Slowly open oil drain valve of test block 63-1/LP and 63-3/LP channel. h. When #1, #3 channels oil pressure of test block drop to 9.31MPa, alarm light EH oil pressure CH1 and EH oil pressure CH3 on ETS panel will be turned on. i. Slowly open oil drain valve of test block 63-2/LP and 63-4/LP channel. j. When #2, #4 channels oil pressure of test block drop to 9.31MPa, alarm light EH oil pressure CH2 and EH oil pressure CH4 on ETS panel will be on. k. Check four AST solenoid valves are de-energized, turbine is tripped, first-out shutoff signal LP (EH oil pressure low)on ETS panel gives an alarm. l. Close oil drain valve of test block; check the oil pressure gauge of test block, pressure should be back to normal. m. Check EH oil pressure CH1, EH oil pressure CH3, EH oil pressure CH2, EH oil DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

pressure CH4 and LP (EH oil pressure)alarm light on ETS panel shall be off. n. Reset ETS panel. o. Test completed, back to original operation mode. 3.2.3.7 OPC test 3.2.3.7.1 OPC solenoid valve test (this test shall be done before turbine reset start and rolling up) a. Before unit start-up, contact I&C personnel relieve the protection of ETS, boiler MFT, etc. Reset ETS panel, no alarm light is on. b. Contact I &C personnel to put DEH system into running. c. Start turbine A.C. lube-oil pump and HP seal oil stand-by pump into normal running. d. Start EH oil pump A (or B) into normal running e. Start compressed air system into normal running f. Open the non-return Valves of all extractions and HP cylinder exhaust check valve. g. Check if DEH system is at OA mode. h. Turbine latching check and open GV, IV, RV, TV. i. Set OPC protection test switch at ON position, OPC solenoid valve action. j. Check GV1-4, IV1-4 should be closed rapidly, without jamming. k. At the same time, all extraction non-return valves and HP cylinder exhaust check valve shall be interlock closed, without jamming. l. Set OPC protect test switch to Cut position. m. Check if GV, IV and extraction non-return valves are open. n. Recover the released protection during test, check and put in OPC protection switch. 3.2.3.7.2 OPC dynamic test (103% over-speed protection function test) a. unit synchronized to grid with load 60MW, then trip generator when warming for 4 hours. b. DEH system is at OA mode. c. drop load to 15MW as normal load reduction shutdown steps. d. Set OPC protection switch at ON position. Contact electrical operator to disconnect generator. e. Set target speed as 3100r/min at DEH speedup control window. f. Set speed acceleration as 50r/min, press START button, light on. g. When speed rise to 3090r/min, OPC protection shall work, GV1-4, IV1-4 close. h. Make sure unit speed is declining, record speed while OPC protection act. i. Check DEH controller and set target speed as 3000r/min. k. Supervising that when actual speed down to target speed, GV, IV shall open automatically. l. Maintain unit speed at 3000r/min. 3.2.3.8 Turbine over-speed test 3.2.3.8.1 Test rule and precautions DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

a. over-speed test must be done under following conditions, e.g. turbine initial startup, after overhaul or continuous running for 12~24 months or after maintenance of governing system, so as to ensure correct action of emergency governor b. Test shall be done after completion of all the following tests and ensure actions are correct., that are, tightness test of HIP stop valve and regulating valve, manual Emergency Shutdown Button test in control room, local manual tripped test and oil filling test, c. During test, it is necessary to supervise unit speed, vibration, lube oil pressure, lube oil temperature, beating pad temperature, axial displacement, LP cylinder exhaust temperature , etc. parameters. d. During test, when turbine speed rise to 3360r/min but protection does not act, it is necessary to trip manually at once, then check that whether turbine steam has been cut and speed has slowed down. e. Mechanical over-speed and electrical over-speed test shall be done twice respectively; speed difference between two tests shall not be more than 18r/min (0.6%). f. After over-speed trip, turbine speed less than 2900r/min. Latch and startup again, acceleration rate can be selected at 250~300r/min. g. During over-speed test, back pressure of turbine shall be less than 12KPa. h. Before over-speed test, it is necessary to on load 60MW and warming for 4 hours, and then disconnection. 3.2.3.8.2 Electrical over-speed test a. Check that DEH system is at OA mode. b. Start turbine A.C. lube-oil pump and HP seal oil stand-by pump into normal running. c. Drop load to 15MW as normal load reduction shutdown steps. d. Contact electrical operator to disconnect generator. e. Check that electrical over-speed cut light on ETS panel shall be off. f. Set OPC over-speed protection switch on CUT position. g. Press target value button, light on, set target speed as 3300r/min. h. Set speedup rate as 300r/min, press START button, light on. i. When speed up to 3300r/min, electrical over-speed protection shall act, TV, RV, GV, IV shall close rapidly. j. Make sure unit speed is declining, record the speed of electrical over-speed protection action. k. When unit speed declines to less than 3000r/min, latch again, maintain unit speed as 3000r/min. l. Set OPC over-speed protection switch at IN position, end test. 3.2.3.8.3 Mechanical over-speed test a. Carry out preparation work as electric over-speed test steps a-d. b. Unit speed 3000r/min, main steam parameter8~10MPa. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

c. Check ETS panel, Electric over-speed cut light shall be on (When mechanical over-speed action g speed > electric over-speed action rotating speed). d. Set OPC protective switch of DEH panel at CUT position. e. Set target speed as 3330r/min, set speedup rate as 300r/min, press Start button, light is on. f. Mechanical over-speed protection acts when speed reaches 3330 r/min, TV, GV, IV, RV shall close rapidly. g. Record the action speed of emergency governor. h. If mechanical over-speed protection does not act when rotating speed reaches 3360r/min, it is necessary to trip and shutdown manually. Do not startup until reasons have been found out. i. Set OPC protection switch of DEH panel, over-speed protection switch of ETS panel at IN position. j. Unit comes back to 3000r/min, synchronization after checking. On load as normal startup procedures. 3.2.3.9 Stop valve, regulating valve tightness test 3.2.3.9.1 Tightness test of stop valve, regulating valve shall be done in the following conditions: a. Before and after unit overhaul. b. Before over-speed test c. Before load dump test d. Do stop valve, regulating valve tightness test annually during operation. 3.2.3.9.2 HPIP stop valve tightness test a. Ensure the starting parameters of unit and all systems meet the requirements of unit rolling up. b. Adopt DEH OA mode, speed up turbine speed to 3000r/min by HP and IP cylinders combined rolling up starting mode. c. Check that operation of all equipments and oil system running is normal. d. Control main steam pressure and reheating steam pressure is above 1/2 rated pressure by bypass system. e. Set DEH control panel to Manual. f. Close HP and IP stop valves at engineer station, fully open regulating valve. Check that bypass trace governing is normal. g. Record the stable speed after speed decline. h. If speed declines to less than 1/3 of rated speed 1000r/min, that means tightness test of stop valve is accepted. 3.2.3.9.3 Tightness test of HP and IP regulating valves a. After completion of HP stop valve tightness test, speed up to 3000r/min again at DEH AUTO mode. b. Check that operation of all equipments is normal, oil system running is normal DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

c. control main steam pressure and reheating steam pressure above 1/2 of rated pressure by bypass system. d. Set DEH control panel as Manual. e. Close HP and IP regulating valves at engineer station, fully open stop valve. Check that bypass trace governing is normal. f. Record the stable speed value after speed decline. if speed declines to less than 1/3 of rated speed 1000r/min, that means tightness test of regulating valve is accepted. g. Speed can be calculated by following formula: test pressure rated speed/ rated pressure = stable speed under test pressure 3.3 startup of turbine 3.3.1 Preparation before turbine startup 3.3.1.1 When the unit start instructions are sent, all the operators must be ready for all the preparation before start. 3.3.1.2 Ensure that all the maintenance work has completed and the work ticket have been taken back. 3.3.1.3 Ensure that all interlocks tests of unit are accepted. 3.3.1.4 Check that control power supply, motor power supply, signal power supply of all auxiliary systems is o.k. 3.3.2 Basic rules for turbine start 3.3.2.1 Definition of turbine start modes Cold start means the metal temperature of HP inner casing governing stage and blade carrier of IP casing first stage is below 204 Celsius degree, while hot start represents the temperature above 240 Celsius degree. 3.3.2.2 No starting conditions a. any unit trip protection is abnormal. b. DEH is abnormal which affect unit startup, shutdown, normal operation and the control can only in manual mode.. c. DEH device cannot maintain idling of turbine, or rotating speed increasing rapidly to exceed actuation speed of emergency safety governor after load dumping. d. Oil filling test or over-speed test of safety governor is not accepted. e. TSI turbine supervisory instrument is abnormal. f. Turbine protection of water induction system is abnormal. g. Action of safety governor is abnormal; and action of main stop valve, governing valve, HP exhaust check valve, extraction check valve is abnormal. h. Expansion of unit is abnormal. i. Eccentricity of rotor is abnormal; rotor eccentricity is over 0.076mm (duplex deviation) before rotor running. DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

j. Oil quality is rejected or oil temperature is lower than set value. AC lubricant pump cannot be started when it is lower than 10 ; turning gear cannot be used when it is lower than 20. When EH oil temperature is lower than 10, it cannot be put into system; when it is lower than 21, long term running is not suitable. k. Oil level in turbine Lube and EH oil tank are lower than stated value. l. Any one of EH oil pump, AC lubricant pump, DC lubricant pump, turning gear is broken or any self-starter of them is broken. m. CCS coordinated control system is abnormal, which effect the operation of unit and it cannot be restored in a short time. n. Main instruments (rotating speed, vacuum, pressure and temperature of main/reheat steam, EH oil pressure, lubricant oil pressure, sealing oil pressure, axial displacement, rotor eccentricity, vibration, cylinder expansion and differential expansion of cylinder, etc.) are missing or failure with no other supervisory methods. o. Compressed air system is abnormal p. Bypass regulating system is abnormal. q. Temperature difference of HIP upper and lower casing is more than 42 . r. Rotating part of T/G unit has obvious frictional noise or turning gear current sway large amplitude with value over normal obviously, and the reason is not motor after checking. s. HIP differential expansion exceeds. t. Steam/water quality is rejected. 3.3.2.4 Selection of turbine starting control mode a. Generally, DEH OA mode is adopted for unit cold start; while DEH OA mode or ATC mode is adopted for hot start. b. After unit synchronization with 26% rated load, put DEH remote control to operation after its conditions are met. c. CCS adopts TF mode. When load increase to 28% rated load, CCS mode was selected. 3.3.2.5 Starting bypass rules Starting without bypass mode is HP cylinder starting mode. Rotating speed and load are controlled by main stop valve (before valve switchover) or HP governing valve (after valve switchover and on load stage); IP governing valve shall be fully open after latching, and only be actuated when protection. Starting with bypass mode is HP and IP cylinder combined starting mode. In this mode, IP governing valve play a role as controlling rotating speed and load, and it shall be fully open at about 35%~40% rated load. After unit latching, reheat main stop valve shall be fully open, operator open IP governing valve fully and totally close main stop valve by valve position limiter. rotating speed can be controlled to 600 r/min by IP governing valve and maintain for some time; then switched to main stop valve/IP governing valve control; at last to turn to valve change while DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

main stop valve/HP governing valve transition. After unit synchronization and the load reaches 35%40% rated load, IP governing valve shall be fully open, and bypass operation mode can

be cut when IP governing valve is full open. 3.3.3 Cold start 3.3.3.1 Before auxiliary equipment and system being put into operation, relevant preparation, inspection and operation before starting shall be done. 3.3.3.2Before boiler ignition, confirm startup and operation state of turbine auxiliary equipments and systems as per the following procedures: a. Water level of 500m3 water tank is normal, put one condensate transfer pump in operation and other two pumps as standby. b. Put closed cooling water system into operation, and water filling and vent of all coolers are over, and valves state is normal. c. Ensure that industrial water, potable water for circulation pump cooling water system operation is normal, put circulating water system into operation. d. Put open cooling water system into operation, put auto control of open cooling water electric water purifier into operation. e. Put closed cooling water pump into operation. f. Put instrumental compressed air system into operation, check the air pressure. g. Put main oil system into operation, and start AC lubricant oil pump and HP seal oil standby pump into operation. h. Put generator sealing oil system into operation, start either one AC sealing oil pump at air hydrogen side into operation. i. Start jacking oil pump, and put turbine turning gear into operation, it is required that continuous gear turning shall be above 4 hours before turbine running to speed,. j. Gas substitution inside generator shall be completed, put stator water system into operation while hydrogen purity above 96% and pressure reaches 0.2MPa. k. Put auxiliary steam system into operation. l. Check if the water level in condenser is normal; put condensate water system into operation. m. When condensate water quality is accepted, fill it into deaerator until the water level is up to normal. n. Heat feed-water in tank to 110; start electric feed-water pump, fill water from HP heater water side. o. Put two BFP oil systems into operation. Continuous turning of BFP turbine shall be more than 3 hours before boiler firing. Steam, drain and shaft seal system of two BFP turbines shall be available before put into operation. p. EH oil system is normal and put into operation. q. Shaft seal system is at standby state, put water side of gland steam condenser into operation. DOCUMENT NO. : HISAR-ZT-07
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Put gland steam system into operation before air extraction.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

r. Vacuum system shall be at standby state, start vacuum pump and close vacuum breaker valve, and then extract vacuum from main and BFP turbine before boiler firing. s. After vacuum is formed in condenser, open all the drain valves of main steam, cold reheat steam, hot reheat steam, extraction steam pipes and cylinder body. t. Make sure all preparation works before turbine startup have been completed and running equipments and systems are working normally, standby equipments and systems are ready for operation. 3.3.3.3 Boiler ignition, heat-up & pressure-up, put bypass system into operation as per boiler procedure. 3.3.3.4 Check following main protection of running turbine a. Trip, while lubricant oil pressure below 0.06MPa. b. Trip, while EH oil pressure below 9.31MPa. c. Trip, while vacuum of condenser below --68.7KPa. d. Trip, while axial displacement above 1mm. e. While rotating speed reaches 3300r/min, electric over-speed protection acts and trip. f. HP cylinder differential expansion value is at +10.2mm or minus 4.5mm, governor shutoff; LP cylinder is at +16mm and minus 1mm for shutoff. g. Trip while shaft vibration above 0.254mm. h. Trip while bypass has been put into operation and ratio of governing stage pressure to HP exhaust pressure is less than 1.7. i. Trip while HP exhaust temperature is higher than 427; return oil temperature of turbine radial bearing and thrust bearing is 82; turbine radial bearing metal temperature is 113; and turbine thrust bearing metal temperature is 107 . j. Temperature difference between upper and lower HIP cylinder is greater than 56. 3.3.3.5 Turbine rotor running 3.3.3.5.1 Cold rotor rolling up conditions a. Parameter: main steam pressure is 6.0Mpa with temperature 335; reheat steam pressure is 1.1Mpa with temperature 315. And main steam, reheat steam have more than 56 degree of superheat. Absolute pressure of condenser exceeds 74KPa. b. Lubricant oil temperature is range within 3842, lube oil pressure is within 0.10.15MPa, oil return of all bearing is normal. c. EH oil pressure is not less than 14MPa, temperature is 4045, and EH oil system operation is normal. d. Temperature difference between upper and lower cylinder is less than 42. e. Eccentricity of shaft is not greater than 0.076mm or less than original value 0.02mm. f. Ensure turbine diaphragm valve upper casing oil pressure is 0.50.8 MPa. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

g. LP heater shall be started in random, open LP heater extraction motor-operated valve, drain water flow from higher stage to lower one. h. HP heater shall be started following the unit, open HP heater extraction motor-operated valve, drain water flow from higher stage to lower one. 3.3.3.5.2 HIP cylinder combined start (turbine startup with bypass) a. Check that if bypass system auto control is normal. b. Select OA mode on DEH control panel. c. Turbine latch, ensure GV, RV are fully open and TV, IV are full closed. Pay attention to turbine rotor speed ascending; check that HP exhaust check valve is closed and HP cylinder exhaust valve is open. d. Trip manually then latch again. Set target rotating speed as 600r/min and speedup rate as 100r/min, turbine speedup is controlled by IV, when rotating speed of turbine is faster than that of turning gear, turning gear shall quit automatically, otherwise trip and shut down. Check the reasons, and restart until the problems being eliminated. e. Turning gear quit, unit trip when rotating speed reaches 500r/min, listen friction sound inside. f. Make sure no abnormal sound inside cylinder and shaft seal, when the speed reducing to 200r/min and unit latch again, set target speed to 2800r/min and rate 100r/min. h. Speed up to 600r/min, maintain turbine rotating speed at 600r/min for 15~30mins, DEH record stable flow of IP cylinder as F1, switchover control mode from IV to TV-IV mode, open TV and IV as the ratio 1: (1+F1) to control rotating speed together, jacking oil pump shall stop automatically, exhaust valve of HP cylinder inlet pipe shall be closed, put spray governing valve auto control into operation, LP cylinder water spray valve shall open. i. When turbine rotating speeds up to 2600r/min, keep 3 mins. DEH record the opening of IV valve at this time, and then IV opening is frozen, only can be modified as per hot reheat steam pressure (when reheat steam pressure changes, IV moves so as to maintain constant flow rate of IP cylinder, ensure cooling of LP cylinder blades and through flow). Control mode is switched over from TV-IV to TV automatically. j. Rotating speed reaches 2900r/min, when wall temperature of inlet chamber is higher than the saturated temperature at main steam pressure, click valve control mode, then click valve switchover. k. Observe valve switchover process by DEH control screen, TV/GV switchover time 2 mins, after completion, check on the spot that TV is full open and GV is in regulating behavior, rotating speed shall maintain 2900r/min. l. Set target rotating speed as 3000r/min, speedup rate as 50r/min on DEH control menu, speed up to 3000r/min. m. After turbine speed up to 3000r/min, check all bearing temperature, return oil temperature, vacuum, vibration, differential expansion, axial displacement, etc. shall be normal, boiler shall DOCUMENT NO. : HISAR-ZT-07
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adjust burning to prepare unit parallel operation and initial loading. 3.3.3.5.3 HP cylinder start up (turbine startup without bypass) a. Select OA mode on DEH control panel.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

b. Turbine latching, make sure GV, RV, IV are full open, TV is full closed, HP exhaust check valve is closed. c. Trip manually then latch again. Set target rotating speed as 600r/min, speedup rate as 100r/min, turbine speedup is controlled by TV, when rotating speed of turbine is faster than turning gear speed, turning gear shall quit automatically, otherwise trip and shut down. Check the reasons, restart rushing turning after the problems being eliminated. d. After turning gear has quit, unit trip while rotating speed reaches 600r/min, start friction sound inspection. e. When everything is right, unit latching again, set target rotating speed as 2800r/min and rate as 100r/min. f. Rotating speed reaches 2900r/min, when wall temperature of inlet chamber is higher than saturated temperature of main steam pressure, click valve control mode, then click valve switchover h. Observe valve switchover process by DEH control screen, TV/GV switchover time is not greater than 2 mins, then check on the spot that TV is full open and GV is in controlling state, rotating speed shall maintain 2900r/min. i. Set target rotating speed as 3000r/min, speedup rate as 50r/min on DEH control menu, and speed up to 3000r/min. j. After turbine speed up to 3000r/min, check all bearing temperature, return oil temperature, vacuum, vibration, differential expansion axial displacement and so on are adjust combustion to be ready for synchronization with initial load. 3.3.3.6.3000r/min constant speed a. Stop AC lubricant oil pump and HP standby sealing oil pump, and pay attention to the change of lubricant oil pressure, and put interlock. b. Carry out tightness test of main stop and governing valve as required. 3.3.3.6Generator synchronization and take 5% initial load. 3.3.3.6.1 Unit synchronization conditions are ready, report to shift supervisor, put generator in operation after get permission. 3.3.3.6.3 If automatic synchronization is adopted, press auto synchronization button in DEH control mode. DEH is controlled by AS until unit synchronization. 3.3.3.6.4 If manual synchronization is adopted, rotating speed shall maintain 3000r/min. 3.3.3.6.5Confirm that initial load of generator is 30MW after synchronization. 3.3.3.6.6 Keep running 15~30 mins for warming with 5% load. 3.3.3.6.7 Check that turbine vibration, differential expansion, absolute expansion, axial DOCUMENT NO. : HISAR-ZT-07
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normal, boiler shall

Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

displacement and all bearing metal temperature are normal, lube oil pressure, all bearing return oil temperature, EH oil pressure are normal; temperature difference of cylinder upper and lower wall is within allowable range. 3.3.3.6.8 Applying HP, IP combined start check if regulating of HP and LP bypass is normal with the load change. 3.3.3.6.9 Check that operation of stator cooling water system and hydrogen cooling system is normal, put hydrogen drier into operation. 3.3.3.6.10 Check and prepare one BFP turbine, and make it in ready state. 3.3.3.7 Main operations during load rise 3.3.3.7.1 Increase load at 4~6MW/min load rise rate. 3.3.3.7.2 When unit load is larger than 60MW, check all drain valves before IP main stop valve shall be closed automatically; while load is larger than 90MW, check LP cylinder water spray valve shall be auto closed. 3.3.3.7.3As unit load is larger than 90MW; make sure BFP steam source has more than 20 degree of superheat. 3.3.3.7.4 As unit load is 120MW, make sure HP drain valve is closed. 3.3.3.7.5 When load is 170MW, make sure bypass is closed, put DEH to remote control when the preconditions are met. 3.3.3.7.6 When load is 180MW, put BFP and reduce the output of electric pump. Cut power loop and pressure loop, put TF co-coordinated control mode. Switch over to station service power. 3.3.3.7.7 While four section extraction pressure 0.2Mpa, heating source of deaerator shall be supplied by four section extraction steam. 3.3.3.7.8Auxiliary steam header to be supplied by cold reheats steam; close the steam from startup boiler. Pay attention to the steam source of turbine and feed-water pump turbine vacuum and shaft seal. 3.3.3.7.9 Check and prepare second turbine driven feed-water pump, and make it in standby state. 3.3.3.7.10 While load is 210MW, as per unit cold start pressure curve, maintain turbine governing valve opening at about 90%, and unit to be shift to sliding pressure operation. 3.3.3.7.11 when unit load is 300MW, add second T-BFP, and steam source shall be changed to fourth extraction steam. Stop motor driven BFP. 3.3.3.7.12 when the fourth extraction steam pressure is higher than 0.8MPa, steam supply of auxiliary header shall be changed to fourth extraction steam, and cold reheat steam shall be put into standby. 3.3.3.7.13 When load reaches 450MW, check self-sealing of shaft seal system, shaft seal header pressure shall be controlled in 22~32KPa by overflow valve. DOCUMENT NO. : HISAR-ZT-07
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3.3.3.7.14 Set unit load as per dispatching requirement, put AGC. 3.3.3.7.15 Carry out overall inspection for unit. 3.3.4 Hot startup precautions

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

3.3.4.1 Before hot startup, check and preparation, starting key points, operation, etc. are the same as cold startup. 3.3.4.2 Before unit hot startup, turbine shall be at continuous turning state. If turning gear needs to be stopped for some reasons, four hours continuous turning again is necessary. 3.3.4.3 Put shaft seal first and then vacuum pumping, so as to avoid quickly cold of turbine rotor. Temperature difference between steam supply of HIP cylinder shaft seal and metal temperature of HIP rotor shall be not higher than 110. 3.3.4.4 Confirm rolling parameter as per cylinder temperature. Make sure main steam temperature shall be 50100 higher than that of governing stage metal, and at least 56 degree of superheat. 3.3.4. 5 Reheat steam temperature shall be 50 higher than IP blade carrier metal temperature, and at least 56 degree of superheat. 3.3.4.6Maximum mismatch between steam temperature and first stage metal temperature shall be not more than 56110. 3.3.4.7 Unit rolling speed up to 600r/min, check everything is normal. Speed up to 2800r/min with 150 300r/min acceleration. Then start valve switchover, speed stabilization, also synchronization and on load rapidly. Add load to the corresponding load of cylinder temperature during cold sliding startup, then increase temperature, pressure and load as per cold sliding startup curve. 3.4 Turbine normal operation 3.4.1 General principles 3.4.1.1 During turbine operation, attendants shall obey all stipulation in operation regulation to ensure unit safe and economical operation. 3.4.1.2 Turbine operation shall accord with the regulation of all limitation. Attendants shall pay close attention to turbine operation parameter, once the parameter are exceeding limit, it is necessary to find out reasons and dispose at once. Make the equipments operation back to normal soon and record time and reasons of exceeding limit. Dispose as per accident disposal rules strictly. 3.4.2 Main parameter and limitation of turbine normal operation Item Unit Rating Unit MW Normal Value 600(full load) Alarm High Limit Low Limit Trip Value Remarks DEH can set high and low limit

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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Main Steam Pressure MPa Reheat Steam MPa Pressure Governing Stage MPa Pressure Main Steam Temp. Reheat Steam Temp. Temp. difference of main & reheat steam Temp. difference between inner & outer wall of steam chest Temp. difference between upper & lower HIP outer cylinder HP cylinder exhaust temp. HP differential mm expansion LP differential mm expansion Bearing vibration mm Axial displacement mm LP cylinder exhaust temp. Condenser pressure Lube oil pressure Lube oil temp. Bearing temp. Thrust bearing temp. Return oil temp. EH oil pressure EH oil temp. EH oil level KPa MPa MPa mm

24.2 3.73 10.13 538 538 14

25.4 4.1 11.25 545 545 28 83 530 530 565 565

Moment shall less than 31.4MPa.

42 less than 15min

42 404 +8-2 020 0.076 0.6 65 4.9 0.0960.124 4045 90 80 65 140.5 3760 438.15-558.5 +9.5/-4 +22.5/-1. 4 0.127 0.89 79 16.9 49 107 99 77 11.03 60 558.5 0.082 35

56

427 +10.2/-4. 8 +23.3/-2. 2 0.254 1.0 121 operation 15min 20.3 0.048 113 107 82 9.31 37 438.15/29 193.54 5.15 1.7

governing stage and HP cylinder exhaust MPa pressure ratio Gland steam pressure KPa Gland steam temp. Unit rotating speed r/min 3.5 Shutdown of turbine

2230 149 3000

32 177

20 121 3300

3.5.1 Preparation before shutdown 3.5.1.1 Preparation before load reduction 1. Make sure steam supply of auxiliary steam header has been switched to startup boiler (or adjacent unit). DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2. Commissioning of unit AC, DC lube oil pump, jacking oil pump, turning gear, HP standby sealing oil pump, etc. are normal. 3. Warming of shaft seal pipeline. 3.5.1.2 Precautious during load reducing 1. Reduce temperature and release pressure as per sliding shutdown curve by boiler. 2. Superheat degree of main steam shall be controlled as higher than 80, but not lower than 56. Pay close attention to the temperature reducing speed of steam and cylinder wall. When boiler outlet steam temperature reduction reaches 50 and temperature drop rate higher than 10/min, shut down unit. 3. Control temperature drop speed of main, reheat steam 1/min, temperature drop rate of metal shall be 0.51 /min. 4. During load reduction, pay close attention to turbine differential expansion, axial displacement, temperature difference between upper and lower cylinder, all bearing vibration and bearing bush temperature which shall be within stated range; otherwise shut down unit. 5. Maintain water level of condenser, deaerator and HP & LP heaters, and condenser vacuum and exhaust temperature is normal. 6. Adjust gland steam pressure to normal in time. 7. Maintain generator seal oil pressure, hydrogen pressure, stator cooling water temperature, and so on to normal 3.5.1.3 Reduce load to 300MW or so, auxiliary steam and fourth extraction steam to be sourced by cold reheat. And gland steam can be supplied by auxiliary steam as per requirement. 3.5.1.4 Reduce load to 270MW, start motor driven BFP, stop one TBFP. 3.5.1.5 Reduce load to 180MW, stop another one T-BFP.. 3.5.1.6 When load is reduced to 180MW or so, stop HP heater. 3.5.1.7 Reduce load to 120MW, put HP and LP bypass systems into operation. 3.5.1.8 Reduce load to 120MW, check the drain valves which pressure below fourth extraction steam can be open normally, and switchover of deaerator steam supply is normal. 3.5.1.9 When load reduce to 90MW or exhaust temperature higher than 80, check LP cylinder water spray valve shall be open automatically. 3.5.1.10 when unit load reduce to 60MW, check the drain valves which pressure above fourth extraction steam can be open normally. 3.5.1.11 When main steam pressure reduce to 4MPa, drop unit load to zero, report to shift supervisor, ready to shutdown. 3.5.2 Works after splitting 3.5.2.1 Start turbine AC lube oil pump, trip when operation is normal. 3.5.2.2 Check that HP, IP auto main stop valves, governing valves and HP exhaust check valves, all extraction check valves are closed tightly. HP cylinder exhaust valve shall be open. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

3.5.2.3 Water level of deaerator shall be normal; condensate water re-circulating valve shall be auto open. 3.5.2.4 Pay attention to unit idle condition; listen to the sound from all part of unit. Check unit vibration, differential expansion, axial displacement, bearing metal temperature, etc. shall be normal. 3.5.2.5 Turbine EH oil system can be stopped when necessary 3.5.2.6 Rotating speed drop to 2600rpm, check LP cylinder spray water shall be stopped, LP cylinder exhaust temperature shall be normal. 3.5.2.7 Rotating speed drop to 600rpm, check and start jacking oil pump, jacking oil pressure shall be within 10~12MPa. 3.5.2.8 Rotating speed drop to 400rpm, break vacuum. Make sure HP and LP bypass valves are closed. 3.5.2.9 Rotating speed drop to 200rpm, stop hydrogen cooler and generator cooling water. 3.5.3 Works after rotor being still 3.5.3.1 When turbine rotating speed becomes zero, turning gear shall be put automatically, otherwise put into manually. 3.5.3.2 Record turbine idle time; Record cylinder temperature, turning gear current, shaft eccentricity, etc. parameters during turning period. 3.5.3.3 Close all oil cooler and cooling water valves in time, stop open water pump as per request. Main oil cooler temperature shall be adjusted to 302. 3.5.3.4 Stop gland steam supply when condenser vacuum drop to zero. Close all steam supply of shaft seal, stop fan of gland steam condenser. 3.5.3.5 After filling water in boiler, stop feed-water pump; exhaust temperature 50, other user of condensate water system have stopped, make sure no steam & water enter condenser; stop condensate water pump. 3.5.3.6 Pay attention to monitor water level of heater, condenser, maintain low water level. 3.5.3.7 Make sure closed cooling water has no user, then stop closed cooling water pump. Stop open cooling water pump as per closed cooling water temperature. 3.5.3.8 When exhaust temperature 50, make sure no hot water & steam enter condenser. Stop the running of circulating pump. 3.5.3.9 Stop other auxiliary equipments as per actual situation. 3.5.3.10 when metal temperature of HP cylinder governing stage is lower than 150, and metal temperature differences between upper and lower casing of HP & IP cylinders are lower than 42, stop running the turning gear, but jacking oil pump shall keep running to ambient temperature. 3.5.3.11Stop seal oil system. 3.5.3.12 when metal temperature of HP cylinder governing stage is lower than 100 , AC lube DOCUMENT NO. : HISAR-ZT-07
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oil pump and HP standby sealing oil pump can be stopped. 3.6 Turbine accident disposal 3.6.1 Principle of accident disposal

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

3.6.1.1 When accident happens, operators shall release person and equipments from threaten rapidly, find out accident causes, continue operation of non-faulted equipments while eliminating malfunctions; disconnect or shut down failure equipments at once if necessary, add load on non-faulted equipments to ensure normal power supply. 3.6.1.2 When troubles come to unit, usually the operators shall ascertain character, position and range of troubles rapidly as per instrument indication or alarm signal as well as unit outer phenomenon. For adapt measure in time and avoid trouble extending. 3.6.1.3 When accident happens, unified command of shift supervisor shall be adopted to dispose malfunction correctly and rapidly. All posts shall contact and cooperate closely, then report accident conditions and adopted measures step by step, so as to prevent accident spreading. 3.6.1.4 During accident disposal, analysis and judgment shall be careful and correct, disposal shall be rapid and decisive, do not hasty and flustered. Repeat the command when get the order. Ask if the order is not clearly understood and feedback to commander after the orders being carried out. 3.6.1.5 After accident, experience and improvement is needed. After the accident had been disposed, unit malfunction phenomenon, time, position and disposal process must be detailed recorded. If possible, print tracing accident data and sum up the accident disposal situation. 3.6.2 Emergency shut down When one of the following malfunctions happens, turbine break vacuum and emergency shutdown a. Turbine rotating speed reaches 3300r/min, but safety governor failure. b. Strong vibration of unit. c. Turbine blades are broken or clear metal rubbing sound from inner cylinder. d. When water hammer occurs to turbine, so that control index show trend of exceeding limit or exceed limit. e. When turbine gland seal has rubbing sound or spark. f. Any one of turbine bearing is out of oil, smoking; or bearing metal temperature and return oil temperature exceed limit. g. When T/G unit or oil system catches fire which cannot be put out, so that safety operation of unit is seriously threatened? h. Oil level of main oil tank drop to minimum level below, and cannot be restored. i. Axial displacement increase suddenly to exceed limit or thrust bearing metal temperature increase to exceed limit. DOCUMENT NO. : HISAR-ZT-07
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j. Smoking from inside generator or hydrogen explosion.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

k. Turbine rotating speed exceeds safety governor speed, and safety governor failure. l. When generator air side sealing oil is interrupted totally and cannot be restored. m. Other troubles happen which may seriously threaten safety operation of unit or human safety. 3.6.3 Failure Shutdown When one of the following failure happens, shutdown the units a. Main & reheat steam temperature exceed specified value, and cannot be recovered in limited time. b. Main & reheat steam temperature drop 50 sharply, and temperature drop rate is higher than 10/min. c. Vacuum is reducing and cannot maintain, though load has been reduced to zero. d. Main protection of unit meets the actuation value, but protection failure. e. LP cylinder A or B exhaust temperature are higher than 79 , but fail in disposal, and continue rise to 121, continuously running for 15min. f. Maximum exhaust temperature difference between two LP outer cylinders reaches 16. g. Two EH oil pump are running, but EH oil pressure is lower than 9.31MPa. Stator cooling water is short of for 30sec. and the protection do not action, or the generator stator winding has water leakage and can not dispose. i. Operation of turbine main oil pump is severely abnormal. j. Main steam, HP feed-water pipes or other steam, water, oil pipes are broken and normal operation of unit cannot be maintained. k. DEH, TSI systems failure, so that some important parameters cannot be monitored and unit operation cannot be maintained. l. Generator hydrogen or sealing oil system has leakage, so that unit normal operation cannot be maintained. m. Turbine no steam continuously operation lasts more than 1 min. n. Exhaust pressure difference between two LP cylinders reaches 8.6KPa, and obviously influence main monitoring parameters (such as water level of condenser, vibration, etc.). 3.6.4 Disposal principles for turbine emergency stop 3.6.4.1 Press emergency stop button in CCR or pull trip handle manually on the spot, make sure generator has been disconnected and turbine speed is reducing, then check HP/IP main steam stop valve and control valve, HP exhaust non-return valve, extraction check valve are closed. 3.6.4.2 Check the drain valves of turbine body, main & reheat steam pipes, extraction steam pipes are open 3.6.4.3 Check lube oil pump shall be put into operation; check oil pressure and temperature are DOCUMENT NO. : HISAR-ZT-07
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normal.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

3.6.4.4 Stop vacuum pump, open vacuum breaker valve, close all drain water valves leading to condenser. 3.6.4.5 When vacuum become 0, stop gland steam supply. 3.6.4.6 Rotating speed drop to 0, check that turning gear auto running shall be normal. Start turning gear manually if it is failed in auto running. Record the following data that is rotor idle time, eccentricity, motor current of turning gear, cylinder temperature, etc. 3.6.4.7 During shut down process, attention shall be paid to unit vibration, lube oil pressure, lube oil temperature, pressure difference between sealing oil & hydrogen. 3.6.4.8 Operators shall come to site and listen to unit inner sound very carefully, if there is clear metal knock or rotor idle time is shortened obviously, start unit again at once is strictly forbidden. 3.6.4.9 Other operations are same as normal shutdown. 3.6.5 Turbine trip conditions a. Over-speed: electric over-speed 3300rpm; mechanical over-speed: 3330rpm. b. Turbine lubes oil pressure 0.06MPa. c. Main turbine vacuum -68.7KPa. d. HP cylinder exhaust temp. 427 e. Pressure ratio of HP cylinder <1.7. f. X & Y direction vibration of bearing is greater than 254um g. Water pressure difference between inlet & outlet of generator stator winding 0.1MPa. h. Conductivity of generator stator outlet water 9.5us/cm; outlet water temperature 85. i. Pressure difference of oil & hydrogen 0.02MPa. j. Turbine axial displacement is 1.0mm. k. Oil level of turbine lube oil tank drop to -417mm. l. Differential expansion of turbine HP cylinder reaches +10.2 or -4.5mm; differential expansion of turbine LP cylinder reaches +16 or -1mm. m. Return oil temperature of turbine radial bearing, thrust bearing are 82 higher; metal temperature of turbine radial bearing is 113; metal temperature of turbine thrust bearing is 107. n. Turbine LP cylinder exhaust temperature is 121, 15min delay. o. Temperature difference between upper and lower casing of HIP cylinder 56. p. Main steam temperature 482. q. Main steam temperature 565. r. HP exhaust pressure is 4.8MPa higher. s. DEH trip. t. Generator protection action.

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u. Boiler MFT. v. Turbine EH oil pressure is 9.31MPa lower. 3.6.6 Typical turbine failure disposal 3.6.6.1 Condenser vacuum decline 3.6.6.1.1 Phenomenon a. Indicated value of all vacuum gauges is down. b. Indicated value on all exhaust temperature gauges are going up. c. Condensate water temperature is increasing.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

d. Under the same load, when main steam flow increases, pressure of governing stage and all monitoring sections shall rise. e. CRT Low vacuum visual and sound alarm, standby vacuum pump interaction. 3.6.6.1.2 Reasons a. Circulating water is cut or short. b. Gland feeding steam is in low pressure or cut, and water seal of gland steam condenser malfunction. c. Vacuum pump malefaction and trip, but standby vacuum pump does not interlock or run abnormally, efficiency is lowing. d. Water level regulation of condenser is failure, copper tubes of condenser leak badly leading to full water of condenser. e. Vacuum system pipeline is broken or valves of vacuum system are opened by mistake, which result in lost of air entering into condenser. f. Safety valves of main and BFP turbine have crack. g. Water level in chemical feed water tank is too low; water level in auxiliary steam drain flash tank is too low, but the drain valve from auxiliary steam drain to turbine flash tank is open. h. Hot well drain valve is not tight or opened by mistake 3.6.6.1.3 Disposal a. Once find vacuum is declining, rapidly check other vacuum gauges and CRT vacuum indicated value as well as change of turbine exhaust temperature; none but vacuum gauge indication is declining, meanwhile turbine exhaust temperature is increasing accordingly, we can say that condenser vacuum is really declined. b. When vacuum is declining, find out causes rapidly and try to recover vacuum. If vacuum drop to 87KPa, put standby vacuum pump into operation; maintain parallel operation of HP condenser A, B and LP condenser A, B vacuum pumps. c. When vacuum is declining, much attention shall be paid to the vibration of LP rotor last stage blade, if turbine vibration is increasing, eliminate vibration by reducing load; if load reducing is ineffectively and vibration keep on increasing, failure shutdown at once while vibration 0.254mm or vibration has the change trend of over limitation. DOCUMENT NO. : HISAR-ZT-07
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d. If vacuum decline due to damage or cracking of vacuum system pipeline or equipments, failure equipments and system shall be isolated at once. When turbine vacuum cannot be maintained, reduce load and shutdown as per regulations. e. If one of two running circulating pump is failure trip, dispose decisively as per vacuum falling speed; if vacuum declines slowly, it is necessary to maintain load as per vacuum. f. If shaft seal pressure is abnormal, check the causes rapidly and recover normal shaft seal pressure. If turbine vacuum declines quickly due to gland steam supply interrupted, failure shutdown at once and break vacuum; if vacuum declines slowly, it is necessary to take measures to recover gland steam supply, otherwise reduce load and shutdown as per regulations. When gland steam is interrupted, pay attention to monitor turbine HP & LP negative differential expansion which cannot exceeds limitation, otherwise emergency shutdown at once. g. When running vacuum pump failure trip, standby vacuum pump shall act accordingly, otherwise start standby vacuum pump manually. If all vacuum pumps are failure, measures shall be taken to resume vacuum pumps. Reduce load or failure shutdown accordingly as per vacuum. h. When condensate pump is failure and condenser is full water, start standby condensate pump. When condenser water level increases abnormally due to condenser copper tubes leakage, reduce load and failure shutdown at once. 3.6.6.2 Steam temperature and pressure abnormal 3.6.6.2.1 During turbine normal operation, steam pressure shall be adjusted as soon as possible to recover normal when main steam pressure rise or fall 3.6.6.2.2 During abnormal condition, main steam pressure maintains at 17.521.67MPa for short time operation is allowable, but whole year total accumulation shall not exceed 12 hours. 3.6.6.2.3 During turbine normal operation, main steam pressure control shall be done by CCS or DEH, when main steam pressure control on DEH panel is put into operation and main steam drop to set pressure, reduce load automatically until load correspond with main steam pressure. 3.6.6.2.4 Normal range of main steam temperature and reheat steam temperature is 535--545 , when the temp. rise high to 547557, it is required that whole year accumulated abnormal operation time shall not exceed 400 hours, if otherwise failure shutdown. It is allowable that steam temperature rise to maximum 565 from rated temperature within 15mins, or operation between 547557, but whole year accumulation shall not exceed 80 hours, otherwise failure shutdown when over temperature again. Failure shutdown at once when steam temperature exceeds 565 . 3.6.6.2.5 When main steam temperature and reheat steam temperature is abnormal, measures shall be taken at once to recover normal steam temperature. During disposal, if main steam and reheat steam temperature continue dropping to lower than rated value 84(482) or steam DOCUMENT NO. : HISAR-ZT-07
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temperature declines rapidly for over 50, temperature drop rate 10min, it is necessary to failure shutdown at once. 3.6.6.2.6 When steam pressure and temperature change abnormally, pay attention to monitor change trend of turbine expansion difference, axial displacement, bearing vibration, monitoring section pressure and all control index, failure shutdown as soon as exceed limitation. 3.6.6.2.7 When left and right main stop valves, reheat steam valves have steam temperature difference, please dispose as per following rules: a. Heat deviation normal value of left & right main stop valves steam temperature 14. b. When heat deviation is running exceed limit, running exceeding limit within 42 for 15min in 4 hours for once is allowed. c. When steam temperature deviation is large, it is necessary to inform boiler to adjust in time. d. Steam temperature deviation of two sides exceed limit for 42, please shutdown in time. 3.6.6.3 Main lube oil pressure decline abnormally 3.6.6.3.1 Phenomenon during oil declining a. Indicated value of CRT and local pressure gauge is declining. b. Lube oil pressure drop to 0.082MPa, Low Lube oil Pressure visual and sound alarm. c. Lube oil pressure drop to 0.082MPa, auxiliary oil pump and AC standby sealing oil pump start automatically. d. Lube oil pressure drop to 0.075MPa, DC lube oil pump start automatically. e. Bearing temperature and return oil temperature have ascending trend. 3.6.6.3.2 Reasons for decline of oil pressure a. Main oil Pump failure during running. b. Main oil Pump inlet oil injector failure. c. Oil system pipeline cracking, mass oil leak. d. Oil system valve is open by mistake, mass oil leak. e. Turbine oil cooler leak badly. 3.6.6.3.3 Disposal for lube oil pressure decline a. When lube oil pressure declines abnormally, find out causes as soon as possible. Start auxiliary oil pump and AC sealing oil standby pump to maintain oil pressure when oil pressure drop to lower than 0.082MPa. If oil pressure continue dropping and cannot be recovered, failure shutdown and break vacuum at once. b. Oil pressure declines due to leakage of lube oil pipe, and the trouble cannot be eliminated, failure shutdown at once. c. Lube oil pressure decline, pay close attention to the temperature of all bearing and return oil, if its temperature (of thrust bearing and support bearing, etc) are high to limit value, shutdown the unit and break vacuum at once. d. During unit starting speedup, if lubricant oil pressure declines due to auxiliary oil pump DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

failure, disposal shall be decided as per unit speed and failure character: if rotating speed is close to 2700r/min and failure cannot be solved in short time, speed up to rated speed and dispose auxiliary lubricant oil pump; if rotating speed is lower than 2700r/min, but auxiliary lubricant oil pump is broken and failure cannot be solved in short time, it is necessary to break vacuum and shutdown at once. 3.6.6.4 Support bearing or thrust bearing temperature rise abnormally 3.6.6.4.1 Reasons a. Bearing is damaged. b. Cooling water in oil cooler is short or interrupted, or cooling water temperature increases, oil temperature increases abnormally. c. Oil film is broken due to abnormal change of oil pressure and temperature. d. Bearing oil inlet is lacking or interrupted, oil quality is worsened. e. Unit vibrates violently. f. Unit load changes rapidly, such as load dump or increase greatly, causes axial thrust force abnormal increase. g. When cold steam and cold water come into turbine badly, that thrust bearing exceeds limit. h. Gland seal of turbine balancing disc is badly worn that balancing axial thrust is out of action. 3.6.6.4.2 When temperature of support bearing and thrust bearing is increasing, operators shall confirm the following data immediately: a. CRT display, indication of return oil temperature shall all increase. b. All bearing temperature increase due to oil cooler outlet oil temperature increase and oil pressure change or turbine vibration. c. Listen to bearing inside carefully at site, whether the sound inside thrust bearing and turbine are normal. d. Verify if axial displacement has abnormal change. e. Verify if unit vibration increases abnormally. 3.6.6.4.3 Disposal for abnormal increase of support bearing and thrust bearing temperature a. Find out reasons, if it is due to cooling water, check regulating if it is normal, manually adjust if it is abnormal. b. If oil pressure is fluctuating, please check the running of main oil pump. c. If it is caused by other reasons, please dispose as per actual situation. c. Any one of support bearing metal temperature increases to 107 or return oil temperature increases to 77, High bearing temperature and High return oil temperature visual and sound alarm. When anyone of support bearing metal temperature increases to 113, failure shutdown and break vacuum at once. e. When thrust bearing metal temperature increase to 99 , High thrust bearing temperature visual and sound alarm. No matter any reason, when thrust bearing metal temperature increase DOCUMENT NO. : HISAR-ZT-07
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to 107, failure shutdown and break vacuum immediately.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

f. Turbine axial displacement increase abnormally, properly change unit load to reduce axial thrust. When axial displacement indicates 0.9mm, alarms; when it up to 1.0mm, unit auto trip, otherwise, trip and shutdown manually. 3.6.6.5 Cold steam and cold water entering into turbine 3.6.6.5.1 Phenomenon a. Temperature of main steam or reheat steam decline rapidly. b. Serious filling of cold steam & cold water is water hammer. And white wet steam come out from steam pipe flanges, cylinder contact surface, valve bushing and turbine gland seal. c. Clearly water sound can be heard from main steam pipes, reheat steam pipes, extraction steam pipes. d. Thrust bearing metal temperature and return oil temperature increase abnormally, axial displacement increases. e. Unit vibration increase, it will vibrates strongly while worse situation. f. Temperature difference between upper and lower casings increase, HP & LP expansion difference change sharply towards negative direction. g. Pressure of governing stage and monitoring section increase abnormally. h. There is metal noise and shock sound inside turbine, serious water hammer will cause serious problems as thrust bearing burnout, friction between rotor & stator of unit, cracks of cylinder or pipes, etc. But due to different situations of cold steam & water, the problems above shall not always happen at the same time. 3.6.6.5.2 Reasons a. Boiler water level control is broken, separator is full of water, or a lot of desuperheated

water come into main steam or reheat steam pipes due to malfunction of boiler steam temperature control, thus resulting in main steam or reheat steam temperature reduce rapidly even water is entered . b. Leaking badly due to heater pipes broken, or HP heater or LP heater are full of water due to malfunction of drain regulation, and heater protection refuse to operation or extraction check valve cannot close tightly due to jam. c. Because of malfunction of gland seal temperature regulation or too low temperature of gland steam, cold water & steam enter into turbine gland seal. d. No.7 & 8 LP heaters are full of water and enter into LP cylinder directly. e. Due to drain difficult during turbine startup or shutdown, lots of water accumulated in steam pipeline or cylinder, or improper switchover of drain valve that cold steam & water enter into turbine. 3.6.6.5.3 Disposal a. Find out reasons, cut off cold steam & water supply, and decidedly dispose as per entering DOCUMENT NO. : HISAR-ZT-07
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cold steam & water. Whatever the reason, manually open main steam pipe, reheat steam pipe, drain valves of all stages steam extraction pipes (including feed-water pump turbine) and turbine generator proper immediately. b. Strictly monitor thrust bearing metal temperature and return oil temperature, axial displacement, HP & LP cylinder differential expansion, upper & lower cylinder temperature difference, unit vibration and listen to unit inner sound, once the control index have tendency of exceeding limit or over limit and endanger unit safety operation, failure shutdown and break vacuum at once. 3.6.6.5.4 Disposal for cold steam & water entering different part of turbine a. If main steam temperature and reheat temperature decline rapidly, disposal shall as per steam temperature abnormal decline. b. Water will enter extraction pipeline if heaters are filled with water badly, if temperature difference of upper & lower cylinders, expansion difference of HP & LP, axial displacement have obvious variation indicates that water has entered turbine, when temperature of upper and lower cylinders is bigger than 56 , failure shutdown and break vacuum at once. c. When High water level of heater alarms, check water level at local as soon as possible. If water level is high but protection device failure to operate, close steam inlet motor-operated valve of fault heater, switch over heater water side to be bypass operation. Close inlet and outlet valves of heater, open drain valve of steam extraction pipes. Force open guide condenser emergency drain valve to strengthen water draining. d. Due to malfunction of gland seal cooling water regulating valve with water entering inside gland seal, rotor is distorted by cold, when turbine expansion difference and vibration increase abnormally, it is necessary to close gland seal cooling water valve and strengthen draining of gland steam system at once. When expansion difference and vibration exceed limits, failure shutdown. e. After turbine failure shutdown due to cold steam & water intrusion, confirm current of turning gear is increases abnormally or not; when rotor is distorted badly or turning gear is blocked due to friction of rotor & stator, force turning is forbidden. f. When turbine failure shutdown due to cold steam & water intrusion, it is necessary record idle time well and truly, listen inner sound of unit carefully, pay attention to thrust bearing temperature, axial displacement, vibration, expansion difference, etc., confirm that if unit can be start again. If idle time is shorten obviously and metal rubbing come from unit inner during idle time or strong vibration occurs before and after turbine trip, then check turbine inner after shutdown, otherwise no starting. g. If turbine cold water & steam intrusion is not serious, and variation of turbine axial displacement, thrust bearing temperature and oil pressure, expansion difference, vibration, upper & lower temperature difference are not obvious, shutdown is not necessary, but DOCUMENT NO. : HISAR-ZT-07
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strengthens draining.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

h. After turbine failure shutdown due to cold steam & water intrusion, only above-mentioned control index and unit inner sound have no abnormal change during idle time, manager can decide if it is allowed to start again. 3.6.6.6 Abnormal vibration of turbine 3.6.6.6.1 Reasons a. Oil film surge during starting speedup. b. Improper warming during turbine startup. c. Turbine rotating speed is in the sympathetic vibration range of critical speed. d. Due to rapid change of load or main steam parameter, axial thrust increases abnormally, and that cause rub between moving and stationary part. e. Bearing oil film is damaged or oil supply is interrupted due to lube oil pressure declining. f. Bearing oil film is damaged due to too high or too low lube oil temperature. g. Bearing bend or differential expansion exceed limit during unit startup or operation. h. Cold water & steam enter turbine or water hammer. i. Turbine blade is broken or inner parts are damaged and fell off. j. Steam excitation occurred during high load operation. k. LP cylinder center drift or last stage blade vibration due to vacuum variation. l. Bad quality of bearing erection, bearing fit and gap are improper adjusted. m. Blade resonance occurred during turbine low cycle operation. n. Unit vibration due to reasons of generator or exciter. 3.6.6.6.2 Disposal (1) If vibration increase abnormally during turbine start up rush rolling and speedup process, dispose as per following principles: a. Before turbine rolling and during gear turning, shaft eccentricity shall 0.076mm, otherwise forbid to run to speed. b. After turbine rolling up, when rotating speed 600rmin, shaft eccentricity0.076mm, please trip, put turning gear into running when rotating speed drop to zero, when shaft eccentricity0.076mm, start the unit again. c. During turbine speedup process, it is forbidden to maintain rotating speed or warming around critical speed. d. During turbine cold start speedup process, if any shaft vibration0.127mm but 0.254mm, pause until shaft vibration 0.125mm, carry out holding speed warming for 1520min, and carry out sound detection carefully, start speed up again after all control items are normal. e. During turbine hot or extreme hot start speedup, if any bearing vibration 0.254mm, failure shutdown at once, record idle time, put turning gear into operation, and analyze vibration DOCUMENT NO. : HISAR-ZT-07
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reasons, then start again. It is forbidden to eliminate vibration by reducing speed to maintain warming or force speedup. (2) If vibration increase abnormally during normal operation, first reduce vibration by reducing load until vibration is reduced. Pay much attention to vibration during load up again, if vibration keeps increasing, it is forbidden to add load, report to leaders. (3) If vibration decline after eliminating excitation from turbine generator, or unit vibrates during voltage boosting, it indicates that vibration is caused by short circuit of generator rotor winding. It is necessary to report to senior leader, and discuss together for disposal. 3.6.6.7 Axial displacement increase 3.6.6.7.1 Reasons a. Turbine load variation increase. b. Extraction steam running mode changes, so that pressure difference of extraction steam increase. c. Water enters turbine or main & reheat steam temperature drop too fast. d. Blades are serious scaling, broken. e. Heater is cut. f. Condenser vacuum declines. g. Thrust bearing failure. h. Cylinder single side admission. i. Generator rotor axial movement. j. Lube oil pressure & temperature change greatly. 3.6.6.7.2 Disposal a. When axial displacement is increasing, check thrust bearing temperature, return oil temperature, expansion difference, vibration, etc. b. When load is increasing, stabilize load as soon as possible. c. If unit axial displacement increases and together with abnormal sound, strong vibration, it shall be disposed as per emergency shutdown. d. When unit axial displacement reaches 1.0mm, turbine shall auto trip. Otherwise shut down unit manually. 3.6.6.8 Interruption of station service power 3.6.6.8.1 Phenomenon a. Boiler MFT interlocks turbine, generator trip, and load drop to zero. b. All AC electromotor of non-protection power source are stopped, ampere meter indicates zero. 3.6.6.8.2 Disposal for interruption of station service power (1) When station service power is interrupted, turbine shall auto trip, otherwise trip shutdown manually at once; make sure BFP turbine is tripped. DOCUMENT NO. : HISAR-ZT-07
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(2) When station service power is interrupted, start turbine DC lubricant oil pump, DC lube oil pump of feed-water pump turbine, DC sealing oil pump at once. (3) After diesel-engine generator being started and on load, carry out following operations: a. Make sure oil pumps in relevant oil systems of turbine, auxiliary equipments are self-started normally, stop DC oil pump. b. Pay attention to the temperature of turbine lube oil, adjust manually if oil temperature is high. c. Pay attention to condenser vacuum, before vacuum drops to zero, try to maintain gland steam supply. (4) When station service power is interrupted, except necessary operation items as per actual situation, generally maintain original state of equipments. Restart after station service power restoration, and put into operation as per following starting procedures: a. Start circulating water pump. b. Start open water pump, closed water pump. c. Start air compressor. d. Put condensate water, feed water systems into operation. e. Start land air extractor and gland seal system, vacuum pump. f. Put deaerator into circulating heating operation. g. Close all extraction motor driven valves, close feed-water pump outlet motor-operated valve; put motor driven BFP and feed-water system into operation. h. Start main and BFP turbine auxiliary oil pump to make oil circulation. i. Start other auxiliary equipments.

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Chapter IV Turbine Auxiliary Equipment Operation


4.1 Technical Specifications of Turbine Auxiliary Equipment 4.1.1 Condenser item A/B condenser cooling area Design cooling temperature water data 17000/17000m2 33 58KPa item Design flow data cooling water 19.07m3/s 2.2m/s

Pipe inside flow speed

Condenser steam 40 KPa resistance Condenser hot well Number of tubes 36192+928+1796 110 m3 volume Water side design Shell side design 0.3 MPa 0.098 MPa pressure(g) pressure Condenser steam side inlet Condenser outlet allowable highest 80 condensate water 20 g/l temperature required oxygen content Condenser circulating water Condenser design end 9 6.32/5.66 allowable temperature rise temperature difference Circulation rate design set 2 61.4 conditions super cooling degree of Shanghai electric manufacturer condensate water on 0.5 works Co.LTD condenser outlet 4.1.2 Motor driven feed water pump group Cooling water resistance 4.1.2.1 Booster pump technical specifications Operating conditions item units rated (guarantee efficiency) model inlet temperature Inlet pressure flow head efficiency MPa(g) m3/h m % 1.35 1100 147 83 5.5 1.35 1260 144 83 5.8 1.35 1260 146 83 5.8 1.35 290 161 37 2.5 1.35 1400 138 81 7 FA1D67 177.6 178.3 178.3 177.6 177.6 Maximum flow Safety valve trip conditions Min flow of single pump Max flow of single pump

Required NPSH m Seal type speed Outlet pressure Shaft output weight r/min MPa(g) kW kg

Mechanical seal 1484 2.62 500 2560


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2.61 529

2.61 537

2.82 320

2.16 564

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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Operating conditions item units rated (guarantee efficiency) Connection flange pressure intake MPa MPa 2.5 3.75 48010 37710 Inverse hourto see from electric motor to booster pump Sliding bearing + thrust pad Electric motor Maximum flow Safety valve trip conditions Min flow of single pump Max flow of single pump

nominal Off take

Connection pipe intake mm specification (S) rotation direction Bearing type Drive mode off take mm

Notice: (g) in the table refers to gauge pressure 4.1.2.2 Motor driven FWP technical specification Operating conditions Safety rated Min flow Max flow item units Maximum (guarantee valve trip of single of single flow efficiency) conditions pump pump type FK4E39(I)M inlet temperature 177.6 178.3 178.3 177.6 177.6 inlet flow m3/h 1100 1260 1260 290 1400 outlet flow m3/h 1070 1230 1230 290 1400 head m 2050 2123 2163 2460 1650 efficiency % 84.2 84.2 84.2 41 80 Required NPSH m 47 54 58 22 60 Seal type Mechanical seal speed r/min 5350 5500 5600 5400 5400 outlet pressure MPa(g) 20.4 20.9 21.45 23.3 18 Shaft output kW 6385 7499 7721 4355 7522 tap pressure MPa(g) 11.2 11.2 11.9 0 0 Tap flow m3/h 30 30 30 0 0 Shaft vibration mm 0.05 0.05 0.05 0.05 0.05 MPa 4 inlet Connection flange MPa 16 Tap nominal pressure MPa 32 outlet mm 37710 Connection pipe inlet specification Tap mm 897 (S) outlet mm 355.627.76 weight kg 11000 Rotation direction clockwiseto see from turbine to water feed pump Bearing type Sliding bearing + thrust bearing Drive mode Electric motor (Notice(g)in the table refers to gage pressure) 4.1.2.3 Feed water pump electric motor technical specification DOCUMENT NO. : HISAR-ZT-07
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NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Parameter Units type -model -Rated output kW Rated voltage V Rated current A Rated frequency Hz Rated speed rpm Number of poles -Protection Degree -Insulation class -Cooling method -Installation location -Working type -Rated load efficiency % Rated load of power factor Maximum /barring /rated torque Barring current multiple Allowable barring time s Acceleration time and start time(rated s load conditions) Motor rotation inertia Kg.m2 noise dB(A) Bearing pedestal vibration amplitude mm Shaft vibration velocity mm/s Stator temperature rise K phase Temperature measuring devices Bearing type Bearing oil trademark Bearing lube method Bearing cooling method Electric motor weight Kg Bearing flowl/min rotation direction

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Remarks Squirrel cage

11000 50 1490 4 IP54 F air-water indoor continuous 96.5 0.88 4.5 15 85 2.8mm/s 80 3 Pt100 Sliding bearing #32 turbine lubricant Pressurized oil lubrication Air -water 35000 25 Clockwise: to see from main shaft to back shaft 32#turbine lubricant PT100

28 29 30 31 32

Recommended lubricant Resistance temp. detector for stator Bearing Resistance temperature 33 detector model 4.1.2.4 Coupling technical specification item manufacturer model Input speed Rated output speed Rated output power weight Speed adjustment range Rated slide error shaft rotation direction DOCUMENT NO. : HISAR-ZT-07 units

r/min r/min kW kg

VOITH R17K500M(interim) 1490 5600 7721 8000 25~100 3 Clockwise(to see from electric motor to BFP)
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4.1.3 TBFP group 4.1.3.1 Main pump

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Operating conditions Safety valve Item Units Rated(guaran Maximu Min flow Max flow take off tee efficiency) m flow of a pump of a pump conditions Pump model FK4E39(I)M inlet temperature 177.6 178.3 178.3 177.6 177.6 outlet flow m3/h 1100 1260 1260 290 1400 outlet flow m3/h 1070 1230 1230 290 1400 head m 2050 2123 2163 2460 1650 efficiency % 84.2 84.2 84.2 41 80 Required NPSH m 47 54 58 22 60 Seal model mechanical seal speed r/min 5350 5500 5600 5400 5400 Outlet pressure MPa(g) 20.4 20.9 21.45 23.3 18 Shaft output kW 6385 7499 7721 4355 7522 Tap pressure MPa(g) 11.2 11.2 11.9 0 0 Tap flow m3/h 30 30 30 0 0 Tap vibration mm 0.05 0.05 0.05 0.05 0.05 connection flange 4(intake) nominal pressure MPa 16(tap lead) 32(off take) 37710(intake) connection pipe mm specification mm 897(tap lead) (S) mm 355.627.76(off take) weight kg 11000 Rotation direction Clockwise(to see from turbine to water-feed pump) Bearing type Sliding bearing + thrust bearing Drive mode turbine 4.1.3.2 BFP turbine technical specification 1) model ND (Z) 84/79/07 2) Name: driven for feed-water pump, variable speed, condensing turbine 3) Type: single-cylinder, impulse, single flow, condensing, RH cold steam switch 4)maximum power11MW 5)rated power6.575MW(turbine rated conditionsBFP efficiency 82.3%speed 5178r/min) 6) Steam parameter Turbine under rated working conditions before LP main steam valve, LP steam pressure: 0.9649MPa (a)

LP steam temperature: 353.9 Under turbine rated working conditions before HP main steam valve: HP steam pressure: 3.813MPa (a)

HP steam temperature: 323.1 7) exhaust steam pressureunder rated working conditions:*6.28kPa (a) 8) Speed DOCUMENT NO. : HISAR-ZT-07
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speed regulation range under continuous operation: 28006000r/min rated speed: efficiency is 82.3%) 9) Emergency governor trip speed: 630050r/min 10) calculated value of rotor critical speed (including moving blade ,emergency governor and turning gear of couplinghereafter is same) (unitsr/min) First stage Rigid support Elastic support 11) Rotation equipment Turbine rotor turning gear speed: 100r/min Rotation equipment AC motor capacity: 15kW 12) Turbine rotor rotation direction: to see from turbine to TBFP is clockwise 13) shaft vibration of peak to peak maximum allowable value in the front and rear bearing Turbine run in the continuous operation speed: Turbine runs passing critical speed: 0.125mm 0.076mm 2514 2353 second stage 10384 7213 *5178r/min(main turbine rated working conditionswhen TBFP

14) Heat rate calculated value: *5.365(kg/KWH) conditionin turbine rated working conditions, speed is *5178r/min 15) Oil system (this item remarks that pressure of oil system refers to gauge pressure) Electric main oil pump (80YG-100A) Electric main oil pump head Electric main oil pump oil capacity 0.85MPa 45m 3/h 30kW

Explosion-proof AC motor (matching Electric main oil pump) output DC lubricant pump (80YG-38) DC lube oil pump head DC lube-oil pump oil flow DC motor (matching DC lube oil pump) output Security system oil pressure Lube system oil pressure Oil system oil storage capacity 4.1.4 Deaerator specification item model type Design pressure Maximum operating pressure Withstand pressure Design temperature DOCUMENT NO. : HISAR-ZT-07 Technical specification YYW-2000 Horizontal spray type 1.4 MPa 1.03 MPa 2.47 MPa 369.1
Page

0.37MPa 50m 3/h 11kW 0.7MPa 0.09810.147MPa 6m3

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item Technical specification Safety valve action pressure 1.28 MPa Rated output 1900T/H 143.1 inlet temperature 185.3 outlet temperature oxygen content of outlet water 7g/L PH value of outlet water 8.09.0 4.1.5 The technical specification of condensate pump CP type Pump operation working conditions

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

C590-6 Design point(guarantee Maximum efficiency) operation point

Item units Inlet temperature 46.09 46.09 Inlet pressure KPa 10.13 10.13 Flow m3/h 940 Head m 320 Efficiency 83.5 Required NPSH m 3.1 speed r/min 1480 1480 Outlet pressure MPa 3.14 Shaft output kW 971 connection flange inlet MPa 1.0 1.0 nominal pressure outlet MPa 4.0 4.0 connection pipe inlet mm 700 700 specificationS outlet mm 450 450 connection direction inlet horizontal outlet horizontal Rotation direction Counter clockwise (from electric motor to pump) The technical specification of condensate pump electric motor Manufactory Shanghai electric motor corporation Model YKKL500-4TH Rated output kW 1120 Rated voltage kV 3.3 Synchronous rotation speed r/min 1500 Frequency Hz 50 Efficiency 94 Power factor 0.9 Barring torque (multiply 0.65 barring current (multiply 6.0 Maximum torque (multiply 2.1 Insulation class F Bearing lubrication method grease Weight kg 5500 Cooling method air-air Rotation direction Counter clockwise(from electric motor to pump) 4.1.6 Main and BFP oil pump technical specification description AC oil pump of main turbine DC oil pump of main turbine hydrogen seal stand-by oil pump of main DOCUMENT NO. : HISAR-ZT-07 model ALD320-202 DLD320-202 2CY-45/9-1 head 40m 40m 9m flow 320m3/h 320m3/h 45m3/h
Page

speed 1450rpm 1450rpm 1470rpm


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turbine jacking oil pump of main turbine AC lube-oil pump of BFP turbine DC lube-oil pump of BFP turbine Oil pump electric motor specification description AC oil pump DC oil pump hydrogen seal stand-by oil pump jacking oil pump AC lube-oil pump of BFP turbine DC lube-oil pump of BFP turbine 4.1.7 HP heater

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

PV29-2R1D-CO2 80YG-100A(11) 80YG-38(11) model YB250-4 Z2-91 YB2-200L-4 YB225M-4 YB30KW Z2-10KWP

85m 38m voltage 415 220 415 415 415 220 No. 6 2009.996 30 213.8 921.6 248.8 1081.4 0.1 3 30 260 45 145.109 3.901 327.6 3040.6 0.069 4.58 360/260 6.87

102 l/min 45 m3/h 50 m3/h output 55 KW 55 KW 45 KW 45KW 30 KW 11 KW

1480rpm 2950 2950 speed 1450 rpm 1500 rpm 1470 rpm 1480 rpm 2950 rpm 2950 rpm

Heater number No. 7 Feed water flow t/h 2009.996 Inlet pressure MPa 30 Inlet temperature 248.8 Inlet enthalpy kJ/kg 1081.4 Outlet temperature 280.7 Outlet enthalpy kJ/kg 1234.9 Max. resistance losses MPa 0.1 Max. allowable pipe side flow m/s 3 Design pressure MPa(g) 30 290 Design temperature Test pressure MPa(g) 45 Extraction steam Flow t/h 155.419 Inlet pressure MPa(a) 6.335 Inlet temperature 392.1 Inlet enthalpy kJ/kg 3153.3 Max. resistance losses MPa 0.069 Design pressure MPa(g) 7.44 Design temperature.(short/long 420/290 section) Test pressure MPa(a) 11.16 Drain water incoming source No. 7 heater Flow t/h 155.419 Temperature 254.4 Enthalpy kJ/kg 1107.5 Drain out coming (flow from high to low ) Flow t/h 155.419 Temperature 254.4 enthalpy kJ/kg 1107.5 End temperature difference of drain 5.6 (bottom) End temperature difference of -1.6 feed-water (top) 4.1.8 LP heater, Gland steam condenser

No. 5 2009.996 30 183 786.4 213.8 921.6 0.1 3 30 230 45 83.500 2.056 458.9 3376.6 0.069 2.43 490/230 3.645

No. 6 heater 300.528 219.3 940.4 300.528 219.3 940.4 5.6 0 384.028 188.6 801.3 5.6 0

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Heater number or model No.3 Condensate water Flow t/h 1602.588 Inlet pressure MPa(a) 4 Inlet temperature 120.5 Inlet enthalpy kJ/kg 506.9 Outlet temperature 151.1 Outlet enthalpy kJ/kg 637.8 Max. resistance losses(maximum 0.1 allowable pressure drop) MPa Max allowable pipe-side flow m/s 3 Design pressure(pipe side) MPa(g) 4 170 Design temperature(pipe side) Test pressure(pipe side) MPa(g) 6 Extraction steam Flow t/h 84.211 Inlet pressure MPa(a) 0.5228 Inlet temperature 278.5 Inlet enthalpy kJ/kg 3020 Max resistance losses(shell side) MPa 0.0345 Design pressure(pipe side) MPa(g) 0.8 310/170 Design temperature(pipe side) Test pressure(pipe side) MPa(g) 1.2 Drain water incoming Source No.3 Flow t/h 84.211 Temperature 126.1 Caloric content kJ/kg 529.7 Drain water out coming (flow from high to low) Flow t/h 84.211 Temperature 126.1 enthalpy kJ/kg 529.7 End temperature difference of 5.6 drain(bottom) End temperature difference of feed-water 2.4 (top) 4.2 Turbine lube and EH oil system 4.2.1 Lube oil system operation No.2 1602.588 4 87.66 368.4 120.5 506.9 0.1 3 4 140 6 85.705 0.2202 187.8 2844.7 0.0345 0.35 210/140 0.525 No.2 169.916 93.26 390.6 169.916 93.26 390.6 5.6 2.8

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

No.1 1602.588 4 46.87 196.2 87.66 368.4 0.1 3 4 130 6 101.273 0.07134 90.1 2656.8 0.0345 0.35 130 0.525

REM

271.189 52.47 219.6 5.6 2.8

4.2.1.1 Make sure FWP group maintenance work is over with working ticket has been checked out, and the piping and equipment are in good condition. 4.2.1.2 Examination according to valve checking card is done. 4.2.1.3 Make sure the oil level of main oil tank is normal and oil quality is accepted. open one side of main lube oil T valve. 4.2.1.4 Test according to testing manual have finished. 4.2.2 Startup of oil system 4.2.2.1 Start smoke exhaust fan of main oil tank and put it into interlock control. 4.2.2.2 Put electric heating device of main oil tank into operation as per oil temperature. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

4.2.2.3 Start AC lube-oil pump, seal oil stand-by pump and put them into oil pump interlock control. 4.2.2.4 When oil enters in system, the oil level of tank will lower sharply; it is time to add oil inside oil tank. 4.2.2.5 When lube oil temperature rise to 35 , main oil tank electric heating device shall exit. When the temperature rise to 40, cooling water of oil cooler shall be put into running for make the oil temperature within 4045.

4.2.2.6 Start jacking oil pump, and put turbine turning gear into operation. 4.2.2.7 During the unit rolling up, rise speed and load, check that lube oil pressure, oil temperature and return oil temp and flow are O.K. stop jacking oil pump when speed reaches 600r/min. 4.2.2.8 Stop high-pressure start-up oil pump and AC lube-oil pump, when unit speed is above 3000r/min, the outlet oil pressure of main oil pump is range from 1.67 to 1.76MPa and lube-oil pressure is normal, the lube-oil pressure change must be paid attention to. 4.2.3 Operation and maintenance 4.2.3.1 When unit is working normally, one smoke exhaust fan is running to maintain the lube oil pressure at minus 100mm water column. 4.2.3.2 When unit is working normally, put AC lube-oil pump, DC lube-oil pump, seal oil stand-by pump, jacking oil pump and turning gear into automatic - start interlock position. 4.2.3.3 When oil pressure of all turbine bearings is higher than 0.082Mpa and the cooling water of oil cooler runs well with outlet oil temperature keeps at 40 . 4.2.3.4 AC lube-oil pump, seal oil stand-by pump, jacking oil pump and turning gear work well, and oil pressure is O.K. 4.2.3.5. oil pressure of auto-stop shall maintain at 0.81.0MPa when Unit is operating normally. 4.2.4 Turbine jacking oil pump and turning gear 4.2.4.1 Startup: 1)Start one turbine jacking oil pump into operating, and start another one when checking the system is no leakage. Put stand-by pump into interlock. 2)Check jacking oil pressure of every bearing is within 5.6 to 8.5MPa. And the journal lifted at height of 0.050 to 0.076mm. 3)Make sure generator seal oil system is working normally. 4)engaged turning gear manually, DCS operation panel. 5)Check turning gear current is normal, eccentricity not greater than 0.076 mm, rotation speed of turbine 2.38r/min. then listen sound of turbine inside, data such as main shaft bending value, turning gear current and current changing value shall be recorded. 4.2.4.2 Stop: DOCUMENT NO. : HISAR-ZT-07
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is

Press startup turning gear button on the local cabinet or

Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1 ensure gland steam supply stops, and HP casing governing stage metal temperature is lower than 149, temperature difference between upper and lower part inside HP/IP casing is less than 42, then stop turning gear operating. 2 turbine jacking oil pump, seal oil pump and AC lube-oil pump can only be stopped when stator is thoroughly still. 3 when HP casing governing stage metal temperature is lower than 100 and every shaft metal temperature is in normal range, stop AC lube-oil pump, high pressure stand-by seal pump and smoke exhaust fan. 4.2.5 Lube oil system setting 4.2.5.1 Lube oil pressure 0.082MPa, alarm; interlock switch is on, interact AC lube-oil pump. 4.2.5.2 Lube oil pressure 0.075MPa, alarm; interlock switch is off , interact DC lube-oil pump. 4.2.5.3 Lube oil pressure 0.060MPa, alarm; trip turbine. 4.2.5.4 Lube oil temperature21, start electrical heating; Lube oil temperature 40, stop lubricant electrical heating. 4.2.5.5 Turbine lube-oil tank pressure is -0.35KPa while interlock switch has been put into operation and Stand-by fan start automatically. 4.2.5.6 While interlock switch has been put into operation, stand-by turbine jacking oil pump should be started automatically when one of the following conditions reached. 1)Turbine jacking oil pump inlet pressure P0.021MPa, turbine rotation speed is lower than 600r/min. 2)Turbine jacking oil pump inlet pressure P0.021MPa, interlock of jacking oil pump, one of other two jacking oil pumps trip. 3)Turbine jacking oil pump inlet pressure P 0.021MPa, turbine jacking oil main pipe pressure P10MPa. 4.2.6 Turbine EH oil system setting 4.2.6.1 1When oil pressure of EH manifold P11.03MPa, EH oil pumps interlocked start. 4.2.6.2 When oil level of EH oil tank is lower than 195mm, EH oil pump stop automatically. 4.2.6.3 When EH oil pressure is lower than 9.31MPa, turbine trip. 4.2.6.4 When EH oil temperature of oil tank is above 53, EH electric heating stop automatically. 4.2.6.5 Shaft seal steam must drain adequately can be operated. After put it into operation, pay attention to temperature difference between turbine upper and lower casing, differential expansion etc. important parameters. 4.2.6.6 When switching auxiliary steam source, pay attention to the change of auxiliary steam pressure and temperature and action of shaft seal pressure and temperature regulator. 4.2.6.7 Pay attention to shaft seal steam temperature must higher than 14 degree of superheat. 4.2.6.8 during unit cold start , temperature of HP/IP shaft seal steam is controlled at 150200

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and that of LP is not lower than 150.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

4.2.6.9 during unit hot start, , temperature of HP/IP shaft seal steam is controlled at 280350, and the temperature difference between HP/IP shaft seal steam and HP casing metal at governing side is not greater than 85 . 4.3 Vacuum and shaft seal steam supply system 4.3.1 The preparation before start water side vacuum pump 4.3.1.1 Make sure vacuum pump maintenance work is over, and working ticket have been check out. System pipe and equipment are in good condition. 4.3.1.2 Inspection according to valve examination card is finished. Open MOV of Condenser vacuum extraction manifold. 4.3.1.3 Make sure CCCW and compressed air system operation is normal. 4.3.1.4 Cooling water of vacuum pump is operated normally. 4.3.1.5 Start water side vacuum pump makeup by-pass valve, after gas-water separator water level is normal, close it. 4.3.1.6 Put unit shaft seal system into operation. 4.3.1.7 Start vacuum pump inlet manual valve. Close condenser vacuum broken valve. 4.3.1.8 Put vacuum pump inlet BFV CS into interlock state; switch the vacuum pump CS to remote state. 4.3.2 Startup of water collar vacuum pump 4.3.2.1 Start one vacuum pump. Start other two vacuum pumps one by one. 4.3.2.2 When vacuum pump inlet pressure12KPa, inlet BFV should be open automatically. 4.3.2.3 When pressure before vacuum pump inlet valve is less than 5KPa, stop one vacuum pump as standby depending on the operation. 4.3.3 The standard operation and maintenance 4.3.3.1 Examine condenser vacuum system a regularly according to patrol inspection institution. 4.3.3.2 Check water side vacuum pump electric current, vibration, voice and bearing temperature is normal or not. 4.3.3.3 Examine gas-water separator water level and water side vacuum pump working cooler operate normally. 4.3.3.4 Stand-by vacuum pump is in good condition, and interlock is put into operation. 4.3.3.5 When stand-by vacuum pump quit to standby mode for examination mode, frequently inspection on working pump shall be intentioned. 4.3.3.6 The temperature difference between vacuum pump working water and CW intake are not allowed to exceed 3, otherwise cooler needs to be washed. 4.3.4 Stop water collar vacuum pump 4.3.4.1 If switchover of stand-by pumps, it should be started firstly. When pressure of vacuum pump inlet valve is less than 6KPa, then stop the previously working pump. DOCUMENT NO. : HISAR-ZT-07
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4.3.4.2 Quit vacuum pump interlock. 4.3.4.3 Stop water side vacuum pump one by one.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

4.3.4.4 Examine and shut vacuum inlet (quickly-shut shaft), condensate vacuum main pipe electric valve, vacuum separator tank makeup valve and cooling water valve. 4.3.5 Vacuum pump main interlock protection 4.3.5.1 When main vacuum pump is operating, inlet pressure0.012MPa (absolute pressure). Stand-by vacuum pump starts automatically. 4.3.5.2 When main and stand-by vacuum pumps are operating, pump inlet pressure 0.006MPa(absolute pressure). Stand-by vacuum pump stops automatically. 4.3.6 Precaution of gland steam supply control 4.3.6.1 shaft seal system could seal automatically when unit load reaches 7075%,. Shaft seal header pressure is 2632KPa which controlled by overflow valve. 4.3.6.2 LP gland steam supply temperature lower limit is 121, upper limit 177. Shaft seal temperature controller setting is 149. 4.3.6.3 Temperature difference between steam supply temperature of HIP cylinder shaft seal and metal temperature of governing stage on HP cylinder shall be less than 85. 4.4 Condensate water and water-feed system 4.4.1 Start Condensate Pump 4.4.1.1 Start CP, condensate water-feed tank feeds water to normal level. 4.4.1.2 Start condensate drain pump. Feed water into condenser to about 700mm high. Put condenser water feed regulating valve into auto mode. Draining pump in the condensate drain pump pit shall be put into operation. 4.4.1.3 Examine and start CP inlet water and air valve. Re-circulation valve put into operation automatically. Chemical refined demineralizing equipment goes by-pass. 4.4.1.4 Examine the manually driven valve for CP sealing water of condensate transfer pump open or not. Regulate sealing water pressure to normal, which is higher than 0.1MPa. 4.4.1.5 Examine and start the isolating valve from condensate to CP. 4.4.1.6 Examine and start CP to condenser air valve. 4.4.1.7 Condensate put into operation to recirculation auto. 4.4.1.8 Start CP. Examine outlet MOV starts automatically or not. 4.4.1.9 After CP outlet pressure is normal, CP sealing water which from condensate transfer pump drainage main pipe supply switchovers to auto-sealing. Shut condensate transfer pump drainage main pipe to CP sealing water manual drive valve. 4.4.1.10 Examine another CP inlet and outlet motor valve open or not. With stand-by condition, put into linkage. 4.4.2 Stop system 4.4.2.1 After unit stopping, exhaust steam casing temperature is lower than 50. Ensure DOCUMENT NO. : HISAR-ZT-07
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condensate is not used by anyone, stop CP. 4.4.2.2 Undo stand-by CP interlock. 4.4.2.3 Stop CP. Isolation if required. 4.4.2.4 Shut CP closed cooling water inlet and outlet valves.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

4.4.2.5 When the condenser short-term discontinuation, condenser circulating water outlet valve close, but inlet valve open. The water side should fully feed water. 4.4.2.6 When the condenser long-term discontinuation, condenser circulating water inlet valve close and drain remaining water of condenser water side. 4.4.2.7 After the condenser vacuum to zero, apply hot water to the condenser is not permitted to avoid breaking atmospheric relief valve. 4.4.3 Condensate system protection 4.4.3.1 Anywhere in CP upper and lower bearings temperature reaches 95, CP trip. 4.4.3.2 CP thrust bearing temperature reaches 80, CP trip. 4.4.3.3 Any CP motor coil temperature reaches 145 , CP trip. 4.4.3.4 When CP is working, shut inlet valve, CP trip. 4.4.3.5 After CP starts 30s, inlet valve close (or after 3s still at closed mode), CP trip. 4.4.3.6 Condensate outlet main pipe pressure2.5MPa, parallel connect stand-by CP. 4.4.3.7 CP flow380T/H, open re-cycling regulating valve; flow 380T/H, shut re-cycling regulating valve. 4.4.3.8 LP cylinder spray valve open automatically when rotor rotation speed reaches 2600rpm. When load is 15%, shut LP cylinder spray valve automatically. 4.4.3.9 Condensate A drains expansion tank spray regulating valve open condition: #1 HP heater high and high come together. 4.4.3.10 Condensate B drain expansion tank spray regulating valve open condition: #2,3 HP heater water level is high and high together. 4.4.3.11 Condensate water-feed tank water level is lower than1.0m, condensate drain pump tripping. 4.4.3.12 CP level800mm, CP drain pump C stop. 4.4.3.13 CP water level500mm, CP drain pumps A, B put into linkage. 4.4.3.14 when interlock switch put into operation, Cp hot well level715mm, CP drain pump C startup. 4.5 H/LP heaters 4.5.1 Start or quit rules of HP/LP heaters 4.5.1.1 When heaters put into operation, water side first, steam side second. When heaters stop, steam side first, water side second. Put heaters into operation, water side and steam side should extract air firstly. 4.5.1.2 Except in special cases, HP and LP heaters start and stop by slide operation. DOCUMENT NO. : HISAR-ZT-07
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4.5.1.3 HP and LP heaters shall be put into operation one by one from LP to HP, and time interval shall be more than 10min. Shutdown sequence is opposite from starting sequence, that is shut down as per pressure one by one from high to low. Time interval shall not be less than 10min. 4.5.1.4 During starting and shutdown of HP heater, temperature-rise speed of HP heater must be strictly controlled to 5/min, and temperature reducing speed shall 2/min. Stop operation if any abnormal condition occurs, find out causes and eliminate. 4.5.1.5 HP and LP heaters can be put into operation if all valves, instruments, level gauges, protection are normal, otherwise, it is forbidden to be put into system. 4.5.2 HP slide operation 4.5.2.1 Ensure that BFP is running, and HP inlet T valves are at close and outlet T valves at open position with HP protection being put into operation. 4.5.2.2 Slowly open the start and operation vent valve at HP steam side, pay attention to the pressure change in deaerator. 4.5.2.3 Open extraction non-return valve of HP heaters No.5, 6, 7. 4.5.2.4 Fully open the motor steam inlet valve of HP heaters No.5, 6, 7 and the HP heaters will be put into slide operation with the load. Check no knocking inside pipes. 4.5.2.5 Open emergency drain valve of HP heaters No.5 and regulate its water level to normal position. 4.5.2.6 Close drain valve before and after the Extraction No.5, 6, 7 non-return valves. Check the drain valve before the HP steam inlet valve is automatically closed when the load reached more than ten percent. 4.5.2.7 Open the isolation valve from HP heater drain to deaerator and put regulation valve of them into auto when the pressure at steam side is higher that that in deaerator 4.5.2.8 Close starting vent valve when all the heaters are in normal. 4.5.2.9 Check if the HP heaters and deaerator are normal, then examine and put all the Heaters protection into operation. 4.5.3 HP heater start during unit normal operation 4.5.3.1 HP heater maintenance work is over, and working ticket have been check out. The working site is tidy. 4.5.3.2 Check and feed power and air source of HP heater motor valve, regulating valve, instrument and protection. 4.5.3.3 Check if the entire valves are in right position as per the HP heater system. 4.5.3.4 Do protection and interlock tests if required. 4.5.3.5 open primary and secondary water valve to fill water in HP heater until the pressure at water side is same as that of FW, then open the outlet and close inlet T valve, at last close primary and secondary water valve when the water flow meet the requirement. 4.5.3.6 Slowly open the starting and operation vent valve at HP steam side, pay attention to the DOCUMENT NO. : HISAR-ZT-07
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pressure change in deaerator.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

4.5.3.7 Put all the HP Heaters protection into operation and open extraction non-return valve of HP heaters No.5, 6, 7. 4.5.3.8 Slowly open the steam inlet valve of HP heaters No.5, 6, 7 (check no knocking inside pipes), and maintain 0.2MPa value at steam side to preheat shell side, and then close vent valve when the air in steam side is completely out. 4.5.3.9 When the heating finished, close drain valve before and after the Extraction No.1, 2, 3 non-return valves. 4.5.3.10 Slowly open steam inlet valve of HP heaters No.5 to full position, then same procedure to that of HP heater No.6 and No.7,pay attention that the FW temperature rise rate is within 2 3 /min during this process. 4.5.3.11 when the pressure at steam side is higher that that in deaerator, open motor valve of drain to deaerator and close bottom drainage valve 4.5.3.12 regulate water level of HP heaters to normal position and put HP heater drain regulating valve into auto mode. 4.5.3.13 Check the water level, pressure, temperature of deaerator is ok. 4.5.4 LP heater start with unit load 4.5.4.1 Check if the water side of LP heater is full and the condensate pump is working. 4.5.4.2 When turbine latch, open motor steam supply valve of heaters, the LP heater shall start following the unit load. 4.5.4.3 Monitor the drain of heater is ok. 4.5.4.4 Extraction drain valve shall be closed automatically when the load reaches 20% of rated value. 4.5.5 LP heater start independently 4.5.5.1 Put the LP heaters in to operation as the sequence from low pressure to higher. 4.5.5.2 Filling at water side is finished. 4.5.5.3 Put into level detector and regulating device into operation. 4.5.5.4 Close the drainage valve at steam side and open the continuously vent valve of condenser. 4.5.5.5 When the vacuum inside LP heater is created, slowly open the extraction valve and pay attention to temperature rise rate is not greater than 2/min. 4.5.5.6 Check water temp and level after the extraction valves are fully open.. 4.5.6 Operation and maintenance of HP/LP heaters 4.5.6.1 Check that all the level indicators are complete and clear, and the action of the drain regulating valve is well and level is ok. 4.5.6.2 No steam and water leakage of HP/LP heaters. 4.5.6.3 Check outlet temperature Rise and end temperature Difference is ok and no knocking to DOCUMENT NO. : HISAR-ZT-07
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all heaters and pipes. If the end temp difference is higher, check vent valves of steam side are fully open and water level is ok. 4.5.7 HP heater stops with unit load 4.5.7.1 Quit of the HP heaters shall follow the sequence from high pressure to lower. 4.5.7.2 Check water level is ok during load down, and switch the HP drain regulating valve to manual control. 4.5.7.3 Ensure that the drain valves before the extraction No. 1, 2, and 3 are open when the load is less than ten percent of MCR. 4.5.7.4 Pay attention to the level are normal when the inside pressure of HP heaters No.3 is approaching that of deaerator. 4.5.7.5 When the unit trip, check that inlet and extraction non-return valves of the extraction No. 5, 6, and 7 are closed and all the pneumatic drain valves in the extraction pipe lines are open, then open drain valve after the extraction non-return valve. 4.5.7.6 Isolate water side of HP heater if required, and open inlet T valve of heater, and bypass water side, then close heaters outlet valve and quit protection, finally open drainage and vent valve to lower the pressure. 4.5.8 The shutdown of HP heater during unit operating normally 4.5.8.1 During HP heater shutdown, should monitor changes of section pressure and load. 4.5.8.2 Shut #7 motor steam inlet valve of HP heater slowly. After #7 motor steam inlet valve of HP heater shutdown, shut #6 motor steam inlet valve of HP heater slowly until shut fully. At last, shut #5 motor steam inlet valve of HP heater slowly until shut fully. Pay attention to control water feed temperature drop rate in 23 /min. 4.5.8.3 According to HP heater level changes, put #7)6)5 HP heater drain regulating valve into manual regulating. 4.5.8.4 When #7 HP heater drain can not transport to deaerator, shut #7 HP heater drain to deaerator regulating valve and motor valve, start #7)#6)#5HP heater steam side bottom water drainage valve. 4.5.8.5 Shut extraction non-return valve of HP heaters No.7, 6, 5. Open front or back drain valve of extraction non-return valve of HP heaters No.7, 6, 5. 4.5.8.6 Isolate water side of HP heater if required, and open inlet T valve of heater, and bypass water side, then close heaters outlet valve and pay attention to changes of water-feed pressure, flow. Open inlet T valve of HP heater firstly and then close HP heater outlet valve, which can not be reversed. 4.5.8.7 Undo the switch of HP heater protection interlock. 4.5.8.8 According to the need, HP heater water side release pressure or drain water. Relevant motor valves shut down and listed.

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4.5.9 LP heater stops with turbine

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

4.5.9.1 Ensure that the extraction drain valve is opened when the load of turbine is dropped to 20 . 4.5.9.2 After turbine trip, 5)6 extraction non-return valve of LP heater and motor valve shut down. 4.5.10 LP heater stops particularly 4.5.10.1 LP heater stops according to pressure from high to low. 4.5.10.2 Shut extraction non-return motor valve, then drain valve opens automatically. Pay attention to control temperature drop rate lower than 2/min. 4.5.10.3 Open water side bypass valve. 4.5.10.4 Shut water side inlet or outlet valve. 4.5.10.5 Shut LP accidental drain manual drive valve and normal drain manual drive valve. 4.5.10.6 Shut valve from LP heater to condenser extraction air manual. 4.5.10.7 Open LP heater water side water drainage valve and air vent valve. Pay attention to vacuum, shutdown immediately if vacuum dropped. 4.5.10.8 Open LP heater steam side water drainage valve and air vent valve to drain. During maintenance, from upper drain manual valve to this drain manual valve shut. 4.5.10.9 Power off extraction non-return valve. 4.5.11 HP heater main interlock protection 4.5.11.1 Open accidental drain regulating valve when HP heater level is higher than value. 4.5.11.2 Extraction motor valves of HP heaters No.7, 6, 5 open conditions: put into operation manual drive or sequence controlling. 4.5.11.3 When #6 HP heater level is high value, shut #7HP heater normal drain regulating valve. 4.5.11.4 When #5 HP heater level is high value, shut #6HP heater normal drain regulating valve. 4.5.11.5 When deaerator tank level is high, shut #5HP heater normal drain regulating valve. 4.5.11.6 Turbine tripping shut extraction motor valve and extraction non-return valve of HP heater. 4.5.11.7 HP heater emergency step out( or any HP heater water level high value):Shut extraction motor valves of HP heaters No.7, 6, 5; shut extraction non-return valves of HP heaters No.7, 6, 5; open extraction non-return front and back drain valve; shut #5 HP heater inlet motor valve; shut #7 HP heater drain motor valve. 4.5.11.8 5HP heater inlet motor valve opening condition: when7HP heater inlet motor valve opens, manual drive or sequence control open 5 heater inlet motor valve. 4.5.11.9 7HP heater inlet motor valve closing condition: When #5HP heater inlet motor valve shuts, manual drive, sequence control or HP heater protection requires shut #7HP heater outlet

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motor valve.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

4.5.11.10 Extraction non-return valve of HP heaters No.7, 6, 5 shut down condition: a. HP heater protection requires shut extraction non-return valve. b. Turbine tripping. c. OPC oil pressure is low. d. Generator oil switch is tripping. e. shut extraction non-return valve on chief operator console. 4.5.12 LP heater and drain system main interlock protection 4.5.12.1 Put LP heater interlock switch into operation. LP heater level high valve and highvalve come together. Fully open accidental drain valve. 4.5.12.2 When LP heater water level high value, open LP heater water side by-pass valve; ; shut LP heater inlet/outlet valve; shut LP heater steam-feed motor valve; shut LP heater steam-feed extraction non-return valve; open LP heater steam extraction drain valve; at the same time shut upper normal drain regulating valve and open upper accidental drain valve. 4.5.12.3 Extraction non-return valves of HP heater No.2, 3 shut down condition: a. #2,#3 LP heater water level protection shuts extraction non-return valve. b. Turbine tripping. c. Generator oil switch is tripping. d. extraction non-return valve shut on chief operator console. e. OPC oil pressure is low. 4.6 Deaerator system 4.6.1 Operation of deaerator 4.6.1.1 When maintenance of deaerator is over, work sheet have been checked out, deaerator checking is finished and valves in every place are in right state. 4.6.1.2 Pressure & temperature of main pipe is checked to be normal. 4.6.1.3 Condensate water recycle system is normal. 4.6.1.4 Water level in condenser is in right level and water quality is qualified. 4.6.1.5 Fill water into deaerator by condenser water pump to normal level, and open re-boiling heating motor driven valve which connect with auxiliary steam and deaerator. 4.6.1.6 Make sure deaerator pressure is manually controlled, thoroughly open adjusting valve and rear motor driven valve which connect with auxiliary steam and deaerator. 4.6.1.7 Manually adjust inlet pressure of auxiliary steam to reboil it to 0.138MPa pressure and hold on for 30minutes. 4.6.1.8 Manually adjust inlet pressure of auxiliary steam to reboil it to 0.138MPa, heat the filled water up to 108 and adjust deaerator to automatic mode. 4.6.1.9 When deaerator flow is found, make deaerator water level adjusting be auto. 4.6.1.10 When the unit is with load and four extraction steam pressure is higher than 0.147MPa, DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

open motor driven valve which connect with four extraction steam and deaerator, automatically close motor driven valve which connect with auxiliary steam of deaerator, and close motor driven valve of reboil heater. 4.6.1.11 When four extraction steam is put into operation, steam of deaerator is supplied by four extraction steam, operation mode of deaerator changed from constant pressure to slide pressure; when turbine operates with rated load, change it to constant pressure mode; during slide pressure course, open motor driven valve which connect with boiler continuous blow down flash tank and deaerator. Close small oxygen vent valve when oxygen content in water is qualified. 4.6.2 Shut down of deaerator 4.6.2.1 Deaerator decreases along with unit, when the load decrease and deaerator pressure is lower than 0.147MPa, close motor driven valve and adjusting valve connected with four extractor and deaerator, and keep deaerator operating under stable pressure of 0.138MPa. 4.6.2.2 After the unit tripped and it is not required to fill water into boiler, close inlet valve of deaerator and set water level mode to manual from auto, and stop filling water into deaerator. 4.6.2.3 Make sure adjusting valve and its rear manual control valve of #5HP drainage is closed, and close constant discharge valve which connected with #7, #6, and #5 HP heater to deaerator. 4.6.2.4 Close air-actuated valve and manually operated valve which connected with continuous blow down flash tank and deaerator. 4.6.2.5 Protect deaerator by filling nitrogen if the deaerator is out of service more than one week, cut off all steam source, water source, discharge all water in water tank, then close vent valve, open nitrogen isolate valve and keep certain nitrogen pressure on deaerator. 4.6.2.6 Deaerator will be heating protected when it is out of service within one week, reboil the water in deaerator by auxiliary steam and keep the pressure at 0.04MPa, and make certain opening of vent valve. 4.6.3 Control parameter of deaerator under normal operation 4.6.3.1 Pressure of deaerator: normal1.046MPa0.147MPa~1.117MPa. 4.6.3.2 Temperature of deaerator: normal: 370.8; max 376.2; min. 20. 4.6.3.3 Water level of deaerator: 2730mm, height 2930mm, height3030mmheight 3330mm, low2530mm, low 1030mm. 4.6.3.4 Oxygen content in water of deaerator: 7g/L. 4.6.4 Shut down of deaerator 4.6.4.1 During shut-up period of the unit, pay attention that the deaerator pressure, temperature and water flow rate should be corresponding with the load. Keep the pressure and water level in deaerator normal. 4.6.4.2 When load of the unit decrease, the pressure of deaerator also decrease. When the pressure decrease to 0.147MPa, switch deaerator steam source to auxiliary steam, and shut up four extractor motor driven valves & return valve. Keep water level normal. DOCUMENT NO. : HISAR-ZT-07
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4.6.4.3 When boiler discharge water with load, close adjusting valve, motor driven valve and manual operated valve which connected with auxiliary steam and deaerator. 4.6.4.4 After the unit shut down, pay attention to the water level in deaerator as so to avoid the water too full to enter into turbine. 4.6.5 Main interlock protection for deaerator 4.6.5.1 When water level higher thanset value, which is 2930mm, CRT will alarm, while lower than this value, close its emergence drainage valve and overflow adjusting valve automatically. 4.6.5.2 When water level higher than set value 3030mm, open overflow drainage motor-valve, while lower than normal level, close it. 4.6.5.3 when water level higher than set value, 3130mm, open its emergence drainage valve, #5 high-pressure heater drain adjusting valve, drain valve behind forth steam extracting inlet valve which is a motor-valve, and drain valve behind steam extracting inverted valve. Close #5 high-pressure heater normal drain adjusting valve, inlet motor-valve between forth steam extracting and deaerator, two inverted valves of forth steam extracting, adjusting valve between assistant steam and deaerator, water level adjusting valve of deareator. 4.6.5.4 When water level lower than value and alarm, closedown starting booster pump, MBFP , TBFP. 4.6.5.5 When water level is lower than value, 1030mm, trip booster pump, MBFP, TBFP. 4.6.5.6 when pressure of forth steam extracting 0.147MPa, open motor-valve between forth steam extracting and deaerator. 4.6.5.7 When deaerator pressure 0.147MPa, close stand-by steam motor-valve. 4.6.5.8 when deaerator pressure 0.147MPa, open stand-by steam motor-valve. 4.6.5.9 when pressure of forth steam extraction 0.147MPa, close motor-valve between forth steam extracting and deaerator, meanwhile closedown it. 4.6.5.10 when deaerator pressure 1.28MPa, deaerator pressure high signal will appear, open drainage valve automatically, close stand-by steam adjusting valve, meanwhile safety valve opening. 4.6.5.11 when turbine trips, close steam inlet motor-valve to deaerator, open stand-by steam adjusting valve. 4.6.5.12 condition to close forth steam extracting inverted valve #1 and #2: a water level of deaerator water tank higher than value, 3130mm b turbine trip c OPC oil pressure is low. d oil switch of generator trip. e shut extraction non-return valve on chief operator console.

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4.7 Feed water steam (motor) pump group 4.7.1 Motor-pump group 4.7.1.1 Preparation before starting

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

4.7.1.1.1 Ensure that the maintenance work is over, and the working sheet has been checked out, system pipe or equipment in good state. 4.7.1.1.2 Check each interlock and protection in good state. 4.7.1.1.3 Adjust valve to its ready to open position according to valve examination card. 4.7.1.1.4 Ensure deaerator water level normal. 4.7.1.1.5 Check oil level of hydraulic coupling normal, start assistant lube oil pump when lube oil pressure 0.15MPa, and oil level of oil tank normal, put lube oil pump interlock. 4.7.1.1.6 Sealing water runs normal, and its pressure difference 0.1MPa greater than unloading water, fill to sealing water return U-pipe, when the water quality of returning condition reached; put U-pipe into running. 4.7.1.1.7 Ensure water-feed pump cooling system is running normal. 4.7.1.1.8 Open inlet valve of booster pump, and fill water to pump proper, drain out air. Open primary and secondary valve of motor pump to heat pump. 4.7.1.2 Start MBFP. 4.7.1.2.1 Switch recycling of water feed pump group to auto 4.7.1.2.2 inform electrical staff to control 6KV bus voltage to upper-limit value, start water feed pump by sequence control or manually, when current normal, and rotating speed of motor stable, open outlet motor-valve, increasing rotating speed gradually, adjust sealing water pressure in time. 4.7.1.2.3 When lube oil pressure 0.3MPa, pay attention to stop assistant oil pump automatically. 4.7.1.2.4 Increasing motor rotating speed, when boiler water filling condition reached, open outlet valve, filling water to boiler. Put water feed control to auto. 4.7.1.2.5 Put water feed to AVT mode, which is adding ammonia and hydrazine, when unit load greater than 30%B-MCR,switch it to CWT mode, which is adding ammonia and oxygen. During stopping unit, when unit load lower than 30%B-MCR, switch it to AVT mode. 4.7.1.2.6 Assistant lube oil pump shall stop automatically when lube oil pressure higher than 0.22MPa, otherwise, stop it by single operation mode, and check lube oil pressure greater than 0.15MPa, work oil pressure of coupling about 0.2MPa. 4.7.1.2.7 When water flow reached to 325 m 3/H, re-cycling adjusting valve shall stop automatically. 4.7.1.2.8 Open intermediate tap motor-valve according to condition, and contact chemical operator to open dose injection valve. 4.7.1.3 Stop motor-pump group 4.7.1.3.1 When unit load rise above 300MW and two TBFP are working under the load, stop DOCUMENT NO. : HISAR-ZT-07
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motor-pump tap valve of TBFP shall be confirmed to open before stop it. 4.7.1.3.2 When unit shutdown and feed water is no need to feed to boiler, MBFP can be stopped. 4.7.1.3.3 Decrease rotating speed of MBFP; switch water flow to other running MBFP, TBFP, and pay attention to water flow and pressure normal. 4.7.1.3.4 When water flow of motor-pump is lower than regulated value, check recycling adjusting valve open automatically. 4.7.1.3.5 When rotating speed is lower than 1500rpm, scoop tube to 0, stop MBFP by sequence control or manually, check current decreasing to 0, record idle time of pump and motor. 4.7.1.3.6 During speed decreasing, check assist ant oil pump start automatically when lube oil pressure is lower than 0.15MPa; maintain it normal, when temperature of working oil lowers than 35 , close inlet valve of cooler to standby. 4.7.1.3.7 After stopping motor-pump, close its water outlet valve according to condition, when air outlet temperature of motor lower than 40, stop its air cooler and its inlet valve. 4.7.1.3.8 Stop dose inlet valve of motor-pump 4.7.1.3.9 If motor-pump in hot stand-by state, maintain lube oil system, water sealing and cooling system, warm pump system running normally. 4.7.1.3.10 If motor-pump is not used for stand-by, stop warm pump valve and intermediate tap valve, water inlet valve of booster pump, and recycling isolating valve. When its case temperature lower than 80 and metal temperature of each bearing lower than 50 , stop its water sealing and cooling system, lube oil system, motor water cooling system, open drainage valve of pump proper and tube. 4.7.1.4 Operation and maintenance for MBFP group a. Check vibration of BFP and hydraulic coupling is not greater than 0.05mm, and that of motor and booster pump bearing not exceed 0.06mm. b. when outlet tem of lube oil cooler increase to 45, open its water inlet valve, control outlet temperature of lube oil within 40 ~45, and not lower than 35, or higher than 55 . Pressure difference between filter two sides shall be lower than 0.06MPa, otherwise, switch to stand-by filter to repair and clean it. c. when oil outlet temperature of working oil cooler increase to 45,open its water inlet valve, control oil outlet temperature within max.. d. Put air cooler into running according to air outlet temperature of motor, control its air outlet temperature within 40~45, not higher than 55 , and motor winding temperature no higher than 130. e. Check intermediate tap pressure normal, and motor-pump running in rated work condition, its pressure shall be about 16.9MPa. f. Check pressure difference between two sides of booster pump and inlet filter should be lower DOCUMENT NO. : HISAR-ZT-07
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40 ~70 , not lower than 35 or higher than 76 at

Operation Manual for 600MW Unit


than 0.06MPa.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

g. Check metal temperature of support bearing and thrust bearing in normal range. h. Its axial displacement 0.45mm. i. in its normal operation range, and its inlet and outlet temperature and flow normal, motor current in limited range. j. return water temperature of Mechanical sealing cooler 80 . k. Oil level, quality and flow of hydraulic coupling are normal. l. lube oil pressure should be about 0.25MPa. Working oil pressure is about 0.2MPa. m. water level, pressure of deaerator is normal, no vaporization and shock in motor-pump. n. No leakage in water cooling system, mechanical sealing system, water sealing system, oil system and water tube. 4.7.1.5 motor-pump trip and in protection a. lube oil pressure 0.08MPa. b. oil inlet temperature of work oil cooler is 130 , oil outlet temperature of coupling is 85. c. oil inlet temperature of lube oil cooler is 75, outlet temperature is 60. d. close inlet valve of MBFP e. inlet pressure lower than 1.25MPa, to trip 30s delay. f. bearing temperature of booster pump or coupling side high to 90. g. bearing temperature of motor-pump radial and thrusting bearing high to 90 . h. temperature of radial and thrusting bearing of hydraulic coupling is up to 95. i. recycling valve malfunction, then stop motor-pump. j. deaerator water level is lower than 1030mm. k. water mechanical sealing temperature for booster pump sucking side or draining side high 90, and high- high 95 . l. mechanical sealing water temperature for motor-pump sucking side or draining side high 90, and high- high 95 . m. motor winding temperature High-high 145 n. radial bearing temperature for booster pump sucking or draining side high 90 o. Water sealing temperature for booster pump sucking or draining side high 80 and high-high 95. p. motor-pump electric trip. 4.7.2 TBFP group 4.7.2.1 Forbid to start condition: a. Speed adjusting system, emergence protection device malfunction, and could not control rotating speed correctly. b. Rotating speed of TBFP turbine emergency governor is not accepted. c. One of main protections for TBFP and its turbine fail. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

d. When the turning gear is engaged, there is friction sound inside TBFP and its turbine. e. Main meters fail. f. turning gear and oil pump runs abnormally, oil level lower or oil quality is not accepted. g. Main valve switch fail, rapid closing valve, HP or LP adjusting valve block or could not close tight. h. Degree of eccentricity monitors alarm. 4.7.2.2 Startup of TBFP group. 4.7.2.2.1 Ensure maintenance of TBFP is over, work sheet have been checked out,, system pipe and equipment in good condition. 4.7.2.2.2 Interlock /protection test have been checked normal, booster pump can be ready for started. 4.7.2.2.3 Single TBFP turbine runs normally. Manual trip test and protection test, over-speed protection test are normal. 4.7.2.2.4 Water level and pressure of deaerator is normal, OCW and CCW of TBFP system is normal. 4.7.2.2.5 Check oil system is o.k., oil level is normal, its difference no greater than 150 mm, oil temperature Adjusting is put to auto control. 4.7.2.2.6 Put each valve in its correct position according to starting demand. 4.7.2.2.7 Put TBFP turbine oil system into running, start main oil pump, check oil pressure normal, start oil tank exhaust fan. Put cooling water into running according to oil temperature. Check oil system no leakage, adjust throttle valve behind lube oil filter, make oil pressure within 0.0981MPa~0.147MPa,temperature 3545 . 4.7.2.2.8 Put oil pump and oil tank exhaust fan to interlock. 4.7.2.2.9 Put EH oil system into running, check its inlet and outlet valve are open, adjusting oil pressure of TBFP turbine is within 10MPa12MPa, oil pressure of accumulator is o.k. and emergency governing oil pressure high than 0.65MPa (g). 4.7.2.2.10 Open booster pump water inlet valve, and fill water, injects air, warm pump proper and pressurizing to booster pump and water feed pump. 4.7.2.2.11 Put water sealing of TBFP into running, water return back to condenser. 4.7.2.2.12 ensure emergency governor valve in disengaging position, HP/LP main steam valve and adjusting valve in closing position. 4.7.2.2.13 Start booster pump and recycling, inlet pressure of BFP is no lower than 1.4MPa. 4.7.2.2.14 Start jacking oil pump, start stand-by oil pump, put turning gear into running. 4.7.2.2.15 steam is supplied from gland steam condenser, and its temperature is 121177, adjust its steam inlet valve, control its pressure at 0.017MPa0.038MPa. 4.7.2.2.16 Open steam exhaust butterfly valve slowly, TBFP turbine extraction air, when its

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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

vacuum degree near to that of main turbine, open butterfly valve completely(the vacuum extraction of TBFP turbine should be simultaneous with main turbine), check steam exhaust pressure lower than 10KPa, monitor main turbine vacuum normal. 4.7.2.2.17 Open drain valve before and behind HP and LP steam inlet motor-valve, drain adjusting valve before main steam auto and manual valve, drain valve in T=BFP proper. Control auxiliary steam or forth extraction steam pressure within 0.15MPa~0.85MPa, when temperature is higher than that of TBFP turbine casing Open auxiliary steam or forth extraction steam motor-valve slowly to warm pipe. After 10~15min., open them completely. 4.7.2.2.18 reset TBFP turbine 4.7.2.2.19 Set target speed, speed rise rate and rotating speed when warm turbine and time depending on the turbine cold or hot state. Item Start from hot statestop in 12h Start from warm statestop in 12~72h Outer case temperature equal to ambient rise to 800rpm stay time in 800rpm To 5800rpm 5m 5m 5m 0m 17.5m 35m 40m 15m 15m 15m 10m

Start from cold statestop longer than 72h 5m

4.7.2.2.20 condition of rolling up of TBFP turbine: steam over-heat temperature is greater than 50, temperature of rolling steam is 20 greater than cylinder temperature, shaft-directional displacement is in regulated value, which is 1.2mm, eccentricity in scope of 0.08mm, and temperature difference between up and down TBFP proper is no higher than 15. 4.7.2.2.21 when rolling starting pays more attention to speed rise, and listen carefully if there is any abnormal noise. 4.7.2.2.22 Switch MEH to local control, check TBFP turbine is in latch mode. Set target rotating speed as 600rpm, and rise speed at 100rpm rate, check parameter in normal range. 4.7.2.2.23 Rotating TBFP turbine speed gets to 600rpm, and warm turbine for 20min. 4.7.2.2.24 after turbine low speed warming, set target rotating speed to 1800rpm, raise rate 200~250rpm. When getting to target speed, run stable for 25min to high speed warming. 4.7.2.2.25 After turbine warming in high speed, set target valve 3000rpm, rise rate 250~300rpm, increase speed, check parameter in normal range. 4.7.2.2.26 when rotating speed gets to 3000rpm; check overall, put MEH to remote control, check no signal of force to manual appeared, set TBFP to auto-control mode 4.7.2.2.27 ensures its vacuum greater than 88KPa, put low vacuum protection into running. 4.7.2.2.28 Parallel pumps according to situation, switch recycling adjusting valve to auto-control, set value 585T/h. 4.7.2.2.29 Increase TBFP rotating speed, make outlet pressure 1~2MPa lower than running pumps, open outlet valve, note recycling adjusting valve acting normal. When inlet flow greater than 585T/h, check recycling adjusting valve in close status, DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

4.7.2.2.30 partly open manual drive valve of TBFP intermediate tap and reheat desuperheating water and open completely when the air is thoroughly out. 4.7.2.2.31 When TBFP turbine rotating speed excess 3000rpm, check pipe and drain adjusting valve closed. 4.7.2.2.32 precautions during speed rise: a. Monitor steam parameter, eccentricity degree, axial direction displacement, and vacuum changing. b. Check oil pressure of each bearing, temperature of radial bearing and thrusting bearing, and oil return temperature are normal. Notice to adjust lube oil temperature in normal when speed is rising. c. Steam exhaust temperature of TBFP turbine shall not exceed limited value, and exhaust spray water control are in auto control. d. Check TBFP water sealing system running normal, inlet and outlet pressure difference should be in normal. e. attention speed rise stable during starting, no heavy fluctuation occurs, pass critical speed smoothly, and forbid to stay in critical rotating speed scope. f. Monitor vibration during increasing speed, and shaft vibration of turbine shall not be greater than 120um, for pump shaft, 40um. 4.7.2.3 Stop TBFP group. a. Ensure intermediate tap valve of another pump open wide enough. b. For pump prepared to stop cut off water feeding auto control. c. Decrease its rotating speed slowly, notice pressure and flow of water feeding, switch water flow to other running pump, and maintain its flow stable. d. When pump inlet flow lower than 260t/h, notice recycling adjusting valve open automatically. e. When stopping pump rotating speed lower to lowest speed 3000rpm, shut off its outlet valve. f. Shutoff TBFP by manually trip emergency governor, check its rapid closing valve and adjusting valve closed, when the speed is reduced, open its drain valve. g. When speed is lower than 500rpm, put turning into running. h. Stop booster pump. i. Stop isolating valve of forth extraction steam and HP exhaust inlet. j. Close steam draining butterfly valve, damage vacuum and close pneumatic drain valve of TBFP k. When vacuum gets to 0, stop gland seal steam, stop inlet returning valve. l. Stop EH system of TBFP turbine. m. continuously turning gear for more than 8h after turbine shut till HP casing temperature is lower than 200 n. if continuous turning gear stop after turbine shut, rotate it manually every 30min for 180 angle degree in 24hrs.. DOCUMENT NO. : HISAR-ZT-07
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o. After rotor stopped, stop all oil pumps.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

p. Close TBFP sealing water and booster pump sealing cooling water, and close cooling water of oil cooler. 4.7.2.4 Operation and maintenance of TBFP a. Oil level and temperature of oil tank in lube oil system normal. b. Outlet oil pressure of main oil pump and stand-by oil pump, bearing temperature and winding temperature are all o.k.. c. Pressure difference between lube oil filter two side is lower than 0.035MPa, when it higher than 0.08MPa, alarm. d. Main supplying pipe pressure of lube oil system, its cooler outlet oil pressure and temperature normal. e. Check no leakage in oil system. h. EH oil pressure is normal, that is in 12.2~14.8MPa. i. booster pump, motor current, winding temperature. Bearing temperature vibration, noise, lube oil pressure and water cooling are o.k. j. pressure and temperature of Inlet and outlet feed-water, pressure of reheater desuperheating water are normal. k. For main water feed pump, lube oil supplying pressure and returning flow are normal 4.7.2.5 Monitoring items: a. Low pressure steam pressure, temperature and flow. b. Steam draining pressure and temperature c. wall temperature of inner and outer wall at TBFP turbine front cylinder d. Steam inlet temperature of adjusting valve. e. Flange wall temperature of main steam pipe. f. oil returning temperature of front and rear radial bearing, thrusting bearing g. oil temperature of front and rear radial bearing, thrusting bearing h. #1,#2 bearing vibration. i. Axial displacement and rotating speed. j. Steam pressure before high pressure steam chamber, pressure behind adjusting stage. k. Pressure behind low pressure main steam valve. l. Pressure behind low pressure adjusting valve. m. Outlet pressure of high pressure main steam valve. n. Water draining temperature before high and low pressure main steam valve. o. Gland seal steam supplying pressure and temperature p. For all drain valves, open them until turbine load gets to 240 MW. During stopping turbine, close them until its load lower to 25%, and open them after turbine tripped. 4.7.2.6 TBFP trip protection (DCS) DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit


a. TBFP Axial direction displacement gets to 0.8mm. b. Steam exhausts temperature high. c. Vacuum -30KPa. d. lube oil pressure below 0.05MPa. e. Boiler MFT. f. turbine driven BFP booster pump stopped.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

g. Water sealing pressure difference low and water returning temperature high of TBFP h. Inlet pressure of TBFP lower than 1.25MPa, delay 30s. i. TBFP Recycling valve fail. j. TBFP Over-speed. k. Radial bearing temperature of sucking and draining side is greater than (or equal) 90, thrusting bearing temperature is greater than (or equal) 90 . l. Water level of deaerator water tank low. m. Radial bearing temperature (fore and rear) is not less than 120. n. Thrusting bearing temperature is not less than 120 . o. Turbine and bearing (fore and rear) vibration(X, Y direction) greater than 0.125mm. 4.7.2.7 Trip protection (MEH) a. manually Stop. b. TBFP Axial direction displacement is greater than 0.8mm. c. Steam exhausts temperature high. d. Vacuum below -30KPa. e. lube oil pressure below 0.05MPa. f. TBFP turbine adjusting oil pressure low. g. Bearing temperature high. h. MEH trip. i. Over-speed protection acts. j. Mechanical over-speed: 6150rpm. Electrical over-speed:6100rpm. 4.7.2.8 Stop TBFP rapidly when any of following conditions occur: a. TBFP Rotating speed surge rapidly to 6000rpm while over-speed protection doesnt act. b. TBFP Running parameter gets to set disengaging valve but protection doesnt act. c. TBFP turbine Water impulse occurs. d. Vibration heavily abruptly or metal friction sound can be heard. e. Any bearing is out of oil, catches a fire or gas emitted from it. f. Oil system catch a fire and could not be put out in time, pump safety operation is ruined. g. Leakage heavily in oil system and could not run continually. h. Steam pipe or water feeding pipe broken and could not isolate them. i. Vaporization in BFP group. DOCUMENT NO. : HISAR-ZT-07
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j. booster pump motor catches a fire or gas emitting, winding temperature greater than 130, bearing temperature greater than 95, pre-pump current excess limited value heavily. k. Booster pump bearing temperature greater than 90, water returning temperature of sealing cooler greater than 95 . l. Oil level of lube oil tank lower than regulated value. m. Speed adjusting system fluctuates largely. 4.8 Open/close cooling system 4.8.1 Set protection valve for open cooling system 4.8.1.1 Inlet valve close during OCP is running, OCP trip. 4.8.1.2 Fore and rear bearing temperature of motor gets to 80 , OCP trip. 4.8.1.3 Motor winding temperature gets to 145 , t OCP trip. 4.8.1.4 Pressure difference between electric filter two sides gets to 500mmH2O, open blow down valve of it automatically. 4.8.1.5 Pressure difference between electric filter two sides lower to 250mmH2O, close blow down valve of it automatically. 4.8.2 Set protection value for close cooling system 4.8.2.1 Motor bearing temperature Higher than 95, CCP stop automatically. 4.8.2.2 CCP Motor fail, its pump stops automatically. 4.8.2.3 CCP electric protection acts, its pump stop automatically. 4.8.2.4 Motor winding temperature gets to 145 , CCP stop automatically. 4.8.2.5 Water level of CCP water tank lower than 1000mm, its make-up valve open automatically. 4.8.2.6 Water level of CCP water tank higher than 1500mm, its make-up valve closes automatically. 4.9 Generator oil sealing system 4.9.1 General regulation 4.9.1.1 Put it into running before turning gearing and generator air replacement is done. 2 Oil sealing system shall maintain running when filling hydrogen or dioxide into generator. 3 Put lube oil system first when generator is full of hydrogen. 4 smoke exhaust fans shall run continually when generator is full of hydrogen. 5 Stop oil sealing system nothing but when generator is stopped and full of air. 4.9.2 Put oil sealing system into running 4.9.2.1 Ensure AC lube oil pump and hydrogen oil sealing pump is running, lube oil system is running normally, oil level of air side oil tank is normal, no oil level high/lower alarm. 4.9.2.2 ensure main and stand by pressure difference control valve, balance valve, safety valve, reducing valve are calibrated to realize pressure difference between air side oil sealing and hydrogen is at 0.0840.1MPa. 4.9.2.3 Each valve is in its normal position and system inspection finished. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

4.9.2.4 Start one of smoke exhaust fan in air side oil tank, put another one to interlock stand by. 4.9.2.5 Start air side DC oil pump, check no leakage in system, stop it when normal. 4.9.2.6 Start one of air side AC oil pumps, after running normally, put same side DC stand by oil pump to interlock. Check ball float valve in hydrogen side oil returning tank work normally, and its liquid level normal. 4.9.2.7 Start hydrogen side AC oil pump, switch same side stand by pump to interlock, check make-up and drain out float valve in oil returning tank work normal. 4.9.2.3 Check oil sealing system overall, no leakage appears, check water level of float water level detector, oil sealing tank and froth breaking tank changing normally. Prevent generator from filling oil or water. Trace each balance valve and pressure difference valve normal, and indicator normal. 4.9.2.9 When oil sealing temperature of two sides increase to 43, put oil cooler into running. 4.9.3 Shutdown seal oil system 4.9.3.1 Make sure inner generator fill with air and keep still. 4.9.3.2 Undo seal oil pump interlock. 4.9.3.3 Shut hydrogen side AC seal oil pump. Stop hydrogen side seal oil cooler supplying water (can stop cooler according to oil temperature). 4.9.3.4 Shut air side AC seal oil pump. Stop to supply water to seal oil cooler at air side (can stop cooler according to oil temperature). 4.9.3.5 Undo smoke exhaust fan interlock. Shut air side seal oil smoke exhaust fan. 4.9.4 Generator seal oil system operation maintenance 4.9.4.1 During normal operation, must ensure sealing oil pressure. Maintain the sealing oil and gas inside the machine pressure difference is 84KPa. Air and hydrogen side sealing oil pressure difference should be lower than 0.49KPa. 4.9.4.2 Pressure and current of sealing oil pump is normal. Stand-by sealing oil pump and DC sealing oil pump in good standby condition during normal operation. 4.9.4.3 Examine and maintain oil level of sealing oil tank at air or hydrogen side o.k. 4.9.4.4 Examine and maintain sealing oil cooler at air or hydrogen side are o.k. Outlet oil temperature should keep in 3849. 4.9.4.5 No oil leakage in the whole system. 4.9.4.6 During normal operation, air side seal oil return tank maintain sub pressure 250 500Pa. 4.9.4.7 Scraper oil filter of seal oil unit turns a handle every eight hours to clean to avoid oil channel blocking. The pressure difference between air and hydrogen side seal oil filter is lower than 50KPa. 4.9.5 Sealing oil source of air side and hydrogen side 4.9.5.1 Oil source of air side sealing oil DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

a. main working oil source: normal working oil source of air side sealing oil shall be supplied by AC sealing oil pump, outlet pressure is 1.0MPa. b. First standby oil source: it is 2.1~2.3MPa HP oil which comes from turbine main oil pump. When main working oil source malfunction and oil-hydrogen pressure difference drops to 0.056MPa,the oil source shall be put into operation automatically by the control of standby pressure difference regulating valve. c. Secondary standby oil source: it is supplied by the hydrogen seal standby oil pump on turbine main oil tank. When turbine rotating speed is lower than 2850r/min or goes wrong and oil-hydrogen pressure difference drops to 0.056MPa, well then sealing oil will be supplied by hydrogen seal standby oil pump. Outlet pressure is 0.81.1MPa.. d. Third standby oil source: it is supplied by DC sealing oil pump. Start DC sealing oil pumps while hydrogen-oil pressure difference drops to 0.035MPa. This oil pump is allowed to running for about 1 hour only. e. Fourth standby oil source: it is supplied by turbine lubricant oil pump, but oil pressure is lower, normal range is 0.050.12MPa. At this time, hydrogen pressure must be reduced to 0.014MPa. 4.9.5.2 Oil source of hydrogen sealing oil: normal working oil source of hydrogen side sealing oil is supplied by AC sealing oil pump. When AC sealing oil pump is blooey, sealing oil shall be supplied by standby sealing oil pump. 4.9.6 I & C interlock protection 4.9.6.1 Operating inlet & outlet pressure difference of hydrogen side sealing oil pump is as low as 0.035MPa, that hydrogen side sealing oil pump shall be started. 4.9.6.2 Oil & hydrogen pressure difference is as low as 0.035MPa; DC oil pump of air side sealing oil shall be started. 4.9.6.3 Inlet & outlet pressure difference of DC sealing oil pump is as low as 0.035MPa, that air side sealing oil DC oil pump shall be started. 4.9.6.4 Inlet pressure of generator air side sealing oil is low, start air side sealing oil DC oil pump. 4.9.6.5 Return oil temperature of air side sealing oil is as low as 40, heater shall start automatically; and it will auto stop when return oil temperature reaches 45 . 4.9.6.6 Return oil temperature of hydrogen side sealing oil is as low as 40 , heater shall start automatically; and it will auto stop when return oil temperature reaches 45 . 4.9.7 Accident Disposal 4.9.7.1 Reasons for reduction of oil/hydrogen pressure difference and disposal. a. If air side AC sealing oil pump malfunction, it is necessary to supply oil for HP standby sealing oil, maintain oil/hydrogen pressure difference as 56KPa. b. If oil/hydrogen pressure difference cannot be maintained, and keep on reducing to 35KPa, put DC sealing oil pump into auto operation, otherwise start it manually. DOCUMENT NO. : HISAR-ZT-07
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c. After DC sealing oil pump being started, if oil/hydrogen pressure difference cannot be maintained, emergency hydrogen exhaust shall be done; hydrogen pressure is reduced to 14KPa or below, unit shutdown. d. If oil/hydrogen pressure difference regulating is failed, contact maintenance men to dispose as soon as possible. 4.9.7.2 Failure of hydrogen side sealing oil pump or interruption of hydrogen side sealing oil a. hydrogen side sealing oil pump is shutdown due to failure, strict monitor hydrogen purity of generator, which shall not be lower than 90%, and ensure the operation of smoke extractor exhaust fan of main oil tank and air side sealing oil tank. b. If air/hydrogen side pressure difference balancing valve is failed, please contact maintenance men to examine & repair in time, and strengthen the monitoring of oil level in defoaming tank. 4.9.7.3 High oil level in defoaming tank: a. When oil level in defoaming tank is increasing, check the operation of air/hydrogen side pressure difference balancing valve, contact maintenance men to examine & repair in time. b. Check the oil level in hydrogen side return oil control tank is normal or not, if high oil level in defoaming tank is caused by this, when oil level in defoaming tank is increasing to alarming value, well then manual open hydrogen side return oil high level float valve to control the oil level in defoaming tank and hydrogen side return oil control tank. If necessary, carefully open oil drain valve of defoaming tank to drain oil. 4.9.7.4 Hydrogen side sealing oil level is extreme low: a. Once oil level reduction is discovered and low oil level alarm is sent out, turn down high level drain floating valve, and open low level filling floating valve to fill in oil tank. Maintain normal oil level. b. If oil level cannot be maintained, it is necessary to close high level drain floating valve. 4.10 Stator cooling water system 4.10.1 Stator cooling water system operation rules 4.10.1.1 Generator must pressurize before system is feed water or begin circulation. 4.10.1.2 Water must be inside cooling system before generator loaded or stator coil charged. 4.10.1.3 Generator hydrogen pressure must be 0.035MPa higher than that of stator inlet cooling. 4.10.1.4 When generator cut excitation, stator cooling water system could shut. 4.10.1.5 Make sure inner cooling water temperature at least higher than hydrogen temperature 1 . 4.10.1.6 When generator stator winding inlet and outlet water pressure difference value reduced to 70% of the rated flow (55t/h), switch differential pressure. According to "three close, take two" logical principle, this acts as the signal of generator water break protection. When the generator stator winding appears water break, allow full loaded 100% rated current running 5 seconds and DOCUMENT NO. : HISAR-ZT-07
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put stand-by pump within 5 seconds into normal operation. If the standby pump in 5 seconds can not run normal, generator must stop or every minute in 2 minutes with the rate of 50% of the stator current will be reduced automatically to 15% of the rated current. At the same time, electrical conductivity of stator cooling water should be controlled in 1.5 cm/s. 4.10.1.7 When the stator cooling water flow is low and at the same time water conductivity lower than 1.5s/cm, generator could operate an hour by 15% rated stator electricity. If stator cooling water flow is low and conductivity is higher than 1.5s/cm, generator must stop immediately. 2.5 minutes later excitation is lost. 4.10.2 Put stator cooling water system into operation 4.10.2.1 Make sure condensate transfer pump put into operation, stator cooling tank feed water source is normal and 4.10.2.2 Examine generator and make sure inner hydrogen pressure set up. 4.10.2.3 Make sure the level of stator cooling tank is normal, water quality qualified, water temperature is normal. 4.10.2.4 Put stator cooling ion exchanger into operation; feed the level of stator cooling tank to normal high level. Water tank water drainage valve blow down, until chemical assay water quality qualified, close tank water drainage valve. 4.10.2.5 Examine stator cooling tank supply nitrogen automatically to 0.014MPa and its pressure regulator normal. 4.10.2.6 Shut cooler, filter drain valve, bypass valve. Start air valve, and then start stator cooling pump, cooler and filter inlet or outlet valve system to feed water to system. Put cooler into

operation, filter air valve leave one circle opening, shut stand-by cooler and filter air valve. 4.10.2.7 Shut stator cooling water pump outlet valve. Shut one group of cooler. Filter inlet valve on standby. 4.10.2.8 Start stator cooling pump; start outlet valve after checking operation normal; adjust control pressure of generator inlet valve to 0.250.35MPa.Stator cooling water flow is about 90t/h. 4.10.2.9 Put another pump interlock and standby. 4.10.2.10 After generator synchronization, put stator cooler into operation when generator inlet stator cooling water temperature is over than 45 and control generator stator cooling water temperature between 4550. 4.10.3 Shutdown stator cooling water pump 4.10.3.1 When standby stator cooling water pump switches, firstly manually start stand-by pump; secondly shut running pump and put stand-by pump into operation. Pay close attention to cooling water flow is normal or not. 4.10.3.2 When unit shuts, stop the stator cooling system immediately according to demand in order to prevent generator overcooling. DOCUMENT NO. : HISAR-ZT-07
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4.10.3.3 Undo stator cooling water pump interlock. Shut stator cooling water pump. Check stator cooling water pump shutdown or not. 4.10.4 Stator cooling water system operating maintenance 4.10.4.1 The normal operation should always check the level of stator cooling tank and make sure stator cooling water pump operate normally. 4.10.4.2 Stator cooling water normal temperature is controlled in 3550. Maintain normal operation constant value 401. 4.10.4.3 Stator cooling water pressure is normal. Stator cooling water pump outlet pressure is about 0.75MPa. Stator cooling water flow is about 90t/h normal. 4.10.4.4 When unit is operating normally, stator cooling water regenerative circuit (ion exchanger) shall be running. Chemical staff should check water quality regularly and make sure stator cooling water electric conductivity in 0.51.5us/cm. 4.10.4.5 When there is nitrogen in the upper of stator cooling water tank, check its normal pressure is 0.014MPa. 4.10.4.6 Ion exchanger operating flow is 35% of total flow and conductivity indication is within 1.5us/cm. 4.10.5 Main interlock protection 4.10.5.1 When stator cooling water main pipe pressure is low, stator pump starts. 4.10.5.2 When inlet and outlet pressure difference of operating stator cooling water pump is lower than 0.014MPa, stator pump starts. 4.10.5.3 When stator tank pressure is higher than 0.035MPa, safety valve of tank opens automatically. 4.10.5.4 When stator water flow is lower than 70% of rated flow 55t/h time lag 30s, generator , tripping. 4.10.6 Accident disposal 4.10.6.1 The reason of stator cooling water low pressure and disposal: a. Pressure difference of stator cooling water sieve or stator cooling water cooler is high, you should switchover sieve or stator cooling water cooler. b. When the stator cooling pump is overloaded, recycling degree shall be increase and start stand-by pump if necessary. c. When the stator cooling pump trip, stand-by pump shall be put into auto operation. d. When the level of water tank is low; feed water to normal level. e. When pipes, valves, flanges etc. leaks; isolation measures must be done to not affecting unit operation. 4.10.6.2 Generator water leaking disposal: a. When generator level detector high alarm, you should immediately discharge liquid in

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situ. If generator contains water more, you should find out reason quickly. Discharging liquid, you should prevent hydrogen leaking largely. b. Hydrogen cooler leakage, you should separate broken hydrogen cooler and decrease load to maintain hydrogen temperature normally. Pay attention to temperature of generator iron core and coil. c. You should low stator cooling water temperature if hydrogen pressure is lower than stator cooling water pressure and generator coil leakage slightly. At the same time, report to leadership to require failure shutdown. d. When leakage is too serious to endanger the safety operation of unit, shut stator cooling water system and separate hydrogen cooler; also start drain valve of generator.

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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Chapter V Electrical Equipment Operation Regulation


5.1 Electrical equipment 5.1.1 General introduction Generator is manufactured by shanghai turbine works LTD, which type is QFSN-600-2, cooling mode is water-hydrogen-hydrogen, that is, stator winding cooled by internal water, rotor winding cooled by internal hydrogen, stator core and its structure surface cooled by hydrogen. Generator rotor and turbine rotor is rigidly linked. 5.1.2 Specification 5.1.2.1 Rated specification Type Rated capacity MVA Max. continuous capacity Stator rated voltage kV No-load rated voltage V Full-load exciting voltage V Power factor(lag) Impact exciting times Rated rotor speed r/min phase Short circuit ratio Total loss kW QFSN-600-2water-hydro-hydro turbine generator 667 Rated power MW Matched to turbine 20 Stator rated current A 139 No-load exciting A 407 Full-load exciting current A 0.9 Excite mode 600 19245 1480 4145 Self shunt state excite 10 50 Double start F 98.94% Air from seam 35 46(max.48)

2.5 Admitted impact time S 3000 frequency Hz 3 Conductor mode 0.54 Stator/rotor insulating class 6399 efficiency(calculated value) Water-hydroge Cooling mode Vent mode n-hydrogen Hydrogen pressure MPa 0.4 Hydrogen cooler water temperature Cooling hydrogen temperature Vent quantity m3/s 35 Max temperature of stator cooling Stator cooling water quantity 90105 50 water m3/h Stator weight t 320 Rotor weight t 66 Rotor moment of inertia kgm2 9500 Critical speed of rotor r/min 760/2120 Rotate direction Clockwise from generator Manufacturer Shanghai turbine works LTD. Note: QFSN----600----2 meaning: QF means turbine-generator, S means internal water cooling mode, N means hydrogen cooling, 600 means unit rated capacity, 5.1.2.2 Exciting transformer type Rated voltage kV Over load capacity in short time impedance IP code dry 20/0.88 110% 6% IP23 capacity MVA 6 Frequency Hz 50 Connect mode Y/d-5 Cooling mode Nature cooling Installation environment In house 1 min power frequency 55 voltage withstand kV 2 means two poles.

Level of shock voltage withstand kV 125 5.2 Generator operation regulation 5.2.1 Start condition

5.2.1.1 for generator or its accessories, like main transformer, high-voltage plant transformer, and plant distribution fixture, no repairing ticket are implemented, or ticket has been implemented, and DOCUMENT NO. : HISAR-ZT-07
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repairing staff have departed.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

5.2.1.2 Have a clean site. Work and emergency lighting system can work normally, have enough illumination, and have enough firefighting facilities. Mark, number and phase color are clear and conspicuous. Other demand of starting unit can be reached. 5.2.1.3 Tests conducted before starting have been done, and reports are clear and correct. 5.2.1.4 Generator, exciting system, and other accessory can be put into running normally. 5.2.1.5 Primary and secondary equipment of generator-transformer unit and plant high-voltage transformer are in normal status. 5.2.1.6 Air tightness test of generator has done and conform. 5.2.1.7 The stator cooling system of generator is in normal status and has been tested, water quality is conformity, and no leakage exists. 5.2.1.8 Protection, synchronizing system, auto-adjusting exciting equipment, and accident recording system in normal status. 5.2.1.9 NCS, DCS and monitor meter, signal meter in normal status. 5.2.1.10 direct power, UPS in normal status. 5.2.1.11 Diesel generator is in normal and spare status. 5.2.1.12 Hydrogen replacement finished. The purity, humidity, and ox-capacity are conformity. Hydrogen leakage is in regulated value. 5.2.1.13 Temperature measuring element is perfect and indicator correctly. 5.2.2 Check before starting generator 5.2.2.1 Check before starting exciting system. 5.2.2.1.1 All work ticket finished. 5.2.2.1.2 Primary and secondary system are checked completely, linked tightly, no loose part, and insulating support parts are tight and stubborn. 5.2.2.1.3 Insulate of measuring system is perfect. 5.2.2.1.4 Insure all DC or AC power on. 5.2.2.1.5 Control cabinet and power cabinet are prepared and locked. 5.2.2.1.6 Turn exciting adjusts equipment, signal, meter power on and check if they are normal, no alarm and troublesome message. . 5.2.2.1.7 The fans of power cabinet, control cabinet run normally, link operation test of power and fan normal. 5.2.2.1.8 Switch exciting system to remote and auto control mode. 5.2.2.1.9 Power of exciting initiating equipment normal. 5.2.2.2 Check before generator starting 5.2.2.2.1 Work ticket of generator system and its primary and secondary equipment is finished. All safety measures and mark plate have been taken back. And technical explanation in paper is detail and complete. The site is clean and bright, each part can be start in any time. DOCUMENT NO. : HISAR-ZT-07
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5.2.2.2.2 Bus ring is linked and tighten well, brush can move smoothly up and down, its frame bottom doesnt contact with bus ring. 5.2.2.2.3 Slip ring, brush and ground brush of main shaft are installed well and contacted well. 5.2.2.2.4 Each linkage, bond and shim of the generator proper are stable, no condensation in their part and illumination is enough. Check exciting system and its equipment no break, moist or dirty and other abnormal situation. Linkage is stable, no loose and broken. 5.2.2.2.5 Running condition of generator-transformer protection, auto exciting system, NSC, DCS is possessed; the clamping bars are in their correct position. 5.2.2.2.6 Check auto synchronizing equipment correct. 5.2.2.2.7 Each test before starting unit is conformity. 5.2.2.2.8 Oil sealing system, hydrogen cooling system, and stator inner cooling water system are put into running normally. Each meter, parameter indicator is correct and agrees with running regulation of generator cooling system. 5.2.2.2.9 insulating of measuring system conform to regulation. 5.2.2.2.10 put micro-pressure vent equipment into running. 5.2.3 Test before starting 5.2.3.1 According to regulated test list before starting generator, conduct tests like interlock, protection, and trip and connect test by hand. 5.2.3.2 All tests should be done while the switchgear of 400kv bus (main and assist) is in break position, work switch of 11kv bus is in test or repair position. 5.2.3.3 Test item 5.2.3.3.1 Main terminal switch trip and close test of generator-transformer. 5.2.3.3.2 De-exciting switch trip and close test and lock to trip main switch test. 5.2.3.3.3 11KV A, B, C work powers inlet line switches trip and close test. 5.2.3.3.4 Assist to relay staff to do protection test. 5.2.3.3.6 Switch over test of emergence lighting system. 5.2.3.3.5 Signal system test. 5.2.3.3.7 Big interlock test of boiler, turbine and generator. 5.2.4 Basic operation step when start generator-transformer 5.2.4.2 Generator transformer turns to warm stand by: 5.2.4.1.1 All work ticket of G-T have finished, equipment is perfect and can be put into running. 5.2.4.1.2 Check primary and secondary system of G-T wiring correctly and perfectly. 5.2.4.1.3 Measure primary and secondary equipment insulation and conformity. 5.2.4.1.4 According to electric relay protection code, put G-T protection, plant high-voltage transformer protection and auto equipment. Check NSC, DCS equipment put into running. 5.2.4.1.5 Check 400kv bus differential protection clamping bar to G-T connected. 5.2.1.4.9 Put slip ring cooler into running. DOCUMENT NO. : HISAR-ZT-07
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5.2.4.1.6 Put high voltage fuse of generator into its position, push switch into work position, close secondary switch. 5.2.4.1.7 Check NSC, DCS equipment and monitor meter in running position. 5.2.1.4.8 Check generator bus micro-pressure equipment in running position. 5.2.1.4.11 put rectifier into running. 5.2.1.4.10 Check exciting initiating power, rectifier cabinet, and exciting adjusting equipment power on. 5.2.4.1.11 change rectifier from cold standby to operation. 5.2.1.4.12 Put exciting system into warm stand-by. 5.2.1.4.13 Put cooling equipment of main transformer into running. 5.2.1.4.14 Put cooling equipment of A, B plant high-voltage transformer into running. 5.2.1.4.15 Check neutral switchgear in closing position. 5.2.1.4.16 Check switches of G-T in broken position. 5.2.1.4.17 Close 400kv bus switchgear according to order. 5.2.1.4.18 put 11kv A, B, C work power switch into warm stand-by. 5.2.1.4.19 Turn the power of plant high voltage t, G-T, de-exciting switch on. 5.2.4.2 Step of put rectifier into running 5.2.4.2.1 Put DC side fuse into position and check it perfect. 5.2.4.2.2 Put AC side fuse into position and check it perfect. 5.2.4.2.3 Turn rectifier power on, 5.2.4.2.4 Turn fan power on. 5.2.4.2.5 Switch fan mode to right fan, check it running correctly. Note: Steps of stop rectifier are just opposite. 5.2.4.3 Steps of generator synchronize to grid. 5.2.4.3.1 Check condition admitted before synchronizing. And parameter display correctly. 5.2.4.3.2 Start g program control after gs speed in 3000r/m stable. 5.2.4.3.3 Watch closely to respective parameter changing, and signal display. 5.2.4.3.4 If synchronize successful, check parameter display correctly, and return main switch on CRT. 5.2.4.3.5 Check exciting system put into running and its switch close perfectly. 5.2.4.3.6 Check G-T switch close perfectly. 5.2.4.3.7 Adjust neutral running mode of 400kv system according to order. Note: if synchronizing is done by hand, finish it according to condition and sequence displayed on diagram. 5.2.5 Inspection after turning (1500r/m or 3000r/m) 5.2.5.1 Temperature, vibration, and oil-back temperature of bearing, bearing pad are normal. 5.2.5.2 Stator cooling water pressure, flow and temperature and outlet water of wire bar and DOCUMENT NO. : HISAR-ZT-07
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inter-lamination are normal.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

5.2.5.3 Hydrogen temperature, pressure and purity and other parameter of hydrogen cooling system are normal. Adjust them if needed. 5.2.5.4 Slip ring brush, shaft brush of g contact well and no vibration, break and crash, temperature is normal. 5.2.5.5 No water or hydrogen leakage in g proper. 5.2.5.6 Check g proper and its exciting system after increasing exciting voltage, insure each parameter, meter indicator correct. 5.2.6 Check after g synchronizing 5.2.6.1 Check stator current evenly and no weave, signal of auto exciting regulator normal. 5.2.6.2 No abnormal sound or discharge sound heard in g and t proper. 5.2.6.3 Check CT, TV no abnormal sound and discharge. 5.2.6.4 Temperature of generator part increase while load increasing. 5.2.6.5 No abnormal sound heard in exciting system, each part temperature is normal. 5.2.6.6 Signal in protection panel is normal when turbine is with load. 5.2.7 Operation regulation after g synchronizing 5.2.7.1 Switch plant power to plant high voltage transformer after boiler flame stable and increase to 180MW. 5.2.7.2 Increasing speed of active load is decided by turbine. When generator started from cold stand by status, stator and rotor current should be insured evenly and slowly. 5.2.7.3 Increasing speed of generator stator and rotor current should be evenly, and in heat status and emergence status, there is no limitation for their increasing speed. 5.2.7.4 Monitor cooling water and hydrogen temperature and its increasing speed, core tem, winding temperature and outlet water temperature. Monitor brush, exciting system running normal, and adjust wattles load to make it running in regulated scope as well as g voltage. 5.2.7.5 When synchronizing and increasing load, monitor water and hydrogen cooling system, insure they are no leaking water and hydrogen. 5.2.7.6 Monitor hydrogen, oil seal system running; check their parameter in regulated scope. 5.2.8 Operation when start generator 5.2.8.1 Start generator after receiving foremans order. 5.2.8.2 Close neutral ground switchgear of main transformer before G-T synchronizes to grid. 5.2.8.3 Check main switch of G-T in their disconnect position before synchronizing. 5.2.8.4 Close 400kv bus switchgear or assist bus switchgear after generator stable in 3000r/m, and condition reached. 5.2.8.5 Exciting mode should be auto. 5.2.8.6 Watch exciting current, voltage and their changing when increasing voltage. The generator voltage should be not excess rated value. DOCUMENT NO. : HISAR-ZT-07
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5.2.8.7 If there is any abnormal found in increasing voltage, stop increasing and decreasing it to 0, after finding out reason, and approved by deputy manager or chief engineer, increasing can continue. 5.2.8.8 Synchronizing condition 5.2.8.8.1 The G-T voltage should be equal to grid voltage (difference no larger than 5%) 5.2.8.8.2 The G-T frequency should be equal to grids (difference no larger than 0.1Hz) 5.2.8.8.3 The phase of G-T should be equal to grids (difference no larger than 15 degree, max. no larger than 20 degree) 5.2.8.9 Check phase rotation after overhaul or synchronizing circuit changed, and false synchronization test should be done to check its circuit correct. 5.2.8.10 Adjust exciting regulator to lowest voltage before start generator. 5.2.8.11 we regard all equipment have power after generator rotor. 5.2.8.12 for new installed or repaired generator, when start it first, increasing speed slowly and monitor generator voice, inspects oil flow of bearing and vibration. 5.2.8.13 Inspect brushes on slip ring no jumping, no block, and contact well when generator rotor speed gets to regulated value. 5.2.8.14 Check generator unit no abnormal signal, after turbine speed stable, can increase its voltage after foremans order. 5.2.8.15 after generator rotating, check display situation, status and alarm on CRT. 5.2.8.16 when rotor current reaches no load rated value while stator voltage doesnt get to rated value, or alarm signal appears, stop operation and find out reason. 5.2.8.17 forbidding put exciting system when rotor speed lowers than 2950r/m. 5.2.8.18 when synchronizing, maintain rotor speed in 3000r/m, or adjusting it. 5.2.8.19 If main switch doesnt close after synchronizing equipment put into running, break it power and find out reason.. 5.2.8.20 Monitor closely three phase current, negative sequence current, active power, wattles power and other parameter while synchronizing to prevent main switch from closing lack of one phase. 5.2.8.21 Put AVR into running, close exciting switch, generator will increase voltage from 0v, note: 5.2.8.21.1 Increasing voltage slowly and make three phase voltage balance, current to 0 or nearly. While rated voltage reached, check rotor voltage and current reaching rated value. Otherwise stop operation. 5.2.8.21.2 Check three voltage balance after stator voltage get to rated value. 5.2.8.21.3 Check no load rotor voltage and current normal while stator in rated value. 5.2.8.22 Take protect measures if asynchronous parallel. 5.2.8.23 Synchronous parallel when frequency difference in 1HZ. 5.2.8.24 Close watch synchronizing equipment when operation. DOCUMENT NO. : HISAR-ZT-07
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5.2.8.25 if synchronizing by hand, reporting to deputy manager or chief engineer is needed. 5.2.9 General regulation while unit running 5.2.9.1 Order should be received if adjusting active load or exciting mode. 5.2.9.2 Close watch each parameter and adjust them correctly, make generator running in good condition. 5.2.9.3 Close watch temperature of generator and exciting transformer, and hydrogen, inner cooling water or other parameter in correct value. 5.2.9.4 Patrol and analyze meters display, report foreman or team leader immediately if any abnormal fact is found and repair it. 5.2.9.5 Put protection, auto exciting regulating, and accident recording equipment into running correctly. 5.2.10 Generator current and voltage regulation 5.2.10.1 Stator voltage is rated value while generator running normally, its changing scope is 5% of rated value, frequency is 50HZ, changing scope is 0.2Hz, and output rated power continuously. 5.2.10.2 Stator current should not be larger than 105% while voltage lowers than 95%, now g temperature should be noticed. 5.2.10.3 The max. changing scope of stator voltage should be not larger than 10% rated value, and when it excess rated value, notice each part running normally. 5.2.10.4 Unbalance current of stator three phase current should be not larger than 8% rated value, now any one phase should be not larger than rated value. 5.2.10.5 The generator should run in delay phase mode normally, rated factor is 0.9, when lower than 0.9, rotor current should not excess rated value. Generator can run in higher factor mode if grid has higher voltage, but monitor system stable ability is needed. 5.2.10.6 Normally, each phase stator current should not excess rated current, as well as rotor current. 5.2.10.7 If exciting adjusting cabinet running normally, and proper grid voltage, generator can run under-excitation operation; the ratio should not excess 0.95.while run in under-excitation operation, control rotor current in rated value, winding temperature, core temperature and its terminal part temperature in limited value. 5.2.11 Exciting system regulation while running 5.2.11.1 Rectifier equipment 5.2.11.1.1 Maintain 5 cabinets running in normal situation. While one cabinet exit, other fours can meet all operation condition, two exit, other threes can meter rated exciting demand and force exciting function should exit. 5.2.11.1.2 There is PCB to limit unbalance current between cabinet to 90%. So check current value to see if they are balance when running normally. DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

5.2.11.1.3 There are some stand-by fans in each cabinet. Switch their power and do interlock test according to demand. 5.2.11.1.4 In normal condition, power #1 work, power #2 stand-by and right fans work, left fans stand-by. 5.2.11.2 Regulation of running exciting adjusting equipment 5.2.11.2.1 There are twin auto channel and twin manual channel which is stand-by in exciting adjusting equipment. And there is manual channel in auto channel also. In normal condition, twin auto channel work, but impulse of one auto channel is locked. When troublesome in the other channel appears, switch automatically to this one and block the others impulse, if there is troublesome in this one, switch to stand-by manual channel. 5.2.11.2.2 In normal condition, forbid manual channel mode to run a long time. 5.2.11.2.3 When synchronizing or de-synchronizing, use auto exciting adjusting mode to increase or decrease voltage. When commissioning or repair, manual mode can be used if needed. 5.2.11.2.4 Forbid to operate any set item on exciting adjusting equipment panel, forbid any person to clear troublesome message on panel when no order received. Any operation which will change running mode should be done under dispatch clerks order or regulation. 5.2.11.2.5 When return any alarm or troublesome signal, record these message and forbid to return it again and again. 5.2.11.2.6 Conduct switch test between auto channel and manual channel to inspect stand-by channel perfect. 5.2.11.2.7 Before conducting switch test, insure signal of ready to channel switch appeared, otherwise, forbid to conduct this test. 5.2.11.2.8 Exciting system can run continuously when exciting voltage and current no larger than 1.1 times of rated value. 5.2.11.2.9 Exciting winding can withstand following over-voltage in short time when in rated load: Time(s) Exciting voltage (%) 10 208 30 146 60 125 120 112

5.2.12 running regulation of stator water cooling system 5.2.12.1 Before put stator water cooling system, rotor and core hydrogen cooling system into use, forbid to blow rotor, exciting and loading. 5.2.12.2 After de-exciting, stator water cooling system can only be stopped. Hydrogen system should be stopped according to repairing demand. 5.2.12.3 Control hydrogen pressure higher than water pressure when running, water temperature higher than hydrogen temperature. When running in low hydrogen pressure, maintain lowest water pressure no lower than 0.15MPa. Now, admit water pressure higher than hydrogens for a short time. 5.2.12.4 For cooling water entering into stator winding: conductivity no larger than 1.5us/cm, DOCUMENT NO. : HISAR-ZT-07
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hardness smaller than 2um/l, PH value: 7.0~8.0.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

5.2.12.5 Each part temperature of generator shall not excess regulated value, otherwise, decrease load. Find out reason and remove it, or report to deputy manager to stop. 5.2.12.6 If quality of stator cooling water, flow and other parameter are nonconformity, forbid to excite and synchronize. 5.2.12.7 For prevent to hurt water passage or winding, stator cooling water temperature and flow shall not change a lot. 5.2.12.8 Regulating parameter for generator and its cooling system Item Lowest water inlet pressure Potential drop of stator cooling water between terminals Pressure difference of hydrogen and water Water inlet flow of stator Water inlet conductivity of stator Outlet conductivity of changer Water inlet temperature of stator Water outlet temperature of stator Temperature increased of outlet and inlet water Winding temperature Winding temperature difference Temperature difference of windings Hydrogen pressure Hydrogen purity Hydrogen humidity Cooling hydrogen temperature Temperature difference of hydrogen cooler Temperature of hot hydrogen Water inlet temperature of hydrogen cooler Core temperature Terminal finger temperature Hydrogen leakage Oil inlet temperature Control value 0.15 MPa 0.150.2 MPa 0.035 MPa 90105 t/h 1.5 us/cm 0.5 us/cm 4550 higher than cooling hydrogens 80 30 90 10 8 0.4 MPa 96% Normal 2 g/m3max. 9.5 g/m3 46 2 4580 35 120 180 11.3 Nm3/day 45 difference between air side and hydrogen side smaller than 2 0.083 MPa 4550 7585

Generator and its cooling water system

Generator and its hydrogen cooling system

Oil pressure higher than hydrogen pressure Cold air temperature Bus rings Hot air temperature 5.2.13 Generator check and repair 5.2.13.1 Check in running

Oil sealing system

5.2.13.1.1 Parameter like current, voltage, exciting current, exciting voltage, power factor, frequency etc., are normal. DOCUMENT NO. : HISAR-ZT-07
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5.2.13.1.2 Generator rotor rotate normally, vibrate normally, no crack, discharge, overheat, odor exist in winding terminal, shim fasten, connecting hose of inlet and outlet perfect, no leak and seep. 5.2.13.1.3 Each part temperature normal, water-hydrogen-hydrogen cooling system and other equipment normal. 5.2.13.1.4 Check hydrogen leakage detector perfect, no alarm signal. 5.2.13.1.5 Check floater leakage detector perfect. 5.2.13.1.6 Check auto, protection equipment perfect, its power, signal, meter, and display normal. 5.2.13.2 Check in exciting system running 5.2.13.2.1 Sound, vibration, outer case temperature of exciting transformer are all normal, meter, signal and parameter correct. 5.2.13.2.2 Signal, meter, display and indicator light are all normal, channel trace correct and ready to switch, fans in cabinet running well, no abnormal sound and odor. 5.2.13.2.3 Check exterior condition and display of de-exciting switch, over connecter, over-voltage protection perfect, connecting part normal. 5.2.13.2.4 Output of each rectifier cabinet is balance and no heat, loose, odor, abnormal sound in cabinet. Cooling fan runs well, its signal, meter and display light correct. 5.2.13.2.5 No dirty, ash accumulated, loose and heat in primary and secondary system, otherwise, notice and repair them. 5.2.14 operate step of de-synchronizing to repair status 5.2.14.1 Decrease load to 180MW before de-synchronizing, switch plant power to start and stand-by transformer. 5.2.14.2 Check plant system perfect, generator proper perfect. 5.2.14.3 Adjust neutral mode of 400kv system according to foremans order. 5.2.14.4 Decrease active and wattles power to 0 gradually. 5.2.14.5 Check de-synchronizing condition reached, start de-synchronizing program. 5.2.14.6 According to program going, close watch parameter changing of stator and rotor, stop program when abnormal situation found. 5.2.14.7 Check de-synchronizing successfully, return switch. 5.2.14.8 Check exciting system exit well, de-exciting switch break well. 5.2.14.9 Check terminal switch of G-T in break status. 5.2.14.10 Turn the power off for plant high-voltage, G-T, de-exciting switch. 5.2.14.11 Open the 400kv bus side switchgear of G-T terminal switch. 5.2.14.12 Stop cooling equipment of main transformer. 5.2.14.13 Stop cooling equipment of A,B plant high-voltage transformer. 5.2.14.14 Stop micro-pressure equipment of g enclosure bus 5.2.14.15 Stop the slip ring cooler of g. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

5.2.14.16 Switch exciting initial equipment and exciting adjusting equipment to cold stand-by if needed. 5.2.14.17 Turn the rectifier cabinet to cold stand-by if needed, take fuse off. 5.2.14.18 for g outlet, take secondary side fuse off and pull secondary trolley out, and then put it in isolation position. 5.2.14.19 Stop the protection and auto equipment of G-T. 5.2.14.20 Turn ingoing switch of 11kv A, B, C section work power to cold stand-by. 5.2.14.21 Turn the G-T to repair status if needed. Note: if it is stopped according to provincial order, steps behind 14th can be omitted. 5.2.14.22 Issue that noticed while stopping g a receive foremans order. b before de-synchronizing, close neutral ground switchgear of main transformer. c after active power meter, wattles power meter, electric energy meter indicate to 0, open outlet switch of G-T. d notice if outlet switch of G-T open phase. e when de-synchronizing, put exciting mode to auto to let it turn to inversion de-exciting. f put rotor into jigger status after stop g. when it need to stop rotor, put its big gears centerline to vertical position, to prevent bend effect. 5.2.15 running regulation of hydrogen system 5.2.15.1 Running condition: installation or repairing have finished, air tightness test has done and conformity. 5.2.15.2 Use carbon dioxide as middle media when change gas in generator. Charge carbon dioxide into generator in gaseity. 5.2.15.3 Change generator air whiles its rotor on static state. If needed to do on jigger state, control gas temperature strictly, but it is forbidden to do during starting or stopping. 5.2.15.4 Prevent carbon dioxide from contacting with inner cooling water of stator, because carbon dioxide dissolved into water will enlarge waters conductivity. 5.2.15.5 Before charging hydrogen into generator, insure oil sealing system running normally. 5.2.15.6 Change air with carbon dioxide, only when its contents larger than 98%, can stop evacuating air. 5.2.15.7 Change carbon dioxide with hydrogen, only when its contents larger than 98%, can stop operation and make up and increase pressure. 5.2.15.8 When generator running normally, purity of hydrogen should be higher than 96%, content of oxygen no larger than 2%, humidity 2g/ m 3, otherwise make up or evacuate hydrogen to make purity, oxygen content and humidity normal. 5.2.15.9 When change hydrogen with carbon dioxide, only when its contents larger than 98%, operation can stop. DOCUMENT NO. : HISAR-ZT-07
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5.2.15.10 Put hydrogen dryer into running when generator running normally, and control temperature 48. 5.2.15.11 Hydrogen leakage should be not larger than 11.3 m3/day; otherwise, leakage inspection should be done. 5.2.15.12 Stop cooling water pump while changing air. 5.2.15.13 when running normally, oil sealing pressure shall be larger than hydrogens 0.05MPa; pressure difference of hydrogen side oil sealing shall not be larger than 0.001MPa. 5.2.15.14 for hydrogen cooler, if one water passage exit in rated hydrogen pressure, load admitted is 80%, and temperature of each part in limited value. 5.2.15.15 When hydrogen pressure lower than regulated value, control generator load according to hydrogen- load curve, and temperature of each part in limited value. 5.2.15.16 if stop generator for a short time, or no repair work done on generator or its assist system, hydrogen evacuating work is admitted to omit. Control each part temperature no lower than 5, and its humidity, purity in regulated value. 5.2.15.17 To prevent generator insulating performance from decreasing, control humidity of hydrogen in generator to make its dew point in -5~-25 under 1 standard atmosphere pressure. Put hydrogen dryer into use while running normally, or make up dry hydrogen which dew point shall be higher than -35. 5.2.15.18 when changing hydrogen, shorten time of carbon dioxide in generator among 24h. 5.2.15.19 after repairing hydrogen system, take some measures like circulating dry air into it to prevent it damp. 5.2.15.20 Parameter Normal pressure (MPa) 0.4 Air quantity replacing CO2 (m3)1.5*110 Leakage 11.3 m /day 5.3 Troublesome of generator 5.3.1 Stop generator emergent 5.3.1.1 If friction sound, clash sound found or vibration going up, and its value excess regulation. 5.3.1.2 Theres explode, smoking or catch a fire in generator. 5.3.1.3 Smoking or catch a fire in exciting transformer, TV or CT. 5.3.1.4 Protection of generator, main transformer, exciting transformer or plant high-voltage refuse to trip while they have troublesome. 5.3.1.5 Water broken for more than 30s, but protection refuses to operate. 5.3.1.6 Water leakage heavily in generator and stator or rotor grounding. 5.3.1.7 Troublesome in oil sealing system, hydrogen leakage heavily in generator. 5.3.1.8 Slip ring, brush catch fire heavily, could not put out. 5.3.1.9 Other emergence situation which can hurt human or risk to human safety. DOCUMENT NO. : HISAR-ZT-07
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3

Volume of generator (m3) 110 CO2 quantity replacing H2 2.5*110

Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

5.3.2 Ask deputy manager or chief engineer to stop generator when one of situation following appears 5.3.2.1 Because of troublesome in oil sealing system, hydrogen pressure could not maintain and its purity decreases to lowest value. 5.3.2.2 Water leakage in generator stator. 5.3.2.3 Water outlet temperature of generator stator gets to nearly 90, or its difference reach to 12K nearly, or temperature difference of stator lamination near to 14K and has trend to increase. 5.3.2.4 Core temperature of generator excess regulated value, and situation maintain after take some measures. 5.3.2.5 Leakage in hydrogen cooler, its humidity excess regulated value. 5.3.3 General operation rules when generator-transformer protection acts 5.3.3.1 Insure G-T switch, exciting system and its de-exciting switch trip. 5.3.3.2 Check plant power switch over correctly, return power of plant system. 5.3.3.3 Check protection operating correctly, record completely and return switch and signal normal. 5.3.3.4 Inspect generator and its protection and its electric equipment, find out accident point and reason, and repair them. 5.3.3.5 If troublesome exist still, contact special repairing person and solve problem. 5.3.3.6 If no troublesome found, report to deputy manager or chief engineer, increase voltage from 0 after approved by them. During increasing, if there is any abnormal situation found, stop and inspect in detail. 5.3.3.7 Test G-T and its system insulation conformity after troublesome resolved, and return to start running. 5.3.4 When troublesome or switch refuse to act among G-T 5.3.4.1 If protection refuse to act, stop generator immediately. 5.3.4.2 If switch refuse to act because of out of control, protection should start and cut off this 400kv line or bus, otherwise open this switch manually. 5.3.4.3 Insure plant power switch over normally. 5.3.5 Generator voltage doesnt go up while increasing voltage 5.3.5.1 Appearance 5.3.5.1 Stator voltage is abnormal while increasing voltage. 5.3.5.2 Exciting voltage and current abnormal. 5.3.5.2 Handle 5.3.5.2.1 Stop increasing voltage operation, inspect exciting initiate equipment, its power and output normal. 5.3.5.2.2 Check exciting adjusting equipment normal. 5.3.5.2.3 If meter of stator and rotor indicate none, inspect de-exciting switch close well, DOCUMENT NO. : HISAR-ZT-07
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over-connector open completely and rectifier cabinet put into running normally. 5.3.5.2.4 Check exciting circuit perfect. 5.3.5.2.5 If meter in rotor circuit indicates while meter in stator circuit indicates none, check meter circuit perfect. 5.3.6 Generator loss of exciting 5.3.6.1 Appearance 5.3.6.1.1 Current and voltage of exciting circuit abnormal. 5.3.6.1.2 Terminal voltage of generator and 400kv system voltage decrease. 5.3.6.1.3 Generator change to asynchronous running 5.3.6.1.4 When exciting loss heavily, exciting loss protection operates and trip generator. 5.3.6.2 Handle 5.3.6.2.1If exciting loss protection operates main switch and de-exciting switch trip, check up reasons and resolves it. 5.3.6.2.2 If exciting loss protection doesnt operate, main switch and de-exciting switch doesnt trip, decrease load to 60% rated value in 60s, to 40% in 90s, and try to increase exciting by best, control stator and rotor current not to excess 1.1 rated current. Asynchronous running time is not admitted excess 15m, if exciting current could not resume, notice special repairing person to repair. 5.3.6.2.3 If protection of exciting loss operate and de-exciting trip, but main switch doesnt trip, open main switch by hand. 5.3.6.2.4 If main switch could not be opened, decrease generator load to 0 then adjust running mode, de-parallel generator by bus connection switch. If situation is urging and vibration is large enough, open all switch connecting to this 400kv bus. 5.3.7 When generator parallel asynchronously 5.3.7.1 Appearance 5.3.7.1.1 Active power, wattles power and stator current wither heavily after parallel. 5.3.7.1.2 Unit vibrates heavily and big sound heard from inner. 5.3.7.1.3 In worst situation, generator protection operate and G-T switch trip. 5.3.7.2 Handle 5.3.7.2.1 If generator vibrates a little and sound is not so big, and meter swing first but slowly stop , no need to stop generator, but exterior inspection is needed, and report to deputy manager and chief engineer to decide if running continuously. 5.3.7.2.2 If shock or heavily vibration occurs, meter pointer swing heavily and no weaken, stop generator immediately. Inspect and test generator completely, the most important is synchronizing system After then, conduct false synchronization test, report deputy manager and chief engineer to decide parallel or not. 5.3.7.2.3 If generator trip because of asynchronous parallel, inspect protection, record, analyze DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

and report to foreman, inspect and test generator and turbine completely, ask deputy manager and chief engineer to parallel or not. 5.3.8 Change generator to motor running 5.3.8.1 Appearance 5.3.8.1.1 Active power meter points to minus. 5.3.8.1.2 Reverse power protection operate. 5.3.8.2 Handle 5.3.8.2.1 Synchronous motor running should not be longer than 60s in normal exciting. 5.3.8.2.2 If cross-protection operate because main steam valve close, generator stopping finished. 5.3.8.2.3 If protection doesnt operate or main switch doesnt trip, take some measures immediately to make generator out of motor running, otherwise de-parallel generator. 5.3.9 Generator vibration heavily 5.3.9.1 Appearance 1) Active power, wattles power, stator current, stator voltage, and other parameter swing periodically. 2) Unit roaring rhythm. 3) Generator enters into constrained current running. 5.3.9.2 Handle 1) Judge this appearance is caused by generator in common plant or not, if it is, increase exciting and decrease active power and make generator synchronization. If troublesome last for one minuet and could not make generator synchronization, de-parallel generator according to foremans order. 2) If it is caused by loss of exciting, de-parallel this generator from system, then report to dispatch clerk. 3) If it is caused by grid, and frequency swing above 50Hz, decrease output and decrease frequency to 49.5Hz, otherwise increase output and increase frequency 49.5Hz. 4) If system swing for 2 to 3 minuet, and system could not resume, report dispatch clerk. 5.3.10 Brush of slip ring heat heavily or catch a fire 5.3.10.1 If it is caused by unbalance force put on slip ring and makes current unevenly, check brush and change shorter or broken brush, adjust spring force, make current evenly. 5.3.10.2 If it is caused by brush blocking in frame or swinging, change them. 5.3.10.3 If caused by different type brush, change them. 5.3.10.4 If cooling system of slip ring, decrease exciting current and find out reason, repair it. 5.3.11 abnormal temperature of generator 5.3.11.1 Appearance 1) Temperature of stator winging or core winding goes to near or excess admitted value. DOCUMENT NO. : HISAR-ZT-07
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2) Outlet temperature of inner cold water increase. 3) Outlet hydrogen temperature increase. 4) Stator current shall be unbalance. 5) Vibration of generator unit shall increase. 5.3.11.2 Handle

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1) Contact professional staff to inspect, analyze and judge if the measuring point is perfect and display correct. 2) If winding bar temperature, each water outlet temperature increase abnormally, check cooling water system pressure, water temperature and other parameters immediately. 3) Monitor and control generator load in limited value. 4) If winding outlet water temperature or winding temperature different larger than admitted value, find out reason, analyze if water passage block. 5) Increase pressure of water passage and flow to cleanse, monitor temperature difference weaken or not. 6) After take measure 5, but no effect, report foreman, ask deputy manager or engineer to backwash or not, or stop generator. 7) Control temperature of different part in limited value, decrease load if need, monitor more and report leader. 8) If temperature of core and its terminal increasing check hydrogen cooler, cold and hot hydrogen temperature, if they are abnormal, report and remove them. 9) If terminal temperature of generator higher, decrease exciting properly, and check terminal temperature going back to normal value. 10) If taking measures above, and bring to no effect, report foreman, ask deputy manager, chief engineer to stop unit. 5.3.12 Troublesome in inner cooling water system 5.3.12.1 Appearance 1) Signals of water broken, flow of stator inner cooling water low appears. 2) 30s after water broken, protection shall operate and trip unit. 5.3.12.2 Handle 1) If unit tripped, operate according to 5.6.1.3 clause. 2) Check inner cooling water system, and repair. 3) If protection refuse to operate after water broken for 30s, stop unit immediately. 4) After cooling water system resume, check water pressure, flow normal, and parallel as soon as possible. 5.3.13 Stator grounding 5.3.13.1 Appearance 1) Protection of 95%stator grounding or 3U0 stator grounding operates. DOCUMENT NO. : HISAR-ZT-07
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2) Generator-unit trip, de-exciting, plant power switch over. 3) Signal of water leakage may appear. 5.3.13.2 Handle 1) If generator unit tripped, operate according to 5.6.1.3 clause.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2) If protection of 3U0 stator grounding, but unit is not tripped, and signal of water leakage appears, stop generator emergently. Otherwise, check stator neutral point grounding or not, report leader and repair. 3) Dont make generator stator grounding for longer than 30m. 5.3.14 Voltage circuit wiring broken 5.3.14.1 Appearance 1) Signal of generator TV wiring broken appears. 2) Voltage display abnormal, protection abnormal or exciting regulator abnormal will appear because of broken point different. 5.3.14.2 Handle 1) Check PT according to different appearance. 2) Exit respective protection. 3) If TV wires broken causes to exciting regulator abnormal, switch it to manual channel. 4) If TV wire broken causes to watt-hour meter abnormal, check out electric energy which meter lost. 5) If it is caused by fuse broken, change them, but take safety measures when changing. 6) If TV troublesome, repair it. 5.3.15 when stator 3 phases current unbalance 5.3.15.1 Appearance 1) 3 phases current of stator unbalance. 2) Outlet hydrogen temperatures may increase abnormally. 3) Abnormal sound or vibration may occur. 5.3.15.2 Handle 1) Check plant power system or rotor normal, when negative sequence current larger than 10%, ask dispatch clerk and take some measures. 2) When negative sequence current smaller than 10% and max. phasing current smaller than rated value also, continue to run, and (I2/IN)2t10s. 3)When unbalance current excess rated value, decrease active power and wattles power, decrease negative sequence current to admitted value, monitor temperature of different part and vibration. 4) Current unbalance is caused by system troublesome, report dispatch clerk and repair in admitted time. 5) If unbalance current is caused by inner troublesome in generator unit, report chief engineer to DOCUMENT NO. : HISAR-ZT-07
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repair. 5.3.16 when running on phase open 5.3.16.1 Appearance

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1) If one phase of main switch close, and other two phases open, two phase currents of three equal nearly, the other phase equal to 0 nearly. Phase that close Stator phase Current a yes A b 0 c yes a yes B b yes c 0 a 0 C b yes c yes

2) if two phases of main switch dont open, two phase stator current of three shall be equal nearly, and equal about 1/2 the other one. Phase that doesnt open Phase Current display 5.3.16.2 Handle AB a big b small c small BC a small b big c small CA a b small c big

1) If G-T switch doesnt trip which it shall trip, then de-parallel G-T unit from grid. 2) If G-T switch doesnt trip, report foreman, maintain generator exciting, and notice turbine major to maintain rated rotor speed, but forbid increasing load and regulating running mode, de-parallel generator using bus connection switch, and repair. 3) After troublesome removed, check and test generator-transformer unit completely according to running mode and report to chief engineer, start unit according to approved measure by chief engineer. 5.3.17. When generator over-exciting 5.3.17.1 Appearance 1) Signal of over-exciting appears. 2) Protection of over-exciting operates and trip. 5.3.17.2 Handle 1) If it is caused by lower system frequency, contact with dispatch clerk to resume frequency, adjust wattles power and voltage of generator and make V/F in limited scope. 2) After V/F protection operate and trip generator, check and test main transformer, generator, exciting circuit normal, confirmed by repairing person, approved by chief engineer, then start generator. 5.3.18 when rotor winding one point grounding 5.3.18.1 Appearance Rotor winding one point grounding protection acts and trips. 5.3.18.2 Handle 1) If generator trip, operating according to 5.6.1.3 clause. 2) Ask if it is caused by operation mistaken or inspect incorrectly. 3) Check exciting circuit grounding or not, measure insulation of rotor circuit by megger after DOCUMENT NO. : HISAR-ZT-07
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change to cold standby, if grounding point is in outside of rotor, eliminate grounding point then start unit again. If grounding point is inside rotor, change generator to repair. 5.3.19 Hydrogen leakage 5.3.19.1 Appearance 1) Display of hydrogen pressure decreases abruptly, make up hydrogen again and again but pressure drop heavily, could not maintain running normal. 5.3.19.2 Handle 1) When generator in stand-by status, check oil sealing system running normally while hydrogen pressure drops, otherwise replace hydrogen, after removing defect of oil seal system, replace hydrogen again. 2) If generator running when hydrogen leakage lightly, find out reason. If pressure drop is in normal scope, make up hydrogen; otherwise find out leakage point and repair. 3) If leakage is heavily, decrease active power when hydrogen pressure drops, and check oil sealing system, hydrogen system immediately, remove defects. Then make up hydrogen. If leakage heavily and could not remove defects, de-parallel generator. Forbid generator running in 0 hydrogen pressure. 5.3.20 when generator explodes or catches a fire 5.3.20.1 Appearance 1) Smoke or odor smell emitted from outer case or terminal part. 2) Big sounds heard in generator, and oil fume emitted from it. 5.3.20.2 Handle 1) De-parallel generator immediately, and isolate it. 2) Charge in carbon dioxide and drain out hydrogen. 3) Maintain rotor speed in 300~500r/m, to prevent shaft bending. 4) Put out fire with 1211 or dry extinguisher; never use foam, water or sand. 5) Maintain cooling water running normally when taking some measures. 6) Dial 100, report foreman and other leaders. 5.3.21 when troublesome in exciting system and removing 1) If exciting system troublesome caused by parameter excess limited value, adjust parameter to admitted value, and return signal. 2) If it is caused by its equipment defect, switch it to stand-by channel, in emergent situation, report to foreman and switch it to manual channel. 3) Analyze and judge troublesome situation according to alarm signal and other troublesome message, if it is caused by equipment, repair it. Otherwise, remove defects and repair. 5.3.22 Rectifier cabinet defect or alarm 1) Check it in site, find out whom is defect. 2) Analyze and judge reason according to signals or appearances, and adjust running mode of DOCUMENT NO. : HISAR-ZT-07
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rectifier cabinet.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

3) Isolating defect cabinet if it is need, and repair it as soon as possible. 5.3.23 Outlet air temperature of rectifier cabinet high and alarm 1) Check fans running normally, or start stand-by fans. 2) Check filter of air passage block or not, cooling air flow normal. 3) Contact repairing staff and remove defect. 5.3.24 when generator over-loads by accident 1) Over load value and time admitted Stator current% 226 Admitted time(S) 10 154 30 146 30 130 60 125 60 116 120 112 120

Rotor current% 208 Admitted time(S) 10

2) Formula of stator over-current time and times I2-1t=37.5s I----nominal value of stator over-current

3) If accident occurs outside of generator, admit stator winding over-load running in short time, as well as rotor, but the times should not excess 2 in a year. 4) When generator over-load, check generators power factor and voltage, and check out times of over-current and last time, control it in value above table. 5) Decrease rotor current, make stator current to limited value, control system voltage not too lower. 6) If stator current doesnt decrease to limited value when decrease rotor current, decrease active power if needed, limit load if dispatch admitted. 7) When generator runs in over-load status, monitor generator, main transformer temperature closely and cooling system, make their parameter in admitted value.

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Chapter VI the Fuel Oil System Operation Regulations


6.1 Fuel system There are two light oil tanks and two heavy oil tanks of the plant fuel system, together with two sets of heavy oil feed pump , light oil feed pump, heavy oil filters, light oil filters, heavy oil heater and one set of heavy oil cooler are provided for each unit. 6.1.1 Equipment function Heavy oil feed pumps transfer the heavy oil from the daily heavy oil tanks to the boiler in order to satisfy the boiler start-up and combustion supporting(when startup), and to meet with the heavy oil system circulation during normal operation. Light oil feed pumps transfer the light oil from the daily light oil tanks to the boiler for satisfy the boiler ignition and the system circulation. 6.1.2 The configuration and pump operation mode There are two heavy oil feed pumps for each boiler. One is in operation and the other one standby during the period of the boiler start-up and combustion supporting. During the normal operation of boilers, one is in operation as an oil circulating pump. Also two light oil pump for each boiler, and one is operation one standby during boiler firing and one is as circulation pump during normal operation. 6.1.3. Technical Data of Fuel Equipment 6.1.3.1 Heavy Oil Feed Pump Model Type Use conditions (operation ) Item Flow Head Efficiency Suction head allowed Speed of the pump oil pressure at the outlet of the pump Shaft power oil temperature at the inlet of pump Style of the shaft joint Safety device bearing lubrication Outside dimension weight(excl. motor) Inlet and outlet direction Nominal pressure of the connection flange of the heavy oil pipe size (S) 3GR100X4-46W Screw pump normal Maximum operation operation Unit m3/h 61 68 mH2O 340 320 65 62 mH2O 5 5 r/min 1470 1470 MPa 3.4 3.2 kW 86 95.5 70 Elastic slider Coupling guard Grease mm 2500900900 Kg 650 Horizontal/ horizontal MPa 1.6 Inlet MPa 6.4 Outlet mm 1594.5 (Inlet) mm 1334.0 (Outlet) Nominal pressure of connection flange of MPa 1.6 (Inlet) steam MPa 1.6(Outlet) mm 252.5(Inlet) pipe size(S) mm 252.5(Outlet) Direction of rotation Clockwise(From the motor to pump) DOCUMENT NO. : HISAR-ZT-07
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6.1.3.2 Heavy oil feed pump motor Item Model Power rating (rated power) Voltage rating (rated voltage) Synchronous speed Frequency Main efficiency characteristics Power factor Block running torque Block running current Maximum torque Vibration grade Rotation inertia Insulation class F Protective level IP54 Cooling Wind Lubrication Grease Weight 6.1.3.3 Light oil feed pump Unit kW kV r/min Hz 94.5 0.89 (times) (times) (times) mm/s Kg.m2

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Data YB315S-4WTH 110 415 1485 50

2.1 7.0 2.4 3.50 4.650

kg

1150

Model of the light oil feed pump 50AY3510 Type of the light oil feed pump Centrifugal pump Use conditions normal Maximum operation operation Item Unit Flow m3/h 16 20 Head mH2O 330 280 Efficiency 47 43 Required NPSH mH2O 3.8 3.8 Speed of the pump r/min 2950 2950 The oil pressure at the outlet of the pump MPa 3.3 2.8 Shaft power kW 30.6 35 The oil temperature at the inlet of the pump ambient temperature Style of the shaft joint Elastic diaphragm coupling Safety feature Coupling guard The method of bearing lubrication Oil dip Outside measurement mm 2400800800 Unit weight(ex motor) Kg 1029 Inlet and outlet direction Horizontal/ horizontal Nominal pressure of Inlet MPa 1.6 Connection flange Outlet MPa 6.4 Connection pipe Inlet mm 594.5 size(S) Outlet mm 594.5 Direction of rotation Counterclockwise (From the motor to pump) 6.1.3.4 Light oil feed pump motor technical data sheet Item Model of the light oil feed pump motor Power rating Voltage rating Rated current Synchronous speed Frequency DOCUMENT NO. : HISAR-ZT-07 Unit kW kV A r/min Hz Data YB200L2-2WTH 37 415 67.9 2950 50
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Leading features Efficiency Power factor Block running torque Block running current Maximum torque 92.0 0.90 (times) (times) (times) mm/s Kg.m2

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Vibration grade Rotation inertia Insulation class Protective level Cooling way Lubrication way Weight 6.1.3.5 Oil filter technical data sheet No. 1 2 3 4 5 6 7 Equipment

kg Light oil feed pump Oil secondary filter SDGLQ-16T-100K Vertical type 100 holes/cm2 16m3/h 25m3/h 1.6MPa 0.021 MPa

2.0 7.5 2.4 2.80 0.730 F IP54 Wind cooling Grease lubrication 305 Heavy oil feed pump Oil primary filter SDGLQ-65T-36K Vertical type 36 holes/cm2 65m3/h 80m3/h 1.6MPa 0.021 MPa DN80 894.5mm None None 1 inch 1 inch 1 inch None 900X1450mm 627 Kg

Model Assemble way Filter precision The rated flow Design flow Design pressure The normal operating pressure difference 8 Oil inlet / outlet flange size DN200 9 Oil inlet / outlet pipe size 2198.5mm 10 Steam inlet / outlet t flange size DN20 11 Steam outlet pipe size 25X2.5mm 12 Drainage hole diameter 1 inch 13 Platoon hole diameter 1 inch 14 Steam blow hole diameter 1 inch 15 Condensate hole 1/2 inch 16 Outside measurement 440X1025mm 17 Equipment weight 86Kg 6.1.3.6 Heavy oil heater and heavy oil cooler technical data sheet No. 1 2 3 Name model Flow rate Oil outlet temperature Heavy oil heater BEM1400-792-3.74/0.6 61m3/h 130

Heavy oil cooler BEM1200-637-3.74/1.0 61m3/h 70

6.2 Shift and equipment inspection 6.2.1 Spell programs 6.2.1.1 Enter in the control room twenty minutes before shift, then change work uniform. Fire source and needle shoes are prohibited inside oil storage area. Make preparation for inspection including work safety facilities. 6.2.1.2 Check previous shift record and know about the equipment state (operation, standby, maintenance) and hygiene in responsible area. Ask shifter if not clear. 6.2.1.3 Enter operation site to inspect equipment.

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6.2.1.4 Report to the foreman. 6.2.1.5 Take part in the brief meeting before shift. 6.2.2 Equipment inspection

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

6.2.2.1 Responsible for equipment inspection, maintenance and cleaning work of oil tank area and fuel supply/discharge, dirt fuel treatment, steam heating, cooling water system, ventilation and fire fighting system. 6.2.2.2 Responsible for the cleaning work of the fire pump room and floors, valves and windows wall inside fences. 6.2.2.3 Responsible for oil feeding, oil unloading and dirty oil processing in accordance with the provisions. 6.2.2.4 Responsible for the fire management and the overhaul supervision within the oil tank area. 6.2.2.5 The heating temperature of oil tank must be strictly controlled within the allowable range as per fuel types. The steam temperature for heating fuel should be less than 130 . 6.2.2.6 Oil storage area and the loading/unloading pipes should be fitted with reliable anti-static safety earthing facilities. Test ground resistance and make records before rainy season every year. 6.2.2.7 Oil storage area and tank must have the strict management system. Fire worksheet must be logged in for visible light work, and reliable security measures must be taken. Fire fighting system must be tested regularly and be recorded. The unqualified fire control facilities should be replaced. 6.2.2.8 The inflammable and explosive objects such as oxygen, acetylene, etc shall not be stored in the oil storage area. Weeds, shrubs, etc must be cleaned regularly. 6.2.2.9 Relevant regulation fire fighting within fuel oil tank area and boiler oil system shall be obeyed. 6.3 Light oil feed pump 6.3.1 Inspection before Fuel oil handling system start up 6.3.1.1 Ensure the overhaul of light oil system finished all pipes) valves and equipment are in good conditions, motor valve, regulating valve are normal, oil flow indication is normal, pipes are in good insulation. 6.3.1.2 All pipes valves without leakage; All equipment without leakage and seepage no inflammable and explosive around. 6.3.1.3 The light oil quality complies with the standards, Tank oil level, temperature is normal. 6.3.1.4 Light oil pump inlet filter clean, filter DP indicating is normal. 6.3.1.5 Check the level of the dirty oil tank in light oil pump room, when the level is high contact the concerned to deal with. 6.3.1.6 Contact I & C to put all manometer, thermometer, flow meter and protect system of fuel oil DOCUMENT NO. : HISAR-ZT-07
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system in service.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

6.3.1.7 Fuel oil tank temperature shall be controlled within 205, when the temperature below 5, start internal heater. Put the internal heater into operation (as an example with # 3tank) 6.3.1.7.1 Check #3 tank oil temperatures below 5. 6.3.1.7.2 Confirm #4 tank internal heater outlet isolation valve is close. 6.3.1.7.3 Open #3 tank inlet air isolation valves. 6.3.1.7.4 Confirm the operation of drain tank is normal, check isolation valve before and after drain tank are opened, and bypass valve are closed. Open bypass valve when the operation of drain tank is abnormal. 6.3.1.7.5 Confirm no light oil flow out from drain tank. 6.3.2 Start light oil transfer system 6.3.2.1 Before boiler running, light oil feed pump is running fuel oil circulation, and confirm all oil gun manual isolation valve are at the closed position. 6.3.2.2 Open fuel oil outlet isolation valve and return oil manual isolation valve of the running tank. 6.3.2.3Start one light oil feed pump, and confirm the pressure is normal; according to the boiler oil quantity requirement. Start light oil feed pump, start of the pump can be done in the control room and local panel. 6.3.2.4 Check the fuel oil pump inlet DP is normal. 6.3.2.5 Confirm boiler light oil system circulation is normal, the temperature below 40. 6.3.2.6 Overhauled oil pump, filter mesh, heater, tube should be filled oil and vented before start up or after start up. 6.3.2.7 Fill oil and vent work should be done carefully and slowly to avoid hot oil hurting. 6.3.2.8 Put a small container at the vent outlet to avoid influence site sanitation, and clean it immediately. 6.3.3 Light oil pump operation 6.3.3.1 Check oil leakage during operation. 6.3.3.2 Check that outlet oil pressure is normal, if below 15bar, the reasons should be identified and timely treatment. 6.3.3.3 One pump run and the other spare, and the two pumps switch every week, detailed regulation see specific provisions of equipment regularly switch and test. 6.3.3.4 Vibration, bearing temperature and current shall be monitored in the operation of fuel oil pump, if something is wrong, switch the pumps and contact maintenance staff to dispose. 6.3.3.5 It is important to check Light oil pump inlet filter, if DP of filter is high, it should be timely switched and contact maintenance staff to clean and overhaul. 6.3.3.6 The LFO temp is 205 and the oil manifold pressure are 16-18bar in normal operation. DOCUMENT NO. : HISAR-ZT-07
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6.3.3.7 Check dirty oil tank level are normal every shift 6.3.4 Stop light oil transfer system

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

6.3.4.1 Stop fuel oil pump operation. Be realized on CCR operation desk, local panel stop button and emergency button. 6.3.4.2 After fuel oil handling system stop, if light oil system need to be overhauled, purging of whole line pipes should be done (purge the pipe remaining oil to running fuel oil tank) and make reliable isolation. 6.3.4.2.1 Fuel oil system by circulating operation before boiler running. (1)Close #3/4 light oil tank outlet feed oil manual valve (2)Close A/B feed oil pump inlet isolation valve. (3)Open A/B feed pump inlet/outlet purge steam isolation valve, open feed oil pipe purge steam isolation valve, open return oil pipe purge steam isolation valve to purge. (4)Purge finished, close the opened purge steam isolation valve, close #3/#4 discharge oil valve before the gate, discharge the remaining oil and confirm the purge finished. Open the return oil manual valve and #3/4 tank return oil manual valve. 6.3.5 Operation and maintenance 6.3.5.1 Light oil tank switching operation Two light oil tank, one is operated, another is spare. When operating oil tank level below 3m, heating(raise) the spare oil tank oil temperature to 20 5 around, and repairing to switch oil tank. When operating oil tank level is 2.0~2.5m, switching oil tank should be done, put the spare oil tank into operation, the procedures according to the following: (1)Shift supervisor agree, repairing to stop feed oil pump and switch oil tank. (2)Stop feed oil pump, inform #1/2 unit fuel oil control valve turn to manual. (3)Close #3tank outlet isolation valves, open #4 tank outlet isolation valve. (4)Close #3tank return oil isolation valve, open #4 tank return oil isolation valve. (5)Start feed oil pump and confirm it in normal, the outlet pressure is normal. 6.3.5.2 Oil Pumps level should be Recorded clear between shift, and struck oil benchmark to confirm the normal oil level which is not correct. 6.3.5.3 Strengthen the inspection and records of oil temperature in oil feeding tank and report timely when the temperature is abnormal. Standby oil tank oil temp should be maintained between 105, while operating oil tank oil temp 205. 6.4 Heavy oil feed pump 6.4.1 The inspection before Fuel oil handling system start-up 6.4.1.1 Heavy oil system maintenance is completed, all pipes, valves, and equipment state are in good condition, motor valve and control valve of the system act smooth and correct. 6.4.1.2 Heavy oil system heating steam operation is normal. 6.4.1.3 Heavy oil quality conform to its standard, oil tank level, temperature are normal. DOCUMENT NO. : HISAR-ZT-07
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6.4.1.4 Fuel oil pump outlet heater is in standby mode. 6.4.1.5 Fuel oil pump inlet filter and heater outlet filter are clean.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

6.4.1.6 Fuel oil tank temperature should be controlled between 6075, if oil temperature lower than 65 a external or internal heater can be put into operation. 6.4.1.7 Internal heater is put into operation. (1)Set oil tank temperature 65 (2)Open the admission isolation valve#1or#2. (3)Confirm internal heater admission regulating valve (#1) / (#2) operation normal (4)Confirm drains operation normal, open the bypass valve if it is not working correctly. (5)No heavy oil flow out from the drainers exit 6.4.1.8 External heater operation: (1)Set oil tank temperature 70. (2)Open the admission isolation valve. (3)Confirm external heater admission regulating valve (#1)/ (#2) operation normal (4)Confirm drainers operate normal, open the bypass valve if it is not working correctly. (5)No heavy oil blow down from the drainers exit 6.4.2 Fuel oil handling system startup 6.4.2.1 Before boiler running, fuel oil transfer pump is running complete oil circulation, and confirm all oil gun manual isolation valve are at the closed position. 6.4.2.2 Open the fuel outlet isolation valve and return oil manual isolation valve of the running fuel oil tank. 6.4.2.3 Start a fuel pump, and ensure the pressure is normal. Another pump shall be into operation according to the fuel oil quantity requirement. Start of the pump can be done in the control room and at local panel. 6.4.2.4 Check the fuel oil pump inlet/outlet filter differential pressure is normal 6.4.2.5 Put into one or more fuel pump outlet heater according to unit need, and temperature is set at 130 6.4.2.5.1 Open the heater admission isolation valve 6.4.2.5.2 Check the drainers operation normal. 6.4.2.5.3 Check Drainers manifold pipe flow to trench is normal and no dirty oil flow outside. 6.4.2.6. Confirmed the oil circuit flow before/after boiler wall is opened, and oil temperature is more than 110. 6.4.2.7 Overhauled oil pump, filter mesh, heater, tube should be filled oil and vented before start up or after start up. 6.4.2.7.1 Fill oil and vent work should be done carefully and slowly to avoid hot oil hurting. 6.4.2.7.2 Put a small container at the vent outlet to avoid influence site sanitation, and clean it immediately. DOCUMENT NO. : HISAR-ZT-07
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6.4.3 Fuel oil pumps operation 6.4.3.1 Check no oil leakage in the pump running.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

6.4.3.2 Check that pump outlet oil pressure are normal, if below 15bar, the reasons should be identified and timely treatment. 6.4.3.3 One pump run and the other spare, and the two pumps switch every week, detailed regulation see specific provisions of equipment regularly switch and test. 6.4.3.4 In low temperature in winter, open the bypass valve of standby fuel pump outlet check valve shortly to maintain a small reserve flow for warming pump continually , and ensure the fuel pump does not froze (to guarantee the pump do not exceed current and trip, the reverse speed shall controlled at the motor fan blade can be high visible). 6.4.3.5 Vibration, bearing temperature and current shall be monitored in the operation of fuel oil pump, if something is wrong, switch the pumps and contact maintenance staff to dispose. 6.4.3.6 Fuel pump outlet regulator stations is in normal operation. 6.4.3.7 Put fuel pump outlet heater into normal operation. 6.4.3.7.1 Put a outlet heater in normal operation, and more outlet heater shall be added when

oil gun are ignited; Quit all outlet heater if running oil tank temperature is more than 85 ,or put outlet heater in operation again when the oil tank temperature is lower than 80. 6.4.3.7.2 Heater temperature set is normal and the outlet temperature is between 130140 . 6.4.3.7.3 Steam side of Heater is in normal operation, control valve, drain tanks and drainage work are in good condition. 6.4.3.7.4 Oil side of heater is without seepage, leakage, and maintain external heater clean. 6.4.3.8 Fuel oil heater outlet filter is in normal operation. Shake the filter to keep normal outlet pressure when the filter differential pressure is increased, contact maintenance treatment if the filter differential pressure is not reduced. 6.4.3.9 The gate of Pump room should be locked when nobody is on duty in the oil pump room. 6.4.3.10 Fuel pipelines and the steam heating system are in normal operation. 6.4.4 Stop fuel oil handling system 6.4.4.1 Stop fuel oil pump operation. Be realized on CCR operation desk, local panel stop button and emergency button. 6.4.4.2 When the fuel oil handling system stops, the outlet heater of fuel oil pump should be quit, but all the accompany steam heating of all handling system and fuel oil burning system should be kept on running. 6.4.4.3 After fuel oil handling system stop, purging of whole line pipes should be done (purge the pipe remaining oil to running fuel oil tank) and make reliable isolation. 6.4.4.3.1The purging from the front of #1 boiler and #2 to running fuel oil tank: (1)Close the manual valve of fuel feeding in the front/back of #1 boiler and # 2 boiler, while open the manual valve of fuel oil return in the front/back of #1 boiler and # 2 boiler. DOCUMENT NO. : HISAR-ZT-07
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(2)Open the blowing steam valve in the front/back of #1 boiler and # 2 boiler to sweep; open the blow down valve of return oil pipe in trench in necessary. (3)Close the steam blowing valve when finishing the blowing of front/back wall of boiler, open the manual valve of fuel oil feeding in the front/back wall. 6.4.4.3.2The blowing from heater of fuel oil pump outlet to the front of #1 boiler and #2 boiler ,then to fuel oil tank: (1) Close the manual valve of fuel oil tank outlet; close the manual valve of pump outlet #1/2/3 heater inlet. (2) Open the steam blowing valve of #1/2/3 heater fuel oil pump outlet; open the blowing valve of inlet/outlet return oil pipe in trench. (3)Close the blowing steam valve of heater after the blowing is confirmed to finish. 6.4.4.3.3 The blowing from the manual valve of fuel oil tank outlet to pressure maintaining valve , then to fuel oil tank: (1)Close the manually operated valve of fuel oil tank; close the manually operated valve of fuel oil pump outlet #1/2/3 heater inlet, and open the by-pass valve of fuel oil pumps pressure maintaining valve. (2)Open the blowing valve of fuel oil tank outlet pipeline. (3)When the blow is confirmed to finish, open the manually operated inlet valve of fuel oil pump outlet heater, close the by-pass valve of fuel oil pump pressure maintaining valve. Do two hours completely blowing to the whole fuel oil system pipeline, then close the blowing valve of fuel oil tank outlet pipe line. (4) Close the return oil manually operated valve of running tank. (5)Blow down after the water deposit in running tank. 6.4.5 Normal running attention 6.4.5.1 The running of heavy fuel: 6.4.5.1.1 One fuel tank is running and the other is standby. when the oil level of running fuel tank below to 4 meter , then heat the standby one to 65 or more ,prepare to switch fuel tank. Heat the standby one to 68 to 70 before switching. When the oil level of running fuel tank is 3 to 2.5 meter, switch the standby one .The procedure is(for example ,#1 tank is running ,#2 is standby, then switch from #1 to #2): (1)Get the shift supervisors permission, prepare to stop running and switching tank. (2)Shake the filter screen of fuel heater outlet to make pressure difference normal, stop the running pump, and control the fuel from automation to manual. (3)Open the outlet isolated valve of #2 fuel tank , put on the lower temperature fuel in outlet pipe of #2 tank and more moisture fuel at bottom of #2 fuel tank to #1 tank. (4)When the oil level of #2tank falls down 0.2 to 0.3 meter, close the outlet isolated valve of #1. (5)Start fuel pump; make sure it runs normal, oil outlet pressure is normal. DOCUMENT NO. : HISAR-ZT-07
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(6)Open the manual isolated valve of return fuel in #2. (7)Close the manual isolated valve of return oil in #1.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

(8)When switch work is finished, informs shift supervisor and #1, #2 unit. (9)When switch work is finished, inform fuel staff to input oil to the fuel tank. 6.4.5.2 The oil level of heavy fuel tank should be recorded carefully when hand over to the next shift. If it estimated that the oil level isnt exactly, move it to check if it is correct. 6.4.5.3 Record and check the temperature of fuel in the heavy fuel tank, when the temperature is abnormal, report it. The temperature of standby tank should be 65 5, the running one should be 70 5, which can be adjusted by the inner heater. If the two boilers doesnt need fuel and the temperature of fuel is greater than 75, the oil temperature setting value of fuel pump outlet heater should be 100, and increases it when needed, 6.4.5.4 Drain the water from the fuel tank at 10:00 every morning. 6.4.5.5 When the oil temperature of running tank is below 65, input the heater outside the tank, but the temperature of outside heater outlet should not be bigger than 70. 6.4.5.6 The filter screen of fuel pump inlet should be checked carefully. When the pressure difference is high, switch and cleans the dirty one. After the screen is cleaned, input oil and exhaust air, and ensure the cap is tightened, make it into standby. 6.5 Principle of accident disposal 6.5.1 The conditions of emergency stop pump The pump should be emergency stopped when the motor or the pump is in anyone of the following conditions: 6.5.1.1 Any electrical equipment is catch smoke, firing, or flooded. 6.5.1.2 Lack of oil or water, serious rubbing, shock, movement occurs between the moving and stationary part of rotation machinery. 6.5.1.3 The temperature of bearing increases sharply and exceeds the rated value, the disposal is failure and smoke is seen in the bearing. 6.5.1.4 The motor noise seriously. 6.5.1.5 The current exceed the rated value and cant be returned. 6.5.1.6 Oil leak and other accident which can not maintain normal operation. 6.5.1.7 Human injury or endanger personnel safety. . 6.5.1.8The oil pipe broken and oil leak seriously. 6.5.2 Common trouble and its solution 6.5.2.1 Motor trouble 6.5.2.1.1 Motor overheat (1)The speed of rotation is higher the rated value, check the motor and its power supply. (2)The flow of fuel pump is higher the permitted, lower the pressure pipe valve (inform the boiler operator). DOCUMENT NO. : HISAR-ZT-07
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(3)When the motor or the pump is worn, check it.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

(4)When the pump is unsuitably assembled, there is rubbing or jam between the moving and stationary part, stop the pump, turning it by hand, find out the rub and jam part to repair or adjust. (5)For three-phase motor, if one phase fuse is burn out, or three phases current does not balance, change the fuse or repair the motor. (6)Low-voltage or insulation fault, stop and repair it. 6.5.2.1.2 Motor vibration is seriously large (1) If anchor bolts are loose, tighten it (2) Align center line, if center of motor and that of pump are not coinciding. (3) If shaft is bending and accompanied with rubbing, shaft shall be adjusted to eliminate friction. (4) Motor vibration is for the reason of the mechanical defects, find and eliminate them. 6.5.2.1.3 High motor current (1) Overload running, decrease the load if the current is still too high, and stop the motor. (2) Voltage too low, electrician come to find out the reason. (3) Alignment of center line, if center of motor and pump are not coincides. (4) Mechanical jam, Find out and eliminate. (5) Two phase operating; electrician should check up and deal with the cause. 6.5.2.1.4 Motor trip (1) When protection and thermocouple is actuated and fuse melt and motor automatically trip, interlocked standby motor failed to auto run, it is necessary to manually started standby motor, and tripped the failed motor. Tripped motor may forced to switch once again if there isnt standby motor and load of whole plant will be affected (tripped motor unable to forced switch if it is in abnormal condition).forced switching is of no effect, operation switch shall be timely closed, and inform shift supervisor. Then electrician on duty shall check and find out the reason. Such as fuse melt and protection action, electrician shall change fuse and reset protection. (2) Power supply is cut off. If power is cut off and standby power source is not immediately put in, all equipments switch must be closed at stop position immediately, and wait for instruction. (3) If accident button is mistaken pressed or malfunction, correct them, and accident button ought to reset. 6.5.2.1.5 Motor current too low, oil flow is interrupted or too small, pump should check by listen its sound. 6.5.2.2 Oil pump malfunction 6.5.2.2.1 Oil pump has not supplied oil (1) If there is air inside pump and oil is not filled full in pump before it starts, pump ought to fill oil to full and exhaust air by open the valve. (2) Air may get into oil line if the oil sucking pipe is not sealed well; systemically check the DOCUMENT NO. : HISAR-ZT-07
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tightness of pump inlet oil line/flange/valve, (3) Pump inlet cap or intake is blocked. Clear up these sundries.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

(4) Oil viscosity is too high. Oil temperature shall be increase in order to decrease oil viscosity. (5) Water seal line is blocked and air is entered. Water seal line shall be checked and cleaned. (6) Installation position is too high. Raise feed oil level or lower pump position and difference height of oil level. (7) Motor rotation speed is not enough; check power voltage and frequency decreased. (8) Motor rotation direction is wrong; wiring shall be changed by electrician. (9) Impeller of pump/oil outlet blocked. Impeller/oil outlet shall be checked and cleaned. 6.5.2.2.2 Flow is little in operation (1) Rotation speed reduced. Motor and power supply ought to be checked. (2) Check oil suction line if air get into it. (3) Resistances of suction line and out line increased. Valve and line shall be checked whether it is blocked in valves and pipeline or too small diameter. (4) Impeller and sealing ring worn. Waste on filter shall be cleaned; impeller and sealing ring ought to be replaced. (5) Filter inlet blocked. Filter shall be taken apart and cleaned. (6) Line and pump leak. The check and handle line and pump, gland packing, flange which is leakage. 6.5.2.2.3 Pump pressure decrease in running (1) Rotation speed reduced. Motor and power supply shall be checked. Boiler oil valve shall be check if opened too large. (2) Air gets into oil. Suction oil line shall be checked. (3) Pressure oil line damaged. Pressured oil valve and check pressure oil line. (4) Impeller and seal worn. They shall be taken apart and maintained or instead. (5) Vibration and noise occur in pump or motor a. Improper installation (such as: the center of pump and motor rotor are not in the same line or bad connection of the coupling) leads to unbalance of pump rotor. In this case, check the coupling wheel and adjust the center line. b. Part of impeller is jammed, and impeller should be cleaned. c. Disassembly or replace the damaged component which have a mechanical defect, for example, shaft bending, moving part jammed, bearing worn. d. Fixed set of the aspirate oil pipe and press oil pipe are loosened, it should be fastened. e. Cavitations happened because oil pumps erection height is too high; the pump must be stopped and installed at lower erection height. DOCUMENT NO. : HISAR-ZT-07
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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

f. Some foundation bolts loosen or foundation beneath oil pump units is unstable. In this case, fasten foundation bolts or strengthen foundation. 6.5.2.2.4 Bearing heating (1) Maintain and adjust the bearing when it is contact bad or clearance is inappropriate. (2) Check, maintain and adjust carefully the bearing which has worn or loose. (3) Oil ring is not moving smartly, oil quantity is small or feed oil interrupted. Check or change oil ring, make the lube system is free-flowing. (4) Quality of oil is not good or run short of oil, or there are sundries in the oil, it should be replaced for filtrated oil after cleaning. (5) Shaft center is at improper position or shaft bending. Adjust shaft center or change pump shaft. (6) Dimension of bearing is wrong, bearing shall be replaced. (7) Cooling water is interrupted, adjust flow. (8) If quantity of vibration or axial shaft movement is out of limits, found out the reason and deal with it. 6.5.2.2.5 Oil line has bumps in side if air is in oil pump and line. Air shall be vented, and the reason of air getting in shall be handled. 6.5.2.2.6 Pump heating (1)Stop pump and repair if rubbing is inside pumps. (2)Pump running within air for long time. After stop pump and vent the air, restart up the pump. (3)Outlet valve is closed or valve open small range, increase valve open degree (oil is not allowed to cut when the pump stopped and switch to standby pump to supply oil.) 6.5.3 Common fault of feeding/return oil line 6.5.3.1 Feeding oil line broken Phenomenon 6.5.3.1.1 Main line pressure decrease immediately, oil pressure reduce, signal bell is loud; visual lamination light, feeding oil pump current suddenly increase, oil ejecting from point of broken point. 6.3.1.2 Reasons Poor pipeline welding; quality of steel is unaccepted or misuse of welding material; incorrect operation; thickness of pipe become thinner for long term brush and corrosion. 6.5.3.1.3 Method of disposal Contact with shift supervisor, switch the system according to operation mode; find out the broken points quickly, and take firefighting measures, and report to department concerned. 6.5.3.2 Return oil line blows up 6.5.3.2.1 Phenomenon Feeding/return oil pressure decrease, oil pump current suddenly increase, inlet
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pressure/current is waving, oil ejecting from broken point. 6.5.3.2.2 Reasons

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Poor welding; material is unaccepted or misuse of steel; incorrect operation; thickness of pipe become thinner for long term brush and corrosion. 6.5.3.2.3 Method of disposal Contact with shift supervisor, switch the system according to operation mode; find out the broken points quickly, and cut its related return oil valve and pipeline, then take firefighting measures, and report to department concerned. 6.5.3.3 Return oil pipe plug 6.5.3.3.1 Phenomenon: Return oil pressure high, temperature decreased, return oil flow is small; current is difficult to control lower. 6.5.3.3.2 Reasons: Return oil temperature low, return oil flow is small. 6.5.3.3.3 Method of treatment: Contact with shift supervisor, report on the workshop; increase feed oil temperature, and regulate oil flow. 6.5.4 APS interruption 6.5.4.1 Phenomenon: Ammeter and voltmeter are back to zero; low oil pressure signal rings, lamination board flash, electronic records are stayed at original place. 6.5.4.2 Method of treatment Reset all switches of running pump to stop position, it is strictly prohibited to contact again; Contact with shift supervisor, and make ready for the preparation of restart equipment. If it can not be in a relatively short time to restore system operation, steam source of oil heater should be cut off. Contact with shift supervisor, and make ready for the preparation of restart equipment and report to workshop. 6.5.5 Light pump vibration 6.5.5.1 May be due to the import or export of oil pump circuit impeded, such as the entrance of pipe or filter plug, export valve does not open, etc.; pump, piping, there are air or there is debris the tank oil level is too low, abnormal changes in temperature or water in the oil is too much, the bearings and other mechanical damage or loose of fuel pump at the end of the foot. 6.5.5.2 Fuel pump vibration should check the oil pump strainer differential pressure, such as confirmation dirty filter should be switched; judge determines the flow of pipeline; check the tank oil level is too low, otherwise the tank should be switching operation; to check the oil temperature of oil tank whether it is normal; such as fuel pumps have air, were carried out in oil-filled exhaust job; such as oil pump mechanical failure should contact maintenance treatment. DOCUMENT NO. : HISAR-ZT-07
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6.5.6 Export pressure of light fuel pump abnormal

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

6.5.6.1 Possible reasons for poor Oil imports are impeded, oil tank oil level is too low, and there is air in the piping and pumps. Oil imports abnormal temperature, oil pump failure, pump export regulator device malfunction. 6.5.6.2 Tank oil level is too low to be running to switch tank; the entrance of filter plug, pumps should be switched and clean; if the pumps and pipelines there is air, should be carried out oil-filled exhaust job; pump failure should be cut to the standby pump running and contact maintenance treatment. 6.5.7 Heavy fuel pump vibration 6.5.7.1 Pumps are the possible reasons for the import or export of Oil impeded, such as the entrance of pipe or filter plug, export valve does not open, etc.; there are air or debris in pump and piping, the tank oil level is too low, abnormal changes in temperature or water in the oil too much, screw, bearings and other mechanical damage or loose of fuel pump at the end of the foot. 6.5.7.2 Fuel pump vibration should check the oil pump strainer differential pressure, such as confirmation dirty filter should be switched; judge determines the flow of pipeline; check the tank oil level is too low, otherwise the tank should be switching operation; to check the oil temperature of oil tank whether it is normal; drain water, etc.; such as fuel pumps have air, were carried out in oil-filled exhaust job; such as oil pump mechanical failure should contact maintenance treatment. 6.5.8 Heavy abnormal hydraulic fuel pump export 6.5.8.1 Possible reasons for the import of Oil impeded, oil tank oil level is too low, there is air in the piping and pumps. Oil imports abnormal temperature, oil pump failure, and pump export regulator device malfunction, such as regulation. 6.5.8.2 Hydraulic abnormal, should check the voltage regulator device reconciliations; tank oil level is too low to be running to switch tank; pumps should be switched to plug the entrance of filter cleaning; if the pumps and pipelines there is air, should be carried out oil-filled exhaust job; pump failure should be cut to standby pump operation and contact maintenance treatment. 6.5.9 Pumps for vaporization Pumps in operation, if a local area and the pressure reduced to the corresponding liquid temperature below the saturation pressure corresponding saturation temperature exceeds the saturation temperature under pressure, then the liquid on the evaporation. The resulting bubble with the liquid flow was taken to the high-pressure areas, suddenly cohesion. In this way, repeatedly appeared centrifugal liquid vaporization and condensation process in centrifugal pump, the final result in the vaporization of oil pump failure. This failure generally occurs in the transmission high temperature and pressure pump, the harm is very serious. Range so that the oil supply pressure, flow rate reduced; heavy pipe led to shock and vibration, pump shaft from a rocky ledge, dynamic and static friction in part to oil supply disruptions. 6.5.9.1 Phenomenon: DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Current, the pressure drop in swing, pumping issued an abnormal voice. 6.5.9.2 The main reason: Oil temperature too high; import and export of pipe and filter plug; the entrance there is leakage of pipes or packing; and misoperation. 6.5.9.3 Method of treatment: Due to higher oil temperature caused evaporation at low pressure pump, one can try to reduce the oil temperature, because the oil temperature exceeds the set value or the pump inlet pressure is lower than the saturation temperature under the pressure caused by vaporization of high-pressure pump, the another may improve the entrance pressure of high-pressure pump; correct mistakes operation; the above treatment fails, contact shift supervisor and switch pump. 6.5.10 Current swing

6.5.10.1 Phenomenon Current meter indication instability \ swing 6.5.10.2 Main reasons: Voltage instability; oil temperature too high; improper operation; motor or pump body malfunction; inhalation pipe plug phenomenon; pump vaporization 6.5.10.3 Treatment methods: Voltage instability caused the current swing, Contact with shift supervisor or electrician to deal with the problem. Reduce the fuel temperature; Operate slowly or stop the operation; Switch running oil tubing or pumps; eliminate pump vaporization phenomenon. 6.5.11 Pressure swing 6.5.11.1 Phenomenon Oil pressure gauge is instability and hand swing seriously. Reasons are as follows: Record of transmission pressure signal is failure; Pump impeller or entrance pipes have plug phenomenon; Oil tank oil level is low; Pump vaporization; Misoperation or improper operation; Rotating mechanical parts has frictions phenomenon. 6.5.11.2 Treatment methods: Inform I & C personnel to check and dispose; check oil flow, if oil level is low, contact to increase oil supply or switch tank; if because of vaporization, the pump should be treat with its dealing method; if there is friction between mechanical parts or jam in pumps inlet pipe and impeller, the pump should be switch-over. And inform maintenance staff to deal with and correct mistakes. 6.5.12 Feed oil Pumps trip 6.5.12.1 Phenomenon Accident horn rings. red light out, green light flash; Current back to zero, pump signal ringing, lamination flash, oil pressure drops. 6.5.12.2 Reasons Protection of action; power failure; If accident button is mistaken pressed or misoperation; motor DOCUMENT NO. : HISAR-ZT-07
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or pump body malfunction. 6.5.12.3 Treatment methods:

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Interlock standby pump to auto start, or start the pump switches on, pull down the tripped pump switch, adjust oil pressure, change interlock switch; if the interlock pump failed to auto start, it should be manfully operated, if the tripped pump has no abnormal phenomenon in advance, it can be forced to switch on again. If still no start, contact shift supervisor and deal with the problems.

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Chapter VII Condensate Polishing Operation and Maintenance Regulations


7.1 introductions 7.1.1 Purpose of condensate polishing Condensate water will have different level of contamination for the reason of condenser seep or leakage, thermal system corrosion, load of turbine changing etc. Condensate water is main supply of feed-water. To improve feed-water quality and meet the strict requirement of sub-critical high parameter Large Capacity unit, it is required not only to purify and desalt boiler make-up water or chemical treatment of boiler water, but also to do further treatment to condensate water for removing of various salt, colloidal silica, metal oxide, suspended matter and some impurity in the condensate water, thus consequently guarantee the feed-water high purity to ensure the unit full load operation with small amount leakage and to leave enough time for applying shutdown with more leakage. 7.1.2 System introduction The 2 600MW sub-critical units has condensate polishing system, which is consists of one group of deep mixed bed and outer regeneration equipment. Deep mixed bed can reduce dissolved salt in the condensate water to a very small content, and can reduce the corrosion products and suspended substances in it. Condensate water of each unit will apply full flow treatment with flow 1616t /h. running pressure is 3-5Mpa with temperature 55. Each unit consists of three mixed beds; each output is design at 50% of condensate water volume. Among the 3 mixed beds, 2 mixed beds are running and 1 mixed bed is standby. The 2 units share one set of outer regeneration system with design pressure 0.7Mpa. Regeneration system adopts complete separation method. This method consists of three regeneration towers: resin separation tower (SPT), cation resin regeneration storage tower (CRT), anion resin regeneration tower (ART).exhausted resin of mixed bed being sent to the "resin separation tower" do preliminary air scrubbing and then backwashing for layer operation. The characteristic of complete separation regeneration technology is that its separation tower is designed as large top and small bottom special structure. Firstly, water upon the resin at top separation tower drains out, secondly, 0-45M3 / H high velocity backwash water is injected in, and quickly to elevate the entire resin bed to the top of the separation tower, thirdly, the backwash water flow will be gradually reduced below the cation resin's critical deposition velocities through a flow-control valve installed on the backwash water, finally at this flow rate, cation resin particles will sink, while the anion resin is still float upon the top of separation tower. Until backwash flows are reduced to zero and anion resin is already settled down thus cation and anion resin is complete separated. Backwash layer flow adjustment is as follows:

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Resin Separation Backwash1 Backwash2 Backwash3 Backwash4 Backwash5 Backwash6 Flow Velocity m 3/h 123 62 31 16 8 4

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Time 6 13 13 13 15 30

Cation resin density is large, so anion resin is on top and cation resin underneath. There is mixed resin layer of 0.9m high between the separation tower's anion and cation resin layer. After backwash layer, anion resin will be unloaded into anion regeneration tower after the layered backwash, and cation resin is unloaded into the cation regeneration & storage tower. In this way, mixed resin layer stays in the separation tower will participate backwash separation of the next mixed bed exhaust resin. After the above separation, resin separation rate can achievecross-contamination of anion resin existed in cation resin and cation resin existed in anion resin is less than 0.1%. The anion/cation resin existed in anion/cation regeneration tower do further air scrubbing and regeneration separately, and then put regenerative anion resin existed in the anion resin into the cation regeneration storage tower to mix anion and cation resin and make forward washing qualified. After 20 minutes of rinse, conductivity is not reached less than 0.1s/cm, consideration should be given to deliver it to resin separation tower for re-separation. 7.1.3 Process description (1) High velocity mixed bed connects with condensate water system. Incoming water is come from condensate pump's outlet water, and goes to low pressure heater. (2)According to the process required, condensate water treatment consists of three parts: chemical demineralizing system, outer regeneration system and auxiliary unit. (3) Each machine chemical demineralizing system includes three high velocity mixed beds, an adjustable automatic bypass, a recirculation pump. (4) Outer regeneration system includes a resin separation tower, cation regeneration tank (storage tower), anion regeneration tank, wastewater resin trap. (5)Auxiliary unit includes electric heating water storage tank, acid/alkali tank, acid unloading pump, alkali unloading pump, acid/alkali measurement device, roots blower, backwash pump, etc. 7.1.3.2 System running description In face of one of the following circumstances, after the system receive the signal, it will automatically open the inner bypass valve 50% or 100% of condensate water flow through the inner bypass system, then automatically turn off the inlet and outlet valve of running mixed bed to protect the Internals and resin of mixed bed and to ensure that the thermal unit and the safe operation of mixed bed: DOCUMENT NO. : HISAR-ZT-07
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(1) inlet condensate water temperature55, inner bypass valve 100% flow adjustment; (2) Fine treatment bypass pressure difference 0.35Mpa, inner bypass valve 100% flow adjustment; (3) 3 mixed beds of system are at the exit or overhaul state, inner bypass valve 100% flow adjustment; (4) 2 mixed bed of system are at the exit or overhaul state (only one mixed bed is running), inner bypass valve 50% flow adjustment; 7.1.3.3 Fine treatment process Diagram Bypass system

Condensate water of main condensate pumphigh velocity mixed bedresin trapShaft Seal heater Outer regeneration system 7.1.4 Main equipment standard of fine treatment 7.1.4.1 Design parameter 1522 T/h Condensate water capacity normal operation needed to be disposed peak load 1616 T/h Condensate water inlet operation pressure 2.9Mpa pressure design pressure 4.0Mpa The number of sets of each unit 3 units mixed bed operation quantity 2 units 38 Condensate water normal operation temperature temperature the largest temperature 55 Mixed bed pressure difference when clean resin bed (including resin trap) 0.2Mpa Mixed Bed maximum flow pressure difference of dirty resin bed (including resin trap) 0.35Mpa Total height of mixed bed layer: 1.1m Anion and cation resin volume proportion:1:1 Reducing valve installed in compressed air main pipe reduce pressure to0.3-0.4Mpa 7.1.4.2 Vessel name fine treatment mixed bed resin trap resin separation tower anion regeneration tank cation regeneration storage tank wastewater resin trap compressed air storage tank electric heating water tank acid storage tank alkali storage tank acid metering box DOCUMENT NO. : HISAR-ZT-07 specification dn3200 dn600 dn2500/1700 dn1500 dn2000 dn1200 10m3 dn1800,10m3 dn2000, 20m3 dn2000, 20m3 dn1100,1.8m3 quantity no.1 no.2 3 3 3 3 common design pressure 4.0MPa 4.0MPa 0.7MPa 0.7MPa 0.7MPa normal 1.0MPa 0.7MPa normal normal

1 1 1 1 1 1 2 2 1
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name alkali metering box acid ejector alkali ejector acid fog absorber co2 absorber safety shower resin adding bucket wastewater pool 7.1.4.3 Pump and fan name recycle pump roots blower specification 450m3/h,h= .32mpa, inlet pressure:4.0mpa10.4m3/min,0.07mpa, specification dn1100,1.6m3 regenerated acid concentration 4-5 regenerated alkali concentration dn500 dn80 one-time filled resin volume: 0.1 m3 300m3 rated power(kW) 75 30 rated voltage 415 415 415 415 415 415 415 415 415 415 quantity no.1 no.2

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

common 1 1 1 1 1 1 1 1

design pressure

normal normal

quantity 2 2 2 2 2 2 2 1 2 2

linkage requirement

linkage linkage linkage linkage

regeneration 100m3/h,0.50mpa, 30 flush pump acid metering 3100 l/h,0.6mpa, 3 pump alkali metering 2000 l/h,0.6mpa, 3 pump acid unloading 13m3/h,0. 2mpa, 3 pump alkali unloading 13m3/h,0. 2mpa, 3 pump electric heating dn1800,10m3,0.7mpa 180 water tank 4x45kw neutralized pool 6.69m3/min,0.058mpa 15 roots blower wastewater 200m3/h 22 pump 7.1.4.4 Control standard of condensate water quality item unit total dissolved g/l solids(calculate at caco3 ) total suspended solid g/l whole iron(calculate at Fe) g/l inlet water long-term start operation 2000 1000 1000 50 500 100 15 20

linkage linkage

outlet water analysis cycle(hour) normal operation 20 10 5 3 hydrogen form operation 0.15 once a month once a month once a week once a week 2 2
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whole copper(calculate at Cu) g/l ph(25) conductivity DOCUMENT NO. : HISAR-ZT-07

8.89. 8.89.2 2 s/cm 20 0.5

Operation Manual for 600MW Unit


chloride ion calculate at Cl) sodium ion(calculate at Na) silica(calculate at si02) g/l g/l 200 20 20 15 1 5

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

once a week 2

500 20 10 2 g/l when unit starts and the whole iron of condensate water is less remark than 1000g / l ,the fine treatment mixed bed put into operation 7.2 Operation of condensate water fine treatment device 7.2.1 The inspection and preparation of initial operation 7.2.1.1 Field preparation (1)Clearing up the site: the site must be cleaned after completing installation and the equipment is ready to start. Remove the materials which have been left over after equipment installation and the rubbish near to the equipment. (2) Pneumatic equipments: It must provide purified dry air to pneumatic equipment to make sure that the pneumatic equipment long-term safe and reliable operation. Air pipes must discharge before connecting to the pneumatic equipment. The air pipeline must be installed pressure regulator to regulate the air pressure, to prevent over-stress to damage the equipment. Checking the tightness of pipelines, then supply air to electric pneumatic plants and adjusting the pressure regulator to the manufacturer's requirements. Re-examining whether pipe interfaces and value film are leakage. Examining whether electromagnetic valve buttons on electromagnetic valve boxes and operation value are one-to-one correspondence, whether the value actions are correct and whether the value numberings on the electromagnetic valve box have been installed correctly. (3) Electrical equipments: It must check the power of electrical components and electrical equipment normal under all operating conditions. (4) Water source: It must turn off all the isolation valve water on the treatment equipment, and connect the water which will be dealt with to the first isolation valve for a test running. 7.2.1.2 Chemical quality The entire chemicals pipeline should be inspected, chemical purity and impurity content should be consistent with the national standard requirements, it is prohibited to use of the chemicals which contain the excessive impurity. Ensure that tightness and support of flanges and pipeline are appropriate, and try operating valves and observing whether the action is correct. The most important factors of ion-exchanger operation are the regenerate quality which is used regeneration process. Applying impurified chemicals will result in permanent loss of resin and the water quality. 7.2.1.3 Mechanical part preparation (1) Checking the internal device of equipment The internal device of all the equipment must conduct a detailed examination before starting (prior to supply water) at the site. Special attention must be paid to check the following content: a) Check the installation gap for the water cap inside the ion exchanger, using feeler to check at DOCUMENT NO. : HISAR-ZT-07
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100 percent inspection rate with gap not more than 0.2mm is accepted. Because the transportation process is likely to cause inner nut loose and make water cap loose; (b) Inspecting the Internal rubber lining quality, whether there is frost crack or other defects. If so, repair it. For small cracks deficiency, epoxy resin adhesive can be used, but for large area lining defects, the problem shall inform the manufacturer to settle. c) Inspecting interior of equipment whether there is impurities, as well as any loosening of fasteners; d) Check nameplate, the installation location and the design drawings equipment of are in line with; (2) Machinery equipment: Confirm that all oil cups are filled full with oil or with suitable lubricants. Start the motor and check the rotation direction. With regard to pumps and metering pumps, it should confirm that pump is full of water or liquid before starting motor, start air pump motor in empty liquid state is prohibited. Safety valve must be installed in roots blower's vent main pipe to prevent the fan's vent valve jam and damage fan. (3) Valve Isolation system (turn off all manual valves), operates diaphragm valve, pneumatic valve, electric valve before water filled and check they are flexible, reliable and close tight. All valves should be maintained in an operable state. In order to revent valve stem jam, lubricant grease should be added. 7.2.1.4 Rinse and clean (1)Rinsing system: Before put stuffing into equipment, the entire system must be thoroughly washed. The proposed washing procedures are as follows: disconnect equipment inlet pipe flange, begin to wash at this point to prevent the dirty and trash entering into the equipment and inlet distribution device. If orifice or flow meter is installed on inlet pipe, this place should be washed first. All other equipments connected to the pipeline should be washed as similar way. Then installing inlet pipe and disconnect equipment outlet flange, disconnect any major external parts from the device. Then washing facilities with water wash any residual dirt away from drainage device. Then Install outlet flange. Fill water and do pressure test before starting. (2)Initial backwash Before the stream passes the empty equipment, equipment should be backwashed. In this backwash process, the backwash flow rate should be greater than the normal speed of the backwash. It should be continuous backwash until the drainage turn to be clean. Backwash may cause blocking and equipment damage, which results in loss of system pressure difference, is not normal, therefore, pressure difference loss should be carefully observed DOCUMENT NO. : HISAR-ZT-07
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pressure in backwash process and enhance water flow carefully. 7.2.1.5 Hydrostatic test

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Before put stuffing in, all pipes and equipments should be carried out tightness hydraulic test. Hydraulic test pressure is as follows Test pressure equals equipment design pressure, namely: medium-pressure front valve of mixed bed test pressure is 4.0MPa. Test pressure of medium-pressure back valve and common regeneration system are 0.7MPa. PH metering box system is normal pressure systems and filling test can be carried out to check water leakage. 7.2.1.6 Setting flow valve and step operation time Adjust the flow with flow valves. It should set valve-control device (limit device) to ensure suitable flow under automatic operation. It suggests that it should set the flow valve one by one when initial regeneration, taking the actual time which is required as the criterion. The flow value of program table is the theoretical value for reference. Step operation sequence generally refers to the time tables regulation, permitting a small amount of adjustment in order to optimize the process more rational. 7.2.1.7 Start-up step 7.2.1.7.1 Initial start-up preparation (1) It is recommended that initial start adopts manual operation; (2) System filled with demi water; (3) Acid/alkali level is normal; (4) Electric heating water tank temperature reach to the set temperature (usually 80-85 C); (5) All automatic valves are working normally at the operational closed state with valve on the solenoid valve box correspondence; But the Roots blower valve step are at open state except the specifically pointed closure. It is the pneumatic diaphragm valve which normally opens; (6) All pumps, fans, metering pumps works normally; (7) Compressed air storage tank pressure are normal, generally may not be less than 0.5MPa; (8)Wastewater pool at low level; (9) Demi water tank is at high level; (10)Clean up the site; 7.2.1.7.2 Filling resin Adding cation and anion resin through the resin adding bucket into cation regeneration storage tank and anion resin regeneration tank respectively. Method of operation: open all the manual valves of wash pumps, the manual valve of return pipe on the wash pump should be in open state, start wash pump, and then open the front jet valve of resin ejector, the dilution valve of adding bucket, resin ball valve of cation and anion tank, pneumatic rinse discharge valve of anion and cation tank, then add the resin into the adding bucket, put resin into their respective tank by resin injector. When a resin loaded completely, the tank should be at full water status. DOCUMENT NO. : HISAR-ZT-07
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Note: pay special attention to resin adding bucket to avoid any impurities entering it and affecting the usage. 7.2.1.7.3 Pretreatment of resin in transition The transition of anion and cation resin usually applying double size regeneration liquid for regeneration with cation resin using not more than 5% of hydrochloric acid and anion resin utilizing not more than 4% of the sodium hydroxide. outer regeneration system send the first batch of qualified pretreated resin to the first condensate fine treatment mixed bed, and load the second batch to the second mixed bed, and then sent the third batch of pretreated resin to third mixed bed Units, and finally the fourth pretreated and keep in standby state. Sometimes the manufacturer provides resin ion type of cation H, onion OH. This situation may not carry out pre-treatment and directly send into the mixed bed for usage. Notes of resin pre-treatment: 1. Taking into account the mixed resin, transition of the first resin mixture need soak 24 hours in acid and alkali liquid and then send to the resin separation tank for regeneration stratified backwash operation. After 6 copies of the remaining resin are in their respective regeneration tank by 24 hours soaking, directly do in-depth regeneration transformation treatment according to the step-by-step sequence provided by regeneration program in their regeneration tank. And then send the anion resin to cation tank for the air mixing and rinse qualified, it can send to the second mixed bed, and so on. 2. New mixed bed should be put into operation in turn, suggest the time interval of 2 mixed beds put into operation is more than 24 hours, in order to avoid regeneration system do not have enough time for regeneration in case both two mixed beds fails simultaneously. 3. The system designed two mixed beds operation, one standby, also permit the 3 mixed beds parallel work. When one is failed, switch to the other 2 parallel operations. 7.2.2 Pre-inspection and preparation of the normal operation (1) Checking the compressed air storage tank pressure normal, generally may not be less than 0.5Mpa, and ensure quality of air is clean and it have adequate quantity. (2) Solenoid valve cabinet whether transmission of electricity and gas is in operating conditions; (3) All measuring instruments (thermal instrumentation, chemical instrumentation, etc.) are in good standby situation; (4) Checking all the valves and related equipment put into operation should be in good standby situation; (5) The inlet and outlet manually operated valve of Mixed Bed put into operation is at opening state; (6) All the analytical instruments are in good condition. Medicines are all ready; (7) Inspecting resin trap is not plugged; (8) Checking the control system is working normally; DOCUMENT NO. : HISAR-ZT-07
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7.2.3 Operation of mixed bed

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

7.2.3.1 The bypass valve of condensate water system is regulating butterfly valve. When it is in normal operation, two mixed beds are running, the other one is spare. When one mixed bed is failed, first start the standby mixed bed, then split the failed mixed bed unit the standby mixed bed put into operation. Therefore, the whole treatment system has always been able to guarantee 100% of processing power. Another 3 mixed beds operate simultaneously can also be maintained 100% flow of condensate water treatment. Therefore the bypass valve always keeps closed. Only when the 2 mixed beds of the system are in maintenance status, which means that only one mixed bed is in operation, bypass valve can automatically adjust 50 percent flow. 7.2.3.2 The two mixed beds put into operation follow the step-by-step sequence. After it confirms the two mixed beds put into operation are normal, shut down the bypass valve of system. 7.2.3.2. If the mixed bed not in operation is not under repair and resin is not exhausted and can be normal operation, it can put the mixed bed not in operation into standby status. 7.2.3.4 After checking the pressure of mixed bed and observe the normal flow of the mixed bed, mixed bed put into operation. 7.2.3.5 Condensate dematerializestandby to service with recycle NO. cd step cd standby 1 time valves open (min) /valve no. 10ldf11aa002 10ldf01aa001 10ldf11aa002 10ldf11aa005 10ldf01aa001 mix bed pressure under working pump/motors instruments comments on no. range

cd cd open sts1 recycle valves

cd cd sts2 recycle

FS

10ldf11aa002 10ldf11aa005 10ldp01ap00 10ldf01aa001 1 10ldp01a003 10ldf11aa002 10ldf01aa001 10ldf11aa002 10ldf11aa003

Recycle pump starts and continues until conductivity is at acceptable level, alarm 0.2s signal if conductivity sating is not reached in preset period(fs) 10ldp11aa003 closure verified by limit switch action. 10ldf11aa003 open verified by limit switch action .close system bypass valve as cd outlet valve is opened.

cd Cd recycle 1 sts3 shutdown Cd open cd outlet 1 sts4 valve

cd Cd in 10ldf11aa002 1 unit goes in service sts5 service 10ldf11aa003 NOTE 10ldf11aa002:mixed bed intake valve, 10ldf01aa001:mixed bed bypass total valve, 10ldf11aa005:mixed bed recycle total valve, 10ldp01aa003 :recycle pump valve,

10ldf01aa001:mixed bed bypass valve, 10ldf11aa003 :mixed bed outlet valve

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7.2.4 Outage of mixed bed

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

7.2.4.1 When one mixed bed need stop, it must confirm that the standby mixed bed put into operation indeed first. 7.2.4.2 When standby mixed bed is unable to put into operation and one mixed bed must stop, only one mixed bed is in operation, bypass valve can automatically adjust 50 percent flow. 7.2.4.3 If fine treatment system quits, it will quit mixed bed to exit status, and the other running mixed bed quit to exit status, with inner bypass automatic 100% open, turn off the sampling frame valve after exit. 7.2.4.4 condensate demineralizer-service to standbytotal time:2 min no. step time (min) valves open/ valve no. 10LDF11AA002 10LDF11AA003 10LDF11 AA002 10LDF01 AA001 10LDF11 AA002 10LDF01 AA001 instruments no. range comments Vessel Operating Open System Bypass Valve as CD outlet valve is closed

CD CD SST-1 SERVICE CD CD 1 SST-2 Close Outlet Valve CD CD SST-3 Maintain Pressure

Inlet stays full open until operator, (1) reopens outlet, or 1 (2) removes CD from line by closing inlet. NOTES: 10LDF11 AA002: mixed bed inlet valve, 10LDF11AA003: mixed bed outlet valve, 10LDF01 AA001: mixed bed bypass valve) 7.2.4.5 Condensate demineralizerstandby to off (total time: 3min)

NO. CD

step

time (min)

valves open/ Valve no. 10ldf11aa002 10ldf01aa001

set point/ pump/ motors on valve no.

instruments no. range

comments vessel pressurized

CD 10ldf01aa001 STO1 CD 10ldf11aa502 open vent STO2 10ldf01aa001 valve CD CD off 1 10ldf01aa001 STO3 NOTES: 10LDF11AA002: mixed bed inlet valve, 10LDF01AA001: mixed bed bypass valve, 10LDF11AA502: mixed bed exhaust valve 7.2.5 System bypasses valve movement condition 7.2.5.1 When the condensate water temperature exceeds 55 C or bypass pressure reaches 0.35MPa, the bypass 100% open automatically, after confirm that it is open fully, and then turn off the inlet and outlet valve of the running mixed bed to protect the pieces and resin of mixed bed. 7.2.5.2 When only one mixed bed put into operation, the bypass valve should open 50% automatically. The bypass valve turns off until it confirms that there are 2 mixed beds put into

CD standby CD removal 1 from standby CD 1 depressurize

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operation. When bypass valve opens, if we close the bypass, it should start 2 mixed beds to put into operation first. And then turn off bypass system after it confirms 2 mixed beds put into operation fully. 7.2.5.3 Due to the high pressure bypass> 0.35Mpa, it illustrates that mixed bed resin is polluted by corrosion products or suspended matters seriously. Mixed bed resin should be put into regeneration system to do the air scrubbing and regeneration. 7.2.5.4 If you want to judge the mixed bed high-pressure difference, you can watch the flow value of mixed bed. When a running mixed bed flow is significantly less than another running mixed bed, it illustrates that small flow mixed bed resin pressure is higher. It should be regenerative. It should consider the need of mixed bed regeneration and air scrubbing when the general flow is less than 500 ~ 600M3 / H. 7.2.5.5 When bypass valve is 100% open, it suggests the bypass valve turns off manually. Before the bypass valve turns off, it must confirm 2 mixed beds have been put into operation, and then close the bypass valve. 7.2.6 Operation mode of mixed bed 7.2.6.1 When any of the following conditions are met, mixed bed is failed and quit running: 7.2.6.1.1 pressure difference of inlet and outlet main pipe of running mixed bed 0.35Mpa 7.2.6.1.2 Mixed bed flow is less than 500 ~ 600M3 / H 7.2.6.1.3 All the index of mixed bed effluent water is higher than the normal operation value or close to standard value. 7.2.6.2 When it is in normal operation, two mixed beds are running, one spare. When one mixed bed is failed, first start standby mixed bed and then trip failed mixed bed. 7.2.6.3 When two mixed beds are in operation, ensure that one mixed bed is in H + / OHoperation and one bed is NH4 + / OH- operation. 7.2.6.4 When unit is in normal operation, the fine treatment mixed bed is strictly prohibited exiting (except mixed bed is failed).If there are special reasons, it can quit after the director agrees. 7.2.7 Characteristics of system operation 7.2.7.1 High velocity mixed bed designed according to operation of H / OH-type. And consider the NH4 + running condition. 7.2.7.2 Outlet water of fine treatment system meets need of the super critical units normal and non-normal operation and start-up. 7.2.7.3 When happens a small amount of condenser leakage, the design of condensate fine treatment system could make turbine-generator continuously work in the maximum output situation by input pre-filters and increase condensate fine treatments regeneration frequency; when the leakage is large, it must ensure necessary run-time of the safety shutdown. 7.2.7.4 When the water conductivity, silicon, sodium, water cycle capacity and any parameter in depressurization of a high velocity mixed bed exceed the set value, the standby mixed bed put DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

into operation and recycle resin, then pass into the system after the effluent water qualified. The failed equipment stops operation. Exhausted resin of out of operation mixed bed was send to regeneration system to do air scrubbing, separation and regeneration. Standby resin of regeneration system is delivered to the mixed bed standby. 7.2.7.5 Pre-filter input, outage, washing of fine treatment system and inputs, outage, resin transfer, regeneration and other steps of mixed bed work according to the control program automatically. 7.2.7.6 Each machine of condensate fine treatment systems has a bypass system, mixed bed bypass should be the automatic full open when the water temperature is higher than 55 and turn off inlet and outlet valves at the same time. When mixed bed inlet and outlet main pipe pressure difference is greater than the 0.35MPa, the bypass valve 100% open. Before one mixed bed splits and resin transfer and put into operation, the bypass valve open according the set. It make bypass flow achieve half of the total flow. The start, stop and regenerative operation of condensate fine treatment system can work automatically, and operation personnel also can confirm conditions in the LCD and then give commands for remote operation and handle it at electromagnetic valve box manually in situ. 7.3 Operation of mixed bed fine treatment regeneration 7.3.1 Preparation of regeneration 7.3.1.1Check the pressure of compressed air is not less than 0.5Mpa 7.3.1.2 Electromagnetic tank have operation condition 7.3.1.3 All detection devices (thermal instrument, chemical instrument, etc.) are in well standby state 7.3.1.4 Check the valve, pump and fan-motor of regeneration device are in well standby state 7.3.1.5 Acid/alkali system and heating system are in operation 7.3.1.6 Control system is working normally 7.3.1.7 Condensate supplement tank has enough demi water 7.3.1.8 Water in wash pump is enough 7.3.2 Regeneration operation of fine treatment 7.3.2.1Mixed bed standby from service. After checking the standby mixed bed has been put into operation, then exit the failed mixed bed, if exit the failed mixed bed in the situation of the standby mixed bed couldnt be put into operation, bypass valve will adjust 50% flow automatically. Inlet and outlet valve of the failed mixed bed closed, discharge valve turn on, waiting for resin transferring. 7.3.2.2 Condensate demineralizerfailed resin transfer to separation. Start the first step of regeneration, output of mixed bed resin 7.3.2.3resin transfer from cation regeneration tank to mixed bed start the second step of regeneration, mixed bed could put into operation when the standby resin in cation regeneration tower have been transferred to mixed bed. DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

7.3.2.4 condensate demineralizeroff to standby put the mixed bed into service. 7.3.2.5transfer the lose efficacy resin in separation tank separate the lose efficacy resin, transfer to the corresponding regeneration tank respectively. 7.3.2.6 Anion regeneration tankregeneration, cation regeneration tankregeneration regenerate the lose efficacy resin in the corresponding tank. 7.3.2.7Anion regeneration tankresin transfer to cation regen, cation regeneration storage tankair mix/rinse standby finish the present step in order, the mixed resin can be used as standby resin. 7.3.3 Operation step and instruction of condensate polishing regeneration 7.3.3.1 Condensate demineralizerexhausted resin transfer to separation tank (total time: 36min)

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no. cd rto-1 cd depressurize step time min 1 valves open/ valve no. 10ldf01 aa502 10ldf11aa501 10ldp01aa501 10ldf11aa005 cd rto-2 cd air resin 10 10ldf11aa008 10ldp51aa002 70ldp13aa008 00ldp76aa001 70ldp13aa003 10ldf11aa501 10ldp01aa501 10ldf11aa005 10ldf11aa008 cd rto-3 cd water/air resin transfer out#2 10 10ldp51aa002 70ldp13aa008 00ldp76aa001 70ldp13aa003 10ldf11aa502 10ldf11aa007 10ldf10aa001 70ldp21ap001 or 70ldp21ap002 pump/motors on set point/no.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

instruments no. range

comments Open vent valve, after closing inlet valve

maintain air dome top head 210m3/h 10ldp61cf201 sluice resin to spt tank.

transfer out#1

maintain air dome bring 31m3/h 210m3/h 70ldp21cf201 10ldp61cf201 water into top head continue sluicing resin

DOCUMENT NO. : HISAR-ZT-06

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10ldf11aa502 cd line flush , cd rto-4 vent drain #1#1 step1 10 10ldf11aa005 10ldp01aa401 10ldf10aa002 70ldp13aa003 70ldp13aa008 00ldp76aa001 10ldf11aa502 10ldf11aa005 cd line flush , cd rto-5 vent drain #2 step2 10ldp01aa401 10ldf10aa002 70ldp13aa003 70ldp13aa008 00ldp76aa001 70ldp11aa011 70ldp21ap001 or 70ldp21ap002 31m3/h 70ldp21ap001 or 70ldp21ap002 31m3/h

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

70ldp21 cf201

drain cd fiush transfer line

70ldp21 cf201

drain cd flush transfer line from 2 sources

note: 10ldf11aa502:exhaust valve, 10ldf11aa501:mixed bed inlet compressed air valve, 10ldf11aa005:mixed bed recycle valve, 10ldf11aa008:mixed bed outlet resin valve, 10ldp51aa002:mixed bed total outlet resin valve, 70ldp13aa008:separation tower inlet resin valve, 00ldp76aa001:regeneration feeding resin main pipe valve, 70ldp13aa003 :separation tower backwash discharge valve), 10ldf11aa007:mixed bed inlet resin valve , 10ldf10aa001:mixed bed inlet rinse water valve, 10ldp01aa401:mixed bed discharge valve), 10ldf10aa002:mixed bed total resin pipe rinse water valve, 70ldp13aa008:separation tower inlet resin valve), 00ldp76aa001:regeneration resin transportation total valve, 00ldp76aa001::regeneration resin transportation total valve, 70ldp11aa011:regeneration rinse water total valve 7.3.3.2 Resin transfer from cation regen tank no. step time valves open/ pump/motors set instruments comments

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no. 70LDP11AA009 70LDP11AA008 00LDP76AA001 10LDP51AA001 10LDF11AA007 10LDF11AA502 10LDF11AA005 10LDP01AA401 70LDP11AA009 70LDP11AA004 70LDP11AA008 00LDP76AA001 10LDP51AA001 10LDF11AA007 10LDF11AA502 10LDF11AA005 10LDP01 AA401 70LDP11AA001 70LDP11AA004 70LDP11AA008 10LDP51AA001 10LDF11AA007 10LDF11AA502 10LDF11AA005 10LDP01AA401

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

range

CD RTI-1

CRT Resin Transfer Pressurized Air

FS

210m3/h

10LDP61CF201

Blowdown Water to remove resin. Time field set

CD RTI-2

CRT Resin Transfer Press Air/ Water

FS

70LDP21AP001 OR 70LDP21AP002

13m3/h 210m3/h

70LDP11CF201 10LDP61CF202

Bring water into bottom of vessel-maintain an air dome at 552KPa

CD RTI-3

CRT Resin Transfer Vessel Flush

FS

70LDP21AP001 OR 70LDP21AP002

13m3/h 31m3/h

70LDP11CF201

Bring water into bottom/top of vessel.

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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

CD RTI-4

CRT Resin Transfer Out-Line Flush CD Fill

FS

70LDP11AA011 10LDP51AA001 10LDF11AA007 10LDF11AA502 70LDP11AA007 70LDP11AA006

70LDP21AP001 OR 70LDP21AP002

31m3/h /

70LDP21CF201

Flushes resin transfer lines . Verify that no resin is left in CRT and that CD resin level is proper. Valve 10LDF10AA002 to open for 1 min. at halfway point of timed step.

NOTE: 70LDP11AA009:cation tower inlet compressed air valve, 70LDP11AA008:cation tower outlet resin tower, 00LDP76AA001:regeneration resin delivery total valve, 10LDP51AA001:mixed bed inlet resin total valve, 10LDF11AA007:mixed bed inlet resin valve, 10LDF11AA502:mixed bed exhaust valve, 10LDF11AA005:mixed bed recycle valve, 10LDP01 AA401:mixed bed discharge valve, 70LDP11AA009:cation tower inlet valve, 70LDP11AA004:cation tower backwahing discharge valve, 70LDP11AA008:cation tower outlet resin valve, 10LDP51AA001:mixed bed inlet , 10LDF11AA007:mixed bed resin-inlet valve, 70LDP11AA001:cation tower rinse admission valve,10LDP51AA001:mixed bed resin-inlet total valve , 70LDP11AA011:regeneration flush water total valve, 70LDP11AA007:cation tower exhaust valve, 70LDP11AA006 :cation tower forward vent valve 7.3.3.3 Condensate demineralizeroff to standby (total time: 1min) no. cd cd ost-1 cd ost-2 cd off cd pressurize 1 mixed bed boost pressure valve 10ldf11aa006 mixed bed admission 10ldf11dp201 <1.5bar step time (min) valves open/ valve no. no. instruments range not in service pressurizer to pds setting interlock service inlet line vessel comments

cd open service inlet

valve 10ldf11aa002

pressurized .10ldf11aa002 open verifled by limit switch action10ldf11aa002

7.3.3.4 Separation and transfer of exhausted resin in separation tank

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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

This step is very important for prolonging the cycle of mixed bed, the resin must inflation as far as possible in the case that it do not run away from the discharge valve which at the top of the tank, then it must sink gradually under control, so the two kinds of resin can be separated completely by their different speed of sinking. Please pay special attention to the waste water trap, if the integrated resin is leak much when operating, you should immediately stop it, then report to the professional executive, and make necessary adjustment to the valves or the scale time. no. step time (min) no. 70LDP11AA011 SPT1 SPT Fill FS 70LDP13AA008 70LDP13AA001 70LDP13AA011 pump/motors on setpoint /no. instruments no. range comments

70LDP21AP001 OR 70LDP21AP002 Air to top of resin bed 60m3/h 70LDP13CF201 N/A SPTinitiated by operator

SPT-2

SPT Pressurized Air Drain 1

FS

70LDP13AA002 70LDP13AA007

210 m3/h

10LDP61CF202

70LDP13AA002 open to allow bed to compact. 70LDP13AA002

SPT-3

SPT Air Scrub

15

70LDP13AA004 70LDP13AA003

70LDP41AN001 OR 70LDP41AN002 70LDP21AP001 OR 70LDP21AP002

700m3/ h

70LDP41CF201

SPT-4

SPT Fill

70LDP13AA005 70LDP13AA003 70LDP13AA002

62m3/h

70LDP13CF201

Restore bottom window.

water level of top

to

sight

SPT-5

SPT Drain

FS

210

N/A

Lower water level to 6

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Operation Manual for 600MW Unit


70LDP13AA007 m3/h

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

above Resin Beds Check resin expansion.

SPT-6

SPT

Resin

70LDP13AA005 6 70LDP13AA006 70LDP13AA003

70LDP21AP001 OR 70LDP21AP002

108m3/ h 3.4m3/h

Adjust flowrate for varying 70LDP13CF201 temperatures. Flow rate is reduced by slowly closing

Separation 1

valve-70LDP13AA005 70LDP13AA005 13 70LDP13AA006 70LDP13AA003 70LDP21AP001 OR 70LDP21AP002 70LDP21AP001 OR 70LDP21AP002 70LDP21AP001 OR 70LDP21AP002 70LDP21AP001 OR 70LDP21AP002 70LDP21AP001 OR 70LDP21AP002
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Flow rate is reduced by 54m3/h/ 3.4m3/h 70LDP13CF201 slowly closing valve

SPT-7

SPT

Resin

Separation 2

70LDP13AA00570LDP13 AA005

SPT-8

SPT

Resin

Separation3

13

70LDP13AA005 70LDP13AA003

27m3/h/ 3.4m3/h

70LDP13CF201

Flow rate is reduced by slowly closing valve

70LDP13AA005 70LDP13CF201 Flow rate is reduced by slowly closing valve

SPT-9

SPT

Resin

Separation4

13

70LDP13AA005 70LDP13AA003

13m3/h/ 3.4m3/h

70LDP13AA005 70LDP13CF201 Flow rate is reduced by slowly closing valve

SPT-10

SPT

Resin

Separation5

13

70LDP13AA006 70LDP13AA003

4m3/h

70LDP13AA006 70LDP13CF201 Flow rate is reduced by slowly closing valve

SPT-11

SPT

Resin

Separation6

30

70LDP13AA006 70LDP13AA003

4m3/h

70LDP13AA006

DOCUMENT NO. : HISAR-ZT-07

Operation Manual for 600MW Unit


SPT Anion Resin SPT-12 Transfer Anion Tank. to Regen 7 70LDP13AA001 70LDP13AA009 70LDP13AA007 70LDP13AA006 70LDP21AP001 OR 70LDP21AP002

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

31 m3/h 4m3/h

70LDP13CF201

Visually check resin levels in SPT and ART

Check resin expansion. SPT Secondary SPT-13 Resin Separation 2 FS 70LDP13AA005 70LDP13AA003 70LDP11AA011 70LDP13AA010 70LDP21AP001 OR 70LDP21AP002 54 m3/h 31m3/h 3.4m3/h Adjust flow rate for varying 70LDP13CF201 70LDP21CF201 temperatures. Flow rate is reduced by slowly closing valve

70LDP13AA005. 70LDP13AA005 SPT Secondary SPT-14 Resin Separation3 FS FS 70LDP13AA006 70LDP13AA003 70LDP11AA011 70LDP13AA010 70LDP13AA005 SPT Secondary SPT-15 Resin Separation4 FS 70LDP13AA006 70LDP13AA003 70LDP11AA011 70LDP13AA010 SPT Secondary SPT-16 Resin Separation5 FS 70LDP13AA006 70LDP13AA003 70LDP21AP001 OR 70LDP21AP002
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70LDP21AP001 OR 70LDP21AP002

27 m3/h 31m3/h 3.4m3/h

70LDP13CF201 70LDP21CF201

Flow rate is reduced by slowly closing valve

70LDO13AA005

70LDP21AP001 OR 70LDP21AP002

13 m3/h 31m3/h 3.4m3/h

70LDP13CF201 70LDP21CF201

Flow rate is reduced by slowly closing valve

70LDO13AA005

Flow rate is reduced by 4m3/h 70LDP13CF201 slowly closing valve

70LDO13AA006

DOCUMENT NO. : HISAR-ZT-07

Operation Manual for 600MW Unit


SPT Secondary SPT-17 Resin Separation6 FS 70LDP13AA006 70LDP13AA003 70LDP13AA001 Resin SPT-18 Transfer 10 70LDP13AA010 70LDP11AA010 70LDP11AA006 70LDP13AA006 10LDF10AA001 SPT-19 Resin Transfer 2 10LDP11AA010 10LDP11AA006 10LDP11AA011 SPT-20 Line Settle 5 70LDP21AP001 OR 70LDP21AP002 N/A 31m3/h 31m3/h 70LDP21AP001 OR 70LDP21AP002 31m3/h 4m3/h/ 70LDP21AP001 OR 70LDP21AP002 2m3/h

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

70LDP13CF201

Visually check for resin cross contamination.

to Resin Regen Tank

70LDP13CF201

PT LS will teminate cation resin sluice if time is too long.

70LDP21 CF201

Sluice resin in header to CRT

Out-Line Flush

N/A

NOTE:70LDP11AA011:regeneration flush water total valve, 70LDP13AA008:separation tower resin-inlet valve, 70LDP13AA001:separation tower upper admission valve, 70LDP13AA011:separation tower exhaust valve, 70LDP13AA002:separation tower compressed air inlet valve,

70LDP13AA007:separation tower forward vent valve, 70LDP13AA004:separation tower inlet air valve, 70LDP13AA003:separation tower reverse vent valve, 70LDP13AA003:separation tower tower backwash admission valve valve, 2, 70LDP13AA005:separation :separation tower tower backwash backwash admission discharge valve valve,

170LDP13AA006:separation

backwash

admission

70LDP13AA003

70LDP13AA001:separation tower rinse admission valve, 70LDP13AA009:separation tower anion resin outlet valve, 70LDP13AA007:anion tower forward discharge valve, 70LDP13AA010:separation tower cation resin outlet valve, 70LDP13AA001:separation tower forward discharge valve, 10LDP11AA010:cation tower resin-inlet valve, 70LDP11AA006:cation tower forward vent valve, 10LDF10AA001:mixed bed flush water inlet total valve,10LDP11AA00 6:cation tower rinse discharge valve 7.3.3.5 Anion regeneration tankregeneration DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit


time min valves no. 70LDP12AA007 FS 70LDP12AA003 70LDP12AA009 70LDP12AA005 70LDP12AA007 70LDP12AA004 FS 70LDP12AA003 70LDP12AA005 70LDP12AA007 FS 70LDP12AA009 70LDP41AN001 OR 70LDP41AN002 70LDP21AP001 OR 70LDP21AP002 357 m3/h 16 m3/h 357 m3/h N/A open/valve

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

instruments pump/motors on/ setpoint/no. no. range Blow N/A down water comments

.no.

step

ART R11

ART Draindown

level to 6 above resin bed

ART R12 ART Scrub RT Backwash ART R13 Air Scrub(Contd) W/Water ART R14 ART Pressurized Air FS

70LDP41CF201

70LDP41CF201 70LDP12CF201

128 m3/h

10LDP61CF202

Establish Air Dome @552KPA Flush fines out

ART R15

ART

Bottom

FS

70LDP12AA006 70LDP12AA009 70LDP12AA003

128 m3/h

Side Flush

10LDP61CF202

through and distributor

underdrain redenerant

ART R2 ART Fill

FS

70LDP12AA001 70LDP12AA007 70LDP81AA002

70LDP21AP001 OR 70LDP21AP002

31 m3/h 10.5 m3/h

70LDP12CF201 70LDP11CF301

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ART ART R3 caustic introduction. 5%NaOH 5%NaOH ART Caustic ART R4 displacement rinse. 30 60 Dilute 70LDP31AA001 70LDP12AA002 70LDP12AA006 70LDP81AA001 70LDP81AA002 70LDP31AA001 70LDP12AA002 70LDP81AA002 70LDP12AA006 ART R5 ART rinse 1 Fast 15 70LDP12AA001 70LDP12AA006 70LDP12AA001 ART R6 ART Fill FS 70LDP12AA007 70LDP12AA002 70LDP81AA002 ART R71 ART Draindown FS 70LDP12AA007 70LDP12AA003 70LDP41AN001 OR 70LDP41AN002 357m3/h 70LDP21AP001 OR 70LDP21AP002 70LDP81BN001 OR 70LDP81BN002 70LDP21AP001 OR 70LDP21AP002 70LDP21AP001 OR 70LDP21AP002 70LDP21AP001 OR 70LDP21AP002 37m3/h 10.5 m3/h 10.5 m3/h 1.4 m3/h

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

70LDP11CF301

70LDP11CF301

70LDP12CF201

31 m3/h 10.5 m3/h

70LDP12CF201 70LDP11CF301

Blowdown N/A N/A N/A

water

level to 6 above resin bed.

ART R72

ART Scrub

Air

FS

70LDP12AA005 70LDP12AA007

70LDP41 CF201

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Operation Manual for 600MW Unit


ART ART R73 Backwash Air Scrub(Contd) W/Water ART R74 ART Pressurized FS FS 70LDP41AN001 70LDP12AA005 70LDP12AA003 70LDP12AA005 70LDP12AA007 OR 70LDP41AN002 70LDP21AP001 OR 70LDP21AP002 70LDP12AA009 128m3/h 357m3/h 16m3/h

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

70LDP41CF201 70LDP12CF201

10LDP61CF202

Establish Air Dome @552KPA Flush fines out

ART R75

ART

Bottom FS

70LDP12AA006 70LDP12AA009 70LDP12AA003 128m3/h 10LDP61CF202

through and

underdrain regenerant

Side Flush

distributor.

ART R8

ART Fill

70LDP12AA001 FS 70LDP12AA007 70LDP12AA002

70LDP21AP001 OR 70LDP21AP002

31m3/h 10.5m3/h

70LDP12CF201

Time adjustable by 25 or ART R9 ART Rinse 2 Final FS OR2 5 70LDP12AA001 70LDP12AA006 operstor. Rinse until 70LDP21AP001 OR 70LDP21AP002 31m3/h 70LDP12CF201 cond. is less than 10 umho/cm. time is Alam if

exceeded

cond. Not achieved time

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Operation Manual for 600MW Unit


ART R10 ART Standby 60

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Notes: 1.Repeat resin cleaning steps (R1-1 TO R1-5 or R7-1 to R7-5) as necessary. 2. 70LDP12AA007:anion tower exhaust valve, 70LDP12AA003:anion tower backwash discharge valve, 70LDP12AA009:anion tower compressed air inlet valve,70LDP12AA005:anion tower inlet air valve, 70LDP12AA007:anion tower exhaust valve, 70LDP12AA005:anion tower backwash admission valve, 70LDP12AA003:anion tower reverse vent valve, 70LDP12AA005:anion tower inlet valve, 70LDP12AA006:nion tower forward vent valve, 70LDP12AA001:anion tower forward admission valve, 70LDP81AA002:mixed bed 3-way admission valve, 70LDP31AA001:hot water 3-way adjusting valve, 70LDP12AA002:anion tower alkali-inlet valve, 70LDP81AA001:mix 3-way alkali-inlet valve 7.3.3.6 CATION REGENERATION TANKREGENERATION) no. CRT R11 CRT R12 CRT Air Scrub CRT Draindown step time (min) FS valves open/ valve no. 70LDP11AA007 70LDP11AA003 FS 70LDP11AA005 70LDP11AA007 70LDP11AA004 FS 70LDP11AA003 70LDP11AA005 70LDP11AA007 FS 70LDP11AA009 70LDP11AA006 70LDP41AN001or 70LDP41AN002 70LDP21AP001or 70LDP21AP002 70LDP41AN001or 70LDP41AN002 128 m3/h 128 m3/h 10LDP61CF202 10LDP61CF202 Establish @552KPA Flush fines out through Air Dome 16 m3/h 357 m3/h 70LDP11CF201 70LDP41CF201 pump/ motors on set point/ valve no. N/A N/A struments no. range Blowdown water level to 6 above resin bed. comments

357 m3/h

70LDP41CF201

CRT R13

CRT Backwash Air Scrub (Contd)W/Water

CRT R14 CRT CRT Pressurized CRT Bottom

FS

DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit


R15 Side Flush 70LDP11AA009 70LDP11AA003 70LDP11AA001 CRT R2 CRT Fill FS 70LDP11AA007 70LDP11AA002 70LDP71AA002 CRT R3 CRT Dilute acid introduction HCL CRT R4 CRT R5 CRT Fast rinse 1 15 5% 60 70LDP11AA002 70LDP11AA006 70LDP7AA001 70LDP71AA002 Acid 70LDP11AA002 30 70LDP71AA002 70LDP11AA006 70LDP11AA001 70LDP11AA006 70LDP11AA001 CRT R6 CRT Fill FS 70LDP11AA007 70LDP11AA002 70LDP71AA002 CRT R71 CRT R72 CRT Air Scrub FS CRT Draindown FS 70LDP11AA007 70LDP11AA003 70LDP11AA005 70LDP11AA007 70LDP41AN001 or70LDP41AN002 N/A 357m3/h 70LDP21AP001or 70LDP21AP002 70LDP21AP001or 70LDP21AP002 40m3/h 70LDP21AP001or 70LDP21AP002 70LDP71BN001or 70LDP71BN002 70LDP21AP001or 70LDP21AP002 10.5m3/h 10.5 m3/h1.4 m3/h 70LDP21AP001or 70LDP21AP002

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

underdrain regenerant distributor

and

31

m3/h

70LDP11CF201 70LDP11CF302

10.5 m3/h

70LDP11CF302

CRT

displacement rinse

70LDP11CF302

70LDP11CF201

40

m3/h

70LDP11CF201 70LDP11CF302

10.5 m3/h

N/A

N/A

Blowdown water level to 6 above resin bed

70LDP41CF201

DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit


CRT Backwash Air Scrub(Contd) W/Wate CRT R74 CRT R75 CRT Pressurized CRT Bottom Side Flush FS 70LDP11AA009 70LDP11AA006 FS 70LDP11AA009 70LDP11AA003 70LDP11AA001 CRT R8 CRT Fill FS 70LDP11AA007 70LDP11AA002 70LDP71AA002 70LDP21AP001 or70LDP21AP002 128m3/h 128m3/h FS 70LDP11AA004 70LDP11AA003 70LDP11AA005 70LDP11AA007 70LDP21AP001 or70LDP21AP002 70LDP41AN001 or70LDP41AN002 16m3/h 357m3/h

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

CRT R73

70LDP11CF201

70LDP41CF201 Establish @552KPA Flush fines out through 10LDP61CF202 underdrain regenerant distributor and Air Dome

10LDP61CF202

40m3/h 10.5m3/h

70LDP11CF201 70LDP11CF302

Time operator. CRT R9 2 CRT Final Rinse 25 or FS 70LDP11AA001 70LDP11AA006 70LDP21AP001 or70LDP21AP002 31m3/h 70LDP11CF201

adjustable

by

Rinse until cond. less than 10 umho/cm. Alarm if time is exceeded cond. not achieved.

CRT R10 Notes: 1. Repeat resin cleaning steps (R1-1 to R1-5 ro R7-1 to R7-5) as necessary.Can also function as rinse down DOCUMENT NO. : HISAR-ZT-07
Page 218 of 228

CRT Standby

60

Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2. 70LDP11AA009:cation tower exhaust valve, 70LDP11AA003:caion tower backwash discharge valve, 70LDP11AA005:cation tower wind-inlet valve 70LDP11AA007:cation tower exhaust valve, 70LDP11AA004:cation tower backwshing inlet valve,70LDP11AA003:cation tower compressed air inlet air,70LDP11AA006:cation tower rinse discharge valve, 70LDP11AA009:cation tower air-inlet valve, 70LDP11AA003:cation tower backwash discharge valve,70LDP11AA001:cation tower rinse admission valve, 70LDP11AA002:cation tower acid-inlet valve, 70LDP71AA002:mix triple inlet valve. 7.3.3.7 ANION REGENERATION TANKRESIN TRANSFER TO CATION REGEN/RESIN STORAGE TANK (Total time is 20mins) no. ART RT1 ART Fast rinse 3 step Time (min) valves open/ valve no. 70LDP12AA001 70LDP12AA006 70LDP12AA009 70LDP12AA004 ART RT2 ART Air Top , Water Bottom Transfer Out 7 70LDP12AA008 70LDP11AA010 70LDP11AA007 70LDP11AA006 70LDP12AA001 ART RT3 ART Top Water Transfer Bottom 70LDP12AA004 8 70LDP12AA008 70LDP11AA010 70LDP11AA006 ART RT4 Transfer Line Flush 2 70LDP13AA003 70LDP11AA011 70LDP21AP001or 70LDP21AP002 31 m3/h 70LDP21CF201 70LDP21AP001 or70LDP21AP002 31 m3/h 4 m3/h 70LDP21AP001or 70LDP21AP002 31 m3/h 128 m3/h 70LDP12CF201 10LDP61CF202 Remove resin from ART. pump/ motors on 70LDP21AP001or 70LDP21AP002 set point/ valve no. 37 m3/h struments comments Verify conductivity is less than 10 umho/cm

70LDP12CF201

70LDP12CF201

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70LDP11AA010 70LDP11AA006

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Comments: 70LDP12AA001:anion tower rinse admission valve, 70LDP12AA006:anion tower rinse discharge valve, 70LDP12AA009:anion tower air-inlet valve, 70LDP12AA004:anion tower backwash admission valve, 70LDP12AA008:anion tower resin-outlet valve, 70LDP11AA010:cation tower resin-inlet valve, 70LDP11AA007:cation tower air vent valve), 70LDP11AA006:anion tower rinse admission valve, 70LDP13AA003:separation tower backwash discharge valve, 70LDP11AA011:regeneration rinse flush total valve 7.3.3.8 CATION REGENERATION/RESIN STORAGE TANKAIR MIX/RINSE STANDBY no. CRT ARS1 CRT ARS2 CRT ARS3 CRT ARS4 CRT Fill 8 CRT Air Mix 12 CRT Gravity Drain FS step time (min) valves open/ valve no 70LDP11AA007 70LDP11AA003 70LDP11AA005 70LDP11AA007 70LDP11AA005 FS 70LDP11AA007 70LDP11AA003 70LDP11AA001 70LDP11AA007 70LDP41AN001or 70LDP41AN002 70LDP41AN001or 70LDP41AN002 70LDP21AP001or 70LDP21AP002 629 m3/h 629 m3/h 40 m3/h 70LDP41CF201 pump/ motors on set point/ valve no instruments no. comments Drain water level to 6 above resin bed by time.

CRT Air Mix and Drain

70LDP41CF201

Air mix and draindown to top of bed.

70LDP11CF201 Time adjustable by operator. Rinse

CRT ARS5 CRT Final rinse 22

70LDP11AA001 70LDP11AA006

70LDP21AP001or 70LDP21AP002

52 m3/h

70LDP11CF201

until

cond.

is Alarm

less if

than time is

0.1umho/cm.

exceeded and cond. not achieved.

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CRT ARS6 CRT Standby

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Rinse as required during standby.

Comments: 70LDP11AA007: cation tower exhaust valve, 70LDP11AA003: cation tower backwash discharge valve, 70LDP11AA005: cation tower wind-inlet valve, 70LDP11AA001: cation tower admission valve, 70LDP11AA006: cation tower rinse discharge valve 7.3.4 Control of electric heating water tank of regeneration system 7.3.4.1 Electric heating water tank is used for heating only 4 to 5 hours before regeneration procedures start. 7.3.4.2 Electric heating water tank is equipped with a water level switch to prevent dry-heating when water level is lower than electric heater. Therefore level switch and electric heater is interlocked. Thermometer and temperature transmitters are also installed on water tank and they are interlocked. 4-group heaters will work as the temperature is lower than 60C and just 2-groups heaters heat as temperature within 60-80C. 7.3.4.3 Electric heater shall be cut off power and be sure in no power state when drain and repairing it, and check that the tank be filled to full, that is water flow from vent pipe, before putting it into operation again,. 7.3.4.4 A three-way valve is installed at outlet of electric heating water tank and is always in operation during every regeneration process. 7.3.4.5 Method to adjust hot water temperature of three-way valve : firstly, adjust the opening of manual isolate valve of it to make a proper proportion of hot and cold water, then adjust by three-way combined adjusting valve when the tank is in operation. It can be also adjusted directly by three-way combined adjusting valve. 7.3.5 Acid-alkali metering tank system 7.3.5.1 It shall be supervised on the site when adding acid/alkali into storage tank in order to prevent acid-alkali overflows accident in case of level gauge faults. 7.3.5.2 Acid day tank refill no. amtr-1 step open valve DOCUMENT NO. : HISAR-ZT-07 fill time (min) 1 valves open/ valve no. 70ldp71aa013 instruments no. 70ldp71cl102 range comments (open fill valve to start filling based on 70ldp71cl102plc position . Close 70ldp71cl102 and stop70ldp71bn001 or
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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

70ldp71bn002 on 70ldp71cl102 alarm.) amtr-2 close valve 7.3.5.3 Caustic day tank refill no. cmtr-1 step open fill valve time (min) 1 valves open/ valve no. 70ldp81aa013 instruments no. 70ldp81cl102 range (open fill valve to start filling based on comments fill fs 70ldp71cl102 Close fill valve to stop filling when acid level reaches preset point on level transmitter.

70ldp81cl102plc position . Close 70ldp81cl102 and stop70ldp81bn001 or 70ldp81bn002 on 70ldp81cl102 alarm.) cmtr-2 close fill valve fs 70ldp81cl102 Close fill valve to stop filling when alkali level reaches preset point on level transmitter. 7.3.6 Common problems and disposal for mixed bed operation 7.3.6.1 Disposal of over pressure /temperature of mixed bed system When over pressure /temperature warning device alarms, by-pass valve is started automatically (100% opening). Firstly check whether its action is reliable, then close mixed bed outlet valve and adjust condensate water temperature. When the temperature is back to normal, operating attendants can reset opening outlet valve, and close by-pass valve, until the mixed bed work normally. BY-PASS VALVE OPEN SEQUENCE FOR over pressure/temperature RE no. CD CD Service step time (min) valves open/ valve no. 10LDF11AA002 10LDF11AA003 DOCUMENT NO. : HISAR-ZT-07
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Pump /motors on

set point/ valve no.

instruments no. range

comments

Operation Manual for 600MW Unit


CD BHDT-1 Open By-pass 5 10LDF11AA002 10LDF11AA003 10LDF01 AA001

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

10LDF01CT001 10LDF01DP201

60 0.35MPa

Open by-pass valve based on high pressure

difference(10LDF01DP201)and/or high temperature(10LDF01CT001)

CD RTI-3

Close Valve

Outlet

10LDF11AA002 10LDF01 AA001

Vessel outlet valve closure on high temperature only

Comments: 10LDF11AA002: mixed bed admission valve, 10LDF11AA003: mixed bed outlet valve, mixed bed bypss valve: 10LDF01 AA001 The system alarms for the reason of over pressure before opening by-pass valve Notice: Only operating staff can reset operation. If system pressure difference excess and no drop, by-pass valve will be opened automatically (100% opening), and mixed bed will quit by releasing pressure. Close both outlet and inlet valves and contact to dispose the fault. 7.3.6.2 Disposal of silicon value and conductivity excess problem Take example of an individual mixed bed, when it alarms for the reason of silicon value and conductivity excess, it shows that the mixed bed is failure and needs to be regenerated. Start the standby mixed bed to put into operation, and the failed one quit by releasing pressure, closes both outlet and inlet valves, and then send resin to regeneration unit. 7.3.6.3 Disposal of excess pressure difference of resin trap Take example of an individual mixed bed, when resin trap pressure difference is up to 0.05Mpa, it alarms. at same time , Start the standby mixed bed to put into operation, then quit the bed with excess pressure difference, and backwash resin trap manually after releasing pressure. It is generally flushed by water, also can by compressed air. if necessary ,remove the manhole cover on trap, lift the cartridge to clean resin fragment or check the mixed bed has resin leakage., the mixed bed can be put into the operation again after these disposals. 7.3.7 Precautions for ensuring mixed bed Ammonia operation 7.3.7.1 During unit normal operation state, mixed bed is not allowed to be put into or out of operation at random to keep resin pressure stable in bed and

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realize continuously operation.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Condensate polishing system can not be quit randomly during unit normal operation. If put the bed into operation only

when unit starts or with poor quality condensate water, the resin is impossible to achieve Ammonia operation. 7.3.7.2 Correctly judge and well control mixed bed operation period to avoid regenerating resin too early or too late. During the transition period from hydrogen-type to ammonia-one, it will appear natrium breakthrough (outlet natrium value is higher than inlet), and present a natrium peak. At last, it comes to a new balance in ammonia-type, which ammonia content of inlet/outlet water is almost equal to natrium value. For this condition regeneration can not be done rashly. If condensate leakage or unit frequently start and shutdown has caused an outlet water index pressure difference, it shall regenerate as earlier as possible as the unit is impossible to achieve Ammonex. 7.3.7.3 Carefully adjust the height of cation and mixed resin during resin separation process. Try to keep water flow stable in delivery of resin, which is key for regeneration operation, otherwise it will affect mixed bed outlet water quality and make the resin failure in advance or even not able to achieve ammonia operation 7.3.7.4 it is better to avoid regenerating resin during unit stop period, and ensure resin is put into operation immediately after they are delivered to mixed bed. However, there are two preconditions for guaranteeing the bed ammonia operation, one is enough resin regeneration degree and the other is no leakage in condenser. 7.4 Treatment for abnormal condensate polishing problem Operation period is short cause 1)Resin has not been transformed Resin layer in mixed bed Advisable treatment totally 1) Check dilution water quantity, acid-alkali density, regeneration specific consumption and acid-alkali liquid quality. 1) Adjust resin mixed wind pressure and quantity in mixed resin tower. 2) Adjust flow speed of transferring resin to mixed bed. 1) analyze water quality 2)check whether condenser is leaky or not

3)inlet water quality changed

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problem cause Advisable treatment 1) confirm by resin analysis 2) clean resin by air scrub 4) Resin contamination.

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

3)soak resin by double acid-alkali specific consumption (5% acid-alkali) 4) change resin

5)Resin aged 6)Resin lost 1)high flow speed High pressure 2)resin contamination 3)too much resin fragments 4) compact 1)Down leakage drainage device

1) change resin 2)check whether inside mixed bed has leakage resin, may confirm by resin trap pressure difference 1)reduce flow speed 1) confirm by resin analysis 2)clean and anabiosis the resin 1)try to drain resin fragments when regeneration 1) Stop mixed bed, resin air scrub and regeneration. 1) Take out resin from device, find out leakage position and mend. 1) Slowdown backwash flow speed (in winter, need to slowdown backwash flow

difference In mixed bed

Resin lost

High backwash flow speed

speed, because the temperature is low and the density is increased. 2)add resin up to normal level

3) wear

1) Its natural to wear or lose some resin after some time operation. check the total time of mixed bed operation , add resin, and check the bed layer height

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problem cause Advisable treatment

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1) Check whether metering pump runs normally and whether operation is smooth or 1)acid-alkali problem metering pump not. 2) Whether inlet valve of metering pump or of acid-alkali is jammed. 3) whether density of acid-alkali is low 4) Whether metering pump stroking adjusting is proper. 2Acid-alkali storage is low is 3)Density meter problem 1)confirm that storage tank level is enough to provide acid-alkali 2)confirm that no problem on acid-alkali inlet valve 1) Calculate and check density meter by using concentration or titration meter .The density meter shall be regularly checked to prevent problem caused by its long term reading error. 4) High pressure of dilution water makes metering pump outlet a high back pressure and makes a little lower inlet flow of acid-alkali. 1)incorrect dilution water flow Deluting base is 2)Temperature control problem 3)Three-way problem Diluting base is The same as stated above adjusting 1) Try to reduce dilution water pressure, such as much open the return line valve which flushes pump. 2) Check whether sluice pump outlet pressure and adjusting valve are working normally. 1) Check whether dilution water flow is correct. 2) measure temperature manually by using thermometer, and confirm that high temperature is not caused by thermometer faults

Regeneration consistency low

temperature high

valve 1)adjust whether combined valve works normally, whether the opening of hot and cold water manual valve before combined valve is proper The same as stated above

temperature

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problem low 1)mixed bed disabled 1)regeneration cause Advisable treatment

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Outlet water is 2) Mixed bed resin is unevenly disqualification mixed. 3) Resin contamination. 1)Eroded and damaged

1) Adjust wind pressure and quantity of mixed compressed air. 1) Double acid-alkali regeneration single consumption and air scrub resin.

acid-alkali filling acid-alkali filling device blocks 1)change acid-alkali filling device is blocked when the distributor regeneration 2) acid-alkali filling valve 1)change and check valve

problem 1)pressure and flow of

Air is not mixed compressed air is not enough to the best 2) High water level in device, resin is layered easily. Air mixed brings Water level in vessel is too high resin out or air flow is too large.

1) Check whether pressure, flow, and valve have problem.

1)adjust water to a proper level(adjust drainage time)

Check whether water level and air flow are proper 1) Acid-alkali leakage happens during regeneration operation, shall stop operating

The container pipe of acid-alkali immediately. Acid-alkali system is eroded to hole or 2) Find out leakage position and cause.(wear protective outfit when checking)

system leakage valve and flange are not sealed, 3) Shall close outlet valve of storage vessel when pipe system leakage happens. even broken. 4) When storage vessel leakage happens, shall report to specialty-in-charge; take measures to transfer the acid-alkali to other container. DOCUMENT NO. : HISAR-ZT-07
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Operation Manual for 600MW Unit


problem cause Advisable treatment 5)contact as soon as possible and 7.5 chemical quality requirements Recommendatory NaOH quality standard for regeneration NaOH Na2CO3 NaCl NaClO3 Na2SO4 SiO2 Al2O3 CaO 35-48% <0.06% <0.007% <0.002% <0.002% <0.002% <0.0006% <0.0005%

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

assist repairing to eliminate leakage

Recommendatory hydrochloric acid quality standard for regeneration HCl Fe Cl2 heavy metal(Hg) Organism contaminant 31% <5ppm <5ppm <2ppm <50ppm

Hydrochloric acid shall be clear with no oxidant or inhibitor.All chemical lines shall be inspected to ensure tightness and support of all flanges and pipe lines are proper, and valves must be operated to check if it works correct. One of the most important factors in ion exchanger operation is regenerate quality used in regeneration process. Impurity in regenerate will affect outlet water quality of mixed bed. So applying impure chemical will result in resin permanent and unable loss with worsening water quality. Acid-alkali quality must be obeyed as said in this chapter. DOCUMENT NO. : HISAR-ZT-07
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