1

MAIN BOILER

Make BHEL

Type
- Natural Circulation
- Dry Bottom
- Single Drum
- Tangential Fired
- Balanced Draft
- Radiant Reheat Type with Direct Corner Fired
- Pulverised Coal System

Coal Analysis

F.C 25% ; V.M 20% ; Moisture 15% ; Ash 40%

CV 3200 kcal / kg

U.H.V =8900 130 (A +M) kcal UHV Useful Heat Value
A Ash
M Moisture
Superheater


DRUM




PLATEN PENDENT
SUPERHEATER SUPERHEATER





FURNACE









S
T
A
C
K

ID
FAN
2
Platen Superheater

Heat transfer is mainly due to Radiation.



Q T
4
(Temperature)
Temp v (velocity of steam)
Pick up (C) AT (Temperature difference between
heating and heated media)






MW
Pendent Superheater

Heat transfer is mainly due to Convection.



Q T (Temperature)
Temp v (velocity of steam)
Pick up (C) v
g
(Volume of flue gas)







MW

Normal Operating Values


STEAM CIRCUIT



270C 354C 413C 518C 540C

LTSH
PLATEN
SH
FINAL
SH

BOILER
DRUM
HP
TURBINE
3
161 ksc 160 ksc 147 ksc


Temperature Limits No. of coils in Boiler

Boiler Tube Metal Temperature LTSH 120
Platen SH 29
NORMAL MAX. Final SH - 89
- LTSH 445 485 Reheater Front 59
- Platen SH 540 565 Reheater Rear - 59
- Final SH 544 565 Economiser 145
- Reheater 575 605

FLOW (T/Hr) OXYGEN v/s LOAD

NCR MCR
Steam at Final SH outlet 603 670
Steam at Reheater outlet 533 593
Water at Economiser 592 670
Coal flow (Design) 147 162
Coal flow (Worst) 180 200
Primary Air at APH outlet 194 207
Secondary Air at APH outlet 551 555
Total Combustion Air 790 874

100 150
Recommended Boiler Chemistry Limits

Drum operating pressure (kg/cm
2
) 60-125 125-165 165-180
Total dissolved solids (ppm) 100 50 25
Sp. Conductivity at 25 C (mho-cm) 200 100 50
Phosphate (ppm) 5-20 5-10 3-7
pH at 25 C 9.1-10 9.1-9.8 9.1-9.8
Silica (ppm) <0.02 <0.02 <0.02

Coal Bunker

Weight Distribution Of Ash :

Bottom Ash hoppers 20%
Economizer hoppers 5%
APH hoppers 5%
E.S.P hoppers 70%


4



Safety Valves Setting :

VALVE NO. SET PRESSURE
(kg/cm
2
)
RESET PRESSURE
(kg/cm
2
)
DRUM : B1 175.8 168.8
DRUM : B2 179.3 170.3
DRUM : B13 181.1 172.0
SH : S-32 163.3 158.4
CRH : R-9 45.5 44.1
HRH : R-19 42.7 41.4


Flue gas path


PLATEN SH REHEATER FINAL SH



1155C 1014C 757C 497C

LTSH

412C

ECONOMISER




143C








DRAFT (mmwcl)

PLATEN SH Inlet -
REHEATER Inlet -6
ECONOMISER Inlet -25
APH Inlet -37
FLAME
S
T
A
C
K

DRUM
ID
FAN
APH
5
ESP Inlet -153
ID FAN Inlet -200

BOILER AUXILLARIES

Secondary Air Path




320 mmwcl 257 mmwcl 163 mmwcl
From Atm. 313C To Furnace
(Windbox to Furnace DP =
140 mmwcl)




FD FAN

Start permissives

1. Control oil pr adequate (>8 ksc)
2. Blade pitch minimum
3. Discharge damper close
4. Bearing temp. Normal (<60 C)
5. Control & Lub oil temp. Normal (<55 C)

Interlock

1. I.D Fan running

Protection

1. Electrical protection
2. Bearing temp high:
Motor 80 C (A), 95 C (T)
Fan 90 C (A), 105 C (T)
3. I.D fan trip.
4. Control oil pr. <6.0 kg/cm
2

5. Post purge trip from FSSS.

SCANNAR AIR FAN

Interlocks

1. Closing of discharge damper from fan trip or stop.
FD
FAN-A
APH-A
APH-B FD
FAN-B

6
2. DC scannar air fan will start from AC scannar air fan trip.
3. Emergency damper will open from both FD fans trip.


Primary Air Path




779 mmwcl 740 mmwcl 687 mmwcl
Mill-A
CAG HAG
Mill-B

646 mmwcl Mill-C

Mill-D

Mill-E

Mill-F
318C



PA FAN

Start permissives

1. IGV minimum
2. Discharge damper close
3. Bearing temp. normal (<60 C)
4. FSSS start permit (Boiler MFR reset & all cold air dampers are <5% open)
5. One FD Fan running.

Protection

1. Electrical protection
2. Bearing temp high :
Motor 85 C (A), 95 C (T)
Fan 95 C (A), 105 C (T)
3. P.A header pr. low. 475 mmwcl (A), 375 mmwcl (T)
4. Boiler trip




APH-B PA
FAN-B

PA
FAN-A
APH-A
7



SEAL AIR FAN

Interlocks

1. Closing of discharge damper from fan trip or stop.
2. Seal air discharge to cold air duct DP low.
3. Auto starting of seal air fan on PA fan starting.


MILL

Permissives

1. PA Fan running.
2. Ignition Permit.
3. Feeder remote.
4. Seal air pressure adequate (>200 mmwcl)
5. Mill outlet temperature less than 220 F.
6. No unsuccessful start command is persisiting.
7. No pulveriser trip.
8. Tramp iron gate open.

Protections

1. EPB pressed.
2. Seal air AP low (<125 mmwcl for more than 1 min.)
3. Boiler MFR trip.
4. PA header pressure lo lo (475 mmwcl 2/3 logic)
5. Motor electrical protection.
6. If any PA fan trips , top elevation running mills trip and rest 3 mills remain in service.



COAL FEEDER

Protection

1. Discharge Plugged
2. Belt Deviation 1
st
Step (A) ; 2
nd
Step (T)
3. Mill trip to Feeder trip
4. Hot air gate closed

8

Flue Gas System





-153 mmwcl


-200 mmwcl
-37 mmwcl



-25 mmwcl







ID FAN

Start permissives

1. IGV minimum
2. Discharge damper close
3. Bearing temp. normal (<60 C)


Interlock

1. Gas path through
2. Air heater running

Protection

1. Electrical protection
2. Bearing temp high :
Motor 75 C (A), 80 C (T)
Fan 95 C (A), 105 C (T)
3. Both APH trip
4. Post purge trip from FSSS.


ESP PASS-A
ESP PASS-B
ESP PASS-C
ESP PASS-D

ECONO
MISER
APH-A
APH-B
ID
FAN-A
ID
FAN-B
C
H
I
M
N
E
Y
9
HFO TRIP VALVE

Permissives

1. Boiler MFR is reset
2. HFO pressure is adequate ( >10 kg/cm
2
)
3. HFO header temp >95 C

Protection

1. HFO pressure low (<3 kg/cm
2
)
2. HFO temp low (<90 C)
3. Boiler trip


BOILER PROTECTIONS:

1. Flame failure
2. Loss of all fuel
3. Loss of 220V DC to FSSS.
4. Elevation power failure.
5. Boiler load <30% and air flow <30%.
6. Furnace pressure hi-hi (+100)
7. Furnace pressure lo-lo (-75)
8. Drum level hi-hi (+225)
9. Drum level lo-lo (-225)
10. Reheater protection
11. All BFPs stopped.
12. Boiler both manual trip buttons pressed.
13. Turbine trip and boiler load >bypass capacity (60%)
14. Loss of ACS power.
15. Both ID fans off
16. Both FD fans off

Loss of All Fuel Protection Logic:


ignitors of any elevation ON (ARMED)


HOTV closed

All oil nozzle valves closed


Feeder OFF
O
R

AND
Loss of All
Fuel
TRIP
10
Boiler Flame Failure logic :

Boiler will trip on flame failure when all elevations are VOTED in FSSS console.

Conditions for VOTED in a single elevation:


Feeder OFF

Elevation power failure

3/4 Safe Scanners intensity <20%

Flickering Freq.<2.5 Hz (OIL)/ 26 Hz (COAL)

2/4 nozzle valves not proven


Flame failure protection is armed when 1
st
feeder is taken into service.

Ignition Permit criteria for different Mills :

MILL-A

nozzle valves of AB elevation are proven

Mill-B loading >50%

Boiler load >30%


MILL-B

nozzle valves of AB elevation are proven

Mill-A loading >50%

Boiler load >30%

Mill-C loading >50%

Boiler load >30%





OR
&
Ignition Permit
for Mill-A


OR
&
Ignition Permit
for Mill-B
&


OR
AND
VOTED
11
MILL-C

nozzle valves of CD elevation are proven

Mill-B loading >50%

Boiler load >30%

nozzle valves of AB elevation are proven

Mill-B loading >50%

Mill-D loading >50%

Boiler load >30%



MILL-D

nozzle valves of CD elevation are proven

Mill-C loading >50%

Boiler load >30%

Mill-E loading >50%

Boiler load >30%


MILL-E

nozzle valves of EF elevation are proven

Mill-D loading >50%

Boiler load >30%

nozzle valves of CD elevation are proven

Mill-D loading >50%

Mill-F loading >50%

Boiler load >30%



OR
&
Ignition Permit
for Mill-C
&
&


OR
&
Ignition Permit
for Mill-D
&



OR
&
Ignition Permit
for Mill-E
&
&
12

MILL-F

nozzle valves of EF elevation are proven

Mill-E loading >50%

Boiler load >30%



Drum Level Protection













TURBINE






IPT LPT
(20 X 2) (8 X 2)


ESV 39 ksc IV 34 ksc
334 C 535 C CONDENSER
0.1187 ksc
36 ksc 34 ksc 49 C
335 C 538 C
147 ksc
535 C




OR
&
Ignition Permit
for Mill-F
REHEATER
HPT
(25 X 1)
HPBP LPBP
HW

OR
ACS(L)
HYD(R)
ACS(R)
ACS(L)
ACS(R) HYD(L)
BOILER TRIP
13
Turbine Diff. Expansions :

ALARM TRIP
HP Turbine +4.5 +5.5
- 2.5 - 3.5
IP Turbine +5.0 +6.0
- 2.0 - 3.0
LP Turbine +25.2 +30.2
- 5.0 - 7.0

Cut-in / Cut-out speeds :

1. BARRING GEAR
Cuts In 250 rpm
Cuts Out 200 rpm
2. J.O.P
Cuts In 540 rpm
Cuts Out 510 rpm

TURBINE PROTECTIONS
Main Steam temperature very low ( <460 C )
Condenser back pressure high ( >220 mm Hg )
Bearing lub oil pressure lo lo ( <2 kg / cm
2
)
Axial shift of turbine shaft ( +1 mm & -1 mm )
Over-speeding ( >3330 rpm )
Boiler trip to turbine trip.
Manual trip Push Button pressed.
Fire Protection 1
1) Push Button pressed
2) Operates automatically when MOT level is
<- 50 mm Alarm appears.
<- 100 mm Protection operates.

When Fire Protection 1 acts,
Vacuum breaker opens.
Turbine comes on barring gear.

- When MOT level <- 150 mm MOT level low alarm appears if TG is on barring
gear.
Fire Protection 2
Does not operate automatically. It is operated manually by pressing the Push Button.
Then Fire Protection 1 acts automatically.
When Fire Protection 2 acts ,
J OP 2 and EOP starts.
Vaccum breaker opens.
Turbine does not come on barring gear.
14


THERMAL POWER PLANT EFFICIENCY









TURBINE THERMAL STRESS


Surface and Mid metal temperature probes in Casing :





55 % (T
M
)

95 % (T
S
)


Rotor Mid metal temperature calculation :

T
M
=T
S
[ 1 (0.692 e
t/T1
+0.131 e
t/T2
+0.177 e
t/T3
) ]

Where,

T
S
Surface Temperature T1 2408.31

T
M
Mid metal Temperature T2 457.08
t Time in minutes T3 56.62

T1, T2, T3 are computed using rotor material thermo-dynamic properties and shaft dia.


Margin Calculation:

AT =T
S
T
M

Thermal Stress AT

Margin =AT
permissible
AT
actual

q
PLANT
= q
BOILER
X q
THERMAL CYCLE
X q
TURBINE INTERNAL
X q
TURBINE MECHANICAL
X q
GENERATOR

(30-40%) (75-90%) (35-40%) (88-90%) (99%) (98-99%)
15



AT
PERMISSIBLE

T


Upper Margin

Operating point
AT
ACTUAL



0
T
M

Lower Margin



AT
PERMISSIBLE







TURBINE OIL SYSTEM

Gov. Rack


Shut-Off valve
LPBP Signal Oil
Lub Oil (Brg.- 1 to 6)


MOT

Barring Gear



J acking Oil (Brg.- 1 to 6)





M
A
I
N


H
E
A
D
E
R

MOP
CONTROL OIL HEADER
COOLER



MAIN
OIL
TANK

AOP


EOP

JOP

16
TG Oil Pumps Start Criteria :

1. Lub oil pr. <7.0 ksc A.O.P 1 starts
2. Lub oil pr. <6.5 ksc A.O.P 2 starts
3. Lub oil pr. <2.2 ksc E.O.P starts
4. J acking oil pr. <90 ksc Stand-by J .O.P starts

BOILER FEED PUMP

Start permissives :

1. De-aerator level adequate ( 700 mm )
2. Bearing temperature normal ( <60 C )
3. Lub oil pressure normal (~ 2 kg / cm
2
)
4. Suction valve full open.
5. Booster pump suction pressure adequate ( >3 kg / cm
2
)
6. Cooling water pressure adequate (~ 2.5 kg / cm
2
)
7. Re-circulation valve 100% open.
8. Scoop position is minimum.

Protections :

1. Bearing temperature high ( >85 C for pump & >90 C for motor )
2. De-aerator level lo lo ( <-230 mm )
3. Lub oil pressure low ( <1 kg / cm
2
for 5 secs)
4. Discharge flow high ( >430 T / Hr for 20 secs)
5. Working oil temp high ( >130 C )
6. Suction pressure low ( <9 ksc for 30 secs)

CONDENSATE EXTRACTION PUMP

Protection & Interlock:

1. Hotwell level very low.
2. Discharge pressure <14 ksc.
3. Electrical protection.
4. Auto starting of stand-by pump from discharge header pressure <16 ksc.

ACW PUMP

Protection & Interlock:

1. Both pumps trip from tank level lo-lo.
2. Auto starting of stand-by pump when running pump trips.
3. Auto starting of stand-by pump when discharge header pressure <3 ksc.

17
ARCW PUMP

Protection & Interlock:

1. Auto starting of stand-by pump when running pump trips.
2. Auto starting of stand-by pump when discharge header pressure is low.

GENERATOR SPECIFICATIONS

Rated parameters :

1. Max continuous MVA rating : 247 MVA
2. Max continuous MW rating : 210 MW
3. Rated terminal voltage : 15.75 kV
4. Rated stator current : 8625 Amps
5. Rated power factor : 0.85 Lag
6. Excitation current at MCR condition : 2600 Amps
7. Slip ring voltage at MCR condition : 310 V
8. Excitation current at no load : 907 amps
9. Slip ring voltage at no load : 102 V
10. Rated speed : 3000 rpm
11. Rated frequency : 50 Hz
12. Efficiency at MCR condition : 98.47 %
13. Direction of rotation as viewed from
slip ring : Clockwise
14. Phase connection : Double star


CAPABILITY CURVE

MW

Turbine Limit

Thermal Limit

Stability Limit Rotor Current o =Load Angle
=Phase Angle
Stator Current


o

MVAR


18

Excitation System

Excitation Power ~ 0.7 0.8 %
~ 1.6 MW
BUS-I
400 KV
BUS-II

(1 Breaker Scheme)


GT

Tie Xr Excitation Xr

SCR
15.75 kV/575V



AC
(Station DB)


Field Breaker Field Flasher

DC
(DCDB)
Arrangement of Thyristors in a single bridge :




3 AC Input Field Winding

ROTOR

DC Output







G
AVR
19

V
DC
=1.35 V
AC
cos o

o is the firing angle of thyristor. It is usually between 5 30 .

Four such bridges are connected in parallel. Total field current is shared by all the four
bridges. Each thyristor in every bridge is provided with the Snubber circuit which protects
the thyristor from heating.

Snubber Circuit of SCR



L Voltage surges are partially charged in the Capacitor C
thereby saving the SCR from high voltages. Also the
Inductor L limits the surge current to some extent.

Resistor R
1
restricts the charging current of Capacitor.

SCR R
1
R
2
is discharge resistor of Capacitor.


C R
2




Hydrogen gas cooling system

1. Generator gas volume : 56 m
3

2. Nominal pressure of hydrogen : ( 3.5 kg / cm
2
)
3. Nominal temperature of Cold gas : 40 C
4. Purity of hydrogen : >97 %
5. Relative humidity of hydrogen at
nominal pressure : 60 %
6. Nominal temperature of cooling
water inlet : 37 C
7. Nominal flow of cooling water : 350 m
3
/ hr
8. Hot gas temperature (alarm) : 75 C

Stator water cooling system

1. Nominal pressure at inlet to winding : 3.09 kg / cm
2

2. Nominal temp. at inlet to winding : 40 C
3. Stator water flow : 27 m
3
/ hr
4. Stator water conductivity : <5 mho / cm
5. Stator water expansion tank vaccum: 200 300 mm of Hg
20

STATOR WATER PUMP

Protection & Interlock:

1. Expansion Tank level low.
2. Auto starting of stand-by pump from stator water pressure <2.8 ksc.

Seal oil system

1. Seal oil temperature after cooler : 20 40 C
2. Seal oil outlet temperature : 40 C
3. Differential pressure across duplex filter : 0.4 kg / cm
2

4. Seal oil pressure at turbine & excitor
end : 5.9 kg / cm
2

DC Seal oil pump starts when :
1. T.E seal oil pr. <3.8 ksc
2. E.E seal oil pr. <3.8 ksc
3. AC Seal oil pump discharge pr. <4.5 ksc

GENERATOR PROTECTIONS

1. Generator Differential (Relay 87G )
2. Stator Earth Fault
(i) Main Protection (Relay 64G1)
(ii) Stand By Protection (Relay 64G2)
3. Rotor Earth Fault
4. Stator Inter Turn Fault (Relay 50G1)
5. Loss of Excitation / Pole Slipping (Relay 40G )
6. Negative Phase Sequence (Relay 46G)
7. Low Forward Power (Relay 32G1)
8. Reverse Power (Relay 32G2 )
9. Over-voltage (Relay 59G )
10. Local Breaker Back up Protection
11. GT Over fluxing (Relay 99GT)
12. Stator water flow low (<13 m
3
/ hr)
13. Stator water conductivity high (>20 mho / cm )

OFFSITE

CW PUMPS

Type : BHM-100 , Single Stage
Motor HP : 950 KW
Make : BHEL
21
Capacity : 16,000 cu. m/hr
Bowl Head : 16.36 mmwcl
Speed : 420 rpm (Nominal)
No. of Stage : One
Max. Working pr. : 2 ksc
Impeller Type : Mixed flow
No. of Vanes : Four
Max. Bearing Temp : 70 C



BFV UNIT 1





BFV UNIT 2






BFV UNIT 3


BFV INTERCONNECTION VALVES



COMPRESSOR

Discharge Pressure : 8 ksc
Free Air Delivery : 25 . 68 cu. m/min
No. of Cylinders : 4
Speed : 670 rpm

Protection

1. Air delivery temperature after intercooler high (>48 C).
2. Lub oil pressure low ( <1 ksc).




CW-1
CW-2
CW-3
CW-4
CW-5
CW-6
CW-7
22

Air Drying Plant


Exhaust to Atm.


De-pressurise








Inlet



Outlet







Re-pressurise
From Atm.





Steps for ADP change-over :

1. Close exhaust valve.
2. Pressurize stand-by ADP.
3. Give ADP change-over command from panel.
4. De-pressurize.
5. Open exhaust valve.
6. Start blower.
7. Switch on the heater.




AD
1


AD
2
HEATER
BLOWER-1
BLOWER-2
23
DIESEL GENERATOR

Manufacturer : NGEF
Excitation System : Brushless
Engine BHP : 720
Stroke : 4
Rated Speed : 1500 RPM
Cooling : Stationary water cooled

D-G auto starting is from under-voltage in EMCC.

415 V
50 Hz
EMCC Unit 1



EMCC Unit 2


EMCC Unit 3



ADDITIONAL INFO ON OFFSITE EQUIPMENTS

Capacity of some pumps :

1. L.P Fly Ash Water Pump : 450 m
3
/hr.
2. H.P Fly Ash Water Pump : 375 m
3
/hr.
3. Bottom Ash L.P Water Pump : 375 m
3
/hr.
4. Seal Water Pump : 90 m
3
/hr.
5. Fly Ash Slurry Pump : 600 m
3
/hr.
6. Fuel Oil Pump : 100 m
3
/hr.

Fuel Oil Tank










DG
1
DG
2

2826 M
3

24
OPERATION GUIDELINES OF MAJOR EQIPMENT

EHC related emergency situations and remedial actions

Sl
no
Emergency situation Observations Action to be taken
1 M/C is on EHC. Power
supply failure in Pressure
control rack/load control
rack / transfer circuit rack
leading to zero EHC output .
Starting device will become
off automatically due to
EHC fault.
Load zero
Machine on bar with
ESV & IV open
(Turbine not tripped)
EHC fault alarm
( Spd. contr. Active
when Load contr.
P.S.failsspd. Ref.
Can be increased)

Confirm HP/LP bypass
opening, isolate EHC
from governing rack and
parallely reduce starting
device position from UCB
Reduce boiler firing to
restrict rise in boiler
pressure.
2 M/C is on EHC. Admission
control rack power supply
fails leading to zero EHC
output. Starting device will
become off automatically
due to EHC fault.
Load zero
Machine on bar with
ESV & IV open
(Turbine not tripped)
EHC fault alarm
Zero starting device
feedback
Zero speeder gear
feedback.
Confirm HP/LP bypass
opening, isolate EHC and
parallely reduce starting
device position from local
Reduce boiler firing to
restrict rise in boiler
pressure..
3 M/C is on EHC pressure
control mode and Throttle
pressure set point becomes
zero. EHC output will
increase.
EHC output may go
to 100%. Starting
device will track to
100%, resulting
wide opening of
HP/IP control
valves.

Tracking should be made
off manually and starting
device to be reduced
manually to adust the load
and pressure.
EHC may be isolated.
4 M/C is on EHC, Tracking on
and Strating device becomes
inoperative due to motor
failure/overload/ jamming.
During increase in
boiler firing Boiler
prassure will
increase due to load
restriction by
starting device
EHC output will go
to 100%
Switch off the electrical
module of starting device
and increase starting
device position from local
so EHC can take control.
5 Starting Device gets
continuous close command
due to malfunctioning of
command circuit. Hydraulic
governing will take control,
Starting device
position and Load
will come down
gradually
Boiler pressure will
Try to switch off the
electrical module
immediately before stop
valves closes. Increase
starting device from local
25
load will reduce gradually,
ultimately stop valves will
close and turbine will trip.
start increasing
resulting in opening
of HP/LP bypass.
so that EHC can take
control. Parallely reduce
boiler firing.
6 Speeder Gear gets
continuous close command
due to malfunctioning of
command circuit. Ultimately
complete unloading and
generator motoring may take
place.
Speeder gear
position and Load
will come down
gradually
Boiler pressure will
start increasing
resulting in opening
of HP/LP bypass.
Try to switch off the
electrical module
immediately before stop
valves closes. Increase
Speeder gear from local
so that EHC can take
control. Parallely reduce
boiler firing.
7 Trim device operated due to
malfunctioning/power
supply failure of solenoid
Trim device
operated alarm
IP control valves
will get throttled in
case of partial load
operation.
reduce boiler firing to
restrict rise in boiler
pressure.
8 M/C is on EHC, power
supply failure in CCA panels
only.
All indication lamps
in atrs console will
go off.
EHC output and
Load will become
zero due loss of
GCB close feedback.
All ATRS drives
will become
inoperative
Confirm HP/LP bypass
opening, isolate EHC,
Adjust starting device
from local. Reduce boiler
firing.
9 Unloading due to
malfunctioning of TSE
margin circuit.
TSE indicator will
show abnormal
margins and load
will come down
Speed controller will
be active if load
comes below
10%(block load)

10 Loss of speed signal

AOP & J OP will
take auto start
Lub oil pressure will
come down in case
of breakage of MOP
shaft






26
GENERATOR GAS PURGING AND FILLING


PURGING OUT HYDROGEN BY CARBON DI OXIDE
PREPARATION
1. Make arrangements for hot water, which will be required during CO2 charging.
2. Check for any leakages in CO2 manifold
3. Ensure sufficient number of CO2 cylinders
4. Inform fire fighting
5. Ensure availability of Flash Evaporator
6. Reduce barring gear speed or do hand barring if conditions permit.
7. Inform Chemistry Department about the program.

ACTIVITY:

1. Depressurise the generator casing by venting Hydrogen out to atmosphere slowly by following
instructions /directions given at the gas valve manifold.
2. Bring down hydrogen pressure to 0.2 ksc
3. Set the valves to CO2 charging and HYDROGEN purging position and pressurise generator
casing to 0.4 ksc by CO2.
4. Purge out the gen casing gas mixture by maintaining 0.1 ksc gas pressure.
5. Do gas analysis after charging 15 cyliders.
6. Purge LLD lines, Gas Driers by CO2 for removing any entrapped Hydrogen.
7. Repeat gas analysis after charging every 5 nos of CO2 cylindrers or at suitable intervals .
8. After attaining about 80% CO2 purity put the barring gear in service for at full barring speed for
15minutes for removing any Hydrogen pockets inside casing.
9. Continue hydrogen purge out till aCO2 purity of 98% is achieved.


PURGING OUT CARBON DI OXIDE BY AIR
PREPARATION
1. Ensure availability of dry compressed air .
2. Clean the air filter
3. Connect the air hose to the air inlet line.

ACTIVITY

1. Purge out CO2 by air.
2. Do gas analysis after at least 30 mins. of air purging.



PURGING OUT AIR BY CARBON DI OXIDE
PREPARATION
1.Make arrangements for hot water, which will be required during CO2 charging.
2.Check for any leakages in CO2 manifold
27
3.Ensure sufficient number of CO2 cylinders
4.Inform fire fighting
5Ensure availability of Flash Evaporator
6.Reduce barring gear speed or do hand barring if conditions permit.
7.Inform Chemistry Department about the program.

ACTIVITY:

1. Depressurise the generator casing by venting Air out to atmosphere slowly by following instructions
/directions given at the gas valve manifold.
2. Bring down Air pressure to 0.2 ksc
3. Set the valves to CO2 charging position and pressurise generator casing to 0.4 ksc by CO2.
4. Purge out the gen casing gas mixture by maintaining 0.1 ksc gas pressure.
5. Do gas analysis after charging 15 cyliders.
6. Purge LLD lines, Gas Driers by CO2 for removing any entrapped Air.
7. Repeat gas analysis after charging every 5 nos of CO2 cylindrers or at suitable intervals .
8. After attaining about 80% CO2 purity put the barring gear in service for at full barring speed for
15minutes for removing any Air pockets inside casing.
9. Continue Air purge out till aco2 purity of 98% is achieved.


PURGING OUT CARBON DI OXIDE BY HYDROGEN
PREPARATION
1. Ensure availability of HYDROGEN Cylinders.
2. Ensure availability of NON SPARKING TOOLS.

ACTIVITY:


1. Bring down CO2pressure to 0.2 ksc
2. Set the valves to HYDROGEN charging and CO2 purging position and pressurise generator
casing to 0.4 ksc byHYDROGEN.
3. Purge out the gen casing gas mixture by maintaining 0.2 ksc gas pressure.
4. Do gas analysis after charging 15 cyliders.
5. Purge LLD lines, Gas Driers by HYDROGEN for removing any entrapped CO2.
6. Repeat gas analysis after charging every 10 nos of HYDROGEN cylindrers or at suitable intervals
.
7. After attaining about 80% HYDROGEN purity put the barring gear in service for at full barring
speed for 15minutes for removing any CO2 pockets inside casing.
8. Continue CO2purge out till a HYDROGEN purity of 98% is achieved.
9. After conferming HYDROGEN purity pressurise Gen.casing to 3.4 Ksc.






28
COOLING PROCESS OF BOILER IN STAGE-1 & STAGE-2

After shutting down the boiler follow the steps to cool the Boiler.

1. Keep one set of ID & FD fan in service in cross path i.e. ID-A with FD-B or ID-B with FD-A.
2. In Stage-2 a) for both SAPH keep gas outlet damper closed while gas inlet & air inlet & outlet
dampers open.
b)for both PAPH keep gas inlet & outlet and air inlet & outlet dampers open.
3. Depressurize the boiler to 10 kg/cm
2
by keeping HP LP bypass system charged then close MSV
and open SH header drains.
4. Evacuate RH coils completely keeping only LP Bypass charged for a while.
5. Adjust Secondary air flow at around 30% of MCR.
6. Do not open manholes and do not break sealing of trough of boiler to prevent unaccountable air
ingress.
7. Control drum top bottom metal temperature difference within 50C. If the difference goes beyond
that regulate air flow and take FW to drum and drain through EBD. Keep CBD closed.
8. Open SH header vents and drum vents at 7 kg/cm
2
and 2 kg/cm
2
drum pressure respectively.
9. When drum metal temperature comes to <150C drain water wall through LPD.
10. After drum metal temperature comes to 120C sealing of trough may be drained and FD fan is to
be stopped. Keep ID fan running.
11. Record the parameters as given in the format.







T
i
m
e
S
A
f
l
o
w
APH
gas
I/L
temp
FW
flow at
Eco
I/L
FW
temp at
Eco O/L
Drum Metal Temperature
Top/Bottom
Left Centre Right












29
HP HEATER CHARGING PROCEDURE OF STAGE-1 UNITS

A) CHARGING FROM WATER SIDE :

01: Open FW outlet drains and vents partially for venting and warming up.
02: Open the manual isolation valves before group bypass pneumatic valves FW 36 & 37 and
check instrument air supply
03: Open FW inlet and outlet valves of HPH 5 & 6 and close individual heater bypass valves.
04: Close all the shell side drains and vents including stand pipe drains & vents.
05: Open the isolating valves before and after emergency drip valve keeping watch on
condensor vaccum.

06: UNLOCK BOTH THE GROUP BYPASS VALVES . FW 35 FIRST THEN FW 34.
07: Open the HPH charging line valves slowly and watch water coming out of the vents and
drains
of the heaters. Close dump valve FW-73.
08: Close vents and drains after proper venting and warming up. Pressure gauge at HPH-6
outlet line
will show almost BFP discharge pressure.
09: Give INSERVICE command to group bypass valves.
10: Confirm full lift of spindle of both FW-34 & 35 from local.
11: Close HPH charging line isolating valve
12. B) CHARGING FROM STEAM SIDE:
13. 1: Ensure that heaters are charged from water side.
14. 2: Open the isolating valves of deaerator side drip and cascading drip of HPH- 6
3: Open the shell vents to condensor slowly keeping watch on condensor vacuum.
4: Ensure instrument air supply to all drip control valves.
5: Open ES-6A and 5A slowly and warm up shell side of the heater. Shell side pressure ,HP
heater
FW outlet temperature and drip temperature will start to increase..
6. After long shut down or maintenance of HPH, shell side is to be flushed. Keep Emergency
drip manual valves closed & shell drain(at minus metre) open. Keep watch on drip level and
vac. Normalise after clear water comes from shell drain.
30
7: After around 30 minutes of heating, open ES-6 and ES-5 slowly and observe drip level to
come
to normal value.
8: Observe HP heater outlet temperature to increase.


C: ISOLATION PROCEDURE OF HP HEATERS:
1. Open ES-6A and ES-5A
2. Close ES-6 and ES-5 slowly. Keep watch on drip level so that HP heaters do not get
bypassed from level protection. Observe increase of load.
3. Close ES-6A and ES-5A. Keep watch on vacuum.
4. Keep open manual isolating valve before dump valve FW-73 . Otherwise, open HP heater 6
outlet line drain valve to avoid frequent opening and closure of group by pass valve during
bypassing of HP heaters from feed water side.
5. Give BY PASS command to group by pass valve after 5 min. of closing of Extraction valves.
6. Confirm full closure of group bypass valve from local.
7. LOCK BOTH THE GROUP BYPASS VALVES.
8. Close isolating valves before and after the emergency , normal and cascading drip line.
9. Open shell side drains and vents. Keep watch on vacuum.
10. Ensure full closure of ES-5/5A,6/6A and depressurisation of shell side.
11. Open FW side drains and vents.









31
CONDENSER BACK WASHING PROCEDURE OF STAGE-I UNITS

01: Ensure supply healthiness and availability of Electrical Operator in front of module of
CW valve 2 & 5.
02: Be prepared for manual operation of valve CW 2 & 5 in case of any emergency.
03: Reduce load to less than 120MW keeping watch on vac.
04: Keep both main ejector in service for safety.
05: Close air evacuation manual valve of pass A.
06: Rotate butter fly valve CW 2 by 90 without stopping. Confirm full rotation of the valve from
arrow indicator on the valve mounting.

NOTE: Butterfly valve CW2 must not be left at intermediate position. It must be brought to final
position by manual operation if stuck up midway.

07: Open air evacuation manual valve of pass A . Confirm condenser vacuum to regain to at least to
original value.
08: Close air evacuation manual valve of pass B.
09: Rotate butter fly valve CW 5 by 90 without stopping. Confirm full rotation of the valve from
arrow indicator on the valve mounting

NOTE: Butterfly valve CW5 must not be left at intermediate position. It must be brought to final
position by manual operation if stuck up midway .
10: Open air evacuation manual valve of pass A . Confirm condenser vacuum to regain to at least to
original value.
11: Stabilise vacuum and normalize load .







32
CEP SUCTION STRAINER BACKWASHING PROCEDURE


1. Ensure the CEP is not running and SLC is Off.
2. Isolate the 6.6 KV breaker of the CEP.
3. KEEP THE DISCHARGE VALVE OPEN .
4. Close the suction valve.
5. Close the vacuum equalising valve.
6. Close the gland sealing inlet valves.
7. Open the strainer drain valve and watch whether air is sucking or water is draining.
8. If air is sucking then close the drain valve. Further tighten the suction & vacuum equalising valve
then repeat step 7.
9. After completion of draining, open the backwasing line valve very slowly and observe water
coming out gently from strainer drain. Continue backwashing for 2 to 3 minutes. DO NOT FULL
OPEN THE BACKWASING VALVE AS OVER PRESSURISATION MAY DAMAGE
SUCTION LINE FLANGE GASKET OF THE STRAINER.


CEP NORMALISATION AFTER BACKWASHING

1. Close the backwashing valve.
2. Close the strainer drain valve.
1. Open the gland sealing inlet valves.
2. Open the vacuum equalising valve wait for sometime.
3. Open the suction valve slowly to full open position.
4. Normalise the 6.6 KV breaker.
5. Check the availability and keep the discharge valve open.
6. After selecting the running pump switch ON the SLC.





33
VACUUM PULLING IN STAGE-1

1. Ensure one CEP is running through main ejectors and GSC.
2. Ensure CW is following through condenser. (CW inlet/outlet valves are about 30%opened.
condition. If valves are not in opened condition then in coordination with UCB-1 open the
valves.
3. Line up one gland steam exhauster ( suction valve open and power supply on)
4. Main ejector and GSC drips are in lined up condition.
5. Ensure Vac breaker in opened condition.
6. Isolating valve before seal steam controller in closed condition and upstream drain to
atmosphere in opened condition.
7. Atmosphere drain of ejector steam header (below main ejector) is in opened condition and
ejector steam header drain to condenser closed condition.
8. Ensure manual isolating valves(CA-1,2 near condenser: CA-3,4 near main ejector) are in
opened condition
9. Open the isolating valve of ejector steam and gland steam at dearator floor.
10. Put into service one starting ejector and open warm up drain valve(as 87) of seal steam header.
11. Open the isolating valve before seal steam controller.
12. At about condenser pressure 600 mm Hg start seals steam exhauster and charge seal steam. Put
seal steam controller on auto, observe seal steam header pressure and close vacuum breaker.
13. At about condenser pressure 500mm Hg put main ejectors in service.
14. Line up the drain from atmosphere to condenser of seal steam line & ejector steam header at
5.5 mt.

VACUUM KILLING IN STAGE-1

1. Close the MS stop valves at boiler end(MS-301/MS-302)
2. Depressurise MS line and RH line by opening HP-LP by pass.
3. Closes all the mal drains which were opened during unit shutdown and line up atmospheric
drains of MS/HRH strainer.
4. After closing HP-LP bypass watch MS pressure (digital). If it increases then manually tighten
the MS stop valves.
5. If it remains at 1 KSC then reduce vacuum by taking out ejectors. Wait for VAC dropping upto
500mm Hg.
6. When back pressure is about 500 mm Hg then close the seal steam control valve and close the
seal steam isolating valve at 5.5 mt. Keep open the VAC breaker. Open atmosphere drain of
seal steam line and ejector steam line (At 2.5 mt).
7. Open the starting ejector air valves and watch the back pressure which should be less than
760mmHg.
8. Check from local whether steam is coming out from FAC breaker or not.
9. If steam is not coming out then close ejector & gland steam root valves at deaerator floor.




34
BFP ISOLATION STAGE-1



1. Ensure that pump is not running and lead/lag selection switch is in normal position.
2. Close the discharge valve and isolate the power supply.
3. Isolate the 6.6KV breaker.
4. Close recirculation valve at deaerator floor.
5. Close the suction valve slowly and watch local suction pressure.
6. If suction pressure increases then open the suction valve and manually further close the discharge
then repeat step-4 till suction pressure remains constant.
7. Open booster discharge vent valve.
8. Open booster pump suction drain and main pump discharge drain.
9. After completion of draining issue the PFW.



BFP NORMALISATION STAGE-1


1. Close the drain valves and keep open vent valves.
2. Crack open the suction valve, watch suction pressure and vent the system.
3. After proper venting close the vent valves.
4. Open the suction valve fulluy.
5. Open the recirulation valve at deaerator floor.
6. Normalise power supply of discharge vavle.
7. Normalise 6.6 KV breaker.
8. Check availability.
9. After Opening the discharge valve keep the selector switch in lead position.






35



CEP ISOLATION STAGE 1


10. Ensure the CEP is not running and SLC is Off.
11. Isolate the 6.6 KV breaker of the CEP.
12. Close the discharge valve and isolate power supply.
13. Close the suction valve.
14. Close the vacuum equalising valve.
15. Close the gland sealing inlet valves.
16. Open the strainer drain valve and watch whether air is sucking or water is draining.
17. If air is sucking then close the drain valve. Further tighten the suction & vacuum equalising valve
then repeat step 7.
18. After completion of draining issue PFW


CEP NORMALISATION STAGE 1

7. Close the strainer drain valve.
8. Open the gland sealing inlet valves.
9. Open the vacuum equalising valve wait for sometime.
10. Open the suction valve slowly to full open position.
11. Normalise the power supply of discharge valve and open it.
12. Normalise the 6.6 KV breaker.
13. Check the availability and kept open the discharge valve.
14. After selecting the running pump switch the SLC.