1.

Other operation emergencies handled during July 2000

a) On 2/7/2000 ID Fan B of Unit # 2 tripped on hydraulic coupling pressure low
when the unit was running at 130 MW. Unit load was brought down manually
to about 90 MW and all other parameters were controlled manually and unit
tripping was avoided.
b) On 3/7/2000 heavy flange leak was observed from boiler feed pump 2A
casing drain when the standby pump was not available. BFP 2A was stopped
immediately and unit load was reduced to about 60 MW and all other
parameters were controlled and tripping was averted.
c) On 3/7/2000 in Unit # 2 the pressure suddenly shot up 128 ksc. Emergency
stopping of one mill group was done and furnace was stabilized avoiding a
potential trip.
d) On 9/7/2000 in Unit # 2 PA fan 2B got tripped and 2 mills got tripped due to
the fan tripping. Oil support was taken just before the fan tripping suspecting
the erratic reading of vibration sensor of PA fan and because of this furnace
flame could be stabilized without leading to a flame failure trip.
e) On 10/7/2000, when Unit # 1 was running at 130 MW, all auxiliary cooling
water pumps and the air compressor tripped due to the tripping of circulating
water pump of Unit # 2. Nitrogen was charged immediately avoiding a trip on
instrument air pressure low. Paralally , 2 auxiliary cooling water pumps were
started and the auxiliary cooling water suction from Unit # 2 was isolated and
unit # 1 was saved from tripping.
f) On 13/7/2000,hunting was observed at the local gauge provided for BFP 2B
suction DP. Apprehending tripping of the pump, BFP 2C (stand by pump) was
started and BFP 2B got tripped just after. Unit load was about 110 MW. The
timely starting of BFP 2C has avoided a potential unit trip on drum level.
g) Compressor surge occurred 4 times (15/7/2000, 17/7/2000, 21/7/2000 and
29/7/2000) and the compressor discharge pressure went as low as 2.5 ksc in
2 cases. By promptly charging the nitrogen with the manual valve provided
(control valve is yet to be installed) unit trip was avoided.
h) On 27/7/2000 in Unit # 1 generator hydrogen drier did not cut off on auto after
regeneration. The defect was promptly noticed and the heater was switched
off averting a major trouble.

Operation emergencies handled other than trippings and restart.

3.1 During the month of August 2000, coal feeder chokage occurred 37 times
and promptly action was taken to avoid potential unit tripping on boiler flame
failure.
3.2 On August 2nd, 2000 current of Mill B of Unit # 1 rised suddenly and
pressure shot up. Unit load was brought down manually and all other
parameters were controlled and unit tripping was avoided.
3.3 On August 4th, 2000 it was observed that Unit # 1 throttle pressure
requirement was much more than what is normally required for full load. On
investigation it was suspected that passing of LPBP was the reason for the
higher pressure. Accordingly it was informed to I & C and LPBP valve was
further closed. Throttle pressure requirement came down from 125 ksc to
117 ksc.
3.4 On August 8th, 2000 Unit # 1was running at 130 MW with 3 Mills and without
corex. Suddenly airflow through Mill B started going down due to hot air
gate feed back problem. On local checking the gate was found fully open.
Hence open feed back was immediately simulated by locally holding the
limit switch and thus airflow could be maintained.
3.5 On August 8th, 2000 JVSL informed to remove the corex immediately, as
there was some emergency in the corex plant. Oil support was taken
immediately and corex burners were removed without any interruption of the
unit.
3.6 On August 9th 2000, in Unit # 2, CO 2 purging could not be carried out.
Purging out of CO2 was required, as hydrogen filling in the generator was
the hold up for restart of the unit. On further study it was observed that the
purging valve was fitted wrongly. The purging valve was refitted correctly
and purging was resumed Possible delay of 4 to 6 hrs in unit restart was
avoided.
3.7 On August 10th 2000 Unit # 2 was running at 110 MW. BFP C tripped on
NPSH very low and stand by BFP was not available. Load was reduced
immediately and all the parameters were controlled and unit load was
stabilized at 60 MW.
3.8 On August 14th, 2000, both the units were running at 130 MW. CW forebay
level dropped to 600mm very fast. It was found that JVSL water supply
was interrupted. Immediately the water supply was normalised, by coordinating with JVSL, without further reduction of the fore bay level.
3.9 On August 19th, 2000 suction filter DP of BFP 2A was maintaining high.
But BFP could not be isolated, as suction valve was not closing. After

repeated attempts with various combinations the suction valve was isolated
and enabled strainer cleaning.
3.10 On August 27th, 2000 Unit # 2 was running at a load of 130 MW with one Mill
and 8 corex burners (105,000 M3/hr flow). Corex Plant tripped without any
prior information. Oil elevation was taken immediately, unit load reduced to
50 MW and thus unit was saved from tripping.
3.11 On August 27th, 2000 both the units were running at full load and
compressor A tripped on inter stage temperature high. Nitrogen was
charged manually and unit tripping was avoided.
3.12 On August 2nd, 2000 Unit # 1 was running at full load with 2 Mills and 6
corex burners. Suddenly Mill B current got increased and pressure shot
up. Fuel was reduced and all other parameters were controlled immediately
to avoid the tripping.
3.13 On August 18th, 2000 Unit # 1 was running at 130 MW with 3 Mills and 6
Corex burners in service. Before the appearance of any alarm, it was
noticed that corex pressure was dropping. Immediately oil support was
taken and in the mean time corex plant got tripped. As oil support was
already established, tripping of corex did not affect our units.
1. Operation emergencies handled other than trippings and restart.
3.14 On September 1st, 6th, 7th & 8th when both the Units were running
with total corex flow more than 120 KNM 3, Corex plant got tripped.
Immediately, on noticing the alarm, oil guns were taken into service
and all the corex burners were removed pair wise, with out affecting
the furnace draft and both the units were saved from potential
tripping.
3.15 On September 9th, 2000, Unit-1 was running at full load. Deaerator
level transmitter A was under permit and transmitter C was kept
selected. Later on it was observed that transmitter C also got stuck
at 67mm and led to wide opening of level control valve on auto.
Immediately the control was taken on manual and system
normalised.

3.16 On September 10th, 2000, both the units were running at 100 MW.
CW forebay level dropped to 600mm very fast. It was found that

forebay make up control valve got closed due to controller problem.

Immediately the water supply was made available through the
bypass line, manually, without further reduction of the forebay level,
which could have resulted in unit tripping.

3.17 On September 12th, 2000, both the units were running at 105 MW.
Compressor surge had come and pressure dropped drastically up to
4.5ksc, an immediate corrective action was taken by charging the
nitrogen line with out further reduction in system air pressure and
hence avoided a potential trip of the units.

3.18 On September 17th, 2000 Unit # 1 was running at 130 MW. It was
found that the condenser vacuum had dropped from 0.90ksc to
0.84 ksc, Even after the second vacuum pump coming into service
the vacuum did not improved. On local checking it was observed
that seal water level of vacuum pump-A was not being maintained,
resulting to low vacuum. Immediately seal water level was brought
up manually, and vacuum got normalised.

3.19 On September 20th, 2000, Unit # 2 was running at 100 MW load and
heavy sparkles were observed in mill reject hopper, locally.
Immediately the mill hot air damper was closed and cold air damper
was opened. There after the feeder was stopped and purged the mill
with cold air, avoiding the chances of possible mill fire.

3.20 On September 21st, 2000, Unit-2 was successfully brought on house

load and was run for more than 30 minutes. All required parameters
were noted and unit resynchronized with the grid again, before
taking the shut down.

3.21 On September 23rd & 24th, at Unit-1, when load was 130 MW and on
September 6th, at unit-2, when load was 105 MW, boiler pressure
shot up very fast due to sudden loading of mill, resulting from wet
coal. Boiler pressure and other parameters were controlled and
avoided possible boiler trip on drum level.

3.22 On September 28th, 2000, when both units were running with total
corex flow more than 130 KNM3, JVSL corex export gas valve SOV
2940 got closed due to transmitter fault. Within 25 sec, after getting
the alarm, oil elevation was taken at both the units, and both units
were saved from tripping.

3.23 On September 29th, 2000, Unit # 1 was running at 100MW load with
2 mill & 6 corex burners. BFP-1A tripped on before cooler lube oil
temp very high, BFP- 1C was not available. Immediately X 2 elevation
2 corex burners were taken out, mill-c feeder was stopped. Load
reduced to 65MW; boiler drum level normalised with single BFP and
possible unit tripping could be averted.
3.24 On September 29th, 2000, Unit-1 was running at 105 MW and Unit2 was running at 112MW. Station Transformer # 1 got tripped on
Buchholz relay operation. As Station Transformer # 2 was already
under permit, all the station buses became dead and all Common
auxiliaries got tripped, including all cooling tower fans. Immediately
firing was reduced in both the units and load was reduced to 40MW.
Thus both the units were saved from potential condenser pressure
high trip due to high cooling water temperature.
Corex plant / system tripped 8 times (all the 8 times unit 1 in
operation and 7 times unit 2 in operation). All the time units were
saved from tripping except for one case in unit 2 in which SOV itself
closed on emergency.
October 2000
There were two (2) unit shutdowns during the month, both in Unit
2, out of which one (1) was for attending generator transformer oil
leakage and one (1) was for internal inspection of Generator
Transformer by BHEL.