Emergency procedures By

Kumar

Condenser Vacuum Low

Likely causes

Air Ingress in to the system

Rupture disc failure or flange Stand by ejector or starting ejector Manhole doors or any instrument tapping & connections Turbine LP side glands CEP& its suction line Condensate return line from BF PRDS

Gland steam pressure is low & drains to condenser are open during start up. Running CW pump tripped High CW inlet temperature Reduction in CW flow to condenser by means of bellow failure or inlet vale closure etc. In sufficient steam pressure to Ejector
PRDS safety lifts & not reseated

Condenser Vacuum Low ( contd.,)

Plant response

Condenser vacuum drops Auto unloading starts at 0 .23 Bara pressure. Unit will trip at 0.3 bar (A) Standby cw pump will start in auto if cw pump trips.

Parameters of concern.

Condenser Vaccum Auxiliary steam pressure Turbine Load CW I/L & O/L pressure & temperature to condenser

Condenser Vacuum Low ( contd.,)

Immediate expected or desirable operator action

Reduce the load & try to reduce the fuel so that HP bypass PCV will not open Start the stand by Cw pump if not started in auto Check the Auxiliary steam pressure & maintain at 11 ksc & take starting ejector into service. If any bellow fails, isolate the particular water box after reducing the load or isolate the particular CW pump if discharge bellow fails. Close the vacuum breaker manually if it opens on loss of air supply. Ensure that all CT fans running

Final correction activity

Check for any leak in steam line to ejector , isolate & attend. Check for any air ingress into the system, Isolate & attend. Check for gland steam pressure & try to increase the same ( during start up)
Gland steam dump connected to LPH-1 Gland steam supply header drain connected to Condenser

After attending the reason, unit load shall be raised & normalize the system.

CEP tripping
Likely causes

Hot well level low low (mm) Pump brg temp very high (oc) Motor DE brg temp very high (oc) Motor NDE brg temp very high (oc) Motor winding temp very high (oc) Any electrical protection

Plant response

Stand by CEP will start in auto SJAE steam inlet valve will go for close if both CEPs stopped for 1 minute

CEP tripping ( contd.,)

Parameters of concern.

Hot well level Deareator level

Immediate expected or desirable operator action

Stand by pump not picked up in auto , close its discharge valve , start manually & open the discharge valve. Reduce the load if possible If above action delays, unit will trip on Hot well level very high.

Final correction activity

Find out reason for tripping, attend the problem. If unit tripped, restart the unit as per hot start up check list.

BFP tripping
Likely causes

Deaerator Level Very Low (Mm) Suction Pressure Low (Bar) Pump Running & Lub Oil Press V. Low (Ksc) Pump DE/NDE Bearing Temp Very High (C) Pump Thrust Brg (Act) Temp V High (C) Motor Winding Temp Very High (C) Motor DE/NDE Bearing Temp Very High (C) Hydro Coupling Brg Temp Very High (C) Working Oil Temp High (C) Hc Scoop Tube O/L Oil Temp High (C) Any electrical protection operated

Plant response

Stand by BFP will start in auto & its scoop will track master in 3 sec FCS DP will come down & FCV will go for open on drum level Running scoop will increase in auto to maintain DP across FCS

BFP tripping ( contd.,)

Parameters of concern.

Drum level Dearator level Running BFP loading & scoop position

Immediate expected or desirable operator action.

Immediately start standby BFP ( if two pumps running), if not started in auto . If single pump running, stand by pump not started in auto, unit will trip on All BFP OFF with TD & Drum pressure > 5ksc & FCV will come to manual & hold. Reduce the fuel gradually, Control drum level Maintain deareator & hot well level

Final correction activity.

Find out reason for tripping, attend the problem. If unit tripped, restart the unit as per hot start up check list.

Both Air compressors tripped

Likely causes
Hp Disch Temp High Ts2 Lp Disch Temp High Ts1 Lube Oil Temp High-Ts5 Lp Cw O/L Temp High-Ts4 Aft Cooler Air O/L Temp Hi-Ts3 Air Receiver Pressure Hi-Ps6 ACW I/L Pr Lo -Ps-5 Any Electrical protection acted

Plant response

If LDO is in service, Unit will trip on Flame failure . N2 PRV will open & will maintain 5.2 ksc if N2 Upstream pressure is healthy. Service air solenoid will close at 4ksc Instrument header air pressure

Both Air compressors tripped(Contd.,)

Parameters of concern.

Instrument air header pressure N2 Upstream pressure Atomizing air pressure & flame intensity.

Immediate desirable operator action

Send field operator in local to reset. Try to start any one air compressor as soon as possible whenever permissive comes If N2 backup came into service inform to EMD to maintain N2 header pressure. Try to operate pneumatic valve as minimum as possible.

Final correction activity.

Find out reason for tripping, attend the problem.

Air Compressor Load/ Unload Failed

Likely causes

Loading/unloading transmitter selection not activated. Heavy air leak in the system.

Load / unload MIV is in close condition

100% loading solenoid valve de energized Any mechanical worn-out in suction valve assembly

Air Compressor Load/ Unload Failed( Contd.,)

Plant response

Air system pressure will go on higher side if unloading not happening. Air system pressure will go on lower side if loading not happening Air compressor will trip at 8.8 ksc air receiver pressure

Parameters of concern.

Instrument air header pressure

Immediate expected or desirable operator action

Start the standby air compressor and stop running one.

Final correction active

Find out reason for failure, attend the problem.

BFG header Pressure or Temperature variation

Likely causes

Network pressure variation due to BF plant problem like furnace slip Accidental opening of N2 header purge solenoid valve. Due to failure in BFG cooling system BFG holder not in service During inter connection of BF 1-2 & BF 3-4

Plant response

BFG header pressure will go either high or low. Drum pressure shoots up or drops down Furnace draft will fluctuate & ID fan loading may vary. Drum level will hunt due to disturbance in firing

BFG header Pressure or Temperature variation

Parameters of concern.

BFG header Pressure &temperature. MS Pressure & temperature Drum level Furnace draft

Immediate expected or desirable operator action.

Reduce the BF gas firing & control the Drum pressure Control the drum level Observe the header pressure if hunting more then remove the burners. Continuously observe the header temperature

Final correction activity.

BFG burners can be taken into service once pressure stabilzes. Unit load can be normalized

TG barring gear fails to come in service.

Likely causes

Lube oil pressure < 1 bar Lube oil temperature < 15 deg Turbine speed > 30 rpm Turning gear blocked or tripped Turning gear ON & Lube oil pressure < 0.8 Turbine casing temperature> 120 deg & Turbine speed < 4 rpm for more than 10 min Jacking oil pump not running Turning gear not engaged properly Solenoid or its supply failure

Plant response

Turning gear not in operation alarm will appear. If shaft comes in standstill condition gland steam will disappear . Vaccum breaker will open.

TG barring gear fails to come in service( Contd.,)

Parameters of concern.

Turbine speed Jop discharge pr. Lube oil pressure

Immediate expected or desirable operator action.

Check Lube oil pump & Jacking oil pump are running. Check Lube oil pressure & temperature normal. Check turning gear face plate & if it is BLOCKED state, reset the same by changing the control mode to MAN or BLOCKED and back to AUTO again. Manual barring can be done after removing Solenoid supply from control oil rack. Engage the gear locally if it is not.

Final correction activity

Normalize the Solenoid supply if removed. Keep the turning gear in auto & Make FG turning gear ON.

Turbine Alone tripped

Sequence of events

GCB will open HP Bypass PCV will open as per logic

If Turbine tripped & PCV in auto, for 30 sec it will open for 30% & later it will operate on pressure set point

Drum level will start dropping & FCV will open

When drum level drops below -100 mmwc, feed forward signal will be added to controller out put to make FCV to pen

BFP Scoop will increase to maintain DP across FCS Boiler getting tripped on Drum level very low CTV &BTV close on MFT ID fans are getting tripped on Furnace draft very low(-175 mmwc)

MS flow rejection FLOW THROUGH HP BP PCV @ 35% On turbine trip, fuel will be reduced in auto Equivalent steam rate Remaining steam rate to be reduced

410 TPH 260 TPH ( APPROX) 20 knm3/hr 50 TPH (approx) 100 TPH

As drum pressure shoots up due to the excess steam rate (100 TPH) will cause drum level to shrink. To avoid drum level to shrink,

Open further HPBP PCV At 30% PCV opening, HPBP downstream temp is maintaining at about 140 deg. HPBP spray CV & its bypass vale will be in full open condition. Both CEP will be in running condition. Further opening will cause down stream temperature to shoot up. At 175 deg , HPBP PCV will go for close. Reduce the fuel to avoid drum pressure to shoot up. Take BFP scoop master to manual & increase the DP across FCS

With above sequence of events, It is clearly evident that chances of saving the boiler when turbine tripped are less.

After boiler tripping, Fans are getting tripped on furnace draft very low which may be avoided to decrease the down time.

By keeping the ID fan I/L regulating dampers in auto , furnace draft control will be faster
In Existing logic, ID fan I/L regulating damper logic is also included & same may be implemented after proper tuning if required. By doing this modfication, we can reduce the down time & immediately purging can be started.

Thank you

D R U M L E V E L S P

CONTROL STATION

FCV 100% COMMAND

FLOW CONVERSION

FW FLOW SET POINT

APID APID DRUM LEVEL

M S F L O W

F W F L O W

FF SIGNAL

Drum level 100 125 150 160 165 170

FF Signal -10 -20 -50 -90 -92 -95

Drum level -100 -101 -120 -130 -140 -150

FF Signal 15 18 30 50 80 95

LP Cylinder

HP Cylinder

Load /unload valve

Drain separator From Air receiver

SV