20mw Operation Manual 355j2i

NAVA BHARAT FERRO ALLOYS LTD POWER DIVISION DHARMAVARAM

STANDARD OPERATING PROCEDURES FOR 20 MW STEAM TURBINE MODEL: C9-R16-ER

PREPARED BY .

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Standard Operating Procedure Steam turbine is a machine, which converts the heat energy available from Boiler main steam into mechanical energy in an economical way. Turbine is associated with Reduction gearbox and Generator, to convert this mechanical energy into electrical energy. One number 0f 32 MW, single cylinder, horizontal, impulse, multistage, multtivalve, axial flow, condensing, one controlled and one uncontrolled extractions with reduction gear and down exhaust type turbo generator supplied by SNM Co Ltd., Japan is installed in our plant. The following are the salient features of Turbine: Machine is having Electro hydraulic governing system assisted with WOOD WARD – 505 governor control system, one Emergency stop valve and 4 nos of inbuilt control valves with one mechanical over speed tripping mechanism. Turbine is having two numbers of steam extractions, 1st steam uncontrolled extraction for HP heater for feed water heating, 2nd steam controlled extraction for Deareator, for deareation and heating purpose and for the sugar plant purpose. Principle of Operation: The steam with 86 Kg/Sq.cm pressure and 515 Deg.C temperatures will enter into turbine through one ESV and 4 numbers Governing control valves. The steam entered into the turbine expands over the moving and fixed blades of turbine releasing the mechanical energy and rotates the turbine rotor at 6194 rpm. The turbine is coupled with the generator rotor through reduction gearbox (6194/1500 rpm) and rotates the generator rotor to convert mechanical energy into Electrical energy. Steam after doing it’s work in turbine, gets collected into Condenser and forms as condensate by giving it’s latent heat to CW water flowing in the tubes of condenser. 2

From condenser the condensate is pumped with Condensate Extraction Pumps (CEP) through ejectors and gland steam cooler upto Deareator. From Deareator, feed water is pumped to boiler Economizer using BFPs through HP heater. Deaerator & HP heaters draw the steam from the turbine to heat the condensate flowing through them. This is known as “Regenerative feed heating system.”

The TG set is provided with the following systems: 1. Turbine and reduction gear box assembly 2. Turbine lube oil and Governing system 3. Condenser and Air Evacuation system 4. Feed water heating system 5. Turbine gland steam system OPERATION - PROCEDURES 1. Cold, warm and hot start up of TG 2.

Loading of Turbine

3.

Planned and Emergency shutdown.

4.

Emergency conditions during Turbine Operation.

5.

Important DOs and DONTs

6.

Operating parameters and alarm trip values as Annexure – I.

7.

Possible troubles, causes and remedies

I. Turbine and reduction Gearbox assembly: The 20 MW steam turbine, type: C9-R16-ER supplied by Shin Nippon Machinery Co. Ltd., Japan is installed in our plant. Steam turbine is horizontal, impulse, 3

multistage, multi valve, axial flow, condensing, nozzle governing, extraction and geared type. The turbine is provided with 16 stages of blades. Steam flow to the HP part is regulated by 4nos steam control valves constituted as a single assembly as HP governor valve. Steam Turbine consists of Casing, fixed blades, moving blades, rotor (on which moving blades are fixed) bearings (journal and thrust), steam flow control valves. The casing or cylinder of turbine is a pressure vessel, which is capable of with -standing the working pressure and temperature. It provides to the fixed blades and rotor bearings. The turbine HP part is made up of Cast alloy and LP part is made up of carbon steel and rotor is made up of Chromium, molybdenum, and vanadium steels. The moving blades are fixed on rotor and rotate between the stationary (fixed) blades. The rotor is mounted on two journal bearings. The front side of the rotor is mounted with thrust bearing to take the axial thrust coming on rotor. Lube oil to the bearings is provided from lubrication system. To reduce the speed of the turbine rotor from 6194 to 1500 rpm, which is required for generator, reduction gearbox was incorporated between turbine and generator rotors. The turbine shaft is coupled with pinion shaft of gearbox and where as generator shaft is coupled with wheel shaft of gearbox. Reduction gearbox assembly also consists of Turning gear motor arrangement and “Main oil Pump” in it. The full load parameters of turbine are “86 kg/Sq.cm g” main steam pressure, 515 Deg.C MS temperature, 6194 rpm, 0.1 Kg/Sq.cm (abs) exhaust steam pressure and 127.61 TPH steam flow through it. The two extraction steam quantities are 14.114 TPH for HP heater, 7.68 TPH for Deareator, and 12.05 TPH for LP heater. And remaining 93.37 TPH gets collected in condenser where it is condensed by using Circulating water. To supply the cooling water for the above condensation process, TWO numbers of CW pumps each of 6900 Cu.M/Hr capacities are installed here. The circulating water gets heated by approx 9 Deg.C in the condenser during condensation process. In order to cool this water by 10 Deg.C, two nos of cooling 4

towers with induced draught fans are installed. The following are the Protections (Trip values) of the Turbine: 1. Steam temperature at turbine inlet high high > 543 Deg.C 2. Steam temp. at turbine inlet low low < 460degC, this protection comes in to service only when MS temperature reaches to 495 deg C and then falls to 460. 3. Steam pressure at turbine inlet low low < 60 kg/sq.cm (may be byed initially for Cold and Warm start ups if required.) 4.Steam pressure at turbine inlet high high >103kg/sq.cm (not incorporated). 5. Control oil pressure low low 8.0+/-0.5 Kg/sq.cm 6. Lube oil pressure low low < 0.62 Kg/Sq.cm 7. Generator heavy fault (Generator trip). 8. Turbine mechanical over speed trip >/= 5632 rpm 9. Turbine electrical over speed trip >/= 5583 rpm 10. Governor heavy fault. 11. Remote trip from turbine governor . 12. Turbine trip from desk push button. 13. Exhaust steam pressure high high > 1.3 Kg/Sq.cm (abs) 14. Exhaust steam Temperature high high > 150 degC 15. Lube oil reservoir level (MOT) low low < 350 mm. 16. Hot well level low low < 300mm 17. Hot well high high 1400 mm 18. Turbine Rotor axial shift high high +0.65, -0.65 mm. 19. Turbine front shaft vibration high high 90 microns 20. Turbine rear shaft vibration high high 90 microns 21. Reduction gear pinion front shaft vibration high high 140 microns 22. Reduction gear pinion rear shaft vibration high high 140 microns 23. Reduction gear wheel front shaft vibration high high 180 microns 5

24. Reduction gear wheel rear shaft vibration high high 180 microns 25. Generator front shaft vibration high high 160 microns 26. Generator rear shaft vibration high high 160 microns 27. Turbine thrust bearing temperature high high (inactive) 120 Deg.C 28. Turbine thrust bearing temperature high high (active) 120 Deg.C 29. Turbine front shaft bearing temperature high high 120 degC 30. Turbine rear shaft bearing temperature high high 120 degC 31. Reduction Gear pinion front bearing temperature high high 120 degC 32. Reduction Gear pinion rear bearing temperature high high 120 degC 33. Reduction Gear wheel front bearing temperature high high 120 degC 34. Reduction Gear wheel rear bearing temperature high high 120 degC 35. Generator front bearing temperature high high 85 degC 36. Generator rear bearing temperature high high 85 degC 37. HP heater level high high 290mm. (Protection should be byed during charging of HP heater.) not incorporated. II. Turbine lube oil system: Turbine lube oil system consists of Main oil tank (MOT), Over head emergency oil tank (OHT), lube oil coolers (2), Main oil pump (MOP), Control oil pumps (2,COP), AC driven Auxiliary oil pump (AOP), DCdriven Emergency oil pump (EOP), and oil vapor extraction fans (2, OVEF) to supply the lube oil to the turbine, reduction gear box and generator bearings during run up, coasting down and for subsequent turning gear operations. The MOP is mounted on reduction gearbox wheel assembly and rotated by turbine rotor and supplies oil to the lubricating system and as well as trip oil to the governing system. It takes over its duty from the AOP when turbine speed is above 4650 rpm. To maintain lube oil temp at 45 degC, Lube oil coolers (2 nos) are provided in the system. Two numbers of vapor fans (one working and one standby) are provided to 6

extract oil vapors from MOT and vent them out to atmosphere. CONTROL OIL PUMP: Control oil pump (COP) supplies oil to the governing system during initial start and continuous operation of turbine. COP is rated to deliver 60 LPM at a head of 16.0 Kg/Sq.Cm (g) and is driven by 415V, 5.5KW, and 2880-rpm motor. Two numbers of COPs are installed, out of two, one is working and another is standby. The autochange over is incorporated between COP-1 and COP-2. Startup Sequence: 01. Ensure the following COP1&2 are ready from Mechanical, Electrical and Instrumentation sides and NO Line Clearance is pending on COP- 1&2, governing and lube oil systems. Power supply and control supply are available. Pressure switches and interlocks are properly checked and incorporated. Discharge valves are opened. Level of oil in MOT is normal (550mm). Valves in oil system supply mains are properly lined up. Ensure oil vapor fan is ready to start (at least one). 02. Start the pump by pressing the start button on DCS. 03. Check the discharge pressure of pump and motor current. 04. Keep the stand by pump in auto, in order to come in to service in auto as per interlock. 05. Observe the control oil filter differential pressure (DP) (not more than 0.8) from local gauge. If necessary, change the filter. NOTE: Before changing the filter, open air vent & Equalizing valve and ensure that both the 7

filters are equalized with oil. After change over, close the air vent.

Shutdown Sequence: As these pumps are intended for continuous supply of governing oil to the turbine, they are to be switched off only when the turbine is not in service. Before switching off these pumps, ensure that the standby pump is in ‘MAN’ mode (if pump is in “AUTO” mode, it will come in to service on interlock). Important Note: When one COP is in service with the turbine running, the standby COP should be in AUTO selection. Otherwise, auto-change over will not take place when running COP trips and this results n trip of Turbine. Interlocks on COPs: Auto Start: COP discharge pressure low (PSL 510) or running COP off, and pump is selected in auto, the AUTO selected pump will come into service in AUTO. Auto Stop: No Auto Stop incorporated. Pump can be switched ON and OFF at any time if it is selected in MAN in DCS. AUXILARY OIL PUMP: AOP is an AC driven pump which supplies lube oil at 1.5 kg/Sq.cm to Turbine, Reduction gear box and generator bearings and trip oil at 4.3 Kg/Sq.cm to the governing system during turbine speed run up and turning gear operations. It has rated capacity of 1019 LPM at 6.5 Kg/Sq.Cm and driven by 415V, 22 KW and 1475rpm motor. At 4650 rpm, MOP takes over the duty of AOP; AOP will be switched off in auto. This pump comes into service in AUTO if lube oil header pressure is less 8

than 0.87+/-0.2 Kg/Sq.Cm and pump is selected in AUTO. In the event of turbine trip due to any reason, AOP comes into service into operation by interlock when oil header pressure drops to 0.87+/-0.2 Kg/Sq.Cm to supply lube oil to all bearings for it’s safe coasting down and subsequent Turning gear operation. This pump also supplies suction to the Jacking oil pumps. The discharge of AOP es through the Lube Oil Coolers.

Start up Sequence: 01.Ensure the following AOP is ready from Mechanical, Electrical and Instrumentation sides and NO Line Clearance is pending on AOP, governing and oil systems. Power supply and control supply are available. Pressure switches and interlocks are properly checked and incorporated. Discharge valve is opened. Level of oil in MOT is normal. Valves in oil system supply mains are properly lined up. Ensure oil vapor fan is in service (at least one). 02. Start the pump by pressing the start button on DCS. 03. Check the discharge pressure of pump and motor current. 04. Keep the pump in auto, in order to come in to service in auto as per the interlock. 05. Observe the lube oil filter DP (< than 0.8) from local gauge. If necessary change the filter. NOTE: 9

Before changing the filter, open air vent & Equalizing valve and ensure that both the filters are equalized with oil. After change over, close the air vent. Shutdown Sequence: As this pump is intended for initial run up of Turbine, this will be switched off in auto when turbine speed is above 4650 rpm (>95% of rated speed). Before switching off AOP manually, keep the pump in MAN selection and ensure that Turbine speed is >95%( MOP has taken over the job of AOP) and Turning gear motor is not in service. Interlocks on AOP: Auto Start: Lube oil header pressure low (PSL504 ) alarm and pump is selected in AUTO, AOP comes in to service in AUTO. Auto Stop: When Turbine speed is greater than 95% of rated speed, AOP will be switched off in AUTO. Pump can always be switched on and off manually at any time.

EMERGENCY OIL PUMP The EOP comes into service in the event of an Emergency. A DC motor drives this. It has rated capacity of 260LPM against a 1.5 Kg/Sq.cm head and is driven by 2.2 KW, 1500-rpm 110V DC motor. In the event of total power failure or if AOP fails to start on it’s interlock due to any reason, EOP comes into operation when lube oil header pressure drops to 0.62Kg/Sq.cm to supply the lube oil to the TG bearings for its safe coasting down. EOP supplies oil only to the bearings. The discharge of this pump will not go through oil coolers. Startup sequence: 01.Ensure the following. 10

EOP is ready from Mechanical, Electrical and Instrumentation sides and NO Line Clearance is pending on EOP, governing and oil systems. DC Power supply and control supply are available. Pressure switches and interlocks are properly checked and incorporated. Discharge valve is opened. Level of oil in MOT is normal Valves in oil system supply mains are properly lined up. 2.

When the above are satisfied, the DC EOP will start by

inter lock, if lube oil header pressure drops to 0.62 Kg/Sq.Cm 3.

If the interlock does not work, the pump can be started by

pressing the start push button on Turbine governor (TGP). 04. After starting the pump check the discharge pressure, motor current. Shutdown sequence: The DC EOP can be stopped from TGP when it is no longer required to run, say, when AC power is restored and AOP has taken into service. To stop the pump, press stop button on TGP. The pump can only be stopped whenever lube oil header pressure is > 0.62Kg/Sq.Cm, otherwise EOP will come into service in auto.

Important Note: During normal running of turbine, EOP should be ready in all respects to come into service with out fail. Trail run may be taken in every shift to check the availability of EOP. While TG is in service or in TGM operation, EOP should be in ‘Auto Standby’ mode on TGP.

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Procedure to take trail run on EOP Check the Healthiness of DC supply. Change the selector switch from USUAL to TEST mode in Governor Control . EOP will start automatically. Observe the lube oil pressure. Check the current. Ensure AOP is in auto. Change the Selector switch from TEST to USUAL mode. Stop the EOP. If lube oil pressure drops to 0.87+/-0.2 kg/sq.cm, AOP will start in auto. EOP should be kept in Standby mode. Observe the lube oil pressure to bearing. After ensuring the lube oil pressure to bearings, Stop AOP. Observe the lube oil pressure. Inter locks on EOP: Auto Start: Lube oil header pressure low low (PSLL 504-1) and EOP auto selected on TGP then EOP come into service in AUTO. Auto Stop: Auto stop isn’t incorporated. Manual start and manual stop can be done at any time from TGP.

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TURNING GEAR Before starting of the turbine and as well as after trip, turbine and generator shafts are to be rotated at certain speed to avoid deflection of rotor due to self weight in high temperature atmosphere. Turning Gear is incorporated in the system to facilitate this operation. In our case, turbine rotates at 40 rpm in turning gear operation. 11 kW, 415V, 1450-rpm motor, drives the turning Gear. Interlocks on TGM: Auto Start: TGM comes in to service in AUTO 200 seconds, after the start permissives were satisfied and if it is selected in AUTO. The start permissives for TGM are Turbine speed <10%(490 rpm) Lube oil header pressure is not low (PSL 504). Auto Stop: If any one of the above conditions is not present the TGM will trip and turns to MAN selection. Manual start can be possible if all the start permissives are satisfied. Manual stop can be done at any time. During turbine rolling, TGM automatically disengages at 100 rpm (approx) of turbine rotor, and TGM trip at 490rpm of Turbine. Whenever the unit trips barring gear will engage automatically, during the barring gear

operation if power fails after restoration power barring gear

should be manually engaged before starting. If it is not so which will lead ton damage the gears of barring gear. Putting Turbine on Turning gear Operation: Ensure the following: MOT oil level is normal. NO line clearance is pending on Turbo Generator, Lube oil and Jacking oil systems and Turning gear motor. 13

Proper functioning of instruments indicating: Axial displacement All turbine, reduction gear box, generator bearing vibrations All bearing metal temperatures Lube oil temperature and pressure Jacking oil pressure Turbine speed Ensure DC EOP is healthy and in standby mode on the Governor . Start AOP as per the procedure and check the Lube oil pressure and parameters mentioned in point 1.c. Throttle the cooling water outlet from oil coolers and maintain oil temperature around 45 Deg.C +/- 5 Deg.C Engage turning gear pinion by rotating the motor shaft with the lever from local. Start the turning gear motor (TPBSSBGMT) and check the following: TGM current Axial displacement All bearing vibrations Turbine speed Lube oil pressure It needs approx. 10 hours to cool down the turbine casing and bearings. After turbine cooling period, the TGM may be stopped. AOP & JOP should be continued in service for another 2 hours.

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III.CONDENSER and AIR EVACUATION SYSTEM: CONDENSER: Condenser is a tubular, non- type heat exchanger, which receives the steam from turbine after doing work, and condenses it to form condensate using CW system. Condensate Extraction pumps are connected to condenser, and they will pump the main condensate to Deareator through Ejector and Gland Steam Cooler. To increase the work done by the turbine and to avoid backpressure on Turbine rotor, pressure inside the condenser is maintained below atmosphere pressure (vacuum). To obtain vacuum in condenser, air and non-condensable gases are to be removed. For this purpose, air evacuation system with Main ejector has been provided. The makeup DM water needed for the system is added in the condenser from UCFT through Normal and Emergency makeup control valve lines. Heat transfer area in condenser : 2435 Sq.M Number of Tubes

: 5016

Dia/Thickness of tubes

: 22.225/0.71mm

Rated CW flow

: 5800 Cu.m/hr

DP across condenser at rated flow: <5300 mmwc AIR EVACUATION SYSTEM (Ejector system): One starting Ejector (Hogging ejector), two numbers of “two stage steam jet air ejectors (as a single unit)” are installed to create and maintain vacuum in the condenser. 1. Ensure the following: TG set is on turning gear operation as per the procedure. At least one CW pump is in service and two CT fans are ready to start. 15

Condenser is charged from CW side. Hot well level is normal. CEP is running on re-circulation through Main Ejector, Gland steam cooler. PRDS steam is available at rated pressure and temperature. Ensure water sealing is provided for all valves connected to condenser and vacuum break valve. 2. Close the following valves: Hand operated valve in airline connected to hogging ejector and

main ejectors.

All drain valves and control valves connected to condenser. Close the vacuum break valve. 3. Warm up the PRDS header by opening the drain valves. 4. By operating the PRDS pressure control valve and Temperature control Valves attain the required 5. PRDS pressure and Temperatures. 6. Ensure PRDS steam is available with 8Kg/Sq.cm and 210 Deg.C 7. Start the GSC exhaust fan. 8. Charge the Gland steam cooler. 9. Open the steam valve to the starting ejector gradually. 10. Slowly open the air valve and watch for vacuum. After attaining required Value, -0.6 Kg/Sq.Cm make ready the main ejector for Keeping in service. 11. Open the steam valves of main ejector slowly and then open-air valve and discharge valve. Charge the glands by opening the HOV in gland sealing line. Ensure Turbine gland sealing steam pneumatic control valve is operating and Gland steam pressure is normal (0.1 to 0.2Kg/Sq.Cm (g)). After attaining –0.70Kg/Sq.Cm (g) of vacuum, isolate the startup ejector by Closing air valve first and steam valve next. With the main ejector in service we can attain – 16

0.9 to –0.95 Kg/ Sq.Cm (g). Important Note: a. Before charging the main ejector, ensure flow of main condensate (CEP discharge) through ejector. b. While charging the ejector, open steam valve and air valve next gradually. c. During cut off of the ejector, close air valve first and steam valve next and discharge valve next. d. Ensure tightness of vacuum break valve manually. Provide water sealing. e. Do not open any drain valve connected to condenser when there is no sufficient vacuum (>0.5Kg/Sq.Cm (abs)). f. Ensure that the drain line isolation valves of condensate trap & casing drain of the running exhaust fan are in open position. g. While charging the main ejectors, ensure that Rotameter isolation valves drain line isolation valves of Condensate Trap are in open position. h. Ensure that the suction valve& casing drain valves of the standby exhaust fan on Gland steam condenser are in closed position.

IV. Main condensate and Feed water system: Main condensate system: After condensing of Exhaust steam in condenser, condensate forms. This condensate is pumped to Deareator using Condensate Extraction pumps through Main ejectors, GSC. The discharge of CEP is also used for 1. Flash box attemperation,2. Valve 17

sealing. From CEP discharge header one line is connected to UCFT with Motor Operated Valve, to drain the excess condensate from the hot well. CONSENSATE EXTRACTION PUMPS: Two numbers of CEPs (one working and one standby) are installed to pump the main condensate from condenser to Deareator through main Ejectors and gland steam cooler. It has rated capacity to deliver 125 METER CUBE/HOUR at 111.6 Kg/Sq.cm and is driven by 415V, 1475 rpm, 75 KW motor. As this pump supplies cooling medium to Main Ejector and GSC, 100% availability of this pump is essential to run the plant. STARTING OF CEP: 1. Check no line clearance is pending on CEP and Condensate system 2. Ensure that hot well level is normal >700mm & UCFT level is > 1500mm. 3. Ensure that suction valve is opened and DP across suction strainer is <0.3 Kg/Sq.cm 4. Ensure that the Pump is primed with condensate by opening air vent. (When there is no vacuum.) 5. Open HOV in line from CEP discharge to mechanical seal. 6. Ensure that MC PCV “TLIC430AM“ in MC line to Deaerator is closed and PCV in re-circulation line is full opened. 7. Ensure that the discharge valve (HOV) is closed. 8. Ensure MOV “ TPBOCMV350“ in CEP shell UCFT line is in closed condition. 9. Ensure that Electrical supply is available. 10. Ensure that valve sealing line is through to suction valves. 11. Open CEP air removal line valve to condenser. 12. Check the lube oil level in the bearing oil cup. 13. Start the Pump from DCS. 14. Check disch. Pressure, Motor current, Brg. temp and hot well level. 15. Open MC PCV gradually and maintain the discharge pressure above 8.0 Kg/Sq.cm.

SHUT DOWN SEQUENCE: 18

When there is no vacuum in Condenser, the pump can be stopped by keeping the Pump in re-circulation. WHAT NOT TO DO: 1. Don’t allow any leakage in suction side. 2. Don’t open any valve, fitting, flange in the suction side. In normal working condition (Condenser is in vacuum), this will cause vacuum to drop the Pump to loose it’s suction. 3. Don’t allow the Pump to start or run with the protection/interlock by . 4. While cleaning suction strainer of stand by CEP, ensure the closed position of the respective suction, discharge valves, air removal valve to condenser, all drain valves between pump suction, discharge valves and open position of suction valve sealing line valve. AUTO CHANGE OVER OF CEP: 1. Check no line clearance is pending on standby CEP. 1. Standby pump should be selected in “AUTO” mode in DCS. 2. Suction and discharge valves should be in open position. 3. HOV in line from CEP discharge to mechanical seal is in open position. Interlocks on CEP: 1. When hot well level Hi switch (TLT300A1) is acted (cond. Level >1000 mm) auto stand by pump comes into service in Auto. 2. When hot well level Low switch (TLT302A) is acted (cond. Level < 550 mm) auto stand by pump trips in Auto. 3. When hot well level Low Low switch (TLT303A) is acted (cond. Level < 300 mm) both pumps will trip. (Turbine trip)

Feed water Heating System (Regenerative system): The thermal gain and economics of feed water heating given rise to regenerative feed heating system. It consists of HP heater and Deareator. Feed water heater is a simple heat exchanger, which is arranged so that water leaving the condenser is preheated before it is fed to the Boiler. HP heater is of surface type heat exchangers, where as deareator is direct type heat exchanger. These feed water heaters extracts the steam 19

from the turbine at high pressure and temperature and heats the feed water flows through them. The condensed steam from HP heater are connected to condenser and deareator respectively. The presence of certain gases like oxygen, carbon monoxide and ammonia, dissolved in water is harmful because of their corrosive attack on metals. Hence these gases are removed in deareator unit. Spraying the water and heating the same by steam achieve the same. The Deaerator consists of two chambers, the deareating column and feed storage tank.

HP heater charging procedure: 1. Ensure open position of air removal line to condenser 2. Ensure Feed water is charged through HP heater 3. Ensure extraction line drain valves before and after Check valve are in open position. 4. Open the extraction check valve of HP Heater 5. Open the HPH extraction motor operated valve 6. Maintain the heater level by operating HPH level control valve to Condenser up to 5Kg/sq.cm extraction steam pressure, and at above 5 Kg/sq.cm pressure maintain the HPH level by operating the level control valve to Deareator.. 7. After charging of heater close the drains before and after check valve. Note: 1. Do not charge the heater with out water flowing through them 1. During cut out of heater, close steam valve first. Charging procedure for Deaerator: Charge the De aerator. after 10 MW load it can be charged from its extraction line. Open drains before and after HPH extraction check valve 20

Open HPH extraction check valve Open HPH extraction by to Deareator MOV Maintain the Deaerator pressure at 4.9 to 5.0 kg/sq.cm by operating the Deareator pressure control valve. After charging of Deaerator close the drains before and after check valve. Charging of Deaerator from its extraction line Open drains before and after Deareator extraction check valve Open Deaerator extraction check valve Open Deaerator extraction MOV and close the HPH extraction by to Deaerator MOV Maintain the Deaerator pressure by operating the Deareator pressure control valve. After charging of Deaerator close the drains before and after check valve. Check the following during increase of pressure in Deareator: 1.

Deareator expands freely.

2.

No abnormal hammering is there in the

pipe line. 3.

Steam and air mixture is being vented

through the vent line. 4.

No major steam/water leakages are

there. Note: Do Not Delay In Charging Deaerator After Charging Of LP Heater. V. Turbine Gland Sealing System: If the pressure at the turbine cylinder (Casing) is higher than the atmosphere pressure, there will be a leakage of steam (from clearance between rotor and stator of turbine) into atmosphere causes wastage of steam. The pressure is less than the atmospheric pressure there will be ingression of air into condenser causing falling of 21

vacuum. To avoid this problem gland sealing is provided with 200 0C temperature and 0.1-to 0.2-kg/sq.cm steam. One 3-way pneumatic control valve is provided for this purpose. During turbine rolling and up to 10MW load the aux. Steam with 8Kg/sq.cm; 1800C is being used for sealing. After 10MW load, the turbine HP gland leak off steam is being used for turbine LP gland sealing. To collect and condense the gland leak off steam from turbine front and rear glands, gland steam piping and gland steam cooler are provided. Turbine glands are to be sealed with gland steam during vacuum pulling after attaining (–) 0.70Kg/sq.cm (g) vacuum in condenser. After trip of turbine, to kill the vacuum stop the glands sealing by closing the hand operated valve before 3 – way pneumatic control valve. VI. Cold, Warm and Hot start of Turbine: Cold Start Of Turbine Turbine start up is termed as cold start up, if it is being started 10 to 12 hours after shutdown or the metal temperature is < 1700C. The main steam parameters should be maintained 30 kg/sq.cm and 350 deg C. However, according to the site conditions, we are able to achieve 40 Kg & 400 deg C. An average increase rate of metal temperature of MS line, ESV, Turbine chest and Turbine casing, should not to exceed given values as below. Metal temperature

increase rate of metal temp. Deg.c/min.

100 deg C to 200 deg C

4.0

200 deg C to 300 deg C

3.0

300 deg C to 400 deg C

2.0

400 deg C to 500 deg C

1.0

500 deg C to 515 deg C

0.6

The maximum increase rate of metal temperature of the ms connecting pipe should not exceed 15deg.c/min. 22

I. Ensure the following: No line clearance is pending on TG set. Boiler is steaming and steam is available. All TG interlocks and protections are checked and checking of all motor operated valves, Pneumatic Operated control valves closing and opening is completed. TG instrumentation / annunciation system is OK. Root valves to transmitter lines are in open Position. DC supply is healthy for EOP and trail run was taken. MOT level is normal. Overhead tank level is normal. Auto start of EOP, COP - 1&2, AOP, are checked. II. Carry out related operations and ensure the following AOP&JOP are running as per the procedure. COP is running as per the procedure. EOP is selected in standby mode on the Governor . Oil flow is normal through the bearings (observe from sight glass). Circulating water is charged in condenser and ACW pump and CW pumps are in service. TG is on Turning Gear Operation as per the procedure. During cold start up, Turbine should be kept in TGM operation 2 hours prior to turbine rolling. Oil cooler is charged from cooling waterside to maintain oil temperature 45 +/- 5 deg C. Ensure ACW to Generator air coolers line valves are in open position. Condenser hot well level is normal and CEP is running through Main Ejector and 23

GSC. Main steam line is charged up to MSV (T). Start vacuum pulling as per the procedure. Check the set pressure of sealing steam (PIC 107) is 0.1 to 0.2Kg/Sq.Cm (g) then open the sealing Steam HOV. After attaining 0.5 Kg/Sq.Cm (a) pressure in condenser, open the drains in extraction lines to remove the Condensate in the pipelines. Ensure the following drains are open Drain before MSV (T). Drain valves in extraction before check valves lines. Isolate the Steam traps of ESV, Turbine Casing and Turbine Chest. Turbine casing drain (Wheel chamber) through Steam trap by. ESV drain through Steam trap by. HP governor chest drain through Steam trap by. Ensure all extraction check valves and MOVs are in closed position. Meanwhile, attain condenser vacuum to -0.9 Kg/Sq.cm (g). Check and record the following Turbovisory readings: Rotor axial displacement Thermal expansion (Local measurement) Turbine, Reduction Gear and Generator rotor vibrations Turbine speed MOT level Lube oil pressure and temperature All bearing temperatures Casing metal temperature MS pressure and temperature 24

Gland steam pressure and temperature Condenser vacuum PRDS pressure and temperature Ensure main steam line is warmed upto MSV (T), then open MSV (T) by valve (H.O.V) and open the drains in MS line and ESV body slowly. (Ensure ESV is in closed condition before doing the above). After warming up ESV body, ensure that no Turbine protection is active (from ‘ Turbine Protection’ graphic) and then give “RESET ON” command from DCS. This will reset all the protections. Reset fault signals by pressing “ Governor Clear” button on TGP. Check lube oil pressure, trip oil pressure, control oil pressure and lube oil temperatures. Check the auto-standby position of COP, & EOP. Open the ESV by pressing the “Turbine Reset” button on TGP. Check the open feed back on TGP and warm up the chest at least 20 min. This is tentative, ensure the chest drain temp. is equal to the MS metal temp. Ensure the Hotness of ESV and Turbine Chest drains. Check AOP & Turning Gear are in service and selected in auto. Open the MSV (T) before going to roll the turbine. Start the Turbine rolling by pressing the “START” button on TGP. The governor will accelerate the speed of the turbo generator and hold it at idle speed 750 rpm. During the speed rise, check for Turning gear motor stop at the set rpm (> 10% of rated rpm). Ensure the Hotness of Turbine Casing drain. Observe the exhaust hood temperature . Observe all the Turbovisory readings. (Mentioned earlier). Feel and listen for any rubbing and abnormal noises during warm up. Check and record the shaft vibrations and axial displacement monitor on TGP. Check whether the turbine casing expansion has started and its pointer is moving on 25

local scale, near turbine front bearing. After ensuring expansion by 1.0 to 1.5mm, Press the “RATED SPEED” button on TGP. The governor will accelerate the speed of the turbine generator automatically to 4897 rpm. Observe for the bearing vibrations in the Critical speed range from 1650 – 2050 rpm. Check AOP are stopped at > 95%(4650 rpm) respectively. Start the CT fans before synchronizing the generator as for the procedure. Synchronize the generator with the GRID as per the procedure. Increase the load on generator to 3 MW. Close all the MS drains. Gradually increase the load (not more than 1.0mw/min) by means of “SPEED/LOAD SETTING” lever on TGP or Generator control . At 6.0 MW load, operator can select for load control when connected with grid. Steam traps of ESV, Turbine Casing, Turbine Chest drains should be kept in service and close the by valves. Ensure the Steam traps are working or not. If they are not working open the by valve slightly. Gradually increase the load as per the “loading procedure”. After paralleling with both the boilers gradually increase the load to 30MW as per the procedure.

26

Warm start up and Hot start up Turbine start up is termed as “Warm startup” if it is being started 3 to 4 hours after trip of turbine. Turbine start up is termed as “Hot Startup” if it is being started with in 2 hours after trip of the turbine. Follow the procedure for the cold startup upto speed up to idle speed (i.e 750 rpm). After reaching 750 rpm, allow the machine for soaking at the idle speed. Ensure that casing expansion has started from local scale during soaking than previous condition. After ensuring that casing expansion has started, then give command for Rated Speed. MS temperature should be maintained 50 0C more than MS skin / MS temp.at Turbine inlet. (Subjected to operating temperature – 530 0C at Turbine inlet.)

For warm and hot startup following parameters can be maintained. If the metal temperatures are

inlet steam parameters must be

300deg.c (warm)

40kg/sq cm and 400 deg.c

350deg.c

50kg/sq cm and 450 deg.c

400deg.c

65kg/sq cm and 480 deg.c

450deg.c

75kg/sq cm and 500 deg.c

During any start of turbine, do not forget to open all the Turbine drains. VII. Loading of Turbine: After synchronizing the turbo generator with grid the minimum load to be maintained is 4MW. Check all Turbovisory instrument readings are normal. Check rise of turbine casing metal temperature and its casing expansion. Ensure smooth running of Turbine. Raise the load at 0.5MW increment (1.0mw/min) by observing MS pressure and 27

temperature at turbine inlet. At above 6 MW load take Generator ‘Automatic Power control’ in to service. At 8MW stable load charge the Deareator as per the procedure. At 12 MW stable load charge the HP heater as per the procedure.

IX. Planned and Emergency Shutdown of Turbine: Planned shut down: Reduce the load on TG gradually to 3 MW, by operating the load/ speed switch on G. When load is at 12 MW cut off HP Heater. When load is at 8 MW cut off Deaerator. Open generator breaker as per the procedure. Manually shut down the turbine (decelerate the turbine speed by pressing the “Remote Trip” button on TGP). Ensure the actuator, ESVand MSSV closes automatically. Ensure all extraction check valves and extraction motor operated valves (MOVs) got closed on interlock. Open all the Before QCVs drains. Close HP heater drip to deaerator & condenser control valves and LP heater drip to condenser. Open MS drains to atmosphere. Ensure COPs, AOP, JOPs, TGM turns to AUTO selection on interlock at 95% speed. Observe AOP to start in auto when lube oil header pressure drops to 0.87+/-0.2 Kg/Sq.Cm. pressure. 28

If it is not started, start the pump manually and observe discharge

Ensure TGM starts in auto at <10% speed with time delay of 150 seconds. If it is not started, engage the turning gear manually at “0” rpm of the turbine and start TGM from DCS. When the shut down period is less than 1.0 hour, maintain the vacuum in condenser. During this period, ensure that gland seal exhaust fans are in continuous service and the PRDS parameters should be reduced to 7.0kg/sq.cm & 150deg.c gradually i.e 5deg.c/min. When the shut down period is more than 1.0 hour, kill the vacuum in condenser by opening the vacuum break valve. Before opening the vacuum break valve, make sure that hand operated valve in gland sealing steam supply line is closed and isolate the Main ejector as per procedure. Before killing the vacuum close all the Before QCVs drains. 1. Stop COP as per the procedure. 2. Run the CW pump 2 hours. 3. Run the CEP in recirculation around 4 hours. 4. Run the GSC Exhaust fan around 4 hours. 5. The coasting down period of the turbine will be approximately 20 minutes. 6. Normal TGM operation period is 10 hours after trip of turbine as per SNM manual, as per SNM Engineer Instructions it is also a measurement of Casing Expansion should be <2 mm on local indicator but practically it is taking 14 to 20 hours to cool down the turbine casing, rotor and the bearings. 7. After cooling down period, stop TGM and run the AOP, OVE fans further 2 hours. 8. After ensuring the bearing Babbitt, oil inlet and drain oil temperature becomes near equal. Stop AOP, When AOP is stopped EOP will start in auto. Stop EOP from TGP. 9. Stop (OVEF) oil vapour fan. 29

Emergency Shut Down 1.

In case of emergency, the turbine can be stopped by either of the

following methods. ‘Remote trip’ button on TGP and G. ‘Manual trip cock’ lever from front bearing (i.e Hand Trip) Turbine trip from Desk push button. 02. For the Emergency shutdown due to abnormality of M/C or tripping of the TG on protection following steps are to be taken: Ensure ESV, MSV (T) are closed, all extraction MOVs, extraction check valves Ensure COPs, AOP, JOPs, TGM turns to AUTO selection on interlock. Ensure AOP has started on Lube oil pressure low interlock. Ensure TGM started in AUTO as per the interlock If required kill the vacuum as per the procedure. Continue AOP, TGM, GSC exhaust fan, OVE fan, CEP, CW pumps in service as per the procedure. 03. Follow the activities mentioned in the above “Planned Shutdown”.

WORK INSTRUCTIONS

30

X. Emergency conditions during Turbine Operation: The following emergency conditions may occur during Turbine operation. The turbine operator should always be ready to take correct decision and act as per the operating procedures. It is also necessary that he should know about the boilers loading status, Tie- feeders positions, import and export power details in his shift. a. b. c. d.

Total power failure Island mode operation Any one boiler trip DCS failure

a. Total power failure: During total power failure, there will be no power supply to the AC drives (BFP, CW & ACW pumps, CEPs, COPs, AOP, Turning Gear, Oil Vapor Exhaust Fans & GSC Exhaust Fans). BFP, CW & ACW pumps, CEP, COP, Oil Vapor Exhaust Fan & GSC Exhaust Fan will be tripped. Turbine will trip on heavy fault protection. In this case, the following operations are to be carried out by the Turbine desk operator: Inform to Turbine field operator about total power failure and subsequent operations to be carried out. Ensure ESV is closed and Extraction check valves are closed on interlock. If not, close them from DCS. Check EOP starts on interlock at < 0.62 Kg/Sq.Cm. If not, start EOP from TGP. Close the following control valves: Normal & Emer. Make up valves by observing the condenser level PRDS pressure control valve to isolate the ejectors and glands. PRDS temperature control valve LPH drip CV to Condenser. HPH drip CV to Condenser HPH drip CV to Deaerator Deaerator pressure control valve to depressurize the Deaerator. Close the Isolation valves in PRDS Pressure CV and Temperature CV. Close HOVs 31

in air and steam lines of Ejector from local. Close HO isolation valve in Gland sealing line. Close all drain valves connected to condenser. And open Vacuum break valve. After restoring the Emergency DG set power, close the following valves: All three extraction MOVs Main steam stop valve (Turbine) Discharge valve of BFP Start AOP after informing to Switchgear operator. Start JOP as per the procedure. After turbine reaches to <10% of rated RPM start TGM as per the procedure. Field Operator’s duty during total power failure: Close isolation valves of PRDS Pressure CV and Temperature CV. Close Main ejector air valves and steam valves. Ensure EOP is started and Lube oil pressure is normal. Close HOV in gland sealing line. Close discharge valves of CW pumps. Close all drains connected to condenser. Ensure turbine gland sealing steam pneumatic control valve is operating and gland steam pressure is normal (0.1 to 0.2Kg/Sq.Cm (g)). b. Island Mode Operation Unit turns to Island mode in the following cases: 1.

Sudden rise / drop in frequency

2.

Sudden drop in load

3.

Internal disturbance in LT / HT systems

4.

Mal operation / mal function.

The following procedure is to be followed: 32

Load drops / rises as per the FAP demand. The turbine rotor speed and MS pressure at turbine inlet will change. Maintain the Generator Frequency at 50HZ by changing the turbine speed from “load/speed change” lever from TGP. Ensure the steam being supplied from the Boiler is sufficient to generate the load on the turbine. If steam flow is less, MS pressure will drop. Ask shift engineer to decrease the load on FAP to the suitable limits. Observe the turbovisory readings like axial shift, all bearing vibrations, all bearing temperature and casing expansion for any change. Do not allow MS temp to fall sharply. LP heater levels, HP heater levels and Deareator pressure may disturb due to load fluctuations. Control the above parameters in manual mode. . DCS failure condition: Course of action for turbine desk operator and field operator, when total DCS CRT’s are not available. Obtain the instructions to run or to trip the unit from GM (PP)/ DGM (O&M)/ Manager (O) Procedure to be followed to run the unit All control loops work in auto. We do not have monitoring from CRT. All protections and interlocks may work. Ensure turbine load / MS pressure control remains in Auto mode. MS pressure, Turbine RPM, Governor valve actuator position can be monitored from “WOOD WARD” system. Monitor and Control PRDS pressure and temperature from local. Condenser level should be monitored from local gauge glass. Deaerator level has to be monitored from local gauge glass. CEP discharge pressure should be observed form local pressure transmeter and gauge. 33

Observe HP, LP, Deareator extraction pressures from local pressure transmitters. LP, HP heater levels to be monitored from local gauge glass and level transmeter anadication. Observe lube oil pressure, governing oil pressure, trip oil pressure, MOT level, vacuum and Gland steam pressure local gauges/transmitters. Maintain the same load. Observe BFP parameters from local. Inform to Boiler operator to maintain constant feed water flow Procedure to be followed to trip the turbine: If any abnormality is found during this period trip the turbine as per the procedure given: Inform the Boiler operator about tripping. Trip the turbine from local hand trip lever or remote trip from TGP. Ensure ESV, all extraction check valves and extraction MOVs closed from TGP and local. Ensure AOP / JOP / TGM has started in sequence as per the interlock. If not start them as per procedure from MCC. If AOP has not started in AUTO, Start EOP from start push button on TGP. Isolate the PRDS station by closing the PRDS pressure CV and Temperature CV isolation hand operated valves. Isolate the Gland sealing line by closing the hand-operated valve in GS supply line. Close LP heater and HP heater drains to condenser CVs isolation valves. Continue AOP, COP, , TGM, OVEF, GSCEF, CEP, CW Pumps, ACW Pump to run. Stop the BFP after taking clearance from Boiler operator from local. (After box up of boiler) Run the CEP in complete Re-circulation. Cut off the lube oil coolers if necessary. 34

XI. Important Dos and DON’Ts during Turbine Operation: DOs: 1. The turbine has to be shutdown immediately in the following cases. 

When the turbine rotor speed increases higher than 5200

rpm. 

Whenever oil pipes, steam pipes, main condensate pipes,

feed water pipes are broken or some cracks / leaks are found in them. 

Whenever some hydraulic shocks are occurred in the piping

or in the turbine casings. 

Some metallic noise is heard clearly in the turbine



When the mechanical over speed lever is defective

2. The turbine is to be tripped emergently with breaking vacuum manually in the following cases:  When the lube oil header pressure drops to <0.45Kg/Sq.cm  When the oil catches fire and fire could not be extinguished immediately.  When the turbine tripped on “Rotor Axial Displacement” protection 3. DO in every shift:  Check Main oil tank level is normal.  Check oil vapour fan and GSC exhaust fan are in service.  Check the availability of DG set.  Check the availability of AOP, Stand by COP and DC EOP.  Check the open position of Discharge valves of AOP, EOP, standby COP.  Ensure the Steam traps of ESV, Turbine Casing and Turbine Chest drains are working normal.  Ensure condensate system and feed water systems are running normal  Ensure CW system is running normal 35

 Ensure Glands sealing steam control valve is functioning normally  Ensure the parameters of turbine and its auxiliaries are within the limits  Check the sealing water to Condenser connected valves are given  Check starting ejector air valve and vacuum break valve are tightly closed  Ensure that all instruments functioning properly  Ensure that standby ACW and stand by CEP discharge valves are in open position. DON’Ts 1. Do not operate the turbine, any equipment bying the interlocks 2. Do not operate the turbine with high vibration values and high bearing temperatures conditions 3. Do not allow sudden drop or rise in MS temperature and MS pressures. 4. Do not start the vacuum pulling with out turbine on Turning Gear operation 5. Do not start the Glands charging with out turbine on Turning Gear operation 6. Do not continue turbine on TGM operation if unusual sound / vibration comes from gland seal, bearings etc. 7. Do not operate the turbine with LOW main oil tank levels. 8. Do not start the TGM with out Over head oil tank level normal 9. Do not start the Turbine with out Over head oil tank level normal 10.Do not start the TGM with out running the AOP&JOP. 11.Do not run Lube oil system with out running the oil vapor exhaust fan. 12.Don’t run Oil vapor Exhaust Fan when MOT level is high. 13.Do not allow hot rotor to stand with out rolling (with out TGM operation) 14.Do not overlook abnormality in any important reading 15.Do not forget to check stand by position and healthiness of DC EOP 16.Do not allow any leakage in the suction side of the CEPs. 17.Do not start the CEP with out opening of Air removal and Gland sealing. 36

18.Do not open any valve, fitting, flange in the suction side of CEPs in normal working condition. When condenser is in vacuum this will cause vacuum to drop and pump (CEP) to loose its suction. 19.While cleaning suction strainer of stand by CEP, ensure closure of suction valve. 20.Do not keep the steam valve of main ejector open for long time if condensate flow is not there through main ejector. 21.Do not run the turbine with open or un tightened flanges on oil tank, oil piping, steam piping. etc. 22.Don’t charge the PRDS line without closing the Turbine Glands Isolation Valve. 23.Do not open the Vacuum break valve with out Isolating the Glands Isolation valve and Steam lines connected to Condenser.

BOILER FEED PUMP: In thermal power plant cycle the feed pumps are placed in the feed water system and are intended to deliver the feed water to the boiler. 100% availability of these pumps are essential to run the plant. This pump delivers feed water at higher pressure against boiler resistance, through feed control station. The feed control station regulates the feed water flow according to drum level. Two numbers of diff type boiler feed pumps supplied by KSP make, are installed here. The BFPs are rated to deliver each 150 cu.m/hr. feed water against a head of 1275 Mlc and is driven by 730 KW, 2980-rpm motor. */Technical Data/* Type of pump : Diff Feed water temperature : 158 Deg.C Flow rate : 166 TPH Developed head : 1285 Mlc Speed : 2980 rpm Net positive suction head : 5.8mlc Recirculation flow : 40 TPH 37

Direction of Rotation

: CCW from Motor DE.

STARTING OF BFP: Ensure no line clearance is pending on BFP, its auxiliaries and its connecting piping and valves. Ensure supply to the Motor is available. Ensure Deaerator level is normal and CEP is in service to maintain its level. Check the lube oil levels of pump DE & NDE bearings. Ensure ACW pump is in service. The inlet and outlet valves of ACW water to BFP should be in open position and check the ACW pressure at BFP is 2.5 Kg/ Sq.cm The following inlet and outlet valves should be in open position: a. Pump NDE side Thrust bearing housing Stuffing box Seal water cooler b. Pump DE side -

Journal bearing housing Stuffing box SSeal water cooler

Ensure the feed water system is through to HP Heater. Ensure open position of suction valve of BFP. Ensure discharge valve is in closed position. Check that hand-operated valves (2 nos) in balancing leak off line (one is at pump and another at Deareator tank) are in open position. Check the HOV in recirculation line (at Deareator tank) is in open position. Ensure all isolation valves in impulse lines are open. Ensure the local Push Button is released. Close the warm up valves for starting the pump. *Ensure that PRDS Attemperation is isolated from BFP discharge. Close the warm up. Start the Pump from DCS and keep the pump in recirculation for 2 minutes and observe the following: a. Suction & discharge pressures. b. Suction & discharge temperatures. c. Bearing temperatures. d. Seal water temperatures. e. Differential pressure across the suction strainer. f. Balancing leak off & re-circulation line pressures. g. Motor currents. 38

h. Any abnormal sounds. i. Lube oil levels in bearing cups. Open the discharge valve from control room DCS. Ensure balancing leak off pressure is higher than suction pressure. Observe the parameters in point no 16.

Shut down sequence: 1. Close the discharge valve. 2. Keep the Pump in re-circulation. 3. Stop the Pump from Control room. NOTE* 1. Observe Motor currents shouldn’t exceed >47 amps. 2. When the Motor currents have crossed 47 amps and tending to increase,

inform Shift In charge or Boiler Desk Operator. 3. Don’t allow the Pump to start or run with Protection interlock by. WHAT NOT TO DO: 1. Don’t close the valves in re-circulation and balancing leak off lines 2. Don’t allow the BFP to run when the bearing temperatures exceeds>80 deg. 3. Don’t run the Pump without ACW pump is in service. 4. Don’t allow the Pump to run when the seal water temp. Exceeds the limit. (>80 deg) 5. Don’t switch on the pump during discharge valve is in open position. STARTING PERMISSIVES: Ensure the following permissive at DCS & Local. 1. Discharge valve is in closed position. 2. Deaerator level is not low >900mm 3. DP across suction strainer is not high. PROTECTIONS FOR BFP: a. Deaerator level low

b. BFP suction pressure low (trip not incorporated). 39

: < 400mm.

c. DP across strainer high d. BFP Brg. temps high

e. DT across pump f. Discharge Pressure low g. Suction temp. Switch active h. Balancing leak Off pressure is high, i. ACW pump discharge pressure with time J. BFP motor winding temp.high high K. BFP motor bearing temp. high high

: : : : : :

> 0.5 Kg/Sq.cm. > 80 Deg C. 20 Deg C. < 105 kg/sq.cm 160 Deg C. >12.0 kg/sq.cm : < 2.0 Kg/Sq.cm

Delay of 15 sec. : 140 deg.c. : 95 deg.c

Note: For Point ‘f’, initial by of protection for a period of 70 seconds is incorporated. CW PUMPS 2 CW pumps (both working) are installed to supply cooling water to condenser. It is rated to deliver 6900 TPH, at 2.10Kg/Sq.cm and is driven by 415V, 550 KW, 740rpm motor. The cooling water pump receives its suction from CT Sump and discharge is returned to CT sump through Condenser and riser pipes. STARTING OF CW PUMPS: 1. Check no line clearance is pending on CW system. 2. Ensure LT supply to the Motor is available. 3. Ensure Sump level is normal. If low, make it normal with CT Sump Make up Pump. (Sump level is > 2800 mm) 4. Ensure CW to Condenser I/L and O/L valves and CT raiser valves are opened. (For one pump one CT riser valve, and for two pumps in operation two riser valves) 5. Open all the 4 air vents of Condenser Water box during initial starting of pump. Close them after air vented out 6. Open Air release cocks located above the Pump to ensure that the Pump is full of water. 7. Ensure Gland cooling water valves are open. 8. Ensure suction valve is opened and discharge valve is in closed position. 9. Release Local Push Button. 10. Start the Pump from DCS. 11. After speed pick up and restoration of normal currents, slowly open the discharge valve. 12. Observe the discharge pressure should be > 1.5 kg/sq.cm at pump. 13. Check the bearing & Glands temperatures Physically. 14. Observe the gland leakage water from Pump DE and NDE. 40

SHUT DOWN SEQUENCE: 1. Close the discharge valve. 2. Switch off the Motor. STARTING PERMISSIVES: 1. CW Sump level is > 2800 mm. PROTECTIONS: 1. Sump level low low. (Value not incorporated.) IMPORTANT NOTE: 1. Don’t start the Pump keeping Discharge valve in open position. 2. Maintain sump level between 2800 and 3000 mm. 3. When both the pumps are in service, ensure that at least two riser valves must be in open position. 4. Discharge valve of the stand by pump should be in closed position. 5. Don’t allow the pump to start or run with protection interlock by.

41

DESK OPERATORS GUIDE: The following are the Protections (Trip values) of the Turbine: 1. Steam temperature at turbine inlet high high > 543 Deg.C 2. Steam temp. at turbine inlet low low < 460degC, this protection comes in to service only when MS temperature reaches to 495 deg C and then falls to 460. 3. Steam pressure at turbine inlet low low < 60 kg/sq.cm (may be byed initially for Cold and Warm start ups if required.) 4.Steam pressure at turbine inlet high high >103kg/sq.cm (not incorporated). 5. Control oil pressure low low 8.0+/-0.5 Kg/sq.cm 6. Lube oil pressure low low < 0.62 Kg/Sq.cm 7. Generator heavy fault (Generator trip). 8. Turbine mechanical over speed trip >/= 5632 rpm 9. Turbine electrical over speed trip >/= 5583 rpm 10. Governor heavy fault. 11. Remote trip from turbine governor . 12. Turbine trip from desk push button. 13. Exhaust steam pressure high high > 1.3 Kg/Sq.cm (abs) 14. Exhaust steam Temperature high high > 150 degC 15. Lube oil reservoir level (MOT) low low < 350 mm. 16. Hot well level low low < 300mm 17. Hot well high high 1400 mm 18. Turbine Rotor axial shift high high +0.65, -0.65 mm. 19. Turbine front shaft vibration high high 90 microns 20. Turbine rear shaft vibration high high 90 microns 21. Reduction gear pinion front shaft vibration high high 140 microns 22. Reduction gear pinion rear shaft vibration high high 140 microns 23. Reduction gear wheel front shaft vibration high high 180 microns 42

24. Reduction gear wheel rear shaft vibration high high 180 microns 25. Generator front shaft vibration high high 160 microns 26. Generator rear shaft vibration high high 160 microns 27. Turbine thrust bearing temperature high high (inactive) 120 Deg.C 28. Turbine thrust bearing temperature high high (active) 120 Deg.C 29. Turbine front shaft bearing temperature high high 120 degC 30. Turbine rear shaft bearing temperature high high 120 degC 31. Reduction Gear pinion front bearing temperature high high 120 degC 32. Reduction Gear pinion rear bearing temperature high high 120 degC 33. Reduction Gear wheel front bearing temperature high high 120 degC 34. Reduction Gear wheel rear bearing temperature high high 120 degC 35. Generator front bearing temperature high high 85 degC 36. Generator rear bearing temperature high high 85 degC 37. HP heater level high high 290mm. (Protection should be byed during charging of HP heater.) not incorporated.

ANNEXURE-I, Turbo Generator Set - Alarms and Trip values S.N Tag No 01

TPT106

02

TTI800

03

TTI801

04

TTI802

05

TTI803 43

Description of Tag Nor Condensate System Exhaust steam press. (Vacuum) 0.086 Kg/Sq.cm (abs) CW Temperature at Cond I/L- 30 1 Deg.c CW Temperature at Cond O/L-38 1 Deg.c CW Temperature at Cond I/L- 30 2 Deg.c CW Temperature at Cond O/L-38 2 Deg.c

Lo

Hi

LL

HH/Trip

0.05 0.3

0.02

0.5/1.3

26

34

25

36

34

42

33

44

26

34

25

36

34

42

33

44

06 07 08 09 10 11 12 13 14 15 16

TTI106

Exhaust steam temperature Deg.c TLT300A Condenser Level mm

44 800

120

150/150

600

1000 300/30 1400/14 0 00 1650 1900 5300 4500 60003500 7000

TLT440 UCFT Level mm TDPT400 DP across Cond. Left mmwc A TDPT400 DP across Cond. Right mmwc 5300 4500 60003500 B TCV440A Emergency Makeup CV Feed FB back TCV440B Normal Makeup CV Feed back FB TCV300A CEP Recirculation CV Feed back FB TLCV430F Deareator level CV Feed back B TPT321 CEP Discharge Pressure 9.0 7.0 11 6.0 Kg/Sq.cm Hot well Temperature Deg.c 44 40 52 35

19

TDPT430 Main Condensate Flow TPH A

25

T480

7000

14.0 55

106

80

120 50

140

CW Header pressure Kg/Sq.cm 1.6

1.4

1.8

2.0

130

165 100

170/170

130

165 100

170/170

140

160 120

160

1.0

BFP & Feed water system 01 02 03

TTI470A FW temperature at BFP-1 158 Suction Deg.c TTI470B FW temperature at BFP-2 158 Suction Deg.c TTI471A FW temperature at BFP-1 Disch 158 44

04

TTI471B

05

TPT460

06

TPT470

07

TTI468A

08

TTI468B

09

TTI469A

10

TTI469B

11

TTI466A

12

TTI466B

13

TTI467A

14

TTI467B

15

TPT103

16

TTI103

17 TTI702A S.N Tag No

Deg.c FW temperature at BFP-2 Disch 158 Deg.c BFP-1 Discharge Pressure 120.5 Kg/Sq.cm BFP-2 Discharge Pressure 120.5 Kg/Sq.cm BFP-1 DE Bearing Temperature 60 Deg.c BFP-2 DE Bearing Temperature 60 Deg.c BFP-1 NDE Bearing 60 Temperature Deg.c BFP-2 NDE Bearing 60 Temperature Deg.c BFP-1 Motor DE Bearing Temp 70 Deg.c BFP-2 Motor DE Bearing Temp 70 Deg.c BFP-1 Motor NDE Bearing Temp 70 Deg.c BFP-2 Motor NDE Bearing Temp 70 Deg.c HPH Ext. Steam pressure 20.5 Kg/Sq.cm HPH Ext. Steam temperature 337 Deg.c HPH Drain temperature Deg.c 154 Description of Tag Nor

140

160 120

110

135 105/10 140 5 135 105/10 140 5 70 80/80

110

70

80/80

70

80/80

70

80/80

90

80/95

90

80/95

90

80/95

90

80/95

18

22

15

300

350 280

360

140 Lo

165 120 Hi LL

180 HH/Trip 160 235 240/29 0 240/29 0

18 19 20

TTI704A FW temp at HPH I/L Deg.c TTI703A FW temp at HPH O/L Deg.c TLT420A HPH level –1 mm

158 220 180

135 190 170

155 120 225 180 220 160

21

TLT420B HPH level –2 mm

180

170

220 160

22

TCV420F HPH drain to Deareator CV B Feed Back TCV420B HPH drain to Condenser CV

23

45

160

25

26 27

Feed Back Deareator Extr Steam Pressure Kg/Sq.cm TTI104 Deareator Extraction Steam Temp Deg.c TPT430 Deareator Pressure Kg/Sq.cm TLT430A Deareator Level – 1 mm

28

TLT430B Deaerator Level – 2 mm

29

TLT430SE Deareator Level Selection mm 1350 650 L

24 25

FB TPT104

5.00

5.51

6

219

240

300

5.0 1150 650

5.5 6.0 1465 500/40 1665 0 1465 500/40 1665 0 1665 500/40 1865 0

1150 650

Main Steam/Aux./Gland steam sys 01

1PT001

02 03

TPT101 TTI101

04

TPT102

05

TTI1021

06 07

TPT164A TTI152A

08

TPT107

09 10 11

TTI108 TTI108 TTI1022

12

TTI1023

M S press at common header 90 Kg/Sq.cm Steam pressure at turbine I/L 90 Steam temperature at turbine 530 I/L Deg.c Steam pres aft turbine 1st stage 65 Kg/Sq.cm Steam temp after turbine 1st stage Deg.c PRDS Pressure Kg/Sq.cm 24 PRDS steam Temperature 370 Deg.c Gland steam Pressure 0.2 Kg/Sq.cm Gland steam temperature Deg.c400 Gland leak steam pressure Metal temp at turbine 1st stage 465 Deg.c Metal temp at turbine 1st stage 465 Deg.c Turbovisory

46

80

95

80 485

95 80 94/102 538 460/46 543/543 0 63 67

22 360

105

475

480

27 20 380 340

30 400

0.08 0.4 360

60/60

0.06

0.45

410 350

420

475

480

475

480

01

TLT500A Lube oil tank level mm

550

02

TPT531A Lube oil pressure to Bearings 1.5 Kg/Sq.cm 03 TTI510A Lube oil temp at cooler I/L 65 Deg.c 04 TTI511A Lube oil temp at cooler O/L 45 Deg.c 05 TPT530 Control oil Pressure Kg/Sq.cm 14 06 TTI804 ACW temp at I/L of oil cooler 30 Deg.c 07 TTI805 ACW temp at O/L of oil cooler-135 Deg.c 08 TTI806 ACW temp at O/L of oil cooler-235 Deg.c 09 TTI807 ACW temp at I/L of Gen cooler 30 Deg.c 10 TTI807A ACW temp at O/L of Gen 35 cooler-1 Deg.c 11 TTI807B ACW temp at O/L of Gen 35 cooler-1 Deg.c 12 TTI807C ACW temp at O/L of Gen 35 cooler-1 Deg.c 13 TTI807D ACW temp at O/L of Gen 35 cooler-1 Deg.c 14 TSE2011 Turbine Seed rated rpm 4900 Turbine Seed 16% rpm 816 Turbine Seed 95% rpm 4650 S.N Tag No Description of Tag Nor 15 TZE2011 Axial shift mm 0 16

TZE2012 Axial shift mm

17

TTI201

18

TTI202 47

0

Turbine bearing temperature – 60 1 Deg.c Turbine bearing temperature – 60

400

800 350/35 870 0 1.17 1.7 0.62/0. 2.0 62 40 70 30 75 40

50

30

55

12 25

34

10 20

17 36

27

39

25

42

27

39

25

42

25

34

20

36

30

39

25

41

30

39

25

41

30

39

25

41

30

39

25

41

4700 5338 4652

5632

Lo Hi LL/Tri HH/Trip -0.45 0.45 -0.65 0.65/0. 65 -0.45 0.45 -0.65 0.65/0. 65 110 120/120 110

120/120

19

TTI203

20

TTI204

21

TTI205

22

TTI206

23

TTI207

24

TTI208

25

TTI209

26

TTI210

27

TVXT201

28

TVYT201

29

TVXT202

30

TVYT202

31

TVXT203

32

TVYT203

33

TVXT204

34

TVYT204

35

TVXT205

36

TVYT205

37

TVXT206 48

2 Deg.c Turbine bearing temperature – 60 3 Deg.c Turbine bearing temperature – 60 4 Deg.c R/G pinion front bearing temp1 Deg.c R/G pinion rear bearing temp-2 Deg.c R/G wheel front bearing temp-3 Deg.c R/G wheel rear bearing temp-4 Deg.c Generator front bearing temp-1 Deg.c Generator rear bearing temp-2 Deg.c Turbine front shaft vib, Horizontal microns Turbine front shaft vibr, Vertical microns Turbine rear shaft vibr, Hor microns Turbine rear shaft vibr, Vertical microns RG pinion front shaft vibr, Hor microns RG pinion frt shaft vibr, Vertical microns RG pinion rear shaft vibr, Hor microns RG pinion rear shaft vibr, Vert microns RG wheel front shaft vibr, Hor microns RG wheel front shaft vibr, Vert microns RG wheel rear shaft vibr, Hori microns

110

120/120

110

120/120

100

120/120

100

120/120

100

120/120

100

120/120

75

85/85

75

85/85

45

90/90

45

90/90

45

90/90

45

90/90

96

140/140

96

140/140

96

140/140

96

140/140

120

180/180

120

180/180

120

180/180

38 39 40 41 42 43 44 45 46 47 48

TVYT206 RG wheel rear shaft vibr, Vert microns TVXT207 Generator front shaft vibr hor microns TVYT207 Generator front shaft vibr Vert microns TVXT208 Generator Rear shaft vibr hor microns TVYT208 Generator Rear shaft vibr vert microns TTI254 Gen cold air temp TTI255 Gen cold air temp TTI256 Gen hot air temp TTI251 Gen Winding temp-1 TTI252 Gen Winding temp-2 TTI253 Gen Winding temp-3 Currents / Winding Temperatures

CCT626A CW Pump – 1 Motor current, Amp 02 CCT626B CW Pump – 2 Motor current Amp 03 CCT626C CW Pump – 3 Motor current Amp 06 CCT625A CT Fan-1 Motor current Amp 07 CCT625B CT Fan-2 Motor current Amp 08 CCT625C CT Fan-3 Motor current Amp 09 CCT670 BFP-1 Motor current Amp 10 CCT671 BFP-2 Motor current Amp 11 CEP motor current Amp 12 AOP motor current Amp 13 COP motor current Amp 14 JOP motor current Amp 15 EOP motor current Amp S.N Tag No Description of Tag 16 OVEF motor current, Amp 17 GSCEF motor current Amp 18 TGM motor current Amp

50 50 77 100 100 100

80 80 80

120

180/180

100

160/160

100

160/160

100

160/160

100

160/160

110 70 110 70 110 70

120 120 120

01

49

Nor

Lo

Hi

LL/Tri HH/Trip

19 20 21 22 23 24 25 26 27 28 29 30

TTI460A BFP-1 Deg.c TTI460B BFP-2 Deg.c TTI461A BFP-1 Deg.c TTI461B BFP-2 Deg.c TTI462A BFP-1 Deg.c TTI462B BFP-2 Deg.c TTI463A BFP-1 Deg.c TTI463B BFP-2 Deg.c TTI464A BFP-1 Deg.c TTI464B BFP-2 Deg.c TTI465A BFP-1 Deg.c TTI465B BFP-2 Deg.c

50

Winding temperature-1

95

140

110

Winding temperature-1

95

140

110

Winding temperature-2

95

140

110

Winding temperature-2

95

140

110

Winding temperature-3

95

140

110

Winding temperature-3

95

140

110

Winding temperature-4

95

140

110

Winding temperature-4

95

140

110

Winding temperature-5

95

140

110

Winding temperature-5

95

140

110

Winding temperature-6

95

140

110

Winding temperature-6

95

140

110

COMMUNICATION To avoid communication gap among all the power plant staff the following stationary to be maintained in addition to the walke talkies and phanes. 1. Line Clearance form for safety. 2. complaint to enter abnormalities. 3. Instructions . 4. Log sheets for each field. 5. Log books for each field. 6. Running hours log book. 7. Coal & bagasse stock log book. 8. Coal & ash analysis log sheets. 9. Daily Generation & consumption log sheets & log books. 10. Water and steam analysis log sheets. Line Clearance form for safety: Before doing any work on running or stanby equipments in running or in shut down the respective maintenance persons should take the Line Clearence from the shift in charge/engineer. The shift in charge/engineer should understand the work to be carried out. If he feels the work can be caried out with out disturbing the running of the plant then he should in form the line or equipment to be Isolated to the concerned field operator. After the isolating the equipment/line the field operator will sign on the line clearence form. After ensuring the line /equipment isolated the shift in charge/engineer con give Line Clearence to carryout the work to concerned maintenance department. Before starting the work the maintenance person should ensure that the 51

field operator & shift in charge/ engineer signed on the L.C form and the equipment is isolated. After completion of the work the maintenance persons has to return the L.C. The concerned operator should keep the equipment ready for operation. The same is to be ensured by shift in charge/engineer. If needed the trail run of the equipment/line to be carried out in presence of shift in charge/engineer & maintenance person. complaint to enter abnormalities: If any abnormalities observed in the system/equipment concerned operator should bring to the notice of shift in charge/ engineer. The shift in charge/engineer should check the equipment/system parameters and the abnormality to be ed in the complaint and inform to the concerned department. If the abnormality is emergency then the maintenance people should be called immediately and the same is to be informed to C.M.(O&M). Instructions : If any special instructions in operations of any equipment/system the same is to be entered in the Instruction by the maintenance depart and the instruction to be duly signed by the C.M(O&M). The instruction should contain the reasons for the specialty and the valid period. Log sheets for each field: Each field operator and desk operator should enter the parameters periodically in the log sheet. The log sheet should be duly signed by the shift in charge in each shift. Log books for each field: 52

Each field operator and desk operator should enter all the events in the log book with time. The log books should be duly signed by the shift inc harge in each shift. Running hours log book: Every day in the C shift the shift in charge should enter the day running hours of every equipment in the . Coal & bagasse stock log book: All the coal & bagasse receipts and consumptions to be entered in this log book shift wise by the shift in charge/engineer and available stock to be evaluated daily. Coal & ash analysis log sheets: The log sheets to be filled daily wise by quality control department and to be sent to shift in charge. Daily Generation & consumption log sheets & log books: Daily in 1st shift the consumptions of all the equipments to be recorded for the previous day. The previous day total generation, total auxiliary consumption, PLF, average frequency and percentage of auxiliary consumption to be recorded. The reasons for any change in the generation & consumption also to be recorded. Water and steam analysis log sheets: The DM plant chemist should enter the periodical water and steam analysis in the log sheets and the duly signed log sheets to be sent to shift in charge for reference and recording.

53

54