POWER PLANT EMERGENCY
Every power plant generation unit or station tried to supply quality and reliable power to grid or customer. So after commercialization of unit, the operation engineers responsibility increased manifold not only providing the quality and reliable power supply but also safety of all running equipments and unit. Operation engineers familiarized with problems and emergencies. Familiarization of all emergency is needed, some problems can be solved easily without losing generation. But some unforeseen incidents occurred in power plant. It requires immediate appropriate action to solve problem to avoid any generation loss or any damage to equipment. So, there are different type of emergencies 1. Boiler emergencies 2. Turbine emergencies 3. Generator emergencies 4. Electrical emergencies ( SWGR) 5. Grid failure. 6. Unit emergencies
Unit emergencies:1. CW P/Ps tripped 2. Compressor tripped 3. Heavy lkg in DM make up line 4. Any major fire in oil system of TDBFP /Main TG etc 5. Failure of work station 6. Loss of 220 V DC 7. Loss of 24V TG 8. Loss of 24V SG 9. UPS failure 10. 11 KV SWGR dead 11. 3.3 KV SWGR dead 12. USS/Unit Emergency SWGR dead
CW P/P tripped
Unit/ Station condition All units running with 500 MW 4 CW P/Ps are running I/C V/Vs are opened Case-1 : One CW P/P tripped Consequence:suction pressure low to ACW P/P Low flow through Condenser -A/B Temp may rise of TG PHE O/L results increasing oil/Brg temp, seal oil temp, Action: Start stand by pump immediately Observe all parameters
Case-2 : One CW P/P tripped and stand by p/p failed to start CW P/P-3B/3C tripped due to dead of 3UB bus CW P/P-3B/3C tripped due to dead of 3UB bus and another p/p fails to start or under PTW
Consequence:Suction pressure low to ACW P/P Low flow through Condenser -A/B Temp may rise of TG PHE O/L results increasing oil/Brg temp, seal oil temp, Action: Start stand by CW P/P
Reduce unit load around 300 MW Observe condenser vacuum and all Brg and oil temp If necessary, throttled TGPHE ACW side v/v to avoid ACW P/P tripping If tripping of any unit due to temp like seal oil or PW etc, Close the
DM Water System Unit/ Station condition All units running with 500 MW Avg make up around 25-30 T/H to hot well ECW tank make lined from DM Normal/emergency make up lined up Case-1 Leakage in DM header ( DM make up system isolation required) Consequence: Hindrance to DM make up to units wastage of DM water Action: Take DM water make up to ECW O/H tank in all units Take up make up in Hotwell and DA and maintain above normal level Start emergency make up system and check /ensure flow to Hotwell
Isolate all units of Hotwell normal make V/v tp avoid air ingress Stop soot blowing of all units for that time Inform chemsitry SCE for not taking DM for U regenartion
Compressor- Instrument air system Unit/ Station condition All units running with 500 MW All Compressors are running I/C V/Vs are opened 10% at stage one end and full opened at stage-II end. Power Source of Compressor- Unit-3 (IAC-1,3,5, PAC-1) Unit-4( IAC-2,PAC-4) Unit-5( IAC-4,PAC-3,5) Unit-6( PAC-2,6) Cooling water sources:- IAC-1-5 and PAC-1-4 from all units and IAC-1-5 and PAC-1-4 from unit-5/6 ( stand by) PAC-5,6 from unit 5 and 6
Case-1 Few IAC tripped due to some protection leads to maintain low header pressure Consequence:
SL.NO
NTPC TAG 1CD-67 SD-62
SERVICE
ACTION
COND SPRAY TO HDFT
MODULATING
BCW LP DRAI MANIF DRAIN V/V
ON/OFF
2DR-18
HPH-5A DRAIN TO HPFT CV
3DR-25
HPH-5B DRAIN TO HPFT CV
4DR-5
HPH-6A DRAIN TO HPFT CV
5DR-11
HPH-6B DRAIN TO HPFT CV
6DR-31
LPH-3 DRAIN TO LPFT C/V
7DM-1
DM N M UP TO HOTWELL C/V
8DR-15
HPH-5A DRAIN TO D/A CV
9DR-22
HPH-5B DRAIN TO D/A CV
AIR TO CLOSE AIR TO CLOSE MODULATING
AIR TO OPEN MODULATING
10DR-28
LPH-3 DRAIN TO LPH-2 C/V
11DMCW-90
ECW PUMP(SG) I/O HDR DP C/V
SD-61 12
BCW ECW LINE INLETV/V
SD-62 13
BCW LP DRAI MANIF DRAIN V/V
DR-37 14
LPH-2 DRAIN TO LPFT C/V
MODULATING
DR-48 15
D/A OVERFLOW LPDFT
ON/OFF
CD-10 16
CEP-A M/N R/C C/V
CD-12 17
CEP-B M/N R/C C/V
CD-14 18
CEP-C M/N R/C C/V
CD-39 19
GSC M/N R/C C/V
CD-43 20
HOTWELL SPILL LVL C/V
DR-2 21
HPH-6A DRAIN TO HPH-5A CV
DR-8 22
HPH-6B DRAIN TO HPH-5B CV
DR-34 23
LPH-2 DRAIN TO LPH-1 C/V
DM-2 24
DM E M UP TO HOTWELL C/V
SD45 25
SH SPRAY C/V LEFT
SD44 26
SH SPRAY C/V LEFT
SD46 27
SH SPRAY C/V RIGHT
SD47 28
SH SPRAY C/V RIGHT
AS-8 33
AUX STEAM TO D/A C/V
MODULATING
FD14 29
LOW LOAD FEED C/V
MODULATING
CD-22 30
D/A LVL C/V MAIN
CD-25 31
D/A LVL C/V STANDBY
DMCW-100 32
ECW PUMP(TG) I/O HDR DP C/V
CRH-6 34
CRH STEAM TO D/A C/V
MODULATING
35CD-72
GLAND SEALING C/V
MODULATING
36SD-43
SH SPRAY BLOCK V/V
ON/OFF
SD-48
RH SPRAY BLOCK V/V
AIR TO OPEN
AIR TO OPEN ON/OFF
AIR TO OPEN AIR TO OPEN
MODULATING
AIR TO CLOSE AIR TO CLOSE
AIR TO CLOSE
AIR TO CLOSE
MODULATING AIR TO OPEN AIR TO OPEN Air to Open MODULATING
Air to Open Air to Open Air to Open
Air to Open MODULATING
Air to Open Air to Open
ON/OFF
Air to Open
Air to Open
An emergency power system/ stand by is an independent power generation system that is legally required to feed equipment or systems whose failure may present a life safety hazard to persons or property.
FAILURE OF UPS
AC supply ,USS
DC
AC
AC
DC
(Rectifier)
( Inverter)
(Inverter)
(Rectifier)
LOAD
Battery Bank By AC supply USS
By AC supply EMCC
AC supply EMCC
ADB-01 (CCR)
ADB-02 (CCR)
PAH-B AIR MOTOR BMCC 3.3R 2.2R
ADB-03 (PRGMR ROOM)
SAH-A AIR MOTOR BMCC 2.4R
ADB-04(U)
SAH-B AIR MOTOR BMCC 4.3R
ADB-05 C&I-MAINT
VMS-II CER
ADB-06 CHIMNEY
SG/TG MMI WS POSE CAB
BHEL PDB-1 MTM
BOILER FLAME SENSING SYSTEM
BHEL PDB-2 MTM
ACCOUSTIC PYROMETER
BHEL PDB-4 AIR HEATER
BLR MAIN WORK STATION
SWAS
BPOS
PA SYS 01
VIB ANALYSER
PA SYS 02
GCC02 SEAL OIL ISNT CAB
VMS-CER
GCC03 STATOR WATER INST. CAB
MASTER CLOCK CER ADB-11 BNKR LVL PAH-A AIR MOTOR BMCC
STATOR END WNDG VIB SYS
ADB-21 HPH LVL SW
VFD C&I ID-A
ADB-22 LPH LVL SW
VFD C&I ID-B
ADB-23 D/A LVL SW
TUBE LIFE ASSESMENT SYSTEM
ADB-24 HOTWELL LVL SW
CJJ13 MARSHELLING
BHEL PDB-3 BCW P/P
TSI FOR BFPDT 1&2
CWPNL VMS
TSC PC & PRNTR.
FLAME SCANER CJF-07
GAS ANALYSE
VAC. P/P -1
PDB FOR APRDS CJCB
SMART ACT. STN (U#3 ONLY)
PARTIAL DISCH. MONITORING
MILL A TO E LVL SW ADB
MDBFP SCOOP KE3
MILL F TO K LVL SW ADB
ADB-19 BRNR TILT
MILL REJECT SYSTEM
Case-1
In case of any one channel failed to supply power, supply will get extend from the other source and alarm will come. No problem is envisaged. In case of both channel failed to supply, then direct sources ( unregulated 415V AC Power) comes in service, no immediate problem will occur but regular supply has to be restored as soon as possible.
Case-2 If there is total failure of power supply from UPS, the following events will happen All BFP will get trip on “ D/A level-Low” since supply of DA Lvl switch from UPS Boiler will trip on “ All BFP OFF” from FSSS ( SG 24V source) Turbine will trip on MFT of boiler and generator will trip on Low Forward Power ID fans will trip due to loss of supply from UPS to VFD, FD fans will trip on interlock Mills and PA fan will trip on MFT No command will be executed from MMI and parameters will not be available for
BHEL CRT, For DDCMIS, HMI/LVS screens will be available for 30 mins Vertical s will be available for operation. Turbine lube oil pumps. Seal oil pumps, barring gear will be available HP/Lp by will be available for operation TSI parameters will not available.
Action Ensure by checking at local, Main TG, TDBFP lube oil pumps, seal oil pumps, air pre heater motors, scanner air fans etc are in service. And check barring gear v/v opened. Inform C & I and EMD ( battery and Charger group) for rectification.SCE/DGM/AGM(O)
FIRE NEAR TG ON OF OIL LEAKAGE OR FIRE IN LUBE OIL SYSTEM/TDBFP/MAIN TG
CASUE
Oil lkg in pipe line, bearing etc Wet cotton which was used for cleaning purpose filter or bearing Above these, high temp of steam lkg and with bared high temp steam line.
ACTION
Oil fire spread very fast, so that machine should be stopped immediately Oil supply should be cut off, DC oil pump should kept off. Steam supply should be cut off. Incase of towards , Main TG trip main TG, H2 purged out. Extinguish fire with help of available of fire extinguisher
Inform to fire station Inform HOD of OPRN/EMD/TMD Revise DC
Fire protection-1 Generator breaker OFF and Either MOT Lvl V Low or Fire protection PB(1/2) pressed Casue Opens the vacuum breaker on protection Stops the HPCF pumps Stops HPCF heater Stops HPCF recirculation pumps Trips the turbine
Fire protection-2 Either MOT Lvl V Low or Fire protection PB(2) pressed Cause Switch off the SGC oil supply program Stops AOP-1 on protection Auto off SLC AOP-1 Stops AOP-2 on protection Auto OFF SLC AOP-2 Auto On SLC EOP Auto OFF SLC jOPs Stops JOP-1 on protection Stops JOP-2 on protection Starts JOP-3 on protection Auto OFF SLC JOP-3 Auto OFF SLC turning gear Trips the turbine Opens the vacuum breaker on protection Stops the HPCF pumps Stops HPCF heater Stops HPCF recirculation pumps Trips the turbine
SL.NO
NTPC TAG 1CD-67 SD-62
SERVICE
ACTION
COND SPRAY TO HDFT
MODULATING
BCW LP DRAI MANIF DRAIN V/V
ON/OFF
2DR-18
HPH-5A DRAIN TO HPFT CV
3DR-25
HPH-5B DRAIN TO HPFT CV
4DR-5
HPH-6A DRAIN TO HPFT CV
5DR-11
HPH-6B DRAIN TO HPFT CV
6DR-31
LPH-3 DRAIN TO LPFT C/V
7DM-1
DM N M UP TO HOTWELL C/V
8DR-15
HPH-5A DRAIN TO D/A CV
9DR-22
HPH-5B DRAIN TO D/A CV
AIR TO CLOSE AIR TO CLOSE MODULATING
AIR TO OPEN MODULATING
10DR-28
LPH-3 DRAIN TO LPH-2 C/V
11DMCW-90
ECW PUMP(SG) I/O HDR DP C/V
SD-61 12
BCW ECW LINE INLETV/V
SD-62 13
BCW LP DRAI MANIF DRAIN V/V
DR-37 14
LPH-2 DRAIN TO LPFT C/V
MODULATING
DR-48 15
D/A OVERFLOW LPDFT
ON/OFF
CD-10 16
CEP-A M/N R/C C/V
CD-12 17
CEP-B M/N R/C C/V
CD-14 18
CEP-C M/N R/C C/V
CD-39 19
GSC M/N R/C C/V
CD-43 20
HOTWELL SPILL LVL C/V
DR-2 21
HPH-6A DRAIN TO HPH-5A CV
DR-8 22
HPH-6B DRAIN TO HPH-5B CV
DR-34 23
LPH-2 DRAIN TO LPH-1 C/V
DM-2 24
DM E M UP TO HOTWELL C/V
SD45 25
SH SPRAY C/V LEFT
SD44 26
SH SPRAY C/V LEFT
SD46 27
SH SPRAY C/V RIGHT
SD47 28
SH SPRAY C/V RIGHT
AS-8 33
AUX STEAM TO D/A C/V
MODULATING
FD14 29
LOW LOAD FEED C/V
MODULATING
CD-22 30
D/A LVL C/V MAIN
CD-25 31
D/A LVL C/V STANDBY
DMCW-100 32
ECW PUMP(TG) I/O HDR DP C/V
CRH-6 34
CRH STEAM TO D/A C/V
MODULATING
35CD-72
GLAND SEALING C/V
MODULATING
36SD-43
SH SPRAY BLOCK V/V
ON/OFF
SD-48
RH SPRAY BLOCK V/V
AIR TO OPEN
AIR TO OPEN ON/OFF
AIR TO OPEN AIR TO OPEN
MODULATING
AIR TO CLOSE AIR TO CLOSE
AIR TO CLOSE
AIR TO CLOSE
MODULATING AIR TO OPEN AIR TO OPEN Air to Open MODULATING
Air to Open Air to Open Air to Open
Air to Open MODULATING
Air to Open Air to Open
ON/OFF
Air to Open
Air to Open