TDBFP | Turbine | Oil Injection Test | 500 MW | BHEL | NTPC | Overspeed ...

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TDBFP Rolling | NTPC | BHEL | 500 MW | Rolling | Steps | Pump | Turbine |

Volumetric Vs Gravimetric Mode : Feeder

Volumetrric Vs Gravimetric Mode : Feeder

• Coal properties constantly vary due to sizing differences and the adverse impact of moisture. These affect heating value, flow characteristics and density.The resultant density changes are measured by the Gravimetric Feeder. 
•  The gravimetric feeder compensates for the variation in bulk density and feeds a fixed weight of coal in response to a boiler fuel demand
•  This ability to accurately weigh the coal provides significant improvement over volumetric types in terms of matching the fuel delivered by the feeder to the actual process energy required on coal fired units. 

Benefits of Gravimetric Feeder

• Fuel Savings through Improved Boiler Efficiency
• Improved Combustion Efficiency/LOI
• Less Slagging and Fouling, leading to Less Corrosion
• Less NOx through Better Control of Excess Air
• Stability and Improved Response of Combustion Controls
• Improved Pulverizer/Cyclone/Combustor Performance
• Reduced Safety Concerns

How It Works : Gravimetric Mode

• Gravimetric feeder weighs material on a belt between two fixed points (span) precisely located in the feeder body.
• A roller, located midway in the span and supported at each end by precision load cells, supports half the weight on the span
• The load cells generate an electrical signal directly proportional to the weight supported. 
•  The microprocessor takes samples of the output of each load cell many times a second. 
• If the load cell outputs are within the expected range, they are added to obtain total weight per unit of belt length. 
• Belt speed is determined by sampling the output of a tachometer attached to the motor shaft, multiplied by a calibration factor to convert it into a belt speed signal
• The microprocessor multiplies the speed and weight signal for the feeder rate of fuel output.
• Finally, the microprocessor matches the feeder output to the output required by the boiler control, by adjusting the feeder motor speed.
• Feeders provide an accuracy of +/- ½ of one percent of totalized weight when calibrated and maintained

Volumetric feeding

• Volumetric feeder is Open-loop device

• Volumetric mode is set-speed constant , choke-fed or flooded infeed of a particulate solid and it feeds by volume only.
• Feed must have consistent bulk density
• As there is no information on  feedback of feeder ouput and drive control system

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Controlled Fast Cooling Procedure

Controlled Fast Cooling Procedure

• Normally Rihand-II and III 500 MW units take 8-9 days to stop Barring
• Using CFCP, it takes roughy 75 Hours after Desynchronisation.
• It is done in 2 stages.
• First Stage: Unit Parameters Lowered By Reducing Load and steam Parameters.
• Second stage: After Desynchronisation, till 350 Deg( HP Casing Temp), it is to be cooled thru Natural Cooling. thereafter by Modulating HPCV and Vacuum( Forced Cooling) maintaining Drop rate 5-6 Deg/Hour.
• During this : Top/Bottom DT, Differential Expansions, Axial shift, Bearing Temperatures, Bearing & shaft Vibrations need to be Observed and Logged in the sheet and if any Deviation Found, should be rectified.And if these deviations are beyond rectification, then abort force Cooling.

Stage I : Parameters Reduction on Load:

• Ensure all Auto Loops and SLCs in service and MS Temp <480 deg to be bypassed in order to lower Temperature. (Desk, Control Desk, SCE  & C&I with Proper logging in Register).
• Start Parameters Reduction Before 6 Hours to shut-down
• First Reduce Load by 5% (25 MW of 500 MW), then stabilise Load and Steam parametrs.
• Then Reduce MS Set point to 525 Deg .( Rate of Reduction of MS Temp :1.5~3 Deg/min)
• Further Reduce Load by 25 MW and stabilise parameters, and after that reduce MS Temp to 515 Deg.(If SH Attemperation in Manual if not maintaning )
• Repeat Above steps, till 300 MW and HP Casing Temp 480 Deg.
• Check HP Exhaust Temp with HP Exhaust Pressure, it should be above Saturation Temp value.
• Do not reduce load and MS Temp together because of DE, Transient vibration, Lower Margin of TSE.
• Open all MAL drains, HP SV/CV, Extraction drains as there may be consensate caused during parameters reduction.
• After HP Casing temp reaches 480 Deg, Desynchronise Machine.
• Ensure AOP, JOP, Barring gear starts as per logic.
• Note down the Coasting down time from 3000 rpm to 510 rpm,210rpm,120 rpm.

Stage II : Controlled Fast Cooling of Turbine

After Depressurisation of Ms Line( Thr Pr=0ksc), Ensure BSVs and their IBVs are Closed & Isolated.

Ensure all MAL drains, Extraction NRV drains are Open as per SLC.

Ensure HP/LP Heaters Extraction Valves are closed and Alternative Drip valve OPEN.

Kill Vacuum and Isolate Seal steam and GSC Ex Fan in On condition for intial cooling.

Isolate Aux PRDS from Unit and Other Interconnection with other Units.

Ensure HPBP Spray v/v closed

CW charged, one CEP in service and monitor LP Exh Hood temp

In 24 Hours, HP casing Temp reduces to 350 Deg

Controlled Fast Cooling by admitting air :

Ensure Turbine on barring gear.All stop & control valve closed

Ensure Casing Temp reached 350 deg by natural cooling

Open air inlet sockets b/w main stop & control valve and cover opening thru mesh

Set Test valve of all stop valves in Closed Condition.

Open HP control v/v. IP CV remain closed using Test motor(closing test oil signal)

Ensure gland area is clean, Pull Vacuum without seal steam charging

Ensure all MAL valve Open & Their isolating manual valve Open, SLC drain OFF

Stop GSC Ext Fan, allow air to be sucked thru Socket and gland area

Maintain vacuum -0.2 ksc initially, monitor TSI, TSE(lower margin in limit)

Maintain 5-6 deg/hour Temp drop by  by regulating HP CVs and vacuum pump.

After 48 Hours, HP Casing temp drops to 110-125 Deg. from 350 Deg

If drop rate is less than 5 deg/hr increase vacuum -0.4ksc

at 110 deg, Stop Barring

Main turbine Vacuum Killing

Main turbine Vacuum Killing

• Ensure Boiler Stop Valves (MS01 & MS02 ) and its IBV ( MS03 , MS04 , MS05 & MS06 ) are in closed condition.
• Ensure all drains to UFT are opened & all drains to SDFT are closed
• Ensure complete de-pressurization of Main Steam line
• Ensure TDBFP common aux steam supply MOV or manual valve (At Aux PRDS Floor ) is in closed condition).
• Ensure MAW15AA001 (Seal steam supply bypass MOV) is in closed condition
• Close MAW10AA011 (Seal steam header Drain going to HPFT) & open its atmospheric drain
• Stop both vacuum pump & its recirculation pump.
• Open Vacuum Breaker. 
• At Vacuum –0.2 ksc , isolate seal steam to turbine by closing the Supply header Control valve & its isolation MOV ( MAW10AA010 ) .
• Stop GSC fan .Open the chimney valve if required.
• Close seal steam manual isolation valve (at 8.5 m).Close also main turbine seal steam motorized valve at  TG 17m
• After Vacuum killing , Main turbine speed is to be monitored . It should be around 65-80 RPM. If speed drops below 65 rpm inform TMD immediately.
• Deaerator & Hot well level is to be maintained at its normal value.

COLTCS OPERATION

COLTCS OPERATION
Filling the system with water

• Ensure that screens are in backwash position.
• Open manually operated isolating ball valves 2 no. each provided in ball extraction and ball injection pipe lines for filling the pipes and pump with water.
• Open vent valve of Ball collector vessel.
• When water flows out of the vent, close the vent valve.

Charging fresh balls in the system

• Ensure that Ball vessel inlet and outlet valves are close.
• Open vent valve of Ball vessel.
• Open drain valve of ball vessel till water level in ball vessel falls to 50%.
• Open hand hole of ball vessel
• Introduce & squeeze cleaning balls (Blue - 300) under water to remove air until the balls sink below surface of water.
• Close hand hole of ball vessel.
• Close vent valve when water starts flowing freely from the vent.

OPERATING PROCEDURE IN MANUAL MODE

• System is properly filled with water and completely vented.
• Ball vessel inlet and outlet valves are close.
• Screens are in ‘Operating Position’.(i.e Screen valves are in closed condition )
• Both C.W. pumps are running and there is adequate flow through the condenser.
• Differential Pressure across screens is < 30 mbar
• Start Ball Re-circulation pump from UCB
• Open Ball vessel inlet valve
• After 5 minutes of inlet valve opening, open ball vessel outlet valve.
• Run the system in operation mode for 60 mins (adjustable). After completion of 60 mins (adjustable), Run the sytem in collection mode (Open Ball vessel bypass valve & close ball vessel outlet valve). After this , the above process is to be repeated till 8 hr ( adjustable ).
• After 8 hr of continuous operation & collection mode , Run the system in Collection mode for 4 hr. Then it is to be put in backwash mode (2 no. outlet screen to be opened). Stop Ball recirculation pump. Ball counting is to be done jointly with TMD/OPN for checking effectiveness of screen.
• If at any point DP is greater than 30 mbar , Back wash mode to be operated immediately.

HPCF Fuller Earth Filter Charging

Purpose of Fuller Earth Filter:
Control fluid is used for 500 MW Turbine governing system. For smooth and trouble free
operation of turbine control valves in all conditions, chemical and mechanical properties of
control fluid is maintained always. Acidity of Control Fluid is to be maintained maximum of
0.1mg of KOH/gm of oil. To maintain this acidity, CF regeneration pump circulates oil through
fuller earth filter.Fuller Earth Filters are used for removal of acids and soluble surface acting
contaminants by adsorption. CF regeneration pump should run on continuous basis even if
Control fluid pump is in stopped condition & its heater should ON/OFF on interlock.

Control Fluid System consists of three numbers of filters:
a) Dry Filter: It will remove dirt & water from filter.
b) Fuller Earth Filter: It is used for neutralization of acidity.
c) Fine Filter: It retains the finest particle of the dirt , both metallic & non-metallic impurities.

Procedure of Isolation of Fuller Earth Filter:
Isolation of fuller earth is required whenever FRF acidity exceeds maximum permissible limit for replacement of filter OR Contamination of the Filter (Filter DP High).Following procedure is to be followed for isolation of filters.
 Open common bypass valve of all filters going to CF tank.
 Isolate all filters by closing inlet and outlet valves.
 Drain individual filters by opening drain line. All drain lines will go to DPT.
 Line up of Suction of CF regeneration pump to be changed to DPT from CF tank , for
transfer of oil to CF tank.
 Observe rise in CF tank level during transfer of oil from DPT.
 After Complete draining of Filter , PTW to be issued to Turbine Maintenance.

CEP ISOLATION / NORMALIZATION PROCEDURE

CEP ISOLATION PROCEDURE

• If CEP is in stopped condition , remove from stand by mode .Close discharge valve & its IBV
• If CEP is running , stop it .Close discharge valve & its IBV
• Ensure Electrical isolation: CEP Motor, Discharge MOV including IBV
• Ensure its discharge MOV & its IBV are in closed condition.
• Close pneumatic Re-circulation control valve & its manual isolating valve.
• Ensure Suction line Relief manual valve is in open condition
• Close manual suction valve
• Close discharge vent manual valve & its solenoid valve
• Close both source of seal water manual valve. Ensure seal water pressure gauge is showing zero & observe vacuum
• Close Canister vent manual valve
• Close ECW cooling inlet and outlet valve to CEP thrust bearing oil cooler jacket if required
• Open Suction strainer vent valve & Ensure no air is sucking from it. If air is sucking ,close this vent & tighten the valve (mention in S.no. 5 ,7, 8 & 10 )
• Issue the permit

CEP NORMALISATION PROCEDURE

• Ensure drain & vent of suction strainer are in closed condition
• Open ECW cooling inlet and outlet valve to CEP thrust bearing oil cooler jacket.
• Ensure Suction line Relief manual valve is in open condition.
• Open Canister vent manual valve & Observe vacuum.
• Open seal water valve going to CEP mechanical seal &
• Note down Pressure in LIR Panel.
• Open suction manual valve
• Open recirculation isolation manual valve. Pneumatic recirculation control valve operation to be checked before starting the CEP. Keep control valve in full open condition.
• Open Discharge vent manual valve & open its solenoid valve
• Restore supply of CEP & its discharge MOV including IBV.
• Release EPB & Start CEP for trial run

BCW Fill & Purge

BCW Fill & Purge

ISOLATION OF CC PUMP

• Remove from Stand by mode if it is in auto
• 1.2 Stop CC pump if running
• Isolate it Electrically
• Close both discharge valve of CC pump if boiler is to be drained.

If Work is to be carried out in Motor Cooling Water Circuit

• Isolate the inlet & outlet manual valve of LP cooler
• Ensure the water flowmeter reading of LP coolercooler shows zero value.

If Work is to be carried out in Pump or in High Pressure line

• Ensure the Unit is under Shutdown
• Ensure that the Suction Manifold temp. is less than 100 deg C.
• Close both discharge valve of all CC pumps.
• Drain the Boiler
• Open the pump casing vent of all CC pumps.
• After water stops coming from all pump casing vent, then open the pump casing drain.
• Ensure that the cavity is completely drained.

CC PUMP FILL PURGE

• Ensure the following :

1. Electrical Isolation of CC pump
2. Both Discharge valve closed
3. Boiler is in drained condition.

• Ensure both manual valves (just before entering pump cavity ) for filling pump cavity are in close condition so that water does not enter pump cavity.
• Ensure DM Make up pump is running.
• Open the basket strainer drain
• Ensure the supply valve from BFP discharge is close and open the supply valve from DM make up pump to basket strainer.
• Flushing is to be carried out from basket strainer drain until clean water starts coming out.
• Open the fine filter drain valve& close the basket strainer drain valve
• Line Flushing to be carried out from fine filter drain valve until clean water starts coming out
• Open the final drain valve just before entering BCW pump cavity& close the fine filter drain valve.
• Line Flushing is to be carried out from drain valve just before entering pump cavity until clean water starts coming out & conductivity is less than 1 μs/cm.
• Inform Chemistry to keep measuring conductivity of water on hourly basis until three consecutive readings of conductivity less than 1 μs/cm is achieved.
• Adjust the flow rate of water coming out of drain to 5 LPM after chemistry clearance. (After three consecutive reading , conductivity less than 1 μs/cm )
• Open the casing vent of all pumps & both the manual valves for cavity filling. Close the drain valve.
• When water starts coming out from pump casing vent, measure the conductivity of water.
• On Achieving three consecutive readings of conductivity less than 1 μs/cm, pump casing vent & cavity filling line manual valves are to be closed.
• Close main supply valve from DM make up pump (For Purge & filling)
• Inform EMD for Motor Meggering.Take Electrical Clearance before starting pump.
• Open Both discharge valves of CC pump after drum filling.
• Normalize cooling water isolation valves & note down the cooling water flow rate of LP & cooler.
• BCW pump can be started & observe its cavity temperature

BUNKER FIRE

BUNKER FIRE
PREVENTION OF BUNKER FIRE

 Ensure Feeder outlet gate closes on auto when Feeder stopped/tripped. Otherwise give
close command for closing.
 Ensure Feeder seal air valve closes on auto when Feeder stopped/tripped. Otherwise
give close command for closing.
 If any Mill was not running since 7 days , it has to be taken in service for minimum 8
hrs
 If any unit is going for annual O/H for one month , maximum number of Bunker has
to emptied & Bunker level have to be maintained at minimum level in rest of the
bunker.
No Welding works to be done at bunker top without CISF fire personnel.
 If red hot observed in any portion of Bunker , particular Mill has to be taken in service
immediately
 Bunker temperature is to be measured weekly once with temperature gun.If temp is
high , particular Mill has to be taken in service immediately

FIRE BROKE OUT IN BUNKER

 Call Fire personnel immediately.
 If fire/smoke observed from bunker , particular Mill has to be taken in service
immediately. Inform CHP to stop bunkering in it.Full Empty the bunker for
inspection.
 Fire water can be used for quenching from outside at fire/smoke point

Bottom Ash Deashing

Bottom Ash Deashing

• Ensure ash slurry sump level is less than 5 m.
• Ensure ash water sump level is adequate.
• Ensure oil converter tank level is adequate (50 %).
• Check availability of power supply to local control panel.
• Select the clinker grinder and open corresponding discharge valve from local control panel.
• Open the hydro ejector inlet valve of selected clinker grinder from OWS.
• Start BAHP and ensure header pressure of 6.0 kg/cm2.
• Ensure seal water pressure to clinker grinder is > 1.5 kg/cm2.
• Open air & oil valves of oil & air converter tank to operate BAH gate.
• Stop BAH filling.
• Release EPBs of selected clinker grinder.
• Observe BAH temperatures during de ashing process

OPERATING PROCEDURE:

• Check BAHP is running.
• Start the selected clinker grinder & check running status on local control panel.
• Flush clinker grinder for 5 minutes in reverse run and for 5 minutes in forward run.
• Open BAH flushing valves one by one, each for 2 minutes maintaining header pressure, for loosening the compactness of ash/clinkers inside BAH.
• Open BAH gate of running clinker grinder and check opening status (local indication).
• Ensure the pressure of 1.0 kg/cm2 at slurry discharge line after discharge valve.
• Check the bottom ash line warm or cold by touching and slurry flow at
• ASPH sump.
• After around 45 minutes, flame will be visible from the view glass at the gate cover, both at front and rear side of BAH.
• After confirming BAH empty, carry out hopper flushing one by one (first top corners 5 minutes and then bottom corners 5 minutes, maintaining header pressure).
• Close BAH gate, check closing status of gate by checking gate indication rod position.
• Flush clinker grinder for 5 minutes.
• Open BAH filling line valve and start BALP.
• Open seal trough flushing valve and nozzle flushing valve once in a shift.
• Open all flushing line valves for 15 minutes for quick filling of BAH.
• Confirm clear water is coming from bottom ash discharge line.
• Stop BAHP.

Normal shutdown of Boiler to Cold / Hot

Normal shutdown of Boiler to Cold :

• Note : In shutting down the boiler, the reduction of firing rate isdetermined by the requirement of the turbine.
• Do soot blowing before reducing load or keeping load more than 75 %
• Check HP / LP bypass operation is O.K.
• After soot Blowing gradually reduce load on the unit by reducing firing in the mills.
• Steam flow will be reduced, Allow the pressure to drop with the reduction in load.
• Reduce the temperature of the rate prescribed by the manufacturer for turbine but never exceeding the forced cooling rate of boiler if required to do some work on turbine or maintain MS and HRH temperature constant.
• Reduce coal firing to 70 % of load .
• Put SADC on manual to maintain wind box to furnace Dp more than 70 mmWCL.
• Take HP / LP bypass into service and reduce steam flow to 300 MW .
• Keep HP bypass atleast 25 % open to facilitate flow through Reheater.
• Take oil support for lower most mill (A, B,C,D). Do APH soot blowing.
• Reduce firing in the top most mill to minimum feeder rate, open cold air damper fully and close HAG after closing hot air damper. When mill outlet temp falls below 60 deg. Cent., stop feeder. Then stop mill after completely emptying it. Close cold air damper and CAD fully.
• Adjust air flow for required O2 %.
• Reduce firing further in top mill by reducing feeder rate. Load 200 MW and throttle pressure to 100 ksc, temp. As per TSE. ( Temp. To be kept more or less constant)
• Stop bottom feeder and mill after emptying it, load 100MW,80ksc.
• Change over FRS from high range to lowrange. ( Ensure mill left is having oil support)
• Open economiser recirculation valves.
• Close CBD if in open condition.
• Start reducing firing in last mill, stop feeder and mill by emptying mill and feeder.
• Reduce load to 50MW and pressure 80ksc. Stop both PA fans.
• Ensure Unit 11 KV bus supply change to stationsource .
• Trip the boiler through E.P.B. Turbine will trip and generator breaker will open.
• PA fan will trip automatically if not stopped earlier.
• Ensure closing of all oil valves, Ignitor valves& trip valveLDO/HFO trip valve and stopping of all feeders and mills.
• Close boiler stop valves, SH/RH spray all isolating valves to avoidpassing.
• Do boiler purging.
• See no flame inside the furnace.
• Keep close watch on HP bypass spray.
• Ensure drain opening before / after stop v/v.
• Close HP bypass, LP bypass close on auto, If not close LP bypass.
• Make ESP fields off & run Rapping motors ( Collecting & Emmitting) for 6 hours then stop rapping & isolate flushing water(after ID fan stopping).
• When APH inlet gas temp. falls below 205 deg.C shut down the FD & ID fans. (ID to FD protection can be checked.)
• Do APH washing.
• Ensure natural circulation
• Close Aux. Steam Control valve, isolating v/v and spray line isolatingv/v and control valve.
• Close atomising and heating steam line.
• Close HFO / HSD station inlet manual isolating valve.
• Open RH startup vents & CRH drains.
• Maintain drum level by BFP.
• Open drum & SH air vents, SH start-up vents, SH header drains when drum pressure falls to 2 ksc.
• Drum vents of 500 MW units can be opened after the stopping of CC pumps only.
• When drum metal temp. Comes to 85 deg. C close FRS control valves and isolating V/V. Stop BFP.
• Open low point drain header drains to blow down tank. Close CC p/ps discharge valves before draining.
• Stop S/C, C/G when no ash is coming through S/C.
• Isolate HP / LP water.

EMERGENCY SHUT DOWN DUE TO SEVERE TUBE LEAKAGE

• Always small tube leakages are detected by hissing sound and increased make-up water requirement. After investigation at the earliest possible time unit should be shutdown in a normal manner.
• A sudden major tube leakage indicate by reduction in load, sudden furnace pressurization, increased ID fan loading and sudden increase in makeup water requirement. D/A and Hot well level could not be maintained after opening normal & emergency make-up.
• The sequence of operation in this case will be as follows.
• Reduce load as fast as possible to 70% of NCR.
• If feed water flow can not be maintained by two BFP’s take third BFP service if available ( pr. 130 ksc ). Check leakage area. Inform SCE & maint. engineer.
• Take oil support for lower most mill.
• Reduce feeder speed of top most mill and ensure mill is empty completely. Reduce load to 40% of NCR. Reduce Pressure gradually.
• Similarly reduce feeder speed of second top most mill, stop mill. Load – 30%of NCR.
• Take HP / LP bypass into service. Try to maintain MS & HRH temp.
• Open economiser recirculation valves. Close CBD if in open condition.
• Stop bottom most mill after emptying mill. Load 50MWpressure 50 ksc.
• Stop second bottom most mill after emptying it.
• Trip boiler . Ensure tripping of PA fans, HFO, Ignitor trip v/v , mills and feeders off , all dampers HAD, CAD , HAG close. All oil valves are closed.
• Close boiler stop v/v. Close HP /LP bypass. Open RH air vent & startup vents
• Open drain after boiler stop valves.
• Maintain drum level.
• Stop one set of ID and FD fans. Stop ESP fields, do the rapping.
• Purge the boiler .
• Run the fans till gas temp. Falls to 205 deg.C at APH inlet.
• Then stop ID and FD fans, only allow natural cooling.
• When drum pressure comes to 2 ksc, open SH, drum air vents and SH startup vents.
• Open SH header drain to blow down tank.
• Do APH’s washing.
• When drum pressure comes to zero or drum metal temp. Is approx. 100 deg.C start one set of ID and FD fan for force cooling. (Cooling rate should not exceed as recommended.)
• Rest follow same procedure as per normal shut down.

** In case tube leakage is major and water level can not be maintained, then trip the boiler from EPB.

• Follow same procedure as per EM shut down.

NATURAL COOLING

• All FG dampers will remain open.
• All air side dampers will remain open.
• All SADC will remain open.
• Keep open IGV, Blade pitch of fans. Air circulation will take place.

NORMAL SHUT DOWN TO HOT STANDBY

It is assumed that the boiler will be shut down for a relative short period of time. It is expected 

that the unit will be restarted in a very short period of time, when the turbine metal temp. will not 

decrease appreciably . 

Here the normal procedure for normal shut down should be followed except 

in reduction in MS pressure to 120 ksc and temp almost constant.

• Mills should be stopped one by one after emptying mill only after HP /LP bypass into service.
• Feeder should not be made empty except particular requirement.
• Boiler stop valve should be closed after tripping the boiler.
• Boiler side drain should not be opened. Purge the Boiler.
• Open only RH vents & RH startup vents after closing HP/ LP bypass.
• One set of ID and FD fan to be kept in service till APH inlet temp. Falls 205 deg.C. After 205 deg.C, stop ID and FD fan. Leave the boiler natural cooling. Efforts to be made to preserve the Boiler heat.
• APH washing may not be done due to short shut down.
• ESP fields may be just made off and keeping rapping motors in normal position.
• Ensure closing of all oil valves, trip valves, Ignitor trip valve and ignitor valves and all mill and feeders off.
• HFO may be kept in short recirculation.
• Ensure CC pumps are running(for 500 MW ).

Boiler Hydro Test

Boiler Hydro Test

PREREQUISITES / STATE OF THE PLANT :-
1) Boiler is completely in drained condition.
2) CW / ACW / ECW pumps in service (at least one from each)
3) Instrument air system is available.
4) Boiler fill pump (or) CEP is ready for operation.
5) MDBFP is available for service and system is lined up.
6) Feed water system is lined up to ECO inlet.
7) All HP heaters all isolated and feed water 100% bypass valve opened.
8) DM make up line is lined up.
9) Ammonia and Hydrazine dosing system is lined up.
10) Necessary clearance given by BMD (pressure parts) for filling the boiler and conducting
the Hydro test.
11) All Other clearances obtained as per protocol (Annexure-I)
12) If Howell is under permit :
Ensure that Deaerator overflow pneumatic valve and its upstream/downstream
manual valve are in closed condition. Ensure Deaerator overflow bypass MOV also

in closed condition & its electrical supply is in isolated condition.

BOILER FILLING & HYDRAULIC TEST PROCEDURE
A) Boiler lineup and filling procedure:
1. Boiler filling can be done either through the Boiler fill pump or through the MDBFP as
Per laid down procedure.
2. Get clearances from Boiler (Pr. Parts) , AHM, EMD, TMD and C&I Dept.
3. Inform DM plant about boiler filling.
4. Open all drum vents- (LEFT SIDE: B-1,B-2,B-3,B-4 RIGHT SIDE: B-5,B-6,B-7,B-8) and
Superheater vents(S11,S12,S13,S14,S22,S23,S24,S25) Superheater start up

vents(S29,S31,S30,S32).
5. Close all Boiler drains (EBD: B65 , B66 CBD:B 68,B-72,B-70,B-69,B-73,B-71 BOTTOM RING
HEADER BLOWOFF :B80,B-81), Economiser drains (E18,E19) & Superheater drains
(S78,S81,S82,S86,S87,S89,S90,S91,S84,).
6. Close boiler stop valves MSV-1 to MSV-2 AND IBV MSV-3,MSV-4,MSV-5,MSV-6.

Boiler filling through Boiler fill pump:

1. Ensure all FRS valves (FDV-13 to FDV-16) are in closed condition.
2. Ensure all BFP discharge valves (FDV-4 to FDV-6 and its IBV) are in closed condition.
3. Close manual valve in LPD station common header to IBD tank interconnection.
4. Open Boiler ring header drain MOV B86 & its isolating manual valve to LPD station and
Economiser drain valve (E19, E18) to LPD station for boiler filling.
5. Open Boiler filling valves to ring header and economizer at LPD station.
6. Start Boiler fill pump and maintain discharge pressure of 12-15 Ksc by adjusting recirculation
valve.
7. Continue boiler filling until hydrastep & Drum level transmitters show water level.
8. Stop Boiler fill pump after reaching desired level.
9. Close all boiler drain valves and economizer drain valves.
10. Close Boiler ring header drain MOV B86 & its isolating manual valve to LPD station and
Economiser drain valve (E19, E18) to LPD station for boiler filling.

Boiler filling with MDBFP:

1. Ensure de-aerator is filled either through condensate system or with boiler fill pump.
2. Ensure all PTWs are closed on MDBFP and feed water system components.
3. Ensure all SH/RH spray manual valves of all BFPs are closed.
4. Ensure Discharge valves of TDBFP-A&B are closed.
5. Close all FRS valves.
6. Start MDBFP on recirculation with minimum scoop with discharge valve closed.
7. Open MDBFP discharge valve IBV and fill feed water circuit up-to FRS with proper venting &
equalise pressure before and after MDBFP discharge valve.
8. Open MDBFP discharge valve
9. Open vent valve before Eco inlet valve(E2)
10. Open FRS Low load control valve and start filling economizer & drum.
11. Close vent valve before economizer once water is coming out of it.
12. Adjust flow through FRS to around 150TPH ( MDBFP Suction flow around 400TPH)
13. Start taking makeup water into condenser/ Deaerator @ 100 to 150 TPH. Start additional
DM make-up water pump
14. Reduce FRS control valve to minimum once water level is observed in Hydra step/drum level transmitters.
15. Maintain normal drum level
16. Total time required for Boiler filling will be around 2 Hours from start of MDBFP

Keeping the circulation system in service:

1. Ensure all PTWs on BCW pumps are cancelled.
2. Fill the boiler drum to around +100mm
3. Normalize power supplies of BCW pumps
4. Ensure local line up of cooling water system and cooling water flow is healthy
5. Ensure discharge valves of BCW pumps are open.
6. Close drum vents B-3,B-4 & B-5,B-6.
7. Flick start any one BCW pump for 5 Seconds and maintain drum level by adjusting FRS valve.
8. Allow drum level to rise again & flick start all BCW pumps one by one.
9. Later One BCW pump can be kept in service continuously. Observe and maintain drum level.
10. Remaining BCW pumps can also kept in service one by one. Keep drum slightly positive
before starting BCW pumps.
11. Ensure BCW pump parameters like current, DP & Cavity temp rise are normal.

B) Boiler Hydro Test Procedure

• Clearance for boiler filling obtained .
• Clearance obtained from Ash handling maintenance Dept regarding Bottom ash hopper and Eco hoppers.
• Clearance obtained from C&I dept regarding Drum & MS line Instrumentation.
• BCW Pumps cavity filled. BCW Pumps shall not be kept in service for hydro test.
• If Hydrotest is to carried out, before starting boiler filling the status of the following valves shall be checked as mentioned against each of them.
• SH header drain master valves : Closed

• Phosphate dosing valves at drum floor : Closed
• Boiler MS stop valve and its integral bypass valves ( MSV-1,MSV-2,MSV-3,MSV-4,MSV-5,MSV-6) : Closed
• Before boiler stop valve drain ( MSV- 101 & MS 102) & its isolating manual valve: Closed
• All SH,RH spray isolation valves at boiler side :Closed
• Discharge valves of BCWP : At least One Open
• All hydra step, level transmitter and gauge glass standpipe valves : Open
• All drum /SH spring loaded safety valves : To be gagged at 120 ksc
• All MS ERV’s & isolating valves valves(S71,71A,73,73A,72,72A,74,74A,75,75A) : Closed
• Soot blowing station isolating valves : Closed
• Drum, MS, Eco sampling line valve after E2 valve : Closed
• MS strainer drain & HP Bypass warm up line drain MSV-105, MSV-106 , BPV-101 & BPV-102 MOV & its manual v/v : Open
• CRH & HRH line drain to atmosphere : Open
• MDBFP recirculation valve pneumatic air : Isolated
• MDBFP SH AND RH spray valve : Isolated
• HP bypass spray manual isolating valve : Closed
• TDBFP-A & TDBFP-B Discharge valve & its IBV : Closed
• Aux PRDS spray manual valve from BFP Discharge Header : Closed
• Sampling line root v/v (MS,DRUM,FW) :Closed
• Bottom ring header rear side v/v (B80 , B81): Closed
• SH attemperation station cleared ( All valves cleared or manual valves closed)
• Condensate system cleared & charged
• Feed water system cleared & charged
• CEP, MDBFP P&I checks completed, Pumps started & kept in service
• HP Bypass valves & main turbine Stop valves are closed
• MS Line to PRDS valve AS-22 Kept closed. Drain before AS-22 kept open.
• MS, CRH & HRH line drains at TG zero meter are kept open
• Necessary C&I indicators and recorders are available
• Men & material removed from Boiler first and second pass
• Men & material removed from bottom ash hopper and economiser hoppers
• Boiler is filled with normal boiler filling procedure as outlined previously & close all drumdrains & Economiser drains.
• Keep drum vents , SH vents and drains open
• Slowly start raising drum level & fill the drum completely.
• Close the drum vents after ensuring water is coming out of them
• Continue drum filling and close all SH vents & drains after ensuring water is coming out of them.
• Close manual valves of Low point drain station and SH drain header going to IBD Tank.
• Continue raising drum pressure with MDBFP @ 10 KSC/minute ( up to 140KSC )
• Rate of rise of Pressure = 10 Ksc / min up to 80 % of design pressure & then 1-2 Ksc /min for balance pressure.
• Ensure MS line pressure on TG side is zero. If pressure raise observed, further tighten the valves MS-1 to MS-6.
• MS and Drum safety valves are gagged by BMD @ 140 KSC (for hydro test pressures above 180 Kg/CM2). Hold the Drum Pressure till gagging is completed.
• Continue raising Drum pressure as per requirement of BMD up to Max 220 KSC by increasing BFP Scoop gradually.
• Monitor MDBFP Thrust bearing temperature & vibrations.
• For external hydro test it is required to raise the drum pressure to 1.25 of drum design pressure i.e. 259 Ksc.
• Hold the boiler pressure at desired max value for 10 minutes. Then reduce the scoop of the
• MDBFP to 120 ksc and observe the drop in drum pressure. It should not exceed 1 ksc / min. and hold there for 5 to 10 Minutes.
• Inform BMD for removal safety valve gags. Ensure all safety valve gags are removed.
• Then slowly reduce drum pressure to 100 KSC. Inform BMD for inspection.

Boiler Checks during Hydraulic Test (To be recorded in protocol):

• Passing of MS line drains to IBD and CBD/EBD valves.
• Passing of MS SV through MS line atmospheric drains.
• Passing HP bypass valves through atmospheric drain at 0 m.
• Passing of any vent v/v in boiler side, valve glands,
• Any Leakage from Eco / WW / SH tube, any welding joints, Drum man holes etc.

C) Boiler Complete Depressurization & Draining:

• After completion of inspection, slowly reduce drum pressure by reducing MDBFP scoop to minimum. Close FRS valves & MDBFP discharge valve.
• Rate of depressurization = 1 Ksc/Min
• Open SH vents and drains & drum vents @ 3KSC
• Bring down drum level to normal value.
• Open MS line drain valves MS-101 & MS-102.
• Open Manual valve of SH drain station header to IBD Tank.
• Open Manual valve of LPD Station to IBD Tank.
• Ensure complete draining of Super heater & MS line by opening all vents & drains.
• Complete Boiler hydro test protocol after successful completion of hydro test. Note down defect for each department 
• Open CBD Root valve, sampling valves, Phosphate dozing to drum Valve.
• Normalise all other isolations done earlier as per requirement.
• Drain the boiler as per BMD requirement by opening CBD and other boiler drains.
• IF Boiler is to be drained, Stop MDBFP & Isolate power supply
• Ensure power supply isolation of all BCW Pumps, If the boiler is drained.

Boiler force Cooling

Boiler force Cooling :

In case of tube leakage:

After Tripping the boiler ,stop FD fan and keep ID fan running at minimum load and ensure furnace pressure negative inside boiler.

Reduce pressure as per boiler cooling curve Annex-1 by opening startup vent /HP/LP bypass and maintain drum level by feed water supply. (During pressure reduction maintain Drum Top/Bottom DT below 50 Deg C )

After two hour of Boiler tripping start FD fan and reduce pressure as per boiler cooling curve ( Annex-1) . Limit Drum Top/Bottom DT below 50 Deg C. during depressurisation.

Open SH drain at 10 KSC and open SH Vents at 4 Ksc.

Open Drum Vents at 2 KSc.

Drain boiler when boiler water temperature is below 94 Degree C

Keep ID & FD fans running till temperature inside boiler becomes comfortable for maintenance personnel to go inside boiler and attend the tube leakage.

Other Than Tube leakage :

• Operate Wall Blower and LRSB during Load reduction
• Gradually reduce load and allow pressure drop to accelerate cooling & steam temperature drop as per Turbine manufacturer recommendation
• Trip the Boiler
• After Tripping the boiler ,stop FD fan and keep ID fan running at minimum load and ensure furnace pressure negative inside boiler.
• Reduce pressure as per boiler cooling curve Annex-1 by opening startup vent /HP/LP bypass and maintain drum level by feed water supply. (During pressure reduction maintain Drum Top/Bottom DT below 50 Deg C )
• After two hour of Boiler tripping start FD fan and reduce pressure as per boiler cooling curve ( Annex-1) . Limit Drum Top/Bottom DT below 50 Deg C. during depressurisation.
• Open SH drain at 10 KSC and open SH Vents at 4 Ksc.
• Open Drum Vents at 2 KSc.
• Drain boiler when boiler water temperature is below 94 Degree C
• Keep ID & FD fans running till temperature inside boiler becomes comfortable for maintenance personnel to go inside boiler and attend the tube leakage.

Note:

• Feed water filling and draining should not be done for accelerating cooling.
• In case of tube leakage in Pent house area ,exhaust fan to be put into service.
• Water washing in water wall area should be done only after draining of boiler.
• Water washing inside the boiler should be done only after tube metal temperature in the location where water washing intended falls below 94 deg C in that location.
• Water washing in the penthouse should be done only after header metal temperature in the location where water washing is intended ,falls below 94 deg C in that location.

Ash slurry Operation

Pre-requistes:

• Ash slurry pit level of corresponding ash slurry p/p is at above low level 3.0 metres.
• BAHP and BALP pumps are running condition depending on the ash water requirement.
• BALP or FAHP water is available for ash slurry pit make up in case level goes low.
• Also the level transmitters and electrical operated make up valves are available to take care of the level.
• At least one HPSW and LPSW pump must be available.
• At least one Cooling water p/p and one CT fan is available at ash slurry pump house end or any alternate source ex. Service water or SG ECW water for hydraulic coupling cooling water requirement.
• Instrument air available for suction/ discharge valve operation.
• Ash slurry swgr-A&B for the ash slurry pump to be run is charged

Line up for starting the pump

• Start any one of HPSW & LPSW pumps after suction valve opening . Gradually open the discharge valve to full, this will charge the seal water supply header for all the pumps.
• Charge seal water to pump gland by opening the solenoid valves , if solenoid valve is not working, seal water can be supplied by opening manual bypass valve of above valves.
• Open isolating valves in cooling water lines for hydraulic cooler. Cooling water pr must be adequate. 
• Check that Oil level for hydraulic coupling scoop tube and the gear box oil is O.K.
• Make hydraulic coupling scoop tube position to minimum.
• Open the suction valve and ensured from the Local.
• Start the F/C pump
• Select normal mode out of normal / flush tab
• Check that seal water pressure for the 1st ,2nd and 3rd pump in series as abov 4.2ksc , 8.4ksc & 12.6 ksc respectively .Start the 1st ash slurry pump
• The pneumatically/motorized operated discharge valve of the pump opens on auto
• Now position of the scoop can be increased and locked at any % as per requirement.
• Start the second and Third pump in the same way.

Line up for flushing the pump

• keeping rest of line same as required for running ,close the suction valve an open flushing line manual valve v/v
• Select flush mode out of normal / flush tab
• Check that seal water pressure for the 1st ,2nd and 3rd pump in series as above 4.2ksc , 8.4ksc& 12.6 ksc respectively .Start the 1st ash slurry pump.
•  Start the flushing pump. 
• Start the 1st ash slurry pump.
• The pneumatically/ motorised operated discharge valve of the pump opens on auto.
• Now position of the scoop can be increased and locked at any % as per requirement.
• Start the second pump in the same way.

415V (DA) bus charging from bus coupler/ Normal incomer

415V (DA) bus charging from bus coupler/ Normal incomer

Bus charging from bus coupler (Only done from Electrical control panel at UCB) :-

1. Select 415v bus coupler breaker
2. Select I/C-A or I/C-B in trip selection (Select the incomer which we want to trip).
3. Put Key (synch selection) in position “1 - check “.
4. Switch ON synchroscope by putting switch in position “2”.
5. If IN PHASE lamp (green LED) glows. Go to step-6. If OUT OF PHASE (RED LED) Glows
check for voltage/frequency difference & inform to EMD.
6. Close Circuit breaker (control switch position “2”). Bus coupler breaker will close &
incomer (which is selected in trip selection) will trip.
7. Change over completed, Switch OFF synchro scope & put key in “0 – OFF” position.
8. Deselect bus coupler .
9. Reset all by pressing Control reset.

Bus charging from normal incomer (Only done from Electrical control panel at UCB) 

1. Select 415 V Incomer breaker ( incomer-1/ incomer-2)
2. Select Bus coupler in trip selection.
3. Put Key (synch selection) in position “1 - check “.
4. Switch ON synchroscope by putting switch in position “2”.
5. If IN PHASE lamp (green LED) glows. Go to step-6. If OUT OF PHASE (RED LED) Glows
check for voltage/frequency difference & informed to EMD.
6. Close Circuit breaker (control switch position “2”). Incomer will close & Bus coupler
breaker will trip.
7. Change over completed, Switch OFF synchroscope & put key in “0 – OFF” position.
8. Deselect incomer breaker ( incomer-1/  incomer-2).
9. Reset all by pressing Control reset.

11KV UNIT BUS ISOLATION/NORMALIZATION:

11KV UNIT BUS  ISOLATION/NORMALIZATION:
ISOLATION PROCEDURE:-

1. Stop IDF-A channel – 1& 2,trip source breakers of both channels & isolate it .
2. Stop PAF-A, CW p/p-1, & isolate their respective breakers.
3. Ensure following procedure to isolate UAT-A,UST-A,ESP LTMSB-A/B/C/D, CT TRF-A, ESP Vac.
TRF-A
              Charge 3CA bus (3.3kv) sec-1 from bus coupler .Trip 3.3kv incomer breaker
                  &Isolate it. Trip 11kv UAT-A breaker at 3BA bus & isolate it.
             Charge 3DA bus (415V – unit service swgr) sec-1 from bus coupler .Trip 415V
                  incomer  &isolate it. Trip 3.3 UST-3A breaker at 3CA-1  & isolate it.
             Charge CT MCC-A from CT transformer-B. Trip LT incomer from CT transformer-3A &
                 isolate it. Trip CT transfer-3A HT (3.3 kv) breaker  & isolate it.
             Charge ESP Vacuum PH MCC sec-A from bus coupler.Trip LT incomer breaker & isolate                   it.
             Charge All ESP LTMSBs (A/B/C/D) from bus coupler ).Trip incomer breakers& isolate.                     Trip 3.3 KV ESP LT MCC breakers & isolate them.
4. After all the feeders from 3BA bus tripped. Once again, ensure that 3BA bus cannot be back
fed from any source.
5. For BUS shutdown following two scenarios –
             CASE-1: If 3BA bus charged from station transformer, tie breaker  is in close
                condition and UT incomer is in open. Isolate incomer breaker . Trip tie breaker &                           isolate it.
             CASE-2: If 3BA bus charged from UT incomer , and tie breaker from  OBA bus (at 3BA                  bus end) is in open condition .Isolate tie breaker. Trip incomer breaker & isolate it.
6. Trip tie breaker  from OBA bus (at OBA end) & isolate it.
7. Ensure voltage/current in all phases showing 0 volt/amp.
8. Switch off both 220V DC control supply sources to 3BA bus from 3FA.


NORMALIZATION PROCEDURE :-

1. Ensure all ptw on the bus cancelled.
2. Before going to charge the bus, physically inspect that there should not be any opening on
backside of the bus & on the top, grounding strip connected properly.
3. Check healthiness of both 220V DC source.
4.Normalize Tiebreaker from OBA bus, (at OBA end) & (At 3BA end). Close
Tiebreaker.
5.Close breaker tiebreaker to charge 3BA from OBA. Check voltage in all phases.[Tie
breaker  may get closed in auto as per logic of turbine trip].
6. Normalize Incomer breaker from UT .Station to UT changeover can be done
whenever required.
7. All feeders from 3BA can be normalized& charged after cancellation of their respective ptws.

3.3 KV bus charging

3.3 KV bus charging from bus coupler/ Normal Incomer

A:    Bus charging from bus coupler: - (Only done from Electrical control panel at UCB)

1. Select 3.3 KV bus coupler breaker
2. Select I/C-A or I/C-B in trip selection (Select the incomer that we want to trip).
3. Put Key (Synch selection) in position “1 - check “.
4. Switch ON synchroscope by putting switch in position “2”.
5. If IN PHASE lamp (green LED) glows. Go to step-6. If OUT OF PHASE (RED LED) Glows
check for voltage/frequency difference & inform to EMD.
6. Close Circuit breaker (control switch position “2”). Bus coupler breaker will close &
incomer (which selected in trip selection) will trip.
7. Change over completed, Switch OFF synchroscope & put key in “0 – OFF” position.
8. Deselect bus coupler .
9. Reset all by pressing Control reset.

B: Bus charging from normal incomer :- (Only done from Electrical control panel at UCB)

1. Select 3.3kv Incomer breaker ( incomer-1/ incomer-2)
2. Select Bus coupler in trip selection.
3. Put Key (synch selection) in position “1 - check “.
4. Switch ON synchroscope by putting switch in position “2”.
5. If IN PHASE lamp (green LED) glows. Go to step-6. If OUT OF PHASE (RED LED) Glows
check for voltage/frequency difference & informed to EMD.
6. Close Circuit breaker (control switch position “2”). Incomer will close & Bus coupler
breaker will trip.
7. Change over completed, Switch OFF synchroscope & put key in “0 – OFF” position.
8. Deselect incomer breaker ( incomer-1/incomer-2).

9. Reset all by pressing Control reset.

Both Unit board Tripped

Both Unit board (11 kv) Tripped

What To Do?

1. DC EOP, SOP, TD-A/B EOP, DC Scanner Fan (& emergency Damper),DC Lights starts on Auto. If not Start Them. Ensure APH Air Motor Starting.
2. Main DG set starts on Auto, If not Manually start from Local and ensure closing of i/c breaker. IF Main DG Fails start standby DG set and close its breaker. DG Board is charged.
3. Ensure Vacuum Breaker is Open on Speed <2000 rpm
4. DC Jop starts at 510 rpm, Ensure Battery Chargers are charged from DG (Bus-coupler to be closed).
5. Start B(or 2) pumps AOP2,AC JOP, TD-A/B LOP-B , SOP(AS)-2,SOP(H2), AC Scanner fan.
6. Ensure Main Turbine, TD-A/B Barring v/v Opening( Or Open from Local)
7. Ensure H2 Pressure. IF Drops. Purge by Co2.
8. Isolate Seal steam manual v/vs of Main Turbine and TDBFP-A/B.
9.  Ensure all Extraction v/v are closed.

Restoration Dos :

1.    Normalize 400 KV Buses 
2.   Normalise 132 KV Buses, 
3.   Normalize 11KV UNIT Buses thru ST. 
4.   Normalise 3.3 kv Unit buses through UATs. 

4.    NORMALIZE LT SWITCHGEARS  USS, SSS, TMCC, BMCC, SERVICE BUILDING MCC, ESP MCC,  AND OFFSITE SWITCHGEARS

5.   SYNCHRONIZE UES BUS WITH USS USING SYNCHRONIZER AND THEN CLOSE THE TIE BREAKER (I/C FROM USS). 

6.    FOR DEAD BUS CHARGING OF UES BY I/C FROM USS PUT DG SELECTION SWITCH ON MANUAL.

7.   TRIP THE DG BREAKER AND THEN STOP DG SET.

Guidelines of Desk Engineer

Guidelines of Desk Engineer

• Each Boiler and TG desk engineer is maintained in all the three shifts by an Engineer. When a Boiler and TG desk Engineer takes over charge from the former  desk Engineer, he gets himself apprised of the status of the equipments related to Boiler and TG. 
• He monitors the parameters and takes corrective action for any deviation of parameter. He checks whether any PTW is pending or not from SAP terminal. 
• During the shift, he monitors and controls the parameters by operating auxiliaries and their control system as per Manuals. 
• Any problem in controlling the parameter beyond his control is reported to UCE. UCE registers defects to concerned Maintenance Department through SAP notification. PTWs are issued to Maintenance Dept after ensuring isolations by UCE. 
• At the end of the shift, Boiler desk engineer and TGDE hands-over charge to next desk engineer and informs him the activities done during the shift.

Guidelines for UCE

Guidelines for UCE:

UCE has to check the following at the beginning of the shift:

• Status of Mills, ID fan, FD Fan and PA fans.
• Status of all the unit Protections.
• Ensure availability of emergency equipments (only in morning shift) & for any defects concerned maintenance & DGM(O) is to be informed.
• Follow changeover schedule & for any defects concerned maintenance & DGM (O) is to be informed.
• Coal Bunker levels.
• ESP fields in service
• Auto loops in service.
• Boiler metal temperatures.
• Grid Frequency.
• Unit Generation.
• Boiler water chemistry parameters.
• Availability of operators at different location.
• Communication system.
• Equipments under PTW.

Normal Operation

• During the shift UCE has to monitor parameters deviations as indicated by the Annunciation window and if required instruct the Desk Engineers to take Corrective actions as per the –

1. Boiler operation  manuals    
2. Turbine operation manuals  
3. Generator operation manual 

• He registers Defects, as reported by desk Engineers or local Operators, to concerned Maintenance Department through SAP notification.
• He ensures availability of the equipments after Return / cancellation of PTWs.
• He has to instruct Desk engineer to modulate the Unit Load as per schedule in co-ordination with the Shift Charge Engineer.
• UCE takes a round to different locations of the Unit to check any abnormality in the Unit i.e. Steam leakage, Coal leakages, safety arrangements etc.
• In case of total Station out he has to act as per the instruction available in the unit “Station Power Failure Operation.”
• In case of Fire, as indicated by the Fire alarm, he communicates immediately to Fire Station (Located inside the Plant) and also SCE.
• In case  of Hydrogen Gas Leakage as indicated  by the H₂ Pr. drop rate  UCE has to check the followings---
• H₂ – Seal oil Diff Pr.
• 1. Seal Oil filter Diff. Pr.
  2. Possibility of H2 Leakage.
  3. Check the leakage using Hydrogen Leak Detector.
  4. Concentration of H₂ leakage should not be allowed to go beyond the fire hazard limit (84 %, though explosive mixture is between 4 - 75 %).
  5. In case of sharp drop in Gen H₂ Pressure UCE has to trip the Turbine manually and instruct local operator to start CO₂ purging.UCE has to instruct the Desk Engineers and local operators to perform daily routine activity

X-CURVES

Ash Handling system Part-II

Ash Handling System