Energy Tab

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 shou...

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 Pos...

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 Isolat...

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 NORMALI...

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 : Electrical Isolation of CC pump Both Discharge valve closed Boiler is in drained condition. Ensure both manual valves (just before e...

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...

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 he...

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 firin...

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 ...

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 dr...

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...

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 Bu...

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 &   ...

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...

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 Open ing( 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....

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: 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 – Boiler operation   manuals      Turbine ope...