Technical Diary

2015
HAND BOOK OF OPERATING IMFORMATIONS FOR BTG EQUIPMENTS

AND ITS INSTRUMENTATION LOGICS
NEYVELI LIGNITE CORPORATION LIMITED.

2*125MW CFBC BOILER AND STEAM TURBINE
BARSINGSAR THERMAL POWER PLANT
HAND BOOK SUBMITTED BY:

P. R.RAJASEKAR DEE/ C&I
V. RAJA DEE/ C&I
Page 1 of 79
ACKNOWLEDGEMENT:
First I would like to thank our NEYVELI LIGNITE CORPORATION, BTPP
Rajasthan for providing us this wonderful opportunity to serve the organization. We
were guided by our department senior level executives who are experts in this field.
I would like to thank our Division HEAD DGM/E&I who provided us supports.
I would also like to thank our chief managers who helped us in learning about the
instrumentation subject and handling the situations with suitable care. They always
inspire us to Learning and implementing the new ideas.
Once again we want to say thanks to all my seniors who helped for Successfully
completion of THE HAND BOOK OF OPERATING INFORMATIONS FOR BTG
EQUIPMENTS AND ITS INSTRUMENTATION LOGICS.
Page 2 of 79
CONTENTS
DESCRIPTION PAGE NO
I. BOILER
A) FANS: Motor & Fan details, permissive & protections
9
1. ID FANS
10
2. SA FANS
3. PA FANS 11
B) BLOWERS: Motor details, permissive & protections

13
1. PURGE AND SEAL AIR BLOWERS
2. SEAL POT BLOWERS 14
3. SEAL POT STADBY BLOWERS 14
4. FBHE EC BLOWERS 15
5. FBHE BLOWERS (BUNDLE CHAMBER)
17
6. FBHE STANDBY BLOWERS (BUNDLE CHAMBER)
18
C) LIGNITE FUEL FEEDING SYSTEM
1. LIGNITE EXTRACTION FEEDER 19
2. LIGNITE TRANSPORT CONVEYOR 20
3. LIGNITE GATE VALVE 22
D) BOILER PROTECTION
1. BOILER PROTECTION 1 (MASTER FUEL TRIP) 22
i. TRIP INPUTS
ii. TRIP OUTPUTS
2. BOILER PROTECTION 2 (OIL FUEL TRIP) 22
I. SUB 1 TRIP CONDITIONS
II. SUB 2 TRIP CONDITIONS
III. BED LANCES 1 TO 6 TRIP CONDITIONS
Page 3 of 79
3. BOILER PROTECTION 3 (LIGNITE & LIME ) 22
4. RH PROTECTION 23
E) SG COOL DOWN AND ITS IMPORTANT OUTPUTS 24
F) UNIT CONTROL PANEL ANNUNCIATIONS 25
II. TURBINE
G) PUMPS:
28
1. BOILER FEED PUMPS
I. PUMP DETIALS
II. START PERMISSIONS
III. PROTECTIONS
2. CONDENSATE EXTRACTION PUMP 29

I. PUMP DETIALS
II. Permissive for CEP Starting
III. Protections for CEP
IV. Interlocks
30
3. Circulating Water Pump
I. PUMP DETIALS
II. Permissive for the CW Pumps
III. MANUAL Mode
IV. AUTO Mode
V. Protections for the CW Pumps
VI. Auto ON for 1C Discharge Valve
4. DM COOLING WATER SYSTEM (DMCW) AND 32

AUXILIARY COOLING WATER SYSTEM (ACW)
I. PUMP DETIALS
II. DMCW Permissive
III. DMCW Protections
Page 4 of 79
IV. Auto Starting of DMCW Pumps
V. ACW Permissive 32
VI. ACW Protections
VII. Auto Starting of ACW Pumps
5. DM COOLING WATER BOOSTER PUMP 33
I. Permissive
II. Protections
III. Auto Starting of DMCW Booster Pump
6. Hot well Make Up Pump 34

I. Pump Details
II. Permissive for the Make-Up Pumps
III. Protections for the Make-Up Pumps
IV. Auto Starting for the Make-Up Pumps
7. EMERGENCY COOLING WATER PUMPS (ECW) 34
I. Pump Details
II. PERMISSIVES
III. PROTECTIONS
IV. AUTO STARTING OF RESERVE PUMP
8. Emergency DM Water Pumps 35

I. Pump Details
II. Permissive for the Emergency DM Water Pumps
III. Protections for the Emergency DM Water Pumps
IV. Auto Starting for the Reserve Pump
9. Boiler Fill Pump

36
I. Pump Details
II. Permissive for the Boiler Fill Pumps
III. Protections for the Boiler Fill Pumps
IV. Auto Starting for the Make-Up Pumps
Page 5 of 79
H) TURBINE OIL SYSTEM/PUMPS
1. Main oil pump (Mop) 38
I. Auto ON for mop
II. Auto OFF for mop
III. Protections OFF for the main oil Pumps
2. AC Lift oil pumps (AC LOP) 38
I. Auto ON for AC LOP
II. Auto OFF for AC LOP
III. Protections OFF for the AC LOP
3. DC Lift oil pumps (DC LOP) 38
I. Auto ON for DC LOP
II. Auto OFF for DC LOP
III. Protections OFF for the DC LOP
4. Emergency Oil Pump (DC EOP) 39

I. Auto ON for DC EOP
II. Auto OFF for DC EOP
III. Protections OFF for the DC EOP
5. Control Oil Pump (COP) 40
I. Auto ON for COP
II. Auto OFF for COP
III. Protections OFF for the COP.
6. Control Oil Recir. Pump (CORP) 41
I. Auto ON for CORP
II. Auto OFF for CORP
III. Protections OFF for the CORP
I) TURBINE HP BYPASS SYSTEM 42
1. Protections & Interlocks 43

2. Oil Supply Unit ( OSU ) for HPBP System
Page 6 of 79
J) TURBINE LP BYPASS SYSTEM 44
1. Function
2. Set Point formation
3. Trip Close Function
4. Auto Control Interface (ACI)
5. LP BYPASS OPERATION 46
K) ELECTRO HYDRUALIC TURBINE CONTROL 47
1. Introduction
2. EHTC Components 47
3. TSLLE 48
4. SPEED / LOAD REGULATION 48
I. SPEED SETPOINT GENERATION
II. LOAD SETPOINT GENERATION
5. MS PRESSURE REGULATION 52
I. LP Mode
II. IP Mode
6. CONTROLLER SELECTION 52
7. VALVE POSITION SET POINT 53
8. Valve Position Controller 53
I. Speed Controller
II. Load Controller
III. Pressure Controller
9. Selection of Control Loops from DCS 55

L) TURBINE PROTECTIONS & DRAIN LOGICS 56
1. TURBINE PROTECTIONS
2. DRAIN LOGICS
60
Page 7 of 79
M) CFBC BOILER COORDINATED MASTER CONTROL 61
(CMC) MODE
1. INTRODUCTION
62
2. Check list for CMC commissioning
3. THINGS TO BE VERIFIED BEFORE CMC
COMMISSIONING
4. RUNBACK OPERATION CHECKS
64
I. Feeder’s runback
II. Secondary Air Fan runback
III. ID Fan runback
IV. PA Fan runback
V. CWP Fan runback
VI. UNIT DEMAND INCREASE / DECREASE BLOCK
VII. UNIT DEMAND RUN UP / RUN DOWN CHECKS
5. RUN BACKS TESTING AND LIMITATIONS 68
I. PROCEDURE FOR KEEPING RUNBACK IN SERVICE

II. TRANSPORT FEEDER RUNBACK LIMITATIONS
III. PRIMARY AIR FAN LIMITATIONS
IV. SECONDARY AIR FAN LIMITATIONS
V. INDUCED DRAUGHT FAN LIMI
VI. TATIONS
70
6. RUNBACK LOGIC MODIFICATIONS
N) GENERATOR PROTECTIONS
75
1. Relays
76
2. GR1 Protections
77
3. GR2 Protections
4. GTR1, GTR2 & GTR3 Protections 78
5. UATR1 & UATR2 Protections 79
Page 8 of 79
I. BOILER
A) FANS:
1. INDUCED DRAFT (ID) FANS:

MOTOR DETAILS:
KW 800 AMB TEMP 50 °C WEIGHT 9500 KG
STATOR 690 DE BEARING NU 232M PHASE / FREQ 3 / 50HZ

VOLTS
STATOR 886 NDE BEARING NU 228M DIVISION BHOPAL
AMPS
RPM 742 YEAR 2007
FAN DETAILS:
KW 800 Q (M3/S) 143.3 Rating of each heater:(MOTOR)
P 400 VOLTS 6600 V VOLTS 240 V

(kgf/m2)
R 1.0365 DIVISION RANIPET WATTS 1000
(kgf/m3)
RPM 740 YEAR 2007
Note:
The following permissive and protections are indicated with

respect to Fan ‘A’. The same permissive and protections are symmetric to
Fan ‘B’ also.
START PERMISSIVE:
 ID fan-1A any motor winding temperature <100 ˚C

 ID fan-1A any motor bearing temperature <85 ˚C
 ID fan-1A fan bearing temperature <77 ˚C
 VFD mode or DOL mode ready.
 (FG path available) or (ID fan-1B ON).
 ID fan-1A source Breaker ON.
 ID fan -1A I/L gate closed.
 ID fan-1A O/L gate closed.
 ID fan-1A I/L guide vane in MIN Position. (5%)
 (ID fan-1B ON & its I/L & O/L gates opened) OR (ID fan-1B OFF & I/L
gate closed & O/L gate closed & ID fan-1B I/L guide vane in MIN
Position).
Page 9 of 79
PROTECTIONS:
o ID fan-1A VFD fault.

o ID fan-1A source breaker electrical trip.
o ID fan-1B & SA fan-1B ON and SA fan-1A tripped.
o ID fan-1A motor bearing temperature > 90 ˚C (2 sec delay).
o ID fan-1A fan bearing temperature > 82 ˚C (2 sec delay).
o ID fan-1A Motor/Fan bearing vibration >12.6 mm/sec (10 sec delay).
o FG at ID fan-1A I/L pr <-40 mbar.
o ID fan-1A ON for 30 seconds & ID fan-1A O/L gate closed.
o ID fan-1 VFD earth fault trip.
2. SECONDARY AIR (SA) FANS:

MOTOR DETAILS:
VOLTS 6600 DE BEARING NU 230M PHASE / FREQ 3 / 50HZ
AMPS 104 NDE BEARING NU 226M DIVISION BHOPAL
RPM 1486 YEAR 2007
FAN DETAILS:
P 1580 VOLTS 6600 V VOLTS 240 v

(kgf/m2)
R 1.0365 MaxTemp 75 °C WATTS 800
(kgf/m3) /DIVISION RANIPET
RPM 1480 YEAR 2007
Note:

Fan ‘B’ also.
START PERMISSIVE:
 Boiler Protection 1 not acted

 (Both ID fans ON) OR (Any one ID fan ON & SA fan-1B OFF)
Page 10 of 79
 Any one P&S air blower running
 Any two seal Pot blowers running
 SA fan-1A motor winding temperature <100 ˚C.
 SA fan-1A motor bearing temperature > 85˚C (5 sec delay).
 SA fan-1A fan bearing temperature <77 ˚C (5 sec delay).
 SA fan-1A SWGR available.
 SA fan-1A lube oil tank level >min (level switch).
 SA fan-1A O/L damper closed.
 SA fan-1A I/L control damper in min Position.
 SA fan-1A I/L control damper in manual.
 SA fan-1A LOP-A or LOP-B on.
 SA fan-1A LOP pressure OK >0.8 ksc (pressure switch).
PROTECTIONS:
o Boiler Protection 1 acted.

o Boiler Emergency PB(UCP) operated.
o SA FAN-1A MTR bearing temperature >90˚C (10 sec ).
o SA FAN-1A FAN bearing temperature >82˚C (10 sec ).
o SA FAN-1A Motor/Fan bearing vibration >12.6 mm/se (10 sec delay).
o Both ID fans OFF.
o ID fan-1A OFF & Both SA fans ON.
o Both P&S air blowers not running for 10 mins.
o Any two Seal pot blowers not running for 60 secs.
o SA fan-1A ON for 3 minutes & SA fan-1A O/L damper not opened.
3. PRIMARY AIR (PA) FANS:

MOTOR DETAILS:
VOLTS 6600 DE STEEVE DIA 125 PHASE / FREQ 3 / 50HZ
AMPS 122 NDE STEEVE DIA 100 DIVISION BHOPAL
RPM 2968 YEAR 2007
FAN DETAILS:
P 2962 VOLTS 6600 V VOLTS 240 V

(kgf/m2)
R 1.0365 DIVISION RANIPET WATTS 800
(kgf/m3)
RPM 2880 YEAR 2007
Page 11 of 79
Note:

Fan ‘B’ also.
START PERMISSIVE:
 Boiler Protection 1 not acted.

 (Both ID fans ON) OR (Any one ID fan ON & PA fan-1B OFF).
 Any P&S air blower running.
 Any two Seal pot blowers running.
 Any one FBHE EC blowers running.
 (Both SA fans ON) or (Any one SA fan ON & PA fan-1B OFF).
 PA fan-1A Motor bearing temperature <85˚C.
 PA fan -1A Fan bearing temperature <77˚C.
 PA fan -1A No SWGR disturbance.
 PA fan -1A SWGR available.
 PA fan -1A Lube oil tank level >MIN.
 PA fan -1A O/L damper closed.
 PA fan -1A I/L control damper in MIN position (< 2%).
 PA fan -1A I/L control damper in manual.
 PA fan -1A LOP-A OR LOP-B ON.
 PA fan -1A LOP pressure OK >0.8 ksc (pressure switch).
 Electrical trip not acted.
PROTECTIONS:

o Boiler emergency PB (UCP) operated.
o PA fan-1A motor bearing temperature >90˚C.
o PA fan -1A FAN bearing temperature >82˚C.
o PA fan -1A Motor/Fan bearing vibration >12.6 mm/sec (10 sec).
o Both ID fans OFF.
o Both SA fans OFF.
o Both P&S air blowers NOT running for 10 mins.
o Any two Seal pot blowers NOT running for 1 mins.
o Both FBHE EC BLOWERS NOT running for 60 secs.
o PA fan-1A ON for 2 minutes & PA fan-1A O/L damper not opened.
Page 12 of 79
B) BLOWERS:
1. PURGE & SEAL AIR BLOWERS:

PURGE & SEAL BLOWERS 1&2 MOTOR DETAILS:

VOLTS
AMPS
RPM 1478 YEAR 2007 Rating of each
heater(Motor):
Note:

respect to Blower ‘1’. The same permissive and protections are symmetric
to Blower ‘2’ also.
START PERMISSIVE:

 (ID fan-1A ON and its I/L & O/L gates opened) OR (ID fan-1B ON and
its I/L & O/L gates opened).
 P&S air blower-1 O/L damper opened.
 P&S air blower-1 motor bearing temperature <85 ˚C.
 P&S air blower-1 SRV closed.
PROTECTIONS:

o Boiler Emergency PB (UCP) operated.
o Both ID fans OFF.
o P&S air blower-1 ON for 10 secs and P&S air blower-1 zero speed
acted.
o P&S air blower-1 on for 30 secs and P&S air blower-1 O/L damper
closed.
o P&S air blower-1 ON and I/L filter DP high for 2 secs (DP swich).
o P&S air blower-1 SRV not closed for 2 secs.
o P&S air blower-1 motor bearing temperature >90 ˚C.
o P&S air blower-1 electrical trip operated.
Page 13 of 79
2. SEAL POT BLOWERS:
SEAL POT 1,2,1&2 Standby BLOWERS MOTOR DETAILS:
VOLTS 415 DE BEARING 6314 PHASE / FREQ 3 / 50HZ
AMPS 94 NDE BEARING 6313 HP 75
RPM 2955 YEAR 2007 EFFICIENCY 92%
Note:

START PERMISSIVES:

 (P&S air blower-1 ON and its O/L damper opened) OR (P&S air blower-
2 ON and its O/L damper opened).
 Seal pot blower-1 O/L damper opened.
 Seal pot blower-1 standby interconnection damper closed.
SEAL POT BLOWERS PROTECTIONS:

o Both ID fans OFF.
o Seal pot blower-1 ON for 10 Secs and Seal Pot blower-1 zero speed
acted.
o Seal pot blower-1 ON for 30 Secs and Seal Pot BLWR-1 O/L damper
closed.
o Seal pot blower-1 ON and I/L filter DP high for 2 secs (DP swich).
o Seal pot blower-1 SRV NOT closed for 2 secs.
Page 14 of 79
3. SEAL POT STANDBY BLOWERS:
START PERMISSIVE:

 (P&S air blower-1 ON and its O/L damper opened) OR (P&S air blower-
2 ON and its O/L damper opened).
 (Seal pot blower-1 OFF) OR (Seal pot blower-2 OFF).
 (Seal pot blower-1 OFF & its O/L damper closed and Seal pot blower-1
standby interconnection damper opened) OR (Seal pot blower-2 OFF &
its O/L damper opened and Seal pot blower-2 standby interconnection
damper closed).
PROTECTIONS:

o Both ID fans OFF.
o Seal pot 1-2 standby blower ON for 10 secs and its zero speed acted.
o Seal pot 1-2 standby blower ON for 30 secs and SP blower-1 standby
interconnection damper closed and SP blower-2 standby
interconnection damper closed.
o Seal pot 1-2 standby blower ON and I/L filter DP high for 2sec .
o Seal pot 1-2 standby blower SRV NOT closed for 2 secs.
o Both P&S Air Blowers NOT Running for 10 mins.
4. FBHE EC BLOWERS:
FBHE EC 1,2 BLOWERS MOTOR DETAILS:

VOLTS
AMPS
RPM 1475 YEAR 2007 Rating of each 240 volts
heater(Motor): 630 watts
Page 15 of 79
Note:

START PERMISSIVE:

 FBHE EC blower-1 selected MAIN.
 Any P&S air blower running for 60 secs.
 Any two Seal pot blowers running for 60 secs.
 FBHE EC blower-1 MTR Winding temperature <100 ˚C.
 FBHE EC blower-1 MTR Bearing temperature <85 ˚C.
 FBHE EC blower-1 No SWGR disturbance.
 FBHE EC blower-1 SWGR available.
 FBHE EC blower-1 O/L damper opened.
 FBHE EC blower-1 SRV closed.
PROTECTIONS:

o Both ID fans OFF.
o FBHE EC blower-1 ON for 10 secs and FBHE EC blower-1 zero speed
acted.
o FBHE EC blower-1 ON for 30 secs and FBHE EC blower-1 O/L damper
closed.
o FBHE EC blower-1 ON and I/L filter DP high for 2sec (DP Switch).
o FBHE EC blower-1 SRV NOT closed for 2 secs.
o Any two Seal pot blowers NOT running for 60 secs.
o FBHE EC blower-1 motor bearing temperature >90 ˚C (10 sec delay).
o FBHE EC blower-1 electrical trip operated.
5. FBHE BLOWERS (BUNDLE CHAMBER) – 1/3/2/4:

FBHE BLOWERS 1,2,3,4, Standby 1&3,2&4 MOTOR DETAILS:

VOLTS
Page 16 of 79
FBHE BLOWERS 1,2,3,4, Standby 1&3,2&4 MOTOR DETAILS:

AMPS
Note:

to Blower ‘2, 3, 4, 1-3, 2-4’ also.
START PERMISSIVE:

 SP blower-2 OR standby blower for SP-1 running (For FBHE blower
1&3].
 SP Blower-1 OR standby blower for SP-2 running [For FBHE blower-
2&4].
 Any FBHE EC blower running.
 FBHE blower-1 motor winding temperature <100 ˚C.
 FBHE blower-1 motor Bearing temperature <85 ˚C.
 FBHE blower-1 no SWGR disturbance.
 FBHE blower-1 SWGR available.
 FBHE blower-1 O/L damper opened.
 FBHE blower-1 IC damper closed.
 SP-2 to FBHE-1 spies valve in man & min position (for FBHE blr-1)
PROTECTIONS:

o Both ID fans OFF.
o FBHE blower-1 ON for 10 secs and FBHE blower-1 zero speed acted.
o FBHE blower-1 ON for 30 secs and FBHE blower-1 O/L damper closed.
o FBHE blower-1 ON and I/L filter DP high for 2sec (DP Switch).
o FBHE blower-1 SRV NOT closed for 2 secs.
o Both EC blowers NOT running for 60 secs.
Page 17 of 79
o SP blower-2 & standby blower for SP-1 not run for 60 secs (For FBHE
blower-1 & 3).
o SP blower-1 & standby blower for SP-2 not run for 60 secs (For FBHE
blower-2 & 4).
o FBHE blower-1 motor bearing temperature >90 ˚C (10 sec delay).
o FBHE blower-1 electrical trip operated.
o HRH temp at RH O/L >560 ˚C (Applicable for FBHE blower -1 only)
o RH Protection operated (Applicable for FBHE Blower -1 only).
6. FBHE BLOWERS (BUNDLE CHAMBER) – 1-3 STANDBY

/2-4 STANDBY
START PERMISSIVES:

 FBHE blowers 1 OR 3 running.
 SP blower-2 OR standby blower for SP-1 running.
 Any FBHE EC blower running.
 FBHE 1-3 standby blower motor winding temperature <100 ˚C.
 FBHE 1-3 standby blower motor bearing temperature <85 ˚C.
 FBHE 1-3 standby blower no SWGR disturbance.
 FBHE 1-3 standby blower SWGR available.
 (FBHE blower-1 OFF & its O/L damper closed & FBHE blower-1 IC
damper opened & Seal pot-1 to FBHE-1 spiess valve in man. &
minimum position) OR
 (FBHE blower-2 OFF & its O/L damper closed & FBHE blower-2 IC
damper opened & Seal Pot-1 to FBHE-2 spiess valve in man. &
minimum position)
PROTECTIONS:

o Both ID fans OFF.
o FBHE 1-3 standby blower ON for 10 secs and FBHE 1-3 standby blower
zero speed acted.
o FBHE 1-3 standby blower ON for 30 secs and FBHE blower-1 IC
damper closed & FBHE blower-2 IC damper closed.
o FBHE 1-3 standby blower ON and FBHE 1-3 standby blower I/L filter
DP high for 2 secs (DP Switch).
o FBHE 1-3 standby blower SRV NOT closed for 2 secs.
Page 18 of 79
o Both EC blowers NOT running for 60 secs.
o SP blower-2 & standby blower for SP-1 not run for 60 sec (For FBHE 1-
3 standby blower).
o SP blower-1 & standby blower for SP-2 not run for 60 sec (For FBHE 2-
4 standby blower).
o FBHE 1-3 standby blower motor bearing temperature>90˚C(10 sec
delay).
o FBHE 1-3 standby blower electrical trip operated.
o HRH temp at RH O/L >560 ˚C and FHBE-1 interconnection damper not
closed.(Applicable for FBHE 1-3 standby blower only)
o RH protection operated .(Applicable for FBHE 1-3 standby blower only)
C) LIGNITE FUEL FEEDING SYSTEM:
1. LIGNITE EXTRACTION FEEDERS:

START PERMISSIVE:
 Lignite Bunker Level Not Low.

 Boiler Protection 1 Not acted.
 DP combustor > 90 mbar.
 Combustor temperatures lower 3 of 4 > 350 ˚C.
 Combustor temperature middle 3 of 4 > 450 ˚C.
 PA Flow > 17 KGS/S (58.4 T/Hr).
 Any one P & S air blower in service.
 Any two Seal pot blower in service.
 Any one PA Fan in service.
 Any one SA Fan in service.
 Any one ID Fan in service.
 Feeder A Conveyor in Minimum & Manual.
 Lignite Gate valve opened (MFT).
 Lignite Transport Conveyor – A ON.
PROTECTIONS:
o DP combustor < 70 mbar.

o Boiler Protection 1 OR 3 acted.
o Combustor temperature lower OR middle 3 of 4 < 450 ˚C.
o PA Flow > 16 KGS/S (55T/Hr).
o Both P & S air blowers Tripped with 10 mins delay.
o Both PAF/SAF Tripped.
o Gate closed & Feeder – A not stopped.
Page 19 of 79
o Feeder – A stopped & Conveyor ON.
o Conveyor – A on & ZS acted.
o Chain Misalignment Conveyor or overload current trip >16A (10 sec).
o Chain Misalignment Feeder –A (for extraction feeder A1 or A2 or A3).
o Both IDF Tripped.
o Gate valve opened & FDR OFF.
o FDR –A ON & ZS ACTED.
o AL FDR ON & ZS ACTED.
o Combustor or Cyclone outlet temperature High, (> 950˚C)
2. LIGNITE TRANSPORT CONVEYOR:

START PERMISSIVE:

 Combustor temperature lower 3 of 4 > 350˚C.
 Combustor temperature middle 3 of 4 > 450˚C.
 PA Flow > 17 KGS/S (58.4 T/Hr).
 Feeder A Conveyor in Minimum (2%) & Manual.
 Lignite Gate valve opened (MFT).
 Lignite AL Feeder – A ON.
PROTECTIONS:

o Combustor temperature lower OR middle 3 of 4 < 450˚C.
o Gate closed & Feeder – A not stopped.
o Feeder – A stopped & Conveyor ON (Extraction feeder 1A only &
Transport conveyor ON with 5s delay).
o Conveyor – A on (30 s delay) & ZS acted.
o Chain Misalignment Conveyor –A (5 sec delay).
Page 20 of 79
o Chain Misalignment Feeder –A (for extraction feeder 1A or 1B or 1C).
o Both ID Fans Tripped.
o Gate valve opened & FDR OFF (feeder 1A or transport feeder).
o Combustor or Cyclone temperature High, (> 950˚C) Press High (> 35
mbar).
o AL FDR ON & ZS ACTED with 10 sec delay.
3. LIGNITE GATE VALVE:

START PERMISSIVE:

 Combustor temperature lower 3 of 4 > 350˚C.
 Combustor temperature middle 3 of 4 > 450˚C.
 PA Flow > 16 KGS/S (58.4 T/Hr).
 C1/C2/C3 & FDR-A conveyor in MIN & Manual.
PROTECTIONS:

o Combustor temperature lower OR middle 3 of 4 < 450˚C.
o Gate closed & Feeder – 1 not stopped.
o Feeder – 1 stopped & Conveyor ON (Extraction feeder 1A only &
Transport conveyor ON with 5s delay).
o Conveyor – 1 on (30 s delay) & ZS acted.
o Chain Misalignment Conveyor –1 (5 sec delay).
o Chain Misalignment Feeder –1 (for extraction feeder 1A or 1B or 1C).
o Both IDF Tripped.
o Gate valve opened & FDR OFF (feeder 1A or transport feeder).
o Combustor or Cyclone temperature High, (> 950˚C)
o AL FDR ON & ZS ACTED with 10 sec delay.
Page 21 of 79
D) BOILER PROTECTION:
1. BOILER PROTECTION 1/MFT(Master Fuel Trip):
I) TRIP INPUTS: (2 out of 3 Trip logic among the elements & three
Channels)
o Boiler emergency trip operated from operator work station/unit control

panel/control desk.
o ID fan -1 & 2 speed <150 rpm.
o Both ID fans off.
o MS PR before Boiler stop valve>20 KSC and Boiler stop valve not open.
o [Turbine trip & (HP bypass-1 & 2)<min(<pos<2%) & MS PR before HP
bypass >40 KSC & Comb lower temp>450˚C] with a delay of 4 sec.
o Inlet convective pass pr. >30 mbar
o Compensated drum level <-225 mm
o Deaerator level <800 mm
o Compensated drum level >+250 mm
o MS temp at SH outlet >560˚C.
o HRH temp at RH outlet >560˚C.
o Instrument air pr <4.5 KSC.
o Both DMCW BPS off with 5 sec delay.
o Comb temp lower >950˚C.
o Comb temp middle >950˚C.
o Cyclone-1 O/L temp >1000˚C.
o Cyclone-2 O/L temp >1000˚C.
II) TRIP OUTPUTS through DCS logics:
 To trip PA fans -1 & 2, SA fans 1 & 2.

 To trip Seal pot blowers 1, 2 & 1-2 standby.
 To trip Purge & Seal air blowers 1 & 2.
 To trip FBHE empty chamber blowers 1 & 2.
 To trip FBHE bundle chamber blowers 1, 2, 3, 4, 1-2 standby & 3-4
standby.
 To trip Ash cooler blowers 1 & 2.
 To trip turbine after 10 secs delay AND to activate BP 2 & 3.
Page 22 of 79
4. BOILER PROTECTION -2 (SUB1,2 AND BED LANCES):
I) SUB 1 TRIP CONDITIONS:
o Boiler Protection 1 Activated.

o No. of failed ignitions>4.
o PA flow<15 Kg/s (54 T/hr).
o SUB 1 emergency PB operated (from OWS / UCP).
o SUB 1 air flow<2.7 Kg/s (9.7 T/hr).
II) SUB 2 TRIP CONDITIONS:
o Boiler protection 1 activated.

o No. of failed ignitions>4.
o PA flow<15 kg/s (54 t/hr).
o SUB 2 emergency PB operated (from OWS / UCP).
o SUB 2 air flow<2.7 kg/s (9.7 t/hr).
III) BED LANCES 1-6 TRIP CONDITIONS:

o Bed lance emergency PB operated (from OWS / UCP)
o Comb lower temp <300˚C.
o Comb middle temp <400˚C.
5. BOILER PROTECTION -3 (LIGNITE & LIME FEEDERS):
o Comb lower temp <350˚C.
o Comb middle temp <450˚C.
o O2 at back pass inlet <min (<2%) with a delay of 30 secs.
 To Trip Lignite Fuel Feeding system 1 & 2 and Lime stone feeding systems
4. RH PROTECTION
1. HRH temp at RH outlet >560˚C
RH PROTECTION OUTPUTS:
1. To trip FBHE blower 1 & 1-3

2. To close SP-1 to FBHE spiess valve 100%
Page 23 of 79
E) SG COOL DOWN AND ITS IMPORTANT OUTPUTS:
SG cool down acted Boiler protection-1 acted & Comb lower temp>450˚C
NO. DESCRIPTION LOGIC CONDITION
1 Both LP bypass will close SG cool down acted & station black out
2 Emergency CW Pump (pre- Comb lower temp>450˚C & [both BFPs

selected) will switch on off(5 sec delay) OR station blackout]
(OR)
SG cool down acted & [both DMCWBPs
off (5 sec delay) or station blackout]
3 DMCW emergency CW valves SG cool down acted and

(CW001 & CW004) will open &
[both DMCWBPs off(5 sec delay) OR
DMCW normal CW valves
station blackout]
(CW002 & CW003) will close
4 Emergency BFP will switch on Comb lower temp>450˚C & [both BFPs
off(5 sec delay) or station blackout] OR
SG cool down acted & [both BFPs off (5
sec delay) or station blackout]
5 Emergency DM make up will SG cool down acted and

switch on
[both CEPs off(5 sec delay) or station
blackout]
6 CBD (BW059 & 060) and EBD SG cool down acted and
(BW054 & 055) isolation valves
[both BFPs off(5 sec delay) or station
will close
blackout]
7 Auto open of HRH vent valves (SG cool down acted & station black out)
(MS 85 & MS 86) OR (LPBP stop valve-1 or CV1 close) &
(LPBP stop valve-2 or CV2 close) &
turbine not run & SG cool down acted
8 Auto open of drain valves in SG cool down acted and condenser

CRH(CRH 123 & 124), HRH (122 vacuum low (>0.3 ata) and (both LPBP
& 123 to UFT and auto close of stop valves closed or station blackout)
drain valves in CRH(CRH 101 &
120), HRH (101 & 102) to HPFT
Page 24 of 79
F) UCP ANNUNCIATIONS:
Sl.No Text Limits
1.01 Flue Gas press. Hi / Lo +30 mbar / -30mbar
1.02 ID-1 Tripped
1.03 ID-2 Tripped
1.04 PAF-1 Tripped
1.05 PAF-2 Tripped
1.06 SAF-1 Tripped
1.07 SAF-2 Tripped
1.08 P&S Blower-1 Tripped
1.09 P&S Blower -2 Tripped
1.10 Any SP Blower Tripped
1.11 Any FBHE Blower Tripped
1.12 Drum level Abnormal V.Hi 250mm, Hi 150mm
Low -125mm, V.Low-250mm
2.01 STN. BLK OUT
2.02 BFP-A Trip
2.03 BFP-B Trip
2.04 DMCW A/B Trip
2.05 ACW-A Trip
2.06 ACW-B Trip
2.07 HW level Abnormal V.Hi 1050mm, Hi 1000mm
Low 800mm , V.Low 150mm
2.08 Dea. Level Abnormal V.Hi 2800mm, Hi 2585mm
Low 1835mm, V.Low 500mm
2.09 Any CWP Trip
Page 25 of 79
2.10 Any LDO Trippd
2.11 HW level Make up Pump
A/B/C Trip
2.12 Any HFO Pump Trip
2.13 Lignite Flow Low < 35 T/ Hr
3.01 Any DMCW BP Trip
3.02 BP-1 Acted
3.03 BP-2 Acted
3.04 BP-3 Acted
3.05 CT Oil supply emergency

OFF
3.06 CT Oil Pump prot OFF
3.07 Cmbstr Temp Low < 450°.C
3.08 Cmbstr Temp V.Hi > 950°.C
3.09 Any FBHE EC Blwr Trippd
3.10 DP across Cmbstr Hi <95 m bar >120 m bar DP WO grade
3.11 Any ACLR Blwr Trip
3.12 Lig. Fdr. SYS-1 TRBLE
3.13 Lig. Fdr. SYS-2 TRBLE
4.01 PA Flow Low < 54 T/Hr
4.02 Bed Mtr Fdr Trip
4.03 Lig Pwdr system Trble
4.04 CEP-A Trippd
4.05 CEP-B Trippd
4.06 Fire Protn Acted
4.07 LOB Pr V.Low < 2.8KSC
4.08 LP BP Man Trip
Page 26 of 79
4.09 LP BP Trip respnd
4.10 TSLLE LT 7.5 PLT
4.11 MOT Level V.Low < 340 mm
4.12 Over Speed Trip > 3300 rpm
5.01 Axial Displ V.Hi -1 to +1 mm
5.02 Cas TB dT V.Hi Variable
5.03 Cond Press V.Hi 0.3 ATA
5.04 Emergency Trip
5.05 DP Across HP Turbine Low < 1.05 KSC
5.06 Gen Protn Optd
5.07 HP Exst stm Temp V.Hi 370°.C / 470 °.C
5.08 IP I/L Temp V.Hi/ V.Low 330 -445 °C / 355- 545 °C
5.09 Liv STM Temp. V.Hi / Lo 380 – 480 °C / 355- 545 °C
5.10 LP Exst Temp V.Hi >110 °C.
5.11 Gen/ Tur Shaft vibrtn Hi >120 / 120 microns
5.12 Turbine Prot Ch A/B acted
5.13 HP BP System Trouble
6.01 IA / SA System TRBLE
Page 27 of 79
II. TURBINE
G) PUMPS:
1. BOILER FEED PUMP:

I. PUMP DETIALS:
There are 2X100% capacity Boiler Feed Pumps available in each Unit.
MOTOR DETAILS:
KW 4000 AMB TEMP 70 °C PHASE / FREQ 3 / 50HZ
VOLTS 6600 DE BEARING 160*146 HP 25
AMPS 405 NDE BEARING 125*115 EFF% 90.5
RPM 1493 WEIGHT 13360 KG MAKE BHEL BHOPAL
GEARED VARIABLE SPEED TURBO COUPLING:
KW 3160 RPM 1485 TEST PR 16 KSC
OPERTNG 8 KSC MAKE VOITH

PR TURBO
CENTRIFUGAL PUMP:
PRM 4940 HEAD 1850m Make BHEL

HYDERABAD
No of 5 Flow 490 m3/ hr
Stages
II. PERMISSIVE:
 Bearing temp Not High ( < 90 / 100 oC )
 Suction Valve is Opened
 No Reverse rotation (from sensor)
 Deaerator level is adequate ( > 1835mm)
 Suction-Discharge DT < 10oC
 Hydro Coupling Tank Oil level > minimum (level switch)
 Working Oil Cooler outlet temp < 75 °C
 Working Oil before Cooler < 110 °C
 Lube Oil temperature after Cooler < 55 °C
 AOP is running
 LO header pressure is > 1.8 KSC
Page 28 of 79
 No Electrical trip
 Switch Gear is available
 Discharge valve Closed, Recirculation Open and Scoop is minimum or
Pump selected as Standby (limit switch) scoop value <4%.
 DMCW inlet valve is Open(limit switch)
 DMCW inlet press at Working Oil Cooler is OK >3 ksc
III. PROTECTIOS:
o Electrical trip (from MCC)
o Bearing temp high(Motor both ends &HC temp:100°C) (3sec in GT fun.)
o Suction-Discharge Differ. temp>15°C & Suction Flow<120T/hr(30sec)
o Working Oil temperature > 130°C (3sec in GT function)
o Suction pressure < 10 KSC & BFP ON(2Sec).
o Deaerator Level < 500 mm(2 out of 3 logic from level switch)
o Lube Oil Pressure Very Low (< 0.5 KSC) & BFP ON
o Suction valve not opened
2. CONDENSATE EXTRACTION PUMP

I. PUMP DETIALS:
 There are 2X100% capacity Condensate Extraction Pumps available in
each Unit.
MOTOR DETAILS:
STATOR 6600 DE BEARING 6222 C3 PHASE / FREQ 3 / 50HZ

VOLTS
STATOR 37.5 NDE BEARING 7322 B MAKE BHEL BHOPAL
AMPS
PUMP DETAILS:
MAKE M/S BHEL HEAD 225 m NPSH 2.19 m
FLOW 390 m3/ hr No of Stages 7
II. PERMISSIVE:
 Suction Valve is Fully Opened
Page 29 of 79
 Hot well level is adequate and above 700 mm
 Ensure Switchgear is available, Power supply is ON and Local latch is
released
 Discharge side SOV air vent valve should be Open.
III. PROTECTIONS:
o Hot Well level is low (150 mm) (level switch)

o CEP JRNL/THRST Bearing temperature is V.high (>90 °C) (3sec in GT
fun.)
o CEP Motor bearing temp very high (>90 °C) (3sec in GT fun.)
o If Suction strainer choke is above 0.5 KSC (DP), manually change over
and clean filter
IV. Interlocks:
 Whenever running pump trips, reserve will start on electrical interlock.

 Whenever the Condensate Discharge Header pressure drops below 17
KSC, reserve will start after a time delay of 10 sec.
 Whenever Discharge Pressure of the running pump drops below 15 KSC,
Reserve will start and the running pump will get tripped after a time delay
of 10 sec.
 Whenever a pump trips, its discharge valve will get Closed unless it is
selected as standby.
3. Circulating Water Pump:

I. PUMP DETIALS:
2 x 50 % CWP for each Unit and a common stand by with Discharge valve
connection to both Units are available. Eight Cooling Tower (CT) fans for each
unit is available, out of which 7 Cells are enough during full load operation. Make
up for the Fore bay is available from PT plant storage tank. Fire Hydrant Pumps
also draw water from the Circulating water pump house Fore bay.
Pump Details: Motor Detail:
Make : KIRLOSKAR Make : ABB
Volts : 6.6 kV Rating : 760 KW
Page 30 of 79
Pump Details: Motor Detail:
Head : 20.17 m Speed : 495 rpm
Flow : 10250 m3/hr Current : 96 Amps
Power : 625.58 Kw Speed : 495 rpm
II. PERMISSIVE:
 Condenser Inlet and Outlet valves are Opened

 CW Pump Discharge valve is Closed
 Motor Winding temperature is not high (130 °C)
 Motor/ Pump Bearing temperatures (DE/NDE) are not high (85 °C)
 Sump level is not low (> 2m)
 Thrust bearing cooling water flow is not low.
 No Reverse Rotation
 Switch Gear available and breaker in remote mode
 Emergency Push Button not operated
III. PROTECTIONS:
o Any guide bearing or Thrust bearing temperature is very high. ( > 85°C)
o Fore bay level is VERY LOW. (< 1.5m)
o Emergency Stop Push Button (Near pump) is operated.
o CW discharge pressure is very high (> 2.0 KSC ) for a sustained period of
90 secs (pressure switch).
o Any electrical trip condition.
IV. Auto ON for 1C Discharge Valve:
 CWP selected as Manual

 Discharge to Unit is selected
 Remote Operation is selected.
Page 31 of 79
4. DM COOLING WATER SYSTEM (DMCW) &
AUXILIARY COOLING WATER SYSTEM (ACW)
I. PUMP DETAILS:
DMCW MOTOR DETAILS:

VOLTS
STATOR 27 NDE BEARING NU 218M MAKE BHEL BHOPAL
AMPS
1850 HEAD 33
FLOW
m3/ hr
ACW MOTOR DETAILS:
RPM 985 YEAR 2008 MAKE MARATHON

ELECTRIC
HEAD 10 1850
FLOW
m3/ hr
NaOH System:
The NaOH solution is periodically dozed in the DMCW O/H Tank and DMCW
Pump suction header for maintaining a pH value of 8.5 to 9.5. An O/H Sodium
Hydroxide solution tank is provided and dozing to DMCW tank is by gravity.
II. DMCW PERMISSIVE:
o DMCV pump motor protection relay should not be acted
o Switch gear should be available
o Switch gear not disturbed
o DMCW motor bearing temp not high < 85˚C
o DMCW respective pump should not be tripped / OFF
o DMCW suction valve must be opened
o Suction pressure not low >1.25KSC
Page 32 of 79
o DMCW header pressure adequate OR overhead tank level not low
<1500mm
III. DMCW PROTECTIONS:
o DMCW suction valve not opened
o DMCV pump motor protection relay acted
o Suction pressure not low <1.25KSC 10sec (pressure switch) & overhead
tank level not low <700mm
o DMCW motor bearing temp very high < 90˚C
o DMCW discharge pressure high >6KSC with 10sec delay (pr. switch)
o DMCW discharge header pressure v.high >8.5KSC with 10sec delay.
IV. DMCW Pump interlocks:
 When the running pumps trips, the standby pump starts automatically.
 When discharge header pressure drops below 3 ksc the stand by pump
will start after a time delay of 5 seconds.
V. ACW PERMISSIVE:
o Switch gear should be available
o Switch gear not disturbed
o ACW Pump suction valve must be opened
o ACW Pump Suction pressure not low <1.4KSC
VI. ACW PROTECTIONS:
o ACW pump MCC Electrical disturbance acted
o ACW pump Discharge pressure high >3.6 KSC(10sec delay) (pr. switch)
o ACW pump Suction pressure low <1.4KSC (10sec delay) (pr. switch)
o ACW discharge header pressure low <0.95 KSC & when Pump is ON
o ACW discharge header pressure V.High>5 KSC (10 sec) &Pump is ON
VII. Auto Starting of ACW Pumps:
 When discharge header pressure drops below 1.3 KSC the stand by
pump will start.
Page 33 of 79
6. DMCW BOOSTER PUMP:
DMCW BP PUMP DETAILS:
DMCW BP MOTOR DETAILS:
RPM 1485 YEAR 2008 MAKE MARATHON

ELECTRIC
HEAD 38 FLOW 850 m3/ hr
I. DMCW BP PERMISSIVES:
o DMCW BP Breaker not disturbed
o DMCW BP suction valve must be opened
o DMCW BP Suction pressure adequate >3.4KSC
o DMCW Overhead tank level not low <1500mm
II. DMCW BP PREOTECTIONS:
o DMCW suction valve not opened
o DMCV pump motor protection relay acted
o DMCW BP Suction Header pressure adequate >3.4KSC(10sec delay)

(pressure switch)
o Both DMCW main Pump OFF
o DMCW BP discharge header pressure Very High >14 KSC ( 10sec)
III. Auto Starting of DMCW Booster Pumps:
When Booster pump discharge header pressure drops below 4.5 KSC the
stand by pump will start after a time delay of 5 seconds.
Page 34 of 79
6. Hot well Make Up Pump:
I. Pump Details:
MOTOR DETAILS:
KW 18.5 AMB TEMP 50 °C PHASE / FREQ 3 / 50HZ
VOLTS 415 DE BEARING 6310 ZZ HP 25
AMPS 33.5 NDE BEARING 6210 ZZ EFF% 90.5
RPM 1460 WEIGHT 315 KG MAKE MARATHON

ELECTRIC
Hot well make up Pump 3 nos each of 100 % capacity, takes DM water from
CST (700 m3) and Discharges to Condensers of both the units through Hot Well
make up control valves DM-27 (High capacity) and DM-30 (Low capacity).
II. PERMISSIVE:
 CST level is adequate >4000 mm
 CST Outlet manual valve is Opened
 Suction Valve is Opened
 Discharge Valve is Opened
III. PROTECTIONS:
o CST Level low <1500 mm

o Discharge pressure is high >6.5KSC with 5sec delay
IV. Auto Starting for the Make-Up Pumps:
 Electrical interlock: When running pump trips, standby is given ON

command automatically.
 Press interlock: If Discharge press falls below 3.5 KSC, standby will start.
7. EMERGENCY COOLING WATER PUMPS (ECW):
I. ECW Pump Details:
MOTOR DETAILS:
KW 30 AMB TEMP 50 °C PHASE / 3 / 50HZ

FREQ
VOLTS 415 DE BEARING 6312 FLOW 80 m3/hr
AMPS 51.5 NDE BEARING 6212 EFF% 92.5
RPM 2955 WEIGHT 315 KG MAKE BHARAT BIJLEE LTD
Page 35 of 79
There are 3X100% capacity ECW pumps connected with Emergency DM
Cooling Water Tank (900 m3). During Station Blackout condition, in the absence
of DMCW and DMCW Booster Pump, it supplies cooling water to Spiess Valves
(7nos.) and to Emergency Boiler Feed Pump (EBFP). On command for this pump
is received from DCS on SG Cool Down Logic.
II. ECW PUMP PERMISSIVES

 ECW Tank level adequate. > 3000 mm
 Suction valve is open. Limit in DCS
 Discharge valve is open. Limit in DCS
IV. ECW PUMP PROTECTIONS
o ECW pump ON & Dish pr low with 5sec delay (pressure switch)
o ECW Pump suction header pressure low (pressure switch)
V. AUTO STARTING OF RESERVE PUMP

When the running pump trips, an ON command goes to the reserve pump
automatically.
8. Emergency DM Water Pumps:

I. EDM water Pump Details:
MOTOR DETAILS:
VOLTS 415 DE BEARING 6313 HP 40
AMPS 52.8 NDE BEARING 6312 EFF% 92

ELECTRIC
Emergency DM water Pump 2 nos each of 100 % capacity, takes DM

water from Emergency DM Tank (350 m3) and discharges to Deaerator of both
the units through the control valve DM-71. Main isolation valves to individual
units are DM 69. During station black out condition it will receive supply from
respective unit DG sets.
II. Emergency DM Water Pumps PERMISSIVE:

 Emergency MU Tank level is not low (> 3000 mm).
 Tank Outlet manual valve (DM_61) is Open (Limit in DCS).
 Suction Valve is Open (Limit in DCS).
 Discharge Valve is Open (Limit in DCS).
Page 36 of 79
III. Emergency DM Water Pumps PROTECTIONS:
o Emergency MU Tank level very low <4000 mm
o Discharge pressure is high > 9.5 KSC with 5sec Delay
IV. Auto Starting for the Reserve Pump:

Electrical interlock: When running pump trips, standby is given ON command
automatically.
Press interlock: If Discharge Header pressure falls below 3.0 KSC, standby will
start.
9. Boiler Fill Pump:
I. Pump Details:
MOTOR DETAILS:
VOLTS 415 DE BEARING 6317 HP 10
AMPS 129.6 NDE BEARING 6317 FLOW 120 m3/hr

ELECTRIC
Boiler Fill Pumps of 2 nos each of 100 % capacity are taking DM water
from CST (700 m3) and discharges for Boiler Filling and Deaerator initial filling of
both the units through the manual valve (DM 37) and MOV (DM 40) at Deaerator
floor. Main isolation valves to individual units are available (DM37).
II. Boiler Fill Pumps PERMISSIVE:
 No Electrical disturbance.
 Suction Valve should be Opened
 Discharge Valve should be Opened
 CST Outlet manual valve DM-45 should be Opened
 CST level is not low >4000 mm
III. Boiler Fill Pumps PROTECTIONS:

o Electrical trip signals.
o CST Level low <1500 mm with 10sec delay
o Discharge header pressure is high >14 KSC with 5sec delay
Page 37 of 79
IV. Auto Starting for the Make-Up Pumps:
 Electrical interlock: When running pump trips, standby selected pump will
start automatically
 Pressure interlock: If Discharge press falls below 9.0 KSC, standby will
start.
H) TURBINE OIL SYSTEM/PUMPS
1. Main oil pump (Mop):
MOTOR DETAILS:
3 Phase induction motor AMB TEMP 50 °C
VOLTS 415 HP 50
AMPS 63 KW 37
RPM 2955
I. Auto ON for MOP
 SLC of MOP command ON & MOP1 Preselected (2sec ON delay)
 SLC of MOP command ON & Running MOP OFF Feedback

& Running MOP electrical fault initiated
 (MOP header pressure<4.8KSC OR Lube oil header PR<3.4KSC)

& SLC of MOP command ON(1.2Sec ON delay) & MOP
Preselected
II. Auto OFF for mop
o (SLC MOP OFF,MOP 1&2 OFF Feedback, SLC DC EOP OFF

feedback, Turning Gear SOV valve OFF feedback, DC EOP OFF
feedback) & The sequence command comes from SGC sequence
master initiated
III. Protections OFF for the main oil Pump
o Fire Protection Channel 1&2 initiates.
2. AC Lift oil pumps (AC LOP):

MOTOR DETAILS:
VOLTS 415 DE BEARING 6312 2RS HP 50
AMPS 63 NDE BEARING 6212 2RS EFFICIENCY 92%
RPM 2955 YEAR 2007 MAKE CROMPTON

CREAVES
Page 38 of 79
I. Auto ON for AC LOP
 SLC of LOP 1 command on & Turbine speed <510rpm
II. Auto OFF for AC LOP
o SLC of LOP 1 command on & Turbine speed >510rpm
o SGC STEP sequence command initiates
III. Protections OFF for the AC LOP
o Fire protection channel 1 & 2 initiated
o LOP pressure after filter <100KSC & SLC LOP 2 Command ON

and Turbine speed <510rpm (5 Sec ON delay)
o AC and DC LOP both pumps OFF Feedbacks & SLC LOP 2

Command ON and Turbine speed <510rpm (5 Sec ON delay)
3. DC Lift oil pumps (DC LOP):

DC MOTOR DETAILS:
ARM 220 DE BEARING 6316 2RS HP 50

VOLTS
DC MOTOR DETAILS:
ARM 197 NDE BEARING 6316 2RS FIELD A 1.43

AMPS
RPM 2900 WEIGHT 900 KG MAKE CROMPTON
CREAVES
I. Auto ON for DC LOP
 LOP pressure after filter <100KSC & SLC LOP 2 Command ON

and Turbine speed <510rpm (5 Sec ON delay)
 AC and DC LOP both pumps OFF Feedbacks & SLC LOP 2

Command ON and Turbine speed <510rpm (5 Sec ON delay)
II. Protections OFF for the DC LOP
o Fire protection Channels 1 & 2 initiated
4. Emergency Oil Pump (DC EOP):

DC MOTOR DETAILS:
KW 15 AMB TEMP 50 °C PHASE / 3 / 50HZ

FREQ
ARM 220 DE BEARING 6213 2RS HP 50
VOLTS
ARM AMPS 80 NDE BEARING 6213 2RS FIELD V/A 220 / 1.0
RPM 2900 WEIGHT 340 KG MAKE CROMPTON CREAVES
Page 39 of 79
I. Auto ON for DC EOP
 SLC of DC EOP command ON is AND with the following logics

(2sec ON delay):
 SLC of MOP command ON & MOP1 OFF Feedback &

MOP1 electrical fault initiated
 SLC of MOP command ON & MOP2 OFF Feedback &

MOP2 electrical fault initiated
 (MOP header pressure<4.8KSC OR Lube oil header

Pressure switch <3.4KSC ) & SLC of MOP command
ON(1.2Sec ON delay)
II. Protections ON for the DC EOP
 Fire protection channel 1&2 initiated
 Lube oil header Pressure switch <2.8KSC
5. Control Oil Pump (COP):

MOTOR DETAILS:
KW 15 AMB TEMP 50 °C
VOLTS 415 MAKE SIEMENS
AMPS 29 PHASE / FREQ 3 / 50HZ
RPM 1450 PF 0.81
I. Auto ON for COP
o Any one of the running pump and its discharge pressure is less
than 140 KSC, then DCS gives auto start command to COP
standby pump with the delay of 5 sec. All condition should be
ensured with SLC ON.
II. Auto OFF for COP
o If BOTH PUMPS RUNNING for the time 10secs and the discharge
header pressure more than 150 KSC, then DCS gives off
command to any one of the running pump (i.e. pump without
preselect). All condition should be ensured with SLC ON.
III. Protection OFF logics for the COP:
 The following conditions are satisfied for COP protection & Turbine
protection OFF:
Page 40 of 79
 Control oil supply emergency off: Tank level very low &
low/Fire Protection 1&2/COP emergency push button from
DCS graphics and ECP panel.
 Control oil pump emergency off: Once the header

pressure reaches above 140KSC & after turbine reset, The
COP’s Discharge and Header pressure reaches below
105KSC with time delay of 5 seconds.
o Any one of the running pump ON feedback & its discharge and
header pressure less than equal to 10 KSC with 120 seconds time
delay, then DCS gives Protection off command.
6. Control Oil Recirculation Pump

MOTOR DETAILS:
KW 0.75 AMB TEMP 45 °C
VOLTS 415 MAKE SIEMENS
AMPS 1.8 PHASE / FREQ 3 / 50HZ
RPM 1415 PF 0.80
I. Auto ON for CO Recir. Pump
 SLC of COP ON command and HSU Tank temperature >53 °C
II. Auto OFF for CO Recir. Pump
o SLC of COP ON command and HSU Tank temperature <51 °C
III. Protection OFF for CO Recir. Pump
o Control oil pump Emergency OFF Push Button Pressed

(5sec Delay)
o Fire protection channel 1&2 initiated
o HSU Tank Level low (level switch 2nos)
Page 41 of 79
H) HP Bypass System
Introduction
The HP Bypass system allows Main Steam (MS )to flow from MS line to
CRH ( Cold Reheat )line during start ups, shut downs and load- throw off
conditions. As the steam by passes the normal path of HP Turbine, this system is
defined as HP by pass system. There are two Bypass valves, BP-5&BP-6; two
spray valves BPE-1 &BPE-2 and a spray water isolation valve BD valve. The
functions of HP Bypass Valves are to reduce the Main Steam parameters to CRH
conditions before admitting in to the CRH path. The water source for spray is
from BFP discharge and EBFP. BP-5 & 6 regulates the pressure based on set
values and BPE 1&2 regulates the spray flow based on the downstream
temperature set value.
The HP Bypass system has a combined capacity to bypass 60 %

(2X121.5TPH) of the 100 % Boiler MCR condition.3 nos. of pressure and
temperature transmitters are provided for controlling the pressure and
temperature. The HP Bypass valves are located in 5ML, condenser rear side near
B row.
HP BP Operation
Ensure that the HP Bypass warm up lines (BP-102,104) are open to AFT.
HPBP valves are opened, 5 % on each side, at a Main steam pressure of about
15 Ksc. (Initially put the valves in auto and again take back into manual mode
for the HPBP valves to open.) RH air vents are kept opened till LPBP is ready and
sufficient vacuum is available. Gradually open BP-5&6, according to the firing in
the boiler, till rolling parameters are achieved. Whenever there is an increase of
firing in boiler, the HP Bypass will further open on AUTO to accommodate the
firing and to maintain pressure. Ensure HPBP opening is sufficient for rolling and
a minimum block load of 5 MW thereafter, after reaching the parameters.
In case of Boiler shutdown/trip, the HP Bypass has to be kept in required open

condition to cool the RH-1coils, which is located in FBHE (Fluidized Bed Heat
Exchanger) where hot bed material fluidization exists. At that time confirm
Page 42 of 79
either LP Bypass system is in service or RH Start vent valves are in open
condition.
In case of TG trip, the HP Bypass has to be kept in service (it has to come in
auto), in order to avoid starvation of RH coils which are immersed in FBHE bed.
Also it is better to save and keep boiler in service when TG trips, by reducing the
lignite flow to 60% of TGMCR values, preferably at 30% TGMCR to avoid
overloading/wastage of fuel. This may help in reducing the period of safety valve
opening.
In case of TG trip, BP has to be opened (it has to come in auto), to avoid

starvation of RH-1 coils. If HP Bypass opening is not possible, boiler firing has to
be reduced to zero, to reduce the period of opening of safety valves.
NOTE:
1. The Drum level control and HP Bypass operation are inter related. In case
of fast opening of HP bypass (due to variation in firing rate etc.), the
Drum level may increase and may lead to opening of EBD valves. Similarly
in case of fast closing also (due to variation in firing rate etc.), the Drum
level may drop in fast manner and may lead to emergencies. The smooth
operation of bypass valves will ensure normal Drum level. For overcoming
this problem, smooth coordination between Drum level control and HP
Bypass operation Board Engineers is essential. Also, firing variations may
be done in gradual manner, for smooth operation of HP Bypass. Normally
these problems will occur during start up/trip condition.
2. During boiler trip/blackout/forced cooling, the permissible steam pressure
drop gradient is 0.25 bar/minute. The HP Bypass opening shall be limited
to the above rate.
3. In case of one HP or one LP bypass is available during start up/trip
condition, the firing rate has to be adjusted to about 30%TGMCR, to avoid
over loading of the system.
1. Protections & Interlocks:
 HPBP valves trip closes if downstream temperatures goes beyond 370 °C.
Page 43 of 79
 BD & BPE Open if BP opening is > 2 %. BP 5&6 opens only if the controller
output is > 2 %.
 HPBP valves Fast Open for duration of 3 sec during the following
conditions:-
o Turbine trip
o Generator Circuit Breaker Opens ( GCB )
o Load Shedding Relay Acted ( LSR )
o RH Protection Trip acted
o Pressure deviation High ( > 8 Ksc )
o Manual Push button Operated ( HMI or DCS )
o SG cool down acted
Once the valve is fully opened in about 3 sec the fast opening signals will
be cut off by the timer set at 4 sec. The control is now shifted to pressure
control set point.
o Boiler Protection-1 will act, in case of Turbine trip & both HP BP <
2% Main steam pressure before bypass > 40 KSc and combustor
lower temperature > 450 ° C for 4 sec.
2. Oil Supply Unit (OSU ) for HPBP System:
The HP BP System valves are operated / controlled hydraulically by the pressure

oil supplied by the Oil Supply Unit (OSU) located at 5 ML.
Oil Level (dip stick) in tank, opening of all valves in the Supply lines (P
line) and return lines (T line) , Power supply and local latch release for the pump
motors are to be ensured before taking HPBP System into service. Pumps start
at low press (120 ksc), and trips at high press (160 ksc). Oil press too low (90
ksc) and too high (180 ksc) indications and pump status are available in DCS.
Running / Idle timings of both the OSU pumps are to be monitored every
shift and the same has to be recorded in Turbine Log Book.
J) LP Bypass System
Introduction
The LP Bypass system allows Steam to flow from HRH line to condenser during
start ups, shut downs and load- throw off conditions. As the steam by passes the
Page 44 of 79
normal path of IP /LP Turbine, this system is defined as LP by pass system. The
LP Bypass system has a combined capacity to bypass 60 % MCR. The functions
of LP Bypass Valves are to reduce the HRH Steam parameters to condenser
conditions before admitting in to the condenser. The water source for spray is
from CEP discharge.
There are two LPBP Stop valves and Control valves for relieving HRH Steam into
Condenser. Control Oil (COP discharge) is used for LPBP Valves actuation. LPBP
Controller has auto / manual provisions in the DCS. The LP Bypass valves are
located in 5ML, condenser front side near A row.
1. Function
LPBP Controller gets its Pressure Set Point from the Fixed/Variable Set points
(MAX Gate Output) and the actual value of HRH Line pressure.
2. Set Point formation:
o Fixed set point: Set at the OWS

o Variable set point: Derived from the wheel chamber pressure
o Flow dependent set point: Depends on injection flow setting
During Start up the Fixed set point is kept at 3.0 Ksc and gradually raised to
6.0 Ksc depending on the firing in Boiler.
Following actions take place at the Controller output values:
LPBP Controller Action

Output (%)
10 Water Injection valves Open
20 Stop Valves Open
35 Control Valves Start Opening
3. Trip Close Function:
 Control Oil System Off
 Condenser pressure high (0.5 ata)
 Water injection flow is less
Page 45 of 79
NOTE:
1. While opening LP Bypass during Light up, care should be taken to see that
condenser vacuum is not disturbed, as RH Vents are in open condition.
2. HP Bypass operation & LP Bypass operation are independent.
4. Auto Control Interface (ACI) :
ACI, when switched on Set Point matching is done when Boiler “Fire-On”
is available. Set Point is given +3 Ksc at starting. On pressure increase beyond
this value, LP B/P Valves open to a constant position of 25 %. Thereafter set
point is matched with actual till 6.0 Ksc and there after it is switched off. After
valve opens to 50 %, set point matching is also switched off.
5. LP BYPASS OPERATION
LP Bypass is used during startup, rolling, TG trip and boiler in service condition
to ensure the steam flow from RH coil to condenser. The CEP discharge water is
used for spray in LP Bypass to control the temperature.
When LP Bypass is in service without TG, the firing in the boiler has to be below
60% of TGMCR, preferably at 30% of TGMCR, to avoid overloading of the
system/wastage of the fuel.
In case LP Bypass closes during operation of boiler in HP-LP bypass system, it

may lead to opening of RH safety valves. Hence LP Bypass opening has to be
always ensured for safe operation of boiler.
The auxiliary steam pressure and temperature has to be closely monitored to

avoid closing of AS-22, which may lead to drop in condenser vacuum, which is
essential for LP Bypass operation.
In case LP Bypass is not available when boiler in HP-LP circuit, the RH start up
vent has to be opened to keep the boiler in service by reducing the firing to
minimum safe level. However, the period is limited due to drop in hot
well/Deaerator level.
Page 46 of 79
K) ELECTRO HYDRUALIC TURBINE CONTROL
1. Introduction
The Speed or Load on the machine is controlled by means of EHTC which varies
the steam flow through the turbine by adjusting the Control Valve openings.
Electro Hydraulic Actuators (EHAs) associated with each control valve helps to
achieve the large forces required for operation within the shortest period of time.
High pressure oil is supplied by the Control Oil System located in MOT (Main Oil
Tank) room.
EHTC consists of three loops namely Speed Control Loop, Load Control Loop and
Pressure Control Loop. Speed Control Loop is used for Rolling and
Synchronizing. Thereafter Load Controller is used to raise the unit load from
12 MW onwards. In Pressure Control mode, MS pressure is maintained
according to the Throttle pressure set point by the Turbine Control Valves, and
therefore the Load output will be proportional to the firing in the Boiler.
EHAs : The type of turbine control system demands the use of modern electro
hydraulic actuators (EHAs) . These actuators receive and process electric signals
exclusively. Hydraulic actuators are employed to generate the large positioning
forces and achieve the short positioning time required. Hydraulic power supply
units supply the necessary high pressure control fluid (approx. 100 bar) to the
actuators. Each power supply unit serves several actuators.
2. EHTC Components:
The controller comprises of four main components:
1. Turbine Start Up and Lift Limiter Equipment (TSLLE)
2. Speed Controller
3. Load Controller
4. Pressure Controller
EHTC helps us to Roll, Synchronize and Load the Turbine. The Loading
gradient is decided by the Turbine Stress Evaluator (TSE). Pressure controller
helps to support the boiler by maintaining the MS (Main Steam) pressure. In
CMC (Co-ordinated Master Control) frequency influence helps to maintain a
Page 47 of 79
healthy grid. Load rejections to House load or part load are controlled. Islanding
operation due to grid faults is possible.
3. TSLLE
It has the tasks of holding and triggering the turbine tripping system, to limit
the control valve position and to Open/Close HP/IP Stop valves.
TSLLE is a ramp generator whose output is from 0 to 100 %. Increase and

decrease switches are provided for controlling and are interlocked with other
logics to take care of Control Oil system, ATT (Automatic Turbine tester) and
limit signal generation.
During Start up the limit signals are at approximately 11, 22, 33 and 44 %
for resetting turbine protections, stop valves, control valves and for opening the
stop valves respectively.
1. Turbine protections get included @ 11%,
2. Stop Valves TSV-1&2 get ‘ON’ @ 22 %,
3. Control Valves TSV-1&2 get ‘ON’ @ 33 % and
4. Pilot Valve get ‘OFF’ thereby fully opening all the Stop Valves @ 44 %.
During Shut down the above events get triggered in the reverse order at a
slightly reduced limit signal values.
46% to 90% of TSLLE output corresponds to -10 to 105 % of Control valve

opening.
4. SPEED / LOAD REGULATION:
I. SPEED SETPOINT GENERATION:
Speed can be set manually within a range of 0 to 3300 rpm from DCS.
The rate of change allowed for Speed set point variation is different in the
zones above and below 2950 rpm. ( ie 0 to 2940 rpm–Fast and 2940 to 3000
rpm – Slow) This helps for a good acceleration in the critical speed ranges and to
Page 48 of 79
fine adjust the speed during synchronizing. An auto synchronizer is available for
synchronizing turbine speed with the grid frequency.
The Speed set point is corrected to “actual speed – STG speed (75
rpm)” during Turbine tripping so that speed set point comes down to zero when
TG shaft reaches STG speed and is kept ready for the next rolling.
When the machine is on load and load controller is active, speed set point
is corrected to “rated speed + aux. power requirement (7.5%)”so that
house load operation is made easy during load rejections.
Acceleration of turbine is monitored between 1000 to 2940 rpm. If dn/dt

falls below 90 rpm/min, machine trips to 600 rpm.
When TSE is ‘ON’, the available temperature margins decide the Speed
gradient. If TSE is ‘OFF’ or margin is sufficient, then the gradient follows the
built-in values.
Speed set point is stopped during
1. “TSE ON AND TSE Faulty”
OR
2. “GCB OFF AND (Speed set point - actual speed) > 20 rpm”.
“Stop Reference Limit” alarm is also generated in the EHC page.
Three speed transducers (MYA01CS 14, 15, 16) provide the speed
measurement. Mean value is selected for control purpose.
II. LOAD SETPOINT GENERATION:
Load set point can be manually selected from the DCS.
Automatic set point matching is done for bump less transfer from Speed to Load
or vice versa.
When Load Control (LC) is switched OFF, set point becomes -10 % and
when LC is made ON, load set point is matched with the time delayed speed set
point.
Page 49 of 79
Load set point gets stopped whenever
1. TSE influence is ‘ON’ and ‘Faulty’
OR
2. When ‘Limit pressure reached’ conditions.
PRTD: Load gradient is decided by the TSE or Manual setting at DCS. Loading of
the TG with the load controller from zero to the target load, is in line with the
permissible load transients. The permissible load transients are derived from the
temperature margins calculated by the TSE. Fixed transients for loading and
unloading can be set at OWS/DCS by the Board Engineer.
Both these gradients can be kept ON or OFF by the operator. While ‘raising’, a
minimum selection (LL-Lower Limit) is made and while ‘lowering’ a maximum
selection (UL-Upper Limit) is made between the above two gradients. The Load
so derived is the PRTD (Load Reference-Time Delayed)
FREQ INFL: When the Grid frequency increases / decreases from the set
value, typically 50 Hz in the FGMO (Free Governing Mode Of Operation) the
turbine will be unloaded / loaded at a rate (a few MW for every 0.1Hz) decided
by the “Droop characteristics” (System frequency stabilization using a
precise frequency to load characteristics –droop- with provision for primary
frequency control ), so as to up keep the stability of the Grid. This is known as
Frequency Influence.
DELTA PR: When turbine is in Load control and there is an increase / decrease
in Pressure, the opening of the control valve has to be decreased / increased so
as to keep the load a constant. This correction for pressure expressed in terms
of MW is termed as Delta PR (to keep the ‘Load-Vs-Control Output’
characteristics within the range).
SIGMA PR: The mathematical sum of these factors is taken as summated load
or sigma PR.
PR MAX: This is the maximum load that the turbo generator is allowed to
produce under the existing conditions of the Unit at that time (decided by the
board engineer).
Page 50 of 79
During IP mode, load set point tracks the actual load.
During IP mode operation, load set point is raised to a higher value so that the
Pressure controller output is selected at the MIN gate (target load).
Absolute Load Limiter can be manually set by operator from DCS, as the upper
load set point limit.
Load set point is switched OFF (LC Off)
1. If actual load < 12 MW (twice aux. power)
OR
2. During load throw off (set-actual load > 5%)
OR
3. GCB Off conditions.
Actual load value is acquired by three load transducers (MKA02FE001 A, B, &

C).
A common regulator receives and processes speed and load error signals. This
also has a frequency component whose influence can be made ON/OFF from
DCS.
In Load Control Mode, Load set point is set at the turbine end and Boiler firing
system is in auto to maintain the system pressure. Hence this mode is also
known as Boiler follow mode, since the Boiler follows the value (ie Load) set at
the turbine side.
Whenever Pressure control or TSLLE controls the Turbine, the upper limit of
speed/load controller tracks a value 2% higher than the position set point. This
is to ensure that in case of a fault/problem with the IP Mode/Pressure Control,
the next mode of control ie Speed/Load Control takes over in a smooth and
bump less way.
Page 51 of 79
5. MS PRESSURE REGULATION:
Main steam pressure set point is provided from boiler controls.
IP/LP Mode can be selected by the operator in DCS.
I. LP Mode:
When LP (Limit Pressure) Mode is selected, MS pressure set point is

trimmed down by nearly 6 ksc, which causes the Pressure Controller output to
drift to Maximum and does not get normally selected at the minimum selector
until the actual pressure drops by that amount.
Here, the controller will keep the load steady even when there is a change
in pressure, till the pressure drop exceeds 6 KSc. Due to decreased firing in
Boiler, if the Pressure drop goes beyond that value, it reduces the Load to keep
the Pressure a constant. The controller starts to function in PC mode from that
point onwards. Now, when the Boiler conditions gets better and the Pressure
starts to improve, 1.The Controller converts it to Load and goes on till the set
Load is reached and 2. Then it increases the Pressure to make it reach the initial
value.
II. IP Mode:
When IP Mode is selected, the above 6 ksc trimming is set to zero. Here
the controller just keeps the Pressure steady, by allowing variations in the Load.
The control valve opening is varied to keep the Throttle Pressure a constant
irrespective of the Load generated.
This mode is also known as Turbine follow mode, as the Turbine Load
follows (by varying the HPCV opening) steam generation by the boiler.
Main Steam pressure before the MSV is measured (Throttle Pressure

transmitter) for the actual value.
6. CONTROLLER SELECTION
Only one output is selected in a minimum gate and is effective out of the three
Controller outputs viz. Speed/Load Controller, Pressure Controller and TSLLE.
Page 52 of 79
Active Control at any time is displayed in the DCS.
7. VALVE POSITION SET POINT
The final controller output is taken for ‘position set point’ of HPCVs. (High
Pressure Control Valves).
A pressure correction is applied to the position set point of HPCV1 for

deviations in MS pressure from rated value.
A provision for ATT is also incorporated with individual drive control.
HPCV2 position set point is equalized to that of HPCV1.
IPCV position set point is matched with that of HPCV position set point
after trimming by a characteristic for ‘Start to Open’ and ‘Full Open’ positions
which comes at around 10% and 60% of turbine controller output.
IPCV position is trimmed as per HP exhaust temperature so as to increase

load sharing by HP Turbine thereby containing its exhaust temperature.
An electrical characteristic compensator produces a linear relation

between the valve position and steam flow.
HP exhaust temperature trimming helps to obtain time optimal response of

Turbo Generator during start up, shut down and load rejections.
8. Valve Position Controller:
Actual valve position is acquired by an analog position transducer.
This is digitized by a A-D ( analog – digital ) converter.
HP and IP Control valve lifts are 0 to 50 mm and 0 to 95 mm respectively,

for valve wide opening. Overload control valve lift is 0 to 40 mm for Valve Wide
Opening.
I. Speed Controller:
The Speed Reference (NR) is set from the OWS. The increase in NR from
zero is decided by the available Turbine Stress Evaluator (TSE) Margin,
depending on the Turbine Metal temperatures. The time delayed Speed set point
Page 53 of 79
(NRTD) after applying the TSE gradient is compared with the actual TG Speed (N
act) and the error signal is fed to the Speed controller (A Pressure correction is
also applied here to take care of the pressure deviations). The Speed Controller
or the Load Controller output gets selected at a MAX Gate, and the MAX Gate
output is fed to a MIN Gate along with Pressure Controller output. The final
output of these two gates will decide the Control valve opening.
II. Load Controller:

The Load Reference (PR) is set from the OWS. The increase in PR from the
minimum set point of 12 MW is decided by the TSE Gradient or Load Gradient
set point, whichever is minimum. The time delayed Load set point (PRTD) after
applying a pressure and frequency correction is compared with the Absolute
Load Limiter (Prmax) at a MIN gate. The output of this MIN gate and the actual
Load (Pact) goes to the Load Controller.
III. Pressure Controller:
The pressure control loop is capable of controlling the turbine on two

operating modes. It can operate on any one of the following two modes on
selection.
 Limit Pressure Mode (LP Mode/ Boiler Follows Turbine).
 Initial Pressure Mode (IP Mode / Turbine Follows Boiler).
On selection of ‘Initial pressure mode’, this control loop takes control of the
turbine directly. In ‘Limit Pressure mode’, it acts as a backup loop for the load
control loop and takes control, in case of drop in pressure by a threshold value
of 6 Ksc.
In ‘Boiler Follows Turbine’ mode (Limit Pressure Mode), the combustion

controller of Boiler automatically adjusts the combustion rate (The fuel and air
flow rate) according to the level of power generation demanded by the load
control loop. When the load set point is altered, the load controller changes the
steam flow rate and the consequent variation in the steam pressure will effect
changes in the fuel and air flow rate. The pressure control loop, in this mode
acts as a backup loop. It comes into action only when the steam pressure gets
reduced below set pressure by 6 Ksc and cannot be restored by the combustion
controller.
Page 54 of 79
In ‘Turbine follows Boiler’ mode (Initial Pressure Mode), the combustion
controller of Boiler is in manual mode and the changes in the rate of combustion
will be reflected as changes in the steam pressure. In this mode, the pressure
control loop takes control of the turbine directly and main steam pressure is
maintained at the set value by effecting changes in the steam flow rate and
hence the level of power generation. This is achieved by closing/opening the
governing valves.
9. Selection of Control Loops from DCS:
Speed Loop is exclusively used during rolling and synchronizing. However

this loop can also be used for all load ranges, if required. After synchronizing,
Load loop can be selected by switching on ‘Load Control’ and raising the load set
point higher than the actual load. Load controller output gets selected through
the ‘Maximum Selection’ in the above case.
After Load control becoming active, Speed control goes to ‘Speed tracking’
thereby getting ready for any load shedding occurrence. LP Mode is selected
while the Load control is active, so that pressure loop acts as a backup in case of
low firing in boiler.
IP Mode can be selected by switching it ‘ON’ in DCS after matching the set
point and actual main steam pressures. Load set point can be kept higher than
the actual load so that Load controller output won’t get selected in the minimum
selection. By reducing Load set point below the generated load, load control gets
selected through the minimum gate.
Page 55 of 79
L) TURBINE PROTECTIONS & DRAIN LOGICS
1. TURBINE PROTECTIONS
s.no Description Logic Alarm set Trip set value

value
1. ATRS Trip 2V3 From ATRS Step
2. Boiler MFT 2V3 BP1 after a delay of
10 sec
3. Control Oil Supply Off 2V3 COP tank LVL Protection/Emergency
V.Low ,Dis/Hdr Off
Pr<105KSC
(TON 5s)
4. Fire Protection Ch -1 2V3 From Local / UCB
Operated. Desk
5. Fire Protection Ch -2 2V3 From Local / UCB
Operated. Desk
6. TSLLE % < 7.5 % < 7.5 %
7. Axial Shift 2V3 0.5 mm > 1.0 mm
8. Control Oil >=1 From Local / From Local / DCS
Emergency Push DCS
Button Operated.
9. Emergency Push >=1 From UCB From UCB Desk
Button Operated. Desk
10. HP /IP Shaft vibration >=1 120 microns 160 microns
Front Journal Bearing.
11. HP /IP Shaft Vibration >=1 120 microns 160 microns
Rear Journal Bearing
12. LP Shaft Vibration >=1 120 microns 160 microns
Rear Journal Bearing.
13. Generator Bearing >=1 120 microns 240 microns
Vibration Front
Journal Bearing
14. Generator Bearing >=1 120 microns 240 microns
Vibration Rear Journal
Bearing
15. Generator Electrical >=1 GP1 or GP2 or GP1 OR GP2 OR
Protection. GCB OFF GCB OFF
16. Condenser Pressure 2V3 >0.2 ata >0.25 ata (based on
(VAR) High (Curve) Curve)
17. Condenser Pressure 2V3 >0.2 ata >0.3 ata
(FXD) High
18. DP Across HP Turbine 2V3 *** ***
19. Drum Level High 2V3 +225 mm +254 mm
20. HP Top–Bottom 2V3 -55 upto 30 % -55 upto 30 % load
Casing Temperature. load (based on (based on Curve)
Curve)
21. HP Exhaust Temp. 2V3 370/470 ° C 350/480 ° C (Curve)
Based on TM (Curve)
22. IP Steam 2V3 330/445 ° C 320/430 ° C (Curve)
Page 56 of 79
Temperature Low (Curve)
23. IP Steam 2V3 355/545 ° C 355/565 ° C (Curve)
Temperature High (Curve)
24. Live Steam 2V3 330/480 ° C 320/450 ° C (Curve)
Temperature Low (Curve)
25. Live Steam 2V3 355/545 ° C 355/565 ° C (Curve)
Temperature High (Curve)
26. LP Exhaust 2V3 >110 ° C >120 ° C
Temperature High
27. Lub Oil Level Low 2V3 <340 or >500 >600 (From Top of
(From Top of tank)
tank)
28. Lub oil Pressure Low 2V3 <3.4 Ksc <3.2 Ksc
<3.2 KSc
29. Over Speed Trip 2V3 hard 3150 rpm 3300 rpm
Channel- A wired
30. Over Speed Trip 2V3 hard 3150 rpm 3300 rpm
Channel- B wired
CHARACTERISTICS CURVES DERIVED AS FOLLOWING PROTECTIONS:
 MS/HRH HIGH TEMP PROTECTION: (ALARM/TRIP VALUES)
 TURBINE CONDENSER PRESSURE PROTECTION: SET POINT

CHARACTERISTICS
 HP EXHAUST TEMP HIGH: (ALARM & PROTECTION VALUES)
 OUTER CASING TOP & BOTTOM TEMP DIFFERENCE Vs ACTIVE POWER
FIGURES SH0WN AS BELOWS:
Page 57 of 79
MS/HRH HIGH TEMP PROTECTION:
ALARM/TRIP VALUES
(295,565)
600
500
(295,545)
MS / HRH Temp oC
(100,380)
400
300
(100,370)
200
100
0
0 50 100 150 200 250 300 350

m HP/IP Shaft
TURBINE CONDENSER PRESSURE

PROTECTION:
Ksc (abs)
SET POINT CHARACTERISTICS

0.3
(5.4, 0.3)
Trip
(3.0, 0.2) Alarm

Condenser Pressure
0.2
Trip
0.1
(0.71, 0.13)
0
0 1 2 3 4 5 6
LP Inlet Pressure Ksc(g)

Page 58 of 79
HP EXHAUST TEMP HIGH
ALARM & PROTECTION:
(250,480)
500 Trip
Alarm
(OC)
(250,470)
400
(100,380)
(250,460)
300
(100,360) (100,370) SLIDING SET POINT:

HP EXH.TEMP
FOR VALVE TRIMMING

200
100
0
0 50 100 150 200 250 300 350

o
m HP Shaft C
Outer Casing Top&Bottom Temp

40
Difference Vs Active Power

30
Trip
+20
20
C
o
+10
Alarm
T (Top-Bot)
10
0
30 100
Active Power (%)
10
-25
20
Alarm
30
-35
40
Trip
50
Page 59 of 79
60
2. DRAIN LOGICS :
SLC DRAINS
HPCV1&2 After Drains: (MAL 15, 16)
OPEN: If T (HPCV~MS) is < 20 oC & HPCV CLOSED
CLOSE: If T (HPCV~MS) is > 50 oC & HPCV NOT CLOSE
IPSV1&2 Before Drains: (MAL 26, 27)
OPEN: If T (IPCV ~ HRH) is < 20 oC & IPSV CLOSED
CLOSE: If T (IPCV ~ HRH) is > 50 oC & IPSV NOT CLOSE
CRH NRV DRAIN:
OPEN: If Any NRV not Full Open Condition.
CLOSE: If Both NRV Full Open Condition.
GS Header Drain MOV: (MAW 10 AA 011)
OPEN: If GS Temp 1 Or 2 is < 120 oC
CLOSE: If GS Temp 1 Or 2 is > 150 oC
EXTRACTION A5/A3: (MAL 47 / 54)
OPEN: If LOAD is < 2 % & EXTN OPEN is < 5 %
CLOSE: If LOAD is > 10 % & EXTN OPEN is > 15 %
EXTRACTION A4: (MAL 51)
OPEN: If EXTN OPEN is < 5 % & P is < 10 mbar
CLOSE: If EXTN OPEN is > 15 % & P is > 32 mbar
HP Exhaust :(MAL 30 AA011)/IP Extraction Insert :(MAL 35

AA011)
OPEN: IF T (Temp ~ Sat Temp) < 20 oC
CLOSE: If T (Temp ~ Sat Temp) > 50 oC
HP-IP CASING: (MAL 24 AA 011)
OPEN: If TOP OR BOTTOM Temp < 300 oC
Page 60 of 79
CLOSE: If TOP OR BOTTOM Temp > 320 oC
Vacuum Breaker Control:
VB Valve Opens during: Shaft vibration very high, Bearing temperature very
high, Axial Shift very high and Fire Protection responded.
FC NRV s:
Close command goes to FCNRV s during: Level very high in Heaters, P high
across the NRV, Depending on Control Valve position (MCV for HPH & IPCV for
LPH), Turbine trip Or Manual Close command.
EXHAUST HOOD SPRAY (MAC01)
OPEN: LP Wall Temperature > 90 oC
CLOSE: TG Speed < 2850 rpm Or Load > 10 %
CRH NRV
OPEN: HPCV opening is < 17 %
CLOSE: HPCV opening is > 22 %
M) CFBC BOILER COORDINATED MASTER CONTROL

(CMC) MODE
1. INTRODUCTION:
General Concept of CMC is that, the Load Set Point, given in CMC, will
generate Unit Demand by taking the Unit Capability, TSE Margins and
Unit Loading Rate.
Based on Unit Demand, Air Flow, Fuel Flow will increase/decrease.
 Based on Unit demand, EHTC load set Point will be generated

with superimposed MW Correction for the Pressure deviation.
 Simultaneously for the Pressure deviation, the Pressure
Controller (CMC) will give the output with superimposed fuel
correction.
Page 61 of 79
 Any Load Set point is to be adjusted in CMC in Unit Load
Set Point only.
 Boiler Master Output limit is set at maximum (taking fuel
quality and other factors into consideration).
 The Sliding set point is a function of Steam Flow i.e., Boiler
load. As soon as the Load set point is increased, this sliding
Pressure set point will not increase immediately. First Air
Flow/Fuel Flow will increase, and then Actual Load will
increase. Based on Actual Load/Steam Flow only, the Sliding
Set point will increase.
 Sliding Pressure Set point is set as per Operation
requirement and it will follow the Actual MW (Steam flow),
Act MW.
2. Check list for CMC commissioning.

Following steps are to be followed for taking CMC in service,
1. The permissible interlocks for CMC

(1) Feed water control (Drum level 3E control) in auto
(2) PA flow control in auto
(3) SA/FD pressure control in auto
(4) Master air flow control in auto
(5) Inlet back pass pressure in CFBC or Furnace draft control in auto.
(6) HPBP fully closed.
(7) Load control in action
(8) Load deviation within limits (unit load sp and load actual within
limits 3MW)
(9) Fuel master in auto
2. Procedure for putting CMC in service.
(1) Ensure following loops are in auto
(a) Feed water control (Drum level 3E control) in auto
(b) PA flow control in auto
(c) SA/FD pressure control in auto
(d) Master air flow control in auto
Page 62 of 79
(e) Inlet back pass pressure in CFBC or Furnace draft control in
auto
(f) HPBP fully closed. ( Optionally revised during CMC operation)
(g) Load control in action
(h) Load deviation within limits (unit load sp and load actual within
limits)
(i) Fuel master in auto
(2) Put Boiler master in auto
(3) Ensure pressure Set point and pressure actual error as minimum
(4) Select CMC button in CMC popup
(5) Select CMC in EHTC scheme.
(6) Ensure CMC load SP(Unit load demand) is reaching in EHTC load SP
(7) Now change in load set point is possible only through Unit load set
point in the CMC page.
(8) Slowly ramp up pressure set point to the required pressure
3. PARAMETER TO BE VERIFIED BEFORE CMC COMMISSIONING:

Before commissioning of CMC whether logics built as below and ensure
that all loops tracking with actual values when system running on manual mode.
All ranging of set points and actual values are confirming to the project
requirement.
MATHEMATICAL EQUATION FOR DIFFERENT MODES OPERATIONS

CMC DEMAND TO BOILER MASTER:
= UNIT DEMAND + PID CONTROLLER OUTPUT WITH SELF

TRACKING + UNIT DEMAND ERROR GENERATED PRESSURE
DEVIATION AGAINST FUEL DEVIATION
BFM DEMAND TO BOILER MASTER:
= RATIO FREEZE DURING BFM MODE MAIN STEAM FLOW

AGAINST ACTUAL LOAD X RUNNING ACTUAL LOAD + PID
CONTROLLER OUTPUT WITH SELF TRACKING (MS PRESSURE
SET POINT – MS PRESSURE ACTUAL)
Page 63 of 79
TFM DEMAND TO BOILER MASTER:
= UNIT DEMAND +PID CONTROLLER OUTPUT WITH SELF

TRACKING (UNIT DEMAND-ACTUAL LOAD)
EHG SETPOINT TO TURBINE:
DURING CMC MODE OPERATION:
= UNIT DEMAND + PRESSURE DEVIATION WITH LOAD

WEIGHTAGE
DURING TFM MODE OPERATION WITH RUN BACK (AUTO SUSPEND

WITH TIME WEIGHTAGE):
= ACTUAL LOAD +PRESSURE DEVIATION WITH LOAD

WEIGHTAGE
DURING TFM MODE OPERATION WITHOUT RUN BACK (AUTO

ENABLE):
=UNIT DEMAND + PID CONTROLLER OUT WITH SELF

TRACKING
CMC/BFM/TFM FUEL DEMAND FROM BOILER MASTER DEMAND:
= RATIO FREEZE OF RUNNING FUEL FLOW TO RUNNING

BOILER MASTER DEMAND WHEN FUEL MASTER SWITCHED
TO AUTO X RUNNING BOILER MASTER DEMAND
CMC/BFM/TFM AIR DEMAND FROM BOILER MASTER DEMAND:
= RATIO FREEZE OF RUNNING AIR FLOW TO RUNNING

BOILER MASTER DEMAND WHEN AIR MASTER SWITCHED
TO AUTO X RUNNING BOILER MASTER DEMAND +
OXYGEN TRIM DEMAND.
4. RUNBACK OPERATION CHECKS:
Whenever runback active (means partial equipment loss) UNIT DEMAND

should be reduced to RUNBACK capability value Boiler load and EHG load should
Page 64 of 79
brought to stable value without disturbing either Boiler or Turbine parameters.
Hence during RUNBACK active switching CMC mode to TFM mode with auto
suspend and ramping down of UNIT DEMAND with time delay weightage, by
releasing sudden pressure rise due runback condition and setting actual load
with addition of pressure deviation weightage as instantaneous demand to EHG
set point and releasing to auto in TFM mode.
For the loss of each equipment weightage to be specified in capability

logics and equipment loss with a delay of 5- 12 sec, so that stand by logics will
be taken care before runback condition generates. On any loss of equipment
immediately stored energy will be utilized in Turbine by throttling control valve
and switching turbine to TFM mode for further stabilization.
I. Feeder’s runback:
Six feeders i.e. three feeders left side and three feeders right side with
load weightage of 25 MW each and 5 feeders are assigned for full load capability.
Any loss of one number feeder from six will not initiates runback, if 5th feeder
trips then run back will be initiated reaming feeder in the left loaded will be
loaded if trip is from left and freezing the demand for right side feeders and vice
versa for right side,
so that temp inside the combustor unaltered. UNIT DEMAND will be ramp
down slowly (depending upon runback rate of equipment or loading /unloading
rate set at CMC desk) to the capability value and CMC mode to TFM mode will be
switched over with auto suspend with a holding time of 20 minutes (till BOILER
and turbine stabilizes due sudden impact of equipment loss), on the turbine desk
LP mode to IP mode will switch over. On stabilization TFM auto will become
active. Now machine can be taken back to CMC and turbine will be switched
back to IP to LP mode.
II. Secondary Air Fan runback:

There are two secondary Air fans with left side one and right side one with
weightage of 60 percent capability i.e. 75 MW. On one equipment loss, the
runback will be initiated to capability will reduces to 75 MW. The UNIT DEMAND
will be ramp down (depending upon runback rate of equipment or loading
Page 65 of 79
/unloading rate set at CMC desk) slowly to 75 MW and CMC mode to TFM mode
will be switched over with auto suspend with a holding time of 20 minutes (till
BOILER and turbine stabilizes due sudden impact of equipment loss), on the
turbine desk LP mode to IP mode will switch over. On stabilization TFM auto will
become active. Now machine can be taken back to CMC and turbine should be
switched back to IP to LP mode.
III. ID Fan runback:

There are two ID fans with left side one and right side one with weightage
of 60 percent capability i.e. 75 MW. On one equipment loss, the runback will be
initiated to capability will reduces to 75 MW. The UNIT DEMAND will be ramp
down (depending upon runback rate of equipment or loading /unloading rate set
at CMC desk) slowly to 75 MW and CMC mode to TFM mode will be switched over
with auto suspend with a holding time of 20 minutes (till BOILER and turbine
stabilizes due sudden impact of equipment loss), on the turbine desk LP mode to
IP mode will switch over. On stabilization TFM auto will become active. Now
machine can be taken back to CMC and turbine should be switched back to IP to
LP mode.
IV. PA Fan runback:

There are two PA fans with left side one and right side one with weightage
of 60 percent capability i.e. 75 MW. On one equipment loss, the runback will be
initiated to capability will reduces to 75 MW. The UNIT DEMAND will be ramp
down (depending upon runback rate of equipment or loading /unloading rate set
at CMC desk) slowly to 75 MW and CMC mode to TFM mode will be switched over
with auto suspend with a holding time of 20 minutes (till BOILER and turbine
stabilizes due sudden impact of equipment loss), on the turbine desk LP mode to
IP mode will switch over. On stabilization TFM auto will become active.
Now machine can be taken back to CMC and turbine should be switched
back to IP to LP mode.
Page 66 of 79
V. CWP Fan runback:
There are three ID fans with left side one and right side one with
weightage of 60 percent capability i.e. 75 MW. On one equipment loss, the
runback will be initiated to capability will reduces to 75 MW. The UNIT DEMAND
will be ramp down (depending upon runback rate of equipment or loading
/unloading rate set at CMC desk) slowly to 75 MW and CMC mode to TFM mode
will be switched over with auto suspend with a holding time of 20 minutes (till
BOILER and turbine stabilizes due sudden impact of equipment loss), on the
turbine desk LP mode to IP mode will switch over. On stabilization TFM auto will
become active. Now machine can be taken back to CMC and turbine should be
switched back to IP to LP mode.
VI. UNIT DEMAND INCREASE / DECREASE BLOCK:
If variation of Process deviation error of Drum level/Furnace pressure/Fuel

flow/Air master/Turbine throttling pressure control crosses limit values (decided
by process variation limits) further increase or decrease of UNIT DEMAND will be
blocked and it will support system to stabilize in CMC/BFM/TFM modes of
operations.
VII. UNIT DEMAND RUN UP / RUN DOWN CHECKS:
If variation of Process deviation error of Drum level/Furnace pressure/Fuel

flow/Air master/Turbine throttling pressure control crosses limit values (decided
by process variation limits) will issue increase or decrease of UNIT DEMAND and
will support system to stabilize in CMC/BFM/TFM modes of operations.
Some extra CMC Interlocks in CFBC
For Boiler Master, Block Increment will occur in the following cases.
1. If Cyclone O/L Temp. Goes above 965 °. C (2 out of 3 of

HNA11CT001, 2, 3) OR (2 out of 3 of HNA12CT001, 2, 3).
For Boiler Master, Block Decrement will occur in the following cases.
1. If any 1 of 4 Combustor Bottom Temp. HHC01CT011,12,13 and 14

goes below 880 °. C
Page 67 of 79
If Cyclone O/L Temp. Goes below 860 °. C (2 out of 3 of HNA11CT001,2,3) OR
(2 out of 3 of HNA12CT001.
5. RUN BACKS TESTING AND LIMITATIONS:
I. PROCEDURE FOR KEEPING RUNBACK IN SERVICE
 Ensure control in CMC.

 Ensure all the down the loops master kept in auto.
 Enable RUNBACK option on CMC desk.
 Ensure the pressure control is not bypassed in EHTC, i.e. pressure control
tag minimum is at 65 %.
 All the control dampers of RUNBACK equipments are in operating
condition and without any mechanical limitations.
 After RUNBACK signal vanishes from CMC desk CMC can be taken in to
manual if required else it will continue to run in TURBINE FOLLOW MODE.
 After taking CMC in manual operator can restore the machine as per field
equipments condition.
 Normalization of machine is entirely manual; the RUNBACK will only keep
machine parameter as per the available capability condition of RUNBACK
equipments.
II. TRANSPORT FEEDER RUNBACK LIMITATIONS
 On tripping of any one lignite transport conveyor RUNBACK will be

initiated.
 The running transport feeder will try to load on tripping of transport
conveyor and will block further increase command on RUNBACK initiation
till completion of RUNBACK condition and will adjust to the CMC fuel set
point as per Boiler master.
 Each feeder is limited to 37.5 TPH fuel flow of particular feeder.
 All the feeders are blocked further increase command on any one
PA/SA/ID fan tripping up to 10 minutes with Boiler Master auto condition.
Page 68 of 79
III. PRIMARY AIR FAN LIMITATIONS
 On tripping of any one PA fan RUNBACK will be initiated.

 Running fan will be loaded as per PA Flow set point derived from Boiler
master demand.
 Primary Air fan vanes(IGV) of tripped fan will go for full close and manual,
running fan damper further opening blocked on 50 % of vane demand and
105 Amp of respective running fan current to avoid electrical over load
tripping.
IV. SECONDARY AIR FAN LIMITATIONS
 On tripping of any one SA fan RUNBACK will be initiated.

 On tripping SA Fan corresponding ID tripping was bypassed.
 PA FLOW SEPOINT switched to 170 TPH on SA/ID fan RUNBACK.
 Secondary Air fan vanes(IGV) of tripped fan will go for full close and
manual, running fan IGV further opening blocked on 70 % of vane
demand and 97 Amperes of respective running fan current to avoid
electrical over load tripping.
 On tripping of any SA fan SUB upper damper demand will reduced to
20 % through override decrease
V. INDUCED DRAUGHT FAN LIMITATIONS
 On tripping of any one ID fan RUNBACK will be initiated.

 Corresponding SA fan will be tripped on ID not on feed back.
 PA FLOW SEPOINT switched to 170 TPH on SA/ID fan RUNBACK.
 ID fan vane and VFD of tripped fan will go for full close and changes to
manual running fan VFD further opening blocked on 950 amperes of VFD
current and 700 RPM VFD speed of respective running fan to avoid
electrical over load tripping.
Page 69 of 79
6. RUNBACK LOGIC MODIFICATIONS
Sl.N Activity Repercussion Modification under trial operation and

o Suggested for implementation.
1 TRC Trips. Overloading of CMC mode:

running TRC in
CMC mode. Lignite flow in the running TRC will freeze
at current flow to avoid overloading of the
conveyor. Lignite flow will start rising as
per fuel master requirement after 10 min.
Reduction in
combustor bottom
temperature.
CMC/Manual mode:
FBHE spiess valve 1 and 4 if open will full

close to maintain combustor bottom
temperature.
2 SA Fan Trips. Overloading of CMC mode:

running SA fan in
CMC mode. PA flow will reduce on auto to 170 Ton/hr
to avoid SUB SA duct choke.
Closing command given on logic to

SUB SA duct Combustor Upper air damper to close in
chokes due to high CMC, to maintain SA header Pressure.
PA flow/low SA
header pressure. Running SA fan will load on auto up to 97
Amps.
Corresponding ID
Manual mode:
trip on logic.
Respective PA fan IGV will be force closed
to 0% if both PA fans are running.
CMC/Manual mode:
Lignite Extraction feeder A1/B1 will trip if

other two feeders are running in each side.
FBHE spiess valve 1 and 4 if open will full

close to maintain combustor bottom
temperature. Earlier Protection of
corresponding ID fan trip removed.
Page 70 of 79
3 PA fan trips. Overloading of CMC mode:
running PA fan in
CMC mode. Running PA fan will load on auto up to
105Amps.
Lignite flow may
CMC/Manual mode:
cause overloading
of running fan. Lignite Extraction feeder A1/B1 will trip if
other two feeders are running in each side.
4 ID Fan trips. Corresponding SA CMC/Manual mode:

fan will trip.
Corresponding SA fan will trip if both the
fans are running and SA fan trip effects as
in Sl.No. 2 will happen.
5 Start Up Burners could be “Auto mode” and “Manuel mode” of

Burners. cut in with pilot operation introduced for burner operation.
flame only. In Auto mode burner could be cut in
satisfying all logics. In manual mode of
operation burner can be cut in without pilot
flame. This helps to cut in burners on
emergencies when combustor bottom
temp. is above 600o C. Also it is easy to do
scheduled checking of gun movement and
gun purging in manual mode.
6 Protection False pick up of any Fan DE/NDE bearing vibration in

tripping of SA, bearing vibration horizontal/vertical directions is combined
PA and ID fan reading will trip the and 2 out of 4 logic introduced with time
on “bearing equipment. delay of 7sec. (Vibration readings of all
vibration high”. fans will be monitored and protection will
be introduced in phased manner).
7 Protection False pick up of If the rate of rise of bearing temp. is more

tripping of SA bearig temp. very than 100/Sec., senses as fault and it will
fan, PA fan, ID high will trip the not cause tripping of the equipment.
fan and blowers equipment.
on “bearing
temp. very
high”.
8 TRC and TRC and Extraction Time delay for TRC and Extraction feeder
Extraction feeder trip on zero tripping on “zero speed”, has been raised
feeder tripping speed with time to 5sec.
on zero speed. delay of 3sec.
Page 71 of 79
9 LALF could be run Logic tripping for preceding equipments
in forward direction introduced in reverse direction of rotation
LALF direction of only as logic of LALF also. Now LALF can be kept in
rotation.
tripping for service in both the directions of rotation.
preceding
equipments was
given in forward
direction only.
10 Lighting up Back pass roof tube Lighting up procedure has been modified
procedure for puncture occurs as follows to ensure adequate steam flow
Boiler. immediately after through steam cooled walls and coils.
unit light up.
During boiler lighting up drum vent and SH
vents except start up vent to be closed at
2 to 3ksc drum pressure. MS stop valve to
be opened at 4 to 5ksc drum pressure.
Open one side HP bypass at 5 to 6 ksc.
SH drains to be closed at 3 to 5 ksc.

observing temp. rise except MS009 and
MS016.
Bottom ring header drain MS009 to be

chocked and closed from 6 to 9 ksc.
LTSH inlet header drain MS016 to be

chocked and closed from 7 to 10 ksc.
Start up vents chocked and closed from 8

to 12ksc after ensuring 20 to 25% HP
bypass opening on one side.
11 Biasing of Fast changes in Manual intervention will help to maintain

Lignite feeding lignite quality will MS pressure and hence unit load.
when unit is in affect load
CMC mode. generation.
12 Trip opening of Starting of pump Ensures flow through pump whenever

LDO without opening pump is started.
recirculation recirculation valve
valve when no will damage the
LDO pump is pump.
running.
Page 72 of 79
13 SH/RH attemp. Sudden variation Isolation valves will open on logic when
isolation valves temperature can control valve opens more than 2%. Closing
open/close on happen if of isolation valve on logic will be removed.
logic when opening/closing of
control valve the valve is not
opens/closes noticed by board
below 2%. engineer.
14 Feed control Sudden variation in Opening of isolation valve on logic will be

station full load drum level can removed. It can be opened manually.
isolation valves happen if opening
open on logic of the valve is not
when steam noticed by board
flow>25% or engineer.
FD20/23 open
more than 2%.
15 Feed control Sudden variation in Opening of isolation valve on logic will be

station low load drum level can removed except for SG cool down
isolation valves happen if opening operation. It can be opened manually.
open on auto of the valve is not
when steam noticed by board
flow<40% or engineer.
FD26 open more
than 2% or SG
cool down
operated.
16 New Respective side The annunciation alerts the board engineer

annunciation TRC will trip if seal to take necessary action before TRC
“seal pot pot pressure persist tripping.
pressure high” at +6mbar for 10
sec. and other side
at seal pot TRC will trip if the
pressure pressure persists
+2mbar. for another 20 sec.
17 “Drum level Drum level low” Annunciation modified so that it will

abnormal” ann. ann. will not appear if any of the drum level
will appear appear if the other transmitters reads abnormal value.
depending on two transmitters
the selected reads high / low
transmitter for level.
drum level.
controller .
Page 73 of 79
18 Both the P&S Tripping of fans Time delay for protection will be raised to
blowers are not and blowers in 10 minutes.
running for sequence which will
60sec. lead to tripping of
all boiler
equipments except
ID fans.
19 Instrument air BP1 protection will Minimum instrument air pressure required
header pr< act. for operation of important control valves
4.5ksc. will be studied during unit shut down.
At present “Instrument air header pressure

low” ann. Will be provided when boiler
area header pressure reaches 5ksc.
(presently pick up for ann. is taken from
compressor outlet header).
Page 74 of 79
N) GENERATOR PROTECTION
GENERATOR DETAILS:
KW 25000 AMB TEMP 44 °C PHASE / FREQ 3 AC / 50HZ
STATOR 10500 ROTOR 365 HP/ WEIGHT 50 / 210 Tons

VOLTS
VOLTS
STATOR 8086 ROTOR 819 ALTITUDE <1000M
AMPS AMPS
RPM 3000 YEAR 2008 MAKE BHEL
HYDERABAD
1. RELAYS:
MAJOR RELAYS
 GR1 SIEMENS MAKE 7UM62

 GR2 SIEMENS MAKE 7UM62
 GTR1 SIEMENS MAKE 7SJ61
 GTR2 SIEMENS MAKE 7UT61
 GTR3 SIEMENS MAKE 7UT61
 UATR1 SIEMENS MAKE 7SJ61
 UATR2 SIEMENS MAKE 7UT61
Group 1 Relays
 GR1
 GTR2 (87GT and 51NGT)
 UATR2 (87 UAT and 64R )
Group 2 Relays
 GR2
 GTR1 ( 51GT and 64R)
 GTR3 (Overall Diff Protection)
 UATR1 (50UAT, 51UAT and 51NUAT)
Page 75 of 79
2) GR1 PROTECTIONS:
ALARM TRIP
S.NO DESCRIPTION PICK UP CALCULATED PICK UP CALCULATED

VALUE VALUE VALUE VALUE
1 Generator Over current NO ALARM 4.26A 8520A

(2 Sec)
2 Negative sequence 7.2% NIL 28% NIL
(20Sec) (2.5Sec)
3 Differential 0.2I/Ino NIL 4 I/Ino NIL
(0 Sec) (0 Sec)
4 Under Excitation / Field failure No alarm Stop vlv close 10sec -0.5%
Stop vlv open 3sec 0.625MW

5 Reverse & low – Forward NO ALARM 0.5MW
power (2 Sec)
6 Back-up impedance NO ALARM I>6.75A&V>80(4sec) if
both 3sec Trip
7 Out of Step (generator primary 120% 12000

amps) NO ALARM
(20 sec) Amps
(20 sec)
8 Under voltage 77% 7.350KV 65% 6.204KV

(2 sec) (2 sec) (0 sec) (0 sec)
Over voltage 110% 10.50KV 119% 11.35KV
(5 sec) (5 sec) (0 sec) (0 sec)
9 Under Frequency 48.5HZ NIL 47.4HZ NIL
(2.5 Sec) (2 Sec)
Over Frequency 51 HZ NIL 51.5 HZ NIL
(1.5 Sec) (1 Sec)
10 Over – Excitation(Volt/Freq 1.12 NIL 1.4 NIL
ratio) (30 sec) (1 Sec)
11 95% Stator Earth – fault NO ALARM 4.8 V NIL
(Voltage operated) (1.5sec)
12 90% Stator Earth – fault NO ALARM 1.10A NIL
(Current operated) 0 Sec
13 100% Stator Earth – fault 168 ohm NIL 84 ohm NIL
(low Freq Injection) 10 sec 10 sec
Rotor Earth-fault protection 80 kohm NIL 5 kohm NIL
14 (Low freq Injection) (10 sec) (1 sec)
1.2A NIL <77V NIL
15 In-advert ant Energisation (1 sec)
Page 76 of 79
3) GR2 PROTECTIONS:
ALARM TRIP
S.NO DESCRIPTION PICK UP CALCULATED PICK UP CALCULATED

VALUE VALUE VALUE VALUE
1 Generator Over current 4.26A 8520A

NO ALARM
(2 Sec)
2 Negative sequence 7.2% NIL 28% NIL

(20Sec) (2.5Sec)
3 Differential 0.2I/Ino NIL 4 I/Ino NIL
(0 Sec) (0 Sec)
4 Under Excitation / Field failure No alarm Stop vlv close 10sec -0.5%
Stop vlv open 3sec 0.625MW

5 Reverse & low – Forward NO ALARM 0.5MW NIL
power (2 Sec)
6 Back-up impedance I>6.75A&V>80(4sec) if
NO ALARM
both 3sec Trip
7 Out of Step
8 Under voltage 77% 7.350KV 65% 6.204KV

(2 sec) (2 sec) (0 sec) (0 sec)
Over voltage 110% 10.50KV 119% 11.35KV
(5 sec) (5 sec) (0 sec) (0 sec)
9 Under Frequency 48.5HZ NIL 47.4HZ NIL
(2.5 Sec) (2 Sec)
Over Frequency 51 HZ NIL 51.5 HZ NIL
(1.5 Sec) (1 Sec)
10 Over – Excitation(Volt/Freq 1.12 NIL 1.4 NIL
ratio) (30 sec) (1 Sec)
11 95% Stator Earth – fault NO ALARM 4.8 V NIL
(Voltage operated) (1.5sec)
Page 77 of 79
4) GTR1 Protections:
ALARM TRIP
S.NO DESCRIPTION PICK UP PICK UP

VALUE VALUE
Generator Transformer NO ALARM 480A (0.6sec)

1 Over Current
Generator Transformer 0.1( 2 sec) 0.1 ( 2 sec)

Earth Fault
0.05A ( 0 sec)
2 Sensitive earth-fault NO ALARM
GTR2 Protections:
ALARM TRIP
S.NO DESCRIPTION
PICK UP PICK UP
VALUE VALUE
Generator Transformer 0.2 I/Ino 10 I/Ino (0 sec)

1 Differential
NO ALARM 0.2A (0 .4sec)

2 Standby earth-Fault
GTR3 Protections:
ALARM TRIP
S.NO DESCRIPTION
PICK UP PICK UP
VALUE VALUE
Generator Transformer Over all 0.2 I/Ino 10 I/Ino

Differential protection (0 sec)
1
Page 78 of 79
5) UATR1 Protections:
ALARM TRIP
S.NO DESCRIPTION
PICK UP PICK UP CALCULATE
VALUE VALUE VALUE
1 UAT-HV Over Current NO ALARM 1.5A 1800A

0.4sec 0.4 sec
2 Sensitive Earth-Fault 0.2A 0.5A

NIL
1 sec 0 sec
UATR2 Protections:
ALARM TRIP
S.NO DESCRIPTION
PICK UP PICK UP
VALUE VALUE
1 UAT Differential
0.2 I/Ino 4.0 I/Ino
0 sec 0 sec
LV Standby Earth-Fault 0.15 I/Ins

2 NO ALARM
0 sec
Page 79 of 79

Technical Diary

Uploaded by

Copyright:

Available Formats

You might also like

Technical Diary

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Technical Diary

Uploaded by

Copyright:

Available Formats

2015

HAND BOOK OF OPERATING IMFORMATIONS FOR BTG EQUIPMENTS

NEYVELI LIGNITE CORPORATION LIMITED.

HAND BOOK SUBMITTED BY:

First I would like to thank our NEYVELI LIGNITE CORPORATION, BTPP

Rajasthan for providing us this wonderful opportunity to serve the organization. We

inspire us to Learning and implementing the new ideas.

completion of THE HAND BOOK OF OPERATING INFORMATIONS FOR BTG

EQUIPMENTS AND ITS INSTRUMENTATION LOGICS.

B) BLOWERS: Motor details, permissive & protections

2. SEAL POT BLOWERS 14

3. SEAL POT STADBY BLOWERS 14

1. LIGNITE EXTRACTION FEEDER 19

2. LIGNITE TRANSPORT CONVEYOR 20

3. LIGNITE GATE VALVE 22

1. BOILER PROTECTION 1 (MASTER FUEL TRIP) 22

ii. TRIP OUTPUTS

2. BOILER PROTECTION 2 (OIL FUEL TRIP) 22

I. SUB 1 TRIP CONDITIONS

II. SUB 2 TRIP CONDITIONS

III. BED LANCES 1 TO 6 TRIP CONDITIONS

E) SG COOL DOWN AND ITS IMPORTANT OUTPUTS 24

F) UNIT CONTROL PANEL ANNUNCIATIONS 25

II. START PERMISSIONS

2. CONDENSATE EXTRACTION PUMP 29

II. Permissive for CEP Starting

III. Protections for CEP

II. Permissive for the CW Pumps

III. MANUAL Mode

IV. AUTO Mode

V. Protections for the CW Pumps

VI. Auto ON for 1C Discharge Valve

4. DM COOLING WATER SYSTEM (DMCW) AND 32

II. DMCW Permissive

III. DMCW Protections

VI. ACW Protections

VII. Auto Starting of ACW Pumps

5. DM COOLING WATER BOOSTER PUMP 33

III. Auto Starting of DMCW Booster Pump

6. Hot well Make Up Pump 34

II. Permissive for the Make-Up Pumps

III. Protections for the Make-Up Pumps

IV. Auto Starting for the Make-Up Pumps

7. EMERGENCY COOLING WATER PUMPS (ECW) 34

IV. AUTO STARTING OF RESERVE PUMP

8. Emergency DM Water Pumps 35

II. Permissive for the Emergency DM Water Pumps

III. Protections for the Emergency DM Water Pumps

IV. Auto Starting for the Reserve Pump

9. Boiler Fill Pump

II. Permissive for the Boiler Fill Pumps

III. Protections for the Boiler Fill Pumps

IV. Auto Starting for the Make-Up Pumps

1. Main oil pump (Mop) 38

I. Auto ON for mop

II. Auto OFF for mop

III. Protections OFF for the main oil Pumps

2. AC Lift oil pumps (AC LOP) 38