Technical Diary

ESSAR POWER MP LIMITED
TECHNICAL DIARY
2×600 MW Thermal Power Plant- Mahan
By Ravi Sagar
Document Approval Sheet

Prepared By Ravi Sagar Signature
Checked By Subhash C. Singh Signature
Approved By HOD Operation Signature
Approved By O&M Head Signature

Content
S. No. Equipment Name Page No.
1 Current Settings of drives
2 MFT
3 Turbine Protection
4 Purge Condition
5 TD BFP
6 MD BFP C
7 EH Oil System
8 Lube Oil Pumps
9 Air/H2 Side SOPs
10 Stator Cooling water Pump
11 CCCW Pump
12 OCCW Pump
13 CEP
14 Vacuum Pump
15 HP/LP Bypass
16 ID Fan
17 FD Fan
18 PA Fan
19 Seal Air Fan
20 BCP
21 Coal Mill
22 Coal Feeder
23 APH
24 Scanner Air Fan
25 CW Pump
26 Air Compressor
27 HFO Forwarding Pump
28 LDO Forwarding Pump
29 Generator
Prepared By: Ravi Sagar Checked By: Subhash C. Singh Approved By: Page 1
Current Rating
S. No. Equipment Name Current Rating(Amps)
1 Air Preheater 39
2 FD Fan 289
3 PA Fan 266
4 Seal Air Fan 303.9
5 ID Fan 274
6 Coal Mill 178
7 BCP 98
8 BCP Booster Cooling Pump 33.1
9 Gland Steam Ext Fan 20.35
10 MD BFP 762
11 MD BFP AOP 20.35
12 TD BFP Booster Pump 152
13 TD BFP LOP 13.875
14 TD BFP DC LOP 53.9
15 Hot well Makeup Pump 52.3
16 CEP 233
17 Vacuum Pump 252
18 OCCW Pump 171
19 CCCW Pump 68.7
20 Turbine AC LOP 95.2
21 Turbine DC LOP 284
22 H2 Seal Backup Pump 33.6
23 MOT Vapour Ext Fan 7.5
24 AC JOP 38
25 DC JOP 156
26 H2 Side AC SOP 10.5
27 H2 Side DC SOP 29
28 Air Side AC SOP 40.7
29 Air Side DC SOP 112
30 EH Oil Pump 79.8
31 Stator Water Pump 83.25
32 CW Pump 237
33 CT Makeup Pump 60
34 HFO Fwd Pump 173.3
35 LDO Fwd Pump 173.3
36 Cooling Tower Fan 219
MFT
S. Alarm Trip Time
No. MFT Conditions Value Value Delay
1 Total air flow < 30 % (of 2346 TPH)BMCR - 704 tph 5 sec
2 2/3 drum level HH 100 mm 300 mm 5 sec
3 2/3 drum level LL -100 mm -381 mm 5 sec
4 2/3 furnace pressure HH 1000 Pa 2230 Pa 3 sec
5 2/3 furnace pressure LL -1000 Pa -1960 Pa 3 sec
All scanner cooling air fan stopped(25 sec) OR 2/3 header
6 5.6 Kpa 3.2 Kpa 35 sec
press LL(35 sec)
7 All BCP trip 5 sec
(i)Unit Load > 30% AND turbine tripped OR
8 -
(ii)Turbine trip AND HP Bypass open < 5 % AND Load <30 %
9 Unit flame failure -
10 Loss of fuel -
11 Furnace purge request, (30 mins no flame after purge over) -
12 FSSS control cabinet power lost 1 sec
13 Any coal feeder ever running & both PAF stopped & no oil
layer in service -
14 MFT manual trip button pressed -
15 All FDF stopped -
16 All IDF stopped -
17 All APH stopped 10 sec
Turbine Protection
S.No Protection Alarm Value Trip Value Time Delay
1 EH Trip(EH oil pressure LL) 11.2 Mpa 8.5 Mpa -
2 Lube oil pr low low 0.08 Mpa 0.048 Mpa -
3 Low Vacuum Trip -85 Kpa -65 Kpa -
4 VB high trip 125 mic 250 mic 2 sec
5 Axial shift High -0.9 mm & 0.9 mm -1 mm & 1 mm -
HP -4.5 & 10.3mm HP -5.1 & 11.1mm
6 Diff exp high
LP - 4.1 & 25.1 mm LP -4.3 & 27.8 mm -
7 HP Exh Temp HH Trip 401 Deg C 427 Deg C -
7 MFT
8 Gen trip
9 TSI Trip
10 Man Trip
11 DEH trip
Turbine DEH Trip

S.No. Protection Alarm Value Trip Value Time Delay
1 Turbine over speed 3090 3300 Rpm -
2 Bearing Metal temp HH trip 113 Deg C 5 sec
3 Any Thrust bearing metal temp HH 107 Deg C 5 sec
4 Breaker open and system speed fail -
5 (i) ATR Trip
AND
(ii) ATC In
AND
(iii) ATC Run
Note: 5* protection will be applicable only in rolling period
Purge Condition
S. No. Purge Condition
1 No MFT existing
2 Total air flow > 30 % and < 40 % of rated air flow(730 tph- 990 tph)
3 Any APH running
4 At least 1 IDF running
5 At least 1 FDF running
6 Both PAF stopped
7 All discharge damper of Mills closed
8 All mills & coal feeder stopped
9 All Hot air & Cold air gates are closed
10 No fire detector detect fire(Unit no flame)
11 Drum level normal(+50 OR -50 MM)
12 Furnace pressure OK
13 LOTV & HFOTV closed
14 All oil corner valves closed
TDBFP
System Description:
Pump Turbine
Discharge Flow 1179 TPH Stage 6
Discharge Press 23.68 MPa Max Speed 5900 rpm
Power 9 MW Critical speed First: 2246 RPM, Second:6532 RPM
4th Extraction & Auxiliary steam Header
Steam
Exhaust Pressure 11.1KPA Low press steam: 0.834Mpa/338.5°C
Source Auxiliary steam: 0.8 MPa/300 °C
TDBFP Permissive
S. No. Start Permissive
1 Booster pump running
2 BFP lube oil pressure not L (<0.088 MPa)
3 BFP Exhaust vacuum not low (<-80KPa)
4 BFP bearing temps are not high
TDBFP Protection
S. No. Protection Stop Alarm Value Trip Value Time Delay
1 TDBFP Flow Low
a) Min r/c valve position is < 5 % AND
b) Boiler feed pump is running for 15 secs AND
c) Feed water flow is low (280 TPH)for 15 secs AND
2 BFP running AND
a) Disch MOV not open AND
b) Min r/c valve position is < 5 %
3 Booster pump stopped -
4 BFP I/L pressure LL 1.2 Mpa 0.8 Mpa
5 Thrust bearing temp HH 90 100 -
6 Radial bearing temp HH 90 100 -
7 Seal water temp HH 80 90 -
8 METS Trip
a) Low vacuum trip <-85 Kpa <-61.5 Kpa -
b) lube oil press LL <0.088 Mpa <0.059 Mpa -
c) shaft displacement ±0.18mm ±0.25 mm -
d) shaft vibration HH 0.08 mm/sec 0.125 mm -
e) Brg temp HH 90 100 -
f) over speed trip 6050 6160 rpm -
g) MEH trip -
h) Manual Trip -
i) DCS trip(Trip from booster pump protection) -
9 Dearator level LL 360 mm 20 sec
TD BFP Booster Pump

System Description:
Pump Motor
Discharge Flow 1179 TPH Power 710 KW
Head 134 M FLC 150 Amp
NPSH_R 4.2 M Voltage 3.3KV
Speed 1490 RPM
TDBFP Booster Pump Permissive

S.
No. Start Permissive
1 R/C valve > 95 %
2 I/L valve opened
3 O/L valve closed
4 Dearator level not Low>1100 mm
5 No protection trip persist
6 Booster pump bearing temperature not high<90 Deg C
TDBFP Booster Pump Protection

S. No. Protection Trip Alarm Value Trip Value Time Delay
1 Bearing Temp HH 90 Deg C 100 Deg C 3 Sec
2 Dearator level LL 1100 mm 360 mm 20 sec
3 Inlet valve closed
4 Booster pump running AND Flow < 280 TPH
AND R/C valve < 5 %
5 Booster pump running AND O/L valve closed
AND R/C valve < 5 %
MD-BFP
System Description:
Pump Motor
Discharge Press 23 MPa FLC 762 Amp
Inlet Press 2.27 MPa Voltage 11 KV
Sealing & Cooling Max
0.4~0.6 MPa 5032 rpm
water Pressure Speed
MD- BFP C Permissive

1 BFP C I/L Valve opened
2 BFP C I/L filter DP not high
3 Deareator level normal(1000 mm)
4 MD- BFP lube oil pressure normal (>0.17 Mpa)
5 Min r/c valve position open (>95 %)
6 Scoup position <15% & Disch valve close
7 No High vibration signal
8 Sealing & cooling water press. Established
9 No high temperature signal
MD- BFP C Protection

S. No. Protection Trip Alarm Value Trip Value Time Delay
1 MD-BFP oil pressure LL 0.15 Mpa 0.08 Mpa -
2 MD- BFP is running for 30 secs & MD-BFP 1.2 Mpa 0.8 Mpa
pump I/L pressure LL -
3 Dearator level LL 360 mm 20 sec
4 MD- BFP vibration HH 0.18 mm/sec 0.28mm/sec 4 sec
5 MD-BFP min Flow low trip
a) Min r/c valve position is < 30 % AND
b) Boiler feed pump is running for 15 secs AND
c) Feed water flow is low (280 TPH)for 15 secs
6 Temperature High trip -
7 BFP running for 30 sec & I/L valve not open -
MD- BFP C Temp Protection

S. No. Temperature Signals ( deg C) Alarm Value Trip Value Time Delay
1 Main thrust brg temp 90 100 -
2 Aux thrust brg temp 90 100 -
3 Radial Brg temp ( Water I/L side) 90 100 -
4 Radial Brg temp ( Water O/L side) 90 100 -
5 Coupler No- 1- 10 brg temp 90 95 -
6 Coupler Lube Oil cooler I/L temp 65 70 -
7 Coupler Lube Oil cooler O/L temp 55 60 -
8 Coupler Working Oil cooler I/L temp 110 130 -
9 Coupler Working Oil cooler O/L temp 75 85 -
10 Booster radial brg temp DE 90 100 -
11 Booster radial brg temp NDE 90 100 -
12 Motor radial brg temp 85 95 -
13 Motor radial brg temp (booster side) 90 100 -
14 Seal metal temp ( water I/L side) 80 90 -
15 Seal metal temp ( water O/L side) 80 90 -
EH Oil Pumps
System Description:
Pump Motor
Discharge Flow 6.6 M3/ Hr Power 45 KW
Max/working
Discharge Press 31.5 MPa/14 Mpa FLC 79.8 Amp
Speed 1450 RPM Voltage 415 V
EH Oil Pump Permissive

1 Tank Level not L ( > 470 mm)
S. No. Auto Start (Standby is in interlock)

1 Pump running & header pressure L (11.2 Mpa)
2 Running pump stopped
EH Oil Pump Protection

1 EH Oil Tank level LL 470 mm 230 mm 1 sec
Lube Oil Pumps

Pump Motor
Discharge Flow 4900 LPM Power 55 KW
Discharge Press 0.37 MPa FLC 95.2 Amp
Turbine AC LOP A
Start permissive
Lube oil tank level not L
Select Switch (select A) and backup mode put in Interlock
Turbine trip AND Start AC
Turbine lube oil pressure L (0.08 Mpa) OR LOP A
Turbine speed < 2850 rpm
Select Switch (select A) and backup mode put in

Turbine trip and pump A not start Interlock
Turbine lube oil pressure LL (0.07 Mpa) AND Start AC
OR
Turbine speed < 2850 rpm and pump A not start LOP B
Pump A trip
Turbine AC LOP B
Start permissive
Lube oil tank level not L
Select Switch (select B) and backup mode put in Interlock
Turbine trip AND Start AC
Turbine lube oil pressure L (0.08 Mpa) OR LOP B
Turbine speed < 2850 rpm
Select Switch (select B) and backup mode put in

Turbine trip and pump B not start Interlock
Turbine lube oil pressure LL (0.07 Mpa) AND Start AC
OR
Turbine speed < 2850 rpm and pump B not start LOP A
Pump B trip
Turbine DC Lube Oil Pump

System Description:
Pump Motor
Discharge Press 0.37 Mpa FLC 284 Amp
Turbine DC EOP Interlock

Turbine lube oil pressure LL (0.06 Mpa)
Interlock
Turbine speed < 2850 rpm & LOP A & B not start OR AND
start DC
LOP A & B emergency trip
Generator Seal Oil System

System Description:
Description Value Unit

Specified differential pressure between seal oil pressure
0.084±0.01 MPa
and hydrogen pressure
Total oil mass of air-side shaft seal ring 220 L/min
Total oil mass of hydrogen-side shaft seal ring 51 L/min
Inlet temperature of seal oil < 52 °C
Outlet temperature of air-side seal oil < 56 °C
Outlet temperature of hydrogen-side seal oil < 64 °C
Working hydrogen pressure 0.4 MPa
Inlet temperature of the secondary cooling water ≤ 38° °C
Inlet amount of the secondary cooling water(air /

120/60 T/h
hydrogen side)
Pressure of the secondary cooling water 0.15~0.3 MPa
Hydrogen purity ≥98 %
Generator Seal Oil System

System Description:
AC/DC SOP at Air Side AC/DC SOP at H2 Side

Discharge Flow 40 M3/Hr Discharge Flow 10.5 M3/Hr
Discharge Press 1 Mpa Discharge Press 1 Mpa
Shaft Power 18 KW Shaft Power 4.9 KW
AC SOP Motor at Air Side AC SOP Motor at H2 Side

Power 22 KW Power 5.5 KW
Voltage 415 V Voltage 415 V
Current 44.5 A Current 11.1 A
Speed 1470 RPM Speed 2900 RPM
DC SOP Motor at Air Side DC SOP Motor at H2 Side

Power 22 KW Power 5.5 KW
Voltage 220V/110V Voltage 220V/110V
Current 113.7 A Current 30.3 A
Speed 3000 RPM Speed 3000 RPM
H2 Side Seal Oil Pumps

H2 side seal oil Ac pump
S.NO. Start Permissive
1 Tank level not L(>-60 mm)
Auto start condition (interlock start)

1 H2 side seal oil Ac spare pump trip
H2 side seal oil Ac spare pump

S.NO. Start Permissive
1 Tank level not L
Auto start condition (interlock start)

1 H2 side seal oil Ac pump trip
H2 side seal oil DC pump

S.NO. Auto start condition (interlock start)
1 H2 side seal oil Ac pump & Ac spare pump trip
2 H2 side seal oil Ac pump running & I/L O/L dp L
3 H2 side seal oil Ac spare pump running & I/L O/L dp L
Air Side Seal Oil Pumps
Air side seal oil Ac pump

1 Air side seal oil Ac spare pump trip
Air side seal oil Ac spare pump

1 Air side seal oil Ac pump trip
Air side seal oil DC pump

1 Air side seal oil Ac pump & Ac spare pump trip
2 Air side seal oil Ac pump running & I/L O/L dp L
3 Air side seal oil Ac spare pump running & I/L O/L dp L
Stator Cooling Water Pump

System Description:
Pump MOTOR
Discharge Flow 115 m³/ hr Power 45 KW
Head/ NPSH 0.75 Mpa/ 4.5 M FLC 76.8 Amps
Speed 2970 RPM Voltage 415 KV
Stator cooling Pump Permissive

1 Tank Level not L (>30cm)

1 Inlet/outlet DP L
CCCW Pump
System Description:
Pump Motor
Discharge Flow 1800 M3/Hr Power 315 KW
Discharge Press 0.7 MPa FLC 68.7 Amp
Speed 1480 RPM Voltage 3.3 KV
NPSH 5.6 M
CCCW Pump Permissive

1 Tank level > 200 mm
2 Pump I/L MOV opened
3 Pump O/L MOV closed or pump is in backup mode
4 All temp OK ( < 70 Deg C)

1 Pump running & header pressure L (0.25 Mpa)
CCCW Pump Protection

1 Pump Motor front & Back brg temp HH 80 Deg C 90 Deg C -
2 (i)Pump I/L Main pipe pressure LL AND 0.17 Mpa
10 sec
(ii)CCCW Exp tank level LL 50cm
3 Pump running over 60 secs ,O/L valve closed

signal not disappear
4 Pump running & I/L valve closed signal comes
OCCW Pump
System Description:
Pump Motor
Discharge Flow 2350 M3/Hr Power 90 KW
Discharge Press 0.3 MPa FLC 171 Amp
NPSH 4.5 M
OCCW Pump Permissive

1 Condenser A or B CW I/L press > 0. 10 Mpa
2 Pump I/L MOV opened
3 Pump O/L MOV closed or pump is in backup mode
4 All temp OK

1 Pump running & header pressure L
OCCW Pump Protection

1 Pump Front & Back brg temp HH 80 Deg C 90 Deg C -
2 Pump I/L pipe pressure LL 0.1 Mpa 0.08 Mpa 10 sec
4 Pump running over 60 secs ,O/L valve closed

signal not disappear -
5 Pump running & I/L valve closed signal comes 3 sec
CEP
System Description:
Pump Motor
Discharge Press 3.23 Mpa FLC 232 Amp
Sealing & Cooling
0.4~0.6 Mpa Voltage 3.3 kV
water Pressure
CEP Permissive
1 Hotwell level not L(>250MM)
2 Any CEP running or minimum R/c > 40 % open
3 I/L MOV open & O/L closed or pump in backup

1 Pump running & header pressure L, delay 10 secs (2.3 Mpa)
2 running pump tripped
CEP Protection
S. No. Protection Alarm Value Trip Value Time Delay
1 O/L MOV closed & pump running
more than 60 secs -
2 I/L MOV not opened while pump is

running -
3 Motor vibration HH 0.15mm 0.25 mm -
4 Condenser B hotwell level LL 250 mm 100 mm 10 sec
5 Pump brg temp HH 70 Deg C 80 Deg C -
6 Motor brg temp HH 85 Deg C 95 Deg C -
Vacuum Pump
System Description:
Pump Motor
Separator Tank Level 20~30 cm Power 132 KW
Extraction Amount >78 Kg/h FLC 252 Amp
Speed 590 rpm Voltage 415 V
Vacuum Pump Permissive

1 Separator Level not low (>18cm)
2 Vacuum Breaker valves closed
3 I/L valve closed
4 vacuum pump temp ok (<80 deg C)

1 Condensor Vacuum L (-85 Kpa) OR I/L valve Pressure H (150 m bar)
2 Running pump tripped
Vacuum Pump Protection

1 Separator level LL 15 cm 90 sec
HP/LP Bypass System

System Description:
HP Bypass Valve LP Bypass Valve

Valve Front Pressure 17.6 Mpa Valve Front Pressure 3.75 Mpa
Valve front Temp 541 DegC Valve front Temp 538 DegC
Valve Rear Pressure 4.17 Mpa Valve Rear Pressure 0.5884 Mpa
Valve Rear Temp 335.6 DegC Valve Rear Temp 160 DegC
Rated Flow 1236 TPH Rated Flow 2*711.5 TPH
Working oil station Pump:
Pump MOTOR
Discharge Flow 7.2 LPM Power 4 KW
Discharge Pressure 24 MPa FLC 9.2 Amps
HP Bypass Quick Open/Close Condition
S.NO. Condition for HP bypasses quick open. Value

2 Turbine trip.
3 Generator trip.
4 MS Pressure HH (AND DP>1.3 MPa) >10 Mpa
5 Generator load reduction. >60%
6 DCS quick open HP bypass.
S.NO. Condition for HP bypass quick close. Value

2 HP bypass outlet temp. HH >380 Deg C
3 HP bypass spray water pressure L <5 MPa
4 DCS quick closed HP bypass.
S.NO. Condition for LP bypass quick open Value

1 HP bypass quick opened.
2 Reheater hot pressure too H >4.1 MPa
3 DCS quick open LP bypass.
S.NO. Condition for LP bypass quick Close Value

1 Condenser A Pressure H#1 >35 Kpa
4 Condenser A temp. H >120 DegC
5 Condenser A level H >1300 mm
6 LP bypass spray water pressure L <1.5 Mpa
7 DCS quick close LP bypass
8 Condenser B Pressure H # 1 >35 Kpa
11 Condenser B Temp. H >120 DegC
12 Condenser B Level H >1300 mm
13 LPBP2 spray water pressure L <1.5 Mpa
ID FAN
System Description:
FAN MOTOR
Discharge Flow 2295222 m³/ hr Power 4250 KW
Discharge Pressure 4849 Pa FLC 274 Amps
Speed 590 RPM Voltage 11 KV
ID FAN Permissive
S. No. ID Fan Start permissive (VFD Bypass Mode)
1 ID Fan in DCS Mode
2 NO Fault Persist
3 NO Trip Signal Persist
4 ID Fan Breaker Ready to Close
5 ID fan Bearing Temp ok (<70 DEG)
6 ID fan Motor Bearing Temp ok (<85 DEG)
7 ID Fan Lube Oil Pressure OK (>0.1 MPa)
8 Respective APH running
9 Respective APH Outlet SA damper Open
10 Respective APH Inlet Flue Gas Damper Open
11 All SA Damper not Closed
12 At Least 1 of 2 cooling fan should be in running condition
13 ID Fan Inlet Flue Gas Damper 1 & 2 closed
14 ID Fan Outlet Flue Gas Damper 1 & 2 open
15 ID Fan in Bypass Mode and Vane Closed (< 5%)
16 Respective FD fan O/L Damper 1&2 Open
17 Respective FD fan Blade Open
S. NO ID Fan Start permissive (VFD Mode)

1 ID Fan in DCS Mode
2 NO Fault Persist
4 ID Fan Breaker Ready to Close
5 ID fan Bearing Temp ok (<70 DEG)
6 ID fan Motor Bearing Temp ok (<85 DEG)
7 ID Fan Lube Oil Pressure OK (>0.1 MPa)
11 All SA Damper not Closed
12 At Least 1 of 2 cooling fan should be in running condition
13 ID Fan Inlet Flue Gas Damper 1 & 2 closed
14 ID Fan Outlet Flue Gas Damper 1 & 2 open
15 ID Fan in VFD Mode and Vane Open (> 95%)
16 Respective FD fan O/L Damper 1 & 2 Open
17 Respective FD fan Blade Open
ID FAN Protection
S.NO Protection Alarm Value Trip Value Time Delay
1 MFT and furnace pressure LL -1000 Pa -2800 pa -
2 ID Fan bearing temperatures HH(Delay only for VFD) 75 ℃ 95 ℃ 10 sec
ID Fan motor bearing temperatures HH(Delay only
3 for VFD) 75 ℃ 95 ℃ 10 sec
4 ID Fan bearing vibration HH 6.3 mm/sec 7.1 mm/sec 3 sec
5 Oil station LUB OIL HDR Pressure LL 0.1 Mpa 0.07 MPa 60 sec
ID Fan lube oil pump A stop and lube oil pump B
6 stop 5 sec
ID Fan running for 60s and IDF gas inlet damper
7 closed -
8 ID Fan running and IDF gas outlet damper closed -
9 Respective FD Fan trip -
10 Respective APH trip 20 sec
FD Fan
System Description:
FAN MOTOR
Discharge Flow 1026827 m³/Hr Power 1400 KW
Rotating Speed 990 RPM Voltage 3.3 KV
FD Fan Permissive
S. No. FD Fan Start permissive
1 FD Fan in DCS Mode
2 NO Fault Persist
4 FD Fan Breaker Ready to Close
5 FD fan Bearing Temp ok (<70 DEG)
6 FD Fan Lube Oil Pressure OK (>0.1 MPa)
7 FD Hydraulic Oil Pressure Not L (>2.5 MPa)
8 FD Fan Lube Oil Flow Not L (>3L/min)
9 FD Hydraulic Oil Box Level Not L (>75%)
13 FD Fan Outlet Damper 1 & 2 Closed
14 FD fan Blade Closed (<5%)
15 Respective ID fan Running
FD Fan Protection
S. No. FD Fan Protection Stop Alarm Value Trip Value Time Delay
1 MFT and furnace pressure HH 1000 Pa 2800 Pa -
2 FD Fan Main Bearing Temp HH 75℃ 95℃ -
3 FD Fan motor front bearing HH 85℃ 95℃ -
4 Oil station Lube Oil HDR Pressure LL. 0.1 Mpa 0.07 Mpa 60 sec
5 Bearing Vibration HH(11mm/sec) 7.1 mm/sec 11 mm/sec 3 sec
FD Fan Outlet Damper still closed, when FD
6 Fan running 60 sec later -
7 FD Fan Both oil pump Stops 5 sec
8 Respective ID Fan trip -
PA FAN
System Description:
FAN MOTOR
Rotating Speed 1490 RPM Voltage 11 KV
PA FAN Permissive
S. No. PA Fan Start permissive
1 PA Fan in DCS Mode
2 NO Fault Persist
4 NO MFT
5 PA Fan Breaker Ready to Close
6 PA fan Bearing Temp ok (<90 DEG)
7 PA Fan Lube Oil Pressure OK (>0.1 MPa)
8 PA Hydraulic Oil Pressure Not L (>2.5 MPa)
9 PA Fan Lube Oil Flow Not L (>3L/min)
10 PA Hydraulic Oil Box Level Not L (>75%)
12 Respective APH Outlet PA damper Close
13 PA Fan Outlet Damper closed
14 PA fan Blade Closed (<5%)
15 PA Fan any cooling fan running
PA Fan Protection
S. No. PA Fan Protection Stop Alarm Value Trip Value Time Delay
1 MFT -
2 PA Fan Main Bearing Temp HH 90 Deg C 100 Deg C -
3 PA Fan motor front and Rear bearing HH 85 Deg C 95 Deg C -
4 Oil station Lube Oil HDR Pressure LL 0.10 Mpa 0.07 Mpa 5 sec
5 PA Fan Bearing Vibration HH 6.3 mm/sec 11 mm/sec 5 sec
PA Fan Outlet Damper still closed, when PA
6 Fan running 60 sec later 60 sec
7 PA Fan Both oil pump Stops 5 sec
8 Respective APH trip 20 sec
Seal Air Fan

System Description:
FAN MOTOR
Speed 1450 rpm Voltage 415 V
Seal Air Fan Permissive

1 Any PA Fan running
2 Seal Air O/L damper closed
3 Seal Air I/L damper opened (>20%)
AND
4 Seal Air filter I/L damper opened
5 Seal Air I/L filter DP not high (< 1 Kpa)
6 NO Electrical fault persisting
S. No. Auto start condition (interlock start)
1 Header Pressure L ( < 12 Kpa)
2 Seal Air/Primary air diff Pressure L ( < 5 Kpa) OR
3 Running fan stopped
Seal Air Fan Protection

1 All PA Fan stopped - - 15 sec
BCP
System Description:
Pump Motor
Discharge Flow 4801m³/h Power 400 KW
Discharge Press 20.54 MPa FLC 98 Amp
Cooling water Motor Cooling water-11 m³/h, 0.65
MPa.
Flow and Thermal Barrier- 2 m³/h, Voltage 3.3 KV
Pressure 0.103～0.172 MPa
BCP Permissive
S.NO BCP Start permissive
1 Drum level not L (< - 105 mm)
2 BCP motor cooling water flow normal
3 BCP metal temp normal ( < 50 Deg C)
4
Difference between cover metal temp & I/L pipe metal temp < 50 Deg C
S. No. Interlock
1 MCR > 60 % & less than 2 pumps running , standby put in interlock
2 One running pump trip, standby put in interlock
BCP Protection
S. No. BCP Protection Alarm Value Trip Value Time Delay
1 BCP motor metal temp HH 55 Deg C 60 Deg C 2 sec
2 BCP DP LL 70 KPa 5 sec
Coal Mill
System Description:
MILL MOTOR
Maximum Output 82.51 TPH Power 800 KW
Outlet Temp 65 Deg C FLC 172 Amps
Coal Mill Speed 23.2 RPM Voltage 3.3 KV
Oil Supply Pressure 0.35 Mpa Rated Speed 992 RPM
Hydraulic oil
342 L/min 15 Mpa
Oil Flow Pressure
Coal Mill Permissive

S. No. Start permissive
1 Coal Mill in DCS Mode
2 NO Fault Persist
4 Coal Mill Breaker Ready to Close
5 Any seal air fan running
6 Any Lube oil pump running
7 All mill O/L discharge damper opened
8 Coal Mill DP seal air to PA > 2 Kpa
9 Coal Mill motor, shaft & retarder bearing temp OK
10 Mill O/L temp normal (> 65 & < 82)
11 Mill sealing air damper opened
12 Mill Hot air & Cold air isolation gate opened
13 Mill air flow OK ( > 92 TPH & < 130 TPH)
Coal Mill Protection

1 Mill O/L temp 90 Deg C 110 Deg C 5 sec
2 Lube oil pressure LL 0.09 Mpa 0.07 Mpa 5 sec
3 Roller Beam Brg oil temp 90 Deg C 110 Deg C 5 sec
5 Motor Brg temp 85 Deg C 95 Deg C 1 sec
6 Thrust Brg temp 70 Deg C 5 sec
7 PA flow LL 60 tph 10 sec
8 Both SAF trip 5 sec
9 Feeder running & 3 flames lost. -
10 Both PA fan and any Feeder in service trip. 2 sec
11 MFT -
12 Both Hydraulic Oil loading pump stopped 5 sec
13 Both Lube oil pumps stopped 5 sec
14 Mill O/L all discharge damper closed 3 sec
Coal Feeder
System Description:
Normal operating Range 10- 85 TPH Type Gravimetric Feeder(4 KW)
Tightness air Pressure 500 Pa FLC 6.08 Amps
Feeder Speed 18-1420 RPM Voltage 415 V
Coal Feeder
S. No. Coal feeder Start Permissive
1 Mill running for 20 secs
2 Coal feeder O/L damper open
3 Sealing damper open
4 FDR in DCS
5 No Trip persist
Coal Feeder Protection

S.NO Protection Alarm Value Trip Value Time Delay
1 Mill trip -
2 MFT -
3 Feeder running and discharge plugged -
4 Feeder O/L damper closed -
Air Pre-Heater (APH)

System Description:
AIR PRE-HEATER MOTOR

Type Trisector, rotary type (Ljungstrom) Motor power 22kW
Speed 0.9 rpm(Normal) /0.23 rpm (Low) FLC/Voltage 39.6 A/415V
APH Main Motor Permissive

S. No. APH main motor Start Permit
1 Main motor is in DCS
2 Auxiliary motor stopped
AND
3 No any main motor transducer fault persisting(& VFD)
S. No. APH main motor Stop permit

1 APH inlet gas temp is < 125 Deg C
2 Auxiliary motor is in auto AND it is in DCS AND no fault persisting OR
3 Respective IDF stopped
S. No. APH main motor auto start

1 Main motor is in backup mode
AND
2 Auxiliary motor stopped delay 2 secs
APH Auxiliary motor

S. No. APH auxiliary motor Start Permit
1 Auxiliary motor is in DCS
2 Main motor stopped
AND
3 No any Aux motor transducer fault persisting
S. No. APH auxiliary motor Stop permit

1 APH inlet gas temp is < 125 Deg C
2 Main motor is in auto, it is in DCS and no fault persisting OR
3 IDF stopped
S. No. APH auxiliary motor auto start

1 Auxiliary motor is in backup mode
AND
2 Main motor stopped delay 2 secs
APH Air motor

S. No. APH air motor auto start
1 APH motor tripped(Aux Mtr stopped & Main Motor stopped & air pressure Ok)
Scanner Cooling Air Fan

System Description:
FAN MOTOR
Discharge Flow 1480 M³/Hr Power 7.5 KW
Speed 2930 RPM FLC 13.04
Discharge Pressure 9480 Pa Voltage 415 V
AC Scanner Cooling Air Fan

S. No. AC scanner cooling air fan start permit
1 AC Scanner cooling air fan power normal
S. No. DC Fan Interlock to start condition

1 DC Scanner cooling air fan B is in interlock mode(Back up On)
2 AC Scanner cooling air fan stopped
AND
3 AC Scanner cooling air fan running and cooling main pipe pressure L, delay
5s ＜5.5Kpa OR
DC Scanner Cooling Air Fan

S. No. DC scanner cooling air fan start permit
1 DC Scanner cooling air fan power normal
S. No. AC Fan Interlock to start condition

1 AC Scanner cooling air fan B is in interlock mode (Back up On)
2 DC Scanner cooling air fan stopped
AND
3 DC Scanner cooling air fan running and cooling main pipe pressure L, delay
5s ＜5.5Kpa OR
CW System
System Description:
PUMP MOTOR
Speed 330 RPM FLC 237 Amps
Discharge Pressure 25 MWC Voltage 11 KV
CWP-Motor Cooling CWP-Motor Cooling
Pump Head 45 M Pump- Power 30 KW
CWP- Motor Cooling CWP- Motor Cooling
Pump Flow 150 M3/Hr Pump- Current 53 Amps
CWP Bearing CWP Bearing Cooling
Cooling Pump Head 28 M Pump- Power 3.7 KW
CWP Bearing CWP Bearing Cooling
Cooling Pump Flow 20 M3/Hr Pump- Current 7.25 Amps
CW Pump Permissive
S. No. CW Pump Start permissive
1 CW Pump in DCS Mode
2 NO Fault Persist
3 CW Pump Breaker Ready to Close
4 CW Pump Motor Cooling Pump should be running for 5 Mins.
5 CW Pump Discharge valve close.
6 CW Pump any temp (Pump bearing and Motor winding) Not H.
7 CW Pump No reverse rotation.
8 Motor bearing cooling pump discharge header flow not low
9 Motor bearing cooling pump discharge header pressure not low
10 Forebay level Not L
11 Condenser Inlet and Outlet valve Open.
12 CW Pump discharge Valve should be in DCS mode.
CW Pump Protection
S. NO Protection Alarm Value Trip Value Time Delay
1 CW Motor Winding Temp 130 Deg C 140 Deg C -
2 CW Pump/Motor Thrust Bearing Temp 90(Trip) -
3 CW Thrust/Motor bearing Vibration 7.1(Trip) 60 sec
CW Pump, Bearing cooling pump discharge header
4 1.2 kg/cm3 1.0 kg/cm3 10 sec
pressure LL
CW Pump, Bearing cooling pump discharge header
5 2.7 m3/hr 1.6 m3/hr 10 sec
flow Low LL
6 CW Motor bearing cooling pump discharge header 140 m3/hr 120 m3/hr 20 sec
flow LL
7 CW Motor bearing cooling pump discharge header 2.5 kg/cm2 2 kg/cm2 10 sec
pressure LL
8 CW pumps discharge header pressure Unit - 1 2.4 kg/cm2 90 sec
9 CW Forebay level/Sump level(One Lvl Tx and One 5M -

one Lvl Switch)
Note: CWP- Motor & Pump bearing cooling pump start/stop logic:
 CWP- Motor cooling pump start permissive will get after hold-up tank level
reached to 1100 mm.
 CWP-Motor cooling pump will trip at hold-up tank level 900mm with 1 sec time
delay.
 CWP Bearing cooling pump start permissive will get after hold-up tank level
reached to 1100 mm.
 CWP Bearing cooling pump will trip at hold-up tank level 900mm with 3 sec time
delay.
Air Compressor
System Description:
Compressor Motor
Discharge Pressure 9.99 kg/cm² FLC/voltage 118 amps/3.3 KV
Compressor Permissive
1 Gear box supply oil temp. 32 0 C minimum.
2 Oil reservoir level normal (70%).
3 Compressor discharge valve open condition.
4 Compressor cooling pump running & Pressure > 0.4 Mpa & cooling circuit through
5 FRP level normal & fan are running condition.
Compressor Protection
S. No. Protection Stop Start Alarm Trip
1 Gear box oil pressure Low 0.2 bar 1 bar
2 DP of air filter HH 0.055 bar
4 Gear box supply oil temp. 32 0 C 57 0 C 630 C
5 Element 1,2,3 temp High 66 0 C
6 Compressor outlet temp High 66 0 C
7 Element vibration 1,2,3 High 43 micron
8 Winding temp High 140 0 C
9 Bearing temp DE & NDE. 100 0 C
10 Compressor outlet Pressure High 16 bar
11 Element 3 outlet pressure Low 0.3 bar
12 Drive motor temp. 55 0 C
HFO Fwd Pump

System Description:
PUMP MOTOR
Speed 1450 RPM FLC 147.3 Amps
Discharge Pressure 3.0 Mpa Voltage 415 V
HFO Fwd Pump Permissive

1 Suction Filter DP < 50 Kpa
2 Auto Start: Discharge header pressure < 0.69 Mpa for 1 sec
LDO Fwd Pump

System Description:
PUMP MOTOR
Discharge Flow 25 m3/hr Power 90 KW
Speed 2950 RPM FLC 146.3 Amps
Head 450 M Voltage 415 V
LDO Fwd Pump Permissive

1 Suction Filter DP < 50 Kpa
2 Auto Start: Discharge header pressure < 2.7 Mpa for 1 sec
Generator
System Description:
 Rated speed: 3000 RPM
 Cooling: Stator winding is Water, Rotor & core are Hydrogen cooled
 Out Put: 705880 KVA
 Power Factor: 0.8
 Voltage / Current: 20000 Volt / 20377 Amp
 Rated Excitation Voltage/Ampere: 465.6 V /4557 A
 No. of Phase: 3 phase
 Terminal frequency: 50 Hz
 AVR Range of control: 30 to 110% (6000-22000 Volt)
Trip condition :
 Low Forward Power Protection - 1.25% FOR 1 SEC.
 Reverse Power Protection - 0.5% FOR 2 SEC.
 Local Breaker Back Protection
 Generator stator ground fault protection 95% (64 G1)
 Generator 100% stator ground fault protection (64G2)
 Generator overvoltage ( 59 G)
 Generator Under voltage( 27 G)
 Under Frequency
 Over Frequency
 Loss of Field or Loss of Excitation Protection
 Generator rotor E/F ( 64F)
 Generator Hydrogen Purity – 90%
 Generator seal oil pressure
 Pole Slip Protection(78 G)
 Generator Differential Protection (87G)
 Negative Sequence or Current Unbalance Protection.

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ESSAR POWER MP LIMITED

Document Approval Sheet

Checked By Subhash C. Singh Signature

Approved By HOD Operation Signature

Approved By O&M Head Signature

Turbine DEH Trip

Note: 5* protection will be applicable only in rolling period

TD BFP Booster Pump

TDBFP Booster Pump Permissive

TDBFP Booster Pump Protection

MD- BFP C Permissive

MD- BFP C Protection

MD- BFP C Temp Protection

EH Oil Pump Permissive

S. No. Auto Start (Standby is in interlock)

EH Oil Pump Protection

Lube Oil Pumps

Select Switch (select A) and backup mode put in

Select Switch (select B) and backup mode put in

Turbine DC Lube Oil Pump

Turbine DC EOP Interlock

Generator Seal Oil System

Description Value Unit

Total oil mass of air-side shaft seal ring 220 L/min

Total oil mass of hydrogen-side shaft seal ring 51 L/min

Inlet temperature of seal oil < 52 °C

Outlet temperature of air-side seal oil < 56 °C

Outlet temperature of hydrogen-side seal oil < 64 °C

Working hydrogen pressure 0.4 MPa

Inlet temperature of the secondary cooling water ≤ 38° °C

Inlet amount of the secondary cooling water(air /

Pressure of the secondary cooling water 0.15~0.3 MPa

Hydrogen purity ≥98 %

Generator Seal Oil System

AC/DC SOP at Air Side AC/DC SOP at H2 Side

AC SOP Motor at Air Side AC SOP Motor at H2 Side

DC SOP Motor at Air Side DC SOP Motor at H2 Side

H2 Side Seal Oil Pumps

Auto start condition (interlock start)

H2 side seal oil Ac spare pump

Auto start condition (interlock start)

H2 side seal oil DC pump

Air Side Seal Oil Pumps

Air side seal oil Ac pump

Air side seal oil Ac spare pump

Air side seal oil DC pump

Stator Cooling Water Pump

Stator cooling Pump Permissive

S. No. Auto Start (Standby is in interlock)

CCCW Pump Permissive

S. No. Auto Start (Standby is in interlock)

CCCW Pump Protection

3 Pump running over 60 secs ,O/L valve closed

OCCW Pump Permissive

S. No. Auto Start (Standby is in interlock)

OCCW Pump Protection

4 Pump running over 60 secs ,O/L valve closed

S. No. Auto Start (Standby is in interlock)