Emergency Operating Procedure

TRN TRN Energy Pvt. Ltd.
TRNEPL/
Shaping the future
2020 2 X 300 MW Power Plant Emergency/ 00
EMERGENCY OPERATING PROCEDURE
Issue No: Issue Date: Revision: Revision Date: File no: Remarks
01 13.03.2020 00 02
TRNEPL 2 X 300 MW
EMERGENCY
OPERATING
PROCEDURES
An Emergency Operating Procedure (EOP) is developed to provide the detailed
and comprehensible emergency conditions & also enabled operator to take action
within stipulated time period for the safe guard of men, machine & environment.
The validation shows that the load and pressure for the workers can be reduced
and the safety of TPP can be enhanced.
Prepared By: - Approved By:-

Sandip Anand Shri.D.N.Patel
Akash Pandey Head - Operation
Lohit Kumar
Kkk
TRN TRN Energy Pvt. Ltd. TRNEPL/

2 X 300 MW Power Plant Emergency/ 00
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INDEX
Station/Unit Emergencies
S. No System Descriptions Page. No
1 Station Blackout 1-4
2 Unit Tripping 5
3 Instrument Air Failure 6-8
4 Automatic Load Shedding (Run Back) 9
5 Hammering In Pipe Line 10-11
6 Fire Disaster 12
7 FLUE Gas One Path Isolation Procedure (Isolated) 13

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INDEX
Boiler & Auxiliaries Emergencies
Sl. No System Descriptions Page. No

1 FD Fan Tripping 15-16
2 ID Fan Trip 17-18
3 PA Fan Tripping 19
4 Surge/Stall of PA, FD & ID Fan 20
5 APH Main Motor Tripped & Auxiliary Motor Not Started 21
6 AC Scanner Fan Tripped & DC Fan Fail To Pickup 22
7 Mill Seal Air Pressure Loss 23
8 Fire in Coal Mill or Mill Explosion 24
9 One or More Than One Coal Mills Tripping 25
10 Boiler Water Wall Tube Leakage 26
11 Economizer Tube Leakage 27
12 Super Heater Tube Leakage 28-29
13 Reheater Tube Leakage 30
14 MS Temperature Falling Fast 31
15 Main Steam Temperature Rising Fast 32
16 Reheater Temperature Falling Fast 33
17 Reheater Temperature Rising Fast 34
18 MS Pressure Rising Fast 35
19 MS Pressure Dropping Fast 36
20 ERV/MS Safety Valve Lifted 37
21 HRH Safety Valve Floating 38
22 Sudden Loading of ID Fan 39
23 Air Flow Going Low And High 40
24 Heavy Furnace Pressure Fluctuation 41
25 PA Header Pressure Dropping Fast 42
26 Oil Level Loss in APH Bearing 43
27 Sudden Increase in Steam Silica 44
28 Boiler Water pH Falling Fast 45
29 Boiler Expansion not OK during Cold Start up 46
30 Bunker Fire 47
31 Oil Spillage Observed in Bottom Ash System 48
32 Loss of Seal Trough level 49
33 LRSB not Retracting 50
34 Boiler Flue Gas Exit Temperature Shoots Up 50
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INDEX
Sl. No System Descriptions Page. No

35 Secondary Combustion 51-52
36 Drum Level Rising Fast 53
37 Drum Level Falling Fast 54
38 DCS Console Hanged/Failed 55-56
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INDEX
Turbine & Auxiliaries Emergencies
Sl. No. System Descriptions Page. No

1 Hot Well Level Raising Fast 58
2 Hot Well Dropping Fast 59
3 Deaerator Level High 60
4 Deaerator Level Low 61
5 CEP Tripped & Standby Fail to Start 62
6 One BFP Tripped 63
7 Any CW Pump Tripped 64
8 One CW Pump Tripped & Standby Not Available 65
9 HP Heater Level Maintaining High 66
10 Turbine Vibration High 67-68
11 Turbine Bearing Temperature High 69
12 High Axial Shift 70-71
13 HP LP Differential Expansion More +Ve 72
14 HP LP Differential Expansion More -Ve 73
15 High Eccentricity 74
16 Turbine Speed Maintaining above 51.5 Hz (Over Speed) 75
17 Barring Gear Not Engaged After Unit Tripping 76
18 All JOP Fail to Start 77
19 One of the HPCV or IPCV fail to close on tripping 78
20 One of the HPCV or IPCV close and turbine on load 79
21 Turbine Starts Rolling on MSV/RSV Opening 80
22 Turbine MOP Failure 81
23 MOT Level Low 82
24 HP Exhausts Temperature Shooting Up 83
25 LP Exhaust Temperature Shooting Up 84
26 Gland Steam Pressure Low 85
27 Gland Steam Temperature Low 86
28 Gland Steam Pressure High 87
29 Gland Steam Temperature High 88
30 EH oil leakage 89
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INDEX

31 EH Oil Pump Failed 90
32 Seal Oil Pressure Going Low 91
33 VOT Level Low 92
34 Seal Oil Pressure Oil Tank Level Low 93-94
35 Seal Oil Pressure Oil Tank Level High 95
36 Hydrogen Purity Low 96
37 Hydrogen Leakage 97
38 Both Vacuum Pump Failed 98
39 Condenser Vacuum Low 99-100
Condenser Pressure Rise After Vacuum Loss (In Blackout & Shut
40 101
Down Condition)
41 Condenser Tube Leakage 102
42 Generator Winding Temperature Rising Fast: 103
43 Water / Oil Detected In Generator Casing 104
44 Cooling Tower Fan Tripped 105
45 Fore Bay Level Dropping Fast 106
46 Water Hammer In Turbine 107
47 Breakage of Turbine Blade 108-109
48 Reverse Rotation of BFP 110
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INDEX
Electrical System Emergencies:
1 Power Supply Failure on Emergency PCC 112
2 DG not Started in Auto 113
3 Station Transformer Failure 114-115
4 UPS Failure 116
5 DCDB Failure 117
6 DC Fails of Motor Feeder 118
7 Fast Bus Transfer Blocked 118-119
8 Flash Over 120
9 Gas Pressure Low of Circuit Breaker 121
10 Fire in Cable Gallery 122
11 Hot Spot 123
12 High Oil/Winding Temperature of Transformer 123
13 Oil Leakage in Transformer CB/CT/PT 124
14 Transformer Tripped 125
15 SCADA not Responding 125-126
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STATION/UNIT - EMERGENCIES
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1. Station Blackout
Likely Causes:
1. Generator parallels off, working power of 6.6 KV all sections are off or UAT/ST transformer trips
and the primary and secondary safety source are not automatically put into operation successfully.
Plant Response:
1. Unit trip, boiler MFT, generator trip and generator parallel-off; alarming and each corresponding
alarm window lights.
2. The auxiliary bus bar voltage of all sections decreases to zero and its green light of power switch is
on.
3. All operating AC auxiliary equipment shut down and the spare AC auxiliary equipment do not
interlock; the electric-driven valve does not operate.
4. Start all DC equipment by interlock.
5. AC illuminating lamp is off, DC illuminating lamp is on and the control room gets dark.
Immediate Action to be taken:
1. Inform to WRLDC (Switchyard Engineer)
2. Ensure turbine DC EOP came into service. If not, start the EOP from DCS. In case of DCS problem,
there is provision to start EOP from desk hardwire push button. If not started from hardwire too, then
ask local operator to start it from local.
3. Ensure DC seal oil pump came into service. If not, start the SOP from DCS. In case of DCS problem,
ask local operator to start it from local.
4. Ensure generator circuit breaker, field breaker and unit bus incoming breakers have opened.
5. Ensure DC scanner fan came into service. If not, start the fan.
6. DG starts in auto and emergency PMCC gets charged. If not, start the DG from local and charge the
emergency EMCC.
7. JOP starts at 2500 rpm in auto. If emergency power (DG) has restored. If not, start the pump after
restoration of DG supply.
8. UPS, DC loads will be met by battery.
9. Diesel fire water pumps (hydrant) are available for fire.
10. Close steam lines & turbine drain valves (manual) to avoid failure of condenser rupture disc.
11. Inform DM plant to isolate CW Chlorine tonner.
12. Ensure both APH are running, if not start from DCS or Local, else rotate it manually.
13. Ensure that all fuel oil trip valves are closed
14. If soot blower was in service, retract manually.
15. Ensure all 6.6 KV drives breakers are open.
Turbine Side:
1. Fast close HP-LP bypass valves if opens in auto otherwise need not to open the same, close turbine
drain MIVs.
2. Open vacuum breakers after isolating all steam lines/drains to condenser, when turbine speed has
fallen to 2700 rpm and close gland steam supply valves.
3. Start turbine auxiliary oil pump. Stop EOP after restoration of emergency (DG) power.
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4. Start AC seal oil pump (A / B) and stop DC seal oil pump after restoration of DG power.
5. Start all BFP AOPs.( Not essential if pump is not in service before blackout )
6. Ensure turbine barring came into service. Otherwise start manual barring.
7. Ensure DCDB and UPS come on AC supply from battery source.
Boiler Side:
1. Close MS stop valves after restoration of DG power

2. Open ERV after restoration of DG supply.
3. Close SH and RH spray MOVs and CV, if not closed.
4. Ensure running of DC scanner fan and take changeover to AC scanner fan after restoration of DG
supply.
5. Start standby motors of RAPH#A/B after restoration of DG power.
6. Start ID, FD, and PA fans lube oil pumps after emergency power restored.
7. Start ID fan motor cooling fan (A / B) after emergency power restored.
8. Start mill’s lube oil pumps.
DC And UPS:
1. Check the healthiness of battery chargers. (Main plant)

2. Check the healthiness of UPS. (Main plant)
3. Check the healthiness of battery chargers. (Switchyard )
4. Check the healthiness of UPS. (Switchyard )
5. CW system DC load will be met by battery. (No emergency power to chargers)
Note:
1. Note down the protections acted in Generator, Transformer, Switchyard, Boiler, Turbine & Switchgear.
2. Check for TG vibration during coasting down and note down the coasting down time and max vibration.
3. Ensure that all normally open tie breakers of 6.6 KV buses are open.
4. Turbine, boiler lifts will be available, don’t operate lifts and isolate the power supply after park at 0
mtr with caution tag.
5. All MOVs, motor operated dampers will be available on emergency power.
Normalization:
Firstly, coordinate with WRLDC clearance for charging the line, after clearance & receive code from
WRLDC & charged the line.
1. Co-ordinate with 400 KV switchyard operators for power restoration.
2. Charge ST once power is available.
3. Charge station switchgear, unit switchgear. (6.6 KV)
4. Charge Unit PMCC, Boiler MCC, Turbine MCC, ESP PCC.
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Normalization Contd..:
5. Charge lighting PCC, Compressor PCC.
6. Charge water supply MCC, chemical water MCC. (DM plant )
7. Normalize EMCC and stop DG.
8. Charge CTMCC
9. Charge CHP PMCC.
10. Ensure DM plant and CHP power restored.
11. Start CCCW pump
12. Start air compressor and dryer.
13. Start circulating water pump as per SOP.
14. Start OCCW pump
15. Start control room air conditioning.
16. Stop diesel fire pumps.
17. Check the healthiness of battery chargers, UPS.
Action if DG fails or Emergency PMCC under Fault:
1. Turbine DC EOP will be in service. Manual barring to be done.

2. DC seal oil pump will be in service.
3. DC scanner fan will be in service.
4. Boiler main steam stops valves to be closed manually.
5. HP/LP bypass will remain close.
6. Rotate APH manually.
7. UPS load will be met by battery.
8. Try to restore DG & normalize power as early as possible.
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Readiness for Blackout:
Emergency drives will not be in service during normal operation. To keep them in good condition and to know
the availability, periodical trial is required. Following points to be ensured for safe handling of blackout.
1. Daily trial of turbine DC EOP.

2. Daily trial of DC Seal oil pump.
3. Daily trial of DG sets.
4. Daily trial of DC scanner air fan.
5. Weekly trial of diesel fire water pumps. (Hydrant pump).
6. Bi-weekly checking of emergency lights. (DC / AC lights in control room )
7. Emergency PMCC , DG are ready for auto charging.( ref: EPMCC charging SOP )
8. UPS battery is in good condition to take load.
9. Drawings of DC drives, Emergency PMCC, DG sets to be kept in location for immediate reference.
10. Turbine manual barring handles to be made available.
11. Spanner to open the cover for manual barring to be made available.
12. APH manual rotation handles to be made available.
13. Soot blower handles (wall blower, LRSB) to be made available to withdraw blower after blackout.
14. Torch lights to be made available in CCR.
15. Search light to be made available in control room.
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2. Unit Tripping
Immediate checks if only turbo generator trips:
1. Ensure generator circuit breaker, field breaker and unit bus incoming breakers have opened and
turbine is coasting down, barring gear to be put into service manually.
2. Ensure turbine’s AOP started, else start manually.
3. Inform to WRLDC.
If boiler has survived:

1. Ensure HP-LP bypass has opened and maintain MS, RH pressure.
2. Maintain LDO pressure and reduce firing as per requirement.
3. Maintain feed water flow by BFP.
Immediate checks if boiler also trips along with TG:

1. Ensure all fuel trip valves are closed.
2. Close HP-LP bypass valve to hold boiler pressure subjected to APRDS has charged with
interconnection from running unit otherwise HP-LP bypass shall be opened to maintain APRDS &
gland steam pressure & temperature till condenser on vacuum.
3. Close boiler MS stop valves.
4. Stop seal air fan.
5. Ensure closure of SH and RH sprays valves.
6. Ensure vacuum is normal, CW, OCCW and CCCW pumps are running.
7. Ensure closure of all extraction block valves.
8. Open all turbine side drains.
9. Ensure JOP starts at 2500 rpm and turbine comes to barring.
10. Ensure deaerator pressure maintaining by auxiliary steam.
11. Maintain hot well level and deaerator level.
12. Ensure DC and emergency power supplies are normal.
13. Ensure air compressors are running and instrument air pressure is normal.
14. Ensure all soot blowers are out and closure of soot blowing MOVs.
15. Inform to AHP, DM plant and CHP and ensure all ESP fields are switched off.
16. Start BFP and feed water to boiler as per boiler operating instructions.
17. Purge and light-up the boiler.
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3. Instrument Air Failure

Likely Causes:
1. Air compressors in operation trip and standby air compressors are not put into operation or air
compressors in operation are not loaded enough.
2. Sudden increase in consumption.
3. Malfunction of air compressor.
4. Instrument air receiver’s air leak/drain valve might be in opened condition.
5. Tripping of ST.
6. Tripping of CCCW pump.
7. Instrument air piping failure at valve flange or pipe welding joints.
8. The safety valve of compressed air system is jammed and cannot blow down after operation.
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Plant Response:
CVs & its Condition during Air Failure:
Turbine Side
Sl. No. Valve Location Valve Descriptions Air Fail Operation
HPH-6 To D/A normal drain Close - air lock relay
Deaerator Floor PRDS To D/A Close
1
(El+22 mtr.) CRH To PRDS Close
CEP To expansion tank Close - air lock relay
Gen. H2 cooler CV Close - air lock relay
Gland steam to LPH#1 dump valve Open
LP bypass 3rd spray CV Close
Hood spray CV Open
Gland steam attemperation CV Open
Turbine Floor
2 LP bypass RHS drain CV Open
(El+6 mtr.) LP bypass LHS drain CV Open
CEP To CST CV Lose - air lock relay
Gland steam header diaphragm valve Open
Gland steam header main CV Open
CRH All POT drain Open
D/A level CV main Line Open - air lock relay
D/A level CV bypass line Open - air lock relay
LPH-03 drip to drain tank CV Open
LP drip pump to LPH-02 O/L CV Close
LPH-04 drip to LPH-03 CV Open
HP flash tank spray CV Close
LP flash tank spray CV Close
LPH-03 emergency drain CV Open
LPH-04 drip CV Open
HPH-06 emergency drain CV Close - air lock relay
HPH-07 emergency drain CV Close - air lock relay
HP turbine casing drain Open
Turbine Floor
3 MS line drain CV Open
(El+0 mtr.) CRH line drain CV Open
HRH line drain CV Open
All extraction drain CV Open
CRH to PRDS drain CV Open
BFP to HPH-06 inlet line drain CV Open
CCCW to turbine lube oil cooler CV Close - air lock relay
HPH 3-way valve drain CV Open
LP drain tank to Hotwell CV Open
Hotwell makeup CV Open
CEP re-circulation CV/CST make up CV Close
Vacuum oil tank level CV Air lock
Stator water temp. CV/Vacuum pump suction valve Open
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Contd…
Boiler Side
Sl. No. Valve Location Valve Descriptions Air Fail Operation
1 Boiler, El+ 14 mtr. Feed control station Open - air lock relay
2 Boiler, El+ 60 mtr. Start-up vent Power cylinder holding type
3 Boiler (all corner) SADC Power cylinder holding type
4 Mill Area, El+10 mtr. Mill discharge valve Power cylinder switching type
5 Mill Area HAG & TAG Power cylinder switching type
6 Boiler, El+63 mtr. Soot blower line Close
7 Boiler, EL+14 mtr. LOTV, HOTV (SOVs) Close
Gun atomizing, purging & fuel oil valve
8 Boiler (all corner) Close
(SOVs)
9 Boiler, EL+14 mtr. LOCV, HOCV Close
10 ESP ESP lift valve & bypass valve Power cylinder switching type
11 Boiler, EL+ 65 mtr. MS line & HRH line PRV Power cylinder switching type
Parameters of Concern:
1. Sudden drop in condenser vacuum.
2. Controlling of unit load not possible.
3. Controlling of condensate flow not possible.
4. Gland steam pressure & temperature.
5. Mill HAGs & TAGs will not operate.
6. Controlling of deaerator level not possible.
Expected Operator’s Action:

1. Try to arrest or isolate the air leakage as soon as possible.
2. Open service/instrument air interconnection and charge instrument air header.
3. Close service air valve if use in plant to maintain instrument air pressure.
4. Hand trip the unit, if instrument air pressure goes very low.
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4. Automatic Load Shedding (Run Back) – Future Reference

Provision not available in our plant
Likely Causes:
1. A primary air fan trip.
2. An induced draft fan trip.
3. A forced draft fan trip.
4. A BFP trip.
5. Any mill trip.
Plant Response:
1. There is trip sound-light alarm of crucial auxiliary equipment and fluctuation of parameters controlled
by tripped auxiliary equipment.
2. Running coal mill is programmed to trip.
3. Unit load declines rapidly too and is stable at the setting load of related equipments.
4. Main steam flow, feed water flow and steam pressure drop by a large margin and the steam
temperature declines to some degree.
1. Load.
2. Air Flow, Feed water flow, drum level.
3. MS, HRH, CRH Temp and pressure.
4. Furnace Draft.
When RB automation succeeds;
1. When there is 50% RB, the automatic tripping sequence of the coal mill from top to bottom is: F→E
mill trip with the interval of 10 seconds until the last four mills remain in operation. The interval of
mill trip is 5 seconds when PA fan trip.
2. Unit control mode is switched from CCS to “turbine follow mode” and reduces the load to 50%
MCR according to RB load reduction setting.
3. Operators shall closely monitor the parameter variation and put oil gun into service timely for
combustion-supporting during automatic RB. No interference shall be applied, only if the automatic
operation is normal until the unit goes steady.
4. If one BFP trip and standby BFP start in interlock immediately maintain feed water flow to maintain
drum level in manual.
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Contd…
5. Boiler load>50% MCR, and one BFP trip while standby BFP pickup in interlock. The load shedding
comes up to 46% MCR.
6. Immediately switch automatic operation into manual operation for adjustment if abnormalities happen
during automatic RB process.
When RB automation does not succeeds;
1. Immediately trip an upper coal mill manually and put the oil gun on one bottom running coal mill into
operation for combustion-supporting. Remove the furnace pressure automation; adjust parameters like
drum water level, drum pressure, furnace pressure, and oxygen content within allowable range
according to specific case. Keep stopping the operation of some coal mills, if necessary.
2. When primary fan trips, immediately disable the furnace pressure automation and closely monitor
primary air pressure variation. If it is not allowed for operation of three pulverizing systems, trip one
coal mill every 5 seconds until the last one coal mill is maintained to operate, and timely put oil gun of
this mill into operation as well as reduce electrical load down to 150 MW.
3. During manual RB operation, pay attention to the variation of main steam temperature and reheater
steam temperature preventing low temperature protection operation when sharply reducing boiler
thermal load to choose coal mills to be tripped.
4. Restore the system with load after fault is cleared.
5. Hammering In Pipe Line

Likely Causes:
1. Proper charging procedure not followed. (e.g.: auxiliary steam header, heaters charging)
2. Sudden entry of steam into water lines.
3. Sudden entry of steam into improperly drained pipelines.
4. Improper warm up during charging steam lines.
5. Faulty drain traps.
6. Sudden opening of high pressure valves.
7. Temperature difference between medians.
8. Improper venting of heaters on water side.
9. Sudden start/stop of high pressure pumps.
10. Not priming the lines before starting.
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Plant Response:
1. Abnormal sound.
2. Damage to pipe lines.
3. Damage to hangers.
1. Thermal shock to piping system.

2. Pipe line failure.
3. Check hangers and supporting systems.
1. Cut off steam supply.

2. Open drains & trap bypass valves.
3. Wait for full draining/proper warm up.
4. Slowly open valve and allow steam to come out of drains.
5. Allow system pressure to build up.
6. Close drains & put trap in to service.
7. If it is a water line ensure no steam/hot water is entering pipeline.
Final Corrective Actions:
1. Put control on auto only after achieving designed system pressure and temperature.
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6. Fire Disaster
If fire disaster happens in the areas charged by the operators, they:
1. Should not leave their posts without permission or run around in panic.
2. Should strengthen the unit operation /maintenance and treat the accident based on rules.
3. Should implement the right order from upper level immediately.
4. Treatment of fire disaster.
5. Rush to the fire scene quickly after fire alarm signal is sent out, learn about the fire situation, check if
the fire-fighting system operates normally and make use of related fire extinguisher correctly to put
out the fire.
6. In case of the electrical equipment is on fire, cut off the power supply firstly, and then use the fire
extinguisher to put out the fire. If the electrical equipment is on fire, which may threaten the safety of
equipment, shut down the equipment and cut off the power supply.
7. Try to prevent the fire spreading, take away the inflammable substances around the fire scene and put
out the fire as soon as possible when the fire is not threatening the unit operation.
8. Strengthen monitoring operation and make preparation for shutdown.
9. Shut down for emergency immediately when fire disaster is seriously threatening the unit safety.
10. If the oil tank is on fire or the fire is near the oil tank, which is seriously threatening the oil tank safety,
open the emergency oil drain valve at the same time while shutting down by breaking vacuum.
However, the lubricating oil should not be interrupted before the unit stops to prevent the bearing
burnt.
11. Shut down for emergency when the fire of sealed oil system cannot be put out immediately and
threatens the equipment safety, and exhaust the hydrogen during the process of idling to ensure that
the sealed oil system can support the unit until it stop.
12. Shut down for emergency and charge CO2 into the generator to extinguish the fire by exhausting H2
when the generator or hydrogen cooling system is on fire. Operation of water cooling system should
be maintained.
Fire extinguishing methods, equipment used and precautions:
1. Fire on sundries without being oil-immersed can be extinguished with water, foam extinguisher and
sands, etc.
2. Fire on oil-immersed sundries shall be extinguished with foam extinguisher and sand, etc.
3. Fire on oil in oil tank or other containers shall be extinguished with foam extinguisher, CO2, DCP.
Wet cloth extinguishing or air isolation can be applied if necessary but sand and water faucet
without nozzle is prohibited for extinguishing.
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4. Fire on charged equipment shall be extinguished with CO2, and powder extinguisher after power cutoff
but foam extinguisher shall not be applied. It is prohibited to extinguish fire of motor by filling sand or
large stream of water into the motor.
5. When charged equipment is on fire, CO2 and DCP extinguisher can be applied for extinguishing if the
power cannot be immediately cut off. It is forbidden to employ other non-insulated extinguisher.
6. When steam pipe or other high temperature components are on fire, CO2 extinguisher shall be
prohibited and water applying shall also be cautious in case thermal stress damages the equipment.
7. If running part and speed-regulating system of the equipment is on fire, sand is not to be applied for
extinguishing. And meanwhile, execute extinguishing fire according to the above mentioned
provisions.
8. Fire on hydrogen system is mainly extinguished with CO2 and DCP.
7. Flue Gas One Path Isolation Procedure

Provision Eliminated
Expected Operator’s Action for path B isolation

1. Clearance and work plan details from mechanical maintenance
2. Inform to WRLDC for load revision.
3. Load reduced up to 150 MW. (export 130 MW)
4. Mill B, C, D, E or A, B, C, D in service (consecutive should be in service & total coal flow more
than 120 TPH for better flame stability)
5. Bypass the logic for APH-B isolation.
6. PA Fan# A/B interconnection damper closed.
7. PA Fan#B blade pitch control taken in manual & PA Fan#A blade pitch control keep in auto.
8. Slowly PA Fan#B blade pitch control reduces up to zero position & monitoring PA Fan#A blade
pitch control.
9. PA Fan# B stopped, discharge damper and by pass damper closed in auto.
10. APH#B hot PA outlet damper closed.
11. FD Fans interconnection damper closed
12. ID Fan#B & FD Fan#B loading reduces up to 10 % & parallel ID Fan#A & FD Fan#A loading
increases as per requirement.
13. Maintain air flow & furnace pressure through ID Fan#A & FD Fan#A.
14. APH#B flue gas inlet damper closed manually/auto & secondary air APH#B outlet damper open
condition for APH cooling.
15. ID Fan#B & FD Fan#B loading reduces to 0 %.
16. FD Fan#B & ID Fan#B stopped.
17. APH#B running condition.
18. APH#B secondary air O/L damper closed.
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BOILER AND AUXILARIES -

EMERGENCIES
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1. FD Fan Trip
Likely Causes:
1. ID fan tripped & general interlock is in service.
2. Respective APH tripped. (delay 01 sec).
3. FD fan bearing bush vibration > 11 mm/s, 3 sec delay.
4. Fan bearing temperature high > 90°, 3sec delay
5. Motor bearing temperature high > 90°C, 3sec delay.
6. Motor winding temperature high > 135°C, 3 sec delay.
7. Lube oil pr. <0.5 MPa.
8. FD fan running & O/L gate closed (delay 60 sec).
9. Electrical protections.
10. Furnace pressure HH > 3000 Pa (delay 1 sec).
11. Any transmitter malfunction.
Plant Response:
1. Tripped fan blade pitch & discharge damper closes.

2. Interconnection damper opens.
3. Total air flow to the wind box reduces.
4. Furnace pressure and secondary air pressure starts falling.
5. Flue gas oxygen percentage reduces.
6. Furnace to wind box DP will come down.
7. ID fan starts adjusting its blade pitch (if in auto).
8. Metal temperature may increase.
9. Second FD fan start loading if it is in Auto.
10. Chance of improper combustion and CO formation.
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1. Blade pitch & discharge damper closure for tripped fan.

2. Running fan current, bearing and winding temperature & vibration.
3. Flue gas oxygen %.
4. Fuel to Air ratio.
5. MS Temperature.
6. MS pressure.
7. Metal Temperature.
8. Load.
9. Ensure no reverse rotation of tripped fan.
1. Close tripped fan blade pitch & discharge damper, if it not closed.
2. Monitor running fan parameters and motor parameters.
3. Reduce coal flow according to total air flow.
4. Keep 4 mills in running (tripping of more mills reduce the PA flow contribution to total air flow).
5. Maintain furnace pressure.
6. Monitor MS temperature & pressure.
7. Reduce load set point w.r.t. MS pressure.
8. Inform local operator to check tripped fan condition.
9. Inform C&I, if any transmitter malfunctions.
1. Find root cause of fan tripping.

2. If fan is available, start it again and maintained load.
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2. ID Fan Trip
Likely Causes:
1. Corresponding APH trip. (Delay 01 sec).

2. Furness Pressure LLL > -3000 Pa, 3 sec delay.
3. Fan bearing temperature HH > 95° C, 3 sec delay.
4. Fan bearing vibration HH > 11 mm/s, 3 sec delay.
5. Fan motor bearing temperature HH > 90° C, 3 sec delay.
6. Fan motor winding temperature HH > 130° C, 3 sec delay.
7. Hydraulic coupling outlet oil pressure ≤0.035 MPa, 10 sec delay.
8. Hydraulic coupling bearing temperature >105°C, 3 sec delay.
9. ID fan overloaded.
10. ID fan lube oil pressure LL or both lube oil pump trip. (Delay 05 sec).
11. Post purge trip.
12. Discharge damper closed
13. Motor protections acted.
Plant Response:
1. Particular FD fan trip (if general interlock put into service)
2. Furnace pressure goes to positive.
3. Oxygen rapidly decreases.
4. Total air flow decreases.
5. Wind box DP rapidly decreases.
6. Furnace flame may disturb.
7. Running ID fan and FD fan loading increase.
8. Top two mills will have to trip and BC layer guns will be taken manually.
9. Power generation will reduce.
1. Oxygen in flue gas at APH inlet.

2. Furnace pressure.
3. Wind box DP.
4. Running ID and FD fan loading.
5. Power generation.
6. Main steam parameters
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1. Trip one top mill immediately, if runback is not active.

2. Reduce coal in other mills up to 50 % of TMCR.
3. Increase running ID and FD fan loading up to rated current.
4. Ensure tripped ID and FD fan discharge damper fully closed and inter connection damper of FD fan
open.
5. If required, trip another mill from top elevation otherwise reduce coal flow from other running mill for
maintaining excess oxygen and total air flow.
6. Maintain feed water flow to control drum Level.
7. Decrease the power generation up to 50%.
1. Ensure lube oil tank level is healthy.

2. Ensure lube oil pressure is healthy and interlock pump available.
3. Ensure fan and motor bearing and winding temperature is healthy.
4. Ensure fan vibration is healthy and all vibration probe reading normal.
5. Start ID fan and take it in to load after necessary checking.
6. Ensure ID fan loading up to rated current.
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3. PA Fan Trip
Likely Causes:
1. Respective APH is tripped.
2. PA fan bearing temperature HH > 90° C, 3 sec delay.
3. PA fan motor bearing> 90° C, 3 sec delay.
4. PA fan motor winding temperature HH> 135° C, 3 sec delay.
5. PA fan bearing vibration HH>11 mm/s.
6. PA fan lube oil pressure LL <0.06 MPa, 5 sec delay.
7. Both lube oil pump tripped.
8. Motor protection acted.
Plant Response:
1. PA header pressure drop rapidly.
2. Furnace pressure decrease.
3. Tripped fan outlet damper close.
4. Mill inlet PA flow and pressure drops.
5. Mill outlet coal velocity decrease.
6. Running PA fan loading increase.
7. Power generation decrease.
8. Main steam pressure & temperature decreases rapidly.
2. PA header pressure.
3. Mill inlet PA pressure and flow.
4. Running PA fan loading.
6. Main steam pressure & temperature.
7. Flue gas oxygen.

1. Immediately trip the mills from top elevation to reach 3 mills operation.
2. Take LDO oil guns immediately.
3. Ensure tripped fan discharge damper fully closed and inter connection damper of PA fan open.
4. Increase running PA fan loading for increase PA header pressure as per requirement up to rated current.
5. Reduce feed water flow as per coal flow to maintain water coal ratio, main steam temperature
6. To maintain feed water flow, trip one BFP (with SCE clearance).
7. Reduce power generation up to 50% by maintaining main steam temp, feed flow.
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1. Ensure lube oil tank level is healthy.
2. Ensure lube oil and hydraulic pressure is healthy and interlock pump available.
3. Ensure fan and motor bearing and winding temperatures are normal.
4. Ensure fan vibration is healthy and all vibration probes reading normal.
5. Start PA fan after necessary checking.
6. Ensure PA fan loading up to rated current.
4. Surge/Stall of PA & ID Fan

Likely Causes:
1. Stall occurs when the pressure rise across a fan increases to the fan’s pressure developing limit & the
flow velocity thru the fan reduces to the point at which it first falls to zero & then reverses. As the
flow thru the fan reverses, it separates from the fan blades and a vortex creates over the tip and got
stalled.
2. Heavy ash deposit in heating surface and air preheater or mistakenly closing of flue gas system baffle
caused increased system resistance giving rise to inaptness between fan moving blade opening and air
or flue gas inflow. That will lead the fan to stall region.
3. Wide fluctuation will lead the fan into stall region during fan moving blade operation.
4. Adjusting property of moving blade is becoming poor and contrary wind occurs in two parallel running
fans or auto control fails to work which leads one of the fans into stall region.
Plant Response:
1. Furnace negative pressure or wide fluctuations of air flow. Frequent auto adjustment of other side of
fan during fan operation and instability of furnace combustion.
2. Large-scale sway occurs to surging fan current and there is serious abnormal sound in local inspection.
3. Tripping of fan.
4. Heavy vibration.
2. Air flow.
3. Drum level.
4. Current fluctuation.
5. Fan vibration.
6. Generation.
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1. Immediately set the fan moving blade control to manual mode. Properly turn down the moving blade
of the stalled fan while harmoniously adjust the forced draft fan and induced draft fan to keep furnace
negative pressure within the allowable range.
2. If stalling occurs during fan parallel operation, parallel operation shall be stopped and stalled fan
moving blade shall be turned down. Only after causes are identified and stalling is removed, parallel
operation can be conducted.
3. If the reason for fan stalling is that damper and baffle of air flue gas system are mistakenly turned off,
immediately turn them on and meanwhile adjust the moving blade opening. If it is damper or baffle
fault, immediately reduce boiler load and contact maintenance personnel for rectification.
4. If stalling is removed after the above mentioned treatment, keep operation conditions stable and
further check causes for corresponding measures to be taken before increasing fan loading gradually;
and immediately stop the fan operation if the above treatments are ineffective or seriously threaten
equipment safety.
1. Avoid wide fluctuation in air flow.
2. Fan paralleling to be done carefully.
5. APH Main Motor Tripped & Auxiliary Motor Not Started
Likely Causes:
1. APH main motor tripped and the auxiliary motor not in interlock
2. APH gear box problem
3. APH jamming and causing the overloading of motor.
4. Auxiliary motor is not ready from electrical (Module & VFD)
Plant Response
1. APH trips and speed comes to zero.
2. Particular ID /FD /PA tripped.
3. Load will reduce.
4. Furnace pressure fluctuation.
5. O2 goes down rapidly.
6. MS/RH temperature and pressure goes down rapidly.
7. Wind box DP decreases rapidly.
8. Running ID/FD/PA fan’s loading increases.
9. Mill’s inlet PA flow and pressure decreases.
Parameters of Concern
3. O2 and wind box DP.
4. MS/RH temperature and pressure.
5. Running ID/FD/PA fan’s loading.
6. Running mills inlet flow and pressure.
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1. Ensure APH inlet flue gas dampers are closed. (Dampers Eliminated)
2. Ensure that primary air /secondary air APH outlet damper and respective tripped fan’s discharge
dampers are closed.
3. Immediately trip two mills from top elevation and take 4 LDO guns.
4. Increase running PA fan’s loading for increasing PA header pressure up to required limit.
5. Adjust ID/FD fan as per furnace pressure O2, wind box DP.
6. Adjust feed water flow to maintain drum level.
7. Reduce load up to 50%.
1. Follow up for causes to maintenance department.
Note: - Unit can’t be survived with aforementioned condition due to elimination of flue gas I/L dampers.
6. AC Scanner Fan Tripped & DC Fan Fail to Pickup

Likely Causes:
1. Both fan got overload/ electrical fault.
2. Standby DC fan fails to start after tripping of running AC fan trip.
3. Both fan running but still discharge pressure is LOW alarm persist by any reason of actual suction
filter choke or malfunctioning of pressure transmitter.
Plant Response:
1. Boiler will trip on < 3.5 Kpa scanner cooling air pressure low.
2. Scanner air fan tripped alarm
3. Inadequate cooling of scanners may cause damage to scanner sensing element.
4. Flame cool fan pressure LOW alarm.
1. Cooling air to scanner.
2. Unit tripping.
1. Try to start the fan by resetting the over load relay, even after boiler trip.

1. DC fan trail to be taken as per trail run schedule.
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7. Mill Seal Air Pressure Loss

Likely Causes:
1. Running seal air fan tripped and S/B has not picked up.
2. Mill’s seal airline MOV closed / malfunctions.
3. Seal air fan suction CV closed.
4. Seal air fan suction filter chocked and seal air discharge header pressure low.
5. PA discharge pressure maintaining low.
6. Seal air leakage from seal airline.
7. Electrical protection operated.
Plant Response:
1. Alarm display on DCS of low seal air pressure.
2. Mill thrust bearing damaged.
3. Coal dust enters to mill seal and damages.
4. Mill current.
1. Mill thrust bearing temp,
2. Mill vibration.
3. Mill current.
4. Mill bowl assembly will be damage.

1. Start another seal air fan, if one fan tripped and not starting in auto.
2. Open mill’s seal air MOV, if closed.
3. Increase PA header pressure.
4. Close any stopped mill seal air MOV for increasing running mills seal air pressure.
1. Fan change over as per change over schedule.

2. Suction filters cleaning at regular interval.
3. S/B Fan filter cleaning.
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8. Fire in Coal Mill or Mill Explosion
Likely Causes:
1. Mill outlet temperature maintaining high.
2. Foreign material in mill.
3. Coal quality (high CV).
4. High VM coal with mill inlet PA temp high.
5. Rejection not cleared for long time.
6. Mill internal damage.
7. Coal accumulation in scraper chamber due to scraper damage.
8. Coal flow established suddenly at high mill outlet temperature.
Plant Response:
1. Mill outlet temperature shoots up.
2. Mill may trip on protection.
3. Surrounding may catch fire.
4. Mill gates and damper may not operate damage done by explosion.
5. Duct and bellow may damage.
6. Fluctuation in furnace pressure.
7. PA header pressure dropped rapidly.
8. Main steam temperature decrease.
9. Power generation decrease.
2. MS temp and PA header pressure.
3. Mill and duct surroundings.

1. Trip the particular mill, if mill is not tripped.
2. Ensure the CAD, HAD/HAG/TAG of that particular mill is closed.
3. If possible, adjust coal to other mill otherwise reduce load as per requirement.
4. Adjust feed water flow to maintain drum level and maintain MS temperature
5. Maintain PA header pressure as well as furnace pressure (it tends to go towards negative side).
6. Check locally for any other damage due to mill explosion.
7. Unit shut down may be needed, if PA duct got damage before HAG.
8. Clear the coal spreader and barricade the area.
9. Inform fire man for through check.
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1. Isolate mill and issue PTW for repair the mill.
2. Ensure steam inerting header charged and individual mill steam inerting MOV OK.
3. Monitor coal bunker level properly and regularly.
4. Monitor coal quality in co-ordination with CHP.
5. Clear the mill rejects every hour.
9. One or More Than One Coal Mill Tripping

Likely Causes:
1. Mill protections acted.
2. 6.6 kV bus side electrical problems.
Plant Response:
1. Load reduces rapidly.
2. MS/RH Temperature goes down rapidly.
3. MS/RH pressure goes down rapidly.
4. Total air flow decreases.
2. MS/RH temperature and pressure.
3. MS Flow.
4. Air flow.
6. Drum level.
CASE 1: One mill tripped.
1. Ensure closure of MDVs, CAD, HAD/HAG & TAG.
2. Maintain PA header pressure.
3. Adjust coal in running mills as per coal mill reliability.
4. Maintain drum level, MS temperature, RH temperature, furnace pressure.
5. Reduce load as per coal flow, if in running mills coal can’t be increased.
CASE 2: Two mills tripped.
1. Ensure closure of CAD, HAD/HAG & TAG of tripped mills.
2. Reduce the load up to 50%.
3. Take BC layer LDO gun for flame stability.
4. Maintain drum level, MS/RH temperature.
5. Maintain furnace pressure.
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1. Follow up for cause to maintenance department.
10. Boiler Water Wall Tube Leakage

Likely Causes:
1. Poor water quality.
2. A metal temperature remains higher side for long time.
3. Feed water flow is not adequate.
4. Any wall blower is in advanced position for long time and steam is charged.
5. Poor tube material and welding joints quality.
6. Furnace to wind box DP is not maintained.
7. Erosion at fire side and corrosion at water side of tubes.
8. Starved water walls.
9. Blocked tubes.
10. Bursting of tubes due to pressure fluctuations.
11. Improper setting of safety valves.
Plant Response:
1. Boiler make-up water consumption will increase.
3. ID Fan will draw more current.
4. Water wall metal temperature will remain high around the leakage.
5. Abnormal sound comes from the boiler furnace.
6. Leakage detectors show high intensity.
7. O2 fluctuation at APH inlet.
8. Generation may vary.
1. DM water make-up.
3. ID fan current.
4. Water wall metal temperatures.
5. Acoustics intensity.
6. O2 %.
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1. Inform shift in charge about the changes in parameters immediately.

2. Check the boiler furnace for any abnormal sound inside.
3. Closely monitor furnace pressure and ID fan current.
4. Closely monitor DM make-up.
5. Reduce the load if necessary.
6. If the leakage is heavy and difficult to compensate feed water, shut down the boiler.
1. After shut down, attend the tube leakage.

2. Take boiler hydro test before taking the boiler into service again.
3. Maintain desired water quality.
4. Maintain parameters like feed water flow, water wall metal temperatures etc.
11. Economizer Tube Leakage

Likely Causes:
1. Poor water quality
2. Feed water flow not maintained adequately
3. Any LRSB is in advanced position for long time and steam is charged
4. Soot blowing steam pressure is very high.
5. Flue gas velocity is very high.
6. Poor metallurgy and weak welding joints.
7. Ash erosion.
Plant Response:
1. DM Water consumption will increase.

2. ID Fan current increase.
3. Flue gas temperature at economizer O/L drops.
4. Abnormal sound comes out from economizer zone.
5. Water coming out of economizer ash hoppers joints.
6. Trouble found in economizer de-ashing.
7. BTLD shows high intensity.
8. Feed water flow will increase.
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1. DM water make-up.
2. Economizer outlet flue gas temperature.
3. ID Fan current.
4. Economizer de-ashing.
5. BTLD intensity.
6. Flue gas temperatures at APH Inlet and Outlet.
1. Check economizer zone in second pass for any abnormal sound inside.
2. Check economizer hoppers for any water leaking.
3. Closely monitor ID fan current.
4. Closely monitor DM water make-up.
5. Reduce the load, if necessary.
6. If the leakage is heavy and difficult to compensate feed water, shut down the boiler.

1. After shut down, attend the tube leakage.
3. Maintain desired water quality.
4. Maintain parameters like feed water flow, soot blowing pressure as desired.
12. Super Heater Tube Leakage

Likely Causes:
1. Main steam pressure very high.
2. Super heater safety valves fail to lift on very high pressure.
3. High super heater metal temp.
5. Erosion by ash due to high flue gas velocity.
6. Boiler running more than BMCR continues for long time.
7. LRSB operation for long time (not retracted).
8. Fire side corrosion.
9. Starvation.
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Plant Response:
2. Increase ID fans loading.
3. Leak detector shows high intensity in particular leakage area.
4. Increase DM water consumption.
5. SH tube metal temperature near to leakage may increase.
6. Drop in flue gas temperature at APH inlet.
7. Abnormal sound comes in boiler.
8. Increase difference between feed water and steam flow.
9. MS pressure and power generation will decrease.
10. Flue gas oxygen reading may go down.
2. ID fans current.
3. SH metal temp.
4. DM water consumption.
6. Flue gas temp.
7. Main steam pressure.

1. Check on line steam leakage detector system.
2. Check boiler at local for any abnormal sound inside.
3. Closely monitoring furnace pressure and ID fan loading and other concern parameters.
4. If require reduce load and increase feed water for maintaining metal temperature.
5. Closely monitor flue gas temperature.
6. Shutdown the unit after confirming the tube leakage.

1. Repair leakage SH tube.
2. Maintain water quality by monitoring SWAS parameters and co-ordination with DM Plant’s chemist.
4. Maintain SH metal temperature and main steam pressure within the limits.
5. Maintain flue gas velocity as per design value.
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13. Reheater Tube Leakage

Likely Causes:
1. High reheater pressure due to IP turbine valve close and HRH safety valve fail to lift.
3. High Reheater metal temperature due to starvation.
4. Erosion of tube due to high flue gas velocity.
5. Boiler running more than BMCR for long time.
6. RH zone LRSB is in advanced position for long time and steam is charged
7. Corrosion due to fly ash component.
Plant Response:
2. Increase ID fans loading.
3. Increase metal temperature after particular tube leakage of reheater tube.
4. Drop of flue gas temperature at APH inlet.
5. Increase in DM water consumption.
6. Leak detector shows high intensity in particular leakage area.
7. Abnormal sound comes in boiler.
8. Power generation will decrease
9. Pressure drop across reheater coil will increase.
10. Flue gas oxygen may go down.
1. ID fans current.
2. Reheater metal temp.
5. Flue gas temperature.
1. Check on line steam leakage detector system.
2. Check boiler at local for any abnormal sound inside.
3. Closely monitoring furnace pressure and ID fan loading and other concern parameters.
4. If require reduce generation and increase feed water for maintaining metal temp.
5. Closely monitor flue gas temp.
6. Shutdown the unit after confirming tube leakage.
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1. Repair leakage reheater tube.
2. Maintain water quality by closely monitoring CPU outlet parameters, SWAS parameters and co-
ordination with DM plant’s chemist.
3. Maintain reheater metal temperature and pressure within limits.
4. Maintain flue gas velocity as per design value.
14. MS Temperature Falling Fast

Likely Causes:
1. Tripping of one or more coal mills.
2. Fuel flow disturbance.
3. Malfunctioning of spray control valves.
4. More spray.
5. Low feed water temperature.
6. Wall blowing may be in service.
7. Coal quality.
8. High excess air.
Plant Response:
1. MS Temperature low alarm will appear.
2. Turbine Differential Expansion may become negative.
3. Axial shift.
4. Turbine shaft vibration.
6. Unit should be tripped manually on MS temperature low w.r. t. load.
1. Main Steam Temperature
2. Feed water flow
3. Coal flow
4. Flue gas O2
5. Total air flow.
1. Close the spray control valve by taking into manual.
2. Check air flow and adjust.
3. Top elevation can be taken in to service / firing can be raised and close secondary air damper if open.
4. Reduce load set point.
5. Stop soot blowing.
6. Adjust feed water flow
7. Check, if any feeders malfunction or chocked.
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1. Initiate LRSB soot blowing if temperatures are maintaining still less.
2. Observation for improvement in temperature.
3. Put back spray control in auto.
15. MS Temperature Rising Fast
Likely Causes:
1. Coal quality varying.
2. Feed water flow reduces.
3. Any BFP recirculation valve got open and feed water flow reduced.
4. SH spray valves malfunction
5. SH spray line leakage
6. Soot deposition on water wall
7. Improper air flow and SADC position.
8. MS flow reduces or pressure high due to HPSV, HPCV malfunction
9. Sudden increase in PA header pressure
10. Top mill got loaded suddenly.
11. Any oil gun admitted.
12. Sudden clear of soot during soot blowing.
Plant Response:
1. Metal temp high alarm will appear.
2. Spray control valves will go for further opening.
3. Load will rise for the same pressure.
4. Feed water flow increase in auto.
1. Metal temperature
2. Feed water flow
3. Total fuel flow
4. Load
5. Air flow and Flue gas oxygen
6. SADC operation
7. Furnace to wind box DP
8. HP turbine casing and Differential expansion
1. Reduce coal flow in top mill.
2. Increase feed water flow
3. Open SOFA dampers and reduce bottom air.
4. Increase load set point, MS flow
5. Open spray systems and setting to desired value.
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6. Do proper wall blowing

7. Maintain proper air flow.
8. Maintain flue gas oxygen %.

1. Proper monitoring of parameters.
2. The operator should have proper idea of rising fast & down temperature limits.
3. Proper working of De-superheater valves.
4. Proper soot blowing schedule.
5. Loading on top mill should be slowly.
16. Reheater Temperature Falling Fast
Likely Causes:
1. High air flow.
2. Tripping of one or more coal mills.
3. More spray.
4. Malfunctioning of spray control valves.
5. MS temperature is low.
6. Burners tilt position on lower side.
Plant Response:
1. Turbine differential expansion may become negative.
2. Axial shift.
3. Turbine shaft vibration.
1. RH temp
2. Feed water flow
3. Coal flow
4. Flue gas O2
5. Total air flow
1. Close the spray control valve by taking in manual.
2. Increase burner tilting position.
3. Rise the air flow
4. Top elevation mill can be taken into service/firing can be raised.
5. Check air flow and adjust SOFA.
6. Close SOFA air damper if open.
7. Reduce load set point.
8. Stop blowing.
9. Adjust feed water flow
10. Check if any feeder malfunctions or chocked.
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1. Initiate LRSB soot blowing if temperatures are maintaining still less.
2. Observation for improvement in temperature.
3. Restore back the controls in auto. (spray control).
17. Reheater Temperature Rising Fast

Likely Causes:
1. Steam flow to reheater reduced suddenly.
2. IPSV/IPCV valves malfunction/close.
3. HP exhausts temperature high.
4. Inadequate spray due to malfunctions of spray valve or spray line leakage.
5. BFPs inter-stage spray MIVs in closed condition for running BFPs.
6. Excess air flow.
7. MS pressure & temperature are high.
8. Furnace slagging.
9. HP heaters are out.
10. Reheater coil tube leakage.
11. Burner tilt position is on higher side.
Plant Response:
1. RH metal temp high alarm will appear.
2. Spray control valves will go for further opening.
3. Load will rise for the same pressure.
1. Reheater tube metal temperature
2. Wall blowing.
3. SADC operation.
4. IP turbine expansion.

1. Reduce coal flow in top mill.
2. Open spray systems and setting to desired value.
3. Decrease burner tilt position.
4. Do proper wall blowing.
5. Maintain proper air flow.
6. Maintain oxygen %
7. Reduce lower elevation SADC.
8. Open SOFA dampers.
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1. Proper monitoring parameters.
18. MS Pressure Rising Fast
Likely Causes:
1. Sudden drop in load.
2. Sudden increase in fuel flow.
3. Any mill choking cleared.
4. Any feeder malfunction.
5. HPSV, HPCV malfunction.
6. Super heater spray valve malfunction.
7. PA header pressure increased.
8. Any HP HEATER extraction closed.
9. Pressure transmitter malfunction.
10. Any oil guns admitted.
11. Main steam temperature is high.
12. Soot blowing is in service.
13. Coal quality improved.
Plant Response:
1. Load variation.
2. HP bypass will open if MS pressure crossed 17.5 MPa.
3. HP bypass will fast open if MS pressure crossed 19 MPa.
4. SH O/L ERV floats at 18.87 MPa.
5. MS safety valve floating if pressure more than 19.06 MPa.
1. Load.
3. Main steam temperature.
4. Drum level
1. Increase generation / load, if margin is there in load set point.
2. Reduce coal flow.
3. Ensure PA pressure is normal and if possible decrease PA pressure for short duration.
4. Maintain drum level, MS temperature and feed water flow.
5. Inform C&I department to attend transmitter malfunction.
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1. Avoid sudden change in fuel and load.
19. MS Pressure Dropping Fast
Likely Causes:
1. One or more coal feeders tripped.
2. Coal flow from running feeder is not proper.
3. Any mill choked.
4. PA header pressure drop.
5. Any mill air flow disturbed or MDV closed.
6. Sudden increase in load.
7. HP/LP Bypass open or passing.
8. Boiler tube leakage.
9. Safety valve passing/lifted.
10. Pressure transmitter malfunction.
11. Change in air flow.
12. Coal quality deteriorating.
Plant Response:
1. Load reduces.
2. MS temperature reduces.
3. Coal feeding increase if mills are in auto.
1. Load.
3. Main steam temperature.
4. Drum level.

1. Find cause of MS pressure dropping.
2. Ensure coal mill healthiness.
3. Find cause of PA header pressure dropping.
4. Increase coal flow.
5. Reduce CV opening/load to hold the pressure.
6. Maintain feed water flow w.r.t fuel.
7. Check status of HP/LP bypass, if opened then close it after watching pressure rise.
8. Check status of safety valve if it passing, inform mechanical maintenance to attend it.
9. Inform C&I if pressure transmitter malfunction.
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1. Smooth operation of control valves.
2. HP/LP bypass should have no passing and should be in closed state.
20. ERV/MS Safety Valve Lifted

Likely Causes:
1. MS Pressure is very high
2. Coal quality improved.
3. Any coal feeder malfunction.
4. HPSV/HPCV malfunction.
5. Turbine tripped and HP bypass not operated.
6. MS stop valve malfunction.
7. Super heater spray valve malfunction.
8. SH spray increased in auto due to high MS temperature.
9. Safety valve malfunction (Setting disturbed).
10. Safety valve passing/ simmering.
11. ERV floating due to pressure transmitter malfunction.
Plant Response:
1. Main steam pressure drop rapidly.
2. Steam flow will increase.
3. Load reduces.
4. Main steam temp reduce.
5. Heavy noise.
1. MS temperature & pressure.
2. Drum level.
3. Fuel flow.
4. Load.
5. Feed water flow.
6. Water consumption.
7. HP/LP Bypass healthiness.
8. Metal temperature.
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1. Reduce MS pressure until safety valve is seated back.
2. Maintained drum level, MS temperature and pressure.
3. Take necessary action if MSSV, HPSV, HPCV malfunction.
4. Informed maintenance to attend passing.
5. Trip the unit if it not seating back, with the shift-in charge clearance.

1. Do safety valve setting.
21. HRH Safety Valve Floating

Likely Causes:
1. HRH pressure is very high
2. HP heater#6/7 extraction cut
3. Any IPSV or IPCV closed
4. HP bypass opened more and LP bypass opened less.
Plant Response:
1. Load reduces.
2. Heavy noise due to valve floating.
3. HRH steam temperature drop.
4. HP heater#6/7 level may disturb.
5. Safety valve floating and simmering.
1. Load.
2. IPSV, IPCV operation.
3. Water consumption, condenser vacuum if LP bypass opened to reduce pressure.

1. Reduce fuel and load to reduce reheater pressure until safety valve is seated.
2. If HPH extraction was cut then charge it slowly.
3. Maintain drum level, MS temperature and pressure.
4. Take necessary action if IPSV, IPCV malfunction
5. Inform maintenance to attend floating or gag it.
6. Trip the unit if it not seating back with the shift-in charge clearance.
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1. Do safety valve setting.
22. Sudden Loading of ID Fan

Likely Causes:
1. Boiler bottom seal trough seal break.
2. Slagging in furnace.
4. Flue gas side duct leakages.
5. DP across APH is high due to blockage.
6. APH leakages.
7. Sudden fuel increase in boiler.
8. FD fan getting loaded suddenly.
9. Other ID fan tripped and respective FD fan not tripped.
Plant Response:
1. Boiler furnace draught variation.
2. ID fan may trip due to overload.
3. Flame stability may disturb.
1. ID fan current /blade pitch.
2. Furnace draught.
3. Flame intensity.
4. Flue gas O2.
5. Unit load.
6. Seal trough over flow.
7. Bottom ash system sump level.
8. Total airflow.
9. Furnace to wind box DP.
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1. Reduce fuel & secondary air to control furnace pressure.
2. In case of ID fan trip, check respective FD fan tripped and trip top mill immediately to reduce load &
running ID fan loading.
3. Check fan control oil pressure for proper blade pitch operation.
4. Check for furnace leakage, ID fan duct leakage.
5. Check boiler seal trough overflow.
6. Check ID fan discharge damper link & blade pitch position
7. Check oil station locally.

1. Identify root cause and rectify.
2. Monitor APH I/L & O/L Pressure.
23. Air Flow Going Low and High

Likely Causes:
1. Problem in SADC i.e., SADC is fluctuating very much.
2. Problem in blade pitch of FD fan i.e., it is loading and unloading continuously.
3. Problem in air flow transmitter.
4. FD fan stalling.
5. APH SA outlet damper closes due to link failure.
6. APH PA outlet damper closes due to link failure.
7. Individual mill PA flows fluctuating.
8. Malfunction of O2 analyzer.
Plant Response:
1. Variation in O2 %.
2. Variation in flue gas temperature.
3. Variation in MS temperature.
4. Variation in FD & ID fan’s blade pitch.
5. Variation in furnace pressure.
3. ID fan’s current as this behavior may lead to spikes in current.
4. FD fan’s current.
5. Flame intensity.
6. MS/RH Temperature.
7. Drum level.
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1. Cross check the blade pitch and current of FD & ID fan.
2. Take the fans in manual mode (if in auto) and then control.
3. Check the SADC position of SADC in the DCS as well as cross check in local. Also check the air
compressor’s pressure for any high fluctuation.
4. If any particular FD fan is loading and unloading, make sure that its blade pitch is in manual mode and
make it constant.
5. Inform maintenance, if damper link is disconnected.

1. Check the SADC regularly in DCS and local.
2. Check for any air leakages so that air pressure is maintained.
3. Always try to keep the currents of FD fan equal.
4. PM work should be done on transmitters regularly.
24. Heavy Furnace Pressure Fluctuation

Likely Causes:
1. Any ID, FD or PA fan tripped.
2. Any one or more coal mills tripping suddenly.
3. Any mill coal feeding suddenly increased.
4. Soot blowing may be in service.
5. Any ID, FD or PA fan blade pitch malfunctioning.
6. Any ID, FD or PA fan path damper malfunctioning.
7. SOFA, SA, AUX dampers malfunctioning.
8. Tube leakage.
9. Bottom seal trough disturbed (over flow not there or seal broken).
10. Malfunctioning of ESP lifting or bypass damper.
Plant Response:
1. Alarm display on DCS of furnace pressure variation.
2. Boiler will trip on heavy furnace fluctuation.
3. Chances of furnace flame disturbance.
1. ID fan current.
3. Blade pitch position.
4. Seal trough over flow.
5. Bottom ash system.
6. Furnace flame.
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1. Put ID fan blade pitch control to manual if it is auto.
2. Check any fan discharge damper closed
3. Start if any one fan tripped.
4. Check SADC operation.
5. Ensure bottom ash system is normal and seal trough overflow is established.

1. All fans’ dampers PM done as per schedule.
2. SOFA, SA and aux air damper’s PM should be done as per schedule.
25. PA Header Pressure Dropping Fast

Likely Causes:
1. Any PA fan trips.
2. Any PA fan unloads suddenly i.e., its blade pitch decreases abnormally or current decreases abnormally.
3. Heavy leakage in hot PA header or duct.
4. PA fan Stalling.
Plant Response:
1. PA I/C damper will open in auto.
2. PA header pressure goes down.
3. Mill PA flow goes down.
4. Decrease in generation.
5. Variation in furnace pressure (towards negative side).
6. Decrease in total primary air.
7. SH/RH temperature will drop.
1. Current of running or loaded PA fan.
2. PA flow in running mills.
3. PA header pressure.
4. Seal air discharge pressure.
5. Main steam and HRH temperature.
6. Flame stability due to mills taken out.
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If header pressure is dropping due to any PA fan tripping with full load and 5 mills in service.
1. A, B, C, D, E, mills – Take out mill D and E gradually.
2. Take BC layer 2 and 4 corner guns for flame stability. Retract guns once flame becomes stable.
3. Maintain the PA header pressure by increasing the blade pitch of running PA fan.
4. Ensure closure of discharge damper for tripped fan.
5. While increasing the blade pitch we must keep an observation on running PA fan’s current and vibration.
6. Ensure the closure of Hot/Cold Air dampers and HAG/TAGs of stopped mills.
7. Operator must observe the furnace pressure and maintain the draft.
8. Reduce generation to around 150 MW
9. FW flow to be reduced fast to maintain drum level, MS/RH temperature.

1. Regular and proper blade pitch trial of PA fan during shutdown.
2. Keep an eye on PA header pressure regularly.
3. Keep the currents of both PA fans as near as possible.
4. Always monitor for any leakages in PA header/ducts.
26. Oil Level Loss in APH Bearing

Likely Causes:
1. Oil leakage from APH bearing (due to oil seal damage).
2. Oil leakage from level gauge (due to damage)
Plant Response:
1. Bearing oil temperature shows high value (Guide and Support).
2. Oil leakage observed in local.
3. APH bearing temperature will rise.
1. Bearing oil temperature and hence the bearing itself.
1. Call for oil top-up.
2. Inform to MMD and see if on line leakage arresting is possible.
3. Make sure that APH is checked for any oil leakages in local regularly.
4. In case of heavy oil leakage, stop APH immediately.
5. Rotate APH manually after stopping.
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1. Make sure that APH is checked and oil top up is done regularly if required.
2. Proper maintenance is done during shut down.
27. Sudden Increase in Steam Silica

Likely Causes:
1. DM plant water silica may be high.
2. System taken into service after overhauling.
3. Condenser tube leakage.
4. Colloidal silica in DM water
Plant Response:
1. As per DM plant report silica will vary.
2. Turbine vibration may be high, during long time operation.
3. Axial shift may increase.
4. Turbine first stage pressure increase.
1. Silica concentration in boiler drum.
2. Drum pressure.
3. Hot well conductivity.

1. Reduce load to maintain less pressure.
2. Confirm whether CPU is in service or not. (Isolated)
3. Ask chemist to confirm panel instrument readings of silica by actual analysis.
4. If the steam quality is affected by the process within the system, shutdown the turbine.

1. Check and correct DM make up quality.
2. Do proper flushing as directed by chemist.
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28. Boiler Water pH Falling Fast

Likely Causes:
1. Make up water faulty.
2. Faulty analyzer.
3. Dosing line may be leaking or choked.
4. Tri sodium phosphate Na3PO4 dosing concentration may be low / poor.
5. Dosing pump not developing pressure.
6. Tripping of dosing pump.
7. Condenser tube leakage or slippage.
Plant Response:
1. Boiler conductivity also comes down
2. Internal corrosion of boiler tubes increases and chance of tube failure, if left for long duration.
3. Silica value variation.
1. Boiler feed water pH.
2. Condensate water pH.
3. Entire water circuit pH will be drop gradually.
4. Main steam pH.

1. Increase Na3PO4 dosing.
2. Consult chemist. Cross check whole regime of the system.
3. Check possibility of condenser tube leakage.
4. Check tri sodium phosphate line for any leakage.
5. Check CPU O/L water quality (N/A).
6. Check CST water quality.
7. Inform chemist to analyze the problem.

1. Find the root cause of the problem, if it is due to dosing then check concentration of the dose and check
consumption per hour as recommended.
2. Ask chemist to check DM water quality.
3. Find the root cause of the problem and attend the same.
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29. Boiler Expansion Not OK During Cold Start Up

Likely Causes:
1. Metal temperature rate of rise may be quite high.
2. Not uniform heating in the boiler due to not rotating the oil guns.
3. Heavy soot deposition in the furnace.
4. In adequate individual oil flow through the oil guns.
5. Improper fuel injection (top gun / top mill)
6. Buck – stay mechanical jam or damaged.
7. Furnace DP not equally maintained.
8. Furnace part welded to boiler structure.
Plant Response:
1. Local expansion reading is uneven,
2. Buck-stay may damage.
3. Boiler structure loading may change.
1. Boiler expansion local readings.
1. Rise metal temperature as per startup curves.
2. Maintain proper air/fuel flow.
3. Check buck stay healthiness.
4. Do local check for any physical obstruction.

1. Follow metal temperature rate of rise degree/min as per SOP.
2. Before boiler light-up, clean all oil guns.
3. Do all LRSB, HRSB and APH blowing when boiler going in shut down.
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30. Bunker Fire

Likely Causes:
1. High volatile matter coal stored in bunker and not in use since long time.
2. Any kind of ignition or fire caught by coal inside the bunker.
3. Higher surrounding temperatures.
4. Spontaneous ignition due to stagnate coal in bunker.
5. Hot coal fed by coal handling plant.
6. Standby coal feeder inlet and outlet gate open, its seal air not charged and hot air passing inside mill.
Plant Response:
1. Smoke or fire comes out from the bunker.
2. Travelling tippler conveyer may damage.
3. Coal feeder belt may damage.
4. Red spots may be observed at the outer wall of the coal bunker.
5. Coal feeder temperature will increase.
1. Bunker level.
2. Coal quality and coal handling plant.
3. Coal feeder belt.
4. Bunker structure.

1. Call the fire man.
2. Spray water inside the bunker.
3. Stop the coal mill, if the fire is in running mills bunker.
4. Close feeder inlet and outlet gate.
5. If necessary, open flange plate facilitated downstream of feeder’s I/L gate and remove the burnt
coal to the atmosphere
6. Stop feeding coal to bunker.
7. Work in coordination with fire department for early action.
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1. Keep frequent local observations.
2. Always keep fire water system healthy.
3. Put sign boards of “NO SMOKING” in the bunker area.
4. During planned shutdown, keep bunkers empty.
31. Oil Spillage Observed in Bottom Ash System

Likely Causes:
During unit start up with oil guns in service, oil spillage may be due to:
1. Improper smoothness in the nozzle.
2. Passing in the oil valve.
3. Oil quality.
4. Improper combustion.
5. Igniters failure.
6. Improper fuel air adjustment through SADC.
7. Oil pressure low/atomizing air pressure is not sufficient.
8. During normal condition oil spillage may be due to passing in the oil corner valves.
Plant Response:
1. No proper flame intensity.
2. Increase in oil flow than normal observed.
1. Flame intensity.
2. Oil pressure.
3. Atomizing steam pressure.

1. Stop oil firing.
2. Oil guns should be properly purged before taking into service.
3. Properly adjust the air/fuel ratio through SADC.
4. Check the oil corner valves for passing. If passing observed, close MIV immediately.
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1. Regular PM for oil guns.
2. Oil leak test to be done.
3. Oil pressure, oil temperature, atomizing steam pressure to be maintained as per design.
32. Loss of Seal Trough level

Likely Causes:
1. Furnace pressure very high.
2. Furnace pressure very low.
3. Seal trough water pump failure.
4. Seal trough makeup sump level low.
5. Any leakages in seal trough make up line.
6. Sealing water temp very high.
7. Seal trough drain valve open condition.
Plant Response:
1. Draught fluctuation.
2. ID fan may trip on over load.
3. Flame may disturb.
4. MS and RH temp variation.

1. Reduce load.
2. Reduce total air flow.
3. Check seal trough makeup water pump.
4. Check for any sealing water line leakages.
5. Check seal trough makeup water temperature.

1. Ensure boiler seal trough overflow regularly.
2. Ensure over flow pumps are running properly
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33. LRSB Not Retracting

Likely Causes:
1. Mechanical jamming.
2. Motor tripped on overload
3. LRSB power cable failure.
4. Power supply failure.
5. Limit switch setting disturbed.
Plant Response:
1. Soot blower may damage.
2. Damage coil tubes due to steam erosion.
1. Specific zone metal temperature.

1. Reduce soot blowing steam pressure and switch off LRSB power supply. Steam source should not be cut
fully till LRSB retracted
2. Retract manually.
3. Inform to maintenance.

1. Pre operating check to be done properly.
2. Ensure availability of soot blowing handle before doing blowing.
3. Scheduled PM for LRSB.
34. Boiler Flue Gas Exit Temperature Shoots Up

Likely Causes:
1. APH fire.
2. APH soot blowing not done for long time.
3. LRSB/HRSB not done for a long time.
4. High flue gas velocity.
5. High air flow.
6. Soot deposition on water wall, super heater and reheater tubes.
7. Secondary combustion.
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Plant Response:
1. Change in ∆P across APH.
2. Rise in metal temperature of SH/RH.
3. Increase in DM water consumption (in case of SH/RH tube leakage)
4. Difference between feed flow and steam flow increases (in case of SH/RH tube leakage)
5. MS temperature going down (in case of high air flow).
6. APH inlet temperature rise.
2. SH/RH metal temperature
4. MS temperature
5. Feed water and steam flow.
6. APH inlet temperature.

1. In case of APH fire, take suitable action as per SOP.
2. In case of SH/RH tube leakage (refer SH/RH tube leakage).
3. Start LRSB and HRSB as per requirement.
4. Start APH soot blowing.
5. Maintain air flow as per coal firing and flue gas oxygen.

1. In case of APH fire, isolate the particular APH and extinguish the fire.
2. In case of SH/RH leakage shut down the unit to attend it.
3. LRSB/HRSB should be done as per schedule.
4. Maintain air flow as per rated parameters.
35. Secondary Combustion
Likely Causes:
1. Mixed combustion time with coal and oil is too long during boiler start up (shutdown) process, so that
fuel materials accumulate at tail heating surface and corrugated plated of air preheater.
2. Time of boiler running with low load is too long that combustible materials pile up in second pass.
3. Coarse pulverized coal or improper combustion adjustment causes unburnt pulverized coal to enter
boiler second pass.
4. Soot blower not available for long time.
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Plant Response:
1. Flue gas temperature at air preheater inlet/outlet and exhaust flue gas temperature rise high while flue gas
pressure goes abnormal. Oxygen content goes low.
2. Air preheater current fluctuates to a large degree. Bearing and case temperature rises high and
stagnation occurs when situation is serious.
3. Hot primary and secondary air temperature rises high.
4. Furnace pressure fluctuates and induced draft fan blade automatically opens wide with induced draft fan
current rising.
5. When re-burning occurs at reheater side, reheated steam temperature will rise high abnormally.
Simultaneously, the temperature at separation screen rises and primary water spray amount is
increasing.
1. MS and RH Temperature.
2. ID fan current.
3. APH current.
4. Furnace draught.
5. Hot SA and PA temperature.

1. When flue gas temperature of air preheater inlet is rising high abnormally, reasons shall be analyzed
and corresponding adjusting measures taken. Meanwhile, soot blowing shall be conducted to flue and
air preheater heating surface.
2. If the handling is invalid and flue gas temperature at air preheater outlet rises up to 250℃, report to
shift engineer for boiler emergency shutdown.
3. After boiler shutdown, stop the induced draft fan and forced draft fan. No ventilation shall be applied to
furnace and relevant soot blower shall be put into operation for fire-extinguishing.
4. When air preheater is burning fiercely, put water washing in operation for fire-extinguishing. Keeps the
air preheater running during fire-extinguishing but it’s forbidden to open its manhole door for
inspection.
5. Verify that the fire is extinguished and conduct ventilation and blowing to prepare for restoring after
receiving order from shift engineer.

1. Mill fineness to be maintained by maintaining classifier speed.
2. Soot blowing to be done as per schedule and when required.
3. APH Firefighting line availability to be ensured.
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36. Drum Level Rising Fast

Likely Causes:
1. Sudden rise in feed water flow.
2. BFP scoop malfunctioning.
3. Wrong command given by operator for level controlling.
4. Drum level transmitter showing wrong value.
5. Sudden change in operating condition leading to swelling of boiler and wrong judgement by operator.
6. Sudden rise in load.
7. Feed water control comes to manual.
8. Air flow increases.
9. Coal feeder fluctuation.
10. HP/LP bypass operation.
Plant Response:
1. Alarm will come on both soft and hard wire panel.
2. All water level transmitters will show high value.
3. Hydra step will show red indication confirming of high water level.
4. SH steam temperature decreases if drum level protection not acted.
5. Feed water flow will be greater than main steam flow.
6. Unit may trip on high drum level if not controlled till protection value +250 mm.
1. Drum level.
2. Feed water flow.
3. Total fuel flow.
4. MS temperature
5. Total air flow.

1. If BFP scoop in auto, take it into manual.
2. Decrease the BFP scoop and decrease feed water flow.
3. If still drum level increasing them open bottom ring header drain valve.
4. If water has entered the superheater then open the superheater line drain valves and close only when
steam temperature restores normal.
5. Decrease air flow.
6. Manually trip the boiler if drum level crossed 250 mm for 5 sec and protection not acted.
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1. Maintain proper feed water flow.
2. Maintain proper fuel.
3. Maintain required air flow.
37. Drum level Falling Fast

Likely Causes:
1. Sudden fall in feed water flow.
2. BFP tripped and stand by BFP not picked up timely.
3. BFP scoop malfunctioning.
4. Wrong command given by operator for level controlling.
5. Sudden rise in fuel.
6. Sudden drop in load.
7. Air flow decreases.
8. Drum level transmitter may be faulty.
9. Sudden change in MS pressure.
10. Sudden change in coal quality.
11. Coal feeder fluctuation.
12. Feed water control comes to manual.
13. Feed water pipe leakage, water wall or eco tubes burst.
14. BFP paralleling problem.
15. HP/LP bypass operation.
Plant Response:
1. Low level alarm will come on both soft and hard wire panel.
2. All for water level transmitter will show low or negative value.
3. Hydra step will show red indication confirming of low water level.
4. Feed water flow will be lesser than main steam flow if feed water system is faulty.
5. Feed water flow will be greater than main steam flow if leakage is there in water wall tubes.
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1. Drum level
2. Feed water flow.
3. Total fuel flow.
4. Total air flow.
1. If BFP scoop in auto, take it into manual.
2. Increase the BFP scoop to increase feed water flow.
3. If still drum level decreasing then close bottom ring header drain valve (if in opened condition).
4. Increase air flow.
5. Manually trip the boiler if drum level crossed -250 mm for 5 sec and protection not acted.
6. Check boiler locally for any leakage
1. Maintain proper feed water flow.
2. Maintain proper fuel.
3. Maintain required air flow.
38. DCS Console Hanged/Failed

Likely Causes:
1. UPS-1&2 failures.
2. Blackout with UPS failure.
3. UPS supply fails to control cabinets.
4. Any other C&I problem. (software or hardware).
Plant Response:
1. No command will be sent from DCS to equipments.
2. Parameter goes to bad quality.
3. DCS console’s power may off.
Local observation of:
1. Turbine speed.
2. Mill status.
3. Lube oil pressure.
4. Seal oil pressure.
5. Jacking oil pressure.
6. Condenser vacuum.
7. Gland steam pressure.
8. GT Breaker.
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1. Ensure GT breaker opening otherwise open manually.
2. Ensure DG started and emergency bus charged (If DG not started refer DG fail emergency SOP).
3. Ensure DC seal oil pump started. Also ensure seal oil DP and H2 pressure is healthy.
4. Ensure BFP/Turbine, DC drive is started, if not, start manually.
5. Closely monitor condenser vacuum in local, at “0” Kpa open vacuum breaker valve.
6. At turbine ‘0’ rpm ensure barring gear is engaged If not due to instrument air pressure low, engage it
manually.
7. Even if barring is not started then open the barring gear door for manual barring.
8. Isolate gland steam to turbine.

1. Follow up for UPS fail reasons to maintenance department.
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TURBINE & AUXILARIES -

EMERGENCIES
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1. Hotwell Level High

Likely Causes:
1. Sudden load through off.
2. One CEP tripped and second not started and make up maintain high.
3. Hotwell makeup control valve not operating properly.
4. Deaerator level maintaining high due to wide opening of heater normal drip CV.
5. HP and LP heater’s emergency drain opened to maximum suddenly.
6. Hotwell makeup bypass valve made 100% opened with CV in service.
8. Level transmitter stands pipe leakage.
9. Deaerator level faulty.
Plant Response:
1. Condenser vacuum start decreasing.
2. Load decreases because of vacuum drop.
2. Hotwell conductivity.
3. Deaerator level.
4. Discharge pressure of CEP.
5. Healthiness of level transmitter.
6. Local level gauge reading.
7. Unit load.
8. Actual level of hotwell, if level transmitter has crossed its range.

1. Closing of hotwell makeup water CV and controlling its level with bypass MOV if the CV is not working.
2. Close make up MIV if needed.
3. Ensuring hotwell level from local level gauge with coordination of field engineer.
4. Ensuring that hotwell level not increases to high so that it comes upon the condenser neck and
get in contact with LP turbine blades.
5. Still if level is not coming down then dump water to CS tank thru CEP R/C line.
6. If level is not maintaining after all action, unit to be tripped and vacuum to be killed and hot well
drain MIV to be opened so as to avoid contact of water from LP blades.
7. Ask chemist to take condensate sample for condenser tube leakage suspicion.
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Final Corrective Actions

1. Rectification from C&I, if level CV is not operating and if level transmitter is showing bad value.
2. Maintaining proper heaters levels.
3. Ensuring hotwell makeup CV, bypass MOV to be closed.
2. Hot Well Level Dropping Fast

Likely Causes:
1. Standby CEP started in auto (both pump running).
2. Hotwell makeup control valve not operating.
3. CST level low.
4. CEP discharge line leakage/drain opened condition.
5. Deaerator level dropping.
6. Transmitter malfunctioned.
8. Deaerator level gauge malfunctioned.
9. LP bypass, exhaust hood, 3rd stage spray CV opened fully.
10. Unit tripped.
Plant Response:
1. Deaerator level drops fast.
2. CEP discharge pressure drop.
3. CEP may trip on hotwell level LL.
1. Condensate water flow.
2. Deaerator level.
3. Discharge pressure of CEP.
4. Healthiness of level transmitter.
5. Local level gauge reading.
6. Unit load.

1. Start standby hotwell make up if single cannot cater.
2. Opening of hotwell level bypass MOV if the CV is not working.
3. Reducing unit load and fuel firing so that deaerator level can be maintained.
4. Starting DM transfer pumps if needed.
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1. Rectification from C&I if level CV is not operating and if level transmitter is showing bad value.
2. Ensuring hotwell level from local level gauge with coordination of field engineer.
3. Maintaining proper CST level.
4. Maintaining deaerator level within limits so that CEP discharge pressure shouldn’t decrease
drastically.
5. Ensuring proper drain closing and checking system thoroughly for leakages.
3. Deaerator Level High
Likely Causes:
1. Deaerator level control valve abnormal operation.
2. HP heater#7 drip coming more.
3. Any BFP tripped.
4. Load reduced very fast.
5. HPH tube leakage.
6. FW demand low (drum level high condition).
Plant Response:
1. Deaerator pressure may drop.
2. Deaerator temperature may drop.
3. Deaerator overflow valve open.
4. Hotwell level variation.
1. Deaerator control valve position.
2. Hot well level.
3. BFP parameters like recirculation valve position and suction flows.
4. CEP discharge pressure.
5. Deaerator overflow valve position.
6. Deaerator pressure and temperature
7. All HP heaters level.
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1. Check deaerator overflow opens or not, if not then open.
2. If deaerator control valve malfunctioning, close MOV after CV and control level by opening
bypass CV & MOV as per requirement.
3. Check extraction#5 cut in auto, if not close the extraction#5 MOV and cut out extraction#5.
4. Maintain deaerator pressure and temperature through deaerator pegging.

1. If level is maintaining to normal value, normalize the system. Charge extraction#5.
4. Deaerator Level Low

Likely Causes:
1. Running CEP tripped and standby not started.
2. Deaerator CV & MOV malfunctioning.
3. Sudden rise in feed water demand.
4. HPH#7 normal drain suddenly closed and emergency drain control valve opened.
5. Extraction#5 cut out.
6. Deaerator drain MOV open/passing.
7. CEP recirculation suddenly open.
8. LPH heater tube leakage is heavy.
Plant Response:
1. Deaerator level low alarm will come.
2. If deaerator level control valve in auto, CEP outlet header pressure will drop & stand by CEP may
pick up.
3. Hot well level may drop.
4. All BFP will trip, if level goes below 400 mm.
1. Deaerator level.
2. CEP parameters like discharge pressure and condensate flow.
3. Deaerator level CV position.
4. HPH#6/7 levels and drip control valve positions.
5. Normal drain MIV position, emergency drain control valve position.
6. Deaerator drain MOV position.
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1. Try to maintain deaerator level, if deaerator level CV & MOV having any problem then try to maintain
level by opening of bypass CV & MOV.
2. If any CEP tripped and standby not started then start standby CEP, if not available then reduce load to
50%.
3. If CEP R/C opens, close it, if it is not operating, then close after/before MOV as per requirement.
4. If any of the HP heater drain valve malfunctioned then normalize it after identifying the problem.
5. Still level is not maintained, reduce the load.

1. Identify the problem and normalize the system as soon as possible.
5. CEP Tripped & Standby Fail to Start

Likely Causes:
1. Hot well level low (250 mm).
2. CEP tripped on any of the protection (check first out) and stand by pump not in interlock.
3. Standby pump tripped on overload.
4. Standby pump electrical protection acted.
5. Pump in interlock but all permissive are not healthy.
Plant Response:
1. D/A level decreases fast.
2. If LP bypass system is in service its outlet temperature will rise and bypass will close on low
cooling pressure.
3. CEP discharge header pressure decreases.
4. Hot well level increases.
5. LP gland steam spray disturbed.
6. 3rd stage and LP exhaust spray disturbed.
1. CEP outlet pressure.
2. Hot well level & deaerator level.
3. Deaerator level control valve position.
4. Running CEP parameters.
5. Hot well level CV position.
6. Unit load.
8. Gland steam temperature.
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1. Start the standby pump after its permissive restored.
2. If standby pump not started, reduce the load to 50%, maintain deaerator level (at load>160MW with
SCE clearance).
3. Again start the standby pump or 2nd pump.
4. Control deaerator level in manual and try to maintain discharge pressure.
5. Reduce the load as quickly as possible and maintain all other parameters constant like MS/RH
temperature, water wall metal temperature, and drum level.

1. Always ensure the standby pump healthiness.
2. If problem is rectified increase the load as per requirement.
6. One BFP Tripped

Likely Causes:
1. BFP tripped on pump, turbine and electrical protection.
Plant Response:
1. Standby BFP picks in auto if is in interlock.
2. Running BFP scoop will increase.
3. Feed water flow decreases.
4. Main steam flow decreases (w.r.t. attemperation).
5. Drum level variation.
6. Main steam temperature increases.
7. Unit load decreases.
1. Unit load.
2. Total coal flow, FW Flow, MS flow, MS temperature.
3. Standby BFP started and scoop percentage.
1. Take scoop of running BFP is in manual mode in order to avoid overload tripping.
2. If standby BFP picked then increase scoop and balance the load on both BFP, then put scoop
in auto.
3. Start standby BFP, if it is not picked up in auto and raise the scoop.
4. If standby BFP not started, trip one coal mill and adjust fuel flow to reduce generation to 50%
TMCR.
5. Increase feed water flow and decrease coal flow so as to maintain drum level.
6. Reduce turbine load set point.
7. Maintain load around 50% TMCR.
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1. Check the reason for BFP tripping, if it is actual according to protection, rectify accordingly.
2. If the BFP has been tripped due to malfunction of any protection than make the BFP ready for bring
it back and raise the load.
3. Check BFP and rectify it and make it available.
7. Any CW Pump Tripped

Likely Causes:
1. Pump discharge MOV closed or its close feedback came.
2. CW pump motor’s stator temperature reached to trip value.
3. CW pump bearing temperature reached to trip value.
4. UPS failure resulted in feedback loss to DCS.
5. Communication card failure.
Plant Response:
1. Condenser vacuum start decreasing very fast.
3. Fall in CW duct pressure.
4. CW forebay level may overflow.
2. Unit load.
3. CW discharge pressure, current and vibration of running pump.
4. Starting of 2nd vacuum pump.
5. OCCW pumps healthiness.
6. Trip pumps discharge valve fully closed and pump is not reverse rotating.
7. CW inlet and outlet temperature.
8. Exhaust hood temperature.

1. Starting standby CW Pump manually.
2. Starting 2nd vacuum pump.
3. If standby pump not starting then reducing load to 60% TMCR.
4. Make arrangements to start stand by CW pump.
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1. Once CW duct pressure comes back to normal, start raising load.
2. Inspect the reason of running CW tripping and if possible bring back the auxiliary to standby.
3. If the problem exists in system then isolate the auxiliary and make it ready after maintenance.
8. One CW Pump Tripped & Standby Not Available

Likely Causes:
1. Standby CW pump not available due to maintenance work.
2. CW tripped on its protection.
3. UPS failure resulted in feedback loss to DCS.
4. Communication card failure.
Plant Response:
1. Condenser vacuum starts decreasing fast.
3. Fall in CW duct pressure.
4. CW forebay level may overflow.
2. Unit load.
3. CW discharge pressure, current and vibration of running pump.
4. Starting of 2nd vacuum pump.
5. OCCW pumps healthiness.
6. Tripped pumps discharge valve is fully closed and pump is not reverse rotating.
7. Turbine exhausts hood temperature and CW temperature.

1. Stop one/two mill and reduce unit load to 60% TMCR and further if vacuum is not maintaining.
2. Start second vacuum pump so as to support vacuum.
3. Start standby CT fans if vacuum not maintaining
4. Stop the CT makeup so as to avoid sump overflow.

1. Maintaining low load till standby pump is available.
2. Bring back the tripped CW pump as soon as possible if standby pump is further unavailable
keeping the HT motor thermal status in focus.
3. If have to run on single CW pump for some time than moderate blow down and makeup as per
condenser inlet water temperature.
4. While bringing back standby pump focus should be on CW duct pressure and physical status of
condenser.
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9. HP Heater Level Maintaining High

Likely Causes:
1. Low feed water inlet temperature.
2. Auto failure of drip control valves.
3. Control valve stuck.
4. Drip interlocks not working properly.
5. Deaerator pressure higher than specified. (Drip may not flow to deaerator)
6. Adjacent heater got bypassed from feed water.
7. Heater tube leakage.
8. Level transmitter malfunction.
9. Level transmitters stand pipe leakage.
Plant Response:
1. Heater will be cut off and bypass if level rising than specified limit.
2. If heater is cut off vacuum may be effected.
3. If heater is cut off turbine axial shift will be increase.
4. If heater is cut off, load rising temporary and then after sometime load will be decreases.
5. Hot well level rise.
6. Deaerator level fall (if heater got bypassed).
1. Generation
2. Feed water temperature
3. Deaerator pressure
4. Heater level
5. Condenser vacuum
6. Axial shift
7. MS pressure, MS temporal flow, feed water flow, feed water temp
8. Extraction pressure
9. Extraction temp
1. Switch over drip controls to manuals and regulate levels.
2. Check control valves operation, or air leakage.
3. Check emergency and normal drain MIV and control valve for opening.
4. Check heater levels in local gauge glass.
5. Check flow to deaerator. If flow does not take place due to high deaerator pressure, or low
extraction pressure or faulty interlock action, rectify it.
6. If deaerator pressure is high, reduce pressure by throttling extraction#5 from turbine.
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If heater cut off then

1. Ensure its extraction is cut off properly by confirming closing position of extraction NRV and MOV.
2. Bypass heater from water side also (in case of tube leakage).
3. Check the drain valves before and after NRV for opening.
4. Ensure opening of emergency drain and closing of drip valve.
5. Control the load fluctuation by load set point, coal firing and feed water flow.
6. Monitor the remaining heater levels sharply and control it.
7. Observe the vacuum and start second vacuum pump if necessary.
8. Maintain deaerator level/hot well level.
9. Monitor axial shift of turbine.
10. Check local for level transmitter standpipe healthiness

1. Check for heater tube leak.
2. Follow up maintenance department for the cause. If tube leakage not there, take the heater in service.
10. Turbine Vibration High

Likely Causes:
1. Sudden change in steam parameters.
2. Sudden change in load, speed, frequency.
3. Heat soaking not done properly, cylinder expansion is not smooth.
4. Rotor eccentricity high.
5. Coupling bolt loose.
6. Lube oil pressure and temperature abnormal.
7. Cold steam and water enters in to turbine.
8. Low condenser vacuum.
9. High temperature difference between HP & IP cylinder.
10. During start and stop, turbine speed is within critical running speed zone.
11. Turbine bearing damages.
12. Moving blades damages.
13. Vibration due to generator due to sudden MVAR change, open phase operation, blade breaking and
imbalanced magnetic field.
14. Gland steam temperature low.
15. High axial shift.
16. Sudden cutoff of any HP Heater.
17. Turbine acceleration not maintained during rolling.
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Plant Response:
1. Turbine vibration high alarm will come.
2. Turbine will trip if shaft vibration reaches to 150 microns.
3. Axial shift may increase.
4. Bearing metal temperature may rise.
5. Unit sound abnormal, vibration of bearing is obvious by hand feeling
1. Turbine vibration.
2. HP-IP differential expansion.
3. Turbine speed.
4. Rotor eccentricity.
5. Axial shift.
6. Lube oil pr. & temperature
8. Gland steam temperature
9. Main steam & Reheat steam parameters.
10. Bearing metal temperature and return oil temperature
11. Physical vibration.
1. Turbine vibration readings are to be crosschecked and also local actual vibration to be checked
physically.
2. Listen for any sound coming at turbine bearings.
3. When turbine vibration is very high, turbine should trip otherwise trip the unit manually.
4. Check and ensure whether lube oil pr. and temperature at bearings are normal whether bearing
metal temperature and return oil temperature is normal. Otherwise take appropriate action.
5. During start-up do proper soaking of turbine.
6. Reduce load to suit the condition.
7. Wait for frequency change, if it is high.
8. Try to maintain turbine steam parameters as per startup curve.
9. Avoid sudden change in steam temperatures & load.
10. Try to maintain axial shift, differential expansion, condenser vacuum, exhaust hood temp,
eccentricity within limits.
11. Isolate the source of cold steam and water and open drain if the vibration is caused by water impact.
Caution:
1. If the turbine vibration is very high, unit should be tripped immediately and fast coasting down to
bring zero rpm.
1. During start up always ensure all the turbine drains should be in open condition, warm the line and
cylinder and follow the starting procedures carefully, sock the turbine and observe the casing
expansion.
2. During normal operation avoid sudden change in turbine operating parameters.
3. Follow the start-up and shutdown curves.
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11. Turbine Bearing Temperature High

Likely Causes:
1. Lube oil pressure is low,
2. Lube oil cooler outlet temp high.
3. Poor oil flow rate, pressure.
4. Bearing is damaged.
5. Vibration high.
6. Overload.
7. High gland steam leakages.
8. Foreign material in oil. (mechanical impurities and moisture)
9. Turbine acceleration is high.
10. One HP turbine CV got closed.
11. Axial shift may be high
12. The jacking oil pressure is low and forced turning. (No load condition)
Plant Response:
1. Bearing temperature high.
2. Bearing return oil temperature high
3. Friction noise at local.
4. Bearing vibration increases.
1. Bearing temperature.
2. Bearing return oil temperature.
3. Bearing vibration.
4. Lube oil temperature
5. Axial shift

1. Check oil flow from return oil gauge glass.
2. If the cooler outlet oil temperature maintaining high, change over the cooler.
3. Reduce load as per the condition.
4. If possible decrease gland steam pressure.
5. If bearing seriously damaged then stop the unit.
6. Bearing temperature increasing, turbine will trip manually (@100° C.
7. During rolling – maintain lube oil temperature and pressure. Ensure flow through the return oil
bearings.
8. Strengthen oil filtering or oil changing if the oiliness is not qualified and shut down based for
treatment as required when the oiliness is seriously aging.
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Caution:
1. If any oil leakage is heavy, immediately contact fire person to prevent fire.

1. After turbine tripped, contact maintenance personal.
2. Wait for suitable condition for inspection of bearing.
3. During rolling maintain acceleration and rated temperature.
12. High Axial Shift

Likely Causes:
1. Abrupt change of load. Sudden drop of steam temperature.
2. Sudden drop of vacuum.
3. Due sudden cut off of HP heaters (increase in too high flow in reheater).
4. Sudden closer of extraction NRV.
5. Lube oil failure of thrust bearing/lube oil pressure/temperature.
6. Turbine overload.
7. Blade deposit is severe.
8. Water hammer in the steam turbine.
9. The thrust pad wears.
10. Blade broken.
11. The unit axial vibration is abnormal.
12. The LP and HP bypass valves are opened by mistake or the HP and IP control valves are closed by
mistake.
13. Steam sealing is seriously worn.
14. HP/IP differential expansion and LP differential expansion high.
Plant Response:
1. Overloading of thrust pads and failure.
2. May contribute to turbine vibration.
3. Unusual sound from turbine.
4. Increase eccentricity.
5. High vibrations.
6. Gradual increase in turbine first stage pressure.
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1. Load rate.
2. Steam temperature.
4. HP heaters status.
5. Extraction NRV position.
6. Lube oil temp/thrust bearing temperature.
7. Axial shift.
8. HP IP differential expansion and LP differential expansion.
9. Turbine vibrations.
10. Eccentricity.

1. Check MS parameters, avoid sudden changes.
2. Control turbine vacuum.
3. Reduce load to reduce axial shift within permissible value.
4. Take HPH in service if possible.
5. Trip turbine in case of too rapid fall of steam temperature.
6. Check return oil from thrust pads through view glass for adequate quantity color and temperature.
7. Turbine will alarm on +0.30 or -0.50 mm.
8. Cut out reheat spray if existing to reduce reheater flow.

1. If axial shift exceeds + 1.0 or -1.0 mm turbine should trip on protection. In case it does not trip
turbine trip manually.
2. Break vacuum to bring rotor to rest fast.
3. After turbine is at rest, run it on barring gear check any rub noise, metallic sound vibration
eccentricity, DEH/DEL. After all parameters in range try to roll turbine slowly with concern SCE
permission.
4. If parameters are not in range than give time to cool turbine and permit to maintenance department
for inspection.
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13. HP/IP/LP Differential Expansion More +VE

Likely Causes:
1. Too fast rolling or too fast pickup of load.
2. Too high steam temperature for rolling
3. Inadequate soaking during rolling as well as during turbine loading.
4. Gland steam temperature high.
Plant Response:
1. Seal rubs can be expected at extreme values. Metallic sound from turbine when interference exists.
2. Possible increase in turbine vibrations, eccentricity.
3. Turbine will high alarm on +6.6 mm in case of HP differential expansion and on +6.0 mm in case of
IP differential expansion and on +8.0 mm in case of LP differential expansion.
4. Turbine will HH alarm on +7.4 mm in case of HP differential expansion and +7.0 mm in case of IP
differential expansion and +9.1 mm in case of LP differential expansion.
1. Main steam temp, turbine metal temp.
2. Acceleration rate.
3. Heat soak time.
4. Gland steam temp.
6. Differential expansion of HP (DEH)/IP (DEH)/LP (DEH).
8. Eccentricity.
1. Reduce boiler steam temperature.
2. Hold turbine load, soak.
3. Check and control gland steam temp.
4. Reduce vacuum in case of LP differential expansion.
5. Maintain the rated steam pressure/temperature as per the startup curves.
1. In case of high positive turbine expansion, tripping of turbine will help in reduction of HP
differential expansion so trip it with concern SCE permission.
2. Break vacuum to reduce damage after turbine tripped to reduce possible damages.
3. After turbine is rest running it on barring gear check any rub noise, metallic sound vibration
eccentricity, DEH/LOCAL. After all parameters in range try to roll turbine slowly with concern
SCE permission
4. If parameters are not in range than give time to cool turbine and permit to maintenance
department for inspection.
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14. HP IP LP Differential Expansion More -Ve

Likely Causes:
1. Boiler steam temperature lower than turbine metal temp.
2. During hot start ups, rolling or loading turbine too slowly
3. Low condenser vacuum.
4. Gland steam temperature low.
Plant Response:
1. Seal rubs can be expected at extreme values. Metallic sound from turbine when interference exists.
2. Possible increase in turbine vibrations, eccentricity.
3. Turbine will have high alarm on -1.2 mm in case of HP differential expansion, -3.5 mm in case of
IP differential expansion & -2.2 mm in case of LP differential expansion.
4. Turbine will HH alarm on -2.0 mm in case of HP differential expansion, -4.5 mm in case of IP
differential expansion & -3.3 mm in case of LP differential expansion.
1. Main steam temp, turbine metal temp.
3. Heat soak time.
4. Gland steam temp.
6. DEH and DEL.
8. Eccentricity.

1. Improve condenser vacuum
2. Increase boiler steam temp and load turbine fast
3. Improve gland stem temp
4. Maintain rated steam pressure/temperature as per the startup curve.
Caution
1. When turbine differential expansion is extreme -ve & turbine has already rolled, tripping is not
ideal solution as it would the situation. Gland steam temperature, boiler parameter correction &
rapid loading are better alternatives.
2. It is essential that we would not roll the turbine with negative mismatch of steam parameters
already when negative expansion is there.
3. If turbine is tripped, break vacuum immediately to reduce possible damage.
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1. In case of negative turbine expansion reaches HH value, turbine will trip manually.
2. Break vacuum to reduce damage after turbine tripped to reduce possible damages.
3. After turbine is at rest, run it on barring gear check any rub noise, metallic sound vibration
eccentricity, DEH/LOCAL. After all parameters in range try to roll turbine slowly with concern SCE
permission.
4. If parameters are not in range than give time to cool turbine and permit to maintenance department for
inspection.
15. High Eccentricity
Likely Causes:
1. Deflection of turbine rotor due to improper cooling after unit trip.
2. Improper draining of steam lines and turbine cylinders contributing water entry to turbine.
3. Abrupt drop of main steam temp due to water carryover from boiler.
4. Moisture in gland steam.
5. Deformation of cylinders.
6. Disengaged barring gear etc.
7. Lube oil temperature, quality.
8. Spray CV is open in turbine rest condition.
9. Barring gear not engaged for long time after rest down to 0 RPM or during blackouts.
Plant Response:
1. Turbine vibration increases, unusual noise from turbine.
1. Eccentricity.
3. Heat socking time.
4. MS Temperature.
5. Lube oil temperature.
8. Vibrations.
9. Barring gear operation
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1. Follow start up procedure regarding steam parameters, draining of steam lines and cylinders & shocking
times etc. strictly.
2. Before rolling turbine, see that eccentricity does not exceed 20 microns and while running not more than
00 or negative
3. See that lube oil temperature is maintained between 40 to 45 °C.
4. Check quality of lube oil, bearing temperature.
5. Ensure barring gear is run as turbine reaches to 0 RPM and ensure shaft is rotating.
1. Minor increase in eccentricity can be reduced by either long barring gear operation and if that is not
possible rotating shaft by 180 degrees at regular intervals.
2. Sometimes if possible running at 500 rpm for 3 to 4 hrs. can reduce eccentricity.
3. If parameters are not in range then give time to cool turbine and permit to maintenance department for
inspection.
16. Turbine Speed above 51.5 Hz (Over Speed)

Likely Causes:
1. DEH control failure.
2. OPC protection failure.
3. Tripping solenoid failure.
4. Grid disturbance.
5. Stop valves and CV close failure due to control failure.
6. The HP and LP automatic main stop valves, speed control valves, steam extraction check valves, etc.
are not tightly closed, is jammed or is not closed in place after generator parallel-off.
7. The speed increases too fast for the miss operation of over speed test.
Plant Response:
1. Turbine vibration goes to higher side.
2. MOP discharge pressure Increases.
3. Unit load fluctuates.
4. Turbine should trip at 110% Electrical protection.
5. Generator current and terminal voltage shoots up.
6. All plant auxiliaries over loaded.
1. Turbine vibrations, unit load, generator current & terminal voltage.
2. Tripping of turbine on 110% electrical protection.
3. DEH system healthiness.
4. Healthiness of other auxiliaries.
5. Availability of DG set.
6. DCDB healthiness.
7. Speed coasting down after unit trips.
8. Closing of Extraction NRV’s.
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1. If unit did not trip, trip the unit manually.
2. If turbine vibrations are increasing very fast then try to trip turbine by PB at desk and kill the vacuum.
3. If failed to trip the turbine from desk than proceed for mechanical tripping mechanism.
4. Trip the boiler and close boiler stop valves.
5. Open HP LP bypass.

1. Check and rectify DEH system so is to make it more reliable.
2. OPC protections to be checked.
3. All solenoids to be checked periodically.
4. Valve tightness test to be checked as per OEM schedule.
5. Mechanical over speed to be checked after annual shut down.
6. Strictly control the steam and water quality index to ensure the water quality is fine to prevent scaling of
valve lever.
17. Barring Gear Not Engaged After Unit Tripping
Likely Causes:
1. Barring gear motor power supply failure.
2. Over load due to JOP individual bearing lifting pressure disturbance.
3. Fluid coupling oil leakage.
4. Lube oil pressure low.
5. Seal oil DP High.
6. Turbine turning gear cover not removed.
Plant Response:
1. Turbine not comes on barring and after coasting down remains stand still.
2. Turbine rotor sagging.
3. TG eccentricity may increase.
4. Rotor may get damaged.
1. Turbine metal temperature.
2. Rotors thermal state.
3. Bearing temperatures.
4. JOP status.
5. Availability of manual barring spanner.
6. Generator H2 pressure.
7. Seal oil system parameters.
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1. Ensuring Manual barring spanner and engaging handle is available.
2. Engage the barring manually and start hand barring.
3. Ensuring JOP is running.
4. Ensuring turbine lube oil system is healthy.
5. Ensuring turbine bearing and metal temperature are normal.
6. Ensuring no rubbing sound is coming during hand barring from bearings.
7. Generator H2 pressure and seal oil system parameters are normal.

1. Check and find out the problem and bring back turbine on motor barring as soon as possible.
2. Always ensuring barring gear motor healthiness.
3. Barring gear engaging gear teeth should be checked during each overhaul.
18. All JOP Fail To Start

Likely Causes:
1. MOT oil level low.
2. AC power failure.
3. Problem from feeder or cable.
4. Over load tripping of motor. Pump mechanical damage.
5. No commands from DCS, due to DCS fail.
Plant Response:
1. Turbine speed less than 2500 rpm and JOP not in service alarm.
2. Barring motor will not start.
3. Bearing temperature and Bearing vibrations will increases
1. Turbine speed.
4. Axial shift.
5. Eccentricity.
6. MOT tank level.
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1. Check MOT oil level from local & DCS if low then top up.
2. If MOT oil level is ok start the JOP from local.
3. If pump not started, open vacuum breaker and kill the vacuum to reduce turbine speed to 0 (reduce
coasting down time).
4. Ensure LOP is running.
5. Find out the reason and start JOP as soon as possible and start barring gear.
6. If JOP is not restored after zero rpm of turbine, start hand barring

1. Ensure continuous healthiness of all the pumps.
19. One of the Turbine’s CV or IPCV Fail to close on Tripping

Likely Causes:
1. Mechanical fault on CV/IPCV.
2. CV/ IPCV servo valve fail.
3. CV/ IPCV servo valve card failure.
4. Heavy steam leakage near CV/IPCV.
5. Tripping circuit fault.
6. Feedback problem
Plant Response:
1. If stop valve is not closed properly turbine may over speed.
2. Turbine vibrations/axial shift may increase.
3. Turbine may not come to barring (if passing is minor).
4. Coasting down time will be greater than 30 minutes.
1. Turbine speed.
2. MSV/CV/RSV/IPCV position.
3. Turbine vibration/axial shift.

1. Operate manual/local trip lever once, near turbine and try to close CV/IPCV.
2. Stop main steam stop valves from boiler immediately.
3. Open HP/LP bypass.
4. Stop EH oil pump.
5. Inspect locally for any oil leakage.
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1. Inform instrument department for checking of servo valve card, servo valve, or any related issue and
rectify it.
2. Inform mechanical maintenance for checking of mechanical stuck up or damage.
20. One of the HPCV or IPCV Close and Turbine on load
Likely Causes:
1. Mechanical fault on HPCV/IPCV.
2. EH oil/ trip oil line oil leakage on that particular HPCV/IPCV.
3. HPCV/ IPCV servo valve fail.
4. HPCV/ IPCV servo valve card / Feedback failure.
Plant Response:
1. Unit Generation may reduce.
2. If IPCV close CRH/HRH pressure will increase, increase reheated temperature
3. In case of HPCV MS pressure will increase, MS temp increase.
4. If one CV closes, other CV opening may increase for same load.
5. Axial shift will increase.
6. Heaters levels may fluctuate.
7. In case of heavy EH oil leakage EH oil tank level drop and EH oil pressure also.
1. MS pressure/temperature.
2. CRH/HRH pressure/temperature.
3. Axial shift.
5. HPCV/IPCV position.
6. HPH/LPH levels.
7. EH oil press/tank level.
8. HP/ LP bypass valve position.
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1. Maintain MS/CRH/HRH pressure/temperature by reducing coal firing.
2. Maintain boiler metal temperature.
3. Watch axial shift /vibrations and other TSI parameters.
4. Maintain HPH/LPH level.
5. Watch EH oil press/level.
6. Watch other HPCV/IPCV positions.
7. Physical check for any steam/EH oil leakage at that area.
8. Physical check any mechanical damage at that HPCV/IPCV.
9. If EH supply oil filter DP is high than open its bypass.
10. Inform instrument department for checking of servo valve card, servo valve, or any related issue and
rectify it.
11. Identify the oil leakage if any and put collector vessel, inform fire department for same.
12. Check physical position of HPCV/IPCV.
13. Ensure both LVDT output is matching (healthiness of LVDT).

1. Trip the unit if heavy oil leakage, mechanical damage, servo valve fail, axial shift raising fast,
vibrations, or HP exhaust temp high and attend the HPCV/IPCV.
2. Inform mechanical maintenance for checking of mechanical stuck up or damage.
21. Turbine Starts Rolling on MSV/RSV Opening

Likely Causes:
1. Any HPCV/IPCV is passing.
2. Any HPCV/IPCV is open.
3. Wrong feedback of CVs.
Plant Response:
1. If passing is heavy or HPCV/IPCV is fully open turbine run fast and may over speed.
2. Turbine vibration/axial shift/DEH/DEL /eccentricity increase.
3. Due to passing acceleration rate may not be maintained.
4. Turbine rolling starts upon MSV/RSV opening.
5. Barring gear disengage.
1. Turbine CV/IPCV position.
2. Turbine speed and acceleration.
3. Turbine vibration/axial shift/DEL/DEH/eccentricity.
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1. Immediately trip turbine manually by PB, if not then trip it from local.
2. Ensure Main steam pressure is as per startup curves.
3. Ensure barring gear is disengage and motor is stopped if speed >54RPM if not do it manually.
4. Confirm the rolling acceleration rate is being maintained.

1. Inform maintenance department to rectify the problem.
22. Turbine MOP Failure

Likely Causes:
1. Drive coupling failure.
2. Suction of MOP failure due to leakage.
3. MOP discharge line heavy leakage.
4. Low oil level in MOT.
5. Failure of NRV on MOP.
Plant Response:
1. AOP start on auto, if it fails to start, EOP will start.
2. If lube oil pressure drop up to 0.08 MPa unit will trip.
1. MOP discharge pressure.
3. MOT level.

1. If MOP fails, start AOP/EOP for bearing lubrication.
2. Watch the abnormal noise at turbine front pedestal.
3. Maintain proper level in MOT.
4. If possible clean MOT strainer.
5. Identify the oil leakage if any and put collector vessel inform fire department for same.

1. Find the causes of above and inform maintenance persons
2. Trip the turbine with SCE concern if problem in MOP, turbo generator, oil leakage.
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23. MOT Level Low

Likely Causes:
1. Oil leakage from turbine bearings view glasses and exciter end piping.
2. Oil cooler leakages.
3. Oil leaks from oil purifier system.
4. Oil level in LLD is high.
5. MOT drain valve passing or open.
6. MOT level gauge leakage.
7. Seal oil system leakages
8. MOT basket filter got chocked
9. Oil transfer system piping valves may be passing.
Plant Response:
1. MOT level decrease.
2. Oil pressure low alarm if oil leaks from oil supply line to bearing.
3. Turbine bearing temperatures may increase.
1. MOT level.
2. Lube oil pr. and temp.
3. Generator LLD.
4. Turbine bearing temperature.

1. If leakage is heavy trip the unit with SCE’s clearance.
2. If lube oil pipe leaks, contact maintenance person for treatment, add oil timely.
3. Observe the bearing temperature during costing down if any temperature is rising, kill the vacuum
by opening vacuum breakers to bring ZERO RPM fast.
4. If oil leaks from seal oil system, take action accordingly and contact maintenance person. If seal oil DP
is not maintaining, reduce the load and H2 pr.
5. If oil leaks from oil purifier system, stop purifier and close i/l valve, isolate the system.
6. If oil leaks from cooler, changeover the cooler.
7. If any oil leaks, contact fire person.
8. If LLD high alarm coming, drain the LLD and make arrangement for collecting the oil in co-
ordination with maintenance person.
9. Closely monitor the local pressure gauge & temperature in DCS.
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Caution:
1. If any oil leakage is heavy, immediately contact fire person to prevent fire.

1. If MOT level is sustaining after attending the problem (any leakages etc.) normalize the load as
requirement.
24. HP Exhaust Temperature Shooting Up

Likely Causes:
1. Insufficient steam flow from HP turbine during IP to HP transfer (HP bypass opened more than
required & load set point is not more).
2. MS temperature high.
3. CRH NRV not fully opened.
4. Continuous low load operation.
5. Closing of any HP/IP turbine control valve.
6. HP heater #7 cut out.
Plant Response:
1. HP exhausts temp HIGH alarm display.
2. HP –IP diff expansion increases.
3. Turbine will trip on HP exhaust temperature>420deg.
4. CRH inlet temperature increases.
1. MS temperature.
2. HP exhausts pressure.
3. CRH pressure.
4. CRH NRV position.
5. Unit load.
6. HP-IP differential expansion.

1. During IP to HP transfer increase steam flow by increasing the load & simultaneously reduce HP
bypass valve position.
2. Ensure full opening of CRH NRV.
3. Maintain rated Main steam temperature during start-up.
4. Increase the load to increase steam flow through HP turbine.
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1. Always ensure healthiness of CRH NRV operation.
2. Reduce low load operation of the unit.
25. LP Exhaust Temperature Shooting Up

Likely Causes:
1. HRH temp maintaining high in cold start up.
2. Low vacuum in condenser.
3. Tripping of any CW pump.
4. At low load exhaust hood spray valve is at closed position.
5. LP bypass spray valve is in closed condition during LP bypass operation.
6. CEP pressure low for LP exhaust spray.
7. Keeping turbine speed 3000rpm for long time without synchronizing.
8. Running unit at low load for long time.
Plant Response:
1. Vacuum decreases.
2. LP turbine differential expansion increases.
3. Turbine vibration increases.
4. LP bypass fast close on condenser vacuum low (-75 KPa) or LP bypass exhaust
temperature>200 deg.
5. Turbine should trip manually on LP exhaust temperature>107deg.
1. RH temperature.
2. HP-LP bypass valve position.
3. HP-LP bypass spray valve position.
4. LP exhausts hood spray valve position.
6. LP differential expansion.
1. Improve the vacuum in condenser.
2. Synchronize the unit and increase the load fast.
3. During low load operation check HP-LP, exhaust hood spray valve condition, if there is
chocking in spray line clear it immediately.
4. Increase the attemperation water pressure from condensate system.
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1. Reduce low load operation of the unit.
26. Gland Steam Pressure Low

Likely Causes:
1. Gland steam pressure control valve failure.
2. Gland steam pressure transmitter reading wrong.
3. Gland steam pressure over flow CV fully open.
4. Air leakage/air valve close of CVs.
5. Auxiliary steam header pressure low (CRH CV /MOV close, excess consumption, valves from
other unit closed).
6. Load is low (for self-sealing) and standby source disturbance.
7. Gland steam piping leakage/drains open.
Plant Response:
1. Condenser vacuum will fall.
2. LP turbines exhaust hood temperature increase.
3. Due to low vacuum air will enter through the seals. This will cause negative expansion.
4. Turbine vibrations and other TSI parameters may affect.
1. Gland steam pressure/temperature.
3. LP exhausts temperature.
4. Aux header pressure.
5. DEH/DEL.

1. Open instrument air valves to GS pressure CV (if close).
2. Close over flow MOV to condenser and LPH#1/2, if overflow CV does not close..
3. Open CRH to aux CV/MOV if any problem.
4. Close valve to other unit from aux. header.
5. Open valve from other unit aux. header.
6. Maintain auxiliary header pressure/temperature.
7. Check for any leak in line / header from HPT CV (leak of line).
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1. If gland steam press not established unit will trip on low vacuum if not, trip manually and break
vacuum.
27. Gland Steam Temperature Low

Likely Causes:
2. Gland steam temperature transmitter reading wrong.
3. Gland steam attemperation valve full open.
4. Condensation in gland steam line takes place.
5. Gland steam line drains closed at charging time.
6. MS temperature/pressure low due to sudden variation if gland steam on self-sealing.
7. Aux header pressure high and temperature is low.
Plant Response:
1. Gland steam line hammering may be observed.
2. Water contamination in lubricating oil and vibration of turbine.
3. Effecting GSC performance and thus vacuum.
4. Due to water collection seals may damage, periodical turbine vibrations may occur.
2. Vibration.
3. GSC level.
4. Vacuum.
5. Moisture in lube oil.

1. Close the attemperation if open.
2. Open all drains in gland steam lines.
3. Maintain MS temperature/pressure
4. Maintain GS pressure by CV bypass MOV
5. Charge GS line after auxiliary header has enough pressure/temperature.
6. Take sample of lube oil and check moisture percentage.

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28. Gland Steam Pressure High

Likely Causes:
2. Gland steam pressure transmitter reading wrong.
3. Gland steam pressure over flow CV fully closed.
4. Air leakage/air valve CVs.
5. Auxiliary header pressure high (CRH full open, sudden loss of consumption).
Plant Response:
1. Gland steam out from seals at turbine shafts.
2. Seal damages.
3. Turbine vibrations increase.
1. Gland steam header pressure.

1. Open bypass MOV of overflow CV if overflow CV does not open and maintain the pressure.
2. Close gland steam press CV inlet MOV if CV does not close (when unit is in self-sealing).
3. Close CRH to aux CV inlet MOV if CRH CV does not close.

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29. Gland Steam Temperature High

Likely Causes:
1. Gland steam pressure control valve failure
2. Gland steam pressure/temperature transmitter reading wrong.
3. Gland steam line drains full opened.
4. LP GS attemperation CV full close.
5. LP GS attemperation. Nozzle chock.
6. MS temp/press high due to sudden variation if GS on self-sealing.
7. Aux header pressure and temperature is high.
8. Gland steam header attemperation line strainer in chocked condition.
Plant Response:
1. DEH/DEL increase.
2. Turbine vibration increase.
3. Damage of seals.
1. Vibration
2. Vacuum
3. GSC level
4. Gland steam temp
5. LP Gland steam attemperation CV Position.

1. Maintain MS temperature/pressure
2. Maintain GS pressure by CV bypass MOV.
3. Charge GS line after auxiliary have enough pressure/temperature.
4. Open gland steam attemperation MOV locally.
5. If LP GS attemperation nozzle chock up is suspected then, trip the turbine and rectify it.
6. Gland steam header attemperation line strainer to be cleaned if it is in chocked condition.

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30. EH Oil leakage

Likely Causes:
1. Rings at various hydraulic devices get damage.
2. Poor piping work.
3. Heavy material falling on pipe lines.
4. Air ingression in the system.
5. CCCW system fails and EH oil temperature got very high.
6. Heavy vibration in MSV/CV/RSV/IPCV/BFP LCV.
Plant Response:
1. If leakage is heavy EH oil tank level, pressure fall and at <9.8 MPa pressure, turbine will trip.
2. If leakage is heavy in specific MSV/CV/RSV that valve will get close.
3. If leakage is heavy in common line, turbine will trip.
1. MSV/CV/RSV position.
2. EH oil tank level.
3. EH oil pressure.
4. EH oil temperature

1. Identify the location and leakage quantity quickly.
2. Monitor EH oil temperature, pressure, level.
3. Put some collecting vessel where the oil is leaking; call fire personals for the same.
4. Call maintenance persons for the same.

1. If leakage is minor continue observe it and rectify it whenever opportunity is given.
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31. EH Oil Pump Failed

Likely Causes:
1. Pump tripped on any electrical protection.
2. EH oil tank level low low.
Plant Response:
1. Standby pump pickup in auto.
2. Turbine will trip on EH oil outlet pressure<9.8MPA.
3. If tank level is low low both EH oil pump will trip.
1. EH oil tank level.
2. Outlet header pressure.
3. Oil temperature.

1. Check normal running of standby pump.
2. Check pump module along with electrical maintenance & try to restart the pump as quickly as
possible.

1. Ensure continuous healthiness of both the pumps.
2. Follow the equipment changeover schedule.
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32. Seal Oil Pressure Going Low

Likely Causes:
1. VOT level dropping fast.
2. One seal oil pump tripped & standby pump not started.
3. Running seal oil pump PRV operated
4. Seal oil line leakages
5. DPR not operating properly.
6. Pump mechanical jamming.
7. Seal oil pump discharge recirculation valve open.
8. Seal oil filter DP high.
9. Motor protections operated.
Plant Response:
1. Standby Pump starts on Seal oil header pressure low
2. Vacuum oil tank level will rise
3. Float oil tank level may rise.
4. In case of Line leakages, MOT level will drop, as oil makeup to VOT increases.
5. H2/seal oil DP drops and H2 escapes from generator.
6. H2 pressure in Generator falls quickly.
7. Generator H2 cold & hot temperature increases.
8. Generator temperature increases.
9. Risk of fire.
1. Seal oil header pressure.
2. H2 pressure
3. Seal oil/H2 DP.
4. Generator winding temperatures.
5. VOT/MOT/POT levels.
6. Seal oil filter DP
7. H2 gas purity.
8. Generation.
1. Monitor seal oil DP, H2 pressure.
2. Immediate change over the filter.
3. Start standby seal oil pump if not started in auto else start from local.
4. Start DC seal oil pump if not started in auto and ensure its recirculation line valve closed fully.
5. Reduce load so as to maintain H2 temp/Gen temp within permissible limits.
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6. Check seal oil pump R/C valve.

7. If seal oil pressure is not restored then take lube oil source backup, trip the unit or reduce the load
watching generator winding temperatures, vent the H2 to certain pressure to maintain seal oil DP.
8. FOT bypass to be opened to maintain FOT level.
9. Check for any line leakages as MOT makeup may be required.

1. Maintain proper VOT level, float oil tank level.
2. Always ensure DC pump R/C valve is in closed condition.
3. Always ensure lube oil source backup.
4. Follow the equipment changeover schedule
.
33. VOT Level Low Due to Seal Oil System
Likely Causes:
1. Trouble in lube oil supply.
2. Major oil leakage in seal oil system.
3. Float valve in vacuum oil tank is not working / stuck up.
4. Level transmitter/switch malfunction.
5. High vacuum in VOT for long time.
Plant Response:
1. If DC seal oil pump does not start or not developing sufficient pressure, seal oil to hydrogen differential
pressure is low, then hydrogen leakage may happen.
2. If DC seal oil pump start and seal oil to hydrogen differential pressure is high than oil may be enter in
generator and continuous LLD alarm may be persisting.
3. If H2 press drops hot/cold gas temp may increase.
4. Generator winding temperatures may increase.
1. DC seal oil pumps current/discharge pressure.
2. VOT level/pressure.
3. H2 pressure.
4. Seal oil DP.
5. LLD alarms.
7. Hot /cold gas temperature.
8. Generator winding temperature
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1. Check DC seal oil pump is start on auto and developing pressure check R/C Valve.
2. Watch seal oil to hydrogen DP is between 35 to 70 KPa if DP is beyond this, then adjust the DP with
bypass MIV of DPR.
3. Ensure hydrogen pressure is not dropping. Rectify the lube oil supply trouble and make it ready as
soon as possible.
4. Identify the leakage if any in seal oil system and make necessary isolation if it is possible put collect
vessel and inform to fire department.
5. Check VOT level locally if it is OK then rectify the level transmitter/ switch problem with C&I.
6. If float valve got stuck, do some soft hammering at VOT and call MMD for the same.
7. After system normalizes drain all LLD at least once.
8. Stop vacuum pump.

1. If DC seal oil pump not start and VOT level is low in local also hydrogen pressure is dropping fast,
then trip the unit, and purge the hydrogen to take the lube oil backup. Establish seal oil parameters
with Lube oil backup.
2. Later purge the hydrogen up to 30 KPa, and start CO2 filling and ensure lube oil to seal oil discharge
header and air deterring section/float oil tank to seal oil discharge header MIV are fully open. Check
the float oil tank level also.
3. Check no sparking at generator exciter end.
4. Keep all persons out near the generator.
5. Inform fire section for the same.
34. Seal Oil’s Pressure Oil Tank Level Low
Likely Causes:
1. Pressure oil tank float not working/stuck up.
2. Pressure oil tank inlet MIV closed.
3. Pressure oil tank bypass MIV open.
4. Pressure oil tank drain MIV open.
5. Seal oil DP low (DPR malfunction).
6. Lube oil system trouble and air deterring section/float oil tank is supplying oil to seal oil system.
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Plant Response:
1. H2 pressure decreases.
2. LLD in enlargement section observed.
1. POT level.
2. H2 pressure.
3. Seal oil DP.
4. Seal oil pump discharge pressure.
5. MOT level.
7. Hot/cold H2 gas temperature.
8. Generator temperature.
9. POT bypass valve position
10. POT inlet valve position.

1. Check seal oil system is healthy and if not try to reestablish it fast.
2. Immediately close if any drain open in float oil tank or enlargement section.
3. Check float oil tank inlet MIV for open.
4. Close POT bypass MIV.
5. Establish proper seal oil DP if it is low.
6. If problem found in float immediately open float tank bypass MIV and isolate POT.
7. If H2 pressure drop H2 filling to be done after pressure hold.

1. Soft hammer on outlet line and POT if then also not operate call MMD for same.
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35. Seal Oil’s Pressure Oil Tank Level High

Likely Causes:
1. POT float may not working/stuck.
2. H2 pressure low.
3. Seal oil DP high (DPR malfunction).
4. Seal oil ring damaged.
5. H2 line MIV at POT closed.
6. POT outlet MIV closed.
Plant Response:
1. If pressure oil tank level is full and still raising the oil may enter in generator.
2. If oil enters in generator insulation value may go down and earth fault may result.
3. LLD in enlargement section and turbine and generator end found continuously.
4. H2 purity drop.
1. Pressure oil tank level.
2. H2 purity. LLD alarms.
3. Seal oil DP.

1. Immediately open POT bypass MIV.
2. Adjust seal oil DP if high.
3. Increase H2 pressure if it is low.
4. Open POT outlet MIV if closed.
5. Open POT H2 side MIV if closed.

1. Soft hammer on outlet line and POT if than also not operate call MMD for same.
2. Drain all LLD if observed.
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36. Hydrogen Purity Low

Likely Causes:
1. Contamination of hydrogen by oil vapors.
2. H2 cylinder/H2 from hydrogen plant lacking in specified purity.
3. Oil/water in generator.
4. H2 dew point is not maintaining.
Plant Response:
1. Purity of hydrogen less than 97% is not desire as heat transfer will not proper.
2. Alarm will appear at 97%.
3. Not safe to run the Unit at <95% H2 purity.
1. Hydrogen purity.
2. LLDS.
3. Hot/cold gas temperature.
4. Generator temperature.
5. H2 Dew Point Temperature.

1. Cross check the H2 purity meter with ORSAT and portable hydrogen meter.
2. Check purity of hydrogen cylinders before filling.
3. To improve purity carry out simultaneous purging and filling of fresh, pure hydrogen till purity improves.
4. In case of cold/hot gas temp is low, raise it with H2 cooler OCCW Outlet CV closing.
5. During purging maintain hydrogen pressure in specified limits.
6. Drain LLDs for checking any oil/water contamination in generator.

1. If purity is not improved by purging/filling of hydrogen than trip the turbine by
SCE permission, Purge hydrogen by filling CO2 and then by air and give permit to
maintenance for inspection.
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37. Hydrogen Leakage

Likely Causes:
1. Seal oil to H2 DP low.
2. Seal oil pump trip due to low VOT level and DC pick up and its R/C valve is in open condition.
3. DPR malfunction.
4. Leakage from generator H2 pipe connections, H2 cooler flanges, near generator bushings etc.
5. Stator bar leakage.
6. LLD drain may be in open condition.
7. H2 leakage from its flange joint, valves, H2 coolers, sampling and filling lines, valves.
8. Float oil tank level is low
9. H2 system purging vent valve is passing
10. H2 driers drain valves are passing
11. H2 feeding line NRV is not holding
Plant Response:
1. High H2 pressure drop rate.
2. H2 leakage alarm will come.
3. Hot-cold gas temperature high alarm will come.
4. Generator winding temp will increase.
5. If leakage is serious, chance of fire near leakage.
1. H2 pressure in generator.
2. Seal oil/H2 DP.
3. H2 leakage alarm.
4. Hot-cold gas temperature.
5. Generator winding temperature.
6. Generation

1. Stop any cutting/welding work near the generator, if it is in progress.
2. If DPR is malfunctioning, maintain seal oil/H2 DP through its bypass valve.
3. Changeover the seal oil pump if the running seal oil pressure is low or start DC seal oil pump
If VOT level is not maintaining (ensure R/C valve is in close condition).
4. If any leakage alarm comes, check locally with H2 detector at respective points.
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5. If H2 pressure cannot be make up and drops further, reduce the load on generator by watching the
hot/cold gas, winding temperature.
6. If any leakage found contact maintenance person and take appropriate action to prevent risk of fire,
inform the fire man too.
7. If serious leakage found, stop the unit and purge the generator with CO2 as per procedure.
8. If H2 pr. stabilizes, fill H2 cylinder and maintain pr. as per requirement.

1. Always ensure the drop rate of H2 pressure during the unit start up and running condition.
2. Always ensure healthiness of float oil and VOT levels.
3. In running unit at least 30 CO2 cylinders should be available always for an emergency.
4. Purge out H2 with CO2 and find out the possible leaking points.
38. Both Vacuum Pump Failed

Likely Causes:
1. One pump tripped & standby fails to start.
2. Both pump running & tripped on electrical protections.
3. Power supply failure.
4. Pump mechanical failure.
Plant Response:
1. Vacuum drops fast.
3. Turbine exhaust hood temperature increases.
4. Howell temp starts increasing.
5. Axial shift may rise.
2. Unit load.
3. Exhaust hood temperature.
4. Hot well temperature.
5. Axial shift.
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1. Check the reason behind tripping.
2. Start the pump immediately if the reason is rectified
3. Reduce the load as quickly as possible.
4. If reason is unknown and still vacuum is dropping then unit will trip on vacuum low low (-75 KPa) if
not hand trip the unit.

1. If necessary take unit shut down and check the reason behind the vacuum tripping thoroughly and
always ensure the healthiness of vacuum system during vacuum pulling.
39. Condenser Vacuum Low

Likely Causes:
1. Any CW pump trip.
2. CW outlet valve closed (partially or fully).
3. Condenser CW inlet or outlet valve closed and CW flow decrease.
4. Sudden increase in load.
5. High condenser Inlet & outlet cooling water temperature.
6. Vacuum pump trips or poor performance of PHE.
7. Vacuum pump air jet valve malfunction.
8. Vacuum breaking valve not fully closed or improper water sealing of vacuum breaking valve.
9. Gland sealing pressure drops, GSC siphon level low.
10. Leakages, ingress of air in to vacuum system through any drain line going to condenser or from loose
flanges, instrument tapping points.
11. Hot well level very high.
12. Condenser tube choking (condenser inlet-outlet DP high) so CW flows low.
13. Relief valve open.
14. CT fans trip.
15. CT fan riser valve closed.
16. Condenser poor performance due to tube scaling /fouling
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Plant Response:
1. Condenser vacuum low alarm.
2. LP exhaust steam temp increase.
3. Hot well temperature increases.
4. Load reduces.
5. Fuel flow increases if unit is in CCS mode.
6. Turbine vibration may increase.
7. Unit trip at – 75 KPa vacuum.
8. Standby vacuum pump will pick up at -81 KPa.
1. LP exhaust steam temperature
2. Hot well water temperature & level.
3. CW inlet/outlet water temperature.
4. Drain manifold temp. Coming to HP/LP flash tank.
5. Condenser pressure.
6. CW flow.
7. Cooling tower range / No fans in service.

1. Check CW inlet and outlet temperature, if it is more than normal then increase the hotwell blow
down and make up.
2. If any CW pump operation (check current, discharge pr.) is abnormal, changeover the pump.
3. If vacuum drops below -81 KPa, ensure second vacuum pump starts in interlock, if not then start
second pump.
4. Check whether gland steam pr. is normal or not, GSC siphon level.
5. Check vacuum breaker is fully close or not.
6. Open the LP exhaust hood spray when exhaust steam temperature Increases above 47 °C and open
fully when temp increase above 80 °C. If the temp increase above 107 °C unit should tripped
manually.
7. Check the condenser CW inlet-outlet valve position on DCS and local, if it is closed then open fully.
8. Check whether there is any leakage or ingress of air to vacuum system, if found any take appropriate
action for isolation.
9. Check the condenser CW inlet-outlet DP. If DP is high then condenser tube should be cleaned.
10. If the vacuum is continuously dropping, decrease the load. If vacuum drops to -75 KPa unit should
trip otherwise trip manually.
11. Start the stand by CT Fan.
Caution:
12. If the turbine vibration is very high, unit should be tripped immediately.
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13. Check thoroughly the reason behind the vacuum loss; if necessary take shutdown of the unit. Always
ensure the healthiness of the vacuum system during vacuum pulling during every start-up.
14. Rubber ball cleaning system should be taken into service as per schedule.
40. Condenser Pressure Rise after Vacuum Loss (In Blackouts & Shut down Condition)
Likely Causes:
1. Vacuum breaker closed condition.
2. Lack of condensation in condenser as CW pumps tripped.
3. Gland steam supply not cut off.
4. HP-LP flash tank attemperation not available as CEP not running.
5. MS, CRH, HRH, extraction line drains, HP heaters and LP heater drains CV open due to instrument air
pressure low and high temperature steam coming to flash tank (any drain to condenser open).
6. LP exhaust hood spray not available.
7. HP-LP bypass open/passing.
8. MS stop valve open (boiler side)/passing.
Plant Response:
1. Condenser vacuum low alarm.
2. LP exhaust temperature increases.
3. LP turbine rupture disc may damage.
1. Condenser pr. and temp.
2. LP exhaust temperature.
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1. Close MS stop valve of boiler side and hand tighten it.
2. Close HP/LP bypass valves.
3. Isolate all turbine drains & cut out gland steam and open the vacuum breaker at Pr.-30 Kpa.
4. Close the MS, CRH, HRH, extraction line drains, HP heaters and LP heater drains MIV.
5. Close the hot well make-up MIV.
6. Start CW pump after power restoration.
7. Start CEP and start flash tank spray.
8. Open the reheater vent if LP bypass is passing.
Caution:
1. If the turbine vibration is very high, unit should be tripped immediately.

1. After restoration of power, start CW pump and CEP for proper circulation.
41. Condenser Tube Leakage

Likely Causes:
1. Sudden steam loading to the condenser.
2. Sudden opening of HP/LP bypass valves.
3. Repeated blackouts.
4. Both CW pumps trips.
5. Manufacturing defect.
6. High COC.
7. High cooling water temperature.
8. CW pressure surges during CW pumps start / stop due to improper air venting.
9. High Vacuum.
10. Sudden opening of high pressure drains like HPT VV and BDV.
Plant Response:
1. Cation conductivity increases in Condenser leak detection system (CLD), CEP outlet and CPU
outlet.
2. CEP outlet Na+ Increases.
3. Condensate & feed water pH value decreases.
4. MS conductivity & Na+ increases.
5. If run for prolonged period chances of boiler tube failure and LP/HP heaters tube leakages, turbine
blade cracking.
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1. Cation Conductivity in CLD & CEP outlet, value of pH, specific Conductivity, Na+ in feed water,
MS & condensate.

1. Ensure CPU is in service
2. Verify the SWAS parameters with DM lab.
3. Identify the tube leakage zone from CLD system and if leak is minor then isolate the respective
pass and attend the leakage.
4. If SWAS parameters is ensured from DM plant and leak is heavy, immediately trip the unit, stop the
BFP and CEP, and do not feed the water to boiler, drain the deaerator.
5. Stop one CW pump after Unit stop or load is below 150 MW.
6. Stop 2nd CW pump considering the Exhaust temperature, Turbine metal temperature, oil temperature,
and OCCW pumps requirement.

1. Avoid sudden loading to the condenser, sudden load variation, sudden opening of HP/LP bypass
valves.
2. Always ensure opening of ARV’s throughout the CW system.
3. Maintain COC within design limits.
42. Generator Winding Temperature Rising Fast

Likely Causes:
1. Overloading of generator.
2. High MVAR loading.
3. Stator cooling water flow low.
4. OCCW flow to hydrogen cooler low.
5. Hydrogen cooler not lined up or air locked.
6. Hydrogen gas temperature may be high
7. H2 purity low.
8. Stator cooling water temperature high.
Plant Response:
1. Generator winding temperature rising.
2. H2 consumption may increase.
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1. Generator winding temperature high alarm.
2. Generator hot and cold gas temperature high.
3. Stator cooling water flow and temperature.
4. H2 pressure.
5. H2 Purity.
6. Unit load
7. Stator water tank level and Makeup frequency.

1. Reduce generator MVAR loading.
2. Reduce generator load gradually till winding temperature rising trend reverse.
3. Increase stator cooling water flow.
4. Vent hydrogen cooler,
5. Fill hydrogen if pressure is low.
6. Purge the hydrogen if purity is low

7. Check thoroughly the reason behind the temperature rising and normalize the system as soon as
possible, if necessary take shutdown of the unit.
43. Water/Oil Detected in Generator Casing
Likely Causes:
1. DPR malfunctioning and maintaining high DP.
2. Defective seal component and oil entering generator casing.
3. H2 dryer not working properly.
Plant Response:
1. LLD level High alarm.
2. Liquid traces in Local LLD gauges
1. LLD level
2. MOT level.
3. Seal oil pressure at generator end.
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4. Hydrogen gas pressure and purity.

5. Seal oil/H2 DP.
6. Float oil tank level.

1. Open LLD drains and empty it and see whether oil or water is coming.
2. Check the quantity and frequency
3. After draining normalized and wait for further liquid level sensing.
4. If oil is coming check seal oil/ hydrogen DP is normal or not.
5. If oil is because of DPR malfunctioning get it attended.
6. Reduce H2/seal oil DP, if it is maintain high.
7. If liquid from drain is continuous plan for unit shut down.
8. Take extra care while Purging the Hydrogen from Generator (maintain float oil tank level).

1. Find out the reason for liquid entry in casing and rectify it.
44. Cooling Tower Fan Tripped

Likely Causes:
1. Protection malfunctioning.
2. Motor protection.
3. CT MCC power supply failure and tie not closed.
Plant Response:
1. Condenser inlet water temperature increases.
2. If more than 2 fans tripped than condenser inlet water temperature increases fast and so vacuum
drops.
1. Condenser inlet water temperature.
3. Unit load.

1. Start Standby CT fan if available.
2. Moderate CW makeup and hot blow down as per condenser inlet water temperature.
3. Reduce unit load if vacuum dropping fast.
4. Check physical status of tripped fan.
5. If CT MCC trips, close tie after checking the reason.
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1. Maintaining proper oil levels in CT fan Gearbox.
2. Isolate the tripped fan and made it available as soon as possible.
3. If CT MCC power supply failed occurs and tie not closing in auto then rectify the problem with
coordination of EMD.
45. Fore-Bay Level Dropping Fast

Likely Causes:
1. Blow down valve opened to full suddenly.
2. Level transmitter faulty.
3. CT makeup valve problem. (not opening)
4. Any other unit make up valve in full open condition.
5. CT makeup pump problem (electrical or mechanical)
6. Make up line heavy leakage.
7. CT basin to forebay gate close or screen chocked.
Plant Response:
1. CW duct pressure may drop if fore bay level go to lower limit.
2. CW pumps vibration will increase.
3. CW pump motor current reduces.
4. CW pump trip on low level.
1. CT makeup valve status.
2. CT makeup pump.
3. Forebay level.

1. Closing the blow down valves to minimum position.
2. If level goes low, reduce load and stop one CW pump.
3. Ensure the opening of CT makeup valve and start CT makeup pump.
4. If CT basin to forebay, screen is chock clear it.
5. Check CT basin to forebay isolation gate, if close opens it.
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1. Once fore-bay level come backs to normal (>295.85mm) start raising load.
2. If the problem exists in system then isolate the auxiliary and make it ready after maintenance.
46. Water Hammer of Steam Turbine

Likely Causes:
1. Sharp decrease of main steam and reheat temperature reaching to saturation temperature.
2. Improper control of drum water level or abnormity of feed water pump causing full of water in the
drum.
3. Feed water heaters level rises up and extraction does not cut in auto.
4. HP bypass attemperation stop and control valve passing.
5. The steam turbine proper or all relevant steam pipe is poorly drained under low load.
6. The shaft seal system is poorly drained, the accumulated water or drain water enters the steam
turbine.
7. The unit load suddenly changes or the steam of low temperature enters the steam turbine.
Plant Response:
1. Main steam and reheat temperature decreases sharply.
2. Water hammer sound and vibration in main and reheat pipe, extraction pipe, bypass piping.
3. Differential expansion and axial displacement have obvious changes or the rotor axial shifts, thrust
pad temperature and oil return temperature rises.
4. The temperature difference of turbine upper and lower cylinder increases.
5. The unit vibration increases and there may be severe vibration.
1. MS and RH temperature.
2. Turbine vibration
3. Thrust bearing temperature.
4. Differential expansion
5. Axial shift.

1. Cut off the relevant steam and water source, intensify the water drain of main and reheat steam
pipe, proper extraction steam pipe and shaft sealed steam mains and relevant systems in case of
steam turbine water hammer.
2. Isolate the feed water heaters and deaerator and open emergency drain to drain extraction line if
hammer caused by water overfeed.
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3. Hand tight HP bypass attemperation stop valve.

4. Adjust the water level of drum boiler and the main and reheat steam temperature to normal.
5. Break the vacuum and shut down for emergency when water hammer is confirmed.

1. Closely monitor the temperature of thrust pad, oil return temperature, axial displacement, the
temperature difference of upper and lower cylinder, cylinder expansion of all cylinders and unit
vibration condition, etc. during shutdown.
2. Correctly record the idling time and shaft bending value and listen carefully to the sound inside the
machine to confirm if the unit can start up again.
3. Report to the related leaders if the idling time is significantly shortened, the value of axial
displacement, thrust pad temperature, shaft bending overruns or there are abnormal sounds inside
the machine to determine if it is necessary to check by uncovering the cylinder.
4. Pay special attention that if the turning current has abnormal increase or change when the turning is
put into operation and forced turning is strictly prohibited.
5. Continuous turning must last more than 24 hrs. after emergency shutdown due to steam turbine
water hammer and start up only when the control parameters such as eccentricity and cylinder
temperature difference, etc. are normal.
47. Breakage of Steam Turbine Blade

Likely Causes:
1. Material defect.
2. High hot well level
3. Turbine over speed.
4. Poor steam quality.
5. Poor steam parameter.
Plant Response:
1. There is metal impact sound inside the cylinder.
2. The unit vibrates severely.
3. The axial displacement and differential expansion changes abnormally, the thrust pad temperature
and oil return temperature increases
4. Steam extraction pressure changes abnormally.
5. In terms of LP cylinder blade breaking, the broken blade may go into the condenser and break the
tube, which will increase the conductivity and hardness of condensate and abnormality increases.
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1. Water and steam quality.
2. Turbine vibration
3. Thrust bearing temperature.
4. Differential expansion
5. Axial shift.
6. Oil return temperature.
7. Heater and hot well level.
8. Turbine speed.
9. Steam temperature.
1. Shut down for emergency when the blade breaking and severe vibration of unit are confirmed.
2. Analyze and find out the causes immediately if there are obvious changes of the pressure on the
monitored section during normal operation of unit, and if the load decreases, temperature of
thrust pad increases and there is large axial displacement, etc. at the same time, please apply for
shutdown for treatment immediately.
3. If it is the breakage of final stage blade of LP turbine, causing the condenser tube leakage
resulting in increase of condensate hardness. If the water quality exceeds the standards, shut down
for emergency and pay attention to steam quality.
4. Maintain the normal water level by discharging water from the outlet valve of LP#4 heater when the
condenser water level increase
Precaution to prevent blade damage:
1. Keep the operation of unit within the allowable cycle range.
2. Keep the unit steam parameters normal.
3. Ensure the normal operation of heater and deaerator and keep the relevant water drain smooth.
4. Keep the normal output of unit and strictly prohibit overrun.
5. Strengthen the monitoring of steam water quality and prevent deposit and corrosion of blade.
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48. Reverse Rotation of BFP

Likely Causes:
1. In stop condition if discharge valve and booster pump suction valve open and discharge NRV passing
(other BFP running)
2. In stop condition if reheater spray MOV open and NRV passing (other BFP running).
Plant Response:
1. The bearing vibration is large.
2. The axial displacement increases at reverse direction.
3. The booster pump outlet pressure is high.
4. The deaerator pressure and water level rises.
1. Deaerator pressure
2. Deaerator level
3. BFP rpm
4. BFP suction and discharge pressure.
5. BFP bearing vibration.

1. Close its outlet motor-operated valve immediately when the pump is found in reverse rotation,
and close the outlet motor-operated valve manually if the valve is jammed or powers off.
2. The inlet motor-operated valve of booster pump of reverse rotation pump cannot be closed.
3. Close the inlet main feed water motor-operated valve of economizer, close the outlet motor-
operated valve of HP heater and stop filling water to the boiler.
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ELECTRICAL SYSTEM - EMERGENCIES
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1. Power Supply Failure on Emergency MCC
Likely Causes:
1. Unit service transformer tripping and DG or stand by DG set not started on auto.
2. Bus fault on boiler/turbine PMCC and DG or stand by DG set not started on auto
3. Emergency MCC bus fault.
4. Fault on any outgoing feeder which extended up to main incomer of emergency MCC.
Plant Response:
1. If power supply fails on EMCC then incomer#1will open EMCC incomer#2 will close automatically.
2. Power supply of EPMCC fail than the unit UPS standby, boiler valve cabinet, Turbine valve cabinet,
AOP, JOP#A/B, SOP#A/B supply will interrupt. (important auxiliaries on EPMCC section are
ID/FD/PA Fan, lube oil supply power, APH#A/B aux motor power)
3. If power supply fails on incomer#2 then main DG will start automatically, if standby DG will not get
started.
1. EMPCC bus voltage.
2. 220 V DCDB voltage and battery voltage of respective section.
3. UPS battery voltage of respective section.
4. Switchyard ACDB voltage and battery voltage of respective section.

1. Ensure the cause of failure of power on EPMCC and failure of DG /Stand by DG.
2. If there is no bus fault on EPMCC then start DG /stand by DG manually.

1. Normalize the supply to EPMCC after rectifying the problem through unit PMCC.
2. Stop the DG set/Stand by DG set and put it on auto mode.
3. Restore UPS supply.
4. Ensure system healthiness.
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2. DG not Started in Auto

Likely Causes:
1. DG in manual mode.
2. Emergency push button operated at DG AMF panel or DG relay.
3. Fuel level is not sufficient.
4. Fuel tank outlet valve or DG inlet/outlet valve are in closed condition.
5. DG control supply failed (from DCDB BUS).
6. Low battery voltage.
7. DG set governor operation is sluggish or jam.
8. DG set protection is already in acted condition.
Plant Response:
1. EMCC charge through standby DG set running.
2. If standby DG set also fails to start, no power at emergency MCC.
3. DC drives will run.
1. Ensure DC emergency drives of Turbine and Boiler are running.
2. Monitor bus voltage of DCDB.
3. Ready to run manually turbine barring gear and APH auxiliary motor.
1. Keep DC drives in service till DG set restore.
2. During both DGs are not started in AUTO, start DG set from local and charge EMCC through 3ZK.
3. DG breaker will close at 415V (approx.), if not, close manually.
4. If EMCC#A/B voltages are healthy, starts AC drives and stop DC drives.
5. Monitor fuel level of DG tank, If require fill main tank.
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1. If unit service transformer is available changeover the load on unit service transformer from DG
set.
3. Station Transformer Failure

Likely Causes:
1. Tripping of 400 kV bus.
2. Tripping of transformer due to internal fault.
3. Tripping of transformer due to fault on 400 or 6.6 kV bus.
Plant Response:
1. 400 kV bus side breakers, 6.6 kV bus incomer will open & tie breaker charged thru FBTS.
2. If station 6.6 kV bus incomer trip on bus fault, then FBTS changeover will be blocked.
3. Respective PCC incomer of station PCC, DM water PCC incomer breaker will open.
4. Coal handling plant incomer will open.
5. Auxiliaries running on above PCC will trip.
6. Auxiliaries running on downstream side MCC of above mentioned PCC like station UPS bypass
supply, service water pump, DM transfer pump, control room AHU, raw water pump, cooling water
pump of VAM/chiller plant, H2 plant, HFO supply pump, IA & SA compressor control supply, mill
reject HP & LP water pump, chemical dozing pump & CHP belt conveyor will trip.
1. Station 6.6 kV/415V PCC/415V MCC bus voltage.
2. Service water header pressure.
3. Instrument air and service air header pressure.
4. Coal bunker level.
5. CST level.
6. If BFP#C is in service then feed water flow.
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1. Check the cause of tripping of station transformer if fault is not on 6.6 kV bus then closing 400 kV
breaker of ST.
2. Ensure stand by auxiliaries of tripped auxiliaries come in to service in auto else start it manually.
3. Normalize all disturbed system.

1. If station transformer tripped due to 400 kV bus side fault charge it as soon as 400 kV bus is charged.
2. Check the cause of tripping if there is internal fault (relay analysis & fault recorder).
3. Charge the station transformer after rectifying the fault.
4. Close the 400 kV breaker of ST.
5. Change load from UAT to Station Transformer.
6. Charge all the PCC from its incomer.
7. Charge all the MCC from its incomer.
8. Check voltage level of whole system and ensure system healthiness.
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4. UPS Failure
Likely Causes:
1. UPS source failure.
2. Rectifier failure and reserve supply not available or reserve switch OFF condition also battery switch
is in OFF condition.
3. Battery voltage goes down then inverter trips and reserve supply not available or reserve switch OFF
condition.
4. Frequency variation between UPS frequency and reserve supply frequency.
5. UPS protection acted condition.
Plant Response:
1. Unit may trip.
2. UPS power to DCS protection not available.
3. Plant parameter readings will go bad.
4. DCS computers may fail.
1. UPS bus voltage, battery current, healthiness of incoming source supply and alarm on UPS panel.

1. Check 415 V supply of UPS from EMPCC and reserve source from unit PMCC.
2. In emergency condition, check availability of DG.
3. Check switches of rectifier, battery and reserve are in ON condition.
4. If UPS tripped due to any reason and not started, shut down completely according below Steps :
a. Switch OFF reserve switch
b. Switch OFF inverter
c. Switch OFF battery
d. Switch OFF rectifier and wait for discharge bus voltage
Normalize by:
a. Switch ON reserve
b. Switch ON rectifier and wait approximate 30 sec to build up DC voltage
c. Switch ON battery
d. Switch ON inverter

1. Rectify the UPS failure causes and normalize the UPS.
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5. DCDB Failure
Likely Causes:
1. Incomer at unit PMCC trips and battery backup source fails.
2. Battery backup source is in service and its voltage becomes low.
3. Electrical fault on DC bus.
4. Electrical fault on outgoing feeder which extended up to bus/ incomer.
Plant response:
1. Incomer at unit PMCC will trip if fault occurs on bus.
2. Remote operation of electrical drives will not possible.
3. Unavailability of DC emergency drives.
4. Protection relay of generator/GT/UAT/ST/6.6 kV bus/415V PCC will not act.
1. DC bus voltage.
2. Battery set voltage.

1. Check the actual cause of DCDB failure i.e. fault is at incomer side or at bus side.
2. If there is not any fault on bus side then parallel it with healthy bus.
3. Check the bus voltage and battery voltage and ensure it is in normal range.

1. After rectifying fault normalizes the system i.e. charge the bus from unit PMCC incomer, open the
bus coupler switch and battery set is in charging mode.
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6. DC fails of Motor Feeder

Likely Causes:
1. DCDB fails.
2. Switchgear main DC SFU is in OFF condition.
3. DC MCB of motor feeder is OFF condition.
Plant Response:
1. Bad feedback comes on DCS of Motor.
2. Motor ON/OFF command not possible from DCS.
3. Motor ON/OFF command possible only through Breaker.
4. Motor electric protection bypass.
1. Flow/pressure/vibration/temperature of motor.
2. Bus voltage.

1. If motor temperature is high or motor is taking high current immediate stop motor from breaker.
2. Check Bus voltage of DCDB.
3. Check DC source in 415V switchgear BUS.
4. Check DC source in motor panel.

1. Rectify the DC failure causes of motor feeder and normalize the motor feeder.
7. Fast Bus Transfer Blocked

Likely Causes:
1. Fast bus transfer relay will not in service.
2. Fast bus transfer will in block condition due to following reasons,
• Protection will be acted in GT/UAT protection panel.
• Bus PT of station switchgear is in racked out condition/fuse not healthy.
• Bus PT of unit switchgear is in racked out condition/fuse not healthy.
• Line PT of unit switchgear incomer is in racked out condition/fuse not healthy.
• Unit switchgear incomer breaker/ unit switchgear tie breaker (Tie to station switchgear)/station
switchgear tie breaker (tie to unit switchgear) DC OFF.
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• Unit switchgear incomer breaker/ unit switchgear tie breaker (tie to station switchgear)/station
switchgear tie breaker (tie to unit switchgear) is in TEST MODE.
• Unit switchgear incomer breaker/ unit switchgear tie breaker (tie to station switchgear)/station
switchgear tie breaker (tie to unit switchgear) is in LOCAL MODE.
• Unit switchgear incomer breaker/unit switchgear tie breaker (tie to station switchgear)/station
switchgear tie breaker (tie to unit switchgear) LOCK OUT RELAY OPERATED in Breaker.
• Station switchgear tie breaker (tie to unit switchgear) is open condition.
3. Fast bus transfer relay control supply OFF condition (DCDB BUS#A).
4. Fast bus transfer relay is in MANUAL MODE.
5. Voltage difference between station and unit switchgear bus.
6. Difference in phase angle between station and unit switchgear bus.
Plant Response:
1. No permissive for bus transfer in FBT relay.
2. Transfer blocked in FBT Relay.
3. Bus transfer not possible (unit to station/station to unit).
1. 6.6 KV bus voltage of unit switchgear.
2. 6.6 KV bus voltage of station switchgear.
3. Unit blackout.

1. Check FBT relay.
2. Check breaker healthy condition i.e. NO lockout operated/breaker in service/breaker in remote/DC
healthy.
3. Check source of FBT relay (DCDB BUS).
4. Maintain equal bus voltage of station switchgear and unit switchgear.

1. Rectify the FBT failure causes and normalize the FBT.
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8. Flash Over
Likely Causes:
1. Flash over due to loose contacts at joints or clamps of bus bar, isolator, and breaker, CT, PT or CVT.
2. Due to heavy wind or stormy condition.
3. Due to accumulation of dust and moisture particle at string and support insulator.
4. Due to misalignment of isolator moving contact.
5. Due to breakdown of live conductor which falls on another live part.
6. Over loading.
7. Due to high oil temperature in case of oil immersed CB/CT/PT/CVT used.
8. CT failure due to opening of secondary coil or mfg. defects.
Plant Response:
1. Tripping of concern section/line/unit/bus bar.
2. Damage occurred to men and equipment due to flashover.
1. Bus voltage.
2. Line loading.

1. Isolate affected section as early as possible.
2. Inform to control room about flash over and any line tripping.
3. Inform to fire station if any fire takes place due to flash over.

1. Charge the tripped section or lines after isolating damaged section.
2. After replacing the damaged part /equipment charge it again.
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9. Gas Pressure Low of Circuit Breaker
Likely Causes:
1. Gasket of circuit breaker is damaged.
Plant Response:
1. At 0.65 MPa gas pressure low alarm will come.
2. At 0.60 MPa gas pressure breaker will lockout.
1. Breaker operating gas pressure.
2. Breaker operation will not possible if lockout occurs.

1. Inform to control room and maintenance dept. To fill gas.
2. If pressure is not maintaining after filling gas then arrange shutdown of breaker to attend leakage.

1. After rectifying the leakage charge the respective dia. and breaker.
2. Monitor gas pressure at regular interval.
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10. Fire in Cable Gallery

Likely Causes:
1. External fire spreading into cable gallery.
2. Overheating or insulation failure of any cable which results into flashover.
3. Fire due to any hot job work in cable gallery.
4. Due to high temperature steam/fluid leakage around cable gallery.
Plant Response:
1. Many auxiliaries will trip if fire is severe.
2. Fire inert gas system charged on auto.
1. Parameter of affected system.
2. 6.6 kV/415V bus voltage.

1. Isolate the power supply immediately.
2. Try to extinguish fire if it is in early Stage.
3. Inform to fire Station and main control room immediately.
4. Isolate the boiler and turbine lift power supply so nobody can use it.

1. If fire is severe safely shutdown the unit.
2. After replacing damaged cable charge the bus/auxiliaries.
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11. Hot Spot

Likely Causes:
1. Loose contacts at joints or clamps of bus bar, isolator, breaker, CT, PT or CVT.
2. Overloading of bus bar, line, isolator or breaker.
Plant Response:
1. Temperature remains high at hot spot winding temp.
1. Temperature at hot spot. It should less than 70 deg. C.
2. Loading of respective line/bus bar/auxiliary.

1. Inform to switchyard maintenance and main control room about hot spot.
2. Check the temperature with temperature Scanner.
3. As per requirement of maintenance dept. Isolate that section to attend hot spot.

1. After attending the hot spot charge that section again.
2. Observe temperature regularly at that point.
12. High Oil/Winding Temperature of Transformer
Likely Causes:
1. Low oil level in conservator tank.
2. Short circuit or inter turn fault of winding.
3. High atmospheric temperature.
4. Malfunction of temperature detector switch.
Plant Response:
1. Winding temperature high alarm at 950 C and tripping at 105 0C.
2. Oil temperature High alarm at 850 C and tripping at 95 0 C.
1. Bus voltage.
2. Line voltage.
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1. Ensure that oil level is normal in conservator tank and no oil leakage from tank or reactor body.
2. Inform to control room and maintenance Staff about high winding /oil temp.
3. Isolate the reactor according to condition if temperature Continues remains on higher side for further
investigation.

1. After rectifying the fault charge the reactor again.
2. Observe winding and oil temperature regularly.
13. Oil Leakage in Transformer CB/CT/PT

Likely Causes:
1. Gasket of circuit breaker is damaged.
2. Damage to equipment due to improper handling.
Plant Response:
1. Transformer winding and oil temperature remains high if oil level goes low.
2. Overheating of CT / PT / transformer core and winding.
1. Transformer winding temperature high alarm will comes at High alarm at 950 C and tripping at 1100 C.
2. Transformer oil temperature High alarm will comes at 850 C and tripping at 95 0C.
3. Feedback from CT/PT will interrupt or goes bad in case of winding damage.

1. Inform to maintenance dept. and main control room about oil leakage.
2. If oil level goes below normal level shutdown the equipment to attend leakage.

1. Charge the equipment after attends leakage.
2. Observe oil level at regular interval.
3. Observe winding temperature and oil temperature.
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14. Transformer Tripped

Likely Causes:
1. Tripping due to bus bar fault.
2. Tripping due to transformer electrical protection operated.
3. Tripping due to high winding temperature.
4. Tripping due to high oil temperature.
5. Tripping due to buchholz relay operation.
6. Malfunction of any of above relay.
Plant Response:
1. Bus voltage will increase.
1. Bus voltage.
2. Line voltage.
3. Generator MVAR.
1. If bus voltage and line voltage is above limit and loading of two parallel line is low then trip one line.
2. Check the cause of tripping.
1. Charge the transformer after rectifying the fault.
2. Charge the outgoing line if it is tripped earlier.
15. SCADA Not Responding

Likely Causes:
1. UPS failure.
2. Software/hardware side problem at engineering station.
Plant Response:
1. Process status will not available.
2. Remote operation will not possible.
3. Switch yard status will not updated in main control room DCS also.
1. Plant running parameter feedback will not update.
2. CB/isolator/earth switch status will not update.
Page 125 of 126

Shaping the future
01 13.03.2020 00 02

1. Check the ups healthiness.
2. If UPS failure changeover to bypass source.
3. If UPS is not healthy than inform maintenance dept. To check for hardware/software problem.
4. If any emergency operation required, do it locally.
5. Check the system status locally and ensure no abnormality, inform to control room if any.

1. After rectifying UPS side problem charge it as per SOP.
2. After rectifying software/hardware side problem restart the SCADA.
3. Ensure system status and it works normally.
Page 126 of 126

Emergency Operating Procedure

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Emergency Operating Procedure

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TRN TRN Energy Pvt. Ltd.

Prepared By: - Approved By:-

TRN TRN Energy Pvt. Ltd. TRNEPL/

S. No System Descriptions Page. No

1 Station Blackout 1-4

3 Instrument Air Failure 6-8

4 Automatic Load Shedding (Run Back) 9

5 Hammering In Pipe Line 10-11

7 FLUE Gas One Path Isolation Procedure (Isolated) 13

Boiler & Auxiliaries Emergencies

Sl. No System Descriptions Page. No

Sl. No System Descriptions Page. No

Turbine & Auxiliaries Emergencies

Sl. No. System Descriptions Page. No

Sl. No. System Descriptions Page. No

1. Close MS stop valves after restoration of DG power

1. Check the healthiness of battery chargers. (Main plant)

Action if DG fails or Emergency PMCC under Fault:

1. Turbine DC EOP will be in service. Manual barring to be done.

Readiness for Blackout:

1. Daily trial of turbine DC EOP.

If boiler has survived:

Immediate checks if boiler also trips along with TG:

3. Instrument Air Failure

CVs & its Condition during Air Failure:

Expected Operator’s Action:

4. Automatic Load Shedding (Run Back) – Future Reference

Expected Operator’s Action:

When RB automation succeeds;

When RB automation does not succeeds;

5. Hammering In Pipe Line

1. Thermal shock to piping system.

Expected Operator’s Action:

1. Cut off steam supply.

Final Corrective Actions:

Fire extinguishing methods, equipment used and precautions:

7. Flue Gas One Path Isolation Procedure

Expected Operator’s Action for path B isolation

BOILER AND AUXILARIES -

1. Tripped fan blade pitch & discharge damper closes.

1. Blade pitch & discharge damper closure for tripped fan.

Expected Operator’s Action:

Final Corrective Actions:

1. Find root cause of fan tripping.

1. Corresponding APH trip. (Delay 01 sec).

1. Oxygen in flue gas at APH inlet.

Expected Operator’s Action:

1. Trip one top mill immediately, if runback is not active.

Final Corrective Actions:

1. Ensure lube oil tank level is healthy.

Expected Operator’s Action:

Final Corrective Actions:

4. Surge/Stall of PA & ID Fan

Expected Operator’s Action:

Expected Operator’s Action:

Final Corrective Actions:

1. Follow up for causes to maintenance department.

6. AC Scanner Fan Tripped & DC Fan Fail to Pickup

Final Corrective Actions:

7. Mill Seal Air Pressure Loss

Expected Operator’s Action:

Final Corrective Actions:

1. Fan change over as per change over schedule.