Power Plant Emergencies

 Boiler Emergencies
 Turbine Emergencies
 Other Emergencies

BOILER EMERGENCIES
 Drum level low
 Drum level high
 Any FD fan trip
 Any ID fan trip
 DCF trip
 Bed temperature too high
 Final Steam temperature too high
 Final Steam temperature too low
 PSH O/L steam temperature high
 Economizer O/L FW temperature high
 High positive draught
 High negative draught
 O/L steam pressure too low
Drum Level Low
 Check BFP discharge header pr. and start another BFP if required
 Check FW control valves position in DCS and in field
 Check position of all MOVs and operate them accordingly.
 Check for any abnormal sound from furnace.

Drum Level High

 Operate IBD as per requirement.
 Check FW control valves position in DCS and in field.
 Close MOVs of Feed Water station as per requirement.
 Observe PSH O/L steam temperatures.
 Observe Final steam temperature and if it starts dropping, close Boiler stop valve
immediately.

Any FD fan trip

 Slump two compartments
 Load the other FD fan
 Reduce load on Turbine according to requirement
 Observe Bed temperature
 Check for reason of tripping
 If the situation diminishes further shut the Boiler stop valve.
 Take compartments into service one by one and load the turbine .

Any ID fan trip

 Cut down air flow by operating FD dampers.
 Slump two compartments.
 Check the load on running fan.
 Reduce load on turbine according to requirement.
 Check for reason of fan tripping.
 Take compartments into service one by one and load the turbine
DCF trip
 Check PA header pr. If it is less increase it.
 Increase feeding in other compartments or boiler.
 Check for reason of DCF tripping.
 In case of all DCF tripping, isolate boiler depending on situation.
 In case of any one DCF tripping, observe final steam pr. And temperature and
if require isolate attemparator.
 Take burner support according to requirement.
 If the problem persists for longer time and pressure drops, reduce load on
turbine.

Bed temperature too high

 Cut down coal feeding to that compartment.
 Increase air flow and PA header pr.
 Check for wind box damper position.
 Constantly observe the wind box pr.
 Charge bed material.
 Check for abnormal sound from furnace.
 Stop the boiler if temperatures still not controlled, bed height decreases rapidly
and abnormal sound is observed.

Final Steam temperature too high

 Take attemparator by – pass into service.
 Reduce feeding in 3rd, 4th compartments.
 Observe the TG inlet steam temperature.
 Reduce the steam temperature in other boiler.
 Check attemparator control valve position in DCS and in field.
 Start stand-by BFP if attemperator flow is less
Final Steam temperature too low
 Isolate attemparator and check for passing/opening of attemparator by – pass.
 Checks drum level.
 Observe constantly the TG inlet steam temperature.
 Increase steam temperature in other boiler.
 Increase feeding in 3rd, 4th compartments.
 If the rate of drop is higher, isolate the boiler immediately

PSH O/L steam temperature high

 Increase load on boiler.
 Minimize furnace draught.
 Check the position of overfeed secondary air dampers and open them.
 Regulate air flow according to requirement.
 Increase bed height.
 Meanwhile confirm that the temperature indication is correct.(Attemperator flow
will increase)

Economizer O/L FW temperature high

 Increase load on boiler.
 Reduce Economizer I/L feed water temperature.
 Minimize furnace draught.
 Check the position of overfeed secondary air dampers and open them.
 Regulate air flow according to requirement.
 Increase bed height.
 Meanwhile confirm that the temperature indication is correct

High positive draught

 Confirm that the draught indication is correct.
 Check and control ID fan speed.
 Check ID dampers position.
 Check FD dampers position.
 Check for abnormal sound from furnace.
High negative draught
 Confirm that the draught indication is correct.
 Check and control ID fan speed.
 Check wind box dampers position.
 Check ID dampers position.
 Check FD dampers position.
 Check APH online and by – pass dampers position

O/L steam pressure too low

 Check bed temperatures and increase coal feeding accordingly.
 Check for jamming of coal hopper, PA lines and clear them accordingly.
 Take burner support if required.
 Ensure that DCF chain is rotating (no shear pin failure).
 Ensure that air flow is sufficient.
 Drain bed material slowly, if bed height is more. Check for passing or
malfunctioning of Boiler safety valves.
 Check for abnormal sound from furnace.
 Check for malfunctioning of Dumping control valve and PRDS control v/v.
 Check and increase the feed water temperature.
 If pressure goes down further and frequency drops, reduce load on turbine.
TURBINE EMERGENCIES
 Turbine trip
 Load throw off
 UAT trip
 CEP trip
 Hotwell level high
 Hotwell level low
 Vacuum drop
 Fire/smoke at turbine area
 Turning gear trip
 Oil temperature high
 Bearing temperature high
 Bearing vibration high
 Steam pressure high after first stage

Turbine trip (sharing mode)

 Safeguard the running unit (Reduce load on turbine if required and Ensure that
CWP, BFP, ACWP, ACC Fan, Inst.air compressor are running)
 Cut down proportionate coal feeding in boilers.
 Observe boiler drum level and take steps accordingly.
 Control steam pressure by operating PRDS and dumping control valves.
 Start AOP, JOP, TTG.
 Investigate the reason of tripping.
 Don’t switch on PEF until unless it is reset and load shedding is switched – off.
Turbine trip (Non – sharing mode)
 Safeguard the running unit (Reduce load on turbine if required and Ensure that
CWP, BFP, ACWP, ACC Fan, Inst.air compressor are running)
 Take grid supply after ensuring Generator breaker has opened.
 Observe boiler drum level and take steps accordingly.
 Control steam pressure by operating PRDS and dumping control valves.
 Ensure that extraction MOV is closed. Start AOP, JOP, TTG.
 Investigate the reason of tripping.
 Don’t switch on PEF until unless it is reset and load shedding is switched – off.
 Maintain hot well level and ensure that CEP is running

Load throw – off

 Check turbine speed, if it is at alarming level and is increasing further, trip the
turbine.
 Observe drum level.
 Slump compartments in boiler according to the amount of load thrown off.
 Take PRDS into service if both extractions are out of service.
 Regulate dumping steam according to dumping header temperature and
condenser vacuum.
 Check for reason of load throw – off.
 If the load throws – off occurs because of any breaker opening, check
thoroughly before closing it.

UAT trip
 Observe the hotwell level and condenser vacuum and if the power is not
resumed within short time, trip the turbine and isolate all steam inputs to
condenser.
 Reduce load on running turbine if required.
 Observe ACW and turbine oil temperatures.
 Check for reason of UAT tripping and charge all remaining feeders/MCC
keeping the faulty feeder/MCC isolated.
CEP trip
 Ensure that standby pump has taken over.
 Check for reason of tripping.
 Check hotwell level and if it is low, take make – up water into hotwell.
 Open hotwell re-circulation valve fully.
 Check for passing of condensate valve B or C and isolate them accordingly.
 If the tripping is because of overload, check for mechanical jamming of pump.

Hotwell level high

 Ensure that standby pump has taken over.
 Check running CEP load.
 Close hotwell circulation valve.

Hotwell level low

 Take make up water into hotwell.
 Open hotwell circulation valve fully.

Vacuum drop
 Check gland steam pressure.
 Check CW temperatures.
 Check hotwell level.
 Check the running ejector.
 Check for air ingress from all vacuum related lines and valves.
 Cut down dumping steam.
 Charge standby ejector if the rate of drop is more.
 If the rate of drop is more, reduce load on turbine.
Fire/smoke at turbine area
 Ensure that vapour extraction fan is running if the fire is because of oil leakage
from any bearing.
 Use CO2 fire extinguisher in case of minor oil and electrical fires. Don’t use
water or other type of fire extinguishers.
 In case of major fire, first isolate the source (trip the turbine and isolate
generator from electrical circuit) and then quench it.

Turning gear trip

 Ensure that jacking oil pressure is sufficient.
 Ensure that lube oil pressure is sufficient.
 Put turbine on manual barring gear.
 Check for reason of turning gear trip.

Oil temperature high

 Ensure that the CW temperatures are not on higher side (All CT fans are
running).
 Stop TOPP if it is running.
 Check oil level in Main oil tank.
 Provide external cooling arrangement.
 Ensure that oil temperature controller is working.
 If the bearing temperatures start increasing, trip the turbine immediately and
provide external cooling arrangement for bearings.

Bearing temperature high

 Charges bleed steam.
 Check oil temperature.
 Check oil level in Main oil tank.
 Ensure proper oil flow to the bearing.
 Check axial shift.
 Provide external cooling arrangement.
 Reduce load on turbine if temperatures goes on raising.
Bearing vibration high
 Confirm that the signal is correct and is matching with Bentley-Nevada
vibration monitoring system.
 Confirm the same in field physically.
 Ensure proper oil flow to the bearing.
 Check casing temperature difference.
 Reduce load on turbine if vibration goes on raising.

Steam pressure high after first stage

 Reduce load on turbine if pressure is at alarming level.
 Reduce bleed steam.
 Check control valve position and turbine speed.
Other emergencies
 BFP trip
 CWP trip
 Inst. Air compressor trip

BFP trip/Discharge header pr. low

 Ensure that standby pump has taken over.
 Monitors drum level (Increase dumping CV opening, if drum level starts
dropping).
 Reduce load on TG.
 Investigate the reason for tripping.
 If both the BFP tripped and standby has not taken over because of any
common problem, trip both TG and box – up the boiler.

CWP trip/ Discharge header pr. low

 Ensure that standby pump has taken over.
 Monitor condenser vacuum.
 Reduce load on TG.
 Cut down dumping.
 Investigate the reason for tripping.
 If both the CWP tripped and standby has not taken over because of any
common problem, trip both TG and isolate all steam inputs to the condenser.

Inst. Air compressor trip/Inst. Air pr. low

 Ensure that standby compressor has taken over.
 Check conserver O/L air pr.
 Monitor boiler drum level, furnace draft, CWP discharge header pr., FD control
dampers position constantly.
 Ensure that running compressor is fully loaded.
 Check for choking of dryer filters.
 Ensure that both dryers power supply is ON.
 Check for leakages in the system.