RIHAND

C&I DEPARTMENT
WELCOMES
YOU

Prepared/Presented By:
T. K. Seal
 HEAD
C&I MAINT.

DGM & SR. SUPDT. -1 SR. SUPDT. -2

SR. SUPDT.-3

SUPDT. SR. ENGR.

SR. ENGR. ENGR.
DY. SUPDT.
SR. ENGR. ENGR.
SR. ENGR.
SR. ENGR. A.E.
SR. ENGR.
SR. ENGR.
ENGR.
SR. ENGR ENGR.
ENGR.
A.E.
ENGR.
ENGR.
ENGR.
Sr. A.E./A.E.=5

WORKMEN 09 WORKMEN 05 WORKMEN 05

 C&I –O&M works distribution

MAIN BOILER MAIN DAS, UPS,

BMS,ACS,SADC TURBINE, ANALYTIC

ID,FD,PA FANS ATRS, TSI, AL

MILLS INSTS. GOV. SYST., INSTS.

FUEL OIL SYST. HPLP BYPASS HVAC,

AUX. BOILER, F/F DM PLANT C&I LAB
SYSTEMS, H2 PLANT, COMPRESS

MAINT, ADPH CW SYSTEM, ORS
CCR INSTS.
CHP, MGR,
SHIFT
C&I systems- areas

To look after PM, BD & OH jobs of C&I systems
through out plant areas

To take up various defects as raised by operation
through work orders, telephone, shift feedback etc.

To take up jobs for defects found during daily checks,
work down checks by C&I etc

To take up scheduled maintc. Job as specified by
MTP.

To take up various initiative to reduce force outage &
reduce partial loading ( CC OS group also put up
issues)

To take PIPs, QC, PC etc & safety awareness etc
C&I systems

To look after plant complete automation & control

To look after all measuring parameters like pressure,
temp, level, speed, load, motor current, flue gas
analyzers, SWAS, belt weigher, coal flow integrator,

To facilitate start/stop of plant activities from CCR
with visual indication for operation flexibility with
protection & interlock in-service.

To provide all CCR instruments LVS, OWS, Indication
of status of drives, valves, recorders, indication etc

To provide all data to operation for SOEs & Alarms,
trends, reports, logs, historical data retrieval etc
C&I systems

Interlock & Protection of boiler, turbine &
their auxiliaries, generator & all associated
system, HT/LT drives, electrical, pneumatic
valve, Hydraulic, solenoid valves, motorise
actuators etc

OFF site PLC like DM Plant, PTDM, PT
Chlorination plant, CPU, Raw water plant, AC
plants, compressors, mill reject system, Ash
slurry plants etc

Renovation & Modernization of C&I obsolete
systems/items
C&I systems- Budgeting &
Procurements

Budget approval & Procument of materials
including indenting by making complete
technical specifications, financial part of
procument, TC nomination, technical
comments & ordering.

Cash purchase of emergency items

Import through authorize agents

Committee purchase.

Purchase through imprest
C&I systems- maintenance

Regular maintenance like Preventive of
various fields systems like transmitters, RTD,
T/C, impulse lines, cables termination,
actuators, all signals like: analog & digital
I/O, processor configuration, HMI,SCADA etc

Overhauling maintc. Of C&I systems.

Brake down maintenance of equipments.
 C&I systems- fields

Field Actuators: pneumatic, hydraulic,
solenoid operated v/v, electrical actuators ,

Field materials: CU tube replacement, damaged
cable replacement , T/C, RTD, Transmitter
replacement etc.

Local controllers: pneumatic, level

Local: Temp. compensating boxes.

Local: transmitters, manifolds, isolating valves,
impulse lines etc

Local: Cable inspection & replacement
C&I others activity

To analyze the trip & subsequent effort
to minimise/eradicate the tripping
condition

To analyze the all alarms & trend etc &
ensure trip or partial loading does not
take place further.

To provide additional alarms , logs,
trend for betterment of operation.
TRIPPING Synchronization Duration REMARKS
Time Date TIME (hrs) (hrs) (PDF) Details (MS Word)
2008 07-05-2008 2:38 Drum Level Low Allahabad line 2 tripped, Prob arose in speed control in EHC & M/C
14:52 17:26 Low unloaded with TDBFPs. Unit tripped on drum level low.
2008 13-05-2008 Both FD Fans During ID fan change over miscommunication happened for bypassing logic
4:52 8:04 Tripped. which requred during change over. On starting 3rd ID fan unit tripped.
Fluctuation appeared in output voltage of BOP charger 2, and resulted
2008 13-05-2008 DPU Faullt / tripping of one stream of MCB in about 15 BOP panels. In CRE 05 panel
11:04 13:15 Charger failure both DPU stopped communicating and unit tripped on flame failure.
Water wall
circulation not
03.06.08 04-06-08 1.82
correct After synchronization from revival of BTL in RH, during ST to UT change
22:47 00:36 protection over Unit tipped due to ST bkr open feed back mechanism problem.
Stage I bunkering stopped due to problem in 48 V DC supply. Stage I units
load reduced to 85 MW (unit I) & 185 MW (unit 2). During low load
28.06.08 28.06.08 9.73
Partial Flame operation with only Mill D & oil guns, one out of 3 guns in EF elevation
08:25 18:08 Failure failed and unit tipped on partial flame failure.
08 23-07-08 32.03 Bottom Ring Hdr leakage. 4 C-corner manhole gasket leakage. All 4
23:19 07:21 Shut Down corners gaskets has been replaced.
08 10-09-08 Tripping of ID
17:28 19:33 Fans Tripping of ID Fans (Speed switch command went due to DDCMIS problem.
Loss of
08 30-09-08 Governor
18:45 21:38 channel 1& 2 Loss of Governor channel 1& 2
Unit tripped on Flame failure at 22:57 Hrs. big slabs of slag had fallen into
bottom-ash hopper causing heavy splashing of water in bottom ash hopper.
08 09-11-2008
Unit tripped on As a
22:57 02:09 Flame failure result, furnace got disturbed and boiler tripped on flame failure protection

BTL 2008-09

2007-08
INDEX
RIPPING Synchronization TIME Duration
DATE Time Date (hrs) (hrs) REMARKS Details
Apr-07 1:59 10-Apr-07 4:59 3:00 Furnace Pressure High
Unit 4 tripped on furnace pr High on 1-05-07. Big slab of slag fallen and found in right side of
May-07 2:13 1-May-07 11:19 9:05 Furnace Pressure High bottom ash.
Unit 2 tripped on Total Flame Failure on 6-5-07. AC Scanner purge air fan discharge
May-07 4:41 6-May-07 7:02 2:21 Total Flame failure damper closed and DC fan took start. Dust went to the scanners

May-07 21:21 30-May-07 22:43 1:22 D/A Level high

-07 9:06 4-Jul-07 12:45 3:39 24V DC supply failure Unit 4 tripped on 24 V DC Supply failure due to failure of SG / TG charger 1 on 04

Sep-07 1:24 4-Sep-07 2:56 1:32 Drum level high Unit 2 tripped on drum level High on Mill Change over on 04-09-07

Sep-07 3:39 23-Sep-07 4:21 0:42 Grid disturbance

Oct-07 21:43 15-Oct-07 22:00 0:17 Grid disturbance Unit 3 tripped during grid disturbances on flame failure on 15-Oct-07

Oct-07 22:03 22-Oct-07 3:01 4:58 Generator interturn fault Unit 4 tripped on Generator inter-turn fault protection on 21 Oct 2007

Oct-07 11:19 21-Oct-07 15:23 4:04 LBB Protection Unit 4 tripped on LBB protection operation in ALD1 line on 21-Oct-07
 Stage-I :SG

ID Protection:

Fan outboard & inboard oil pr low 2/3 logic

Fan coupling oil pr low 2/3 logic

Lub oil flow low 2/3 logic
# Lub oil flow data is not available (In remote)

FD Protection:

Motor outboard & inboard oil pr low 2/3 logic.

PA Protection:

Fan outboard & inboard oil pr low 2/3 logic

Lub oil flow low 2/3 logic

Motor inboard & outboard oil pr low 2/3 logic
# Lub oil flow data is not available.(In remote)
 Stage-I :SG

BCP Protection:

Motor cavity temp 1/1 logic

Cooling water flow 1/1 logic

BCP D/P 2/2 logic
# No space available for mounting flow switches
cavity temp: T/C 1 for ACS, 1 FOR DAS & 1 local
gauge: no additional T/C provision in there in motor cavity.
flow switch: 1 permissive, 1 trip & other alarm
In new DCS this will be tried to make 2/2
 Stage-I - SG & CW

Mill Protection:

Mill PA/seal air DP low 1/1 logic

PA flow low with mill in service 1/1 logic
As extra tapping point N/A

CW protection:

Pump brg flow 1/1 logic

Flushing water 1/1 logic

Flow, lub oil cooler flow 1/1 logic

Motor cooler flow low trip 1/1 logic
# No space available for mounting such flow switches

Reverse rotation 1/1 logic

Suction level 1/1 logic
# No space available for reverse rotation.

Suction level is immersion type ( position at -30 meter) level switch
( bestobell mobrey ). Alternate type to be tried.
 Stage-I : BFP

BFP Protection:

Gland seal flow 1/1 logic

Cooling water flow 1/1 logic
# No space for additional flow switch

Lub oil pr low 1/2 logic
# Lub oil protection require additional relays which will be made 2/3 in
new DCS sys.

D/A level switches 1/1 logic
# To be made 2/3 in new DCS

Lub oil temp 1/1 logic

Working oil temp 1/1 logic

Balance return line temp 1/1 logic
# OS & Engg. To suggest suitable alternative for the above
protections so that same can be implemented in the DAS R&M
works, being executed by CC Engg group.
Stage-I :BFP Gauge Rack
Stage-I :BFP LEC
 Stage-I :TG

TG Tripping :

Generator hydrogen gas temp high 2/2 logic

Stator water flow low 2/2 logic

FRF pr low 2/2 logic

Steam inlet pr low 2/2 logic

LP exh. Temp high 2/2 logic
# All logics are 2/2 with redundant trip channel.
# Os & engg. To suggest suitable alternative for the
above protections
# For all above protection cases ATRS/GOV R&M
being processed by CC R&M group
Stage-I :Control Desk
Stage-I :Governor Panel
Stage-I: Governor -Comp Ch (CC)
Stage-I :Interlock Panel
Stage-I : FRF Pr Low
 Field Instruments
SG & TG Stage-I:
Field devices trip switches supplied by OEM ,Delta
make- temp switch, pressure switch etc which are still
working even after 20 years of operation.
All transmitters : Rosemount/Emerson
SG & TG Stage-II:
Field devices trip switches mostly supplied by BHEL are
of PS: Switzer make, TS: Indfoss make except
furnace/PA header : SOR make.
All Pr /DP transmitters : Yokogawa.
 Problems of Field Instruments
SG & TG Stage-I: Nil.
SG & TG Stage-II:
TS: Indfoss make : set point : drifting problem
RTD: BFP thrust brg- sensor/cable cutting problem( quality to improve,
original RTD –M/s Weir make is very good).
Local TB & DCS- Push fit ( Wago) Terminals - getting loose. No screws are
provided ( in Electrical switch Gear push fit with screw tightening used).
Similar philosophy is used in St-I which are reliable.
Heat prone areas of SG & TG (Mill & Air heater) existing cable are getting
damaged. Steps taken
a) Layout of several location changed b) high temp cable being used

OS & Engg to look for using high temp armored cables in critical heat
prone location
Problems of Field Instruments
SG & TG Stage-II:
-Oxygen Probes – Flue gas O/L oxygen probes
getting eroded fast particularly in SAH A&B due
to duct design( failing within 3 months).
-T/C at same location also getting eroded
Step taken: extra shielding provided.
- Inferior quality sol. Should not be used in
important location: like Nucon, Avcon, Rotex.
 Problems & Strategies adopted
to Maintain DCS (H/W, S/W & Network)

Problems: Data back up for trends, events &
configuration

Strategies adopted: in every months trends & events &
configuration : in every two months which are saved in
different network PC & DVD back up

maxDNA trouble shooting chart prepared for easy
diagnosis ( enclosed).

Network security at Rihand enclosed

OFC failure, disables the functioning of remote I/O
panels of CW pp house. In this situation-

No protection will be in service & CW pp will continue to run.

Whether DPU to be provided at local?
# OS/Engg may look for the provision.
 Problems in DCS / PLC system
• Error in one port gets transmitted to all.
• CRE 18 & SBC panels always run in secondary,
problem could not be identified.
• maxDNA binary input having no open ckt
monitoring
• Electrical breaker commissioning prob before
commg of DCS.
• Availability of as-built logics print out at site in time.
• No provision of SOE for OFF site PLC.
• Integration of OFF site package( PLC) with main
DCS system
 C&I Tripping
• 2007-08 till date: one no.: U4 tripped on 24 volt
charger output over voltage ( Amara Raja).
• Action plan: PE Engg/ Amara Raja are working for
designing a suitable protection for charger
• 2006-07: 02 no. Y adapter & mother rack failure in
PA fan panel of U4 led to trip .
• Action plan: Redundant analog output module
jumper setting change from ‘fail-to-reset’ from ‘fail-
to-hold’ is possible.
Analog Control DPU communication loss with I/O
modules should not cause unit trip if corresponding
protection DPU is in service.
Think Today For Better Tomorrow

THANK YOU