DUTIES & RESPONSIBILITIES OF

SHIFT ENGINEERS
G.S.R.BHAVANI PRASAD
AE/BM-III/KTPS V STAGE
 UNIT CONTROL
BOARD

FSSS FEED WATER GENERATOR

 CHARGE TAKEN OVER (C.T.O)
Always listen and understand the charge delivered from
your relievers.
Observe all the alarms appeared on the alarm panel
 Verify and cross check the equipments ( Drives & their
lube oil system) as written in previous Log.
 Check whether the available equipment is in auto stand by
or not
B(BOILER)T(TURBINE)G(GENERATOR)
 FSSS PANEL
FURNACE SAFEGAURD SUPERVISORY
SYSTEM (FSSS)
REGENERATIVE AIR HEATERS ( 2 NO’S)
INDUCED DRAFT FANS ( 2 NO’S)
FORCED DRAFT FANS ( 2 NO’S)
PRIMARY AIR FANS ( 2 NO’S)
BURNER MANAGEMENT SYSTEM (BMS)
BALL TUBE MILLS ( 3 NO’S)
RAW COAL GRAVIMETRIC FEEDERS ( 6 NO’S)
 PARAMETERS TO BE LOGGED
Unit load (250 MW load)
Drum pressure ( 166 Kg/cm2)
Furnace pressure/Set point ( -5 mmwcl)
Total fuel flow ( 186 TPH)
O2 in flue gas ( 3.57%)
Total Primary air flow/Secondary air flow L&R/Bypass air flow ( 240/576 TPH)
Wind box pressure L/R & Wind box Differential pressure ( 100 mmwcl)
Primary air Header pressure/ Set point ( 850 mmwcl)
Scanner discharge Header pressure ( 350 mmwcl)
HO pressure/Temperature ( 12 kg/cm2/ 120 degree )
Flame scanner Intensities ( >20 & < 80)
Daily Routine of FSSS Operator
 Lamp test of Alarm panel & annunciations
 Start release permissive of HFO guns
 Trail run of RAH air motors
 Standby Mill auxiliary motor on barring/inching for about 30
minutes
 Testing of oil Guns/pair in every 1st Shift
 Air heater soot blowing in every shift
 IMPORTANT PARAMETERS OF FSSS PANEL
FURNACE PRESSURE
O2 IN FLUE GAS
WINDBOX PRESSURE DP
AIR FLOWS (PA,SA & BYPASS AIR)
LUBE OIL PUMPS (MILLS & FANS)
Tank level, Lube Oil pressure, control oil pressure, oil flows, oil
temperatures & VISCOCITY
Flame scanners
Mill energy levels
HFO pressure/Temperature/atomizing steam pressure
LDO pressure/Temperature/atomizing air pressure
B(BOILER)T(TURBINE)G(GENERATOR)
FSSS PANEL
FEED WATER PANEL
 FEED WATER
BOILER FEED PUMPS
BEARING COOLING WATER PUMPS
COOLING WATER PUMPS
CONDENSATE EXTRUSION PUMPS
TURBINE LUBE OIL PUMPS
VACUUM PUMPS
OIL VAPOUR EXTRACTION PUMPS
SEAL STEAM EXHAUST BLOWERS
 PARAMETERS TO BE LOGGED
Unit load (250 MW load)
Condenser vacuum ( -0.93 Kg/cm2)
DM makeup
Hot well level/ set point ( +25 mm)
Condensate discharge header pressure ( 21 Kg/cm2)
Condensate flow ( 660 TPH)
De aerator pressure /Temperature/ Level ( 6.0 Kg/cm2/165 C )
DP across Feed control station ( 2 Kg/cm2 [3E] / 5 Kg/cm2 [dp] )
Feed flow/Main steam flow (760/750TPH)
Drum level/ set point (-5 mm)
MS/RH Temperatures & Pressures, Burner tilt position (540 C/540 C & 150/36 kg/cm2)
APRDS flow/Temperature/ header pressure(2 TPH/280 C/ 8.5 Kg/cm2)
Axial Shift ( .>-1 & < +1)
DAILY ROUTINE OF FEED WATER
OPERATOR
 Start permissives of all standby pumps
 LP & HP heaters, Deaerator, APRDS in charged condition.
Turbine LOP’s & SLC drains in SLC
 Trail run of DC JOP, AC EOP & DC EOP in every 1st Shift
 Soot blowing ( LRSB’s & WWSB’s) which ever necessary.
 IMPORTANT PARAMETERS OF FEED WATER PANEL

Condenser Vacuum
 DM makeup
 Condensate discharge header pressure
 Hotwell, Deaerator & Drum levels
 LP heaters & HP heaters levels
 Gland steam header pressure
 MS & RH Temperatures
 APRDS pressure & Temperature.
B(BOILER)T(TURBINE)G(GENERATOR)
FSSS PANEL
 FEED WATER PANEL
 GENERATOR PANEL
 GENERATOR PANEL
AC & DC SEAL OIL PUMPS
SEAL OIL VACUUM PUMP
BEARING CHAMBER EXHAUST BLOWERS
 PARAMETERS TO BE NOTED
Unit load (250 MW load)
MVAR ( -100 to +100 )
Frequency ( 50 Hertz)
Station currents R/Y/B ( 9000 Amperes)
Rotor current ( 1600 Amperes)
Generator terminal voltage ( 16.5 KV)
Bus voltage ( 220 KV)
Hydrogen pressure/Purity ( > 98.0)
Seal oil/H2 dp ( 1.4)
Cold gas Temperatures[ A/B,C/D] ( < 45 degree)
BCW inlet & Outlet Temperatures ( 30/ 40 degree)
Hot air Temperature after main Exciter ( 54 degree)
Seal oil Temperature before & after cooler (60/ 35 degree)
DAILY ROUTINE OF GENERATOR PANEL OPERATOR
24 volts DC chargers in service
 Conduct Lamp test, AC fail test & DC fail test on 6.6 KV station transformer board
Trail run of DC seal oil pump
Inspection of TG floor, Cable gallery, EMC board, SSS board, boiler & turbine LT
boards & HT boards.
Switchgear Status ( Relay availability)
Selector switches/Incomers of Bus Couplers
Temperature of Resistance boxes
DC Lighting system
Generator draining system – Casing & Top/Bottom Bushings
Trail run of DG sets
 IMPORTANT PARAMETERS OF GENERATOR PANEL

 MVAR
 Bus Voltages of 6.6 KV boards
 H2 pressure & Purity
 Seal oil/ H2 Differential pressure
 Cold gas H2 Temperatures
 CHARGE HANDING OVER (C.H.O)
 Log the running equipment & standby equipment clearly.
 Special attention regarding permissions & Permit to works
(PTW’s)
 Elaborate the whole sequence of operations happened in
your shift to your relievers
 Log complaints if any in SAP before you handover the
charge, else do inform your relievers to log
HOW TO STUDY & ANALYSE AN
EQUIPMENT ??
BOILER FEED PUMP ( BFP)
 START PERMISSIVES OF BFP
 Deaerator level adequate
 Suction valve open
 Pump or motor bearing temp not high
 Lube oil Pressure OK
 AOP ON
 Discharge valve closed position
 Discharge bypass valve closed position
 Recirculation valve in open position
 Scoop position kept in minimum position
 Electrical switchgear OK
NO trip Conditions persist
 TRIP CONDITIONS OF BFP
 Deaerator level very low
 Pump or motor bearing temp very high
 Motor Winding temp very high
 Lube oil Pressure low
 Suction Discharge Differential Temperature very high
 Working oil Temperature before cooler very high
 Booster pump Discharge pressure very low
 BFP Electrical Protection Operated
 Suction Strainer DP high
 RESPONSIBILITES
ATTENTIVE TO ALARMS
OBSERVE TRENDS REGULARLY
MONITOR IMPORTANT PARAMETERS REGULARLY
OBSERVE MIMICS ON CRT MONITOR AS & WHEN REQUIRED
SPECIAL ATTENTION IN WRITING LOG BOOKS
EQUIPMENT AVAILABILITY- PERMISSIONS & PTW’S.
FEEDBACK FROM LOCATION STAFF
LOGDING COMPLAINTS IN SAP
ATTENTIVE TO ALARMS
OBSERVE TRENDS REGULARLY
OBSERVE PARAMETERS REGULARLY
OBSERVE MNEMONICS ON CRT MONITOR
SPECIAL ATTENTION IN WRITING LOG BOOKS

EQUIPMENT AVAILABILITY- PERMISSIONS & PTW’S
 Always Ensure that Standby Drives are in service
position
 51 0000  SPRING CHARGED

SPRING DISCHARGED
 WHEN IGNORED AVAILABILTY OF DRIVES

 16:00 hrs Mill AB,CD are in service, Unit load is 250 MW

 16:05 hrs Mill AB tripped on “ Mill Lubrication not ok”
 16:05 hrs HFO guns 1&3, 2 &4 cut-in in CD elevation. Unit load
dropped to 150 MW
 16:06 hrs Planned to take standby mill EF but Mill EF main motor did
not start as breaker is in TEST Position. A delay of about 30 minutes took
place as the shift Engineer ignored to Check the availability of Mill breaker.
 FINANCIAL LOSS
 Loss of Generation for 30 minutes : ( 250-150)* (½)*1000
= 50,000 units
 cost of each unit : 3 rupees
Financial loss due to generation loss : 3* 50,000 = 1,50,000
Loss due to Oil Consumption : 4* (1/2)* 2 = 4 KL ( 1 Gun hour = 2 KL)
cost of 1 KL of HFO oil : 40,000 rupees
Financial loss due to oil consumption = 2* 40,000= 80,000 /-approx.)
Total financial loss of about 2,30,000/- due to sheer IGNORANCE of shift
Operators.
 FEEDBACK FROM LOCATION STAFF
 Never rely on Instrumentation feedbacks on BTG. Always
ensure the same from location staff.
Status of the equipment locally
LODGING NOTIFICATIONS IN SAP
Thank You 