NTPC RAMAGUNDAM

STAGE –I(200 MW UNITS)

PROTECTION AND INTERLOCKS
Compiled by MOHD. NIZAMUDDIN.
Supdt.(O&M).
1.1.0. General:
Adequate and reliable protections are provided for safeguard
the various equipments under abnormal and dangerous operating
conditions. The operation of protections shall be accompanied by
visual and audible annunciations, which will provide definite
indication of primary causes of operation of the protection.
Equipment disconnected by the protection will be again put into
operation either by remote or automatic or local control only after
elimination of the fault causing the operation of protection. The set
values for various protections/permissives given in this write-up
are tentative and may have to be changed depending on the actual
performance of the equipment.

The protections and interlocks are divided into the following

groups.

I. Protections causing tripping of the unit.

II. Protection causing tripping of boiler.
III. Protection causing tripping turbine.
IV. Protections and interlocks of other auxiliaries.

Protections causing tripping of the unit.

I. Generator tripping.
II. Turbine tripping.
III. Boiler tripping.

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1.1.0.Protections causing tripping of boiler.

I. Loss of both ID fans.

II. Loss of both FD fans.
III. Loss of both APHs ESPs.
IV. Very low furnace pressure trip value –200 mm wcl
alarm – 40 mm wcl.
V. Very high furnace pressure trip value + 200 mm wcl
alarm + 40 mm wcl.
VI. Drum level very high trip +250 mm DT 5 sec
alarm +100 mm
VII. Drum level very low trip -250 mm DT 5 sec.
alarm –100 mm
VIII. Loss of fuel to furnace. This protection shall act when complete
fuel is cut off to furnace (No mill is running and no burner
valve is not closed.)
IX. Loss of flame. This protection shall act when there is one or
more fuel to furnace and at least one flame is not detected.
X. Loss of control air to BMS. (Kept by passed)
XI. At least one milling system is in service and seal air pressure
very low with in 3 min. time delay Trip value: 900 mm wcl,
alarm 1050 mm wcl (protection is kept by passed in all the 3
units).
XII. Trip from unit protection. This protection shall act when turbine
tripped and boiler load is more than 60% and at least one set of
HP and LP bypass fail to open in seconds.
XIII. Airflow is less than 30 % and at least one pair of burners/ one
mill is in service.
XIV. PF burner emergency trip (Push button operated from console).
XV. Purge validity time expired.

The means of indicating of above of above protections is provided on

BMS master logic control insert. And also it gives the first –up. It will
disappear only after the completion of boiler purging.

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1.1. PROTECTIONS AND INTERLOCKS FOR BOILER

AUXILIARIES:

ID fans and FD fans:

The above said fans can be started from UCB and provision is
made to facilitate stopping from UCB and local. For starting and stopping
a separate control switch is provided individually for fans (FD AB And
ID AB). The control switch can be turned to one of the following three
positions. i.e. 1.Stop 2. Normal 3. Start.

1.Stop:
a. If the equipment is running and is desired to stop, the control
switch is to be brought to stop position from normal position
to give stop impulse. The moment switch is released it goes
to normal position.
b. If the running fan trips on protection and is desired to start
CS is to be brought to stop position before giving start
impulse.
2.Normal:
Soon after releasing the CS from Start/ Stop position it spring
returns to normal position.
3. Start:
By bringing the CS to start position, start impulse can be given to
start the equipment provided all permissives are through.

Just above the CS three bulbs (green, white and red) are provided to give
a visual indication about the status of the fan.
Green: This indication indicates the breaker is in service position
and fan is not in running condition.
White: This indication indicates that the fan has tripped on one of
its protection .It will disappear only after brining the control switch to
stop position.
Red: This indication indicates that the fan is in service. In addition
to above a set of amber lamps are provided above the Cs to indicate the
status of permissives.

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1.1.1.Protection and Interlocks for ID fans :

PERMISSIVES:

i. Inlet vane minimum position.

ii. Inlet / outlet damper closed( deleted)
iii. Bearing temperature normal.
iv. Other ID fan is running or clear path permissive (Clear path
permissive is bypassed).
v. Scoop oil temp. normal / scoop oil pressure adequate.
vi. Emergency push button is in released condition.
vii. At least one APH should be in service.

PROTECTION:

i. Emergency push button pressed.

ii. Fan is running and scoop oil pressure low set value0.25 ksc DT
3 min. But annunciation will come as soon as pressure drops to
0.25 ksc.
iii. Scoop oil temp. high 80 C.
iv. Both air preheaters tripped.
v. Electrical protection.

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1.1.2.Protections and interlocks for FD fans:

Permissive:

i. Inlet vane minimum position.

ii.
a. Other FD fan is not running and at least one ID fan is in service.
b. Other FD fan is in service and both ID fans are in service

OR
c. Both ID fans are in service.
iii. Bearing temp. normal.
iv. Discharge damper closed.
Damper closes on interlock after giving start command in the case
of first fan being started.
v. Emergency push button is reset position.
vi. Corresponding APH must be in service.

PROTECTIONS:

i. Stop from local emergency push button.

ii. Trips on corresponding APH trips, Fan trips after a time delay of 30
sec after APH trips.
iii. Trips on ID fan trip.
a. Only one FD is running, FD fan trips only on both ID Fans trip.
b. Both FD and ID fans are in service, FD fan trip when
corresponding ID fan trips.

iv. Stop from UCB.

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1.1.3.PROTECTION AND INTERLOCKS FOR APH.

There are two APH’s A AND B having two electric drivers (main
and aux) and one air motor each.

Permissives:
i. Bearing temp. normal.
ii. Overload relays in reset condition.
iii. Single phase preventer not acting.
iv. APH air motor solenoid valve should be de-energised condition.
Note: top de- energise Stop command has to be given.
v. Selector switch should be in the required drive position.
vi. EPB of the corresponding drive should be in released condition.

PROTECTION:
i. Bearing temp. high (Bypassed)
ii. Overload relay actuated.
iii. Single phase preventer acting.
iv. APH air motor solenoid valve( if the corresponding relay for
solenoid valve) energises.
v. EPB of the corresponding drive pressed.

NOTE

i. If APH is running on main motor, on changing selector switch to

stand by motor position, main motor stops and stand by motor starts.
But not vice versa. If APH is running on stand by motor and is
required, to be started on main motor. Selector switch has to be
changed to main motor position and the start command has to be
given. (No need to give stop command before start)

ii. If APH is running on stand by motor and Trips on EPB pressing,

soon after releasing EPB the motor (stand by motor) will take start
without any start command from control room.

iii. If APHs are running (on any electric drive) and supply failure takes
place, on restoration of supply APHs start on stand by motors without
any command provided EPB is in released condition. (This happens
only if APH stand still condition is not sensed.

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AIR MOTOR:

It can be started( APH should be in stand still condition and both

electrical drives should be in off condition) or stopped from UCB
control switch. ( APH motion is sensed by two limit switches mounted
in APH top bearing housing. If none of the switches are actuated in 50
sec it is considered as APH in stand still position.)

INTERLOCKS:

i. APH is running on main motor and trips on protection, APH

standby motor takes start and alarm comes in UCB (if the alarm is
already persisting due to the other APH running on standby motor,
no alarms comes for this change over.)

ii. If the APH is running on either main motor or standby motor

and trips on protection and both electric drives are off and APH
control switch (of electric drive) is not reset after reaching the
standstill condition air motor takes start. ( as soon as APH comes to
standstill alarm comes in UCB and will reset after APH rotation is
sensed by the switches.)

iii. If APH trips corresponding ID fan trips after a time delay of 30

sec.

iv. If running APH trips and the other APH is off both ID fans will
trip.

v. If both ID and FD fans are running and one ID fan trips

corresponding FD fan will trip. If both ID fans trip both FD fans
trip.

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1.1.4.APH AIR AND GAS DAMPERS:

Condition : Both ID and FD Fans are Off.

i. When both APHs are off all dampers remain open.

ii. On starting one APH the air and gas dampers of the other non-
running APH will close.

iii. After starting the second APH all its dampers will open.

Condition: Both APHs and IDs are running .

i. On starting First FD fan ( A or B) gas and air dampers of APH

corresponding to other ‘FD fan(B or A) will close.
ii. On taking the Second FD Fan all dampers pf both APHs will
open.

NOTE:

i. On loss of air supply , dampers will not operate and remain in

the same position.
ii. On loss of power supply to the damper, will cause indication
failure and will not operate. They will remain in the same position.

1.1.5. FD FAN DISCHARGE AND TEMPERING AIR

DAMPERS:

i Both FD fans off and their control supply on all dampers

remain open.

ii Both FD fans off and their control supply off all dampers
remain close.

iii Both FD fans off and one FD fan start command is given,
discharge and tempering air dampers of the particular fan
will close first and after the fan starts its dampers open and
dampers of the other non running FD fan will close. On
starting the second fan all dampers go to open position.

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1.2. PROTECTIONS AND INTERLOCKS FOR TURBINE

AUXILIARIES:

1.2.1. BFP BOILER FEED PUMP.

Each BFP is provided with

1. A control switch to enable start/stop the pump. This

switch can also be kept in lock position when the
pump is under maintenance.
2. Thee position selector switch( Lead/Normal/Lag ) for
starting the pump manually from the control room
selector switch should be in Normal position.

When selected on LEAD BFP takes start when the running pump trips
or discharge header pressure is low and one pump is running and all start
permissives are available for the lead selected pump.

When selected on LAG and all start permissives are available for this
pump, the LAG selected pump will start when.

1. Pump on normal mode trips and its control switch is

not reset and lead selected pump fails to start with in
30 sec

OR

2. Running lead selected pump trips

OR

3. At least one pump is running and the discharge

header pressure low after delay 30s

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PERMISSIVES:

1. Suction valve should be in open condition (Bypassed)

2. Bearing temp. Normal.
3. EPB in reset condition.
4. Suction pressure normal (D/A level normal, D/A level low alarm
resets)
5. Lub oil pressure adequate (After giving start command, provided
the lube oil pump is selected in remote and not running it takes
start and permissive will be available once the pressure attains 0.7
ksc.)
6. Cooling water pressure normal ( taken from clarified water pr.
switch set value is 2 ksc.)
7. Discharge valve closed/ common header pr. adequate.
8. Recirculation valve open.
9. Selector switch should be in normal mode.

PROTECTION:

1. Main pump EPB pressed.

2. Lube oil pressure low 0.5 ksc.
3. Balancing leak off pr. high 25 ksc.
4. Hydraulic coupling temp. high. 130 C
5. Discharge temp. high FW 240 C
6. D/A level low low.
7. Running pump discharge pr. low 50 ksc.
8. suction pr. low-low 7 ksc.
9. BFP flow Hi- Hi 360 t/h (bypassed)
10. BFP flow low- low 50 t/h (bypassed)
11. Motor cooling water flow low- low .

INTER LOCKS:

1. Recirculation valve control switch in control is modified to stay put

type. It can be kept permanently in open/ close/auto. When kept in
auto mode and main pump is not in service the valve remains in
open condition. Valve closes when the pump flow is more than 180
t/h . Valve opens again when flow drops below 80 t/h.
2. Recirculation valve will open on loss of air/ loss of power supply
to solenoid valve.
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3. Lube oil pump:

a. It has a local selector switch with two-position local/ remote

and local start/stop push button. By keeping the switch in
local, pump can be started from local. Pump can be stopped
from stop push button irrespective of local selection switch
position.
b. When the local switch is in remote and main pump not
running lub oil pump will be off position. On giving start
command to main pump lub oil pump takes start. After main
pump start and lub oil pr. is more than 3.5 ksc lub oil pump
will be stopped. If because of any reason the lube oil pr
drops below 1 ksc oil pump immediately takes start.
c. If main pump trips on any protection, lub oil pump takes
start soon after the lub oil pr drops to 1 ksc and will continue
to run as long as the main pump control switch in control
room is not reset. The moment switch is reset lub oil pump
stops.
d. If pump is stopped from control room, lub oil pump takes
start soon after the lub oil pr drops to 1 ksc and will continue
to run for only 30 sec.
e. If control room selector switch is in LEAD remote lub oil
pump will run continuously.
f. Lube oil pump will run continuously when
i. Local selector switch is in remote and
ii. Control room selector switch is in LAG position and
iii. One of the other two BFPs is selected in LEAD and
the Lead selected BFP is not running (BPF CS should
be in normal after stop position.)

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1.2.2. CONDENSATE EXTRACTION PUMP (CEP)

Each CEP is provided with

1. A control switch to enable start/stop the pump. This switch can

also be kept in lock position when the pump is under maintenance.
2. Two position selector switches ( Auto/ Manual ) for starting the
pump manually from control selector switch should be in Manual
position.

PERMISSIVES:

1. Suction valve open. ( valve opening is to be confirmed physically)

2. Hot well level normal ( Alarm reset condition)
3. Recirculation valve in open position(by passed while starting the
first pump its opening is to be ensured.)
4. EPB reset condition.
5. Selector switch of the corresponding pump in manual position for
manual starting and in auto for auto starting .

PROTECTIONS:
1. EPB pressed.
2. Hot well level low low.
3. Suction valve not open.
4. Individual pump discharge pr. is less than25 ksc for more than
30 sec.

INTERLOCKS:

Any pump can be selected as stand-by keeping the selection switch in

auto position.

1.Stand-by pump will start if other CEP is running and discharge

header pressure is less than 26 ksc for more than 10 sec Or flow is more
than 630 t/p.
2.Running pump trip and the control switch is not reset stand-by
pump starts.

NOTE:.

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1.In case of Hot well level becoming low .Level low alarm appears and
permissive disappears preventing starting of stand-by pump. Evening
case of the above interlocks.

2.In case of running CEP trips on hot well level low –low stand by pump
also will not start.

3.Pr setting done in unit O/H.

1.2.3.ARCW PUMPS:

Each pump is provided with a control switch in control room to start/ stop
the pump. The pump can be started / stopped from the local push buttons.

PERMISSIVES:

1.EPB is in released condition.

2.Pump suction pressure is adequate.(pr low-low switch is in reset
condition.)

PROTECTIONS:

1.EPB pressed.
2.Pump suction pressure is low- low <0.8 ksc.

INTERLOCKS:

1.If the discharge pressure drops below 4 ksc stand by pump takes start
provided the pump is started from control room. (In case pump has been
started from local close command is to be given from the control room to
make the interlock work.)

2.In case running pump trips on protection (except Suction pr. lo-lo)
stand-by pump will take start.

3. In case suction pressure goes low stand-by pump will not start on
interlock.

3.1.0. Do’s and Don’ts for Boiler operation.

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3.1.1. Boiler must be hand tripped independent of the action of the

relevant protection under following condition.
a. Loss of both ID fans.
b. Loss of both FD fans.
c. Loss of both APHs ESPs.
d. Very low furnace pressure trip value –200 mm wcl alarm –
40 mm wcl.
e. Very high furnace pressure trip value + 200 mm wcl alarm +
40 mm wcl.
f. Drum level very high trip +250 mm DT 5 sec
alarm +100 mm
g. Drum level very low trip -250 mm DT 5 sec. alarm –
100 mm
h. Loss of fuel to furnace. This protection shall act when complete
fuel is cut off to furnace (No mill is running and no burner valve
is not closed.)
i. Loss of flame. This protection shall act when there is one or more
fuel to furnace and at least one flame is not detected.
j. Air flow is less than 30 % and at least one pair of burners/ one
mill is in service.

NOTE:
1. If instrument air pressure goes very low, PF valve may close,
and also no pneumatic operated dampers/valves will operate.
Hence in case of low instrument air pressure no attempt to be
made for any load variation or oil support to be tried. If there is
no chance of instrument air pressure improvement trip the unit.

2.On boiler tripping ensure that:

a. All mills, PA fans and feeders have tripped.
b. All oil shut off valves have closed.
c. All igniters oil shut off valves have closed.
d. HFO LFO & igniters trip valves have closed.
e. Close attemperation SH & RH valves.

3.Whenever boiler drum is opened, through inspection of drum

internals is to be done for verifying good condition of equipment
and removal of foreign material before boxing up.

4. After an outage of unit for long period and restarting, check

the following before light up.

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f. Internal inspection of furnace for scaffolds

clamps etc, removal and then boxing up
manholes.
g. Inspection of complete boiler for boxed up
condition.
h. Bottom ash hopper is cleared and filled with
water trough seal filled with water.
i. Inspection of boiler to ensure that there is no
obstruction for free expansion of boiler as it
comes on load, by ensuring that there are no fixed
points.
j. Boiler expansion indicators are in place and in
good condition.
k. Inspection of ducts for free expansion.
l. Inspection of ID, FD fans and boxing up.
m. Check that all the safety valves are in released
condition before light up.
n. Check all protections and interlocks for all
auxiliaries including unit protection before light
up.
o. Check that all soot blowers are in retracted
condition and furnace probe is available before
light up.
p. Ensure that all C&I systems are available and
switched ON before light up.
q. Ensure that all the systems necessary for boiler
start up are lined-up.
r. Ensure smooth running of both air preheaters by
running an air motor locally before continuous
service.

5. Boiler (drum SH& RH) vents are installed in the highest

points to discharge air during filling or the pressurizing phase.

Keep the boiler vents open when filling the boiler even after
light up till a pressure of 1.7 ksc too ensure that all air is
completely discharged.

When cooling, open the boiler vent at 1.0 ksc pressure to avoid
creation of vacuum.

6. Furnace probe can be used to measure the gas temperature

just before the super heater tubes at furnace exit. It permits
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continuous observation of the gas temp. during light up and

monitoring of rate of rise of temp.

Note: a. Retract the furnace probe one gas temp. in this zone
reaches 500 C.
b. Retract the furnace probe before cutting in mill to
prevent damage, in case it does not retract on interlock.

7. Till a steam flow sufficient to ensure cooling is established,

flue gas temp. in SH & RH tubes zone should not exceed the max.
Permissible metal temp. in the zone

8. SAFETY VALVES:
a. Safety valves should be in released condition before
light-up
b. In case hydraulic test is to be performed above the normal
operating pressure, these safety valve are to be gagged,
gagging should be remove as soon as test is over.
c. If any maintenance is carried out on safety valves, they
have to be pressure set.
d. No adjustment should be tried on a safety valve near its
operating pressure.

9.Boiler filling(initially.)

Fill gradually with vents open. The difference of water temp. and
drum metal temp. should not be more than 50 C.

Maintain drum level lower than the normal before light up to

accommodate for swelling of level on lightup.

Check drum level alarms and protections before light up.

10. While light up keep superheater startup vent valve open till MS
lines are charged.

11.To reduce thermal stress in Y piece in MS line, charge MS lines

for gradual heating by opening boiler stop valves bypass valves.
Keep the MS drains before turbine stop valves open.

12. Keep economizer recirculation valve open while light up till boiler
feed water is continuous.
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13.During light up regulate firing so that water temp. rises by not more
than 2 C /min.

14.Drum metal top/bottom temp. difference should be controlled

within 50 C during light up and cooling.

15. Use of SH/ RH spray should be avoided as far as possible during

low load conditions.

16.Reheat attemperation spray is envisaged for emergencies and

during load variation.

17. Drum level gauge glass: At least one drum glass should be
maintained in working condition.

Top connections between drum and gauge glass should be un-

insulated and bottom connection between drum and gauge glass
should be insulated. This way slight circulation takes place due to
condensation.

Gauge glass should be drained always slowly.

While charging steam side valve should be opened first and allow
condensation to fill before opening water side valve.

18. Monitor SH & RH tube metal temp. frequently during light-up.

19.Maintain a min. airflow of 30 % during purging and even after

light-up.

20.Air vents are not to be closed till it is ensured that all air is bled out
till a pressure of
appro. 1.7 ksc in drum.

21.Start scanner air fan before light-up on purge complete.

22. Rise in steam pressure must correspond to boiler water temp. (i.e.
1.5 C/min.)

23. Maintain drum level during light up. It may result in tube failure
with water entrapped in due to sudden change in temp. Use emergency
blow down if necessary.
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24.Keep RH gas dampers closed during light up after initial purging

till flow is established through RH tubes.

25. Safety valves floating.

a. Choose a calibrated pressure gauge.

b. Safety valves not to be tested are to be gagged only after
attaining 70% of the operating pressure.
c. Kill the fire once the safety valve floats.
d. Establish proper communication between control room and
safety valve area before floating.

26.Ensure air temp. is at least more than 150 C /Furnace exit gas
temp more than 400 C before starting coal firing.

27. Boiler shutdown: following points are to be observed.

a. Reduce steam pressure by 10 % compared to operating
pressure to take care of pressure rise due to thermal
inertia before stopping boiler.
b. Bring drum drum level to max. then stop feeding, open
eco recirculation valve.
c. Clean air and gas path (i.e purge boiler) and then stop
fans.
d. Keep scanner air fans in service till furnace temp drops to
120 C.
e. Keep air preheaters in continuous service till flue gas
inlet to APH” temp is less than 180 C.
f. Allow for natural cooling of boiler by keeping vanes and
dampers open.
g. Allow for natural pressure drop.
h. When pressure is 1 ksc open all vents.
i. If faster cooling is required keep the ID /FD fans in
service Maintain the temp. gradient half of that used for
starting. Also drum top/ bottom metal temp. difference
should be within limits i.e. less than 50 C.
j. Boiler is not to be drained till furnace is cooled to such an
extent that a man can enter and stay inside.

28. Boiler water and steam parameters are to be monitored

properly.

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a. Condensate: In the presence of O2 and CO2, NH 3 attacks on

surface of the brass tubes of condenser. Reducing N2H4 dozing in
case of excess NH3.

b. Feed water: Oxygen presence beyond permissible limits is

extremely dangerous for economizer and boiler.

c. CBD:
i) Less pH is dangerous – aids corrosion.
ii) Hardness should be NIL – if hardness is
greater than 2.5 ppm of total hardness for
more than 24 hours load and pressure in boiler
should be reduced to prevent irreversible scale
in boiler.
iii) Excessive silica is dangerous for both boiler
and turbine. It is to be controlled by giving
blow down.
iv) If hardness is more than 2.5 ppm for more
than 24 hours in such case a TPS dosing
should be done upto 5 ppm equivalent PO4..

29. In case of boiler leakage boiler should be stopped the earliest to

restrict the damage to min.

In case of water wall tube leak, trip the boiler and stop
feeding water to prevent thermal shocks at drum to prevent leaks at
expanding and weldings to tubes due to temp. diff between feed
water and metal .Reduce air flow to min. Keep ID /FD fans in
service.

30. Continuous O2 monitoring is important.

31. Losses in efficiency :

Major causes for efficiency drop area:
a. Losses due to latent heat of flue gas.
b. Unburnt substances in slag and ash.

32. High exit flue gas temp. with normal excess air and large losses
of draught indicates heat absorbing surfaces of APH are dirty and
therefore need soot blowing and washing.

33. High excess air result in increase temperature of exit flue gas
and draught loss. Air/fuel ratio is to be resulted.
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34. High unburnt elements in ash and slag indicate poor quality of
combustion control to be checked and corrective action taken.

33..11..11 A
AIIR
R PPR
REEH
HEEA
ATTE
ERR::

a. Inspect thoroughly before starting.

b. Check the smooth rotation by running locally the air motor
before continuous operation.
c. Check the direction of rotation with both main and aux motor
before continuous service.
d. Initially slight overload may be there due to excessive seals
friction. It should become normal after sometime. If overload
and seals friction persist continuously, seals are to be
readjusted.
e. Check protections and interlocks after long outage.
f. Keep both air preheaters in service before boiler light up even if
one alone is used. The idle air preheater dampers should be in
closed condition.
g. While taking the idle air preheater in service open the air
dampers first and then the flue gas dampers.
h. Air preheater soot blowing should be done twice in a shift of
eight hours.
i. In case of oil firing during boiler light up APH soot blowing
should be done frequently ( at least once in two hours)
j. Even after unit trip, air preheaters should be in continuous
service till flue gas inlet temp. drop to 180 C to prevent high
temp. causing ignition of any fuel deposits on the heating
elements left by previous operation.
k. APHs should not be stopped till flue gas inlet temp. drops
below 100 C.
l. APH motor failure- No seriouw damage will immediately occur
if flue gas inletr temp is less than 480 C .Following precautions
are to be taken .Ensure that flue gas inlet and air dampers close
fully. Run air preheater on air motor.
m. If APH is standstill even with dampers closed, the parts exposed
to flue gas may have seals bent. Start APH at intervals to slowly
rotate the air preheater to make rotor dilatation uniform before
continuous operation. If it is not possible for electrical drive
disconnect power supply, rotate on air motor or manually
slowly a few rotations. After few revolutions the rotor dilatation
should be uniform for continuous service. As soon abs air
preheater is started, start soot blowing.
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n. Corrosion reduces heat exchange surface. The zone mostly

affected by corrosion is cold end. To prevent this radial seals
must be efficient to prevent air leaks. Also cold end temperature
should be maintained above dew point.
o. Excessive DP across indicates the need for APH
washing/cleaning.
p. In case of fire trip the boiler, stop the fans, leave the dampers
open to allow steam to escape open fire-water and flood the air
preheater with water, Keep the hopper drains open.
q. If necessary charge SCAPH to improve cold end temp. during
light up.
r. Air preheaters air bypass dampers can be opened to improve
cold end temp.

3.1.2. ID AND FD FANS:

a. If any fan is under shutdown, keep the dampers closed to

prevent back flow.
b. Start FD fan with dampers closed and inlet vane in min.
c. Ensure that scoop position is zero before starting ID fans.
d. Continuous operation with very low scoop position is to be
avoided. Always operate with scoop position 50 % and above
for continuous operation.
e. ID fans have a trip protection on scoop oil temp. high. Ensure
cooling water flow for oil cooler. Before starting ID fans.

3.1.3. MILLING SYSTEM

a. Operate the reject gate s and remove rejects immediately after

each mill start .
b. The position of all individual classified vane of mill should be
same( i.e. 40 or 50 deg.
c. If classified opening angle is more fineness increased. It also
increases motor load.
d. Min. velocity of airflow 18 m/s is required to prevent choking
of coal pipes.
e. Air flow rate is based on grinding capacity index.50 deg. HG
and a product fineness of 70 % through 200BS sieve (75
microns) Air flow rate is to be varied from 70 % to 100 % ( i.e.
34 to 48 Tph ) corresponding to coal flow rated of 50 to 100 % (
i.e. 13.5. to 27 tph).

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f. Once a mill is empty, increase PA flow momentarily to clean

mill system and mill pipes thoroughly.
g. Always maintain correct air /fuel ratio.
h. In case of a longer mill outage empty feeder also.
i. 1 kg of coal and 20 cu m of air forms an explosive mixture very
low coal flow and high air flow rate should be avoided as far as
possible.
j. Excessive rejects may cause fire Avoid reject chamber over
filling.
k. Fire in mill under shut down : Isolate the mill and charge CO2,
Do not use water or other liquid as it may cause grinding
elements crack.
l. Fire in mill on duty: Noticed by sudden rise in mill temp. For
same condition of coal air, IN case use max cold air, increase
coal flow ( keep air flow control manual ) till PA flow starts
dropping. Maintain Rich coal air mixture till mill temperature
become normal. Then slowly restore the correct fuel/air ratio. If
temperature does not come under control stop the system,
isolate mill and charge CO2.
m. If excessive rejects are check the following.

i. Reject flap (i.e. counter weight) might have remained

open.
ii. Grinding balls worn out.
iii. Less air flow.
iv. Excessive groove gap.
n. Excessive sparks in flames, heavy scales on walls, high unburnt
content in ash indicate worse grinding.
o. If coal finesses is poor check for the following.
i. Classifier erosion, having holes or outsides seals.
ii. Classifier adjustment not OK.
iii. Mill over loaded.
iv. Bad fuel
v. Air to fuel ratio high
vi. Worn out balls.
3.1.4. R.C. Feeder.:

i. Ensure that purge air valve is open.

ii. Check belt tension regularly.
iii. New belt should be inspected at least 2-3 times a shift for at
least one day till belts stretch is established.

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iv. Running RC feeder in forward direction ( locally with mill in

stopped condition will choke feeder outlet pipe.) Ensure that feeder
outlet pipe is clear before boxing up feeder.
v. Feeder is emptied locally by running in reverser direction after
removing the backside plate in the feeder. Before boxing up, ensure
that back plate is fitted back in position.
vi. If clean out conveyor is not in service, the coal accumulation
below the belt can damage ht belt. Stop milling system, if clean out
conveyor cannot be put back in service. Empty the feeder before
stopping in such a case.
vii. In case bunker becomes empty, keep the bunker gates closed
and feeder front and rear doors open to prevent drought action and
to prevent damage of feeder belt from fire.

3.1.5. ELECTROSTATIC PRECIPITATOR.

a. Switch ON heating of hoppers and HT insulator housing at

least 12 hours before light up.
b. Keep rapping and vibrators in service at least one hour
before light up
c. Switch on HT fields just before coal firing. Before opening
the manhole of ESP for maintenance isolation of
rectiformers and earthing of fields to be ensured. Both
auxiliary and main supply for the pass and inlet/ outlet
dampers are to be closed fully.

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3.2.0. Do’s And Don’ts For Turbine Operation.

1. Allowable pressure and temperature variations.

a. The pressure at the turbine main steam stop valve shall be

controlled so that it does not exceed rated pressure at
rated output. During the abnormal conditions the pressure
may exceed momentarily by 30 % but the aggregate
duration of such swings shall not exceed 12 hrs per 12
months operation period.
b. The pressure at the HP turbine exhaust may exceed,
momentarily by 25 % but the aggregate duration of such
swings shall not exceed 12 hours per 12 months operating
period.
c. The average main steam temp. at the inlet of the turbine
over any 12 months of operation shall not exceed 545 C .
In maintaining the average the temperature shall not
exceed 543 C except those swings up to 549 C but the
aggregate duration of such swings shall not exceed 100
hrs per 12 months operating period. The continuous
duration of any swing in the range of 549- 563 C shall not
exceed 15 min. and aggregate duration such swings shall
not exceed 80 hours per 12 months operation period.
d. The allowable reheat steam temperature variation is same
as for that of main steam temperature variation.
e. Limitations on main steam and reheat steam temperature
variations: in this type of turbine where the main steam
and the reheat steam admissions are in the same casing.
The axial temp. gradient in the outer shell can be
increased by excessive difference between main steam
and reheat steam temperature.

i. At rated flows, rated temperatures can normally be

maintained. The main steam should not be hot by 30 C
above reheat steam temp. The reheat steam temp. should
not be hot by 40 C above main steam temperature.

ii. At lower flows, where rated temperatures cannot be

normally maintained. The reheat temperature may go below
the main steam temperature by as much as 170 C as no load
flow is achieved. The main steam temperature should not be
less than reheat temperature.
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2. Share fluctuation of temperature and or load on turbine

should be avoided as far as possible.

3. Regulating stage pressure is noramally 123 ksc. It should not

exceed 135 ksc. If it further exceeds load is to be reduced so that
the pressure drops less than 135 ksc.

4. Turbine operation with steam exhaust to atmosphere is

forbidden. In case of rapid drop vacuum and opening of
atmospheric valves on condenser, the turbine should be
stopped immediately.
5. The main steam and reheat steam temperature should
preferably be equal and they should be more than the metal
temperature under any circumstances.
6. When the turbine has tripped, check the operation of the
following equipments
a. Closure of ESV,CRV and control valves.
b. Extraction NRV’s
c. CRH line NRV’s
d. Disconnection of Generator from grid.
e. Opening of blow down valve and ventilation valves .
f. Starting of AOP.

7. If there are more than one indicator for the same

measurement, then the one which is service favorable
reading should not be assumed to be correct one.
8. If the load on the turbine cannot be raised , all parameters
being normal, check for any accidental closure of control
valves by comparing the pressure readings after the control
valves.
9. The turbine must be stopped manually independent of the
action of relvent protection under the following conditions.

a. Sudden appearance of excessive vibrations.

b. Water hammering in the turbine.
c. Lub oil catching fire.
d. Emergency governor out of order.
e. Sharp rising of bearing metal temperature up to 105C.
f. Fast drop in the oil tank level below the lowest
permissive level 1140 mm and level goes on further
dropping.

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g. Appearance of metallic noise in the turbine steam flow

path.
h. Axial shift exceeding +/- 0.8 mm.,HP difference exp. –
3.2/+8.3, LP diff exp.-4.5/12.6.
i. Increase in main steam and reheat steam temperature
beyoud 565 C.
j. Sharp fall in the main steam teperature.
k. Drop in lubrication oil pressure to less than 0.9 ksc at
front standard.
l. Increase in speed beyond 3300 rpm.
m. Seizure of ESV, CRV or CV’s.
n. Flooding of heaters.

10. Measures should be taken for restoring frequency, if it

exceeds 50.5 hz or if it drops to less than 47.8 hz.
11. Loading rate and temperature ramp rates are to be controlled
if the diff expansions are nearing the limit values.
12. If HP diff expansion is reaching the limiting value control
the rise of the steam temperature and stop further loading of
the machine (i.e. further soak the machine) till the
expansions is controlled.
13. If the HP diff exp. is reaching the limiting value on the
negative side increase the steam temperature and also the
load if possible.
14. If the LP diff exp. is reaching the limiting value on the
positive side slightly reduce the vacuum.
15. If the LP diff exp. is reaching the limiting value on the
negative side improve the vacuum and also increase the load
if possible.
16. During rolling a positive mismatch of 28-55 C is to be
maintained (i.e. the steam should be hotter than the
corresponding metal temperature.)
17. Try to trip the turbine at less than 5% load during planned
shut down except in emergency cases where the turbine can
be tripped any load.
18. Do not operate the hot turbine at less than 10 % load for
longer periods.
19. During load reduction on turbine, open the drains as
follows:

Goup C drains at 30 % load.

LPH-3,LPH-2 D/a extraction line drains.

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Group B drains at 15 % load.

CRH, HRH line drains

CRV seat drain
Turbine casing drain
HPH 6 extraction line drain

Group A drains after trip.

Main steam lines drain

ESV before seat drain
ESV after seat drain

20. Close the drains while rolling and loading as follows:

Group A- after start of rolling.

Group B at 25 % load.

Group C at 30 % load.
21.Always trip the TG set through turbine tripping. If generator
breaker is to be opened, it is to be done only after ensuring the closure of
ESV CRV And CVs.

22. If any time after a shut down the eccentricity higher than the
usual the machine is to be kept on turning gear until the eccentricity has
reached and maintained its normal minimum value for atleast one hour.
23. Do not roll, if the eccentricity is more than the normal value.

24. During cold start, the turbine should not be over speed tested
until it has carried 25% or greater load for at least 3 hours.

25. Trip the turbine if the boiler trips.

26. While rolling the TG set should never hold the machine at less
than 800 rpm for more than 5 min.
27. Minimise the use of LP spray water.

28.Motoring of the turbo generator should be avoided.

29. Do not break the vaccum at higher speeds . If desired vacuum

can be broken at less than 2000 rpm .In emergencies like high vibrations ,
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vacuum can be broken at any speed after taking out load and closing
steam to the turbine.
30. Do not Operated the unit continuously if the exhaust hood
temperature is more than 80 C.
Load is to be slowly raised till the exhaust hood temperature reaches less
than 52 C.

31. Maintain gland seal steam pressure at 0.21 to 0.28 ksc.

32. Maintain a vacuum of 75- 125 mm wcl in the gland steam

condenser.

33. Keep the steam seal diverting valve open to condenser as long
as:
a. Seal steam feed bypass valve is open.
b. LPH-1 extraction steam temperature is more than 150 C
c. Load is less than 50 %.
34. Ensure blowdown valve is open when the control valves are
open and vice-versa. Also ensure that ventilator valves open with
the opening of the blow down valve and vice-versa.

35. Maintain an oil pr of 1.75 ksc to 2.1 ksc at bearing inlet.

36.Oil temperature should not be less than 27 C on barring gear

and should be brought to at least 38 C at rated speed.

37.The raise of the oil temperature of the oil temperature across the
bearing should be less than 20 C.

38. The normal oil temperature to the bearings should be 42-49 C

during running of the machine.

39. During deceleration of the unit after trip out, during down the
oil temperature to about 30 C to 32 C.

40. Vacuum of about 13 to 26 mm of wcl is to be maintained in the

oil tank by throttling of the inlet damper of oil vapour extractor.

41. Trip the turbine when the oil pressure drops to 0.7 ksc.

42.Trip the turning gear when the oil pressure drops to 0.6 ksc.

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43. Do not run the unit if the pressure drops across the ERV and
CRVs is more than 10 %.

44. Do not change over to the standby oil cooler till it is filled
through the filling line.

45.Condenser should never come under + ve pressure.

46.The oil temp of 27- 32 C is to be maintained while on turning

gear.

47. Machine is to be kept on turning gear at least the hottest point

of the casing is less than 120 C and lub oil is to be circulated at
least till the max metal temp is less than 100 C.

48. For a hot turbine, seal the glands only from main steam.

49. For a hot machine, seal the glands first and immediately start
pulling vacuum. While sealing the glands care should be taken to
see that condenser s not coming under positive pressue.

50. While breaking the vacuum do not cutt off the gland steam till
the vauum drops to less than 100 mm of Hg.

51. Do not open any drains to flash tank unless there is vacuum in
the condenser.

52.During hot start up, rolling and loading should be done quickly
so that steam flow is established through HP turbine also.

53.During rolling and loading, please ensure that the turbine metal
temperatures are having raising trend.

54. It is not desirable to run the unit with full opening of control
valve servomotor. If the unit operation with full servomotor
opening is unavoidable, at least once in the shift, try to reduce the
load and ensure that the servomotor is moving in the closing
direction.

55. Do not allow hot rotor to stand without rolling .

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56. In case of excessive vibrations, Diff expansion, Axial shift and

loss of lubrication, trip the unit and bring the rotor to barring at the
earliest by breaking vacuum.

57.Always maintain water level in the condensate reserve tank.

58. Do not attempt to roll the TG set if the eccentricity on turning

gear is more the 0.07 mm.

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3.2.1.Important Do’s and Don’ts of CEP:

1. After carrying out any maintenance work on the CEP , it should be
properly primed before taking into service or keeping it as standby.
2. CEP pressure equalization line valves should be always kept open
unless the pump is taken for maintenance.
3. Do not bypass any permissives and protections and interlocks.
4. While in service if the ammeter starts hunting stop the pump
immediately.
5. Do not operate the pump with suction strainer DP more than 0.6
mm WC.
6. After starting the pump if the discharge valve does not open within
a minute trip the pump.
7. While pump is in service check and record every hour suction
pressure discharge pressure suction strainer DP, thrust-bearing
temp. bearing oil level, bearing cooling water inlet and outlet temp.
and cooling water flow.
8. Gland sealing water line valves of both running and standby pumps
should be always open.
9. Emergency sealing water line valves to both running and standby
pumps should be always open.
10. Do not run the pumps with excessive gland leakages.
11. Do not bypass LP heater 1 while unit is in service.
12. Variation in D/A pressure should be slow and gradual.
13. When the unit trips D/A Pressure change over should be checked
and pressure shall be maintained with aux. Steam.
14. CEP bearing oil should be periodically checked for any
contamination. Visual inspection of the gauge glass oil column will
indicate the oil contamination.
15. Discharge valve of the standby pump should be kept header
pressure.

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3.2.2. Important Do’s and Don’ts of BFP:

1. All interlocks, permissives and protections should be checked and
ensured before taking the pumps into service after a long shutdown.
2. If any maintenance works were carried out on the BFP/ Booster
pump system, pumps and suction piping should be properly primed
before taking into service or keeping as standby.
3. D/A pressure variations should be slow and gradual.
4. Suction valves of the pumps should always be fully open.
5. At less load on the pump, R/c valve should be open full. Min. flow
of 80 T/h should be maintained while pump in service.
6. Stop the pump immediately if the ammeter / discharge pressure
start hunting.
7. After stopping the pump check the AOP starts in auto 1.5 ksc lube
oil pressure .If not starting manually start the oil pump.
8. After starting the pump, check the motor cooling water valve opens
on auto. If it does not open, open it manually.
9. For charging the feed water system from empty condition system
should be charged with only bypass line of the BFP discharge
valve. Open the discharge valve only when the feed water system is
fully charged with water.
10. Discharge valve of the standby pump should be kept open and
scoop control on auto.
11. Record all parameters of the pump every hour in the log sheet.
12. In case of any abnormal noise from the pump or sudden high vib.
Trip the pump immediately and inform to the control room.

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3.2.3. Important Do’s and Don’ts of Steam Seal

System.
Do’s:

1. Check that gland steam regulator is maintaining 0.28 ksc header

pressure.
2. Check that the gland steam exhauster is in running condition and its
suction and discharge pressure is maintaining.
3. Check that gland steam line from Aux. Steam is charge upto the
control valve P61 557 meeting the seal steam requirements.
4. Check at the suction of the gland steam exhauster both the
temperature and the pressure.

Don’ts.:

1. Do not charge seal steam system unless turbine is kept on barring

gear and gland steam exhauster is in service.
2. Do not put the seal steam regulator straight way in service. First
maintain the seal steam header pr. through pneumatic regulating
valve P61 F557 then open the seal steam regulator bypass valve
N31 F002. Now maintaining the header pressure close P61 F557
and charge the seal steam regulator and slowly close the bypass
valve N31 F002.

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3.2.4. Important Do’s and Don’ts of Centrifuge.

Do’s:

1. Check that the MOT level is normal.

2. Check any leakage is there in the system.
3. Check the flow of oil through the sight glass.
4. Check the water level in the indirect oil heater.
5. Check the DP of the oil filter, if it is high bypass the oil filters.
6. Check whether anti-flood tank drain is closed or not if it is not
closed, close it.
7. Check the anti-flood float switch, for its healthiness before
taking the system in service.
8. Check there are sufficient number of fire fighting extinguishers
available in the location.
9. Check the control panel lamps are OK by doing lamp test.

Do Not’s:

1. Do not allow anybody to do welding work or cutting near the

oil purifier.
2. Do not allow oil in centrifuge without giving water seal first.
3. Do not switch On the heater without maintaining proper water
level in the heater.
4. Do not charge the polishing filter when the oil temp. is low.

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3.2.5. Important Do’s and Don’ts of HYDROGEN

system:
Do’s

1. Always isolate the filling panel system after H2 filling.

2. Always close oil valve to avoid gas leakage.
3. Before opening the valves of hydrogen bottles make sure that
their connection is well done.
4. All siphons connected with liquid detectors are filled with oil up
to a level of 400 mm.
5. Always sufficient numbers of CO2 and H2 cylinders available
near the filling post.
6. By pass valve if F033 float trap is in closed condition.
7. Check that purity of gas is normal.
8. Instruments and materials are available for filling operation.
9. Check that sufficient numbers of fire fighting cylinder are
available in the area.

Do Not’s:

1.Do not allow anybody to work without permit near the gas
system.
2.Do not allow any welding work to be carried out in near by areas.
3.Do not allow any gas leakage from the manifold or from system.
4.Do not allow bypassing any action when annunciation appears.
5.Do not allow smoking and other fire hazards in the area.
6.Do not allow the gas system operation without drier in service
unless instructed.

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2.0.0 LIMIT VALUES OF PROTECTION AND

INTERLOCKS
Boiler protections:
Sl.No. Protection Set value
1. Both ID fans trip Trip
2. Both FD fans trip Trip
3. Both APH trip Trip
4. Both ESP trip Trip( excluded)
5. Air flow less than 30% Trip <210 tph
6. Furnace pressure very high >200 mm.
7. Furnace pressure very low < 200 mm.
8. Boiler trip EPB pressed.
9. Drum level high-high +200 mm Wcl
10. Drum level low-low -200 mm Wcl
11. Loss of all flame
12. PF partial loss of flame Trip
13. Loss of control air to BMS Trip (excluded)
14. Loss of all fuel to furnace.
15. HP/LP bypass valve closed load more Trip
than 60% and turbine tripped
16. Seal air pr. too low for more than 3 min. Trip (excluded)
and any mill in service

Turbine Protections
Sl.No. Protection Set value
1. Condenser vacuum very low 570 mm Hg
2. Turbine EPB Trip
3. Exhaust hood temp. very high 105 C (excluded)
4. Over speed 112% electrical backup 3360 rpm
5. Oil tank level very low 1140 mm
6. Thrust bearing wear excess both sides +/- 0.8mm
7. EHC trip
a. Governing oil pr low 5.5 ksc.
b. Emergency trip oil pr. low 6ksc.
c. All control valves closed
8. Bearing oil pr. very low 0.5 ksc.
9. Bearing temp. very high after cooler 65 C
10. Hydraulic over speed
11. Boiler trip to turbine trip
12. Gen. Protection trip to turbine Trip

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Boiler:
Sl.no. Alarm/protection Units Oprt. Low Lo-lo Hi Hi-hi Remarks
Val
1. F.O.suction line C 60-70 20 80
temp.
2. F.O. discharge pr. Ksc 14 1
3. F.O temp. C 105 90 125
4. LFO/ign oil filter Mmwcl
DP
5. HFO header pr at Ksc 10 4 Trip
BF
6. LFO header pr. at Ksc 14` 3 2 Trip
BF
7. Igni. Pr Ksc 5 1.5 1 Trip
8. Atomizing air Ksc 3 2.5 Trip
pr(ignitor)
9. Atomizing air pr( Ksc 6 5.6 4.5 Trip
LFO)
10. Atomizing steam Ksc 10 7 5 Trip
pr.`
11. scanner air pr. Mm 500 400 S/b auto
wcl start
12. Seal air fan pr. Mm 1000 900 Trip
wcl bypassed
13. Mill lube oil pr Ksc 1.5 0.8 0.5 Trip.
14. Mill loading Ksc 36 28` 18 Mill trip
nitrogen pr
15. PA temp to mill C 200 150 310
16. PA pressure Mm 300 950
wcl
17. PA flow Tph 34 to 31 50
48
18. Mill DP MmWcl 250 750
19. Mill to furnace MmWcl 50 200
DP
20. ID fan coupling Ksc 0.4 0.25 DT 3 min
oil pr.
21. ID fan coupling C 40 80 130
oil temp. high
22. Drum level Mm +20/ -100 (MFT) +100/ +250
-30 –250 (MFT)
23. Furnace pr. Mm -40 -200 +40 +200
wcl (MFT) (MFT)
24. Aux. Steam pr. Ksc 16 14.5 17.5 19
25. Aux. Steam temp. C 230 240 250
26. Air flow less than Tph 210
30%

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Turbine:
Sl.no. Alarm/protection Units Oprt. Low Lo-lo Hi Hi-hi Remarks
Val
1. Condenser Ksc 0.9 0.83 0.66 0.45
vacuum Mm 670 640 570 (Trip)
Hg
2. AOP auto start Ksc 12.2
3. Turbine brg. Oil Ksc 2.2 1.6(0.9) 1.3(0.5) (TRIP
pr. reduced)
4. TGOP start Ksc 8.75
5. EOP start Ksc 1.60
6. Turning gear Ksc 0.6
motor interlock
7. AOP pump Ksc 8
running
8. TGOP running KSC 2
9. EOP running Ksc 2
10. Hydraulic oil pr. Ksc 14 11.7 5.5 (TRIP)
11. Exhaust hood C 45 85 105 (TRIP B/p)
temp
12. Turbine Rpm 3000 3300 3360
overspeed 110% 112%
hyd Elec
13. Turbine seal Ksc 0.25 0.21 0.35 (ATRS)
steam pr 0.15 ACS
0.1 DAS
14. Turbine IP diff Mm +8.3 -4.6
exp.
15. MOT oil level Mm 1350 1140 1390
16. Emergency oil pr. Ksc 6 (TRIP)
low
17. Turbine LP diff Mm +12.6 -3.2
exp.
18. Turbine brg vib Micron 80 Al(125)
19. Turbine brg. C 80 95
Temp
20. Turbine thrust C 75 90
bearing temp
21. Exhaust water Ksc 2 Al 3.5
spray in operation
22. Turbine lube oil C 65
temp form cooler (TRIP)
23. Turbine thrust Mm +/- +/-0.5 +/-0.8
wear 0.3
24. Steam seal cond Mm +/- 5950
level 5800
25. Oil drains brg C 60 85
high temp
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Sl.no. Alarm/protection Units Oprt. Low Lo-lo Hi Hi-hi Remarks

Val
26. Oil filter high DP Ksc 0.3 0.5
27. HP cyl DT upper C +/- 50
IP Cyl DT lower +/- 50
28. Upper/lower 5 th C +/- 50
DT

29. Upper/lower 6 th C +/- 50

DT

30. HRH temp afte IV C 535 400 400

L/R
31. SH/RH OUTLET C 540 535 545
TEMP
32. HPT EXHAUST C 540 535 545 350
TEMP 335
33. HP bypass down Ksc 40
stream pr.
34. Condenser Ata 0.45
vacuum for LP
Bypass
35. Condenser level Mm 710
high
36. LP bypass down Ksc 6
steam pr.
37. LP bypass spray Ksc 32 25
water pr low
38. HP bypass down C 335 350
steam temp.
39. Control oil pr Bar 120 90
low(Hp bypass)
40. CRH drain pot Mm
level
41. Feed storage pr. Ksc 11 11.8 12.5
42. HPH-6 steam pr. Ksc 39 10% up
43. HPH-5 steam pr. Ksc 22.539 Ext. pr.
44. HPH-5&6 drip Mm 350 200 500 860
level
45. D/A level Mm 2600 1000 480 2950 3050
46. LPH 2- & 3 level Mm 150 87 196 296
47. LPH-1 level Mm 250 187 120 205 460
48. Condenser level Mm 460 310 150 650 750
49. CRT level Mm 750 2500
50. CEP disc.pr. Ksc 32 28.5 27.5
51. CEP bearing C 26.5 25 70 30 sec DT
&75 motor brg
52. CEP suction Mwcl 0.6
strainer DP
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Sl.no. Alarm/protection Units Oprt. Low Lo-lo Hi Hi-hi Remarks

Val
53. CEP hot air temp. C 90
54. CPU pr. high Ksc
55. Cond pr. to Ksc 25
LP-bypass
56. BFP BP suction Mwcl 3.5
DP
57. BFP thrust brg C 75
temp
58. BFP mech seal C 80
water outlet temp.
59. BFP delivery C 236 (trip)
temp
60. BFP suction temp. C 200
61. BFP journal brg C 75
temp
62. BFP hyd coupling C 90 130
brg temp.
63. BFP motor hot air C 55/90 Cold/hot(air
temp Trip)
64. BFP working oil C 75/130
to/from cooler
temp
65. BFP lube oil C 95/55
to/from cooler
temp
66. BFP reduction C 90
gear bearing
temp.
67. BFP disch header Ksc 170 155 120
Pr
68. BFP suction pr. Ksc 10 7(trip)
69. BFP lube oil pr. KSC 1 0.5
70. BFP cooling Ksc 2
water header pr.
71. BFP suction 0.6
strainer DP
72. BFP booster T/h 50
pump flow
73. BFP balancing Ksc 23 25
line pr.
74. BFP lube oil pr. KSC 1.2 0.7 0.5 0.8(perm 3.5( FOR
for BFP starting
AOP )
75. BFP BP suction Ksc 11 6
pr
76. BFP motor Lpm 200 (BPF trip
cooling water bypassed)
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Sl.no. Alarm/protection Units Oprt. Low Lo-lo Hi Hi-hi Remarks

Val
flow
77. HP flash tank C 50 100
78. Cond.Water box Mwcl 5
DP
79. Raw water pr. Ksc 5 3
80. MOT cooling Lpm 1400
water flow
81. Centrifuge oil C 60 70 90 Water temp
outlet temp
82. BFP pump Ksc 70 50
discharge pr

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GENERATOR PROTECTION SETTINGS:

Sl.no. Protections Set values

1. Gen diff protection 87 G -0.25amp
2. Gen transformer overall diff 87 GT -30% of 5 amps
3. Gen stator earth fault 64G1 TMS –0.2
4. Gen standby earth fault 64 G2
5. Gen Over voltage relay 59 G -116.5V
6. Gen reverse power 37 G Timer 1-2 sec
2-50 sec
7. Gen low forward power 32G -t: 2sec
8. Gen loss excitation
a) without under voltage –40G k-1=0.91 ,k2=2.5
b) with under voltage –40G k3=0.5,k4=2.0
k5=13.4
trip time 2 sec reset time
Under voltage relay aux to loss of excitation 10 sec
relay 70-80%
9. Gen pole slipping 98G 2TO k1=0.90 k2=0.55
95G k3=4 Q1 –q2=75
t=56msec XI=1.02
VTGM k1=2.0,k2=0.74,k3=2.0
k4=1,k5=1.55,Q=75
10. Gen overload alarm –57G 4.8amp t=15sec
11. Gen backup imp.-21G K1-12,k2=0.63 t=1.5sec
and 2 sec
12. LBB protection 86G Current 0.1A timer 0.2sec
13. Gen under frequency 81G Alarm 48.5 hz t=5sec
14. GT restricted earth fault 64GT 0.1 A
15. GT backup E/F protection 51NGT PS-0.1A,TMS 0.3
16. GT over fluxing 99GT V/4-1.13-timer 0.5sec
alarm,-30sec trip)
17. Gen cold gas temp 65 C
18. Gen seal oil DP low 0.2 ksc
19. UT diff 30%
20. UT backup O/L protection P5.0.75Amm
TMS 0.3 sec.
21. Over head line diff 0.2 amp.

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Generator:

Sl.no. Alarm/protection Units Oprt. Low Lo- Hi Hi- Remarks

Val lo hi
1. Gen cold gas temp C 50 60 65
(trip)
2. Gen hydrogen Ksc 2 0.22 2.2
pressure
3. Hydrogen purity % 98 92
4. Seal oil filter DP Mwcl 0.5 0.8
5. Seal oil vacuum MmHG 750
tank
6. Vacuum tank level -150 +150
7. Seal oil feed pr Ksc
8. Seal oil- hydrogen Ksc
DP
9. Gen hydrogen Lpm 6 5.5
cooler water flow
10. S.O.Cooler flow Lpm 0.35 0.3 0.2
11. High level in seal Mm 87
oil discharge tank
12. Water /oil losser Cucm
13. Gen stator winding
temp U,V,W
14. Seal oil feed pr. Ksc 5.6
15. Hydrogen drier C 75
heater cut out temp

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Transformer (H.T.)

Sl.no. Alarm/protection Units Alarm Trip

1. GT winding temp C 100 110
2. GT oil temp C 85 95
3. GT overfluxing ratio % 1.1(30sec)
V/F
4. UT A/B winding temp C 90 100
5. UT A/B oil temp C 80 90
6. UT A/B cooling fans C 65 75
Auto starting/stopping Gr-1 Gr-2
7. Station transf. ½ C 90 100
winding temp
8. Station transf ½ oi l C 80 90
temp
9. Stan.trf1/2 cooling C 65 75
fans/pumps Gr-1 Gr-2
Auto starting/stopping
10. Stantion trf O/L
protections
11. CW trf winding temp C 90 100
12. CW trf oil temp C 80 90
13. CW trf overload % 125 0.25sec
protection
14. CW.trf cooling fans C 65 75
Auto starting/stopping Gr-1 Gr-2
15. WTP trf winding temp C 90 100
16. WTP trf oil temp C 80 90
17. WTP trf overload % 125 0.8 sec
protection
18. Col trf winding temp C 95 105
19. Col trf oil temp C 90 100
20. Col trf overload % 100 0.7 sec
protection
21. Auto transf. ½ winding C 90 100
temp
22. Auto transf ½ oi l temp C 80 90
23. Auto.trf1/2 cooling C 60/70
fans/pumps
Auto starting/stopping
24. Auto trf O/L protections %
25. Auto transf. ¾ winding C 90 100
temp
26. Auto transf 3/4oi l temp C 80 90
27. Auto.trf3/4 cooling C 60/70
fans/pumps
Auto starting/stopping

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Sl.no. Alarm/protection Units Alarm Trip

28. Auto trf3/4 O/L %
protections
29. Tie transf. ½ winding C 90 100
temp
30. Tie transf ½ oi l temp C 80 90
31. Tie.trf1/2 cooling C 60/70
fans/pumps
Auto starting/stopping
32. Tie trf O/L protections % 100 110
33. SY compressors Ksc 130/125 120/135
1/2/3/Auto 1/2 /3/cutoff
cut in./cut off
34. 400 kv /220 Kv breakers
a)SF6 pr Bar 6.7+/-0.1 (auto
Normal pr 8 bar reclose lock out)
7.0- 6.5+/-
0.1(trip lock)

b)Air pr (30.6/32) Bar 28 (auto reclose

lockout)
27.3 close
lockout
c)Oil pr(pump Bar 26 trip lockout
on/off){BHEL types} 325+/-3, 312+/-3
273+/- 3(closing
lockout)
253+/-
3(OPENING
d)Chandrapur lockout)
lindes(400KV SF6) Bar 6.5 Lockout
Air Pr ( comp Bar
Start/stop) 7.
37—36
34auto reclose
lockout
32alarm
31close lockout
30trip lockout
35 Shunt reactor winding C 105 115

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Transformer (L.T.) Protections:

Sl.no. Alarm/protection Units Alarm Trip

1. Unit service trf winding C 100 105
temp
Unit service trf oil temp C 85 90
Unit service trf O/L % 1400%
2. Unit lighting trf winding C 100 105
temp
Unit lighting trf oil temp C 85 90
Unit lighting trf O/L % 1200%
3. ESP trf winding temp C 100 105
ESP trf oil temp C 80 90
ESP trf O/L % 500%
4 Station LT trf winding C 100 105
temp
Station LT trf oil temp C 80 90
Station LT trf O/L % 1400%
5. Ash slurry trf winding C 100 105
temp
Ash slurry trf oil temp C 80 90
Ash slurry trf O/L % 1400%
6. Ash slurry LTG trf O/L % 1400%
7 F.O LTG trf O/L % 1400%
8 Ash water trf O/L % 1400%
9 CT trf O/L % 1400%
10 S/Y trf O/L % 1400%
11 WTP LT trf O/L % 1400%

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HT motors current settings in AMPs.

Sl.no. Name of motor Normal Hi-Alarm Hi-hi Trip

current
1. ID fan motor O/L 125.2 132 158
2. FD fan motor O/L 143.9 154 192
3. PA fan motor O/L 43.7 46 54
4. BFP motor O/L 322.3 340 432
5. CEP motor O/L 75.6 80 96
6. Mill motor O/L 26.4 28.9 32.4
7. Clarified water pump 21 22.2 26.1
motor O/L
8. Raw water pump motor 31 33 34.5
O/L
9. Cw pump motor O/L 154 160 192
10. IAC motor O/L 21 22.2 26.1
11. PAC motor O/L 20 25.2 32.4

Most of the trips setting are at high value itself for safety of the motors.

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