EMERGENCY OPERATING APL- (PH 3 & 4) REV NO

PROCEDURE 5 x 660 MW 0.0

APL - 660MW UNITS

EMERGENCY
OPERATING PROCEDURE
HAND BOOK

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Dear All, Dt.03.02.2012

An effort has been made to prepare a hand book on 660MW Emergency

Operation procedures,Rev.0 that may occur during 660MW Supercritical Units
Operation. This book contains 112 Emergencies with its possible causes, plant
response to the emergency, parameters of concern and immediate operator
actions. The emergencies are sectionalized as Station/Unit, Boiler &
Auxiliaries, Turbine & Auxiliaries, Electrical system.

This book will be helpful for Operation Engineers in understanding the

emergency occurred, and course of effective action to control the Unit
parameters. This book will be useful to Operation Engineers as refreshing
course.

Suggestions are always welcome to improve the effectiveness of this book.

660MW –Operation Team H.O.D-O&M

INDEX

A. Station/Unit Emergencies

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S.NO SYSTEM DESCRIPTION PAGE.NO

1 Station Blackout 12

2 Unit Tripping 14

3 Instrument Air Failure 15

4 Hammering In Pipe Line 16

B. Boiler & Auxiliaries Emergencies

S.NO SYSTEM DESCRIPTION PAGE.NO

1 19
FD Fan Tripping
2 20
ID Fan Trip
3 21
PA Fan Tripping
4 22
APH main motor Tripped and Auxiliary Motor not started

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5 AC Scanner Fan tripped and DC Fan fail to Pickup 23

6 Mill Seal Air Pressure Loss 24

7 Fire in Coal Mill OR Mill Explosion 24

8 One OR More than One Coal Mills Tripping 26

9 Boiler Water Wall Tube Leakage 27

10 Economiser Tube Leakage 28

11 Super Heater Tube Leakage 29

12 Reheater Tube Leakage 30

13 MS Temperature Falling Fast 31

14 Main Steam temperature rising fast 32

15 Reheater Temperature Falling Fast 33

16 Reheater Temperature rising Fast 34

17 Boiler Separator or MS Pressure Rising Fast 35

18 Boiler Seperator or MS Pressure dropping fast 36

19 ERV/MS Safety Valve Lifted 37

20 HRH Safety Valve Floating 38

21 OHDR Falling Fast 38

22 OHDR rising Fast 39

23 Arch Inlet Temperature Rising Very Fast 40

24 Sudden Loading of ID Fan 41

25 Air Flow Going Low and High 42

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26 Heavy Furnace Pressure Fluctuation 43

27 PA Header Pressure Dropping Fast 44

28 Oil Level Loss in APH Bearing 45

29 Sudden Increase in Steam Silica 45

30 Boiler Water pH Falling Fast 46

31 Boiler Expansion not OK during Cold Start up 47

32 Bunker Fire 47

33 Water Level in Separator at Load >300MW 48

34 Oil Spillage Observed In Bottom Ash System 49

35 Loss of Seal Trough level 50

36 Bottom Ash Scraper Conveyer Failure 51

37 Bottom Ash Cooling Tower Sump Level Low 51

38 LRSB Not Retracting 52

39 Boiler Flue Gas Exit Temperature Shoots Up 52

40 Heavy Ash Built Up In Any ESP Hopper 53

41 BCP Cooling Water Temperature High 54

42 DCS Console Hanged/Failed 55

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C. Turbine & Auxiliaries Emergencies

S.NO SYSTEM DESCRIPTION PAGE.NO

1 Hot well level raising fast 57

2 Hot well dropping fast 58

3 59
Deaerator Level High
4 Deaerator Level Low 59

5 CEP Tripped and Standby Fail To Start 60

6 TDBFP Tripped 61

7 One TDBFP Tripped and MDBFP not available 62

8 Any CW pump tripped 64

9 One CW pump tripped and Standby not available 65

10 HP Heater level Maintaining High 66

11 67
Turbine Vibration High
12 Turbine Bearing Temperature High 69

13 High axial Shift 70

14 HP LP Differential Expansion more Positive 71

15 HP LP Differential Expansion more Negative 72

16 High Eccentricity 73

17 Turbine Speed maintaining below 47.5Hz 74

18 Turbine Speed maintaining above 52Hz 75

19 Barring gear not established after unit tripping 76

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20 Both JOP Fail To Start 77

21 One of the Turbine’s CV or CRV Fail to close on Tripping 78

22 One of the Turbine’s CV or CRV Close and turbine on load 78

23 Turbine starts rolling on MSV/RSV opening 80

24 Turbine MOP failure 80

25 MOT Level Low 81

26 HP Exhausts Temperature Shooting Up 82

27 83
LP Exhaust Temperature Shooting Up
28 Gland Steam Pressure Low 84

29 Gland Steam Temperature Low 85

30 86
Gland Steam Pressure High
31 86
Gland Steam Temperature High
32 Control oil (EH oil) leakage 87

33 88
Control Oil (EH) Oil circulation Pump Failed
34 Seal Oil Pressure Going Low 89

35 VOT Level Low 90

36 Seal oil float tank level low 91

37 Seal oil float tank level high 92

38 Hydrogen purity low 93

39 Hydrogen Leakage 94
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40 95
Both Vacuum Pump Failed
41 Condenser Vacuum Low 96

42 Condenser Pressure Rise After Vacuum Loss (In Blackouts and Shut 97
Down Condition)

43 Condenser Tube Leakage 98

44 Generator winding temperature rising fast: 99

45 Water / Oil Detected In Generator Casing 100

46 Cooling Tower Fan tripped 101

47 Fore bay level dropping fast 101

48 All Sea Intake Water Pumps Tripped 102

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D.Electrical system Emergencies

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S.NO SYSTEM DESCRIPTION PAGE.NO

1 Power supply failure on emergency PCC 105

2 DG Not Started in Auto 106

3 Station transformer failure 107

4 UPS Failure 108

5 DCDB Failure 109

6 110
DC fails of Motor Feeder
7 High Bus Transfer Blocked 110

8 Flash over 111

9 Fire in cable gallery 112

10 Gas pressure low of circuit breaker 113

11 Hot spot 113

12 High oil/winding temperature of reactor 114

13 Oil leakage in reactor CB/CT/PT 114

14 Two reactor tripped back to back 115

15 SCADA not responding 116

16 All ESP field trips 116

17 117
Repeated tripping of rapping motor of ESP

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STATION/UNIT - EMERGENCIES

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1.Station Blackout

Immediate Action to be taken:

1. Inform to SLDC (SCE)
2. Ensure Turbine EOP came into service. If not, start the EOP from DCS. Incase of DCS problem, there is provision to start
EOP from backup panel.
3. Ensure DC seal oil pump came into service. If not, start the SOP from DCS. Incase of DCS problem, there is provision to start
SOP from backup panel.
4. Ensure Generator breaker, Field breaker and Unit bus incoming breakers have opened.
5. Ensure TDBFP-A EOP came into service. If not, start the EOP. Ensure TDBFP-B EOP came into service. If not, start the
EOP.
6. Ensure DC scanner fan came into service. If not , start the fan.
7. DC JOP starts at 2000 RPM in Auto. If not, start the pump.
8. UPS, DC loads will be met by battery.
9. Diesel fire water pumps (Hydrant, spray) are available for fire / spray water requirement.
10. Close steam lines & turbine drain valves (manual) to avoid failure of condenser rupture disc.
11. Inform DM plant to Isolate CW Chlorine tonner
12. DG starts in Auto and Emergency PCC, Boiler, Turbine Emergency MCCs gets charged. If not, start the DG from local and
charge the emergency PCC.
13. Ensure both APH are running, if not start from DCS or Local.
14. Ensure that all fuel oil trip valves are closed
15. If soot blower was in service, retract manually.
16. Close separator overflow drain MOV/MIV
17. Ensure all 6.6 KV drives breakers are open.

Turbine Side:
1. Close MS stop valves, Close HP-LP bypass valves, Close turbine drain MIVs.
2. Open vacuum breakers after isolating all steam lines/drains to condenser and close gland steam supply valves.
3. Close CW hot blow down valve.
4. Start Turbine Lube oil pump. Stop EOP.
5. Start AC seal oil pump (A / B). Stop DC pump.
6. Start AC JOP. Stop DC JOP.
7. Start MD BFP AOP.( Not essential if pump is not in service before blackout )
8. Ensure turbine barring came into service. Otherwise start manual barring.
9. Ensure TDBFPs EOP remains in service as No emergency power to LOP
10. Ensure DCDB and UPS come on AC supply from battery source.

Boiler Side:
1. Ensure running of DC scanner fan. ( No emergency supply for AC fan )
2. Open RH vent valve.
3. Start ID, FD, and PA fans lube oil pumps.
4. Start ID fans bearing cooling fan .( A / B )
5. Start mills lube oil pumps.

DC And UPS:
1. Check the healthiness of battery chargers.( Main plant )
2. Check the healthiness of UPS.( Main plant )
3. Check the healthiness of battery chargers.( switchyard )
4. Check the healthiness of UPS.( switchyard )
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5. CW system DC load will be met by battery. ( No emergency power to chargers )

Note:
1. Note down the protections acted in Generator, Transformer, switchyard, Boiler, Turbine. Switchgear.
2. Check for TG vibration during coasting down and note down the coasting down time and max vibration
3. Remove all 6.6 KV from Stand-by mode and give one stop command pulse.
4. Ensure that all normally open tie breakers of 6.6/11 KV buses are open
5. Turbine, Boiler lifts will be available, don’t operate lifts and isolate the power supply after park at 0mtr with caution tag.
6. All MOVs, Motor operated dampers will be available on emergency power.

Normalization:
After blackout 11kv, 6.6 kV switchgear incomers, Motor feeders, PCC incomers will open on under voltage. MCC incomers
will remain close. CHP, CW 6.6 kV breakers will remain close. Operate all breakers from control room with local operator
clearance.
1. Co-ordinate with 220 KV/400 KV switchyard operators for power restoration.
2. Charge ST 5, 6 once power is available.
3. Charge Station switchgears , Unit switchgears.(11, 6.6 KV)
4. Charge Boiler PCC, Turbine PCC, ESP PCC.
5. Charge lighting PCC, Maintenance PCC.
6. Charge Water supply PCC , Chemical water PCC.( DM plant )
7. Normalize EPCC and stop DG.
8. Charge CMCTF PCCs ( CT )
9. Charge CHP PCC.
10. Start TD BFPs lube oil pumps. Stop DC pumps.( No emergency supply for AC pumps )
11. Start AC scanner fan. Stop DC fan. ( No emergency supply for AC fan )
12. Ensure DM plant, RO plant and CHP power restored.
13. Start service water pump.
14. Start air compressor and dryer.
15. Start circulating water pump as per SOP.
16. Start CTP.
17. Start ACW pump
18. Start CCCW pump.
19. Start control room air conditioning.
20. Stop diesel fire pumps.
21. Check the healthiness of battery chargers, UPS.

Action If DG fails or EPCC under Fault:

1. Turbine DC EOP, DC JOP will be in service. . Manual barring to be done.
2. TDBFPs EOPs will be in service.
3. DC seal oil pump will be in service.
4. DC scanner fan will be in service.
5. Vacuum breakers to be opened manually.
6. Boiler main steam stop valves to be closed manually. Close separator overflow drain MOV/MIV manually.
7. HP, LP bypass will remain close.
8. Rotate APH manually.
9. DC, UPS load will be met by battery.
10. Try to restore DG / Normal power as early as possible.

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Readiness for Blackout:

Emergency drives will not be in service during normal operation. To keep them in good condition and to know the availability
periodical trial is required. Following points to be ensured for safe handling of blackout.

1. Biweekly trial of Turbine EOP.

2. Biweekly trial of TDBFPs EOPs.
3. Biweekly trial of DC Seal oil pump.
4. Daily trial of DG sets.
5. Biweekly trial of DC scanner air fan.
6. Biweekly trial of diesel fire water pumps. (hydrant, spray)
7. Weekly checking of emergency lights.( DC / AC lights in control room )
8. EPCC , DG are ready for auto charging.( ref: EPCC charging SOP )
9. DC chargers, UPS battery is in good condition to take load.
10. Drawings of DC drives, Emergency PCC, Emergency MCC, DG sets to be kept in location for immediate reference.
11. Turbine manual barring handle to be made available.
12. Spanner to open the cover for manual barring to be made available.
13. APH manual rotation handles to be made available.
14. Soot blower handles (wall blower, LRSB) to be made available to withdraw blower after blackout.
15. Torch lights to be made available for every person.
16. Search light to be made available in control room.

2.Unit Tripping

Immediate checks if only Turbo Generator trips:

1. Ensure Generator breaker, Field breaker and Unit bus incoming breakers have opened and Turbine is coasting down, TOP and
MSP started on auto.
2. Ensure HBT changeover happened successfully.
3. Inform to SLDC.

If Boiler Has Survived:

1. Ensure HP-LP bypass has opened and maintain MS, RH pressure.
2. Maintain LDO and HFO pressure and reduce firing as per requirement.
3. Maintain feedwater flow by MDBFP and BCP.

Immediate checks if Boiler also trips along with TG:

1. Ensure all fuel trip valves are closed.

2. Close HP-LP bypass valve to hold boiler pressure.
3. Ensure closure of SH and RH spray valves.
4. Ensure Vacuum is normal, CW, ACW and CCCW pumps are running.
5. Ensure closure of all Extraction block valves.
6. Open all Turbine side Drains.
7. Ensure JOP starts at 2000 rpm and Turbine comes to barring.
8. Ensure auxiliary steam header interconnection valve opened to maintain auxiliary steam pressure and Gland steam pressure
and temperature.
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9. Ensure Deaerator pressure maintaining by auxiliary steam.

10. Start CTP to maintain Hotwell level and reduce Deaerator control valve to maintain Deaerator level.
11. Ensure DC and Emergency power supplies are normal.
12. Ensure Air compressors are running and Instrument air pressure is normal.
13. Ensure all soot blowers are out and closure of Sootblowing mov.
14. Inform to AHP, DM plant and CHP and ensure all ESP fields are switched off.
15. Start MDBFP and feed water to boiler as per boiler operating instructions.
16. If separator level normal start BCP.
17. Purge and Lit-up the Boiler.

3.Instrument Air Failure

Likely causes:
1. Tripping of air compressor.
2. Sudden increase in consumption.
3. Malfunction of air compressor.
4. Instrument air receiver air leak/Drain valve might be in opened condition.
5. Tripping of Station transformer.
6. Tripping of Service water pumps.
7. Tripping of compressor lube oil pumps due to power supply failure.
8. Instrument air piping failure at valve flange or pipe welding joints.

Plant Response:
1. TDBFP, MDBFP recirculation valve will open fully.
2. All extraction NRVs will close on air failure.
3. Ventilation valve will open fully.
4. BDV valve will open.
5. CEP recirculation will open fully.
6. Stator CW PCV,TCV will open fully.
7. All heaters emergency control valve will open fully.
8. All extraction line drains will open.
9. MSV,MSCV,HRH CV,CRH line drains will open.
10. Deaerator overflow valve will open .

Parameters of Concern:
1. Sudden drop in condenser vacuum.
2. Feedwater flow will decrease.
3. OHDR will rise suddenly.
4. Condensate flow will go down;
5. Unit load will rise.
6. SH,RH temperature will rise.
7. Mill HAGs will not operate.
8. Deaerator level will drop.

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Expected Operators Action:

1. Try to arrest or isolate the air leakage as soon as possible.
2. Start IAC-5A in case of ST failure.
3. Start compressor lube oil pump by normalizing AHP 415v supply.
4. Open service air interconnection from unit-4 and charge instrument air header through air dryer.
5. Check Service water pressure, if required start second pump.
6. Close service air valve to maintain Instrument air pressure.
7. Hand trip the Unit, if Instrument air pressure goes very low.

Final Corrective Actions:

1. One service water pump supply to be changed from Unit bus.
2. Compressors lube oil pumps stand-by power source to be provided.
3. Compressors parameters to be given in control room DCS for better monitoring.
4. Air lock relay/ receiver tank to be provided for critical valves.

4.Hammering In Pipe Line

Likely causes:
1. Proper charging procedure not followed.(eg: Auxiliary steam header, Heaters charging)
2. Sudden entry of steam into water lines.
3. Sudden entry of steam into improperly drained pipelines.
4. Improper warm up during charging steam lines.
5. Faulty drain traps.
6. Sudden opening of high pressure valves.
7. Temperature difference between medians.
8. Improper venting of heaters on water side.
9. Sudden start/stop of high pressure pumps.
10. Not priming the lines before starting.

Plant Response:
1. Abnormal sound.
2. Damage to pipe lines.
3. Damage to hangers.

Parameters of Concern:
1. Thermal shock to piping system.
2. Pipe line failure.
3. Check hangers and supporting systems.

Expected Operators Action:

1. Cut off steam supply.

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2. Open drains & trap bypass valves.

3. Wait for full draining/proper warm up.
4. Slowly open valve and allow steam to come out of drains.
5. Allow system pressure to build up.
6. Close drains & put trap in to service.
7. If it is a water line ensure no steam/hot water is entering pipeline (eg: close CEP to Booster pump sealing line valve) .

Final Corrective Actions:

1. Put control on auto only after achieving designed system pressure and temperature .

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BOILER AND AUXILARIES -

EMERGENCIES

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1.FD Fan Tripping

Likely causes:
1. ID fan Tripped & general interlock is in service.
2. Respective APH tripped.
3. FD fan bearing bush vibration > 7.1 mm/s.
4. Hydraulic oil supply pressure low & low low.
5. Fan bearing temperature high > 95°C.
6. Motor bearing temperature high > 95°C.
7. Motor winding temperature high > 120°C
8. Both hydraulic oil pumps tripped.
9. FD fan Running & O/L gate closed (Delay 20 sec).
10. Electrical protections.
11. Furnace pressure HH > 4 Kpa. (post purge trip).
12. Any Transmitter malfunction.

Plant Response:
1. Tripped fan blade pitch & discharge damper closes.

2. Interconnection damper opens.

3. Total air flow to the wind box reduces.

4. Furnace pressure and secondary air pressure starts falling.

5. Flue gas Oxygen percentage reduces.

6. Furnace to Wind box DP will come down.

7. ID fan starts adjusting its blade pitch (if in auto).

8. Metal temperature may increase.

9. Second FD fan start loading if it is in Auto.

10. Chance of improper combustion and CO formation.

Parameters of Concern:
1. Blade pitch & disc damper closure for tripped fan.
2. Running fan current, Bearing and winding temperature, Vibration.
3. Fuel cut out to 50% to 60% TMCR.
4. Flue gas Oxygen %.
5. Fuel to Air ratio.
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6. Main stream temperature.

7. MS pressure.
8. Metal temperature.
9. Load.
10. Ensure no reverse rotation of tripped fan.

Expected Operators Action:

1. Close tripped fan Blade pitch & disc damper if it not closed.
2. Monitor running fan parameters and motor parameters.
3. Reduce coal flow according to total air flow.
4. Keep 4 mills in running (tripping of more mills reduce the PA flow contribution to total air flow ).
5. Maintain furnace pressure.
6. Monitor MS Temperature, pressure, OHDR.
7. Reduce load set point with respect to MS pressure.
8. Inform local operator to checked tripped fan condition.
9. Inform C&I if any transmitter malfunctions.

Final Corrective Actions:

1. Find root cause of fan tripping.
2. If fan is available, start it again and maintained load.

2.ID Fan Trip

Likely causes:
1. APH trip.
2. Fan bearing temperature HH.
3. Fan bearing vibration HH.
4. Fan motor bearing temperature HH.
5. Fan motor winding temperature HH.
6. ID fan overloaded.
7. ID fan lube oil pressure LL or both lube oil pump trip.
8. Post purge trip.
9. Discharge damper closed
10. Motor protections acted.

Plant Response:
1. Particular FD fan trip(if general interlock put in service)
2. Furnace pressure goes to positive.
3. Oxygen rapidly decreases.
4. Total air flow decreases.
5. Wind box DP rapidly decreases.
6. Inter connection damper of FD fan open upon FD trip.
7. Furnace flame may disturb.
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8. Running ID fan and FD fan loading increase.

9. Top two mills will trip if runback is in service
10. Power generation will reduce.

Parameters of Concern:
1. Oxygen in flue gas at APH inlet.
2. Furnace pressure.
3. Wind box DP.
4. Running ID and FD fan loading.
5. Power generation.
6. Main steam parameters

Expected Operators Action:

1. Trip one top mill immediately if runback is not active.
2. Reduce coal in other mills up to 50 % of TMCR.
3. Increase running ID and FD fan loading up to rated current.
4. Ensure tripped ID and FD fan discharge damper fully closed and inter connection damper of FD fan open.
5. If required trip another mill from top elevation otherwise reduce coal flow from other running mill for maintaining excess
oxygen and total air flow.
6. Maintain feed water flow w.r.t. water coal ratio.
7. If required one TDBFP may be cut out after paralleling the MDBFP (with SCE clearance).
8. Decrease the power generation up to 50%.

Final Corrective Actions:

1. Ensure lube oil tank level is healthy.
2. Ensure lube oil and hydraulic pressure is healthy and interlock pump available.
3. Ensure fan and motor bearing and winding temperature is healthy.
4. Ensure fan vibration is healthy and all vibration probe reading normal.
5. Start ID fan and take it in to load after necessary checking.
6. Ensure ID fan loading up to rated current.

3.PA Fan Tripping

Likely causes:
1. Respective APH is tripped.
2. PA fan bearing temperature HH.
3. PA fan motor bearing or winding temperature HH.
4. PA fan bearing vibration HH.
5. PA fan lube oil pressure LL or both lube oil pump tripped.
6. Motor protection operated.

Plant Response:
1. PA header pressure drop rapidly.
2. Furnace pressure decrease.
3. Tripped fan outlet damper close.
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4. If RUNBACK is IN top two mills trip consequently with 2 second delay.

5. Mill inlet PA flow and pressure drops.
6. Mill outlet coal velocity decrease.
7. Running PA fan loading increase.
8. Power generation decrease.
9. Main steam pressure & temperature and OHDR decreases rapidly.
10. Inter connection damper opens.

Parameters of Concern:
1. Furnace pressure.
2. PA header pressure.
3. Mill inlet PA pressure and flow.
4. Running PA fan loading.
5. Power generation.
6. Main steam pressure & temperature and OHDR.
7. Flue gas oxygen.

Expected Operators Action:

1. Immediately trip the mills from top elevation to reach 3 mills operation.
2. Take LDO elevation 4 oil guns immediately.
3. Ensure tripped fan discharge damper fully close and inter connection damper of PA fan open.
4. Increase running PA fan loading for increase PA header pressure as per requirement up to rated current.
5. Reduce feed water flow as per coal flow to maintain water coal ratio, main steam temperature and OHDR.
6. To maintain feed water flow trip one TDBFP (with SCE clearance) after parallel MDBFP
7. Close SOFA dampers.
8. Reduce power generation up to 50% by maintaining main steam temp, feed flow and OHDR.

Final Corrective Actions:

1. Ensure lube oil tank level is healthy.
2. Ensure lube oil and hydraulic pressure is healthy and interlock pump available.
3. Ensure fan and motor bearing and winding temperatures are normal.
4. Ensure fan vibration is healthy and all vibration probes reading normal.
5. Start PA fan after necessary checking.
6. Ensure PA fan loading up to rated current.

4.APH main motor Tripped and Auxiliary Motor not started

Likely causes:
1. APH main motor tripped and the Auxiliary motor not in interlock
2. APH gear box problem
3. APH jamming and causing the overloading of Motors
4. Auxiliary motor is not ready from electrical(Module & VFD)

Plant Response:
1. APH trips and speed comes to Zero.
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2. Particular ID /FD /PA tripped.

3. Load will reduce.
4. Furnace pressure fluctuation.
5. O2 goes down rapidly.
6. MS/RH temperature and pressure goes down rapidly.
7. Wind Box DP decreases rapidly.
8. Running ID/FD/PA Fan’s loading increases.
9. Mills’ inlet PA flow and pressure decreases.

Parameters of Concern:
1. Power generation.
2. Furnace pressure.
3. O2 and Wind Box DP.
4. MS/RH temperature and pressure.
5. Running ID/FD/PA Fan’s loading.
6. Running Mills’ inlet flow and pressure.

Expected Operators Action:

1. Ensure APH inlet flue gas dampers are closed.
2. Ensure that primary air /secondary air APH outlet damper and respective tripped fan’s discharge dampers are closed.
3. Immediately trip two mills from top elevation and take 4 LDO guns.
4. Increase running PA Fan’s loading for increasing PA Header pressure up to required limit.
5. Adjust ID/FD fan as per furnace pressure O2, Wind Box DP.
6. Adjust feed water flow to maintain water coal ratio, MS temperature, OHDR as per coal flow.
7. Reduce load up to 50%.

Final Corrective Actions:

1. Follow up for causes to maintenance department.

5.AC Scanner Fan tripped and DC Fan fail to Pickup

Likely causes:
1. Both fan got overload/ electrical fault.
2. Standby DC fan fails to start after tripping of running AC fan trip.
3. Both fan running but still discharge pressure is LOW alarm persist by any reason of actual discharge filter choke or
malfunctioning of pressure transmitter.

Plant Response:
1. Boiler will trip on < 2.8 kpa scanner cooling air pressure low.
2. Scanner air fan tripped alarm
3. In adequate cooling of scanners may cause damage to scanner sensing element.
4. Flame cool fan pressure LOW alarm.
5. If flame cool fan suction filter is chocked discharge DP alarm switch act.

Parameters of Concern:
1. Cooling air to scanner.
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2. Unit tripping.

Expected Operators Action:

1. Try to start the fan by resetting the over load relay, even after Boiler trip.

Final Corrective Actions:

1. DC fan trail to be taken as per trail run schedule.

6.Mill Seal Air Pressure Loss

Likely causes:
1. Running seal air fan tripped and S/B has not picked up.
2. Mill Seal air line MOV or MIV closed / Malfunction.
3. Mill seal air fan suction manual valve closed.
4. Seal air fan Suction filter chocked and seal air discharge Header Pressure Low.
5. PA discharge pressure marinating low.
6. Seal Air leakage from seal air line.
7. Electrical protection operated.

Plant Response:
 Alarm display on DCS of Low seal air Pr.
 Mill thrust bearing damaged.
 Coal dust enters to mill seal and damages.
 Mill current.

Parameters of Concern:
1. Mill thrust bearing temp,
2. Mill vibration,
3. Mill current,
4. Mill bowl assembly will be damage.

Expected Operators Action:

1. Start another seal air fan if one fan tripped and not starting in auto.
2. Open Mill seal air MOV/MIV if closed.
3. Increase PA header pressure.
4. Close any stopped mill seal air MOV for increasing running mills Seal air pressure.

Final Corrective Actions:

1. Fan change over as per change over schedule.
2. Suction filters cleaning at regular interval.
3. S/B Fan filter cleaning.

7.Fire in Coal Mill OR Mill Explosion

Likely causes:
1. Mill outlet temperature maintaining high.
2. Foreign material in mill.
3. Coal quality (high CV).
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4. High VM coal with mill inlet PA temp high.

5. No material on feeder belt for few minutes and fire fighting SOV not open.
6. Rejection not cleared for long time.
7. Mill internal damage.
8. Coal accumulation in scraper chamber due to scraper damage.
9. Coal flow established suddenly at high mill outlet temperature.

Plant Response:
1. Mill outlet temperature shoots up.
2. Mill may trip on protection.
3. Surrounding may catch fire.
4. Mill gates and damper may not operated damage done by explosion.
5. Duct and bellow may damage.
6. Fluctuation in furnace pressure.
7. PA header pressure dropped rapidly.
8. Water coal ratio increase.
9. OHDR and main steam temperature decrease.
10. Power generation decrease.

Parameters of Concern:
1. Furnace pressure.
2. Water coal ratio and OHDR.
3. Main steam temp and PA header pressure.
4. Mill and duct surroundings.
5. Power generation.

Expected Operators Action:

1. Trip the particular mill if mill is not tripped.
2. Ensure the CAG/CAD, HAG/HAD of that particular mill is closed.
3. If possible adjust coal to other mill otherwise reduce load as per requirement.
4. Adjust feed water flow as per coal water ratio and OHDR to maintain MS temperature
5. Maintain PA Header pressure as well as furnace pressure (it tends to go towards negative side).
6. Check locally for any other damage due to mill explosion.
7. Unit shut down may be needed if PA duct got damage before HAG.
8. Clear the coal spreaded and barricade the area.
9. Inform Fire man for through check.

Final Corrective Actions:

1. Isolate mill and issue PTW for repair the Mill.
2. Always ensure Fire Fighting Solenoid valve availability.
3. Monitor Coal bunker level properly and regularly.
4. Monitor coal quality in co-ordination with CHP.
5. Clear the mill rejects every hour.

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8.One OR More than One Coal Mills Tripping

Likely causes:
1. Coal chocking in bunkers.
2. Mill protections acted.
3. 6.6kv bus side electrical problem.

Plant Response:
1. Load reduces rapidly.
2. MS/RH Temperature goes down rapidly.
3. MS/RH pressure goes down rapidly.
4. OHDR decreases rapidly.
5. Separator level rises if OHDR becomes zero.
6. Total air flow decreases.

Parameters of Concern:
1. Power generation.
2. OHDR and hence MS/RH temperature and pressure.
3. MS Flow.
4. Separator level.
5. Air flow.
6. Furnace pressure.
7. Water Coal ratio.

Expected Operators Action:

CASE 1: One mill tripped.
1. Ensure closure of MDV, CAG/CAD, HAG/HAD and open inerting valve of tripped mill.
2. Operate bunker air cannon if bunker outlet chock is suspected.
3. Maintain PA header pressure.
4. Adjust coal in running mills as per coal mill reliability.
5. Reduce Feed water flow to maintain water-coal ratio, OHDR, MS temperature as per coal flow. Maintain furnace pressure.
6. Reduce load as per coal flow to maintain MS pressure/temperature, Water-coal ratio.
CASE 2: Two mills tripped.
1. Ensure closure of CAG/CAD, HAG/HAD of tripped mills.
2. Reduce the load up to 50%.
3. Reduce Feed water flow rapidly to maintain water-coal ratio, OHDR, MS temperature as per coal flow.
4. Maintain furnace pressure.
5. Incase of two mills tripping due to Runback active(during load>580MW), to reduce feedwater flow rapidly, One TD-BFP
may be tripped after paralleling MD-BFP.

Final Corrective Actions:

1. Follow up for cause to maintenance department.

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9.Boiler Water Wall Tube Leakage

Likely causes:
1. Poor water quality
2. Metal temperatures remains higher side for long time
3. Feed water flow is not adequate.
4. Any wall blower is in advanced position for long time and steam is charged.
5. Poor tube material and welding joints quality.
6. Furnace to wind box DP is not maintained.
7. Corrosion at fire side and water side of tubes.
8. Starved water walls.
9. Blocked tubes.
10. Bursting of tubes due to pressure fluctuations.
11. Improper setting of safety valves.

Plant Response:
1. Boiler make-up water consumption will increase.
2. Fluctuation in furnace pressure.
3. I.D.Fan will draw more current.
4. Water wall metal temperature will remain high around the leakage.
5. Abnormal sound comes from the boiler furnace.
6. Leakage detectors show high intensity.
7. O2 fluctuation at APH inlet.
8. Generation may vary.

Parameters of Concern:
1. D.M.Water make-up.
2. Furnace pressure.
3. I.D.Fan current.
4. Water wall metal temperatures.
5. Acoustics intensity.
6. O2 at APH inlet.

Expected Operators Action:

1. Inform shift in charge about the changes in parameters immediately.
2. Check the boiler furnace for any abnormal sound inside.
3. Closely monitor furnace pressure and ID fan current.
4. Closely monitor D.M. make-up.
5. Reduce the load if necessary.
6. If the leakage is heavy and difficult to compensate feed water, shut down the boiler.

Final Corrective Actions:

1. After shut down, attend the tube leakage.
2. Take boiler hydro test before taking the boiler into service again.

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3. Maintain desired water quality.

4. Maintain parameters like feed water flow, OHDR, water wall metal temperatures etc.

10.Economiser Tube Leakage

Likely causes:
1. Poor water quality
2. Feed water flow not maintained adequate.
3. Soot blowing steam pressure is very high.
4. Flue gas velocity is very high.
5. Poor metallurgy and weak welding joints.
6. Ash erosion.

Plant Response:
1. DM Water consumption will increase.
2. ID Fan current increase.
3. Flue gas temperature at economizer O/L drops.
4. Abnormal sound comes out from economizer.
5. Water coming out of economizer ash hoppers joints.
6. Trouble found in economizer deashing.
7. ASLD shows high intensity.
8. APH inlet O2 reading decreases.
9. Feed water flow will increase.

Parameters of Concern:
1. DM Water make-up.
2. Economiser outlet flue gas temperature.
3. ID Fan current.
4. Economiser deashing.
5. ASLD intensity.
6. O2 reading at APH inlet.
7. Flue gas temperatures at APH Inlet and Outlet.

Expected Operators Action:

1. Check economizer zone in second pass for any abnormal sound inside.
2. Check economizer hoppers for any water leaking.
3. Closely monitor ID fan current.
4. Closely monitor DM make-up.
5. Reduce the load if necessary.
6. If the leakage is heavy and difficult to compensate feed water, shut down the boiler.

Final Corrective Actions:

1. After shut down, attend the tube leakage.
2. Take boiler hydro test before taking the boiler into service again.

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3. Maintain desired water quality.

4. Maintain parameters like feed water flow, soot blowing pressure as desired.

11.Super Heater Tube Leakage

Likely causes:
1. Main steam pressure very high.
2. Super heater safety valves fail to lift on very high pressure.
3. High super heater metal temp .
4. Poor water quality.
5. Erosion by ash due to high flue gas velocity.
6. Boiler running more than BMCR continues for long time.
7. LRSB operation for long time(not retracted).
8. Fire side corrosion.
9. Starvation.

Plant Response:
1. Fluctuation in furnace pressure.
2. Increase ID fans loading.
3. Leak detector shows high intensity in particular leakage area.
4. Increase DM water consumption.
5. SH tube metal temperature near to leakage may increase.
6. Drop in flue gas temperature at APH inlet.
7. Abnormal sound comes in boiler.
8. Increase difference between feed water and steam flow.
9. MS pressure and power generation will decrease.
10. Flue gas Oxygen reading may go down.

Parameters of Concern:
1. Furnace pressure.
2. ID fans current.
3. SH metal temp.
4. DM water consumption.
5. Furnace pressure.
6. Flue gas temp.
7. Main steam pressure.
8. Power generation.

Expected Operators Action:

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

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6. Shutdown the unit after confirming the tube leakage.

Final Corrective Actions:

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

12.Reheater Tube Leakage

Likely causes:
1. High reheater pressure due to IP turbine valve close and HRH safety valve fail to lift.
2. Poor water quality.
3. High Reheater metal temperature due to starvation.
4. Erosion of tube due to high flue gas velocity.
5. Boiler running more than BMCR continues for long time.
6. Advance any LRSB for long time.
7. Corrosion due to fly ash component.

Plant Response:
1. Fluctuation in furnace pressure.
2. Increase ID fans loading.
3. Increase metal temperature after particular tube leakage of reheater tube.
4. Drop of flue gas temperature at APH inlet.
5. Increase in DM water consumption.
6. Leak detector shows high intensity in particular leakage area.
7. Abnormal sound comes in boiler.
8. Power generation will decrease
9. Pressure drop across reheater coil will increase.
10. Flue gas Oxygen may go down.

Parameters of Concern:
1. ID fans current.
2. Reheater metal temp.
3. DM water consumption.
4. Furnace pressure.
5. Flue gas temperature.
6. Power generation.

Expected Operators Action:

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

Final Corrective Actions:

1. Repair leakage reheater tube.
2. Maintain water quality by closely monitoring CPU outlet parameters, SWAS parameters and co-ordination with DM chemist.
3. Maintain reheater metal temperature and pressure within limits.
4. Maintain flue gas velocity as per design value.

13.MS Temperature Falling Fast

Likely causes:
1. Tripping of one or more coal mills.
2. Fuel flow disturbance.
3. Malfunctioning of spray control valves.
4. Less air flow.
5. More spray.
6. Low feed water temperature.
7. Malfunctioning of gas biasing damper.
8. Inhering load set point fast.
9. Wall blowing may be in service.
10. Feed Water flow may be more.
11. Coal quality.
12. High excess air.

Plant Response:
1. Ms Temperature low alarm will appear.
2. Turbine expansion may become negative.
3. Axial shift.
4. Turbine shaft vibration.
5. Load will reduce.
6. Unit will trip <474 0C of MS temperature.

Parameters of Concern:
1. Main Steam Temperature,
2. Feed water flow,
3. Coal flow,
4. Flue gas O2,
5. Total air flow.
6. Transforming Parameters.

Expected Operators Action:

1. Close the spray control valve by taking into manual.
2. Check air flow and adjust.
3. Top elevation can be taken in to service / firing can be raised and close secondary air damper if open.
4. Reduce load set point.
5. Stop soot blowing.
6. Adjust feed water flow

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7. Check if any feeders malfunction or chocked.

Final Corrective Actions:

1. Initiate LRSB soot blowing if temperatures are maintaining still less.
2. Observed for improvement in temperature.
3. Put back spray control in auto.

14.Main Steam temperature rising fast

Likely causes:
1. Improper water and coal ratio.
2. Coal quality varying.
3. Feed water flow reduces.
4. Any BFP recirculation valve got open and feed water flow reduced.
5. SH spray valves malfunction
6. SH spray line leakage
7. Soot deposition on water wall
8. Improper air flow and SADC position.
9. Main stream flow reduces or pressure high due to HPSV, HPCV malfunction
10. Sudden increase in PA header pressure
11. Any mill got loaded suddenly
12. Any coal feeder feeding more coal than actual value.
13. Any oil gun admitted.
14. Sudden clear of soot during soot blowing.

Plant Response:
1. OHDR increases.
2. Metal temp high alarm will appear.
3. Spray control valves will go for further opening.
4. Load will rise for the same pressure.
5. Feed water flow increase in auto.

Parameters of Concern:
1. Metal temperature
2. Feed water flow
3. Total fuel flow
4. OHDR
5. Load
6. Air flow and Flue gas oxygen
7. SADC operation
8. Furnace to wind box DP
9. HP turbine casing and Differential expansion

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Expected Operators Action:

1. Reduce coal flow in top mill.
2. Increase feed water flow
3. Open SOFA dampers
4. Increase load set point , MS flow
5. Open spray systems and setting to desired value.
6. Do proper wall blowing.
7. Maintain proper air flow.
8. Maintain flue gas oxygen %
9. Adjust OHDR.

Final Corrective Actions:

1. Proper monitoring of parameters.
2. The operator should have proper idea of temperature limits of rising fast and down of temperature.
3. Proper working of Desuperheater valves.
4. Proper soot blowing schedule.

15.Reheater Temperature Falling Fast

Likely causes:
1. High air flow.
2. Tripping of one or more coal mills.
3. More spray.
4. Malfunctioning of spray control valves.
5. Malfunctioning of gas biasing dampers.
6. MS Temperature is low.

Plant Response:
1. ‘’Negative’’ Turbine expansion.
2. Turbine expansion may become negative.
3. Axial shift.
4. Turbine shaft vibration.
5. Load will reduce.
6. Axial shift.

Parameters of Concern:
1. RH temp,
2. Feed water flow,
3. Coal flow,
4. Flue gas O2,
5. Total air flow.
6. Transforming Parameters.

Expected Operators Action:

1. Close the spray control valve by taking in manual.
2. Open gas biasing dampers.
3. Rise the air flow
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4. Top elevation mill can be taken into service/firing can be raised.

5. Check air flow and adjust SOFA.
6. Top elevation can be taken in to service / firing can be raised and close secondary air damper if open.
7. Reduce load set point.
8. Stop blowing.
9. Adjust feed water flow
10. Check if any feeder malfunction or chocked

Final Corrective Actions:

1. Initiate LRSB soot blowing if temperatures are maintaining still less.
2. Observe for improvement in temperature.
3. Restore back the controls in auto.(spray control).

16.Reheater Temperature rising Fast

Likely causes:
1. Steam flow to reheater reduced suddenly.
2. RSV/CRV valves malfunction / close.
3. HP exhausts temperature high.
4. Inadequate spray due to mal function of spray valve or spray line leakage.
5. BFPs inter-stage spray MIVs in closed condition for running BFPs.
6. BFP tripped.
7. Excess air flow.
8. Ms Pressure & temperature are high.
9. Malfunctioning of RH gas damper(more opening)
10. SH gas damper closed due to link failure.
11. Furnace slagging
12. HP Heaters are out.
13. Reheater coil tube leakage.

Plant Response:
1. RH metal temp high alarm will appear.
2. Spray control valves will go for further opening.
3. Load will rise for the same pressure.

Parameters of Concern:
1. Reheater tube metal temperature
2. Wall blowing.
3. SADC operation.
4. IP turbine expansion.

Expected Operators Action:

1. Reduce coal flow in top mill.
2. Open spray systems and setting to desired value.
3. Do proper wall blowing.
4. Maintain proper air flow.
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5. Maintain oxygen %
6. Reduce lower elevation SADC.
7. Open SOFA dampers.
8. Inform maintenance department if any damper malfunction.

Final Corrective Actions:

1. Proper monitoring parameters.

17.Boiler Separator or MS Pressure Rising Fast

Likely causes:
1. Sudden drop in load.
2. Sudden Increase in fuel flow.
3. Any feeder malfunction.
4. MSV, TSV, HPCV malfunction.
5. Superheater spray valve malfunction.
6. PA header pressure increased.
7. Any HPHEATER extraction closed.
8. Pressure transmitter malfunction.
9. Any oil guns admitted.
10. Main steam temperature is high.
11. Soot blowing is in service.

Plant Response:
1. MS pressure will increase
2. Load variation.
3. HPBP will open if MS pressure crossed 24.8 MPa
4. ERV floats at 27.5 MPa.
5. MS safety valve floating if pressure more than 28.5 MPa.

Parameters of Concern:
1. Load.
2. Main steam pressure.
3. Main steam temperature.
4. OHDR.
5. Water To Coal ratio.

Expected Operators Action:

1. Increase generation / load , if margin in load set point.
2. Reduce coal flow.
3. Ensure PA pressure is normal.
4. Maintained OHDR, MS Temperature and feedwater flow.
5. Inform C&I department to attend transmitter malfunction.

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Final Corrective Actions:

1. Maintain constant water to coal ratio.
2. Avoid sudden change in fuel and load.

18.Boiler Seperator or MS Pressure dropping fast

Likely causes:
1. One or more coal feeders tripped.
2. Coal flow from running feeder is not proper.
3. PA Header pressure drop.
4. Any mill air flow disturbed or MDV closed.
5. Sudden increase in load.
6. HP LP Bypass open or passing.
7. Boiler tube leakage.
8. Safety valve passing/lifted.
9. Pressure transmitter malfunction.
10. Change in Air flow.

Plant Response:
1. MS pressure will decrease.
2. Load reduces.
3. MS temperature reduces.
4. Coal feeding increase if mills are in auto.

Parameters of Concern:
1. Load.
2. Main steam pressure.
3. Main steam temperature.
4. OHDR.
5. Water to coal ratio.

Expected Operators Action:

1. Find cause of MS pressure dropping.
2. Ensure coal mill healthiness.
3. Find cause of PA header Pressure dropping.
4. Increase coal flow.
5. Reduce CV opening/ load to hold the pressure.
6. Maintain feed water flow with respect to fuel.
7. Check status of HP LP bypass.
8. Check status of safety valve if it passing inform mechanical maintenance to attend it.
9. Inform C&I if pressure transmitter malfunction.
10. Check ASLD for boiler tube leak.

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Final Corrective Actions:

1. Water to Coal ratio to be maintained.
2. Smooth operation of control valves.
3. HP LP bypass should have no passing and should be in closed state.

19.ERV/MS Safety Valve Lifted

Likely causes:
1. Main steam Pressure is very high
a. Coal quality improved.
b. Any coal feeder malfunction.
c. TSV/HPCV malfunction.
d. Turbine tripped and HPBP not operated.
e. MS stop valve malfunction.
f. Superheater spray valve malfunction.
g. SH spray increased in auto due to high MS temperature, OHDR.
 Safety valve malfunction (Setting disturbed).
 Safety valve passing/ simmering.
 ERV floating due to Pressure switch malfunction.

Plant Response:
1. Main steam , separator pressures drop rapidly.
2. Stream flow will increase.
3. Load reduces.
4. Main steam temp reduce.
5. Heavy noise.

Parameters of Concern:
1. OHDR.
2. MS Temperature & Pressure.
3. Fuel flow.
4. Load.
5. Feed water flow.
6. Water consumption.
7. HPLP Bypass healthiness.
8. Metal temperature.

Expected Operators Action:

1. Reduce MS pressure until safety valve is seated back.
2. Maintained OHDR, MS temperature and pressure.
3. Take necessary action if MSSV, TSV, HPCV malfunction.
4. Informed maintenance to attend passing.

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5. Trip the unit if it not seating back ,with the Shift-Incharge clearance.

Final Corrective Actions:

Do safety valve setting.

20.HRH Safety Valve Floating

Likely causes:
1. HRH Pressure is very high
a. HP Heater 2 or 3 extraction cut
b. Any RSV or RCV closed
c. HPBP open and LPBP not operate

Plant Response:
1. Load reduces.
2. Heavy noise due to valve floating.
3. HRH steam temperature Drop.
4. HP HEATER #2 & # level may disturb.
5. Safety valve floating and simmering.

Parameters of Concern:
1. Load.
2. RSV RHCV operation.
3. Water consumption,
4. Condenser Vacuum if LPBP opened to reduce pressure.

Expected Operators Action:

1. Reduce fuel and load to reduce Reheater pressure until safety valve is seated.
2. Maintain OHDR, MS temperature and pressure.
3. Take necessary action if RSV,RCV malfunction
4. Inform maintenance to attend floating or gag it.
5. Trip the unit if it not seating back with the shift-incharge clearance.

Final Corrective Actions:

Do safety valve setting.

21.OHDR Falling Fast

Likely causes:
1. Sudden rise in feed water flow.
2. Sudden cut out in fuel.
3. Sudden rise in load.

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4. Air flow increases.

5. Water coal ratio improper.
6. Coal feeder fluctuation.

Plant Response:
1. Water wall metal temperatures decrease.
2. SH Steam temperature decrease.
3. SH Steam pressure decrease.
4. Arch inlet temperature falls.
5. Water coal ratio increases.

Parameters of Concern:
1. OHDR.
2. Feed water flow.
3. Total fuel flow.
4. Water wall metal temperatures.
5. Total air flow.
6. Arch inlet temperature.
7. Water coal ratio.

Expected Operators Action:

1. Decrease the feed water flow and maintain proper water coal ratio.
2. Decrease air flow.
3. Close the sofa dampers by watching wind box DP

Final Corrective Actions:

1. Maintain proper feed water flow.
2. Maintain proper fuel.
3. Maintain required air flow.
4. Maintain water coal ratio.

22.OHDR rising Fast

Likely causes:
1. Sudden fall in feed water flow.
2. Sudden rise in fuel.
3. Sudden drop in load.
4. Air flow decreases.
5. Water coal ratio decreases.
6. Transmitter calculated saturation temperature may be faulty.
7. Sudden change in MS pressure.
8. Sudden change in coal quality.
9. Coal feeder fluctuation.
10. Feed water control comes to manual.

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11. TD BFP and MD BFP paralleling problem.

12. Oil guns in service.
13. Wet to dry change over state is reached and fuel is high.

Plant Response:
1. Water wall metal temperatures increase.
2. SH Steam temperature rises.
3. SH Steam pressure rises.
4. Arch inlet temperature increases.
5. Water coal ratio drops.

Parameters of Concern:
1. OHDR.
2. Feed water flow.
3. Total fuel flow.
4. Water wall metal temperatures.
5. Total air flow.
6. Arch inlet temperature.
7. Water coal ratio.

Expected Operators Action:

1. Increase the feed water flow.
2. Or, decrease fuel flow.
3. Increase air flow.
4. Open the sofa dampers by watching wind box DP.
5. Adjust SADC according to the fuel elevation in service.
6. Maintain the water wall temperature.

Final Corrective Actions:

1. Maintain proper feed water flow with respect to fuel flow.
2. Maintain proper fuel.
3. Maintain required air flow.
4. Maintain water coal ratio.

23.Arch Inlet Temperature Rising Very Fast

Likely causes:
1. Feed water flow low.
2. Sudden fuel increase in boiler.
3. Improper Water coal ratio.
4. Any boiler feed water pump trip.
5. Water wall tube leakage.
6. Any leakage in feed water line.
7. Down comer line heavy leakage.

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Plant Response:
1. Boiler may trip on arch inlet temperature high.
2. Over heat degree will rise fast
3. Boiler metal temperature will rise.

Parameters of Concern:
1. Arch inlet temperature.
2. Water wall metal temperature.
3. Main steam temperature & pressure.
4. Flue gas temperature.
5. Feed water flow.
6. Furnace pressure.

Expected Operators Action:

1. Reduce fuel.
2. Maintain correct coal water ratio.
3. Maintain proper feed water flow.
4. Regulate SADC damper as per boiler operating instruction.
5. Maintain proper air flow.

Final Corrective Actions:

1. Maintain correct coal water ratio
2. Maintain proper airflow.

24.Sudden Loading of ID Fan

Likely causes:
1. Boiler bottom seal trough seal break
2. Slagging in furnace
3. Boiler Tube leakage
4. APH is tripped and respective ID fan not tripped
5. Flue gas side duct leakages
6. DP across APH is high due to blockage
7. APH leakages.
8. Sudden fuel increase in boiler.
9. FD fan getting loaded suddenly.
10. Other ID fan tripped and respective FD fan not tripped.

Plant Response:
1. Boiler furnace draught variation.
2. ID fan may trip due to overload.
3. Flame stability may disturb.

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Parameters of Concern:
1. ID fan current /Blade pitch.
2. Furnace draught.
3. Flame intensity.
4. Flue gas O2.
5. Unit load.
6. Seal trough over flow.
7. Bottom ash system sump level.
8. Total airflow.
9. Furnace to wind box DP.

Expected Operators Action:

1. Reduce fuel & secondary air to control furnace pressure.
2. In case of ID fan trip, check respective FD fan tripped and trip top mill immediately to reduce load & running ID fan loading.
3. Check fan HP oil pressure for proper blade pitch operation.
4. Check for furnace leakage, ID FAN duct leakage.
5. Check boiler seal trough overflow.
6. Check ID FAN discharge damper link & blade pitch position
7. Check oil station locally.

Final Corrective Actions:

1. Identify root cause and rectify.
2. Monitor APH I/L & O/L Pressure.

25.Air Flow Going Low and High

Likely causes:
1. Problem in SADC i.e., SADC is fluctuating very much.
2. Problem in blade pitch of FD Fan i.e., it is loading and unloading continuously.
3. Problem in air flow transmitter.
4. FD Fan stalling.
5. APH SA outlet damper closes due to link failure.
6. Malfunction of O2 analyzer (in Auto mode).

Plant Response:
1. Variation in O2 %.
2. Variation in flue gas temperature.
3. Variation in water wall temperature.
4. Variation in FD & ID Fan’s blade pitch.
5. Variation in furnace pressure.

Parameters of Concern:
1. Furnace pressure.
2. Wind Box DP.

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3. ID Fan’s current as this behaviour may lead to spikes in current.

4. FD Fan’s current.
5. Flame intensity.
6. MS/RH Temperature.

Expected Operators Action:

1. Cross check the blade pitch and currents of FD & ID fan.
2. Take the fans in manual mode (if in auto) and then control.
3. Check the SADC position of SADC in the DCS as well as cross check in local. Also check the air compressor’s pressure for
any high fluctuation.
4. If any particular FD Fan is loading and unloading, make sure that its blade pitch is in manual mode and is constant.

Final Corrective Actions:

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

26.Heavy Furnace Pressure Fluctuation

Likely causes:
1. Any ID, FD or PA fan tripped.
2. Any one or more coal mills tripping suddenly.
3. Soot blowing may be in service.
4. Malfunctioning SH/RH gas dampers.
5. Any ID, FD or PA fan blade pitches malfunctioning.
6. Any ID, FD or PA fan suction damper close.
7. SOFA, SA, AUX dampers malfunctioning.
8. Tube leakage.
9. Bottom seal trough disturbed (Over flow not there or seal broken).

Plant Response:
1. Alarm display on DCS of furnace pressure variation.
2. Boiler will trip on heavy furnace fluctuation.
3. Chances of furnace flame disturb.

Parameters of Concern:
1. ID fan current,
2. Furnace to wind box DP,
3. Blade pitch position,
4. Seal trough O/F,
5. Bottom ash system.

Expected Operators Action:

1. Put ID fan blade pitch control to auto if it is manual.
2. Check any fan discharge damper closed
3. Start if any one fan tripped.

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4. Check SADC operation.

5. Ensure bottom ash system is normal and seal trough Overflow is established.

Final Corrective Actions:

1. All fans’ damper’s PM done as per schedule.
2. SOFA, SA and AUX dampers PM should be done as per schedule.

27.PA Header Pressure Dropping Fast

Likely causes:
1. Any PA Fan trips.
2. Any PA Fan unloads suddenly i.e., its blade pitch decreases abnormally or current decreases abnormally.
3. Heavy leakage in hot PA Header or duct.
4. PA Fan Stalling.

Plant Response:
1. PA I/C damper will open in auto.
2. PA header pressure goes down.
3. Mill PA flow goes down.
4. Decrease in generation.
5. Variation in furnace pressure (towards negative side).
6. Decrease in total primary air.
7. SH/RH temperature will drop.

Parameters of Concern:
1. Current of running or Loaded PA Fan.
2. PA Flow in running mills.
3. PA Header Pressure.
4. Seal air discharge pressure.
5. Main Steam and HRH Temperature.
6. Flame stability due mills taken out.

Expected Operators Action:

If header pressure is dropping due to any PA Fan tripping with full load and 5 mills in service.
1. B, C, D, E, F MILLS – Take out mill F and E gradually.
2. Maintain the PA Header pressure by increasing the blade pitch of running PA Fan.
3. Ensure closure of discharge damper for tripped fan.
4. While increasing the blade pitch we must keep an observation on running PA Fan’s current and vibration.

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5. Take the LDO guns and HFO guns.

6. Ensure the closure of Hot/Cold Air dampers and gate of stopped mills.
7. Operator must observe the furnace pressure and see whether the ID Fan’s are in auto and maintaining the draft.
8. Reduce generation to 350 MW
9. FW flow to be reduced fast to maintain MS/RH Temperature.

Final Corrective Actions:

1. Regular and proper blade pitch trial of PA Fan during shutdown.
2. Keep an eye on PA Header pressure regularly.
3. Keep the currents of both PA fan as near as possible.
4. Always monitor for any leakages in PA Header/Ducts.

28.Oil Level Loss in APH Bearing

Likely causes:
1. Oil leakage from APH bearing (due to oil seal damage).
2. Oil leakage from level gauge (due to damage).

Plant Response:
1. Bearing oil temperature shows high value (Guide and Support).
2. Oil leakage observed in local.
3. APH bearing temperature will rise.

Parameters of Concern:
1. Bearing oil temperature and hence the bearing itself.

Expected Operators Action:

1. Call for oil top-up.
2. Inform to MMD and see if on line leakage arresting is possible.
3. Make sure that APH is checked for any oil leakages in local regularly.
4. In case of heavy oil leakage, stop APH immediately.
5. Rotate APH manually after stopping.

Final Corrective Actions:

1. Make sure that APH is checked and oil top up is done regularly if required.
2. Proper maintenance is done during shut down.

29.Sudden Increase in Steam Silica

Likely causes:
1. DM plant water silica may be high.
2. System taken into service after overhauling.
3. Condenser tube leakage.
4. Coliadal Silica in DM water
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Plant Response:
1. As per DM plant report Silica will vary.
2. Turbine vibration may be high, duringlong time operation.
3. Axial shift may increase.
4. Turbine first stage pressure increase.

Parameters of Concern:
1. Silica concentration in separator steam.
2. Separator pressure.
3. Howell conductivity

Expected Operators Action:

1. Reduce load to maintain less pressure.
2. Maintain NH 3, N2H4 concentration around 4%.
3. Ask chemist to confirm panel instrument readings of silica by actual analysis.
4. If the steam quality is affected by the process within the system, shutdown the turbine.

Final Corrective Actions:

1. Check and correct DM make up quality.
2. Do proper flushing as directed by chemistry.

30.Boiler Water pH Falling Fast

Likely causes:
1. Make up water faulty.
2. Faulty analyzer.
3. Dosing line may be leaking or choked.
4. Ammonia NH 3 dosing concentration may be low / poor.
5. Dosing pump not developing pressure.
6. Tripping of dosing pump.
7. Condenser tube leakage or slippage.

Plant Response:
1. Boiler conductivity also comes down
2. Internal corrosion of boiler tubes increase and chance of tube failure if left for long duration.
3. Silica value variation.
4. Condenser tube leakage.

Parameters of Concern:
1. Boiler feed water pH,
2. pH of condensate water,
3. Entire water circuit PH will be drop gradually.
4. Main steam PH

Expected Operators Action:

1. Increase AMMONIA dosing
2. Consult chemist. Cross check whole regime of the system
3. Check possibility of condenser tube leakage.

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4. Check Ammonia line for any leakage.

5. Check CPU O/L water quality .
6. Check CST water quality.
7. Inform chemist to analyze the problem.

Final Corrective Actions:

1. Find the root cause of the problem, if it is due to dosing then check concentration of the dose and check consumption per
hour as per recommended.
2. Ask chemist to check DM water quality.
3. Find the root cause of the problem and attend the same.

31.Boiler Expansion not OK during Cold Start up

Likely causes:
1. Metal temperature rate of rise may be quite high.
2. Not uniform heating in the boiler due to not rotating the oilguns.
3. Heavy soot deposition in the furnace.
4. In adequate individual oil flow through the Oil guns .
5. Improper fuel injection (Top gun / Top Mill)
6. Buck – stay mechanical jam or damaged.
7. Furnace DP not equally maintained.
8. Furnace part welded to boiler structure.

Plant Response:
1. Local expansion reading is uneven,
2. Buck-stay may damage.
3. Boiler structure loading may change.

Parameters of Concern:
1. Local reading.

Expected Operators Action:

1. Rise Metal temperature as per startup curves.
2. Maintain proper air/Fuel flow.
3. Check buck stay healthiness.
4. Do local check for any physical obstruction.

Final Corrective Actions:

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

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32.Bunker Fire

Likely causes:
1. High Volatile Matter coal stored in bunker and not in use since long time.
2. Any kind of ignition or fire caught by coal inside the bunker.
3. Higher surrounding temperatures.
4. Spontaneous ignition due to stagnate coal in bunker.
5. Air passing through the air cannon cylinder.
6. Hot coal fed by Coal Handling Plant.

Plant Response:
1. Smoke or fire comes out from the bunker.
2. Transfer conveyer may damage.
3. Coal feeder belt may damage.
4. Black spots may be observed at the outer wall of the coal bunker.
5. Coal feeder temperature will increase.

Parameters of Concern:
1. Bunker level.
2. Coal quality and Coal Handling Plant.
3. Coal feeder belt.
4. Bunker structure.

Expected Operators Action:

1. Call the fire man on 54123, 54321, 9687660224, and 9687660225.
2. Open the nozzle valve of CO2.
3. Spray water inside the bunker through fire hydrant.
4. Stop the coal mill if the fire is in running mills bunker.
5. Close air supply to air cannons system.
6. Close feeder inlet gate.
7. If necessary, open three way pipe gate of bunker and remove the burnt coal to the atmosphere.
8. Operate bunker fire fighting system at boiler 0 meter.
9. Stop feeding coal to bunker.
10. Make arrangement to remove burnt coal from the bunker.
11. Work in co ordination with fire department for early action.

Final Corrective Actions:

1. Keep frequent local observations.
2. Always keep fire water and CO2 system healthy.
3. Put sign boards of “NO SMOKING” in the bunker area.
4. During planned shutdown, keep bunkers empty.

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33.Water Level In Separator at Load >300MW

Likely causes:
1. OHDR decreases suddenly up to zero due to:
a. Sudden reduction in coal flow.
b. Sudden increase in feed water flow.
2. Separator to SH Spray control valve closed.
3. Sub cooling MOV got opened or passing.
4. Faulty feed water flow measurement
5. Faulty fuel flow measurement
6. Sudden cutout of oil guns at low loads

Plant Response:
1. Separator level increases.
2. Water carries over to Super heaters.
3. SH temperature goes down rapidly.
4. Sudden cooling of separator metal

Parameters of Concern:
1. Water coal ratio.
2. Water carryover.
3. Super heater metal temperature.
4. Main steam temperature.

Expected Operators Action:

1. Increase OHDR by adjusting feed water flow as per coal flow.
2. Ensure separator to SH Spray control valve open.
3. If sub cooling MOV is passing then tighten it and if required close the sub cooling MIV.
4. Adjust mill loading , SADC damper position.
5. Cross check the Feed water and fuel flow measurements.

Final Corrective Actions:

1. Closely monitor OHDR, FEED water flow and coal flow.
2. Follow up for causes to maintenance department.

34.Oil Spillage Observed In Bottom Ash System

Likely causes:
1. During unit start up with oil guns in service; oil spillage may be due to :
a. Improper smoothness in the nozzle.
b. Leakage in the oil gun pipe.
c. Improper combustion.
d. Igniters failure
e. Improper fuel air adjustment through SADC.

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f. Oil pressure low /atomizing steam pressure is not sufficient.

2. During normal condition oil spillage may be due to passing in the oil corner valves.

Plant Response:
1. No proper flame intensity.
2. Increase in oil flow than normal will be observed.
3. Oil tank level will go down.

Parameters of Concern:
1. Flame intensity.
2. Oil pressure.
3. Atomising steam pressure.

Expected Operators Action:

1. Stop oil firing.
2. Oil guns should be properly purged before taking into service.
3. Properly adjust the fuel air for oil through SADC.
4. Check the oil corner valves for passing. If passing observed, close MIV immediately.

Final Corrective Actions:

1. Regular PM for oil guns.
2. Oil leak test to be done.
3. Oil pressure, oil temperature. , Atomizing steam pressure to be maintained as per design.

35.Loss of Seal Trough level

Likely causes:
1. Furnace Pressure very high.
2. Furnace Pressure very low.
3. Cooling Water Pump failure.
4. Seal trough makeup sump level low.
5. Any leakage in cooling water line.
6. Cooling water temp very high.

Plant Response:
1. Draught fluctuation.
2. ID fan may trip on over load.
3. Flame may disturb.

Parameters of Concern:
1. Furnace pressure.

Expected Operators Action:

1. Reduce load.
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2. Reduce total air flow.

3. Check seal trough makeup water pump.
4. Check for any cooling water line leakages.
5. Check seal trough makeup water temperature.
6. Emergency makeup can be done by using fire water.

Final Corrective Actions:

1. Ensure boiler seal trough overflow regularly.
2. Ensure over flow pumps are running properly
3. Firewater to be kept ready for emergency make-up.

36.Bottom Ash Scraper Conveyer Failure

Likely causes:
1. SSC motor overload
2. Hydraulic pump failure
3. Any leakage in hydraulic oil line.
4. SSC Chain broken.
5. Cooling water supply failure.
6. Heavy bottom ash.
7. Take-up device failure.

Plant Response:
1. More bottom ash collection in SSC.

Parameters of Concern:
1. SSC water temperature.

Expected Operators Action:

1. Reduce load.
2. Do not operate soot blowers.

Final Corrective Actions:

1. Check oil level &oil temperature regularly.
2. Check cooling water supply is normal.
3. Check take-up device, pump as per schedule.

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37.Bottom Ash Cooling Tower Sump Level Low

Likely causes:
1. Over flow pump failure.
2. Malfunction of overflow sump level switch.
3. HEC drain heavy passing.
4. Heavy leakage in over flow pumps discharge line.
5. Insufficient Make-up water.

Plant Response:
1. Cool and hot water pump may trip.
2. Seal trough water level will go down; concentrator water level will go down.

Parameters of Concern:
1. Cold water sump level.
2. Boiler water seal trough overflow.

Expected Operators Action:

1. Check healthiness of over flow pump.
2. Check concentrator water level.
3. Check boiler seal trough.
4. Provide sufficient make water.

Final Corrective Actions:

1. Ensure boiler seal trough overflow regularly.
2. Ensure over flow pumps are running properly
3. Firewater to be kept ready for emergency make-up.

38.LRSB Not Retracting

Likely causes:
1. Mechanical jamming.
2. Motor tripped on overload
3. LRSB power cable failure.
4. Power supply failure.

Plant Response:
1. Soot blower may damage.
2. Damage super heater coil due to steam erosion.

Parameters of Concern:
1. Specific zone metal temperature.

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Expected Operators Action:

1. Reduce soot blowing steam pressure and Switch off LRSB power supply.
2. Retract manually.
3. Inform to maintenance.

Final Corrective Actions:

1. Pre operating check to be done properly.

39.Boiler Flue Gas Exit Temperature Shoots Up

Likely causes:
1. APH fire.
2. APH soot blowing not done for long time.
3. LRSB/SRSB not done for a long time.
4. High flue gas velocity.
5. High air flow.
6. Oil firing in service for long period.
7. Soot deposition on water wall, super heater and reheater tubes.

Plant Response:
1. Change in ∆P across APH.
2. Rise in metal temperature of SH/RH.
3. Increase in DM water consumption (in case of SH/RH tube leakage)
4. Difference between feed flow and steam flow increases(in case of SH/RH tube leakage)
5. MS temperature going down (in case of high air flow).
6. APH inlet temperature rise.

Parameters of Concern:
1. Furnace pressure.
2. SH/RH metal temperature
3. DM water consumption.
4. MS temperature
5. Feed and steam flow.
6. APH inlet temperature.

Expected Operators Action:

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

Final Corrective Actions:

1. In case of APH fire , isolate the particular APH and extinguish the fire.

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2. In case of SH/RH leakage shut down the unit to attend it.

3. LRSB/SRSB should be done as per schedule.
4. Maintain air flow as per rated parameters.

40.Heavy Ash Built Up In Any ESP Hopper

Likely causes:
1. De-ashing problems like:
a. No proper transport air pressure.
b. Failure to carry out ash evacuation.
c. No proper fluidization (due to problem in heater).
d. Problem in dome valve.
e. ESP field failure.
f. Evacuation line choking /moist ash / heater failure.

Plant Response:
1. Ash build up in hopper may lead to tripping of CRM/ERM.
2. It will restrict the flue gas flow.
3. It may lead to field tripping.
4. Overloading on fields which are not tripped.
5. Build up of high tension emitting system, causing short circuit.
6. Dusts carry over through chimney.
7. High SPM.

Parameters of Concern:
1. Spark rate
2. ESP performance.
3. Environmental pollution.

Expected Operators Action:

1. Hopper having high ash build-up must be evacuated as early as possible in co-ordination of maintenance personnel.
2. Vessel’s capacity can be increased by increasing the filling time.
3. Check the transport air pressure.
4. If required that field should be discharged fully and then hopper is to be evacuated.
5. If required reduce generation.
6. Check heaters and rapping system.

Final Corrective Actions:

1. Make sure that the hoppers are evacuated regularly and properly.

41.BCP Cooling Water Temperature High

Likely causes:
1. No proper circulation of HP cooling water inside BCP motor.
2. CCCW temperature is high.
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3. Thermal gland damaged.

4. BCP motor high pressure cooling water system leakage.
5. Strainer chocking in BCP filling line.
6. Overloading of BCP.

Plant Response:
1. Temperature high indication will come on DCS.
2. If HP cooling water temperature becomes > 65 °C, BCP will trip and unit may trip on FW flow low -low.

Parameters of Concern:
1. BCP Motor’s winding temperature as higher temperature will lead to its damage.
2. Impurity level in the BCP filling water.

Expected Operators Action:

1. Make sure that the temperature indication is correct. Check locally and also by touching the motor body.
2. BCP should be stopped and its strainer should be cleaned.
3. CCCW temperature should not be allowed to increase beyond limits.
4. Search for leakages if any.
5. Increase the amount of cooling water in heat insulation jacketing and high pressure cooler if BCP could not be shut down.
Immediately shut it down in case of serious leakage.
6. Confirm cooling water for cooler is completely injected .Open high pressure injection valve to control the flow so as to make
water temperature of cooler below 50 °C.

Final Corrective Actions:

1. Do BCP filling as per SOP.
2. BCP strainer to be cleaned during long shutdown.

42.DCS Console Hanged/Failed( Detail discussion required)

Likely causes:
1. UPS-1&2 failure.
2. Blackout with UPS failure.
3. UPS supply fails to control cabinets.
4. Any other C&I problem (software or hardware).

Plant Response:
1. No command will sent from DCS to equipments.
2. Parameter goes to bad quality.
3. DCS console’s power may off.

Parameters of Concern:
LOCAL OBSERVATION OF:
1. Turbine speed.
2. Mill status.
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3. Lube oil pressure.

4. Seal oil pressure.
5. Jacking oil pressure.
6. Condenser vacuum.
7. Gland steam pressure.
8. GT Breaker.

Expected Operators Action:

1. Ensure GT breaker opening otherwise open manually.
2. Ensure DG started and Emergency Bus charged (If DG not started refer DG fail emergency SOP).
3. Ensure DC Seal oil pump started. Also ensure Seal oil DP and H2 pressure is healthy.
4. Ensure TDBFP/Turbine/JOP DC drive is started, if not, start manually.
5. Closely monitor condenser vacuum in local, at “0” Kpa Open vacuum breaker valve.
6. At turbine ‘0’ rpm ensure barring gear is engaged If not due to inst. Air pressure low, engage it manually.
7. Even if barring is not started then open the barring gear door for manual barring.
8. Isolate Gland steam to turbine.

Final Corrective Actions:

1. Follow up for UPS fail causes to maintenance department.

TURBINE & AUXILARIES -

EMERGENCIES
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1.Hot well level raising fast

Likely causes:
 Sudden Load through off.
1. One CEP tripped and second not started and make up maintain high.
2. Hotwell makeup control valve not operating properly.
3. Dearator level maintaining high due to wide opening of Heater normal drip CV.
4. HP and LP heater Emergency Drain opened to maximum suddenly.
5. Hotwell makeup bypass valve made 100% opened with CV in service.
6. Condenser Tube leakage.
7. Level Transmitter stands pipe leakage.
8. Dearator level faulty.

Plant Response:
1. Condenser vacuum start decreasing.
2. Load decreases because of vacuum drop.

Parameters of Concern:
1. Condenser Vacuum.
2. Hotwell Conductivity.
3. Dearator level.
4. Discharge pressure of CEP.
5. Healthiness of level transmitter.
6. Local level gauge reading.
7. Unit load.
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8. Actual level of hotwell if level transmitter has crossed its range.

Expected Operators Action:

1. Closing of hotwell level CV and controlling its level with bypass valve if the CV is not working.
2. Close make up MIV if needed.
3. Ensuring hotwell level from local level gauge with coordination of field engineer.
4. Ensuring that hotwell not increases to high so that it comes upon the condenser neck and get in contact with LP turbine
blades.
5. If level is not maintaining after all action Unit to be tripped and vacuum to be killed and hot well drain MIV to be opened so
as to avoid contact of water from LP blades.

Final Corrective Actions:

1. Rectification from C&I if level CV is not operating and if level transmitter is showing bad value.
2. Maintaining Proper heaters levels.
3. Ensuring hotwell makeup CV bypass MIV to be closed in normal operations.

2.Hot well dropping fast

Likely causes:
1. Standby CEP started in auto.
2. Hotwell makeup control valve not operating.
3. CST level low.
4. CEP discharge line leakage/drain opened condition.
5. Dearator level dropping.
6. Transmitter malfunctioning.
7. Feed Water line leakage.
8. Boiler tube leakage.
9. Dearator level gauge malfunctioning.
10. LPBP, exhaust hood, 3rd Stage Spray CV opened fully.
11. Unit Tripped.

Plant Response:
1. Condenser vacuum start decreasing
2. Dearator level drops fast.
3. CEP Discharge pressure drop.
4. CEP may trip on Hotwell level LL.

Parameters of Concern:
1. Condenser Vacuum.
2. Condensate Water Flow.
3. Dearator level.
4. Discharge pressure of CEP.

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5. Healthiness of level transmitter.

6. Local level gauge reading.
7. Unit load.

Expected Operators Action:

1. Start CTP.
2. Opening of hotwell level CV bypass valve if the CV is not working.
3. Reducing Unit load and fuel firing so that Dearator level can be maintained.
4. Starting DM transfer pumps if needed.
5. Ensuring hotwell level from local level gauge with coordination of field engineer.

Final Corrective Actions:

1. Rectification from C&I if level CV is not operating and if level transmitter is showing bad value.
2. Maintaining proper CST levels.
3. Maintaining Dearator level within limits so that CEP discharge pressure shouldn’t decrease drastically.
4. Ensuring Proper drain closing and Checking System thoroughly for leakages.

3.Deaerator Level High

Likely causes:
1. Deaerator control CV abnormal operation.
2. HP heater 3 drip coming more.
3. Any BFP tripped.
4. Load reduced very fast.
5. HPH tube leakage.
6. FW demand low.
7. More no of CEP in service(3 CEPs ).

Plant Response:
1. Deaerator pressure may drop.
2. Deaerator temperature may drop.
3. Deaerator overflow valve open.
4. Hotwell level decreases.
5. Hotwel level variation.

Parameters of Concern:
1. Deaerator control CV position.
2. Hot well level.
3. BFP parameters like Recirculation valve positions and Suction flows.
4. CEP discharge Pressure.
5. Deaerator overflow valve position.
6. Hotwell level.
7. Deareator pressure and temperature
8. Extraction-4 MOV position.
9. All HP heater level.

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Expected Operators Action:

1. Check Deaerator overflow opens or not, if not then open.
2. If deaerator Control CV malfunctioning, close MIV before CV and control level by opening bypass MOV as per
requirement.
3. Check Extraction-4 cut in auto, if not close the extraction-4 MOV and cut out extraction-4.
4. Maintain Dereator pressure and temperature

Final Corrective Actions:

1. If level is maintaining to normal value, normalize the system. Charge extraction-4.

4.Deaerator Level Low

Likely causes:
1. Any CEP tripped.
2. Deaerator control CV malfunctioning.
3. Sudden rise in feed water demand
4. HPH-3 normal drain suddenly closed and emergency drain control valve opened.
5. Extraction-4 cut out.
6. Deaerator drain MOV open/passing.
7. CEP recirculation suddenly opens.
8. HP heater tube leakage is heavy

Plant Response:
1. Deaerator level low alarm will come.
2. If deaerator level control valve in auto CEP outlet header pressure will drop & stand by CEP may pick up.
3. Hot well level may drop.
4. 2 BFP will tripped if level goes below -1500mm.

Parameters of Concern:
1. Deaerator level.
2. CEP parameters like discharge pressure and condensate flow.
3. Deaerator level control CV position.
4. HPH-3 levels and Drip control valve positions
5. Normal drain MOV position, emergency drain control valve position.
6. Deaerator drain MOV position.

Expected Operators Action:

1. Try to maintain deaerator level, If Deaerator level control CV having any problem then try to maintain level by opening of
bypass MOV.
2. If any CEP tripped and standby not started then start standby CEP, If not available then reduce load to 50%.
3. If CEP RC open, close it, If it is not operating, then close after-before MIV as per requirement.
4. If any of the HP heater drain valve malfunctioned then normalize it after identifying the problem.
5. Start 3 rd CEPto maintain the level.
6. Still level is not maintain reduce the load.
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Final Corrective Actions:

1. Identify the problem and normalize the system as soon as possible.

5.CEP Tripped and Standby Fail To Start

Likely causes:
1. Hot well level low (200mm).
2. CEP tripped on any of the protection (check first out) and stand by pump not in interlock.
3. Standby pump tripped on overload.
4. Standby pump electrical protection acted.
5. Pump in interlock but all permissive are not healthy.

Plant Response:
1. D/A level decreases fast.
2. Overloading of other pump, running TDBFP or MDBFP booster pump sealing pressure reduces and other attemperation
pressure reduces.
3. If LP bypass system is in service its outlet temperature will rise.
4. CEP discharge header pressure decreases.
5. Hot well level increases.
6. LP gland steam spray disturbs
7. 3rd stage and LP exhaust spray disturbs

Parameters of Concern:
1. CEP outlet pressure,
2. Hot well level& Deareator level,
3. Deareator level control valve position,
4. Running CEP parameters,
5. Hot well level CV position,
6. Unit load,
7. Condenser vacuum,
8. Gland steam temperature.

Expected Operators Action:

1. Reduce the load to 50% and maintain Dearator and hot well level.
2. Control D/A level in manual and try to maintain discharge pressure.
3. Start the standby pump.
4. If standby pump not started, trip one TDBFP to maintain Deareartor level, at load>580MW(With SCE clearance).
5. Reduce the load as quickly as possible and maintain all other parameters constant like MS/RH temperature, water wall metal
temperature, OHDR.

Final Corrective Actions:

1. Always ensure the standby pump healthiness.

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1. If problem is rectified increase the load as per requirement.

6.TDBFP Tripped

Likely causes:
1. TDBFP Booster pump Tripped due to any of the following reasons
 Dearator level less than 1500mm.
 TDBFBP suction pressure <1.5 Mpa for more than 3 seconds.
 TDBFBP Suction MOV Closed.
 TDBFBP booster pump bearing temperature high.
2. Lube oil pressure ≤ 0.07Mpa.
3. EH oil pressure is ≤7.8 Mpa.
4. Exhaust steam temperature ≥150°C.
5. Axial shift of turbine rotor is on trip value. (≥0.4mm or ≥-0.6mm).
6. Vacuum low.
7. Shaft bearing vibration ≥0.2mm.
8. TDBFP thrust bearing temperature ≥110°C and Bearing temperature ≥115°C.
9. Tripped on Over speed (≥6380 RPM).
10. Manual push button operated.
11. MEH trip Output.
12. Any Protection Malfunctioned.
13. Any Of the Instrument showing bad value.

Plant Response:
1. MDBFP picks in auto if is in interlock and scoop open by 30% in auto.
2. Second TDBFP comes to manual.
3. Feed water flow decreases.
4. Main steam flow decreases.
5. Water to Coal Ratio decreases.
6. OHDR increases.
7. Water Wall metal temperature increases.
8. Arch inlet temperature increases.
9. Main steam temperature Increases.
10. Separator Tank Pressure Decreases.
11. Unit Load decreases.

Parameters of Concern:
1. Unit Load.
2. Total coal flow, FW Flow, W/C ratio, MS flow, MS temperature, Arch inlet temperature, WW metal temperature, Separator
Tank pressure, total air flow.
3. MDBFP Started and scoop percentage.

Expected Operators Action:

1. Trip one Coal mill and adjust fuel flow to reduce generation to 75% TMCR.

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2. Start MDBFP if it is not picked up in auto and raise the scoop.

3. Increase feed water flow and decrease coal flow so as to maintain Water to Coal ratio same as before TDBFP tripping.
4. Optimise air flow keeping water wall metal temperature in view.
5. Reduce turbine load set point.
6. Maintain load under 75% TMCR.

Final Corrective Actions:

1. Check the reason for TDBFP tripping, if it is actual according to protection, rectify accordingly.
2. If the TDBFP has been tripped due to malfunction of any protection than made the TDBFP ready for rolling and bring it back
and raise the load.

7.ONE TD-BFP Tripped and MDBFP not available

Likely causes:
1. TDBFP Booster pump Tripped due to any of the following reasons
 Dearator level less than 1500mm.
 TDBFBP suction pressure <1.5 Mpa for more than 3 seconds.
 TDBFBP Suction MOV Closed.
 TDBFBP booster pump bearing temperature high.
2. Lube oil pressure ≤ 0.07Mpa.
3. EH oil pressure is ≤7.8 Mpa.
4. Exhaust steam temperature ≥150°C.
5. Axial shift of turbine rotor is on trip value. (≥0.4mm or ≥-0.6mm).
6. Vacuum low.
7. Shaft bearing vibration ≥0.2mm.
8. TDBFP thrust bearing temperature ≥110°C and Bearing temperature ≥115°C.
9. Tripped on Over speed (≥6380 RPM).
10. Manual push button operated.
11. MEH trip Output.
12. Any Protection Malfunctioned.
13. Any Of the Instrument showing bad value.
14. MDBFP not available as it is under PTW.

Plant Response:
1. Second TDBFP comes to manual.
2. Feed water flow decreases.
3. Main steam flow decreases.
4. Water to Coal Ratio decreases.
5. OHDR increases.
6. Water Wall metal temperature increases.
7. Arch inlet Main steam temperature increases.
8. Main steam temperature Increases.

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9. Separator Tank Pressure Decreases.

10. Unit Load decreases.

Parameters of Concern:
1. Unit Load.
2. Total coal flow, FW Flow, W/C ratio, MS flow, MS temperature, Arch inlet temperature, WW metal temperature, Separator
Tank pressure, total air flow, OHDR.
3. Auxiliary steam header pressure and its availability (Interconnection opened from neighbour Unit).

Expected Operators Action:

8. Trip Two Mills at safe interval.
9. Reduce the coal flow as fast as possible to maintain the water wall metal temperature, Arch inlet temperature, MS
temperature.
10. Increase feed water flow by increasing running TDBFP speed and decrease coal flow so as to maintain Water to Coal ratio
same as before TDBFP tripping.
11. Optimise air flow keeping water wall metal temperature in view.
12. Reduce turbine load set point as fast as possible keeping main steam pressure in view.
13. If the running TDBFP steam source is from extraction 4 only than change over it with aux. Steam.
14. Maintain load 50% BMCR.
15. Do not admit oil immediately.
16. If soot blowing in progress, stop it.

Final Corrective Actions:

1. Check the reason for TDBFP tripping, if it is actual according to protection, rectify accordingly.
2. If the TDBFP has been tripped due to malfunction of any protection than made the TDBFP ready for rolling and bring it back
and raise the load.

8.Any CW pump tripped

Likely causes:
1. Pump discharge hydraulic control valve closed by 75°.
2. CW pump motor stator temperature reached to trip value.
3. CW pump bearing temperature reached to trip value.
4. Emergency Push button operated.
5. Hydraulic oil supply failure.
6. PLC, UPS failure resulted in Feed back loss to DCS.
7. Communication card Failure.

Plant Response:
1. Condenser Vacuum start decreasing very fast.
2. Unit Load Decreases.
3. Fall in CW Duct pressure.
4. CW sump may overflow.

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Parameters of Concern:
1. Condenser Vacuum.
2. Unit load.
3. CW discharge Pressure, current and vibration of running pump.
4. Starting of 2nd vacuum pump.
5. ACW pumps healthiness.
6. Trip Pumps discharge valve fully closed and pump is not reverse rotating.
7. CW temperature.
8. Exhaust Hood Temperature.

Expected Operators Action:

1. Starting Standby CW Pump keeping CW duct pressure in view.
2. Starting 2nd Vacuum pump.
3. Reducing load to 60% TMCR.
4. Closing Blow down valves (hot and cold).
5. Make arrangements to start Stand by CW pump.
6. After pressure Fluctuation reduced start the Standby CW pump .

Final Corrective Actions:

1. Once CW Duct pressure come backs to normal (.3-.35Mpa) start raising Load.
2. Inspect the reason of auxiliary tripping and if possible bring back the auxiliary to standby.
3. If the problem exists in system then isolate the auxiliary and make it ready after maintenance.

9.One CW pump tripped and Standby not available

Likely causes:
1. Pump discharge hydraulic control valve closed by 75°.
2. CW pump motor stator temperature reached to trip value.
3. CW pump bearing temperature reached to trip value.
4. Emergency Push button operated.
5. Hydraulic oil supply failure.
6. Standby CW pump not available due to maintenance work.
7. PLC, UPS failure resulted in Feedback loss to DCS.
8. Communication Card failure.

Plant Response:
1. Condenser Vacuum starts decreasing fast.
2. Unit Load Decreases.
3. Fall in CW Duct pressure.
4. CW sump may overflow.

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Parameters of Concern:
1. Condenser Vacuum.
2. Unit load.
3. CW discharge Pressure, Current and vibration of running pump.
4. Starting of 2nd vacuum pump.
5. ACW pumps healthiness.
6. Effluent pit level.
7. Tripped pumps discharge valve is fully closed and pump is not reverse rotating.
8. Turbine Exhaust hood temperature and CW temperature.

Expected Operators Action:

1. Stop one Mill and Reduce Unit load to 60% TMCR and further if vacuum is not maintaining.
2. Close at least 5 Riser MOVs so that to maintain CW duct pressure.
3. Close the blow down MOV (Hot and Cold).
4. Start second vacuum pump so as to support Vacuum.
5. Reduce the Makeup CV position so as to avoid sump overflow.
6. Ensure Effluent pit level and if required stop the lift pump.

Final Corrective Actions:

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

10.HP Heater level Maintaining High

Likely causes:
1. High feed water flow than rated or sudden increase in feed water flow.
2. Low feed water inlet temperature.
3. Auto failure of drip control valves.
4. Control valve stuck.
5. Drip interlock not working properly.
6. Dearator pressure higher than specified.
7. Inadequate extraction from turbine (ext NRV or MOV not fully open).
8. Adjacent heater got bypassed from feed water.
9. Heater tube leakage.
10. Level transmitter malfunction.
11. Level transmitters stand pipe leakage.

Plant Response:
1. Heater will be cut off and bypass if level rising than specified limit.
2. If heater is cut off vacuum may be effected.

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3. If heater is cut off turbine axial shift will be increase.

4. If heater is cut off load rising temporary and than after sometime load will be decreases .
5. If level is rising fast in heater than there is possibility of water entering in turbine.
6. Hot well level rise..
7. Dearator level fall.

Parameters of Concern:
1. Generation
2. Feed water temperature
3. Dearator pressure
4. Heater level
5. Condenser vacuum
6. Axial shift
7. MS pressure,MS temp,coal flow, feed water flow, feed water temp
8. Extraction pressure
9. Control valves position
10. Extraction pressure
11. Extraction temp
12. Feed water flow

Expected Operators Action:

1. Switch over drip controls to manuals and regulate levels.
2. Check control valves operation, air valves opening or air leakage.
3. Check emergency and normal drain MIV and control valve for opening.
4. Check heater levels in local gauge glass.
5. Check flow to dearator. If flow does not take place due to high dearator pressure, or low extraction pressure or faulty
interlock action, rectify it.
6. If dearator pressure is high, reduce pressure by throttling extraction 4 from turbine.
If heater cut off then
1. Ensure its extraction is cut off properly by confirming closing position of extraction NRV and MOV.
2. heater bypass from waterside also.
3. Check the drain fast valves before and after NRV for opening.
4. Ensure opening of emergency drain and closing of drip valve.
5. Control the load fluctuation by load set point ,coal firing and feed water flow.
6. Monitor the remaining heater levels sharply and control it.
7. Observe the vacuum and start second vacuum pump if necessary.
8. Maintain dearator level/hot well level.
9. Monitor axial shift of turbine.
10. Check local for level transmitter standpipe healthiness.

Final Corrective Actions:

1. Check for heater tube leak.
2. Compare the BFP suction flow to boiler feed water flow and drip opening.
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3. Follow up maintenance department for the cause. If tube leakage not there, take the heater in service .

11.Turbine Vibration High

Likely causes:
1. Sudden change in steam parameters.
2. Sudden change in load, speed, frequency.
3. Heat soaking not done properly, cylinder expansion is not smooth.
4. Rotor eccentricity high.
5. Lube oil pressure and temperature abnormal.
6. Cold steam enters in to turbine.
7. Low condenser vacuum.
8. High temperature difference between HP & IP cylinder.
9. During start and stop, turbine speed is within critical running speed zone.
10. Turbine bearing damages.
11. Impeller blades damages.
12. Vibration due to generator due to sudden MVAR change.
13. Gland steam temperature low.
14. High axial shift.
15. Sudden Cutoff of Any HP Heater.
16. Turbine acceleration not maintained during rolling.

Plant Response:
1. Turbine vibration high alarm will come.
2. Turbine will trip if shaft vibration reaches to 250 microns.
3. Axial shift may increase.
4. Bearing metal temperature may rise.

Parameters of Concern:
1. Turbine vibration.
2. HP-IP differential expansion.
3. Turbine speed.
4. Rotor eccentricity.
5. Axial shift.
6. Lube oil pr. & temperature
7. Condenser vacuum.
8. Gland steam temperature
9. Main steam & Reheat steam parameters.
10. Bearing metal temperature Return oil temperature
11. Physical vibration.

Expected Operators Action:

1. Turbine vibration readings are to be crosschecked and also local actual vibration to be checked physically.
2. Listen for any sound coming at Turbine bearings.
3. When turbine vibration is very high, Turbine should be tripped otherwise trip the unit manually.

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4. Check and ensure whether lube oil pr. and temperature at bearings are normal whether bearing metal temperature and
return oil temperature is normal . Otherwise take appropriate action.
5. During start-up do proper soaking of turbine .
6. Reduce load to suit the condition.
7. Wait for frequency change if it is high.
8. Try to maintain turbine steam parameters as per startup curve.
9. Avoid sudden change in steam temperatures & load.
10. Try to maintain axial shift, differential expansion, condenser vacuum, exhaust hood temp, eccentricity within limits.

Caution:

11. If the turbine vibration is very high, unit should be tipped immediately and fast coasting down to bring zero rpm.

Final Corrective Actions:

1. During start up open always ensure all the turbine drains should be in open condition, warm the line and cylinder and follow
the starting procedures carefully, sock the turbine and observe the casing expansion.
2. During normal operation avoid sudden change in turbine operating parameters.
3. Follow the start-up and shutdown curves.

12.Turbine Bearing Temperature High

Likely causes:
1. Lube oil pressure is low,
2. Lube oil cooler outlet temp high.
3. Poor oil flow rate, pressure.
4. Bearing is damaged.
5. Vibration high.
6. Overload.
7. High gland steam leakages.
8. Foreign material in oil (mechanical impurities and Moisture).
9. Turbine acceleration is high.
10. One HP turbine CV got closed.
11. Axial Shift may be high

Plant Response:
1. Bearing temperature high.
2. Bearing return oil temperature high
3. Friction noise at local.
4. Bearing vibration increases.

Parameters of Concern:
1. Bearing temperature.
2. Bearing return oil temperature.
3. Bearing vibration.

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4. Lube oil temperature

5. Axial shift

Expected Operators Action:

1. Check oil flow from return oil gauge glass.
2. If the cooler inlet temperature maintaining high, change over the cooler
3. Reduce load as per the condition.
4. If possible decrease gland steam pressure.
5. If bearing seriously damaged then stop the unit.
6. Bearing temperature increasing, turbine will trip(@121deg).
7. During rolling – maintain lube oil temperature and pressure. Ensure flow through the return oil bearings

Caution:
1. If any oil leakage is heavy, immediately contact fire person to prevent fire.

Final Corrective Actions:

1. After turbine tripped, contact maintenance person, wait for suitable condition for inspection of bearing.
2. During rolling maintain acceleration and rated temperature.

13.High axial Shift

Likely causes:
1. Abrupt change of load.
2. Sudden drop of steam temperature.
3. Sudden drop of vacuum.
4. Due Sudden cut off of HP Heaters (increase in too high flow in reheater).
5. Sudden closer of extraction NRV.
6. Lube oil failure of thrust bearing/lube oil pressure/temperature.
7. Too fast pick up of load.
8. Turbine overload.
9. Salting in turbine.

Plant Response:
1. Overloading of thrust pads and failure.
2. May contribute to turbine vibration.
3. Unusual sound from turbine.
4. May result in abnormal turbine differential expansion.
5. Increase eccentricity.
6. High vibrations.
7. Gradual increase in turbine first stage pressure.

Parameters of Concern:
1. Load rate.
2. Steam temperature.
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3. Condenser Vacuum.
4. Hp heaters status.
5. Extraction NRV position.
6. Lube oil temp/thrust bearing temperature.
7. Axial shift.
8. HP IP Differential Expansion and LP differential expansion.
9. Turbine vibrations.
10. Eccentricity.

Expected Operators Action:

1. Check MS parameters ,Avoid sudden changes.
2. Control turbine vacuum.
3. Reduce load to reduce axial shift within permissible value.
4. Take HPH in service if possible.
5. Trip turbine in case of too rapid fall of steam temperature.
6. Check return oil from thrust pads through view glass for adequate quantity color and temperature.
7. Turbine will alarm on +0.6 or -1.05.
8. Cut out reheat spray if existing to reduce reheater flow.

Final Corrective Actions:

1. If axial shift exceeds + 1.2 or -1.65 turbine should trip on protection. In case it does not trip turbine trip it manual.
2. Break vacuum to bring rotor to rest fast.
3. After turbine is rest running it on barring gear check any rub noise, metallic sound vibration eccentricity, DEH/DEL. After all
parameters in range try to roll turbine slowly with concern SCE permission.
4. If parameters are not in range than give time to cool turbine and permit to maintenance department for inspection.

14.HP LP Differential Expansion more Positive

Likely causes:
1. Too high steam temperature for rolling.
2. Too fast rolling or too fast pickup of load.
3. Inadequate soaking during rolling as well as during turbine loading.
4. Gland steam temperature high.

Plant Response:
1. Seal rubs can be expected at extreme values. Metallic sound from turbine when interference exist.
2. Possible increase in turbine vibrations, eccentricity.
3. Turbine will alarm on +10.3 incase of HP differential expansion and on +19.8 in case of LP differential expansion.
4. Turbine will trip on +11.6 incase of HP differential expansion and on +24.6 in case of LP differential expansion.

Parameters of Concern:
1. Main steam temp, turbine metal temp.
2. Acceleration rate

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3. Heat soak time

4. Gland steam temp
5. Condenser vacuum
6. DEH and DEL
7. Turbine vibrations
8. Eccentricity

Expected Operators Action:

1. Reduce boiler steam temperature.
2. Hold turbine load, soak.
3. Check and control gland steam temp.
4. Reduce vacuum in case of LP differential expansion.
5. Maintain the rated steam pressure/temperature as per the startup curves.

Final Corrective Actions:

1. In case of high positive turbine expansion, tripping of turbine will help in reduction of HP differential expansion so trip it
with concern SCE permission.
2. Break vacuum to reduce damage after turbine tripped to reduce possible damages.
3. After turbine is rest running it on barring gear check any rub noise, metallic sound vibration eccentricity, DEH/DEL. After all
parameters in range try to roll turbine slowly with concern SCE permission.
4. If parameters are not in range than give time to cool turbine and permit to maintenance department for inspection.

15.HP LP Differential Expansion more Negative

Likely causes:
1. During hot start ups, rolling or loading turbine too slowly.
2. Boiler steam temperature lower than turbine metal temp.
3. Low condenser vacuum.
4. Gland steam temperature low.

Plant Response:
1. Seal rubs can be expected at extreme values. metallic sound from turbine when interference exist.
2. Possible increase in turbine vibrations, eccentricity.
3. Turbine will alarm on -5.3 incase of HP differential expansion and on -4.6 in case of LP differential expansion.
4. Turbine will trip on -6.6 incase of HP differential expansion and on -8.0 in case of LP differential expansion.

Parameters of Concern:
1. Main steam temp, turbine metal temp.
2. Acceleration rate.
3. Heat soak time.
4. Gland steam temp.
5. Condenser vacuum.
6. DEH and DEL.

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7. Turbine vibrations.
8. Eccentricity.

Expected Operators Action:

1. Improve condenser vacuum
2. Increase boiler steam temp and load turbine fast
3. Improve gland stem temp
4. Maintain rated steam pressure/temperature as per the startup curve

Caution
1. When turbine differential expansion is in extreme negative and the turbine has already
rolled ,tripping is not ideal solution as it would worst the situation .Gland steam temp, boiler parameter correction, rapid
loading are better alternatives.
2. It is essential that we do not roll turbine with negative mismatch of steam parameters already when negative expansion is
there.
3. If turbine is tripped break vacuum immediately to reduce possible damages.

Final Corrective Actions:

1. In case of negative turbine expansion reaches trip value, turbine will trip. If not trip, trip manual.
2. Break vacuum to reduce damage after turbine tripped to reduce possible damages.
3. After turbine is rest running it on barring gear check any rub noise, metallic sound vibration eccentricity, DEH/DEL. After
all parameters in range try to roll turbine slowly with concern SCE permission.
4. If parameters are not in range than give time to cool turbine and permit to maintenance department for inspection .

16.High Eccentricity

Likely causes:
1. Deflection of turbine rotor due to improper cooling after unit trip.
2. Improper draining of steam lines and turbine cylinders contributing water entry to turbine.
3. Abrupt drop of main steam temp due to water carryover from boiler.
4. Moister in gland steam.
5. Deformation of cylinders.
6. Disengaged barring gear etc.
7. Lube oil temperature, quality.
8. Spray CV is open in turbine rest condition.
9. Barring gear not engaged for long time after rest down to 0 RPM or during blackouts.

Plant Response:
1. Turbine vibration increases, unusual noise from turbine.

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Parameters of Concern:
1. Eccentricity.
2. Acceleration rate.
3. Heat socking time.
4. MS Temperature.
5. Lube oil temperature.
6. Bearing temperature.
7. Gland steam temperature.
8. Vibrations.
9. Barring gear operation

Expected Operators Action:

1. Follow start up procedure regarding steam parameters, draining of steam lines and cylinders. Socking times etc strictly
2. Before rolling turbine see that eccentricity does not exceed 30microns and while running not more than 00 or negative
3. See that lube oil temperature is maintained between 40 to 45
4. Check quality of lube oil, bearing temperature.
5. Keep spray control valves of bypass system properly isolated on rest turbine.
6. Ensure barring gear is run as turbine reaches to 0 RPM and ensure shaft is rotating.

Final Corrective Actions:

1. Minor increase in eccentricity can be reduced by either long barring gear operation and if that is not possible rotating shaft by
180 degrees at regular intervals.
2. Sometimes if possible running at 500rpm for 3 to 4 hrs can reduce eccentricity.
3. If parameters are not in range then give time to cool turbine and permit to maintenance department for inspection.

17.Turbine Speed maintaining below 47.5Hz

Likely causes:
1. DEH control Failure.
2. Stop valve and CV close failure after unit goes out of synchronisms.
3. Turbine not coasting down due to stop valve and CV heavy passing.
4. Solenoid supply failure and Stop valves passing.
5. One or more control valves got closed.
6. Generator overload.

Plant Response:
1. Turbine Vibration goes to higher side if its maintaining in its 3rd critical speed range.
2. MOP discharge pressure decreases.
3. Unit goes out of synchronism with grid and trips @ 47.0Hz.
4. Rubbing sound may come from bearings.
5. HBT should occur in auto.

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Parameters of Concern:
1. Turbine Vibrations.
2. Unit goes out of synchronism and Generator breaker opened.
3. Turbine bearings status.
4. DEH system healthiness.
5. Healthiness of Unit auxiliaries.
6. Availability of DG set.
7. DCDB and UPS healthiness.
8. HBT occurs in auto.
9. Excitation current.

Expected Operators Action:

1. Trip the unit manually if it is not tripped.
2. Ensure JOP starts at <2000rpm.
3. Do HBT if it not occurs in auto.
4. Trip the Boiler if not Tripped.
5. Try to Make Boiler side stop valve close manually.

Final Corrective Actions:

1. Check and rectify DEH system so is to make it more reliable.
2. All protections to be checked periodically.
3. All solenoids to be checked periodically.
4. Healthiness of valves to be ensures during each start up and annual shutdown.

18.Turbine Speed maintaining above 52Hz

Likely causes:
1. DEH control Failure.
2. OPC protection Failure.
3. Tripping Solenoid Failure.
4. Grid Disturbance.
5. Stop valves and CV close failure due to control failure.

Plant Response:
1. Turbine Vibration goes to higher side.
2. MOP discharge pressure Increases.
3. Unit load fluctuates.
4. Turbine should trip at 110% Electrical protection.
5. Generator current and Terminal voltage shoots up.
6. All plant auxiliaries over loaded.

Parameters of Concern:
1. Turbine Vibrations.
2. Unit load and Generator current and terminal voltage.

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3. Tripping of turbine 0n 110% Electrical protection.

4. DEH system healthiness.
5. Healthiness of other auxiliaries.
6. Availability of DG set.
7. DCDB healthiness.
8. Speed coasting down after unit trips.
9. Opening of BDV and VV.
10. Closing of Extraction NRV’s.

Expected Operators Action:

1. If unit did not trip, Trip the unit manually..
2. If turbine Vibrations are increasing very fast then try to trip turbine by PB at Desk and kill the Vacuum.
3. If failed to trip the turbine from Desk than proceed for Mechanical tripping mechanism.
4. Trip the boiler and close boiler stop valves.
5. Open HP LP bypass.

Final Corrective Actions:

1. Check and rectify DEH system so is to make it more reliable.
2. OPC Protections to be checked during each start up.
3. All solenoids to be checked periodically.
4. Valve tightness test to be checked as per OEM schedule.
5. Mechanical over speed to be checked after annual shut down.

19.Barring gear not established after unit tripping

Likely causes:
1. Barring gear motor Power supply failure.
2. Engaging pneumatic solenoid air supply fails.
3. Engaging pneumatic solenoid malfunctioned.
4. Barring gear not meshing with gear on turbine rotor due to wear and tear.

Plant Response:
1. Turbine not comes on barring and after coasting down remains stand still.
2. Turbine rotor sagging.
3. TG eccentricity may increase.
4. Rotor may get damaged.
5. Hydrogen may escape generator.

Parameters of Concern:
1. Turbine metal temperature.
2. Rotors thermal state.
3. Bearing temperatures.

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4. JOP status.
5. Availability of manual barring spanner.
6. Generator H2 pressure.
7. Seal oil system parameters.

Expected Operators Action:

1. Ensuring Manual barring spanner and engaging handle is available.
2. Engage the barring manually and start hand barring.
3. Ensuring JOP is running.
4. Ensuring Turbine lube oil system is healthy.
5. Ensuring turbine bearing and metal temperature are normal.
6. Ensuring no rubbing sound is coming during hand barring from bearings.
7. Generator H2 pressure and seal oil system parameters are normal.

Final Corrective Actions:

1. Check and find out the problem and bring back turbine on motor barring as soon as possible.
2. Always Ensuring Barring gear motor healthiness.
3. Always ensuring that barring gear engaging solenoid air supply is available.
4. Barring Gear engaging gear teeth should be checked during each overhaul.

20.Both JOP Fail To Start

Likely causes:
1. Lube oil pressure low (pump inlet pressure).
1. Both JOP not in auto.
2. AC power failure & DC power supply off.
3. Supply fuses blown out.
4. Pump module problem.
5. Over load tripping of motor.
6. Pump mechanical damage.
7. No command from DCS, due to DCS fail

Plant Response:
1. Turbine speed less than 2000 rpm and JOP not in service alarm.
2. Barring motor will not start.
3. Bearing temperature and Bearing vibrations will increases

Parameters of Concern:
1. Turbine speed.
2. Turbine vibration.
3. Bearing temperature.

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4. Axial shift.
5. Eccentricity.

Expected Operators Action:

1. Check lube oil pressure; if necessary take lube oil pump changeover.
2. If lube oil pressure is ok start the JOP from hard wiring switch.
3. Check module, fuses and reset the module, and start auxiliary pump.
4. If pump not started, open vacuum breaker and kill the vacuum to reduce turbine speed to 0(reduce coasting time down).
5. Ensure LOP is running.
6. Try to Start AC JOP from Module
7. Find out the reason and start JOP as soon as possible and start barring gear.
8. If JOP is not restored after zero rpm of turbine, start hand barring.

Final Corrective Actions:

1. Ensure continuous healthiness of both the pumps.

21.One of the Turbine’s CV or CRV Fail to close on Tripping

Likely causes:
1. Mechanical fault on CV/CRV.
2. CV/ CRV servo valve fail.
3. CV/ CRV servo valve card failure.
4. Heavy steam leakage near CV/CRV.
5. Tripping circuit fault.
6. Feedback problem.

Plant Response:
1. If stop valve is not closed properly turbine may over speed.
2. As HPT vent valve opens on Turbine trip, condenser vacuum may fall.
3. Turbine vibrations/axial shift may increase.
4. Turbine may not come to barring (if passing is minor).
5. Coasting down time will be greater than 60 minutes.

Parameters of Concern:
1. Turbine speed.
2. MSV/CV/RSV/CRV position.
3. Turbine vibration/axial shift.
4. Condenser vacuum.

Expected Operators Action:

1. Operate Manual/local trip lever once, near turbine and try to close CV/CRV.
2. Stop main steam stop valves from boiler immediately.

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3. Open HP/LP bypass.

4. Stop EH oil pump.
5. Inspect locally for any oil leakage.

Final Corrective Actions:

1. Inform instrument department for checking of servo valve card, servo valve, or any related issue and rectify it.
2. Inform mechanical maintenance for checking of mechanical stuck up or damage.

22.One of the Turbine’s CV or CRV Close and turbine on load

Likely causes:
1. Mechanical fault on CV/CRV.
2. EH oil/ Trip oil line oil leakage on that particular CV/CRV.
3. EH oil to CV/ CRV filter chock on that particular CV/CRV.
4. CV/ CRV servo valve fail.
5. CV/ CRV servo valve card / Feed back failure.
6. Heavy steam leakage near CV/CRV.

Plant Response:
1. Unit Generation may reduce.
2. If CRV close CRH/HRH pressure will increase, increase reheated temperature.
3. In case of CV MS pressure will increase, MS temp increase.
4. If one CV closes, other CV opening may increase for same load.
5. Axial shift will increase.
6. Heaters levels may fluctuate.
7. Incase of heavy EH oil leakage EH oil tank level drop and EH oil pressure also.

Parameters of Concern:
1. Ms pressure/temperature.
2. CRH/HRH press/temperature.
3. Axial shift.
4. Turbine vibration.
5. CV/CRV position.
6. HPH/LPH levels.
7. EH oil press/Tank level.
8. CV/CRV EH oil DP alarm.

Expected Operators Action:

1. Maintain MS/CRH/HRH pressure/temperature by reducing coal firing.
2. Maintain boiler metal temperature.
3. Watch axial shift /vibrations and other TSI parameters.
4. Maintain HPH/LPH level.
5. Watch EH oil press/level.

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6. Watch other CV/CRV positions.

7. Physical check for any steam/EH oil leakage at that area.
8. Physical check any mechanical damage at that CV/CRV.
9. If EH supply oil filter DP is high than open its bypass.
10. Inform instrument department for checking of servo valve card, servo valve, or any related issue and rectify it.
11. Identify the oil leakage if any and put collector vessel, inform fire department for same.
12. Check physical position of CV/CRV.
13. Ensure both LVDT output is matching (healthiness of LVDT).

Final Corrective Actions:

1. Trip the unit if heavy oil leakage, mechanical damage, servo valve fail, axial shift raising fast, vibrations, or HP exhaust
temp high and attend the CV/CRV.
2. Inform mechanical maintenance for checking of mechanical stuck up or damage.

23.Turbine starts rolling on MSV/RSV opening

Likely causes:
1. Any CV/CRV is passing.
2. Any CV/CRV is open.
3. Wrong feedback of CV.

Plant Response:
1. If passing is heavy or CV/CRV is fully open turbine run fast and may over speed.
2. Turbine vibration/axial shift/DEH/DEL /eccentricity increase.
3. Due to passing acceleration rate may not be maintained.
4. Turbine rolling starts upon MSV/RSV opening.
5. Barring gear disengage.

Parameters of Concern:
1. Turbine CV/CRV position.
2. Turbine speed and acceleration.
3. Turbine vibration/axial shift/DEL/DEH/eccentricity.

Expected Operators Action:

1. Immediately trip turbine if not then trip it manually.
2. Ensure Main steam pressure is as per startup curves.
3. Ensure barring gear is disengage and motor is stopped if speed >20 RPM if not do it manually.
4. Confirm the rolling acceleration rate is being maintained.

Final Corrective Actions:

1. Inform maintenance department to rectify the problem.

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24.Turbine MOP failure

Likely causes:
1. Drive coupling failure.
2. Bearing of MOP failure.
3. Suction of MOP failure due to turbo device failure or leakage.
4. MOP discharge line heavy leakage.
5. Low oil level in MOT.
6. Failure of NRV on MOP.
7. MSP not developing enough pressure or not started during start up.

Plant Response:
1. TOP start on auto, if it fails to start, EOP will start.
2. If Lube oil pressure drop up to .07mpa unit will trip.

Parameters of Concern:
1. MOP discharge pressure.
2. Lube oil pressure.
3. MOT level.

Expected Operators Action:

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

Final Corrective Actions:

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

25.MOT Level Low

Likely causes:
1. Oil leakage from Turbine bearings view glasses and exciter end piping.
2. LP turbine bearings oil overflow.
3. Oil cooler leakages.
4. Oil leaks from oil purifier system.
5. Oil level in LLD is high.
6. MOT drain valve passing or open.
7. MOT level gauge leakage.
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8. Seal oil system leakages

9. MOT basket filter got chocked
10. MOT and TD-BFP oil tanks, oil transfer system piping valves may be passing
11. Oil purifier improper line up

Plant Response:
1. MOT level decrease.
2. Oil pressure low alarm if oil leaks from oil supply line to bearing.
3. Turbine bearing temperatures may increase.

Parameters of Concern:
1. MOT level.
2. Lube oil pr. and temp.
3. VOT level.
4. Generator LLD.
5. Turbine bearing temperature

Expected Operators Action:

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

Caution:
1. If any oil leakage is heavy, immediately contact fire person to prevent fire.

Final Corrective Actions:

1. If MOT level is sustaining after attending the problem (any leakages etc.) normalize the load as requirement.

26. HP Exhausts Temperature Shooting Up

Likely causes:
1. Insufficient steam flow from HP turbine during IP to HP transfer (HP bypass opened more than required & load set point is
not more).
2. MS temperature high.
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3. CRH NRV not fully opened.

4. HPBP spray valve malfunction during start up.
5. Continuous low load operation.
6. Closing of any HP/IP turbine control valve.
7. HP heater 1 cut out.

Plant Response:
1. HP exhausts temp HIGH alarm display.
2. HP –IP diff expansion increases.
3. Turbine will trip on HP exhaust temperature>460deg.
4. CRH inlet temperature increases.

Parameters of Concern:
1. MS temperature.
2. HP exhausts pressure.
3. CRH pressure.
4. HP bypass valve position.
5. HPBP spray valve position.
6. CRH NRV position.
7. Unit load.
8. HP-IP differential expansion.

Expected Operators Action:

1. During IP to HP transfer increase steam flow by increasing the load & simultaneously reduce HP bypass valve position.
2. Ensure full opening of CRH NRV.
3. Maintain rated Main steam temperature during start-up.
4. Increase the load to increase steam flow through HP turbine.

Final Corrective Actions:

1. Always ensure healthiness of CRH NRV operation.
2. Reduce low load operation of the unit.

27.LP Exhaust Temperature Shooting Up

Likely causes:
1. HRH temp maintaining high in cold start up.
2. Low vacuum in condenser.
3. Tripping of any CW pump.
4. At low load exhaust hood spray valve is at closed position.
5. LP bypass spray valve is in closed condition during LP bypass operation.
6. CEP pr low for LP exhaust spray.
7. LP gland steam temp too high.
8. Keeping turbine speed 3000rpm for long time without synchronising.
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9. Running unit at low load for long time.

Plant Response:
1. Vacuum decreases.
2. LP turbine differential expansion increases.
3. Turbine vibration increases.
4. LP bypass fast close on condenser vacuum low (78 kpa) OR LP exhaust temperature>80deg.
5. Turbine will trip on LP exhaust temperature>107deg.
6. There is chance of explosive diaphragm rupture.

Parameters of Concern:
1. RH temperature.
2. HP-LP bypass valve position.
3. HP-LP bypass spray valve position.
4. LP exhausts hood spray valve position.
5. Condenser vacuum.
6. LP Differential Expansion.
7. Turbine vibration.

Expected Operator’s Action:

1. Improve the Vacuum in condenser.
2. Synchronise the unit and increase the load fast.
3. During low load operation check HP-LP, exhaust hood spray valve condition, if there is chocking in spray line clear it
immediately.
4. Increase the attemperation water pressure from condensate system.

Final Corrective Actions:

1. Reduce low load operation of the unit.

28.Gland Steam Pressure Low

Likely causes:
1. Gland steam pressure control valve failure.
2. Gland steam pressure transmitter reading wrong.
3. BDV opened.
4. Gland steam pressure over flow CV fully open.
5. Air leakage/air valve close of CVs.
6. Auxiliary steam header pressure low (CRH CV /MOV close, excess consumption, valves from other unit closed)
7. Load is low (for self sealing) and standby source disturbance
8. Gland steam piping leakage/drains open.
9. Gland steam temperature is low due to high spray or poor warm up.

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Plant Response:
1. Condenser vacuum will fall.
2. LP turbines exhaust hood temperature increase.
3. Due to Low vacuum air will enter through the seals. This will cause negative expansion.
4. Turbine vibrations and other TSI parameters may affect.

Parameters of Concern:
1. Gland steam pressure/temperature.
2. Condenser vacuum.
3. LP exhausts temperature.
4. Aux header pressure.
5. DEH/DEL.

Expected Operators Action:

1. Open instrument air valves to GS pressure CV close if any.
2. Close over flow MOV to condenser and LPH 7 if overflow CV does not close.
3. Open gland steam header CV bypass MOV if CV does not open.
4. Open CRH to aux CV/MOV if any problem.
5. Close valve to other unit from aux. header.
6. Open valve from other unit aux. header.
7. Check/close BDV position.
8. Maintain auxiliary header pressure/temperature.
9. Check for any leak in line / header from HPT CV.

Final Corrective Actions:

1. If gland steam press not established unit will trip on low vacuum if not, trip manually and break vacuum.
2. Follow up for cause to maintenance department.

29.Gland Steam Temperature Low

Likely causes:
1. Gland steam pressure control valve failure.
2. Gland steam pressure transmitter reading wrong.
3. Gland steam attemperation valve full open.
4. Condensation in gland steam line takes place.
5. Gland steam line drains closed at charging time.
6. LP attempt CV full open.
7. MS temperature/pressure low due to sudden variation if Gland Steam on self sealing.
8. Aux header pressure High and temperature is low.

Plant Response:
1. Gland steam line hammering may be observed.
2. Negative DEH/DEL.

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3. Water contamination in lubricating oil and vibration of turbine.

4. Effecting GSC performance and thus vacuum.
5. Due to water collection seals, periodical turbine vibrations may occur.

Parameters of Concern:
1. Gland steam temperature.
2. DEH/DEL.
3. Vibration.
4. GSC level.
5. Vacuum.
6. Moisture in lube oil.

Expected Operators Action:

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

Final Corrective Actions:

2. Follow up for cause to maintenance department.

30.Gland Steam Pressure High

Likely causes:
1. Gland steam pressure control valve failure.
2. Gland steam pressure transmitter reading wrong.
3. Gland steam pressure over flow CV fully closed.
4. Air leakage/air valve CVs.
5. Auxiliary header pressure high (CRH full open, sudden loss of consumption).

Plant Response:
1. Gland steam out from seals at turbine shafts.
2. Seal damages.
3. Turbine vibrations increase.

Parameters of Concern:
1. Gland steam header pressure.
2. Turbine vibrations.

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Expected Operators Action:

1. Check BDV position.
2. Open bypass MOV of overflow CV if overflow CV does not open and maintain the pressure.
3. Open MOV of overflow to LP condenser and LPH 7.
4. Close gland steam press CV inlet MOV if CV does not close (when unit is in self sealing).
5. Close CRH to aux CV inlet MOV if CRH CV does not close.

Final Corrective Actions:

1. Follow up for cause to maintenance department.

31.Gland Steam Temperature High

Likely causes:
1. Gland steam pressure control valve failure
2. Gland steam pressure/temperature transmitter reading wrong.
3. Gland steam attemperation valve not working.
4. Gland steam line drains full opened.
5. LP GS attempt CV full close.
6. LP GS attempt. Nozzle chock.
7. MS temp/press high due to sudden variation if GS on self sealing.
8. Aux header pressure and temperature is high.
9. Gland steam header attemperation line strainer in chocked condition.

Plant Response:
1. DEH/DEL increase.
2. Turbine vibration increase.
3. Damage of seals.

Parameters of Concern:
1. DEH/DEL
2. Vibration
3. Vacuum
4. GSC level
5. Gland steam temp
6. LP Gland steam attemperation CV Position.

Expected Operators Action:

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

Final Corrective Actions:

1. Follow up for cause to maintenance department.

32.Control oil (EH oil) leakage

Likely causes:
1. O rings at various hydraulic devices get damage.
2. Poor piping work.
3. Heavy material falling on pipe lines.
4. Air ingression in the system.
5. CCCW system fails and EH oil temperature got very high.
6. Heavy vibration in MSV/CV/RSV/CRV/TDBFP LSV, LCV.

Plant Response:
1. If leakage is heavy EH oil tank level, pressure fall and at <7.6 Mpa pressure Turbine will trip.
2. If leakage is heavy in specific MSV/CV/RSV/CRV/TDBFP LSV, LCV that valve will get close.
3. If leakage is heavy in common line turbine will trip.
4. If leakage is heavy in TDBFP or both TDBFP line they will trip.

Parameters of Concern:
1. MSV/CV/RSV/CRV position.
2. EH oil tank level.
3. EH oil pressure.
4. EH oil temperature.
5. Both TDBFP LSV/LCV position.

Expected Operators Action:

1. Identify the location and leakage quantity quickly.
2. Monitor EH oil temperature, pressure, level.
3. Put some collecting vessel where the oil is leaking; call fire personals for the same.
4. Call maintenance persons for the same.
5. If leakage is in TDBFP supply line trip it, check possibility of isolation of line by closing MIV at EH oil station otherwise
trip turbine with SCE approval.

Final Corrective Actions:

5. If leakage is minor continue observe it and rectify it whenever opportunity is given.

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33.Control Oil (EH) Oil Pump Failed

Likely causes:
1. Pump tripped on any electrical protection.
2. EH oil tank level low low.

Plant Response:
1. Standby pump pickup in auto.
2. Turbine will trip on EH oil outlet pressure<7.8MPA.
3. If tank level is low low both EH oil pump will trip.
4. TDBFP A & B will trip on low oil pressure.

Parameters of Concern:
1. EH oil tank level.
2. Outlet header pressure.
3. Oil temperature.

Expected Operators Action:

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

Final Corrective Actions:

1. Ensure continuous healthiness of both the pumps.
2. Follow the equipment changeover schedule.

34.Seal Oil Pressure Going Low

Likely causes:
1. VOT level dropping fast.
2. One seal oil pump tripped & standby pump not started.
3. Running seal oil pump PRV operated
4. Seal oil line leakages
5. DPR not operating properly.
6. Pump mechanical jamming.
7. Seal oil pump discharge recirculation valve open.
8. Seal oil filter DP high.
9. Motor protections operated

Plant Response:
1. Standby Pumpstarts on Seal oil header pressure low

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2. Vacuum oil tank level will rise

3. Float oil tank levelmay rise.
4. Incase of Line leakages, MOT level will drop, as oil makeup to VOT increases.
5. H2/seal oil DP drops and H2 escapes from generator.
6. H2 pressure in Generator falls quickly.
7. Generator H2 cold & hot temperature increases.
8. Generator temperature increases.
9. Risk of explosion.

Parameters of Concern:
1. Seal oil header pressure.
2. H2 pressure
3. Seal oil/H2 DP.
4. Generator stator winding temperatures.
5. VOT / FOT / MOT levels
6. Seal oil filter DP
7. H2 gas purity
8. Generation

Expected Operators Action:

1. Monitor seal oil DP, H2 pressure.
2. Immediate change over the filter.
3. Start standby seal oil pump if not started in auto.
4. Start DC seal oil pump if not started in auto and ensure its recirculation line valve closed fully.
5. Reduce load so as to maintain H2 temp/Gen temp within permissible limits.
6. Check seal oil pump R/C valve.
7. If seal oil pressure is not restored then take lube oil source backup, trip the unit or reduce the load watching generator
winding temperatures, vent the H2 to 100 Kpa to maintain seal oil DP.
8. FOT bypass to be opened to maintain FOT level
9. Check for any line leakages as MOT makeup may be required.
10. Seal oil vacuum pump performance may be checked.

Final Corrective Actions:

1. Maintain proper VOT level, float oil tank level.
2. Always ensure DC pump R/C valve is in closed condition.
3. Always ensure lube oil source backup once in a shift.
4. Follow the equipment changeover schedule.

35.VOT Level Low

Likely causes:
1. Trouble in lube oil supply.
2. Major oil leakage in seal oil system.

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3. Float valve in vacuum oil tank is not working / stuck up.

4. DC seal oil pump bypass MIV is open and dc seal oil pump is running.
5. Level transmitter/switch malfunction.
6. High vacuum in VOT.

Plant Response:
1. Dc seal oil pump start if it is in interlock on -75 mm of VOT level.
2. Second A.C seal oil pump does not start because of not getting start permissive.
3. Recirculation pump trip on interlock.
4. If DC seal oil pump does not start or not developing sufficient pressure, seal oil to hydrogen differential pressure is low, then
hydrogen leakage may happen.
5. If DC seal oil pump start and seal oil to hydrogen differential pressure is high than oil may be enter in generator and
continuous LLD alarm may be persisting.
6. If H2 press drops hot/cold gas temp may increase.
7. Generator winding temperatures may increase.

Parameters of Concern:
1. DC seal oil pumps current/discharge pressure.
2. VOT level/pressure.
3. H2 pressure.
4. Seal oil DP.
5. LLD alarms.
6. Lube oil pressure.
7. Hot /cold gas temperature.
8. Generator winding temperature.

Expected Operators Action:

1. Check DC seal oil pump is start on auto and developing pressure if not developing pressure check its bypass MIV and close
it.
2. Watch seal oil to hydrogen DP is between 35 to 75 KPa if DP is beyond this, then adjust the DP with bypass MIV of DPR.
3. If DP is maintaining high, control the DP with DC seal oil pump bypass MIV.
4. Ensure hydrogen pressure is not dropping.
5. Rectify the lube oil supply trouble and make it ready as soon as possible.
6. Identify the leakage if any in seal oil system and make necessary isolation if it is possible put collect vessel and inform to fire
department.
7. Check VOT level locally if it is OK then rectify the level transmitter/ switch problem with ICM .
8. If float valve got stuck, do some soft hammering at VOT and call MMD for the same.
9. After system normalizes drain all LLD at least once.
10. Stop vacuum pump.

Final Corrective Actions:

1. If DC seal oil pump not start and VOT level is low in local also hydrogen pressure is dropping fast, then trip the unit, and
purge the hydrogen to 100Kpa to take the Lube oil backup. Establish Seal oil parameters with Lube oil backup.
2. Later purge the hydrogen up to 25kpa, and start CO2 filling and ensure lube oil to seal oil discharge header and air deterring
section/float oil tank to seal oil discharge header MIV are fully open. Check the float oil tank level also.
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3. Check no sparking at generator exciter end.

4. Keep all persons out near the generator.
5. Inform fire section for the same.

36.Seal oil float tank level low

Likely causes:
1. Float oil tank float not working/stuck up.
2. Float oil tank inlet MIV closed.
3. Float tank bypass MIV open.
4. Float oil tank drain MIV open .
5. Seal oil DP low (DPR malfunctions).
6. Enlargement section tank drain MIV open.
7. Lube oil system trouble and air deterring section/float oil tank is supplying oil to seal oil system.
8. LLD alarm.

Plant Response:
1. H2 pressure decreases.
2. LLD in enlargement section observed.

Parameters of Concern:
1. FOT level.
2. H2 pressure.
3. Seal oil DP.
4. Seal oil pump discharge pressure.
5. MOT level.
6. Lube oil pressure.
7. Hot/cold gas temperature.
8. Generator temperature.
9. FOT bypass valve position

Expected Operators Action:

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

Final Corrective Actions:

1. Soft hammer on outlet line and FOT if then also not operate call MMD for same.

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37.Seal oil float tank level high

Likely causes:
1. FOT float may not working/stuck.
2. H2 pressure low.
3. Seal oil DP high (DPR malfunctions).
4. Seal oil ring damaged.
5. H2 line MIV at FOT closed.
6. FOT outlet MIV closed.

Plant Response:
1. If float tank level is full and still rising the oil may enter in generator.
2. If oil enters in generator insulation value may go down and earth fault may result.
3. LLD in enlargement section and turbine and generator end found continuously.
4. H2 purity drop.

Parameters of Concern:
1. Float oil tank level.
2. H 2 purity.
3. LLD alarms.
4. Seal oil DP.

Expected Operators Action:

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

Final Corrective Actions:

1. Soft hammer on outlet line and FOT if than also not operate call MMD for same.
2. Drain all LLD if observed.

38.Hydrogen purity low

Likely causes:
1. Contamination of hydrogen by oil vapors.
2. H2 cylinder lacking in specified purity.
3. Oil/water in generator.
4. H2 dew point is not maintaining.

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Plant Response:
1. Purity of hydrogen less then 97% is not desire as heat transfer will not proper.
2. If purity lower further and if oxygen in the mixture exceeds 1.2explosion risk is there.
3. Alarm will appear at 97%.
4. Not safe to run the Unit at <95% H2 purity.

Parameters of Concern:
1. Hydrogen purity.
2. LLDS.
3. Hot/cold gas temperature.
4. Generator temperature.

Expected Operators Action:

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

Final Corrective Actions:

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

39.Hydrogen Leakage

Likely causes:
1. Seal oil DP low.
2. Seal oil pump trip due to low VOT level and DC pick up and its R/C valve is in open condition.
3. DPR malfunction.
4. Leakage from generator H2 pipe connections,H2 cooler flanges, near generator bushings etc.
5. Stator bar leakage.
6. LLD drain may be in open condition.
7. H2 leakage from its flange joint, valves, H2 coolers, sampling and filling lines, valves.
8. Float oil tank level is low
9. H2 system purging vent valve is passing
10. H2 driers drain valves are passing
11. H2 feeding line NRVis not holding

Plant Response:
1. High H2 pressure drop rate.
2. H2 leakage alarm will come.
3. Hot-cold gas temperature high alarm will come.
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4. Generator winding temp will increase.

5. If leakage is serious, chance of explosion near leakage.

Parameters of Concern:
1. H2 pressure in generator.
2. Seal oil/H2 DP.
3. H2 leakage alarm.
4. Hot-cold gas temperature.
5. Generator winding temperature.
6. H2 dew point.
7. Generation

Expected Operators Action:

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

Final Corrective Actions:

1. Always ensure the drop rate of H2 pressure during the unit start up and running condition.
2. Always ensure healthiness of float oil and VOT levels.
3. In running unit at least 25 CO2 cylinder should be available always for an emergency.
4. Purge out H2 with CO2 and find out the possible leaking points.

40.Both Vacuum Pump Failed

Likely causes:
1. One pump tripped & standby fails to start.
2. Both pump running & tripped on electrical protections.
3. Power supply failure.
4. Pump mechanical failure.
5. Pump operation at high vacuum.

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Plant Response:
1. Vacuum drops fast.
2. Unit load decreases.
3. Turbine exhaust hood temperature increases.
4. Howell temp starts increasing.
5. Axial shift may rise.

Parameters of Concern:
1. Condenser vacuum.
2. Unit load.
3. Exhaust hood temperature.
4. Hot well temperature.
5. Axial shift.

Expected Operators Action:

1. Check the reason behind tripping.
2. Start the pump immediately if the reason is rectified.
3. Reduce the load as quickly as possible.
4. If reason is unknown and still vacuum is dropping then unit will trip on vacuum low low (74 kpa) if not hand trip the unit.

Final Corrective Actions:

1. If necessary take unit shutdown and check the reason behind the vacuum tripping thoroughly and always ensure the
healthiness of vacuum system during vacuum pulling.

41.Condenser Vacuum Low

Likely causes:
1. Any CW pump trips,
2. CW outlet valve closed (partially or fully).
3. Condenser CW inlet or outlet valve closed and CW flow decrease.
4. Sudden increase in load.
5. High condenser Inlet & outlet cooling water temperature.
6. Vacuum pump trips or poor performance of PHE.
7. Vacuum pump air jet valve malfunction.
8. Vacuum breaking valve not fully closed or improper water sealing of vacuum breaking valve.
9. Gland sealing pressure drops, GSC siphon level low.
10. Leakages, ingress of air in to vacuum system through any drain line going to condenser or from loose flanges, instrument
tapping points.
11. Hot well level very high.
12. TDBFP vacuum system leaks (When it is in stopped condition).
13. Condenser tube choking (Condenser inlet-outlet DP high) so CW flow low.
14. VV valve open condition due to instrument air failure.
15. CT fans trip.
16. CT fan riser valve closed.
17. Condenser poor performance due to tube scaling /fouling

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Plant Response:
1. Condenser vacuum low alarm.
2. LP exhaust steam temp increase.
3. Hot well temperature increases.
4. Load reduces.
5. Fuel flow increases if unit is in CCS mode.
6. Turbine vibration may increase.
7. Unit trip at 74Kpa vacuum.
8. Standby vacuum pump will pick up.

Parameters of Concern:
1. LP exhaust steam temperature
2. Hot well water temperature & level.
3. CW inlet/outlet water temperature.
4. Drain manifold temp. Coming to HP-LP flash tank.
5. Condenser pressure.
6. CW flow.
7. Cooling tower range / No fans in service.

Expected Operators Action:

1. Check CW inlet and outlet temperature, if it is more than normal then increase the hot blow down and make up.
2. If any CW pump operation (check current, discharge pr.) is abnormal, changeover the pump.
3. If vacuum drops below 86 kpa, ensure second vacuum pump starts in interlock if not then start second pump.
4. Check whether gland steam pr. is normal or not, GSC siphon level, Overflow valve position.
5. Check vacuum breaker is fully close or not, ensure overflow of water from vacuum sealing line.
6. Open the LP exhaust hood spray when exhaust steam temperature Increases above 47 °C and open fully when temp increase
above 80 °C. If the temp increase above 107 °C unit trips
7. Check the condenser CW inlet-outlet valve position on DCS and local, if it is closed then open fully.
8. Check whether there is any leakage or ingress of air to vacuum system, if found any take appropriate action for isolation.
9. Check the condenser CW inlet-outlet DP. If DP is high then condenser tube should be cleaned.
10. If the vacuum is continuously dropping, decrease the load. If vacuum drops to -74 kpa unit should trip otherwise trip
manually.
11. Start the CT Fans after rectifying the cause.
Caution:
1. If the turbine vibration is very high, unit should be tipped immediately.

Final Corrective Actions:

1. Check thoroughly the reason behind the vacuum loss; if necessary take shutdown of the unit. Always ensure the healthiness of
the vacuum system during vacuum pulling during every start-up.
2. Rubber ball cleaning system should be taken into service.

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42.Condenser Pressure Rise After Vacuum Loss (In Blackouts and Shut Down Condition)

Likely causes:
1. Vacuum Breaker closed condition.
2. Lack of condensation in condenser as CW pumps tripped.
3. Gland steam supply not cut off.
4. HP-LP flash tank attemperation not available as CEP not running.
5. MS, CRH, HRH, extraction line drains, TDBFP steam line drains, HP-LP bypass line, HP heaters and LP heater drains CV
open due to Instrument air pressure low and high temperature steam coming to flash tank(Any drain to condenser open).
6. LP exhaust hood spray not available.
7. HP-LP bypass open/passing.
8. MS stop valve open (Boiler side)/passing.

Plant Response:
1. Condenser vacuum low alarm.
2. LP exhaust temperature increases.
3. LP turbine rupture disc may damage.

Parameters of Concern:
1. Condenser pr. and temp.
2. LP exhaust temperature.

Expected Operators Action:

1. Close MS stop valve of boiler side and hand tighten it.
2. Close HP-LP bypass valves.
3. Isolate all turbine drains & cut out gland steam and open the vacuum breaker at Pr.-30 Kpa
4. 4. Close the MS, CRH, HRH, extraction line drains, TDBFP stem line drains, HP heaters and LP heater drains MIV.
5. Isolate the Auxiliary flash tank to condenser line drain MIV.
6. Close the Hot well make-up MIV.
7. Start CW pump after power restoration.
8. Start CEP and start flash tank spray.
9. Open the re heater vent if LP Bypass is passing.
Caution:
1. If the turbine vibration is very high, unit should be tipped immediately.

Final Corrective Actions:

1. After restoration of power, start CW pump and CEP for proper circulation.

43.Condenser Tube Leakage

Likely causes:
1. Sudden steam loading to the condenser.
2. Sudden opening of HP/LP bypass valves.
3. Repeated blackouts.
4. Both CW pumps trips and ARV’s close condition.
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5. Manufacturing defect.
6. High COC.
7. High cooling water temperature.
8. CW pressure surges during CW pumps start / stop due to improper air venting.
9. High Vacuum
10. Sudden opening of high pressure drains like HPT VV and BDV.

Plant Response:
1. Cation conductivity increases in CLD, CEP outlet and CPU outlet.
2. CEP outlet Na+ Increases.
3. Condensate & feed water pH value decreases.
4. MS conductivity & Na+ increases.
5. If run for prolonged period chances of boiler tube failure and LP/HP heaters tube leakages, Turbine blade cracking
6.

Parameters of Concern:
1. Cation Conductivity in CLD & CEP outlet, value of pH ,specific Conductivity, Na+ in feed water, MS & condensate.

Expected Operators Action:

1. Ensure CPU is in service
2. Verify the SWAS parameters with DM lab.
3. Check for any hot well drain valve passing from field.
4. Identify the tube leakage zone from CLD system and if leak is minor then isolate the respective pass and attend the leakage.
5. If SWAS parameters is ensured from DM plant and leak is heavy, immediately trip the unit, stop the BFP and CEP, and do
not feed the water to boiler, drain the Dearator.
6. Stop one CW pump after Unit stop or load is below300MW.
7. Stop 2nd CW pump considering the Exhaust temperature, Turbine metal temperature, oil temperature,ACW pumps
requirement.

Final Corrective Actions:

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

44.Generator winding temperature rising fast:

Likely causes:
1. Overloading of generator.
2. High MVAR loading.
3. Stator cooling water flow low.
4. CCCW flow to hydrogen cooler low.
5. Hydrogen cooler not lined up or air locked.

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6. Hydrogen gas temperature may be high

7. H2 purity low.
8. Stator cooling water temperature high.

Plant Response:
1. Generator winding temperature rising.
2. H2 consumption may increase

Parameters of Concern:
1. Generator winding temperature high alarm.
2. Generator hot and cold gas temperature high.
3. Stator cooling water flow and temperature.
4. H2 pressure.
5. H2 Purity.
6. Unit load
7. Stator water tank level and Makeup frequency.

Expected Operators Action:

1. Reduce generator MVAR loading.
2. Reduce generator load gradually till winding temperature rising trend reverse.
3. Increase stator cooling water flow.
4. Start the CCCW pump if stator cooling water temperature/hydrogen hot and cold gas temp is high.
5. Vent hydrogen cooler,
6. Fill hydrogen if pressure is low.
7. Purge the hydrogen if purity is low

Final Corrective Actions:

8. Check thoroughly the reason behind the temperature rising and normalise the system as soon as possible, if necessary take
shutdown of the unit.

45.Water / Oil Detected In Generator Casing

Likely causes:
1. Hydrogen cooler leakage.
2. DPR malfunctioning and maintaining high DP.
3. Defective seal component and oil entering generator casing.

Plant Response:
1. Liquid in generator casing alarm.
2. Liquid traces in Local LLD gauges

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Parameters of Concern:
1. LLD level
2. MOT level.
3. Seal oil pressure at generator end.
4. Hydrogen gas pressure and purity.
5. Seal oil/H2 DP.

Expected Operators Action:

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

Final Corrective Actions:

1. Find out the reason for liquid entry in casing and rectify it.

46.Cooling Tower Fan tripped

Likely causes:
1. CT fan Gearbox oil temperature Exceeded >80°C.
2. CT fan Vibration Switch Actuated.
3. Protection malfunctioning.
4. CT fan Gearbox oil level low due to which fan tripped on protection.
5. Gearbox oil temperature measuring RTD Showing wrong temperature.
6. Emergency Push button actuated.
7. CMCTF Power supply failure and tie not closed.

Plant Response:
1. Condenser Inlet water temperature increases.
2. If more than 2 fans tripped than condenser inlet water temperature increases fast and so vacuum drops.

Parameters of Concern:
1. Condenser inlet water temperature.
2. Condenser vacuum.
3. Unit load.

Expected Operators Action:

1. Start Standby CT fan if available.
2. Moderate CW makeup and hot blow down as per condenser inlet water temperature.
3. Reduce unit load if vacuum dropping fast.

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4. Check physical status of tripped fan and position of emergency push button.
5. Reset the vibration switch with coordination of I&C team and start the fan if vibration switch had malfunctioned.
6. If CMCTF trips, close tie after checking the reason.

Final Corrective Actions:

1. Maintaining proper oil levels in CT fan Gearbox.
2. If EPB actuated by accident then release it and start the fan.
3. Isolate the tripped fan and made it available as soon as possible.
4. If CMCTF power supply failed occurs and tie not closing in auto then rectify the problem with coordination of EMD.

47.Fore bay level dropping fast

Likely causes:
1. All running sea intake pumps got tripped.
2. CW Trash Screen in Chocked Condition.
3. Blow Down valve opened to full suddenly.
4. Trash Screen in Damaged condition.
5. CW makeup valve closes to 0%.
6. Sea water intake pumps trash cleaner chocked.
7. Level Transmitter faulty.
8. Clarifier Inlet valve or Fore bay Makeup Valve close.
9. Any other Unit make up valve in full open condition.
10. Any seawater discharge line problem.

Plant Response:
1. CW duct pressure may drop if fore bay level go to lower limit.
2. CW pumps vibration will increase.
3. CW pump motor Current reduces.

Parameters of Concern:
1. Condenser Vacuum.
2. Sea Intake pumps status.
3. CW makeup valve status.
4. CW Duct Pressure.

Expected Operators Action:

1. Starting Standby Sea Intake pump as per Availability.
2. Closing the Blow down valves to minimum position.
3. Reducing load if the condenser vacuum falling fast, if level goes more low stop one CW pump.
4. Increasing the opening of CW makeup valves.
5. Operate Trash Screen for some time if there are particles which are choking the inlet of pump.
6. Stopping Running Effluent pit pump as it may go out of suction if blow down closed to full.

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Final Corrective Actions:

1. Once Fore bay level come backs to normal (>6500mm) start raising Load.
2. If the problem exists in system then isolate the auxiliary and make it ready after maintenance.

48.All Sea Intake Water Pumps Tripped

Likely causes:
1. Station Blackout.
2. PLC failure
3. Pump tripped on any protection.
4. Both pump discharge valve closed, pump tripped in interlock.
5. Both pump cooling water supply failure.
6. Loss of suction head due to suction pool level low or trash cleaner choking.
7. All sea water pumps discharge valves supply from Sea water MCC , which is feeding from CMCTF-5B and CMCTF-6B.

Plant Response:
1. CW forebay level drops fast.
2. CL2 system makeup water loss
3. 20MLD plant makeup loss

Parameters of Concern:
1. CW temperature.
2. CW forebay level.
3. Hot blow down/ Cold blow down valve opening status
4. Chlorination system
5. 20 MLD plant

Expected Operators Action:

1. Close Hot / Cold blow down valve to maintain forebay level.
2. Reduce load to reduce the evaporation loss.
3. If CW forebay level is dropping fast then reduce the load, stop one CW pump, 7 CT fans & close its risers.
4. Find out the problem and start the pumps as soon as possible

Final Corrective Actions:

1. Find out the problem and start the pump as soon as possible.

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ELECTRICAL SYSTEM -
EMERGENCIES

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1.Power supply failure on emergency PCC

Likely causes:
1. Boiler transformer tripping and DG/Stand by DG set not Started on auto.
2. Bus fault on boiler PCC and DG/Stand by DG set not Started on auto
3. Emergency PCC bus fault.
4. Fault on any outgoing feeder which extended up to main incomer of emergency PCC.

Plant Response:
1.If power supply fails on EMPCC-A then incomer to EMPCC-A will open.
2.Power supply to turbine EMCC-A, boiler EMCC-A, UPS supply-A, 220v DCDB supply-A, switchyard DCDB-A, boiler valves
MCC supply will interrupt.(important auxiliaries on boiler EMCC-A section are ID/FD/PA fan # A lube oil supply power,
coal mill a/b/c lube oil supply power,TDBFP a MEH panel power, Aph-A Standby power. Important auxiliaries on turbine
EMCC-A section are TDBFP-A barring gear, EH oil pump-A, seal oil pump-A, Ac Jop , turbine lift, generator duct
pressurization compressor., switchyard UPS-A power supply.)
3.If power supply fails on EMPCC-B then incomer to EMPCC b will open.
4.Power supply to turbine EMCC-B, boiler EMCC-B, UPS supply-B , 220v DCDB supply-B, turbine valve MCC supply will
interrupt.(important auxiliaries on boiler EMCC-B section are ID/FD/PA fan # B lube oil supply power, coal mill d/e/f lube
oil supply power,TDBFP-B MEH panel power, APH-B b Standby power and boiler lift power. Important auxiliaries on
turbine EMCC-B section are TDBFP-B barring gear, turbine barring gear,EH oil pump-B ,seal oil pump b ,top, MDBFP
AOP)
5.Turbine valve MCC supply will interrupt.
6.DCDB and ups battery backup charged of respective section.
7.Switch yard DCDB and ups battery backup charged of respective section.
8.Control room emergency lighting will changeover on battery source.

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Parameters of Concern:
1. EMPCC bus voltage.
2. 220v DCDB voltage and battery voltage of respective section.
3. Ups battery voltage of respective section.
4. Switchyard DCDB voltage and battery voltage of respective section.
5. Switchyard UPS battery voltage of respective section.

Expected Operators Action:

1. Close the tie breaker of TEMCC locally, open respective incomer.
2. Close the tie breaker of BEMCC locally, open respective incomer.
3. Restore the auxiliaries of above EMCC.
4. Change over the supply source of boiler MOV MCC and turbine mov MCC to normal PCC side source.
5. Ensure the cause of failure of power on EMPCC and failure of DG /Stand by DG.
6. If there is no bus fault on EMPCC then Start DG /Stand by DG manually.
7. If power restoration is delayed then parallel the 220 v DCDB section and switchyard DCDB section with healthy section to
prevent discharging of battery set.
8. Change over UPS to reserve source to prevent discharging of battery set.

Final Corrective Actions:

1. Normalize the supply to EMPCC after rectifying the problem.
2. Stop the DG set/Stand by DG set and put it on auto mode.
3. Close the incomer of BEMCC/TEMCC and open the bus coupler locally.
4. Change over the supply source of boiler mov MCC and turbine mov MCC to emergency source.
5. Restore UPS supply to normal source from reserve source.
6. Charge the 220v DCDB and switchyard DCDB from normal source and open the tie switch.
7. Ensure system healthiness.

2.DG Not Started in Auto

Likely causes:
1. DG in manual mode.
2. Emergency push button operated at DG AMF panel or DG relay.
3. Diesel level is not sufficient.
4. Diesel tank outlet valve or DG inlet/outlet valve are in closed condition.
5. DG control supply failed (From DCDB BUS-B).
6. Low battery voltage.
7. DG set governor operation is sluggish or jam.
8. DG set protection is already in acted condition.

Plant Response:
1. DG fails to start alarm on DCS (EALM12-DG three trials fail).

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2. After three crank cycle of main DG command will go to Start Standby DG set.
3. EPCC charge through Standby DG set running.
4. If Standby DG set also fails to start , no power at Emergency PCC.
5. No power at Turbine Emergency MCC and Boiler Emergency MCC.
6. DCDB and UPS will switch over to Battery source.
7. DC drives will run.
8. Check Tie Breakers of EPCC-A and EPCC-B will be in closed condition.

Parameters of Concern:
1. Ensure DC emergency drives of Turbine and Boiler are running .
2. Monitor bus voltage of DCDB.
3. Monitor bus voltage of UPS-1 and UPS-2.
4. Ready to run manually turbine Barring Gear and APH auxiliary motor.

Expected Operators Action:

1. Keep DC drives in service till DG set restore
2. Tie Breakers of EPCC-A and EPCC-B have to be in closed condition if not closed manually
3. During both DGs are not stated in AUTO, Start DG set from local and charge EPCC
4. DG breaker will close at approximate 415V, if not close manually
5. If EPCC-A/B voltage are healthy, Start AC drives and Stop DC drives
6. TD BFP EOP and DC Scanner air fan has to run although DG Start
7. Monitor Diesel level of tank, If require fill main tank from Buffer tank

Final Corrective Actions:

1. If Station Transformer is available changeover the load on Station Transformer from DG set.

03.Station transformer failure

Likely causes:
1. Tripping of 220 kV bus.
2. Tripping of transformer due to internal fault.
3. Tripping of transformer due to fault on 6.6kv/11kv bus.

Plant RESPONSE:
1. 220kv bus side breaker , 11 kv bus incomer , 6.6kv bus incomer will open ( in case of under voltage or blackout all
breaker remains close ) .
2. Under voltage occurs on respective OA and OB bus.
3. Respective PCC incomer at common PCC, water supply PCC , lighting PCC, maintenance PCC and chemical water
PCC will open.
4. Coal handling plant incomer will open.
5. Bus coupler at above mentioned PCC will close.
6. Auxiliaries running on above PCC will trip.

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7. Auxiliaries running on downstream side MCC of above mentioned PCC like Service water pump, Dm transfer pump,
control room AHU, switch yard AHU, circulation water pump and cooling water pump of VAM/ chiller plant, cooling
tower fan and pump of VAM system , hot water pump and cooling tower fan of HEC, switchgear room AHU, CPU r/c pump,
chemical dozing pump , CHP belt conveyor , EOT crane, normal lighting, TG area exhaust fan will trip.
8. Compressors B, C and D, MDBFP will trip if they are running condition.
9. Switch yard control room normal lighting, power supply for operation of isolator,breaker,earth switch will interrupt.
10. Switchyard UPS reserve supply will interrupt.

Parameters of Concern:
1. Station 11kv/6.6kv/415 v PCC/415v MCC bus voltage.
2. Service water header pressure.
3. Instrument air and service air header pressure.
4. Coal bunker level.
5. CST level.
6. If MDBFP is in service then feed water flow.

Expected Operators Action:

1. Ensure bus coupler on common PCC, water supply PCC, chemical water PCC, lighting PCC and maintenance PCC close on
auto.
2. If any of above bus coupler not closed in auto close it manually.
3. If any bus coupler is not closing due to any problem the close all downstream side MCC bus coupler locally.
4. Check the cause of tripping of Station transformer if fault is not on 11kv/6.6kv bus then parallel bus with healthy
bus by closing OA to OB tie.
5. Ensure Stand by auxiliaries of tripped auxiliaries come in to service in auto else Start it manually.
6. Normalize all disturbed system .

Final Corrective Actions:

1. If Station transformer tripped due to 220kv bus side fault charge it as soon as 220kv bus is charged.
2. Check the cause of tripping if there is internal fault.
3. Charge the Station transformer after rectifying the fault.
4. Open the OA to OB tie if it closed.
5. Charge all the PCC from its incomer and open bus coupler.
6. Charge all the MCC from its incomer and open bus coupler.
7. Check voltage level of whole system and ensure system healthiness.

4.UPS Failure

Likely causes:
8. UPS source failure.
9. Rectifier failure and Reserve supply not available or Reserve switch OFF condition also Battery switch is in OFF condition.
10. Inverter trips and Reserve supply not available or Reserve switch OFF condition.
11. Frequency variation between UPS frequency and Reserve supply Frequency.
12. UPS protection acted condition.

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Plant Response:
1. Unit may trip.
2. UPS power to DCS protection not available.
3. Plant parameter readings will go bad.
4. DCS computers may fail.

Parameters of Concern:
1. UPS bus voltage, Battery current, healthiness of incoming source supply and alarm on UPS panel

Expected Operators Action:

 Check 415V supply of UPS from EPCC and Reserve source from Boiler PCC.
 In Blackout condition, check availability of DG.
 Check switches of Rectifier, Battery, and Reserve are in ON condition.
 If UPS tripped due to any reason and not Started, shutdown completely according below Steps :
1. Switch OFF Reserve switch
2. Switch OFF Inverter
3. Switch OFF Battery
4. Switch off Rectifier and wait for discharge bus voltage
Normalise by:
1. Switch ON Reserve
2. Switch ON Rectifier and wait approximate 30sec to build up DC voltage
3. Switch ON Battery
4. Switch ON Inverter
 Reserve supply may kept OFF during blackout condition.

Final Corrective Actions:

1. Rectify the UPS failure causes and normalize the UPS

5.DCDB Failure

Likely causes:
1. Incomer at EMPCC trips and battery backup source fails
2. Battery backup source is in service and its voltage becomes low .
3. Electrical fault on DC bus.
4. Electrical fault on outgoing feeder which extended up to bus/ incomer .

Plant response:
1. Incomer at EMPCC will trip if fault occurs on bus.
2. Remote operation of electrical drives will not possible.
3. Unavailability of DC emergency drives.
4. Protection relay of generator/GT/UAT/ST/11kv bus/6.6kv bus/415v PCC will not act.

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Parameters of Concern:
1. DC bus voltage.
2. Battery set voltage.

Expected Operators Action:

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

Final Corrective Actions:

1. After rectifying fault normalize the system i.e. charge the bus from EMPCC incomer, open the bus parallel switch and
battery set is in charging mode.

6.DC fails of Motor Feeder

Likely causes:
1. DCDB fails.
2. Switchgear Main DC MCB is in OFF condition (Breaker of Incomer Line PT).
3. DC MCB of Motor feeder is OFF condition.

Plant Response:
1. Bad feedback comes on DCS of Motor.
2. Motor ON/OFF command not possible from DCS.
3. Motor ON/OFF command possible only through Breaker.
4. Motor Electric protection bypass.

Parameters of Concern:
1. Flow/Pressure/Vibration/Temperature of Motor.
2. Bus voltage.

Expected Operators Action:

1. If Motor Temperature is high or motor is taking high current immediate Stop Motor from Breaker.
2. Check Bus voltage of DCDB.
3. Check DC source in 6.6KV switchgear BUS.
4. Check DC source in Motor Panel.

Final Corrective Actions:

1. Rectify the DC failure causes of Motor feeder and normalise the Motor feeder.

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7.High Bus Transfer Blocked

Likely causes:
1. HBT relay will not in service.
2. HBT will in block condition due to following reasons,
 Protection will be acted in GRP panel.
 Bus PT of Station switchgear is in racked out condition/fuse not healthy.
 Bus PT of Unit switchgear is in racked out condition/fuse not healthy.
 Line PT of Unit switchgear Incomer is in racked out condition/fuse not healthy.
 Unit switchgear Incomer breaker/ Unit switchgear Tie breaker (Tie to Station switchgear)/Station switchgear Tie breaker
(Tie to Unit switchgear) DC OFF.
 Unit switchgear Incomer breaker/ Unit switchgear Tie breaker (Tie to Station switchgear)/Station switchgear Tie breaker (Tie
to Unit switchgear) is in TEST MODE.
 Unit switchgear Incomer breaker/ Unit switchgear Tie breaker (Tie to Station switchgear)/Station switchgear Tie breaker (Tie
to Unit switchgear) is in LOCAL MODE.
 Unit switchgear Incomer breaker/ Unit switchgear Tie breaker (Tie to Station switchgear)/Station switchgear Tie breaker (Tie
to Unit switchgear) LOCKOUT RELAY OPERATED in Breaker.
 Station switchgear Tie breaker (Tie to Unit switchgear) is Open condition.
3. HBT relay control supply OFF condition (DCDB BUS-A).
4. HBT relay is in MANUAL MODE.
5. Voltage difference between Station and Unit switchgear bus.
6. Difference in Phase angle between Station and Unit switchgear bus.

Plant Response:
1. No permissive for Bus Transfer in 6.6KV Unit switchgear DCS screen.
2. Transfer Blocked in HBT Relay.
3. Bus Transfer not possible (Unit to Station/Station to Unit).

Parameters of Concern:
1. 6.6KV Bus voltage of Unit switchgear.
2. 6.6KV Bus voltage of Station switchgear.
3. Unit Blackout.

Expected Operators Action:

1. Check HBT relay.
2. Check Breaker healthy condition i.e. NO lockout operated/Breaker in Service/Breaker in Remote/DC healthy.
3. Check source of HBT Relay (DCDB BUS-B).
4. Maintain equal Bus voltage of Station switchgear and Unit switchgear.

Final Corrective Actions:

1. Rectify the HBT failure causes and normalise the HBT.

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8.Flash over

Likely causes:
1. Flash over due to loose contacts at joint’s or clamps of bus bar, isolator, breaker, CT, PT or CVT.
2. Due to heavy wind or stormy condition.
3. Due to accumulation of dust and moisture particle at string and support insulator.
4. Due to misalignment of isolator moving contact.
5. Due to breakdown of live conductor which falls on another live part.
6. Over loading.
7. Due to high oil temperature in case of oil immersed CB/CT/PT/CVT used.
8. CT failure due to opening of secondary coil or mfg. Defects.

Plant RESPONSE:
1. Tripping of concern section/line/unit/bus bar.
2. Damage occurred to Men and Equipment due to flashover

Parameters of Concern:
1. Bus voltage.
2. Line loading.

Expected Operators Action:

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

Final Corrective Actions:

1. Charge the tripped section or lines after isolating damaged section.
2. After replacing the damaged part /equipment charge it again.

09.Gas pressure low of circuit breaker

Likely causes:
1. Gasket of circuit breaker is damaged.

Plant RESPONSE:
1. At 0.55mpa gas pressure Low alarm will come
2. At 0.50mpa gas pressure Breaker will lockout.

Parameters of Concern:
1. Breaker operating gas pressure

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2. Breaker operation will not possible if lockout occurs.

Expected Operators Action:

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

Final Corrective Actions:

1. After rectifying the leakage charge the respective dia. and breaker.
2. Monitor gas pressure at regular interval.

10.Fire in cable gallery

Likely causes:
1. External fire spreading into cable gallery.
2. Overheating or insulation failure of any cable which results into flashover.
3. Fire due to any hot job work in cable gallery
4. Due to high temperature steam/fluid leakage around cable gallery.

Plant Response:
1. Many auxiliaries will trip if fire is severe.
2. Fire inert gas system charged on auto.

Parameters of Concern:
1. Parameter of affected system.
2. 11kv/6.6kv/415v bus voltage.

Expected Operators Action:

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

Final Corrective Actions:

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

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11.Hot spot

Likely causes:
1. Loose contacts at joints or clamps of bus bar, isolator, breaker, CT, PT or CVT.
2. Overloading of bus bar, line, isolator or breaker.

Plant RESPONSE:
1. Temperature remains high at hot spot. Winding temp.

Parameters of Concern:
1. Temperature at hot spot. It should less than 70 deg. C
2. Loading of respective line/bus bar/auxiliary. .

Expected Operators Action:

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

Final Corrective Actions:

1. After attending the hot spot charge that section again.
2. Observe temperature regularly at that point.

12.High oil/winding temperature of reactor

Likely causes:
1. Low oil level in conservator tank.
2. Short circuit or inter turn fault of winding.
3. High atmospheric temperature.
4. Malfunction of temperature detector switch.

Plant RESPONSE:
1. Winding temperature High alarm at 100 deg c and tripping at 110 deg c.
2. Oil temperature High alarm at 90 deg c and tripping at 100 deg c.

Parameters of Concern:
3. Bus voltage.
3. Line voltage.

Expected Operators Action:

1. Ensure that oil level is normal in conservator tank and no oil leakage from tank or reactor body.
2. Inform to control room and maintenance Staff about high winding /oil temp.
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3. Isolate the reactor according to condition if temperature Continues remains on higher side for further investigation.

Final Corrective Actions:

1. After rectifying the fault charge the reactor again.
2. Observe winding and oil temperature regularly.

13.Oil leakage in reactor CB/CT/PT

Likely causes:
1. Gasket of circuit breaker is damaged.
2. Damage to equipment due to improper handling.

Plant RESPONSE:
1. Reactor winding and oil temperature remains high if oil level goes low.
2. Overheating of CT / PT /reactor core and winding.

Parameters of Concern:
1. Reactor oil temperature High alarm will comes at 90 deg c. and tripping at 100 deg c.
2. Reactor winding temperature high alarm will comes at 100 deg c. and tripping at 110 deg c
3. Feedback from ct/pt/ will interrupt or goes bad in case of winding damage.

Expected Operators Action:

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

Final Corrective Actions:

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

14.Two reactor tripped back to back

Likely causes:
1. Tripping due to bus bar fault.
2. Tripping due to reactor electrical protection operated.
3. Tripping due to high winding temperature.
4. Tripping due to high oil temperature.
5. Tripping due to buchollz relay operation.
6. Malfunction of any of above relay.

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Plant RESPONSE:
1. Bus voltage will increase.

Parameters of Concern:
1. Bus voltage.
2. Line voltage.
3. Generator MVAR.

Expected Operators Action:

1. If bus voltage and line voltage is above limit and loading of two parallel line is low then trip one line.
2. Check the cause of tripping.

Final Corrective Actions:

1. Charge the reactor after rectifying the fault.
2. Charge the outgoing line if it is tripped earlier.

15.SCADA not responding

Likely causes:
1. Ups failure
2. Software/hardware side problem at engineering Station.

Plant RESPONSE:
1. Process status will not available.
2. Remote operation will not possible.
3. Switch yard status will not updated in main control room DCS also.

Parameters of Concern:
1. Plant running parameter feedback will not update.
2. CB/isolator/earth switch status will not update.

Expected Operators Action:

1. Check the ups healthiness
2. If UPS failure changeover to bypass source.
3. If ups is healthy the inform maintenance dept. To check for hardware/software problem
4. If any emergency operation required do it locally.
5. Check the system status locally and ensure no abnormality, inform to control room if any.

Final Corrective Actions:

1. After rectifying UPS side problem charge it as per sop.
2. After rectifying software/hardware side problem restart the SCADA .

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3. Ensure system status and it works normally.

16.Repeated tripping of rapping motor of ESP

Likely causes:
1. Electrical fault of rapping motor.
2. Overloading of rapping motor.
3. Misalignment or poor coupling between motor and rapping shaft which results into motor overloading.
4. High ash level in respective hopper.

Plant RESPONSE:
1. Field loading will increase.
2. Spark rate will rise in respective field
3. Field may got tripped due to high spark rate

Parameters of Concern:
1. Loading of field.
2. Spark rate of field.
3. Dust percentage at chimney outlet.

Expected Operators Action:

1. Isolate power of rapping motor and check for any electrical fault.
2. Rectify mechanical side problem if any.
3. Reduce ash level of hopper if it is at higher side.
4. Switch off field if spark rate remains above permissible limit.

Final Corrective Actions:

1. Put rapping motor into service after rectifying electrical/mechanical fault.
2. Charge the field if it switch off previously.

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