KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )

Operations Manual, Version: 01

KOTHAGUDEM THERMAL POWER STATION

1X500 MW- UNIT-11

OPERATIONS MANUAL
(Version-01)

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

INDEX

Chapter-I SALIENT INFORMATION ABOUT KTPS-VI STAGE UNIT-XI

(1X500MW)

Chapter-II WATER SUPPLY AND SYSTEM

Chapter-III COAL, OIL AND ASH HANDLING PLANTS:

Chapter-IV SALIANT TECHNICAL PARAMETERS OF BOILER

Chapter-V SALIANT TECHNICAL PARAMETERS OF TURBINE

Chapter-VI SALIANT TECHNICAL PARAMETERS OF GENERATOR

Chapter-VII INTERLOCKS & PROTECTION

Chapter-VIII PLANT MAIN PARAMETERS

Chapter-IX BOILER AND AUX. PROTECTIONS

Chapter-X SG SIDE PROTECTIONS AND INTERLOCKS

Chapter-XI TG SIDE PROTECTIONS AND INTERLOCKS

Chapter-XII ELECTRICAL PROTECTIONS

Chapter-XIII START UP AND SHUTDOWN PROCEDURES

Chapter-XIV EHG, CMC ETC CONTROLS

Chapter-XV EMERGENCY OPERATIONS

Chapter-XVII HT AND LT DRIVES LOCATIONS ON BOARDS

Annexure-I NAME PALTE DETAILS

Annexure-II SAFETY VALVE SETTINGS

Annexure-III TDBFP DETAILS

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

Chapter-I

SALIENT INFORMATION ABOUT KTPS-VI STAGE UNIT-XI (1X500MW)

Kothagudem Thermal Power Station is located at a distance of 36km from the

temple town of Bhadrachalam and 300km from Hyderabad by road. The nearest railway
station, BDCR railway station is at the end of tap off line from Dornakal railway station
on the Kazipet-Vijayawada broad gauge main line. It is accessible by road from the
Kothagudem to Bhadrachalam National Highway which branches off to the power
station site near village Paloncha. The altitude of the location is above mean sea level
varies from 89.0M to 93.0M. Total water supply is met by the dedicated Kinnerasani
Project situated at a distance of 15Km. Recently a separate water supply pipe line
through pumping station from Godavari River.

Kothagudem Thermal Power Station consists of 11 units in total as follows:

Sl.No Station Stage Inst. Capacity Commissioned Year

1. A-station Stage-I2X60MW in 1965

2. A-station stage-II
2X60MW in 1967
3. B-Station Stage-III
2X110MW** in 1975
4. C-station Stage-IV
2X110MW** in 1978
5. D-station Stage-V2X250MW in 1997
6. E-Station Stage-VI
1X500MW in 2011
** (Later modified to 120MW after R&M)
Major Events and Mile stones of KTPS-VI Stage, Unit-11 (1X500MW):

1. Start of Boiler erection :

2. Drum Lifting :
3. Start of Condenser erection :
4. Start of Turbine erection :
5. Boiler Hydraulic test :
6. Boiler light up :
7. Turbine Box-up :
8. Completion of turbine flushing :
9. TG on barring gear :
10. Steam blowing completion :
11. Synchronisation :
12. First 500MW reached :
13. Commercial Operation Date :

Temperature Profile of the Station:

1. Ambient Minimum extreme : 47.20 o C

2. Minimum (annual average) : 9.40 o C
3. Mean temperature (hourly mean) : High: 36.85 o C (310oK)
Low: 13.85oC (287oK)
4. Design ambient temperature : 50.000c
5. Wet bulb temperature (max) : 25.70c
6. Design wet bulb temperature : 28

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Auxiliary Power Supplies details :

Auxiliary electrical equipment shall be suitable for Operation on the following supply
system:
(a) For motors rated above 175 : 11000V, 3 phase, 3 wire, 50 Hz medium KW
resistance earthed AC 33000V, 3 phase, 3 wire, 50 Hz medium resistance earthed AC (up
to 1500 KW)

(b) For motor control center: 415V, 3 phase, 3 wire solidly earthed AC

(c) For motor rated 175 kW and : 415, 3 phase, 3 wire solidly earthed AC below

(d) DC motor starters, DC : 220 V DC, 2 wire, unearthed DC solenoids, DC alarm,

control and protections

(e) AC control & protective : 110 V resistances. The single-phase 110V devices AC
supply shall be derived by Contractor by providing 415V/110V control transformers of
adequate rating with MCCB / MCB on both the primary and secondary sides.

(f) Uninterrupted power supply: 230 V, 1 phase, 50 Hz, 2 wire AC supply from UPS
system for I&C (including indicator recorders) and UCMS only

(g) Space heaters (for motors : 240V, 1 phase, 2 wire, 50 Hz AC system rated 30 KW
and above) with effectively earthed neutral. The power supply shall be derived by
CONTRACTOR by providing 415V / 240V transformer of adequate rating with MCCB /
MCB on primary / secondary sides.

(h) Solid state controls (including : 24V DC, 2 wire (24 V DC derived from UPS
solenoid valves) supply)

(i) Solid state controls (including : 24 V DC, 2 wire (24V DC derived from UPS
solenoid valves) supply).

(j) Lighting fixtures; and space : 240V, 1 phase, 2 wire, 50 Hz system heaters in
panels

(k) The above voltages may vary as follows: All devices shall be suitable for
continuous operation over the entire range of voltage and frequency indicated below
without any change in their performance.

i) AC supply : Voltage variation + 10% Frequency variation + 5% Combined

voltage & frequency variation +10%
ii) DC supply: Voltage variation + 10% - 20%

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Coal Analysis:

(This is the analysis of coal received to KTPS now a days)

Sl. Description Units Design Range for Design Worst Coal

No Coal & correction curves
for guarantees
A PROXIMATE ANALYSIS
(As received basis)
1 Moisture (total) % 9 6.0-15.0 8.86
2 Ash % 33.2 25.0-38.0 50.1
3 Fixed carbon % 29.1 22.0-38.0 26.66
4 Volatile matter % 28.7 22.0-38.0 19.99
B ULTIMATE ANALYSIS
Carbon % 46.86 40.0-55.0 44.08
Hydrogen % 2.94 1.88-5.0 1.88
Sulphur % 0.47 0.47-0.55 0.55
Nitrogen % 122 0.6-1.6 0.62
Moisture % - 6.0-15.0 3.58
Ash % - 25-38 -
Oxygen (by % 6.31 3.0-10.5 3.26
difference)
Hard grove % 52 45.0-65.0 54.3
grindability
LHV (kJ/kg) initial 18,330 15280-20940 15350
deformation
Temperature (under Deg.C 1180 >1180 1200
reducing atmosphere

ASH ANALYSIS (for Designed coal):

S.No. Description % by weight Range

1 Silica SiO2 64.7 55 65
2 Alumina Al2O3 25.3 18 - 28
3 Iron Oxide Fe2O3 1.2 1 -15
4 Titanium Oxide TiO2 1.3 1-2
5 Calcium Oxide CaCO3 1.8 1-8
6 Magnesium Oxide MgO 1.5 1-6
7 Sulphuric anhydride SO3 1.4 0.5 - 5
8 Phosphoric anhydride P2O3 0.5 0.2 - 2
9 Alkalis (by diff.) Na2O + K2O 2.3 1-5

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Chapter-II

WATER SUPPLY AND SYSTEM

RAW WATER SYSTEM:

A reservoir of effective storage capacity of 1,50,000 m 3 is built to store raw water

required for Stage-VI, Unit-XI (1X500MW) form 3 days. The new reservoir is located
adjacent to the existing Stage-V reservoir. The bed and maximum water level in the
reservoir is 101.8m and 106.68m respectively and thus no pumping is required.

PRE-TREATMENT PLANT:

The raw water passes through motorized butterfly valve to Cascade Aerator to
Stilling Chamber through Parshall flume (Flow Measuring Element) to Flash Mixer
(Retention Time of 1 minute). The flash mixer is having slow speed agitator with baffles
and the drainage is connected to the sludge sump. One no. clari-flocculator is arranged
with rake mechanism and telescopic type continuous sludge discharge arrangement. The
clari-flocculator outlet is connected to Rapid Gravity Filters (RGF). Four (4) numbers
RGFs (each of 600TPH capacity) with roof over filter beds for the dual media filtering
material with valve chambers are available. The RGFs outlet pipes are connected to
filtered water reservoir. Chlorination facility is available for raw water and potable water.
Details of PTP:

Rapid Gravity Filter (Dual Media)

Number of filters : Four (4)
Capacity : 600 m3/Hr (600 TPH)
Filteration rate : not more than 8 m3/Hr/m2
Backwash rate : 30 m3/Hr/m2
Backwash interval : 24 Hrs

Filter Air Blowers

Number of blowers : Two (1Working + 1Stdby)
Capacity :

Filtered Water Sump

Number : One (in two sections)
Effective capacity : 5000m3
Type of tank : Under ground, fully covered, RCC
tank
Filter Backwash Sump
Number : One
Effective capacity : 200m3
Type of tank : Underground

Water Pumps:
CT(W) Make up Pumps
Numbers : Three (2W + 1S)

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Type : Vertical Turbine

Capacity : 750 m3/Hr (TPH)
Head : 20 m

APH/ESP Wash Water Pumps

Numbers : Three (2W + 1S)
Type : Vertical Turbine
Capacity : 275 m3/Hr (TPH)
Head : 20 m

Service Water Pumps

Numbers : Two (1W + 1S)
Type : Vertical Turbine
Capacity : 275 m3/Hr (TPH)
Head : 55 m

RGF Back Wash Pumps

Numbers : Three (2W + 1S)
Type : Vertical Turbine
Capacity : 275 m3/Hr (TPH)
Head : 20 m

DEMINERALISED WATER SYSTEM:

One D.M.Water Storage Tank (DMWST) of capacity 1000m3 is constructed at the

existing DMW Plant near existing 3 DMW storage tanks of capacity each of 1000m3.
Inlet to all the tanks is common from the Stage-V DMW plant. Two numbers of
D.M.Water Transfer Pumps of 100 m3 capacity and 50m (MWC) head are available
especially for Stage-VI, water can also fed from the existing DMW pumps at the plant,
and i.e. discharge header is common.

One number D.M.Water Day Tank (DMWDT) of capacity 500 m3 is located in

DMW pump house of Stage-VI near CPU regeneration area. This tank is suction for the
two numbers Hotwell normal make up pumps and two numbers CPU regeneration pumps.
Two numbers of Hotwell Normal Make up Pumps of capacity 80 m3/Hr with adequate
head to transfer the DM Water to maintain the Hotwell level or to transfer the water to
CST are available.

One number Condensate Storage Tank (CST) of capacity 500 m3 is also located
besides the DMWDT and is the suction for Two numbers Emergency Hotwell Make up
Pumps of 150 TPH capacity each and Two numbers Boiler Fill Pumps of 150 TPH
capacity each.

CW CLORINATION AND CHEMICAL DOSING SYSTEM:

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To prevent microbiological fouling in the circulating water pits and in the entire
CW system, a chlorination plant is provided in a separate building near the CWPH to
dose chlorine into the pump suction pits on a continuous basis, to operate the cooling
tower at minimum COC 4 or higher and to prevent buildup of suspended solids a
chemical dosing system consisting of Biocide, anti-scalent and corrosion inhibitor are
provided along with Sulphuric acid dosing system to control the PH of circulating water
and maintain m-alkalinity in the range of 150 to 200 ppm. 12 nos. chlorine cylinders each
of capacity 900 Kg are available at chlorine plant. 1 No. Bulk Acid (98% H2SO4) storage
tank of 12 m3 along with 5 m3 acid measuring facility are also available in the plant

Safety Warning: - In case of chlorine leak, run away from the location in the
direction of wind flow shown by the wind sack.

CIRCULATING WATER PUMPS:

4 nos. each of capacity of 19500 m3/Hr. CWPs to cater the cooling water
requirement of Condenser of main Turbine as well as 2 Nos. Drive Turbines of BFPs are
available in the CWPH. The shaft bearings are of less rubber type with flushing grove and
forced water lubricated type. The CW system at VI stage is in closed cycle from
Condenser to Cooling Tower through CW Pumps with filter water as makeup and the
system is having natural draught Cooling Tower. Stop log gates and coarse screens are
available at the upstream of the CW Pumps. The Stop log assembly units and screens
shall be lifted /lowered with a speed of 1 to 2 m/min. under balanced conditions of load
only. The coarse screening is designed for 50% choking condition.
Details
Total No.of Pumps : Four (3W+1S)
Pump capacity : 19500 m3/Hr (TPH)
Type of Pump : Vertical Mixed flow
Motor rating : 1600 KW (115% of duty point)/

11 KV

AUXILIARY COOLING WATER SYSTEM:

Auxiliary Cooling Water (ACW) system supplies water required for plate heat
exchanger (PHE) of SG,TG and other unit auxiliaries. This system comprises of 3 Nos.
ACW Pumps of 2200 m3/Hr capacity, two working and one as standby. These pumps are
available in CWPH adjacent to CW Pumps.

Details
Total No. of Pumps : Three (2W+1S)
Pump capacity : 2200 m3/Hr (TPH)
Type of Pump : Vertical Mixed flow
Motor rating : 375 KW/ 3.3 KV/
Fore-bay level settings:
Normal : 90.2 msl
High : 90.5 msl
Very Low : 88.7 msl (all CWPs trip)
Very Very Low : 88.5 msl (all ACWPs trip)

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NATURAL DRAUGHT COOLING TOWER:

One natural draught cooling tower with cooling water basin is available and outlet
channel from the basin is connected to the Fore bay of CW Pumps sump together with
sludge removal sump along with valve pit are also available. Cooling Tower (CT) shell is
of hyperbolic paraboloid shape. The CT basin is designed for a water depth of one meter
from normal water level with a free board of 0.3 m above maximum water level , the CT
basin is divided into two equal parts by water tight RCC partition for the cleaning and
maintenance of one half while the other half is in service. Arrangements for water
drainage are also provided. The cold water from the CT basin flows by gravity to open
approach channel leading to the Fore Bay. The cold water channel is provided with
independent stop logs and screens. In accordance with official regulations, aviation
warning lights are installed along the perimeter of the tower opening. The drift loss will
be around 0.005% of the mass of water circulating.

Details:-
Height of the Cooling Tower : 163 mtrs.
Type of Cooling Tower : Counter flow, splash bar type
Cooling range : 10.33 deg.C
Designed wet bulb temp. : 28 deg.C
Approach : 5 deg.C
Fill type : splash bar type (PVC)
Nozzles, orifices, splash cups : PVC
Drift eliminators

EFFLUIENT TREATMENT PLANT (ETP):

The plant waste water treatment is carried out in ETP with maximum recovery and
minimum discharge i.e. to achieve zero discharge. The following lines connected to ETP:

1. Boiler Blow Down: Power cycle blow down is collected through pipes in local
boiler blow down (BBD) sump. This blow down is pumped to Common
Collection Sump (CCS1).The average flow rate may be around 20 m3/Hr.
2. Transformer Area Oily Waste: The effluent generated in the event of fire,
subsequent water spray and leakage of oil from the transformer etc. are collected
in CCS2 through drain channels. Oil is pumped to Corrugated Plate Interceptor
{(CPI) 1 No., 20 PH capacity} and skimmed oil will be collected in drums and the
left out oily water is pumped back to CCS. Treated water after CCS flows to clari-
flocculator.
3. Oily Waste Water from TG/Boiler Area: Oily waste from TG/Boiler area is
collected through drain channels in collection sump located in Boiler area and
treated in CPI separator and clear water flows to CCS3.
4. Wash Water from TG/Boiler Area: The effluents from floor washing in TG/Boiler
area contain suspended solids are collected in a Boiler area sump for further
process
5. Cooling Tower Blow Down: The excess blow down from the CT is collected in
CCS.

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6. Fly Ash Silo Area: Wash water from ESP area and Ash Silo area are collected in
local sumps and pumped to CCS for treatment.
7. Clari-flocculator: A Lamella Clarifier of 450 m3/Hr capacity is provided to
remove TSS. Clear water from clarifier is let to clarified water sump by gravity.
8. Filters: Four (3W+1S) Dual Media Filters each of 150 m3/Hr capacity are
provided with back wash and air scouring facilities. The filtered water passes
through filter membrane to achieve SDI less than 3 before feeding to RO module.
9. Ultra filtration Modules: Four (3W+1S) UFMs each of 150 m3/he capacity with
90% recovery are provided reduce the SDI less than 3. The ultra filtered water is
stored in an intermediate storage tank and pumped to RO modules later.
10. Reverse Osmosis (RO) Modules: Four (3W+1S) RO modules each of 150 m3/He
capacity with 80% recovery are provided. The UF water is pumped by means of
RO feed pumps through micron cartridge filters and high pressure pumps to RO
modules to De-gasser system and stored in de-gassed water storage tank. The
permeate water is pumped to CT basin for CW makeup.
Note: The reject water is collected in sump and used for dust suppression,
floor washing and green belt development etc.

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Chapter-III

COAL, OIL AND ASH HANDLING PLANTS:

COAL HANDLING PLANT:

At TP-S crushed coal from set of conveyors-10A/B is fed either to existing

conveyors 11A/B (to Stage-V bunkers) or to conveyors 13A/B (to stage-VI bunkers) and
from there to 14A/B, 15A/B and four RHS bunkers through 16A/B and three LHS
bunkers through 17A/B. The designed capacity of coal handling system is 1200 MT/Hr
and the bunkers have a storage capacity of 12 hours coal requirement of Boiler. Dust
extraction and Dust suppression systems at various TPs are provided to control the
pollution.

Details:
Belt conveyors : 13A/B to 17A/B
Twin stream conveyor of 1200 TPH
Capacity
Belt weighers : 2 Nos. on 13A/B
Traveling trippers : 4 Nos. 1200 TPH (each on 16A/B
and 17A/B)
Maximum belt speed : 3 m/s
Belt Width : 1400 mm
Trough angle : 35 deg.
Crisscross feeding
Arrangement (A->B, B->A) : Available at TP-U and TP-V only
No of plies in a conveyor : Four plies
Belt type : Synthetic fabric of nylon/nylon,
polyester/polyamide

Bunker Level Quantity of coal

in meters in MT
1 0.33
2 1.66
3 4.49
4 9.31
5 16.65
6 26.99
7 40.83
8 58.69
9 81.07
10 108.46
11 141.37
11.9 176.12
12 180.34
13 222.58
14 264.82
15 307.06
16 349.30
17 391.54

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18 433.78
19 476.02
20 518.26
21 560.30
21.8 594.30
22 610.40
23 618.40
24 650.00

OIL HANDLING SYSTEM:

The existing 2 Nos. HFO tanks each of capacity 4525 KL are used for the storage
of HFO. The existing 1 No LDO storage tank of capacity 750 KL is used for the storage
of LDO. 2 Nos HFO pumps and 2 Nos. LDO pumps are available. HFO pressure of 8
Kg/Cm2 shall be maintained when the guns are in service, at that pressure an average
consumption of HFO is 2.5 KL/gun Hr.

Heat Values of various fuels:

Coals

Solid fuel GCV

Liginite 5000 Kcal/Kg
Bitumious 7600 Kcal/Kg
B 5547 to 5966 KCal/Kg
C 5042 to 5546 KCal/Kg
D 4467 to 5041 KCal/Kg
E 3815 to 4466 KCal/Kg
F 3065 to 3841 KCal/Kg
G 2976 to 3064 KCal/Kg
Liquid fuels
1. Heavy oil 11,000 Kcal/Kg
2. Diesel 11,000 Kcal/Kg
3. Petrol 11,600 Kcal/Kg

ASH HANDLING SYSTEM:

Ash Handling System includes Bottom ash handling system, coarse ash handling
system (Economiser Hoppers) and fly ash system (APH hoppers, In-Duct hoppers, ESP
hoppers and Stack hoppers). Bottom ash is collected in the water impounded bottom ash
hopper and conveyed to ash slurry sump through jet pumps and further pumped to Hydro-
bins or to stage-V slurry sump using ash disposal pumps. Coarse ash from the Eco.
Hoppers is extracted by means of flushing with LP water and the slurry is conveyed to
BAH. Fly ash is extracted through vacuum and conveyed to intermediate fly ash (IFA)
Silo or to Remote fly ash (RFA) Silos through pressure conveying system using Transport
Air Compressors (TACs).The fly ash collected in the IFA Silo is disposed in wet form
through HCSD system to existing ash pond. Fly ash collected in RFA Silo is disposed in
dry form through Trucks.
Chapter-IV

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SALIANT TECHNICAL PARAMETERS OF BOILER:

SALIENT FEATURES OF KTPS STAGE VI

Conventional coal fired : 500MW unit.
Aux. power consumption : ~ 4.5%.
Main fuel : Coal.
GCV of coal : 4400 Kcal/Kg.
Specific fuel consumption : 0.522Kgs/Kwh.
Raw water requirement : 1455M/Hr.

Designed Coal Analysis:

PROXIMATEANALYSIS
Fixed carbon : 28.7%
Volatile matter : 28.3%
Moisture : 9.0%
Ash : 34%
Grindability Index : 52.HGI
Size of coal to mill : 25 mm
UTIMATE ANALYSIS
Carbon : 46%
Hydrogen : 2.70%
Sulphur : 0.50%
Nitrogen : 1.49%
Oxygen : 6.2%
Moisture : 9.0%
Ash : 34%

STEAM GENERATOR
Single Drum, controlled circulation, radiant, single reheat, dry bottom, two pass,
balanced draft, out door, sub critical conventional boiler.
Two stream air and flue gas system.
Steam capacity :1625 T/Hr.
Main steam parameters : 175 bar / 540C.
Reheat parameters : 43 bar/540C.
Drum pressure : 193 bar.
Gas temp leaving furnace : 1389C.
FG Temp at AH outlet : 125C.
Gross efficiency : 89.02%.
BCWP`s (3) Motor capacity : 350KW, 3.3 KV
Residence time for fuel particles in the furnace 3 secs.
Furnace volume : 14,272 M
Furnace Protected area : 7610 M
Fuel Heat input : 1181.9 X 10Kcal/hr
Water Wall Soot Blowers (WWSBs) : 88
Long Retractable Soot Blowers : 44
(LRSBs)

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MILLS:

7 Nos. bunkers shall be sized for 12 hours storage capacity.

Gravimetric feeder & - processor based.
7 Nos mills of capacity 65 T/Hr ( XRP 1003).
Output at specified input condition 54 T/Hr.
Minimum stable load W/O Oil 40% TGMCR.
Drive motor 525 Kw / 3.3KV.
Mills Type : XRP 1003
o Speed : 600rpm
o System : Cold PA
Mill loading : 82.4% (65T/H max)
Air flow per mill : 95 T/H
Air Temp at mill I/L : 239C
Mill outlet : 66C to 100C
Finesse through 200 mesh : 70
Seal air fans (2) : 55 KW/415V

Electro Static Precipitator:

4 Nos ESPs with 9 fields / ESP.

No of gas streams / ESP 2.
Max 8 hrs dust loading without emptying.
99.82% efficiency to achieve outlet dust concentration of 80mg/Nm
With (n-1) field is 100mg/ Nm

REGENERATIVE AIR PREHEATER:

Type & Number ---- Trisector & 2 X 50%

On load cleaning Medium ---- Steam
Off load cleaning Medium ----Water
Air preheater leakage ----<10% of total air
Speed -----1.03 Rpm
SCAPH ----- 2 Nos of Finned Straight Tube
Air preheater Main motor -----18.53 KW/415V
FANS
ID Fan PA Fan FD Fan
No.of fans 2 2 2
Type Radial Axial Axial
Capacity (Nms) 526 164 230
Total Head (mmwc) 420 1300 345
Fan Efficient at 81.0 82.5 84.0
MCR (%)
Motor Rating(KW) 2800 2500 950

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Flow Rating(KW) VFD Variable BLADE

Pitch

Motor Load 3000KW 2650KW 1025kw

Voltage 11KV 11K V 3.3KV

Lube oil pumps : 3.7KW/415V

(I D, FD& PA)

Stack
1 No. Stack of height 275M.
Single refractory flue
Stack comprises RCC shell, stair cases, lift, aviation lamps, FG sampling &
analyzer equipment etc.

Soot Blowers:

The unit is having three types of soot blowers. They are 88 numbers Water Wall
Soot Blowers (WWSBs), 44 numbers Long Retractable Soot blowers (LRSBs) and 2
numbers Air Heaters Soot Blowers (AHSBs). 88 numbers of WWSBs are distributed in
four elevations each with 22 numbers one below Windbox and three elevations above
windbox as follows. The steam for soot blowing is taken from the outlet header of
Divisional Panelette. Operating pressure is 25KSc and the temperature is 250-300 deg.C.
A pressure of 25Kg/Cm2 is maintained via a control valve and all the drain valves are in
open condition till the steam in the line reaches above 250 deg.C. A safety valve is
provided in the line with suitable setting. Drain lines, four from WWSBs, 2 from LRSBs
and 2 from AHs, are connected IBD flash tank (IBDFT).

WWSBs:
L/S F/S R/S Rr/S
18-26 1-6 7-11 12-17
40-44 23-28 29-33 34-39
62-66 45-50 51-55 56-61
84-88 67-72 73-77 78-83
And 89 to 104 envisaged but not provided.

LRSBs:
105 to 162. Out these envisaged only 44 are provided at Super Heaters zone barring 145
to 162 (except 153 and 154).

AHSBs:
AH-A 163
AH-B 164

Steam Leak Detectors:

In ASLD scheme 24 numbers noise pick ups have been arranged at various locations. If
noise range crosses 20dB, it shows a red indication on bar graph and at 16dB alarm
appears, in case of steam leak. The arrangement of ASLDs on boiler is as follows:

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
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1 LS 57.9m 13 RS 70m
2 Front 57m 14 LS 70m
3 LS 20m 15 LS LTSH Upper 66m
4 LS Top of WB 16 Upper LTSH LS 58.1m
5 RS Top of WB 17 Eco. Upper LS 51.2m
6 Near FTP LS 51.7m 18 Eco. Lower LS 44.3m
7 RS 20m 19 RS LTSH Upper 66m
8 LS Top of WB 20 Upper LTSH RS 58.1m
9 RS Top of WB 21 Eco. Upper RS 51.2m
10 Near FTP RS 51.7m 22 Eco. Lower RS 46.3m
11 RS 57.9m 23 RS 66.4m
12 LS 66.4m 24 RS 70m

Materials with codes used at SG side:

Economiser System
Sl.
Description Material Design Temp.
No.
Coils SA 210 Gr A1 326
1. Economiser
Headers SA 106 Gr C 398

Circulating System
Sl.
Description Material Design Temp.
No.
1. Drum SA 299 368
Tubes SA210 Gr C 398
2. Water Walls
Headers SA 299, SA106 Gr C 370

Roof & Steam Cooled walls

Sl.
Description Material Design Temp.
No.
Tubes SA 213 T11 413
1. Roof
Headers SA106 Gr C 368

Tubes SA210 Gr C 405

2. SC walls
Headers SA106 Gr C 368 -394

Super heater System

Sl.
Description Material Temp. Range
No.
Coils T11 404 - 477
1. LTSH SA106 Gr. C
Headers 394 -452
SA335 P12

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Coils T11, T22, T91 409 - 535

2. Div. Panelette
Headers SA335 P12 420 - 496
Coils T22, T91, TP347H, 478 - 600
3. Platen SA335 P12
Headers 489 - 572
SA335 P22

Re-heater System
Sl.
Description Material Temp. Range
No.

T11, T22, T91,

Coils 351 - 589
TP347H,
1. RH
SA106 Gr C
Headers 361 - 590
SA335 P22

STEAM GENERATOR & ACCESSORIES

Sl.
Description Unit Particulars
No.
Single Drum, controlled circulation,
rifle tube, radiant, single reheat, dry
Type of Steam Generator
bottom, two pass, balanced draft, out
door
1 Capacity at 100% SG MCR T/hr 1625
2 Steam pressure at super heater outlet Bar (a) 175.49
o 540 5 (60% TGMCR 100%
3 Steam temperature at SH outlet C
SGMCR)
o 540 5 (60% TGMCR 100%
4 Steam temperature at RH outlet C
SGMCR)
Silica in steam leaving final SH at
5 ppm 0.01 (max)
100% TG MCR
Flue gas temperature at AH outlet o
6 C 125
(considering leakages in AH)
7 Explosion force / Implosion 889 mm WC at YEILD POINT
BASE LOAD / CONST. PRESS /
8 Operation
SLIDING PRESS
9 Code IBR
kcal /
10 Volumetric basis 1,00,000
m3/hr
kcal /
11 Net heat input to plan area (NHI/PA) 4.75 x106
m2/hr
kcal /
12 Burner Zone 1.55x106
m2/hr
Gas Temp. at Furnace outlet at o
13 C 1050
SGMCR
14 NOx Emission limits (for coal firing) 260 grams per GJ of heat input.
15 Unburnt combustibles in the flue gas % 1.5 of fly ash at Economizer outlet
o
16 Ambient temp. for performance test C 31
17 Furnace tube arrangement Membrane
Type of tubes and headers for
18 Seamless
pressure parts
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19 Flue gas velocity in SG second pass m/s 10

Unit capability data at SGMCR

20 Superheater flow Kg/s 451.39 (1625 TPH)
Steam conditions at super heater
21
header outlet
a) Pressure Bar (a) 175.49
b) Temperature Deg. C 540
22 Re-heater flow Kg/s 386.4 (1391 TPH)
23 Steam conditions at re-heater inlet
a) Pressure Bar (a) 44.97
b) Temperature Deg, C 339.2
24 Steam conditions at re-heater outlet
a) Pressure Bar (a) 42.8
b) Temperature Deg. C 540.0
25 Drum operating pressure Bar (a) 193.13
Maximum allowable working
26
pressure for
a) Drum Bar (a) 205.8
b) Re-heater Bar (a) 52.4
27 Feed water inlet temperature Deg. C 254.6
28 Fuel consumption Kg/s 75.0 (Design Coal) (270 TPH)
29 Efficiency based on fuel GCV % 89.02
30 Excess air at furnace exit % 20
31 Excess air at outlet of air heater % 29
32 Flue gas temperature at APH outlet Deg. C
Considering leakage in APH 125
Without considering leakage in AH 131
Flue gas temperature at ID fan
33 Deg. C 125
outlet

Performance requirement
60% TG 80% TG SG
for constant pressure TG MCR
MCR MCR MCR
operation
Steam quantity leaving final
34 T/hr 886.48 1185.60 1496.84 1625
super heater outlet
Steam quantity leaving final 1391.1
35 T/hr 812.99 1071.63 1333.99
re-heater outlet 6
Steam generator efficiency
36 % 89.20 89.10 88.98 89.02
based on the GCV of the fuel
Combustion air requirement 446.2 =
37 Kg/s 270.8 353.3 488.7
(without leakage) 1605TPH
38 Drum pressure Bar (a) 175.0 181.3 189.3 193.13
Feed Water Pressure at
39 Bar (a) 178.0 184.7 193.5 197.6
economizer inlet
Gas temperature leaving
40 Deg. C 1396 1413 1409 1389
furnace
41 Feed water temperature
a) Entering economizer Deg. C 230 243 254 255

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b) Leaving economizer Deg. C 296 304 312 312

Gross efficiency based on
42 % 89.20 89.10 88.98 89.02
GCV of fuel

Time required to shut down the unit from

43 30 to 45 minutes
load condition
Restart capability of the unit immediately
44 45 to 60 minutes
after full load rejection
Total dissolved solids in steam leaving drum
45 ppm 0.05 (max)
at 100% TG MCR
ECONOMISER
46 Effective Heating Surface(gas side) M2 19000
47 Gas flow path area M2 146
48 Gas velocity at SG MCR m/s <10
49 Pressure Bar (a) 210.3

REGENERATIVE AIR PREHEATER

50 Type & Number Trisector (2x50%)
51 On load cleaning medium Steam
52 Off load cleaning medium Water
Shall not exceed 10% of
53 Air pre-heater leakage
total air requirement
54 Speed rpm 1.03
STEAM COIL AIR PREHEATER
(SCAPH)
55 Number of SCAPH per SG unit 2 Nos.
56 Type Finned straight tube
DEAERATOR
Oxygen in the effluent feed water from 10%
57 STG MCR to TG VWO with 3% make up
when tested by ASTM D888 method
cc/lit 0.005
CO2 in the effluent feed water from loads of
58 10% STG MCR to TG VWO with 3% make Not traceable
up when tested by APHA method
cc/lit

COAL MILLS
59 Type of coal mills XRP 1003
60 Number required 7 (A,B,C,D,E,F,G)
61 Mill inside condition Pressurized
62 Capacity T/hr 65 (with 9% moisture & 52 HGI)
Output per mill at specified input
63 T/hr 54.0
size & moisture
Minimum stable load without oil
64 40% TGMCR
support

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65 Turn down ratio of coal burner 2:1

70% through 200 mesh and 98%
66 Coal fineness at mill outlet
through 50 mesh
67 Coal feeder & control Gravimetric & -processor based
68 Mill drive motor rating/Speed KW/rpm 525/985
Pulveriser speed (Mill Bowl Speed) rpm 42
BOILER WATER CIRCULATION PUMPS (i.e.CC Pumps)
69 Type Glandless wet motor
70 Number of pumps 3
71 Total circulation Kg/s 902 (2 pumps in operation)
3
72 Capacity of each pump M /hr 1625
73 Total dynamic head mlc 1.72
74 Speed rpm 1450
FLUE OIL PUMPS
75 Pressurizing pumps Gear / Screw ; 2x100%
76 Type of bearing Anti friction, heavy duty & external
DRAUGHT FANS ID Fan PA Fan FD Fan
77 No. of fans 2 2 2
Radial Axial Axial
78 Type
NDZV 47 PAF19-10.6-2 FAF24.5/11.8-1
79 Capacity (Nm3/s) 526 164 230
80 Total Head (mmWc) 420 1300 345
Fan Efficiency at MCR
81.0 82.5 84.0
(%)
81 Motor Rating (kW) 3000 2650 1025
82 Flow Control VFD Variable blade pitch (Blade Pitch Control)
SOOT BLOWING
SYSTEM
Rotary blowers, long retractable blowers, short
83 Designation retractable blowers, air pre-heater blower or
Acoustic.
84 Cleaning medium Super heated steam
85 Drive Dual electric drive for traverse and rotary motion.
Accessories required
Emergency hand crank
86 Yes
for every soot blower
Facility to adjust angular
87 travel of short retractable Yes
soot blower
88 Pressure reducing valve Yes
89 Thermal drain valves Yes
Speed reducers, cam
90 Yes
chain drive etc.
91 Steam pressure Bar (a) 30.4
92 Steam temperature Deg. C 350
FUEL OIL BURNERS LDO HFO
12 @4 at AB,
93 Numbers per SG 4 at AB Elvn
CD, EF Elvns
94 Type Air cooled
95 Capacity of each burner Kg/hr 7.5% MCR 30% MCR

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96 Turn down ratio 1.5 : 1

ELECTROSTATIC PRECIPITATOR
FAA-9x37.5-
97 Type
2x96135-2
98 No. of ESP per steam generator 4
99 No. of gas stream per ESP 2
No. of hrs. ESP can run at specified gas flow and dust
100 Hrs. 8
loading without emptying any hopper
Tumbling
101 Rapping system type
hammer
102 Total number of rappers per SG 72 ( one per field)
103 Duty Continuous
Dust concentration at outlet of ESP with specified coal
104 range:
mg/Nm3 80
with all fields in service
- with (n-1) fields in service mg/Nm3 100 (max)

COAL FEEDER
105 Type Gravimetric
106 Model Size:36 inches
107 Capacity T/Hr 76
108 Speed rpm 0.8 to 8.0
109 Belt Width mm 1168 4
110 Accuracy of measurement % 0.5
111 Type of control -processor based

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Chapter-V

SALIANT TECHNICAL PARAMETERS OF TURBINE:

STEAM TURBINE

Governor- Redundant (Digital) Electro- hydraulic with backup facility

LP Exhaust hood temp 110C
Heat Rate- 1944.5 Kcal/Kwh at 0% makeup and designed CW 32C I/L temp
ST Exhaust at 0% makeup 1005 T/Hr, 0.107 KG/Cm46.7C
CW quantity 54,300M/Hr

STEAM TURBINE

1. Single reheat tandem compound, regenerative condensing, multi cylinder

design with separate HP, IP, LP casings.
2. Output -500MW, 95% valves open, 3% make up
3. Turbine inlet at 170 bar, 537 deg. C
4. Constant pressure >95%, sliding pressure 40-95%
5. Capacity 1587.7T/Hr with VWO Position.
No. stages: HP/IP/LP: 17/12X2/6X2/All Reaction flow.
Auxiliary oil pump (2) : 110 KW/415V
Jacking oil pump (1) : 60 KW/415V
CT make up pumps (2) : 90 KW/415V
Service water pumps (2) : 110KW/415V
Turbine Barring Gear : 80 rpm
Absolute bearing vibrations : 84 (Alarm) 106 (Trip)
Shaft vibrations : 200 (Alarm) 320 (Trip)
Bearing temperature high : 110 (Alarm) 130 (Trip)
Differential expansions HP : - 5.0 mm to +3.5 mm
IP : - 1.0 mm to + 5.5 mm
LP : - 3.0 mm to +35 mm
Overall expansions HP :
IP :
Axial Shift : 0.5 mm to 1.0 mm
Condenser in let and out let temp. Diff
Mini: 5c: Max: 8c.

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STEAM TURBINE & ACCESSORIES AND REGENERATIVE CYCLE SYSTEM

STEAM TURBINE & ACCESSORIES

Sl.
Particulars Units Technical Particulars
No.
Reheat condensing with
regenerative feed water
heating including de-
aerating feed water heater.
1. Type of steam turbine
Provision of de-aerating
condenser in lieu of de-
aerating feed water heater is
not acceptable.
a) Constant pressure
above 95% TGMCR
2. Operating mode b) Sliding pressure
between 40% TGMCR
and 95% TGMCR
100% TG MCR gross output at the generator
terminals requirements:
500 MW, without exceeding
3. a) Guarantee condition with 3% makeup and
governing valves opening
including auxiliary steam requirements for the
by 95%.
plant, temperature.
a)Steam pressure at HP
turbine 170 kg/cm2 (a)
Turbine generator steam parameters at STG b) Steam temperature at HP
4.
stop valves turbine: 5370C
c) Steam temperature at IP
turbine: 5370C
3000 rpm, directly coupled
5. Turbine speed
to electric generator
Redundant (Digital)
6. Type of governor Electro-hydraulic with
back-up facility.
Two cooling water passes.
Bottom mounted single
shell with divided water box
7. Type of condenser
to facilitate unit operation
with one half under
maintenance.
Oxygen in condensate at hotwell outlet
8. with 3% make-up from 30% TG MCR to
cc/litre Not to exceed 0.03
TGVWO
STEAM TURBINE & ACCESSORIES
Maximum continuous rating at generator
9. MW 500
terminals (MCR)
10. Turbine rated speed 3000

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Operating frequency range for turbine and Turbine-47.5 to 51.5

11. Hertz
auxiliaries Aux. 47.5 to 52.5
Steam turbine swallowing capacity with
12. turbine control valves in valve wide open
T/h 1587.7
(VWO) position
Maximum allowable temperature at LP 0
13. C 110
turbine exhaust hood
Coast-down time after turbine trip to
14.
turning gear speed
a) With vacuum min 43 to 60
b) with vacuum breakers opened min 18 to 25
15. Mode of governing Throttle
16. Type of governor Electro-hydraulic
17. Turbine protection system
110 Mechanical (3300
% of rated
a) Emergency over speed trip governor rpm)
speed
111 Electronic (3330 rpm)
Steam turbine generator capability under
different combinations of more than one
18.
closed feed water heater out of service MW 500
(either adjacent or non-adjacent)
19. Performance guarantees
a) Output at 100% TG MCR and design
condenser cooling water inlet temperature
when operating as a normal regenerative
MW 500
cycle and design condenser back pressure
and 0% make-up.
b) Heat rate at zero percent make-up and
design condenser cooling water inlet
temperature Kcal/kWh 1944.5
100% TG MCR.
SURFACE CONDENSER
20. Type of condenser Surface type
Number of surface condensers per STG
21. No. One
unit
22. Number of passes No. Two
Steam from turbine exhaust at turbine
23. VWO condition at design cooling water
temperature and 0% make-up
a) quantity T/h 1004.877
b) pressure Kg/cm2 (a) 0.107, -0.9893 vacuum
0
c) temperature C 46.7
d) enthalpy Kcal/kg 566.2
24. Cooling water design parameters
a) Quality Raw water
3
m /Hr
b) Flow quantity 54300
(TPH)
c) density Kg/m3 1000
25. Oxygen content in condensate at
condenser hotwell outlet with 3% make- cc/lit 0.03

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up to hotwell from 30% TG MCR to

TGVWO
CONDENSATE EXTRACTION
PUMPS
26. Number of pumps per STG unit No. 3X50% (2 working, 1 stdby)
27. Type of pump Vertical, canister type
28. Design capacity per pump m3/h 775
29. Run-out flower per pump m3/h 830
30. Minimum flow per pump m3/h 200
31. Total head at design capacity mlc 265
32. Shut-off head mlc 350
33. Pump efficiency at design point % 81
34. Drive motor rating KW 900
CONDENSATE POLISHING UNIT
35. Capacity of service vessels 2 x 50%
36. Resin transfer pumps 2 x 50%
37. Resin operation time Days 15
38. Mode of CCP operation Cycle H2 / (H2 & NH3)
39. Total solids in the effluents ppb 20
40. Silica concentration in effluent ppb 5
Effluent conductivity after removal of
41. -mho/cm 0.1 at 25 0C
ammonia & amines
BOILER FEED PUMP
42. Model No. No. FK 6D30
3 (2 Nos. TDBFPs + 1 No.
43. Number of BFP sets pet STG unit Nos.
MDBFP)
Centrifugal multi-stage barrel
type main pump and
44. Type of pump horizontal split type booster
pump (connected to a
common motor for MDBFP).
Variable speed hydraulic
45. Type of coupling for MDBFP
coupling
46. Performance particulars of BFP Main BFP Booster Pump
0
a) Design temperature of feed water C 162.7 162.7
b) rated capacity m3/hr 990 990
c) inlet flow m3/hr 990 990
d) minimum flow through the pump m3/hr 400 400
e) runout flow (one pump at design
m3/hr 1100 1100
speed)
f) total dynamic head at rated speed
mlc 2025
and capacity
g) Maximum shut off head mlc 3062 266
h) efficiency % 81 81.5
47. Impeller arrangement Horizontal Horizontal
48. No. of stages 4 1
49. Thrust Bearing Type Tilting pad Tilting pad
50. Power required by pumps KW 7160
Total dynamic head of BFP set at
51. mlc 2190
rated speed

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
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52. Capacity T/h 855

53. Type of BFP Suction strainer Simplex Basket
54. Strainer Mesh size Microns 350
Lubricating oil system
Shaft A.C. D.C.
driven standby emergency
55. Type of pump Screw Screw Screw
56. No. of pump 1 1 1
57. Speed Rpm 1450 1450 1450
58. Motor rating kW 90 90 90

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Chapter-VI

SALIANT TECHNICAL PARAMETERS OF GENERATOR:

GENERATOR

Two pole synchronous Generator with water + Hydrogen cooled.

Output - 524.204 MW, TGVWO, 3% make up.
Terminal Voltage 21 KV.
Efficiency 98.64% (100%).
Brushless excitation with DAVR.
Generator Name Plant Details
Rated out put : 500 MW / 588 MVA
Rated stator current : 16,166 Amp
P.F : 0.85
Rated Excitation : 4,040 A/340V
Short Circuit Ratio : 0.48
Rated H2 Pressure : 3.5 Kg / cm

TRANSFORMER YARD

4 Nos (3 Nos. working + 1No.spare) single phase, oil cooled 207 MVA,
21/400KV Generator Transformers
1 Nos. 50MVA, 220KV, /11KV,Station transformer. ST-6A
1 Nos. 80 MVA, 400/11 KV, 3 winding station Transformer.ST-6B
2 Nos. 25 MVA, 21 KV/11.50 KV unit transformers.
2 Nos. 12.5 MVA,11/3.6 Unit Auxiliary Transformers.
2 Nos. 16 MVA, 11/3.6 Station Auxiliary Transformers.
ST-6B

Cooling : ONAN / ONAF /OFAF

Rating HV : 48/64/80 MVA
Rating LV1/LV2 : 24 / 32/40 MVA
Normal Voltage : 400 KV
Normal LV1 /LV2 : 11.5/11.5 KV
Line Current HV : 115.5 Amps
LV1/LV2 : 2008.5 Amps
* Bushing Tans value < 0.0070
* Overall BDV Value > 40KV
> 70KV good.

400 KV SWITCH YARD

400 KV Switch Yard of size 265 M X 265 M

Switch yard is provided with 9 bays.
2 bays for Generator Transformer.
3 bays for PST 315 MVA, 220/400KV and 440/11 KV ST.
3 bays feeder for power evacuation.

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1 spare bay

GENERATOR, AUXILIARIES & TRANFORMERS

Sl.
Description Unit Particulars
No.
GENERATOR
1. Type and model number THDF 115/59
(a) Gross power output at TGVWO condi-tion with 3%
2 makeup and design cooling water temperature and rated power
MW 524.204
factor.
MW 500
(b) Max. continuous rating
MVA 588
3. Rated terminal voltage KV 21
4. Rated stator current Amps 16166
5. Rated frequency Hz 50
6. Rated power factor 0.85 lag
7. Rotor current at MCR Amps 4040
8. Maximum permissible variation range in:
a) Rated terminal voltage % 5
b) Rated frequency with/without time limits % 5
9. Synchronous speed rpm 3000
10. Number of phases No. 3
11. Generator efficiency at:
a) 100% load % 98.64
b) 75% load % 98.62
c) 50 % load % 98.41
Minimum guaranteed short circuit ratio corresponding to
12. 0.48
maximum capability
13. Designation for method of cooling as per IS / IEC standards ICW37H71
Basic impulse insulation withstand voltage of stator winding KV
14. (4 Ur + 5)
with respect to earth (peak)
15. Maximum permissible capacitive loading at full load MVAR 160
16. Permissible tolerance on all guaranteed reactance values % 15
Guaranteed temperatures at rated hydrogen pressure and max
17.
inlet cooling water temp. at rated load
o
a) Stator windings C 120
o
b) Stator core C 120
o
i) In contact with insulated winding C 120
o
ii) Not in contact with insulated winding C 120
o
c) Rotor windings C 105
Class F with
temp rise limited
18. Class of stator winding insulation
to class B
values

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
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Sl.
Description Unit Technical Particulars
No.
ROTOR WINDING PARTICULARS
Class F with temp rise limited
19. Class of field winding insulation
to class B value.
GENERATOR MISCELLANEOUS
PARTICULARS
Noise level in free field / semi-reverberant
20.
conditions
a) No load dB (A)
As per MOEF guidelines.
b) On load dB (A)
EXCITATION SYSTEMS
21. Excitation System Parameter
Type of excitation system offered, Brushless
22. Brushless
essential.
a) Nominal field voltage Volts 340
b) Ceiling / Field forcing voltage Volts 680
c) Minimum and maximum field current 1378A - min
Amps
with generator at 100 % load 4040A - max
23. Brushless Excitation System
Ratings:
(a) Continuous max. Output kW 1375
(b) Rated voltage Volts 340
(c) Rated Current Amps 4040
(d) Rated full load speed Rpm 3000
(e) rated frequency Hz 150
(f) Ceiling voltage Volts 680
(g) Response ratio S Greater than 2.0
Voltage Regulator and Accessories
24. Type and quantity Digital Voltage regulator
25. No. of auto & manual channels Two Auto + Two manual
26. Guaranteed sensitivity 0.5% (accuracy)
27. Range of voltage level setting
- Auto Auto - 90 to 110% of Ugn
- manual Manual - 0 to 110% of Ifn
No critical speed shall fall within
28. Critical speed
6% of the rated speed
HYDROGEN COOLING SYSTEM
29. Type & total number of coolers provided Nos. Shell & Tube type-4 Nos
Number of coolers required in simultaneous
30.
use at MCR Nos. 4
Load that can be carried with one cooler out
31.
of service MVA 392
Current and kVA rating of generator at 15396 A / 588 MVA at 105% rated
32. Amps
voltage above 100% voltage
DIGITAL AUTOMATIC VOLTAGE REGULATOR
5% of rated voltage in auto
33. Accuracy of voltage regulation %
channel
34. Response time ms <20
35. Operating frequency range Hz 300 5%

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
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36. Dead band Negligible

37. Range of reactive droop adjustment % 0 to 10
38. Ambient conditions
a) Temperature C 0 to 50
b) Humidity % 0 to 95 (non-condensing)
39. Power for thyristor set of brushless DAVR PMG supply
3-, fully controlled thyristor
40. Type of converter
bridge
41. EMI/EMC immunity Shall confirm to IEC 255-4
42. Auto channels No. 2
43. Manual channels No. 2

Sl.
Description Unit Technical Particulars
No.
1. Generator Transformer
2. Type Outdoor, single phase, 50Hz
3. Applicable standard IS: 2026
4. Quantity 4 Nos. (3+1 spare)
5. Full load rating MVA 207
6. Rating of each windings MVA HV = 207, LV = 207
7. Rating of no load voltage HV / LV kV 400/3/21
8. Rated frequency Hz 50
9. System earthing on HV side Solid
10. Type of tap changer- off circuit/on load OFF Circuit
110% continuous,125% for 1
11. Overfluxing capacity
minute,140% for 5 second
Impulse withstand voltage of winding
12. KVp 1425/125
HV/LV/HV neutral
Maximum temperature rise at full load with
13.
100% coolers:
o
(a) Oil C 50
o
(b) Winding C 55
Efficiency at
14. (a) full load 99.77 apprx.
(b) 75% load 99.79 apprx.
15. Off Circuit Tap Changer
16. Rated Voltage Volts 60,000
17. Rated Current Amps 1,200
No. of cooler banks and capacity of each
18. 2X100%
cooler bank
Guaranteed No load current
At 100 % - 80 Amps
19. When excited from LV side at 100% and
Amps At 110% - 170 Amps
110% rated voltage
Max. Flux density when rated and 110%
20. Wb/m2 1.9
ratedvoltage
Vacuum withstand capability main tank, mm of
21. Full Vacuum (except Conservator)
radiators and accessories Hg.

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

Capacity of transformer to remain in

22. operation from hot conditions after failure Min. 10 minutes
of forced cooling with full load

Station Transformer-1
24. Type 3-winding, 3 phase, outdoor
25. Full load rating MVA 80/40-40
26. Rated no load voltage HV/LV KV 400/11.5-11.5
Rating of different cooling methods 60% / 80% / 100%
27.
ONAN/ONAF ONAN/ONAF/OFAF
At 80 MVA base HV-LV1 &
28. Impedance value % HV-LV2: 19%
LV1-LV2: 34% (min)
29. Rated frequency Hz 50
Winding connection of different windings
30. YNynyn0
and vector group
System earthing
31. (a) HV HV Solidly earthed
(b) LV LV through NG resistor
32. Type of tap changer OLTC
33. Tapping range and number of steps -12.5% to + 7.5% (17 steps)
Maximum temperature rise at full load with
100% coolers: o
34. C 50
(a) Oil o
C 55
(b) Winding
35. Applicable standard for bushing IS 2099
36. No load loss kW 69 max
37. Load loss kW 305 max.
38. Cooler loss kW 8 max
39. Efficiency @pf=1
(a) At full load % 99.5 apprx.
No. of cooler banks and capacity of each
40. 2x50% Radiator bank
cooler bank
Guaranteed No load current
41. When excited from LV side at 100% and
110% rated voltage Amps <1%
Max. Flux density when rated and 110%
42
rated voltage Wb/m2 1.9 (Max)
Vacuum withstand capability of main tank, mm of
43 Full vacuum except Conservator
radiators and accessories Hg
Capability of transformer to remain in
44 operation from hot conditions after failure Min As per IS: 6600
of forced cooling with full load
Station Transformer-2
45 Type 3-winding, 3 phase, outdoor
46 Full load rating MVA 50/40/30
47 Rated no load voltage HV/LV KV 220/11.5
Rating of different cooling methods 80% / 100%
48
ONAN/ONAF OFAF/ONAF/ONAN

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

49 Type of Tap changer OLTC

Unit Transformer
50 Type 3-winding, 3 phase, outdoor
51 Full load rating MVA 25
52 Rated no load voltage HV/LV KV 21/11.5
53 Number required No. 2
54 Cooling method ONAN/ONAF
Type of Tap changer Off circuit
Station Auxiliary Transformer
56 Type Two winding, 3-phase, 50Hz
57 Full load rating MVA 16.0
58 Rated no load voltage HV/LV KV 11/3.6
59 Cooling method ONAN
60 Number required No. 2
61 Type of Tap changer Off circuit
62 Earthing Medium Resistance
Unit Auxiliary Transformer
63 Type Two winding, 3-phase, 50Hz
64 Full load rating MVA 12.5
65 Rated no load voltage HV/LV KV 11/3.6
66 Cooling method ONAN
67 Number required No. 2
68 Type of Tap changer Off circuit
69 Earthing Medium Resistance

Isolated & Segregated Phase Bus Ducts

Isolated Phase bus duct
70 Voltage class & type kV 24, continuous
71 Rating A 19000 (130 kA rms)
72 Type of cooling Natural air cooling
Aluminum Alloy Grade 19501 or
73 Material of enclosure
Grade 63401 as per IS:5082
74 Creepage distance for insulators & bushing mm/kV 25 mm/kV of rated voltage
75 Type of insulation for CT & NGT Cast epoxy resin
Segregated phase bus ducts
76 Class kV 12 & 3.3
Same as associated Switch Gear
77 Rating
rating
78 Material of bus conductor Alu. Alloy grade 63401
79 Reference Standard IS:5082
80 Class of Bus support insulators kV 12 / 3.6
81 Insulator material Porcelain / epoxy resin cast
o
Max. temperature rise of conductor over C 40 For SPBD
82
50 oC ambient o
C 40 For NSPBD
o
Max. temperature rise of enclosure over C 20 For SPBD
83
50 oC ambient o
C 20 For NSPBD
84 Insulation of bus conductors sleeves XLPE
11 & 3.3 kV Switchgear
85 Change over scheme between unit aux. Automatic fast change over with
source to station source -processor based numerical

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

BTS
5% over the maximum SC fault
86 SC current rating
current on the bus
87 Short time current withstand duration seconds 1
88 Continuous current rating of the buses 20% over the maximum bus load
89 Type of CBs SF6 / Vacuum

Chapter-VII

INTERLOCKS & PROTECTION:

Divisional Engineer/E&P/KTPS-VI Page 33 of 110

 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

TDBFP A PROTECTION

BFP DT A Lub oil Hdr pressure V. low.

BFP DT A Exhaust steam Temp. V. High.
BFP DT A Live steam pressure V. High.
BFP DT A Exhaust steam pressure V. High.
BFP DT A Governor oil pressure V. Low.
BFP DT A Turbine Axial displacement V. High
BFP DT A Turbine Eccentricity V. High.
BFP DT A GB O/P VIB V. High
BFP DT A GB I/P VIB V. High
BFP DT A Over speed V. High
BFP DT A Turbine FJB VIB V. High
BFP DT A Turbine RJB VIB V. High
Deaerator level V. High
BFPDT A Gear Box Temp V. High
BFP DT A Turbine BRG Temp V. High
BFP DT A Booster pump BRG Temp V. High
BFP DT A BP Thrust BRG Temp V. High
BFP DT A BFP BRG Temp V. High
BFP DT A Diff temp. of FW Sucl V. High
BFP DT A Suction flow < 50T/H V. High
BFP DTA Trip COWS ( LVS) Turbine
BFP DT A Trip PB
BFP DT A Working
BFP DT A Suction flow V. low and Gate 150sec. delay
BFP DT A Suction VLV Not open
BFP DT A Trip oil pressure V. low
BFP DT A Trip condition N. Present
BFP DT A Reset Cows/LVS Turbine Reset
BFP DT A ESV Closed.

MD BFP C Protections

BFP Suc. Flow low CLCS.

MDBFP Suc. Flow < 50T/H
Lub oil HDR Pressure < 0.8 Kg/cm
Working oil temp very high.
Working oil pressure very low
Suc. VLV .N .open
BFP suc. Temp > 15c & flow low
Lub oil temp. down steam low coolers very high.
BFP . JR. BRG Temp. very high.
BFP. THR. BRG Temp. >105c.
BFP MTR WDG. Temp.very high.
Detractor Level very low
BFP MTR. Jr.BRG temp. very high
MD BFP TH. JR.BRG temp. very high
MD BFP HC BRG Temp.very high
MD BFP suc. Present low.

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

MDBFP NOT Permitted (Red colour)

MD BFP. Aop on & low pressure<2 kg/cm2
Suc. VLV.open.
Dea.LVL N.low
Working oil temp. up steam cooler N. High.
Lub. Oil temp. down steam cooler N.High.
BFP casing ToP-BOP dift. Temp N. High.
BFP JR. BRG.Temp N.High
BFP THR. BRG.Temp N. High.
Hyd. Coupling BRG Temp. N.High
BFP MTR BRG Temp. N. High.
MTR.WDG Temp. N.High
SWDR.Available N,Distrub.
W.O. Temp. Down steam cooler very high.
Rec. VLV. Open
CW VLV CLRS
Dis.IBVCLRs & MDBFP ON STDY
SOV. 92930 N& SCP PS Min or HCMIN
BP. JR. TH BRG. Temp very high.
MDBFP FW SUC. Dis. Temp. N.High.
MDBFP HC Tank LVL N.LO& N.High.
MD BFP CW HDR Pf.>3kg/cm2
MD BFP Not STBY 7 REV.ROT. Act.

MILLS
I. Permissive:
1. Seal air header DP adequate >250mmwcl.
2. Pulveriger ready.
3. Pulveriger OFF.
4. Ignition permit available.
5. Switch gear available.
II. First outs
1. Loss of PA/FD Fans.
2. MFT
3. Mill Lub oil system.
4. Pulverige discharge valve not open.
5. Ignition Energy req. not available.
6. Electrical Trip.
7. SA Hdr/Pul/ DP low <200mmwcl.
8. Loss of primary air <500mmwcl.
9. Pulveriger start fail.
Feeders
I. First Outs

1. Pulveriger OFF
2. No coal flow trip.
3. MFT.
4. Elevation No ignition Energy.
5. Feeder not remote.
6. Feeder Seal air valve not open.

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

II. Mill LOP:

1. Lube oil level low.
2. Tank level temperature very low.
3. Auto STOP LP 1.
4. LO Discharge pressure low & Pump 1 ON <0.8 kg/cm2
5. STOP LOP 1 & Pulveriger Normal ON.
6. Any LOP Normal ON & (Auto start LP-1 & LP-2)

ID Fan Tripping CH-1

1. VFD CH-1 fault.
2. Source breaker CH-1 trip.
3. Fan/MTR bearing temperature very high. 90C0
4. Motor winding temperature very high. 130C0.
5. Fan/MTR bearing vibration very high.
6. Motor exciter winding temperature very high.
7. Post purge trip.
8. Fan ON and outlet gate Closed.
9. ID fan A ON & LOP pressure low.
10. Fan ON and inlet gate closed.

FD fan
1. Post purge fan trip from FSSS.
2. FD Fan-A motor bearing temperature very high. 105C0
3. FD Fan-A motor winding temperature very high. 105C0
4. ID Fan-A & B OFF.
5. FD Fan A&B ON and ID Fan A OFF.
6. FD Fan A ON and O/L damper close.
7. FD Fan A On and LO pressure very low.

PA fan
1. PA Fan-A lub oil pressure very low and PA Fan-A ON MFT OPTD.
2. PA Fan-A 3motor bearing temperature very high. 105C0
3. PA Fan-A motor winding temperature very high. 105C0
4. PA Fan-A motor bearing vibration very high. Both FD Fan OFF.
5. PA Fan-A ON and discharge damper closed.

BCW Pumps
1. Motor cavity temperature very high >66 degC
2. Discharge valve system- 1 N opened.
3. Discharge valve system -2 N opened.

Chapter-VIII

PLANT MAIN AUXILIARIES PARAMETERS:

Divisional Engineer/E&P/KTPS-VI Page 36 of 110

 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

(Sample collected at a unit load of 505MW)

Note: These sample values are provided by Dr.NTTPS, Vijayawada and can only be taken for general
understanding.

TURBINE SIDE PARAMETERS:

1. Load : 505 MW
2. Frequency : 50.01 HZ
3. Turbine Speed : 3005 RPM
4. Coal flow : 244 TPH
5. M.S Pr L/R : 174/174 Kg/Cm
6. M.S Temp L/R : 539/539 C
7. HRH Pr. L/R : 44.7/44.5 Kg/ Cm
8. HRH Tem L/R : 535/536 C
9. CRH Pr. L/R : 47.4/47.4 Kg/ Cm
10. CRH Temp L/R : 347/346
11. Aux. PRDS Pr/Temp : 17/210
12. Vacuum : -0.92 Kg/Cm
13. Seal steam Pr/Temp : 325mmwcl/290 C
14. CEPs disc. Flow : 1445 TPH
15. CEP HDR Pr : 23.44 Kg/Cm
16. CWP I/L temp : 28C
17. CWP O/L temp : 37C
18. ACWP disc Pr : 3.5 Kg/Cm
19. DMCW disc Pr : 7.5 Kg/Cm
20. Hot well level : 15.6 MM
21. LP exhaust temp : 43C
22. HPT Blanding Pr : 170 Kg/Cm
23. Shaft expansions
(HPTF / IPTR /LPTR) : 17.7/14.29/21.33 mm
24. Axial shift : 0.08/0.04/0.08 mm
25. Differential expansion (HP / IP) : -0.34/3.24 mm
26. Over all expansion (HP / IP) : 18.9/11.30 mm
27. Turbine BRGs VIB : 1. 18/20 2. 15/10 3. 21/23
4. 41/32
5. 14/64 6. 22/40 7. 19/30
28. Turbine shaft VIB : 1.213/97 2.151/77 3.92/64
4.35/57
5.35/75 6.62/74 7.53/60
29. MS flow : 1583 TPH
30. HP Bypass down steam temp L/R : 262/262C
31. EX5 Pr / temp : 24.6 Kg/Cm/ 412
32. EX4 Pr / temp : 6.69 Kg/Cm/ 292
33. EX3 Pr/temp : 3.13 Kg/Cm / 203
34. EX2 Pr/temp : 0.63 Kg/Cm / 118

35. Turbine BRG temps : 1. 84/63 2. 71/58 3.

74/67
4. 82/78 5. 90/89 6.78/77
7. 78/71 Ex.64/60
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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

36. Lub oil pressure : 4.0 Kg/Cm

37. Lub oil temp : 45C
38. EHG position : 76 %
39. DP across CWPs : 0.45 Kg/Cm

BOILER SIDE PARAMETERS:

1. No. of mills service : 6 (7th Mill is Standby)

2. PA HDR Pr. : 922 MMWCL
3. Total secondary air flow : 1305 TPH
4. Total primary air flow : 600 TPH
5. Total air flow : 1905 TPH
6. ECO O/L O2 : 3.6 / 3.3 %
7. Furnace Pr. : -15 MMWCL
8. BT Position : 85 %
9. SH/RH spray : 45 / 5 TPH
10. Feed water flow : 1560 TPH
11. Drum level : 25 MM
12. Drum Pr. : 193 Kg/ Cm
13. Deaerator Pr/level : 6.6 Kg/ Cm / 5 MM
14. Fuel oil HDR Pr/temp :` 8 Kg/ Cm/ 100C
15. Light oil HDR Pr : 6 Kg/ Cm
16. Wind box pressure : 55/56
17. Seal air fan disc pressure : 1300 MMWCL
18. Scanner air fan disc . Pr : 320 MMWCL
19. ECO I/L Feed water temp : 258C
20. ECO O/L temp : 320 C
21. F.G temp at ECO O/L : 341 / 340C
22. F.G temp at APH O/L : 112 / 128C
23. FG temp at ID O/L : 117 / 110C
24. Feed water disc. Pr. : 206 Kg/ Cm
25. Metal LTSH O/L temp (max) : 429/395C
HTRH O/L (max) : 559/490 C
HTSH O/L (max) : 547/508 C
26. DP across BCWP (I/L O/L ) : 1.7 Kg/ Cm
27. Atomibsing steam HDR Pr. : 14 Kg/ Cm / 205C
28. Mills outlet temp : 80 C
29. Mills DPs : 268 MMWCL
30. Mills fuel flow : 300 TPH
31. Mills inlet temp : 280C
32. Mills PA flow : 105 TPH
33. Soot blower HDR Pr/temp : 25 Kg/ Cm / 280 C
34. LTSH TEMP (Max.Min) : 429/395 C
35. HTRH Metal Temp (Max/Min) : 559/490 C
36. HTSH Metal Temp (Max/Min)`` : 547/508 C
37. SH Div Panel Metal Temp : 485/455 C
38. Drum Metal Temp : 365/344 C
39. ID Fan Currents (A/B) : 417/430 A
40. FD Fan Currents (A/B) : 107/106 A
41. PA Fan Currents (A/B) : 106/106 A

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

42. BCW Pumps Currents (A/C) : 45/45 A

43. Mill Currents (A/C/D/E/F/G) : 108/95/84/88/78/96 A
44. DMCW TG Aux. Currents (A/C) : 46/46
45. DMCW SG Aux. Currents : 45/46/46
46. CEP Currents (B/C) : 136/141 A
47. CWP Currents (A/C/D) : 95/97/93 A
48. ACWP Currents (B/C) : 69/68 A

IMPORTANT AUXILIARIES PARAMETERS:

Divisional Engineer/E&P/KTPS-VI Page 39 of 110

 TDBFPs
Lub Oil Parameters TDBFP-A TDBFP-B
KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
LOP Discharge header pressure (Kg/Cm2) 11.63 12.9 Version: 01
Operations Manual,
2
Lub Oil header pressure(Kg/Cm ) 2.96 2.3
Lub Oil temp before/ after coolers 56 / 43 54 / 42
Lub Oil Tank level (mm) 1191 1348
Governing Parameters
Trip Oil pressure (Kg/Cm2) 9.77 7.99
2
HP secondary oil pressure (Kg/Cm ) 3.3 3.5
CRH / Aux header Governing valve pressure
(Kg/Cm2) 1.16 1.49
2
Control OilChapter-IX
header pressure (Kg/Cm Boiler ) and Auxiliaries Protections
10.3 10.3
Sl.No
Oil pressure above / below piston stop valveDESCRIPTION
1
(Kg/Cm 2
) All ID fans OFF / 9.71 / 7.7
Temperatures
BFP2 100%All FD fans
casing OFF (oC)
temperature 286 293
BFP3 50% casing
Emergency trip (EPB)
temperature (oC) 278 284
o
Exhaust
4 hood temperature
Flame Failure Trip ( C) 43 43
Turbine
5 speed
Loss of all fuel trip 5379 5369
Steam parameters
CRH6 steamLess than fire
pressure ball and Loss
/ temperature to BFPof AC (at any elevation
44.86 / 343in service)
45.6 />2 344sec
Aux7 steamWater circulation
pressure not correct >5 sec.
/ temperature 17 / 210 17 / 233
Live
8 steamRH pressure/temperature
Protection (with a delay of 10 sec.) 6.34 / 293 6.4 / 292
Steam flow 53 52
9 Furnace Pressure Very2 high ( +150 mmWCL) 2/3 Logic, Alarm at +125 mmWCL
Exhaust steam pressure (Kg/Cm ) -0.93 -0.92
10 steam
Exhaust Furnace Pressure(Very
temperature o
C) low (-175 mmWCL) 2/341 Logic, Alarm 42 at -175 mmWCL
11Top / Drum
BFP bottomlevel
barrelvery high (+250mm),
temperature (oC) Alarm at160 +125mm
/ 166 175 / 177
Gland
12 steam header pressure / temperature
Drum level very low (-375), Alarm at -175mm 207 / 174 175 / 178
o
Gland steam inlet temperature ( C)
13 Loss of unit DC (220V) >2 sec
FW parameters
14 Pump
Booster Air flow <30%
suction MCR (675TPH/2000TPH) 8.8 /164
pressure/temperature 8.87 / 164
BP15Discharge Boiler
temperature
Feed Pumps OFF >10 sec. 164 164
BP16strainerAllDPAir(mmwcl)
Heaters OFF. 725 674
BFP strainer DP(mmwcl) -133 -135
17 Loss of Unit 24V DC
BFP Discharge Feed Water flow 912 925
18 Any two MFT panel
BFP Suction / Discharge pressures (Kg/Cm ) both networks 2 failed 2/3 Logic
26.7 / 200 26.7 / 202
o
BFP suction temperature ( C) 166 166
o
BFP DischargeBEFORE temperature ( C)
PURGE CHECK THE FOLLOWING EQIPMENT 168 168
Booster
1 Pump
Establish AC & DC power to FSSS and the related equipment.
Booster Pump Thrust bearing temperature NDE/
DE2 Establish proper drum water level. 65 / 75 54 / 45
3
Booster PumpKeepJournal
at leastbearing
one IDtemperature
and one FD NDE/ fan in service.
DE4 Establish air flow between 30% and 40% MCR 60value.
/ 65 (>600TPH52 / 55 to <800TPH)
BP bearing vibrations DE / NDE (mm/sec) 5-Aug 2.4 / 2.3
Gear Box
PURGE PERMISSIVES.
BFPDT Gear Box input FJB temperature (oC) 61 53
1
BFPDT GearNo Box
boiler trip RJB
input (Above 18 trips should
temperature (oC) not present) 63 66
2 H.O Trip valve closed
BFPDT Gear Box input TB temperature ( C) o
69 63
3
BFPDT GearL.O. tripoutput
Box valve FJB
closed temperature (oC) 59 52
o
BFPDT
4 GearAll Box output all
Elevations RJB H.O.temperature
Nozzle valves( C) closed 69 55
BFPDT
5 Gear Box output RJB vibrations
Elevations AB all L.O. Nozzle valves closed (Microns) 8.8 / 8.4 16.3 / 16.4
BFPDT Gear Box input RJB vibrations (Microns) 5.3 / 4.9 6 / 5.7
6 All PA fans OFF
BFP Turbine
7
BFPDT TBAll feedersTemperature(
(Active) OFF o
C) 79 66
BFPDT Journal Bearing metal temperature
Divisional
NDE(oC)Engineer/E&P/KTPS-VI 65 55Page 40 of 110
BFPDT Turbine RJB temperature(oC) 69 54
Casing Expansion (mm) 3.05 4.84
0.046 /
 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

8 All hot air gates closed

9 All auxiliary air dampers modulating
10 Air flow >30% and <40% (600TPH to 800TPH)
11 All scanners scanning no flame
12 MFT DPU not FROZEN
SG SIDE ALARM AND TRIP VALUES

SL.
NO. DESCRIPTION NORMAL ALARM TRIP
<6.3 mm/s 9.9mm/sec
1 FD FAN MOTOR VIBRATION PEAK 6.3 mm/sec (>10sec.)
2 FD FAN BEARINGTEMPERATURE 95 C0 105 C0
<6.3 mm/s
3 PA FAN MOTOR VIBRATION PEAK 6.3 mm/sec 9.9 mm/sec
4 PA FAN BEARINGTEMPERATURE - 95 C0 105 C0
PA, FD FAN MOTOR
- 95 C0 105 C0
5 BEARING+WINDING
12.6 mm/s
6 PAFAN, FD FAN BEARING VIBRATION <6.3 6.3 mm/s peak peak
7 DP ACROSS SCANNER AIR FILTER (Low) 10mmwc <5 * -
DP ACROSS SCANNER AIR FILTER
8 (High) 10 MM Wc >15 * -
9 DP SCANNER AIR TO FURNACE (Low) <125*
12 HFO PUMPS SUCTION STRNR DP (High) 0.1 >0.15 -
HFO PRESSURE PUMPS I/L COMMON
13 LINE (Low) -0.1 -0.15
14 HFO PRESSURE AT PUMPS I/L (Low) -0.5 -0.5
15 HFO PRESSURE AT PUMPS O/L (Low) 30 KG/CM2 29 KG/CM2
16 HFO PRESSURE AT PUMPS O/L (Low) 30 KG/CM2 28.5
TEMPERATURE BEF. OPERATING
17 FLOOR STRAINER OK 130c0 <90 C0
18 PRESSURE BEF. OPERATING FLOOR OK 23 KG/CM2 <23 KG/CM2
19 DP ACROSS OPERATING FLOOR (High) 0.15 >0.3
20 HFO HDR. PRESSURE (Low) 17.5 4.5 KG/CM2
21 HFO HDR. PRESSURE (2/3) (Low) 17.5 4. KG/CM2
22 HFO HDR. TEMPERATURE (Low) <95 C0
23 HFO HDR. TEMPERATURE (2/3) (Low) <85 C0
ATOMISING STEAM HDR. PRESSURE
24 (Low) 7.5 KG/CM2 <4.0
ATOMISING STEAM HDR. PRESSURE
25 (2/3) (Low) 7.5 KG/CM2 <3.5KG/CM2

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

LDO,DP ACROSS SUCTION STRAINER

26 (High) 0.15 >0.3
27 PRESSURE AT LDO PUMP I/L (Low) -0.3KG/CM2 0.3
-0.5
28 PRESSURE AT LDO PUMP I/L KG/CM2 -0.5
29 LDO PUMPS O/L PRESSURE 23 KG/CM2 22.5 KG/CM2
30 LDO PUMPS O/L PRESSURE 23 KG/CM2 22.0 KG/CM2
31 PRESSURE BEF. LOTV >18 KG/CM2 >18 KG/CM2
14.5
32 LDO HDR PRESSURE (2/3 LOGIC) (Low) KG/CM2 3.5KG/CM2
14.5
33 LDO HDR PRESSURE (Low) KG/CM2 3.8 KG/CM2
5.6 TO7
34 ATOMISING AIR HDR PRESSURE(Low) KG/CM2 4.0 KG/CM2
5.6 TO7
35 ATOMISING AIR HDR PRESSURE (Low) KG/CM2 5.5 KG/CM2
36 DP ACROSS PH D.O STRAINER 0.15 0.15 KG/CM2
BOILER FLOOR D.O. TANK STRAINER 0.15
37 D.P. (High) KG/CM2 0.15 KG/CM2
LTSH I/L HDR TUBE METAL
38 TEMPERATURE (High) <365c0 >470 C0
SH. DISCHARGE VALVE TUBE METAL
39 TEMPERATURE <5180C 518 C0
40 PLATEN SH TUBE <5920C 592 C0
SL.
NO. DESCRIPTION NORMAL ALARM TRIP
41 RH TUBE METAL TEMPERATURE <6190C 619 C0
42 MS TEMPERATURE 540c0 550 C0
BCW PUMP MOTOR CAVITY
43 TEMPERATURE <60c0 60 C0 66c0
44 LP COOLANT O/L FLOW 4.5 m3/hr
45 DP ACROSS HP FILL LINE FILTER 0.35 1.76
46 S.B PRESSURE 30 KG/CM2 >18.4KG/CM2
47 LRSB LINE FLOW 5.45 T/H <2.16
48 W. W. SB LINE FLOW 2.52 T/H <1.8
49 HOT PA HDR PRESSURE 830mmwcl 625 mmwcl 500mmwcl
51 MILL MOTOR VIBRATION <6.3 mm/sec 6.3 9.9
52 MILL VIBRATION <6.3 mm/sec 6.3 9.9
>95C0 HAG

53 MILL OUT LET TEMPERATURE (HIGH) 66-90 C0 closes >30 sec.

95DegC
<60C0
54 MILL OUT LET TEMPERATURE (LOW) 66-90 C0 <65Deg is permissive
60DegC

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55 DP ACROSS MILL <289 mmwc >300

DP ACROSS SA PRESSURE/CA
56 PRESSURE >1175 mmwc <250
57 SEAL AIR TO BOWL D.P >1175 mmwc 250mmwc 200
<0.7 Kg/Cm2
Imp: Bolier trips
on WW circ.
Problem if 3
<1.5 Kg/Cm2 CCPs DP is
62 BCW DP - (10PSI) <0.7KSC
DP ACROSS HP FILL LINE & PURGE <1.7 Kg/Cm2
63 LINE FILTER HIGH - (25 PSI) -
64 D.T.ACROSS BCWP SUC/CAS - >38 C0 -
AH - AIR PRESSURE BEF. SOL. VALVE
65 LOW - <5 KG/CM2 -
66 AH COLD END TEMPERATURE HIGH - 450 C0 -
67 AH G.B/S.B OIL TEMPERATURE HIGH - >70 C0 -
68 PULVERISER L.O. PR. LOW - <3.5 bar -
69 PULVERISER L.O. DIS. FILTER DP HIGH - >1.5 KG/CM2 -
70 PULVERISER L.O. TEMPERATURE HIGH - >80 C0 -
>36 C0
(Permit)
71 PULVERISER L.O. TEMPERATURE
72 PULVERISER L.O. TEMPERATURE LOW <30 C0
73 PULVERISER L.O. TANK LEVEL LOW - <10mm -
74 PULVERISER VIBRATION - 4.5mm/sec -
75 PULVERISER MTR BRG. TEMPERATURE - >85 C0 -
PULVERISER MTR WDG.
76 TEMPERATURE - >125 C0 -
77 DRUM METAL TEMPERATURE - >371C0 -

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
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Chapter-X

SG SIDE PROTECTIONS AND INTERLOCKS

ID FANS INTERLOCKS

ID FAN A
START PERMISSIVES
1. Inlet Guide vane position minimum.
2. Hyd. Coupling scoop position minimum.
3. SAPH A/B Running and inlet / outlet dampers open & any FD discharge damper
open.
4. Hyd. Coupling oil pump ON and pr. Adequate. > 1.2 kg/cm.
5. Inlet / outlet dampers fully closed.
6. Hyd. Coupling oil level normal.
7. Hyd. Coupling oil temp. at cooler inlet normal.<95c
8. Hyd. Coupling oil temp. at cooler outlet normal.<65c
9. Temp. of Motor, Fan &8H.C. bearings are normal.<80c

TRIP CONDITIONS
1. Any hyd. coupling temp very high. >85c
2. Hyd. Coupling oil temp at cooler inlet very high. >100c
3. Hyd. Coupling oil temp at cooler outlet very high. >75c
4. Fan /motor bearing temp. Hi Hi>85c
5. Hyd. Coupling oil pressure lo lo <0.5 kg/cm.
6. Discharge dampers / gate does not open fully within specified time. 3 min after the
fan start.
7. Post purge furnace pressure hi/lo from FSSS.
8. Electrical protection Trip
9. Emergency PB pressed.

HYDROCOUPLING OIL PUMP INTERLOCKS

The pump selected to lead start under the following conditions :

1. When the ID fan start command is give the pump start and runs for 40 secs.
2. The pump start if the oil pr. Is less than specified limit <1.8 kg/cm.
3. The pump start and runs for 25 mins after the ID fan stops.
The pump selected to lead stops under the following conditions:
1. Stops after 40 secs of ID fan start command and oil pr. reaches the specified limit.
>2.2 kg/cm.[NB The pump selected to lag starts when lead pump fails to start.]

FD FAN A
START PERMISSIVE
1. Blade pitch position min.
2. Control oil pressure adequate >8 kg/cm.
3. Lub oil pressure adequate >0.5 kg/cm.
4. Any ID fan running AND no FD fan running
-OR-
Two ID fans running
5. Discharge damper fully closed.

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TRIP CONDITIONS
1. No ID fan is running.
2. Fan / motor bearing temp. Hi Hi >85c.
3. Discharge damper does not open fully within specified time after 2 min starting
fan.
4. Post purge furnace pr. Hi / Lo from FSSS
5. FD fan B running. ID fan B running on BUS B & running ID fan A trips.

F.D. FAN OIL pump interlocks

When the selector switch is in Auto. The oil pump starts under the following conditions.

1. LEAD pump start when FD fan start command is give.

2. Fan running and control oil pr. is <6 kg/cm
3. When the LEAD pump trips. LAG pump starts within 1 sec.

PA FAN A
START PERMISSIVES :

1. F.D fan A or B running but PA fan B not running or both FD fan A & B running.
2. Blade pitch position minimum.
3. Outlet damper fully closed.
4. Start permit from FSSS

TRIP CONDITIONS

1. Fan / motor bearing temp Hi-Hi>85c

2. Discharge damper does not fully open within 100secs.
3. Trip from FSSS (MFT)
4. Both PA A & B running, on FD A trip PA A trip.
5. Electrical protection trip.
6. Emergency PB pressed.
PA fan oil pump interlocks :

When the selector switch is in Auto the oil pump start under the following conditions.

1. Pump selected to LEAD pump start when fan start command is give.
2. Start by (LAG) pump starts when fan is running and control <6 kg/cm oil
pressure is low.
3. LAG pump starts when fan is running and LEAD pump trips.

B.C.W PUMP INTERLOCKS

START PERMISSIVES :

1. Both the discharge valves 1 &2 fully open.

2. Motor cooling water flow adequate
3. Motor cavity temp. not High.
4. Pump cavity suction manifold diff. temp adequate.

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TRIP CONDITIONS

1. Any of the discharge valves not fully open.

2. Motor cavity temp. high for more than 5 sec.
3. Electrical protection trip / EPB Pressed.

AUTO START

Pump selected auto start when

1. Any running pump trips and 2 secs not over.
2. Boiler load > 60% & only 1 pump is effective .

ID FAN INTERLOCKS
1. Conditions existing when the unit is shut down and prior to starting of ID fans.
a. ID fan `A` & ID fan `B` off.
b. Regulating damper of fans A&B fully open.
c. Inlet gates of fans A&B open.
d. Outlet gates of fans A&B open.
e. The regulating dampers & VFD control will be on manual control during
shutdown, and impulse from furnace draft control to regulating damper of ID fans
disconnected.
f. Lube oil pumps of ID fans off.
Starting ID Fan `A` (ID fan `B` is off)
(a). ID fan `A` shall be prohibited from starting till the following conditions are satisfied :
i. Flue gas path available.
ii. Regulation dampers of Fan A in minimum position.
iii. Outlet gate of Fan A closed.
iv. Inlet gate Fan A closed.
v. Fan/Fan motor bearing temperature not very high.
vi. Motor winding temperature is not very high.
vii. One of the air heater is running with its inlet and outlet dampers kept open.
ix VFD system per missives satisfied (Refer clause 7.0)
x. VFD system `channel 1 ready` or `channel 2 ready` signal available (one
contact for
each channel).
xi. VFD system `channel 1 start permissive` or `channel 2 start permissive
available
from VFD system.
(b). The starting of ID fan `A` shall be done in following sequence
i. VFD system channel 1 start command starts fan `A` and runs up fan A to
minimum speed.
ii. When fan `A` reaches minimum speed. Impulse for VFD channel 2 start is
given by operator.
When ID fan `A` is started (ID Fan B is off ), impulses shall be given for.
iii. Opening the inlet gate and outlet gate of fan A.
iv. Connecting the regulating dampers / VFD control of Fan A to the auto control.
v. Closing the inlet gate and the outlet gate of ID fan B and bringing the
regulating dampers
to minimum Position.

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vi. Permission to start either FD Fan A or FD Fan B.

Tripping of ID Fan A (ID Fan B is off)

ID fan `A` trip shall mean that `stop` impulses shall be given to VFD channel 1 and
channel 2 simultaneously.
a.ID fan `A` shall trip automatically under following conditions.
i. ID fan A bearing temperature too high (prior to this, ID fan A bearing
temperature high
shall be annunciated in UCB) contacts shall be generated from RTD.
ii. ID fan A motor bearing /winding temperature too high
iii. Post purge fan trip from FSSS.
iv. Vibration level of fan/motor very high. For fan, trip shall be initiated with a
delay of 10
minutes during starting and running of fan.
v. ID Fan A VFD channel 1/channel2 input breaker (11kv) trip. Here only the
channel shall be issued stop impulse.
vi. Lube oil pressure of ID fan A too low
b. When ID fan A trips
i. Opening the outlet gate of ID fan B.
ii. Opening the inlet gate of ID fan B.
iii.Disconnecting the impulse from auto control system to regulating damper and
VFD control.
iv. Opening the regulating damper of ID fan A to wide open position.
v. Opening the regulating damper of ID fan B to wide open position.
vi. Tripping the working FD fans.
Vii Boiler tripping through FSSS
viii. To keep the inlet gate and outlet gate of ID fan A open.

Starting of ID fan B
a. ID fan B shall be prohibited from starting unless the following conditions are
satisfied :
i. Outlet gate of fan B is closed.
ii. Inlet gate of fan B is closed.
iii. Regulating damper of fan B is in minimum position.
iv. Fan/Fan motor bearing temperature not very high.
v. Motor winding temperature not very high.
vi. Lube oil system per missives satisfied .
vii. VFD system `auxiliary supplies healthy` permissive satisfied.
viii. VFD system `channel 1 ready` or channel 2 ready` .
ix. VFD system `channel 1 start permissive` or channel 2 start permissive
available.

b. The starting of ID fan `B` shall be done in following sequence.

i. VFD system channel 1 command start fan `B` and runs up fan `B` to
minimum speed.
ii. When fan `B` reaches minimum speed, impulse for VFD channel 2 start is
given by operator.
iii. When ID fan B is started, impulses shall be given for:
iv. Opening the inlet gate and outlet gate of fan B after the motor reaches the

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prescribed speed.
v. Connecting the regulating damper and VFD control fan `B` to auto control
vi. Permission to start other FD fan.

General
a. Variable frequency drive
i. Individual start/stop push buttons shall be provided in UCB/CRT for each
VFD channel.
ii. Source breakers of VFD system have to be closed from plant I&C system
only if source
breaker close permissive is available from VFD system.
iii. The signal interface drawing of VFD system supplier shall be referred to
for preparation
of interlock schemes.
b. Fan outlet gate
If one ID Fan is started when the other ID Fan is of, the outlet gate of starting fan
shall be opened with starting of the fan to reduce the load of electrically operated
gate.
When starting the second fan the respective outlet gate shall be opened after the
fan reaches minimum speed

FD FAN INTERLOCKS
Conditions prior to starting FD Fans
a. FD Fan A and FD Fan B off.
b. Fan impellers tilted to maximum opening.
c. Outlet dampers are fully open.
d. Fan impeller regulator disconnected.
e. Lube oil pumps of FD fans off.
Starting FD Fan A
a. FD fan A shall be prohibited from starting until the following conditions are
satisfied.
i. ID Fan A or ID Fan B is on.
ii. Fan A damper in the minimum position.
iii. Outlet damper or fan A in closed position.
iv. Fan / motor bearing temperature not very high.
v. Motor winding temperature not very high.
vi. Lube oil system permissives satisfied.
b. when FD fan A is started impulses shall be given for.
i. Outlet damper of fan A to opened after the motor reaches rated speed.
ii. The outlet damper of FD fan B close & impeller blades of fan B to be
driven to minimum position.
iii. Connecting the impeller of fan A control drive to auto control.

Tripping of FD A
a. FD fan A shall trip automatically under the following conditions.
i. FD fan bearing temperature too high.
ii. FD fan A motor bearing /winding temperature too high.
iii. Both ID fans trip.
iv. Post purge fan trip.

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v. Vibration level fan or motor very high. For fan, trip shall be initiated with
a delay of 10 minutes during starting and running of fan.
vi. Lube oil pressure of FD fan A too low.
b. when FD A trips impulses shall be given for.
i. Disconnecting the impeller control drove from auto control system.
ii. Bringing the impeller of fan A to the maximum position.
iii. Bringing the impeller of FD fan B to the maximum position.
iv. Opening the outlet damper of FD fan B.
v. To open the emergency scanner air damper.
vi. Boiler tripping.
vii. The outlet damper of FD fan A shall remain open.

PA FAN INTERLOCKS:
Conditions prior to start up
a. PA fan A and PA fan B off.
b. Outlet dampers of fan A and fan B closed.
c. Regulating vanes of fan A and fan B in closed position.
d. Regulating vane regulator disconnected.
e. Lube oil pumps of PA Fan off.

Starting PA fan A
a. PA fan A shall be prohibited from starting until the following conditions are
satisfied.
i. Regulation vanes of PA Fan A in the minimum position.
ii. Outlet damper of PA fan A in closed position.
iii. Anyone FD fan is on.
iv. Purge complete.
v. PA fan and fan motor bearing temperature not very high.
vi. Motor winding temperature is nit very high.
vii. Lube oil system permissives satisfied.
b. When PA fan A is started, impulses shall be given for:
i. Opening the outlet damper of PA Fan A.
ii. Connecting the regulating vanes of PA fan A to auto control.
iii. Bringing the regulating vanes of PA fan B to the minimum position.
iv. Closing the outlet damper of PA fan B.
v. Permission to start any three coal elevation through FSSS.
Tripping of PA fan A
a. PA fan A shall trip under the following conditions:
i. PA fan A bearing temperature too high.
ii. PA fan A motor bearing /winding temperature too high.
iii. Boiler trips.
iv. Vibration level of fan or motor very high. For fan, trip shall be initiated
with a delay of 10 minutes during starting and running of fan.
v. Lube oil pressure of PA fan A too low.
b. When PA fan A trip, impulses shall be given for :
i. Opening the outlet damper of PA fan B after the motor reaches rated speed.
ii. Connecting the regulating vanes of PA fan B to auto control.
iii. Permission to put in service remaining coal elevation through FSSS.

GENERAL

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i. If one PA Fan is stated when the other PA Fan off, the outlet gate of starting
fan shall be opened with starting of the fan to reduce the load of electrically
operated gate.
ii. When starting the second fan , the respective outlet gate shall be opened after
the fan reaches full speed.

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
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Chapter-XI

TG SIDE PROTECTIONS

MAIN TURBINE TG PROTECTION TRIP SETTINGS

S. NO. DESCRIPTION TRIP SETTINGS ALARM SETTING

>0.2 kg/cm2 (ABS)
>0.3 kg/cm2 (abs), > - 0.7 > - 0.8 kg/cm2 2/3
1 Condenser pressure, speed >540rpm kg/cm2 2/3 logic logic
2 Lube oil pressure <1.2 kg/cm2, 2/3 Logic @brg
3 Generator Mech. Protection Ch-1:
a) Cold Gas temperature H2 cooler A&B >600C, 2/3 Logic. >550C
b) Cold Gas temperature H2 cooler C&D >600C, 2/3 Logic. >550C
c) Hot air temperature main exciter. >800C, 2/3 Logic. >750C
d) Primary water temperature >600C, 2/3 Logic. >550C
e) Stator winding flow <40m3/Hr, 2/3 Logic. >10 sec. <54m3/hr
f) Flow main bush R (R phase) <1.33m3/Hr, 2/3 Logic. >10 sec. <1.4m3/hr
g) Flow main bush S (B phase) <1.33m3/Hr, 2/3 Logic. >10 sec. <1.4m3/hr
h) Flow main bush T (Y phase) <1.33m3/Hr, 2/3 Logic. >10 sec. <1.4m3/hr
i) Seal oil temperature >550C, 2/3 Logic. >500C
4 Reverse power relay 1/2 acted. -
5 MFT relays 2/3 Logic. -
6 Gen. Electrical protection. 2/3 Logic. -
7 Axial shift (+1.0mm) 2/3 Logic. >+0.5 mm
>1000C, 2/3 Logic with
8 HPT diff. temperature. load>100MW >900C
>450C, 2/3 Logic,with
9 IPT front diff. temperature. load>100MW >300C
>450C, with load >100MW.
10 IPT Rear diff. temperature. 2/3 logic >300C
0.0, 2/3 Logic, with
11 Condenser protection (VSP) speed>540RPM. >5 minutes** -
12 HPT exhaust temperature. >5000C, 2/3 Logic. >4850C
13 TG bearing temperature
a) HPT from Brg. Temp. Ch1 >1300C, 2/4 Logic. >1000C
b) HPT Rear Brg. Temp. Ch1 >1300C, 2/4 Logic. >1000C
c) Axial Brg. Temp. Ch1 >1300C, 2/4 Logic. >1000C

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d) IPT rear Brg. Temp. bottom front Ch1 >1300C, 2/4 Logic. >1000C
e) LPT rear Brg. Bottom front Temp. Ch1 >1300C, 2/4 Logic. >1000C
f) Gen. Brg. Temp. TE Ch1 >1300C, 2/4 Logic. >1000C
g) Gen Brg. Temp. EE Ch1 >1300C, 2/4 Logic. >1000C
h) Exciter Brg. Temp. Ch1 >1300C, 2/4 Logic. >1000C
on MOT level
< -150mm (1050mm from top)
Note: normal level - 0.0mm
14 Fire Prot. Optd. (900mm from top) < -50mm
15 UCB/UCP EPB optd. -
16 ATRS shut down CMD -
17 Emergency PB-HMI. -

** Difference (Condenser Actual Pr. Condenser calculated pr. As per curve) < 0,
i.e. actual condenser pressure falls below calculated value

CW PUMPS
ALARM
S.No TRIP CONDITION TRIP SETTING SETTING
0.9 KG/CM2
1 DISCHARGE PRESSURE V. LOW >90 sec
4.0 KG/CM2
2 DISCHARGE PRESSURE V. HIGH >90 sec
3.0 KG/CM2 >10
3 DISCHARGE HDR PRESSURE V. HIGH sec
SUMP LEVEL V.LOW (for cascade tripping of all
4 CWPs) 88.5 MSL 88.7 MSL
5 MOTOR WINDING TEMP. V. HIGH >140 0C >110C0
6 MOTOR BEARING TEMP. V. HIGH >95 0C >85C0
7 PUMP BEARING TEMP V. HIGH >95 0C >85C0
8 PUMP ON & DISCHARGE VALVE NOT OPEN

9 MOTOR ELECRTICAL PROTECTION OPERATED

ACW PUMPS
ALARM
S.No TRIP CONDITION TRIP SETTING SETTING
1 DISCHARGE PRESSURE V. LOW 2.0 KG/CM2
2 DISCHARGE PRESSURE V. HIGH 5.0 KG/CM2
3 DISCHARGE HDR PRESSURE V. HIGH 5.0 KG/CM2
4 SUMP LEVEL V.LOW 88.0 MSL 88.7 MSL
5 MOTOR WINDING TEMP. V. HIGH >140 0C >110C0
6 MOTOR BEARING TEMP. V. HIGH >95 0C >85C0

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7 PUMP BEARING TEMP V. HIGH >95 0C >85C0

8 PUMP ON & DISCHARGE VALVE NOT OPEN

9 MOTOR ELECRTICAL PROTECTION OPERATED

TG DMCW PUMPS
ALARM
S.No TRIP CONDITION TRIP SETTING SETTING
6.5 KG/CM2 (

1 DISCHARGE PRESSURE V. LOW 5.0 KG/CM2 HDR)

2 DISCHARGE PRESSURE V. HIGH 10.0 KG/CM2 9.0 KG/CM2 (HDR)

3 SUCTION HDR PRESSURE LOW 2.0 KG/CM2 2.7 KG/CM2
4 MOTOR WINDING TEMP. V. HIGH >120 0C >110 0C
5 MOTOR BEARING TEMP. V. HIGH >90 0C >85 0C
6 PUMP ON & DISCHARGE VALVE NOT OPEN

7 MOTOR ELECRTICAL PROTECTION OPERATED

UNCOMMANDED OFF(LOCAL EMERGENCY
8 PB)
9 SUCTION VALVE NOT OPEN
SG DMCW PUMPS
ALARM
S.No TRIP CONDITION TRIP SETTING SETTING
1 DISCHARGE PRESSURE V. LOW 6.0 KG/CM2 6.5 KG/CM2
2 DISCHARGE PRESSURE V. HIGH 10.0 KG/CM2 9.0 KG/CM2
3 SUCTION HDR PRESSURE LOW 2.0 KG/CM2 2.7 KG/CM2
4 MOTOR WINDING TEMP. V. HIGH >120 0C >110 0C
5 MOTOR BEARING TEMP. V. HIGH >90 0C >85 0C
6 PUMP ON & DISCHARGE VALVE NOT OPEN
7 MOTOR ELECRTICAL PROTECTION OPERATED
UNCOMMANDED OFF(LOCAL EMERGENCY
8 PB)
9 SUCTION VALVE NOT OPEN

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*STG SIDE ALARM AND TRIP VALUES

TDBFP-A/B
Trip Set Normal
S. N. Description Value Alarm Value working Value
< 2.0
1 Lube oil header pressure very low (2/3 logic). 1 KG/CM2 KG/CM2 2.5 KG/CM2
2 Exhaust. Steam temperature very high (2/3 logic). 1200C 850C 50-600C
> 11.2, < 4.5 7.0 - 9.0
3 Live steam pressure very high (2/3 logic). 12.5 KG/CM2 KG/CM2 KG/CM2
>-0.60 (-) 0.87
4 Exhaust steam pressure very high (2/3 logic). -0.4 KG/CM2 KG/CM2 KG/CM2
5 Gov. oil (Control Oil) pressure very low (2/3 logic) <4.5 KG/CM2 <6.5 KG/CM2 ~7.5 KG/CM2
+0.7/-0.7 +0.5/-0.5
6 Axial displacement very high (2/3 logic). KG/CM2 KG/CM2
Turbine Vibration high
8 G.B. O/P Vibration very high.5 sec. delay. 174 119 45
9 G.B. I/P Vibration very high.5 sec. delay. 174 119 45
11 Turbine F.J.B. Vibration very high, 5 sec. delay. 174 119 45
12 Turbine R.J.B. Vibration very high, 5 sec. delay. 174 119 45
6000 Mech.
10 Over speed (2/3 logic) (rpm) 6300 Elect. 4000 - 5800
13 D/A level very low (2/3 logic). -1510 0
7 Turbine Eccentricity High. <300 rpm - > 137 45
Temperature very high.
14 G.B bearing temperature, 1/6 Logic 1200C > 1050C 600C
a ) G.B. IP FJ temperature 1200C > 1050C 600C
b) G.B. IP RJ temperature 1200C > 1050C 600C
c) G.B. IPTBTM1 (IP Shaft) 1200C > 1050C 600C
d) G.B. IPTBTM2. 1200C > 1050C 600C
e) G.B. OP FJ temperature. 1200C > 1050C 600C
f) G.B. OP RJ temperature. 1200C > 1050C 600C
Turbine bearing temperature very high >2 sec.,
15 Logic
a) TB Act. temperature 1200C > 1050C 600C
b) TB Nact. temperature 1200C > 1050C 600C
c) TBFJB temperature 1200C > 1050C 600C
d) TB RJB temperature 1200C > 1050C 600C
16 B.P. bearing temperature very high Logic
a) B.P. bearing temperature D.E. side 950C 900C 650C
b) B.P. bearing temperature N.D.E. side 950C 900C 650C

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B.P. thrust bearing temperature very high

17 >2 sec. Logic
a) B.P. thrust bearing temperature 1. 1050C 1000C 750C
b) B.P. thrust bearing temperature 2. 1050C 1000C 750C
c) B.P. thrust bearing temperature 3. 1050C 1000C 750C
d) B.P. thrust bearing temperature 4. 1050C 1000C 750C
18 BFP bearing temperature >2 sec., Logic
a) BFP bearing temperature D.E. 950C 900C 650C
b) BFP bearing temperature N.D.E. 950C 900C 650C
B.F.P. thrust bearing temperature >2 sec.,
19 Logic
a) B.F.P. thrust bearing temperature-1. 1050C 1000C 750C
b) B.F.P. thrust bearing temperature-2. 1050C 1000C 750C
c) B.F.P. thrust bearing temperature-3. 1050C 1000C 750C
d) B.F.P. thrust bearing temperature-4. 1050C 1000C 750C
D.T. Suction/Discharge high and BFP working, and
20 Suction flow very low, ( 2/3 logic) >30sec. 150C/-10 100C
Man/Console P.B
23 Emergency PB (On Standalone Panel)
22 Trip from console (OWS/LVS)
BFP working & suction flow low. ( difference of
actual suction flow to speed derived suction flow is
21 low) (>15sec) <-50T/Hr.
25 Suction valve not open
26 Trip Oil Pressure Very Low, 2/3 Logic <2ksc <4ksc 7 8 ksc
MDBFP - C

Trip Set Normal

S. N. Description Value Alarm Value working Value
Suction flow low & pump on (difference of actual
1 flow to speed derived flow). 50T/Hr.
MDBFP suction flow low >30sec.
2 (to avoid reverse rotation) <-50T
3 Lube oil header pressure low, 2/3 logic. 0.8 KG/CM2 1.0 KG/CM2 3.0 KG/CM2
4 Working oil temperature very high, 2/3 Logic. 1300C 1100C 1000C
5 Working oil pressure low, 2/3 Logic, 5 sec delay. 2.2 KG/CM2 2.5 KG/CM2 3.0 KG/CM2
6 Suction valve not open.
Suction Discharge temperature high & suction flow
7 low.
8 Luboil temperature downstream of coolers high. >600C >550C 500C
9 BFP Jr. bearing temperature very high Logic 950C 900C 650C
10 BFP thrust bearing temperature very high Logic 1050C 1000C 750C

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11 BFP motor winding temperaure very high. 1300C 1250C 1200C

12 D/A level very low (mm) -1510 0
13 BFP motor JR. bearing temperature very high 900C 850C 750C
Thrust -
BFP Thrust, JR bearing temperature very high, 1000C, JR - Thrust - 650C,
14 (booster pump) 105, 950C 900C JR - 650C
15 Hydraulic coupling bearing temperature very high. 950C 900C 850C
16 Suction pressure low &pump ON 10 KG/CM2 15 KG/CM2 26 KG/CM2

CEPs
Trip Set Normal
S. N. Description Value Alarm Value working Value
<18KG/CM2
>10sec.
1 Pump ON & discharge pr. low 21 KG/CM2 28 KG/CM2
2 Hotwell level low -1955mm -250mm 0
<300 TPH
>10sec
3 Flow through CEP low
4 Thrust brg temperature very high Logic >1050C 1000C 800C
5 Motor brg temperature very high Logic 900C >2sec
850C 700C
>1300C
>2sec
6 Motor wdg. temperature very high 2/6 Logic 1250C 1000C
7 Suction valve not open
8 Emergency stop P.B.

* STG Steam Turbo-Generator

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Chapter-XII

ELECTRICAL PROTECTIONS

CLASS A
1. Differential protection:-

i. Generator differential protection 87(R,Y,B)

ii. GT HV winding differential cum over head line protection 87 HV (R,Y,B)
iii. UT Differential 87UT(A,B)
iv..GT Differential 87 T
v. GT overall Differential protection 87 GT

2. Earth Fault Protection:-

i. Stator earth fault 64G.
ii. GT standby E/F protection 51NGT
3. Negative phase sequence.
4. Generator Back up impedance protection stage I 21GRY, 21GRB, 21GBR.
5. Stator inter - turn fault.
6. Loss of excitation 40G.
7. Over voltage.
8. Over fluxing
9. Low forward power
10. Reverse power
11. Rotor earth fault
12. GTPRV R/Y/B 30GT/P/A
13. Generator transformer protection
a). Buchholtz operation
b). Winding temperature high.
c). Oil temperature high.
d). Fire protection.
14. UT fire 30UT 1
15. UT PRV
16. Bus Bar protection
17. GT fire
18. GT OLTC
19. Dead Machine 61

CLASS B
1. Fire failure 40G
2. GT HV WT1 R/Y/B 30GTA R/Y/B
3. GT LV WT1 R/Y/B 30GB R/Y/B

CLASS C
1. Negative phase sequence protection 46G.
2. Generator Back up impedance stage I 21G.
3. Gen. under frequency 81G3.
4. Pole slip protection 78G
5. GT standby earth fault stage I 51NGT

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Low Forward Power Protection:

When the generator load drops to less than 0.5%, generator low forward power
relay gets energized and with turbine tripped or stop valves closed, trips the generator
with a time delay of 2secs.

1. GT Over fluxing:
The iron core of the GT carries the flux to produce required E.M.F. If there
generator, GT becomes over saturated resulting in high magnetizing current. This is
turn leads to high iron losses which will increase the winding temp. of the
transformer. Since core can be damaged because of the over heating, protection has to
be provided against it. The flux is dependent on ratio of voltage and frequency.
The condition of over fluxing could arise in case the voltage at the machine
terminal rises or its frequency drops or both occurring simultaneously. Practically this
condition will arise. If the machine AVR misbehaves there by unduly increase the
voltage even when the gird frequency is low.
Setting for relay is V/f = 1.18 P.U, i..e 20% higher than rated V/f ratio.
Alarm is set. at 5secs and trip 2secs. V/f relay also generator AVR Raise
block.

3. Generator Back up Impedance protection (21)

A three phase zone impedance of generator against external three phase and phase
to phase fault in 400KV system. The zone of impedance relay should be extended
beyond 400KV switch yard and it should be connected to trip the generator after a
time delay 2 seconds so that the generator is tripped only when 400KV protection has
not cleared the fault even is the second zone.

Relays: 21GRY, 21GRB, 2GBR

4. Field failure:- (40G)

Failure of the field system leads to losing of synchronism and resulting in running
above synchronous speed. It acts as an induction generator, the main flux being
produced by wattles stator current drawn from the system. Operation as an induction
generator necessitates the flow of slip frequency current is the rotor, damper winding,
slot wedges, excitation under these conditions requires a large reactive component
which approaches the valve of rated out put of the machine since rotor would get over
heated due to slip frequency current, the machine should not run mode than few
seconds without excitation Also it could overload the gird which may not able to
supply the required excitation MVAR
When loss of excitation is accompanied by under voltage it will initiate class A
trip other wise class B trip

5. Negative Phase Sequence: (46)

A three phase balanced load produces a reaction field which is constant and
rotates synchronously with the rotor field system. Any unbalanced condition could be
solved into positive, negative and zero sequence components. The positive sequence
component is similar to the balance load. The zero sequence component does not
produce armature reaction. The negative sequence is similar to that of positive se
quence but the resulting reaction field rotates in the opposite direction. Hence the flux
produced by the negative phase sequence current cuts the rotor at double the

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rotational speed there by inducing double frequency current. As a result, eddy current
produces are very large and cause severe heating of the rotor winding particularly
damper windings.
For any current conditions in the three phases, the amount of unbalance can be
determined from the values of the negative sequence components of current by the
method of symmetrical components.
( 46GA, 46GT time delay 5sec.)

Differential Protection (87)

i. Generator Differential (87G)

ii. GT HV winding Differential cum over head protection (87HV)
iii. UT Differential (87UT)
iv. GT Differential protection (87GT)
v. GT overall Differential Protection (87G)

i) Generator differential Protection:

A direct short circuit between different phase with or without ground fault of the
winding causes a severe fault current to flow inside the affected machine and cause
highly extensive damage. As a result, there is a distinct difference between the current
at the neutral and terminal ends of the particular winding. This difference is detected
by the differential relay.
The current entering and learning the protection object is determined by current
transformers and compared by relays by means of a differential circuits
If the differential current exceeds a set percentage of the current flowing in the
protected object, the relay pick up.
If is set to operate current 5% of 5A.

ii. GT HV winding differential cum over head protection (87HV)

The 400kv busing of the generator transformer are connected to the switch yard
by double moose conductor over head line. Any fault occurring on these lines is
detected by over head line differential protection.

0.1A with stabilizing resistor of 685 ohm. It picks upto 100A fault current .

iii) UT Differential (87UT)

UT`s are connected directly to the stator windings, so it has been provided
with a based differential so it has been provided with a based differential protection is
a similar circulation current scheme.

iv) GT Differential protection (87T) [GT Restricted earth fault]

The H.V winding of the generator transformer is star connected and the neutral is
solidly earthed. The protection is meant for complete protection of HV winding of
generator transformer. The delta side of the generation transformer is considered as a
part of the generator and its earth fault would cause earth fault current to flow towards
the generator neutral and be detected as generator earth fault (64GT).

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v) GT Overall Differential (87GT)

Generator transformer is directly connected to it would be proper to include the
transformer winding including those for UT HV side and conduction is a current
protection scheme.
Biased setting of 30% is used to prevent the relay operation in case of a through
fault when the current transformer may saturate and produce an erroneous secondary
current.

6. Generator transformer protection.

a) Buchholtz operation
b) Winding temperature high
c) Oil temperature high
d) Fire protection

7. Rotor Earth fault

Ground leakage in the rotor circuit of a generator does not adversely affect if a
second fault occurs only at one point. Danger arise if a second fault occurs causing the
current to be diverted in part at least from the intervening turns which can burn the
conduction causing server damage to rotor. If a large portion of winding is shorted the
filed flux pattern may change causing the flux concentration at one pole and wide
dispensation at the other. The attractive forces which are proportional to the attractive
forces which are proportional to the sequence of the flux density will be stronger at
one pole than the other which will cause high vibration and may damage the bearing
and may sutticienlty displace rotor there by fouling the stator
Rotor E/F is provided by monitoring the I/R valve of rotor winding
<80K ohm Alarm
<5K ohm Trip.

Stator inter turn Fault (95G)

When leakage occurs between the turns in the same phase of a winding the
induced voltage is reduced and there will be a voltage difference between the center
of the terminal voltage triangle and the neutral of the machine
Therefore, in a generator having one winding per phase, a voltage transformer is
connected between each phase terminal and neutral of the winding, the secondary
transformer leads being connected in open delta, when inter turn leakage occurs at
the ends of the open delta, it is detected by a polarized voltage relay.
For Generator having several parallel windings per phase, the neutral ends are
connected together to from as many neutrals as three are parallel windings per phase.
These neutrals are there joined through voltage transformer to current relays. If an
inter turn fault occurs in the machine, the current transformer carries a transient
current or alternatively voltage transformer produces a voltage there by picking up the
relay and tripping the generator.
IDMT [Inverse Definite Minimum Time]

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Chapter-XIII

STARTUP AND SHUT DOWN PROCEDURES

CHARGING OF ELECTRICAL SYSTMES

1. Charge station transformer ST-VIA(50 MVA) or ST-VIB (80 MVA)

2. Ensure that all electrical breakers are in service mode and in off condition
3. Ensure that D.C supply is available to all the electrical breakers are in service mode
and in off condition
4. Ensure supply to unit service switch gear, emergency bus through normal breakers
5. Ensure that supply is available to various MCC. (Turbine MCC, Boiler MCC, TVDC,
BVDC, lube oil MCC)
6. Charge ESP and Ash handling transformers
7. Check unit bus voltage, voltage can be adjusted by changing the TAP position of
station transformer
8. Normalize MD BFP breaker through station bus OBA

D.G set

1. Check the D.G set physically for oil level, cooling water, battery voltage

COLD START UP PROCEDURE

1. Ensure electrical supply to C.W P& ACW pumps and other associated axillaries are
available
2. Ensure that all line clears (LC) are returned. All men and materials removed from
equipment and site
3. Ensure all soot blowers are in home position
4. Ensure RAW, fire fighting system is available for service
5. Get clearance in chimney from boiler maintenance wing for start up of boiler
operations
6. Start new pumps by checking permits & first outs, kept the other pump in Auto
Stand by
7. Start TG DMCW and SG DMCW pumps, check the pressures and kept the other
pump in Auto standby
8. Start SAC and IAC and check the service and instrument air pressure adequate i.e.
>6.5 kg/cm2
9. Fill the deareator with boiler fill pump make ready the chemicals to be mixed in
deareator
10. Start the MDBFP by checking all permits and kept in recirculation mode.
11. Start the dosing pump for adding chemicals to the MDBFP suction
12. After getting required chemical values start filling of drum. Check the drum level
Hydro Step & transmitters. Check for all control and Instrumentation system are
available for service
13. Start boiler circulating water pumps, observe and maintain drum level
14. Check MOT level and control fluid tank levels
15. Check CW duct filling .If not filled start filling by opening ACW to CW
interconnection valve

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16. Start CW pumps .check condenser A&B DP` s

17. Start APH A&B. check I/L & O/L dampers of Flue gas, SA path.
18. Start ID fan by ensuring all permits
19. Start FD FAN by ensuring all permits and maintain the draft about -15 MMWCL
20. Start (AC) scanner air fan and check D C scanner air fan healthness. Check scanner
air fan discharge pressure (250 mmwcl)
21. Take HFO pump A or B,
22. In case of non availability of Aux. PRDS initially, take LDO pump. And check the
pressure.
23. Check the HFO system in short recirculation. Observe the oil pressure &
temperatures.
24. Take one CEP. Kept in recirculation. Check CEP`S discharge pressures
25. Charge the condensate line to deareator by opening discharge valve bypass valve.
26. Check the deareator level normal position.
27. Start MDBFP by checking all permits and first outs open the discharge valve and start
filling of drum with FRC station CV FDV 14 controlling.
28. Check the drum level transmitter & Hydro steps healthiness by raising the drum level
to high alarm and reduce to maintain normal drum level.
29. Increase the SA flow through SCAPH and maintain >30 %&< 40 %; for boiler purge
permit.
30. Check for all purge permits
31. Start purging of boiler.
32. Open (HOTV) If Aux PRDS available, other wise, open (LOTV)
33. In case of HOTV opened, kept in long recirculation to maintain HO temperature up to
1000C. Check atomizing steam pressure Take HO guns (LO guns incase of non
availability of Aux. PRDS) one pair in A elevation. After 15 minutes take other pair in
AB elevation.
34. After attaining drum Pressure >2kg/cm2, close the drum vents, observe the Drum
metal temps, water side & steam side difference should be less than 20c.
35. After attaining SH O/L Pr >5kg/m2, observe the steam through SH vent, Then Close
the SH vents one by one except start up vents and close all SH drains after observing
steam through drains.
36. Open MS line drains MSV 101, MSV 102, and observe the temperatures.
37. Open MS bypass stop valves MSV 3, 5 & 4, 6 to warm up the MS line.
Afterqualizing the temperatures then open MSV 1&2. Observe auto closing of
MSV 3, 5, &4, 6.
38. Charge the Aux. PRDS, by opening the following drains, after getting MS pr.
20kg/cm2 & temp .3000C. Then open the bypass valves ASV76&77 to warm up the
HT Aux. PRDS HDR. After getting required Pr. &temp, 14kg/cm 2& 3000C. Then
change the HT Aux PRDS by opening ASV2 1 and CV (100%)
39. After observing HT Aux. PRDS parameters [Temp.>280 0C. and Pr. about 14KG/cm2]
open seal steam warm up drain, observe the PRDS line to seal steam header Temp>
2800C & Pr. about 14kg/cm2
40. Incase of vacuum breaker in open condition, close the vacuum barker, and start the
vacuum pump 1&2. and observe the vacuum increase up to - 0.2 and give seal steam
to turbine by opening seal steam isolation valve and control valve and maintain the
HDR pressure 350 MMWCL. Observe the vacuum raising.
41. Open the following drain valves
I. Drain before ESV seats
II. Drain before IV seats MAL 26 & 27

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III. MS strainer drain valves (MSV 109&110 DRN to flash box

IV. MS header drain valves MSV 105&106 UFT
V. CRH header drain valves CRHV 101
VI. Drain before extraction NRVs and HPT exhaust NRV (MAL
47,51,52,54,55)
IV. Drain after control valves
VIII.HRH header drain valves HRHV 105&106 F.B, HRHV
101&102 UFT.
IX. HP casing drains MAL 22
X. Drain before and after IP control valves MAL 31&32
42. HP/LP charging.
I. Check the condenser vacuum.
II. Check HP bypass drains and LP bypass drains are open.
III. Establish drum pressure 8- 10 kg/cm2 pressure 10kg/m2, and open HP
bypass more than 5% check the BD valve position.
IV. Ensure LP bypass system is functioning normally on auto. Adjust the fixed
Set point to 4kg/cm2.

43. Gradually increase the HP Bypass up to rated parameters.

MS Pr: 50kg/cm2 HRH Pr: 4- 6 kg/cm2
0
Temp 320 to 350 C Temp 320 to 3500C
44. Wait for criteria full filling.
45. Check the TSI parameters (expansions axial shift, Brg. vibrations, shaft vibrations)
46. After fulfilling the criteria, reset the turbine trip by reducing the SLLD (starting
device) to zero and observe the oil pressures. Check that the turbine trip gear reset.
47. Ensure the Hydrogen pressure in Generator casing is more than 3.35 Ksc ( at Full load
condition the H2 pressure shall be maintained at 3.5 ksc) and H2 purity is more than
96%. Charge all hydrogen coolers on DMCW side. Check the primary water system
and maintain the conductivities.
48. Open the STOP valves by increasing SLLD about 35 to 36% and observe the STOP
valves opening. Check the TSI parameters. Observe the speed.
49. Open MAL 11&12 drain valves.
50. Increase the starting device up to 85% and above. Also observer the speeder Gear
Position is at 100%
51. Set the speed ref .set point to 360 RPM and confirm the ramp. Observe the speed
raising and TSI parameters.
52. Kept the turbine under soaking condition. Up to full filling of next criterias and
observe the differential expansion of HPT and IPT.
53. After getting rated speed criterias, observe the MS Pr & HRH Pr. of rated values.
Raise the speed ref. to 3000 RPM. And observe the speed raise (DN/DT). Observe
TSI parameters at critical speeds.
54. At speed of about 2960rpm then AOP should be switched off as main oil pump takes
over.
55. Soak the turbine speed at 3000rpm till IP shaft mean temperature with respect hot
reheat temperature as per the rolling X-curves is satisfied.
56. Close the Generator field breaker from AVR console.
57. Raise the AVR set point to build the Generator Voltage to about 21KV.
58. Match the auto and manual set point of the AVR and Transfer the AVR to auto mode.
59. Ensure that load controller is on with load gradient Kept at 20 MW/Minute

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60. Check load reference set point more then 20 MW and less then 35 MW depending
upon main steam pressure.
61. Adjust the Voltage so that incoming and running Voltages values are same.
62. Adjust the turbine speed so that synchroscope is slowly rotating in clock wise
direction showing incoming frequency is slightly higher than gird.
63. Switch ON Auto synchronizer after two mimintes Generator breaker closed.
64. Immediately raise the load with help of speed reference upto 25MW.
65. Close HP/LP Bypass valves.
66. Slowly change speed control mode to load control mode.
67. Close all the drains which were opened during rolling.
68. Check the generator slot core, exciter air and hydrogen cold gas temperatures.
69. Check that pressure limiter valve slowly increase also ensure that load reference set
point is higher than the actual load valve.
70. Slowly increase Boiler firing with help mills and increase the load depending upon
main steam pressure
71. Raise the HP bypass pressure set point to about 180kg/cm 2 and temperature set point
to about 3400c to avoid HP bypass opening on auto.

HOT START UP PROCEDURE

Check the following conditions exist immediately after the unit tripping.
Generator / Field Breaker are tripped.
UAT`s Supply to unit buses are tripped and station supply takes over
automatically.
Generator AVR trips to manual mode.
All the turbine stop valves are closed.
CRH NRV at HPT Exhaust closed.
Turbine trip oil, Aux. Sec. oil and secondary oil pressure became zero.
All the feed water heaters Extraction Block valves are closed automatically.
Drain before HP control valves are closed.

Verify
Main turbine Aux. oil pump1 starts automatically. (if SLC is on).
Turbine gate valve gearing is opened automatically at 210 rpm (if SLC on ).
JOP1 start automatically if at 510rpm if SLC is on.
Turbine gate valve gearing is opened automatically at 210rpm ( if SLC is on).
Drum, SH / RH pressures rise on interruption of steam to turbine.
HP /LP bypass open , if on auto with proper set points.
Condenser vacuum breaker may open if tripping is because of fire protection or
axial shift.
SH/RH attemperation block valves are closed if spry control valves are less than
5% open.
Drum level may sink.
All mills & feeders with both PA fans tripped.
HFO trip valve may close as per oil gun logics.
Furnace vacuum dips to very low value due to implostion.
All wind box dampers open up after unit tripping.

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Stop one set of ID /FD fans to avoid forced cooling of the boiler. Stablise &
Maintain the draught & air flow.

1. Take ACW, DMCW, CEP and MDBFP ( BFP C) pumps and maintain drum
level .
2. Take APH, ID Fans & FD Fans, increase the secondary air flow more than
680TPH.
3. Ensure all purge prmissivess are available and give push to purge command after
5 min. Boiler MFR gates reset. The first cause of Unit Tripping gates reset.
4. Ensure deaeretor pressure is maintain at 3.5 kg/cm and Auxiliary steam pressure
is maintained at 14 kg/cm .
5. Establish condenser vacuum 0.90 kg/cm.
6. Reset generator trip relay and turbine trip with the help of Starting device is
brought to 0% and observe trip oil pressure comes to 6.8 kg/cm (approx.).
7. Light up the Boiler with `CD` and EF elevation oil guns.
8. Ensure that minimum stable fire is established in the Boiler.
9. Open the following drain valves. (As per requirement)

a. MS strainer drains to SDFT (MSV-109&110 )

a. CRH pot drain to SDFT (CRHV101)
b. HRH strainer drains to SDFT (HRH-105&106 )
c. LP Bypass line drains (HRHV 109&110)
d. LP Bypass warm up line drains (HRHV 109&110)
e. Open all drains of Turbine system except Mal-22 (HPT casing drain).
Mal -11,12,26,31,27,32,47,51,54,52,81,55,65
10. Charging steam lines and commence warm up
11. Open HP By pass valves so as to establish 10% flow through them, and see that
temperature control loop is function normally.
12. Ensure LP By pass system is functioning on auto adjust the fixed set point to 6 to
8 kg/cm2
13. HP By pass valves can further be opened to assist in increasing steam parameters
(up to rolling parameters) if required mill can be taken into service.

TURBINE ROLLING AND SYNCHRONISING:

Turbine can be rolled to rated speed either by ATRS rolling or manual rolling through
Electro Hydraulic Governor.

The following conditions are to be checked before rolling.

The turbine should be on barring gear (115rpm).
Condenser pressure is less than 0.5Kg/cm2
At least one condensate exaction pump is on.
Trip fluid pressure is more than 5Kg/ cm2
Differential temperature between HP casing mid section top and is less than 30C
Differential temperature between IP casing mid section top/bottom (Both front and
rear) is less than 30C.
HP control fluid temperature is maintained between 50C to 55C/
Lub oil temperature after cooler is more than 35C.(38-47C)

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Degree of super heater of main steam before HP By pass is more than mid metal
temperature of H.P control valves/
Raise the starting Device above 42% and then to 56%/
1) Verify that all ESVs have opened.
2) Verify that drains before HP control valves are in auto and valves have
opened.
3) Put seal steam controller on auto.
4) Verify that the following generator conditions are fulfilled.

Any generator bearing vapour exhaust fan is on.

Hydrogen temperature controller is in auto.
Hydrogen purity is more than 97%.
Hydrogen pressure is more than 3Kg/.cm2
One air side seal oil pump is on.
One Hydrogen seal oil pump is on.
Differential pressure between seal oil air side and Hydrogen side (both turbine
and Exciter end is more than 0.7Kg/cm
Turbine side prechamber level is low.
Generator bushing box liquid level is low (less than90mm)
One primary water pump is on.
Primary water temperature controller is on auto
Primary water conductivity is less than 1.5Micro mho/cm.
Primary water pressure is adequate (>1.33kg/cm)
Primary water flow > 48 TPH.

Before Opening the control valves, verify the following:

a) The degree of superheat of main steam before turbine is more than 50C.
b) M.S. temperature before turbine is more than either midwall temperature of
HP casing or simulated mid section temperature of HP shaft.
c) HRH temperature before turbine is more than simulated mid section
temperature of IP shaft.

During the warm up and hot start up of the turbine, observe the following parameters.
Differential Expansions.
Axial Shaft
Temperature difference between top and bottom of the HP/IP casing.
Bearing temperature and vibration.
Steam parameters.
TSE margin recorders for the following components HPS/HPC/IPS.
Operating parameters of condensing system.
Operating parameters of turbine oil& control fluid systems
Maintain MS temperature and pressure at turbine inlet as per start up curve.

14. Turbine Rolling

HYDRAULIC ROLLING

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Procedure 1
1. Initial speeder gear - 60 to 65%.
2. Isolate EHTC Hydraulic levers.
3. Generate Trip oil pressure by raising SLLD.[ SLLD bring it to 0 % to raise
trip oil pressure and then rise SLLD till STOP valves open about 35 to 36 %].
4. Observe the TSI parameters at Critical speeds 860, 1300 to 1500, 2400 to 2600.
5. Open and observe the SLLD about 35% Stop valves opened.
At about 42.4 % speed start raising and maintaining at 350RPM. Kept under
soaking to get the X-Ctiterias.
6. After fulfilling the X-Criterias raise the turbine speed by increasing the SLLD.
While raising the speed observe the dN/dT. Maintain it around 600RPM / Min and
should not less than 108RPM/min.( SLLD 60.3% 2900RPM Sec. oil HP :
4.34 ,Sec oil IP : 4.54,Aux sec :3.71)
7. Try to reduce speeder gear and observe the slightly change in turbine speed. That
means speeder gear is controlling speed. After ensure that, slowly increase SLLD
to 100% and leave it.
8. Match the turbine speed with grid frequency by controlling the speeder gear. Raise
the inching time of Speeder gear from 2sec to 4sec.
9. Synchronize the Unit by Manually.
10. After synchronization immediately raise the load up to 50MW to prevent low
forward power trip.
11. After reaching load 100MW change over the control from speeder gear to SLLD
care fully and raise speeder gear to 100%. Reduce speeder gear inch time from
4sec to 2sec.
12. Then control the load by using SLLD by observing the MS pressure.

Procedure 2
1. Check EHTC hydraulic levers are closed or not. If not closed, close the levers.
2. Increase speeder gear Inch. Time from 2sec. to 4sec. and keep the speeder gear at
20%.
3. Reduce the SLLD to 0% to turbine trip reset and slowly raise. At about 35% stop
valves open. At bout 42% speed starts raising. At around 48% speed will maintain
at 360RPM.
4. After fulfilling all X -criterias , raise SLLD slowly and check speed upto 2600
RPM
5. Then raise speeder gear and check speed is raising. Slowly raise the speed with
speeder gear to grid frequency.
6. Immediately after synernization, raise speeder gear fastly to load the generator.
After raising load about 50 to 60 MW slowly reduce the SLLD and check for
taking over of control and raise speeder gear to 100%. Reduce speeder gear inch
time from 4sec to 2sec.
7. Then control load with SLLD based on MS Pr.

***Raise the speed set point so as admit steam to the turbine &start rolling.
Raise the speed to 360rpm for warming up the casing.
Verify that gate valve gearing has closed.
Close all the drains valves as mentioned earlier for warm up of steam lines.
While admitting steam to the turbine, ensure that permissible wall temperature of
limit curves are not exceeded

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Hold the speed at 360rpm for soaking purpose.

Close the drains before HPCVS.
Close the drains after HPCV if differential temperature between HPCV & saturated
steam is more than 50C.
Raise the speed to 3000rpm provided the following parameters are with in the limits.
a. The Differential Expansion of the casing.
HP Turbine IP Turbine LP Turbine
+5mmto -3mm +8mm to -2mm +30mm to -3mm
b. The differential temperature between the top & bottom of the casing less than
45C.
c. Bearing temperature and vibration are less than 90C and 45microns respectively.
d. HP turbine exhaust hood temperature is less than 500C

AT 3000rpm
Verify that the following conditions are fulfilled.
1) Both AOP`s are off.
2) HRH temperature before LP bypass than IP shaft mid metal temperature.
3) Cold Hydrogen gas temperature is less than 45C
4) Main Exciter hot air temperature is less than 45C.
5) Cold primary water temperature is less than 50C
6) Cold primary water flow through bushing is more than 0.37 dm /sec and windings is
more than 13.3 dm /sec.
7) Differential temperature between primary water & Hydrogen is more than 1C.

Synchronizing and Load Raising:

a) Put AVR on Auto & Switch on field Breaker.

b) Verify that Generator terminal voltage is 95%.
c) Switch on the Synchronise the Generator with Grid when incoming
Frequency, voltage and phase sequence match the running system.
d) Raise the starting device and take a block load of 10% by raising Nref
from AVR console /Turbine console.
e) Close HP Bypass and check LP Bypass closes on auto, when sliding set
point is more than Hot reheat pressure.
f) Charge Unit Auxiliary transformer to change over 6.6 KV supplies
from station to UAT.
g) Raise the Turbine inlet Main steam pressure at the rate of 0.8 K/g cm
per minute up to Kg/cm at 25% load wards at 1.65Kg/ cm per minute
such that rated throttle pressure is achieved at 55% load.
h) Raise turbine inlet Main steam temperature at rate of 1.6C / minute up
to 485Cat 50% load.
i) Close HP casing drain valve provided HP casing bottom temperature is
more than 300C.
j) Verify that drains before HP Turbine exhaust NRVs have closed with
the opening of NRVs. The drains before and after IPCVs when
difference between IPCV and hot reheat steam is more than 50C.
Open the Extraction steam block valves to LPH 2,3& Deaerator.

Main steam temperature can be raised at the rate 1.6C up 485C and at the
rate of 0.6C above 485C till it reaches 540C.

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Raise the turbine load at the rate of 4 MW/ min up to 125MW

Verify that drain before LPH 2&3 closed when opening of respective
extraction NRV is more than 15%.
Verify that drain before Deaerator extraction line NRV closes when opening
extraction NRV is more than 15% & differential pressure across NRV is more
than 300mm wc.
Put hot well control and deaerator level control on auto.
Above 20% Boiler load index, drum level three element control can be put on
auto.
Raise the turbine load at the rate of 2MW/ min to 485 MW.
At 27%Turbine load, cut in the first mill and at 43% turbine cut in the second
mill.
At 40% Turbine load, combustion controls can be put on auto. HP Heaters
5&6 can be taken into service.
Around 50% Turbine load, cut in the second set of Boiler and Turbine
Auxiliaries such as I.D Fan, P.A. Fan, Boiler Circulating pump Condensate
Extraction Pump and the second Boiler Feed Pump.

Mills are put in operation in the following sequence:

No of mills Turbine load
IIIrd 50%
IVth 60%
Vth 70%
Vth 74%
Above 55% Boiler MCR, SH, RH temperature controls can be put on Auto.
Between 50%and 75% load, maintain turbine inlet main steam temperature at
485C. From 97% to turbine load, raise the turbine inlet temperature at the rate of
0.6C per minute to 535C.

UNIT SHUTDOWN PROCEDURE:

1. Cut the mills from top up to C-mill one by one and reduce the load depending
upon the MS pressure.
2. At load 300MW, take MDBFP-C and kept in recirculation mode.
3. Take oil support in AB elevation.
4. Reduce the load along with Firing.
5. Change over the APRDS from CRH to MS.
6. At around 80kg/cm pressure, take the HPBP in to manual and open about >2%.
Oberve the opening of LPBP.
7. At 150 MW Trim device kept in Trim.
8. Trip the Turbine at 50MW load.
9. Observe the Turbine speed. At around 2850 RPM AOP starts in AUTO. Other
wise start the AOP manually.
10. Observe the Turbo supervisory parameters.
11. Observe the Turbine speed, At around 510 RPM JOP starts in AUTO. Otherwise
take manually.
12. It is recommended to maintain seal steam till 300RPM.

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13. Observe the turbine speed, At around 210RPM Barring gear valve opened in
AUTO.
14. Observe the Turbine speed and is maintaining constantly around 110 RPM.
15. Observe LP exhaust Temp is maintaining around 45 C.
16. Kill the vacuum by switching OFF Vacuum Pump and Open Vacuum Breaker.
17. After reaching Vacuum -0.3Kg/cm2 Cutoff the seal steam by closing Seal steam
valve and open leak steam valve.
18. Exhauster Fan stopped and I/P isolating valve closed.
Chapter-XIV

EHG and CMC etc Controls

ELETRO HYDRAULIC CONTROLLER

The turbine is equipped with electro hydraulic governing system to facilitate the
operation of the turbo set in an inter-connected grid system. Three numbers of digital
speed measuring probes are installed in bearing house. The EHG system consist the
following control loops.

1) Speed control loop

2) Load control loop
3) Pressure control loop

1) Speed control loop: The speed controller essentially compares the speed
reference generated by the speed reference limiter circuit and actual speed
of turbine and accordingly provides an out put for the valve lift controller.
The speed reference is generated by the speed reference limiter control
loop. The desired reference speed valve can be set remotely from control
desk of manually at the cabinet.
DN/DT Monitoring is provided to avoid rolling of the turbo-set at
or near critical speed. The acceleration of the set is monitored in the range
700RPM to 2850RPM. In case dn/dt goes below set valve the speed set
point is rolled back to the soaking value and set also.

2) Load control loop: The load controller receives the reference load signal
from the loaf reference limiter and also from the frequency controller
depending upon the frequency of the grid. These two signals are summed
in the load controller and the net value deriver for controlling the valve
position. The droop characteristics of the frequency controller can be
varied from 2.5 % to 8% in steps of 0.5%.

3) Pressure control loop: The pressure controller controls the turbine load
w.r.t the main steam pressure deviation and prevents a pressure drop, eg:
during a quick load increase. The to operational modes are
a) Initial Pressure control: Operation of the initial steam
pressure controller initiates the unloading of the set in the event of
initial steam pressure falling below a preset value. The unloading
of the set continues proportional to the available pressure the
loading of the set begins only if the firing rate in the boiler is

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increased. In this mode of operation load is controlled by the

boiler and main steam pressure.
b) Limit Pressure control: The boiler storage capacity is
utilized in this mode of operation. The controller influence MS
control valves to support boiler pressure only when a preset
minimum deviation is exceeded. This allows load controller to
handle small, quick load variations, until the pick up limit of the
limit pressure control is reached.
EHG TO HG TRANSFER

1. Put the Tracking device OFF.

2. Slowly reduce the starting and load limiting device (SLLD) and observe the take
over by observing the reduction in load slightly. If load reduction is observed, it
means that HG is taken over the control.
3. Slowly raise the load ref. set point, to increase EHTC position set point about 97%
but <98%.
4. Then switch OFF plunger coil and observe E/H converter position 1&2 goes to
100%.
5. Then Isolate EHG by isolating the 2 Nos manual isolation levers at governing rack
(While isolating valves observe carefully the load change and control with SLLD).
6. Observe the Sec. oil pressures of HPCV & IPCV.
7. Then control the load with SLLD or Speeder gear by observing the MS pressure
carefully.

HG TO EHG TRANSFER

1. See the MS pressure set point and actual pressure deviation shall be less and in
negative side.
2. See that tacking device in OFF condition. It should be in OFF condition.
3. In this condition, plunger coil in OFF condition. Switch ON plunger coil.
4. Raise the load ref. set point to increase the EHTC position set point to 100% and
check the feed backs 1&2.
5. If everything is OK, parallel the EHG and HG Isolation manual leavers on
governing rack. Check the sec.oil pressures of HPCV & IPCV.
6. Then slowly reduce the load ref. set point (point by point) and observe the E/H
converter output and position feedbacks, load variation. When load variation
observed, start raising SLLD slowly and observe load, there should not be any
change in load. Raise the SLLD up to 85%.
7. Then put the tracking device ON. Then control the load by changing load ref. set
point.

COORDINATED MASTER CONTROL (CMC)

The unit load demand is fed to Boiler master to generate Boiler demand i.e Air & Fuel
requirement and to Turbine control to sat Turbine demand i.e MW.

The control system envisages following modes of operation that are selectable manually.

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1. Coordinated Mode : - In this mode both Boiler master and Turbine control are put in
`Auto` and unit load demand is fed to both Boiler and Turbine to compute their individual
load demands. The load demand signal will be added by Throttle pressure difference
before going to EHG & Boiler master.

2. Boiler Follow Mode : - In this mode Turbine takes load and the boiler follows. It is
adopted when Turbine control is in manual. The Turbine seta the MW load and boiler
controls throttle pressure as a follower. The load demand signal will go directly to EHG.

3. Turbine Follow Mode : - In this mode boiler takes load and the Turbine follows. It is
adopted during Runback situation. The boiler controls MW while the Turbine maintains
throttle pressure. The load demand signal will be added by throttle pressure difference
before going to EHG.

4. Manual Mode : - In this mode both boiler master and turbine controller are switched
over to manual and unit is controlled manually.

5. Throttle Pressure Control : - Fixed or variable pressure mode of operation can be

selected from the pressure setter. With Fixed pressure operation, the set point can be fixed
manually while in variable pressure operation the steam flow signal representing the load
index is programmed through function generator to generate variable pressure set point.
The actual pressure is measured by 3 redundant transmitters and median value is taken
as process value. The pressure error is given to Boiler master / Turbine control as required
by the operation mode mentioned above.

6. Run Down / Run Back : - `Run down` is switched ON automatically when the
process error i.e Feed water, Airflow etc. becomes excessive and the control element goes
to maximum position making process uncontrollable. Under the situation, unit load
demand is reduced to a valve as permitted by the process to get over the blockage.

Similarly `Run back` is initiated automatically in the event of tripping of unit auxiliaries
i.e BFP, IDF etc. to match unit demand with reduced unit capability.

`Up/ Down directional blockings` are introduced whenever process error i.e. Feed water ,
Air flow etc. becomes high or associated control element goes to maximum position to
hold the unit load demand till such time the process recovers. Under generator circuit
breaker OPEN and turbine trip the unit is run under house load operation.

Drum Level Control Scheme

The objective of this control system is to maintain the drum level to the normal water
level of the drum at all loads. At lower loads (<30%), the start up feed control valve will
be used as final control element and at higher loads, speed control of Boiler feed water
pumps will be used. Drum level is measured by 3transmitters through temperature
compensated constant head unit. The pressure compensated drum level signal may be
selected by Mid value Auto selection (MVAS) circuit of control.

Low Load:- The drum level measured signal is compared with the drum level set point.
The error signal will have a proportional, integral and differential action is the single

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element controller. This controller out put will be the position demand signal for the start
up feed control valve.

High Load:- At higher loads the start up control valve shall be closed. The steam flow
shall be measured . In order to prevent sudden response due to drum swell and shrink on
load change, a time cog unit shall be included in the steam flow signal. Temperature
compensated feed water flow signal is computed by according feed water flow at
economizer inlet and super heater spray water flow. The error signal produced between
drum level measured signal and drum level set point shall have proportional integral and
differential action in the three element drum level controller this will be added with steam
flow signal which is the feed water flow demand signal (set point). This will be compared
with the feed water flow in the feed water controller. Deviation it any will have a
proportional and integral action in the feed water controller. This controller out put will be
the designed speed signal for the individual Boiler feed water pumps speed control
system. Position indicator is provided for the motor driven BFP hydraulic coupling scoop
position indication and speed indicator is provided for turbine drive BRP speed
indication.

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Chapter-XV

EMERGENCY OPERATION

Emergency 1 : MOP COUPLING FAILURE

CAUSE : MECHANICAL FAILURE

1.
Pilot oil pressure low alarm will appears.
2.
Standby AOP will start on AUTO.
3.
HPT front bearing vibration become high.
4.
TG bearing vibration high ( >35 microns).
5.
ABS shaft vibration BRGI casing front & BRG rear
increases.
6. Speed controller output will go to maximum.
7. MW goes up due to control valve opening.
8. Turbine rpm indicator will show gradual fall.
9. Speeder gear become ineffective.
NOTE : Prolonged operation under this condition is not recommended

Emergency 2 : MAIN TURBINE EHTC FAILS HI

CAUSE : SPURIOUS ELECTRICAL MALFUNCTION

1. Plunger coil output increases.

2. EHTC fault annunciation appears.
3. Operation of HP control vlv increases a result of higher EHTC output.
4. Unit load increases unless tracking device is ON.
5. Else tracking device will take control and stabilize load.

NOTE : Turbine should be taken on Hydraulic governor to control unit load.

Emergency 3 : FIRE PROT OPERATED (fro fire protection 2)

CAUSE : SPURIOUS SIGNAL

Electrical turbine trip is initiated

1. Fire protection operated alarm comes on.

2. HP control fluid pump trip.
3. SLC Aux. oil pump 2 goes off.
4. SLC jack oil pump goes off.
5. SLC jack oil pump 3 goes off.
6. SLC turning gear goes off.
7. SGC oil supply goes off
8. SLC emergency oil pump goes on
9. Vacuum breaker opens
10. HP CTRL fluid pumps 1&2 off.
11. HP CTRL fluid pressure comes to Zero.
12. LP CTRL fluid pressure comes to Zero.
13. SLC Aux. oil pump goes off
14. SLC jack oil pump goes off
15. SLC turning gear goes off

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Emergency 4 : TURBINE TRIP DUE TO TOP / BOT DT

CAUSE : THERMO COUPLE FAULT (PARTIALLY BURNT) (BOTTOM
SENSER)
1. Differential temperature of turbine casing high.
2. Top /Bot diff temp reaches turbine trip limit (+45K)
3. Annunciation HP/IP casing diff temp High / Trip appear.
4. DT HP out cas Top/Bot high alarm appears.
5. Turbine Trips.
6. Turbine trip annunciation appears.

Emergency 5 : ALL TGDMCW PMPS TRIP

CAUSE : PRESSURE SWITCH LATCHES ON AND GETS STUCK, DUE

TO LOW SUCTION PRESSURE ON STARING 3rd DMCW PUMP
WITH DISCHARGE VALVE FULLY OPEN OR HEAVILY
PASSING.

1. Start permissive for all CEPs will go Motor cooling water flow LO.
2. All CEP bearing temperature start rising.
3. DM water pump discharge pressure decreases.
4. If DMCW pump A trips : DMCW pump A motor current decreases to Zero
DMCW pump A motor status become trip DMCW pump A motor trip.
5. If DMCW pumps B trips : DMCW pump B motor current decreases to Zero
DMCW pump B motor status becomes trip DMCW pumps B motor trip.
6. If DMCW pump C trip : DMCW pump C motor current goes to zero DMCW
pump C motor status become trip DMCW pumps C motor trip.
7. DM water pump discharge pressure decreases.
8. All bearing temperature will rise, Hydrogen gas, PW, exciter hot air temperatures
increases. Unit may trip on any of the above temperature high protection.

Emergency 6 : 220 V DC FAILURE

CAUSE : GRP DC SUPPLY FUSE BLOWN
1. All HT breaker indication lamp will stop glowing.
2. DC voltmeter will read zero.
3. Boiler will trip by FSSS.
4. Turbine will trip through MFR.
5. Generator will start motoring.
6. Feeders will trip.
7. Mills, Fans, CEPs will continue to run.
8. Generator protection will not be available.
9. Generator breaker will be operable from UCB.
10. DC pumps, fans will not be available.
11. HOTV, HORV will close.
12. Vacuum breaker will remain closed.
13. Field breaker will not be operable.
14. Extraction FCNRVs close.
15. MDBFPs can not be started if not be started if not already running.
16. TDBFPs AOPs will continue to run
17. SADCs will open full.

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18. Deaerator overflow valve opens full.

19. HP heater protection will not be available.
20. Scanner air fan outlet damper and emergency dampers will remain stay put.
21. In ATRS panel DC AOP&DC JOP will have fault lamps glowing ; if they were in
service they will stop with red fault lamp.
22. Trip device will lose supply
23. Load shedding relay will lose supply (this relay has 220v d.c supply but load
shedding solenoid is having 24v supply)

Emergency 7 : FAILURE OF + 24 V DC
CAUSE : REASON NOT KNOWN

Identification :

All ATRS panel lamps will o off.

Consequences :
1. EHC command will go to maximum, hence all control valves will open 100% load
will shoot up to maximum with CVs wide open condition. Tracking device will go
to manual. UCB console EHC command NR PR will read zero. Hydraulic
governor will become active.
2. ATRS panel supply fails.
3. All turbine protection will not be available ( Mechanical protections will be
available)
4. LP BP will not be available.
5. TSE fails
6. Hydraulic governor stating device motor control not available.
7. Lub oil temperature, HPCF temp., PW temp., coal gas temp., MAL 11,12,13,14
temp. controllers will remain stay put.
8. DC EOP will take start if the SLCs ON and lub oil pressure is less than 1.1kg/cm.
9. JOP 3 will not start even if SLC is ON before the DC failure.
10. Excitation system pulse cards will be blocked and excitation collapses.

Emergency 8 : -24V DC FALURE

CAUSE : REASON NOT KNOWN

1. ATRS console lamps will remain healthy.

2. All turbine protection and extended turbine protection will remain healthy.
3. Remote control of all turbine side drives available.
4. LPBP not available.
5. Speeder gear and starting device UCB indication not available.
6. Lub oil temp., PW temp., cold gas temp., MAL 11,12,13,14 and HPCF temp.
controllers will remain stay put.
7. EHC command will go to maximum, HP & IP secondary oil pressure will be
maximum, UCB desk indication and EHC position, NR, PR starting device,
speeder gear, indicator show zero.
8. EOP and JOP 3 can be started from the console.

NOTE : a). Confirm the starting of EOP. Trip the Turbine in case restoration of
24v

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supply not possible.

b). Restoration of 24v supply : plunger coil will remain ON & EHC will
take
original / less valve position.

Emergency 9 : UPS FAILURE

CAUSE :

1. FSSS trips the Boiler.

2. Turbine will trip on protection.
3. SADC will go full open.
4. Hydrastep indication will not be available.
5. DAS will be available
6. Annunciation system will not be available.
7. ACS supply will not be available.
8. Total instrumentation supply will go OFF.
9. Burner tilt will be stay put, feedback indication will show zero as power to ACS is
not available.
10. Analog controller goes to zero.

Emergency 10 : FD FANS LUB OIL PRESS LO

CAUSE : LUBE OIL DUPLEX FILTER CHOKED

1. DP across FD fan A/B lube oil filter becomes H1 ( > 1.2 Kg/cm) with a short
delay.
2. Annunciation FD fan cont/lube oil press low comes in (<0.8 Kg/cm)
3. FD Fan A/B lube oil pressure becomes low
4. FD Fan A/B bearing temp monitor shows increasing valve as the temperature
increases gradually with a time delay of 6-8 minutes.
5. Annunciation FD fan / motor bearing temperature high comes on after
sometime.
6. FD fan lub oil pressure adequate permissive lamp will go off
7. FD fan A/B Motor/ fan brg temperature high comes in (>90/105c)

Emergency 11 : ID FANS TRIP

CAUSE : LUBE OIL PRESSURE LOW DUE TO GRADUAL CHOKING OF
DUPLEX FILTER

1. The ctrl oil drops below 1.8Kg/sq cm. This causes the lead pump to
take auto start red ON lamp comes, green OFF lamp goes off.
2. ID fan control/lub oil pr continues to drop, the permissive lamp
hydraulic coupling oil pr adequate goes off at pr less than 1.2
Kg/cm)
3. ID fan vibration high alarm also comes
4. ID fan control oil pr low annunciation appears ( <0.8 kg/cm)
5. Running ID fan A HC oil pr low alarm appears
6. ID fan trips on hydraulic oil pr low protection bkr trip white lamp
appears ( <0.5 Kg/cm)
7. ID fan tripped/start failure annunciation appears

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8. ID fan amps drop down to zero

9. ID fan inlet vane and hydraulic coupling control is forced to
manual yellow LED glows
10. ID fan inlet outlet damper GD 19,22 starts closing and closed
green lamp comes.
11. Inlet/outlet dampers full close permissive lamp glows.
12. FD fan A trips on interlock white trip lamp glows
13. FD fan blade pitch control is force to manual and auto release
lamps starts flickering as ID fan A ctrl is not on Auto
14. FD fan tripped / start failure annunciation appears
15. FD fan discharge damper closes on auto Tripping of FD fan causes
PA fan A to trip, white trip light comes.
16. PA fan tripped / start failure annunciation appears
17. PA fan amps drop down to zero
18. Co ordinated control system (CCS) transfers to run back mode
and initial pr mode.
19. SPCM comes down to approx 60% and unit capability drops down
20. ID fan trip / FD fan trip facia glows on CCS insert
21. Unit run back in operation annunciation appears
22. Boiler master output drops down to approx. 60% value
23. Fuel master controller output also drop down
24. Fuel flow and coal flow drops down
25. Air flow also drops down as a result
26. Furnace pr fluctuates widely
27. The HP control vlv opening reduces
28. Boiler pr/temp drop down
NOTE : Loss of both ID fans at full load will cause a boiler trip.

Emergency 12 : ABNORMAL ASH BUILD UP ON REHEATER PENDENT

CAUSE : CHANGE IN ASH CHARCTERISTICS. OF COAL BEING
BURNED
CAUSES ASH TO ACCUMULATE ON THE REHEATER TUBE
SURFACES

1. Hot reheat temp. at IP turbine inlet decreases

2. The flue gas differential pr across reheater increases
3. MS/RH steam super heat low alarm appear (<480)
4. Final SH inlet and Eco. Inlet flue gas temp. increases
5. RH steam temperature control will reduce attemperation and /or raise burner tilt to
compensate for falling temp.
6. SH temperature begins to increase
7. Flue gas pressure at RH inlet decreases
8. Flue gas press. At economizer inlet decreases
9. Flue gas pressure at RAPH inlet decreases
10. Furnace pressure increases slightly
11. ID fan control will go wide open and ID fan motor overload alarm appears
12. If Existing state is retained soot blowing should be done.
13. The flue gas differential pr across reheater decereacese to normal value
14. Flue gas pressure at RH inlet gradually increases to normal value
15. Flue gas press. At economizer inlet gradually increases to normal value

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16. Flue gas pressure at RAPH inlet gradually decreases to normally value
17. Furnace pressure gradually decreases to normal value.

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Chapter-XVI

HT and LT drives Locations on Various Boards

Services on EMCC, USS and DCDB

Emergency Service Board @12.5 mts Elevation

Sl. No. Feeder Name Module No Capacity
1 Incomer from Station Service Switch Board #ODA 1F 2500A
2 DG Incomer (11DGG1 CB) 2F 2500A
3 Incomer 3 from Station Service Switch Board #ODA 3F 2500A
4 AOP-2 110KW 4F1 630A
5 Spare (From TG Cont Supply) 4F2
6 Bus PT 5F1
7 LP Bypass Cooling Fan-2 5F2 0.25 KW
8 BC Exhaust Fan-2 5F3 1KW
Control Transformer 415/415 AC 5F4
9 HP bypass OSU-1 6F1 7.5KW
10 MOT OVE-1 6F2 0.75KW
11 Oil Vapour extraction Fan -1 TD BFP-A 6F3 0.37KW
12 Lube oil pump -1 TDBFP-A 6F4
13 HPBYPASS OSU-2 7F1 7.5KW
14 APH-ALOP-A support bearing 7F2 0.75KW
15 Oil Vapour Extraction fan-2 TDBFP-A 7F3 0.37KW
16 Lube oil Pump TDBFP-A 7F4 90KW
17 SOP-2 Air side 8F1 7.5KW
18 APH-ALOP-A Guide bearing 8F2 0.75KW
19 Oil vapour extraction fan-1 TDBFP-B 8F3 0.37KW
20 Lube oil Pump -1 TDBFP-B 8F4 90kW
21 Feeder for Turbine valve DB-2 9F1 26.54KW
22 Spare 9F2
23 Marshalling Compartment 9F3
24 Spare 10F1
25 AH-BLOP-A Support bearing 10F2 0.75KW
26 Oil Vapour Extraction fan -2 TDBFP-B 10F3 0.375KW
27 Lube oil pump TDBFP-B 10F4 90KW
28 Jacking oil Pump TDBFP-A 11F1 3.7KW
29 AH-B LOP -A Guide bearing 11F2 0.75KW
30 LP bypass Recirculation -2 11F3 0.37KW
31 Spare 11F4 90KW
32 Spare 12F1 3.7KW
33 Spare 12F2 0.75KW
34 G.S.Steam Valve Unit PUMP 12F3 0.37KW
35 Jacking oil Pump -1(ACJOP) 12F4
36 Jacking Oil PUMP TDBFP-B 13F1 3.7KW
37 Leak Steam Pump 13F2 0.37KW
38 Spare 13F3
39 Spare 13F4
40 Feeder for 220V Unit battery charger 5R1 250A

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

41 LP bypass-2 control fluid pump-2 5R2 7.5KW

42 ACSOP Starter cabinet 5R3 32A
43 Feeder for plant communication 5R4 32A
44 ATRS DDCMIS panel supply 5R5
45 Space heating transformer 415/240VAC 5R6 5KVA
46 Feeder for220V Station battery charger 6R1 250A
47 Feeder for 220V Stand by float battery charger 6R2
48 Feedr for UPS ( main fine system protection) UPS-1 6R3 32A
49 Feedr for UPS ( main fine system protection) UPS-2 6R4 32A
50 Feeder for single phase outlets 6R5
51 UPS 7R1 85KW
52 Spare 7R2
53 Feeder for UPS (Main Fine system protection 32A 7R3 SCVS
54 Primary water pump-2 7R4
55 Feeder for Boiler valve and Damper 2 8R1 113.37KW
56 Air preheater-1(A) 8R2
57 Scanner Air fans 8R3
58 Spare 8R4
59 Feeder for 24V battery charger (SG/TG)-1 9R1 60KW
60 Air heater-2 (B) 9R2 18.5KW
61 Marshalling Compartment 9R3
62 Feeder 24V battery Charger(SG/TG)-2 60KW 10R1
63 Spare 10R2
64 Spare 10R3
65 AOP motor for MBFP 10R4 30KW
66 Feeder for 24V Battery Charger (BOP-1) 11R1 60KW
67 Feeder for 24V battery charger (BOP-2) 11R2 60KW
68 Main Steam Bypass valve S141 (MSV4) 11R3 2.2KW
69 Main Steam Bypass valve S142 (MSV6) 11R4 2.2KW
70 Spare 11R5
71 Emergency lighting 12R1
72 Spare 12R2
73 Main steam Bypass valve S131 (MSV3) 12R3 2.2KW
74 Main steam Bypass Valve S132 (MSV5) 12R4 2.2KW
75 Air Preheater Solenoid Valve 12R5 2KW
76 240V AC supply source for SOP & starter cabinet 12R5
77 24 V batter y charger (CW Pump) 12R6 2KW
78 TG BLDG Elevator Passengercum Goods 13R1 37KW
79 Spare 13R2
80 Feeder for 24V Battery charger Fuel Oil 13R3 2KW
81 TD BFP -A Barring gear 13R4
82 TDBFP-B Barring gear 13R5
83 Turbine Barring Gear v/V 13R6
84 Exhaust fans Battery Room 13R7

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

KTPS-VI Stage(1X 500 MW) , Palvancha

SSS MCC 415V at Mtrs Elevation
Sl.No Feeder name Module No. Capacity
1 Emergency SWBD-1 3F1,3F2,3F3 2500 A
2 TG BLDG AC MCC-1 2F1 1250 A
3 Chlorination Plant 2F2 1250 A
4 Clean Oil Transfer Pump 6F1 3.7 KW
5 DG room floor drain Transfer Pump-1 6F2 1.3 KW
6 Transformer O-W Transfer Pump-1 6F3 1.3 KW
7 TG Building luboil Transfer Pump-1 6F4 1.3 KW
8 TG Hall EOT Crane (72KW) 5F1 250 A
9 GT CK Power Supply-1(40KW) 5R1 125 A
10 Welding DB (Compressor Bldg) (30KW) 6R1 125 A
11 11BB SWBD Space Heating (30KW) 5R2 63 A
12 11BA SWBD Space Heating (30KW) 5R3 63 A
13 Air Dryer#1(15KW) 6F5 32A
14 0BB SWBD Space Heating (15KW) 6F6 32 A
15 0BA SWBD Space Heating (15KW) 6F7 32 A
16 0CB SWBD Space Heating (15KW) 7F2 32 A
17 11BB SWBD I/C SPB Space Heating (10KW) 8F5 32 A
18 0BX SWBD I/C SPB Space Heating (10KW) 8F6 32 A
19 11CA SWBD OCA Tie I/C SPB Space Heating (10KW) 9F2 32 A
20 0CB SWBD I/C SPB Space Heating (10KW) 5R5 32 A
21 11BB SWBD 0BB Tie I/C SPB Space Heating (10KW) 5R6 32 A
22 0BX SWBD 0BA Tie I/C SPB Space Heating (10KW) 6R2 32 A
23 11CB SWBD I/C SPB Space Heating (10KW) 6R3 32 A
24 V/S Crane in Air Compressor House (6KW) 6R4 32 A
Electric Hoist in Emergency DG room layout-Air
25 Comp.room(5.3KW) 6R5 32 A
26 Compressor Control Panel-2 (5KW) 6R6 32 A
27 Compressor Control Panel-4 (5KW) 7R2 32 A
28 Compressor Control Panel-6 (5KW) 7R3 32 A
29 ST-2CCC Power Supply-1 (5KW) 7R4 32 A
30 ST-2CCC Power Supply-2 (5KW) 7R5 32 A
31 UPS Compressed air System (UPS-2) (5KW) 7R6 32 A
32 Ventilation Service Building (5KW) 8R2 32 A
33 UT 11BAT01 CCC Power Supply-1 (3KW) 8R3 32 A
34 UAT 11CAT01 CCC Power Supply-1 (3KW) 8R4 32 A
35 SAT 0CAT01 CCC Power Supply-1 (3KW) 8R5 32 A
36 UT 11BAT01 CCC Power Supply-2 (3KW) 8R6 32 A
37 UAT 11CAT01 CCC Power Supply-2 (3KW) 8R7 32 A
38 SAT 0CAT01 CCC Power Supply-2 (3KW) 8R8 32 A
39 Single phase DB outlets (5KW) 7R7 32 A
40 Single phase DB TG Building (5KW) 8R9 32 A
41 Space Heating T/F-1 415/240V AC 5R7 5 KVA
42 Test Bus Control T/F-1 415/240V 6R7 1 KVA
43 Motor for Ball Recirculating Pump-1 8F3 5.5KW
44 Ball Seperator Screen Actuator A-1 5F3 1.1 KW

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

45 Ball Seperator Screen Actuator B-1 9F3 1.1 KW

46 Feeder for OLTCS System panel (15KW) 9R2 32 A
47 Condenser inlet ISOL V/V-1 (5KW) 9R3 32 A
48 Condenser outlet ISOL V/V-1 (5KW) 9R4 32 A
49 Feeder for UPS(OLTCS) UPS-1 9R5 32 A
50 Feeder for UPS(OLTCS) SCVS-1 9R6 32 A
51 Feeder for lighting T/F-1 (TG Bldg) (175KVA) 9R7 400A
52 Feeder for lighting T/F-1 (Boiler house) (150KVA) 8F1
53 Bus PT-1 9F1
54 Incoming-1 from station SWBD#0BA 1F1,1F2,1F3 4000 A
55 Bus Coupler 10F1,10F2,10F3 4000 A
56 Incoming-2 from station SWBD#0BB 19F1,19F2,19F3 4000 A
57 Bus PT-2 11F1
58 OBX SWBD Space Heating 11F2
59 Ball Seperator Screen Actuator A-2 11F3 1.1 KW
60 Ball Seperator Screen Actuator B-2 11F4 1.1 KW
61 Space Heating T/F-2 415/240V AC 15R7 5 KVA
62 Test Bus Control T/F-2 415/240V 14R7 1 KVA
63 Emergency SWBD-2 17F1,17F2,17F3 2500 A
64 TG Building AC MCC-2 16F1,16F2,16F4 1250 A
65 Dirty oil Transfer Pump 12F2 3.7 KW
66 220V Station Battery Charger 12F1
67 Air Dryer#2 (15KW) 12F4 32 A
68 Marshalling bay 7F4
69 Feeder for LTG Transformer-2(BH) 13F1 150 KVA
70 Feeder for LTG Transformer-2(TG Bldg)) 11R7 175 KVA
71 24V SG/TG Battery Charger-1 15F1
72 24V SG/TG Battery Charger-2 7R1
73 Compressor Control Panel-1 11R5
74 Compressor Control Panel-3 11R6
75 50MVA ST-1 CCC Power Supply-1 12R2
76 50MVA ST-1 CCC Power Supply-2 12R3
77 UPS Compressed air System (UPS-1) (5KW) 12R5 5 KW
78 UPS air system CH 12R4
79 UAT 11CBT01 CCC Power Supply 12R7 3 KW
80 Single phase DB outlets (5KW) 12R8
81 GT CK Power Supply-2(40KW) 13R1 40 KW
82 SAT OCBT01 Power Supply-1 13R2 3 KW
83 UAT 11CBT01 Power Supply-2 13R4 3 KW
84 SAT OCBT01 Power Supply-2 13R5 3 KW
85 Common PLC Control Panel 13R6 1.25KW
86 Compressor Control Panel-5 13R8
87 24V BOP Charger-2 14R1
88 Condenser Inlet ISOL V/V-2 (5KW) 14R4 5 KW
89 Condenser Outlet ISOL V/V-2 (5KW) 14R5 5 KW
90 11CB SWBD Space Heating (30KW) 15R2 30KW
91 11CA SWBD Space Heating (30KW) 15R3 30KW
KTPS-VI Stage(1X 500 MW) , Palvancha
UNIT SERVICE SWITCH BOARD

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

Sl.No Feeder name Module No. Capacity

1 Incoming from-1 Unit Service T/F 11DAT01 1F1,1F2,1F3 4000 A
2 Feeder for turbine MCC-1 2F1,2F2,2F3 630 A
3 Feeder for turbine MCC-1 3F1, 3F2, 3F3 1600 A
4 Spare Breaker 4F1, 4F2, 4F3 1600 A
5 BUS PT-1 5F1 415 V
6 Feeder for 220V Battery Charger (250A) 5F2 250 A
7 Feeder for Boiler ACDB-1 5F3 250 A
8 Spare module 6F2 32 A
9 Feeder for USP-1 (Unit Service Board) (250A) 6F3 250 A
10 Space Heating Transformer-1 415/240 V AC 6F4 3 KVA
11 Bus Coupler 7F1, 7F2, 7F3 4000 A
12 Bus PT-2 8F1 415 V
13 Feeder for Boiler ACDB-2 8F2 250 A
14 Feeder for USP-2 (Unit Service Board) (250A) 8F3 250 A
15 Spare module 9F3 250 A
16 Space Heating Transformer-2 415/240 V AC 9F4 3 KVA
17 Feeder for Boiler MCC-2 10F1, 630 A
18 Spare breaker 10F2 630 A
19 Feeder for Turbine MCC-2 11F1, 11F2, 11F3 1600 A
20 Spare breaker 12F1, 12F2, 12F3 1601 A
21 Incoming from-2 Unit Service T/F 11DAT02 13F1, 13F2, 13F3 4000 A
22
23 Spare module 5R1 250 A
24 Feeder for Single phase outlets 5R5 32 A
25 Feeder for Boiler valve& damper-1 6R2 125 A
26 Spare module 6R5 125 A
27 Spare module 8R2 125 A
28 Feeder for Single phase DB 8R3 32 A
29 Feeder for Turbine volve DB-1 9R2 125 A
30 Spare module 9R3 32 A
31 Feeder for Single phase outlets 9R5 32 A

220V DCDCB FOR UNIT AND STATION SWITCH BOARD

220V DCDCB FOR UNIT AND STATION SWITCH BOARD

1FA 415V Switch Yard PMCC control supply-1

1FB DC Supply-1 for electric control panel
1FC 11 KV Station Switch Board OBA control Supply-1
1FD Spare
1FE Incomer from DC Station Battery charge

2FA
2FB 11KV Station switch board OBB Control Supply-1
2FC 11KV Station switch board OBX Control Supply-1
2FD 3.3KV Station Aux. switch board OCA Control Supply-1
2FE 3.3KV Station Aux. switch board OCB Control Supply-1
2FF Station Transformer-1 CCC Supply
2FG Station Transformer-1 RTCC Supply
2FH Emergency Lighting

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

3FA Scanner Air Fan DC Starter Box

3FB MSSV Left
3FC 415V ESP Supply Board control supply-1 A-Pass
3FD 415V ESP Supply Board control supply-1 B-Pass
3FE 415V ESP Supply Board control supply-1 C-Pass
3FF Electro magntic relief valve remote marshalling TB
3FG VFD Control for ID Fan A
3FH GT CCC Supply
3FI UAT CCC Supply

4FB 3.3KV Unit Switch Board 1CA Control Supply-1

4FC Spare
4FD SV of VAC Breaker
4FE Sequence Tripping Device
4FH Spare

5FA Bus Coupler

5FB Incomer from D.C. Station Battery Charger

6FA Bus Coupler

6FB TG Vent MCC Control Supply-2
6FC 415V BOP PMCC Control Supply-2
6FD 415V ETP PMCC Control Supply-2
6FE 11 KV Unit Switch Board Control Supply-2
6FF CRH NRV Test Solenoid Valve

7FA Spare
7FB EOP
7FC TDBFP-B EOP
7FD Spare

8FA 3.3KV Unit Switch Board 1CA Control Supply-2

8FB 3.3KV Unit Switch Board 1CB Control Supply-1
8FC GT 1B Y-Ph CCC Supply
8FD GT 1C B-Ph CCC Supply
8FE UAT(1BB T01) CCC Supply
8FF 415V SILO Hydrobin PMCC Control Supply-2
8FG 415V Switchyard PMCC Control Supply-2
8FH 415V Station Service SWBD Control Supply-2
8FI 415V Fire water MCC Control Supply-2
8FJ 415V PTP PMCC control Supply-2
8FK 415V ESP Board control Supply-2 A-Pass
8FL SH Electric relief Valve Right

9FA Electro magnetic relief valve remote marshalling TB

9FB ATRS-1 &TP for BFPTD-A
9FC ATRS-1 &TP for BFPTD-B
9FD Solenoid valve-5 TDBFP-B
9FE Solenoid valve-6 TDBFP-B
9FF Solenoid valve-7 TDBFP-B
9FG Incomer from DC Unit Battery Charger

1RA
1RB Fire Water MCC-1
1RC ID FO-1
1RD SSS-1
1RE TG AC MCC-1
1RF TG vent MCC-1
1RG BOP-1

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

1RH CHP & AHP-1

1RI DAVR
1RJ DAVR-3

2R
2RA TDBFP-A EOP
2RB Spare
2RC PTP-1
2RD Silo,Hydrobin,PMCC
2RE SAT-1
2RF ETP-1
2RG Spare

3R
3RA SOP
3RB 11kv - 11BA-1
3RC 11BB-1
3RD UAT-1
3RE 11CB-1
3RF USS-1
3RG Boiler MCC-1
3RH Turbine MCC-1
3RI EMC-1
3RJ D Pass Control Supply

4R
4RA ATRS-SGC Turbine& SLL Drain
4RB ATRS-SGC Oil Supply Hp Controls Fluid
4RC Sol Valve-3 TDBFP-A
4RD Sol Valve-4 TDBFP-A
4RE Sol Valve-5 TDBFP-A
4RF Sol Valve-6 TDBFP-A
4RG Sol Valve-7 TDBFP-A
4RH Sol Valve-8 TDBFP-A
4RI Load shedding relay & Auto synchroniser
4RJ GCP-GRP Control supply
4RK MSSV left

5R
5RA Nil
5RB
5RC
5RD
5RE
5RF
5RG Alarm module
5RH Incomer from AHP-6R4

6R
6RA Sol valve-1 TDBFP-B
6RB Sol valve-2 TDBFP-B
6RC Sol valve-3 TDBFP-B
6RD Sol valve-4 TDBFP-B
6RE Spare
6RF Jacking oil pump-2

7R
7RA OBA-2
7RB OBB-2
7RC OBX-2
7RD OCA-2

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

7RE ATRS
7RF BTS-1 Source-2
7RG SH electric Relief valve left
7RH GCP & GRP
7RI DAVR
7RJ VFD control for ID fan
7RK Scanner Air fan DC motor

8R
8RA 11BB-2
8RB OCB-2
8RC ST-280 MVA CCC supply
8RD ST-2 RTCC supply
8RE SAT-2 CCC supply
8RF TG AC MCC CS-2
8RG ID & FO MCC
8RH UAT-CCC supply (UAT-2)
8RI ESP Board CS-2
8RJ D Pass
8RK AHP & CHP Control supply-2
8RL FSSS

9R
9RA Sol valve-8 TDBFP-B
9RB C-Pass-1
9RC USS-2
9RD B Pass
9RE Boiler MCC-2
9RF Turbine MCC-2
9RG EMC Control supply-2
9RH ECP-2
9RI
9RJ
9RK
9RL

Annexure-I

Name Plate Details of HT and Some other imp. Motors:

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

MDBFP-C

Make :- BHEL
Specification :- IS325
Frame :- 11F7842
Duty :- Continuous
KW :- 10,000
RPM :- 1,495
Stator Volts :- 11,000
Rotor Volts :- ------
Temp Rise :- 70oC
Insulation Class :- F
Phase :- 3
Freq :- 50 HZ
Connection :- Stator Rotor :-
Amb-Temp :- 50oC
Stator Amps :- 605A
Rotor Amps :- -----
Rotor type :- SQ Cage - Rotor
DE Bearing :- 220X140
NDE Bearing :- Q220X140
Deg.Of Protection :- IP 55
Serial. No :- 46244A 421-41-01
Division :- Bhopal
Year :- 2009
Weight :- 23,000Kg.

P.A. FAN:- 11A&11B

Make :- BHEL
Specification :- IS-325
Frame :- ILA7904-4
Duty :- Continuous
KW :- 2650
RPM :- 1494
Stator Volts :- 11,000
Rotor Volts :- ------
Temp rise :- 70oC
Ins Class :- F
Phase :- 3
Frequency :- 50HZ
Connection :- [STAR]
Amb- temp :- 50oC
Stator Amp :- 152 A
Rotor type :- Cage type
DE Bearing-1 :- NU 236m
DE Bearing-2 :- 6236 C3
NDE Bearing :- NU 232 m
Deg-of Protection :- IP 55
Division :- Bhopal
Year :- 2008
Weight :- 3500 Kg
Cooling Code :- IC 0151

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

F.D. FAN:- 11A&11B

Make :- BHEL
Frame :- 11 A 7714 68
Duty :- Continuous
KW :- 1025
Stator Volts :- 3300 V
Stator Amps :- 229 A
Rpm :- 993
Phase :- 3
Frequency :- 50 HZ
Insulation Class :- F
Specification :- IS 325 1996
Connection :- [STAR]
Amb temp :- 50oC
Deg.Of Protection :- IP 55
DE Bearing-1 :- NU 230 m
DE Bearing-2 :- 6230 C3
NDE Bearing :- NU 226 m
Year :- 2009
Weight :- 7550 Kg
Division :- Bhopal
Rotor type :- SQ-Cage

ID FAN-A/B
FRAME. : ILA4344
Phase/freq : 3ph/50HZ
Stator Voltage : 2X2300V
Stator amps : 4X461
EDCC amps : 291A
rpm : 505
Connection : STAR
Type : synchronous motor
Rating : 3000KW

C .W. PUMP:- 11A,11B,11C&11D

MILL MOTOR:- 11A,11B,11C,11D,11E,11F&11G

Make:- BHEL
Frame :- ILA 7636 6
Duty :- Continuous
KW :- 525
Stator Volts :- 3300 V
Stator Amps :- 130 A
Rpm :- 985
Phase :- 3
Frequency :- 50HZ
Insulation class :- F
Specification :- IS 325 1996
Connection :- [STAR]
Amb temp :- 50oC
DE Bearing-1 :- NU 228 m
DE Bearing-2 :- 6228 C3

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

NDE Bearing :- NU 224 m

Weight :- 7500 Kg
Division :- Bhopal
Year :- 2009

C.E.P:- 11A,11B&11C
Make:- BHEL
Frame :- 1LA7634-4
Duty :- Continuous
KW :- 900
Stator Volts :- 3300V
Stator Amps :- 194A
Rpm :- 1486
Phase :- 3
Hz :- 50
Insulation class :- F
Specifications :- 1s : 325-1996
Connection :- [STAR]
Amb-temp :- 50oC
Deg- of Protection :- IP55
DE Bearing :- 6226 C3
NDE Bearing :- 7322 B
Year :- 2009
Weight :- 5500Kg
Division :- cage

SGDMCW PUMP-A/B
FRAME. : ILA7500-4
Phase/freq : 3ph/50HZ
Stator Voltage : 3300V
Stator amps : 229
rpm : 1483
Connection : STAR
Type : induction motor
Rating : 150KW

TGDMCW PUMP-A/B/C
FRAME. : ILA7500-4
Phase/freq : 3ph/50HZ
Stator Voltage : 3300V
Stator amps : 55
rpm :1479
Connection : STAR
Type : induction motor
Rating : 250 KW

NAME PLATE DETAILS OF SOME IMP. MOTORS

Equipment Area Capacity(KW) Voltage(V) Current(A) Flow(m3/hr) Press
PA Fan SG 2500 11 152 627 13
FD Fan SG 1025 3.3 229 835 4
ACWP CWPH 340 3.3 92 2200 4.8

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

CWP CWPH 1850 11 136 19500 2.5

DM Tr Pump DMPH 30 415 54.5 100
Hotwell Emg . Pump DMPH 45 415 77 210
Boiler Fill Pump DMPH 132 415 227 150 2
CPU Reg. Pump DMPH 9.3 415 18.8 49.9
BCW Pump SG 365 3.3 86 2884 30
Vacuum Pump TG 160 306
IAC Comp House 300 3.3 38.3
SAC Comp House 300 3.3 38.3
APH Motor SG 18.53 415 33.2
Scanner Fan AC SG 5.5 415 10.1
Scanner Fan DC SG 5.5 415 30
CEP SG 900 3.3 196 830 2
Control Fluid Pump TG 121 415 200 85.8 3
LDO Pump SG 18.5 415 32.5 13.26
HFO Pump SG 75 415 128 50.36
TGDMCW Pump TG 250 3.3 55 1548
SGDMCW Pump SG 150 3.3 38 572
AOP TG 110 415 173 360 9.0
EOP TG 13 220 97 2.5
JOP AC TG 60 415 95 120 175
JOP DC TG 60 220 310 120 175
PWP TG 37 415 63 70 8.0
Hydrant Pump TG 150 415 255 273 109
Spray Pump TG 150 415 255 273 109
Jocky Pimp TG 15.5 220 37.2 25 114.6
TAC BOP 200 415 40 48.59 4.5
Ash Slurry Pump BOP 160 415 275 680 47
HP Pump BOP 90 415 154 400 47
LP Pump BOP 11 415 20.1 25 20
Ref.Pump BOP 37 415 65 280 25
Seal water BOP 18.5 415 23.5 20 90mm
CT Makeup pump BOP 75 415 131 750 22.43
APH back wash
pump BOP 132 415 227 275 20.33
FBW BOP 45 415 81 750 13.44
Service water pump BOP 110 415 190 275 90.34

Annexure-II

SAFETY VALVES SETTING OF UNIT-11 OF KTPS-VI STAGE

Locati Tag No. Name & Designed Pr. Actual Pr. %B Relievin % of Silen
on Make (Kg/Cm2) (Kg/Cm2) D g Cap, Evap cer
(CONSO Kg/Hr orati

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 KOTHAGUDEM THERMAL POWER STATION-VI Stage (1X500MW )
Operations Manual, Version: 01

Ope Clos Ope Clos

L) on
n e n e
Drum SV001(RR) 1750 WB 209.0 200.6 209.5 200.0 4 212800 85.18 YES
SV002(LR) 1750 WB 211.1 200.5 211.1 Trevi 5 214928 85.18 NO
SV003(RF) 1750 WB 213.2 202.5 213.2 Trevi 5 217056 85.18 NO
SV004(LF) 1750 WB 213.2 202.5 Pending 5 217056 85.18 NO
SV005(RM
1740 WB 215.3 204.5 215.3 Trevi 5 261228 85.18 NO
)
SV006(LM) 1740 WB 215.3 204.5 215.3 Trevi 5 261228 85.18 NO
SH SV007(left) 1740 WB 188.5 181.0 186.7 180.3 4 187670 23.09 YES
SV008(rig
1740 WB 188.5 181.0 189.0 179.5 4 187670 23.09 YES
ht)
SH 1538VX-
SV009(left) 184.7 180.3 Pending 2.4 86110 10.6 YES
ERV 10W
SV010(rig 1538VX-
184.7 180.3 Pending 2.4 86110 10.6 YES
ht) 10W
CRH SV011(left) 1786 WB 52.4 49.8 51.3 48.7 5 207461 59.85 NO
SV012(rig
1786 WB 52.4 49.8 51.7 50.0 5 207461 59.85 NO
ht)
SV013(left) 1786 WB 54.0 51.3 52.8 49.8 5 2141148 59.85 NO
SV014(rig
1786 WB 54.0 51.3 52.9 49.2 5 2141148 59.85 NO
ht)
HRH SV015(left) 1786 WB 49.0 46.6 48.5 46.3 5 162601 46.89 YES
SV016(rig
1786 WB 49.0 46.6 49.0 46.6 5 162601 46.89 YES
ht)
SV017(left) 1786 WB 50.5 48.0 49.6 47.9 5 167698 46.89 NO
SV018(rig
1786 WB 50.5 48.0 50.9 47.8 5 167698 46.89 NO
ht)
Will be done
1811LC
SB SV023 40.0 38.4 during SB 4 29970 NO
6X
opn.
Aux
ASV32 17.50 17.4
PRDS
ASV33 18.80 18.9
ASV34 19.25 19.9
ASV64 19.50 20.3
Dearat
FST(L1) 8.50 8.5
or
FST(L2) 9.00 9.0
FST(R1) 8.50 8.5
FST(R2) 9.00 9.0
Dearator(t
8.50 8.5
op1)
Dearator(t
8.50 8.5
op2)
Note:- All safety valves of Drum and MS have been tested with
Hydro devise (Trevi method)

Annexure-III

TURBO-DRIVEN BOILER FEED PUMP

1. TURBINE INFORMATION

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Casing:
The casing serves to contain and support the stationary and rotating parts of the
turbine. The casing has been horizontally split in the plane of the shaft centerline.
The vertical joint is made up permanently at the factory. The upper half of the
casing contains the high pressure steam chest, the steam admission valve seats and
the upper halves of the diaphragms.
The casing supports have been designed to minimize effects of thermal expansion
and hold the turbine in axial alignment.

Shaft Packing:
Shaft packings are provided at both ends of the turbine casing where the rotor
passes through it. These packings are of the metal labyrinth type and they are piped
to and work in conjunction with the steam seal system to minimize leakage of
steam from or air into the turbine case along the shaft.
Each labyrinth ring is composed of four spring loa ded, butt jointed segments
which are recessed into bores of the labyrinth housings or turbine casing.

Oil Guards:
Shaft oil guards serve to prevent leakage of oil from the bearings along the shaft.
The horizantally split oil guards are fitted into grooves in the lower bearing
brackets and the bearing bracket caps.

Diaphragms:
The diaphragms, mounted in grooves in the turbine casing act as partitions to
divide the turbine into separate compartments for each stage. They contain
stationary nozzles which direct the steam into the following rotating stages. Each
diaphragm is horizontal split through the plane of the shaft centerline.

A drain hole is drilled through the bottom of each diaphragm to remove any
condensate.

Stage Packing:
To minimize steam leaka ge between turbine stages where the shaft passes through
each diaphragm, labyrinth type metal packing is used. These stage packings each
consist of a number of segments. The segments are mounted in grooves in the
inner periphery of the diaphragms.

Main Bearings:
The main bearings supporting the rotor, are of the babbit-lined, multiple tilting pad
type. The bearings are similar in construction and are pressure lubricated.

Thurst Bearing:
The rotor is axially positioned by a double acting thurst bearing of the multiple-
shoe, self-aligning and equalizing type. This thrust bearing is mounted in the front
bearing pedestal next to the radial bearing.

Rotor:
The turbine rotor consists essentially of a shaft with wheels and blades, coupling
hubs, a thurst collar and a spur gear used for the electronic governor and used for the
tachometer. The spur gear has been mounted to the turbine rotor on high pressure
end.

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Turning Gear:
An electric motor driven "B.H.S." turning gear type RDV-2 is furnished for
turning the rotor at a speed of 100 rpm upon start up and after stopping the turbine,
in order to maintain an equal heat distribution in the turbine rotor. For manual
operation, the free end of the electric motor has been provided with a square. A
ratchet wrench that fits on this square, can be used for manual turning. The
turning gear can only be started when the turbine is at stand still.

a) Automatic start - When the turbine is tripped, the turbine is at stand still
and the disconnect coupling is at disengaged position, the release solenoid is
shortly energised. This releases the swinging arm from the latch. The pinion will
come down on the toothed wheel rim, which is mounted on the turbine shaft.
When the pinion and toothed wheel rim engage, (detected by a limit switch) the gear
motor will be started. When the pinion and the toothed wheel rim do not engage
within a set time, operational mode will change from "automatic" to "off". One must
then locally engage the mentioned gears by slight turning of the hand wheel of the
electric motor. Now press push button "on" to start turning gear.

b) Start by push button command - This start is similar to the automatic start
except that the disconnect coupling is not nece ssarily disengaged position.

c) Automatic stop at starting the turbine - When the turbine gear is driving the
turbine rotor the forces on the teeth of the pinion and the toothed wheel rim are
directed such that engagement is positively maintained. Now when turbine is
started and speed increases, the turbine will have the tendency to drive the
turning gear. Due to this the forces on the teeth of the pinion are in such
direction as to disengage the turning gear. This causes an immediate and
automatic release of the pinion from the toothed wheel rim through the lift of the
swinging arm. This a rm catches a latch and remains in disengaged position.
Disengagement of the gear is detected by a limit switch which causes the E-motor
to be switched off. The turning gear can also be stopped by:

i) Push button "off". This stops E-motor directly.

ii) By lowering the swing lever. The E-motor is stopped now via the
limit switch.
iii) At lack of lube oil pressure the turning gear motor is automatically
stopped.

Axial Position Device:

At thurst bearing end the turbine is provided with two Bently Nevada probes to
sense the axial position of the rotor. These probes, together with their connected
instruments, will give electrical alarm and a trip signals, when the axial
displacement becomes greater than a preset value. A dual voting system is used
to reduce the possibility of a false alarm or shut down due to instrument failure.
Simply stated a dual voting system consists of two transducers observing the same
variable and their respective readouts. When a specific event occurs, both readouts
must agree before an alarm or a trip is allowed.

Rotor Vibration Device:

Two Bently Nevada probes are mounted at right angles in the bearing bracket cap
over each end of the turbine shaft. These probes, together with their connected

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instrumentation, will measure the shaft vibration and total run out and will give
an electrical alarm signal, when the vibration level rises above a preset value.

Differential Expansion Device:

This device provides continuous monitoring of rotor growth relative to the turbine
casing. On each side of the turning gear wheel a probe has been mounted which
will give , together with the connected instruments, an alarm signal if the
relative rotor displacement becomes greater than a preset value.

Case Expansion Device:

A Bently Nevada probe has been mounted on the high pressure end of the turbine to
indicate the thermal expansion during warming up.

Speed Indicator:
The turbine is provided with an electric speed indicator consisting of a gear, a
probe, a transmitter and an indicator. The probe is mounted on the front bearing
housing and it senses the rotation of a gear with 60 teeth. The gear is mounted
on the turbine shaft. The probe produces a pulse every time a tooth passes through
its magnetic field. These pulses are converted into a "mA" signal that is fed into the
indicator.

Breakable Diaphragm:
A breakable diaphragm has been installed on the top of the exhaust casing. It
consists of a rupture disk clamped between flanges. The disk will burst if the
turbine exhaust gauge pressure will rise to 0.5 bar. Exhaust steam will pass then
to atmosphere, reducing the excess exhaust pressure.

Seal Steam System:

This system is designed to prevent leaka ge of steam from, or of air into the turbine.
the system is used on the turbine when it is started up and while it is in operation.
the pressure in the steam seal line is controlled by the seal steam control valve.
During starting preparations the vacuum in the turbine would tend to suck air into
the turbine. This is prevented however, by forming seals of steam in the sealing
pockets of the shaft pac king at the inlet and exhaust end of the turbine. During
normal operation the first stage pressure causes steam to leak outward through the
innermost gland packing at high pressure end of the turbine. Upon reaching the first
steam seal pocket, most of this steam, together with leakage steam from the HP
glands of the control valves, is piped through this steam seal line to maintain a
positive pressure at the exhaust end sealing pocket. If the seal steam system pressure
rises, steam is dumped, via the seal steam control valve, to a flash tank.
Seal steam is prevented from escaping to atmosphere by maintaining a
slight vacuum in the leak off pockets. This pockets are connected with the leak off
system of the main turbine. Leakage steam from the glands of the trip throttle valves
and the LP glands at the control valves, is also sucked off by this main turbine leak
off system.

Steam Drain System:

The steam drains supplement the previously described internal turbine drains and
are used to drain water from the turbine, the seal ste am line, the HP control
valve casing and from the trip throttle valves before the turbine started and while
it is running. Essentially this system c onsist of pipes and it is valved where required.

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These valves are opened during starting to remove any accumulation of condensate
and they are closed when the equipment is in operation.

2. PUMP INFORMATION
General:
The pump is a multi-stage type having all impellers mounted in series and facing in
the same direction. Liquid enters the suction nozzle, passes through the impellers
and leaves through the discharge nozzle at opposite end of the casing. Each
impeller operates within a diffuser which converts velocity to pressure. This
process is repeated in the successive stages, each stage adding an increment of
pressure. Discharge pressure is admitted to areas between inner and outer casing
thus utilizing hydraulic forces to maintain sealing of individual stage joints and of
the internal joints between the inner a nd outer c asing.

Outer Casing:
The outer casing is a forged cylindrical shell or barrel, which has nozzles to conduct
the pumped fluid to and from the inner casing and rotor.

Inner Assembly:
The inner assembly consists of diaphragms, diffusers and a rotor which are
assembled together to form a single assembly. The inner assembly is positioned
into the outer casing by a cylindrical fit and held in that position by bolts.

Inner Casing:
The inner casing portion of the inner a ssembly consists of a combination of chrome
steel diaphragms & diffusers. These form the hydraulic passages between successive
stages.
Rotating Element:
The rotor basically consists of several impellers, a thrust collar, shaft sleeves and
a balance drum mounted on the chrome steel shaft.

End Head:
The end head closes the outer casing a fter insertion of the inner assembly. The end
head supports the outboard seal housing and the outboard bearing housing.

Gaskets:
The joint between the end head and outer casing is the sole high pressure outside
joint in the pump. This joint contains a confined flexitallic gasket which has been
compressed by the heavy alloy steel bolting which secures the end head to the
outer casing. This flexible gasket assures proper sealing even during transient
temperature changes. There are no gaskets used at the internal high pressure joints
nor at the inter stage joints.

Axial Balancing Device:

The pressure difference acting on each impeller produces an axial force towards its
inlet. The sum of the individual impeller thrust forces is counteracted by the axial
balancing device. This device consists of a stationary balance sleeve and a rotating
balance drum. The labyrinth teeth of the ba lance drum run in close clearance with

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the bore of the balance sleeve, acting as a pressure reducing bushing between the
pump discharge and pump inlet pressures. The water, which leaks past the balance
drum, is returned to the pump suction. The diameter of the balance drum and the
pressures acting on it are such that an axial force is produced on the rotor,
which counteracts the axial force caused by the impellers. For design reasons the
axial force of the impellers is not fully counteracted by the down force for the whole
of the working area of the pump. Therefore a double acting thrust bearing has been
installed which takes up the resultant axial force. The stationary balance sleeve is
bolted to the end head and sealed by a confined flexitallic gasket. The rotating
balance drum is mounted with a shrink fit on a tapered portion of the shaft using a
hydraulic tool. This type of mounting securely locks the balance drum against
rotational and axial movement. In addition the drum is held in place by a retaining
ring fitted in a groove in the shaft and shouldered against the drum. An "O" ring
and a back-up ring are fitted in the balance drum bore to prevent leakage of
hydraulic pressure oil when mounting or dismounting the balance drum.

Main Bearing:
The rotor is supported by Glacier Babbitt lined, multiple tilting pad type bearings.
The pads of each bearing are fitted into slots in a two-piece bearing housing and are
located by screws. The horizontal split bearing housing is mounted in a bore in
the bearing bracket. The bearing housing is prevented from rotation by a pin.
Pressure lubrication is employed. Oil piped from the lubrication system flows to the
bearings through passages in the bearing brackets. This oil passes out through the
individual bearing drain.

Thrust Bearing:
A thrust bearing, consisting of a rotating collar, which is mounted on the pump
shaft and operating between two identical thrust elements, is provided to maintain
the axial position of the rotor under all operating conditions. This bearing is
located in a thrust bearing housing formed by the bearing bracket at non driver side.
The bearing is lubricated by oil from the main oil system. The oil is led into the
thrust bearing through holes in the bearing bracket and is sprayed between the
shoes and the thrust collar at the leading edge of each pad. On reaching the collar,
it turns outward between the shoes and escapes around the collar. The thrust
bearing cleara nces are such that during normal operation there is an oil film on
both sides of the collar, between the colla r and the thrust faces. Thermocouples
are installed in some of the thrust bearing shoes to measure the bearing
temperatures.

Serrated Bushing Seal:

The injection type serrated bushing seal consists of a seal housing containing a
throttle bushing. Hardened, serrated type shaft sleeves are used to protect the
shaft and serve as pressure breakdown devices. Cooled injection water is used to
block the escape of high temperature water from the inside of the pump and also to
form the seal. A temperature controlled injection type shaft seal system
automatically controls the leakage of water along the shaft, and prevents the
flashing of water in the shaft seal. The controlled variable for this system is the
temperature of the drain water leaving the shaft seal. The temperature (about 750C.)
of the drain water is controlled by regulating the flow of injection water to the
seal. Strainers, in the supply line assure clean injection sealwater.

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Warming-Up System:
Warming-up system has been installed on the pump to keep the temperature
differance between the discharge end and the suction end below 250 C. Normally
the pump is warmed up with the discharge line closed and the suction line open.
Then the warm-up liquid is admitted to the pump through the warm-up
connection and out through the suction nozzle. Thermocouples have been
installed on the suction and discharge end which provides, together with a
temperature switch, control signals for a motor operated valve in the warming-up
supply line.

Axial Displacement Probes:

The main pump has been provided with Bently Nevada probes by means of which the
driver will be tripped if the axial displacement becomes greater than a preset
value. A dual voting system is used to reduce the possibility of a false alarm or
shutdown due to instrument failure.

3. OIL SYSTEMS
The oil unit supplies lube oil to the turbine, main pump, coupling, Tacke gearbox,
BHS turning gear and the booster pump. It also supplies oil to the governing oil
system of the turbine. The oil reservoir supplies the oil required to operate the
systems. Condition of the oil should be checked at least twice a year.

Lubrication System: Lubrication oil is supplied from the main oil reservoir. This
reservoir is a
fabricated steel tank having a maximum operating capa city of about 4050 liters
and a stand still capacity of 4500 liters, the tank scale is about 45 liters to a cm
height. The tank is fitted with a deaeration tray to prevent foaming of oil
entering the tank through the filler pipe or draining back to the tank from the oil
system. A level glass is mounted on the side of the tank. The reservoir is equipped
with a tank drain, an oil filter cap, two motor driven oil vapour extractors and
low & high level a larm switc hes. The AC electric motor driven main oil pump is an
"Allweiler" pump designed to deliver 855 l/min. at a gauge pressure of 15kg/cm2.
The AC electric motor driven auxiliary oil pump is identical to the main oil
pump. It will take over the oil supply if the main oil pump fails for any reason or
when the control oil gauge pressure drops to 7 kg/cm2 or when lube oil gauge
pressure drops to 1.6 kg/cm2.The oil system is also provided with a DC electric
motor driven emergency lube oil pump which will start if the lube oil gauge
pressure drops below 1.2 kg/cm2 for any reason. The main and auxiliary oil pump
discharge lines are fitted with relief valves, set at gauge pressure of 16 kg/cm2 to
protect the pumps from damage due to excess pressure. Pressure indicators are
installed on the discharge lines to determine the output pressure of the pumps and
pressure switches are installed to start the standby pump if the discharge pressure of
the running pump drops to a gauge pressure of 7 kg/cm2. The relief valve behind
the emergency oil pump is set at a gauge pressure of 5.2 kg/cm2.After passing
through check valves, the oil is directed to a three-way transfer valve. This valve
permits passage of oil to either or both of the oil coolers, where the oil is cooled if
necessary to the proper operating temperature of 400 C. Thermometers are fitted at
the inlet and discharge of the coolers, so that the operation of the coolers can be
checked. A temperature switch has been installed on the cooler outlet line for
giving an alarm when the oil temperature is too high. The switch has been set at

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500 C. After passing from the discharge of the coolers, the oil is piped to a duplex
oil filter. The filter is fitted with a pressure differential indicator and a pressure
differential switch which will give an alarm signal at too high pressure
difference, setting 0.8 kg/cm2. Before switching over a filter or cooler, make sure
that the filter or cooler, that will be taken into service, is filled with oil and vented.
From the filter, the oil at a ga uge pressure of 10 kg/cm2, is piped to the turbine
control oil system and, via orifice and check valve, to the bearings of the turbine
and the pumps, to the turning ge ar, to the coupling between the turbine and the
main pump and to the gear box. Several switches have been installed on the oil
system. An oil separator has been installed on the oil unit. This separator
should be in operation as long as the oil unit is in operation.

Control System:
Oil at a gauge pressure of 10 kg/cm2 is delivered to the turbine control system.
This system is described in the next section.

4. CONTROL SYSTEM
(Please refer CONTROL OIL DIAGRAM BFP TURBINE in schematic diary for
the various valve numbers & solenoids mentioned in this chapter.)
The turbine electronic controller provides electical outputs to position the steam
admission valves. The electrical signals are converted to mechanical movements by
a proportional electric/ hydraulic/mechanical actuator. The mechanical output of
this actuator will position the control linkage of a hydraulic relay valve power
servomotor. The servomotor positions the steam admission valves. The admission
valves are designed so that the HP valve opens after fully opening of the LP
valves. The turbine drives the booster pump and the main boiler feed pump. At
normal operation the turbine speed will be controlled by signals from the boiler
control system. The controller can be devided into three parts, namely:

1) The speed controller

2) The position controller
3) The switchover from speed control to position control and reversed.

Speed Control / Position Control:

Three speed sensors each receive signals from one of the three magnetic speed
pickups. The pick ups are installed on the turbine and they face a 60 teeth gear
wheel, which is mounted on the turbine rotor. Each pick up generates an output
voltage pulse every time a gear tooth goes through the pick up magnetic field.
Because the gear has 60 teeth the frequency equals the number of revolutions of the
turbine shaft. The AC pick up signal is converted in the speed sensor to a DC
voltage, which is proportional to the speed of the turbine. This DC voltage speed
signal is sent through a high signal selection circuit to the speed control in such a
way, that when one speed sensor fails the speed control continuous operation. If all
three speed sensors fail, the system will automatic transfer from speed control" to
"position control". In this control mode the speed governor no longer sets the turbine
control valves but this is done then by the position control. The ste am admission
valves will lock in the position they had just before the failure occurs. In this
situation the position of the valves can be change d manually by push button

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commands raise/lower to the "digital ramp position control" in order to maintain the
required feed water needs.
A bumpless automatic transfer is provided to return from "position control"
to "speed control". This basically operates as follows:
After a "request mode transfer" is given by push button command, the speed
set point will automatically be set such that the output of the speed governor
equals the output of the position control. This is done by a window comparator
that compares the output of the speed governor with the output of the position
control and gives raise lower signals to the "digital speed reference". When the
output of the speed governor equals the output of the position control the transfer
from "position control" to "speed control" takes automatically place, the
automatic tracking of the "digital speed reference" stops and the automatic tracking
of the "digital ramp position control" for normal operation starts again. Thus the
position control follows the speed governor output again.
At frequencies below 350 Hz (equals to 350 rpm) the signal from the speed
pickup is insufficient to drive the speed sensor. This means that below this speed
the control system is in "position control" mode. Consequently the turbine is
started up using the position control and when the turbine speed is above 500
rpm the system is transferred to the "speed control" mode.

Speed Reference: The speed set point is provided by a "digital speed reference".
The "digital
speed reference" can be operated manually by push button raise/lower or by the
analog 4-20 mA feed water control signal (or automatically, when changing from
"position control" to "speed control" mode, as described above). When the feed
water control signal sets the speed set point, raise/lower signals are given to the
"digital speed reference" by a window comparator that compares the output of
the "digital speed reference" with the feed water control signal. The speed range
that can be set manually by push buttons is 500 rpm to trip speed. The speed
range that can be set by the feed water control signal is 2000 rpm to max.
continuous speed. Upon loss of the feed water control signal (signal being far
below 4mA) the speed setting automatically switches to manual.

Power Supplies:
The speed governor is powered by power supply 1 or 2. At failure of one power
supply the speed governor remains in operation. The position control is powered by
power supply 3. Consequently the powers for the speed governor can be
switched off for repairs of the speed governor while the turbine remains in
operation by means of the position control during operation.
The three independent overspeed switches receive power from all 3 power
supplies. This means that these overspeed switches are always powered when the
turbine is in operation. The switches have been set at 5925 Hz(rpm).

Servomotor:
The function of the servomotor is to open or close the turbine steam admission
valves in response to governing demands. It consists of a pilot valve and a power
piston (the power piston's stem is connected to the valve lifting lever) a hydraulic
amplifier which also consists of a pilot valve (which is connected to the output shaft
of the Woodward actuator) and a power piston. The power piston of the hydraulic
amplifier acts to position the servomotor pilot valve. The operation of the
servomotor is as follows: Assume that the pilot va lve of the hydraulic amplifier is
moved downward by the Woodward actuator. Oil will be admitted at the bottom

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side of the amplifier's power piston causing the piston to move upward. The pilot
valve of the servomotor will also be moved upward and oil will be admitted to the
top side of the main power piston and oil from the bottom side is ported to drain.
This strokes the main power piston downward, thereby opening the steam admission
valves. When the power piston move, the pilot valves will be returned to their
central position by the action of the respective external feedback linkages. Limit
switches have been installed for valve position indication and they will give a
reset condition signal to the reset system when the valves are closed.

Steam Admission Valves:

These valve s control the flow of steam through the turbine by means of the nozzle
valves and operating gear. The assembly includes the high pressure control valve
and the low pressure nozzle valves. All the valves are operated by the servomotor
through a common linkage. The valve gear is adjusted so that all the low
pressure nozzle valves open in sequence before the high pressure control valve
starts to open. When the high pressure control valve is wide open, so are all the
low pressure nozzle valves. The high pressure control valve is mounted in a lifting
block and is aligned with its valve seat. The lifting block is carried by a lifting rod,
which is connected to the valve lever by the lifting link. The servomotor power piston
actuates the valve lever to position the high pressure control
valve through
a connecting linkage. When the lifting block is raised, the high pressure control
valve is opened. The admission valves closing spring on the HP control valve will
close the steam admission valves in the event of a governor oil pressure or linkage
failure.

Tripping System:
Automatic tripping is accomplished by turbine overspeed, too high bearing metal
temperature, too high axial displacement and too low lube oil and/or trip oil
pressure. Under all these actions the turbine trip solenoids will be activated and
trip oil pressure is released to drain, allowing the steam trip valves to close, thus
shutting off the steam flow to the turbine and causing the turbine to shut down. At a
trip of the turbine, also the turbine control valves will be closed through a contact
that causes the Woodward actuator to run to the closed position.

Trip Valves:
The high pressure, and low pressure steam inlet lines are provided with a trip
valve. These valves will immediately shut off the steam supply to the turbine
when a turbine trip occurs. These valves are opened by the trip oil pressure and
will be closed by spring force if the trip oil pressure drops below a certain value.
The va lves are provided with an electronic exercise system for checking the
functioning of the electronic overspeed trip system and the freedom of the trip
valve moving parts during operation. This system consists of a signal generator,
several relays and switches and solenoid valves. The system functions as follows:
By pushing the "TEST" knob circuit 1,2 or 3 the output of the signal
generator is supplied to the speed switch 1,2 or 3 of the Woodward. At the same
time, solenoid 307 will be switched into the test position and will prevent the
turbine from tripping when solenoid valve 308 is energized (opened). Increase the
output of the signal generator, upon reaching the trip frequency, solenoid valve 308
will be energized and oil is drained from the trip valve cylinder causing the piston
to move in the valve closing direction by spring force. The piston stops
automatically as soon as the piston closes drain hole. This position will be

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indicated by the lamp "Trip valve test position". Decrease the output of the
signal ge nerator and release the "Test" knob.
Check to see that the trip valve's piston returns to its normal position. Repeat
this procedure for the second trip valve. The above described test should be done
once a week. The oil cylinder of each trip valve is equipped with a relay valve which
opens a large flow area around it for fast tripping upon loss of trip oil pressure,
without using large oil lines. When the emergency system is reset, the relay valve
closes under influence of the trip oil pressure. On steam side the valves are fitted
with an integral steam strainer.

Overspeed Trip:
Besides the three electronic speed switches as described above, the unit is also
provided with a mecha nical overspee d trip. This device is a spring loaded
plunger set radially in the overspeed trip body. This body is mounted to the pinion
of the gearbox. At the designed tripping speed(5900 rpm) the centrifugal forc e of
the plunger overcomes the counteracting force of thr plunger spring, the plunger
moves outward and strikes the nut of the handtrip device causing trip oil pressure to
drain, which results in closing of the trip valves. For test purposes the overspeed trip

can be made to act at operating speed (without tripping the unit) by filling the plunger
with oil. To test the mechanical overspeed trip during operation handle as
follows:

1) While running the unit at 4700 50 rpm. push the test va lve 310 into
test position. This will prevent the turbine from tripping.
2) Open valve 301, Thus admitting oil into the overspeed plunger
causing the plunger to move outward.
3) Make sure that the plunger has struck the hand trip device nut. If
necessary readjust the overspeed trip device.
4) Close valve 301, wait a few minutes so that oil can leave the plunger
causing the plunger to retract.( TO AVOID DAMAGE TO THE
HAND TRIP DEVICE, DO NOT ATTEMPT TO RESET IT
BEFORE THE PLUNGER OF THE OVERSPEED HAS
RETRACTED.)
5) Reset the hand trip device.(TO PREVENT THE TURBINE FROM
TRIPPING, THE HAND TRIP DEVICE M UST BE RESET.
BEFORE RETURNING TEST VALVE 310 TO THE NORMAL
POSITION.)
6) Release test valve 310 so that it returns to the normal position.

The above described test should be done at lea st every two months. During
this test the mechanica l overspeed trip can not shutdown the turbine. The unit
however is still protected against overspeed by the overspeed switches which are
part of the woodward governor.

Handtrip Device:
This device is mounted on the gearbox at free pinion end. When the stem of this
device is moved by the overspeed trip plunger, it will be moved into the valve
body. This opens the valve and releases the pressure in the trip oil line, causing
the trip valves to close. The hand trip device can be manually reset, but normally
this will be done by the action of its solenoid 311. The solenoid is energised then
for some time to close the valve against spring force until it is held closed by trip

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oil pressure.
BEFORE RESETTING THE HAND TRIP DEVICE, MAKE SURE THAT
THE OVERSPEED PLUNGER HAS RETRACTED. IF NOT, RESETTING
WILL CAUSE DAMAGE TO THE TRIPPING MECHANISM.

Testing Tripping Mechanisms:

The operation of all tripping mechanisms should be checked on initial starting and
each time the unit is started after a prolonged shut down or overhaul. The
functioning of the trip system should be tested at stand still and in the following
manner:

1) Make sure that the main steam block valves are closed.
2) Start the main or auxiliary lube oil pump and check the oil pressures.
3) Reset the trip oil system.
4) Trip the unit by releasing lube oil pre ssure.
5) Observe the action of the trip valves to see that they trip instantly With no
evidence of sticking or binding.

5. OPERATION
Normal Starting Preparations:
1. Energize all control and alarm circuits and verify their action.
2. Make sure that the HP trip valve is closed.
3. Make sure that the LP trip valve is closed.
4. Place the turbine controller in the position control mode.
5. Make sure that the output of the position controller is 0%.
6. Make sure that the gland steam condensor is ready for operation.
7. Drain condensate from the steam lines, turbine case and trip throttle valves by
opening their respective drain valves.
8. Check the oil level and the condition of the oil. Be sure, the oil is in good
condition, uncontaminated by water sludge or other foreign matter.
9. Start the main oil pump and vent the oil system thoroughly. Fill the stand by
oil cooler and filter. Start the oil vapour extractor of the oil reservoir.
10. Check the oil pressures. Lube oil gauge pressure should be 2 kg/cm2 at the
turbine. If necessary adjust relief valve 109. Control oil gauge pressure should
be 10 kg/cm2 at the turbine. If necessary adjust relief valve 108. Make sure
that the auxiliary oil pump and the emergency oil pump start at the correct oil
pressures.
11. Engage the coupling between the turbine and the main boiler feed pump.
12. Start the turning gear.
13. Open the turbine drains.
14. Start the steam supply to the turbine gland seal system. Gland seal steam
gauge pressure should be 0.1 kg/cm2.
15. Put the condensing system into operation.

16. Warm the boiler feed pump thoroughly by putting the warming up system in
the automatic mode, check to see that:

A) Temperature differential between suction and discharge ends

of pump case is 250degC or less.
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B) Higher pump case temperature is within 300degC of operating

temperature.
C) In emergencies it is allowed to start a pump without warming
up.

17. After warming up the pump, close the valve in the warming up supply line.
18. .Make sure that the drains of the pump case are closed and that the pump the
discharge valve is closed
19. Make sure that the valves in the gland seal water lines to the opened. main
pump and in the seal water lines to the booster pump are Vent the seal water
system and coolers thoroughly.

19. Make sure that the drain lines from the seal housings are open.
21. Open the valves in the recirculation line.
22. Fill the pump with boiler feed water, being sure pump is fully vented. Pump
may be filled from seal injection system, or through warm up connection.
23. Set control valves for the seal injection system (approximately 750degC.).
24. When the water pressure in the pump approximates the suction pressure,
open the valve in the suction line.
25. Make sure that the booster pump is ready to operate.
26. Thoroughly drain and preheat the steam supply lines.
27. Make sure that the turbine vacuum is below 0.3 kg/cm2 absolute.
28. Reset the turbine trip system and test the tripping mechanisms as described in
control section.
29. After testing the trip mechanisms, reset the trip system again.M ake sure that
the trip valves open.
30) When the lube oil temperature has reached at least 350degC., and the steam just
before the LP trip valve is at least 400degC. superheated, open the steam
admission valves (by raising the output of the position control) to bring the
turbine up to speed of about 1000 rpm so that the turbine may be heated
evenly.
NOTE: After a black out the turbine can be started with auxiliary steam of 16
bar and 2100degC. It must be ensured that no water, from the inlet piping, can
enter the turbine.
31) Operate at 1000 rpm for not less than a quarter of an hour. During the
warming up period listen care fully for any rubbing, unusual noise or
vibration. Also during the warming up period check oil pressures, oil
temperatures, oil flow to bearings and general me chanical performance of the
unit.
NOTE: If abnormal vibration, noise or any other erratic condition should
develop, shut the unit down immediately and investigate the cause.
32) Throttle all steam drain valves to a quarter turn open.
33) After the turbine has been thoroughly warmed (that means casing
temperature is within 500degC. from the steam temperature) and the vibrations
are normal, and vacuum is below 0.3 kg/cm2 absolute, increase the speed by
raising the output of the position control. Increase the speed in steps of 20
rpm/sec. The control system will a utomatically change over from position
control to speed control when the turbine speed reaches the minimum speed
setting of the digital speed reference.
CAUTION: Care should be exercised when the unit is accelerating or
decelerating through the critical speeds. Prolonged operation is
limited to speeds at least 10% removed from critical.

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34) Increase the speed by means of raising the digital speed reference.
35) The boiler feed pump is discharging through the recirculation line. The unit
can be operated satisfactory under these conditions until the pump is ready to
be put on the line.
36) Check the operation of the oil system. The cooling water flow through the oil
cooler should be adjusted so that the temperature of the oil leaving the cooler is
500degC.
37) Check that the seal steam gauge pressure is 0.1 kg/cm2. Make required
correction.
38) Close the turbine drains except the drain behind the HP t rip valve. This drain
must always be open.
39) Open the pump discharge valve to put the pump on the line.
40) Increase the speed up to the minimum feed water control speed. At reaching
this speed, the feed water control signal will be balanced with the actual speed
setting. This balancing is completed when the feed water controller has no
intention to provide a raise or lower command to the digital speed reference.
The contact for remote speed setting can now be closed and the feed water
signal will provide raise and lower commands to the digital speed reference.
41) Check to see that the proper vacuum is being maintained on the turbine exhaust.

NOTE: - In Unit # 4,5 & 6 TDBFP B, a new controller has been installed &
commissioned under R & M. The operating procedure for this controller is as
follows:
1. After ensuring all permissive, give RESET c ommand.
2. After turbine RESET, for rolling the turbine give GOVERNOR START command.
3. After giving GOVERNOR START command give RAISE command for control valve
opening.
4. After attaining the turbine speed 1000 rpm SPEED CONTROL will be automatically active
(no need of REQUEST CHANGE).
5. After attaining the speed 1000 rpm, further give RAISE command till saturation
(until RAISE push button lamp glows). This will not affect control valve opening
or turbine speed.
6. After 1000 rpm turbine speed, control valve opening will be controlled by SPEED
SET POINT.
7. After 1000 rpm, by raising the SPEED SET POINT turbi ne speed can be increased for
required loading.

RUNNING - A least once every shift, the following log checks should be made:

1) Unit speed
2) Oil te mperature and pressure. The condition of the oil should be checked at
least every six months.
3) Bearing temperatures. The unit must be tripped when the bearing metal temperature
increases to 1200degC. The alarm setting should be adjusted at 50 C. above the
initial stabilised operating temperature.
4) Unit vibrations. Any sudden increase in vibration level must be investigated and the cause
corrected before operation is continued.
5) Seal steam pressure. Check to see that the gland steam system operates properly.
6) Exhaust vacuum.
7) Sealing water temperature. Make sure that the control valves of the seal water system are
set properly(approx. 750degC.).If the temperature of the booster pump sealing
water outlet, exceeds the normal va lue of 650degC., check the sealing chamber and

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the cooling water supply to the sealing water cooler. If every thing is found o.k., inspect
the filters and coolers in the sealing water system. If the temperature of the main pump
seal water outlet, exceeds 800degC, check the sealing chamber, the water supply to
the se als and the seal water filters.
8) Pump inlet and outlet pressures and temperatures. Make sure that there always a
sufficient normal suction head is available, the pump may get damaged if the normal
suction head is too low. Therefore, pay special attention to the filters in the suction
piping. Also a pressure drop in the deaerator may lead to a loss of normal suction head.
For this reason the pressure drop must be restricted.
09) Pump flow.
10) Flow through the balance piping, kicker stage and bleed off line.
11) Under certain conditions, the temperature differentials of a running pump
may be higher than the differentials given for putting a cold or standby pump
on the line. This is permissible, only if the flow through the pump exceeds the
recirculation flow of the pump.
12) Test the electronic exercise system off the turbine trip valves once a week as
described in the control section.
13) Test the mechanical over speed trip device every two months as described in
the control section.

STOPPING

1) Decrease the speed until the minimum flow valve opens and the pump does not supply
feed water to the boiler any longer.
2) Trip the turbine with help of the hand trip device or with one of the other trip devices.
Make sure that the trip valves close instantly.
3) After turbine rotor comes to the rest, disengage the coupling between the main pump
and the turbine, and start the turning gear.
4) Open the turbine drains.
5) Break the turbine vacuum.
6) Stop the steam supply to the gland steam system.
7) The turning gear can be stopped when the turbine casing temperature is below 700degC.
8) The oil supply can be stopped when the turbine rotor is at stand still.

NOTE - If it should be necessary to restart the unit before it has cooled down, it
should be done in accordance with the start up curve.

Turbine Driven Boiler Feed Pump

Line up of TDBFP
Charging of pump on feed water side
Keeping on Barring Gear
Vacuum Pulling
Turbine Protections & Interlocks
Turbine Reset & Opening of ESV
Speed raising & Soaking of TDBFP at 1500 & 3000 RPM
Loading of TDBFP
Paralleling with other BFP

Line up of TDBFP

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1. TDBFPs main steam valve at aux PRDS HT header is in open

position
2. TDBFP individual aux. PRDS valve is in open position
3. TDBFP individual seal steam valve in its aux PRDS line is in
open position
4. At 8.5 mts Aux. control valve before drain open
5. All drains in extraction steam line connected to LP flash tank
are in open position
6. TDBFPs main extraction valve from IP turbine exhaust is kept
open
7. TDBFPs individual extraction steam isolating valve is in open
position
8. Start up vent in extraction steam line before main control
valve open
9. TDBFP exhaust steam butterfly valve close position
10. TDBFP aux. PRDS header drain before seal steam hdr. Open
position
11. TDBFP seal steam exhauster valve connected to main
turbine seal steam exhaust line open position
12. Open all isolating valves in turbine exhaust-hood spray
station

Charging of Pump

1. Open all air vents - at booster pump suction strainer air vent,
booster pump top, main pump suction strainer air vent, line air
vent after main pump.
2. Open BFP suction valve slowly and let off air in the system & then
completely open the suction valve. Close all air vents.
3. Ensure Recirculation valve & its isolating valve open position
4. Ensure all isolating valves in Booster pump & main pump jacket
cooling water line & ensure TG DMCW cooling water line up
5. Ensure cooling water valves open to lube oil coolers

Keeping in Barring gear

1. Start DC EOP and take one oil vapour extraction fan into service
2. After establishing lube oil header pressure & observe return oil
flow from all return lines
3. Start any one lube oil pump
4. Start JOP & observe rise in JOP pressure.
5. Stop DE JOP & kept its SLC in on position
6. Engage the main pump to the turbine through engage/disengage
solenoids after starting power pack.
7. Ensure main pump recirculation is in open position
8. Open Barring gear valve & observe speed rise of turbine to 320
RPM
Vacuum Pulling

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1. Open seal steam header drain connected to LP flash tank &

ensure that Aux PRDS temp to seal steam more than 200C.
2. Open GSC controller & raise the seal steam header pressure up
to 250 mmwcl after observe rise in seal steam header
temperature.
3. Open all TDBFP casing drains d1,d2 & d3
4. Observe raise in casing temperature 50% & 100%
5. Open TDBFPs exhaust butterfly valves bypass valve locally &
observe rise in exhaust pressure & duly observe main turbine
vacuum without much fall. (Assumed main turbine already
vacuum pulled & 2 Nos vacuum pumps running)
6. Slowly open the exhaust valve and equalize the vacuum with
main turbine vacuum & then open fully and ensured it locally.

Turbine Protections & Interlocks

1. Lube oil pressure low < 2.0 ksc

2. Trip oil header pressure low < 2.0 ksc
3. Live steam pressure high > 12.5 ksc with 3 min delay
4. Exhaust steam temperature high > 120 C
5. Exhaust steam pressure high > 0.4 ksc (abs)
6. Gov./Lube oil pressure low < 4.5 ksc
7. Axial shift high/low 0.7 mm with 5 sec delay
8. Eccentricity high > 92 s
9. Turbine over speed trip > 6000 rpm
10. Vibration trip RJB / FJB > 76 s with 5 sec delay or > 90 s
trip
11. Gear box o/p shaft vibration high > 76 s with 5 sec delay
12. Gear box i/p shaft vibration high > 76 s with 5 sec delay
13. Deaerator level low 2/3 logic (-910 mm)
14. Gear box thrust brg. Temp. high > 120 C
15. Booster pump brg. Temp. high > 95 C
16. Booster pump thrust brg. Temp high > 120 C
17. BFP journal brg. Temp high > 95 C
18. BFP thrust brg. Temp high > 105 C
19. t temp high 15 C with 30 sec delay
20. Suction flow low < 50 t/hr 10 sec delay
21. Suction valve not open

Turbine Reset & opening of ESV

1. Ensure the speed controller output (OCAT) to zero and reference

speed is also zero
2. Open the turbine protection page & press turbine reset button
3. Observe the trip valves open
4. Open the remote engage tile & press ON button, observe the
raise in trip oil pressure. At trip oil pressure 8ksc (at least>4.5

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ksc), the remote engage will go to off position and ensure this for
proceeding further.
5. Open the ESV tile and give open command, observe the raise of
startup oil pressure above piston and after some time trip oil
pressure below piston of stop valve develops and stop valve
slowly starts opening and the start up oil above the piston gets
de-pressurised.(Ensure the close feed back of control valve prior
to this step).

Speed raising and soaking of TDBFP at 1500 rpm & at 3000 rpm

1. Open the speed reference tile and give 1500 rpm, confirm it and
observe the speed raise & monitor the turbine vibrations, TSC.
2. Soak the turbine at 1500 rpm till the casing temperature reaches
150 degC. Raise the speed further to 3000rpm and soak it.
3. Load the TDBFP after crossing the casing temperature 220 degC.

Loading and paralleling of TDBFP:

1. Raise the speed reference of other TDBFP equal to that of in

service and match the discharge pressures.
2. Check whether the suction flow is raising on raising the speed
reference and recirculation valve is closing on decreasing the
speed reference of other TDBFP
3. Raise the Unit load more than 350 MW and keep both the TDBFPs
in auto.
4. Observe the operation of TDBFPs in auto while raising the load on
the Unit. MDBFP can be tripped after reaching the load to 450
MW or above

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