Interlock Protection Handbook PDF

Power from knowledge
Interlock & Protection

Handbook
WPCL, Warora
KSK Energy Ventures Ltd (4 X 135 MW)

INDEX
Sr. Description Page
No. no.
1 Interlock & Protection of Boiler 3
2 Interlock & Protection of ID fan system 4
3 Interlock & Protection of FD fan system 7
4 Interlock & Protection of APH system 9
5 Interlock & Protection of PA fan system 13
6 Interlock & Protection of Coal Pulveriser 15
7 Interlock & Protection of Coal Feeder 21
8 Interlock & Protection of Seal Air Fan 22
9 Interlock & Protection of Scanner Air Fan 23
10 Interlock of Boiler 24
11 Interlock & Protection of FSSS 25
12 Interlock test checklist of steam and water 28
system
13 Interlock test checklist of fuel oil system 30
14 Interlock & Protection of Turbine 37
15 Condensate Extraction Pump (CEP) 38
16 Circulating water system 40
17 Boiler Feed Pump Interlock & Protection 42
18 Vacuum system 45
19 Lube oil system & EH oil system 46
20 Deaerator,HPH & LPH system 47
21 50
Main steam and drainage system
22 Bypass system 53
2
23 Turbine 54
Boiler& Auxiliaries
Interlock & Protection
WPCL, Warora
3
Interlock & Protection of ID fan system
Start permissive
 Front and rear fan bearing temperature normal (<80ºc).

 Front and rear motor bearing temperature normal (<95ºc).
 Motor coil temperature is normal (<120ºc).
 Scoop tube position is low (<5%).
 Inlet vane position is low (<5%).
 Inlet and outlet damper has been closed.
 Bearing temperature of coupler is normal (<85ºc).
 No protection tripped condition.
 Corresponding APH is running.
 Corresponding side channel condition of flue gas and air system is satisfied.
 Outlet secondary air damper Of Corresponding side APH has been opened.
 Inlet and Outlet flue gas damper Of Corresponding side APH has been opened.
 Inlet and Outlet flue gas damper Of Corresponding side IDF has been opened; Inlet vane has not been opened.
 Outlet second air damper Of B side FDF has been opened and inlet vane has not been closed.
 Furnace All second vane has been opened (80%damper opening position are more than 80%).
 Fuel gas by-pass damper all opened.
Protections
 Front or rear fan bearing temperature is very high, delay 2 sec (>90ºc).
 Front or rear motor bearing temperature is very high, delay 2 sec (>105ºc).
 Motor coil temperature is very high (<135ºc).
 Corresponding side APH (both main motor & DC motor) stopped, delay 300 sec.
 Accident button action.
 Outlet damper closed and ID fan running, delay 5 sec.
 Outlet flue gas damper has been closed when IDF startup, time delay 60 seconds.
 Front bearing (x direction) vibration is very high, time delay 5 seconds (7.1mm/s).
4
 Front bearing (y direction) vibration is very high, time delay 5 seconds (7.1mm/s).
 Rear bearing (x direction) vibration is very high, time delay 5 seconds (7.1mm/s).
 Rear bearing (y direction) vibration is very high, time delay 5 second (7.1mm/s).
 Inlet oil pressure of coupler is very low, after IDF is running, time delay 10 seconds (<0.05MPa).
 Inlet oil pressure of coupler is very low, when IDF startup, time delay 30 seconds (<0.035MPa).
 Inlet oil temperature of coupler is very high, time 5s (>85ºc).
 Outlet oil temperature of coupler is very high, time delay 5 seconds (>95ºc).
 Bearing temperature of coupler is very high, time delay 5 seconds (>95ºc).
 Furnace pressure is low-low (2of3), time delay 25 seconds (-1470Pa).
 Furnace pressure is high-high (2of3), time delay 25 seconds (+1470Pa).
ID Fan inlet electric damper

Permission conditions of closing
 ID fan stopped
Interlock conditions of opening
 ID fan started, time delay 10sec open damper.
 All IDF and FDF has been stopped, open damper, time delay 5 minutes (from asking for free ventilation)
Interlock conditions of closing
 This side IDF trip and the other side IDF is running, close damper.
IDF outlet electric damper
 IDF stopped.
 This side IDF startup, time delay 10 seconds , open damper.

 all IDF and FDF have been stopped, open damper, time delay 5 minutes(from asking for free ventilation)
 This side IDF trip and the other side IDF is running, close damper
5
IDF inlet control damper (IGV)
 All IDF and FDF have been stopped, open damper, time delay 5 minutes(from asking for free ventilation)
 This side IDF trip and the other side IDF is running, close damper
IDF scoop tube
Interlock condition of closing

 This side IDF trip, close scoop tube.
Sequence start procedures
 Place Scoop tube position at minimum.

 Place inlet vane position at minimum
 Close inlet flue gas damper
 Close outlet flue gas damper
 Start IDF motor
 Delay 10 second, open outlet/inlet electric damper
 Release inlet vane
Sequence stop procedure
 Place Scoop tube position at minimum

 Place inlet vane position at minimum
 Close inlet flue gas damper
 Stop IDF motor
 Close outlet flue gas damper
6
Interlock & Protection of FD fan system
Start permissive
 Outlet damper has been closed, FDF

 Inlet vane position is at minimum, FDF <5%
 This side IDF is running
 This side APH is running
 Front and rear bearing temperature is normal, ,FDF (<75°C)
 Front and rear motor bearing temperature is normal, FDF (<80°C)
 Motor coil temperature is normal, FDF (<120°C)
 No protection trip conditions, FDF
Protection
 Front / rear bearing temperature is very high, delay 2 seconds (>90°C)

 Front / rear motor bearing temperature is very high, delay 2 seconds (>105°C)
 Motor coil temperature is very high, delay 2 seconds (>135°C)
 Bearing vibration is very high (x direction),delay 2 seconds (>7.1mm/s)
 Bearing vibration is very high (y direction),delay 2 seconds (>7.1mm/s)
 Motor Bearing vibration is very high (x direction),delay 2 seconds (>7.1mm/s)
 Motor Bearing vibration is very high (y direction),delay 2 seconds (>7.1mm/s)
 This side APH stopped ,delay 300 seconds
 This side IDF stopped after IDF is running
 Two IDF stopped after two IDF are running
 Accident button action
 Furnace pressure is high-high(2 of 3) ,delay 2 second (1470PA)
7
 Outlet shut-off damper closed after FDF is running, delay 5 second
 Outlet shut-off damper not opened when FDF startup, delay 20 seconds
FDF outlet electric damper
Permission condition of closing
 This side FDF stopped
 After this side FDF startup, delay 10 seconds open damper

 all IDF and FDF have been stopped, open damper, time delay 5 minutes (from asking for free ventilation)
Interlock close conditions
 This side FDF tripped and the other FDF is running, close damper
FDF inlet vane
Interlock conditions of opening (or)
 Asking for free ventilation ,delay 5 minutes, open damper
Interlock conditions of closing (or)
 This side FDF trip and the other side FDF is running, close damper
8
 Close outlet damper
 Place inlet vane at minimum position
 Start FDF motor
 Open outlet damper
Sequence stop procedures

 Stop FDF motor
 Close outlet damper
Interlock & Protection of APH system
Start permissive conditions of main driving motor
 No fault of main driving motor

 No fault of clearance adjustment
 No fault of fire alarm
 No fault of oil station
 Guide bearing oil station has been started(intrain)
 Support bearing oil station has been started (intrain)
 Auxiliary driving motor stopped
 Remote state of main motor
 Main driving motor stopped operation
 Outlet second air damper closed
 Outlet/inlet primary air damper closed
9
 Inlet flue gas damper closed
 Outlet flue gas damper closed
Stop permissive conditions of main driving motor
 Inlet flue gas temperature<150°C

 IDF and FDF of this side stopped
Trip conditions of main driving motor
 Main driving motor fault

Startup permissive conditions of auxiliary driving motor
 Auxiliary driving motor stopped

 Remote state of auxiliary driving motor
 No fault of auxiliary driving motor
 No fault of auxiliary driving motor fan
 Main motor stopped
Stop permissive conditions of auxiliary driving motor
 Inlet flue gas temperature<150°C

 IDF AND FDF of this side stopped
Trip conditions of auxiliary driving motor
 Fault of auxiliary driving motor

10
Interlock test of main driving motor and auxiliary driving motor
 Auxiliary motor starts, if main motor tripped

After running, in manner of interlock
Interlock of air pre-heater and inlet flue gas damper
 Ask for free ventilation, time delay 5 minutes, open damper
 APH (main motor and aux. motor) of this side stopped

And no asking for free ventilation, delay 300sec
Interlock of air pre-heater and outlet flue gas damper
 Ask for free ventilation time delay 5 minutes, open damper
 APH (main motor and AUX. motor) stopped and no asking for free
Ventilation, delay 300 second, close damper
11
Interlock of air pre-heater and outlet secondary air damper
 Ask for free ventilation time delay 5 minutes, open damper
 APH (main motor and AUX .motor)stopped and no asking for free
Ventilation, time delay 300 seconds, close damper.
Sequence startup procedures
 Conditions: remote state and no fault of oil station

Instruction: start oil station of APH.
 Condition: oil station operation is normal
Instruction: start main motor.
 Condition: main motor operates for 10 second
Instruction: open outlet second air damper.
 Condition outlet second air damper has been opened
Instruction: open inlet flue gas damper.
 Condition: inlet flue gas damper has been opened
Instruction: open inlet/outlet primary air damper.
 Condition: inlet/ outlet primary air damper has been opened
Instruction: start procedures fulfilled.
 CONDITION inlet flue gas temperature<150°C

IDF and FDF of this side stopped
Instruction: close inlet flue gas damper
12
 Condition: inlet flue gas damper has been closed
Instruction: close outlet second air damper
 Condition: outlet second air damper has been closed
Instruction: close inlet/outlet air primary damper
 Condition: inlet/outlet air primary damper has been closed
Instruction: stop main motor of APH
 CONDITION: main motor of APH has been stopped
Instruction: stop procedures fulfilled
Interlock test of air pre-heater oil station
 Outlet Oil pressure of working pump is low (<0.12MPa), start standby pump
 Fault of working pump, start standby pump.
 Outlet Oil pressure of two pumps operation is high (0.3MPa), stop working pump
 Guide bearing temperature is
High (>55°C), alarm, start working pump
High (>70°), alarm
Low (<45°), stop operating pump
 Support bearing temperature is
High (>55°), alarm, start pump
High (>70°), alarm
Low (<45°), stop pump
13
Interlock & Protection of PA fan system
Start permissive
 Outlet damper closed ,PA

 Place Inlet vane at minimum position, PA <5 %
 Front / rear bearing temperature is normal, PA (<80°C)
 Front / rear motor bearing temperature is normal , PA (<95°C)
 Motor coil temperature is normal, PA (<125°C)
 This side IDF and FDF are running
 This side APH is running and inlet/outlet primary damper has been opened
 No protection trip condition
 No MFT condition
Inspection of trip condition
14
 Front / rear bearing temperature is very high, delay 2 seconds (>90°C)
 Front / rear motor bearing temperature is very high, delay 2 seconds >105°C)
 Motor coil temperature is very high, delay 2 seconds (>135°C)
 Bearing vibration(x direction) is very high, delay 2 seconds (>7.1mm/s)
 Bearing vibration (y direction)is very high ,delay 2 seconds (>7.1mm/s)
 Motor bearing vibration(x direction) is very high, delay 2 seconds (>7.1mm/s)
 Motor bearing vibration(y direction) is very high, delay 2 second (>7.1mm/s)
 MFT action
 This IDF stopped after this IDF is running
 Two IDF stopped after two IDF are running
 Two FDF stopped after two FDF are running
 Outlet damper closed after PA fan is running, delay 5 seconds
 Outlet damper closed when PA fan startup, delay 20 seconds
Outlet electric damper of primary air fan

 This side PA fan has been stopped
 This side PA fans startup, open damper, delay 10 seconds
 This side PA fan tripped and the other PA fan is running, close damper
Inlet vane of PA fan

 This side PA fan tripped and the other PA fan is running, close damper.

 Open Outlet outlet primary damper of this side APH
15
 Open Outlet inlet primary damper of this side APH
 Close Outlet damper
 Start PA fan motor
 Open Outlet damper

 Place inlet damper at minimum position
 Stop PA fan motor
 Close Outlet inlet primary damper of this side APH
 Close Outlet outlet primary damper of this side APH
Interlock & Protection of Coal Pulveriser
Start permissive
 Barring gear motor retreated.
 Coal ignition of corresponding layer permitted
 Suitable temperature at outlet of coal pulverizer (55> t <-90 °C)
 Coal puverizer high oil system OK (≥2.5MPa)
 Coal Pulveriser lube oil system OK

o Any oil pump is running
o Temperature of gear box oil ≥28°
16
o Inlet pressure of oil distributor ≥0.13MPa
 Temperature of thrust bearing ≤50°C
 High differential pressure between seal air and primary air of coal pulverizer
(≥2kPa)
 Primary cold/hot valve opened;
 Any primary air fan operating, with normal primary air pressure (≥10.5kPa)
 Coal pulverizer outlet valve opened;
 No MFT trip conditions
 Suitable temperature of coal pulverizer bearing; (less than 95°C)
 Suitable air flow at inlet of coal Pulveriser (≥0.65Q);( ≥39000cu m ./hr)
 Cobble coal bunker inlet valve opened.
 No coal pulverizer trip conditions
 coal feeder outlet dampers closed
Interlock trip conditions for coal pulverizer

 Operator sends instruction for coal pulverizer stop;
 MFT
MFT
 One or more outlet dampers closed during the operation of coal pulverizer;
 Primary air volume low(delay 3 second )30000M3/H (<0.5Q)
 Temperature at outlet of coal pulverizer greater than (≥100°C), time delayed 5s;
 Low differential pressure between seal air and primary air of coal pulverizer (≤1.5kPa), time delayed 60s
 Loss of coal flame (3of4) (after coal feeder is running time delay 3 minutes ,loss of coal layer flame )
 Temperature of coal pulverizer bearing ( ≥95°C)(2of3), time delayed 2s;
 Temperature of coal pulverizer motor bearing (≥90° C) (1of2), time delayed 2s;
 Temperature of coal pulverizer motor coil (≥140°C) (3of6), time delayed 2s;
 Loss of lube oil (<0.1MPa)
 Loss of primary air: two primary air fans stopped
 When two primary air fans are running, and three OR excess three operating coal pulverizers are running ,any one PA tripped
 Temperature of coal pulverizer reducer thrust pad greater than 70°C (2of3), time delayed 2s;
17
 Coal feeder stopped, time delayed 10min
 Loading pump stopped ,time delay 2s
 Loading oil pressure <2.0MPa, time delay 2s
Common conditions of coal firing

 Temperature of secondary hot air temp >177°C
 Furnace air volume >30% (from MCS)
 No MFT signals
 At least seal air fan operating
 Drum steam pressure >3.5 MPa
 Primary air pressure normal >7 KPa
 Furnace pressure normal (from MCS)(-600 to 0 Pa)
Condition of coal firing satisfied (ignition energy)( AND)

 Common condition of coal firing satisfied
 Oil gun of adjacent layer is running OR adjacent coal feeder , feeder rate <50% AND boiler load is more than 40 % OR
boiler load is more than
60 %
Roller action of Coal pulverizer
 Lift roller
 Fall roller
Coal pulveriser interlocked after being tripped

 Trip coal feeder
 Close coal feeder outlet valve
 Close coal feeder inlet valve
 Close inlet cold air damper
 Close inlet hot air damper
 Close coal pulverizer outlet damper
 Lower the coal pulverizer roller, time delayed 60s
 Open steam fire-fighting valve
18
Interlock damper conditions
Steam fire-fighting valve of coal pulverizer

Opening permission condition
 Any one seal air fan is running
Interlock opening conditions (or)
 Temperature at outlet of coal pulverizer greater than 120°C, time delayed 5s;
 mill tripped
Interlock closing conditions
 steam fire-fighting valve opened, reached 8 minutes and temperature at outlet of coal pulverizer is greater than 90° C(2 of 3)
Seal fan valve of mill
 Any one primary fan is running ,delay 5 seconds
Closing permission condition
 Mill stopped, delay 5 seconds
Interlock closing condition (or)
 All seal air fans stopped
 Mill stopped, delay 12 minutes

Inlet hot shut-off damper of mill
 No MFT
Interlock closing condition
 MFT
Inlet cold shut-off damper of mill
Open permission condition
 No MFT
 MFT
 Mill stripped pulse
Inlet valve of coal feeder
19
 Remote position AND NO MFT
Closing permission condition:
 Remote position

 Coal feeder tripped
 Mill stopped
Start conditions for sequence control of coal pulverizer :( AND)
 Any primary air fan operating

 Any seal air fan operating for 60s
Start procedures for sequence control:

 Start low speed oil pump of coal pulverizer thin oil station;
 After low speed oil pump started for 4min and the temperature of thin oil station gear box oil >28°, start high speed oil pump
A/B of coal pulverizer;
 Open seal air electric valve of coal pulverizer
 Start hydraulic station to load oil pump
 Open fire steam valve of coal pulverizer;
 Fire steam valve of coal pulverizer has been open for 8min, close fire steam valve of coal pulverizer
 Open cutoff valves at 1-4 outlets of coal pulverizer
 Open cold and primary hot air cutoff valves of coal pulverizer
 Suitable temperature at outlet of coal pulverizer;
 Rise coal pulverizer roller
 Start coal pulverizer
 Open coal feeder outlet valve
 Open inlet valve of coal feeder;
 Start coal feeder
20
 Start coal pulverizer, constant load
Stop conditions for sequence control:

 Coal pulverizer operating
 Closing permission condition : remote operation
 Interlock closing condition: coal feeder stopped
 Coal feeder stopped
 Mill stopped
Stop procedures for sequential control
 Inform MCS to lower the coal feeder rpm to its minimum value
 Close primary hot air cutoff valve of coal Pulveriser
 After the temperature at outlet of coal feeder <60°C, close the valve at inlet of coal feeder
 Stop coal feeder; time delayed 1min
 Close valve at outlet of coal feeder; time delayed 1 minute
 Lift coal pulverizer roller
 Stop coal pulverizer
 Lower coal pulverizer roller
Lube oil station of coal pulverizer

Start conditions of low speed pump (and)
 Place lube oil station at remote control position
 Oil temperature>27°C
Start conditions of high speed pump (and)
 Place lube oil station at remote control position
 Oil temperature>28°C
Interlock starting standby pump
 When Main work oil pump faultily stopped, start standby oil pump in manner of interlock
 When Main work oil pump is running and outlet oil pressure is low (<0.105MPa), start standby oil pump in manner of
interlock
21
Stop permission condition
 Mill stopped, time delay 120 minute
Electric heater of lube oil station

Start permission condition
 Any Oil pump is running
 Oil level is normal
Interlock start condition
 Oil box temperature <30°C
Interlock stopping condition (or)
 Electrical heater tripped
 All oil pump stopped
 Oil box temperature >40°C
 Oil lever is low
Hydraulic oil station loading pump
 Place loading oil station at remote control position
 Oil level is normal
Stop permission condition
 Mill stopped, time delay 120 minute
Electric heater of hydraulic oil station
 Loading Oil pump is running
 Oil lever is normal
Interlock starting condition
 Oil box temperature <20°C
Interlock stopping condition (or)
 Oil box temperature >30°C
 Oil level is low
22
Interlock & Protection of Coal Feeder
Startup conditions for coal feeder

 Coal pulverizer operating
 Instruct coal feeder at a rpm of minimum.
 Coal ignition of corresponding layer permitted
 No MFT
Trip condition for coal feeder

 Coal pulverizer stopped
 Coal feeder keep running, lower valve closed, time delayed 5s
 MFT
 Inner over temperature of coal feeder, time delayed 120s (none)
 No-coal on belt during the operation of coal feeder, time delayed 120s
 Coal plugging at outlet during the operation of coal feeder, time delayed 2s
Result check after coal feeder tripped

 Inlet valve of coal feeder opened
 Outlet valve of coal feeder opened
 Instruct coal feeder at a rpm of minimum value 0rpm
Interlock & Protection of Seal Air Fan
23
Start permission conditions
 Any one primary air fan is running

 Inlet vane has been closed
 Bearing temperature of the seal air fan is normal (<75°C)
 Motor Bearing temperature of the seal air fan is normal (<75°C)
 No fault of the seal air fan
Stop permission conditions
 When two seal air fans is running, outlet main pipe pressure is normal, permit stopping any a fan.
 All primary air fans stopped
 MFT tripped
Interlock startup conditions

 Main air fan stopped
 Outlet manifold pressure is low, time delay 2 second <16 KPa
Interlock stop conditions
 All the primary air fans stopped, trip this seal air fan
 Front / rear Bearing temperature is very high, delay 2 second >85°C
 Front /rear motor Bearing temperature is very high, delay 2 second >85°C
24
Interlock & Protection of Scanner Air Fan
Start permission conditions

 Remote position
 No fault
Interlock start conditions
 Flame detector cool main pipe pressure is low, interlock start the standby fan(.<3.78 KPa)
 Running fan trip, interlock start the standby fan..
 Difference value of Flame detector cooling air and furnace pressure is low, interlock start the standby fan.(<3.0 KPa)
Stop permission
 When two Flame detector cooling fans is running, outlet main pipe pressure is normal, permit stopping any a fan.
 After MFT tripped, have 3 hours and flue gas temperature is less than 80 degree.
Interlock & Protection of Temperature Probe
Interlock conditions of Flue gas probe
 Overload protection, alarm

 Temperature of Flue gas is higher, alarm >538 °C
 Temperature of Flue gas is highest, automatically retract, alarm >580°C
25
Interlock of Boiler
 Two airpreheaters tripped after delay 5 minute, trip two induced draft fans, two primary air fans, 4 coal pulverizers, 4 coal
feeders in manner of interlock, close feeding oil quick close valve in manner of interlock, and trip all the oil guns
 Two induced draft fans tripped, trip 4 coal pulverizers, 4 coal feeders in manner of interlock, close feeding oil quick close
valve in manner of interlock, and trip all the oil guns
 Two induced draft fans tripped, trip two primary air fans, 4 coal pulverizers, 4 coal feeders in manner of interlock, close
feeding oil quick close valve in manner of interlock, and trip all the oil guns
 Two primary air fans tripped, trip 4 coal pulverizers, 4 coal feeders
 One airpreheater tripped after delay 5 minute, trip this side induced draft fan, one this side primary air fan
 One induced draft fan tripped, trip this side forced draft fan, trip this primary air fan
 When three or excess three operating coal pulverizers are running. One primary air fan tripped , trip 2 coal pulverizers of A
and D, 2 coal feeders of A and D
Interlock & Protection of FSSS

Purge Permissives
 No MFT trip conditions

 At least one forced draft fan operating.
 At least one induced draft fan operating.
 Two airpreheater operating.
 All the flame detector probes cannot detect flame, and all the flame detectors no fault.
 (Two) Feeding oil quick close valves closed, (two) return oil quick close valves closed, all the oil angle valve closed;
 All the coal pulverizers stopped and all outlet valves closed
 All coal feeders stopped;
 all the oil angle valve closed;
 All primary air fans stopped
 Furnace air volume>30% BMCR<40%
 Secondary air dampers in purging place (openings off 80% or more secondary air dampers )
 Furnace pressure normal ±400Pa(FROM MCS)
26
 Flame detector cooling air pressure normal (4KPa)
 Steam drum water level normal (-230> drum level<200mm)
 MFT conditions
 Two forced draft fans stopped.

 Two induced draft fans stopped.
 Manual MFT: the two buttons of MFT pressed by operator at the same time
 Steam drum water level greater than (+200mm) (it lasts for 5s at least in case of 2/3)
 Steam drum water level less than (-230mm) (it lasts for 5s at least in case of 2/3)
 High pressure of furnace pressure: three hard input signals (2of3), this condition must last for 2s at least (+1470Pa)
 Low pressure of furnace pressure: three hard input signals (2of3), this condition must last for 2s at least (-1470Pa)
 Boiler air volume<30%, three hard input signals (2of3), this condition must last for 25s at least (<180T/hr)
 a. Load >40%, steam turbine tripped 10 s.
 b. In case of load<40%, steam turbine tripped, time delayed 10s, and bypass invalid, boiler MFT;
 During the operation of any coal layer, two primary air fans stopped, and all oil guns (heavy oil, light oil) unenabled.
 All airpreheaters stopped, time delayed 5 minutes
 Flame out of entire furnace: loss of all flame with burning memory (heavy oil, light oil, coal
 Loss of flame detector cooling air; low pressure of furnace cooling air, this condition must last for 15s at least.
 All fuel tripped with burning memory (heavy oil OFT, light oil OFT, all coal pulverizers tripped
 All feed water pumps stopped delay 5 s.
Result checklist after MFT tripped

 Alarm, ask for furnace Purging requirement
 Trip MFT relay;
 Trip all oil combustors (close all oil angle valves, add MFT relay hard trip)
 OFT action, Close light oil supply fast valve of oil manifold
 OFT action, Close weight oil supply fast valve of oil manifold
 Trip all coal pulverizers
 Trip all coal feeders
 Shut-off valves of coal pulverizer
27
 Close all cold/hot air valves of coal pulverizer
 Trip all primary air fans
 Send the MFT action signal to soot blower, tripped
 Open all dampers of fuel air and auxiliary air.
 Send the MFT.action signal to electric dust catcher ,tripped
 Turbine tripped
Result checklist of hard wire logic after MFT tripped
 All primary fans tripped

 All mill tripped
 All coal feeder tripped
 Close all fuel oil returned valves
 Close supply oil shut-off valves(light oil and weight oil)
 All oil angle valves(light oil and weight oil)
 Close main valves of superheater detemperaturer
 Close main valves of reheater detemperaturer
 Electric dust-catcher tripped
 Soot blowing system tripped
Interlock of BTG
 Boiler MFT tripped ,trip turbine, trip generator oil

Switch
 Turbine tripped and load>40%, trip MFT,trip generator oil
Switch
 Generator transformer block protection tripped, trip turbine; when turbine tripped and load >40%,trip MFT
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Interlock test checklist of steam and water system
Boiler steam pressure protection test

 Steam header steam pressure is more than 14.07MPa,ERV solenoid pressure relief valve is automatically opened
 Steam header steam pressure is less than 13.6MPa,ERV solenoid pressure relief valve is automatically closed
Steam exhaust electric valve1#, 2# is started in boiler superheat steam header
 Steam exhaust electric valve2# is closed, interlock close valve1#

 Steam exhaust electric valve 2# is opened, interlock open valve1#
Steam exhaust electric valve1#, 2# is started in boiler reheat steam header
 Steam exhaust electric valve2# is closed, interlock close valve1#
 Steam exhaust electric valve 2#is opened, interlock open valve 1#
Boiler emergency blow-off electric valve for water1#, 2# (set interlock switch)
 When the water level of drum decreases from 100mm to 50MM, interlock close emergency blow-off electric valve1#,2#, low
water level alarm
 When the water level of drum increases to 100MM, interlock open emergency blow-off electric valve1#,2#, high water level
alarm
Electric valve and control valve interlock condition of boiler desuperheating water
 When MFT is started or the load is less than 20%, interlock close superheat steam system desuperheating water sub-electric-valve,
each desuperheating water control valve automatically changed to manual control, and interlock close
 When superheater primary desuperheating water control valve of side A is closed(<3%),or MFT starts, or the load is less than
20%,interlock closes corresponding desuperheating water sub-electric-valve
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 Superheater primary desuperheating water control valve of side A is opened (>3%), interlock opens corresponding superheater
desuperheating water sub-electric-valve.
 When superheater primary desuperheating water control valve of side B is closed(<3%）,or MFT starts, or the load is less than
 Superheater primary desuperheating water control valve of side B is opened (>5%), interlock opens corresponding superheater
 When superheater secondary desuperheating water control valve of side A is closed(<5%,or MFT starts, or the load is less than
 Superheater secondary desuperheating water control valve of side A is opened (>5%), interlock opens corresponding superheater
 When superheater secondary desuperheating water control valve of side B is closed(<5%,or MFT starts, or the load is less than
 Superheater secondary desuperheating water control valve of side B is opened (>5%), interlock opens corresponding superheater
 MFT starts or the load is less than 20%,interlock closes reheating system desuperheating water electric sub-electric-valve, each
desuperheating water control valve automatically changed to manual control, and interlock close
 When reheater desuperheating water control valve of side A is closed(<5% or MFT starts, or the load is less than 20%,interlock
closes corresponding reheat desuperheating water sub-electric-valve
 Reheater desuperheating water control valve of side A is opened >5% interlock opens corresponding reheater desuperheating
water sub-electric-valve.
 When reheater desuperheating water control valve of side B is closed(<5%,or MFT starts, or the load is less than 20%,interlock
closes corresponding reheat desuperheating water sub-electric-valve
 Reheater desuperheating water control valve of side B is opened >5% interlock opens corresponding reheater desuperheating
water sub-electric-valve.
 Reheater emergency spray water control valve is closed<5% or MFT starts, or the load is less than 20%, interlock close
corresponding reheater emergency spray water electric valve
 Reheater emergency spray water control valve is opened >5% interlock open corresponding reheater emergency spray water
electric valve
Boiler (startup) hearth heating steam general electric valve
 The temperature of furnace is less than 80° and MFT starts, startup is accessible
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 No MFT, interlock is closed, startup is not accessible.
 The pressure of drum is to 0.2Mpa, interlock close, startup is forbidden.
Interlock test checklist of fuel oil system
Light oil system
LDO supply pump
Start condition
 Remote control
Trip condition
 Motor fault
Interlock start conditions of LDO supply pump
 Outlet pressure is low, start standby pump
 Motor fault of operating pump, start standby pump
Test checklist of light oil OFT

Trip conditions of light oil:
 Main fuel trip: MFT relay tripped or any MFT condition available or with “MFT memory”
 Manual light oil OFT: Operation gives off light oil OFT instruction from operator station frame
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 Light oil manifold pressure low: Low pressure of oil manifold (2of 3) lasts for more than 5s, and some oil angle valves still
open (<1.8MPa)
 Light oil supply fast valve closed, and some oil angle valves still open;；
 Low pressure of compressed air (2of 3) lasts for more than 10s, and some oil angle valves still open
Start the following equipments in manner of interlock after OFT

 Close all angle valves of light oil
 Close light oil stream valve
 Close light oil supply cut-off valve
 Close light oil return cut-off valve (pulse)
 Withdraw light oil ignition gun
OFT reset conditions
 All angle valves closed
 MFT relay reset
 Light oil OFT (soft) trip conditions not available.
 Open main inlet fast shut-off valve of light oil
Test checklist of light oil leakage procedures

Light oil leakage test permissive conditions:
 MFT relay tripped
 OFT tripped (soft)
 Light oil feeding quick-closing valve closed
 All the oil angle valve closed
 Oil return quick close valve closed
 All the flame detector indicate no flame
Light oil system fuel leakage test sequence

 If permissive conditions are met, command to start up leakage test can be sent from the operator station screen
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 Open the oil return quick close valve of light oil (meanwhile, open the fuel pressure regulation valve), closed after 10s. And
display "light oil fuel leakage test Actual actions proceeding" on operator station screen;
 Within 300s, if the manifold pressure after the light oil feeding quick close valve low (difference value <0.05MPa), then the
light oil feed quick close valve leakage test passed; Or else, light oil feeding quick close valve considered leaked, fuel oil
leakage test failed, and it will be displayed on the operator station screen
 If the light oil feeding quick close valve leakage test passed, open the light oil feeding quick close valve, charge oil: After the
manifold pressure becomes high
 Within 180s, if manifold pressure after the light oil feeding quick close valve high (>2.8MPa, difference value <0.4MPa), then
the light oil return oil quick close leakage test passed; Or else, light oil return oil quick close valve considered leaked, leakage
test failed, and it will be displayed on the operator station screen
Oil leakage test interrupting conditions
 10min after the oil leakage test begins

 Ignition oil charging failed
 Oil leakage test succeeded
 Oil leakage test failed
Test checklist of light oil combustor
Light oil startup permissive
 Flame detect no fault
 Flame detector not flame on
 Local cabinet power supply well.
 Local operation request no.
 Oil valve AND purge valve closed.
Trip Conditions
 Light oil OFT
 Ignition failed
 Oil valve open failed
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 Oil valve not closed AND oil gun not forward
Sequence Start
 Forward light oil gun
 Forward igniter gun
 Open light oil valve
Sequence stop
 Close light oil valve
 Forward light oil gun
 Forward igniter gun
 Open purge valve
 Close purge valve
 Backward light oil gun
Heavy oil system
HFO supply pump
Start condition
 Remote control
Trip condition
 Motor fault
Interlock start conditions of LDO supply pump

 Outlet pressure is low, start standby pump
 Motor fault of operating pump, start standby pump
Test checklist of heavy oil OFT

Trip conditions of heavy oil:
 Main fuel trip: MFT relay tripped or any MFT condition available or with “MFT memory”
 Manual light oil OFT: Operation gives off heavy oil OFT instruction from operator station frame
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 Heavy oil manifold pressure low: Low pressure of oil manifold (2of 3) lasts for more than 5s, and some oil angle valves still
open;
 Heavy oil supply fast valve closed, and some oil angle valves still open;；
 Low pressure of atomizing steam (2of3) lasts for more than 10s, and some oil angle valves still open
 Low temperature of heavy oil, time delayed 1min, and oil angle valve still open
Start the following equipments in manner of interlock after OFT

 Close all oil valves of heavy oil
 Close all purging valves of oil gun
 Close heavy oil supply cutoff valve;
 Close heavy oil return cutoff valve (pulse);
 Close atomizing valve of heavy oil
OFT reset conditions

 All angle valves closed
 MFT relay reset
 Heavy oil OFT (soft) trip conditions not available.
 Open main inlet fast shut-off valve of weight oil
 Test checklist of Heavy oil leakage procedures
Weight oil leakage test permissive conditions
 MFT relay tripped
 OFT tripped (soft)
 Heavy oil feeding quick close pneumatic main valve closed;
 Heavy oil leakage test valve closed;
 All the oil angle valve closed;
 Return oil quick close valve closed
 All the fire detector indicate no flame;
 Oil source pressure permissive.
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Weight oil system fuel leakage test sequence
 If permissive conditions are met, command to start up leakage test can be sent from the operator station screen;
 Open the oil return quick close valve of heavy oil (meanwhile, open the fuel volume regulation valve), closed after 10s.
 Within 300s, if the manifold pressure after the heavy oil feeding quick close valve low (<0.3MPa), then the heavy oil feeding
quick close main valve leakage test passed; Or else, heavy oil feeding quick close main valve considered leaked, fuel oil
leakage test failed, and it will be displayed on the operator station screen.
 The heavy oil feeding quick close main valve leakage test passed, open the heavy oil feeding quick close main valve, charge
oil: After the manifold pressure becomes high, close heavy oil feeding quick main valve.
 Within 180s, if manifold pressure after the heavy oil feeding quick close main valve high (>1.2MPa, difference value
<0.4MPa), then the heavy oil return oil quick close valve and oil valve leakage test passed; Or else, heavy oil return oil quick
close valve considered leaked, leakage test failed, and it will be displayed on the operator station screen.
Oil leakage test interrupting conditions
 10m after the oil leakage test begins

 Ignition oil charging failed
 Oil leakage test succeeded
 Oil leakage test failed
Test checklist of Heavy oil combustor

Heavy oil startup permissive
 Flame detect no fault
 Flame detector not flame on
 Local cabinet power supply well.
 Exists igniter power.
 Heavy oil valve AND purge valve closed.
 Heavy oil atomizing valve closed.
 Corresponding light oil flame existed OR corresponding coal layer existed OR load of boiler is more than 60%
 Trip Conditions
MFT tripped
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 Heavy oil OFT
 Il gun not feeded in place
 Ignition failed
 Oil valve open failed
 Oil valve not closed AND oil gun not forward
 Oil valve opened AND atomizing valve not opened.
Sequence Start
 Forward Heavy oil gun
 Open heavy oil atomizing valve
 Open heavy oil valve.
Sequence stop
 Close heavy oil valve
 Close atomization valve
 Forward heavy oil gun
 Open purge or atomizing valve
 Close purge or atomizing valve
 Backward heavy oil gun
ESP & Bag filter
 When the flue temperature ≤180°C, treats it as the normal situation, close the Bypass system and open the shield air circuit.
 When the flue temperature >180°C, the Flue temperature will be bad for the filter bag, the control system will open the bypass
Valve and close the lifting valve in bag field, then the flue go though bypass directly to the outlet.
 When the flue temperature descends to ≤160°C, the Control system will open the bag field’s lifting valve, and close bypass
valve. Right now the system is considered as normal status.
 Seriously monitor the conditions of flue temperature, pressure drop and pressure of precipitator’s each point, makes a record
each 30 min, immediately contact with the supervisor or boiler mid-control while appears abnormal situation.
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.
Turbine & Auxiliaries Interlock &

Protection
WPCL, Warora
Condensate Extraction Pump (CEP)

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Sequence startup procedures of condensate pump
 Close outlet valve

 Startup motor
 After condensate pump is operated for 5sOpen outlet valve
Sequence stop procedures of condensate pump

 Close outlet valve of condensate pump
 Stop condensate pump
Inspection of startup permissive conditions of condensate pump
 Hot well water level of condenser normal (320mm to 795mm)

 Condensate pump's outlet valve closed or standby one enabled
 CEP winding temp <130◦C
 Thrust bearing of A/B condensate pump temperature less than 70◦C
 Condensate recycle channel opened
 No trip condition
 Breaker Healthy or in test position.
Inspection of protective tripping conditions of condensate pump
 Hot well water level of condenser low low (<120mm)

 CEP motor bearing temperature high NDE (alarm ≥ 70◦C Trip ≥ 80◦C)
 CEP motor bearing temperature high DE (alarm ≥ 70◦C Trip ≥ 80◦C)
 CEP motor winding temp high (1 of 6) (alarm ≥ 130◦C Trip ≥ 140◦C)
 Local push button operated
 CEP thrust bearing temperature high (1 of 2) (alarm ≥ 70◦C Trip ≥ 80◦C) After pump startup for 20s, it is still "Close" signal at
outlet valve
 CEP running AND outlet valve closed delay 20 S
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 Vibration of CEP shaft is high (alarm≥ 7.1mm/s Trip≥ 11.2mm/s)
Interlock
 CEP running delays 5sec, open outlet motor valve

 CEP stop ,close outlet motor valve
 Enable CEP as standby , open CEP outlet motor valve
 Enable CEP standby, CEP emergency tripped, immediately standby CEP starts.
 Enable CEP standby , when CEP main pipe pressure ≤ 1.32 MPa delays 3 s ,start standby CEP
 Condenser level lower , open make up water motor valve (≥ 300mm)
 Condenser level higher, close make up water motor valve( ≤ 795mm)
 When condensate flow <120t/hr, open recirculation motor valve
 When condensate flow >240t/hr , close recirculation motor valve
LP casing spraying desuperheating water valve opened automatically
 LP casing exhaust temperature high <65◦C, closed in manner of interlock

 LP casing exhaust temperature high >80◦C, opened in manner of interlock
Condensate to steam turbine proper drainage flash chamber desuperheating water valve
 Proper flash chamber temperature high (≥60◦C), opened in manner of interlock, non-high release
Condenser hot well water level regulation valve
 Hot well water level high, closed in manner of interlock, non-high release
 Hot well water level low, opened in manner of interlock
Condenser 3-stage desuperheating water valve
 LP bypass opened and opened in manner of interlock

 Temperature downstream LP bypass < 60◦C close in a manner of interlock
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 Temperature downstream LP bypass > 100◦C open in a manner of interlock
Circulating water system
Startup permissive conditions of CW pump
 Remote CWP control

 CWP thrust bearing temp <80◦C
 CWP guide bearing temp <75◦C
 CWP under bearing temp <80◦C
 CWP proper thrust bearing temp <80◦C
 Lube cooling water flow low
 Condenser inlet/outlet motor valve open
Protective tripping conditions of CW pump
 CWP under bearing temp high (alarm 80◦C trip 85 ◦ C)

 Thrust bearing temperature of CW pump motor high (alarm 80◦C trip 90 ◦ C)
 Motor coil temperature of CW pump is high (alarm 120◦C trip 125 ◦ C)
 CWP guide bearing temp high (alarm 75◦C trip 80 ◦ C)
 CWP proper thrust bearing temp high alarm (80◦C trip 90 ◦ C)
 Local push button operated
Interlock
 When running CWP emergency tripped starts standby CWP in interlock
 When Header pressure is low automatically start the standby pump in interlock
 Discharge butterfly valve automatically after pump startup
 When butterfly valve open 20deg CWP startup
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 After CWP startup 60 sec outlet butterfly valve accident, stop CWP
 When CWP outlet valve close to 20 deg, stop CWP
 When CWP tripped, outlet butterfly valve automatically closes
Sequence startup procedures of CW pump
 Close CW PUMP outlet valve

 Open CW PUMP inlet valve
 When Outlet valve of CW pump open 15°or CW pump operating, startup A CW pump
Sequence stop procedures of CW pump
 Close outlet valve of CW pump to 75°
 Stop motor of CW pump

Cooling water booster pump startup
When running cooling water booster pump tripped and enable standby pump, interlock start up the standby pump
When cooling water booster pump main pipe pressure lower, start standby pump in interlock
Pump suction pressure <0.1MPa both pump will not start
Sequence startup procedures of A cooling water booster pump

 Close outlet motor valve of cooling water booster pump
 Startup cooling water booster pump
 Delay 5s,open outlet motor valve of cooling water booster pump
Sequence stop procedures of A cooling water booster pump

 Close outlet motor valve of cooling water booster pump
 Stop cooling water booster pump
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Boiler Feed Pump Interlock & Protection
Protection
 Deaerator water level LL (2of3) ≤380mm
 Lube oil pressure LL ≤0.05 MPa
 BFP operating booster pump inlet motor valve closed
Inlet oil temp working oil ≥130°C alarm 110°C
BFP thrust bearing temp ≥95°C alarm 80°C
 Motor bearing temperature of booster pump end ≥90°C alarm 80°C delay 3 sec

 Motor bearing temperature of hydraulic coupler end ≥90°C alarm 80°C delay 3 sec
 Booster pump drive/free end bearing temp ≥90°C alarm 75°C delay 3
 BFP inside /outside radial bearing temp ≥90°C alarm 75°C delay 3
 BFP hydraulic couples radial bearing temp ≥95°C alarm 85°C delay 3 (1-7)
 BFP winding temp ≥130°C alarm 110°C delay 3 (1 -6)
 Local emergency button operated
 When BFP operation, flow ≤128 t/hr and minimum flow valve is closed., delay 15 sec BFP will tripped.
 Motorized feed water pump operating and booster pump inlet valve closed
Start Permissives
43
 Booster pump inlet motorized valve & Recirculation valve fully opened
 Lube oil pressure normal ≥0.1MPa
 Deaerator water level normal
 Booster pump inlet valve opened
 Scoop tube position≤5%
 Booster pump drive/free end radial bearing temperature <75°C
 Motor bearing temperature of booster pump end <80°C
 Motor bearing temp of hydraulic-coupler end <80°C
 Hydraulic coupling bearing (10th point )< 85°C
 BFP thrust bearing temp(upside, downside) <85°C
 BFP winding temperature <110°C
 Working oil cooler inlet temp<110°C
 BFP outlet motor valve closed OR standby
 Differential pressure of inlet screen for motorized feed water pump and booster pump is abnormal
Sequence startup procedures

 Startup auxiliary oil pump and lube oil pressure normal, Scoop tube at minimum position (<5%)
 Open recirculation valve
 Open booster pump inlet valve
 Close motor outlet valve
 Startup motor
 Open motor outlet valve

 Startup auxiliary oil pump and lube oil pressure not low
 Scoop tube placed at minimum position (<5%)
 Close outlet valve
 Stop the motor
44
Actions to enable motorized feed water pump as standby
Startup auxiliary oil pump

 Open booster pump motor inlet valve
 Open BFP outlet motor valve
 Scoop tube placed at minimum position
 Open motor valve of Reheater
Interlock
 Running BFP tripped, immediately start standby BFP in interlock

 BFP enabled as standby, open the valve in manner of interlock
 BFP stopped, close outlet valve in manner of interlock
 When BFP operation and flow ≤128T/Hr Recirculation valve opened
 When BFP operation and flow ≥283T/Hr Recirculation valve closed
 When enable standby, scoop tube position of standby BFP adjust as the same scoop tube position of running BFP
Auxiliary oil pump interlock of motorized feed water pump
 Motorized feed water pump operating and lube oil pressure lower than 0.08 MPa, automatic startup
 Enable motorized feed water pump as standby and start in manner of interlock
 Motorized feed water pump stopped and protection ON
 BFP operating and lube oil pressure higher than 0.3 MPa , delay 5 sec and auxiliary oil pump automatically stop
Vacuum system
Vacuum pump startup permissive conditions

 Vacuum pump inlet pneumatic valve closed
 Control by remote
45
 Steam/water separator level is normal
Interlock
 Start vacuum pump, interlock start-up circulate pump and open inlet butterfly valve
 Stop vacuum pump, interlock close inlet butterfly valve
 Running pump trip, interlock start standby pump
 Steam/water separator level low, delay 5 min trip the pump
 Vacuum pump A operating or standby, and separator water level low, automatically open water makeup solenoid valve of
steam-water separator
 Vacuum pump A water level high, automatically close water makeup solenoid valve of steam-water separator
 When condenser pressure >14 Kpa and one pump in operation , interlock start standby pump.
Lube oil system

Interlock
 When lube oil pressure is low, interlock start AC lube oil pump (Pr. ≤0.049MPa)
 When turbine trips interlock start AC lube oil pump
 When lube oil pressure is lower interlock start DC LOP (Pr ≤0.0392MPa)
 AC lube oil pump emergency tripped, interlock start DC LOP.
 When running JOP tripped interlock start standby JOP
 When JOP running and outlet pressure is low , interlock start standby pump
(Pr ≤ 7MPa)
 Turbine rotational speed (>1220rpm) , stop JOP.
 Turbine rotational speed (<1220rpm), start JOP.
Start permissive barring gear motor

 Jacking oil pressure ≥ 8 MPa
 Lube oil pressure ≥ 0.08 MPa
Tripped
 Lube oil pressure low (Pr. ≤0.029MPa)
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EH oil system
EH oil pump interlock protection
 EH oil manifold pressure lower to 11.2 MPa alarm, and start up standby EH oil pump by means of interlock
 DEH oil pump emergency trip, interlock start standby pump.
Start-up permissive
 Oil tank level normal
 Oil temperature is >20 deg C.
Deaerator system
Interlock
 Deaerator water level HH (.2550mm), Deaerator overflow valve opened in manner of interlock,
 Deaerator water level not high,(<2350mm) Deaerator overflow valve closed in manner of interlock
 When water level is high II, close MOV of extraction # 3 , check valve of extraction # 3 , close drain control valve of HP
heater # 2 to dearator.(>2650mm)
Close 1 to 5 extraction check valve & close 1 to 6 Extraction MOV

 Turbine trips
 Generator tripping
 OPC acts
HP heater system
Interlock
 HPH # 1 water level is high II, open emergency drain control valve. (>600mm)
 HPH # 1 water level is low I, close emergency drain control valve. (<250mm)
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 HPH # 1 water level is high III, HP heater is tripping (.>800mm)
 HPH # 2 water level is high II, open emergency drain control valve, close normal drain control valve from HPH # 1 to HPH #
2 (>600mm)
 HPH # 2 water level is low I, close emergency drain control valve. (<250mm)
 HPH # 2 water level is high III, HP heater is tripping (.>800mm)
 Drain valve in front of HPH # 1 extraction MOV interlock open

 Turbine tripping
 Turbine load <10%
 Check valve of extraction # 1 is close
 MOV of extraction # 1 is close
 Extraction temperature difference between up & down wall is > 40 deg C
 Drain valve in front of HPH # 2extraction MOV interlock open
 Turbine tripping
 Turbine load <10%
 Extraction temperature difference between up & down wall is > 40 deg C
LP heater system
Startup procedures for sequence control of LP heater

 Close LP heater emergency drain valve
 Open pipe drain valve after steam extraction electric valve/before check valve of LP heater
 Open the LP heater outlet electric valve
 Open the LP heater inlet electric valve
 Close the LP heater bypass electric valve
 Open the LP heater steam-extraction electric valve,
 Open the LP heater steam-extraction electric valve
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 10s delay and load larger than 30% , close pipe drain valve after electric valve/before check valve for 4th stage steam
extraction
Stop procedures for sequence control of LP heaters

 Close the LP heater steam extraction electric valve
 Close the LP heater steam-extraction check valve
 Open pipe drain valve after steam extraction electric valve of LP heater
 Open the pipe drain valve before check valve of LP heater
 Open LP heater bypass electric valve
 Close LP heater inlet electric valve
 Close LP heater outlet electric valve
 Open LP heater emergency drain valve
 5s delay, open pipe drain valve after steam extraction electric valve/before check valve of LP heater
Inspection of LP heater quitting conditions

 Steam turbine tripping
 Generator quitting
 LP heater water level HHH (1050mm)
 Manual quitting > OPC action
Interlock
 LPH # 4 water level is high II, open emergency drain control valve, close extraction # 4 check valve & MOV , open extraction
# 4 drain valve, Water side bypass MOV open & i/l & o/l MOV closed. (>1050mm)
 LPH # 4 water level is high I , open emergency drain control valve .(>900mm)
 LPH # 4 water level is low I, close emergency drain control valve to condenser. (<600 mm)
 LPH # 5 water level is high II, open emergency drain control valve, close extraction # 5 check valve & MOV, open extraction
# 5 drain valve, Water side bypass MOV open & i/l & o/l MOV closed. (>1050mm)
 LPH # 5 water level is high I , open emergency drain control valve to LPH # 6 & close normal drain control valve from LPH #
4 to LPH # 5.(>900mm)
 LPH # 5 water level is low I, close emergency drain control valve to condenser. (<600 mm)
 LPH # 6 water level is high I, choose any one of the CDP (drain water pump) as standby , then interlock starts the drain pump
& open’s the pump outlet control valve. (>900mm)
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 LPH # 6 water level is high II, open emergency drain control valve, close LPH # 5 normal drain to LPH # 6 control valve ,
close extraction #6 MOV , open extraction # 6 drain valve, Water side bypass MOV open & i/l & o/l MOV closed.
(>1050mm)
 LPH # 6 water level is low I close emergency drain control valve (<700mm)
 LPH # 6 water level is low II , interlock stop drain water pump. (≤550mm)
 Drain valve in front of LPH # 4 extraction MOV interlock open
 Turbine load is <20%
 Drain valve in front of LPH # 5extraction MOV interlock open

 Turbine load is <20%
Main steam and drainage system
Load <10%, open following valves automatically
 Left side main steam pipe drain valve

 Right side main steam pipe drain valve
 HP guide steam pipe drain valve
 Steam turbine HP main steam valve (left) upper seat drain valve
 Steam turbine HP main steam valve (left) lower seat drain valve
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 Steam turbine HP main steam valve (right) upper seat drain valve
 Steam turbine HP main steam valve (right) lower seat drain valve
 Steam turbine HP casing steam exhaust pipe (left) drain valve
 Steam turbine HP casing steam exhaust pipe (right) drain valve
 Steam turbine HP casing steam exhaust manifold drain valve
 Drain valve before 1st stage steam extraction electric valve
 Drain valve before 1st stage steam extraction check valve
 Drain valve after 1st stage steam extraction electric valve
 Drain valve after 1st stage steam extraction check valve
 HP bypass pipe drain valve
Load >10%, Close following valves automatically
 Left side main steam pipe drain valve

 Right side main steam pipe drain valve
 HP guide steam pipe drain valve
 Steam turbine HP main steam valve (left) upper seat drain valve
 Steam turbine HP main steam valve (left) lower seat drain valve
 Steam turbine HP main steam valve (right) upper seat drain valve
 Steam turbine HP main steam valve (right) lower seat drain valve
 Drain valve before 1st stage steam extraction electric valve
 Drain valve before 1st stage steam extraction check valve
 Drain valve after 1st stage steam extraction electric valve
 Drain valve after 1st stage steam extraction check valve
 HP bypass pipe drain valve
51
 Left side reheating steam pipe drain valve
 Right side reheating steam pipe drain valve
 Steam turbine combined reheat valve (left) drain valve
 Steam turbine combined reheat valve (right) drain valve
 Drain valve before 3rd stage steam extraction electric valve
 Drain valve after 3rd stage steam extraction check valve
 Drain valve before 4th stage steam extraction electric valve
 Drain valve after 4th stage steam extraction check valve

 Left side reheating steam pipe drain valve
 Right side reheating steam pipe drain valve
 Steam turbine combined reheat valve (left) drain valve
 Steam turbine combined reheat valve (right) drain valve
 Drain valve before 3rd stage steam extraction electric valve
 Drain valve after 3rd stage steam extraction check valve


52
 Drain tank water level HH, opened in manner of interlock, not high, closed in manner of interlock
 Steam pipe drain valve before LP bypass valve A
 Steam pipe drain valve before LP bypass valve B
 Steam pipe drain valve after LP bypass valve A

 Steam pipe drain valve after LP bypass valve B
 Steam turbine tripping or generator quitting, HP casing left side steam exhaust check valve closed in manner of protection
 Steam turbine tripping or generator quitting, HP casing right side steam exhaust check valve closed in manner of protection
Shaft seal system

Self start of shaft seal fan A
 Enable interlock, and pump B tripped under emergency
Self start of shaft seal fan B
 Enable interlock, and pump A tripped under emergency
Bypass system
HP Bypass
Automatic opening
53
 Turbine trip
Automatic closing
 Temperature behind HP bypass is High (360◦C)
 Desuperheating water pressure is low (switch)
Interlock
 HP bypass valve open, open desuperheating isolating valve
 HP bypass closes, interlock close desuperheating isolated valve
 HP bypass closed, interlock close desuperheating control valve
 Relief valve is close, desuperheating control valve is forbidden to open
LP bypass
Automatic opening
 Turbine trip
Automatic closing
 Condenser vacuum low ≤-70Kpa (2/3)
 Condenser temperature high ≥70◦C
 After-LP bypass valve temperature high ≥170◦C
 LP bypass spray water pressure low
Interlock
 LP Bypass open, open desuperheating control valve is open
 LP Bypass control valve open, open desuperheating isolating valve
 LP Bypass control valve close, close desuperheating isolating valve
Turbine
54
 Lubricating oil pressure is low II (≤.0392MPa ≤.0392MPa Trip)
 Over speed (DEH 3300rpm, TSI 3300rpm)
 EH oil pressure is low II (≤7.8MPa ≤7.8 MPa Trip)
 Bearing vibration is high (.25mm/s .127mm/s)
 Vacuum is low (19.7 Kpa /14.7 KPa )
 Displacement of axial direction is high (alarm +0.6mm,-1.05mm. trip +1.2mm,
 -1.65mm)
 Differential expansion of HP MP casing is high (alarm +6.2mm,-3mm. trip +6.2mm,
 -3.2mm)
 Differential expansion of LP casing is high (alarm +7mm,-6mm. trip +7.2mm, -6.2mm)
 LPT Exhaust temperature is high (alarm 80◦C trip 120◦C)
 Bearing temp is high (alarm 105◦C trip 115◦C)
 Thrust bearing temp is high (alarm 100◦C trip 110◦C)
 Trip in the control room
 Local trip turbine
 Boiler MFT
 Main protection of generator acts
 DEH fault.
55
Procedure of Latching and Rolling
Before Latching : Start EH oil Pump
Screen Status
Auto Control In message screen 1) Trip 2) Auto 3) All control valve closed
Solenoid
monitor All solenoids should be green ( Discharged )
Auto Control Click on ' LATCH' ( Gray )
Solenoid
monitor Solenoid 5, 6, 7 and 8 turn ' RED'.
Auto Control Check ' LATCH ' turned ' RED'
With above sequence Latching get completed. Now turbine ready to roll, If all parameters built up as per Turbine condition
Auto Control Click on 'RUN'

Solenoid
monitor
Auto Control Main steam and Reheat steam stop valve will open.
For starting Rolling ( Increasing speed )
Auto Control Click on ' SPEED RATE ' and give a value ( Exa.- 100 - 200 RPM/Minute)
Click on ' TARGET ' and give a value ( Exa- 500 RPM )
Auto Control Click on ' GO/HOLD ' and select 'GO' and watch the speed rise.
Then as per the Turbine temperature diffrence between top and bottom, Diffrencial Expansion,Bearing Vibration soak the turbine .
56
BLACKOUT CHECKLIST
1) Ensure DG start and emergency bus charged.

2) Ensure EOP and APH DC motor started (IF EOP/AOP not Pick up then open vacuum breaker
valve
3) All proper drains valves from to be close from DCS as well as isolation valve to be close from local
to avoid condenser pressurization.
4) Ensure Boiler & Turbine MOV panel charged from Emergency Bus.
5) Close both side M.S.S.V
6) Ensure HP LP by pass valve in close condition otherwise start EH pump & close it.
7) Ensure all Extraction MOV and NRV are in close condition.
8) Start Scanner Air Fan & kept other in interlock.
9) Ensure both BFP AOP are in service otherwise start it.
10) Open R.H Vent
11) Close Blow down valves.
12) Ensure all soot blowers are in retract position.
13) At -30 Kpa vacuum open breaker valve and isolate gland sealing.
14) Ensure JOP has pick up at 1200 rpm
15) Start AOP and stop EOP(KEEP it in interlock in)
16) Ensure TG came to barring gear as soon as TG 0 speed reached.
57
AUTO SYNCHRONIZATION
: 1 /2
Operation task:generator Unit-1 voltage up through auto excitation; auto synchronization
ti
Seq. Operation Item √ m
e
一 safety measures
Implement operation supervision system strictly. The supervisor should be experienced operator or
1
above.
2 Wear insulation gloves and proper working tools.
3 The staff is both physically and psychologically well and familiar with the system.
二 operation measures
1 Rehearse the operation mentally.
2 Unit-1 Check the cooling water system of generator Unit-1 air cooler is working normally.
# 1 Check the rotation speed of turbine Unit-1 is steady. Maintain the rotation speed of the turbine be
3
the same with grid frequency.
Unit-1 Verify that generator transformer Unit-1 is put into service correctly.(only
4
one set of rotor earthing protection is to be put into service)
5 Close “power Ⅰto operation box 4QF”and “power Ⅱ to operation box 5QF”
Unit-1 “CH1” AVR ON” “REMOTE” Check AVR of generator Unit-1 excitation room(small) is
6 running at "CH1", "AVR ON" lamp is on and "REMOTE" lamp is off.
DCS # 1 “Excitation Launch” Click AVR Unit-1 on the DCS panel and enter its
7 interface. Close excitation suppression switch and take “Excitation Launch”.
8 Unit-1 Check the generator excitation system of Unit Unit-1 is put into service normally.
Unit-1 13.11kV 13.8*0.95Check the voltage of generator Unit-1 automatically rises to around 13.11kV.
9 13.8*0.95
10 “INC EXC” 13.8 kVUg=U（220KVg）×13.8／235
58
Use “INC EXC”button to increase the generator voltage to the rated value of 13.8kv;
(follow busbar voltage regulating and slightly higher than busbar voltage)
Ug=U（220KVg）×13.8／235
Unit-1 75.4v； 567.4A) Verify that 3 phases voltage of generator Unit-1 is balanced
11 and no-load excitation parameters such as voltage and current are correct.( compare
to no-load rated parameters 75.4v； 567.4A)
12 # 1 DCS Verify that there is no abnormal signal in generator Unit-1 protection
panel, excitation room and DCS.
13 “SELF” Confirm that synchronization select switch is at “SELF”position.
1 SWJ 2ZK Confirm that the SWJ power 22K of mazaic control panel #1 is already
14 closed and synchronization is put into service.
3 1MCB Confirm that the power MCB of synchronizing unit of mazaic control panel #3
15
is already closed.
16 4 STK "AUTO" Confirm "AUTO" is selected at mosaic control panel #4 STK.
4 ATRESIA（QK “Exit atresia” Confirm “Exit atresia” is selected at mosaic control
17
panel #4 ATRESIAQK
1 #1 1DL “CLOSE”
DCS 1DL “START” Change outlet breaker 1DL of generator transformer Unit-1 on mosaic control
18
panel Unit-1 over to “CLOSE”and put synchronization into service.(or click "START" at the interface
of DCS generator transformer outlet breaker 1DL to put synchronization into service)
59
DEH AUTO Control “sync” Check the interface of DEH AUTO Control and verify that
19
“sync”lamp is on (RED)
DEH AUTO Control “sync”，DEH Click "sync" in the interface of DEH AUTO Control to put
20
DEH synchronization into service.
DEH Check DEH to send synchronization permission signal and the synchronization meter
21
should be charged.
22 Manually adjust the generator frequency and voltage to be the same with those of grid system.
3 “START UP Press close button of auto sync "START UP" breaker on mosaic control panel
23
#3.
Verify that synchronization unit is working normally.(it automatically regulate the generator frequency and
24
voltage be the same with those of the grid system.
25 # 1 1DLVerify that the auto closing of generator Unit-1 breaker 1DL is normal. (Red lamp on)
26 # 1 Verify that the indication of stator 3-phases current is correct..
27 DEH “sync” Verify the DEH synchronisation request is cancelled.（“sync” becomes grey）
DCS 1DL “Exit” Click "EXIT" on the interface of DCS generator transformer outlet breaker 1DL to cancel
28
synchronization.
1 SWJ DEH Confirm the SWJ on the control panel 1 should be reset.(sync out and withdraw
29
from "request sync from DEH" signal)
# 1 1DL Confirm that synchronization of 1DL breaker of generator transformer Unit-1 is cancelled.(lamp of
30
synchronization meter dies)
4 MANUAL HANDLE(STK)开关选择"UNCHAN"
31
Select "UNCHAN" of MANUAL HANDLE(STK) switch on mosaic control panel #4.
# 1 A 屏 19XP Disconnect “19XP GENERATOR START\STOP EARTH FAULT” protection on
32
protection panel A of generator transformer Unit-1.
# 1 A 屏 28XP Disconnect “28XP ACCIDENTAL ENERGISATION RELAY” protection on protection
33
panel A of generator transformer Unit-1.
# 1 A 屏 31XP Disconnect “31XP FLASH OVER”protection on protection panel A of generator
34
transformer Unit-1.
# 1 A “4XB CLOSE MAIN VALVE I ” Put “4XB CLOSE MAIN VALVE I ” protection into service
35
on protection panel A of generator transformer #1.
# 1 A “23XB CLOSE MAIN VALVE II” Put “23XB CLOSE MAIN VALVE II” protection into
36
service on protection panel A of generator transformer #1.
# 1 B 19XP Disconnect “19XP GENERATOR START\STOP EARTH FAULT” protection on protection
37
panel B of generator transformer Unit-1.
# 1 B 19XP Disconnect “19XP GENERATOR START\STOP EARTH FAULT” protection on protection
38
panel B of generator transformer Unit-1.
# 1 B 31XP Disconnect “31XP FLASH OVER”protection on protection panel B of generator
39
transformer Unit-1.
40 Unit-1 Verify that generator Unit-1 is working normally. 60
# 1 B “4XB CLOSE MAIN VALVE I ” Put “4XB CLOSE MAIN VALVE I ” protection into service
41
on protection panel B of generator transformer #1.
# 1 B “23XB CLOSE MAIN VALVE II” Put “12XB CLOSE MAIN VALVE II” protection into
42
service on protection panel B of generator transformer #1.
Turbine Triping and Alarm
S.No. ETS Protection TURBINE TRIP ALARAM Action
+1.2mm,-
1
Axial position 1.65mm (+0.6/-1.05) Auto
2 Shaft Vibration >0.25mm (>0.125mm) Auto
3 EH oil pressure low <7.8Mpa <12MPA Auto
4 Lube oil pressure low <0.0392Mpa <0.049MPA Auto
5 19.7Kpa
Vaccum of condenser low 14.4KPA Auto
6 TSI overspeed 3300 RPM 3240RPM Auto
7 DEH Over speed 3300rpm Auto
8 DEH Failure Auto
9 Boiler MFT action Auto
TURBINE TRIP
10 Electrical Generator and transformer protection Auto
11 Remote manual emergency shutdown Auto
12 Thrust Brg. Temp HI Auto
a.Thrst. Pad temp. >110 ºC >100 ºC Auto
b. Brg. Metal.temp.
>115 ºC >105 ºC
13 Auto
LP exhaust temp.HI >120 ºC >80 ºC Auto
14 Local manual emergency shutdown TURBINE TRIP
61
15 HIP Differential expansion +6.2mm/-3.2mm +6mm/-3mm Auto
16 LP Differential expansion +7.2mm/-6.2mm +7.2mm/-6mm Auto
17
Bearing cap vibration high 0.08mm Auto
18 >65 ºC
Bearing Drain Oil Temptreture
19 Main Steam Pressure High >16.4 MPAºC Manual
20 >30Um
Eccentricity of rotor
21 >0.13MPA&<0.02MPA
Pressure of Gland Seal
ALL CVs & ICVs AUTO CLOSE Over speed protection Control(OPC) act)
1 Generator Circuit Breaker Open
And Load > 15 % (20.25MW)
2 Rotational Speed > 103 %
3 Acceleration of Speed > 5 RPM/Min.
RESETS
LOAD ≥ 20.25 MW for 0.8 sec
220 V DC supply to DEH relay cabinate FAIL
All CVs & ICVs AUTO CLOSE
62
COORDINATED MASTER CONTROL
In a Thermal Power Unit operation the critical internal unit parameters related to production are MW, Main steam pressure. The
critical external parameter is frequency of the network. In a boiler the steam production depends on combustion control (Fuel control
and Air flow control). So one of the unit parameters MW or main steam pressure must be used for Boiler control. Turbine Generator
produces electrical output (MW) proportional to steam input to turbine. The turbine control system (EHC) varies steam input to
turbine to achieve unit parameter MW or Main steam pressure. The network stability always depends on the balance of power
production and power consumption. Any unbalance in the power production and power consumption leads to change in the frequency
of operation in the direction of attaining natural stabilization i.e., balancing of power consumption with power production. However as
the capacity of this stabilization is limited for the network for stability, proportional frequency correction is given in turbine control
system to vary the power production in the direction to achieve stability of network. The 5% regulation used generally in thermal
power units, gives 100% load correction for 5% frequency disturbance in the network. This is selected mainly to achieve network
stability within the rotating machines speed variation of 95% to 105%. At 110% Turbo generators have over speed trip protection.
In a network the power production or power consumption can change due to several reasons like units tripping on some internal
problems or load breaker tripping. So to ensure the stability of network it is necessary to have frequency regulation in Turbine control
it is also to be emphasized here that if only few units in the network implement the frequency control the total disturbance in the
network will be passed on to the units having regulation by the many units which do not have regulation. Frequency is network
parameter which can not be controlled by few units in the network.
In Thermal Power Units the Turbines are fastly responding components and Boilers are having transport lag and Thermal inertia
and hence delayedly respond with variation in command. So the Turbine will be able to meet MW demand or main steam pressure set
value quickly by positioning the control valves of Turbine to the required values. Turbine will be able to maintain only one unit
parameter MW or main steam pressure. The other is to be controlled, naturally by the boiler. The modes of operating the unit are
named as turbine follow mode and boiler follow mode. In Turbine follow mode Turbine maintains throttle steam pressure. The MW
depends on the steam output from the Boiler. The variations in the Boiler steam output will be resulting variations in MW output.
Boiler steam output variations can result from changing Calorific values of coal etc. Turbine follow mode gives more stability to unit
by controlling main steam pressure perfectly and fastly which is a very important unit parameter. If Boiler combustion controls fuel
and air are in Auto corrective actions will be taken by boiler controllers to change combustion to give desired steam for the set MW.
63
These responses will be slow when compared to turbine responses. So it may be reemphasized that this mode of operation gives
maximum stability to unit operations with slow response to grid
Contd……….2/-
64
::02::
requirements by initiating combustion controls first and turbine valves positioning after steam production. However the combustion
controls will be responding to grid requirements if frequency influence in CMC console is in ‘ON’ position only.
In Boiler follow mode Turbine maintains MW demands and Boiler maintains main steam pressure. Turbine will be responding
to grid requirement fastly because of droop characteristic set in EHC and Boiler will be following to maintain main steam pressure if
combustion controls are in Auto. This mode of operation gives maximum stability to network because MW requirements are met by
Turbine fastly and lesser importance to unit stability, because the action by Turbine will be disturbing main steam pressure. If all units
in the network do not implement 5% regulation then the network disturbances will be passed on to the units in Boiler follow mode
disturbing their MW level of operation often. Boiler combustion controls must be kept in Auto in this mode of operation which will be
taking main steam flow and main steam pressure error as inputs for control. The main steam pressure is the final trimming signal to
boiler for boiler follow mode of operation. Response of Turbine to grid requirements is quickly perceived by boiler controls through
main steam flow variations. Finally Boiler controls ensure the set throttle pressure.
In coordinated mode of operation unit/master control station sets MW set point which will be pursued by combustion controls
by taking main steam pressure error as final trimming input signal. Turbine will be controlling the MW at the set point or changes in
grid frequency will be leading to changes in the MW. Main steam pressure error will have proportional influence for stability of the
unit. Boiler will be trying to control main steam pressure. Coordinated mode and boiler follow mode are similar in response except
that base signal required for boiler combustion control is MW set point in coordination mode and main steam flow signal in Boiler
follow mode.Sustained throttle pressure controller output will be the result due to calorific value deviation from design calorific value
and this output will be getting added to unit demand going to boiler master .the calorific value correction controller in auto mode takes
the output of throttle pressure controller as input and works as long time integrator to produce output to represent calorific value
which works as multiplier for fuel demand to boiler .In the process of this long time action, the throttle pressure controller output
returns to almost zero. The advantages in this control action are better transient response since the calorific value is as per actual
calorific value of coal going to the boiler and the throttle pressure controller has margins all the time on both positive and negative
sides.
Unit capability is capacity of the unit to produce the MW at that time. Unit capability signal depends on the number of
Auxiliaries in service and their contribution is expressed as MW signal which they can support. For example if six mills are required
to produce 500MW each mill capability will be taken as 85 MW approximately. The capability will be computed from each type of
Auxiliaries and minimum of all these will be the unit capability. On any running Auxiliary tripping, unit capability signal will be
dependent on the type of auxiliary tripped.
65
::03::
In Runback mode Boiler combustion controls give commands in proportion to unit capability and boiler will be coming to the state
of steady combustion and hence will be stabilizing. Turbine will be controlling main steam pressure as this will give maximum
stability to the unit. Runback mode gives highest stability to
unit because unit has gone to instability (ex.Mill/BFP/ID/FD tripped) this Runback mode gets selected automatically and ensures
stability. Whenever unit capability is less than unit master command the Runback mode sets in automatically.
The four modes of operation described above can be summarized in the following way.
Mode Boiler Controls Turbine Controls Input to Boiler Input to Turbine
Controls Controls
Turbine MW Pressure MW Set point Pressure error
follow (base signal)
MW error signal
Boiler Pressure MW Steam Flow MW error
follow (base signal)
Pressure error
Coordinated Pressure MW MW set point MW error
Mode (base signal)
Pressure error
Runback Produces steam Pressure Unit capability Pressure error
mode as per unit signal
capability (computed)
The Coordinated Master Control is written with a view to bring all concepts in it together to give a complete view of it.
Emphasis is given on concepts rather than on the CMC scheme.
66
67

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Power from knowledge

Interlock & Protection

KSK Energy Ventures Ltd (4 X 135 MW)

Power from knowledge

KSK Energy Ventures Ltd (4 X 135 MW)

 Front and rear fan bearing temperature normal (<80ºc).

ID Fan inlet electric damper

 This side IDF startup, time delay 10 seconds , open damper.

Interlock conditions of closing

Interlock conditions of opening

Interlock conditions of closing

Interlock condition of closing

Sequence start procedures

 Place Scoop tube position at minimum.

Sequence stop procedure

 Place Scoop tube position at minimum

 Outlet damper has been closed, FDF

 Front / rear bearing temperature is very high, delay 2 seconds (>90°C)

FDF outlet electric damper

Permission condition of closing

 This side FDF stopped

Interlock conditions of opening

 After this side FDF startup, delay 10 seconds open damper

Interlock close conditions

FDF inlet vane

Interlock conditions of opening (or)

 Asking for free ventilation ,delay 5 minutes, open damper

Interlock conditions of closing (or)

Sequence start procedures

Sequence stop procedures

 Place inlet vane at minimum position

Interlock & Protection of APH system

Start permissive conditions of main driving motor

 No fault of main driving motor

Stop permissive conditions of main driving motor

 Inlet flue gas temperature<150°C

Trip conditions of main driving motor

 Main driving motor fault

 Auxiliary driving motor stopped

Stop permissive conditions of auxiliary driving motor

 Inlet flue gas temperature<150°C

Trip conditions of auxiliary driving motor

 Fault of auxiliary driving motor

 Auxiliary motor starts, if main motor tripped

Interlock of air pre-heater and inlet flue gas damper

Interlock conditions of opening

 Ask for free ventilation, time delay 5 minutes, open damper

Interlock conditions of closing

 APH (main motor and aux. motor) of this side stopped

Interlock of air pre-heater and outlet flue gas damper

Interlock conditions of opening

 Ask for free ventilation time delay 5 minutes, open damper

Interlock conditions of closing

Interlock conditions of opening

 Ask for free ventilation time delay 5 minutes, open damper

Interlock conditions of closing

Sequence startup procedures

 Conditions: remote state and no fault of oil station

Sequence stop procedures

 CONDITION inlet flue gas temperature<150°C

Interlock test of air pre-heater oil station

 Outlet damper closed ,PA

Inspection of trip condition