Safe operation of Mill Mills Should be operated smoothly keeping Coal level in the mill to normal level. Keep watch on following parameter continuously to ensure healthiness of mill: Choking of mi The mill current along with previous current trend is clear indication healthiness of mill. if mill current suddenly starts decreasing more than 7-8 amps from existing current it is clear indication that coal level in mill has started increasing. Immediately check mill from site by tech/J.En from back side of mill and if no sound of jon to this balls were heard at site itis established that coal level in,mill has started increasing. In ad following parameter also shows that mill is on heavier side. (a) The classifier outlet temperature starts decreasing. (b) Mill discharge pressure at classifier outlet starts decreasing even at normal seal air D.P (c) Coal leakage from both side of (4) Mill inlet air starts decreasing even at full damper opening Now when itis established mill is on heavier side following remedial action is to be taken: (a) Immediately reduce feeder speed to minimum and watch on mill current, mill classisifier outlet temperature/pressure, if mill current, classifier outlet temperature and pressure starts in this condition till mill current and other parameter has normalized. increasing ,continue to run mi (b) If by reducing feeder speed to minimum there is no improvement in mill parameters as described above trip one feeder and try to normalize mill. Also continuously watch on mill inlet air and if there is tendency of primary air to mill inlet decreasing then it is clear indication that coal has entered in hot air box and obstructing path of air. In this condition following action is to be taken: 1. Increase cold air to maximum to avoid blast in hot air box. 2. Trip both feeders for 6-7 minutes and again take one feeder (to reset 10 minute logic of mill tripping) for one minute and again trip feeder. This exercise is to be done till primary air to mill has started increasing. If primary air at mill inlet has reduced 3. Intimate maintenance/support staff about condition of to zero and above mentioned exercise is not fruit full then mill has completely choked. In this condition after consultation with support/maintenance wing mill should be tripped to avoid any blast in hot air box. . After tripping of mill hot air box is to be get cleaned by majntenance staff 2nd coal deposition around mill is to be evacuated immeédiately to avoid fire hazard. ~ 5. Firefighting staff is to be intimated Immediately to take control of area.Emptying of Mil If following things has occurred it clearly indicate that mill has emptied: 1, The mill current starts increasing. . - 2. The classifier outlet temperature and pressure starts increasing beyond normal value. © 3, Heavy sound of balls heard at the site. 4, Main steam pressure starts decreasing. In this condition mill has emptied. The feeder speed is to be increased till all parameter described above &e normalized. Indication of Failure of Drive bar: decreasing suddenly and reduced to zero. appears.) ¥ Immediately check mill from site for screw conveyor rotation and if screw conveyor is not rotating ~ immediately take following actions: 7 1. Immediately trip corresponding feedef. 2. Inform to maintenance/support staff for mill change over.OGL LCE EC &U-O@ OS OUBae YOO eed aot wad dboe Ee SS MILL CHANGEOVER 1, If unit is running on full load, reduce load to around 220 MW and stabilize the unit. ke the unit on pressure control mode if it is running in CMC mode. 3. Furnace draft should be maintained slightly more negative than normai (Say -20 mmwc) for cutting in an elevation so that it may not become positive during purgihg of PC pipes. 4. Hot PA header pressure should be maintained 700-750 mae 5. I. Selection of elevation to be taken in first:- : It is better to select the elevation adjacent to the mill to be taken out for cutting in first. For example if mill AB & EF are running and EF is to replaced by CD , than take elevation D first so that if need arises to take out an elevation , elevation F may be tripped by supporting E with D. Similarly elevation -C should be taken first in this case if mill AB is to be replaced buy mill CD. IL. Selection of elevation to be taken out first:- The elevation which is not adjacent to the elevation cut in should be taken out first, but before that the elevation cut in and its adjacent elevation must be in a position to provide * Ignition Permit’ to each other. 6. Before giving ON command to the elevation to be taken in , all the points & procedure mentioned for cutting in a new mill have to be followed. 7. Now take the elevation in service and increase its loading (PA/BPA flow and feeder speed) slowly maintaining all the parameters stable and decreasing the loading of elevation ‘to be taken out first. Here caution has to be taken in reducing the RA flow of the elevation to be taken out first. It shouid not be reduced to the extent it is not able to provide ' Ignition Permit’ to the other elevation of the Mill to be taken out until the PA flow of the elevation cut in starts providing ‘Ignition Permit’ to the other elevation.+= Ve = el er 3 GSHEHEHOHKHHHHHOHHHOHOHECOEeEe Fe OE MLL LS MLS Page 6 of 8 IGNITION PERMIT :- "Ignition permit * for an elevation to be cut in becomes available around 37 TPH PA flow in adjacent elevation although this permit is withdrawn at around 20 TPH PA flow if boiler load is more than 30 % i.e. steam flow is »250 TPH. Below this steam flow * Ignition Permit" becomes available only when three oil guns are in service at the elevation in question. . Reduce the loading of the elevation to be taken out first to minimum. ). Now take the other elevation of the mill to be cut in , in service establish its feeder and load,it slowly to the extent both elevations of this mill start providing “Ignition Permit" to each other. PA flow to these el can be maintained around 35-40 TPH for better stability. 10. Get the mill cut in inspected thoroughly by operator at site. 1L.If the mill cut in is OK, the elevation of the other mill, selected to take out first and reduced to'the minimum loading already can be tripped now. 12. Now reduce the loading of the other elevation of the mill to be taken out, maintaining load and other parameters with the help of the mill cut in, to the minimum and trip this elevation also. 13. Purging of PC pipes also takes place in the stop sequence of an elevation , therefore , keep watch on furnace draft, Hot PA header pressure and boiler drum level in that duration. 14, Mill main motor trips after some time delay provided (10 minutes here) after tripping of both RC Feeders and then aux. motor starts (there may be some time delay of 3 minutes or so). Both RC Feeders of a mill should not be kept tripped for 10 Minutes if mill is not ready for tripping within 10 ininutes. 15. Most important thing to be taken care of while changing over a mill is the stability of unit. Unit load must be maintained quite constant and if it disturbs it should be stabilized first before proceeding further. wa ‘Superintending Engineer (Opr.) STPS, RVUN, Suratgorhe201 ReeortSElope Ope. SupportActi lan_For_Dealing.Hoilerdoe Action plan for dealing Boiler side Emergencies on tripping of fans 10. When One ID fan trips. One FD trips automatically, if not trip manually. Upper most elevation trips automatically, if not, trip manually Next steps to be taken in sequence Stabilize the furnace by cutting in oil guns at suitable elevation Check the loading of running FD fen. Take it on “ manual” and limit its loading to the safe value. (65 Amps. - 68 Amps.). Now check the loading of running ID fan. It will automatically come down to its normal value. Keep the draft control on “Auto” and maintain it normal - / Now reduce /adjust the unit load by reducing coal fecding to maintain appropriate oxygen in flue gas ut APH inlet. Do not allow the unit to run with low oxygen for too long. Stabilize the unit and all the parameters in this situation Now if the second ID fan (Standby) is available, take it into service and normalize the loading of both ID fans and put it on “Auto”. Take the second FD fan in service and normalize the loading of both FD fans and put the FDs on “ Auto”. ‘ ke the upper most elevation in service which had tripped mes when AB & EF mills are in Operation and F-clevation S-elevation may also trip on “ Ignition Permit — Not “vaxfavie”. In such case, both elevations of the mill tripped will have to be taken in service in this step. Normalize the load and take out oil guns. ‘ The ID fan tripped can be checked & get attended now. Note:- In step-2 when the FD fan is taken out on manual, unit would switch over to “ Load Control” mode if it has been on “CMC”. The parameters would have to be taken care of in that stage too However, unit can also be taken over to “ Pressure control" mode at this stage. AAAAAAAAAGoodedd o@g ee GC GCOdPGbPOCOPCPCbOCOKCCECEKCEHTECEGOE ii When One PA fan trips a iii Upper most elevation trips automatically, if not, trip manually. Next stcps to be taken in sequence Stabilize the furnacc by cutting in oil guns at suitable elevation. Check the loading of running PA fan. Take it on “ manual” and limit its loading to the safe value. (Less than 125 a s. -130 Amps.) while maintaining Hot PA Header Pressure notithen S00 mmiwe, Take out all the mill dampers on “ manual” to keep PA flow fixed. Reduce the PA flow of Mills to suitably lower value to relieve the running fan of its higher loading and increase the Hot PA header Pressure. It is bettcr to maintain Hot PA Header Pressure around 700 mmwe. Now reduce / adjust the unit load by reducing coal fecding to maintain appropriate oxygen in flue ges at APH inlet. Do not aliuw the unit to run with very low oxygen for too long. Stabilize the unit and all the Parameters in this new situation. Have a constant watch on Hot PA header Pressure and PA fan current. If everything is normal, the PA fan can be put on “ Auto now. Now, if the second PA fan (Standby) is available, normative the |; on“ Auto”, take it in service, loading of both PA fans and put the second PA fan Take the upper most elevation in service which had tripped. Sometires when AB & EF mills aré in Operation and F- Elevation trips, E-clevation may also trip on “Ignitipn Permit Not Available”. In such case, both elevations of the mill tripped will -have to be taken in service in this step. Normalize the load and take out oil guns. The PA fn tripped can be checked & get attended now. When One FD fan trips Upper most elevation trips automatically, if not, trip manually Next steps to be taken in sequencePe 2\OLD RecordSF(ope\Opr. Support\Actia n_For_Deating Mailer sloe 1. Stabilize the furnace by cutting in oil guns at Suitable elevation 2. Check the loading of running FD fan. Take it on “ manual” and limit it’s loading to the safe value. (65 Amps. 68 Amps.). 3. Check the loading of both ID fans and maintain draft on "Auto". 4. Now reduce / adjust the unit load by reducing caal feeding to maintain appropriate exygen in flue gas at APH inlet. Do not allow the unit to run with very low oxygen for too long. , 5. Stabilize the unit and all the parameters in this new situation 6. Check the FD tripped and get it attended as soon as possible 7. Take the FD fan in service, ncrmalize the loading of both FD fans and put them on “ Auto”. 8. Now take the upper most elevation in service, which had tripped Sometimes when AB & EF mills are in opcration and F- Elevation trips, E-elevation may also trip on “Ignition Permit - Not Available”. In such case, both elevations of the mill tripped will have to be taken in service in this step. 9. Normalize the load ond take out oil guns. Note:- In <'ep-2 when the FD fan is taken out on manual, unit would sw hover to “ Load Control” mode if it has been on “CMC”. The pe -neters woul have to be taken care of in that stage too However, unit can also be taken over to “ Pressure control” mode at this stage. iv Failure of Drive Bar of the Mill. ° (i) If Bypass air of a side of a mill starts decreasing itself gradually. (ii) “Discharge pressure at classifier outlet of a side also seduces simultancously (iii) The “Discharge plug choked” alarm appears which causes respective RC feedcr to trip immediately. These may be indications of failure of drive bars of that side of the mill and choking of screw conveyer area, coal pipe from feeder outlet to mill inlet and even feeder compartment. Action Plan :- 1. Immediately check the spherical roller bearing of screw conveyanof = that side and if no rotation of shaft is found there, RC feeder of that side should be tripped immediately (If not tripped earlier) and, mill must be taken out of service maintaining the stability of unit.4 For_ Dealing Woilerdoc ormal I. If the rotation there is found absolutely normal, and n¢ sound is heard at :nills, measurements of bypass tr discharge pressure at classifier outlet should be got checked tron the C&l staff and in the case of ‘Discharge-plug Choke ~ RC feeder can be taken again in service after inspecting the fecder compartment. However, a cbnstant watch on all the paramcters of mill and unit load should be kept till it is ensured that everything is normal with the mill Emergency operation of BFP’s. Always keep third BFP on “Auto stand by” mode when two BED's atcont” and on‘Auto” Now if - "s unload Or Hydraulic scoop of,one of the two running BFP’s fails or stucks up tor operation. “ One of the two running BF Or Ling BFP closes to some fault Or : One of the two running | Ps trip and stand by BFP does not start on “puto.” Discharge valve of . Give “ON” command to the stand by BFP immediately. Whether third BFP is on stand by or not and as soon as it starts and shares load, ‘rip ® the BFP which is malfunctioning, carefully maintaining the “Drum level” normal in all condition. If there is significaht difference in the loading of two running BFP’s, it should be equalized as soon as it is possible| Mercury level(mm) Table of Condenser vacuum according to mercury level (Mercury level/735.5) | Calculated vacuum(kg/cm?) 1. 600mm ~0.816 (kg/cm?) _ 2. 610mm -0.829 (kg/cm’)_ 3. 620mm_ -0.843 (kg/cm?) 4. 630mm -0.857 (kg/cm) _ 5. 640mm _ :-0.870.(kg/cm”) ‘6. 650mm : -0.884 (kg/cm’) 7. . 660mm 897 (kg/cm’)_ 8. 670mm 941 (kg/cm’) 9 680 mm +0. 925, ( (kg/em )Precaution to be taken if all compressor of any unit tripped 1. First of all close the interconnection valve between two units, if the interconnection valve of instrument air is open. 2. If the instrument air pressure is low, take the compressor in service which is off in running unit 3. Check the cooling water pressure of the compressor in the unit which is tripped. If itis adequate then:- (i) Take the compressor one by one in service of the unit which is tripped in consultation with operation support wing. . (ii) After the pressure is maintained the interconnection valve between two units can be made crack open in consultation with operation support wing.Vale Seam Temp. Woyenela EFFECT OF CRITICAL PARAMETERS ——\ ON HEAT RATE ae | Effect on Heat R +2.3 kcalikWh Main Steam Press. Reheat Temperature Rel neat Spray Yandancar Rack — : Pressure fat mmHala) -1 Kg/cm +1 kcal/kWh Piste. Se ae '-5°C /+2.3 kcal/kWh “T41%6(MS Flow) |+3.0 keal/kWh 42.0 keal/kWh HPY Efficiency IPT Efficiency excess 02 Flue Gas Temperature -1% —|44> keal/kWh -1% +3 keal/kWh | 41% +7.2 keal/kWh '+5°C +4.6 kcal/kWhOPERATION SUPPORT-II ACTION TO BE TAKEN ON TRIPPING OF UNIT IN TURBINE AREA: 1. In case of normal tripping:- I Ensure starting of AOP at 2800 rpm. Il. Watch vibrations/Brg. Temp. during coasting down. Ill. Ensure starting of JOP at 510 rpm. Iv. Ensure turning gear solenoid valve position is (green) i.e. closed. Vv. Maintain Gland seal steam pressure>0.01 Kg/CM? and temp.>240°C. (47 AS) per VIL Maintain hotwell ,CST and Dea. Level. VII. — Nok Lod it etal h le Close all LP/HP heaters Extraction valves. VIIT. Open drains as mentioned in encl.(oprn. of drains.) Ix. Don't cut Dea. Pegging completely. Maintain Dea. Pressure 1-1.5 kg/CM? if Dea. Water temp. are > 100 °C. x. Open CRH atmospheric drain. xi. Keep BD isolating valve closed if HPbypass is not chargrd. —% XII. Open LP/HP bypass after getting clearance from boiler © side(as per procedure enclosed.) XIIr. Reset Turbine by reducing starting Device to zero pe - Reset all relays of Generator side. xIv. Put Load set point 40 MW. xv. Keep Pressure controller on “LIMIT” mode. XVI. Ouring LP- bypass operation keep HRH pr. set point 10-12 kg/cm? during hot start-up,8-10 kg/cm? during warm start-up and 6-8 kg/cm? during cold start-up. XVII. Opening of Stop valves ,soaking and Synchronization as Per procedure earlier explained in “Turbine start up”. aor AoOPERATION SUPPORT-II Iv. VI. VII. VIII. Ix. xr. xIt. xuIL. 2. Action to be taken in case of TOTAL SUPPLY FAILURE/Grid Failure: °°” Ensure that DC EOP start on Auto and Lub Oil Pr. Should be maintained more than 2.1 kg/cm? Ensure that DG set started and supply on Emergency Bus restorted,EOP-AC will start on Auto, if not started | Acknowledge discrepancy, Give start command and change- over from EOP-DC to EOP-AC. If either EOP-AC or EOP-DC not started and Turbine speed is ey below 2800 rpm, Start JOP-DC manually and when supply on 27 * Emergency Bus is resorted, Change-over from JOP-DC to JOP- AC. Open Vacuum breaker to avoid pressurization of Condenser. Maintain Hot well Level by Closing CD-58,DM-2,DM-4 and their =manual isolating valves manually. Cut the Turbine Gland sealing by closing the manual isolating valve at PRDS Floor. Close manual isolating valves of seal steam control valve and its bypass valve. Open seal steam header drain valve to atmosphere. Do not open any drains connected to Condenser, Close all drains manually if any found open. All MAL drains, Drip line drains of LP, HP heaters to flash Tank and all other drains connected to condenser should be closed. Put SLC Turbine drains ‘off’ manually. Close all Extraction valves (EX-17, 18, 9, 10, 11, 12, 13) of LP, HP heaters and Deaerator. Ensure LOP’s of BFP’s have started Take out standby auxiliaries like BFP, CEP, CWP, ACWP, and DMCW Pumps from Auto start mode to manual mode. Ensure closing of HP bypass spray manual isolating valve of BD valve. Cut Deaerator pegging by closing manual isolating valve at PRDS header. Immediately check that DC Seal Oil Pump has started on auto. oe aot 0OPERATION SUPPORT-II PRECAUTIONS TO BE TAKEN TO AVOID BARRING GEAR SEIZUR 1, Maintain seal steam temp. from PRDS above 220° C. 2. Whenever seal steam/PRDS is charged from another unit, tight close spray valve of PRDS Header of self unit manually. If the PRDS is charged from self unit, D/A pegging line vent from PRDS be kept in open condition. » During vacuum pulling, charge seal steam only when vacuum is -0.10 kg/cm’. Also switch on seal steam exhauster Fan. . Cut-off seal steam supply only when vacuum drops to -0.10 kg/cm?.Simuntaneously switch off seal steam exhauster fan. . When turbine gland sealing is not charged, seal steam exhauster fan must be kept off. . Maintain seal steam header pressure between +0.01 to +0.02 kg/cm?. . In case B/G speed starts decreasing(below 40 rpm) :- (a) Ensure turning gear solenoid valve position is (green) e. closed. (b) Ensure the difference in JOP Discharge header pressure and Discharge pressure is below 6 kg/cm? if more change JOP filter. (c) Switch off all vacuum pumps. (4) Cut off seal steam supply when vacuum drops to -0.1, kg/cm?. Also close manual isolating valve of seal steam supply line at 8.5 m and switch off seal steam exhauster fan. (e) Keep vacuum breaker in open condition. - In case of grid failure open Tur. LO Temp. Control valve 100%. After normalization of ACW System reduce the position of above valve gradually to maintain Lube oil temperature. IF possible, rotate the rotor by hand barring at an interval of 15 minutes, shifting the rotor position by 90° in one instance. Inform the maintenance wing immediately. Do not manipulate the inlet valve of jacking oil lines to bearings and speed regulating valve in absence of maintenance engineers. 10. He= e this stage, iv Failure of Drive Bar of the Mill. ( air of a side of a mill starts decreasing itself gradually arge pressurr- at classifier outlet of a side also geduces, meously. ii) ‘The “Discharge pluy choked” alarm appears which causes respective RC feeder to trip immediately These may be indications of failure of drive bars of that side of the mill and choking of screw conveyer arca, coal pipe from feeder outlet to mill inlet and even feeder compartment. Action Plan :- Immediately check the spherical roller bearing. of serew conucyas.of that side and if no rotation of shaft is found there, RC ferder 0 that side should be tripped immediately ( If no! tripped earlier) an mill must be taken out of service maint ining the stability of unit DETAILS OF PROTECTIONS OF HT ORIVES AS ONST 1204 I cH] Name of Watall of Protection 1 Saget OF Teautme! a Tine Daag [Tap Vas Tine ay i Tira T SO raNa Mating Teme 139 | Weideges | ——“ssee a0 cages] 35 Miler Gearing Te. V. High Sa] W0 dogo [—~5Sec Too cegee | 3 sae —— 7 [Fan Searing Temp. V. High 7 82 degree ‘SSec, ‘82 degree S See. ¥ IHC Control Oi Pr. VLow OB KoURE | Ses sraing [OSKgERD] Sating ay Delay a 39 Se eee 5 Cabs OFF V.Ta Takgend | No Gea; [Oz KgeRE| ——3aer °[ ic Wting 01 Tene ar OF casey Wig eb degee-t No bea | wees — oe ct HE Working Of Temp. Bf OF Cooler V. Fish = No Delay [110 éeyee| Ra Gast 1 TO Sec wih staing leer |___Fan Bearing ViratonV. High Deeerrone| Briers | 1a See |PostBuge Fan Tip No Delay Hoa aI Fixe [FOF or Wing Yam. GE | 1a degree |S See Tab gages] 352 a Moor Bearing emo. V. High ZEB Gogee | sSee | soaegee | 3 See 2 Fan Bening Tomo, V igh 30-| 105 capes | Sec._—[1os goes] Set F TO See wih sa Fan Bearing Vbraon V. High srirons | Cero tincume| amen | 10Se. “jouer Barer rat Open Wet conrcted 0 Sesh svaing Deaya [PostPurge Fan Trip ‘Nooamy T Noes ube Of Pressure V- Low Dakyent |“ $See, Wal Comectes | S| ]F0 Fan Tip on 10 Fan TH Ne Daly NoDeay FAs ater Winding Tema VR 1a | Ta degies | 5 See [a0 eagree| 55 sur Moto Bearing Tém.V.Figh 5] 90 degree [5 Sel. | 60 degree |S See Lt Fan Searing Temp. V.Figh 9] 108 degree | —— 8 Sez_—[105 degen] 8 sae TOSse wih sag OSes win srg] | freee vr veh beayatrouin Prom [Sena ain t [Sutet Damper Nol Open Tl Coonactad 70 Sees svatng Dalay I? T lube Or. V. tow Taigend | Nodeay —Tesugen] Sec 4 THER Trp Neel To De | ! [BFFs [ator Winging Tenp.V. Aah Toaegee |S See [0 cepa | Sg oo isereas one me Sane [tse —| asses | — Se t BoosterPump Bearing Temp. V. HD ol Connect 08 See [SucDisch Dif. Temp V. High & Sucton Flow e100 TPH = ssdagee | 26see | rseepee | _s0see abe OF FEV. Law Targen2 | —NoDeiay —[08agen2 | — No Onay t : 30 degree | “No Dela; | 30 gegree| No Dia Working Oi Temp. V.Figh ey NoDei—[ 130 Nebea = [Dearestor Level V-Low Taloge | NoDeay Ro be i Suction Valve Not Open a =e Hsseuae| ase t oto Winding Temp. V. High pp jeuee | See. _ sete | — Se [Motor Bearing Temp. V. High pees = a ie Teng V- Fah [see ocegree | 8 See ier ning en Fah 35 dea Sse} i i iI | ~Fullload [Normal | S.No. | Equipment Rating (KW) | Stage Current | current | SPEED(RPM) | } (amps.) (Amps.) at | be ___ 250mW 1__| 1D Fan Motor _ 1750 ttow | 192 150-155 745 2__| FD Fan Motor “700 Ito IV BS 38-40 1491 3_| PAFan Motor 1400 Ito IV 143 6265 1492 4 | Mill Motor 2400 Ito IV 266 150-170 1488 | 5 __| BFP Motor 4600 Ito IV 469 350-355 1485, __6 | CEP Motor 325 Ito IV 35.4 _ 3 1486 7 | DMCCWP Moto! 220 u 25 2123984 | DMCCWP Motor 220 Mw 26 224986 DMCCWP Motor 180 wv 20.3 18-20 1487 8 | CWP Motor 1485 1 169 145-155 496 CWP Motor 1850 " 209 190-200 494 "CWP Motor 1850 m 206 190-200-498 | CWP Motor _ 1800 Vv 205 1195-200 496 9 | ACWP Motor 525 1 60 ___ 54-55 988 [ACWP Motor 500 u 37 Ce | ACWP Motor 500 | m1 [ees7, 75355. 988 ACWP Motor _ 550 v — 59 S455 989