Report 1

A STUDY PROJECT
ON
"A DETAILED STUDY ON KTPS-VII STAGE 1X800MW
OVERVIEW"
A dissertation submitted in partial fulfilment of the requirement of the award of the
Bachelor of Technology (2022 -2023)

In
MECHANICAL ENGINEERING
Submitted by
G. RAHUL VARMA Roll No. :21MEB0A22
Under the Esteemed Guidance of
Mr B. RAGHUVEER
A.E./BM/KTPS- VII STAGE, PALONCHA
DEPARTMENT OF MECHANICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY
WARANGAL, TELANGANA
TELANGANA STATE POWER GENERATION
CORPORATION LIMITED
CERTIFICATE
This is to certify that Sri G. RAHUL VARMA (Roll No. : 21MEB0A22) Studying
B. Tech. 2nd-year MECHANICAL ENGINEERING at the NATIONAL
INSTITUTE OF TECHNOLOGY, WARANGAL, completed 30 days STUDY
PROJECT on “A DETAILED STUDY ON KTPS-VII STAGE 1X800MW
OVERVIEW” with a specific view on KTPS - VII Stage at PALONCHA during the
academic year 2022-2023.
Mr B. RAGHUVEER Mr. J.V.K. PRASAD

Assistant Divisional Engineer, Divisional Engineer,
Boiler Maintenance, Boiler Maintainece,
KTPS-VII stage, KTPS-VII stage,
Paloncha, kothagudem. Paloncha, kothagudem.
TELANGANA STATE POWER GENERATION
CORPORATION LIMITED
CERTIFICATE
THIS IS TO CERTIFY THAT A 15 DAYS STUDY PROJECT ON
"A DETAILED STUDY ON KTPS-VII STAGE 1X800MW
OVERVIEW "
IS CARRIED OUT BY
G. RAHUL VARMA Roll No: 21MEB0A22
Studying B.Tech. 2nd-year MECHANICAL ENGINEERING at the

NATIONAL INSTITUTE OF TECHNOLOGY, WARANGAL, under the guidance
of Mr B. RAGHUVEER, A.E/BM/KTPS - VII STAGE and submitted in partial
fulfilment of the requirement for the award of the degree in Bachelor of Technology.
Mr. B. RAGHUVEER Mr. J.V.K. PRASAD

Assistant Engineer, Divisional Engineer,
Boiler Maintenance, Boiler Maintenance,

KTPS-VII stage, KTPS-VII stage,
Paloncha, kothagudem. Paloncha, kothagudem.
ACKNOWLEDGEMENT
Our 15 days internship has been completed. We are pleased to thank those
people, whose suggestions, comments and critics greatly encouraged us in our
internship.
We also thank Mr B. RAGHUVEER, A.E./BM/KTPS-VII STAGE
and Mr. J.V.K. PRASAD, DE/BM/KTPS-VII STAGE who helped us with

the completion of this internship.
We are grateful to Mr. B. RAGHUVEER, A.E./B.M./KTPS -VII STAGE

who guided us in every aspect of our internship and provided valuable knowledge.
They helped us understand our subjects' theoretical concepts from a practical point
of view.
Internship by:
G. RAHUL VARMA
ABSTRACT
These days electrical energy plays an important role in every aspect of our day–to–day life. This
electrical energy can be generated from thermal, hydel, Nuclear as well as Gas power plants. To our
surprise, we came to know that 70% of the total electrical energy is generated from THERMAL
POWER PLANTS only.
In thermal plants, every object is having a vital role in electrical power generation. So, the
Thermal plant is to be protected carefully to ensure the availability of electrical energy without
interruption to every load connected to the system. So, precautions must be taken so that the
equipment not only operates as nearly as possible to peak efficiencies but also that it is protected from
accidents.
The object of our project gives an insight into an overall view of Thermal power plants and
power generation transmission and protection schemes of objects in thermal power plants.
CONTENTS
S.No. Chapter Name Pag
e
No.
1. Introduction to TS Generation
1.1 Profile of Kothagudem Thermal Power Station
1.2 Renovation and modernization activities
1.3 Stages of K.T.P.S
1.4 Overview and schematic view of Thermal Power Plant
2. PRINCIPLE OF OPERATION
2.1 Rankine cycle
2.2 Reheat cycle
2.3 Regenerate cycle
2.4 Coal to steam process
2.5 Steam to mechanical power
2.6 Mechanical power to electrical power
2.7 Electrical power to the transmission
3. BOILER
3.1 Introduction
3.2 Principle of combustion
3.3 Pressure paths
3.4 Types of Fans
3.5 Air Heaters
4. CONDENSATE PATH DEVICES

4.1 Condenser
4.2 Condensate extraction pump
4.3 Gland steam condenser
4.4 De-aerator
4.5 Working principle of the boiler feed pump
5. STEAM TURBINE INTRODUCTION

5.1 Principle of operation of steam turbine
5.2 Main turbines
6. GENERATOR
6.1 Working principle
6.2 Gestor components
6.3 Generator cooling
6.4 Construction details
7. COAL MILL AND COAL HANDLING PLANT

7.1 Introduction of coal
7.2 Types of Coal
7.3 Introduction of coal mill
7.4 Types of Coal Mills
7.5 Components of ball mills
7.6 Principle of Operation of Ball Mills
7.7 Firing protection
8. ASH HANDLING SYSTEM

8.1 Wet ash handling plant
8.2 Working Principle of ash handling plant
9. ESP (ELECTRO STATIC PRECIPITATOR)

9.1 Types of Precipitators
10. WATER PLANT

10.1 Use of DM water plant
11. COOLING TOWER & CHIMNEY

11.1 Cooling tower
11.2 Chimney
12. CONCLUSION
CHAPTER – 1
z
INTRODUCTION
1.1 INTRODUCTION TO THERMAL POWER PLANT:
Both the historical and the present-day civilizations of mankind are closely
interwoven with energy, and there is no reason to doubt that in the future our
existence will be more and more dependent upon energy. Electrical energy occupies
the top position in the energy hierarchy. It finds innumerable uses in the home,
industry, agriculture, and even in transport. Besides its use for domestic,
commercial and industrial purposes it is required for increasing defence and
agricultural production. In agriculture, it is used for pumping water for irrigation
and for improving the methods of production and numerous other operations.
Electrical energy is a convenient form of energy because it can be generated centrally
in bulk and transmitted economically over long distances and is almost pollution
free at the consumer level. Further, it can be adopted conveniently in the domestic,
industrial and agricultural fields. The process of modernization, increase in
productivity in industry and agriculture and improvement in the quality of life of the
people depend so much upon the supply of electrical energy that the annual per
capita consumption of electrical energy has emerged these days as an accepted
yardstick to measure the prosperity of the nation. Some of the advanced and
developed nations of North America and Europe have a very high annual per capita
consumption of electrical energy; say from 8 to 13 thousand kWh, while in most of
Africa, and America it is too low to be considered. India had an annual per capita
consumption of electrical energy of 15.5 kWh in 1950, 105 kWh in 1975, 131 kWh in
1979, 154 kWh in 1984, 299 kWh in 1993, and 349 kWh in 1997, The annual per
capita consumption of Japan 8,000 kWh, UK 7,200 kWh and USSR 6,000 kWh. The
United States has only 6% of the world's population but accounts for over 30% of the
electrical consumption of the world.
The industrial growth of a nation requires increased consumption of energy,
particularly electrical energy. This has led to an increase in the generation and
transmission facilities to meet the increased demand. In the U.S.A., till the early
seventies, the demand develops every ten years. In developing countries, like India,
the demand doubles every seven years which requires considerable investment in
the electrical power sector.
Coal-based thermal power stations are presently the mainstay of power
development a this is likely to be so in the immediate future also, considering the
present status of the projects and various constraints in the development of hydro
and nuclear power. Besides quantity, the quality of Indian coal has been a major
problem and concern for the power supply industry. With the ash content of coal
being in the range of 30-50%, the beneficiation of coal assumes special significance.
Advantages of thermal power plant:
● Low initial cost
● Since located near the load centre, the cost of transmission and the losses
due to transmission is considerably reduced.
● The construction and commissioning of a thermal power plant takes a lesser
period.
Disadvantages of thermal power plant:
● Fuel is a non-renewable source of energy.
● Efficiency decreases with decreasing load.
● Cost of power generation is high.
● Smoke produced by burning the fuel causes air pollution.
● Life of a thermal power plant is 25 years. The efficiency decreases to less
than 10% after its life period.
1. ABOUT TSGENCO:
Vision:
To be the best-performing power utility in the country, and one of the best utilities
in the world with the use of state-of-the-art technology and smart solutions.
Mission:
To generate adequate, reliable, cost-effective, and eco-friendly power by
spearheading accelerated power development through the proper planning and
implementation of new power projects.
2. GENERAL LAYOUT & BASIC IDEA:

A control system of the station works on the Rankine cycle. Steam produced
in a boiler is exported in the prime mover and is condensed in the condenser to be
fed into the boiler again. In the practice of good no modifications are affected to
have heat ea economy and to increase the thermal efficiency of the plant.
“A generating station which converts heat energy of coal combustion into

electrical energy” is known as a Thermal power station.
A steam power station works on the Rankine cycle. Steam is produced in
the boiler by utilising the heat of coal combustion. The steam is then expanded in
the prime mover (i.e., steam turbine) and is condensed in a condenser to be fed
into the boiler again. The steam turbine drives the alternator which converts the
mechanical energy of the turbine into electrical energy. This type of power station
is suitable where coal and water are available in abundance and a large amount of
electric power is to be generated.
Advantages
• The fuel (i.e., coal) used is quite cheap.
• Less initial cost as compared to other generating stations.
• It can be installed at any place irrespective of the existence of coal. The coal
can be transported to the site of the plant by rail or road.
• It requires less space as compared to the hydroelectric power station.
• The cost of generation is lesser than that of the diesel power station.
Disadvantages
• It pollutes the atmosphere due to the production of large amounts of smoke
and fumes.
• It is costlier in running cost as compared to the hydroelectric plant.
Schematic Arrangement of Thermal Power Station

Although a steam power station simply involves the conversion of the heat from coal
combustion into electrical energy, it embraces many arrangements for proper
working and efficiency. The schematic arrangement of a modern steam power station
is shown in Figure. The whole arrangement can be divided into the following stages
for the sake of simplicity:
1. Coal and ash handling arrangement 4. Alternator

2. Steam generating plant 5. Feed water
3. Steam turbine 6. Cooling arrangement
1. Coal and ash handling plant: - The coal is transported to the power
station by road or rail and is stored in the coal storage plant. Storage of coal is
primarily a matter of protection against coal strikes, failure of transportation systems
and general coal shortages. From the coal storage plant, coal is delivered to the coal
handling plant where it is pulverised (i.e., crushed into small pieces) to increase its
surface exposure, thus promoting rapid combustion without using a large quantity of
excess air. The pulverised coal is fed to the boiler by belt conveyors. The coal is burnt
in the boiler and the ash produced after the complete combustion of coal is removed
to the ash handling plant and then delivered to the ash storage plant for disposal. The
removal of the ash from the boiler furnace is necessary for proper burning of coal. It
is worthwhile to give a passing reference to the amount of coal burnt and ash
produced in a modern thermal power station. A 100 MW station operating at a 50%
load factor may burn about 20,000 tons of coal per month and ash produced may be
to the tune of 10% to 15% of coal-fired i.e., 2,000 to 3,000 tons. In fact, in a thermal
station, about 50% to 60% of the total operating cost consists of fuel purchasing and
handling.
2. Steam generating plant. The steam generating plant consists of a boiler

for the production of steam and other auxiliary equipment for the utilisation of flue
gases.
• Boiler: The heat of combustion of coal in the boiler is utilised to convert water
into steam at high temperatures and pressure. The flue gases from the boiler
make their journey through the superheater, economiser, and air pre-heater
and are finally exhausted to the atmosphere through the chimney.
• Superheater: The steam produced in the boiler is wet and is passed through
a superheater where it is dried and superheated (i.e., the steam temperature
increased above that of the boiling point of water) by the flue gases on their way
to the chimney. Superheating provides two principal benefits. Firstly, the
overall efficiency is increased. Secondly, too much condensation in the last
stages of the turbine (which would cause blade corrosion) is avoided. The
superheated steam from the superheater is fed to the steam turbine through the
main valve.
• Economiser: An economiser is essentially a feed water heater and derives heat
from the flue gases for this purpose. The feed water is fed to the economiser
before supplying to the boiler. The economiser extracts a part of the heat of flue
gases to increase the feed water temperature.
• Air preheater: An air preheater increases the temperature of the air supplied
for coal burning by deriving heat from flue gases. Air is drawn from the
atmosphere by a forced draught fan and is passed through the air preheater
before supplying to the boiler furnace. The air preheater extracts heat from flue
gases and increases the temperature of the air used for coal combustion. The
principal benefits of preheating the air are increased thermal efficiency and
increased steam capacity per square metre of boiler surface.
3. Steam turbine. The dry and superheated steam from the superheater is fed
to the steam turbine through the main valve. The heat energy of steam when passing
over the blades of the turbine is converted into mechanical energy. After giving heat
energy to the turbine, the steam is exhausted to the condenser which condenses the
exhausted steam utilizing cold-water circulation.
4. Alternator. The steam turbine is coupled to an alternator. The alternator

converts the mechanical energy of the turbine into electrical energy. The electrical
output from the alternator is delivered to the bus bars through a transformer, circuit
breakers and isolators.
5. Feed water. The condensate from the condenser is used as feed water to the
boiler. Some water may be lost in the cycle which is suitably made up from external
sources. The feed water on its way to the boiler is heated by water heaters and
economiser. This helps in raising the overall efficiency of the plant.
6. Cooling arrangement. To improve the efficiency of the plant, the steam

exhausted from the turbine is condensed using through. Water is drawn from a
natural source of suppliance as a river, canal or lake circulates content ser circulating
water takes up the heat of the exhausted steam and itself becomes hot. This hot
water coming out from the condenser is discharged at a suitable location down the
river. In case the availability of water from the source of supply is not assured
throughout the year, cooling towers are used. During the scarcity of water in the
river, hot water from the condenser is passed on to the cooling towers where it is
cooled. The cold water from the cooling tower is reused in the condenser.
Conclusion. All the above factors cannot be favourable in one place. However,
keeping in view the fact that nowadays the supply system is a.c and more importance
is being given to generation than transmission, a site away from the towns may be
selected. In particular, a site by riverside where sufficient water is available, no
pollution of the atmosphere occurs and fuel can be transported economically, may
perhaps be an ideal choice.
Equipment of Steam Power Station: -

A modern steam power station is highly complex and has numerous equipment and
auxiliaries. However, the most important constituents of a steam power station are
• Steam-generating equipment
• Condenser
• Prime Mover
• Water treatment plant
• Electrical equipment.
1. Steam generating equipment. This is an important part of the steam

power station. It is concerned with the generation of superheated steam and
includes such items as boilers, boiler furnaces, superheaters, economisers, air
pre-heater and other heat reclaiming devices.
(i) Boiler. A boiler is a closed vessel in which water is converted into steam by
utilising the heat of coal combustion. Steam boilers are broadly classified into the
following two types:
(a) Water tube boilers (b) Fire tube boilers
In a water tube boiler, water flows through the tubes and the hot gases of combustion
flow over these tubes. On the other hand, in a fire tube boiler, the hot products of
combustion pass through the tubes surrounded by water. Water tube boilers have
several advantages over fire tube boilers viz., require less space, the smaller size of
tubes and drum, high working pressure due to the small drum, are less liable to
explosion etc. Therefore, the use of water tube boilers has become universal in large-
capacity steam power stations.
(ii) Boiler furnace. A boiler furnace is a chamber in which fuel is burnt to

liberate the heat energy. In addition, it provides support and enclosure for the
combustion equipment i.e., burners. The boiler furnace walls are made of refractory
materials such as fire clay, silica, kaolin etc. These materials have the property to
resist change of shape, weight or physical properties at high temperatures. There are
following three types of construction of furnace walls:
(a) Plain refractory walls
(b) Hollow refractory walls with an arrangement for air cooling
(c) Water walls.
The plain refractory walls are suitable for small plants where the furnace
temperature may not be high. However, in large plants, the furnace temperature is
quite high and consequently, the refractory material may get damaged. In such cases,
refractory walls are made hollow and air is circulated through hollow space to keep
the temperature of the furnace walls low. The recent development is to use water
walls. These consist of plain tubes arranged side by side and on the inner face of the
refractory walls. The tubes are connected to the upper and lower headers of the
boiler. The boiler water is made to circulate through these tubes. The water walls
absorb the radiant heat in the furnace which would otherwise heat the furnace walls.
(iii) Superheater. A superheater is a device which superheats the steam i.e., it

raises the temperature of steam above the boiling point of water. This increases the
overall efficiency of the plant. A superheater consists of a group of tubes made of
special alloy steels such as chromium-molybdenum. These tubes are heated by the
heat of flue gases during their journey from the furnace to the chimney.
The steam produced in the boiler is led through the superheater where it is
superheated by the heat of flue gases. Superheaters are mainly classified into two
types according to the system of heat transfer from flue gases to steam viz.
(a) Radiant superheater (b) Convection superheater
The radiant superheater is placed in the furnace between the water walls and receives
heat from the burning fuel through the radiation process. It has two main
disadvantages. Firstly, due to high furnace temperature, it may get overheated and,
therefore, requires careful design. Secondly, the temperature of the superheater falls
with an increase in steam output. Due to these limitations, radiant superheater is not
finding favour these days. On the other hand, a convection superheater is placed in
the boiler tube bank and receives heat from flue gases entirely through the
convection process. It has the advantage that the temperature of the superheater
increases with the increase in steam output. For this reason, this type of superheater
is commonly used these days.
(iv) Economiser. It is a device which heats the feed water on its way to the
boiler by deriving heat from the flue gases. This results in raising boiler efficiency,
saving fuel and reducing stresses in the boiler due to the higher temperature of feed
water. An economiser consists of a large number of closely spaced parallel steel tubes
connected by headers of drums. The feed water flows through these tubes and the
flue gases flow outside. A part of the heat of flue gases is transferred to feed water,
thus raising the temperature of the latter.
(v) Air Pre-heater. Superheaters and economisers generally cannot fully extract
the heat from flue gases. Therefore, pre-heaters are employed which recover some of
the heat in the escaping gases. The function of an air pre-heater is to extract heat
from the flue gases and give it to the air being supplied to the furnace for coal
combustion. This raises the furnace temperature and increases the thermal efficiency
of the plant. Depending upon the method of transfer of heat from flue gases to air, air
pre-heaters are divided into the following two classes:
(a) Recuperative type (b) Regenerative type
The recuperative type air heater consists of a group of steel tubes. The flue gases are
passed through the tubes while the air flows externally to the tubes. Thus, the heat of
flue gases is transferred to the air. The regenerative type air pre-heater consists of a
slowly moving drum made of corrugated metal plates. The flue gases flow
continuously on one side of the drum and air on the other side. This action permits
the transference of heat of flue gases to the air being supplied to the furnace for coal
combustion.
2. Condensers. A condenser is a device which condenses the steam at the

exhaust of a turbine. It serves two important functions. Firstly, it creates a very low
pressure at the exhaust of the turbine, thus permitting the expansion of the steam in
the prime mover to a very low pressure. This helps in converting the heat energy of
steam into mechanical energy in the prime mover. Secondly, the condensed steam
can be used as feed water to the boiler. There are two types of condensers, namely:
i) Jet condenser (ii) Surface condenser
In a jet condenser, cooling water and exhausted steam are mixed. Therefore, the
temperature of cooling water and condensate is the same when leaving the
condenser. The advantages of this type of condenser are low initial cost, less floor
area required, less cooling water required and low maintenance charges. However,
its disadvantages are: condensate is wasted and high power is required for pumping
water. In a surface condenser, there is no direct contact between cooling water and
exhausted steam. It consists of a bank of horizontal tubes enclosed in a cast iron
shell. The cooling water flows through the tubes and exhausts steam over the surface
of the tubes. The steam gives up its heat to water and is itself condensed. Advantages
of this type of condenser are: condensate can be used as feed water; less pumping
power is required and the creation of better vacuum at the turbine exhaust. However,
the disadvantages of this type of condenser are: high initial cost, requires large floor
area and high maintenance charges.
3. Prime movers. The prime mover converts steam energy into mechanical
energy. There are two types of steam prime movers viz., steam engines and steam
turbines. A steam turbine has several advantages over a steam engine as a prime
mover viz., high efficiency, simple construction, higher speed, less floor area
requirement and low maintenance cost. Therefore, all modern steam power stations
employ steam turbines as prime movers. Steam turbines are generally classified into
two types according to the action of steam on moving blades viz.
(i) Impulse turbines (ii) Reactions turbines
In an impulse turbine, the steam expands completely in the stationary nozzles (or
fixed blades), the pressure over the moving blades remaining constant. In doing so,
the steam attains a high velocity and impinges against the moving blades. This
results in the impulsive force on the moving blades which sets the rotor rotating. In a
reaction turbine, the steam is partially expanded in the stationary nozzles, the
remaining expansion takes place during its flow over the moving blades. The result is
that the momentum of the steam causes a reaction force on the moving blades which
sets the rotor in motion.
4. Water treatment plant. Boilers require clean and soft water for longer life
and better efficiency. However, the source of boiler feed water is generally a river or
lake which may contain suspended and dissolved impurities, dissolved gases etc.
Therefore, it is very important that water is first purified and softened by chemical
treatment and then delivered to the boiler. The water from the source of supply is
stored in storage tanks. The suspended impurities are removed through
sedimentation, coagulation and filtration. Dissolved gases are removed by aeration
and degasification. The water is then ‘softened’ by removing temporary and
permanent hardness through different chemical processes. The pure and soft water
thus available is fed to the boiler for steam generation.
5. Electrical equipment. A modern power station contains numerous

electrical equipment. However, the most important items are
(i) Alternators. Each alternator is coupled to a steam turbine and converts the
mechanical energy of the turbine into electrical energy. The alternator may be
hydrogen or air-cooled. The necessary excitation is provided employing main and
pilot exciters directly coupled to the alternator shaft.
(ii) Transformers. A generating station has different types of transformers,

(a) main step-up transformers which step up the generation voltage for transmission
of power.
(b) station transformers which are used for general service (e.g., lighting) in the
power station.
(c) auxiliary transformers which supply individual unit-auxiliaries.
(iii) Switchgear. It houses such equipment which locates the fault in the system
and isolates the faulty part from the healthy section. It contains circuit breakers,
relays, switches and other control devices.
The “KOTHAGUDEM THERMAL POWER STATION” is divided into Four main

circuits.
● Fuel and ash circuit
● Air and gas circuit
● Feed water and steam circuit
● Cooling water circuit
LAYOUT OF THERMAL POWER PLANT
CHAPTER – 2
PRINCIPLE OF OPERATION
The fundamental forms of energy with which thermal stations are principally
concerned are heat and work. Heat produces work and this work is further converted into
electrical energy through a medium i.e. electrical generator. For the purse of understanding
thermal plants, the phenomenon of the thermodynamic vapour power cycle's explained here
under.
• Rankine cycle
• Reheat cycle
• Regenerative cycle
2.1 RANKINE CYCLE:
This is the simplest theoretical vapour cycle, which is the basis for the operation of a
steam plant Superheated steam from the boiler is fed into the prime mover (Turbine) and is
expanded there. After which it enters the condenser emerging as condensate. With the help
of a pump, this condensate is again fed into the boiler.
The main purpose of superheating steam and supplying it to the prime movers is to avoid too
much wetness at the end of the expansion. The moisture content of steam would result in
under-blade erosion. The maximum wetness in the final stage of steam that may be tolerated
without any appreciable harm to the turbine blades is about 12%. Also, the use of a
superheater in a boiler helps in reducing the stack temperature by extracting heat from the
flue gases before these are passed out of the chimney.
2.2. REHEAT CYCLE:

In its simplest form, the cycle involves drawing the steam from the turbine at some
intermediate stage, returning it to the steam generator where a separate superheater is
provided in the gas path for superheating the steam after which it is re-introduced into the
turbine at the following stage. It reduces the wetness of the steam at the final stage and
improved the efficiency of the cycle
2.3. REGENERATIVE CYCLE:

This cycle is an attempt to induce reversibility in the ordinary Rankine cycle and thus
increase its efficiency. The mixing of cold condensate with saturated steam and
water mixture in the boiler constitutes the principal irreversible process of the cycle and
regeneration aims at reducing this irreversibility by heating the feed water near the
saturation temperature through the utilization of heat of steam which is partially expanded
in the prime mover. Since the purpose is the thermal regeneration of condensate the cycle is
known as regenerative.
2.4. COAL TO STEAM PROCESS:

Coal from the coal wagons is unloaded in the coal handling plant. The coal is
transported up to the raw coal bunkers with the help of belt conveyors. Coal is then
transported to Ball mills through feeders where the coals are pulverized to powder form. This
crushed coal is taken away to the furnace through pulverized outlet dampers with the help
of a hot and cold air mixture from a PA fan. PA fan takes atmospheric air, a part of which is
sent to air pre-heaters for heating while a part goes directly to the mill for temperature
control. Atmospheric air from the FD fan is heated in the air heaters and sent to the furnace
as combustion air. The water is taken from the condenser whenever the water in the
condenser is less at that time water is taken from the DE-MINERALISED plant. The water
is flow from the condenser to LPI and LP2 through CEP. The low-pressure heaters increase
the temperature and pressure of the water. And that water is flow from LP heaters to de-
aerator. The de-aerator removes the oxygen particles & undissolved from the water because
due to oxygen particles& undissolved gases make the pipe undergoes corrosion. To avoid
corrosion remove the oxygen particles. The water in the de-aerator is drawn by the MDBFP
or TDBFP and given to HP4 and HP5. These heaters increase the temperature and pressure
of water. This water goes to the economizer, in the economizer the water is heated by the flue
gases. This hot water goes from the economizer to the drum, in the drum the steam and water
are separated. The separated steam goes to the turbine through the primary superheater and
the secondary superheater. These two superheaters increase the temperature and pressure.
Flue gases from the furnace are extracted by an induced draft fan, which maintains a
balanced draft in the furnace (-10 to -15 mmol) with a forced draft fan. These flue gases
emit their heat energy to various superheaters in three penthouses and finally pass through
air pre-heaters and go to an electrostatic precipitator, where the ash particles are extracted.
Electrostatic precipitators consist of metal plates, which are electrically charged. Ash
particles are attracted onto these plates so that they do not pass through the chimney to
pollute the atmosphere. Regular mechanical hammer blows cause the accumulation of ash
to fall to the bottom of the precipitator. Where they are collected in a hopper for disposal.
The ash is mixed with water to form a slurry and is pumped to the ash pond.
2.5. STEAM TO MECHANICAL POWER:
A steam pipe conveys steam to the turbine through a stop valve and control valves
that automatically regulate the supply of steam to the turbine. Steam from the control valves
enters the high-pressure cylinder of the turbine, where it passes through a ring of stationary
blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring
of moving bladed mounted on a side secured to the turbine shaft. This second ring turns the
shaft as a result of the force of the steam the stationary and moving blades together
constitute a stage of the turbine and in practice many stages are necessary so that the
cylinder contains several rings of stationary blades with rings of moving blades arranged
between them. The Steam passes through each stage in turn until reaches the end of the
high-pressure cylinder and in its passage, some of its heat energy is charged into mechanical
energy.
The steam leaving the high-pressure cylinder goes back to the boiler for reheating and
enters the intermediate-pressure cylinder through HRH lines. Hence it passes through
another series of stationary and moving blades.
Finally, steam is taken to the low-pressure cylinders, each of which enters at the centre
for flowing outwards in opposite direction through the rows of turbine bladed-an
arrangement known as double flow to the extremities of the cylinder. As the steam gives up
its heat energy to drive the turbine, its temperature and pressure fall and it expands. Because
of this expansion, the blades are much larger and longer towards the low-pressure ends of
the turbine.
When as much energy as possible has been extracted from the steam it is exhausted
directly to the condenser. This runs the length of the low-pressure part of the turbine and
may be beneath or on either side of it. Cold water from the river, sea or cooling tower is
circulated through the tubes in the condenser and as the steam from the turbine passes
around them it is rapidly condensed into water condensate. Because water has a much
smaller comparative volume than steam, a vacuum is created in the condenser, this allows
the steam to reduce down, to a pressure below that of the normal atmosphere and more
energy can be utilized.
From the condenser, the condensate is pumped through low-pressure heaters by the
extraction pump, after which its pressure is raised to the boiler pressure by the boiler feed
pump. It is passed through further feed heaters to the economizer and the boiler for
conversion into steam.
2.6. MECHANICAL POWR TO ELECTRICAL POWER

The basic principle of Electrical power Generation is from Faraday's laws. It says that
when a conductor rotates in a magnetic field, the E.M.F. will be induced in a conductor and
is proportional to the rate of change of flux lines cut by the conductor and the capacity of the
magnetic field. For higher capacities of the generation vice versa principle is used, i.e., the
conductors are placed constantly (Stator) and the magnetic field will be rotating (Rotor)
Magnetic field will be rotating (Rotor). The magnetic field is obtained from a separate system
called an Excitation system. The excitation system is classified into two types i.e. Static
Excitation and Brush-less Excitation. The magnetic field will be generated in the rotor circuit
and to obtain the rate of change of flux lines, the rotor will be rotated by a steam turbine at a
constant speed.
The speed of the turbine is determined by the frequency of the electrical system used in
the country i.e., 50 HZ. Proportional to this the speed of the turbine is 3000 rpm, and at this
speed, a two-pole generator must be driven to generate alternating current at a frequency of
50 cycles per second
2.7. ELECTRICAL POWER TRANSMISSION:
Electrical power is usually produced in the stator windings of large modern generators at
about 15.75 KV and is fed through terminal connections to one side of a generator
transformer that step up the voltage to 220 KV and transmitted. Now a- day's power
transmission is carried out even with a high voltage of 400 KV. increasing the transmission
voltage reduces the line losses and increases the efficiency of the overall system.
CHAPTER-3
BOILER
2. BOILER AND ITS AUXILIARIES
2.1 Boilers, Their Classification and Types:
• Boiler is a device for generating steam for power, processing or heating purposes. Boilers are
designed to transmit heat from an external combustion source (usually fuel combustion to a
fluid) contained within the boiler itself.
• The heat-generating unit includes a furnace in which the fuel is burned. With the advent of
water-cooled furnace walls, superheaters and economizers, the term ‘steam generator
evolved as a better description of the apparatus.
• Boilers may be classified based on any of the following characteristics:
• Use.
• Pressure.
• Materials.
• Size.
• Tube content.
• Tube shape and position.
• Firing.
• Heat source.
• Fuel.
• Fluid.
• Circulations.
• Furnace position.
• Furnace type.
• General shape.
• Trade name.
• Special features.
Categorization of boilers: Boilers are generally categorized as follows:
• Steel boilers
• Fire tube type
• Water tube type
• Shell type
• Cast iron boilers
• Special design boilers
• Nuclear reactors
2.2 Arrangement of Main Boiler:
The various components of the boiler are briefly described as follows:
2.2.1 Furnace:
It has four walls, consisting of water tubes. The two water walls depth-wise, are called front
and rare water walls and the remaining two water walls, width-wise, are called left and right-side
water walls.
The furnace front water wall tubes are bent at the top to form the roof of the furnace. The
furnace front and rare water wall tubes are bent at the bottom to form the hopper slope. Furnace
rare water wall tubes are bent at the top into the furnace from the nose portion. These tubes are also
bent back in the furnace to form a slag screen and to permit the furnace gases to pass from the
furnace to the heat recovery area.

2.2.2. Boiler Drum:
The function of the steam drum is to separate the water from the steam generated in the
furnace walls and to reduce the dissolved solid contents of the steam to below the prescribed limit
of 1ppm. The drum is located on the upper front of the boiler.
The steam drum is provided with many stub tubes, connected to the boiler tubes, level gauge
connections, safety valve connections, air vent connections, feed water connections, chemical feed
connections, continuous blowdown connections and boiler water sampling connections.
Drum internals is provided inside the drum. The drum metal thermocouples, which are used
when starting the boiler, are attached to the upper and lower parts of near the drum centre and both
ends of the drum shell. The thermo-couples for measuring boiler water temperature in the drums
are attached to the two feeder tubes.
2.2.3 Economiser:
The purpose of the economizer is to preheat the boiler feed water before it is introduced into
the steam drum by recovering heat from the flue gases leaving the boiler.
Feed water enters the boiler drum through the economizer section, which is located in the
lower gas temperature zone. Steaming in the economizer is undesirable. Therefore, the water
temperature, leaving the economizer is designed below the saturation at the operating pressure
during the normal operating period. The economizer is located under the primary superheater
horizontal section in the heat recovery area.
It is preferable that the oxygen content of the feed water does not exceed 0.007ppm and that
the PH value of the feed water is kept at 8.8-9.0 unsuitable feed water causes the formation of an
excessive quantity of deposit in the economizer. Drain valves, provided on the economizer inlet
headers, should not be used as blow-down valves since they cannot blow down a sufficient amount
of water to remove sludge from the economizer.

The economizer shall not be drained when the gas temperature at the economizer is above
370 c.
2.2.4. Air-heater:
Air-heater consists of two types i.e., main air-heater and mills air-heater and mill air-heater.
The mill air heater is used only when the moisture content in coal is large and the main heater outlet
air temperature is not high enough to dry coal.
Flue gases flow inside the tubes and air outside of the tubes. Air supplied to the mill air heater
is extracted from the main air-heater outlet hot air duct and after getting heated in the mill air
heater, enters the primary Air fan. Gas used for the mill air heater is extracted from the primary
superheater outlet section and after leaving the mill air heater enters the main air-heater inlet flue.
A shot cleaning equipment is provided to remove soot and ash accumulated inside the tubes
in the low-temperature zone.
2.2.5 Drum level control:
The feed water control equipment is provided to maintain the drum water level at the
specified value. The drum water level is always controlled to maintain a constant value, main steam
flow to feed water flow ratio by adjusting the speed of the feed water pump. Further, the drum water
level is re-adjusted by the real drum water level signal detected from the drum level transmitter.
2.2.6 Heat recovery area:
The heat recovery area is surrounded by the furnace's rear water wall tubes, spaced
tangentially, the superheater tubes connected from the drum to the primary superheater inlet
header and left and right-side water wall tubes the left and right side water wall tubes and
superheater tubes from the heat recovery area.
2.2.7 Superheater:
Superheater consists of primary and secondary superheaters. The dry saturated steam
leaving the drum flows down the rear wall tubes of the heat recovery area and enters the primary
superheater inlet header. The steam then leaves both ends of it and passes through the transfer pipe
running outside the boiler to the primary superheater intermediate header.
The steam passes through the spray pipe platen loop tubes hung before the furnace slag
screen and pendant loop tubes to the secondary superheater outlet header.
These platen and subsequent loop tubes are called “secondary superheaters”. Thermocouples
are installed to measure tube metal temperatures. They are installed at the stab tubes of the primary
superheater intermediate header and represent the locations of the tubes near the secondary
superheater inlet and outlet headers. To indicate the steam temperature distribution across the
width of the superheater. It is essential that tubes are arranged in good order, and kept clean on
both external and internal surfaces at all times. Fly ash on slag accumulation results in unequal gas
distribution and cause inefficient heat transfer and possible overheating.
Soot blowers are provided to clean the external surfaces of tubes. Proper feed water
treatment and control of steam quality and carry-over are essential to assuring the cleanliness of
the internal surfaces of superheater tubes. Overloading, fluctuating loads, high water level, foaming,
high concentration, etc. All contributions to deposits inside the tubes will lead to unit failures.
Periodic checks of steam pressure drop across the superheater under initial load conditions
usually indicate whether solid deposits are present or not within the elements.
2.2.8 Super heater spray temperature control:
The superheater outlet temperature is controlled at 505 c from a steam generator output of
178 tons/h v steam flow by employing two de-super heater spray nozzles one in each connecting
piping between the primary superheater outlet header and the secondary superheater inlet header.
The final steam temperature is controlled at the desired value by varying the quantity of feed water
admitted to the steam through these nozzles.

2.3 Boiler auxiliaries:
1) I.D. fans
2) F.D. fans
3) P.A. Fans
4) Mills (i.e. pulveriser A & B)
5) Coal feeders
Purpose:
2.3.1 I.D FAN:
The purpose of an I.D. fan is to suck the gasses out of furnaces and through them into the
thermal stack. The boiler is to provide two numbers of induced draft fans. Each I.D fan is provided
with regulating damper control and scoop control for controlling loading on fans, and input/outlet
gates for isolation to facilitate startup/ maintenance of fan. Flue gas interconnection with damper
is provided before E.S.P to maintain balanced flow through both A.P.H/second pass when only one
I.D fan is running.
The major sub-assemblies of the fan are as follows:
❖ Impeller with shaft assembly
❖ Bearing and thermometers
❖ Suction chamber &spiral casing
❖ Shaft seals
❖ Hydraulic coupling
An oil circulation system is provided for cooling and lubrication of fan bearings which consists
of one pair of filters & coolers, one each being stand-by oil drawn by the pump through a suction
strainer. The discharge oil from the pump passes through a duplex filter gets cleaned and passes
through the oil cooler, gets cooled and a sufficient number of valves are provided in the system to
control the flow of oil in various pipelines.
2.3.2 F.D. FAN:
The purpose of F.D. fans is to supply the excess air required for complete combustion. The
boiler is provided with two F.D. fans. Each F.D. fan is provided with blade pitch control for
controlling the loading on fans, and an outlet damper for isolation to facilitate startup/maintenance
of the fan.
The fan consists of the following components:
• Suction chamber assembly
• Impeller casing
• Diffuser assembly
• Main bearing assembly
• Hydraulic servo motor linkage assembly
• Silencer
Oil for the main bearing assembly and servo motor operation is provided by an oil-circulating
system. The pressure in the system is maintained by a recirculation valve. Oil from the pump is
cooled and filtered after the filter, oil branches into two sections one leading to the servo system
known as the “control oil line” and the other to the main bearing assembly for lubrication termed
as “Lubricating oil line”. The motor is an asynchronous squirrel cage induction motor with a grease
lubricant antifriction bearing at both ends of the rotor.
Specifications :
Description ID FAN FD FAN
Number of fans per boiler 2 2
Type of inlet control Speed control Inlet vane control
Flow temperature at the inlet 165°C 42°C

No. of inlet boxes 2 2
Density at flow temp. 0.825 Kg/m^2 1.10 kg/m^2
Method of speed control Fluid coupling Constant speed
Starting torque 45 Kg-m 20 Kg-m
The speed at the designed rating 909 rpm 989 rpm
Static suction pressure at fan entry -228 mm of WG -42 mm of WG
No. of blades 18 18
2.3.3 P. A. FAN:
The primary air fan has got two functions viz., during the coal and transportation into the
furnace. The boiler is provided with two PA fans. Each PA fan is provided with blank pinch control
for controlling the loading on fans, an outlet damper for isolation to the facility ate
starter/maintenance of the fan.
The fan consists of the following components: -
* Suction chamber
* Fan housing with guide vanes (stage 1)
* Rotor consists of a shaft, two impellers with adjustable blades the pinch control mechanism
* Main bearing (anti-frictional bearings)
* Outer guide vane housing with guide vanes (stage 2)
* Diffuser
* Silencer
Oil for main bearing assembly and servomotor operation is provided by the circulation
system. The pressure in the system is maintained by a re-circulation valve. Oil from the pump is
filtered. The filter oil branches into two sections, one leading to the servo system known as the
“control oil line” and the other to the main bearing assembly for lubrication termed as
“lubricating oil line” Motor is an asynchronous squirrel cage induction motor with the grease
lubricated anti-friction bearing at both ends of the rotor.

Specifications:
Description PA FAN
Type Single suction, single stage, Radial vane
Number per boiler unit 2
Type of drive Directly coupled with motor
Speed 1500 rpm
Capacity at NTP 490 M^2/min
Pressure at the fan outlet 660 mm of WG
Electrical input 4700 KW
Pressure at the fan inlet 10 mm of WG
2.3.4 Coal feeders:

In most of the power stations, the types of feeders used for transporting coal from the RC bunker
to the mills are:
(a) Chain feeders
(b) Belt feeders
(c) Table-type rotary feeders
(d) Gravimetric type of feeders
In chain type of feeders, a continuous chain is moving around the sprockets in which a sprocket
is driven by a variable speed DC motor and other sprocket chains chain at different intervals, MS
plates are connected which are called scraper feeders. When the scraper moves it will scrap the coal
and the end of the table or platform the coal into the pulverisers.
The actual fuel bleed thickness carried by the scraper will be more to restrict this, a height
regulating plate is provided so that the height of fuel scraped by the scraper can be controlled.
Specifications:
Type: Drag link type
Number per boiler unit: 4
Type of drive: constant speed motor
Method of flow control: infinitely variable speed gears
Capacity: 22 tons/hour
Feed ranges from: 2.2 tons/hr to 22 tons/hr
2.3.5 Coal Mills:
Description:
There are three hundred per cent capacity ball tube mills per unit; they operate at a speed of
15 rpm. The mill drum carrying the balls rotates on the anti-friction bearing. Raw coal is fed to the
drum through the inlet elbow and gets crushed to the powder inside the mill drum. The balls and
the coal are carried to a certain height inside the drum and allowed to fall. Due to the impact of balls
on coal particles and due to attrition, as the particles slide over each other and also over the levers,
the coal gets crushed. The classifier for frothier grinding returns the crushed particles.
Primary air in the case of tube mills has dual functions to perform. It is used for drying as
well as transporting the same mil output and is regulated to have proper pulverized fuel outlet
temperature to avoid excess sweeping of coal from the mill, only part of primary air directly
proportional to the boiler load demand is passed through the mill. Further to ensure and maintain
the sufficient velocity of pulverized fuel and to avoid setting in power factor pipes an additional
quantity of primary air (by-pass air) is fed into the mixing box on the raw coal circuit.
Tube mill output, while responding to boiler load demand, is controlled by regulating primary
airflow. Mill level control electric sensing the decrease in coal level in the mill increases the feeder
speed and vice versa, the mill pressurized and plenum chamber around the rotating ensures
tightness trunnions filled with pressurized seal air.
Specifications:
Number of boiler units = 2
Type of drive = Double reduction gear, coupler with motor
Method of speed control = Constant speed
Throughput variation = 9 tons/hour to 27.7 tons/hour
Maximum capacity = 29.7 tons/hour
Electrical input per ton coal = 35 KWH

CONDENSATE PATH:
Exhaust stream from the LP turbine enters into the condenser, condensates into the water by
exchanging its heat energy with the cooling water, Cold water from the river or cooling tower is
circulated through the tubes in the condenser and as the steam from the turbine passes round
them it is rapidly condensed into water.
CEP extracts the condensate from the condenser and pumps to enter into the ejector which
extracts the non-condensing gases from the condenser and heat exchangers of the turbine. The
pressure and discharge of non-condensing gases depend upon the conditions of working of
condensers and ejectors. This water enters the deaerator through a gland steam condenser, drain
cooler, and LPH1&2 LP heaters 1,2 are used to heat the water. The function of the deaerator is to
remove dissolved non-condensable gases to heat boiler fuel water. The deaerator protects the feed
pumps, piping, boiler & any other piece of equipment used in the boiler from corrosion.
FEED WATER PATH:
A boiler feed pump is a multistage pump provided for pumping feed water from the deaerator to
the economizer. Generally, two pumps each of 100% of the total capacity are used in the KPTS-VII
station. The pump increases the pressure energy of a fluid with the help of centrifugal action. In
between the deaerator & economizer HP heaters are used to heat the water. By this we can
increase the temperature up to 200°C, then water enters into the economizer. The function of the
economizer is a steam-generating unit is to absorb heat from the flue gases and add this as
sensible heat to the feed water that enters the evaporative circuit of the boilers
STEAM GENERATOR (BOILER)
TYPE
The steam generator is two passes, balanced–draft, once-through sliding pressure
supercritical, single reheat, dry bottom, semi-indoor, welded water wall spiral wound and
vertical construction, tilting tangential firing type.
● There is no Div Panel SH in our UNIT

The steam generator will produce steam flow to a turbine generator with boiler
BMCR outlet conditions of the main steam flow of 2585 T/hr, 568 oC @ 255 kg/cm- g and
RH outlet steam flow of 2042T/hr, 596"C @ 59.9 kg/cm' g.
The once-through system is characterized by placing water separators at the end
of the evaporative sections. ln a once-through system, the fluid flows only once through
the evaporator circuit with no recirculation. Between minimum once-through load and
maximum load, the water separator operates in a dry mode (no water level).
For the start-up of a boiler, a minimum flow feed water flow must be established
and maintained before firing commences. This minimum flow is typically around 30-
40% MCR flow and it determines the ‘minimum once-through load’. This fixed minimum
flow is necessary to provide adequate cooling to the furnace wall tubes. The excess water
over and above the extent of steam generation is dumped/re-circulated through a start-
up separator vessel by a level control loop. Once steam generation matches the minimum
feed water flow the separating vessel will run dry and once-though mode is then
established. The feed water flow must then be increased to match the increase in steam
generation.
For supercritical units, since there is no energy reserve in the form of a steam
drum, the control system must match, exactly and continuously, feed water flow and
boiler firing rate (both fuel and air) to deliver the desired generator power. The ability of
the control system to achieve stable and steady-state operation, without oscillations is
critical to achieve supercritical unit efficiency. The lower thermal storage capacity of the
once-through boiler means that the pressure is more sensitive to system upsets
The salient features of the supercritical units as compared to subcritical units are:
• Improved thermal performance
• Reduction in emission
• Plant availability
• Load response
• Fuel flexibility
• Requirement of improved material
DATASHEET OF BOILER
• Design, manufacturing and inspection as per IBR

• Separator design pressure 292.1 Kg/cm2(g)
• Super heater design pressure 270.3 Kg/cm2(g)
• Super heater design temperature 568 + 5 = 573oC
• Reheater design pressure 71.4 Kg/cm2(g)
• Reheater design temperature 596 + 5 = 601 oC
• Hydraulic test pressure at the site
• For boiler including economizer and superheater - 438.15 Kg/cm2(g)
• For Reheater 107.1 Kg/cm2(g)
• Steam flow at superheater outlet 2585 TPH
• Furnace width 21840 mm
• Furnace depth 19188 mm
• Backpass depth 16002 mm
• Extended backpass depth 7783
mm HEATING SURFACE AREA (in m2)
a) Economizer 33069
b) Furnace walls 8611
c) Superheater
I. Platen superheater 5187
II. Finish superheater 9180
d) Steam-cooled wall 5249
e) Superheater roof 850
f) Reheaters
I. LTRH 27139
II. Finish Reheater 4915
TOTAL 94300
DESIGN PRESSURE AND TEMPERATURE OF SOME CRITICAL HEADERS

AND CRITICAL PIPELINES
DESIG DESIGN
SL
DESCRIPTI N TEMP. IN OC
NO
ON PRESSU
RE
IN Kg/cm2
I CIRCULATION SYSTEM
1 FURNACE LOWER INLET HEADER 4 314.2 347
No’s FRONT(F-01),REAR(F-07), 2
SIDES(F-16)
2 FURNACE INTERM HEADER 4 295.4 408
No’s FRONT, REAR, 2 SIDES
3 FURNACE UPPER HEADER 4 No’s 292.7 455
FRONT(F-05), REAR(F-14), 2SIDES(F-20)
4 FURNACE RISERS 4X4=16 No’s 292.7 455
FRONT(F-06), REAR(F-15), 2SIDES(F-
21)
5 SEPERATOR 292.1 430
6 FURNACE CONNECTING SPHERE 295.3 452
7 WATER STORAGE DOWNCOMER 298.1 347
8 BOILER CIRCULATION PUMP 323.5 348
SUCTION/DISCHARGE LINE
II ECONOMIZER SYSTEM
1 ECONOMIZER INLET HEADER (E-05) 316 328
2 ECONOMIZER JUNCTION HEADER (E-07) 313.2 377
3 ECONOMIZER OUTLET HEADER (E-09) 310.4 351
4 ECONOMIZER WATER WALL INLET LINK 314.2 347
III REHEATER SYSTEM
1 LTRH INLET HEADER (R-04) 71.4 389
2 LTRH OUTLET HEADER (R-08) 71.4 540
3 FINISH REHEATER INLET HEADER (R-11) 71.4 520
4 FINISH REHEATER OUTLET HEADER (R-14) 71.4 601
IV SUPERHEATER SYSTEM
1 SH FURNACE ROOF INLET HEADER (S-02) 290 430
2 SH FURNACE ROOF OUTLET HEADER (S-05) 290 437
3 EXTENDED BACKPASS SIDE INLET HEADER (S-11) 290 437
4 EXTENDED BACKPASS SIDE FLOOR OUTLET 290 472
HEADER (S-09)
5 BACKPASS UPPER SIDE INLET HEADER (S-11) 290 437

6 BACKPASS LOWER HEADER 4 290 472
No’s FRONT(S-14), REAR(S-13),
2SIDES(S-17)
7 BACKPASS FRONT OUTLET HEADER (S-22) 290 479
8 PLATEN SH INLET HEADER (S-32) 285.1 438
9 PLATEN SH OUTLET HEADER (S-34) 276.3 526
10 FINISH SH INLET HEADER (S-38) 274.9 504
11 FINISH SH OUTLET HEADER (S-41) 270.3 573
SAFETY VALVE DETAILS

DESCRIPTION QUANTITY SET Pr RESET Pr
(Kg/Sq Cm (g)) (Kg/Sq Cm (g))
SEPARATOR Safety valves 8 Nos 291.1 282.4
SUPER HEATER OUTLET 2 Nos (L) 270.3/270.6 262.2/262.6

Safety Valves
2 Nos (R) 270.3/270.6 262.2/262.6
SUPER HEATER O/L ERV 2 Nos 267.6 259.6
CRH Safety Valves 2 Nos (L) 71.4/73.5 69.3/71.3

2 Nos (R) 71.4/73.5 69.3/71.3
HRH Safety Valves 3 Nos (L) 68.0/68.4/69.1 66.0/66.3/67.0
3 Nos (R) 68.0/68.4/69.1 66.0/66.3/67.0
HRH ERV 2 Nos 67.3 65.3
Soot Blowing Safety 1 No 40.0 38.4
valve
Total Safety valves 27 Nos
Safety valves and ERVs are selected for the following conditions
● Maximum evaporation is 2585 TPH of steam

● Maximum allowable boiler separator pressure is 291.1 Kg/sq cm (g)
● Maximum superheater steam temperature is 568 deg C
● Maximum flow through Reheater is 2042 TPH
● Maximum allowable Reheater pressure is 71.4 Kg/sq cm (g)
● Maximum temperature of steam entering the Reheater is 360.8 °C and that
leaving the Reheater is 596 °C
HEAT BALANCE DIAGRAM
(TMCR/800MW/0% MU)
STEAM TURBINES
In thermal power stations, electrical power is generated by rotating the rotor shaft
of an alternator with the help of a steam turbine. A steam turbine extracts energy from
steam generated from the Boiler. The high-pressure and high-temperature steam
supplied by the boiler enters a turbine with a lot of heat energy in it. A steam turbine
continuously converts that heat energy into shaft work. The utilized steam is then
exhausted to a condenser at low pressure and low temperature. Excellent speed stability
is possible with appropriate control equipment. The stability of speed is one of the most
TYPE:
Three–casing condensing turbine with reheat for STP -- Type SST5-6000 HP
TURBINE: Type H70
18 reaction stages including 1 low reaction stage and 17 twisted drum-stages IP
TURBINE: 15 + 15 Stages LP TURBINE: 7 + 7 stages
• Maximum Continuous Rating (MCR): 800 MW
• Maximum capability: 840 MW
• Maximum Overload capability: 918 MW
• Steam pressure: 242 bara
• Steam Temperature: 565 0C
• Exhaust Steam pressure: 0.084 bara
• Maximum turbine cycle Heat Rate: 1810 (with MD-BFP),
STEAM PRESSURES
TEMPERATURES
DESCRIPTION UNIT NOMINAL LONG- SHORT-

TERM TERM
Main steam bara/0C 242.3/565 254.5/573 290.8/579
before 1st HP drum stage bara 235.7 247.4 247.4
HPT Exhaust bara/0C 59.5/344.5 67.4/379 73.5/441
at the inlet to reheat bara/0C 55.5/593 63.5/597 69.3/603
valve the of IP turbine
Extraction 8 bara/0C 80.2/387.1 90.9/411 90.9/460
Extraction 5 bara/0C 12.7/365.7 16/431 16/435
Before 1st LP Drum stage bara 5.35 6.68 6.68
LPT 1 Exhaust bara/0C 0.097/45 0.3/90 0.3/110
LPT 2 Exhaust bara/0C 0.074/40 0.3/90 0.3/110
Long-term values- Upper limit, permissible without time restriction. The
quoted maximum long-term values are annual average values. The pressure and
temperature shall not exceed the quoted max. long-term pressure. Accidental
pressure increases above the max. long term pressure shall not exceed the
quoted max. short-term pressure.
Short-term values - Operation with maximum short-term conditions is only
allowed for brief swings of 15 min or less, provided that the total operating time
does not exceed 80 hours during any 12-monthly operating period.
Set safety valves such as to ensure that this value is not exceeded during short-term
operation.
TURBINE EXTRACTIONS
1 8th Extraction HPT 7TH Stage HP Heater 8 A/B
2 7th Extraction CRH HP Heater 7 A/B
3 6th Extraction IPT 7th Stage HP Heater 6 A/B (through DSH
6A/B)
4 5th Extraction IPT 11th Stage De-aerator, TD BFP
5 4th Extraction IPT Exhaust LP Heater 4
6 3rd Extraction LPT -1&2 2nd Stage LP Heater 3
7 2nd Extraction LPT-2 5&6th Stage LP Heater 1B/2B
8 1st Extraction LPT-1 5&6th Stage LP Heater 1A/2A
ESTIMATED LUBE OIL FLOW REQUIREMENT OF BEARINGS:
DESCRIPTION UNIT FLOW

Bearing 1 (ahead of HP-Turbine) L/sec 0.76
Bearing 2 L/sec 12.07
Generator Front Bearing L/sec 9.94
Generator rear Bearing L/sec 9.94
Excitor Bearing L/sec 0.5
LIFT/JOCK OIL PUMP “CUT-IN” and “CUT-OUT” SPEEDS

Lift oil pump must be in operation at a turbine speed is < 510 rpm
Lift oil pump should be cut out at speed >540 rpm
If the steam turbine I&C system receives a fire protection signal, the lift oil
pumps will be automatically switched off.
Before the lift oil pumps can be switched on again, the emergency oil pump
must be activated via the operating monitor.
LIMIT AND SET VALUES FOR STEAM TURBINE
DESCRIPTION UNI Alarm at Trip to be initiated

T at
HPT steam temperature 470 480
oC
at the exhaust end
IPT steam temperature 292 330
oC
at the exhaust end
The steam temperature 180 230
o C
at LPT blading before the
last stage
The steam temperature 110 130
o C
at LPT blading last row
exit
HI TURBINE / LIMIT SIGNAL FORMATION-SETTINGS(inbuilt in

TSE)
DESCRIPTION UNIT WARNING TURBINE TRIP

Turning gear operation K +30 +55
-45 -55
Startup to speed K +30 +55
-45 -55
Power operation K +30 +45
-30 -45
Permissible steam temperature difference between parallel steam
admission pipes:
• without time limit: 17 K
• for short periods (15 min): 28 K

The steam temperatures in the hottest pipes must not exceed the limits given
above.
LIMIT AND SET VALUES FOR STEAM TURBINE

Bearing Temperatures
DESCRIPTION UNI Alarm at The unit shut
T down at
Limit radial bearing 1 90 130
C
o
Limit axial bearing 2 100 130

C
o

C
o

C
o

C
o

C
o
VIBRATIONS
Absolute bearing Relative shaft vibration
casing vibration
Alarm setting “warning 9.3 mm/s 165 μm
high” (pk-pk)
Turbine Trip limit 11.8 mm/s 240 μm
“very high” (pk-pk)
A temperature rise of oil in bearings
normal 20 K
A temperature rise of oil in turbine bearings
maximal 25 K
| 27
Vacuum trip
setting
Electrical vacuum trip 0.3 (-0.7) bara

Electrical vacuum trip for 0.6 (-0.4) bara
bypass operation
Vacuum low alarm 0.2 (-0.8) bara
Non-coincidence limit 0.04 bara
Technical release 540 rpm
Motoring of the generator in multi-shaft plants

During motoring the turbine is driven by the generator at rated speed
with the stop valves or control valves closed. Windage power in the blading
causes turbine components to heat up. To prevent components from
heating up beyond permissible temperatures, the motoring of the
generator must be limited to one minute.
If turbine protection criteria initiate a turbine trip, motoring of the
generator must be limited to 4s.
Turbine Gland Sealing System:
Turbine glands are a part of the Turbine so that Steam cannot
escape from the higher-pressure parts of it and Air cannot enter the lower-
pressure parts of the Turbine. However, many parts of the turbine operate
at such high pressure that it cannot leak to the full extent. On the other
hand, the lower pressure parts operate at a sub-atmospheric region so air
ingress is not eliminated. This sub-system is provided to seal the glands in
such a way that leakage of steam from the higher side is controlled at a
certain pressure and extra steam from the control valve outlet is delivered
to the lower pressure (LP)side glands to arrest air ingress by maintaining
a certain pressure.
SEAL STEAM PRESSURE CONTROL:
The task of the seal steam control system is to maintain the
pressure in the seal steam header and in turn to ensure reliable sealing of
the shaft seal in all operational conditions. A seal steam pressure
controller with PI action acts on valve actuators of the seal steam supply
valve and leaks the off valve according to the deviation of the point and
actual steam pressure in the seal steam header. The
The controller has an adjustable gain and Integral time. The controller output is
limited to -105 % to +105 %. This output is used to generate position set points for seal
steam leaking off valves with approx. 5 % over the negative time output range is
primarily used for leaking off the steam valve whereas the positive output range is used
for sealing the steam valve.
SEAL STEAM TEMPERATURE CONTROL:

During full load, steam exited from HP Turbine is used to seal IP/LP turbine. In
the case of the shaft, the steam temperature rises due to hotter steam from HP, the
seal steam supply valve is opened to admit comparatively cool steam the from auxiliary
steam header to reduce the temperature. Steam admitted through the seal steam
supply valve causes an increase in shaft steam header pressure. Leak off valve is
opened to maintain shaft steam header pressure by dumping excess steam in the
condenser.
TURBINE PROTECTION:
The Turbine protection system initiates turbine trip in case of endangering
operating conditions for the Turbo set and its auxiliary systems.
The Turbine control system monitors operating and process conditions and keeps
these conditions under permissible limits. In the event of failure in keeping these
conditions under limits, the turbo set is tripped by closing control and stop valves and
interrupting the steam flow to turbo set.
Criteria are built in control system for various operating conditions. Operating
conditions are compared with predefined process/operation limits, if any of the
protection criteria is met, in form of exceeding the process parameter with respect to
predefined limit, fast response solenoid valves of valve actuators trip the system through
the break current circuit and turbine valves are closed.
Turbine Tripping
Conditions:
SL Trip Condition Set values / remarks
N
O
1 Over Speed Electrical Over Speed Trip EOST
: > 3300rpm (110%of rated speed)
2 Rotor position abnormal (Axial (From “K” neutral position)
Shift) Alarm: > +/- 0.5mm Trip : > +/-1.0mm
3 Bearing pedestal vibration. Alarm: > 9.3 mm/sec
Trip : > 11.8 mm/sec
4 Bearing temperature Very High Trip: > 130oC
4 Condenser vacuum low Alarm: > -0.8 bar (0.2 Bara)
Trip : > -0.7 bar (0.3 Bara)
5 Condenser Pressure Protection Condenser 1/2 Pressure (VAR) High: > 0Bar
(Condenser pressure (0-1.3 Bara) Condenser 1/2 Pressure (Fxd) High : > 0.3Bar
–
LP CSVR Pressure (0-10 Bara)) &
Condenser Pressure DP > 0 Kg/cm2
6 Differential expansion Rotor long Rotor short
Alarm: > +18.3mm Alarm : < -2.8mm
Trip : > +19.8mm Trip : < -3.1mm
7 HPT Exhaust Temperature D.T Trip: >0 Co
(Diff. Temp=function of HPT Inner High Alarm: >= -10oC

Casing Temp – HPT Exhaust (if DT >= -15oC after 5sec HPT Trip and after
Steam 1sec OFF Delay pulsed HPCV Close)
Temp)
8 HPT Exhaust Temperature Trip: >480oC
High Alarm: >470 oC
9 IPT Wet Steam Protection: Trip DT >0 oC
Saturation Temp IPT Exhaust Minimum DT <10oC
10 LPT 1/2 Exhaust steam temperature Spray: > 90°C

high Alarm : > 110°C
Trip : > 130°C
11 Main steam temperature High High Trip ： 593°C
12 Main steam temperature Low Load (%) 100 % 80 % 60% 40%
Alarm 488 466 437 400
Trip 460 438 409 372
13 Turbine Trip on Lube Oil Trip: Lube Oil Header Pressure < 2.3 Bar
Protection & Turbine Speed Not < 10 rpm
Low Alarm: Lube Oil Header Pressure < 2.5
Bar & Turbine Speed Not < 10 rpm.
LOP Change over at Oil Pressure <2.5 bar and
LO pressure at manifold <5.3 bar
14 Lube Oil Tank Level V.High Trip : +1480 mm (zero level : 1400mm)
V.Low Trip : -1320 mm
❖ IPT Wet Steam Protection Release:
● Release 1 : Speed is not <402 rpm & TM Groove IP Shaft >200 oC &
Both IP Control Valves not Closed.
● Release 2 : Release 1 & Speed is not <2700 rpm
Additional Station Protection – 1 (Trip)
Any one of the following conditions
P Bus Coupling System fault.
Oil Tank Level Protection.
Lube Oil Pressure Protection.
HPT Exhaust Protection.
IP wet steam Protection.
Additional Station Protection –
2 (Trip) Any one of the following
conditions
• SGC ST Turbine (MS)
• Oil Supply Emergency Operation.
• Control Fluid Supply Protection OFF.
• Control Fluid Supply Turbine / Bypass Valve Protection OFF.
• ST Processor /Communication Fault
• Bearing Protection.
• Bearing Pedestal Absolute Vibration.
• HRSG Drum Level High Protection.
• Boiler Protection.
ACTIONS ON INITIATION OF MFT & TURBINE TRIP
MFT Initiation will cause.
•Tripping of all Mills, Feeders, HOTV and LOTV.
•Turbine Trip
•All Hot air gates closes.
•Tripping of PA fan – A&B.
•FCV of MD-BFP enabled
•Closing of SH/RH Block Valves.
•Auto Close of MDBFP Discharge valve.
•Fuel/FW Ratio protection disabled.
•MDBFP Scoop demand set to 15% for 15 sec.
•Protection Open of HWL -1 and 2 Isolation valves.
•Protection Close of Warm keeping isolation valve and warm-up
relief valve.
•BWCP inlet and outlet isolation valves Protection open.
•Common trip of TDBFP - A & B.
• All SH/RH Spray CVs priority lower.
•ULD Runback Reset.
•MS to PRDS - 1 & 2 inlet MOV auto close.
•Feed water flow bias set to zero.
TURBINE TRIP Initiation will cause
• Closing of ESV and ISVs .

• Closing of all Turbine Governor valves and ISVs .
• Initiating Low forward Protection for Tripping GCBs .
• All HP Heaters, De-aerator and LP Heaters inlet steam MOVs,
NRVs protection/Auto close .
• All turbine extraction drain MOVs both upstream and downstream SOVs
protection/Auto open .
• CRH NRVs auto close .
• Ventilator MOV upstream drain SOV protection/auto open.
• Condenser curtain spray SOV protection/auto open .
• HPBP PCV - 1 & 2 quick opens for 3 sec when boiler is in service.
• LPBP PCV set point to 12 Bar .
• LPBP spray CVs quick opens for 2 sec .
• CRH Steam to TDBFP - A/B inlet MOV protection open .
• Gland Steam Header Pressure Set point changes to 0.18 bar .
• Turning Oil Pump ON Gland Steam Header Pressure Set point changes to
▪ 0.18 bar.
• HP Inner and Outer Casing Drains OPEN .
• MS and HRH Lead Pipe Drain Valves OPEN.
• Turning Oil Pump ON
Boiler Protection (MFT
Conditions)
The steam generator is two pass, balanced – draft, once- through, sliding
pressure supercritical, single reheat, dry bottom, semi-indoor, welded
water wall spiral wound and vertical construction, tilting tangential firing
type.
Sl.no MFT trip condition remarks/values
1 Loss of any unit critical power

2 Both ID Fans OFF
3 Both FD Fans OFF
4 Loss of Reheater protection : logic of RH Protection
5 Unit Air Flow less than 30% : 892 TPH
6 All feed water pumps are OFF for more
than20 sec and loss of Fuel Trip Arming
7 Furnace Pressure High : + 152 mmWC
8 Furnace Pressure Low : - 178 mmWC
9 Emergency Trip (SOFT) Initiated
10 Emergency Trip from PB/ECP
11 Loss DCS Control Capability for : Failure of any DCS
More than 10 sec Controller of
Emerson
12 MFT Relay Trip pulse
13 Unit Flame Failure
14 Loss of Fuel Trip
15 Evaporator tube metal temperature : any 4 tags of 76 tags
High for more than 3 sec become more than 471oC
16 Loss of power at any Oil Elevation
In service with all feeders OFF
(Less than Fireball)
17 Seperator Level High : 13.63 mtr
18 Seperator pressure High : 292.5 Kg/cm2
19 Economizer inlet feed water flow low : 745
TPH For more than 10 sec and Loss of fuel
Trip Arming
REHEATER PROTECTION
o Reheater Arming Conditions :
• Both Furnace Temperature probes (FTP) are not in forward end position
• Any one of the following conditions. This condition will be reset on Boiler Trip
o MS flow is >10%
o Generator synchronized
o Total corrected fuel flow >10%
• FTP temperature is >540oC (Left or Right)
• Total corrected fuel flow – Main Steam flow is +ve after 240secs
• Reheater Trip Conditions :
• HP Bypass or LP Bypass valves are not open and Turbine valves closed
• Total corrected fuel flow – Main Steam flow is >0 with 240secs delay and all Turbine
valves closed.
• Total corrected fuel flow – Main Steam flow is >0 with 240secs delay and any of the
following conditions arises.
o ULD runback in progress with 50 sec delay.
o on House load with 50 sec delay
• FTP temperature is >593 oC
▪ For issuing MFT Trip condition on Reheater protection, Both Arming

condition should prevail and satisfy any one of the trip conditions with 10
sec delay will issue Loss of Reheater protection command to MFT.
FANS:
• Air is the most desired constituent after fuels for combustion to take place.
There are many types of fans used in modern thermal power plants
depending on type of fuels. The supply of air and withdrawal of the product
of combustion are handled by the fans.
INDUCED DRAUGHT FAN:
An induced draught fan (ID Fan) is provided to maintain a negative pressure in
the furnace by sucking the products of combustion from it with a slight positive pressure
at the discharge end vis-à-vis the bottom of the chimney/stack. This positive pressure,
assisted by the stack effect of the heated chimney (120oC), causes the flue gas to leave the
chimney and mixes it with the surrounding atmosphere. Dampers automatically
controlled, are also a part of the SG plant that maintains the approximate furnace draught
within a safe margin.
START PERMISSIVES for ID FAN-A (similarly IDF-B)
• Flue gas path available
• ID Fan – B in Service
• ID Fan – A lube oil tank level “Adequate >75%”, (low <=60%, Very low <=50%)
• ID Fan – A “OFF” (Switchgear)
• ID Fan – A “Not Tripped”
• ID Fan – A “No Switchgear Disturbance”
• ID Fan – A Switchgear “Available”
• ID Fan – A Cooling/ Sealing air fan outlet pressure “Adequate”
(>75
mbar - Adequate, =<75 mbar - Low, <10 mbar – very Low)
• ID Fan Hydraulic room temperature “Not High” (>=80oC)
• ID Fan – A Bearing room temperature “Not High” (>=80oC)
• ID Fan – A Blade pitch close (<3%)
• ID Fan – A inlet isolation damper “CLOSE”
• ID Fan – A Outlet isolation damper “CLOSE”
• ID Fan – A Motor Bearing DE/NDE vibrations X/Y “OK” (<9 mm/sec)
• ID Fan – A Motor winding temperature “OK” (<110 oC)
• ID Fan – A Motor Bearing DE/NDE temperature “OK” (<90oC)
• ID Fan – A Control Oil pressure “OK” (> 22 Kg/cm2) (C.O Pr. Low < 16.5
Kg/cm2)
• ID Fan – A Lube Oil pressure “OK” (7.5 Kg/cm2)
• ID Fan – A Lube Oil Flow “OK” (> 8.5L/min) (low <6.0 L/min)
• ID Fan – A Bearing temperature “OK” (< 90oC)
• ID Fan – A Vibrations X/Y “OK” (<9mm/sec)
| 36
FORCED DRAUGHT
FAN:
The air is supplied through the forced draught fan (FD Fan) and air ducts. Before
reaching the combustion chamber, air is pre-heated using an air heater in order to
increase the overall efficiency of the Boiler. Furnaces usually have a negative pressure for
various reasons and automatically controlled dampers are part of this system to control
the desired quantity of air which takes care of the differential pressure of the supply air
and the furnace.
Start Permissive for FD Fan – A (Similarly FD Fan – B)
Furnace Draft Control in “AUTO”

FD Fan – A in “OFF”
Any one ID Fan is in service
FD Fan – A “Not Tripped”
Air Preheater –A (or) Air Preheater- B in Service.
FD Fan Motor Winding Temperature OK ( < 125 oC) .
FD Fan Motor Bearing DE/NDE Vibration X/Y OK ( < 9 mm/sec).
FD Fan Vibration X/Y Axis OK ( < 9 mm/sec) .
FD Fan Bearing Temperature OK ( < 90 oC).
FD Fan – A lube oil tank level “Adequate” ,
(Adequate >750mm, low <=600 mm, Very low <=500 mm)
FD Fan – A lube oil flow “Adequate” (Adequate >2.3 L/min, low < 1.7 L/min)
FD Fan Lube Oil Pressure OK (adequate > 8 Bar) (Low <5bar)
FD Fan Control Oil Pressure OK ( > 20.5Bar with 5 sec time duration)
FD Fan Blade Pitch Control Close ( < 3%).
FD Fan O/L Isolation Damper Close .
FD Fan ON Permissive From ID Fan.
FD Fan-B in Service (OR) FD Fan - B Flow Path available ( Blade pitch > 3%
and outlet damper open).
FD Fan-A Switchgear Available.
FD Fan Motor Bearing DE/NDE Temperature OK ( < 90 oC)
FD Fan Trip Interlocks:
FD Fan Local Electrical Push Button Operated.

FD Fan Switchgear Disturbance .
FD Fan O/L Trip .
FD Fan Master Trip .
FD Fan Trip (Both ID Fans LOST) .
Post Purge FD/ID Fan Trip.
FD Fan Motor Winding Temperature Hi Hi ( > 130 oC).
FD Fan Motor Bearing DE/NDE Vibration X/Y Hi Hi ( > 15 mm/sec with 5 sec
time delay).
FD Fan Bearing Temperature Hi Hi ( > 110 oC with 2 sec time delay).
FD Fan Vibration X/Y Axis Hi Hi ( > 15 mm/sec with 5 sec time delay) .
FD Fan Motor Bearing DE/NDE Temperature Hi Hi ( > 110 oC with 2 sec time delay)
Lube Oil Scheme
Start Lube Oil tank level “Adequate”

Permissive (level
> 75%)
Trip Interlocks d. ID Fan local Elec. Push
button Operated.
e. ID Fan local Elec. Push
button Operated.
f. ID Fan Lube Oil Tank Level
Very Low (<50%)
Auto ON a. LOP Main Selection & ON
Conditio Command from Start
n Sequence.
b. LOP on Standby &
Running Pump Trip.
c. LOP on Standby & Lube Oil
Pressure Low ( (<16.5 bar &
any one LOP ON) with 30sec
time delay.
d. other LOP fail to ON
Protection ON ID Fan ON & Other LOP OFF
AUTO OFF ID Fan OFF with time delay of
1800 sec
Protection OFF IDF Lube Oil Tank Level Low Low
( < 50%)
FD FAN TECHNICAL
DATA
Quantity 2 No’s
power 2125 KW
Rated Voltage 11KV
Full load 133.5 Amps
Current
No load 28 Amps
Current
Rated Speed 995 rpm
F.L Efficiency 96.0 %
Flow 350 m3/Sec
Pressure 445 mmWC
Temperature 53 oC
PRIMARY
AIR FAN
The function of the Primary Air Fan (PA Fan)is to transport the fine grains of solid
fuels in the required quantity at the correct temperature with the automatically
controlled dampers, this is done by the proportioning of cold PA with hot PA that is
obtained by heating a portion of the PA using Air Heaters.
Start Permissive for PA Fan – A (Similarly PA Fan – B)
• Both FD Fans are in Service

o OR
• any FD Fan “ON” and PA Fan- B “OFF”
• PA Fan- A in “OFF” / Not Operated
• PA Fan-A Elec. Push Button “Not Operated”
• PA Fan- B in “ON”
o OR
• PA Fan- B in “OFF” and PA Fan- A start permissive OK
• Both Air preheater “ON” and Both primary air path Available
• OR
▪ any Air preheater “ON” OR any primary air path Available and PA Fan-B
OFF
• PA Fan- A Switchgear “OK”
• PA Fan- A “No Switchgear Disturbance”
• PA Fan- A lube oil tank level “Adequate”
• (Adequate >75%, Low <60%, very Low <50%)
• PA Fan- A lube oil flow “Adequate”
• (flow adequate >4.5 L/min, flow Low <4.2 L/min, very low <2.8 L/min)
• PA Fan Lube Oil Pressure OK ( > 18 Bar with 5 sec time duration)
• (Adequate > 18 bar and low < 13.5 bar)
• PA Fan- A Motor winding temperature “Not High” (<135 oC)
• PA Fan- A Blade Pitch Control Close ( < 3%) or Minimum and Manual
• PA Fan-A O/L Isolation Damper Close.
• PA Fan-A Motor Bearing DE/NDE Vibration X/Y OK ( < 9 mm/sec) .
• PA Fan-A Vibration X/Y Axis OK ( < 9 mm/sec with 120 sec time duration)
• PA Fan-A Motor Winding Temperature OK ( < 135 OC) .
• PA Fan-A Motor Bearing DE/NDE Temperature OK ( < 90 OC)
• PA Fan-A Bearing Temperature OK ( < 90 OC)
PA FAN TECHNICAL
DATA
Quantity 2 No’s
power 4700 KW
Rated Voltage 11KV
Full load 277 Amps
Current
No load 45 Amps
Current
Rated Speed 1490 rpm
Flow 240 m3/Sec
Pressure 1355 mmWC
Temperature 58 oC
| 40
Seal Air
Fans:
A Seal air fan (SA Fan) is used to provide air at slightly higher than PA pressure
to seal all the dust-laden equipment, - namely the mills / pulverizers with associated
dampers, relevant parts of the feeders, and so on.
Scanner Air Fans:
The purpose of the these a scanner air fan (Sc A Fan) is to cool the flame
scanners heads meant for detecting the presence and quality of the flame.
BURNER MANAGEMENT SYSTEM
Boiler Purge Permissive
1. No Boiler Trip Command Exists (2/3 logic)
2. Heavy Oil Recirculation Valve Closed
3. All Elevations all Heavy Oil Nozzle valves Closed
4. All Light Oil Nozzle valves Closed
5. Light Oil Trip valve Closed
6. Heavy Oil Trip valve Closed
7. All Pulverizers OFF
8. All Coal Feeders OFF
9. Nozzle Tilt Horizontal and Air Flow <40%
10. All FSSS System Power Available.
I. All individual Coal Elevations (A,B,C,D,E,F,G&H) power available.
II. All individual Heavy Elevations (AB,CD,EF,GH)) power available.
III. Unit Critical Power Available.
a. 220 V DC power available (2/3 logic)
b. Unit Interrogation power available (2/3 logic)
c. MFT Interrogation power available (2/3 logic)
11. All Elevation Disc.Flame Scanners and Fire ball flame Scanners “No Flame”
a. All Oil Elevations (AB,CD,EF&GH) Disc. Scanners “No Flame”
b. All Elevations (AB,BC,CD,DE,EF,FG,GH&HH) ¾ Fireball Scanners “No
Flame”
12. Both Primary Air Fans “OFF”
13. All Auxiliary Air Dampers are “Modulating”
14. All SOFA (Separated Over Fired Air) Dampers Closed
15. Unit Air Flow is greater than 30% (892 TPH)
16. All Hot Air Gates Closed.
| 42
LOTV / HOTV On
Permissions:
• Elevations A, B, C, D, E, F, G & H oil (nozzle) valves remain closed (Heavy

Oil Trip Valve).
• Elevation A oil (nozzle) valves remain closed (Light Oil Trip Valve).
• The oil supply pressure is “satisfactory”.(i.e 13 kg/cm2 for HOTV , 9.0
kg/cm2 for LOTV)
• The oil header temperature is “satisfactory” ( 110 °C heavy oil only).
• Once the Oil Header Trip Valve is opened, the oil elevation “trip
command” is removed.
LOTV/ HOTV Protection Close:
o The Oil Trip Valve is proven “not closed”, any oil (nozzle) valve is “not
closed” and either the following conditions exist, for more than two seconds.
• The oil header pressure is “low”. ( < 2.5 kg/cm2 for both HO & LO)
• For Atomizing header pressure is “low” ( HO: < 4.5 kg/cm2 & LO: <3.5 Kg/cm2).
o A “Master fuel trip” signal is established.
Boiler No Flame trip Conditions:
• If all elevations voted, Boiler trips on No flame. For voting in each elevation, the
following are the interlocks.
• For Fuel Elevations: ( A/B/C/D/E / F/G/H):
• Feeder is OFF.
• Both the following conditions:
• Any oil valve not closed in the same elevation.
• Two out of Four guns not proven in the same elevation.
• Both the following conditions:
• Less than 2 out of Four scanners show flame of same elevation.
• Two out of four guns not proven of same elevation. For Auxiliary
Elevations: ( AB/BC/CD/DE/EF/ FG/GH/HH)
• Both the adjacent feeders off ( Ex: for AB: A&B and For HH-Only H Feeder)
• Less than two out of Four scanners show flame of same elevation.
SADC (Secondary Air Damper Control)
Auxiliary Air dampers :
• To maintain wind box air flow distribution.
• Overriding control in the event of high wind box DP.
• Bias capability of elevation dampers.
Up 30% Unit Load, all wind box auxiliary dampers are modulated to maintain wind
box to furnace DP. For above 30% load, BMS will issue close command to elevations of
auxiliary dampers that are not required for elevations of fuel currently in service. These
signals are issued at 10 sec intervals from top of the wind box. This close command sets
corresponding elevation of dampers to a load dependent Out of service damper
position, which ensures minimum damper cooling air flow.
Other BMS command, Position for Oil firing sets the corresponding damper
position to a predetermined position.
Final demand will be subject to the following override commands:
• Opening of all dampers if Furnace to wind box DP is high.

• Master Fuel Trip.
Fuel Air damper control:

• Control fuel air dampers to optimize combustion.
• Bias capability for elevation dampers.
• Incorporating BMS Commands.
Fuel air dampers are positioned on elevation basis as a function of the

corresponding coal feeder speed. Final demand overrides by command “Close
position” which is load dependent. This position ensures minimum damper cooling
air flow.
Close coupled over fire Air damper Control :( To reduce NOX).

Two elevations of CCOFA dampers provided will work on open loop, which are
positioned as a function of Total Measured Air flow.
• Overriding control opens these dampers in response to BMS initiated

Open commands to assist in minimizing negative Furnace pressure
excursion associated with MFT.
• In case of high Wind box to furnace DP, these dampers will not open.
Separated Over fire Air damper Control ( To reduce NOX).There are four
elevations of SOFA dampers, which are opens on individually on open loop basis positioned
as a function of Total Air flow.
• Overriding control opens these dampers in response to BMS initiated

Open commands to assist in minimizing negative Furnace pressure
excursion associated with MFT.
• In case of high Wind box to furnace DP, these dampers will not open.
AIR PREHEATERS:
An air heater is the last element of the flue gas path where the residual heat
contained in the gas is used for air drying before taking part in the combustion chamber
to improve overall efficiency; this is done by better and spontaneous burning of fuel and
a lower stack outlet temperature. Air Heaters outlet combustion air temperature is higher
compared to a Boiler without them affects fuel saving in the range of 5 to 10%. The
preheated air for the combustion process increases Boiler efficiency practically at all
loads. For larger capacity modern power plants, tubular or regenerative air heaters are
the best suited and are used for higher gas and air pressure as per the recent trend.
START PERMISSIVE
• Air Preheater power supply for Air Motor solenoid valve “available”
• Air Preheater is in “OFF” condition.
• Elec. Motor Switchgear “No Disturbance”
• Air Preheater Support/Guide Bearing Temperature “Not Very High”
• (High Trouble >82 oC, very high >70 oC , High >40 oC, Low <38oC)
• Air Preheater Support / Guide Bearing LOP A/B Switchgear available.
• Plant air Inlet to Air Preheater pressure is “Not Low”
Trip Interlocks
o Air Preheater local Elec. Push Button Operated
o Air Preheater Electrical Disturbance
o Air Preheater Fire Protection
▪ Any Hot end Temperature (out of 14 no’s) > 450oC from 3secs
▪ Any Cold end Temperature (out of 14 no’s) > 450oC from 3secs
Trip Interlocks:
• Air Preheater GB/SB LOP local Elec. Push Button Operated
• Air Preheater GB/SB LOP Electrical
Disturbance AUTO ON:
• LOP on Main Selection & Other LOP in OFF condition & GB/SB
Temperature > 46 OC .
• Pump on Auto Standby & Other Running Pump Run Trip & GB/SB
Temperature > 46 OC.
Steam coil Air Preheater (SCAPH)

The steam coil air preheater (SCAPH) is located just before the air preheater in the
air path so that air temperature increases while entering the air heater. Here steam is
passed through the coil whereas air passes through the shell to exchange heat from
auxiliary steam to heat up air. During the cold rainy season, or in some cases of startup,
this is used to heat air before admitting to the air heater. This system is useful to avoid
acid corrosion in the air heater. Here, the average of gas outlet and air inlet temperatures
are taken as the measured variables and controlled against a calculated preset
temperature, which will not allow the acid condensation.
Corrosion is a common phenomenon that occasionally takes place when air heater
metal temperature comes down below a certain level (i.e., acid dew point ) particularly at
the flue gas outlet/air inlet end. The flue gas containing sulfur from various types of fuels,
moisture, etc. are responsible for very low concentrations of even a few ppm combined
with moisture content in the flue gas. This can severely damage metal components when
the temperature of the surface exposed to the flue gas falls below the H2SO4 dew point
temperature. Under those conditions, corrosion occurs because of the presence of a thin
film of acidic electrolytes over the surface, giving rise to localized and uniform corrosion.
Boiler Circulation Pump:

For super / ultra critical SG plants the Boiler circulating water pump is necessary
used for better circulation of feed water with its suction connected to steam separator
tanks and a discharge connected to the economizer inlet of feed water path, this pump is
necessary for startup and low-load operation. In normal load operation, it is kept “OFF”
using an interlocked operation. Furnace height may be reduced by having BCWP.
The advantage of a recirculation pump is that the frictional loss through the tubes
may be more by using small-diameter tubes to minimize hoop stress at very high
pressures.
The Start-up System pump in conjunction with the MEFC valve provides the
necessary minimum once through furnace wall flow to permit safe firing of the boiler.
Pump operation is necessary up to and including 40% TMCR boiler load. With the
minimum once through flow supplied by the pump there is sufficient recirculation in the
furnace walls to prevent tube overheating. The pump need not be de-energized at or
slightly above the minimum once through load. Pump operation can continue above the
minimum once through load until the need for the startup system is assured to be over.
Typically the control system will shut down the pump when it reaches approximately 5%
in load over the minimum once through load of 40% TMCR.
Note: 1. The pump starting recommendations anticipate a normal rate of boiler water
temperature rise of about 400°F (222°C) per hour [that is, 100°F (56°C) in 15 minutes].
Quick boiler starts can create temperature changes approaching 150°F (83°C) in 15
minutes. A pump should not be started during intervals of rapid boiler water temperature
change.
Start Permissive:
• Boiler Circulation Pump Switchgear available
• BCP Inlet Isolation Valve “Opened”
• BCP Discharge Valve “Opened”
• Minimum Eco. Flow Control Valve at “start up” condition.(28 to 33%)
• BCP Thermal Barrier Return line Flow “Not Low”
• BCP thermal water Return line Flow “Not Low”
• Seperator Storage Tank Level >4mtrs (and)
Circulation Shut OFF valve “Opened”.
▪ (OR)
• Economizer inlet feed water flow > 192 TPH
• BCP Casing /Suction line Abs (Delta) temperature “OK” (>55 OC) ,
▪ ( if Economizer inlet flow is > 192 TPH, Abs Temperature = BCP
Surface Temperature – BCP Suction line Temperature, Otherwise Abs
Temperature = BCP Surface Temperature – water Seperator metal
Temperature average )
• BCP Motor Cavity Temperature “OK” (>4 oC)
• BCP Motor Cavity Temperature not Hi Hi (<66 oC)
Trip Interlocks:
• BCP Local Elec. Push Button Operated

• BCP Switchgear Disturbance.
• BCP O/L Trip
• BCP Master Trip.
• BCP ON & Inlet Isolation Valve Closed
• Boiler in Auto Dry Mode
• Minimum Eco. Flow Control valve minimum (< 10%)
• BCP ON and Economizer Inlet Flow < 137.3 TPH for 3 secs.
• Differential Pressure at BCP < 65.5 mtrs.
• BCP Motor Cavity Temperature High ( > 66oC)
• BCP ON and Discharge Valve Closed.
BCP TECHNICAL DATA

Vendor THORISHIMA
Model No HLAV250-
395/1K
Motor rating 830 KW
Type Wet Stator
Squirrel cage
Rated Voltage 3.3 KV
F.L Current 206 Amps
F.L Speed 2930 RPM
N.L Current Approx 40Amp
AUTO ON: Separator in Auto Wet Mode (Not in Dry Mode).
AUTO OFF: Separator in Auto Dry Mode.
DRY Mode Conditions and Auto Operations:

Separator Auto Dry Mode Conditions:
• Loss of All Fuel Trip Arming
• MS Flow >38.6% .
• Seperator Outlet Steam Superheated (>12.0oC) (OR)
▪ Economizer inlet Feed Water Temperature - Boiler Feed
Water temperature (HPH-8 outlet) < 5oC
ACTIONS ON BOILER AUTO DRY MODE INITIATION:
• Auto Open of Warm Up Inlet Stop Valve.

• Auto Open of Warm Up Relief line MO valve.
• Auto Open of Warm keeping LCV Isolation MO Valve.
• On Open Feedback of Warm keeping LCV Isolation MOV, LCV comes to Auto.
• Auto OFF Command to BCP.
• On BCP OFF Feedback, MEFCV comes to Manual and opens to 100%.
• Auto Close of Circuit Shut-Off Valve.
• Auto Close of BCP Inlet MO Valve.
• Auto Close of BCP Discharge Isolation MO Valve.
ACTIONS ON BOILER AUTO WET MODE INITIATION:
• Auto Close of Warm Up Inlet Stop Valve.

• Auto Close of Warm Up Relief line MO Valve.
• Auto Close of Warm keeping LCV Isolation MO Valve.
• On Close Feedback of Warm keeping LCV Isolation MOV, LCV comes to Manual.
• MEFCV Closes to 20% .
• Auto Open of Circuit Shut-Off Valve .
• Auto Open of BCP Inlet MO Valve.
• Auto Open of BCP Discharge Isolation MO Valve.
• Auto ON Command to BCP (On attaining Start Permit).
• On BCP ON Feedback, MEFCV comes to Auto.
HWL ISOLATION VALVES - 1 & 2:
AUTO OPEN: Separator in Auto Wet Mode (OR) MS Flow < 40% (OR) Separator
Storage Tank Level >1 Meter.
PROTECTION OPEN: AUTO CLOSE:
MFT with 2sec time duration. Main Steam Flow > 50%HWL CONTROL
VALVES
HWL CONTROL VALVES
HWL CONTRHOL VALVE-1 EMERGENCY CLOSE:
HWCV-1 Position Feedback Bad.

Separator Storage Tank Level < 0.5 Meters & HWL CV-1 Position Feedback > 2%.
HWL CONTROL VALVE-2.EMERGENCY CLOSE:
HWL CV-2 Position Feedback Bad.

Separator Storage Tank Level < 1.5 Meters & HWL CV-2 Position Feedback > 2%.
Seperator Pressure >102 Bar
Parameters of Hydraulic System:
HYDRAULIC SYSTEM COMMON FOR HWL CV - 1 , 2 & MEFCV
System Pressure MP1 : 140 Bar.

Accumulator Charging Pressure Range MSP : 216 to 240 Bar
Standby Pump ON Pressure : 201 Bar.
Standby Pump OFF Pressure : 216 Bar .
System Pressure Too Low : P<<120 Bar.
System Pressure Too High : P>>250 Bar
Oil Level Low : L<200mm
Cooling Fan ON @ Tank Temperature 55 oC.
Cooling Fan OFF @ Tank Temperature < 50 oC
Details of Soot Blowers
Water wall soot Blowers : 104 No’s + 26 No’s for future provisions
Long Retractable soot Blowers : 48 No’s + 44 No’s for future provisions
Air Heater soot Blowers : 2 No’s
Furnace Temperature Probes : 2 No’s
PULVERIZERS (Type: HP 1103)

For solid fuels, mills and pulverisers are supplied with the main equipment so as
to achieve higher efficiencies through of finely powdered fuel. The type of mills and
pulverisers depends on the type of fuels. Associated feeders and other things are also a
part of this system.
The mills/pulverisers duty is to convert raw feed into fine dust particles. For
efficient accomplishment of this, a hot air supply to dry the raw feed is necessary. For all
type of mills / pulverisers, this is done by proper mixing of hot and cold PA for drying and
transporting purposes.
The differential pressure across the mill is maintained at a constant pressure to
ensure enough raw feed storage capacity inside the mill.
| 50
Feeders:
The feeders that have variable speeds are provided to feed the raw fuel. For mills, the
speeds varies in proportion to the Boiler demand. The raw feed already available inside the
mills/pulverizers acts as storage for meeting the immediate requirement and then the proper
feeder speed takes care of the situation by bringing storage status back to within acceptable limits.
PULVERISER (MILL) DATA :
Type of Mill : HP 1103, Vertical spindle bowl mill

No. of Mils/Boiler : EIGHT (8)
Max. input coal size : 50 mm
PF Fineness at rated capacity : 70% through 200 mesh and
98 % through 50 mesh
Mill motor rating : 696 KW & 986 rpm
Type & drive transmission : Planetary gear box (PGB)
No. & type of roller : 3 & insert type
No. & type of Grinding rings : One set & Bull ring Segments
Type of Mill-Motor Coupling : flexible coupling
Mill capacities : Design coal Worst coal
• Max. capacity T/Hr 80.4 92.8
• Total moisture in raw coal 11.0% 10.0%
• HGI of raw coal 49 60
No. of Mill in service
100% BMCR 7 8
100% TMCR 6 7
Description Indigenou Imported Imported Imported

s F- Grade coal Type-I coal Type-II coal Type-III
HGI 50 45-60 45-60 45-60
GCV (HHV) 3400 6300 5700 6000
Kcal/Kg
Blending analysis of 50% indigenous + 50% Imported coal
Description
With type- I With type - II With type - III
HGI 50 50 50
GCV(HHV) Kcal/Kg 4850 4550 4700
Mill Differential pressure : 460 mmWC
Mill turn down ratio : 2:1
Mill rejects rate
Average :0.5% of Mill throughput
Maximum :1.0% of Mill throughput
Mill Seal air per Mill (T/Hr) : 4.8 (approx.,)

Seal air header pressure : 877 mmWC at BMCR DC
Mill lube oil flow rate : 250 LPM
Mill noise level : 85-95 dB (A)
FUEL REQUIREMENT FOR COD
(given by BHEL) FOR 800MW
HHV Efficiency Coal Qty Qty/day

No. of mill
% T/Hr
Coal 100% Indian 3000* 7 84.9 78.9 552.3
Coal (50% + 50%) 4375* 6 77.7 62.47 374.8
Coal 100% Imported 5750* 6 58.4 46.95 281.7
*Depending on Actual HHV / Moisture /Ash content received at site coal consumption
per day will vary.
Mill Maximum Capacity : 80.4 TPH (100%)
Guaranteed Value : 72.4 TPH (90%) and Maximum input coal size : 50 mm
| 52
Start Permissives:
Ignition Energy Available: (Any of the condition will initiate Ignition

permission for starting the mill)
Condition MILL- A MILL-B MILL-C MILL-D MILL-E MILL-F

MILL-G MILL-H
Feeder BFeeder A Feeder B Feeder C Feeder D Feeder E
Feeder F Feeder G
Load is is provenis proven is proven is proven is proven is proven
is proven is proven
>30% Feeder C Feeder D Feeder E Feeder F Feeder G
Feeder H
is proven is proven is proven is proven is proven
is proven
Elevatio Elevatio Elevatio Elevatio Elevatio Elevatio
Elevatio Elevatio
n B n A n B n C n D n n E F n G
Proven Proven Proven Proven Proven Proven
Proven Proven
Load is & & & & & & & &
<30% Feeder Feeder Feeder Feeder Feeder Feeder
Feeder Feeder
B Proven A Proven B Proven C Proven D Proven E Proven
F Proven G Proven
Elevatio Elevatio Elevatio Elevatio Elevatio
Elevatio
n C n D n E n F n n G H
Proven Proven Proven Proven Proven
Proven
& & & & & &
Feeder Feeder Feeder Feeder Feeder
Feeder
C Proven D Proven E Proven F Proven G Proven
H
Proven
(Elevation Proven – 3 out of 4 guns to be proven & Feeder Proven : Feeder Speed : >50 %)
No MFT Exists.
Any of the following condition exists:
● Tilt is horizontal and unit air flow is < 40 %.
● Any feeder is proven for at least 50 secs
All pulveriser discharge valves open.
Pulveriser outlet temperature is not high ( i.e 104 °C or Difference between Set
Point &Process Value <11)
Feeder local control switch in remote.
No pulveriser trip persists .
Lube oil system start permissive:
● Pulveriser LOP C (or) D ON.
● Pulveriser lube oil Return Pr OK.
● Pulveriser LOP-A (or) B ON.
● Pulveriser LO supply temp > 35°C.
● Pulveriser lube oil Supply Pr high.
● Pulveriser Lube oil Flow not low.
● All Thrust bearing temp normal.
● LOP A/B ON & temp < 40 oC & Filter DP > Hi.
Pulveriser cold air gate is in open.
Primary air permit is available (634 mmWcl) .
Bunker isolation valve and manual valves are in open condition.
Seal air header to bowl DP is ok (>203 mmwcl)
On Starting the pulveriser, the following events occurs:
● Run Cold air damper to 5% signal sent to DCS is removed.
● Open Cold air damper to 100 % signal will be sent to DCS
Pulveriser Trip Conditions:
Master Fuel Trip.
Pulveriser – Seal air Bowl DP < 102 mmWcl
(Operating value: 203 mmWC and maximum value is 320 mmWC).
Pulveriser Discharge Valves Not Open.
Loss of Ignition Energy in 180 Sec on start of pulveriser.
Emergency Push Button Operated.
Master Trip from Switchgear.
Loss of PA Header Pressure Very Low 507 mmWC.
Loss of PA Header pressure Low 634 mmWC with 5 sec delay.
Trip from Pulveriser Lobe Oil System.
● Lube Oil Supply Temperature Low <29oC.
● Any Lube Oil Pump ON and Flow to Planetary Gearbox is very low for 5
sec.(i.e <175 LPM)
● Any Lube Oil Pump ON and Pressure Not Adequate (i.e <0.8 Bar)
● Lube Oil Filter DP High (>2.0 Bar).
● Lube Oil Tank Level Low (i.e <460 mm from Tank Top).
● Lube Oil Tank Temperature Low (<29oC).
● Lube Oil Supply Temperature High after cooler (>65oC).
● Gear box Bearing Temperature High (>85oC).
● Motor Bearing Temperature High (105oC).
● Motor Winding Temperature High (130oC)
● When both LOPs are not ON for more than 2 secs.
● LOP ON and Lube Oil Pressure is <0.5 bar after cooler is very low
with a time delay of 15 sec
Tripping of Pulverizers on PA Pressure Low / PA Fan Trip:
Loss of Primary Air exists when any of the following conditions exist:
The primary air duct to furnace differential pressure is low for more than five
sec. ( 634 mmwcl).
The primary air duct to furnace differential pressure is low low. (
507 mmwcl).
Both primary air fans are Not ON and any pulverizer is O.
PULVERISER LUBE OIL SYSTEM:
1. Cooling water parameter:

Temperature : Inlet 39oC Outlet 42oC Flow 20 m3/Hr.
2. Lube Tank Capacity : 1600 Ltrs
Oil Type : Survo mesh SP 320.
3. Lube Oil DP: set point 2.0 bar normal operating value 0.85 bar
4. Cooler DP: set point 0.8 bar normal operating value 2.0 bar.
5. Cooler outlet Temp : set point 60oC normal operating value 50oC
6. Oil Tank Temp: set point 29oC normal operating value 55oC.
7. Lube Oil Heater : ON at 29oC OFF at 40oC.
8. Lube Oil Pressure : > 0.8 bar
9. Lube Oil Flow at Gearbox : >200 LPM.
10.LubeOil Temperature at Cooler outlet is >30oC.
LOP Trip Conditions:

The LOP stops / shall be stopped when any one of the following conditions are
acknowledged or satisfied.
1. Lube Oil Tank level is low (2/3 logic) <460 mm from tank top.
2. Pulveriser OFF for more than 60 minutes.
3. Pump Stop Push button actuated.
Standby Pump Start Conditions:
1. The running pump is ON for more than 60 sec and discharge pressure at
pump outlet is low <0.8 bar, the standby pump to start.
2. When pump-1 (main) fails to start on giving start command , after 10 sec time
delay ,the standby pump to start.
3. Running pump trips on fault, the standby pump shall be start immediately, the
time delay is 30 sec
PLOS ALARM LIST
The following ALARM signals are provided.
Lube Oil Tank Level Low (2/3 logic : 460 mm from tank top)
Lube Oil Tank Level High (2/3 logic : 80 mm from tank top)
Lube Oil Flow to Gearbox is Low <200 LPM
Oil Temperature after cooler is High > 60oC
Any lube oil pump ON for more than 60 sec. and Oil Pressure after cooler low
(2/3 logic : < 0.8 Bar)
Lube Oil Filter Dirty (DP >2.0 Bar)
Lube Oil Temperature in tank is Low <29 oC
Mill Gearbox Bearing Temperature is High >75 oC
Both Lube Oil Pumps failed to start.
| 55
FEED
WATER SYSTEM:
After de-aeration in the de-aerator, the condensate is taken to the (3x50%) capacity
boiler feed pumps. Two of the boiler feed pumps are turbine driven and one electric motor
driven through variable speed hydraulic coupling. Individual recirculation control loops
are envisaged for the pumps to maintain required minimum flow. A common feed water
outlet from BFPs is taken to the parallel banks of HP heaters nos. 6A & its de-superheater,
7A & 8A and 6B & its de- superheater, 7B & 8B. Each of the HP heater banks are provided
with inlet and outlet motorized isolating valves. Two 50% flow bypass lines are provided
in parallel to heaters banks to serve isolation of one bank or both the heater banks. Each
bypass line will have 50% capacity spring loaded bypass valve.
Feed water to the boiler shall be regulated during low load operation by regulating
30% low capacity control valve and during higher load operation, flow shall be regulated
by controlling the speed of the BFPs.
The attemperation water for boiler reheat steam temperature control is drawn from
feed pump inter stage tap off. The attemperation water for HP bypass station is drawn
from the main feed water line upstream of the HP heaters. The attemperation water for
boiler main steam temperature control is drawn from boiler feed pump discharge line
after HP Heaters.
During normal operation HP heater no. 8A / 8B drains are cascaded to HP heater-
7A / 7B and HP heater no. 7A / 7B drains together with drains from HP heater-8A / 8B
are cascaded to HP heater-6A / 6B respectively. HP heater-6A / 6B drains are cascaded to
deaerator. Under high level conditions heater drains are directly led to the condenser via
flash tank-A.
BFP MINIMUM RECIRCULATION CONTROL:

Individual minimum feed water recirculation lines have been envisaged at the
upstream of the discharge check valves. ON/OFF type control valves FCV-1, FCV-2 & FCV-
3 are provided in the recirculation lines from the boiler feed pumps to de-aerator to ensure
minimum flow requirement of BFP’s especially during start up & low load conditions.
Flow elements between BFP suction and booster pump discharge of the individual pumps,
monitor flow and initiate pump recirculation by opening the minimum recirculation
control valve as per speed dependent set point of recirculation flow. The minimum
recirculation valve gets automatically closed, whenever the flow reaches twice the speed
dependent set point of recirculation flow with an additional margin of 50 T/hr.
FEED WATER PUMPS:
The outlet of the De-aerator its connected to the Boiler feed pump (BFP) Suction
and from there to reach the Boiler proper. It impels the feed water with requisite pressure
that dictates the working or operating point of steam generation. BFPs are always supplied
in a redundant configuration to avoid interruption of operation. Normally, one motor-
driven BFP is kept for startup and emergency situations and two Turbine-driven BFPs are
kept for operating up to a full load.
During normal operation boiler feed pump turbines are fed with steam drawn from
IP turbine intermediate stage, beyond approx. 30% load. During start-up, steam for BFP
turbine is supplied from cold reheat line as well as external supply source i.e. auxiliary
steam header. BFP turbines exhausts are connected to condenser through motorized
butterfly valves.
| 57
FEED WATER PUMP :

DESIGN PARAMETERS
Description Boiler Feed Pump Booster Pump

Type of Pump MDG455; 5 stage, double MLC450X350H; Single
casing type with a simple stage, double Volute
cylindrical outer casing & type casing and casing
casing cover and cover and double
horizontally split inner suction impeller
volute casing,
opposed impellers
Type of Drive Motor (MDBFP) / Drive Motor (MD BP) / Turbine-
turbine (TDBFP) Gear Box (TD BP)
Temp. of feed water 188.5 oC 188.5 oC
(Suction)
Suction Flow Rate 1600 m3/Hr 1600
m3/Hr
Total Differential Head 3370 mlc
242
(including BFP+BP) mlc
Rated Speed 4995 1495
rpm rpm
Efficiency 83.9 % 81 %
NPSH Required 43.7 mlc 8.2 mlc
Min. Recirculation Flow 650 m3/Hr
Suction Pressure 36.25 Kg/cm2 15.07 Kg/cm2
Balancing Leak-off Flow 15-25 m3/Hr
Shaft Vibrations Alarm : 90µm(p- *NPSH – Net Position
p), Trip : Suction Head
150µm(p-p) *mlc - Meters of liquid
BFP Trip Speed 5495 column
rpm
Arrangemen : TD BFP 2 X 50%
t
BFP SET PARAMETERS STEAM PARAMETERS
TD BFP FLOW / BFP HEAD Specific INLET INLET Exhaust
Condition PUMP (Including Gravity PRESS TEMPERATU Pressure
(M3/Hr BP) URE RE (OC)
) (ML (ata)
C) (ata)
Desig
1600 3370 0.878 1 361.1 0.0871 /
n 2 0.1089
Point .
4
1
Emergency
1480 3610 0.879 1 358. 0.0876 /
Point 1 9 0.1089
.
9
8
Best
Efficienc 1320 3260 0.880 1 363. 0.0836 /
y 1 3 0.1038
Point .
8
6
Arrangemen : MD BFP 1 X
t 50%
BFP SET PARAMETERS MD BFP MOTOR
MD BFP FLOW / BFP HEAD Specific DETAILS
Condition PUMP (Including Gravity Type : SCIM
(M3/Hr) BP) Rated Output :
(MLC 20500 KW
) Rated Voltage : 11 KV
Desig Rated Full load Current : 1226
1600 3370 0.878
n Amps
Point
Rated No Load Current : 230
Emergency
1480 3610 0.879 Amps
Point
Rated Power Factor : 0.90
Best
Efficienc 1320 3260 0.880 Efficiency at Full Load : 97.5
y %
Point HYDRAULIC COUPLING
Under DETAILS
1400 3640 0.881 Type : R111KGS
Frequency
Input Speed :
1495 rpm
Output Speed
: 4995 rpm
Speed regulating range
: 25 – 100 % Slip : 3.4
% , Efficiency : 95.6 %
MD BFP Start Permissives:
• MD BFP Switchgear “OK”

• MD BFP-C Differential Temperature between De-aerator/Booster pump
• suction and BFP Upper Barrel is <70oC
o MD BFP-C Differential Temperature between BFP Upper Barrel casing and BFP
Lower Barrel casing is <40oC
• AOP ON and Lube Oil Header Pressure >1.2 Kg/cm2
• BFP Suction Valve Opened.
• De-aerator Level not Low Low
• (full : 3600 mm, Low Low : -2467 mm, High : 1133 mm, Low-Trip:-950mm)
• Working Oil Temperature at upstream coolers “not High”
▪ (2/3 logic , High : >110 oC, Very High :> 130oC)
• Working Oil Temperature at downstream coolers “not High” (High: >75oC)
• Lube Oil Temperature at downstream of coolers “Not High”
▪ (High : >55 oC, Very High :> 60oC)
• Hydraulic Coupling Control Oil Pressure “ Adequate”
• (2/3 logic , Adequate : >2.5 Kg/cm2, Low : < 2.5 Kg/cm2, Very Low : <2.2 Kg/cm2)
• BFP Journal Bearing Temperature DE/NDE “Not High”
▪ (High : >85oC, Very High : >90oC)
• BFP Trust Bearing Temperature DE / NDE “Not High”
• (High : >90oC, Very High : >95oC)
• BFP Hydraulic Coupling Bearing Temperature “Not High”
• (any one of 12 Bearings i.e 10 points , High : >40oC)
• BFP Motor Journal Bearing Temperature “Not High”
• (High : > 80oC, Very High : > 90oC)
• BFP Motor Winding Temperature “ Not High”
• (High : >120oC, Very High :>130OC)
• BFP Pump /Motor Bearing Vibration “ Not High”
• (2/3 logic High : , Very High : )
• BFP Recirculation Valve Opened.
• DMCW Valve Closed.
• BFP Discharge Valve Closed and Discharge Bypass Valve Closed
OR
▪ BFP ON Standby
• BFP rapid Startup solenoid valve ON & Scoop Position minimum
▪ OR
▪ BFP Hydraulic Coupling minimum
•
• Booster Pump Journal Bearing AOP AUTO Start :
Temperature DE/NDE “Not High”
▪ (High : >85oC, Very High : • AOP remote selected & BFP ON & Lube Oil
>90 C)
o Header Pressure <1.2 Kg/cm2
• Booster Pump Trust Bearing Temperature ▪ OR
DE / NDE “Not High” AOP Start
▪ (High : >90oC, Very High : OR
>95oC) BFP reverse
Protection acted &
• BFP Cooling water Header Pressure : >3.0
Kg/cm2 BFP OFF OR
BFP OFF for
• Hydraulic Coupling Tank level “above
1.5 sec
normal”
OR
• BFP Reverse Protection” Not Acted”
AOP Local
▪ (BFP Suction Pressure : >
Selected & AOP start
35 Kg/cm2 – Reverse Rotation
▪ < 15
Kg/cm — Recirculation Valve AUTO Open:
2
Low
(2sec ) Suction Flow – (maximum
▪ < 10 value of
Kg/cm — 2 actual
Very Low Speed
(10sec )) function
and
• MD BFP Trip Conditions: 650T/H
r) OR
• BFP Suction Flow – Speed X 0.8 = < 0 TPH Suction Flow measured fault & BFP ON
& BFP ON for time delay 5 sec.
• BFP Suction Flow < x TPH Recirculation Valve Opened
• ( Low : <330 TPH, High : >1050 TPH)
• BFP Lube Oil Header Pressure very Low
Recirculation Valve Protection
• (very Low : < 0.8 Kg/cm2, Low : < 1.0 Open:
Kg/cm2, High : < 3.0 Kg/cm2)
Suction Flow <330 T/Hr OR BFP
• BFP Working Oil Temperature at upstream OFF
of coolers Very High.
• BFP Journal Bearing Temperature DE/NDE Recirculation Valve AUTO Closed:
“ very High”
• BFP Trust Bearing Temperature DE / NDE Suction Flow – (maximum value
“Very High” of comparison of 640 T/Hr to
• BFP Motor Winding Temperature “ Very actual Speed function) =>50
High” T/Hr after 1.5
• De-aerator Level “Very Low” (-950mm) sec OR
• BFP Motor Journal Bearing Temperature Suc
“Very High” tion Flow is >1050 T/Hr
• BFP Hydraulic Coupling Bearing ● DP across BFP / Booster Pump
Temperature “Very High” Strainer
• Booster Pump Journal Bearing High : > 1500mmWC , Very
Temperature DE/NDE “Very High” High : >2000 mmWC.
• Booster Pump Trust Bearing Temperature
● DP across HC Filter : High >0.6
DE / NDE “Very High”
Kg/cm2
• BFP Suction Pressure : < 10 Kg/cm2 & BFP
ON.
● BFP/BP Mechanical seal cooler SW
Inlet Temperature : High > 80oC.
• BFP Pump / Motor Bearing Vibration “Very
High” ● BFP/BP Mechanical seal cooler SW
• Separator Level “Very High” (>14 meters) Outlet Temperature : High > 70oC.
● BFP/BP Mechanical seal cooler CW
Inlet Temperature : High > 50oC.
Turbine Driven BFP

Make
: BHEL , HYDERABAD
Type
: NK 63/71-3
Machine No.
: T-1131 to T-1132
Type of Governing
: EHTC
No of Drive Turbines
: 2 (2 X50% for each BFP)

Steam admission
: Dual
Operating Speed range
: 1093 – 4995 rpm

Rated Speed(MCS)
: 4995 rpm
Trip Speed
: 5494 rpm
No of Stages 11
Steam source
:
D
u
r
i
n
g
n
o
r
m
a
Design & lOperating Conditions
Steam
o condition at Drive Turbine inlet at full
loadp(TMCR/800 MW /0% makeup)
e Pressure
r : 11.86 Kg/cm2(a)
a Temperature
t : 363.3oC
Drive
i Turbine operating Speed
o
: 4770 rpm 1. Main Oil Pump 2500 S
Shaft power at full / BFP
Design case 2. Auxiliary Oil Pump 2500 S
3. Emergency Oil Pump 425 C
: 12489/15790 KW Steam
consumption for two Drive
Turbines
: 61.367/59.481
Exhaust Steam Pressure at
TDBFP Outlet
: 0.1038/0.0836 Kg/cm2(a)
Maximum allowable
temperature at exhaust
: 85oC
Turbine inlet parameters at low load
operationt
Pressure
: 11.9 Kg/cm2(a)
Temperature
: 375.3oC
Lube oil and Control system
Total Oil System Capacity
: 16700 litres
Oil Tank Capacity
: 10000 litres 1. Differential Pressure

Normal lube oil pressure across TD BFP-A
Booster Pump / BFP
: 0.8 – 1.8 Kg/cm2(g) Suction Strainer
Oil flow through lubrication system High : >0.15 Kg/cm2
2. TD BFP-A Suction Pressure
: 805 lit/min
High : >35 Kg/cm2
When Lube Oil is used as the Control 3. TD BFP-A Suction Pressure
fluid Low
1. Normal Governing oil pressure : <15 Kg/cm2
: 8.0 Kg/cm2(g) 4. TD BFP-A Suction Pressure
2. Oil flow through Governing V.Low
system : <10 Kg/cm2
: 458 lit/min 5. TD BFP-A Discharge Pressure
Low
Oil Pumps Flow(LPM) Type : <40 Kg/cm2
No./unit
Drive
6. Differential Pressure across BP
mech.seal filter DE/NDE High :
0.1 Kg/cm2 22. BFP Exhaust Hood Temperature
7. Differential Pressure across BFP High : 85oC
mech.seal filter NDE 23. TD BFP Booster Pump Thrust
High : 0.1 Kg/cm2 Brg temp High : 90oC
8. BFP/BP Mechanical seal cooler Very High : 95oC
SW Inlet Temperature 24. TD BFP Booster Pump Journal
High : > 80oC. Brg temp High : 85oC
9. BFP/BP Mechanical seal cooler Very High : 90oC
SW Outlet Temperature 25. TD BFP Thrust Brg temp
High : > 70oC. High : 90oC Very High : 95oC
10. BFP/BP Mechanical seal cooler 26. TD BFP Journal Brg temp
CW Inlet Temperature High : 85oC Very High : 90oC
High : > 50oC. 27. TD BFP DE/NDE Bearing
11. BFP Discharge Pressure Vibration X/Y
Adequate : > 50 Kg/cm2 High : 90 μm Very High : 150
12. BFP Lube Oil Header Pressure μm
Low : <1.5 Kg/cm2 ,Very Low: 28. TD BFP DE/NDE Brg Housing
<1.1 Kg/cm2 Vib X/Y High : 8.4mm Very
13. BFP Control Oil Header High : 11.2mm/s
Pressure 29. TD BFP Axial Displacement
Low : <6.50 Kg/cm2 High : 0.5 mm Very High :
14. BFP Control Oil Header 0.7mm
Pressure 30. BFP DT Gland Steam Header
Very Low : <4.50 Kg/cm2 Pressure
15. BFP Trip Oil Header Pressure Adequate : > 700 mmWC
Very Low 31. BFP DT Gland Steam Header
: <2.0 Kg/cm2 temperature Adequate : >330oC,
16. BFP Diff. Pressure across Low
Governing Oil Filter
Very High
: > 1.5 Kg/cm2
17. BFP Diff. Pressure across at
Gland Steam Header Inlet High
: 150 mmH2O
18. BFP Live Steam Pressure
High : 7.5 Kg/cm2
19. BFP Live Steam Pressure
Very High
: 16.0 Kg/cm2
20. BFP Exhaust Steam Pressure
Very High
: 0.6 Kg/cm2
21. BFP Exhaust Steam temperature
Very High
: 120oC
32. BFP DT Gearbox Input front/rear journal Brg & Thrust Brg
temperature High : 80oC Very High : 90oC
33. BFP DT Gearbox Output front/rear journal Bearing
temperature High : 80oC Very High : 90oC
34. BFP DT Thrust Brg Active /non-active
temperature High : 100oC Very High :
110oC
35. BFP DT TB front / rear Journal Bearing
temperature High : 100oC Very High :
110oC
36. CRH Steam to BFP DT-A&B Pressure High : 15 ata
37. CRH Steam to BFP DT-A&B temperature High : 287oC
38. Aux. Steam to BFP DT-A&B Pressure High : 12 ata
39. Aux. Steam to BFP DT-A&B temperature High : 287oC
40. IP Exhaust Steam to BFP DT-A&B Pressure High : 8 ata
41. IP Exhaust Steam to BFP DT-A&B temperature High : 350oC
42. Turbine zero Speed Detector Low :120 rpm High : 200 rpm
43. BFPDT Gear Box Low speed side rear/front Bearing
Vibration X/Y High : 46 μm Very High : 70 μm
44. BFP DT Turbine rear/front Bearing
Vibration X/Y High : 126 μm Very High :
185 μm
45. BFP DT Turbine axial displacement High : 0.5 mm Very High : 0.7 mm
46. BFP DT Turbine Eccentricity High : >75 μ
47. BFP DT Turbine rear / front Journal Brg Housing
Vibration X/Y High : 13 mm/s Very High : 18 mm/s
48. BFP DT Turbine Casing Expansion High : 5.0 mm
49. BFP DT Turbine Differential Expansion High : 2.6 mm
50. BFP DT Gear Box LSS Axial Displacement High : 0.24mm very
High:34mm
51. TD BFP Lube Oil Tank level (from top of the tank) High : 1000mm, Low:1100
mm
52. TD BFP Lube Oil Tank temperature High : > 55oC
53. TD BFP Lube Oil Tank temperature after cooler High : > 50oC
54. TD BFP Turbine F.J.B + T.B Drain Oil temperature High : >70oC
55. TD BFP Turbine R.J.B + Coupling Drain Oil temperature High : >70oC
56. TD BFP Gear Box Drain Oil temperature High : >70oC
57. TD BFP Jacking Oil Header Pressure Low : 100 Kg/cm2
2 TD BFP Main pump / BP Bearing DE/NDE Drain Oil Temp High : >80oC
Drive Turbine BFP-A Start Permissive: (Similarly TD BFP-B)
TD BFP-A “No Alarms”

TD BFP-A Start up Drives in “AUTO”
TD BFP-A Suction Valve “Opened”
De-aerator level “Adequate”
TD BFP-A Pump Barrel Casing temperature <40oC
Condenser Pressure <0.6 Kg/cm2
TD BFP-A Lube oil Header Pressure “ Not Low”
TD BFP-A Lube oil temperature after cooler “ Not High”
TD BFP-A Governing oil Pressure “Not Low”
TD BFP-A Gearbox Bearing temperature “Not High”
TD BFP-A Turbine Bearing temperature “Not High”
TD BFP-A Booster Pump Journal Bearing temperature “Not High”
TD BFP-A Booster Pump Thrust Bearing metal temperature “Not High”
TD BFP-A BFP Journal Bearing temperature “Not High”
TD BFP-A BFP Thrust Bearing metal temperature “Not High”
TD BFP-A LOP A/B “ON”
TD BFP-A not working.
TD BFP-A Speed >30 rpm.
TD BFP-A Aux. Steam Block Valve “Opened”
Aux. Steam to TD BFP -A&B Pressure >12 ata
Aux. Steam to TD BFP-A&B temperature >287oC
Aux. Steam to TD BFP-A&B Superheat (function of pressure & temp) >
50OC
CW pumps discharge header pressure not low ( > 1 Bar)
TD BFP-A drain tank level “not low low”
TD BFP-A discharge “Closed”
TD BFP-A reverse rotation “Not detected”
TD BFP-A recirculation valve ”Opened”
TD BFP-A warm up valve “Opened for 2 Hrs”
TD BFP-A drain tank level “not high”
Gland steam header pressure “Not low”
Gland steam header temperature “Not low”
TD BFP-A Trip Conditions: (Similarly TD BFP-B)
Trip Oil Pressure “Not Very Low” & any one the following exists
TD BFP-A Lube Oil Header Pressure “Very Low”

TD BFP-A Exhaust Steam temperature “Very High”
TD BFP-A Exhaust Steam Pressure “Very High”
TD BFP-A Live Steam Pressure “Very High”
TD BFP-A Governing Oil Pressure “Very Low”
TD BFP-A Turbine Axial Displacement “Very High”
TD BFP-A BFP Axial Displacement “Very High”
TD BFP-A Gear Box LSS Axial Displacement “Very High”
TD BFP-A Drive Turbine Bearing Vibrations “Very High”
TD BFP-A BFP & BP Bearing Vibrations “Very High”
TD BFP-A Over Speed “Acted”
De-Aerator level “Very Low”
TD BFP-A Gear Box Bearing temperature “Very High”
TD BFP-A Turbine Bearing temperature “Very High”
TD BFP-A Booster Pump Journal Bearing temperature “Very High”
TD BFP-A Booster Pump Thrust Bearing metal temperature “Very High”
TD BFP-A BFP Journal Bearing temperature “Very High”
TD BFP-A BFP Thrust Bearing metal temperature “Very High”
TD BFP-A Suction Pressure “Very Low”
TD BFP-A working & TD BFP-A Diff. Temp between Suction & Discharge
>15oC and time delay 30 sec.
TD BFP-A Suction Flow Very Low i.e (Speed dependent Set
point of minimum flow function with 0.8 and compared with
Suction flow is
<50 TPH) with 5 sec time delay and 10 sec pulse.
TD BFP-A Trip from OWS / LVS
TD BFP-A manual Trip PB Pressed
TD BFP-A working & TD BFP-A Suction Flow Very Low i.e (Suction
flow – function of Speed dependent Set point of minimum flow -10
TPH) with 15 sec time delay.
TD BFP-A Suction Valve “Not Opened”
Turbine Driven Boiler Feed Pump:
Lineup of TDBFP.
Charging of pump on feed water side.
Keeping on Barring Gear.
Vacuum Pulling.
Turbine Reset & Opening of ESV
Speed raising & Soaking of TDBFP at 1500 & 3000rpm.
Loading of TDBFP.
Paralleling with other BFP.
Lineup of TDBFP
a. TDBFPs main steam valve at aux PRDS HC header is in open position
b. TDBFP individual aux. PRDS valve is in open position
c. TDBFP individual seal steam valve in its aux PRDS line is in open position
d. At 8.5mts Aux. control valve before drain open
e. All drains in extraction steam line connected to LP flash tank are in open
position.
f. TDBFPs main extraction valve from IP turbine exhaust is kept open
g. TDBFPs individual extraction steam isolating valve is in open position
h. Startup vent in extraction steam line before main control valve open
i. TDBFP exhaust steam butterfly valve close position
j. TDBFP aux. PRDS header drain before seal steam header Open position.
k. TDBFP seal steam exhauster valve connected to main turbine seal steam
exhaust line open position.
l. Open all isolating valves in turbine exhaust-hood spray station.
Charging of Pump
1. Open all air vents – at booster pump suction strainer air vent, booster pump
top, main pump suction strainer air vent, line air vent after main pump.
2. Open BFP suction valve slowly and let off air in the system & then
completely open the suction valve. Close all air vents.
3. Ensure Recirculation valve & its isolating valve open position.
4. Ensure all isolating valves in Booster pump & main pump jacket cooling
water line & ensure TGDMCW cooling water lineup.
5. Ensure cooling water valves open to lube oil coolers.
Keeping in Barring gear
1. Start DC EOP and take one oil vapour extraction fan in to service.
2. After establishing lube oil header pressure & observe return oil flow from all
return lines.
3. Start any one lube oil pump.
4. Start JOP & observe rise in JOP pressure.
5. Stop DC EOP & kept its SLC in on position.
6. Engage the main pump to the turbine through engage
/disengage solenoids after starting power pack.
7. Ensure main pump recirculation is in open position.
8. Open Barring gear valve & observe speed rise of turbine to 320RPM
Vacuum Pulling:
1. Open seal steam header drain connected to LP flash tank & ensure
that Aux PRDS temp to seal steam more than 200°C.
2. Open GSC controller & raise the seal steam header pressure up
to 250 mmwcl after observe rise in seal steam header
temperature.
3. Open all TDBFP casing drains d1, d2 & d3.
4. Observe raise in casing temperature 50 % & 100%.
5. Open TDBFP’s exhaust butterfly valve’s bypass valve locally &
observe rise in exhaust pressure & duly observe main turbine
vacuum with out much fall. (Assumed main turbine already vacuum
pulled & 2Nos vacuum pumps running)
6. Slowly open the exhaust valve and equalize the vacuum with main
turbine vacuum & then open fully and ensured it locally.
Turbine Reset & opening of ESV
1. Ensure the speed controller output (OCAT) to zero and reference
speed is also zero.
2. Open the turbine protection page & press turbine reset button.
3. Observe the trip valves open.
4. Open the remote engage tile & press‘ ON’ button, observe the raise in
trip oil pressure. At trip oil pressure 8ksc (at least >4.5ksc), the
remote engage will go to off position and ensure this for proceeding
further.
5. Open the ESV tile and give open command, observe the raise of
startup oil pressure above piston and after some time trip oil
pressure below piston of stop valve develops and stop valve slowly
starts opening and the start up oil above the piston gets de-
pressurized. (Ensure the close feedback of control valve prior to this
step).
Speed raising and soaking of TDBFP at 1500 rpm & at 3000rpm
1. Open the speed reference tile and give 1500 rpm, confirm it and
observe the speed raise & monitor the turbine vibrations, TSC.
2. Soak the turbine at 1500 rpm till the casing temperature reaches
150degC. Raise the speed further to 3000 rpm and soak it.
3. Load the TDBFP after crossing the casing temperature 220degC.
| 68
Loading and paralleling of TDBFP:
1. Raise the speed reference of other TDBFP equal to that of in

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

STEP NO SEQUENCE OF OPERATION
1. Start up sequence ON
2. TD BFP-A Exhaust steam block Closed &
TD BFP-A Gland Steam leakage to GSC valve Closed
3. TD BFP-A Gland steam Control valve kept in manual & minimum
through EHTC
OR
Kept Gland Steam Pressure & Temperature Adequate
4. CRH Steam to BFPDT-A Block valve Closed
OR
kept CRH Steam Pressure (>15 ata) & Temperature (>287oC) &
Superheat (>50oC)
5. TD BFP-A Aux. Steam CV warm up valve Closed
OR
CRH Steam to TD BFP-A Block valve Opened
6. IP Extraction Steam to TDBFP-A Block valve Closed
OR
TD BFP-B Working & Extraction Steam Pressure (>8.0 ata) & IP
Extraction Steam to TDBFP-A Block valve Opened
7. IP Extraction to TDBFP-A &B line drain valve Opened
OR
TD BFP-B Working & Extraction Steam Pressure (>8.0 ata) & IP
Extraction Steam to TDBFP-A Block valve Opened
8. Drain valve upstream of TDBFP-A Emergency Stop valve (ESV)
Opened &
Drain valve downstream of TDBFP-A aux Control valve Opened &
CRH Steam to BFPDT-A drain valve U/S of Isolation valve Opened
9. Gland Seal Steam Header drain valve Opened & Aux Steam to
TDBFP-A Drain valve before Block valve Opened
10. TDBFP-A Aux. CV warm up valve Opened & TDBFP-A Vent valve
upstream of ESV Opened
11. TDBFP-A Casing drain valve Opened (both) & TDBFP-A Casing cross
drain valve Opened & maintained Condenser Pressure <0.6
Kg/cm2(a)
12. Maintain Aux Steam Header Pressure >12.0 ata & TDBFP-A Gland
Steam Header drain valve Opened & maintain TDBFP-A speed > 30rpm
& Aux Steam temperature at TDBFP-A inlet on Gland Steam line >
300oC
13. Put the Gland Steam Control valve in Auto & maintain Gland Steam
Header Pressure >700 mmWC & Temperature >330oC
14. TDBFP-A Gland Steam Inlet Header drain valve Closed & TDBFP-A
Gland Steam Header drain valve Closed
15. Maintain any one of the following
Aux. Steam to TDBFP-A&B Pressure, temp.& Superheat OR
CRH Steam to TDBFP-A&B Pressure, temp.& Superheat OR
IP Extraction Steam to TDBFP-A&B Pressure, temp.& Superheat
16. CRH Steam to TDBFP-A Block valve Opened
17. Aux. Steam to TDBFP-A Block valve Opened
18. IP Extraction Steam to TDBFP-A Block valve Opened
19. CRH Steam to TDBFP-A Block valve Opened
OR
Aux. Steam to TDBFP-A Block valve Opened
OR
IP Extraction Steam to TDBFP-A Block valve Opened
20. Maintain TDBFP-A Lube Oil Header Pressure not Low and
De-aerator level adequate & TDBFP-A Suction valve Opened &
TDBFP-A Pump barrel top/bottom diff. temp < 40oC
21. TDBFP-A Recirculation valve Opened
22. TDBFP-A Discharge valve & Discharge bypass valve Closed
23. TDBFP-A Trip Condition present & TDBFP-A Remote engage
solenoid permissive available (energize)
24. Maintain remote engagement oil pressure > 5.0 Kg/cm2
25. TDBFP-A Remote engagement De-energized
Aux. Steam to TDBFP-A&B Pressure, temp.& Superheat OR
CRH Steam to TDBFP-A&B Pressure, temp.& Superheat
OR
27. TDBFP-A Main Control valve Closed to <2% &
TDBFP-A Aux. Control valve Closed to <2% & maintain remote
engage Oil pressure > 5.0 Kg/cm2
28. Maintain TDBFP-A Gland Steam Pressure adequate & Condenser
pressure < 0.6 Kg/cm2(a)
29. TDBFP-A Exhaust Block valve Opened & Gland Steam leakage to
GSV valve Opened
30. TDBFP-A ESV 1&2 Opened & maintain trip oil pressure after SV-
2220 >4.0 Kg/cm2
Aux. Steam to TDBFP-A&B Block valve Opened & Aux. Steam to
TDBFP-A&B Pressure, temp.& Superheat
OR
CRH Steam to TDBFP-A&B Block valve Opened & CRH Steam to
TDBFP-A&B Pressure, temp.& Superheat
OR
IP Extraction Steam to TDBFP-A&B Block valve Opened &
32. Open main Control valve > 2% OR Aux Control valve >2% and
maintain Speed > 1500rpm
33. TDBFP-A Discharge pressure Not < 40 Kg/cm2 & TDBFP-A
Turbine and GB LSS axial Displacement Not High & TDBFP-A ,
GB,BP Vibrations are not High & TDBFP-A Turbine, BFP, BP.GB
Bearing temp are not High & TDBFP-A and BP Thrust Bearing
metal temp are not High
34. TDBFP-A Discharge isolation bypass valve Opened
35. TDBFP-A Discharge valve Opened
36. TDBFP-A Discharge isolation bypass valve Closed
(FW Control release)
37. TDBFP-A FW Control kept in Auto and make TDBFP-A suction
flow >30% and TDBFP-A 100% casing temp > 140oC
38. TDBFP-A all the drain valves Closed
39. TDBFP-A Suction flow > 850 T/Hr OR
TDBFP-A variable speed set point for RCV Closed &
TDBFP-A Speed pick up No fault
40. TDBFP-A Recirculation valve Closed
41. Maintain all the critical parameters of TDBFP-A are within the
limits
42. TDBFP-A Startup sequence completed
TD BFP SGC SHUT DOWN SEQUENCE PROCEDURE:
STEP NO SEQUENCE OF OPERATION
1. SGC TD BFP-A Shutdown sequence ON

2. TD BFP-A Trip Oil Pressure Very Low & TD BFP-A emergency
Stop valve Closed &
TD BFP-A Main Control valve position <2% & TD BFP-A Aux.
Control valve position <2%
3. All the drain valves Opened
(TD BFP-A Casing drain valve 3 no’s & Drain valve upstream of
TD BFP-A ESV ,Aux. CV & Vent valve & Drain valve before Aux.
Steam Block valve & Drain valve upstream of CRH Steam Block
valve & Gland Steam inlet Header Drain valve & Gland Steam
Header Drain valve & Extraction Steam drain valve)
4. Drain valve after IP /IL Steam Block valve to TDBFP-A/B is
Opened OR
TD BFP-B is in service & IP/LP Bleeding Pressure > 8.0Kg/cm2 &
Extraction Steam to TD BFP-A/B Block valve Opened
5. TD BFP-A EHTC Controller is in Minimum and manual & FW
Control in manual
6. TD BFP-A Recirculation valve Opened & Discharge valve Closed &
Discharge IB valve Closed
7. TD BFP-A warm to Aux. CV Closed & TD BFP-A CRH Steam
Block valve Closed
8. Extraction Steam to TD BFP-A Block valve Closed OR TD BFP-
B is in service & Extraction Bleeding Pressure > 8.0Kg/cm2 &
Extraction Steam to TD BFP-A/B Block valve Opened
9. TD BFP-A Exhaust Steam valve to Condenser is Closed & TD
BFP-A Gland Steam leakage to GSC valve Closed
10. TD BFP-A ESV Closed , main CV & Aux. CV Closed to < 2% &
Recirculation valve Opened
Shutdown sequence Completed
Remote Engagement Solenoid permissive Available:
• TD BFP-A Suction valve Open
• De-aerator level adequate
• TD BFP-A Top & Bottom DT < 40oC
• Condenser Pressure <0.6 Kg/cm2
• TD BFP-A Lube Oil Pressure not low
• TD BFP-A Lube Oil temperature after cooler not High
• TD BFP-A Control Oil Header Pressure not Low
• TD BFP-A Recirculation valve Open
• TD BFP-A Discharge valve Close
• TD BFP-A Turbine Bearing temperature not High
• TD BFP-A Gear Box Bearing temperature not High
• TD BFP-A BFP/BP Thrust Bearing metal temperature not High
• TD BFP-A BFP/BP Journal Bearing metal temperature not High
• TD BFP-A Trip Oil Header Pressure not >5.0 Kg/cm2
CONDENSERThe function of the Condenser is to condensate the steam coming from the
Turbine Exhaust. High vacuum is maintained to extract steam and then cool it vis-à-vis
condensation through exchange of heat with the cooling water from a separate source.
The following comprise the subsystems of Condenser:

● Steam ejectors or External Vacuum Pumps and Vacuum breaker
● Cooling water system and Cooling tower
● Condensate Extraction Pumps
● Heat Exchangers (Drain Coolers, Gland Steam Condenser and LP Heaters)
Condenser details:
2 nos. single pass condenser having different back pressures have been provided
per set in cooling water side of Condensers which are put in series. Cooling Water flows
from one Condenser to another Condenser in-series manner. As CW inlet temperature in
both Condensers is different, hence back pressures are also different with first Condenser
having much deeper vacuum than the second Condenser.
The condenser is of box type construction with divided water box design which
facilitates the operation of one half of the condenser while the other half is under
maintenance. The steam space is of rectangular cross-section. The condenser is provided
with integral air cooling section from where air and non- condensable gases are drawn out
with the help of air evacuation equipment.
Water Box
The water boxes of the condenser have been designed for smooth entry and
uniform distribution of cooling water to all the tubes. The front water boxes are hinge type
and have been provided with necessary hinged manholes for easy access to the interior for
inspection. Each water box has been provided with a vent and drain connection. The
circulating water connections of adequate size have been provided with water boxes.
Safety guards have been provided at CW inlet and outlet connections to protect the
operating personnel from falling-in, during inspection or maintenance.
Hot Well
The hot well (of adequate capacity) is divided longitudinally for detecting
contamination of the condensate in each condenser half. Suitable manholes are provided
in each of the hot well sections for easy access and inspection. The provision of drainage
of condensate has been provided at the bottom of the hot well to drain it completely if
required.
The condensate produced in the condenser and the drains entering through flash
vessels collect in the condenser hot well from where they pass to the condensate pumps.
CONDENSER DATA:
DESCRIPTION UNIT CONDENSER-1 CONDENSER-2
Design C.W Temperature oC 33.0 37.72
C.W Temperature raise oC 4.72 4.66
Condenser back Pressure mmHg (a) 56.93 72.96
C.W Flow Quantity TPH 84200
C.W side Pressure Drop MLC 2.86 2.86
No. of Tubes No. 29755 29755
Tube OD X Thickness mm X mm 25.4X0.7112/25.4X0.889 (top 2)
Vacuum pumps:
Start permissions:
Vacuum Pump Seal Water Flow Not Low ( Flow Switch)
Gland Steam Header Pressure Not Low (> 0.1 Bar)
Vacuum Pump MCC Available
Vacuum Pump at NO LEPBO
Vacuum Pump recirculation water Temperature NOT Hi (< 65 oC)
Vacuum Pump Separator Tank Level Not Low
Recirculation Pump ON
Vacuum Pump NO Electrical Disturbutor
CONDENSATE EXTRACTION PUMPS
The Condensate Extraction Pumps (CEP) are connected to the Condenser Hot well to
take out the condensate and deliver it to the rest of the water circuit of the whole cycle.
3x50% condensate extraction pumps (CEP) are provided; normally two pumps are
working while the third pump is on standby. Any one of the pump can be selected as a
working pump with the help of a switch. One pump will be in operation up to 50% load.
In case of high-pressure drop (0.125 kg/cm2) alarm in the suction strainer, the
working pump is to be tripped & isolated remote manually after bringing standby pump
in to service.
CEP MOTOR Technical Data:
Make : BHEL , BHOPAL
Type of Motor/Enclosure : SCIM / TETV
Rated Continuous Output (KW) : 1450 KW
Rated Speed (rpm)/ Slip (%) : 1492 / 0.53
Rated Voltage : 3300 V
Full Load Current (apms) : 302.0
No load Current (apms) : 61.5
No Load losses (KW) 31
Full Load Efficiency (%) : 95.5
Noise Level : 85 dB (A)
Vibration Level (Rigid Mounting) : 37 µ (displacement) /2.3 mm/s
CEP PUMP Technical Data:

Model of Pump : 144RND
Make : BHEL, HYDERABAD
No. of Pumps /Orientation : 3X50% duty / Vertical
Impeller Type : 1st stage double Suction and
other stages single Suction
No. of Stages 4
Design flow : 925 m3/Hr
TDH Developed at design flow : 335 mlc
Temp. of Condensate water : 42.7 oC
Specific weight : 991 Kg/ m3
Pump Efficiency : 77.5 %
Pump input power at design flow : 1079 KW
Minimum flow through pump : 270 m3/Hr
Suction Pressure at design capacity : 0.66Kg/cm2
Discharge Pressure at design capacity : 33.9 Kg/cm2
Maximum Vibration level : 10 mm/sec
(rms)
Noise Level : 85 dB (A) at 1meter from equipment.
Type of Bearing : Tilting Pad
Suction Strainer mesh size : 350 microns
Pressure Drop (kg/cm2) : 0.06 (Clean) & 0.10 (50% clogged)
CEP Start Permissive for CEP-A: (SIMILARLY B&C)
• CEP-A not Tripped

• CEP-A is in OFF Condition
• CEP-A Switch gear available
• CEP-A No Switch gear disturbance
• CEP-A Suction valve Opened
• Hot well Level adequate
• CEP-A Thrust Bearing metal temperature Not High
• CEP-A Motor Bearing Temperature Not High
• CEP-A Motor Winding Temperature Not High
• GSC minimum Recirculation valve 30% Opened (or) CEP-B ON (or) CEP-C
ON
• CEP-A Vent valve Opened
• CEP-A Discharge valve Closed (or) CEP-A Standby selected & CEP-A
Discharge valve Opened
CEP Trip Interlocks:
● CEP-A local EPB Operated

● CEP-A Switch gear disturbance
● CEP-A master Trip
● Hot well Level very Low
● CEP-A ON with 10 sec delay & Discharge Pressure Low
● CEP-A ON with 10 sec time delay & Flow through CEP is <300 TPH with 5 sec
time delay
● CEP-A Thrust Bearing Temperature Very High
● CEP-A Motor Bearing Temperature Very High
● CEP-A Motor Winding Temperature Very High
● CEP-A Suction valve Not Opened for 2 secs
● CEP-A Bearing Vibrations Very High
● CEP-A ON & CEP-A Discharge valve failed to Opened
CEP Standby Selection Set:

CEP-A Sequence start permissive available & CEP-A Select Standby
CEP Standby Selection Reset:

Any one of the following:
CEP-A not standby selection (or)
All CEPs OFF Condition with 120 sec time delay (or) CEP-A
ON for 30 sec time delay
CEP AUTO Start Command:
CEP-A Standby Selection & any one of the following
((CEP-B ON with 30 sec time delay & CEP Discharge Header Pressure Low) with 10
sec time delay & CEP-C OFF Condition) with 2 sec time delay
OR
(CEP-C ON with 30 sec time delay & CEP Discharge Header Pressure Low) with 5 sec
time delay
OR
CEP-C Tripped
OR
(CEP-C Tripped & CEP-C Not ON) with 2 sec time delay
OR
(CEP-B ON & CEP ON with 2 sec time delay) with 5 sec OFF time delay & CEP-B
Tripped
*Standby CEP-A failed to start:

AUTO start Command with 10 sec time delay & CEP-A OFF
List of Alarms:
• Hot well-2 Level (2/3 logic) in mm Adequate : > + 405

▪ Low : < + 255 , V. Low : < - 50 , High : > + 550 , V. High : > + 705
• CEP Pump /Motor DE/NDE Bearing Vibrations X/Y High: > 11 mm/sec
• CEP Thrust Bearing Thrust /Journal pad Temperature High :
> 90oC , V. High : > 95oC
• CEP Motor Bearing DE/NDE Temperature High : > 80oC , V. High : > 95oC
• CEP Discharge Header Pressure
▪ Adequate : > 30 Kg/cm2 ,Low : < 28 Kg/cm2, V. Low : < 24 Kg/cm2
• Hot well-1 Level (2/3 logic) in mm Adequate : > + 623
▪ Low : < + 473 , V. Low : < +168 , High : > + 773 , V. High : > + 923
• Flow through CEP (2/3 logic) Low : < 300 TPH
• CEP Motor Winding temperature
• High : > 110oC , V. High (any 2 out of 6) : > 130oC
• CEP Strainer DP High : > 0.125 Kg/cm2 , V. High : > 0.175 Kg/cm2
• CEP Thrust Bearing Oil temperature High : > 80Oc
Gland Steam Condenser:
Gland steam condenser along with exhausters has been provided for condensing the
gland seal leak steam, thereby retrieving the heat energy by heating the condensate
and to maintain the desired steam pressure in the turbine gland seals.
Gland steam condenser is supported by 2 x 100 % air -exhausters for removal of air
from the system. One of the exhausters is meant for normal operation and the other one,
along with the chimney, is for standby purpose. When Gland Steam condenser needs
isolation, the chimney provided in gland sealing system cuts into operation through which
gland steam is directly led to atmosphere. Isolation and cutting in of the exhauster, gland
steam condenser and chimney is done manually. Siphon has been provided in the air drain
pipe line connection of gland steam condenser to ensure draining of condensate into
condenser in the event of tube failure. This prevents water entry into turbine.
Exhauster removes the non condensable gases along with the left out vapour of the
gland seal leak steam, thereby inducing flow of turbine gland seal leak steam into the heat
exchanger where heat energy is retrieved by regenerative heating of the condensate.
Gland steam condenser is a shell and tube type of heat exchanger. It does not have
conventional type water boxes. Pipe stubs / reducers are provided or either side of tube
plate for connecting with condensate pipes at inlet / outlet end. Tubes have been fixed on
either ends in the end tube plates by roller expansion. Condensate and leak steam are kept
on tube side and shell side respectively. Shell is connected with the exhauster for
discharging non - condensable gases along with vapour either through the exhauster
discharge end or through the chimney as the case may be.
GSC DATA SHEET

DESCRIPTION UNIT Data (full vacuum)
Shell side Design Pressure Kg/cm2 (g) 47
Tube side Design Pressure Kg/cm2 (g) 47
Shell side Design Temperature oC 250
Tube side Design Temperature oC 100
Surface area Provided m2 60.17
No. of Tubes No. 862
Tube OD X Thickness Mm X mm 19 X 0.889
Condensate Polishing Unit

The proposed Condensate Polishing Plant (CPU) will treat the entire condensate of
the power station. The condensate polishing vessels (CPV) will comprise 3 x 50% mixed
bed filters of spherical shape with outlet resin trap. There will be one external regeneration
facility (ERF). The function of the CPU is to purify the condensate effluent from the
condenser by removing total dissolved solids with the aim to reduce corrosion and
deposition in the water steam cycle.
The incoming crud condensate composition and the targeted composition of the
effluent treated condensate will be as furnished in the Process & Sizing Calculation. The
external Regeneration facility will ensure removal of dirt / crud from the resin bed and
also maintain required Sodium Limits as specified and as ensured by keeping the
conductivity of the treated condensate below the specified limits during service run.
The CPU is designed so that the cycle time for service run in hydrozen cycle of each
CPV is 10 days or 240 hrs (normal service run) and 48 hrs during start-up and condenser
tube leakage condition. The design flow rate / vessel is 838.3m3/Hr.
Condensate Polishing Vessels (CPV):

The relevant CPV will be taken out of service automatically when any one of the
following conditions occurs :
• When the cation conductivity of treated condensate from a particular CPV reaches 0.1
micro siemens/Cm.
• When the pressure drop across the CPV including resin trap under dirty condition
exceeds the limit (3.57 kg/cm2) as registered by the differential pressure transmitter for
each CPV. For considering the pressure drop across CPV between inlet and outlet of CPV
it is envisaged the same shall not exceed 2.04 kg/cm2 with clean resin bed
• When condensate temperature exceeds 53 deg C.
▪ Whenever line of the CPV differential pressure reaches 3.57 kg/cm2, the
by-pass modulating valve will be out of modulating control and open to the
extent of 50% of the total condensate flow and that particular CPV will be
automatically out of service. When the 2nd CPV pressure drop also reaches
3.57 kg/cm2, the by-pass valve will open to the extent of 100% of the total
condensate flow and the 2nd CPV will also be automatically isolated.
There are few analyzer used to monitor the quality of influent, service vessel outlet
& effluent i.e Ph, Conductivity, Silica & Sodium analyzer
INTERLOCKS:
All necessary interlocks for safe operation of the plant shall be provided. They shall
specifically include the following as minimum requirement.
• Service vessels can be taken up for resin transfer only after they have been completely
isolated form the condensate system and depressurized.
• Resin can be transferred to and from only one service vessel at a time
• Wherever possible, completion of all timed steps in the regeneration and resin
transfer process shall be physically verified by effluent conductivity etc. as applicable.
The automatic sequence shall be prevented from advancing to next step, till these
required physical conditions are achieved and at the same time this delay shall be
annunciated in the control desk to draw the attention of the operator. The automatic
sequence of operations shall be interruptive at any time by the operator and he shall be
able to take over the control to manual from that step onwards. Further operator should
be able to over ride sequence, if required. It shall be possible for the operator to extend
the timing of a particular step by isolating the timer for the duration and the timer will
restart from that value where it was stopped when the operator puts back the system on
'auto' and the other steps will then follow as programmed.
• The regeneration sequence shall be prevented from advancing further in the event of
tripping of a running motor or other fault condition which do not permit the various
desired parameter of this step to be achieved.
▪ In general, Normal and trouble free operation of the plant shall not activate
any of these alarms.
• Adequate diluent water flow shall be established before starting of the relevant metering
pumps for acid and alkali injection.
• The immersion heater in the hot water tank can be put on only when there is adequate
water level in the tank.
• Service vessels can be back in service only after they have been pressurized.
• Resin transfer between the service and the regeneration skids shall be permitted only
when the receiving vessel is initially empty. (to be varified manually)
• A particular mixed bed polisher can not be put in service if the same is under resin
transfer.
• The regeneration operation cannot be started unless the resin transfer of a specific mixed
bed polisher is completed.
• In case of tripping of condensate extraction pumps the mixed bed polishers will be
automatically isolated by closing their respective inlet and oulet valves.
• In case of inlet condensate temperature exceeds 53 deg C, the running mixed bed
polishers will be automatically isolated by closing their inlet / outlet valves and the
bypass valve will automatically open 100% to bypass the requisite flow.
• Regeneration sequence can commence only when the level in the waste neutralization
pit is low enough to receive the entire quantity of waste water from the regeneration
operation.
Evacuation of the Condenser:
Evacuation of the Condenser is a must for the following reasons:
It is well know that the total pressure in a system is the sum of the partial pressure
of the component gases. If more gas in to the system from outside or is generated
within the system, the total pressure in the condenser will increase, thus there will
be a decrease in turbine efficiency and output.
Undesirable gases will cloud the outer surface of the condenser tubes, thus
seriously hampering the heat transfer of the exhaust steam to the CW resulting in
high temperature vis-à-vis pressure, lowering turbine efficiency and output.
Free oxygen is always hazardous to the metal piping and components in the system
for it is corrosiveness by nature. it must be removed from the condenser to improve
the life expectancy of the cycle components including steam generators.
For the purposes evacuation of the condenser, air ejectors or vacuum pumps are
used; these are the devices instrumental for discharging any leakage air or
undesirable gases from the condenser into the atmosphere.
De-aerator:
A de-aerator provides mechanical-type and chemical type for removal of the
dissolved gases (CO2 and O2), which is highly desirable for safe boiler operation. The
same is accomplished prior to dose chemical oxygen scavengers (Hydrazine) by heating
feed water with steam. This process reduces the concentration of oxygen and carbon
dioxide from FW. Being most economical, it can reduce the oxygen content up to 0.005
mg/liter. Steam is preferred for de- aeration because steam is essentially free from O2 and
CO2. Readily available steam adds the heat required to complete the process.
Data sheet for De-aerator
Description Steam Condensate Feed water
entering entering leaving
Pressure ( ata) 11.85 --- 11.80
Quantity (TPH) 107.250 1724.427 2313.765
Enthalpy (Kcal/Kg) 760.3 149.3 189.0
No of spray valves / trays 144 / 792
Design pressure (ATG) 14 & FV
Design temperature (Dea heater /tank) 395 / 260 oC
Operating Pressure / Temperature 11.8 Ata /186.3 oC
HP & LP BYPASS SYSTEMS:

HP Bypass System:
Two number HP bypass pressure control valves are provided to maintain main steam
pressure at desired set point during start-up, shutdown, load rejection, normal unit
operation or turbine trip condition.
The station is provided with two nos. electro-hydraulically operated HP Bypass
valves, BPV-1 and BPV-2 along with associated spray system capable to pass total 1551
T/hr (60% of BMCR steam flow), at rated live steam parameters of 247 ata and 5650 C.
Each valve has been sized to pass 775.5 T/hr of rated live steam. It shall be designed for
constant / sliding / modified sliding pressure modes of operation. Spray system, with
tap-off from BFP discharge, comprising an electro-hydraulically operated block valve
BD-1/ BD-2 in individual spray line, electro-hydraulically operated control valves BPE-
1 and BPE-2 in individual spray lines to each bypass valve, and non-return valves BPV-
8 & BPV-9 in the individual spray lines near the bypass valves. Spray to HP Bypass
Valves.
When in operation, the HP bypass valves provide the path for the steam at main
steam parameters to be reduced and discharged into the cold reheat line by spraying water
from BFP discharge.
The HP bypass control valve shall be positioned by main steam header pressure
controller. Depending upon the initial pressure condition at the time of boiler firing, the
pressure set point is to be adjusted to a value equal to steam pressure ahead of bypass
valves plus a negative bias pressure. This would result in opening the valves. During load
throw-off, whenever pressure ahead of bypass valve increases by about 5 to 8 kg/sq.cm.
(adjustable) above the turbine throttle pressure ,the bypass valve opens.
The bypass station would operate in parallel with TG during load rejection on
turbine due to grid condition. In view of large steam flows handled by the bypass valve
during such operation the control system shall meet the following features:-
● For a part load rejection, if bypass operates on its pressure controller, the
downstream temperature shall be maintained with minimum overshooting or
undershooting of the controlled variable from the set value.
● During large load rejections, the bypass shall open in about 3 seconds after
initiation of signal from any of the following:-
a. Generator breaker open.
b. Turbine trip.
c. Turbine load shedding relay operates.
d. Control deviation greater than preset value.
e. Manual action for Emergency fast-open.
● The HP bypass shall be closed if condenser vacuum is poor (>0.6 ata) or HP
bypass downstream temperature is very high (>360 oC).
The following interlocks shall be provided for the system:-
• The spray water isolation valve (BD) automatically closes if the openings of
HP bypass valve are below 2%.
• If opening of the HP Bypass valve is above 2% or controller opening is > 2
% then the spray water isolation valve shall open immediately and the
control of spray water control valves shall be changed to auto mode not
withstanding their initial conditions.
• If the steam temperature at the downstream of HP bypass station becomes
very high (>360 oC) despite full opening of spray valve, the closing signal to
HP bypass valve is initiated and the positioning loop changed to manual
mode. This shall be accompanied with an alarm.
| 84
HPBP Valve DATA

Sheet:
Description Unit Data

Valve Type -- AV140R
Medium -- Superheated steam
Design Pressure Kg/cm2 271.7
Design Temperature oC 573
Hydraulic System Pressure Bar 130
Operating State 60% HPBP Opening
Pressure before Valve Kg/cm2 247.0
Temperature before Valve oC 565
Pressure after Valve Kg/cm2 58.083
Temperature after Valve oC 360.0
Pressure after BDO (Break Down Orifice) Kg/cm2 37.14
Pressure Drop Kg/cm2 209.86
Maximum Flow per Valve TPH 775.50
Maximum Valve Stroke mm 74
BPE Valve DATA Sheet:

Description Unit Data
Valve Type -- E45S
Medium -- Spray water
Design Pressure Kg/cm2 351
Design Temperature oC 200
Hydraulic System Pressure Bar 130
Operating State 60% HPBP Opening
Pressure before Valve Kg/cm2 268.290
Temperature before Valve oC 142
Pressure after Valve Kg/cm2 211.251
Temperature after Valve oC 142
Pressure after BDO (Break Down Orifice) Kg/cm2 ---
Pressure Drop Kg/cm2 56.939
Maximum Flow per Valve TPH 163.656
Maximum Valve Stroke mm 43
| 85
LP Bypass
System:
LP bypass pressure control valves are provided to maintain reheat steam pressure at desired set
point during start-up, shutdown, load rejection, normal unit operation or turbine trip condition.
The LPBP Protection System is a redundant digital system in which all the individual
safety circuits for bypass protection are built in. If any of the individual protections is
relayed, the LPBP trip is released, thereby closing the single stem control valves. For each
LPBP station, tripping criteria’s are separately determined.
Each LPBP control valve is provided with 2 trip solenoid valves (TSV). The TSVs
are connected in 1v2 hydraulic circuit. The LPBP protection system keeps the TSVs
energized under normal operating conditions. Trip signal coming from any of the
individual protection circuits, act through the protection system, to de- energize the
TSVs.
TRIPPING CRITERIA:
LPBP 1 TRIPPING CRITERIA:
•The LPBP 1 trips automatically under any of the following conditions. The
initiating signal in each case actuates both the trip channels separately.
• Condenser 1 vacuum protection: The protection acts if absolute pressure
in the condenser 1 rises above 0.6 Kg/cm2 (abs).
• Condenser 1 temperature high: The protection acts if the condenser 1 wall
temperature rises above 90 °c. Three thermocouples are provided in condenser
wall and the trip signal is initiated in 2-out-of-3- logic.
• Water Injection flow protection 1: For the water injection flow protection,
the permissible LPBP 1 flow is specified through a set point derived as specified.
An adjustable margin mwp (10 to 50%) is added to this calculated WI flow .
Then final output value is compared continuously with water injection flow
measured by each Flow Transmitter at W.I. valve upstream. If the differential
flow exceeds the set limit a trip signal is formed in each channel. Initial value of
mwp is kept as 10 %.
LPBP 2 TRIPPING CRITERIA:
• The LPBP 2 trips automatically under any of the following conditions. The
initiating signal in each case actuates both the trip channels separately.
• Condenser 2 vacuum protection: The protection acts if absolute pressure
in the condenser 2 rises above 0.6 Kg/cm2 (abs). The trip signal is initiated by
three pressure transmitters in 2-out-of-3-logic (MAG10CP012,13,14).
• Condenser 2 temperature high: The protection acts if the condenser 2 wall
temperature (MAN52CT001,02,03) rises above 90 °c. Three thermocouples are
provided in condenser wall and the trip signal is initiated in 2-out-of-3- logic.
Water Injection flow protection 2: For the water injection flow protection, the
permissible LPBP 2 flow is specified through a set point derived as specified. An
adjustable margin mwp (10 to 50%) is added to this calculated WI flow . Then final
output value is compared continuously with water injection flow measured by each
Flow Transmitter at W.I. valve upstream. If the differential flow exceeds the set
limit a trip signal is formed in each channel. Initial value of mwp is kept as 10 %.
Difference of the LPBP 2 flow and water injection flow is continuously compared
with a limit signal in each of the channels. If the differential flow exceeds the set
limit a trip signal is formed in each channel.
Condenser level protection: The protection acts if the condenser hot well level
rises above admissible level. 2 hot well level trip signals are received from station
C&I and processed in 1 v2 to affect the trip. The trip signal is initiated from station
C&I by three level transmitters in 2 out of 3 logic.
HPSU Header Pressure Low: In case both the CF pumps are working and
header pressure falls below 120 Kg/cm2 , LPBP trip is initiated.
HPSU Emergency off : HPSU provides control fluid at high pressure for
operating the control Valve . In case of control fluid temp exceeds the admissible ,
oil level fall below pre determined value , or Emergency off push button imitated.
HPSU emergency off signal is generated if any of above parameter reaches an
impermissible level , LPBP trip is initiated.
MANUAL TRIP : Pushbutton/Control button is provided on the HPSU skid for
each bypass system for individual tripping of bypass system 1 & 2.
BYPASS TRIP SYSTEM : If the following trip criteria coming any of the
individual protection system responded then SR flip flop is set and along with water
injection protection responded and passed thru OR gate for related LPBP TSVs ,
tag nos. MAN52AA013, 14 and MAN55AA013,14 to get de-energized.
o Condenser hot well level Protection
o LPBP condenser press protection
o LPBP condenser temperature protection
o HPSU emergency off
o HPSU header press too low
o LPBP trip switch Operated.
The SR flip flop reset when LPBP reset sw operated from OWS or position set point
of LPBP is < -40% derived from controller output. <- 40 % is used for resetting
bypass trip corresponds to lift set point of LPBP controller operating in negative
direction. Controller o/p range is -100 to 105%.
| 87
Unit Start-up up to
synchronization
Load Pressure SP
840 57
800 54.6
640 44
320 23.6
240 17.4
0 12
At Boiler Super Heater outlet pressure of approx. 5.5 Kg/cm2, ensuring the Main
Steam Stop valves (Boiler side) open position, put both the HP & LP bypass valves
including Master control in auto with Logic Set Point selection
HP BYPASS START UP MODES LP BYPASS START UP MODES

HPBP MINIMUM FLOW MODE
● AUTO Set Point Selected
● Boiler flame ON LPBP Minimum Pressure control mode
● Main Steam Pressure < 12
Kg/cm2 (minimum pressure) On Boiler flame on & when HRH pressure
at LP bypass > 2 Kg/cm2, on operator
HPBP MINIMUM PRESSURE MODE intervention LP bypass valves will control
● Main Steam pressure > or = 12 Kg/cm2 the same pressure (i.e. SP = Kg/cm2)
● HPBP Valve position < 30%
● Main Steam pressure less than
Synchronizing pressure (i.e 100
Kg/cm2)
HPBP Pressure ramp mode LPBP Pressure raise control mode
● When HP bypass valve demand When LP bypass valves demand reaches
reaches the 50% opening, HP the 50% opening, LP bypass valves will
bypass valves will start operating at start operating at constant 50% position
constant 50% position
● Maintained the MS pressure between
> Pmin and < Psync
HPBP Fixed Pressure mode LPBP Fixed Pressure mode
● Once main steam has attained the Once HRH steam has attained the floor
floor pressure/turbine run-up pressure 12 Kg/cm2, LP bypass valves will
pressure of 100 Kg/cm , HP bypass
2 control the same pressure (i.e. SP=12
valves will control the Kg/cm2)
same pressure (i.e. SP = 100 Kg/cm ) 2
HPBP FOLLOW MODE LPBP FOLLOW MODE

● Once Generator is synchronized and ● Once generator synchronized,
Unit load > 10% ● Boiler Master in kept AUTO
● Boiler Master or Turbine Master is in ● HRH Pressure at LPBP is >12
kept AUTO Kg/cm2 and LPBP PCV demand is
● Main Steam pressure at HP bypass is less than 2%
> 100 Kg/cm2 and HPBP PCV ● LPBP PCV By Follow mode will Set.
demand is < 2% And PCV controller set-point will be
● HPBP PCV By Follow mode will Set. following the function of load + 3
and PCV controller set-point will be Kg/cm2 Bias.
following ULD Main Steam Pressure
Modeling Set
Point + 6 Kg/cm2 Bias.
ULD Main Steam Pressure Modeling LPBP PCV Set Point as a function
Set Point: of Load:
● When Sliding Pressure Not in Auto,
ULD Main Steam Pressure Modeling
Set Point = HPT Inlet MS Pressure
● When Sliding Pressure is in Auto,
ULD Main Steam Pressure Modeling
Set Point = Sliding Pressure Set
Point
*ULD = Unit Load Dictation
*PCV = Pressure Control Valve
HP/LP Bypass different modes of operation with pressure/position set points
LPBP mode of Operation Pressure Set Point Position/Dema

(Kg/cm2) nd
Minimum Pressure Mode 2 ---
Pressure Raise (Ramp) Mode --- 50%
Constant Pressure Mode 12 ---
Follow Mode Function of Load + 3 ---
House Load 22.4 ---
Boiler Trip or Turbine Trip or 12 ---
Both
Quick Open --- 15%
Quick Close --- 0%
HPBP mode of Operation Pressure Set Point Position/Dema

(Kg/cm2) nd
Minimum Flow Mode --- 15%
Minimum Pressure Mode 12 ---
Pressure Raise (Ramp) Mode --- 50%
Constant Pressure Mode 100 ---
Follow Mode ULD Main Steam ---
Pressure Modeling Set
Point + 6
House Load Set at 172.8 ---
(Operator Reset
Available)
Boiler ON & Turbine 100 ---
Trip (Irrespective of MS
Pressure)
Boiler Trip & MS Pressure at HPBP 100 ---
is less than 100 Kg/cm2
Boiler Trip & MS Pressure at HPBP is Set at Last MS Pressure ---
greater than 100 Kg/cm2 and less value at HPBP at the time
than 180 Kg/cm2 of boiler trip
(Operator Reset
available)
Boiler Trip & MS Pressure at Set at 180 ---
HPBP is greater than 180 (Operator Reset
Kg/cm2 available) On Operator
Reset, it follows any of
the available modes
depending on MS
Pressure at
HPBP on boiler trip
Quick Open --- 100%
Quick Close --- 0%
Note:
Maximum value of the logic Sp to HPBP PCV = 255 Kg/cm2
Maximum value of the logic Sp to LPBP PCV = 57 Kg/cm2
HP Bypass quick open conditions:
when boiler in service and on any of the following conditions
a. Turbine tripped
b. GT CB (both breakers) opened
c. Turbine Load Shedding Relay (LSR) Operated
d. Emergency fast Open from Desk / HMI
e. RH Protection Acted
f. HPBP pressure control deviation > 8 Kg/cm2
HP Bypass quick close conditions:

Down stream temperature >360 oC
Spray water pressure low (BFP Inter stage pressure shall be less than
HPBP down stream Pressure + 16 Kg/cm2)
Both Condenser Vacuum Low Low (<-0.7Bar g)
HPSU system not healthy
LP Bypass Quick open conditions:

15% open for 15 sec duration on turbine trip
LP Bypass Quick close conditions:

HPSU system not healthy
LPBP spray water pressure low ( Condensate pressure after Gland Steam
Condenser < 15 Kg/cm2)
Operator quick close command
Condenser vacuum low low (<-0.7Bar g)
LP Bypass - 1 spray water flow low ( LPBP-1 spray water TCV demand
> 95% & LPBP - 1 spray water TCV deviation >10% for 15 sec)
LP Bypass - 2 spray water flow low ( LPBP-2 spray water TCV demand
> 95% & LPBP - 2 spray water TCV deviation >10% for 15 sec
HP Bypass Oil supply Units (HPSU) Healthy:

HP BP HPSU Pressure Not Low low (<140 Kg/cm2)(i.e High:< 160 Kg/cm2)
HPSU Oil Tank level not Low Low (<16 mm)
HPSU Oil supply temp Healthy ( High: >55 OC & V. High:>60 OC)
HP/LP Bypass and Spray Water Controllers healthy
HPSU Oil System in Auto
Aux. Pressure Reducing & De-Superheating
Station:
Auxiliary steam system is designed to provide steam for the turbine auxiliaries &
boiler auxiliaries during start-up, low loads and normal running of unit.
The system comprises of:
● A "High capacity PRDS", Controlled by ASV-22, with tapping off steam from
main steam line to meet auxiliary steam requirements during unit start-up,
low loads & intermittent requirements,
● A "Low Capacity PRV", Controlled by ASV-26, with steam tapped from CRH
line to meet auxiliary steam requirements during normal running.
● Spray water required for de-superheating will be tapped off from
condensate extraction pump discharge. Spray water for HCPRDS is
controlled through the control valve CDV-138.
● CDV-141, a 100% bypass motorized regulating valve for HCPRDS spray
control.
The HCPRDS will reduce the pressure and temperature of the steam tapped off
from main steam line to 16 kg/cm2 (abs) & 290o C. The LC-PRV shall reduce the pressure
of steam tapped from CRH line to 16 kg/cm2 (abs) and temperature in the range of 280o
C to 310o C, depending upon the CRH parameters at corresponding load.
Motorized bypass regulating globe valve (ASV-29) has been provided for low
capacity PRV which can be operated remote manually in case of mal- operation of main
control valve.
The change-over from Low capacity PRV to High capacity PRDS & vice- versa is
automatic with manual override facility. During high capacity PRDS operation, low
capacity PRV remains in operation also.
The low & high capacity PRDS can be operated independently either in auto or
remote manually from the unit control desk. However, manual operation overrides the
auto operation.
Auto change-over from LC-PRV to HC-PRDS & vice versa:

• During normal running LC-PRV is in operation. Fall in auxiliary steam header pressure
due to increased auxiliary steam requirement, automatically cuts in HC-PRDS into
operation.
• HC-PRDS also comes into operation automatically when LC-PRV (ASV-26) lift goes
above 90%, while LC-PRV remains in operation.
• HC-PRDS (ASV-22) shall be on forced auto mode, automatically when:-
• Auxiliary steam header pressure comes down to 15 kg/cm2 (a)
• Continues to be 15 kg/cm2(a) for 0-10 secs (adjustable).
• OR when LC-PRV (ASV-26) lift goes above 90%.
•
• When HC-PRDS (ASV-22) opens automatically, controls will be transferred to HC-
PRDS, i.e. when both HC & LC valves are in operation, controls are transferred to HC
valve.
• However, once HC-PRDS (ASV-22) opens on force auto, immediately reason for
increased auxiliary steam consumption should be investigated and fault, if any, should
be immediately rectified.
• Facility shall be provided to close LC-PRV manually in case HC-PRDS is operating at low
lift condition. However, operation/closure of LC-PRV is left on the judgment of operator.
Nevertheless, prolonged & repeated operation of control valves at very low opening is
undesirable.
• When HC-PRDS (ASV-22) lift goes below 10% due to decrease in auxiliary steam
requirement, the LC-PRV cuts in automatically and controls are transferred to LC-PRV.
HC-PRDS will be given a force close command with a time delay of 0-100 secs.
(adjustable).
List of Alarms:
APRDS Header Pressure High : >17.5 Kg/cm2
APRDS Header Pressure Low : <15 Kg/cm2 APRDS
Header temperature Low : < 260oC APRDS Header
temperature High : > 305oC APRDS Header
temperature Very High : > 310oC
Condenser Cooling water (CW) Pumps:
The CW system shall be closed circuit re-circulating type with Natural Draught
Cooling Tower. The CW system will deliver cooling water to Condenser. Cooling water
shall be supplied to Condenser through CW pumps installed in CW pump House. The hot
water return from Condenser & ACW system shall be led together to Cooling Tower for
cooling. The cooled water from cooling tower shall be returned to CW sump by gravity for
recirculation in the closed cycle CW system. Make up water shall be added in the CW
forebay of CW system.
Pump Details:
● 5 x 25% capacity CW pumps viz. 4 working and 1 standby.
● Pump rated Capacity : 22500TPH
● Pump Total Head : 26.85 MWC
● Temperature raise across Condenser : 9.4oC
● Pump rated Speed : 420 rpm
● No. of Stages/type of Impeller : One / Semi-Open
Motor Details:
● Rated Capacity : 2500 KW
● Rated Voltage : 11 KV
● Full Load Current : 164 Amp
● No Load Current : 60 Amp
● Full Load Efficiency : 95.50
● Vibration Level (Vel/Disp) : 2.3 mm/sec /37 microns
Start Permissive for CWP – A (similarly other CWPs) :

CWP-A is not in tripped condition
CWP-A is in OFF Condition
CWP-A Switch gear Available
CWP-A EPB not Operated
CWP-A Motor Winding Temperature not High
(High : > 110oC Very High : > 120oC)
CWP-A Sump Level Adequate
(Adequate : >101.3 M, Low : <100.9M , Very Low : <100.4M)
CWP-A Discharge valve Closed
CWP-A Discharge valve actuator not Disconnected
CWP-A Pump/Motor Bearing Temperature Not High
(High : >100oC , Very High : > 110oC)
CWP-A Reverse Rotation Switch not Acted
*Maximum value of Vibration(rms) in mm/sec :
Operating value :6.1 , Alarm : 7.6 , Trip : 11.9
*CWP-A Discharge Pressure Low : < 1.2 Kg/cm2, High : > 2.8Kg/cm2
Trip interlocks:
CWP-A ON for 5sec and Discharge valve not Opened for 5sec
CWP-A Winding Temperature Very High
CWP-A Pump /Motor Bearing Temperature Very High
CWP-A Motor Bearing Vibration Very High
CWP-A Sump Level Very Low
CWP-A Standby AUTO Startup:
✔ CWP-A Standby Selected &
✔ any One of CWP is in ON position with 60 sec on time delay & CWPs
Discharge Header Pressure Low
(OR)
Any One of CWP Tripped
Auxiliary Cooling water (ACW)
Pumps:
ACW system takes suction from ACW sumps located in CW pump house and cooling
water shall be supplied to Plate Heat Exchangers and vacuum pump heat exchangers
by ACW Pumps. Self-Cleaning Strainers shall also be installed on the common
discharge line of ACW Pumps. The hot water return from ACW system shall join the
CW hot water return header downstream of Condenser.
Start Permissive for ACWP-A (similarly B&C):

o ACWP-A not Tripped
o ACWP-A is in OFF Condition
o ACWP-A Switchgear Available
o ACWP-A No Switchgear Disturbance
o ACWP-A EPB Not Operated
o ACWP-A Motor Winding temperature Not High
(High : > 110oC Very High : > 120oC)
o ACWP-A Sump Level Adequate
o ACWP-A Discharge valve Closed
o ACWP-A reverse rotation switch Not Operated
o ACWP-A Pump /Motor Bearing Temperature Not High
(High : >100oC , Very High : > 110oC)
o ACWP-A Discharge valve No Actuator Disturbance
Trip Interlocks:
o ACWP-A ON & ACWP-A Discharge valve Open Not more than 10%
o ACWP-A Motor Winding Temperature Very High
o ACWP-A Pump /Motor Bearing Temperature Very High
o ACWP-A Motor Bearing Vibration Very High
o ACWP-A Sump Level Very Low
ACWP-A Standby AUTO Startup:

o ACWP-A Standby Selected &
o any One of ACWP is in ON position with 60 sec on time delay & ACWPs
Discharge Header Pressure Low
o (OR)
• Any One of ACWP Tripped
CLOSED COOLING WATER
SYSTEM
The CCW system takes care of the cooling water requirements of all the auxiliary
equipment such as Turbine & Generator auxiliaries (TG DMCW) and steam Generator
Auxiliary (SG DMCW) i.e Turbine Lube Oil /Control Oil Coolers, H2 and Seal Oil
Coolers, stator Winding water coolers ,BFP auxiliaries, CEP Bearings , all sample
coolers , Air Compressor auxiliaries, all Boiler auxiliaries coolers , etc.
The primary part of this CCW system is actually that utilizes DM Water as cooling
medium
The components of this system are:
● Redundant ACW pumps
● Plate –type Heat Exchangers
● Overhead expansion tank
TG DMCW PUMP
DMCW PUMP-A Start permissive : (Similarly B&C)

DMCW PUMP-A is in OFF Condition
DMCW PUMP-A is Not Tripped Condition
DMCW PUMP-A Switchgear Available
DMCW PUMP-A EPB not Operated
DMCW PUMP-A Suction Valve Opened
DMCW PUMPs Suction Header Pressure Adequate
Adequate : > 2.5 Kg/cm2 , Low : < 1.2 Kg/cm2 , Very Low : < 1.1 Kg/cm2
DMCW PUMP-A Pump Bearing Temperature Not High High :
> 80 oC , Very High : > 90 oC
DMCW PUMP-A Motor Bearing Temperature Not High High :
DMCW PUMP-A Motor Winding Temperature Not High High :
DMCW PUMP-A Discharge Valve Closed (or) (DMCW
PUMP-A Discharge Valve Opened &
DMCW PUMPs Discharge Header Pressure Adequate & Other DMCW
PUMP-A ON Condition)
Discharge Header Pressure Adequate : > 6.5 Kg/cm2 , Low : < 1.2 Kg/cm2 , Very Low :
< 1.1 Kg/cm2 , High : > 7.5 Kg/cm2 , Very High : > 8.0 Kg/cm2.
DMCW O/H Tank Level Adequate (or)
DMCW PUMP-A Standby Selected & DMCW O/H Tank Level not Very Low Tank Level
Adequate : >1100 mm , Low : <250 mm , Very Low : <50 mm
DP across PHEs is not High High: > 9.5 Kg/cm2
● DMCW PUMP-A Discharge Pressure Not low Low
: < 5.6 Kg/cm2 , High : > 7.7 Kg/cm2
SG DMCW PUMP
DMCW PUMP-D Start permissive : (Similarly E)
• DMCW PUMP-D is in OFF Condition

• DMCW PUMP-D is Not Tripped Condition
• DMCW PUMP-D Switchgear Available
• DMCW PUMP-D EPB not Operated
• DMCW PUMP-D Suction Valve Opened
• DMCW PUMPs Suction Header Pressure Adequate
▪ Adequate : > 2.5 Kg/cm2 , Low : < 1.2 Kg/cm2 , Very Low : < 1.1 Kg/cm2
• DMCW PUMP-D Pump Bearing Temperature Not High High :
• DMCW PUMP-D Motor Bearing Temperature Not High High :
• DMCW PUMP-A Motor Winding Temperature Not High High :
• DMCW PUMP-D Discharge Valve Closed (or) (DMCW
PUMP-D Discharge Valve Opened &
▪ DMCW PUMPs Discharge Header Pressure Adequate & Other DMCW
PUMP-D ON Condition)
▪ Discharge Header Pressure Adequate : > 8.5 Kg/cm2 , Low : < 1.2 Kg/cm2
, Very Low : < 1.1 Kg/cm2 , High : > 9.6 Kg/cm2 , Very High : > 9.6 Kg/cm2
(10 sec time delay)
• DMCW O/H Tank Level Adequate (or)
▪ DMCW PUMP-D Standby Selected & DMCW O/H Tank Level not Very
Low Tank Level Adequate : 1040 mm , Low : 440 mm , Very Low : 265
mm
TG DMCW PUMP-A Trip Interlocks: (Similarly B&C, SG DMCW D&E)

• DMCW PUMP-A Stop Command from OWS
• DMCW PUMP-A EPB Operated
• DMCW PUMP-A Stopped from Switchgear
• DMCW PUMPs Discharge Header Pressure Very High
• DMCW PUMPs Suction Header Pressure Very Low
• DMCW PUMP-A Discharge Valve Failed to Open
• DMCW PUMP-A Motor Bearing Temperature Very High
• DMCW PUMP-A Motor Winding Temperature Very High
• DMCW PUMP-A Pump Bearing Temperature Very High
• DMCW PUMP-A Pump /Motor Bearing Vibration Very High
• DMCW PUMP-A Suction Valve Not Opened for 2 sec
DM Transfer Pump:
Start Permissive:
• Condensate Storage Tank Level Not High
▪ High : > 7850mm , Low : < 1500mm , Very Low : < 850mm
• DM Water Storage Tank Level Adequate
• DM T/F Pump Discharge Valve Opened
• DM T/F Pump Suction Valve Opened
• DM T/F Pumps Recirculation Valve Opened
• DM T/F Pump No MCC Disturbance
Trip Interlocks:
• DM T/F Pump-A ON & Discharge Valve Not Opened
• DM T/F Pump-A Suction Valve Not Opened
• DM T/F Pumps Discharge Header Pressure
High High : > 9.0 Kg/cm2 , Low : < 4.5 Kg/cm2.
• DM Water Storage Tank Level Very Low
• Condensate Storage Tank Level High.
LP HEATERS:
LP HEATERS – 1A/1B & 2A/2B:

A feed water heater is a shell & tube type Heat Exchanger which heats the
condensate passing through its tubes by means of steam (for condensing zone ) /
condensate (for drain cooling zone ) on the shell side . Steam which is extracted from
turbine gets condensed in this process .
L .P. Heaters can be horizontal having 2 -pass on water side with welded ( water
box - tube plate - shell ) type construction. Shell side drain is cascaded during normal
operation to lower heater and through Drain Cooler which is connected to the Condenser
through Flash Tank.
Provision has also been made for diverting the drain of L .P. Heater 2 & L .P.
Heater- 3 to Condenser throughthe flash tank by-passing the Drain Cooler and L .P.
Heater 1.
Description LP Heater 1A/1B LP Heater2A/2B
Type Shell & Tube Shell & Tube
Design Pressure (Kg/cm2g) Shell side 47&Full Vacuum 47&Full Vacuum
Tube Side 3.0& Full Vacuum 3.0& Full Vacuum
Design Temperature (oC) Shell side 150 150
Tube Side 150 150
Total Tube surface area (m2) 698.2 649.6
No. of water passes Two Two
Total No of U tubes 348 348
| 97
LP Heaters 3&4
The extraction steam for the LP heater-4 is supplied steam from IP turbine exhaust.
Steam for the LP heaters nos. 1, 2 & 3 are extracted from various stages of the LP turbines.
During normal operation LPH-4 drain is cascaded to LPH-3. LPH-3 drain is fed
back into the main condensate cycle by 2x100% drip pumps after LPH-3. LPH-2A/2B
drains are led to drain cooler-2 and then drain cooler-1 and finally to condenser via flash
tank-B. Under high level conditions LPH-4 /LPH-3 and LPH- 2A/2B drains are directly
led to condenser via flash tank-B. No level is maintained in LPH-1A/1B. Its drain is
connected through a siphon to condenser via drain cooler-1 and flash tank-B.
Description Unit LP Heater-3 LP Heater-4
Steam entering Pressure ATA 2.71 5.12
Drain Entering Pressure ATA ~ 5.4 --
Condensate entering Pressure ATA 15.8 14.8
Condensate Leaving Pressure ATA ~ 14.8 ~ 13.8
Drain leaving Pressure ATA ~ 2.5 ~ 5.4
Steam entering Temperature oC 190.4 255.2
Drain Entering Temperature oC 131.7 NA
Condensate entering Temperature oC 80.0 127.0
Condensate Leaving Temperature oC 126.6 149.2
Drain leaving Temperature oC 129.6 131.7
Steam entering Quantity T/Hr 130.048 67.942
Drain Entering Quantity T/Hr 67.942 ---
Condensate entering Quantity T/Hr 1526.438 1724.427
Condensate Leaving Quantity T/Hr 1526.438 1724.427
Drain leaving Quantity T/Hr 197.989 67.942
No of tube passes/tubes provided No 2 / 1145 2/ 1145
Condensate velocity m/sec 1.65 1.87
Design tube Pressure ATG 47 & FV 47 & FV
Design Temperature (shell / Tube) oC 210/152 275/173
LP Heaters Interlocks: Auto Close Interlock

Open Permissive Respective heater bypassed
STG trip condition
Respective Heater level not high Respective heater level
Respective heater in service extremely high
TG not tripped DP across NRV negative
Respective turbine extraction ready GT HVCB open
Heater level not high high Respective turbine extraction not
ready
HP HEATERS
EXTRACTION STEAM FOR HP HEATERS
The extraction steam for the top HP heaters-8A & 8B is extracted from HP turbine
intermediate stage. HP heaters-7A & 7B are fed with steam drawn from the cold reheat
pipe. HP heaters-6A & 6B are fed with steam extracted from the IP turbine intermediate
stage, after desuperheating by HPH-6A & 6B desuperheaters.
Pneumatically operated non-return valves are provided in extraction lines to HPH-
8A & 8B, HPH-6A & 6B desuperheaters, de-aerator & BFP turbines, LPH - 4 and LPH-3
to prevent backflow of steam into the turbine during a trip. These valves are controlled
from ATRS. Motorized block valves are provided in extraction lines to HPH-8A & 8B,
HPH-7A & 7B, HPH-6A & 6B desuperheaters, de- aerator & BFP turbines, LPH-4 & LPH-
3. Extraction lines to HPH-8A & 8B, HPH- 7A & 7B, HPH-6A & 6B desuperheaters, de-
aerator & BFP turbines, LPH-4 are also provided with ordinary nnon-returnvalves.
DATA Sheet for HP Heater- 6A/6B
Description Pressure Temp (oC) Quantity
(Ata) (TPH)
Steam entering 23.50 393.278 48.332
Drain Entering ~58.6 222.0 192.712
Feed Water entering 302.86 191.8 1156.882
Feed Water Leaving ~299.33 217.3 1156.882
Drain leaving ~ 22.5 196.6 241.044
No of tube passes/tubes provided 2 / 1850 “U” tube
Feed Water velocity 1.74 m/sec
Design tube /shell Pressure 350 / 32 & FV
Design Temperature (shell / Tube/skirt) 325 / 240 / 325 OC
DATA Sheet for HP Heater- 7A/7B
Description Pressure Temp (oC) Quantity
(Ata) (TPH)
Steam entering 59.12 343.9 137.277
Drain Entering ~ 78 278.6 55.435
Feed Water Leaving ~ 298.33 273.9 1156.882
Drain leaving ~ 58.6 222.0 192.712
Design tube/shell Pressure 350 / 74 & FV
| 99
DATA Sheet for HP
Heater- 8A/8B
Description Pressure(Ata Temp (oC) Quantity(TPH

) )
Steam entering 78.59 383.5 55.435
Drain Entering -- -- --
Feed Water Leaving ~ 297.33 292.3 1156.882
Drain leaving ~ 78 278.6 55.435
DATA Sheet for De-SH of HP Heater- 6A/6B
Description Pressure(Ata) Temp (oC) Quantity(TPH
)
Steam entering 23.53 460.3 48.332
Drain Entering -- -- --
Feed Water Leaving 296.33 300.30 404.91
Drain leaving ~ 23.5 308.30 48.332
Extraction Steam NRVs (HP heater stream bypassed

Heaters) Open Permissive • GT HVCB open
• Any one heater stream (A or B)

in service and
• Respective Turbine extraction
ready and
• Any heater level (Stream A or
Stream B) not extremely high
and
• TG not tripped
Auto Close Interlock
• Any heater level (Stream A or
Stream B) extremely high or
• Respective Turbine extraction
not ready or
• TG trip condition
• DP across NRV negative Both
Extraction Steam
Isolation valve
Controls (De-
aerator)
Open Permissive
• De-aerator level not high
• De-aerator level not extremely
high
• IP extraction stage 8 NRV open
• De-aerator NRV open
• STG not tripped
• Respective upstream drip
leg SOV open
• IP extraction stage 8
pressure > DA pressure with
addition of 0.5 bar(g)
• IP extraction stage 8 extraction
ready
Auto Close Interlock
• TG trip condition
• De-aerator level
extremely
high(Derived
from switch &
transmitter)
• GT HVCB open
• IP extraction stage 8
extraction not ready
COLD START-UP PROCEDURE
Ensure all the Line Clears (L.C’s) are returned, and All men and materials
removed from the equipment and site.
Ensure all Soot Blowers are in home position.
Start ACW Pump and fill the CW duct through interconnection valve.
Ensure CW Duct filling, if it is filled, close the interconnection valve.
Start CW Pumps and check the pressures and DPs at both Condensers, and kept
the other pumps in AUTO standby.
Start TG DMCW & SG DMCW pumps , check the pressures and kept the other
pumps in AUTO standby.
Start Service Air Compressors and instrument Air Compressors, check the service
air and instrument air pressures, and maintain instrument air pressure is > 6.5
Kg/cm2.
Fill the De-aerator and Hot well with Boiler Fill Pump.
Charge the Aux. PRDS through Aux. Boiler and make pegging to De-aerator ,
maintain De-aerator temperature 105oC.
Start LDO & HFO Pumps, check the discharge pressures & temperature of HFO oil
and oil leakages if any, Start Recirculation.
Check the all start permissive of Air Pre-heaters and Start Air Pre-heater – A&B ,
check Inlet & Outlet Dampers of Flue gas path and Secondary air path.
Start ID Fan by ensuring all permits. (If the unit is started with only one ID & FD
Fan, one PA Fan in service, the following Damper positions apply to the equipment
to be started. Dampers associated with the idle equipment should be closed).
Start FD Fan by ensuring all permits, maintain total air flow is greater than 892
TPH (i.e 30% of total air flow) and the draft about -15 mmWC.
1. The SCAPH Inlet & Outlet Dampers are open and the Bypass Dampers are
closed. Alternately, if Steam air-preheating is not desired, then the SCAPH
Inlet & Outlet Dampers are closed and the Bypass Dampers are open.
2. The ESP Isolation Gates are open.
3. The OFA Dampers (CCOFA & SOFA) are closed.
4. The Wind box Auxiliary Air Dampers are open or modulating.
5. One Seal Air Fan Inlet Shutoff Damper is open with the associated Fan ready.
Start A.C Scanner / Igniter Air Fans and check the healthiness of D.C Scanner air
fan and maintain the discharge pressure approx. 500 mmWC
Ensure all boiler vents in open condition– eco, separator, roof, back pass, start-up
and Reheater vents.
Ensure all drains of Turbine- MS, CRH, HRH, CRH NRV drain, HRH line drains,
HP bypass drains, LP bypass drains, CRH pipe line drains are in open position.
Check all start permissive of MD BFP and check the lube oil system.
Start MD BFP by ensuring all permits and fill the Boiler parts (i.e Economizer,
water walls and Separator system etc.,)
(The differential temperature between the Feed water and Boiler Metal must
never exceed 111o C. If the Metal temperature is less than 38 C and the Feed water
temperature is higher, a minimum fill rate should be used.
To avoid oxygen corrosion in the Boiler, the use of de-aerated Feed water
with a temperature of greater than 102 C is recommended.)
During a Startup, the Feed water flow should be controlled in automatic
mode for best results.
Start Boiler Recirculation pump by ensuring all start permits.
1. It is assumed that the following preparatory work has been completed:
2. Feed water quality within specified limits.
Turbidity λ Cation λ
pH Fe(ppb) Si(ppb)
(NTU) µS/cm µS/cm
<3 9.0 – 9.2 <100 <100 <10 <1
3. Feed water flow set point at 10% BMCR.
4. SST water level stable with HW L-1 at stable opening (auto).
5. Cooling Water flow to the HP Cooler of the BRP adequate.
6. Suction Valves and Discharge Valves are open.
7. Set the MEFCV at minimum (Pump start) position, select MEFCV to auto,
and start BRP as per the BRP Procedure.
Take one CEP and kept in recirculation. Check CEP`S discharge pressures.
Charge the condensate line to de-aerator by opening discharge valve bypass valve.
Check the de-aerator level normal position.
Check the MOT level .
Start AOP & JOP and kept the other pumps in AUTO.
Take the turbine in turning gear operation.
Boiler light up:
Check all purge permissive are satisfied.

Purge the Boiler.
Open LDO Trip valve and HFO Trip valve after complete the Boiler purging.
Keep the wind box, CCOFA and SOFA dampers are in auto.
Light up the Boiler with LDO guns in AB-elevation.
Keep the HFO system in long recirculation for raising HFO temperatures.
Set Warm-up Fuel flow control to auto and adjust the set point to 5% of BMCR
Firing rate.
Progressively increase Firing rate as required to increase Separator pressure /
temperature at the desired rate (firing rate 222oC/hr max) and to ensure sufficient
Steam flow through the SH, Firing rate should not be further increased until 7
kg/cm2 (g) is measured in the Water Separator and without exceeding the Furnace
Exit Gas temperature limitation(593oC)
Note: It is strongly recommended to have the APH soot blowing system continuously
in service when firing oil to startup a Boiler. This measure is intended to help avoid
APH fires due to accumulation of oil vapour on heating surfaces or Ash particles in
the APH baskets.
Check all metal temperatures of Spiral &Vertical water walls, PSH , FSH,LTRH and
FRH are raising.
Observe rise in separator metal temperatures to 120 °C
Sufficient Steam flow must be maintained at all times to assure clearing the SH &
RH elements of condensate. Do not close the Startup (MS line) Drains completely
until steady (10% or more) Steam flow through the HP / LP Bypass is established.
Once flow is established, progressively close Startup (MS line) Drain & Vent Valves
to transfer flow to the HP Bypass.( drains closed at 2.5 Kg/cm2 and vents closed at
5.0 Kg/cm2 of MS Pressure)
Commence HFO firing in B- elevation after reaching separator metal temp
> 130 °C.
In case of vacuum breaker in open condition, close the vacuum breaker, and start
the vacuum pump1&2, and observe the vacuum increase upto-0.2 bara and give
seal steam to turbine by opening seal steam isolation valve and control valve and
maintain the seal steam header pressure 350mmWC. Observe the vacuum raising.
Start pulling of Vacuum in condenser and rise up to -0.91 bar.
Check & record the Boiler expansions in all four corners and increase the HFO
firing @ 93°C/hr.
The SH Back pass Drain Valve can be closed when Separator pressure reaches 5.3
kg/cm2.
Open MS bypass stop valves MSV–3,5 & 4,6 to warm up the MS line.
Charge the MS line through bypass valve of MS-1&2 at MS pressure 5.4 bar,
Observe auto closing of MSV 3,5 & 4,6.
Observe gradual rise in MS metal temperatures at turbine end up to 150 °C.
Open HP bypass valve more than 2% and start warm up Boiler Reheater coils. Close
the Boiler startup drains and start up vents.
As the HP Bypass opens, the RH will be warmed and pressurized as Steam is passed
through the LP Bypass and RH Drains. Progressively increase LP Bypass set point
toward 12 kg/cm2. In parallel, progressively throttle the RH Drains to transfer flow
and pressure control to the LP Bypass station.
Close the RH Outlet Drain Valves when RH pressure reaches 5 kg/cm2.
When Steam pressure at HP Bypass reaches 12 kg/cm2 (g), the HP Bypass Valve is
released to “Pressure ramp” mode. The Valves will move to nominal 30% position,
then modulate to control the Boiler pressure ramp- up to the required Startup
pressure (minimum 100 kg/cm2(g)). Firing rate can now be increased in
accordance with the allowable pressure / temperature ramp.
Start 2nd CEP and maintain the De-aerator level.
Raise the HFO firing, progressively increase Firing rate to 15% BMCR.
When Boiler pressure reaches the required Startup pressure, the HP Bypass Valve
is reached to “Pressure Control mode” and maintains a constant pressure during
Turbine rolling, synchronization, and initial loading.
Do not exceed the Furnace Exit Gas temperature limit of 593oC below 10%
BMCR load.
Above 10% BMCR load, automatic interlocks provide protection from over-firing.
Raise the MS pressure to 87 bar and temperature 350°C and maintain steam flow
approx. 260 T/Hr and also maintain HRH pressure-12 bar and temp-350°C.
NOTE: The Steam pressure should be increased slowly during the initial start of the
new Boiler. This allows sufficient time for checking expansion movements and
permits the operators to become familiar with the characteristics of the Boiler
and Auxiliary equipment. Once these characteristics have been established,
subsequent Startups may be made at the fastest possible rate consistent with
maintaining the Furnace Exit Gas temperature limitation of 593 oC.
While the unit is heating up, check the Boiler expansion movements frequently &
Expansion movements should be recorded for comparison with future Startups.
Take 2nd set of ID & FD fans into service.
Maintain Storage Separator Tank (SST) Water level at normal set point via auto
Feed water flow control and check the Water concentrations and constituents as
frequently as necessary to maintain proper Boiler Water conditions. Sample
connections are located on the SST.
Chlorides λ Cation λ
pH Fe(ppb) Si(ppb)
(ppb) µS/cm µS/cm
<5 9.0 – 9.2 <5 <10 <10 <0.3
Rolling and Synchronizing the Turbine
• Confirm the Steam conditions, pressure, temperature, and Steam purity, at the
Turbine are correct for Turbine roll.
• Wait for criteria full filling and Check the TSI parameters (expansions ,axial
shift, Bearing vibrations and shaft vibrations)
• After fulfilling the criteria, reset the turbine trip by reducing the TSLLDE
(starting device) to zero and observe the oil pressures. Check that the turbine
trip gear reset.
• Ensure the Hydrogen pressure in Generator casing is more than 4.7 Kg/cm2 (at
Full load condition the H2 pressure shall be maintained at 5kg/cm2)
and H2 purity is more than 96%. Charge all hydrogen coolers on DMCW side.
Check the primary water system and maintain the conductivities.
Open the STOP valves by increasing Starting Device about 35to36% and observe
the STOP valves opening. Check the TSI parameters. Observe the speed. Increase
the starting device up to 85% and above. Also observe the speeder Gear Position is
at 100%.
Set the speed ref. set point to 500 rpm and confirm the ramp. Observe the speed
raising and TSI parameters. Kept the turbine under soaking condition. Up to
fulfilling of next criteria’s and observe the differential expansion of HPT and IPT.
After getting rated speed criteria’s, observe the MS Pressure & HRH Pressure of
rated values. Raise the speed ref. to 2200 rpm and kept in to Hot Soaking.
Raise the speed ref. to 3000 rpm and observe TSI parameters at critical speeds.
Soak the turbine speed at 3000 rpm till IP shaft mean temperature with respect hot
reheat temperature as per the rolling X-curves is satisfied.
Close the Generator field breaker from AVR console.
Raise the AVR set point to build the Generator Voltage to about 27KV.
Match the auto and manual set point of the AVR and Transfer the AVR to auto
mode.
Ensure that load controller is on with load gradient kept at 40MW (5% of full
load) / Minute.
Check load reference set point more then40MW and less then55MW depending
up on main steam pressure.
Adjust the Voltage, so that in coming and running Voltages values are same.
Adjust the turbine speed so that synchronoscope is slowly rotating in clockwise
direction showing in coming frequency is slightly higher than gird.
Switch ON Auto synchronizer after two minutes Generator breaker closed.
Immediately raise the load with help of speed reference up to 40MW.
Close HP/LP Bypass valves.
Slowly change speed control mode to load control mode.
Close all the drains which were opened during rolling.
Check the generator slot core, exciter air and hydrogen cold
gas temperatures.
Check that pressure limiter valve slowly increase also ensure that load reference
set point is higher than the actual load valve.
Slowly increase Boiler firing with help mills and increase the load depending up
on main steam pressure
Raise the HP bypass pressure set point to about full load pressure plus 6 Kg bias
and temperature set point to about 340 oC to avoid HP bypass opening on auto.
| 106
WARM START-UP
Assuming that the unit has been down for a short period of time (less
than approximately 48 hours), the unit can be re-started in a similar
sequence to Cold Start-up procedure as outlined below:
1. Boiler separator metal temperature > (100 OC). and
2. Boiler pressure < (50 kg/cm2)
Warm start-up is carried out following the same procedure as for cold
start-ups. Refer to the section on cold start-up for details.
| 107
HOT STARTUP:
Assuming the unit has been down for a comparatively short period of time (< 8
Hours) following a normal unit shutdown and considerable steam pressure has been
maintained, use the following procedures to restart the unit:
Hot Startup conditions:
● Boiler Separator metal temperature >316oC
● Main steam pressure > 84 Kg/cm2
● Turbine requirements are met
Preparations & Lighting off:
Make a general inspection of the steam generator and check the points outlined in
the Preparations for Lighting Off for Cold Start Ups.
The BRP should still be in service.
lf the air heaters and fans were shut down at reduced temperature, start the air
heaters and fans. Increase the secondary air flow more than 890TPH.
Check all purge permissive are satisfied.
Purge the Boiler, after 9min. Boiler MFR gates reset. The first cause of Unit
Tripping gates reset.
Ensure de-aerator pressure is maintained at 3.5kg/cm² and Auxiliary steam
pressure is maintained at 16kg/cm².
Establish condenser vacuum 0.90kg/cm²
Open LDO Trip valve and HFO Trip valve after complete the Boiler purging.
Keep the wind box, CCOFA and SOFA dampers are in auto.
Light up the Boiler with ‘CD’ and ‘EF’ elevation oil guns.
Ensure that minimum stable fire is established in the Boiler.
Open wide all superheater drains to allow complete draining of superheater
headers and/or elements. After draining, close all drains except the superheater
back pass lower header drains and the start-up drains (main steam line vents and
drains). Keep the back pass header drains open until only steam is discharged. Keep
the start-up drains open. Reheater drains and vents are open and also Open the
following Turbine side drain valves. (As per requirement)
i. MS strainer drains to SDFT (MSV-109 & 110)
ii. CRH pot drain to SDFT (CRHV101)
iii. HRH strainer drains to SDFT (HRH-105&106)
iv. LP Bypass line drains (HRHV109&110)
v. LP Bypass warm up line drains (HRHV109&110)
vi. Open all drains of Turbine system except Mal-22 (HPT casing drain).
Mal-11,12,26,31,27,32,47,51,54,52,81,55,65.
Charging steam lines and commence warm up.
Set the HP and LP bypass control set-point to the existing pressure in auto
mode.
For hot start-ups, the fuel startup sequence should follow this table (A
elevation is the bottom elevation):
Seq. Elevation Notes
step
1 C warm up
2 D warm
up
3 C Coal If C Coal not available, Start D
Coal
4 D Coal If D Coal not available, Start E
Coal
5 E Coal
6 B Coal
7 A Coal
8 F Coal
9 G Coal
10 H Coal
Set warm-up (HFO Oil) flow control to auto and increase fuel flow set point to 5%
of BMCR firing rate, After a 5 minute stabilization period, progressively increase
firing rate to 10% BMCR. Increase separator pressure / temperature at the
desired rate.
When steam pressure at HP bypass begins to increase, the HP bypass valve is
released to "pressure ramp" mode. The valves will then control the boiler pressure
ramp-up to the required startup pressure [minimum 84 kg/cm2] or to existing
pressure if greater than 84 kg/cm2.
As the HP bypass opens, the Reheater will be pressurized as steam is passed
through the reheat vents and drains. Set the LP bypass station to minimum set
point in auto mode. The LP bypass will open in response to increasing reheat
pressure. Progressively throttle the reheat vents and drains to transfer flow and
pressure control to the LP bypass station. (Ensure LP Bypass system is functioning
on auto adjust the fixed set point to 12 kg/cm2)
HP Bypass valves can further be opened to assist in increasing steam parameters
(up to rolling parameters) if required mill can be taken into service.
Increase the firing rate, as prescribed, to raise the pressure and steam production.
The rate of pressure rise should follow the prescribed start-up curves.
When boiler pressure reaches the required startup pressure (minimum 84 kg/cm2)
(or existing pressure), the HP bypass valve is released to “pressure control” mode,
and maintains a constant pressure during turbine rolling, synchronization, and
initial loading.
When steam is admitted to roll the turbine, there should be a minimum steam-to-
turbine metal temperature differential. This can be achieved by raising boiler load
while on HP/LP bypass.
| 109
Turbine Rolling and
Synchronization:
• Confirm the steam conditions, pressure, temperature, and steam purity, at the
turbine are correct for turbine roll.
• Turbine can be rolled to rated speed either by ATRS rolling or manual rolling
through Electro Hydraulic Turbine Controller (EHTC).
The following conditions are to be checked before rolling.

● The turbine should be on barring gear(55rpm)
● Condenser pressure is less than 0.5Kg/cm2
● At least one condensate exaction pump is on
● Trip fluid pressure is more than 5Kg/cm2
● Differential temperature between HP casing mid section top and bottom is less
than30 oC
● Differential temperature between IP casing mid section top/ bottom(Both front
and rear) is less than 30ºC.
● HP control fluid temperature is maintained between 50 oC to 55 oC
● Lube oil temperature after cooler is more than 35 oC.(38-47 oC)
● Verify that the following generator conditions are fulfilled.
1 Any generator bearing vapour exhaust fan is ON.
2 Hydrogen temperature controller is in Auto.
3 Hydrogen purity is more than 97%.
4 Hydrogen pressure is more than 3Kg/.cm2.
5 One air side seal oil pump is ON.
6 One Hydrogen seal oil pump is ON.
7 Differential pressure between seal oil air side and Hydrogen side
(both turbine and Exciter end) is more than 0.7 Kg/cm²
8 Turbine side pre-chamber level is low.
9 Generator busing box liquid level is low(less than 90 mm)
10 One primary water pump is ON.
11 Primary water temperature controller is on Auto.
12 Primary water conductivity is less than 1.5 Micromho/cm.
13 Primary water pressure is adequate (>1.33kg/cm²)
14 Primary water flow >48 TPH.
Before Opening the control valves, verify the following:
A. Degree of super heater of main steam before HP Bypass is more than mid
metal temperature of H.P control valves.
B. The degree of superheat of main steam before turbine is more than 50ºC.
C. M.S. temperature before turbine is more than either mid wall temperature of HP
casing or simulated mid section temperature of HP shaft
D. HRH temperature before turbine is more than simulated mid section
temperature of IP shaft.
During the warm up and hot startup of the turbine, observe the following
parameters.
Differential Expansions.
Axial Shaft
Temperature difference between top and bottom of the HP/IP casing.
Bearing temperature and vibration.
Steam parameters.
TSE margin recorders for the following components HPS /HPC /IPS.
Operating parameters of condensing system.
Operating parameters of turbine oil & control fluid systems Maintain MS
temperature and pressure at turbine inlet as per startup curve.
Steam Turbine Start-up Permissive Condition:

• All Bearing Metal Temperatures not High.
• HP-IP Outer Casing TOP/BOT Metal Temp Difference Not High (< 42oC)
• Bearing Oil Pressure >0.75 bar.
• Shaft Position and Diff Expansion Not High.
• Oil Cooler I/L water CV in Auto.
• HP Oil pressure > 7.5 bar.
Before Keeping the ATRS IN, keep the Stress Control IN. Turbine rolling:
Sequence of Steps when press the “ATRS ON PB” (Before Keeping the ATRS ON, keep
the Stress Control ON.
● Turbine reset by raising the startup device (TSLLE) up to 12.5%, auto
startup oil and Electro Hydraulic Oil pressure built up.
● Further raise the TSLLE to 22.5% for Open the Stop valves of HP & IP
turbines.
● Further raise the TSLLE to 32.5% for Open the Control valves of HP & IP
turbines.
● Raise the TSLLE to 39% for Close the Pilot valve of IPT and raise to 42% close
the Pilot valve of HPT.
● Speed start raising and maintaining at 360RPM. Rub Check as per MODE.
● For Rub checking MSVs will full close, speed fall (coasting) down and field
engineer has to check any rubbing at turbine seals. With the clearance from
field engineer press “RUB CHECK OUT” PB.
● Speed reaches to 970 rpm.
● Heat Soaking at 970 rpm, Kept under soaking to get the X- Criteria’s.
● Speed set point 3000 rpm.
● Speed reaches to 3000 rpm with MSVs.
● When Steam chest temperature reaches to saturation temperature of MS, Valve
transfer will take place, with this ATS operation completes.
● With Valve Transfer Feedback, permit for field breaker will get.
● Close the Generator field breaker
from AVR console.
● Raise the AVR set point to build the Generator Voltage to about 27KV.
● Match the auto and manual set point of the AVR and Transfer the AVR to auto
mode.
● Ensure that load controller is on with load gradient kept at 40MW (5% of full
load) / Minute.
● Check load reference set point more then40MW and less then55MW
depending up on main steam pressure.
● Adjust the Voltage, so that in coming and running Voltages values are same.
● Adjust the turbine speed so that synchronoscope is slowly rotating in
clockwise direction showing in coming frequency is slightly higher than gird.
● Switch ON Auto synchronizer after two minutes Generator breaker closed.
● Immediately raise the load with help of speed reference up to 40MW.
● Close HP/LP Bypass valves.
● Slowly change speed control mode to load control mode.
● Close all the drains which were opened during rolling.
● Check the generator slot core, exciter air and hydrogen cold gas
temperatures.
● Check that pressure limiter valve slowly increase also ensure that load
reference set point is higher than the actual load valve.
● Slowly increase Boiler firing with help mills and increase the load
depending up on main steam pressure.
Loading of Machine:
I. Charge the LP heaters at 7% load.
II. Raise the Unit load @ as per the ramp rate given, by cut in mills one by one.
III. Take 2nd PA fan into service and parallel with the 1st PA fan.
IV. Charge the HP heaters at 15% load.
V. Charge the De-aerator with IP extraction steam at 20% load.
VI. Raise the load 45% and observe change in evaporator temperatures from wet to
dry mode.
VII. Parallel 1st TDBFP with MDBFP at 45% load and raise the load further.
VIII. Parallel 2nd TDBFP-B with TDBFP-A at 70% load and Unload & stop
MDBFP-C.
IX. Raise the load to full load 800 MW and stabilize the parameters.
EMERGENCY PROCEDURES
1. Reheater Protection:
Stopping or significantly reducing steam flow through the reheater when the
entering flue gas temperature is above 1100 oF (593 oC) can cause overheating and damage
to the reheater tubing.
To prevent this condition, the following measures are taken with the automatic
reheat protection interlocks:
Turbine Valve Closure due to Grid Disconnection:
lf a loss of load should cause the turbine valves to close due to grid
disconnection, the turbine will be rundown to house load and the boiler should be
rundown to match the HP bypass capacity (60% BMCR or 65% TMCR at full
pressure).
Initially the SG is runback to 65% TMCR at a target rate of 50% per minute
at constant MS pressure = 242 bara. Simultaneously, the ST is runback to house
load. The bypass quick-opens and the balance of SG flow (65% TMCR less ST house
load) is transferred to the bypass.
SG Load is held at650/o TMCR for a stabilization period.
After stabilization, ST load is maintained at house load, while the balance of
SG flow is controlled by the bypass.
lf the HP bypass is not proven open within a short time delay, then all fuel
should be tripped automatically and instantaneously.
When a master fuel trip is caused by turbine control valve closure, an
immediate restart is feasible in most instances. lf an immediate turbine restart is
not possible and the turbine is tripped, the reheater drains should be opened.
Turbine Trip:
lf a loss of load occurs in which the turbine is tripped, then boiler should be
rundown to match the capacity of the HP bypass (60% BMCR or 65% TMCR at full
pressure).
Initially the SG is runback to 65% TMCR at a target rate of 50% per minute
at constant pressure MS pressure = 242 bara. The bypass quick- opens and the total
SG flow is transferred to the bypass.
SG is held at this condition for a stabilization period.
After stabilization, if desired the SG load and pressure can be reduced at a
controlled rate of<3% per minute within SG temperature gradient limitations and
within the bypass capacity limitation.
lf the HP bypass is not proven open within a short time delay, all fuel should
be tripped automatically and instantaneously.
The superheater and reheater safety valves will protect against
overpressure. The reheater drains to the condenser should be opened to evacuate
the steam in the reheater in the event of a unit trip.
Post-Trip Procedures:
The furnace must be purged immediately following a master fuel trip.
Empty any pulverizer containing coal as soon as possible.
To permit firing during start-up, the initiating fuel trip circuits associated
with the turbine must be disarmed before opening the turbine valves. They must
then be rearmed at a suitable point in the start-up sequence, such as when
synchronizing the turbine.
CAUTION:
Operators should be alert to detect the symptoms of water carry- over from
the boiler and introduction of water into the turbine, such as:
a. A sudden, unexplained drop in steam temperature in either the main
steam or hot reheat line.
b. Vibration in the steam piping resulting from water hammer.
c. Abnormal vibration and differential expansion readings from the
turbine supervisory instrumentation.
Operators must be prepared to take necessary steps to prevent turbine
damage upon detecting the introduction of water.
Turbine Protection upon Loss of Load:
Extreme care must be taken following a trip of the turbine and boiler to
prevent water from entering the turbine during a unit restart. Condensation may
cause water to collect in the main steam line(s) and cold reheat lines. Water may
be introduced into the superheater due to overflow from the separator (inadvertent
high water level). Water may be introduced into the superheater and/or reheater
through the desuperheaters due to open or leaking spray water control valves.
Inadvertent introduction of water into the steam lines must be prevented.
The lines must be drained prior to opening the turbine stop valves. When a master
fuel trip occurs automatically through normal interlocks, or is initiated manually
by an operator, all fuel shall be tripped instantaneously. If coal is being fired, the
pulverisers shall be tripped immediately. The master fuel trip will automatically
trip the feeders and close the hot air gates and close the cold air shutoff gates on
pulverisers that were in service at the time of the trip.lf warm-up fuel was being
fired, the fuel trip valves and individual nozzle shutoff valves should be closed
immediately.
The following steps should be taken immediately following an emergency fuel trip:
✔ If unit airflow is in excess of 30%, maintain unit airflow at the pre-trip value for at
least 1 minute and then gradually reduce the airflow to the purge rate (30% airflow)
and complete a unit post trip purge.
✔ If the master fuel trip was caused by a low airflow trip or if unit airflow less than
30% at the time of the trip, the unit airflow shall be maintained at the existing rate
for a 5 minute period and then gradually increased to the purge rate (30% airflow)
to complete a unit post trip purge.
✔ Procedure after Master Fuel Trip when all lD and FD Fans are off:
The ID and FD fans discharge dampers shall be opened to allow natural
ventilation of the unit. Opening of fan(s) dampers shall be timed or controlled to
avoid excessive furnace pressure excursions during fan(s) coast-down. The fans
discharge dampers shall remain open for a period of at least 15 minutes.
During this 15-minute period, the lD and FD fans shall not be started.
At the end of the 15-minute period, the lD/FD fans may be started in
accordance with ID/FD fan(s) start-up procedures.
If the unit will not be re-started for an extended time, a flow of air through
the unit shall be maintained.
✔ If warm-up fuel was in service when the fuel trip occurred, make sure the warm-up
header trip valve and individual nozzle shutoff valves are closed.
✔ If all auxiliaries are lost during a fuel trip, The cooling flow must be maintained for
the Boiler Circulating Pump.
✔ If pulverisers are in service when the fuel trip occurs, all operating pulverisers will
be automatically inverted. The pulverisers must remain under inverting until they
can be cleared of coal or cooled to ambient. After a boiler trip at a high pressure, a
controlled pressure reduction is carried out to the highest pressure with which a
restart is possible (to approximately 180 bar) to obtain reliable SST level indication.
✔ The BRP should be placed back in service and recirculation established to maintain
uniform temperatures throughout the boiler circulation system and to enable a
restart of the boiler. The boiler must be refilled to re- establish normal SST level for
BRP restart and the minimum recirculation flow must be re-established as a
prerequisite for re-firing. This process will naturally cause pressure to decay,
concurrent with the controlled pressure reduction.
✔ Check that the startup system is ready for operation and the drain transfer system
is ready for operation. Place the BFPMD in service, stabilize de- aerator conditions,
and establish feed water flow of 10% BMCR to the boiler to refill to normal SST
level. Follow the same procedure for boiler filling as outlined previously. When SST
level is stable with HWL-1 at stable opening and all BRP start permissive are
satisfied, start the BRP. Zero the feed water flow as SST level recovers and attains
the operational set point. lf restart of the BRP is delayed, excessive HWL action will
result in draining of water at pressure, oscillatory dump-feed action, with further
reduction in boiler pressure and extension of startup time.
✔ The pre-firing furnace purge can be initiated once all purge permissive are met.
✔ If the boiler can be immediately restarted, then raise load to >20 % on auxiliary
fuel utilizing the HP/LP bypass and successively clear the pulverisers using the
steam transport system as described below while the SG is operated on bypass
at>20% BMCR firing auxiliary fuel.
pulveriser clearing procedure instructions:
a. Close the pulveriser discharge gates on all other idle pulverisers containing
coal during each steam transport procedure. This prevents hot furnace gases
from being carried back into the
pulverisers in the event of a furnace pressure rise when a pulverizer is
started.
b. Start the lower elevation of warm-up fuel and establish the ignition energy
required to start a pulverizer.
c. lf RH flow has not been establish via the HP bypass or via turbine
synchronization, then reduce furnace exit gas temperature to 900- 950 deg
F (482-510oC) by adjusting warm-up fuel flow. before transport steam flow
is initiated.
d. Clear pulverizer A by following the pulverizer transport procedure located
in the steam inerting supplier's instructions.
e. Shut down pulverizer A.
f. Clear pulverizer B as per the same procedure.
g. Continue with normal unit start up sequence until both pulverisers are in
service and the turbine is synchronized.
h. When boiler load is approximately 20%, the remaining pulverisers may be
cleared one at a time using the steam transport procedure and returned to
normal service or shut down in a normal fashion if not required for load
regulation.
i. If the pulveriser will be retained in service, when the pulveriser has
completed the clearing process, open the hot air shutoff gate, bring the
pulveriser up to normal operating temperature and start the associated
feeder.
j. If the pulverizer will not be retained in service, stop it after completely
clearing the coal. The pulverizer discharge gates should remain open to
allow a flow of cooling air through the empty pulverizer.
✔ lf, due to load conditions and/or requirements to the Burner Management System,
it is impossible to establish ignition permissives to allow steam transport, inerting
steam shall be maintained until each pulverizer can be cleared of coal using steam
transport or cooled to ambient.
✔ lf the boiler cannot be re-started and the auxiliary steam source cannot be
continued indefinitely, then the pulverizers must be switched to an alternate steam
inerting source or to an alternate inerting medium until they can be cooled to
ambient and manually emptied.
| 120
Loss of All Feed water

Pumps:
lf all feed water pumps are tripped at any time, cooling of all boiler circuits will be
lost. All fuel must be automatically tripped with a maximum 20 second time delay.
Low Airflow:
lf airflow drops below 25% at any time, combustion conditions could become
dangerously unstable. All fuel shall be automatically tripped immediately.
Furnace Pressure High/Low:
lf furnace pressure exceeds the high-high or low-low set point at any
time, all fuel shall be automatically tripped immediately. A warning alarm is
generated at high and low set points.
Separator Storage Tank Level High:
lf the SST level exceeds the high-high level set point, then all fuel shall
be tripped immediately. A warning alarm is generated at high set point, at
which time the operator should check operation of the HWL valves, SST level
control, or the balance of feed water and firing rate (possible that firing rate
is too low for feed water flow).
Airheater Gas Outlet Temperature High:
lf the gas temperature leaving the airheater exceeds the high set point,
load must be automatically reduced to reduce the gas temperature. This is to
protect downstream equipment from over-temperature. The cause for the
excessive gas temperature should be investigated and corrected.
Both FD Fans Off or Both lD Fans Off:
lf at any time both FD or both ID fans are off while firing the boiler,
then all fuel shall be automatically tripped immediately.
Load Run-Backs:
Upon loss of the following equipment, load must be automatically reduced to a level
that can be supported by the remaining equipment. The load reduction is typically at a
target rate of 50% per minute (except for individual pulverizer trips). The reduction of fuel
input is accomplished by the equal decrease of coal feeder speed or by trippingthe of the
pulverizer(s) (for loss of PA fan or BFP).
One out of two FD fans.
One out of two LD fans.
One out of two PA Fans.
One out of two feed water pumps.
Any pulverizer(s) (depending on boiler load and number of pulverizers in service).
One out of two air heaters. Turbine
trip (as described above).
Disconnection from the electrical grid without turbine trip (as described above).
Run-Back Initiator Target Load Run-Back Rate
One PA Fan ON 50% 50% per minute
One FD Fan ON 50% 50% per minute
One ID Fan ON 50% 50% per minute
One Air Heater ON 50% 50% per minute
One TDBFP ON and One 75o/o or capacity of TDBFP + 50% per minute
MDNFP MDBFP
One TDBFP ON 50% or TDBFP capacity 50% per minute
One MDBFP ON 30% or MDBFP capacity 50% per minute
Main Turbine Trop 60% (within HP Bypass capacity) 50% per minute
List of Function Curves:

1. SH Outlet Steam Flow Vs Load
2. SH Outlet Pressure Vs Load
3. SH Outlet/RH Outlet Temperatures Vs Load
4. Excess air Vs Load
5. SH / RH Spray Vs Load
6. SH Steam Temp. after DESH Vs Load
7. Burner Tilt Vs Load
8. Total Air Flow Vs Load
9. Coal Flow Vs Load
10. O2 Set Point Vs Load
11. PA Flow Vs Coal flow per Mill
12. PA / Furn. Pr. DP Setpoint Vs Coal feeder speed
13. WB/Furn. DP Set Point Vs Load
14. Fuel Air Damper Position Vs Coal Feeder Speed
15. OOS WB Damper Position Vs Load
16. Under Fire Air Damper Position Vs Coal feeder speed
17. Evap outlet time Const. Adj. Vs Load
18. Avg SHDESH Delta T Vs Load
19. Separator Steam Temp. Setpoint Vs Load
20. HWL-1,2 Demand Vs Separator Level
21. BCP Head I BCP DP Vs BCP Suction Temp.
22. SOFA demand Vs Main WB Tilt
23. WB Tilt Position Vs Load
24. CCOFA-A, B Damper Position Vs Load
25. SOFA-A, B, C, D Damper Position Vs Load
26. RH Outlet steam Temp. set point Vs Load
27. SH Steam Temp. Set point Vs Load
52 596
1.O2 set point Vs Load 35 513 2.PA flow Vs Coal flow per
Mill
X Y X Y
35 3.54 X Y 0 89647
52 3.54 100 568 21795 89647
60 3.54 90 568 81514 114119
70 3.54 70 568 87181 122053
90 3.54 60 568
100 3.54 52 568 5.Fuel air damper position Vs
35 513 Coal feeder speed
4.WB/Furn. Pr DP set
point Vs Load X Y
0 0
X Y 24.9 0.1
0 38.1 25 50
30 38.1 60 80
50 63.5 100 90
60 101.3
100 101.6 8.Avg SH Desh Delta T
110 101.6 Vs Load
X Y
8. Under fire air
35 21
damper
52 21
position Vs 60 25
Coal feeder 70 27
speed 90 30
X Y 100 33
0 0
25 0 11.CCOFA-A, B Damper
25 90
position Vs Load
50 95
100 100 CCOFA-A CCOFA-B
X Y X Y
9. WB Tilt Vs 0 0 0 0
Load 35 0 45 0
45 80 55 80
X Y1 Y2
46 90 56 90
52 -6 30
100 100 100 100
60 -22 30
70 -30 27
SH Steam Temp set point
90 -30 14
Vs Load
100 -30 -30
Y1- 50% IND + 50% IMP
Y2-100% imported Coal
13.RH outlet steam temp set

point Vs Load
X Y
100 596
90 596
70 596
60 596
| 128
2. PA/Furn. Pr DP
set point Vs Coal
Feeder Speed
X Y
0 635
25 635
100 945
6. OOS WB
Damper
position
Vs Load
X Y
0 0
25 0
50 0
60 10
70 15
80 16.5
90 17.5
100 18
110 18
10. SAFA
Demand
Vs main
WB Tilt
X Y
0 33.3
25 33.3
33.3 33.3
50 50
66.7 66.7
75 66.7
100 66.7
12.SOFA –A,B,C,D Damper

position Vs Load
A B C D Pos
0 0 0 0 0
55 65 75 85 0
65 75 85 95 80
66.2 76.2 86.2 96.2 90
90 90 95 100 100
Coordinated Master Control –
CMC Introduction
In a thermal Power plant to meet the load requirement of the grid most efficiently
the Boiler steam generation and its expansion in the turbine have to be coordinated to
achieve the best efficiency and heat rate of the Boiler and Turbine. Boiler control refers to
mainly combustion control and Turbine control refers to mainly Turbine speed and Load
control. CMC control system provides the reference demand signal to Boiler as well as
Turbine control to meet the grid demand.
The combustion control system computes the amount of fuel and air required for the
furnace depending upon the load demand on the Boiler, which in turn is generated by the
CMC Loop. The CMC loop also generates Load signals for Turbine EHG- Electro hydro
Governor.
The unit load demand signal is based on the electrical load requirement from the Load
dispatch centre (LDC) or as decided by the Operator.
How Steam pressure changes as the Load demand changes
As the Electrical load on the generator Changes, the mechanical load on the coupled
turbine also changes. The turbine copes with these load changes by increasing or
decreasing the steam mass passing through it by modulating the steam inlet control
valves. The turbine inlet valves are closed to reduce the steam flow thru the turbine and
vice versa.
As the turbine inlet valves tend to close the instantaneous effect on the Boiler is an
increase in steam pressure at the Boiler outlet. The fuel input to the steam generator is
required to be reduced to adjust to the reduced requirement of steam. The dynamic
response of the steam generator to change in the steam quantity required is quite sluggish
due to the inherently slow chain of fuel preparation and fuel firing equipment. So till the
effect of reduction in firing rate takes place the Boiler will tend to produce an excessive
quantity of steam and its discharge pressure will tend to increase, since flow through the
Turbine is decreasing. This extra pressure is killed across the turbine inlet steam control
valve.
This will lead to the opening of the steam inlet valve to let more steam flow thru the
turbine. The boiler is not able to produce this extra steam, therefore the Steam pressure
at the Boiler outlet tends to fall. This sudden reduction of steam pressure in the steam
generator prompts an insanity expulsion of steam mass due to an increase in the specific
volume of the steam within the confines of the system. This provides a temporary load
increase even before the increase in fuel handling and the fuel firing system provides more
fuel to the Boiler. To provide more steam on a sustained basis, more fuel is to be fired into
the furnace.
Importance of Steam Pressure Control
A turbine can give the required load capability at varying steam pressure at its input
provided it gets the requisite steam mass having the required energy or enthalpy. The
steam can be delivered by Boiler at constant pressure or variable pressure. The important
point is to produce the steam at an optimum cost of fuel and at the same time with a quick
response of the boiler and turbine to the varying load conditions of the electrical grid to
which the turbine and generator are connected.
Constant Pressure operation V/S Sliding pressure mode of Operation

of the Boiler
Constant pressure control mode implies stable pressure of the main steam over the unit’s
entire operating range.
In the Sliding Pressure control mode of operation, the Combustion control system
operates in the manner that Boiler steam pressure varies in proportion to the steam
pressure required at the turbine inlet throttling valves
If the boiler main steam pressure is controlled in a manner that it follows the pressure
required at each turbine load, then this is called the “Pure sliding pressure” mode of
operation However when we speak of sliding Pressure, we often speak of “Modified
sliding Pressure operation” Mode of Operation. In the modified sliding Pressure
operation, the range of pressure control at the boiler outlet is limited. It lies between Pure
and constant pressure mode.
A unit operating at constant boiler steam pressure will have significant load reserve at any
reduced load due to significant capacity available at the Turbine input
throttling valve, but leads to lots of energy wastage as a throttling loss. A pure sliding
operation can not offer a dynamic load response. Therefore modified sliding pressure
mode is used for control.
To handle the rapid and continuous load ramping ( which is of great interest due to high
fuel cost), turbine temperature transients are minimized by operating in sliding pressure
mode
CMC Loop- Control Modes.
CMC control station provides flexibility to the operator to control the Boiler and
turbine in Manual or Coordinated mode depending upon the physical condition of the
Boiler and turbine auxiliaries and operational requirements of unit startup and
shutdown.
In manual mode, the Boiler input demand is manually generated by the operator. Main
Steam pressure is controlled by operating the steam turbine in by-pass mode during the
start-up.
In Coordinated Control Mode, the target load is dictated either by AUTOMATIC LOAD
DISPATCH SYSTEM (ADS) or set manually if ADS is not functional.
The target load signal is processed for minimum/maximum load limits which are
manually adjustable, and corrected for grid frequency variation before feeding to the
Ramp circuit for the generation of Unit load demand. DEFEAT SWITCH is provided to
the operator for introducing the frequency deviation. The Ramp circuit is provided with ‘
down directional blocking to regulate unit load demand during process disturbance.
TURBINE STRESS EVALUATOR ‘HOLD’ signal is interfaced for holding the rate of
integration and load changed rate limits to control load demand variation. In case of Unit
disturbance Run down / Run back conditions are generated and the unit load demand is
automatically reduced to the low limit as permitted by the Process.
The Unit load demand is fed to Boiler Master to generate Boiler demand i.e. Air & Fuel
requirement and to Turbine Control to set Turbine demand i.e. MW.
The Control System envisages the following modes of operation which are selectable
manually:
| 132
COORDINATED
MODE
In this mode both Boiler Master and Turbine Control are put in ‘Auto’ and unit load
demand is fed to both Boiler and Turbine to compute their load demands. The turbine
bypass valves act as pressure relief valves and are generally fully closed.
BOILER FOLLOW MODE
In this mode, the turbine takes the load and the boiler follows. It is adopted when turbine
control is Manual. The turbine sets the MW load and the boiler controls throttle pressure
as a follower.
TURBINE FOLLOW MODE
In this mode, the boiler takes the lead and the turbine follows. The boiler input demand
is manually generated by the operator and the turbine governor system controls the main
steam pressure. It is automatically selected during the Run down / Runback situation.
MW is controlled by the boiler while throttle pressure is maintained by the turbine.
MANUAL MODE
In this mode, both the boiler master and turbine controller are switched over
to manual and the unit is controlled manually.
RUN DOWN/RUN BACK
‘Run down’ is switched ON automatically when the Process error i.e. Feed water, Airflow
etc. becomes excessive and the control element goes to maximum position making the
process uncontrollable. Under the situation, Unit load demand is reduced to a value as
Permitted by the process to get over the blockage.
Similarly, ‘Run back’ is initiated automatically in the event of tripping of unit auxiliaries
ie. BFP, IDF etc. to match unit demand with reduced unit capacity.
‘Up/Down directional blockings’ are introduced whenever process error i.e. Feed water,
Airflow etc. becomes high or the associated control element goes to maximum position to
hold the unit load demand till such time the process
recovers. Under the generator circuit breaker OPEN and turbine trip, the unit is run under
house load operation.
THROTTLE PRESSURE CONTROL
Fixed or Variable Pressure modes of operation can be selected from the Pressure setter.
With Fixed Pressure operation, the set point can be fixed manually while with invariable
Pressure Operation, the steam flow signal representing the load index is programmed
through a function generator to generate Variable Pressure set point. The actual pressure
is measured by 3-redundant transmitters and the median value is taken as the Process
value. The pressure error is given to Boiler Master / Turbine Control as required by the
operation mode mentioned above.
Various Manual interface stations available with the operator
• Coordinated Mode / Boiler follow mode / Turbine follow mode selection station
• Master control auto-manual station to select the load demand signal from the load
dispatch centre or to be set by the operator in a Coordinated mode of operation
• Boiler Master Auto-manual
setter
• Frequency Influence ON/OFF
• Minimum Load limit setter
• Maximum Load Limit setter
Steam Turbine Control
Steam Turbine Control functions include automatic startup and speed control,
synchronization, load control, frequency control and valve testing. The system
includes means to …
Accelerate the turbine to operating speed while providing variable rates of

acceleration
Control electrical load

Test control valves while
maintaining the load
Override the normal valve position signal to prevent the valve from exceeding a limit
Speed Control
The system accelerates the turbine from the turning gear to synchronous speed. An
automatic time v/s speed program is provided to assure a safe and fast startup. In
addition, a rotor stress calculation program may be employed to ensure the turbine will
start up in the minimum time with minimum stress. The operator can adjust the speed
reference and acceleration through any workstation.
Depending upon the turbine design, the unit is synchronized. The speed is trimmed by the
system until speed and phase angle are matched with the line. Note that the median of
three-speed signals is used in the system.
Valve Management
The system provides individual control of all the steam admission valves (main throttle or
stop valves, control or governor valves and the intercept valves). Each valve has a different
purpose depending upon the mode of control. Sequential control of these valves during
startup, automatic load control and shutdown is performed automatically by the system.
Switching control modes is automatic and bump-less.
During startup, when controlling speed, the throttle valve (typically a bypass valve
built into one of the stop valves) controls the steam flow. Under these conditions the
control/governor valves are wide open, thus allowing steam admission to the entire
nozzle block. Depending upon the turbine design, transfer to sequential control
(control valves/governor valves) takes place before or after synchronization. At the
transfer point, the governor valves are closed in sequence and the throttle/stop bypass
valve continues to control steam flow. When the throttle bypass valve reaches its full
open limit, control is transferred to the control (governor) valves that then open in
sequence to increase speed or load. All throttle/stop valves are opened to their limit at
a controlled rate.
When reducing load, the reverse transfer occurs automatically at a preset load point. On
a rapid loss of load, the transfer will take place after the reheater has been unloaded.
Load Control
Load control is used after synchronization takes place and above a preset low load limit.
The system allows the operator to set the load reference in MW and the rate of change or
loading rate in MW per minute. The system will automatically control the governor valves
to increase the load in a linear fashion which duplicates the load demand curve as
established by the operator or the Automatic Dispatch System (ADS).
Note that the system employs the Unit Constraint Coordinator, which permits the
operator to set the loading rate at a level higher than most other systems.
Automation employs a unique approach that uses turbine first-stage pressure (P1), gross
generation (MW) and system frequency in a cascade control loop. This control loop
provides optimum performance, with or without a coordinated control system (CCS). It
makes maximum use of boiler-stored energy and linearizes the governor valves.
Frequency Correction
There are two elements to frequency control – the “natural” element provided by the
turbine control (governor) and the planned element provided by the Energy Management
System (EMS). The turbine control provides for natural frequency correction capability.
Frequency control capability is necessary for area-wide frequency control as well as
system-wide control. Without frequency correction, the network would not be stable.
Frequency correction is the change in steady state speed expressed in per cent of rated
speed when the power output of the turbine is gradually reduced from rated power to
zero power output. It can also be stated as the per cent speed (frequency) change that
results from a full opening or closing of the governor valves. Thus the greater the value of
per cent regulation, the less will be the sensitivity.
% frequency correction = [(S1-S2)/S2] X 100

S1 = Speed at zero load S2 =
Speed at rated load
Per cent, correction is adjustable up to 10% with a nominal setting of 7%. Frequency
correction is used even when the unit is in coordinated control mode.
Throttle Pressure Control
There are circumstances when it is necessary to control pressure with the governor’s
valves. This is normally referred to as turbine follow mode. In this mode, the valves
respond to the throttle pressure error by closing the valves to increase pressure and vice
versa.
Turbine follow mode is normally used when in an emergency condition and it is important
to immediately balance the boiler with the turbine.
If Turbine Base mode is available with the boiler control this can be initiated after boiler
turbine stability has been restored.
Turbine follow mode is automatically initiated when the throttle pressure drops below a
dangerously low limit. This is done to protect the turbine from water induction.
The turbine control system positions the steam admission valves by sending demand
signals to servomotors (servos) mounted on or near the hydraulic valve actuators.
Hydraulic fluid is controlled by the spring-loaded pistons of the servos. An I/O module,
called a “valve positioner”, provides an analogue output to the servo. Since most servos
have two coils, dual outputs are provided.
The “valve-positioner” also has the means to receive two valve position feedback signals
from LVDTs mounted on the valve. The positioning algorithm uses the greater of the two
signals. Since the LVDTs are nonlinear and vary with temperature, means are provided to
calibrate the LVDT periodically.
A proportional-plus-integral (PI) positioning algorithm is executed every 5 ms. The

position demand for each control valve is computed in the Distributed Processing Unit
(DPU) and updated over the I/O bus.
6
The “valve positioner” also can receive a speed signal. The “valve positioner”
includes signal conditioning and a resistor network for matching the coil to
the proper output.
Unit Constraint Coordinator

One of the most significant challenges to operators today is to provide maximum
response to requests for a load change and not overstress ageing plant equipment.
Care must be taken to not put undo stress on super-heater headers, turbine rotors,
reheat headers, boiler drums, as well as pumps, fans and valves.
During a load change the Plant Constraint Coordinator monitors critical

turbine and boiler parameters and will automatically reduce the unit-loading rate if
it is determined that excessive stress is likely to occur. When the transient condition
clears and stress rates are reduced, the loading rate is automatically returned to the
original operator-adjusted setting. The stress determination is calculated in real-
time and is available for review by plant operators.
The Constraint Coordinator also monitors, in real time, the availability of plant
auxiliaries, such as fans, pumps, coal pulverizers, etc. It automatically adjusts the
maximum and minimum limits for load changes based on this availability.
Benefits of Constraint Coordinator
Improve unit ramping rate consistent with instantaneous

load-changing capabilities
Enable unit response to ADS
requirements Operate with stress
limits for extended life
Avoid purchased power cost due to slow load
response Extend the life of auxiliaries

CONCLUSION
The fundamental forms of energy with which thermal stations are principally
concerned are heat and work. Heat produces work and this work is further
converted into electrical energy by the Generator.
A thermal power plant uses a dual (vapour liquid) phase cycle. It's a closed
cycle to enable the working fluid (water) to be used again and again. The cycle used
is "The Rankine Cycle' which is the simplest theoretical vapour cycle and has an
efficiency of 29%.
In a modern thermal power plant, the Rankine Cycle is modified to include

superheating of steam, regenerative feed water heating and reheating of the steam.
Superheating the steam reduces the wetness of the steam at the final stage and
the efficiency of the cycle.
Reheating the steam after it has partially expanded, improves the thermal cycle
efficiency by 4 to 5%. Regenerative feed water heating by using Low pressure and
High-pressure heaters also improves the thermal cycle efficiency by 6 to 7%.
So, the efficiency of a modern thermal power plant is about 42%.

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A STUDY PROJECT

Bachelor of Technology (2022 -2023)

G. RAHUL VARMA Roll No. :21MEB0A22

Under the Esteemed Guidance of

DEPARTMENT OF MECHANICAL ENGINEERING

Mr B. RAGHUVEER Mr. J.V.K. PRASAD

Studying B.Tech. 2nd-year MECHANICAL ENGINEERING at the

Mr. B. RAGHUVEER Mr. J.V.K. PRASAD

Boiler Maintenance, Boiler Maintenance,

We also thank Mr B. RAGHUVEER, A.E./BM/KTPS-VII STAGE

and Mr. J.V.K. PRASAD, DE/BM/KTPS-VII STAGE who helped us with

We are grateful to Mr. B. RAGHUVEER, A.E./B.M./KTPS -VII STAGE

4. CONDENSATE PATH DEVICES

5. STEAM TURBINE INTRODUCTION

7. COAL MILL AND COAL HANDLING PLANT

8. ASH HANDLING SYSTEM

9. ESP (ELECTRO STATIC PRECIPITATOR)

10. WATER PLANT

11. COOLING TOWER & CHIMNEY

2. GENERAL LAYOUT & BASIC IDEA:

“A generating station which converts heat energy of coal combustion into

Schematic Arrangement of Thermal Power Station

1. Coal and ash handling arrangement 4. Alternator

2. Steam generating plant. The steam generating plant consists of a boiler

4. Alternator. The steam turbine is coupled to an alternator. The alternator

6. Cooling arrangement. To improve the efficiency of the plant, the steam

Equipment of Steam Power Station: -

1. Steam generating equipment. This is an important part of the steam

(ii) Boiler furnace. A boiler furnace is a chamber in which fuel is burnt to

(iii) Superheater. A superheater is a device which superheats the steam i.e., it

2. Condensers. A condenser is a device which condenses the steam at the

5. Electrical equipment. A modern power station contains numerous

(ii) Transformers. A generating station has different types of transformers,

The “KOTHAGUDEM THERMAL POWER STATION” is divided into Four main

2.2. REHEAT CYCLE:

2.3. REGENERATIVE CYCLE:

2.4. COAL TO STEAM PROCESS:

2.6. MECHANICAL POWR TO ELECTRICAL POWER

2.1 Boilers, Their Classification and Types:

fluid) contained within the boiler itself.

evolved as a better description of the apparatus.

• Boilers may be classified based on any of the following characteristics:

• Tube shape and position.

Categorization of boilers: Boilers are generally categorized as follows:

• Fire tube type

• Water tube type

• Cast iron boilers

• Special design boilers

2.2 Arrangement of Main Boiler:

The various components of the boiler are briefly described as follows:

furnace to the heat recovery area.

of 1ppm. The drum is located on the upper front of the boiler.

connections, continuous blowdown connections and boiler water sampling connections.

are attached to the two feeder tubes.

horizontal section in the heat recovery area.

of water to remove sludge from the economizer.

air temperature is not high enough to dry coal.

in the low-temperature zone.

2.2.5 Drum level control:

2.2.6 Heat recovery area:

superheater tubes from the heat recovery area.

running outside the boiler to the primary superheater intermediate header.

distribution and cause inefficient heat transfer and possible overheating.