•February 17, 2022 •1

Any abnormal situation which has a potential to result in;

• Equipment damage or Failure
• Unit Outage
• Station Outage

And affecting significantly

• Safety to Human beings and Equipment
• Forced Outage (Down time) / Partial loading
• Efficiency
• O & M cost

Most of the emergencies if handled ably and judiciously, can

mitigate and in some cases can prevent the adverse impact.

•February 17, 2022 •2

• Equipment failures , Operation related emergencies
• Fires , Accidents or Disasters

STEPS TO BE TAKEN DURING EMERGENCIES

• Safety first-don’t take chances
• Follow standard operating procedure.
• Do not easily reach at conclusion on the basic of indication
only it may be spurious. use input from all your resource
available.
• Help in prevention/mitigation and finding root cause.
• Unless until clear about what happen don’t take any auto
loop in manual mode.
•February 17, 2022 •3
•February 17, 2022 •4
Cause
• Running BFP tripped and Stand By BFP did not start on Auto/Manual
• Feed control valve stuck up
• Boiler tube leak
• Sharp drop in load
• Mill force outage
• Furnace draft variation
Effect
• Boiler will trip / Damage may occur if protection bypassed
Action
• Attempt to control with feed control valve on “Manual” (if in auto)
• If the feed control valve is stuck up, open stand by line valve
• Take care while increasing feed flow to avoid running BFP from
tripping.
• If running BFP tripped, Start S/B BFP immediately.
• 2022
•February 17, If drum level decreases below the limit, allow the unit to trip •5
Cause
• Failure of drum level controller
• Extra ordinary increase in load
• Sudden increase in firing rate
Effect
• Water may enter turbine and serious damage to turbine may occur.
• Joints & valves on steam line may leaks(Hammering)
• Carry over with sharp fall in steam temperatures will follow turbine vibration
Action
• Attempt to control with feed valves
• If feed control valve is stuck up, close the valve(MOV/MIV).
• Control the rising drum level with blow down CBD & EBD(Never operate IBD)
• If above measure fails, trip B.F.P.
• If main steam temp. drops, open steam line drains.
• If main steam temp. drops sharply, trip the unit.
• If drum level increases above the limit, allow the unit to trip
•February 17, 2022 •6
Cause
• Faulty operation of ID fan vane control
• Disturbed combustion(Mill trip / mill Overfeed)
• Sudden falling clinkers in furnace
• Soot blowing in operation.
• Burner tilt not in synchronism
• Flue Gas path damper closed
Effect
• Unit will trip if variation is more
• Variation in drum level
• Bottom ash hopper water splashing
• Flame coming out from peep holes may damage equipment / Cables
Action
• Take ID or FD fan control on manual / local
• Disturbed combustion due to mill trouble, take oil support,
• Adjust burner tilt in synchronism
• If furnace draft has increased beyond the limit, boiler will trip.
• If soot blowing is in operation, stop it.
• Check gas path dampers are open
•February 17, 2022 •7
Cause
• FD fan vane closed
• Disturbed combustion : Mill/RCF tripped
• Clinker fallen
• Soot blowing in operation
• Burner tilt not in synchronism
Effect
• Unit may trip on Furnace draft very low
• Variation in drum level
Action
• Adjust FD fan vane manually / locally
• Introduce oil support
• Close HAG of troubled mill
• Stop soot blowing if in operation
• If draft variation will reach trip value, unit will trip

•February 17, 2022 •8

Cause
• Sudden drop in load (which may be due to variation in system frequency )
• Uncontrolled fuel entry, i.e. Over feeding
• Mal operation of pressure controller
• Turbine trips / One of the valves in main steam line closed
Effect
• Disturbance in drum water level
• Safety valve lifts if pressure increases up to that limit
• Generator load increases
• If drum level increases up to trip value, boiler trips
• Boiler may trip on “Boiler pressure very high” trip protection if
incorporated.
Action
• Control fuel input. Closely monitor furnace draft
• Control drum level
• Increase the load on the unit if it has dropped with a look on drum level
• If one of the valves in main steam line closed, the unit has to be tripped
due to unbalanced flow of steam.
•February 17, 2022 •9
Cause
• Electrical motor protection relay operated
• Fan brg. temp. Very high trip
• Motor brg. temp. Very high trip
• loss of lubrication
• loss of cooling water to lubricating/ Hydraulic coupling oil cooler
Effect
• Furnace may get pressurized / disturbed (unit may trip)
• Corresponding FD fan will trip
• Variation in drum level
• May result in damage to equip. / cables if flame comes out from pip holes
Action
• Restore furnace draft by operating running draft fan(auto/manual control)
Reduce the load to @60% by reducing the pressure
• if require Introduce oil support for flame stability.
• Maintain drum level
• Restart the ID fan by checking the cause of tripping and corrective action.
•February 17, 2022 •10
Cause
• Unit Auxiliary bus supply failed (No power supply to run fan)
• One ID fan tripped and second ID fan trips on Over load.
• Running fan trip on fan protection operated.
• Running fan trip on fan Motor protection operated.

Effect
• Unit will trip on loss of both ID Fan.
• Both ID fans discharge and suction dampers wide open

Action
• Start ID fan by taking corrective action.
• Purge the boiler and lit-up the boiler.

•February 17, 2022 •11

Cause
• Corresponding ID Fan tripping
• Electrical motor protection operated
• Fan/motor brg. Temp. Very High
• Loss of lubrication oil or cooling water to lubricating oil cooler
Effect
• Furnace may get in suction
• Corresponding I.D. Fan will trip (If in logic)
• Bottom elevation 3 mills will run and other mills will trip
• Total air flow declines Furnace will disturb.
• Drum level get disturbed
Action
• Restore furnace draft by operating running draft fan(auto/manual control).
• Reduce the load to @60% by reducing the pressure
• Restart the FD fan by checking the cause of tripping and rectifying it by
corresponding corrective action.
• Maintain drum level
• If require Introduce oil support for flame stability
•February 17, 2022 •12
Cause

• Fan trips due to any of the reasons

• Unit Aux supply failed
• One FD fan has tripped on one of the following reasons and second FD fan
trips on Over load.
• Running fan trip on fan protection operated.
• Running fan trip on fan Motor protection operated.

Effect

• Unit trips on both FD fan trip

Action
• Restart FD fans after removing cause of tripping.
• Restart the boiler

•February 17, 2022 •13

Cause
• Electrical motor protection operated
• Fan/motor brg. Temp. Very High
• Class “A” or “MFT” operated
Effect
• Pulveriser will trip till bottom 3 pulveriser remain in service.
• Flame will disturb
• Drum level will go down
• All pulveriser will trip if PA Header Pressure went down to trip value.
Action
• Reduce the load on the unit controlling drum level.
• Introduce oil support for flame stability
• Close the discharge damper of the tripped fan if it has not closed.
• Restart the fan after taking corrective action.

•February 17, 2022 •14

Cause
• Unit Aux supply failed
• One PA fan has tripped on one of the following reasons and second PA fan
trips on Over load.
• Electrical motor protection operated
• Fan/motor brg. Temp. High
• Class “A” or “MFT” operated

Effect
• All pulverizes will trip.
• If no RFO in service, unit will trip.
• Variation in furnace draft and drum level

Action
• Restart the fan after taking corrective action.
• If unit had tripped restart it after purge.
•February 17, 2022 •15
Cause
• Motor overloaded
• Loss of power supply
• Water on rotor post from Eco hopper leads to uneven metal temperature.
• Rapid firing in furnace during post overhauling start-up.

Effect
• Hydraulic coupling failure due to jamming
• Tripping of APH
• Mill outlet temp. drop sharply

Action
• Reduce the load upto 60%
• Introduce oil support for flame stability
• Maintain mill outlet temp.
• Restart the APH after taking corrective action.
•February 17, 2022 •16
Cause
• Malfunction of Desuperheating spray station valves.
• Top elevation mills in service
• High burner tilt
• High excess air
• Low feed water temperature
• HP Heaters not in service
• Sudden increase in firing rate to increase steam pressure.
Effect
• Rise in positive turbine expansion
• Creep rate increases in tube metal, turbine parts, steam piping
• SH / RH tube may failure if desired action not performed.
Action
• Slow down firing rate
• Reduce excess air
• Check spray valve and burner tilt
• Adjust mill loading, increase loading of lower elevation mills, reduce loading
on top mills, if possible change mills
• Initiate wall blowers and restore spray and burner tilt
•February 17, 2022 •17
Cause
• Fouling/ slagging on SH and RH Tubes
• Malfunction of Desuperheating spray station valves and burner tilt.
• Tripping of top elevation mills
• High Economiser inlet temp.
• Sharp increase in load and pressure drop.
• High drum level (Priming / carry over in drum)
• Wall blowing in operation
Effect
• Turbine expansion may go towards negative
• Chilling may occur resulting in thermal stress.
Action
• Operate long soot blowers
• Control manually desuperheating spray station valves.
• Increase burner tilt
• Check feed water temp.
• Avoid
•February sharp rise in load and pressure drop
17, 2022 •18
Cause
• Only oil in service and Oil burner flame is disturbed.
• Mill force outage(particularly when high ash low volatile coal in use).
• Mill in service are at gap and loading of mills are less (Poor ignition energy)
• Chockage of any one discharge pipe of mill in service
• Water wall tube failure
• Soot blower operation at low load.
• Falling of clinker in furnace.
• ID /FD fan vane malfunctioning.
Effect
• Flame will become unstable
• Fluctuation in furnace draught
• Secondary fuel (Oil) consumption if used for flame stability
• Unit may trip on “Flame failure” or “Furnace draft high / low”.
• Increase in Fly /Bottom ash unburnt.
•February 17, 2022 •19
Action
• It can be visualized by naked eye or flame intensity meter.
• Check oil burners in service, change it, if required replace it
• Check furnace for tube failure
• Put oil support to coal burner, if the flame is not much disturbed.
• Check the mill discharge pipes.
• Adjust the furnace to mill differential pressure to 40 mmwc if load is less than
30% or 100 mmwc if load is more than 30% .
• Close HAG of mill in which coal interruption took place
• Adjust fuel air ratio if it is less
• Stop soot blowing operation. Operate all LRSB & WB after stable operation.
• Keep oil support during soot blowing if required at part load.
• When boiler load is less than 30% keep at least 3 out of 4 guns in mill
elevation or if mill loading is less than 50% adjacent mill loading should be
more than 50%.
• Keep close watch on excess air.
• Maintain min. 30% of air during lit up & low load to ensure air rich furnace
•February 17, 2022 •20
Cause
• Entry of unburnt fuel during lit-up
• Inadequate air (very high CO ppm in flue gas)
• Starting of mill with out proper igniting energy
• Secondary combustion
• Fuel did not cut off after unit trip on MFT
Effect
• Furnace explosion can cause severe damage to water wall , SH, RH , steel
structure etc.
Action
• Ensure fuel inlet valve, PA fan and hot air gate to mills are closed with unit
tripping.
• Do not introduce fuel without sufficient ignition energy.
• Intact Flame failure, Loss of all fuel, Furnace draft high / low protections
• Regularly check proper functioning of FSSS equipments
•February 17, 2022 •21
Cause
• Starvation (Boiler did not trip on low drum level)
• Sustained flame impingement on water wall tube
• Block tube, eroded tube, Soot blower steam impingement & Salt deposition
Effect
• Erosion of other tubes
• Fluctuation in draft (unit may trip)
• Unstable flame (unit may trip)
• High feed flow for given steam generation(High make up)
• Increase in ID Fan Loading, Lower flue gas temp. & Loud noise.
Action
• Every shift check the furnace, listen furnace to detect steam noise.
• Check flame not impinging furnace water wall.
• Rise in DM water consumption may be due to leak.
• Once the leak is confirmed, start reducing load to avoid further damage.

•February 17, 2022 •22

Cause
• Ash erosion is the prime cause
• Pitted - corroded- thinned tube (Erection problems)

Effect
• Increase in ID Fan loading
• Drop in flue gas temp after Economizer
• Noise in Economizer zone
• Water coming from Economizer hopper
• High DM water consumption
• Economizer hoppers Ash evacuation problems

Action
• Rise in DM water consumption may be due to leak.
• Continuously monitor Flue gas temp.
• As soon as leakage is detected, start load reduction boiler at earliest possible
• Try to locate leak through manholes before boiler is depressurized.
• Every shift check Economizer hoppers for water leakage.

•February 17, 2022 •23

Cause
• Sustaining high metal temp due to high flue gas temp at boiler outlets on
account of heavy slagging on Water walls OR inadequate steam flow and high
flue gas temp. during hot start up.
• Erosion on tubes, Blocked tubes, Salt deposition in tubes due to Carry over.
Effect
• Increase in ID Fan loading
• Drop in flue gas temp
• High feed water consumption compared to steam flow
• Erosion of other tubes and subsequent damage
Action
• As soon as leakage is detected, start load reduction at earliest possible.
• Try to locate leak through manholes before boiler is depressurized. Particularly
during Reheater tube leak, once the boiler is hand tripped, Reheater will
depressurized and later on to be back charged from other source to locate the
leak.
• Rise in DM water consumption may be due to leak.
•February 17, 2022 •24
Cause
•Unburnt fuel oil.
•Oil used for preservation of baskets
Effect
•fire may occur during Unit start up.
•Improper combustion may results in unburned or partially burned oil condensing and
depositing of the air preheater heating element surface.
•This deposit can ignite ,as temperature increases to 315 to 370 deg.
•Ignited deposit remains undetected it will continue to generated heat until the metal
heat transfer elements reaches 730 to 765 deg. C .
•At this point metal may ignite with temperature reaching 1650 deg. C and higher. 
•Metal fires are self – sustaining and would require more water than is normally
Action
•Trip the boiler immediately and Stop ID & FD fans
•Open APH Fire water valves.
•Open APH hopper plugs .
•Ensure fire is completely extinguished.
•February 17, 2022 •25
Cause
• Excessive mill outlet Temperatures.
• Excessive Accumulations of Pyrites or Coal on the Mill Bottom or in the air inlet.
• Excessive Accumulations of coal in areas above the Bowl:
• Improper or Unusual Operation.
Effect
• Mill outage and it may damage .
Action
• Close the hot air shut off gate.
• Keep feeder on manual control and continue feeding coal at high rate.
• Cool the mill by admitting steams or water.
• after the mill outlet temperature has dropped and all sign of fire has gone;
• Shut off the steam or water being admitted to the system.
• Stop the feeder.
• Run the mill for several minutes to completely purge the system and to reduce
the possibility of accumulation of water.
•February 17, 2022 •26
•February 17, 2022 •27
Cause
• Motor protection relay operates.
• Working oil temperature high.
• Discharge flow very high.
• Discharge Temp high
• Suction pressure low/dearator level very low.
• Lube oil pressure very low.
• Motor bearing temp high.

Effect
• Drum level will start going down.
• Another pump will start if on auto.

Action
• Start another pump manually.
• After starting check its check operation of recirculation, warm up and C.W.
valve operation.
• Decrease the drum level control valve manually if the earlier feed pump had
tripped on feed flow very high.
• Analyse the tripping of feed pump and put back in available condition.
•February 17, 2022 •28
Cause
• Motor protection.
• Hotwell level very low.
• CEP discharge pressure very low (not on discharge header
pressure).

Effect
• Deaerator level will start falling.
• Hotwell level will start increasing.
• Condenser vacuum will start falling.
• If no CEP is running unit will have to be tripped.

Action
• Start standby CEP if it not starts on auto.
• If only one pump is running then reduce the load accordingly.
•February 17, 2022 •29
Cause
• Excess make up to hot well and faulty deaerator level regulator

Effect
• Risk of water entering to LP turbine gland through steam piping of
LP gland steam is being taken from deaerator.
• Risk of water entering in PRDS steam piping and the temperature
of the steam will reduce.
• Overflow valve will open if deaerator system is on auto.

Action
• Check the operation of deaerator level controller if necessary
take it on manual.
• If level is too high open overflow valve.
•February 17, 2022 •30
Cause
• Mal operation of DEA level control valve.
• Closure of valve between CEP and deaerator.
• Boiler tube leakage.

Effect
• Danger of loss of suction pressure of boiler feed pump.
• Drum level will go down.
• To maintain drum level we have to, reduce the load on the unit.

Action
• Check the DEA level control valve.
• Open the valve between CEP and deaerator if found close.
• Feed the boiler until there is some danger of cold-water entry and thermal
shocks on drum-if water tube leakage is heavy, trip the unit.
• If suction pressure is low and not increasing –switch off the feed pumps and
trip the unit.
• If CEP trip at full load start standby pump and to maintain deaerator level.
•February 17, 2022 •31
Cause
• HP heater drain to deaerator level controller is faulty (not operating properly)
or control valve stuck up.
• HPH-6 drain to HPH-5 valve do not open/operate.
• Deaerator pressure is higher than normal.
• Inadequate extraction pressure to HP heater.
• Tube failure In HP heater
Effect
• HP heater’s drain to FLASH tank will open on HP heater level V.high.
• HP heater get by passed from water and steam side on auto.
• If level in HP heater build up rapidly there is a possibility of water entering into
the turbine.

Action
• Take HP heater’s level controller on manual and maintain the level.
• Check the operation of heater’s drain valve. Open it manually if required.
• Adjust deaerator pressure if it is more.
• Adjust the steam extraction pressure if valves are throttle open them.
• By pass HP heaters manually if level is very high and are not getting by passed
automatically.
•February 17, 2022 •32
Cause
• LP heater level may go high due to difficulty in level controller.
• Tube failure in LP heaters.
• Low extraction pressure in LP heaters

Effect
• Possibilities of water entering into turbines if level are high and
un-controllable.

Action
• Check the level controller of the heaters, if require take it on
manual and try to maintain the level.
• Adjust the extraction pressure of valves are throttle.
• By pass the heaters if level in LPH are high and uncontrollable

•February 17, 2022 •33

Cause
• Air lock in oil cooler.
• MOP suction failure.
• Duplex oil filter chocked up/line filters chocked up.
• Leakage in oil lines flanges, bearings etc..
• Excessive oil consumption in generator seal oil system.
• MOP failure.
• Rise in brg. Metal temperature.
• Turbine trips on lubrication oil pressure Very-Low
Effect
• Bearing lubrication will insufficient leads to metal temp. rise
• Possibilities of Bearing damage
• Turbine get trip on bearing temp very high.
Action
• Check for any oil leakages.
• Trip the turbine if oil pressure does not improve.
• Check the oil cooler change over the defective one to the stand by. Remove
the air lock from the cooler.
• Check the oil filters regularly change over to stand by. If difference in pressure
increase gets it clean.
•February 17, 2022 •34
Cause
• Water side valves in oil coolers are open more than required.
• Malfunctioning of turbine oil temp. control valve.
• Check Turbine oil temp. control valve in auto and SLC “ON”.

Effect
• Unstable oil film in bearings.
• It may damage the bearings.
• Brg. Vibration may rise.
• Sluggish operation of turbine control valves.

Action
• Throttle the cooling water valves of the oil coolers. (if required).
• If the machine is off load-do-not roll it till oil temperature attains an acceptable
working value.
• If the machine is on-load-temperature should be rapidly raised to the
acceptable.
• Oil centrifuge heater can be taken in service.
•February 17, 2022 •35
Cause
• Failure of DMCW system.
• Oil coolers are dirty. (Heat transfer is very low).
• Air locking in oil coolers.
• Malfunctioning of turbine oil temp. control valve.
• Check Turbine oil temp. control valve in auto and SLC “ON”.

Effect
• Rise in brg. Metal temperature.
• Brg. Vibration may rise.
• Rise in seal oil temperature.

Action
• Restore the DMCW system
• Remove the air lock from the cooler by proper venting.
• Put stand by oil cooler in service if available.
• Trip the unit if lubricating oil temperature rises continuously and is
uncontrollable.

•February 17, 2022 •36

Cause
• Motor protection relay operated.
• 6.6 KV auxiliary supply failure.

Effect
• Turbine vacuum will fall.
• Lubricating oil temperature, seal oil temperature and H2 temperature may rise
unit will trip exhaust pressure hi-hi if all CW pumps trip.

Action
• Restore CW pump/pumps after checking.
• Start the stand by CW pump immediately if available.
• Reduce the load on machine till the 2nd pump is taken in service.
• Restore 6.6 Kv auxiliary supply starts the pump.
• Trip the unit, if vacuum drops considerably.
• Watch the exhaust hood temperature and LP differential expansion. If
disturbed try to control.

•February 17, 2022 •37

Cause
• Oil leakage from oil lines.
• Bearing oil collected on laggings and reaches to the ignition point.

Effect
• Extensive damage to the turbine and surroundings.

Action
• Take care of oil leakage and try to arrest it.
• Use dry CO2 powder as soon as smoke is detected. Inform the fire section. If
the fire is extensive use CO2 powder cylinders.
• Trip the turbine, if fire is beyond control.
• Expel the H2, if fire is near the H2 zone (with CO2).
• Do not allow the oil to lodge on the leggings. Take corrective and do not
neglect even very small leakage or collection of all to prevent the fire.

•February 17, 2022 •38

Cause
• Oil leakage from oil lines.
• Short circuit
• Maintenance work.

Effect
• Extensive damage to the MOT , Turbine and surroundings.

Action
• When MOT fire take place operate the push button of Fire Protection 2 from
desk, or from MOT area.
• Take care of oil leakage and try to arrest it.
• Inform the fire station, Use dry CO2 powder as soon as smoke is detected.
• If the fire is extensive use CO2 powder cylinders.
• Trip the turbine, if fire is beyond control.
• Expel the H2, if fire is near the H2 zone (with CO2).
• Do not allow the oil to lodge on the leggings. Take corrective and do not
neglect even very small leakage or collection of all to prevent the fire.
•February 17, 2022 •39
Cause
• CEP trip/Vacuum pump trip/CW Pump trip/CT FAN tripped.
• Loss of gland steam pressure.
• Defect in gland steam pressure regulator.
• Improper sealing of valves/glands in the vacuum system.
• Air ingress in vacuum system or puncture.
• Mal operation of vacuum breaker valve.
• Deaerator level control valve stuck up.
• Mal operation of heaters vent/drain valve to atmosphere.
• Over head Surge tank empty.

Effect
• Vacuum may drop slowly.
• If it drops rapidly-unit will trip on exhaust pressure hi-hi.
• Over heating of LP turbine casing and exhaust hood.

•February 17, 2022 •40

Action
• Start stand by CEP/ Vacuum pump/CW pump/CT FAN if available.
• Try to make available tripped pump and reduce the load simultaneously.
• In case of gland steam lost, please check the Header pressure, if it is not
proper maintain it by opening it’s control valves bypass valve if required.
• In case of defect in gland steam pressure regulator, put it on manual or
control by bypass valve.
• Check the sealing water to valves/glands in the vacuum system maintain it.
• Check the position of vacuum breaker valve. It should be close.
• Check the position if deaerator level control valve, if it has stucked up in close
position
• Change over the vacuum pump if the first one is not maintain vacuum.
• Check vent/drain valves of heaters.
• If vacuum falls at a faster rate, trip the unit immediately.
• Check the surge tank level if it is empty fill it.

•February 17, 2022 •41

Cause
• Vacuum falls/CW pump trip.
• High steam temperature during cold start up.
• Turbine running at 3000 RPM without synchronizing/or running at low load for a longer period. (Churning)

Effect
• LP differential expansion will go towards negative side.
• Prolonged high exhaust hood temperature may lead to vibration

Action
• Check the reason for the fall in vacuum.
• Start stand by C.W. pump if available.
• HP drains to condenser hot well should be reduced.
• Control system temperature and pressure during the cold start.
• Control gland steam pressure and temperature.
• Start make up water spray in condenser.
• If machine is required to run at 3000 RPM (or at lower load) for a longer time, take following necessary action to control the
exhaust hood temperature (make-up) surplus can be establish to check temp rise.
• Keep the vacuum as high as possible.

•February 17, 2022 •42

Action
Cause
• High lubricating oil inlet temperature to the turbine bearing.
• Excessive vibration of the bearing.
• Bearing failure.
• Contaminated lubricating oil high moisture dirt etc.
• Inadequate oil flow or low lubricating oil pressure.

Effect
• Result to bearing failure.
• Increment in bearing vibration.

Action
• Check and maintain the oil temperature, oil pressure, oil low flow through the turbine bearing. Check duplex oil
filter DP, if requires change over it.
• Check the oil for moisture and contamination periodically. Keep oil continuously in service as per recommendation.
Drain the collected water from the MOT regularly.
• Keep watch on oil cooler out let temperature.

Action
•February 17, 2022 •43
Cause
• Abrupt changes in load ,Sudden drop in steam temperature.
• Sudden drop in vacuum.
• Lubricating oil failure to thrust bearing.
• Silica deposition in turbine.
• Worn out of thrust pads.

Effect
• Overloading of thrust pads.
• May contribute turbine vibration.
• Abnormal turbine differential expansion.

Action
• Check the boiler parameters and control the sudden changes.
• Control the turbine vacuum.
• Reduce the unit load.
• Check the flow pressure and temperature through bearing.
• For deposition of silica, unit shut down is required for washing the turbine.
• If axial shift has increased rapidly and is beyond control even after reduction in load trip the m/c and bring to standstill
condition as soon as possible.

Action
•February 17, 2022 •44
Cause
• High steam temperature.
• Poor insulation.
• Gland steam temperature high.
• Fast rolling or fast load ramp up.
• Inadequate soaking period.
• High condenser vacuum, (LP effect on differential expansion).
Effect
• Seal rub can be expected.
• Metallic rub sound from the turbine when interference exist.
• Turbine vibration may increase.
Action
• Soak the turbine properly.
• Load the turbine gradually.
• Check the insulation and if found poor get it attended.
• Remove the silica deposition by washing if required.
• If it is beyond control try to control the boiler parameters and if turbine is tripped, drop the vacuum immediately.
• If LP differential expansion is increasing drop the vacuum to a certain extent (to an acceptable limit).

Action
•February 17, 2022 •45
Cause
• Time taken during rolling, and loading is more than required or rolling at 3000 RPM for longer time.
• Increment in exhaust hood temperature.
• Low condenser vaccum.

Effect
• Seal rub can be expected.
• Metallic rub sound from the turbine when interference exist.
• Turbine vibration may increase.

Action
• During hot start up rolling and loading of the machine should be as per the starting curve.
• Start standby vacuum pump to improve the vacuum.
• Try to bring down the exhaust hood temperature.
• If turbine tripped due to -ve maximum differential expansion open the vaccum breaker to avoid the possible damage.
• Increase the boiler steam temperature and load the machine asap.
• If differential expansion is extremely -ve and machine rolling has started don’t trip the turbine control the boiler
parameters.

Action
•February 17, 2022 •46
Cause
• Rapid changes in the turbine inlet steam temperature
• Low lubricating oil temperature.
• In correct shaft alignment ,Rotor mechanically unbalance or Eccentricity high.
• Uneven expansion (high differential expansion and temperature difference
between top and bottom cylinder exceeds).

Effect
• Eccentricity may go high.
• If machine is allowed to run at higher vibration may damage the machine.

Action
• Roll the machine smoothly with rated acceleration rate (dn/dt)
• Maintain the steam parameters.
• Maintain the lubricating oil pressure & temperature.
• Check the gland steam temperature and pressure.
• Control the differential expansion
• Control the eccentricity if found high.
• Reduce the unit load, if bearing vibrations are still high.
• Rotor balancing to be done in case of unbalancing.
•February 17, 2022 •47
Cause
• Corrosion erosion of the tubes.
• Condenser inlet CW pressure high-leads to take the tube from expanded part.
• Low CW flow through condenser tube causing the high terminal difference.
Effect
• Conductivity of condensate will go high.
• Boiler PH will fall and boiler water conductivity will rise.

Action
• Isolation one PASS of the condenser and ensure, if conductivity falls after the
isolation or not.
• Reduce the turbine load by 50%.
• Repair the leakage and after bringing back the condenser in to service, check
the conductivity.

•February 17, 2022 •48

Cause
• Sudden increase in air consumption.
• Sudden line leakage develops.
• Air compressors trip.
• 415 V auxiliary supply is not available.

Effect
• All the auto controls using air will become inoperative
• Burner tilt gradually slips down to extreme minimum position.
• BFP recalculating valves will open and the BFP may trip on feed flow high.
• Boiler drum level deaerator level hot well, HP & LP heaters level expander level
etc. will have to maintained by operating the local valves (may by pass valves).
• Unit may trip due to disturbances.
Action
• Lock the burner tilt at horizontal position.
• Try to put the compressors into service.
• Isolate the leaky airline, if possible and restore the system back.
• Restart the unit, if it has tripped after taking corrective action for instruments.
•February 17, 2022 •49
 THANK
YOU

•February 17, 2022 •50