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KORBA SIMULATOR 1

KORBA SIMULATOR 2
KORBA SIMULATOR 3
CONTENTS

CHAPTER NO. TOPIC PAGE NO

1. CHARGING OF ELECTRICAL SYSTEM 7-11

2. CONDENSATE AND FEED WATER SYSTEM

CEP OPERATION 15-20

BFP OPERATION 21-28

3. BOILER SYSTEM

AUXILIARY PRDS CHARGING 31-32

HEAVY FUEL OIL SYSTEM CHARGING 33-34

FSSS LOGICS 35-74

AIR PRE-HEATER OPERATION 75-78

ID FAN OPERATION 79-84

FD FAN OPERATION 85-88

FURNACE PURGE 89-91

BOILER LIGHT UP 92-96

PA FAN OPERATION 97-102

PULVERISER OPERATION 103-108

4. TURBINE AND GENERATOR SYSTEM

VACUUM PULLING 111-114

HP/LP BYPASS CHARGING 115-116

TURBINE START-UP 117-120

TURBINE ROLLING 121-124

KORBA SIMULATOR 4
GENERATOR SYNCHRONISATION 125-128

UNIT SUPPLY CHANGEOVER 129-130

LP HEATERS CHARGING 131-132

HP HEATERS CHARGING 133-134

SH/RH STEAM TEMPERATURE CONTROL 135-136

SOOT BLOWING OPERATION 137-139

5. UNIT COLD START-UP 141-156

6. UNIT HOT START-UP 157-162

7. AUTOMATIC TURBINE RUN-UP SYSTEM (ATRS) 163-208

SGC OIL SYSTEM 171-182

SGC TURBINE SYSTEM 183-208

8. UNIT PLANNED SHUTDOWN

BOILER SHUTDOWN 211-212

TURBINE SHUTDOWN 213-215

GENERATOR SHUTDOWN 216

9. EMERGENCY HANDLING 217-255

10. EFFICIENCY ASPECTS OF POWER PLANTS 257-288

11. SIMULATED MALFUNCTION LIST 289-296

12. APPENDIX

BOILER STARTUP CURVES 299-306

TURBINE STARTUP CURVES 307-317

KORBA SIMULATOR 5
CHARGING OF ELECTRICAL SYSTEM

KORBA SIMULATOR 6
KORBA SIMULATOR 7
CHARGING OF ELECTRICAL SYSTEM

UNIT POWER SUPPLY: SINGLE LINE DIAGRAM

ACTION OBSERVATION REMARKS

1. ENSURE all the - ADEQUATE service air - Local check/ operation.


following conditions pressure is available Not simulated.
are satisfied, before for 400 KV breakers
charging the unit (30 Kg/cm2 )
HT/LT buses.
- Bus section coupler on - Switchyard check.
400 KV lines is
CLOSED

- Bus-coupler on 33 KV - Switchyard check &


Bus in OPEN. operation

KORBA SIMULATOR 8
- Tie Xmers 1 & 2 are - Switchyard operation.
CHARGED from 400 Not simulated.
KV and 33 KV sides.

- 33 KV bus voltage is - Switchyard check.


NORMAL.

- 220 V DC supply is - Switchyard check.


AVAILABLE.

- All the protections are - EMD Engineer's


HEALTHY and in clearance, required.
SERVICE.

- Bus couplers - Not simulated.


connecting buses SA &
SC and SB& SD are
OPEN.

- Station transformer's - Not simulated.


incoming breakers
from 33 KV buses
outgoing to 6.6 KV
buses (SA, SB, SC &
DC) are CLOSED.

"Power available" - Common Station


indications are ON, to Supply Auxiliary
all the four station Electrical Panel.
buses (SA, SB, SC & C.S.S.A.E.P.
SD).

2. CLOSE both the HT Buses I A and I B get UCB Operation/check.


(6.6 KV) incomer charged and their
breakers to unit voltages come to 6.6
auxiliary buses 1-A KV , " 6.6 KV bus
and 1-B from station volts/ VT trouble",
buses SA & SB. alarm gets reset.

3. CLOSE the H.T. side - Bus sections LA and - UCB indications.


breakers and then L.T. LB get charged and
side breakers of the their voltages come to
unit service 415 V (approx.)
transformers (UST).

- USTs in rush current - UCB indication.


momentarily shoots up
meter pegs out and
drops to no load value.

- All the "power/control - UCB annunciation.

KORBA SIMULATOR 9
supply fault" and
"UATs cooler/ OLTC
trouble and "415 V
boiler/turbine MCC
fault" annunciations
reset.

4. CLOSE the normal - AC emergency section - UCB operation


tiebreaker to AC tie breaker gets
emergency section. charged and voltage
shows 415 V (approx.)

- All annunciations - UCB indications


pertaining to
Emergency MCC get
reset.

5. CLOSE the incomer - "ESP switch gear - UCB indication


breakers to ESP & trouble" alarm gets .
lighting Xmers. reset.

KORBA SIMULATOR 10
KORBA SIMULATOR 11
CONDENSATE
AND
FEED WATER SYSTEM

KORBA SIMULATOR 12
KORBA SIMULATOR 13
CEP OPERATION
PRE-START CHECKS OF CEP

CONDENSATE SYSTEM

ACTION OBSERVATION REMARKS

1. CHECK if all start - CEP suction valves - Local operation.


permissive for starting MC-1/MC-2 are OPEN.
CEP is satisfied.

- Hot well level is - UCB indication. Also to


ADEQUATE (300 mm be locally checked.
wcl.)

- Bearing temperature of - UCB indications and


CEPs is NOT HIGH 60 also to be locally
0 C.) checked

- CEP re-circulation - Hotwell level controller


valve MC-33 is OPEN output is zero.
100%.

KORBA SIMULATOR 14
- CEP discharge valves - UCB operation.
are CLOSED (MC-5/ Interlock, before
MC-6). starting the first CEP.

2. CHECK that CEPs are - Condensate pump - Local operation. Not


locally lined up for gland sealing water- simulated.
starting. isolating valve is
OPEN.

- Condensate pump - Local operation Not


priming (pressure simulated.
equalising) valve is
OPEN.

- CEP bearing cooling - Local operation. Not


water line isolating simulated.
valve is OPEN.

- CEP bearing oil level is - Local check.


adequate.

- Local emergency push - Local operation check.


button is released.

- CEP electrical supply is - Breaker is in


AVAILABLE. Service/Remote
position.

3. ENSURE condensate - Main ejectors - Local operation. Not


system is lined up inlet/outlet- valves are simulated.
before starting CEP. OPEN (MC-11/MC-12
and MC-13/MC-14).
Bypass valve (MC-15)
is closed.

- Gland steam cooler - Local operation. Not


inlet/outlet valves MC- simulated.
19/MC-20 are open
and bypass valve (MC-
21 is CLOSED.

- LPHs (1-2-3) inlet/ - Local operation


outlet valves (MC- (Remote function).
61/MC-63, MC-67/
MC-68, MC-72/MC-73)
are CLOSED.

- LPHs (1-2-3) bypass - Local operation. LPHs


valves (MC-64/MC- are bypassed initially
69/MC-74) are OPEN. to minimise corrosion.

KORBA SIMULATOR 15
- Deaerator inlet valve - Local check Not
(MC-75) is OPEN. simulated.

- CEP header vents and - Local operation Not


line vents OPEN. simulated.

- HW level controller, DA - UCB operation and


level controller and check.
cycle make-up
controller valves are
CLOSED. (MC-27,
MC-41 and MC-55)

- Bypass valves of HW, - UCB operation and


DA and cycle make-up check.
controllers (MC-
28/MC-42/MC-55
respectively) are also
CLOSED.

- Local operator - Use plant PA system to


intimated prior to inform the operator.
starting of pump.

GLAND STEAM COOLER AND EJECTOR CONNECTIONS

KORBA SIMULATOR 16
STARTING PROCEDURE OF CEP

WHEN BOTH THE PUMPS ARE OFF

ACTION OBSERVATION REMARKS

1. CHECK before starting - All pre-start checks are - Local /UCB checks &
any condensate pump. OVER. operation

- All permissive are - Associated saffron


AVAILABLE. lamps on.

2. START the CEP motor. - CEP starting current - UCB ammeter


comes down to 20A indication.
after 5 sec.

- CEP discharge - UCB indication.


pressure increases to
25 Kg/cm2. Approx.

- CEP's discharge valves - Associated red lamps


(MC-5 MC-6) open come on.
100%.

3. CLOSE the air vents on - The air vents are - Local operation Not
condensate lines. locally closed. simulated

4. LOAD the condensate - CEP current starts - UCB ammeter.


pump by opening MC- increasing
27.
- CEP discharge - UCB check.
pressure decreases
proportionately.

- Condensate flow to - UCB indication.


D/A starts increasing

5. INSTRUCT the local - Limiting values of - UCB OMNIGUARD brg


operator to check bearing temp and temp and vibration
bearing temperatures vibrations are: indicators must be
and vibrations. regularly checked.

Alarm Trip
Bearing Temperature 75 oC 90 oC
Vibration 40 microns 75 microns

KORBA SIMULATOR 17
6. CHECK that the - Breaker control switch - UCB control switch on
second condensate is on 'Normal After 'off' position
pump is ready for Stop' position.
starting and is
available on STANDBY.

- Pump OK standby - All permissive are - UCB check.


SATISFIED.

- All local line ups are - Refer to pre-start


COMPLETE checks list.

WHEN ONE PUMP IS RUNNING

ACTION OBSERVATION REMARKS

1. CHECK before- - All pre-start checks are - UCB/local check.


starting the second OVER.
condensate pump that
all these conditions
are satisfied.

- All permissive are - All associated saffron


AVAILABLE LAMPS ARE ON.

2. START the CEP motor - CEP motor breaker - At a discharge


gets closed. pressure of 17.5
Kg/cm2., the standby
- CEP discharge header CEP can take start
pressure improves a automatically.
little.

- The motor current of


the other CEP drops
slightly.

- CHECK bearing - Bearing temperatures - UCB OMNIGUARD


temperatures and and vibration limits are and vibration
vibrations locally. indicators must be
monitored regularly.

Alarm Trip
Bearing Temperature 75 oC 90 oC

Vibration 40 microns 80 microns

KORBA SIMULATOR 18
CEP SHUTDOWN PROCEDURE

WHEN ONE PUMP IS RUNNING

ACTION OBSERVATION REMARKS

1. Start the other CEP if - Discharge pressure - Maintain hotwell level


it is available. improves slightly approx 500 mm wcl.

- MC-27 closes slightly


on auto.

2. STOP the first - Discharge pressure - Hotwell level HI alarm is


condensate pump. falls slightly. at 600 mm wcl.

3. CLOSE the suction - Suction and - Hotwell level LO Alarm


and discharge valves. discharge valve 400 mm.
If any maintenance is closed indication
to be carried out, comes on.
rack-out the motor
breaker.
- Hotwell level LO-LO Trip
is at 250 mm wcl.

WHEN BOTH PUMPS ARE RUNNING

ACTION OBSERVATION REMARKS

1. TRANSFER MC-27 - Manual mode on - M/A release push


control to MANUAL indication comes button must be pressed
and CLOSE it to 20% on. for all auto/ Manual
approx. change over.

- Discharge header
pressure goes up
slightly.

STOP the CEP motor. - The discharge - If required, close MC-27


header pressure more to maintain
may tend to drop discharge header
further. pressure.

KORBA SIMULATOR 19
BFP OPERATION

PRE-START CHECKS OF BFP

ACTION OBSERVATION REMARKS

1. CHECK all the - Deaerator level is - UCB indication, also


BFP start ADEQUATE (700 mm wcl) check locally.
permissive is
satisfied before
starting any BFP.
- BFP suction valve (FW- - Local operation.
1/FW-2/FW-3) is OPEN UCB permissive
100%. indication. Not
simulated
- BFP booster pump suction - Local check. UCB
pressure is ADEQUATE indication for
(>3.0 KSC) permissive.

- BFP pneumatic re- - Re-circulation


circulation valve (FW- controller output is
8/FW-9/FW-10) is 100% 100% and valve
OPEN. open indication
available.

- BFP manual re-circulation - Local check only.


valves at the Deaerator are Not simulated.
100% OPEN.

- BFP cooling water pressure - Local operation and


is ADEQUATE 2.5 Kg/cm
2 check.

- BFP bearing temperatures - UCB and local


are less than 60 OC. CHECK Saffron
lamp on indication
is available.
- BFP lub oil pressure is - AOP for the BFP is
ADEQUATE (2.0 Kg/cm ).
2 on and on "Remote".
If not, start the AOP
from UCB.
- BFP selector switch is on - For UCB operation
NORMAL. (interlock).

- BFP scoop tube is on - Operator check only


MINIMUM position.

KORBA SIMULATOR 20
2. CHECK that before - BFP lub oil, working oil - Local operations.
BFP is locally and seal water coolers are Not simulated.
LINED UP starting. in CHARGED position. All
manual valves for cooling
water to bearings are
OPEN.

- BFP motor air box cooling - Local operation and


water-inlet/ outlet manual check. Not
valves are OPEN. simulated.

- BFP suction strainer DP is - Local check.


0.2 Kg/cm2

3. CHECK that feed - All air vents on suction - Local check. Not
water system is and discharge lines of BFP simulated.
lined-up (Required and feed regulating station
only for the first are OPEN.
BFP to be started).

- Spray pressure control - UCB check only.


valves on HP bypass &
AUX. PRDS station are
CLOSED.

- Suction strainer drain - Local check.


valve is in CLOSED
position.
- HPHs are in BYPASSED Group bypass valves
condition. are in 'Bypass' mode
or individual HPHs
Bypass valves are
open.
- Feed regulating station - UCB check.
control valve are in
CLOSED position.

- Economiser inlet valve E-2 - UCB check only


is open.

- Header block valves on - UCB and local


super heater and reheater check.
attemperation lines are
CLOSED.

- BFP local operator


intimated before starting of
BFP.

KORBA SIMULATOR 21
FEED WATER SYSTEM

BFP STARTING PROCEDURE

WHEN BOTH PUMPS ARE OFF

ACTION OBSERVATION REMARKS

1. CHECK before starting - All pre-start checks are - Local/UCB


any BFP. COMPLETED checks.

- All BFP permissive are ON. - Associated


saffron lamps
are ON.

2. START the boiler feed - Breaker closed indication - Red indication


pump motor. comes on. ON.

- Motor takes starting current - UCB check.


and then comes to no load
current of 125 amps.approx.
- BFP header discharge Pr. - Associated red
increases up to 85 Kg/cm2. & green lamps
are on
- Integral bypass valves of the - UCB indication.
BFP main discharge valve (FW-

KORBA SIMULATOR 22
101/FW102/FW-103) start
opening.

- After integral bypass valves are - Interlock.


fully open, BFP main discharge
valve starts opening
Suction flow increases to - UCB check.
150 T/Hr. approximately.

- Motorised cooling water valve, - Supplies


(BCW-72/98/124 starts cooling water to
opening. motor air box
and working oil
coolers.
- BFP aux. oil pump goes off as - Interlock.
the main oil pump takes over.

- Scoop control transfers to - Interlock.


AUTO with a time delay of 5
secs.

3. TRANSFER to manual & - BFP discharge pressure rises. - If on auto BFP


RAISE BFP scoop tube scoop tube can
position to get desired be operated
feed water through BFP
master.

- Feed water flow through the


BFP starts increasing above
150 T/Hr.

- BFP header pr. low alarm gets - UCB indication.


reset.

- Re-circulation valve auto


release becomes available, if
BFP flow exceeds 150 T/Hr.

4. OPEN feed regulating - Integral bypass valves of FW- - UCB indication


station low range 99/100, A and B open up.
controllers isolating
valves

- Main Isolating valves of FW-


99/100 open up.

5. ADJUST re-circulation - Re-circulation flow set point is - M/A releases


flow set point to 30% provided above the recirculation push button for
and TRANSFER control valve controller. auto/ manual
to auto. transfer.

KORBA SIMULATOR 23
- Re-circulation valve control
transfers to auto.

6. INSTRUCT Local - Various bearing temperatures - Monitor Brg


operator to check and vibration limits are: temp and
bearing vibration and vibration
temperatures locally indicators.

Alarm Trip
Brg. temp. 95 oC 105 oC
Working oil outlet temp 95 oC 130 oC DAS/Local indication.
Vibration 9 mm/sec. 12 mm/sec. DAS/local point.
Motor wdg temp. 110 oC 135 oC

WHEN ONE PUMP IS RUNNING

ACTION OBSERVATION REMARKS

1. CHECKS before - All pre-start checks are - UCB/local check,


starting the second OVER.
BFP.

- All BFP start Permissive is - UCB check only.


AVAILABLE.

- BFP main discharge valve - UCB check only.


OPEN.

- Aux. oil pump is ON and lub - IF not, start the


oil pressure is ADEQUATE. AOP.

- BFP scoop tube position is - UCB indication.


MINIMUM
- BFP selector switch is on - UCB check.
NORMAL.

2. START the BFP - Breaker closed indication - UCB indication.


motor comes on.

- BFP scoop tube controller - Interlock. UCB


transfers to auto and follows indication.
master controller output.

- Motorised cooling water - Interlock. UCB


valve, (BCW-72/98/124) indication
open up.
- BFP aux. oil pump trips - Interlock.

KORBA SIMULATOR 24
automatically as the main
oil pump takes over.

3. ADJUST re- - Re-circulation flow control - Re- circulation valve


circulation flow set transfers to auto. control trips to
point to 30% and manual & opens
TRANSFER control 100% if BFP flow
to auto. drops below 130
T/Hr

- Re-circulation valve
modulates to maintain set
re-circulation flow.

4. ADJUST scoops of - BFPs discharge pr. flow - UCB check only.


the two running indications must become
BFPs to equalise approx. equal.
loads.

5. ADJUST BFP bias - BFP biasing set has been - M/A release must be
to 50% and provided above BFP scoop pressed for
ADJUST BFP control. auto/manual
master controller transfers
equal to BFPs scoop
tube position.
- Controller error on the
scoop controls of the
running BFPs becomes
zero.

6. TRANSFER running - BFPs scoop controls - UCB indication


BFP SCOOP control transfer to auto. Maintain DP across
to auto. 2
FRS 6-8 Kg/cm .

7. Adjust FRS DP, set - Controller error on BFP - UCB M/A release
to 60% -80% and master Controller becomes push button is to be
TRANSFER BFP zero, when actual& set pressed for auto/
master control to values of DP are matching manual changeovers.
auto.
- BFP master trips to
manual if any of the
running BFPs trips or
individual BFP
control is changed to
manual mode.

KORBA SIMULATOR 25
BFP SHUTDOWN PROCEDURE

ACTION OBSERVATION REMARKS

1. TRANSFER scoop - Scoop control transfers to - UCB indication.


control of the BFP manual.
to manual.

- BFP master also transfers to - UCB indication.


manual.

2. REDUCE scoop - BFP discharge pressure and - If needed, start the


tube controller of flow start decreasing standby BFP, or
the BFP to reduce unit load to
minimum position. 80 MW - 100 MW.

3. STOP the BFP - BFP motor breaker opens. - Associated green


motor. lamp comes on.

- BFP re-circulation valve - UCB indication.


opens 100%

- Motorised cooling water valve - UCB check only.


starts closing.

- If no other BFP is in service - Interlock.


the discharge valves of all
BFPs start closing.

4. Close the BFP


suction valve and
rack out breaker if
any maintenance to
be carried out.

NOTE:- Before closing the suction valve, please ensure that discharge valve is
closed & there is no passing in the discharge valve and NRV. Otherwise,
due to back pressurising booster pump glands may fail, leading to leakages
etc. Watch for any increase in suction pressure when closing suction valve.

KORBA SIMULATOR 26
SINGLE ELEMENT FEEDWATER CONTROL

THREE ELEMENT FEEDWATER CONTROL

KORBA SIMULATOR 27
BOILER SYSTEM

KORBA SIMULATOR 28
KORBA SIMULATOR 29
AUXILIARY PRDS CHARGING
ACTION OBSERVATION REMARKS

1. CHECK these - Station start-up boiler - Refer to the


conditions are satisfied has been started operating instruction
before charging the already. of the Aux. Boiler.
aux. steam header. Not simulated.
- Aux. steam isolating
valve S-16 and its
bypass from aux. boiler
side are CLOSED.

- The entire header drains - Not simulated. Local


DW-238/239 DW-178 operation.
/179, DW-182 /183,
DW-186/187 and DW-
190/191 on the station
header are OPEN fully.

- Station header inlet vlv


AS-3 is OPEN 100%.
- All the unit aux. header - Not simulated.
drains and vents DW-
194/195 are OPEN.

- Unit interconnecting - UCB operation.


valve AS-31 to Unit-1
and/or other units are
CLOSED.
- Valve AS-10, Unit PRDS - Local operation Not
connection to unit simulated
header, is CLOSED.

- All header drains can be - Local operation.


closed after charging the
header.

3. OPEN-UP AS-31 fully to - Unit aux. header - UCB indications


charge unit aux. pressure increases up to
header. 15 Kg/cm2 and '' aux.
steam pressure low''
alarm clears off.

4. ENSURE all the - Oil tank level is - Local check only. Not
conditions are satisfied ADEQUATE & oil pump simulated.
before charging the unit is RUNNING and its
PRDS system. pressure is ADEQUATE.

KORBA SIMULATOR 30
- All hydraulic valves' - Local
controls are on operation/check. Not
REMOTE. simulated.
- Isolating valve AS-6 and - Local operation. Not
AS-9 are OPEN 100% simulated.

- Isolating vlv AS-4 and - UCB check.


AS-7 are CLOSED fully.

- Main steam pressure is - UCB check. Interlock


2
more than 50 Kg/cm . for opening AS-4/7.

- All iso. valves on F.W. - Not simulated.


line for de-superheating
are OPEN 100%.
- Steam pressure and - UCB operation.
temperature set points
2
at 14 Kg/cm and 220
deg. C., respectively.

5. OPEN AS-4 and AS-7 - Integral isolating valves - UCB operation.


from the UCB to charge 4A and 7A open-up and
unit PRDS header. then AS-4/7 start
opening

6. OPEN AS-10 fully and - PRDS-1 (30% line) - UCB indication


PRDS pressure starts opening.
controller gradually and
transfer control to auto.
- Temp controller - UCB indication.
transfers to auto to
maintain set temp after
de-super heater

- Spray pressure - UCB check only.


controller maintains
feed water pressure at
2
20 Kg/cm (for 30% line)
- PRDS-2 starts opening - Interlock
after a certain controller
output.

- Spray pressure set point - Auto interlock.


2
ramps up to 40 Kg/cm
(for 100% line)
7. CLOSE AS-31 after unit - PRDS header pressure - At 300 deg. C all
PRDS is fully charged. is to be maintained at PRDS valves are trip
14 Kg/cm2 closed.

KORBA SIMULATOR 31
HEAVY FUEL OIL SYSTEM
In coal fired Thermal Power Plants, the Fuel Oil plays a vital role in initial firing of the
Boilers and running it up to 25-30% of its capacity. The fuel oil is also used as a
stabilising fuel in the coal fired boilers till the coal flame stabilises in the furnace and
for proper coal burning while the load is reduced in the boiler for a shut down.

All the main storage tanks are generally interconnected to the suction side of
unloading pumps so that oil from one tank can be transferred to another for the
purpose of any maintenance work. The storage tanks are equipped with Magnetic type
float switches and Mechanical type float level Indicators to measure the quantity of oil
stored.

In order to keep the viscosity of oil in storage tank low, it is essential to keep the oil
warm between 50 0C to 70 0C so that the oil from main tanks can be transferred to
service tanks for normal / daily utilisation of fuel oil for the firing. For this purpose a
steam floor-heating coil has been laid at the bottom of the tank. Thermostatic
temperature controller installed at the inlet of steam heating coil, controls the
temperature of oil tank at the desired point selected between 500C to 700C.

The HFO passes through the oil strainer on the suction side of the high-pressure
screw pump. Heavy oil pumping unit consists of oil suction strainers and screw
pumps each coupled through flexible coupling and mounted on a common frame.

HEAVY FUEL OIL SYSTEM

KORBA SIMULATOR 32
The screw pump, when connected to an induction motor with constant speed, is a
constant quantity pump and valves in the delivery line control the delivery pressure.
When only a small quantity of oil is fired, the excess oil from the pump discharge
should be bypassed. This is done automatically by electrically operated, pressure
maintaining valve bypassing the excess quantity through the return oil line to storage
tank and the delivery pressure of oil is maintained constant at the pump outlet,
whatever be the quantity of fuel oil.

HFO from the delivery side of the HFO pumping unit enters the HFO pre-heater where
it is heated from pumping temperature to a temperature corresponding to an
atomising viscosity. The outlet temperature of HFO from the heat exchanger is
automatically maintained at a constant value by the automatic temperature-
regulating valve, mounted on the steam supply line to heaters. The temperature-
regulating valve controls the quantity of steam to the heater according to the outlet
temperature of the oil from the heater.

H.F.O STORAGE TANKS:


3 Numbers, Capacity: 2500 M3 each
H.F.O. Pressuring Pump:
3 Numbers, Type: Triple screw type, Bornemann
Motor Rating 50 KW, 415 V, 3 ph., 50 Hz
Power Required 32 KW at 370 cst.
Capacity 430 litres / min. at 370 cst.

KORBA SIMULATOR 33
FURNACE SAFEGUARD AND SUPERVISORY SYSTEM
FSSS facilitates remote manual/automatic control of fuel firing equipments through
mechanised system with suitable interlocks and logics. It is designed to ensure the
execution of a safe, orderly operating sequence in start up and shutdown of fuel
firing equipments, and thereby to prevent errors or omissions in following such
procedure.

The system provides protection against malfunction of fuel firing equipments and
associated air system. The safety feature of system is designed for protection in most
common emergency situations. FSSS comprises of control circuits, various logics and
indicators to carry out the following:

• To start furnace purge when all technological conditions are fulfilled.


• To start and monitor the Ignitors.
• HFO Gun starting, stopping and supervision.
• Pulveriser and Feeder starting, stopping and supervision.
• Flame Scanner intelligence and checking.
• Furnace flame monitoring and overall furnace flame failure protection.
• To trip out all boiler fires when boiler safety is threatened.
• To start/stop ignitor and scanner air fans.
• To regulate the Secondary Air Dampers depending upon the fuel flow
variation.
• To provide boiler trip signal to other system such as PA Fan, Mills,
Turbine, Generator etc.

FSSS equipments can be grouped under three heads:

1. The Operating and Indicating Console Insert in UCB:

This consists of all switches for initiating controls and also indications of status of
all fuel firing equipment & their auxiliaries.

2. Relay and Logic Cabinets:

The cabinets consist of relays, timers, programmers, circuit breakers for AC and
DC control supplies flame scanner unit, number of coal flow units etc. They
control the process logic.

3. Field Equipment:

Field equipments are those which help in actual remote operation of fuel firing
equipments and those, which provide the status to the operating, console and
relay logic cabinet.

KORBA SIMULATOR 34
Field Equipment Includes:

Ignitor/HFO Trip Valves, HFO atomising steam, Scavenging steam/ Nozzle valves
(Hydra motor type), gun advance/retract mechanisms, oil gun assembly, ignitors
and its cabinets, flame scanner and ignitor air fans, pressure switches,
temperature switches, flow switches and limit switches, Mill Discharge valves, hot
air gates, seal air valves, cold air, tramp iron gate etc.

FSSS POWERSUPPLY ARRANGEMENT

KORBA SIMULATOR 35
220 V AC SUPPLY SYSTEM
1. ANALOGUE CONTROL SYSTEM (ACS) : (H&B)
2. ANNUNCIATION
3. AUX. PRDS :(SULZER)
4. AUX. RELAY PANEL
5. DATA ACQUISITION SYSTEM (DAS)
6. FEEDER CABINET
7. FSSS AC SUPPLY
8. HP BYPASS CABINET: (SULZER)
9. HYDRASTEP
10. SECONDARY AIR DAMPER CONTROL (SADC)

110 V AC SUPPLY SYSTEM


1. ATOMISING STEAM NOZZLE VALVES
2. FLAME SCANNER MODULE
3. HFO NOZZLE VALVE MOTOR
4. IGNITOR FAN DISCHARGE DAMPER
5. LAMP INDICATION + LOGIC POWER
6. MILL DISCHARGE VALVE
7. MILL FEEDER CONTROL
8. MILL SEAL AIR DAMPER
9. SCAVENGE STEAM NOZZLE VALVE MOTOR
10. SEAL AIR FAN DISCHARGE DAMPER

220 V DC SUPPLY SYSTEM


1. HFO TRIP VALVE
2. HFO RE-CIRCULATION VALVE
3. IGNITOR OIL TRIP VALVE
4. MILL MOTOR CONTROL
5. SCANNER FAN DISCHARGE DAMPER
6. SCANNER FAN EMERGENCY SUCTION DAMPER

KORBA SIMULATOR 36
FSSS LOGICS AND INTERLOCKS

FURNACE PURGE

Furnace purge is required after every boiler trip-out and before light up to expel all
unburnt fuel particles, gases, vapour etc. from the boiler, so that possibilities of
explosion are eliminated, when ignition energy is made available.

Boiler purging cycle is of 5 minutes duartion. 'PURGE READY' appears only when all
the purge permissives are satisfied. Pressing ‘PURGE START’ push button will start
purging. When purge cycle is completed, 'PURGE COMPLETE' signal will come. This
is an indication that boiler MFR is reset and now boiler can be lighted up. If any time
during purging, any of the Purge Permissive conditions are violated, 'PURGE READY'
signal will disappear, and purging cycle is to be started once again after establishing
'PURGE READY' conditions. Once purging is completed, boiler will trip if any of the
'Boiler Trip' conditions occur.

PURGE READY CONDITIONS

The conditions to get Purge Ready are:

1. No Boiler Trip
2. Warm-up valves closed
3. All auxiliary air dampers modulating and wind-box to furnace DP O.K.
4. All feeders off.
5. All elevation flame scanners show 'no flame'.
6. Both PA fans off.
7. All ignitors and Warm-up Trip valves closed.
8. Hot Air Gate closed.
9. Ignitor Valves closed.
10. All pulverisers off.
11. Nozzle Tilt Horizontal AND Airflow less than 40%.

IGNITOR TRIP VALVE INTERLOCK

A) Ignitor trip valves will open when trip valve 'open' Push Button is pressed
provided all the following conditions are fulfilled:

2
a. Ignitor oil supply pressure is adequate, more than 13 Kg/cm
b. All ignitor valves are closed
c. No boiler trip command is persisting.
d. Scanner air to wind box differential pressure more than 125 mm WCL.
When ignitor trip valve is fully open, 'Open' signal comes on FSSS console.

KORBA SIMULATOR 37
B) Ignitor trip valve will close under following conditions:

a. 'Close' push button is pressed from console or


b. Ignitor oil header pressure falls below 9 Kg/cm2 for more than 2 seconds
AND any ignitor valve not closed.
c. Boiler MFR trip command is present.

When ignitor trip valve is closed, the valve ''closed'' green lamp comes on.

Ignitor Starting

There is no separate ignitor start switch provided for any of the elevation AB, CD
or EF Ignitors. Pressing any one pair of oil gun ' START' or STOP' push button
gives a starting impulse to all four ignitors of that elevations. The spark is applied
for 10 seconds only for every pressing of ignitor start push button.

Ignitor Stopping

All four ignitors of each elevation are provided with one 'STOP' push button for
taking out ignitors from service. Also ignitor gets stop command, at the end of stop
time trial of HFO oil elevation. When individual ignitors get stop command its
motorised oil/air valve closes thus taking out ignitors from service.

HEAVY OIL FIRING

Heavy oil can be fired at AB, CD and EF elevation. Heavy oil gun have been
programmed to light up on pair basis, diametrically opposite corners (1,3 and 2,4)
form the pairs. Each pair is provided with start/stop push button.

HFO guns can be lighted up only if at least 3 out of 4 ignitors at corresponding


elevations are in service.

HFO guns are self-sustaining only when elevation firing rate is at 30%, hence,
ignitors corresponding to HFO guns in service must only be removed when HFO
burner header pressure is above 3 Kg/cm2 (g) and at least 3 HFO guns at the
elevation are in service and corresponding flame scanners are sensing flame.

Flame scanners monitor heavy oil guns flame only when the following conditions
are fulfilled.

i. HFO firing rate (elevation load) is above 30%.


ii. 3 or more HFO guns at the elevation.
iii. Ignition energy removed.

KORBA SIMULATOR 38
HFO TRIP VALVE INTERLOCK

A. HFO Trip Valve (HOTV) can be opened by pressing 'OPEN' push button,
provided the following conditions are fulfilled.

a. Boiler Trip Command (MFR) is RESET, and


b. All HFO nozzles of AB, CD and EF oil guns are proven fully closed.
2
c. HFO supply pressure is adequate (more than 16 Kg/cm ).
O
d. HFO header temperature adequate (more than 95 C)
OR HFO recirculation valve is open 100% (Bypass conditions for all the above.)

B. HO trip valve closes under any of the following conditions:

• HFO header pressure is low (<3.5 Kg/cm2) OR


• HFO header temperature is low (< 95 0C) OR
• Atomising steam pressure is low (<7.5 Kg/cm2.) AND all HFO nozzle valves
not closed. OR A boiler trip occurs, OR
• HFO trip valve 'CLOSE' P.B. is pressed, when HFO trip valve is fully closed,
valve 'CLOSED' green light appears.
HFO Re-circulation Valve Interlock

Opening: HFO re-circulation valve can be opened following a boiler trip and before
starting furnace purge cycle by pressing valve 'open' push button. Valve opens
provided:

a. All of the HFO nozzle valves are fully closed, and


b. Re-circulation Valve ' OPEN' command is given.
Closing: HFO re-circulation valve closes automatically when anyone of the nozzle
valves (Hydra motor) is not closed, or manual ' CLOSE' command is given.

Heavy Oil Gun Elevation Start Permissive:

a. D.C. power available


b. Ignitor trip valve is proven fully open.
c. No boiler trip command persists.
d. HFO trip valve is proven fully open.

e. Heavy oil temperature above 100oC.


f. Airflow adjusted between 30% and 40% of full load airflow.
g. Burner tilt placed in horizontal position.
The last two conditions are not required if any one feeder is PROVEN.

KORBA SIMULATOR 39
HFO Corner Start Permissive

At each main oil corner to be placed in service, following conditions should be


satisfied:-

a. The main oil guns are inserted in guide pipe and coupled.
b. The local maintenance control switch is placed in REMOTE.
c. HFO manual isolation valve is open.
d. Atomising steam manual isolation valve is open.
e. Scavenging steam valve is closed.
f. 'Elevation Start' Permissive available

HFO Gun Starting Sequence

When HFO Pair start push button is pressed a pair of HFO guns is placed in
service in following sequence (provided HFO elevation start premissives are
satisfied).

• Within first 10 seconds of pair start trial time associated elevation ignitors are
started. When ignitors are proven, Ignitor 'ON' signal comes on. If the flame is
not proven, sparkwill cease and Jamesbury Valve is closed after 10 seconds.

• When minimum 3 out of 4 ignitors at the associated elevation are proven ‘ON’ at
the end of 10 seconds, a start command is given to heavy oil gun no. 1 (if pair 1
- 3 is selected) or to heavy oil gun no. 2 (if pair 2 - 4 is selected), if corner-
scavenging valve is closed.

• Twenty five seconds later a start command is sent to corner no 3 (in case of 1 -
3 pair) or corner no. 4 (in case of 2 - 4 pair)

When an individual heavy oil corner receives a 'start' command and its associated
ignitor is proven 'ON' it is placed in service in following sequence.

a. Heavy Oil gun advances to firing position. 'Gun Retracted' lamp


goes out and 'ADVANCE' light glows.
b. When the gun is fully advanced, the atomising steam valve
opens.
c. When the atomising steam valve is proven fully open, the heavy
oil nozzle valve opens placing the HFO gun in service.
All ignitors can be removed by pressing Ignitor Stop push button.

- 3 out of 4 HFO nozzle valves are proven open.


- Elevation loading is about 30%.

KORBA SIMULATOR 40
- Minimum 3 out of 4 flame scanners sensing flame at that
elevation.
Unsuccessful Corner Start:

At the end of 90 seconds of pair start trial time a heavy oil corner trip is
initiated for any corner when -

a. Heavy oil nozzle valve is not proven fully open.


b. Associated ignitor is not proven 'ON'.
Heavy oil Elevation Shutdown

Heavy oil elevation is removed from service on a pair basis. Depressing the
associated elevation pair stop P.B. will initiate a 375 sec. time trial to
shutdown and scavenge the associated pair of heavy oil guns as follows:

a. During first 10 seconds of stop time trial associated elevation of


ignitors is started.
b. At the end of start time a stop command is sent to corner no. 1
(when pair 1 & 3 is stopped) or corner no. 2 (when pair 2 & 4 is
stopped).
c. Fifteen seconds later, a stop command is sent to corner no. 3
(when pair 1 & 3 stopped) or corner no. 4 (when pair 2 & 4 is
stopped).

When an individual heavy oil gun that is in service, receives a stop command:

a. A scavenge command for that corner is initiated and HFO nozzle


valve closes. The atomising steam valve remains open.
b. When the HFO valve is proven fully closed and if the associated
ignitor is proven ON and the atomising steam valve has remained
open, the scavenge valve opens.
c. When the scavenge valve is proven fully open, a five minute
scavenge period is started.
d. At the end of 5 minutes scavenge period, the atomising steam
valve close.
e. When both the valves are proven fully closed, the HFO gun is
retracted from firing position.

Six minutes after, remaining pair of HFO guns stop is initiated, a back-up trip

KORBA SIMULATOR 41
signal is established which will remove the associated elevation of ignitors
from service and initiate a close signal to all HFO nozzle valves, all of the
scavenge valves at the elevation to ensure they are closed. Fifteen seconds
later an 'Unsuccessful Elevation Shut-down' alarm comes if –

a. Any HFO gun is not retracted from firing position at any


elevation,
OR
b. Any HFO nozzle valve is not closed at any elevation.

PULVERISER INTERLOCKS

Pulveriser Ready Permits

At the respective Pulveriser, all of the following conditions are to be satisfied:

1. Start Permit.
2. Pulveriser discharge valve open.
3. Seal air O.K.
4. Cold air gate open.

5. Pulveriser outlet temperature less than 200o F.


6. Primary air permit.
7. No Pulveriser trip.
8. Feeder local selector switch is on REMOTE.
9. No unsuccessful start.
10. Tramp iron hopper valve open.

When all the above conditions are satisfied for the respective Pulveriser, its
associated 'Pulveriser Ready' light appears.

Availability of Ignition Permit for Pulveriser Operation:-

Prior to starting any Pulveriser, ignition energy must be adequate to support


coal firing. This is accomplished as follows:

Pulveriser-A

i. A minimum 3 out of 4 elevation AB heavy oil nozzle valves proven


open.
OR

ii. Boiler loading is greater than 30% and feeder B is in service at


greater than 50% loading.

KORBA SIMULATOR 42
Pulveriser-B

i. A minimum 3 out of 4 elevation AB heavy oil nozzle valves open,

OR

ii. Boiler loading is greater than 30% and feeder A or C is in service


at greater than 50% loading.

Pulveriser - C

i. A minimum 3 out of 4 elevation CD heavy oil nozzle valves proven


open.
OR

ii. Boiler loading is greater than 30% and feeder B or D is in service


at greater than 50% loading.
OR

iii. A minimum 3 out of 4 elevation AB heavy oil nozzle valves proven


open and feeder B is in service at greater than 50% loading.

Pulveriser - D

i. A minimum 3 out of 4 elevation CD heavy oil nozzle valves proven


open.
OR

ii. Boiler loading is greater than 30% and feeder C or E is in service


at greater than 50% loading.

Pulveriser - E

i. A minimum 3 out of 4 elevation EF heavy oil nozzle valves proven


open.
OR

ii. Boiler loading is greater than 30% and feeder D or F is in service


at greater than 50% loading.
OR

iii. A minimum 3 out of 4 elevation CD heavy oil nozzle valves


proven and feeder-D is in service at greater than 50% loading.

Pulveriser - F

i. A minimum 3 out of 4 elevation EF heavy oil nozzle valves proven


open.
OR

KORBA SIMULATOR 43
ii. Boiler loading is greater than 30 % and feeder-E is in service and
greater than 50 % loading.

Condition (i) is not required if any coal feeder is already 'PROVEN'

Pulveriser Start

When both ''Ignition Permit'' and 'Pulveriser Ready' are established for the respective
Pulveriser, the Pulveriser may be placed in service as follows:

• Start the Pulveriser by depressing its associated push button.


• When the Pulveriser is proven ON as indicated by its (red) indication open the
hot air gate by pressing its open push button and allowing the Pulveriser
outlet temperature to come up to more than 60oC. Adjusting Hot/Cold air
controlling dampers does this.

• When the Pulveriser temperature comes up to (Approx. 60-90oC) start the


feeder by depressing its associated START push button (associated elevation of
fuel air dampers should be closed for feeder starting).

Coal flow must be proven either by the coal flow detector or satisfactory Pulveriser
amps within five seconds after the feeder is started. Fifteen seconds after the feeder
is started, the feeder output is released to automatic control, and the fuel air damper
is opened to modulate as a function of feeder speed.

When a minimum of two feeders are established at greater than 50% load the
associated elevation of oil guns may be shutdown provided the feeder has been on for
a minimum of three minutes.

Feeder Start Permissive and Interlocks

a. Feeder speed minimum (controller position less than 20%).

b. Pulveriser 'ON' and its outlet temperature more than 55oC.


c. All Pulveriser ready conditions as mentioned above are satisfied.
d. Coal silo gate open (Operator check only).
Feeder Interlocks.

Either of the following conditions will force the feeder speed to manual and
minimum until the initiating condition is corrected.

i). Pulveriser bowl differential pressure high (>250 mm WCL)


ii). Pulveriser grinding current above 38 Amperes.

Loss of coal flow and low Pulveriser power as confirmed by Pulveriser amps will trip
the feeder. Any Pulveriser trip shall trip the associated feeder instantly.

KORBA SIMULATOR 44
Hot/Cold Air Dampers and Hot Air Gate Interlocks

All cold air dampers (CADs) will close to less than 5% open when the START
command is given to any PA Fan if no PA fan is running.
All CADs shall open 100% if boiler trips.
When the start command is given to any Pulveriser, the associated cold air
damper is open 100%.

When any Pulveriser outlet temperature is more than 95oC the CAD is open
100% and HAD is closed 100%.
Operation release for the CAD is obtained when the associated HAG (hot air gate)
is opened 100%.
The HAG can be opened manually when the associated Pulveriser is 'ON'. or it
can be opened automatically when Pulveriser on command is given on 'AUTO'.
HAG of any Pulveriser will close if the temperature at outlet of Pulveriser is more

than 95oC or the associated feeder trips with a time delay of 40 sec.
The HAG will close instantaneously if the associated Pulveriser trips from
service.

PULVERISER TRIP CONDITIONS

The following conditions will initiate a Pulveriser trip command:

• Pulveriser discharge valve not open.


• Loss of unit critical power for more than 2 seconds.
• Pulveriser ignition permit is not available or lost when supporting
ignition is required if the feeder is 'on' for less than 3 min.
• Boiler MFR trip.
• Primary air header pressure very low (< 585 mm wcl).
Note:

1. When both PA fans are tripped or hot PA pr. falls below the low set point of
585 mm wcl all pulverisers in service receive a trip command with a time delay
of 5 seconds. When hot primary air duct pressure falls below very low set
point of 525 mm WCL, all pulverisers in service are tripped instantaneously.

2. When only one PA fan trips or stopped and four or more pulverisers are in
service, a trip command will be initiated to trip the running Pulveriser from
the top until the number of pulverisers running is reduced to three.

KORBA SIMULATOR 45
BOILER TRIP CONDITIONS (200MW)

FSSS protects the boiler by trippingout all fuel inputs, under the
following conditions

1. Simulate Trip.
2. Loss of 220V DC to FSSS.
3. Elevation Power Failure.
4. Flame failure.
5. Loss of all fuel.
6. Airflow falls below 30% (MCR).
7. Furnace pressure high (+ 200 mm WCL).
8. Furnace pressure low (- 200 mm WCL).
9. Drum level high (+ 225 mm).
10. Drum level low (-225 mm).
11. Re-heater protection trip.
12. Turbine Trip with boiler load more than HP/LP Bypass capacity (60%).
13. Loss of all Boiler Feed Pumps.
14. Both Emergency Push Buttons pressed.
15. Loss of ACS Power.
16. Loss of Unit Critical Power.
17. Both FD Fans OFF.
18. Both ID Fans OFF.

KORBA SIMULATOR 46
KORBA SIMULATOR 47
STEPWISE OPERATION LOGICS OF F.S.S.S. (200 MW)
1. PURGE PERMISSIVE & PURGE COMPLETE
2. IGNITOR WARM-UP & RE-CIRCULATION FUEL TRIP VALE
3. IGNITOR FAN AND OUTLET DAMPER CONTROL
4. SCANNER AIR FAN CONTROL
5. WARM-UP ELEVATION START PERMIT
6. PAIR 1-3 AND 2-4 WARM-UP ELEVATION CONTROL
7. SELECTION OF OPERATION MODE
8. OPERATION IN ELEVATION MODE
9. WARM-UP ELEVATION IGNITOR CONTROL
10. WARM-UP ELEVATION CORNER NOZZLE CONTROL
11. PULVERISER READY
12. PULVERISER TRIP
13. COAL ELEVATION PULVERISER CONTROL
14. PULVERISER SEAL AIR VALVE & DISCHARGE VALVE CONTROL
15. FEEDER CONTROL
16. AUTO CLOSE COMMAND FOR HOT AIR GATE
17. HOT AIR GATE CONTROL
18. COLD AIR DAMPER CONTROL
19. MILL FEEDER SPEED DEMAND TO MINIMUM
20. MILL FEEDER PROVEN SIGNAL
21. RELEASE FOR AIR AND TEMP. CONTROL TO AUTO
22. PULVERISER IGNITION PERMIT A & F
23. PULVERISER IGNITION PERMIT B & E
24. PULVERISER IGNITION PERMIT C & D
25. CONTROL OF SEAL AIR FAN

KORBA SIMULATOR 48
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KORBA SIMULATOR 72
KORBA SIMULATOR 73
OPERATION PROCEDURE
AIR PRE-HEATER OPERATION
PRE-START CHECKS

ACTION OBSERVATION REMARKS

1 CHECK all the - Support bearing/ guide - Associated red lamp is


pre-start bearing lub oil pumps on
conditions are RUNNING and lub oil
satisfied. coolers are CHARGED.

- Bearing temperature NOT - Ascertain from local


HIGH (less than 60oC) operator.

- Electrical supply is - If not, line-up air motors.


AVAILABLE. Local operation.

- Isolating valves of air - Local operation Not


motors are 'OPEN' and simulated
bypass valves of air motor
solenoids are 'CLOSED'.

- 'Air motors' lub oil level - Local check.


ADEQUATE

- Service air pressure is - Local/UCB check.


ADEQUATE (> 5 Kg/cm2)

APH STARTING PROCEDURE

WHEN BOTH APHS ARE OFF

ACTION OBSERVATION REMARKS

1 START air - Air motors ON indications - Corresponding red lamp


motors of both come on glow.
APHs.
- Isolating dampers of APHs - UCB indications.
start opening.

2 START air heater - Breaker CLOSED - UCB indication.


electrical motor. indication comes on

- Associated air motor - UCB indication.


stops.

KORBA SIMULATOR 74
- Starting current shoots up - UCB indication.
and comes down to
normal load current.

- Isolating dampers of the - Associated red lamps on.


air heater remain open.

- Isolating dampers of the - Associated green lamps


other air heater, not in come on.
service, start closing if its
air motor is not ON.

3 INSTRUCT local - There should be no - UCB check.


operator to abnormal hunting in air
check, locally, heater amperes meter
for any readings.
abnormal
sounds from
bearings/seals.

- There should be no - Local check.


abnormal sounds from air
pre-heater seals or
bearings.

- Bearing temperatures - UCB OMNIGUARD


must be within the normal indicators must be
range (65 oC -75 oC) frequently monitored.

Note: Air pre-heaters air motors can be started manually provided electrical motors
are off, isolating valves of air motor solenoid are open and service air pressure
is normal. The air motors come into service on auto interlock, when
corresponding electrical motors trip-out on any protection.

WHEN ONE APH IS RUNNING

ACTION OBSERVATION REMARKS

1 CHECK before - All pre-start checks are - Local/UCB.


starting any COMPLETED.
APH.
- Support bearing / guide - Corresponding red lamps
bearing lub oil pumps are ON.
ON.

- Bearing temperature NOT - Ascertain from local


HIGH (< 60 oC) and lub oil operator.
coolers are CHARGED

KORBA SIMULATOR 75
- Electrical supply is - Refer to the respective
AVAILABLE modules.

- Air motor is ON - UCB check only.

All isolating dampers of - Red lamps on.


the air pre-heater are
OPEN.

2 START air pre- - Breaker CLOSED - Red lamp on.


heater electrical indication comes on.
motor.

- Starting current goes up - UCB/Local check.


and comes down to
normal load current

- Air motor goes off. - UCB indication Interlock.

- Air heater isolating - UCB check.


dampers remain open.

There should be no UCB indication.


ABNORMAL hunting of
ampere reading.

3 INSTRUCT local There should be no Local checks.


operator to abnormal sounds from air
check for pre-heater seals/
healthy running bearings.
of air heater.

The bearing temperatures UCB OMNIGUARD


must be within the normal indicators must be
range (60 oC to 75 oC). checked for bearing temp
frequently.

SHUT DOWN PROCEDURE

ACTION OBSERVATION REMARKS

1 CHECK - Corresponding ID& FD - Associated breaker


Fans are running. closed indication are on.

2 UNLOAD The other pair of ID/FD Operator's action, if fan


associated fans (if running) starts controls are on manual.
ID/FD fans, loading up on auto.
gradually.

KORBA SIMULATOR 76
3 STOP the - Fan breaker goes open. - Maintain desired oxygen
associated FD percentage.
fan.

- Furnace total airflow - Reduce firing if required.


indication drops slightly.

4 STOP the - Furnace pressure - Maintain furnace draft


associated ID increases slightly. between-5 to - 10 mm
fan. wcl.

5 STOP air heater - Air heater electrical motor - Breaker off green lamp
electrical motor. goes off. comes on

- With a few seconds time - Associated green lamps


delay, the isolating come on.
dampers of the air heater
are closed, if the other AIR
HEATER is in service.

KORBA SIMULATOR 77
ID FAN OPERATION
PRE-START CHECKS

ACTION OBSERVATION REMARKS

1 CHECK all the - Fan lub oil pressure is - If not, ask the local
start permissive ADEQUATE (1.2 Kg/cm2). operator to start the lub
are satisfied oil pump and check the
before starting pressure.
the ID Fan.
- Fan inlet/outlet dampers - The dampers start
(GD 17/18, GD 21/22 is closing after the first fan
CLOSED. start command is given.

- Fan inlet guide vanes are - This permissive is


at MINIMUM position. fulfilled after the first fan
start command is given.

- Fan bearing temperature - Local/UCB check. Fan


is NOT HIGH (< 60 oC .) start permissive. are
available.

2. CHECK if the - Electrical supply for - Local operation/check.


fan is lined-up various motor operated Boiler VDDC / MCC
for operation. dampers is ON. panels to be checked.

- Lub oil system is lined up - Local operation. Not


and water/oil coolers are simulated.
CHARGED.

- Oil level in the tank is - Local check. Not


ADEQUATE. simulated.

- Anyone or both APH - UCB check. Interlock.


are ON.

- EPBs are in RELEASED - Local operation/check


position.

- Inlet guide vanes are - Local check. IGVs are


100% open when both ID OPERATIONAL and ON
fans are off. REMOTE

- Instrument air pressure


is ADEQUATE.

KORBA SIMULATOR 78
3 CHECK if flue - ID fans' suction/ - Local check.
gas path is discharge dampers are
LINED-UP for ID OPEN 100% and
Fan operation. operational.

- Manual isolating dampers - Local operation. Not


on suction / discharge simulated.
ducts of ID fans (GD-
19/20/23/24) are OPEN.

- Sealing/flushing water - Local check.


supply for ESPs, Not simulated.
economiser, APHs and
bottom ash hoppers is
AVAILABLE.

- Gas isolation dampers for - UCB indications.


ESPs and APHs are open.

- Changeover dampers GD- - UCB indication


5/6 before ESPs are
OPEN.

- Changeover dampers after - Local check. UCB


ESPs (GD-15/16) are indication and interlock.
operational and CLOSED.

- Gas path is through for - For ID Fan-A gas path


starting ID fan. (ESPs) A & clear interlock.
B isolation dampers, APH-
A gas and secondary air
isolation dampers are Gas path ready
OPEN. OR ESPs C & D conditions for ID
isolation dampers + APH- Fan-B can be found out
B gas isolation dampers by symmetry
are OPEN. OR APH-B gas
isolation dampers+ ESPs
A&B isolation dampers +
GD-5 and GD-6 are OPEN.

- ID Fan breaker is on - Local operation.


SERVICE/REMOTE
position.

KORBA SIMULATOR 79
STARTING PROCEDURE

WHEN BOTH THE FANS ARE OFF

ACTION OBSERVATION REMARKS

1 Check before starting - All pre-start checks are - ''Inlet guide vanes
ID Fan. OVER. min.'' & Inlet/outlet
dampers closed''
permissive become
available after the fan
start command is
given.

- All permissive for the


fan AVAILABLE.

- Local operator is
informed before the fan
is started.

2 START fan. - Inlet/outlet dampers - UCB indication.


start closing

- Inlet vanes come to - Controller output


minimum. minimum.

- The fan breaker is - Breaker closed red


CLOSED after indication comes on.
inlet/outlet dampers
close fully.
- Starting current goes up - UCB indication.
to 500A and comes
down to no load current
of 45 A.

- Change-over dampers - Corresponding red


(GD-15, GD-16 start lamps come on.
opening. (After fan
starts).

- Inlet/outlet dampers - UCB indication.


open up.

- Inlet/outlet dampers of - Associated green


the other fan go closed lamps on & controller
and regulating vanes go position of IGV
to minimum position. becomes zero.

3 ADJUST inlet guide - Fan amperes go up with - UCB indication.

KORBA SIMULATOR 80
vanes to maintain vane position increasing
furnace draught (Controller output
between - 5 mm. to - increasing).
10 mm.

- Furnace draft starts - UCB indication for


improving. furnace pressure
moves down below
zero.

- Furnace airflow
indication increases
slightly.

4 INSTRUCT the local - Bearing vibrations must - UCB indications.


operator to check for be within 40-50 micron.
abnormal bearing
vibration and
temperature.

- Bearing temperatures - UCB OMNIGUARD or


should be below 85 oC DAS indications.
(Alarm) or 105 oC (Trip).

WHEN ONE FAN IS RUNNING

ACTION OBSERVATION REMARKS

1 CHECK before starting - All pre-start checks are - UCB/Local checks.


the ID Fan. OVER.

- Lub oil motor On. Lub - Associated red &


oil pressure ADEQUATE saffron lamps on.
2
(>1.2 Kg/cm )

- Xover dampers GD-15, - UCB check only.


GD-16 are OPEN.

- Regulating vanes are at - Controller output


MINIMUM position. zero (minimum).

- Inlet/outlet dampers are - Green lamp on.


CLOSED.

- Both APH s are ON. - Interlock.


- Bearing temperatures - Permissive.
are NORMAL (<60 oC )

KORBA SIMULATOR 81
2 START fan motor - Fan motor current - Breaker closed
settles down at 45A. indication comes on.

- Inlet/outlet dampers - Associated red


start opening. lamps come on.

- GD-15 and GD-16 get - Interlock.


closed.

3 REGULATE fan vanes to - Maintain furnace draft - As per the boiler


equalise load on both -5 mm wcl. load.
the fans.
- Maintain desired
airflow.

4 CHECK locally & in - Bearing temperature - UCB OMNIGUARD


UCB the brg limits are Alarm Trip indicators may be
temperature and checked.
vibration level.
Alarm Trip
Fan 95 oC 105 oC
Motor 75 oC 80 oC
5 ADJUST bias to 50% - Furnace draught set - Operator action.
and furnace draught set point and biasing set
point to 45%. points have been
provided above Fan-A &
Fan-B vane controls
respectively.

- Check furnace draught - UCB checks.


is maintained between -
5 mm wcl to-10 mm wcl.

6 TRANSFER vane - Vane controllers - UCB INDICATION


controllers of both fans transfer to AUTO
to ''AUTO''.

- Inlet vanes modulate to - Furnace draft high


maintain set value of alarm at + 50 mm &
furnace draught. low alarm at -50 mm.

KORBA SIMULATOR 82
SHUT DOWN PROCEDURE

ACTION OBSERVATION REMARKS

1 SELECT IGV controls - IGVs control transfers to - M/A release push


of both fans to manual. button must be pressed
manual. for auto manual
changeover.
2 REGULATE IGVs of - ID fan discharge - Maintain furnace
the ID Fan to pressure decreases. draught at -5 mm wcl
minimum. by loading the other ID
fan.
- ID fan current come to
minimum load current
of 45 amps.

3 STOP the ID fan. - The flue gas after EP - Associated red lamps
interconnecting dampers come on.
open on interlock.

- Total airflow drops - Maintain airflow more


slightly avoid Boiler trip than 30%.

- The inlet and outlet - UCB indication.


dampers close on
interlock.

4 REGULATE the inlet - Maintain furnace - If the need be, reduce


guide vanes of the draught at -5 mm wcl. boiler firing to approx.
running ID fan to 50% to maintain
desired loading. furnace draught &
prevent running ID fan
over-loading.

- Maintain desired
amount of oxygen
percentage.

5 CHECK the motor - Motor winding - DAS indication


winding temperature temperature limits are
of the running ID fan

Normal 100 0C
Trip 130 0C

Note : If associated FD fan is in service it will be necessary to unload FD fan and


stop it before stopping ID fan; to avoid airflow fluctuations (Refer to FD fan
shutdown procedures). With ID fan being stopped corresponding FD fan
will also trip.

KORBA SIMULATOR 83
FD FAN OPERATION
PRE START CHECKS

ACTION OBSERVATION REMARKS

1 CHECK before starting - Fan control oil temp is - UCB/local check.


the FD fan, all start NORMAL (<55 oC)
permissive is satisfied.
- Fan blade pitch is - This permissive is
MINIMUM and Discharge satisfied after the first
damper is CLOSED fan start command is
given.
- Fan control / lub oil - UCB indication and
pressure is ADEQUATE. Local operation

- Fan bearing temperature - UCB/local check.


is NOT HIGH (<60 0C.)

2 CHECK if FD fan is - Fan lub oil system is - Local check


lined up locally for LINED UP and oil coolers /operation.
starting. are charged.

- Lub oil tank level is - Local check.


ADEQUATE.
- Anyone LOP is ON and - Local operation.
other one are on AUTO.

- Fan EPBs are in - Local operation.


RELEASED position.

- FD fan discharge - UCB check.


dampers are OPEN
100%.

- FD fan blade pitch - Local


controller is check/operation.
OPERATIONAL and is on
REMOTE. Instrument
air pressure is
AVAILABLE.
- Any or both ID fans: ON - Interlock. UCB check.

3 CHECK if secondary - APHs' secondary air - UCB


air system is lined-up isolating dampers are check/indication.
before starting FD fan. OPEN.

- SCAPH is available - Local


operation/check.

KORBA SIMULATOR 84
- FD fan discharge - UCB checks.
dampers are
OPERATIONAL and
electrical supplies are
AVAILABLE.

STARTING PROCEDURE

WHEN BOTH THE FANS ARE OFF

ACTION OBSERVATION REMARKS

1 CHECK before - All pre-start checks are OVER. - "Blade pitch minimum"
starting FD Fan. and "Discharge damper
closed" permissive are
available after the fan
start command is given
- Control/lub oil pressure: OK
- Bearing temp is NOT HIGH.
- Blade pitch is MINIMUM.
- Discharge damper is CLOSED.
- Control oil temp is NORMAL.
- Local operator is INFORMED.
2 START the FD - Discharge dampers start closing - UCB indication.
fan motor.
- Blade pitch comes to minimum. - Controller output 0%.
- As soon as discharge damper - Associated saffron lamp
closes, "Blade pitch minimum" on.
permissive comes on.

- Fan takes starting current (300A - Red lamp ON indication


approx and comes down to no comes
load current of 15A).

- Discharge damper starts opening - Refer to the dampers


(for the fan started). logics.

- FD fan discharge pressure - UCB indication


increases.

- Blade pitch for the other fan - Associated saffron


goes to minimum. lamps come on.
- Discharge damper for the other - Interlock.
fan closes

KORBA SIMULATOR 85
3 Instruct local - Bearing temperature and - UCB OMNIGUARD
operator to vibration limits are: indicators must be
check bearing regularly checked for
vibration and bearing temperatures.
temperature.
Alarm Trip
Fan 90 oC 105 oC UCB indication
Motor 80 oC 95 oC UCB indication
Vibration. 2 mm/sec 2.5 mm/sec. UCB indication
Motor wdg temp. 120 oC 135 oC DAS indication

4 ADJUST the - Fan discharge pressure - Maintain furnace


blade pitch increases. draught between-5 to
controller to get 10 mm wcl and airflow
desired airflow. 30%-40% during
purging.
- Fan amperage changes
accordingly.

- Oxygen percentage varies


accordingly.

- Wind box pressure also varies,


with FD fan loading

5 MAINTAIN the - Wind box to furnace DP should - UCB indication.


Wind box to be maintained as shown: -
furnace DP as Boiler load<30%-30 to 40 mm of
per boiler wcl Boiler load>30% - 100 mm of
loading. wcl

WHEN ONE FAN IS RUNNING

ACTION OBSERVATION REMARKS

1 CHECK all fan - Bearing temperature is NOT - Associated saffron lamps


start permissive HIGH. (<60 oC) on
in the UCB.

- Control/lub oil pressure is OK. - Local check & operation

- Blade pitch controller position - Local/UCB check.


is at MINIMUM.

- Discharge damper CLOSED. - Interlock.

- Both ID fans are in SERVICE. - UCB check only.

KORBA SIMULATOR 86
- Control oil temperature is - Local check.
NORMAL

- Local operator duly informed.

2 START the FD fan - The fan breaker gets closed. - Red lamp ON.

- Discharge damper of the fan - UCB indication


starts opening

- Furnace pressure and total - UCB indication.


airflow increases slightly.

3 ADJUST the blade - Fan discharge pressure - UCB indication.


pitch to maintain increases
desired airflow
and wind box
pressure.
- Fan amperage increases - Maintain furnace draft &
accordingly Wind box DP

- Furnace pressure increases


slightly

4 CHECK vibration - The limiting values of vibration - UCB vibration & bearing
and bearing & bearing temperatures are: temperature indicators
temperatures in must be monitored
the UCB. regularly.
Alarm Trip
Vibration. 2mm/ sec.pk 3mm/ sec.pk - Check locally also.

Fan brg. 90oC 105oC

Motor Brg. 80oC 95oC

5 ADJUST biasing - Biasing setpoint comes to 50%. - It ensures equal fan


set pt. to 50%. loadings on auto mode.

6 TRANSFER FD - FD fan blades modulate to - Oxygen set point is


fans blade pitch maintain set oxygen generated as per boiler
control to AUTO. percentage. load. (Boiler master
output)

- Oxygen in flue gas varies - Maintain 3% to 6%


accordingly oxygen before APHs
depending on boiler
load.

KORBA SIMULATOR 87
FURNACE PURGE PROCEDURE
ACTION OBSERVATION REMARKS

1. CHECK ALL THE - "No boiler trip" command - Associated lamps


PURGE PERMISSIVE is AVAILABLE. corresponding to
IS satisfied on the each permissive
FSSS console. comes on in the FSSS
console.
- All ignitor valves are - UCB indication.
CLOSED.

- All HFO nozzle valves are - UCB indication.


CLOSED.

- HFO and ignitor trip - UCB check only.


valves are CLOSED.
- All pulverisers and - UCB indication.
associated raw coal
feeders are OFF.

- All mill hot air gates are - UCB operation from


CLOSED mill console
- Both PA fans are OFF - UCB check only.
- All fire ball and oil - UCB check only.
discriminating flame
scanners must be sensing
NO FLAME.

- AC/DC electrical power - UCB alarms


supplies to FSSS panels indications are reset
are AVAILABLE.

- All auxiliary air dampers - Permissive. UCB


of the wind box are check
MODULATING& furnace to
wind box DP > 40 mm wcl.

2. ADJUST aux. air and - Damper controllers come - UCB operation.


oil air dampers' to 50%
controllers to 50%
position &
TRANSFER damper
controls to auto
- After damper reset - Refer to the note in
programme is over, wind the end of the
box dampers modulate to section.
maintain set WB/F DP if
put on auto.

KORBA SIMULATOR 88
- Oil elevation dampers also - Refer to the
modulate with aux. air secondary air damper
dampers when no oil gun control logics
is in service

3. ADJUST ID and FD - Boiler airflow less than - On the total airflow


fan vanes and wind 30% annunciation goes indicator 27% and
box dampers to get off. 36% airflow
desired airflow and corresponds to 30%
wind box pressure. and 40% boiler MCR
airflow values.
- Boiler airflow and wind
box pressure are
maintained at less than
40% and 40 mm wcl,
respectively.

4. ADJUST burner tilt - All burners at all - UCB indication.


controller to 50% elevations and in all
position corners, come to
horizontal position

- "Burner tilts horizontal - UCB indication.


and Airflow less than 40%"
permissive comes ON.

- If all other permissive are - UCB check only.


satisfied, "Purge Ready"
indication comes ON.

5. PRESS "push to - "Purging" indication comes - UCB indication.


purge" button on the on the FSSS console.
FSSS console

- If in the meanwhile none - Refer to the FSSS


of the permissive are lost, logics
"Purge complete"
indication comes on FSSS
console, with a time delay
of 5 minutes.

- MFR-A & MFR-B get reset. - Indication on FSSS

- Boiler Trip "cause" also


resets.

- "Boiler MFR Trip" - UCB annunciation.


annunciation clears off.

KORBA SIMULATOR 89
WIND BOX CORNER NOZZLE ASSEMBLY

As soon as "NO BOILER TRIP" permissive becomes available, a "post trip damper
reset programme" is initiated. A separate timer starts and after a time delay of 5
minutes, coal air dampers are closed in a phased sequence, from the top. Elevation,
F, E and D closes first; then with a time delay of 5-second, elevation C, B and A
close. After all the coal air dampers are closed, 10 sec later, all auxiliary air and oil
air dampers are released for modulation. If the air damper controllers are in manual,
auxiliary dampers and oil dampers together follow auxiliary air damper controller
output. If the controllers are in auto, they will modulate together to maintain set
wind box to furnace DP. When oil is introduced, oil air dampers modulate as a
function of oil header pressure. After feeders are started, corresponding coal air
dampers modulate as a function of feeder speed, if put on auto.

Wind box to furnace DP must be maintained 40 mm wcl, when boiler loading is less
than 30% MCR. Above 30% loading wind box to furnace DP must be constantly
ramped up to the maximum of 100 to 120 mm wcl, at full load.

KORBA SIMULATOR 90
BOILER LIGHT-UP
PREPARATION FOR BOILER LIGHT-UP

ACTION OBSERVATION REMARKS

1. INSTRUCT fuel - HFO supply header pressure - Minimum 17


station operator to starts increasing, up to 24 2
kg/cm supply
start HFO & light oil Kg/cm .
2
header Pressure
(HSD), pumps. is required for
- Ignitor oil pressure opening HOTV.
(HSD) comes up, at the unit
fuel station locally.

2. INSTRUCT firing floor - Atomising steam pressure - UCB indication.


operator to charge starts increasing up to
HFO heating and 8.5 Kg/cm .
2

Atomising steam lines


locally - HFO temperature starts - Associated steam
increasing, provided line drains must
HFO re-circulation is charged. be opened.
Local.

3. OPEN HFO short - HO-55 valve open indication - UCB indication.


Re-circulation valves, comes on & oil flow is Not required if
HO-55. established up to the HFO trip other units are
valve. on oil firing.

4 INSTRUCT local
operator to

Put all HFO guns in - Oil gun ADV/RETRACT - Local operation


- their guides. indication comes in the UCB.

Check guns - Corresponding indication - Local operation


- ADVANCE/ RETRACT comes on, in the UCB.
mechanism.

'Put guns' selector - Associated gun on REMOTE - Permissive.


- switches on indication comes in the UCB. Local Operation
REMOTE.

Open all isolating - No indication in the UCB. - Gun start


- valves on oil & permissive.
steam lines of all Not simulated.
HFO guns

KORBA SIMULATOR 91
BOILER LIGHT-UP PROCEDURE

ACTION OBSERVATION REMARKS

1. CHECK these - Boiler "MFR TRIP" is RESET. - Purging


conditions before the complete. UCB
boiler light up indication.
- Pre-start checks for boiler - Local/UCB
light up have been check.
COMPLETED.

- Fuel oil system is adequately - Local operators


LINED-UP. responsibility.

- Super heater / Reheater air - Local operation.


vents are OPEN.

- SH/RH start-up vents are - UCB operation


OPEN.

- Ignition air fans are LINED- - Local operation


UP for operation

2. Open heavy fuel oil re- - HFO re-circulation valve - UCB indication
circulation valve opens up. Interlock before
opening HFO
trip valve.

3. OPEN heavy fuel oil - HFO trip valve opens up. - UCB indication
trip valve on FSSS
console.
- Short re-circulation valve - Interlock. UCB
closes. indication.

4. OPEN heavy fuel oil - HFO header pressure rises up - UCB indication.
control valve. 2
to 10 Kg/cm (approx.)

- "HFO" inlet and re-circulation - UCB


flow start increasing annunciation.

- "HFO header pressure very


low" alarms clear off.

- HFO temperature in the HFO - UCB indication.


header increases up to 110 oC
5. OPEN Ignitor oil trip - Ignitor oil trip valve opens up. - Associated red
valve lamp comes on.

- Ignitor air fans A & B, start - Refer to ignitor

KORBA SIMULATOR 92
automatically. trip valve logics.

- Ignitor oil and ignitor air - UCB indication.


pressure increase up to 23
2
Kg/cm and 400 mm wcl,
respectively.

- "Ignitor air to furnace DP low" - UCB


& "Ignitor oil/Atomising air annunciations
pressure low" & "Ignitor /Indication.
oil/HFO trip valve closed"
alarms clear off.

6. CHECK these - Drum level normal (-60 mm. - To take care of


parameters are within to 0, preferably on lower side). swelling effect
their operation limits.

- HFO temp. 110 oC . (Min. - HFO trip valve


temp. required is 95 oC). closes at 93 oC.

HFO atomising steam HFO trip valve


pressure 8.75 Kg/cm
2 is tripped at
2
6.5 Kg/cm
atomising
steam pr.
Light oil pressure more than
2
15 Kg/cm .

Ignitor atomising air pressure Ignitor trip


5 to 7 Kg/cm
2 valve closes at 8
2
Kg/cm of light
oil pressure and
2
4.5 Kg/cm of
instrument air
pressure.
Wind box pressure between
35 to 40 mm wcl

ADJUST HFO header - HFO header pressure set - M/A release


7. pressure set point to point is provided above the must be pressed
2
50%(13 Kg/cm ) and HFO pressure controller. for auto /
TRANSFER its control manual
to auto. changeover.

- HFO pressure controller


transfers to auto and
modulates to maintain the set
HFO header pressure.

KORBA SIMULATOR 93
8. CLOSE heavy fuel oil - HFO re-circulation flow valve - UCB indication.
re-circulation valve. closes.
- HFO re-circulation flow comes - UCB check
to minimum position only.

- HFO header pressure goes up - Controller


and is brought down to set action.
HFO pressure by auto
controller

9. PUSH " Pair 1-3 or 2-4 - In the first 10 secs of the pair - Associated
Start" push button. start trial time; ignitors 1-3 ignitors “ON”
and 2-4 are proven, in the indications
associated oil elevation. come on.

- "Ignitor Stop" light goes off in - If the flame is


the associated elevation. not proven,
spark ceases
and ignitor
Jamesbury
valve closes.

If minimum 3 ignitors are - Minimum three


proven on, command goes to ignitors should
corner 1 or 2, for the gun to be proven ON.
advance to the firing position,
provided associated ignitor is
on

- Gun. "Advance",
lamps come on

- Command is given to open the - Refer to the


associated atomising steam FSSS logics.
valve after the gun is fully
advanced.

- After the atomising steam - Refer to the


valve is fully open, command FSSS logics
is given to open the
corresponding HFO corner
nozzle valve.

- 25 second later command - UCB indication


goes to corner 3 or 4, as the
case may be, HFO nozzle valve
to open.

- Associated discriminating oil - Refer to the


flame scanners start sensing FSSS logics.
flame.

KORBA SIMULATOR 94
- HFO control valve modulates - Maximum HFO
to maintain set HFO header header pressure
pressure must not be
more than 13
Kg/cm2 (alarm)

10. ADJUST heavy oil - HFO header pressure changes - HFO trip valve
pressure controller to accordingly trips at the
desired firing header pressure
of 3.5 Kg/cm2

- Oil scanner performance


improves with increasing
header pressure.

11. PUSH second pair - HFO guns advance and - Refer to the
"Start"(Pair 1-3/2-4) corresponding nozzle valves FSSS oil gun
push button. open up. logics.

12. PUSH "Ignitor Stop" - All the elevation ignitors go - UCB indication.
push button to remove off.
ignitors if the oil flame
is stable in every corner
in the elevation

- If any discriminating scanner


flickers to show 'no flame',
corresponding oil nozzle valve
is closed automatically

KORBA SIMULATOR 95
PA FAN OPERATION
PRE-START CHECKS

ACTION OBSERVATION REMARKS

1 CHECK that all PA - PA fan bearing temp - Local/UCB checks.


fans start permissive NOT HIGH (<60oC.).
is satisfied.
- PA lub oil pressure is - If not, instruct local
ADEQUATE. operator to line-up.
- PA fan inlet guide vanes - This permissive is
are at MINIMUM satisfied after the
position. first PA fan start
command is given.

- PA fan FSSS start - This permissive is


command is AVAILABLE satisfied after the
(BOILER MFR: RESET & first fan start
all mill cold air dampers command is given.
are less than 5% OPEN).

- PA fan discharge damper - Interlock.


is CLOSED.

2 CHECK that PA fan is - PA fan lub oil coolers are - Local operation. Not
locally line up for CHARGED from aterside. simulated.
starting.
- PA Fan LOP : ON and - Local operation and
other pump is on AUTO check.

- PA fan lub oil tank level - Local check.


is ADEQUATE.

- PA fans EPBS are in - Local operation. Not


RELEASED position. simulated.

- PA fan guide vanes are - Local operation/


on REMOTE. Instrument check.
air pre. is AVAILABLE.

- PA fan discharge damper - Local check.


is OPERATIONAL and
power supply is
AVAILABLE.
3 CHECK. if air system - APHs primary air - UCB indication.
is lined up before isolation dampers are
starting PA fan. OPEN.

KORBA SIMULATOR 96
- Seal air fans are LINED- - Local operation. Not
UP and their suction simulated.
dampers AD-31/32/33
are OPEN.

- Mills' cold air dampers - Local operation Not


on REMOTE. Instrument simulated
air pre. is AVAILABLE.

- Furnace purging is - FSSS start command


COMPLETED and MFRs requirement is met.
are in RESET condition.

- All man material is - Local check.


removed from the
pulverisers.

STARTING PROCEDURE

WHEN BOTH THE FANS ARE OFF

ACTION OBSERVATION REMARKS

1 CHECK these - All pre-start checks - Local/UCB check.


conditions before COMPLETED.
starting the PA fan.

- Fan discharge dampers - UCB check only.


100% OPEN.

- Regulating vanes are 100% - UCB indication


OPEN.

- Lub. oil pressure is - If not, ask the local


ADEQUATE. (>.1.8 Kg) operator to line-up.

- FSSS start command (MFR - This permissive


- A&B reset on the FSSS becomes available
console and all mills cold once the first PA fan
air dampers are less than start command is
5% open) is ON. given.

- Bearing temperature NOT - Saffron lamp on.


HIGH. (<60 O C). (Permissive)

2 START the - Discharge damper starts - Associated red and


PA fan motor. closing. green lamps come
on.
- Regulating vanes of the fan - Saffron lamps
get closed. (permissive) glow on.

KORBA SIMULATOR 97
- All mills cold air dampers - Saffron lamp
go to less than 5% open (permissive) glow on.
and "FSSS start command"
permissive comes on.

- CB closed indication comes - Associated red lamp


on. comes on.

- Fan current shoots up to - UCB PA Fan


700A and comes to No load ammeter.
current 70A.

- Discharge damper opens - UCB indication.


and for the other fan, it
closes and regulating vanes
of the other fan also goes to
minimum position

3 ADJUST the PA fan - PA fan discharge pressure - Maintain furnace


guide vanes to get goes up. draught (-5 to -10
desired hot PA mm.)
header pressure of
760 mm wcl
- PA fan current go up. - Maintain desired
airflow in furnace.

- PA header pressure goes up


to 760 mm wcl, gradually.

4 INSTRUCT the local - Limiting values of bearing - UCB OMNIGUARD &


operator to check temperature and vibrations vibration indicators
bearing Temperature must be regularly
& vibration locally. monitored when the
fan is running.
Alarm Trip
Fan 96oC 105oC
Motor 85oC 95oC
Vibration 2 mm/ sec. 3 mm / sec.
Motor winding temp. 110oC 130oC - DAS points
- There must be no abnormal - Local check
sound from the fan or
bearings.

KORBA SIMULATOR 98
WHEN ONE FAN IS RUNNING

ACTION OBSERVATION REMARKS

1 CHECK before starting - All pre-start checks - Local/UCB check.


the PA fan. are COMPLETED.

- LOP: ON. Lub. oil - Corresponding saffron


pressure ADEQUATE lamp (permissive) on.
(1.8 -2.5 KSC)
- Discharge damper - UCB check.
(AD-15/16: CLOSED.
- Regulating vanes are - Associated controller
in MINIMUM position. output is 0%.

- Bearing temperature - Associated saffron


NOT HIGH (< 60 O C ) lamp is on.

- FSSS start command - Permissive.


is AVAILABLE.
- Local operator
informed prior to
starting of the fan.
2 START the PA fan - Breaker closed - Red lamp is on.
motor. indication on.
- Fan current goes up -
to 700A and comes
down to no load
current of 70A.
Discharge damper
AD-15/16 open up.

3 INSTRUCT the local - Limiting value of - Vibration and the


operator to check bearing vibration and OMNIGUARD bearing
bearing vibration and temperatures are: temperature indicators
temperature locally. in UCB must be
monitored regularly.
Alarm Trip
Fan. 95oC 105oC
Motor 85oC 95oC
Vibration. 2 mm / sec. pk. 3 mm / sec. pk.
- There should be no - Local checks.
abnormal sound from
the fan/bearings,
locally

KORBA SIMULATOR 99
4 ADJUST the fan guide - Fan discharge - Maintain PA Header
vanes to get desired PA pressure read approx. pressure
header pressure and 800 mm wcl. 760 mm wcl
equalise fan loadings. constantly
- PA header pressure
rises to 760 mm wcl.

ADJUST the fan - Header pressure and - Biasing set point can
biasing and header biasing set points be altered suitably to
pre. set point to 50% & have been provided change the fan
80% respectively and over the IGV loadings.
transfer vane controllers of PA fan
controllers to auto. A&B respectively.

- IGVs of both fans - Normal biasing is 50%


modulate to maintain for ensuring equal fan
set header pressure. loadings.

SHUT DOWN PROCEDURE

WITH BOTH THE FANS RUNNING

ACTION OBSERVATION REMARKS

1 TRANSFER the IGV - Manual mode - Use the M/A release


controls to manual indication comes on.
2 STOP all the - Three pulverisers only - If needed, stop more
pulverisers in excess of can be in service with pulverisers, to maintain
three from the top. one PA fan. the PA header pressure
at 760 mm wcl
Cut-in oil support if -
odd combination of
mills are running.

3 REDUCE IGVs of the - Fan discharge - UCB indication.


fan to their minimum pressure comes down.
position.
- Notice the other fan - If needed keep the
loading going up, to second fan also on
maintain the set manual & maintain PA
header pressure. header pressure.

4 STOP the fan motor. - The fan breaker opens - UCB indication.
- Discharge damper - Associated green lamps
(AD-15/AD-16), starts come on.
closing.

- Regulating vanes go to - UCB/local check.


minimum, position

KORBA SIMULATOR 100


WITH ONE FAN RUNNING

ACTION OBSERVATION REMARKS

1 SHUTDOWN all - Boiler total fuel flow - Adequate oil elevation must
running pulverisers starts decreasing. be cut-in before stopping
one by one. pulverisers.

- Oxygen percentage in - Ensure adequate FD fan


the flue gases starts loading & wind box
increasing. dampers opening to prevent
airflow from going < 30%
tripping the boiler
inadvertently.

- Associated mills cold


air dampers start
closing.

- Total airflow keeps


on decreasing.

- ID fan vanes
modulate (on auto),
to maintain set
furnace draught.

2 REDUCE the IGV of - PA fan discharge - UCB check only.


the PA fan to its pressure starts
minimum position. decreasing.

- PA header pressure - Maintain airflow and


decreases to 400 mm furnace draught
wcl, approximately.

3 STOP the PA fan & - Breaker open - UCB indication.


Rack-out the breaker indication comes on.
if required for
maintenance.
- Guide vanes of both - Associated red lamps come
PA fans will remain on.
at minimum
position.

- Discharge dampers
of both PA fans go to
100% open.

KORBA SIMULATOR 101


PULVERISER OPERATION
PRE-START CHECKS

ACTION OBSERVATION REMARKS

1 CHECK that all the - Pulveriser START PERMIT - Alternatively, if anyone


pulveriser start is AVAILABLE. (Boiler coal feeder is proven then
permissive is total airflow is < 40% and start permit will come
satisfied. all burners are from the proven feeder.
HORIZONTAL).

- Mill discharge valves at all - UCB operation.


four corners are OPEN.
- Local feeder selector - Local operation/check.
switch is ON Not simulated.
REMOTE.

- Mill tramp iron gate is - Local operation. Not


100% OPEN. simulated.

- Cold air gate of the mill is - Local operation Not


100% OPEN. simulated.

- Pulveriser seal air valve is - Local operation Not


100% open. simulated. Seal air valve
opens on interlock when
pulveriser is started.

- "No unsuccessful start" - Refer to FSSS logics.


permissive for pulveriser UCB check only
is ON.

- "No pulveriser trip" - UCB check. Refer to


command is present. FSSS permissive

- Pulveriser PA Fan permit - Anyone or both PA fan on


is AVAILABLE. and PA header pressure
700 mm WCL

- Mill ignition energy permit - Interlock. Refer to FSSS


conditions are SATISFIED. logics for more details on
(Minimum 3 out of 4 gun ignition energy condition
nozzle valves in adjacent requirements.
elevation are open and
elevation oil flow is more
than 30% OR adjacent
feeder speed is more than
50% and boiler load is
more than 30%.

KORBA SIMULATOR 102


2 CHECK if the - All man and material - Local check.
pulveriser is locally removed from site.
lined up for
operation.

- Pulveriser oil bath level is - Local check.


ADEQUATE

- Cooling water isolation - Local operation. Not


valves to oil bath coolers simulated.
are OPEN.

- Mill cold air and hot air - Local check and


dampers are operation. Not simulated.
OPERATIONAL and on
REMOTE. Instrument air
pressure is available

- Seal air to pulveriser - UCB alarm and


differential pressure is indication.
125 mm wcl.

- Raw coalbunker level is - Local check/operation.


ADEQUATE and bunker
gate is OPEN.

MILL STARTING PROCEDURE

ACTION OBSERVATION REMARKS

1 CHECK these - All pre-start checks are - UCB/Local check.


before starting any OVER.
mill.
- All per missives are - Local check lamps are on
AVAILABLE.

- Electrical supply is - Local check. (Not


AVAILABLE. Breaker is simulated).
RACKED IN/REMOTE
position and feeder
selection switch is in
remote position.
- Mill's cold and hot air - CADs are <5% open.
dampers (CAD/HAD)
CLOSED.

- P.A. permit is - Anyone PA fan 'ON' & PA


AVAILABLE. Hdr pr. 770 mm wcl.

KORBA SIMULATOR 103


- Pulveriser on MANUAL - If not, set on manual.
MODE.

2 START the - Pulveriser start red lamp - It's a good practise to


pulveriser. comes on. keep primary header
pressure control on
AUTO, so that at the time
of sudden opening
of CAD, pulveriser does
not trip(time delay 5 sec.)
due to dip in the PA
header pressure(585
mm.).

- Pulveriser starting
current settles down at 12
amps.

- Mill cold air damper


opens 100%.

- Mill airflow 80 T/Hr.


(app.).

- Mill differential pressure


goes up to 100 mm wcl
approximately.

- PA header pressure dips


slightly until auto
controller opens the PA
fan guide vanes.

3 OPEN the - Hot air gate open - UCB check.


CAD/HAD to temperature increases.
maintain desired
airflow and mill
outlet temperature.

- Mill differential pressure - Maintain mill outlet temp


goes up to 100 mm wcl, at 75 O C & mill airflow
approximately. at 60 T/Hr

4 CHECK before - Coal silo gate is OPEN. - If not, get it opened.


starting the mill
feeder.

- Feeder speed is MINIMUM - Feeder start permissive.


(0% - 20%), corresponding
to 9 T/Hr.

KORBA SIMULATOR 104


- The entire mill permissive - ''Pulveriser Ready'' lamp
is AVAILABLE. indication is on.

- Mill outlet temperature > - Feeder start permissive.


55 O C.

- Mill ignition permit is - UCB Check.


AVAILABLE.
5 START the mill - Feeder ON indication - Maintain mill temp and
feeder. comes on. airflow, as
recommended.

- Coal flow indicator reads - Maintain furnace


9 T/Hr. approx. draught.

- Mill current starts - UCB check only.


increasing.

- Mill outlet temperature - Control coal-firing rate


tends to come down. to control mill outlet
temperature.

6 RAISE mill feeder - Mill differential pressure - Watch the flame quality
speed gradually. goes up to 180 mm wcl. at improving in coal flame
34 T/Hr. coal firing, scanners. If flame is not
depending upon coal good, instruct the local
quality & mill condition.). operator to check the
furnace flame and oil
flame. If the need be
increased the HFO
pressure by adjusting
HFO control valve (to
2
approx. 12 Kg/cm .) to
improve flame quality.
- Mill current goes up to 30
-32 amp. At maximum
loading of 34 T/Hr.
depending upon the coal
grindability (Hargrove
index).

- Mill outlet temperature


may tend to drop.

7 ADJUST flow & - Flow & temp Control set - Refer to ACS drawings
temp control set points are provided over for details of flow and
points to 70% and CAD & HAD respectively. temperature controllers
50% respectively of the pulveriser.
and RELEASE mill
air control to auto.

KORBA SIMULATOR 105


- CAD & HAD modulates to
maintain 60 T/Hr.of
airflow and 75 O C of mill
outlet temperature.

8 CHECK the mill - There should be no - Local check only.


locally for any abnormal hunting of mill
abnormal sounds, current, which is
reject indicative of foreign
rate and return oil material ingress, usually.
flow.
Return oil continuous - Whenever the mill amp
flow should be noticed or DP is rising mill
through local Sight glass. rejects must be
evacuated.

NOTE:

- Oil support can be withdrawn or reduced depending upon LOAD,


IGNITION ENERGY and FEEDER PROVEN criteria.

- Operator must monitor continuously the mill temperature and bowl DP,
which should not exceed 95 oC and 200 mm wcl respectively.

- Before starting mill, operator must make sure water supply for oil bath
coolers.

- Mill outlet temperature should be in between 80 oC to 85 oC during


start-up. In no case it should be less than 60 oC and more than 90 oC.

- Coal feeding should be reduced if desired mill temp. is not maintained.


(When hot air damper is 100% open).

KORBA SIMULATOR 106


MILL SHUTDOWN PROCEDURE

ACTION OBSERVATION REMARKS

1 TRANSFER mill - Fuel master and feeder - M/A release push


feeder and fuel control transfer to button must be pressed
master controller manual. for auto/manual
to manual. changeover.

2 REDUCE feeder - Coal flow to mill starts - Maintain `mill


speed to minimum, coming down. temperature and airflow.
gradually.

- Other running feeders - Maintain loading on the


start loading up, to running mills by
maintain boiler loading, if adjusting the fuel
on auto. master.

3 STOP the mill - Feeder Off' indication - Associated green lamp


feeder. comes on, in the mill comes on.
console.

- Hot air gate closes with a - UCB indication.


time delay of 30 sec
approx.

- Mill current and - UCB indication.


differential pressure start
reducing as the mill
becomes empty,
gradually.

4 EVACUATE the - Mill temperature comes - UCB check.


mill reject chamber down to less than 50oC. Local operation.
locally and STOP
the mill.

- Mill CAD goes to <5% - UCB check.


open Interlock.

- Airflow to furnace drops


slightly.

KORBA SIMULATOR 107


TURBINE AND GENERATOR
SYSTEM OPERATION

KORBA SIMULATOR 108


KORBA SIMULATOR 109
VACUUM PULLING

ACTION OBSERVATION REMARKS

1 CHECK before - Auxiliary steam header - Aux. steam pr. must


starting vacuum charged and its pressure be 14 Kg/cm
2

pulling operation. ADEQUATE.

- Ejector PRDS is CHARGED - “Ejector steam pr.


and Ejector steam pressure is low" alarm should
ADEQUATE ( 7.5 Kg/cm )
2 not be there.

- At least one condensate pump - UCB operation


is ON.

- Main ejectors and GSC - Local operation DAS


CHARGED from the waterside check points Refer
(MC-11, 12, 13, 14, 19, 20 to condensate
OPEN & MC-15, 21 CLOSED). system.

- Condenser air valve CA-1/CA- - Local operation. Not


2 & air valves to main simulated
ejectors, CA-3/CA-4, are
OPEN.

KORBA SIMULATOR 110


- Surge tank level ADEQUATE. - UCB operation.
Condenser siphon filling - Local operation. Not
COMPLETED. simulated.

- Condenser vacuum breaker - UCB Local


valve must be CLOSED. Water operation.
sealing done.

- Condenser inlet & outlet - UCB operation.


valves are CLOSED. DAS indication

- Steam line drains to flash - UCB operation &


tank, are CLOSED check.

- MOT level is NORMAL and - UCB check and SGC


"MOT level low" alarm is 'Operation Release'
RESET. condition.

- At least one MOT vapour - SGC operation


extractor fan is ON. release criteria.
UCB operation and
check.

- Generator hydrogen pressure - UCB/SGC check.


2
must be 3.5 Kg/cm .

- Generator hydrogen purity > - UCB indication.


97%. SGC criteria.

- Hydrogen seal oil pressure - UCB indication &


should be more than 4.8 SGC criteria.
2
Kg/cm .

- Seal oil to hydrogen DP is - UCB indication &


ADEQUATE, 1.2-1.5 kg/cm .
2 SGC criteria.

2 START AOP and - "Control oil pressure low" and - UCB indication &
one JOP. "Lub. Oil pressure low" alarms check only.
get cleared off.

- Control oil pressure increases - UCB indication.


2
to 6.8 Kg/cm .
- Jack oil pressure increases up - UCB indication.
2
to 130 Kg/cm . "Jacking oil
pressure low" alarm clears off.

3 SWITCH-ON SLCs - Corresponding SLCs come on. These operations up


of AOPs, JOPs, to Step-3 can be
EOP, Gate valve executed

KORBA SIMULATOR 111


gearing and the automatically by
Lub. Oil temp SGC OIL Start-up
controller. programme.

- Turbine starts barring at 110 -


rpm approximately.

- Lub oil temperature controller


modulates to maintain set lub
oil temperature.

4 CHARGE - AS-83, CA-15 & CA-16 are - Local operator DAS


condenser priming opened. check.
ejector from steam
& airside.
- Condenser water box priming
initiated.

5 INSTRUCT local - CW header pressure - DAS indication.


operator to start increases, slightly.
one CW pump and
CHARGE both
condensers 50 %
approx., to curb
CW power
consumption.
- Condenser inlet & outlet - UCB operation.
valves are partially opened.

- Condenser flow starts - DAS indication.


increasing.

6 CUTOUT the - Priming ejector's steam and - Local operation.


priming ejector airside valves are closed.
after CW water
starts coming from
the air vents of
priming ejector.
7 OPEN seal steam - AS-85 and SLC gland steam - UCB operation.
line and header drains are opened.
drains & CHARGE
gland sealing
steam into the
turbine glands.
- Gland seal steam control - UCB operation.
opens up and gland steam
header pressure starts
increasing.

TRANSFER seal - Seal steam pressure control - Maintain a pressure

KORBA SIMULATOR 112


steam control to transfers to auto mode. 2
of 0.01 Kg/cm in
auto. the seal steam
header.
8 CHARGE starting - Starting ejector steam supply - UCB operation.
ejector by opening valve AS-80/ AS-81 is opened.
ejector’s steam
supply & air
suction valve.
- Air suction valve to starting - UCB operation after
ejector (CA-5/CA-6) is opened. steam supply valve
is 100% open
- Condenser vacuum starts - UCB indication.
2
increasing to 0.7 Kg/cm .

9 OPEN steam - Vacuum builds up to 0.92 - UCB indication.


supply valve to any 2
Kg/cm i.e 72 mm Hg (approx)
one main ejector as
per desired
vacuum.
- Turbine barring speed - UCB check only.
increases up to 220-RPM
approx.

- "Condenser vacuum low" - UCB annunciation.


alarm gets cleared off.

10 ISOLATE starting - Air suction valve (CA-5/CA-6), - UCB indication.


ejector by closing gets closed first. Interlock.
air suction valve
first and then
steam supply valve.

- Ejector steam supply valve - UCB operation.


(AS-0/As-81) is closed.

11 MAINTAIN rated - Condenser vacuum is - Condenser


condenser vacuum 2
maintained at 0.92 Kg/cm . backpressure high
of 73 mm Hg (back alarm is at 150 mm
pressure) Hg and turbine
tripping at 225 mm
Hg.

KORBA SIMULATOR 113


HP BYPASS AND LP BYPASS CHARGING
ACTION OBSERVATION REMARKS

1 CHECK before - Boiler stop valves S-42 & - UCB operation.


charging HP/LP S-64 are OPEN
bypass system.

- M S pressure 12 Kg/cm .
2 - UCB check.

- CRH and HRH steam line - UCB operation.


drains are OPEN.

- HP bypass oil unit's oil - Local check.


level NORMAL, its Pump
ON and its pressure
ADEQUATE.

- LP bypass rack is LINED - Local operation


UP and all setting &
tripping values checked.

- HP bypass downstream - Can be altered to


temperature set point is maintain desired HRH
at 200 O C approx. steam temp.

- HP bypass spray - UCB operation.


pressure set point: 70
2
Kg/cm .

- All isolating valves before - Local operation/ check. Not


the spray pressure simulated.
controller are OPEN.

- HP bypass upstream - Can be altered later to


pressure (main steam maintain desired main
pressure) set point is at steam pressure.
2
10 Kg/cm .

2 TRANSFER LP - LP bypass control - UCB indication.


bypass control to transfers to auto.
auto and SWITCH-
ON the Automatic
Control Interface
(ACI).

- HRH fixed set point - Refer to the text on LP


comes to 3 Kg/cm .
2 bypass. (Volume-1)

KORBA SIMULATOR 114


3 TRANSFER HP BP - HP bypass control - UCB operation.
control to auto. transfers to auto.

- HP bypass valves (BP- - UCB alarm "HP bypass


1/BP-2) start opening if valves open" comes on.
MS pr. is more than the
set point.

- CRH pressure starts - UCB indication.


increasing.

- HP bypass temp - Interlock.


controller and spray
pressure controller
transfer to auto and
maintain set values of
downstream temp &
spray pressure.

4 ADJUST main - Main steam pressure is - HP bypass console


steam pressure set maintained as per the set indication.
point to obtain point.
desired MS
pressure.

- HP bypass valves open or - Biasing should be


close, depending on maintained positive (set
whether set point is less point less than MS Pr.)
or more than the MS to ensure that HP
pressure respectively. bypass remains open to
maintain sufficient
steam flow in R/H

NOTE: -

1. MS pressure set point must not fall too much below the actual MS pressure;
otherwise due to pressure interlock (error deviation + 10), a fast opening
command is given to HP bypass control valves.

2. At 380 O C, HP bypass valves receive a closing command and their control trips
to manual. The temperature set point must be suitably altered to maintain the
desired HRH temperature.

3. For details on ACI (Automatic Control Interface) device, please refer to the text
on HP/LP bypass system (Volume-1)

KORBA SIMULATOR 115


TURBINE START- UP
PRE-START CHECKS

ACTION OBSERVATION REMARKS

1 CHECK that all the - All UCB indicators and - If required, contact
turbo-Supervisory recorders are functional the related C&I
instrumentations are and healthy. engineer for
functional. maintenance.

- All recorders are inked and


all instruments are
calibrated.

2 CHECKS before - Electro-hydraulic controller - Electrical supply for


starting the turbine for turbine is ON. the EHC must be
run-up ON (C&I).

- EHC isolating valves on sec - Local operation


oil lines to control valves
are open.

- Electro-hydraulic - Indication on
controller's output is zero. governor console.

- "EHC control fault" and - UCB annunciation.


"EHC Plunger coil off" If alarms are on,
alarms do not appear in the inform C&I
UCB. maintenance

- Speed reference set point - If not, bring it down


for the Speed Controller is to zero. The
zero or less than the indication is on
barring speed. turbine governor
console.

- Load reference set point for - If not, bring it down


the Load Controller and the to zero.
load limiter output are
zero.

- Speeder gear position is - If not, raise the


100%. speeder gear
position to 100%.

- Starting device is at 0% - UCB operation.


position. UCB indication.

KORBA SIMULATOR 116


- The alarms "TSE influence - TSE influence can
off" "Turbine stress effects be made on from
off" and "Turbine stress turbine relay panels.
cubicle fault" are not on. Local operation.
TSE influence is ON.

- Unit trip relay (A & B) are - If not, reset UTRs


in RESET condition after resetting MFR.
GTRs and checking
if stator water flow &
conductivity are
normal (UTR reset
permissive)

- "Turbine Trip" and "Turbine - UCB check only


Trip gear operated" alarms
are not on and Trip oil
2
pressure > 5 Kg/cm

All differential
expansions of the
turbine are NORMAL
and within the alarms
values
Alarm Trip
HPT +4.5mm +5.5mm
-2.5mm -3.5mm
IPT +5.0mm +6.0mm
-2.0mm -3.0mm
LPT +25 mm +30 mm
- 5 mm - 7mm
- Condenser vacuum is - "Condenser vacuum
NORMAL. 0.92 Kg/cm
2 low" (150 mmHg) &
approx. "Turbine electric
protection for low
vacuum" (225 mm
Hg) are not ON.

- Turbine SLC Drains is ON - These drains can be


and NOT FAULTED. "SLC switched ON/OFF
Drains fault" Alarm is not from the SLC
ON. section on turbine
panel.

KORBA SIMULATOR 117


- Turbine stop valves (ESV- - Check from both
1&2, IV-1&2). Control UCB indicators and
valves (HPCV-1&2), IPCV- local indicators.
1&2). Extraction block
valves (ES-1,2,3,7,5,6) are
CLOSED.

- Extraction NRV's (A2, A3, - UCB indication.


A4, A5) and CRH line
NRV's L/R are CLOSED.

- The turbine is on BARRING - Gate valve gearing is


and there is no abnormal open.
sound from the turbine &
its bearings.

- The Speed of rotation of - UCB indication.


shaft is between 200 and
220 rpm.

- Turbine "Control oil - Normal value is 6.5


pressure" is greater than 5 to 6.8 Kg/cm2 with
2
Kg/cm AOP and 7.5-8.5
2
Kg/cm with MOP.
- Turbine lub oil temperature - UCB indication.
after coolers is normal i.e.
45oC. (40oC + 5O C )

- Lub oil pr. is normal at 3.5 - UCB check


2
Kg/cm before coolers.

- Main oil tank level is - Local check. Normal


NORMAL. value is zero.

- Thrust bearing oil filters - Local check.


are NOT CHOKED. UCB alarm reset.

3 CHECK that the - MS strainer drains - Indications of all


entire turbine MS (DW-51/52/53/54) to flash electrical drains
strainer drains CRH tank are OPEN. available in UCB. In
drains HRH strainer case anyone is not
drains and ESV & IV open (indicated by
before seat drains are green lamp on),
open. open the same with
the respective
control switch.

KORBA SIMULATOR 118


- CRH drains
(DW-160/161/162/163) to
flash tank are OPEN.

HRH strainer drains to


flash tank,
(DW125/126/131/132) are
OPEN

ESV & IV before seat drains


to flash tank (DW-121/
122/123/124 and DW-
127/128/129/130) are
OPEN.

4 CHECK that the - Generator hydrogen - 2


3.5 Kg/cm max.
generator seal oil and pressure is NORMAL, more UCB/local
stator water system than 3 Kg/cm2 indication.
are in service and
healthy

- Seal oil pressure (turbine - UCB check


and exciter side) is more
2
than 4.8 Kg/cm

- Seal oil to hydrogen DP is - UCB recorder.


2
NORMAL (1.2 Kg/cm )

- Stator water flow is more - Normal value is


3 3
than 23 m /Hr. 27 m /Hr.

- Stator water specific - Maximum allowable


conductivity is less than 1 value is 5 micro
micro mho/cm. mho/cm.

- Stator water pressure is - UCB / local


NORMAL. (2.8 Kg/cm )
2 indication

- Generator and field - UCB operation.


breakers are in RESET
condition and Generator
/Field breakers tripped" & - UTR reset permissive
"Generator trip relay
operated" alarms are reset.

KORBA SIMULATOR 119


TURBINE ROLLING PROCEDURE
ACTION OBSERVATION REMARKS

1 CHECK turbine start- - Main steam, at the turbine - Applicable during all
up criteria as inlet should have minimum turbine start-ups.
determined from the of 50 oC superheat.
X-curves.
- M.S. pressure is 30 KSC - For cold start-up
approx. & temp. 280oC only.

- Criteria for Opening - Max/Min. SH steam temp. - Start-up curves X-


the ESVs. depending upon mid wall 1, X-2 and X-3
temp. of HPCV.
- Rolling to warm-up - Max. MS temp depending - Start-up curves X-4
speed of 600 rpm. upon saturated steam temp and X- 5.
and mid body temperature
of HP casing/ shaft
- Rolling up to rated - Required minimum mean - Start-up curve X-6
speed of 3000 rpm. metal temp of H.P Shaft
depending upon available
MS temp.

- Loading the turbine - Required minimum mean - Start-up curve X-7


after synchronisation. metal temp of IP shaft,
depending upon the
available HRH steam temp.
2 Maintain boiler side - The MS/HRH temp and - UCB indicators are
steam parameters as pressures are within the available for all these
required for turbine determined ranges. values.
start-up.
- HRH steam pressure - Low HRH pr. during
should not be more than startup is to prevent
2
15 Kg/cm during rolling. HP exhaust temp
rising too high.
3 RAISE starting device - Start-up oil pr. Falls to 1.8 - UCB indication on
to 70% gradually. KSC and HP ESVs (1&2) turbine governor
open 100% at 42% position console.
of starting device.

- Interceptor stop valves - UCB indication on


(1&2), open 100% at 56% turbine governor
position of starting device. console.

- Start-up oil pre. = 0 at 70% - UCB indication.


of starting device position.

KORBA SIMULATOR 120


Aux Sec oil pressure UCB indication
increases up to 4 KSC
4 SWITCH ON SLC - Drains before HP control - Refer to the SLC
"Warm-up controller" valves, (HPCV-1/2), start logics.
is required (during opening, 100%.
cold rolling)
- HP ESVs and control - Surface and mean
valves, heating starts and temp start rising.
their respective temp. start Indicated on TSE
increasing. recorders.

- Wait until the mean - Min. temp


temperatures of HPCVs requirement for HPSV
come to min. 200 - 250 oC. /HPCV is only for
absolute cold start-
ups
- Upper TSCmargin for - Maintain all TSE
admission channel starts margins of Admission
droping slowly & after channel > 30 K.
minimum temp are
attained, starts improving
again.

- The metal temperatures of - The heating-up of


ESV/CV body are within stop/control valves is
30oC of the MS temp complete.
preferably.

5 RAISE speed - EHC starts increasing from - Speed controller is in


reference set point to its initial zero position. action during turbine
600 rpm. rolling.

- HP CVs start opening. - UCB indication.


- Turbine speed starts rising - TSE/UCB indication.
to 600 rpm at a rate
selected by TSE.
- The gate valve for turbine - Refer to the SLC
barring starts closing when logics for gate valve
turbine speed comes to 240 gearing.
rpm. "Gate valve gearing
not closed" alarm starts
flashing and resets after
the valve gets fully closed.

- The JOP trips in auto as - Refer to SLC logics for


the turbine speed comes to JOPs.
540 rpm. UCB indication.

KORBA SIMULATOR 121


6 MAINTAIN turbine - DT (MS temp. – Mean HP - Start-up curve X-6.
speed and soak till shaft temp) becomes less
required HP shaft than the value specified by
temp is attained. turbine start-up graphs.

- HP shaft mean temp - Maintain all TSE


becomes steady after 40 margins more than
minutes (approx) 30 K.

7 RAISE turbine speed - Turbine EHC's output - Indication on


reference set point to starts increasing slowly. governor console.
3030 rpm.
- Turbine control valves - Indication on
(HPCV & IPCV) start governor console.
opening more.

- Turbine speed starts - Ensure TSE margins


increasing gradually at a to ensure a min.
rate decided by turbine speed gradient of >
stress evaluator. 108 rpm /minute to
avoid DN/DT
protection.

- "Turbine/Gen. bearing - Critical speeds.


vibration high" and (RPM)
"Turbine absolute shaft
1370
vibration high" alarms flash
1544
when turbine speed crosses
2125
1400 rpm and 2200 rpm
(approx.) and vibration
levels increase appreciably
and again become normal

Bearing temperatures - If vibrations are


display an upward trend already on higher side
before the critical
speeds, DO NOT
ROLL and soak at
600 for some more
time until vibrations
become normal.

8 MAINTAIN turbine - DT (HRH steam temp- - Start-up curve X-7.


speed. Soak until Mean IPS temp) becomes
required IP shaft less than the value
temp is reached and specified by turbine start-
SET load reference at up graphs.
20-40 MW and load
gradient at 10 MW
/Minute (Max).

KORBA SIMULATOR 122


- Load limiter set point
must be more than
load ref.

- Load controller is set at 20- - Refer to the generator


40 MW to ensure speed loading
controller transfers to load recommendations.
controller after
synchronising.

- CHECK all the - All bearing pedestal - UCB/DAS


turbine / generator vibration is less than 35 indications.
parameters before microns.
synchronisation.
- All relative shaft vibrations - UCB/DAS
are less than 150 microns indications.

- All bearing babbit metal - UCB/DAS indication.


temp are less than 80 oC

- Bearing return oil flow is - To minimise ageing of


normal and temp < 77 oC. turbine oil.

- All casing absolute - HPT - < 15 mm.


expansions are within IPT - < 10 mm.
normal range.

- Thrust bearing oil filters - Local checks.


are clean (not choked).

- Axial shift < + 0.3 mm. - UCB indication.

- Turbine casing top/ bottom - UCB indication.


temperature is< 30 oC.
- Condenser vacuum is - UCB check.
2
normal at 0.92 Kg/cm

- Gen hydrogen pressure is - Local/UCB check.


normal at 3.5 KSC
- Stator water flow is More - Local/UCB check.
3
than 27 m /Hr.

- Stator water specific - UCB check.


conductivity is less than 5
micro mho/cm.

- Seal oil to hydrogen DP is - UCB check.


2
normal (1.2-1.50 Kg/cm ).

KORBA SIMULATOR 123


GENERATOR SYNCHRONISATION
ACTION OBSERVATION REMARKS

1 CHECK all the - Stator cooling water flow - UCB indication


generator Parameters more than 21 T/Hr.
are healthy
- Stator cooling water temp - UCB indication
less than 40 oC.

- Cold end hydrogen temp - UCB indication


less than 40 oC

- Seal oil pressure at turbine - UCB indication


and 5.0 KSC

- Seal oil pressure at exciter - UCB indication.


end 5.0 KSC

- Seals oil D.P. between1.2 - - UCB indication


1.5 KSC

Generator stator water UCB indication.


specific conductivity is less Alarm: 12 µ mho/cm
than 5 µ mho/cm Trip: 20 mho/cm
Gen. hydrogen and stator Local operation.
water coolers are charged Remote function.
and ''Clarified water
pressure to hydrogen &
stator water coolers low''
alarm is not on.

2 CHECK before closing - Turbine RPM is more than - UCB & switchyard
the field breaker 2980 rpm. Generator operator's
before isolators are closed from responsibility/ UCB
synchronisation switchyard. indication

- Generator excitation control - Field breaker does


is on REMOTE. not close from UCB if
control is on local.

- Generator excitation control - UCB indication.


is on MANUAL OR AUTO.

- AUTO/MANUAL excitation - Associated white


controllers are on HOME lamp is ON. If not,
position. lower it down to
home position.

KORBA SIMULATOR 124


3 CLOSE the generator - Generator field breaker gets - Associated red lamp
field breaker. closed & Generator voltage comes on.
increases to 10 KV, 15.75
KV approx. on manual /
auto excitation control,
respectively.

- Field current and voltage - UCB indication


also increases 700 A &
90 V respectively

4 RAISE generator Generator voltage comes to UCB indication.


excitation manually, 15.75 KV approx.
to raise gen. voltage.
- Field current and voltage - UCB recorders.
increase to 900A & 105V
respectively.

- Generator gas and rotor Maintain all temps


winding temperatures start within LIMITS.
increasing.

Alarm Trip
Cold gas temp. (HI) 47oC -

Hot gas temp. (HI) 52oC 75oC

Rotor wdg. temp. (HI) 85oC 110oC

5 CHECK all the - All the three phases - UCB indication


generator voltages should read equal voltages
(phase to phase).
6 SWITCH-ON the - IN-COMING/RUNNING - UCB indication &
synchroscope to voltages and frequencies operation.
CHECK mode. start showing on their
Corresponding meters.

- Alternatively - Synchroscope needle starts - If the direction of


synchroscope is put on rotating at a rate rotation is clockwise
Check mode and auto proportional to difference the incoming
synchroniser can be between the generator and generator frequency
switched on. grid frequencies. is higher than the
grid & vice-versa.

7 ADJUST turbine speed - Incoming and grid - Synchroscope


reference to match frequencies should become indications.
generator freq with the equal.
grid (running).

KORBA SIMULATOR 125


- Synchroscope needle slows - Incoming freq. must
down as the frequencies be higher than that
match. of grid before
synchronising.

8 ADJUST generator - Grid and generator - UCB/synchroscope


excitation to match the voltages start meter readings.
gen. voltage with that matching.
of grid.
- As synchroscope needle - With synchroscope
comes to 11'O clock on check mode the
position (clockwise), the generator can be
green CHECK lamp comes synchronised
on & the red lamp goes off. (breaker closed) only
At 12' O clock position the when the green lamp
check lamp goes off and is on.
red lamp comes on again.

9 CLOSE the generator - ''Generator Breaker'' gets - If the breaker fails to


breaker when the closed, if all parameters close.'' Gen. Breaker
check lamp is green. are matching during the Trip'' alarm comes on.
''close'' command. re-set and try again.

- ''Generator motoring'' alarm


comes on.

- Synchroscope needle gets - Synchroscope red


locked in 12'O clock lamp stays "ON"
position.

- Generator line charging - Power factor becomes


MVAR (approx.-80 MVAR) leading for some
indication comes on. moments and
becomes unity again
depending upon the
gen. Load and
excitation.

9A INCREASE Starting Starting device comes to UCB indication.


Device to 100% 100 %.

10 RAISE speed - Turbine load increases to - Speed reference can


reference slightly to 20 MW approximately. be operated from
increase Gen load, generator desk if the
immediately after ATRS selector switch
closing the generator is on UCB mode.
breaker.
- ''Generator motoring'' alarm - UCB indication
clears off.

KORBA SIMULATOR 126


- ''Speed controller'' transfers - UCB indication
to 'Load controller'' after
some time delay.

11 RAISE excitation auto - Excitation null voltage - UCB indication.


set point until the becomes zero.
excitation null voltage
becomes zero and
TRANSFER excitation
to auto.
- Automatic voltage regulator - Manual channel
gets transferred to Auto. backs the auto
channel if AVR is on.

12 CHECK all the - Generator winding - UCB indication.


generator parameters temperatures less than 85
are OK and all O C (alarm.)

phases show equal


currents.
- Generator transformer - UCB indication.
winding temp less than
90 O C (alarm.).

- Rotor winding temp are less - UCB indication.


than 85 O C (alarm).

- Gen. cold gas temp is less - UCB recorders.


than 47 O C (alarm).

- Hydrogen cooler inlet water - Local/DAS check.


temp is less than 36 OC
(max.)

- Hydrogen cooler outlet - DAS/Local check.


water temp is less than 43
OC. (max.).

- Stator water temp at the - DAS/Local check.


inlet of stator is less than
44 O C (maxi.).

- Stator water outlet - UCB/Local check.


temperature is less than 70
OC. (max.)

KORBA SIMULATOR 127


UNIT SUPPLY CHANGEOVER FROM STATION TO UAT
ACTION OBSERVATION REMARKS

1 CHECK before - Unit load is more than 40 - UCB check.


changing over MW
6.6 KV bus supply
station to unit
auxiliary
transformers.
- All HT buses incomer - Local operation.
breakers from UATs are in Must be done before
SERVICE/REMOTE closing field breaker.
position.

- UATs (A&B) on load, tap - Local check.


changer gearbox oil levels
NORMAL.

- UATs conservator tank oil - Local check.


level ADEQUATE.

- UATs cooler cubicle power - From TG MCC.


supply is normal.

- UATs breather silica gel - Local check.


colour NORMAL.

- UATs mulsifire system - Local


AVAILABLE. Its air check/operation.
pressure and water
pressure NORMAL.

2 SWITCH-ON - RUNNING/INCOMING - UCB indication.


synchroscope voltage comes on and (Synchroscope
to CHECK mode. indications come on. switch CS-1006, S-
20 and CS-1007, S-
26 for bus A & B
respectively).

- Unit synchroscope red lamp


comes on and needle comes
to its zero vertical position.

KORBA SIMULATOR 128


3 ADJUST OLTC (on - Synchroscope green lamp - Without the green
load tap changer) of comes on after the two lamp CHECK that
the UAT (A or B) to voltages are matching associated breakers
make incoming cannot be closed.
voltage equal to
running voltage.

- Incoming/running voltage - UCB/Synchroscope


and frequency indications indication.
match.

4 CLOSE UAT (A/B) - UAT incomer to bus - Associated red lamp


incomer to Unit bus. breaker gets closed. comes on.

- ''Unit/Station transformers - UCB annunciation


paralleled'' annunciation Generator panel
comes on.

5 Immediately OPEN - Station breaker opens up. - Associated green


the station breaker. lamp comes on.

- ''Unit/Station transformers - UCB annunciation.


paralleled'' alarm clears off.

6 ADJUST OLTC & - UAT winding temperature - Alarm 85 0C UCB


MAINTAIN Unit bus starts rising. indication
(A/B) voltage at 6.6
KV.

NOTE: For changing-over the supply from UATs to station or station to UATS use
appropriate synchroscope switches. OLTC operation of station transformer
is not simulated. In the reference plant the same is operated from CSSAEP
panel located in UCB-1.

KORBA SIMULATOR 129


LP HEATERS CHARGING

ACTION OBSERVATION REMARKS

1 CHECK these - Generator load is at least - UCB check only.


conditions are 40 MW.
satisfied before
charging the LP
heaters.

- All LP heaters are - Local check and local


CHARGED from waterside function.
and their bypass valves are
closed.

- All LP heaters airline to - Air vents not


condenser, are OPEN. simulated

- Local operation, not


simulated.
- All pneumatic drain valves - Local
are OPERATIONAL & on operation/check.
REMOTE.

2 OPEN LPH-1 - LPH-1 extraction block - UCB operation.


Extraction steam valves opens.
block valve ES-1.

- Condensate temperature - DAS/Local check.


across LPH starts rising.

3 OPEN LPH-2 - LPH-2 extraction block - UCB indication


extraction block valve valve goes open
ES-2.
- Associated line drain valve - Interlock.
DW-83 starts closing after
the extraction block valve
opens 100%.

- LPH-2 alternate drain to - Interlock.


condenser HD-14 starts
closing.

- "LPH-2 level low" alarm - UCB annunciation.


clears off.

KORBA SIMULATOR 130


- LPH-2 normal drain valve - Associated Green/red
HD-11, starts modulating indication come on.
to maintain the level.

- Condensate temperature - Levels can be


after LPH-2 starts rising monitored locally
(DAS check). only.

4 OPEN LPH-3 - LPH-3 extraction valve ES-3 - UCB indication.


extraction block valve goes open 100%
ES-3.

- Associated line drain valve - Interlock.


DW-80 starts closing after
ES-3 opens 100%.

- Alternate drain valve HD-19 - Interlock


starts closing.

- "LPH-3 level Low" alarm - UCB annunciation.


clears off.

- LPH-3 normal drain valve - Associated green and


HD-16 starts modulating to red lamps start
maintain the LPH-3 level. glowing.

- Condensate temperature - DAS/Local check.


across LPHs starts rising.

5 INSTRUCT local Airlines can be fully It is preferable that all


operator to throttle all isolated after 80 MW load. feed heaters be
LPH's airlines to evacuated at least
condenser and check once in the shift by
LPHs levels. opening their
respective side air
vents to condenser

LPHs levels are maintained


within alarm limits

KORBA SIMULATOR 131


HP HEATERS CHARGING
ACTION OBSERVATION REMARKS

1 OPEN extraction - Extraction block valve ES-7 - UCB indication.


steam block valve ES- opens 100%.
7 to Deaerator.
(Extraction to DA is
charged immediately
after 40 MW)
Associated line drain valve - UCB check.
DW-79 closes 100% Interlock.

- De-aerator pressure - At higher loads DA


increases to 4 Kg/cm
2 pressure varies with
(approx.) IPT exhaust
pressure.

2 ADJUST Deaerator - D/A pressure set point is - Use M/A release


pre. set point to 35% provided over
( 3.5 KSC) & release D/A pr. controller.
its control to auto.
- D/A pre. controller valve - UCB indication
starts closing if extraction
steam pre. is >3.5 KSC.

3 CHECK before - Unit load is more than - UCB check only


charging the HPH- 120 MW.
(5&6).
- HPHs inlet/outlet valves - Give ''In-Service''
(FW-43/44/46/47) are command to HPHs
OPEN and individual after opening vents
bypass valve FW-45/48 are on the feed water
CLOSED. lines of HP heater.

- HPHs group bypass valves - FW-34/35, the group


are IN-SERVICE position bypass valves can be
and "HPHs bypassed" alarm operated (de-
is NOT On. energised) from UCB.
And opening of
pressurising valve
locally cause group
bypass to open, in
case they are not
open previously)

- All HPHs shell drains are - Local operation. Not


OPEN. simulated.

KORBA SIMULATOR 132


- All HPHs airlines to - Local operation. Not
condenser isolating valves simulated
are open.
4 OPEN HPH-5 extr. - Extraction steam block - UCB indication.
steam block vlv ES-5. valve ES-5 opens 100%.

- After ES-5 is open, extr. - Interlock.


line drain DW-73 closes.

- HPH-5 alternate drain to - Refer to the


condenser HD-31 closes associated logics.

- "HPH-5 level low'' alarm - HPH level start


clears off. building-up.
- HPH-5 normal drain to D/A - Level checks local
starts modulating to only.
maintain the level.
- Feed water temp after HPH- - DAS/local
5 starts increasing. indications.

5 OPEN HPH-6 - Extraction block valve - UCB indication.


extraction steam ES-6 opens 100%.
block valve ES-6.
- Extraction line drain - UCB indication.
DW-74/75 valves close. Interlock.
- HPH-6 alternate drain to - Interlock. UCB
condenser closes and annunciation panel
''HPH-6 level low'' alarm indication.
clears off.
- HPH-6 normal drain to D/A - Level checks local
HD-51 starts modulating to only.
maintain HP heater level.
- Feed water temp after - DAS/local
HPH-6 starts increasing. indications.

6 INSTRUCT local - NOTE: HPH-6 drain to - UCB operation &


operator to close all HPH-5 can be charged, ckeck.
feed line vents and provided extraction steam
shell drains of the HP pressure to HPH-5 is more
heaters. than 3 KSC and there is no
''level high'' command in
HPH-5 (Block valve HD-39
can be opened).

NOTE :
Isolating valve of Group Bypass charging line (pressurising line) locally has
to be opened. This only causes group bypass to operate after some time.
''HPHs bypass'' indication is from the group bypass valve limit switch, not
from the solenoids.

KORBA SIMULATOR 133


SUPERHEAT AND REHEAT STEAM TEMP. CONTROL
ACTION OBSERVATION REMARKS

1 OPEN super-heater - Super-heater block valve - RH block valves: DC


and reheater spray S-80 and re-heater block solenoid operated
water header block valve R-40 is opened 100%. and the SH block vlv
valves. are motor operated.
2 OPEN S/H and R/H - S/H attemperation block - Associated red lamps
attemperation block valves S-83/S-86 on are on. One block
valves, one stream A stream-A & S-89/S-92 on valve each on stream
& B. stream-B open 100%. A&B is to be opened.

- R/H attemperation block - Associated red lamps


valves R-43/R-46 on come on.
stream-A and R-49/ R-52
on stream-B open 100%.

- Manual/auto release - UCB indication.


flickering stops, enabling
the releasing of associated
controllers to auto.

3 OPEN Manual - Valves S-88, S-85, S-91, - Local operation. Not


isolating valves after S-94 and R-48, R-45, R-51 simulated. DAS
control valves (A & B) and R-54 are open indication.

4 OPEN S/H - S/H attemperation flow - UCB recorders.


attemperation control increases.
valves.
- After attemperation - UCB recorders.
temperature starts Maximum diff.
dropping and the difference permissible is 50oC.
between before & after
attemperation starts
increasing.

5 ADJUST S/H outlet - S/H temperature set points - M/A release must be
temp set points to are provided over respective pressed for manual
90% each. (540oC). controllers. to auto transfers.

- ADJUST hot reheat - Hot reheat temperature set - Auto controller for
temp set point to 90% point is provided over SH/HR temp trips to
and biasing set point burner tilt controller. manual if BFP DP
to 50%. across FRS is >
20KSC

KORBA SIMULATOR 134


- RELEASE burner tilt - Burner tilt controller and
controller & SH/RH SH/RH control valves
steam temperature modulate to maintain set
controllers to AUTO. steam temperature.

NOTE : Hot reheat temperature should be primarily controlled by controlling firing


rate. If firing rate cannot be reduced, burners can be tilted downwards,
provided boiler loading is adequate and furnace flame is stable. THE
REHEATER ATTEMPERATION MUST BE RESORTED TO IN THE LAST.

The re-heater attemperation causes a great loss in the cycle efficiency, as


the HRH steam does not do any work in the HP turbine.

KORBA SIMULATOR 135


SOOT BLOWER OPERATION
ACTION OBSERVATION REMARKS

1 CHECK these - Boiler load is more than - Furnace stability


conditions before 75%. criteria.
soot blowing.
- Furnace flame is STABLE. - If not, cut in oil
support.
- Soot blower MCC power - Supply is provided in
supply (220V) is ON. the Boiler MCC
panel.

- Soot blowers control supply


(415V) A/C) is ON.

- All blowers are in 'HOME' - No red lamp


position. indication should be
'on' on the UCB panel.

- Soot blower header drain - UCB operation


valves are in OPEN position.

- Main steam inlet isolating - SB 109 is UCB


valves to soot blower operated.
system, SB-108/SB-109 are
CLOSED.
- SB 108 is locally
operated (not
simulated).

- Soot blower steam pressure - Root valve not


control valve SB-4 simulated.
(pneumatic) is Pneumatic pressure
OPERATIONAL and its control valve
impulse/root valve is OPEN. maintains approx. 20
2
Kg/cm of steam
pressure tapped off
from SH header No.
10.

- Uni-selector (stepper) relay - Sequence Complete


is in its STARTING indication is ‘ON’ on
POSITION. the soot-blowing
panel.

KORBA SIMULATOR 136


- Soot blowers' selection - Individual switches
switches should be on are provided on the
AUTO or BY-PASS positions UCB soot-blowing
as per soot blowing panel.
requirements.

- Individual blowers' overload - Local operation from


tripping must be RESET'. (If individual blower
operated) MCC. Not simulated.

- Blower control panel - UCB operation


selector switch is on
'PANEL' position.

2 OPEN electrical - SB-109 opens up 100% - UCB indication lamp


isolating valve comes on.
SB-109 completely.

- Steam pressure and - 'Pr. Low' and 'Temp.


temperature gradually raise Low' indication gets
to approx. 20 Kg/cm2 and reset on the soot
blowing panel.
280 oC respectively.
- OPEN manual
isolating valve SB-
108 gradually for
warming up lines.

3 CHECK steam - Temperatures in all four- - Temp low is a


temperature drain lines must be greater sequence interrupting
in all the four drain' than 220 oC each. protection/ condition.
points by operating
the selector switch
provided on the
panel. CLOSE all the
four drain valves
once the required
steam temperature
is achieved.

- All four-drain valves on soot - UCB operation.


blower header are CLOSED. Drains closed is an
Interlock/
Permissive for
sequence starting.

KORBA SIMULATOR 137


4 PUSH ' Reset' Push - ''Soot blower system - UCB indication.
Button on UCB soot trouble'' alarm clears off
blower panel and
then SEQUENCE
START push button.

- 'Pressure/temp low' alarms - UCB indication on


get reset. soot blower panel.

- ‘‘Sequence On’’ indications - Red indication comes


come on. Wall soot blower on the soot blower
leaves its 'HOME' position panel.
and advances to its
operating position (provided
it is selected on (AUTO).

- Steam header pressure dips - Steam pressure


slightly as the soot blower maintained by the
opens. Pressure control valve.

- After approximately 1.5 - RED indication goes


min. the blowers retracts to off.
its home position.

- Next blower on Auto comes - Total 56 nos of wall


into service with a time blower are provided in
delay of 3 seconds and the boiler, each with a
sequence continue. One blowing time of 1.5
blower at a time. minutes.

NOTE :

1. LRSBs are numbered from 57 onwards up to 80 for soot blowing in platen


S/H, final S/H, horizontal S/H and economiser respectively.

2. Blowing time for LRSBs is approx. 8 min. and blowing operation for LRSB
continues right from the moment it leaves its home position unlike wall
blowers in which case, blowing starts after the blower reaches blowing
position.

3. APH soot blowing is also possible through auto sequential operation


besides independent/manual operation with aux. steam. Their total
blowing time is approx. 45 min. and blowing takes place only during the
forward stroke.

4. Recommended frequency for wall blowers is once a shift, for LRSBs it is


once a day and for APH soot blowers during oil firing or whenever the
gas/air DPs across APH exceed the normal value by 30-40 mm wcl.

KORBA SIMULATOR 138


KORBA SIMULATOR 139
UNIT COLD START-UP

KORBA SIMULATOR 140


KORBA SIMULATOR 141
UNIT COLD START UP PROCEDURE
ACTION OBSERVATION REMARKS

1. CHECK all pre-start - All work permits on main - Refer to the PTW
conditions are boiler, all electrical panels, record book and
satisfied before all aux. Systems are unit controller's
starting the unit CANCELLED logbook.
from cold.
- All man/materials are - Local checks.
REMOVED from equipments
and site.
- Lube oil levels in bearing - Local Checks. Not
and MOT/oil tanks are simulated.
ADEQUATE.
- Clarified/Raw water pumps - Local checks/
are ON and water systems operation.
are LINED-UP. Not simulated.
- Ash hopper sealing/ flushing - HP/LP water pump
water Supplies are are ON Not
AVAILABLE. simulated.
- Service/Instrument Air Pr. - Local operation.
ADEQUATE (7-8 kg/cm ).
2 UCB indications.

- Water treatment division has - Shift-charge’s


been INFORMED and DM responsibility.
water storage is ADEQUATE.

- Generator hydrogen filling - Local operation. Not


system is LINED-UP. simulated.
- Generator seal oil system is - Local operation. Not
line-up. simulated.

2 OPEN all drains/ - Valves AS-5, AS-6 AS-8, AS- - Local operation.
vents on aux. steam 9, AS-10 are OPEN. Not simulated.
header & line-up unit
aux. steam hdr for
charging.
- All aux. steam (unit) supply - Local operation.
valves AS-11/ 12/ 13/ 14/
16/17/18 19/32 are OPEN.
3 OPEN AS-31, the - Unit aux. steam pressure - UCB indication.
interconnection starts rising to 13 kg/cm
2

between aux. steam


hdr of U#1, U#2, U#3.

KORBA SIMULATOR 142


- Aux. steam temperature goes - DAS/UCB
up to 220oC (approx.) indicated.

4 CLOSE all associated - All aux. steam hdr drains & - Local operation.
drains and vents on vents are closed after the Not simulated.
the aux. steam aux. steam header reaches
header to 2-3 kg/cm
2

5 INSTRUCT local - Hydrogen pressure in the - Local/UCB check (If


operator to charge generator starts rising and air is filled-up then
seal oil system and comes to 3.5 kg/cm
2 CO2 must be
then hydrogen (approx.) H2 pressure will be charged to expel the
cylinders into 2 air and after
raised to 3.5 kg/cm only
generator casing. recommended CO2
after achieving the gas
purity. Before that pr. is to purity is achieved
be maintained 2 to 3 kg/cm
2 hydrogen filling is
to reduce H2 consumption. started.

Seal oil to H2 DP is to be UCB indication.


maintained at 1.2-1.5 Local operation.
2 Not simulated.
kg/cm

6 ENSURE before boiler - At least one condensate and - Refer to the


filling, all one boiler feed pump is respective operation
preparations have LINED-UP and READY for instruction.
been made operation.

- Condensate and feed water - Local/UCB checks.


systems are
LINED UP.

Economiser and super- Local operation.


heater air vent are OPEN Not simulated.

Drum air vents and SH/RH Local UCB


start up vents are OPEN operation.
fully.

Drum emergency blow-down UCB operation.


valves B-82, B-83 and
intermittent blow down
valves B-105, B-106 are
CLOSED.

KORBA SIMULATOR 143


CBD and low point drains Local operation
(LPDs) are CLOSED. (Remote functions).
LPDs not
simulated.

HP/LP chemical dozing UCB operation &


stations are LINED-UP & local checks.
AVAILABLE.

Boiler Economiser re- UCB operation.


circulation valves E-27, E-29 Not simulated.
are OPEN.

Aux steam connection to UCB/Local check.


D/A, AS-64 & AS-16 is
OPEN.

D/A pressure set point is at UCB operation.


10%-15%. (Corresponding to
1.5 kg/cm2 DA pressure)

D/A storage tank heating Local operation.


valves AS-76, AS-77 are Not simulated.
OPEN.

Isolating valves of D/A pr. Local operation.


controller, S-66, AS-67 are Not simulated.
OPEN.

7 START one CEP for Deaerator level starts UCB indication


D/A filling, after increasing and comes up to
filling the condenser 1500 mm wcl.
hot well.

Maintain D/A and Hotwell UCB Operation.


levels at 1500 mm & 500
mm wcl respectively

8 CHARGE D/A feed D/A feed storage tank water DAS indication.
storage tank heating temp starts rising.
by opening AS-78
slightly and transfer
D/A pr controller to
auto control after DA
pressure is 1.5
kg/cm2.
D/A pressure starts building AS-78 not
up to 1.5 kg/cm2, gradually. simulated. Local
operation.

KORBA SIMULATOR 144


DA pressure controller Set point can be
maintains the set pressure. raised to 20% and
40% at TG loads 40
MW and 80 MW
respectively.

9 START one BFP to fill- Drum level starts increasing UCB/DAS/Local


up the boiler by gradually. indications.
operating low range
feed control valve.

Maintain drum level at (-) 60 Boiler fill pump


mm wcl before boiler light- connections to DA
up economiser, SH and
boiler W/W ring
header for direct fill-
in, is not simulated.

10 START one LP dozing Hydrazine concentration UCB checks.


(hydrazine) pump and before economiser starts
adjust its stroke as rising after some time (max.
required, after feed 0.05 ppm).
water temp comes to
150oC.

Oxygen in feed water to be As per boiler


maintained 0.007-ppm max. manufacturer’s
recommendations.

11 START one HP dozing PH value of drum water to be UCB indication or


(phosphate) pump if maintained at 9.0-9.4. chemist's
drum water pH value recommendations.
is lower than
required.

Residual phosphate to be UCB check and


maintained at 5-10 ppm. at indications.
full load.

12 ENSURE all pre-start Both APHs are IN-SERVICE UCB operation.


Conditions for
purging and light up
are satisfied.

One set of ID &FD fans and Refer individual


associated air & flue gas operating
systems are lined-up and instructions.
IN SERVICE.

KORBA SIMULATOR 145


All wind-box dampers are UCB/Local checks.
OPEN.

All purge per missives are UCB checks


ON. operation.

Two HFO and one light oil Local operation.


pumps are IN-SERVICE. (Remote functions).

Aux. steam to atomising Local operation.


steam hdr, HFO heating and (Remote functions)
SCAPH, is CHARGED.

All drum. SH, RH air & start- Start up vents is


up vents and drains are UCB operated.
OPEN.

Furnace probes are IN- UCB operation.


SERVICE positions. (100%)

13 START furnace MRF (A&B) are reset after "MFR TRIP” alarm
purging. five minutes. goes off.

First cause of trip resets. UCB indication


FSSS - console.

14 LIGHT-UP the boiler Drum metal temperature DAS indications.


with AB elevation oil starts increasing, gradually.
guns Initially, CD
elev. Guns can be
taken after drum Pr
reaches up to 2 KSC
Rate of saturation temp rise DAS indications.
to be maintained 110 oC per
hour (maximum).

Drum differential temp to be DAS indications.


maintained below 50oC
(maximum).

15 SWITCH-ON the "Green ON lamp comes on" UCB check only.


vapour extractor fan and associated alarm clears
of the MOT & SGC off.
OIL to auto.

Aux. oil pump-1 and Jack oil UCB operation


pump no.-1 become on. /check.

OR

KORBA SIMULATOR 146


SWITCH-ON Turbine gate valve gearing UCB indication.
Individual opens-up and turbine speed
SLCs on the turbine goes up to 110 rpm
console manually. (approx.)Oil temperature
control valve starts
modulating.
All other valves under SLCs UCB indication.
start modulating as per their
logic programme.

16 ENSURE all pre-start Condenser water box Local operation.


checks for vacuum priming ejector's steam and (Remote function).
pulling are over. airside valves are OPEN. Condenser air
valves not
simulated.

Condenser CW inlet/ outlet UCB operation.


valves are OPEN.

Condenser vacuum breaker UCB operation


valve is CLOSED & Water check.
sealing is AVAILABLE.

Gland sealing header/ line UCB operation.


drains are OPEN.

17 OPEN AS-80/81 and Condenser vacuum starts UCB operation. Any


CA-5/6 of one building up gradually to 0.7 one starting ejector
starting ejector for Kg/cm2 can be taken in
pulling vacuum and service.
transfer seal steam
pressure controller to
auto.

Gland seal steam pr. UCB check only.


controller transfers to auto Associated alarms
and maintains 0.01 Kg/cm
2 are reset.
(g) of seal steam pressure.

18 OPEN AS-52/ 54 of Vacuum builds up to 0.92 UCB indication


one main ejector and Kg/cm
2 Main ejector air
cut out the starting valves are not
ejector. simulated.

Turbine speed increases up UCB indication


to 220 rpm. (Approx.)

KORBA SIMULATOR 147


19 OPEN all Main steam Valves DW- UCB indication
CRH and HRH drains 153/154/155/156, DW-
to BD tank. 171/172/173/174 and' DW-
164/165/141/142 are
OPEN.

20 CLOSE all drum SH SH-RH and drum air vents Local operation
and RH air vents after closed. Not simulated.
the drum pr. comes
2
to 2-3 Kg/cm and
throttle start-up
vents.
S-28, S-23, R-15 and R-20 UCB operation.
are throttled.

Drum pressure starts rising. UCB/DAS


indication

21 At a drum pr. of 6 Valves MSBP - 1 and MSBP- UCB/DAS


Kg/cm2 , OPEN 3 are to be opened 100%. indication.
integral bypas valves
to main steam stop
valves, for MS line
Heating, gradually.

Valves MSBP-2 and MSBP-4 UCB operation


are to be throttled & opened Interlock.
gradually, after MSBP-1/3
are fully open.

22 ENSURE all prestart All turbine line drains to UCB operation.


checks for charging flash tank are OPEN and to Refer respective
HP/LP Bypass system BD tank are CLOSED. operation
& Rolling turbine are instructions.
over.

Turbine starting-device is at UCB operation


0% position and UTRs (unit GTRs must be in
trip relays) are RESET. reset position and
stator water
conductivity and
flow must be normal
before one can reset
UTR

All turbine and generator UCB/DAS check.


parameters are NORMAL.

KORBA SIMULATOR 148


TSE and Frequency UCB check only.
influence on EHG are NOT
OFF.

Speeder gear is at 100% and UCB operation,


EHC 'NOT FAULTED' and is Electro hydraulic
0% Governor is at
selected.

All HP/LP bypass set points Refer to the


are ADJUSTED as per corresponding
procedures. Operating
instructions.

Turbine SLC drains is ON. UCB operation.

23 CHARGE MS lines - Valves S-42, S-64 are being - UCB operation.


100% and raise boiler OPEN 100%.
firing to raise steam
parameters to 40 KSC
of MS Pr. and 300oC
of MS temp (mini),
before turbine rolling.
CLOSE start-up vent
valves and SH header
drain valves.
- The bypass valves MSBP - Interlocks.
1/2/3/4/ are automatically
closed.

- HP/LP bypass valves start - UCB operation.


modulating to maintain set
steam parameters, to be
adjusted upwards.

- Steam temperatures
must be maintained
at minimum values
as indicated to
minimise soaking
times.

- Steam parameters start - Refer to the turbine


rising, depending upon firing start-up curves.
rate and HP/LP bypass
operation.

KORBA SIMULATOR 149


24 At MS pressure 25-30 - HP stop valves open at 42% - UCB operation.
2
Kg/cm RAISE of starting device position.
starting device to 70%
position and SWITCH
ON the SLC warm up
controller.

- IP stop valves open at 56% of - UCB Observation.


starting device position.

- Aux. secondary oil pressure - UCB check only


2
increases to 3 Kg/cm
(approx.)

- Start-up oil pressure - UCB check only


becomes zero.

- Warm-up drains after HP - UCB check only.


stop valves start opening for Warm-up drain
warming up HPCV and close valves must be put
after set TSE margins are on auto & set point
achieved. to be adjusted by
the operator, as
required.
- HPSV & HPCV mean -
temperatures increase
gradually to 220oC.

25 RAISE speed - Turbine speed gradually - UCB check only


reference to 600 RPM increases to 600 RPM.
and SOAK turbine at
600 RPM until
required mean HP
shaft temp is attained
(speed-up criteria)

- Gate valve gearing starts - Interlock, if


closing at 240 rpm. corresponding SLC
is on.
- Jack oil pump trips at 540 - Interlock, if
rpm corresponding SLC
is on.
- HP shaft mean temperature - TSE recorder’s
starts increasing gradually. indications, in the
UCB.

KORBA SIMULATOR 150


ENSURE all pre-start - All TSE margins are more - Check TSE
checks for rolling up than 30oC. recorders &
to the rated speed Indicator
and Synchronising,
are completed.

All Generator conditions are UCB/DAS checks.


HEALTHY.

All differential expansions UCB/DAS checks.


are less than MAXIMUM
(+ve/-ve)

HP turbine and LP turbine UCB/DAS


exhaust temperatures are indications are
less than MAXIMUM. below 480oC AND
90oC respectively.

All casing (HP & IP) top- UCB/DAS


bottom temp differences are indication.
less than 35oC.

All bearing temp are less UCB/DAS checks.


than 90oC.

All bearing and shaft UCB/DAS checks.


vibrations are less than 30 &
100 microns.

Generator stator water and Local operation


hydrogen cooling systems (Remote functions)
are CHARGED.

27 RAISE turbine speed Turbine speed goes up to UCB indications.


reference to 3000 rpm 3000 rpm gradually,
without stopping and depending upon the TSE
soak until required margins available
IPT mean shaft temp
is reached.
(Loading criteria)
Ensure all vibrations are
below the maximum limit.

AOP cuts-out at 2950 rpm if UCB indication.


SGC oil is on or switch off Interlock.
the AOP maually

IPS mean temperature Refer to TSE


increases gradually to 275OC recorders.

KORBA SIMULATOR 151


28 SWITCH-ON the load Load gradient and load UCB check only.
controller and load controller become on. Load limiter to be
gradient controller. set more than load
CLOSE the field reference.
breaker and ADJUST
the excitation to the
required Gen. voltage.

Ensure excitation M/A


channels controls are at
MINIMUM, (HOME) Position

Generator voltage builds up UCB indications.


to 15.75 KV.

29 RAISE starting device Aux. Secondary oil pressure UCB indications.


to 100% and load ref. goes up to 4.5 Kg/cm2
& load gradient set (approx.)
points to 20 MW & 5
MW/MIN respectively.

All turbine and generator Local/UCB check.


parameters to be maintained
within their normal,
Specified limits.

30 Close the Bus isolator - Generator breaker gets - UCB operation.


and Generator closed.
isolator and switch on
the synchroscope and
synchronise the Gen.
with the Grid.
- Generator block loading is to - Refer to
be done to avoid tripping of synchronising
the gen. on "REVERSE Procedures.
power" protection.

- EHC speed controller - Refer to EHC


transfer to load controller, control logics.
after some time delay.

31 LINE-UP and CUT-IN - Turbine load increases to 40 - UCB operation.


one PA fan and any MW.
one mill and feeder,
RAISE load to 40 MW.

- Generator voltage to be - Refer to the


maintained at rated value of generator Capability
15.75 KV. curves.

KORBA SIMULATOR 152


32 LINE-UP and - Condensate temperature to - DAS points.
CHARGE all L.P. D/A starts increasing..
heaters one by one.
CLOSE all turbine
drain & close HP/LP
bypass system.
- Main steam pressure - UCB indications.
increases slightly.

32 CUT-IN another - Unit loading increases - UCB indication.


pulveriser and RAISE gradually up to 60 MW. Load must follow
firing. RAISE load on the MS pressure
the unit.
- MS pressure keeps
Increasing.

- Main steam pressure - UCB indications.


2
Comes to 70-80 Kg/cm

34 CHANGEOVER from - Unit bus voltages to be - Refer to the bus


station supply to unit maintained at 6.6 KV with changeover
aux. transformers tap changers. procedures.
(U.A.T.s), and
CHARGE unit aux.
Steam header from
main steam lines.
CHARGE D/A
extraction from the IP
turbine.

- Aux. steam pressure to be - Refer to the


maintained at 14-15 Kg/cm 2 operating
Instructions.
- D/A pressure modulates - Aux. Steam header
with the unit load. can be charged only
after MS pr is 50
Kg/cm2 or more.
Interlock.

35 START the second set - MS pressure to be - UCB operation.


of ID, FD, PA fans & maintained at 148 Kg/cm
2

BFP and START the after 100 MW.


third pulveriser feeder
and RAISE load to
150 MW. CHARGE
high-pressure heaters
one by one.
- Unit load increases up to - UCB check only.
150 MW.

KORBA SIMULATOR 153


- Feed water temperature rises - DAS points.
up gradually.

Unit heat rate improves - DAS point.


gradually.

36 CUT-IN 4th pulveriser - Unit load increases up to - UCB operation.


and raise load to 200 MW.
200MW
- MS/HRH steam temperature - UCB operation.
to be maintained at 535oC.

37 TRANSFER all ID, FD, - ID fan vanes transfer to auto - UCB operation.
PA fans controls and & maintain set furnace Furnace draft of -5
BFP scoop controller vacuum. to –10 mm wcl is to
to auto. be maintained

- FD fan blades modulate to - Boiler master


maintain Oxygen in flue controller out put
gases. generates oxygen
set point.

- PA fan vanes transfer to auto PA header pressure


& maintain set PA hdr. of 750 mm wcl is to
Pressure. be maintained.

- BFP Master maintains the - Feed regulating


set feed water DP across the station DP is to be
feed regulating station. maintained. at 5-8
2
Kg/cm

38 ENSURE the mill PA - Auto lamp of both the - Both the controller
flow and temp control controller is ON. must be in auto
on auto. mode before feeders
are put in auto.

39 ADJUST raw coal - The feeder speed controller's - UCB check only.
feeders' biasing to error deviation comes to 0%
50% and the Fuel (biasing may be adjusted to
Master Controller’s get dev. 0% for a given fuel
output, as per master output).
requirement.

40 ADJUST throttle - Error deviation on boiler - Before putting


pressure set point master comes to 0% control on auto
equal to the main corresponding error
steam pressure & deviation must be
SET boiler master's zero to avoid
output as required. hunting.

KORBA SIMULATOR 154


- Errors deviation on fuel
master comes to 0%.

41 RELEASE all mill, - Boiler firing can be adjusted - UCB operation.


feeders and fuel from Boiler Master,
master controller to manually.
auto.

42 ADJUST Unit Master - Boiler Master controls the - Refer to the CMC
output equal to the boiler firing rate, depending logics.
T/ G load and set on the unit load demand and
max/min. load limits throttle pressure set point.
and load rate on CMC
console. RELEASE
Boiler master
controller to auto and
unit control to CMC.

- Unit Master on auto - Before putting Unit


modulates according to the Master on auto,
load demand signal from the unit master’s
load dispatch centre. output to be made
equal to the load
demand signal from
ALDS.

KORBA SIMULATOR 155


UNIT HOT START-UP

KORBA SIMULATOR 156


KORBA SIMULATOR 157
UNIT HOT START-UP PROCEDURE

ACTION OBSERVATION REMARKS

1 CHECK the - Generator/Field breakers - UCB annunciation.


conditions existing are tripped with the
immediately after corresponding alarms.
the unit tripping.

- UATs' supply to unit buses - UCB indications.


is tripped and station supply Inter-lock.
takes over automatically.

- Generator AVR trips to - UCB annunciation.


manual mode, automatically
with an alarm.

- All the turbine stop and - Refer to Turbine


control valves are closed. governing system.

- Turbine trip oil, aux. - UCB check only.


secondary oil, and secondary
oil pressure become zero

- All LP / HP heaters - UCB check only.


extraction block valves are
closed automatically.

- All extraction line NRVs are - Refer to turbine


closed. governing system.

- Turbine AOP -1 starts - Interlock.


automatically (if SLC is on).

- The JOP -1 starts - Interlock.


automatically at 510 rpm. (If
SLC is on).

- Turbine gate valve gearing is - Interlock. Check


opened automatically at 200 locally also.
rpm. (If the SLC is on).

- HP/LP bypass valves open- - UCB checks. Refer


up if on auto with proper set to the HP/LP
points, to limiter set bypass interlocks.
position.

- Condenser vacuum breaker - Interlock. Refer to


valve may open if tripping is the tripping logic

KORBA SIMULATOR 158


on Fire protection or axial (turbine)
shift.

- SH/RH steam attemperation - Interlock. Steam


block and control valves are flow < 15% MCR
closed.

- Drum level dips to very low - UCB check only.


values.

- All running mills and their - Refer to FSSS logics


feeders with both PA fans and interlocks.
are tripped.

- HFO and ignitor trip valves - Refer to FSSS logic.


are closed automatically. UCB check.

- All HFO guns and ignitors - UCB check only.


are tripped and their Check locally too.
associated oil/steam/air
valves closed.

- Furnace vacuum dips to - UCB indications.


very low values due to
implosion.

- All wind-box dampers open- - UCB check.


up after unit tripping.

2 ENSURE all the ''*'' - ''Control interface fault'' or - UCB annunciations


marked conditions ''Control interface status
are fulfilled fault'' or ''Running time
immediately after a exceeded'' etc. alarms are
tripping. If not present.
interlocks do not
act, fulfil the
conditions
manually.

- Any fault lamps (red) on - If alarms are on, get


ATRS or SGC console are the faults rectified
not ON. and cut in the
associated system
manually.

3 STOP any one set - Furnace draught is - UCB operation.


of ID & FD fans to maintained at -5 to -10 mm
avoid forced cooling wcl.
of the boiler.
STABILISE and
maintain draught &

KORBA SIMULATOR 159


airflow.

- Furnace airflow is to be - UCB indication


maintained between 30% to
40%.

- Burners to be brought to - UCB operation


horizontal position, quickly.

4 ENSURE all purge - Boiler MFR (A&B) gets reset - UCB operation.
permissive are after a time delay of 5
available and do minutes.
furnace purging for
5 minutes.

- The first cause of unit - Indication on FSSS


tripping gets reset along with console.
MFR. reset.

5 ENSURE Deaerator - D/A pressure controller - UCB check only.


Pressure is must be on auto and
maintained at 3.5 pressure set point to be at 3-
Kg/cm2 and aux. 4 Kg/cm2.
steam pressure at
14 Kg/cm2

ESTABLISH - If MS pressure falls below 70 - Isolating valve of


condenser vacuum Kg/cm2 aux steam header unit PRDS are
if it has may be charged other units. closed at MS pr. of
deteriorated on 50 ata.
protection.

- Cond. vacuum must be more - UCB operation.


than 0.8 Kg/cm2 before
charging HP/LP bypass
system.

6 CLOSE HP/LP - Main steam pressure is to be - UCB operation.


bypass system to maintained below 100
avoid drop in steam Kg/cm2, preferably for hot
pressure start-up.

7 RESET generator - Starting device is brought to - UCB operation for


trip relay and unit 0% position turbine resetting.
trip relays and
turbine.

- Turnine gets reset. - UCB indication

8 LIGHT UP the - Maximum and minimum - Refer to the turbine

KORBA SIMULATOR 160


boiler with the steam temp required for hot start-up curves XI -
upper elevation rolling might be determined X7. Roughly steam
guns and a mill if from HPCV and HPS mid temperature >
required to hold the metal temperatures. (HPCV temp.+ 50 O
MS/HRH temp. C)
CHARGE HP/LP
bypass.

- HRH steam temp tend to


drop with the charging of
HP/LP bypass systems. (Min
Required is 480oC).

9 Roll the turbine to - Gate valve gearing & JOP - Interlocks.


600 rpm and SOAK cut out of service at 240 and
for 5 minutes. 540 rpm respectively.

10 RISE speed to 3000 - Load gradient can be raised - UCB operation.


rpm and above 10 MW/min. for
SYNCHRONISE as loading, however the
per procedures. generator loading
recommendations must be
adhered to.

KORBA SIMULATOR 161


AUTOMATIC
TURBINE RUN-UP SYSTEM
(ATRS)

KORBA SIMULATOR 162


KORBA SIMULATOR 163
AUTOMATIC TURBINE RUN-UP SYSTEM (ATRS)
A successful start-up of the turbine normally requires acquisition and analysis of
wide variety of information pertaining to various parameters like speed, steam
temperature, vacuum, oil pressure, warm-up condition of turbine and pipelines.

Apart from this, it is important to know whether vital auxiliary equipment is on


automatic control loop or not. It is an arduous task for the operator to handle and
collect so many bits of information swiftly and correctly. Automatic Run-up System
performs this task swiftly, accurately and at the appropriate time. The chances of
mal-operation due to error, improper judgments of the situation get practically
eliminated. Automatic Run-up System relieves the operator of arduous task involving
in surveying the various parameters and thus the entire attention is diverted to
watching the performance of the main equipment.

BASIC CONCEPT

The Automatic Run-up System is based on 'Functional Group Control' philosophy,


means that the main plant is divided into clearly defined technical sections called
functional groups.

Each functional group is sub-divided into


'sub-group control' and 'sub loop control'
and 'interface control'. It is apparent that
each functional group continues to
function automatically all the times
demanding 'Enabling Criteria' from other
functional groups. In case the red
'Enabling Criteria' is not available from
neighboring 'Functional Group Control',
the system would automatically act in
such a manner as to ensure the safety of
the main turbine. This method avoids a
major difficulty generally encountered in
laying down priority and correct
sequence of the various steps in single
logical chain of events.

DEFINITION OF TERMS USED IN ATRS

Functional Group Control (FGC)

Functional Group Control is the automatic control of a largely independent plant


section (functional group) or a process section.

This term comprises:

• Group controls
• Sub group controls
• Sub loop controls

KORBA SIMULATOR 164


Group Controls (GC)

The Group Controls contain the logic for controlling the subordinated subgroup
controls. They utilise gating logic.

The function of the Group control is to decide when, how many and which of the
subordinated group controls should start or shutdown and realise the fault
changeover in case of several subgroups

Sub Group Controls (SGC)

Sub Group Controls contain the sequence logics for switching units ON and OFF,
and all the associated auxiliary equipments. Normally, step techniques are preferred
for the design of subgroup controls.

Sub Loop Controls (SLC)

Sub Loop Controls comprise only a part of the automated operation of a functional
group or unit. They are always of logic gating design. They may (as in the case of
subordinated sub loop controls) form part of a functional group control and be
switched ON or OFF by it.

Sub Loop controls (with the exception of unit changeover controls) differ from sub-
group control in that although they can be switched ON and OFF manually they can
only receive direction-dependent commands (control elements HIGHER/LOWER,
Motor ON/OFF) through criteria (e.g. automatic controls for auxiliary oil pumps,
pressure or level switches).

Sub Loop Controls include the unit changeover controls. These come into action
when changeover operations are required for units of the same type during fault
conditions. In general, changeover controls cannot be switched off directly from their
own desk tile. If the design concept calls for a changeover control that can be
switched off, a manual-automatic module shall be provided.

Command

A command is an instruction for a change of status.

Protective Logic (PL)

Protective logic consists in logic gating between ON or OFF commands with criteria,
which serve, to the plant (e.g. boiler interlocking) or the unit (e.g. unit interlocking).
Protective logic cannot be switched off.

Sequential Control

Sequential Control is a control arrangement with Boolean operations, storage


provisions and its functions proceeding step by step. Advance to the next step
depends on process signals and/or time factors.

KORBA SIMULATOR 165


MODE OF OPERATION

Each functional group is divided into logical steps arranged in a proper sequence.
Prior to the commencement of any step, it is necessary that certain conditions
regarding status of plant get fulfilled and the relevant Parameters acquire the desired
value. All these pre-conditions are meticulously planned for each step and demanded
from the system as 'Enabling Criteria' for next step.

ATRS - STRUCTURE AND GENERAL FEATURES

Automatic Turbine Run-up System is essentially organized in two sub-group controls


namely Turbine System (SGC Turbine) and Oil System (SGC Oil). These groups in
conjunction with wall stress analyser and electro-hydraulic governing system
accomplish the various functions. A sub-group control essentially executes a set of
steps in a proper sequence. Sub-group control at times envisages a sub-loop control
that essentially executes commands based on the availability of 'Enabling Criteria'.

Sub-group control for the turbine run up acts directly on:

• Sub-loop controls (SLC) for the drains.


• Electro-hydraulic Governing System.
• Auto Synchronizer

KORBA SIMULATOR 166


Sub-group control for the oil directly actuates:

• SLC for the DC lube oil pump.


• SLC for lub oil System.
• SLC for turning gear operation and
• Interface devices for selected few pumps.

ATRS OPERATION CONSOLE

According to the pre-determined sequence, SGC & SLC ensure various requirements
of control oil, lube oil, oil for hydraulic turning etc. under run-up, shutdown and trip
conditions.

The sub-loop controllers get switched on and off according to the pre-defined
sequence logic built in the SGC. However, the actual execution of command of a SLC
takes place only if the enabling criteria for the fulfilment of a particular command are
completely satisfied. It is possible to intervene manually at any level namely interface
sub-loop control or sub-group control.

The enabling criteria at the various level of hierarchy are of different nature. For
instance, the enabling criteria at the ‘Interface Level’ envisaged are based on the
equipment protection point of view rather than the process consideration.

It is also possible to manually start the plant up to any level/status then ask the
sub-group control to perform the remaining functions. To facilitate such modes of
operations, the sequential logic has been development in such a manner the sub-
group control shall quickly skip to the proceeding step done manually and
accomplish the steps automatically in the desired logical manner. The SGC Turbine
logics for (ATRS) incorporating various steps and criteria required to execute each
steps are in the following sections.

KORBA SIMULATOR 167


KORBA SIMULATOR 168
KORBA SIMULATOR 169
SGC OIL SYSTEM LOGICS

KORBA SIMULATOR 170


KORBA SIMULATOR 171
KORBA SIMULATOR 172
KORBA SIMULATOR 173
KORBA SIMULATOR 174
KORBA SIMULATOR 175
SUB LOOP CONTROL - AUXILIARY OIL PUMP - 1
2
1. When SLC AOP - 1 is ON AND AOP - 2 trips OR Oil pressure < 4.8 Kg/cm ,
command is given to switch on Aux. Oil Pump - 1

SUB LOOP CONTROL - AUXILIARY OIL PUMP - 2


2
1. When SLC AOP - 2 is ON AND AOP - 1 trip OR Oil pressure < 4.5 Kg/cm ,
command is given to switch on Aux. oil Pump - 2

SUB LOOP CONTROL - DC EMERGENCY OIL PUMP

1. When SLC emergency oil pump is ON AND if lube oil pressure < 1.1
2
Kg/cm command is given to switch on EOP.

SUB LOOP CONTROL - JACKING OIL PUMP - 1

1. When SLC JOP - 1 is ON AND if turbine speed < 510 RPM, command is
given to switch on JOP -1,
2. If turbine speed > 540 RPM, command is given to switch off JOP - 1

SUB LOOP CONTROL - JACKING OIL PUMP - 2


2
With SLC JOP - 2 is ON, if JOP - 1 trips OR if jack oil pressure < 120 Kg/cm , with
turbine speed < 510 rpm with a delay of 5 seconds, command is given
1. To switch ON JOP 2
2. To switch OFF JOP 1
3. To switch OFF SLC JOP-1

SUB LOOP CONTROL - TURNING GEAR

1. With SLC turning gear is ON AND if turbine speed < 200 RPM, command is
given to open the gate valve gearing.
2. If turbine speed is greater than 240 RPM, Command is given to close gate
valve gearing

KORBA SIMULATOR 176


SUB LOOP CONTROL: OIL SYSTEM
STARTUP OPERATION RELEASES

1. OIL VAPOUR EXTRACTOR (1) OR (2) ON


2. OIL TANK LEVEL ADEQUATE
STEP -1
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

CRITERIA FOR STEP - 2


1. STEP-01 COMPLETED OR
2. STEP-08 COMPLETED AND TURBINE SPEED < 510 RPM OR
3. STEP-11 COMPLETED AND TURBINE SPEED < 2800 RPM
STEP - 2
1. SWITCH ON AUXILIARY OIL PUMP -1
2. MONITORING TIME 2 SEC

CRITERIA FOR STEP - 3


1. AOP - 1: ON OR AOP - 2 : ON OR TUR. SPEED > 2950 RPM
2
2. PRESSURE-OIL PRESSURE > 4.8 KG/CM

STEP - 3
1. SWITCH ON SLC OIL TEMPERATURE CONTROLLER
2. MONITORING TIME 20 SEC

CRITERIA FOR STEP - 4


1. SLC OIL TEMPERATURE CONTROLLER ON
2. GEN. SEAL OIL GAS DP > 0.8 KG/CM2

3. GEN SEAL OIL TURB. SIDE PRESS > 3.8 KG/CM2

4. GEN. SEAL OIL EXCITER PRESS. > 3.8 KG/CM2

5. HYDROGEN PURITY > 97%


6. GEN. GAS PRESS. > 3.4 KG/CM2

7. LIQUID IN GENERATOR NOT PRESENT.

KORBA SIMULATOR 177


STEP - 4
1. SWITCH SLC TURNING GEAR ON
2. MONITORING TIME 60 SEC

CRITERIA FOR STEP - 5


1. GATE VALVE GEARING OPEN OR TURBINE SPEED > 250 RPM
2. SLC TURNING GEAR ON

STEP-5
1. SLC AOP-1: ON
2. SLC AOP-2: ON
3. SLC EOP: ON
4. SLC JOP-1: ON
5. SLC JOP-2: ON
6. MONITORING TIME 200 SEC

CRITERIA FOR STEP - 6


1. SLC AOP-1: ON
2. SLC AOP-2: ON
3. SLC EOP: ON
4. SLC JOP-1: ON
5. SLC JOP-2: ON
6. TURBINE SPEED > 15 RPM
STEP - 6
1. NO COMMAND ISSUED.
2. MONITORING TIME BLOCKED

CRITERIA FOR STEP - 7


1. TURBINE SPEED > 540 RPM
STEP - 7
1. NO COMMAND ISSUED
2. MONITORING TIME 60 SEC

KORBA SIMULATOR 178


CRITERIA FOR STEP - 8
1. JACKING OIL PUMP-1: OFF
2. JACKING OIL PUMP-2 : OFF
3. GATE VALVE GEARING CLOSED
STEP - 8
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

CRITERIA FOR STEP - 9


1. TURBINE SPEED > 2950 RPM
2
2. PRESSURE-OIL PRESSURE > 7 KG/CM

STEP - 9
1. SWITCH AUXILIARY OIL PUMP (1) OFF
2. SWITCH AUXILIARY OIL PUMP (2) OFF
3. MONITORING TIME 0.5 SEC

CRITERIA FOR STEP - 10


1. WAITING TIME 0.5 SEC

STEP - 10
1. NO COMMAND ISSUED
2. MONITORING TIME 10 SEC

CRITERIA FOR STEP - 11


1. WAITING TIME 10 SLC OR GEN LOAD > 10%
2. AUXILIARY OIL PUMP - 1 OFF
3. AUXILIARY OIL PUMP - 2 OFF
4. EMERGENCY OIL PUMP OFF

STEP - 11
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

KORBA SIMULATOR 179


SUB LOOP CONTROL : OIL SYSTEM
SHUTDOWN PROGRAMME

CRITERIA FOR STEP: 51


1. TEMP HP CASING TOP < 100 OC
2. TEMP HP CASING BOTTOM < 100 OC

STEP: 51
1. SLC TURNING GEAR: OFF
2. GATE VLV GEARING: CLOSE
3. MONITORING TIME 60 SEC

CRITERIA FOR STEP: 52


1. SLC TURNING GEAR: OFF
2. GATE VLV GEARING: CLOSED

STEP: 52
1. NO COMMAND ISSUED
2. MONITORING TIME: 100 SEC

CRITERIA FOR STEP: 53


1. TURBINE SPEED < 10 RPM

STEP: 53
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

CRITERIA FOR STEP: 54


1. WAITING TIME 1000 SEC

STEP: 54
1. SLC JOP 1 OFF
2. SLC JOP 2 OFF
3. SLC OIL TEMP CONTROL OFF
4. JOP 1 OFF
5. MONITORING 4 SEC

KORBA SIMULATOR 180


CRITERIA FOR STEP: 55
1. SLC JOP 1 OFF
2. SLC JOP 2 OFF
3. SLC OIL TEMPR CONTROL OFF
4. JOP 1 OFF
5. JOP 2 OFF
STEP: 55
1. SLC AOP 1 OFF
2. SLC AOP 2 OFF
3. SLC EOP OFF
4. AOP 1 OFF
5. AOP 2 OFF
6. OIL TEMP CNTRL VLV CLOSED
7. MONITORING 30 SEC

CRITERIA FOR STEP: 56


1. SLC AOP 1 OFF
2. SLC AOP 2 OFF
3. SLC EOP OFF
4. AOP 1 OFF
5. AOP 2 OFF
6. OIL TEMP CONTRLR OFF
7. EOP OFF
STEP: 56
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

KORBA SIMULATOR 181


SGC TURBINE SYSTEM LOGICS

KORBA SIMULATOR 182


KORBA SIMULATOR 183
KORBA SIMULATOR 184
KORBA SIMULATOR 185
KORBA SIMULATOR 186
KORBA SIMULATOR 187
KORBA SIMULATOR 188
KORBA SIMULATOR 189
KORBA SIMULATOR 190
KORBA SIMULATOR 191
KORBA SIMULATOR 192
KORBA SIMULATOR 193
KORBA SIMULATOR 194
KORBA SIMULATOR 195
KORBA SIMULATOR 196
SUB LOOP CONTROL: TURBINE SYSTEM
STARTUP OPERATION RELEASE
1. STARTING DEVICE 0%
2. POSITION SET POINT OF TURBINE CONTROL < 0% (EHC OUTPUT)
3. GENERATOR FIELD BREAKER OFF
4. GENERATOR BREAKER OFF
5. DRAIN BEFORE HP CONTROL VALVE - 1 NOT CLOSED
6. DRAIN BEFORE HP CONTROL VALVE - 2 NOT CLOSED
7. LIMIT PRESSURE OPERATION ON
8. LOAD CONTROLLER ON
9. SYNCHRONIZER OFF
2
10. TRIP OIL PRESSURE > 4.8 Kg/cm
STEP: 1
1. SWITCH ON SLC DRAINS
2. MONITORING TIME 2 SEC
CRITERIA FOR STEP: 2
1. SLC DRAINS ON
2. ALL ESVS CLOSED
3. HP-CONTROL VALVE-1 CLOSED
4. HP-CONTROL VALVE-2 CLOSED
5. INTERCEPT VALVE -1 CLOSED
6. INTERCEPT VALVE-2 CLOSED
7. CRH NRV LHS CLOSED
8. CRH NRV RHS CLOSED
9. EXTRACTION VALVE A5 < 5%
10. EXTRACTION VALVE A4 < 5%
11. EXTRACTION VALVE A3 < 5%
12. EXTRACTION VALVE A2 < 5%

STEP: 2
1. NO COMMAND ISSUED
2. MONITORING TIME: 500 SEC
STEP-2 COMPLETED AND IF TURBINE SPEED < 900 RPM AND
SPEEDER GEAR < 100%, COMMAND IS ISSUED TO RAISE SPEEDER GEAR.

KORBA SIMULATOR 197


CRITERIA FOR STEP: 3
2
1. TRIP FLUID PRESSURE > 5 Kg/cm
2. TURBINE SPEED > 15 RPM
3. CONDENSATE PUMP DISCHARGE PRESSURE: OK
4. SLC DRAINS NO FAULT
5. DT HP CASING (TOP-BOT) > MINUS 40 K
6. DT HP CASING (TOP-BOT) > PLUS 40 K
7. DT IP CASING FR (TOP-BOT) > PLUS 40 K
8. DT IP CASING FR (TOP-BOT) > MINUS 40 K
9. DT IP CASING REAR (TOP-BOT) > PLUS 40 K
10. DT IP CASING REAR (TOP-BOT) > MINUS 40 K
STEP: 3
1. CLOSE DRAIN BEFORE HP CTRL VALVE -1
2. CLOSE DRAIN BEFORE HP CTRL VALVE -2
3. SWITCH SLC WARM UP CONTROLLER: OFF
4. MONITORING TIME: 60 SEC

CRITERIA FOR STEP: 4


1. DRAIN BEFORE HP CTRL VLV-1: CLOSED
2. DRAIN BEFORE HP CTRL VLV-2: CLOSED
3. SLC WARM-UP CONTROLLER: OFF
STEP: 4
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

CRITERIA FOR STEP: 5


1. BOILER FIRE ON
2. STEAM BEFORE HPBP-1 > 30 K SUPERHEAT
3. STEAM BEFORE HPBP-2 > 30 K SUPERHEAT
4. STEAM BEFORE LPBP-1 > 30 K SUPERHEAT
5. STEAM BEFORE LPBP-2 > 30 K SUPERHEAT
6. DT (HPBP-1 -CNTRL VALVE MID) > X 1.1
7. DT (HPBP-2 -CNTRL VALVE MID) > X 1.2

KORBA SIMULATOR 198


8. TOTAL BOILER STEAM FLOW > 15%
9. DT (WET STEAM- CNTRL VALVE -1.) > X 2.1
10. DT (WET STEAM- CNTRL VALVE -2.) > X 2.2
11. DT (HPBP-1 -CNTRL VALVE MID) < X 3
12. DRN BEFORE HP ESV-1 NOT CLOSED
13. DRN BEFORE HP ESV-2 NOT CLOSED
14. DRN BEFORE INTCPT ESV-1 NOT CLOSED
15. DRN BEFORE INTCPT ESV-2 NOT CLOSED
16. OIL TEMPERATURE AFTER COOLER > 35 0 C
STEP: 5
1. STARTING DEVICE RAISE
2. MONITORING TIME 30 SEC

CRITERIA FOR STEP: 6


1. ANY HP ESV OPEN

STEP: 6
1. NO COMMAND ISSUED
2. MONITORING TIME 60 SEC
CRITERIA FOR STEP: 7
1. HP ESV1 OPEN
2. HP ESV2 OPEN
STEP-7
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

CRITERIA FOR STEP: 8


1. TOTAL STEAM FLOW >15%
2. STEAM BEFORE HP BYP 1 > 30 K SUPERHEAT
3. STEAM BEFORE HP BYP 2 > 30 K SUPERHEAT
4. STEAM BEFORE LP BYP 1 > 30 K SUPERHEAT
5. STEAM BEFORE LP BYP 2 > 30 K SUPERHEAT
6. BOILER FIRE ON

KORBA SIMULATOR 199


7. DT (HP BYP1-CTRL VLV) > X 1.2
8. DT (HP BYP 2-CTRL VLV) > X 1.1
9. CONDENSER PRESSR < 0.5 kg/cm2
STEP: 8
1. SLC WARM UP CTRL ON
2. MONITORING TIME 2 SEC

CRITERIA FOR STEP: 9


1. SLC WARM UP CTRL ON

STEP: 9
1. STARTING DEVICE RAISE
2. MON TIME 20 SEC

CRITERIA FOR STEP: 10


1. STARTING DEVICE > 56%
2. INTCPT ESV - 1 OPEN
3. INTCPT ESV - 2 OPEN
STEP: 10
1. NO COMMAND ISSUED
2. MONITORING TIME 30 SEC

CRITERIA FOR STEP: 11


1. DRAINS NO FAULT
2. SPEEDER GEAR 100%
3. GLAND STEAM PESSR CONTRLR ON
4. SLC OIL TEMPR CTRL ON
5. ANY OIL VAPOUR EXTRACTOR ON
6. HYDROGEN PURITY > 97%
7. GEN GAS PRESSR > 3.4 kg/cm2
8. GEN SEAL OIL / GAS DP > 0.9 kg/cm2
9. GEN SEAL OIL TURB SIDE PRESSURE > 3.8 kg/cm2
10. GEN SEAL OIL EXCITER SIDE PRESSURE > 3.8 kg/cm2
11. LEVEL IN PRE-CHAMBER – 1&2 < MAX

KORBA SIMULATOR 200


12. GEN CW FLOW > 21 M3/Hr
13. GEN STATOR CW PRESSURE > 2.4 kg/cm2
14. STATOR CW INLET TEMPERATURE < 44 0 C
15. HYDROGEN COOLER CW PRESSURE > 2.5 kg/cm2
16. LIQUID IN GEN NOT PRESENT
17. GEN STATOR WATER CONDUCTIVITY < 5 MHO/CM
STEP: 11
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

CRITERIA FOR STEP: 12


1. ALL CRITERIA FOR STEP 11
2. STEAM BEFORE HP ESV 1 SUP HEAT > X4.1
3. STEAM BEFORE HP ESV 2 SUP HEAT > X4.2
4. DT (HP ESV 1-HP CASING) > X5.1
5. DT (HP ESV 2-HP SHAFT) > X5.2
6. TURBINE SPEED > 15 RPM
7. DT (LP BYP 1-IP CASING) > 30 K
8. DT (LP BYP 2-IP CASING) > 30 K
9. STEAM BEFORE LP BYP 1 > 480 0 C
10. STEAM BEFORE LP BYP 2 > 480 0 C
11. DRAIN BEFORE HP CONTROL VLV-1 NOT CLOSED
12. DRAIN BEFORE HP CONTROL VLV-2 NOT CLOSED
13. POWER SET POINT > 10 %
14. CONDENSER PRESSURE < 0.2 Kg/cm2
15. REL EXP CAS 1 FRONT < +8 mm
16. REL EXP CAS 1 REAR > -2 mm
17. REL EXP CAS 2 FRONT < +8 mm
18. REL EXP CAS REAR > -2 mm
19. REL EXP CAS 3 FRONT < +8 mm
20. REL EXP CAS 3 REAR > -2 mm

KORBA SIMULATOR 201


STEP: 12
1. TURBINE SPEED SET POINT RAISE
2. MONITORING TIME 40 SEC

CRITERIA FOR STEP: 13


1. SPEED SET POINT > 650 RPM

STEP: 13
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

CRITERIA FOR STEP: 14


1. TURBINE SPEED > 600 RPM

STEP: 14
1. TSE TEST PROGRAMME BLOCK
2. WAIT TIME 180 SEC

CRITERIA FOR STEP: 15


1. WAITING TIME 180 SEC
2. DT (HP BYP-HP SHAFT TEMP) < X6
3. TURBINE STRESS MARGIN > 30 K
4. BRG VIBRN CAS1 FRONT < 35 MICRON
5. BRG VIBRN CAS1 REAR < 35 MICRON
6. BRG VIBRN CAS2 FRONT < 35 MICRON
7. BRG VIBRN CAS2 REAR < 35 MICRON
8. GEN BRG VIBRN FRONT < 50 MICRON
9. BRG VIBRN GEN FRONT < 50 MICRON
10. BRG VIBRN GEN REAR < 50 MICRON
11. BRG VIBRN GEN REAR < 50 MICRON
12. BRG VIBRN HP SHAFT FRONT < MAX
13. BRG VIBRN HP SHAFT REAR < MAX
14. BRG VIBRN IP SHAFT < MAX
15. BRG VIBRN LP SHAFT < MAX

KORBA SIMULATOR 202


16. RAD BRG1 CAS FRONT LH TOP TEMP < MAX
17. RAD BRG1 CAS FRONT RH TOP TEMP < MAX
18. RAD BRG1 CAS FRONT LH BOT TEMP < MAX
19. RAD BRG1 CAS FRONT RH BOT TEMP < MAX
20. RAD BRG1CAS REAR LH TOP TEMP < MAX
21. RAD BRG 1CAS REAR RH TOP TEMP < MAX
22. RAD BRG1 CAS REAR LH TOP TEMP < MAX
23. RAD BRG1 CAS REAR RH BOTTOM TEMP < MAX
24. AX BRG1 CAS R/F LH TEMP < MAX
25. AX BRG1 CAS R/F RH TEMP < MAX
26. AX BRG1 CAS R/R LH TEMP < MAX
27. AX BRG1 CAS R/R RH TEMP < MAX
28. RAD BRG2 CAS REAR TEMP < MAX
29. RAD BRG2 CAS REAR R/R RHB TEMP < MAX
30. RAD BRG2 CAS REAR R/F RHB TMP < MAX
31. RAD BRG3 CAS REAR R/R RHB TEMP < MAX
32. REL EXP < MAX
33. GEN FRONT BRG TEMP < 90 0 C
34. GEN REAR BRG TEMP < 90 0 C
STEP: 15
1. SLC WARM UP CONTROLLER OFF
2. MONITORING TIME 2 SEC

CRITERIA FOR STEP: 16


1. SLC WARM UP CONTROLLER OFF

STEP: 16
1. TURB SPEED SET POINT: RAISE
2. DRN BEF HP CONTROLL VLV-1: CLOSE
3. DRN BEF HP CONTROLL VLV-2: CLOSE
4. MON TIME 200 SEC

KORBA SIMULATOR 203


CRITERIA FOR STEP: 17
1. SPEED SET POINT > 3036 RPM.

STEP: 17
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

CRITERIA FOR STEP: 18


1. TURBINE SPEED > 2950 RPM
2. BEAR VIB CAS GEN < MAX
3. SHAFT VIB < MAX
4. BEARING TEMP. < MAX
STEP: 18
1. DRAIN BEFORE HP CTRL VLV-1: CLOSE
2. DRAIN BEFORE HP CTRL VLV-2: CLOSE
3. MONITORING TIME 40 SEC

CRITERIA FOR STEP: 19


1. DRAIN BEFORE HP CTRL VLV-1: CLOSED
2. DRAIN BEFORE HP CTRL VLV-2: CLOSED
STEP: 19
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

CRITERIA FOR STEP: 20


1. BOTH AOPS : OFF
2. DT (LP BYPASS 1 – IP SHAFT) < X7
3. GEN CONDITIONS FULFILLED
4. FIELD FLASH SUPPLY ON
5. AVR CONTROL SUPPLY ON
6. AVR PROT. SUPPLY ON

STEP: 20
1. GEN FIELD BREAKER ON
2. WAIT TIME 15 SEC

KORBA SIMULATOR 204


CRITERIA FOR STEP: 21
1. WAIT TIME 15 SEC
2. GEN FIELD BREAKER ON
3. GEN VOLTAGE >15 KV
STEP: 21
1. SYNCHRONISER: ON
2. MONITORING TIME 60 SEC

CRITERIA FOR STEP: 22


1. GEN BREAKER ON

STEP: 22
1. STARTING DEVICE RAISE
2. MONITORING TIME 100 SEC

CRITERIA FOR STEP: 23


1. GEN LOAD > 10%

STEP: 23
1. NO COMMAND ISSUED
2. WAIT & MONITORING TIME 2 SEC

CRITERIA FOR STEP: 24


1. WAIT TIME 2 SEC
STEP: 24
1. STARTING DEVICE RAISE
2. MONITORING TIME 60 SEC
CRITERIA FOR STEP: 25
1. STARTING DEVICE 100%

STEP: 25
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

KORBA SIMULATOR 205


SUB LOOP CONTROL : TURBINE SYSTEM
SHUTDOWN PROGRAMME

STEP: 51
1. SLC DRAINS ON
2. MONITORING TIME 2 SEC

CRITERIA FOR STEP: 52


1. SLC DRAIN ON

STEP: 52
1. POWER SET POINT LOWER
2. MONITORING TIME BLOCK

CRITERIA FOR STEP: 53


1. SPEED CONTROLLER IN ACTION
2. POWER SET POINT 0% OR GEN BRKR OFF
STEP: 53
1. TURBINE SPEED SET POINT LOWER
2. MONITORING TIME 60 SEC

CRITERIA FOR STEP: 54


1. STEP-53 COMPLETED WITH TIME DELAY 100 SEC
OR GENERATOR BREAKER OFF
STEP: 54
1. ELEC TURB TRIP - CHANNEL 1
2. ELEC TURB TRIP - CHANNEL 2
3. SYNCHRONISER OFF
4. MONITORING TIME 2 SEC

CRITERIA FOR STEP: 55


1. SYNCHRONISER OFF
2. TRIP FLUID PRESSR < 5 kg/cm2
3. GEN FIELD BRKR OFF
4. ALL ESVS CLOSED

KORBA SIMULATOR 206


STEP: 55
1. STARTING DEVICE LOWER
2. DRAIN BEFORE HP CONTROL VLV-1 OPEN
3. DRAIN BEFORE HP CONTROL VLV-2 OPEN
4. SLC WARM-UP CONTROL OFF
5. MONITORING TIME 120 SEC

CRITERIA FOR STEP: 56


1. DRAIN BEFORE HP CONTROL VLV-1 OPEN
2. DRAIN BEFORE HP CONTROL VLV-2 OPEN
3. STARTING DEVICE 0%
4. DRAINS NO FAULT
5. SLC WARM-UP CONTROLLER OFF
STEP: 56
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED

KORBA SIMULATOR 207


UNIT PLANNED SHUTDOWN

KORBA SIMULATOR 208


KORBA SIMULATOR 209
BOILER SIDE SHUTDOWN OPERATIONS

ACTION OBSERVATION& REMARKS

1. ENSURE all oil guns Available.


2. REDUCE mills firing Maintain furnace Draught.

3. WATCH and ensure Steam Gradual reduction in steam


temperatures to be brought parameters.
down by Attemperation, for the
purpose of force cooling

4. Soot-blow boiler at160 MW. MAINTAIN load at 160 MW until


soot blowing is over.
160 MW
5. BRING DOWN Deaerator D/A pressure must not fall below
2 2
set point to 3.5 Kg/cm 3.5 Kg/cm to prevent cavitation.

6. REDUCE load to 130 MW. CUT- If needed, take adequate oil


OUT one top pulveriser support.

7. REDUCE firing gradually.

8. CUTOUT one more mill. Monitor ignition energy


considerations.

120 MW
9. CLOSE ES-7. Ensure AS-64 opens up at CRH
2
pressure less than 9 Kg/cm .
10. STOP one P.A. Fan.
11. REDUCE load to 80 MW.
12. STOP one set of ID/FD Fan.
CHECK APH tripping interlock.
13. CHECK APH gates isloated from
gas/air side.
80 MW
14. CHECK changeover dampers
before ID Fan have opened.
15. STOP one B.F.P
16. REDUCE firing of the remaining Boiler airflow may be reduced to
two mills.
maintain only the required amount

KORBA SIMULATOR 210


of excess air, to ensure optimum
efficiency.
17. STOP mills and the second P.A.
Fan.

18. Reduce steam temperatures by


attemperation and cutting out
oil elevation.

TURBINE STOPPED
19. PURGE boiler for 5-minutes Any of the boiler protections can
keeping all auxiliary /
be tested after the turbine is
secondary / fuel dampers open.
tripped.
20. STOP remaining ID/FDFans,
ignitor fans.

21. ENSURE all inlet / outlet


dampers, guide/regulating vane,
mill cold air dampers and
discharge valves and all wind-
box dampers are OPEN.
22. FILL boiler to maximum drum
level.

23. CLOSE SH stop valves.


24. ISOLATE feed control station.
25. STOP B.F.P.
26. At 2 Kg/cm2 drum pressure
OPEN drumvents/SH and RH
vents and SH drains.

27. At flue gas temperature of


1400C, STOP APH and scanner
fans.

KORBA SIMULATOR 211


TURBINE SIDE SHUTDOWN OPERATIONS

ACTION OBSERVATION & REMARKS

1. REDUCE load reference to 160 Monitor TSE margins and turbine


MW. bearing vibrations/temperatures
etc.
Steam temperature / pressure
start dropping.

SET load gradient to 5 MW/min.

210 MW
2. ENSURE HP/LP bypass Keep the HP/LP Bypass control on
operation. AUTO.

3. REDUCE load reference to 120 Load must be reduced only if


MW steam pressure drops.

160 MW
4. ENSURE AS-62 is open.
(CRH steam to Deaerator)

5. CUT OUT HP heaters

120 MW

6. CARRY OUT automatic turbine Refer to the chapter on ATT.


test.

7. SET load reference to


50 MW.

80 MW

8. ENSURE changeover of gland


seal steam controller from leak
off to gland steam pressure
controller supply.

9. ENSURE changeover from


UAT to station supply.

50 MW

10. Ensure steam temperature is Maintain TSE lower margin and


reducing. casing Differential temperature.

KORBA SIMULATOR 212


11. REDUCE load reference to 30
MW.

12. CUT OUT LPHs.


13. SWITCH OFF load controller. 'Speed Controller Acting' indication
comes on.

30 MW

14. TRANSFER operation to speed


controller.

15. REDUCE speed reference to less


than actual.

(CHECK 'Reverse Power


Protection').

Turbine Trip

ENSURE turbine ESV's and IV's Testing of any of generator


closed. protections can be done.

Trip fluid pressure zero.

CRH NRVs are closed.

Extraction NRVs and block


valves closed.

Generator/field breaker opened.


2
Control Oil Pre. 4.8 Kg/cm .

16. AOP-1 starts on auto.


(Approx. at 2950 rpm).

510 RPM

17. JOP-1 starts on AUTO

210 RPM

18. Gate valve gearing opens up.

19. LOWER speed reference to "0".

20. LOWER starting device to 0%.

KORBA SIMULATOR 213


21. ENSURE opening of the
following drains:

HP casing drain.
Drain after CRH NRV's
Drain before/after IV's. NRV's.
Drain before extraction NRV's
Seal steam header drain.
Drain before ESV's.
22. STOP turbine barring. Barring can be stopped after
casing/shaft temp. have reduced
below 150oC
23. SHUTDOWN all condensate
pumps.

At Casing temp. of 100 O C

24. SHOUTDOWN oil system

25. SWITCH-OFF all SLCs.

26. SHUT-DOWN JOP only when no


movement of journal in bearing
is expected due to rotor cooling.

KORBA SIMULATOR 214


GENERATOR SIDE SHUTDOWN OPERATIONS

ACTION OBSERVATION & REMARKS

1. REDUCE MVAR with load

2. CHANGEOVER to station supply


from UAT at 40 MW.

3. ISOLATE hydrogen coolers after


15 to 20 minutes of generator
tripping.

4. OPEN line isolators.

5. REDUCE excitor controller to


minimum.

6. PURGE hydrogen by filling CO2


purge the by fiiling dry compresed
air

7. STOP stator water pump

KORBA SIMULATOR 215


EMERGENCY HANDLING

KORBA SIMULATOR 216


KORBA SIMULATOR 217
CONDENSATE WATER SYSTEM

1. HOTWELL LEVEL LOW.

FAULT CONSEQUENCE ACTION

''Hotwell level low'' Loss of NPSH for the pump. Open Hotwell make-up
alarm comes on at 400 valves MC-49/48.
mm wcl of
Hot well level.
CEP will trip at 250 mm wcl Ensure cycle makeup
of hot well level. from surge tank MC-54
is open.

Excessive flow to D/A LP bypass valves close/trip CST level is adequate.


from Hotwell on condensate discharge pr.
low protection.

Some leakage in If the condensate pumps In case two pumps are


steam/water (feed) trip. Cond. vacuum may running, stop one
circuit (water-wall start dropping as the main pump immediately,
super heater, ejector performance after closing Hotwell
Economiser etc.). deteriorates; Cycle level control valves
efficiency comes down with sufficiently.
falling vacuum.
ACS Xmitter Reduce flow to D/A or
failure/fault. surge tank. Close MC-
41 or/ and MC-27.

DM make-up may be Ensure there is no


inadequate. leakage in condensate
system and CBD, EBD
DM make up pump & IBD are closed.
may have tripped.

2. HOTWELL LEVEL HIGH.

FAULT CONSEQUENCE ACTION

Hotwell level high Vacuum will start Close DM make up


annunciation comes at deteriorating if level goes valves to Hotwell.
600 mm wcl. higher than 1600 mm wcl.

MC-27 may be closed. Deaerator level will start Close cycle make-up if
(No flow to Deaerator coming down, if the flow it is open.
or surge tank). from Hotwell has been
stopped.
Too much DM make-up Running BFPs can trip on CHECK & ADJUST set
to Hotwell. ''D/A level very low''. point less than 600
mm wcl.

KORBA SIMULATOR 218


Hotwell set point too Boiler can trip on ''loss of CHECK if MC-27 is not
high. all BFPs'' protection open sufficiently,
OPEN and take some
water to D/A or surge
tank. If the need be,
open The electrical
bypass V/Vs of MC-27
& MC-41 (MC-28 and
MC 42 respectively.
ACS transmitter fault. Unit will trip due to boiler
tripping.

Condenser tube Cond. water conductivity


leakage. will increase and pH value
may drop. This will cause
the boiler- water chemistry
to deteriorate beyond
permissible limits.
Condensate pumps If the need be, (2nd
may have tripped pump comes into
service automatically
if discharge pressure
comes below 17 KSC.

CONDENSER COOLING WATER & VACUUM SYSTEM

1. LOSS OF CIRCULATING WATER PUMP

FAULT CONSEQUENCE ACTION

Operation of motor Condenser Vacuum may Immediately reduce the


protection. deteriorate due to load on the unit to
inadequate water flow. 50%.

Loss of lub water pump Turbine may trip on Immediately throttle


of CW pumps. ''Vacuum low'' protection. condenser outlet valves
2
(0.72 Kg/cm ). of both condensers to
maintain the CW
header pressure.

Pump mechanical Condenser exhaust hood Ensure LP water


failure. temp may increase with the injection valve opens to
increase in back pressure maintain ex. Hood
and cause LPT diff. exp. (+) temp below 80 deg. C
to increase.

''CW pump trip'' alarm Due to reduced header Cut in additional


comes on DAS. pressure (CW), the other ejectors, if needed, to
running units may maintain vacuum at
experience low vacuum. 2
0.92 Kg/cm (rated).

KORBA SIMULATOR 219


Circulating water Boiler firing may increase
header pressure drops on CMC mode due to low
slightly. cycle efficiency.

CW flow through the Start the standby CW


condensers Decreases. pump, immediately, if
it's available.

3. CONDENSER VACUUM IS DETERIORATING, GRADUALLY.

FAULT CONSEQUENCE ACTION

Air ingress in the Turbine vacuum starts Immediately decrease


condenser has deteriorating and LPT unit load low enough
increased. exhaust temp rises. to sustain vacuum.

Cond. surge tank level Turbine control valves open Take additional air
may be very low. more to meet load demand ejectors in service.
and boiler firing increases
on CMC.

Hotwell level may be Turbine may trip on Ensure hot-well CST


very high. ''Vacuum low'' protection level and gland seal
and the boiler may trip on steam pr. are OK and
R/H protection. cond pumps are on.
Also ensure ejector
steam pr. is adequate.

Cond. pump may have Low vacuum causes the Ensure CW header pr.
tripped or MC-27/28 is cycle efficiency to decrease. and condenser
closed & MC-33/34 is circulating water flows
not open. are normal.

Cond. CW pumps may Due to high cond back If any condenser is


have tripped. pressures, the diaphragm found choked carry out
may get ruptured. cond. Backwashing

Ejector steam pressure On hydraulic governing Ensure all cond. CW


is low. mode unit output will pumps, cooling tower
reduce due to Low cond. pumps and fans are
vacuums. running normally.
Cond. CW temp may be
higher (CT pp. may not
be in service).

Condenser tubes may


be fouled up or even
choked.

KORBA SIMULATOR 220


3 . CONDENSER WATER BOX DP HIGH (ALARM)

FAULT CONSEQUENCE ACTION


Condenser tubes may Condenser choking may Find out the
be choked or badly result in bad heat transfer condenser, which is
fouled-up. and reduce CW condenser choked by seeing CW
flow flow (low) temp. (High)
or diff. from DAS or
locally.

Due to inadequate Consequently condenser Reduce load to 80 MW


chlorination, some vacuum may fall, causing (approximately)
biological growth has low thermal efficiency.
taken place at the
cond. inlet.

Condenser CW flow Unit may trip on low Cut-in one more main
decreases and its condenser vacuum and ejector and starting
differential temp cause low plant load ejector, if required.
increases. (DAS factors/availability
indication).

Condenser vacuum Charge priming ejector


may start falling (alarm and close CA-1 or CA-2
2
at 0.8 Kg/cm .) air valve of the cond. to
be back-washed.

Reverse the direction of


4-way butterfly valve of
the condenser.

OPEN CA-1/2 that was


closed and close the
other one and
backwash the 2nd
condenser.

BOILER FEED PUMP

1. BFP RE-CIRCULATION VALVE FAILS CLOSED.

FAULT CONSEQUENCE ACTION


BFP discharge Increased differential Adjust the re-
pressure may increase. pressure across the FW circulation of the BFP
regulating valve causes the such that BFP flow
BFP speed to be reduced if does not fall less than
it is on auto. 150T/Hr.

KORBA SIMULATOR 221


'BFP'' suction flow low Insufficient feed flow If re-circulation cannot
alarm may come at 125 through the BFP may cause be maintained take
T/Hr. churning and may lead to another BFP in service
seizure of the pump and stop the one with
ultimately due to prolonged the problem.
operation of BFP with
insufficient feed flow.

BFP bearing
temperature may
increase due to
cavitations or
churning.

2. BFP LOSS OF LUB. OIL PRESSURE

FAULT CONSEQUENCE ACTION

Lub oil pressure low Any feed pump; trip ping Ensure immediately
alarm comes. out of service may cause that standby BFP is
serious drum level available.
disturbances.

Lub oil pres sure Lo-Lo Boiler may trip on drum Maintain level
alarm comes level protection. otherwise, unit may
trip on 'Low' drum level
protection.

BFP trips & brings on Bearing starvation and


alarm of BFP trip. damage may take place.

Filters may be chocked Drum level will drop Unit may run back on
up momentarily and Deaerator CMC mode. Avoid any
may increase slightly possible failure by
cutting in oil elevation

BFP's lub oil Pressure Other running BFP goes


switch may have fully loaded
malfunctioned.

("lub. oil pr. adequate" The standby BFP gets an If the standby BFP has
lamp remains on). auto start command & not started, then start
comes into service after 5 it manually.
sec. time delay
Instruct local operator
to change over the oil
filters (duplex).

KORBA SIMULATOR 222


3. BFP BEARING VIBRATION: HIGH

FAULT CONSEQUENCE ACTION

Lub oil quality bad. BFP may trip at high (7 Unit runs back on
mm/sec.) vibration level. CMC if any BFP trips
and the standby pump
do not come into
operation within 10 sec
Damaged bearing. Boiler may trip if no other
Mechanical problems BFP is in operation
in pump
Cavitation due to Boiler may also trip on Avoid any possible
air/vapour ingress into drum level fluctuations flame failure due to
BFP. (V.HI / V.LO). unloading of the mills
on CMC runback, Cut-
in oil elevation.

Unit may trip or run back Ensure the D/A pr. is


on CMC to its lower load not dropping rapidly
limit after a tripping; and
BFP suction pr. is
adequate.

4. BFP HYDRAULIC COUPLING OUTLET OIL TEMPERATURE IS GOING HIGH.

FAULT CONSEQUENCE ACTION


BFP may be running At 130oC working oil outlet Instruct local operator
on low scoop tube temperature, the BFP may to change over working
position for a long trip and can cause drum oil coolers.
time. level
Fluctuations.

BFP working oil cooler Unit may run-back on CMC Ensure ARCW pump
may be fouled up. to lower load limit. pr. is adequate.

BFP cooling water pr. Unit may trip due to loss of Increase BFP scoop
(ARCW) may be low. all BFPs. tube position.

''BFP brg. metal/oil


temp high''& "BFP
hydraulic coupling oil
temp high'' alarms may
start flashing.

5. BFP SUCTION PRESSURE IS FALLING LOW.

FAULT CONSEQUENCE ACTION

Deaerator pressure BFP may trip on low Ensure standby BFP is

KORBA SIMULATOR 223


may be falling. suction pressure. (< 6.5 available and comes
Kg/cm )
2 on, in service.

BFP suction strainer Boiler/unit may trip or run- Maintain D/A


chokes. back on CMC. pressure.

''BFP suction pressure BFP may cavitate and seize Shut-down the BFP
low'' and ''BFP suction ultimately. for strainer cleaning
strainer clogged'' and maintenance.
alarms start flashing.

6. BOILER FEED PUMP MASTER SPEED CONTROLLER FAILS HIGH.

FAULT CONSEQUENCE ACTION

BFP speed controllers Drum level will start Transfer the BFP
go to maximum. increasing. master controller to
manual mode.

F.W. control valve The high range feed control Reduce the individual
differential pres- sure valve will start closing in speed controller’s
indicator goes to zero. response of high feed water output to bring down
flow and drum. the Water flow, if
needed.

Feed water flow BFP may trip on account of If BFP flow is more
increases. high feed flow. than 430 T/hr. for
more than a minute,
BFP will trip
immediately reduce the
scoop controllers

BFP flow high alarm Drum level high alarm


may come. comes if the level reaches
125 mm.

Unit trip will occur if level Watch the drum level


reaches 225 mm and & ensure it is
remains for more than 10 maintained normal.
secs.

KORBA SIMULATOR 224


REGENERATIVE FEED HEATING SYSTEM

1. EXTRACTION SHUT- OFF VALVE ES-6 TO HP HEATER-6 FAILS CLOSED

FAULT CONSEQUENCE ACTION

Extraction shut- off FW temperature leaving Give ES-6 an opening


valve es-6 to hp heater- HPH-6 will be equal to FW command.
6 fails closed temp out of HPH-5.

Spurious electrical HP control valve position If it does not open


fault. decreases slightly on reduce the boiler firing
increasing MW. and RH outlet.

Indication/ Causes: Drum level drops due to Watch the steam


shrinkage. temperature at SH
outlet and RH outlet

Extraction block Throttle pressure increases Check the steam


valve ES-6 close momentarily and then temperature before
indication comes. drops. attemperation. If it is
increasing, then
increase the
attemperation slowly to
control the main
steam/ reheat
temperature
HPH-6 normal drain Firing rate increases if unit
valve goes closed as is on CMC and slight loss of
soon as ES-6 closes efficiency caused by loss of
completely. a feed water heater.

Normal drain to HPH-5


goes closed.

Drum level drops.

2. LP HEATER-3: TUBE LEAK.

FAULT CONSEQUENCE ACTION


Extraction steam line NRVs Drain the affected
to Heater-3 will close down. heater and try to
charge the heater

Possible Causes: Extraction line drain valve If level does not come
on turbine panel opens down, try to bypass the
when NRV is less heater.

KORBA SIMULATOR 225


Tube rupture Condensate flow to Check the proper
Deaerator drops by 100 closure of extraction
T/hr. block valve and NR
valves.

LP Heater-3 level high Deaerator level controller Instruct the local


alarm comes. output increases on operator to bypass the
decreasing D/A level heater from feed
waterside.
LPH-3 alternate drain Deaerator level controller Maintain the Deaerator
valve begins to open. output increases on level and condensate
decreasing Deaerator level. pump discharge
pressure.

LPH-3 normal drain Condensate discharge Take Hotwell level


valve closes. header pr. decreases since control in manual and
condensate is re-circulating reduce its out- put to
through LPH-3. maintain the
condensate pump
discharge pressure.
LPH-3 level Hi-Hi
alarm comes in DAS
LP heater extraction If condensate discharge
steam block valve ES-3 header pressure drops
2
below 17.5 Kg/cm for 15
secs., condensate pump will
trip.
LPH-3 extraction line
drain valve DW-80
opens.

Feed water temp. to


deaerator will decrease.

3. HP HEATER TUBE LEAK.

FAULT CONSEQUENCE ACTION


HPH-6 level high Extraction steam line NR Under very high level
alarm comes. valves to Heater-6 will close HP heaters get
down. bypassed on waterside
and extraction valve
closes. However, it is
advised not to wait for
this action.
HPH-6 alternate drain Extraction line drain valves
valve to condenser on turbine panel open when
opens. Red light comes NRV is less than 5% open.
on.

KORBA SIMULATOR 226


Feed water temperature Bypass the heaters by
leaving HPH-6 drops down. energising the group
bypass valves

HPH-6 level high and Drum pressure will increase Tilt the burner tilts to
hi-hi alarm comes in due to closure of extraction negative side to
DAS. valve. prevent the shooting
up of R/H
temperature.
HPH-6 & HPH-5 heater Flue gas temperature Watch the drum level.
extraction drain valves leaving furnace will Take it on manual if
ES-6 and ES-5 set increase. necessary
closed.

Main steam temperature NOTE: one can


leaving furnace will maintain full load
increase. without HP Heater also

Extraction steam line Drum level drops due to Check the heater level
drains DW-75 and DW- shrinkage. from the local.
74 open.

HPH-6 normal drain Throttle pressure drops as


valves HD-37 and HD- the efficiency drops.
51 to HPH-5 and
deaerator closes.

4. HPH-6 ALTERNATE DRAIN VALVE FAILS OPEN.

FAULT CONSEQUENCE ACTION

Spurious control When all the condensate has Restore instrument air
signal. got drained out of the FW pressure if possible.
heater, steam will start
blowing directly through the
heater and into the
condenser.
Instrument air Reset and put on
failure. Remote, if needed; the
pneumatic control valves,
after air supply is
restored.

HPH-6 alternate If required, get the


drain valve HD- 43 alternate drain closed
open indication manually.
comes HPH-6
normal drain to
HPH-5 closes.
If there is water in the heater Ensure HPH level is

KORBA SIMULATOR 227


due to higher surface area, maintained normal.
the FW temperature should
increase slightly.

If the heater is drained


completely, then the FW
temperature will drop, as
latent heat of steam is not
being utilised for feed water
heating.

Boiler heat rate goes up and


fuel firing has to increase to
maintain steam parameters.

AIR PRE-HEATER

1. AIR PRE HEATER BEARING TEMPERATURE VERY HIGH.

FAULT CONSEQUENCE ACTION


Cooler may be At high bearing temp 100oC Normalise cooling
fouled up. the APH can trip. water pressure and
flow.
Lub. oil pump may Due to interlock if APH trips If lub. oil pump is
have tripped on corresponding ID/FD Fan found tripped start the
coupling failure will also trip. standby pump.

Inadequate cooling Unit load comes down to Restart the APH, ID


water flow. approx. 50% on CMC. and FD fan and raise
the unit load.

Alarm comes on at Furnace/flame gets Note: Starting of 2nd


75oC. disturbed, depending on guide brg. pump
flame configuration. Boiler automatically brings in
may trip on loss of flame or the second oil cooler
furnace pressure high or into service provided
low. it's charged from the
water side.

2.A. AIR PRE-HEATER ELECTRIC MOTOR TRIPPED.

FAULT CONSEQUENCE ACTION


''APH electrical motor trip'' Corresponding ID/FD Ensure the air motor
alarm comes on in UCB. Fans will trip if the air comes into service.
motor does not come
on interlock.

The bearing temperature Due to inadequate If possible restore

KORBA SIMULATOR 228


very high protection may excess air in boiler electrical supply and
have acted. (fuel rich mixture) start the APH
flame out may occur immediately.
and boiler can trip.

Motor/breaker protection Fuel rich mixtures may Ensure sevice air pr.
may have acted. cause boiler explosion is adequate and air
and result in damages motor isolating valves
to boiler supports. are open.

Electrical supply may have Unit runs back on If air motor is not
failed. CMC mode due to available, cut in oil
ID/FD fans tripping. elev. & reduce boiler
firing to approx (50%)
and transfer load of
the corresponding
ID/FD Fans on the
other pair completely.

2.B. APH ELECTRIC DRIVE TRIPPED AND AIR MOTOR FAILS TO START.

FAULT CONSEQUENCE ACTION

Air motor may not be With a time delay of 30 Ensure service air pr.
lined up. secs. tripped APH's is adequate and the
isolating dampers are isolating valves of the
closed and corresponding air motor are open.
ID/FD fans also trip-out.

Service air pressure Unit runs back on CMC. If air motor is not
< 5 Kg/cm .
2 available,
immediately transfer
load of ID/FD fans to
the other pair or start
afresh the 2nd pair of
ID/FD FANS &
maintain draft &
airflow in boiler.

Solenoid may be Boiler may trip due to Reduce boiler firing


faulty. furnace disturbances or immediately.
flame failure.

3. AIR PRE-HEATER ON FIRE.

FAULT CONSEQUENCE ACTION


Oil deposition on air Overall damage to the air Unload and stop
pre-heater element. pre-heater element and corresponding ID/ FD

KORBA SIMULATOR 229


parts. Fans quickly.

High flue gas Loss of generation due to Stop air heater and
temperature unavailability of one set of ensure isolation
APH/ID/ FD Fans. dampers are closed.

''APH fire detection Lower cycle efficiency due Wait until all
temperature trouble'' to part load operation. temperatures become
alarm comes in the normal. Then start
UCB. air heater electrical
motor again

Flue gas temp. before APH soot blowing


/after air heater and must be done
secondary air temp. regularly in each
increases. shift& positively after
every boiler light up.

Note : Any APH may be allowed to run on air motor (or air motor bypass mode)
provided the gas inlet temperature of the APH is maintained within 370oC
(max.)

INDUCED DRAUGHT FAN

1. ID FAN LUB. OIL PRESSURE / BEARING TEMPERATURE TROUBLE.

FAULT CONSEQUENCE ACTION


Lub. oil may be ID Fan may trip on tank Ensure the stand- very
inadequate. level by lub. oil pump low lub. oil pump is
pressure or very high taken into service.
bearing temperature.

Lub. oil filters may be Unit runs back on CMC Top-up oil level in the
choked. to low load limit. (Approx. lub. oil tank. Clean the
50%). filters.

Greasing long over- Corresponding FD Fan Reduce load on the


due in fan bearings. can also trip due to ID troubled ID Fan and
fan tripping. also on the unit, if
furnace is geting
pressurised.

Corresponding alarm Undesirable furnace Stablise furnace.


will indicate the pressurisation.
problem area.
Boiler/unit may trip due Cut-in oil as quickly as
to ''all IDs tripping'' or ''all possible to avoid flame
FDs tripping''. failure trip.

KORBA SIMULATOR 230


Boiler/unit may trip due If available, get ID Fan
to ''all IDs tripping'' or bearing greased up and
''all FDs tripping''. Gradually increase
loading, on the fan.

If unavoidable,
shutdown the ID Fan.
The other fan set must
be running before
shutting down any ID
Fan.

2. ID FAN TRIP.

FAULT CONSEQUENCE ACTION


Motor over-loaded. Corresponding FD Fan Immediately cut in
shall trip. suitable oil elevations.

Corresponding Unit runs back on CMC to Reduce boiler firing from


FD Fan has 50% load. the upper elevations to
tripped. make it compatible with
available airflow; to avoid
fuel rich furnace.

Spurious electrical Furnace pressure increases


fault. (above atmospheric).

Lub. Oil pressure The other ID/FD Fan pair Immediately cut in
problem. becomes over-loaded if on suitable oil elevations.
auto.

Bearing temperature May lead to partial flame Reduce boiler firing from
problem. failure due to fuel rich the upper elevations to
mixtures in the furnace make it compatible with
and cause a lot of furnace available airflow; to avoid
disturbance. fuel rich furnace.

Corresponding Reduce Unit load to


APH may have approx. 50% manually
tripped.

All annunciations If possible, restart ID Fan


pertaining to the and the corres- ponding
causes of tripping FD Fan and stablise unit
will annunciate. at 200 MW.

KORBA SIMULATOR 231


FORCED DRAUGHT FAN

1. FD FAN TRIPPED.

FAULT CONSEQUENCE ACTION


Lub oil pressure Unit runs back on CMC If load does not drop
trouble. to minimum load set automatically, reduce the
point. load manually to 50% to
suit one fan set.
Bearing Load is reduced to 105
temperature MW
trouble.
ID fan has tripped. Oxygen in flue gas Cut in oil to avoid flame
decreases. failure.

FD lub. Oil Fuel flow drops down to Maintain O2 (3%-5%) in


pressure low. available airflow. the flue gases.
(‘‘Lub. Oil pressure
low'' alarm comes
in.
Corresponding ID fan Maintain furnace draught
trips out. between -5 mm wcl. to -
10 mm wcl.

''FD Fan trip'' Flame fluctuations. may If boiler has tripped then
alarm and white take place. make preparation for
trip lamp comes light-up again.
on.
Boiler may trip on ''all FD
fans tripped''.

2. FD FAN BEARING TEMPERATURE GOING HIGH.

FAULT CONSEQUENCE ACTION


Cooling water flow Load drops down to 100 Reduce load on the FD
may be inadequate MW approx. as unit Fan. INSTRUCT local
runs back on CMC to operator to charge the
min. load set point. other lub. Oil cooler.

Coolers may be fouled Corresponding ID Fan


up. trips.

Bearing temperature Unit may trip on '' All If the other fan set is
increases. Alarm FDs tripped''. not running and
comes in at 95oC. available for operation,
put them in to avoid a
unit trip.

KORBA SIMULATOR 232


FD Fan-A trips when
bearing temperature
reaches 105oC.

PRIMARY AIR FAN

1. PA FAN TRIPPED

FAULT CONSEQUENCE ACTION

''PA Fan Trip'' annunciation Hot primary air Maintain furnace


comes on. header pressure may draught (-5 mm wcl to
dip and cause '' PA 10 mm wcl).
header pressure low''
alarm at 585 mm wcl.

If the tripping is due to high Mills start tripping Maintain PA header


bearing temp. (104oC). from top until no pressure at 760 mm.
Corresponding alarm comes more than three mills
on before tripping of the fan are in service.
(85oC).

If the 2nd fan is Check the bearing


running and control temperature
is on auto, 2nd fan indcations locally and
takes up load and in UCB, for the fan.
bring up the PA
header pressure to
normal (760 mm).

Spurious electrical tripping. Discharge damper of Check the running


tripped fan closes mills for possible
and regulating vanes choking.
comes to minimum
position. Turbine
load comes down up
to approx. 50% on
CMC.
Boiler has tripped. Unit runs back
on CMC. If not on
CMC, reduce load
on turbine up to
40%-50% manually.

Lub. Oil pressure may be CHECK the lub. Oil


very low. pump system.

If possible, RESTART
and load the PA Fan

KORBA SIMULATOR 233


and stablise unit at
200 MW.

2. PA FAN VIBRATION TROUBLE

FAULT CONSEQUENCE ACTION


''PA Fan vibration High vibration can damage Reduce loading in the
high'' annunciation the bearing and shaft of fan immediately, load
comes on (1.5 the fan the other fan if that's
mm/sec) running or take the
second fan into service.
Damaged bearing. At 2.5 mm /sec pk., PA fan
is recommended to be
tripped.

Pulverisers in excess of 3, Instruct the local


may have to be stopped operator to check up
and unit load may have to the bearings, lub. oil
be lowered. pressure, bearing
temp and vibration etc.
Loose bearing pedestal Reduced boiler efficiency at
bolts. part load.

Quality of lub oil may Machine down time If required (on account
have deteriorated. increases the maintenance of high vibration) stop
overhead. the fan immediately.
(Follow shutdown
procedures).

3. PA FAN LUB. OIL TROUBLE

FAULT CONSEQUENCE ACTION


Corresponding It can starve the bearing of Check if lub. oil pump
facia/window glows oil, brg. Temperature can is running and
on. go high. It can even pressure adequate(2.5
damage the bearing. g/cm2.)

Lub. oil pressure may Fan trips if lub. oil CHECK if the other
be lower than 1.6 pressure Lo-Lo alarm pump comes on
Kg/cm2. comes on at 1.2 Kg/cm2. interlock, at 1.6
kg/cm2. if pressure
keeps falling.

Filters may be choked. Pulverisers in excess of 3 Changeover the lub. oil


will trip and the boiler load filters to maintain lub.
reduces. oil pressure.

KORBA SIMULATOR 234


Pump glands may be
leaking.

COAL PULVERISER SYSTEM

1. PULVERISER DP GOES HIGH.

FAULT CONSEQUENCE ACTION

''Pulveriser DP high'' The pulveriser may be Maintain pulveriser


alarm comes at 240 mm choked up completely. outlet temperature at 75
wcl. mill DP. This may damage the 0C.
dust guard or the motor
(if needed, take control
or the mill coupling
on manual).
because of overloading.

Coal pulveriser may be Boiler steam Cut in another mill Raise


Choking up. pressure/temp may load on T/G.
come down. Turbine
load comes down.

Pulveriser motor gets Reduce feeding. See if


overloaded. DP improves.

Pulveriser out-let Choking reduces the Also check up locally the


temperature falls low. mill output. condition of reject mouth
whether it is choked up
and air is coming.

Too much coal feeding. At high DP (240 mm) or NOTE:


mill current (38 amp.), If pulveriser is
feeder speed runs back completely choked up,
to minimum. STOP feeder, STOP mill.
Issue, work permit to
BMD (Boiler
Maintenance Division).

Reject mouth choked up Oxygen (%) goes high


because of some foreign due to reduced coal
material stuck up in input to furnace.
reject sprout (not
simulated).

Moisture content of the


coal may be high.

KORBA SIMULATOR 235


2. COAL FEEDER TRIPPED.

FAULT CONSEQUENCE ACTION


Motor may be Feeder tripping will stop After feeder tripping check if
overloaded. the coal flow to the mill. hot air damper & gate have
Hot air damper closes closed & cold air opened
after a time 100%.
delay of 30 secs.

Silo gate closed.

No coal flow to the Mill current goes no load Check the healthiness of
pulveriser for amps Boiler/ unit load feeder's electrical supply.
more than 10 also comes down. Change
secs. fuse if needed.

Adjacent mill will trip (if Transfer fuel master to


it's feeder is not manual control & prevent
established) due to loss of the overloading of other
ignition energy. running coal feeders.
Take the other available
pulveriser in service and
raise load.

3. PULVERISER TRIPPED

FAULT CONSEQUENCE ACTION

Ignition energy may If the adjacent mill Restore ignition support


have been lost. feeder is not and cut-in the tripped
established, that mill adjacent mill.
trips out.

PA header pressure Boiler/unit load may Stabilise furnace draft and


may be low (585 come down. bring down the O2% to 4%
mm wcl). - 5%.

Anyone PA fan Oxygen percentage Cut in oil guns and


trips. will start increasing. transfer fuel master to
manual, if found
necessary.
Boiler may trip due to
furnace/flame
disturbances.

KORBA SIMULATOR 236


4. MILL OUTLET TEMPERATURE GOING HIGH.

FAULT CONSEQUENCE ACTION

Mill discharge At 95 0C mill cold air damper Ask local operator


temperature high opens 100% and hot air to remove all men
alarm comes on at damper and gate close fully. working near/on
95 0C. the mill.
Change in coal Mill temp. starts coming Ensure HAG/HAD
quality(volatile down, increasing the of the mill are
matter). possibility of mill choking if closed and CAD is
coal feeding is not reduced opened
immediately

Pulveriser fire due Prolonged operation of the Cutting all air


to lean (explosive) mill with high outlet temp supply and coal
air coal mixtures in increases the possibility of over feeding can
the mill. explosion. smother small
fires.

Ensure continuous
coal supply for the
mill.

Temperature Mill fire may spread to other


controller may have parts of the mill piping.
failed.

Cold air damper If needed, transfer


may be jammed-up. the mill air control
to manual &
maintain temp.
/flow.

5. MILL CURRENT HIGH (MORE THAN 38 AMP.)

FAULT CONSEQUENCE ACTION

Grindability index low. Mill requires more Reduce feeder speed to


power for the same prevent motor overloading.
output.
Pulveriser capacity At motor load of 38 Put another pulveriser in
reduced due to the Amp. Feeder speed service to maintain unit
classifier setting too runs back to load.
high. minimum (30%)
rated).

Pulveriser may be Unit load comes Maintain PA header


choking up. down. pressure at 760 mm wcl to
avoid coal hang-up in mill.

KORBA SIMULATOR 237


Pulveriser may not Discharge Instruct local operator to
have been cleared for temperature of the operate the reject gate to
a long time. mill tends to increase evacuate the mill.
back.

At 95 O C hot air Instruct shift chemist to


damper closes. HAG check for coal fineness and
also closes after a re-adjust the classifier
time delay. setting.

Mill may trip on over


load and other
running feeders will
overload, if on auto

6. COAL FLOW TO MILL INDICATION GOES OFF.

FAULT CONSEQUENCE ACTION

Feeder belt may be Pulveriser discharge temp. Maintain furnace draft


broken and feeder may increase. Pulveriser and oxygen
coal flow is lost. DP reduces. percentage.

Feeder discharge HAD & HAG close at 95 0C Take associated oil


chute may get and CAD goes to 100 % guns in service to
plugged. opening stabilise furnace.

Mill motor current comes Stop the mill after it


down due to gradual loss gets emptied.
of coal, as mill inlet chute
is getting plugged.

Feeder coal flow HAD & HAG close at 95 Take associated oil
transmitter may be 0C. as mill outlet temp guns in service to
faulty. goes up with loss of coal to stabilise furnace
mill. draught.

Feeder trips on overload, Adjust fuel master to


as the coal chute is maintain loads on the
completely plugged. running feeders (auto).

Other feeders start loading If other mill is


up, if on auto. available, cut-in the
mill and raise unit
load.

Look for reasons for


the too much moisture
in coal.

KORBA SIMULATOR 238


7. FUEL FLOW RUN BACK TO LESS THAN DEMAND (DROPS BY 20%).

FAULT CONSEQUENCE ACTION

Spurious electrical All feeders get unloaded Raise fuel master


malfunction. by 20% (Combustion output to increase
control is on Auto). load.

Combustion control Airflow reduces by 20%. Continue operation on


trips to manual. 'Manual' mode.

''ACS auto to manual Drum level drops due to Maintain mill


transfer’’ alarm shrinking. parameters.
comes in.
Boiler pressure also Maintain boiler
drops. parameters.

Unit load decreases. Maintain unit load at


100% MCR.

If no action taken, load If required, take the


steadies down at 80% of other available mill in
rate value (approx.). service.

8. PULVERISER HOT AIR GATE FAILS CLOSED.

FAULT CONSEQUENCE ACTION

Spurious electrical Pulveriser cold air damper Cut in corresponding oil


signal causes the goes 100% open. HAD goes elevation to stabilise
HAG to close. closed. flame.

Someone may have Reduce coal feeder


closed hot air gate loading to avoid mill
locally. choking due to low
temperature operation.

Pulveriser temperature starts Instruct local operator


dropping. to open the hot air gate
locally or inform C&I
maintenance.

Pulveriser current runs up if If unavoidable, stop the


feeder speed is not reduced pulveriser and cut-in a
(Because of poorer new mill.
grindability of high moisture
coal).

Pulveriser DP may go low due Stabilise unit load at

KORBA SIMULATOR 239


to reduced air volume if CAD 200 MW.
is not opened.

NOTE: All pneumatically operated dampers must be reset and put on remote
operation, only after ensuring E/P converter and the actual damper position
are matching.

9. PULVERISER AIRFLOW FEED BACK OFF SET 25% HIGH AIRFLOW READING)

FAULT CONSEQUENCE ACTION

Flow measuring HAD and CAD close Reduce feeder speed


pitot tube may be partially to compensate slightly to maintain
plugged. for increased airflow pulveriser DP.
feed back signal.

UCB instrument for Mill DP increase as the Take mill air control on
airflow indicator coal retention in the mill manual and adjust the
may be faulty. goes up due to airflow to the required 60
decreased airflow; hence T/Hr.
mill DP goes up along
with pulveriser current.

Mill air control, Pulveriser output comes Instruct local operator to


if on auto reduces down and reject rate evacuate mill reject
the actual mill goes up. locally.
airflow and airflow
reading drops a
little.
Boiler/unit load comes If possible, load up other
down and oxygen mills to maintain unit
percent increases load.

10. Pulveriser PA flow Temperature Compensation Thermo-Couple Fails.

FAULT CONSEQUENCE ACTION

Thermocouple wire Airflow indication Reduce feeder speed to


broken. comes down but contain mill DP.
actual airflow remains
as it was initially.

Hot Primary Air HAD/CAD modulate If feeder runs back, due


temperature to restore airflow; to high mill DP; let mill
indication goes up to thus raising the get emptied and stabilise
400 deg. C. (falsely) actual airflow through mill.
on DAS and ''Hot PA mill.

KORBA SIMULATOR 240


to mill temp. HI''
alarm comes on DAS.
Mill DP goes up due Transfer mill air control
to excessive airflow. to manual to control mill
Airflow and temperature.

11. COAL FEEDER FLOW INDICATION LOST.

FAULT CONSEQUENCE ACTION


Belt broken. If belt is broken coal Immediately take the fuel
flow to pulveriser stops master on manual and
after sometime and prevent over- loading of
pulveriser current other feeders.
comes down.

Transmitters failure (In If pulveriser is running Maintain O2 % approx.


this case, feeder trips to normal (without drop in 3%-4%.
manual from auto) and current) that indicates
' ACS to manual' flow transmitter failure,
annunciation flashes. in which case other
feeders overload to
maintain boiler load, if
on auto.
If other feeders have
overloaded, reduce their
out- put gradually.

A fuel rich mixture may If flame quality has


result in furnace deteriorated (as shown
explosion if boiler does by scanners) and opacity
not trip on flame has increased,
failure, on account of immediately’ hand-trip'
increased firing and the pulveriser (if severe
insufficient airflow. fluctuations of furnace
draught are noticed) and
see if things improve.

11. PRIMARY AIR PRESSURE CONTROLLER MALFUNCTION


(P A HEADER PRESSURE DOES NOT CHANGE WHEN REQUIRED).

FAULT CONSEQUENCE ACTION


Fan vanes freeze. At PA header pressure As soon as drop in
Mechanical jamming. of 585 mm wcl. all header pressure is
pulveriser trip out after noticed immediately trip
5 sec.time delay. the new mill, which is
being taken in service.

If more air is Boiler will trip if no oil Ask local operator to


demanded (while elevation is in service check the freeness of
taking another and all pulverisers trip guide vanes, control air

KORBA SIMULATOR 241


pulveriser), controller out. supply & local switch on
output goes to 100% Remote for operation
But actually header from UCB.
pressure drops).
At 525 mm wcl PA
header pressure, all NOTE:
mills trip E/P converter and the
instantaneously. IGV positions must be
made equal before it's
Pulverisers coal output put on 'Remote'; to avoid
reduces at reduced any inadvertent change
pressure of primary air. in PA header pressure.

TURBINES AND AUXILIARY SYSTEM

1. TURBINE SHAFT OIL PUMP FAILURE.

FAULT CONSEQUENCE ACTION

Broken impeller due to High vibrations can Immediately trip the


material defect. damage the bearings of unit manually from
the turbine. UCB.

Lub oil/ control oil Continued operation of Cut-down boiler fire


pressure drops, AOP-1 the turbine in this immediately but
comes on AUTO (inter- condition is not gradually and
lock). recommended. It may shutdown
result in damage to
other turbine parts.
High vibration in Once Trip oil Pr. is <5.0 Turbine will Trip
bearing No.1. 2
Kg/cm . ESVs will without any fault
CLOSE indication

2. TURBINE LUB OIL RESERVOIR LEVEL LOW.

FAULT CONSEQUENCE ACTION

A leak in the lub oil At -900 mm. MOT If possible quickly,


cooler or oil line. level fire protection-1 switch over the
operates. Turbine leaking cooler to the
electrical trip is one on standby and
initiated. see if MOT level
improves.

''MOT level low' alarm Vacuum breaker If unit trips, RESET


annunciation' in UCB'. opens. turbine fire protection
and make-up lub. Oil

KORBA SIMULATOR 242


level in MOT.

''Fire protection oil tank LP bypass, if charged, Proceed to revive the


level LOW'' alarm comes trips on low condenser unit, after getting the
on in UCB. vacuum. lub oil leakage
attended and MOT
level topped up.

Boiler trips on R/H


protection after 10
secs time delay.

3. LOSS OF TURBO SUPERVISORY POWER.

Power supply to turbo- All turbo-supervisory Get the fuse replaced.


supervisory cabinet parameter indications Mean while do not
failed due to blowing associated with the TSI change any
up of the fuse. will be lost, including parameters.
vibration expansion
and shaft position.

TSI power supply


failure alarm comes in

4. BROKEN LAST STAGE BLADE OF L. P. TURBINE.

Turbine bearing vibrations go up, - Immediately trip the turbine/unit


especially bearing No.4. from UCB.

Broken pieces from the blade may - Prepare for shutting down the boiler
damage the condenser tubes, by cutting out the coal firing.
resulting in condenser tube leakage.

5. MAIN TURBINE ELECTRO-HYDRAULIC CONTROLLER FAILS HIGH.

The machine becomes Immediately start


overloaded unduly reducing the
hydraulic governer to
get the desired load.
(When the speeder
gear position gets low
enough to take over
from EHC, a slight
decrease in secondary
oil pressure to HP/IP
control valves is seen.)

KORBA SIMULATOR 243


''EHC Faulted'' alarm Boiler metal temp goes up
comes on. as the boiler loads up (If
the unit is on CMC or
boiler follow mode).

EHC output goes to Generator/generator


100%. transformer winding
temperatures start going
up, as generator
overloads.

Turbine loads up to Continued and prolonged Lowering of starting


max limit set by operation may lead to device, instead of the
hydraulic speed tripping of T/G unit on speeder gear, brings
control. high winding the load change much
temperatures of generator faster. After the
or transformers due to desired load has been
overload. reached, speeder gear
is lowered until it
takes over; and then
starting device is
again raised to 100%

HP control valves go
100% open and the
boiler firing goes up
on boiler follow mode.

6. TURBINE AXIAL SHIFT HIGH.

"Thrust bearing metal Unit may trip on high Immediately de- crease
temp high'' alarm may thrust pad wear load on M/C and watch
come in UCB. protection (0.6 mm). if axial shift improves.
Otherwise, unit trips
on thrust pad wear
protection. (Boiler may
trip on R/H protection)

Unit load may have to


be reduced, resulting in
loss of generation

''Axial shift high'' Excessive axial shifts


alarm may appear. can cause rubbing of
moving and stationary
parts.

Silica/ chemicals may Vacuum breaker valve If unavoidable, trip the


have deposited on the opens up after tripping turbine manually from

KORBA SIMULATOR 244


turbine blades. and vacuum gets the UCB for
killed. investigations by the
T/G maintenance.

7. TURBINE LUB. OIL TEMPERATURE IS GOING UP.

Lub. Oil coolers may be Oil viscosity comes Take in service the
fouled-up. ''Lub oil down with increasing standby lub oil cooler
temperature after temperature of lub oil. if available.
coolers high'' alarm at That may lead to
47 0C. (UCB boundary lubrication
and metal-to-metal
annunciation).
contact. It may cause
extensive damages to
T/G bearing and high
brg. Vibrations.
If high vibrations are
observed, trip the
turbine immediately.

''Turbine lub. Oil Bearing outlet oil temp Ensure ARCW/CW


temperature high'' increases. Brg. outlet water pressure is
alarm at 47 0C. (UCB oil temp more than 78 adequate.
oC causes accelerated
alarm)
aging of oil and so
additional revenue
losses for each oil
change.
Bearing metal temp Maintain bearing outlet
goes up ''Brg. temp oil temp below 78 oC to
high'' alarm comes at curb aging of oil.
90oC.

8. LOSS OF CONTROL POWER TO TURBINE EHC SYSTEM.

Control supply may HP/IP control valves go Start reducing the


have gone off due to fully open and unit starting device till the
earth fault or blown load goes up to max. load comes back to
fuse etc. and ''EHC desired value.
control fault’’ alarm
comes on.
Generator overloading Reduce speeder gear
may lead to winding till a further decrease
temperatures increase. in load is observed.
Raise the starting
device to 100%.
EHC output goes to Boiler firing may
100%. increase depending on

KORBA SIMULATOR 245


the operation mode &
overload the mills.

Indications on turbine Furnace pressure may Close the isolating


control console goes go very high. ID fans valves on secondary oil
off. may get overloaded. lines from EHC.

Maintain unit load &


ask the boiler operator
to maintain the mill
firing, furnace draft &
drum level and steam
parameters.

9. TURBINE STRESS EVALUATOR.

Electrical fault. Operator will have to Instruct the local


go by matching operator to switch off
individual metal the TSE influence
temperature of turbine (TSE influence off
with available steam annunciation comes
temperature. No on).
indications direct) of
stress limits shall be
available.

''Turbine stress
Cubicle fault' and
'Turbine stress effect
off annunciations come
on.

'Stop reference limiter' Frequent changes in On the turbine console


light comes on and any steam temperatures housing AOP/JOP
further increase in may cause undue SLCs etc., press the
speed or load is stops. stresses in turbine, as master set point
visual stress levels' release push button to
indications will not be remove ''Stop ref.
available for operator limiter'' lamp. Now the
to go by. load or speed reference
can be manipulated to
maintain desired load/
speed.

On the TSE, the red Maintain recommended


lamp starts flashing. rate of turbine load
changes.

KORBA SIMULATOR 246


GENERATORS AND ELECTRICAL SYSTEM

1. STATOR COOLING WATER TUBE LEAK.

Broken hose (connecting the Stator/Rotor wdg Immediately reduce


conductors header). temp goes up. T/G load keeping with
unit should be the H2 pressure.
tripped at 105 oC. (Refer to generator
capability curve.).

H2 pressure drops (Pressure Generator will trip Reduce excitation


2 on generator ground keeping with the
low alarm at 2.8 Kg/cm ).
fault relay load.
protection

'Liquid in generator' alarm Reduced hydrogen Cut down firing to


comes on after H2 pressure pr. requires part maintain MS
2 loading of the unit. pressure.
has dropped to 2.5 Kg/cm
Hence the overall
efficiency will
reduce.
Generator winding In emergency, trip
temp may start the generator/unit
going high due to manually.
inadequate DM
water flow in the
windings.

DC seal oil pump comes on NOTE:


low discharge pressure Stator water
interlock with associated conductivity and H2
alarms. purity changes
should be closely
monitored.

2. HYDROGEN COOLER TUBE LEAKAGE.

Tube bursting ''Liquid in generator'' H2 gas coolers


alarm appears after should be cut out
some time delay. one by one to
identify the leaking
coolers. Isolate the
leaking coolers.

Cold gas temperature may After sometime


rise. (Alarm at 47 0C). Generator will trip on
generator ground
fault relay protection.

KORBA SIMULATOR 247


H2 pressure drops. Hydrogen leakage Continued
will require more operation at
hydrogen cylinders to reduced load (165
be charged. Hyd. MW) with 3 gas
consumption coolers is
increases. permissible.

3. LOSS OF H2 / SEAL OIL PRESSURE.

''Generator cooling /seal oil Seal oil DP goes low. Instruct local
working filters clogged'' alarm (Alarm at 0.9 operator to charge
may come on. Kg/cm )
2 more hydrogen
cylinders.

Seal babbit liners may be H2 may leak out of Maintain Gen. load
damaged. So due to the system. as per generator
increased clearances more capability curves;
seal oil may drain. with falling H2 Pr.

Rotor temperature
goes up.

''Seal oil pressure low'' alarm Hot gas temperature Ensure rotor and
comes at 3.6 Kg/cm2 and high alarm comes at gen. winding temp
reserve seal oil pump comes 75 0 C. are within limits.
on interlock.
Under extreme If DPR is found to
conditions generator be malfunctioning
may have to be get it bypassed,
tripped, manually. locally.

4. GENERATOR HYDROGEN LEAKAGE.

H2 pressure drops. Hot gas Reduce load


temperature goes immediately.
up (High alarm at
75 0C.

H2 pressure (2.8 Kg/cm2 Rotor temperature Instruct local operator


goes up. to charge more
low alarm sounds.
hydrogen cylinders &
maintain H2
pressure at 3.5
2
Kg/cm

Seal oil pressure decreases to T/G may have to


maintain DP. Reserve seal oil be tripped due to
pump may come on high rotor winding

KORBA SIMULATOR 248


interlock. temp at 105 0C.

Hydrogen Maintain generator


consumption per stator and rotor
shift increases. winding temperatures
within limits.

5. GENERATOR HYDROGEN TEMPERATURE HIGH.

Hydrogen cooler surfaces Hot gas and rotor Reduce load as


may be fouled up. temperature rise per generator
brings in associated capability curve.
alarms.

Cooling water flow may be Unit may have to be Check if hydrogen


inadequate. tripped on high rotor cooler outlet
winding temperature valves are fully
(105 0C.). open.

Unit's generator MVA Reduce excitation


may have to be in keeping with
checked and lowered. grid voltage & the
load.

Cold gas temp starts going Part load operation to


up and brings in high alarm the generator leads to
at 45 oC. lower cycle efficiency.

6. STATOR COOLING WATER FLOW LOW.

Clogged filters. Generator trips at Switch over stator


3
13 m /hr. of stator water filters.
water flow.

''Generator cooling/ seal oil Second stator Unload machine to


working filters temp plugged'' water pump takes 160 MW (approx.)
alarm comes in. auto start at a pr. to keep generator
of 2.3 Kg/cm .
2 winding within 85
0C.

''Stator water flow low'' alarm Generator winding Check-up stator


comes in at 18 m3/hr. temp may start water system for
increasing, due to any leakage or any
reduced stator problems.
water flow.

KORBA SIMULATOR 249


T/G may trip due
to low stator water
flow at 13 m3/hr.

MISCELLANEOUS SYSTEMS

1. LOSS OF STATION AIR PRESSURE.

Leakage in the pipe At a pressure o f 3.5 Immediately


2
Kg/cm , ignitor oil/atom increase heavy oil
air pressure low alarm pr. to 12.5 Kg/cm2.
comes and all ignitors trip
out.

Compressor tripping.

Pressure indication in This may lead to oil valves Attend to the fault
UCB starts to drop. tripping if corresponding & get the leakages,
oil flame scanners are if any, rectified.
flickering and possibility
to boiler tripping on 'Loss
of all fuel' or 'Flame
Failure'.
Low service air OPEN Instrument&
pressure alarm comes service air inter-
2
at 6 Kg/cm . connection valve.

2. LOSS OF INSTRUMENT AIR PRESSURE.

Compressor tripping. 2
At 5 Kg/cm instrument Decrease load gradually
air pressure the to keep drum level in
following valves will control and also the
OPEN rate of vacuum drop.

Leakage from the Maintain drum level by


flange. scoop adjustment and
do not change anything
on the unit.
Pressure indication 1 DA overflow valve (MC-
drops. 84).

Low instrument air 2 BFP re-circulation


Pr. alarm at 5.5 valves.
Kg/cm2

KORBA SIMULATOR 250


3 Condenser re- Meanwhile make
circulation valve (MC- arrangements to restore
33). instrument air
pressure.
4 HPH-6 normal drain to
DA (HD-51).

5 HPH-5 alternate drain - Feed water temperature


to condenser (HD-31). after HPHs drop slightly
and cycle efficiency
decreases.
6 LPH-2 alternate drain
HD-14.

7 LPH-3 alternate drain


HD-19

8 All auxiliary dampers. Furnace pressurises


slightly.
The following valves will
CLOSE

1 Hotwell level controller


MC-27.

2 D/A level controller


MC-41.

3 Make-up controller MC- Hotwell and D/A level


54. can be maintained by
operating electrical
bypass valves of the
corresponding
controllers.
4 HPH-6 normal drain to
HPH-5 (HD-37).

5 HPH-6 alternate drain


HD-43.

6 HPH-5 normal drain to - Get AS-90 (bypass


D/A HD-34. ejectors PRDS opened.
(Not simulated).
7 LPH-2 normal drain to
HD-11.

8 LPH-3 normal drain


HD-16.

KORBA SIMULATOR 251


9 Ejector steam pressure
controller AS-56, AS-
79.
10 Steam to D/A controller
AS-68.

All other pneumatic


actuators will remain
frozen at their position.
Turbine may trip on
vacuum protection or
boiler can trip on low
drum level.

2. REHEATER TUBE LEAK OR SECONDARY SUPER HEATER TUBE LEAKAGE.

Overheating of tubes. Hot R/H or main steam Immediately cut down


pressure drops. firing and reduce
pressure and unit load.

Fire side corrosion. HP control valves open Unit may have to be


more to maintain load shutdown immediately
as per reference value. for maintenance as
these leakages can
damage the
neighbouring tubes.

Severe fluctuations in Furnace draught


flue gas DP across becomes unstable and
platen S/H, RH, goes up.
economiser etc. take
place.
ID fans load more to
maintain draught.
Make-up consumption
goes up.

Furnace pressure goes Pulveriser fires more to


up. keep the throttle
pressure up. If on auto,
flue gas temperatures
increase.
Boiler pressure
(MS/RH) drops.

Relevant alarms will Metal temperature in


annunciate. boiler goes up and
steam attemperation

KORBA SIMULATOR 252


goes up.

D/A level tends to drop.


Neighbouring tubes
may also get damaged
depending upon the
severity of leakage.

4. WATER WALL TUBE LEAKAGE.

Corrosion. It can damage the Reduce load to about 150


neighbouring tubes. MW

Over heating of tubes. Feed water flow goes Reduce firing to keep steam
up, to maintain temperature under control.
drum level.
Indications will be Make-up Eventually unit has to be
consumption shut down. So make
increases. preparation for a planned
shut- down.

Drum level drops D/A level Hotwell


depending upon the level drop gradually
severity of leakage.
Throttle pressure Condenser surge
drops. tank level low
annunciation comes
on if cycle make-up
is open.

NOTE:
A decrease in boiler Boiler metal temp go
water pH is the up as firing
primary indication of increases to
any water wall tube maintain throttle
leakage. pressure which goes
down due to leakage

Furnace draught
starts hunting.

KORBA SIMULATOR 253


5. BOILER WATER SILICA HIGH.

'Boiler water Silica carry-over Start HP dosing and open


chemistry trouble' increases resulting CBD. Reduce load and
alarm comes in. in formation of drum pressure, as per
silicates on turbine chemist's advice to
blades. Turbine maintain drum water
efficiency comes silica not more than 0.5
down over a time. ppm
.
Dust ingress into
phosphate and
hydrazine dozing
tank. Also during
shutdowns because
of SH /RH tube
leakages.

KORBA SIMULATOR 254


KORBA SIMULATOR 255
EFFICIENCY ASPECTS
OF
POWER PLANTS

KORBA SIMULATOR 256


KORBA SIMULATOR 257
EFFICIENCY ASPECTS OF POWER PLANTS
With tremendous rise in electricity demand throughout the world, need of enormous
increase in sizing and installation of power plant has been felt two to three fold. This
has imposed an urgency to ensure that the plant is operated and maintained as near
to optimum conditions as possible. Cost of fuel (Coal, oil, gas) is rising day by day
and unless proper measures are not taken to optimise the usage, operating power
plants most efficiently and economically will not come true. At current Indian fuel
prices, loss of one percent in efficiency will incur an additional fuel (coal) cost of over
Rs. 23 millions per annum (equivalent of additional 250 Tones of coal/day).

It is of paramount importance that power plant engineers get aware of causes of poor
efficiency and adopt methods to control and keep check on process parameters those
will be affecting the power plant efficiency.

In this chapter, an attempt has been made to educate engineers so as to find the
means and ways in solving numerous problems concerning efficiency losses in power
station operation.

The Temperature–Entropy (T-S diagram) is


represented by area between the curve and
the entropy figures (0-10 KJ/kgK).
Temperature starts from –273 0C to 0 to 700
0C. The curve representing boiling water

starts from 1000C and reaches to around


3700c and in rising side entropy scale to 4-6
KJ/kgK and the lowering side represents the
dry saturated steam. Sensible heat is
represented between y-axis and x-axis
before latent heat covers. Latent heat is
represented by the rectangle between the
curves traced by entropy figures. A
horizontal line gives the pressure and
extends upwards. The critical point occurs
at the conditions (221.2 bar abs, 374.15 OC
temp and 3.17cm3/kg volume) and at the
more elevated condition the steam reaches
in super critical stage.

The curve represents the total heat, useful heat & the rejected heat as well. An ideal
Rankine Cycle incorporating reheat and regenerative feed water heating can be
represented by the curve.

In the ideal cycle the steam expands in the turbine and the expansion is assumed to
be frictionless and adiabatic. The expansion of steam continues until some reduced
pressure. Condensation at a constant temperature takes place until all latent heat
had removed (rectangle covered under X line as rejected Heat). The formulae that
follow can be referred for calculating the thermal efficiency. There are two ways to
improve the basic Rankine efficiency. Those are: Reduce the rejected heat
component and then increase the useful heat component.

KORBA SIMULATOR 258


The rejected heat component is dependent primarily upon the condensation
temperature and this in turn is determined by the cooling water temperature.(usually
is controllable a little.).The useful heat is determined largely by steam temperature.
The efficiency can be improved by restricting limits of upper & lower temperature by
actually resorting to Reheating. Ideal Cycle efficiency for turbine conditions at 158.6
bar/566 oC/566 oC is about 47.2 %. A combination of reheating and feed heating
will give an even higher ideal efficiency.

The Carnot efficiency is obtained for any substance working between the limits of
temperatures and the Carnot efficiency is given by (T1-T2)/T1 in which T1 is the
upper absolute and T2 is the lower absolute temperature and the heat addition &
heat rejection are isothermal process and that the expansion and compression of the
working substance is isentropic. Of course no such substance as portrayed in the
Carnot cycle exists. However the Equivalent Carnot cycle is one, which is equivalent
of a given Rankine cycle. The temperature is assumed to be constant at the average
temperature at which heat is received in Rankine cycle; they give the same results.
Let us take a case of a unit having different figures.

TSV pressure: 240 bars


TSV Temperature: 590(0C)
Final feed temperature: 270(0C)
Back Pressure: 30 mbar
Reheat temperature: 570(0C)
Reheat pressure:50 bars abs.
The efficiency of Unit –2 converts 83% of the available heat into electrical output.

Selected parameters and its complete T-S Diagram (Ideal Steam Cycle)

Steam Parameters: Ms Pr = 160 Bar, SH temp = 570oC,Cond.pr = 30 mbar,


RH temp = 570oC, RH Pr. = 44 Bar

Carnot Efficiency Basic: 52.1%(with dry/sat steam between 347oC & 24oC)
64.8%(Between 570oC and 24oC)

Rankine Cycles Efficiency (Ideal): 41.4%


Rankine Cycle Efficiency with S/H: 45.7%
Rankine Cycle efficiency with S/H & R/H: 47.5%
Rankine Cycle Efficiency

(with SH, RH &Regenerative feed heating): 53.2%(with feed Water temp = 180oC)
55.8% (with Feed water Temp. 250oC)

Useful heat
Thermal efficiency =
Total heat

KORBA SIMULATOR 259


Total heat - Rejected heat
=
Total heat
Rejected Heat
= 1-
Total Heat

Condensate temperature:24(297.1)0C/K
Entropy of final feed: 2.9763 KJ/kgK
Total heat at TSV: 3469.9 -do-
Entropy at TSV: 6.3539 -do-K
Total heat at R/H inlet: 3013.0 -do-
Total heat at IP inlet: 3595.1 -do-
Entropy at IP inlet: 7.1769 -do-K
Heat in final feed water: 1185.2 -do-
Heat added in Boiler (H1-hf):2284.7-do-
Heat added in R/H(H1-H2): 582.1-do-
Total Heat added: (1) 2866.1 -do-
Entropy change(S2-S1):(2) 4.2006 -do-K
Heat rejected T.(S2-S1):(3) 1248.0 -do-
Work done :(1)-(3): (4) 1618.8 -do-
Ideal cycle frequency:(5) (4)100/(1):56.5%
Alternatively
Average temp. (1)/(2): 682.5 K (6)
Equivalent Carnot efficiency: (7) 56.5 %
= { (6) –T } 100/(6)
Overall efficiency: 46.9%

If a comparison is made between the efficiency of a basic Rankine Cycle without


reheat regenerative feed heating and the one with reheat and regenerative feed
heating an apparent gain in efficiency of the cycle can be noticed. It can be explained
on the basis of equation for efficiency of cycle; incorporating reheating increases the
total heat, input, and incorporating feed heating, reduces the amount of heat
rejected, thereby increasing the cycle efficiency.

In general, entire cycle efficiency of a power station depends upon the efficiency of its
components i.e. boiler, turbine, generator, pumps etc., efficiency of which in turn
depends on many other factors as discussed here.

Cycle Efficiency (ξ)= ξ (S.G) *ξ (Tur) *ξ (Gen.)

BOILER EFFICIENCY

There are two ways of determining the boiler efficiency: i) Direct & ii) Loss method.

Direct method was standard for long time, but is little used nowadays. It is
basically the straight forward of measuring the heat supplied in a given time
and heat added to the steam in the boiler. By this method the efficiency of a
non-reheat boiler is:

KORBA SIMULATOR 260


Efficiency = {Enthalpy of (steam – feed)* steam flow} 1/Cv.(coal) *Coal quantity
Per unit time

Losses Method: The efficiency of a modern boiler is dependent basically upon the
efficiency of combustion and the heat transfer within the boiler.

The efficiency of the Boiler is therefore 100% -losses. Thus, if the losses are known,
the efficiency can be derived easily.

The losses in the boiler comprises of the following:

1. Dry flue gas loss.


2. Moisture loss: a. Moisture in fuel.
b. Combustion of hydrogen.
c. Moisture in ambient air
3. Unburnt carbon loss: a. Carbon in bottom ash.
b. Carbon in flue gas
4. Incomplete combustion.
5. Radiation and unaccounted losses.
6. Ash hopper loss.
7. Mill rejects loss.

Dry Flue Gas Loss

This loss is due to residual thermal energy contained in the dry flue gas when its
temperature is too low for further useful work. At this point it is exhausted to
atmosphere. This loss constitutes the largest portion of boiler losses and is
dependent upon-
a. Quantity of dry combustion gases.
b. Temperature rise between FD Fan inlet and gas exit temperature.
c. Mean specific heat of the flue gases (Constant pressure).
The amount of excess air supplied over and above the theoretical air, has the greatest
bearing upon this loss as this causes both quantity and temperature of the flue to
deviate. A change in excess air quantity by 5% effects + 1.0% in dry flue gas loss.

Dry flue gas loss ={100/12*(CO2+CO) + C/100+(S/267)-C ash}*30.6 (T-t) K J/Kg. (In
fuel)

Alternatively
Dry flue gas loss % = K x (T-t) (on GCVv basis)

In the dry gas loss equations, the abbreviations are as under:

C is %carbon/kg , CO2,CO,N2 all in % by vol. as present in dry flue gas


S %/kg fuel, M is Moisture /kg fuel; H is %kg fuel; h is moisture in kg/kg air
Ma is dry air for comb in kg/ kg fuel; c is carbon in refuge in kg
A is ash content in kg/kg fuel.
GCVv gross calorific value KJ/kg, NCVp is net calorific value KJ/kg
t is F.D. air inlet temp., T is the exit air temp at A/H outlet

KORBA SIMULATOR 261


K is constant and have values as given below.
K = 0.68 for anthracite
= 0.63 for bituminous
= 0.70 for coke
= 0.56 for fuel oil.

Optimisation of Total air supply Optimum Co2 % at Boiler outlet

Wet Flue Gas Loss (Moisture Loss)

This loss is the thermal energy in water vapour entrapped in flue gases leaving boiler.
The water is in the form of superheat steam if exit gas temperature is above the dew
point at the stack. The total moisture loss is due to water derived from three sources:
-

i) Total sum of free & inherent moisture in fuel.


ii) Products of combustion of hydrogen in coal;
iii) Moisture in atmospheric air.

Wet flue gas loss =(M + 9H)/100 [1.88 (T-25) + 2442 + 4.2(25-t)] KJ/Kg. of fuel.
Sensible heat in water vapour. = Wet flue Gas Loss - (GCV - NCV)
Moisture in combustion air loss = Ma*h*1.88(T-t) KJ/Kg.fuel
For solid liquid fuels Ma =3.034 N2/ (CO2 + CO ){C/100 + S/267 -C in ash}

Unburnt Carbon Losses

The main source of this loss is due to the carbon contained in bottom ash or
entrained in fly-ash leaving boiler furnace.

KORBA SIMULATOR 262


This loss is dependent upon:
i) Coal fineness.

ii) Burner tilt,

iii) Gas velocity in the furnace,

iv) Combustion quality.

Unburnt carbon loss = c ash* A/100 * 33820 KJ/Kg. of fuel.


Where, c ash =Carbon in ash
A=mass of ash, Kg/Kg. fuel
CV of carbon burnt to Co2 KJ/Kg.= 33820
11.1.4 Incomplete Combustion Loss

Loss due to incomplete


combustion seldom occurs in
modern high capacity PF boilers
under normal operating
conditions due to excess air
supplied for combustion.
However, this loss is calculated
by the following formulae:
Unburnt Gas Loss:
=CO/(CO2 + CO) { (C/100) +
(S/267)-Cash}23717 KJ/Kg.
Where
CV of burning 1 Kg. of carbon in
CO to CO2 is =23717

Radiation and Ash Hopper Losses: For modern boilers, these losses can be as small
as 0.25%. Additionally some unaccountable losses may occur due to additional heat
loss at hoppers and sensible heat in ash.

In case of wet hoppers or where


sprays are used, water absorbs heat
and gets vaporised and turns to
superheated steam in furnace; leading
to moisture losses.
Radiation Losses = Log10 B
= 0.1867 - 0.4238 Log10C.
(B=Radiation and unaccounted loss
& C=Specific boiler capacity in Kg/s.)

Boiler load versus % radiation loss

KORBA SIMULATOR 263


Mill Reject Loss

This loss may be kept very small if the milling plant is designed, operated and
maintained correctly. It can be calculated by sample of reject for calorific value and
weight of rejects.

Note: Efficiency calculations done on the basis of NCVp yield higher values than
GCVv. Hence, calorific values must be specified clearly.

Most of these boiler losses can be kept under acceptable limits by ensuring complete
combustion at minimum excess air. Control of combustion process requires
regulation and distribution of fuel & air to and within the furnace using:

i) Milling plant; ii) Burners; iii) Air control equipments.

The other factors, which must be considered, are

a. The need to cool the combustion products below the softening


temperature of ash before the leaving the combustion chamber.

b. The need to avoid deposition of burnt coal onto wall tubes. This can
induce corrosion of tubes, ultimately involving a loss of plant availability.

c. The need to avoid acid corrosion of lower temperature flue gases. (The
excess air quantity and flame temperature can influence Dew point
temperature).

TURBINE EFFICIENCY

The efficiency of turbine is dependent upon the following factors.

Internal Losses

Nozzle Friction: The effect of nozzle friction is to reduce the effective heat drop of
steam as it passes over the nozzle. The velocity of steam is reduced as it
subsequently strikes the moving blades. Because of reduction of velocity there will be
some shock as steam strikes the blades because blade profile is designed so that
steam glides over it (for a particular steam velocity).

Blade Friction: Its effect is same as of nozzle friction. Without friction the outlet
relative velocity of steam would be same as inlet but because friction cannot be
avoided, velocities are reduced to 90%. As friction increases, steam expansion tends
to be more ''irreversible''.

Actual heat drop


Stage efficiency =
Isentropic heat drop

Disc Friction: The discs on impulse turbine shafts rotate in an atmosphere of steam.
The disc surface friction causes some drag and produces eddies of steam causing
loss of power. This effect is more pronounced where the steam is densest.

KORBA SIMULATOR 264


Diaphragm Gland and Tip Leakage: In pressure-compounded turbine there is a
pressure drop across each fixed nozzle of diaphragm. Therefore, the gap between
diaphragm and shaft is a source of steam leakage, which can be minimised by
providing inter-stage glands for sealing. There are balancing holes on the discs
through which steam can leak and cause disturbances when it joins the steam
coming from the nozzles. It is extremely important, therefore, to maintain eccentricity
to minimum during start-up and loading.

On impulse/reaction machines, there is pressure drop across each stage or blade;


thus there is steam flow around tips of all fixed and moving blade. Seals at the tips in
radial & axial directions are provided. Because of wear & tear of the seals, leakage
loss can amount from 0.55% to 1.0%.

Partial Admission Loss: In nozzle-governed machines in particular, and in throttle


governed machines at part load conditions, steam is subjected to Throttling. Apart
from that in nozzle-governed machine, steam is admitted to one or more areas of the
inlet nozzle ring. The valve lifts are varied in sequence, as the turbine is loaded until
at full load the valves are fully open. The moving blades alternately come in and off
contact of any running arcs. In the process, they run full of steam while in contact
with running arc and from eddies when they come in line with non-running arcs.
This leads to windage losses. However, nozzle governed machine can be said to be
more efficient than throttle governed machines, at part load. While, at full load the
throttle governed machines are more efficient.

The basic construction and assembly of partial arc and full arc i.e. nozzle governed
and throttle governed turbines, are a lot similar with only real difference being the
absence of the control stage in full arc admission turbine. This arrangement
dispenses with excessive stresses in the HP turbine blades and enhances the
reliability of full arc admission turbines and improves their efficiency.

Upon comparing the thermal performance curves of the two types of turbines it can
be noted that the throttle governed, full-arc-admission turbine has better efficiency.

Although as compared to the throttle governed, the nozzle controlled partial arc
admission turbine does show a lower net heat rate in the lower load range; when
operated in constant pressure mode, the full arc admission turbines can also exhibit
a better performance in the upper load range with only periodic load drops; by way of
both, better heat rate and energy consumption. Various degrees of hybrid operation
(combination of both, constant pressure and variable pressure mode) of both types
further improve the thermal performance of each at partial loads also.

The variable pressure mode of operation is best suited for full arc admission
turbines, whereas the partial arc admission turbine operates over the entire load
range with some what a lower heat rate level. For constant pressure operation, the
load changing characteristics of both types of turbines indicate a better ability of full
arc admission turbines to deal with severe load transient conditions, because they
exhibit smaller changes in temperatures for a given load change.

Load dependent temperature changes can, however, be minimised by applying hybrid


pressure mode operation or can be totally eliminated by adopting the variable
pressure mode operation.

KORBA SIMULATOR 265


In the overall analysis, the throttle controlled, full arc admission turbine exhibits
better characteristics in all cases, with the exception of excessive heat rate in the
partial load range while in the constant pressure mode of operation.

Sliding Pressure Control:

Considering a throttle governed turbine reduction of load is achieved by straight-


forward throttling at constant enthalpy as shown by line AB. Turbine expansion line
becomes at reduced load BE, resulting in reduced available heat drop.

On the other hand if control valves are left fully open and boiler pressure is reduced
for maintaining full steam temperature, the turbine expansion line becomes CD
resulting in increased available heat drop and reduced wetness after LPT exhaust, as
a bonus. Sliding pressure control is very common at part load.

In nozzle governed machines when operating at part load the control valves are wide
open. Hence with increase of pressure the available energy increases and efficiency
improves. Consequently sliding pressure control is not applicable to this type of
machine.

Exhaust Losses: The kinetic energy of steam leaves the last LP stage cannot be
gainfully employed to do any useful work and hence it is a loss.

Leaving loss =1/2 ( mvo2 )


Where, m = mass steam flow,
vo= Absolute velocity of steam at outlet of last row of blades

The loss varies with (velocity) 2 and velocity varies with backpressure change.

KORBA SIMULATOR 266


Wetness Loss

The wetness of steam goes


on increasing towards the
last stages of a turbine, at
a given set of parameters.
Condensation of steam
causes wetness or
formation of water
droplets on blades, which
lose some mechanical
work in throwing off the
drops. Apart from that
severe erosion is also
caused to the blade tips of
last stages. Generally, 1%
increase in wetness
causes 1% loss in
efficiency

External Losses: Shaft gland leakage.; Journal and thrust bearing; Governor and oil
pump.

MONITORING TURBINE PERFORMANCE

Cylinder efficiency Test

By accurately measuring the temperature and pressure of steam before and after HP
and LP cylinder, it is quite easy to determine the respective cylinder efficiency. The
LP cylinder efficiency can't be ascertained as the steam is wet there and exact 'state
point' can't be located.The cylinder efficiencies do not change appreciably with load,
as ratio of blade to steam speed (u/V) remains constant with load. However, due to
deteriorating cylinder efficiencies, change in turbine heat rate can be computed with
the following formulae:

HP Cylinder
∆(HR) = {{0.43 (H-h) ∆ (n)%}1/ Kwa} *2.36 Qr/ HRa _ 2.158 Qh/3600}

Where,
∆(HR) = % change in heat rate value.
H = Enthalpy at TSV, KJ/Kg. (ref. data)
h = Enthaply at HPT exhaust, KJ/Kg. (ref. data)
∆n % = % change of efficiency from designed value.
KWa = Ref. alternator output, KW
Qr = Reheater steam flow (present) Kg/hr.
HRa = Reference test heat rate, KJ,/KWH
Qh = Present steam flow to HP cylinder, Kg/hr.

KORBA SIMULATOR 267


IP Cylinder
∆(HR) = ∆n % { 0.928 (H1-H2)* Qr) *1/ KWa *3600 -1}
Common causes of cylinder efficiency deterioration include:
Damage to blades caused by debris past the strainers.
Damaged seals and glands.
Deposition on blades.
Increased roughness of blade surfaces.

The surface roughness affects the HP cylinder maximum, then IP cylinder and then
comes LP cylinder. Larger machines are affected to a lesser extent as compared to
smaller machines.

Turbine Pressure Survey

This is a very useful tool indicating the internal condition of turbine. Following steps
are followed for preparing the pressure survey diagram

i) Choose a pressure scale on Y-axis from zero to any pressure above ESV pressure,
say, at rated load.
ii) From acceptance test results or design reference, mark off various pressures at
various points of tapping as shown below.
iii) Join all points with a straight line.

Basic Pressure survey diagrams & effect of Heaters out of service :2

If at some later date, the pressures are noted at each point while the load is the same
as plotted, as before, the points will lie on the same line if the cylinder condition has
not deteriorated. But, if the load is lower and the condition of machine is same the
points will plot on a line lower than the previous. When plotted pressure points are
on the optimum pressure line for a particulars load it is indicative of general wear of

KORBA SIMULATOR 268


diaphragm, seals etc. If the line has 'kink', then it indicates some restriction in the
turbine. The pressure before the restriction will be higher, after that lower than
optimum.

LP cylinders are difficult to assess on pressure survey scale, as pressures can't be


plotted accurately. Nevertheless, chances of rubbing and wearing are less due to
liberal clearances, but there remains a possibility of silica deposits. Hence, LP inlet
and bled steam pressure should be checked regularly.

Effects of Internal Restrictions Effects of load changes

Silica can enter the system through reheater leaks during shutdown because of
vacuum built up in the steam space as steam condenses. This can happen especially
when vents are not opened prior to pressure decay. Also BFP and feed heaters when
they are opened for maintenance, silica can enter the system.

EFFECT OF OPERATING PARAMETERS ON CYCLE EFFICIENCY

The complexity of a power station unit offers scope for many parameters to have
deviation from optimum. Fortunately technical expertise and know-how gathered
over the years facilitate ascertaining the causes of efficiency loss due to deviation
from optimum, by monitoring just a few terminal conditions. They are

a. Turbine backpressure.
b. ESV steam pressure.
c. ESV/RH steam temperature.
d. Amount of attemperation spray.
e. Final feed water temperature.
f. Boiler excess air.

KORBA SIMULATOR 269


g. Combustibles in ash.
h. APH gas outlet temperature.
i. DM water make up rate.
j. Auxiliary power.
k. Unit load.
Turbine Back Pressure

This is the most important parameter that severely affects efficiency of a power plant
cycle. It is dependent upon

1. Condenser air tightness.

2. CW inlet temperatures.

3. Condenser tube fouling.

4. Effect of variations of heat transferred.

5. CW flows in condenser.

Generally speaking, improving the backpressure improves the amount of work done
by steam, but up to a limit. Because, with increase in certain losses also increases.

Backpressure correction curves Minimum Back press.at different loads

They can be listed as follows:

1. CW pumping power.
2. Leaving/exhaust loss.

KORBA SIMULATOR 270


3. Reduced condensate/feed water temperature.
4. Wetness losses.
The losses mentioned will eventually significantly affect the results. Continued
operation with reducing backpressure will result in net improvement in heat
consumption becoming progressively less until a point is reached where gains equal
the losses. There is no point for further reducing back pressure beyond this.

Loss due to high CW inlet temperature may be due to inefficient cooling tower
operation; can be compensated by increasing flow of CW. But the gain in efficiency
must be weighted against loss due to increased CW pumping power.

Loss due to incorrect CW flow can be eliminated. If the temperature rise across the
condenser is less, that means more than optimum CW flow. It can be reduced.
Excessive CW flow can cause under cooling of the condensate, ultimately lowering
the final condensate temperature.

Loss due to air ingress is entirely preventable and steps must be taken to ascertain
air tightness and points of leakages, if any. Remember, 1 mm. thick air sheet has the
same resistance as 17 mm. copper slab.

Deviations in backpressure due to fouling cannot be eliminated thoroughly during


operation. Off load cleaning of tubes is a must. However, if any increase in frequency
of back washing is noted, it should be ensured that chlorination is adequate.

ESV Steam Pressure

On a throttle governed machine the output is proportional to 'after control valve'


pressure or first stage pressure. It can be assumed that even if throttle control valves
are 100% open, there is a drop of 5% - 10% in ESV pressure at control valves.

Variation of turbine steam pressure causes

a. The total heat drop to vary, higher pressure causes increased heat drops
(at the same inlet temperature conditions).

b. Increasing exhaust wetness at higher pressures.

c. Increased turbine output for a given control valve opening such that 10%
increase of pressure will produce 10% extra output.

For more common reheat type machine, variation of ACV (after control/throttle valve)
pressures are proportionally dependent on load conditions, such that 50% reduction
of load will reduce ATV pressure by 50% as shown in the figure. Ignoring pressure
drops in reheat lines at 100% expansion lines in HP and IP/LP turbine is AB and CD
respectively as shown in the figure. At. 50% output turbine expansion is EF and GH
as shown.

KORBA SIMULATOR 271


It can be seen that

• HPT enthalpy drop remains same.

• IPT/LPT enthalpy drop becomes smaller in spite of increased IP inlet specific


enthalpy because of reduced slope of temperature lines with respect to
consistent slope of condenser pressure line.

Controlling load by sliding pressure operation on the CE boilers supplied by BHEL to


NTPC within a + 10% of the rated value may yield some benefit by way of reduced
throttling losses at part load.

This may also have the following disadvantages:

a. Boiler pressure is reduced hence cycle efficiency is very much lower than
optimum at full load conditions.
b. At very low pressure, at higher loads steam volume is more, which tends to
envelop water in the boiler tubes, leading to film boiling and subsequently
overheating of tubes.

Any deviation in turbine inlet pressure can change the steam flow through turbine,
because of which stage pressure and extraction pressure will change, changing feed
water temperature. The volumetric flow to condenser also changes accordingly.
Hence, ramifications of a small pressure change can be seen through out the cycle.
CE make Korba Boiler is not designed for Sliding Press. Operation.

KORBA SIMULATOR 272


Re-heater Line Pressure Drop:
On account of reducing slope of
temperature line with respect to
consistent slope of condenser pressure
line, the turbine expansion line ABCHI
(under ideal 'no pressure drops'
conditions) denotes optimum heat drops
across HP/IP turbines. However a
practical steam turbine has about 5% to
7% pressure drops in reheat line.
Subsequently turbine expansion lines
now become ACCDEFG, which indicates
a far less efficient steam utilisation It
must always be ensured that cold reheat
NRVs are functioning freely. Opening out
along the steam flow.

Also reheat pressures along with HPT exhaust pressure at various load must be
recorded for a healthy machine so that the same can be used for comparisons at a
future date.

Throttle governing

In modern, large machines the economic rating coincides with the maximum rating.
The steam flow is controlled by the degree of opening of the throttle valves, which are
located in the HP cylinder steam chest. Obviously the up-stream steam pressure at
the throttle valves will be constant, irrespective of the turbine load, but the pressure
after the throttle valves will reduce as the valve opening reduces. This will cause the
available energy per kilogram of steam due to expansion to be reduced, as well as the
mass flow of steam. This is illustrated for a non-reheat turbine the in fig.

The turbine stop valves conditions are


105 bars and 565oC. At full-load, the
loss of steam pressure due to the
throttling effect of the turbine stop and
throttle valves is about 5%. Hence the
after throttle valve (ATV) pressure is,
say, 100 bar absolute. The steam does
work in the turbine by expansion until
40 m bar backpressure is reached, the
state-point of the steam being
represented by the line AB,
representing 80% efficiency. At half-
load, the ATV pressure will be half of
that at full-load, as shown at C. The
expansion of the steam is shown from
C to D.
Specific Entropy vs Enthalpy steam state-point lines in throttle governing

KORBA SIMULATOR 273


Similarly, for 25% load, the ATV pressure will be a quarter of full load and the
expansion EF. Notice that the specific enthalpy of the inlet steam remains unaltered
for the range of loads. However, the available energy is reduced significantly as the
loading falls, as shown in Table.

Heat drop per Kg of steam at various loads (at 80% efficiency)

Load Enthalpy KJ/Kg Heat drop KJ/Kg


at inlet at exhaust
100% 3357 2343 1194
50% 3537 2419 1118
25 % 3537 495 1042
This reduction of heat drop, coupled with the reduced flow of steam, causes the
turbine output to be reduced as the throttle valves close. Notice that the slope of the
expansion line remains the same for all loads, so the efficiency of the expansion
remains the same, which is what one would expect from the earlier discussion about
cylinder efficiency. On the other hand, it should be realised that throttling incurs
losses as the steam pressure and temperature are adversely affected.

Nozzle Governing

Here the first-stage nozzles are divided into a number of groups, sometime more than
ten. The steam admitted to each a valve controls group, and each valve is opened in
turn as loading is increased as shown in the fig. Consider a four-valve arrangement
where the first valve only is in service from no-load to quarter-load, and at quarter
load it is fully open. This is followed by the second half-load, and then valves three to
three-quarter load. Finally, the last permits maximum loading when fully open. The
only valve operating in the throttling mode is the last one to be brought into service,
all the previous ones being wide open, so the losses due to throttling are not so great
as with the previous type, so operation is more efficient.

This is illustrated in the fig where


the conditions are similar except
for the governing used. At full-
load, the expansion is from A to
B, similar to the previous
example. However, at 50% load,
only two valves are open, but
again a pressure of 50 bar is
required. This is achieved more
efficiently than before, so the line
for two nozzle operation is shown
from A to C. Thereafter the
expansion is from C to D.
Similarly one nozzle operation is
shown from A to E, and hence
from E to F.

KORBA SIMULATOR 274


Nozzle governing differs from throttle governing as follows:

*The turbine efficiency is higher at part-loads because of reduced throttling loss

*The va.lve control gear is more complicated.

*The internal efficiency of throttle and nozzle governed machines can be the same
(Represented by slope of the expansion lines on H-S diagram) after the wheel case.

*Because of their improved part-load efficiency, nozzle-governed machines are


preferable where the loading regime involves prolonged operation under these
conditions.

ESV/RH Steam Temperature

Variations in steam temperature results in variations of specific volume of the steam


and this result in change of steam flow according to

Fa = Fo*{(Pa *Vo)/ (Po * Va)}1/2

Where F=flow, P= Pressure, o= Optimum condition; V= Sp. volume of steam of ESV


a= Actual condition

Other effects for reduced steam temperature for a non-reheat set are:

a. Total energy-reduces hence turbine efficiency is also reduced.

b. Wetness increases at the exhaust of L.P.T. turbine.

c. Change of flow and pressure of steam.

For reheat machines as shown in the figure reduction of main steam temperature
causes available energy of steam to be reduced causing reduction in efficiency. Also,
extra heat is required in reheater to have the same hot reheat temperature.
Expansion in IP/LP turbine remains unchanged as long as HRH temperature is
constant:

KORBA SIMULATOR 275


If the reheater temperature is reduced and MSV temperature is constant, IP/LP
turbine output reduces due to less available heat drop, exhaust wetness increases
and heat addition in R/H is reduced. The HPT is not affected.

High temperature yield high heat drops but cause significant reduction in operation
life of high temperature components.

Effect of Inlet Temperature changes


ATV temperatureoC 570 560 580 570 570
o
Reheater temperature C 570 570 570 560 580
Exhaust temperatureoC 29.0 29.0 29.0 29.0 29.0
Exhaust wetness % 14.7 14.7 14.0 15.1 14.1
Heat drop in HPC KJ/Kg 421.8 414.8 428.3 421.3 421.8
Heat drop in R/H KJ/Kg 1407.4 1407.4 1407.4 1394.3 1422.9
Total heat drop 1829.2 1822.2 1835.7 1816.1 1844.7

Note that the effect of reducing the ATV temperature to 560OC is significant with
reference to total heat drop even though it only affects the HP cylinder heat drop and
does not affect the wetness.

Steam Attemperation

Attemperation of steam invariably causes loss of power output and increase in heat
rates. But is not entirely avoidable in modern high capacity boilers.

Especially reheat attemperation should be avoided until absolutely necessary. As far


as possible, the reheater steam temperature should be controlled by the burner tilt.
The basic objection to reheat attemperation is that the steam so formed does work
only in IP and LP turbines bypassing the HP turbine; hence there is a considerable
reduction in cycle efficiency.

KORBA SIMULATOR 276


Feed Water Temperature

The feed water temperature at boiler inlet is another main important factor
determining cycle efficiency. It is mainly dependent on

a. Heater performance.
a. Feed flow through heaters.
c. Terminal Temperature difference (outlet feed water temperature steam
saturation temperature at the extraction pressure).
d. Bled steam pipe pressure drop.
e. Steam temperature at heater inlet.

One degree centigrade rise in TTD (Terminal Temperature Difference) leads to 0.027%
drop in efficiency. A bad heater performance can be attributed to the following:

- Air blanketing
- Waterside contamination.
- Steam side contamination.
- Drainage defects.
In order to avoid this factor, the boiler must be operated at constant pressure, so
that feed flow remains optimum. Proper and frequent air venting of heaters,
prevention of oxygen ingress and thus exfoliation i.e. flaking of tubes causing
subsequent choking and TTD increase; and maintaining of proper pH value in
Condenser should be practiced.

Boiler Excess Air

Boiler combustion efficiency largely depends upon supplying adequate quantity of


excess air, too much of which results in increased dry flue gas losses and flame
instability, leading to poor efficiency and reliability of operation.

Too much of excess air can be through ingress points such as

a. Suction milling plants.

b. Expansion joints on ducts.

c. Openings like peepholes.

d. Ash hopper doors open.

e. Ash hopper seals.

These leakages put extra burden on ID Fans and limitations on unit loading. The
leakages after air pre-heaters do not affect the efficiency significantly.

KORBA SIMULATOR 277


Air Pre-heaters Gas Outlet Temperatures

Low air pre-heater gas outlet temperature may be due to the following:

a. Light up of cold boiler.


b. Excessive air leakage in the APHs (damaged seals).
c. Very high wind box pressure.
d. Inadequate air supply in boiler.
e. Poor fuel quality.
f. Air pre-heater sooting.

High APH gas temperature may be due to

a. APH sooting or ineffective soot blowing.


b. Holed and torn element at cold ends, due to corrosion.
c. Sooting of boiler.
d. Excessive air supply to boiler.
e. Film boiling due to poor circulation in boiler.
f. Low feed water temperature.
g. Poor milling and longer burn-off times of coal.
h. Use of higher elevation burners at low loads.
i. Excessive firing.
j. Air ingress into furnace.

Generally speaking a 20 OC rise in final gas temperature causes a drop of 1% in


efficiency.

DM Water Make-up Rate


DM water make up is a must in modern power station due to certain problems which
warrant invariable blow-downs soot-blowing etc. There are four usual sources of loss

Soot blowing
Soot blowing must be done selectively and only when required. Frequency of soot
blowing is also dependent upon coal quality and furnace temperature and firing
configuration.

Boiler Blow down


During initial start-ups it is unavoidable, hence very conditions that lead to outages
must be avoided. On load condition it is a loss of DM water and useful heat. So all
attempts should be taken to keep dust ingress into the boiler water to a minimum,
and to have good boiler water chemistry.

A good maintenance schedule to prevent any leakage or passing of valves must be

KORBA SIMULATOR 278


envisaged. The operators must take due care to avoid any undesirable overflowing of
DM storage tank, deaerator, drum etc.

Auxiliary Power Consumption


These are the following factors contributing to excessive auxiliary power
consumption.

Machine Loading
As the unit load is decreased, percentage aux. power rises as shown in the fig. In
common practice, operator must have three mills running at full load rather than
four mills running at part capacity. CW pump flow must be controlled in accordance
with optimum backpressure requirements so that benefits from running equipments
should be more than the cost of running them.

Variable Speed Drives


Power consumption of variable speed drives varies as the cube on the speed. Hence,
precaution must be taken to affect only the minimum speed, which will do the job.
For example, BFP discharge should be maintained to give the lowest required
differential pressure across feed water station at any load.

Parallel Operation of Auxiliaries


Two pumps in parallel do not give twice the output of one pump. In fact it is quite
common to derive only marginal increase by running second pump and adds to
higher auxiliary power consumption, which reduces overall station efficiency.

Milling Plant Power Consumption


Attempts should be made to run the existing mills at full load rather than starting
new mills to be run at part load. Moreover, classifier settings should be regularly
checked to give just the required fineness of coal, not more. More fines puts extra
burden on the pulverisers.

Mill outlet temperatures must be maintained at the rated value. Low temperature
puts a limitation on loading of the mill. High mill reject operation puts extra burden
on PA Fans and also it is a loss in terms of loss of some pulverized coal from the mill.

KORBA SIMULATOR 279


Unit Loading

The efficiency of a unit improves as the loading improves. So, all out attempts must
be made to ensure, there is no part loading or outages to maintain a high load factor,
and shortfalls should be kept to minimum. Because fixed heat has to be sustained at
all loads. It is important to generate every possible megawatt while on high load. One
important way of preventing short-falls, is to ensure that boiler firing must be
controlled to control boiler pressure not, by varying load on T/G.

CONDENSER PERFORMANCE

Even a small worsening of backpressure is very expensive in terms of extra heat


required for a given output. To illustrate this for a 200MW station, if the
backpressure worsened by just 100 mm (Hg.), the resulting extra fuel cost would be
about Rs. 6,000,000/- per annum. Hence condenser performance is undoubtedly the
most important operating parameter on a unit. So the factors affecting backpressure
must be clearly recognised so that effective remedial measures can be taken once
they are detected.

It is evident that work obtained from the


turbine increases if backpressure is
reduced. So it is always desirable to
operate at minimum economic
backpressure i.e. condenser temperature is
as low as possible. If the condensing
surfaces were infinitely large, condensing
temperature would equal the CW inlet
temperature. However there is a practical
limit and in practice the average condenser
temperature is 15OC above the inlet CW
temperature, but even then the size of
condensing plant is considerable. For
example, on 660 MW unit the condenser
may have 20000 x 25 mm diameter tubes,
each 20m long. Reason for this is apparent
when we realise that for generated output
of 660 MW, 780 MW is surrendered to the
condenser.

Determination of deviation

The manufacturer supplies various performance curves for the condensing plant,
which should be verified by test as soon as possible. Two important relationship
must be established - load vs. CW temperature rise and load vs. terminal
temperature difference.

KORBA SIMULATOR 280


Knowledge of these optimum values is basic to much condenser performance.
Importance of CW temperature is obvious but TTD (Terminal Temperature Difference)
needs a bit of understanding.

To make heat flow from condensing steam to cooling water requires some
temperature gradient, steam temperature being higher than that of cooling water.
Excellent heat transfer requires small gradient whereas bad heat conduction requires
a large gradient. Hence TTD is a measure of effectiveness of heat transfer.

Condenser condition graph

As has been explained the backpressure in condenser depends mainly on-

- Variation of CW inlet temperature


- Variation of CW flow
- Interference with heat transfer
Effect of these factors can be illustrated with the help of condenser condition graph
shown in the adjoining fig. For example optimum and actual conditions for a

KORBA SIMULATOR 281


condenser are listed below.

Parameter Optimum Actual


- CW inlet temp. oC 16.5 20.0

- CW outlet temp. oC 25.0 26.0

- CW temp. rise oC 8.5 6.0

- Saturated steam 30.5 36.0


temperature
corresponding to
back pressure oC

- TTD. oC 5.5 10.0

- Back pressure mbar 43.7 59.4

To determine the contribution of each of the main factor to the total deviation in
backpressure from optimum we can use condenser condition graph.

Contribution due to CW inlet Temperature

Plot a line vertically from actual CW inlet temperature point up to the optimum CW
rise line and then horizontally to the optimum TTD. From this point drop a vertical
line to intercept the saturation temperature line at 34OC with corresponding
backpressure of 53.2 mbar. So the backpressure deviation due to CW inlet
temperature alone is (53.2 - 43.7) = 9.5 mbar.

Contribution due to incorrect CW flow

In the list it can be seen that actual rise is less, hence the CW flow must be more
than optimum. To determine its component affecting backpressure, plot a line from
actual CW inlet to actual CW rise, then to optimum TTD line, finally downward to cut
saturated steam temperature line at 31.5OC. Equivalent backpressure is 46.2 mbar.
Therefore, the pressure deviation due to high flow is 46.2 - 53.2 = 7 mbar. High CW
flow improves the backpressure by 7 mbar.

Contribution due to heat transfer

Deduct from actual backpressure of 59.4 the backpressure of 46.2 (= 13.2 mbar).
This is the deviation caused by high TTD.

Shift Monitoring

For this purpose, the required curves are CW temperature rise v/s. load, optimum
TTD v/s. load (both have been illustrated earlier) and target back pressure for
various CW inlet temperature v/s, load.

KORBA SIMULATOR 282


Once per shift during the period when load is steady, backpressure on the unit
should be monitored to determine backpressure deviations and their removal. A
standard form can be used as shown below (typical for a 500 MW set).

The air suction temperature is required because it is an indication of air ingress to


the condenser. For example if there were no air ingress, air suction temperature of
vacuum pump inlet would be 4-5oC lower than the saturated steam temperature. Air
ingress causes the temperature or the suction of vacuum pump to fall further as per
'Dalton's Law of Partial Pressure. The total pressure of inlet to the pump is made up
of partial pressure of air and water vapour. But the temperature of mixture is due
only to the water vapour. Consequently as the vapour quantity is reduced, so is the
temperature.

The effect of internal tube deposits and the effect of air blanketing on outside of
tubes are indistinguishable in their effect on TTD. Hence, when the air ingress is
ascertained and rectified, then any deviation in back pressure ascribed in air/dirty
tubes will be due only to the dirty tubes and hence a decision can be taken to clean
dirty tubes.

SPOT BACK PRESSURE CHECK

UNIT NO. DATE

1. Actual back pressure mbar 52.3


2. Saturated steam temperature oC 33.7
3. CW inlet temperature oC 17.9
4. CW outlet temperature oC 26.8
5. Exhaust steam temperature oC 33.7
6. Condensate temperature oC 34.9
7. Air suction temperature oC 24.9
8. CW outlet valve position % 55%
9. Target back pressure mbar 48.4
10. Optimum CW temp rise oC 9.0
11. Optimum TTD oC 5.2

Back pressure due to CW inlet


12. mbar 47.8
= (3) + (10) + (11)

Back pressure due to CW flow


13. mbar 47.5
= (4) + (11)

Variation due to CW inlet temperature


14. mbar -0.6
= (12) - (9)

KORBA SIMULATOR 283


15. Variation due to CW flow = (13) - (12) mbar -0.3

Variation due to air/dirty tubes


16. mbar 4.8
= (10 - (13)

17. BP variation = (1) - (12) mbar 4.5


18. No of air pumps in service

FEED WATER HEATER PERFORMANCE

In modern power stations direct and indirect feed water heaters are invariably in use
to enhance the unit performance. Usually the number of feed water heaters provided
on a power plant depends on the trade off between the full costs saved by a
particular no of heaters balanced against the annual fixed charge on heater
investment for minimum generating cost. Economically justifiable maximum number
of heaters on a plant is ten. It is common to find 6-7 feed water heaters on power
generating units in our country.

Heat transfer to feed water in non-contact type heater is achieved by the surrender of
latent heat of steam primarily because heat recovery by de-superheating and drain
cooling is about 6%-8% of the total latent heat recovered by feed water.

The two important parameters used in assessing heater performance are TTD
(Terminal Temperature Difference) and Drain Approach. TTD is defined as the
difference between saturation temperature of extraction steam and feed water
temperature after the heater. Where as drain TTD or drain approach is defined as
difference between feed water temperature at inlet to heater and drain outlet
temperature after the heater.

Factor Causing Deterioration of Heater Performance

It is not sufficient to just measure final feed water temperature to determine if the
heaters are operating efficiently, because trouble at one heater can be compensated
for by other heaters doing more work. This causes bled steam flow to heaters, to alter
and thus affect the work done. So cycle efficiency is altered. Therefore, it is
necessary to check individual heaters from time to time, checking particularly the
TTD and drain approach as a general rule, preferably twice in a year, heaters
(individually) investigation must be carried out.

Deterioration of heater performance occurs on account of one or more reasons as


shown below:

• Air accumulation
• Steam side fouling
• Water side fouling
• Drainage defects.

KORBA SIMULATOR 284


Air Accumulation

Air is a superb thermal insulator, hence, highly undesirable. Proper vents are
generally provided on heaters (to condenser) body to prevent accumulation of air. Air
can get into heaters when extraction pressure in them is reduced below atmosphere
i.e. wherever the machine load is reduced or machine is off-loaded.

Hence, the vents of sub-atmospheric heaters must be permanently open while those
on the rest should be open long enough to vent them thoroughly while machine
comes on load and periodically thereafter. It needs to be emphasised that steam
(generally 0.5%) passing through the vents is a loss to the system.

Accumulation of air manifests itself in the following:

• Reduced drain approach.


• Increased TTD
• Elevation of steam to heater temperature.
• Reduced temperature rise of feed water heater.
Steam Side Fouling

Cupro-nickel (70/30) alloys was generally used in the past. However, it was found
that this material exfoliates (i.e. it flakes off like a dead skin). Due to this the space
between the tubes in the cluster becomes blocked with debris and heat transfer is
progressively reduced. It has been practically established in one case that TTD rose
from 4 OC to 14 OC continuously over a period of 7 years.

Alternatively now 90/10 cupro-nickel, Monel metal, mild steel etc. are used as tube
material to reduce problems of exfoliation.

The effect of exfoliation include:

• Progressive increase of TTD.


• Drain temperature of unaffected.
• Reduced feed temperature rise
• Eventual tube failures due to weakening
• Accumulation of debris in heater shell.
When the heater is out of service, it is important that there is no standing water at
tubes such as those in the drain cooling section to prevent corrosion. Also, oxygen
percentage must be kept under recommended units to keep the rate of corrosion to
minimum.

Water Side Fouling

Most common cause of waterside fouling is oil. Oil can get into the system from
leaking bearings and important gland seals of LP turbine. Deposition of them occurs
in HP heaters affecting them all but being worst at the highest-pressure heater.
Thermal manifestations of troubles are similar to those for exfoliation except that the

KORBA SIMULATOR 285


onset of increasing TTD is usually sudden and rate of deterioration is rapid.

Slightly fouled tubes can be chemically cleaned. In the worst cases high pressure
water jetting may be required.

Drainage Defects

Apart from obvious problems such as passing valves etc. the usual troubles are due
to

a. Damaged flash box internals


b. Reduced/enlarged orifice opening
c. Heater drains pump defects.

A typical flash box has an orifice followed by a diffuser, which diverts the flashing
drain downward on to water reservoir. If the diffuser disintegrates, its pieces can
create obstruction in pipes and cause flooding. Further flashing steam/water may
cause erosion of flash box internals.

Reduction due to fouling, of the orifices is very common. It results in drain blocking
up to previous flash box resulting in flooding and some water droplets are carried
into flash steam to the bled steam pipe. Heat is taken up by the water and steam to
heater temperature drops.

Conversely, orifice size can increase due to erosion and can reduce differential
pressure from inlet to outlet. The orifice plate does not alter the bled steam pressure
at upstream and downstream heater so the reduced differentials achieved by
lowering the water level in upstream heater. Sometimes high-pressure heater drain
cascade to a drain pump which pump it to deaerator. At deaerator pressure the
O
saturation temperature is of the order of 160 C approx. and if the pump suction
head is not sufficient then water can flash in the pump itself interfering with the
pumping. This causes heater level to rise; consequently drain to condenser opens up
and results in lowering heater efficiency.

Effect of Heater out of Fouling

Fouled heater gives increased TTD, as is already evident i.e. lower feed water out
temperature. This relatively cold water goes to the next heater, which has to work
harder to maintain its TTD and draws more steam in the process. This steam is not
available for doing work hence cycle efficiency is lost. Increased steam flow also
causes mechanical damage to the nearing tube bundles because of increased velocity
and mass flow.

Effect of Heater out of Service

Anyone heater being out of service considerably affects the cycle efficiency. Feed
water outlet is lowered and the next heater has to do extra work as is explained
earlier. If the final (highest pressure) heater is taken out the feed water to boiler is at
lower temperature and has to have extra heat given to it in the boiler. Further bled

KORBA SIMULATOR 286


steam, which is now not being bled, can do extra work in the turbine, significantly
improving the unit output although at the expense of lower thermal efficiency.
(Incremental heat rate of the additional MWs is very high hence this is a very
expensive method of generation).

As a general guide to the effect of having a heater out of service, the following
efficiency reductions may be used.

TSV pressure Up to 100 bar over 100 bar


L.P. Heater 0.5% 0.5%
Last HPH 1.3% 1.5%

Monitoring of Feed Water System

Feed heater surveys can be conducted every six months to detect any early
deterioration of heater performance. Operations staff must keep a routine check of
the performance on a shift-to shift basis noting down final FW temperature, heater
TTD and steam-to heater temperature.

Feed Water Chemistry (High Oxygen Regime)

Magnetic layer, against corrosion by feed water, protects low alloy/mild steel tubes.
O O
At temperature between 140 C and 200 C magnetic layer is more porous than it
would be if it is formed under higher temperature. Since it has slight solubility it can
be removed by turbulent/ past feed flows in heaters. A fresh layer is formed and
eroded and go on causing metal loss at bends and bifurcations.

To deal with these problems, 20-150 micro gm. per litre of oxygen is injected into
feed water before heater drain. This oxygen causes iron oxide to be deposited as
hematite. To save this layer of hematite feed water should have low anion content
(low chlorides, sulphate), or i.e. should have low after cation conductivity, usually
below 20 micro siemens /m. This can be achieved by good condensate polishing.

KORBA SIMULATOR 287


SIMULATED
MALFUNCTION LIST

KORBA SIMULATOR 288


KORBA SIMULATOR 289
LIST OF SIMULATED MALFUNCTIONS

BOILER SYSTEM MALFUNCTIONS


B01 Pulveriser A to F choking or loading up
B02 Coal Feeder A to F trip
B03 Pulveriser A to F trip
B04 Pulveriser A to F Fire
B05 Pulveriser A to F reduced capacity
B06 Coal Feeder A to F fail to deliver coal
B07 Water Wall Tube leakage
B08 A or B ID Fan trip
B09 A or B FD Fan trip
B10 A or B PA Fan trip
B11 A or B I D Fan out board bearing temp. high
B12 A or B FD Fan outboard bearing temp high
B13 A or B PA Fan outboard bearing vibration high
B14 A or B I D Fan outboard bearing vibration high
B15 Flame Scanner Elevation AB, CD or EF shows flame continuously
B16 Fuel Flow run back to less than demand
B17 Drum Steam Pressure Transmitter fails low
B18 Low Drum level
B19 RH Tube leakage
B20 Secondary SH Tube leakage
B21 Electromatic Safety Valve fails open
B22 APH Primary Air Output Damper AD-20 fails closed
B23 Pulveriser A to F tempering Air Damper froze
B24 Plugged Air Heater
B25 Aux Air Dampers adjacent to coal elevation faulty modulating
B26 FSSS AC Supply fail
B27 FD Fan A or B Discharge Damper AD-3 / AD-4 fails closed
B28 Aux Air Dampers not modulating
B29 Drum Emergency blow-down Valve B-82 or B-83 fails open
B30 Left side Furnace Pressure low
B31 Burner Tilt fails high
B32 HO Header Pressure low
B33 HO Trip Valve fails closed
B34 HO Temperature low
B35 HO Supply Header Pressure low
B36 Aux PRDS Valve fails closed

KORBA SIMULATOR 290


B37 A or B APH main drive motor trip
B38 Firing Rate limited
B39 Airflow run back to less than demand
B40 I D Fan A or B Inlet Vane froze
B41 High Drum Level
B42 High SH tube metal temp
B43 Boiler Water Silica concentration high
B44 Throttle Pressure Transmitter fail
B45 Loss of Seal Air to Pulveriser A to F
B46 Airflow less than 30%
B47 Airflow more than 40% during start-up
B48 All Pulverisers trip
B49 Boiler Purge Timer failure
B50 Flame Scanner failure, elevation AB, BC, DE and EF
B51 Ignitor pair 1 and 3 of elevation AB, CD and EF fail Off
B52 Elevation AB Oil Gun # 1 Scavenging Valve stuck open
B53 No Start Permissive for Pulverisers A to F
B54 Pulveriser A to F Primary Airflow Temperature Thermocouple fail
B55 Pulveriser A to F Hot Air Gate fails closed
B56 Pulveriser A to F motor stator temperature high
B57 Pulveriser A to F Airflow feedback offset 25% high
B58 Pulveriser A to F fails to start
B59 Loss of Coal Flow Indication of Feeders A to F
B60 Loss of Drum Level Transmitter
B61 Furnace walls badly slagged
B62 Abnormal Ash build-up on RH pendant
B63 Ash build up in Economiser
B64 PA Header Pressure Controller malfunction
B65 Furnace Pressure Controller A or B malfunction
B66 Purge Ready condition cannot be met
B67 Air Heater A or B fire
B68 Aux Air Damper control power failure
B69 Burner Tilt position difference
B70 ACS Power Supply failure
B71 Boiler Master Controller failure
B72 Economiser Tube leakage
B73 A or B SH Attemperation Spray Block Valves fail closed
B74 A or B RH Spray Valve fails
B75 Failure of Final RH Temperature Controller

KORBA SIMULATOR 291


B76 SH outlet steam temperature swinging
B77 RH outlet steam temperature swinging

ELECTRICAL SYSTEM MALFUNCTIONS


E01 Stator Cooling Water tube leakage
E02 Hydrogen Cooler tube leakage
E03 Loss of Hydrogen Seal Oil pressure
E04 Generator Hydrogen leakage
E05 Generator Cold Gas temperature high
E06 Low Stator Cooling water flow
E07 Loss of Outside Power to buses 1A or 1B
E08 Generator Trip
E09 Generator Auto Voltage Regulator failure
E10 Grid Frequency drops down to 49.5 Hz
E11 System Voltage drops low
E12 Loss of Generator Excitation
E13 Unequal Generator Phase Loading
E14 Loss of 220V DC bus to FSSS
E15 Loss of 415 V AC Bus
E16 Loss of Normal Power to Emergency Bus
E17 Megawatt Transducer fails
E18 Low Stator Water Resistance
E19 Loss of one Hydrogen Cooler
E20 Generator Bearing # 1 babbit temperature
E21 High Stator Cooling Water Temperature
E22 Seal Oil leakage into the generator
E23 Auto Synchroniser failure
E24 Generator Seal Oil temperature high
E25 Main Power Transformer oil temperature high
E26 UAT A or B failure
E27 Loss of Emergency Supply Power
E28 Generator Auto Voltage Regulator oscillating
E29 DC Seal Oil Pump fails to start
E30 Stator Cooling Water Pump A or B trip
E31 220V DC Bus fuse blown

KORBA SIMULATOR 292


FEED WATER SYSTEM MALFUNCTIONS
F01 Loss of CW Pump 1-3
F02 HPH-6 Extraction Valve fails closed
F03 LPH-3 tube leakage
F04 HPH-6 tube leakage
F05 HPH-6 alternate drain valve fails open
F06 HPH-6 normal drain fails closed
F07 HP heaters Group Bypass Valve fails open
F08 BFP A-C Re-circulation Valve fails closed
F09 BFP A-C Speed Controller failure
F10 Fluctuating FW Control Valve
F11 One FW Regulating Valve fails open
F12 BFP A-C loss of Oil Pressure
F13 BFP A-C high Bearing Vibration
F14 BFP A-C loss of Suction
F15 BFP A-C Re-circulation Valve fails open
F16 Condensate Re-circulation Valve MC-33 fails open
F17 DA Overflow Valve failure
F18 DA Level Control Valve MC-41 fails open
F19 DA Extraction/Pegging Steam Valves AS-62/ES-7 goes closed
F20 DA level transmitter used for ACS, freezes at present level position
F21 Condensate Surge Tank low level switch (DC 43) fails
F22 Hot Well level high
F23 Hot Well level transmitter failure
F24 Condenser Tube leakage
F25 Condenser Air leakage
F26 CEP A or B trip
F27 LPH-3 Extraction Steam Valve fails closed
F28 BFP A-C trip
F29 BFP A-C Hydro coupling Oil temperature high
F30 LPH-3 Normal Drain level controller failure
F31 DA Pressure Controller failure
F32 CW Differential Pressure high
F33 HPH-5 Extraction Valve fail to close on demand
F34 Condensate Re-circulation Valve fails closed
F35 HPH-5 Normal Drain Valve fails closed

KORBA SIMULATOR 293


TURBINE SYSTEM MALFUNCTIONS
T01 Turbine AOP A or B trips
T02 Low Secondary Oil pressure to Intercept Control Valve
T03 Gland Steam Condenser tube leakage
T04 Loss of Gland Sealing Steam
T05 Gland Steam Pressure high
T06 Emergency Stop Valve # 2 fails closed
T07 Intercept Stop Valve # 1 fails closed
T08 Turbine Control Valve malfunction
T09 Loss of Exhaust Hood Spray
T10 Turbine Shaft Oil Pump fails
T11 Low MOT level
T12 Turbine Bearing Vibration high
T13 ATRS Sub Group Control Turbine failure
T14 ATRS Sub Loop Control Drains failure
T15 Loss of TSI Power
T16 Broken last stage turbine blade
T17 Main Turbine EHG control fails high
T18 Main Turbine Thrust Bearing temp signal monitor fails high
T19 Turbine Axial Shift high
T20 Turbine Over Speed
T21 Main Turbine Lub Oil Cooler cooling capacity reduced
T22 Barring Gear Valve stuck closed
T23 HPT Differential Expansion high
T24 Turbine EOP fails to auto start
T25 Condenser Back Pressure high
T26 Turbine Thrust Bearing Trip Device faulty
T27 Seat Drain Valve before Emergency Stop Valve will not open
T28 Loss of 415 V AC to turbine EHG system
T29 Turbine Initial Pressure Limiter (IPL) transmitter fails low
T30 Turbine trip
T31 HP Bypass Valve fails open
T32 LP Bypass Spray Valve fails closed
T33 Water in turbine Inlet Steam
T34 Turbine Stress Evaluator failure
T35 LP Bypass fails to open on demand
T36 HP Bypass fails to open on demand
T37 Turbine Lub Oil Pressure controller failure

KORBA SIMULATOR 294


T38 Turbine Lub Oil Pressure Low trip device faulty
T39 ATRS Control Power failure
T40 ATRS Sub Group Control fails
T41 Low Vacuum Trip Device fails to function
T42 Plugged Oil Line disarms Trip Devices

MISCELLANEOUS SYSTEM MALFUNCTIONS


M01 Loss of Station Air Pressure
M02 Loss of Instrument Air Pressure
M03 Aux Cooling Water Pump Motor A or B trips
M04 Loss of Aux Steam
M05 Stuck Water wall Soot Blower (B-8)
M06 APH A or B Cold End temperature low
M07 Loss of Gland Steam Vapour Extractors
M08 Loss of MOT Vapour Extractor A or B
M09 Scanner Air Fan A or B trips
M10 UPS Power failure
M11 Loss of Soot blowing steam
M12 Retractable Soot blower (R-4) failure
M13 APH Air Motor A or B fails to auto start
M14 Hydrazine BD Valve's CRH temperature interlock bypassed
X01 HP Bypass BD Valve’s CRH temperature interlock bypassed
X02 Starting Device frozen
X03 Mill A trip
X04 Mill B trip
X05 Mill C trip
X06 Mill D trip
X07 Mill E trip
X11 FD Fan-B trip

KORBA SIMULATOR 295


APPENDIX

KORBA SIMULATOR 296


APPENDIX

TITLE Page No

1. Load Vs Superheater outlet Pressure 327

2. Boiler Load Vs Airflow 328

3. Wind box to Furnace DP Vs Load 328

4. Load Vs Superheater and Reheater Temperature & Spray 329

5. Deaerator Pressure Vs Load 329

6. Drum Pressure change during start-up and shutdown 330

7. Boiler start-up after 250 hours shutdown 331

8. Boiler start-up after 160 hours shutdown 332

9. Boiler start-up after 36 hours shutdown 333

10. Boiler start-up after 8 hours shutdown 334

11. Turbine start-up curves 335-345

KORBA SIMULATOR 297


ASSUMING SUITABLE PRESSURE DROP IN THE MS LINE
FOR THE VARYING FLOW CONDITIONS

LOAD Vs SUPER HEATER OUTLET PRESSURE


(PREDICTED)

KORBA SIMULATOR 298


WIND BOX TO FURNACE DIFFERENTIAL Vs LOAD

KORBA SIMULATOR 299


LOAD Vs SUPERHEATER AND REHEATER TEMPERATURE

DEAERATOR PRESSURE Vs LOAD CURVE

KORBA SIMULATOR 300


MAXIMUM ALLOWABLE RATE OF PRESSURE CHANGE
FOR NORMAL START-UPS AND SHUTDOWNS

KORBA SIMULATOR 301


BOILER START-UP CURVES AFTER 250 HOURS SHUTDOWN

NOTE:
Aux steam is available from external source The Deaerator drawl from CRH is expected to cut in
after synchronisation and at least 20% loading is done.
Steam temperature downstream of HP Bypass HP Heaters from CRH may cut in afterwards at 30%
need not be regulated by spray until the MS Temp is load.
above 300OC. Then HP BP downstream temp may
be regulated to 230OC. SH Spray need not be used for controlling SH outlet
temp until the boiler flow is at least 160 T/H. SH & RH
temp may be regulated and allowed to raise along
the suggested curve at higher loads.

KORBA SIMULATOR 302


BOILER START-UP CURVES AFTER 160 HOURS SHUTDOWN

NOTE:
The metal temp anticipated: HP Casing: 140OC The Deaerator drawl from CRH is expected to cut in
ST Valve: 50OC after synchronisation and at least 20% loading is
Boiler : Ambient. done. HP Heaters from CRH may cut in afterwards at
30% load.
Aux steam is available from external source.
SH Spray need not be used until the boiler flow is at
Steam temperature downstream of HP Bypass least 160 T/H. SH & RH temp may be regulated and
need not be regulated until MS temp is above 300 allowed to raise along the suggested curve at higher
OC. Then this may be regulated to 230 OC. loads.

KORBA SIMULATOR 303


BOILER START-UP CURVES AFTER 36 HOURS SHUTDOWN

NOTE:
The metal temp anticipated: HP Casing: 350OC SH Spray need not be used until the boiler flow is
ST Valve: 210 OC. at least 120 T/H.

Steam temperature downstream of HP Bypass need Aux steam is available from external source.
not be regulated until 90 T/H bypass flow is established.
Afterwards this may be regulated to 260 OC. Deaerator is to be kept pegged at 140 OC
minimum before firing the unit.
Only Deaerator steam is extracted from CRH. HP
Heaters are anticipated to be put into service only Reheater temp control by spray may be adopted
after synchronisation. if required, after HP bypass closes.

KORBA SIMULATOR 304


BOILER START-UP CURVES AFTER 8 HOURS SHUTDOWN

NOTE:
The metal temp anticipated: HP Casing: 465OC Full vacuum should be available before firing.
ST Valve: 410OC.
SH Spray need not be used for controlling SH
Aux steam is available from external source. outlet temp until the boiler flow is at least 160 T/H. SH
& RH temp may be regulated and allowed to raise
Deaerator is to be kept pegged at 140 OC along the suggested curve at higher loads.
minimum before firing the unit.
Turbine can be loaded along the dotted line i.e.
Steam temperature downstream of HP Bypass 21 MW/Minute. For this, the boiler should be at rated
need not be regulated until 50 T/H bypass flow is parameters before rolling using HP and LP bypass.
established.

KORBA SIMULATOR 305


TURBINE START-UP CURVES
Warming-up and Starting the Turbine Temperature Criteria

Fig: 1 STEAM WITH 50O SUPERHEAT

KORBA SIMULATOR 306


Fig: 2 RECOMMENDED MINIMUM CURVE (CURVE-A) AND
MAXIMUM (CURVE-B) MAIN STEAM TEMPERATURE AHEAD
OF TURBINE WHEN OPENING THE MAIN STOP VALVES.

KORBA SIMULATOR 307


Fig: 3 ALLOWABLE MAXIMUM MAIN STEAM PRESSURE
AHEAD OF TURBINE WHEN OPENING THE MAIN STEAM STOP
VALVES.

KORBA SIMULATOR 308


Fig: 4 RECOMMENDED MINIMUM MAIN STEAM
TEMPERATURE AHEAD OF TURBINE BEFORE OPENING THE
MAIN CONTROL VALVES

KORBA SIMULATOR 309


Fig: 5 RECOMMENDED MINIMUM REHEAT TEMPERATURE
AHEAD OF IP TURBINE BEFORE OPENING THE REHEAT
CONTROL VALVES

KORBA SIMULATOR 310


Fig: 6 RECOMMENDED MAXIMUM MAIN STEAM
TEMPERATURE AHEAD OF TURBINE BEFORE THE TURBINE
IS BROUGHT TO RATED SPEED

KORBA SIMULATOR 311


Fig: 7 RECOMMENDED MAXIMUM MAIN REHEAT
TEMPERATURE BEFORE TURBINE IS LOADED

KORBA SIMULATOR 312


KORBA SIMULATOR 313
KORBA SIMULATOR 314
KORBA SIMULATOR 315
KORBA SIMULATOR 316

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