UNIT EMERGENCIES

Unit emergencies can be categorized as

1) 2) 3) 4) condensate desk emergencies boiler desk emergencies turbine desk emergencies generator desk emergencies

Condensate desk emergencies can be 1) 2) 3) 4) 5) 6) Two CEPs tripped or one CEP tripped and lead CEP didnt take start. All three CEPs tripped. Any ACW tripped and lead ACW didnt take start. Any BFP tripped and standby BFP didnt take start. MC-36 is stuck up. As-102 full open.

Boiler desk emergencies can be 1) 2) 3) 4) 5) 6) One ID and FD tripped One PA tripped One APH tripped and corresponding air motor didnt take start. One seal air fan trip and standby didnt take start Ac scanner trip and dc scanner didnt take start. One limb of high range malfunctioning and second one is not opening.

Turbine desk emergencies can be 1) 2) 3) 4) 5) 6) 7) HP and LP bypass opens HP heater group bypass. Running drip p/p trip and standby didnt take start. As-51 close. Gc-2 level high/low. Mot level low. Lub oil temperature rising.

Generator desk emergencies can be 1) Running SSW trip and standby SSW didnt take start. 2) Thyrestor block trip. 3) HST level high/low alarm appears.

4) Damper tank level low alarm appears. 5) One unit bus tripped.

Condensate desk emergencies

Emergency Action to be taken Two CEPs tripped or one CEP 1) Directly trip one upper trip and lead CEP didnt take mill. Reduce coal flow in start other four mills so that load can be brought to 90 MW. 2) Reduce MC-36 opening watching CEP discharge header pressure 3) Open BFP recirculation to maintain working oil temperature below tripping value. 4) Charge AS-58 All three CEP tripped 1) Close MC-36 and give starting command to all CEP one by one. 2) If any CEP didnt take start or not taking load, trip unit. One ACW tripped and standby 1) Open clarified to ACW ACW didnt take start interconnection. 2) Start one clarified pump and monitor clarified water pressure. Parameters to be watched 1) CEP discharge header pressure and condensate flow to dearator. 2) BFP working oil temperature and back pressure.

One BFP trip and lead BFP 1) Give tripping command to two didnt take start mills if five mills are i/s and one mill if four mills are I/s.Reduce coal flow to bring load up to 120 MW. 2) Give opening command to scoop of running BFP with observation of BFP current. It should be less than 340 Amp. 3) Take high range controller in manual mode. Open it manually to maintain drum level. 4) Take AS-58 in service and

1) Maintain BFP working oil temperature within 130 deg. 2) Watch clarified pressure. Should be more than 3 ksc. 3) Seal liner temperature should be below 90 degree. 4) mill bearings temperature should be below 90 deg. 1)mills I/s to be tripped a) ABCDE AE b) BCDEF EF c) ACDEF AF d) ABDEF AF e) ABCEF EF f) ABCDF AF 2) Drum level and feed water flow. 3)DP cross FRS

maintain ejector pressure from local.

MC-36 become full close /open

1) Close manual isolating of MC-36 and Charge MC-37 gradually and maintain CEP discharge header pressure and deaerator level.

1) CEP discharge header pressure. Condensate flow to dearator. Hot well level. CEP current.

As-102 becomes full open.

1) Close AS-101 and open AS- 1) PRDS pressure and MS flow 103, open AS-104 gradually to to PRDS. maintain PRDS pressure if required.

Boiler desk emergencies

Emergency One ID and tripped. FD 1) 2) 3) 4) 5) 6) Action to be taken Parameters to be watched Take other ID fan in manual mode. 1) During tripping of mills Take out two mills if five mills I/s and flame condition to be one mill if four mill I/s. monitored. If flame is poor Take AS-58 in service and maintain then oil guns to be taken in ejector pressure from local. service. Close tripped ID & FD IGV, blade Furnace pressure pitch respectively and their discharge 3) Back pressure dampers also. 4) Tripped ID & FD reverse Open BFP recirculation to maintain rotation to be checked from working oil temperature below tripping local. If any one or both value. rotating in reverse direction Open cross over dampers (GD-5, 6, 15, then action to be taken to stop 16). it.

One PA tripped

1) Give service command to all oil guns. All mills will be tripped leaving upper three mills in service. Increase PRDS pressure up to 16 ksc and temp 250 deg from other units. 2) Take other PA fan in manual mode. Increase its IGV watching its current and PA header pressure. PA header pressure should be at least 580 to 600 mmwcl. Current should be less than 140 Amp. 3) Close IGV of tripped PA fan and close its discharge damper. 4) Take AS-58 in service and maintain ejector pressure from local. 5) Open BFP recirculation to maintain working oil temperature below tripping value. 1) If APH-A trips then unload ID fan-A and if APH-B trips then unload ID fanB.Take upper mill out of service and maintain APH outlet temperature up to 250 deg. Start APH soot blowing. 2) APH hydraulic coupling to be checked for oil leakage and also open

1) Watch running PA fan current. 2) Furnace pressure, flame condition. 3) Back pressure and BFP working oil temperature. 4) Tripped PA fan reverse rotation to be checked from local. If it is rotating in reverse direction then action to be taken to stop it.

One APH tripped and corresponding air motor didnt take start

1) Reduce coal flow in such a manner so that mill outlet temperature would be around 60 deg. Otherwise trip the mill. 2) Monitor APH flue gas outlet temperature. It will be

One seal air fan trip and standby seal air fan didnt take start

Ac scanner trip and dc scanner didnt take start. One limb of high range malfunctioning and second one is not opening.

air motor solenoid bypass valve. restricted to 250 deg. 3) Inform rotary parts people to rotate Otherwise reduce load. APH manually. 4) If APH didnt take start then trip the machine. 1) Open manual isolating from PAC header 1) PAC header pressure. connected to each mills seal air header. 2) Mill bearing temperature. 2) Monitor service air pressure. Maintain up to 4.5 ksc. If required take one PAC in service. 3) Monitor mill bearings temperature. it shouldnt be more than 90 deg. 1) Increase FD fan discharge maintaining furnace draft slightly positive. 2) Inform rotary parts and C&I people. 1) Quickly charge both low range 1) Drum level, feed water flow and limbs. Increase command of low range DP across FRS. controller. 2) Flame condition. 2) Take out two mills if five mills are BFP current I/s or one mill if four mills are I/s. 4) Back pressure and ejector Bring load up to 120 MW. pressure. 3) Take both BFP in manual mode and increase its scoop position and maintain DP. 4) Take AS-58 in service and maintain ejector pressure from local.

Turbine desk emergencies

Emergency HP bypass opens

. LP bypass opens

Action to be taken Parameters to be watched 1) Give close command from UCB 1) HP bypasses outlet 2) If HP bypass valve not getting close temperature. To be maintained from UCB, charge spray line by near about 330 deg. opening spray manual isolating valve 2) Control HRH temperature near HP heater-7. within excursion limit. 3) Maintain HP bypass outlet temperature at around 330 deg. 4) Inform C&I people to close the valve by manual intervention. 5) If C&I people fails to close it inform TMD to close it. 1) Give close command from UCB 1) LP bypasses outlet 2) If LP bypass valve not getting close temperature. To be maintained from UCB, charge spray line by around 100 deg. opening spray manual isolating valve 2) Exhaust hood temperature above drip pump. around 90 deg. 3) Open MC-39/57 from UCB. 3) Dearator pressure and 4) Maintain LP bypass outlet temperature condenser vaccum. at around 100 deg. 5) Charge dearator through ES-6.if Es-6 fails to come in service charge AS-58. 6) Inform C&I and TMD people.

HP heater group bypass

1) Check whether all extraction valves are 1) HP heater levels. closed or not. If not give close command from UCB. 2) Open alternate valve of HP heater whose level is high. 3) Check control valve operation of normal drip line of HP heater whose level is high. 4) When heater level comes normal then again put group bypass I/s and charge heaters from steam side. 5) If group bypass again occur due to same heaters level rise then inform TMD for checking heater tube leakage. 6) If group bypass occur due to some other heaters level rise then check all three HP heaters control valve operation of normal drip line. 1) LP heaters level to be maintained by 1) All LP heaters level. opening alternate valves. 2) LP heater-4 level to be maintained

Running drip p/p trip and standby didnt take start

As-51 close.

carefully so that it shouldnt get bypassed. If LPH-4 gets bypassed then dearator pressure and back pressure to be monitored.As-58 to be taken I/s if back pressure starts rising. 1) As soon as gland steam pressure low alarm appear operation of AS-51 to be checked. 2) If it is not opening from UCB command, open AS-53 and maintain gland steam pressure. level

1) Gland steam pressure and back pressure.

Gc-2 high/low

Mot level low.

Lub oil temperature rising.

1) Check operation of HD-1. GC-2 level. 2) If HD-1 operation is o.k. and level is 2) Gland steam pressure and low then maintain level by closing one back pressure. manual isolating valve. 3) Open gland steam header 3) If HD-1 operation is o.k. and level is drain to find out water traces. rising, check whether both manual 4) Moisture content in bearing isolating valves are full open. return drain oil. 4) If gland steam temperature is falling and water coming from gland steam header drain and back pressure increasing with increasing moisture level in bearing return oil then trip the machine as GC-2 developed tube leakage. 1) Check lub oil and seal oil system to 1) MOT level. find out any external leakages. 2) If rate of fall is very slow then check turbine lub oil cooler water for oil traces by opening its water side vent. 3) If rate of fall is fast then check seal oil cooler water for oil traces by opening its water side vent. 4) If oil traces found in any cooler then isolate it and take other cooler in service. 1) Open water outlet valve of turbine 1) Lub oil temperature. lub oil cooler. 2) Turbine babbit metal 2) If temperature is not controlled then temperature. water venting should be done. 3) Change ACW strainer if ACW suction pressure reduced. 4) If still temperature rising ,then take third cooler in service.

Generator desk emergencies

Emergency Action to be taken Parameters to be watched Running SSW trip 1) Reduce load. Watch generator slot 1) Generator slot temperature to be and standby SSW temperature. It should be maintained up watched. didnt take start. to 90 deg. 2) Check fuses of SSW pumps. 3) Open expansion tank make up bypass and gas trap to take fresh cold water in PSW system. 4) Open SSW water vent in PSW cooler and direct make up in SSW tank. 5) If SSW pump not restored and generator slot temperature rising above limit then trip the machine. 1) As soon as Thyrestor block failure 1) Thyrestor blocks current. alarm appears check thyrestor block current. If one block trip monitor block current. It should not be more than 700 Amp. 2) If two block trip, reduce load up to 150 MW and monitor block current. HST level high/ Check HST level in gauge glass. 1) Monitor HST level low alarm appears. 2) If level is high then open bypass valve continuously. of float and monitor level in gauge glass. If gauge glass comes down again close bypass valve. 3) If level is low close manual isolating of float valve. Maintain HST level by opening bypass valve and monitor level in gauge glass. Damper tank level Increase DP by charging DPR bypass. 1) Damper tank level through low alarm appears 2) Check damper tank level through gauge glass. gauge glass. If level is normal then 2) DP across seal oil pressure inform C&I people. and hydrogen pressure. 3) Damper tank drain should be closed. One unit bus (Bus-A) tripped. 1) Take three oil guns in service in any 1) Monitor hot well and dearator elevation. level and CEP discharge header 2) Trip feeder F and monitor flame pressure. condition 2) If dearator level is -300 mm 3) Take BFP-C in service in BUS-B then DM plant to be asked to start and BFP-B in manual mode. Increase one KSB pump and open manual scoop BFP-C and maintain drum level. isolating of direct dearator make Also maintain BFP working oil up. temperature by recirculation flow. 3) Furnace pressure and back Thyrestor trip. block

4) Take ID fan-B and PA fan-B in pressure to be watched. manual mode. Close outlet dampers of tripped ID, FD, and PA. Stabilize furnace draft. 5) Charge AS-58 and maintain ejector pressure from local. 6) CEP discharge header pressure to be maintained by MC-36 command. 7) Check bus coupler of USS-A&B closed in auto or not. If not close it manually. 8) Check all outgoing feeders of UNIT BUS-A. Isolate the breaker in which relay has been operated and UAT incomer breaker. 9) Charge the BUS through station incomer. 10) Start all the equipments in UNIT BUS-A. NOTE:-if UNIT BUS-B trip, check USS BUS coupler came in service in auto or not. If not close it manually. If USS BUS coupler does not come in service then DG set incomer breaker to EMCC to be closed as soon as EMCC incomer voltage is available. USS bus coupler to be closed manually from swgr.