BTG - INTERLOCKS AND PROTECTIONS

AMRAVATI TPP ( 5 X 270MW )

REV - 1
 BTG - INTERLOCKS AND PROTECTIONS
Amravati Thermal Power Plant,
(5 X 270 MW)

Prepared By,

 Dulal Chandra Satpathi, Sr. Manager  Atanu Bhattacharyya, Manager

 Jay Nandan Patel, Dy. Manager  Swarup Kumar Mukherjee, Dy. Manager
 Vivek Jadhav, Sr. Engg.  Ankush Khadse, Sr. Engg.
 Manish singh Thakur, Sr. Engg.  Anil Singh, Sr. Engg.
 Bhagwan Thakur, Engineer  Arjun Ramaraju, Engineer
 Aditi Rathod, Engineer  Alok Singhal, Engineer
 Sachin Gupta, Engineer  Manish Nangliya, GET
 Manhar Walia, GET  Prince Khurana, GET
 Pravin Biyani, GET  Anish Batra, GET
 Jinesh Doshi, GET  Anirban Sinha, GET

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 FOREWORD

In the present time, efficient and economical power generation is the only answer to realise our ambitious
plan in Power Sector. It is the need of the hour that available human resources who are the at the whelm of the
affairs managing the large thermal power plants having sophisticated technology and complex controls, is to be
properly channelised and trained.

The Protection & Interlock Diary of Phase-1 (5X270MW) Main Plant (BTG) provide the information
comprehensively covering all the aspects of Main Plant Protection & Interlocks, which can be useful for fresh as
well as experienced engineers of Operation and C&I department.

I am pleased to dedicate this Diary prepared by C&I engineers in a lucid way under the able guidance of C&I
HOD and senior members of C&I Team.

I sincerely hope that readers will find these manuals very useful and the best learning aid to them. I
believe that in spite of all sincere efforts and care of C&I Team Members, some area of improvement might have
remained unnoticed. Hence, your valuable suggestions and comments will always be well received and acted
upon.

( Jaydev Chakrabarti )
VP (O&M)

Message from DGM (C&I)

It gives me immense pleasure to introduce the technical diary for the interlock and protection of IPL
270MWunits. Team of C&I engineers have put their untiring efforts to bring this in shape. I appreciate the
initiative taken by each and every member of the team. At this stage when we are proceeding to take command
of 1st unit of Indiabulls Power Limited with latest state of art automation and control system, this technical diary
will be a treasure of knowledge for operation and maintenance engineers.

I congratulate, appreciate and thank to all the engineers of C&I who contributed their best to make it
possible to publish the C&I technical diary. Finally we welcome your valuable feedback concerning errors or
deficiencies that you find in this first edition.

GITESH KUMAR AMBASTA

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SR NO DESCRIPTION PAGE NO
BOILER
1 ID FAN 5
2 FD FAN 7
3 PA FAN 8
4 APH 10
5 FSSS 12
6 Scanner Air Fan Control 18
7 Auxiliary Air Damper Control 19
8 Fuel (Coal) Air Dampers Control 20
9 Furnace Temperature Probe 20
10 Soot Blower 20
11 Re-heater protection 22
12 Fuel Oil Pumps 23
13 Coal Mills 23
TURBINE
14 Turbine Protection 26
15 Turbine Lube Oil System 28
16 Turning gear 29
17 Fire Protection 30
18 Seal Oil System 30
19 SGC Oil Supply 31
20 SGC –Evacuation System 32
21 Vacuum Pump 34
22 HPBP System 35
23 BFP 36
24 CEP 37
25 DMCW & DMCW Buster PUMP 38
26 ACW 39
27 LP BYPASS SYSTEM 40
28 CW PUMP 41
29 DOSING SYSTEM 43
30 BIDIRECTIONAL VALVES I & P 45
31 APRDS 50
32 COLTCS 52
33 LPH 54
34 HPH 56
35 CO2 FLASH EVAPORATOR 57
36 MAIN EXCITER 58
37 SELF CLEANING STRAINER 59

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 BOILER
ID FAN:
Two ID fans are required for boiler 100% MCR. If any one of the two running ID fans
Trips, the boiler load shall be run down to 50% MCR.
ID fans (each rated for 60 % MCR) of radial type with hydraulic coupling

ID Fan “A” Start Permissive

ID fan ‘A’ shall be prohibited from starting till all the following conditions are satisfied:-
1) Regulating dampers of fan-A in minimum position (<5% )
2) ID Fan I/L & O/L gate closed.
3) Fan and Fan Motor bearing temp. Not very high (< 90oC).
4) Motor winding temp. Not very high (< 110oC).
5) ID Fan A HC WO temp. Not high (< 100oC).
6) Lube oil permissive satisfied (Any LOP ON and Lube oil pr. > 0.8 Ata).
7) ID Fan A Hyd. Cupl. Should be minimum position < 30%
8) ID Fan A Hyd. Cupl. Should be Manual position
9) ID Fan A Off F/B from Swgr. Available.
10) Fan Not tripped ( From Swgr)
11) ID Fan A Swgr. Available.
12) ID Fan A MTR Not operated.
13) ID Fan A Swgr. Not Disturbance.
14) F.G Path available OR ID Fan B ON

ID Fan “A” Protection (Any one of the conditions)

1) ID Fan “A” tripped from FSSS post purge

2) Motor Wind. Temp Very High ( > 130 Deg. C, 2/6 logic)
3) Motor/ Fan Berg. Temp. Very High ( > 105 Deg. C)
4) Fan Berg. VIB. Very High ( > 12.6mm/s, True peak ) 10 Sec TD
5) Motor Berg. VIB. Very High ( > 9.9mm/s, True peak ) 10 Sec TD
6) ID Fan A lube Oil pr. Very Low at H.C < 0.6 bar with TD 2 sec
7) ID Fan A MTR Operated (from Swgr).
8) ID Fan A HC WO temp. Very High (> 110 Deg. C ) with TD 2 sec
9) ID Fan A HC WO temp. at CLR O/L Very High (> 90 Deg. C ) TD 2 sec
10) ID Fan A ON and O/L Gate not Opened (within 30 Sec)

Fan outlet gate:

• If one ID Fan is started when the other ID Fan is off, the outlet gate of starting fan shall be opened with
Starting of the fan to reduce the load of electrically operated gate.

• When starting the second fan (i.e. ID Fan A started when B is ON or vice versa), the respective outlet gate shall
be opened after the fan reaches rated speed.
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Different Settings of ID Fan

1) ID Fan A LUB Oil Pr. ADEQ( at HC) > 0.8 ATA

2) ID Fan A LUB Oil Pr. Low.(At HC) < 0.6 ATA
3) ID Fan A DP ACRS Filter High (HNV10AE201_XG01) > 0.6 ATA
4) ID Fan A Oil Tank Level Normal (HNV10CL201_XG01) > 50% of tank level
5) ID Fan A HC WO TEMP at CLR V. High (HNC10CT101_XG01) > 90 Deg.C
6) ID Fan A HC WO TEMP V. High (HNC10CT101_XG01) > 90 Deg.C
7) ID FAN A MTR BRG Temp V.High 110 Deg. C & High 90 Deg. C (10 Sec TD)
8) ID FAN A FAN BRG Temp V.High 105 Deg. C & High 90 Deg. C(10 Sec TD)
9) ID FAN A MTR WDG Temp V.High 130 Deg. C & High 110 Deg. C (2/6 Logic &10 Sec TD)
10) ID FANS A FAN BRG Vib. (X&Y) V.High 12.6 mm/s & High 6.3 mm/s (10 Sec TD)
11) ID FANS A FAN MTR Vib. (X&Y) V.High 9.9 mm/s & High 6.3 mm/s (10 Sec TD)

When ID fan A trip, (ID Fan B is OFF) impulses shall be given for:

1) Opening the inlet & outlet gate of ID fan B

2) Opening the Inlet damper of ID fan B to wide open position.
3) Disconnecting the impulse from auto control system (output from A/M station) to Inlet damper control.
4) Disconnecting the impulse from auto control system (output from A/M station) to Hydraulic coupling.
5) Opening the Inlet damper of ID fan A to wide open position.
6) Opening the scoop control of ID fan A to wide open position.
7) Tripping the Corresponding working FD fans.
8) Boiler tripping through FSSS (ID Fan B is already OFF)
9) Inlet gate and outlet gate of ID fan A open

When ID fan 'A' is started (ID Fan B is OFF), impulses shall be given for:

1) Opening the inlet gate and outlet gate of ID fan A after the motor reaches rated speed.
2) Connecting the inlet damper of ID fan A to the auto control.
3) Connecting the of ID fan A to the auto control after the following conditions are satisfied:
 Differential pressure across ID fan A Hydraulic coupling oil filter is low (Annunciation only)
 ID fan A Hydraulic coupling lube oil pressure is adequate > 0.8 ATA
 ID fan A Hydraulic coupling working oil temperature is low. (< 1000c)
4) Closing the inlet gate and the outlet gate of ID fan B.
5) Bringing the Inlet damper to minimum position.
6) Bringing scoop to minimum position.
7) Permission to start either FD Fan A or FD Fan B.

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FD Fan:

Any one of the two running FD fans trip, the boiler load shall be run down to 50% MCR.
FD fans (each rated for 60 % MCR) of axial type FD fans A Drive Start Permissive (FD Fan-A and ID Fan-B off.)

FD fan ‘A’ shall be prohibited from starting till the following conditions are satisfied:-

1) ID Fan A/B (or both) ON & Corrs. I/L & O/L Gate opened and FD Fan B OFF (Flow path to Stack opened)
2) FD Fan A Off F/B from Swgr
3) FD Fan Fan/ Motor bearing temp. Not very high (< 90oC, 2/6 logic).
4) Motor winding temp. Not very high (< 110oC).
5) FD Fan A Swgr. Available.
6) FD Fan A MTR Not operated.
7) FD Fan A Swgr. Not Disturbance
8) Lube oil Tank level not < 50%
9) Any LOP ON and Lube Oil Pr Adqe.(>13 bar)
10) FD Fan A Blade pitch control Min < %
11) FD Fan A Blade pitch control Manual mode
12) F.G O/L Damper Closed
Flow path to Stack open

1) ID Fan A ON , I/L & O/L Gate Opened OR ID Fan B ON, I/L & O/L Gate Opened OR Both
2) FD Fan B OFF

FD Fan “A” Protection

1) Motor Winding Temp Very High (> 130 Deg. C, 2/6 logic, 10 sec TD )
2) Motor/ Fan Berg. Temp. Very High ( > 110 Deg. C, 10 sec TD)
3) Motor Berg. VIB. Very High ( > 9.9 mm/s, True peak )
4) Fan Berg. VIB. Very High (>12.6 mm/s, True peak )
5) Both ID Fan OFF
6) FD Fan A & B ON and ID Fan A OFF
7) FD Fan O/L damper not opened within 120 sec of FD Fan A ON f/b
8) FD Fan A MTR Operated (from Swgr).
9) FD Fan A Post Purge trip from FSSS

INTERLOCKS FOR FD FAN LUBRICATING OIL SYSTEM:

FD Fan A lube oil system:
1) Pump A will start automatically if pump B trips provided, A/M switch is in auto Position Pump A will start
automatically with a time delay of 30 seconds.
2) If lube oil pressure falls below a set value and the pump B is working provided A/M Switch is in auto
position. Pump B will start automatically.
3) If pump A trips/has not started provided A/M switch is in auto position. Pump B will Start automatically
with a time delay of 30 seconds.
4) If lube oil pressure falls below set value and the pump A is working provided A/M switch in Auto.
5) Both lube oil pumps are switched OFF automatically after a delay of 30 min. after the FD Fan A-OFF

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PA Fan:

PA Fan “A” Drive Start Permissive

PA fan ‘A’ shall be prohibited from starting till all the following conditions are satisfied:-

1) PA Fan B off AND any One/Both FD Fan ON OR Both the FD Fan ON

2) Purge Complete from FSSS
3) PA Fan A Fan/ Motor bearing temp. Not very high (< 90oC, 2/6 logic).
4) Motor winding temp. Not very high (< 120oC, 2/6 logic).
5) PA Fan A Protection not acted.
6) PA Path Available
7) Any LOP ON and Control Oil Pr Adequate.
8) PA Fan A Blade pitch control Minimum
9) FD Fan A Blade pitch control Manual mode
10) PA Fan A Oil tank level OK.
11) PA Fan A O/L gate Closed.
12) Start Permissive from FSSS.
13) PA Fan A Off F/B from Swgr
14) PA Fan A Swgr. Available
15) PA Fan A MTR Not operated.
16) PA Fan A Swgr. Not Disturbance
17) PA Fan A not tripped.

PA Fan “A” Protection (Any of Followings)

1) Motor Windg. Temp Very High ( > 120 Deg. C, 2/6 logic, 10 sec TD )
2) Motor/ Fan Berg. Temp. Very High ( > 105 Deg. C, 10 sec TD)
3) Motor Berg. VIB. Very High ( > 9.9 mm/s, True peak )
4) Fan Berg. VIB. Very High (>12.6 mm/s, True peak)
5) Both FD Fan OFF
6) PA Fan O/L damper not opened within 120 sec of PA Fan A ON f/b
7) PA Fan A MTR Operated (from Swgr).
8) MFT from FSSS.

Different Settings of PA Fan

1) PA Fan Motor Bearing Temp. Very High DE >90oC

2) PA Fan Motor Bearing Temp. Very High NDE >90oC
3) PA Fan- FAN Bearing Temp. Very High >105oC
4) PA Fan Motor Winding Temp. Very High 2/6 >120oC
5) PA Fan Control Oil Pr. OK > 20 BAR
6) PA Fan Control Oil Pr. LOW < 14 BAR
7) PA Fan Lube Oil Pr. LOW < 3 BAR

8
When PA fan A is started (PA fan B is off), impulses shall be given for:
1) Opening the outlet gate of PA Fan A
2) Connecting the blade pitch of PA fan A to auto control
3) Bringing the blade pitch control of PA fan B to the minimum position
4) Closing the outlet gate of PA fan B
5) Permission to start any three coal elevation through FSSS.

When PA fan B trips (PA fan A is on), impulses shall be given for:

1) Disconnecting the blade pitch control of PA fan B from auto control

2) Bringing the blade pitch control of PA fan B to minimum position
3) Closing the outlet gate of PA fan B
4) Reducing boiler load to 50% MCR
5) Tripping any three coal elevations through FSSS.
Note:
 If one PA Fan is started when the other PA Fan is off, the outlet gate of starting fan shall be opened with
starting of the fan to reduce the load of electrically operated gate.
 When starting the second fan (i.e. PA Fan A started when B is on or vice versa), the respective outlet
gate shall be opened after the fan reaches full speed.

INTERLOCKS FOR PA FAN LUBE OIL SYSTEM

PA fan A lube oil system:

1) Pump A will start automatically if pump B trips provided A/M switch is in auto position
2) Pump A will start automatically with a time delay of 30 seconds if oil pressure falls below a set value and
the pump B is working provided A/M switch is in auto position.
3) Pump B will start automatically if pump A trips/has not started provided A/M switch is in auto position.
4) Pump B will start automatically with a time delay of 30 seconds if lube oil pressure falls below a set
value and the pump A is working provided A/M switch in auto position.
5) Pump A or pump B can be started/tripped by pressing the respective push button provided on local
pushbutton box when A/M switch is in manual position.
6) PA fan A shall be prohibited from starting until the lube oil pressure is adequate.
7) Both lube oil pumps are switched OFF automatically after a delay of 30 min. after the PA fan A is OFF.

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APH SYSTEM

AH (A) Start Permissive: (All the conditions):-

1) AH- A MTR SOV Power Available

2) AH- A Air Pr. Before SOV(HLD01CP201_XG01) not Low
3) AH-A OFF f/b from swgr. Available.
4) AH-A MTR no disturbance from MCC
5) AH- Support Brg. Oil Temp. not High ( < 70’C )
6) AH- A Guide Brg. Oil Temp. not High ( <70’C )
7) Flue Gas path available
8) AH- A GB/SB. LOP MCC Healthy.
9) AH- A Support Brg. LOP-A No disturbance from MCC.
10) AH- A Guide Brg. LOP-A No disturbance from MCC.
11) AH-A Not Tripped

AH (A) Protection Trip (Any of the conditions):-

 AH –A Rotor Stoppage Alarm

 AH –A Electric Motor Tripped & Air Pr. after Solenoid Low (TD 1sec)

AH (A) Electric Motor Start Permissive: (All the conditions):-

1) AH –A Motor Off f/b coming form MCC

2) AH –A Motor MCC Not Disturbance.
3) AH –A Supp. Brg. Oil temp. Not High (< 70’C)
4) AH –A Guide Brg. Oil temp. Not High (< 70’C

 AH (A) Electric Motor Tripping taken on MCC Disturbance.

Oil Circulation Pumps of support bearing

2 x 100% oil circulation pump have been provided for the support bearing. Anyone of the two oil circulation
pumps can be pre-selected as main pump and the other as standby.
Interlocks for:
The main oil circulation pump/stand-by oil circulation pump shall Trip on
 The temperature of the support bearing falls below a preset value (38 deg.C).
 Manual operation of the lube oil pumps shall be prohibited when the ambient
Temperature is too low. Since viscosity of the oil will be high so that the pump couldn't be started.

AH (A) Supp. Brg./Guide Brg. LOP Start Permissive: (All the conditions) :-

1) AH –A Brg. Oil temp. Not Low (>40’C)

2) No MCC Disturbance

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AH (A) Supp. Brg./Guide Brg. Stand By LOP Start Condition:-

1) AH (A) ON feedback coming from MCC

2) Running LOP Tripped OR Main LOP running and Oil flow Low.
3) Support / Guide Bearing Oil Temperature High > 70Deg.C
4) Support / Guide Bearing Oil Temperature Low < 40Deg.C
5) AH (A) Cold End/ Hot End Temperature High > 450 Deg.C

Air Motor

The Drive Solenoid of Air Motor is de-energized to open

SOV permissive to open (all the condition):-

1) AH (A) supp. & Guide Brg. Oil temp not high

2) Electric motor OFF
3) Air Pr. before SOV not low.

SOV protection to open:-

 Electric Motor tripped

SOV permissive to Close

1) Electric Motor ON
OR
2) Boiler tripped

Flue Gas Path Available:-

1) ESP A I/L Gate 1&2 & O/L Gate 1&2 Opened

OR

ESP B I/L Gate 1&2 & O/L Gate 1&2 Opened

2) ID Fan A I/L & O/L Gate Opened

OR

ID Fan B I/L & O/L Gate Opened

Both AHs are working, when AH A trips & AH B continues to run:

The gas inlet damper, the secondary air outlet damper and primary air outlet damper of the tripped AH
shall be automatically closed. The primary air inlet damper, the secondary Air inlet damper and the gas outlet
damper of the tripped AH need not be closed. However if the operator wants to manually close these dampers
they can be closed

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FSSS
Introduction

The furnace safeguard supervisory system (FSSS) is designed to ensure the execution of safe, orderly
operating sequence in the start up and shutdown of fuel firing equipments and to prevent errors or omissions
and commissions in following such a safe operating procedure.
The system provides protection, should there be a malfunction of fuel firing equipments and associated
air systems. The safety features of the system are designed for protection in most common emergency
situation.

Basically the system is designed to perform the following functions:-

1) Prevent any fuel firing unless a satisfactory furnace purge sequence has first been completed.
2) Prevent start-up of individual fuel firing equipment unless certain permissive interlocks have first been
satisfied.
3) Monitor and control the proper sequence (manual or automatic) during start-up and shutdown of fuel
firing equipment.
4) Make continued operation of fuel firing equipment subject to certain safety interlocks remaining
satisfied.
5) Provide status feedback to the operator and in some cases, to the unit control system.
6) To provide flame supervision when fuel firing equipment is in service and effect a fuel trip upon certain
adverse operating conditions.
7) Initiate a fuel trip when certain abnormal operating condition exists.

The following operational functions are included in FSSS:-

1) Furnaces purge supervision.
2) Secondary air damper modulation on/off control and supervision.
3) Light oil on-off control and supervision.
4) Heavy oil on-off control and supervision.
5) Pulveriser & feeder on-off control and supervision.
6) Flame scanner intelligence and checking.
7) Overall boiler flame failure protection.
8) Boiler trip protection.

 The furnace safeguard supervisory system has been designed for energies to open and de-energies to
close philosophy. This means any on/off device or equipment has to get a continuous command to
maintain its present state and upon loss of power or on removal of this command, it will regain its
original state

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Furnace purge

Before any fuel firing can take place initially or following a boiler trip), a satisfactory purge cycle must be
completed. To start a furnace purge cycle proceed as follows:-

1) Energies all the system power Supplies (AC & DC).

2) Place atleast one ID (induced draft) fan in service.
3) Place atleast one FD (forced draft) fan in service.
4) Establish a minimum of 30% of full load air flow through the unit and furnace draft at the appropriate
value.
5) Establish a proper water level in the drum.

After the “PURGE READY” and the “PUSH TO PURGE” Signals are available, a furnace purge cycle can be
started. When both these Signals come on it indicates that all the purge requirements are satisfied

Note:-
If both the “PURGE READY” and the “PUSH TO PURGE” Signals do not come on after conditions 1
through 5 above are satisfied, check to see that :-

Permissive for purge ready:-

1) Elevation AB all Light oil nozzle valves are proven closed.

2) The Light oil Trip valve is proven closed.
3) The Heavy oil Trip valve is proven closed.
4) All the Heavy oil nozzle valves are proven closed
5) All feeders are off.
6) All P.A. Fans off.
7) All Hot Air gates are fully closed
8) All flame Scanners show no flame.
9) “No Boiler Trip” (Boiler trip A/B/C) command is present.
10) Air flow between >30%; and <40% MCR.
11) All aux. dampers modulating.

The furnace purge cycle can be started after all the purge requirements are satisfied and the “PURGE
READY” light is on. The furnace purge cycle is started by depressing the PUSH TO PURGE PB. This will start a five
minutes purge timer and the “PURGING” light will come on

Note:-
Loss of the purge permissive at any time during the five minutes purging period will reset the purge
timer. When this happens, the purge requirements must be re-established (“PURGE READY”) and another
furnace purge cycle started by depressing the “PUSH TO PURGE PB”.
At the end of the Five minutes furnace purge cycle, provided the purges permissive remain satisfied, the
boiler trip is reset. This is indicated by the “MFR TRIP” light going off, the “PURGING” and “PUSH TO PURGE”
Lights going off. A “No MFR Trip” condition is now established and the “CAUSE OF TRIP” Memories are reset.
The operator may open the various trip valves as described in the following sections

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Selection of Light Oil / Heavy Oil Firing
Either Light Oil or Heavy Oil can be fired at elevation AB, when selected by the operator. Provided
All the HO nozzle valves and LO nozzle valves are fully closed AND both pairs have been stopped.
EL. AB LIGHT OIL SELECTED Signal comes When the "Select Light Oil”
Command is given and EL.AB HEAVY OIL SELECTED Signal comes When the "Select Heavy Oil”
Command is given.

Light Oil Trip Valve (LOTV)

Depressing the “Light oil trip valve OPEN PB” after the furnace purge cycle is completed, (boiler trip reset)
will open the light oil trip valve, provided the following conditions are satisfied (Permissive of Light Oil Trip Valve
Open).
 Light oil supply pressure is adequate.
 Elevation AB all the light oil nozzle valves remain closed.

When the oil trip valve open condition is indicated by a light coming on, the “LO elevation trip” command is
removed and LO elevation start permit is now established. Pressing the “LOTV CLOSE” PB will close the valve &
The LOTV will also close automatically under following conditions provided the valve is not closed:

LOTV Auto CLOSE conditions:-

 Master fuel trip

 Any light oil nozzle valve not closed AND Light Oil header pressure very low(From 2/3 logic)
 Any light oil nozzle valve not closed AND Atomizing air pressure very low (From 2/3 logic) AND No light
oil elevation in start or stop in Elevation AB.
The LOTV is commanded to close on Loss of unit Critical Power (+24V DC).

HEAVY OIL TRIP VALVE (HOTV)

The Heavy oil must be heated to the proper temperature to attain the correct viscosity before it can be
fired. This is accomplished by re-circulating the oil through the oil recirculation system by means of HOTV and
HORV. The Heavy OIL RECIRCULATION VALVE MUST BE OPENED BEFORE THE Heavy oil trip valve can be
opened. By pressing the “HO Trip valve OPEN PB” will open the Heavy Oil Trip Valve if either of the following
Conditions are present

HO Trip valve (HOTV) OPEN Conditions:

 HO recirculation valve is fully open AND HO trip valve Close command is present.
OR Both of the following
 All heavy oil nozzle valves are closed AND The heavy oil supply pressure is adequate
 The heavy oil temperature is adequate AND No MFT condition is present.

When the Heavy oil trip valve is opened the “HO Trip Valve OPEN” light comes on. The “Ho elevation trip
command” is removed. “HO Elevation start permit” is now established.

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HOTV automatically Close conditions are

 Master Fuel Trip AND HO Recirculation valve is not opened

 Atomizing steam pressure very low AND Any Heavy Oil Nozzle valve not Closed AND No HO start or Stop
in any elevation for more than 5 sec.
 Heavy Oil Header Pressure very low AND Heavy Oil nozzle valve not closed.
 Heavy Oil Header Temperature very low AND Heavy Oil nozzle valve not closed.
 Heavy Oil recirculation valve open

The HOTV is commanded to close on Loss of unit Critical Power (+24V DC).

Heavy Oil Recirculation Valve (HORV)

The Heavy oil must be heated to the proper temperature to attain the correct viscosity before it can be
fired. This is accomplished by re-circulating the oil through the system when the heavy oil recirculation valve
and other manual valves are open.

The Heavy OIL RECIRCULATION VALVE MUST BE OPENED BEFORE THE Heavy oil trip valve can be
opened. Depressing the “HO recirculation valve OPEN PB” will open the Ho recirculation valve, provided all
heavy oil nozzle valves are closed. When the recirculation valve is open the “HO RECIRC. VALVE OPEN” light
comes on. The HO trip valve can now be opened. Depressing the “HO recirculation valve CLOSE PB” will close
the HO Recirculation valve.

 HO Recirculation can be performed even during MFT by keeping the HORV & HOTV open.
 Before furnace purge cycle is started HOTV must be proven closed.
Note: - HO Recirculation can be performed even during MFT by keeping the HORV & HOTV open.

BOILER TRIP CONDITIONS

Master Fuel Trip (MFT):-

Master Fuel Trip is initiated by any one of the following conditions:-

1) Both F.D. (forced draft) fans are off.

2) Both I.D. (included draft) fans are off.
3) Drum water level “Very High” for more than 10 sec. (2/3 logic) (+225 mm).
4) Drum water level “Very Low” for more than 5 sec. (2/3 logic) (-225 mm).
5) Air flow less than 30%.
6) Furnace pressure “Very Low” (2/3 Logic) (-175 mmwc).
7) Furnace pressure “Very High” (2/3 Logic) (+150 mmwc).
8) Reheater protection acted.
9) Less than fireball and loss of AC in any Elevation in service (see Note1).
10) Both “EMERGENCY TRIP” PB’s depressed (Operator initiated).
11) Loss of All Fuel trip (see Note2).
12) Unit Flame Failure Trip (see Note3).
13) Loss of unit 220V DC power for more than 2 sec.
14) Any two MFT (Net A & Net B both) Network failed.

15
Note:-

A spare channel for boiler tripping is provided for use at a later date if required. Otherwise it should be
left unconnected. MFT Operated by condition 2/3 logic (MFT A, B, C)

MFT command will initiate the following actions.

 All fuel inputs are stopped by tripping all the mills,

 Tripping of all the feeders,
 Closing all Hot air gates,
 Closing all the nozzle valves (LO/HO) and trip valves (LO/HO).
In addition to the above,

1) The HO elevations revert to “pair operation”.

2) The upper (elevations D, E, F) and lower (elevations A, B, C) fuel air dampers are opened and transfer to
manual.
3) Transfer the auxiliary air control to manual and open all aux. air dampers.
4) After five sec. the “loss of fuel trip arming” signal is removed and the “loss of fuel trip arming” memory
is reset.
5) The furnace pressure recorder speed is changed for 30 sec. When the furnace pressure is not high and
not low after 30 sec. the recorder reverts to its original speed.
6) After a “Master fuel trip” occurs, a “feed forward to furnace draft control” signal is established for 30
sec. After 30 sec. this signal is removed.
Note:-

“Less than fire ball and loss of AC in any elevation in service” condition occurs, when all the mills are
not in service and there is a loss of power supply (110V AC) at any of the elevation in service. Under this
condition as ignition energy will not be proper ;(no fire ball), the HO elevation (Oil) cannot be allowed to run
without control (as there is no power supply). Hence the boiler has to be tripped to shut down the elevation

Note:-

Loss of All Fuel Trip circuit is armed as soon as oil firing is introduced into the furnace, through any one
of the following conditions i.e., if any oil burner comes into service. This condition also indicates that the
“Boiler is on”.

Condition for all Fuel Trip (any One of the followings)

1) Elevation AB any LO nozzle valves NOT closed

2) Elevation AB any HO nozzle valves NOT closed
3) Elevation CD any HO nozzle valves NOT closed
4) Elevation EF any HO nozzle valves NOT closed

16
Loss of All Fuel Trip
Loss of All Fuel Trip” condition is generated if all the following conditions exists along with “Loss of all fuel trip
arming” condition:-
 All feeders are off AND HOTV is not open
OR
 Elevation AB Backup trip OR All HO nozzle valves are closed
AND
 Elevation CD Backup trip OR All HO nozzle valves are closed
AND
 Elevation EF Backup trip OR All HO nozzle valves are closed
AND
 LO trip valve is not open OR Elevation AB All LO nozzle valve closed

UNIT FLAME FAILURE TRIP

During light up and until any main fuel (coal) is in service at a fire condition, the flame scanners do not
Take part in the overall flame failure protection system. A fire ball condition is established for coal firing when
either or both the adjacent feeders are proven and 2 out of 4 fireball scanners show flame. An elevation voting
for "No Flame" condition is as described below for the respective coal and oil elevations.
Elevation ‘A’:

 Feeder ‘A’ is not proven.

OR
 Elevation ‘AB’ 3 out of 4 Fireball Scanners shows no flame. AND Elevation ‘AB’ HO/LO 2/4 nozzle valves
not open
OR
 Elevation AB Started and Loss of 110 V AC power..

Elevation ‘B’

 Feeder ‘A’ is not proven.

OR
 Elevation ‘AB’ 3/4 Fireball Scanners shows no flame. AND Elevation ‘AB’ HO/LO 2/4 nozzle valves not
open
OR
 Elevation AB Started and Loss of 110 V AC power
AND
 Elevation ‘BC’ 3/4 Fireball Scanners shows no flame

Elevation ‘C’:

 Feeder ‘A’ is not proven.

OR
 Elevation ‘CD’ 3/4 Fireball Scanners shows no flame. AND Elevation ‘CD’ HO/LO 2/4 nozzle valves not
open
OR
 Elevation CD Started and Loss of 110 V AC power AND Elevation ‘BC’ 3/4 Fireball Scanners shows no
flame.
17
Elevation ‘D’:

 Feeder ‘D’ is not proven.

OR
 Elevation ‘CD’ 3/4 Fireball Scanners shows no flame. AND Elevation ‘CD’ HO/LO 2/4 nozzle valves not
open
OR
 Elevation CD Started and Loss of 110 V AC power AND Elevation ‘DE’ 3/4 Fireball Scanners shows no
flame
Elevation ‘D’:

 Feeder ‘E’ is not proven.

OR
 Elevation ‘EF’ 3/4 Fireball Scanners shows no flame. AND Elevation ‘EF’ HO 2/4 nozzle valves not open
OR
 Elevation EF Started and Loss of 110 V AC power AND Elevation ‘DE’ 3/4 Fireball Scanners shows no
flame
Elevation ‘F’:

 Feeder ‘F’ is not proven.

OR
 Elevation ‘EF’ 3/4 Fireball Scanners shows no flame. AND Elevation ‘EF’ HO 2/4 nozzle valves not open
OR
 Elevation EF Started and Loss of 110 V AC power
NOTE:

All elevation voting for “No Flame" as described above will cause a unit trip on Flame Failure, provided
the flame failure circuit is armed. (Unit Flame failure Trip circuit is armed 2 seconds after any coal elevation is
put into service. i.e. any feeder proven.

Scanner Air Fan Control

Two scanner air fans (1 AC main + 1 DC stand-by) are provided for the unit.
Either scanner air fan can be placed in service in the following manner.
Start command to any of the scanner fan can be given from the CRT / Unit Console insert.

 A start command is also established automatically for scanner air fan ‘A’ (AC operated), if the scanner
duct to furnace diff. pressure is “low” for more than 5 sec. If this low condition exists for more than 10
sec., the same is annunciated as “Scanner Duct to Furnace DP Low” greater than 10 sec. signals.
 A start command is also established for the stand-by scanner air fan (i.e. DC) if the first fan fails to start
within 5 sec. after receiving the start command or if it trips. Loss of unit 24V DC establishes start
command for both scanner air fans

The scanner air fan can be stopped by momentarily depressing the “STOP PB”, provided the scanner
duct of furnace diff. pressure is not low. The status of Scanner air Fans is displayed on the CRT / Console insert.
The scanner emergency damper is opened when both FD fans are off AND Unit 24V DC power is lost. If both
these conditions are not present, the scanner emergency damper will be closed. Auto Transfer damper has been
provided at the outlet of the Scanner Air Fan.
18
Auxiliary Air Damper Control:

The function of Secondary Air Damper Control (SADC) System is to proportion the total air around the
firing elevation as per the criteria spelt above. In fact the SADC system is a combination of both analog and
digital system, as the amount of fuel fired and the number of firing elevations decides the damper position.
The auxiliary air damper control system positions the auxiliary air dampers to maintain a wind box to furnace
differential pressure (Refer Figure-2). The auxiliary air dampers are positioned to maintain the required wind
box to furnace differential pressure according to the boiler load.

All elevations of the aux. air dampers will be automatically switched to “Manual” control and then
commanded to open 100%, if any one of the following conditions exist.

 Both FD fans are off.

 Both ID fans are off.
 Master fuel trip exists for more than 2 sec.
 Loss of Unit 24V DC.

When the aux. air control is placed in the “Auto” mode of operation, the aux. air dampers modulate to
control wind box to furnace diff. pressure at a predetermined set point.

During the furnace purge cycle, all aux. air dampers modulate to maintain wind box to furnace diff.
pressure at a predetermined set point.
When the unit load exceeds 30% of MCR, the following events occurs:-

The wind box to furnace diff. set point is gradually increased as the unit load is increased. Conversely,
the diff. pressure set point is gradually decreased as unit load is decreased. The rate of increase (or decrease) is
controlled by the aux. damper controller.

When the Unit Load is increased above 30% MCR

The Aux. air dampers on Elevation AB, BC, CD, DE, EF, GH, HJ, JK & KK are closed in a timed sequence (10
sec. interval) provided the associated coal elevations are not in service and the associated oil elevations are not
in service. The auxiliary air dampers are closed, starting from the top elevation, progressing towards the lowest
elevation.

When the unit load is reduced below 30% of MCR, the following events occur:-

 The wind box to furnace differential pressure set point reverts to its original value.
 The auxiliary air dampers associated with the coal and LO / HO elevations not in service are opened in a
timed sequence (10 sec. interval) starting at the lowest elevation, progressing towards the top.
When a LO / HO Elevation is started (i.e. when the associated “elevation back-up” trip is removed) the
associated auxiliary air dampers in that elevation are set to preset position for LO / HO firing.

When the “Post Trip Purge Time Expired” command is established and both FD / ID fans are not OFF
and a Master fuel trip” command doesn’t exist, then a 35 sec. counting period is started. After it expires, the
“Open All Auxiliary Air Dampers” command is removed from memory.

19
Fuel (Coal) Air Dampers Control

All elevations of fuel air dampers are commanded to open 100% when any one of the following
conditions exists:-
1) Both F.D. fans are OFF.
2) Both I.D. fans are OFF.
3) Master fuel trip exists for more than 2 sec.
4) Loss of Unit 24V DC.

When a coal elevation is in service, the associated fuel air dampers modulate as a function of mill air
flow as indicated by the associated coal elevation “MODULATING” light coming on.
When the coal elevation is shut down, the associated fuel air dampers are closed, as indicated by a “CLOSED”
light. When the “Post Trip Purge Time Expired” command is established and “Both FD and ID fans are
not off” and “Master fuel trip” command doesn’t exist, the “Open upper fuel air dampers (Elevation F, E,
D & both OFA )” command is removed from memory. Thirty seconds later open lower fuel air dampers
(Elevation C, B & A)” command is removed from memory.

FURNACE TEMPERATURE PROBE

 Furnace temperature probe can be advanced/retracted using the pushbuttons Provided in DDCMIS as
well as from local starter box.
 Furnace temperature probe shall be prohibited from being advanced further into The furnace if furnace
temperature sensed by it is more than 540 deg. C
 If furnace temperature probe is inside the furnace and the temperature exceeds 540 Deg. C it will be
retracted back automatically.

SOOT BLOWER START PERMISSIVES

1) SB main steam isolation valve (S118) shall be in open condition.

2) All blowers in home position.
3) Blower motor not ON
4) No Fault in system.
5) SB steam pressure adequate.
6) LR Blower jamming signals not available (Applicable for LR Blower only).
7) SB in REMOTE mode.

SEQUENTIAL OPERATION

1) Switch on Panel Power Supply.

2) Put Local / Remote selector in Remote mode.
3) Select the required auto sequence.
4) Ensure start permissive Conditions.
5) After attaining the required drain temperature & adequate steam pressure, to start the sequence press START SEQ
button along with selected SEQ button. The first blower will start as per selected programme and the
sequence will continue. Blower operating indication will be available on Mimic. The selected SEQ will
automatically get reset after operation the “SEQUENCE COMPLETED” indication will become on.

20
 6) At any point of time the selected sequence can be reset by pressing RESET button Along with selected
SEQ button.
7) During the sequence operation if any fault occurs, he sequence will stop at that step and the
operating blower will be commanded to retract back to home position for Faults ii to viii. After
resetting the fault, the sequence can be continued for the Remaining blowers by pressing SEQ
START button along with selected SEQ Button. However for fault blower cannot be
retracted. Hence suitable Annunciation shall be made to operator for intervention and
manually retracting blower back from field. Similarly for other faults also if blower
Is not retracting based annunciation has to be made for operator intervention.

Fault conditions are listed below: -

 110V AC control supply at SBMCC failure

 Blower over run.
 LR Blower mechanical jamming Blower steam flow low.
 Blower motor overloaded.
 Boiler Trip
 SB Steam Pressure Low
 Auto Sequence Interrupted

BL O W E R O P E RA T I O N

WALL BLOWER: -
As soon as the start impulse is given, the traverse motor of Wall blower gets Supply and the blower
moves forward. The red lamp in mimic glows to indicate the operation of that blower. The yellow lamp for
indication of ‘Blower Forward’ also glows. When the blower reaches the traverse motor trips and the rotary
motor gets supply and rotates the lance. The yellow lamp for “Blower rotating” glows. Simultaneously Steam
Valve will open and allow the Steam for blowing. When the lance complete one Rotation the Rotary motor trips,
Travers Motor gets supply and the home position the mimic lamp goes off. Now the next blower in the
sequence gets the pulse and start operating.

LONG RETRACTABLE BLOWER

hen the Long Retractable blower gets the pulse, first the rotary motor starts rotating. The ‘NO' contact
of contactor ‘CRO' for rotary motor closes and the traverse motor starts and holds through limit switch LS-2
contact. The blower moves forward. The Red lamp in mimic glows to indicate blower operation. Yellow
indication lamps for ‘Blower Forward' & ‘Blower rotating’ glows. When the blower reaches the forward end
position, it actuates Limit switch LS-1 which stops forward motion of the blower. Immediately the blower
reverses. The yellow lamp for ‘Blower Retracting' as it comes back to home position, both traverse and rotary
motors are stopped and lamps in mimic go off.

AIR HEATER BLOWER

When the AHB starter receives an impulse to start, the motor starts rotating & the lance starts
sweeping. Start impulse from SBC shall be ‘ON’ for 5 minutes continuously to enable limit switch LS- 1 to make
and hold the power supply across the power contactor. Simultaneously the solenoid operated control valve is
opened and steam flows.
21
 When the lance moves from the initial position, the limit switch LS-1 reset and holds supply to the starter.
The OFF-DELAY timer contact holds the supply across limit switch LS-1, when operated under manual mode from local, until
it resets during start-up. The Red lamp in mimic glows to indicate blower operation. When the lance reaches the forward end
position the limit switch LS-2 trips and the solenoid control valve is closed. The motor runs in the same direction and by
the link arrangement the lance comes back to the initial position. During the reverse sweep there is
no soot blowing. When lance reaches initial position LS-1 trips, motor stops rotating, and the mimic
lamp goes off.

NOTE:-
 At a time, one blower can be operated in sequence.
 CRT/Key Boards are common for FSSS, SBC & SADC System.
 SB operation can be made through CRT/Key Board.

Reheater protection logic

This protection is provided to protect the Reheater against starvation of steam flow during abnormal conditions.
To take care of Reheater protection, the boiler shall be tripped after 10 seconds, when any of the conditions
occur:-
Condition for Boiler Tripped from loss of Reheater Protection (All of Followings):-

Condition: 1

1) Generator circuit breaker opened

2) Reheater Protection Enabled.
3) HP Bypass or LP bypass valves remain closed less than 2%.

Condition: 2

1) Reheater Protection Enabled.

2) HP VLV & HPBP OR IP VLV & LPBP remain closed less than 2%.

Condition for Reheater protection Enabled (All Condition):-

1) Boiler Drum Pressure > 8 ata

2) Any Feeder on from FSSS
3) Boiler Firing ON from FSSS
4) HPBP-1, BP <2% open.
5) HPBP-2, BP <2% open.
6) LPBP-1, BP <2% open
7) LPBP-2, BP <2% open

Condition for HP VLV & HPBP OR IP VLV & LPBP Closed:-

1) Turbine Any HPSV Full Closed and HPBP valve ( HPBP1/HPBP2) Opened less than 2%
OR
2) Turbine Any IPSV (IPSV 1/2) Full Closed and LPBP CV (cv1/cv2) opened less than 2%.

22
Condition for HPBP OR LPBP Closed:-

1) HPBP valve 1/2 opened Less than 2 %.

2) LPBP valve 1/2 opened Less than 2 %.

INTERLOCKS FOR FUEL OIL PUMPS:

2x100% LFO pumps common for 2 boilers, 1x100% drain oil pumps each for pump house and boiler
front have been provided.

Interlocks for Light Fuel oil pumps:

Any one of the two pumps can be preselected as main pump A and other as standby
Pump B. Following interlock shall be provided:
LFO pump A can be started remote manually provided suction pressure of LFO pump A is not low, LFO pump A
shall automatically start if pump A is in “Auto” mode, pump B is ON and LFO discharge pressure is low.

COAL MILLS INTERLOCKS & PROTECTION

Mill start permit from PLOS

1) Any Lube Oil Pump ON

2) Sump/Lube oil temp not high <65oC
3) LOP discharge pressure not low >0.8 kg/cm2
4) Lube oil Filter DP not high <1.5 kg/cm2
5) Sump oil level Adeq. (10mm below CL)
6) Lube Oil pressure not very low > 0.5 kg/cm2

Mill Ready Conditions

1) No pulv. Unsuccessful elevation start

2) Bunker outlet gate open
3) Feeder inlet gate open
4) Mill discharge valve open
5) Mill start permit from PLOS (see conditions as above)
6) Mill outlet temp not high < 94 oC
7) Cold air gate open
8) Tramp Iron Hopper valve open
9) Mill/Oil elevation star permit
10) No mill Trip
11) Primary air permit yes
12) All burners Isolation gates open
13) Feeder switch in remote

23
Mill Start Permissive

1) Mill ready conditions as above

2) SA HDR/Pulv Bowl DP adequate >350mmwc
3) MILL motor SWGR available
4) MILL status off & ignition permit available

Mill Protections

1) Motor winding temp. V high > 130˚C (2/6)

2) Motor Brg. Temp. V high >85˚C (1/2)
3) Mill Brg. Temp very high >85˚C (1/4)
4) Mill trip from PLOS
5) Pulv H/W Trip from MCC ( MTR Operated)
6) Pulv. On & SA HDR/Bowl DP low (TD 1 min) <200 mm WC
7) MFT Acted
8) Ignition energy required not available.
9) Pulv command on and failed to start TD 10 sec
10) Pulv discharge valve not open
11) Any burner isolating gates not open
12) Loss of primary air (See Condition Below)
13) Loss of elevation +24 power supply

Mill Trip from PLOS

1) MILL On and LO Temp high (TD 60 Min) >65˚C

2) MILL On & Both Lube Oil Pumps off (TD 2 Sec)
3) LO Pres V low & LOP in Service ( TD 15 Sec) <0.5 bar
4) Lube oil level very low
5) Lube oil flow to gearbox is very low (10.5 LPM )

Start permissive for MILL LOP

1) Lube Oil level Adequate

2) No Lube Oil trip command
3) Flow Not Low & Adequate
4) MILL OFF > 5min
5) Both lube oil pumps ON

Standby LOP Auto start Conditions

1) Lube Oil pump running & pressure low< 0.8 bar

2) Lube Oil pump fail to start (TD 10 sec)
3) Running LOP Trips.

24
MILL Dampers
MILL HOT AIR DAMPER

AUTO CLOSE CONDITION (Any of Followings)

1) Auto air flow decrease command from APS
2) Hot Air Gate Close Command
3) MILL Status Off

AUTO OPERATION ENABLED CONDITIONS:

HAG Open & MILL on & HAG No command persists & MILL air flow control auto permissive

AUTO REGULATION COMMANDS DISABLED CONDITIONS:

Same conditions as Auto Close Conditions

MILL COLD AIR DAMPER

AUTO CLOSE CONDITIONS:

 MILL Status Off
AND
 MFT Not Operated & any PA Fan start Pulse conditions are present. In case auto-closing pulse is active
then the minimum demand is set to 5%
NOTE: Auto Close shall be disabling if MFT Has operated > 5 min.

AUTO OPEN CONDITIONS:

MFT Operated for more than 5 min

MILL status on & (Either HAG is closed or HAG Close command is persisting).
NOTE: A command of 1 sec is generated in case auto open conditions are present.

OPERATION ENABLED CONDITIONS:

HAG Open & MILL On & HAG No close command persists & Mill Temp control auto permissive is
present.

AUTO REGULATION COMMANDS DISABLED CONDITIONS (Any of Followings):

1) Auto close command persists
2) Auto Open Command persists

MILL HOT AIR GATE

PROTECTION CLOSE# (Command 2) CONDITION (Any of Followings):

1) MILL Status Not ON
2) MILL Outlet Temp High > 94˚C
3) Feeder Off OR Pulv. > Unsuccessful Start

 Closed Command 2 is issued instantaneously whereas the protection close command for conditions b-c is
issued with Time delay of 30 Sec. The close command will persist till close feedback is received

25
CLOSE PERM # (Command 1) CONDITIONS (Any of Followings):

1) Mill HAG Manual Closed Command

2) Close command from SGC Logic

 Closed command 1 is issued instantaneously whereas the Permissive for close will be issued after a time
delay of 30 Sec. The close command will persist till close feedback is received.

OPEN PERMISSIVES CONDITIONS:

 MILL Status ON & No HAG Close command 1 & 2.

MILL COLD AIR GATE

CLOSE PERMISSIVES CONDITIONS:

 MILL On & Outlet Temp Not Adequate < 55˚C

GRAVEMETRIC FEEDER

Start Permissive

1) Feeder Switch in remote &

2) MFT not acted
3) Mill outlet temp not low >55˚C &
4) Mill status on &
5) Auto/manual stop commands not present &
6) Coal on belt &
7) Mill ready & Fdr. Speed Min & Feeder outlet Gate open
8) Mill Ignition Permit Available and mill ignition support required
9) Feeder SA Valve Not Open
10) Pulveriser ON

Protection from Logic (Any of Followings):

1) Feeder Switch not in remote

2) MFT operated
3) Mill Status off
4) Auto/Manual Stop command
5) Feeder on >5sec & no coal on belt & Mill motor
6) current not low
7) Pulv. Ignition Permit Not available and ignition Support required
8) Feeder SA valve Not Open

26
Protections from Microprocessor Panel

1) Demand Signal Out Of Range

2) Loss Of Both Tachos
3) Loss Of Tacho – 1
4) Loss Of Tacho – 2
5) Belt Motn. Moni. Timed Out
6) Feeder Discharge Plugged
7) Material On Belt In Local
8) Motor Starter Fault
9) Rpm Deviation
10) CF Monitor Fault
11) AIM Module Bad
12) DIM Module Bad
13) PIM Module Bad
14) AOM Module Bad
15) DOM Module Bad
16) No Material on Belt In Remote

27
 TURBINE

Turbine Trip Protection

1) HP Exhaust Steam Temp. High 2/3, >500 Deg.C (2/3 logic)

2) Cond. Press. Protection Operated (Variable)
3) Lub Oil pressure very low (before thrust Brg.), <1.2 Kg/sq.cm (2/3 logic)
4) Condenser vacuum low (VPS) trip 2/3, 0.3 Kg/cm2
5) Axial shift very high, > +/- 1 mm
6) Bring Metal Temp. Very High, >130 Deg.C (2/3 logic)
7) Main Steam Temp. Very Low, <480 Deg.C (2/4 logic)
8) Reverse Power Relay Operated
9) Fire Protection (from MOT tank level low) 2/3, <850 mm from top
10) HPT REAR MTL Temp. very high, > 130 Deg.C (2/3 logic)
11) THRUST BRG MTL Temp. very high, > 130 Deg.C (2/3 logic)
12) IPT/LPT BRG MTL Temp. very high, > 130 Deg.C (2/3 logic)
13) GEN/EXT BRG MTL Temp. very high, > 130 Deg.C (2/3 logic)
14) TG Shaft VIB very high ( X/Y) & Speed >2850rpm, > 320 Micron
15) Emergency Trip from UCB
16) Emergency Trip from OWS & push button desk
17) Emergency Trip from ATRS rpm.
18) Generator Protection Trip From Electrical
19) Boiler trip to Turbine trip (MFT Operated).
20) Generator Protection Trip From Mechanical
21) HPSU Emergency OFF.
22) CF Pumps 1&2 Protection OFF
23) Over Speed Tripped CH-1/ CH-2, >110%

Generator Protection trip from Mechanical

1) Liquid Main Leads Top > maximum 2/3 logic

2) Cold Gas after CLR Temp (A+B) very high > 55 Deg.C (2/3 logic)
3) Cold Gas after CLR Temp (C+D) very high > 55 Deg.C (2/3 logic)
4) Hot Air Temp. Main Exct. very High > 85 Deg.C (2/3 logic

28
Turbine Lube Oil System

AOP 1 Auto Start Condition any one

1) SLC ON & AOP – 2 OFF & AOP – 2 status discrepancy.

2) SLC ON & discharge header pressure is < 4.8 KSC.

AOP 1 Auto Stop Condition

1) AOP-1 & 2 will auto stop with SGC ON & turbine speed > 2850 rpm & discharge
hdr. Oil pr. > 7 kg/sq.cm
2) Fire Protection - 1 or 2’ Acts. (Protection Stop)

AOP 2 Auto Start Condition

1) AOP – 2 will auto start with SLC ON & AOP-1 OFF & AOP-1 status discrepancy.
2) AOP-2 will auto start with SLC ON & discharge header pressure is < 4.8 KSC.

AOP 2 Auto Stop Condition

1) AOP-1 & 2 will auto stop with SGC ON & turbine speed > 2850 rpm & discharge
hdr. Oil pr. > 7 KSC
2) Fire Protection - 1 or 2’ Acts (Protection Stop).

DC EOP Auto Start Condition

1) DC EOP auto start with SLC ‘ON’ and lub oil pr. < 1.1 KSC.
2) DC EOP will auto start with memory relay ‘ON’ & Lub oil pr. < 1.1 KSC.
3) Fire Protection Acted-Protection start. OVEF1 Auto Start
4) OVEF 2 OFF & OVEF-2 MCC Dist.
5) OVEF1 OFF & OVEF-1 MCC Dist

JOP-1 Auto Start Condition

1) JOP-1 will auto start with SLC ON & Turbine speed <510 RPM & JOP-2 is OFF.
2) JOP-2 will auto start with SLC ON & JOP header pressure <120 KSC for
5 sec. & turbine speed < 510 RPM

DC JOP-2 Auto Start Condition

1) DC JOP-2 will auto start with SLC ON & JOP-1 OFF & status discrepancy.
2) DC JOP-2 will auto start with SLC ON & JOP-1 voltage failure and Turbine speed <2800 rpm.
3) DC JOP-2 will auto start with SLC ON & turbine speed < 510 RPM and JOP hdr. pr. < 120 KSC for 7 sec. From
Fire protection acted.
 Any 2 no’s of JOP’s can’t run simultaneously either with SLC ON or OFF. For Pump changeover, running
Pump is stopped first, and then standby pump comes in service.

29
JOP-1 Auto Stop Condition

1) JOP-1 will auto OFF with SLC ON and turbine speed >540 rpm.
2) JOP -1 will auto OFF if Fire protection acted.

Turning gear valve opening permissive (any of the conditions

1) Seal oil DP is adequate & Seal oil pr. is adequate

2) Turbine speed > 15 rpm.
3) Turning gear valve auto open with SLC ON & turbine speed < 210 RPM

Turning gear valve Auto Close

1) Turning gear valve auto close with SLC ON & turbine speed > 240 RPM.
2) Turning gear valve auto close with lub oil pr. < 1.2 KSC.

The effects on ‘Fire Protection - 1 or 2’ acted

1) AOP-1, AOP-2 & SLC AOP-1, SLC AOP-2 get auto OFF.
2) JOP-1 & SLC JOP gets auto OFF.
3) DC JOP auto start and SLC of DC JOP get auto OFF.
4) DC EOP & SLC DC EOP get auto ON.
5) SLC Turning gear gets OFF.
6) SGC oil supply system gets OFF

SEAL OIL SYSTEM

 After Switching ON the SLC, both AC SOP-1 & 2 start automatically. If discharge pressures of both pumps
are > 7 kg/sq.cm, SOP-2 continues to run but SOP-1 is switched off.

Auto Start of AC SOP 2

1) Running SOP-1 Tripped OR

2) SOP-1 ON, SLC AC SOP ON and Seal Oil header Pr.<6.5 kg/sq.cm in 2 Sec

Auto Start of AC SOP 1

1) Running SOP-2 Tripped OR

2) SOP-2 ON, SLC AC SOP ON and Seal Oil header Pr.<6.5 kg/sq.cm in 2 Sec

Starting of DC SOP (any of the condition)

1) DC SOP- Auto start with SLC ON and both AC SOP – 1 & 2 OFF or disc. pressure of both pumps are < 4
kg/sq.cm
2) DP between seal oil and H2 pr. is less than 1.7 kg/sq.cm

30
Stopping of DC SOP

 DC SOP – Can be stop after 5 seconds if either AC SOP – 1/2 is running or their discharge pressure is > 7
kg/sq.cm.

Manual stop SOP-1

 Seal oil pump-2 on AND seal discharge pressure > 5 kg/cm2.

Manual stop SOP-2

 Seal oil pump-1 on AND seal discharge pressure > 5 kg/cm2

Seal Oil Vacuum Pump 1 ON conditions

1) SO VAC Pump selected and any SOP running & Pr. At SO vac. tank >-0.4kg/sq.cm
2) SO VAC Pump selected and any SOP running & running vacuum pump tripped.

Seal Oil Vacuum Pump 2 ON conditions

1) SO pump 1/ 2 ON and
2) SO Vacuum Pump 1 tripped.

SGC Oil Supply (start up)

SGC Oil supply Operation ON

 Step- 1
Command: Oil Vap Extractor 1 ON

 Step- 2
Condition: All AOP OFF, JOP OFF & Turbine speed < 510 rpm
Command: AOP ON

 Step- 3
Condition: Any AOP ON & Oil Pr. >4.8kg/sq.cm
Command: SLC Oil Temp cont. ON

 Step- 4
Condition: SLC Oil Temp cont. ON & Liquid in Gen (TE) < Max. & Brg. Exhaust Fan ON & H2 Purity .95%
Pr. H2- Stator Frame > 2.8 kg/sq.cm & liquid Main Leads BTM < max.
Command: Turning Gear SOV OFF
SLC AOP 1 ON
SLC AOP 2 ON
SLC EOP 0 DC ON

31
  Step- 5
Condition: Step 4 Complete, & Turning Gear SOV OFF & SLC AOP 1 ON & SLC AOP 2 ON
& SLC EOP 0 DC ON
Command: SLC JOP 1 ON
SLC JOP 2 ON

 Step- 6
Condition: SLC JOP 1 ON & SLC JOP 2 ON & Turbine Speed > 15 rpm
Command: Nil

 Step- 7
Condition: Step 6 Complete, & Turbine Speed > 540 rpm
Command: Nil

 Step-8
Condition 1: JOP 1 OFF & JOP 2 OFF & Step 7 completed
Command: Release to step 9

 Step-9
Condition: Turbine speed > 2850 rpm & Oil Pr. > 7kg/sq.cm
Command: AOP 1 OFF
AOP 2 OFF Watch time Start

 Step-10
Condition: Step-9 complete & Watch time Start
Command: Nil

 Step-11
Condition: Step-10 complete & AOP 1&2 OFF & EOP (DC) OFF
Command: Nil

Monitoring time Blocked (as Turbine speed < 2800 RPM)

STEPS COMPLETE

SGC –Evacuation Start Up

Operation Release

1) Seal steam cond. Exh. Fan 1 or 2 ON

2) One CEP ON
3) Condenser Pr. < 0.12 kg/sq.cm
4) Any VAC. Pump system OFF

32
  Step-1
Command – SLC Drain ON
 Step-2
Command- Vacuum Breaker Close
Gland steam Pr. Cont. Valve in manual
Gland steam Cont. Valve close

 Step-3
Condition- Vacuum Breaker Closed
Gland steam Pr. Cont. Valve in manual
Gland steam Cont. Valve closed

Command- SOL VLV iv 1 & iv 2 Open

Vacuum Pump 1 & 2 ON
CW Recirculation Pump 1 & 2 ON

 Step-4
Condition- SOL VLV iv 1 & iv 2 Opened
Vacuum Pump 1 & 2 ON
CW Recirculation Pump 1 & 2 ON
Command- Intermediate Signal

 Step-5
Condition- Intermediate Signal from Step 4
Turbine Speed > 15rpm
Condenser Pr. <0.85 kg/sq.cm
Command- Gland Steam Pr. Cont. in Auto

 Step-6
Condition- Gland Steam Pr. Cont. in Auto mode
Gland Steam Pr. > 200 mmwc
Gland Steam Pr. < 450 mmwc
Command- permissive to step 7

 Step-7
Condition- Condenser Pr. <0.12 kg/sq.cm
Generator Power > 5%
Permissive to step 6
Command- Intermediate Signal (for Vac. Pump off Cmd)

 Step-8
Condition- Permissive to step 7
Command- SLC Vacuum Pump ON.
 Step-9
Condition- SLC Vacuum Pump ON
Command- Start Wait Time

33
SGC –Evacuation Shut Down

Control Coordinator Shutdown ON.

 Step-1
Condition- Intermediate Signal from Step 4
Turbine Speed > 15rpm
Command- SLC VAC Pump OFF
SOL VLV IV Closed
VACC. Pump OFF
CW Recirculation Pump OFF
 Step-2
Condition- SLC VAC Pump OFF
SOL VLV IV Closed
VACC. Pump OFF
CW Recirculation Pump OFF
Command- Vacuum Breaker Open
 Step-3
Condition- Vacuum Breaker Open
Command- SLC Drains Open
Gland Stm. Pr. Cont. Manual Mode.
Gland Stm. Cont. Vlv Close.
 Step-4
Condition- SLC Drains Open
Gland Stm. Pr. Cont. Manual Mode.
Gland Stm. Cont. Vlv Close
Command- Nil
 Step-5
Condition- SLC Drains Open
Gland Stm. Pr. Cont. Manual Mode.
Gland Stm. Cont. Vlv Close
Command- Nil

Vacuum Pump:
Vacuum Pump Start Permissive
1) Separator Water level > 360 mm
2) Re-Circulation Pump ON

Vacuum Pump 1/2 Auto OFF Condition

1) Vacuum pump selected & Intermediate Signal (for Vac. Pump Off Cmd) from step 7
2) Cmd. From Control coordinate shut down

Vacuum Pump 1/2 Auto ON Condition

1) Cmd. From Control coordinate shut down (step 3)

2) Vac Pump SLC ON & Condenser Pr. >0.12 kg/sq.cm & SV of Vacuum Breaker closed.

34
Interlock of Vacuum Pump:

1) Inlet valve closes with vacuum pump tripping.

2) Separator tank make up valve auto open at tank level < 330mm and auto close at tank level > 360mm.
3) Generator Power >5% AND Cond. PR. >0.12 Kg/cm2- >Switch ON STBY /VAC
4) Generator Power >5% AND Cond. PR. >0.12 Kg/cm2- AND Vac. Pump ON Switch OFF STBY/VAC

CW Re-Circulation Pump 1/2 Auto OFF Condition

1) Vacuum pump selected & Intermediate Signal (for Vac. Pump Off Cmd) from step 7
2) Cmd. From Control coordinate shut down

CW Re-Circulation Pump 1/2 Auto ON Condition

1) Cmd. From Control coordinate step 3
2) Vac Pump SLC ON & Condenser Pr. >0.12 kg/sq.cm & SV of Vacuum Breaker closed.
3) Vac. Pump ON

HPBP SYSTEM

OIL SUPPLY PUMP FOR HP BYPASS:

1) Pump off: >160Kg/cm2

2) Pump on: <110Kg/cm2
3) Pressure too high >170 Kg/cm2
4) Pressure too low <90Kg/cm2

BY PASS PRIORITY CLOSE CONDITIONS:

1) Condenser vacuum low <0.6Kg/cm2

2) Selected Downstream temp signal V high > 370˚C

BD VALVE AUTO OPENS CONDTIONS:

1) BP Valve PI demand >2%

OR

2) BP-1 Or BP-2 Valve open >2%

35
BFP “A” Drive Start Permissive

BFP A shall be prohibited from starting till the following all conditions are satisfied:-
1) BFP A OFF F/B coming from MCC
2) Any Bearing temp. Not very high (< 90oC with2sec TD).
3) Motor winding temp. Not very high (< 125oCwith 2 sec TD).
4) BFP A Suction valve Opened.
5) Deaerator Level Normal.
6) BFP A Swgr. Available.
7) BFP A MTR Not operated.
8) Hyd Cup Tank Oil Lvl not Low.
9) Suc./Disch Temp. Diff. not > 10oC
10) Working Oil Temp. at CLR I/L not High (< 110oC)
11) Working Oil Temp. at CLR O/L not High (< 70oC)
12) Lube Oil Temp. at CLR I/L not High (< 65oC)
13) Lube Oil Temp. at CLR O/L not High (<55oC)
14) Lube oil pressure at Comn HDR OK (Lube oil pr. > 0.8 KG/Cm2).
15) BFP A Min Rec Valve (FC1) Opened.
16) BFP A Disch. Valve (FD4) Closed.
17) BFP A Disch. Integral Bypass Valve Closed.
18) BFP A Scoop position Minimum

BFP “A” Protection (Any one of the conditions)

1) BFP “A” any Vibration Very High ( > 18mm/s with 5 sec TD)
2) Motor Wind. Temp Very High ( > 130 Deg. C, 2/6 logic)
3) Motor Berg. Temp. Very High ( > 100 Deg. C)
4) BFP A ON & Suc. Flow <120 T/HR AND BFP A Suc/Dish Temp Diff >15 Deg(TD 5 Sec)
5) Deaerator Level Very Low ( 2/3 logic)
6) Working Oil temp at CLR I/L very high
7) Lube oil pressure at Comn HDR Very Low OR Lube oil Temp. at Clr O/L very High And BFP A ON f/b
from MCC.
8) BFP A Suction Valve not Opened.
9) BFP A Suc Press Very Low.
Different Settings of BFP

1) Lube Oil Temp at O/L From ClR Very High > 60oC
2) Lube Oil Pressure at Comn HDR Very High > 2.9 KG/CM2
3) Lube Oil Pressure at Comn HDR Very Low <0.5 KG/CM2
4) Working Oil Temp at I/L to ClR Very High >130oC
5) BFP A Vibration Very High > 18 mm/s
6) BFP A MTR Winding TEMP Very High >125Deg.C
7) BFP A MTR Bearing TEMP Very High >100Deg.C
8) BFP A HYD Bearing TEMP Very High >95Deg.C
36
CEP A Drive Start Permissive

CEP A shall be prohibited from starting till the following all conditions are satisfied:-
1) CEP A OFF F/B coming from MCC
2) CEP Thrust Bearing Metal temp. Not very high (< 90oC with2sec TD).
3) CEP MTR Bearing temp. Not very high (< 90oC with2sec TD).
4) Motor winding temp. Not very high 1of 6 (< 125oCwith 2 sec TD).
5) CEP A Suction valve Opened.
6) CEP A Discharge valve Opened OR CEP A Standby selected And Disch. Valve Opened.
7) CEP A Vent valve Opened.
8) Hotwell Level not Low.
9) CEP B ON OR CEP A Recirculation Valve 40% Open
10) CEP A Swgr. Available.
11) CEP A MTR Not operated.

CEP “A” Protection (Any one of the conditions)

1) Hotwell Level Very Low.

2) CEP A ON And Discharge Pressure Very Low < 16kg/ Cm2 with TD 5 Sec.
3) CEP A ON And Discharge Flow < 240 T/HR with TD 5 Sec
4) Motor Wind. Temp Very High ( > 130 Deg. C, 1/6 logic)
5) Motor Berg. Temp. Very High ( > 90 Deg. C)
6) Thrust Berg. Temp. Very High ( > 80 Deg. C)
7) CEP A Suction Valve not opened.
8) CEP A Electrical Trip (MTR).
9) CEP A Vibration Very High (18 mm/s, Alarm 11 m/s).

CEP Alarm & Trip setting

1) CEP Thrust Bearing Temp. Very High (1/6) >80oC

2) CEP Motor Bearing Temp. Very High )>90oC
3) CEP Discharge Header Press Low <18 KG/CM2
4) CEP Discharge Header Press Very Low <14 KG/CM2
5) CEP Motor Bearing Vibration Very High 11 mm/s
6) DP across Suction Strainer Very High 0.05 KG/Cm2.
7) CEP Winding temp High >110 oC

37
DMCW PUMP A Drive Start Permissive

DMCW Pump A shall be prohibited from starting till the following all conditions are satisfied:-

1) DMCW A OFF F/B coming from MCC

2) DMCW A Suction HDR Pressure adequate (1.8 Kg/ Cm2)
3) DMCW A Suction Valve opened.
4) DMCW A Discharge Valve Closed.
5) DMCW O.H Tank Level Adequate (1000mm).
6) DMCW A Swgr. Available.
7) DMCW A MTR Not operated.
DMCW Pump Trip Conditions

1) DMCW Pump Discharge Header Pr. Very High > KG/CM2 (6.82 kg/cm² Trip)
2) DMCW Pump Suction Header Very Pr. Low <(0.8 kg/cm2 Trip)
3) MTR Operated.
4) MCC Disturbed (EPB)-Trip.

DMCW Pump B Auto Start Conditions

1) DMCW Pump B Stand by Selected AND (2/3/4/5)

2) Pump C ON & Header Pr. Low and Pump A Not ON
OR
Pump A ON & Header Pr. Low
OR
Pump A Not ON & Pump C Tripped
OR
Pump A ON & Pump C ON And Pump C Tripped
DMCW Pump Alarm & Trip setting

1) DMCW Pump Discharge Header Pr. High > KG/CM2

2) DMCW Pump Discharge Header Pr. Very High > KG/CM2
3) DMCW Pump Discharge Header Pr. Low < KG/CM2
4) DMCW Pump Suction Header Pr. Low < KG/CM2
5) DMCW Pump Suction Header Very Pr. Low <
6) DMCW Pump Suction Header Pr. Adequate >
DMCW BOOSTER PUMP A Drive Start Permissive

1) DMCW Booster Pump A OFF F/B coming from MCC

2) DMCW Booster Pump A Suction HDR Pressure adequate
3) DMCW Booster Pump A Suction Valve opened.
4) DMCW Booster Pump A Discharge Valve Closed.
5) DMCW Booster Pump Discharge Header Pr. Not Very High.
6) DMCW A Swgr. Available.
7) DMCW A MTR Not operated.
 DMCW Booster pump tripped only from MCC disturbance.

38
Settings of DMCW Booster Pump

 DMCW BP’s Discharge Pr. Very High > 7.9 Kg/ cm2
 Discharge Pr. High > 7.77 Kg/ cm2
 Discharge Pr .Low > 7.23 Kg/ cm2
 Discharge Pr .Adqe. > 7.5 Kg/ cm2

ACW PUMP “A” Drive Start Permissive

ACW Pump A shall be prohibited from starting till the following all conditions are satisfied:-

1) ACW A OFF F/B coming from MCC

2) ACW A Suction HDR Pressure adequate
3) ACW A Suction Valve opened.
4) ACW A Discharge Valve Closed OR Standby selected.
5) ACW Pump MCC Not Disturbed.

ACW Pump Trip setting

 ACWP Suction Header Pr. Very Low < 1 KG/CM2 (2 Sec.)

 ACWP Discharge Header Pr. High > 4 KG/CM2 (2 Sec.)
 ACWP MCC Disturb.

ACW Pump Alarm & Trip setting

1) ACWP Suction Header Pr. Adeq. > 1.5 KG/CM2

2) ACWP Suction Header Pr. High > 2 KG/CM2
3) ACWP Suction Header Pr. Low < 1.2 KG/CM2, Very Low < 1 KG/CM2
4) ACWP Discharge Header Pr. Low < 2.5 KG/CM2, Discharge Header Pr. High > 4 KG/CM2

“Auto Start Conditions”

1) ACW Pump C Standby selected

AND
2) ACW Pump A ON Discharge HDR Pressure Low.
OR
3) ACW Pump B ON Discharge HDR Pressure Low.
OR
4) ACW Pump B Tripped.
OR
5) ACW Pump B Not ON & ACW Pump A Tripped.
OR
6) ACW Pump A & B ON & Pump A Tripped

39
LP BYPASS SYSTEM:

In certain operating conditions, the IP turbine can’t accommodate the system produced by the boiler,
The LP Bypass system enables to establish an alternate path for dumping this excess Steam from the Reheater
outlet directly into the Condenser at suitable steam parameters, Bypassing the LP & IP Turbine.

LPBP is a redundant digital system in which all the individual safety circuit for bypass proction are built
in. If any of the individual protection is relayed, the LPBP trip is released thereby closing the LPBP Stop & Control
Valves. For each LPBP Station, tripping criteria’s are separately determined. The LPBP Stop Valve is provided
with 2 Trip Solenoid Valve (TSV), which energized under normal condition and de-energized during protection
acted.

TRIPPING CONDITIONS OF LPBP

LPBP will automatically Tripped any of the following conditions

1) Condenser Wall Temp. Protection > 90deg. C (1/2 Logic)

2) LPBP Condenser Low Vacuum Protection: (6.6 Kg/ cm2
3) Condenser. Pr > 0.6 Kg/Cm2 (2/3 Tx. Value) & Pos. Set PT. LPBP Controller > -40%
4) LPBP Water Wall Flow Protection: The difference of Water Wall Injection Flow
And the LPBP 1 Flow is more than a set limit.
5) HPSU Emerg. OFF
6) Position Set Point LPBP Controller > - 40 %
7) LPBP Manual Tripped from UCB

LPBP- HPSU

The following functions & settings of HPSU:

1) With SLC ON, Both Pumps will start.

2) Stopping of the "stand- by pump" and charging valve when pressure comes up to 216 bar (Stand by
pump off").
3) Energizing of "stand- by pump" and charging valve, if pressure drops to 201 bar with main pump already
running.
4) Both pumps Switches off, if pressure too low longer than 2 minutes (<120 bar)
5) Energizing of main charging valve when pressure drops to 216 bar("P ACV ON").
6) De-energizing of main charging valve when pressure gets up to 240 bar ("P ACV off").
7) Automatic start of filter pump (recirculation pump) when one main pump is running at 120 bar.
8) Automatic stop of the main pumps if: level too low (170 l), temperature too high (>65 °C), pressure Very
high (>250 bar) .
9) Starting of cooling fan with temperature rising up to 55 °C and stopping with temperature dropping to
50°C.
10) Main Pumps changer will take place if Differential Pressure detected over filter high.
11) Recirculation pump changeover will take place if low flow after pump detected.
12) Standby pump will start, If running pump trips.
13) If SLC ON, oil temp 60 Deg C, second recirculation pump and cooling fan will start.
14) Recirculation unit pump will trip if Oil level too low 170mm.

40
LPBP HPSU INTERLOCKS

LPBP CF Pump Selection:

1) If Main Pump Disch. PR Low OR HPSU Header PR V.HIGH, then Pump Changeover on Fault will get
Activated.
2) One CF Pump will be running and other one will be in standby.
3) If Fire Protection acted or Emergency OFF PB is ON, then HPSU OFF will be there.

INTERLOCKING LOGICS:
HPSU HDR PR Too Low Signal Will be Generated if following conditions is Satisfied.

1) Control Fluid Pump-1 AND CF Pump-2 ON AND HPSU HDR PR =120 Kg/cm2(This signal is verified for 120
sec i.e. ON-Time Delay of 120 Sec. is given)

2) LPBP CFP Protection will act if:

 HPSU Tank Level <170mm OR CTRL. Fluid Temp. =65 C OR HDR PR.>240 Kg/cm2 Provided
HPSU Control is in AUTO.
ALARM: If Both Control Fluid Pumps are ON AND HPSU HDR PR.=120 Kg/cm2,HPSU HDR PR. too Low.

CW PUMP:

Operation philosophy for CW pump house.

The CW pump house has 11 nos. of Vertical turbine (CW) pumps (10 Working & 1 standbys catering to
the requirement 5 X 270 MW thermal power plants Circular Water System. CW Pumps are catering the
requirement of five unit’s circular water system. Each unit has generating capacity of 270 MW Power. The
configuration of pumps are- two pumps for each unit. And one standby pump as common for all five units.
Operation of the Pumps, all auxiliaries / drives and the discharge butterfly valves shall be possible from DCS
located in central control room. The logic of interlocks and permissive for the operation of main pumps and
associated butterfly valves will be performed from DCS through Remote IO panel in pump house control room,
and final “start” or “stop” command for motors & open or close command for valves shall be issued from DCS
through Remote IO panel in pump house control room to MCC / Switchgear panels Each pump set will be having
permission pump discharge valve “OPEN” & “CLOSE”.

Starting sequence for next CW pump (one CW pump

1) Starting of next CW Pump is to be prohibited for approximately 60 seconds (should be field settable &
to be decided during commissioning) from start of first CW pump.
2) Other sequence for starting of this pump will be same as that indicated in clause A above

Stopping sequence of CW pump will be as follows (Normal stop when no tripping condition is prevailing)

1) 100% close command shall be given to pump discharge BFV.

2) When BFV is closed up to 80 %,( limit switches provided) (settable at site) ‘STOP COMMAND’ shall be
given for CW motor.
3) Ensure BFV is 100 % close within specified time.

41
Start Permissive for CW pump.(following all conditions are to be satisfied:-

1) Discharge BFV is 100% closed.

2) Motor DE/NDE Bearing temperatures are not high (<85 Deg C).
3) Motor stator winding temperature is not high (<120 Deg C).
4) Pump thrust bearing temperature is not high (<100 Deg C).
5) Pump thrust bearing oil temperature is not high (<80 Deg C).
6) Pump reverse rotation is not detected.
7) CWP running feedback not available from HT panel.
8) Sump level is normal. = -1.4 M
9) Fore bay level normal. = -1.4 M
10) Switchgear not disturbed
11) TRIP Circuit Healthy (MTR)
12) Motor Vibration is Normal.(<80 Micron)
13) Pump Vibration is Normal.(<80 Micron)
14) Any of condenser paths is open (1 set of valve and corresponding outlet valve open).
15) The pumps set have not completed the Limit of (3 Cold starts per hour or 2 Hot starts per hour) –
(Manual, permissive).

Interlock

 After CW pump has started:

1) Command shall be given to open discharge BFV 100 % (BFV open command shall be given after receiving
the required pressure signal to PLC/DCS from PT at discharge of pump).
2) Motor space heater shall automatically switch off from switchgear (hard wire interlock).

CW Pump Protection (Any one of the conditions)

1) DE / NDE bearing temperature is very high (90 Deg C).

2) Motor stator winding temperature is very high (130 Deg C).
3) Pump thrust bearing temperature is very high (110 Deg C).
4) Pump thrust bearing oil temperature is very high (85 Deg C).
5) Sump water level is very low. -3M.
6) Emergency stop push button (Near motor) is operated. (Directly wired to MCC).
7) CW discharge pressure is very high for a sustained period of 60 seconds.(settable at Site)
8) Motor sustained vibrations are very high (100 micron).
9) Pump sustained vibration are very high (100 micron)
10) Any protection relay of motor is actuated.
11) Pump Reverse Rotation Detected.
12) During pump running if discharge BFV is close up to 80% (20 % open) (without any command received)
the pump shall trip.
13) After starting of CW pump if BFV discharge valve opening feedback (i.e. 20 % open) is not achieved
within specified time, the pump should be tripped. Under any of the above conditions, pump will be
tripped and close command will be given to BFV.

42
CW Pump Alarm & Trip Settings:

1) CW pump sump level low – 2.8M and very low-3M

2) CW Pump Fore Bay level low –2.8M and very low-3M.
3) CW pump reverse rotation detected.
4) CW pump motor NDE bearing temperature high (85 Deg C) & very high (90 Deg C).
5) CW pump motor DE bearing temperature high (85 Deg C) and very high (90Deg C).
6) CW pump motor winding temperature high (120 Deg C) and very high (130Deg C).
7) CW pump bearing temperature high (100 Deg C) and very high (110 Deg C).
8) Pump thrust bearing oil temperature high (80 Deg C) and very High (85 Deg C).
9) CW pump motor stop push button (Near motor ) is operated
10) BFV does not open fully (100 %) within pump/valve manufacturer’s recommended.

DOSING SYSTEM:
HYDRAZINE DOSING

Main Drive Pump Start Permissive

1) HYD. Dosing Duplex strainer DP normal (DP across strainer < 1KG/cm2)
2) HYD. Dosing MCC not disturbed
3) HYD.MIXING/STORAGE Tank Level not Low

Auto start Conditions of Stand-by Pumps

1) Main Pump running and Discharge HDR Pr. Low

2) Running Pump Tripped

HYD. MIXING/STIRRING DRIVE STARTS PERMISSIVE:

1) Mixing tank level not Low

2) Swgr. MCC not disturbed

Protection Trip: Tank Level Low

ALARMS:

 Hyd. Dosing Duplex Strainer chocked >1 Kg/cm2)

 Measuring tank Level Low (LVL<250mm)
 Measuring tank Level very Low (LVL<200mm)
 Measuring tank Level High (LVL>1100mm)
 Mixing Tank Level Low (LVL<300mm)
 Mixing Tank Level Very Low (LVL<200mm)
 Mixing Tank Level High (LVL>1100mm)
 DISCH. HDR PR. Low (PR<5Kg/cm2)
 DISCH. HDR PR. High (PR>50Kg/cm2)
43
AMMONIA DOSING;

AMMONIA DOSING MAIN DRIVE-START PERMISSIVE:

1) strainer DP normal (DP across strainer < 1KG/cm2)

2) Mixing tank level not Low (>250mm)
3) Swgr. MCC not disturbed

MIXING/STIRRING DRIVE STARTS PERMISSIVE:

1) Mixing tank level not Low

2) Swgr. MCC not disturbed

ALARMS:
 Ammonia Dosing Duplex Strainer chocked >1 Kg/cm2))
 Measuring tank Level Low (LVL<250mm)
 Measuring tank Level very Low (LVL<200mm)
 Measuring tank Level High (LVL>1100mm
 Mixing Tank Level Low (LVL<300mm)
 Mixing Tank Level Very Low (LVL<200mm)
 Mixing Tank Level High (LVL>1150mm)
 Disc. HDR. Pr. High( >50Kg/cm2)
 Disc. HDR PR. Low (<5Kg/cm2)

NaOH DOSING:

 All Permissive same as above

ALARMS:

 Na OH Dosing Duplex Strainer chocked >1 Kg/cm2)

 Mixing Tank Level Low (LVL<250mm)
 Mixing Tank Level Very Low (LVL<175mm)
 Mixing Tank Level High (LVL>1050mm)
 Disc. HDR PR. Low (<5Kg/cm2)
 Disc. HDR. Pr. High (>8.5Kg/cm2)

HP DOSING (PHOSPHATE DOSING)

DOSING PUMP START PERMISSIVE:
1) Measuring Tank Lvl. Adequate
2) Dosing Pump Suction valve opened
3) Swgr. MCC not disturbed

Preparation Tank Agitator Start Permissive:

1) Tank Lvl. Adeq.
2) Swgr. MCC not disturbed.

44
BI DIRECTIONAL VALVE PROTECTION AND INTERLOCKS
CRH EXT STM IV, EX-11(LBS40AA001)

OPEN PERMISSIVE:
1) Deaerator level should not be high.
2) Ext stm pr. to dea. >3.5 ata

CLOSE PERMISSIVE = 1

(i.e. permissive will always be there to close the drive)

PROTECTION CLOSE:

If Deaerator (Lvl = v. high) or (turbine trip), then command will go to close the drive.

MAIN STM STOP VLV RIGHT, MS-1(LBA10AA001)

OPEN PERMISSIVE:
MS line bypass valve-r, ms-3 should be open and MS bypass regulating valve should be open by>50%
then command will go to open the drive after verifying for 5 sec.(on time delay=5 sec.), till the drive gets
opened( s-r flip flop is reset after open feedback is There and command stops).

CLOSE PERMISSIVE =1(i.e. permissive will always be there to close the drive)

MS LINE BYP VLV-R, MS-3 LBA10AA002

Open command will go to open the valve if command open command is present for ms-1(ms stop valve-r)

CLOSE COMMAND:

1.5 sec pulse command will go to close the valve if opened feedback is available or ms-1 close command is there
(From ows)

ALARM: ms-1 closed and its IBV’s open (isolating bypass valve open) If ms stop valve, ms-1 closed feedback
present (with verification for 300 sec i.e. on time delay=300 sec AND ms-3 opened AND ms-5 opened.

MS LINE BYP REG VLV-R, MS-5 LBA10AA051

AUTO CLOSE COMMAND

MS STOP VALVE - R , MS -1 LBA10 AA001 OPENED

45
CRH EXT STM IV, EX-13

A UTO OPEN: PERMISSIVE:

1) HPH-6 FW I/L VLV FD-10 OPEN(LAB51AA001)

2) HPH-6 FW O/L VLV FD-12 OPEN (LAB52AA001)
3) HPH-6 FW BYP VLV FD-11 CLOSE(LAB53AA001)
Auto close protection:

HPH-6 LVL V. HIGH, LBQ60AA001 valve close after 1.5 sec. & open EX-101.

EX-6 O/L DRN VLV, EX-132

1) Auto open condition;

2) HPH -6 LVL V.high

(Same for EX-133 valve applicable)

HPH-6 FW I/L VLV FD-10

Open permissive:

HPH-6 FW I/L VLV IBV OPENED

Auto close condition;

HPH -6 level V. High

(Same for HPH-6 O/L VLV applicable)

HPH-6 FW I/L VLV IBV LAB51AA011

Auto close protection:

HPH-6 level v. high

Auto close command:

HPH -6 fw i/l iv,fd-10 opened

HPH-6 FW BYP VLV FD-11 LAB53AA001

AUTO OPEN PROTECTION COMMAND:

HPH-6 LEVEL V.HIGH

46
HPH-6 FW BYP IBV LAB53AA0

AUTO OPEN PROTECTION:

HPH-6 LEVEL V. HIGH.

AUTO CLOSE PROTECTION:

HPH-6 FW BYP VLV, FD-11 OPENED

HPH-5 EXT STM VLV, EX-12 LBQ50AA001

AUTO OPEN PERMISSIVE:

1) HPH-5 FW I/L ISO VLV FD-7 OPEN(LAB41AA001)

2) HPH-5 FW O/L ISOVLV FD-9 OPEN (LAB42AA001)
3) HPH-5 FW BYP VLV FD-8 CLOSE(LAB43AA001)

AUTO CLOSE:

HPH-5 LVL V. HIGH

EXT -8 O/L DRN VLV, EX-104(LBQ54AA001)/EX-7 O/L DRN VLV EX-106 LBQ53AA001

AUTO OPEN:

HPH-5 LVL V. HIGH

HPH-5 FW I/L ISO VLV FD-7(LAB41AA001)/HPH-5 FW O/L ISO VLV FD-9(LABV42AA001)

Open permissive:

HPH -5 fw i/l IV IBVopened

AUTO CLOSE:

HPH-5 LVL V. HIGH

HPH-5 FW I/L IV IBV VLV (LAB41AA011)/HPH-5 FW O/L IV IBV VLV (LABV42AA011)

PROTECTION CLOSE:

HPH-5 LVL V. HIGH

AUTO CLOSE CMD:

HPH-5 FW I/L ISO VLV FD-7(LAB41AA001) OPENED

47
HPH-5 FW BYP VLV FD-8 (LAB43AA001)

AUTO OPEN:

HPH-5 LVL V. HIGH

HPH-5 FW BYP IBV VLV FD-8 (LAB43AA011)

AUTO OPEN:

HPH-5 LVL V. HIGH

AUTO CLOSE:

HPH-5 FW BYP VLV FD-8 (LAB43AA001) OPENED

MAIN COND CV I/L VLV CD-13(LCA40AA001)

OPEN PERMISSIVE:

DEAERATOR LEVEL NOT HIGH

AUTO OPEN CMD:

MAIN CONDENSATE CV>2%OPEN

Close protection:

Deaerator level very high

AUTO CLOSE CMD:

MAIN CONDENSATE CV<2%OPEN

MAIN COND CV I/V VLV CD-83(LCA41AA001)

OPEN PERMISSIVE:

DEAERATOR LEVEL NOT HIGH

AUTO OPEN CMD:

MAIN CONDENSATE BYP CV>2%OPEN

Close protection:

deaerator level very high

AUTO CLOSE CMD:

MAIN CONDENSATE BYP CV<2%OPEN

48
DIRTY OIL TRANSFER PUMP -1, CLEAN OIL TRANSFER PUMP-1

AUTO OFF CMD:

Dirty oil tank level low (level switch)

CRH NRV & LINE DRN CRH-101(LBC12AA001)

AUTO OPEN CMD:

CRH STEAM DRN POT LEVEL HIGH AND CRH STEAM DRN POT LEVEL V. HIGH

EX-1 O/L DRN VLV EX-127 (LBS 24AA001)/EX-2 O/L DRN VLV EX-128 (LBS 23AA001)

AUTO OPEN CMD:

LPH-2 LEVEL V.HIGH

LPH-3 EX STEAM IV EX-10(LBS31AA001)

OPEN PEMISSIVE:

1) LPH-3 COND I/L VLV CD-35 OPEN 2. LPH-3 COND O/L VLE CD-36OPEN
2) LPH-3 COND BYPASS REG VLV CD-37 CLOSE
AUTO CLOSE CMD:

LPH-3 LVL V HIGH.

EX-4 O/L DRN VLV EX-126 LBS33AA001/EX-3 O/L DRN VLV ,EX-125(LBS34AA001)

AUTO open cmd:

LPH-3 level v high.

LPH-3 I/L VLV, CD-35 (LCA60 AA002)/LPH-3 O/L VLV, CD-36(LCA70AA001)

AUTO close cmd:

LPH-3 level v high.

LPH-2 EX STEAM IV EX-9(LBS 21AA001)

OPEN PERMISSIVE

1) LPH-2 COND I/L VALVE CD-32 OPEN

2) LPH-2 COND O/L VALVE CD-33OPEN
3) LPH-2 COND BYPASS REG VALVE CD-34 CLOSE
AUTO CLOSE CMD

LPH-2 LEVEL V.HIGH.

49
LPH-3 BYPASS REG VLV CD-37(LCA61AA051)

AUTO OPEN CMD:

LPH-3 level v. high

LPH-2 I/L VLV CD-32(LCA50AA002)/LPH-2 O/L VLV CD-33(LCA60AA001)

AUTO CLOSE CMD

LPH-2 LEVEL V. HIGH.

LPH-2 BP REG VLV CD0-34 (LCA51 AA051)

AUTO OPEN CMD:

LPH-2 level v. high

LPH-1 O/L VLV CD-30(LCA50AA001)/DRN COOLER I/L VL CD-29 (LCA40AA002)

AUTO CLOSE CMD

LPH-1 LEVEL V. HIGH.

LPH-1 AND DC BP REG VLV CD-31(LCA42AA051)

AUTO OPEN CMD:

LPH-1 level v. high

LPH-1 EX STEAM I/L EX-17 (LBS 11 AA001)/LPH-1 BP EXT STEAM I/L EX-18(LBS 11 AA002)

AUTO CLOSE CMD:

LPH-1 LEVEL V. HIGH.

APRDS Control Scheme

HC PRDS CV I/L ISO, AS-9(LBG10 AA001)

OPEN PEMISSIVE:
1) HC PRDS CV IL IBV OPEN
2) CEP DISCH PR OK.
3) MCC NOT DISTURBS.
4) SPRAY WATER PRESS>THRESHOLD

AUTO OPEN: .MS TO APRDS PR CV AS10>2% AND MS TO APRDS PR CV IN AUTO

AUTO CLOSE: MS TO APRDS PR CV AS10 <2% OPEN OR MS PR TO APRDS<15 KG/CM2

50
HC PRDS CV I/L IBV (LBG10 AA002)

AUTO OPEN:
MS TO APRDS pr cv as10 >2% open.

AUTO CLOSE:

1. HC PRDS cv il iso as9 open

2. MS TO APRDS pr cv as10 <2% open.

HC PRDS CV I/L ISO AS34(LBG 11AA001)

AUTO OPEN:

HC APRDS BP iso ibv open and ms to aprds pr cv as35>2% open

AUTO CLOSE:

1. MS TO APRDS pr cv as35 <2%open

2. MS PR TO APRDS <15 kg/cm2.

HC PRDS CV I/L IBV (LBG11AA011)

AUTO OPEN:

MS TO APRDS pr cv as35>2% open.

AUTO CLOSE:

1. MS PR TO APRDS <15 kg/cm2

2. MS TO APRDS pr cv as35<2% open.

LT PRDS CV I/L ISO AS15 (LBG20AA001)

AUTO OPEN:
CRH TO APRDS pr cv as16>2% open and crh to aprds pr cv as16 in auto and spray water pr.>threshold.

AUTO CLOSE:

CRH TO APRDS PR CV AS16>2% open or CRH to APRDS PR <15 kg/cm2.

HC APRDS SRPY IV CD-64(LAF20AA001)

AUTO OPEN:

APRDS SPR cv cd65 in auto and APRDS spray cv, cd-65 >2% open auto close:APRDS spray cv cd65 <2%open.

51
APRDS SPR CV BP REG CD67 (LAF21AA051)

OPEN PERMISSIVE:

HC APRDS spry cv cd 65 not in auto

LC PRDS SPR ISO CD 69(LAF30AA001)

AUTO OPEN:

APRDS spray CV, CD-70>2% open AND lc aprds spr cv cd70 in auto.

AUTO CLOSE:

APRDS SPRAY CV, CD-70 <2% open.

LT APRDS SPR CV BP REG CD-72(LAF31AA051)

OPEN PERMISSIVE:

LT APRDS spry CV, CD- 70 not in auto mode.

HT AS HDR TO LT HDR VLV,AS 23(LBG31AA001)

OPEN PERMISSIVE:

APRDS hi temp hdr pr high.

CLOSE PERMISSIVE:

APRDS low temp hdr temp v.high.

COLTCS (CONDENSER ON LINE TUBE CLEANING SYSTEM)

Remote (DCS) mode of operation. Remote mode has facility of both manual and Sequence mode as defined
below.

 Manual Mode.
 Sequence Mode

Manual Mode

The system can be operated activating individual drives from OWS, if sequences mode is kept OFF. This
mode is used predominantly for testing & commissioning purposes only.

52
Note: Please note down there will be no interlocking of equipments in manual mode except for ball recirculation
pump and any equipment can be operated at any stage. Ball recirculation pump can be started if CW flows
through condenser is available.

Sequence Mode

Sequence mode in envisaged for ball injection cycle startup I shutdown and normal backwash.

Permissive for Sequence mode operation for Ball injection cycle startup:

 BALL RECIRCULATING PUMP should be in OFF position.

 BALL COLLECTOR must be in COLLECTION position.
 All manually operated valves (BV-01, 02, 03, 04, 05, 06, 07, 08) should be in the OPEN position. Ball
Vessel vent and drain valves (BV-17, 18, 19) should be in CLOSE position. This is to be ensured by
operator.
 Minimum one number CW pump should be ON and CW flow through condenser is available.
 Selector switch in SWGR panel should be in 'DCS' position.
 All electrical drives should be healthy i.e. no electrical disturbance.

OPERATION IN SEQUENCE MODE FOR BALL INJECTION:

Following operation are performed automatically in steps:

1) Ball Separator screen actuator goes from backwash position to operation position.

2) Ball Recirculation pump starts.

3) Ball Collector will go from collection mode to operation mode.

4) Ball Collector remains in operation mode for 60 mins (adjustable). After completion of 60 mins
(adjustable), Ball Collector will go to collection mode and will remain in collection mode for 60 min
(adjustable). After completion of 60 mins (adjustable), Ball Collector will go to operation mode. This
sequence will continue for 24 hrs.

5) Ball oversize monitor starts for each 60 mins (adjustable) interval, whenever Ball Collector actuator is in
collection position.

6) Ball Recirculation monitor starts for 10 mins (adjustable) interval, whenever Ball Collector actuator is in
operation position.

7) System shall be in operation for 24 hour before operator performs backwash Operation.

53
SHUT .DOWN SEQUENCE

Ball collector will go from operation mode to collection mode.

1) After 60 mins (adjustable) when all Balls are collected, ball recirculation pump stops.
2) During Normal injection cycle, if selector switch position on switchgear panel is changed from DCS to Local,
Then System will automatically go to the Shut down cycle.
3) During normal injection cycle, if ball over size monitor gives 'over size ball count short' alarm, then system
will automatically go to the shut down cycle.

LOW PRESSURE HEATER INTERLOCKS

LP Heaters no. 1, 2 & 3 get the heating steam from the LP turbine. Hydraulically operated non-return
valves are provided in extraction lines of LP heaters no. 2 & 3 to prevent the back flow of steam into the Turbine
during a trip. These valves are controlled from ATRS. Motorized Block valves are also provided in extraction lines
for LPH-2 & 3.

LP HEATER-3:
1) 'LOW LEVEL' in LPH-3 is annunciated in the control room. 'NORMAL LEVEL' in LPH-3 is maintained by
Cascading the drain to LPH-2 through control valve DR-19
2) 'HIGH LEVEL' in LPH-3 is annunciated in the control room and this level is controlled by diverting the
drain to LP Drain flash tank through control valve DR-22.
3) When the high level control is in operation to open alternate drain to condenser, the normal drain
control valve DR-19 will also remain open unless it has been closed from the interlocks of LPH-2.
4) ‘HIGH HIGH LEVEL' in LPH-3 is annunciated in the control room and the following interlock actions are
initiated simultaneously:
 Extraction steam line block valve EX-10 closes
 Motorized drain valves EX-125 & EX-126 on the extraction line open
 Repeat command given to alternate drain line control valve DR-22 to open fully
 QCNRV in extraction line EX-3 is closed through ATRS
 The heater is bypassed on condensate side automatically by opening bypass valve CD-37 and closing the
isolating Valves CD-35 & CD-36

 The normal drain control valve DR-19 is released to auto control only after the LPH-2 has been charged
on steam side and there is no 'HIGH. HIGH LEVEL' in LPH-2. The control shall be put in auto mode by the
operator.

LP HEATER-2:
1) 'LOW LEVEL' in LPH -2 is annunciated in the control room.
2) 'NORMAL LEVEL' in LPH-2 is maintained by cascading the drains to LPH-1through control valve DR-25.
3) 'HIGH LEVEL' in LPH-2 is annunciated in the control room and this level is controlled by diverting the
drain to LP Drain flash tank through control valve DR-28.
4) When the high level control is in operation to open alternate drain to condenser, the normal drain
control valve DR-25 will also remain open unless it has been closed from the interlocks of LPH-1.
5) HIGH HIGH LEVEL' in LPH-2 is annunciated in the control room and the following interlock actions are
initiated simultaneously:
54
  Extraction steam line block valve EX-9 closes
 Motorized drain valves EX-127 & EX-128 on the extraction line open
 Normal drain control valve DR-19 from LPH-3 to LPH-2 closes
 Repeat command given to alternate drain line control valve DR-28 to open fully
 QCNRV in extraction line EX-1 is closed through ATRS
 The heater is bypassed on condensate side automatically by opening bypass valve CD-34 and closing the
isolating Valves CD-32 & CD-33

 The normal drain control valve DR-25 is released to auto control only after the LPH-1 has been charged
on steam Side and there is no 'HIGH, HIGH LEVEL' in LPH-1. The control shall be put in auto mode by the
operator.

LP HEATER-1:

 No level is maintained in the LPH-1. The LPH-1 drain is led to the drain cooler through a siphon loop and
finally to condenser through LP drain flash tank.
 'HIGH LEVEL' in LPH-1 is annunciated in the control room.
 ‘HIGH HIGH LEVEL' in LPH-1 is annunciated in the control room and The following interlock actions are
initiated simultaneously:
1) Normal drain control valve DR-25 from LPH-2 to LPH-1 closes
2) The heater is bypassed on condensate side automatically by opening bypass valve CD-31 and closing the
isolating valves CD-29 & CD-30

OPERATION PH:
1) LP heaters 1, 2 & 3 are brought into service on steam side immediately after synchronization of unit. LP
heaters are properly charged from water side before charging it from steam side by opening heater
vent and expelling the Air out of the heater.

2) During the start up mode until the LP heaters are charged the motorized drain valves on the extraction
lines shall
Be kept open. These drain valves shall be manually closed after the heaters are put in service.

Level / Set Points LPH-1 LPH-2 LPH-3

Very high level -520 -140 -140
High level -535 -440 -375
Normal level -560 -525 -460
Low level -565 -610 -545

55
HIGH PRESSURE HEATER INTERLOCKS

HP Heater no. 5 GETS the heating steam from the IP turbine. Hydraulically operated non-return valve is
provided in extraction line to HPH-5 controlled from ATRS. HP HEATER no. 6 GETS the heating steam from the
CRH line. Pneumatically operated non-return valve is provided in extraction line to HPH-6. Motorized block valve
are also provided in extraction lines for HPH-5 & HPH-6.

HP HEATER-6:
1) 'LOW LEVEL' in HPH-6 is annunciated in the control room.
2) 'NORMAL LEVEL in HPH-6 is maintained by cascading the drain to HPH-5 through control valve DR-2 and
to Deaerator through control valve DR-6. The control valves DR-2 & DR-6 operate in split rang Mode in
such a way that in the initial phase of control range, DR-2 operates and in subsequent phase of control
Range, DR-6 operates.
3) 'HIGH LEVEL' in HPH-6 is annunciated in the control room and this level is controlled by diverting the
drain to condenser via HP drain flash tank through control valve DR-9.
4) When the high level control is in operation to open alternate drain to Condenser, the normal drain
control valve DR-2 will also remain open unless it has been closed from the interlocks of HPH-5.
5) In case the extraction pressure at HPH-5 is below a preset value (Adjustable), the drain control valve DR-
2 shall close automatically. When the extraction pressure is above a preset value, the drain control valve
DR-2 shall modulate under automatic operation.
6) 'HIGH HIGH LEVEL' in HPH-6 is annunciated in the control room and Following interlock actions are
initiated simultaneously:
 Extraction steam line block valve EX-13 closes
 Motorized drain valves EX-132 & EX-133 in the extraction line opens.
 Repeat command given to alternate drain valve DR-9 and Normal drain valves DR-2/DR-6 to open fully.
 Heater is bypassed on the feed water side by opening bypass valve FD-11 and closing isolating valves FD-
10 & FD-12. When Deaerator level reaches ‘’HIGH HIGH LEVEL', the HPH-6 drain control valve DR-6 to
Deaerator shall close automatically

HP HEATER-5:

1) 'LOW LEVEL' in HPH-5 is annunciated in the control room

2) 'NORMAL LEVEL' in HPH-5 is maintained by cascading the drain to Deaerator through Control valve
DR-13.
3) 'HIGH LEVEL' in HPH-5 is annunciated in the control room and this level is controlled by diverting the
drain to condenser via HP Drain flash Tank through control valve DR-16.
4) When the high level control comes into operation to open alternate drain to condenser, the normal
drain control Valve DR-13 will also remain open.
5) V HIGH LEVEL in HPH-5 is annunciated in the control room and Following interlock actions are initiated
simultaneously:
 Extraction steam line block valve EX-12 closes.
 Motorized drain valves EX-104 & EX-106 in the extraction line Open.
 Repeat command given to alternate drain control valve DR-16 and normal drain control valve DR-13 to
open fully
 QCNRV in extraction line EX-7 is closed through ATRS
56
  Normal drain control valve DR-2 from HPH-6 to HPH-5 closes
 Heater is bypassed on feed water side by opening bypass valve FD-8 and closing isolating valves FD-7 &
FD-9. In case pressure in HPH-5 falls below a preset value, an overriding command is given to close the
control valve DR-2 in the drain from HPH-6 to HPH-5. When the Deaerator level reaches ‘’HIGH HIGH
LEVEL', the HPH-5 drain control valve DR-13 to Deaerator shall close automatically

CO2 FLASH VAPOUR EVAPORATOR

AUTO ON:

Temp. Of CO2 EVAPORATOR <145 *DEG AND SLC ON

NOTE:-THIS SLC TO BE SWITCHED ON ONLY WHEN H2 PURGING /CO2 FILLING IS REQUIRED FOR
GENERATOR.

AUTO OFF:

Temp. OF CO2 EVAPORATOR >150*DEG

SEAL OIL VACCUM PUMP-1

AUTO START:

1) Seal Oil Pump-1 ON OR Seal Oil Pump -2 ON AND Seal Oil Vacuum Pump 2 OFF AND Seal Oil Vacuum
Pump -2 MCC DIST.
2) Seal Oil Pump-1 ON OR Seal Oil Pump -2 ON AND Seal Oil Vacuum Pump -1 Selection.
3) Seal Oil Pump -1 ON OR Seal Oil Pump -2 ON AND Seal Oil Vacuum Pump -1 Selection.
AND
Pressure at Seal Oil Vacuum Tank >-0.4 KG/CM2
AUTO STOP
PR at Seal Oil Vacuum Tank <-0.65 KG/CM2
STOP PERMISSIVE

1) PR. at Seal Oil VAC Tank <-0.4 KG/CM2

2) Seal Oil Vacuum Pump -2 ON
3) SLC Seal Oil Pump OFF.

SEAL OIL VACCUM PUMP-2

AUTO START:

1) Seal Oil Pump-1 ON OR Seal Oil Pump -2 ON AND Seal Oil Vacuum Pump 1 OFF AND Seal Oil Vacuum
Pump -1 MCC DIST.
2) Seal Oil Pump -1 ON OR Seal Oil Pump -2 ON AND Seal Oil Vacuum Pump -2 Selection.
3) Seal Oil Pump -1 ON OR Seal Oil Pump -2 ON AND Seal Oil Vacuum Pump -2 Selection AND PR at Seal Oil
Vacuum Tank >-0.4 KG/CM2

57
AUTOSTOP

PR at Seal Oil Vacuum Tank <-0.65 KG/CM2

STOP PERMISSIVE

1) PR at Seal Oil Vacuum Tank <-0.4 KG/CM2

2) Seal Oil Vacuum Pump -1 ON
3) SLC Seal Oil Pump OFF.

MAIN EXCITER:
Dry air blower (MKC75AT001)

AUTO ON:

Dry air blower SLC ON AND TURBINE speed <210 rpm.

AUTO OFF:

Exciter shut down heater off AND Turbine speed>240 rpm.

Off permissive:

Ex shut down heater off

EXCITER SHUT DOWN HEATER:

Permissive:

Dry air blower ON

AUTO ON (Following all conditions):

 Cold air temp of exciter <40 DegC.

 Turbine speed <210 DegC
 Generator air dryer on.
 Exciter shut down heater SLC on
Protection off:

Dry air blower off OR cold air temp of exciter >90* c.

Auto off (Following all conditions):

 SLC off AND turbine speed <210 rpm

 Exciter Shutdown Heater slc off
 Cold Air Temp. Of Main Exciter >50 Deg C OR turbine speed >240 rpm.

58
SELF CLEANING STAINER

1) Initial condition
 ACW ‘ON’ feedback should be available.
 No ‘Fail’ indication should be available.
 Debris Discharge valve should be in ‘Closed’ position.
 Geared motor should be ‘Off’.
2) Manual Operation
 Debris Discharge valve ‘Open/Closed’.
 Geared motor ‘On/Off’.
3) Auto Operation (Timer mode)
 Check whether the initial conditions are satisfied.
 Press ’Auto Start’ in DCS.
 “Debris Discharge valve” will ’Open’.
 Once the debris discharge valve is ‘Opens’, Geared motor drive is switched ‘On’.
 Flushing timer picks up for 3 minutes.
 Geared motor drive is switched ‘Off’.
 Debris Discharge valve will be ‘Closed’.
 System cycle timer 4 hours is energized.
 Once the system cycle timer is elapsed the flushing operation will again start.
4) SCS operation in DP mode(Set point1)

This operation will take place when the DP across the strainer exceeds 110 mbar. DP high sequence lead
timer will energize for 30 secs. After 30 secs if DP is still above 110 mbar, then following sequence:

 DP high indication will be illuminated.

 “Debris Discharge valve” will ’Open’.
 Geared motor drive is switched ‘On’.
 Flushing timer picks up for 3 minutes.
 On elapsed of flushing timer,”Geared motor drive” is switched ‘off’.
 “Debris Discharge valve” will be ’closed’.
If DP is still above 110 mbar after flushing the following sequence will commence:
 “Debris Discharge valve” will ’Open’.
 Geared motor drive is switched ‘On’.
 DP fails timer picks up for 10 minutes.
 On elapsed of flushing timer, “Geared motor drive” is switched ‘off’.
 “Debris Discharge valve” will be ’closed’.
Now if DP is less than 160 mbar system cycle timer will reset & fresh timer starts. If DP still above
110 mbar then flushing operation continues:
 Check & clean manually message will be displayed.

5) SCS Operation in DP mode (set point 2)

 This operation will take place when the DP across the strainer exceeds 160 mbar.
DP high sequence lead timer will energize for 30 secs. After 30 secs if DP is still above 160
mbar, then following sequence will commence:
 DP high indication will be illuminated.
 “Debris Discharge valve” will ’Open’.
59
 Geared motor drive is switched ‘On’.
 Now manual intervention is required to stop flushing.
 Press geared motor ‘Stop’.
 Press Debris Discharge valve ‘close’.
 Manually check & clean the strainer.
 System Automatic stop operation
If during flushing cycle auto stop is pressed, the following sequence is placed:

 Geared motor drive will be switched ‘Off’.

 “Debris Discharge valve” will be ’closed’.
 The system will now go to stop mode & the system cycle of 4 hrs will not energize.

60
 OVERVIEW OF C&I SYSTEMS FOR AMRAVATI TPP (5 X 270 MW)

Sr.
AREA SYSTEM MADE MODEL
NO
BHEL
1 MAIN PLANT - BTG DCS maxDNA - 4F
(METSO)
2 WATER TRAETMENT PLANT (WTP) PLC ROCKWELL ControlLogix-5000

3 EFFULENT TREATMENT PLANT (ETP) PLC ROCKWELL ControlLogix-5000

4 COAL HANDLING PLANT (CHP) PLC SIEMENS S7400H

5 WAGON TIPLLER (WT) PLC SIEMENS S7400H
6 ASH HANDLING SYSTEM (AHS) PLC SIEMENS S7400H

7 MILL REJECT SYSTEM (MRS) PLC SIEMENS S7400H

8 RAW WATER PUMP HOUSE (RWPH) PLC ROCKWELL ControlLogix-5000

FUEL OIL HANDLING SYSTEM

9 PLC SIEMENS S7400H
( UNLOADING & STORAGE)

HEAT VENTILATION AND AIR

10 PLC SIEMENS S7400H
CONDITIONING (HVAC)

11 CMPRESSED AIR SYSTEM ( CAS ) PLC SIEMENS S7400H

FIRE PROTECTION & DETECTION
12 PLC SIEMENS S7400H
SYSTEM ( FP&DS )
13 HYDROGEN GENERATION PLANT (HGP) PLC SIEMENS S7400H
14 COOLING TOWER ( CT ) PLC ROCKWELL ControlLogix-5000
15 MISC. INSTRUMENTS SIEMENS
16 FIELD INSTRUMENTS SIEMENS
17 AAQMS SIEMENS
18 MERCURY ANALYSER SIEMENS
GE & FB
19 VMS for BOP'S (GE)
(SHINKAWA)
20 CW PUMP KBL
21 MISC.PUMPS KBL

61
 Indiabulls Power Ltd.

Address: Indiabulls Power Limited, Plot no. D-2 & D-2 (PART) at Additional Industrial area, Nandgaon peth,

Amravati – 444901 (Maharashtra)

www.indiabulls.com/power

62