Power from knowledge

Interlock & Protection

Handbook
WPCL, Warora

KSK Energy Ventures Ltd (4 X 135 MW)

INDEX

Sr.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Description
Interlock & Protection of Boiler
Interlock & Protection of ID fan system
Interlock & Protection of FD fan system
Interlock & Protection of APH system
Interlock & Protection of PA fan system
Interlock & Protection of Coal Pulveriser
Interlock & Protection of Coal Feeder
Interlock & Protection of Seal Air Fan
Interlock & Protection of Scanner Air Fan
Interlock of Boiler
Interlock & Protection of FSSS
Interlock test checklist of steam and water
system
Interlock test checklist of fuel oil system
Interlock & Protection of Turbine
Condensate Extraction Pump (CEP)
Circulating water system
Boiler Feed Pump Interlock & Protection
Vacuum system
Lube oil system & EH oil system
Deaerator,HPH & LPH system
Main steam and drainage system
Bypass system

Page
no.
3
4
7
9
13
15
21
22
23
24
25
28
30
37
38
40
42
45
46
47
50
53
2

23

Turbine

54

Power from knowledge

Boiler& Auxiliaries
Interlock & Protection
WPCL, Warora

KSK Energy Ventures Ltd (4 X 135 MW)

Interlock & Protection of ID fan system

Start permissive
Front and rear fan bearing temperature normal (<80c).
Front and rear motor bearing temperature normal (<95c).
Motor coil temperature is normal (<120c).
Scoop tube position is low (<5%).
Inlet vane position is low (<5%).
Inlet and outlet damper has been closed.
Bearing temperature of coupler is normal (<85c).
No protection tripped condition.
Corresponding APH is running.
Corresponding side channel condition of flue gas and air system is satisfied.
Outlet secondary air damper Of Corresponding side APH has been opened.
Inlet and Outlet flue gas damper Of Corresponding side APH has been opened.
Inlet and Outlet flue gas damper Of Corresponding side IDF has been opened; Inlet vane has not been opened.
Outlet second air damper Of B side FDF has been opened and inlet vane has not been closed.
Furnace All second vane has been opened (80%damper opening position are more than 80%).
Fuel gas by-pass damper all opened.
Protections

Front or rear fan bearing temperature is very high, delay 2 sec (>90c).
Front or rear motor bearing temperature is very high, delay 2 sec (>105c).
Motor coil temperature is very high (<135c).
Corresponding side APH (both main motor & DC motor) stopped, delay 300 sec.
Accident button action.
Outlet damper closed and ID fan running, delay 5 sec.
Outlet flue gas damper has been closed when IDF startup, time delay 60 seconds.
Front bearing (x direction) vibration is very high, time delay 5 seconds (7.1mm/s).
4

Front bearing (y direction) vibration is very high, time delay 5 seconds (7.1mm/s).
Rear bearing (x direction) vibration is very high, time delay 5 seconds (7.1mm/s).
Rear bearing (y direction) vibration is very high, time delay 5 second (7.1mm/s).
Inlet oil pressure of coupler is very low, after IDF is running, time delay 10 seconds (<0.05MPa).
Inlet oil pressure of coupler is very low, when IDF startup, time delay 30 seconds (<0.035MPa).
Inlet oil temperature of coupler is very high, time 5s (>85c).
Outlet oil temperature of coupler is very high, time delay 5 seconds (>95c).
Bearing temperature of coupler is very high, time delay 5 seconds (>95c).
Furnace pressure is low-low (2of3), time delay 25 seconds (-1470Pa).
Furnace pressure is high-high (2of3), time delay 25 seconds (+1470Pa).

ID Fan inlet electric damper

Permission conditions of closing
ID fan stopped
Interlock conditions of opening
ID fan started, time delay 10sec open damper.
All IDF and FDF has been stopped, open damper, time delay 5 minutes (from asking for free ventilation)
Interlock conditions of closing
This side IDF trip and the other side IDF is running, close damper.
IDF outlet electric damper
Permission conditions of closing
IDF stopped.
Interlock conditions of opening
This side IDF startup, time delay 10 seconds , open damper.
all IDF and FDF have been stopped, open damper, time delay 5 minutes(from asking for free ventilation)
Interlock conditions of closing

This side IDF trip and the other side IDF is running, close damper

IDF inlet control damper (IGV)

Interlock conditions of opening

All IDF and FDF have been stopped, open damper, time delay 5 minutes(from asking for free ventilation)

Interlock conditions of closing

This side IDF trip and the other side IDF is running, close damper
IDF scoop tube
Interlock condition of closing
This side IDF trip, close scoop tube.
Sequence start procedures

Place Scoop tube position at minimum.

Place inlet vane position at minimum
Close inlet flue gas damper
Close outlet flue gas damper
Start IDF motor
Delay 10 second, open outlet/inlet electric damper
Release inlet vane

Sequence stop procedure

Place Scoop tube position at minimum

Place inlet vane position at minimum
Close inlet flue gas damper
Stop IDF motor
Close outlet flue gas damper

Interlock & Protection of FD fan system

Start permissive

Outlet damper has been closed, FDF

Inlet vane position is at minimum, FDF <5%
This side IDF is running
This side APH is running
Front and rear bearing temperature is normal, ,FDF (<75C)
Front and rear motor bearing temperature is normal, FDF (<80C)
Motor coil temperature is normal, FDF (<120C)
No protection trip conditions, FDF

Protection

Front / rear bearing temperature is very high, delay 2 seconds (>90C)

Front / rear motor bearing temperature is very high, delay 2 seconds (>105C)
Motor coil temperature is very high, delay 2 seconds (>135C)
Bearing vibration is very high (x direction),delay 2 seconds (>7.1mm/s)
Bearing vibration is very high (y direction),delay 2 seconds (>7.1mm/s)
Motor Bearing vibration is very high (x direction),delay 2 seconds (>7.1mm/s)
Motor Bearing vibration is very high (y direction),delay 2 seconds (>7.1mm/s)
This side APH stopped ,delay 300 seconds
This side IDF stopped after IDF is running
Two IDF stopped after two IDF are running
Accident button action
Furnace pressure is high-high(2 of 3) ,delay 2 second (1470PA)
7

Outlet shut-off damper closed after FDF is running, delay 5 second

Outlet shut-off damper not opened when FDF startup, delay 20 seconds

FDF outlet electric damper

Permission condition of closing

This side FDF stopped

Interlock conditions of opening

After this side FDF startup, delay 10 seconds open damper

all IDF and FDF have been stopped, open damper, time delay 5 minutes (from asking for free ventilation)

Interlock close conditions

This side FDF tripped and the other FDF is running, close damper

FDF inlet vane

Interlock conditions of opening (or)

Asking for free ventilation ,delay 5 minutes, open damper

Interlock conditions of closing (or)

This side FDF trip and the other side FDF is running, close damper

Sequence start procedures

8

Close outlet damper

Place inlet vane at minimum position
Start FDF motor
Open outlet damper
Release inlet vane

Sequence stop procedures

Place inlet vane at minimum position

Stop FDF motor
Close outlet damper
Release inlet vane

Interlock & Protection of APH system

Start permissive conditions of main driving motor

No fault of main driving motor

No fault of clearance adjustment
No fault of fire alarm
No fault of oil station
Guide bearing oil station has been started(intrain)
Support bearing oil station has been started (intrain)
Auxiliary driving motor stopped
Remote state of main motor
Main driving motor stopped operation
Outlet second air damper closed
Outlet/inlet primary air damper closed
9

Inlet flue gas damper closed

Outlet flue gas damper closed

Stop permissive conditions of main driving motor

Inlet flue gas temperature<150C

IDF and FDF of this side stopped

Trip conditions of main driving motor

Main driving motor fault
Accident button action
Startup permissive conditions of auxiliary driving motor

Auxiliary driving motor stopped

Remote state of auxiliary driving motor
No fault of auxiliary driving motor
No fault of auxiliary driving motor fan
Main motor stopped

Stop permissive conditions of auxiliary driving motor

Inlet flue gas temperature<150C

IDF AND FDF of this side stopped

Trip conditions of auxiliary driving motor

Fault of auxiliary driving motor

Accident button action

10

Interlock test of main driving motor and auxiliary driving motor

Auxiliary motor starts, if main motor tripped

After running, in manner of interlock

Interlock of air pre-heater and inlet flue gas damper

Interlock conditions of opening

Ask for free ventilation, time delay 5 minutes, open damper

Interlock conditions of closing

APH (main motor and aux. motor) of this side stopped

And no asking for free ventilation, delay 300sec

Interlock of air pre-heater and outlet flue gas damper

Interlock conditions of opening

Ask for free ventilation time delay 5 minutes, open damper

Interlock conditions of closing

APH (main motor and AUX. motor) stopped and no asking for free
Ventilation, delay 300 second, close damper

11

Interlock of air pre-heater and outlet secondary air damper

Interlock conditions of opening

Ask for free ventilation time delay 5 minutes, open damper

Interlock conditions of closing

APH (main motor and AUX .motor)stopped and no asking for free
Ventilation, time delay 300 seconds, close damper.
Sequence startup procedures

Conditions: remote state and no fault of oil station

Instruction: start oil station of APH.

Condition: oil station operation is normal
Instruction: start main motor.
Condition: main motor operates for 10 second
Instruction: open outlet second air damper.
Condition outlet second air damper has been opened
Instruction: open inlet flue gas damper.
Condition: inlet flue gas damper has been opened
Instruction: open inlet/outlet primary air damper.
Condition: inlet/ outlet primary air damper has been opened
Instruction: start procedures fulfilled.

Sequence stop procedures

CONDITION inlet flue gas temperature<150C

IDF and FDF of this side stopped
Instruction: close inlet flue gas damper
12

 Condition: inlet flue gas damper has been closed

Instruction: close outlet second air damper

Condition: outlet second air damper has been closed

Instruction: close inlet/outlet air primary damper
Condition: inlet/outlet air primary damper has been closed
Instruction: stop main motor of APH
CONDITION: main motor of APH has been stopped
Instruction: stop procedures fulfilled

Interlock test of air pre-heater oil station

Outlet Oil pressure of working pump is low (<0.12MPa), start standby pump
Fault of working pump, start standby pump.
Outlet Oil pressure of two pumps operation is high (0.3MPa), stop working pump
Guide bearing temperature is
High (>55C), alarm, start working pump
Guide bearing temperature is
High (>70), alarm
Guide bearing temperature is
Low (<45), stop operating pump
Support bearing temperature is
High (>55), alarm, start pump
Support bearing temperature is
High (>70), alarm
Support bearing temperature is
Low (<45), stop pump
13

Interlock & Protection of PA fan system

Start permissive

Outlet damper closed ,PA

Place Inlet vane at minimum position, PA <5 %
Front / rear bearing temperature is normal, PA (<80C)
Front / rear motor bearing temperature is normal , PA (<95C)
Motor coil temperature is normal, PA (<125C)
This side IDF and FDF are running
This side APH is running and inlet/outlet primary damper has been opened
No protection trip condition
No MFT condition

Inspection of trip condition

14

Front / rear bearing temperature is very high, delay 2 seconds (>90C)

Front / rear motor bearing temperature is very high, delay 2 seconds >105C)
Motor coil temperature is very high, delay 2 seconds (>135C)
Bearing vibration(x direction) is very high, delay 2 seconds (>7.1mm/s)
Bearing vibration (y direction)is very high ,delay 2 seconds (>7.1mm/s)
Motor bearing vibration(x direction) is very high, delay 2 seconds (>7.1mm/s)
Motor bearing vibration(y direction) is very high, delay 2 second (>7.1mm/s)
Accident button action
MFT action
This IDF stopped after this IDF is running
Two IDF stopped after two IDF are running
Two FDF stopped after two FDF are running
Outlet damper closed after PA fan is running, delay 5 seconds
Outlet damper closed when PA fan startup, delay 20 seconds

Outlet electric damper of primary air fan

Permission conditions of closing
This side PA fan has been stopped
Interlock conditions of opening
This side PA fans startup, open damper, delay 10 seconds
Interlock conditions of closing
This side PA fan tripped and the other PA fan is running, close damper

Inlet vane of PA fan

Interlock conditions of closing
This side PA fan tripped and the other PA fan is running, close damper.
Sequence start procedures
Open Outlet outlet primary damper of this side APH
15

Open Outlet inlet primary damper of this side APH

Close Outlet damper
Place inlet vane at minimum position
Start PA fan motor
Open Outlet damper
Release inlet vane

Sequence stop procedures

Place inlet damper at minimum position
Stop PA fan motor
Close Outlet inlet primary damper of this side APH
Close Outlet outlet primary damper of this side APH
Release inlet vane

Interlock & Protection of Coal Pulveriser

Start permissive
Barring gear motor retreated.
Coal ignition of corresponding layer permitted
Suitable temperature at outlet of coal pulverizer (55> t <-90 C)
Coal puverizer high oil system OK (2.5MPa)
Coal Pulveriser lube oil system OK
o Any oil pump is running
o Temperature of gear box oil 28
16

o Inlet pressure of oil distributor 0.13MPa

Temperature of thrust bearing 50C
High differential pressure between seal air and primary air of coal pulverizer
(2kPa)
Primary cold/hot valve opened;
Any primary air fan operating, with normal primary air pressure (10.5kPa)
Coal pulverizer outlet valve opened;
No MFT trip conditions
Suitable temperature of coal pulverizer bearing; (less than 95C)
Suitable air flow at inlet of coal Pulveriser (0.65Q);( 39000cu m ./hr)
Cobble coal bunker inlet valve opened.
No coal pulverizer trip conditions
coal feeder outlet dampers closed

Interlock trip conditions for coal pulverizer

Operator sends instruction for coal pulverizer stop;
MFT
MFT
One or more outlet dampers closed during the operation of coal pulverizer;
Primary air volume low(delay 3 second )30000M3/H (<0.5Q)
Temperature at outlet of coal pulverizer greater than (100C), time delayed 5s;
Low differential pressure between seal air and primary air of coal pulverizer (1.5kPa), time delayed 60s
Loss of coal flame (3of4) (after coal feeder is running time delay 3 minutes ,loss of coal layer flame )
Temperature of coal pulverizer bearing ( 95C)(2of3), time delayed 2s;
Temperature of coal pulverizer motor bearing (90 C) (1of2), time delayed 2s;
Temperature of coal pulverizer motor coil (140C) (3of6), time delayed 2s;
Accident button action
Loss of lube oil (<0.1MPa)
Loss of primary air: two primary air fans stopped
When two primary air fans are running, and three OR excess three operating coal pulverizers are running ,any one PA tripped
Temperature of coal pulverizer reducer thrust pad greater than 70C (2of3), time delayed 2s;
17

 Coal feeder stopped, time delayed 10min

Loading pump stopped ,time delay 2s
Loading oil pressure <2.0MPa, time delay 2s
Common conditions of coal firing
Temperature of secondary hot air temp >177C
Furnace air volume >30% (from MCS)
No MFT signals
At least seal air fan operating
Drum steam pressure >3.5 MPa
Primary air pressure normal >7 KPa
Furnace pressure normal (from MCS)(-600 to 0 Pa)
Condition of coal firing satisfied (ignition energy)( AND)
Common condition of coal firing satisfied
Oil gun of adjacent layer is running OR adjacent coal feeder , feeder rate <50% AND boiler load is more than 40 % OR
boiler load is more than
60 %
Roller action of Coal pulverizer
Lift roller
Fall roller
Coal pulveriser interlocked after being tripped
Trip coal feeder
Close coal feeder outlet valve
Close coal feeder inlet valve
Close inlet cold air damper
Close inlet hot air damper
Close coal pulverizer outlet damper
Lower the coal pulverizer roller, time delayed 60s
Open steam fire-fighting valve
18

Interlock damper conditions

Steam fire-fighting valve of coal pulverizer
Opening permission condition
Any one seal air fan is running
Interlock opening conditions (or)
Temperature at outlet of coal pulverizer greater than 120C, time delayed 5s;
mill tripped
Interlock closing conditions
steam fire-fighting valve opened, reached 8 minutes and temperature at outlet of coal pulverizer is greater than 90 C(2 of 3)
Seal fan valve of mill
Opening permission condition
Any one primary fan is running ,delay 5 seconds
Closing permission condition
Mill stopped, delay 5 seconds
Interlock closing condition (or)
All seal air fans stopped
Mill stopped, delay 12 minutes

Inlet hot shut-off damper of mill

Opening permission condition
No MFT
Interlock closing condition
MFT
Inlet cold shut-off damper of mill
Open permission condition
No MFT
Interlock closing condition
MFT
Mill stripped pulse
Inlet valve of coal feeder
19

Opening permission condition

Remote position AND NO MFT
Closing permission condition:
Remote position
Interlock closing condition
Coal feeder tripped
Mill stopped
Start conditions for sequence control of coal pulverizer :( AND)
Any primary air fan operating
Any seal air fan operating for 60s
Start procedures for sequence control:
Start low speed oil pump of coal pulverizer thin oil station;
After low speed oil pump started for 4min and the temperature of thin oil station gear box oil >28, start high speed oil pump
A/B of coal pulverizer;
Open seal air electric valve of coal pulverizer
Start hydraulic station to load oil pump
Open fire steam valve of coal pulverizer;
Fire steam valve of coal pulverizer has been open for 8min, close fire steam valve of coal pulverizer
Open cutoff valves at 1-4 outlets of coal pulverizer
Open cold and primary hot air cutoff valves of coal pulverizer
Suitable temperature at outlet of coal pulverizer;
Rise coal pulverizer roller
Start coal pulverizer
Open coal feeder outlet valve
Open inlet valve of coal feeder;
Start coal feeder
20

 Start coal pulverizer, constant load

Stop conditions for sequence control:
Coal pulverizer operating
Closing permission condition : remote operation
Interlock closing condition: coal feeder stopped
Coal feeder stopped
Mill stopped
Stop procedures for sequential control
Inform MCS to lower the coal feeder rpm to its minimum value
Close primary hot air cutoff valve of coal Pulveriser
After the temperature at outlet of coal feeder <60C, close the valve at inlet of coal feeder
Stop coal feeder; time delayed 1min
Close valve at outlet of coal feeder; time delayed 1 minute
Lift coal pulverizer roller
Stop coal pulverizer
Lower coal pulverizer roller
Lube oil station of coal pulverizer
Start conditions of low speed pump (and)
Place lube oil station at remote control position
Oil temperature>27C
Start conditions of high speed pump (and)
Place lube oil station at remote control position
Oil temperature>28C
Interlock starting standby pump
When Main work oil pump faultily stopped, start standby oil pump in manner of interlock
When Main work oil pump is running and outlet oil pressure is low (<0.105MPa), start standby oil pump in manner of
interlock
21

Stop permission condition

Mill stopped, time delay 120 minute

Electric heater of lube oil station

Start permission condition
Any Oil pump is running
Oil level is normal
Interlock start condition
Oil box temperature <30C
Interlock stopping condition (or)
Electrical heater tripped
All oil pump stopped
Oil box temperature >40C
Oil lever is low
Hydraulic oil station loading pump
Start permission condition
Place loading oil station at remote control position
Oil level is normal
Stop permission condition
Mill stopped, time delay 120 minute
Electric heater of hydraulic oil station
Start permission condition
Loading Oil pump is running
Oil lever is normal
Interlock starting condition
Oil box temperature <20C
Interlock stopping condition (or)
Oil box temperature >30C
Oil level is low

22

Interlock & Protection of Coal Feeder

Startup conditions for coal feeder
Coal pulverizer operating
Instruct coal feeder at a rpm of minimum.
Coal ignition of corresponding layer permitted
No MFT
Trip condition for coal feeder
Coal pulverizer stopped
Coal feeder keep running, lower valve closed, time delayed 5s
MFT

Inner over temperature of coal feeder, time delayed 120s (none)

No-coal on belt during the operation of coal feeder, time delayed 120s
Coal plugging at outlet during the operation of coal feeder, time delayed 2s
Result check after coal feeder tripped
Inlet valve of coal feeder opened
Outlet valve of coal feeder opened
Instruct coal feeder at a rpm of minimum value 0rpm

Interlock & Protection of Seal Air Fan

23

Start permission conditions

Any one primary air fan is running

Inlet vane has been closed
Bearing temperature of the seal air fan is normal (<75C)
Motor Bearing temperature of the seal air fan is normal (<75C)
No fault of the seal air fan

Stop permission conditions

When two seal air fans is running, outlet main pipe pressure is normal, permit stopping any a fan.
All primary air fans stopped
MFT tripped
Interlock startup conditions
Main air fan stopped
Outlet manifold pressure is low, time delay 2 second <16 KPa
Interlock stop conditions
All the primary air fans stopped, trip this seal air fan
Front / rear Bearing temperature is very high, delay 2 second >85C
Front /rear motor Bearing temperature is very high, delay 2 second >85C

24

Interlock & Protection of Scanner Air Fan

Start permission conditions
Remote position
No fault
Interlock start conditions
Flame detector cool main pipe pressure is low, interlock start the standby fan(.<3.78 KPa)
Running fan trip, interlock start the standby fan..
Difference value of Flame detector cooling air and furnace pressure is low, interlock start the standby fan.(<3.0 KPa)
Stop permission
When two Flame detector cooling fans is running, outlet main pipe pressure is normal, permit stopping any a fan.
After MFT tripped, have 3 hours and flue gas temperature is less than 80 degree.

Interlock & Protection of Temperature Probe

Interlock conditions of Flue gas probe
Overload protection, alarm
Temperature of Flue gas is higher, alarm >538 C
Temperature of Flue gas is highest, automatically retract, alarm >580C

25

Interlock of Boiler
Two airpreheaters tripped after delay 5 minute, trip two induced draft fans, two primary air fans, 4 coal pulverizers, 4 coal

feeders in manner of interlock, close feeding oil quick close valve in manner of interlock, and trip all the oil guns
Two induced draft fans tripped, trip 4 coal pulverizers, 4 coal feeders in manner of interlock, close feeding oil quick close
valve in manner of interlock, and trip all the oil guns
Two induced draft fans tripped, trip two primary air fans, 4 coal pulverizers, 4 coal feeders in manner of interlock, close
feeding oil quick close valve in manner of interlock, and trip all the oil guns
Two primary air fans tripped, trip 4 coal pulverizers, 4 coal feeders
One airpreheater tripped after delay 5 minute, trip this side induced draft fan, one this side primary air fan
One induced draft fan tripped, trip this side forced draft fan, trip this primary air fan
When three or excess three operating coal pulverizers are running. One primary air fan tripped , trip 2 coal pulverizers of A
and D, 2 coal feeders of A and D

Interlock & Protection of FSSS

Purge Permissives

No MFT trip conditions

At least one forced draft fan operating.
At least one induced draft fan operating.
Two airpreheater operating.
All the flame detector probes cannot detect flame, and all the flame detectors no fault.
(Two) Feeding oil quick close valves closed, (two) return oil quick close valves closed, all the oil angle valve closed;
All the coal pulverizers stopped and all outlet valves closed
All coal feeders stopped;
all the oil angle valve closed;
All primary air fans stopped
Furnace air volume>30% BMCR<40%
Secondary air dampers in purging place (openings off 80% or more secondary air dampers )
Furnace pressure normal 400Pa(FROM MCS)
26

 Flame detector cooling air pressure normal (4KPa)

Steam drum water level normal (-230> drum level<200mm)
MFT conditions

Two forced draft fans stopped.

Two induced draft fans stopped.
Manual MFT: the two buttons of MFT pressed by operator at the same time
Steam drum water level greater than (+200mm) (it lasts for 5s at least in case of 2/3)
Steam drum water level less than (-230mm) (it lasts for 5s at least in case of 2/3)
High pressure of furnace pressure: three hard input signals (2of3), this condition must last for 2s at least (+1470Pa)
Low pressure of furnace pressure: three hard input signals (2of3), this condition must last for 2s at least (-1470Pa)
Boiler air volume<30%, three hard input signals (2of3), this condition must last for 25s at least (<180T/hr)
a. Load >40%, steam turbine tripped 10 s.
b. In case of load<40%, steam turbine tripped, time delayed 10s, and bypass invalid, boiler MFT;
During the operation of any coal layer, two primary air fans stopped, and all oil guns (heavy oil, light oil) unenabled.
All airpreheaters stopped, time delayed 5 minutes
Flame out of entire furnace: loss of all flame with burning memory (heavy oil, light oil, coal
Loss of flame detector cooling air; low pressure of furnace cooling air, this condition must last for 15s at least.
All fuel tripped with burning memory (heavy oil OFT, light oil OFT, all coal pulverizers tripped
All feed water pumps stopped delay 5 s.

Result checklist after MFT tripped

Alarm, ask for furnace Purging requirement

Trip MFT relay;
Trip all oil combustors (close all oil angle valves, add MFT relay hard trip)
OFT action, Close light oil supply fast valve of oil manifold
OFT action, Close weight oil supply fast valve of oil manifold
Trip all coal pulverizers
Trip all coal feeders
Shut-off valves of coal pulverizer
27

Close all cold/hot air valves of coal pulverizer

Trip all primary air fans
Send the MFT action signal to soot blower, tripped
Open all dampers of fuel air and auxiliary air.
Send the MFT.action signal to electric dust catcher ,tripped
Turbine tripped

Result checklist of hard wire logic after MFT tripped

All primary fans tripped

All mill tripped
All coal feeder tripped
Close all fuel oil returned valves
Close supply oil shut-off valves(light oil and weight oil)
All oil angle valves(light oil and weight oil)
Close main valves of superheater detemperaturer
Close main valves of reheater detemperaturer
Electric dust-catcher tripped
Soot blowing system tripped

Interlock of BTG
Boiler MFT tripped ,trip turbine, trip generator oil
Switch
Turbine tripped and load>40%, trip MFT,trip generator oil
Switch
Generator transformer block protection tripped, trip turbine; when turbine tripped and load >40%,trip MFT

28

Interlock test checklist of steam and water system

Boiler steam pressure protection test
Steam header steam pressure is more than 14.07MPa,ERV solenoid pressure relief valve is automatically opened
Steam header steam pressure is less than 13.6MPa,ERV solenoid pressure relief valve is automatically closed
Steam exhaust electric valve1#, 2# is started in boiler superheat steam header
Steam exhaust electric valve2# is closed, interlock close valve1#
Steam exhaust electric valve 2# is opened, interlock open valve1#
Steam exhaust electric valve1#, 2# is started in boiler reheat steam header
Steam exhaust electric valve2# is closed, interlock close valve1#
Steam exhaust electric valve 2#is opened, interlock open valve 1#
Boiler emergency blow-off electric valve for water1#, 2# (set interlock switch)
When the water level of drum decreases from 100mm to 50MM, interlock close emergency blow-off electric valve1#,2#, low
water level alarm
When the water level of drum increases to 100MM, interlock open emergency blow-off electric valve1#,2#, high water level
alarm
Electric valve and control valve interlock condition of boiler desuperheating water
When MFT is started or the load is less than 20%, interlock close superheat steam system desuperheating water sub-electric-valve,
each desuperheating water control valve automatically changed to manual control, and interlock close
When superheater primary desuperheating water control valve of side A is closed(<3%),or MFT starts, or the load is less than
20%,interlock closes corresponding desuperheating water sub-electric-valve
29

 Superheater primary desuperheating water control valve of side A is opened (>3%), interlock opens corresponding superheater
desuperheating water sub-electric-valve.

When superheater primary desuperheating water control valve of side B is closed(<3%,or MFT starts, or the load is less than
20%,interlock closes corresponding desuperheating water sub-electric-valve
Superheater primary desuperheating water control valve of side B is opened (>5%), interlock opens corresponding superheater
desuperheating water sub-electric-valve.
When superheater secondary desuperheating water control valve of side A is closed(<5%,or MFT starts, or the load is less than
20%,interlock closes corresponding desuperheating water sub-electric-valve
Superheater secondary desuperheating water control valve of side A is opened (>5%), interlock opens corresponding superheater
desuperheating water sub-electric-valve.
When superheater secondary desuperheating water control valve of side B is closed(<5%,or MFT starts, or the load is less than
20%,interlock closes corresponding desuperheating water sub-electric-valve
Superheater secondary desuperheating water control valve of side B is opened (>5%), interlock opens corresponding superheater
desuperheating water sub-electric-valve.
MFT starts or the load is less than 20%,interlock closes reheating system desuperheating water electric sub-electric-valve, each
desuperheating water control valve automatically changed to manual control, and interlock close
When reheater desuperheating water control valve of side A is closed(<5% or MFT starts, or the load is less than 20%,interlock
closes corresponding reheat desuperheating water sub-electric-valve
Reheater desuperheating water control valve of side A is opened >5% interlock opens corresponding reheater desuperheating
water sub-electric-valve.
When reheater desuperheating water control valve of side B is closed(<5%,or MFT starts, or the load is less than 20%,interlock
closes corresponding reheat desuperheating water sub-electric-valve
Reheater desuperheating water control valve of side B is opened >5% interlock opens corresponding reheater desuperheating
water sub-electric-valve.
Reheater emergency spray water control valve is closed<5% or MFT starts, or the load is less than 20%, interlock close
corresponding reheater emergency spray water electric valve
Reheater emergency spray water control valve is opened >5% interlock open corresponding reheater emergency spray water
electric valve
Boiler (startup) hearth heating steam general electric valve
The temperature of furnace is less than 80 and MFT starts, startup is accessible
30

 No MFT, interlock is closed, startup is not accessible.

The pressure of drum is to 0.2Mpa, interlock close, startup is forbidden.

Interlock test checklist of fuel oil system

Light oil system
LDO supply pump
Start condition
Remote control
Trip condition
Motor fault
Interlock start conditions of LDO supply pump
Outlet pressure is low, start standby pump
Motor fault of operating pump, start standby pump

Test checklist of light oil OFT

Trip conditions of light oil:
Main fuel trip: MFT relay tripped or any MFT condition available or with MFT memory
Manual light oil OFT: Operation gives off light oil OFT instruction from operator station frame

31

 Light oil manifold pressure low: Low pressure of oil manifold (2of 3) lasts for more than 5s, and some oil angle valves still
open (<1.8MPa)

Light oil supply fast valve closed, and some oil angle valves still open;
Low pressure of compressed air (2of 3) lasts for more than 10s, and some oil angle valves still open
Start the following equipments in manner of interlock after OFT
Close all angle valves of light oil
Close light oil stream valve
Close light oil supply cut-off valve
Close light oil return cut-off valve (pulse)
Withdraw light oil ignition gun
OFT reset conditions
All angle valves closed
MFT relay reset
Light oil OFT (soft) trip conditions not available.
Open main inlet fast shut-off valve of light oil

Test checklist of light oil leakage procedures

Light oil leakage test permissive conditions:
MFT relay tripped
OFT tripped (soft)
Light oil feeding quick-closing valve closed
All the oil angle valve closed
Oil return quick close valve closed
All the flame detector indicate no flame
Light oil system fuel leakage test sequence
If permissive conditions are met, command to start up leakage test can be sent from the operator station screen

32

 Open the oil return quick close valve of light oil (meanwhile, open the fuel pressure regulation valve), closed after 10s. And
display "light oil fuel leakage test Actual actions proceeding" on operator station screen;
Within 300s, if the manifold pressure after the light oil feeding quick close valve low (difference value <0.05MPa), then the
light oil feed quick close valve leakage test passed; Or else, light oil feeding quick close valve considered leaked, fuel oil
leakage test failed, and it will be displayed on the operator station screen
If the light oil feeding quick close valve leakage test passed, open the light oil feeding quick close valve, charge oil: After the
manifold pressure becomes high
Within 180s, if manifold pressure after the light oil feeding quick close valve high (>2.8MPa, difference value <0.4MPa), then
the light oil return oil quick close leakage test passed; Or else, light oil return oil quick close valve considered leaked, leakage
test failed, and it will be displayed on the operator station screen
Oil leakage test interrupting conditions

10min after the oil leakage test begins

Ignition oil charging failed
Oil leakage test succeeded
Oil leakage test failed
Test checklist of light oil combustor
Light oil startup permissive
Flame detect no fault
Flame detector not flame on
Local cabinet power supply well.
Local operation request no.
Oil valve AND purge valve closed.
Trip Conditions
Light oil OFT
Ignition failed
Oil valve open failed
33

 Oil valve not closed AND oil gun not forward

Sequence Start
Forward light oil gun
Forward igniter gun
Open light oil valve
Sequence stop
Close light oil valve
Forward light oil gun
Forward igniter gun
Open purge valve
Close purge valve
Backward light oil gun
Heavy oil system
HFO supply pump
Start condition
Remote control
Trip condition
Motor fault
Interlock start conditions of LDO supply pump
Outlet pressure is low, start standby pump
Motor fault of operating pump, start standby pump

Test checklist of heavy oil OFT

Trip conditions of heavy oil:
Main fuel trip: MFT relay tripped or any MFT condition available or with MFT memory
Manual light oil OFT: Operation gives off heavy oil OFT instruction from operator station frame

34

 Heavy oil manifold pressure low: Low pressure of oil manifold (2of 3) lasts for more than 5s, and some oil angle valves still
open;
Heavy oil supply fast valve closed, and some oil angle valves still open;
Low pressure of atomizing steam (2of3) lasts for more than 10s, and some oil angle valves still open
Low temperature of heavy oil, time delayed 1min, and oil angle valve still open
Start the following equipments in manner of interlock after OFT
Close all oil valves of heavy oil
Close all purging valves of oil gun
Close heavy oil supply cutoff valve;
Close heavy oil return cutoff valve (pulse);
Close atomizing valve of heavy oil
OFT reset conditions
All angle valves closed
MFT relay reset
Heavy oil OFT (soft) trip conditions not available.
Open main inlet fast shut-off valve of weight oil

Test checklist of Heavy oil leakage procedures

Weight oil leakage test permissive conditions
MFT relay tripped
OFT tripped (soft)
Heavy oil feeding quick close pneumatic main valve closed;
Heavy oil leakage test valve closed;
All the oil angle valve closed;
Return oil quick close valve closed
All the fire detector indicate no flame;
Oil source pressure permissive.
35

Weight oil system fuel leakage test sequence

If permissive conditions are met, command to start up leakage test can be sent from the operator station screen;
Open the oil return quick close valve of heavy oil (meanwhile, open the fuel volume regulation valve), closed after 10s.
Within 300s, if the manifold pressure after the heavy oil feeding quick close valve low (<0.3MPa), then the heavy oil feeding
quick close main valve leakage test passed; Or else, heavy oil feeding quick close main valve considered leaked, fuel oil
leakage test failed, and it will be displayed on the operator station screen.
The heavy oil feeding quick close main valve leakage test passed, open the heavy oil feeding quick close main valve, charge
oil: After the manifold pressure becomes high, close heavy oil feeding quick main valve.
Within 180s, if manifold pressure after the heavy oil feeding quick close main valve high (>1.2MPa, difference value
<0.4MPa), then the heavy oil return oil quick close valve and oil valve leakage test passed; Or else, heavy oil return oil quick
close valve considered leaked, leakage test failed, and it will be displayed on the operator station screen.
Oil leakage test interrupting conditions

10m after the oil leakage test begins

Ignition oil charging failed
Oil leakage test succeeded
Oil leakage test failed

Test checklist of Heavy oil combustor

Heavy oil startup permissive
Flame detect no fault
Flame detector not flame on
Local cabinet power supply well.
Exists igniter power.
Heavy oil valve AND purge valve closed.
Heavy oil atomizing valve closed.
Corresponding light oil flame existed OR corresponding coal layer existed OR load of boiler is more than 60%
Trip Conditions
MFT tripped
36

Heavy oil OFT

Il gun not feeded in place
Ignition failed
Oil valve open failed
Oil valve not closed AND oil gun not forward
Oil valve opened AND atomizing valve not opened.

Sequence Start
Forward Heavy oil gun
Open heavy oil atomizing valve
Open heavy oil valve.
Sequence stop
Close heavy oil valve
Close atomization valve
Forward heavy oil gun
Open purge or atomizing valve
Close purge or atomizing valve
Backward heavy oil gun

ESP & Bag filter

When the flue temperature 180C, treats it as the normal situation, close the Bypass system and open the shield air circuit.
When the flue temperature >180C, the Flue temperature will be bad for the filter bag, the control system will open the bypass
Valve and close the lifting valve in bag field, then the flue go though bypass directly to the outlet.
When the flue temperature descends to 160C, the Control system will open the bag fields lifting valve, and close bypass
valve. Right now the system is considered as normal status.
Seriously monitor the conditions of flue temperature, pressure drop and pressure of precipitators each point, makes a record
each 30 min, immediately contact with the supervisor or boiler mid-control while appears abnormal situation.
37

Power from knowledge

Turbine & Auxiliaries Interlock &

Protection
WPCL, Warora

KSK Energy Ventures Ltd (4 X 135 MW)

Condensate Extraction Pump (CEP)

38

Sequence startup procedures of condensate pump

Close outlet valve
Startup motor
After condensate pump is operated for 5sOpen outlet valve
Sequence stop procedures of condensate pump
Close outlet valve of condensate pump
Stop condensate pump
Inspection of startup permissive conditions of condensate pump

Hot well water level of condenser normal (320mm to 795mm)

Condensate pump's outlet valve closed or standby one enabled
CEP winding temp <130C
Thrust bearing of A/B condensate pump temperature less than 70C
Condensate recycle channel opened
No trip condition
Breaker Healthy or in test position.

Inspection of protective tripping conditions of condensate pump

Hot well water level of condenser low low (<120mm)
CEP motor bearing temperature high NDE (alarm 70C Trip 80C)
CEP motor bearing temperature high DE (alarm 70C Trip 80C)
CEP motor winding temp high (1 of 6) (alarm 130C Trip 140C)
Local push button operated
CEP thrust bearing temperature high (1 of 2) (alarm 70C Trip 80C) After pump startup for 20s, it is still "Close" signal at
outlet valve
CEP running AND outlet valve closed delay 20 S

39

 Vibration of CEP shaft is high (alarm 7.1mm/s Trip 11.2mm/s)

Interlock

CEP running delays 5sec, open outlet motor valve

CEP stop ,close outlet motor valve
Enable CEP as standby , open CEP outlet motor valve
Enable CEP standby, CEP emergency tripped, immediately standby CEP starts.
Enable CEP standby , when CEP main pipe pressure 1.32 MPa delays 3 s ,start standby CEP
Condenser level lower , open make up water motor valve ( 300mm)
Condenser level higher, close make up water motor valve( 795mm)
When condensate flow <120t/hr, open recirculation motor valve
When condensate flow >240t/hr , close recirculation motor valve

LP casing spraying desuperheating water valve opened automatically

LP casing exhaust temperature high <65C, closed in manner of interlock
LP casing exhaust temperature high >80C, opened in manner of interlock
Condensate to steam turbine proper drainage flash chamber desuperheating water valve
Proper flash chamber temperature high (60C), opened in manner of interlock, non-high release
Condenser hot well water level regulation valve
Hot well water level high, closed in manner of interlock, non-high release
Hot well water level low, opened in manner of interlock

Condenser 3-stage desuperheating water valve

LP bypass opened and opened in manner of interlock

Temperature downstream LP bypass < 60C close in a manner of interlock
40

 Temperature downstream LP bypass > 100C open in a manner of interlock

Circulating water system
Startup permissive conditions of CW pump

Remote CWP control

CWP thrust bearing temp <80C
CWP guide bearing temp <75C
CWP under bearing temp <80C
CWP proper thrust bearing temp <80C
Lube cooling water flow low
Condenser inlet/outlet motor valve open

Protective tripping conditions of CW pump

CWP under bearing temp high (alarm 80C trip 85 C)

Thrust bearing temperature of CW pump motor high (alarm 80C trip 90 C)
Motor coil temperature of CW pump is high (alarm 120C trip 125 C)
CWP guide bearing temp high (alarm 75C trip 80 C)
CWP proper thrust bearing temp high alarm (80C trip 90 C)
Local push button operated

Interlock
When running CWP emergency tripped starts standby CWP in interlock
When Header pressure is low automatically start the standby pump in interlock
Discharge butterfly valve automatically after pump startup
When butterfly valve open 20deg CWP startup
41

 After CWP startup 60 sec outlet butterfly valve accident, stop CWP
When CWP outlet valve close to 20 deg, stop CWP
When CWP tripped, outlet butterfly valve automatically closes

Sequence startup procedures of CW pump

Close CW PUMP outlet valve
Open CW PUMP inlet valve
When Outlet valve of CW pump open 15or CW pump operating, startup A CW pump
Sequence stop procedures of CW pump
Close outlet valve of CW pump to 75
Stop motor of CW pump
Cooling water booster pump startup
When running cooling water booster pump tripped and enable standby pump, interlock start up the standby pump
When cooling water booster pump main pipe pressure lower, start standby pump in interlock
Pump suction pressure <0.1MPa both pump will not start
Sequence startup procedures of A cooling water booster pump
Close outlet motor valve of cooling water booster pump
Startup cooling water booster pump
Delay 5s,open outlet motor valve of cooling water booster pump
Sequence stop procedures of A cooling water booster pump
Close outlet motor valve of cooling water booster pump
Stop cooling water booster pump

42

Boiler Feed Pump Interlock & Protection

Protection
Deaerator water level LL (2of3) 380mm
Lube oil pressure LL 0.05 MPa
BFP operating booster pump inlet motor valve closed
Inlet oil temp working oil 130C alarm 110C
BFP thrust bearing temp 95C alarm 80C
Motor bearing temperature of booster pump end 90C alarm 80C delay 3 sec

Motor bearing temperature of hydraulic coupler end 90C alarm 80C delay 3 sec
Booster pump drive/free end bearing temp 90C alarm 75C delay 3
BFP inside /outside radial bearing temp 90C alarm 75C delay 3
BFP hydraulic couples radial bearing temp 95C alarm 85C delay 3 (1-7)
BFP winding temp 130C alarm 110C delay 3 (1 -6)
Local emergency button operated
When BFP operation, flow 128 t/hr and minimum flow valve is closed., delay 15 sec BFP will tripped.
Motorized feed water pump operating and booster pump inlet valve closed

Start Permissives
43

Booster pump inlet motorized valve & Recirculation valve fully opened
Lube oil pressure normal 0.1MPa
Deaerator water level normal
Booster pump inlet valve opened
Scoop tube position5%
Booster pump drive/free end radial bearing temperature <75C
Motor bearing temperature of booster pump end <80C
Motor bearing temp of hydraulic-coupler end <80C
Hydraulic coupling bearing (10th point )< 85C
BFP thrust bearing temp(upside, downside) <85C
BFP winding temperature <110C
Working oil cooler inlet temp<110C
BFP outlet motor valve closed OR standby
Differential pressure of inlet screen for motorized feed water pump and booster pump is abnormal

Sequence startup procedures

Startup auxiliary oil pump and lube oil pressure normal, Scoop tube at minimum position (<5%)
Open recirculation valve
Open booster pump inlet valve
Close motor outlet valve
Startup motor
Open motor outlet valve
Sequence stop procedures
Startup auxiliary oil pump and lube oil pressure not low
Open recirculation valve
Scoop tube placed at minimum position (<5%)
Close outlet valve
Stop the motor

44

Actions to enable motorized feed water pump as standby

Startup auxiliary oil pump

Open recirculation valve

Open booster pump motor inlet valve
Open BFP outlet motor valve
Scoop tube placed at minimum position
Open motor valve of Reheater

Interlock

Running BFP tripped, immediately start standby BFP in interlock

BFP enabled as standby, open the valve in manner of interlock
BFP stopped, close outlet valve in manner of interlock
When BFP operation and flow 128T/Hr Recirculation valve opened
When BFP operation and flow 283T/Hr Recirculation valve closed
When enable standby, scoop tube position of standby BFP adjust as the same scoop tube position of running BFP

Auxiliary oil pump interlock of motorized feed water pump

Motorized feed water pump operating and lube oil pressure lower than 0.08 MPa, automatic startup
Enable motorized feed water pump as standby and start in manner of interlock
Motorized feed water pump stopped and protection ON
BFP operating and lube oil pressure higher than 0.3 MPa , delay 5 sec and auxiliary oil pump automatically stop

Vacuum system
Vacuum pump startup permissive conditions
Vacuum pump inlet pneumatic valve closed
Control by remote
45

 Steam/water separator level is normal

Interlock
Start vacuum pump, interlock start-up circulate pump and open inlet butterfly valve
Stop vacuum pump, interlock close inlet butterfly valve
Running pump trip, interlock start standby pump
Steam/water separator level low, delay 5 min trip the pump
Vacuum pump A operating or standby, and separator water level low, automatically open water makeup solenoid valve of
steam-water separator
Vacuum pump A water level high, automatically close water makeup solenoid valve of steam-water separator
When condenser pressure >14 Kpa and one pump in operation , interlock start standby pump.

Lube oil system

Interlock
When lube oil pressure is low, interlock start AC lube oil pump (Pr. 0.049MPa)
When turbine trips interlock start AC lube oil pump
When lube oil pressure is lower interlock start DC LOP (Pr 0.0392MPa)
AC lube oil pump emergency tripped, interlock start DC LOP.
When running JOP tripped interlock start standby JOP
When JOP running and outlet pressure is low , interlock start standby pump
(Pr 7MPa)
Turbine rotational speed (>1220rpm) , stop JOP.
Turbine rotational speed (<1220rpm), start JOP.

Start permissive barring gear motor

Jacking oil pressure 8 MPa
Lube oil pressure 0.08 MPa
Tripped
Lube oil pressure low (Pr. 0.029MPa)
46

EH oil system
EH oil pump interlock protection
EH oil manifold pressure lower to 11.2 MPa alarm, and start up standby EH oil pump by means of interlock
DEH oil pump emergency trip, interlock start standby pump.
Start-up permissive
Oil tank level normal
Oil temperature is >20 deg C.

Deaerator system
Interlock
Deaerator water level HH (.2550mm), Deaerator overflow valve opened in manner of interlock,
Deaerator water level not high,(<2350mm) Deaerator overflow valve closed in manner of interlock
When water level is high II, close MOV of extraction # 3 , check valve of extraction # 3 , close drain control valve of HP
heater # 2 to dearator.(>2650mm)
Close 1 to 5 extraction check valve & close 1 to 6 Extraction MOV
Turbine trips
Generator tripping
OPC acts

HP heater system
Interlock
HPH # 1 water level is high II, open emergency drain control valve. (>600mm)
HPH # 1 water level is low I, close emergency drain control valve. (<250mm)
47

 HPH # 1 water level is high III, HP heater is tripping (.>800mm)

HPH # 2 water level is high II, open emergency drain control valve, close normal drain control valve from HPH # 1 to HPH #
2 (>600mm)
HPH # 2 water level is low I, close emergency drain control valve. (<250mm)
HPH # 2 water level is high III, HP heater is tripping (.>800mm)
Drain valve in front of HPH # 1 extraction MOV interlock open
Turbine tripping
Turbine load <10%
Check valve of extraction # 1 is close
MOV of extraction # 1 is close
Extraction temperature difference between up & down wall is > 40 deg C
Drain valve in front of HPH # 2extraction MOV interlock open
Turbine tripping
Turbine load <10%
Check valve of extraction # 2 is close
MOV of extraction # 2 is close
Extraction temperature difference between up & down wall is > 40 deg C

LP heater system
Startup procedures for sequence control of LP heater
Close LP heater emergency drain valve
Open pipe drain valve after steam extraction electric valve/before check valve of LP heater
Open the LP heater outlet electric valve
Open the LP heater inlet electric valve
Close the LP heater bypass electric valve
Open the LP heater steam-extraction electric valve,
Open the LP heater steam-extraction electric valve

48

 10s delay and load larger than 30% , close pipe drain valve after electric valve/before check valve for 4th stage steam
extraction
Stop procedures for sequence control of LP heaters
Close the LP heater steam extraction electric valve
Close the LP heater steam-extraction check valve
Open pipe drain valve after steam extraction electric valve of LP heater
Open the pipe drain valve before check valve of LP heater
Open LP heater bypass electric valve
Close LP heater inlet electric valve
Close LP heater outlet electric valve
Open LP heater emergency drain valve
5s delay, open pipe drain valve after steam extraction electric valve/before check valve of LP heater
Inspection of LP heater quitting conditions
Steam turbine tripping
Generator quitting
LP heater water level HHH (1050mm)
Manual quitting
> OPC action
Interlock
LPH # 4 water level is high II, open emergency drain control valve, close extraction # 4 check valve & MOV , open extraction
# 4 drain valve, Water side bypass MOV open & i/l & o/l MOV closed. (>1050mm)
LPH # 4 water level is high I , open emergency drain control valve .(>900mm)
LPH # 4 water level is low I, close emergency drain control valve to condenser. (<600 mm)
LPH # 5 water level is high II, open emergency drain control valve, close extraction # 5 check valve & MOV, open extraction
# 5 drain valve, Water side bypass MOV open & i/l & o/l MOV closed. (>1050mm)
LPH # 5 water level is high I , open emergency drain control valve to LPH # 6 & close normal drain control valve from LPH #
4 to LPH # 5.(>900mm)
LPH # 5 water level is low I, close emergency drain control valve to condenser. (<600 mm)
LPH # 6 water level is high I, choose any one of the CDP (drain water pump) as standby , then interlock starts the drain pump
& opens the pump outlet control valve. (>900mm)
49

 LPH # 6 water level is high II, open emergency drain control valve, close LPH # 5 normal drain to LPH # 6 control valve ,
close extraction #6 MOV , open extraction # 6 drain valve, Water side bypass MOV open & i/l & o/l MOV closed.
(>1050mm)
LPH # 6 water level is low I close emergency drain control valve (<700mm)
LPH # 6 water level is low II , interlock stop drain water pump. (550mm)
Drain valve in front of LPH # 4 extraction MOV interlock open
Turbine load is <20%
Check valve of extraction # 4 is close
MOV of extraction # 4 is close
Drain valve in front of LPH # 5extraction MOV interlock open
Turbine load is <20%
Check valve of extraction # 5 is close
MOV of extraction # 5 is close

Main steam and drainage system

Load <10%, open following valves automatically

Left side main steam pipe drain valve

Right side main steam pipe drain valve
HP guide steam pipe drain valve
Steam turbine HP main steam valve (left) upper seat drain valve
Steam turbine HP main steam valve (left) lower seat drain valve
50

Steam turbine HP main steam valve (right) upper seat drain valve
Steam turbine HP main steam valve (right) lower seat drain valve
Steam turbine HP casing steam exhaust pipe (left) drain valve
Steam turbine HP casing steam exhaust pipe (right) drain valve
Steam turbine HP casing steam exhaust manifold drain valve
Drain valve before 1st stage steam extraction electric valve
Drain valve before 1st stage steam extraction check valve
Drain valve after 1st stage steam extraction electric valve
Drain valve after 1st stage steam extraction check valve
HP bypass pipe drain valve

Load >10%, Close following valves automatically

Left side main steam pipe drain valve

Right side main steam pipe drain valve
HP guide steam pipe drain valve
Steam turbine HP main steam valve (left) upper seat drain valve
Steam turbine HP main steam valve (left) lower seat drain valve
Steam turbine HP main steam valve (right) upper seat drain valve
Steam turbine HP main steam valve (right) lower seat drain valve
Steam turbine HP casing steam exhaust pipe (left) drain valve
Steam turbine HP casing steam exhaust pipe (right) drain valve
Steam turbine HP casing steam exhaust manifold drain valve
Drain valve before 1st stage steam extraction electric valve
Drain valve before 1st stage steam extraction check valve
Drain valve after 1st stage steam extraction electric valve
Drain valve after 1st stage steam extraction check valve
HP bypass pipe drain valve

Load <20%, open following valves automatically

51

Left side reheating steam pipe drain valve

Right side reheating steam pipe drain valve
Steam turbine combined reheat valve (left) drain valve
Steam turbine combined reheat valve (right) drain valve
Drain valve before 3rd stage steam extraction electric valve
Drain valve after 3rd stage steam extraction check valve
Drain valve before 4th stage steam extraction electric valve
Drain valve after 4th stage steam extraction check valve

Load >20%, Close following valves automatically

Left side reheating steam pipe drain valve
Right side reheating steam pipe drain valve
Steam turbine combined reheat valve (left) drain valve
Steam turbine combined reheat valve (right) drain valve
Drain valve before 3rd stage steam extraction electric valve
Drain valve after 3rd stage steam extraction check valve
Drain valve before 4th stage steam extraction electric valve
Drain valve after 4th stage steam extraction check valve
Load <30%, open following valves automatically
Drain valve before 5th stage steam extraction electric valve
Drain valve after 5th stage steam extraction check valve
Drain valve before 6th stage steam extraction electric valve
Drain valve after 6th stage steam extraction check valve
Load >30%, Close following valves automatically
Drain valve before 5th stage steam extraction electric valve
Drain valve after 5th stage steam extraction check valve
Drain valve before 6th stage steam extraction electric valve
Drain valve after 6th stage steam extraction check valve
52

Steam turbine HP casing steam exhaust pipe (left) drain valve

Drain tank water level HH, opened in manner of interlock, not high, closed in manner of interlock
Steam turbine HP casing steam exhaust pipe (right) drain valve
Drain tank water level HH, opened in manner of interlock, not high, closed in manner of interlock
Steam turbine HP casing steam exhaust manifold drain valve
Drain tank water level HH, opened in manner of interlock, not high, closed in manner of interlock
Steam pipe drain valve before LP bypass valve A
Drain tank water level HH, opened in manner of interlock, not high, closed in manner of interlock
Steam pipe drain valve before LP bypass valve B
Drain tank water level HH, opened in manner of interlock, not high, closed in manner of interlock

Steam pipe drain valve after LP bypass valve A

Drain tank water level HH, opened in manner of interlock, not high, closed in manner of interlock
Steam pipe drain valve after LP bypass valve B
Drain tank water level HH, opened in manner of interlock, not high, closed in manner of interlock
Steam turbine tripping or generator quitting, HP casing left side steam exhaust check valve closed in manner of protection
Steam turbine tripping or generator quitting, HP casing right side steam exhaust check valve closed in manner of protection

Shaft seal system

Self start of shaft seal fan A
Enable interlock, and pump B tripped under emergency
Self start of shaft seal fan B
Enable interlock, and pump A tripped under emergency

Bypass system
HP Bypass
Automatic opening
53

 Turbine trip
Automatic closing
Temperature behind HP bypass is High (360C)
Desuperheating water pressure is low (switch)
Interlock
HP bypass valve open, open desuperheating isolating valve
HP bypass closes, interlock close desuperheating isolated valve
HP bypass closed, interlock close desuperheating control valve
Relief valve is close, desuperheating control valve is forbidden to open

LP bypass
Automatic opening
Turbine trip
Automatic closing
Condenser vacuum low -70Kpa (2/3)
Condenser temperature high 70C
After-LP bypass valve temperature high 170C
LP bypass spray water pressure low
Interlock
LP Bypass open, open desuperheating control valve is open
LP Bypass control valve open, open desuperheating isolating valve
LP Bypass control valve close, close desuperheating isolating valve

Turbine
54

Lubricating oil pressure is low II (.0392MPa .0392MPa Trip)

Over speed (DEH 3300rpm, TSI 3300rpm)
EH oil pressure is low II (7.8MPa 7.8 MPa Trip)
Bearing vibration is high (.25mm/s .127mm/s)
Vacuum is low (19.7 Kpa /14.7 KPa )
Displacement of axial direction is high (alarm +0.6mm,-1.05mm. trip +1.2mm,
-1.65mm)
Differential expansion of HP MP casing is high (alarm +6.2mm,-3mm. trip +6.2mm,
-3.2mm)
Differential expansion of LP casing is high (alarm +7mm,-6mm. trip +7.2mm, -6.2mm)
LPT Exhaust temperature is high (alarm 80C trip 120C)
Bearing temp is high (alarm 105C trip 115C)
Thrust bearing temp is high (alarm 100C trip 110C)
Trip in the control room
Local trip turbine
Boiler MFT
Main protection of generator acts
DEH fault.

55

Procedure of Latching and Rolling

Before Latching : Start EH oil Pump
Screen
Auto Control
Solenoid
monitor
Auto Control
Solenoid
monitor
Auto Control

Status
In message screen 1) Trip 2) Auto 3) All control valve closed
All solenoids should be green ( Discharged )
Click on ' LATCH' ( Gray )
Solenoid 5, 6, 7 and 8 turn ' RED'.
Check ' LATCH ' turned ' RED'

With above sequence Latching get completed. Now turbine ready to roll, If all parameters built up as per Turbine condition

Auto Control
Solenoid
monitor
Auto Control

Click on 'RUN'
Main steam and Reheat steam stop valve will open.
For starting Rolling ( Increasing speed )

Auto Control
Auto Control

Click on ' SPEED RATE ' and give a value ( Exa.- 100 - 200 RPM/Minute)
Click on ' TARGET ' and give a value ( Exa- 500 RPM )
Click on ' GO/HOLD ' and select 'GO' and watch the speed rise.

Then as per the Turbine temperature diffrence between top and bottom, Diffrencial Expansion,Bearing Vibration soak the turbine .

56

BLACKOUT CHECKLIST
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)

Ensure DG start and emergency bus charged.

Ensure EOP and APH DC motor started (IF EOP/AOP not Pick up then open vacuum breaker
valve
All proper drains valves from to be close from DCS as well as isolation valve to be close from local
to avoid condenser pressurization.
Ensure Boiler & Turbine MOV panel charged from Emergency Bus.
Close both side M.S.S.V
Ensure HP LP by pass valve in close condition otherwise start EH pump & close it.
Ensure all Extraction MOV and NRV are in close condition.
Start Scanner Air Fan & kept other in interlock.
Ensure both BFP AOP are in service otherwise start it.
Open R.H Vent
Close Blow down valves.
Ensure all soot blowers are in retract position.
At -30 Kpa vacuum open breaker valve and isolate gland sealing.
Ensure JOP has pick up at 1200 rpm
Start AOP and stop EOP(KEEP it in interlock in)
Ensure TG came to barring gear as soon as TG 0 speed reached.

57

AUTO SYNCHRONIZATION
: 1 /2
Operation task:generator Unit-1 voltage up through auto excitation; auto synchronization
Seq.

Operation Item

safety measures
Implement operation supervision system strictly. The supervisor should be experienced operator or
above.
Wear insulation gloves and proper working tools.

The staff is both physically and psychologically well and familiar with the system.

operation measures

Rehearse the operation mentally.

Unit-1 Check the cooling water system of generator Unit-1 air cooler is working normally.
# 1 Check the rotation speed of turbine Unit-1 is steady. Maintain the rotation speed of the turbine be
the same with grid frequency.
Unit-1 Verify that generator transformer Unit-1 is put into service correctly.(only
one set of rotor earthing protection is to be put into service)
Close power to operation box 4QFand power to operation box 5QF
Unit-1 CH1 AVR ON REMOTE Check AVR of generator Unit-1 excitation room(small) is
running at "CH1", "AVR ON" lamp is on and "REMOTE" lamp is off.
DCS # 1 Excitation Launch Click AVR Unit-1 on the DCS panel and enter its
interface. Close excitation suppression switch and take Excitation Launch.
Unit-1 Check the generator excitation system of Unit Unit-1 is put into service normally.
Unit-1 13.11kV 13.8*0.95Check the voltage of generator Unit-1 automatically rises to around 13.11kV.
13.8*0.95
INC EXC 13.8 kVUg=U220KVg13.8235

3
4
5
6
7
8
9
10

ti
m
e

58

11
12
13
14
15
16
17
18

Use INC EXCbutton to increase the generator voltage to the rated value of 13.8kv;
(follow busbar voltage regulating and slightly higher than busbar voltage)
Ug=U220KVg13.8235
Unit-1 75.4v 567.4A) Verify that 3 phases voltage of generator Unit-1 is balanced
and no-load excitation parameters such as voltage and current are correct.( compare
to no-load rated parameters 75.4v 567.4A)
# 1 DCS Verify that there is no abnormal signal in generator Unit-1 protection
panel, excitation room and DCS.
SELF Confirm that synchronization select switch is at SELFposition.
1 SWJ 2ZK Confirm that the SWJ power 22K of mazaic control panel #1 is already
closed and synchronization is put into service.
3 1MCB Confirm that the power MCB of synchronizing unit of mazaic control panel #3
is already closed.
4 STK "AUTO" Confirm "AUTO" is selected at mosaic control panel #4 STK.
4 ATRESIAQK Exit atresia Confirm Exit atresia is selected at mosaic control
panel #4 ATRESIAQK
1 #1 1DL CLOSE
DCS 1DL START Change outlet breaker 1DL of generator transformer Unit-1 on mosaic control
panel Unit-1 over to CLOSEand put synchronization into service.(or click "START" at the interface
of DCS generator transformer outlet breaker 1DL to put synchronization into service)

59

25

DEH AUTO Control sync Check the interface of DEH AUTO Control and verify that
synclamp is on (RED)
DEH AUTO Control syncDEH Click "sync" in the interface of DEH AUTO Control to put
DEH synchronization into service.
DEH Check DEH to send synchronization permission signal and the synchronization meter
should be charged.
Manually adjust the generator frequency and voltage to be the same with those of grid system.
3 START UP Press close button of auto sync "START UP" breaker on mosaic control panel
#3.
Verify that synchronization unit is working normally.(it automatically regulate the generator frequency and
voltage be the same with those of the grid system.
# 1 1DLVerify that the auto closing of generator Unit-1 breaker 1DL is normal. (Red lamp on)

26

# 1 Verify that the indication of stator 3-phases current is correct..

27

DEH sync Verify the DEH synchronisation request is cancelled.sync becomes grey
DCS 1DL Exit Click "EXIT" on the interface of DCS generator transformer outlet breaker 1DL to cancel
synchronization.
1 SWJ DEH Confirm the SWJ on the control panel 1 should be reset.(sync out and withdraw
from "request sync from DEH" signal)
# 1 1DL Confirm that synchronization of 1DL breaker of generator transformer Unit-1 is cancelled.(lamp of
synchronization meter dies)
4 MANUAL HANDLE(STK)"UNCHAN"
Select "UNCHAN" of MANUAL HANDLE(STK) switch on mosaic control panel #4.
# 1 A 19XP Disconnect 19XP GENERATOR START\STOP EARTH FAULT protection on
protection panel A of generator transformer Unit-1.
# 1 A 28XP Disconnect 28XP ACCIDENTAL ENERGISATION RELAY protection on protection
panel A of generator transformer Unit-1.
# 1 A 31XP Disconnect 31XP FLASH OVERprotection on protection panel A of generator
transformer Unit-1.
# 1 A 4XB CLOSE MAIN VALVE I Put 4XB CLOSE MAIN VALVE I protection into service
on protection panel A of generator transformer #1.
# 1 A 23XB CLOSE MAIN VALVE II Put 23XB CLOSE MAIN VALVE II protection into
service on protection panel A of generator transformer #1.
# 1 B 19XP Disconnect 19XP GENERATOR START\STOP EARTH FAULT protection on protection
panel B of generator transformer Unit-1.
# 1 B 19XP Disconnect 19XP GENERATOR START\STOP EARTH FAULT protection on protection
panel B of generator transformer Unit-1.
# 1 B 31XP Disconnect 31XP FLASH OVERprotection on protection panel B of generator
transformer Unit-1.
Unit-1 Verify that generator Unit-1 is working normally.
# 1 B 4XB CLOSE MAIN VALVE I Put 4XB CLOSE MAIN VALVE I protection into service
on protection panel B of generator transformer #1.
# 1 B 23XB CLOSE MAIN VALVE II Put 12XB CLOSE MAIN VALVE II protection into
service on protection panel B of generator transformer #1.

19
20
21
22
23
24

28
29
30
31
32
33
34
35
36
37
38
39
40
41
42

60

Turbine Triping and Alarm

S.No.

ETS Protection

TURBINE TRIP

ALARAM

Action

Axial position

+1.2mm,1.65mm

(+0.6/-1.05)

Auto

Shaft Vibration

>0.25mm

(>0.125mm)

Auto

EH oil pressure low

<7.8Mpa

<12MPA

Auto

Lube oil pressure low

<0.049MPA

Auto

Vaccum of condenser low

19.7Kpa

14.4KPA

Auto

6
7

TSI overspeed
DEH Over speed

3300 RPM
3300rpm

3240RPM

Auto
Auto

DEH Failure

Boiler MFT action

Electrical Generator and transformer protection

10
11
12

Remote manual emergency shutdown

Thrust Brg. Temp HI
a.Thrst. Pad temp.
b. Brg. Metal.temp.

13
LP exhaust temp.HI
14

Local manual emergency shutdown

<0.0392Mpa

Auto
TURBINE TRIP

>110 C

>100 C

>115 C

>105 C

>120 C

>80 C

Auto
Auto
Auto
Auto
Auto
Auto
Auto

TURBINE TRIP

61

15

HIP Differential expansion

+6.2mm/-3.2mm

+6mm/-3mm

Auto

16

LP Differential expansion

+7.2mm/-6.2mm

+7.2mm/-6mm

Auto

Bearing cap vibration high

0.08mm

17
18

Bearing Drain Oil Temptreture

19

Main Steam Pressure High

20

Eccentricity of rotor

21

Auto
>65 C
>16.4 MPAC

Manual

>30Um

Pressure of Gland Seal

>0.13MPA&<0.02MPA

ALL CVs & ICVs AUTO CLOSE Over speed protection Control(OPC) act)
1

Generator Circuit Breaker Open

And Load > 15 % (20.25MW)

Rotational Speed > 103 %

Acceleration of Speed > 5 RPM/Min.

RESETS
LOAD 20.25 MW

for 0.8 sec

220 V DC supply to DEH relay cabinate FAIL

All CVs & ICVs AUTO CLOSE

62

COORDINATED MASTER CONTROL

In a Thermal Power Unit operation the critical internal unit parameters related to production are MW, Main steam pressure. The
critical external parameter is frequency of the network. In a boiler the steam production depends on combustion control (Fuel control
and Air flow control). So one of the unit parameters MW or main steam pressure must be used for Boiler control. Turbine Generator
produces electrical output (MW) proportional to steam input to turbine. The turbine control system (EHC) varies steam input to
turbine to achieve unit parameter MW or Main steam pressure. The network stability always depends on the balance of power
production and power consumption. Any unbalance in the power production and power consumption leads to change in the frequency
of operation in the direction of attaining natural stabilization i.e., balancing of power consumption with power production. However as
the capacity of this stabilization is limited for the network for stability, proportional frequency correction is given in turbine control
system to vary the power production in the direction to achieve stability of network. The 5% regulation used generally in thermal
power units, gives 100% load correction for 5% frequency disturbance in the network. This is selected mainly to achieve network
stability within the rotating machines speed variation of 95% to 105%. At 110% Turbo generators have over speed trip protection.
In a network the power production or power consumption can change due to several reasons like units tripping on some internal
problems or load breaker tripping. So to ensure the stability of network it is necessary to have frequency regulation in Turbine control
it is also to be emphasized here that if only few units in the network implement the frequency control the total disturbance in the
network will be passed on to the units having regulation by the many units which do not have regulation. Frequency is network
parameter which can not be controlled by few units in the network.
In Thermal Power Units the Turbines are fastly responding components and Boilers are having transport lag and Thermal inertia
and hence delayedly respond with variation in command. So the Turbine will be able to meet MW demand or main steam pressure set
value quickly by positioning the control valves of Turbine to the required values. Turbine will be able to maintain only one unit
parameter MW or main steam pressure. The other is to be controlled, naturally by the boiler. The modes of operating the unit are
named as turbine follow mode and boiler follow mode. In Turbine follow mode Turbine maintains throttle steam pressure. The MW
depends on the steam output from the Boiler. The variations in the Boiler steam output will be resulting variations in MW output.
Boiler steam output variations can result from changing Calorific values of coal etc. Turbine follow mode gives more stability to unit
by controlling main steam pressure perfectly and fastly which is a very important unit parameter. If Boiler combustion controls fuel
and air are in Auto corrective actions will be taken by boiler controllers to change combustion to give desired steam for the set MW.
63

These responses will be slow when compared to turbine responses. So it may be reemphasized that this mode of operation gives
maximum stability to unit operations with slow response to grid
Contd.2/-

64

::02::
requirements by initiating combustion controls first and turbine valves positioning after steam production. However the combustion
controls will be responding to grid requirements if frequency influence in CMC console is in ON position only.
In Boiler follow mode Turbine maintains MW demands and Boiler maintains main steam pressure. Turbine will be responding
to grid requirement fastly because of droop characteristic set in EHC and Boiler will be following to maintain main steam pressure if
combustion controls are in Auto. This mode of operation gives maximum stability to network because MW requirements are met by
Turbine fastly and lesser importance to unit stability, because the action by Turbine will be disturbing main steam pressure. If all units
in the network do not implement 5% regulation then the network disturbances will be passed on to the units in Boiler follow mode
disturbing their MW level of operation often. Boiler combustion controls must be kept in Auto in this mode of operation which will be
taking main steam flow and main steam pressure error as inputs for control. The main steam pressure is the final trimming signal to
boiler for boiler follow mode of operation. Response of Turbine to grid requirements is quickly perceived by boiler controls through
main steam flow variations. Finally Boiler controls ensure the set throttle pressure.
In coordinated mode of operation unit/master control station sets MW set point which will be pursued by combustion controls
by taking main steam pressure error as final trimming input signal. Turbine will be controlling the MW at the set point or changes in
grid frequency will be leading to changes in the MW. Main steam pressure error will have proportional influence for stability of the
unit. Boiler will be trying to control main steam pressure. Coordinated mode and boiler follow mode are similar in response except
that base signal required for boiler combustion control is MW set point in coordination mode and main steam flow signal in Boiler
follow mode.Sustained throttle pressure controller output will be the result due to calorific value deviation from design calorific value
and this output will be getting added to unit demand going to boiler master .the calorific value correction controller in auto mode takes
the output of throttle pressure controller as input and works as long time integrator to produce output to represent calorific value
which works as multiplier for fuel demand to boiler .In the process of this long time action, the throttle pressure controller output
returns to almost zero. The advantages in this control action are better transient response since the calorific value is as per actual
calorific value of coal going to the boiler and the throttle pressure controller has margins all the time on both positive and negative
sides.
Unit capability is capacity of the unit to produce the MW at that time. Unit capability signal depends on the number of
Auxiliaries in service and their contribution is expressed as MW signal which they can support. For example if six mills are required
to produce 500MW each mill capability will be taken as 85 MW approximately. The capability will be computed from each type of
Auxiliaries and minimum of all these will be the unit capability. On any running Auxiliary tripping, unit capability signal will be
dependent on the type of auxiliary tripped.

65

::03::
In Runback mode Boiler combustion controls give commands in proportion to unit capability and boiler will be coming to the state
of steady combustion and hence will be stabilizing. Turbine will be controlling main steam pressure as this will give maximum
stability to the unit. Runback mode gives highest stability to
unit because unit has gone to instability (ex.Mill/BFP/ID/FD tripped) this Runback mode gets selected automatically and ensures
stability. Whenever unit capability is less than unit master command the Runback mode sets in automatically.
The four modes of operation described above can be summarized in the following way.
Boiler Controls
Turbine Controls Input to Boiler
Input to Turbine
Controls
Controls
Turbine
MW
Pressure
MW Set point
Pressure error
follow
(base signal)
MW error signal
Boiler
Pressure
MW
Steam Flow
MW error
follow
(base signal)
Pressure error
Coordinated Pressure
MW
MW set point
MW error
Mode
(base signal)
Pressure error
Runback
Produces steam
Pressure
Unit capability
Pressure error
mode
as per unit
signal
capability
(computed)
Mode

The Coordinated Master Control is written with a view to bring all concepts in it together to give a complete view of it.
Emphasis is given on concepts rather than on the CMC scheme.

66

67