G -1 GENERATOR

1.1.0 General Description: The stator body is a totally enclosed gas tight fabricated structure, suitably ribbed internally to ensure high rigidity. It is designed mechanically to withstand internal pressure and forces as a result of unlikely event of explosion of hydrogen & air mixture without any residual deformation. The Hydrogen gas coolers (4 Nos.) are housed longitudinally inside the stator body. The stator core is made up of segmental varnished punching of Electro technical sheet steel with low loss factor. There are twelve nos. RTDs available to measure the core iron temperature at various points with another 12 nos. provided as standby. The stator has a three phase, double layer, short pitched and bar type of windings having two parallel paths. Each slot accommodates two bars. Each bar consists of solid as well as hollow conductors with cooling water passing through. The stator bar insulation is done with epoxy mica thermosetting insulation. The stator bar top & bottom are connected by means of copper pipes at exciter end. The PTFE (Teflon) hoses are connected between nipple on the stator bar and nipple on the inlet and outlet water headers at turbine end. The stator winding temperature is measured by 60 nos. RTDS & 60 nos. of standby RTDS. The rotor shaft is made up of chromium nickel molybdenum and vanadium steel, the rotor winding is made up of silver bearing copper and rotor slot wedges are made up of Duralumin. The rotor windings are cooled by means of direct cooling method of gap pick up method. In this type of cooling, the hydrogen in the gap is sucked through the elliptical holes serving as scoop on the rotor wedges and it is directed to flow along lateral vent ducts on rotor copper coil to bottom of the coil. The rotor cooling gas is circulated by two single stage axial flow propeller type fans. The slip rings are connected to the field winding through semi flexible copper leads and current carrying bolt placed radially in the shaft. The rotor shaft is supported by pedestal type of bearings. The exciter end bearing has spherical seating to allow self-alignment. The turbine side bearing is accommodated in the bearing housing of LP Turbine rear bearing. On the top of the bearing pedestal, a vent pipe emerges connecting bearing chamber to the suction of the centrifugal fan for venting oil vapour or traces of hydrogen.

A current collector located just above the rotor shaft and touching it is also mounted on the bearing body to give shaft voltage for rotor earth fault protection. To prevent the flow of shaft current, slip rings, bearings and connecting pipes are insulated from earth. The generator bearings are provided with a hydraulic shaft lifting device to avoid barring friction during start up bearing gear operation. To measure the bearing Babbitt temp. 4 nos. RTDs are provided. In order to prevent the escape of hydrogen from generator casing along the rotor shaft, shaft seals provided with oil under pressure are used. The shaft seal is provided with seal oil by a separate closed circuit system. To ensure free movement of the seal ring, the shaft seals are provided with pressure oil for ring relief from governing oil system. The seal oil supplied to the shaft seals, are drained from both air & hydrogen sides. The air side seal is directly drained to the seal oil tank via. float valve. The oil drained towards hydrogen side is passed through pre-chambers and intermediate oil tank before draining to the seal oil tank. Temperature is supervised continuously by monitoring seal oil flow and seal oil drain temperature. For visual check on the flow of the oil towards hydrogen side, oil flow view glasses are provided at either end of the generator. To provide means for safely filling H2 gas into or taking it out of the machine, and to maintain gas pressure in the machine at the desired value, the hydrogen gas system is provided with racks for providing hydrogen & carbon dioxide cylinders, carbon dioxide vaporizer, regulators etc. For cooling the stator winding, phase connectors and bushing stator water is circulated in a closed circuit. To ensure uninterrupted generator operation, 100 % capacity standby pumps are provided. In the event of failure of one pump, the standby pump immediately comes on Auto. All valves and pipes of the system are made of stainless steel materials. The main supply for the Excitation system is tapped from the bus duct through an excitation transformer, where the generator voltage is stepped down to 575 V AC & is converted into DC by means of 6 nos. Thyristor Bridges. The converted DC voltage is applied to the slip rings in the rotor through field breaker.

1.2.0 Technical Data: Max. Continuous KVA Rating Max. Continuous KW Rating Rated Terminal Voltage Rated Stator Current Rated Power Factor Excitation Current at MCR condition Excitation Voltage at MCR condition Rated Speed Rated Frequency Efficiency at MCR condition Negative Sequence Direction of rotation when viewed from slip ring end Phase connection No. of Terminals brought out 1st critical speed of rotor (calculated) 2nd critical speed of rotor (calculated) Total gas volume of generator CO2 for expelling Hydrogen with Unit at Stand still CO2 for expelling Hydrogen with Unit under rolling Hydrogen filling quantity with Unit at stand still Hydrogen filling quantity with Unit under rolling Stator winding distillator filling quantity Nominal pressure of Hydrogen Permissible variations Maximum Temp. of Cold Gas Purity of Hydrogen (min) Flow of distillate through Stator Winding Permissible variation Nominal Temp. of distillate at inlet winding Nominal conductivity of distillate Maximum conductivity of distillate Consumption of oil per generator bearing (excluding shaft seal) Oil pressure at the inlet of bearing Consumption of oil in both the shaft seals No. of carbon brushes required 2,47,000 KVA 2,10,000 KW 15,750 V 9,050 A 0.85 lag 2,600 A 310 V 3000 RPM 50 Hz 98.55 % 2 t = 8 Clockwise Double Star 9 (6 neutral & 3 ) 1370 RPM 3400 RPM 56 cum 120 cum. 168 cum. 300 cum 336 cum 0.35 cum. 3.5 Kg/ Sq.Cm. + 0.2 Kg/ Sq.Cm. 44 deg.C 97 % 27 cum/Hr. + 3 cum/Hr. 45 deg.C 5 micro siemens / cm. 13.3micro siemens / cm. 300 lit/min. 0.3-0.5 Kg/ Sq.Cm. 77 lit/min. 96+242.

1.3.0 Pre Start Checks: 1) Ensure that no work permit is pending and all maintenance works are completed, with men and material cleared in generator. Generator transformer, generator breaker and concerned auxiliaries. 2) Check that the lube oil system is in service with sufficient pressure. The Auto start of the stand by AOP and DC EOP should already have been checked by turbine operator. 3) Check that the drain oil flow through the bearings are normal through the oil flow inspection glass window. 4) Check that the seal oil system is in normal service with AC seal oil pump in service and DC seal oil pump in Auto standby. The Auto start of DC seal oil pump should have already been checked while taking seal oil system into service. 5) Check that the Hydrogen gas pressure inside the generator casing is maintained at 3.5 Kg/Sq. Cm. 6) Check that sufficient No. of Hydrogen cylinders are available in the gas room for emergency and routine make up. Preferably at least 10 to 15 cylinders should be available. 7) At least 15 Nos. carbon dioxide cylinders should be available in the gas room for emergency purging of hydrogen from generator casing. 8) Check that the purity of Hydrogen gas in generator casing is more than 98%. 9) Check that the stator water system is in service with the cooler in service charged on ACW side also. The Auto standby condition of the other pump should have been checked and confirmed, while taking stator water into service. 10)Check the stator water flow (27 cum./Hr.) conductivity (less than 3 micro siemens /cm.) and inlet to generator casing pressure (about 3.5 Kg/ Sq.Cm.) and the performance of the pumps. 11)Check that gas trap is kept open slightly and water flow maintained. 12)Check that the level in expansion tank is maintained by float valve and the level in the stator water make up tank maintained.

13)Check that the earthing brush near slip ring is fixed and in position. 14)Check that the gas coolers are charged and air released through the air vents of individual coolers. The outlet valves (4 Nos.) are kept closed, to prevent water flow through coolers, so that the IR value of the generator will not come down. 15)Check that the generator breaker and its isolators are in open condition. Check the bulbs for the indication of these. 16)The field breaker will be in open condition and AVR control on manual mode. 17)Check that all instruments in the generator control panel are in working condition with the supply switched on for the recorders. 18)The Excitation Transformer cooling blowers are in 'off' condition. 19)The generator Transformer cooling fans and circulation pumps shall be selected for Auto start, with the relevant supplies "on". 20)All the relays in generator relay panel will be checked for reset condition. 21)There should be no annunciation persisting in the generator desk. 22)Check that the AC plant air handling units are in service for AVR cubicle room. The window Air-conditioners shall also be available for service. 23)The cooling blowers for Thyristor room shall be in service. 24)Check that LAVT cubicles are in service position with all the MCBs in the PT Marshalling box should be in "on" condition. 25)Check that any of the 230 KV Bus (Bus I/II/III for Normal Breaker) is healthy and alive, with the grid feeders in service, for evacuating power.

1.4.0 Checks during Start Up: 1) The Generator should be started according to the starting instructions of the turbine and speed raised as per turbine operating instructions. 2) The set shall be kept at 600 RPM for observation. During running up and at 600 RPM check the following. a) Generator bearing vibrations (should be less than 35 microns) b) Abnormal noise and rubbing noise should be watched. c) Bearing temperature and drain oil temperature of seal oil. d) Seal oil pressure and differential pressure between seal oil and hydrogen. e) The oil quantity draining on hydrogen side and the level in the seal oil tank. f) The brush gear and performance of brush etc. 3) Open the gas cooler outlet valves at 600 RPM. Check the flow through the gas coolers. The total quantity of ACW flow should be around 350 m3/ Hr. 4) While picking up the speed :a) The field flashing module shall be switched on. b) The isolators of the generator breaker shall be closed from Switch Yard and got confirmed from switchyard. 5) At rated speed, again check the parameters as above (item 2) 6) After ensuring smooth operation of generator at rated speed only, we proceed for synchronization of the set. 1.5.0 Synchronizing and Picking up load: 1) Check and select the AVR on manual mode. 2) Get clearance from turbine operator and switch yard for synchronization of the set. Inform boiler also. 3) Close the field breaker on remote mode. The field breaker and field flashing breaker will close and the generator voltage builds up. At 70% of the rated voltage, the field flashing breaker will trip on auto. Build up the rated voltage gradually by manual raise / low switch. 4) By adjusting Auto raise / Low switch bring the matching voltmeter reading to zero. Then change over the AVR control on Auto mode. Slightly vary the voltage on Auto mode and see that the variation is alright.

5) Switch on synchronoscope and SY Switch at manual mode. Adjust voltage and speed. 6) The generator should be synchronized manually by closing the generator breaker precisely at a position slightly prior to 12 O Clock position and when the synchronize permissive lamp (Red) glows. The following conditions are to be satisfied for synchronizing the generator with the grid. a) Phase sequences of generator voltage and system voltage are same. b) Effective values of both the voltages are same. c) Frequency of both the voltages are same. The speed of the prime mover should match with the synchronous speed of the grid frequency. d) Both the voltages are in phase. 7) For synchronizing on Auto mode, select the SY switch in Auto mode and auto synchronizing mode in EAST console and wait for the generator breaker to close, when the conditions are matched for synchronizing. 8) Immediately on synchronizing, pick up a load of about 10 MW and VAR on slightly lagging side. 9) Switch off synchronoscope and the synchronizing switch. 10) Check up the parameters of the generator and locally observe the conditions of various systems such as seal oil, stator water and gas systems. Monitor the following parameters a) Cold and Hot gas temperatures. b) Inlet and Outlet temperatures of Stator water c) Generator winding and core temperature d) Bearing temperatures and vibrations. 11) a) b) c) d) e) f) The loading of the generator is limited to the following Stator current limitation Rotor current limitation Rotor angle limitation Cold gas temperature limitation. Outlet stator water temperature limitation Other parameters limited to turbine and boiler.

12) The loading of the generator shall be done as per the start up curves of the turbine under various conditions. 13) The AVR should be on Auto mode as far as possible.

14) When the unit load is more than 70 MW, change over from station supply to unit supply as follows. UNIT-I :- Close 6.6 KV UAT incomer breakers1A/1B.Check for the auto tripping of Station Tie Breaker C1A / C1B respectively. UNIT-II :- Close 6.6KV UAT incomer breakers 2A / 2B. Check for the auto tripping of Station Tie Breaker C2A / C2B respectively. UNIT-III :- Close 6.6KV UAT incomer breakers 3A / 3B. Check for the auto tripping of Station Tie Breaker C2A / C1B respectively. 15) While in service, the casing gas temperature and pressure shall be monitered. If drop in gas pressure is abnormal (Max. make up of 2 nos. hydrogen cylinder per day can be allowed), inform maintenance staff and leakages if any. 16) The Generator voltage shall be maintained at 15.75 KV as far as possible, to have the grid voltage at optimum level. However, the terminal voltage shall be reduced to 14.8 KV, in case of necessity, to limit the rotor current, under high MVAR (lag) load conditions. 1.6.0 Shutting down the Generator: 1) Reduce load on the machine gradually, as determined by the turbine operating condition. At 70 MW tie breakers C1A-C1B for unit I (Tie breaker C2A/C2B for unit II, C2A/C1B for unit III) are to be closed from control room. The incomers from UAT 1A/1B for Unit I (UAT 2A/2B for Unit II, UAT 3A/3B for Unit III) will trip on auto. 2) At a load of about 20 MW, trip the turbine from UCB, by depressing the turbine emergency trip push button in the EAST console. The generator breaker will trip on reverse Power Protection. 3) Inform Switch yard operator to open the isolators of the generator breaker, immediately and subsequently, confirm the same from switch yard. 4) Stop the excitation cooler fan.

5) The UAT A & B incomer breakers shall be taken to Test position after switching off the DC control supply. 6) Close the ACW outlet valves of the generator coolers. 7) Seal oil system and stator water system shall continue to be in service with their vacuum pumps. 8) For prolonged shut down, the generator stator water can be drained after stopping the system and arranged for drying the winding with instrument air. 9) The TG set should be on barring gear, until the HP casing temperature falls below 100 deg.C. If not the rotor should be turned by 180 degrees periodically, say twice in an Hr to avoid thermal deflection of rotor. 1.7.0 Abnormal Conditions: The capacity of the generator should not be increased above the rated value of 247 MVA in any case, except for the short duration as mentioned. The operation of the generator shall be governed by the capability diagram given by the manufacturers. 1. Variation in Terminal Voltage: Generator can develop rated power at rated power factor continuously, when terminal voltage changes within 5% of the rated value. The stator current should accordingly be changed with 5% of rated value, as given below:Sl.No. 01. 02. 03. Terminal Voltage (KV) 16.54 15.75 14.96 Output in MVA 247.0 247.0 247.0 Stator Current (KA) 8.598 9.050 9.503

In extreme conditions of operation depending upon system requirements, generator may be operated up to + 10% over voltage (17.32 KV) or - 10% undervoltage (14.18 KV) provided MVA rating is reduced to 217 MVA and 232 MVA respectively. While operating generator with voltage variation more than 5% frequency variation is not allowed.

2. Frequency Variation: The generator can be operated continuously at rated output within a frequency variation of 6 5% over the rated value, from 47.5 to 52.5 Hz. However, the performance of the generator with frequency variation is limited by the turbine. For the turbine, the LP turbine blades are very sensitive of frequency variation. Operation of the TG set above 51.0 Hz or below 48.0 Hz is not advisable. 3. Temperature of the Coolants and Winding: a) Hydrogen If the temperature of the cold gas increases beyond the rated value of 45 deg.C, generator has to be unloaded suitably as recommended by manufacturers. The operation of the generator with cold gas temperature more than 55 deg.C is not permitted. Similarly, operation of the generator with a cold gas temperature below 20 deg.C is also not recommended. b) Stator Water If cold stator water temperature at stator water inlet of stator winding increased beyond 45C the generator has to be unloaded suitably. The operation of the generator with stator water inlet temperature more than 48C is not permitted. Operation of the generator with cold water inlet temperature below 35C is not recommended. c) Winding, core etc. The maximum allowed temperature of the stator core and winding should not exceed 95C as measured by embedded resistance thermo-meters. The rotor winding temperature can be allowed to go up-to 115C as measured by the resistance method, but at the same time, the temperature rise of rotor winding over cold gas temperature should not exceed 70C.The maximum temperature of the stator water outlet form stator windings is 85C and the hot hydrogen gas is 75C as recommended by the manufacturers. Operation of the generator in Air medium is not allowed.

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4. Over loading of Generator: Under abnormal conditions, the generator can be overloaded for short duration. Permissible values of short time overloads in terms of stator and rotor currents and corresponding duration are given below: Stator Current in K. Amps Time in Mts. Rotor Current in K. Amps Time in Secs. 5. Unbalanced Load Conditions: The turbo-generator is capable of operating continuously on an unbalanced system loading provided that continuous negative sequence phase current during this regime shall not exceed 5% of the rated stator current. It implies that maximum difference between line currents is above 10% of the rated value. At the same time, current in maximum loaded phase should not exceed the permissible value for given conditions of the operation of the turbo-generator under unbalanced loads. At a value of negative sequence current of about 20% of the rated value, trip relay should be operated to disconnect the generator from grid automatically. 6. Unsymmetrical Short Circuit: The duration of the unsymmetrical short circuit should be such that the product of square of negative sequence component of current I2 expressed in terms of per unit value of stator current and its duration in seconds does not exceed. The permissible values of negative sequence currents and the corresponding duration are given below: Sl.No. 01. 02. 03. Duration of Short Circuit Current in Sec. 1.2 5.0 10.0 Negative sequence current in per unit Value 2.30 1.15 0.80 13.57 1 5.2 20 12.22 3 3.9 60 11.31 5 3.12 240 10.41 15 2.75 3600 9.95 60

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7. Asynchronous Operation: Asynchronous (induction Generator) operation of the generator on field failure is allowed depending upon the permissible degree of voltage dip and acceptability of the system from the stability point of view. During the failure of the field, field suppression shall be cut off from the circuit and active load on the generator shall be decreased to 60% load within 30 secs. and 40% load within the following 1.5 mins. As the above process could not be carried out in practice, in NCTPS for loss of excitation generator trip is connected. 8. Motoring Action: In case of sudden closure of ESVs and IVs and control valves, stopping the entire steam flow to turbine, if the generator breaker is not getting tripped on relay protection, then motoring of the TG set will take place, taking power from the grid for meeting the losses. However, steam less regime operation is not allowed for turbine. Hence, in case the generator breaker has not tripped on protection, the same has to be tripped from UCB or from switchyard manually. If it is not possible, the 230 KV bus to which it is connected, has to be made dead by tripping the outgoing feeders and bus section breakers immediately to avoid damage to generator. 1.8.0 Generator Protection System: Sl.No. 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Class A Generator Reverse Power Protection I stage Generator Reverse Power Protection II stage Generator Differential Protection UAT-A Differential Protection UAT-B Differential Protection Overall Differential Protection Generator Inter turn Differential Protection 90% Stator Earth Fault Protection 95% Stator Earth Fault Protection 100% Stator E/F Protection Generator Over fluxing Protection (High Set ) Generator Over fluxing Protection (Low Set) Generator Loss of Excitation (Stage-II) Gen. Backup Impedance Protection (Stage-I) Gen. Over Voltage Protection (Stage-I&II) GT Restricted Earth Fault Protection GT Backup Earth Fault Protection UAT-A Backup Over Current & Inst. Protection UAT-B Backup Over Current & Inst. Protection GT Bucholtz II Stage
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Relay No. 32 G1 32 G2 87 G 87 UAT-A 87 UAT-B 87 GTU 87 GI 64 G2 64 G4 64 G3 99 G1 99 G2 40 G2 2-21G 59G1 & 59G2 64 GT 51NGT 50/51 UAT-A 50/51 UAT-B. 63 GT-II

21. 22. 23. 24. 25. 26. 27. 28. 29.

63 UAT A 63 UAT B 63 PRGT 63 PR UAT-A 63 PR UAT-B 61 B SEE 50 LBB 50LBB-UAT A&B Sl.No. Class B Relay No. 01. Generator Low Forward Power - Without turbine 32 G1, G2 trip protection 02. Generator Rotor Earth Fault Protection Stage-II 64 F2 03. Loss of Excitation (Stage - I) 40 G1 04. Generator Negative sequence I & II stage 46 G1 & 46 G2 05. Generator Winding Temp. Very High 49 GTW 06. Generator Oil Temp. Very High 49 GTO 07. UAT-A Oil Temp. Very High 49 UTA-OII 08. UAT-A Winding Temp. Very High 49 UTA-WII 09. UAT-B Oil Temp. Very High 49 UTB-OII 10. UAT-B Winding Temp. Very High 49 UTB-WII 11. External Class-B Trip from Stator Water system 12. Class - B Trip from AVR SEE Sl.No. 01. 02. 03. 04. 05. 06. Class C Generator Backup Impedance Protection Generator Negative Sequence 1&II State GT B/U Over current Protection Generator Pole Slip Protection Bus bar protection Generator Under Frequency Protection UNIT I & II :- Under Frequency Protection Trip UNIT III :- Under Frequency Protection Trip Over Frequency Protection Trip Relay No. 21 G 46 G1 & 46 G2 51 GT 78 G 96 B 81 G1, G2 81 G3, G4 81 G1, G2 81 G3, G4 (C) (C) (C) (D)

UAT-A Bucholtz II Stage UAT-B Bucholtz II Stage GT Pressure Relief Operated UAT-A Pressure Relief Operated UAT-B Pressure Relief Operated Dead Machine Relay Class-A Trip from AVR Generator Breaker Struck up Protection Unit Incomers 2A & 2B - 50 LBB Protection

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1.8.0. AVR PROTECTION :Class-A :1) 48V Supply Fail (Both AC/DC & DC/DC Converter). 2) Excitation transformer Over Current (Delayed Stage-II). 3) Excitation Transformer Over Current (Instantaneous). 4) Rotor Over Voltage Positive and Negative. 5) Thyristor bridge failures > 5. 6) SEE Direct Tripping a) Field Flashing disturbed. b) Regulation Cubicle Under Test. Class B. 1) Regulator Supply Failure. 2) Excitation Transformer Winding Temperature Very High. 3) Manual Channel failure only if the AVR is in manual mode. ************

2.0 GENERATOR SEAL OIL SYSTEM

2.1.0 INTRODUCTION The use of hydrogen gas for cooling generator has necessitated a reliable and adequate sealing system, during all regimes of operation, to prevent hydrogen escaping to atmosphere. Any abnormality in these seals or the associated seal oil system may lead to hydrogen escape from the machine, and may even cause an explosion in the worst case. Therefore, it is very essential that the utmost care is paid while operating and maintaining this system. 2.2.0 DESCRIPTION The generator sealing is provided by means of single flow ring type shaft seals. These seals are supplied with pressurized oil from an exclusive closed loop oil system to prevent hydrogen escape at the shaft and ingress of air into generator. The oil in the seal oil system is the same as that used in TG bearings and turbine governing system. During normal operation, AC seal oil pump draws the seal oil from the seal oil tank and feeds to the shaft seals through coolers and filters. The seal oil supplied to the shaft seals is drained towards hydrogen and airside through the annular gap between the shaft and the seal ring. The airside seal oil is returned directly into the seal oil tank through a float valve. The oil drained on the hydrogen side, first flows into the pre-chambers, and then flows into the intermediate oil tank, before returning into seal oil tank. The seal oil in the seal oil tank is kept under vacuum to prevent deterioration of hydrogen purity in the generator casing.
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A single stage rotary sliding vane type vacuum pump, which utilizes gas ballast for the operation, is used for this purpose. The gases entrapped in the seal oil are removed, and the seal oil pumps draw only degassed oil. For oil circulation, two (2) 100% capacity screw pumps, one AC motor driven, and the other DC motor driven, are provided. Upon failure of normal AC seal oil pump due to mechanical or electrical fault, the standby DC seal oil pump automatically takes over the supply. Upon failure of both the pumps, the seal oil system is taken over by the turbine governing oil system without any interruption of oil supply. The vacuum pump is kept in operation when either of the seal oil pumps is running. The seal oil is kept at a higher pressure than the gas pressure at the generator seal rings by a specified differential pressure for reliable functioning of shaft seals. With the seal oil pumps in operation, the seal oil pressure is controlled by differential pressure regulating valve (DPRV)-A. Depending on the differential pressure setting, and the signal oil and gas pressures prevailing, a larger or smaller amount of oil is returned into the seal oil tank, so that the required seal oil pressure is established at the shaft seals. The gas pressure and the signal oil pressure act in opposite direction in the valve actuator, and the valve stem is moved upwards or downwards depending on the pressure prevailing. The valve cone is so arranged that the downward movement of the valve stem closes the valve further resulting in a rise of the seal oil pressure at the shaft seals by reducing the flow to the seal oil tank. The setting of the desired differential pressure to be maintained by the valve is carried out by corresponding preloading of the main bellows through a compression spring. Two (2) seal oil coolers, each of 100% capacity, are provided, one of which is in normal operation, while the other serves as stand by. The seal oil flow can be changed over from one cooler to the other by operation of the associated isolating valves, even during unit in service. Two (2) 100% capacity mesh type duplex seal oil filters are provided after the seal oil coolers for screening any foreign particle entrained in the oil and thus preventing any damage to the seal Babbitt and shaft. By means of change over valve assembly provided at the filters, any one filter can be taken out of service for cleaning, without interruption of the oil flow to shaft seals. From the shaft seals, the oil drains out in two parts, viz. one towards the hydrogen side and the other towards the air side. The oil drained towards the hydrogen side is at first passed through the pre-chambers, at both ends. These pre- chambers serve for calming down the oil, permitting the escape of entrained gas bubbles, and de-foaming of oil. At the down stream of pre-chambers, they combine together, and flow into the intermediate oil tank (IOT). The oil from the IOT is continuously returned into the seal oil tank together with the oil drained in the air side through float valves. One float valve provided on intermediate oil
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tank maintains a fixed level in this tank, so that hydrogen in the lines does not escape into drain system. The float valve provided on the seal oil tank permits the inflow of oil so that the level of oil does not go above high level. Any surplus oil which is not accepted by the seal oil tank, is returned to the seal oil storage tank, and finally to the drain line to turbine main oil tank. In the case of any short fall in oil level in the seal oil tank, the oil flows from the seal oil storage tank automatically and maintains the required constant level. The seal oil tank is kept under vacuum for removing dissolved gases by the vacuum pump. When the shaft seal oil supply is obtained from the governing oil system, the pressure is regulated by means of DPRV-B. The valve DPRV-B opens at a downward movement of valve stem (occurs at falling oil pressure in the seal oil system). The regulated oil further takes the same path to the shaft seals through the coolers and filters. Since the oil is not drawn from the SOT the float valve of the seal oil tank will not open and the drain oil will flow towards seal oil storage tank, from where it further flows into the main turbine oil tank In this case, a slow deterioration of hydrogen purity in the generator will take place, necessitating the scavenging of hydrogen to improve its purity. The small amount of hydrogen entrapped with oil does not pose any danger to the generator surroundings, since the seal oil storage tank is provided with 2*100% duty vapour extractors. Moreover, additional extractor is also provided on turbine oil tank. To ensure the free floating condition of sealing ring, in the seal body, even at high machine gas pressures, the shaft seals are provided with ring relief oil, obtained from governing oil supply line through a simplex filter, and is admitted on the side of both shaft seals. 2.3.0 Technical Data Seal Oil System: Type of shaft seal Hydrogen pressure Seal oil/H2 diff.pressure Temperature. of seal oil at inlet Quantity of seal oil per seal Quantity of seal oil flowing - towards hydrogen side - towards air side Pressure of ring relief oil above seal oil (approx.) Pressure of oil from governing oil system Single flow, ring type 3.5 kg/ sq.cm.(g) 1.5 kg/sq.cm 40C 38.5 lpm. 1/3 rd of Qty. of seal oil per seal. 2/3 rd of Qty.of seal oil per seal. 0.5 kg/sq.cm. 7.5 kg/sq.cm.

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a) Seal Oil Pumps Type Capacity (lpm) Head (kg/sq.cm.) Speed (rpm) Motor rating (k w / V) b) Seal Oil Coolers Hot seal oil inlet temperature Cooled seal oil outlet temperature. Quantity of oil cooled Inlet pressure of oil to cooler Pressure drop at oil side Pressure drop at water side CW temperature. at inlet CW temperature. at outlet CW flow CW pressure c) Oil Filters Duplex Type Mesh size (mm) Flow rate (cu.m. /hr.) Design pressure Wire Mesh 0.2 4.62 16 Simplex Wire Mesh 0.2 5.10 16 70 C 40C 4.8 cu.m./hr. 10.5 kg/sq.cm.(g) 8.5 MWC 1.8 MWC 36C 36.8C 72 cu.m. /hr. 10.5 kg/sq.cm (g) A.C SOP Three Screw positive displacement 125 12 960 4.85 / 415 D.C SOP Three screw positive displacement 125 12 960 5.6 / 220

d) Differential pressure Regulating Valve ( DPRV ). DPRV A Bellow actuated, Spring loaded, Indirect acting (Kg/ Sq.Cm) Diff. Pressure operating 0 - 3.5 range Design pressure rating 16 (e) Vacuum Pumps Type Single stage, Rotary vane type
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DPRV B Bellow actuated, Spring loaded, Direct acting (Kg/ Sq.Cm) 0 - 3.5 16

Type

Suction capacity Rotational speed Motor rating 2.4.0 PRE-START CHECK i)

4.2 cu.m. / Hr. 1500 rpm 0.18 k w

Check that all the work permits covering seal oil pumps, coolers, filters, oil tanks, DPRVs, exhausters, etc. are cleared and they are in order. Prepare the AC and DC seal oil pumps and check that the motor and pump units are properly lubricated. Before filling the system, set all level switches at seal oil unit, seal oil storage tank and pre-chambers. Ensure that all stop and non-return shut off valves are initially in closed condition, before filling the system with oil.

ii) iii) iv)

2.5.0 Filling the Seal Oil System i) ii) Open the pressure gauge/pressure switch isolating valves at the seal oil unit; also open the pressure transducer isolating valves. Open the isolating valves on gas/oil impulse lines at the seal oil unit; and the isolating valves for differential pressure transducer impulse lines. Open the valve-55 at the seal oil storage tank. Open the valves at the seal oil unit; a) V-19 for oil from governing system, b) V-16 before DPRV-B, c) V-3 after IOT, d) V-15 before SOT, e) V-1 before AC seal oil pump, f) V-2 before DC seal oil pump, g) V-21 after DPRV-A, h) V-8 after seal oil pumps, i) V-27 before the vacuum pump, j) V-10, V-22, V-23 for relief ring oil. Open the valves V-31 & V-32 at generator for seal oil supply.

iii) iv)

v)

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vi) vii)

Set one seal oil cooler for operation by opening the corresponding inlet/outlet valves (V-61 & V-64/V-62 & V-65). Set any one of the seal oil filter in operation by means of changeover cocks (V-49 & V-50/V-51 & V-52).

2.6.0 Taking the seal oil system into operation i) Set the turbine lubricating oil system into operation, if not already working. Oil flows from seal oil storage tank to SOT through the valve V-55 and SOT level is controlled by the float valve V-11. Now start the AC seal oil pump for filling in the system.

ii) Note: a)

To avoid chocking of the pump lines due to the air locking, the AC seal oil pump should be switched off and on, again and again till the pressure gauges PG-3 & PG-4, show a constant pressure. After that, the seal oil pump can remain in operation. The quantity of oil that flows towards Hydrogen side of shaft seals fills the IOT when there is no gas pressure in the generator, the oil level rises above level gauge LG-1

b) In case the lub oil system can not be brought in operation, alternative method of filling the seal oil storage tank, and the system through seal oil storage tank may be adopted. iii) iv) v) vi) Vent the DPRV-A & DPRV-B by slackening the screw joints in the oil impulse lines. Vent the seal oil coolers by opening the vent valves to vent the gases until the oil comes out of the valves, and then close them. Vent the seal oil filters by opening the respective vent plugs. Vent the pressure gauges & switches PG-1 to PG-9 and PS-1 to PS-5, through the venting screws at respective pressure gauges/switches isolating valves.

2.7.0 Setting of Oil Pressure i) Slacken the check nut at the valve stem. Turn the adjusting nut to set DPRV-A for differential pressure of 2.3 kg/sq.cm. so that the seal oil
19

pressure of 1.5 kg/sq.cm. above the gas pressure at the generator shaft seals is established (clockwise turning of the adjusting nut increases the seal oil pressure at shaft seals). Note: Differential pressure of 2.3 Kg / Sq. Cm includes the static head value of 0.8 Kg / Sq. Cm. ii) iii) iv) Fill the seal oil filter SF by means of change over valve V47/V-48 and vent the filter by opening the vent plug. Stop AC seal oil pump. Adjust DPRV-B by adjusting nut for differential pressure (DP) of 2.0 kg/sq.cm. to obtain seal oil pressure of 1.2 kg/sq.cm. above the gas pressure at generator shaft seals. Normally DPRV-A remains in operation and in case of failure of pumps and as soon as the (differential pressure) at generator shaft seals drops to 1.2 Kg / Sq. Cm, the DPRV-B opens and the oil from governing oil system flows to the shaft seals. DPRV-B is set at a value less by 0.3 Kg / Sq. Cm from the actual set value of DPRV-A. v) Set the ring relief oil pressure by means of valves V-22 & V-23 to a value of 0.5 kg/ sq. cm. above seal oil pressure at shaft seals, i.e. operating value as read on PG-5/PG-6 shall be 6.4 kg/sq. cm. with rated gas pressure of 3.5 kg/sq. cm.

2.8.0 Setting of Alarm and Pressure Switches i) The change over contact in the pressure switch PSI after the AC seal oil pump initiates automatic starting of the standby DC seal oil pump, on falling of oil pressure. The change over contacts of PS-2 & PS-3 activates alarm 'Seal Oil Pressure Low'. Set the level switches at seal oil unit, seal oil storage tank and prechambers, as prescribed. Check the level switches on pre-chambers as follows: Screw out the hexagonal plug from the pre-chamber. Close stop valve V-3 on seal oil unit. The oil level in the generator pre-chamber rises.

ii) iii) iv)

20

The alarm activates as soon as the oil level reaches the level transmitter. Open the stop valve V-3 immediately, the oil level drops and the alarm gets reset. Replace the hexagonal plug ensuring that a gas tight seal is obtained. v) Set the thermostat TS1 at 45C. After a seal oil temperature of 30C has been reached, regulate the cooling water flow for maintaining seal oil temperature below 40C. The system is charged and the normal routine can be started now.

2.9.0 Draining the Seal Oil System Following are the prerequisites before draining the seal oil system: i) ii) iii) The machine has been run down and the generator is at standstill. The hydrogen has been purged out, and there is no gas/air in the generator. The seal oil pump is not running, and the valve V-19 on seal oil unit for supply of oil from Governing Oil System has been closed. Now for draining the seal oil tank i) ii) iii) Close the valves V-8, V-21 & V-26 at seal oil unit and V-55 at seal oil storage tank. Open the valve V-18. Start seal oil pump and vacuum pump, and maintain the pumps in operation until all seal oil has been drained off from SOT. Stop the pumps immediately and close the stop valve V-18. Drain the residual oil quantity left in the IOT by removal of the drain plug. Open the seal oil drain valves of the seal oil coolers and collect the same in a suitable container. Open the drain plugs of Duplex and Simplex seal oil filters and collect the seal oil in a suitable container
21

iv) v) vi)

vii)

For draining the pipes between coolers, ring relief oil supply and pumps, loosen the flanges at non-return shut of valve V-9,and drain and collect the oil. Tighten the flanges after draining.

viii) Drain the oil impulse lines to DPRV-A & DPRV-B by opening the drain valves V-59 & V-60 respectively. Draining of the seal oil system is completed.

2.10.0 ABNORMAL CONDITIONS: 1) "Oil level in any of the pre-chambers - High" a) The isolation valve of the float valve of the intermediate oil tank (V-3) should be checked for open condition. b) The float valve of the intermediate oil tank (V-12) may be defective-The bypass valve V26 of the float valve can be operated slightly till the defective valve is attended. 2) Oil level in the intermediate oil tank - Low" a) Bypass valve of the float valve (V-26) at IOT might have been kept open inadvertently. The same has to be checked for closed condition.

b) The float valve V-12 may not be closing properly or passing heavily. The isolation valve V-3 can be closed suitably and maintain level in IOT. 3) Oil level in seal oil tank - High" a) The float valve V-11 in the seal oil tank may not be closing fully or passing heavily. The isolation valve V-15 can be closed till the level gets normalized. Now gradually open the valve, so that the level is maintained at normal. The float valve has to be attended at the earliest opportunity.

4) Oil level in seal oil tank - low"

22

a)

The isolation valve V-15 shall be checked for open condition.

b) The valve V-55 connecting the seal oil storage tank to seal oil unit might have been kept closed-check for open position. c) The SOT might have been pressurized due to closing of inlet/outlet valves of vacuum pump and also the atmospheric bypass valve, when the vacuum pump is not running. Normalize the valve position so that the SOT is connected to vacuum or to atmosphere. d) The float valve V-11 in seal oil tank may not be functioning properly. As a temporary measure, the level can be controlled through the bypass valve till the float valve is attended.

5) "Seal oil pressure - Low" a) When AC/DC seal oil pump trips, this alarm will appear. Check that DPRV-B is in service. Due to malfunctioning of DPRV-A the oil pressure may drop. Check up the operation and correction may be done, if necessary. Check that the differential pressure across the Duplex filter is not High. The emergency supply system to seal oil through DPRV-B may be checked up for normal condition.

b)

c) d)

***************

23

3.0. GENERATOR GAS SYSTEM

3.1.0 INTRODUCTION: The Hydrogen gas is used as cooling medium in generator because of its higher heat transfer capacity and light weight. However, it is having the property of forming an explosion mixture when mixes with air. But the risk of explosion is almost eliminated, when the Hydrogen gas quantity is less than 4 % or more than 74 %. Therefore, in generator wherein hydrogen gas is employed in closed circuit, the purity has to be always maintained beyond 90 %. In practice, a hydrogen gas purity of about 99 % is maintained inside the generator casing. The hydrogen gas system performs the following functions: i) ii) iii) iv) Provides means for safety filling of hydrogen gas into or purging out of the machine. Maintains gas pressure inside the machine at the desired value. Indicates the operator, at all times the condition of the gas in the machine, its pressure and purity. Removes moisture from the gas in the machine, which may from seal oil. get into it

3.2.0 SUPPLY SYSTEMS: 3.2.1 Hydrogen supply system: The hydrogen gas is obtained from hydrogen generating plant, and brought to gas room in steel cylinders at a pressure of 150 Kg/sq. cm. The hydrogen supply for the generator is obtained from a hydrogen gas distributor where 8 Nos. hydrogen cylinders can be placed at a time. The pressure has to be reduced before admission to the generator casing. There are two pressure regulators for this purpose of expansion to the intermediate pressure of 8-9 Kg/sq. cm. This pressure is further reduced to generator casing pressure by two pressure regulators available in the gas unit. The safety relief valves are inbuilt with pressure regulators on low pressure as well as high pressure headers. Because of two parallel pressure regulators, large quantities of hydrogen can be handled during hydrogen filling operation, whenever necessary by making use of both of them at a time. The low pressure header is maintained at constant pressure, as one of the gas cylinders remains open during generator operation for routine make up.
24

Hydrogen is admitted to the generator through a three-way valve, H-9 and hydrogen feed pipe. The filling line is connected to the perforated pipe header inside generator extending along the casing at the top. 3.2.2 Carbon dioxide supply system: As a precaution against explosion hazard, the air must neither be directly replaced with hydrogen during generator filling nor the hydrogen replaced directly with air during the emptying operation. In both cases, the generator must be scavenged with an inert gas such as carbon dioxide for the purpose. The carbon dioxide gas is obtained in steel cylinders and it is in a liquid state in the cylinder due to pressure. The cylinders should be of siphon type to ensure complete emptying of the cylinders as well as to avoid evaporation of liquid carbon dioxide in cylinder itself, which may result in carbon dioxide snow formation and consequent choking of cylinder valve and reduced supply. The arrangement of carbon dioxide distribution is similar to that of hydrogen distribution. The carbon dioxide leaves the cylinder in liquid state and is evaporated and expanded in the carbon dioxide vapouriser. The necessary heat for vapourisation and expansion is supplied to the vapouriser by the electrical heaters. A thermostat is provided in the carbon dioxide vapouriser to ensure the desired temperature so that freezing of carbon dioxide in the pipe is prevented as well as the heat transfer liquid does not change its characteristics or composition by high temperature. A safety valve each on high and low pressure sides of the vapouriser protects the pipe system against high pressure. An expansion orifice after vapouriser is provided for controlling carbon dioxide pressure being fed during carbon dioxide filling operation. Carbon dioxide is fed to the bottom of the generator casing through a three way valve. Being a heavy gas, it will displace the lighter gas like hydrogen or air from the top of the generator casing, as the carbon dioxide fills up from bottom. 3.2.3 Air supply system: For removing carbon dioxide from the generator, compressed air supply with moisture separator and air pressure regulator is connected to the compressed air supply system of the power station. Instrument air is used for this purpose. Under all conditions of operation, except for carbon dioxide purging with air, the compressed air hose arranged between the filter and the generator pipe system should be kept disconnected. It is to ensure that no air can be admitted into the generator filled with hydrogen.

25

3.2.4 Filling & Purging operations: For removal of air from the generating casing before filling with hydrogen, carbon dioxide is admitted until a mixture of 95 % of carbon- dioxide in air (min) is obtained in the discharged gas to atmosphere. Hydrogen is then admitted at the top of the casing through hydrogen feed pipe and the carbon dioxide is discharged to atmosphere through carbon dioxide feed pipe. When a mixture of 96 to 98 % hydrogen (min) in the gas discharged is obtained, the discharge valve to atmosphere HC-1, should be closed. Hydrogen feeding to the casing is continued until required pressure of 3.5 Kg/sq.cm and purity of 99% of hydrogen is obtained. Hydrogen is purged out of the generator by admitting carbon- dioxide. The hydrogen pressure is first reduced to 0.15 to 0.20 Kg/cm} before admitting carbon dioxide. Carbon dioxide is then admitted through carbon dioxide feed line until a carbon dioxide purity in excess of 96 % is obtained in the discharge gas. After achieving this, air filling is started to expel the carbon dioxide out of the machine. After reducing carbon- dioxide concentration to the level of 4 to 5 %, air pressure can be raised if necessary. For convenience of operation and to simplify erection, all necessary equipments, instruments, and valves required during gas filling, purging and normal operation of turbo-generator are mounted on a gas unit. This is assembled and tested in works and is only required to be piped up-to generator, Hydrogen and Carbon dioxide distributors at site. To facilitate the operation of various valves during different operations, gas unit is provided with a mimic diagram. 3.3.0 OTHER AUXILIARIES: 3.3.1 Gas drier: Two gas driers, one working and the other as standby are connected to the ventilation circuit of the generator for removing moisture from the hydrogen gas. The gas driers contain silica gel as absorbent and are provided with electrically heated regeneration facility. For regeneration of the drier, close the inlet and outlet valves of the drier, and open the drain valve and release hydrogen to atmosphere. Switch on the heater, which is provided in a separate chamber of the gas drier. The moisture evaporated from saturated silica gel (pink color) will be vented out to atmosphere. The regeneration will be completed when the temperature of the silica gel reaches 120 oC, indicated by the tripping of the heater by the thermostat provided in the drier. After regeneration, the color of the silica gel will turn blue. At this stage, the drain valve H-35/H-36 is opened to drain the moisture condensed in the vent pipe. The drier is ready for reuse now.

26

3.3.2 Liquid leakage detector: To detect the presence of water or oil in the generator casing, a condition, which could result from a leaky tube in the gas cooler or from stator water header nipples or oil flow from shaft seals into the generator casing, a Liquid Leakage Detector (LLD) is provided. It is connected to drain line from the bottom of the generator casing. This device actuates the magnetic switch float and operates an alarm. There are two other LLDs provided one each from the end shield positions in order to monitor the performance of hydrogen seals. They are connected for alarm, whenever liquid collection, (mostly seal oil) is sensed. 3.3.3 Gas Purity Meters: a) Purity meter working on thermal conductivity principle: Gas purity meters are used for measuring the purity of hydrogen in the generator during normal operation as well as for the analysis of the gas mixtures (Carbon dioxide/air and Carbon dioxide/Hydrogen) during filling and purging operation of the generator. The gas required for measurements is taken from the generator or from the filter cum pressure regulator and discharged to the atmosphere-outside machine hall. A safety relief valve HC-5, is provided on the low pressure side of the pressure regulator to avoid excessive pressure in the gas analyser. The purity of hydrogen gas during normal operation is monitored by gas analyser indicator. Another purity indicator during purging operations (range 0-100 % carbon dioxide in air and 0-100 % Carbon dioxide in Hydrogen) is also provided. A gas analyser indicating recorder is provided in UCB for monitoring hydrogen purity during normal operation of generator. A terminal connection for collecting gas sample for chemical analysis in the lab, is provided in the gas unit. The gas analyser consists of a wheat-stone bridge each arm of which contains a fine glass coated platinum wire. One pair or parallel arms are sealed in a reference gas of well known thermal conductivity and the other pair is exposed to the sample gas. A constant current is passed through the bridge network. When the thermal equilibrium is achieved, due to heat generated by the current in the gas medium (the temperature of the surrounding gas and hence the resistance of the wire is a function of thermal conductivity) the unbalance created in the bridge due to difference between the thermal conductivity of the reference gas and sample gas, will give the indication, directly the purity of Hydrogen in percentage. b) Mechanical purity indicator: Mechanical differential pressure indicator mounted on 'gas unit', is meant for monitoring purity of hydrogen in the generator casing during normal operation of the machine.
27

The DPT is connected across the suction and discharge side of the cooling fan mounted on the TG rotor. The mechanical hydrogen purity metering system utilizes the physical relationship between the hydrogen generator casing pressure and the differential fan pressure, which in turn depends upon the fan speed and the specific gravity of the medium handled by fan. Since generator speed is almost constant during normal operation of the machine and the gas pressure in the generator casing is kept at a predetermined level a variation of the differential fan pressure is therefore indicative of change in gas purity. 3.3.4 Carbon dioxide vapouriser: The carbon dioxide vaporizer is used to prevent icing when carbon- dioxide liquid is expanded into gas for filling in the generator casing. The carbon dioxide vaporizer consists of a cylindrical housing closed by flanges at both ends. At one end, the electrical heating elements are fixed and on the other flange, the inlet and outlet to the coiled copper pipe of the vaporizer are fixed. The horizontally arranged housing is filled with heat transfer liquid to ensure a better heat transfer to the copper pipe coil and thus to the carbon dioxide flowing through the pipe coil. For protection against excessive heating, thermostat is installed in the housing. For protection against possible high pressures relief valves one at the inlet and another at the outlet of the vapouriser are provided. The orifice at the carbon dioxide outlet of the copper coil provides for an expansion of the carbon dioxide obtained from the cylinders to a pressure of 0.5 to 1.8 Kg/sq.cm. 3.3.5 Gas unit: For convenience of operation and to simplify erection, all necessary equipments instruments and valves required during gas filling, purging and normal operation of generator are mounted on the gas unit. This is assembled and tested at works and is only required to be piped upto generator, Hydrogen and Carbon dioxide distributors at site. To facilitate operation of various valves during different operations, gas unit is provided with mimic diagram. 3.4.0 Technical Data: Sl. No 01. 02. 03. 04. 05. 06. 07. Description Rated hydrogen pressure inside generator casing Maximum H2 pressure at which signal is initiated Minimum H2 pressure at which signal is initiated Rated cold gas temperature Max. permissible hot gas temperature. Min. purity of hydrogen permissible Max. permissible moisture content in hydrogen
28

Unit 3.5 Ksc 3.7 Ksc 3.3 Ksc 44C 75C 97% 4500 ppm

08. 09.

10. 11. 12.

Generator gas volume Amount of hydrogen required to fill the generator, to rated pressure at NTP a) When machine is stationary b) When machine is running Max. make up required per day Quality of carbon dioxide required for purging Amount of carbon dioxide required to remove hydrogen from gen. Casing (NTP) a) When machine is stationary b) When machine is running Amount of carbon dioxide required to remove air from gen. Casing (NTP) a) When machine is stationary b) When machine is running Capacity of hydrogen cylinder / each Volume of hydrogen in each cylinder Pressure of hydrogen in gas cylinder No. of cylinders required to fill gen. Casing at machine stand still No. of cylinders required when the machine is running No. of hydrogen cylinders required for make up per day (max) Capacity of carbon dioxide cylinder / each Equivalent gas volume No. of carbon dioxide cylinders required for purging out hydrogen at stand still No. of carbon dioxide cylinders required for purging out hydrogen when machine is running No. of carbon dioxide cylinders required for purging out air when machine is at rest No. of carbon dioxide cylinders required for purging out air when machine is at running Quantity of compressed air required for carrying out air tightness test

56 cu.m 300 cu.m 340 cu.m 15 cu.m Grade II as per IS :30766 120 cu.m 168 cu.m

13.

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

90 cu.m 112 cu.m 46.7 litres 7 cu. M 150 Ksc 50 Nos. 55 Nos. 2 to 3 Nos. 30 Kg. 15 cu. m 11 Nos. 14 Nos. 8 Nos. 10 Nos. 500 cu. m (NTP)

3.5.0 Operating instructions for carrying out purging operations: 1) Never use fire or an open flame (welding, cutting, smoking etc.) near the generator, and hydrogen gas system.

29

2) Filling and emptying of hydrogen gas can be carried out with the generator at rest or on turning gear. Filling during turning gear operation will result in higher gas consumption. 3) The seal oil system and bearing vapour exhaust fan shall be in service and will positively remain in service before starting purging operations. 4) The carbon dioxide vapouriser shall be filled with heat transfer liquid upto the required level. 5) Ensure that the compressed air hose is not connected with the air line. Making this connection should only be done when compressed air from the station air system is required for removing the carbon- dioxide from the generator or for performing air tightness test. 6) Check to ensure that all shut off and three way valves in the gas unit at the gas drier and in the distributor are closed. 3.5.1 Purging out air with carbon dioxide: All the lines carrying carbon dioxide gas during this operation are represented by yellow lines on the mimic diagram of the gas unit. 1) Open all the pressure gauge isolation valves. 2) Establish supply to the carbon dioxide vapouriser and switch on. Check that the heater is getting switched off as and when the temperature reaches the set value in the thermostat. 3) Open the shut off value in hydrogen vent gas line (HC-1) 4) Turn the three-way valve H-9 in the hydrogen vent gas position. 5) Turn the three-way valve C-3 in position of carbon dioxide filling. 6) Open the isolation valve C-2 in the carbon dioxide cylinders header. 7) Take the carbon dioxide purity measuring transmitter into service. The carbon dioxide / hydrogen purity transmitter shall be kept in 0 -100% carbon dioxide in air position. 8) Empty the carbon dioxide cylinders in such a manner the pressure in generator casing is maintained around 0.5 Kg/sq.cm

30

9) Filling with carbon dioxide can be terminated when a purity in excess of 96 % carbon dioxide in air is reached. 10) If the already opened carbon dioxide cylinders are not completely empty when the carbon dioxide purity in air is 96 %, the residual carbon dioxide also should be emptied into the generator. 11) Switch off the heater supply for the carbon dioxide vapouriser. 12) Close the three way valve C-3 in carbon dioxide filler line. 13) Close the header valve C-2 in the rack of carbon dioxide cylinders. 14) Close the H-9 three way valve from the gas vent position. 15) Close all shut off valves at carbon dioxide distributor manifold and at carbon dioxide cylinders. 3.5.2 Filling generator with hydrogen: Note ; Prior to starting filling up of hydrogen gas inside generator, ensure that sufficient numbers of carbon dioxide cylinders are available nearby for next purging in case of emergency. 1) Open the following valves for lining up the system for hydrogen filling. a) b) c) d) C-3 three way valve in carbon dioxide vent gas position. H-9 three way valve in hydrogen filling position. H-8 three way valve after the Hydrogen Pressure Reducer HPR-3 & HPR-4. H-7A valve before the hydrogen pressure reducer HPR-3 or H-8A valve before the hydrogen pressure reducer HPR-4 e) H5 isolation valve before HPRs f) H-4A and H-3A valves before and after HPR-1 or H-4B and H-3B valves before and after HPR-2 g) H-2 the isolation valves from cylinders to the hydrogen gas manifold 2) Keep other valves in closed condition. 3) Check the pressure after the second pressure reducer, which should not in any case exceed 3.5 Kg/cm, the rated pressure of generator.

31

4) Turn the selector in carbon dioxide / hydrogen purity transmitter to the appropriate position for measuring the hydrogen purity. 5) Continue filling hydrogen until the indicator as well as sample reading as tested by chemist gives purity above 98 % of hydrogen in air. 6) Raise the pressure of hydrogen to the required value; say 3.0 Kg/cm initially. 7) The raising of pressure of hydrogen can be done during run up of TG set or even at rated speed. 3.5.3 Taking hydrogen gas drier into service: 1) The gas from the generator flows through drier inlet valve into the gas drier chamber, from where it passes through the silica gel. Then it returns to the generator casing, by means of the differential pressure created by the generator rotor fan. 2) Close the inlet and outlet valves of the working drier. 3) Open the inlet valve of the stand by drier, allow a very small amount of hydrogen through the drain, and then close the drain valve. 4) Open the outlet valve and the drier is in service. 5) The colour of the silica gel indicates saturation with moisture by changing from deep blue to pink. 6) Switch on the heater of the drier, which has been isolated on hydrogen side, for reactivation. The heating cycle is controlled by thermostat, at 80c 7) After reactivating for four hours, allow drier to cool down for four hours. 8) Drain off the water if any collected. The drier is again ready for reuse. 3.5.4 Purging out hydrogen with carbon dioxide: 1) Prior to removing hydrogen from generator casing, ensure that sufficient carbon dioxide cylinders are available and carbon dioxide vapouriser is in working condition. 2) Close the following valves in the system. a) H-9 hydrogen filling line, b) H-8A, H-8B hydrogen pressure reducing unit, H-7A, H-7B isolation valves, H-3A, H-3B, H-4A, H-4B. c) H-5 isolation valve in between HPRs
32

d) e)

H-2 shut off valves at H2 manifold. H-1 shut off valve at H2 manifold.

3) Lower the gas pressure in the generator casing by operating the three way valve H-9 in position of 'Hydrogen vent gas' to atmosphere via orifice OP and valve HC-1. Bring the pressure to 0.5 Kg/sq.cm 4) Switch on the heater for carbon dioxide vapouriser and wait until the thermostat switches off the heater. 5) Open the following valves in the system. a) HC-1 Shut off valve in vent gas system. b) C-3 Three way valve in position of carbon dioxide filling c) H-9 Three way valve in position hydrogen vent gas. 6) Then open shut off valves at carbon dioxide cylinders and carbon- dioxide distributor manifold. Replace empty cylinders with full cylinders. 7) Carbon dioxide/Hydrogen purity measurement shows the purity of the vent gas. 8) Take samples parallely and check for purity of carbon dioxide in hydrogen. 9) When generator is filled with carbon dioxide in excess of 96 % in hydrogen, filling of carbon dioxide can be stopped. 10)Close the following valves. a) C-3 Three way valve in carbon dioxide filling line. b) H-9 Three way valve for measuring gas. c) C-2 The isolation valve in the carbon dioxide manifold d) C-1 The shut off valves in the manifold and cylinders 11)Switch off the heater of the carbon dioxide vapouriser. 12)Start filling the generator with dry air, as the carbon dioxide can not be left inside generator casing indefinitely. 3.5.5 Filling generator with air: 1) 2) All the lines carrying gas during this procedure are represented by blue lines on the mimic diagram. Select range selector in carbon dioxide/Hydrogen purity transmitter to the position giving 0-100 % carbon dioxide in air.

33

3) 4)

Establish hose connection between compressed air filter and shut off valve A-1. Open the following valves. a) A-1 Air inlet valve after air pressure regulator b) A-2 Shut off valve in the compressed air line. c) C-3 Three way valve in position carbon dioxide vent gas. Ensure that instrument air is clean and dry. Adjust the compressed air pressure by means of shut off valve A-2 so that the pressure in generator casing will not exceed 1 Kg/sq.cm initially. Check the purity of carbon dioxide in air by meter as well as sample testing. When 0% of carbon dioxide in air is achieved, it can be taken that carbon dioxide has been purged out. Open shut off valves downstream of the liquid level detectors and close three way valve C-3 for purging the pipes to the level detectors. After purging, change the three way valve C-3 to position carbon- dioxide vent gas, and close shut off valves down stream of liquid level detectors. Close the valves A-1 and A-2

5)

6)

7) 8) 9)

10) Remove hose connection between compressed air filter and shut off valve A-1 11) Maintain air pressure of 1 Kg/sq.cm if it is required to keep the machine on barring gear. If the machine is sufficiently cooled and barring gear is going to be stopped, then the pressure can be killed, before stopping the barring and stopping seal oil system. ****************

34

4.0. STATOR WATER COOLING SYSTEM

4.1.0 Introduction: The Turbo generator employs a closed loop circulation of high quality demineralised water through hollow conductors of stator winding. The generator can deliver its rated load only when the stator water system functions properly. Exciting the machine without stator water is prohibited. 4.2.0 Description: The stator water supply system consists of the following main components: 1) 2) 3) 4) 5) 6) 7) 8) Centrifugal pumps (2*100%) Stator water coolers (2*100%) Polishing unit (1*10%) Mechanical filters (2*100%) Magnetic filter (1*100%) Gas trap. Expansion tank. Vacuum pumps (2*100%)

The centrifugal pump is meant for circulating the DM water taken from expansion tank through cooler, mechanical filter, magnetic filter, winding and back to the expansion tank. Failure of the working pump to maintain required pressure or failure of power supply to the running motor will cause the standby pump to come on auto, by sensing the drop in stator water pressure below a set value. The heat absorbed by the stator water in the generator is dissipated in the stator water cooler, the cooling medium being the ACW DM water. The polishing unit is provided for constantly improving the specific resistivity of the stator water. It is a mixed bed, consisting of cat ion exchanger and anion exchanger. The exchanger resins are capable of accepting ions from stator water, while releasing equivalent amount of other ions viz., hydrogen ions from cat ion exchanger and hydroxyl ions from the anion exchanger. This process takes place with in a very short time, while the stator water is passed through the ion exchanger. The mechanical filter eliminates any foreign particles in the water, which may choke or erode the hollow conductors. Difference of pressure at inlet & outlet of the filter is an indication of the degree of choking.

35

The magnetic filter prevents any magnetic particles from entering the generator. Any accidental leakage of hydrogen gas into the main stator water stream is detected by gas trap. The water from the outlet of stator winding collects in an overhead expansion tank, which provides a constant level of water during normal running of the system. The hot water enters the tank through perforated pipe in the form of spray thus releasing any entrapped gas. A vacuum pump is connected to expansion tank for maintaining vacuum for the purpose of removing any traces of dissolved gases or hydrogen gas which may be present as a result of hydrogen leakage into stator water. Level signaling device & level switches are provided in the expansion tank to monitor the high and low level. Two out of three low level contacts initiate a tripping command for stator water pump. Make up DM water to the expansion tank is admitted through a float operated valve from stator water surge tank at 27m level. Two separate stator water pumps are provided in the DM plant to fill up the surge tank as and when required. The quantity of DM water flowing through the windings is measured by a system of orifice plate, flow transducers, and flow indicators & recorder. Signaling contacts are available in flow switch & indicator which are set to annunciate a low flow of 20 cum/hr through winding and initiate a tripping of the machine after 60 seconds at emergency flow of 13 cum/hr. on the principle of two out of three logic. Continuous monitoring of the conductivity of stator water is done by two conductivity cells and suitable indicator and recorder. Conductivity high alarm is initiated at 13.3 micro siemens/ cm. and at very high specific conductivity of 20 micro siemens / cm, the tripping is initiated. 4.3.0 Technical Data: a) Pumps :Total Nos. Type Capacity Total head Motor rating Full load current Speed b) Stator Water Coolers:Total Nos. Quantity of flow ACW flow ACW pressure ACW inlet temperature. ACW outlet temperature.
36

2 Nos. Horizontal, centrifugal 39.6 cum./hr. 45 m 9.3 KW, 12.5 hp. 18 Amps. 2930 rpm 2 Nos. 27 m3 / hr. (Normal) 110 cum./hr. 5 Kg / Sq. cm 36C 42.2C

Stator water inlet temperature. Stator water outlet temperature. c) Stator Water Expansion Tank:Capacity Vacuum Material Normal level

72.6C 45C 2.11 cum. 300 mm Hg (Normal) Stainless Steel 850 mm.

d) Mechanical Filter (Wire Mesh - Disc type):Rated discharge 30 cum /hr. Max. pressure rating 12 Kg / Sq. Cm Min. size of particle that can be filtered 0.224 mm Pressure drop across filter during normal 0.1 to 0.2 Kg / Sq. Cm running Pressure drop across filter at which cleaning 0.4 Kg / Sq. Cm is recommended No. of filter element / filter 45 e) Magnetic Filter (Permanent Magnet):Maximum inductive density 4000 gauss Capacity 36 cum / hr. Pressure Not more than 10 KSC f) Stator Water Vacuum System :Make Model Max . Vacuum achievable Displacement HP Required RPM Drive Sealant Required Heat Exchanger a) Design Pressure (Shell Side) b) Design Pressure (Tube Side) c) Tested Pressure (Shell Side) d) Tested Pressure (Tube Side) e) Heating Surface area f) Shell side g) Tube side ACMEVAC Pumps Ltd., 2T 30 720 mm Hg. 51 M3/hr. 3 HP 2850 Directly coupled 11 LPM 4 Kg / Sq. Cm 4 Kg / Sq. Cm 6 Kg / Sq. Cm 6 Kg / Sq. Cm 1 Sq. Cm Working Water ACW

37

g) Polishing Unit:Capacity 2 m3 / hr. Design conductivity of water at I/L 1 micro mho / cm. Design conductivity of water at O/L 0.44 micro mho / cm. PH value of water at I/L 6 to 7 PH value of water at O/L 7 0.2 Operating period of resin bed 6 months Resin & Regenerant Quantities for each exchanger Resin Quantity (Lit) Regenerant Qty (Kg) Tulsion T- 42 11.5 Hcl -30% 20.3 Tulsion A -27HP 115 NaOH 100% 11.5 h) Quality of Stator Water:Conductivity PH Dissolved Oxygen Dissolved carbon dioxide Ammonia Chloride Dissolved / Un dissolved copper Dissolved / Un dissolved Iron Other requirements Less than 5 micro mho / cm. Preferably 1 micro mho / cm. 6.5 to 7 Less than 100 ppb Nil Nil Nil Less than 20 ppb Less than 20 ppb The water should be free of any chemicals from treatment processes, such as hydrazine, morpholine, phosphate etc.

4.4.0 Prestart Checks & Lining Up: 1) Check that all work permits, covering the stator water coolers, magnetic filters, mechanical filters, specific resistivity measuring device, stator water pumps, supply modules etc. are returned and got cancelled. 2) Ensure that the stator water surge tank is clean and filled with DM water by stator water makeup pumps available in DM plant. While filling the surge tank, check the annunciations for low and high levels. 3) Take all instruments into service and check the supply availability for the stator water panel. 4) Check the stator water pumps, ensure proper lubrication, and lube oil level.
38

5) Check that the isolation valves of both stator water coolers are kept opened fully, and that air vents are open. 6) Check that the ACW isolation valves of both the coolers are kept open. 7) Check that the suction valves of both the stator water pumps are open. 8) Ensure the isolation valves of both the mechanical filters are open. 9) Check that root valves to the flow measuring impulse lines are open. 10) Check that inlet and outlet valves of the stator water lines to the windings are fully closed and the re-circulation valve is open. Check that the stator winding vent valves and isolating valves of gas trap are open. 11) Before filling up expansion tank, check that the drain valve is closed at the bottom of the tank. 12) Check that the drain valve at stator water pump suction is closed. 13) Check that the drains at the stator water inlet line to the windings and outlet line are kept closed. 14) Now fill the expansion tank from the stator water surge tank. At the normal level, the float will automatically close, to maintain the level under all conditions. 15) For checking the level low alarm and flushing the tank, the expansion tank filling valve may be kept closed, and drain valve at pump suction opened, till the expansion tank is fully drained. Then close the drain valve and fill up the expansion tank. 16) Prime the stator water pump and gradually fill the stator water coolers, by opening the discharge valve of any one of the pumps. Observe free flow of water through the air vents and then close the vents. 4.5.0 Taking the System into Service: 1) Check that the level in expansion tank is maintained by the float valve. 2) Check that the discharge valve of both the pumps is closed. 3) Switch on supply to the stator water local panel for both the pumps, and keep the selector switch in UCB in manual and local.

39

4) Start any one of the pumps form local and gradually open the discharge valve. Check the load current, which should not exceed the rated current. 5) The stator water flow will be on re-circulation without going into the winding. 6) Check the conductivity of the sample by testing in the lab. This value and the 'on line' conductivity value shall be compared and correctness verified. 7) If the conductivity is more than 5 micro siemens /cm, the entire water shall be drained and refilled, till we get at least a value of 5 micro siemens /cm for admitting into the winding. 8) Once we get a satisfactorily pure water, the pump shall be stopped locally after closing the discharge valve. 9) Then open inlet and outlet valves to the stator winding and the re-circulation valve throttled. 10) Open the discharge valves of any one of the pumps and fill the system by gravity. 11) Observe free flow of water through the vents in gas trap and wait till the normal level in expansion tank is attained. 12) Then close the discharge valve, start any one of the pump locally, and open the discharge valve fully, observing the load current. 13) Adjust the flow to the winding by adjusting the RC valve and outlet valve to have the rated flow of 27 cum/hr. 14) Check the conductivity. If the conductivity is less than 3 micro siemens /cm the flow through the gas trap can be reduced. 15) After achieving normal value (<3 micro siemens /cm), the outlet valve of any of the coolers can be kept closed and kept as standby. Check that the ACW outlet isolation valve for that particular cooler is kept closed. 16) Isolate any one of the mechanical filters and keep it as standby. 17) Open the discharge valve of the other stator water pump. 18) From UCB, check the auto start of the standby pump and select the standby pump on auto.(During commissioning of the pump from overhaul, the actual pressure of the stator water to the winding shall be dropped by
40

throttling inlet valve, to see that the standby pump starts on `pressure low' interlock). 19) After keeping the system in service, take any of the vacuum pumps into service, by opening the inlet and exhaust valves and keeping the seal water. Ensure that always slight sealing water overflow is maintained. Maintain a vacuum of about 250-300 mm Hg by suitably adjusting the vent valve. 20) Take the polishing unit into service by suitably opening the inlet valve, air vents and isolation valves of the ion exchanger. Before admitting the polished water back into the system, by opening the outlet valve of the polishing unit, the conductivity shall be checked by the `on line' instrument and by testing in the lab. 4.5.1. To Stop the Vacuum Pump : 1) Close the suction valve to the vacuum pump. 2) Switch off the electric motor. 3) Close the working water inlet valve to the pump. 4.6.0. Checks while in service: 1) Check the load current of the pump, which shall not exceed the rated value. 2) Check the lubrication oil level and the vibration and temperature of bearings by hand touch. 3) Check the pump discharge pressure and pressure of stator water at various points including at inlet to the winding. 4) Note the differential pressure across the mechanical filter. If it exceeds 0.5 Kg/Sq. Cm., arrange for cleaning the filter. However, before taking the other filter into service, care must be taken to see that, the stagnant water having high conductivity shall not cause the generator trip. It is always better to wait for a shut down/trip out for changing over to the standby cooler or standby filter. 5) Check the conductivity of stator water. If the value is more than 3 micro siemens / cm. increase the flow through the gas trap so that fresh water will be added to the system for improving the value. 6) Check the vacuum in expansion tank check the performance of the vacuum pump and the flow of a little quantity of sealing water to atmosphere.
41

7) Check the level in expansion tank. It shall be maintained constant under all circumstances by the float valve. 8) Check the level in the stator water surge tank, physically in the gauge glass or in the tank at-least once in a shift. 9) Check the stator water flow. 10) Check the stator water temperature at inlet to windings and at outlet. 11) Check the ACW flow to the stator water cooler and the inlet and outlet temperatures (by hand touch). 12) Check the entire system for any leakages. If any leakages are observed, the maintenance staff shall be informed for prompt action. 4.7.0 Limiting Values, Protections & Interlocks: 1) Exciting the generator without establishing stator water flow is prohibited. 2) The normal conductivity of stator water shall be maintained below micro siemens / cm. 3) The normal flow through the winding shall be maintained at cum./hr. 4) Stator water inlet pressure to winding will be about 3.5 Kg/Sq.Cm. 5) Stator water inlet temperature to winding will be about 35 to 40C. 6) The conductivity at the outlet of the polishing unit shall be about 0.5 micro siemens / cm. 7) If the stator water inlet temperature exceeds 45C, unload the generator suitably, as per the instructions given in generator. 8) If the differential pressure across the mechanical filter is more than 0.4 Kg/Sq.Cm., arrange for cleaning the same at the earliest opportunity. 4.8.0 Alarms/Protections/Interlocks: Conductivity HI-Alarm Conductivity HI-HI-Trip Flow low - Alarm 13.3 micro siemens/cm. 20.0 micro siemens/cm. 21 cum./hr.
42

3 27

Flow low-low-Trip Stator water inlet Temp. low Stator water inlet Temp. HI Stator water outlet Temp. HI

13 cum./hr. 35C 45C 75C

1) If the conductivity is >20mcs/cm (specific-resistivity =50 K.ohm. cm.) the generator will trip under class B protections. 2) If the stator water flow is less than 13 cum./hr. for one minute, the generator will trip under class-B protections. 3) If any of the two level low-low switches in expansion tank act, then the running stator water pump will trip and the permissive for the other pump to come on interlock will not be available. Hence the generator will trip, after one minute. 4) If the pressure low switch at inlet to stator winding acts (at 2.8 Kg/ Sq. Cm.) the stand by pump will start on auto, provided the selector switches at UCB are selected in remote and auto. 5) There is no auto standby provision available for the vacuum pumps. ******************

6.0. D.C. SUPPLY SYSTEM.

43

6.1.0 INTRODUCTION: A reliable power supply and control supply for emergency drives, emergency lighting, protection & interlocking circuits and computer systems are absolutely essential in a large thermal power stations. For this purpose D.C., supply systems are provided with necessary batteries and chargers. The main components of the D.C. system are battery, chargers and switchgears. There are three D.C supply systems available in N.C.T.P.S. Viz 1. 220V D.C supply system. 2. 24V D.C supply system. 3. 360V D.C U.P.S Back up Battery supply. 6.2.0 BATTERY: Basically, battery is an electro-chemical energy converter. Chemical energy is converted into electrical energy in battery. The main components of battery cell are container, positive and negative plates, electrolyte and separators. The commonly used batteries are lead acid type. The electrolyte and the plates are placed in the acid proof container. To keep positive plates and negative plates from coming in contact with each other, separators are inserted between them. The number and size of the positive and negative plates depend upon the ampere-hour capacity of the cell. The positive plate is of lead peroxide and the negative plate is of spongy lead. The electrolyte used is diluted sulphuric acid. The reaction during discharging; PbO2 + Pb + 2H2SO4 ( + ve) ( - ve) PbSO4 + PbSO4 + 2H2O ( + ve) ( - ve)

As water is formed during discharge along with formation of sulphates, the specific gravity of the electrolyte falls. During charging the chemical reaction is reversed. The active materials are converted back into lead peroxide and spongy lead simultaneously releasing hydrogen. The H2 combines with sulphates and sulphuric acid is formed, thus increasing the Sp.gr of the electrolyte.

6.2.1. 220V BATTERY: In NCTPS there are 5 Nos. 220V batteries as detailed below; Sl No NAME FEEDING TO
44

1 2 3 4 5 6.2.2.

Unit 1 220V Battery Unit 2 220V Battery Unit 3 220V Battery Station 220V Battery Switchyard 220V Battery + 24V BATTERY:

Unit 1 220V DCDB Unit 2 220V DCDB Unit 3 220V DCDB 220V Station DCDB -1&2 Switchyard 220V DCDB

There are 3 Nos +24V batteries in each Unit as detailed below, Sl No NAME FEEDING TO 1 +24V BHEL -1 Battery C&I Panels through 24V Unit 2 +24V BHEL -2 Battery DCDB at LT Switchgear room 3 +24V THL - 1 Battery C&I Panels through 24V DCDB at UCB Panels room 6.2. 3. - 24V BATTERY:

There are 3Nos 24V batteries in each Unit as detailed below Sl No NAME FEEDING TO 1 -24V BHEL -1 Battery C&I Panels through 24V Unit 2 -24V BHEL -2 Battery DCDB at LT Switchgear room 3 -24V THL - 1 Battery C&I Panels through 24V DCDB at UCB Panels room 6.2.4. 360V U.P.S BATTERY:

There are 2Nos UPS batteries in each Unit as detailed below 1) 360V UPS Battery-Bank-1. 2) 360V UPS Battery-Bank-2. 6.2.5. Technical Data. Capacity 1400 AH 300 AH 1600 AH 800 AH 400 AH No of cells 104 104 13 13 180

System Make 220V DC Unit &Station UB-MEC 220V DC Switchyard UB-MEC +24V DC Unit Standard -24V DC Unit Standard 360V DC UPS EXIDE All batteries are of Lead-acid type. Specific gravity of electrolyte: 1.200 6.3.0. FLOAT AND BOOST CHARGERS:

45

Float charger feeds the load current and trickle charges the battery connected with it. It works on the constant voltage mode and keeps the output voltage constant at set value. Boost charger is used to boost charge the battery whenever required. It works on the constant current mode and keeps the output current constant at set value. During boost charge the battery voltage will be high. Hence, 80% tap from the battery will come across the load and changes over to 100% connection when A.C supply fails/Boost charger trips. During change over there will be no supply interruption. Battery will feed the load when there is no A.C supply and when the float charger trips. Float/Boost charger consists of Power circuit and control system. Power circuit consists of mainly a step down power transformer, thyristor bridge, filter circuit, power contactor, MCCB, fuses. A 3-phase A.C supply is given to the input and a D.C supply is taken from the output. Control system consists of a power supply card, firing circuit, feed back/control circuit, protection and annunciation circuit. Power supply card supplies + 12V, - 12V, + 24V D.C supply to the electronic circuits and relays. Firing circuit gives firing pulses to the thyristors in the bridge circuit. Feed back/control card measures the output voltage/current, compares it with the set value and gives out a reference voltage. In auto mode this reference voltage controls the firing angle and keeps the output voltage/ current constant at the set value. In manual mode the reference voltage is from a potentiometer and the output voltage/current is controlled manually by adjusting the potentiometer manually. 6.3.1. 220V CHARGER:

There are 5Nos 220V Battery chargers as detailed below 1.Unit 1 220V charger, 2.Unit 2 220V charger, 3.Unit 3 220V charger, 4.Station 220V charger, 5.Switchyard 220V charger. a) Unit charger gets A.C supply from N/E Switch Gear. b) Station charger gets A.C supply from SSS A&B Switch Gear. c) Switchyard charger gets A.C supply from Switchyard AC DB. d) Unit charger feeds Unit 220V DCDB and trickle charges Unit battery.
46

e) Station charger feeds Station DCDB 1&2 and trickle charges Station battery. f) Switchyard charger feeds Switchyard DCDB and trickle charges Switchyard battery. Each charger consists of a main float charger, a stand by float charger, a main boost charger, a stand by boost charger and a change over panel. One float charger will be in service and it can be selected from the change over panel. The boost charger can also be selected and used for boost charging the battery. 6.3.2. TECHNICAL DATA: 1 2 3 4 5 6 7 8 9 6.3.3. Make In put Current Power factor Efficiency Out put Current Regulation Ripple Kaybee powerlec Chennai-96 A.C Voltage - 415V 10% 3 Phase 3 Wire 96 Amps (Float) 94 Amps (Boost) 0.80 Lag minimum 80% D.C Voltage - 200 -230V (Float) - 200-300V (Boost) 200A (Float) 150A (Boost) 1% 3% w/o Battery

Switching ON of charger:

a) Switch ON main AC MCCB. b) Switch ON DC out put switch. c) Select auto/manual mode. d) Bring auto and manual pot to minimum. e) Press the ON PB (Red). Now the power contactor will close. f) Slowly raise the auto/manual pot watching voltage and current. g) Raise the DC voltage to 225V limiting the battery charging current to 50A. 6.3.4. Issuing LC on the Charger and Battery; a) Switch ON Link switches in Unit DCDB and Station DCDB. Now the two DCDBs will be in parallel with their chargers. Note the current and voltage on the chargers and confirm to be normal. b) Switch OFF the charger on which LC is required and ensure there is no interruption of DC supply in the DCDB.

47

c) Switch OFF In comer from charger in the DCDB. Now the charger and the battery are isolated from the DCDB. Note the current and voltage on the charger in service. Issue LC on the charger switched off and the battery. 6.3.5. Normalising after Return of LC. a) Switch ON In comer from charger in the DCDB. b) Switch ON the charger. Now the two DCDBs will be in parallel with their chargers. c) Switch OFF Link switch in Unit DCDB/Station DCDB. Now the two DCDBs are isolated with their charger and operate individually. 6.4.1. 24 V Charger. In each Unit, there are 4 Nos +24V Battery chargers and 4 Nos -24V Battery chargers as detailed below; 1) +24V BHEL 1 & -24V BHEL 1. 2) +24V BHEL 2 & -24V BHEL 2. 3) +24V THL 1 & -24V THL 1. 4) +24VTHL 2 & -24V THL 2 (These two chargers have no Batteries). The above chargers get AC supply from N/E Switch Gear of the respective unit. I) ii) 24V BHEL 1&2 chargers feed 24V BHEL DCDB in the L.T SGs room. 24V THL 1&2 chargers feed 24V Tata Honeywell DCDB in the UCB panels room.

Each charger unit consists of one float charger and one boost charger. Float chargers feed the load and trickle charges the batteries. Boost chargers are used for boost charging the batteries. 6.4.2. TECHNICAL DATA: 6.4.3. +24V Charger: Make : Kerala State Electronics Development Corp. Ltd.

a) Float charger:
48

1 2 3 4 5 6 7 8

In put Out put Out put Current Out put regulation Out put ripple Type of control Cooling Ambient temp

415 10% 3 Phase 3 Wire 27.95V - 28.6V 502A 1% 3% SCR half controlled, bridge rectifier Force Cooled 45 deg C

b) Boost charger: 1 2 3 4 5 6 In put Out put voltage Out put Current Out put regulation Out put ripple Type of control 415 10% 3 Phase 3 Wire 24V - 36V 225A 1% 3% SCR half controlled, bridge rectifier

6.4.4. - 24V CHARGER: Make Input Voltage Power Factor Electra Power Supply Systems (P) Ltd., 415V, 3 Phase, 3 Wire Better than 0.8 Lag

a) Output of Float charger: Voltage Current Regulation Ripple Efficiency at rated load Type of Control b) Output of Boost charger Voltage Current Regulation Ripple Efficiency at rated load Type of Control 21 36 V 125 A 1% 3% 80% SCR full wave fully controlled bridge. 25 32 V 125 A 1% 3% 80% SCR full wave fully controlled bridge.

6.4.5. Switching ON of +24V charger:

49

1) 2) 3) 4) 5) 6)

Switch ON main AC MCCB & MCB. Switch ON DC out put MCCB. Select auto/manual switch. Reduce Vol-Adj. Press ON Push button. With delay Voltmeter will read. Adjust Vol-Adj to read voltage 30V limiting battery charging current to 50A. Switching ON of 24V charger:

6.4.6. 1) 2) 3) 4) 5) 6) 7)

Switch ON main AC MCCB. Switch ON DC out put MCCB. Put load selector switch in Normal. Select battery selector switch to Float/Boost. Select auto/manual switch. Reduce Vol-Adj. Press down Charger on Switch (Toggle switch). Now a power contactor will close and with delay, voltmeter will read. 8) Adjust Vol-Adj to read voltage 30V limiting battery charging current to 30A. 6.4.7. Issuing LC on the 24V Charger: As two chargers are feeding the system in parallel, one set of 24V charger can be switched off for issuing LC with out interruption to the system. 6.4.8. LC on the 24V BHEL Chargers feeding BHEL system. 1) Switch ON Bus coupler switch on the 24V BHEL DCDB(see note). Now Bus A with 24V BHEL-1 charger and Bus B with 24V BHEL-2 charger will be in tie. 2) Trip one set of chargers (+24V and 24V chargers) on which LC is required. 3) Note the current and voltage on the chargers in service and confirm to be normal. 4) Ensure paralleling of the bus sections A&B by observing the current flow through the bus coupler switch. 5) Switch OFF the In comer from +24V charger and In comer from 24V charger on the 24V BHEL DCDB. 6) Give LC on the chargers and batteries. Note; Bus A and Bus B on the 24V BHEL DCDB are feeding each C&I panel in parallel. Either Bus A or Bus B can feed the entire system. But some times some loads may have one source only from either Bus A or Bus B for some
50

reasons. Hence, to be on the safer side the bus coupler switch is closed before tripping one set of chargers for issuing LC. For issuing LC on the Bus also the bus coupler switch need not be closed. 6.4.9. LC on the 24V THL Chargers feeding Tata Honeywell system:

1) Trip one charger (+24V charger or 24V charger) on which LC is required. 2) Note the current and voltage on the chargers in service and confirm to be normal. 3) Switch OFF the In comer from +24V charger / In comer from -24V charger on the Tata Honeywell DCDB, in source 1 panel in the case of 24V THL-1charger and in source-2 panel in the case of 24V THL-2 charger. 4) Give LC on the charger and battery. Important Notes: There is no bus coupler switch between Source-1&2 buses. Source-1 Bus is having battery back up, but Source-2 Bus has no battery back up. Hence feeding the system with source-2 only is not reliable 6.4.10. General instructions: While switching on of a charger, the battery will draw high charging current and the semiconductor fuses may blow out. Hence, the charging current should be limited while raising the out put DC voltage. While switching on of a charger on auto mode, if there is no voltage raise, switch over to manual mode and raise the voltage. Inform to the maintenance engineer. The charger may trip on supply interruption, voltage dip, and N/E Supply change over and it should be charged immediately. Note the battery current on every shift and it should be on the charging side. 6.5.0 220V DCDB: In NCTPS, there are 5 Nos 220V DCDBs as detailed below; 1) Unit 1 220V DCDB. 2) Unit 2 220V DCDB. 3) Unit 3 220V DCDB. 4) Station 220V DCDB-1& DCDB-2. 5) Switchyard 220V DCDB .

51

1) All 220V DCDBs are having A Bus and B Bus with bus coupler switch in NC. All Unit 220V DCDBs can be alternatively fed from station 220V DCDB and vice versa. 2) The switchyard 220V DCDB can be alternatively fed from station 220V DCDB 3) Unit DCDB is having one incomer from unit float charger and battery on Bus A. 4) Station DCDB-1 is having one incomer from station float charger and battery on the Bus B and tied with station DCDB-2. 5) H.T. Switchgear panels L.T. Switchgear panels GRPs etc are provided with double DC sources. One from A Bus and other from B Bus. Source required will be selected at load ends. 6) While issuing LC on the one bus, confirm that DC sources at the load ends are selected on the other bus. 7) While issuing LC on the A Bus of Unit DCDB B Bus will be fed from station DCDB and vice versa. 6.5.1. DC Leakage System. Each of the 220V DCDB bus sections have been provided with leakage checking arrangements with voltmeter & Push buttons in addition to leakage current E/F relay to give alarm. Further, a voltmeter with selector switch has been provided in the GCDP of each unit (UCB) for checking DC leakage in the unit DC supply. 6.6.0. 6.6.1. UNINTERRUPTED POWER SUPPLY General.

UPS System provides security of supply. They are used for important and sensitive equipments having critical survival time. In spite of the present general high reliability of electrical power system, the problems like voltage drops, switching surges, and short-term interruptions can always occur. Modern computer and telecommunication systems place heavy demands on availability of power supply. In computer systems, any interruption even in the order of mille seconds durations can cause loss of data program or even damage to the hardware. The requirements of UPS system are the availability and quality of power supply at all time.

6.6.2 Types of UPS System:

52

There are three types of UPS system, namely, (1) ON-Line UPS, (2) OFF-Line UPS, & (3) Electronic generators. In ON-Line UPS System, whether the main power is ON or OFF, the inverter is ON all the time and supplies the AC out put voltage. In OFF-Line UPS and Electronic generators, the inverter is OFF when the main power is present and the out put supply is from the mains supply. The inverter is ON only when the main supply goes OFF and feeds the loads. 6.6.3. UPS System in NCTPS:

Each Unit consists of one ON-Line UPS system. 2*65KVA 110V AC single phase 50 Hz. This system consists of UPS modules 1&2, one common battery boost charger, By pass supply from SCVS, and one System Out put Assembly (SOA). 6.6.4. UPS module:

Each UPS module consists of one rectifier, one battery, and one inverter with filter. UPS module
VM S2 USS A/B 415V AC 3 INPUT CB-1 Rectifier Battery 360V 400AH 180 NOs CBB VM AM 405V DC Inverter CB-2 110V AC 1 AM VM AM

A). RECTIFIER AND BATTERY: Rectifier receives 3 phase 415V AC supply from USS Switchgears .It is rectified to 405V DC and fed to 405V DC bus. The battery is connected in parallel with the rectifier out put and is trickle charged. B). INVERTER AND FILTER:
53

Inverter receives DC supply from the 405V DC bus and converts it into 110V AC square waves. The output frequency will be in synchronism with the by pass supply from the SCVS. The out put voltage can be controlled by adjusting the firing angle. The filter converts this square waves into sine waves suitable for connection to the computer loads. In the event of power failure the inverter draws its power from the battery instead of from the rectifier. There will be no interruption of output supply. When power returns the rectifier feeds the inverter and trickle charges the battery. 6.6.5 COMMON BATTERY BOOST CHARGER:
VM AM Hz Battery-Set-1

CBB-1 USS A/B 415V AC 3 Ph CB 1 Input Rectifier VM AM CB-2

O O O

Mod-1 Off CBB-1 Mod-2

Module-1 Charger

Module-2 Charger

Battery-Set-2

There is one separate common battery boost charger for UPS module 1&2. This can be selected for boost charging of the batteries in UPS module 1&2. 6.6.6
VM N/E 415V AC 3Ph Input Voltage stabilizer

BY PASS SUPPLY:(SCVS) VM
AM VEE connected Transformer-65KVA 110V AC 1 Ph Output To SOA

54

Supply from N/E Switch gear fed to servo controlled voltage stabilizer is used as By pass supply in this system. It consists of a VEE connected transformer, a variac, and allied electronic circuits. In auto mode the servo motor alters the variac arm and keeps the out put voltage at set value of 110V AC. In manual mode, the variac arm is altered manually. In the event of fault in UPS modules 1&2, this by pass supply feeds the loads. 6.6.7 SYSTEM OUTPUT ASSEMBLY: (SOA) K3
KK SCVS

110V.AC-1Ph To Load 110 V UPS BUS UPS-module-1 UPS-module-2

K2

SOE is responsible for changing over of supply to loads, from UPS module bus to bypass supply and vice versa. 110V AC supply from UPS modules 1&2 and SCVS are fed into this panel. Normally supply from UPS bus is fed into the load through the contactor K2.When there is no supply in the UPS bus the load will be fed from SCVS through the contactor K3 automatically. This may also be achieved manually by means of a selector switch (S8) on the SOE panel. During change over there will be no supply interruption. The static bypass short circuits K3 during the transfer period and provides a true NO-Break supply to the critical load. 6.6.8 Technical data: 1 2 3 4 5 6 Make Capacity Input supply Output voltage Frequency Wave form of the O/P Voltage
55

TATA Liebert Limited, Bombay 65 KVA (each UPS module) 415 V A.C 3 Phase 110 V A.C single Phase 50 Hz Sinusoidal

7 8 9 10 11 12 13 14 6.6.9 1 2 3 4 5 6

Total Harmonic distortion (THD) Power factor Inverter efficiency Over load permissible Short time rating Cooling Out put frequency tolerance Ambient temperature Battery and charger Charger out put voltage Type Floating voltage No of cells Voltage Voltage at the end of discharge

<4% RMS 0.8 Lag 89 % 125 % for 10 minutes 150 % for 10 sec Forced air 0.5% 0 - 40 deg. C

405 V DC Float& Boost 2.25 V/cell 180 360 V 300 V

6.6.10 LED Indications - UPS module: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Fuse failure. Over load. Over load shut Down (Alarm : load exceeds 100% . Trip: 150% & 10 Sec). Emergency shut Down. DC over voltage (Trip at 440 V DC). Spare. Equipment over Temp. Low battery (Alarm at 307 V). Battery circuit breaker. Battery on load (Alarm DC bus below 360 V). Main failure. Fan failure. DC Ground fault. Control power failure.

6.6.11 LED Indication---SOA. 1- 6 Module 1-6 Fault (Alarm). 7. Load on by pass. 8. Static by pass inhibited. 9. Out put over voltage (+10%). 10. Out put under voltage(-10%). 11. Battery on load. 13. Low battery. 14. Over load(100%).

************
56

7.0. ELECTRICAL SUPPLY SYSTEM

7.0. INTRODUCTION: There are four levels of voltages for evacuating power and driving auxiliaries, viz., 230 KV, 15.75KV, 6.6KV and 415V. The Generator output voltage is 15.75KV, which is stepped up to 230 KV through Generator Transformer and tied with 230 KV Bus and power is pumped to the grid through seven 230 KV feeders. 230 KV Bus and 15.75 KV Bus feed 6.6 KV switch gear panels through 230 KV / 7.0 KV 7.0 KV Station Transformers and 15.75 KV / 7.0 KV Unit Auxiliary Transformers for 6.6 KV motors and 6.6 KV / 415V Service transformers. The 15.75 KV Bus also feeds self excitation transformer. 6.6KV / 415V Service Transformers feed L.T Switchgear panels for feeding L.T motors, lighting loads etc. 7.1.0.0. 230KV SUPPLY SYSTEM: Indoor switchyard is employed for the 230KV System in view of the saline atmosphere near the Station and to prevent deposition of dusts on the insulators and equipments, leading to flash over and breakdown. 7.1.1.0. BUS ARRANGEMENT : There are two buses in the Switch yard. One is called main bus and the other one is transfer bus. The main bus is divided into three sections, viz., Bus section-I, Bus Section-II and Bus Section-III with 2 Nos. Bus Section Breakers in between them. Normally these breakers will be in ON condition. During fault in one section, these breakers will trip and isolate the faulty Bus Section. All the feeders and Station transformers are fed from this Bus through their breakers and isolators. GT-I, II & III is tied with Bus Section I,II & III respectively. The transfer bus can be tied with main Bus through one TIE Breaker. This arrangement can be used to feed any one of the 230KV feeder or transformer in the event of L.C on the respective breaker. The feeders and Transformers connected to each bus section are given below :57

7.1.1.1. BUS SECTION-I : 1) 2) 3) 4) Station Transformer I 230KV ETPS Feeder GT-I 230KV Kilpauk Feeder

7.1.1.2. BUS SECTION-II : 1) 2) 3) 4) 5) Transfer Breaker ST-II GT-II 230KV Tondiarpet Feeder 230KV Gummudipoondi Feeder-I

7.1.1.3. BUS SECTION-III: 1) 2) 3) 4) 5) 230KV Gummudipoondi Feeder - II 230KV Sriperumbudur Feeder GT-III 230KV Mosur Feeder ST-III

7.1.2.0. PROTECTION SCHEME : 7.1.2.1. 230KV FEEDER PROTECTION 7.1.2.2. MAIN-I PROTECTION :ABB make distance relay type RAZFE is used for Main-I Protection. This has the following main features. a) b) c) d) e) f) g) Static three phase design Minimum operating time approximately half a cycle. Superior ground fault measurement by shaped polar characteristic. Accurate and selective measurement with small transient over reach. Separate measuring element at all steps for ground and phase faults. Very low burden on current and voltage instrument transformers. Suitable for single phase tripping.

7.1.2.3. INDICATORS :1) RN Start indication for Single Phase fault RN 2) SN Start indication for Single Phase Fault SN
58

3) TN Start indication for single Phase fault TN. 4) 2Ph- Start indication for two-phase faults (RS, ST, TR). 5) 3Ph- Start indication for three-phase faults. 6) U - General tripping. 7) TK2- Operation of step 2 time lag relay. 8) TK3 Operation of Step 3 time-lag relay. 9) P - Power Swing blocking. 10) = - DC Power supply interruption. The indicators are reset electrically by a push-button in the front of the Unit. 7.1.2.4. FAULT LOCATOR :Main-I protection panel also consists of one ABB make fault locator Type RANZA. The distance to the fault is presented as a percentage of the linesection length on a front mounted display. 7.1.3.1. MAIN-II PROTECTION :ABB make static distance relay type LZ96 is used for Main-II Protection. This has the following main features. a) Very rapid, un switched with four measuring systems. b) Protects very long, heavily loaded lines. c) Four steps, three of which are directional distance steps, the fourth being nondirectional. 7.1.3.2. LED INDICATIONS: Starting Time Steps Tripping Tripping blocked Tripping by signal received } from opposite station } Ready for operation Internal monitor operated } (Protection out of action) } - Yellow R, S, T - Yellow 2,3,4 - Red D - Yellow D Yellow H (HF Off) - Green - Red, Yellow

Earth fault protection: ALIND Alstom make DIR E/F relay is provided in Main I & Main II Panels.

59

7.1.4.0. STATION TRANSFORMER & GT PROTECTIONS :a) Differential Protection (87) b) Restricted E/F Protection (64) c) Over current protection (50) & (51) d) Earth fault protection (64) e) Negative sequence (46) (ST - Trip not connected, GT- Trip connected) f) HV winding temperature high (Trip- 95, Alarm- 85) g) LV winding temperature high (Trip- 95, Alarm-85) h) Bucholz protection (Top-Alarm, Bottom-Trip) i) OLTC Bucholz protection (Trip) j) Pressure relief valve (Trip) k) MOG Oil level low (Alarm) l) Oil Temp. high (Trip-85, Alarm-75) m) Fire protection (Not connected) 7.1.5.0. OLTC :OLTC is provided for each station transformer and will be operated between 6.4 KV and 6.8 KV. 7.1.6.0. 230KV Bus Protection: 1. Diff. Protection Main Zone - Trips all the breakers connected with the faulty bus Section. Check Zone Trips all the breakers connected with the Bus section I,II & III. 2. Over current protection :- Trips the Bus Coupler Breaker only. 3. Earth fault protection :- Trips the Bus Coupler Breaker only.

7.1.7.0. 230kv Breaker protection & Annunciation :a) 50 LBB (Local breaker backup) Trips all the breakers in the particular zone. b) Trip circuit-1 faulty (Alarm) c) Trip circuit-2 fault (Alarm) d) Pole discrepency (Trip) e) Air pressure low (lock out alarm) f) Gas pressure low (Lock out alarm) g) DC failure (Alarm) h) Compressor motor O/L Trip (Alarm) i) Compressor oil level low (Alarm)
60

7.1.7.1. DISTURBANCE RECORDER AND EVENT LOGGER DISTURBANCE RECORDER :For each 230KV feeder, Station transformer, GT and Bus coupler there is one disturbance recorder panel. It records continuously voltage, frequency of the grid and records the following inputs. Disturbance recorder panel for G.T is located in GRP at UCB. 7.1.7.2. For 230kv Feeders :a) b) c) d) e) f) g) h) i) 50 LBB CH-1 DIR Trip CH-2 DIR Trip A/R Operated Main-I Trip- 21L1 E/F-1 operated Main-2 Trip- 21L2 E/F-2 operated 87B Operated

7.1.7.3. For Station Transformer & G.T a) Diff. protection operated b) HV winding temperature c) LV1 winding temperature d) LV2 winding temperature e) Pressure relief trip f) OLTC PRV Trip g) Oil level low h) Res. E/F operated i) O/L + E/F operated j) Bucholz trip k) Oil temperature trip l) Fire protection trip m) LBB Operated n) 87B Operated 7.1.7.4. For Bus Coupler :a) 50 LBB operated b) O/L + E/F operated c) B/B Protection zone-1 operated d) B/B protection zone-2 operated e) CT circuit zone faulty f) B/B protection GR A/B DC fail g) 50 LBB Bus transfer operated
61

7.1.8.0. EVENT LOGGER :Three panels are there for all the systems in the switchyard. It records a) Every operation of isolators. b) Every operation of Breakers. c) CB Trip circuit 1 & 2 faulty. d) CB pole discrepancy. e) Group A&B DC fail. f) CB Compressor oil level low. g) CB Air pressure low. h) CB Gas pressure low. i) CB Lock out alarm. j) CB Compressor motor O/L alarm. k) 50 LBB out of service operated. l) Every protection Relay operation. m) Transformer winding temperature trip. n) Transformer oil temperature trip. o) Bucholz trip. p) Pressure relief trip q) A/R unsuccessful And other trip relays and annunciation relays operation. 7.2.0. 6.6KV SUPPLY SYSTEM :There are two 6.6KV supply systems. One is 6.6KV Station supply system. The other is 6.6KV unit supply system. 7.2.1.0. 6.6KV STATION SUPPLY SYSTEM :6.6KV Station supply system is fed from 230KV / 7.0 KV 7.0KV Station transformers I, II & III. It comprises of the following switchgears. a) 6.6KV C1A & C1B Switchgear in Unit I fed from Station Transformer I. b) 6.6KV C2A & C2B Switchgear in Unit-II fed from Station transformer II. c) 6.6KV C3A & C3B Switchgear in Unit-III fed from Station Transformer III. d) 6.6KV Coal handling plant switchgear A Bus is fed from C1A switch gear and B bus is fed from C2B Switchgear. e) 6.6KV Ash handling plant switchgear A Bus is fed from C2A switchgear and B; bus is fed from C1B Switchgear. f) 6.6KV ECH Switchgear A Bus & B Bus are fed from C3A & C3B Switchgears.

62

These switchgears feed 1) 2) 3) 4) 5) 6) 6.6KV Unit switch gears when the concerned unit is not in service. Coal handling plant loads (ICH & ECH). Ash Handling Plant loads. Water treatment Plant loads through service transformers. Dry fly ash carrying system loads through service transformers. Standby BFP 1C, 2C & 3C.

To give LC on any one of the Station Transformers, there are tie bus ducts for extending 6.6KV supply from the other Station Switchgears. 7.2.1.1. 6.6KV UNIT SUPPLY SYSTEM :In each unit, there are two 6.6KV Unit switchgears, fed from their unit auxiliary transformers as detailed below a) 6.6KV U1A & U1B switchgear in Unit-I fed from UAT 1A & 1B. b) 6.6KV U2A & U2B Switchgears in Unit II fed from UAT 2A & 2B. c) 6.6KV U3A & U3B switchgears in Unit III fed from UAT 3A & 3B. There is no Bus coupler between A Bus and B Bus. Initially the buses are fed from 6.6KV Station switchgears. When the unit comes on stable load say about 70 MW, the UATs are cut in. When unit trips, 6.6KV UAT supply will be cut out and Station Supply will be extended. The switchgears in each unit feed their a) b) c) d) e) f) g) h) i) j) k) l) Boiler feed pumps Cooling water pumps Condensate Extraction Pumps Induced Draft fans Forced Draft fans Primary Air fans Coal Mills ESP transformers Unit Service Transformers CWP Service Transformers FOPH Service transformers Excitation transformer -A&B - A, B & C -A&B -A&B -A&B -A&B - A to F - 2 Nos. -A&B - Only during Separate Excitation arrangement.

63

7.2.2.0. PROTECTION SCHEME :7.2.2.1. 6.6KV BUSES & FEEDERS :6.6 KV Buses, feeders and Ties are given over current protection through ABB make over current relays in R,Y,B Phases and its current settings are furnished below. Description 6.6KV Station switchgear bus 6.6KV Unit switchgear bus 6.6KV AHP Feeder 6.6KV CHP Feeder 6.6KV TIE bus from one Station Switchgear to other 6.6KV TIE Station to Unit 7.2.2.2. TRANSFORMERS :Service transformers are given 3 O/L and 1 E/L protection, Bucholz relay protection, winding temperature and oil temperature protections. Winding temperature alarm is set at 85 deg C and Trip at 95 Deg C. Oil temperature alarm is set at 75 Deg C and trip at 85 Deg C. Current Setting :SST UST ESP Tr. FOPH Tr. CWP Tr. 200 Amps 200 Amps 150 Amps 150 Amps 50 Amps Current Setting 3000 Amps 1500 Amps 600 Amps 750 Amps 3000 Amps 1500 Amps

7.2.2.3. 6.6 KV MOTORS :All the 6.6KV motors are provided with ABB make motor protection relays Type RAMDE. This relay is having the following protective functions and characteristics. a) Thermal overload relay, which continuously monitors the thermal content in the stator winding. Issues an alarm signal at 95% and trips the motor at 104% of permissible thermal content. ( Value) b) Short-circuit protection . ( I > ) [Set value : 6.8 to 9.0 times FL Current]

64

c) Stator ground fault relay ( I > ) [Set value : 10%] d) Current unbalance protection ( I >) (t I) [Set value 0.12 to 0.16 with 5 sec delay] e) Protection against locked rotor ( I > stall) [Set value 1.5 times Full load Current] f) Protection against prolonged starting times (t start) [set value 6 sec to 35 sec] g) Blocking of un permitted startings (t sv) [Set value 2 min] h) Numerical presentation on a display of set values, actual values during protection and trip values. i) Continuous monitoring of internal circuits and auxiliary voltage. 7.2.2.4. Current Settings I b CWP CEP BFP ID Fan FD Fan PA Fan Coal Mill motor 138 Amps 58.5 Amps 370 Amps 176 Amps 114 Amps 135 Amps 50.4 Amps

Further, all the motors are provided with under voltage protection. When the 6.6KV Bus voltage comes down to 5.28 KV (80%) or dead, all the breakers of running motors will trip with a delay of 3 seconds. 7.2.2.5. INDICATORS IN RAMDE RELAYS:Green LED In Service Shows a fixed light When the relay is in service Shows the motors thermal content as a percentage of the thermal content in the steady state condition at rated load. I b indicator lights up at the same time. Thermal content is higher than 95% Tripped due to thermal over load. Red I b indicator
65

Yellow LEDs > 95 Trip

shows a flashing light. Lock out - Starting of the motor is blocked. Manual resetting is required if the lock-out selector switch is in position-I. If it is in position- 0, the indicator automatically extinguishes when the blocking is removed.

Red LEDs Mode Pushbutton - When the mode PB is repeatedly depressed, the LEDs light up in consecutive order and indicate with a fixed light the protective function which is to be set. Service Value / Reset PB Service Values :1. Load current 2. Thermal Content 3. Unbalance current 4. Latest starting time 5. Latest Starting current 6. Accumulated starting time in starting time register I Load I load and I > t Start I Start t start - When the service value PB is repeatedly depressed, the LEDs indicate the function, and the service values are shown on the display.

Tripping is always indicated by the flashing of one red LED only. The LED indication is reset manually by depressing the Reset P.B after noting down the pre trip service values. BFP motors are provided with differential relay ABB DIX- 111 and Locked rotor relay R X I G 21 in addition to RAMDE relays. 7.2.2.6. Other Relays in 6.6KV Panels :1) Anti pumping relay 2) Trip supervision relay 3) Neutral displacement relay - Available in each breaker. - Available only for I/C panels. - Available in Bus PT Panels.

7.3.0. 415V SUPPLY SYSTEMS :415V LT Supply system is meant for the LT motors, lighting transformers and other power supplies required for the station and the units. This system consists of the following switchgears.
66

7.3.1.0. SWITCHGEARS IN POWER HOUSE BUILDING :1) Station Service Switch gears A&B (SSS-A&B) SSS-A in Unit-I and SSS-B in Unit-II. 2) Unit Service Switch gears A&B (USS-A&B) One switchgear in each unit named as USS - 1A & 1B in Unit I USS - 2A & 2B in Unit II USS 3A & 3B in Unit III 3) TG Valve MCC (TVDC) one switch gears in each unit named as T.G valve Unit I, TG Valve Unit II, TG Valve Unit-III. 4) Boiler motor control cubicle (BMCC) A&B One switch gear in each unit named as BMCC 1A & 1B in Unit-I BMCC 2A & 2B in Unit II BMCC 3A & 3B in Unit III 5) Boiler valves &Dampers Control Cubicle (BVDC) one switch gear in each unit. 6) Soot Blower MCC one switch gear in each unit. 7) Normal / Emergency supply (N/E switch gear) One switch gear in each unit. 8) AC Plant switchgear. 7.3.1.1. SWITCH GEARS IN PERIPHERAL :1. 2. 3. 4. 5. 6. 7. 8. 9. 10. DG Switch gear CWPH Switch gear ( Cooling water Pump House) Water treatment plant switch gear Raw water plant switch gear Fire fighting switch gear AHP Switch gear (Ash Handling Plant) CHP Switch gear I & II ( Coal handling Plant) PDFACS Switch gear (Pressurised Dense Fly Ash Collecting System) FOPH Switch gear (Fuel Oil Pump House) ESP Switch gears I, II &III

67

7.3.1.2. STATION SERVICE SWITCH GEARS A & B (SSS A & B) SSS-A & B are fed through LT Bus ducts from station service transformers A&B respectively. There is also one link bus duct between them. Normally SSS-A&B are fed individually from the transformers. However, in case, if any of the incomer trips, the tie breaker will close automatically except for certain protection tripping. The important station auxiliaries fed from the Station service switch gears are :1) 2) 3) 4) 5) 6) 7) 8) 9) AC Plant switch gear one feeder from SSS-A and stand by from SSS-B one feeder will be in service at a time. Service air compressors A in SSS-A and B in SSS-B. Station building EOT Crane - one feeder from SSS-A & stand by from SSS-B. 220V DC Station battery charger Main from SSS-A and Standby from SSS-B. Service water booster pump. (A in SSS-A & B in SSS-B) Air pre heater wash pump. (A in SSS-A and B in SSS-B) Station building light. Switchyard ACDB. Lighting Transformers.

10) Oil transfer pump. 11) Switch yard sump pump. 12) Feeder to Fire fighting switch gear. (SSS-A)- Alternate Source. 7.3.1.3. UNIT SERVICE SWITCH GEARS A&B USS A & B are fed through LT Bus ducts from unit Service Transformer A&B respectively. There is one Bus coupler breaker between A and B buses and normally in open. However, in case any of the incomer trips, the bus coupler

68

will close automatically except for certain protection tripping. The important auxiliaries connected to the buses are :1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) TG Valve MCC N/E Switch gear BMCC Turbine AOP & JOP Vacuum pump Instrument air compressors ACW Pumps SWB Pumps Lighting transformer DB Boiler fill pump UPS System Hot well make up pump Stator water pump panel Chemical dosing pump

7.3.1.4. TG VALVE MCC :This switchgear is fed from USS A&B, one feeder from each. At a time, one feeder will feed this switch gear. Turbine side valve actuators are supplied from this switch gear. 7.3.1.5. BMCC This switchgear is having two buses A & B fed from USS-A & B respectively. The Bus coupler breaker will be normally open. Whenever any one source fails, the bus coupler will close automatically extending supply to that bus. The important auxiliaries connected to these buses are :1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) Soot Blower MCC Boiler valve MCC Seal air fans Ignitor air fans Scanner air fan-B Lighting transformer DB 6.6KV Duct & motor heater transformer D.B 24V AC Transformer D.B Air pre heaters Gravimetric feeders Boiler TRU feeders

7.3.1.6. BOILER VALVE MCC :69

The Boiler side valve actuators, dampers, gates etc. are fed from the switch gear. The bus is having two sources, one from BMCC-A and other from BMCC-B. However, the bus is not sectionalized. The supply can be changed over to the other source after switching off, without affecting any service. 7.3.1.7. SOOT BLOWER MCC :This switch gear is fed from BMCC. This feeds APH soot blowers, wall blowers and long retractable blowers. 7.3.1.8. NORMAL / EMERGENCY SWITCH GEAR :N/E Switchgear is fed normally from USS-A switchgear. When the incomer breaker trips for no voltage, the respective D.G set will start immediately and supply will be resumed to N/E bus without much time delay. Important LT auxiliaries are connected to this bus. The LT motors under service, in this switchgear will stop for no voltage and will restart automatically when DG supply is resumed within 6 seconds. The auxiliaries connected to this switch gear are :1) 2) 3) 4) 5) 6) 7) 8) Lub oil pumps for mills APH, BFP, PA Fans and ID Fans 24v Battery chargers 220V DC Unit Battery charger Turbine AOP & JOP Lighting transformer D.B UPS System Field flash Scanner air fan A.

7.3.1.9 AC PLANT SWITCH GEAR :This switch gear is having two I/Cs, one from SSS-A and other from SSSB. Being single bus, one source will be in service at a time. The second source will be as standby. 7.3.1.10. DG SWITCH GEAR :This switchgear is having 3 Incomer Breaker panels from DG-1, DG-2 & DG-3 and three out going breaker panels to N/E-1, N/E-2 & N/E-3. Two Nos. Bus coupler breaker panels are also there for isolating DG-I supply, DG-2 supply and DG-3 supply. Normally B/C Breaker will be in open. The O/G Breaker to N/E Switchgears will be in close condition. Whenever the I/C Breaker at N/E Switch gear trips for no voltage, the concerned DG Set will start automatically. When the DG Supply voltage builds up to rated voltage, the concerned I/C
70

Breaker in the DG Switch gear will close and supply will be extended up to N/E switch gear. This will be sensed by the DG I/C Breaker at N/E end and will close to charge the N/E Switchgear. The Bus coupler breaker can be used to extend one unit DG set supply to other unit N/E Switch gear in the event of break down of one DG Set. 7.3.1.11. OTHER SWITCH GEAR IN PERIPHERALS :The switchgears in CWPH, DM Plant, Raw water Pump House, AHP, CHP, ESP, FOPH are having two buses fed from their respective service transformers A&B. The bus coupler breaker will be in open condition. This will close automatically on tripping of any one I/C breaker except in DM Plant & CHP. In DMP Plant & CHP B/C breaker operation is done manually. PDFACS Switch gear is not having B/C breaker. One I/C breaker will be in service at a time. The FF ( Fire Fighting)Switch gear is having the regular I/C fed from Raw Water Pump House Switchgear with one more I/C from SSS-A as stand by source. 7.3.2.0. PROTECTION SCHEME :7.3.2.1. LT Buses :All the Bus incomer breaker is provided with 3 phase over current relays for over current protection. In USS & SSS Buses, Neutral displacement relay is provided for indications. Under voltage relay / No voltage relay with fuse failure relay and timer are provided for supply change over. 7.3.2.2. LT Feeders :All the feeders to other Switch gear panels are provided with 3 O/L relays for over current protection. However, for TG Valve switch gear and S.B switchgear HRC fuses are provided for O/L protection. 7.3.2.3. LT Motors :Thermal over current relays are provided for motors up to 100 KW. For 110 KW motors (ACW) in addition to Thermal Over load relays, definite time over current relay EE make Type CAUM is provided. For 150 KW motors (Compressor motor) EE make Motor protection relays are provided. 7.3.2.4. Transformers :-

71

For lighting transformer D.Bs etc. HRC Fuses are provided for over current protection. 7.4.0. TECHNICAL DATA :7.4.1.1. GENERATOR TRANSFORMER. 1) Make : BHEL / Bhopal 2) Type of cooling : OFAF / ONAF / ONAN 3) Rating HV : 250 MVA / 187.5 / 125 4) Rating LV : 250 MVA / 187.5 / 125 5) No load Voltage HV : 230 KV LV : 15.75 KV 6) Line current HV : 628.3 A LV : 9175.15 A 7) Temp. rise Oil C : 50C Winding C : 55C 8) Phase :3 9) Frequency in Hz. : 50 10) Connection symbol : YN d1 11) Impedence volts at 250MVA Max. tap % : 14.80 Normal tap % : 14.18 Minimum Tap % : 14.01 12) Core & winding Kg. : 120900 13) Weight of oil Kg. : 42940 14) Total weight Kg. : 221730 15) Oil quantity in Liters. : 49360 16) Transport weight Kg. : 136000 17) Un-tanking weight Kg. : 120900 7.4.1.2. G.T- OFF CIRCUIT TAP CHANGER OFF Circuit Tap Changer Tap Position 1 (max) 2 3 4 5a 5b 5c 6 7 Lead Connection 2-8 2-7 2-6 2-5 2-4 2-3 2-8 2-7 2-6 HV link terminals 1u, 1V, 1W Line Volt Line current in (KV) (A) 250 MVA Base 253.0 571.18 247.25 584.46 241.50 598.38 235.75 612.97 230.00 224.25 218.50
72

LV Line terminals 2U, 2V, 2W Voltage Current KV A

} } }

628.30 644.41 661.37

15.75

9175.15

8 2-5 212.75 679.24 9 (min) 2-4 207.00 698.10 7.4.2.1. UNIT AUXILIARY TRANSFORMER 1) Make :VOLTAMP Transformers. 2) Transformer Specification : Ref. IS 2026 1977 / 81 3) Type of cooling : ONAN 4) KVA : 16000 5) Volts at No load HV : 15750 LV : 7000 6) Amperes HV : 586.81 LV : 1319.66 7) Phase HV :3 LV :3 8) Vector Group : DYn-11 9) Impedence Voltage % : 7.42 10) Frequency : 50 Hz. 11) Core and winding : 15000 Kg. 12) Weight of oil : 5600 Kg. 13) Total weight : 28950 Kg. 14) Oil quantity in Liters. : 6920 Liters. 15) Transport weight : 23500 Kg. 16) Diagram of Conn. No. : PT 3D.922 17) Guaranteed maximum temperature rise over ambient of 45 Oil : 50C Winding : 55C 7.4.2.2. UAT- TAP SWITCH W.T.I.C.T Basic Insulation level Impulse volt HV 125 KVP LV 60 PF Voltage HV 50 KV RMS LV 22 Switch Position 1 2 3 4 5 Tap Leads Connected 5-6 6-4 4-7 7-3 3-8 No load Voltage HV LV 16357.50 7000 16143.75 7000 15750.00 15356.25 7000 14962.50 7000

7.4.3.0 230KV STATION TRANSFORMER 1) Make 2) Specification 3) Transformer specification 4) Type : TELK (ST I & II) APEX (ST-III) : With on load Tap changer : Ref . I S 2026 (Parts I,II & IV) 1977 & Part III 1981 : SALOCR FORM 3MNYCP
73

5) KVA

HV LV-1 LV-II TV 6) Volts at No Load HV LV-1 LV-II TV 7) Ampere Line HV LV-I LV-II TV 8) Weight of HV Coil/Phase 9) Weight of LV Coil / Phase 10) Weight of TV Coil / Phase 11) Weight of coil Assembly / Phase 12) No. of Phases 13) Frequency 14) Diagram Drawing No. 15) Type of cooling 16) Impedence Volts HV LV-I HV LV-II 17) 31.5 MVA Base LV-I to LV-II 18) Rated Tap HV to LV 19) Connection symbols 20) Mass of core and winding 21) Mass of oil 22) Total mass 23) Mass of heaviest p(kg) Kg 24) Un-tanking Mass 25) Un taking height 26) Volume of oil 27) Air circulation m3/min. 26) Guaranteed maximum temp rise in oil 27) Guaranteed maximum temp rise in winding

: 30000 / 50000 : 18900 / 31500 : 18900 / 31500 : 10000 / 16670 : 230000 : 7000 : 7000 : 4000 : 75 / 126 : 1561 / 2601 : 1561 / 2601 : 1285 / 2141 : 2595 Kg. : 2050 Kg. : 463 Kg. : 5560 Kg. :3 : 50 Hz. : TK 206919 : ONAN / ONAF : 11.67 % : 11.70 % : 22.67 % : 9.86% : YN Yno Yno (d1) : 62,500 Kg. : 27,540 Kg. : 1,16,000 Kg. : 7,88,000 Kg. : 62,500 Kg. : 7920 m : 30,600 Liters. : 4 x 368 m3/min. : 50 C : 55 C

74

Impulse Test Winding HV Line HV Neutral LV-I LV-II TV Voltage KV peak 950 95 60 60 95

Power Frequency Test Voltage KV (RMS) 395 38 20 20 38

7.4.3.1. S.T - Tap Changer + 7.5% to 12.5 % Tap Position 01 02. 03. 04. 05. 06. 07. 08. 09a. 09b. 09c. 10. 11. 12. 13. 14. 15. 16. 17. Connection U V W Tap Change over switch Selection 13 12 11 10 09 08 05 - 04 07 06 05 04 13 12 11 10 09 08 05 - 03 07 06 05 HV Line Terminals Voltage Current (Volt) (Amps) 247250 116.9 244375 118.3 241500 119.7 235625 121.1 235750 122.6 232875 124.1 230000 125.7 227125 127.3 224250 128.9 224250 128.9 224250 128.9 221375 130.6 218500 132.3 215625 134.0 212750 135.8 209875 137.7 207000 139.6 204125 141.6 201250 143.6

Neutral earthed with NGT & NGR NGT Volt 4000 / 400 400 KVA Amps 100 / 1000 1 Phase NGR :75

0.657 Ohm, 704 Amps, 400V, 325 KW 7.4.3.2. ON LOAD TAP CHANGER NAME PLATE DETAILS :1) Type 2) Ref. STD 3) No. of Poles 4) Rated Voltage 5) No. of Phases 6) No. of Taps 7) Weigh without oil 8) Oil volume in DS 9) Class 10) Frequency : Y-B-2 : TE 0214 :1 : 66 KV :3 : 19 : 390 Kg / Pole : 145 L / Pole :I : 50 Hz.

7.4.3.3. 230KV SF6 CIRCUIT BREAKER :1) Make 2) Type 3) Lightening impulse withStand voltage 4) Rated short circuit breaking Current 5) Operating pressure 6) Gas Pressure : Crompton Greaves Ltd., : 200 SFM 40A : 1050 KVP : 40 KA : 15 Kg / Cm2 Lockout 12 Kg/Cm2 : 6 Kg / Cm2 Lockout - 5 Kg/Cm2 (at 20 C) : 1.3 : 40 KA / 3 Sec. : 21 Kg. : 245 KV : 1250 A ( 2000A for B/C Breaker) : 220V DC : 220V DC : 415V AC 50 Hz.

7) First pole to clear factor 8) Duration at short circuit current 9) Gas weight 10) Rated Voltage 11) Rated Normal current 12) Rated closing voltage 13) Rated opening voltage 14) Rated voltage & frequency for aux. Current 15) Total weight with gas : 3900 Kg. 16) Year : 1992 17) STD : 1EC56 18) Compressor : Ingersollrand Small Compression Division Size : 3 x 2 Model No. : 234 19) Compressor motor : KW (HP) : 2.2 (3) Frame : ND100 Start : 14.5 Kg/Cm2
76

Stop 7.4.4.1.
Description

: 15.5 Kg/Cm2

6.6KV SERVICE TRANSFORMERS

Make Capacity HV Side Voltage/A mps 6.6 KV / 174.96A LV Side Voltage/ Amps 433 V / 2666.82A Type of cooling ONAN Impeda nce Voltage 9.097% 9.250% 9.400% 10.31% Vector group Dyn11 Dyn11 Dyn11 Normal Tap position 3 3 3 -

UST SST WTP PDFACS

Vigneswara Electricals, Coimbatore ETE Thethana, Electric Supply Co. Ltd., Vigneswara Electricals, Coimbatore Vigneswara Electricals, Coimbatore

2 MVA

2 MVA

6.6 KV / 175 A

433 V / 2666 A

ONAN

ESP AHP FOPH CWPH

1.6 MVA

6.6 KV / 139.97A

433 V / 2133.96 A 433 V / 840 A

ONAN

7.33% 7.88% 7.524% 4.27%

Dyn11 Dyn11 Dyn11 Dyn11

3 3 3 3

630 KVA

6.6 KV / 55.11A

ONAN

Neutral earth with 350 Ohm NGR. All are with OFF Load Tap changer. No. of Tap : 5 Nos. on the HV Winding. (+5 % to 5%) 7.4.4.2 6.6KV SF6 CIRCUIT BREAKER :1) Circuit Breaker 2) Standard 3) Rated Voltage 4) Insulation Level 5) Rated Frequency 6) Rated Current 7) Breaking Current 8) Making Capacity 9) Rated Short Time Current 10) Auxiliary Voltage- Closing Coil Opening Coil 11) Motor 12) Indicator 13) SF6 Pressure at 20C : HPA 12/1240 CF , YEAR.92 : IEC 56 : 12KV : 28/75 KV : 50 Hz. : 1250/2000/3150 A : 40 KA : 100 KA : 40 KA : 220V DC : 220 V DC : 220V DC : V : 2 - 2.5 Bar (0.2 0.25 MPA)
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14) SF6 Gas Per Pole 15) Mass Approx. Note :

: 0.25 Kg : 185 Kg.

Station switchgear incomer breaker & Tie breaker Unit Switchgear Incomer breaker Other breaker & TIE from Station switchgear. 7.4.5.0. D.G Set :A.C GENERATOR a) Make b) Frame c) KVA d) RPM e) Volts f) Amps g) Excitation voltage h) Excitation current i) Rating j) Excitation Transformer k) Insulation Class l) ALTD m) Frequency n) Phase o) Power Factor p) Connection. q) Cooling Temp. r) Bearings s) Grease / Oil t) Quantity (gm) u) Lubing Interval. v) Phase Sequence. w) Rotation (reversible) viewing at driven end

- 3150 Amps - 2000 Amps - 1250 Amps

: Kirloskar Electric Co. Ltd., Bangalore : 4AB 450 / Z MK II : 500 : 1500 : 415 : 696 : 61 V : 2.0 A : SI TO IS 4722 1968 : AC : STF / RTF / EXF : 1000 : 50 Hz :3 : 0.8 : Star : 40C : DE NU 324 / NDE 6324 : CAS FROUL AP3 : DE 70 / NDE 70 : DE 2700 Hrs. / NDE 2700 Hrs. : IS 4728 U V W : Anti Clock Wise

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7.5.

OPERATING INSTRUCTIONS

7.5.1. 230KV INDOOR SWITCH YARD 7.5.1.1. When the feeder trips at both ends :Operating sequences :a) b) c) d) e) Feeder trips at both ends. The line voltmeter shows zero. Accept the annunciation bell and note down the annunciation. Note down the relay indications at NCTPS end. Contact the other end and ensure 1) Feeder has tripped. 2) Relay indications. f) Ascertain the conditions of the feeder bay in the yard and confirm that everything is normal. g) Check that whether any other feeder or transformer has tripped, if tripped note down the relay indications. h) After ensuring everything normal, request the operator at other end to test charge the feeder and confirm. i) The line voltmeter also confirms the feeder is charged. j) Plug in the extension cord of the synchronizing trolley. k) Confirm the synchronizing selector switch in Manual. l) Confirm the Mode selector in CP. m) Cut 1N synchroscope. n) Check for synchronizing. o) Close the feeder breaker and confirm stood OK. p) Cut OUT synchroscope. q) Plug out the extension cord of the syn .trolley. r) Ensure that the ammeter in the three phase show equal current. s) Inform EE/Shift, AEE/General, and if necessary, EE/MRT, EM Engineers, LD Centre. While charging the feeder from other end if the feeder trips again, the feeder may be declared faulty. Inform the concerned. CAUTION :- The faulty feeder or the tripped feeder should not be test charged from NCTPS end.

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7.5.1.2.

Feeder Trips at NCTPS End only :-

The feeder may trip at NCTPS end under the following conditions. a) When there is a bus fault at NCTPS b) When the breaker backup (50 LBB) operates in any other panel in the particular bus section at the time of tripping. c) When there is an uncleared / delayed clearance of the fault beyond the receiving substations. d) Mal functioning of the breaker controls or any distance relays at NCTPS. Operating Sequence :a) Confirm that everything is normal in the switch yard. b) Ensure the conditions at the other end. c) Keeping the operator at the other end over phone, this feeder may be tied by closing the SF6 gas Breaker. 7.5.1.3. Feeder Trips at the receiving end S.S :-

a) Observe that load current in feeder comes to zero. Feeder is holding at NCTPS end. b) The operator at the other end confirms that the feeder breaker has tripped at his end. Obtain and record the relay indications. c) Confirm that there is nothing abnormal in the yard and other end. Confirm no relay indications in relay panels and annunciation. d) Request the operator at the other end to close the breaker at his end. e) Watch the current in all the Phases. Inform EE/Shift, MRT etc. 7.5.2. TRANSFER BREAKER CONTROL FOR GENERATORS In the 230KV transfer breaker scheme same protection relays are utilized for the protection of both main and transfer breakers by means of a three way selector switch, Trip Transfer Switch (TTS), available in each of the feeder and transformer panel at SCP. In the normal position, the main breaker only will trip for any fault, and in inter position, both main and transfer breaker will trip for fault and at transfer position, the transfer breaker alone will trip for any fault. For the feeders the transfer breaker control is from the bus transfer panel at SCP and for Generators the transfer breaker control is from the respective generator control desk.

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7.5.2.1. Normal Conditions :a) Generator is in service. b) Generator breaker is ON and its No.1 and No.2 isolators are in closed conditions. c) No.1 & No.2 isolators of Transfer Breaker are open. d) Transfer Breaker is OFF. e) No.3 isolator of generator is also open. 7.5.2.2. For changing over main to Transfer Breaker :Confirm no other service is fed through Transfer Breaker and no LC is pending on Transfer Breaker. a) No.1 & No.2 of transfer breaker isolators are to be closed. b) No.3 of the concerned Generator is to be closed locally. c) Select the TTS in the switchyard CP to transfer position (GT Panel). Select the SCP / GCDP switch at switchgear to GCDP, both in GT Panel and Transfer Breaker panel. Select the TTS in the GCDP to interposition. d) Switch on the synchronizing switch at GCDP and close the transfer breaker from GCDP & confirm whether the breaker has actually closed. e) Trip the Main breaker from GCDP & confirm. Select the TTS in the GCDP to transfer position. Open the isolators No.1 & No.2 of main breaker after ensuring Transfer Breaker is closed. 7.5.2.3. For changing over of Transfer to Main Breaker :Condition:a) Generator is in service, through transfer breaker. b) TTS is in transfer position in SCP & GCDP c) No.1 & No.2 of Transfer Breaker isolators are closed. d) No.3 isolator of concerned Generator is closed. e) No.1 & No.2 isolators of Generator breakers are open. f) Generator Breaker is in tripped condition. Operations :Close No.1 & No.2 isolators of Generator Breaker. Select the TTS switch in inter position in GCDP & Normal in SCP. Close the main breaker after checking synchronism. Hand trip the transfer breaker from GCDP. Select the TTS to normal. Open the isolators No.1 & No.2 of transfer breaker and No.3 of concerned Generator transformer. 7.5.2.4. Synchronising Directly through Transfer Breaker :Condition:a) Generator not in service.
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b) c) d) e) f)

No.1 & No.2 isolators of Generator Breaker are open. No.1 & No.2 isolators of Transfer breaker are open. No.3 isolator of Generator breaker is open. Main breaker is in OFF condition. Transfer breaker is OFF.

Operation :a) Close the isolator No.1 & No.2 of transfer breaker from yard. b) Close No.3 isolator of Generator transformer locally. Select the TTS in Transfer (Both in CP & GCDP). Select SCP / GCDP position in transfer breaker panel to GCDP and also in UCB. c) Switch ON the synchronizing switch and close the transfer breaker from UCB after checking the synchronism. 7.5.3. OPERATING INSTRUCTION FOR CHANGE OVER TO TRANSFER BREAKER FOR FEEDERS & STATION TRANSFORMER BREAKERS. Condition:a) The feeder/ST is in service. b) Its bus & line isolators are closed. c) The TTS switch in the SCP is in normal position. Operating Sequence :a) Confirm no other service is fed through transfer SF-6 breaker and no L/C on transfer bus. b) Close No.1 & No.2 isolators of the transfer breaker. c) Close the concerned No.3 isolator from the yard. d) Confirm the proper closing of the isolator blades. e) Put the SCP / GCDP selector switch to SCP. Select the TTS switch to inter position. f) Close the transfer bus breaker from control panel, after checking synchronizing. g) Hand trip the main breaker from control room. Select the TTS Switch to transfer. h) Open NO.1 & No.2 isolators of Main Breaker. 7.5.4. INSTRUCTION FOR CHANGE OVER OF TRANSFER BUS BREAKER TO MAIN FEEDER BREAKER :Conditions :a) Bus transfer breaker is in service. b) TTS Switch in transfer position.
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c) SCP / GCDP selector switch in SCP position. Sequence of operation :a) b) c) d) Confirm all the LC in the main breaker has been returned. Close the bus & line isolators of the Main breaker. Select the TTS switch in the control panel to interposition. Close the Main Breaker from control room and trip out the transfer breaker. e) Select the TTS switch in the control panel to Normal position. f) Open the No.1 & No.2 isolators of Transfer breaker. g) Open No.3 isolator of Main Breaker. 7.5.5. ISSUING OF LINE CLEARS :7.5.5.1. L/C ON THE SF-6 BREAKER ALONE :a) When L/C is required on SF-6 breaker alone, the concerned bay may be transferred to transfer bus and fed through transfer breaker. The main breaker may be tripped and its bus No.1 and line No.2 isolators may be opened. The L/C may be issued to the concerned maintenance Engineers. b) While normalizing after the L/C on breaker is returned. Confirm 1) All the earth rods have been removed. 2) The air & gas pressure is normal. 3) All the L/R switches are in remote except isolators. 4) One Electrical Closing & Tripping may be checked from the yard, if it is not done by the maintenance Engineer before returning. Operating Sequence :1) 2) 3) 4) Close the No.1 & No.2 isolators and confirm the proper closing. Confirm the TTS switch in inter position. Put the synchronizing switch in manual position. Then the breaker may be closed. The transfer breaker and isolator may be opened. 5) Select TTS to normal. 7.5.5.2. L/C ON 230KV LINE :1) Confirm that the Shut down on the line has been approved by LDC and the same has been intimated to the other end also. 2) Load flow may be monitered so that on tripping of the line, there is no over loading of the other feeders and the feeders emanating from the nearby receiving substations.
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Operating Sequence :1) With approval of EE/Shift and intimation to the AEE/General, AE/Shift at the other end. Hand trip the line breaker & inform and request the operator at the other end to trip the breaker. 2) After confirming that the feeders has been tripped at the other end, the bus and line isolators may be opened. 3) The operator at the other end may be requested to open the Bus and line isolators at his end. 4) Then operator at the other end may be requested to close the earth switch. After confirming that the earth switch has been closed at the other end, the earth switch at NCTPS end may be closed. L/C may be issued and the same be intimated to the operator at the other end also. 7.5.5.3. NORMALISING AFTER L/C RETURN 1) Confirm that all L/C are returned. 2) Open the earth switch at NCTPS end and request the operator at other end to open the earth switch at his end. 3) Request the operator at other end to close the bus and line isolators at his end. The line and Bus isolators at NCTPS end may also be closed and confirm that the blades are properly closed. 4) Request the OD at other end to charge the feeder. Confirm it from the reading of line voltmeters. Switch on the synchronizing switch and check for synchronism. The feeder may be then tied. Confirm the current in three phases. Inform EE/Shift and AEE/LDC/Chennai. 7.5.6.0. Bus shut Down :7.5.6.1 To isolate 230KV Bus Section :-

1. Confirm that shut down on the bus section has been approved by the LDC/Chennai. 2. Confirm that shutdown on the lines emanating from the bus section has been approved by the LDC and the same has been intimated to the other end also. 3. Confirm that the unit connected with the bus section is under shut down. 4. Isolate the Station Transformer after transferring the connected load at 6.6 KV SWGR end. 5. Load flow may be monitered so that on tripping of the lines, there is no over loading of the other feeders.

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6. Trip out all the feeders emanating from the bus section, by keeping other end ODs over phone. 7. Inform LDC, EE/Shift, AEE/General, EE/MRT, EE/EM-I 8. Trip the bus coupler breaker / breakers to isolate the bus section. 9. Confirm that there is no over loading of feeders on service. 10.Open the Bus & line isolators of the tripped out feeders. 11. Open the bus section isolators. 12. Remove the secondary fuses of bus PTs. 13. Provide Earth rods on the bus. 14. Issue L/C on the bus. 15. Inform LDC. 7.5.6.2. Normalisation :a) Confirm all the line clears are returned. b) Confirm all the discharge rods and earth in the Bus are removed. c) Inform LD centre, EE/Shift, AEE/General, EE/MRT, and EE/EM-I about the normalisation. d) Restore the secondary fuses and confirm. e) Close all the line and Bus isolators of the feeders and bus coupler isolators. f) Put one feeder synchronizing switch to Manual position. g) Keeping the other OD over phone, the feeder breaker shall be closed thus charging the Bus section. Put synchronizing switch to OFF position. h) Check the Voltmeter reading in the Bus section panel that all phase voltages are equal. i) Close the Bus section breakers one by one through synchronizing panel. j) Check that the current in three phases in the feeder panel are equal. k) Normalise the other feeders and Station Transformer. l) Inform about the normalisation to AEE/LD, AEE/General, EE/Shifts, AEE/MRT and EE/EM-I. 7.5.6.3. OPERATING INSTRUCTIONS FOR ENERGISING STATION TRANSFORMER AND 6.6KV STATION BUSES :The 230KV Station transformer breaker is in OFF condition. No.1 & No.2 isolators are in open condition. 1) Confirm that no LC is pending on the Station transformer Breaker, 6.6KV bus ducts, 6.6KV Switchgear panels etc. 2) Confirm that all the earth rods were removed. 3) Confirm that all the relays were reset. 4) Confirm that the 6.6KV I/C Breaker in 6.6KV Buses A&B are in test / service position and in tripped condition. Note :- If the breaker is removed out, the HV Breaker will not close. 5) Close the 230KV isolators No.1 & No.2 of the Station transformer.
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6) Inform 6.6KV Switchgear operator. 7) Close the breaker through synchronizing trolley, keeping the 6.6 KV SWGR operator over phone. 8) Check the ammeter for no load currents. 7.5.7.1. CHARGING OF 6.6KV BUSES :Case : 1 : - Bus dead 1) Confirm all the breakers are in tripped condition. 2) Switch off DC supply in bus PT panel and confirm all the relays are reset. (If not the I/C Breaker will trip on charging). 3) Rack in 6.6KV Breaker to Service position. 4) Switch ON DC Supply in I/C Panel. 5) Put L/R switch in L. 6) Charge the Breaker 7) Check Bus voltage in RY, YB, BR. 8) Switch ON DC Supply in Bus PT Panel. Normalise other breaker. Case-2 : Bus alive 1) 2) 3) 4) 5) Rack in 6.6KV I/C panel to service position. Put L/R Switch in L position. Switch ON DC Supply I/C Panel. Close the Breaker and check the ammeter readings. Trip the TIE Breaker.

7.5.7.2. OPERATING INSTRUCTIONS FOR TAKING OUT STATION TRANSFORMER - OPERATION AT 6.6KV SWITCH GEAR ROOM :1) Trip all the O/G feeder breakers in 6.6KV Station switchgear (A&B) panels after making alternate arrangement or close the TIE breaker in A&B buses and parallel with the other unit Switch gear. 2) Trip the I/C 6.6KV panel breakers. 3) Switch OFF DC supply, rack out the breakers to test position. 4) Inform AE/Shift/Switchyard. Operation at Switchyard control room :1) Trip the station transformer breaker. 2) Open the isolators No.1 & No.2 3) Inform AEE/General. 7.5.7.3. Charging of 6.6KV Unit Switchgear :1) All the Breakers in Unit Switch gear panels are in tripped condition.
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2) 3) 4) 5)

Put link in service position. In Unit bus PT, both U/V & No Voltage should have acted. 6.6 KV Station supply should be in healthy condition. Charge the TIE to unit switchgear breaker by local mode at station switch gear or give close command to the UAT I/C breaker from UCB (Remote) in manual mode. 6) Check bus voltages in all the phases. 7.5.7.4. Cutting IN of UAT Breaker from UCB:1) Unit is in service Above 70 MW Generation & UAT panel in remote mode. 2) Put the Auto / Manual switch of UAT Breaker at GCDP in auto. (Normally in OFF position). 3) Switch ON synchronizing switch of 6.6KV synchroscope. Check permission lamp. 4) Close the UAT Breaker. 5) The TIE breaker in station switch gear will trip on auto. If it does not trip then UAT I/C breaker itself will trip. 6) Check the Bus voltages in all the phases. Switch off Auto / Manual switch and synchronizing switch. 7.5.7.5. Cutting OUT of UAT Breaker from UCB :1) TIE & UAT panel in remote mode. 2) Put the Auto / Manual switch of TIE Breaker ( at GCDP) in Auto. (Normally in OFF position). 3) Switch ON synchronizing switch of 6.6KV synchroscope. Check permission lamp. Close the TIE Breaker. 4) The UAT breaker will trip on auto. 5) Check the bus voltages in all the phases. 6) Switch off Auto / manual switch and synchroscope switch. 7.5.7.6. Issuing LC On Any One Of The 6.6KV Station BusA Or Bus B Case I :- when unit is running When the unit is running, the unit buses will be fed from UATs. Hence TIE Breaker to unit bus will be in tripped condition. 1) Arrange to transfer all the loads from the bus to other source. 2) Confirm no load from the ammeter readings and trip all the feeders one by one. 3) Tie the other bus with the other unit station bus. 4) Trip incomers in A Bus & B Bus.
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5) Inform to switchyard operator to trip the station transformer feeding this bus through I/C breakers. 6) Switch off DC supply and rack out the breakers one by one. 7) Rack out the link in the Unit Bus. 8) Rack out the Tie breaker in the other unit. 9) Request to rack out the breaker at the other end switchgear. (AHP Switch gear / CHP Switch gear) 10) Confirm that the 230KV Breaker and isolators are opened for the station transformer. 11) Issue line clear on the Bus. Case-II :- When unit is not running :When the unit is not running, the station bus will also feed the unit Bus. Hence, arrange to transfer all the loads in both station bus and unit bus to other source and proceed from 2 to 11 as above. 7.5.7.7. ISSUING LC ON ANY ONE OF THE 6.6KV UNIT BUS :1) Arrange to transfer all the loads from this bus to other source. 2) Confirm no load from the ammeter readings and trip all the feeders one by one. Case-I :- When the unit is running :a. Tie breaker to unit bus will be in OFF and UAT I/C breaker will be in ON. b. Switch off DC supply in Tie breaker panel. c. Rack out TIE breaker. d. Put auto / manual switch on the back panel in manual. e. Trip the UAT I/C breaker from UCB back panel and switch off auto / manual switch. f. Switch off DC supply and rack out all the breakers one by one. g. Issue LC on the Bus. Case-II :- When the unit is not running :TIE breaker to unit bus will be in ON and UAT I/C Breaker will be in OFF and racked out condition. a. Put auto / manual switch on the back panel in manual. b. Trip the TIE Breaker from UCB back panel and switch off A/M switch. c. Switch off DC supply and rack out the TIE breaker and also other breaker in Unit Bus.
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d. Issue LC on the bus. 7.5.8.0. 415 VOLTS LT BUSES :7.5.8.1. Energising USS :-

Bus A&B are dead I/C breakers A&B are open and in service position with remote selection. B/C breaker is open and in service position. 1) Check that UST A & B HT breakers are closed. 2) Select the bus coupler breaker for local & Manual. 3) To avoid under voltage tripping when charging the dead bus, the DC supply to the bus PT shall be kept off and reset the timer relay both for A Bus and B bus. 4) Select TIE on the back panel. 5) Select A/M switch for I/C A to Manual in back panel. 6) Close I/C A from back panel through synchroscope and put A/M Switch in OFF. 7) Check voltage readings on R, Y, B in A Bus 8) Switch ON bus PT supply. For charging B bus follow from 4 to 8. 9) Check DC supply for B/C panel and select Remote and Auto. 7.5.8.2. 1) 2) 3) 4) 5) 6) 7) 8) For taking out one UST and charging the Bus through the B/C breaker (Say UST-A) :-

Select 1NC-1 on the back panel. Select A/M switch for B/C breaker to Auto in back panel. Auto/Manual switch for B/C at USS should be in Manual position. Local/Remote switch for B/C at USS should be in Remote position. Close the B/C breaker from back panel through synchroscope. Confirm B/C breaker has closed and I/C-A breaker has tripped. Put A/M switch for B/C in back panel in OFF. Trip the HT breaker for UST-A and rack out in HT breaker and LT breaker.

7.5.8.3. NORMALIZING UST-A :1) Confirm no LC is pending on the transformer and bus duct etc. 2) Rack in HT breaker and LT breaker. 3) Charge HT breaker and confirm OK.
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4) 5) 6) 7) 8)

Confirm for I/C A breaker DC is ON and in Remote position. Confirm remote and auto for B/C breaker. Confirm selection of TIE on the back panel. Select auto / manual switch for the I/C A on the back panel to auto. Close I/C A breaker from back panel through synchroscope and confirm closing of I/C A breaker and tripping of B/C breaker. 9) Select A/M switch on the back panel to OFF. 7.5.8.4. ISSUING LC ON ANY OF THE BUS (SAY USS-A) :-

1) Arrange to change over loads to USS-B (TVDC etc.) 2) Confirm B/C breaker in BMCC is in service position, DC ON, A/M Switch in auto mode. 3) Trip the BMCC O/G Breaker in USS-A. 4) Confirm tripping of I/C from USS-A in BMCC & closing of B/C breaker in BMCC. 5) Confirm DG set is ready for service and in auto mode and other condition in N/E Switchgears. 6) Trip the N/E O/G feeder in USS-A 7) Confirm tripping of I/C in the N/E Switchgear and supply is extended from DG Set. 8) Confirm TIE mode on the back panel. Manual position for B/C in USS. 9) Put A/M switch of I/C-A in manual and trip the I/C-A. Put A/M switch in OFF. 10) Switch off DC supply in B/C panel and rack out the breaker. 11) Switch off DC supply in I/C-A panel and rack out the breaker. 12) Switch off DC supply and rack out the breakers in this bus one by one. 13) Trip the SST-A H.V side breaker and rack out the breaker. 14) Issue LC on the USS-A Bus. 7.5.8.5. ENERGIZING N/E SWITCHGEAR :-

Confirm DG Set in manual mode. Confirm DG set I/C breaker in N/E is in service position and OFF and also in local mode. Confirm I/C breaker in N/E in OFF and service position. 1) Close the N/E Out Going Breaker in USS-A 2) Select local & Manual mode in N/E switchgear I/C Panel. Switch off DC supply in Bus PT and reset timer relay. 3) Close the I/C breaker in N/E. 4) Check the voltage on all the phases and switch ON DC supply on the Bus PT module and reset under voltage relays. 5) Select Local and Auto on the I/C Panel. 6) Select remote on the DG Set I/C panel and confirm DC supply is ON.
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7) Confirm AMF supply switch module in N/E is ON. 8) Put the DG Set on auto mode. Note :- When AC supply in N/E S.G fails, the I/C breaker will trip. DG set will start and DG I/C breaker will close. 7.5.8.6. CUTTING OUT DG SUPPLY AND NORMALISING N/E SWITCHGEAR :-

1) The upstream breaker of N/E I/C from USS at USS end should be in closed condition. 2) Select I/C Panel in N/E for local and manual. 1) Select DG Set I/C panel for local. 2) Switch OFF DC Supply in Bus PT module. 3) Hand trip the DG Set I/C breaker. 4) Close the I/C breaker. 5) Check supply in all the phases. 6) Select local and auto in I/C Panel. 7) Select remote in DG set I/C panel. 8) Switch on DC supply in Bus PT module and reset the U / V relay flags. 9) Switch off DG set in DG house. 7.5.8.7. BMCC :1) B/C breaker will be normally in auto selection and breaker in OFF. 2) Whenever one I/C breaker trips on follow up trip or hand trip the B/C breaker will close. (No u/v trip for the I/C breaker). 3) To isolate one bus to give LC a) Put the B/C breaker in manual selection. b) Trip the BMCC feeder breaker in USS. The I/C breaker in the BMCC will also trip on follow up trip. c) Rack out the above two breakers and B/C breaker and give LC on the dead bus. 4) When I/C A is ON, B/C is ON, I/C-B is OFF. Put I/C-B in service. Select B/C for manual mode, trip B/C breaker and close I/C-B breaker. Select auto mode on B/C. 7.5.8.8. STATION SERVICE SWITCH GEAR :1) The bus charging, interlocks and protections are similar to USS as described above. 2) Remote operation only in UCB-I for both SSS-A and SSS-B. 3) TIE breaker in SSS-B will be normally in close condition.

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4) TIE breaker in SSS-A has auto / manual selection and will close for tripping of one I/C breaker in one switch gear under no voltage or manual trip. 7.5.8.9. ESP, CWP & FOPH SWITCHGEARS :1) B/C breaker will be normally in auto selection and breaker in OFF. 2) When over one I/C breaker trips on follow up trip or hand trip, the B/C breaker will close. (No under voltage trip for the I/C breaker except in ESP). 3) To isolate one bus to give L.C. a) Put the B/C breaker in manual selection. b) Trip the I/C breaker. c) Trip the 6.6KV breaker feeding the transformer. d) Rack out the B/C breaker, I/C breaker and the HV side breaker. e) Give LC. 4) To normalize when the B/C breaker is feeding the other bus (Say A Bus). a) Select the B/C breaker panel to manual mode. b) After charging the transformer on the HV side put the I/C breaker in service position and switch on DC supply. c) Trip the B/C breaker and charge the I/C breaker. d) Select the B/C breaker to auto mode. Note :- In ESP Switchgear, Switch OFF bus PT DC Supply before closing I/C breaker and then switch ON, to avoid tripping of I/C under no voltage timer trip. 7.6.0. ROUTINE CHECKS TO BE CARRIED OUT :7.6.1. 230KV Control Room :The following routine checks may be carried out by the Asst. Engineer / Shift at switch yard / Switch gear room. I. All the annunciating lamp test, trip circuit healthiness, relay coil healthiness, DC bus voltage, DC leakage may be checked immediately after taking over the shift. II. The following checks may be done in shift. 1) Load current in three phases of all the services, with MW and MVAR. Any abnormal power flow may be confirmed from LDC and logged. 2) Bus voltages in the 230KV buses.

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3) Gas pressure and Air pressure in all the 230 KV breakers may be checked. 4) Frequent starting of compressors or prolonged running of compressors may be reported. 5) Any abnormal relay indications to be noticed and recorded with reasons. 6) The temperatures of GT, UAT and ST Transformers have to be watched. Any abnormal rise has to be reported. 7) Oil level in conservator tank in power transformers shall be checked personally and recorded. 8) During Night hour, all the lights inside the yard may be switched OFF and any arcing in any equipments or jumpers may be checked and reported to the concerned Maintenance Engineer. 9) The leakage current reading of the LAS may be checked. 10) The Healthiness of the Station Battery, communication battery and their chargers may be checked. Any abnormal change in the load current may be investigated and got rectified. 11) Carrier (Inter Trip) Test may be conducted and the fact recorded. 7.6.2. 6.6KV BUS GENERAL CHECKS :1) Ensure always that the backdoors of the breaker panels are closed when the bus is alive. 2) Confirm that the trip circuit Healthy indication is available before the equipment is ON and also while in service for all the 6.6KV Breakers. 3) Whenever the 6.6KV bus is charged after availing line clear, the bus U/V relays in Bus PT shall be reset manually. 4) Any operation of relays, LEDs and abnormal indication may be observed and reported immediately. 5) Any abnormal electrical discharges and heating in the switchgear panels may be watched and reported immediately. 7.6.3. MOTOR FEEDERS :The following precautions may be followed when racking in any 6.6KV breaker and giving clearance for starting the HT Motor. 1) No line clear is pending. 2) IR Value of the HT Motor may be confirmed if the motor is started after about 10 days. 3) The backdoor is closed. 4) The protection supply is ON and the Trip healthy lamp indication is available. 5) All the relays are got reset.

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6) The 6.6KV bus voltage is within the allowable limit (above 6.2 KV & below 6.7 KV). 7) A local close/trip operation may also be checked in test position. 8) When the breaker is inserted to service position, confirm that the spring is charged, got racked in fully and locked perfectly. 9) After starting of the motor, ensure that the three phase currents are almost equal. 10) It is preferable not to start more than one motor at a time. If the motor trips on fault (indicated by motor protection relay) at the time of start or during running, the relay indications may be immediately conveyed to UCB operator, concerned maintenance and MRT Engineers. The breaker may be racked out. The faulty motor should never be restarted without the clearance from the maintenance Engineer. However, if the motor trips on interlock, the same can be restarted after clearing the interlock trip. Immediate restart of the motor in hot condition i.e., after tripping while in service, or tripping while starting, is allowed once only. If the motor again trips due to any reason at-least 20 mts. should lapse before attempting for another start. The reason for the tripping of the motor should be studied in the meanwhile and eliminated before attempting for another start. 7.6.4. LT BUSES & MODULES :1) All the LT incomers are provided with IDMT type O/C relays for the three phases. The incomer breaker from the transformer is provided with Neutral Displacement Relays for Bus / Transformer LV fault. 2) The higher size LT drivers above 110 KW are provided with breaker outlet with independent motor protection relays for Thermal short circuit (Instantaneous O/C) and locked rotor protection. 3) All other LT drivers are fed from draw out type modules with Bimetallic thermal over load relays and backup fuses. Whenever a LT module is switched ON the operation of K2 / Contractor may be ensured. 4) As the red lamp in LT breaker panel is an indication of trip circuit healthiness when the breaker is ON, the failure of red lamps may be reported immediately. 5) Before energising any LT bus after a line clear, the bus PT Module DC shall be kept off. The same may be switched ON after energizing the LT bus and ensuring the healthiness of Bus supply. After any pre-arranged line clear of any 6.6KV Bus, the following operations may be checked with the help of MRT and Maintenance Engineers at the time of normalizing the bus.

94

1) Auto changeover of supply (from standby supply through bus coupler or tie breaker). 2) Parallel operations of the two breakers feeding the bus (Parallel Closing and auto tripping). ****************

8. UNIT START UP PROCEDURES

8.1.0 INTRODUCTION: The no. of auxiliaries, the limitations in heating various components of boiler / turbine parts, and the parameters to be monitored etc. during starting up of the unit requires careful attention, in order to have trouble free operations, in the long run. The procedure varies for starting the unit from cold condition or from hot condition. The firing rate of the boiler for controlling Pressure & Temperature of steam and loading rate of the turbine are given in the start up curves of the unit under various start up conditions. The Furnace Safeguard Supervisory System (FSSS) supervises the firing systems and protects the boiler during start up and normal running conditions. The Electronic Automation of Steam Turbine (EAST) similarly supervises the turbine parameters and protects the turbine during start up & normal running conditions. Note: The detailed operating instructions for various systems should be followed carefully for taking the equipments / systems into service. 8.2.00 COLD START-UP If the machine is started from ambient temperature or from the TG set at rest, (the HP casing temperature, below 100 deg. C then it can considered as cold start up. The gradual warming up of boiler, steam lines, HP & IP casings etc. are required. The turbine will have to be soaked at 600 rpm till sufficient TSE margins are achieved for proceeding further. To get rolling parameters, normally 12 % of Boiler MCR firing rate will be adequate which will give approximately 70 t/hr steam flow through HP / LP bypass system. This should be sufficient to get main steam parameters of 40 Kg/sq.cm and 320deg.C with RH pressure 12 Kg/sq.cm and Temperature 320 deg. C. The boiler firing rate should not exceed to cause more than 110 deg. C per hour increase in saturated steam temperature in boiler. Hence, to achieve the rolling parameters, it should take about 3 hrs. In order to match boiler firing rate and boiler steam pressure, the HP bypass should be adjusted once the turbine is rolled. Coal mills can be started one after the other at 10 %, 25 %, 50 % and 75 % of full load depending upon the quantity of oil fired at that time. During loading of the turbine, the RH temperature shall be watched and maintained close

95

to SH Temperature. The loading rate is decided by the TSE Margins available, and the prescribed Start-up curves. 8.2.10 Pre-Start Checks Before arranging for lighting up of the boiler and proceeding further, the following systems shall be kept ready / kept in service as indicated below: 1) Ensure that NO line clears are pending in the systems which are being taken into service, with men and material cleared. Ensure Man hold doors, Peephole doors are closed. 2) Check lubricants levels in all the equipments and arrange topping up if necessary. 3) Ensure the availability of 24V DC, 220V DC and other Electrical supplies. 4) Check up CST level and top up the level to at least 70% 5) Line up ACW system as per the relevant operating instructions and keep one A.C.W pump in service. Maintain ACW make up tank level by Boiler fill pump. 6) Line up cooling water system and take one / two CW pumps into service with the condenser outlet valves throttled suitably according to one / two CW pumps in service. Start Priming Pump before CW pumps are started. 7) Charge seawater booster pumps and one of the self-cleaning strainers and line up the heat exchangers. 8) Take at-least one No. SWBP into service and Keep self cleaning strainer controls on auto mode. 9) Ensure sea water supply to Ash handling system. If necessary take one more seawater booster pump into service. 10) Start Instrument air Compressors (2 Nos.) and keep the system charged. Take instrument air driers into service. 11) Take one no. Service air Compressors into service, if already not in service for the other unit. If the pressure is inadequate, start the other SAC also, since service air pressure should be adequate for air atomization of light oil during light up. 8.2.11 Boiler Side:

96

12) Confirm that Ash Water Pumps are in service and bottom ash hopper seal trough and ESP wetting pot seals are filled up. 13) Ensure that all manholes, peep holes are kept closed in boiler and flue gas ducts, including ESP. 14) a) b) c) d) e) f) g) h) i) j) k) l) m) Check and ensure the opening of the following valves. SH, RH, Drum, economizer and start up vents. SH drains and their header drains to IBD. The common isolation valve at 2.5 ML to IBD. The isolation valves on the turbine side drains to FT4 Economizer Recirculation valves. Isolation valves on the drain line before MSV (Left and Right) to IBD. Atomizing Steam system drains. Heavy Oil short RC valve & Elevation return valves. SCAPH drains to IBD tank. PRDS drains. Hot well excess return to CST. Deaerator Over flow isolation valves. All sampling valves.

15) The following valves shall be kept closed before arranging for lighting up of the boiler. a) b) c) d) The down comer drains. The ring header drains. The Economizer drains. Deaerator drains to IBD to CST.

16) Ensure that purge air to Ignitors is open in all four corners and in all elevators. 17) Line up flue gas and secondary air systems 18) Establish supply to FSSS panels. 19) Line up light oil and heavy oil systems 20) Line up phosphate Dosing System 21) Establish supply & Switch on modules and make ready the following systems. a) Draught System
97

b) c) d) e) f)

Electrostatic Precipitator & rapping Systems. Air preheating system Auxiliary PRDS. Secondary Air Damper Controls. Seal Air System.

22) Keep emitting electrode & collecting electrode rapping motors in Service and Switch ON supply for hopper heaters. 23) Boiler shall be kept filled upto normal level by chemically treated / deaerated water as per relevant operating instructions. 8.2.12 Turbine-Generator Side: 24) Keep the following systems lined up with supplies / modules on and breakers ready for operation. a) b) c) d) e) f) g) h) i) j) k) l) m) n) Condensate System Feed water system Gland sealing and air evacuation system Turbine Oil System EAST HP / LP Bypass system Excitation System Stator Water System Generator Hydrogen gas / cooling System Hydrazine / morpholine dosing system. Power supplies for all valves. Generator Protection system ready. Switch ON all indicating & recording instruments. Blower system in AVR Room.

Separate operating instructions are already available for the above systems. 8.2.20 Taking Systems into Service: A. Boiler Side: 01 02. PRDS APH System Charge PRDS from other unit & maintain pressure & temperature a) Take Guide bearing & Support bearing lube oil system into service. b) Take air motor into service and keep APH
98

03.

04.

05. 06.

07. 08. 09. 10.

A & B in rotation. c) Start main drive and see that Air motor cuts off automatically. d) Check operation of the other drive also and keep one in service. e) Keep APH Soot blowing system ready. Fuel Oil a) Take light oil pump into service. System b) Take any one heavy oil pump into service on RC through short RC. The FORV is open. c) Charge heating steam line from PRDS and raise the heavy oil Temperature to125C in 18ML. FCV shall be kept open partially with trip valve open. d) Charge atomizing air / steam lines. Draft System a) Take one ID Fan into service. b) Take on FD Fan into Service. c) Load the fans suitably for 30% airflow and maintain furnace draft at 5 mmwc. d) Take scanner fan into service. Ensure that atmospheric suction damper is closed. SCAPH Charge SCAPH and maintain sec. Air temperature at APH inlet at 75C. Boiler a) Ensure no safety valve is gagged. b) Check & Open the isolation hand valve of ERV and Establish supply. Keep the control on auto. c) Ensure that all wall blowers and LR blowers are in retracted position. d) Fill up boiler upto normal level as per operating instructions, if not already done. It is always preferable to feed deaerated and chemically treated water to boiler. e) Make burner tilt horizontal. f) Ensure that boiler is free to expand. ESP Rapping motors and hopper heaters are in service. SADC Ensure that all auxiliary air dampers in wind box are open, before purging. Milling System Keep the system ready with Raw Coal bunkers filled up. Soot Blowers Keep the system ready for starting APH Soot blowers with PRDS Steam.

99

B.T.G. Side 1. Turbine Oil System: a) b) c) d) e) Start one oil vapour extraction fan. Keep one jack oil pump in service with one AOP. Take TG rotor on barring gear and take the turbovisory readings. Ensure that starting device is in minimum position. Keep lube oil temp. controller on auto, and see the temperature is maintained at 45C. f) Ensure that SLC is switched ON for AOPs, JOP, DCEOP and Gate Valve gearing. g) Watch MOT level and arrange for topping up if necessary. Note: The lub oil System can be started through SGC till the machine comes on barring gear. h) Check that isolation valves are open in Governing rack and LP Bypass rack. 2. Condensate Systems: a) b) c) d) Keep the hotwell level normal by hot well make up pump. Take CEP into Service on RC and Select SLC for the Pumps. Watch hot well conductivity for normal value (say 3 to 5 mic.S / cm.) If the silica in CEP discharge is > 0.05 ppm, dump the condensate to waste by opening the excess return line drain valve to sewage. Maintain Deaerator level by means of boiler fill pump. e) Charge all LP heaters on main condensate side, and maintain deaerator level, through CEP after bringing down silica level in condensate. 3. Feed Water System: i) If the boiler has to be filled up the BFP, then the pump can be kept on RC to be ready for making up drum level when necessary. 4. ACW System: If necessary, one more ACW pump can be taken into service along with one more SWBP. 5. Chemical Dosing System: a) Morpholine dosing can be given at CEP discharge till the pressure in boiler reaches 40 Kg / Sq. Cm or till synchronizing the set.
100

b) The Hydrazine dosing system can be taken into service for feeding into BFP suction. These systems shall be managed by the shift chemist as per requirement.

6. Stator Water System: a) Take stator water system into service, after checking auto start of the pumps. b) Take polishing unit into service. c) Watch the stator water conductivity and flow. 7. Hydrogen Cooling System: a) Before arranging for lighting up the boiler, the generator casing should be filled with hydrogen with purity above 99%. b) The gas cooler shall be kept charged on ACW side and outlet valves closed. 8) HP by pass: a) Check & open all isolation hand valves in FW injection line. b) Check that HP bypass oil pump is in service and both pumps kept in auto mode. c) Keep the pressure and injection valves in closed condition. 9) Turbine: a) Open all the hand valves in MS, HRH, CRH, HPBP Pot drain, CRH Pot drain & CRH drain lines to Flash tank 4. b) Keep the electrical isolation valves in the MS, HRH, CRH drain to FT4 in open position and all drains to condenser (flash tank) are in closed position. c) If the feed pump is in service charge HP heater on feed water side. 10) Switch Yard: Ensure that all line clears are returned. Keep the isolators and Generator breaker ready for operation from UCB with fuses inserted and controls on 'remote'. 8.2.30 Lighting Up & Pressurizing: Time in Condition
101

Operation

min. .. Purge the boiler after Purge ready condition If No boiler trip persists, see that HO trip valve is closed, Airflow is more than 30%, and drum level is normal. After 5 minutes of giving push to purge impulse, purge complete lamp will appear. a) Maintain light oil pressure at 15 20 Kg / Sq. Cm at FOPH. b) See that atomizing air at adequate pressure is available. c) The light oil system is made ready in all four corners of the boiler, with gun assemblies fixed in position. a) Light up with a pair of light oil guns. b) Check up flame in the boiler. c) Adjust furnace to wind box DP to 40 mmwc.

..

Check up the system ready for L.O firing in AB elevation before opening Trip Valve Boiler ready for light up.

00

Note: 1) The maximum firing rate should not exceed to cause more than 110C per hour rise in saturated steam temperature. 2) Adequate flow through super heater and Reheater should be ensured as the firing rate is increased. 3) The steam flow through start up vent shall be allowed till HP / LP bypass system is charged. 4) The turbine rolling parameters to 40 Kg/Sq.cm and 325C can be achieved within about 3 hours. 5) Light Oil is the ideal fuel for lighting up of boiler from cold condition, in view of its low Sulphur content (1.5%), low viscosity (10 cst) and possibility of air atomization, without need for steam during startup. Once the Boiler is lighted up carry out the following operation: Time in Condition min. 05 Boiler Lighted up Operation a) Start HP dosing (phosphate) and maintain chemical regime. b) Start one Boiler feed pump on Recirculation and keep the feed line charged.
102

c)

15

Boiler warming up

60

Vents and drains closing

75

Vacuum pulling

Charge heating steam to feed tank from PRDS & close the over flow valve. After attaining a temperature of 75 to 80C, admit pegging steam from PRDS and maintain a pressure of 2 to 2.5 Kg / Sq. cm after cutting out heating steam. d) Keep drum level normal by blow down if necessary, as swelling takes place. e) Maintain deaerator level through CEP, simultaneously making up hot well level. d) Maintain chemical regime of feed water by taking up hydrazine & Morpholine dosing system into service. a) Take additional pair of light oil guns. b) Ensure SCAPH is charged & Sec. Air at APH inlet is about 75C. c) If the flame is satisfactory, withdraw AB elevation Light oil guns from service. d) Close the light oil trip valve and select HO firing for AB elevation. e) After proving AB elevation. HO guns, withdraw CD elevation. HO guns from service. f) During the above period, ensure that the rate of rise of saturated steam temperature is within limits. g) Start APH soot blowing from PRDS. a) When the drum pr. Is about 2.0 Kg/Cm and as soon as free steam flow is observed, close drum, economizer and SH vents. b) Start up vents shall be fully open. c) Close SH drains only after attaining a pressure of 7 10 g / cm d) Keep open the self-PRDS drains on steam lines and injection lines. e) Open the electrically operated drains to FT-4 from turbine side. f) Warm up the gland steam line from PRDS. a) CEP and CW pumps already in service. b) Start one sealing steam exhaust fan and ensure that its inlet valve is open & the inlet of the other fan is closed. c) Start vacuum pump as per normal operating procedure for pulling vacuum
103

85

MSL warming up & HP/LP bypass charging

130

Turbine warming MS Pr. 20 Ksc MS Temp 250C HRH temp

quickly. d) Gradually start admitting the gland steam when condenser vacuum reaches about 0.2 Kg/ Sq.Cm. Note: - Vacuum pulling can be done through SGC also. e) After vacuum is >0.85 Kg/Sq. cm open all drains (MSL, HPBP, LPBP, HRH, CRH) to flash tank-2 & close the drains to flash tank 4. f) Ensure that gland steam admission temperature is always > 200 Deg C. g) Open the HP bypass injection hand valve and LP bypass warm up valve. h) Ensure that HPBP Pressure control valves, BD valve injection valve & LP Bypass valves are closed. i) Keep the SLC drains control on. a) Switch on the automatic control interface of LP bypass. b) Open Main Steam stop valve by pass valves L & R for warming up MSL. c) Wait for sufficient warming. See that the MS outlet temp. (L) & (R) are equal. Difference in temp. max. allowed is below 17C. d) Open M.S.V. e) After obtaining steam purity, open HP bypass valves gradually. Initially keep open at 5% for some time for warming up. Then as per the boiler pressure required, open the HP bypass valves. f) LP BP valves will open to 25% if RH pressure is > 2 kg / Sq. Cm. The fixed set point will gradually go upto 12 Kg / Sq.cm & freeze at that value. The RH pressure will then be maintained at 12 Kg / Sq. Cm by the LP BP valves automatically. g) Close start up vents, once the HP bypass valves are opened. a) Adjust firing rate to achieve the parameters indicated in the start up curves. b) Open the seat drains of HPESVs & IPESVs and MAL drains. c) Check and ensure that speed set point is
104

250C

zero and speeder gear and start up device are in zero position. d) Ensure TSE influence is ON. e) Open HPESVs and IPESVs for warming up by moving the starting device to approximately 42% from zero position watching the Trip oil and start up oil pressures. f) Switch ON trimming device. Note: - Turbine warming up, Rolling and synchronizing can be carried out through SGC also.

8.2.4 Turbine Rolling (Through Hydraulic Governing): 160 MS Pr. 40 Ksc MS.Temp: 325C, HRH Pr12 Ksc HRH temp. 325C a) Keep the firing rate and position of HPBP valves suitably adjusted to have the prescribed boiler parameters. b) Wait for the TSE margins to increase beyond 30C. c) Ensure that the EHG is isolated at the governing rack. Set the Electro Hydraulic controller at 100% position in the control desk. d) Gradually raise the starting device to bring the speed to 600 rpm. The position of starting device will be around 55%

During rolling of turbine, watch the following parameters closely a) b) c) d) e) f) g) h) i) j) 210 Turbine Expansion. Turbine stress Margin Turbine & Generator bearing temperature TG bearing vibrations. Turbine shaft vibration Performance of seal oil system and seal oil flow. Hydrogen pressure and purity 3 Kg / sq. cm & > 98.00 % Stator water flow and conductivity 27.5 T/Hr. < 3 mic.S / cm. Keep the Hydrogen gas coolers charged at 600 rpm. Ensure that gate valve gearing valve closes at 240 rpm and JOP gets tripped at 540 rpm. Turbine at 600rpm & ready for going upto a) Before picking up speed ensure that sufficient TSE margin is available. b) Close 230KV isolators and confirm proper
105

3000 rpm and closing from Switchyard. synchronizing c) Confirm that Gen. Breaker is ready for operation from remote. d) Switch On field flashing module. e) Cut in additional HO oil guns if necessary. f) Start additional CW and ACW pumps as required. g) Allow about 45 mts. At 600 rpm for proper warming up of turbine. h) Ensure resetting of T-5 Relay. Now raise the speed to 2400 rpm smoothly through starting device at the rate of 600 rpm / min. Then further increase the speed to 3000 rpm through speeder gear smoothly without giving any pause. a) The starting device position will be at 90%. b) The speeder gear position will be corresponding to the position of the speed required for synchronizing the set (50% to 60%) c) Monitor bearing, and shaft vibrations, lube oil and bearing temperatures, generator winding, core temperatures & TSE margins. d) Ensure that AOP is stopped. 225 TG at 3000 rpm a) Close field breaker and flash the field & Ready for bringing up voltage on manual control to the synchronizin rated value. Match the select auto control. g b) Adjust voltage & speed approximately to the required level and select auto synchronizing. c) Once the generator is synchronized with the grid, ensure that about 15 MW load is picked up automatically. d) Anyway, be ready for picking up the load by suitably raising the speeder gear. e) Increase the HP BP pressure set point to close the Pressure control valves or close the valves manually, immediately on synchronizing, watching the drum level. f) Close the MSL, HP BP, LP BP, HRH & CRH drains to flash tank. g) Keep the SLC drains on. Turbine Rolling (Thro EHG) MS. Pr.- Ksc MS.Temp -325C a) Keep the firing rate and position of HP BP valves suitably adjusted to have the
106

160

HRH Pr-12 Ksc HRH Temp 325C

b) c) d) e) f)

g) 210 Turbine at 600 rpm & ready for going upto 3000 rpm and synchronizin g a) b) c) d) e) f) g) h) i)

prescribed boiler parameters. Wait for the TSE margins to increase beyond 30C Ensure that the isolating valves for EHG in control rack are kept open. Check that speed out point is zero & speeder gear is at 100%. Raise the starting device to about 70% Raise the speed out point to 600 rpm and watch the actual speed. Ensure the closing of gate valve gearing at 240 rpm and stopping of jacking oil pump at 540 rpm. Monitor turbo supervisory readings bearing temp. etc. carefully (as given above) Before picking up speed ensure that sufficient TSE margin is available. Close 230 KV isolators and confirm proper closing from Switchyard. Confirm that Gen. Breaker is ready for operation from Remote. Switch ON field flashing module. Cut in additional HO oil guns if necessary. Start additional CW and ACW pumps as required. Allow about 45 mts. At 600 rpm for proper warming up of turbine. Ensure resetting of T-5 Relay. Switch on tracking device.

Now raise the speed set point to 3000 rpm. The speed will rise at the rate of 600 rpm / min. a) Monitor TG bearing & shaft vibrations, bearing temperature, seal oil system etc. b) Ensure that AOP is stopped. 225 TG at 3000 rpm & Ready for synchronizing. MS Pr.40 Kg/ cm2. MS Temp. 340C a) Close field breaker and flash the field bringing up voltage on manual control to the rated value. Match and select auto control. b) Adjust voltage & speed approximately to the required level and select auto synchronizing.
107

c) d) e)

f) g)

Once the generator is synchronized with the grid, ensure that about 15 MW load is picked up automatically. Anyway, be ready for picking up the load by suitably raising the speeder gear. Increase the HP BP pressure set point to close the Pr. Control valves or close the valves manually, immediately on synchronizing, watching the drum level. Close the MSL, HP BP, LP BP HRH & CRH drains to flash tank. Keep the SLC drains ON.

8.2.5. PROCEEDING FURTHER FOR LOADING THE TG SET: 240 Load 20 MW a) b) c) d) e) f) 275 Load 40 MW. MS Pr.40 Kg/ cm2. MS Temp. 400C a) b) c) d) Start the second set of ID and FD Fan Start PA fans. Seal Air fan will start on auto. Take first mill (Preferably A or B) into service, after lining up the systems. Charge ESP fields. Take ash handling system into service along with scrapper feeder & Clinker grinders. Make ready SH & RH spray systems. Cut in LP heaters 1,2 & 3 and put level controllers on auto. Take load controller into service Change over pegging steam from APRDS to CRH and maintain deaerator pressure at 3 Kg / Sq. cm. Bring the pressure controller into service, in limit pressure mode. Cut in second mill and watch the MS & RH temperature. If necessary control the same using burner tilt. Avoid SH spray controls as far as possible. Ensure that the Wind box / furnace DP is raising to almost 100 mmwc. Second BFP shall be started and kept ready for sharing the feed flow. Change over gland steam to CRH line. Extraction 4 steam may be given for deaerator pegging and controls put on auto. Warm up HP heaters by opening the extraction valves slightly and keeping open
108

300

Load 80 MW. MS Pr.75 Kg/ cm2. MS Temp. 450C HRH Pr. 15 Ksc. MS Temp. 450C

a) b) c) d) e)

330

Load 120 MW. MS Pr. 100 Ksc. MS Temp. 490C. HRH Pr. 20 Ksc.

f) a) b) c) d) e) f)

360

Load 160 MW. MS Pr. 149 Ksc. MS Temp. 490C Load 210 MW MS Pr. 149 Ksc. MS Temp. 540C

a)

the heater drain valves to flash tank. Bring both UATs into service. Take third mill into service, preferably continuous mills such as A, B and C. Above 120 MW, oil elevations can be removed gradually after all three mills are loaded beyond 30 T / Hr. Cut out SCAPH & take self PRDS. After loading both the BFPs equally, cut in feed flow control auto loop. The other auto controls can be taken into service one after the other. Divert trip of HPH-6 to 5 and HPH-5 to Deaerator and put level controllers on auto. Cut in fourth mill and raise the feeder loading.

390

a)

Raise the firing rate to achieve a TG load of 210 MW. b) If not able to achieve full load, cut in fifth mill and reach 210 MW.

8.2.6. IMPORTANT NOTE: a) Keep always the stand by equipments in trim condition and ready for start in case of emergency. If auto start is provided, keep the equipments in auto mode. b) Wall blowers / LR blowers shall be operated as per normal schedule or whenever required. c) Watch oxygen level in flue gas and by adjusting FD Fan load maintain the same by 3 to 3.5 % d) Ensure that HP & LP heaters of turbine are always in service with level controller on auto mode. 8.3.0 WARM START UP (After 48 Hrs.) A warm start up is one in which the max. HP casing / HP shaft temperature is above 100deg.C,but below 350deg.C. The steam parameters are derived based on the absolute temperature of HP casing and HP shaft. Under these conditions, not all equipments / systems will be shut down. The TG will necessarily be on turning gear. The steam parameters will be normally brought up with HO firing without going in for Mills operation. The unit condition and the procedure for warm start up are given below:

109

Sl. Unit / Auxiliaries Condition No. 01. Both APHs are in service 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. 15. 16. 17.

Operation

If they had been stopped for taking up any emergency work, start the same on return of L.C. C.W.Pumps Keep at least one CW pump in service. Sea Water Booster Pump Keep at least 2 Nos. pumps in service with heat Exchangers in service. ACW System in Service At least 2 Nos. pumps shall be in service. Inst. Air compressors in If not, start 2 Nos. compressors. Service Service Air compressors in 2 Nos. compressors already in service Service for other units. Seal Oil System in service DC SOP shall be ready for auto start. Turbine on B/G with JOP & SLC for pumps, including DCEOP shall AOP in service be ON. Scanner air fan in service Scanner fan shall be ready for auto start. Generator Hydrogen gas The standby Stator water pump shall be system and Stator Water selected for auto start. Keep H2 gas pr System in Service above 3.2 ksc. HP / LP Bypass system HP Bypass oil pump will be selected for ready in all respects auto start. EAST System Ready in all respects ESP ready for charging of Hopper heaters and rapping motors in fields service. HP / LP Dosing system Ready for feeding chemicals Furnace bottom ash hopper. Seal trough filled up and ready for service. The scrapper feeder will be kept in service. Vacuum pump Lined up and ready for operation Gland steam System Lined up and ready for service

8.3.1 PREPARATION FOR LIGHTING UP OF BOILER: 01. Boiler PR. 0 Ksc Temp: >150C 02. Condensate System lined up 03. Feed water system lined up 04. Chemical Dosing System Charge PRDS from other unit and admit steam to FOPH for HO heating station. Take on CEP into service and maintain hot well level. Start on BFP and charge feed water lines. Maintain Chemical regime of feed water with BFP on R.C.
110

05. Steam to deaerator

06. 07.

08. 09. 10.

11. 12.

a) Charge heating steam to deaerator from PRDS and b) Admit pegging steam. After 80 Deg C cut out heating steam as the pressure rises. Boiler filling Top up drum level and maintain deaerator level with CEP. Heavy Oil System Start one Heavy oil pump with short RC open. Raise the oil temperature to 125 Deg C and establish flow through elevation return lines. Close the short RC valve. Light Oil System Start one light oil pump and charge the line upto Boiler firing floor. Draft System Start one ID Fan and one FD fan. Maintain airflow > 30% and furnace draft at 5 mmwc. Steam lines, Vents & Line up MS, CRH & HRH lines. Open Drains drains to FT-4 with elec. Isolation valves to FT-2 tank closed. Boiler stop valve and by pass valves are closed. SH Start up vent, drum & ECO Vents, ECO RC valves, SH drains are open. Ash Handling System Keep the system in Service. Purging the Boiler After bringing purge ready conditions, purge the boiler 5 mts.

8.3.2. LIGHTING UP OF BOILER; Time Condition 00 Boiler purged out & ready for light up. TG on barring gear 20 HO Firing Operation Light up with AB elevation Light oil guns. After ensuring satisfactory flame condition, keep 4 guns in service. a) Cut in CD elevation HO guns and prove the same. b) Change over AB elevation Light oil. c) Cut out CD elevation HO guns. d) Take HP/LP chemical dosing systems into service for maintaining chemical values. a) Start gland steam exhaust fan & Vacuum pump. b) Maintain gland steam pressure. Ensure gland steam temperature is always above 200C. a) Close SH, drum & ECO vents when drum pr. is > 2 Ksc. or as and when free
111

30

Pull Vacuum

35

Drains & Vents

b) c) 75 d) Charging HP / LP a) bypass system. MS.Pr.10 KSC. b) Temp. 200C c) d) 90 MS.Pr.20 KSC. Temp. 250C a) b) c) d) a)

100

Turbine warming up.

b)

steam flow is observed. Close SH drains at 7 10 Kg/Sq.cm. Change over FT-4 to FT-2 drains at Turbine side when the vacuum is > 85% Switch on SLC drains. Open MSV bypass valves & Wait for the MS lines to warm up. Ensure that self-PRDS drains in open condition. Then open MS Valves. Switch on Automatic control Interface of LP Bypass system. Open HP bypass slowly & allow the system for warming up. Keep HP BP spray control on auto. Increase firing rate suitably for raising boiler parameters to match HP turbine / shaft temperature. Open seat drains of HPESVs and IPESVs and MAL drains. Check and ensure that speed set point is zero and speeder gear and in zero position. Ensure that TSE is ON. As and when M.S. temp is about 50 deg C more than HP casing / shaft temperature open HPESVs and IPESVs for warming up, by moving the starting device to approximately 42% zero position. Switch on trimming device.

8.3.3. ROLLING THROUGH EHG: Wait for the Margin to increase beyond 30 Deg C.

112

130 Turbine is ready for rolling. Typical parameters MS.Pr.40 KSC. MS.Temp.350C HRH Pr.12 KSC. HRH Temp.350C HP bypass steam flow > 70 T / Hr.

a) Raise starting device to 70%. b) Raise the speeder gear position to 100%. c) Raise the speed set point to 600 rpm, and watch the actual speed. d) Ensure closure of gate valve gearing at 240 rpm. e) Ensure tripping of jacking oil pumps at 540 rpm. f) Switch on Tracking device (if not already done) and see that starting device automatically tracks the EHC position. g) Charge generator gas coolers.

140 Turbine is at 600 rpm a) During this period, monitor bearing and ready for picking vibrations, bearing temperatures, shaft up speed vibration, TSE margins and differential expansions. b) Switch on field flashing module. c) Close 230 KV isolators and confirm from Switch Yard after checking locally. d) Get clearance from switchyard for synchronizing the unit. e) Now raise the speed set point to 3000 rpm. f) Speed will pick up at the rate of 600 rpm /m. Closely monitor bearing temperature, vibrations, seal oil to Hydrogen diff. Pressure, turbovisory readings and TSE margins. g) Stop AOP at 2950 rpm and switch on SLC. h) Start Soot blower APH. 140 Turbine speed 3000 a) Close field breaker and flash the field. rpm b) Adjust voltage and select AVR for auto controls. c) Adjust the turbine speed approximately equal to the speed corresponding to grid frequency. d) Synchronize the generator on auto and ensure that a load of 20 MW is picked up. e) Increase HP BP set point and confirm that HP BP is fully closed, and also spray valves. f) Close all drains on turbine side and
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keep SLC drains ON. g) Take CW pumps, ACW pumps and seawater booster as required for full load operations. h) Take other set of ID and FD Fans into service. 8.3.4. LOADING THE UNIT: 155 Load 20 MW a) b) c) d) e) f) a) Cut in LP heaters and have drains controls on auto. Peg deaerator from CRH line cutting out PRDS steam and maintain the pressure at 3 Kg. / Sq. cm Start PA Fans, Seal air fan will start on auto. Start one bottom mill and load the mill. Line up SH & RH sprays controllers. Charge ESP fields. Control MS Temperature. Start the second mill and load the same gradually. Start second BFP at 70 to 80 MW. Change over gland steam to CRH line. Cut in third mill second seal air fan cut in to service on auto. After taking the load to 125MW and after ensuring satisfactory flame conditions, with draw oil support completely. Cut in HP heater and put level controls on auto. Cut in both UATs. Take self PRDS into service. Start 4th mill and raise the load to full load, watching TSE margins. Change over pegging steam for deaerator to extraction steam. Watch all parameters on turbine and generator side for normal. Limit the MS temperature and RH temperature by attemperation and burner tilt. Bring Parameters to optimum and rated values.
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200 Load 40 MW. MS Pr. 55 KSC. MS.Temp 400C b) c) 230 Load 100 MW. a) MS Pr. 100 KSC MS.Temp 450C b)

c) d) e) a) b) c) d) 320 Load 210 MW. MS Pr. 145 KSC a)

250 Load 140 MW. MS Pr. 130 KSC MS.Temp 475C

MS.Temp 535C

b)

Check up chemical regime of steam boiler and feed water etc. c) Carry out soot blowing as per regular sequence. d) Stop one vacuum pump.

8.4.0 HOT START-UP: The start up of the unit immediately after a trip out or within 8 hours after shut down & boxing up of the boiler, is termed as Hot Start-up. Under these conditions, the HP casing / HP shaft temperature shall be more than 350deg.C. There will be steam pressure in the boiler and the furnace will be hot, allowing direct heavy oil and coal firing. Start-up curves available for such hot start shall be used for raising parameters. The steam parameters required for the particular conditions will be assessed from HP casing / HP shaft temperature and match with suitable firing rate, establishing steam flow through HP/LP by pass system. There will be no swelling of drum level during hot start of boiler and therefore Boiler feed pump shall be kept in service before lighting up the boiler. If the unit is lighted up immediately after a trip out, most of the systems will be already in service; However the operations required to be carried out, for lighting up of the boiler, after boxing up of the same for a short duration, are indicated below, as a typical example for hot start. 8.4.1 Pre-start Conditions: Sl. No. 01. 02. 03. 04. Unit Condition Operation

05.

Boiler Side: Both air pre-heaters shall be Service air and Instrument Air in service with Air motor as systems shall be kept in service. auto stand by. PRDS shall be kept charged Till such a time self steam is charged. initially from other unit. FOPH and atomizing steam Self-PRDS drains shall be kept open. lines and steam tracking lines shall be kept charged. HO pump will be in service, Raise HO temp to 125C using short if not start one HO pump and RC or through elevation Return line, with flow control valve slightly kept open. Scanner fan shall be in The other scanner fan will be on auto service with atmospheric stand by. suction damper in open condition.
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06. 07.

08.

09. 10. 11. 12.

Phosphate dosing pumps are Ensure chemicals in the mixing & ready for operations. metering tank for immediate use. ESP is kept ready in all Keep hopper heaters in service. The respects rapping motors for collecting and limiting electrodes shall be kept in service. The furnace bottom ash Before light up keep the scrapper system and seal trough are feeder in service with all gates open. lined up. The clinker grinders can be started at a later stage. Ash handling system shall be Fly ash water pump, seal water pump, ready for operations. slurry pump etc. shall be available readily. FSSS system. Ready in all respects. AB, CD elevations in boiler Line up for HO firing. Keep open the ECO Close these valves as and when the recirculation valves. unit is synchronized. Turbine Side: Cooling water system in is service, at least with 2 Nos. CW pumps ACW System is in service Seawater booster (2 Nos. min.) shall be in service. Turbine is on barring gear with AOP & JOP in service. HP / LP bypass system is ready for use. EAST - system Vacuum pump. Screen wash system chlorine dosing system. Etc. shall be available for operation. Keep at least 2 Nos. of ACW pumps in service. The self-cleaning strainers shall be available (One No. in service and other stand by) on auto mode. AOP, EOP, JOP & gate valve gearing shall be in SLC ON condition. Ensure that all pressure and Temp. control valves are in closed condition. Ready in all respects. Line up with sealing water and cooling water for its heat exchanger. The gland steam line shall be warmed up to the control valve

01. 02. 03. 04. 05. 06. 07. 08.

09.

10.

Gland steam admission & leak system controllers are lined up & ready for operation Generator H2 gas system Maintain Hydrogen gas pressure at 3.4 stator water system and seal to 3.5 Kg/Sq.cm oil system are already in service. Ensure CEP is in service on Maintain hot well level. re-circulation.
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11. 12. 13.

Line up MS, CRH, HRH & HP/LP Bypass steam lines Take one BFP in Service. Admit heating / Pegging steam in deaerator from PRDS.

Open drains to FT- 4 / FT-2 where ever available. Maintain deaerator level by CEP. Maintain a Pr. Of about 2 to 3 KSC

8.4.2 Pre-Light up operations: Sl. Operation Remarks No. 01. Start on ID fan and one FD Load the fans suitably to maintain an Fan airflow of >30% rated flow and furnace drain 5 mmwc. 02. Check that Burner tilt Ensure that guns are fixed in raises to position. 2 kg/Cm the LP bypass will open by 25% and then remain 03. Charge atmoising steam and Ensure that the atomizing pressure steam tracing lines, control valve is working satisfactorily and the pressure is maintained at 7 Kg / Sq. cm. 04. Charge SCAPH Maintain air pressure at APH inlet at 75 deg C. 05. Check that SADC is selected Maintain furnace to wind box DP at on auto mode. 40 mmwc initially. 06. Purge out boiler after bringing purge ready conditions 07. Pull vacuum in condenser, by Ensure that gland steam pressure is starting vacuum pump. maintained. 8.4.3. LIGHTING UP OF BOILER: Time 00 Condition Boiler is ready for light up Operation a) Light up with one pair and then other pair of HO guns in AB elevation. b) Open the start up vents. c) If the boiler pressure is less than 10-15 Kg/Sq.cm open SH drains for about 10 mts. and then close the same. d) Maintain chemical regime of feed water & boiler water. Charging of HP / LP a) Open bypass valves of main steam stop bypass system valves for warming up M.S. lines. b) Check that drains in self-PRDS lines
117

15

c) d) e)

f)

30

g) Increasing firing rate a) b) c) d)

e) f) g)

are open. Check that vacuum in condenser is more than 0.85 Kg/Sq. cm. Open boiler stop valves after keeping open the bypass valves for about 5 to 10 mts. Open HP bypass valves gradually by about 5 to 10%. Ensure that HP bypass injection valves are selected on auto and maintain the down stream temp. Switch on automatic control Interface of LP bypass. As the RH pr. At that position, till the RH / pressure rises to 12 Kg/ Cm. After than the RH pr. will be maintained at 12 Kg/ Cm at the fixed set point. Close the start up vents. Take CD elevation into service. Take other ID, FD Fans into service Take both PA fans into service, with two seal air fans. Take one mill into service. Depending upon the MS temperature requirement the mill to be taken into service will be decided. After cutting in the mill, one elevation of oil can be withdrawn from service. Open the seat drains of control valves and MAL drains. Cut in additional mill if required.

8.4.4. ROLLING AND SYNCHRONIZING: Note: - Warming up and Rolling of Turbine EHC is given below: 45 to 60 Turbine warming up a) As and when the MS temp. and pressure is reached corresponding to the HP casing / shaft temperature turbine stop valves will be opened, by suitably raising the starting device. Steam pressure before HP bypass may be maintained below 100 Kg/Cm. b) Watch the TSE margin and ensure that TSE influence is ON. c) Ensure the differential expansions of
118

d) e) 50 to 65 Turbine Rolling a) b) c)

turbine are normal. Ensure that speed set point is zero. Speeder gear in max. position i.e., 100% and EHC in minimum position i.e., zero. Adjust the firing rate and HP bypass valves suitably to have the prescribed boiler parameters for rolling. After achieving a TSE margin of > 300K, raise the starting device to about 70% Raise the speed set point to 600rpm and watch the actual speed picking upto 600 rpm.

60 to 70

Turbine ready for going to 3000 rpm and synchronizing

d) Ensure closing of gate valve gearing and tripping of JOP. e) Watch the HP exhaust temperature and ensure opening of CRH NRVS. Temperature will raise gradually permissible max. 450C. Take remedial measures at 425C. f) Monitor the bearing temp. vibration, shaft vibration carefully. g) Charge Hydrogen gas coolers. h) Switch on field flashing module. i) Close 230 KV isolators. Confirm the same from switchyard and get clearance for synchronizing the unit. j) Start additional CW pump, ACW, Seawater booster pumps etc. as required for full load condition. a) Raise the speed set point to 3000 rpm. The speed will rise at the rate of 600 rpm / min. b) Monitor bearing and shaft vibrations and bearing temperatures. c) Watch the seal oil system. d) Stop AOP at 3000 rpm. e) Close field breaker and flash the field bringing up voltage on manual control to the rated value. Match and select auto control. f) Adjust voltage & Speed approximately to the required level and select auto synchronizing.
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g) h) i)

j) k) 8.4.5. LOADING THE SET: -

Once the generator is synchronized with the grid, ensure that about 15 MW load is picked up automatically. Anyway, be ready for picking up the load by suitably raising the speed ref. Increase the HPBP pressure set point to close the Pr. Control valves or close the valves manually, immediately on synchronizing, watching the drum level. Close the MSL, HPBP, HRH & CRH drains to flash tank. Keep the SLC drains ON.

Proceed further for loading the set as per the TSE margin available by suitably increasing the firing rate. Note: 1) Cut in LP heater after synchronizing the unit. 2) Cut in both the UATs at 70 MW load. 3) Cut in HP heater at 90 to 100 MW load. Change over deaerator pegging steam from PRDS to CRH after synchronizing. 4) Change over deaerator pegging steam from CRH to extraction steam at about 80 MW. 5) Change over gland steam to CRH line at 80 MW. 6) Take over BFP into service at a load of 80 to 90 MW. 7) Cut out SCAPH after watching flue gas temp. at APH inlet > 125 deg C. 8) Completely remove oil support in the boiler after cutting in third mill and raising the load to 140 MW. 9) Cut in all auto controls one by one. 10) APH soot blowing / water wall / LR blower operations shall be carried out as per regular schedule.

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9. INTERLOCKS 9.1. L.T SWITCHGEAR

9.1.1. USS CHANGEOVER SCHEME: 9.1.1.0. USS Buscoupler Closing: 9.1.1.1. Auto Change Over Scheme: 1. 2. 3. 4. Relays of both incomers should not have acted. Auto/Manual Switch at Buscoupler of USS Should be in Auto position. Local/Remote Switch at Buscoupler of USS Should be in Remote position. (a) For a Supply Failure in USS-A Bus: With conditions that i) USS- A Incomer breaker is in tripped condition. ii) USS-A Bus is having no supply(monitored by U/V relay) iii) USS-B Bus is having normal supply, the Bus Coupler breaker closes on Auto to extend the supply from B Bus to A Bus. (b) For a Supply Failure in USS-B Bus: With conditions that i) USS- B Incomer breaker is in tripped condition. ii) USS-B Bus is having no supply(monitored by U/V relay) iii) USS-A Bus is having normal supply, the Bus coupler breaker closes on auto to extend the supply from A Bus to B Bus. 9.1.1.2. Remote Closing : 1) Auto / Manual Switch at Bus coupler of USS should be in Manual position.
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2) Local/Remote Switch at Bus coupler of USS Should be in Remote position. 3) Auto/Manual selector switch of USS Bus coupler at GCDP Should be in Auto. 4) Trip selector switch at GCDP should be selected for Incomer-A or IncomerB as required. On closing the Buscoupler breaker from GCDP through synchroscope, the B/C will close and the breaker selected through Trip selector switch will trip on Auto. 9.1.1.3. Local Closing:

1) Local/Remote switch should be in Local position. 2) Close the Bus coupler Breaker from USS. 9.1.2. 9.1.2.1 USS INCOMER BREAKER CLOSING: Remote Closing :

1) Local /Remote switch at respective incomer panel in USS Should be in Remote position. 2) The respective Unit Service Transformer breaker at 6.6KV switchgear must be in closed condition. 3) Protection Tripping relay of Bus coupler Breaker should not have acted. 4) Auto/Manual selector switch of respective USS Incomer breaker at GCDP should be in Auto position. 5) i) For closing of Incomer A, Trip selector switch at GCDP should be either in Incomer B or in Tie (B/C) as required to trip the breaker concerned. ii) For closing of Incomer B, Trip selector switch at GCDP should be either in Incomer A or in Tie (B/C) as required to trip the breaker concerned. 6) Close the Incomer breaker from GCDP through synchroscope. 9.1.2.2 Local Closing : 1) Local/Remote switch at respective incomer panel in USS should be in Local position. 2) The Respective Unit service Transformer at 6.6KV switchgear must be in closed condition. 3) Protection Tripping Relay of B/C Breaker Should not have acted. 4) The Bus coupler Breaker should be in Tripped condition. 5) Close the respective incomer breaker from USS. 9.1.3. SSS CHANGEOVER SCHEME:

122

9.1.3.0. SSS TIE BREAKER CLOSING: 9.1.3.1. Auto Change over Scheme: 1) Protection tripping Relays of both incomers should not have acted. 2) Auto/Manual Switch at Tie breaker of SSS in UNIT-I should be in Auto position. 3) Local/Remote Switch at Tie breaker of SSS in UNIT-I should be in Remote position. 4) Tie breaker at UNIT-II should be in closed condition. (a) For a Supply Failure in SSS-A Bus: With conditions that a) SSS-A Incomer breaker is in tripped condition. b) SSS-A Bus is having no supply (monitored by U/V relay) & c) SSS-B Bus is having normal supply, the Tie breaker at UNIT-I closes on Auto to extend the supply from B Bus to A Bus. (b) For a Supply Failure in SSS-B Bus: With conditions that a) SSS- B Incomer breaker is in tripped condition. b) SSS-B Bus is having no supply(monitored by U/V relay) & c) SSS-A Bus is having normal supply, the Tie breaker at UNIT-I closes on Auto to extend the supply from A Bus to B Bus. 9.1.3.2. Remote Closing:

1) Auto/Manual Switch at Tie breaker of SSS in UNIT-I should be in Manual position. 2) Local/Remote Switch at Tie breaker of SSS in UNIT-I should be in Remote position. 3) Auto/Manual selector switch of SSS Tie breaker at GCDP should be in Auto. 4) Trip selector switch at GCDP should be selected for Incomer-A or Incomer-B as required. On closing the Tie breaker from GCDP through synchroscope, the Tie breaker will close and the breaker selected through Trip selector switch will trip on Auto. 9.1.3.3. Local Closing: 1) Local/Remote switch should be in Local position. 2) Close the Tie breaker from SSS. 9.1.4. SSS INCOMER BREAKER CLOSING: 9.1.4.1. Remote Closing:
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1) Local / Remote switch of respective incomer panel in SSS should be in Remote position. 2) The Respective Station Service Transformer breaker at 6.6KV switchgear must be in closed condition. 3) Protection Tripping Relay of Tie Breaker at UNIT-I should not have acted. 4) Auto/Manual selector switch of respective SSS Incomer breaker at GCDP should be in Auto position. 5) i) For closing of Incomer A, Trip selector switch at GCDP should be either in Incomer B or in Tie (B/C) as required to trip the breaker concerned. ii) For closing of Incomer B, Trip selector switch at GCDP should be either in Incomer A or in Tie (B/C) as required to trip the breaker concerned. 6) Close the Incomer breaker from GCDP through synchroscope. 9.1.4.2. Local Closing: 1) Local/Remote switch should be in Local position. 2) The respective Station Service Transformer breaker at 6.6KV switchgear must be in closed condition at 6.6KV switchgear. 3) Protection Tripping Relay of Tie Breaker at UNIT-I should not have acted. 4) The Tie Breaker at UNIT I should be in Tripped condition. 5) Close the respective Incomer breaker from SSS. 9.1.5. 9.1.5.1. N/E SWITCHGEAR: Auto Changeover Scheme:

1) Protection Tripping Relay of N/E Incomer Breaker from USS at N/E should not have acted. 2) In N/E Bus PT under voltage Relay should have acted. 3) N/E Incomer Breaker from USS at N/E should be in tripped condition. 4) The up stream breaker at DG switchgear should be in closed condition. 5) Auto/Manual switch of N/E incomer breaker from USS at N/E should be in Auto position. 6) Local/Remote switch of N/E incomer breaker from DG switchgear at N/E should be in Remote position. 7) The voltage build up in DG set should be more than 80%. 8) Then N/E Incomer Breaker at from DG switchgear at N/E end will close on Auto. 9.1.5.2. Closing of N/E Incomer from USS Breaker:
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1) The Local/Remote switch of N/E Incomer from USS at N/E should be in Local position. 2) The Local/Remote switch of N/E Incomer from DG switchgear at N/E should be in Local position. 3) The upstream breaker of N/E Incomer from USS at USS end should be in closed condition. 4) Protection Tripping Relay of N/E Incomer from DG switchgear at N/E should not have acted. 5) First, Trip the N/E Incomer from DG switchgear at N/E and then immediately close the N/E Incomer from USS breaker at N/E.

9.2. INTERLOCKS FOR 6.6KV SWITCHGEAR

9.2.1. STATIO N - UNIT TIE CHANGEOVER: 9.2.1.0. CLOSING OF STATION-UNIT TIE BREAKER: 9.2.1.1. Fast Auto changeover Scheme:

1) The Disconnector should be in service position. 2) Protection Tripping Relay of UAT Incomer breaker should not have acted. 3) The respective UAT Incomer breaker at 6.6KV switchgear should be in tripped condition. 4) In GRP either CLASS A or CLASS B protection should have acted. 5) Then Station-Unit Tie breaker at switchgear will close on Auto. 9.2.1.2. Slow Auto Changeover scheme: 1) The Disconnector should be in service position. 2) Protection Tripping Relay of UAT Incomer Breaker should not have acted. 3) In Unit Bus PT both Under Voltage and No Voltage should have acted. (6.6KV Unit Bus should be unhealthy) 4) 6.6 KV Station supply should be in healthy condition. 5) The UAT Incomer Breaker at 6.6KV switchgear should be in tripped condition. 6) The respective Station - Unit Tie Breaker should be in OFF condition. 7) Then, Station Unit Tie Breaker will close on auto.
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9.2.1.3. 1) 2) 3) 4) 5) 6) 7) 8)

Dead Bus Charging:

The Disconnector should be in service position. Protection tripping Relay of UAT Incomer Breaker should not have acted. The respective UAT Incomer Breaker should be in Tripped condition. In Unit Bus PT both Under Voltage and No Voltage should have acted. (6.6KV Unit Bus should be unhealthy) 6.6 KV Station supply should be in healthy condition. Auto/Manual selector switch of Station - Unit Tie at GCDP should be in Manual position. Local/Remote switch of Station - Unit Tie at switchgear should be in Remote. On giving the close command to the respective Station - Unit Tie Breaker from GCDP, the Tie Breaker will close.

9.2.1.4. Closing of Station - Unit Tie when UAT Incomer Breaker is in service 1) Local/Remote switch of respective Station - Unit Tie Breaker should be in Remote position. 2) Auto/Manual switch of respective Station Unit Tie Breaker at GCDP should be in Auto position. 3) On giving the Close command to the respective Station - Unit Tie Breaker from GCDP, the Tie Breaker will close and then UAT Incomer Breaker will trip on Auto. If the UAT Incomer Breaker does not trip, then Station -unit tie Breaker itself will trip on auto. 9.2.2.0. 9.2.2.1. CLOSING OF UAT INCOMER BREAKER: When Station - Unit Tie is in service:

1) Master Relay of Station - Unit Tie Breaker should not have acted. 2) The respective 230KV GT Breaker at switchyard should be in closed condition. 3) Local/Remote switch of UAT Incomer Breaker at 6.6KV switchgear should be in Remote position. 4) Auto/Manual switch of UAT Incomer Breaker at GCDP should be in Auto position. 5) On giving the Close command to the respective UAT Incomer Breaker through synchroscope, the respective UAT incomer Breaker will close and

126

then the corresponding Station - Unit Tie Breaker will trip on auto. If it does not trip then UAT Incomer Breaker itself will trip. 9.2.2.2. When Station - Unit Tie is in OFF condition:

1) Protection tripping Relay of Station - Unit Tie Breaker should not have acted. 2) Local/Remote switch of respective UAT Incomer Breaker at 6.6KV switchgear should be in Remote position. 3) Auto/Manual switch of respective UAT Incomer Breaker at GCDP should be in Manual position. 4) In Unit Bus PT, No voltage Relay should have acted. 5) The respective Station - Unit Tie Breaker at 6.6KV switchgear should be in OFF condition. 6) On giving the Close command to the respective UAT Incomer Breaker from GCDP, the UAT incomer Breaker will close to energize the bus. 9.3. INTERLOCKS FOR GT BREAKER CLOSING 9.3.1. Manual Closing of GT Breaker:

1) The NIT switch at GCDP should be in Normal (N) position. 2) The GCDP/SCP switch at CPG panel (switchyard) should be in GCDP position. 3) The NIT switch at CPG panel (switchyard) should be in Normal or Inter position. 4) Bus Bar protection Relay should not have acted. 5) Both Trip coils of GT Breaker should be in Healthy condition. For this K95 Relay in GRP should be acted. 6) All Master Relays in GRP should be in Reset condition. For this K8 Relay in GRP should be acted. 7) Local / Remote switch at BMB (Bay Marshalling box) should be in Remote position. 8) Isolators 1 & 2 of GT Breaker should be in closed condition. 9) Local/Remote switch in Breaker panel (switchyard) should be in Remote position. 10) Gas pressure and air pressure lockout relays should not have acted. 11) The Field breaker must be in closed condition. 12) Auto/Manual switch of GT Breaker at GCDP should be in Manual position. 13) After getting the Synchronising permissive, close the GT Breaker from GCDP.

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9.3.2.

Auto closing:

1) Repeat the above points from 1 to 11. 2) Auto/Manual switch of GT Breaker at GCDP should be in Auto position. 3) After getting the Synchronising permissive, the GT Breaker will close on Auto. 9.4. INTERLOCKS FOR FIELDBREAKER CLOSING 9.4.1. Remote closing:

1) Local/UCB selector switch at GCDP should be in UCB position. 2) Field Breaker should be in Tripped condition. 3) All protection tripping Relays in GRP should be in Reset condition. 4) Both trip coils 1 & 2 should be in healthy condition. For this K6 & K3.1 should have acted. 5) Generator Speed should be above 2700 RPM. 6) Field breaker closing coil should be in healthy condition. For this K2.5 relay should have acted. 7) Field breaker tripping relay should not have acted. 8) Both Auto & Manual reference should be in minimum position. This can be checked by lamp indications at GCDP. 9) Switch on the Field flashing supply at N/E switchgear. 10) Switch on the Blower fans. 11) Close the field breaker from GCDP. 9.4.2. Local Closing:

1) Local / UCB Selector switch at GCDP should be in local position. 2) Repeat the same points from 2 to 10. 3) Close the Field breaker from AVR. ************************* ****************

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129