NTPC RAMAGUNDAM

STAGE –I (200 MW UNITS)

PROTECTION AND INTERLOCKS

1.1.0. General:
Adequate and reliable protections are provided for safeguard the various
equipments under abnormal and dangerous operating conditions. The operation of
protections shall be accompanied by visual and audible annunciations, which will
provide definite indication of primary causes of operation of the protection. Equipment
disconnected by the protection will be again put into operation either by remote or
automatic or local control only after elimination of the fault causing the operation of
protection. The set values for various protections/permissives given in this write-up are
tentative and may have to be changed depending on the actual performance of the
equipment.

The protections and interlocks are divided into the following groups.

I. Protections causing tripping of the unit.

II. Protection causing tripping of boiler.
III. Protection causing tripping turbine.
IV. Protections and interlocks of other auxiliaries.

Protections causing tripping of the unit.

I. Generator tripping.
II. Turbine tripping.
III. Boiler tripping.
NTPC RAMAGUNDAM

1.1.0. Protections causing tripping of boiler.

I. Loss of both ID fans.

II. Loss of both FD fans.
III. Loss of both APHs ESPs.
IV. Very low furnace pressure trip value –200 mm wcl alarm – 40 mm wcl.
V. Very high furnace pressure trip value + 200 mm wcl alarm + 40 mm
wcl.
VI. Drum level very high trip +250 mm DT 5 sec alarm +100 mm
VII. Drum level very low trip -250 mm DT 5 sec. alarm –100 mm
VIII. Loss of fuel to furnace. This protection shall act when complete fuel is cut off to
furnace (No mill is running and no burner valve is not closed.)
IX. Loss of flame. This protection shall act when there is one or more fuel to furnace
and at least one flame is not detected.
X. Loss of control air to BMS. (Kept by passed)
XI. At least one milling system is in service and seal air pressure very low with in 3
min. time delay Trip value: 900 mm wcl, alarm 1050 mm wcl (protection is kept by
passed in all the 3 units).
XII. Trip from unit protection. This protection shall act when turbine tripped and boiler
load is more than 60% and at least one set of HP and LP bypass fail to open in
seconds.
XIII. Airflow is less than 30 % and at least one pair of burners/ one mill is in service.
XIV. PF burner emergency trip (Push button operated from console).
XV. Purge validity time expired.

The means of indicating of above of above protections is provided on BMS master logic
control insert. And also it gives the first –up. It will disappear only after the completion of
boiler purging.
NTPC RAMAGUNDAM

1.1. PROTECTIONS AND INTERLOCKS FOR BOILER AUXILIARIES:

ID fans and FD fans:

The above said fans can be started from UCB and provision is made to facilitate
stopping from UCB and local. For starting and stopping a separate control switch is provided
individually for fans (FD AB And ID AB). The control switch can be turned to one of the
following three positions. i.e. 1.Stop 2. Normal 3. Start.

1.Stop:
a. If the equipment is running and is desired to stop, the control switch is to be
brought to stop position from normal position to give stop impulse. The moment
switch is released it goes to normal position.
b. If the running fan trips on protection and is desired to start CS is to be brought
to stop position before giving start impulse.
2.Normal:
Soon after releasing the CS from Start/ Stop position it spring returns to normal
position.
3. Start:
By bringing the CS to start position, start impulse can be given to start the equipment
provided all permissives are through.

Just above the CS three bulbs (green, white and red) are provided to give a visual indication
about the status of the fan.
Green: This indication indicates the breaker is in service position and fan is not in
running condition.
White: This indication indicates that the fan has tripped on one of its protection .It will
disappear only after brining the control switch to stop position.
Red: This indication indicates that the fan is in service. In addition to above a set of
amber lamps are provided above the Cs to indicate the status of permissives.
NTPC RAMAGUNDAM

1.1.1. Protection and Interlocks for ID fans :

PERMISSIVES:

i. Inlet vane minimum position.

ii. Inlet / outlet damper closed( deleted)
iii. Bearing temperature normal.
iv. Other ID fan is running or clear path permissive (Clear path permissive is bypassed).
v. Scoop oil temp. normal / scoop oil pressure adequate.
vi. Emergency push button is in released condition.
vii. At least one APH should be in service.

PROTECTION:

i. Emergency push button pressed.

ii. Fan is running and scoop oil pressure low set value0.25 ksc DT 3 min. But
annunciation will come as soon as pressure drops to 0.25 ksc.
iii. Scoop oil temp. high 80 C.
iv. Both air preheaters tripped.
v. Electrical protection.
NTPC RAMAGUNDAM

1.1.2. Protections and interlocks for FD fans:

Permissive:

i. Inlet vane minimum position.

ii.
a. Other FD fan is not running and at least one ID fan is in service.
b. Other FD fan is in service and both ID fans are in service

OR

c. Both ID fans are in service.

iii. Bearing temp. normal.
iv. Discharge damper closed.
Damper closes on interlock after giving start command in the case of first fan being
started.
v. Emergency push button is reset position.
vi. Corresponding APH must be in service.

PROTECTIONS:

i. Stop from local emergency push button.

ii. Trips on corresponding APH trips, Fan trips after a time delay of 30 sec after APH trips.
iii. Trips on ID fan trip.
a. Only one FD is running, FD fan trips only on both ID Fans trip.
b. Both FD and ID fans are in service, FD fan trip when corresponding ID fan trips.

iv. Stop from UCB.

NTPC RAMAGUNDAM

1.1.3. PROTECTION AND INTERLOCKS FOR APH.

There are two APH’s A AND B having two electric drivers (main and aux) and one air
motor each.

Permissives:
i. Bearing temp. normal.
ii. Overload relays in reset condition.
iii. Single phase preventer not acting.
iv. APH air motor solenoid valve should be de-energised condition.
Note: top de- energise Stop command has to be given.
v. Selector switch should be in the required drive position.
vi. EPB of the corresponding drive should be in released condition.

PROTECTION:
i. Bearing temp. High (Bypassed)
ii. Overload relay actuated.
iii. Single phase preventer acting.
iv. APH air motor solenoid valve( if the corresponding relay for solenoid valve) energises.
v. EPB of the corresponding drive pressed.

NOTE

i. If APH is running on main motor, on changing selector switch to stand by motor position,
main motor stops and stand by motor starts. But not vice versa. If APH is running on stand
by motor and is required, to be started on main motor. Selector switch has to be changed to
main motor position and the start command has to be given. (No need to give stop
command before start)

ii. If APH is running on stand by motor and Trips on EPB pressing, soon after releasing
EPB the motor (stand by motor) will take start without any start command from control
room.

iii. If APHs are running (on any electric drive) and supply failure takes place, on restoration
of supply APHs start on stand by motors without any command provided EPB is in
released condition. (This happens only if APH stand still condition is not sensed.

AIR MOTOR:

It can be started( APH should be in stand still condition and both electrical drives
should be in off condition) or stopped from UCB control switch. ( APH motion is sensed
by two limit switches mounted in APH top bearing housing. If none of the switches are
actuated in 50 sec it is considered as APH in stand still position.)

INTERLOCKS:
NTPC RAMAGUNDAM

i. APH is running on main motor and trips on protection, APH standby motor takes start
and alarm comes in UCB (if the alarm is already persisting due to the other APH
running on standby motor, no alarms comes for this change over.)

ii. If the APH is running on either main motor or standby motor and trips on protection
and both electric drives are off and APH control switch (of electric drive) is not reset
after reaching the standstill condition air motor takes start.
( as soon as APH comes to standstill alarm comes in UCB and will reset after APH
rotation is sensed by the switches.)

iii. If APH trips corresponding FD fan trips after a time delay of 30 sec.

iv. If running APH trips and the other APH is off both ID fans will trip.

v. If both ID and FD fans are running and one ID fan trips corresponding FD fan will
trip. If both ID fans trip both FD fans trip.
NTPC RAMAGUNDAM

1.1.4. APH AIR AND GAS DAMPERS:

Condition : Both ID and FD Fans are Off.

i. When both APHs are off all dampers remain open.

ii. On starting one APH the air and gas dampers of the other non-running APH will
close.

iii. After starting the second APH all its dampers will open.

Condition: Both APHs and IDs are running .

i. On starting First FD fan ( A or B) gas and air dampers of APH corresponding to

other ‘FD fan(B or A) will close.
ii. On taking the Second FD Fan all dampers pf both APHs will open.

NOTE:

i. On loss of air supply , dampers will not operate and remain in the same position.
ii. On loss of power supply to the damper, will cause indication failure and will not
operate. They will remain in the same position.

1.1.5. FD FAN DISCHARGE AND TEMPERING AIR DAMPERS:

i Both FD fans off and their control supply on all dampers remain open.

ii Both FD fans off and their control supply off all dampers remain close.

iii Both FD fans off and one FD fan start command is given, discharge and
tempering air dampers of the particular fan will close first and after the fan
starts its dampers open and dampers of the other non running FD fan will close.
On starting the second fan all dampers go to open position.

1.2. PROTECTIONS AND INTERLOCKS FOR TURBINE AUXILIARIES:

1.2.1. BFP BOILER FEED PUMP.

Each BFP is provided with

1. A control switch to enable start/stop the pump. This switch can also be
kept in lock position when the pump is under maintenance.
2. Thee position selector switch( Lead/Normal/Lag ) for starting the pump
manually from the control room selector switch should be in Normal
position.
NTPC RAMAGUNDAM

When selected on LEAD BFP takes start when the running pump trips or discharge header
pressure is low and one pump is running and all start permissives are available for the lead
selected pump.

When selected on LAG and all start permissives are available for this pump, the LAG selected
pump will start when.

1. Pump on normal mode trips and its control switch is not reset and lead
selected pump fails to start with in 30 sec

OR

2. Running lead selected pump trips

OR

3. At least one pump is running and the discharge header pressure low
after delay 30s
NTPC RAMAGUNDAM

PERMISSIVES:

1. Suction valve should be in open condition (Bypassed)

2. Bearing temp. Normal.
3. EPB in reset condition.
4. Suction pressure normal (D/A level normal, D/A level low alarm resets)
5. Lub oil pressure adequate (After giving start command, provided the lube oil pump is
selected in remote and not running it takes start and permissive will be available once
the pressure attains 0.7 ksc.)
6. Cooling water pressure normal ( taken from clarified water pr. switch set value is 2
ksc.)
7. Discharge valve closed/ common header pr. adequate.
8. Recirculation valve open.
9. Selector switch should be in normal mode.

PROTECTION:

1. Main pump EPB pressed.

2. Lube oil pressure low 0.5 ksc.
3. Balancing leak off pr. high 25 ksc.
4. Hydraulic coupling temp. high. 130 C
5. Discharge temp. high FW 240 C
6. D/A level low low.
7. Running pump discharge pr. low 50 ksc.
8. Suction pr. low-low 7 ksc.
9. BFP flow Hi- Hi 360 t/h (bypassed)
10. BFP flow low- low 50 t/h (bypassed)
11. Motor cooling water flow low- low .

INTER LOCKS:

1. Recirculation valve control switch in control is modified to stay put type. It can be kept
permanently in open/ close/auto. When kept in auto mode and main pump is not in
service the valve remains in open condition. Valve closes when the pump flow is more
than 180 t/h . Valve opens again when flow drops below 80 t/h.
2. Recirculation valve will open on loss of air/ loss of power supply to solenoid valve.
3. Lube oil pump:

a. It has a local selector switch with two-position local/ remote and local start/stop
push button. By keeping the switch in local, pump can be started from local.
Pump can be stopped from stop push button irrespective of local selection
switch position.
b. When the local switch is in remote and main pump not running lub oil pump
will be off position. On giving start command to main pump lub oil pump takes
start. After main pump start and lub oil pr. is more than 3.5 ksc lub oil pump
will be stopped. If because of any reason the lube oil pr drops below 1 ksc oil
pump immediately takes start.
NTPC RAMAGUNDAM

c. If main pump trips on any protection, lub oil pump takes start soon after the lub
oil pr drops to 1 ksc and will continue to run as long as the main pump control
switch in control room is not reset. The moment switch is reset lub oil pump
stops.
d. If pump is stopped from control room, lub oil pump takes start soon after the lub
oil pr drops to 1 ksc and will continue to run for only 30 sec.
e. If control room selector switch is in LEAD remote lub oil pump will run
continuously.
f. Lube oil pump will run continuously when
i. Local selector switch is in remote and
ii. Control room selector switch is in LAG position and
iii. One of the other two BFPs is selected in LEAD and the Lead selected
BFP is not running (BPF CS should be in normal after stop position.)
NTPC RAMAGUNDAM

1.2.2. CONDENSATE EXTRACTION PUMP (CEP)

Each CEP is provided with

1. A control switch to enable start/stop the pump. This switch can also be kept in lock
position when the pump is under maintenance.
2. Two position selector switches ( Auto/ Manual ) for starting the pump manually from
control selector switch should be in Manual position.

PERMISSIVES:

1. Suction valve open. ( valve opening is to be confirmed physically)

2. Hot well level normal ( Alarm reset condition)
3. Recirculation valve in open position(by passed while starting the first pump its opening
is to be ensured.)
4. EPB reset condition.
5. Selector switch of the corresponding pump in manual position for manual starting and
in auto for auto starting .

PROTECTIONS:
1. EPB pressed.
2. Hot well level low low.
3. Suction valve not open.
4. Individual pump discharge pr. is less than25 ksc for more than 30 sec.

INTERLOCKS:

Any pump can be selected as stand-by keeping the selection switch in auto position.

1.Stand-by pump will start if other CEP is running and discharge header pressure is less
than 26 ksc for more than 10 sec Or flow is more than 630 t/p.
2.Running pump trip and the control switch is not reset stand-by pump starts.

NOTE:.
1.In case of Hot well level becoming low .Level low alarm appears and permissive disappears
preventing starting of stand-by pump. Evening case of the above interlocks.

2.In case of running CEP trips on hot well level low –low stand by pump also will not start.

3.Pr setting done in unit O/H.

1.2.3.ARCW PUMPS:

Each pump is provided with a control switch in control room to start/ stop the pump. The pump
can be started / stopped from the local push buttons.

PERMISSIVES:
NTPC RAMAGUNDAM

1.EPB is in released condition.

2.Pump suction pressure is adequate.(pr low-low switch is in reset condition.)

PROTECTIONS:

1.EPB pressed.
2.Pump suction pressure is low- low <0.8 ksc.

INTERLOCKS:

1.If the discharge pressure drops below 4 ksc stand by pump takes start provided the pump is
started from control room. (In case pump has been started from local close command is to be
given from the control room to make the interlock work.)

2.In case running pump trips on protection (except Suction pr. lo-lo) stand-by pump will take
start.

3. In case suction pressure goes low stand-by pump will not start on interlock.

3.1.0. Do’s and Don’ts for Boiler operation.

3.1.1. Boiler must be hand tripped independent of the action of the relevant protection under
following condition.
a. Loss of both ID fans.
b. Loss of both FD fans.
c. Loss of both APHs ESPs.
d. Very low furnace pressure trip value –200 mm wcl alarm – 40 mm wcl.
e. Very high furnace pressure trip value + 200 mm wcl alarm + 40 mm wcl.
f. Drum level very high trip +250 mm DT 5 sec alarm +100 mm
g. Drum level very low trip -250 mm DT 5 sec. alarm –100 mm
h. Loss of fuel to furnace. This protection shall act when complete fuel is cut off to
furnace (No mill is running and no burner valve is not closed.)
i. Loss of flame. This protection shall act when there is one or more fuel to furnace and at
least one flame is not detected.
j. Air flow is less than 30 % and at least one pair of burners/ one mill is in service.

NOTE:
1. If instrument air pressure goes very low, PF valve may close, and also no
pneumatic operated dampers/valves will operate. Hence in case of low instrument
air pressure no attempt to be made for any load variation or oil support to be tried.
If there is no chance of instrument air pressure improvement trip the unit.

2.On boiler tripping ensure that:

a. All mills, PA fans and feeders have tripped.
b. All oil shut off valves have closed.
c. All igniters oil shut off valves have closed.
NTPC RAMAGUNDAM

d. HFO LFO & igniters trip valves have closed.

e. Close attemperation SH & RH valves.

3.Whenever boiler drum is opened, through inspection of drum internals is to be

done for verifying good condition of equipment and removal of foreign material before
boxing up.

4. After an outage of unit for long period and restarting, check the following before
light up.
f. Internal inspection of furnace for scaffolds clamps etc, removal
and then boxing up manholes.
g. Inspection of complete boiler for boxed up condition.
h. Bottom ash hopper is cleared and filled with water trough seal
filled with water.
i. Inspection of boiler to ensure that there is no obstruction for free
expansion of boiler as it comes on load, by ensuring that there are
no fixed points.
j. Boiler expansion indicators are in place and in good condition.
k. Inspection of ducts for free expansion.
l. Inspection of ID, FD fans and boxing up.
m. Check that all the safety valves are in released condition before
light up.
n. Check all protections and interlocks for all auxiliaries including
unit protection before light up.
o. Check that all soot blowers are in retracted condition and furnace
probe is available before light up.
p. Ensure that all C&I systems are available and switched ON before
light up.
q. Ensure that all the systems necessary for boiler start up are lined-
up.
r. Ensure smooth running of both air preheaters by running an air
motor locally before continuous service.

5. Boiler (drum SH& RH) vents are installed in the highest points to discharge air
during filling or the pressurizing phase.

Keep the boiler vents open when filling the boiler even after light up till a pressure
of 1.7 ksc too ensure that all air is completely discharged.

When cooling, open the boiler vent at 1.0 ksc pressure to avoid creation of vacuum.

6. Furnace probe can be used to measure the gas temperature just before the super
heater tubes at furnace exit. It permits continuous observation of the gas temp. during
light up and monitoring of rate of rise of temp.

Note: a. Retract the furnace probe one gas temp. in this zone reaches 500 C.
b. Retract the furnace probe before cutting in mill to prevent
damage, in case it does not retract on interlock.
NTPC RAMAGUNDAM

7. Till a steam flow sufficient to ensure cooling is established, flue gas temp. in SH
& RH tubes zone should not exceed the max. Permissible metal temp. in the zone

8. SAFETY VALVES:
a. Safety valves should be in released condition before light-up
b. In case hydraulic test is to be performed above the normal operating
pressure, these safety valve are to be gagged, gagging should be remove as
soon as test is over.
c. If any maintenance is carried out on safety valves, they have to be pressure
set.
d. No adjustment should be tried on a safety valve near its operating pressure.

9.Boiler filling(initially.)

Fill gradually with vents open. The difference of water temp. and drum metal temp.
Should not be more than 50 C.

Maintain drum level lower than the normal before light up to accommodate for swelling
of level on light up.

Check drum level alarms and protections before light up.

10. While light up keep superheater startup vent valve open till MS lines are charged.

11.To reduce thermal stress in Y piece in MS line, charge MS lines for gradual heating by
opening boiler stop valves bypass valves. Keep the MS drains before turbine stop valves
open.

12. Keep economizer recirculation valve open while light up till boiler feed water is
continuous.

13.During light up regulate firing so that water temp. rises by not more than 2 C /min.

14.Drum metal top/bottom temp. difference should be controlled within 50 C during light
up and cooling.

15. Use of SH/ RH spray should be avoided as far as possible during low load conditions.

16.Reheat attemperation spray is envisaged for emergencies and during load variation.

17. Drum level gauge glass: At least one drum glass should be maintained in working
condition.

Top connections between drum and gauge glass should be un-insulated and bottom
connection between drum and gauge glass should be insulated. This way slight circulation
takes place due to condensation.

Gauge glass should be drained always slowly.

NTPC RAMAGUNDAM

While charging steam side valve should be opened first and allow condensation to fill
before opening water side valve.

18. Monitor SH & RH tube metal temp. frequently during light-up.

19.Maintain a min. airflow of 30 % during purging and even after light-up.

20.Air vents are not to be closed till it is ensured that all air is bled out till a pressure of
appro. 1.7 ksc in drum.

21.Start scanner air fan before light-up on purge complete.

22. Rise in steam pressure must correspond to boiler water temp. (i.e. 1.5 C / min.)

23. Maintain drum level during light up. It may result in tube failure with water entrapped
in due to sudden change in temp. Use emergency blow down if necessary.

24.Keep RH gas dampers closed during light up after initial purging till flow is established
through RH tubes.

25. Safety valves floating.

a. Choose a calibrated pressure gauge.

b. Safety valves not to be tested are to be gagged only after attaining 70% of the
operating pressure.
c. Kill the fire once the safety valve floats.
d. Establish proper communication between control room and safety valve area
before floating.

26.Ensure air temp. is at least more than 150 0 C /Furnace exit gas temp more than
400 C before starting coal firing.

27. Boiler shutdown: following points are to be observed.

a. Reduce steam pressure by 10 % compared to operating pressure to take care
of pressure rise due to thermal inertia before stopping boiler.
b. Bring drum level to max. then stop feeding, open eco recirculation valve.
c. Clean air and gas path (i.e purge boiler) and then stop fans.
d. Keep scanner air fans in service till furnace temp drops to 120 C.
e. Keep air preheaters in continuous service till flue gas inlet to APH” temp is
less than 180 C.
f. Allow for natural cooling of boiler by keeping vanes and dampers open.
g. Allow for natural pressure drop.
h. When pressure is 1 ksc open all vents.
i. If faster cooling is required keep the ID /FD fans in service Maintain the
temp. Gradient half of that used for starting. Also drum top/ bottom metal
temp. Difference should be within limits i.e. less than 50 C.
j. Boiler is not to be drained till furnace is cooled to such an extent that a man
can enter and stay inside.
NTPC RAMAGUNDAM

28. Boiler water and steam parameters are to be monitored properly.

a. Condensate: In the presence of O2 and CO2, NH 3 attacks on surface of the brass tubes
of condenser. Reducing N2H4 dozing in case of excess NH3.

b. Feed water: Oxygen presence beyond permissible limits is extremely dangerous for
economizer and boiler.

c. CBD:
i) Less pH is dangerous – aids corrosion.
ii) Hardness should be NIL – if hardness is greater than 2.5 ppm
of total hardness for more than 24 hours load and pressure in
boiler should be reduced to prevent irreversible scale in boiler.
iii) Excessive silica is dangerous for both boiler and turbine. It is to
be controlled by giving blow down.
iv) If hardness is more than 2.5 ppm for more than 24 hours in
such case a TPS dosing should be done upto 5 ppm equivalent
PO4..

29. In case of boiler leakage boiler should be stopped the earliest to restrict the damage
to min.

In case of water wall tube leak, trip the boiler and stop feeding water to prevent
thermal shocks at drum to prevent leaks at expanding and weldings to tubes due to
temp. diff between feed water and metal .Reduce air flow to min. Keep ID /FD fans in
service.

30. Continuous O2 monitoring is important.

31. Losses in efficiency:

Major causes for efficiency drop area:
a. Losses due to latent heat of flue gas.
b. Unburnt substances in slag and ash.

32. High exit flue gas temp. with normal excess air and large losses of draught indicates
heat absorbing surfaces of APH are dirty and therefore need soot blowing and washing.

33. High excess air results in increase temperature of exit flue gas and draught loss.
Air/fuel ratio is to be resulted.

34. High unburnt elements in ash and slag indicate poor quality of combustion control
to be checked and corrective action taken.

AIIR
33..11..11 A REEH
R PPR R::
ATTEER
HEEA

a. Inspect thoroughly before starting.

b. Check the smooth rotation by running locally the air motor before continuous
operation.
c. Check the direction of rotation with both main and aux motor before continuous
service.
NTPC RAMAGUNDAM

d. Initially slight overload may be there due to excessive seals friction. It should
become normal after sometime. If overload and seals friction persist continuously,
seals are to be readjusted.
e. Check protections and interlocks after long outage.
f. Keep both air preheaters in service before boiler light up even if one alone is used.
The idle air preheater dampers should be in closed condition.
g. While taking the idle air preheater in service open the air dampers first and then the
flue gas dampers.
h. Air preheater soot blowing should be done twice in a shift of eight hours.
i. In case of oil firing during boiler light up APH soot blowing should be done
frequently ( at least once in two hours)
j. Even after unit trip, air preheaters should be in continuous service till flue gas inlet
temp. drop to 180 C to prevent high temp. causing ignition of any fuel deposits on
the heating elements left by previous operation.
k. APHs should not be stopped till flue gas inlet temp. drops below 100 C.
l. APH motor failure- No serious damage will immediately occur if flue gas inlet
temp is less than 480 C .Following precautions are to be taken .Ensure that flue gas
inlet and air dampers close fully. Run air preheater on air motor.
m. If APH is standstill even with dampers closed, the parts exposed to flue gas may
have seals bent. Start APH at intervals to slowly rotate the air preheater to make
rotor dilatation uniform before continuous operation. If it is not possible for
electrical drive disconnect power supply, rotate on air motor or manually slowly a
few rotations. After few revolutions the rotor dilatation should be uniform for
continuous service. As soon abs air preheater is started, start soot blowing.
n. Corrosion reduces heat exchange surface. The zone mostly affected by corrosion is
cold end. To prevent this radial seals must be efficient to prevent air leaks. Also
cold end temperature should be maintained above dew point.
o. Excessive DP across indicates the need for APH washing/cleaning.
p. In case of fire trip the boiler, stop the fans, leave the dampers open to allow steam
to escape open fire-water and flood the air preheater with water, Keep the hopper
drains open.
q. If necessary charge SCAPH to improve cold end temp. During light up.
r. Air preheaters air bypass dampers can be opened to improve cold end temp.

3.1.2. ID AND FD FANS:

a. If any fan is under shutdown, keep the dampers closed to prevent back flow.
b. Start FD fan with dampers closed and inlet vane in min.
c. Ensure that scoop position is zero before starting ID fans.
d. Continuous operation with very low scoop position is to be avoided. Always
operate with scoop position 50 % and above for continuous operation.
e. ID fans have a trip protection on scoop oil temp. high. Ensure cooling water flow
for oil cooler. Before starting ID fans.

3.1.3. MILLING SYSTEM

a. Operate the reject gate s and remove rejects immediately after each mill start .
b. The position of all individual classified vane of mill should be same( i.e. 40 or 50
deg.
NTPC RAMAGUNDAM

c. If classified opening angle is more fineness increased. It also increases motor load.
d. Min. velocity of airflow 18 m/s is required to prevent choking of coal pipes.
e. Air flow rate is based on grinding capacity index.50. HG and a product fineness of
70 % through 200BS sieve (75 microns) Air flow rate is to be varied from 70 % to
100 % ( i.e. 34 to 48 Tph ) corresponding to coal flow rated of 50 to 100 % ( i.e.
13.5. to 27 tph).
f. Once a mill is empty, increase PA flow momentarily to clean mill system and mill
pipes thoroughly.
g. Always maintain correct air /fuel ratio.
h. In case of a longer mill outage empty feeder also.
i. 1 kg of coal and 20 cu m of air forms an explosive mixture very low coal flow and
high airflow rate should be avoided as far as possible.
j. Excessive rejects may cause fire Avoid reject chamber over filling.
k. Fire in mill under shut down: Isolate the mill and charge CO2, Do not use water or
other liquid as it may cause grinding elements crack.
l. Fire in mill on duty: Noticed by sudden rise in mill temp. For same condition of
coal air, IN case use max cold air, increase coal flow (keep air flow control
manual) till PA flow starts dropping. Maintain Rich coal air mixture till mill
temperature become normal. Then slowly restore the correct fuel/air ratio. If
temperature does not come under control stop the system, isolate mill and charge
CO2.
m. If excessive rejects are check the following.

i. Reject flap (i.e. counter weight) might have remained open.

ii. Grinding balls worn out.
iii. Less airflow.
iv. Excessive groove gap.
n. Excessive sparks in flames, heavy scales on walls, high unburnt content in ash
indicate worse grinding.
o. If coal finesses is poor check for the following.
i. Classifier erosion, having holes or outsides seals.
ii. Classifier adjustment not OK.
iii. Mill over loaded.
iv. Bad fuel
v. Air to fuel ratio high
vi. Worn out balls.
3.1.4. R.C. Feeder.:

i. Ensure that purge air valve is open.

ii. Check belt tension regularly.
iii. New belt should be inspected at least 2-3 times a shift for at least one day till belts
stretch is established.
iv. Running RC feeder in forward direction ( locally with mill in stopped condition will
choke feeder outlet pipe.) Ensure that feeder outlet pipe is clear before boxing up
feeder.
v. Feeder is emptied locally by running in reverser direction after removing the
backside plate in the feeder. Before boxing up, ensure that back plate is fitted back in
position.
NTPC RAMAGUNDAM

vi. If clean out conveyor is not in service, the coal accumulation below the belt can
damage ht belt. Stop milling system, if clean out conveyor cannot be put back in
service. Empty the feeder before stopping in such a case.
vii. In case bunker becomes empty, keep the bunker gates closed and feeder front and
rear doors open to prevent drought action and to prevent damage of feeder belt from
fire.

3.1.5. ELECTROSTATIC PRECIPITATOR.

a. Switch ON heating of hoppers and HT insulator housing at least 12 hours before

light up.
b. Keep rapping and vibrators in service at least one hour before light up
c. Switch on HT fields just before coal firing. Before opening the manhole of ESP
for maintenance isolation of rectiformers and earthing of fields to be ensured.
Both auxiliary and main supply for the pass and inlet/ outlet dampers are to be
closed fully.
NTPC RAMAGUNDAM

3.2.0. Do’s And Don’ts For Turbine Operation.

1. Allowable pressure and temperature variations.

a. The pressure at the turbine main steam stop valve shall be controlled so that
it does not exceed rated pressure at rated output. During the abnormal
conditions the pressure may exceed momentarily by 30 % but the aggregate
duration of such swings shall not exceed 12 hrs per 12 months operation
period.
b. The pressure at the HP turbine exhaust may exceed, momentarily by 25 %
but the aggregate duration of such swings shall not exceed 12 hours per 12
months operating period.
c. The average main steam temp. at the inlet of the turbine over any 12 months
of operation shall not exceed 545 C . In maintaining the average the
temperature shall not exceed 543 C except those swings up to 549 C but the
aggregate duration of such swings shall not exceed 100 hrs per 12 months
operating period. The continuous duration of any swing in the range of 549-
563 C shall not exceed 15 min. and aggregate duration such swings shall not
exceed 80 hours per 12 months operation period.
d. The allowable reheat steam temperature variation is same as for that of main
steam temperature variation.
e. Limitations on main steam and reheat steam temperature variations: in this
type of turbine where the main steam and the reheat steam admissions are in
the same casing. The axial temp. gradient in the outer shell can be increased
by excessive difference between main steam and reheat steam temperature.

i. At rated flows, rated temperatures can normally be maintained. The

main steam should not be hot by 30 C above reheat steam temp. The reheat
steam temp. should not be hot by 40 C above main steam temperature.

ii. At lower flows, where rated temperatures cannot be normally

maintained. The reheat temperature may go below the main steam temperature
by as much as 170 C as no load flow is achieved. The main steam temperature
should not be less than reheat temperature.

2. Share fluctuation of temperature and or load on turbine should be avoided as far

as possible.

3. Regulating stage pressure is normally 123 ksc. It should not exceed 135 ksc. If
it further exceeds load is to be reduced so that the pressure drops less than 135 ksc.

4. Turbine operation with steam exhaust to atmosphere is forbidden. In case of

rapid drop vacuum and opening of atmospheric valves on condenser, the
turbine should be stopped immediately.
5. The main steam and reheat steam temperature should preferably be equal and
they should be more than the metal temperature under any circumstances.
6. When the turbine has tripped, check the operation of the following equipments
a. Closure of ESV,CRV and control valves.
b. Extraction NRV’s
NTPC RAMAGUNDAM

c. CRH line NRV’s

d. Disconnection of Generator from grid.
e. Opening of blow down valve and ventilation valves .
f. Starting of AOP.

7. If there are more than one indicator for the same measurement, then the one
which is service favorable reading should not be assumed to be correct one.
8. If the load on the turbine cannot be raised , all parameters being normal, check
for any accidental closure of control valves by comparing the pressure readings
after the control valves.
9. The turbine must be stopped manually independent of the action of relvent
protection under the following conditions.

a. Sudden appearance of excessive vibrations.

b. Water hammering in the turbine.
c. Lub oil catching fire.
d. Emergency governor out of order.
e. Sharp rising of bearing metal temperature up to 105C.
f. Fast drop in the oil tank level below the lowest permissive level 1140 mm
and level goes on further dropping.
g. Appearance of metallic noise in the turbine steam flow path.
h. Axial shift exceeding +/- 0.8 mm., HP difference exp. –3.2/+8.3, LP diff
exp.-4.5/12.6.
i. Increase in main steam and reheat steam temperature beyond 565 C.
j. Sharp fall in the main steam temperature.
k. Drop in lubrication oil pressure to less than 0.9 ksc at front standard.
l. Increase in speed beyond 3300 rpm.
m. Seizure of ESV, CRV or CV’s.
n. Flooding of heaters.

10. Measures should be taken for restoring frequency, if it exceeds 50.5 hz or if it

drops to less than 47.8 hz.
11. Loading rate and temperature ramp rates are to be controlled if the diff
expansions are nearing the limit values.
12. If HP diff expansion is reaching the limiting value control the rise of the steam
temperature and stop further loading of the machine (i.e. further soak the
machine) till the expansions is controlled.
13. If the HP diff exp. is reaching the limiting value on the negative side increase
the steam temperature and also the load if possible.
14. If the LP diff exp. is reaching the limiting value on the positive side slightly
reduce the vacuum.
15. If the LP diff exp. is reaching the limiting value on the negative side improve
the vacuum and also increase the load if possible.
16. During rolling a positive mismatch of 28-55 C is to be maintained (i.e. the
steam should be hotter than the corresponding metal temperature.)
17. Try to trip the turbine at less than 5% load during planned shut down except in
emergency cases where the turbine can be tripped any load.
18. Do not operate the hot turbine at less than 10 % load for longer periods.
19. During load reduction on turbine, open the drains as follows:
NTPC RAMAGUNDAM

Group C drains at 30 % load.

LPH-3, LPH-2 D/a extraction line drains.

Group B drains at 15 % load.

CRH, HRH line drains

CRV seat drain
Turbine casing drain
HPH 6 extraction line drain

Group A drains after trip.

Main steam lines drain

ESV before seat drain
ESV after seat drain

20. Close the drains while rolling and loading as follows:

Group A- after start of rolling.

Group B at 25 % load.

Group C at 30 % load.
21.Always trip the TG set through turbine tripping. If generator breaker is to be opened,
it is to be done only after ensuring the closure of ESV CRV And CVs.

22. If any time after a shut down the eccentricity higher than the usual the machine is to
be kept on turning gear until the eccentricity has reached and maintained its normal minimum
value for atleast one hour.
23. Do not roll, if the eccentricity is more than the normal value.

24. During cold start, the turbine should not be over speed tested until it has carried
25% or greater load for at least 3 hours.

25. Trip the turbine if the boiler trips.

26. While rolling the TG set should never hold the machine at less than 800 rpm for
more than 5 min.
27. Minimise the use of LP spray water.

28.Motoring of the turbo generator should be avoided.

29. Do not break the vacuum at higher speeds. If desired vacuum can be broken at less
than 2000-rpm .In emergencies like high vibrations, vacuum can be broken at any speed after
taking out load and closing steam to the turbine.
30. Do not Operated the unit continuously if the exhaust hood temperature is more than
80 C.
Load is to be slowly raised till the exhaust hood temperature reaches less than 52 C.
NTPC RAMAGUNDAM

31. Maintain gland seal steam pressure at 0.21 to 0.28 ksc.

32. Maintain a vacuum of 75- 125 mm wcl in the gland steam condenser.

33. Keep the steam seal-diverting valve open to condenser as long as:
a. Seal steam feed bypass valve is open.
b. LPH-1 extraction steam temperature is more than 150 C
c. Load is less than 50 %.
34. Ensure blowdown valve is open when the control valves are open and vice-versa.
Also ensure that ventilator valves open with the opening of the blow down valve and
vice-versa.

35. Maintain an oil pr of 1.75 ksc to 2.1 ksc at bearing inlet.

36.Oil temperature should not be less than 27 C on barring gear and should be brought
to at least 38 C at rated speed.

37.The raise of the oil temperature of the oil temperature across the bearing should be
less than 20 C.

38. The normal oil temperature to the bearings should be 42-49 C during running of the
machine.

39. During deceleration of the unit after trip out, during down the oil temperature to
about 30 C to 32 C.

40. Vacuum of about 13 to 26 mm of wcl is to be maintained in the oil tank by

throttling of the inlet damper of oil vapour extractor.

41. Trip the turbine when the oil pressure drops to 0.7 ksc.

42.Trip the turning gear when the oil pressure drops to 0.6 ksc.

43. Do not run the unit if the pressure drops across the ERV and CRVs is more than
10 %.

44. Do not change over to the standby oil cooler till it is filled through the filling line.

45.Condenser should never come under + ve pressure.

46.The oil temp of 27- 32 C is to be maintained while on turning gear.

47. Machine is to be kept on turning gear at least the hottest point of the casing is less
than 120 C and lub oil is to be circulated at least till the max metal temp is less than 100
C.

48. For a hot turbine, seal the glands only from main steam.
NTPC RAMAGUNDAM

49. For a hot machine, seal the glands first and immediately start pulling vacuum.
While sealing the glands care should be taken to see that condenser s not coming under
positive pressure.

50. While breaking the vacuum do not cut off the gland steam till the vacuum drops to
less than 100 mm of Hg.

51. Do not open any drains to flash tank unless there is vacuum in the condenser.

52.During hot start up, rolling and loading should be done quickly so that steam flow is
established through HP turbine also.

53.During rolling and loading, please ensure that the turbine metal temperatures are
having raising trend.

54. It is not desirable to run the unit with full opening of control valve servomotor. If
the unit operation with full servomotor opening is unavoidable, at least once in the
shift, try to reduce the load and ensure that the servomotor is moving in the closing
direction.

55. Do not allow hot rotor to stand without rolling.

56. In case of excessive vibrations, Diff expansion, Axial shift and loss of lubrication,
trip the unit and bring the rotor to barring at the earliest by breaking vacuum.

57.Always maintain water level in the condensate reserve tank.

58. Do not attempt to roll the TG set if the eccentricity on turning gear is more the 0.07
mm.
NTPC RAMAGUNDAM

3.2.1.Important Do’s and Don’ts of CEP:

1. After carrying out any maintenance work on the CEP , it should be properly primed
before taking into service or keeping it as standby.
2. CEP pressure equalization line valves should be always kept open unless the pump is
taken for maintenance.
3. Do not bypass any permissives and protections and interlocks.
4. While in service if the ammeter starts hunting stop the pump immediately.
5. Do not operate the pump with suction strainer DP more than 0.6 mm WC.
6. After starting the pump if the discharge valve does not open within a minute trip the
pump.
7. While pump is in service check and record every hour suction pressure discharge
pressure suction strainer DP, thrust-bearing temp. bearing oil level, bearing cooling
water inlet and outlet temp. and cooling water flow.
8. Gland sealing water line valves of both running and standby pumps should be always
open.
9. Emergency sealing water line valves to both running and standby pumps should be
always open.
10. Do not run the pumps with excessive gland leakages.
11. Do not bypass LP heater 1 while unit is in service.
12. Variation in D/A pressure should be slow and gradual.
13. When the unit trips D/A Pressure change over should be checked and pressure shall be
maintained with aux. Steam.
14. CEP bearing oil should be periodically checked for any contamination. Visual
inspection of the gauge glass oil column will indicate the oil contamination.
15. Discharge valve of the standby pump should be kept header pressure.
NTPC RAMAGUNDAM

3.2.2. Important Do’s and Don’ts of BFP:

1. All interlocks, permissives and protections should be checked and ensured before
taking the pumps into service after a long shutdown.
2. If any maintenance works were carried out on the BFP/ Booster pump system, pumps
and suction piping should be properly primed before taking into service or keeping as
standby.
3. D/A pressure variations should be slow and gradual.
4. Suction valves of the pumps should always be fully open.
5. At less load on the pump, R/c valve should be open full. Min. flow of 80 T/h should be
maintained while pump in service.
6. Stop the pump immediately if the ammeter / discharge pressure start hunting.
7. After stopping the pump check the AOP starts in auto 1.5 ksc lube oil pressure .If not
starting manually start the oil pump.
8. After starting the pump, check the motor cooling water valve opens on auto. If it does
not open, open it manually.
9. For charging the feed water system from empty condition system should be charged
with only bypass line of the BFP discharge valve. Open the discharge valve only when
the feed water system is fully charged with water.
10. Discharge valve of the standby pump should be kept open and scoop control on auto.
11. Record all parameters of the pump every hour in the log sheet.
12. In case of any abnormal noise from the pump or sudden high vib. Trip the pump
immediately and inform to the control room.
NTPC RAMAGUNDAM

3.2.3. Important Do’s and Don’ts of Steam Seal System.

Do’s:

1. Check that gland steam regulator is maintaining 0.28 ksc header pressure.
2. Check that the gland steam exhauster is in running condition and its suction and
discharge pressure is maintaining.
3. Check that gland steam line from Aux. Steam is charge up to the control valve P61 557
meeting the seal steam requirements.
4. Check at the suction of the gland steam exhauster both the temperature and the
pressure.

Don’ts.:

1. Do not charge seal steam system unless turbine is kept on barring gear and gland steam
exhauster is in service.
2. Do not put the seal steam regulator straight way in service. First maintain the seal steam
header pr. through pneumatic regulating valve P61 F557 then open the seal steam
regulator bypass valve N31 F002. Now maintaining the header pressure close P61 F557
and charge the seal steam regulator and slowly close the bypass valve N31 F002.
NTPC RAMAGUNDAM

3.2.4. Important Do’s and Don’ts of Centrifuge.

Do’s:

1. Check that the MOT level is normal.

2. Check any leakage is there in the system.
3. Check the flow of oil through the sight glass.
4. Check the water level in the indirect oil heater.
5. Check the DP of the oil filter, if it is high bypass the oil filters.
6. Check whether anti-flood tank drain is closed or not if it is not closed, close it.
7. Check the anti-flood float switch, for its healthiness before taking the system in
service.
8. Check there are sufficient number of fire fighting extinguishers available in the
location.
9. Check the control panel lamps are OK by doing lamp test.

Do Not’s:

1. Do not allow anybody to do welding work or cutting near the oil purifier.
2. Do not allow oil in centrifuge without giving water seal first.
3. Do not switch On the heater without maintaining proper water level in the heater.
4. Do not charge the polishing filter when the oil temp. is low.
NTPC RAMAGUNDAM

3.2.5. Important Do’s and Don’ts of HYDROGEN system:

Do’s

1. Always isolate the filling panel system after H2 filling.

2. Always close oil valve to avoid gas leakage.
3. Before opening the valves of hydrogen bottles make sure that their connection is
well done.
4. All siphons connected with liquid detectors are filled with oil up to a level of
400 mm.
5. Always sufficient numbers of CO2 and H2 cylinders available near the filling post.
6. By pass valve if F033 float trap is in closed condition.
7. Check that purity of gas is normal.
8. Instruments and materials are available for filling operation.
9. Check that sufficient numbers of fire fighting cylinder are available in the area.

Do Not’s:

1.Do not allow anybody to work without permit near the gas system.
2.Do not allow any welding work to be carried out in near by areas.
3.Do not allow any gas leakage from the manifold or from system.
4.Do not allow bypassing any action when annunciation appears.
5.Do not allow smoking and other fire hazards in the area.
6.Do not allow the gas system operation without drier in service unless instructed.

2.0.0 LIMIT VALUES OF PROTECTION AND INTERLOCKS

Boiler protections:
Sl.No. Protection Set value
1. Both ID fans trip Trip
2. Both FD fans trip Trip
3. Both APH trip Trip
4. Both ESP trip Trip( excluded)
5. Air flow less than 30% Trip <210 tph
6. Furnace pressure very high +200 mm. Wcl
7. Furnace pressure very low - 200 mm. Wcl
8. Boiler trip EPB pressed.
9. Drum level high-high +250 mm
10. Drum level low-low -250 mm
11. Loss of all flame
12. PF partial loss of flame Trip
NTPC RAMAGUNDAM

13. Loss of control air to BMS Trip (excluded)

14. Loss of all fuel to furnace.
15. HP/LP bypass valve closed load more than 60% Trip
and turbine tripped
16. Seal air pr. too low for more than 3 min. and Trip (excluded)
any mill in service

Turbine Protections
Sl.No. Protection Set value
1. Condenser vacuum very low 570 mm Hg
2. Turbine EPB Trip
3. Exhaust hood temp. very high 105 C (excluded)
4. Over speed 112% electrical backup 3360 rpm
5. Oil tank level very low 1140 mm
6. Thrust bearing wear excess both sides +/- 0.8mm
7. EHC trip
a. Governing oil pr low 5.5 ksc.
b. Emergency trip oil pr. low 6 ksc.
c. All control valves closed
8. Bearing oil pr. very low 0.5 ksc.
9. Bearing oil temp. very high after cooler 65 C
10. Hydraulic over speed
11. Boiler trip to turbine trip
12. Gen. Protection trip to turbine Trip

Boiler:
Sl.no. Alarm/protectio Units Oprt. Low Lo-lo Hi Hi-hi Remarks
n Val
1. F.O.suction line C 60-70 20 80
temp.
2. F.O. discharge pr. Ksc 14 1
3. F.O temp. C 105 90 125
4. LFO / igniter oil Mmwcl
filter DP
5. HFO header pr at Ksc 10 4 Trip
BF
6. LFO header pr. at Ksc 14` 3 2 Trip
BF
7. Igniter. Pr Ksc 5 1.5 1 Trip
8. Atomizing Air Ksc 3 2.5 Trip
pr(igniter)
9. Atomizing air pr Ksc 6 5.6 4.5 Trip
( LFO)
10. Atomizing steam Ksc 10 7 5 Trip
pr.
11. Scanner air pr. Mm 500 400 S/b auto
wcl start
Sno Description Units Oprt. Low Lo-lo Hi Hi-hi Remarks
NTPC RAMAGUNDAM

Val
12. Seal air fan pr. Mm 1000 900 Trip
wcl bypassed
13.
14. Mill lube oil pr Ksc 1.5 0.8 0.5 Trip.
15. Mill loading Ksc 36 28 18 Mill trip
nitrogen pr
16. PA temp to mill C 200 150 310
17. PA pressure Mm 300 950
wcl
18. PA flow Tph 34 to 31 50
48
19. Mill DP MmWcl 250 750
20. Mill to furnace MmWcl 50 200
DP
21. ID fan coupling Ksc 0.4 0.25 DT 3 min
oil pr.
22. ID fan coupling C 40 80 130
oil temp. high
23. Drum level Mm +20/ -100 (MFT) +100/ +250
-30 –250 (MFT)
24. Furnace pr. Mm -40 -200 +40 +200
wcl (MFT) (MFT)
25. Aux. Steam pr. Ksc 16 14.5 17.5 19
26. Aux. Steam temp. C 230 240 250
27. Air flow less than Tph 210
30%

Turbine:
Sl.no. Alarm/protection Units Oprt. Low Lo-lo Hi Hi-hi Remarks
Val
1. Condenser Ksc 0.9 0.83 0.66 0.45
vacuum Mm 670 640 570 (Trip)
Hg
2. AOP auto start Ksc 12.2
3. Turbine brg. Oil Ksc 2.2 1.6(0.9) 1.3(0.5) (TRIP
pr. reduced)
4. TGOP start Ksc 8.75
5. EOP start Ksc 1.60
6. Turning gear Ksc 0.6
motor interlock
7. AOP pump Ksc 8
running
8. TGOP running KSC 2
9. EOP running Ksc 2
10. Hydraulic oil pr. Ksc 14 11.7 5.5 (TRIP)
11. Exhaust hood C 45 85 105 (TRIP B/p)
temp
12. Turbine Rpm 3000 3300 3360
NTPC RAMAGUNDAM

Sl.no. Alarm/protection Units Oprt. Low Lo-lo Hi Hi-hi Remarks

Val
overspeed 110% 112%
hyd Elec
13. Turbine seal Ksc 0.25 0.21 0.35 (ATRS)
steam pr 0.15 ACS
0.1 DAS
14. Turbine IP diff Mm +8.3 -4.6
exp.
15. MOT oil level Mm 1350 1140 1390
16. Emergency oil pr. Ksc 6 (TRIP)
low
17. Turbine LP diff Mm +12.6 -3.2
exp.
18. Turbine brg vib Micron 80 Al(125)
19. Turbine brg. C 80 95
Temp
20. Turbine thrust C 75 90
bearing temp
21. Exhaust water Ksc 2 Al 3.5
spray in operation
22. Turbine lube oil C 65
temp form cooler (TRIP)
23. Turbine thrust Mm +/- +/-0.5 +/-0.8
wear 0.3
24. Steam seal cond Mm +/- 5950
level 5800
25. Oil drains brg C 60 85
high temp
26. Oil filter high DP Ksc 0.3 0.5
27. HP cyl DT upper C +/- 50
IP Cyl DT lower +/- 50
28. Upper/lower 5 th C +/- 50
DT

29. Upper/lower 6 th C +/- 50

DT

30. HRH temp afte IV C 535 400 400

L/R
31. SH/RH OUTLET C 540 535 545
TEMP
32. HPT EXHAUST C 540 535 545 350
TEMP 335
33. HP bypass down Ksc 40
stream pr.
34. Condenser Ata 0.45
vacuum for LP
Bypass
NTPC RAMAGUNDAM

Sl.no. Alarm/protection Units Oprt. Low Lo-lo Hi Hi-hi Remarks

Val
35. Condenser level Mm 710
high
36. LP bypass down Ksc 6
steam pr.
37. LP bypass spray Ksc 32 25
water pr low
38. HP bypass down C 335 350
steam temp.
39. Control oil pr Bar 120 90
low(Hp bypass)
40. CRH drain pot Mm
level
41. Feed storage pr. Ksc 11 11.8 12.5
42. HPH-6 steam pr. Ksc 39 10% up
43. HPH-5 steam pr. Ksc 22.539 Ext. pr.
44. HPH-5&6 drip Mm 350 200 500 860
level
45. D/A level Mm 2600 1000 480 2950 3050
46. LPH 2- & 3 level Mm 150 87 196 296
47. LPH-1 level Mm 250 187 120 205 460
48. Condenser level Mm 460 310 150 650 750
49. CRT level Mm 750 2500
50. CEP disc.pr. Ksc 32 28.5 27.5
51. CEP bearing C 26.5 25 70 30 sec DT
&75 motor brg
52. CEP suction Mwcl 0.6
strainer DP
53. CEP hot air temp. C 90
54. CPU pr. high Ksc
55. Cond pr. to Ksc 25
LP-bypass
56. BFP BP suction Mwcl 3.5
DP
57. BFP thrust brg C 75
temp
58. BFP mech seal C 80
water outlet temp.
59. BFP delivery C 236 (trip)
temp
60. BFP suction temp. C 200
61. BFP journal brg C 75
temp
62. BFP hyd coupling C 90 130
brg temp.
63. BFP motor hot air C 55/90 Cold/hot(air
temp Trip)
64. BFP working oil C 75 /130
NTPC RAMAGUNDAM

Sl.no. Alarm/protection Units Oprt. Low Lo-lo Hi Hi-hi Remarks

Val
to/from cooler
temp
65. BFP lube oil C 95 / 55
to/from cooler
temp
66. BFP reduction C 90
gear bearing
temp.
67. BFP disch header Ksc 170 155 120
Pr
68. BFP suction pr. Ksc 10 7 (trip)
69. BFP lube oil pr. KSC 1 0.5
70. BFP cooling Ksc 2
water header pr.
71. BFP suction 0.6
strainer DP
72. BFP booster T/h 50
pump flow
73. BFP balancing Ksc 23 25
line pr.
74. BFP lube oil pr. KSC 1.2 0.7 0.5 0.8 3.5 ( FOR
(perm starting
for BFP AOP )
75. BFP BP suction Ksc 11 6
pr
76. BFP motor Lpm 200 (BPF trip
cooling water bypassed)
flow
77. HP flash tank C 50 100
78. Coldwater box DP Mwcl 5
79. Raw water pr. Ksc 5 3
80. MOT cooling Lpm 1400
water flow
81. Centrifuge oil C 60 70 90 Water temp
outlet temp
82. BFP pump Ksc 70 50
discharge pr
NTPC RAMAGUNDAM

GENERATOR PROTECTION SETTINGS:

Sl.no. Protections Set values

1. Gen diff protection 87 G -0.25amp
2. Gen transformer overall diff 87 GT -30% of 5 amps
3. Gen stator earth fault 64G1 TMS –0.2
4. Gen standby earth fault 64 G2
5. Gen Over voltage relay 59 G -116.5V
6. Gen reverse power 37 G Timer 1-2 sec
2-50 sec
7. Gen low forward power 32G -T: 2sec
8. Gen loss excitation
a) Without under voltage –40G k-1 = 0.91 ,k2=2.5
b) With under voltage –40G k3 = 0.5, k4 = 2.0
k5 = 13.4
trip time 2 sec reset time
Under voltage relay aux to loss of excitation 10 sec
relay 70-80%
9. Gen pole slipping 98G 2TO k1=0.90 k2=0.55
95G k3=4 Q1 –q2=75
t=56msec XI=1.02
VTGM k1=2.0,k2=0.74,k3=2.0
k4=1,k5=1.55,Q=75
10. Gen overload alarm –57G 4.8amp t=15sec
11. Gen backup imp.-21G K1-12,k2=0.63 t=1.5sec
and 2 sec
12. LBB protection 86G Current 0.1A timer 0.2sec
13. Gen under frequency 81G Alarm 48.5 hz t=5sec
14. GT restricted earth fault 64GT 0.1 A
15. GT backup E/F protection 51NGT PS-0.1A,TMS 0.3
16. GT over fluxing 99GT V/4-1.13-timer 0.5sec
alarm,-30sec trip)
17. Gen cold gas temp 65 C
18. Gen seal oil DP low 0.2 ksc
19. UT diff 30%
20. UT backup O/L protection P5.0.75Amm
TMS 0.3 sec.
21. Over head line diff 0.2 amp.
NTPC RAMAGUNDAM

Generator:

Sl.no. Alarm/protection Units Oprt. Low Lo- Hi Hi- Remarks

Val lo hi
1. Gen cold gas temp C 50 60 65
(trip)
2. Gen hydrogen Ksc 2 0.22 2.2
pressure
3. Hydrogen purity % 98 92
4. Seal oil filter DP Mwcl 0.5 0.8
5. Seal oil vacuum MmHG 750
tank
6. Vacuum tank level -150 +150
7. Seal oil feed pr Ksc
8. Seal oil- hydrogen Ksc
DP
9. Gen hydrogen Lpm 6 5.5
cooler water flow
10. S.O.Cooler flow Lpm 0.35 0.3 0.2
11. High level in seal Mm 87
oil discharge tank
12. Water /oil losser Cucm
13. Gen stator winding
temp U,V,W
14. Seal oil feed pr. Ksc 5.6
15. Hydrogen drier C 75
heater cut out temp
NTPC RAMAGUNDAM

Transformer (H.T.)

Sl.no. Alarm/protection Units Alarm Trip

1. GT winding temp C 100 110
2. GT oil temp C 85 95
3. GT overfluxing ratio % 1.1(30sec)
V/F
4. UT A/B winding temp C 90 100
5. UT A/B oil temp C 80 90
6. UT A/B cooling fans C 65 75
Auto starting/stopping Gr-1 Gr-2
7. Station transf. ½ C 90 100
winding temp
8. Station transf ½ oi l C 80 90
temp
9. Stan.trf1/2 cooling C 65 75
fans/pumps Gr-1 Gr-2
Auto starting/stopping
10. Stantion trf O/L
protections
11. CW trf winding temp C 90 100
12. CW trf oil temp C 80 90
13. CW trf overload % 125 0.25sec
protection
14. CW.trf cooling fans C 65 75
Auto starting/stopping Gr-1 Gr-2
15. WTP trf winding temp C 90 100
16. WTP trf oil temp C 80 90
17. WTP trf overload % 125 0.8 sec
protection
18. Col trf winding temp C 95 105
19. Col trf oil temp C 90 100
20. Col trf overload % 100 0.7 sec
protection
21. Auto transf. ½ winding C 90 100
temp
22. Auto transf ½ oi l temp C 80 90
23. Auto.trf1/2 cooling C 60/70
fans/pumps
Auto starting/stopping
24. Auto trf O/L protections %
25. Auto transf. ¾ winding C 90 100
temp
26. Auto transf 3/4oi l temp C 80 90
27. Auto.trf3/4 cooling C 60/70
fans/pumps
Auto starting/stopping
28. Auto trf3/4 O/L %
NTPC RAMAGUNDAM

Sl.no. Alarm/protection Units Alarm Trip

protections
29. Tie transf. ½ winding C 90 100
temp
30. Tie transf ½ oi l temp C 80 90
31. Tie.trf1/2 cooling C 60/70
fans/pumps
Auto starting/stopping
32. Tie trf O/L protections % 100 110
33. SY compressors Ksc 130/125 120/135
1/2/3/Auto 1/2 /3/cutoff
cut in./cut off
34. 400 kv /220 Kv breakers
a)SF6 pr Bar 6.7+/-0.1 (auto
Normal pr 8 bar reclose lock out)
7.0- 6.5+/-
0.1(trip lock)

b)Air pr (30.6/32) Bar 28 (auto reclose

lockout)
27.3 close
lockout
c)Oil pr(pump Bar 26 trip lockout
on/off){BHEL types} 325+/-3, 312+/-3
273+/- 3(closing
lockout)
253+/-
3(OPENING
d)Chandrapur lockout)
lindes(400KV SF6) Bar 6.5 Lockout
Air Pr ( comp Bar
Start/stop) 7.
37—36
34auto reclose
lockout
32alarm
31close lockout
30trip lockout
35 Shunt reactor winding C 105 115
NTPC RAMAGUNDAM

Transformer (L.T.) Protections:

Sl.no. Alarm/protection Units Alarm Trip

1. Unit service trf winding C 100 105
temp
Unit service trf oil temp C 85 90
Unit service trf O/L % 1400%
2. Unit lighting trf winding C 100 105
temp
Unit lighting trf oil temp C 85 90
Unit lighting trf O/L % 1200%
3. ESP trf winding temp C 100 105
ESP trf oil temp C 80 90
ESP trf O/L % 500%
4 Station LT trf winding C 100 105
temp
Station LT trf oil temp C 80 90
Station LT trf O/L % 1400%
5. Ash slurry trf winding C 100 105
temp
Ash slurry trf oil temp C 80 90
Ash slurry trf O/L % 1400%
6. Ash slurry LTG trf O/L % 1400%
7 F.O LTG trf O/L % 1400%
8 Ash water trf O/L % 1400%
9 CT trf O/L % 1400%
10 S/Y trf O/L % 1400%
11 WTP LT trf O/L % 1400%
NTPC RAMAGUNDAM

HT motors current settings in AMPs.

Sl.no. Name of motor Normal Hi-Alarm Hi-hi Trip

current
1. ID fan motor O/L 125.2 132 158
2. FD fan motor O/L 143.9 154 192
3. PA fan motor O/L 43.7 46 54
4. BFP motor O/L 322.3 340 432
5. CEP motor O/L 75.6 80 96
6. Mill motor O/L 26.4 28.9 32.4
7. Clarified water pump 21 22.2 26.1
motor O/L
8. Raw water pump motor 31 33 34.5
O/L
9. CW pump motor O/L 154 160 192
10. IAC motor O/L 21 22.2 26.1
11. PAC motor O/L 20 25.2 32.4

Most of the trips setting are at high value itself for safety of the motors.