POWER PLANT EMERGENCY

Every power plant generation unit or station tried to supply quality and reliable power to grid or customer. So after commercialization of unit, the operation engineers responsibility increased manifold not only providing the quality and reliable power supply but also safety of all running equipments and unit.
Operation engineers familiarized with problems and emergencies. Familiarization of all emergency is needed, some problems can be solved easily without losing generation. But some unforeseen incidents occurred in power plant. It requires immediate appropriate action to solve problem to avoid any generation loss or any damage to equipment. So, there are different type of emergencies 1. Boiler emergencies 2. Turbine emergencies 3. Generator emergencies 4. Electrical emergencies ( SWGR) 5. Grid failure. 6. Unit emergencies

Unit emergencies:1. CW P/Ps tripped 2. Compressor tripped 3. Heavy lkg in DM make up line 4. Any major fire in oil system of TDBFP /Main TG etc 5. Failure of work station 6. Loss of 220 V DC 7. Loss of 24V TG 8. Loss of 24V SG 9. UPS failure 10. 11 KV SWGR dead 11. 3.3 KV SWGR dead 12. USS/Unit Emergency SWGR dead

CW P/P tripped

Unit/ Station condition All units running with 500 MW 4 CW P/Ps are running I/C V/Vs are opened
Case-1 : One CW P/P tripped Consequence:suction pressure low to ACW P/P Low flow through Condenser Pass-A/B Temp may rise of TG PHE O/L results increasing oil/Brg temp, seal oil temp, Action: Start stand by pump immediately Observe all parameters

Case-2 : One CW P/P tripped and stand by p/p failed to start CW P/P-3B/3C tripped due to dead of 3UB bus CW P/P-3B/3C tripped due to dead of 3UB bus and another p/p fails to start or under PTW

Consequence:Suction pressure low to ACW P/P Low flow through Condenser Pass-A/B Temp may rise of TG PHE O/L results increasing oil/Brg temp, seal oil temp, Action: Start stand by CW P/P

Reduce unit load around 300 MW

Observe condenser vacuum and all Brg and oil temp If necessary, throttled TGPHE ACW side v/v to avoid ACW P/P tripping If tripping of any unit due to temp like seal oil or PW etc, Close the

DM Water System Unit/ Station condition All units running with 500 MW Avg make up around 25-30 T/H to hot well ECW tank make lined from DM Normal/emergency make up lined up Case-1 Leakage in DM header ( DM make up system isolation required) Consequence: Hindrance to DM make up to units wastage of DM water Action: Take DM water make up to ECW O/H tank in all units Take up make up in Hotwell and DA and maintain above normal level Start emergency make up system and check /ensure flow to Hotwell

Isolate all units of Hotwell normal make V/v tp avoid air ingress
Stop soot blowing of all units for that time Inform chemsitry SCE for not taking DM for CPU regenartion

Compressor- Instrument air system Unit/ Station condition All units running with 500 MW All Compressors are running I/C V/Vs are opened 10% at stage one end and full opened at stage-II end. Power Source of Compressor- Unit-3 (IAC-1,3,5, PAC-1) Unit-4( IAC-2,PAC-4) Unit-5( IAC-4,PAC-3,5) Unit-6( PAC-2,6) Cooling water sources:- IAC-1-5 and PAC-1-4 from all units and IAC-1-5 and PAC-1-4 from unit-5/6 ( stand by) PAC-5,6 from unit 5 and 6

Case-1 Few IAC tripped due to some protection leads to maintain low header pressure Consequence:

SL.NO 1CD-67 SD-62 2DR-18 3DR-25 4DR-5 5DR-11 6DR-31 7DM-1 8DR-15 9DR-22 10DR-28 11DMCW-90 SD-61 12 SD-62 13 DR-37 14 DR-48 15 CD-10 16 CD-12 17 CD-14 18 CD-39 19 CD-43 20 DR-2 21 DR-8 22 DR-34 23 DM-2 24 SD45 25 SD44 26 SD46 27 SD47 28 AS-8 33 FD14 29 CD-22 30 CD-25 31 DMCW-100 32 CRH-6 34 35CD-72 36SD-43 SD-48

NTPC TAG COND SPRAY TO HDFT BCW LP DRAI MANIF DRAIN V/V HPH-5A DRAIN TO HPFT CV HPH-5B DRAIN TO HPFT CV HPH-6A DRAIN TO HPFT CV HPH-6B DRAIN TO HPFT CV LPH-3 DRAIN TO LPFT C/V DM N M UP TO HOTWELL C/V HPH-5A DRAIN TO D/A CV HPH-5B DRAIN TO D/A CV LPH-3 DRAIN TO LPH-2 C/V ECW PUMP(SG) I/O HDR DP C/V BCW ECW LINE INLETV/V BCW LP DRAI MANIF DRAIN V/V LPH-2 DRAIN TO LPFT C/V D/A OVERFLOW LPDFT CEP-A M/N R/C C/V CEP-B M/N R/C C/V CEP-C M/N R/C C/V GSC M/N R/C C/V HOTWELL SPILL LVL C/V HPH-6A DRAIN TO HPH-5A CV HPH-6B DRAIN TO HPH-5B CV LPH-2 DRAIN TO LPH-1 C/V DM E M UP TO HOTWELL C/V SH SPRAY C/V LEFT SH SPRAY C/V LEFT SH SPRAY C/V RIGHT SH SPRAY C/V RIGHT AUX STEAM TO D/A C/V LOW LOAD FEED C/V D/A LVL C/V MAIN D/A LVL C/V STANDBY ECW PUMP(TG) I/O HDR DP C/V CRH STEAM TO D/A C/V GLAND SEALING C/V SH SPRAY BLOCK V/V RH SPRAY BLOCK V/V

SERVICE

ACTION MODULATING ON/OFF AIR TO CLOSE AIR TO CLOSE MODULATING

AIR TO OPEN MODULATING AIR TO OPEN

AIR TO OPEN ON/OFF MODULATING ON/OFF AIR TO OPEN AIR TO OPEN AIR TO CLOSE AIR TO CLOSE

MODULATING

AIR TO CLOSE

AIR TO CLOSE

MODULATING AIR TO OPEN AIR TO OPEN Air to Open MODULATING Air to Open Air to Open Air to Open MODULATING MODULATING Air to Open MODULATING Air to Open Air to Open MODULATING MODULATING ON/OFF ON/OFF Air to Open Air to Open

An emergency power system/ stand by is an independent power generation system that is legally required to feed equipment or systems whose failure may present a life safety hazard to persons or property.

FAILURE OF UPS

AC supply ,USS

DC
(Rectifier)

AC
( Inverter)

AC
(Inverter)

DC
(Rectifier)

AC supply EMCC

LOAD

Battery Bank
Bypass AC supply USS Bypass AC supply EMCC

ACPDB-01 (CCR)

ACPDB-02 (CCR)
ACPDB-03 (PRGMR ROOM) ACPDB-04(UCP) ACPDB-05 C&I-MAINT ACPDB-06 CHIMNEY BHEL PDB-1 MTM BHEL PDB-2 MTM BHEL PDB-4 AIR HEATER SWAS PA SYS 01 PA SYS 02

PAH-B AIR MOTOR BMCC 3.3R 2.2R

SAH-A AIR MOTOR BMCC 2.4R SAH-B AIR MOTOR BMCC 4.3R VMS-II CER SG/TG MMI WS POSE CAB BOILER FLAME SENSING SYSTEM ACCOUSTIC PYROMETER BLR MAIN WORK STATION BPOS VIB ANALYSER GCC02 SEAL OIL ISNT CAB

VMS-CER
MASTER CLOCK CER ACPDB-11 BNKR LVL PAH-A AIR MOTOR BMCC

GCC03 STATOR WATER INST. CAB

STATOR END WNDG VIB SYS VFD C&I PANEL ID-A VFD C&I PANEL ID-B TUBE LIFE ASSESMENT SYSTEM

ACPDB-21 HPH LVL SW ACPDB-22 LPH LVL SW ACPDB-23 D/A LVL SW ACPDB-24 HOTWELL LVL SW

CJJ13 MARSHELLING PANEL

TSI FOR BFPDT 1&2 TSC PC & PRNTR. GAS ANALYSE PDB FOR APRDS CJCB PARTIAL DISCH. MONITORING MDBFP SCOOP KE3 ACPDB-19 BRNR TILT

BHEL PDB-3 BCW P/P

CWPNL VMS FLAME SCANER CJF-07 VAC. P/P -1 SMART ACT. STN (U#3 ONLY) MILL A TO E LVL SW ACPDB MILL F TO K LVL SW ACPDB MILL REJECT SYSTEM

Case-1

In case of any one channel failed to supply power, supply will get extend from the other source and alarm will come. No problem is envisaged.
In case of both channel failed to supply, then direct sources ( unregulated 415V AC Power) comes in service, no immediate problem will occur but regular supply has to be restored as soon as possible.

Case-2 If there is total failure of power supply from UPS, the following events will happen All BFP will get trip on D/A level-Low since supply of DA Lvl switch from UPS Boiler will trip on All BFP OFF from FSSS ( SG 24V source) Turbine will trip on MFT of boiler and generator will trip on Low Forward Power ID fans will trip due to loss of supply from UPS to VFD, FD fans will trip on interlock Mills and PA fan will trip on MFT No command will be executed from MMI and parameters will not be available for

BHEL CRT, For DDCMIS, HMI/LVS screens will be available for 30 mins
Vertical panels will be available for operation. Turbine lube oil pumps. Seal oil pumps, barring gear will be available HP/Lp bypass will be available for operation TSI parameters will not available.

Action Ensure by checking at local, Main TG, TDBFP lube oil pumps, seal oil pumps, air pre heater motors, scanner air fans etc are in service. And check barring gear v/v opened. Inform C & I and EMD ( battery and Charger group) for rectification.SCE/DGM/AGM(O)

FIRE NEAR TG ON ACCOUNT OF OIL LEAKAGE OR FIRE IN LUBE OIL SYSTEM/TDBFP/MAIN TG

CASUE

Oil lkg in pipe line, bearing etc Wet cotton which was used for cleaning purpose filter or bearing Above these, high temp of steam lkg and contact with bared high temp steam line.

ACTION

Oil fire spread very fast, so that machine should be stopped immediately Oil supply should be cut off, DC oil pump should kept off. Steam supply should be cut off. Incase of towards , Main TG trip main TG, H2 purged out. Extinguish fire with help of available of fire extinguisher

Inform to fire station Inform HOD of OPRN/EMD/TMD Revise DC

Fire protection-1 Generator breaker OFF and Either MOT Lvl V Low or Fire protection PB(1/2) pressed Casue Opens the vacuum breaker on protection Stops the HPCF pumps Stops HPCF heater Stops HPCF recirculation pumps Trips the turbine

Fire protection-2 Either MOT Lvl V Low or Fire protection PB(2) pressed Cause Switch off the SGC oil supply program Stops AOP-1 on protection Auto off SLC AOP-1 Stops AOP-2 on protection Auto OFF SLC AOP-2 Auto On SLC EOP Auto OFF SLC jOPs Stops JOP-1 on protection Stops JOP-2 on protection Starts JOP-3 on protection Auto OFF SLC JOP-3 Auto OFF SLC turning gear Trips the turbine Opens the vacuum breaker on protection Stops the HPCF pumps Stops HPCF heater Stops HPCF recirculation pumps Trips the turbine

SL.NO 1CD-67 SD-62 2DR-18 3DR-25 4DR-5 5DR-11 6DR-31 7DM-1 8DR-15 9DR-22 10DR-28 11DMCW-90 SD-61 12 SD-62 13 DR-37 14 DR-48 15 CD-10 16 CD-12 17 CD-14 18 CD-39 19 CD-43 20 DR-2 21 DR-8 22 DR-34 23 DM-2 24 SD45 25 SD44 26 SD46 27 SD47 28 AS-8 33 FD14 29 CD-22 30 CD-25 31 DMCW-100 32 CRH-6 34 35CD-72 36SD-43 SD-48

NTPC TAG COND SPRAY TO HDFT BCW LP DRAI MANIF DRAIN V/V HPH-5A DRAIN TO HPFT CV HPH-5B DRAIN TO HPFT CV HPH-6A DRAIN TO HPFT CV HPH-6B DRAIN TO HPFT CV LPH-3 DRAIN TO LPFT C/V DM N M UP TO HOTWELL C/V HPH-5A DRAIN TO D/A CV HPH-5B DRAIN TO D/A CV LPH-3 DRAIN TO LPH-2 C/V ECW PUMP(SG) I/O HDR DP C/V BCW ECW LINE INLETV/V BCW LP DRAI MANIF DRAIN V/V LPH-2 DRAIN TO LPFT C/V D/A OVERFLOW LPDFT CEP-A M/N R/C C/V CEP-B M/N R/C C/V CEP-C M/N R/C C/V GSC M/N R/C C/V HOTWELL SPILL LVL C/V HPH-6A DRAIN TO HPH-5A CV HPH-6B DRAIN TO HPH-5B CV LPH-2 DRAIN TO LPH-1 C/V DM E M UP TO HOTWELL C/V SH SPRAY C/V LEFT SH SPRAY C/V LEFT SH SPRAY C/V RIGHT SH SPRAY C/V RIGHT AUX STEAM TO D/A C/V LOW LOAD FEED C/V D/A LVL C/V MAIN D/A LVL C/V STANDBY ECW PUMP(TG) I/O HDR DP C/V CRH STEAM TO D/A C/V GLAND SEALING C/V SH SPRAY BLOCK V/V RH SPRAY BLOCK V/V

SERVICE

ACTION MODULATING ON/OFF AIR TO CLOSE AIR TO CLOSE MODULATING

AIR TO OPEN MODULATING AIR TO OPEN

AIR TO OPEN ON/OFF MODULATING ON/OFF AIR TO OPEN AIR TO OPEN AIR TO CLOSE AIR TO CLOSE

MODULATING

AIR TO CLOSE

AIR TO CLOSE

MODULATING AIR TO OPEN AIR TO OPEN Air to Open MODULATING Air to Open Air to Open Air to Open MODULATING MODULATING Air to Open MODULATING Air to Open Air to Open MODULATING MODULATING ON/OFF ON/OFF Air to Open Air to Open