diff --git "a/data/processed/text_chunks.json" "b/data/processed/text_chunks.json" new file mode 100644--- /dev/null +++ "b/data/processed/text_chunks.json" @@ -0,0 +1,2634 @@ +[ + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 0, + "chunk_content": "1. What is the Declared Annual Dependable Capacity of LP/PG for\ncurrent year?\nDeclared annual dependable capacity or ADC of Lalpir and Pakgen is as follows\nLalpir Power Limted: 350 MW Net Sent out\nPakgen Power Limited: 350 MW Net Sent Out\n\n\n1. Ho1w2 WA0P.4D0 A ca0.n35 disp0a.3t5c h both complexes?\nWAPDA/NPCC requests for dispatch as per merit list revised fortnightly based\non different factors including fuel cost, variable O&M cost, any other specific\ncost in terms of Rs/kWhLalpir/Pakgen Power Plant 6\nCCR Qualification Book\n1\n\n1. What is FTADL amount in Rs/kWh for each kWh outside the\ntolerance?\nFTADL Amount in Rs / kWh = 0.3\u00d7IE \u00d7 kWh outside the tolerance\nt\n2", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_010" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 1, + "chunk_content": "2. What are the Scheduled Outage months for LP/PG? In which WAPDA\nnotification they are covered?\nPursuant to Section 6.2(a)(i) of PPA , WAPDA has to send \u201cYear Ahead\nNotification\u201d to the company mentioning \u201cMaintenance Months\u201d. After its receipt,\nwithin 45 days, company shall propose to WAPDA its schedule outage period\nwithin those mentioned \u201cMaintenance Months\u201d.\n\n\n2. What are the technical limits regarding to Unit start up? (NTS)\nTechnical limits regarding to Unit startup (NTS) are as follows\nStandby/shutdown duration less than 2 hours: 50 Min\nStandby/shutdown duration less than 8 hours 90 Min\nStandby/shutdown duration less than \n\n2. If the Company is unable to meet the requested Dispatch for a\ncontinuous period of three (", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_011" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 2, + "chunk_content": "3. How and when Maintenance Outage can be taken?\nMaintenance outage can be taken any time during the year. As the need arises,\ncompany shall inform to WAPDA / NPCC of such need mentioning\ncommencement and duration of such outage. NPCC / WAPDA will then\napprove/allow such outage in light of their need for energy from the unit and the\nnecessity of the outage.\n\n\n3. Describe classification of start-up of the unit?\nAs per PPA Unit startup is classified as follows\nNTS within 8 hours of shutdown: Hot\nNTS within 150 hours of shutdown: WARM\nNTS within 8 hours of shutdown: Cold\n1\n\n3. What are consequences if we do not meet NTS time\na. We synchronize the unit late\nb. We synchronize the unit early\nIn case of Late Unit Sync, delayed time will be treated as forced outage and\npartial forced outage till the time company meets WAPDA/NPCC demand\nIn case of early sync, FTADL will be given by NPCC/WAPDA\n2", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_012" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 3, + "chunk_content": "4. What is the difference between Scheduled Outage and Maintenance\nOutage?\nScheduled Outage is the outage planned within the consent of NPCC/WAPDA\nduring maintenance months designated in \u201cYear Ahead Notification\u201d.\nWhereas Maintenance Outage is the outage requested to NPCC / WAPDA for\nnecessary maintenance of the equipment and half of its duration in hours will be\ndeducted from maintenance allowance of 500 hours\n\n\n4. What are the limits of start-up regarding to (numbers)/ years?\nLimits of Startups per year are as follows\nHot start \n\n4. What are droop ranges of Automatic Voltage Regulator (AVR) and\nTurbine Governor as per PPA? What is current droop setting of\nTurbine Governor?\nThe AVR will control the generator voltage over the range of \u2013 10% of rated\nvoltage with a droop characteristic of \u2013 0.5%.\nThe Unit/Turbine governor droop is adjustable in the range 1.", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_013" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 4, + "chunk_content": "5. What is the difference between Forced Outage and Partial Forced\nOutage?\nForced Outage is the non-availability of complex to dispatch electricity to NPCC\ndue to any reason\nPartial forced outage is partial availability of complex. In other words during\npartial forced outage complex is unable to meet NPCC / WAPDA demand.\n\n\n5. What is complex load ramping rate?\nCold Rate Hot Rate\nGen Load Run up Rate Run up Rate\n0 \u2013 90 MW 1% of Gross Capacity 1% of Gross Capacity\n90 \u2013 180 MW 1% of Gross Capacity 2% of Gross Capacity\n180 \u2013 MCR 1% of Gross Capacity 3% of Gross Capacity\n1\n\n5. What is meant by Force Majeure?\nA \"Force Majeure Event\" is any event or circumstance or combination of events\nor circumstances that is beyond the reasonable control.\n2", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_014" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 5, + "chunk_content": "6. What links are provided to communicate with WAPDA?\nHotline, Direct Number and Cell Phone (to Shift Managers)\n\n\n6. What is stabilization time? During load ramping during cold /warm/hot\nstart?\nStabilization time is time given for turbine temperature stabilization e.g its casing\nexpansion, its casing/rotor diff expansion.\nCold Rate Hot Rate\nGen Load Hold time Hold time\nOn Sync 30 Mins 0\nAt 90 MW 10 min 10 min\n180 MW 10 min 10 min\n1\n\n6. What does \u201cPrudent Utility Practices\u201d mean?\nOperating the complex within the technical limits and as per merit order is\nnormally termed as \u201cPrudent Utility Practice\u201d\n2", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_015" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 6, + "chunk_content": "7. What is dependable capacity, when it is required to demonstrate?\nDependable capacity is the full capacity of complex, which can be delivered to\nWAPDA/NPCC.\nTo continue receiving \u201cCapacity Purchase Price\u201d per month , it is required to\ndemonstrate complex capacity for consecutive six hours on any day mutually\nagreed by both parties within the \u201cDemonstration Period\u201d.\n\n\n7. What are Generator technical limits for frequency/power\nfactor/voltage?\nFrequency technical limit is \u00b15% on 50 Hz\nPower factor technical limit is 0.\n\n7. What is MDI? How is it calculated? What is current rate of MDI\npenalty?\nMDI is maximum demand index.\nMaximum kWh imported during any half hour in a month is MDI and it is\ncalculated as \u201cMax kWh Imported in half hour \u00d7 prevailing MDI Rate \u00d7 2\u201d\n2", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_016" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 7, + "chunk_content": "8. What are the benefits of ADC on capacity payment?\nADC has direct impact on \u201cCapacity Purchase Price\u201d.\n\u201cCPP\u201d has two portions of capacity payment. Capped Capacity & Added\nCapped Capacity\nLalpir capacity is capped at 347.3 MW while Pakgen Capacity is capped at\n343.7 MW. Complex Capacity above this capped capacity is termed as Added\nAdded Capped Capacity.\nAny Increase in capacity will result in increase in added capped capacity portion\nof \u201cCPP\u201d and vice versa.Lalpir/Pakgen Power Plant 4\nCCR Qualification Book\n\n\n8. What advantage does the Company get if it reduces the Scheduled\nOutage period below thirty days?\nFor each 24 hours reduction in scheduled outage, company gets 12 hours of\nmaintenance allowance in addition to 500 hours.\nFor thirty days reduction in scheduled outage, company will get additional 15\ndays hours of maintenance allowance.Lalpir/Pakgen Power Plant 7\nCCR Qualification Book\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_017" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 8, + "chunk_content": "9. What are liquidated damages with respect to forced outage/ partial\nde-rating?\nAs per PPA, Company has been provided with 500 hours of maintenance\nallowance against each MW. For each forced outage and partial forced outage\n(Partial De-rating) , MW are calculated. If hours calculated during total forced\noutage and partial forced outage duration exceeds 500 hours maintenance\nallowance, Company will have to pay penalty equivalent to 1.6 times of Capacity\npurchase price against each exceeded MWh.Lalpir/Pakgen Power Plant 5\nCCR Qualification Book\n\n\n9. Under what conditions WAPDA shall be entitled to suspend the\nCapacity Payments? How these payments will be restored?\nIf for a period of consecutive 18 days , company fails to deliver more than 50%\nof the dispatch level requested by NPCC/WAPDA, then capacity payment will\nbe suspended (subjected to the event other than schedule outage, maintenance\noutage or force majeure)\nWhen company is able to meet dispatch level requested by NPCC / WAPDA, it\nwill notify and have to deliver more than 50% of the dispatch level consecutively\nfor 3 hours , only then capacity payments will be restored.\n20. What is tolerance level of dispatch level is case of:\na. Ramping\nb. Steady load\nFor ramping , tolerance limit is 4.5% of the net electrical output and for steady\nload tolerance is 3% of the net electrical output.\n21. What is FTADL amount in Rs/kWh for each kWh outside the\ntolerance?\nFTADL Amount in Rs / kWh = 0.3\u00d7IE \u00d7 kWh outside the tolerance\nt\n22. If the Company is unable to meet the requested Dispatch for a\ncontinuous period of three (3) hours, then how shall such shortfall\nbe treated as?\nIt will be treated as Partial forced outage due to FTADL, and the non-\ncompliance MW\u2019s will be deducted from 500 hours of maintenance allowance.\n23. What are consequences if we do not meet NTS time\na. We synchronize the unit late\nb. We synchronize the unit early\nIn case of Late Unit Sync, delayed time will be treated as forced outage and\npartial forced outage till the time company meets WAPDA/NPCC demand\nIn case of early sync, FTADL will be given by NPCC/WAPDA\n24. What are droop ranges of Automatic Voltage Regulator (AVR) and\nTurbine Governor as per PPA? What is current droop setting of\nTurbine Governor?\nThe AVR will control the generator voltage over the range of \u2013 ", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_018" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 9, + "chunk_content": "10. What is the weighting factor applicable to FO/PD/MO during peak & non-\npeak hours? What are new Weighting Factors effective from year 2021?\nFollowing are the weighting factors applicable to FO, PD, and MO.\nMonth PEAK N.PEAK SUN\n1 2.50 2.00 1.50\n2 0.90 0.30 0.20\n3 0.80 0.50 0.50\n4 1.50 0.75 0.50\n5 1.50 0.75 0.50\n6 1.50 0.90 0.50\n7 1.50 0.90 0.50\n8 0.95 0.60 0.40\n9 0.95 0.60 0.40\n10 0.95 0.60 0.40\n11 0.90 0.30 0.21\n12 2.00 1.50 1.00\nWeighting factor effective from next agreement year\nMonth PEAK N.PEAK SUN\n1 1.00 0.80 0.65\n2 1.00 0.80 0.65\n3 1.00 0.80 0.65\n4 1.00 0.80 0.65\n5 2.20 1.50 1.20\n6 2.20 1.50 1.20\n7 2.20 1.50 1.20\n8 2.20 1.50 1.20\n9 0.40 0.35 0.35\n10 0.40 0.35 0.35\n11 0.40 0.35 0.35\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_019" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 10, + "chunk_content": "11. Ho1w2 WA0P.4D0 A ca0.n35 disp0a.3t5c h both complexes?\nWAPDA/NPCC requests for dispatch as per merit list revised fortnightly based\non different factors including fuel cost, variable O&M cost, any other specific\ncost in terms of Rs/kWhLalpir/Pakgen Power Plant 6\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0110" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 11, + "chunk_content": "12. What are the technical limits regarding to Unit start up? (NTS)\nTechnical limits regarding to Unit startup (NTS) are as follows\nStandby/shutdown duration less than 2 hours: 50 Min\nStandby/shutdown duration less than 8 hours 90 Min\nStandby/shutdown duration less than 32 Hours ", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0111" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 12, + "chunk_content": "13. Describe classification of start-up of the unit?\nAs per PPA Unit startup is classified as follows\nNTS within 8 hours of shutdown: Hot\nNTS within 150 hours of shutdown: WARM\nNTS within 8 hours of shutdown: Cold\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0112" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 13, + "chunk_content": "14. What are the limits of start-up regarding to (numbers)/ years?\nLimits of Startups per year are as follows\nHot start 52 per year & 500 Total Startups during the PPA Term\nWarm start 26 per year & 600Total Startups during the PPA Term\nCold start 6 per year & 60 Total Startups during the PPA Term\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0113" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 14, + "chunk_content": "15. What is complex load ramping rate?\nCold Rate Hot Rate\nGen Load Run up Rate Run up Rate\n0 \u2013 90 MW 1% of Gross Capacity 1% of Gross Capacity\n90 \u2013 180 MW 1% of Gross Capacity 2% of Gross Capacity\n180 \u2013 MCR 1% of Gross Capacity 3% of Gross Capacity\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0114" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 15, + "chunk_content": "16. What is stabilization time? During load ramping during cold /warm/hot\nstart?\nStabilization time is time given for turbine temperature stabilization e.g its casing\nexpansion, its casing/rotor diff expansion.\nCold Rate Hot Rate\nGen Load Hold time Hold time\nOn Sync 30 Mins 0\nAt 90 MW 10 min 10 min\n180 MW 10 min 10 min\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0115" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 16, + "chunk_content": "17. What are Generator technical limits for frequency/power\nfactor/voltage?\nFrequency technical limit is \u00b15% on 50 Hz\nPower factor technical limit is 0.85 lagging and 0.90 leading power factors on 24\nkV,\nVoltage range is \u00b110% on the 220 kV systems\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0116" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 17, + "chunk_content": "18. What advantage does the Company get if it reduces the Scheduled\nOutage period below thirty days?\nFor each 24 hours reduction in scheduled outage, company gets 12 hours of\nmaintenance allowance in addition to 500 hours.\nFor thirty days reduction in scheduled outage, company will get additional 15\ndays hours of maintenance allowance.Lalpir/Pakgen Power Plant 7\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0117" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 18, + "chunk_content": "19. Under what conditions WAPDA shall be entitled to suspend the\nCapacity Payments? How these payments will be restored?\nIf for a period of consecutive 18 days , company fails to deliver more than 50%\nof the dispatch level requested by NPCC/WAPDA, then capacity payment will\nbe suspended (subjected to the event other than schedule outage, maintenance\noutage or force majeure)\nWhen company is able to meet dispatch level requested by NPCC / WAPDA, it\nwill notify and have to deliver more than 50% of the dispatch level consecutively\nfor 3 hours , only then capacity payments will be restored.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0118" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 19, + "chunk_content": "20. What is tolerance level of dispatch level is case of:\na. Ramping\nb. Steady load\nFor ramping , tolerance limit is 4.5% of the net electrical output and for steady\nload tolerance is 3% of the net electrical output.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0119" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 20, + "chunk_content": "21. What is FTADL amount in Rs/kWh for each kWh outside the\ntolerance?\nFTADL Amount in Rs / kWh = 0.3\u00d7IE \u00d7 kWh outside the tolerance\nt\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0120" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 21, + "chunk_content": "22. If the Company is unable to meet the requested Dispatch for a\ncontinuous period of three (3) hours, then how shall such shortfall\nbe treated as?\nIt will be treated as Partial forced outage due to FTADL, and the non-\ncompliance MW\u2019s will be deducted from 500 hours of maintenance allowance.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0121" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 22, + "chunk_content": "23. What are consequences if we do not meet NTS time\na. We synchronize the unit late\nb. We synchronize the unit early\nIn case of Late Unit Sync, delayed time will be treated as forced outage and\npartial forced outage till the time company meets WAPDA/NPCC demand\nIn case of early sync, FTADL will be given by NPCC/WAPDA\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0122" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 23, + "chunk_content": "24. What are droop ranges of Automatic Voltage Regulator (AVR) and\nTurbine Governor as per PPA? What is current droop setting of\nTurbine Governor?\nThe AVR will control the generator voltage over the range of \u2013 10% of rated\nvoltage with a droop characteristic of \u2013 0.5%.\nThe Unit/Turbine governor droop is adjustable in the range 1.5% to 8%.Lalpir/Pakgen Power Plant 8\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0123" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 24, + "chunk_content": "25. What is meant by Force Majeure?\nA \"Force Majeure Event\" is any event or circumstance or combination of events\nor circumstances that is beyond the reasonable control.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0124" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 25, + "chunk_content": "26. What does \u201cPrudent Utility Practices\u201d mean?\nOperating the complex within the technical limits and as per merit order is\nnormally termed as \u201cPrudent Utility Practice\u201d\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0125" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 26, + "chunk_content": "27. What is MDI? How is it calculated? What is current rate of MDI\npenalty?\nMDI is maximum demand index.\nMaximum kWh imported during any half hour in a month is MDI and it is\ncalculated as \u201cMax kWh Imported in half hour \u00d7 prevailing MDI Rate \u00d7 2\u201d\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0126" + }, + { + "chapter_numbre": "Chapter_1", + "chapter_name": "Chapter 01", + "chunk_index": 27, + "chunk_content": "28. What is Power Factor Penalty? How is it calculated?\nIf import power factor is less than 90%, then company has to pay power factor\npenalty. It is calculated as \u201c2 \u00d7 MDI Panely \u00d7 Differential P.F\u201d\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0127" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 0, + "chunk_content": "1. Write down the salient features of Lalpir Safety & Environmental\nPolicy?\nSalient features of Lalpir Safety & Environmental Policy are\n\u2022 Comply with or exceed requirements of global, national, state, and local\nstatutes, regulations, and standards protecting the environment, human\nhealth and safety. In the absence of laws and regulations, or where they\nare simply not adequate for our operations, we will apply sound\nOccupational, health and safety (OHS) management practices.\n\u2022 Strive for continual improvement in Environment, health and safety to a\nworld class performance using external bench marking system.\n\u2022 Establish global EHS standards that are robust, scientifically sound, and\nprotective of the environment, human health and safety.\n\u2022 Implement EHS management systems to identify and manage EHS\nrisks, obligations, and opportunities.\n\u2022 Conduct regular audits to verify compliance with regulatory\nrequirements and company standards.\n\u2022 Establish specific EHS metrics to measure and report on our\nperformance.\n\u2022 Incorporate EHS considerations into our business decision-making\nprocesses.\n\u2022 Work to prevent ill health, accidents, injuries, and unsafe work\nconditions; promote energy and water conservation; encourage the\nreuse and recycling of materials; and reduce waste, emissions and the\nuse of hazardous substances in our operations.\n\u2022 Monitor emerging issues and keep abreast of regulatory changes,\ntechnological innovations, and stakeholder interests.\n\u2022 Strive to develop effective and sustainable solutions to EHS challenges\narising from our business activities.\n\u2022 Regularly communicate relevant and meaningful information about our\nEHS performance to our internal and external stakeholders.\n\n\n1.\nEMS is an Environmental Management System also known as ISO 14001Lalpir/Pakgen Power Plant 10\nCCR Qualification Book\n3. Define environmental Aspects and Impacts? Write down the factors to\nbe considered while determining the environmental Aspects and\nImpacts?\nThe elements of organization\u2019s activities or services that can interact with the\nenvironment are called environmental aspects.\n\u2022 Air emission\n\u2022 Liquid hazardous waste\n\u2022 Noise\n\u2022 Transportation of material\nEnvironmental Impacts:\nAny change to the environment, whether adverse or beneficial Resulting from\nthe company's activities, products and services\n\u2022 Increase in ambient, CO, SOx, NOx etc.\n\u2022 Ground water contamination\n\u2022 Deterioration of hearing capability\n\u2022 Spillage & leakage of hazardous waste\n4. What are the requirements of EPA permits? List down the\nenvironmental limits for effluents and stack emissions?\nParameters Limits and units\nEffluent Flow (M3/hr)\nPH 6-9\nTemperature: 40 oC\nTemperature rise =< 3 oC\nTSS 200 mg/l\nOil & Greases 10 mg/l\nGaseous Emission Monitoring\nEmissions Emission Standards and Units\nCarbon monoxide 800 mg/Nm3\nOxide of Nitrogen (NOx) 600 mg/Nm3\nSulphur Oxide (SOx) 1700 mg/Nm3 x mg/Nm3\nParticulate Matter 300 mg/Nm3\n5. List down the priority parameters those need to be reported to EPA\nfor effluents and stack emissions?\nEffluents parameters are; pH, TSS and Oil & Greases\nStack Emission Parameters are: CO, NOx, Sox and Particulate matter\n6. What are the environmental targets and objectives of Lalpir?\nSafety and environmental targets and objectives of AES Lalpir thermal power\nstation are as follows;\n\u2022 To be always in compliance with all applicable laws and regulations\n\u2022 To work for continuous improvement of environmental management\nsystem\n\u2022 To prevent environmental excursions/threats\n\u2022 Identifying environmental Aspects and impacts\n\u2022 Improving environmental efficiencyLalpir/Pakgen Power Plant 11\nCCR Qualification Book\n7. Write down On Line monitoring system for stack emission and\neffluents?\nFollowing on line systems are present to monitor the effluents and the emissions\nof industrial gases:\nCEMS (Continuous Emission Monitoring System) to monitor the parameters of\nstack emissions.\nOn line monitoring system to check the chemistry of effluents.\n8. List down the operational controls on environment taken by Lalpir?\nThe Operational Controls taken by LalPir are as follows;\n\u2022 NOx Emission Control\n\u2022 Fugitive Emission Control:\n\u2022 Effluent Treatment\n\u2022 Noise Management Program:\n\u2022 SO2 Emission Control\n9. Define the types of NO and describe NO control in Lalpir?\nx x\na) Two-Stage Combustion Process to Control NOx\nThe two Staged combustion processes significantly reduce NOx emissions. In\nthe initial stage of combustion, the air supplied to the burners through fuel air\ndampers is less than the amount required to completely burn the fuel. During\nthis stage, fuel bound Nitrogen is released but cannot be oxidized due to\ndeficient Oxygen, so it forms stable molecules of harmless molecular Nitrogen\n(N2). Other components of the fuel are also released without being fully\noxidized. By adding a second stage combustion through auxiliary air dampers\nthe flame temperature doesn\u2019t increase up to level where NOx be generated.\nb) Over Fire Combustion Process to Control NOx\nThe over fire air is used at the top of the flame because the temperature is very\nhigh at the top of the flame and here is the possibility of thermal NOx formation.\nThe over fire air passes through the nozzle type dampers and its velocity is high\nwhich is sufficient for reducing the temperature of the flame at the top. This\nreduction in temperature in NOx formation zone controls the excess NOx\nformation.\nc) GRF Re-circulation Process to Control NOx\nBasically, the flue gas re-circulation is used to control the re-heat outlet steam\ntemperature in the boiler. But at the same time it is used to control the NOx.\nd) Burner Tilting Process to Control the NOx\nBasically, burner tilting causes to lift the flame up wards and increases the re-\nheat outlet steam temperature. It is also used to control the NOx. By lifting the\nflame up wards the greater portion of the fireball comes in front of the nozzle\ntype over fire air dampers. Hence, the temperature of the flame goes down\nimmediately due to the turbulence and hence NOx formation is controlled.\ne) Corner Firing Process to Control the NOx\nBasically, the corner firing system is used to form one continuous flame and it\ncauses the equal distributed heat transfer throughout the furnace. In this flame\nthe temperatures are very high at top and the ultra violet rays are also present\nat this stage, here the over fire dampers are provided to control the NOx by\ncausing reduction in temperatures through creating turbulence.Lalpir/Pakgen Power Plant 12\nCCR Qualification Book\n10. Define SO and how it can be controlled?\n2\nLalpir and Pakgen units are High Sulphur Heavy Fuel Oil (HSFO) Fired Power\nPlants. The range of Sulphur present in HSFO may vary between 2.5 to 3.5 %.\nDuring combustion of HSFO, Sulphur which is present in the fuel is oxidizes to\nsulfur dioxide (SO2).\n(To be in compliance with environmental regulations of World Bank regarding\nSOx (for Pak Gen), a provision has been made for the Sulphur dioxide removal\nplant (FGD).\nThis plant has been designed to reduce SO2 emission to 90 %).\n11. Define particulate matter and Fugitive emission, also describe their\ncontrol?\nThe particulate matter is formed due to inefficient combustion control in the\nfurnace and high level of ash contents in High Sulphur Furnace Oil (HSFO). To\nbe always in compliance with environmental requirements Lalpir and Pakgen\nunits are using Less than 0.03% of ash content in the HSFO.\nLalpir and Pak Gen units have a very precise and optimized combustion control\nprocess with very low Carbon monoxide emission rate.\nFugitive emissions may be expected from the fuel oil storage tanks or through\ndistributed piping. Petroleum hydrocarbons vapors may be released into the\natmosphere due to vapor pressure of the fuel at ambient temperature.\nAt Lalpir the fugitive emissions are minimized by providing cone roofs to the\nstorage tanks. Fugitive emissions from distributed piping are controlled by\nsealed system, proper maintenance and leakage monitoring.\n1\n\n1. Workplace Hazard Identification\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_020" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 1, + "chunk_content": "2. Define safety & environmental management system in light of ISO\n14001 & 45001? Also give an overview of QMS & EMS?\nISO 14001 covers the implementation of an Environmental Management\nSystem (EMS), placing focus on an organisation\u2019s impact on the external\nenvironment. The standard aims to reduce an organisation\u2019s waste, pollution\nand energy consumption.\nISO 45001 on the other hand, focuses on an organisation\u2019s internal\nenvironment. Whilst ISO 14001 requires the implementation of an EMS, ISO\n45001 is based on an OHSMS (Occupational Health and Safety Management\nSystem).\nThe standard aims to reduce workplace injuries and illnesses and provide a\nframework for managing health and safety responsibilities.\nGetting certified in ISO 14001 displays a commitment to the environment, while\nISO 45001 shows a commitment to your employees\nQMS is a Quality Management System also known as ISO ", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_021" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 2, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_022" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 3, + "chunk_content": "3. Define environmental Aspects and Impacts? Write down the factors to\nbe considered while determining the environmental Aspects and\nImpacts?\nThe elements of organization\u2019s activities or services that can interact with the\nenvironment are called environmental aspects.\n\u2022 Air emission\n\u2022 Liquid hazardous waste\n\u2022 Noise\n\u2022 Transportation of material\nEnvironmental Impacts:\nAny change to the environment, whether adverse or beneficial Resulting from\nthe company's activities, products and services\n\u2022 Increase in ambient, CO, SOx, NOx etc.\n\u2022 Ground water contamination\n\u2022 Deterioration of hearing capability\n\u2022 Spillage & leakage of hazardous waste\n\n\n3. What are EIA and EIS? Why are these necessary?\nEIA\nEnvironmental Impact Assessment (EIA) is the term applied to the systematic\nexamination of the likely impacts of development proposals on the environment\nprior to the beginning of any activity.\nUNEP defines Environmental Impact Assessment (EIA) as a tool used to\nidentify the environmental, social and economic impacts of a project prior to\ndecision-making. It aims to predict environmental impacts at an early stage in\nproject planning and design, find ways and means to reduce adverse impacts,\nshape projects to suit the local environment and present the predictions and\noptions to decision-makers. By using EIA both environmental and economic\nbenefits can be achieved, such as reduced cost and time of project\nimplementation and design, avoided treatment/clean-up costs and impacts of\nlaws and regulations.\nEIS\nThose proposing to undertake certain projects had to show that their projects\nwere not going to significantly affect the environment. They had to produce what\nis called an Environmental Impact Statement (EIS) to show the nature and scale\nof their project, the affected environment, and the likely impacts and measures\ntaken to reduce/monitor these impacts.\nA description of the likely significant effect, direct and indirect, on the\nenvironment of the development, explained by relevance to its possible impact\non:\n\u2022 Human beings\n\u2022 Flora\n\u2022 Fauna\n\u2022 Soil\n\u2022 Water\n\u2022 Air\n\u2022 Climate\n\u2022 The landscape\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_023" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 4, + "chunk_content": "4. What are the requirements of EPA permits? List down the\nenvironmental limits for effluents and stack emissions?\nParameters Limits and units\nEffluent Flow (M3/hr)\nPH 6-9\nTemperature: 40 oC\nTemperature rise =< 3 oC\nTSS 200 mg/l\nOil & Greases 10 mg/l\nGaseous Emission Monitoring\nEmissions Emission Standards and Units\nCarbon monoxide 800 mg/Nm3\nOxide of Nitrogen (NOx) 600 mg/Nm3\nSulphur Oxide (SOx) 1700 mg/Nm3 x mg/Nm3\nParticulate Matter 300 mg/Nm3\n\n\n4. Write down important environmental parameters those need to be\nconsidered before issuing modification?\nImportant Environmental parameters are as follows;\n\u2022 Emission Control\n\u2022 Effluent Treatment/Control\n\u2022 Noise Management Program\n\u2022 Areas Aspects and their operational controls\n\u2022 Spillage Control\n\u2022 Hazards associated with EnvironmentLalpir/Pakgen Power Plant 14\nCCR Qualification Book\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_024" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 5, + "chunk_content": "5. List down the priority parameters those need to be reported to EPA\nfor effluents and stack emissions?\nEffluents parameters are; pH, TSS and Oil & Greases\nStack Emission Parameters are: CO, NOx, Sox and Particulate matter\n\n\n5. What is Waste Management? Write down the benefits of waste\nmanagement? What control Lalpir has on waste?\nLalpir Power Ltd has a documented waste management procedure defining the\ntypes of waste along with the responsibilities for collection and disposal. Our\nwaste disposal program briefly given below,\nWaste Type Storage Handling / Plan\nRed dust Transferred to Scrap yard at designated place\nPaper\nbin and then to outside.\nGeneral solid Green dust Transferred to Scrap yard at designated place\nwaste bin and then to outside.\nMetallic Green dust Transferred to Scrap yard at designated place\nWaste bin and then to outside.\nOily Cotton Yellow dust\nTransferred to Scrap yard at designated place.\nrags bin\nDrain the container in HFO pump house oil pit\nUsed Oil In container\nand then transfer it to HFO tank.\nSoot Drums Transferred in open yard and stored.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_025" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 6, + "chunk_content": "6. What are the environmental targets and objectives of Lalpir?\nSafety and environmental targets and objectives of AES Lalpir thermal power\nstation are as follows;\n\u2022 To be always in compliance with all applicable laws and regulations\n\u2022 To work for continuous improvement of environmental management\nsystem\n\u2022 To prevent environmental excursions/threats\n\u2022 Identifying environmental Aspects and impacts\n\u2022 Improving environmental efficiencyLalpir/Pakgen Power Plant 11\nCCR Qualification Book\n\n\n6. Discuss the tag out lockout procedure; prepare a tag out order from\nbeginning to completion.\nLOTO Procedure\nPre-Requisites\nTag out Request/ Application/Request for an Isolation Guarantee\nPreparation of a Switching Order and Preparation for Shutdown\nSwitching Order Verification\nPreparing for Equipment Shutdown\nEquipment Shutdown\nApplication Steps\nStep # 1 \u2013 Equipment & Job Description\nStep # 2 \u2013 Tags description\nStep # 3 - Isolation (Application of Tags)\nStep # 4 - Verifications\nStep # 5 - CRE Approval and Authorization to work\nStep # 6 - Craft Acceptance / Release\nStep # 7 - Completion\nStep # 8 - Equipment restored for operational use:\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_026" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 7, + "chunk_content": "7. Write down On Line monitoring system for stack emission and\neffluents?\nFollowing on line systems are present to monitor the effluents and the emissions\nof industrial gases:\nCEMS (Continuous Emission Monitoring System) to monitor the parameters of\nstack emissions.\nOn line monitoring system to check the chemistry of effluents.\n\n\n7. What is TTR, when it required, how you will proceed when some\nrequest a TTR?\nTTR is temporary tag out release. It is required when a tagout is accepted by\ntwo or more than two craft person and one craft person has completed his job or\na part of job and it requires partial restoration of equipment to check the job\nprogress or equipment status.\nTTR will be requested by any one or more than one craft person.\nAll craft person has to release the tagout , remove their locks,\nReleased tagout tags will be placed in lock box\nCRE/Shift Manager will start the procedure for TTR as per safety form\nPerson who has requested the TTR, will accept the TTR\nAfter the job completion , TTR will be released by the craft person\nTags will be re-applied and verified by area engineer\nCraft person(s) will re-accept the tag\nCRE/Shift Manager will re-authorize the tagoutLalpir/Pakgen Power Plant 15\nCCR Qualification Book\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_027" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 8, + "chunk_content": "8. List down the operational controls on environment taken by Lalpir?\nThe Operational Controls taken by LalPir are as follows;\n\u2022 NOx Emission Control\n\u2022 Fugitive Emission Control:\n\u2022 Effluent Treatment\n\u2022 Noise Management Program:\n\u2022 SO2 Emission Control\n\n\n8. Describe how to issue a hot work permit?\nA Hot Work Permit is required when any work that produces a spark or flame\nthat may cause ignition of flammable substances in the vicinity of that activity.\na) Welding and allied processes\nb) Heat treating\nc) Grinding\nd) Thawing pipes\ne) Hot riveting\nf) Similar applications producing a spark, flame, or heat\nFollowing steps are taken before issuing a hot work permit\nA. Physical Inspection by area engineer\nB. Environment Testing and logging\nC. Fire Watch availability\nD. Fire extinguisher availability\nE. Craft AcceptanceLalpir/Pakgen Power Plant 16\nCCR Qualification Book\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_028" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 9, + "chunk_content": "9. Define the types of NO and describe NO control in Lalpir?\nx x\na) Two-Stage Combustion Process to Control NOx\nThe two Staged combustion processes significantly reduce NOx emissions. In\nthe initial stage of combustion, the air supplied to the burners through fuel air\ndampers is less than the amount required to completely burn the fuel. During\nthis stage, fuel bound Nitrogen is released but cannot be oxidized due to\ndeficient Oxygen, so it forms stable molecules of harmless molecular Nitrogen\n(N2). Other components of the fuel are also released without being fully\noxidized. By adding a second stage combustion through auxiliary air dampers\nthe flame temperature doesn\u2019t increase up to level where NOx be generated.\nb) Over Fire Combustion Process to Control NOx\nThe over fire air is used at the top of the flame because the temperature is very\nhigh at the top of the flame and here is the possibility of thermal NOx formation.\nThe over fire air passes through the nozzle type dampers and its velocity is high\nwhich is sufficient for reducing the temperature of the flame at the top. This\nreduction in temperature in NOx formation zone controls the excess NOx\nformation.\nc) GRF Re-circulation Process to Control NOx\nBasically, the flue gas re-circulation is used to control the re-heat outlet steam\ntemperature in the boiler. But at the same time it is used to control the NOx.\nd) Burner Tilting Process to Control the NOx\nBasically, burner tilting causes to lift the flame up wards and increases the re-\nheat outlet steam temperature. It is also used to control the NOx. By lifting the\nflame up wards the greater portion of the fireball comes in front of the nozzle\ntype over fire air dampers. Hence, the temperature of the flame goes down\nimmediately due to the turbulence and hence NOx formation is controlled.\ne) Corner Firing Process to Control the NOx\nBasically, the corner firing system is used to form one continuous flame and it\ncauses the equal distributed heat transfer throughout the furnace. In this flame\nthe temperatures are very high at top and the ultra violet rays are also present\nat this stage, here the over fire dampers are provided to control the NOx by\ncausing reduction in temperatures through creating turbulence.Lalpir/Pakgen Power Plant 12\nCCR Qualification Book\n\n\n9. Discuss the confined space entry procedure, prepare a confined\nspace entry?\nSteps for Preparation for Confined Space Entry are as follows\n\u2022 Confined Space Isolation through tagout\n\u2022 Ventilation of Confined Space\n\u2022 Protection of Confined Space: Appropriate barriers, boundaries and\nsigns to be established surrounding Entry Points and other openings of\nConfined Spaces to prevent unauthorized persons from Entering the\nConfined Space\n\u2022 Communication with Entrants: Equipping entrants with communication\ndevice (Radio). At least one Entrant must, at all times, have a radio in\nplant critical confined spaces\n\u2022 Atmospheric Testing: Using certified and in working condition gas\ndetector, Tester will test the atmosphere of Confined space for the\npresence of any toxic gases.Following conditions must be met before\ngiving entry permission for confined space\nOxygen content: The oxygen concentration level shall be\no\nmonitored continuously and shall be in the 19.5% to 23.5%\nrange\nFlammable gases or vapors: Concentrations shall not exceed\no\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_029" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 10, + "chunk_content": "10. Define SO and how it can be controlled?\n2\nLalpir and Pakgen units are High Sulphur Heavy Fuel Oil (HSFO) Fired Power\nPlants. The range of Sulphur present in HSFO may vary between 2.5 to 3.5 %.\nDuring combustion of HSFO, Sulphur which is present in the fuel is oxidizes to\nsulfur dioxide (SO2).\n(To be in compliance with environmental regulations of World Bank regarding\nSOx (for Pak Gen), a provision has been made for the Sulphur dioxide removal\nplant (FGD).\nThis plant has been designed to reduce SO2 emission to 90 %).\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0210" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 11, + "chunk_content": "11. Define particulate matter and Fugitive emission, also describe their\ncontrol?\nThe particulate matter is formed due to inefficient combustion control in the\nfurnace and high level of ash contents in High Sulphur Furnace Oil (HSFO). To\nbe always in compliance with environmental requirements Lalpir and Pakgen\nunits are using Less than 0.03% of ash content in the HSFO.\nLalpir and Pak Gen units have a very precise and optimized combustion control\nprocess with very low Carbon monoxide emission rate.\nFugitive emissions may be expected from the fuel oil storage tanks or through\ndistributed piping. Petroleum hydrocarbons vapors may be released into the\natmosphere due to vapor pressure of the fuel at ambient temperature.\nAt Lalpir the fugitive emissions are minimized by providing cone roofs to the\nstorage tanks. Fugitive emissions from distributed piping are controlled by\nsealed system, proper maintenance and leakage monitoring.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0211" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 12, + "chunk_content": "12. What is the purpose of constructing high stack chimney?\nThe purpose of high stack is to provide the draft to flue gases for emission into\natmosphere. At that point flue gases would mix easily in air.Lalpir/Pakgen Power Plant 13\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0212" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 13, + "chunk_content": "13. What are EIA and EIS? Why are these necessary?\nEIA\nEnvironmental Impact Assessment (EIA) is the term applied to the systematic\nexamination of the likely impacts of development proposals on the environment\nprior to the beginning of any activity.\nUNEP defines Environmental Impact Assessment (EIA) as a tool used to\nidentify the environmental, social and economic impacts of a project prior to\ndecision-making. It aims to predict environmental impacts at an early stage in\nproject planning and design, find ways and means to reduce adverse impacts,\nshape projects to suit the local environment and present the predictions and\noptions to decision-makers. By using EIA both environmental and economic\nbenefits can be achieved, such as reduced cost and time of project\nimplementation and design, avoided treatment/clean-up costs and impacts of\nlaws and regulations.\nEIS\nThose proposing to undertake certain projects had to show that their projects\nwere not going to significantly affect the environment. They had to produce what\nis called an Environmental Impact Statement (EIS) to show the nature and scale\nof their project, the affected environment, and the likely impacts and measures\ntaken to reduce/monitor these impacts.\nA description of the likely significant effect, direct and indirect, on the\nenvironment of the development, explained by relevance to its possible impact\non:\n\u2022 Human beings\n\u2022 Flora\n\u2022 Fauna\n\u2022 Soil\n\u2022 Water\n\u2022 Air\n\u2022 Climate\n\u2022 The landscape\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0213" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 14, + "chunk_content": "14. Write down important environmental parameters those need to be\nconsidered before issuing modification?\nImportant Environmental parameters are as follows;\n\u2022 Emission Control\n\u2022 Effluent Treatment/Control\n\u2022 Noise Management Program\n\u2022 Areas Aspects and their operational controls\n\u2022 Spillage Control\n\u2022 Hazards associated with EnvironmentLalpir/Pakgen Power Plant 14\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0214" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 15, + "chunk_content": "15. What is Waste Management? Write down the benefits of waste\nmanagement? What control Lalpir has on waste?\nLalpir Power Ltd has a documented waste management procedure defining the\ntypes of waste along with the responsibilities for collection and disposal. Our\nwaste disposal program briefly given below,\nWaste Type Storage Handling / Plan\nRed dust Transferred to Scrap yard at designated place\nPaper\nbin and then to outside.\nGeneral solid Green dust Transferred to Scrap yard at designated place\nwaste bin and then to outside.\nMetallic Green dust Transferred to Scrap yard at designated place\nWaste bin and then to outside.\nOily Cotton Yellow dust\nTransferred to Scrap yard at designated place.\nrags bin\nDrain the container in HFO pump house oil pit\nUsed Oil In container\nand then transfer it to HFO tank.\nSoot Drums Transferred in open yard and stored.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0215" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 16, + "chunk_content": "16. Discuss the tag out lockout procedure; prepare a tag out order from\nbeginning to completion.\nLOTO Procedure\nPre-Requisites\nTag out Request/ Application/Request for an Isolation Guarantee\nPreparation of a Switching Order and Preparation for Shutdown\nSwitching Order Verification\nPreparing for Equipment Shutdown\nEquipment Shutdown\nApplication Steps\nStep # 1 \u2013 Equipment & Job Description\nStep # 2 \u2013 Tags description\nStep # 3 - Isolation (Application of Tags)\nStep # 4 - Verifications\nStep # 5 - CRE Approval and Authorization to work\nStep # 6 - Craft Acceptance / Release\nStep # 7 - Completion\nStep # 8 - Equipment restored for operational use:\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0216" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 17, + "chunk_content": "17. What is TTR, when it required, how you will proceed when some\nrequest a TTR?\nTTR is temporary tag out release. It is required when a tagout is accepted by\ntwo or more than two craft person and one craft person has completed his job or\na part of job and it requires partial restoration of equipment to check the job\nprogress or equipment status.\nTTR will be requested by any one or more than one craft person.\nAll craft person has to release the tagout , remove their locks,\nReleased tagout tags will be placed in lock box\nCRE/Shift Manager will start the procedure for TTR as per safety form\nPerson who has requested the TTR, will accept the TTR\nAfter the job completion , TTR will be released by the craft person\nTags will be re-applied and verified by area engineer\nCraft person(s) will re-accept the tag\nCRE/Shift Manager will re-authorize the tagoutLalpir/Pakgen Power Plant 15\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0217" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 18, + "chunk_content": "18. Describe how to issue a hot work permit?\nA Hot Work Permit is required when any work that produces a spark or flame\nthat may cause ignition of flammable substances in the vicinity of that activity.\na) Welding and allied processes\nb) Heat treating\nc) Grinding\nd) Thawing pipes\ne) Hot riveting\nf) Similar applications producing a spark, flame, or heat\nFollowing steps are taken before issuing a hot work permit\nA. Physical Inspection by area engineer\nB. Environment Testing and logging\nC. Fire Watch availability\nD. Fire extinguisher availability\nE. Craft AcceptanceLalpir/Pakgen Power Plant 16\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0218" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 19, + "chunk_content": "19. Discuss the confined space entry procedure, prepare a confined\nspace entry?\nSteps for Preparation for Confined Space Entry are as follows\n\u2022 Confined Space Isolation through tagout\n\u2022 Ventilation of Confined Space\n\u2022 Protection of Confined Space: Appropriate barriers, boundaries and\nsigns to be established surrounding Entry Points and other openings of\nConfined Spaces to prevent unauthorized persons from Entering the\nConfined Space\n\u2022 Communication with Entrants: Equipping entrants with communication\ndevice (Radio). At least one Entrant must, at all times, have a radio in\nplant critical confined spaces\n\u2022 Atmospheric Testing: Using certified and in working condition gas\ndetector, Tester will test the atmosphere of Confined space for the\npresence of any toxic gases.Following conditions must be met before\ngiving entry permission for confined space\nOxygen content: The oxygen concentration level shall be\no\nmonitored continuously and shall be in the 19.5% to 23.5%\nrange\nFlammable gases or vapors: Concentrations shall not exceed\no\n10% of the LEL. If the area\u2019s oxygen level is not in the range\ngiven above, check that the Gas Detector is functioning\nproperly.\nChlorine Content: The chlorine concentration level shall be\no\nmonitored and shall be less than 0.5ppm.\nCO Content: The CO (Carbon Monoxide) concentration level\no\nshall be monitored and be less than 2ppm.\n\u2022 Heat: The Tester shall also sense the temperature inside the Permit\nRequired Confined Space where deem necessary. Although the limit is\nwhat ever is bearable for the Entrant, an indication of the temperature\ninside will give the Entrant guidance as to the duration that he will feel\ncomfortable inside the Confined Space.\n\u2022 Dust: Airborne Combustible dust: Dust levels must not exceed its LEL.\n.\nAfter the completion of above steps, Confined Space Entry Permit shall be\nissued by entering following information in the form.\n\u2022 Name of permit space to be entered,\n\u2022 Name of requester / craft person\n\u2022 Atmospheric Test results\n\u2022 Tester's initials or signature\n\u2022 Purpose of entry and known space hazards\n\u2022 The minimum environmental conditions which are acceptable for entry\nand working in the space\n\u2022 Measures to be taken to isolate permit spaces and to eliminate or\ncontrol space hazards\n\u2022 Date and authorized duration of entry\n\u2022 Communication equipment to maintain contact during entry\n\u2022 Any personal protective equipment that is necessary for the entry or\nrescue of the workers in the confined space.\n\u2022 If hot work will be necessary in the space, it must be authorized on the\nEntry Permit or a separate Hot Work permit must be attached to the\nentry permit. In this case, the issuance of the Hot Work permit is then\nnoted on the entry permit itself.\n\u2022 Any other information needed to ensure employee safety.\n\u2022 A means for assuring and certifying that all pre-entry requirements have\nbeen met.Lalpir/Pakgen Power Plant 17\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0219" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 20, + "chunk_content": "20. Define Risk Assessment and hazard categories? Prepare sample risk\nassessment of any hazard? List down risk control measures?\nOverall process comprising a risk analysis (Identification of hazards, estimation\nof risk) and a risk evaluation (evaluating the significance of risk)\nThe hazard identification process involves two main activities:\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0220" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 21, + "chunk_content": "1. Write down the salient features of Lalpir Safety & Environmental\nPolicy?\nSalient features of Lalpir Safety & Environmental Policy are\n\u2022 Comply with or exceed requirements of global, national, state, and local\nstatutes, regulations, and standards protecting the environment, human\nhealth and safety. In the absence of laws and regulations, or where they\nare simply not adequate for our operations, we will apply sound\nOccupational, health and safety (OHS) management practices.\n\u2022 Strive for continual improvement in Environment, health and safety to a\nworld class performance using external bench marking system.\n\u2022 Establish global EHS standards that are robust, scientifically sound, and\nprotective of the environment, human health and safety.\n\u2022 Implement EHS management systems to identify and manage EHS\nrisks, obligations, and opportunities.\n\u2022 Conduct regular audits to verify compliance with regulatory\nrequirements and company standards.\n\u2022 Establish specific EHS metrics to measure and report on our\nperformance.\n\u2022 Incorporate EHS considerations into our business decision-making\nprocesses.\n\u2022 Work to prevent ill health, accidents, injuries, and unsafe work\nconditions; promote energy and water conservation; encourage the\nreuse and recycling of materials; and reduce waste, emissions and the\nuse of hazardous substances in our operations.\n\u2022 Monitor emerging issues and keep abreast of regulatory changes,\ntechnological innovations, and stakeholder interests.\n\u2022 Strive to develop effective and sustainable solutions to EHS challenges\narising from our business activities.\n\u2022 Regularly communicate relevant and meaningful information about our\nEHS performance to our internal and external stakeholders.\n\n\n1.\nEMS is an Environmental Management System also known as ISO 14001Lalpir/Pakgen Power Plant 10\nCCR Qualification Book\n3. Define environmental Aspects and Impacts? Write down the factors to\nbe considered while determining the environmental Aspects and\nImpacts?\nThe elements of organization\u2019s activities or services that can interact with the\nenvironment are called environmental aspects.\n\u2022 Air emission\n\u2022 Liquid hazardous waste\n\u2022 Noise\n\u2022 Transportation of material\nEnvironmental Impacts:\nAny change to the environment, whether adverse or beneficial Resulting from\nthe company's activities, products and services\n\u2022 Increase in ambient, CO, SOx, NOx etc.\n\u2022 Ground water contamination\n\u2022 Deterioration of hearing capability\n\u2022 Spillage & leakage of hazardous waste\n4. What are the requirements of EPA permits? List down the\nenvironmental limits for effluents and stack emissions?\nParameters Limits and units\nEffluent Flow (M3/hr)\nPH 6-9\nTemperature: 40 oC\nTemperature rise =< 3 oC\nTSS 200 mg/l\nOil & Greases 10 mg/l\nGaseous Emission Monitoring\nEmissions Emission Standards and Units\nCarbon monoxide 800 mg/Nm3\nOxide of Nitrogen (NOx) 600 mg/Nm3\nSulphur Oxide (SOx) 1700 mg/Nm3 x mg/Nm3\nParticulate Matter 300 mg/Nm3\n5. List down the priority parameters those need to be reported to EPA\nfor effluents and stack emissions?\nEffluents parameters are; pH, TSS and Oil & Greases\nStack Emission Parameters are: CO, NOx, Sox and Particulate matter\n6. What are the environmental targets and objectives of Lalpir?\nSafety and environmental targets and objectives of AES Lalpir thermal power\nstation are as follows;\n\u2022 To be always in compliance with all applicable laws and regulations\n\u2022 To work for continuous improvement of environmental management\nsystem\n\u2022 To prevent environmental excursions/threats\n\u2022 Identifying environmental Aspects and impacts\n\u2022 Improving environmental efficiencyLalpir/Pakgen Power Plant 11\nCCR Qualification Book\n7. Write down On Line monitoring system for stack emission and\neffluents?\nFollowing on line systems are present to monitor the effluents and the emissions\nof industrial gases:\nCEMS (Continuous Emission Monitoring System) to monitor the parameters of\nstack emissions.\nOn line monitoring system to check the chemistry of effluents.\n8. List down the operational controls on environment taken by Lalpir?\nThe Operational Controls taken by LalPir are as follows;\n\u2022 NOx Emission Control\n\u2022 Fugitive Emission Control:\n\u2022 Effluent Treatment\n\u2022 Noise Management Program:\n\u2022 SO2 Emission Control\n9. Define the types of NO and describe NO control in Lalpir?\nx x\na) Two-Stage Combustion Process to Control NOx\nThe two Staged combustion processes significantly reduce NOx emissions. In\nthe initial stage of combustion, the air supplied to the burners through fuel air\ndampers is less than the amount required to completely burn the fuel. During\nthis stage, fuel bound Nitrogen is released but cannot be oxidized due to\ndeficient Oxygen, so it forms stable molecules of harmless molecular Nitrogen\n(N2). Other components of the fuel are also released without being fully\noxidized. By adding a second stage combustion through auxiliary air dampers\nthe flame temperature doesn\u2019t increase up to level where NOx be generated.\nb) Over Fire Combustion Process to Control NOx\nThe over fire air is used at the top of the flame because the temperature is very\nhigh at the top of the flame and here is the possibility of thermal NOx formation.\nThe over fire air passes through the nozzle type dampers and its velocity is high\nwhich is sufficient for reducing the temperature of the flame at the top. This\nreduction in temperature in NOx formation zone controls the excess NOx\nformation.\nc) GRF Re-circulation Process to Control NOx\nBasically, the flue gas re-circulation is used to control the re-heat outlet steam\ntemperature in the boiler. But at the same time it is used to control the NOx.\nd) Burner Tilting Process to Control the NOx\nBasically, burner tilting causes to lift the flame up wards and increases the re-\nheat outlet steam temperature. It is also used to control the NOx. By lifting the\nflame up wards the greater portion of the fireball comes in front of the nozzle\ntype over fire air dampers. Hence, the temperature of the flame goes down\nimmediately due to the turbulence and hence NOx formation is controlled.\ne) Corner Firing Process to Control the NOx\nBasically, the corner firing system is used to form one continuous flame and it\ncauses the equal distributed heat transfer throughout the furnace. In this flame\nthe temperatures are very high at top and the ultra violet rays are also present\nat this stage, here the over fire dampers are provided to control the NOx by\ncausing reduction in temperatures through creating turbulence.Lalpir/Pakgen Power Plant 12\nCCR Qualification Book\n10. Define SO and how it can be controlled?\n2\nLalpir and Pakgen units are High Sulphur Heavy Fuel Oil (HSFO) Fired Power\nPlants. The range of Sulphur present in HSFO may vary between 2.5 to 3.5 %.\nDuring combustion of HSFO, Sulphur which is present in the fuel is oxidizes to\nsulfur dioxide (SO2).\n(To be in compliance with environmental regulations of World Bank regarding\nSOx (for Pak Gen), a provision has been made for the Sulphur dioxide removal\nplant (FGD).\nThis plant has been designed to reduce SO2 emission to 90 %).\n11. Define particulate matter and Fugitive emission, also describe their\ncontrol?\nThe particulate matter is formed due to inefficient combustion control in the\nfurnace and high level of ash contents in High Sulphur Furnace Oil (HSFO). To\nbe always in compliance with environmental requirements Lalpir and Pakgen\nunits are using Less than 0.03% of ash content in the HSFO.\nLalpir and Pak Gen units have a very precise and optimized combustion control\nprocess with very low Carbon monoxide emission rate.\nFugitive emissions may be expected from the fuel oil storage tanks or through\ndistributed piping. Petroleum hydrocarbons vapors may be released into the\natmosphere due to vapor pressure of the fuel at ambient temperature.\nAt Lalpir the fugitive emissions are minimized by providing cone roofs to the\nstorage tanks. Fugitive emissions from distributed piping are controlled by\nsealed system, proper maintenance and leakage monitoring.\n1\n\n1. Workplace Hazard Identification\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0221" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 22, + "chunk_content": "2. Define safety & environmental management system in light of ISO\n14001 & 45001? Also give an overview of QMS & EMS?\nISO 14001 covers the implementation of an Environmental Management\nSystem (EMS), placing focus on an organisation\u2019s impact on the external\nenvironment. The standard aims to reduce an organisation\u2019s waste, pollution\nand energy consumption.\nISO 45001 on the other hand, focuses on an organisation\u2019s internal\nenvironment. Whilst ISO 14001 requires the implementation of an EMS, ISO\n45001 is based on an OHSMS (Occupational Health and Safety Management\nSystem).\nThe standard aims to reduce workplace injuries and illnesses and provide a\nframework for managing health and safety responsibilities.\nGetting certified in ISO 14001 displays a commitment to the environment, while\nISO 45001 shows a commitment to your employees\nQMS is a Quality Management System also known as ISO 9001.\nEMS is an Environmental Management System also known as ISO 14001Lalpir/Pakgen Power Plant 10\nCCR Qualification Book\n3. Define environmental Aspects and Impacts? Write down the factors to\nbe considered while determining the environmental Aspects and\nImpacts?\nThe elements of organization\u2019s activities or services that can interact with the\nenvironment are called environmental aspects.\n\u2022 Air emission\n\u2022 Liquid hazardous waste\n\u2022 Noise\n\u2022 Transportation of material\nEnvironmental Impacts:\nAny change to the environment, whether adverse or beneficial Resulting from\nthe company's activities, products and services\n\u2022 Increase in ambient, CO, SOx, NOx etc.\n\u2022 Ground water contamination\n\u2022 Deterioration of hearing capability\n\u2022 Spillage & leakage of hazardous waste\n4. What are the requirements of EPA permits? List down the\nenvironmental limits for effluents and stack emissions?\nParameters Limits and units\nEffluent Flow (M3/hr)\nPH 6-9\nTemperature: 40 oC\nTemperature rise =< 3 oC\nTSS 200 mg/l\nOil & Greases 10 mg/l\nGaseous Emission Monitoring\nEmissions Emission Standards and Units\nCarbon monoxide 800 mg/Nm3\nOxide of Nitrogen (NOx) 600 mg/Nm3\nSulphur Oxide (SOx) 1700 mg/Nm3 x mg/Nm3\nParticulate Matter 300 mg/Nm3\n5. List down the priority parameters those need to be reported to EPA\nfor effluents and stack emissions?\nEffluents parameters are; pH, TSS and Oil & Greases\nStack Emission Parameters are: CO, NOx, Sox and Particulate matter\n6. What are the environmental targets and objectives of Lalpir?\nSafety and environmental targets and objectives of AES Lalpir thermal power\nstation are as follows;\n\u2022 To be always in compliance with all applicable laws and regulations\n\u2022 To work for continuous improvement of environmental management\nsystem\n\u2022 To prevent environmental excursions/threats\n\u2022 Identifying environmental Aspects and impacts\n\u2022 Improving environmental efficiencyLalpir/Pakgen Power Plant 11\nCCR Qualification Book\n7. Write down On Line monitoring system for stack emission and\neffluents?\nFollowing on line systems are present to monitor the effluents and the emissions\nof industrial gases:\nCEMS (Continuous Emission Monitoring System) to monitor the parameters of\nstack emissions.\nOn line monitoring system to check the chemistry of effluents.\n8. List down the operational controls on environment taken by Lalpir?\nThe Operational Controls taken by LalPir are as follows;\n\u2022 NOx Emission Control\n\u2022 Fugitive Emission Control:\n\u2022 Effluent Treatment\n\u2022 Noise Management Program:\n\u2022 SO2 Emission Control\n9. Define the types of NO and describe NO control in Lalpir?\nx x\na) Two-Stage Combustion Process to Control NOx\nThe two Staged combustion processes significantly reduce NOx emissions. In\nthe initial stage of combustion, the air supplied to the burners through fuel air\ndampers is less than the amount required to completely burn the fuel. During\nthis stage, fuel bound Nitrogen is released but cannot be oxidized due to\ndeficient Oxygen, so it forms stable molecules of harmless molecular Nitrogen\n(N2). Other components of the fuel are also released without being fully\noxidized. By adding a second stage combustion through auxiliary air dampers\nthe flame temperature doesn\u2019t increase up to level where NOx be generated.\nb) Over Fire Combustion Process to Control NOx\nThe over fire air is used at the top of the flame because the temperature is very\nhigh at the top of the flame and here is the possibility of thermal NOx formation.\nThe over fire air passes through the nozzle type dampers and its velocity is high\nwhich is sufficient for reducing the temperature of the flame at the top. This\nreduction in temperature in NOx formation zone controls the excess NOx\nformation.\nc) GRF Re-circulation Process to Control NOx\nBasically, the flue gas re-circulation is used to control the re-heat outlet steam\ntemperature in the boiler. But at the same time it is used to control the NOx.\nd) Burner Tilting Process to Control the NOx\nBasically, burner tilting causes to lift the flame up wards and increases the re-\nheat outlet steam temperature. It is also used to control the NOx. By lifting the\nflame up wards the greater portion of the fireball comes in front of the nozzle\ntype over fire air dampers. Hence, the temperature of the flame goes down\nimmediately due to the turbulence and hence NOx formation is controlled.\ne) Corner Firing Process to Control the NOx\nBasically, the corner firing system is used to form one continuous flame and it\ncauses the equal distributed heat transfer throughout the furnace. In this flame\nthe temperatures are very high at top and the ultra violet rays are also present\nat this stage, here the over fire dampers are provided to control the NOx by\ncausing reduction in temperatures through creating turbulence.Lalpir/Pakgen Power Plant 12\nCCR Qualification Book\n10. Define SO and how it can be controlled?\n2\nLalpir and Pakgen units are High Sulphur Heavy Fuel Oil (HSFO) Fired Power\nPlants. The range of Sulphur present in HSFO may vary between 2.5 to 3.5 %.\nDuring combustion of HSFO, Sulphur which is present in the fuel is oxidizes to\nsulfur dioxide (SO2).\n(To be in compliance with environmental regulations of World Bank regarding\nSOx (for Pak Gen), a provision has been made for the Sulphur dioxide removal\nplant (FGD).\nThis plant has been designed to reduce SO2 emission to 90 %).\n11. Define particulate matter and Fugitive emission, also describe their\ncontrol?\nThe particulate matter is formed due to inefficient combustion control in the\nfurnace and high level of ash contents in High Sulphur Furnace Oil (HSFO). To\nbe always in compliance with environmental requirements Lalpir and Pakgen\nunits are using Less than 0.03% of ash content in the HSFO.\nLalpir and Pak Gen units have a very precise and optimized combustion control\nprocess with very low Carbon monoxide emission rate.\nFugitive emissions may be expected from the fuel oil storage tanks or through\ndistributed piping. Petroleum hydrocarbons vapors may be released into the\natmosphere due to vapor pressure of the fuel at ambient temperature.\nAt Lalpir the fugitive emissions are minimized by providing cone roofs to the\nstorage tanks. Fugitive emissions from distributed piping are controlled by\nsealed system, proper maintenance and leakage monitoring.\n12. What is the purpose of constructing high stack chimney?\nThe purpose of high stack is to provide the draft to flue gases for emission into\natmosphere. At that point flue gases would mix easily in air.Lalpir/Pakgen Power Plant 13\nCCR Qualification Book\n13. What are EIA and EIS? Why are these necessary?\nEIA\nEnvironmental Impact Assessment (EIA) is the term applied to the systematic\nexamination of the likely impacts of development proposals on the environment\nprior to the beginning of any activity.\nUNEP defines Environmental Impact Assessment (EIA) as a tool used to\nidentify the environmental, social and economic impacts of a project prior to\ndecision-making. It aims to predict environmental impacts at an early stage in\nproject planning and design, find ways and means to reduce adverse impacts,\nshape projects to suit the local environment and present the predictions and\noptions to decision-makers. By using EIA both environmental and economic\nbenefits can be achieved, such as reduced cost and time of project\nimplementation and design, avoided treatment/clean-up costs and impacts of\nlaws and regulations.\nEIS\nThose proposing to undertake certain projects had to show that their projects\nwere not going to significantly affect the environment. They had to produce what\nis called an Environmental Impact Statement (EIS) to show the nature and scale\nof their project, the affected environment, and the likely impacts and measures\ntaken to reduce/monitor these impacts.\nA description of the likely significant effect, direct and indirect, on the\nenvironment of the development, explained by relevance to its possible impact\non:\n\u2022 Human beings\n\u2022 Flora\n\u2022 Fauna\n\u2022 Soil\n\u2022 Water\n\u2022 Air\n\u2022 Climate\n\u2022 The landscape\n14. Write down important environmental parameters those need to be\nconsidered before issuing modification?\nImportant Environmental parameters are as follows;\n\u2022 Emission Control\n\u2022 Effluent Treatment/Control\n\u2022 Noise Management Program\n\u2022 Areas Aspects and their operational controls\n\u2022 Spillage Control\n\u2022 Hazards associated with EnvironmentLalpir/Pakgen Power Plant 14\nCCR Qualification Book\n15. What is Waste Management? Write down the benefits of waste\nmanagement? What control Lalpir has on waste?\nLalpir Power Ltd has a documented waste management procedure defining the\ntypes of waste along with the responsibilities for collection and disposal. Our\nwaste disposal program briefly given below,\nWaste Type Storage Handling / Plan\nRed dust Transferred to Scrap yard at designated place\nPaper\nbin and then to outside.\nGeneral solid Green dust Transferred to Scrap yard at designated place\nwaste bin and then to outside.\nMetallic Green dust Transferred to Scrap yard at designated place\nWaste bin and then to outside.\nOily Cotton Yellow dust\nTransferred to Scrap yard at designated place.\nrags bin\nDrain the container in HFO pump house oil pit\nUsed Oil In container\nand then transfer it to HFO tank.\nSoot Drums Transferred in open yard and stored.\n16. Discuss the tag out lockout procedure; prepare a tag out order from\nbeginning to completion.\nLOTO Procedure\nPre-Requisites\nTag out Request/ Application/Request for an Isolation Guarantee\nPreparation of a Switching Order and Preparation for Shutdown\nSwitching Order Verification\nPreparing for Equipment Shutdown\nEquipment Shutdown\nApplication Steps\nStep # 1 \u2013 Equipment & Job Description\nStep # 2 \u2013 Tags description\nStep # 3 - Isolation (Application of Tags)\nStep # 4 - Verifications\nStep # 5 - CRE Approval and Authorization to work\nStep # 6 - Craft Acceptance / Release\nStep # 7 - Completion\nStep # 8 - Equipment restored for operational use:\n17. What is TTR, when it required, how you will proceed when some\nrequest a TTR?\nTTR is temporary tag out release. It is required when a tagout is accepted by\ntwo or more than two craft person and one craft person has completed his job or\na part of job and it requires partial restoration of equipment to check the job\nprogress or equipment status.\nTTR will be requested by any one or more than one craft person.\nAll craft person has to release the tagout , remove their locks,\nReleased tagout tags will be placed in lock box\nCRE/Shift Manager will start the procedure for TTR as per safety form\nPerson who has requested the TTR, will accept the TTR\nAfter the job completion , TTR will be released by the craft person\nTags will be re-applied and verified by area engineer\nCraft person(s) will re-accept the tag\nCRE/Shift Manager will re-authorize the tagoutLalpir/Pakgen Power Plant 15\nCCR Qualification Book\n18. Describe how to issue a hot work permit?\nA Hot Work Permit is required when any work that produces a spark or flame\nthat may cause ignition of flammable substances in the vicinity of that activity.\na) Welding and allied processes\nb) Heat treating\nc) Grinding\nd) Thawing pipes\ne) Hot riveting\nf) Similar applications producing a spark, flame, or heat\nFollowing steps are taken before issuing a hot work permit\nA. Physical Inspection by area engineer\nB. Environment Testing and logging\nC. Fire Watch availability\nD. Fire extinguisher availability\nE. Craft AcceptanceLalpir/Pakgen Power Plant 16\nCCR Qualification Book\n19. Discuss the confined space entry procedure, prepare a confined\nspace entry?\nSteps for Preparation for Confined Space Entry are as follows\n\u2022 Confined Space Isolation through tagout\n\u2022 Ventilation of Confined Space\n\u2022 Protection of Confined Space: Appropriate barriers, boundaries and\nsigns to be established surrounding Entry Points and other openings of\nConfined Spaces to prevent unauthorized persons from Entering the\nConfined Space\n\u2022 Communication with Entrants: Equipping entrants with communication\ndevice (Radio). At least one Entrant must, at all times, have a radio in\nplant critical confined spaces\n\u2022 Atmospheric Testing: Using certified and in working condition gas\ndetector, Tester will test the atmosphere of Confined space for the\npresence of any toxic gases.Following conditions must be met before\ngiving entry permission for confined space\nOxygen content: The oxygen concentration level shall be\no\nmonitored continuously and shall be in the 19.5% to 23.5%\nrange\nFlammable gases or vapors: Concentrations shall not exceed\no\n10% of the LEL. If the area\u2019s oxygen level is not in the range\ngiven above, check that the Gas Detector is functioning\nproperly.\nChlorine Content: The chlorine concentration level shall be\no\nmonitored and shall be less than 0.5ppm.\nCO Content: The CO (Carbon Monoxide) concentration level\no\nshall be monitored and be less than 2ppm.\n\u2022 Heat: The Tester shall also sense the temperature inside the Permit\nRequired Confined Space where deem necessary. Although the limit is\nwhat ever is bearable for the Entrant, an indication of the temperature\ninside will give the Entrant guidance as to the duration that he will feel\ncomfortable inside the Confined Space.\n\u2022 Dust: Airborne Combustible dust: Dust levels must not exceed its LEL.\n.\nAfter the completion of above steps, Confined Space Entry Permit shall be\nissued by entering following information in the form.\n\u2022 Name of permit space to be entered,\n\u2022 Name of requester / craft person\n\u2022 Atmospheric Test results\n\u2022 Tester's initials or signature\n\u2022 Purpose of entry and known space hazards\n\u2022 The minimum environmental conditions which are acceptable for entry\nand working in the space\n\u2022 Measures to be taken to isolate permit spaces and to eliminate or\ncontrol space hazards\n\u2022 Date and authorized duration of entry\n\u2022 Communication equipment to maintain contact during entry\n\u2022 Any personal protective equipment that is necessary for the entry or\nrescue of the workers in the confined space.\n\u2022 If hot work will be necessary in the space, it must be authorized on the\nEntry Permit or a separate Hot Work permit must be attached to the\nentry permit. In this case, the issuance of the Hot Work permit is then\nnoted on the entry permit itself.\n\u2022 Any other information needed to ensure employee safety.\n\u2022 A means for assuring and certifying that all pre-entry requirements have\nbeen met.Lalpir/Pakgen Power Plant 17\nCCR Qualification Book\n20. Define Risk Assessment and hazard categories? Prepare sample risk\nassessment of any hazard? List down risk control measures?\nOverall process comprising a risk analysis (Identification of hazards, estimation\nof risk) and a risk evaluation (evaluating the significance of risk)\nThe hazard identification process involves two main activities:\n1. Workplace Hazard Identification\n2. Job Hazard Analysis\nAfter approval of risk control measures, the concerned Area Team Leader shall\nbe responsible for implementing the Risk Control measures. The Safety\nCommittee shall monitor and follow-up the implementation of risk control\nmeasures and evaluate whether the risk control measures are effective to\neliminate or reduce the risks. In case the control measures are found ineffective,\nnew control measures shall be identified or recommended, which will be\nreviewed and then approved for implementation.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0222" + }, + { + "chapter_numbre": "Chapter_2", + "chapter_name": "Chapter 02", + "chunk_index": 23, + "chunk_content": "21. What is the difference between TTR and IRF?\nTemporary Tag Out Release (TTR)\nThere may be occasions when testing, positioning, making adjustments or to\nperform other work on an isolated equipment or system, a TTR procedure is\nnecessary. It should be remembered that the TTR should only be used for the\napproved work.\nOnly one Craft Person or Craft Group Leader shall accept a TTR at a time. Any\nother Craft Person or Craft Group Leader can only accept a TTR once the TTR\nhas been released by the previous Craft Person or Craft Group Leader. The\nonly exception to this is during a craft shift change when the arriving Craft\nPerson or Craft Group Leader will accept the TTR before the leaving Craft\nPerson or Craft Group Leader Releases the TTR.\nIRF (Item Release Form)\nThe IRF can be issued by the CRE who will be responsible to ensure the safety\nof the relevant Lockout Tag out Order.\nIn case of a block permit, when many jobs are in progress under one Tag out\nOrder, where change in any one or more Isolation point\u2019s position is required,\nIRF may be requested.\nThe portable earth / ground wires shall be removed before issuance of IRF\nwhere applicable.\nThe Area Team leader will review the risk assessment and approves issuance\nof IRF.\nCraft People will signs off in release column of IRF in verification of the fact\nthat work has been suspended on that particular equipment and portable earth /\nground wires has been removed where applicable.\nAfter the change of Isolation, job will be performed and IRF will be completed.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0223" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 0, + "chunk_content": "1. Briefly describe the main architecture of DCS.\nDCS has following sub systems.\nAPC \u2013 Automatic Plant Control\nBMS \u2013 Burner Management System\nDEH \u2013 Digital electro Hydraulic\nSEQ1\u2013 Sequence 1\nSEQ2 \u2013 Sequence 2\nIPU\u2013 Input Output Unit\nEach system has two CPU\u2019s. One remains in service and 2nd is standby.\nIn addition to these, Accessories control stations are also provided for logging\nevents and reports.\nThough, initially DCS had separate printer for Report, Event and Alarm, but now\nsystem is modified and one printer is used for every print function.\n\n\n1. What are the sources of power supply for OPS, how you can change\nthe power from UPS to 110V AC emergency services?\nThere are two sources of power supply.\na. UPS AC 110 volt.\nb. Emergency MCC 110 volt.\nc. Tie in b/w unit-1 and unit-2 only for OPS 3&4.\nWhen it is required to change over the power supply from UPS to Emergency\nMCC or UPS, switch is having three following positions.\na) UPS\nb) Off\nc) 110 volt\nSelect from one power supply to other power supply. (This operation is\npreferred to perform in the presence of E&I personal)\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_030" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 1, + "chunk_content": "2. Identify the functions of various keys on the keyboard?\n\n\n2. What is the function of interlock?\nInterlock means operating protection of equipment or system, when Interlock is\n\"IN\" interlock is effective. If system does not meet the interlock requirement, it\nwill not let the interlock activate.\nWhen Interlock is \"OUT\" interlock is not effective. When some system error\nappears, system is capable to go to manual and it can be cared manually.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_031" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 2, + "chunk_content": "3. Discuss the alarm list and event tracing?\nIn alarm summary all the alarms are summarized in sequence. 20 alarms can\nbe displayed in one screen and 200 alarm massages can be displayed as the\nmaximum.\nAlarm Summary page has 6 columns and show following information\nSr #, Level, Time Stamp, Tag, Description, Limit , current , Unit\nAlarm number is defined according to time sequence.\nNo. 1 means latest alarm and No. 200 means oldest alarm\nAlarm mark and color are distinguished according to alarm grade\nAlarm mark has the function of touch target to confirm and reset each alarm\nIn Event Tracing, 34 recorded events are shown in 8 columns per page as per\ntime stamp. Event page columns are as follows.\nNo. Type, Level, Time Stamp, Tag, Description, Status, Equipment\nEvent list keeps all the entries recorded for a particular time and during this\nspecific time alarms or event list can be retrieved for a particular period of time\nor particular KKS number. Event list doesn't delete like alarm summary when\nalarm returns to its normal position.Lalpir/Pakgen Power Plant 19\nCCR Qualification Book\n\n\n3. Demonstrate the understanding of following logic gates w.r.t. DCS\nlogic tracing:\na. Function of AND,OR,NOT gates\nb. Function of Set/Reset latch\nDemonstrated to Shift Manager\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_032" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 3, + "chunk_content": "4. Which filters we can apply on Alarm List and Event Tracing?\nIn alarm summary filter can be applied by Equipment or by priority or by both.\nIn Event Tracing filter can be applied on Date/time, Tag Message, and\nType/State\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_033" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 4, + "chunk_content": "5. How can we put \u2018soft lock\u2019 on drives on DCS?\nGo to \u201cDrive Loop Plate\u201d Click on \u201cTagging\u201d, Click on 2nd button from left with\nscreen tip as \u201cPut a new Tag\u201d, Enter required information against each heading ,\nselect \u201cForbid\u201d in Mode section, and click on Registration. This will put soft lock\non drive and it can not be started now.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_034" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 5, + "chunk_content": "6. How a control loop can be locked and unlocked on OPS?\nOpen control loop , click on \u201cLock\u201d button . Now control loop is locked and\noperator / CRE can perform function manually .\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_035" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 6, + "chunk_content": "7. How to set a new trend explain to display and scan a trend?\nPress \u201cOPS Explorer\u201d navigate to Lalpir/Pakgen \uf0e0 Master Data\uf0e0 Real Time\nTrend Function \uf0e0 Trends or Trend\nVarious trends are pre-configured in DCS. They can be edited to include or\nexclude any selectable function.\nEach trend can plot maximum 16 parameters with an option of \u201cON/OFF\u201d , \u201c\u2206\u201d,\nScale. Each parameter line color can be selected from the preset options.\nMaximum last 30 days data can be plotted on each trend with the time scale of\n1 sec to one day.\nEach parameter value along with graph is displayed in trend, and adding time\nmark will show the spot value in trend.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_036" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 7, + "chunk_content": "8. How you will print a report from OPS?\nPress \u201cOPS Explorer\u201d navigate to Lalpir/Pakgen \uf0e0 Master Data\uf0e0 OPS\nfunctions \uf0e0 Online printing /Storage management\nThis \u201conline printing /storage management\u201d log and store pre-configured log\nreports in \u201cReport Group Management\u201d folder. All reports in this folder are saved\nin DC (Data Collection) PC folder \u201c D:\\ACEExtSave\\LGD\u201d. From Data collection\nPC these reports can be printed and can be written on DVD\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_037" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 8, + "chunk_content": "9. How you will print a trend or graphic on printers?\nPressing Hard Copy on keyboard will print current screen on printer.\nTo print trend , open it, and press Hard Copy.\nSimilarly to print a graphic , press Hard Copy on keyboardLalpir/Pakgen Power Plant 20\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_038" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 9, + "chunk_content": "10. Describe main sequence and sub sequence and drive level control?\nMain Sequence:\nMain sequence is the system for start-up and shutdown of set of equipment\u2019s. It\nis configured as per start-up and shut down program and sends command for\nstart-up and shut down when system meets all the requirements.\nThis system take cares of all the following.\na. Time, when they are required to start and when they are required to\nshut down, countdown of start-up time for all the equipment\u2019s involved\nin that sequence and if it exceeds from the specific time limit it initiates\nan abnormal alarm to alert operator to take necessary action. Ultimately\nsequence will not proceed forward for the next step.\nb. Interlocks, it takes care of all the interlocks required for all the major\nequipments as well as all the associated equipments.\nc. It provides start-up and shutdown permissive requirements and if\nsystem doesn't meet the all required start or shutdown permissive, it\nrestricts the CRE to start or shutdown the equipments.\nd. In case of maintenance system or equipments start-up can be locked\nfrom the main group, so that equipments can be isolated to get a safe\nmaintenance of the equipments.\ne. It provides redundancy of all the group equipments based on order of\nselectivity if next equipment meets the requirement.\nf. It looks after all the steps involved in the safe and proper start-up and\nshutdown of set of equipments.\nSub Sequence:\nSub sequence is the system for start-up and shutdown of individual equipment's\nand its associated accessories. This system take cares of all the following.\na. Time when they are required to start and when they are required to shut\ndown, countdown of start-up time for set of equipments involved in that\nsub sequence and if it exceeds from the specific time limit it initiates an\nabnormal alarm to alert operator to take necessary action. Ultimately\nsequence will not proceed forward for the next step.\nb. Interlocks, it takes care of all the interlocks required for all the sub group\nequipments as well as all the associated equipments.\nc. It provides start-up and shutdown permissive requirements and if\nsystem doesn't meet the all required start-up or shutdown permissive, it\nrestricts the operator to start or shutdown the equipments.\nd. In case of maintenance, sub-system or equipments start-up can be\nlocked from the main group, so that equipments can be isolated to get a\nsafe maintenance of the equipments.\nDrive Control:\nDrive control is the system for start-up and shutdown of individual equipment.\nThis system take cares of all the following.\na. Drive control system provides the direct start stop facility of the\nequipment like hard-wired control systems.\nb. Interlocks, it takes care of all the interlocks required for the equipment.\nc. It provides start-up and shutdown permissive requirements and if\nequipment doesn't meet the all required start-up or shutdown\npermissive, it restricts the operator to start or shutdown the equipment.\nd. In case of maintenance, equipment start-up can be locked from the\nCRT, so that equipments can be isolated to get a safe maintenance of\nthe equipment.Lalpir/Pakgen Power Plant 21\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_039" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 10, + "chunk_content": "11. What are the sources of power supply for OPS, how you can change\nthe power from UPS to 110V AC emergency services?\nThere are two sources of power supply.\na. UPS AC 110 volt.\nb. Emergency MCC 110 volt.\nc. Tie in b/w unit-1 and unit-2 only for OPS 3&", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0310" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 11, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0311" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 12, + "chunk_content": "12. What is the function of interlock?\nInterlock means operating protection of equipment or system, when Interlock is\n\"IN\" interlock is effective. If system does not meet the interlock requirement, it\nwill not let the interlock activate.\nWhen Interlock is \"OUT\" interlock is not effective. When some system error\nappears, system is capable to go to manual and it can be cared manually.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0312" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 13, + "chunk_content": "13. Demonstrate the understanding of following logic gates w.r.t. DCS\nlogic tracing:\na. Function of AND,OR,NOT gates\nb. Function of Set/Reset latch\nDemonstrated to Shift Manager\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0313" + }, + { + "chapter_numbre": "Chapter_3", + "chapter_name": "Chapter 03", + "chunk_index": 14, + "chunk_content": "14. Demonstrate the logic tracing of the following:\na. Start permissive of any boiler feed water pump\nb. Start permissive of HFO transfer pump\nDemonstrated to Shift Manager\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0314" + }, + { + "chapter_numbre": "Chapter_4", + "chapter_name": "Chapter 04", + "chunk_index": 0, + "chunk_content": "1. What is the furnace purge permissive, why it is important?\nFurnace purge permissive is the \u201cConditions that must be fulfilled\u201d before\nstarting furnace Purge. Mainly all boiler main equipments operation is included\nin this permissive e.g Igniter Oil , Diesel Oil, Flame detectors, Auxiliary dampers\nmodulation, Any FDF & GRF Operation, at least one BCP operation and MFT\ncondition.\nThese conditions are important as their healthy operation is necessary for boiler\noperation and to remove combustible mixture from boiler. In case of\nunavailability of any condition we will not be able to operate boiler.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_040" + }, + { + "chapter_numbre": "Chapter_4", + "chapter_name": "Chapter 04", + "chunk_index": 1, + "chunk_content": "2. How long furnace purge will take to complete? What is the basis of\nselection of this time duration?\nFurnace purge takes 300 seconds (5 minutes) to complete. This time is required\nto pass air from whole boiler to remove any unburned fuel oil from furnace.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_041" + }, + { + "chapter_numbre": "Chapter_4", + "chapter_name": "Chapter 04", + "chunk_index": 2, + "chunk_content": "3. How much time is required for leak test to complete?\nAll leak tests (Igniter Oil, diesel Oil, HFO) duration is 180 seconds.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_042" + }, + { + "chapter_numbre": "Chapter_4", + "chapter_name": "Chapter 04", + "chunk_index": 3, + "chunk_content": "4. What conditions will be required to be fulfilled before starting HFO,\ndiesel and igniter oil leak test?\nIgniter Oil Leak Test Permissive\na) Air flow >30%\nb) All auxiliary dampers modulated\nc) All igniters off\nd) All Igniters Shut off Valve close (MFT)\ne) Igniter Oil supply pressure : Normal\nDiesel Oil Leak Test Permissive\na) Air flow >30%\nb) All auxiliary dampers modulated\nc) All diesel oil burner valves close\nd) All burners Shut off Valve close (MFT)\ne) Diesel Oil supply pressure : Normal\nf) Any Diesel Oil pump in service\nHFO Leak Test Permissive\na) Air flow >30%\nb) All auxiliary dampers modulated\nc) All fuel oil burner valves close\nd) All burners Shut off Valve close (MFT)\ne) HFO supply pressure : NormalLalpir/Pakgen Power Plant 23\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_043" + }, + { + "chapter_numbre": "Chapter_4", + "chapter_name": "Chapter 04", + "chunk_index": 4, + "chunk_content": "5. Explain in sequence the different steps of HFO, diesel and igniter oil\nleak test?\nOn furnace purge command, Igniter / Diesel leak test will start automatically.\n(Igniter / Diesel can be started individually through their respective loop plate,\nbut it is recommended to let them start on auto)\nStep 1: Diesel, Igniter main shut off valve open for 10 seconds to develop\npressure in their respective header\nStep 2: Diesel, Igniter shut off valve close\nStep 3: If pressure in header remains constant and it do not decrease by 1 Bar,\nLeak lest will be completed.\nIn case of pressure drop to 1 bar or more, leak test is un-successful and it has\nto be restarted.\nFor HFO leak test all steps are same.\nBefore starting HFO Leak test, close HFO stabilizing valve manually.\nFollowing are oil pressure of HFO, Diesel, and Igniter.\nHFO > 24 KG / cm2\nIgniter & Diesel oil > 10 kg / cm2\n.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_044" + }, + { + "chapter_numbre": "Chapter_4", + "chapter_name": "Chapter 04", + "chunk_index": 5, + "chunk_content": "6. When does HFO warm up MOV goes to full close position on auto\ndemand?\nOn HFO Leak test it will close on auto demand and after Unit synchronization,\nWhen 3rd Burner is fired, HFO WARM UP valve close on auto.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_045" + }, + { + "chapter_numbre": "Chapter_5", + "chapter_name": "Chapter 05", + "chunk_index": 0, + "chunk_content": "1. What conditions must exist for light up igniters?\n\u201cIgniter Oil Conditions\u201d Established and\nFor Lighting up full row igniters , all four igniters must on on \u201cMain\u201d and give\nthem Startup Command from their respective loop plate from BMS screen\nFor Individual igniter light up, select it on sub first and give On command from\nFurnace flame screen.\nIgniter Oil Conditions include following conditions further\na) MFT Reset\nb) Atomizing Air pressure\nc) Igniter Oil Header Pressure\nd) Igniter Oil shutoff Valve in Open Position\ne) Igniter Oil header temp normal.\nf) Flame detector cooling air in service\ng) Air flow is greater than 30%\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_050" + }, + { + "chapter_numbre": "Chapter_5", + "chapter_name": "Chapter 05", + "chunk_index": 1, + "chunk_content": "2. At what conditions we can shift diesel oil firing to HFO firing?\nWe can shift to HFO firing after completion of HFO Leak test and achieving HFO\nheader temperature equal to or greater than 90 Deg C. It is recommended to\nraise Stack inlet flue gases temperature greater than 100 Deg C before taking\nHFO burners in service.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_051" + }, + { + "chapter_numbre": "Chapter_5", + "chapter_name": "Chapter 05", + "chunk_index": 2, + "chunk_content": "3. What is the starting permissive of:\na) FD fans\nStart Permissive\nRespective fan\u2019s side Air Heater in service\nInstrument and cooling air available\nb) Air heaters\nStart Permissive\nIts Lube Oil temp less 55 Deg C or its respective Lube oil pump on Auto\nInstrument and cooling air available\nc) Cooling air fans\nIt can be started manually. No Specific permissive required.\nd) Igniter fan\nIt can be started manually. No Specific permissive required.\ne) GR fans\nRespective side FDF in service along with AH and\nInstrument air & Cooling water normal\nf) BCP\nBCP Motor side caity temp less than 57 Deg C\nCooling water flow normal\nBoiler drum Level is greater than low levelLalpir/Pakgen Power Plant 25\nCCR Qualification Book\ng) Boiler feed pumps\nMain Feed Water pumps Startup permissive\nCasing Temperature normal\nLube Oil pressure is normal\nDA level Normal\nHeader pressure greater than 160 kg/cm2 , If it is less than 160kg/cm2\nthen following valve position must be ensured.\nValve Position\nPump\u2019s Minimum flow valve open\nPump\u2019s Disch Valve close\nFeed water MOV\u2019s (main and backup) Close\nFeed water CV close\nSH & RH DSH Shutoff Valves Close\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_052" + }, + { + "chapter_numbre": "Chapter_5", + "chapter_name": "Chapter 05", + "chunk_index": 3, + "chunk_content": "4. When do we get Air and Gas OFF permit while shutting down the\nboiler?\nAfter 5 minutes of MFT. This is to ensure removal of any un-burnt fuel\nmixture from the furnace.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_053" + }, + { + "chapter_numbre": "Chapter_5", + "chapter_name": "Chapter 05", + "chunk_index": 4, + "chunk_content": "5. On what conditions do we get Air Heaters OFF permit?\nAir Heater\u2019s respective FDF in Off Position will give AH Off permit in its\nrespective sub-sequence control loop plate.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_054" + }, + { + "chapter_numbre": "Chapter_5", + "chapter_name": "Chapter 05", + "chunk_index": 5, + "chunk_content": "60 kg/cm2 , If it is less than 160kg/cm2\nthen following valve position must be ensured.\nValve Position\nPump\u2019s Minimum flow valve open\nPump\u2019s Disch Valve close\nFeed water MOV\u2019s (main and backup) Close\nFeed water CV close\nSH & RH DSH Shutoff Valves Close\n4. When do we get Air and Gas OFF permit while shutting down the\nboiler?\nAfter 5 minutes of MFT. This is to ensure removal of any un-burnt fuel\nmixture from the furnace.\n5. On what conditions do we get Air Heaters OFF permit?\nAir Heater\u2019s respective FDF in Off Position will give AH Off permit in its\nrespective sub-sequence control loop plate.\n6. On what conditions do we get AC Cooling Fan OFF permit?\nOn Boiler drum metal temperatures less than 100 Deg C , AC Cooling\nfan off permit appears.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_055" + }, + { + "chapter_numbre": "Chapter_6", + "chapter_name": "Chapter 06", + "chunk_index": 0, + "chunk_content": "1. What is MFT?\nMFT stands for Master Fuel Trip. In case, any Boiler/Turbine trip\nprotection operates, MFT also operates simultaneously.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_060" + }, + { + "chapter_numbre": "Chapter_6", + "chapter_name": "Chapter 06", + "chunk_index": 1, + "chunk_content": "2. What conditions cause the MFT, explain briefly?\nBoiler Manual Trip\nBoiler Interlocks for MFT\na) Both FDF Trip\nb) Both AH Trip\nc) Both AC , DC cooling fan trip\nd) Both BCP Trip\na. Low Diff Pressure 0.5kg/cm2 for greater than 3\nseconds\ne) V.Low HFO burner header pressure (7kg/cm2)\nf) V.Low Atomizing steam header pressure (Less than 6 kg/cm2)\ng) V.Low DO burner header pressure\nh) V.Low Atomizing air pressure\ni) Air flow less than 30% for more than 3 seconds\nj) High furnace pressure for more than 3 seconds\nk) All Flame loss\nl) RH Protection (if unit is in startup mode)\nm) 3rd Burner in service (If unit is in startup mode)\nn) BMS Power loss\no) APC Failure\nTurbine Trip\nGenerator Trip\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_061" + }, + { + "chapter_numbre": "Chapter_6", + "chapter_name": "Chapter 06", + "chunk_index": 2, + "chunk_content": "3. What actions are required on occurrence of MFT, explain in detail your checks and actions?\nThere are two cases for MFT\na. Controlled Unit Shut down\nb. Unit Tripping\nControlled Unit Shutdown\nIn controlled unit shutdown, MFT occurs after all burner guns have been\nretracted and all igniters are turned off. In this case after 5 minutes Air and\nGas Off permit will appear. Turn off Air and Gas sequence and put it on\nHot Banking or Normal as per requirement\nUnit Tripping\n52C-Generator Breaker and Excitation breaker 41E1 Open, If not , open\nthem from mimic panel\nConfirm turbine trip, If not, trip Turbine\nConfirm all Fuel Shutoff Valves are Close (Igniter, Diesel, and Furnace Oil)\nClose SH & RH DSH Shutoff valves\nBoth GRF stopped and their Turning gear came in service\nBoth Air heater rotor drive is in service\nConfirm opening of turbine drains,\nTurbine MSV , GV, and RSV , ICV\u2019s are close\nTurbine AOP in service.\nFollow \u201cShut Down\u201d Check sheet furthur\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_062" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 0, + "chunk_content": "1. Explain in sequence the startup of air and gas system; what is\nrequired to be checked at DCS before starting the air and gas\nsystem?\nPre Check for Air and Gas system start command:\n\u2022 FDF(s), GRF(s) 11kv breakers are close and their VFD\u2019s are\nenergized.\n\u2022 Instrument air pressure normal\n\u2022 Cooling water (BCWP) in service.\n\u2022 MFT exists.\nAir and Gas start sequence.\nWhen air and gas sequence On command is given from \u201cAir and Gas\u201d\nmain sequence, following main steps are performed in order.\n Step 1: A/B Air Heater On\n Step \n\n1. Give different reasons of furnace explosion, how it can be avoided?\nThe main reason of Furnace explosion is accumulation of fuel oil and its\nuncontrolled ignition. Fuel oil accumulation may be due to\nAccumulation of unburnt fuel in furnace\n\u2022 Any off-load burner fuel shutoff valve passing (be it HFO or HSD)\n\u2022 Diesel Oil passing from any off-load igniter\n\u2022 Improper Fuel Combustion\nOther contributing reasons include Human error, bypassing furnace\npurging during startups and shutdowns\nFurnace explosion can be avoided by proper furnace purging during\nstartups and shutdowns, removal of all oil leaks in furnace, and periodic\ntesting of Boiler Interlocks.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_070" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 1, + "chunk_content": "2. What do you mean by excess air, what are its effects on combustion\nand what is its setting at different load?\nAir in excess to theoretical air required for complete combustion is\nexcess air. At maximum load it\u2019s range is from 1% to 2% while at 50%\nload , it is 2~3%. At 20% load , it ranges from 7~8%\n\n\n2. What is the biggest loss in the boiler, how it can be reduced with in\nsafe limits?\nChimney losses is the biggest loss of boiler, other losses are as follows.\n\u2022 Radiation losses due to poor refractory (insulation).\n\u2022 Valve leakage / passing.\n\u2022 Soot deposits on the boiler tubes.\n\u2022 Scaling due to poor chemistry.\n\u2022 Poor fuel quality\n\u2022 CBD\nThese losses can be reduced by\n\u2022 Maintaining AH flue gas outlet temperature just above due\npoint.\n\u2022 Any steam/water/fuel leakage or passing shall be rectified\n\u2022 CBD operation as per LAB recommendation only\n\u2022 Continuous check on chemical parameters of Boiler water and\nsteam\n\u2022 Sootblowing\n\u2022 Periodic maintenance and replacement (if required) of refractory\nand insulation\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_071" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 2, + "chunk_content": "3. Why it is important to keep wind box pressure higher than furnace?\nIt is important to keep wind box pressure higher than furnace to keep\nPositive air combustion air flow towards furnace. Also in case of less\nwind box pressure, hot flue gases will travel towards wind box.\n\n\n3. Which drives in Air and Gas system are fed from 400V Emergency\nBus?\n\u2022 A&B AH rotor drives\n\u2022 GRF turning gear motorsLalpir/Pakgen Power Plant 30\nCCR Qualification Book\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_072" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 3, + "chunk_content": "4. What is the purpose of fuel air, aux. Air and over fire dampers?\nFuel air dampers.\nFuel air dampers modulate to adjust fuel air as per requirement. Each\nburner has its own fuel air damper.\nAux air dampers.\nAuxiliary air dampers maintain differential pressure between wind box\nand furnace. Each burner has two aux. air dampers.\nOver fire dampers.\nOver fire damper maintains No level, two over fire dampers are provided on each corner top.\n\n\n4. What are Furnace pressure High, HH and trip limits?\nLalpir\nFurnace Pressure High 5", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_073" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 4, + "chunk_content": "5. What is the importance of combined back end temperature, what is\nthe safe limit of this temp at our plant and how you will achieve that?\nCombined back end temperature is the average temperature of Steam\nAir Heater air outlet temperature and AH flue gas outlet temperature.\nThe importance of this temperature is to maintain the dew point at air\nheaters. Combined back temperature should be maintained with in limit\nto avoid achieving dew point at AH cold end, flue gas duct and stack\ninlet.\nSafe Limit, 1250C\nControlling the air temperature at AH inlet by SAH can control the\ncombined back end temperatureLalpir/Pakgen Power Plant 28\nCCR Qualification Book\n\n\n5. What action should be taken on receiving above mentioned alarms to\navoid boiler tripping?\n\u2022 Check O2 and O2 Bias. O2 shall be on auto and its bias shall be 0\n\u2022 Check auxiliary dampers. They should be on auto.\n\u2022 Check FDF VVVF . It should be on auto and its bias shall be 0\n\u2022 Both air heaters Gas inlet dampers. They shall be open and on auto\n\u2022 Check air and gas side parameters to confirm blockage in furnace\nIf above mentioned all things are checked and are found OK,\nimmediately drop Load until furnace pressure drops and becomes\nnormal.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_074" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 5, + "chunk_content": "6. What is the purpose of GR fans and burner tilt?\nGR fans are used to re-circulate flue gases from economizer outlet to\nfurnace. This increase in volume of flue gases increases re-heat\ntemperatures. GR fans have now Variable voltage variable frequency\ndrives installed and their frequency is managed to increase/decrease\nre-heat temperatures. When selected on Commercial mode, their outlet\nvanes are manipulated to control re-heat temperatures.\nBurner Tilt controls the fire ball position in the furnace, +ve change in\nburner tilt increases re-heat temperature and vice versa.\n\n\n6. Describe the single leg operation of Air and Gas system? What\nprecautions should be taken while operating in this mode?\nLalpir /Pakgen boiler has two FDF\u2019s with their respective Steam Air\nHeater, Gas Air Heater and GRF\nEach FDF with its respective SAH, GAH and GRF is termed as One\nLeg.\nUnavailability of one FDF or one GAH makes whole leg un-available,\nand operating unit with only one FDF with its respective GAH is termed\nas One Leg Operation or Single Leg operation.\nPrecautions for Single Leg Operation of Air & Gas System:\nClose all dampers of unavailable Leg (FDF inlet, FDF Outlet, GAH inlet\nand GAH Outlet).\nMake sure unavailable side GAH rotor drive is in service.\nMonitor unavailable side temperature parameters.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_075" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 6, + "chunk_content": "7. Where cooling and sealing air is being used and why it is important to\nprovide a DC cooling air fan in the system?\nCooling and sealing air cools down and seals various equipment to\navoid leakage of hot flue gases through respective equipment. The\nareas where cooling and sealing air is used are TV camera; flame\ndetectors, Dampers shaft seals, Burners guns, igniters, peepholes.\nDC cooling air fan is provided to avoid the failure of flame scanners due\nto high Temperature, which causes the MFT. In case of AC cooling fan\nfailure the DC cooling air fan will cut in automatically to avoid the\ndamaging of flame scanners.\n\n\n7. What is difference between VFD and commercial mode for FDF? How\ncan we change from VFD to commercial and vice versa?\nVVVFD\u2019s (Variable Voltage, Variable frequency drives) are installed at\nboth FDF\u2019s to control air flow as per unit load by varying FDF input\nfrequency and voltages.\nIn VVVF mode, air flow is primarily controlled by varying voltage,\nfrequency and secondary controlled by FDF Inlet Guide Vanes.\nDue to any reason, if VVVF system is not available, VVVF system can\nbe put on bypass from DCS by selecting \u201cCommercial\u201d as a start mode\nfrom loop plate at A/B FDF top side on Air and Gas flow screen.\nIn commercial mode, frequency will remain constant at 50 Hz and FDF\nIGV\u2019s will modulate to maintain air flow.Lalpir/Pakgen Power Plant 31\nCCR Qualification Book\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_076" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 7, + "chunk_content": "8. What do you mean by the corrected NOx and what is its allowable limit?\nNO is abbreviation of gasses formed by the reaction of Nitrogen and Oxygen, where x is the number of oxygen atoms reacted with the Nitrogen.\nAt high temperatures in furnace, nitrogen in air and nitrogen in fuel\nreacts with oxygen and form oxides of nitrogen. (Nitrous oxide, Nitric\nOxide, Nitrogen dioxide, Nitrogen monoxide, and nitrogen pentaoxide)\nAs oxides of nitrogen are mostly toxic and are harmful , therefore they\nare diluted by giving excess air.\nConcentration of NOx gases after the addition of excess air is known as\ncorrected NOx.\nAs per World Bank requirements, its allowable limit is 130 gm/Gj\nNOx is continuously monitored through online analyzer. Its calculation\nformula is as follows.\nNOx (PPM) \u00f7 [1-(O2 % \u00f7 20.95)]\n \n\n\n8. What is difference between VFD and commercial mode for GRF?\nVFD\u2019s (Variable frequency drives) are installed at both GRF\u2019s to control\nflue gases air flow as per requirement to control Reheater super heater\ntemperatures by varying GRF\u2019s input frequency\nIn commercial mode, frequency will remain constant at 50 Hz and GRF\nIGV\u2019s will be modulated to maintain air flow.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_077" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 8, + "chunk_content": "9. What is opacity, what is its limit?\nOpacity is the opaqueness of flue gasses. It is the measurement of\nstack inlet flue gas density. The more flue gases are dense, the more\nopacity is. Less opacity co-relates to less density of flue gases and less\npollution.\nOpacity depends mainly on unburnt fuel , soot content and excess air.\nIts allowable limit is less than 40% and normal limit is 10 ~ 15%Lalpir/Pakgen Power Plant 29\nCCR Qualification Book\n\n\n9. How can we change from VFD to commercial and vice versa?\nDue to any reason, if VFD system is not available, VFD system can be\nput on bypass from DCS by selecting \u201cBY-PASS\u201d as a start mode from\nloop plate at A/B GRF top side on Air and Gas flow screen.\n20. Write down the energy optimization procedure from shutdown to cold\nconditions and in different seasons?\n\u2022 Stop both BCP\u2019s as soon as unit is shutdown\n\u2022 Take out last burner, Turn Off all igniters.\n\u2022 Keep only one HFO pump in service.\n\u2022 Stop Igniter Oil pump\n\u2022 Put Boiler on Hot Banking as soon as permit is available.\n\u2022 At GAH inlet temp less than 90 Deg C , Stop GAH turning motor\n\u2022 At GRF inlet temp less than 90 Deg C, Stop GRF turning motor\n\u2022 At drum metal temperature less than ", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_078" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 9, + "chunk_content": "10. What is the importance of SOx and NOx , how it can be controlled to safe limits?\nSOx is the abbreviation of oxides of sulfur, where x is the number of\noxygen atoms reacted with sulfur atom. When oxides of sulfur are\nreleased in the atmosphere, they react with hydrogen in the atmosphere\nor get absorbed in the moisture and forms sulfuric acid. In rainy season,\nSOx becomes more dangerous as they results in acidic rain. \nSOx is controlled by using low sulfuric acid fuel and using flue gas de-\nsulphurizer Unit (FGD). Its allowable limit as per World bank was 0.2\nTon/MW/Day. Though Lalpir/Pakgen no more follow world bank\nstandards, but it is our moral obligation not to pollute atmosphere\nNOx is abbreviation of gasses formed by the reaction of Nitrogen and\n\nOxygen, where x is the number of oxygen atoms reacted with the\nNitrogen.\nNOx is controlled by managing excess air and over fire air dampers.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_079" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 10, + "chunk_content": "11. Give different reasons of furnace explosion, how it can be avoided?\nThe main reason of Furnace explosion is accumulation of fuel oil and its\nuncontrolled ignition. Fuel oil accumulation may be due to\nAccumulation of unburnt fuel in furnace\n\u2022 Any off-load burner fuel shutoff valve passing (be it HFO or HSD)\n\u2022 Diesel Oil passing from any off-load igniter\n\u2022 Improper Fuel Combustion\nOther contributing reasons include Human error, bypassing furnace\npurging during startups and shutdowns\nFurnace explosion can be avoided by proper furnace purging during\nstartups and shutdowns, removal of all oil leaks in furnace, and periodic\ntesting of Boiler Interlocks.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0710" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 11, + "chunk_content": "12. What is the biggest loss in the boiler, how it can be reduced with in\nsafe limits?\nChimney losses is the biggest loss of boiler, other losses are as follows.\n\u2022 Radiation losses due to poor refractory (insulation).\n\u2022 Valve leakage / passing.\n\u2022 Soot deposits on the boiler tubes.\n\u2022 Scaling due to poor chemistry.\n\u2022 Poor fuel quality\n\u2022 CBD\nThese losses can be reduced by\n\u2022 Maintaining AH flue gas outlet temperature just above due\npoint.\n\u2022 Any steam/water/fuel leakage or passing shall be rectified\n\u2022 CBD operation as per LAB recommendation only\n\u2022 Continuous check on chemical parameters of Boiler water and\nsteam\n\u2022 Sootblowing\n\u2022 Periodic maintenance and replacement (if required) of refractory\nand insulation\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0711" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 12, + "chunk_content": "13. Which drives in Air and Gas system are fed from 400V Emergency\nBus?\n\u2022 A&B AH rotor drives\n\u2022 GRF turning gear motorsLalpir/Pakgen Power Plant 30\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0712" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 13, + "chunk_content": "14. What are Furnace pressure High, HH and trip limits?\nLalpir\nFurnace Pressure High 550 mm H2O\nFurnace Pressure HH 575 mm H2O\nTrip Limit 590 mm H2O greater than 3 Seconds\nPakGen\nFurnace Pressure High 550 mm H2O\nFurnace Pressure HH 575 mm H2O\nTrip Limit 590 mm H2O greater than 3 Seconds\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0713" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 14, + "chunk_content": "15. What action should be taken on receiving above mentioned alarms to\navoid boiler tripping?\n\u2022 Check O2 and O2 Bias. O2 shall be on auto and its bias shall be 0\n\u2022 Check auxiliary dampers. They should be on auto.\n\u2022 Check FDF VVVF . It should be on auto and its bias shall be 0\n\u2022 Both air heaters Gas inlet dampers. They shall be open and on auto\n\u2022 Check air and gas side parameters to confirm blockage in furnace\nIf above mentioned all things are checked and are found OK,\nimmediately drop Load until furnace pressure drops and becomes\nnormal.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0714" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 15, + "chunk_content": "16. Describe the single leg operation of Air and Gas system? What\nprecautions should be taken while operating in this mode?\nLalpir /Pakgen boiler has two FDF\u2019s with their respective Steam Air\nHeater, Gas Air Heater and GRF\nEach FDF with its respective SAH, GAH and GRF is termed as One\nLeg.\nUnavailability of one FDF or one GAH makes whole leg un-available,\nand operating unit with only one FDF with its respective GAH is termed\nas One Leg Operation or Single Leg operation.\nPrecautions for Single Leg Operation of Air & Gas System:\nClose all dampers of unavailable Leg (FDF inlet, FDF Outlet, GAH inlet\nand GAH Outlet).\nMake sure unavailable side GAH rotor drive is in service.\nMonitor unavailable side temperature parameters.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0715" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 16, + "chunk_content": "17. What is difference between VFD and commercial mode for FDF? How\ncan we change from VFD to commercial and vice versa?\nVVVFD\u2019s (Variable Voltage, Variable frequency drives) are installed at\nboth FDF\u2019s to control air flow as per unit load by varying FDF input\nfrequency and voltages.\nIn VVVF mode, air flow is primarily controlled by varying voltage,\nfrequency and secondary controlled by FDF Inlet Guide Vanes.\nDue to any reason, if VVVF system is not available, VVVF system can\nbe put on bypass from DCS by selecting \u201cCommercial\u201d as a start mode\nfrom loop plate at A/B FDF top side on Air and Gas flow screen.\nIn commercial mode, frequency will remain constant at 50 Hz and FDF\nIGV\u2019s will modulate to maintain air flow.Lalpir/Pakgen Power Plant 31\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0716" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 17, + "chunk_content": "18. What is difference between VFD and commercial mode for GRF?\nVFD\u2019s (Variable frequency drives) are installed at both GRF\u2019s to control\nflue gases air flow as per requirement to control Reheater super heater\ntemperatures by varying GRF\u2019s input frequency\nIn commercial mode, frequency will remain constant at 50 Hz and GRF\nIGV\u2019s will be modulated to maintain air flow.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0717" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 18, + "chunk_content": "19. How can we change from VFD to commercial and vice versa?\nDue to any reason, if VFD system is not available, VFD system can be\nput on bypass from DCS by selecting \u201cBY-PASS\u201d as a start mode from\nloop plate at A/B GRF top side on Air and Gas flow screen.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0718" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 19, + "chunk_content": "20. Write down the energy optimization procedure from shutdown to cold\nconditions and in different seasons?\n\u2022 Stop both BCP\u2019s as soon as unit is shutdown\n\u2022 Take out last burner, Turn Off all igniters.\n\u2022 Keep only one HFO pump in service.\n\u2022 Stop Igniter Oil pump\n\u2022 Put Boiler on Hot Banking as soon as permit is available.\n\u2022 At GAH inlet temp less than 90 Deg C , Stop GAH turning motor\n\u2022 At GRF inlet temp less than 90 Deg C, Stop GRF turning motor\n\u2022 At drum metal temperature less than 100 Deg C, stop AC Cooling fan\n\u2022 At drum metal temperature less than 100 Deg C , use spool piece for\ndrum filling\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0719" + }, + { + "chapter_numbre": "Chapter_7", + "chapter_name": "Chapter 07", + "chunk_index": 20, + "chunk_content": "21. How you will handle high fuel and low air situation?\nHigh Fuel:\n\u2022 Observe burner header pressure at burner firing and burner shutdown.\n\u2022 Ask area engineer to have a through round and check pressure at\neach individual burner, and report of any difference.\n\u2022 Ask area engineer to check FCV and PCV position and get it matched\nfrom DCS\nLow Air Situation\n\u2022 Check O2 and O2 Bias. It should not be \u2013ve\n\n\u2022 Check for \u2013ve Bias on FDF\u2019s VVVF. It should be Zero.\n\u2022 Check FDF\u2019s inlet guide vanes. They should be open, on auto and\nshould not have \u2013ve bias\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_0720" + }, + { + "chapter_numbre": "Chapter_8", + "chapter_name": "Chapter 08", + "chunk_index": 0, + "chunk_content": "1. What is the purpose of economizer re-circulation valve, when it opens\nand closes automatically?\nDuring boiler start-up there is no continuous feed water flow through\neconomizer. So there is chance of overheating or steaming in the economizer\ndue to heat exchange from flue gases.\nRecirculation valve is provided to maintain continuous feed water flow through\neconomizer to avoid overheating and steaming in economizer tube.\nEconomizer recirculation valve remains open till 20% load and closes at load\ngreater than 20%.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_080" + }, + { + "chapter_numbre": "Chapter_8", + "chapter_name": "Chapter 08", + "chunk_index": 1, + "chunk_content": "2. Why it is important to use boiler drains, what is the role of these\ndrains to achieve the steam conditions?\nDrains are provided in boiler at all super heaters (1ry, 2ry, 3ry), Steam drum\nblow down, Economizer, mud drum, HRH drain and Leg Drain. These drains\nare manipulated for different needs. At DCS , control is provided for following\ndrains.\n\u2022 Primary SH Drain\n\u2022 Tertiary SH Drain\n\u2022 Steam drum Blowdown\n\u2022 Hot Reheat drain\n\u2022 Leg Drain\nPrimary SH & Tertiary SH Drain\nThese drains are used primarily in startup to drain any condensate and to\nachieve required steam parameters as per startup mode. They are also used\nin forced outage for boiler forced cooling\nSteam Drum Blow Down (CBD)\nIt is used to control the boiler chemistry. If chemical parameters (mainly Iron\nand Silica) are poor, then it is opened as per Lab recommendation to drain\nsteam drum in controlled way.\nHot Reheat Drain\nIt is used to remove accumulated condensate in hot reheat line. It can be\nopened either towards CBD tank or towards Condenser.\nLeg Drain\nThis drain is used to drain accumulated moisture from main steam line to avoid\ntravelling of condensate towards HP Turbine. It is also used to achieve steam\nparameters during startup.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_081" + }, + { + "chapter_numbre": "Chapter_8", + "chapter_name": "Chapter 08", + "chunk_index": 2, + "chunk_content": "3. What is the function of main steam leg drain, what interlock is\nassociated with this valve, what you will check before opening this\nvalve?\nThis drain is used to drain accumulated moisture from main steam line to avoid\ntravelling of condensate towards HP Turbine. Therefore its opening is\nconfigured in its auto operation on MFT. During unit shut down , it is\nrecommended to keep it close on manual to avoid its opening due to this\nconfiguration.\nThis valve\u2019s auto control is also configured in turbine stress control and its\nopening / closing is manipulated on auto to control turbine stress during\nstartup. If this valve is on manual, SP1 permit will not appear. It has to be on\nauto before SP1 command.Lalpir/Pakgen Power Plant 33\nCCR Qualification Book\nDuring startup, when HP bypass opening is not available, this valve is opened\non manual to achieve turbine inlet steam parameters for startup.Before\nopening this valve, it is recommended to keep temperature difference between\nmain steam line and super heater outlet less than 50 Deg C to avoid\nhammering of steam and accumulated condensate in main steam line.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_082" + }, + { + "chapter_numbre": "Chapter_8", + "chapter_name": "Chapter 08", + "chunk_index": 3, + "chunk_content": "4. Why we have CBD provided with steam drum, what is the role of this\nvalve in chemistry control?\nCBD is used to control the boiler chemistry. If chemical parameters (mainly\nIron and Silica) are poor, then it is opened as per Lab recommendation to drain\nsteam drum in controlled way. Addition of fresh water then dilutes iron and\nsilica concentration in steam drum and after periodic testing, when these\nparameters came within limits, CBD is closed.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_083" + }, + { + "chapter_numbre": "Chapter_8", + "chapter_name": "Chapter 08", + "chunk_index": 4, + "chunk_content": "5. How many safety valves are provided on steam drum, SH, RH and\nwhat is their setting?\nSuper Heater Outlet\nSr # Popping Pressure Reset Pressure\n1 181.8 179.5\n2 185.4 179.5\nSteam Drum\n1 199 191.4\n2 204.9 197.1\n3 204.9 197.1\n4 204.9 197.1\nReheat Inlet\n1 46 44.3\n2 47.5 45.5\n3 47.5 45.5\n4 47.5 45.5\n5 47.5 45.5\n6 47.5 45.5\nReheat Inlet\n1 42.5 40.9\n2 43.5 41.8\nAuxilaty Steam Header\n1 21 19.53\nSoot Blower Header\n1 35 32.55\nAux Steam To DA\n1 10 9.3\nDearator\n1 10 9.3Lalpir/Pakgen Power Plant 34\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_084" + }, + { + "chapter_numbre": "Chapter_8", + "chapter_name": "Chapter 08", + "chunk_index": 5, + "chunk_content": "6. Why SH safety valve setting is low as compared to drum safety\nvalve?\nSafety valve is used to release excess pressure by opening & blowing steam\nin the atmosphere. Super Heaters are in fire / radiation zone inside furnace,\nand steam flow maintain super heater tubes temperatures by absorbing heat.\nAs super heater safety valve pressure is set point is low, therefore it will lift and\nrelease pressure in atmosphere earlier as compared to steam drum safety\nvalve. Steam will travel from steam drum towards Super heaters and save\nthem from starvation due to absence of steam.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_085" + }, + { + "chapter_numbre": "Chapter_8", + "chapter_name": "Chapter 08", + "chunk_index": 6, + "chunk_content": "7. What will the effect be of SH safety valve popping on the system,\nwhat action you will take to handle the situation?\nOn SH safety valve popping, steam will rush from steam drum, resulting in its\nlevel fluctuation. Increased flow of cold make up water inside steam drum will\nreduce steam temperatures and pressure. To maintain steam parameters,\nboiler master will increase fuel flow. To match fuel air for complete combustion,\nFDF\u2019s VVVF drives and their IGV\u2019s will respond. If SH safety valve remains\npopping, this phenomenon will occur again and again resulting in abnormal\nparameters.\nIf safety valve keeps popping or it does not closes properly, then reduce steam\npressure, load till the time it closes properly. If problem persists , unit has to be\nshut down and safety valve has to be restored in closed position for safe unit\noperation.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_086" + }, + { + "chapter_numbre": "Chapter_9", + "chapter_name": "Chapter 09", + "chunk_index": 0, + "chunk_content": "1. Explain the function of BCP.\nBCP is the abbreviation of Boiler circulation pump.\nCirculation wise , there are two type of boilers.\na. Natural circulation type\nb. Forced circulation type\nIn natural circulation type boilers, water in furnace water walls rises naturally,\nwhereas in forced circulation boilers, pumps are used to circulate water\nbetween steam drum and water drum (bottom reservoir for water).\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_090" + }, + { + "chapter_numbre": "Chapter_9", + "chapter_name": "Chapter 09", + "chunk_index": 1, + "chunk_content": "2. What are the advantages of providing a BCP over the natural\ncirculation boiler?\nForced circulation of water between steam drum and mud drum, increases\nheat transfer, reduces furnace height , increased rate of temperature rise.\n(110oC as compared to 60OC in natural circulation), reduces chances of\noverheating during startups and shutdown\nDuring shutdown, they also facilitate for even distribution of chemicals.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_091" + }, + { + "chapter_numbre": "Chapter_9", + "chapter_name": "Chapter 09", + "chunk_index": 2, + "chunk_content": "3. What is the temperature limitation of BCP cavity?\nBCP Cacity maximum limit for temperature is 57OC, on reaching cavity\ntemperatures to 60oC pump will trip.\nNormal operating temperatures are 40oC .\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_092" + }, + { + "chapter_numbre": "Chapter_9", + "chapter_name": "Chapter 09", + "chunk_index": 3, + "chunk_content": "4. In case of loss of power or cooling water flow, what automatic actions\nwill take place to keep cool the cavity of the BCP?\nBCP cooling water has two sources.\na. From BCWP Cooling water header (Main source)\nb. From Service water header (Backup Source)\nIn case of loss of power, service water is available as service water pump A is\non emergency bus bar. In this case, BCP cooling water SOV will close and\nBCP cooling water drain blow valve will open to maintain cooling water flow in\nBCP cavity coolers.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_093" + }, + { + "chapter_numbre": "Chapter_9", + "chapter_name": "Chapter 09", + "chunk_index": 4, + "chunk_content": "5. While BCP sequence is on, when second BCP will cut in\nautomatically?\nAt 30 kg/cm2 steam drum pressure second BCP will cut in on auto\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_094" + }, + { + "chapter_numbre": "Chapter_9", + "chapter_name": "Chapter 09", + "chunk_index": 5, + "chunk_content": "6. What are the pre start checks in local and in control room before\nstarting 1st BCP?\n\u2022 Permit: BCP Cooling water flow must be greater than 7 m3/hr\n\u2022 Drum Level is normal (Low Low alarm is not standing)\n\u2022 BCP Cooler inlet / outlet valves are open and cooling water medium is\nBCWP\n\u2022 BCP cavity temperature is less than 57OC\n\u2022 Instrument air pressure is normalLalpir/Pakgen Power Plant 36\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_095" + }, + { + "chapter_numbre": "Chapter_9", + "chapter_name": "Chapter 09", + "chunk_index": 6, + "chunk_content": "7. Write down the BCP cooler cleaning procedure when unit is at\nmaximum, minimum and is shut down?\nBCP Cleaning at Maximum Load, minimum load :\nThough it is not recommended to clean BCP cooler at full load, but if it is\ninevitable to clean BCP cooler, following is the procedure.\n\u2022 Increase Feed Water Header pressure appox 10 kg/cm2 than\nprevailing pressure at Steam Drum.\nFlushing valves are available at each step for the rust removal from lines.\nPlease flush each line before taking it in service\n\u2022 Open cavity purging water valve from BFP Header (Area Acitvity)\n\u2022 Take purge water cooler in service by opening its cooling water inlet\n/outlet valve\n\u2022 Open cavity purging water cooler outlet valve\n\u2022 Open cavity purging water cooler supply to cavity valve\nPurging will be started, control pressure and temperature within limits\n\u2022 Close cooling water supply valve to cavity cooler\n\u2022 Close cooling water return valve to cavity cooler\n\u2022 Observe the temperatures ( They must remain stable)\n\u2022 Go ahead to open cooler inlet side flange with the help of MMD\n\u2022 Back flush the cooler by opening its outlet valve\n\u2022 Install cooler inlet side flange with the help of MMD\n\u2022 Open Cooler inlet/outlet cooling water supply valves\n\u2022 Close purge cavity supply valve\n\u2022 Close cavity purging water valve from BFP header\n\u2022 Open any drain from system to de-pressure the system and close it after de-pressurization\nCheck valve line up thoroughly and observe cavity temperatures.\nDuring Shutdown, close cooling water supply and return valves, open cooler\ninlet side flange and open cooling water supply outlet valve for back flushing.\nDuring this activity, remove any external media form tubes by mechanical\nmeans (Rodding) with the help of MMD\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_096" + }, + { + "chapter_numbre": "Chapter_9", + "chapter_name": "Chapter 09", + "chunk_index": 7, + "chunk_content": "8. Why do we prefer BCP-A to take into service on first priority?\nBCP motor is of 6.6kV and initially both A&B BCP transformers were dry type\nand were installed in 11kV room. At startup, when BCP A was started, its dry\ntype transformer tripped multiple times and had to be replaced with oversize oil\ntype transformer installed out of 11kV room near PFI panel.\nAs , it has oil type transformer sufficient enough to maintain its temperatures at\nhigh currents, it is therefore preferred to start on first priority.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_097" + }, + { + "chapter_numbre": "Chapter_10", + "chapter_name": "Chapter 10", + "chunk_index": 0, + "chunk_content": "1. How many sources of aux steam are available at our plant?\nThere are three sources of auxiliary steam at our plant.\na. From 3ry SH side inlet header\nb. From Cold Re-Heat header\nc. Auxiliary boiler\nIn addition to these two sources, an inter unit tie is also provided to support\nother unit auxiliary header.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_100" + }, + { + "chapter_numbre": "Chapter_10", + "chapter_name": "Chapter 10", + "chunk_index": 1, + "chunk_content": "2. What is the normal value of aux steam header pressure?\nNormal value of auxiliary steam header is 15 kg/cm2\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_101" + }, + { + "chapter_numbre": "Chapter_10", + "chapter_name": "Chapter 10", + "chunk_index": 2, + "chunk_content": "3. If aux steam from 3ry side not available at low load, how you can\nmanage the system?\nAs stated above, an inter unit tie is provided to support 2nd unit in case of\nemergency/requirement. However, if aux steam is not available from other unit,\nfollowing measures will be taken to keep aux steam line up from cold reheat\nheader, as aux steam header pressure will drop at low load\n\u2022 Stop main ejector and take vacuum pumps in service.\n\u2022 Close SAH TCV\u2019s\nIn addition to this, auxiliary boiler may be taken in service for auxiliary steam to\nsupport the unit\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_102" + }, + { + "chapter_numbre": "Chapter_10", + "chapter_name": "Chapter 10", + "chunk_index": 3, + "chunk_content": "4. Why aux steam flow is less at high load and more at low load?\nAt full load following main aux steam consumers are out of service, therefore\naux steam flow is less at high load as compared to low load.\n\u2022 SAH \u2013 Heating steam is from Extraction 5\n\u2022 DA \u2013 Heating steam is from Extraction 5\n\u2022 Gland Steam \u2013 Spill over takes control of gland steam header\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_103" + }, + { + "chapter_numbre": "Chapter_10", + "chapter_name": "Chapter 10", + "chunk_index": 4, + "chunk_content": "5. Where aux steam is being used?\nAux Steam consumers are as follows\n\u2022 SAH\n\u2022 Steam Jet Air Ejector\n\u2022 Turbine gland steam\n\u2022 Steam converter (Primary Steam )\n\t>Steam converter bypass (HFO suction/discharge heater, HFO tank heaters)\n\u2022 HFO decanting (Discontinued)\n\u2022 Atomizing Steam\n\u2022 Dearator\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_104" + }, + { + "chapter_numbre": "Chapter_10", + "chapter_name": "Chapter 10", + "chunk_index": 5, + "chunk_content": "6. What precautions are required when you open the crosstie between\nunit 1 and unit 2?\nWhile opening the Aux steam tie valve observe Aux steam header pressure\nand open the tie valve very slowly with the coordination of both CRE\u2019s.\n\u2022 Crack open the tie valve for initial heating and make sure there is no\ncondensation on receiving end to avoid hammering.\n\u2022 Divert steam converter condensate to the aux steam supply unit\n\u2022 Close steam converter condensate shutoff valve to LP-2 heater of Aux\nsteam receiving unit\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_105" + }, + { + "chapter_numbre": "Chapter_11", + "chapter_name": "Chapter 11", + "chunk_index": 0, + "chunk_content": "1. What permissive are required opening the HFO shut off valve?\nHFO Shut Off Valve is main protection of boiler furnace to close fuel supply in\ncase of Boiler tripping. Following are required conditions for its opening\n\u2022 Furnace purging is completed\n\u2022 HFO Leak test is completed.\nAfter successful completion of above two conditions , HFO Shut Off valve will\nopen.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_110" + }, + { + "chapter_numbre": "Chapter_11", + "chapter_name": "Chapter 11", + "chunk_index": 1, + "chunk_content": "2. How much time is provided for flame to stabilize before igniter goes\noff?\nAfter firing burner, igniter must be kept in service for minimum ", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_111" + }, + { + "chapter_numbre": "Chapter_11", + "chapter_name": "Chapter 11", + "chunk_index": 2, + "chunk_content": "3. Explain the sequence of events that occurs when a burner is coming\nin service?\nSequence of event for burner firing (Cut In) is as follows\n\u2022 Igniter On\n\u2022 Burner gun will advance\n\u2022 Atomizing steam SOV will open\n\u2022 Combustion air dampers will open.\n\u2022 Burner fuel supply SOV will open.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_112" + }, + { + "chapter_numbre": "Chapter_11", + "chapter_name": "Chapter 11", + "chunk_index": 3, + "chunk_content": "4. Explain the sequence of events that occurs when a burner is going\nout of service?\nSequence of event on burner off command (Cut In) is as follows\n\u2022 Igniter On\n\u2022 Burner fuel supply SOV will close\n\u2022 Atomizing steam SOV will close\n\u2022 Burner purge SOV will open for 60 seconds of burner Off command\n\u2022 Burner purge SOV will close\n\u2022 Burner gun will retract.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_113" + }, + { + "chapter_numbre": "Chapter_11", + "chapter_name": "Chapter 11", + "chunk_index": 4, + "chunk_content": "5. Discuss how to put HFO control oil on auto and how to shift diesel oil\nfiring to HFO firing?\nShifting from Diesel Oil firing to HFO firing\n\u2022 HFO Leak test is completed.\n\u2022 HFO temperature at burner header are equal to or more than 90OC\n\u2022 Stack inlet gas temperatures are greater than 100OC\n\u2022 Take Stage-B igniters in service from BMS screen (all 4 igniters will\ncome in service in this way)\n\u2022 Put B-Row burners on \u201cSUB\u201d from their respective loop plate on\nFurnace flame screen\n\u2022 Take one diesel burner out of service\n\u2022 Give only One HFO burner from B row \u201cOn Command\u201d\n\u2022 After B-Row burner is fired successfully, take remaining A-Row burner\nout of service.\n\u2022 Change fuel and atomizing media selection from Diesel to HFO and\nAir to Steam from BMS screenLalpir/Pakgen Power Plant 39\nCCR Qualification Book\nShift HFO Control Oil on auto\nHFO Control oil can be shifted on auto after unit Synchronization in following\nway\n\u2022 Unit is synchronized and block load is achieved\n\u2022 Increase HFO Header pressure up to 18~20 kg/cm2 so that on firing\nnext burner, header pressure may not drop to its low limit. In worst\ncase if header pressure is dropped to 6 kg/cm2, MFT will occur.\n\u2022 Give Burner On command to 3rd HFO Burner\n\u2022 HFO Warm Up MOV (return line MOV) will start closing and this will\nincrease burner header pressure\n\u2022 Take HFO Control Valve control loop on Small increment mode and\nreduce its opening to keep burner header pressure within limit (Less\nthan 21 kg/cm2)\n\u2022 After HFO Warm up MOV is fully closed , put HFO control valve\ncontrol on auto.\n\u2022 Make sure , BMS control is on auto.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_114" + }, + { + "chapter_numbre": "Chapter_11", + "chapter_name": "Chapter 11", + "chunk_index": 5, + "chunk_content": "6. When BMS is on auto, in what sequence burners cut in and cut out on\nload demand?\nBurners Cut in sequence on Load Demand when BMS is on auto\nBurners (\u201ccut in\u201d) came in service in the form of pair (stage wise) when BMS is\non auto.\nAfter synchronization when 3rd burner is fired and HFO control is shifted on\nauto, B-Row (Stage-B) 4th HFO burner had to be fired on manual. Then as per\nload demand following burners will cut in on auto\nStage \u2013 C burners (C \u2013 1 , C \u2013 3)\nStage \u2013 C burners (C \u2013 2 , C \u2013 4)\nStage \u2013 A burners (A \u2013 1 , A \u2013 3)\nStage \u2013 A burners (A \u2013 2 , A \u2013 4)\nStage \u2013 D burners (D \u2013 1 , D \u2013 3)\nStage \u2013 D burners (D \u2013 2 , D \u2013 4)\nBurners Cut out sequence on Load Demand when BMS is on auto\nOn load decrease command, burners will come out of service in the following\nway\nStage \u2013 D burners (D \u2013 2 , D \u2013 4)\nStage \u2013 D burners (D \u2013 1 , D \u2013 3)\nStage \u2013 A burners (A \u2013 2 , A \u2013 4)\nStage \u2013 A burners (A \u2013 1 , A \u2013 3)\nStage \u2013 C burners (C \u2013 2 , C \u2013 4)\nStage \u2013 C burners (C \u2013 1 , C \u2013 3)\nOn further load decrease, take BMS on manual and take B rows burners out of\nservice manually.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_115" + }, + { + "chapter_numbre": "Chapter_11", + "chapter_name": "Chapter 11", + "chunk_index": 6, + "chunk_content": "7. What is the purpose of atomizing steam, what is its normal pressure\nand temp?\nAtomizing steam is used to disburse HFO in the form of fine droplets / mist in\nfurnace for its better combustion.\nAtomizing Steam pressure = 12 kg/cm2\nAtomizing Steam temp. = 190\u00baC\nTripping pressure = < 5.0 kg/cm2\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_116" + }, + { + "chapter_numbre": "Chapter_11", + "chapter_name": "Chapter 11", + "chunk_index": 7, + "chunk_content": "8. What is the purpose of HFO stabilizing and warm up valve?\nStabilizing valve:-\nAfter MFT, HFO shutoff valve is closed so HFO is circulated through\nStabilizing valve back to HFO tank.Lalpir/Pakgen Power Plant 40\nCCR Qualification Book\nHFO Warm Up MOV:-\nHFO warm up MOV opens after HFO Leak test is completed and HFO Shutoff\nValve is open. This MOV re-circulates HFO from HFO Ring header to HFO\ntank through HFO pumps. This MOV remains open till 3rd HFO burner comes\nin service. On 3rd HFO burner firing, this MOV closes automatically (if its\ncontrol is on auto)\nSimilarly , while shutting down the unit, this MOV opens on auto as soon as 3rd\nHFO burner is taken out of service ( remaining HFO burners are 2).\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_117" + }, + { + "chapter_numbre": "Chapter_11", + "chapter_name": "Chapter 11", + "chunk_index": 8, + "chunk_content": "9. Why we maintain the HFO temp, what are the temp settings at\ndifferent locations?\nHFO is pre-heated in different stages near to its flash point for its complete\ncombustion. Stage wise / Location wise temperature settings are as follows\n\u2022 HFO tank = 35 \u2013 45\u00baC\n\u2022 HFO suction heater outlet = 60\u00baC\n\u2022 HFO discharge heater outlet = ", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_118" + }, + { + "chapter_numbre": "Chapter_11", + "chapter_name": "Chapter 11", + "chunk_index": 9, + "chunk_content": "100 \u2013 120\u00baC\nIf HFO temperature is less than 90OC, burner On permit will not appear, as this\ntemperature is much less than HFO flash point.\n10. Discuss the alarms and trips associated with fuel oil and atomizing\nsteam & air?\nAlarms on HFO:-\n\u2022 HFO tank level low. 4.0 meter\n\u2022 HFO tank level low low. 3.7 meter\n\u2022 HFO tank level high. 14.3meter\n\u2022 HFO tank level high high. 14.5meter\n\u2022 HFO pump suction temperature low. <40\u00baC\n\u2022 HFO firing pump suction pressure low. 0 kg/cm2\n\u2022 HFO firing pump discharge heater temp low. 90\u00baC\n\u2022 HFO firing pump discharge heater temp high. 130\u00baC\n\u2022 HFO burner header pressure low. <7.0 kg/cm2\n\u2022 HFO burner header pressure low low (trip). <6.0 kg/cm2\n\u2022 HFO burner header pressure high. >27 kg/cm2\n\u2022 HFO receiving strainer dp high. >0.2 kg/cm2\n\u2022 HFO pump suction strainer dp high. >0.2 kg/cm2\n\u2022 HFO pump discharge strainer dp high. >0.2 kg/cm2\n\u2022 Drain oil tank level high. >1.6 meter\n\u2022 Drain oil tank level high high. >1.63 meter\n\u2022 Drain oil tank level low low. 0.3 meter\n\u2022 Drain oil pump discharge pressure high. >6.0 kg/cm2\n\u2022 Drain oil pump suction strainer dp high. >0.2 kg/cm2\n\u2022 Burner drain oil tank level high high. >1.15 meter\n\u2022 Burner drain oil tank level low low >0.2 meter\n\u2022 Drain oil pump discharge pressure high burner area >4.5 kg/cm2\n\u2022 Drain oil pump suction strainer dp high. >0.2 kg/cm2\n\u2022 APC upper limit.\n\u2022 Fuel upper limit.\n\u2022 BMS abnormal.\n\u2022 Load program on manual.\nTrips on HFO:-\n\u2022 HFO pressure v.low.\n\u2022 HFO tank level v. low.\n\u2022 Atomizing steam pressure v. low.\n\u2022 Reheat protection due to oil flow high.Lalpir/Pakgen Power Plant 41\nCCR Qualification Book\nAlarm on Diesel Oil:-\n\u2022 Diesel oil tank level low. 1.5 meter\n\u2022 Diesel oil tank level high 8.4 meter\n\u2022 Diesel oil tank level high high 8.6 meter\n\u2022 Diesel oil burner header pressure low 6.0 kg/cm2\n\u2022 Diesel oil burner header pressure low low 3.0 kg/cm2\n\u2022 Diesel oil burner header pressure high >13 kg/cm2\n\u2022 Diesel oil burner header pressure high at low load >23 kg/cm2\n\u2022 Diesel oil burner temp low 10\u00baC\n\u2022 Diesel oil burner temp high 40\u00baC\n\u2022 Diesel oil pump discharge pressure low low <9.0 kg/cm2\n\u2022 Diesel oil pump discharge pressure low low at low load <12 kg/cm2\n\u2022 Diesel oil and igniter oil pump suction pressure low <0.5 kg/cm2\n\u2022 Diesel oil igniter header pressure low <3.0 kg/cm2\n\u2022 Diesel oil igniter header pressure high >7.0 kg/cm2\n\u2022 Igniter oil burner temperature high 40\u00baC\n\u2022 Igniter oil burner temperature low 10\u00baC\nTrips On Diesel Oil: -\nDiesel oil burner pressure v.low 3.5 kg/cm 2\nDiesel oil tank level v. low.\nAbove tripping only takes place when only diesel oil burners are in service.\nAtomizing Steam:-\nAtomizing steam pressure low. <7.0 kg/cm2\nAtomizing steam pressure low low <5.0 kg/cm2\nAtomizing steam pressure high high >13 kg/cm2\nAtomizing steam temp low 180\u00baC\nAtomizing steam temp low low 150\u00baC\nAtomizing steam temp high 230\u00baC\nAtomizing steam temp high high 300\u00baC\nTrips On Atomizing Steam:-\nAtomizing steam pressure v.low.\nAtomizing Air:-\na) Burner atomizing air pressure low <4.0 kg/cm2\nb) Igniter atomizing air pressure low <4.0 kg/cm2\nTrips on Atomizing Air\nAtomizing air pressure v .low.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_119" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 0, + "chunk_content": "1. What alarms and trips are associated with feed water system?\nDe-aerator Alarms:-\nDe-aerator level high. >+200 mm\nDe-aerator level high high. >+350 mm\nDe-aerator level high high high. >+500 mm\nDe-aerator level low -200 mm\nDe-aerator level low low -400 mm\nDe-aerator level low low low -2060 mm\nDe-aerator overflow CV open. >+640 mm\nDe-aerator inlet steam cut off operate >+500 mm\nDe-aerator pressure high >8.0 kg/cm2\nDe-aerator pressure low <1.2 kg/cm2\nBFP Alarms: -\nSuction strainer differential pressure high. >0.\n\n1. When 2nd BFP will cut-in and cut-out during load ramp up and ramp\ndown respectively?\nFeed water sequence when selected on auto, will automatically give On\ncommand to 2nd BFP at steam flow greater than 575 T/hr and will cut out 2nd\nBFP at steam flow less than 500 T/hr\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_120" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 1, + "chunk_content": "2. How a feed water pump can be started on main group sequence and\nsub group sequence?\nFeed Water pump Start from main sequence\n11kV breaker is Closed\nVFD\u2019s are energized\nDA Level is normal and condensate pump is in service\nRespective Pump\u2019s AOP in service and put it on auto\nClose Discharge MOV put it on auto and Minimum flow shutoff valve on auto\nSelect pump priority\nPump on auto from its loop plate.\nGive on command from sequence (After unlocking it , if it\u2019s lock)\nFeed Water pump Start from Sub sequence\n11kV breaker is Closed\nVFD\u2019s are energized\nDA Level is normal and condensate pump is in service\nClose Discharge MOV and Minimum flow shutoff valve on auto\nLock main sequence\nGive on command from sub sequence\n\n\n2. What will happen if 2nd BFP does not cut-in on auto demand during\nload ramping-up?\n3rd BFP will cut in on auto demand. In case it also fails to cut in , unit load will\nnot increase.Lalpir/Pakgen Power Plant 45\nCCR Qualification Book\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_121" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 2, + "chunk_content": "3. What will happen if one feed water pump trip at full load and what will\nbe your action?\nIn case of feed pump tripping at full load, Standby pump (3rd BFP) will cut in on\nauto. In case it fails to cut in , Unit run back will operate and unit load will drop\nto 50%.\nAction:\nTry to start stand by pump if fails to start watch closely the drum level,\ncombustion, Deaerator level, Deaerator pressure, Drum pressure, condenser\nlevel and turbine TSI. If runback occurs, do not try to take any control on\nmanual. After run back, take thorough observations of unit by scrolling all\ngraphic screens. Inform to NPCC accordingly.\n\n\n3. What is difference between VFD and commercial mode for BFP? How\ncan we change from VFD to commercial and vice versa?\nOn VFD mode, VFD is main cotroler for steam drum level and it changes\nBPF\u2019s frequency to maintain steam drum. Whereas on commercial mode,\nFrequency is constant at 50 Hz and does not changes w.r.t steam drum level.\nIn this mode, Feed Water control valve is on main control to maintain steam\ndrum level.\nWe can change its selection from VFD to commercial or vice versa from\npump\u2019s control loop plate.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_122" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 3, + "chunk_content": "4. What is the purpose of minimum flow valve in feed water pump?\nEvery centrifugal pump provided with minimum flow line back to its reservoir\nequipped with its control valve. This is designed to protect pump from\ncavitation and maintain flow through the pump.\nAs an impeller's move through a fluid, low-pressure areas are formed as the\nfluid accelerates around and moves past the blades. The faster the blade\nmoves, the lower the pressure can become around it. As it reaches vapor\npressure, the fluid vaporizes and forms small bubbles of gas. This is cavitation.\nWhen the bubbles collapse later, they typically cause very strong local shock\nwaves in the fluid, which may be audible and may even damage the blades.\n\n\n4. Write down the energy optimization procedure from shutdown to cold\nconditions and in different seasons?\nEnergy Optimization regarding feed water system:\nStop main feed water pump by filling steam drum upto 600 mm approx..\nStop all AOP\u2019s for BFP\u2019s\nOpen their 11kV breakers.\nTurn off HVAC system of BFP\u2019s VVVF Room ( Local Operation) after\nmaintaining proper temperature.\nUse BFP D for steam drum filling as and when required.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_123" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 4, + "chunk_content": "5. What is a single element and three-element control, when control can\nbe shifted from single element to three elements?\nSingle Element:\nIn single element control, feed water control valve follows only one parameter\ni.e. Drum Level.\nThree Element;\nIn three element control, feed water control valve regulates/control feed water\nagainst three parameters i.e. Steam Drum Level, Main Steam Flow, and Feed\nwater flow.\nWhen selected on auto, Feed water control shifts automatically from 1 Element\nto 3 Element after unit synchronization at 80 MW Gross.\n\n\n5. When we take BFP D in service, what is its benefit?\nBFP D is taken in service during startup till 80 MW gross load. It consumes\nless power as compared to main feed water pumps and hence not only\nreduces import electricity but also reduces MDI during startup.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_124" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 5, + "chunk_content": "6. When main feed water control can be put on auto?\nMain feed water control can be put on auto at 130 kg/cm2 steam drum\npressureLalpir/Pakgen Power Plant 44\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_125" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 6, + "chunk_content": "7. How you will change the drum level control from main feed control\nvalve to back up control valve and vice versa?\nSteam drum level is controlled primarily by BFP\u2019s VVVF , however feed water\ncontrol valves has secondary control on drum level.\nTo change control from main to back FW CV, follow following steps.\nOpen backup Feed water control valve inlet MOV\nSlightly open backup feedwater control valve and put it on auto.\nObserve steam drum level and BFP\u2019s frequency.\nSelect backup control from feed water control graphic as a main controller.\nClose main feedwater control valve and its inlet MOV\nTo change FW CV selection when it is selected as a main controller follow\nfollowing steps.\nMake sure main feedwater control valve is on auto.\nSlightly open backup feedwater control valve.\nObserve steam drum level, Main feed water control valve will respond by\nclosing to maintain drum level.\nWhen main feedwater control valve is fully closed, put it on manual\nSelect backup control from feed water control graphic as a main controller and\nput it on auto.\nClose inlet MOV of main feed water control valve.\nSame procedure has to be followed to shift control from backup feedwater\ncontrol valve to main feedwater valve\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_126" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 7, + "chunk_content": "8. Why the aux steam is being used in deaerater?\nBoiler feed water is stored in dearator storage tank after pre-heating from Low\npressure heaters. At LP 4 outlet, its temperature & pressure is above boiling\npoint at standard temperature and pressure. Therefore, it is necessary to keep\ndearator pressurized so that feedwater remains below its saturation\ntemperature by providing auxiliary steam.\nIn addition to this, though our condenser is under vacuum, still a part of non\ncondensable gases ingress in the closed cycle and are absorbed in\ncondensate. Those non condensable gases are removed by dearation with the\nhelp of auxiliary steam on Dearator.\nAuxilary steam also contributes to BFP\u2019s NPSH.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_127" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 8, + "chunk_content": "9. At what rate you will fill the drum when the boiler is hot standby?\nSteam drum filling will be done at very slow rate to avoid thermal stress,\npreferably at 80~", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_128" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 9, + "chunk_content": "10. How feed water cycle efficiency is improved?\nFeed water cycle efficiency can be improved by maintaining feed water\nheater\u2019s DCA and TTD\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_129" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 10, + "chunk_content": "11. When 2nd BFP will cut-in and cut-out during load ramp up and ramp\ndown respectively?\nFeed water sequence when selected on auto, will automatically give On\ncommand to 2nd BFP at steam flow greater than 575 T/hr and will cut out 2nd\nBFP at steam flow less than 500 T/hr\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1210" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 11, + "chunk_content": "12. What will happen if 2nd BFP does not cut-in on auto demand during\nload ramping-up?\n3rd BFP will cut in on auto demand. In case it also fails to cut in , unit load will\nnot increase.Lalpir/Pakgen Power Plant 45\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1211" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 12, + "chunk_content": "13. What is difference between VFD and commercial mode for BFP? How\ncan we change from VFD to commercial and vice versa?\nOn VFD mode, VFD is main cotroler for steam drum level and it changes\nBPF\u2019s frequency to maintain steam drum. Whereas on commercial mode,\nFrequency is constant at 50 Hz and does not changes w.r.t steam drum level.\nIn this mode, Feed Water control valve is on main control to maintain steam\ndrum level.\nWe can change its selection from VFD to commercial or vice versa from\npump\u2019s control loop plate.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1212" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 13, + "chunk_content": "14. Write down the energy optimization procedure from shutdown to cold\nconditions and in different seasons?\nEnergy Optimization regarding feed water system:\nStop main feed water pump by filling steam drum upto 600 mm approx..\nStop all AOP\u2019s for BFP\u2019s\nOpen their 11kV breakers.\nTurn off HVAC system of BFP\u2019s VVVF Room ( Local Operation) after\nmaintaining proper temperature.\nUse BFP D for steam drum filling as and when required.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1213" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 14, + "chunk_content": "15. When we take BFP D in service, what is its benefit?\nBFP D is taken in service during startup till 80 MW gross load. It consumes\nless power as compared to main feed water pumps and hence not only\nreduces import electricity but also reduces MDI during startup.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1214" + }, + { + "chapter_numbre": "Chapter_12", + "chapter_name": "Chapter 12", + "chunk_index": 15, + "chunk_content": "16. Describe the logic for main and backup feed water control valve\nbriefly?\nEach feedwater control valve is designed for full load, Backup feedwater\ncontrol valve is provided to increase system availability.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1215" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 0, + "chunk_content": "1. What is the purpose of feed water heaters in feed cycle, how these\naffect the plant efficiency?\nFeed water heaters increase the feedwater temperature / system enthalpy\nbefore entering the economizer. This regenerative feedwater heating reduces\nheat load on boiler as feedwater will be at higher temperature when entering\nthe steam drum.\nHP , IP and LP steam turbine is compact and is designed in such a way that\nspecific volume of steam is required at a set temperature and pressure to get\nrequired output/work done.\nAs steam passes through the turbine blades, it expands after work done and\nhence its volume is increased. This expanded volume is reduced by providing\nextractions from different stages of steam turbine. These extractions are then\nused to pre-heat the feed water through feed water heaters. This increases\noverall efficiency of the plant.\n\n\n1. What is the nominal temperature and pressure of our boiler at MCR,\nwhat is the importance of this temp and pressure?\nBoiler SH out pressure (176 kg/cm 2)\nBoiler outlet temp. (540\u00baC)\nCold reheat pressure (41 kg/cm 2)\nCold reheat temp. (338\u00baC)\nHot reheat pressure (38 kg/cm 2)\nHot reheat temp. (540\u00baC)\nOur turbine is designed on these temperatures and pressure parameters. Any\ndeviation in these parameters ultimately contribute to turbine stress.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_130" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 1, + "chunk_content": "2. At what load feed water heaters will come in services, if a feed water\nheater fails to come in service on sequence how you will take these in\nservice?\nLP Heaters will start to cut in automatically at 54 MW and HP heaters will cut in\nat 74 MW load, if sequence is on AUTO.\nIf sequence fails LPH & HPH should be taken into service manually as follows:\nLock the Main sequence.\n\u2022 Select Extraction MOV on manual.\n\u2022 Ensure heaters LCV on AUTO.\n\u2022 Partial open the extraction MOV to respective heater for pre-heating\nand then slowly open to full.\n\u2022 Open ext. steam v/v in sequence 3,4 and 5 accordingly.\n\u2022 Note that after full opening of ext. steam v/v, drains should be closed\n\u2022 on AUTO.\nFollow above procedure for taking HPH in sequence of 6,7 and ", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_131" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 2, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_132" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 3, + "chunk_content": "3. Explain cascade drain system?\nIn cascade drain system, High pressure heater drain goes towards low\npressure heater as a heating steam. Cascade sequence for HP and IP Heaters\nis as follows\nHP heater 8 Drain goes as heating steam to HP heater 7\nHP heater 7 Drain goes as heating steam to HP heater 6\nHP heater 6 Drain goes to Dearator\nLP heater 4 Drain goes as heating steam to LP heater 3\nLP heater 3 Drain goes as heating steam to LP heater 2\nLP heater 2 Drain goes as heating steam to LP heater 1\nAnd LP heater 1 drain goes to condenser.\n\n\n3. Why de-super heater spray introduced at the inlet of 3ry super\nheater?\nDe-Superheater uses feed water nearly at 250 Deg C to control main steam\ntemperatures. Reason to introduce it at the inlet of 3ry SH inlet header is to\nconvert this spray into dry super-heated steam.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_133" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 4, + "chunk_content": "4. What is the purpose of startup vent and continuous vent?\nHeaters startup vent is used to vent accumulated gases in heater during long\nunit shutdown. Whereas continuous vent is provided to continuously remove\nnon-condensable gases from heater shell side.\n\n\n4. What is the normal temp of hot reheat steam and how it is being\ncontrolled?\nHot reheat temperature normal temperature is 540 Deg C. It is controlled\nmainly by GRF, Burner Tilt and by De-superheater at cold re-heat inlet header.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_134" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 5, + "chunk_content": "5. Why heater trips on high level?\nAs heaters heating steam is extraction from turbine, therefore on high level,\nthere is possibility that condensate might reach turbine blades and may\ndamage them as they are not designed for condensate at high RPM. Heaters\ntrip on high level to save turbine from this happening.Lalpir/Pakgen Power Plant 47\nCCR Qualification Book\n\n\n5. What is the function of GRF and burner tilt in controlling reheater\ntemp?\nGRF increases re-heat temperatures by re-circulating portion of hot flue gases\nfrom economizer to furnace.\nBurner tilt controls the reheat temperatures by controlling the height of fire ball\nwith the help of burner guns vertical angle manipulation. Maximum burner tilt isa\u00b1 300\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_135" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 6, + "chunk_content": "6. What will the effect on boiler and turbine on tripping of one HP heater\nand on all HP heaters, what will be your action as a CRE?\nOne HP heater trip:\nOn HP Heater tripping, its inlet steam MOV (Extraction MOV) will close,\nresulting in\n\u2022 Increase in pressure at HP turbine 1st Stage if HP Heater 8 Trips\n(Minor Load Increase)\n\u2022 Slight increase in Cold Re-heat if HP heater 7 Trips\n\u2022 IP turbine inlet pressure will increase if HP 6 Trips (Minor Load\nIncrease)\n\u2022 Slight decrease in feedwater to economizer, which will result in slight\nincrease in SH temperatures due to increased fuel flow\nAll HP Heaters Trip:\nOn all HP heaters trip event, all extraction MOV\u2019s will be closed and as a result\nof increase in turbine first stage pressure, increase in IP Inlet pressure, Unit\nload will increase. Turbine efficiency will drop also.\nEffect on Boiler\nFeedwater inlet temperature to boiler economizer will decrease, this will result\nin more heat transfer from flue gases to feed water. Consequently, this will\nreduce flue gases temperatures bear to or below their dew point. To increase\noutlet flue gas temperatures, inlet air temperatures had to be increased by\nopening more auxiliary steam towards Steam air heater.\nFuel flow will increase to increase low feed water temperatures, this will result\nin increased SH temperatures. Consequently, more De-super heater spray\nwould be required, this will increase load on BFP\u2019s.\nAir flow will also increase as soon as fuel flow increases, this will put FDF\u2019s\nunder load and furnace pressure will increase resultantly.\nAs a CRE, one should judge, if problem is resolvable, decrease unit load by\n20% to maintain parameters like fuel , air , SH temperature in control and take\nHP heaters in service one by one in ascending order (Starting from 6 to 8).\nIf it is not possible to take HP Heaters in service, shut down the unit and\naddress the problem as continuous operation in this condition may increase\nturbine stress and thermal load on boiler.\n\n\n6. What are the possible reasons of temp difference at LH side and RH\nside of 3ry-inlet header?\nFollowing are the possible reasons of temperature difference at LHS and RHS\nof 3ry SH inlet header\nDSH control valve passing.\nDue to uneven deposition of soot on different sections of super heaters\nIn-sufficient steam flow from super heaters\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_136" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 7, + "chunk_content": "7. What are the load limitations with different sets of feed water heaters\nout of service?\nThe load limitations are,\na) If one HPH will out, 10% load should be decreased manually if on MCR.\nb) If all HPH out 20 % load should be decreased manually.\n\n\n7. At what pressure vents can be opened?\nAt 2.0 Bar it is safe to open boiler vents.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_137" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 8, + "chunk_content": "8.\n3. Explain cascade drain system?\nIn cascade drain system, High pressure heater drain goes towards low\npressure heater as a heating steam. Cascade sequence for HP and IP Heaters\nis as follows\nHP heater 8 Drain goes as heating steam to HP heater 7\nHP heater 7 Drain goes as heating steam to HP heater 6\nHP heater 6 Drain goes to Dearator\nLP heater 4 Drain goes as heating steam to LP heater 3\nLP heater 3 Drain goes as heating steam to LP heater 2\nLP heater 2 Drain goes as heating steam to LP heater 1\nAnd LP heater 1 drain goes to condenser.\n4. What is the purpose of startup vent and continuous vent?\nHeaters startup vent is used to vent accumulated gases in heater during long\nunit shutdown. Whereas continuous vent is provided to continuously remove\nnon-condensable gases from heater shell side.\n5. Why heater trips on high level?\nAs heaters heating steam is extraction from turbine, therefore on high level,\nthere is possibility that condensate might reach turbine blades and may\ndamage them as they are not designed for condensate at high RPM. Heaters\ntrip on high level to save turbine from this happening.Lalpir/Pakgen Power Plant 47\nCCR Qualification Book\n6. What will the effect on boiler and turbine on tripping of one HP heater\nand on all HP heaters, what will be your action as a CRE?\nOne HP heater trip:\nOn HP Heater tripping, its inlet steam MOV (Extraction MOV) will close,\nresulting in\n\u2022 Increase in pressure at HP turbine 1st Stage if HP Heater 8 Trips\n(Minor Load Increase)\n\u2022 Slight increase in Cold Re-heat if HP heater 7 Trips\n\u2022 IP turbine inlet pressure will increase if HP 6 Trips (Minor Load\nIncrease)\n\u2022 Slight decrease in feedwater to economizer, which will result in slight\nincrease in SH temperatures due to increased fuel flow\nAll HP Heaters Trip:\nOn all HP heaters trip event, all extraction MOV\u2019s will be closed and as a result\nof increase in turbine first stage pressure, increase in IP Inlet pressure, Unit\nload will increase. Turbine efficiency will drop also.\nEffect on Boiler\nFeedwater inlet temperature to boiler economizer will decrease, this will result\nin more heat transfer from flue gases to feed water. Consequently, this will\nreduce flue gases temperatures bear to or below their dew point. To increase\noutlet flue gas temperatures, inlet air temperatures had to be increased by\nopening more auxiliary steam towards Steam air heater.\nFuel flow will increase to increase low feed water temperatures, this will result\nin increased SH temperatures. Consequently, more De-super heater spray\nwould be required, this will increase load on BFP\u2019s.\nAir flow will also increase as soon as fuel flow increases, this will put FDF\u2019s\nunder load and furnace pressure will increase resultantly.\nAs a CRE, one should judge, if problem is resolvable, decrease unit load by\n20% to maintain parameters like fuel , air , SH temperature in control and take\nHP heaters in service one by one in ascending order (Starting from 6 to 8).\nIf it is not possible to take HP Heaters in service, shut down the unit and\naddress the problem as continuous operation in this condition may increase\nturbine stress and thermal load on boiler.\n7. What are the load limitations with different sets of feed water heaters\nout of service?\nThe load limitations are,\na) If one HPH will out, 10% load should be decreased manually if on MCR.\nb) If all HPH out 20 % load should be decreased manually.\n8. What are the advantages of erecting LP heaters1&2 inside the\ncondenser?\nTo gain the maximum thermal efficiency of LP turbine as these heaters remain\nunder slightly vacuum so these are also used to minimize the moisture\ncontents at LP turbine and off course play an important role in gaining overall\nsystem efficiency.Lalpir/Pakgen Power Plant 48\nCCR Qualification Book\n\n\n8. At what temp boiler water can be drained?\nAt less than 75oC , it is safe to drain boiler waterLalpir/Pakgen Power Plant 50\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_138" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 9, + "chunk_content": "9. How you will monitor the performance of a heater, what are the\npossible causes of poor performance of a heater? Explain TTD and\nDCA and what are their impacts on heater performance?\nWe can observe / calculate the efficiency of HPH from differential temp. Of FW\nCauses of Poor Efficiency:-\na) Due to high level in HPH.\nb) Due to low level in HPH.\nc) Leakage.\nd) Poor insulation ( Radiation losses )\ne) Scaling on tubes.\nf) Poor automation in control system.\ng) Any passing in drains.\n\nChapter 14\nBoiler Temperature & Pressure\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_139" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 10, + "chunk_content": "1. What is the purpose of feed water heaters in feed cycle, how these\naffect the plant efficiency?\nFeed water heaters increase the feedwater temperature / system enthalpy\nbefore entering the economizer. This regenerative feedwater heating reduces\nheat load on boiler as feedwater will be at higher temperature when entering\nthe steam drum.\nHP , IP and LP steam turbine is compact and is designed in such a way that\nspecific volume of steam is required at a set temperature and pressure to get\nrequired output/work done.\nAs steam passes through the turbine blades, it expands after work done and\nhence its volume is increased. This expanded volume is reduced by providing\nextractions from different stages of steam turbine. These extractions are then\nused to pre-heat the feed water through feed water heaters. This increases\noverall efficiency of the plant.\n\n\n1. What is the nominal temperature and pressure of our boiler at MCR,\nwhat is the importance of this temp and pressure?\nBoiler SH out pressure (176 kg/cm 2)\nBoiler outlet temp. (540\u00baC)\nCold reheat pressure (41 kg/cm 2)\nCold reheat temp. (338\u00baC)\nHot reheat pressure (38 kg/cm 2)\nHot reheat temp. (540\u00baC)\nOur turbine is designed on these temperatures and pressure parameters. Any\ndeviation in these parameters ultimately contribute to turbine stress.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1310" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 11, + "chunk_content": "2. At what load feed water heaters will come in services, if a feed water\nheater fails to come in service on sequence how you will take these in\nservice?\nLP Heaters will start to cut in automatically at 54 MW and HP heaters will cut in\nat 74 MW load, if sequence is on AUTO.\nIf sequence fails LPH & HPH should be taken into service manually as follows:\nLock the Main sequence.\n\u2022 Select Extraction MOV on manual.\n\u2022 Ensure heaters LCV on AUTO.\n\u2022 Partial open the extraction MOV to respective heater for pre-heating\nand then slowly open to full.\n\u2022 Open ext. steam v/v in sequence 3,4 and 5 accordingly.\n\u2022 Note that after full opening of ext. steam v/v, drains should be closed\n\u2022 on AUTO.\nFollow above procedure for taking HPH in sequence of 6,7 and 8.\n\n\n2. How main steam temp is being controlled, from where temperature\ncontrol valves taking sense to control the temp?\nMain steam temperature is controlled by attemperators (De-\nSuperheater spray) installed at the inlet of both tertiary Super heater inlet\nheaders (Right and Left). These attemperators take sensing from 3ry SH outlet\nsteam temperature.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1311" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 12, + "chunk_content": "3. Explain cascade drain system?\nIn cascade drain system, High pressure heater drain goes towards low\npressure heater as a heating steam. Cascade sequence for HP and IP Heaters\nis as follows\nHP heater 8 Drain goes as heating steam to HP heater 7\nHP heater 7 Drain goes as heating steam to HP heater 6\nHP heater 6 Drain goes to Dearator\nLP heater 4 Drain goes as heating steam to LP heater 3\nLP heater 3 Drain goes as heating steam to LP heater 2\nLP heater 2 Drain goes as heating steam to LP heater 1\nAnd LP heater 1 drain goes to condenser.\n\n\n3. Why de-super heater spray introduced at the inlet of 3ry super\nheater?\nDe-Superheater uses feed water nearly at 250 Deg C to control main steam\ntemperatures. Reason to introduce it at the inlet of 3ry SH inlet header is to\nconvert this spray into dry super-heated steam.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1312" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 13, + "chunk_content": "4. What is the purpose of startup vent and continuous vent?\nHeaters startup vent is used to vent accumulated gases in heater during long\nunit shutdown. Whereas continuous vent is provided to continuously remove\nnon-condensable gases from heater shell side.\n\n\n4. What is the normal temp of hot reheat steam and how it is being\ncontrolled?\nHot reheat temperature normal temperature is 540 Deg C. It is controlled\nmainly by GRF, Burner Tilt and by De-superheater at cold re-heat inlet header.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1313" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 14, + "chunk_content": "5. Why heater trips on high level?\nAs heaters heating steam is extraction from turbine, therefore on high level,\nthere is possibility that condensate might reach turbine blades and may\ndamage them as they are not designed for condensate at high RPM. Heaters\ntrip on high level to save turbine from this happening.Lalpir/Pakgen Power Plant 47\nCCR Qualification Book\n\n\n5. What is the function of GRF and burner tilt in controlling reheater\ntemp?\nGRF increases re-heat temperatures by re-circulating portion of hot flue gases\nfrom economizer to furnace.\nBurner tilt controls the reheat temperatures by controlling the height of fire ball\nwith the help of burner guns vertical angle manipulation. Maximum burner tilt isa\u00b1 300\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1314" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 15, + "chunk_content": "6. What will the effect on boiler and turbine on tripping of one HP heater\nand on all HP heaters, what will be your action as a CRE?\nOne HP heater trip:\nOn HP Heater tripping, its inlet steam MOV (Extraction MOV) will close,\nresulting in\n\u2022 Increase in pressure at HP turbine 1st Stage if HP Heater 8 Trips\n(Minor Load Increase)\n\u2022 Slight increase in Cold Re-heat if HP heater 7 Trips\n\u2022 IP turbine inlet pressure will increase if HP 6 Trips (Minor Load\nIncrease)\n\u2022 Slight decrease in feedwater to economizer, which will result in slight\nincrease in SH temperatures due to increased fuel flow\nAll HP Heaters Trip:\nOn all HP heaters trip event, all extraction MOV\u2019s will be closed and as a result\nof increase in turbine first stage pressure, increase in IP Inlet pressure, Unit\nload will increase. Turbine efficiency will drop also.\nEffect on Boiler\nFeedwater inlet temperature to boiler economizer will decrease, this will result\nin more heat transfer from flue gases to feed water. Consequently, this will\nreduce flue gases temperatures bear to or below their dew point. To increase\noutlet flue gas temperatures, inlet air temperatures had to be increased by\nopening more auxiliary steam towards Steam air heater.\nFuel flow will increase to increase low feed water temperatures, this will result\nin increased SH temperatures. Consequently, more De-super heater spray\nwould be required, this will increase load on BFP\u2019s.\nAir flow will also increase as soon as fuel flow increases, this will put FDF\u2019s\nunder load and furnace pressure will increase resultantly.\nAs a CRE, one should judge, if problem is resolvable, decrease unit load by\n20% to maintain parameters like fuel , air , SH temperature in control and take\nHP heaters in service one by one in ascending order (Starting from 6 to 8).\nIf it is not possible to take HP Heaters in service, shut down the unit and\naddress the problem as continuous operation in this condition may increase\nturbine stress and thermal load on boiler.\n\n\n6. What are the possible reasons of temp difference at LH side and RH\nside of 3ry-inlet header?\nFollowing are the possible reasons of temperature difference at LHS and RHS\nof 3ry SH inlet header\nDSH control valve passing.\nDue to uneven deposition of soot on different sections of super heaters\nIn-sufficient steam flow from super heaters\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1315" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 16, + "chunk_content": "7. What are the load limitations with different sets of feed water heaters\nout of service?\nThe load limitations are,\na) If one HPH will out, 10% load should be decreased manually if on MCR.\nb) If all HPH out 20 % load should be decreased manually.\n\n\n7. At what pressure vents can be opened?\nAt 2.0 Bar it is safe to open boiler vents.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1316" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 17, + "chunk_content": "8.\n3. Explain cascade drain system?\nIn cascade drain system, High pressure heater drain goes towards low\npressure heater as a heating steam. Cascade sequence for HP and IP Heaters\nis as follows\nHP heater 8 Drain goes as heating steam to HP heater 7\nHP heater 7 Drain goes as heating steam to HP heater 6\nHP heater 6 Drain goes to Dearator\nLP heater 4 Drain goes as heating steam to LP heater 3\nLP heater 3 Drain goes as heating steam to LP heater 2\nLP heater 2 Drain goes as heating steam to LP heater 1\nAnd LP heater 1 drain goes to condenser.\n4. What is the purpose of startup vent and continuous vent?\nHeaters startup vent is used to vent accumulated gases in heater during long\nunit shutdown. Whereas continuous vent is provided to continuously remove\nnon-condensable gases from heater shell side.\n5. Why heater trips on high level?\nAs heaters heating steam is extraction from turbine, therefore on high level,\nthere is possibility that condensate might reach turbine blades and may\ndamage them as they are not designed for condensate at high RPM. Heaters\ntrip on high level to save turbine from this happening.Lalpir/Pakgen Power Plant 47\nCCR Qualification Book\n6. What will the effect on boiler and turbine on tripping of one HP heater\nand on all HP heaters, what will be your action as a CRE?\nOne HP heater trip:\nOn HP Heater tripping, its inlet steam MOV (Extraction MOV) will close,\nresulting in\n\u2022 Increase in pressure at HP turbine 1st Stage if HP Heater 8 Trips\n(Minor Load Increase)\n\u2022 Slight increase in Cold Re-heat if HP heater 7 Trips\n\u2022 IP turbine inlet pressure will increase if HP 6 Trips (Minor Load\nIncrease)\n\u2022 Slight decrease in feedwater to economizer, which will result in slight\nincrease in SH temperatures due to increased fuel flow\nAll HP Heaters Trip:\nOn all HP heaters trip event, all extraction MOV\u2019s will be closed and as a result\nof increase in turbine first stage pressure, increase in IP Inlet pressure, Unit\nload will increase. Turbine efficiency will drop also.\nEffect on Boiler\nFeedwater inlet temperature to boiler economizer will decrease, this will result\nin more heat transfer from flue gases to feed water. Consequently, this will\nreduce flue gases temperatures bear to or below their dew point. To increase\noutlet flue gas temperatures, inlet air temperatures had to be increased by\nopening more auxiliary steam towards Steam air heater.\nFuel flow will increase to increase low feed water temperatures, this will result\nin increased SH temperatures. Consequently, more De-super heater spray\nwould be required, this will increase load on BFP\u2019s.\nAir flow will also increase as soon as fuel flow increases, this will put FDF\u2019s\nunder load and furnace pressure will increase resultantly.\nAs a CRE, one should judge, if problem is resolvable, decrease unit load by\n20% to maintain parameters like fuel , air , SH temperature in control and take\nHP heaters in service one by one in ascending order (Starting from 6 to 8).\nIf it is not possible to take HP Heaters in service, shut down the unit and\naddress the problem as continuous operation in this condition may increase\nturbine stress and thermal load on boiler.\n7. What are the load limitations with different sets of feed water heaters\nout of service?\nThe load limitations are,\na) If one HPH will out, 10% load should be decreased manually if on MCR.\nb) If all HPH out 20 % load should be decreased manually.\n8. What are the advantages of erecting LP heaters1&2 inside the\ncondenser?\nTo gain the maximum thermal efficiency of LP turbine as these heaters remain\nunder slightly vacuum so these are also used to minimize the moisture\ncontents at LP turbine and off course play an important role in gaining overall\nsystem efficiency.Lalpir/Pakgen Power Plant 48\nCCR Qualification Book\n\n\n8. At what temp boiler water can be drained?\nAt less than 75oC , it is safe to drain boiler waterLalpir/Pakgen Power Plant 50\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1317" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 18, + "chunk_content": "9. How you will monitor the performance of a heater, what are the\npossible causes of poor performance of a heater? Explain TTD and\nDCA and what are their impacts on heater performance?\nWe can observe / calculate the efficiency of HPH from differential temp. Of FW\nCauses of Poor Efficiency:-\na) Due to high level in HPH.\nb) Due to low level in HPH.\nc) Leakage.\nd) Poor insulation ( Radiation losses )\ne) Scaling on tubes.\nf) Poor automation in control system.\ng) Any passing in drains.\n\nChapter 14\nBoiler Temperature & Pressure\n1. What is the nominal temperature and pressure of our boiler at MCR,\nwhat is the importance of this temp and pressure?\nBoiler SH out pressure (176 kg/cm 2)\nBoiler outlet temp. (540\u00baC)\nCold reheat pressure (41 kg/cm 2)\nCold reheat temp. (338\u00baC)\nHot reheat pressure (38 kg/cm 2)\nHot reheat temp. (540\u00baC)\nOur turbine is designed on these temperatures and pressure parameters. Any\ndeviation in these parameters ultimately contribute to turbine stress.\n2. How main steam temp is being controlled, from where temperature\ncontrol valves taking sense to control the temp?\nMain steam temperature is controlled by attemperators (De-\nSuperheater spray) installed at the inlet of both tertiary Super heater inlet\nheaders (Right and Left). These attemperators take sensing from 3ry SH outlet\nsteam temperature.\n3. Why de-super heater spray introduced at the inlet of 3ry super\nheater?\nDe-Superheater uses feed water nearly at 250 Deg C to control main steam\ntemperatures. Reason to introduce it at the inlet of 3ry SH inlet header is to\nconvert this spray into dry super-heated steam.\n4. What is the normal temp of hot reheat steam and how it is being\ncontrolled?\nHot reheat temperature normal temperature is 540 Deg C. It is controlled\nmainly by GRF, Burner Tilt and by De-superheater at cold re-heat inlet header.\n5. What is the function of GRF and burner tilt in controlling reheater\ntemp?\nGRF increases re-heat temperatures by re-circulating portion of hot flue gases\nfrom economizer to furnace.\nBurner tilt controls the reheat temperatures by controlling the height of fire ball\nwith the help of burner guns vertical angle manipulation. Maximum burner tilt isa\u00b1 300\n6. What are the possible reasons of temp difference at LH side and RH\nside of 3ry-inlet header?\nFollowing are the possible reasons of temperature difference at LHS and RHS\nof 3ry SH inlet header\nDSH control valve passing.\nDue to uneven deposition of soot on different sections of super heaters\nIn-sufficient steam flow from super heaters\n7. At what pressure vents can be opened?\nAt 2.0 Bar it is safe to open boiler vents.\n8. At what temp boiler water can be drained?\nAt less than 75oC , it is safe to drain boiler waterLalpir/Pakgen Power Plant 50\nCCR Qualification Book\n9. What is the minimum allowable SH and RH metal temperature?\nSH metal temp (550\u00baC) Normal (600\u00baC) Alarm.\nRH metal temp. (550\u00baC) Normal (580\u00baC) Alarm.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1318" + }, + { + "chapter_numbre": "Chapter_13", + "chapter_name": "Chapter 13", + "chunk_index": 19, + "chunk_content": "10% load should be decreased manually if on MCR.\nb) If all HPH out 20 % load should be decreased manually.\n8. What are the advantages of erecting LP heaters1&2 inside the\ncondenser?\nTo gain the maximum thermal efficiency of LP turbine as these heaters remain\nunder slightly vacuum so these are also used to minimize the moisture\ncontents at LP turbine and off course play an important role in gaining overall\nsystem efficiency.Lalpir/Pakgen Power Plant 48\nCCR Qualification Book\n9. How you will monitor the performance of a heater, what are the\npossible causes of poor performance of a heater? Explain TTD and\nDCA and what are their impacts on heater performance?\nWe can observe / calculate the efficiency of HPH from differential temp. Of FW\nCauses of Poor Efficiency:-\na) Due to high level in HPH.\nb) Due to low level in HPH.\nc) Leakage.\nd) Poor insulation ( Radiation losses )\ne) Scaling on tubes.\nf) Poor automation in control system.\ng) Any passing in drains.\n\nChapter 14\nBoiler Temperature & Pressure\n1. What is the nominal temperature and pressure of our boiler at MCR,\nwhat is the importance of this temp and pressure?\nBoiler SH out pressure (176 kg/cm 2)\nBoiler outlet temp. (540\u00baC)\nCold reheat pressure (41 kg/cm 2)\nCold reheat temp. (338\u00baC)\nHot reheat pressure (38 kg/cm 2)\nHot reheat temp. (540\u00baC)\nOur turbine is designed on these temperatures and pressure parameters. Any\ndeviation in these parameters ultimately contribute to turbine stress.\n2. How main steam temp is being controlled, from where temperature\ncontrol valves taking sense to control the temp?\nMain steam temperature is controlled by attemperators (De-\nSuperheater spray) installed at the inlet of both tertiary Super heater inlet\nheaders (Right and Left). These attemperators take sensing from 3ry SH outlet\nsteam temperature.\n3. Why de-super heater spray introduced at the inlet of 3ry super\nheater?\nDe-Superheater uses feed water nearly at 250 Deg C to control main steam\ntemperatures. Reason to introduce it at the inlet of 3ry SH inlet header is to\nconvert this spray into dry super-heated steam.\n4. What is the normal temp of hot reheat steam and how it is being\ncontrolled?\nHot reheat temperature normal temperature is 540 Deg C. It is controlled\nmainly by GRF, Burner Tilt and by De-superheater at cold re-heat inlet header.\n5. What is the function of GRF and burner tilt in controlling reheater\ntemp?\nGRF increases re-heat temperatures by re-circulating portion of hot flue gases\nfrom economizer to furnace.\nBurner tilt controls the reheat temperatures by controlling the height of fire ball\nwith the help of burner guns vertical angle manipulation. Maximum burner tilt isa\u00b1 300\n6. What are the possible reasons of temp difference at LH side and RH\nside of 3ry-inlet header?\nFollowing are the possible reasons of temperature difference at LHS and RHS\nof 3ry SH inlet header\nDSH control valve passing.\nDue to uneven deposition of soot on different sections of super heaters\nIn-sufficient steam flow from super heaters\n7. At what pressure vents can be opened?\nAt 2.0 Bar it is safe to open boiler vents.\n8. At what temp boiler water can be drained?\nAt less than 75oC , it is safe to drain boiler waterLalpir/Pakgen Power Plant 50\nCCR Qualification Book\n9. What is the minimum allowable SH and RH metal temperature?\nSH metal temp (550\u00baC) Normal (600\u00baC) Alarm.\nRH metal temp. (550\u00baC) Normal (580\u00baC) Alarm.\n10. Give some reasons of flue gases temperature high at air heater outlet,\nhow it can be kept in safe limits?\nHigh flue gas temperatures at air heater outlet can be due to high cold end\nmetal temperature set point at steam air heaters. Lowering steam air heater\nTCV set points can lower flue gas temperatures.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1319" + }, + { + "chapter_numbre": "Chapter_14", + "chapter_name": "Chapter 15", + "chunk_index": 0, + "chunk_content": "1. How many pumps have been provided in lube oil system, explain the\nfunction of each one briefly?\nFour lube oil pumps are provided in lube oil system. They are\na. AOP (AOP provides HP oil and LP oil at less than 2950 rpm)\nb. TOP (Provides lube oil, when turbine is on turning gear)\nc. EOP (Provide lube oil in case of A/C TOP failure, it is in fact back up of\nTOP)\nd. Turbine shaft mounted MOP (Provide HP oil & lube oil while turbine is\nrunning at 3000 rpm)\n\n\n1. Describe the lube oil cooler duty changeover, what important\nparameter need to closely watch during this changeover?\nNormally both coolers remained in service. But if there is due to some reason\n1 cooler in service and we have to take 2nd cooler out of service. The\nprocedure is as under.\na. First confirm the cooling water inlet/outlet valves are opened and\nair is purged.\nb. Then slowly open the oil balancing line valve to fill the standby\ncooler\nc. Open vent to confirm air purging.\nd. When oil is coming from stand by cooler and air is purged slowly\nopened the selective valve towards stand by cooler\ne. Close the balance line valve\nf. Standby cooler is in service.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_150" + }, + { + "chapter_numbre": "Chapter_14", + "chapter_name": "Chapter 15", + "chunk_index": 1, + "chunk_content": "2. What is the function of jacking oil pump, at which bearings jacking oil\nhas been provided?\nJOP provides HP pressure oil to bearing number 3 & 4 to lift the rotor while\nturbine is on turning gear\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_151" + }, + { + "chapter_numbre": "Chapter_14", + "chapter_name": "Chapter 15", + "chunk_index": 2, + "chunk_content": "3. What is the difference between HP oil, Auto stop oil and control oil,\nwhat is their normal value and what is their function?\nHP Oil:\nOperate the MSV\u2019s / GV\u2019s / RSV\u2019s/ ICV\u2019s. its pressure is 20~22 kg/cm 2\nAuto Stop Oil :\nIt will drain through solenoid v/v in case of any protection operates. Its\npressure is 9.0 - 10 kg/cm 2\nControl Oil:\nIt is used to operate the servo motor of MSV\u2019s / GV\u2019s / RSV\u2019s/ ICV\u2019s. Its\nnormal pressure is 3.0 kg/cm 2\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_152" + }, + { + "chapter_numbre": "Chapter_14", + "chapter_name": "Chapter 15", + "chunk_index": 3, + "chunk_content": "4. When turbine is on normal operation, how lube oil pressure being\nmaintained and how suction to main oil pump being provided?\nWhen turbine remains in normal operation main oil pump supplies lube oil to\nT/G bearing through ejector and gets suction oil pressure through an ejector\nwhich is fed from MOP discharge line.\nMOP discharge Pressure 22 kg/cm 2\nMOP suction pressure 1.2 kg/cm 2\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_153" + }, + { + "chapter_numbre": "Chapter_14", + "chapter_name": "Chapter 15", + "chunk_index": 4, + "chunk_content": "5. During run up, when jacking oil pump and aux oil pump will cut out?\nJOP: -\nJacking oil pump cut out at 800 rpm while increasing speed\nAOP: -\nAOP will cut in when condenser vacuum reaches to 550 mm Hg and will cut\nout at 2950 rpm turbine speed while increasing speed\nTOP: -\nIt will cut out at 550 mmHg of condenser vacuum\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_154" + }, + { + "chapter_numbre": "Chapter_14", + "chapter_name": "Chapter 15", + "chunk_index": 5, + "chunk_content": "6. During run down when AOP, JOP and TOP will cut in?\nDuring run down when turbine speed comes below 2950 RPM, AOP will cut in\non auto . It will also cut in on auto if lube oil pressure drops to 0.85 kg/cm2 or\nwhen MOP discharge pressure drops to or below 17.0 kg/cm2\nJOP will cut in at 800 rpm while decreasing speed.\nTOP will cut in when turbine speed comes down to 100 rpm and and also, will\ncut in if lube oil pressure drops to 0.", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_155" + }, + { + "chapter_numbre": "Chapter_14", + "chapter_name": "Chapter 15", + "chunk_index": 6, + "chunk_content": "7. How the lube oil temperature being controlled?\nThere are two lube oil coolers with a common TCV on discharge line, which\ncontrols the cooling water flow to maintain lube oil temperature.Lalpir/Pakgen Power Plant 52\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_156" + }, + { + "chapter_numbre": "Chapter_14", + "chapter_name": "Chapter 15", + "chunk_index": 7, + "chunk_content": "8. Why it is recommended to keep oil temp at 35 C during turning gear\noperation?\nAt 35 Deg C, lube oil has required viscosity for 3 RPM on turning gear.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_157" + }, + { + "chapter_numbre": "Chapter_14", + "chapter_name": "Chapter 15", + "chunk_index": 8, + "chunk_content": "9. What is the purpose of vapor extractor?\nVapor extractor fan extract / pull out the gases/ vapors from the main oil tank.\nIt maintains slightly negative pressure 150 to 200 mm H2O\n\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_158" + }, + { + "chapter_numbre": "Chapter_14", + "chapter_name": "Chapter 15", + "chunk_index": 9, + "chunk_content": "10. What are the possible causes of main oil tank level increase?\nFollowing are the possible causes of main oil tank level increase.\n\u2022 Mixing of water in oil due to early condensation of gland steam at\nlabyrinth\n >This may be due to failure of gland steam condenser exhauster fan or due to higher gland steam pressure.\n\u2022 Over filling of tank.\n\u2022 Increase in oil temperature will also increase oil volume.\n\u2022 During unit shut down all system oil will drain to main oil tank, it can\ncause the high level.\n\u2022 Seal oil tank over flow to main oil tank.\n\u2022 Due to Instrument malfunctioning.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_159" + }, + { + "chapter_numbre": "Chapter_14", + "chapter_name": "Chapter 15", + "chunk_index": 10, + "chunk_content": "11. Describe the lube oil cooler duty changeover, what important\nparameter need to closely watch during this changeover?\nNormally both coolers remained in service. But if there is due to some reason\n1 cooler in service and we have to take 2nd cooler out of service. The\nprocedure is as under.\na. First confirm the cooling water inlet/outlet valves are opened and\nair is purged.\nb. Then slowly open the oil balancing line valve to fill the standby\ncooler\nc. Open vent to confirm air purging.\nd. When oil is coming from stand by cooler and air is purged slowly\nopened the selective valve towards stand by cooler\ne. Close the balance line valve\nf. Standby cooler is in service.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1510" + }, + { + "chapter_numbre": "Chapter_14", + "chapter_name": "Chapter 15", + "chunk_index": 11, + "chunk_content": "12. What is our turbine run down time, what indicates if this time\nincreases or decreases?\nTurbine run down time is approx. 60 minutes. Increase in its coasting down\ntime indicates steam passing from MSV\u2019s / GV\u2019s and lower lube oil viscosity ( it\nmay be due to high lube oil temperatures). Decrease in coasting time may be\ndue to higher lube oil viscosity (It may be due to lower lube oil temperatures)\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1511" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 0, + "chunk_content": "1. What is the purpose of turning gear?\nLarge steam turbines are equipped with a turning gear assembly to slowly\nrotate the turbine and generator rotors during periods of cooling down after a\nshutdown, while warming during startup, and during periods when the unit is\noff-line and on standby. Turbine components, especially rotors, can be\ndamaged as a result of thermal stresses when uneven cooling or heating is\nallowed to take place.\nRotation of the turbine rotors helps even out the internal temperature\ndistribution within the turbine shells and internal components with respect to\nthe rotor. This helps reduce chances of thermal stress damage, such as rotor\nbowing and subsequently steam seal damage. By slowly rotating, the turbine\nrotors stay in a substantially straight and balanced condition during cooling,\nwarming, and standby\n\n\n1. What is the purpose of balance (dummy) piston, where its leak off\ngoes?\nBalance piston is provided in steam turbines and more particularly to reheat\nsteam turbines, wherein two opposed flow turbine elements are disposed in a\nsingle casing and are supplied by two separately actuated valve sets supplying\nthe two respective turbine elements.\nCommon turbine design today for reheat cycle steam turbines often utilize an\nopposed flow configuration within a single casing for the high pressure and\nintermediate pressure turbine elements. For normal operation, this\nconfiguration is inherently almost balanced with respect to axial thrust along\nthe shaft generated by the two opposed flow elements. The residual or net\nthrust developed can be carried by a thrust bearing of reasonable capacity. As\nthe thrust bearing size increases, the frictional losses increase, and economy\ndictates a small thrust bearing.\nUnder certain conditions, the \"control\" valves (MSV\u2019s / GV\u2019s) supplying high-\npressure steam to the high-pressure turbine element may remain open, while\nthe \"intercept\" valves (RSV\u2019s/ICV\u2019s) supplying reheat steam to the\nintermediate pressure element may close. In this event, a transiently high axial\nthrust will be developed by the high-pressure element, and it has been\nnecessary to provide a thrust bearing which is large enough to accommodate\nthis temporary phenomena. Consequently, it would be desirable to minimize\nthe thrust bearing size so as to avoid large losses during normal operation and\nyet be able to accommodate the aforesaid transient conditions.\nTherefore thrust balancing or \"dummy\" piston at the packing is provided to\ncompensate for axial thrust imposed in the opposite direction on the shaft due\nto steam flowing through the blading,\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_160" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 1, + "chunk_content": "2. What is the start permissive of turning gear?\nThe start permissive of turning gear is,\n\u2022 Instrument air pressure normal.\n\u2022 Bearing oil pressure normal.\n\u2022 Hydrogen/stator coolant differential pressure not low.\n\u2022 Liquid chamber level not high.\n\u2022 GCCC alarm power supply healthy.\n\u2022 Gen. Seal oil differential pressure normal 0.3 kg/cm 2\n\u2022 Jacking oil pump in service. (<50 kg/cm2)\n\n\n2. What is turbine soaking, why it is required on 2200 rpm only?\nHeat soaking is the time given for a cold steam turbine to be warmed up so\nthat all the internal parts approach operating temperatures before it is put on\nload or before unit synchronization.\nMetals expand and contract at high temperatures and at low temperatures\nrespectively. At cold startup mode when turbine first stage metal temperature\nis less than 120 Deg C, temperature of HP-IP shell and of LP Shell is at\nambient condition and thermal expansion in turbine rotor is negligible.\nAfter unit synchronization, turbine would have to operate continuously at high\ntemperature and high pressure, it\u2019s rotating and stationary parts will expand.\nTherefore before unit synchronization, after completion of Set point 2 i.e. 2200\nRPM, steam flow is sufficient to uniformly increase the temperature of turbine\ncomponents/internals.Lalpir/Pakgen Power Plant 56\nCCR Qualification Book\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_161" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 2, + "chunk_content": "3. At what speed turning gear will engage and disengage automatically?\nTurning gear will engage at Zero Speed and will disengage at RPM greater\nthan 3\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_162" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 3, + "chunk_content": "4. When lube oil solenoid valve will open and how you can provide lube\noil if solenoid valve fail to open?\nAt 100 RPM lube oil solenoid valve opens and if it fails to open , its bypass\nvalve is also provided, it should be opened to maintain lube oil supply\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_163" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 4, + "chunk_content": "5. What do you understand about eccentricity and why it is important to\nbring eccentricity normal before rolling?\nEccentricity is distance between central axis of rotation and actual axis of\nrotation in turbine\nWhen a turbine rotor has temporary bowing, it is likely to have high vibration\nduring startup and until it straightens out with heat. The eccentricity probe\nsystem basically shows whether the eccentricity is consistent with previous\nstartups and whether the rotor bowing is stable or changing while on turning\ngear.\nIt should be normal before rolling as high eccentricity would indicate a bow in\nrotor and difference between central axis of rotation and actual axis of rotation.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_164" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 5, + "chunk_content": "6. What is differential expansion, what is its normal operating range?\nThe difference between rotor and casing expansion is called differential\nexpansion. Normal operating range is +15.5 to \u2013 1.7 mm\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_165" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 6, + "chunk_content": "7. What are the maximum allowable bearing metal temp and bearing\ndrain oil temp?\n\u2022 Bearing metal temperature range 107 ( alarm) & 113 ( Tripping)\n\u2022 Bearing oil temperature range ", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_166" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 7, + "chunk_content": "8. What is the purpose of thrust bearing, what do you understand about\nthrust wear?\nEvery turbine has a thrust bearing assembly responsible for keeping the\nstationary and rotating elements in their proper axial relationships. The thrust\nwear protection system monitors the rotor axial position for evidence of thrust\nbearing wear and will alarm and possibly shut the turbine down when the\nthrust bearing fails or might be expected to fail within a short period. The\nturbine thrust bearing assembly holds the rotor and the stationary components\nin their correct relative axial position.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_167" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 8, + "chunk_content": "9. What are the high bearing vibration alarm and trip settings for turbine\nand generator?\nBearing vibration 125 mm ( alarm) & 250 mm ( tripping)\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_168" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 9, + "chunk_content": "10. What are the possible causes of high bearing vibration?\nThe causes of high bearing vibration are,\n\u2022 Turbine blade broken.\n\u2022 High eccentricity.\n\u2022 Lube oil temp very high / very low.\n\u2022 Bearing misalignment.\n\u2022 Lube oil contamination.\n\u2022 Sharp load variation.\n\u2022 Water induction.\n\u2022 Over loading.\n\u2022 Critical speed.\n\u2022 Instrumentation malfunctioning.\n\u2022 Vibration transfer nearby machine.\n\u2022 Shaft imbalance.Lalpir/Pakgen Power Plant 55\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_169" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 10, + "chunk_content": "11. What is the purpose of balance (dummy) piston, where its leak off\ngoes?\nBalance piston is provided in steam turbines and more particularly to reheat\nsteam turbines, wherein two opposed flow turbine elements are disposed in a\nsingle casing and are supplied by two separately actuated valve sets supplying\nthe two respective turbine elements.\nCommon turbine design today for reheat cycle steam turbines often utilize an\nopposed flow configuration within a single casing for the high pressure and\nintermediate pressure turbine elements. For normal operation, this\nconfiguration is inherently almost balanced with respect to axial thrust along\nthe shaft generated by the two opposed flow elements. The residual or net\nthrust developed can be carried by a thrust bearing of reasonable capacity. As\nthe thrust bearing size increases, the frictional losses increase, and economy\ndictates a small thrust bearing.\nUnder certain conditions, the \"control\" valves (MSV\u2019s / GV\u2019s) supplying high-\npressure steam to the high-pressure turbine element may remain open, while\nthe \"intercept\" valves (RSV\u2019s/ICV\u2019s) supplying reheat steam to the\nintermediate pressure element may close. In this event, a transiently high axial\nthrust will be developed by the high-pressure element, and it has been\nnecessary to provide a thrust bearing which is large enough to accommodate\nthis temporary phenomena. Consequently, it would be desirable to minimize\nthe thrust bearing size so as to avoid large losses during normal operation and\nyet be able to accommodate the aforesaid transient conditions.\nTherefore thrust balancing or \"dummy\" piston at the packing is provided to\ncompensate for axial thrust imposed in the opposite direction on the shaft due\nto steam flowing through the blading,\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1610" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 11, + "chunk_content": "12. What is turbine soaking, why it is required on 2200 rpm only?\nHeat soaking is the time given for a cold steam turbine to be warmed up so\nthat all the internal parts approach operating temperatures before it is put on\nload or before unit synchronization.\nMetals expand and contract at high temperatures and at low temperatures\nrespectively. At cold startup mode when turbine first stage metal temperature\nis less than 120 Deg C, temperature of HP-IP shell and of LP Shell is at\nambient condition and thermal expansion in turbine rotor is negligible.\nAfter unit synchronization, turbine would have to operate continuously at high\ntemperature and high pressure, it\u2019s rotating and stationary parts will expand.\nTherefore before unit synchronization, after completion of Set point 2 i.e. 2200\nRPM, steam flow is sufficient to uniformly increase the temperature of turbine\ncomponents/internals.Lalpir/Pakgen Power Plant 56\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1611" + }, + { + "chapter_numbre": "Chapter_15", + "chapter_name": "Chapter 16", + "chunk_index": 12, + "chunk_content": "13. What is turbine force cooling, when it is required and how you will do\nit?\nOperating steam turbine at low pressure and temperature will cool down its\ninternals. It is required to carry out maintenance job on turbine components /\ninternals.\nReduce the unit load to (20% load)\nDuring the load reduction, main steam temperature shall be reduced by using\nDe-SH, burner tilt and GRF inlet damper manually.\nMain burner shall be changed from Stage-B to Stage-A\nWhen the Turbine 1st stage metal temperature is reduced to 350 ~ 360 deg C,\nturbine forced cooling down can be finished.\nKeep an eye on first stage metal temperature. Main steam temperature should\nalways +55 0C superheat\nDuring forced cooling keep thermal stress, vibration and rotor expansion in\nrange.\n1st stage metal temp rate should not increase > 24oC /Hr\nFollow the graph for controlling force cooling parameters\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1612" + }, + { + "chapter_numbre": "Chapter_16", + "chapter_name": "Chapter 17", + "chunk_index": 0, + "chunk_content": "1. How many devices are provided for vacuum pulling, explain briefly the\npurpose of each?\n3 type of vacuum devices are provided for vacuum pulling.\n1) Startup Ejector ( Hogging ejector) \u2013 Used during startup to establish\nvacuum upto 550 mm of Hg\n\n\n1. Explain briefly the procedure to take vacuum system in services?\nPre-requisites;\n\u2022 BCWP (any) in service (for main CP-motor cooling)\n\u2022 Main condensate pump (any) in service\n>As all vacuum system related valves gland sealing water is\n supplied from main condensate pump header\n>Condensate of auxiliary steam from main ejector is used to preheat condensate in Gland steam condenser. In the\nabsence of condensate water, gland steam condenser tubes may overheat.\n\u2022 Auxiliary steam header pressure is greater than 13 kg/cm2\n\u2022 Turbine on turning gear\n\u2022 Instrument air pressure is normal\n\u2022 Vacuum system condensate trap bypass valves open (local activity to\nremove any accumulated condensate)\nAction On CRT:-\nConfirm following equipments status as\n\u2022 Condenser vacuum breaker v/v ON AUTO.\n\u2022 Gland steam condenser exhauster fan ON AUTO.\n\u2022 Gland steam PCV inlet MOV ON AUTO.\n\u2022 Startup ejector air & steam MOV ON AUTO.\n\u2022 Main ejector air & steam MOV ON AUTO.\n\u2022 Both vacuum pumps subsequence LOCK.\nGive \u201cON\u201d command from turbine sequence master. Vacuum system will start\nas per following steps.\n1) Selected Gland steam exhauster fan will start as per priority.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_170" + }, + { + "chapter_numbre": "Chapter_16", + "chapter_name": "Chapter 17", + "chunk_index": 1, + "chunk_content": "2. What is the normal vacuum of condenser, what are the effects of low\nvacuum?\nNormal condenser vacuum is 692 mmHg.\nEffects of low vacuum: -\n\u2022 Steam consumption / kWh will increase.\n\u2022 Exhaust hood temp. Will increase.\n\u2022 Boiler fuel consumption will increase.\n\u2022 Heat rate will increase.\n\u2022 Over all plant efficiency will drop.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_171" + }, + { + "chapter_numbre": "Chapter_16", + "chapter_name": "Chapter 17", + "chunk_index": 2, + "chunk_content": "3. What are the possible reasons of low vacuum, what will be your\nactions in case of vacuum drop?\nThere can be one of the following reasons:\n\u2022 Due to malfunctioning of steam jet ejector trap.\n\u2022 Due to trap vent.\n\u2022 Air ingress.\n\u2022 High Cooling water temperatures.\n\u2022 Inadequate Supply Steam pressure to ejector.\n\u2022 Scaling on condenser tubes.\n\u2022 High Condenser level.\n\u2022 Low Condenser level.\n\u2022 Low efficiency of cooling tower.\n\u2022 Cooling water flow is less than the requirement.\n\u2022 Due to rupturing or damaging of LP turbine rupture disc.\nACTION:\n\u2022 Start vacuum pump\n\u2022 Check auxiliary steam pressure.\n\u2022 Check main ejector steam and air MOV\u2019s\n\u2022 Request area engineer to take area round and check LP turbine\nrupture disks.\n\u2022 Cooling water parameters ( CT fans , their frequency)\n\u2022 If vacuum continues to drop, drop the unit load till the point vacuum\nbecomes normal.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_172" + }, + { + "chapter_numbre": "Chapter_16", + "chapter_name": "Chapter 17", + "chunk_index": 3, + "chunk_content": "4. When vacuum breaker will open and close automatically, what type of\npower is provided for this valve, identify the power breaker?\nVacuum breaker will open on 400 rpm while shutting down the unit and will\nclose on 100 mmHg during vacuum pulling in startup.\nVacuum breaker is DC powered and is located in UPS roomLalpir/Pakgen Power Plant 58\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_173" + }, + { + "chapter_numbre": "Chapter_16", + "chapter_name": "Chapter 17", + "chunk_index": 4, + "chunk_content": "5. What is the role of sealing water in vacuum system, how sealing\nwater header pressure being maintained?\nSealing water is provided to all valves connected to vacuum system, and\ncondenser to avoid air ingress through their glands into the condenser.\nAn orifice is provided from condensate pumps discharge header to maintain\nthe sealing water pressure in secondary header. Pressure can also be\nadjusted by manual isolation v/v.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_174" + }, + { + "chapter_numbre": "Chapter_16", + "chapter_name": "Chapter 17", + "chunk_index": 5, + "chunk_content": "6. What is the purpose of gland steam, where gland steam has been\nprovided?\nPurpose of gland steam is to provide a positive seal to avoid air ingress inside\nturbine or to avoid steam leakage form the turbine .it is provided on HP and LP\ncylinder glands through labyrinth seal.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_175" + }, + { + "chapter_numbre": "Chapter_16", + "chapter_name": "Chapter 17", + "chunk_index": 6, + "chunk_content": "7. What is the gland steam normal header pressure and how it is being\nmaintained?\nNormal header pressure is 0.20 to 0.35 kg/ cm2 and it is maintained through\nPCV. Steam is supplied by auxiliary steam header up to 30% load after that\nleak off steam from turbine glands is sufficient to fulfill the requirements\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_176" + }, + { + "chapter_numbre": "Chapter_16", + "chapter_name": "Chapter 17", + "chunk_index": 7, + "chunk_content": "8. What is the purpose of gland steam exhauster, what will happen if\nrunning fan trip and standby did not cut in, what will be your actions?\nGland steam exhauster maintains vacuum > 500 mm H2O to evacuate the\ngland steam before condensation at seals. If steam condenses at seals there\nare chances that this water may mix with lube oil.\nIf, for any reason both are not available, then we have provision of a spray v/v\n(water supplied by condensate pump discharge header) on steam path.\nOpening that valve will maintain temperature delta due to which steam flow will\nbe maintained.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_177" + }, + { + "chapter_numbre": "Chapter_16", + "chapter_name": "Chapter 17", + "chunk_index": 8, + "chunk_content": "9. What is the importance of exhaust hood temp, how vacuum affects\nthis temp, at what temp spray will start?\nThe likely causes of high exhaust hood temperature are either low condenser\nvacuum or continuous operation at a very low steam flow.\nExhaust Hood Temperature plays a vital role to save LP turbine blades in the\nlast few stages of the turbine. \u201cExhaust Hood Temperature\u201d is the chief\ncriterion for \u201cCondenser Vacuum V. Low\u201d which signifies the lower density and\nlower mass flow rate in the last stages of LP Turbine so the temperature in the\nexhaust hood rises as less heat is removed to the condenser and more stays\nin the hood area (Famously known as churning), which in turn causes un even\nthermal expansion of last stage LP Turbine blades and ultimately damage to\nthese turbine blades.\nCondenser vacuum is inversely proportional to condenser exhaust hood\ntemperature. Exhaust hood temperatures will increase as soon as condenser\nvacuum drops.\nAt 70 Deg C exhaust hood temperatures, exhaust hood spray will open.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_178" + }, + { + "chapter_numbre": "Chapter_16", + "chapter_name": "Chapter 17", + "chunk_index": 9, + "chunk_content": "10. What is the normal temp of LP gland steam, how it is being controlled,\nwhat will your action if this temp start to increase?\nNormal temperature of LP gland steam is 150 to 180 0C It is controlled by\nspray water, which is supplied by condensate pumps outlet.\nIf LP gland steam temp start increase then check the behavior of TCV, if it is\nmalfunctioning, try to control with bypass iso valve.Lalpir/Pakgen Power Plant 59\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_179" + }, + { + "chapter_numbre": "Chapter_16", + "chapter_name": "Chapter 17", + "chunk_index": 10, + "chunk_content": "11. Explain briefly the procedure to take vacuum system in services?\nPre-requisites;\n\u2022 BCWP (any) in service (for main CP-motor cooling)\n\u2022 Main condensate pump (any) in service\n>As all vacuum system related valves gland sealing water is\n supplied from main condensate pump header\n>Condensate of auxiliary steam from main ejector is used to preheat condensate in Gland steam condenser. In the\nabsence of condensate water, gland steam condenser tubes may overheat.\n\u2022 Auxiliary steam header pressure is greater than 13 kg/cm2\n\u2022 Turbine on turning gear\n\u2022 Instrument air pressure is normal\n\u2022 Vacuum system condensate trap bypass valves open (local activity to\nremove any accumulated condensate)\nAction On CRT:-\nConfirm following equipments status as\n\u2022 Condenser vacuum breaker v/v ON AUTO.\n\u2022 Gland steam condenser exhauster fan ON AUTO.\n\u2022 Gland steam PCV inlet MOV ON AUTO.\n\u2022 Startup ejector air & steam MOV ON AUTO.\n\u2022 Main ejector air & steam MOV ON AUTO.\n\u2022 Both vacuum pumps subsequence LOCK.\nGive \u201cON\u201d command from turbine sequence master. Vacuum system will start\nas per following steps.\n1) Selected Gland steam exhauster fan will start as per priority.\n2) Gland steam MOV will open about 15 to 20 % to warm up the system.\n3) After warming up, gland steam MOV will full open , PCV will take\ncontrol and maintain the pressure between 0.35 to 0.40 kg/cm", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1710" + }, + { + "chapter_numbre": "Chapter_16", + "chapter_name": "Chapter 17", + "chunk_index": 11, + "chunk_content": "2.\n4) Startup ejector steam side MOV will open, and then airside MOV will\nopen.\n5) At 100 mmHg condenser vacuum, vacuum breaker MOV will close.\n6) It is good practice to start both vacuum pumps to achieve the vacuum\neasily and efficiently.\n7) At 550 mmHg condenser vacuum start up ejector will cut out and main\nejector will take load automatically.\n8) At 550 mmHg condenser vacuum AOP will cut in and TOP will cut off\nautomatically.\n9) AT 650 mmHg turbine by pass open permissive will appear.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_1711" + }, + { + "chapter_numbre": "Chapter_17", + "chapter_name": "Chapter 18", + "chunk_index": 0, + "chunk_content": "1. How you will start the 1st condensate pump?\n\u2022 Fill condenser up to normal level (Zero mm)\n\u2022 Start BCWP for its motor cooling water\n\u2022 Make sure instrument air pressure is normal\n\u2022 Lock condensate pump sequence.\n\u2022 Put condensate pump\u2019s recirculation valve on auto\n\u2022 Coordinate with area engineer (He will partially close its discharge\nvalve to save motor from drawing high current)\n\u2022 Give start command from pump control loop plate\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_180" + }, + { + "chapter_numbre": "Chapter_17", + "chapter_name": "Chapter 18", + "chunk_index": 1, + "chunk_content": "2. What is the purpose of minimum flow valve, when it opens and close?\nThe purpose of minimum flow recirculation is to keep the sufficient flow\nthrough steam jet air ejector and gland steam condenser during unit start up\ncondition for steam cooling.\nIt has interlock with de-aerator LCV. When de-aerator LCV starts to open it\nstarts to close. When de-aerator LCV closes below 20%, condensate pump\nrecirculation starts to open\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_181" + }, + { + "chapter_numbre": "Chapter_17", + "chapter_name": "Chapter 18", + "chunk_index": 2, + "chunk_content": "3. How hot well level is being maintained, what are the effects of low and\nhigh hot well level?\nHot well level can be maintained by the condenser makeup water (LCV)\nthrough condensate storage tank (normal lineup) or through demin pumps\ncommon header bypassing condensate storage tank (Shutdown / Startup\nlineup).\nAt hot well level very low condensate pumps will also trip on \u2013200 mm.\nAt very high level spill over will open to condensate storage tank in order to\nmaintain level.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_182" + }, + { + "chapter_numbre": "Chapter_17", + "chapter_name": "Chapter 18", + "chunk_index": 3, + "chunk_content": "4. What is the purpose of condensate storage tank, how its level is being\nmaintained?\nThe purpose of condensate storage tank is to hold the sufficient amount of\nmakeup water to maintain condenser level.\nIn case of high hot well level it absorbs the water through spill over v/v.\nIts level is maintained from the demin water pumps header through LCV.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_183" + }, + { + "chapter_numbre": "Chapter_17", + "chapter_name": "Chapter 18", + "chunk_index": 4, + "chunk_content": "5. Why spill over valve is provided, when it opens and closes, where spill\nover water will go?\nSpill over v/v is provided to maintain condenser / hot well level.\nIt opens at 250 mm condenser level and closes at 100 mm. Spilled water goes\nback to condensate storage tank.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_184" + }, + { + "chapter_numbre": "Chapter_17", + "chapter_name": "Chapter 18", + "chunk_index": 5, + "chunk_content": "6. What are the systems using condensate water?\nSystems using condensate water are,\n\u2022 Boiler feed water storage tank (DA Storage Tank).\n\u2022 For gland sealing of condensate pumps / vacuum pumps / valves.\n\u2022 Exhaust hood spray.\n\u2022 LP gland steam spray.\n\u2022 HP by pass spray.\n\u2022 BCP motor cavity filling.\n\u2022 Condensate pump strainers back washing.Lalpir/Pakgen Power Plant 61 CCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_185" + }, + { + "chapter_numbre": "Chapter_17", + "chapter_name": "Chapter 18", + "chunk_index": 6, + "chunk_content": "7. When the 2nd condensate pump will cut in and cut out on sequence?\nAt 145 MW Gross condensate pump will cut in increasing load.\nAt unit load less than 135 MW gross , 2nd condensate pump can be stopped\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_186" + }, + { + "chapter_numbre": "Chapter_18", + "chapter_name": "Chapter 19", + "chunk_index": 0, + "chunk_content": "1. What is the start permissive of a CWP?\nStart permissive of a CWP has only two conditions\nAny (A/B) CWP lube water pump On and CWP lube water outlet pressure is\nnormal\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_190" + }, + { + "chapter_numbre": "Chapter_18", + "chapter_name": "Chapter 19", + "chunk_index": 1, + "chunk_content": "2. What are the steps when a CWP start command given from Main or\nsub sequence?\nPre-checks\nLube water pump for CWP\u2019s bearing is in service and its pressure /flow is\nnormal\nCWP Start command from main Sequence\nGo to Aux Sequence 1 screen\nSelect Aux 1 Sequence \u201cCirculation water sequence Master group\u201d\n\u201cLock\u201d the sequence\nPut desired pump and its discharge valve control mode on \u201cauto\u201d\nSet priority as per desired pump\nCheck On permit on main sequence\nUnlock the main sequence.\nGive on command to sequence.\nThis will give on command to priority selected CWP\nCWP Start command from Sub Sequence\nGo to Aux Sequence 1 screen\nSelect Aux 1 Sequence \u201cCirculation water sequence Master group\u201d\n\u201cLock\u201d the sequence\nPut desired pump and its discharge valve control mode on \u201cauto\u201d\nGive on command to desired pump from its sub sequence.\nThis will give on command to selected CWP\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_191" + }, + { + "chapter_numbre": "Chapter_18", + "chapter_name": "Chapter 19", + "chunk_index": 2, + "chunk_content": "3. What are the sources of lube/ cooling water for CWP bearing?\nThere are two sources of lube/cooling water for CWP\n1) CWP cooling water pump taking suction from CT basin\n2) Discharge line from CWP\u2019s discharge line.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_192" + }, + { + "chapter_numbre": "Chapter_18", + "chapter_name": "Chapter 19", + "chunk_index": 3, + "chunk_content": "4. What is the normal temp difference across the condenser, what\nindicates the increase or decrease of this temp difference?\nDifferential temp across the condenser is 10 ~ 15 0C\nIncrease in temperature indicates that cooling tower efficiency is not up to\nmark.\n\u2022 Effect of Humidity and atmospheric temp.\n\u2022 Restriction of flow in cooling water.\nDecrease in temp indicates that there is some scaling inside the tubes or on\nouter surface of the tubes.\n\u2022 Maximum CW flow at minimum requirements.\n\u2022 More Cooling tower fans are in service than required.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_193" + }, + { + "chapter_numbre": "Chapter_18", + "chapter_name": "Chapter 19", + "chunk_index": 4, + "chunk_content": "5. How cooling towers efficiency affects the unit heat rate?\nThe primary task of a cooling tower is to reject heat into the atmosphere. At\nour unit, cooling water absorbs heat from steam through condenser and rejects\nit into the atmosphere in the continuous cycle.\nIf for any reason, it absorbs less heat or rejects less heat into the atmosphere,\nit will not effectively condense steam and hence it will increase backpressure\non turbine. This will increase fuel flow and have \u2013ve impact on unit heat rate.Lalpir/Pakgen Power Plant 63\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_194" + }, + { + "chapter_numbre": "Chapter_18", + "chapter_name": "Chapter 19", + "chunk_index": 5, + "chunk_content": "6. Explain condenser tube leak detection and plugging? Is it possible at\nminimum load, write the procedure for it?\nCondenser Tube Leakage Detection\n\u2022 Reduce unit load <50%.\n\u2022 Isolate half portion of condenser cooling water.\n\u2022 Drain the water Box.\n\u2022 Perform LOTO\n\u2022 Open inlet and outlet cooling water side man holes.\nIt is preferable to drain the water boxes and open the access doors while the\ncondenser tube sheet is still hot. This helps leak detection by drying off the\noutside of the tube sheet faster.\nMethod-1 (Off load)\n\u2022 Fill the condenser shell side through the hot well\n\u2022 Monitor the level as it rises.\n\u2022 Continue filling until the level is above the upper tubes\n\u2022 Inspect the tube sheet for leaks from the tubes or from the tube-to-\ntube sheet joints\n\u2022 Mark any leaky points.\nMethod-2 (On load)\n\u2022 Try to detect leaky tube with the help of candle flame.\n\u2022 Where the candle flame moves towards tube, mark the tube.\n\u2022 Confirm these suspected leaky tubes from the other end of condenser\nwith the same candle flame procedure.\nDefective Tube plugging\n\u2022 Insert a plug (brass or nylon) into the tube end and drive it in lightly\n\tusing a hammer until snug.\n\u2022 Insert a plug into the opposite end of the tube and drive it in lightly.\n\u2022 Both ends of a defective tube must be plugged.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_195" + }, + { + "chapter_numbre": "Chapter_19", + "chapter_name": "Chapter 20", + "chunk_index": 0, + "chunk_content": "1. What are the start permissives of canal water pump, describe the\nprocedure to start the canal water pump from sequence?\nPermissives:-\n\u2022 A-Canal water pump cooling water \u201cON\u201d or\n\u2022 B-Canal water cooling water pump \u201cON\u201d\n\u2022 A-Canal water pump cooling water flow < Low \u201cNOT\u201d\nStart up:\n\u2022 Lock the main sequence.\n\u2022 Lock the sub sequence.\n\u2022 Select the settling basin.\n\u2022 Put selection on RAINY.\n\u2022 Select WELL & CANAL.\n\u2022 Check cooling water pump on \u201cAUTO\u201d\n\u2022 Check the selected pump on \u201cAUTO\u201d.\n\u2022 Make sure that pump suction and discharge v/v are open in field.\n\u2022 Recirculation v/v should on \u201c AUTO\u201d. (Its setting is on 2.1bar).\n\u2022 Settling basin LCV should on AUTO.\n\u2022 Unlock the sub sequence.\n\u2022 Unlock the main sequence.\n\u2022 Give \u201cON\u201d command.\n2. How well water sequence works, discuss the procedure to change\ncanal water to well water and vice versa?\nShifting from Canal Water to Well Water\n\u2022 Lock the main sequence.\n\u2022 Lock the sub sequence.\n\u2022 Put selection on \u201cDRY\u201d\n\u2022 Put line selection on \u201cWELL LINE\u201d.\n\u2022 A/B settling basin level should be \u201cNORMAL\u201d.\n\u2022 Make sure that the discharge v/v is open for the selected pumps.(local check)\n\u2022 Stop canal water pump\n\u2022 Start well water pump as per cooling tower makeup and filter water basin filling\nrequirement\nAs well pumps conductivity and calcium hardness differs from each other, so their priority\nis set as per chemical analysis in Lab. To follow their priority, they are kept on manual and\nstarted as per requirement.\nShifting from Canal Water to Well Water\nPre-checks (Local Activity)\nClarifier and DMF system is in service and Canal level is normal\n\u2022 Lock the main sequence\n\u2022 Lock subsequence of canal water pumps\n\u2022 Put selection on Rainy\n\u2022 Put main pump and its cooling water pump on auto\nStop well water pumps\nUnlock & give on command to canal water pump from sub sequence.\nUnlock & give on command to main sequence.Lalpir/Pakgen Power Plant 65\nCCR Qualification Book\n3. Which settling basin can be used for both units, explain how you can\nselect this basin with unit 2?\nSettling basin B can be used for both units, to select it for unit 2, open its LCV\nfrom Unit 1. Ask area engineer to divert well water pumps of Unit 2 towards\nsettling basin B\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_200" + }, + { + "chapter_numbre": "Chapter_19", + "chapter_name": "Chapter 20", + "chunk_index": 1, + "chunk_content": "2. How well water sequence works, discuss the procedure to change\ncanal water to well water and vice versa?\nShifting from Canal Water to Well Water\n\u2022 Lock the main sequence.\n\u2022 Lock the sub sequence.\n\u2022 Put selection on \u201cDRY\u201d\n\u2022 Put line selection on \u201cWELL LINE\u201d.\n\u2022 A/B settling basin level should be \u201cNORMAL\u201d.\n\u2022 Make sure that the discharge v/v is open for the selected pumps.(local check)\n\u2022 Stop canal water pump\n\u2022 Start well water pump as per cooling tower makeup and filter water basin filling\nrequirement\nAs well pumps conductivity and calcium hardness differs from each other, so their priority\nis set as per chemical analysis in Lab. To follow their priority, they are kept on manual and\nstarted as per requirement.\nShifting from Canal Water to Well Water\nPre-checks (Local Activity)\nClarifier and DMF system is in service and Canal level is normal\n\u2022 Lock the main sequence\n\u2022 Lock subsequence of canal water pumps\n\u2022 Put selection on Rainy\n\u2022 Put main pump and its cooling water pump on auto\nStop well water pumps\nUnlock & give on command to canal water pump from sub sequence.\nUnlock & give on command to main sequence.Lalpir/Pakgen Power Plant 65\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_201" + }, + { + "chapter_numbre": "Chapter_19", + "chapter_name": "Chapter 20", + "chunk_index": 2, + "chunk_content": "3. Which settling basin can be used for both units, explain how you can\nselect this basin with unit 2?\nSettling basin B can be used for both units, to select it for unit 2, open its LCV\nfrom Unit ", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_202" + }, + { + "chapter_numbre": "Chapter_19", + "chapter_name": "Chapter 20", + "chunk_index": 3, + "chunk_content": "1. What are the start permissives of canal water pump, describe the\nprocedure to start the canal water pump from sequence?\nPermissives:-\n\u2022 A-Canal water pump cooling water \u201cON\u201d or\n\u2022 B-Canal water cooling water pump \u201cON\u201d\n\u2022 A-Canal water pump cooling water flow < Low \u201cNOT\u201d\nStart up:\n\u2022 Lock the main sequence.\n\u2022 Lock the sub sequence.\n\u2022 Select the settling basin.\n\u2022 Put selection on RAINY.\n\u2022 Select WELL & CANAL.\n\u2022 Check cooling water pump on \u201cAUTO\u201d\n\u2022 Check the selected pump on \u201cAUTO\u201d.\n\u2022 Make sure that pump suction and discharge v/v are open in field.\n\u2022 Recirculation v/v should on \u201c AUTO\u201d. (Its setting is on 2.1bar).\n\u2022 Settling basin LCV should on AUTO.\n\u2022 Unlock the sub sequence.\n\u2022 Unlock the main sequence.\n\u2022 Give \u201cON\u201d command.\n2. How well water sequence works, discuss the procedure to change\ncanal water to well water and vice versa?\nShifting from Canal Water to Well Water\n\u2022 Lock the main sequence.\n\u2022 Lock the sub sequence.\n\u2022 Put selection on \u201cDRY\u201d\n\u2022 Put line selection on \u201cWELL LINE\u201d.\n\u2022 A/B settling basin level should be \u201cNORMAL\u201d.\n\u2022 Make sure that the discharge v/v is open for the selected pumps.(local check)\n\u2022 Stop canal water pump\n\u2022 Start well water pump as per cooling tower makeup and filter water basin filling\nrequirement\nAs well pumps conductivity and calcium hardness differs from each other, so their priority\nis set as per chemical analysis in Lab. To follow their priority, they are kept on manual and\nstarted as per requirement.\nShifting from Canal Water to Well Water\nPre-checks (Local Activity)\nClarifier and DMF system is in service and Canal level is normal\n\u2022 Lock the main sequence\n\u2022 Lock subsequence of canal water pumps\n\u2022 Put selection on Rainy\n\u2022 Put main pump and its cooling water pump on auto\nStop well water pumps\nUnlock & give on command to canal water pump from sub sequence.\nUnlock & give on command to main sequence.Lalpir/Pakgen Power Plant 65\nCCR Qualification Book\n3. Which settling basin can be used for both units, explain how you can\nselect this basin with unit 2?\nSettling basin B can be used for both units, to select it for unit 2, open its LCV\nfrom Unit 1. Ask area engineer to divert well water pumps of Unit 2 towards\nsettling basin B\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_203" + }, + { + "chapter_numbre": "Chapter_20", + "chapter_name": "Chapter 21", + "chunk_index": 0, + "chunk_content": "1. What is the importance of chemistry in a power plant?\nChemical parameters directly affect the plant life as they are important to avoid\ncorrosion, scaling, silica, pitting, pH control and other similar parameters.\nPlant outward waste chemical parameters are also important to reduce waste /\nexcess usage of chemical and to protect the environment.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_210" + }, + { + "chapter_numbre": "Chapter_20", + "chapter_name": "Chapter 21", + "chunk_index": 1, + "chunk_content": "2. What type of chemical dosing is being done in feed water system,\nwhat is the purpose of each, indicate the different dosing points?\nThe different types of chemicals use for feed water system are,\nHydrazine :\nIt is helpful in scavenging of oxygen & dissolved gases.\nHydrazine dosing points are situated after de-aerator.\n\u2022 One point is given for the filling of economizer through demineralized\nwater in startups (by adding spool piece on boiler 5th floor).\nAmmonia:\nIts purpose is to control the pH\nAmmonia dosing points are situated right after de-aerator at discharge of\ncondensate pumps.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_211" + }, + { + "chapter_numbre": "Chapter_20", + "chapter_name": "Chapter 21", + "chunk_index": 2, + "chunk_content": "3. What is the role of Deaerater in chemistry control, how it works?\nD/A is open tray type heat exchanger where oxygen other non-condensable\ngases are removed by thermal de-aeration.\nCondensate water is fed from the top of de-aerator and de-aerating\nSteam is supplied from the bottom.\nCondensate water is distributed in fine droplets over the steam through trays\nand its path is diverted through baffle plates. This phenomenon causes flash\nbetween steam and condensate and thus non condensable gases get\nseparated from water.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_212" + }, + { + "chapter_numbre": "Chapter_20", + "chapter_name": "Chapter 21", + "chunk_index": 3, + "chunk_content": "4. What do you know about hideout phenomenon?\nSodium tri phosphate is being used in the boiler to dissolve the silicates.\nIn high pressure boilers sodium tri phosphate sticks with the walls on high load\nif there is uneven temperature distribution. Therefore in normal tests it cannot\nbe detected. At low load the sticky layer of phosphate can be dissolved in the\nsystem and can be measured\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_213" + }, + { + "chapter_numbre": "Chapter_20", + "chapter_name": "Chapter 21", + "chunk_index": 4, + "chunk_content": "5. What is the purpose of Vanadium Inhibitor dosing, what type\nVanadium Inhibitor is being used in Lalpir?\nVanadium Inhibitor is Magnesium based solution and is injected in the fuel\nheader just before entrance in boiler. It reacts with vanadium and converts into\nvanadium penta oxide due to which vanadium sticking temperature range\nincreases and gets carried over with flue gases into stack. As a result it\nincrease the boiler efficiency and increase the life of air heaters as pH of soot\nincreases from 3.5 to 5.0 due to which it does not forms the sulfuric acid at air\nheater on cold end.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_214" + }, + { + "chapter_numbre": "Chapter_20", + "chapter_name": "Chapter 21", + "chunk_index": 5, + "chunk_content": "6. What alarms and indications relating to chemical dosing available on\nCRT?\n\u2022 Low / High pH. (Condensate pump / sampling rack / cooling water system).\n\u2022 Conductivity high.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_215" + }, + { + "chapter_numbre": "Chapter_20", + "chapter_name": "Chapter 21", + "chunk_index": 6, + "chunk_content": "7. What is the first indication of condenser tube leak?\nCondensate conductivity increase is the first indication. (Condensate\nconductivity normal range is 2 to 6 micro siemens)Lalpir/Pakgen Power Plant 67\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_216" + }, + { + "chapter_numbre": "Chapter_20", + "chapter_name": "Chapter 21", + "chunk_index": 7, + "chunk_content": "8. What are the pH and conductivity limits in condensate water, feed\nwater, drum water and main steam?\nParameter pH Conductivity (Micro\nSiemens)\nCondensate Water 8.8 ~ 9.2 2 ~ 6\nFeed Water 8.8 ~ 9.2 2 ~ 6\nDrum Water 9.0 ~ 9.8 <38\nSteam 8.8 ~ 9.2 2 ~ 6\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_217" + }, + { + "chapter_numbre": "Chapter_20", + "chapter_name": "Chapter 21", + "chunk_index": 8, + "chunk_content": "9. What is the silica limit in make-up water, condensate water, drum and\nmain steam?\nMake up Water, Cond. Water, and Main Steam silica should be less than 20\nppb & drum silica should be less than 200 ppb\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_218" + }, + { + "chapter_numbre": "Chapter_20", + "chapter_name": "Chapter 21", + "chunk_index": 9, + "chunk_content": "10. What is the purpose of N blanketing, what are the systems where N\n2 2\nblanketing facility has been provided?\nN2 blanketing is used for preservation purpose. Positive pressure of N2 is\nmaintained to avoid the presence/ingress of air, which can cause the\ncorrosion.\nN is also used to purge out the inflammable hazards from system.\n2\nN is provided on Boiler, D/A, HPH and HFO header.\n2\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_219" + }, + { + "chapter_numbre": "Chapter_21", + "chapter_name": "Chapter 22", + "chunk_index": 0, + "chunk_content": "1. What is the technical data of our generator, what parameters relating\nto generator are available on CRT?\nRating 365 MW\nNominal rated capacity at 4.5 bars abs. hydrogen pressure 430,000 kVA\nPower factor 0.85 lagging\n0.90 leading\nRated Hyd. Pressure 4.5 bar abs\nNumber of phases 3\nNumber of poles 2\nFrequency 50 Hz\nRated Speed 3000 rpm\nTerminal voltage \n\n1. What is reverse power, what is its setting on our unit?\nReverse power is a type of protection which protects the generator from\nmotoring effect. This protection is provided for the turbine to avoid windage\nlosses. It will operate at 3 MW generator load (approx.).\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_220" + }, + { + "chapter_numbre": "Chapter_21", + "chapter_name": "Chapter 22", + "chunk_index": 1, + "chunk_content": "2. Discuss the capability curve of generator, what are the effects if we go\nbeyond this curve?\nIf we look at the capability curve it is drawn on x-axis and y-axis. On y-axis\nthere is MW and on X-axis there are MVAR leading and lagging sides are on\nleft and right sides respectively.\nThere is one white parabolic cure showing the extreme MVAR limits and blue\nline reflects the MW limits, along with these lines dotted lines indicate power\nfactor and curser position shows the present running status point.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_221" + }, + { + "chapter_numbre": "Chapter_21", + "chapter_name": "Chapter 22", + "chunk_index": 2, + "chunk_content": "3. Discuss in detail how to synchronize the generator with system?\nIf we will be on beyond the limits on leading side then our synchronous tie with\nsystem will be very weak and any minute deflection in system can cause de\nsynchronization and ultimately we will be cut off from the system as generator\nbreaker will open. Before this following alarms will appear.\na) AVR limit exceeds.\nb) AVR below manual restriction.\nIf we will be on positive side beyond the limits then excitation current will start\nto increase which will result in increase of rotor temperatures.\nOn top of the curve if we will exceed the MW then generator load high alarm\nwill appear. Even then if we will go up to 380 MW (or load will increase 10% of\nfull load due to system problem), then there will be run back up to 300 MW.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_222" + }, + { + "chapter_numbre": "Chapter_21", + "chapter_name": "Chapter 22", + "chunk_index": 3, + "chunk_content": "4. What interlock is provided for generator field breaker 41E to be closed\nduring unit start up and why?\nGenerator isolator has to be closed before closing the generator field breaker.Lalpir/Pakgen Power Plant 69\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_223" + }, + { + "chapter_numbre": "Chapter_21", + "chapter_name": "Chapter 22", + "chunk_index": 4, + "chunk_content": "5. Why hydrogen is being used as a cooling media in generator, what is\nthe maximum Allowable temp of cold gas?\nHydrogen has good heat transfer characteristics and has good heat transfer\ncoefficient as compared to air. It removes heat from generator through\nhydrogen coolers. It has less windage losses and light in weight. Allowable\nTemp limits:\nNormal set point is 400 C.\nHigh alarm on 47 0C.\nHigh . High alarm at 50 0C.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_224" + }, + { + "chapter_numbre": "Chapter_21", + "chapter_name": "Chapter 22", + "chunk_index": 5, + "chunk_content": "6. What is the purpose of seal oil system, what is the importance of seal\noil/ H2 differential pressure?\nSeal oil system is provided for proper sealing of hydrogen in generator casing\nso that it may not be in direct contact with air.\nSeal oil pressure is higher than hydrogen and its differential is about 0.8 bar\nwhich does not allow the hydrogen to come out of the generator casing and\navoid air ingress to avoid any explosion.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_225" + }, + { + "chapter_numbre": "Chapter_21", + "chapter_name": "Chapter 22", + "chunk_index": 6, + "chunk_content": "7. What is the purpose of stator coolant water, what is the importance of\nconductivity of this system and how it is being maintained?\nThe purpose of stator cooling water is to provide a cooling media for stator as\ndue to high current flow its temp increases.\nStator cooling water is demineralized water. Due to low conductivity (< 0.5\nmicro.S/ cm) it is bad conductor and there are no chances of any current flow.\nIts conductivity is being maintained by providing polisher (mixed bed) in close\nloop. Approx. 30% of total water passes through this polisher\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_226" + }, + { + "chapter_numbre": "Chapter_21", + "chapter_name": "Chapter 22", + "chunk_index": 7, + "chunk_content": "8. How you will come to know if there is cooling water leak inside\ngenerator casing?\nThere are no chances that cooling water will leak inside the generator as\nhydrogen pressure is kept greater than cooling water pressure. One indicator\nof leakage on stator coolers is that hydrogen pressure will drop frequently\nIf hydrogen seal oil system is working efficiently and on cooling water cycle\ndetraining chamber is releasing the gas frequently it means that gas is mixing\nsomewhere in water and the most critical area is stator itself\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_227" + }, + { + "chapter_numbre": "Chapter_21", + "chapter_name": "Chapter 22", + "chunk_index": 8, + "chunk_content": "9. What are the generator protections, explain briefly?Lalpir/Pakgen Power Plant 70\nCCR Qualification Book\nDevice / Function\nRelay\nNumber\n21 Distance \u2014 Backup for system and generator zone phase faults.\n24 Volts/Hz \u2014 Protection for generator over-excitation.\n25 Synchronism Check \u2014 Synchronism verification when\nparalleling\n27 Under voltage \u2014 Under voltage protection.\n27-3N Under voltage \u2014 Third harmonic under voltage protection.\n32 Reverse Power \u2014 Anti-motoring protection\n400 Loss-of-field \u2014 Protection for failure of the excitation system,\nreactance based.\n40Z Loss-of-field \u2014 Protection for failure of the excitation system,\nimpedance based.\n46 Current Negative Sequence \u2014 Unbalance current protection\n47 Voltage Negative Sequence \u2014 Unbalance voltage protection\n49 Temperature \u2014 Stator thermal protection\n51 Time Overcurrent \u2014 Phase Overcurrent protection\n51G Time Overcurrent \u2014 Ground Overcurrent protection\n51 N Time Overcurrent \u2014 Neutral Overcurrent protection\n51V Time Overcurrent \u2014 Overcurrent with voltage-controlled or\nvoltage-restrained. Backup protection for system or generator\nphase faults.\n59 Overvoltage \u2014 Generator overvoltage protection for phase\nand/or ground faults.\n59N Ground Overvoltage \u2014 Generator ground fault protection\n60 Voltage Balance \u2014 Detection of blown voltage transformer fuses\n(loss of phase)\n62 Time Delay \u2014 Provide a time delay for either the opening or\nclosing of a contact.\n63 Pressure Switch \u2014 Transformer overpressure fault protection\n64 F Field Ground \u2014 Detection of a generator field ground\n78 Out-of-Step \u2014 Protection for out-of-step or pole slip conditions\n810 Over frequency \u2014 Protection for over frequency\n81 U Under frequency \u2014 Protection for Under frequency\n86 Lockout Relay \u2014 A latching trip relay or device that requires an\noperator to reset.\n87G Differential \u2014 Generator current differential protection\n87N Differential \u2014 Ground differential protection\n87T Differential \u2014 Transformer current differential protection\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_228" + }, + { + "chapter_numbre": "Chapter_21", + "chapter_name": "Chapter 22", + "chunk_index": 9, + "chunk_content": "10. What is the purpose of lockout relay, where it is located?\nGen. lock out relay will operate in case of any generator protections actuates\nand it provides easiest path for track down.\nIt is situated on mezzanine floor inside relay room.Lalpir/Pakgen Power Plant 71\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_229" + }, + { + "chapter_numbre": "Chapter_21", + "chapter_name": "Chapter 22", + "chunk_index": 10, + "chunk_content": "11. What is reverse power, what is its setting on our unit?\nReverse power is a type of protection which protects the generator from\nmotoring effect. This protection is provided for the turbine to avoid windage\nlosses. It will operate at 3 MW generator load (approx.).\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2210" + }, + { + "chapter_numbre": "Chapter_21", + "chapter_name": "Chapter 22", + "chunk_index": 11, + "chunk_content": "12. Why and how Generator neutral is grounded?\nGenerator neutral is ground through NGR\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2211" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 0, + "chunk_content": "1. What are the voltage limits of 220kV system? What is our role in\ncontrolling this voltage?\nAs per clause 1.3 of Schedule 2 of PPA , Lalpir / Pakgen is designed to\noperate within \u00b110% on the 220kV high voltage system. So 220kV voltage limit\nis between 198 kV to 242 kV.\nThe Complex is subject to tripping if voltage fluctuations outside the ranges\nstated in PPA schedule 2 clause 1.3(b) occur\nGSU is equipped with on load tap changer. Increasing its tap will decrease\n220kV system voltages and decreasing its tap will increase 220kV system\nvoltages.\nOperation of GSU tap changer is recommended in consultation with Shift\nmanager and NPCC (If required)\n\n\n1. What type of Circuit Breakers is provided in 220kV switchyard? What\nquenching media is used and what is operating mechanism of these\nbreakers?\n3 pole single chamber Air operated circuit breaker is used in 220KV switch\nyard. SF6 gas is used as quenching media in 220KV breakers\n1\n\n1.\n(Lock out relay need to be reset before closing the 2\n\n1.\n>1BCA42 Cooling Tower \u201cB\u201d Transformer 1T12\n>1BCA44. Water Treatment -B transformer 1T10\n\n\u2022 Open Cooling Tower Power Center 1A, 1B page at CRT. After confirming that\ncooling tower transformers 1T11 & 1T12 have been energized & 400 volts are\nappearing at their secondary side.\n\u2022 Close 400 Volts incoming breaker 1BFB16 supplying Cooling Tower\nPower Center Bus 1-A 1BFB10.\n\u2022 Close 400 volts incoming breaker 1BFB42 supplying Cooling Tower\nPower Center 1-B 1BFB 40.\nClose following 400 Volts breakers located at Cooling Tower Power Center 1A &1B.Lalpir/Pakgen Power Plant 77\nCCR Qualification Book\n1BFB\n\n1. aaa\n2", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_230" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 1, + "chunk_content": "2. What is the 220kV lines maximum capacity?\n1200 Amperes is the maximum capacity of each 220kV line\n\n\n2. No two isolators\nat same bay can be closed at same time.\n9. How the line side disconnect switch (isolator) is interlocked with line\nground switch and why?\nGround switch also known as earthing switch is used to ground the residual\ncharge in power lines after disconnecting the line from source. When a circuit\nis broken or open by the circuit breaker and Isolator, there is a residual charge\nremaining in the circuit. So to discharge the charge earthing switch is used.\nMechanical interlock is provided on all 220kV line isolators to prevent the\nclosing of earthing switch in closed line isolator operation. To close the\nearthing switch, respective line isolator must have to be in open position.\nThis interlock is provided to avoid human error in closing energized line\u2019s\nearthing switch.\n10. What is the purpose of Bus Coupler?\nBus coupler is a combination of isolator and circuit breaker to connect one high\nvoltage bus bar to the other high voltage bus bar\n11. What type of Circuit Breakers is provided in 220kV switchyard? What\nquenching media is used and what is operating mechanism of these\nbreakers?\n3 pole single chamber Air operated circuit breaker is used in 220KV switch\nyard. SF6 gas is used as quenching media in 220KV breakers\n12. What are normal pressure of SF6 and Air used in 220kV breakers?\n\nNormal pressure of SF6 gas is 6.5~7 bar and normal air pressure is 1.7~2.0\nbar.Lalpir/Pakgen Power Plant 74\nCCR Qualification Book\n1\n\n2. What do you understand about ATS, what are the three incoming\nsources and which bus it is supplying?\nATS stands for Auto Transfer Switch and it has three incoming sources:\na. Primary ATS, source is Boiler Turbine Power Center-A\nb. Secondary ATS, source is Boiler Turbine Power Center-B\nc. Third source is Emergency Diesel Generator.\n2", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_231" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 2, + "chunk_content": "3. Draw a single line diagram of 220kV switchyard.\n\n\n3. What will be 220kV breaker state if\na. SF6 pressure is low low\nb. Air pressure is low low\nThe SF6 is the insulation and arc-quenching medium. 220kV circuit breaker\nwill be un-responsive / inoperative if SF6 pressure is low low as in case of\noperation it is quite possible that insulation and arc quenching medium is\ninsufficient.\n220kV circuit breaker will open if air pressure is low low.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_232" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 3, + "chunk_content": "4. What do we mean by a Bay? How many bays are there in Lalpir\n220kV switchyard?\nIn electrical terminology, combination of connecting mechanism of a circuit to\nother high voltage bus bar is termed as bay. Each bay consist of a circuit\nbreaker, isolator, and CT\u2019s & PT\u2019s (optional)\nThere are total 8 bays in each unit\u2019s switchyard. (5 on bur bars , one on GSU ,\nand one on each 220kV line)\n\n\n4. Why DC power is supplied in 220kV switchyard?\n110V DC control power is supplied for switching of 220kV isolators and\nbreakers.\n1\n\n4. Water Treatment -B transformer 1T10\n\n\u2022 Open Cooling Tower Power Center 1A, 1B page at CRT. After confirming that\ncooling tower transformers 1T11 & 1T12 have been energized & 400 volts are\nappearing at their secondary side.\n\u2022 Close 400 Volts incoming breaker 1BFB16 supplying Cooling Tower\nPower Center Bus 1-A 1BFB10.\n\u2022 Close 400 volts incoming breaker 1BFB42 supplying Cooling Tower\nPower Center 1-B 1BFB 40.\nClose following 400 Volts breakers located at Cooling Tower Power Center 1A &1B.Lalpir/Pakgen Power Plant 77\nCCR Qualification Book\n1BFB24 Cooling Tower 400 Volts MCC 1A.\n1BFB", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_233" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 4, + "chunk_content": "5. What is the function of Wave Trap?\nSwitchyard components are designed to operate at 50 hz frequency.\nFrequency higher than 50 Hz \u00b15% may damage the components.\nTo prevent these high frequency waves from entering the switchyard, wave\ntraps are used to create high impedance to the high frequency waves (typically\ncarrier wave high frequencies)Lalpir/Pakgen Power Plant 73\nCCR Qualification Book\n\n\n5. Why dual power (AC) is provided in switchyard?\nIn case of power failure or any maintenance activity on respective unit AC\npower supply , alternate AC supply is provided from the other unit to operate\nisolators, circuit breakers.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_234" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 5, + "chunk_content": "6. What is the purpose of Current Transformer?\nCurrent transformers are used on high voltage transmission lines to produce\nan alternating current in its secondary side in proportional to the AC current in\nits primary side. Measuring instruments can be used on its secondary side.\n\n\n6. Explain the procedure of isolating and grounding a 220kv line?\nCommunication and approval from NPCC is required for such activity.\n\u2022 If unit is in service or SUT is in service, Confirm 2nd line load. It should\nbe normal.\n\u2022 Confirm Close position of bus coupler or energized line must be\nconnected on same bus as that of GSU/SUT.\n\u2022 Open line controlling circuit breaker.\n\u2022 Open respective circuit breaker\u2019s line isolators.\n\u2022 Confirm de-energisation and isolation from 2nd end (NPCC Hot line/fax)\n\u2022 Confirm \u201cZero Voltage\u201d on CCR Switchyard Control Panel.\n\u2022 Close ground isolator.\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_235" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 6, + "chunk_content": "7. What is the purpose of Potential Transformer? What is CCVT? Why\nCCVT is required and how many CCVTs are there in Lalpir 220kV\nswitchyard?\nPotential Transformer or Voltage transformer or Capacitor-coupled voltage\ntransformer (CCVT), is a transformer used in power systems to step down\nextra high voltage signals and provide a low voltage signal, for metering or\noperating a protective relay.\nThere are total 6 CCVT (PT\u2019s) in Lalpir/Pakgen switchyard.\n1 on each line, bus bar and on GSU , SUT\n\n\n7. How you will changeover aux load from UAT to SUT and vice versa,\nwhat is the generator load limitation with this changeover?\nSwitchover / changeover from UAT to SUT and vice versa is recommended at\nGenerator load greater than 50 MW.\nSteps to changeover from UAT to SUT and vice versa\n\u2022 Confirm generator load is greater than 50 MW\n\u2022 Press 52/1ABT (to take SUT in service) or press 52/UAT1 ( to take UAT\nin service) on synchro panel\n\u2022 \u201cSynchro Check Relay\u201d on synchro panel will match the conditions of\nboth supplies and on matching the conditions , it will give \u201c1\u201d indication,\nindicating that all parameters are in synchronization.\n\u2022 Pull and turn clockwise 52/UAT1 lever (To take UAT in service ,\n52/1ABT-11kV bus bar tie breaker will trip automatically) or 52/1ABT (To\ntake SUT in service , 52-UAT1 breaker will trip automatically) on\nsynchro panel\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_236" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 7, + "chunk_content": "8. What is the function of Isolators? What interlock is provided with\nCircuit Breaker and its associated isolators?\nIsolator is a mechanical device to connect or disconnect an electrical circuit\nfrom other electrical circuit. They are of two types, On Load and Off Load.\nAt Lalpir and Pakgen they are of Off Load type and interlock is provided to stop\ntheir on-Load operation.\nIn addition to their interlock with circuit breaker, Isolators on Bus Bar 1 have\nother interlock with the open/close position of the respective bay\u2019s Bus Bar 2\nisolator. Either bus bar 1 isolator can be closed or bus bar \n\n8. What is the purpose of 11kv inter tie, when it can be used, what is\nload limitation with this inter tie?\nBoth units 11kV bus bar B is inter-connected with 11kV breaker to support\nother unit auxiliary load in case of power unavailability.\n11kV inter unit tie breaker 2BCA18 is of same rating as of 11kv bus bar A&B\ntie breaker 52/ABT. However, if other unit is also shut down, it is\nrecommended to operate minimum possible auxiliaries to avoid excessive\nimport and keep MDI within range.Lalpir/Pakgen Power Plant 75\nCCR Qualification Book\n19. After a complete blackout, what are the important things to be\nchecked, how you will normalize the system?\n\u2022 Check that generator D.C. seal oil pump (DC Lube oil pump will cut in by its\npressure switch and it will take some time) & D.C. operated turbine lube oil\npump have cut in on AUTO. If not then start by manually from CRT or\nannunciator panel in CCR.\n\u2022 Make sure that Emergency Diesel Generator has cut in on auto & 400 volts\nEmergency Services MCC has been energized. If EDG not cut in on AUTO then\nenergize 400 volts Emergency Services MCC as per procedure.\n\u2022 Make sure that generator breaker is open, if not open it manually.\n\u2022 Make sure turbine is coasting down.\n\u2022 Make sure that boiler is on natural purging i.e. all dampers are open to remove\ncombustibles from furnace.\n\u2022 Be ready to open LP turbine manholes to avoid over pressurization.\n\u2022 Open economizer recirculation valve manually to provide circulation.\n\u2022 If service air is not available, arrange to rotate the air heaters manually.\n\u2022 Change over DC equipments to AC as emergency bus energized from EGD.\n\u2022 Watch BCP cavity temperatures and arrange service water by opening tie valve\nor by starting service water pump.\n\u2022 Close ejector steam isolation valve to avoid hammering in ejector condenser.\n\u2022 Close gland steam isolation valve to avoid hammering in gland condenser.\n\u2022 Open vacuum breaker valve as turbine speed reaches to 1800 rpm to reduce\ncoasting down time.\n\u2022 One of the CRE must Contact with NPCC to ask him for restoration of power\nsupply.\n\u2022 Seek help from E&I along with area engineer, check which relays operated and\nwhy? In the light of operation of these relays, make decision to energize the\nelectrical system.\n\u2022 Check that stator coolant pump (Stator coolant pumps are not supplied from\nemergency bus, it will be started after restoration of normal power) , Boiler A.C.\ncooling fan, Service water pump, Lube oil tank vapor extractor fan , GRF turning\nmotor, Air Heaters rotor drives are in operation. All these motors to be started\nmanually after energizing emergency bus.\n\u2022 Ask area engineer to start Service air compressor-A\n\u2022 Have a close look on TSI, turbine exhaust hood temperature, Turbine drains,\nH.P. turbine by pass temperature, boiler drum level.\n\u2022 Determine the reason of tripping, if CRE is satisfied & E& I give go ahead then\nafter coordinating with NPCC close the 2", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_237" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 8, + "chunk_content": "2. What is the 220kV lines maximum capacity?\n1200 Amperes is the maximum capacity of each 220kV line\n3. Draw a single line diagram of 220kV switchyard.\n4. What do we mean by a Bay? How many bays are there in Lalpir\n220kV switchyard?\nIn electrical terminology, combination of connecting mechanism of a circuit to\nother high voltage bus bar is termed as bay. Each bay consist of a circuit\nbreaker, isolator, and CT\u2019s & PT\u2019s (optional)\nThere are total 8 bays in each unit\u2019s switchyard. (5 on bur bars , one on GSU ,\nand one on each 220kV line)\n5. What is the function of Wave Trap?\nSwitchyard components are designed to operate at 50 hz frequency.\nFrequency higher than 50 Hz \u00b15% may damage the components.\nTo prevent these high frequency waves from entering the switchyard, wave\ntraps are used to create high impedance to the high frequency waves (typically\ncarrier wave high frequencies)Lalpir/Pakgen Power Plant 73\nCCR Qualification Book\n6. What is the purpose of Current Transformer?\nCurrent transformers are used on high voltage transmission lines to produce\nan alternating current in its secondary side in proportional to the AC current in\nits primary side. Measuring instruments can be used on its secondary side.\n7. What is the purpose of Potential Transformer? What is CCVT? Why\nCCVT is required and how many CCVTs are there in Lalpir 220kV\nswitchyard?\nPotential Transformer or Voltage transformer or Capacitor-coupled voltage\ntransformer (CCVT), is a transformer used in power systems to step down\nextra high voltage signals and provide a low voltage signal, for metering or\noperating a protective relay.\nThere are total 6 CCVT (PT\u2019s) in Lalpir/Pakgen switchyard.\n1 on each line, bus bar and on GSU , SUT\n8. What is the function of Isolators? What interlock is provided with\nCircuit Breaker and its associated isolators?\nIsolator is a mechanical device to connect or disconnect an electrical circuit\nfrom other electrical circuit. They are of two types, On Load and Off Load.\nAt Lalpir and Pakgen they are of Off Load type and interlock is provided to stop\ntheir on-Load operation.\nIn addition to their interlock with circuit breaker, Isolators on Bus Bar 1 have\nother interlock with the open/close position of the respective bay\u2019s Bus Bar 2\nisolator. Either bus bar 1 isolator can be closed or bus bar 2. No two isolators\nat same bay can be closed at same time.\n\n\n2. What are normal pressure of SF6 and Air used in 220kV breakers?\n\nNormal pressure of SF6 gas is 6.5~7 bar and normal air pressure is 1.7~2.0\nbar.Lalpir/Pakgen Power Plant 74\nCCR Qualification Book\n13. What will be 220kV breaker state if\na. SF6 pressure is low low\nb. Air pressure is low low\nThe SF6 is the insulation and arc-quenching medium. 220kV circuit breaker\nwill be un-responsive / inoperative if SF6 pressure is low low as in case of\noperation it is quite possible that insulation and arc quenching medium is\ninsufficient.\n220kV circuit breaker will open if air pressure is low low.\n14. Why DC power is supplied in 220kV switchyard?\n110V DC control power is supplied for switching of 220kV isolators and\nbreakers.\n15. Why dual power (AC) is provided in switchyard?\nIn case of power failure or any maintenance activity on respective unit AC\npower supply , alternate AC supply is provided from the other unit to operate\nisolators, circuit breakers.\n16. Explain the procedure of isolating and grounding a 220kv line?\nCommunication and approval from NPCC is required for such activity.\n\u2022 If unit is in service or SUT is in service, Confirm 2nd line load. It should\nbe normal.\n\u2022 Confirm Close position of bus coupler or energized line must be\nconnected on same bus as that of GSU/SUT.\n\u2022 Open line controlling circuit breaker.\n\u2022 Open respective circuit breaker\u2019s line isolators.\n\u2022 Confirm de-energisation and isolation from 2nd end (NPCC Hot line/fax)\n\u2022 Confirm \u201cZero Voltage\u201d on CCR Switchyard Control Panel.\n\u2022 Close ground isolator.\n17. How you will changeover aux load from UAT to SUT and vice versa,\nwhat is the generator load limitation with this changeover?\nSwitchover / changeover from UAT to SUT and vice versa is recommended at\nGenerator load greater than 50 MW.\nSteps to changeover from UAT to SUT and vice versa\n\u2022 Confirm generator load is greater than 50 MW\n\u2022 Press 52/1ABT (to take SUT in service) or press 52/UAT1 ( to take UAT\nin service) on synchro panel\n\u2022 \u201cSynchro Check Relay\u201d on synchro panel will match the conditions of\nboth supplies and on matching the conditions , it will give \u201c1\u201d indication,\nindicating that all parameters are in synchronization.\n\u2022 Pull and turn clockwise 52/UAT1 lever (To take UAT in service ,\n52/1ABT-11kV bus bar tie breaker will trip automatically) or 52/1ABT (To\ntake SUT in service , 52-UAT1 breaker will trip automatically) on\nsynchro panel\n18. What is the purpose of 11kv inter tie, when it can be used, what is\nload limitation with this inter tie?\nBoth units 11kV bus bar B is inter-connected with 11kV breaker to support\nother unit auxiliary load in case of power unavailability.\n11kV inter unit tie breaker 2BCA18 is of same rating as of 11kv bus bar A&B\ntie breaker 52/ABT. However, if other unit is also shut down, it is\nrecommended to operate minimum possible auxiliaries to avoid excessive\nimport and keep MDI within range.Lalpir/Pakgen Power Plant 75\nCCR Qualification Book\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_238" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 9, + "chunk_content": "9. How the line side disconnect switch (isolator) is interlocked with line\nground switch and why?\nGround switch also known as earthing switch is used to ground the residual\ncharge in power lines after disconnecting the line from source. When a circuit\nis broken or open by the circuit breaker and Isolator, there is a residual charge\nremaining in the circuit. So to discharge the charge earthing switch is used.\nMechanical interlock is provided on all 220kV line isolators to prevent the\nclosing of earthing switch in closed line isolator operation. To close the\nearthing switch, respective line isolator must have to be in open position.\nThis interlock is provided to avoid human error in closing energized line\u2019s\nearthing switch.\n\n\n9. After a complete blackout, what are the important things to be\nchecked, how you will normalize the system?\n\u2022 Check that generator D.C. seal oil pump (DC Lube oil pump will cut in by its\npressure switch and it will take some time) & D.C. operated turbine lube oil\npump have cut in on AUTO. If not then start by manually from CRT or\nannunciator panel in CCR.\n\u2022 Make sure that Emergency Diesel Generator has cut in on auto & 400 volts\nEmergency Services MCC has been energized. If EDG not cut in on AUTO then\nenergize 400 volts Emergency Services MCC as per procedure.\n\u2022 Make sure that generator breaker is open, if not open it manually.\n\u2022 Make sure turbine is coasting down.\n\u2022 Make sure that boiler is on natural purging i.e. all dampers are open to remove\ncombustibles from furnace.\n\u2022 Be ready to open LP turbine manholes to avoid over pressurization.\n\u2022 Open economizer recirculation valve manually to provide circulation.\n\u2022 If service air is not available, arrange to rotate the air heaters manually.\n\u2022 Change over DC equipments to AC as emergency bus energized from EGD.\n\u2022 Watch BCP cavity temperatures and arrange service water by opening tie valve\nor by starting service water pump.\n\u2022 Close ejector steam isolation valve to avoid hammering in ejector condenser.\n\u2022 Close gland steam isolation valve to avoid hammering in gland condenser.\n\u2022 Open vacuum breaker valve as turbine speed reaches to 1800 rpm to reduce\ncoasting down time.\n\u2022 One of the CRE must Contact with NPCC to ask him for restoration of power\nsupply.\n\u2022 Seek help from E&I along with area engineer, check which relays operated and\nwhy? In the light of operation of these relays, make decision to energize the\nelectrical system.\n\u2022 Check that stator coolant pump (Stator coolant pumps are not supplied from\nemergency bus, it will be started after restoration of normal power) , Boiler A.C.\ncooling fan, Service water pump, Lube oil tank vapor extractor fan , GRF turning\nmotor, Air Heaters rotor drives are in operation. All these motors to be started\nmanually after energizing emergency bus.\n\u2022 Ask area engineer to start Service air compressor-A\n\u2022 Have a close look on TSI, turbine exhaust hood temperature, Turbine drains,\nH.P. turbine by pass temperature, boiler drum level.\n\u2022 Determine the reason of tripping, if CRE is satisfied & E& I give go ahead then\nafter coordinating with NPCC close the 220 K.V. lines breaker D3Q1& D5Q1.\n(Lock out relay need to be reset before closing the 220 KV lines and Lines will\nbe closed through Synch check.)\n\u2022 After restoration of power, take extra care for filling the drum with very slow rate\nto avoid stress in economizer which is at about 350 C and feed water\ntemperature is already low. Try to maintain filling rate 30 to 40 t/h\n\u2022 Watch drum pressure carefully and if it comes down very fast during hot\ncondition, there are chances of hammering in economizer.\nNOTE: Actions taken should be deliberate, in a logical manner, neither\nrushing nor causing undue delay. Nothing should be taken for granted.\n\u2022 Have a look that SUT 220 K.V. breaker D2Q1, its related isolators D2Q11 or\nD2Q12 & D2Q10 are in closed position. (Lock out relay need to be reset before\nclosing the SUT 220 KV breaker and breaker will be closed through Synch\ncheck.)\n\u2022 Now come at the unit synchronizing panel & synchronize the SUT 11 K.V\nincoming breaker 1BCA 16 (52/ SUT1). (Lock out relay in 11KV room need to\nbe reset by closing SUT 11 KV breaker.)Lalpir/Pakgen Power Plant 76\nCCR Qualification Book\n\u2022 Close 11 K.V. breaker 1BBA17 & 1BCA13 feeding 11 K.V. unit switch gear 1-C\n& 1-D\n\u2022 Asked area Engineer to Close 11 K.V. breaker 1BBA 45 feeding LalPir\ncommunity.\n\u2022 After coordination with area engineer close 11 K.V.breakers located at 11 K.V.\nUNIT SWITCH GEAR 1B & supplying as follows.\n\u2022 1BCA20 administration building transformer 0T7\n\u2022 1BCA26, unit common \u2013B transformer 1T6\n\u2022 1BCA12 , boiler/turbine B transformer 1T4\n\u2022 1BCA 14 raw water intake \u2013 B transformer 1T2\n\u2022 Now come at 11 K.V. UNIT SWITCH GEAR 1A & close 11 K.V. breakers as\nfollows,\n\u2022 1BBA20 unit common A transformer,\n\u2022 1BBA18 boiler / turbine \u2013A transformer\n\u2022 1BBA16 feeding raw water intake \u2013A transformer.\n\u2022 Now come at MCC page, close 400 volts incoming breakers as follows,\n\u2022 1BFC20GS101F unit common motor control center 1A\n\u2022 1BFC48GS108F unit common motor control center 1B. Lighting on the\nplant will be available.\n\u2022 1BFK13GS104F Raw water intake motor control center 1-A\n\u2022 1BFK41GS101F raw water intake motor control center 1-B.\n\u2022 0BHA11GS201F feeding administration building 400 volts MCC. (This\nbreaker normally do not open on under voltage)\n\u2022 Open Boiler / Turbine Power Center 1A, 1B Page at CRT.\n\u2022 Close incoming breaker 1BFA20 for Boiler Turbine Power Center 1-A\n1BFA10.\n\u2022 Close incoming breaker 1BFA50 for Boiler Turbine Power 1-B 1BFA40.\n\u2022 Check & Close following 400 volts breakers located at Boiler Turbine\nPower Center Buses 1A &1B.\n>1BFA18 Feeding Boiler 400 volts MCC 1A 1BFD10.\n>1BFA16 Feeding Turbine 400 volts MCC 1A 1BFE10.\n\n>1BFA42 Feeding Boiler 400 volts MCC 1B 1BFF10.\n>1BFA46 Feeding Turbine 400 volts MCC 1B 1BFG10.\n\n(These breakers do not open on under voltage)\nMake sure by monitoring the amperes on CRT or by asking area / electrical\nengineer that Boiler, Turbine MCC 1A & 1B have been energized.\n\u2022 Open 11 K.V. Unit Switch Gear 1C & 1D page at CRT & coordinate with BOP\nEngineer. Close following breakers located at 11K.V. Unit Switch Gear 1C & 1D\nbus 1BBA40 & 1BCA40 respectively.\n>1BBA46 Water Treatment -A transformer 1T9.\n>1BBA44 Cooling Tower \u201cA\u201d Transformer 1T11.\n>1BCA42 Cooling Tower \u201cB\u201d Transformer 1T12\n>1BCA44. Water Treatment -B transformer 1T10\n\n\u2022 Open Cooling Tower Power Center 1A, 1B page at CRT. After confirming that\ncooling tower transformers 1T11 & 1T12 have been energized & 400 volts are\nappearing at their secondary side.\n\u2022 Close 400 Volts incoming breaker 1BFB16 supplying Cooling Tower\nPower Center Bus 1-A 1BFB10.\n\u2022 Close 400 volts incoming breaker 1BFB42 supplying Cooling Tower\nPower Center 1-B 1BFB 40.\nClose following 400 Volts breakers located at Cooling Tower Power Center 1A &1B.Lalpir/Pakgen Power Plant 77\nCCR Qualification Book\n1BFB24 Cooling Tower 400 Volts MCC 1A.\n1BFB50 Cooling Tower 400 Volts MCC 1B.\nAsk area Engineer to make sure from Local that Cooling Tower MCC 1A &1B have\nbeen energized.\nOpen water treatment MCC page at CRT. After making sure that Water Treatment\ntransformers 1T9 & 1T10 have been energized, close following breakers.\n\u2022 1BFJ12GS108F 400 Volts incoming breaker for Water Treatment\nMCC1-A 1BFJ10.\n\u2022 1BFJ48GS108F 400 Volts incoming breaker for Water Treatment\nMCC1-B 1BFJ40.\n\u2022 Normalize the 400 volts Emergency Services MCC 1BMA10 as per procedure\n20. How you can control 11kV voltage?\n21. aaa\n22. What do you understand about ATS, what are the three incoming\nsources and which bus it is supplying?\nATS stands for Auto Transfer Switch and it has three incoming sources:\na. Primary ATS, source is Boiler Turbine Power Center-A\nb. Secondary ATS, source is Boiler Turbine Power Center-B\nc. Third source is Emergency Diesel Generator.\n23. Explain briefly about DC system and UPS?\nDC System\nDC bus is energized through voltage compensation device being fed from Plant DC\nDistribution panel A & B.\nPlant DC distribution panel A&B has dual power source.\na) Plant battery charger A&B , C&D\nb) 110 Cell 3400 Amp hr plant battery bank for each distribution panel\nc) Plant battery chargers are fed from Emergency Service Bus bar through\nATS.\nDC source is has following main services:\na. Switch yard.\nb. A different protection supplies.\nc. Interlock supplies.\nd. DC seal oil pump.\ne. DC lube oil pump. (EOP)\nf. DC jacking oil pump.\ng. DC cooling fan.\nh. DC lights.\nUPS System:\nUPS-Uninterrupted power supply, system provides a reliable, regulated, filtered &\nuninterrupted 110V, 50Hz, single phase AC electrical power to essential plant\nauxiliary & low voltage load & control system.\nIn addition, it provides for a safe unit shut down in the event of a unit power system\nblackout.\n\u201c1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_239" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 10, + "chunk_content": "10. What is the purpose of Bus Coupler?\nBus coupler is a combination of isolator and circuit breaker to connect one high\nvoltage bus bar to the other high voltage bus bar\n\n\n10.\n\u2022 Close incoming breaker 1BFA50 for Boiler Turbine Power 1-B 1BFA40.\n\u2022 Check & Close following 400 volts breakers located at Boiler Turbine\nPower Center Buses 1A &1B.\n>1BFA18 Feeding Boiler 400 volts MCC 1A 1BFD10.\n>1BFA16 Feeding Turbine 400 volts MCC 1A 1BFE10.\n\n>1BFA42 Feeding Boiler 400 volts MCC 1B 1BFF10.\n>1BFA46 Feeding Turbine 400 volts MCC 1B 1BFG10.\n\n(These breakers do not open on under voltage)\nMake sure by monitoring the amperes on CRT or by asking area / electrical\nengineer that Boiler, Turbine MCC 1A & 1B have been energized.\n\u2022 Open 11 K.V. Unit Switch Gear 1C & 1D page at CRT & coordinate with BOP\nEngineer. Close following breakers located at 11K.V. Unit Switch Gear 1C & 1D\nbus 1BBA40 & 1BCA40 respectively.\n>1BBA46 Water Treatment -A transformer 1T9.\n>1BBA44 Cooling Tower \u201cA\u201d Transformer 1T11.\n>1BCA42 Cooling Tower \u201cB\u201d Transformer 1T12\n>1BCA44. Water Treatment -B transformer 1T10\n\n\u2022 Open Cooling Tower Power Center 1A, 1B page at CRT. After confirming that\ncooling tower transformers 1T11 & 1T12 have been energized & 400 volts are\nappearing at their secondary side.\n\u2022 Close 400 Volts incoming breaker 1BFB16 supplying Cooling Tower\nPower Center Bus 1-A 1BFB10.\n\u2022 Close 400 volts incoming breaker 1BFB42 supplying Cooling Tower\nPower Center 1-B 1BFB 40.\nClose following 400 Volts breakers located at Cooling Tower Power Center 1A &1B.Lalpir/Pakgen Power Plant 77\nCCR Qualification Book\n1BFB24 Cooling Tower 400 Volts MCC 1A.\n1BFB50 Cooling Tower 400 Volts MCC 1B.\nAsk area Engineer to make sure from Local that Cooling Tower MCC 1A &1B have\nbeen energized.\nOpen water treatment MCC page at CRT. After making sure that Water Treatment\ntransformers 1T9 & 1T10 have been energized, close following breakers.\n\u2022 1BFJ12GS108F 400 Volts incoming breaker for Water Treatment\nMCC1-A 1BFJ10.\n\u2022 1BFJ48GS108F 400 Volts incoming breaker for Water Treatment\nMCC1-B 1BFJ40.\n\u2022 Normalize the 400 volts Emergency Services MCC 1BMA10 as per procedure\n20. How you can control 11kV voltage?\n21. aaa\n22. What do you understand about ATS, what are the three incoming\nsources and which bus it is supplying?\nATS stands for Auto Transfer Switch and it has three incoming sources:\na. Primary ATS, source is Boiler Turbine Power Center-A\nb. Secondary ATS, source is Boiler Turbine Power Center-B\nc. Third source is Emergency Diesel Generator.\n23. Explain briefly about DC system and UPS?\nDC System\nDC bus is energized through voltage compensation device being fed from Plant DC\nDistribution panel A & B.\nPlant DC distribution panel A&B has dual power source.\na) Plant battery charger A&B , C&D\nb) ", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2310" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 11, + "chunk_content": "11. What type of Circuit Breakers is provided in 220kV switchyard? What\nquenching media is used and what is operating mechanism of these\nbreakers?\n3 pole single chamber Air operated circuit breaker is used in 220KV switch\nyard. SF6 gas is used as quenching media in 220KV breakers\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2311" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 12, + "chunk_content": "12. What are normal pressure of SF6 and Air used in 220kV breakers?\n\nNormal pressure of SF6 gas is 6.5~7 bar and normal air pressure is 1.7~2.0\nbar.Lalpir/Pakgen Power Plant 74\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2312" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 13, + "chunk_content": "13. What will be 220kV breaker state if\na. SF6 pressure is low low\nb. Air pressure is low low\nThe SF6 is the insulation and arc-quenching medium. 220kV circuit breaker\nwill be un-responsive / inoperative if SF6 pressure is low low as in case of\noperation it is quite possible that insulation and arc quenching medium is\ninsufficient.\n220kV circuit breaker will open if air pressure is low low.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2313" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 14, + "chunk_content": "14. Why DC power is supplied in 220kV switchyard?\n110V DC control power is supplied for switching of 220kV isolators and\nbreakers.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2314" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 15, + "chunk_content": "15. Why dual power (AC) is provided in switchyard?\nIn case of power failure or any maintenance activity on respective unit AC\npower supply , alternate AC supply is provided from the other unit to operate\nisolators, circuit breakers.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2315" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 16, + "chunk_content": "16. Explain the procedure of isolating and grounding a 220kv line?\nCommunication and approval from NPCC is required for such activity.\n\u2022 If unit is in service or SUT is in service, Confirm 2nd line load. It should\nbe normal.\n\u2022 Confirm Close position of bus coupler or energized line must be\nconnected on same bus as that of GSU/SUT.\n\u2022 Open line controlling circuit breaker.\n\u2022 Open respective circuit breaker\u2019s line isolators.\n\u2022 Confirm de-energisation and isolation from 2nd end (NPCC Hot line/fax)\n\u2022 Confirm \u201cZero Voltage\u201d on CCR Switchyard Control Panel.\n\u2022 Close ground isolator.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2316" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 17, + "chunk_content": "17. How you will changeover aux load from UAT to SUT and vice versa,\nwhat is the generator load limitation with this changeover?\nSwitchover / changeover from UAT to SUT and vice versa is recommended at\nGenerator load greater than 50 MW.\nSteps to changeover from UAT to SUT and vice versa\n\u2022 Confirm generator load is greater than 50 MW\n\u2022 Press 52/1ABT (to take SUT in service) or press 52/UAT1 ( to take UAT\nin service) on synchro panel\n\u2022 \u201cSynchro Check Relay\u201d on synchro panel will match the conditions of\nboth supplies and on matching the conditions , it will give \u201c1\u201d indication,\nindicating that all parameters are in synchronization.\n\u2022 Pull and turn clockwise 52/UAT1 lever (To take UAT in service ,\n52/1ABT-11kV bus bar tie breaker will trip automatically) or 52/1ABT (To\ntake SUT in service , 52-UAT1 breaker will trip automatically) on\nsynchro panel\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2317" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 18, + "chunk_content": "18. What is the purpose of 11kv inter tie, when it can be used, what is\nload limitation with this inter tie?\nBoth units 11kV bus bar B is inter-connected with 11kV breaker to support\nother unit auxiliary load in case of power unavailability.\n11kV inter unit tie breaker 2BCA18 is of same rating as of 11kv bus bar A&B\ntie breaker 52/ABT. However, if other unit is also shut down, it is\nrecommended to operate minimum possible auxiliaries to avoid excessive\nimport and keep MDI within range.Lalpir/Pakgen Power Plant 75\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2318" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 19, + "chunk_content": "19. After a complete blackout, what are the important things to be\nchecked, how you will normalize the system?\n\u2022 Check that generator D.C. seal oil pump (DC Lube oil pump will cut in by its\npressure switch and it will take some time) & D.C. operated turbine lube oil\npump have cut in on AUTO. If not then start by manually from CRT or\nannunciator panel in CCR.\n\u2022 Make sure that Emergency Diesel Generator has cut in on auto & 400 volts\nEmergency Services MCC has been energized. If EDG not cut in on AUTO then\nenergize 400 volts Emergency Services MCC as per procedure.\n\u2022 Make sure that generator breaker is open, if not open it manually.\n\u2022 Make sure turbine is coasting down.\n\u2022 Make sure that boiler is on natural purging i.e. all dampers are open to remove\ncombustibles from furnace.\n\u2022 Be ready to open LP turbine manholes to avoid over pressurization.\n\u2022 Open economizer recirculation valve manually to provide circulation.\n\u2022 If service air is not available, arrange to rotate the air heaters manually.\n\u2022 Change over DC equipments to AC as emergency bus energized from EGD.\n\u2022 Watch BCP cavity temperatures and arrange service water by opening tie valve\nor by starting service water pump.\n\u2022 Close ejector steam isolation valve to avoid hammering in ejector condenser.\n\u2022 Close gland steam isolation valve to avoid hammering in gland condenser.\n\u2022 Open vacuum breaker valve as turbine speed reaches to 1800 rpm to reduce\ncoasting down time.\n\u2022 One of the CRE must Contact with NPCC to ask him for restoration of power\nsupply.\n\u2022 Seek help from E&I along with area engineer, check which relays operated and\nwhy? In the light of operation of these relays, make decision to energize the\nelectrical system.\n\u2022 Check that stator coolant pump (Stator coolant pumps are not supplied from\nemergency bus, it will be started after restoration of normal power) , Boiler A.C.\ncooling fan, Service water pump, Lube oil tank vapor extractor fan , GRF turning\nmotor, Air Heaters rotor drives are in operation. All these motors to be started\nmanually after energizing emergency bus.\n\u2022 Ask area engineer to start Service air compressor-A\n\u2022 Have a close look on TSI, turbine exhaust hood temperature, Turbine drains,\nH.P. turbine by pass temperature, boiler drum level.\n\u2022 Determine the reason of tripping, if CRE is satisfied & E& I give go ahead then\nafter coordinating with NPCC close the 220 K.V. lines breaker D3Q1& D5Q", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2319" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 20, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2320" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 21, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2321" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 22, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2322" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 23, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2323" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 24, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2324" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 25, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2325" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 26, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2326" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 27, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2327" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 28, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2328" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 29, + "chunk_content": "44. Water Treatment -B transformer 1T", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2329" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 30, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2330" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 31, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2331" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 32, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2332" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 33, + "chunk_content": "", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2333" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 34, + "chunk_content": "20. How you can control 11kV voltage?\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2334" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 35, + "chunk_content": "21. aaa\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2335" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 36, + "chunk_content": "22. What do you understand about ATS, what are the three incoming\nsources and which bus it is supplying?\nATS stands for Auto Transfer Switch and it has three incoming sources:\na. Primary ATS, source is Boiler Turbine Power Center-A\nb. Secondary ATS, source is Boiler Turbine Power Center-B\nc. Third source is Emergency Diesel Generator.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2336" + }, + { + "chapter_numbre": "Chapter_22", + "chapter_name": "Chapter 23", + "chunk_index": 37, + "chunk_content": "23. Explain briefly about DC system and UPS?\nDC System\nDC bus is energized through voltage compensation device being fed from Plant DC\nDistribution panel A & B.\nPlant DC distribution panel A&B has dual power source.\na) Plant battery charger A&B , C&D\nb) 110 Cell 3400 Amp hr plant battery bank for each distribution panel\nc) Plant battery chargers are fed from Emergency Service Bus bar through\nATS.\nDC source is has following main services:\na. Switch yard.\nb. A different protection supplies.\nc. Interlock supplies.\nd. DC seal oil pump.\ne. DC lube oil pump. (EOP)\nf. DC jacking oil pump.\ng. DC cooling fan.\nh. DC lights.\nUPS System:\nUPS-Uninterrupted power supply, system provides a reliable, regulated, filtered &\nuninterrupted 110V, 50Hz, single phase AC electrical power to essential plant\nauxiliary & low voltage load & control system.\nIn addition, it provides for a safe unit shut down in the event of a unit power system\nblackout.\n\u201c110V , 50hz AC essential services distribution panel\u201d is being fed from Plant DC\ndistrubtion panel A&B through primary and secondary UPS. In addition to this ,\n\u201c110V , 50hz AC essential services distribution panel\u201d is also supplied with third\nsource i.e regulating transformer which is being fed directly from emergency bus\nbar.\nUPS system has following main consumers.\na. APC\nb. DEH\nc. SEQ-1\nd. SEQ-2\ne. BMS\nf. DAS\ng. IPU\nh. ALARM PRINTERS\ni. OPS\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2337" + }, + { + "chapter_numbre": "Chapter_23", + "chapter_name": "Chapter 24", + "chunk_index": 0, + "chunk_content": "1. Discuss the various trip signals that will cause to trip the turbine?\nThe various trip signals which causes to trip the turbine are,\n\u2022 Bearing vibration very high. 250 mm.\n\u2022 Rotor position abnormal. \u00b11 mm.\n\u2022 Lube oil pressure very low 0.5 kg/cm2\n\u2022 Condenser vacuum very low. 535 mm Hg.\n\u2022 Turbine bearing temp. very high 113 C.\n\u2022 Generator Trip.\n\u2022 Boiler trip.\n\u2022 Manual Trip.\n\u2022 Remote trip.\n\u2022 Over speed. 110 % & 111 % of normal speed.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_240" + }, + { + "chapter_numbre": "Chapter_23", + "chapter_name": "Chapter 24", + "chunk_index": 1, + "chunk_content": "2. What are your actions on turbine trip?\nThe actions on turbine trip are,\n\u2022 First check, gen. Breaker and gen. Excitation breaker open.\n\u2022 Check MSV, ICV & RSV fully close.\n\u2022 Turbine all drains should open.\n\u2022 Extraction NRVS should close.\n\u2022 Check turbine speed is coming down.\n\u2022 AOP should start at 2950 rpm.\n\u2022 Stop one CW pump and CT fans.\n\u2022 Check JOP, it should cut in at 800 rpm.\n\u2022 At 400 rpm give off command to gland steam sequence.\n\u2022 TOP cut in at 100 rpm and AOP cut off on auto.\n\u2022 At zero speed turning gear should cut in on auto.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_241" + }, + { + "chapter_numbre": "Chapter_23", + "chapter_name": "Chapter 24", + "chunk_index": 2, + "chunk_content": "3. What happens to turbine when turbine trips?\nWhen turbine trips, Generator breaker opens and unit is no more synchronized\nwith the system. In synchronous condition, its RPM are controlled by frequency\nand load as per following formula.\nNs=120f/P, where Ns is the number of turns/speed in RPM, f is frequency and\nP is the number of poles.\nIn unsynchronized condition, there are chances that turbine RPM may\nincrease beyond safe limits, therefore its controlling valves (MSV, GV, RSV,\nICV) will close to reduce its speed.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_242" + }, + { + "chapter_numbre": "Chapter_23", + "chapter_name": "Chapter 24", + "chunk_index": 3, + "chunk_content": "4. Discuss the conditions that will permit the turbine to reset?\nThe conditions that will permit the turbine reset are,\n\u2022 MFT reset.\n\u2022 Gen. Lock out relay reset.\n\u2022 No any protection for turbine should in operating conditions.\n\u2022 AOP running.\n\u2022 Turbine casing top and bottom temp with in limit.\n\u2022 Turbine differential expansion normal.\n\u2022 Bearing oil drain temp normal.\n\u2022 Turbine bolt differential temp normal.\n\u2022 HP valve metal differential temperature normal.\n\u2022 GV setter on auto standby mode.\n\u2022 LL setter on AUTO.\n\u2022 Valve transfer on AUTO mode.\n\u2022 Turbine rolling parameters should be normal.\n\u2022 Condenser vacuum is normal.Lalpir/Pakgen Power Plant 80\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_243" + }, + { + "chapter_numbre": "Chapter_23", + "chapter_name": "Chapter 24", + "chunk_index": 4, + "chunk_content": "5. Explain the difference between electrical and mechanical over speed,\nwhich is back up?\nMechanical over speed: Mechanical over speed trip mechanism is installed\non the turbine rotor extension shaft with a thread opposite to the direction of\nthe rotation and is locked in place by a setscrew. The trip weight is carried in a\ntransverse hole in the body, with its center of gravity offset from the axis of\nrotation so that centrifugal force tends to move it outward at all times. Normally\nthis weight is held in its inner position by the compression spring and weight\nspring retainer. If the speed of the turbine increases to the point (about 110%\nof normal speed) for which mechanism is set to operate, the increased\ncentrifugal force overcomes the compression of spring and trip weight move\noutward. In this outer position, the weight strikes the trip trigger and rotates it\non fulcrum pin and moves the trip relay, which causes to drain the trip oil.\nThe drainage of trip oil cause to drain auto stop oil. The drainage of auto stop\noil cause to drain MSV, GV, RSV and ICV control oil at respective E/H\nconverters and MSVs, GVs, RSVs and ICVs get close.\nElectrical over speed: Electrical over speed trip mechanism is watching the\nturbine speed, If turbine doesn't trip on MOST protection, at 112% of normal\nspeed the EOST mechanism will operate over speed trip solenoid valve and\ndrain the trip oil.\nThe drainage of trip oil cause to drain auto stop oil. The drainage of auto stop\noil cause to drain MSV, GV, RSV and ICV control oil at respective E/H\nconverters and MSVs, GVs, RSVs and ICVs get close.\nThe EOST protection is the back up of MOST protection.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_244" + }, + { + "chapter_numbre": "Chapter_23", + "chapter_name": "Chapter 24", + "chunk_index": 5, + "chunk_content": "6. What is OPC (over speed control), how it works?\nOPC will operate in case of tribune tends to over speed 107 % of rated speed\nthat is 3210 rpm. When OPC protection operates, the OPC solenoid valves are\nenergized, draining the control oil between the E/H converter and servomotor\nand thereby closing the servomotors, while decreasing the governing valves\n(GVs) and interceptor valves (ICVs) E/H converter also closes the\nservomotors.\nWhen speed of the turbine decreases towards rated speed after the steam\nentrapped in the reheat system is dissipated, the interceptor valves are open.\nAt rated speed, the governor valves will take over the control of turbine and\nkeep the unit at rated speed.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_245" + }, + { + "chapter_numbre": "Chapter_24", + "chapter_name": "Chapter 25", + "chunk_index": 0, + "chunk_content": "1. What are the different tests required to be carried out on routine\nbasis, what is purpose of these tests?\nLube oil pumps cut in test \u2013 Turbine: (Weekly Routine)\nThis test is performed to test and ensure the healthiness of lube oil pressure\ntransmitter and lube oil pumps . This test include following pump\u2019s cut in test\nAOP Auto Cut-in\nTOP Auto Cut-in\nEOP Auto Cut-in\nTurbine Protective Devices Test:\nThis test is performed on first Monday of every month to test and ensure the\nhealthiness of turbine protective devices. This test inclue\nCondenser Low Vacuum Test\nThrust Wear Failure\nOverspeed Oil Trip Test\nLube Oil Pressure Low\nTurbine Valves Freedom Test\nThis test is performed Bi-Weekly (Alternate Monday) to ensure MSV\u2019s and\nGV\u2019s healthiness. Following valves test is performed.\nRH MSV/GV's\nLH MSV/GV's\nRH RSV/ICV's\nLH RSV/ICV's\nLP and HP Heaters High Level Protection Test\nThis test is performed annually; once after annual outage at least. H&HH alarm\nappears on CRT and extraction MOV closes in this test. LP heater 3,LP heater\n4,HP heater 6,HP heater 7,HP heater 8 high level protection test is performed.\nTurbine Overspeed test (EOST or MOST)\nThis test is performed Weekly (Every Monday) to ensure overspeed protective\ndevice.\nHydro Test on Boiler:\nThis test is performed after every outage , be it annual or forced outage. This\ntest is performed to detect any leakage in boilerLalpir/Pakgen Power Plant 82\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_250" + }, + { + "chapter_numbre": "Chapter_24", + "chapter_name": "Chapter 25", + "chunk_index": 1, + "chunk_content": "2. Explain the stem free test procedure, what is the load limitation with\nthis test?\nMSV/GVs Test:\na. Turbine load must be 25% to 70% i.e. 279 MW or less.\nb. Put DEHC on manual from \u201cDEHC Valve Test\u201d display. Turbine Master\nwill be shifted on Manual and mode will be shifted on Boiler follow.\nc. Change Turbine Master on manual mode.\nd. Select \u2018IMP in\u2019 and on \u2018auto\u2019.\ne. Select the \u2018LH Test\u2019 mode from the \u2018LH-MSV/GV Test\u2019 block on the\nscreen and at local, watch smooth closing of LH side GVs l and 3 and\nthe MSV. Also watch the bearing temperatures & GVs of the right\nhand side 2 and 4 opening (for maintaining constant load).\nf. In CCR, check close indication of both GVs and MSV of LH side.\ng. Select the (LH Reset)\u2019push button to restore initial conditions.\nh. At local, check re-opening of LH side MSV and then GVs and closing\nof RH side (GVs for load adjustment).\nh. Follow the same steps 5 to 8 mentioned above for testing RH side\nMSV und GVs by selecting \u2018RH Test\u2019 mode from RH-MSV/GV Test\u2019\nblock on the screen.\nOnce the above test is completed, proceed with the following:\nRSV/ICV Test:\ni. Select \u2018LH Test\u2019 push button on \u2018LH RSV/ICV test block on the screen\nand at local, watch smooth closing of LH side ICV and RSV. In CCR,\ncheck close indication of LH side ICV and RSV.\nj. Select \u2018LH Reset\u2019 push button to restore initial conditions.\nk. At local, check re-opening of LH side RSV and ICV.\nl. Repeat steps 1-4 mentioned above, for testing RH side RSV and ICV\nby selecting \u2018RH Test\u2019 push button from \u2018RH-RSV/ICV Test\u2019 block on\nthe screen.\nm. Select IMP out\u2019 and \u2018auto\u2019 to \u2018manual\u2019.\nn. DEHC from manual to auto mode.\nw. Change Unit control from Boiler follow to coordinate control.\nRefer to section 4-6-13 of turbine manual for the above rests.\nTest sequence for each set of valves\nDo a functional test of the (Main Stop) and reheat stop valves weekly with the\nturbine under load. The purpose of the test is to help maintain proper operation\nof these valves.\na) A maintenance technician observes valve operation during the\nfollowing test sequence for each set of valves.\nCheck that movement of the valve linkage is smooth and free. Jerky or\nintermittent motion indicates:\na. Buildup of deposits on the valve shaft (s) or stem (s) (such\ndeposits may require cleaning)\nb. Bent valve stem (s) or shaft (s).\nc. EH converter oil pressure fluctuation.\nd. Valve misalignment.\nb) Find and correct the cause for shaft or stem deposits.Lalpir/Pakgen Power Plant 83\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_251" + }, + { + "chapter_numbre": "Chapter_24", + "chapter_name": "Chapter 25", + "chunk_index": 2, + "chunk_content": "3. Describe the procedure of turbine protective device test from turbine\ndeck, how turbine prevented from actual trip?\nDuring turbine protective device test procedure, turbine is prevented from\nactual trip by pressing the \u201cTest Lever\u201d on turbine deck. This lever block the\ndraining port of auto stop oil from servo motor. Before normalizing and\nreleasing this lever area engineer ensures the normal pressure of auto stop oil.\nAll of the Turbine protective test can be performed in one go by pressing Test\nLever, or they can be performed individually.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_252" + }, + { + "chapter_numbre": "Chapter_24", + "chapter_name": "Chapter 25", + "chunk_index": 3, + "chunk_content": "4. Describe lube oil pumps auto cut in test, what actions required from\ncontrol room during this test?\nLube Oil cut in test is performed to confirm the healthiness of lube oil system.\nThis test includes starting of AOP, TOP, and EOP one by one.\nDuring this test, when\nAOP starts, it has to be shifted on manual has to be stopped on manual to\ncheck next pump operation in case of its unavailability at low lube oil pressure.\nAfter stopping AOP , again lube oil pressure is lowered from local gauge, this\ntime TOP will cut in . It has to be shifted on manual and has to be stopped on\nmanual to check next pump operation in case of its unavailability.\nAfter stopping TOP , again lube oil pressure is lowered from local gauge, this\ntime DC TOP (EOP) will cut in .\nStop the EOP pump on manual , wait for the area engineer to normalize the\nvalves at local , and after his confirmation , turn bank EOP, TOP and AOP on\nauto.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_253" + }, + { + "chapter_numbre": "Chapter_24", + "chapter_name": "Chapter 25", + "chunk_index": 4, + "chunk_content": "5% to 70% i.e. 279 MW or less.\nb. Put DEHC on manual from \u201cDEHC Valve Test\u201d display. Turbine Master\nwill be shifted on Manual and mode will be shifted on Boiler follow.\nc. Change Turbine Master on manual mode.\nd. Select \u2018IMP in\u2019 and on \u2018auto\u2019.\ne. Select the \u2018LH Test\u2019 mode from the \u2018LH-MSV/GV Test\u2019 block on the\nscreen and at local, watch smooth closing of LH side GVs l and 3 and\nthe MSV. Also watch the bearing temperatures & GVs of the right\nhand side 2 and 4 opening (for maintaining constant load).\nf. In CCR, check close indication of both GVs and MSV of LH side.\ng. Select the (LH Reset)\u2019push button to restore initial conditions.\nh. At local, check re-opening of LH side MSV and then GVs and closing\nof RH side (GVs for load adjustment).\nh. Follow the same steps 5 to 8 mentioned above for testing RH side\nMSV und GVs by selecting \u2018RH Test\u2019 mode from RH-MSV/GV Test\u2019\nblock on the screen.\nOnce the above test is completed, proceed with the following:\nRSV/ICV Test:\ni. Select \u2018LH Test\u2019 push button on \u2018LH RSV/ICV test block on the screen\nand at local, watch smooth closing of LH side ICV and RSV. In CCR,\ncheck close indication of LH side ICV and RSV.\nj. Select \u2018LH Reset\u2019 push button to restore initial conditions.\nk. At local, check re-opening of LH side RSV and ICV.\nl. Repeat steps 1-4 mentioned above, for testing RH side RSV and ICV\nby selecting \u2018RH Test\u2019 push button from \u2018RH-RSV/ICV Test\u2019 block on\nthe screen.\nm. Select IMP out\u2019 and \u2018auto\u2019 to \u2018manual\u2019.\nn. DEHC from manual to auto mode.\nw. Change Unit control from Boiler follow to coordinate control.\nRefer to section 4-6-13 of turbine manual for the above rests.\nTest sequence for each set of valves\nDo a functional test of the (Main Stop) and reheat stop valves weekly with the\nturbine under load. The purpose of the test is to help maintain proper operation\nof these valves.\na) A maintenance technician observes valve operation during the\nfollowing test sequence for each set of valves.\nCheck that movement of the valve linkage is smooth and free. Jerky or\nintermittent motion indicates:\na. Buildup of deposits on the valve shaft (s) or stem (s) (such\ndeposits may require cleaning)\nb. Bent valve stem (s) or shaft (s).\nc. EH converter oil pressure fluctuation.\nd. Valve misalignment.\nb) Find and correct the cause for shaft or stem deposits.Lalpir/Pakgen Power Plant 83\nCCR Qualification Book\n3. Describe the procedure of turbine protective device test from turbine\ndeck, how turbine prevented from actual trip?\nDuring turbine protective device test procedure, turbine is prevented from\nactual trip by pressing the \u201cTest Lever\u201d on turbine deck. This lever block the\ndraining port of auto stop oil from servo motor. Before normalizing and\nreleasing this lever area engineer ensures the normal pressure of auto stop oil.\nAll of the Turbine protective test can be performed in one go by pressing Test\nLever, or they can be performed individually.\n4. Describe lube oil pumps auto cut in test, what actions required from\ncontrol room during this test?\nLube Oil cut in test is performed to confirm the healthiness of lube oil system.\nThis test includes starting of AOP, TOP, and EOP one by one.\nDuring this test, when\nAOP starts, it has to be shifted on manual has to be stopped on manual to\ncheck next pump operation in case of its unavailability at low lube oil pressure.\nAfter stopping AOP , again lube oil pressure is lowered from local gauge, this\ntime TOP will cut in . It has to be shifted on manual and has to be stopped on\nmanual to check next pump operation in case of its unavailability.\nAfter stopping TOP , again lube oil pressure is lowered from local gauge, this\ntime DC TOP (EOP) will cut in .\nStop the EOP pump on manual , wait for the area engineer to normalize the\nvalves at local , and after his confirmation , turn bank EOP, TOP and AOP on\nauto.\n5. At what conditions actual over speed test can be carried out, how\nfrequent it is required?\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_254" + }, + { + "chapter_numbre": "Chapter_25", + "chapter_name": "Chapter 26", + "chunk_index": 0, + "chunk_content": "1. What do you understand about: -\na) APC b) DEH c) BMS d) SEQ 1&2 e) IPU\na) APC - It is abbreviation of AUTO PLANT COTROL and is related with\nall critical signals, which coordinates the boiler and turbine and it sums\nanalog as well as digital signals\nb) DEH - It is abbreviation of DIGITAL ELECTRO HYDRAULIC system\nand it includes all signals related with governing system of turbine.\nc) BMS: It is abbreviation of BURNER MANAGEMET SYSTEM and it\nincludes burners cut in cut out sequence / demand, and HFO leak\ntests, dampers and associated alarms for this particular system.\nd) SEQ-1: It includes mostly boiler related Logics, some generator and\nturbine related sequences like seal oil and stator coolant.\ne) SEQ-", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_260" + }, + { + "chapter_numbre": "Chapter_25", + "chapter_name": "Chapter 26", + "chunk_index": 1, + "chunk_content": "2. Explain the following modes:\n(a) Turbine follow\n(b) Boiler follow\n(c) Co-ordinate control\nTurbine Follow:-\nIn turbine-following mode the boiler master following the turbine parameters\nand turbine master is in automatic mode. The turbine master controls boiler\nsteam pressure by modulating the turbine governor valves (GV\u2019s). Megawatts\nare then produced in the generator and pushed to the grid as a function of the\nboiler load\nBoiler follow:-\nIn this mode of operation, the boiler master is in automatic and the turbine is\nnot. Turbine GV\u2019s will respond to boiler pressure.\nCoordinate Control:-\nMeans both turbine and boiler masters are on AUTO and will follow the each\nother parameters.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_261" + }, + { + "chapter_numbre": "Chapter_25", + "chapter_name": "Chapter 26", + "chunk_index": 2, + "chunk_content": "3. What is the function of IPR and vacuum unloader? Explain in detail?\nIPR:\nIf at any stage due to any reason main steam set point pressure reduces down\nto 10 % of set value then this protections operates and start to reduce the load\nuntil the parameters does not come in control.\nVacuum Unloader:\nIf due to any reasons condenser vacuum drops down up to 630 mm Hg, then\nthis protection operates and starts to reduce the load until the parameter does\nnot come in range.Lalpir/Pakgen Power Plant 85\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_262" + }, + { + "chapter_numbre": "Chapter_25", + "chapter_name": "Chapter 26", + "chunk_index": 3, + "chunk_content": "4. What is the difference between governor control and load limiter\ncontrol, which is preferable?\nActually these both are load controls :\nGovernor Control:-\nStands for governor control and it watches the system frequency and droop\nand adjust the load accordingly by opening or closing G.Vs. and its setting is\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_263" + }, + { + "chapter_numbre": "Chapter_25", + "chapter_name": "Chapter 26", + "chunk_index": 4, + "chunk_content": "5. What is stress control, how it works?\nStress control is designed to maintain / control the \u201cmismatch\u201d of the turbine\nand its casing expansion\u201d. If stress control is on Auto position, and actual\nstress increases up to 90\u00baC, this system will not allow increasing turbine speed\n(during rolling) or load will not increase during normal operation.\nActually this system is very active to control the thermal stability of the turbine\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_264" + }, + { + "chapter_numbre": "Chapter_25", + "chapter_name": "Chapter 26", + "chunk_index": 5, + "chunk_content": "6. What is speed droop and what is our unit droop set?\nOur unit droop set is 5%. It means when turbine speed reduced or increased to\n5% of rated speed then governor valve take action to maintain the turbine\nspeed. In this way governor valve hunting can be avoided\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_265" + }, + { + "chapter_numbre": "Chapter_25", + "chapter_name": "Chapter 26", + "chunk_index": 6, + "chunk_content": "7. What is the run back, what is the equipment which causes run back?\nWhat are CREs actions when Run Back operates?\nRun back mean decreasing of load automatically to maintain the system\nparameters.\nFollowing are the equipment\u2019s, whom un-availability tripping will initiate run\nback\nPump Run Back Load Ramp Rate\nTarget\nBFP 146 MW 18.25 MW/S\nFDF 182.5 MW 18.25 MW/S\nAH 182.5 MW 18.25 MW/S\nBCP 219 MW 6.08 MW/S\nCP 200.75 MW 6.08 MW/S\nCWP 200.75 MW 6.08 MW/S\nRun back permit: Turbine Master on auto, Feed Water CV on auto, Fuel CV on\nauto\nRun back active: Gross Load equal to or above 115 MWLalpir/Pakgen Power Plant 86\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_266" + }, + { + "chapter_numbre": "Chapter_25", + "chapter_name": "Chapter 26", + "chunk_index": 7, + "chunk_content": "8. Define the cold, warm and hot start: -\na) According to PPA\nb) With reference to technical limits?\nWARM WARM\nHOT COLD\nI II\nShutdown\nPPA Duration in 8 32 <150 >150\nhrs\nTurbine 1st\nTech Stage Upto Greater than Less than\nLimits Metal 350 C 120 C 120 C\nTemp\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_267" + }, + { + "chapter_numbre": "Chapter_25", + "chapter_name": "Chapter 26", + "chunk_index": 8, + "chunk_content": "9. Discuss the turbine rolling; what are the permissive for turbine reset,\nsp1, sp2 and sp3?\nTurbine Reset & SP1 Permissive are as follows (They can also be found from DCS\non \u201cDEHC\u201d screen)\n\u2022 Bearing vibration normal\n\u2022 Diff expansion normal.\n\u2022 Rotor position normal.\n\u2022 Bearing oil pressure normal.\n\u2022 HP oil pressure normal.\n\u2022 Bearing metal temperature normal.\n\u2022 Bearing oil drain temp normal.\n\u2022 Oil cooler oil temp normal.\n\u2022 HP casing metal temp differential normal.\n\u2022 Turbine bolt Diff. temp normal.\n\u2022 HP control valve metal Diff. temp normal.\n\u2022 Condenser vacuum normal.\n\u2022 GOV setter Auto stand by mode.\n\u2022 LL setter Auto stand by mode.\n\u2022 Speed setter Auto mode.\n\u2022 Speed rate setter Auto mode.\n\u2022 Valve transfer Auto mode.\n\u2022 Stress control in service.\n\u2022 Turbine is reset.\n\u2022 Start mode selected\n\u2022 Steam temp and pressure conditions fulfilled.\n\u2022 Speed rate Auto selected.\n\u2022 Main steam super heat degree >55\u00baC.\n\u2022 GV LH full open.\n\u2022 GV RH full open.\nNote: For SP2 all above conditions along with SP1 should be fulfilled. Similarly for\nSP3, SP1 & SP2 conditions should be fulfilled.\nSP1 command: When SP1-Set Point 1 command is given to the turbine, MSV\u2019s\nopen and steam admission is started. Turbine speed is increased to 500 RPM and\nlube oil temperature set point remains as 35\u00baC.\nAfter the completion of \u201cSet Point 1\u201d SP1, Rub check is performed to ensure smooth\nturbine rooling.\nSP2 command: SP2 command increases turbine speed up to 2200 RPM. When\nSP2 command is given to the turbine, at 800 RPM jacking oil pumps will stop and at\n900 RPM lube oil temperature control valve set point changes to 45\u00baC.Lalpir/Pakgen Power Plant 87\nCCR Qualification Book\nDuring cold startup turbine speed is kept hold at this point for heat soaking of\nturbine as per OEM provided graph.\nSP3 command: SP3 command increases turbine speed up to 3000 RPM. At\nturbine speed 2950 RPM AOP will stop automatically.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_268" + }, + { + "chapter_numbre": "Chapter_25", + "chapter_name": "Chapter 26", + "chunk_index": 9, + "chunk_content": "10. What is full arc admission and partial arc admission, what are the\nbenefits of full arc admission during start up, what are the conditions\nrequired to be fulfilled before valve transfer?\nFull Arc admission: In full Arc condition steam flow is control by the MSV\u2019s\nwhile GV\u2019s are full open and partial Arc admission is vise versa.\nThe benefits of full arc are,\na. Even heating.\nb. Time reduction i.e. rolling time.\nIt is preferable for large turbine.\nValve transfer permissive:\na. GV setter on Auto mode.\nb. LL setter on Auto standby mode.\nc. V/V transfer on Auto mode.\nd. Stress control in service.\ne. Initial load achieved. (for cold startup)\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_269" + }, + { + "chapter_numbre": "Chapter_26", + "chapter_name": "Chapter 27", + "chunk_index": 0, + "chunk_content": "1. Write down the rating of following transformers\na) GSU\nRated Power: 430 MVA, 3 Phase, 50 Hz\nPrimary Side: 24kV ,\nSecondary Side 220kV\nCooling Method: ONAN-ONAF-OFAF\nRated Current: (HV) 1128.5A (LV) 10344A\nTapping Range: 193.6 kV to 255.2 kV (1 to 15 High)\nb) SUT\nRated Power: 44 MVA, 3 Phase, 50 Hz\nPrimary Side: 220kV ,\nSecondary Side 11kV\nCooling Method: ONAN-ONAF\nRated Current: (HV) 115.5A (LV) 2309.4A\nTapping Range: 242 kV /198 kV (1 to 17) High\nc) UAT\nRated Power: 40 MVA, 3 Phase, 50 Hz\nPrimary Side: 2", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_270" + }, + { + "chapter_numbre": "Chapter_26", + "chapter_name": "Chapter 27", + "chunk_index": 1, + "chunk_content": "2. What protections are provided on above mentioned transformers?\nTransformer differential protection To protect against short circuit faults\nExcessive volts protection To protect against high volts\nA high set instantaneous element To protect against heavy close-in faults\nA restricted ground differential zone element\nPhase and ground time over-current back-up relays\nBuchholz relay for detecting faults in the transformer main windings\nAn oil surge protective relay. For detecting a fault in the OLTC compartment.\nTwo over pressure relief devices for the main tank. Each of these devices\ninitiates trippingLalpir/Pakgen Power Plant 89\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_271" + }, + { + "chapter_numbre": "Chapter_26", + "chapter_name": "Chapter 27", + "chunk_index": 2, + "chunk_content": "3. GSU radiator fans are out of order, what will be its effect of\ntransformer performance? What limitations will be imposed in this\nscenario?\nThe losses occurring in the GSU transformer are converted into heat which\nincreases the temperature of the windings and the core. In order to dissipate\nthe heat generated cooling should be done.\nTo dissipate this heat, GSU transformer is equipped with radiator and cooling\nfan for radiator.\nThe radiator of transformer accelerates the cooling rate of transformer.\nTransformer cooling fans accelerate the cooling process in oil-cooled GSU.\nThey circulate air around the exterior of the transformer's radiator as oil works\nits way through the inside to dissipate heat and reduce the temperature of the\nwindings and the core.\nIn case, radiator fans are out of order, higher peak load cannot be achieved as\nheat produced at higher load cannot be dissipated and this will increase oil\ntemperature beyond its flash point. At temperature beyond flash point, oil may\ncatch fire.\nIn addition to high oil temperatures, insulation of transformer windings are\ndesigned at specific temperatures. At higher temperatures, transformer\nwinding insulation will also damage, reducing the useful life of transformer.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_272" + }, + { + "chapter_numbre": "Chapter_26", + "chapter_name": "Chapter 27", + "chunk_index": 3, + "chunk_content": "4. Why tap changing facility is provided on transformers? On which\ntransformers on-load tap changers are provided?\nTransformer with tap-changing facility constitutes an important means of\ncontrolling voltage throughout the system at all voltage levels by changing tap\nlevels. On SUT and GSU online tap changers are provided\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_273" + }, + { + "chapter_numbre": "Chapter_26", + "chapter_name": "Chapter 27", + "chunk_index": 4, + "chunk_content": "5. What precautions will be observed while operating On-Load Tap\nChanger provided on GSU?\nGenerator MVAR\u2019s and Power Factor as well as load in capability curve. In any\ncase , cursor shall not exceed safe limits defined in capability curve\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_274" + }, + { + "chapter_numbre": "Chapter_26", + "chapter_name": "Chapter 27", + "chunk_index": 5, + "chunk_content": "6. Why silica gel is used in transformer breather tank and when its\nreplacement is done?\nSilica gel is used in breather transformers for controlling the level of moisture\nand prevents it from entering the equipment. They are mainly useful in\nprotecting the transformer oil from the damaging effects of moisture. When its\ncolor is changed or moisture deposits are found , it shall be replacedLalpir/Pakgen Power Plant 90\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_275" + }, + { + "chapter_numbre": "Chapter_26", + "chapter_name": "Chapter 27", + "chunk_index": 6, + "chunk_content": "7. Draw a single line diagram of plant distribution system showing\ndistribution transformers?\n\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_276" + }, + { + "chapter_numbre": "Chapter_26", + "chapter_name": "Chapter 27", + "chunk_index": 7, + "chunk_content": "8. What type of transformer is installed in MCC room? Why temperature\nmonitor is provided in these transformers?\nDry type transformers are installed in MCC room. Temperature sensors\nprovide continuous real-time monitoring of dry type transformer temperature at\nwinding to quickly detect overload and fault conditions\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_277" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 0, + "chunk_content": "1. Explain briefly the main steps of complete unit start-up.\nMain Steps of complete unit startup are as follows\n\u2022 Cooling tower basin filling\n\u2022 Demin Tank top up\n\u2022 Boiler Drain \u2013 If required\n\u2022 Condenser filling\u2013 If required\n\u2022 DA Filling\u2013 If required\n\u2022 Drum Filling\u2013 If required\n >From Demin pumps header through Eco Spool Piece (Cold Startup)\n >From BFP (Preferably by BFP D) for Warm & Cold Startup\n\u2022 Cooling Water On Command\n >CWP\n >BCWP\n\u2022 Removal of Eco Spool Piece\n\u2022 Air & Gas Sequence On Command\n\u2022 Furnace Purge & Leak Test\n\u2022 Boiler Firing (Keep Metal temp rise rate < 110 Deg C)\n\u2022 Operation of Boiler drain valves as per requirement to meet steam\nconditions as per Startup\n\u2022 Aux Header Charging\n\u2022 Vacuum Pulling\n\u2022 HFO Leak Test and HFO Burners\n\u2022 HP Bypass operation at Vacuum above 635 mm of Hg\n\u2022 Meet Steam parameters by opening of SH\u2019s , Leg Drain MOV\u2019s\n\t>Steam Conditions as per turbine Startup type\n\t\t\uf0a7 Hot \u2013 100 kg/cm2 & 4\n\n1. When will you stop following auxiliaries after unit shutdown?\na. Main Condensate water pump\n\tMain Condensate water pump can be stopped after 8 hours of shut down\nb. Main Circulating water pump and BCWP\n\tMain CWP and BCWP can be stopped after 8 hours of shutdown\nc. Open 11kV breakers of BFPs and FDFsLalpir/Pakgen Power Plant 94 CCR Qualification Book\nAfter 8 hours of shut down they can be opened\nd. Optimize BFP, FDF,GRF and CT fans VFD room HVAC\nAfter 8 hours of unit shut down when 11kV breakers are opened\ne. Service air compressor\nAs soon as other unit also shut down , one SAC can be took in service for\nboth off bar units.\nf. Stator coolant pump\nAfter 8 hours of unit shut down\ng. Turbine turning gear and lube oil system\nAs soon as turbine first stage metal temperature reaches to or below 120\nDeg C\nh. AC cooling fan\nAs soon as drum metal temperature reaches to or below 100 Deg C\ni. GAH rotor drive\nAs soon as GAH inlet temp decreases to or below 90 Deg C\nj. GRF turning gear\nAs soon as GRF inlet temp decreases to or below 90 Deg C\nk. HFO firing pump\nAfter 32 hours of Unit shutdown (WARM II)\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_280" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 1, + "chunk_content": "2. Technically how many types of startups are available? What is the\nCriteria for the type of technical start-up?\nTechnical startup is of 3 types based on turbine first stage metal temperatues.\n\t\uf0a7 Hot \u2013 100 kg/cm2 & 420 Deg C\n\t\uf0a7 Warm \u2013 80 kg/cm2 & 360 Deg C\n\t\uf0a7 Hot \u2013 60 kg/cm2 & 350~420 Deg C\n\n\n2. With which frequency will you operate following equipment during unit\ncold mode\na. Turbine turning gear\nWeekly routine to take in service for 1 hour duration\nb. BCP with Hydrazine in dozed in boiler\nAs per requirement for 15 minutes\nc. CWP\nAs per requirement to maintain chemistry\nd. Stator coolant pump\nFortnightly routine to start for approx. 2~3 hours (subjected to conductivity\nnormalization)\ne. Air and Gas dampers\nFortnightly routine\nf. Fuel air dampers\nFortnightly routine\n1\n\n2.\nFrom ", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_281" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 2, + "chunk_content": "3. How will you decide from where to (Lalpir or Pakgen) import power for\nstart-up in following scenarios?\na. When both units are shut down, one unit\u2019s start-up is required\nand solar power is available.Lalpir/Pakgen Power Plant 92\nCCR Qualification Book\nb. When both units are shut down, one unit\u2019s start-up is required\nand solar power in not available.\nc. When both units are shut down, both unit\u2019s start-up is required\nand solar power in not available.\nd. When one unit is in service and other unit\u2019s start-up is required.\n\ta) For Both units Off Bar with solar power available, Community will be\n\tconnected to the unit under startup to take advantage of solar power.\n\tb) For Both units Off Bar with solar power available, Community will be\n\tconnected to the unit in shut down mode.\n\tc) Both units SUT will be taken in service and PFI will be connected with Lalpir\n\td) Connect the 2nd unit under startup with the On Bar unit to save import\n\tpower and MDI\n\n\n3. Which stage of PFI plant will you take in service during unit shutdown\ncondition?\nIn shutdown condition , PFI 1st stage will be taken into service\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_282" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 3, + "chunk_content": "4. When will you change over fuel from HSD to HFO in case of\n\ta. Hot start-up\n\tb. Warm start-up\n\tc. Cold start-up ?\n\t\nSwitching from HSD to HFO for all three startup modes can be done after HFO\nleak test completion and achieving HFO temperatures more than 90 Deg C\nand cold end metal temperatures more than 100 Deg C\n\n\n4. When will you connect hot air blower to low pressure turbine?\nWhen turbine first stage temperature reaches below 120 Deg CLalpir/Pakgen Power Plant 95\nCCR Qualification Book\n1", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_283" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 4, + "chunk_content": "5. One unit\u2019s start-up is in progress and 11kV unit tie breaker 2BCA18 is\nclosed to import power from running unit. When will you take start-up\nunit\u2019s SUT in service? What precautions will you take while this\nchangeover?\nOn unit under startup mode, when its turbine SP3 is completed and Valve\ntransfer is also completed (for Hot and WARM only), SUT for unit under startup\nmode can be taken in service.\nBefore taking SUT in service, make sure that its 11kV breaker is Rack In , and\nits Lock out ralay is Reset. In addition to this, confirm it\u2019s close permit from\nSUT 11kV breaker loop plate\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_284" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 5, + "chunk_content": "6. When do we require to open following drain valves? When are they\nclosed?\na. SP lower header drain valve\nb. 2ry Super Heater drain valve\nSP lower header drain valve is opened during startup after forced outage\n2ry super heater drain valve is opened to meet steam conditions during\nstartups\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_285" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 6, + "chunk_content": "7. What action will you take to keep MDI within its KPI for different types\nof start-ups i.e. hot, warm and cold?\nTake BFP-D in service that too on minimum possible frequency\nOperate GRF on possible minimum frequency\nMinimize operation of Waste water pumps, canal/well pumps\nCommunity shall be connected to other unit (If solar power is not available)\nControlled operation of Condenser dumping and boiler CBD\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_286" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 7, + "chunk_content": "8. Which stage of PFI plant is taken into service during unit start-up and\nwhy?\n2nd Stage of PFI plant is taken into service to import less MVAR\u2019s as more\n11kV motors are in serviceLalpir/Pakgen Power Plant 93\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_287" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 8, + "chunk_content": "9. Both units are under start-up mode. One unit is under hot start-up\nmode and other unit\u2019s cold start-up is just initiated. To which unit you\nwill connect the PFI plant?\nPFI Plant will be connected to Unit under Hot Startup Mode.\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_288" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 9, + "chunk_content": "10. Explain briefly the main steps of complete unit shutdown.\n\u2022 Set Load target to 18 MW\n\u2022 Stop 2nd BFP, CWP & CP as per Load and 2nd HFO pump at minimum\nload.\n\u2022 Reduce main steam pressure and take aux steam MOV on manual\n\u2022 Take 11kV bus tie breaker 52AB/T in service and take UAT out of\nservice\n\u2022 Ask area engineer to close Reheat TCV isolation valve\n\u2022 Check all turbine drains opened at <20% steam flow\n\u2022 Check economizer recirculation MOV opened at <20% steam flow\n\u2022 Check HP extraction out and its drain valves are open at load <50 MW\n\u2022 Select Main steam leg drain to manual (To avoid its opening on MFT)\n\u2022 BMS on manual and last stage burner selected manual\n\u2022 Turbine tripped from \u201cTrip Sequence\u201d at < 20 MW\n\u2022 Make sure all MSV, GV, RSV and ICV closed\n\u2022 Check Generator breaker opened on low forward power\n\u2022 Check excitation breaker opened\n\u2022 Check AOP cut in on turbine tripped\n\u2022 Take PFI in service\n\u2022 Check MFT do not occur on turbine trip\n\u2022 Lock BFP\u2019s and Condensate Pumps sequence\n\u2022 All cooling tower fans stopped\n\u2022 Give Vacuum System OFF command\n\u2022 Take out last burner\n\u2022 Switch off BCP\u2019s.\n\u2022 Make up drum level and stop main BFP\n\u2022 Close DA PCV & ask A/E to by-pass Condensate Storage Tank\n\u2022 Condenser spill over CV Shift to manual / closed\n\u2022 Take igniters out of service after last burner purging\n\u2022 Switch off igniter oil pump\n\u2022 Close SAH TCV ( Take care of Aux steam header pressure)\n\u2022 Select boiler on \u201cHot Bank\u201d and give \u201cOFF\u201d command to Air & Gas\nsequence after its post purging time completed\n\u2022 Check Air & Gas system completed and all dampers are closed\n\u2022 Open generator breaker isolator\n\u2022 Check AC jacking oil pump cut in at turbine speed 800 rpm\n\u2022 Check vacuum breaker opened at turbine speed 400 rpm\n\u2022 Check Gland steam MOV closed at vacuum < 50 mmHg\n\u2022 Check TOP cut in and AOP stopped at turbine speed 50 rpm\n\u2022 Close aux steam MOV 3ry side (open tie if required)\n\u2022 Check T/G motor started at turbine zero speed and turning gear\nengaged. Confirm turbine triggering on TSI panel. Note down turbine\ncoasting down time\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_289" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 10, + "chunk_content": "11. When will you stop following auxiliaries after unit shutdown?\na. Main Condensate water pump\n\tMain Condensate water pump can be stopped after 8 hours of shut down\nb. Main Circulating water pump and BCWP\n\tMain CWP and BCWP can be stopped after 8 hours of shutdown\nc. Open 11kV breakers of BFPs and FDFsLalpir/Pakgen Power Plant 94 CCR Qualification Book\nAfter 8 hours of shut down they can be opened\nd. Optimize BFP, FDF,GRF and CT fans VFD room HVAC\nAfter 8 hours of unit shut down when 11kV breakers are opened\ne. Service air compressor\nAs soon as other unit also shut down , one SAC can be took in service for\nboth off bar units.\nf. Stator coolant pump\nAfter 8 hours of unit shut down\ng. Turbine turning gear and lube oil system\nAs soon as turbine first stage metal temperature reaches to or below 120\nDeg C\nh. AC cooling fan\nAs soon as drum metal temperature reaches to or below 100 Deg C\ni. GAH rotor drive\nAs soon as GAH inlet temp decreases to or below 90 Deg C\nj. GRF turning gear\nAs soon as GRF inlet temp decreases to or below 90 Deg C\nk. HFO firing pump\nAfter 32 hours of Unit shutdown (WARM II)\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2810" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 11, + "chunk_content": "12. With which frequency will you operate following equipment during unit\ncold mode\na. Turbine turning gear\nWeekly routine to take in service for 1 hour duration\nb. BCP with Hydrazine in dozed in boiler\nAs per requirement for 15 minutes\nc. CWP\nAs per requirement to maintain chemistry\nd. Stator coolant pump\nFortnightly routine to start for approx. 2~3 hours (subjected to conductivity\nnormalization)\ne. Air and Gas dampers\nFortnightly routine\nf. Fuel air dampers\nFortnightly routine\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2811" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 12, + "chunk_content": "13. Which stage of PFI plant will you take in service during unit shutdown\ncondition?\nIn shutdown condition , PFI 1st stage will be taken into service\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2812" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 13, + "chunk_content": "14. When will you connect hot air blower to low pressure turbine?\nWhen turbine first stage temperature reaches below 120 Deg CLalpir/Pakgen Power Plant 95\nCCR Qualification Book\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2813" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 14, + "chunk_content": "15. How will you perform boiler forced cooling? What is the criterion to\nterminate forced cooling? How will you optimize electricity import\nduring boiler forced cooling?\nThumb Rule for maximum allowable change in boiler metal\ntemperature is 110oC per hour. Whenever there is need for boiler\nforced cooling, this rate must be followed. In addition to this, VFD\u2019s\nare installed on FDF\u2019s and BFP\u2019s , Keep their frequency on possible\nminimum requirement.\nIf boiler is at high pressure, first open Boiler drains (Leg drain , 1ry,\n2ry, 3ry SH drains) upto 15% till the pressure decreases to 30\nkg/cm", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2814" + }, + { + "chapter_numbre": "Chapter_27", + "chapter_name": "Chapter 28", + "chunk_index": 15, + "chunk_content": "28\nUnit Startup and Shutdown\n1. Explain briefly the main steps of complete unit start-up.\nMain Steps of complete unit startup are as follows\n\u2022 Cooling tower basin filling\n\u2022 Demin Tank top up\n\u2022 Boiler Drain \u2013 If required\n\u2022 Condenser filling\u2013 If required\n\u2022 DA Filling\u2013 If required\n\u2022 Drum Filling\u2013 If required\n >From Demin pumps header through Eco Spool Piece (Cold Startup)\n >From BFP (Preferably by BFP D) for Warm & Cold Startup\n\u2022 Cooling Water On Command\n >CWP\n >BCWP\n\u2022 Removal of Eco Spool Piece\n\u2022 Air & Gas Sequence On Command\n\u2022 Furnace Purge & Leak Test\n\u2022 Boiler Firing (Keep Metal temp rise rate < 110 Deg C)\n\u2022 Operation of Boiler drain valves as per requirement to meet steam\nconditions as per Startup\n\u2022 Aux Header Charging\n\u2022 Vacuum Pulling\n\u2022 HFO Leak Test and HFO Burners\n\u2022 HP Bypass operation at Vacuum above 635 mm of Hg\n\u2022 Meet Steam parameters by opening of SH\u2019s , Leg Drain MOV\u2019s\n\t>Steam Conditions as per turbine Startup type\n\t\t\uf0a7 Hot \u2013 100 kg/cm2 & 420 Deg C\n\t\t\uf0a7 Warm \u2013 80 kg/cm2 & 360 Deg C\n\t\t\uf0a7 Hot \u2013 60 kg/cm2 & 350~420 Deg C\n\u2022 Turbine Rest\n\u2022 SP1, Rub Check, SP2, SP3 & valve transfer (Hot & WARM start only)\n\u2022 Close Generator Isolator\n\u2022 Close Excitation breaker \u2013 41E1\n\u2022 Turn 52C \u2013 Generator Breaker ON\n\u2022 Put Sync selection on Auto\n\u2022 Unit Sync\n\u2022 Valve Transfer (Cold Only)\n\u2022 Load Target\n\u2022 Main Steam Target (Subjected to chemistry)\n\u2022 HP-LP Heaters in service\n\u2022 CBD operation\n2. Technically how many types of startups are available? What is the\nCriteria for the type of technical start-up?\nTechnical startup is of 3 types based on turbine first stage metal temperatues.\n\t\uf0a7 Hot \u2013 100 kg/cm2 & 420 Deg C\n\t\uf0a7 Warm \u2013 80 kg/cm2 & 360 Deg C\n\t\uf0a7 Hot \u2013 60 kg/cm2 & 350~420 Deg C\n3. How will you decide from where to (Lalpir or Pakgen) import power for\nstart-up in following scenarios?\na. When both units are shut down, one unit\u2019s start-up is required\nand solar power is available.Lalpir/Pakgen Power Plant 92\nCCR Qualification Book\nb. When both units are shut down, one unit\u2019s start-up is required\nand solar power in not available.\nc. When both units are shut down, both unit\u2019s start-up is required\nand solar power in not available.\nd. When one unit is in service and other unit\u2019s start-up is required.\n\ta) For Both units Off Bar with solar power available, Community will be\n\tconnected to the unit under startup to take advantage of solar power.\n\tb) For Both units Off Bar with solar power available, Community will be\n\tconnected to the unit in shut down mode.\n\tc) Both units SUT will be taken in service and PFI will be connected with Lalpir\n\td) Connect the 2nd unit under startup with the On Bar unit to save import\n\tpower and MDI\n4. When will you change over fuel from HSD to HFO in case of\n\ta. Hot start-up\n\tb. Warm start-up\n\tc. Cold start-up ?\n\t\nSwitching from HSD to HFO for all three startup modes can be done after HFO\nleak test completion and achieving HFO temperatures more than 90 Deg C\nand cold end metal temperatures more than 100 Deg C\n5. One unit\u2019s start-up is in progress and 11kV unit tie breaker 2BCA18 is\nclosed to import power from running unit. When will you take start-up\nunit\u2019s SUT in service? What precautions will you take while this\nchangeover?\nOn unit under startup mode, when its turbine SP3 is completed and Valve\ntransfer is also completed (for Hot and WARM only), SUT for unit under startup\nmode can be taken in service.\nBefore taking SUT in service, make sure that its 11kV breaker is Rack In , and\nits Lock out ralay is Reset. In addition to this, confirm it\u2019s close permit from\nSUT 11kV breaker loop plate\n6. When do we require to open following drain valves? When are they\nclosed?\na. SP lower header drain valve\nb. 2ry Super Heater drain valve\nSP lower header drain valve is opened during startup after forced outage\n2ry super heater drain valve is opened to meet steam conditions during\nstartups\n7. What action will you take to keep MDI within its KPI for different types\nof start-ups i.e. hot, warm and cold?\nTake BFP-D in service that too on minimum possible frequency\nOperate GRF on possible minimum frequency\nMinimize operation of Waste water pumps, canal/well pumps\nCommunity shall be connected to other unit (If solar power is not available)\nControlled operation of Condenser dumping and boiler CBD\n8. Which stage of PFI plant is taken into service during unit start-up and\nwhy?\n2nd Stage of PFI plant is taken into service to import less MVAR\u2019s as more\n11kV motors are in serviceLalpir/Pakgen Power Plant 93\nCCR Qualification Book\n9. Both units are under start-up mode. One unit is under hot start-up\nmode and other unit\u2019s cold start-up is just initiated. To which unit you\nwill connect the PFI plant?\nPFI Plant will be connected to Unit under Hot Startup Mode.\n10. Explain briefly the main steps of complete unit shutdown.\n\u2022 Set Load target to 18 MW\n\u2022 Stop 2nd BFP, CWP & CP as per Load and 2nd HFO pump at minimum\nload.\n\u2022 Reduce main steam pressure and take aux steam MOV on manual\n\u2022 Take 11kV bus tie breaker 52AB/T in service and take UAT out of\nservice\n\u2022 Ask area engineer to close Reheat TCV isolation valve\n\u2022 Check all turbine drains opened at <20% steam flow\n\u2022 Check economizer recirculation MOV opened at <20% steam flow\n\u2022 Check HP extraction out and its drain valves are open at load <50 MW\n\u2022 Select Main steam leg drain to manual (To avoid its opening on MFT)\n\u2022 BMS on manual and last stage burner selected manual\n\u2022 Turbine tripped from \u201cTrip Sequence\u201d at < 20 MW\n\u2022 Make sure all MSV, GV, RSV and ICV closed\n\u2022 Check Generator breaker opened on low forward power\n\u2022 Check excitation breaker opened\n\u2022 Check AOP cut in on turbine tripped\n\u2022 Take PFI in service\n\u2022 Check MFT do not occur on turbine trip\n\u2022 Lock BFP\u2019s and Condensate Pumps sequence\n\u2022 All cooling tower fans stopped\n\u2022 Give Vacuum System OFF command\n\u2022 Take out last burner\n\u2022 Switch off BCP\u2019s.\n\u2022 Make up drum level and stop main BFP\n\u2022 Close DA PCV & ask A/E to by-pass Condensate Storage Tank\n\u2022 Condenser spill over CV Shift to manual / closed\n\u2022 Take igniters out of service after last burner purging\n\u2022 Switch off igniter oil pump\n\u2022 Close SAH TCV ( Take care of Aux steam header pressure)\n\u2022 Select boiler on \u201cHot Bank\u201d and give \u201cOFF\u201d command to Air & Gas\nsequence after its post purging time completed\n\u2022 Check Air & Gas system completed and all dampers are closed\n\u2022 Open generator breaker isolator\n\u2022 Check AC jacking oil pump cut in at turbine speed 800 rpm\n\u2022 Check vacuum breaker opened at turbine speed 400 rpm\n\u2022 Check Gland steam MOV closed at vacuum < 50 mmHg\n\u2022 Check TOP cut in and AOP stopped at turbine speed 50 rpm\n\u2022 Close aux steam MOV 3ry side (open tie if required)\n\u2022 Check T/G motor started at turbine zero speed and turning gear\nengaged. Confirm turbine triggering on TSI panel. Note down turbine\ncoasting down time\n11. When will you stop following auxiliaries after unit shutdown?\na. Main Condensate water pump\n\tMain Condensate water pump can be stopped after 8 hours of shut down\nb. Main Circulating water pump and BCWP\n\tMain CWP and BCWP can be stopped after 8 hours of shutdown\nc. Open 11kV breakers of BFPs and FDFsLalpir/Pakgen Power Plant 94 CCR Qualification Book\nAfter 8 hours of shut down they can be opened\nd. Optimize BFP, FDF,GRF and CT fans VFD room HVAC\nAfter 8 hours of unit shut down when 11kV breakers are opened\ne. Service air compressor\nAs soon as other unit also shut down , one SAC can be took in service for\nboth off bar units.\nf. Stator coolant pump\nAfter 8 hours of unit shut down\ng. Turbine turning gear and lube oil system\nAs soon as turbine first stage metal temperature reaches to or below 120\nDeg C\nh. AC cooling fan\nAs soon as drum metal temperature reaches to or below 100 Deg C\ni. GAH rotor drive\nAs soon as GAH inlet temp decreases to or below 90 Deg C\nj. GRF turning gear\nAs soon as GRF inlet temp decreases to or below 90 Deg C\nk. HFO firing pump\nAfter 32 hours of Unit shutdown (WARM II)\n12. With which frequency will you operate following equipment during unit\ncold mode\na. Turbine turning gear\nWeekly routine to take in service for 1 hour duration\nb. BCP with Hydrazine in dozed in boiler\nAs per requirement for 15 minutes\nc. CWP\nAs per requirement to maintain chemistry\nd. Stator coolant pump\nFortnightly routine to start for approx. 2~3 hours (subjected to conductivity\nnormalization)\ne. Air and Gas dampers\nFortnightly routine\nf. Fuel air dampers\nFortnightly routine\n13. Which stage of PFI plant will you take in service during unit shutdown\ncondition?\nIn shutdown condition , PFI 1st stage will be taken into service\n14. When will you connect hot air blower to low pressure turbine?\nWhen turbine first stage temperature reaches below 120 Deg CLalpir/Pakgen Power Plant 95\nCCR Qualification Book\n15. How will you perform boiler forced cooling? What is the criterion to\nterminate forced cooling? How will you optimize electricity import\nduring boiler forced cooling?\nThumb Rule for maximum allowable change in boiler metal\ntemperature is 110oC per hour. Whenever there is need for boiler\nforced cooling, this rate must be followed. In addition to this, VFD\u2019s\nare installed on FDF\u2019s and BFP\u2019s , Keep their frequency on possible\nminimum requirement.\nIf boiler is at high pressure, first open Boiler drains (Leg drain , 1ry,\n2ry, 3ry SH drains) upto 15% till the pressure decreases to 30\nkg/cm2.\nFrom 30 kg/cm2 to 10 kg/cm2 , increase Leg drain . 1ry and 3ry SH\ndrain MOV opening to 50%\nFrom 10 kg/cm2 to 02 kg/cm2 , increase Leg drain . 1ry and 3ry SH\ndrain MOV opening to 100%\nOn reaching 02 kg/cm2 drum pressure, ask boiler area engineer to\nopen steam drum vents.\nCBD can be opened upto 15% initially till 30kg/cm2 and its opening\ncan be increased afterwards keeping steam drum level in range and\ncooling rate in range..\nPlease make sure to keep eco recirculation valve in fully open\nposition during this activity.\nOn reaching drum pressure upto 60kg/cm2 , air and gas system can\nbe started depending on the requirement.\nAs per standard forced cooling can be terminated at boiler drum metal\ntemperature of 90Deg C\n", + "source": "CCR Qual Book", + "chunk_id": "ccr_chapter_2815" + } +] \ No newline at end of file