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7/30/2019 19148386 Boiler Steam and Water System Procedure
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CONTENTS
SECTION........... .............. .............. ............... .............. .............. .............. .............. .............. ............... .............. ...... ..... ..... ..... PAGE #
1. SYSTEM STARTUP...........................................................................................................................................................................4
1.1 PRECAUTIONS...............................................................................................................................................................................41.2 I NITIAL CONDITIONS ......................................................................................................................................................................6
1.3 FILLING BOILER WITH THE STARTUP BOILER FEED PUMP......................................................................................................................81.4 I NITIAL FILLING AND VENTING OF BOILER CIRCULATING PUMP..............................................................................................................101.5 PURGING OF BOILER CIRCULATING WATER PUMP...............................................................................................................................151.7 NORMAL SYSTEM STARTUP...........................................................................................................................................................20
1.7.1 Placing Boiler Circulating Pump In Operation - Unit Cold-Pump Cold...............................................................................201.7.2 Placing Boiler Circulating Pump In Operation - Unit Hot-Pump Cold and Empty..............................................................211.7.3 Placing Boiler Circulating Pump In Operation - Unit Hot-Pump Hot (Hot Standby)...........................................................27
1.8 R AISING BOILER PRESSURE...........................................................................................................................................................29
2. SYSTEM NORMAL OPERATION...................... ............... .............. .............. .............. .............. .............. ........... ..... ..... ..... ..... ...30
2.1 R OUTINE OPERATION....................................................................................................................................................................30
3. SYSTEM SHUTDOWN.................... .............. ............... .............. .............. .............. .............. .............. ............... .............. ......... .....31
3.1 BOILER CIRCULATING PUMP SHUTDOWN...........................................................................................................................................31
3.1.1 Boiler Hot - Pump To Be Placed In Hot Standby....................................................................................................................313.1.2 Boiler Hot - Pump To Be Isolated For Maintenance..............................................................................................................313.1.3 Boiler Cold and Full - Pump To Be Isolated For Maintenance.............................................................................................33
3.2 BOILER SHUTDOWN......................................................................................................................................................................35
4. SYSTEM ABNORMAL OPERATION..........................................................................................................................................36
4.1 BOILER CIRCULATING PUMPS DIFFERENTIAL PRESSURE LOW-LOW.........................................................................................................364.1.1 Causes......................................................................................................................................................................................36 4.1.2 Results......................................................................................................................................................................................36 4.1.3 Corrective Actions...................................................................................................................................................................36
4.2 BOILER CIRCULATING PUMPS DIFFERENTIAL PRESSURE LOW................................................................................................................374.2.1 Causes......................................................................................................................................................................................37 4.2.2 Results......................................................................................................................................................................................37 4.2.3 Corrective Actions...................................................................................................................................................................37
4.3 BOILER CIRCULATING PUMP TRIP....................................................................................................................................................384.3.1 Causes......................................................................................................................................................................................384.3.2 Results......................................................................................................................................................................................384.3.3 Corrective Actions...................................................................................................................................................................38
4.4 BOILER CIRCULATING PUMP MOTOR CAVITY TEMPERATURE HIGH.........................................................................................................394.4.1 Causes......................................................................................................................................................................................394.4.2 Results......................................................................................................................................................................................394.4.3 Corrective Actions...................................................................................................................................................................39
4.5 MAIN STEAM (SUPERHEATER ) TEMPERATURE HIGH............................................................................................................................404.5.1 Causes......................................................................................................................................................................................404.5.2 Results......................................................................................................................................................................................404.5.3 Corrective Actions...................................................................................................................................................................40
4.6 MAIN STEAM TEMPERATURE LOW..................................................................................................................................................424.6.1 Causes......................................................................................................................................................................................424.6.2 Results......................................................................................................................................................................................424.6.3 Corrective Actions...................................................................................................................................................................42
4.7 R EHEAT STEAM TEMPERATURE HIGH...............................................................................................................................................434.7.1 Causes......................................................................................................................................................................................434.7.2 Results......................................................................................................................................................................................434.7.3 Corrective Actions...................................................................................................................................................................43
4.8 R EHEAT STEAM TEMPERATURE LOW................................................................................................................................................454.8.1 Causes......................................................................................................................................................................................454.8.2 Results......................................................................................................................................................................................454.8.3 Corrective Actions...................................................................................................................................................................45
4.9 MAIN STEAM PRESSURE HIGH.......................................................................................................................................................46
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4.9.1 Causes......................................................................................................................................................................................46 4.9.2 Results......................................................................................................................................................................................46 4.9.3 Corrective Actions...................................................................................................................................................................46
4.10 MAIN STEAM PRESSURE LOW......................................................................................................................................................474.10.1 Causes....................................................................................................................................................................................47 4.10.2 Results....................................................................................................................................................................................47 4.10.3 Corrective Actions.................................................................................................................................................................47
4.11 DRUM LEVEL HIGH...................................................................................................................................................................48
4.11.1 Causes....................................................................................................................................................................................484.11.2 Results....................................................................................................................................................................................484.11.3 Corrective Actions..................................................................................................................................................................48
4.12 DRUM LEVEL LOW....................................................................................................................................................................504.12.1 Causes....................................................................................................................................................................................504.12.2 Results....................................................................................................................................................................................504.12.3 Corrective Actions.................................................................................................................................................................50
4.13 BOILER WATER SILICA CONTENT HIGH..........................................................................................................................................524.13.1 Causes....................................................................................................................................................................................524.13.2 Results....................................................................................................................................................................................524.13.3 Corrective Actions.................................................................................................................................................................52
4.14 WATERWALL TUBE LEAK ............................................................................................................................................................534.14.1 Causes....................................................................................................................................................................................534.14.2 Results....................................................................................................................................................................................53
4.14.3 Corrective Actions.................................................................................................................................................................534.15 SECONDARY SUPERHEAT TUBE LEAK .............................................................................................................................................54
4.15.1 Causes....................................................................................................................................................................................544.15.2 Results....................................................................................................................................................................................544.15.3 Corrective Actions.................................................................................................................................................................54
4.16 R EHEATER TUBE LEAK ...............................................................................................................................................................554.16.1 Causes....................................................................................................................................................................................554.16.2 Results....................................................................................................................................................................................554.16.3 Corrective Actions.................................................................................................................................................................55
4.17 MAIN STEAM PRESSURE HIGH.....................................................................................................................................................564.17.1 Causes....................................................................................................................................................................................56 4.17.2 Results....................................................................................................................................................................................56 4.17.3 Corrective Actions.................................................................................................................................................................56
4.18 ECONOMIZER TUBE LEAK ...........................................................................................................................................................57
4.18.1 Causes....................................................................................................................................................................................57 4.18.2 Results....................................................................................................................................................................................57 4.18.3 Corrective Actions.................................................................................................................................................................57
5. SYSTEM VALVE LINEUP..............................................................................................................................................................58
6. POWER SUPPLY LINEUP.............................................................................................................................................................74
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1.SYSTEM STARTUP
1.1Precautions
1. Water quality must be within the following parameters:
Sample Source Parameter Range
Boiler Drum Unit 1 Specific conductivity 5.6 - 11.3
pH 9.2 - 9.7
P Alk. (ppm) 0.1 - 2.8
M Alk. (ppm) 2.8 - 6.6
Total Hard 0
Cl (ppm) 0
SiO2 (ppb) <85
PO4 (ppm) 0.5 - 2.0
Boiler Drum Unit 2 Specific conductivity 6.1 - 13.6
pH 9.2 - 9.9
P Alk. (ppm) 0.2 - 3.8
M Alk. (ppm) 3.1 - 7.6
Total Hard 0
Cl (ppm) 0SiO2 (ppb) <85
PO4 0.5 - 2.0
1. The maximum temperature differential between the drum metal andthe incoming feedwater must be less than 200oF.
2. Steam drum level should be closely monitored during startup due toboiler water swelling; initially fill drum to approximately 0 inches.
3. Purge the boiler circulation pump motor rotor cavity of the motor veryslowly (less than one-half gallon per minute). Due to the complexity of passages in the motor through which the water must flow, it isnecessary to fill the rotor cavity very slowly to displace all the air.
4. Water temperature for filling the boiler circulation pump rotor cavityand purge should never be greater than 120oF.
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5. Remove and store flanged spool piece from the low pressure fillconnection prior to use of the high pressure fill system.
6. Prewarm the Startup Boiler Feed Pump (SUBFP) such that the higherpump casing temperature is within 25oF of DA water temperature andthe suction and discharge temperatures are within 50oF.
7. Two successive starts are permissible on the startup boiler feed pump,after which motor should be allowed to cool by standing idle for one(1) hour or motor operating at rated temperature for 1/2 hour.
8. Closely monitor and maintain deaerator level to ensure adequateNPSH (Net Positive Suction Head) protection on SUBFP.
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1.2Initial Conditions
1. All necessary Clearance Orders removed.
2. Power available in accordance with the Power Supply Lineup, Section6.
3. Boiler Steam and Water System aligned in accordance with SystemLineup, Section 5.
4. Instrument air is in operation with normal pressure to the instrumentair header and to the control valves.
5. Verify Boiler Circulation Pump start permissives are satisfied:
a) Cooling water (Closed Cooling Water) flow not low
b) Motor cavity temperature not high
c) Suction valve 100% opend) Bus differential lockout relay reset
e) Restart permitted light (not interlocked into the starting circuit)should be acknowledged unless an emergency situation exists
6. Verify the operability of boiler system valves:
a) Boiler drain valves
b) Economizer recirculation valves
c) Steam line drain valves
7. Verify adequate water level in deaerator.
8. Verify deaerator water purity and oxygen concentrations areacceptable and temperature above 215oF.
9. Verify electromatic pressure relief valve is operational and valved outbelow 500 psi steam pressure (per manufacturer).
10. Verify proper lineup for boiler system drains and vents.
11. Verify economizer recirculation valves are open.
12. Open economizer link vents if economizer empty, otherwise close.
13. Verify boiler steam and water sample lines valved in service.
14. Verify drum level and pressure transmitters valved in.
15. Verify sootblower air supply block valves are open, and the air to thepressure regulating valves (on 21st floor) and the individual large IRsootblowers and the thermal drains are open.
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16. Verify MOV block valves SG11-1619/2619 and SG11-1620/2620 areopen.
17. Verify that seal trough on bottom ash system is clean and full of waterto prevent boiler expansion problems during warmup.
18. The startup permissives for the SUBFP are as follows:
a) Bus lockout relay reset
b) Motor lockout relay reset
c) Deaerator level above -51”(LS-1099)
d) Suction valve full open
e) Pump lube oil pressure normal (SUBFP Auxiliary Lube Oil pumprunning)
19. Verify the chemical injection system and sampling system for thefeedwater system are operational.
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1.3Filling Boiler With The Startup Boiler Feed Pump
1. Boiler water system aligned in accordance with Section 5 of thisprocedure.
2. The condensate system is in operation with normal DA level andchemistry.
3. Verify startup permissives for the SUBFP are satisfied:
a) Bus lockout relay reset
b) Motor lockout relay reset
c) Deaerator level above -51”(LS-1099)
d) Suction valve full open
e) Pump lube oil pressure normal (SUBFP Auxiliary Lube Oil pump
running)4. Verify the SUBFP suction valve is open.
5. Prewarm the SUBFP until the inner and outer barrel temperatures arewithin 50oF of each other and the higher barrel temperature is within25oF of DA temperature.
6. Verif ythe
SUBFP suction and discharge casing ends are within 50oF of eachother.
7. Verify the SUBFP auxiliary lube oil pump local control is selected to theRUN position.
8. Verify the SUBFP recirculation control is selected to the AUTO position.
9. Verify the desuperheater pressure control valve FW01-19 is closed.
10. Select the SUBFP to the START position and verify:a) The auxiliary oil pump will auto start if not already running
b) The SUBFP recirculation valve travels to full open
c) The pump motor starts
d) The pump motor amps return to the normal
e) Return the SUBFP auxiliary oil pump to AUTO.
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NOTEThe DA temperature is normally about 250oF from pegging steam tohelp remove oxygen before the feedwater system is filled and water is
added to the steam drum.
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NOTEWith the SUBFP running the prewarming to the turbine BFP’s may be lined up if desired.
11. Adjust the cooling water flow on the SUBFP lube oil cooler to maintainoil temperature between 110-120oF.
12. Select the HP and LP prewarm valve control from building heating tothe CLOSE position.
13. Vent economizer if required.
14. Verify Feedwater Heaters 16, and 17 are in auto bypass.
15. Open SUBFP discharge valve FW01-38.
16. Regulate feed-rate with Feed Regulating Valve FW01-37.
17. Fill the boiler upper drum to plus 10” above the recommended 0inches operating level. This will prevent loss of drum level duringstarting of boiler circulation pump.
18. Close the startup flow control valve FW01-37.
19. Shut the SUBFP discharge valve FW01-38.
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1.4Initial Filling and Venting of Boiler Circulating Pump
1. Verify boiler filled or fill in accordance with Section 1.3 of thisprocedure.
2. Verify closed cooling water is aligned to boiler circulating pumps priorto filling:
a) Closed cooling water supply valve SG03-9 (21) open
b) Closed cooling water control valve inlet isolation valve SG03-11
(22) openc) Closed cooling water control valve SG03-1 (66) in Auto
d) Bypass SG03-216 is closed
e) Valve 2, Thermal barrier emergency cooling supply is closed
3. Verify boiler circulating pump thermal barrier valves are locked open:
a) Boiler circulating pump 11/21
i) Thermal barrier supply valve SG03-20
ii) Thermal barrier return valve SG03-28 (16)
b) Boiler circulating pump 12/22
i) Thermal barrier supply valve SG03-21
ii) Thermal barrier return valve SG03-29 (16)
c) Boiler circulating pump 13/23
i) Thermal barrier supply valve SG03-22
ii) Thermal barrier return valve SG03-30 (16)
d) Boiler circulating pump 14/24
i) Thermal barrier supply valve SG03-23
ii) Thermal barrier return valve SG03-31 (16)
4. Verify boiler circulating pumps closed cooling water return header isaligned as follows:
a) Closed cooling water return control valve inlet isolation valveSG03-15 (62) is open
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NOTE
Water used to fill the pump(s) must be of condensate quality. The temperature of thefill water must be between 70oF and 120oF.
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b) Closed cooling water return control valve inlet SG03-3 (67) inAuto
c) Closed cooling water return control valve outlet isolation valveSG03-17 (62) is open
d) Bypass SG03-217 is closed
e) Valve 4, Thermal barrier emergency cooling drain to bell-up isclosed
NOTEEmergency cooling to the BCP thermal barriers comes from a tank on 13th floor (suppliedfrom service water). This tank is supposed to last for approximately 8 hours. If thissystem is supplying thermal cooling, the drain (return) switches to a drain to bell-up.
5. Close or Verify Closed boiler circulating pump suction valve asappropriate:
a) Boiler circulating pump 11/21 suction valve SG03-5 (2)
b) Boiler circulating pump 12/22 suction valve SG03-6 (2)
c) Boiler circulating pump 13/23 suction valve SG03-7 (2)
d) Boiler circulating pump 14/24 suction valve SG03-8 (2)
6. Close or Verify Closed boiler circulating pump discharge valve asappropriate:
a) Boiler circulating pump 11/21 discharge valves SG03-126 (3),and SG03-127 (3)
b) Boiler circulating pump 12/22 discharge valves SG03-128 (3),and SG03-129 (3)
c) Boiler circulating pump 13/23 discharge valves SG03-130 (3),and SG03-131 (3)
d) Boiler circulating pump 14/24 discharge valves SG03-132 (3),and SG03-133 (3)
7. Close boiler water circulating pump bypass valves as appropriate:a) Boiler circulating pump 11/21 bypass valves SG03-94 (5), and
SG03-106 (6)
b) Boiler circulating pump 12/22 bypass valves SG03-95 (5), andSG03-108 (6)
c) Boiler circulating pump 13/23 bypass valves SG03-96 (5), andSG03-110 (6)
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d) Boiler circulating pump 14/24 bypass valves SG03-97 (5), andSG03-112 (6)
8. Close or verify closed drain valves:
a) Boiler circulating pump 11/21 SG03-238, 278, 254, 258
b) Boiler circulating pump 12/22 SG03-239, 279, 255, 259
c) Boiler circulating pump 13/23 SG03-240, 280, 256, 260
d) Boiler circulating pump 14/24 SG03-241, 281, 257, 261
9. Verify Closed Strainer drain valves SG03-44, and SG03-45.
10. Close boiler circulating pump motor cavity isolation valve:
a) Boiler circulating pump 11/21 motor cavity valve SG03-246 (10A)
b) Boiler circulating pump 12/22 motor cavity valve SG03-247 (10A)
c) Boiler circulating pump 13/23 motor cavity valve SG03-248 (10A)
d) Boiler circulating pump 14/24 motor cavity valve SG03-249 (10A)
11. Close boiler circulating pump motor cavity cooling water return:
a) Boiler circulating pump 11/21 motor cavity cooling water valveSG03-250
b) Boiler circulating pump 12/22 motor cavity cooling water valveSG03-251
c) Boiler circulating pump 13/23 motor cavity cooling water valveSG03-252
d) Boiler circulating pump 14/24 motor cavity cooling water valveSG03-253
12. Open bypass valves, and vent valves:
a) SG03-102 (5A), SG03-107 (6A), (7), and (57)
b) SG03-103 (5A), SG03-109 (6A), (7), and (57)
c) SG03-104 (5A), SG03-111 (6A), (7), and (57)
d) SG03-105 (5A), SG03-113 (6A), (7), and (57)
13. Install low pressure fill spool piece.14. Open low pressure fill spool piece outlet isolation valve SG03-39 (50),
and inlet isolation valve SG03-37 (51).
15. Open boiler circulating pump fill filter inlet isolation valve asappropriate:
a) Boiler circulating pump 11/21 fill filter inlet valve SG03-234
b) Boiler circulating pump 12/22 fill filter inlet valve SG03-235
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c) Boiler circulating pump 13/23 fill filter inlet valve SG03-236
d) Boiler circulating pump 14/24 fill filter inlet valve SG03-237
24. Close boiler circulating pumps fill strainer inlet (SG03-42), and outlet(SG03-43) isolation valves.
25. Close low pressure fill spool piece outlet isolation valve SG03-39 (50).
26. Close low pressure fill spool piece supply isolation valve SG03-37 (51).
27. Remove low pressure fill spool piece.
28. Verify closed boiler circulating pump motor cavity cooling water valve
a) Boiler circulating pump 11/21 motor cavity cooling water valveSG03-250
b) Boiler circulating pump 12/22 motor cavity cooling water valveSG03-251
c) Boiler circulating pump 13/23 motor cavity cooling water valveSG03-252
d) Boiler circulating pump 14/24 motor cavity cooling water valveSG03-253
29. Open boiler circulating pump filter inlet valve:
a) Boiler circulating pump 11/21 filter inlet valve SG03-242
b) Boiler circulating pump 12/22 filter inlet valve SG03-243
c) Boiler circulating pump 13/23 filter inlet valve SG03-244
d) Boiler circulating pump 14/24 filter inlet valve SG03-245
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1.5Purging of Boiler Circulating Water Pump
1. Verify closed cooling water is aligned to boiler circulating water pumpsprior to filling:
a) Closed cooling water supply valve SG03-9 (21) open
b) Closed cooling water control valve inlet isolation valve SG03-11(22) open
c) Closed cooling water control valve SG03-1 (66) in Auto
d) Bypass SG03-216 closed
e) Emergency thermal barrier cooling valve SG03-2 closed
2. Verify boiler circulating pump thermal barrier valves are locked open:
a) Boiler circulating pump 11/21
i) Thermal barrier supply valve SG03-20
ii) Thermal barrier return valve SG03-28 (16)
b) Boiler circulating pump 12/22
i) Thermal barrier supply valve SG03-21
ii) Thermal barrier return valve SG03-29 (16)
c) Boiler circulating pump 13/23
i) Thermal barrier supply valve SG03-22
ii) Thermal barrier return valve SG03-30 (16)d) Boiler circulating pump 14/24
i) Thermal barrier supply valve SG03-23
ii) Thermal barrier return valve SG03-31 (16)
3. Verify boiler circulating pumps closed cooling water return header isaligned as follows:
a) Closed cooling water return control valve inlet isolation valveSG03-15 (62) is open
b) Closed cooling water return control valve inlet SG03-3 (67) inAuto
c) Closed cooling water return control valve outlet isolation valveSG03-17 (62) is open
d) Bypass SG03-217 closed
e) Emergency thermal cooling drain SG03-4 closed (vlv 14 open)
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4. Close or Verify Closed boiler circulating pump suction valve asappropriate:
a) Boiler circulating pump 11/21 suction valve SG03-5 (2)
b) Boiler circulating pump 12/22 suction valve SG03-6 (2)
c) Boiler circulating pump 13/23 suction valve SG03-7 (2)
d) Boiler circulating pump 14/24 suction valve SG03-8 (2)
5. Close or Verify Closed boiler circulating pump discharge valve asappropriate:
a) Boiler circulating pump 11/21 discharge valves SG03-126 (3),and SG03-127 (3)
b) Boiler circulating pump 12/22 discharge valves SG03-128 (3),and SG03-129 (3)
c) Boiler circulating pump 13/23 discharge valves SG03-130 (3),
and SG03-131 (3)
d) Boiler circulating pump 14/24 discharge valves SG03-132 (3),and SG03-133 (3)
6. Close boiler water circulating pump bypass valves as appropriate:
a) Boiler circulating pump 11/21 bypass valves SG03-94 (5), andSG03-106 (6)
b) Boiler circulating pump 12/22 bypass valves SG03-95 (5), andSG03-108 (6)
c) Boiler circulating pump 13/23 bypass valves SG03-96 (5), andSG03-110 (6)
d) Boiler circulating pump 14/24 bypass valves SG03-97 (5), andSG03-112 (6)
7. Open drain valves (44) and (18).
8. Verify Closed Strainer drain valves SG03-44, and SG03-45.
9. Close boiler circulating pump motor cavity isolation valve:
a) Boiler circulating pump 11/21 motor cavity valve SG03-246 (10A)
b) Boiler circulating pump 12/22 motor cavity valve SG03-247 (10A)
c) Boiler circulating pump 13/23 motor cavity valve SG03-248 (10A)
d) Boiler circulating pump 14/24 motor cavity valve SG03-249 (10A)
10. Close boiler circulating pump motor cavity cooling water valve:
a) Boiler circulating pump 11/21 motor cavity cooling water SG03-250
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b) Boiler circulating pump 12/22 motor cavity cooling water SG03-251
c) Boiler circulating pump 13/23 motor cavity cooling water SG03-252
d) Boiler circulating pump 14/24 motor cavity cooling water SG03-
25311. Open bypass valves and vent valves:
a) SG03-102 (5A), SG03-107 (6A), (7), and (57)
b) SG03-103 (5A), SG03-109 (6A), (7), and (57)
c) SG03-103 (5A), SG03-111 (6A), (7), and (57)
d) SG03-104 (5A), SG03-113 (6A), (7), and (57)
12. Verify low pressure fill spool piece is removed and outlet isolationvalve SG03-39 (50) is closed.
13. Open boiler circulating pumps high pressure fill isolation valve SG03-36 (38).
14. Open boiler circulating pumps fill strainer inlet (SG03-42) isolationvalve.
15. Blowdown fill line through fill strainer drain valves SG03-44, and SG03-45.
16. Open boiler circulating pumps fill outlet (SG03-43) isolation valves.
17. Verify filter inlet valve isclosed as appropriate:
a) Boiler circulatingpump 11/21 filter
inlet valve SG03-242
b) Boiler circulating pump 12/22 filter inlet valve SG03-243
c) Boiler circulating pump 13/23 filter inlet valve SG03-244
d) Boiler circulating pump 14/24 filter inlet valve SG03-245
18. Open boiler circulating pump fill filter inlet isolation valve asappropriate:
a) Boiler circulating pump 11/21 fill filter inlet valve SG03-234
b) Boiler circulating pump 12/22 fill filter inlet valve SG03-235
c) Boiler circulating pump 13/23 fill filter inlet valve SG03-236
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NOTEEnsure the fill line is free of scale and other
impurities.
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b) Boiler circulating pump 12/22 filter inlet isolation valve SG03-243
c) Boiler circulating pump 13/23 filter inlet isolation valve SG03-244
d) Boiler circulating pump 14/24 filter inlet isolation valve SG03-245
27. Open boiler circulating pump suction and discharge valves and placeor leave on prewarm.
a) Boiler circulating pump 11/21 suction SG03-5 (2), and dischargeSG03-126 (3), and SG03-127 (3) valves
b) Boiler circulating pump 12/22 suction SG03-6 (2), and dischargeSG03-128 (3), and SG03-129 (3) valves
c) Boiler circulating pump 13/23 suction SG03-7 (2), and dischargeSG03-130 (3), and SG03-131 (3) valves
d) Boiler circulating pump 14/24 suction SG03-8 (2), and dischargeSG03-132 (3), and SG03-133 (3) valves
28. Isolate boiler circulating pump by Closing bypass valves:
a) BCP 11/21 SG03-102 (5A), SG03-94 (5), SG03-106 (6), and SG03-107 (6A)
b) BCP 12/22 SG03-103 (5A), SG03-95 (5), SG03-108 (6), and SG03-109 (6A)
c) BCP 13/23 SG03-104 (5A), SG03-96 (5), SG03-110 (6), and SG03-111 (6A)
d) BCP 14/24 SG03-105 (5A), SG03-96 (5), SG03-112 (6), and SG03-
113 (6A)
1.6
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NOTEBypass valves SG03-90, SG03-91, SG03-92, and SG03-93 (BCP 11/21, 12/22, 13/23,and 14/24 respectively) are normally open. The orifice in this line provides a slight flowof water between the pump suction and discharge system of idle pumps to maintainuniform temperatures for proper piping expansion.
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1.7Normal System Startup
1.7.1Placing Boiler Circulating Pump In Operation - Unit Cold-Pump Cold
1. Verify the boiler circulating pump is filled and vented prior to placingin operation.
2. Verify the boiler circulating water system is aligned in accordance withSection 5.
3. Verify temperature differential between the suction manifold andpump casing does not exceed 100oF.
4. Verify pump differential pressure indicators are in operation.
5. Open boiler circulating pump suction and discharge valve(s) asapplicable:
a) Boiler circulating pump 11/21 suction SG03-5 (2), and dischargeSG03-126 (3), and SG03-127 (3) valves
b) Boiler circulating pump 12/22 suction SG03-6 (2), and dischargeSG03-128 (3), and SG03-129 (3) valves
c) Boiler circulating pump 13/23 suction SG03-7 (2), and discharge
SG03-130 (3), and SG03-131 (3) valves
d) Boiler circulating pump 14/24 suction SG03-8 (2), and dischargeSG03-132 (3), and SG03-133 (3) valves
6. Start boiler circulating pump 11/21, 12/22, 13/23, or 14/24 as
Page 20 Rev. 8/27/2009
NOTEWe normally start the outside BCPs first because these pumps feed both the front andrear water walls.
NOTE
Closed cooling water must be capable of maintaining the pump motor cavitytemperature below 140oF.
NOTEIf drum pressure is less than 50 psig, purge the boiler circulating pump using
Purging procedure in Section 1.4.
NOTENormally start a center boiler circulating pump first to limit drum level swings end-to-end.
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i) Thermal barrier supply valve SG03-23
ii) Thermal barrier return valve SG03-31 (16)
4. Verify boiler circulating pumps closed cooling water return header isaligned as follows:
a) Closed cooling water return control valve inlet isolation valveSG03-15 (62) is open
b) Closed cooling water return control valve inlet SG03-3 (67) inAuto
c) Closed cooling water return control valve outlet isolation valveSG03-17 (62) is open
d) Bypass SG03-217 closed (vlv 18 open)
e) Emergency thermal cooling drain SG03-4 closed (vlv 14 open)
5. Verify boiler circulating pump suction valve closed as applicable:
a) Boiler circulating pump 11/21 suction valve SG03-5 (2)
b) Boiler circulating pump 12/22 suction valve SG03-6 (2)
c) Boiler circulating pump 13/23 suction valve SG03-7 (2)
d) Boiler circulating pump 14/24 suction valve SG03-8 (2)
6. Verify boiler circulating pump discharge valve closed as applicable:
a) Boiler circulating pump 11/21 discharge valves SG03-126 (3),and SG03-127 (3)
b) Boiler circulating pump 12/22 discharge valves SG03-128 (3),and SG03-129 (3)
c) Boiler circulating pump 13/23 discharge valves SG03-130 (3),and SG03-131 (3)
d) Boiler circulating pump 14/24 discharge valves SG03-132 (3),and SG03-133 (3)
7. Verify boiler circulating pump bypass valves closed as appropriate:
a) Boiler circulating pump 11/21 bypass valves SG03-94 (5), andSG03-106 (6)
b) Boiler circulating pump 12/22 bypass valves SG03-95 (5), andSG03-108 (6)
c) Boiler circulating pump 13/23 bypass valves SG03-96 (5), andSG03-110 (6)
d) Boiler circulating pump 14/24 bypass valves SG03-97 (5), andSG03-112 (6)
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8. Open drain valves (44) and (18).
9. Verify Closed Strainer drain valves SG03-44, and SG03-45.
10. Close boiler water circulating pump motor cavity isolation valve:
a) Boiler circulating pump 11/21 motor cavity valve SG03-246 (10A)
b) Boiler circulating pump 12/22 motor cavity valve SG03-247 (10A)c) Boiler circulating pump 13/23 motor cavity valve SG03-248 (10A)
d) Boiler circulating pump 14/24 motor cavity valve SG03-249 (10A)
11. Close boiler water circulating pump motor cavity cooling water return:
a) Boiler circulating pump 11/21 motor cavity cooling water valveSG03-250
b) Boiler circulating pump 12/22 motor cavity cooling water valveSG03-251
c) Boiler circulating pump 13/23 motor cavity cooling water valveSG03-252
d) Boiler circulating pump 14/24 motor cavity cooling water valveSG03-253
12. Install low pressure fill spool piece.
13. Open low pressure fill spool piece outlet isolation valve SG03-39 (50),and inlet isolation valve SG03-37 (51).
14. Verify filter inlet valve is closed as appropriate:
a) Boiler circulating pump 11/21 filter inlet valve SG03-242b) Boiler circulating pump 12/22 filter inlet valve SG03-243
c) Boiler circulating pump 13/23 filter inlet valve SG03-244
d) Boiler circulating pump 14/24 filter inlet valve SG03-245
15. Open boiler circulating pump fill filter inlet isolation valve asappropriate:
a) Boiler circulating pump 11/21 fill filter inlet valve SG03-234
b) Boiler circulating pump 12/22 fill filter inlet valve SG03-235
c) Boiler circulating pump 13/23 fill filter inlet valve SG03-236
d) Boiler circulating pump 14/24 fill filter inlet valve SG03-237
16. Open boiler circulating pumps fill strainer inlet (SG03-42), and outletSG03-43 valves.
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17. Blowdown fill line through drain valve (54).
18. Open vent valves:
a) BCP 11/21 SG03-107, and (7)
b) BCP 12/22 SG03-109, and (7)
c) BCP 13/23 SG03-111, and (7)
d) BCP 14/24 SG03-113, and (7)
19. Fill boiler circulating pump by cracking Open motor cavity valve andestablish a 1.5 gallon per minute flow rate:
a) Boiler circulating pump 11/21 motor cavity valve SG03-246 (10A)
b) Boiler circulating pump 12/22 motor cavity valve SG03-247 (10A)
c) Boiler circulating pump 13/23 motor cavity valve SG03-248 (10A)d) Boiler circulating pump 14/24 motor cavity valve SG03-249 (10A)
20. Close vent valve (7) when a clear stream of air free water isdischarged from each vent.
21. Close boiler circulating pump motor cavity valve when full:
a) Boiler circulating pump 11/21 motor cavity valve SG03-246 (10A)
b) Boiler circulating pump 12/22 motor cavity valve SG03-247 (10A)
c) Boiler circulating pump 13/23 motor cavity valve SG03-248 (10A)
d) Boiler circulating pump 14/24 motor cavity valve SG03-249 (10A)
22. Close low pressure fill spool piece outlet isolation valve SG03-39 (50).
23. Close low pressure fill spool piece supply isolation valve SG03-37 (51).
24. Remove low pressure fill spool piece.
25. Open boiler circulating pumps high pressure fill isolation valve SG03-36 (38).
26. Open boiler circulating pumps fill strainer inlet (SG03-42) isolationvalve.
27. Blowdown fill line and purge line through fill valve (54). When a clearstream of water is discharge, Close valve (54).
28. Crack Open motor cavity valve filter inlet Valve SG03-246 (10A) andSG03-242 gradually pressurize pump to system pressure:
a) Boiler circulating pump 11/21 motor cavity valve SG03-246(10A), and filter inlet valve SG03-242
Page 24 Rev. 8/27/2009
NOTEEnsure the fill line is free of scale and other
impurities.
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b) Boiler circulating pump 12/22 motor cavity valve SG03-247(10A), and filter inlet valve SG03-243
c) Boiler circulating pump 13/23 motor cavity valve SG03-248(10A), and filter inlet valve SG03-244
d) Boiler circulating pump 14/24 motor cavity valve SG03-249
(10A), and filter inlet valve SG03-24529. Crack Open vent valve (7). When a clear stream of water is
discharged from valve (7), Close valve (7).
30. Open bypass valves:
a) BCP 11/21 SG03-94 (5), SG03-102 (5A), and SG03-106 (6)
b) BCP 12/22 SG03-95 (5), SG03-103 (5A), and SG03-108 (6)
c) BCP 13/23 SG03-96 (5), SG03-104 (5A), and SG03-110 (6)
d) BCP 14/24 SG03-97 (5), SG03-105 (5A), and SG03-112 (6)
31. Wait a minimum of 10 minutes before opening boiler circulating pumpsuction valve:
a) BCP 11/21 SG03-5 (2)
b) BCP 12/22 SG03-6 (2)
c) BCP 13/23 SG03-7 (2)
d) BCP 14/24 SG03-8 (2)
32. Close bypass valves:
a) BCP 11/21 SG03-102 (5A), and SG03-106 (6)b) BCP 12/22 SG03-103 (5A), and SG03-108 (6)
c) BCP 13/23 SG03-104 (5A), and SG03-110 (6)
d) BCP 14/24 SG03-105 (5A), and SG03-112 (6)
33. Remove the air trapped in the rotor cavity by running the boilercirculating pump for five seconds and allowing the pump to stand for
Page 25 Rev. 8/27/2009
NOTEThe pump casing temperature must be within 100oF of the downcomer temperaturebefore the pump is started. If frequent startups occur, limit the pumpcasing/downcomer differential temperature to 50oF to prevent unnecessarily exposing apump to the maximum differential of 100oF
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fifteen minutes. Repeat this step twice more. Pre-warm the BCPs priorto bumping if necessary.
34. Open boiler circulating pump discharge valve:
a) Boiler circulating pump 11/21 discharge valves SG03-126 (3),and SG03-127 (3)
b) Boiler circulating pump 12/22 discharge valves SG03-128 (3),and SG03-129 (3)
c) Boiler circulating pump 13/23 discharge valves SG03-130 (3),and SG03-131 (3)
d) Boiler circulating pump 14/24 discharge valves SG03-132 (3),and SG03-133 (3)
35. Start the boiler circulating pump.
36. Close bypass valves:
a) BCP 11/21 SG03-94 (5),and SG03-102 (5A)
b) BCP 12/22 SG03-95 (5),and SG03-103 (5A)
c) BCP 13/23 SG03-96 (5), and SG03-104 (5A)
d) BCP 14/24 SG03-97 (5), and SG03-105 (5A)
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NOTE After starting a BCP, isolate the
prewarming.
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1.7.3Placing Boiler Circulating Pump In Operation - Unit Hot-Pump Hot(Hot Standby)
1. Verify the boiler circulating pump is filled and vented prior to placingin operation.
2. Verify the boiler circulating water system is aligned in accordance withSection 5.
3. Verify temperature differential between the suction manifold andpump casing does not exceed 100oF.
4. Verify pump differential pressure indicators are in operation.
5. Open boiler circulating pump suction and discharge valve(s) asapplicable:
a) Boiler circulating pump 11/21 suction SG03-5 (2), and dischargeSG03-126 (3), and SG03-127 (3) valves
b) Boiler circulating pump 12/22 suction SG03-6 (2), and dischargeSG03-128 (3), and SG03-129 (3) valves
c) Boiler circulating pump 13/23 suction SG03-7 (2), and dischargeSG03-130 (3), and SG03-131 (3) valves
d) Boiler circulating pump 14/24 suction SG03-8 (2), and dischargeSG03-132 (3), and SG03-133 (3) valves
6. Start boiler circulating pump 11/21, 12/22, 13/23, or 14/24 asapplicable.
7. Close bypass valves on applicable boiler circulating pump:
a) BCP 11/21 bypass valves SG03-94, and SG03-102
b) BCP 12/22 bypass valves SG03-95, and SG03-103
c) BCP 13/23 bypass valves SG03-96, and SG03-104
d) BCP 14/24 bypass valves SG03-97, and SG03-105
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NOTEClosed cooling water must be capable of maintaining the pump motor cavitytemperature below 140oF.
NOTEIf drum pressure is less than 50 psig, purge the boiler circulating pump usingPurging procedure in Section 1.4.
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8. Verify normal boiler circulating pump temperatures.
9. Verify normal pump vibration on running boiler circulating pump(s).
10. Check system for leakage.
11. Laboratory department maintain chemistry as required.
Page 28 Rev. 8/27/2009
NOTEDuring normal operation, the motor cavity temperature should not exceed 131oF. The
alarm setpoint for the motor cavity is 140oF.
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2.SYSTEM NORMAL OPERATION
2.1Routine Operation
1. Check boiler circulating pump motor running currents. Normal runningamperage is 45 - 50 amps (low/fluctuating amps could be caused bylow or swinging drum levels). High amperage readings or fluctuatingmotor current is indicative of wear or partial seizure occurring at thebearing surfaces.
2. Check boiler circulating pump motor cavity temperatures. Normalmotor cavity temperature is 105 - 115oF. Motor cavity temperaturesshould not exceed 131oF.
3. Check closed cooling water is being maintained to boiler circulatingpump coolers and thermal barrier.
4. Verify normal pump vibration on running boiler circulating pump(s).
5. Check system for leakage.
6. Check that all parameters are within normal ranges:
a) Boiler drum level within 3 inches of centerline
b) Primary superheater outlet temperature approximately 725oF
c) Secondary superheater outlet temperature approximately 1000of
d) Reheater outlet temperature approximately 1000oF
7. Check for steam leaks on steam piping, boiler tubes, valve stem
packing, gasket interfaces, fittings, etc.
8. Check for furnace, superheater, reheater, and economizer fouling dueto slag, soot, or ash accumulation. Use sootblowers as required.
9. Ensure boiler continuous blowdown is performed as per chemistinstructions.
10. Inspect all safety valves for signs of leakage, chattering, or weeping.
11. Verify that chemical injection to boiler and feedwater system operable;chemical tanks have adequate supply, equipment operates properly
and chemicals are fed per chemist instructions.
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3.SYSTEM SHUTDOWN
3.1Boiler Circulating Pump Shutdown
3.1.1Boiler Hot - Pump To Be Placed In Hot Standby
1. Place running boiler circulating pump in OFF.
2. Leave boiler circulating pump suction and discharge valves open asapplicable:
a) Boiler circulating pump 11/21 suction SG03-5 (2), and dischargeSG03-126 (3), and SG03-127 (3) valves
b) Boiler circulating pump 12/22 suction SG03-6 (2), and dischargeSG03-128 (3), and SG03-129 (3) valves
c) Boiler circulating pump 13/23 suction SG03-7 (2), and dischargeSG03-130 (3), and SG03-131 (3) valves
d) Boiler circulating pump 14/24 suction SG03-8 (2), and dischargeSG03-132 (3), and SG03-133 (3) valves
3. Leave closed cooling water aligned to the boiler circulating pump.
4. Open bypass valves to provide circulation of boiler water through thepump casing, suction and discharge lines.
a) BCP 11/21 SG03-94 (5), and SG03-102 (5A)
b) BCP 12/22 SG03-95 (5), and SG03-103 (5A)c) BCP 13/23 SG03-96 (5), and SG03-104 (5A)
d) BCP 14/24 SG03-97 (5), and SG03-105 (5A)
3.1.2Boiler Hot - Pump To Be Isolated For Maintenance
1. Place running boiler circulating pump in OFF.
2. Close boiler circulating pump suction and discharge valves:
a) Boiler circulating pump 11/21 suction SG03-5 (2), and discharge
SG03-126 (3), and SG03-127 (3) valvesb) Boiler circulating pump 12/22 suction SG03-6 (2), and discharge
SG03-128 (3), and SG03-129 (3) valves
c) Boiler circulating pump 13/23 suction SG03-7 (2), and dischargeSG03-130 (3), and SG03-131 (3) valves
d) Boiler circulating pump 14/24 suction SG03-8 (2), and dischargeSG03-132 (3), and SG03-133 (3) valves
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3. Verify bypass valves are Closed:
a) BCP 11/21 SG03-94 (5), SG03-102 (5A), and SG03-106 (6)
b) BCP 12/22 SG03-95 (5), SG03-103 (5A), and SG03-108 (6)
c) BCP 13/23 SG03-96 (5), SG03-104 (5A), and SG03-110 (6)
d) BCP 14/24 SG03-97 (5), SG03-105 (5A), and SG03-112 (6)4. Leave closed cooling water aligned to the boiler circulating pump.
5. Depressurize the boiler circulating pump by slowly Opening bypassand vent valves:
a) SG03-107 (6A), and (7)
b) SG03-109 (6A), and (7)
c) SG03-111 (6A), and (7)
d) SG03-113 (6A), and (7)
6. Close drainvalve (7) whenboilercirculating
pump is depressurized.
7. Monitor boiler circulating pump motor cavity pressure on gauge (47)to verify pressure does not build up in the pump due to systemleakage.
8. If the boiler circulating pump is to be drained, open bypass and ventvalves:
a) SG03-107 (6A), and (7)
b) SG03-109 (6A), and (7)
c) SG03-111 (6A), and (7)
d) SG03-113 (6A), and (7)
9. Drain the pump casing by Opening drain valves:a) BCP 11/21 SG03-102 (5A), and (57)
b) BCP 12/22 SG03-103 (5A), and (57)
c) BCP 13/23 SG03-104 (5A), and (57)
d) BCP 14/24 SG03-105 (5A), and (57)
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NOTEThe cooldown rate should not exceed 35oF in 15 minute
intervals.
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10. When the pump casing is drained, Open motor cavity drain valves(44), and (18).
11. Collect samples of water drained for chemical analysis.
12. Close closed cooling water valves:
a) BCP 11/21 SG03-24 (25), SG03-32 (15), SG03-20 (16), and SG03-28 (16)
b) BCP 12/22 SG03-25 (25), SG03-33 (15), SG03-21 (16), and SG03-29 (16)
c) BCP 13/23 SG03-26 (25), SG03-34 (15), SG03-22 (16), and SG03-30 (16)
d) BCP 14/24 SG03-27 (25), SG03-35 (15), SG03-23 (16), and SG03-31 (16)
3.1.3Boiler Cold and Full - Pump To Be Isolated For Maintenance
1. Assumption - Pump is not running.
2. Close boiler circulating pump suction and discharge valves:
a) Boiler circulating pump 11/21 suction SG03-5 (2), and dischargeSG03-126 (3), and SG03-127 (3) valves
b) Boiler circulating pump 12/22 suction SG03-6 (2), and dischargeSG03-128 (3), and SG03-129 (3) valves
c) Boiler circulating pump 13/23 suction SG03-7 (2), and dischargeSG03-130 (3), and SG03-131 (3) valves
d) Boiler circulating pump 14/24 suction SG03-8 (2), and dischargeSG03-132 (3), and SG03-133 (3) valves
3. Verify bypass valves are Closed:
Page 33 Rev. 8/27/2009
NOTE
Valves (44), and (18) should be used to drain the pump motor only after the boiler circulating pump has been depressurized and the pump casing drained. Draining hotwater from the pump casing through the motor cavity will result in damage to the motor windings.
NOTEIf the thermal barrier cooling for a pump must be isolated for / during pump maintenancethe flow switch must be jumpered or keyed out to prevent BCP emergency thermal barrier cooling system activation and BCPs trip / unit trip.
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a) BCP 11/21 SG03-94 (5), and SG03-106 (6)
b) BCP 12/22 SG03-95 (5), and SG03-108 (6)
c) BCP 13/23 SG03-96 (5), and SG03-110 (6)
d) BCP 14/24 SG03-97 (5), and SG03-112 (6)
4. Verify boiler circulating pump motor cavity fill valve is Closed:a) BCP 11/21 SG03-246 (10A)
b) BCP 12/22 SG03-247 (10A)
c) BCP 13/23 SG03-248 (10A)
d) BCP 14/24 SG03-249 (10A)
5. Open bypass valves:
a) BCP 11/21 SG03-102 (5A), SG03-107 (6A), and (7)
b) BCP 12/22 SG03-103 (5A), SG03-109 (6A), and (7)
c) BCP 13/23 SG03-104 (5A), SG03-111 (6A), and (7)
d) BCP 14/24 SG03-105 (5A), SG03-113 (6A), and (7)
6. Open drain valve (57) to drain pump casing.
7. When pump casing is drained, Drain motor cavity by Opening drainvalves (44), and (18)
8. Collect samples of water drained for chemical analysis.
9. Close closed cooling water valves:
a) BCP 11/21 SG03-24 (25), SG03-32 (15), SG03-20 (16), and SG03-28 (16)
b) BCP 12/22 SG03-25 (25), SG03-33 (15), SG03-21 (16), and SG03-29 (16)
c) BCP 13/23 SG03-26 (25), SG03-34 (15), SG03-22 (16), and SG03-30 (16)
d) BCP 14/24 SG03-27 (25), SG03-35 (15), SG03-23 (16), and SG03-31 (16)
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3.2Boiler Shutdown
1. Shutdown the mills according to fuel and burner system procedure.
2. After a negative load is achieved on the generator, very the mainturbine and generator trips on reverse power after a 3 second timedelay.
3. When the boiler pressure drops to approximately 0 psig or 212oF ,open drum vents.
4. If boiler is to be blanketed with nitrogen, blanket when boiler pressureis at normal N2 pressure (approximately 3 - 5 psi).
5. If boiler is not blanketed, open the steam side vents and drains whenthe pressure is zero.
6. Shutdown the chemical feed system.
7. If maintenance is required on boiler drain when cool.
8. Drain the boiler by opening all downcomer drains as much as possiblewithout flooding the boiler blowdown tank.
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NOTEDrain the boiler when water temperature is approximate 200oF. This ensures the boiler tubes will dry out and limit water wall inside tube corrosion.
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4.SYSTEM ABNORMAL OPERATION
4.1Boiler Circulating Pumps Differential Pressure Low-Low
4.1.1Causes
1. Low drum level.
2. Boiler circulating pump failure and incoming differential press low-low (12psid) condition developing.
3. System leakage.
4. Instrument malfunction.
4.1.2Results
1. Differential pressure low low alarm (12 psid).2. Differential pressure alarm 16 psid.
3. Differential low low trip 8 psid.
4. Unit Fuel Trip.
4.1.3Corrective Actions
1. Take appropriate actions for Unit Fuel Trip.
2. If differential pressure low low due to low drum level, return level to
normal.3. If differential pressure low low due to system leakage, isolate leakage.
4. If due to instrument failure, find cause and correct.
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4.2Boiler Circulating Pumps Differential Pressure Low
4.2.1Causes
1. Low drum level.
2. Boiler circulating pump failure and incoming differential press lowcondition developing.
3. System leakage.
4. Instrument malfunction.
1. Low/low differential pressure alarm is 12 psi, 8 psi differential pressureunit trip.
4.2.2Results
1. Differential pressure low alarm condition (16 psid).
4.2.3Corrective Actions
1. Investigate cause of alarm.
2. If differential pressure low due to low drum level, return to normal.
3. If differential pressure low condition due to pump failure reduce unitload as applicable for operating pumps.
a) Three of four pumps operating - Unit may be operatedcontinuously or intermittently at normal full load and pressure for
a cumulative period of 72 hours. Load is to be reduced to 90%M.C.R. for operation in excess of 72 hours.
b) Two of four pumps operating - The unit can be operated at 60%M.C.R. continuously with the remaining two pumps.
c) One of four pumps operating - Unit operation is not permitted.An automatic fuel trip will occur. Take appropriate actions forUnit Fuel Trip.
4. If due to instrument malfunction, isolate pressure transmitter andoperate off available instrumentation.
5. Find cause and correct.
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4.3Boiler Circulating Pump Trip
4.3.1Causes
1. Cooling water flow low to boiler circulating pump (4.9” H2O differential).
2. Motor cavity high temperature (149oF).
3. Suction valve not 100% open.
4. Ground overcurrent.
5. Motor overload greater than 200%.
6. Bus differential lockout relay trip.
4.3.2Results
1. Unit load restrictions may apply depending on availability of boiler
circulating pumps.
2. Possible unit trip if at a high load (the low/low diff. trip spikes in).
4.3.3Corrective Actions
1. Three of four pumps operating - Unit may be operated continuously orintermittently at normal full load and pressure for a cumulative periodof 72 hours. Load is to be reduced to 90% M.C.R. for operation inexcess of 72 hours.
2. Two of four pumps operating - The unit can be operated at 60% M.C.R.
continuously with the remaining two pumps.
3. One of four pumps operating - Unit operation is not permitted. Anautomatic fuel trip will occur. Take appropriate actions for Unit Fuel
Trip.
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4.4Boiler Circulating Pump Motor Cavity Temperature High
4.4.1Causes
1. Restricted or loss of closed cooling water flow to the motor cavity cooler.
2. Improper draining of the pump and motor casing.
3. High pressure cooling system leak.
4. Malfunction of temperature switch.
4.4.2Results
1. Motor insulation breakdown.
4.4.3Corrective Actions
1. Restore normal flow and temperature of closed cooling water to themotor cooler and thermal barrier is temperature rise due to closedcooling water malfunction.
2. If high temperature condition due to high pressure coolant leak,initiate high pressure purge flow to the pump.
3. Check temperature sensing and alarm devices for possiblemalfunction.
4. If abnormal temperature condition due to improper draining of motorcavity prior to pump casing. Stop draining operation. Initiate high
pressure purge flow to the pump and restore temperature to normal(less than 131oF).
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4.5Main Steam (Superheater) Temperature High
4.5.1Causes
1. Excessive furnace slagging or soot buildup.
2. High excess air flow.
3. Attemperator malfunctions.
4. Attemperator flow limited.
5. Secondary combustion.
6. Improper air distribution.
7. High pressure feedwater heater bypassed.
8. Rapid closure of turbine valves.
9. Rapid increase in boiler firing.10.High burner tilt position.
4.5.2Results
1. Increased unit load.
2. Unit load above unit master setting or above assigned load.
3. If on unit master control, the automatic controls will reduce load to setpoint and reduce firing rate, air flow and feedwater flow.
4. Increased main steam attemperator flow.5. Possible increased reheat temperature and attemperator flow.
6. Turbine differential expansion may increase (rotor long).
7. Change in turbine metal temperature.
8. Possible steam - turbine metal differential temperature abnormal.
9. Possible turbine vibration increase if temperature rise is rapid.
10. Possible superheat tube burnout and failure.
11. Possible complete unit load, temperature, and pressure swing.
4.5.3Corrective Actions
1. Verify main steam temperature high.
2. Check attemperator flow increasing, increase in MANUAL if necessary.
3. Check attemperator supply/superheat inlet pressure differentialadequate for full attemperator control.
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4. Verify turbine valve position, stop valve closure if necessary.
5. Reduce burner tilt position.
6. Check excess air percentage normal, Economizer O2 normal forexisting load.
7. Check all mill firing rates stable
8. Check individual compartment air/pulverizer loadings to assurefurnace coal/secondary air balance.
9. Determine reason for slagging if present and correct.
10. Reduce load on unit until temperature can be controlled.
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4.7Reheat Steam Temperature High
4.7.1Causes
1. Excessive furnace slagging or soot buildups on superheater and furnace.
2. High excess air flow.
3. Reheat attemperator malfunctions.
4. Attemperator flow limited.
5. Rapid drop in control valve position.
6. Rapid increase in boiler firing rate.
7. Secondary combustion.
8. Improper air distribution.
9. High pressure feedwater heater bypassed.10.High burner tilt position.
4.7.2Results
1. Increased unit load.
2. Unit load above unit master setting or above assigned load.
3. If on unit master control, the automatic controls will reduce load tosetpoint and reduce firing rate, air flow, and feedwater flow.
4. Increased reheat attemperator flow.5. Change in turbine metal temperature.
6. LP and IP turbine differential expansion increase (rotor long).
7. Possible steam - turbine metal differential temperature abnormal forLP and IP turbine.
8. Possible LP and IP turbine vibration increase if temperature rise israpid.
9. Possible reheater tube burnout and failure.
10. Possible complete unit load, temperature, and pressure swing.
4.7.3Corrective Actions
1. Verify reheat steam temperature is high.
2. Check reheat attemperator responding and check flow increasing,increase flow in MANUAL if necessary.
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3. Check attemperator supply/reheat inlet pressure differential adequatefor full attemperator control.
4. Check excess air percentage normal, economizer O2 normal for load.
5. Reduce burner tilt position.
6. Check all mill firing rates stable.
7. Check individual compartment air/pulverizer loadings to assurefurnace coal/secondary air balance.
8. Determine reason for slagging if present and blow affected areas asrequired.
9. Reduce load on unit until temperature can be controlled.
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4.8Reheat Steam Temperature Low
4.8.1Causes
1. Loss of fire.
2. Rapid increase in control valve position.
3. Rapid decrease in boiler firing rate.
4. Slag buildup in reheater.
5. Attemperator malfunction.
6. Low excess air flow.
7. Low burner tilt position.
4.8.2Results
1. Possible loss of unit load.
2. Possible thermal stresses created in IP turbine.
3. Possible thermal stresses created in LP turbine.
4. Possible increase in firing rate.
5. Possible decrease in LP and IP turbine differential expansion.
4.8.3Corrective Actions
1. Verify reheat steam temperature locally.
2. Check and remove excess attemperation.
3. If boiler pressure is also low, increase boiler firing or reduce turbineloading as necessary to control pressure and temperature.
4. Raise burner tilt position.
5. Verify proper air flow and adjust if required.
6. Blow sootblowers in affected area.
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4.9Main Steam Pressure High
4.9.1Causes
1. Firing rate too high.
2. Rapid decrease in control valve position.
3. Fuel/Air malfunction.
4. Increase in superheat attemperation flow.
5. Power Load Unbalance (PLU) actuation on the turbine control system.
6. Rapid change in line loading (dispatch system upset).
4.9.2Results
1. Possible lifting of electromatic relief valve, steam line safety valves,
and steam drum safety valves.
2. High superheat and reheat temperatures.
3. Rapid drop in boiler drum level, until boiler safeties lift which cancause excessive swell in the steam drum.
4.9.3Corrective Actions
1. Verify main steam pressure high.
2. Reduce firing rate or increase turbine control valve position asnecessary.
3. Increase feedwater flow if drum level is low.
4. Verify superheat attemperator control is not swinging boiler pressure,and take manual control if necessary.
5. Verify system frequency normal.
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4.10Main Steam Pressure Low
4.10.1Causes
1. Firing rate too low.
2. Rapid increase in unit load.
3. Slagging on furnace walls.
4. Feeder plugging/loss of coal.
5. Feeder/pulverizer trip.
6. Turbine loading exceeding existing pulverizer capability.
4.10.2Results
1. Rapid decrease of main steam temperature.
2. Possible load reduction.
3. Possible main steam temperature reduction.
4. Overloading of remaining pulverizers.
4.10.3Corrective Actions
1. Verify main steam pressure low.
2. Increase firing rate, start additional pulverizer.
3. Reduce feedwater flow if drum level is high.
4. Reduce load temporarily to increase main steam pressure.
5. Blow soot as required.
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4.11Drum Level High
4.11.1Causes
1. Excessive feedwater flow.
2. Failure of feedwater control valves if using SUBFP
3. Improper operator action with controls in manual.
4. Lighting off boiler with too high an initial level.
5. Insufficient blowdown during startup.
6. Speed control failure of boiler feed pump turbine.
7. Starting a partially loaded pulverizer.
8. Rapid drop in boiler pressure.
9. Lifting of boiler safety valve(s).
4.11.2Results
1. Drum level indicator indicates high level.
2. Possible water carryover in steam lines causing water induction intothe turbine.
3. Master fuel trip at drum level high at +10”.
4.11.3Corrective Actions
1. Verify high drum level.
2. Check feedwater controls setting.
3. If caused by starting a loaded pulverizer, stop the pulverizer.
4. Place feedwater controls in MANUAL and reduce feedwater flow (DONOT reduce flow to zero).
5. If thehigh
level is due to a drop in boiler pressure, Close turbine control valves toincrease drum pressure.
6. Open boiler drain valves if below pressure limit on the drain system,this action should only be used on initial firing at low boiler pressures.
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7. If the high level is due to initial unit synchronization and loading,attempt to get the first pulverizer started and hold the turbine loadingas low as possible until boiler pressure starts increasing and drumlevel returns to normal.
8. If drum level continues out of sight on indications, trip boiler and boiler
feed pump.9. Determine if carryover is present.
10. If carryover is detected, trip the turbine and open the necessarydrains.
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4.12Drum Level Low
4.12.1Causes
1. Insufficient feedwater flow/pressure.
2. Failure of feed water control valves on SUBFP.
3. Boiler feed pump tripped.
4. Boiler tube leakage.
5. Improper operator action with controls in MANUAL.
6. Defective boiler feed pump.
7. Rapid load decrease causing high boiler pressure.
8. Steam flow above capacity of operating feed pump(s).
9. Boiler pressure above 1000 psig while on the SUBFP.10.Failure of boiler feed pump turbine speed control.
11.Failure of boiler feed pump recirculation valve(s).
4.12.2Results
1. Control room and local drum level indicators may indicate a low drumlevel.
2. Possible automatic boiler trip-loss of fires if level reaches lower limit.
3. Low circulating water pump differential pressure.4. Possible boiler metal damage if boiler fails to trip.
5. Drum level low trip at -12”.
4.12.3Corrective Actions
1. Verify low drum level.
2. Check feedwater controls setting.
3. If the low level is due to high pressure, increase turbine valve position
to drop boiler pressure.4. Place feedwater controls in MANUAL and increase feedwater flow.
5. Start standby boiler feed pump, if available and needed.
6. If boiler tripped, flow may be reestablished if the maximum feedwatertemperature to drum metal temperature differential is not exceededand the feedwater to the drum temperature is within 300oF of thedrum lower temperature.
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7. Re-establish normal drum level and proceed with boiler purge, andlight off.
8. If boiler tube leak is indicated, make preparations for repairs.
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4.13Boiler Water Silica Content High
4.13.1Causes
1. Insufficient continuous blowdown.
2. Condensate makeup water contamination.
3. Condenser tube leak.
4. Instrument failure.
5. Startup after a unit trip.
6. Boiler upset, large swing in boiler pressure or firing rates.
4.13.2Results
1. Possible damage to turbine blading.
2. Possible scale formation in boiler tubes.
4.13.3Corrective Actions
1. Verify high silica content by having plant chemist run tests.
2. Reduce drum pressure until silica levels are in accordance with theboiler silica curves.
3. Check continuous blowdown system and open if not already open.
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4.15Secondary Superheat Tube Leak
4.15.1Causes
1. Internal tube wearing by steam impingement.
2. High temperature failure due to slagging buildup or partial plugging.
3. Popped valve fails open on a sootblower.
4. Low steam flow during period of high firing.
4.15.2Results
1. Drum level and pressure may drop due to increased flow.
2. Feedwater flow may increase to compensate for leakage. This canincrease BFPT speed and lower deaerator level.
3. Furnace pressure can increase if steam sprays into boiler.
4. Superheater outlet tubes may overheat if the leakage causes sometubes to be starved of steam.
5. Air heaters may plug due to wet soot.
6. Boiler water chemistry may change.
7. Excessive condensate makeup.
4.15.3Corrective Actions
1. Verify superheater tube leak.2. Check steam drum level.
3. Check deaerator level.
4. Compare feedwater flow to steam flow to verify feedwater flowexcessive for existing steam flow.
5. Closely monitor tube metal temperatures. If temperatures increaseabove their limits, the firing rate must be lowered or the unit tripped.
6. Closely monitor the boilers water consumption.
7. If directed by supervisor remove boiler from service.
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4.16Reheater Tube Leak
4.16.1Causes
1. Internal tube wearing by steam impingement.
2. High temperature failure due to slagging buildup or partial plugging.
3. Popped valve fails open on a sootblower.
4. Low steam flow during period of high firing.
4.16.2Results
1. Feedwater flow may increase to compensate for leakage.
2. Furnace pressure can increase if steam sprays into boiler.
3. Reheater outlet tubes may overheat if the leakage causes some tubes
to be starved of steam.
4. Air heaters may plug due to wet soot.
5. Excessive condensate make up.
6. Change in boiler water chemistry.
7. Drop in reheat pressure and turbine load.
4.16.3Corrective Actions
1. Verify reheater tube leak.
2. Closely monitor tube metal temperatures. If temperatures increaseabove their limits, the firing rate must be lowered or the unit tripped.
3. Closely monitor the boiler’s water consumption.
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4.17Main Steam Pressure High
4.17.1Causes
1. Firing rate too high.
2. Low drum level with no reduction in firing rate.
3. Rapid decrease in control valve position.
4. Fuel/Air malfunction.
5. Increase in superheat attemperation flow.
6. Power Load Unbalance (PLU) actuation on the turbine control system.
7. Rapid change in line loading (dispatch system upset).
4.17.2Results
1. Possible lifting of electromatic relief valve, steam line safety valves,and steam drum safety valves.
2. High superheat and reheat temperatures.
3. Rapid drop in boiler drum level, until boiler safeties lift which cancause excessive swell in the steam drum.
4.17.3Corrective Actions
1. Verify main steam pressure high.
2. Reduce firing rate or increase turbine control valve position asnecessary.
3. Increase feedwater flow if drum level is low.
4. Verify superheat attemperator control is not swinging boiler pressure,and take manual control if necessary.
5. Verify system frequency normal.
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4.18Economizer Tube Leak
4.18.1Causes
1. Internal tube wearing by erosion.
2. High temperature failure due to soot buildup or partial plugging.
3. Poppet valve fails open on a sootblower.
4. Low water flow during period of high firing.
4.18.2Results
1. Drum level may drop due to loss of flow.
2. Feedwater flow may increase to compensate for leakage. This canincrease BFPT speed and lower deaerator level.
3. Economizer outlet tubes may overheat if the leakage causes sometube to be starved of water.
4. Air heaters may plug due to wet soot.
5. Possible damage to precipitator due to water carryover causing shortcircuits.
6. Excessive condensate make up.
7. Boiler water chemistry may change.
8. Drop in economizer gas outlet temperature.
9. Water discharged from the economizer ash hoppers/plugging.
4.18.3Corrective Actions
1. Verify economizer tube leak.
2. Check steam drum level.
3. Check deaerator level.
4. Closely monitor the boilers water consumption.
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5.SYSTEM VALVE LINEUP
Vlv Number Valve Name Desired Pos Actual Pos Initials
Legend
Fill (F)Before Firing (BF)
Valve numbers in parentheses are from individual Boiler Circulating Pump Drawing
SG03-39(50)
Low Press. Fill From Condensate Isol. Closed
SG03-37(51)
Low Press. Fill Supply From Condensate Isol. Closed
SG03-40(38)
High Press. Fill From Feedwater Closed
SG03-42 Boiler Circulating Pumps Fill Strainer Inlet Isol. Closed
SG03-43 Boiler Circulating Pumps Fill Strainer Outlet Isol. Closed
SG03-44 Strainer Flush and Drain Isol. Closed
SG03-45 Strainer Flush and Drain Isol. Closed
SG03-5 (2) Boiler Circulating Pump (BCP) 11/21 SuctionLine Gate
Closed
SG03-106(6)
Bypass Valve - Pump Suction Valve Open
SG03-107(6A) Bypass Valve - Pump Suction Valve Open
SG03-86(59)
Suction Valve Drain LockedOpen
SG03-126(3)
BCP 11/21 Discharge Line Stop Check Closed
SG03-127(3)
BCP 11/21 Discharge Line Stop Check Closed
SG03-102(5A)
BCP 11/21 Discharge Valve Bypass Valve Closed
SG03-216 BCP 11/21 Internal Pump Discharge Isol. Open
SG03-20(16)
LP Coolant to and from Thermal Barrier LockedOpen
SG03-28(16)
LP Coolant to and from Thermal Barrier LockedOpen
SG03-122(17)
Closed Cooling Water Return from BCP 11/21Thermal Barrier Relief Valve
Not Gagged
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Vlv Number Valve Name Desired Pos Actual Pos Initials
SG03-90(49)
BCP 11/21 Jumper Heating Line Isol. LockedOpen
SG03-94 (5) BCP 11/21 Jumper Heating Line Isol. Open
SG03-98 BCP 11/21 Jumper Heating Line Isol. Open
SG03-114 (7) BCP 11/21 Jumper Heating Line Isol. Open
SG03-246 BCP 11/21 Motor Cavity Fill Isol. Closed
SG03-250 BCP 11/21 Motor Cavity Cooling Water Return Open
SG03-195 BCP 11/21 Motor Cooler 11/21 Drain Closed
SG03-194 BCP 11/21 Motor Cooler 11/21 Vent Closed
SG03-24(25)
Closed Cooling Water Supply to BCP 11/21Motor Cooler 11/21 Supply
Open
SG03-9 (21) Closed Cooling Water Supply Isol. to Motor
Coolers
Open
SG03-210 Drain Closed
SG03-185(26)
Closed Cooling Water Supply to HP Fill andPurge Cooler 11/21
Closed
SG03-184(28)
HP Fill and Purge Cooler 11/21 Relief Valve Not Gagged
SG03-211 Vent Open
SG03-36(27)
Closed Cooling Water Return from HP Fill andPurge Cooler 11/21
Closed
SG03-11 (22) BCPs Cooling Water Control Valve Inlet Isol. Open
SG03-1 (66) BCPs Cooling Water Control Valve Auto
SG03-2 (70) BCPs Cooling Water Control Valve (Emergency) Auto
SG03-3 (67) BCPs Cooling Water Control Valve Auto
SG03-15(62)
BCPs Cooling Water Control Valve Inlet Isol. Open
SG03-17(62)
BCPs Cooling Water Control Valve Outlet Isol. Open
SG03-212 Drain Closed
SG03-4 BCPs Cooling Water Control Valve (Emergency) Auto
SG03-14 BCPs Cooling Water Control Valve (Emergency) Open
SG03-209 Drain Closed
SG03-32(15)
Closed Cooling Water Return Isol. from Motor Cooler 11/21
Open
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Vlv Number Valve Name Desired Pos Actual Pos Initials
(17) Thermal Barrier Relief Valve
SG03-91 BCP 12/22 Jumper Heating Line Isol. Open
SG03-95(5A)
BCP 12/22 Jumper Heating Line Isol. Open
SG03-99 BCP 12/22 Jumper Heating Line Isol. Open
SG03-115 (7) BCP 12/22 Jumper Heating Line Isol. Open
SG03-247 BCP 12/22 Motor Cavity Fill Isol. Closed
SG03-251 BCP 12/22 Motor Cavity Cooling Water Return Open
SG03-197 BCP 12/22 Motor Cooler 12/22 Drain Closed
SG03-196 BCP 12/22 Motor Cooler 12/22 Vent Closed
SG03-25 Closed Cooling Water Supply to BCP 12/22Motor Cooler 12/22 Supply Header Vent
Closed
SG03-33 Closed Cooling Water Return Isol. from Motor Cooler 12/22
Open
SG03-205 Closed Cooling Water Return Header Vent fromMotor Cooler 12/22
Closed
SG03-204 Closed Cooling Water Supply Header Vent toMotor Cooler 12/22
Closed
SG03-119(11)
Closed Cooling Water Return Header Relief Valve from Motor Cooler 12/22
Not Gagged
SG03-47 BCP 12/22 Fill Isol. Closed
SG03-235 Flow Element Inlet Isol. Open
SG03-243 BCP 12/22 Fill Filter Bypass Closed
SG03-239 Sample Isol. Closed
SG03-279 Sample Isol. Closed
SG03-77 Fill Isol. To Heating Line Closed
SG03-83 Fill Isol. To Heating Line LockedClosed
SG03-255 Fill Isol. To Heating Line Closed
SG03-259 Fill Isol. To Heating Line LockedClosed
SG03-7 (2) Boiler Circulating Pump (BCP) 13/23 SuctionLine Gate
Closed
SG03-110 (6) Bypass Valve - Pump Suction Valve Open
SG03-111(6A)
Bypass Valve - Pump Suction Valve Open
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Vlv Number Valve Name Desired Pos Actual Pos Initials
SG03-88(59)
Suction Valve Drain LockedOpen
SG03-130(3)
BCP 13/23 Discharge Line Stop Check Closed
SG03-131(3)
BCP 13/23 Discharge Line Stop Check Closed
SG03-104(5A)
BCP 13/23 Discharge Valve Bypass Valve Closed
SG03-218 BCP 13/23 Internal Pump Discharge Isol. Open
SG03-22 LP Coolant to and from Thermal Barrier LockedOpen
SG03-30(16)
LP Coolant to and from Thermal Barrier LockedOpen
SG03-124(17)
Closed Cooling Water Return from BCP 13/23Thermal Barrier Relief Valve
Not Gagged
SG03-92(49)
BCP 13/23 Jumper Heating Line Isol. Open
SG03-96 (5) BCP 13/23 Jumper Heating Line Isol. Open
SG03-100 BCP 13/23 Jumper Heating Line Isol. Open
SG03-116 (7) BCP 13/23 Jumper Heating Line Isol. Open
SG03-248 BCP 13/23 Motor Cavity Fill Isol. Closed
SG03-252 BCP 13/23 Motor Cavity Cooling Water Return OpenSG03-199 BCP 13/23 Motor Cooler 13/23 Drain Closed
SG03-198 BCP 13/23 Motor Cooler 13/23 Vent Closed
SG03-26 Closed Cooling Water Supply to BCP 13/23Motor Cooler 13/23 Supply Header Vent
Closed
SG03-34 Closed Cooling Water Return Isol. from Motor Cooler 13/23
Open
SG03-207 Closed Cooling Water Return Header Vent fromMotor Cooler 13/23
Closed
SG03-206 Closed Cooling Water Supply Header Vent toMotor Cooler 13/23
Closed
SG03-120(11)
Closed Cooling Water Return Header Relief Valve from Motor Cooler 13/23
Not Gagged
SG03-48 BCP 13/23 Fill Isol. Closed
SG03-236 Flow Element Inlet Isol. Open
SG03-244 BCP 13/23 Fill Filter Bypass Closed
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Vlv Number Valve Name Desired Pos Actual Pos Initials
SG03-240 Sample Isol. Closed
SG03-280 Sample Isol. Closed
SG03-79 Fill Isol. To Heating Line Closed
SG03-84 Fill Isol. To Heating Line LockedClosed
SG03-256 Fill Isol. To Heating Line Closed
SG03-260 Fill Isol. To Heating Line LockedClosed
SG03-8 (2) Boiler Circulating Pump (BCP) 14/24 SuctionLine Gate
Closed
SG03-112 (6) Bypass Valve - Pump Suction Valve Open
SG03-113
(6A)
Bypass Valve - Pump Suction Valve Open
SG03-89(59)
Suction Valve Drain LockedOpen
SG03-132(3)
BCP 14/24 Discharge Line Stop Check Closed
SG03-133(3)
BCP 14/24 Discharge Line Stop Check Closed
SG03-105(5)
BCP 14/24 Discharge Valve Bypass Valve Closed
SG03-219 BCP 14/24 Internal Pump Discharge Isol. OpenSG03-23 LP Coolant to and from Thermal Barrier Locked
Open
SG03-31(16)
LP Coolant to and from Thermal Barrier LockedOpen
SG03-125(17)
Closed Cooling Water Return from BCP 14/24Thermal Barrier Relief Valve
Not Gagged
SG03-93(49)
BCP 14/24 Jumper Heating Line Isol. Open
SG03-97 BCP 14/24 Jumper Heating Line Isol. OpenSG03-101 BCP 14/24 Jumper Heating Line Isol. Open
SG03-117 (7) BCP 14/24 Jumper Heating Line Isol. Open
SG03-249 BCP 14/24 Motor Cavity Fill Isol. Closed
SG03-253 BCP 14/24 Motor Cavity Cooling Water Return Open
SG03-202 BCP 14/24 Motor Cooler 14/24 Drain Closed
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Vlv Number Valve Name Desired Pos Actual Pos Initials
SG03-201 BCP 14/24 Motor Cooler 14/24 Vent Closed
SG03-27 Closed Cooling Water Supply to BCP 14/24Motor Cooler 14/24 Supply Header Vent
Closed
SG03-35 Closed Cooling Water Return Isol. from Motor
Cooler 14/24
Open
SG03-215 Closed Cooling Water Return Header Vent fromMotor Cooler 14/24
Closed
SG03-208 Closed Cooling Water Supply Header Vent toMotor Cooler 14/24
Closed
SG03-121(11)
Closed Cooling Water Return Header Relief Valve from Motor Cooler 14/24
Not Gagged
SG03-49 BCP 14/24 Fill Isol. Closed
SG03-237 Flow Element Inlet Isol. Open
SG03-245 BCP 14/24 Fill Filter Bypass Closed
SG03-241 Sample Isol. Closed
SG03-281 Sample Isol. Closed
SG03-81 Fill Isol. To Heating Line Closed
SG03-85 Fill Isol. To Heating Line LockedClosed
SG03-257 Fill Isol. To Heating Line Closed
SG03-261 Fill Isol. To Heating Line LockedClosed
SG03-19 BCP Emergency Cooling Water Tank 11/21Drain
LockedClosed
SG03-18 BCP Emergency Cooling Water Tank 11/21 Isol. Open
SG03-189 Sample Table Isol. Open
SG03-188 Sample Table Isol. Open
SG03-190 Phosphate Feed Pumps Isol. Open
SG03-191 Phosphate Feed Pumps Isol. OpenSG03-192 Phosphate Feed Pumps Isol. Open
SG03-193 Phosphate Feed Pumps Isol. Open
Instrumentation Valve Lineup
SG03-186(13)
BCP Cooling Water Supply Press. Ind. PI-1058/2058 Isol.
Open
SG03-62 BCP 11/21 Fill Before Flow Element Press. Ind. Open
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Vlv Number Valve Name Desired Pos Actual Pos Initials
(37) PI-1059/2059 Isol.
SG03-67 BCP 11/21 Fill After Flow Element Press. Ind.PI-1063/2063 Root Isol.
Open
SG03-66 BCP 11/21 Fill After Flow Element Press. Ind.
PI-1063/2063 Isol.
Open
SG03-274 BCP 11/21 Cooling Water Filter D/P Press. Sw.PS-1916/2916 HP Isol.
Open
SG03-270 BCP 11/21 Cooling Water Filter D/P Press. Sw.PS-1916/2916 LP Isol.
Open
SG03-63 BCP 12/22 Fill Before Flow Element Press. Ind.PI-1060/2060 Isol.
Open
SG03-69 BCP 12/22 Fill After Flow Element Press. Ind.PI-1064/2064 Root Isol.
Open
SG03-68 BCP 12/22 Fill After Flow Element Press. Ind.PI-1064/2064 Isol.
Open
SG03-275 BCP 12/22 Cooling Water Filter D/P Press. Sw.PS-1917/2917 HP Isol.
Open
SG03-271 BCP 12/22 Cooling Water Filter D/P Press. Sw.PS-1917/2917 LP Isol.
Open
SG03-64 BCP 13/23 Fill Before Flow Element Press. Ind.PI-1061/2061 Isol.
Open
SG03-71 BCP 13/23 Fill After Flow Element Press. Ind.
PI-1065/2065 Root Isol.
Open
SG03-70 BCP 13/23 Fill After Flow Element Press. Ind.PI-1065/2065 Isol.
Open
SG03-276 BCP 13/23 Cooling Water Filter D/P Press. Sw.PS-1918/2918 HP Isol.
Open
SG03-272 BCP 13/23 Cooling Water Filter D/P Press. Sw.PS-1918/2918 LP Isol.
Open
SG03-65 BCP 14/24 Fill Before Flow Element Press. Ind.PI-1062/2062 Isol.
Open
SG03-73 BCP 14/24 Fill After Flow Element Press. Ind.PI-1066/2066 Root Isol.
Open
SG03-72 BCP 14/24 Fill After Flow Element Press. Ind.PI-1066/2066 Isol.
Open
SG03-277 BCP 14/24 Cooling Water Filter D/P Press. Sw.PS-1919/2919 HP Isol.
Open
SG03-273 BCP 14/24 Cooling Water Filter D/P Press. Sw.PS-1919/2919 LP Isol.
Open
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Vlv Number Valve Name Desired Pos Actual Pos Initials
SG03-135 BCP 11/21 Motor Cooler Cooling Water FlowPress. Sw. PS-1310/2310 & 1318/2318 LP Isol.
Open
SG03-134 BCP 11/21 Motor Cooler Cooling Water FlowPress. Sw. PS-1310/2310 & 1318/2318 HP Isol.
Open
SG03-137 BCP 11/21 Thermal Barrier Cooling Water FlowPress. Sw. PS-1319/2319 & 1320/2320 LP Isol.
Open
SG03-136 BCP 11/21 Thermal Barrier Cooling Water FlowPress. Sw. PS-1319/2319 & 1320/2320 LP Isol.
Open
SG03-139 BCP 12/22 Motor Cooler Cooling Water FlowPress. Sw. PS-1321/2321 & 1322/2322 LP Isol.
Open
SG03-138 BCP 12/22 Motor Cooler Cooling Water FlowPress. Sw. PS-1321/2321 & 1322/2322 HP Isol.
Open
SG03-141 BCP 12/22 Thermal Barrier Cooling Water Flow
Press. Sw. PS-1323/2323 & 1324/2324 LP Isol.
Open
SG03-140 BCP 12/22 Thermal Barrier Cooling Water FlowPress. Sw. PS-1323/2323 & 1324/2324 LP Isol.
Open
SG03-143 BCP 13/23 Motor Cooler Cooling Water FlowPress. Sw. PS-1325/2325 & 1326/2326 LP Isol.
Open
SG03-142 BCP 13/23 Motor Cooler Cooling Water FlowPress. Sw. PS-1325/2325 & 1326/2326 HP Isol.
Open
SG03-145 BCP 13/23 Thermal Barrier Cooling Water FlowPress. Sw. PS-1327/2327 & 1328/2328 LP Isol.
Open
SG03-144 BCP 13/23 Thermal Barrier Cooling Water FlowPress. Sw. PS-1327/2327 & 1328/2328 LP Isol.
Open
SG03-147 BCP 14/24 Motor Cooler Cooling Water FlowPress. Sw. PS-1329/2329 & 1330/2330 LP Isol.
Open
SG03-146 BCP 14/24 Motor Cooler Cooling Water FlowPress. Sw. PS-1329/2329 & 1330/2330 HP Isol.
Open
SG03-149 BCP 14/24 Thermal Barrier Cooling Water FlowPress. Sw. PS-1331/2331 & 1332/2332 LP Isol.
Open
SG03-148 BCP 14/24 Thermal Barrier Cooling Water FlowPress. Sw. PS-1331/2331 & 1332/2332 LP Isol.
Open
SG03-165 BCP Differential Press. Trans. PT-1066/2066Root Isol
Open
SG03-174 LP Head Chamber Drain Closed
SG03-168 LP Head Chamber Vent Closed
SG03-159 BCP Differential Press. Trans. PT-1066/2066 LPIsol.
Open
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Vlv Number Valve Name Desired Pos Actual Pos Initials
SG03-180 BCP Differential Press. Trans. PT-1066/2066Equalization
Closed
SG03-160 BCP Differential Press. Trans. PT-1066/2066 HPIsol.
Open
SG03-169 HP Head Chamber Vent Closed
SG03-175 HP Head Chamber Drain Closed
SG03-150 Pump Suction Manifold Root Isol. Closed
SG03-156 Pump Suction Manifold Need Valve Throttled
SG03-152 Front Lower Drum Isol. Open
SG03-166 BCP Differential Press. Trans. PT-1067/2067Root Isol
Open
SG03-177 LP Head Chamber Drain Closed
SG03-171 LP Head Chamber Vent Closed
SG03-162 BCP Differential Press. Trans. PT-1067/2067 LPIsol.
Open
SG03-181 BCP Differential Press. Trans. PT-1067/2067Equalization
Closed
SG03-161 BCP Differential Press. Trans. PT-1067/2067 HPIsol.
Open
SG03-170 HP Head Chamber Vent Closed
SG03-176 HP Head Chamber Drain Closed
SG03-151 Pump Suction Manifold Root Isol. Closed
SG03-157 Pump Suction Manifold Need Valve Throttled
SG03-153 Front Lower Drum Isol. Open
SG03-167 BCP Differential Press. Trans. PT-1068/2068Root Isol
Open
SG03-179 LP Head Chamber Drain Closed
SG03-173 LP Head Chamber Vent Closed
SG03-164 BCP Differential Press. Trans. PT-1068/2068 LPIsol.
Open
SG03-182 BCP Differential Press. Trans. PT-1068/2068Equalization
Closed
SG03-163 BCP Differential Press. Trans. PT-1068/2068 HPIsol.
Open
SG03-172 HP Head Chamber Vent Closed
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Vlv Number Valve Name Desired Pos Actual Pos Initials
SG03-178 HP Head Chamber Drain Closed
SG03-154 Pump Suction Manifold Root Isol. Closed
SG03-158 Pump Suction Manifold Need Valve Throttled
SG03-155 Front Lower Drum Isol. OpenSG05-15 Upper Drum Vent East MOV Open (F),
Closed (BF)
SG05-16 Upper Drum Vent East MOV Open (F)
Closed (BF)
SG05-115 Economizer Recirculation Valve Open
SG05-113 Economizer Link Vents Isol. Closed
SG05-114 Economizer Link Vents Isol. Closed
SG05-123 Economizer Link Vents N2 Isol. ClosedSG05-111 Reheat Link Vents Open
SG05-112 Reheat Link Vents Open
SG05-109 Hot Reheat Vents Open
SG05-110 Hot Reheat Vents Open
SG05-99 Superheat Link Vents from Desuperheater Open (F)
SG05-100 Superheat Link Vents from Desuperheater Open (F)
SG05-103 Superheat Pend. Link Outlet Vent Open
SG05-104 Superheat Pend. Link Outlet Vent Open
SG05-116 Superheat Pend. Link Outlet Vent N2 Isol. Closed
SG05-95 Main Steam Vent Open
SG05-96 Main Steam Vent Open
SG05-120 Mains Steam Vent N2 Isol. Closed
SG05-1 Power Relief Valve Isol. Open
SG05-101 Superheat Pend. Outlet Vent Open
SG05-102 Superheat Pend. Outlet Vent Open
SG05-117 Superheat Pend. Outlet Vent N2 Isol. Closed
SG05-97 Superheat Link From Desuperheater Vent Open (F)
Closed (BF)
SG05-98 Superheat Link From Desuperheater Vent Open (F)
Closed (BF)
SG05-107 Hot Reheat Vent Open
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Vlv Number Valve Name Desired Pos Actual Pos Initials
SG05-108 Hot Reheat Vent Open
SG05-13 Upper Drum Vent (West) Open (F)
Closed (BF)
SG05-14 Upper Drum Vent (West) Open (F)Closed (BF)
SG05-32 Superheat Desuperheater Isol. Open
SG05-33 Superheat Desuperheater Isol. Open
SG05-34 Superheat Desuperheater Isol. Open
SG05-35 Superheat Desuperheater Isol. Open
SG05-24 Superheat Desuperheater Isol. Closed
SG05-25 Superheat Desuperheater Isol. Closed
SG05-26 Superheat Desuperheater Isol. Closed
SG05-27 Superheat Desuperheater Isol. Closed
SG05-79 Superheat Finishing Outlet Header Drain Open
SG05-80 Superheat Finishing Outlet Header Drain Open
SG05-93 Aux. Steam Outlet Closed(Capped)
SG05-94 Aux. Steam Outlet Closed(Capped)
SG05-77 Superheat Finishing Outlet Header Drain OpenSG05-78 Superheat Finishing Outlet Header Drain Open
SG05-17 Boiler Drum Purge and Bleed Vents Open (F)
Closed (BF)
SG05-18 Boiler Drum Purge and Bleed Vents Open (F)
Closed (BF)
SG05-19 Boiler Drum Purge and Bleed Vents Open (F)
Closed (BF)
SG05-20 Boiler Drum Purge and Bleed Vents Open (F)
Closed (BF)
SG05-85 Superheat Back Pass Inlet Header Drain Open
SG05-86 Superheat Back Pass Inlet Header Drain Open
SG05-91 Superheat Back Pass Outlet Header Drain Open
SG05-92 Superheat Back Pass Outlet Header Drain Open
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Vlv Number Valve Name Desired Pos Actual Pos Initials
SG05-87 Superheat Back Pass Rear Outlet Header Drain Open
SG05-88 Superheat Back Pass Rear Outlet Header Drain Open
SG05-89 Superheat Back Pass Rear Outlet Header Drain Open
SG05-90 Superheat Back Pass Rear Outlet Header Drain OpenFW01-21 Economizer Inlet Valve Open
FW01-245 Economizer Drain Valve Closed
FW01-246 Economizer Drain Valve Closed
SG05-64 Boiler Circulating Pump Manifold Drain Closed
SG05-65 Boiler Circulating Pump Manifold Drain Closed
SG05-81 Superheat Back Pass Rear Inlet Header Drain Open
SG05-82 Superheat Back Pass Rear Inlet Header Drain 1/2 Turn
Open (BF)SG05-83 Superheat Back Pass Rear Inlet Header Drain Open
SG05-84 Superheat Back Pass Rear Inlet Header Drain 1/2 TurnOpen (BF)
SG05-66 Lower Drum Blowdown (Front) Isol. Closed
SG05-67 Lower Drum Blowdown (Front) Isol. Closed
SG05-62 Lower Drum Blowdown (Rear) Isol. Closed
SG05-63 Lower Drum Blowdown (Rear) Isol. Closed
SG13-16 Main Steam Lead Drain OpenSG13-13 Main Steam Lead Drain Open
SG05-47 Upper Drum (West) N2 Fill Isol. Closed
SG05-48 Upper Drum (West) N2 Fill Isol. Closed
SG05-49 Upper Drum (East) N2 Fill Isol. Closed
SG05-50 Upper Drum (East) N2 Fill Isol. Closed
SG05-7 Superheat Drain Control Valve Auto
SG05-8 Superheat Drain Control Valve Outlet Isol. Open
SG05-132 Superheat Drain Orifice Inlet Isol. Open
SG05-133 Superheat Drain Orifice Inlet Isol. Open
SG05-134 Superheat Drain Orifice Outlet Isol. Open
SG05-135 Superheat Drain Orifice Bypass Closed
SG05-59 Sample Line Isol. Closed andCapped
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Vlv Number Valve Name Desired Pos Actual Pos Initials
SG05-60 Sample Line Isol. Closed andCapped
SG05-10 Drum Continuous Blowdown Open
SG05-34 Upper Drum Gauge Glass Blowdown Isol. Closed
SG05-33 Upper Drum Gauge Glass Blowdown Isol. Closed
SG05-35 Upper Drum Gauge Glass Blowdown Isol. Closed
SG05-36 Upper Drum Gauge Glass Blowdown Isol. Closed
SG05-158 Vent Closed
SG05-159 Cleanout Isol. Closed
SG05-9 Boiler Blowdown Tank To Site Drain BottomIsol.
Closed
SG05-68 Upper Drum Sample Isol. Open
SG05-69 Upper Drum Sample Isol. Open
SG05-70 Upper Drum Sample Isol. Open
SG05-71 Upper Drum Sample Isol. Open
SG05-72 Upper Drum Sample Isol. Open
SG05-73 Upper Drum Sample Isol. Open
SG05-74 Upper Drum Sample Isol. Open
SG05-75 Upper Drum Sample Isol. Open
SG05-76 Sample Table Isol. OpenSG05-124 Sample Table Isol. Open
SG05-21 Upper Drum Blowdown Header Isol. Closed
SG05-22 Upper Drum Blowdown Header Isol. Closed
SG05-11 Upper Drum To Aux. Steam Header Isol. Closed
SG05-12 Upper Drum To Aux. Steam Header ControlValve Inlet Isol.
Closed
SG05-136 Main Steam To Aux. Steam Control Valve
SG05-27 Test Connection ClosedInstrumentation Valve Lineup
SG05-23 Gauge Glass 1021/2021 Root Isol Open
SG05-24 Gauge Glass 1021/2021 Root Isol. Open
SG05-144 Gauge Glass 1021/2021 Isol. Open
SG05-143 Gauge Glass 1021/2102 Isol. Open
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Vlv Number Valve Name Desired Pos Actual Pos Initials
SG05-53 Upper Drum (West) Combined Inst. Isol. Open
SG05-54 Upper Drum (West) Combined Inst. Isol. Open
SG05-149 Vent Closed
SG05-148 Level Switch LS-1523/2523 Isol. OpenSG05-146 Level Switch LT-1052/2052 Isol. Open
SG05-51 Upper Drum (West) Combined Inst. Isol. Open
SG05-52 Upper Drum (West) Combined Inst. Isol. Open
SG05-145 Level Switch LT-1052/2052 Isol. Open
SG05-147 Level Switch LS-1523/2523 Isol. Open
SG05-42 Level Transmitters LT-1023/2023 and LT-1043/2043 Isol
Open
SG05-41 Level Transmitters LT-1023/2023 and LT-1043/2043 Isol Open
SG05-40 Level Transmitters LT-1023/2023 and LT-1043/2043 Isol
Open
SG05-39 Level Transmitters LT-1023/2023 and LT-1043/2043 Isol
Open
SG05-45 Level Transmitters LT-1022/2022 and LT-1043/2043 Isol
Open
SG05-46 Level Transmitters LT-1022/2022 and LT-1043/2043 Isol
Open
SG05-43 Level Transmitters LT-1022/2022 and LT-1043/2043 Isol
Open
SG05-44 Level Transmitters LT-1022/2022 and LT-1043/2043 Isol
Open
SG05-58 Upper Drum (East) Combined Inst. Isol. Open
SG05-57 Upper Drum (East) Combined Inst. Isol. Open
SG05-153 Level Switch LS-1522/2522 Isol. Open
SG05-155 Level Switch LS-1524/2524 Isol. Open
SG05-151 Level Switch LT-1053/2053 Isol. Open
SG05-56 Upper Drum (East) Combined Inst. Isol. Open
SG05-55 Upper Drum (East) Combined Inst. Isol. Open
SG05-150 Level Switch LT-1053/2053 Isol. Open
SG05-152 Level Switch LS-1522/2522 Isol. Open
SG05-154 Level Switch LS-1524/2524 Isol. Open
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6.POWER SUPPLY LINEUP
PP/MCC/BUS Component Desired Pos Actual Pos Initials
BUS 11/21 Boiler Circulating Pump 11/21 Closed
MCC 101/201 Boiler Circulating Pump 11/21 Suction ValveSG03-5 Closed
BUS 12/22 Boiler Circulating Pump 12/22 Closed
MCC 102/202 Boiler Circulating Pump 12/22 Suction ValveSG03-6
Closed
BUS 11/21 Boiler Circulating Pump 11/21 Closed
MCC 101/201 Boiler Circulating Pump 13/23 Suction ValveSG03-7
Closed
BUS 12/22 Boiler Circulating Pump 12/22 Closed
MCC 102/202 Boiler Circulating Pump 14/24 Suction ValveSG03-8
Closed
125 VDC to Switchgear Bus 11 Cub. 3 andCub. 5
Closed
125 VDC to Switchgear Bus 12 Cub. 3 andCub. 6
Closed
120 VAC to Relay Cabinet 11 Section 1 Closed
120 V Continuous AC to Relay Cabinet 11Section 1
Closed
MCC 112/212 West Steam Drum Vent SG05-13 Closed
MCC 112/212 West Steam Drum Vent SG05-14 Closed
MCC 113/213 East Steam Drum Vent SG05-15 Closed
MCC 113/213 East Steam Drum Vent SG05-16 Closed
MCC 101/201 Front Lower Drum Drain SG05-66 Closed
MCC 101/201 Front Lower Drum Drain SG05-67 Closed
MCC 112/212 West Superheater Outlet Header BlowdownSG05-77
Closed
MCC 112/212 West Superheater Outlet Header BlowdownSG05-78
Closed
MCC 113/213 East Superheater Outlet Header BlowdownSG05-79
Closed
MCC 113/213 East Superheater Outlet Header BlowdownSG05-80
Closed
MCC 112/212 West Superheater Inlet Header Blowdown Closed
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PP/MCC/BUS Component Desired Pos Actual Pos Initials
SG05-81
MCC 101/201 West Superheater Inlet Header BlowdownSG05-82
Closed
MCC 113/213 East Steam Inlet Header Blowdown SG05-83 Closed
MCC 101/201 East Steam Inlet Header Blowdown SG05-84 Closed
MCC 113/213 East Superheater Drain SG05-85 Closed
MCC 113/213 East Superheater Drain SG05-86 Closed
MCC 112/212 West Superheater Drain SG05-87 Closed
MCC 112/212 West Superheater Drain SG05-88 Closed
MCC 112/212 West Superheater Drain SG05-89 Closed
MCC 112/212 West Superheater Drain SG05-90 Closed
MCC 113/213 East Superheat Drain SG05-91 ClosedMCC 113/213 East Superheat Drain SG05-92 Closed
MCC 113/213 Main Steam Vent SG05-95 Closed
MCC 113/213 Main Steam Vent SG05-96 Closed
MCC 112/212 West Superheater Desuperheater Vent SG05-97 Closed
MCC 112/212 West Superheater Desuperheater Vent SG05-98 Closed
MCC 113/213 East Superheater Desuperheater Vent SG05-99 Closed
MCC 113/213 East Superheater Desuperheater Vent SG05-
100
Closed
MCC 112/212 West Superheater Vent SG05-101 Closed
MCC 112/212 West Superheater Vent SG05-102 Closed
MCC 113/213 East Superheater Vent SG05-103 Closed
MCC 113/213 East Superheater Vent SG05-104 Closed
MCC 112/212 West Hot Reheat Vent SG05-107 Closed
MCC 112/212 West Hot Reheat Vent SG05-108 Closed
MCC 113/213 East Hot Reheat Vent SG05-109 Closed
Chapter #12 Boiler Steam and Water System Coal Creek Station