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When Unit is coming off line at 100 MW’s the Boiler Assistant should open these valves
economizer recirculating valves
During Unit Start-up, at 200 lbs what should the Boiler Assistant do?
What should the pump room Assistant do?
close saturated and ring header drains
Start 200 lb blow on downcomers on one down comer and rotate out down comers every 15 minutes till unit is at 400 pounds.
What are the steps to reset the turbine?
- A) Place load limit hand wheel in manual.
- B.) Close load limit handwheel.
- C.) Push vacuum reset button.
- D.) Pull HP & LP reset handles (reheat and intercept valves should open).
- E.) Open load limit handwheel wide open and place in remote.
What are steps for lining sootblowing steam up from Unit on line to Unit off line?
- A) Close manual valve before sootblowing regulator on Unit that is off.
- B) Close drain valves at tie valves.
- C) Open sootblowing tie valves for Unit that is off and Unit getting steam from.
What floor is the Superheater spraywater valve located on?
When does the Assistant open and close this valve?
heater bay floor
open when unit ties on line, close when unit comes off line
Where are the turbine oil cooler regulators located for units 1 & 2 ?
Behind B circulator in pump room
What should the Boiler Assistant do when the Unit trips?
- Close spraywater valve on heater bay floor.
- Open economizer recirculating valve
- Verify manual bypass valves on oil ignitors is closed.
- Check Air preheaters, if not running place on air, when PCO starts electric motor close air.
- Open boiler drains if PCO instructs you to.
- Open Channel drains on HP heaters
What should the Turbine Assistant do when the Unit trips?
- Place a circulating water pump in service and line up in backwash position.
- Place Gland Steam Exhauster that was in service prior to trip, back in service.
- Open all Turbine drains ( all after seat, reheat & intercept before seats, 12th stage shell drain, crossover bowl drain, & hot reheat drains )
- Open all extraction and cold reheat trap bypasses)
- Verify Air compressor cooling tower is in service.
When instructed by PCO open superheater vents and stop valve before seat drains.
- When turbine speed is around 1000 rpm’s open vacuum breakers to zero vacuum or lower vacuum to around 10-15 inches if unit is coming back on line.
- If vacuum is to be zeroed communicate to pump room assistant to take condenser vacuum pump off.
- When vacuum reaches zero take gland steam exhauster off and close off steam feed to steam seals.
- When HP & LP turbines stop, place on turning gear.
What should the Pump Room Assistant do when the Unit Trips?
- Check air compressors, restart any that tripped.
- Check General service water pumps, if any tripped place pumps back in service. Verify pump is not running backwards.
- Check ash sluice pumps, if any tripped place back in service, verify pump is not running backwards.
- Check HP & LP seal oil equipment, verify main seal oil pumps and vacuum pumps are running and take dc emergency seal oil pumps off.
- Make sure air compressor cooling tower pump skid is in service.
Where is the condensate regulator located and what is it controlling?
B floor next to hand rail and it controls dea level
What floor are the saturated and ring header drain root valves located on?
Where is the General service water tie valve tying units 1&2 to units 3&4 located?
by stairwell in pump room between units 2 & 3
During start-up when exhaust hood temperature gets high what should turbine assistant do?
open spraywater valve at turbine console
Unit is off line and the pump room assistant has been instructed to drain the waterbox, waterbox has been draining for lets say an hour, assistant tries to open the waterbox doors but they do not want to open, what is the problem?
when draining the waterbox the vents were not opened, the waterbox is still full of water, do not open door
Unit trips before equipment can be started back what must the operator do?
What is this called when the unit tripped and there is no station service and the operator swaps from running to starting station service?
swap to starting station service
cold drop out
This is especially true for the fall season, it has been raining very hard what should the assistants keep a close check on?
intake screens for carry over and stopped up jets, tunnel water level, strainers in pump room, cooling water to all equipment
Where is the general service water tie valve from units 3&4 to unit 5 located?
B floor by I-beam in front of extraction valves
Where is the general service water tie valve from units 3&4 to unit 5 located?
B floor by I-beam in front of extraction valves
Where are 6A & 6B extraction trap bypasses located?
turbine floor between B & C BFP’s
When we take the clinker grinder out of service we usually open the disconnect, the 600v breaker for the clinker grinder feeds another piece of equipment besides the clinker grinder, what is it?
penthouse blower on 6th floor
Where are the Unit 2 baghouse inlet and bypass dampers located?
out the back door between units 2 & 3 on the left and up the ladder
What is the proper sequence for putting a seal on turbine and taking seal off turbine?
Putting seal on turbine:
- around 400-500 lbs drum pressure open steam feed to steam seal regulator on turbine console and maintain 4-5 psig.
- Place gland steam exhauster in service. (condensate pump and auxiliary oil pump must be left on at this time)
- Start condenser vacuum pump and stand-by condenser vacuum pump
- Close vacuum breakers, fill with condensate.
- Taking seal off turbine:
- a. Open vacuum breakers when speed is around 1000 rpm’s
- b. Take condenser vacuum pump off
- c. When vacuum zeroes take gland steam exhauster offClose steam feed to seals
If steam seal regulator fails, how do you control steam seal pressure?
open steam feed to packing on console
Where does steam seal get its steam from?
Main steam leak off, Steam seal root valve is on Main steam line before left hand main stop valve
Operator gives the turbine Assistant a switching order to rack out Precipitator 4160v breaker. On the switching it states to check breaker for open, the assistant finds the breaker still closed in, where do you open this breaker from?
located in precipitator house
Where is the stop valve bypass located?
B floor on right hand main stop valve
If the unit is still on line, before isolating the ash pit what must the pump room assistant do?
Place temporary seal on ash pit
Where is the hydrovactor tie valve located?
6th floor unit 3
What valves need to be closed when lining up to air test boiler?
- Drum vents
- Grab sample at drum
- Continuous blowdown at drum
- Chemical feed at drum
- Left and Right hand Primary superheater outlet drains
- Left and Right hand Secondary superheater outlet drains
- Left and Right hand Saturated Steam header drains
- Left and Right hand Ring header drains
- Before seat drains
- Superheater Vents
- Steam feed to Steam Seal regulator
- Steam feed to Steal Packing
- Connect hose and open valve at drum, start adding air.
Where is office annex steam located and what supplies it?
Dea extraction supplies steam, located by #3 heater
What is normal air preheater sootblowing pressure?
Where do you check air preheater sootblower to see if it is turning?
bottom of air heater
Where is the air preheater wash water valve located?
by door going to fan yard between units 1 & 2
What air compressors do units 1 & 2 supply power to?
unit 1 #3 , and standby, unit 2 is # 2
Why are IK’s 23-28 so short?
half of IK is in the boiler, 2 nozzles
Where are sucker valves located?
side of condenser by seal oil equipment
You are the Turbine Assistant and while on the B Floor you notice the safety lifting on the heat exchanger, what should you do?
put more water on heat exchanger or take some of the steam off. PCO can add more water
Lab calls and says air-in leakage is high, where are some places to check for air-in leakage?
Pump room APCO can check tell-tale for closed, check hotwell drain, check level in gland steam exhauster trap, check pressure relief valves on condensate pumps, drains on suction lines to condenser vacuum pumps, Turbine APCO check vacuum breakers water level, Boiler APCO check atmospheric vents on LP heaters
Where is the pulverizer seal air tie valve for units 1&2 to units 3&4?
Above 3A pulverizer.
Where is the Ash sluice tie valve for units 1&2 to units 3&4?
B floor between units 3 & 4 next to handrail
Where is the emergency blowdown valve located?
Turbine floor inside HP turbine
If unable to run a gland steam exhauster while unit is on line what should the Turbine APCO do?
open desuperheater spray valve, Unit 1’s located on I beam next to 1A gland steam exhauster, Unit 2’ s located on I beam next to 2A gland steam exhauster
Normally when sending crossover steam to Unit 5, we get steam from 3 different units, but sometimes we can only get steam from 2 units what must the boiler assistant close when getting crossover from just 2 units?
6A & 6B extraction valves on units crossover steam is sent from
The heat exchanger safety is lifting and you ask the PCO to put more water on the heat exchanger to stop it from lifting, safety continues to lift and you remove
some of the steam but safety continues to lift, what is probably the problem?
floor valve supplying water is closed
An IK sootblower gets hung in the boiler what should you do?
Notify PCO to try to reverse IK from control room, if this fails, reset forward and reverse coils to see if this will solve the problem, if not, hold reverse coil in for a couple of seconds and let off, keep doing this until IK is out of boiler. Ask PCO what his / her amps look like, DO NOT HOLD COIL IN TOO LONG OR YOU WILL BURN UP COIL. Close down approximately 1 round on the steam valve this will help when reversing, DO NOT CLOSE DOWN ON IK’s 1 or 2 THOUGH, AND DO NOT CLOSE COMPLETELY OFF. May have to use impact wrench to get IK out. Ask for help if needed. If unable to remove IK from boiler then Steam valve needs to be closed to prevent steam from cutting boiler tube
Before backwashing Unit 1 Condenser, what is it a good practice to do and why?
Take hydrovactor supply pumps off to prevent hydrovactor strainers from stopping up
Where is the Boiler Auxiliary water valve located and what does it supply?
B floor next to handrail, supplies cooling water to ID fans, FD fans, Air Prehater Support brgs, Primary Air fan brgs and BFP’s
At approximately what load does 5A & 5B heaters start flashing to #3 heater?
Where are the economizer drains located?
3rd floor by hammer valves
Why do you open the economizer recirculating valves around 100 mw’s when unit is coming off line?
to keep from overheating economizer
If there was a fire at the seal oil equipment, oil storage house, or Main or Station service transformers, where would you find the valves for water deluge system for these areas?
next to windows on turbine floor
What are the 7 major components of the condensate system?
1. Condenser/hotwell 2. Condensate pumps 3. Gland steam exhauster 4. Heat exchanger 5. Low Pressure Drain Cooler 6. Low Pressure Heaters 7. Deaerator/Surge Tank
Why is it important to remove an IK that is hung in the boiler as soon as possible?
an IK that is in the boiler but not moving can cause a tube leak due to constant steam flow to same section of tubing
Where are the Superheater spraywater regulators located?
5th floor, south side of boiler
During an outage we sometimes flood the condenser above the expansion joint to check it for leaks, what does the Pump Room Assistant need to do before we flood the condenser this high?
close sucker valves and valve out air-in leakage monitor, valve out and line gland steam exhauster trap to floor
Where are the Intercept equalizer valves located?
Turbine floor inside HP turbine
Where is the 208v breaker for the seal oil vacuum pumps located?
Unit 1- by 1C BFP on south end corner of control room, Unit 2- by 2A BFP on south end corner of control room
When a boiler leak is suspected but not obvious, what should the boiler man do before sounding out the boiler?
Make sure PCO is not blowing any sootblowers then close the manual valve before the sootblowing regulator, then sound out the boiler
Where is the 208v breaker for condenser crossover, inlet & outlet, and partition valves located?
in cabinets on north side of turbine floor behind old exciters, between units 1 & 2
Where is the grab sample root valve located?
west end of drum
What does the economizer recirculating line tie into?
#1 and #4 downcomers
Where is the gland steam exhauster trap located?
pump room close to 4 inch make-up, on unit 2 it behind the shack
When pegging the Dea during start-up, the operator closes the Dea Extraction valve from the control room, but if it does not close, he/she asks you to try to manually close this valve, what must you do to get it to close?
open the disconnect on the side of the wall, then hold lever down on the valve, then turn handwheel in close direction. Once valve is closed some, close disconnect, and place control in local position and try to close the valve at the push button station. If valve operates, close valve completely and return to remote position
Unit has been off line, and Circulating Water Pumps will not prime what should the Turbine Assistant do?
Check screens for carry over, check tunnel for differential, cut load on units on line and place condensers in backwash
What should ash sluice pressure run?
approx. 160 lbs
What should control air pressure run?
approx. 80-85 lbs
Where are the Primary Superheat, Secondary Superheat, and Boiler Hot Reheat drain root valves located?
Why does the LP turbine turn slower (1800 rpm’s) than the HP turbine (3600 rpm’s)?
LP is 4 pole, HP is 2 pole
There are times we may have to tie into Unit 5’s control/service air, to either supply them with air or receive air from them. Where is this tie valve located?
next to #4 Air Compressor receiving tank
What should the maximum hotwell temperature be when running a condensate pump?
We sometimes have to heat the water up in the hotwell prior to filling the boiler, we use sparging steam to do this. This steam may be used off of any units 1,2, or 3. Although there are several valves that need to be checked for open, the 3 primary valves are located where?
Main supply valve on the 5th floor next to the reheat spraywater regulators, steam supply valve to acid manifold on the feeder floor in front of B row of burners, sparging steam valve at the hotwell next to hotwell temperature gauge
Where are the manifold drives and the outlet dampers for Unit 2 Baghouse located?
4th floor, go out the door by the man lift, turn to the left
Where do you put a seal on the boiler at?
seal trough at ashpit
Where is the steam seal root valve located?
just before the L.H. Main Steam Stop Valve
Where are the disconnects for Boiler feed Pump discharge valves located?
between A & B Boiler Feed Pumps
What should you do when the Operator tells you he/she has a coal stoppage, or a feeder has tripped?
If it is a coal stoppage the Operator will use the air cannon to clear the stoppage, if this doesn’t work then the Assistant will have to try to knock the coal down, There is a port hole above the feeder where you can place an air lance to try to get the coal to fall. If unable to knock the coal down, then have the Operator stop the feeder and run the primary air in the hole, You may then open the feeder door to inspect. If the feeder trips more than likely it is due to a discharge plug fault, this usually happens when the coal is wet, it could actually mean the feeder pipe below the feeder is stopped up, or that the probe has wet coal stuck to it, which is usually the case. The Operator needs to run the primary air in the hole, so that you can open the feeder door to determine if the feeder pipe is plugged or the probe just needs to be cleaned. Once the problem is solved, close the door and reset the fault on the feeder. Do Not Open The Feeder Door Until The Operator Has Run The Primary Air In The Hole. If the feeder pipe is stopped up the mill needs to be running before knocking the coal down in the feeder pipe.
Why is it very important for the Boiler Assistant to keep a close check on the flyash during each shift?
Assistant needs to check vacuum trend to verify each hopper is pulling properly. Verify vacuum is normal and each hopper is emptying. Normal vacuum is 6-7 inches if hopper is full, when vacuum drops to below 4.5 inches for 20 seconds then it should swap over to the next hopper. Vacuum must reach 6 inches before the next hopper will open. If the flyash system gets hung up on a particular hopper and is not monitored, flyash will get behind and precipitators could start tripping causing opacity problems. If vacuum is too low for hoppers to open, there could be a problem with the hydrovactors (strainers stopped up, splash plates etc.) or there may be a valve not closing off killing the vacuum.
Where is the Steam Seal regulator?
Between A & B Boiler Feed Pumps
When adding hydrogen to the generators you notice the hydrogen pressure is not coming up or it could actually even drop what is probably the problem?
Unit 5 Assistant needs to check the nitrogen bottle at the hydrogen tank, pressure is probably low and needs to change out nitrogen bottle
If the Main Seal Oil pump will not run and the emergency seal oil will not run what is the 3rd source of sealing oil and what must the Assistant do when this source is being used?
Check Valve 254 from Turbine bearing header, assistant will need to vent hydrogen down to 8-10 psi
Where is Perkins Pond located?
Just north of the Civil War monument in front of the Plant
If any oil is fond in Perkins Pond where did the oil come from?
Switchyard drains or CT drains, need to check the drains in the switchyard and CT to determine source of spill
Where do the drains in the Fan yard drain to?
Mother of all sumps, located behind Unit 5 underneath SCR structure
If a Boiler Feed Pump coupling is losing oil what should you do?
re-route cooling water from oil separator to the sump and notify C&R and Team Leader
Where do the drains in 1-4 sub- basement drain to?
Unit 5 outdoor sump
Where do 1-4 ID fans cooling water drain to?
East end oil/water separator, next to mother of all sumps
What is the purpose of the house service tanks?
Back up general service water if pressure drops below set point, also if station service is lost and can’t be restored it provides cooling water until bearings coast down
Where does the House Service tank get its water from?