Hindalco

TCI-AA078-16
WRITEUP ON ATRS Sheet 1 Of 28
HYDERABAD REV.NO : 00
TITLE: WRITE-UP ON ATRS LOGIC DIAGRAMS.
OWNER: HINDALCO INDUSTRIES LIMITED

(UNIT: MAHAN AND ADITYA ALUMINIUM)
2X (6X150) MW CAPTIVE POWER PLANT
BARGAWAN, DISTT: SINGRAULI
& LAPANGA, SAMBALPUR
CONSULTANT: DEVELOPMENT CONSULTANTS PVT. LTD.

CONSULTING ENGINEERS
KOLKATA, CHENNAI, MUMBAI, NEW DELHI
REF. DRG. ATRS LOGIC DIAGRAMS:3-133-00-62112
FORMAT Prepared by: Checked by: Approved by: Date:

TD-201
REV-00 L.V.A.B P.S.V.S P.S.V.S 08.04.10
REF-DOC COPYRIGHT AND CONFIDENTIAL
HINDALCO-
ATRS-R00.DOC The information on this document is the property of BHEL. It must not be used
directly or indirectly in any way detrimental to the interest of the company.
TCI-AA078-16
CONTENTS
1.0 INTRODUCTION
2.0 PHILOSOPHY
3.0 SYSTEM DESCRIPTION
4.0 SGC OIL SUPPLY
5.0 SGC CONDENSATE AND EVACUATION
6.0 SGC TURBINE
REFERENCE P&IDs.
LUBE OIL SCHEME DRG.NO. 2-131-00-90301
TO
INSTRUMENT AIR SCHEME DRG.NO. 2-131-00-90329
HYDRAULIC SUPPLY UNIT DRG.NO. 1-131-00-90309
HP/IP TURBINE SCHEME DRG.NO.1-131-00-90318
TSI SCHEME DRG.NO. 2-133-00-62027

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1.0 INTRODUCTION:
With the increase in unit capacity associated with increased capital costs and the steep
rise in fuel cost. It is necessary to maintain the availability of thermal power sets at as
high a level as possible.
For startup acquisition and analysis of a wide variety of information pertaining to
various parameters of steam turbine demand quick decisions and numerous operations
from the operating personnel. In order to reduce the arduous task of monitoring
various parameters and effect sequential start up, minimise the possible human errors
and to achieve start up in minimum time in the optimum way Automatic Turbine Runup
System (ATRS) is introduced. The operation of ATRS is from Man Machine Interface
(MMI) of TG DCS. The operation of critical drives is also available from Backup console
(Please refer console OGA for the EDN).
2.0 PHILOSOPHY:
2.1 The ATRS is based on functional group philosophy i.e. the main plant is divided into
clearly defined sections called sub group controls SGC such as oil system, condensate
and evacuation, Turbine system. Each SGC is organised and rearranged in sub loop
controls (SLC) and control interface (CI).
2.1.2 SUB GROUP CONTROL (S.G.C.) :
A subgroup control executes commands, to bring the equipment upto a particular
defined state and contains the start up and shut down programme of the respective
group. S.G.C. issues commands either to control interface level or switches on SLC.
Desired number of criteria act as pre conditions before S.G.C. can take off to execute
its defined programme comprises of steps. For each step there is provision for

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“monitoring time” and “waiting time”. Waiting time implies that the subsequent step
could not be executed unless the specified time elapsed. The time between command
signal and appearance of check back signal is known as monitoring time and when it is
being executed alarm is initiated and the programme will not be proceeding further. In
addition, execution of any step is also permitted only if the conditions specified for that
particular step are completely fulfilled. Bypass conditions are included to enable
switching ON after S.G.C. at any stage after completing certain task manually if so
desired. In addition to normal sequential start up, the following modes are possible.
1) operator guide mode 2) step mode.
Operator guide mode:
In this mode data is received from the plant but no commands are issued to the control
interface. Commands must be issued manually. This mode is useful for
commissioning and training.
Step mode:
This mode enables the programme to be executed one step at a time, even if step
criteria are absent and the automatic mode is malfunctioning. This is useful when
system criteria have been met and cannot be preceded due to transmitter
malfunctioning.
2.1.3 CONTROL INTERFACE:
The control interface forms the link between the individual commands and the power
plant. Each remote controlled drive has a control interface. It consists of command
section, monitoring section, power supply and alarm section. The command section
provides the control commands according to the priority and validity and passes
actuation signals to the interposing relays in the switch gear. It monitors status

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discrepancies, running time between command output and check back actuation and
blocking of command output by protectective logic.
SUBLOOP CONTROL (SLC):
When SLC is switched ON, it actuates the connected mechanical process condition.
No sequential logic is involved. SLC can be switched ON/OFF either manually or
through SGC.
3.0.0 SYSTEM DESCRIPTION:
Automatic Turbine Run up System consists of three sub group controls viz. Oil
supply system, condensate and evacuation system and turbine system. These
groups in conjunction with electro-hydraulic speed control and turbine stress evaluator
achieves the task of synchronising and block loading of the machine or orderly shut
down as required.
4.0.0 SGC OIL SUPLY SYSTEM (MAV10EC001):
The sub-group control for oil system performs its tasks comprising starting relevant oil
pumps. Ensuring turning of turbine as and when demanded by the process and
ensuring the Lubricating oil under various circumstances. The programme is
accomplished through a number of steps and SLCs.
4.1.0 OPERATION:
If the operator switches “ON” SGC and presses the manual push button for “operation”,
the programme would proceed to execute various steps, provided the release criterion:
Oil tank level is above min (MAV10CL021, MAV10CL022) is available.
STEP 1 & 2
“SLC Main Oil pumps (MAV21EE001)” and “SLC oil vapour exhaust fans
(MAV82EE001)” are switched “ON”. Within the 10s one of the Main oil pumps

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(MAV21AP021, MAV21AP022) and oil vapour exhaust fans (MAV82AN001,
MAV82AN002) must be in operation.
STEP 3
This is a control step where the generator criterion is checked (if applicable).
STEP 4
SLC emergency oil pump (MAV24EE001) are switched ON and the solenoid valve of
turning gear (MAV51AA012) is switched off. With this measure, the availability of
emergency oil pump is ensured and turning gear is ready to rotate the turbine.
STEP 5
SLC Jacking oil pumps (lifting oil pumps) (MAV31EE001, MAV32EE001) are switched
ON and the turbine begins to rotate driven by hydro motor which is admitted with high
pressure oil from the lifting oil pump.
STEP 6
This is a waiting step to check the operation of lifting oil pumps and the minimum
turbine speed.
STEP 7 & 8
As soon as the turbine speed is 9 S-1 (i.e. 540 RPM) the lifting oil pumps
(MAV31AP001, MAV32AP001) are switched OFF and are checked. With this the start
up programme of lube oil system is completed. However in case, the turbine speed is
less than 8.5 S-1 (i.e. 510 RPM), the programme goes back to step 1 for recycling.
4.2.0 SHUT DOWN:
The shut down program essentially switches OFF all the equipments in the oil system.
The shut down program would be started if the SGC is ON and operator presses the
button for “shut down”. The release criterion for shut down program is “HP mean shaft

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temperature (MAV01EP154) and HP inner casing temperature (MAA50CT011) is less
than 100°C”.
STEP 51
Solenoid valve of turning gear is (MAV51AA501) switched ON. This means turning
device is switched OFF so that turbine can coast down to stand still.
STEP 52 & 53
Step 52 is a waiting step, so that the turbine speed decreases. If the turbine speed is
less than 0.15 S-1 (i.e. 9 RPM) the program goes to step 53 where it waits for 20 min
before the program goes to 54.
STEP 54
SLC lifting oil pumps are switched OFF.
STEP 55
SLC main oil pump (MAV21EE001), SLC emergency oil pumps (MAV24EE001), SLC
OVEF (MAV82EE001), Main oil pumps (MAV21AP021, MAV21AP022), AC EOP
(MAV25AP001), OVEF 1 & 2 (MAV82AN001 & MAV82AN002) and sol-valve turning
gear are switched off.
STEP 56
This is the last step of shut down program.
4.3.0 SLC MAIN OIL PUMPS (MAV21EE001):
From the SGC steps, the SLC is switched ON or OFF. If SLC-is switched ON,
whenever the oil pump discharge header pressure (MAV21CP001) or lube oil header
pressure (MAV42CP019) falls below the set value, the standby pump is automatically
switched ON.

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4.4.0 SLC EMERGENCY OIL PUMP (MAV24EE001):
If SLC is ON, the emergency oil pump (MAV24AP001) is switched “ON” automatically
whenever lube oil pressure falls below set value. Additionally as a safety measure an
independent pressure switch (MAV42CP012) shall give direct command to DC starter
of emergency oil pump (MAV24AP001). This feature has been built to guard against
the non-availability of 24 V DC supply to SLC.
4.5.0 SLC LIFTING OIL PUMP (AC) (MAV32EE001):
If SLC is ON, the lifting oil pump-1 (LOP) (MAV32AP001) is switched ON, if speed falls
below 510 RPM and switched OFF if speed raises above 540 RPM automatically.
4.6.0 SLC LIFTING OIL PUMP (DC) (MAV31EE001):
If SLC is ON, the lifting oil pump-2 (LOP) (MAV31AP001) is switched ON, if speed
remains below 8.5 S-1 (i.e. 510 RPM) for more than 5s and lifting oil pressure
(MAV35CP011) is below set value (less than 100kg/cm2G).
4.7.0 SLC OIL PUMP VAPOUR FANS (MAV82EE001):
If SLC is ON, the preselected fan would be switched ON automatically and also the
stand by fan would be switched ON automatically if oil vapour exhaust flow is less than
set value.
5.0.0 SGC CONDENSATE AND EVACUATION (MAY01EC001):
This accomplishes the task of ensuring one condensate pump in operation, evacuating
the condenser, maintaining the condenser pressure and breaking the vacuum when
required by process.

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5.1.0 PROGRAM OPERATION:
If the operator switches ON SGC and press the manual push button for operation of the
program, it would proceed to execute various steps, provided the “Release criteria” as
listed below are available:
1. Level in hotwell is above normal level (MAG11CL101, MAG12CL101, 102).
2. Air isolation valves of both the main ejectors open (MAJ12AA301, MAJ13AA001).
STEP 1:
At this step, ’SLC condensate pump (LCB00EE001)’ is switched ON.
STEP 2:
In this step program issues command to switch ON ‘SLC drains (MAL00EE001)’. This
SLC is primarily hooked up with the “SGC turbine” program, but “SGC condensate and
evacuation system” also controls the same. Before executing step No. 02 the program
seeks the availability of criteria as detailed below:
1. Condensate pump-1 (LCB10AP001) ON or Condensate pump-2 (LCB20AP002)
ON.
2. SLC condensate pumps (LCB00EE001) ON.
STEP 3:
In this step the program issues the following commands:
1. Vacuum breaker valve (MAG10AA001) close.
2. Gland steam pressure controller (MAW20DP001) on manual.
3. Gland steam control valve close. Vacuum breaker valve is closed as a first step for
building vacuum inside condenser. However, before execution of above command
the program checks command in Step No: 2 is executed.

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STEP 4:
In this step the command is issued for opening the steam-isolating valve to “Starting
Ejector-1 (LBG36AA001)”. This step itself gets bypassed if the system is already
evacuated and absolute pressure in condenser (MAG01CP005) is less than 0.26
KG/CM2(abs). Before execution of this step, the program checks availability of the
following criteria:
1. The commands of Step No. 3 executed.
2. Condensate pump discharge header pressure (LCA20CP101) is more than
minimum value.
3. Steam pressure in header supplying steam to the Ejectors (LBG20CP101/
LBG20CP102) more than 5.5 KG/CM2 (g).
STEP 5:
In this step the command is issued for opening the air-isolating valve connected to
starting ejector. This step itself gets bypassed if the absolute pressure in the condenser
is less than 0.26 KG/CM2(abs). Before executing this step the program checks back
the availability of the criterion that the command of Step No. 4 has been executed.
STEP 6:
In this step the command is issued for opening the isolating valves supplying steam to
the main ejectors (LBG37AA301, LBG38AA301). However, before executing the step
the program checks back the commands issued in Step No. 5 are executed. This step
itself gets bypassed if pressure in condenser (MAG01CP003, 004,005) is below 0.12
KG/CM2 (abs).
STEP 7:

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No specific command is issued from this step and it acts as an ‘AND’ gate to check
back the commands issued in Step No. 6 are executed.
STEP 8:
In this step command is issued to switch ON gland steam pressure controller
(MAW20DP001). Before executing the command the program checks that the turbine
is operating on Turning gear i.e. the speed of the turbine is more than 0.25S-1 (i.e. 15
rpm) and the pressure in condenser (MAG01CP00,004,005) is less than 0.85
KG/CM2(abs).
STEP 9:
In this step no specific command is issued in this step and acts as a ‘GATE’ to check
back that the command of Step No. 8 has been executed and the pressure of steam in
the gland steam header (MAW20CP001) is between 1.04 and 1.06 KG/CM2. The
monitoring time is blocked as all the ejectors are evacuating in entire system, and
process is in progress.
STEP 10:
In this step the valve in the air extraction line to the staring ejector-1 (MAJ11AA301) is
closed as a prelude to stop the starting ejector since the starting ejector is not effective
for evacuating the system after the condenser pressure (MAG01CP003,004,005) has
fallen below 0.26 KG/CM2 (abs). Before executing the command for Step No. 10, the
program checks back that the absolute pressure in the condenser
(MAG01CP003,004,005) is below 0.26 KG/CM2(abs).
STEP 11:

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In this step command is issued to stop the supply of steam to starting ejector-1 by
closing the steam isolation valve (LBG36AA301). This command is initiated after
checking back the commands of Step No.10 have been executed.
STEP 12:
No command is issued from this step. The main ejectors continue the task of pulling
the vacuum until absolute pressure in condenser (MAG01CP003,004,005) has reduced
below the 0.12 KG/CM2 (ABS) and generator load is more than 5%. Monitoring time is
blocked to enable these two criteria to be fulfilled.
STEP 13:
In this step command is issued for closing one of the two main ejectors. Only one main
ejector shall be sufficient to maintain the vacuum after the turbine has taken block load.
A manual selection switch has been envisaged through which any of the main ejectors
can be selected. For stopping the ejector the command of Step No. 13 closes the
steam supply to the ejector, which has not been selected. Before issuing the command
of Step No. 13, the program checks back that the absolute pressure in condenser
(MAG01CP003,004,005) is less than the 0.12 KG/CM2 (ABS) and turbine has been
loaded to above 5%.
STEP 14:
In this step command is issued for switching ON SLC main steam ejectors
(MAJ20EE001).
STEP 15:
This step is the last step, which completes operation sequence.
5.2.0 SHUTDOWN PROGRAMME:

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The shutdown programme can also be initiated by the operator provided the following
release criteria are available:
(i) The speed of turbine is less than 4S-1(i.e. 240 rpm); and
(ii) LP bypass system has closed.
STEP 51:
In this step command is issued to close the supply of steam to both the ejectors and
starting ejector by closing the respective steam isolation valves.
STEP 52:
In this step command is issued for opening the vacuum breaking valve (MAG10AA051)
and air isolation valve of starting ejector (MAJ11AA301). Before initiating command
the program shall check back the execution of command of Step No. 51.
STEP 53:
In this step commands are issued for :
1. Force closing the gland steam pressure control valve without manual intervention;
and
2. Switching ON SLC drains (MAL00EE001).
Before executing this step, the programme shall check back the execution of
commands of Step No. 52.
STEP 54:
In this step commands are issued to switch OFF both the condensate pumps
(LCB10AP001, LCB20AP002); as well as SLC condensate pumps (LCB00EE001).

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Before executing this step the programme checks back the execution of commands of
Step No. 53.
STEP 55:
No specific command is issued from this step. This programme remains stay-put in
this step. Accordingly the monitoring time is blocked.
5.3.0 SLC CONDENSATE PUMPS (LCB00EE001):
This SLC is switched ON from Step No. 01 and switched OFF from Step No. 54 of
SGC condensate and evacuation system. A manual push button is also provided in the
MMI to – switch ON or OFF this SLC. Selection of service pump shall be manual. The
other pump shall serve as reserve pump. If SLC is ON it shall perform the following
tasks:
5.3.1 Switch ON condensate pump No. 1 or 2 (LCB10AP001/LCB20AP002) preselected as
service pump.
5.3.2 Switch ON condensate pump-1 (LCB10AP001) if there is discrepancy in condensate
pump-2 (LCB20AP002) and pump-2 is OFF.
5.3.3 Switch ON condensate pump-2 (LCB20AP001) if there is discrepancy in condensate
pump-1 (LCB10AP001) and pump-1 is OFF.
5.3.4 Switch ON condensate pump-1 (LCB10AP001) after 0 – 100 sec, in case pump-2
(LCB20AP002) is selected and discharge pressure of pump-2 is below a specified
value, i.e. in case preselected pump-2 is not able to build up its discharge pressure
within 0 –100 sec, after switch ON SLC.
5.3.5 Switch ON condensate pump-2 (LCB20AP002) after 0 – 100 sec, in case pump-1
(LCB10AP001) is selected and discharge pressure of pump-1 is below a specified

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value, i.e. in case preselected pump-1 is not able to build up its discharge pressure
within 0 –100 sec, after switch ON SLC.
5.3.6 Switch ON reserve condensate pump if condensate pumps discharge header pressure
is below specified value after 0 – 200 sec, of switchin ON of SLC.
5.3.7 Open the discharge valve of both the pumps if pressure in any of the pumps is of more
than preset value.
5.3.8 Switch OFF condensate pump-1 (LCB10AP001) if pump-1 was selected but the pump
is not able to build its discharge pressure after 0 – 100 sec, of switching ON the SLC.
This action and the action mentioned in 5.3.5 shall take place simultaneously.
5.3.9 Switch OFF condensate pump-2 (LCB20AP002) if pump-2 was selected but the pump
is not able to build its discharge pressure after 0 – 100 sec, of switching ON the SLC.
This action and the action mentioned in 5.3.4 shall take place simultaneously.
6.0.0 SGC TURBINE (MAA00EC001):
The sub group control turbine, during start-up executes the tasks, which comprises of
warming up the turbine, speed increase, synchronization and subsequent block
loading. This subgroup also shuts down the turbine, which comprises of unloading,
closure of steam supply to turbine, isolation from grid and bringing the turbine drains to
desired position. The start-up and shut down are accomplished in a number of
sequential steps, which are described below.
6.1.0 OPERATION:
If the operator switches ON SGC and presses manual PB for operation i.e. start-up the
program would proceed to execute the steps in a sequential order after seeking the
availability of Release criterion.
STEP 1:

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The SGC EHA oil supply is switched ON and its readiness is checked before
proceeding to step 2.
STEP 2:
Here the operation readiness for bypass operation is checked. Readiness means:
- Condenser vacuum is less than 0.6 bar(A)
- LP bypass trip is not actuated.
- Condensate system check.
- Cooling water system check.
STEP 3:
LP bypass control and automatic set point matching (ASM) are switched ON. This
ensures opening of LP bypass control valves and the spray water injection valve.
STEP 4:
Command is issued for switching ON SLC drains (MAL00EE001); SLC warm-up drains
(MAL10EE001) and HP exhaust temperature control ON and Auto.
STEP 5:
Before warming up operation all valves and NRV positions are checked during this
step, it checks for closing of all turbine stop valves and control valves, Closing of CRH
NRV’s, Closing of all Extraction NRV’s. (Which is over ridden if generator load > 10%).
STEP 6:
Essential secondary systems are checked before commencing the warming operation
in this step.
That is it checks the following:
- Turbine trip is not operated.
- One of the oil vapours exhaust fans is ON (MAV82AN001 / MAV82AN002).
- Lube oil coolers outlet temperature (MAV42CT001) greater than 35°C.

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- SLC drains no fault.
STEP 7:
SLC warming control is switched OFF and drains before HP control valves are closed.
STEP 8:
In this step it waits for the following parameters to be satisfied before opening the
turbine stop valves warming in Main steam line.
- Live steam minimum flow (LBA00CF001).
- Minimum superheat of steam before HP bypass (LBA10CT901) ensured.
- Minimum superheat of steam before LP bypass (LBB10CT901) ensured.
- X1, X2, X3criterion.
- All the above conditions are bypassed for cold start i.e. of wall temperature HP
control valve < 100°C.
The remaining parameters to be satisfied before proceeding to next step are:
- Boiler fire is ON.
- Condenser pressure (MAG01CP005) is less than 0.5 KG/CM2(Abs).
- Barring operation checked (i.e. speed > 15 rpm).
STEP 9:
Emergency stop valves are opened by raising the starting device (Turbine startup and
lift limit equipment or TSLLE) set point.
The TSLLE can be operated from the main control room. The turbine startup and
limiting device (TSLLE) has the following tasks:
a) Holding and triggering of central tripping system.
b) Providing an analogous position value for each control valve for limiting the
valve position.
c) Providing blocking signals for the actuator unit HP/IP control for the opening and
closing of stop-valves.
STEP 10:
Actual opening of emergency stop valve is checked.

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STEP 11:
Gland pressure control on Auto is checked. Also whether one of the oil vapour exhaust
fans ON and SLC drain ‘no fault’ is checked.
STEP 12:
This is a dummy step, which can be used in future if required.
STEP 13:
SLC warm up control is switched ON. It is essentially a waiting step for suitable
parameters for opening the governing valve to be satisfied. The suitable parameters
are
- Minimum steam flow (LBA00CF001) is checked.
- X4 criterion satisfied (i.e. minimum temperature measured before ESV)
- X5 criterion satisfied (MS temperature before HP ESV greater than HP rotor
temperature)
- X6 criterion satisfied (MS temperature before HP ESV greater than IP rotor
temperature).
- HP valve body drain is checked (it is bypassed if HP valve body temperature is
greater than 370°C)
- Turbine speed greater than 15 RPM.
- Condenser pressure trip not operated.
- HP casing Top/Bottom differential temperature not high.
- Superheat temperature before LP bypass greater than 30 deg K.
- Load set point greater than 10%.
- Steam purity is checked.

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STEP 13:
Turbine speed set point is raised upto 690 RPM.
STEP 14:
Actual speed is checked for reaching upto 630 RPM.
STEP 15:
It is a waiting step for suitable warm up of turbine to go to rated speed. Minimum
waiting time is 180 sec. It checks for the following conditions to be satisfied.
- X7 criterion satisfied
- Minimum upper temperature margin greater than 30 deg K.
- HP Casing flange temperature greater than 60 deg C.
- DT (HP shaft surface / mean) < 12 deg K
STEP 16:
Turbine speed set point raised upto 3030 rpm and drains before HP control valves are
closed.
STEP 17:
Actual turbine speed is checked to have reached 2940 rpm. (It can be bypassed if gen.
Brk. is closed)
STEP 18:
AVR is put on Auto and it is checked.
STEP 19:
Here the generator readiness for excitation is checked.
STEP 20:
This is a waiting step for suitable warming of the turbine to take a minimum load. It
checks the following criterion.
- Criterion X 8 checked.

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- Any other generator criterion for synchronization is checked.
STEP 21:
Synchroniser is “ON” and generator breaker closed condition is checked before
proceeding to next step.
STEP 22:
Starting device (TSLLE) is raised to 100% to remove the valve limitation.
STEP 23:
Power set point is raised and checked for the generator is carrying a load greater than
10% for more than a second.
STEP 24:
It is the end step which completes operation sequence.
6.1.1 SHUTDOWN:
The shutdown sequence can be started by operator manually or automatically on
protection.
STEP 51:
SLC drains (MAL00EE001) is switched ON and it is checked.
STEP 52:
In this step power set point is lowered upto 0% value, so that speed controller takes
over the control.
STEP 53:
Speed set point is lowered.
STEP 54:

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Turbine trip channel is actuated, synchronizer is put OFF AVR is put on Auto, drain
before HP control valves are closed.
STEP 55:
Starting device is lowered upto 0% and SGC control oil supply shutdown is initiated.
STEP 56:
It is the last step.
The programme logic ends here and the programme would remain stay put in this step.
6.1.2 SLC TURBINE DRAINS (MAL00EE001):
SLC drains is switched ON from step No.1 and 51 of SGC turbine (MAA00EC001) and
/ or SGC condensate and evacuation (MAY01EC001) system.
6.1.2.1 Drain valves after HP control valve 1 and 2
SLC opens the drain valves after HP control valve 1 and 2. If the following criterion are
satisfied.
a) Differential temperature between HPCV & wet steam is less than 20 deg K and
b) HP control valve 2 is closed.
If the command for opening the drain valves exist and these drain valves do not open,
an alarm signal is generated and also used as SLC drain fault signal. Drain valves
after HP control valve 1 & 2 closed by SLC if the criteria are available.
a) Differential temperature between HPCV and wet steam is greater than 50 deg K
and
b) HP control valve 2 is not closed.
6.1.3 DRAIN VALVES BEFORE AND AFTER INTERCEPTOR 1 & 2:
The valves get opened by SLC if

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a) IP control valve is closed and
b) Differential temperature of IP stop valves and wet steam is less than 20 deg K.
These valves are closed by SLC if
a) Interceptor valve 2 temperatures is hotter than hot reheat saturation temperature
by 50 deg K.
b) Interceptor valve is not closed.
6.1.4 DRAIN VALVES NRV IN COLD REHEAT LINES LEFT AND RIGHT HAND:
Drain valves are given a command to open by the SLC if any of the NRV is closed or
not fully open. These drain valves are closed by the SLC if both the NRV’s are open.
6.1.5 GLAND STEAM HEADER DRAIN (MAL81AA011):
This drain valve is given a command to open if one of the two-gland steam temperature
measured by two sensors is below 120oC.
Gland steam drain valve is closed by SLC if temperature of gland steam measured by
both the sensors reaches above 1500C.
6.1.7 DRAIN VALVES IN EXTRACTION A5 (MAL47AA011), A3 (MAL54AA011):
SLC issues a command to, open this drain valve under the condition that generator
load is less than 2% or respective extraction valve is less than 5% open. For closing
this drain valve SLC checks that both generator load is more than 10% and respective
extraction valve is more than 15% open.
6.1.8 DRAIN VALVE IN EXTRACTION A4 (MAL51AA011):
SLC issues command to open the drain valve under condition that extraction valve A4
is open by less than 5% or differential pressure across extraction valve A4 is less than

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TCI-AA078-16
10m bar. As extraction valve A4 is connected to deaerator this criteria will be present
upto the turbine takes sufficient load.
Similarly to close this valve program seeks that extraction valve A4 is more than 15%
open and differential pressure across extraction valve A4 is more than 32m bar.
6.1.9 DRAINS FROM, HP EXHAUST (MAL30AA011) AND IP EXTRACTION INSERT
(MAL35AA011):These drains are closed when the corresponding temperatures are
more than 50 deg K than saturation steam temperature and opens when the
corresponding temperature is less than 20 deg K than saturation temperature.
6.1.10 DRAIN FROM HP/IP CASING (MAL34AA011):
The drain is closed when the casing Top, bottom temperatures are more than 320 deg
C and opened when these temperatures are less than 300 deg C.
6.1.11 GLAND STEAM WARMUP DRAIN (MAW10AA011):
It is opened if the difference between temperature ahead of seal steam supply valve
and set point is smaller than a adjustable value. The set point is generated from
maximum value selection of saturated steam temperature and a variable set point
depending on average shaft temperature.
It is closed when the steam temperature ahead of seal steam supply valve is more than
adjustable value above set point and pressure ahead seal steam supply valve exceeds
minimum pressure.
6.1.12 SLC DRAINS FAULT:
If SLC commands a drain valve to open but actually it does not open within 200
seconds then a signal is generated called “SLC drains fault”.
6.2 VACUUM BREAKER CONTROL VALVE:
The vacuum breaker valve in the condenser has the task of essentially reducing the
coast down time of turbo generator set in case of turbine trip due to :

HINDALCO -
TCI-AA078-16
i) Shaft vibration too high.
ii) Bearing temperature too high.
iii) Axial displacement too high.
iv) Fire protection responded.
By reducing the coast down time the extent of possible consequential failures can be
kept low in emergency. The ingress of air through the opening the vacuum breaker
valve as well as the steam which is led into the condenser through the LP bypass
station brings about a quicker increase in condenser pressure.
In order to protect the end stages of LP turbine the condenser pressure is restricted by
open/ close of the valve as a function of speed. This action takes place automatically.
With vacuum breaker valve open/close as a function of speed the coasting down time
is almost the same as with the valve continuously open.
The opening and/or closing of the vacuum breaker takes place with the help of solenoid
valve operated pneumatic actuator either automatically as described above or
manually. The vacuum breaker valve can be manually opened/closed from the control
room. The switch open by hand is stored and released with the enabling signal.
6.3 NON-RETURN VALVE (NRV):
Non-return valves can be controlled by auxiliary means or may swing freely. A solenoid
valve is assigned to each NRV with auxiliary drive for control.
Solenoid valve open (energize) – means to release the NRV in the direction of opening.
Solenoid valve close (de-energize) – means to apply closing force to the NRV.
The closing action of the NRV is taken for the following criteria:
a) Water level “high high” of the corresponding preheater.
b) Differential pressure between the NRV’s “high”. This criteria applies to
extraction lines to deareator.

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TCI-AA078-16
c) The NRV’s are automatically closed after certain output (corresponding to
control valve position set point). The NRV’s of HP extractions are
controlled by limit signal of position set point of live steam control valve,
and the NRV’s of IP/LP extractions by that of position setpoint of intercept
control valve.
d) Turbine trip command from turbine protection.
e) Manual close command.
Opening of NRV can be done manually or automatically when position set point of
control valve (NRV of HP extractions by HP control valve and NRV of IP extractions by
IP control valve) is greater than 15% provided the release criteria of corresponding
preheater level is less than high level.
6.4 LP EXHAUSTHOOD SPRAY WATER SOLENOID VALVE (MAC01AA001):
In case of condensation turbine, the temperature in the exhaust steam nozzle should
not exceed a preset limiting value.
Water injection is controlled by means of solenoid valve. The solenoid valve is opened
when
a) In case of LP casing wall temperature (MAC10CT071) > 90 0C.
The Solenoid valve is closed when
a) Turbine speed n < 47.5 /sec
b) Turbine load > 10% of (Rated load).
6.5 CRH NRV:
Two NRV’s are provided in the steam pipe between HP-turbine stage and reheater.
The control is executed depending upon the position set point of the live steam control
valve through two solenoid valves arranged in 1 of 2 arrangements. The NRV’s are

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TCI-AA078-16
closed when the position set point live steam control valve is < 17% and opened when
the position set point live steam control valve is > 22%.
For verification of operability, a push button “Testing release of CRH NRV” is available
in the control room for each NRV. The actuation of the PB is stored. The release signal
enables ATT to test the CRH NRVs. The ATT signal controls both solenoid valves (1-
of-2) in closing direction. The monitoring of actuation time is activated while the 100%
position, if the NRV does not reach a certain intermediate position in the reset time
then an alarm signal is generated in the control room.
6.6 FIRE PROTECTION (FP):
In the event of fire, to reduce hazards the Fire protection has to be actuated manually.
This has two channels. Each channel is operated in duplicated command channel as
well as duplicated logic circuits for redundancy. The fire protection is initiated from
push buttons is main control room or in machine building.
6.6.1 FIRE PROTECTION CH1 & CH2:
On operation of any of the push buttons citied above commands are issued to do the
following:
- Turbine trip channel ON.
- SLC main oil pumps,
Main oil pumps, lifting oil pump1, SLC lifting oil pumps, SLC AC EOP.
AC EOP are switched off.
- EHA control unit emergency off.
- DC Emergency oil pump and DC lifting oil pump2 and sol. VIV from
turning gear are switched ON.
- SGC oil supply is switched Off.

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TCI-AA078-16
- Vacuum breaker valve is opened.
X – CRITERIA
6.6.2 CRITERIA X1 : THIS CRITERIA SHALL BE CHECKED BEFORE OPENING OF ESV

Criterion : Main steam temperature is greater than Midwall temperature of main steam
control valve by X1.

Criterion: Main steam saturated temperature is greater than Midwall temperature of
main steam control valve by X2.

Criterion: Main steam temperature is greater than Mean wall temperature of main
steam strainer by X3
6.6.5 CRITERIA X4 : THIS CRITERIA SHALL BE CHECKED BEFORE OPENING OF

CONTROL VALVES
Criterion: Main steam temperature is greater than main steam saturated temperature
by X4.
6.6.6 CRITERIA X5 : THIS CRITERIA SHALL BE CHECKED BEFORE OPENING OF

CONTROL VALVES
Criterion: Main steam temperature is greater than Mean rotor temperature of high-
pressure shaft (simulated).
6.6.7 CRITERIA X6: THIS CRITERIA SHALL BE CHECKED BEFORE OPENING OF

CONTROL VALVES
Criterion: Reheat steam temperature is greater than Mean rotor temperature of
intermediate pressure shaft (simulated).
6.6.8 CRITERIA X7 : THIS CRITERIA SHALL BE CHECKED BEFORE SPEEDING UP TO

RATED SPEED
Criterion : Differential temperature of Main steam temperature and Mean rotor
temperature of high pressure shaft (simulated) shall be less than X7.
6.6.9 CRITERIA X8 : THIS CRITERIA SHALL BE CHECKED BEFORE LOADING THE

GENERATOR
Criterion : Differential temperature of Reheat steam temperature and Mean rotor
temperature of intermediate pressure shaft (simulated) shall be less than X8.

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TCI-AA078-16
RECORDS OF REVISION
REV. DATE REVISION DETAILS REVISED APPROVED

NO.
00 08.04.10 ISSUE
P.S.V.S

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TCI-AA078-16

WRITEUP ON ATRS Sheet 1 Of 28

TITLE: WRITE-UP ON ATRS LOGIC DIAGRAMS.

OWNER: HINDALCO INDUSTRIES LIMITED

CONSULTANT: DEVELOPMENT CONSULTANTS PVT. LTD.

REF. DRG. ATRS LOGIC DIAGRAMS:3-133-00-62112

FORMAT Prepared by: Checked by: Approved by: Date:

3.0 SYSTEM DESCRIPTION

4.0 SGC OIL SUPPLY

5.0 SGC CONDENSATE AND EVACUATION

6.0 SGC TURBINE

LUBE OIL SCHEME DRG.NO. 2-131-00-90301

HYDRAULIC SUPPLY UNIT DRG.NO. 1-131-00-90309

HP/IP TURBINE SCHEME DRG.NO.1-131-00-90318

TSI SCHEME DRG.NO. 2-133-00-62027

REF-DOC COPYRIGHT AND CONFIDENTIAL

high a level as possible.

For startup acquisition and analysis of a wide variety of information pertaining to

(Please refer console OGA for the EDN).

controls (SLC) and control interface (CI).

2.1.2 SUB GROUP CONTROL (S.G.C.) :

A subgroup control executes commands, to bring the equipment upto a particular

REF-DOC COPYRIGHT AND CONFIDENTIAL

1) operator guide mode 2) step mode.

Operator guide mode:

interface. Commands must be issued manually. This mode is useful for

commissioning and training.

2.1.3 CONTROL INTERFACE:

REF-DOC COPYRIGHT AND CONFIDENTIAL

blocking of command output by protectective logic.

SUBLOOP CONTROL (SLC):

No sequential logic is involved. SLC can be switched ON/OFF either manually or

3.0.0 SYSTEM DESCRIPTION:

4.0.0 SGC OIL SUPLY SYSTEM (MAV10EC001):

ensuring the Lubricating oil under various circumstances. The programme is

accomplished through a number of steps and SLCs.

Oil tank level is above min (MAV10CL021, MAV10CL022) is available.

REF-DOC COPYRIGHT AND CONFIDENTIAL

(MAV21AP021, MAV21AP022) and oil vapour exhaust fans (MAV82AN001,

MAV82AN002) must be in operation.

pressure oil from the lifting oil pump.

4.2.0 SHUT DOWN:

REF-DOC COPYRIGHT AND CONFIDENTIAL

temperature (MAV01EP154) and HP inner casing temperature (MAA50CT011) is less

before the program goes to 54.

SLC lifting oil pumps are switched OFF.

OVEF (MAV82EE001), Main oil pumps (MAV21AP021, MAV21AP022), AC EOP

(MAV25AP001), OVEF 1 & 2 (MAV82AN001 & MAV82AN002) and sol-valve turning

gear are switched off.

This is the last step of shut down program.

4.3.0 SLC MAIN OIL PUMPS (MAV21EE001):

REF-DOC COPYRIGHT AND CONFIDENTIAL

4.4.0 SLC EMERGENCY OIL PUMP (MAV24EE001):

independent pressure switch (MAV42CP012) shall give direct command to DC starter

the non-availability of 24 V DC supply to SLC.

4.5.0 SLC LIFTING OIL PUMP (AC) (MAV32EE001):

4.6.0 SLC LIFTING OIL PUMP (DC) (MAV31EE001):

(MAV35CP011) is below set value (less than 100kg/cm2G).

4.7.0 SLC OIL PUMP VAPOUR FANS (MAV82EE001):

5.0.0 SGC CONDENSATE AND EVACUATION (MAY01EC001):