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Abnormality Report_Final.pdf

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ankit shukla

At 14:07:08 hrs on 09.04.2023, a total power failure occurred at the GNFC complex due to an upstream breaker tripping from the MRS substation, cutting load to 12.8 MW. This caused TG-1 and TG-2 to trip at 14:28 hrs due to decreasing steam pressure and BFW flow from tripped BFP. Power was restored to emergency loads by 16:00 hrs after the DG set started and CPSU supply was fed to CPP. Normal power supply was restored at 16:51 hrs after power was restored at MRS.

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ABNORMALITY REPORT OF TOTAL POWER FAILURE-2023 Page 1 of 7 CPSU/Elect./M-103/2023 Date: 10.04.2023 Sub: Abnormality report for total power failure on 09.04.2023. Date& Time of Event: On 09.04.2023 at 14:07:08 hrs. Effect on Plant: At 14:28 Hrs, TG-1 & TG-2 tripped in island condition. Hence total power failure in GNFC complex. Description of events: Before event, TG-1 was running @ at 8.5MW (APR mode) & TG-2 was running @ 10.27MW (AFR mode/50Hz) in island condition. Total plant load was 18.9MW. GT was under shutdown, Boiler-3 and Boiler-4 were running. Boiler 1 & Boiler-2 were under shutdown. At 14:07:08 Hrs, load cut-off to 12.8 MW (TG-1= 7.09MW & TG-2 = 5.73MW). This was due to upstream breaker tripped from MRS to An-TDI 1&2; Boiler 1,2 & 3; Urea-1 & Ammonia -1 & 2 feeders. At the same time CCB contact and TG-2 isolation from grid flickers for 06 times. (TG-2, 25 A Relay & DCS event). Due to the event TG-1 (3 MVAR) & TG-2 (-2 MVAR) reactive power supply got negative, same was normalised after making Capacitor bank off from MRS. Boiler-3 tripped at 14:07:00 hrs due to Boiler 3.3 KV SWGR INC-1A, 1B, 2,3A&3B tripped on up-stream breaker contact. Boiler 1 & 2 were under shutdown. At 14:28:09:241 & 14:28:09:272 hrs; TG-1 and TG-2 tripped respectively on 86 T relay as BFW flow and steam pressure continuously on decreasing trend since 14:07:00 hrs due to BFP tripped in ammonia. Further due to decrease in frequency DAVR V/F limiter came into action and TG-1, TG-2 GCB & FCB tripped on under voltage (86U1 &U2 operated)
ABNORMALITY REPORT OF TOTAL POWER FAILURE-2023 Page 2 of 7 CPP 11 KV swgr 11 KV INC-1 & 2 tripped on line under voltage at 14:28:09 hrs and subsequently all downstream feeders of CPP & CPSU tripped on line under voltage. CPSU DG set started as per scheme at 14:28:22 Hrs. DG supply restored in CPP EMCC (C-15) as per scheme at 14:28 hrs. During total power supply failure, GT black stat-up activities started. Following equipments charged on DG power. EMCC GT MCC Bus section B & A. (INC-II & B/C- on, INC-I off) Instrument air compressor on DG power. Meanwhile, at 15:35:05 & 15:35:22 clearance received from MRS and 11kV IC-1 & IC-2 line charged respectively. Subsequently, all downstream feeders normalize except emergency supply of CPP & CPSU. At 15:44:29 both IC-1 & IC-2 of CPP tripped again on line under voltage. Further all downstream feeders tripped on line under voltage. Since DG set was not normalized in mean time, DG supply was available at CPP & CPSU. At around 15:49 hrs, running DG set-2 of ammonia plant got triped on overload. (DG-1 was already under shutdown due to lube oil problem). Hence emergency supply was not available for CPP from ammonia. Hence CPSU-CPP emergency power supply interlink charged and CPSU DG set supply fed to CPP Emergency SWGR at around 16:00 hrs. During the event, Barring gear motor -1 & 2, DC EOP- 1 & 2 for TG-1 & TG-2 and other emergency supply were running normal. 220 Volt & 110 volt Vertiv chargers, CPP & CPSU UPS, 220 VOLT & 125 volt HBL chargers were running normal. (CPP incoming MCCB once tripped due to starting current of AOP motors; MCCB-630A old sett- Ir: 0.4*In @ 2.5sec; revised sett- Ir: 0.68In@2.5sec ). At around 16:10Hrs, as per request from ammonia substation, CPP EMCC (which was charged from CPSU EMCC) DG incomer breaker made on to fed emergency power supply to ammonia DG set panel to start air compressor of DG set, to enable starting of DG set as no any power supply was available at ammonia plant. At 16:51:35 hrs CPP 11 KV SWGR INC-1 & II switched on after DGVCL power supply restored at MRS. Subsequently, normalised power supply of 3.3 KV swgr, PCC and MCC of CPP and CPSU plant.
ABNORMALITY REPORT OF TOTAL POWER FAILURE-2023 Page 3 of 7 During normalizing of power in CPSU EMCC, DG voltage and frequency synchronised with EMCC INC-2 supply (Raise / lower volt & freq by push buttons on DG incomer). At that instance Syn led lit up on inc-2 ref relay, so mechanically closed INC-2 breaker, DG inc breaker got tripped on interlock. MCO carried out by closing Inc-1 and B/c got tripped. CPSU DG set switched off at 17:20 Hrs. Clearance given to ammonia after normalizing DG IC-3 CB at C-15. Refer Annexure-A for trends and sequence of events as bellow. TG-1 GPR-R Relay events: Time Duration Event Setting 14:27:38:71 1 - 00:00:30:53 0 81-1 Picked up_ ON 14:27:39:70 7 - 00:00:29:53 4 81-1 Trip_ ON 48 HZ & 1 Sec. 14:27:58:21 0 - 00:00:11:03 1 81-2 Picked up_ ON 14:28:08:20 7 - 00:00:01:03 4 81-2 Trip_ ON 47.5 HZ &10Sec 14:28:09:2 41 00:00:00:0 00 86T Trip_ ON 14:28:11:08 5 00:00:01:84 4 24-1 v/f> picked up_ ON V/F -1.10 (Reduce excitation) 14:28:20:32 2 00:00:11:08 1 27-1 Under voltage V < picked up_ ON 87.3 % V 14:28:21:08 2 00:00:11:84 1 24-1 v/f> warning stage_ ON V/F -1.10 & 10 sec. 14:28:21:22 2 00:00:11:98 1 27-1 Under voltage V < Trip_ ON 87.3 % & 0.9 sec.
ABNORMALITY REPORT OF TOTAL POWER FAILURE-2023 Page 4 of 7 14:28:22:47 9 00:00:13:23 8 27-2 Under voltage V << Picked up_ ON 14:28:25:4 77 00:00:16:2 36 27-2 Under voltage V << Trip_ ON 83.6 % & 3.09 sec. 14:28:25:4 82 00:00:16:2 41 86 U1U2 optd_ ON 14:28:25:54 7 00:00:16:30 6 FLCB&EXCON_ OFF 14:28:25:60 8 00:00:16:36 7 52G1 Close_ OFF TG-2 GPR-M Relay events: Time Duration Event Setting 14:27:38:73 9 - 00:00:30:53 3 81-1 Picked up_ ON 14:27:39:73 8 - 00:00:29:53 4 81-1 Trip_ ON 48 HZ & 1 Sec. 14:27:58:19 7 - 00:00:11:07 5 81-2 Picked up_ ON 14:28:08:19 3 - 00:00:01:07 9 81-2 Trip_ ON 47.5 HZ &10Sec 14:28:09:2 72 00:00:00:0 00 86T Trip_ ON 14:28:09:86 5 00:00:00:59 3 24-1 v/f> picked up_ ON V/F -1.10 (Reduce excitation) 14:28:19:43 4 00:00:10:16 2 27-1 Under voltage V < picked up_ ON 87.3 % V 14:28:19:86 3 00:00:10:59 1 24-1 v/f> warning stage_ ON V/F -1.10 & 10 sec.
ABNORMALITY REPORT OF TOTAL POWER FAILURE-2023 Page 5 of 7 14:28:20:33 3 00:00:11:06 1 27-1 Under voltage V < Trip_ ON 87.3 % & 0.9 sec. 14:28:21:66 2 00:00:12:39 0 27-2 Under voltage V << Picked up_ ON 14:28:24:6 58 00:00:15:3 86 27-2 Under voltage V << Trip_ ON 83.6 % & 3.09 sec. 14:28:24:6 83 00:00:15:4 11 86 U1U2 optd_ ON 14:28:24:73 9 00:00:15:46 7 FLCB&EXCON_ OFF 14:28:24:81 8 00:00:15:54 6 52G1 Close_ OFF Remedial action: System worked as per scheme. Supply redundancy can be explored for 125V CPSU DC and 110V CPP DC for emergency. Boiler & CPSU power link redundancy can be explored. QEHSEn (ISO 14001, 45001, 9001 & 50001) related impact: Nil
Freq. overshhots to 51.242 Hz AFR contact (CCB) status flckered, changed to APR & back 40.0 42.0 44.0 46.0 48.0 50.0 52.0 54.0 0 20 40 60 80 100 120 140 160 2:05:01 PM 2:05:15 PM 2:05:29 PM 2:05:43 PM 2:05:57 PM 2:06:11 PM 2:06:25 PM 2:06:39 PM 2:06:53 PM 2:07:07 PM 2:07:21 PM 2:07:35 PM 2:07:49 PM 2:08:03 PM 2:08:17 PM 2:08:31 PM 2:08:45 PM 2:08:59 PM 2:09:13 PM 2:09:27 PM 2:09:41 PM 2:09:55 PM 2:10:09 PM 2:10:23 PM 2:10:37 PM 2:10:51 PM 2:11:05 PM 2:11:19 PM 2:11:33 PM 2:11:47 PM 2:12:01 PM 2:12:15 PM 2:12:29 PM 2:12:43 PM 2:12:57 PM 2:13:11 PM 2:13:25 PM 2:13:39 PM 2:13:53 PM 2:14:07 PM 2:14:21 PM 2:14:35 PM 2:14:49 PM 2:15:03 PM 2:15:17 PM 2:15:31 PM 2:15:45 PM 2:15:59 PM 2:16:13 PM 2:16:27 PM 2:16:41 PM 2:16:55 PM 2:17:09 PM 2:17:23 PM 2:17:37 PM 2:17:51 PM 2:18:05 PM 2:18:19 PM 2:18:33 PM 2:18:47 PM 2:19:01 PM 2:19:15 PM 2:19:29 PM 2:19:43 PM 2:19:57 PM 2:20:11 PM 2:20:25 PM 2:20:39 PM 2:20:53 PM 2:21:07 PM 2:21:21 PM 2:21:35 PM 2:21:49 PM 2:22:03 PM 2:22:17 PM 2:22:31 PM 2:22:45 PM 2:22:59 PM 2:23:13 PM 2:23:27 PM 2:23:41 PM 2:23:55 PM 2:24:09 PM 2:24:23 PM 2:24:37 PM 2:24:51 PM 2:25:05 PM 2:25:19 PM 2:25:33 PM 2:25:47 PM 2:26:01 PM 2:26:15 PM 2:26:29 PM 2:26:43 PM 2:26:57 PM 2:27:11 PM 2:27:25 PM 2:27:39 PM 2:27:53 PM 2:28:07 PM 2:28:21 PM Parameters Trend_CPP TG1_MW TG2_MW MS Pressure B#4 BFW pressure Total Power Load MW Frequency (Refer secondary Y axis for frq.) TG-1 & TG-2 tripped on 86T followed by U/v (Class-A) 48Hz+200ms; Step-1 Load shedding at s/s level 47.9Hz+400ms; Step-2 Load shedding at s/s level Before the Event Scenario Following feeders tripped from MRS: - Ammonia-1 /Ammonia-2 - Boiler-1/Boiler-2/Boiler-3 - AniTD-1/AniTDI-2 & Urea-2 Freq. overshhots to 51.242 Hz and then stablised at 50.3 Hz AFR contact (CCB) status flckered, changed to APR & back Freq. decay due to BFW press low Annexurte-A

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Abnormality Report_Final.pdf

  • 1. ABNORMALITY REPORT OF TOTAL POWER FAILURE-2023 Page 1 of 7 CPSU/Elect./M-103/2023 Date: 10.04.2023 Sub: Abnormality report for total power failure on 09.04.2023. Date& Time of Event: On 09.04.2023 at 14:07:08 hrs. Effect on Plant: At 14:28 Hrs, TG-1 & TG-2 tripped in island condition. Hence total power failure in GNFC complex. Description of events: Before event, TG-1 was running @ at 8.5MW (APR mode) & TG-2 was running @ 10.27MW (AFR mode/50Hz) in island condition. Total plant load was 18.9MW. GT was under shutdown, Boiler-3 and Boiler-4 were running. Boiler 1 & Boiler-2 were under shutdown. At 14:07:08 Hrs, load cut-off to 12.8 MW (TG-1= 7.09MW & TG-2 = 5.73MW). This was due to upstream breaker tripped from MRS to An-TDI 1&2; Boiler 1,2 & 3; Urea-1 & Ammonia -1 & 2 feeders. At the same time CCB contact and TG-2 isolation from grid flickers for 06 times. (TG-2, 25 A Relay & DCS event). Due to the event TG-1 (3 MVAR) & TG-2 (-2 MVAR) reactive power supply got negative, same was normalised after making Capacitor bank off from MRS. Boiler-3 tripped at 14:07:00 hrs due to Boiler 3.3 KV SWGR INC-1A, 1B, 2,3A&3B tripped on up-stream breaker contact. Boiler 1 & 2 were under shutdown. At 14:28:09:241 & 14:28:09:272 hrs; TG-1 and TG-2 tripped respectively on 86 T relay as BFW flow and steam pressure continuously on decreasing trend since 14:07:00 hrs due to BFP tripped in ammonia. Further due to decrease in frequency DAVR V/F limiter came into action and TG-1, TG-2 GCB & FCB tripped on under voltage (86U1 &U2 operated)
  • 2. ABNORMALITY REPORT OF TOTAL POWER FAILURE-2023 Page 2 of 7 CPP 11 KV swgr 11 KV INC-1 & 2 tripped on line under voltage at 14:28:09 hrs and subsequently all downstream feeders of CPP & CPSU tripped on line under voltage. CPSU DG set started as per scheme at 14:28:22 Hrs. DG supply restored in CPP EMCC (C-15) as per scheme at 14:28 hrs. During total power supply failure, GT black stat-up activities started. Following equipments charged on DG power. EMCC GT MCC Bus section B & A. (INC-II & B/C- on, INC-I off) Instrument air compressor on DG power. Meanwhile, at 15:35:05 & 15:35:22 clearance received from MRS and 11kV IC-1 & IC-2 line charged respectively. Subsequently, all downstream feeders normalize except emergency supply of CPP & CPSU. At 15:44:29 both IC-1 & IC-2 of CPP tripped again on line under voltage. Further all downstream feeders tripped on line under voltage. Since DG set was not normalized in mean time, DG supply was available at CPP & CPSU. At around 15:49 hrs, running DG set-2 of ammonia plant got triped on overload. (DG-1 was already under shutdown due to lube oil problem). Hence emergency supply was not available for CPP from ammonia. Hence CPSU-CPP emergency power supply interlink charged and CPSU DG set supply fed to CPP Emergency SWGR at around 16:00 hrs. During the event, Barring gear motor -1 & 2, DC EOP- 1 & 2 for TG-1 & TG-2 and other emergency supply were running normal. 220 Volt & 110 volt Vertiv chargers, CPP & CPSU UPS, 220 VOLT & 125 volt HBL chargers were running normal. (CPP incoming MCCB once tripped due to starting current of AOP motors; MCCB-630A old sett- Ir: 0.4*In @ 2.5sec; revised sett- Ir: 0.68In@2.5sec ). At around 16:10Hrs, as per request from ammonia substation, CPP EMCC (which was charged from CPSU EMCC) DG incomer breaker made on to fed emergency power supply to ammonia DG set panel to start air compressor of DG set, to enable starting of DG set as no any power supply was available at ammonia plant. At 16:51:35 hrs CPP 11 KV SWGR INC-1 & II switched on after DGVCL power supply restored at MRS. Subsequently, normalised power supply of 3.3 KV swgr, PCC and MCC of CPP and CPSU plant.
  • 3. ABNORMALITY REPORT OF TOTAL POWER FAILURE-2023 Page 3 of 7 During normalizing of power in CPSU EMCC, DG voltage and frequency synchronised with EMCC INC-2 supply (Raise / lower volt & freq by push buttons on DG incomer). At that instance Syn led lit up on inc-2 ref relay, so mechanically closed INC-2 breaker, DG inc breaker got tripped on interlock. MCO carried out by closing Inc-1 and B/c got tripped. CPSU DG set switched off at 17:20 Hrs. Clearance given to ammonia after normalizing DG IC-3 CB at C-15. Refer Annexure-A for trends and sequence of events as bellow. TG-1 GPR-R Relay events: Time Duration Event Setting 14:27:38:71 1 - 00:00:30:53 0 81-1 Picked up_ ON 14:27:39:70 7 - 00:00:29:53 4 81-1 Trip_ ON 48 HZ & 1 Sec. 14:27:58:21 0 - 00:00:11:03 1 81-2 Picked up_ ON 14:28:08:20 7 - 00:00:01:03 4 81-2 Trip_ ON 47.5 HZ &10Sec 14:28:09:2 41 00:00:00:0 00 86T Trip_ ON 14:28:11:08 5 00:00:01:84 4 24-1 v/f> picked up_ ON V/F -1.10 (Reduce excitation) 14:28:20:32 2 00:00:11:08 1 27-1 Under voltage V < picked up_ ON 87.3 % V 14:28:21:08 2 00:00:11:84 1 24-1 v/f> warning stage_ ON V/F -1.10 & 10 sec. 14:28:21:22 2 00:00:11:98 1 27-1 Under voltage V < Trip_ ON 87.3 % & 0.9 sec.
  • 4. ABNORMALITY REPORT OF TOTAL POWER FAILURE-2023 Page 4 of 7 14:28:22:47 9 00:00:13:23 8 27-2 Under voltage V << Picked up_ ON 14:28:25:4 77 00:00:16:2 36 27-2 Under voltage V << Trip_ ON 83.6 % & 3.09 sec. 14:28:25:4 82 00:00:16:2 41 86 U1U2 optd_ ON 14:28:25:54 7 00:00:16:30 6 FLCB&EXCON_ OFF 14:28:25:60 8 00:00:16:36 7 52G1 Close_ OFF TG-2 GPR-M Relay events: Time Duration Event Setting 14:27:38:73 9 - 00:00:30:53 3 81-1 Picked up_ ON 14:27:39:73 8 - 00:00:29:53 4 81-1 Trip_ ON 48 HZ & 1 Sec. 14:27:58:19 7 - 00:00:11:07 5 81-2 Picked up_ ON 14:28:08:19 3 - 00:00:01:07 9 81-2 Trip_ ON 47.5 HZ &10Sec 14:28:09:2 72 00:00:00:0 00 86T Trip_ ON 14:28:09:86 5 00:00:00:59 3 24-1 v/f> picked up_ ON V/F -1.10 (Reduce excitation) 14:28:19:43 4 00:00:10:16 2 27-1 Under voltage V < picked up_ ON 87.3 % V 14:28:19:86 3 00:00:10:59 1 24-1 v/f> warning stage_ ON V/F -1.10 & 10 sec.
  • 5. ABNORMALITY REPORT OF TOTAL POWER FAILURE-2023 Page 5 of 7 14:28:20:33 3 00:00:11:06 1 27-1 Under voltage V < Trip_ ON 87.3 % & 0.9 sec. 14:28:21:66 2 00:00:12:39 0 27-2 Under voltage V << Picked up_ ON 14:28:24:6 58 00:00:15:3 86 27-2 Under voltage V << Trip_ ON 83.6 % & 3.09 sec. 14:28:24:6 83 00:00:15:4 11 86 U1U2 optd_ ON 14:28:24:73 9 00:00:15:46 7 FLCB&EXCON_ OFF 14:28:24:81 8 00:00:15:54 6 52G1 Close_ OFF Remedial action: System worked as per scheme. Supply redundancy can be explored for 125V CPSU DC and 110V CPP DC for emergency. Boiler & CPSU power link redundancy can be explored. QEHSEn (ISO 14001, 45001, 9001 & 50001) related impact: Nil
  • 6. Freq. overshhots to 51.242 Hz AFR contact (CCB) status flckered, changed to APR & back 40.0 42.0 44.0 46.0 48.0 50.0 52.0 54.0 0 20 40 60 80 100 120 140 160 2:05:01 PM 2:05:15 PM 2:05:29 PM 2:05:43 PM 2:05:57 PM 2:06:11 PM 2:06:25 PM 2:06:39 PM 2:06:53 PM 2:07:07 PM 2:07:21 PM 2:07:35 PM 2:07:49 PM 2:08:03 PM 2:08:17 PM 2:08:31 PM 2:08:45 PM 2:08:59 PM 2:09:13 PM 2:09:27 PM 2:09:41 PM 2:09:55 PM 2:10:09 PM 2:10:23 PM 2:10:37 PM 2:10:51 PM 2:11:05 PM 2:11:19 PM 2:11:33 PM 2:11:47 PM 2:12:01 PM 2:12:15 PM 2:12:29 PM 2:12:43 PM 2:12:57 PM 2:13:11 PM 2:13:25 PM 2:13:39 PM 2:13:53 PM 2:14:07 PM 2:14:21 PM 2:14:35 PM 2:14:49 PM 2:15:03 PM 2:15:17 PM 2:15:31 PM 2:15:45 PM 2:15:59 PM 2:16:13 PM 2:16:27 PM 2:16:41 PM 2:16:55 PM 2:17:09 PM 2:17:23 PM 2:17:37 PM 2:17:51 PM 2:18:05 PM 2:18:19 PM 2:18:33 PM 2:18:47 PM 2:19:01 PM 2:19:15 PM 2:19:29 PM 2:19:43 PM 2:19:57 PM 2:20:11 PM 2:20:25 PM 2:20:39 PM 2:20:53 PM 2:21:07 PM 2:21:21 PM 2:21:35 PM 2:21:49 PM 2:22:03 PM 2:22:17 PM 2:22:31 PM 2:22:45 PM 2:22:59 PM 2:23:13 PM 2:23:27 PM 2:23:41 PM 2:23:55 PM 2:24:09 PM 2:24:23 PM 2:24:37 PM 2:24:51 PM 2:25:05 PM 2:25:19 PM 2:25:33 PM 2:25:47 PM 2:26:01 PM 2:26:15 PM 2:26:29 PM 2:26:43 PM 2:26:57 PM 2:27:11 PM 2:27:25 PM 2:27:39 PM 2:27:53 PM 2:28:07 PM 2:28:21 PM Parameters Trend_CPP TG1_MW TG2_MW MS Pressure B#4 BFW pressure Total Power Load MW Frequency (Refer secondary Y axis for frq.) TG-1 & TG-2 tripped on 86T followed by U/v (Class-A) 48Hz+200ms; Step-1 Load shedding at s/s level 47.9Hz+400ms; Step-2 Load shedding at s/s level Before the Event Scenario Following feeders tripped from MRS: - Ammonia-1 /Ammonia-2 - Boiler-1/Boiler-2/Boiler-3 - AniTD-1/AniTDI-2 & Urea-2 Freq. overshhots to 51.242 Hz and then stablised at 50.3 Hz AFR contact (CCB) status flckered, changed to APR & back Freq. decay due to BFW press low Annexurte-A