Standard Operation Procedure

POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
STANDARD OPERATING PRACTICES

1X 20 MW CAPTIVE POWER PLANT
TRINETRA CEMENTS ,BANSWARA,RAJASTHAN
THERMAX
POWER DIVISION
THERMAX LTD,
PUNE
Prepared by: Thermax Limited, Power Division (O&M)
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
THERMAX LTD.
POWER DIVISION (O& M)
1X 20 MW POWER PLANT
OPERATING PRESSURE: - 88 KG/ Sq. cm.
OPERATING TEMPERATURE: - 5205 Degree C.
STEAM GENERATION: - 95 TPH BFG BOILER
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
THIS SECTION COVERS BOILER ACCESSORIES AND

MOUNTING DETAILS & SOP
WATER TUBE,
SINGLE DRUM, TOP SUPPORTED,
CFBC BOILER
OPERATING PRESSURE: - 43.0 Kg. / SQ.CM.
OPERATING TEMPERATURE: - 4405 0 CEN.
STEAM GENERATION: - 22 TPH BFG FIRED BOILER
SAFETY VALVES
NOS.-03
DESCRIPTION
DRUM 1
DRUM 2
SH
MAKE
TYCO SANMAR LTD.
TYCO SANMAR LTD.
TYCO
LTD.
SET PR.
53 KG/CM2
54 KG/CM2
50.5 KG/CM2
TAG NO.
1-PSV 2196
1-PSV 2197
1-PSV 2193
RELIEVING CAP.
9680 KG/HR
9680 KG/HR
4840 KG/HR
TYPE
SPRING LOADED
SPRING LOADED
SPRING LOADED
SIZE ORIFICE
1.5 H2 3
1.5 H2 3
1.5 H2 3
FLUID
SAT. STEAM
SAT. STEAM
SH STEAM
SANMAR
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
OPERATING TEMP.
270C
BOILER FEED PUMPS
SOP
270C
NOS.-02
MAKE
KSB PUMPS, PUNE
TYPE
HAD 50/14
SL. NO.
5111016442
CAPACITY
27 M3 /HR.
HEAD
655 MTRS
SPEED
2900 RPM
PUMP POWER
76.9 KW
BEARING OIL
SERVO VG 46
SPECIFIC GRAVITY
0.9429
SHUT OFF HEAD

NPSH
772 M
4.1 M
NOM.EFFICIENCY
60%
SHAFT SEAL TYPE &

SIZE
MOTOR
MECHANICAL
SEAL,ESSIL NFAF
P13
CGL(90KW/2960)
COUPLING
MAKE/TYPE/SIZE
BFP MOTOR BRG.
D.E./ND.E
MAKE RATHI/GEAR
TYPE WITH SPACER
6315 FOR BOTH
ENDS
BURNER
445C
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
MAKE
SOP
THERMAX BABCOCK
AND WILCOX LTD.
FORCED
OPERATING
DRAUGHT TYPE
TYPE OF AIR
CONTROL
ACCOSSORIES
AIR QUANTITY FOR
BURNER
EXCESS AIR
FUEL FLOW AT
MCR(INDICATIVE)
NO.OF FLAME
SCANNER
LEAD LAG
ARRANGEMENT,VALVE
AT FAN SUCTION
CONTROL
24805KG/HR FOR BFG
33% BFG
33117 KG/HR (100%) BFG
2NOS
DM WATER TRANSFER PUMP 02

MAKE
GRUNDFOS
MODEL NO
A96571029P10938
TYPE
CRNCM5-13A-FGJ-G-VHQQV
DISCHARGE
5.8 M3 /HR
HEAD
66.1 MTRS
SPEED
2899 RPM
MOTOR MAKE
CG
MOTOR TYPE
MMG0901-2-24-FT-115-E2
MOTOR
POWER
2.2 KW
BRG.D.E/N.D.E
6305ZZ/6205ZZ
FANS
DUTY
CONDITION
UNIT
MAKE
MODEL
QUANTITY
NO.
FD FAN
ID FAN
SCANNER COOILNG
FAN
FLAKTWOOD(INDIA)
LTD.
HABB-7-063-115-02-6-1
FLAKTWOOD(INDIA)
LTD.
HABB-7-112-183-04-18
1X100%
FLAKTWOOD(INDIA)
LTD.
HD-8-41-C-R3
1X100%
2X100%
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
NATURE OF
MEDIUM
DESIGN MASS
AIRFLOW
AIR TEMP. AT
FAN INLET
ABSORBED
POWER AT
OPERATING
TEMP.WITH
SPEED
CONTROL
FAN SPEED
SOP
CLEAN AIR
CLEAN AIR
CLEAN AIR
KG/SEC
8.3
19.3
0.07M/SEC
DEG.CEN.
55
195
40
KW
35
95
1.3
RPM
1447
980
2900
22218 CK,
HOUSING SNA 518
,SAME FOR BOTH
ENDS
45KW,4 POLE,FRAME
SIZE-ND 250M,MAKE
CG
RESILIENT
TYPE,MAKE-GBM
NO-8MC-108Z-MZ67
22222 EK/C3
HOUSING SNA 522,
SAME FOR BOTH
ENDS
110KW,6
POLE,FRAME SIZEND 315 LX,MAKE CG
RESILIENT
TYPE,MAKE-GBM
NO-11MC111Z-M-308
HOUSING NO. SNA

508-607,BRG.FOR
OUTLET DAMPER
FL204(UC 202)
3.7 KW,2 POLE,
,MAKE MARATHON
FREE/FIXED
BEARING
MOTOR
COUPLING
MODEL
/MAKE
RESILIENT
TYPE,MAKE-GBM
NO-IFC-101ZK-K18/35
LP DOSING SYSTEM
SL
NO.
DESCRIPTION
PARAMETER
HP DOSING SYSTEM
LP DOSING SYSTEM
MAKE
RAVI INDUSTRIES
RAVI INDUSTRIES
I.D.750X750HTX5THK./300LI
T.
0-10LPH. 61 KG/CM
I.D.750X750HTX5THK./300LIT
TANK(SS) SIZE
VOLUME
PUMP
CAPACITY/PRESSURE
PUMP MAKE
METACHEM
METACHEM
TYPE & SPEED
RECIPROCATING
PLUNGER,VARIABLE
STROKE
RECIPROCATING
PLUNGER,VARIABLE
STROKE
NO. OF PUMPS
2 SET
2 SET
0-10LPH. 6KG/CM
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
MOTOR
MOTORIED
AGITATOR / MOTOR
PRESSURE RELIF
VALVE SET
PRESSURE
SOP
0.5HP,0.37KW,1500RPM,450
V,TEFC IP55
0.5HP,0.37KW,1500RPM,450
V,TEFC IP55
75 KG/CM
0.5HP,0.37KW,1500RPM,450V,
TEFC IP55
0.5HP,0.37KW,1500RPM,450V,
TEFC IP55
10KG/CM
MOUNTINGS
DRUM GAUGE GLASS - LHS & RHS
MAKE
PRODUCT S.NO.
CHEMTROLS SAMIL (I)

PVT.LTD.
LG-2579/2578
VISIBILITY
320 MM
TAG No.
1LG-2199/2198
SIZE
1X600 #,C/C500 MM
ATTEMPERATOR
NOS. -01
ACTUATOR
MAKE
FISHER
SIZE
34 INCH
SR. NO.
TA45844
TRAVEL
INCH
VALVE BODY
MAKE
FISHER
SIZE
1 INCH
SR. NO.
TA45844
TYPE
FZ
PORT SIZE
1/4INCH
ATING
600RF
PLUG
316 SST/COCR-A FQL-2
STEM
316 SST
BODY
WCC
SEAT
316SST/COCR-A
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
SOOT BLOWER
MAKE- SITSON INDIA LIMITED
SL
NO.
DESCRIPTION
TYPE OF SOOT BLOWER

ROTARY SB
SB NUMBER
SB 1
SB 2
SB 3& 4
SB 5& 6
QUANTITY
1 EACH
1 EACH
1 EACH
1 EACH
LOCATION
PSH
SSH
ECONOMISER
BLOWING PRESSURE
KG/CM (G)
BLOWING ANGLE
DEGREES
STEAM CONSUMPTION
(KG/NOZZLE/MIN)
NOZZLE
21
21
21
CONVECTION
BANK
21
360
360
SB 3-180
SB-4-360
2
SB- 5 360
SB-6 180
2
20 ODX 20 LG
20 OD X 20 LG
20 OD X 20 LG
20 OD X 20 LG
BLOWING
TIME/BLOWER (MIN)
1&2
1&2
1&2
1&2
5
6
7
8
INDUCED DRAFT FAN (ID FAN).

START UP: For starting Boiler ID Fan proceed as stated below.
Ensure the tightness of all the foundation bolts, & the coupling bolts.
Ensure all interlocks (Motor & Fan) are Healthy.
Ensure Drum level is at NWL.
Ensure suction damper is in CLOSE condition.
Get the Required clearance from Field Engineer.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
Start the fan from LPB (LCS) or from PLC.

Open the suction damper as per requirement & observe Furnace Draft.
Check all parameters, Bearing temperatures, vibrations, Motor body
temperatures etc.
STOPPING: To Stop INDUCED DRAFT FAN follow below mentioned Steps.
Close the suction damper.
Give STOP command either from LPB (LCS) or from PLC.
ALLOWING FOR MAINTENANCE:
Local Push Button should be pressed.
Isolate from Electrical side.
FORCED DRAFT FAN (FD FAN).
START UP: For starting Boiler FD Fan proceed as stated below.
Ensure all interlocks (Motor & Fan) are Healthy.
Ensure ID fan is Running.
Ensure FD fan suction damper is in closed condition.
Ensure Furnace pressure is Normal.
Start the fan from LPB (LCS) or from PLC.
Open the suction damper as per requirement & observe the FD air flow.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
10

temperatures etc.
STOPPING: To Stop FORCED DRAFT FAN follow below mentioned Steps.
Close the Suction damper.
SCANNER COOLING AIR FAN
START UP: For starting Scanner cooling air Fan proceed as stated below.
Start the fan from LPB (LCS).
Open the manual suction damper.
temperatures etc.
STOPPING: To Stop Scanner cooling air fan follow below mentioned Steps.
Close the Suction damper.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
11

BOILER FEED WATER PUMP (BFP).
START UP: For starting Boiler Feed Water pump proceed as stated below.
Ensure Deaerator level is Healthy.
Ensure all interlocks (Motor & also Pump) are Healthy and in Service.
Pump and Motor are properly lubricated and Oil cups contain Oil up to
NORMAL LEVEL.
Keep Feed control valve (FCV) & its by-pass valve are in closed position.
Ensure CT sump level is NORMAL, CT Fans are running, ACW pump is
running.
Ensure cooling water I/L & O/L valves for Bearings cooling, Gland cooling &
etc. are opened.
Ensure SUCTION DP is below 0.2 kg/cm2.
Open SUCTION Valve.
Keep DISCHARGE valve closed.
Ensure Min Re-circulation & Balancing Leak off line Valves are opened.
START pump either from LPB (LCS) or PLC.
Gradually open DISCHARGE Valve.
Check all parameters, Bearing temperatures, vibrations, Suction/Discharge
pressures, balance leak off pressure Motor winding temperatures etc.
STOPPING: To Stop BOILER FEED PUMP follow below mentioned Steps.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
12
Isolate the feed water control valve and Discharge valve.

IF THE PUMP IS KEPT AS STAND BY:
Dont Isolate:
a).Gland Cooling Water, Bearing Cooling Water Lines.
b).Suction Valve, Balancing Leak-Off Valve, Discharge Valve,
Isolate the bearing cooling water Line valves.
Isolate Gland Cooling Water.
Isolate the Suction Valve.
Isolate Discharge and min-recirculation valves.
Isolate Balancing Leak-Off Valves.
BOILER GAUGE GLASS OPERATION
This procedure is applicable wherever maintenance activities of gauge glass has been
completed, and cleared for service. Assume that all the isolating valves on steam and
waterside are closed and drains and vents are open. Follow the below steps to take
boiler gauge glass in service.
Close gauge glass vent valve (s).
Open steam side isolation valve partly.
Allow steam to flow through drain to heat up gauge glass at least for
fifteen minutes.
Close drain and see that steam is getting condensed in the gauge glass
to build up level.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
13
When condensate level in gauge glass is found to be more than 50%,

open water side valve gradually.
See that the level is stabilized at 50% of gauge glass.
Open both steam and water side valves full.
Match level of gauge glass with that of control room indication.
TO FLUSH GAUGE GLASS

Follow the steps given below to flush the gauge glass. Flushing of gauge glass should
be carried out at least once in a day.
Close steam side valve.
See that gauge glass is filled with water.
Close waterside valve and drain valve of gauge glass.
Crack open steam side valve.
See that gauge glass gets emptied.
Repeat above said activities at least twice.
Normalize the gauge glass valves and match local level with that of
control room indication
CHARGING OF MAIN STEAM LINE:
Ensure that boiler has achieved at least 60% of its rated pressure.
Ensure that all the drain line valves are open along with steam trap by
pass.
Open MSSV by pass when the steam pressure reaches 10 Kg/cm2, and
ensure heating of line till dry steam is coming out of all the drains.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
14
Increase the pressure by throttling all the drains and heat up for another
10 min.
Once dry steam is observed to come out from all the drains, close the
steam trap by pass and keep all the traps in service.
Increase pressure of the steam line by throttling all the drains in such a
way that pressure before and after MSSV should be near about same
then open the Boiler MSSV.
Increase pressure and temperature as required for turbine start up.
It is to be noted that increase of temperature up to 300 C should be 3-5

C per minute. Above 300 C the increase of main steam line should be
5-7 C per minute.
DEAERATOR CHARGING:
Follow the steps below for charging of deaerator.
Ensure that deaerator is filled with DM water with above

60% level.
Deaerator vent is open.
Open the trap by pass drains in the Auxiliary line and

remains open till no condensate found.
Open the isolation valve of PCV slowly and operate the

PCV and TCV to maintain the 10 kg/cm2 pressure and 250C Temp.
Ensure that steam line is charged and Pegging steam line is

heated up to the Pegging steam PCV.
Open the Pegging steam PCV in such a way to maintain the

Deaerator operating pressure of 1 kg/cm2.
While charging steam to deaerator hammering/ rolling sound

will be observed from deaerator.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
15
If the sound / noise is beyond tolerable limit, reduce the

steam pressure.
See that FW temperature is gradually increasing.
SOP
Once deaerator pressure at 1 kg/cm2 is achieved and

temperature is being maintained at 120 deg C, put PCV & TCV on
auto.
If bleed steam is available for change over, proceed as
follows.
Heat up the bleed line by opening the drain lines.
Ensure that Turbine inlet steam flow is 12 TPH before

charging the bleed line.
Ensure that turbine bleed steam pressure is around 10

kg/cm2, open the QCNRV.
Ensure that the steam has charged up to the Pegging steam

PCV, and then operate the pegging steam PCV in such a way to
maintain the deaerator operating pressure.
SOP FOR CHARGING PROCESS STEAM LINE.
Ensure drain before and after Process PCV is open.

Ensure that T.G Bleed steam pressure is around 10Kg/cm2g.
Communicate with BF control room to open the header drain.
After getting clearance from BF control room open manual isolation
valve fully & maintain the pressure of 6Kg/cm2g & Flow of 1.2 TPH
through PCV & FCV.
Ensure steam flow at BF battery limit.
Close all the Trap By-Pass drain valves once it is ensured no condensate
is entrapped in the system.
Incase bleed is not available maintain the same through Boiler PRDS-1
system.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
16
SOP OF PUMPS
DM TRANSFER PUMP
START UP: For starting DM transfer pump proceed as stated below.
When a PUMP is kept in Remote & Auto MODE Its Suction & Discharge will be kept open, unless specific logic & Protection
is implemented & its minimum recirculation valve is open condition.
START UP CHECKS
Ensure clearance from maintenance and get clearance from Field Operator to
start.
Ensure DM storage tank level is Normal.
All field instruments are in service.
Ensure SUCTION valve is in OPEN condition.
Coupling Guard is in position & fastened firmly.
Ensure DISCHARGE Valve is in CLOSED condition.
Ensure Deaerator Make Up control valve & its by- pass valve are in closed
condition.
Ensure Boiler initial filling line valve is in closed condition.
Ensure its minimum recirculation valve is in open condition.
Ensure that all the protections & interlocks are in service.
Give START command by operating LPB (LCS) or from PLC.
Once Pump achieves normal speed, Open DISCHARGE valve slowly.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
17
Check for any abnormal Sound, Current, Vibration, Bearing Temperatures etc
& Record.
STOPPING: To Stop a DM transfer Pump follow below mentioned Steps.
Dont Isolate:
A).Suction Valve, Minimum Recirculation Valve, Discharge Valve,
START UP CHECKS: To Take MCW & ACW in to Service, Proceed as stated
below.
Coupling Guard is in position and fastened firmly.
Ensure all interlocks are Healthy (Motor).
Ensure that Cooling Tower sump level is up to Normal Working level.
Ensure Cooling Water Return line Valves inlet to CT is in OPEN condition.
Charge BFP cooling water, LO cooler, Generator cooler, sample cooler.
Ensure Pump SUCTION is in OPEN condition.
Ensure Pump DISCHARGE is in CLOSED condition.
Prime the Pump by opening Air Release valve on the Pump.
Start MCW & ACW pump and after ensuring pump rotates with full RPM,
gradually open DISCHARGE valve.
Check Motor Amps, Discharge pressure, vibration, bearing temperatures.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
18
Maintain Required FLOW & HEADER PRESSURE by throttling Cooling

Water Return line Valves inlet to CT as per requirement.
Maintain the Sump level is Normal.
NOTE: Before putting MCW/ACW pump in AUTO
Isolate Discharge valve.
COOLING WATER PUMP (MCW/ACW)
STAND-BY) Mode, Ensure pumps Suction and Discharge valves are open and
Priming of Pump is done.
STOPPING: To Stop MCW/ACW Pump follow below mentioned Steps.
Close DISCHARGE valve.
Close the Suction Valve.
Close Discharge Valve.
CONDENSATE EXTRACTION PUMP (CEP)
START UP CHECKS: To Take CEP in to Service, Proceed as stated below.
Ensure clearance from maintenance and get clearance from Field Operator to
start.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
19
Ensure Hotwell level is Normal.

Ensure Gland cooling & sealing water line valves are OPEN.
Ensure Hotwell level is just above NWL (Around 40%, before Starting CEP).
Vacuum balancing line valve is in OPEN condition.
Ensure Suction & Discharge Valves are in OPEN Condition.
Ensure Hotwell Level Control Valve is in CLOSE condition and Recirculation
control valve is in OPEN condition (Up-stream and Down-stream isolation
valves are in open condition and bypass valve is in CLOSE condition).
Ensure condensate I/L & O/L valve of Ejector condenser is opened.
Check Suction Strainer Differential Pressure (DP - < 0.5 kg/cm).
START pump either from LPB (LCS) or from PLC.
Put the pump in Re-circulation (Hotwell level control valve position 0)
mode, if passing through Hotwell level control valve is observed close
isolation valve before Hotwell level control valve.
After starting CEP adjust Discharge pressure by opening Recirculation
By- pass valve.
STOPPING: To Stop CEP follow below mentioned Steps.
Close DISCHARGE valve.
Dont Isolate:
a).Gland Cooling Water, Bearing Cooling Water Lines.
b).Suction Valve, Balancing Leak-Off Valve, Discharge Valve,
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
20
Isolate Gland Cooling Water.

Isolate Discharge and min-recirculation valves.
Isolate vacuum Balancing line Valve.
SOP FOR FILTER CHANGE OVER AND CLEANING

CHANGE OVER: Follow the below mentioned steps for change over of filter. This
procedure is valid for duplex filter.
Filter DP (0.8) is high enough to change the running filter on to stand by
filter.
Ensure that stand by filter is provided with filter element, which is cleaned
or replaced with a new one.
Open the vent of the filter.
Open the filter equalizer line.
See that air is coming out of filter, close vent as soon as full bore liquid
comes out of it.
Change the position of the lever watching arrow facing to the direction of
stand by filter.
Observe that filter DP has come down to minimum DP position in the
indicator.
Close the equalizer line. Now choked filter is isolated and fresh stand by
filter is in service.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
21
SOP FOR CLEANING OF CHOKED FILTER ELEMENT

Follow below steps to clean or replace filter element.
Open drain and vent of choked filter.
Ensure complete draining of filter body.
Open the filter flange and remove the filter element(s).
Clean the filter body from inside.
Clean the filter element with fresh water and dry it with dry air.
Close the filter flange.
Close the drain of filter
Open the equalizer of filter to prime the filter.
Close filter vent when air is completely removed.
Check for any leakage from the flange. If no leakage persists, close
equalizer.
SOP FOR OIL COOLER CHANGE OVER:

This procedure is valid where duplex type oil cooler is provided. When running cooler
is required to do maintenance due to leakage, non-performing etc., it needs to change
over to standby one. Proceed as per below mentioned steps for cooler change
operation.
Ensure stand-by one ready for operation.
Ensure vents on both tube and shell side of the incoming cooler is
open.
Ensure the cooler drains are closed.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
22
Charge Cooling water in the cooler and close waterside vents after
removing entrapped air.
Open cooler oil equalizer line. It takes some times to fill a cooler.
Close oil vent once entrapped air is completely removed.

Change the position of the lever watching arrow facing to the direction
of stand by cooler.
Check all the parameters of oil and cooling water.
Control oil temperature by operating CW valve.

SOP FOR EJECTOR SYSTEM
TO TAKE HOGGER IN SERVICE
Ensure that all the drains in the auxiliary steam line are in open
condition.
Before going for vaccum pulling seal the glands of Turbine.
Ensure air line valves are closed for service air ejectors.
Vacuum breaker valve is in closed condition.
Ensure that Steam for ejector is available at its design pressure &
temperature.
Open steam valve for hogger ejector and wait for few minutes till it is
ensured no water vapour is coming out fro the exhaust line.
Open the air valve of hogger ejector.
See that vacuum is being built up in the turbine exhaust system.
TO TAKE SERVICE EJECTOR OPERATION

POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
23
Ensure that CEP is in operation and Hotwell level is being maintained

on auto.
Ensure minimum quantity of condensate is flowing through ejector

condenser.
Identify the ejector set and Open steam for second stage ejector of
service ejector.
Open air line for second stage ejector.
Open steam for 1st stage ejector.
Open air lines for 1st stage ejectors.
Now hogger ejector and service ejector are in line.
ISOLATION OF HOGGER EJECTOR
Close air valve for hogger ejector.
Close steam for hogger ejector.
See that vacuum is being maintained by service ejector set
TURBINE-GENERATOR SECTION
TURBINE: - MAKE- SIEMENS
ALTERNATOR: - TD POWER SYSTEMS LTD.
GEAR BOX
:- TRIVENI ENGINEERING & INDUSRY LTD.
THIS SECTION GIVES YOU DETAILS OF TURBINE-GENERATOR AND OTHER RELATED

EQUPMENTS
& SOP
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
24
TURBINE
MAKE-
SIEMENS
TYPE
HORIZONTAL,IMPULSE,MULTI STAGE,MULTI VALVE,AXIAL

FLOW,CONDENSING
MODEL NO.- SST200VE25A

POWER RATED : 4700KW
MAX.
: 4700KW
P INLET
41 KG/CM2
T INLET
P EXTR. 1
10 KG/CM2
T EXTR. 1
P EXHAUST
-0.9 KG/CM2
T EXHAUST
435 C
274.2 C
45.5 C
ALTERNATOR
MAKE TOYO DENKI POWER SYSTEMS LTD.
( AC GENERATOR )
OUTPUT
5875KVA
SPEED
1500 RPM
TYPE
TC125
NO. OF POLES
NO. OF PHASE
COOLING SYSTEM
IC81W7
ENCLOUSER SYSTEM
IP54
CURRENT AC
514 A
VOLTAGE AC
6600V
FREQUENCY
50HZ
TURBINE & GENERATOR GEAR BOX

POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
25
MAKE TRIVENI ENGINEERING & INDUSTRY LTD.

WORK NO.
2908
OIL VISCOSITY
ISOVG-46
SL. NO.
0600x000006HSGH
RATED SPEED
INPUT/OUTPUT
12056/1500
(RPM)
RATED POWER
5050 KW
RATIO
8.037
CONDENSER
MAKE :- GODAVARI ENGG. LTD.
ORDER NO
9422
NO OF
TUBES
1442
DESIGN
CONDENSER SURFACE
AREA
TUBE SIDE
PRESSURE
5 KG/CM
TEMPERATURE
50C
SHELL SIDE
1 KG/CM
100C
OIL CIRCULATION SYSTEM

MAIN OIL TANK
MAKE- ENPRO IMDUSTRIES PVT.LTD.

RESERVOIR
CAPACITY
445m
7000 LTRS
EMERGENCY OIL PUMP (DC DRIVE)

ROTARY GEAR PUMP
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
MAKE
SOP
26
MODEL
RDRN-200L
SIZE
DELPD PUMPS &

GEARS (P) LTD.
50 NB
PRESSURE
1.5 KG/CM2
SPEED
1500RPM
FLOW
200 LPM
MOTOR
MAKE
CROMPTOM
GREAVES
FREQUENCY
50HZ
POWER
2.2 KW
SPEED
1500 RPM
CURRENT
28AMPS
AUXILIARY OIL PUMP

MAKE
TUSHACO
PUMP MODEL
T3ST 70/54
PUMP CAPACITY
495 LPM
SPEED
1450 rpm
DISCHARG PRESSURE
5 KG/CM
MOTOR
MAKE
CROMPTON
GRAVES
TYPE
1LA0133-AY81
POWER
7.5 KW
SPEED
1450 RPM
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
FREQUENCY
SOP
27
50HZ
OVEF EXHAUST FAN

FAN
MAKE
TCF-NADI
INDUSTRIAL FANS
MODEL
TBR-R13V
VOLUME
700CMH
STATIC PRESSURE
150 MMWC
MOTOR
MAKE
CROMPTOM
GREAVES
TYPE
1LA0090-24A80
POWER
1.5 KW
SPEED
2860 RPM
LUBE OIL FILTER
02 Nos.
MAKE BHAGWATI FILTER LTD

TYPE
BASKET
DESIGN PR.
4 BAR
FLOW
325 LPM
MESH RATING
25 MICRON
CONTROL OIL FILTER
02 Nos.
MESH RATING
10 MICRONS
FLOW
46 LPM
PRESSURE
9.5 BARG
TYPE
BASKET
OIL COOLER
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
28
MAKE - ENPRO INDUSTRIES PVT. LTD.

WORK ORDER :: 8080
MODEL
BEM
HEAT DUTY
170457 KACAL/HR
TEST PR
10.5 BAR
OIL CENTRIFUGE
MAKE- ALFA LEVEL
.
TYPE
MAB-103B-24
PUMP NO
4180365
SL NO
4180365/09
BOWL
524700-88
PRODUCT NO
881145-09-01
MAX.SPEED (BOL)
8571RPM
SPEED(MOTOR
1500RPM
POWER
MAX.DENSITY OF
FEED
1100KG/CU.MTR
MAX.DENSITY OF
SEDIMENT
PROCESS TEMP.
MIN/MAX
0/100 DEG.CENT
CONDENSATE EXTRACTION PUMP
5000KG/CU.MTR
02 NOS
MAKE
KSB
CAPACITY
22 M 3 /HR
TYPE
CPX-EO-40-250
HEAD
70 MT
SL. NO.
5111019641
MOTOR POWER
15KW
SPEED
3000 RPM
MOTOR
MAKE-ABB
MOTOR BEARING
DE-6309ZZC3,NDE6308ZZC 3
TYPE
HX160MLD2
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
MAIN COOLING WATER PUMPS

MAKE
SOP
29
02 NOS
PUMP BRG. NO.

D.E./N.D.E
CAPACITY
6309ZZ
TYPE
FLOW MORE PVTD.

LTD.
FIG 5821 SIZE 30H
HEAD
25MT
SPEED
1460 RPM
MOTOR
POWER
MAKE-ABB
MOTOR BEARING
DE - 6319 C3
NDE-6316C3
132 K.W.
AUXILARY COOLING WATER PUMPS NO
1430 M3/HR
02 NOS
MAKE
FLOW MORE PVTD. LTD.
PUMP BRG. NO.

D.E./N.D.E
6307
TYPE
FIG 5823 125X100 SIZE
CAPACITY
140 M3/HR
HEAD
30 MTRS
SPEED
1460 RPM
MOTOR
BEARING
D.E.-6310ZZC3
N.D.E.-6309ZZC3
MOTOR
POWER
MAKE- ABB
18.5 K.W.
STEAM EJECTOR
MOTIVE STEAM PR.
10 KG/CM2
MOTIVE STEAM TEMP.
350C
MOTIVE STEAM CONSUMPTION
300 KG/HR
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
STEAM CONSUMPTION FOR HOGGER
SOP
30
350 KG/HR
STANDARD OPERATION PRACTICE

FOR
TURBINE ROLLING.
COLD START-UP PROCEDURE.
Put Power, cooling water and air in service.
Check all valves of pressure gauges, pressure switches, level switches if they are
open.
Ensure Oil level in MOT (Main Oil Tank) is Healthy i.e. above 30%.
Start Oil Vapor Extraction Fan and energize Heaters in MOT to raise the Oil
Temp to 40-42C.
Start the Auxiliary oil pump, Control oil pump-1 and put the Emergency oil pump
and another control oil pump-2 in AUTO.
Keep the position of changeover valve of Oil Cooler to be taken into service.
Charge the water side of Oil Cooler after ensuring ACW Pump is in service (open
cooling water I/L valve 100% and open the cooling water side vent. Than open
cooling water O/L valve 100% after ensuring water is coming out from the water
side vent and than vent valve is to be closed.). Ensure water side drain valves are
closed. Ensure all water side drain & vent valves of stand by Oil Cooler are
closed.
Open the shell side vent of Oil Cooler to release the air entrapped inside the shell
and ensure drains of shell side are closed. Ensure shell side all drain & vent valves
of stand by Oil Cooler are closed. After ensuring oil is coming out from shell side
vent of Oil Cooler, vent is to be closed.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
31
Open the Lube Oil Filter vent to release the air entrapped inside the Filter &
ensure drain of Lube Oil Filter is closed. All drain & vent of stand by Lube Oil
Filter are closed. After ensuring oil is coming out from vent of Lube Oil Filter,
vent is to be closed.
Open the Control Oil Filter vent to release the air entrapped inside the Filter &
ensure drain of Control Oil Filter is closed. All drain & vent of stand by Control
Oil Filter are closed. After ensuring oil is coming out from vent of Control Oil
Filter, vent is to be closed.
After Starting AOP Ensure OHOT (Over Head Oil Tank) Level is raised up to the
required Level.
Ensure Lube Oil Header Pressure is above 3.0 kg/cm2.
Ensure Lube Oil Outlet flow through Sight Glasses provided
Put the TG set on Barring gear for the following minimum periods of time:
Shaft Stand Still
Minimum Turning Time
o Less than 1 day
2 Hours
o Up to 7 days
6 Hours
o 7 to 30 days
12 Hours
o More than 30 days
24 Hours
Ensure all the steam drains, warm up vent are in open condition, use trap by- pass
in line during warm up of steam line.
Open Boiler MSSV by-pass at 10 Kg/cm2 and start line heating of PRDS system.
Open the Boiler MSSV at 25 Kg/cm2 and close the By-pass valve.
Close the Trap By-pass and take steam trap in line once it is ensured that all the
condensate is removed from the system.
Charge the gland sealing once the required pressure 10 kg/cm2 and temperature
above 250 C.
Maintain the gland sealing pressure and Temperature as mentioned below.
Front Gland Sealing pressure & Temp. - .08 Kg/cm2 & 400C.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
32
Rear Gland Sealing pressure & Temp. - .08 Kg/cm2 & 250C
o To maintain the Gland sealing temperature in Rear side TCV is
provided.
o Keep both the Gland sealing PCV and TCV in Auto.
Pull the Vaccum once the required Aux. Steam pressure 10 Kg/cm2 and Temp.
above 300C is achieved.
Open slowly Turbine MSSV by-pass valve till the pressure reaches 25- 30
Kg/cm2 (g) to ESV inlet.
Open the manual isolation valve of Turbine steam stop valve, once the all the
parameters achieved as mentioned below:
Turbine Inlet Steam Pressure- 40 Kg/cm2.
Turbine Inlet Steam Temperature-420C.
Vaccum Achieved (-0.9 Kg/cm2g).
From the keyboard of control and Protection (PLC) system give Reset and then
Run command to Turbine.
ESV will open with its pilot and thereafter fully open with the pressure rise in the
control valve block.
Check that LP valve demand is 100% closed and HP opening demand is around
18% to 19%.
Ensure in the field that three LEDs of the Solenoid valve will start glow also the
LP servomotor will close fully.
Live steam flows into the control valve block to warm up the valve casing and
then out to the drain. Temperature increases app.4C/min.
Close manually controlled drain from the control valve block after warming-up is
finished.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
33
The speeding of the turbo set can be started by WOODWARD governor.

Speeding should be carried out according to start-up graphs, respecting the stand
still time (thermal conditions of turbine).
The MOP (main oil pump) feeds the oil system for all duties sufficiently. Cut out
AOP at app. 80-90% normal speed if not switched off automatically. Put AOP on
Auto mode.
Resulting matching of frequency, voltage, phase sequence &rotating field
direction of generator. In Auto synchronization the speed of the turbine,
frequency, voltage will be matched automatically.
After synchronizing increase the load to app. 2% of its rated load in order to avoid
the activation of reverse power relay.
Continue increasing the load according to start-up graphs by pushing the
corresponding keys on the WOODWARD Do not allow exhaust steam
temperature to exceed 105C.For cooling them spray condensate into the exhaust
hood neck.
Once the rated speed of the Turbine is achieved go for synchronizing, which can
be done either manually or Auto.
Manual synchronizing can be done by manually adjusting the speed of the turbine
GOVERNOR.
During loading check all parameters and check also the control stage pressure.
Check the cooling air temperature of generator and open cooling water to the air
cooler if required.
HOT START-UP PROCEDURE
Once the tripping reason is detected and the cause is eliminated, and ready to start
up then follow the steps: Keep the live steam line up to the emergency stop valve pressurized and gland
steam open unless turbine rests far longer than 60 minutes.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
34
Open the Turbine drains trap by pass, it will be remain open until it is ensured that
no condensate is trapped.
The oil unit remains in full operation, maintain the oil temperature between 45C
to 49C.
Keep the Turning gear in permanent operation.
Open the ESV and raise the speed through WOODWARD GOVERNER.
Once the rated speed is achieved do the synchronization either manually or
automatically.
SIEMENS SYSTEM WRITE UP
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
35
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
36
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
37
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
38
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
39
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
40
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
41
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
42
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
43
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
44
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
45
Boiler Start up procedure
Boiler Hot start up

Boiler hot start up is called when boiler started with in 5-10 Hrs after shut down.
PREPARATION
Resume the power supply .
Ensure instrument air pressure 6.0 kg/cm2.
Aux. cooling water pressure & flow is sufficient.
All drains are closed, MSSV also closed.
All sample cooler inlet v/v should be closed.
There should be no pet coke in surge hopper & in DCF.
Start BFP as per requirement.
Start booster pump.
BOILER START UP PROCEDURE
Open the start up vent.
Fill the drum up to NWL through 40% FCV.
Now start the ID fan open suction & discharge damper and maintain furnace draft -1 or -2
mmWC.
Start SA fan and maintain SA pressure 400 mmWc.
Now start PA fan & opened suction damper 100%.
Gradually increased PA air flow.
Continuously watch on bed temp.
Start DCF at minimum rpm.
Once there will be sudden rise in bed temp, so start screw feeder to control bed temp.
Now watch the bed temp. If it is increased rapidly stop DCF.
Now increased PA air flow 40-45TPH.
Now increased DCF speed as per behavior of bed temp.
Start bed material RAV for bed inventory.
When bed temp. Reached 850-900 degree stable boiler on coal
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
46
As the steam temp. & pressure achieved charged the steam line.
Closed the start up vent and main steam drain before, after.
Put furnace draft in Auto.
Set SA pressure as per requirement & put both SA fan in auto.
Watch the drum level and put it in auto.
BOILER OPERATING PROCEDURES

1. START UP OF A COLD BOILER
START UP OF A COLD BOILER
Boiler start up can be termed as cold startup when
1. the boiler has been idle for more than 1 or 2 days
2. there is no pressure in steam drum and temp is less than 70 deg C
PREPARATION
Inspect the boiler prior to startup and check the following
Take Power clearance from electrical side also take clearance from instrumentation side.
All the access doors are closed.
All personnel are cleared.
All material are removed from furnace and other circuits.
Starting equipment interlocks are in position
Boiler is filled with D.M water up to NWL.
WATER AND STEAM CIRCUIT
Check the following valves are in closed condition.
Control valves and their bypass valves.
Blow down valves.
Main steam stop valve.
Drain valves of water level gauges.
All drain valves of water wall headers and economizer headers.
Check the following valves are in open condition
All isolation valves before and after feed control valves
Drum air vents
Main steam line drain
Valves of water level gauges, pressure gauges and level transmitters
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
47
All isolation valves for instruments
AIR AND FLUE GAS CIRCUIT

Ensure the following
I.D. Fan inlet damper is closed.
S.A. Fan inlet damper is closed.
Over fire air damper is closed.
P.A. Fan inlet damper is closed.
Wind box damper is closed.
Manual bed drain gates are closed.
Bed ash cooler drain gates are closed.
ESP and chimney are free from men and materials and doors are closed.
WATER FILL UP IN BOILER
Filling water temp should not be more than 38 deg C of the boiler metal temp and minimum
feed water temp acceptable is 20 deg C.
During filling of a cold boiler, the ambient temp should be used as an indicator of the boiler
metal temp.
Assuming an ambient temp of 40 deg C, the maximum temp of filling water shall be 78 deg C.
Boiler water fill up shall be of following two methods

1.
2.
Normal filling circuit by boiler feed water pump (Top fill up)
Initial startup line through D.M. transfer pump (Bottom fill up) to Eco bottom header.
NORMAL FILLING CIRCUIT (TOP FILL UP)
Ensure Economizer inlet & outlet header vents, steam drum vent, wing wall vents, saturated
steam header vent, and startup vent are all kept full open.
During water fill up, post an attendant at the drum level to monitor the local gauge glass and
to communicate control room when the drum level reached 50 mm below NWL (NWL is 50%
of drum level)
Start boiler feed water pump and open discharge valve gradually to full open condition
Open 40% feed control valve gradually (10 to 15%) and fill the water at a slow rate to ensure
removal of entrapped air from the pressure parts.
Close the air vents one by one after water flows out in the vents in the order of economizer,
steam drum , wing wall , saturated steam header and super heater
Once water comes out of super heater vent, close feed control valve and BFW pump discharge
valve and finally stop BFW pump
Steam drum level has to be brought down to NWL after super heater coils and headers are
filled with water by opening IBD valve
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
48
Before draining ensure vents of wing wall, super heater and drum are opened after BFW pump
is stopped
INITIAL START UP FILLING (BOTTOM FILL UP)
Ensure Economizer inlet & outlet header vents, steam drum vent, wing wall, super heater
vents and startup vent are all kept full open
Ensure the economizer inlet header drain valves are open
Start the transfer pump.
Close the air vents one by one after water flows out in the vents in the order of economizer,
steam drum , wing walls and super heater
Once water comes out of final super heater vent, close the Eco. bottom header initial filling
isolation valve and transfer pump discharge valve and finally transfer pump shall be switched
off
Before draining ensure vents of, super heater and drum, wing walls & saturated steam header
vents are opened after transfer pump is stopped
BED MATERIAL FILLING PROCEDURE
Start I.D. fan

Start S.A. Fan
Start P.A. fan
Maintain the furnace pressure as -2 to -5 mmWc
Start Bed material RAV at full speed.
Slowly increased air flow to avoid any chocking of nozzles.
Continuously watch furnace and co-ordinate with control room.
Bed height should be 700mm from bubble cap.
After getting sufficient bed height give a minimum fluidization.
Not down the wind box pressure for minimum fluidization.
Now decrease the air flow and check the bed that there is uniform fluidization in bed.
BOILER START UP PROCDURES

Start LDO pump at least 3 hours before start up & keep oil in recirculation mode.
Light up the oil burner as per Burner startup procedures and maintain the oil pressure 4.5-5.5
kg/cm2.
Maintain SA air flow for burner 12TPH and furnace pressure -2 to -3 mmWC.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
49
Slowly increased PA air flow proper heat transfer through bed material.
After getting 2 kg/cm2 drum pressure gradually increase oil flow.
When the drum pressure reaches 2 kg/cm2 close the drum vent valve, wing walls vents,
saturated steam header vents & super heater vents.
Main steam startup vent valve should be kept in open condition till the boiler is connected to
load to safeguard the super heater coils from overheating.
Now increased the PA air & keep bed in minimum fluidization state.
Gradually increase oil flow and monitor drum level. If necessary, give blow down and
maintain NWL
Observe the bed temp rise in bed. The expected heat up is around 50-70 deg C per hour till
100 deg C
Watch the bed for uniform fluidization. The bed temp will start rising fast due to the radiation
heat of the oil burner.
Once the bed temp reaches around 400 deg C start introduction of coal to the comp.
INTRODUCTION OF COAL TO BED AND STABILISATION
Once the bed temp is around 450 to 500 deg C in any one of the thermocouples, start the drag
chain feeder and run at minimum speed.
Observe the bed and check coal burning or not.
Without flame in the bed do not continue fuel feeding for prolonged time.
Slowly increase the fuel feeding RPM when the bed temp is around 600 deg C and in rising
trend.
Once the fuel is admitted to the bed there will be a rapid bed temp raise and should be
controlled by adjusting the fuel to the combustor and adjusting air flow to the bed.
Also start screw feeder to avoid sudden temp rise of bed.
Bed temp is to be stabilized around 850 deg C for coal and once the temp is stabilized burner
can be withdrawn when the temp rising rate is so fast.
Once the bed temp reaches 850 deg C bed material additions shall be taken up and bed level
shall be raised from the existing level to 1400-1500 mm.
On the water side watch the drum level maintain drum level to NWL by switching on feed
pump
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
50
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
51
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
52
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
53
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
54
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
55
TURBINE ALARM & TRIP SET POINT LIST

4.7 MW Captive Power Plant
S.NO.
Instr.Tag
No.
Description
Unit
Set Values
Alarm
Trip
DPI-501
Lube Oil Filter
Kg/Cm2
0.8
DIP-401
Control Oil Filter
Kg/Cm2
0.8
DPS201A
/DPS201B
CEP Differential Pressure

(DP)
Kg/Cm2
0.5
PI-101
Main steam pressure Low

Low
Kg/Cm2
26
20
PI-101
Main steam pressure High

High
Kg/Cm2
43
44
TI-101
Main steam temperature

Low Low
Deg C
425
420
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
56
TI-101

High High
Deg C
435
449
PSL-401
Control Oil Pressure Low

Low
Kg/Cm2
8.5
7.5
PI-103
Exhaust Pressure High

High
Kg/Cm2
-0.85
-0.81
10
TI-103/TI104
Exhaust Temperature
High High
Deg C
105
120
11
OSP- 901
Over Speed trip from

Governor
RPM
12
LSHH-201
Hotwell level High High
13
PBLT1
/PBLT2
Emergency trip (PB) from

Gauge Panel
14
D86GT
Generator Differential
Relay acted
15
PI-502
Lube oil Pressure Low

Low
16
EMG PLC
Emergency trip command

for DCS
17
YI-801B/YI802B
Turbine front bearing

vibration High High
Microns
63
83
18
YI803B/YI804B
Turbine rear bearing

vibration High High
Microns
63
83
19
YI-805B/YI806B
Gearbox Pinion (DE)

bearing vibration High
High-High Speed
Microns
66
125
20
TI - 809
Gearbox Pinion (NDE)

bearing vibration High
High-High Speed
Microns
66
125
Kg/Cm2
13180
70%
90%
2 out of 2
0 = Trip
D86GT
From relay : = 1
2.55
1.8
DCS Push
Button
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
57
21
ZI-801B
Rotor axial displacement

High High
MM
22
TI - 801
Turbine thrust Non-Active

side temperature High
High
Deg C
95
100
23
TI-803
Turbine thrust Active side

temperature High High
Deg C
95
100
24
TI-805
Turbine front journal

bearing temperature High
High
Deg C
110
120
25
TI-806
Turbine rear journal

High
Deg C
110
120
26
TI-810
Gearbox pinion shaft (DE)

High
Deg C
100
110
27
TI-809
Gearbox pinion shaft

(NDE) bearing
temperature High High
Deg C
100
110
28
TI-807
Gearbox Gear shaft (DE)

High
Deg C
100
110
29
TI-808
Gearbox Gear shaft (NDE)

High
Deg C
100
110
30
TI-851
Gearbox Gear shaft Thrust

(NDE) Temperature
Deg C
100
110
31
TI-850
Gearbox Gear shaft Thrust

(DE) Temperature
Deg C
100
110
32
TI-811
Alternator front bearing

Temperature High High
Deg C
85
90
33
TI - 811
Alternator rear bearing

Temperature High High
Deg C
85
90
34
ESD - 901
Emergency shutdown
command from Govenror
Governor
0 to trip
0.4/+0.4
0.6/+0.6
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
58
35
TI 811
Alternator front bearing

temperature
Deg C
85
90
36
TI 812
Alternator rear bearing

temperature
Deg C
85
90
37
TI 813
Alternator winding
temperature - U1 phase
Deg C
140
145
38
TI 814
Alternator winding
temperature - V1 phase
Deg C
140
145
39
TI 815
Alternator winding
temperature - W1 phase
Deg C
140
145
40
TI 816
Alternator winding
temperature - U2 phase
Deg C
140
145
41
TI 817
Alternator winding
temperature - V2 phase
Deg C
140
145
42
TI 815
Alternator winding
temperature - W2 phase
Deg C
140
145
43
TI 823
Alternator core
temperature - 1
Deg C
130
135
44
TI 824
Alternator core
temperature - 1
Deg C
130
135
45
TI 825
Alternator core
temperature - 1
Deg C
130
135
46
TI 819
Alternator inlet air

temperature - 1
Deg C
52
47
TI 820
Alternator outlet air

temperature - 1
Deg C
80
48
TI 821

temperature - 1
Deg C
52
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
49

temperature - 1
TI 822
SOP
Deg C
59
80
BOILER ALARM & TRIP SET POINT LIST

4.7 MW Captive Power Plant
S.NO.
Instr.Tag
No.
Description
Unit
Set Values
Alarm
Trip
LI-101
A/B/C
Drum Level Low Low
25
20
LI-101
A/B/C
Drum Level High High
70
80
PI-112
Main steam pressure Low

Low
Kg/Cm2
43
PI-112
Main steam pressure High

High
Kg/Cm2
46
TI-121

Low Low
Deg C
420
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
60
TI-121

High High
Deg C
460
PI-114 A/B
Furnace Pressure High High
mmwc
130
140
PI-114 A/B
Furnace Pressure Low Low
mmwc
-130
10
PI-116
BFG Presuure High High
mmwc
350
500
11
PI-116
BFG Pressure Low Low
mmwc
150
50
12
PI-206
Deaerator Pressure High
Kg/Cm2
1.5
13
PI-206
Deaerator Pressure Low
Kg/Cm2
0.5
14
LI-201
Deaerator Level Low Low
20
140
10 BFP will
TRIP
START, STOP PERMISSIVE AND INTERLOCKS

TURBINE RESET PERMISSIVE
1.EOP Should be ready and will be selected in Auto mode.
2.Lube oil tank level should be greater than 30%.
3.Overhead oil tank level switch should be healthy.
4.Emergency Push Button from the TSP panel should be released.Reset Command from PLC
At 10800 RPM AOP manual stop and MOP change over function.
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
61
COASTING DOWN TESTS

Turbine coasting down time = 6 mins 8 sec.
LOGICS AND INTERLOCKS TEST
1. Auxillary Oil Pump
Start Permissive
1.Pump should be in Remote selection.
2.Pump should not tripped in overload.
AOP will start in Auto
1. When Lube oil header Pressure becomes low of 2.5 Kg/cm2.
AOP will Stop in Auto/Protection
1.When Lube oil header pressure becomes greater than 3 Kg/Cm2.
2.When Turbine speed will achieved 90% of rated RPM with 120 Sec of time delay
3.When AOP motor will trip in overload.
2.Emergency oil pump
Start Permissive
1. EOP ready to start signal will display in
PLC
2. EOP should not trip in overload.
Emergency oil pump will start in Auto/Interlock
1.When Lube oil pressure becomes low low of 1.8Kg/Cm2
2.Incase of Turbine speed is greater than 20 RPM and Lube oil
pressure is low low irrespective of mode selection in PLC,EOP will start
automtaically and cannot be stopped untill the pressure becomes
normal or Turbine speed come to stand still.
3.Barring Gear Motor
Start Permissive
1.Barring Gear motor should not trip in overload.
2.Lube oil pressure is greater than 2.55 Kg/cm2.
3.Turbine speed is less than 20 RPM.
Barring Gear will Start in Auto.
1.When turbine speed is less than 20 RPM.
Auto stop command / Protection
1.When Lube oil header pressure is less than 2.55 Kg/Cm2
2.When turbine speed is greater than 315 RPM
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
4.Control Oil Pump

Start Permissive
1.Pump should be in Remote selection.
2.No over load trip activated.
3.MOT tank level not low low i.e. greater than 30%
Stand By COP will start in Auto Mode
1.When Control oil pressure becomes low of 8.5 Kg/Cm2.
2.When running Control oil pump tripped in overload.
COP will stop in Auto/Protection
1. When MOT level goes below 30%.
2. When pump will be overloaded.
5. Oil Vapour Extractor Fan - 1
Start Permissive
1.Fan selection should be in Remote.
2.Fan should not be over load trip.
OVEF will start in Auto Mode.
1. Auxiliary oil pump should be in running condition.
2.Emergency oil pump should be in running condition.
3.Turbine speed should be greater than 90% RPM.
Auto Stop command / Protection
1.Vapour extractor fan overload tripped.
6. CONDENSATE EXTRACTION PUMP - 1
Start Permissive
1.Hotwell level should be normal greater than 50%.
2.CEP pump shoullde be Remote selected.
3.Pump should not be over load trip.
CEP will start in Auto
1.Stand By Pump wil start in Auto if Condensate discharge pressure becomes low
i.e. less than 3.0Kg/Cm2.
2.Stand By Pump wil start in Auto if Hotwell level becomes High of 70%.
3.Runnig Condensate extraction pump Tripped.
CEP will Stop in Auto/Protection
1.Pump will trip in Auto if Hotwell level becomes low low 20%.
2.Running Condensate extraction pump Tripped.
7.VACUUM BREAKER VALE (VBV201)
62
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
63
Vaccun Brekaer valve will open in AUTO.

1.When Turbine Axial Displacement is greater than 0.6 mm
2.When Lube oil pressure becomes low low i.e. less than 1.8Kg/Cm2
3.when Generator tripped due to Differential protection.
4.When Turbine speed is less than 70% of rated speed.
Manual Open Command Block
1. If the turbine speed is greater than 8400 RPM manual open command is blocked.
2. Valve can be manually closed when all the protection is normal.
8. DEAREATOR BLEED VALVE
OPEN PERMISSIVE
1. Main steam flow should be greater than 10 TPH.
2.Pressure difference across the bleed valve should be less then 0.1 Kg/Cmm2
3. Turbine should not be in tripped condition.
Bleed valve Auto close/Protection
1. When Turbine inlet Main steam flow less than 9 TPH.
2. When Turbine Trip.
PLANT TRIP INTERLOCK CHECKING FORMAT

STEAM TURBINE
S.No.
DESCRIPTION
Hand Trip test
by Push button
on Local TSP
panel
Remote Trip
test by Push
button on
Governor panel
UOM
SET
VALUE
ACTUAL
VALUE
METHOD OF TESTING
RESULT
EXPECTED
Trip
Put STG on turning

gear, by pass vacuum
protetction,reset STG
Turbine trip
& ESV
close
Trip
as above
as above
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
Over speed Trip

from Governor.
Over speed Trip

from OSP
system
Exhaust
Pressure High
High
Main steam
temperature
High High
8
9
10
11
Main steam
temperature
Low Low
Exhaust
Temperature
High High
Turbine thrust
Non-Active side
temperature
High High
Turbine thrust
Active side
temperature
RPM
RPM
Kg/cm2
SOP
64
13188
Operate the turbine at

working speed and do
the OS testing through
Woodward it is advised
to test the electrical OS
at operating speed by
resetting OS electrical at
operating speed. After
testing normalize the set
value
Turbine trip
13250
Operate the turbine at

working speed and do
the OS testing through
Woodward. it is advised
to test the electrical OS
beyond mechanical OS
value as back up
protection
Turbine trip
-0.81
Put STG on turning

gear, normalize pass
vacuum protection to
reset STG otherwise,
pull some vacuum
above trip value and
reset the STG Now
reduce vaccum by
controlling ejector steam
pressure to trip value.
Note the trip value
STG will not

get reset, in
the second
case turbine
must trip
Turbine trip
deg C
449
Put STG on turning

gear, by pass vacuum
protetcion,reset
STG,simulate through
DCS
deg C
420
as above
Turbine trip
deg C
120
as above
Turbine trip
deg C
100
as above
Turbine trip
deg C
100
as above
Turbine trip
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
65
High High
12
13
14
15
16
17
18
19
20
Turbine front
journal bearing
temperature
High High
Turbine rear
journal bearing
temperature
High High
Gearbox pinion
shaft (DE)
bearing
temperature
High High
Gearbox pinion
shaft (NDE)
bearing
temperature
High High
Gearbox Gear
shaft (DE)
bearing
temperature
High High
Gearbox Gear
shaft (NDE)
bearing
temperature
High High
Gearbox Gear
shaft Thrust
(NDE)
Temperature
Gearbox Gear
shaft Thrust
(DE)
Temperature
Alternator front
bearing
Temperature
High High
Alternator rear
bearing
Temperature
High High
deg C
120
as above
Turbine trip
deg C
120
as above
Turbine trip
deg C
110
as above
Turbine trip
deg C
110
as above
Turbine trip
deg C
110
as above
Turbine trip
deg C
110
as above
Turbine trip
deg C
110
as above
Turbine trip
deg C
110
as above
Turbine trip
deg C
90
as above
Turbine trip
deg C
90
as above
Turbine trip
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
26
Hotwell level
High High
90
28
LUB OIL
PRESSURE LL
Kg/cm2
1.8
SOP
66
Reset turbine and check

the hotwell level by
actually rising the same
Turbine trip
Turbine trip

Standard Operation Procedure

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Standard Operation Procedure

Загружено:

Авторское право:

Доступные форматы

POWER DIVISION

STANDARD OPERATING PRACTICES

TRINETRA CEMENTS ,BANSWARA,RAJASTHAN

Prepared by: Thermax Limited, Power Division (O&M)

Prepared by: Thermax Limited, Power Division (O&M)

THIS SECTION COVERS BOILER ACCESSORIES AND

TYCO SANMAR LTD.

TYCO SANMAR LTD.

Prepared by: Thermax Limited, Power Division (O&M)

BOILER FEED PUMPS

KSB PUMPS, PUNE

SHUT OFF HEAD

SHAFT SEAL TYPE &

Prepared by: Thermax Limited, Power Division (O&M)

DM WATER TRANSFER PUMP 02

Prepared by: Thermax Limited, Power Division (O&M)

HOUSING NO. SNA

TYPE & SPEED

Prepared by: Thermax Limited, Power Division (O&M)

CHEMTROLS SAMIL (I)

316 SST/COCR-A FQL-2

Prepared by: Thermax Limited, Power Division (O&M)

TYPE OF SOOT BLOWER

INDUCED DRAFT FAN (ID FAN).

Start the fan from LPB (LCS) or from PLC.

Prepared by: Thermax Limited, Power Division (O&M)

Check all parameters, Bearing temperatures, vibrations, Motor body

Isolate from Electrical side.

Prepared by: Thermax Limited, Power Division (O&M)

Isolate the feed water control valve and Discharge valve.

Close gauge glass vent valve (s).

Open steam side isolation valve partly.

When condensate level in gauge glass is found to be more than 50%,

See that the level is stabilized at 50% of gauge glass.

Open both steam and water side valves full.

Match level of gauge glass with that of control room indication.

TO FLUSH GAUGE GLASS

Close steam side valve.

See that gauge glass is filled with water.

Close waterside valve and drain valve of gauge glass.

Crack open steam side valve.

See that gauge glass gets emptied.

Repeat above said activities at least twice.

CHARGING OF MAIN STEAM LINE:

Increase pressure and temperature as required for turbine start up.

It is to be noted that increase of temperature up to 300 C should be 3-5

Ensure that deaerator is filled with DM water with above

Open the trap by pass drains in the Auxiliary line and

Open the isolation valve of PCV slowly and operate the

Ensure that steam line is charged and Pegging steam line is

Open the Pegging steam PCV in such a way to maintain the

While charging steam to deaerator hammering/ rolling sound

Prepared by: Thermax Limited, Power Division (O&M)

If the sound / noise is beyond tolerable limit, reduce the

Once deaerator pressure at 1 kg/cm2 is achieved and

Heat up the bleed line by opening the drain lines.

Ensure that Turbine inlet steam flow is 12 TPH before

Ensure that turbine bleed steam pressure is around 10

Ensure that the steam has charged up to the Pegging steam

Ensure drain before and after Process PCV is open.

Prepared by: Thermax Limited, Power Division (O&M)

Maintain Required FLOW & HEADER PRESSURE by throttling Cooling

Ensure Hotwell level is Normal.