KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/ECOS/01

Power from knowledge
SOP For Eco Ash System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 1 of 6

STANDARD OPERATING INSTRUCTION

FOR

ECO ASH SYSTEM

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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/ECOS/01

Power from knowledge
SOP For Eco Ash System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 2 of 6

STANDARD OPERATING PROCEDURE FOR BOTTOM ASH SYSTEM

OBJECTIVE: For Smooth Operation of Eco Ash System.
SCOPE: This SOP is applicable for 6 nos. of Eco Ash System.
INTRODUCTION: Eco ash system is required to collect the economizer ash particles from boiler and
dispose it to slurry sump. There are 06 nos Eco ash system for 06 units.

ECO ASH SYSTEM TECHNICAL DATA:-

EQUIPMENT CAPACITY MAKE
Eco Ash Hopper Tecpro Systems Limited
Wetting Unit 32 TPH Tecpro Systems Limited
Collector Tank 0.5 m3 Tecpro Systems Limited
Jet Pulsion Pump 176 m3/h Tecpro Systems Limited
ECO HP Pump 220 m3/h Shijiazhuang Kingda Pump
Industry Group Co.Ltd.
Slurry Pump 960 m3/h Shijiazhuang Kingda Pump
Industry Group Co.Ltd.

RESPONSIBILITY: Unit Control Engineer, Field Engineer and Desk Engineer.

SAFTEY PRECAUTIONS:
1. Ensure no permit to work is pending on regarding this system by checking with EE/MRSE.

SAFTEY PPE’s: Ear Plugs, Safety Goggles, Hand Gloves, etc.

SPECIAL TOOLS/ EQUIPMENTS: NIL

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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/ECOS/01

Power from knowledge
SOP For Eco Ash System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 3 of 6

PRECHECKS AND ACTION BY FIELD ENGINEER

S No Description Ok Not Ok Remarks
1 All permits and cross permits have been returned.
2 Area is clear of any other materials.
3 Check chain guard/ belt guard/ coupling guard is not touching with
chain/ belt/ coupling.
4 Check all equipment are properly bolted & grouted.
All piping are clamped properly, flange, gasket, valve & nut & bolt
5 should be tightened.
6 Check instrument air is available.
7 Check seal water is available for HP Pump & slurry pump.
8 Check HP Pump is available for Eco de-ashing.
9 Check slurry pump is available for slurry discharge.
10 Check all the local push button is released.

PRECHECKS AND ACTION BY DESK ENGINEER

S No Description Ok Not Ok Remarks
1 All permits and cross permits have been returned.
2 Check all power sources are available.
3 Check instrument air is available for operation of valves.
4 Check seal water pump is running & required pressure is available.
5 Check HP pump is running & required pressure is available.
6 Check slurry sump level is normal.
7 Check slurry sump agitator is running.

OPERATING PROCEDURE -
Sr. RESPONSIBILITY
Description
No. UCE DE FE EE
PRE- START CHECKS:
1 All permits and cross permits have been returned.
2 Power supply and control power supply available.
3 Check instrument air is available for operation of valves.
4 Slurry discharge line pneumatic valve open.
5 HP water pressure normal & all line valves should be open.

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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/ECOS/01

Power from knowledge
SOP For Eco Ash System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 4 of 6

6 Slurry sump agitator is running.

START PERMISSIVE :
1 HP water pump running.
2 HP water pressure normal.
3 Slurry discharge line valve open.
4 Slurry sump level normal.
ECO SYSTEM START UP SEQUENCE :
1 All seal water line, HP water line & slurry discharge line valve open.
2 Start HP seal water pump & then HP water pump start.
3 Start slurry sump agitator.
4 Start slurry pump seal water pump.
5 Open slurry suction valve.
6 Start slurry pump.
7 Open slurry discharge valve.

SHUTDOWN SEQUENCE:

1.PLANNED SHUTDOWN :

1 After completion of complete de-ashing of Eco ash hopper.

2 Close seal water valve.
3 After flushing the line stop HP water pump if other related system is/are not running.
4 Stop the seal water pump.

2.TRIPPING OF ECO SYSTEM: If suddenly trips

1 If HP water pump is tripped then run the stand by pump.
2 Flush the slurry discharge line & rectify the problem.
3. EMERGENCY SHUT DOWN:
1 If slurry discharge line is chocked then emergency shutdown required.
2 If all HP water pump is in trouble then emergency shutdown required.
3 If all slurry pumps in trouble or slurry line is chocked then emergency shutdown
required.

INTERLOCKS : Remarks
1 If HP water pump is stopped then close the hopper discharge valve.
2 If Seal water pump is tripped then HP water pump will stop & hopper discharge

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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/ECOS/01

Power from knowledge
SOP For Eco Ash System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 5 of 6

valve will close

ABRIVIATIONS / NOTATIONS:-
o SOP: Standard Operating Procedure
o UCE: Unit Control Engineer
o DE: Desk Engineer
o FE: Field Engineer
o DCS: Distributed Control System
o EE: Electrical Shift Engineer
o MFT: Main Fuel Trip.
o RB : Run Back

DO’s & DONT’s :

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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/ECOS/01

Power from knowledge
SOP For Eco Ash System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 6 of 6

DO’s :

1. During ECO De-ashing, ensure that Ash Intake Valve is fully open.

2. Ensure material flow from ECO Ash Hoppers during ECO de-ashing .

3. During ECO De-ashing, if suction pressure at Jet pump inlet drops down below 6 Bar, close the Ash Intake
Valve immediately.

4. Ensure Discharge is closed before stating the HP Water Pump.

DONT’s :

1. Don’t close the Ash Intake Valve until the ECO Ash Hopper is completely empty.

2. Don’t stop the system until Line Flushing (ECO Hopper to Slurry Sump) is properly done.

3. Don’t stop the HP Water Pump during ECO De-ashing.

4. Don’t close the Suction/Discharge Valve before stopping the HP Water Pump.

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