Professional Documents
Culture Documents
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
THERMAX
POWER DIVISION
THERMAX LTD,
PUNE
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
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
NOS.-03
DESCRIPTION
DRUM 1
DRUM 2
SH
MAKE
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
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Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
OPERATING TEMP.
270C
SOP
270C
NOS.-02
MAKE
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
772 M
4.1 M
NOM.EFFICIENCY
60%
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
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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
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
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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
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
RECIPROCATING
PLUNGER,VARIABLE
STROKE
RECIPROCATING
PLUNGER,VARIABLE
STROKE
NO. OF PUMPS
2 SET
2 SET
0-10LPH. 6KG/CM
POWER DIVISION
THERMAX LIMITED
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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.
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
STEM
316 SST
BODY
WCC
SEAT
316SST/COCR-A
POWER DIVISION
THERMAX LIMITED
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Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
SOOT BLOWER
MAKE- SITSON INDIA LIMITED
SL
NO.
DESCRIPTION
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
POWER DIVISION
THERMAX LIMITED
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Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
10
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
11
POWER DIVISION
THERMAX LIMITED
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Document
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
12
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.
Prepared by: Thermax Limited, Power Division (O&M)
POWER DIVISION
THERMAX LIMITED
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Document
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
13
Normalize the gauge glass valves and match local level with that of
control room indication
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.
Prepared by: Thermax Limited, Power Division (O&M)
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THERMAX LIMITED
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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.
DEAERATOR CHARGING:
Follow the steps below for charging of deaerator.
POWER DIVISION
THERMAX LIMITED
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
15
SOP
follows.
POWER DIVISION
THERMAX LIMITED
Project
Document
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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.
Prepared by: Thermax Limited, Power Division (O&M)
POWER DIVISION
THERMAX LIMITED
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Document
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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.
Give STOP command either from LPB (LCS) or from PLC.
IF THE PUMP IS KEPT AS STAND BY:
Dont Isolate:
A).Suction Valve, Minimum Recirculation Valve, Discharge Valve,
ALLOWING FOR MAINTENANCE:
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
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Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
18
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
Page
1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
19
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
20
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
21
Clean the filter element with fresh water and dry it with dry air.
Check for any leakage from the flange. If no leakage persists, close
equalizer.
Ensure vents on both tube and shell side of the incoming cooler is
open.
POWER DIVISION
THERMAX LIMITED
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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.
Ensure that all the drains in the auxiliary steam line are in open
condition.
Ensure air line valves are closed for service air ejectors.
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.
POWER DIVISION
THERMAX LIMITED
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
23
Identify the ejector set and Open steam for second stage ejector of
service ejector.
TURBINE-GENERATOR SECTION
TURBINE: - MAKE- SIEMENS
ALTERNATOR: - TD POWER SYSTEMS LTD.
GEAR BOX
:- TRIVENI ENGINEERING & INDUSRY LTD.
& SOP
Prepared by: Thermax Limited, Power Division (O&M)
POWER DIVISION
THERMAX LIMITED
Project
Document
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
24
TURBINE
MAKE-
SIEMENS
TYPE
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
POWER DIVISION
THERMAX LIMITED
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
25
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
445m
7000 LTRS
POWER DIVISION
THERMAX LIMITED
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
MAKE
SOP
26
MODEL
RDRN-200L
SIZE
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
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
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
FREQUENCY
SOP
27
50HZ
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
02 Nos.
BASKET
DESIGN PR.
4 BAR
FLOW
325 LPM
MESH RATING
25 MICRON
02 Nos.
MESH RATING
10 MICRONS
FLOW
46 LPM
PRESSURE
9.5 BARG
TYPE
BASKET
OIL COOLER
Prepared by: Thermax Limited, Power Division (O&M)
POWER DIVISION
THERMAX LIMITED
Project
Document
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
28
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
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
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THERMAX LIMITED
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
29
02 NOS
6309ZZ
TYPE
HEAD
25MT
SPEED
1460 RPM
MOTOR
POWER
MAKE-ABB
MOTOR BEARING
DE - 6319 C3
NDE-6316C3
132 K.W.
1430 M3/HR
02 NOS
MAKE
6307
TYPE
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
350C
300 KG/HR
POWER DIVISION
THERMAX LIMITED
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Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
30
350 KG/HR
POWER DIVISION
THERMAX LIMITED
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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.
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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
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1 x 20 MW CPP
TRINETRA CEMENTS
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SOP
33
POWER DIVISION
THERMAX LIMITED
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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.
POWER DIVISION
THERMAX LIMITED
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
35
POWER DIVISION
THERMAX LIMITED
Project
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
36
POWER DIVISION
THERMAX LIMITED
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
37
POWER DIVISION
THERMAX LIMITED
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Document
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
38
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
Rev.
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
39
POWER DIVISION
THERMAX LIMITED
Project
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
40
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
41
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
42
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
43
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
44
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
45
POWER DIVISION
THERMAX LIMITED
Project
Document
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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.
POWER DIVISION
THERMAX LIMITED
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
47
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.
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.
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
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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
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
POWER DIVISION
THERMAX LIMITED
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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.
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
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
50
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
51
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
52
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
53
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
54
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
55
Instr.Tag
No.
Description
Unit
Set Values
Alarm
Trip
DPI-501
Kg/Cm2
0.8
DIP-401
Kg/Cm2
0.8
DPS201A
/DPS201B
Kg/Cm2
0.5
PI-101
Kg/Cm2
26
20
PI-101
Kg/Cm2
43
44
TI-101
Deg C
425
420
POWER DIVISION
THERMAX LIMITED
Project
Document
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
56
TI-101
Deg C
435
449
PSL-401
Kg/Cm2
8.5
7.5
PI-103
Kg/Cm2
-0.85
-0.81
10
TI-103/TI104
Exhaust Temperature
High High
Deg C
105
120
11
OSP- 901
RPM
12
LSHH-201
13
PBLT1
/PBLT2
14
D86GT
Generator Differential
Relay acted
15
PI-502
16
EMG PLC
17
YI-801B/YI802B
Microns
63
83
18
YI803B/YI804B
Microns
63
83
19
YI-805B/YI806B
Microns
66
125
20
TI - 809
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
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
57
21
ZI-801B
MM
22
TI - 801
Deg C
95
100
23
TI-803
Deg C
95
100
24
TI-805
Deg C
110
120
25
TI-806
Deg C
110
120
26
TI-810
Deg C
100
110
27
TI-809
Deg C
100
110
28
TI-807
Deg C
100
110
29
TI-808
Deg C
100
110
30
TI-851
Deg C
100
110
31
TI-850
Deg C
100
110
32
TI-811
Deg C
85
90
33
TI - 811
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
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
58
35
TI 811
Deg C
85
90
36
TI 812
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
Deg C
52
47
TI 820
Deg C
80
48
TI 821
Deg C
52
POWER DIVISION
THERMAX LIMITED
Project
Document
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
49
TI 822
SOP
Deg C
59
80
Instr.Tag
No.
Description
Unit
Set Values
Alarm
Trip
LI-101
A/B/C
25
20
LI-101
A/B/C
70
80
PI-112
Kg/Cm2
43
PI-112
Kg/Cm2
46
TI-121
Deg C
420
POWER DIVISION
THERMAX LIMITED
Project
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
60
TI-121
Deg C
460
PI-114 A/B
mmwc
130
140
PI-114 A/B
mmwc
-130
10
PI-116
mmwc
350
500
11
PI-116
mmwc
150
50
12
PI-206
Kg/Cm2
1.5
13
PI-206
Kg/Cm2
0.5
14
LI-201
20
140
10 BFP will
TRIP
POWER DIVISION
THERMAX LIMITED
Project
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
61
POWER DIVISION
THERMAX LIMITED
Project
Document
Title
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TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
62
POWER DIVISION
THERMAX LIMITED
Project
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
SOP
63
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
Turbine trip
& ESV
close
Trip
as above
as above
POWER DIVISION
THERMAX LIMITED
Project
Document
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1 x 20 MW CPP
TRINETRA CEMENTS
BANSWARA,RAJASTHAN
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
Turbine trip
13250
Turbine trip
-0.81
Turbine trip
deg C
449
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
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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
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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
Turbine trip
Turbine trip