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THERMAX LIMITED POWER DIVISION

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JKLC, Sirohi, Rajasthan Standard Operating 0 1
Procedure 1x15 MW Power
Plant

STANDARD OPERATING PROCEDURE

FOR 1X 15 MW POWER PLANT WITH 5 NO. WHRB


AT JK LAKHSMI CEMENT,
SIROHI

The plant has 6 boilers operating on the waste heat from the Cement Kiln.

1. 3 Nos. PH Boilers heated by the exit gases from the preheater kilns 1/2/3
2. 3 Nos. AQC Boilers heated by exit gases from Grate Cooler Kilns 1/2

PH -1 12.575 TPH

PH – 2 23.0 TPH

PH – 3 21.865 TPH

AQC-1A 4.340 TPH

AQC-1B 6.5 TPH

AQC-2 10.220TPH

Turbine Siemens make 15MW


Generator TDPS make 15MW

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THERMAX LIMITED POWER DIVISION

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JKLC, Sirohi, Rajasthan Standard Operating 0 2
Procedure 1x15 MW Power
Plant

STANDARD PROCEDURE
FOR
DAMPER OPERATION

DAMPER OPERATION DURING WHRB START UP

 Ensure that waste heat gas is available at required temperature with


required quantity.
 WHRB by pass damper is open.
 Boiler drum level is maintained at operating level ( 50%)
 Recirculation pump is in operation and recirculation flow is established at
requisite value
 The gas I/L damper are open close type whereas the bypass damper will
be regulating type and controlled by CPPLC. The Motorized Dampers also
have end portion limit switches which indicate open/close position of
dampers.
 Gas bypass damper will be opened/closed step by step and controlled by
CPPLC.
 Increase in WHRB inlet gas temperature and draft across boiler will ensure
the flue gas flow through WHRB.
 Check boiler inlet flue gas parameter like flue gas temperature & draft.

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THERMAX LIMITED POWER DIVISION

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JKLC, Sirohi, Rajasthan Standard Operating 0 3
Procedure 1x15 MW Power
Plant

STANDARD START UP AND SHUT DOWN PROCEDURE FOR WHRB

1X 15 MW WHRB BASE POWER PLANT

START UP OF WHRB

1. Ensure that

 Normal operating level of water is maintained in boiler.


 All the vents are open.
 All the boiler drains are closed
 Start up vent is fully open.
 Flue gas is available with requisite temperature and flowing through
the WHRB bye- pass line
 Recirculation pump is in operation and recirculation flow is established
at requisite value.
 Hammering system of PH Boilers is in operating condition. Before
operating the hammering system ensure that all the hammers are free
to rotate.

2. Start DCC’s and RAV’s of the corresponding boiler and observe that Boiler
ON Permissive is generated. Also ensure the Boiler is not tripped. Hence,
the damper operation will start automatically.

3. After Boiler ON Permissive the damper operation is as follows

a) WHRB flue gas inlet damper will be opened.

b) WHRB outlet damper will be opened.

c) Close Bypass damper is steps

4. Observe that Damper Group Ready signal is generated on DCS upon


successful completion of damper operation.

5. As the bypass damper is partially closed, gas starts flowing through


WHRB.

6. Control the gas flow through WHRB by closing ( step wise) bypass damper
in such a way that increase in Main steam temperature does not increase
more that 3 deg C per minute.

7. See that WHRB starts steaming.

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JKLC, Sirohi, Rajasthan Standard Operating 0 4
Procedure 1x15 MW Power
Plant

8. Close vents at drum pressure at 2 kg/cm2.

9. Start one BFP if required and maintain drum level

10. Charge Main steam line at 12 to 14 kg/cm2 and temp at 300 deg C (if 1st
boiler is started). Open the main steam line when normal operating pressure
and temp are achieved for connecting with the main steam header.

11. Gradually close bye-pass damper and close start up vents fully as steam
demand is increased.

12. Start HP & LP dosing pump.

SHUT DOWN PROCEDURE OF WHRB

Follow below mentioned steps for stopping of WHRB

1. Inform JKLC control room for stoppage of WHRB

2. Slowly operate bypass damper for by passing flue gas from WHRB

3. Observe that steam generation is decreasing

4. Reduce load in STG

5. Once steam generation becomes zero, close MSSV

6. Open bypass damper fully.

7. Close flue gas outlet damper and subsequently close inlet damper

8. Maintain drum level

9. Keep RC pump operation for further one 1 hr.

10. Stop hammering system after 1 hr of stoppage of boiler

10. Stop HP dosing pump

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THERMAX LIMITED POWER DIVISION

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JKLC, Sirohi, Rajasthan Standard Operating 0 5
Procedure 1x15 MW Power
Plant

STANDARD START UP AND SHUT DOWN

PROCEDURE FOR

TOTAL POWER PLANT

START UP PROCEDURE OF POWER PLANT

.
Follow below mentioned steps for start up of power plant.

1. Put turbine on Barring gear by starting AOP


2. Start CEP on recirculation mode and maintain CST level.
3. Start PH2 and AQC2 as per start procedure of WHRB
4. Charge steam line and heat up line up to turbine inlet by opening warm up
vent line and drain lines.
5. Pull vacuum in condenser by taking hogger ejector first and maintain
vacuum by taking service ejector in line.
6. Once requisite temperature ( 324 deg C) is achieved, roll the turbine as
per turbine startup procedure.
7. While steam line is charged with the steam from PH and AQC boilers,
make ready to start other WHRB . (Please note that with only PH1 and
AQC1 alone, turbine can not be loaded. So it is advisable to have at
least one more WHRB ready before synchronizing the turbine)
8. Synchronize STG with two WHRB’s in line.
9. Gradually increase load in STG.
10. Start cooling tower fans as per requirement.
11. Subsequently take other WHRB in line one by one.
12. Stabilize the power plant and note down all the parameter.

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JKLC, Sirohi, Rajasthan Standard Operating 0 6
Procedure 1x15 MW Power
Plant

SHUT DOWN PROCEDURE OF POWER PLANT

Follow below mentioned steps for taking shut down of power plant

1. Take shut down of WHRB as per standard procedure of WHRB shut down.

During shut down reduce load and maintain turbine inlet steam pressure.

2. Subsequently take shut down of other WHRB one by one following above

mentioned step.

3. Accordingly reduce load to STG. During reduction of load maintain steam

pressure by opening start up vents of WHRBs.

4. Open generator breaker.

5. Ensure that lube oil pressure is maintained.

6. Ensure barring gear auto start at 150rpm speed of STG.

7. Keep CEP in operation for another one hour.

8. Keep STG on barring gear till the bearing temperature is around 40 deg C.

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THERMAX LIMITED POWER DIVISION

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JKLC, Sirohi, Rajasthan Standard Operating 0 7
Procedure 1x15 MW Power
Plant

EMERGENCIES

IN

1X 15 MW WHRB BASE POWER PLANT

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THERMAX LIMITED POWER DIVISION

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JKLC, Sirohi, Rajasthan Standard Operating 0 8
Procedure 1x15 MW Power
Plant

EMERGENCIES IN 15 MW POWER PLANT

Following emergencies are envisaged during operation of 15 MW power plant.

1. Stuck up of Flue gas damper.

2. Tripping of Recirculation pump.

3. Tripping of Boiler feed pump.

4. Shearing of Drag chain conveyor Shear pin.

5. Increase in flue gas temperature beyond 400 deg C.

6. Tripping of ash Screw/Pan conveyor.

7. Tripping / stoppage of WHR Boilers.

8. Tripping of kiln

9. Tripping of turbine and all WHRBs are in service.

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JKLC, Sirohi, Rajasthan Standard Operating 0 9
Procedure 1x15 MW Power
Plant

1. Stuck up of Flue gas damper

Take following actions while flue gas damper/s are stuck up

 Operate damper manually as per sequence mentioned in Damper


Operation Procedure

 Boiler can be kept in operation even by operating the dampers manually.

 During shut down please stop/ close damper as per the sequence
mentioned in damper operation procedure.

2. Tripping of Recirculation pump.

Take following actions are to be taken while Recirculation pump trips

 RC pump shall trip on low drum level and electrical fault.


 If the pump trips on electrical fault restart stand by pump. ( Normal
drum level ensures that RC pump tripped on electrical fault)
 If there is low drum level, try to maintain drum level as early as possible.
 If drum level can not be maintained within 10 minutes, by pass flue gas to
take shut down of the boiler.
 During bypassing ,the sequence of damper operation shall be as per the
damper operating procedure.

3. Tripping of Boiler feed pump

Boiler feed pump may trip due to low deaerator level or due to any electrical
fault

If BFP trips on electrical fault, start stand by BFP immediately (within 5


minutes).

If stand by can not be started due to any reason follow the steps to take shut
down of all the boilers

 Open flue gas by pass damper.


 Close WHRB outlet damper.
 Close inlet damper.

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JKLC, Sirohi, Rajasthan Standard Operating 0 10
Procedure 1x15 MW Power
Plant

 Isolate main steam line valves.

4. Shearing of Drag chain Shear pin

 Inform Cement plant control room.


 Start by passing flue gas and accordingly reduce load in STG.
 Once flue gas is totally by passed, replace shear pin.
 Once the Drag chain feeder is operatable, start taking flue gas in WHRB as
per WHRB start up procedure.
 Increase load in STG.

5. Increase in flue gas temperature beyond 400 deg C

By increasing flue gas temperature, MS temp will increase beyond 325 deg C.

 Open by pass damper partially and see that Main steam temperature is
under control and WHRB steam generation has reduced.
 Decrease STG load.
 Inform JKLC control room.
 Once Flue gas temp is within 400 deg C, gradually close the by pass
damper.
 See that boiler load has again increased, increase STG load and normalize.

6. Tripping of ash screw conveyor

 Inform JKLC control room as maintenance of screw/pan conveyor is in


customer’s scope.
 IF the same is not attended within 10 minutes, by pass flue gas from
WHRB following the damper operating sequence.

7. Tripping / stoppage of WHRB

 Inform JKLC control room and gradually decrease load in STG.


 Ensure that WHRB flue gas by passing has been done as per damper
operation procedure.

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JKLC, Sirohi, Rajasthan Standard Operating 0 11
Procedure 1x15 MW Power
Plant

8. Tripping of kiln

 Once kiln is tripped/ stopped, corresponding Boiler is required to be


stopped.
 Stop the Boiler as per Boiler Shut down procedure mentioned above.
 Reduce STG load gradually. At 1.5 MW load open the generator breaker.
 Stop turbine as per normal shut down procedure.

9. Tripping of turbine and all WHRBs are in service

 Maintain drum pressure by opening start up vents of all the WHRB


 Inform JKLC control room.
 By pass flue gas from WHRBs one by one
 Take shut down of all WHRBs one by one as per shut down procedure.
 Maintain drum level all the time.

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THERMAX LIMITED POWER DIVISION

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JKLC, Sirohi, Rajasthan Standard Operating 0 12
Procedure 1x15 MW Power
Plant

Dos AND Don’ts

FOR

1X 15 MW WHRB BASE POWER PLANT

IMPORTANT Dos AND Don’ts DURING PLANT OPERATION

Dos

1. Go through all SOPs in details and keep sequence of dampers operation in


mind.

2. Do ask in case of any doubts to your seniors before any operation.

3. Do note all parameter of WHRBs and STG areas on regular basis.

4. Do take safety measures while working in power plant.

Don’ts

1. Do not carry out any of the operation in hurry and with out understanding
the reason for operation.
2. Do not do any maintenance activities without Work permit and informing
JKLC CCR.
3. Do not allow any unauthorized person to perform plant operations from
DCS.
4. Do not by pass any protection and interlock of the power plant
5. Do not hesitate to ask in case of doubts.

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JKLC, Sirohi, Rajasthan Standard Operating 0 13
Procedure 1x15 MW Power
Plant

STEAM TURBINE GENERATOR – 1NO. (FREE SUPPLY, ERECTION AND


COMMISSIONING BY CUSTOMER)

Parameter Unit Value

Power at generator terminal (Approx) kW 15000

Main Steam Pressure at Turbine inlet Ata 15

Main Steam Temperature at Turbine inlet °C 324.3

Main Steam Flow at Turbine inlet including auxiliaries TPH 72

Exhaust steam Pressure Ata 0.2

Cooling water Inlet Temperature °C 33

Cooling water outlet Temperature °C 42

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