KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL / Opr. / CEP/ 01

SOP FOR Condensate Extraction Pump

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Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 1 of 1

STANDARD OPERATING INSTRUCTION

FOR

Condensate Extraction Pump

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Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Name:
Designation: Asst. Mgr Designation: Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / Opr. / CEP/ 01
SOP FOR Condensate Extraction Pump

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Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 2 of 1

STANDARD OPERATING PROCEDURE FOR CONDENSATE EXTRACTION PUMP

OBJECTIVE: For Smooth Operation of Condensate Extraction Pump.
SCOPE: This SOP is applicable for 2 no. of Condensate Extraction Pump.

INTRODUCTION: Condensate from condenser hot-well is pumped through LP heaters up to

deaerator by condensate extraction pump(CEP).

.CEP TECHNICAL DATA:-

TECHNICAL SPECIFICATION FOR CEP MOTOR

S.No. Parameter Unit Data
1 Maker Shanghai/Xiangtan Motor Plant

2 Type YKSL2240-4/1180-1
3 Rated Power kW 2240
4 Rated V. kV 11
5 In-phase rotating speed. r/min 1500
6 Start-up Current A 837.6
7 Rated Current A 139.6
8 Frequency Hz 50
9 Efficiency % 94
10 Power factor 0.89
11 Blocking torque 0.8
12 Blocking current A 6
13 Max. torque 1.8
14 Insulation F
15 Weight kg 14400

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Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Name:
Designation: Asst. Mgr Designation: Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / Opr. / CEP/ 01
SOP FOR Condensate Extraction Pump

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16 Cooling method air-water

17 Rotation (see from the motor end) Anticlockwise

TECHNICAL SPECIFICATION FOR CEP

S.No. Parameter Unit Data
1 Maker KSB SHANGHAI
2 Type NLT500-570x5S
3 Inlet Temp. ºC 46.7
4 Head mH2O 366
5 Inlet Pressure Kpa(a) 10.3
6 Flow m³/hr 1640

7 Closed valve head mH2O 460

8 Designed pressure pump body Mpa(g) 5
9 Impeller stage. 5
10 Min. Flow t/h 415
11 Operation temp. t/h 46.7
12 Head at the Min. flow. mH2O 449
mH2O
13 NPSH (R) 5.4
14 Efficiency % 84.4
15 Shaft Power KW 1931.4
16 Rotating speed r/min 1480
17 Rotation Direction Anti clockwise(motor end)

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

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Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Name:
Designation: Asst. Mgr Designation: Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / Opr. / CEP/ 01
SOP FOR Condensate Extraction Pump

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Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 4 of 1

SAFETY PRECAUTIONS:
1. Ensure no permit to work is pending on regarding this system by checking with
EE/MRSE.
2. Electrical cable insulation and motor termination to be ensured.
3. Operation of local start / stop push button shall be ensured for perfect operation to
facilitate for stopping of equipment in case of emergency.

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

SPECIAL TOOLS/ EQUIPMENTS: NIL

Pre-Checks:
PRECHECKS AND ACTION BY FIELD ENGINEER

S Description Ok Not Remarks

No Ok

1 All permits and cross permits have been returned.  

2 Area is clear of any other materials.  

3 Check coupling guard is not touching with coupling.  

4 Power supply available in all MOV’s.  

5 Proper venting of CEP suction strainer and its drain

closed.  

6 Hotwell drain closed, local level gauge charged and

hotwell level normal.  

7 Motor power cable termination proper.  

8 Pump bearing oil level normal.  

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Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Name:
Designation: Asst. Mgr Designation: Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / Opr. / CEP/ 01
SOP FOR Condensate Extraction Pump

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Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 5 of 1

9 GSC before and after manual isolation valve is open

and bypass MOV is close  

10 Condensate dumping line control station before and

after manual isolation valve and CST tank inlet manual
isolation valve is open.  

11 Hotwell make up line manual isolation valve is open.  

12 Pump mech. sealing water line manual valve (coming

from CTP discharge header) is open.  

13 Vacuum balancing line manual isolation valve is  

opened.
14 Thrust bearing cooling water inlet, outlet valves are  
open. (from CCCW)
PRECHECKS AND ACTION BY DESK ENGINEER

S Description Ok Not Remarks

No Ok

1 All permits and cross permits have been returned.  

2 Hotwell level normal.  

All interlocks are tested, Qualified and relevant meters

3 are working.  
CCCW pump, condensate make up pump and air
4 compressor are running normal.  

5 CEP suction motorized valve is open.  

6 CEP discharge motorized valve is closed.  

Deaerator control station inlet and outlet MOV’s are

7 opened and bypass MOV is closed.  

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Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Name:
Designation: Asst. Mgr Designation: Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / Opr. / CEP/ 01
SOP FOR Condensate Extraction Pump

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Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 6 of 1

LP Heaters 8/7/6/5 condensate inlet, outlet valves are

open, bypass valves of LPH 5 & 6 are closed (Inlet,
8 outlet, bypass is common for LP heaters 8/7 A,B)  

9 GSC bypass MOV is closed.  

CEP min recirculation Inlet and outlet MOV’s are open

10 and bypass MOV is closed.  

11 CEP min recirculation control valve is opened > 95 %.  

CEP motor upper and down bearing temperature

12 normal.  

CEP thrust bearing temperature normal.

13  
 

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, control power and instrument air supply available. √ √
3 CEP motor and pump bearing temperature is in permissible limit. √ √
4 At least one CCCW, one condensate make up pump is running √ √
5 Suction inlet MOV is opened. √ √
6 Discharge MOV is closed. √ √
START PERMISSIVE :

1 Condenser hotwell level > 600 mm √ √

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Name: Bhupendra Sahu Name: Name:
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 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / Opr. / CEP/ 01
SOP FOR Condensate Extraction Pump

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2 Inlet MOV is opened. √ √

3 Outlet MOV is closed. √ √

4 CEP motor bearing (Up & under) temperature< 70º C. √ √

5 CEP pump thrust bearing temperature < 75 º C. √ √

6 CEP motor winding temperature < 130º C √

7 Emergency push button is in release condition. √

8 No interlock trip condition √

PUMP START UP SEQUENCE :

1 Open sealing water valve from condensate make up pump outlet to √
condensate water pump, put condensate water pump sealing water
into operation.
2 Open air vent of condensate pump inlet strainer and close after √ √
proper water comes through it.
3 Fill CEP discharge header with CTP and vent the line √
4 After coming sufficient water out of this vent close header line filling √
manual isolation valve.

5 Ensure CEP recirculation control valve is open.

6 Start the pump.

7 Its discharge valve will open.

8 Open deaerator CV as per requirement
9 Observe for closing of min recirculation CV based on CEP flow

SHUTDOWN SEQUENCE:

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Name: Bhupendra Sahu Name: Name:
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 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / Opr. / CEP/ 01
SOP FOR Condensate Extraction Pump

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Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 8 of 1

1. PLANNED SHUTDOWN :

1 Reduce the load on the pump by reducing the opening of deaerator √

level control valve

2 Open pump recirculation valve fully. √

3 Release interlock of standby pump ( If in interlock) √

4 Stop the pump. √ √

5 Observe for closing of discharge valve, if not close it by giving √
command

6 When CEP is to be isolated for maintenance, close pump outlet

valve, close inlet valve, close sealing water pump from CEP outlet √
to pump, close sealing water valve from DM make up pump to
CEP.
7 √ √
4. TRIPPING OF PUMP
1 Condensate pump inlet MOV is confirmed to be close. √ √
2 Condensate pump outlet MOV not opened after 30s of pump running √ √
3 Condenser hotwell level low - < 200 mm
4 Condensate pump motor stator winding temperature HH – 140ºC
5 Condensate pump motor bearing temperature HH - 80ºC
6 Condensate pump thrust bearing temperature HH - 80ºC
7 When condensate pump is running, condensate water flow <415t/h
and recirculation valve regulating valve position<50%
3. EMERGENCY SHUT DOWN:
1 There is the apparent abnormal noise after starting the pump. √ √
2 The pump bearing temperature is higher than 80 deg C and √ √

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Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Name:
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 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / Opr. / CEP/ 01
SOP FOR Condensate Extraction Pump

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continues to rise.
3 When endangering the safety of person and equipment. √ √ √ √

INTERLOCKS : Remarks

1 Condensing water pump trips or outlet head pipe pressure is lower

than 2.5MPa, standby pump puts into operation by interlock
2 Condensate pump inlet valve will be permissible closed when pump
stop
3 Condensate pump outlet motorized valve will open when pump runs

4 Condensate pump outlet motorized valve will close when pump stops

5 Condensate pump outlet motorized valve will opened when pump is

in interlock.
6 LP Turbine Cylinder spray water valve automatic opening at LP
exhaust temperature > 80℃
7 LP Turbine Cylinder spray water valve automatic opening at
Generator load ＜15%
8 LP Turbine Cylinder spray water valve automatic close at all the LP
exhaust temperatures＜65℃
9 LP Turbine Cylinder spray water valve automatic close at Generator
load >15%

ABBREVIATIONS / 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.

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Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Name:
Designation: Asst. Mgr Designation: Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / Opr. / CEP/ 01
SOP FOR Condensate Extraction Pump

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o RB : Run Back

Important Note:

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Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Name:
Designation: Asst. Mgr Designation: Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / Opr. / CEP/ 01
SOP FOR Condensate Extraction Pump

Power from knowledge

Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 11 of 1

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Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Name:
Designation: Asst. Mgr Designation: Designation: