®

HMEL
HPCL-Mittal Energy Limited
Guru Gobind Singh Refinery, Bathinda

SOP for Start-up & Shut Down of Boiler Feed Water Pump
2x300 TPH CFBC BOILER.
9112-575-0PR-704-00050 Rev:01

O&M By:

801 LEI~S
HEAVY ENGINEERING LTD

Mr. Ashish Kumar

Mr.Rajesh Mitra
01 23/06/18 IFI SI
PM (ISGEC) Dy. Mgr
(ISGEC)
(HMEL)
Mr. K.Raju Mr. Amresh Mr. Laxman Tan
00 20101/20 IFI Mr. M.Samal Eng Mr.Rajesh Mitra
Asst.Mgr Kumar SI Dy Mgr
17 (ISGEC) PM (ISGEC)
(ISGEC) (ISGEC) (HMEL)

ISSU E
REV STATUS PREPARED REVIEWED CHECKED APPROVED CONCURRED
DATE
This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written con sent of HPCL·
MITT AL ENERGY LTD . The copyright of this document is vested in HPCL-MITT AL ENERGY LTD. All rights reserved . Neither the whole nor any part of this
document may be reproduced , stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical , reprographic, recording or
otherwise) without the prior written consent of the copyright owner.. Format No, 9111·000-PCT -007 -00006 Rev-OO
 HPCL-Mittal Energy Limited Revision 01
--_._---
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water Pumps
Next Review 23/06/2019
2X300 TPH CFBC Boiler
HMEL Page 2 of 24
9112·575·0PR· 704 ·00050

REV DATE REV DETAILS'

I
--"-_ .. --

00 20-Jan-2017 Issued for Implementation

01 23-Jun-2018 Issued for Implementation

List of Person Participated in Preparation/review of SOP

----- - -----

S No. Name Designation

1 Mr. Laxman Tari Deputy Manager Operations

--- ------1-

2 Mr. Amit kumar Deputy Manager Operations

3 Mr. Rajesh Mitra Plant Manager-O&M

4 Mr. Dharmendra Kr. khare Operation Manager-O&M

---""------- i_

Mr. Ashish kumar Shift In charge- O&M

5
6 Mr.Prashanth Kumar Sharma Control Room Engineer- O&M

Note:

The Owner of this Document is Department OPERATION at BATHINDA_ Please Contact AGM 1 OPERATION Manager- for any clarifications,
I Updates or Revisions.
I
,- ~------ - ~"----- ------ ------- - --------------
 HPCL-Mittal Energy Limited Revision 01

SOP for Start-up & Shut down of Boiler Feed Water Pumps Issue Date 23/06/2018
Next Review 23/06/2019
"
2X300 TPH CFBC Boiler
HMEL Page 3 of 24
9112·575·0PR· 704 ·00050

S. No. DESCRIPTION

1 Purpose

2 Scope

3 Responsibility and Accountability

4 Tools & equipment's 4

5 Safety precaution 4-5

6 Safety, Health & Environment Consideration

7 Related Document and Reference 5

8 Definition and Abbreviation 6

9 Detail Procedure 7-19

10 Pre-requisite for training and competency 19

11 . Flow sheet / Detail drawing 19

12 Performance indicators 19

13 Records

14 Change Register

15 DCS & Field Checklist

 HPCL-Mittal Energy Limited
.,~
Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water
Next Review 23/06/2019
Pumps2X300 TPH CFBC Boiler
HMEL Page 40f 24
9112·575·0PR·704 ·00050
1. Purpose:

The purpose of this procedure is to ensure the safestartup& Shut downof Boiler
feedpumps.

2. Scope:

Scope of this procedure is limited to start-up of Boiler feed pumps.

3. Responsibility and Accountability:

a) The Operation Manager is responsible for the maintenance and Job cyclic review of
this procedure.
b) The Shift in Charge is responsible for execution all operation activity as per the
procedure.
c) Shift In charge will inform and take approval from Operation Manager for any
deviations in procedure.
d) The Assistant Shift In charge is responsible for execution the procedure through Field
engineer and shall personally reconfirm all the line-up are correct and as per
prescribed checklist.

4. Tools & equipment's:

a) -Motorola Communication Set for field Engineer, Control room Engineers, Assist.
Shift In charge and shift in charge for proper communication with Field Engineerl
Operator and DCS.
b) Mandatory PPE'S like Helmet, Full Cover, Hand gloves, Goggles, safety shoes, Ear
plug, Safety Belts.
c) Proper size of F-Key for opening the valves, if required.
d) Torch lights (24V DC) as per required standard.

5. Safety Precautions:

• Only trained and authorized personnel will carry out the activity.
• Before performing the activity, all work permits shall be cancelledl closed, system to
be normalized.
• Shift In-charge on duty during the progress of work should be fully aware of the
activities being carried out.
• All jobs shall be well planned prior to execution.
• Before clearing the work permit, inform all personnel who are involved in activity.
• Verify all piping, guards and instrument connections are made before starting the
activity.
• Verify that all valves, controls, trip mechanisms and safety devices are in good
operating condition.
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shutdown of Boiler Feed Water
Next Review 23/06/2019
® Pumps2X300 TPH CFBC Boiler
HMEL Page 50f24
9112·575·0PR·704 -00050
• All interlocks & protections are in service, if any deviation, risk assessment &
necessary approval to be taken.
• Before initial charging, after maintenance or after an extended shutdown, ensure
leak check & purge has been done by nitrogen gas & all blinds have been removed
from the lines, which were provided for isolation.

6. Safety, Health & Environment Consideration:

61 S af ety:
t
51 No. Hazard Precaution ACTION BY
1 Slip and fall hazard Keep the area dry. FE
2 Entanglement in Do not wear ornamental chains or FE
rotation or moving loose clothing I See that coupling
parts guards are in place.

6.2 Health:
51 No. Hazard Precaution ACTION BY
1 Ergonomics - Use standard valve keys. FE
Operating of valves Use hand gloves while operating
can result in back valves.
injury, injury to arms Use ladder, platform or stand for
operating valves at height.
2 Heat stress & Immediately shift victim under the FE
dehydration shed.
Take rest & drink plenty of water.
ORS may be provided if more
dehydration felt.
6.3 Environment:
S.No. Hazard Precaution ACTION BY
1 Water Ensure all the area is FE
Spillage paved.

2 Oil Spillage Ensure oil spills to be FE

cleaned. Arrest oil
leakages ontoppriority.

7.0 Related Document:

~ P&I Drawing: JB0940-S0990200-PID-0004, JB0940-S0990200-PID-0048, 49

JB0940-S0990200:.PID:.0053, S4.
~ ISGEC Manual: Volume-II (Part 1 of 4).
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/0612018
SOP for Start-up & Shut down of Boiler Feed Water
Next RevIew 23/0612019
® Pumps2X300 TPH CFBC Boiler
HMEL 9112·575·0PR·704 ~00050 Page 6of24

8;0 Definition 'and Abbreviation:

8.1 Definitions of Label

LABEL DEFINITIONS

DANGER:
DANGERS alert you to an immediate hazard that causes serious injury or death and
requires special Precautions to be taken
CAUTION:
CAUTION alert you to a potential hazards that causes serious damage to equipment!
Pro ert under certain condition
WARNING:
WARNING alert you to a potential hazard that causes serious injury or death under
certain condition

I NOrQ NOTE:
Note emphasize or remind you of an important place of information

Abbreviation:
BFP: Boiler Feed Pump
FE: Field Engineer
CRE: Control Room Engineer
ASIC: Assistant Shift In-charge
SIC: Shift In-charge

8.2 System overview of Boiler Feed Pump~

A boiler feedpump is used to pump the feed water from De-aerator or FWST to a
steam drum in boiler.

~ Design flow :370ml11/Hr.

~ Design Head: 1585mmWc
~ Discharge pressure: 157kg/cm 2
~ Temperature: 135°C
~ Boiler feed pump discharge pressure: 151.05 Kg/cm 2 (g).
~ BFP suction pressure: 3.57 Kg/cm 2 (g).
~ Feed water density: 930.49 Kg/m3.
~ Motor: 2.2 MW.
~ Speed:2980RPM
~ Auxiliary Cooling water pressure required: 3 Kg/cm2.
~ Lube oil system details: 50 LPM 1 with header pressure of 2 kg/cm 2.
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water Pumps
Next Review 23/06/2019
"
2X300 TPH CFBC Boiler
HMEL Page 7 of 24
9112·575·0PR-704 -00050

9.0 Detail Procedure:

9.1 Startup & Shut down Procedure for Boiler Feed pump-A

Protections & set points For Boiler Feed Pump-A

For AOP:
""-"

51. No. Description TAG No. Alarm Value

1 Lube Oil tank level not low i4-LT-2801 180mm

--- ---~~-~
Safety Interlock
Alarm
51. No. Description TAG No. Value Trip Value
1 Motor Winding Rl phase Temperature 14TI0301A 110 120° C
2
--------"
Motor Winding R2-phase Temperature 14TI0302A 110 120° C
--"
3 Motor Winding Vi-phase Temperature 14TI0303A 110 120° C
4 Motor Winding V2-phase Temperature 14TI0304A 110 120° C
5 Motor Winding Bl-phase Temperature 14TI0305A 110 120° C
6 Motor Winding B2- phase Temperature 14TI0306A 110 120° C
7 Motor Non Drive end Bearing Temperature 14TI0308A 95 105° C.
8 Motor Non Drive end Bearing Temperature 14TI03088 95 105° C.
9 ' Motor Drive end Bearing Temperature 14TI0307A 95 105° C.
10 Motor Drive end Bearing Temperature 14TI03078 95 105° C.
Pump Drive end Radial Bearing Temperature
11 14TI0309A 80 90 0 C
Transmiter-1
I
Pump Drive end Radial Bearing Temperature I
12 14TI0310A 90 100 0 C
Transmiter-2
Pump Drive end LHS Thrust Bearing
13 14TI0311A 90 1000 C
Temperature Transmiter-1
Pump Drive end LHS Thrust Bearing
14 14TI0311B 90 1000 C
Temperature Transmiter-2

15
i Pump Drive end RHS Thrust Bearing 14TI0312A 90 1000 C
I Temperature Transmiter-1
Pump Drive end RHS Thrust Bearing
16 14TI0312B 90 1000 C
Temperature Transmiter-2
Pump Non-Drive end Radial Bearing
17 14TI0313A 90 1000 C
Temperature Transmiter-1
--
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water
Next Review 23/06/2019
® Pumps2X300 TPH CFBC Boiler
HMEL 9112·575·0PR-704 -00050 Page 8 of 24

Pump Non-Drive end Radial Bearing

18 14TI0314A 90 1000 C
Temperature Transmiter-2
19 Pump DE Vibration X- Axis 14VI0305 84\.Jm 126\.Jm
20 Pump DE Vibration Y-Axis 14VI0306 84IJm 126\.Jm
21 Pump NDE Vibration X- Axis 14VI0307 84IJm 126IJm
22 Pump NDE Vibration Y- Axis 14VI0308 84\.Jm 126\.Jm
23 Motor DE Vibration X- Axis 14VI0301 6mm/sec 7.1mm/sec
24 Motor DE Vibration Y-Axis 14VI0302 6mm/sec 7.1mm/sec
25 Motor NDE Vibration X- Axis 14VI0303 6mm/sec 7.1mm/sec
26 Motor NDE Vibration Y-Axis 14VI0304 6mm/sec 7.1mm/sec
Process Interlock
14PDI0302A
1 DP Across BFP Suction strainer 14PDI0302B 1200 mmwc 1600mmwc
14PDI0302C
14L10201A
2 De-aerator <20% 14L10201 B -1435 -2020
14L10201C
12PI1201A
3 Cooling water pressure 12PI1201 B 2.5 kg/cm2 2 Kg/cm2
12PI1201C
Suction pressure Vs Suction
4 Temperature Refer BFP Suction Press Vs D/A Temp (X)
14PI2806A
5 Lube Oil Pressure 14PI2806B 1 kg/cm2 0.8 Kg/cm2
14PI2806C
14TI2804A
6 Lube Oil Temperature 14TI2804B 48 52 Deg C
14TI2804C
Start Permissive
14L10201A
1 De-aerator <35% 14L10201B -1435 -2020
14L10201C
2 AOP RunninQ indication 12XLPM011A Yes
BFP Suction Manual Valve Open feed
Yes
3 back 14-ZSH-0301
BFP Suction Manual Valve Open feed
Yes
4 back 14-ZSH-0302
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start~up & Shut down of Boiler Feed Water
Next Review 23/06/2019
® Pumps2X300 TPH CFBC Boiler
HMEL Page 90f24
9112·575-0PR-704 -00050

9.2 Pre-checks:

S ACTION BY
DESCRIPTION
No FE CRE SIC
01 Ensure no work permit should be pending from any department.
2 Ensure that the cooling water pressure is above 3 kg/cm2. ~ ~

All cooling water inlet valve (14-GTV-2615) & outlet valves-(14- ~

3
GLV-2614) are in open condition.
Cooling water valves (14-GTV-2607, 14-GTV-2601) is in open ~
4
condition.

5 Ensure local emergency push bottom should be released. ~

Ensure that the De-aerator air vents valves (14-GTV-0241, 0242, ~

6
0280, and 0281) are in open condition.
Ensure that the corresponding BFP-A suction valve-(14-GTV- ~ ~
7
0306, 14-GTV-0307) is in open condition.
Ensure that the minimum re-circulation line valve-{14-GLV-0327, ~ ~
8
14-GTV-0294) (Near De-aerator) is in open condition.
Ensure that corresponding BFP-A Discharge MOV - (14-MOV- ~ ~
9
0302, 0301) is in closed condition.
Ensure that corresponding BFP-A Discharge Manual isolation
10 valve-(14-GTV-0329, 03136) is in open condition i.e. (14-ZSH- ~ ~
0306).
Check the De-aerator level, the level should be above 60% ~ ~.
11
(2100mmWc).
12 Ensure that the Lube oil tank level above 225 mm. ~ ~

13 Ensure that the coupling is fully covered by coupling guard. ~

Observe the Cooling water floats in the view glass for flowing of ~
14
water.
Ensure that the Lube oil AOP suction valve (14-GTV-2808) &
15 MOP Discharge valve (shaft driven) (14-NV-2804) is in open ~
condition.
Ensure that the Lube oil AOP discharge valve (14-GTV-2015) &
16 MOP Discharge valve (shaft driven) (14-GTV-2011) is in open ~
condition.
Ensure that the header (14-GTV-0321) spray water attemperator ~ ~
17
valve will be closed.
Ensure that the (14-GTV-0368, 03150) (Bypass), (14-GTV-
18 03142/03151) (Bypass) valve Towards UB04 Existing feed water ./
discharge header valves will be closed.
Ensure that the SWAS line valves (14-GLV-03120, 03124) are ~
19
closed.
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water
Next Review 23/0612019
Pumps2X300 TPH CFBC Boiler
HMEL Page 100f24
9112·575·0PR·704 ·00050

9.3 Startup& Shut down Procedure for BFP-A:

Auxiliary Oil pump Startup:

S ACTION BY
DESCRIPTION
No FE CRE SIC
Start the lube oil heater-(575-14-E-001) for initially raising of ./
1
the oil temp keeps the Heater in auto.
2 Ensure that the lube oil temperature above 420 C ./ ./
3 Ensure that the AOP (575-14-PM-011) is selected.manual. ./
Ensure that the AOP Emergency local push button is ./
4
released from Local.
After ensuring all the above conditions, start the (AOP 575- ./
S
14-PM-011) from DCS.
Ensure that the discharge lube oil pressure (14-PI-2802) is ./ ./
6
>5 kg/cm2.
Ensure that the Lube oil header pressure - (14-PT-2806 A, ./ ./
7
B, C) is 2 kg/cm2.
Ensure that the Lube oil (DP-14-PDT-2807) is normal like ./
8
below 0.5 kg/cm2,
9 Check for any lube oil leakages in the lines, flanges. ./
Check the view glasses for oil flow through the bearings ./
10
stuffing box.
Charge AOP oil cooler if the lube oil temperature goes ./ ./
11
above 450 C

9.4 Boiler feed pump-A Startup:

S ACTION BY
DESCRIPTION
No FE CRE SIC
Open the BFP-A Casing drain valve (14-GTV-2612), Ensure that
1 the water is coming, in case when the De-aerator is not in charge ./
condition. Close the Casing drain valve (14-GTV-2612).

In case when the De-aerator is charging condition, leave the

Casing drain valve (14-GTV-2612) open for some time for uniform ./
2
heating of casing. Close the Casing drain valve (14-GTV-2612)
after attaining the temperature.
3 Release the Emergency push button from the field. ./

4 Ensure that the BFP-A (575-14-BFPM-001) is selected manual. ./

S Ensure that the BFP-A start permissive OK. ./

 H L-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water Pumps
Next Review 23/06/2019
2X300 TPH CFBC Boiler
HMEL 9112·575·0PR· 704 -00050 Page 11 of 24

6 Ensure that the BFP-A Safety interlock OK. ../

,---
7 Ensure that the BFP-A Process interlock OK. ../
Ensure that the BFP-A Discharge valve MOV-(14-MOV-0301, 2) is ../ ../
8
closed.
9 Start the BFP-A, and note down the shut off pressure. ../
10 Observe that any abnormal sound in the field. ../
----- c----
11 Observe that the BFP-A starting Current in Amps. ../ ../

12 After attaining the BFP-A full RPM, Open the MOP priming valve ../

(14-NV-2807) for priming of the Shaft driven pump (MOP 575-14- ../
13
P-01O.)
Observe the Shaft driven MOP Discharge Pressure (14-PT-2804) ../ ../
14
if the pressure is above 5kg/cm2.

l~5__ (575-14-PM-011).
Close the priming valve (14-NV-2807); stop the Motor Driven AOP ../

Observe the Oil pressure will be maintained by BFP-A Shaft driven ../ ../
I 16 pump MOP.
17 Keep the Motor Driven AOP (575-14-PM-011) in Auto. ../
Open the BFP Discharge valve Bypass MOV-(14-MOV-0302),
after full opening of bypass MOV, open the Discharge Main MOV- ../
18
(14-MOV-0301), after full opening of Main MOV, and close the
Bypass MOV.
Check the vibrations of Motor & Pump and the bearing ../
19
temperatures.
-
Ensure that no abnormal sound, heating of bearings, water ../
, 20
I leakage from any flange jOints & glands.
Note down the Suction pressure, Minimum Recirculation line ../ ../
21
pressure, suction DP, Discharge Pressure.
22 If any abnormality found stop the Boiler Feed pump-A. ../
We can Charge the UB05, UB06 Feed water lines based on the ../ ../
23
requirement.
Observe the Motor winding Temperatures if the temperatures are ../ ../
24
increasing then check the motor cooling fan arrangement.
After ensuring all healthiness of BFP - A parameters & normalizing
the drum level of UB05 or UB06, Open the Feed Water ../ ../ ../
25
Interconnecting valve of CFBC & CPP after communication with
---
STEAG CRE & SIC
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water
Next Review 23/06/2019
® Pumps2X300 TPH CFBC Boiler
HMEL Page 12 of 24
9112-575·0PR-704 -00050

9.5 UB-05 Feed water line ~harging:

S ACTION BY
DESCRIPTION
No FE CRE SIC

Slowly open the Bypass isolation valves (12-GTV-03153, 12-GTV- ./

1
03148) first then the Main valve (12-GTV-03138, 12-GTV-03152).

2 Corresponding UB05 Feed Regulating station can be charged. ./

9.SUB-OS Feed water line charging:

S ACTION BY
DESCRIPTION
No FE CRE SIC
Slowly open the Bypass isolation valves (13-GTV-03147, 12-GTV-
1 03149) first then the Main isolation valve (12-GTV-0370, 12-GTV- ./
0371).

2 Corresponding UB06 Feed Regulating station can be charged. ./

9.7SHUT DOWN:

S ACTION BY
DESCRIPTION
No FE CRE SIC
Close the Discharge MOV-(14-MOV-0301) by ensuring the feed ./
1
water requirement in the Boilers.

2 Ensure that the Motor Driven AOP (575-14-PM-011) is in Auto. ./

Maintenance Mode Logic has been implemented as when any BFP A

or B goes for maintenance & its AOP is to be stopped in that case
3 before stopping the AOP activate its maintenance mode so that when
AOP is stopped its RTS will be unhealthy in that case any existing
BFP of CPP will not start in Auto mode.
After ensuring the safe activation of maintenance mode go for
4
stopping of BFP-A
5 Stop the BFP-A (575-14-BFPM-001). ./
After stopping the BFP-A Priority Selection to be done as per
6
discussion with STEAG SIC
After stopping of the BFP-A ensure that the Motor driven AOP
7 (AOP575-14-PM-011) starts, & maintain the Lube oil pressure if BFP- ./
A to be taken in Auto mode.
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water
Next Review 23/06/2019
® Pumps2X300 TPH CFBC Boiler
HMEL Page 13 of 24
9112·575·0PR·704 -00050

9.8 Startup& Shut down Procedure for Boiler Feed pump-B

Protections & set points for Boiler FeedPump-B

For Auxiliary Oil Pump:

SI. Alarm
Description DeS TAG No.
No. Value
1 Lube Oil tank level not low 14-LT-2802 180mm
Safety Interlock
SI. Alarm
Description TAG No. Trip Value
No. Value
1 Motor Winding R1 phase Temperature 14TI0315B 110 1200 C
2 Motor Winding R2-phase Temperature 14TI0316B 110 1200 C
3 Motor Winding Y1-phase Temperature 14TI0317B 110 1200 C
4 Motor Winding Y2-phase Temperature 14TI0318B 110 1200 C
5 Motor Winding B1-:phase Temperature 14TI0319B 110 1200 C
6 Motor Winding B2- phase Temperature 14TI0320B 110 1200 C
7 Motor Non Drive end Bearing Temperature 14TI0322A 95 1050 C
8 Motor Non Drive end Bearing Temperature 14TI0322B 95 1050 C
9 Motor Drive end Bearing Temperature 14TI0321A 95 1050 C
10 Motor Drive end Bearing Temperature 14TI0321B 95 1050 C
Pump Drive end Radial Bearing Temperature
11 14TI0323B 90 1000 C
Transmiter-1
Pump Drive end Radial Bearing Temperature
12 14TI0324B 90 1000 C
Transmiter-2
Pump Drive end LHS Thrust Bearing
13 14TI0325A 90 1000 C
Temperature Transmiter-1
Pump Drive end LHS Thrust Bearing
14 14TI0325B 90 1000 C
Temperature Transmiter-2
Pump Drive end RHS Thrust Bearing
15 14TI0326A 90 1000 C
Temperature Transmiter-1
Pump Drive end RHS Thrust Bearing
16 14TI0326B 90 1000 C
Temperature Transmiter-2
Pump Non-Drive end Radial Bearing
17 14TI0327B 90 1000 C
Temperature Transmiter-1
Pump Non-Drive end Radial Bearing
18 14TT0328B 90 1000 C
Temperature Transmiter-2
19 Pump DE Vibration X- Axis 14VI0313 841.lm 1261.lm
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water
Next Review 23/06/2019
® Pumps2X300 TPH CFBC Boiler
HMEL Page 14 of 24
9112·575·0PR· 704 ·00050

20 Pump DE Vibration Y- Axis 14VI0314 841..1m 1261..1m

21 Pump NDE Vibration X- Axis 14VI0315 84 1..1 m 1261..1m
22 Pump NDE Vibration Y-Axis 14VI0316 84 1..1 m 1261..1m
23 Motor DE Vibration X- Axis 14VI0309 6mm/sec 7.1mm/sec.
24 Motor DE Vibration Y-Axis 14VI0310 6mm/sec 7.1mm/sec.
25 Motor NDE Vibration X- Axis 14VI0311 6mm/sec 7.1mm/sec.
26 Motor NDE Vibration Y- Axis 14VI0312 6mm/sec 7.1mm/sec.
Process Interlock
14PDI0309A
1 DP Across BFP Suction strainer 14PDI0309B 1200mmwc 1600mmwc
14PDI0309C
14L10201A
2 De-aerator <20% 14L10201B -1435 -2020
14L10201C
12PI1201A
3 Cooling water pressure 12PI1201B 2.5 kg/cm2 2 Kg/cm2
12PI1201C
Suction pressure VIS Suction
4 Refer BFP Suction Press VIS D/A Temp (X)
Temperature
14PI2813A
5 Lube Oil Pressure (2 out of 3 Logic) 14PI2813B 1 kg/cm2 0.8 Kg/cm2
14PI2813C
14TI2808A
6 Lube Oil Temperature 14TI2808B 45 520 C
14TI2808C
start Permissive
14L10201A
1 De-aerator Level >35% 14L10201 B -1435 -2020
14L10201C
2 AOP Running condition 12XLPM013A Yes
3 BFP Suction Manual Valve Open feed back 14-ZSH-0303 Yes
4 BFP Suction Manual Valve Open feed back 14-ZSH-0304 Yes
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water
Next Review 2310612019
® Pumps2X300 TPH CFBC Boiler
HMEL 9112·575·0PR·704 -00050 Page 150f24

Boiler FeedPump Suction Pressure Vs Temperature:

BFP Suction Header BFP Suction press
51.
Temperature 0 C trip value(Kg/cm2)
No.
14·TI·0301 A,301 B 14·PI· 311 A,B,C
1 0 0..7
2 100 0.7
3 105 0.7
4 110 0.7
5 115 0.7
6 120 0.7
7 125 0.9
8 130 1.26
9 135 1.65
10 140 2.09
11 145 2.58
12 150 3.13
13 155 3.75
14 160 4.44
15 165 5.2
16 170 6.05
17 175 6.98
18 180 8
19 185 9.12
In the Above table illustrates that the BOiler Feed pump Suction pressure VIS BFP Suction
Header Temperature. If the Boiler Feed pump Suction pressure 0.; 7 kg/cm2 matches the BFP
suction header temperature of 1000 C, the Boiler feed pump will trips vice versa, if the
corresponding Pressure VIS Temperature meets, the Boiler Feed pump will trip.

9.9 Pre·checks:
5 ACTION BY
DESCRIPTION
No FE CRE SIC
1 Check the Free rotation of the Pump and motor shaft. ./ ./
2 Ensure that the cooling water pressure is above 3 kg/cm2. ./
All main supply cooling water inlet valve (14-GTV-2630) & outlet valves- ./
3
(14-GLV-2629) are in open condition.
Cooling water inlet valves (14-GTV-2622, 14-GTV-2616) is in open ./
4
condition.

s Ensure that there is no loose terminal from BFP-B motor side, ./

Ensure that the De-aerator air vents valves (14-GTV-0241, 0242, 0280, ./ ./
6
and 0281) are in open condition.
Ensure that the corresponding BFP-A suction valve-(14-GTV-0331, 14- ./ ./
7
GTV-0332) is in open condition.
 HPCL-Mittal Energy Limited Revision 01

SOP for Start-up & Shut down of Boiler Feed Water Issue Date 2310612018
Next Review 2310612019
Pumps2X300 TPH CFBC Boiler
HMEL 9112·575·0PR·704 -00050 Page 16 of 24

Ensure that the minimum re-circulation line valve-(14-GLV-0352, 14- ./ ./

8
GTV-0295) (Near De-aerator) is in open condition.
Ensure that corresponding BFP-A Discharge MOV - (14-MOV-0303, ./ ./
9
0304) is in closed condition.

Ensure that corresponding BFP-A Discharge Manual isolation valve-(14- ./ ./

10
GTV-0330, 03137) is in open condition i.e. (14-ZSH-0307).

Check the De-aerator level, the level should be above 60% ./ ./

11
(2100mmWc).
12 Ensure that the Lube oil tank level above 225 mm ./
13 Ensure that the coupling is fully covered by coupling guard. ./

14 Observe the Cooling water floats in the view glass for flowing of water. ./

Ensure that the Lube oil AOP suction valve (14-GTV-2829) & MOP ./
15
suction valve (shaft driven) (14-GTV-2825) is in open condition.

Ensure that the Lube oil AOP discharge valve (14-GTV-2837) & MOP ./
16 ./
Discharge valve (shaft driven) (14-GTV-2833) is in open condition.

Ensure that the (14-GTV-0368, 03150) (Bypass), (14-GTV-

17 03142/03151) (Bypass) valve Towards UB04 Existing feed water ./
discharge header valves will be closed .

18 Ensure that the SWAS line valves (14-GLV-03120, 03124) are closed. ./

9,10 Startup& Shut down Procedure for BFP-B:

A uXllary
T 0'1I pump-startsup:
S ACTION BY
DESCRIPTION
No FE CRE SIC
1 Ensure that the AOP (575-14-PM-013) is selected manual. ./
Ensure that the Pump Emergency push button released from ./ ./
2
Local.
After ensuring all the above conditions, start the AOP (575-14-PM- ./
3
013) from DCS.
Start the lube oil heater-(575-14-E-002) for initially raising of the oil ./
4
temp keep the Heater in auto.
5 Ensure that the lube oil temperature above 420 C. ./
Ensure that the discharge lube oil pressure (14-PI-2809) is >5 ./ ./
6
kg/cm2.
Ensure that the Lube oil header pressure-(14-TI-2808A. B, C) is 2 ./ ./
7
kg/cm2.
Ensure that the Lube oil DP (14-PDT-2814) is normal like below ./
8
0.5 kg/cm2.
9 Check for any lube oil leakages in the lines, flanges. ./
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water
Next Review 23/0612019
® Pumps2X300 TPH CFBC Boiler
HMEL Page 17 of 24
9112·575·0PR·704 ·00050
Check the view glasses for oil flow through the bearings stuffing
box.

t rt up:
9118 01'I er f ee d pump- B sa
S ACTION BY
DESCRIPTION
No FE CRE SIC
Open the BFP-B Casing drain valve (14-GTV-2627), Ensure that the
1 water is coming, in case when the De-aerator is not in charge ./
condition. Close the Casing drain valve (14-GTV-2627).
In case when the De-aerator is charging condition, leave the Casing
drain valve (14-GTV-2627) open for some time for uniform heating of ./
2
casing. Close the Casing drain valve (14-GTV-2627) after attaining
the temperature.
3 Release the Emergency push button from the field. ./
4 Ensure that the BFP-B (575-14-BFPM-002) is selected manual. ./
5 Ensure that the BFP-B start permissive OK. ./
6 Ensure that the BFP-B Safety interlock OK. ./
7 Ensure that the BFP-B Process interlock OK. ./
Ensure that the BFP-B Discharge valve MOV-(14-MOV-0303, 4) is ./ ./
8
closed.
9 Start the BFP-B, and note down the shut off pressure. ./
10 Observe that any abnormal sound in the field. ./
11 Observe that the BFP-B starting Current in Amps, ./ ./
After attaining the BFP-B full RPM, Open the MOP priming valve (14- ./
12
NV-2828) for priming of the Shaft driven pump MOP (575-14-P-012).
Observe the Shaft driven outlet Pressure (14-PT-2811), if the
13 pressure is above 5kg/cm2, stop the Motor Driven AOP (575-14-PM- ./
013).
Close the priming valve (14-NV-2828); stop the Motor Driven AOP ./ ./
14
(575-14-PM-013).
Observe the Oil pressure will be maintained by BFP-B Shaft driven ./
15
pump.
16 Keep the Motor Driven AOP (575-14-PM-013) in Auto. ./ ./
Open the Discharge valve Bypass (MOV-14-MOV-0304), after full
17 opening of bypass MOV, open the Discharge Main (MOV-14-MOV- ./
0303), after full opening of Main MOV, and close the Bypass MOV.
18 Check the motor & pump vibrations and the bearing temperatures. ./
Ensure that no abnormal sound, heating of bearings, water leakage ./
19
from any flange joints & glands.
Note down the Suction pressure, Minimum Recirculation line ./
20
pressure, suction DP Discharge Pressure.
21 If any abnormality found stop the Boiler Feed pump-A. ./ ./
We can Charge the UB05, UB06 Feed water lines based on the ./
22
requirement.
Observe the Motor winding Temperatures, if the Temperatures are
23 increasing, open the Cooling water inlet & outlet valves of BFP-B ./ ./
Motor.
After ensuring all healthiness of BFP - B parameters & normalizing ./ ./ ./
24
the drum level of UB05 or UB06, Open the Feed Water
 HPCL-Mittal Energy Limited Revision 01

SOP for Start-up & Shut down of Boiler Feed Water Issue Date 23/06/2018
Next Review 23/06/2019
® Pumps2X300 TPH CFBC Boiler
HMEL 9112·575·0PR·704 -00050 Page 180f24

Interconnecting valve of CFBC & CPP after communication with

STEAG CRE & SIC

9.12Shut down:

S ACTION BY
DESCRIPTION
No FE CRE SIC
Close the Discharge (MOV-14-MOV-0303) by ensuring the feed ..r
1
water requirement in the Boilers.
2 Ensure that the Motor Driven AOP (575-14-PM-013) is in Auto. ..r
Maintenance Mode Logic has been implemented as when any BFP A
or B goes for maintenance & its AOP is to be stopped in that case
3 before stopping the AOP activate its maintenance mode so that when
AOP is stopped its RTS will be unhealthy in that case any existing
BFP of CPP will not start in Auto mode.
After ensuring the safe activation of maintenance mode go for
4
stopping of BFP-A
5 Stop the BFP-B (575-14-BFPM-002). ..r
After stopping the BFP-B Priority Selection to be done as per
6
discussion with STEAG SIC
After stopping of the BFP-B ensure that the Motor driven AOP
7 (AOP575-14-PM-013) starts, & maintain the Lube oil pressure if BFP- ..r
B to be taken in Auto mode.

913 BFP cooler back wash·

S ACTION BY
DESCRIPTION
No FE CRE SIC
Close Inlet & Outlet valve of cooling water line of Stand By Oil ..r
1
Cooler. ,

Open the Vent & Drain Valve of water box to drain out all water inside ..r
2
the tube & chamber
Full Open the Cooling water Outlet Valve. (Inlet valve will remain ..r
3
Close)
Crack open the Vent & Drain. Flush the Cooling water through Stan ..r
4
By Cooler 15 Min.
5 Observe the Water quality coming out from Vent & Drain. ..r
6 Inform the cooling water quality to CRE and SIC. ..r
After 15 Min flushing of Cooler Close Cooling Water Out let Vlv of ..r
7
stand By Cooler.
8 Charge the Cooler from cooling water Inlet V/v. ..r
Crack open the Vent & Drain for removal of Trapped Air through Vent ..r
9
& Drain.
10 Ensure the complete Trapped Air released from Cooler. ..r
 HP L-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water Pumps
Next Review 23/06/2019
"
2X300 TPH CFBC Boiler
HMEL 9112·57 5·QPR· 704 ·00050 Page 19 of 24

I~·-
!I 11
1---
J~ -
--
Full Open the Cooling Water Out Let Vivo
Open Inlet & Outlet Cooling water line & after proper venting close
./
./
12
the vent
13 Inform the Status of Backwash to CRE & SIC. ./

14 Mention the activity in Field and CRE log book. ./

9 14 BFP priority selection'

I~
ACTION BY
DESCRIPTION
No FE CRE SIC

1 1 Ensure that BFP in auto mode before take in priority selection ./

I
2 After that take the BFP in stand-by mode from manual mode. ./
I After that select the priority 1/2/3. Priority is depends upon the
3 operating condition that out of 5 BFP which will be take in priority 1, 2 ./
II.- and 3.

10. Prerequisite training and competency:

S Job Role Qualification Experience Training CertificationN alidat Special

No
-- ion Skill
i 1 Field ITllDiploma/Degree 3-5 years On job

I~---' Control Room

Yearly
Engineer training
12 DegreelDiploma 3-7 years On job Yearly
Engineer training
DegreelDiploma
3 Assistant Shift 5-10 years On job Yearly
In charge training

I~- Shift
charge
In
Degree/Diploma
7-12 years On
training
job Yearly

11. Flow sheet IDetaii Drawing:

12. Performance Indicator:

Suction Pressure Minimum Recirculation pressure, Discharge pressure, Motor current,
vibrations, Motor winding temperature, and Lube oil pressure

13. Record:
 HPCL-Mittal Energy limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water
Next Review 23/06/2019
® Pumps2X300 TPH CFBC Boiler
HMEL Page 20 of 24
9112·575·0PR·704 -00050
Field Log sheet, Log book.

14. Change Register. Change from previous revision of Procedure

Sr. No Page No Clause No. Previous Clause Revised Clause

-~~

3 ~-Index Index change

19 BFP Priority - BFP Priority

Selection Added Selection Added

15. Check list:

DCS check list:
SI.
Description Responsibility Status Feedback
No.
BFP suction valve. 14-GTV-
1 CRE Open/Close
306/307.
2 BFP suction temp,14-TI-0301A,B CRE Healthy/Unhealthy
BFP suction pressure. 14-PI-
3 CRE Healthy/Unhealthy
304A/B/C
4 ACW line Pressure CRE Healthy/Unhealthy
BFP discharge MOV.14-MOV-
5 CRE Open/Close
0301
BFP discharge Bypass mov.14-
6 CRE Open/Close
MOV-0302
Motor Winding Rl phase
7 CRE Healthy/Unhealthy.
Temperature,14Tl0301A
Motor Winding R2-phase
8 CRE Healthy/Unhealthy.
Temperature,14Tl0302A
Motor Winding Vi-phase
9 CRE Healthy/Unhealthy.
Temperature,14Tl0303A
Motor Winding Y2-phas€
10 CRE Healthy/Unhealthy.
Temperature,14Tl0304A
Motor Winding Bl-phase
11 CRE Healthy/Unhealthy.
Temperature,14Tl030SA
Motor Winding B2- phase
12 CRE Healthy/Unhealthy.
Temperature,14Tl0306A
Motor Non Drive end Bearing
13 CRE Healthy/Unhealthy.
Temperature,14Tl0308A
 HPCL-Mittal Energy Limited Revision 01

SOP for Start-up & Shut down of Boiler Feed Water Issue Date 23/06/2018
Next Review 23/06/2019
® Pumps2X300 TPH CFBC Boiler
HMEL 9112·575·0PR·704 -00050 Page 21 of 24

Motor Non Drive end Bearing

14 eRE Healthy/Unhealthy.
Temperature,14TI0308B
Motor Drive end Bearing
15 eRE Healthy/Unhealthy.
Temperature ,14TI0307 A
Motor Drive end Bearing
16 eRE Healthy/Unhealthy.
Temperature,14TI0307B
Pump Drive end Radial Bearing
17 Temperature Transmiter-l, eRE Healthy/Unhealthy.
14TI0309A
Pump Drive end Radial Bearing
18 Temperature Transmiter-2, eRE Healthy/Unhealthy.
14TI0310A
Pump Drive end LHS Thrust
19 Bearing Temperature eRE Healthy/Unhealthy.
Transmiter-l, 14TI0311A
Pump Drive end LHS Thrust
20 Bearing Temperature eRE Healthy/U nhealthy.
Transmiter-2, 14TI0311B
Pump Drive end RHS Thrust
21 Bearing Temperature eRE Healthy/Unhealthy
Transmiter-l,14Tl0312A
Pump Drive end RHS Thrust
22 Bearing Temperature eRE Healthy/Unhealthy
Transmiter-2, 14TI0312B
Pump Non-Drive end Radial
23 eRE Healthy/Unhealthy
Bearing temp-l, 14T10313A
Pump Non-Drive end Radial
24 Bearing Temperature eRE Healthy/Unhealthy
Transmiter-2, 14TI0314A
Pump DE Vibration X- Axis
25 eRE Healthy/Unhealthy
,14VI0305
Pump DE Vibration Y- Axis
26 eRE Healthy/U nhealthy
,14VI0306
Pump NDE Vibration X- Axis,
27 eRE Healthy/Unhealthy
14VI0307
Pump NDE Vibration Y- Axis
28 eRE Healthy/U nhealthy
,14VI0308
Motor DE Vibration X- Axis,
29 eRE Healthy/Unhealthy
14VI0301
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water
Next Review 23/06/2019
® Pumps2X300 TPH CFBC Boiler
HMEL Page 22 of 24
9112·575·0PR·704 -00050
Motor DE Vibration Y- Axis
30 CRE Healthy/Unhealthy
,14VI0302
Motor NDE Vibration X- Axis,
31 CRE Healthy/Unhealthy
14VI0303
Motor NDE Vibration Y- Axis,
32 CRE Healthy/Unhealthy
14VI0304
DP Across BFP Suction strainer,
33 CRE Healthy/Unhealthy
14PD10302A.
DP Across BFP Suction strainer,
34 CRE Healthy/Unhealthy
14PD10302B.
DP Across BFP Suction strainer,
35 CRE Healthy/Unhealthy
14PD10302C.
36 Lube oil tank level,14l12801 CRE Healthy/Unhealthy
37 Lube oil pr,14PI2806A,B,C CRE Healthy/Unhealthy
38 LUBE OIL TEMP14TI2804A.B.C CRE Healthy/Unhealthy
DE aerator level 14l10201C,
39 CRE Healthy/Unhealthy
14l10201C, 14l10201C
Cooling water pressure.
40 CRE Healthy/Unhealthy
12PI1201A

Field Check list·

Sr.
Description Responsibility Status Feedback
No.
BFP suction valve. 14-GTV-
1 FE Open/Close
306/307
De-aerator level 14-LG 0203A, 14-
2 FE HI/LOW
LG 0203B, 14-LG 0203C

3 Lube oil tank level FE HI/LOW/MEDIUM

BFP suction pressure isolation

4 FE Open/Close
valves.14-GTV-0315,316,317,318

5 BFP suction pressure,14-PG-0303 FE Healthy/U nhealthy

BFP strainer DP line isolation valve

6 open or not 14-GTV- FE Open/Close
0309/310/311/312/313/314

BFP ARC line open or not, 14-

7 FE Open/Close
ARC-0301 /14-GLV-0327
 HPCL-Mittal Energy Limited Revision 01

SOP for Start-up & Shut down of Boiler Feed Water Issue Date 23/06/2018
Next Review 23/06/2019
® Pumps2X300 TPH CFBC Boiler
HMEL 9112·575·0PR·704 -00050 Page 23 of 24

BFP minimum recirculation line

8 FE Open/Close
pressure gauge 14-PG-0307

BFP main oil cooler water I/l, Oil

9 FE Open/Close
valve open or not

10 BFP Casing drain,14-GTV-2612 FE Open/Close

BFP oil cooler water I/l valve
11 FE Open/Close
open or not
BFP oil cooler water Oil valve
12 FE Open/Close
open or not
13 Oil filter vent FE Open/Close
14 ACW line Pressure FE Healthy/Unhealthy
BFP motor bearing temp RTD
Coupled / de-
15 properly connected or not, 14-TG- FE
coupled.
2615/2616
16 ACW line isolation 14-GTV-2615 FE Hea Ithy/U nhea Ithy
BFP Pump bearing temp
probes. 14-TE-0311A,14-TE-
17 FE Healthy/Unhealthy
0325A,14-TE-0309A,14-TE-
0310A, 14-TE-0313A3 ,0314A
BFP motor bearing temp.14-TG-
18 FE Healthy/Unhealthy
2615/2616
19 BFP discharge valve. 14-GTV-03136 FE Open/Close
BFP discharge valve Bypass.14-
20 FE
GTV-0329
21 BFP discharge MOV.14-MOV-0301 FE Open/Close
BFP discharge Bypass mov.14-
22 FE
MOV-0302

23 BFP Main lube oil line isolation FE Open/Close

BFP lube oil pressure gauge

24 FE Open/Close
isolation .14GTV -2606

BFP HEAT EXCHANGER line drain

25 FE Open/Close
open or not

BFP HEAT EXCHANGER line vent

26 FE Open/Close
open or not
 HPCL-Mittal Energy Limited Revision 01
Issue Date 23/06/2018
SOP for Start-up & Shut down of Boiler Feed Water
Next Review 23/06/2019
® Pumps2X300 TPH CFBC Boiler
HMEL Page 24 of 24
9112·575·0PR·704 -00050

27 Lube oil pressure,14-PG-2601 FE HealthyjU nhea Ithy.

29 BFP coupling FE coupledjdecoupled