STANDARD OPERATING PROCEDURE

PPGCL Super Thermal Power Plant

3 X 660 MW.
FIELD SOP FOR FLY ASH HIGH PRESSURE WATER PUMP. PMPL

Document No.: Revision No.: 01

Effective Date: Page 1 OF 6
PMPL/SOP/01 Revision Date:

STANDARD OPERATING
PROCEDURE
FOR
FA HIGH PRESSURE WATER PUMP

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In- Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
Charge
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR FLY ASH HIGH PRESSURE WATER PUMP. PMPL

Document No.: Revision No.: 01

Effective Date: Page 2 OF 6
PMPL/SOP/01 Revision Date:

List of Contents

• Objective

• Scope

• Description of the system

• Responsibility

• Safety PPE’s

• Safety Precaution During operation

• Equipment Technical Details

• Pre checks and Action By Field Engineer

• Operating Procedure

• Shut Down Procedure

• Tripping.

• Abbreviations / Notations

• References

• Point to be checked by operator in every shift

• Checking of system after shut down

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In- Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
Charge
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR FLY ASH HIGH PRESSURE WATER PUMP. PMPL

Document No.: Revision No.: 01

Effective Date: Page 3 OF 6
PMPL/SOP/01 Revision Date:

• Objective:

This SOP is for Smooth Operation of FA high Pressure water Pump.

• Scope:

This SOP is applicable for FA high Pressure water Pump.

• Description of the system

1. Each FA HP water pump caters to the need for one unit fly ash wet disposal system.
2. There are Four no. FA HP water pumps, out of which maximum two will be working at a time.
The FA HP water pumps will be operated from the main PLC. One no. pressure indicator is provided to
monitor the pressure locally. For interlocking purpose one pressure switch is also provided at the common
header.

• Responsibility:

Unit Control Engineer, Desk Engineer and Field Engineer.

• Safety PPE’s

Ear Plugs, Safety Goggles & Hand Gloves.

• Safety Precaution During operation:

Ensure no permit to work is pending on regarding this system by checking with EE/FE.

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In- Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
Charge
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR FLY ASH HIGH PRESSURE WATER PUMP. PMPL

Document No.: Revision No.: 01

Effective Date: Page 4 OF 6
PMPL/SOP/01 Revision Date:

• Equipment Technical Details:

APPLICATION FA HP PRESSURE WATER SUPPLY

QUANTITY 04 No.s (3W+1S).
Type Horizontal
Capacity 525M3/Hrs.
TDH 72 M
No. OF Stage Single
Motor rating 160KW/1485RPM/264Amps

• Pre checks and Action By Field Engineer

• Ensure no PTW is pending for FA HP pump.

• Ensure ASH water tank level is more than low level (>=2.5 mtr).

• Pump breaker/panel is in service, Remote end are reset position.

• Ensure pump protections are in service and all parameters indication is healthy.

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In- Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
Charge
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR FLY ASH HIGH PRESSURE WATER PUMP. PMPL

Document No.: Revision No.: 01

Effective Date: Page 5 OF 6
PMPL/SOP/01 Revision Date:

• Operating Procedure

• Open pump suction valve 100%.

• Open discharge valve in crack position (i .e 5-10%).

• Open recirculation valve.

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In- Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
Charge
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR FLY ASH HIGH PRESSURE WATER PUMP. PMPL

Document No.: Revision No.: 01

Effective Date: Page 6 OF 6
PMPL/SOP/01 Revision Date:

• Release local push button switch.

• Start pump from SCADA.

• Open discharge valve gradually.

• Check discharge press. 7.20 kg/cm2 in discharge pipe line pressure gauge.

• Adjust the recirculation valve according to discharge pressure requirement.

• Now observe the vibration and temperature of pump and motor bearing.

• Periodically check ash water tank level and adjust water make up as per requirement.

• For any abnormalities record logbook and inform shift in charge.

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In- Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
Charge
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR FLY ASH HIGH PRESSURE WATER PUMP. PMPL

Document No.: Revision No.: 01

Effective Date: Page 7 OF 6
PMPL/SOP/01 Revision Date:

• Shut Down Procedure

• Close discharge valve upto 80 to 90%.

• Then stop the FAHP water pump.

• Then after close discharge valve fully.

11. TRIPPING CONDITION

1. MCC Disturbance.
2. Ash water level below 1mtr.
3. Emergency Stop.

12. Abbreviations / Notations

• FA: Fly Ash

• SOP: Standard Operating Procedure

• UCE: Unit Control Engineer

• DE: Desk Engineer

• FE: Field Engineer

• DCS: Distributed Control System

• EE: Electrical Engineer

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In- Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
Charge
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR FLY ASH HIGH PRESSURE WATER PUMP. PMPL

Document No.: Revision No.: 01

Effective Date: Page 8 OF 6
PMPL/SOP/01 Revision Date:

13. Reference

• O&M Manual AHP.

• POINTS TO BE CHECKED BY OPERATOR IN EVERY SHIFT

• EQUIPMENT CLEANING

• PHYSICALLY VIBRATION CHECKING

• PHYSICALLY TEMPRATURE CHECKING

• OIL LEVEL AND GREASE CHECKING

• CHECKING OF SYSTEM AFTER SHUT DOWN

• PHYSICALLY CHECK BOTTOM ASH HOPPER AFTER OPENING THE MAN HOLE
DOOR AS LIKE FOREIGN MATERIAL AFTER THAT CHECK THE ROTATION OF
CLINKER GRINDER IN FORWARD AND REVERSE DIRECTION.

• CHECK THE OIL LEVEL FREENESS.

• PHYSICALLY ALL VALVE CHECKING MANUALLY OPERATION THROUGH PLC AS

WELL.

• FIRST ENSURE SLURRY AND ASH WATER SUMP CLEANING AND THEN FILL
THE SUMP.

• CHECK THE SEAL PRESSURE OF ALL DOME VALVE PHYSICALLY.

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In- Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
Charge
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR FLY ASH HIGH PRESSURE WATER PUMP. PMPL

Document No.: Revision No.: 01

Effective Date: Page 9 OF 6
PMPL/SOP/01 Revision Date:

• CHECK THE LINE VACUUM AND SHUT OFF VACUUM OF ALL PASSES.

• CHECK FLUIDIZING BLOWER AIR OF INDIVIDUAL HOPPER.

• CHECK THE PURZING OF BUFFER HOPPER AND SILO BAG FILTER.

• IF ANY PROBLEM OBSERVED IN EQUIPMENT THEN INFORM TO SHIFT IN

CHARGE/ OPERATION IN CHARGE IMMEDIATLY.

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In- Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
Charge