STANDARD OPERATING PROCEDURE

PPGCL Super Thermal Power Plant

3 X 660 MW.
SOP FOR BUFFER HOPPER D-PUMP.
Document No.: Revision No.: 01
Effective Date: Page 1 OF 7
PMPL/AHP/SOP/17 Revision Date:

BUFFER HOPPER D-PUMP

1. Equipment Technical Details:
Conveying of fly ash from ESP to 6000T SILO. In dry system ash conveying in two modes of
operation 1) vacuum conveying-ESP to buffer hopper, 2) pressure conveying- buffer hopper to
6000T silo through D-pump. In vacuum conveying by using vacuum, fly ash can be transferred
from ESP to Buffer hopper tower. By using conveying pressure, fly ash can be transferred Buffer
hopper to 6000T Silo through D-Pump
2. Pre checks And Action By Field Engineer:
 Ensure IAC and BA seal water pump is running.
 Ensure selection switch valve is selected in dry mode.
 Dry mode vacuum and ash conveying switch valves are open condition and wet mode
vacuum and ash conveying switch valves are close condition.
 Ensure one out of two blowers is available.
 Ensure vacuum pumps are available.
 Ensure PTAC is available.
 Ensure all switch valves, dome valves, plate valves, dump valve operate freely.
 Ensure particular dump valve selected for particular silo.
 Ensure level, purging, vent fan availability for selected Silo.

3. Operating Procedure:
 Start the bag filter purging.
 Start the blower and heater; ensure heater temperature ok.
 Start the vacuum pumps take the shut off and line vacuum.
 Start the silo purging and vent fan.
 Start the TAC and charge the silo conveying lines from D-pumps to Silo in Auto timer mode.
 If shut off, line vacuum ok, start the vacuum conveying from ESP to buffer hopper in Auto timer
mode.
 Check the all the dome valves and switch valves operating properly.
 Check the ESP hoppers, buffer hopper, D-pumps properly emptying after start.
 For any abnormalities record logbook and inform shift incharge.
Important Settings:
Besides above timer settings, major pressure switch settings shall be as follows:
1. All switch valve seal pr. Switches: 5.5 Bar rising.
Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):
Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
SOP FOR BUFFER HOPPER D-PUMP.
Document No.: Revision No.: 01
Effective Date: Page 2 OF 7
PMPL/AHP/SOP/17 Revision Date:

Line Vacuum transmitter set point for smooth operation of vacuum system.

SL NO Set SET PT DESCRIPTION SET POINT SET POINT IMPLICATION

point

1 SP 1 Line vacuum low <90 mmHg Hopper empty

2 SP 2 Line vacuum permissive >150mmHg MHV open
3 SP 3 Line Vacuum normal 200 to 400 Material conveying smooth
mmHg (with fly ash)
4 SP 4 Line Vacuum normal >325 mmHg Open air intake valve (AIV)
5 SP 5 Line vacuum high >425 mmHg Close MHV (Air intake valve
already open )
6 SP 6 Line vacuum below high <200 mmHg Close air intake valve
7 SP 7 Line Vacuum normal >200 mmHg Re open MHV (Air intake
valve already closed )
8 SP 8 Line Vacuum very high >450 mmHg + Air intake open , MHV closed
10 sec delay & open ash line vacuum
breaker

9 SP 9 Line Vacuum normal <300 mmHg Closed ash line vacuum

breaker

Line pressure transmitter:

One no. Of pressure transmitter provided on the conveying line is used to monitor the
material flow. Following setting points are defined in AHP PLC from this pressure transmitter.

S.NO SET POINT SET POINT SET POINT SENT POINT

NAME DESCRIPTION IMPLICATION
1 SP-1 Line pressure low Below 0.5 bar Material not
conveying/line
empty
2 SP-2 Line pressure below Below 1.2 bar Line not
normal loaded/blockage
cleared
3 SP-3 Line pressure normal ok Below 2.0 bar Material
conveying smooth
4 SP-4 Line pressure high Above 2.4 bar Line getting

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

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
SOP FOR BUFFER HOPPER D-PUMP.
Document No.: Revision No.: 01
Effective Date: Page 3 OF 7
PMPL/AHP/SOP/17 Revision Date:

chocked
5 SP-5 Line pressure high high Above 3.0 bar Line chocked

9. Shutdown procedure
 After completion of ESP dry ash De-ashing select all passes in manual mode.
 Close the entire hoppers dome valve.
 Close all the passes of the switch valve except one row.
 Flushing all passes ash evacuation line from switch valve to buffer hopper.
 After flushing completed, open vacuum breaker valve at first ash evacuation line
then vacuum line.
 Stop the vacuum pump.
 Close seal water valve of vacuum pump.
 After completion of flushing of the system from buffer hopper D-pump to silo, then
stop the PTAC.
 Stop fluidizing blower and heater.
4. POINTS TO BE CHECKED BY OPERATOR IN EVERY SHIFT

 EQUIPMENT CLEANING
 PHYSICALLY VIBRATION CHECKING
 PHYSICALLY TEMPRATURE CHECKING
 OIL LEVEL AND GREASE CHECKING
1. 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.

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

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
SOP FOR BUFFER HOPPER D-PUMP.
Document No.: Revision No.: 01
Effective Date: Page 4 OF 7
PMPL/AHP/SOP/17 Revision Date:

 FIRST ENSURE SLURRY AND ASH WATER SUMP CLEANING AND THEN FILL
THE SUMP.
 CHECK THE SEAL PRESSURE OF ALL DOME VALVE PHYSICALLY.
 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-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head