KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL / CRITICAL/BOILER / APH/

18

SOP FOR AIR PREHEATER (APH)

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

STANDARD OPERATING PROCEDURE FOR AIR PRE-HEATER (APH)

OBJECTIVE: For Smooth Operation of Air Preheater.

SCOPE: This SOP is applicable for two APH.

INTRODUCTION: APH is a heat recovery system which absorbs the heat from flue gas and
supplies the heat to primary and secondary air for the purpose of combustion and increasing the
boiler efficiency by reducing the flue gas heat loss.

SAFETY PRECAUTIONS:
 Ensure no permit to work is pending on this system.
 Use proper PPE where necessary.
 Maintain proper distance at the time of light-up during flame checking in local.
 Proper tools to be used for field operation.
 Ensure all Manual Call Points, Public Address System and Fire Alarms in working condition.
 No oil spillage near APH.
 Leakages to be informed and barricading the same should be ensured.
 Area should be clear of any material.
 Ensure proper approach to valves, pressure gauges, and temperature gauges.
 Proper insulation of hot surfaces to be ensured.

SPECIAL TOOLS/ EQUIPMENTS: APH manual rotating handle.

OPERATING PROCEDURE

Sr. RESPONSIBILITY
Description
No. UCE DE FE EE
PRE- START CHECKS:
1. All permits and cross permits have been returned. √ √ √
2. No person present inside & all Manhole are closed in Air Path √ √
3. Area is clear of any other material √

1|Page

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Subrata Kumar Mishra Name:
Designation: AM Designation: GM Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / CRITICAL/BOILER / APH/
18

SOP FOR AIR PREHEATER (APH)

Power from Knowledge
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 2 of 4

4. Ensure Main & Control power supplies of following: 4 Guide Bearing oil
Pumps, 4 Support Bearing oil Pumps, 2 APH main AC motors and 2 √
APH auxiliary motors and the earthing of motor shell is complete

5. Check oil level of APH Gear box, Guide Bearing & Support Bearing √
6. All guide bearing and support bearing pumps are properly primed/
vented before start and CCCW water lines for cooling are charged & √
flow is unobstructed. Press> 0.25 MPa.

7. All links between MOV and dampers are checked. √

8. Couplings of Gears with main & auxiliary motors must be checked. √
Ensure Flue Gas inlet damper (04 Nos.), Secondary air outlet damper
9. (02 Nos.) and Primary air outlet damper to APH open. open √ √

Check the seal gap automatic adjustment device is in good condition

10. and lifted to maximum position. √

11. Check the APH fire alarm device is put into operation √ √
12. Check the APH ash hopper valve should be close condition. √
13. Fire Fighting Water is available for Both APH √
Check the interlocking protection test of lubrication pump and motor
14. protection qualified √ √

Ensure air source for Air Motor normal , control Solenoid valve closed
15. condition, Ensure before and after valve of Solenoid valve open √ √

16. Check all the permissive available for the APH to be started √
START PERMISSIVE :

2|Page

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Subrata Kumar Mishra Name:
Designation: AM Designation: GM Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / CRITICAL/BOILER / APH/
18

SOP FOR AIR PREHEATER (APH)

Power from Knowledge
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 3 of 4

1 APH Main Motor No driver fault (i.e.. no motor fault)

2 Auxiliary Motor in stop condition.

3 Local fire detection cabinet running.

4 Guide bearing and support bearing oil pump running

START UP SEQUENCE :
1 Start APH guide and support oil Pump and put other pump in standby.
2 After three minutes, start air preheater auxiliary motor and put in
stand by Main motor (interlock).
3 After two minutes stop auxiliary motor and check pick up of main
motor.
4 If Main motor running normal put auxiliary in standby.
POST START UP CHECK UP.
1 Check the starting and running currents of Pump motors & APH
motors.
2 Check for no oil leakages near Guide Bearings & Support Bearings.
3 Check for no abnormal sound or restriction in movements of APH
motors & pumps.
4 After boiler light up ensure continuous soot blowing until oil support
withdrawn , check from local
5 Soot blowing steam temperature and pressure has to be normal (1.0
MPa & 250 ° c)
With the same sequence other APH can be taken in service
SHUTDOWN SEQUENCE:
1.PLANNED SHUTDOWN : (STOPPING OF BOTH APH)
When flue gas inlet temperature is <125˚C

1 Close the flue gas inlet damper, Close the primary air outlet damper,
and then close the secondary air outlet damper
3|Page

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Subrata Kumar Mishra Name:
Designation: AM Designation: GM Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / CRITICAL/BOILER / APH/
18

SOP FOR AIR PREHEATER (APH)

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

2 Release the interlock of standby Auxiliary Motor

3 Stop the Main motor of APH , APH stoppage signal alarm activated

INTERLOCKS AND SHUTDOWN CONDITION Remarks

1 Interlock start up condition between main and auxiliary motors of air heater
a. The air heater auxiliary motor tripping on failure will start, through
interlock, the main motor when it is placed standby.
b. The air heater main motor tripping on failure will start, through
interlock, the auxiliary motor when it is placed standby.
2 Guide bearing oil pumps
Interlock start up conditions
a. The interlock of guide bearing oil pump put into operation, the guide
bearing oil temperature > 60˚ C
b. The interlock of guide bearing oil pump put into operation, the running
pump stopped
Shutdown condition
a. When guide bearing oil temperature <50 ˚ C
3 Supporting bearing oil pump
Interlock start up conditions
a. The interlock of supporting bearing oil pump put into operation, the
supporting bearing oil temperature >50 ˚ C
b. The interlock of supporting bearing oil pump put into operation, the
running pump stopped
Shutdown condition
a. When supporting bearing oil temperature <45 ˚ C
Do’s & Don’ts
 Do’s:
 Ensure continuous soot blowing during oil firing.
 Test safety controls and devices on a periodic basis.
 Ensure local operators are adequately trained to assure safe and efficient operation.

4|Page

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Subrata Kumar Mishra Name:
Designation: AM Designation: GM Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / CRITICAL/BOILER / APH/
18

SOP FOR AIR PREHEATER (APH)

Power from Knowledge
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 5 of 4

 Inspect the equipment daily for proper operation, and/or adverse conditions.
 Maintain a log of incidents and parameters that effect equipment operation.
 Allow only authorized person to work and attend any leakages.
 Regular maintenance and calibration of instruments to be ensured.

 Don’ts
 Avoid operating without fire alarm, rotor stoppage alarm & oil carryover probe.
 Avoid bypassing permissive/protection logics.
 Permit unqualified personnel to operate the equipment.

REFERENCE DOCUMENTS:
 Boiler Operation Manual
 DCS logics.

CURVES & CHARTS

 NA

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.
o RB : Run Back

5|Page

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Subrata Kumar Mishra Name:
Designation: AM Designation: GM Designation: