SESI-TSPL-OPN-SOP-BTG-017 (Charging Auxiliary Steam Header)

TALWANDI SABO POWER LIMITED,
3 x 660MW POWER PLANT, MANSA.

SOP for charging of auxiliary steam header
Standard Operating Procedure for

Charging of Auxiliary steam header
Modification Proposal Issue 01 Rev 0 Page 1 of 11

Document Control No SESI-TSPL-OPN-SOP-BTG-017 Date 22.09.2017
Prepared By. Reviewed By Approved by
Table of Content
1 PURPOSE...............................................................................................................................3
2 SCOPE............................................................................................................................3
3 INPUT............................................................................................................................3
4 OUTPUT........................................................................................................................3
5 RESPONSIBILITY.............................................................................................................3
6 SYSTEM DESCRIPTION....................................................................................................3
7 DETAILS.........................................................................................................................4
8 ELECTRICAL FEEDER DETAILS..........................................................................................4
9 ABBREVIATIONS.............................................................................................................4
10 START- UP PROCEDURE..................................................................................................5
10.1 PRESTART CHECKS...........................................................................................................5
10.2 START-UP......................................................................................................................5
10.2.1 Case 1: Charging from Adjacent unit Auxiliary Steam Header/Auxiliary boiler
System 5
10.2.2 Case2: Switching Steam Supply Source to CRH................................................6
10.2.3 Case 3: Switching Auxiliary Steam Header to Fourth Extraction.......................6
11 SHUTDOWN PROCEDURES.............................................................................................7
11.1 NORMAL SHUTDOWN:....................................................................................................7
11.2 EMERGENCY SHUTDOWN.................................................................................................7
12 ISOLATION PROCEDURES...............................................................................................7
13 RECORDS.......................................................................................................................9
14 REFERENCE....................................................................................................................9
15 SAFETY..........................................................................................................................9
16 Environment..........................................................................................................................9

1 PURPOSE
This Procedure is intended to provide guidance and instructions for carrying out
charging of Auxiliary steam header.
2 Scope
This procedure is applicable to Auxiliary steam system located at TSPL.
3 Input
Not Applicable
4 Output
Not Applicable
5 Responsibility
Field operator, desk operator and shift in charge.
6 System Description
The Auxiliary Steam System is to provide steam for the following services under
various operating load condition of the plant. Working press is 0.6 to 1.2 Mpa &
temperature is 260-360 deg C.
 Steam for preheating requirements like De-aerator pegging, steam
supply to de-aerator during load rejections etc.
 Start-up and Backup steam for turbine gland seal system.
 Steam supply for HP casing warm-up during start up.
 Start-up and Back up Steam for air pre-heater soot blowers.
 Steam for mill fire fighting.
 Starting and back up steam supply source to BFP turbines.
 To provide steam for fuel oil heating.
 Steam supply for SCAPH.
 Steam supply for HFO atomization from separate header located in
boiler area and steam source is CRH (common header of unit 1, 2 and
3) and Auxiliary Boiler. It comprises of two safety valves for safety of
the header during abnormal pressure surge and drain arrangement.
Sources of Steam:
 During start up steam source for auxiliary steam header is from
Auxiliary Boiler or from other running adjacent unit.
 When load is 120MW, auxiliary steam can be changed to CRH.
 When load is 450MW, auxiliary steam source can be changed from
cold re-heater steam to 4TH extraction.
 In normal condition, steam to auxiliary steam header is supplied by
fourth extraction.
7 Details
 Vessel category: Type II
 Volume: 4.19 m3
 Header design pressure: 3.02 Mpa
 Header design temperature: 4000C
 Working pressure: 0 - 1.6 Mpa
 Working temperature: 360 0C
8 Electrical Feeder Details

S. No. Description Feeder no. KKS
1 motor-operated valve 1 used for
#1 unit auxiliary steam header 00LBG75AA001
interconnecting with #2 and #3 111K
unit auxiliary steam header
#2 unit auxiliary steam header 112k 00LBG75AA002
interconnecting with #1 and #3
#3 unit auxiliary steam header 113K 00LBG75AA003
interconnecting with #1 and #2
4 motor-operated valve from NO.4
extraction to auxiliary steam 115K 10LBG10AA001
5 motor-operated valve before

pneumatic control valve from cold 116K 10LBG20AA001
reheat steam to auxiliary steam
6 motor-operated valve after
pneumatic control valve from cold 117K 10LBG20AA002
reheat steam to auxiliary steam
9 Abbreviations
9.1. CRH - Cold Re Heat
9.2. CEP- Condensate Extraction Pump
9.3. MOV- Motor Operated Valve
9.4. MIV- Manual Isolation Valve
9.5. PTW- Permit To Work
9.6. TDBFP-Turbine Driven Boiler Feed Pump

10 Start- up procedure
10.1 Prestart checks
10.1.1. No PTW is pending.
10.1.2. Open drain valve in Aux steam header which is open to
atmosphere.
10.1.3. Open drains and vents in interconnection header. (For
interconnection from Adjacent Unit or Aux boiler)
10.1.4. Interconnection valve on unit aux header is open. If adjacent
unit is not available, then line up from Auxiliary Boiler system.
10.1.5. All other incoming & outgoing lines connected to Unit Auxiliary
header are closed. Valve from CRH can be kept open as CV will
be in closed position.
10.1.6. Adjacent unit’s Auxiliary steam header is charged or Auxiliary
boiler is started.
10.2 Start-up
10.2.1 Case 1: Charging from Adjacent unit Auxiliary Steam
Header/Auxiliary boiler System
 Crack open all the interconnection line drains and auxiliary
Header drain which is to be charged.
 Put the interconnection MOV’s in local (both from adjacent
unit and aux boiler).
 Crack open MOV of auxiliary header which is to be charged
 Crack open the MOV on adjacent unit side or MOV of
Auxiliary Boiler system header to warm up the line from local.
 This will ensure the proper warming of line and auxiliary
header which is to be charged.
 Ensure condensate is draining out completely and steam
starts to come from drain without condensate.
 Further open MOV from adjacent unit side/Auxiliary Boiler
system header, auxiliary header pipe pressure should not be
higher than 0.1 MPa. Make sure that there is no impact or
hammering in pipes.
 After temperature rises to 200℃, open auxiliary steam MOV
of adjacent unit side further to increase auxiliary steam

header pressure to 0.2MPa.
 Then slowly open the MOV full if there is no hammering in the
line.

 Keep the MOV crack open of auxiliary header which is to be

charged.
 Close the drain valves on interconnection header after
ensuring the proper warming.
 Now charge the auxiliary header by slowly opening the MOV
(on the header) by observing the pressure of adjacent header
also.
 After auxiliary steam header parameters reaches to normal
operating parameters then close the drain valve of aux
header.
 If adjacent Unit is in service, then interconnection header will
remain in service. Keep interconnection valve from Auxiliary
Boiler system in close position. Slowly open the
interconnection valve on Aux header to charge adjacent Unit
header.
10.2.2 Case2: Switching Steam Supply Source to CRH

 Ensure that boiler is in stable combustion and unit load is
≥20% (120MW)
 CRH to Aux steam MOV on aux header is open.
 CRH to Aux steam, MOV power supply is ON with remote
selection.
 Drain valve before MOV1 & after MOV2 are open.(Turbine
floor)
 Open both MOV’s fully and charge the line by slowly opening
of CV from remote.
 After charging keep the control valve in Auto.
 Open CV inlet MOV after condensate is drained.
 Keep CV set point, slightly more than Aux header pressure.
CV opens slowly.
 Ensure proper warm up of pipe line and no condensation in
the line.
 Slowly close the interconnection MOV from adjacent Unit or
from Auxiliary Boiler by observing pressure.
 System requirement will be met by CRH.
 Close the drain valves, before MOV1 and after MOV2.
Note:- Interconnection MOV to be closed only after charging
from CRH line is done.

10.2.3 Case 3: Switching Auxiliary Steam Header to Fourth Extraction

 When unit runs stable and fourth extraction pressure reaches
to >0.60MPa, switch auxiliary steam to 4th extraction.
 Drain valve before MOV is open.
 4th Extraction to Aux steam, valve power supply is ON.
 Ensure proper warm up and no condensation in the pipe
lines.
 Slowly open the 4th Extraction MOV.
 CRH to Aux header, CV closes slowly.
 Close the drain valve before 4th Ext MOV after header is
charged properly by observing the temperature and pressure.
11 Shutdown procedures
11.1 Normal shutdown:
11.1.1 If auxiliary steam system needs to be stopped, it can be stopped
after confirming that there is no auxiliary steam user.
11.1.2 Shutdown is possible in Unit shut down only.
11.1.3 Close interconnection to adjacent unit.
11.1.4 Close interconnection to Auxiliary boiler.
11.1.5 Close CRH to Aux steam valve.
11.1.6 Close 4th extraction to Aux steam valve.
11.1.7 Open Aux steam header drain valve.
11.2 Emergency shutdown

Action In case Of Unit Tripping -CRH, 4 th extraction sources will not be
available.
11.2.1 Open adjacent unit interconnection valve immediately to supply
gland steam to turbine.
11.2.2 If Adjacent Unit source is not available, then line up for Auxiliary
boiler system.
12 Isolation Procedures
12.1. After unit tripping and for long shut down of unit, Close Steam supply MOV
one by one.
12.2. Close the interconnection MOV from adjacent unit and switch off power
supply MCB.
12.3. Close MOV and CV from CRH tapping ,open its relevant drain line and
Ensure Ex-4 MOV and FCNRV is closed and drain line are open, Close
power Supply MCB for MOV and air line for CV.

12.4. Close Supply steam MOV and control valves to D/A and open its drain line
MOV and MIV, isolate the power supply MCB.
12.5. Close Supply steam MOV to Gland steam Header and isolate power
supply.
12.6. Close Supply steam MOV to TDBFP and open its drain line MIV, and
isolate MOV power supply.
12.7. Close Supply steam MOV to Boiler side header and open its drain line,
and isolate MOV power supply.
12.8. Close Supply steam MOV to turbine Pre heating line and open its drain
line, and isolate MOV power supply.
Isolation Checklist:
Positio Power
S. No. Isolation Remarks
n supply
1.
MOV in CRH line before CV Close MCB off
2.
MOV in CRH line after CV Close MCB off
3.
Interconnection line MOV Close MCB off
4.
Ext 4 MOV and FCNRV Close MCB off
5.
D/A Pegging steam line MOV before CV Close MCB off
6.
D/A Pegging steam line MOV after CV Close MCB off
7.
MOV in TDBFP steam supply line Close MCB off
8.
MOV in turbine warm up line Close MCB off
9.
MOV in steam supply line to boiler Close MCB off
10.
All drains of Aux header open

13 Records
13.1. Field Boiler Operator Log Book
13.2. Boiler Desk operator Log Book
13.3. Shift in-charge log book
14 Reference
14.1 Turbine O&M manual
14.2 SEPCO O&M manual
14.3 Auxiliary steam system P&ID
15 Safety
15.1. Ensure PPE's are worn. Ensure adequate lighting near the work
place.
15.2. Ensure orderly execution of the entire activities with respect to
mechanical electrical system.
15.3. Always wear safety shoes, helmet and earplug.
15.4. While racking in and racking out the electrical breaker, wear Arc suit
and rubber gloves.
15.5. 16.5 Before releasing the equipment for offline permit, ensure that
the equipment is electrically and mechanically isolated.
15.6. While racking in the breaker, ensure that the breaker is not in closed
condition and it is not in charged condition. Also ensure that the
earth switch is in released condition while normalizing the breaker.

15.7. Wear cotton gloves while operating valves. Use F-rod, which is in
good condition for valve operation.
16 Environment
16.1. If any steam leakage is there, inform to maintenance department for
arresting the same either on line or offline depending on the
condition.


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TALWANDI SABO POWER LIMITED,

3 x 660MW POWER PLANT, MANSA.

Standard Operating Procedure for

Modification Proposal Issue 01 Rev 0 Page 1 of 11

Modification Proposal Issue 01 Rev 0 Page 2 of 11

8 Electrical Feeder Details

5 motor-operated valve before

Modification Proposal Issue 01 Rev 0 Page 4 of 11

 After temperature rises to 200℃, open auxiliary steam MOV

of adjacent unit side further to increase auxiliary steam

Modification Proposal Issue 01 Rev 0 Page 5 of 11

 Keep the MOV crack open of auxiliary header which is to be

10.2.2 Case2: Switching Steam Supply Source to CRH

Modification Proposal Issue 01 Rev 0 Page 6 of 11

10.2.3 Case 3: Switching Auxiliary Steam Header to Fourth Extraction

11.2 Emergency shutdown

Modification Proposal Issue 01 Rev 0 Page 7 of 11

Modification Proposal Issue 01 Rev 0 Page 8 of 11

earth switch is in released condition while normalizing the breaker.

Modification Proposal Issue 01 Rev 0 Page 10 of 11

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