SOP FOR CONDENSER RUBBER BALL CLEANING SYSTEM

DOC. # SEPCOIII-HBS-OPR-SOP-31 Issue # 00 Issue Date: 26-05-2019

Standard Operating Procedure for

Condenser Rubber Ball Cleaning System

Copyright

The copyright of this procedure, together with all confidential information contained herein is the
sole property of SEPCOIII Haveli Bahadur Shah 1230 MW Combined Cycle Power Plant.

It may be copied in full or in parts only by the Management / personnel and only for the purpose of
Company related activities. Disclosure and copying of any information contained within this
procedure to any person (s) outside the employee of company without written
permission/authorization of the Management Representative or Plant Manager is strictly prohibited.

Drafted By: _________________________ 2nd April, 2019

Operation Manager

Reviewed: _________________________ 24th May, 2019

Sr. Consultant

Approved By: _________________________ 26th May, 2019

Plant Manager
 SOP FOR CONDENSER RUBBER BALL CLEANING SYSTEM
DOC. # SEPCOIII-HBS-OPR-SOP-31 Issue # 00 Issue Date: 26-05-2019

Amendment Sheet
Section Amendment
Date Revision # Amendment Detail Signatures
Affected Approved by
 SOP FOR CONDENSER RUBBER BALL CLEANING SYSTEM
DOC. # SEPCOIII-HBS-OPR-SOP-31 Issue # 00 Issue Date: 26-05-2019

1.0 SCOPE & PURPOSE

This operating procedure describes the standard and reliable operating guidelines to safely start the
Rubber Ball Cleaning System leading to its normal operation resulting in the optimum performance
within specified operating limits. This procedure also covers the shutdown of the Rubber Ball Cleaning
System.

2.0 REFERENCES

 P&ID # 33-F09221S-J0901-02,
 Vendor Technical Manuals
 Operation and Maintenance Manual for Rubber Ball Cleaning System

3.0 PREREQUISITE

 All PTW job card work request on system are cancelled and de-isolations have been done.
 General Safety checks have been carried out.
 Once through or Cooling Tower circulating water system is in operation.
 System valves lined up as per APPENDIX-I
 System Instruments checked as per APPENDIX-II
 Electrical Distribution System status is as per APPENDIX-III
 The 11 kV and 400 V electrical systems are energized for providing the electrical power required
for starting and sustaining the operations of the relevant electrical equipment.
 There is no obstruction in the motor cooling air path(s).

4.0 GENERAL PRECAUTION AND LIMITATION

The following precautions and limitations apply specifically to the operation of the Rubber Ball
Cleaning System.
 Exposed parts of all rotary equipment must be guarded properly.
 All personnel handling the system should be familiar with the following:

 Equipment Operating Procedures

 Evacuation Procedures
 Leak/Spill Emergency Response Procedures
 First Aid and Rescue Procedures
 Location and use of Fire Fighting Equipment
 Proper Use of Protective Clothing
 Proper Use of Breathing Apparatus
 Location of safety showers and eyewash stations
 SOP FOR CONDENSER RUBBER BALL CLEANING SYSTEM
DOC. # SEPCOIII-HBS-OPR-SOP-31 Issue # 00 Issue Date: 26-05-2019
 Prearranged Procedures for Emergency Medical Care

CAUTION
In addition to the items listed above, it is duty of every person who may be
concerned with work on or adjacent system to make themselves conversant with
safety rules and requirement relating to any activities with which they an
involvement. It remains the responsibility of all employees to take reasonable care
for health and safety for themselves, their colleagues and the general public who
may be affected by their acts or omissions.

5.0 SPECIAL TOOLS, MATERIAL AND EQUIPMENT

Required PPEs – unique task related

Number PPE
1 PPE’s for routine operations like safety shoes, helmet, safety
glasses
2 Hearing protection (Ear plugs/Muffs) if required.

Tools and Test Equipment

Number Tool Description Meter & Test Equipment
ID
1 Flash Light N/A
2 Radio

Materials, Chemicals and Reagents

Number Chemical/Material Description MSDS
1 N/A N/A

CAUTION
Immediately following start-up, check the system to verify that conditions are normal.
Abnormal conditions, alarms or malfunctions are to be investigated and corrected as
soon as possible.
 SOP FOR CONDENSER RUBBER BALL CLEANING SYSTEM
DOC. # SEPCOIII-HBS-OPR-SOP-31 Issue # 00 Issue Date: 26-05-2019

CAUTION
Particular attention should be given to normal operating conditions of the Rubber
Ball Cleaning System, its equipment, and components to detect variations from
their normal operating conditions and function. Abnormal conditions, alarms or
malfunctions are to be investigated and corrected as soon as possible.

6.0 PROCEDURE

System Brief Description

Since there are microorganism, organism, sand etc in circulating water and flowing speed of circulating
water is generally low, it is easy to form soft and hard scale on internal wall of condenser stainless steel
tube, It not only affects heat exchange coefficient and increase difference between cooling ends, but
also lowers through-flow area and increase flow resistance. Therefore, it weakens economy of
operation severely.
The function of condenser rubber ball cleaning system is to apply rubber ball in condenser water
chamber with rubber ball cleaning pump, squeeze the rubber balls with the diameter of slightly more
than that of cooling stainless steel tube which are distributed in circulating water evenly through the
stainless steel tube depending on the pressure of circulating water so that it can improve the cleanness
of cooling stainless steel tube by removing scale on stainless steel tube wall when unit is in operation.
Therefore, it is favorable for enhancing thermal economy of unit operation.
Main equipment’s are comprised of two sets of independent devices of rubber ball dispensing and
recovery, local control panels and relevant valves and pipes. One or two sets of rubber ball cleaning
devices can be started for single or two-side cleaning of condenser.

This procedure consists of three main steps:

6.1 System Filling
6.2 STARTUP
6.3 SHUT DOWN

6.1 SYSTEM FILLING

6.1.1 Ensure all the valves are aligned as per Appendix-I of this procedure.
6.1.2 Ensure Once through or Cooling Tower circulating water system is in operation
 SOP FOR CONDENSER RUBBER BALL CLEANING SYSTEM
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6.1.3 Ensure all the drain valves in the system are in closed position.
6.1.4 About 1200 rubber balls taken and should be immersed in warm water for 24h.
6.1.5 After immersing, unqualified rubber balls should be removed if there’s a great
number of unqualified ones, spare rubber balls should be used.

6.1.6 Open vent and drain valve of ball collector.

6.1.7 Confirm that no water or gas is ejected. Open the upper cover of ball collector and
put in the rubber balls that have been immersed.
6.1.8 Close the upper cover, vent valve and drain valve of ball collector.
6.1.9 Open the vent valve of ball collector for priming.
6.1.10 Open all the valves on loop. Such as all supply and return manual valves and outlet
electric valve of ball collector. Then fill water in pipe.
6.1.11 After water comes out from vent valve of ball collector, vent valve should be
closed.

6.2 STARTUP

6.2.1 Ensure all the breakers are in the appropriate position as per Appendix III of this
procedure.
6.2.2 Local selector switch keep on AUTOMATIC REMOTE position.
6.2.3 Go to DCS Main Menu Screen. From this screen go to Condensate CIR WTR system
Screen.
6.2.5 Click on CNDSR RBCS #1 OR 2, a control pop-up will appear.
6.2.6 Give start command to the respective CNDSR RBCS.
6.2.7 Start the ball recirculating pump water is carried through the ball recirculating pipe. The
screens are in final position OPERATION in order to separate the cleaning balls released
from the ball collector from the cooling water flow.

6.3 SHUTDOWN
6.3.1 Go to DCS Main Menu Screen.
6.3.2 Click on CNDSR RBCS #1 OR 2, a control pop-up will appear.
6.3.3 Give stop command to the respective CNDSR RBCS.
6.3.4 A timer for 7200 second start for collect the ball in ball collector and outlet MOV of
ball collector close. When timer finished ball recirculating pump stop automatically.
 SOP FOR CONDENSER RUBBER BALL CLEANING SYSTEM
DOC. # SEPCOIII-HBS-OPR-SOP-31 Issue # 00 Issue Date: 26-05-2019

7.0 SUPPLEMENTAL ACTION

N/A

8.0 APPENDICES

8.1 APA8.1 APPENDIX-1 Pre start check list for valves line up.
8.2 APPENDIX-2 Pre start check list for instrumentation.
8.3 APPENDIX-3 Pre start check list for Electrical distribution.

APPENDIX-I

PRE-START VALVE LINE UP CHECK LIST

Sr.No KKS DESCRIPTION STATUS
1 10PAH01AA001 Rubber ball screen return isolation OPEN
valve side-1 before distributer
2 10PAH01AA002 Rubber ball screen return isolation OPEN
valve side-1 before distributer
3 10PAH01AA004 Rubber ball pump-1 discharge OPEN
isolation valve side-1
4 10PAH01AA005 Rubber ball loading chamber OPEN
outlet isolation valve side-1
5 10PAH01AA006 Rubber ball supply isolation valve OPEN
side-1 after distributer.
6 10PAH01AA007 Rubber ball supply isolation valve OPEN
side-1 after distributer.
7 10PAB01AA401 Rubber ball loading chamber vent CLOSE
valve side-1
8 10PAB01AA402 Rubber ball loading chamber drain CLOSE
valve side-1
9 10PAH02AA001 Rubber ball screen return isolation OPEN
valve side-2 before distributer
10 10PAH02AA002 Rubber ball screen return isolation OPEN
valve side-2 before distributer
11 10PAH02AA004 Rubber ball pump-2 discharge OPEN
isolation valve side-2
12 10PAH02AA005 Rubber ball loading chamber OPEN
outlet isolation valve side-2
13 10PAH02AA006 Rubber ball supply isolation valve OPEN
side-2 after distributer.
14 10PAH02AA007 Rubber ball supply isolation valve OPEN
side-2 after distributer.
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SOP FOR CONDENSER RUBBER BALL CLEANING SYSTEM
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10PAB02AA401 Rubber ball loading chamber vent CLOSE
valve side-2
16 10PAB02AA402 Rubber ball loading chamber drain CLOSE
valve side-2

APPENDIX II

PRE-START INSTRUMENT CHECK LIST

S. No KKS DESCRIPTION
1 10PAH01AP001 Rubber ball pump-1 discharge pressure gauge
2 10PAH02AP001 Rubber ball pump-2 discharge pressure gauge

APPENDIX-III

PRE-START ELECTRICAL DISTRIBUTION CHECK LIST

S. No Description Status
1 Rubber ball screen MOV CB side-1 ON
2 Rubber ball pump-1 CB ON
3 Rubber ball collector MOV CB side-1 ON
4 Rubber ball screen MOV CB side-2 ON
5 Rubber ball pump-2 CB ON
6 Rubber ball collector MOV CB side-2 ON