FEED WATER SYSTEM

Chanar Energy Limited Tandlianwala

Faisalabad
1. SCOPE & Purpose:

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

2. REFERENCE

 Piping, Process and Instrumentation Diagrams

 3005022006
 Vendor Technical Manuals

3.PREREQUISITE

 Safety Documents cancelled and de-isolations have been done.

 Feed water valve line-up as per APPENDIX-I
 System Instruments lined up as per APPENDIX-II.
 Electrical Distribution System is lined up as per APPENDIX-III.
 Instrument Air System is in operation.
 ACW system is in operation.
 De-mineralized water supply system is in operation
 Condensate System is in operation.
 Check HP pumps oil levels are normal.
 Check LP Dosing System is ready for operation.

4.GENERAL PRECAUTION AND LIMITATION

The following precautions and limitations apply specifically to the operation of the Feed
Water System.
 Exposed parts of all rotary equipment must be guarded properly.
 All the manhole covers of DA & HP Drums are properly secured.
 All personnel working on Feed water 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
 Prearranged Procedures for Emergency Medical Care

CAUTION
In addition to the items listed above, it is expected that the Operator exercise common
sense, safety considerations, and industry acceptable techniques when operating plant
equipment.
 1x22 MW
Operation Department
Cogeneration
Chanar Energy DOC #: CEL/OPS/SOP-04
Limited
Feed Water System

5.SPECIAL TOOLS, MATERIAL AND EQUIPMENT

Required PPEs – Unique task related

Numbe PPE
r
1 PPE’s for routine operations like safety shoes, helmet, safety glasses
2 Face shield, Chemical splash suit, Chemical resistant gloves
3 Hearing protection (Ear plugs/Muffs)

Tools and Test Equipment

Numbe Tool Description Meter & Test Equipment ID
r
1 Radio
2 Flashlight

Materials, Chemicals and Reagents

Nu Chemical/Material Description MSDS
mbe
r
1 Carbohydrazide Available at local
2 Phosphate Available at local

6.PROCEDURE

This procedure consists of three main steps:

6.1 System Filling

6.2 STARTING
6.3 SHUT DOWN

Prepared By: Shift Manager

Nov-2018
Page 2 of 11
Revision:0 Approved By: General Manager
 1x22 MW
Operation Department
Cogeneration
Chanar Energy DOC #: CEL/OPS/SOP-04
Limited
Feed Water System
6.1. SYSTEM FILLING/PRIMING

6.1.1 De-aerator Filling

 Ensure Demin Water pumps or condensate system is in operation.

 Check DA vent valve are in open position.
 Check DA drains are in close position.
 Check DA Level control vale is on Manual and fully closed.
 Open DA inlet manual valves 1022 / 1023.
 Start Carbohydrazide dosing pumps.
 Stop DA filling when the DA high-level alarm appears.
 Stop Carbohydrazide dosing pumps if not required.
 Stop condensate pump / demin water pumps if not required.

6.1.2 HP Feed Water Circuit Filling

 Ensure Demin water pumps or condensate system is in operation

 Ensure Discharge line vent valves of HP Feed water pumps are in
open position.
 Ensure HP Economizers and Drum vents are in open position.
 Start Carbohydrazide dosing pumps.
 Open Suction valve and Discharge MOVs of HP Feed water pumps.
 Maintain DA level manually through DA level control valve.
 Ensure priming of the pumps.
 Close discharge line vent valves.
 Close discharge MOVs.
 Start HP Feed water pump as per 6.2.1 of this procedure.
 Gradually open HP drum level control valve.
 Start HP Phosphate dosing pump if required.
 When proper flow starts from HP Economizer vents close vent valves.
 When HP drum level reaches about 40% close drum level control
valve.
 Stop Phosphate and Carbohydrazide dosing pumps if not required.
 Stop condensate pump if not required.
 Ensure purging of impulse lines of all associated instruments.

6.2. STARTING

Prepared By: Shift Manager

Nov-2018
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Revision:0 Approved By: General Manager
 1x22 MW
Operation Department
Cogeneration
Chanar Energy DOC #: CEL/OPS/SOP-04
Limited
Feed Water System
6.2.1.Taking HP Feed water pump in service.

Note:
Following series of permissive checks will be initiated when start up pulse to
Motor is given
 DA Level > 35%
 HP Feed water pump inlet valve opened.
 HP Feed water pump outlet MOV closed.
 HP Feed water pump bearing temperature < 100 oC
 HP Feed water motor bearing temperature < 135 oC
 HP Feed water pump motor winding temperature < 150 oC
 Cooling water pressure >2 bar.
 Suction DP<1500 mmH2O

 Ensure Demin water / condensate system is in service.

 Ensure DA level is normal and its level control valve on Auto.
 Ensure ACW flow through the pump coolers.
 Check pump recirculation line isolation valve is in open position.
 Ensure all the start permissive is satisfied.
 Ensure HP Feed water pumps and associated MOVs are selected
normal on DCS.
 Make sure HP Feed water pumps local control switches are
selected on remote and the Emergency push buttons are in the
released condition.
 Give start command to the respective pump from DCS.
 Check that the pump discharge bypass MOV started opening.After
that check if the discharge main MOV has started opening.
 Check the pump discharge pressure is normal and discharge MOV
is in full open position.
 Check if discharge bypass MOV have closed on auto.
 Check for any abnormality in the field.
 Monitor pump/motor bearing and winding temperatures closely for
at least 30 minutes.
Prepared By: Shift Manager
Nov-2018
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Revision:0 Approved By: General Manager
 1x22 MW
Operation Department
Cogeneration
Chanar Energy DOC #: CEL/OPS/SOP-04
Limited
Feed Water System
 Select standby on auto and verify that the discharge MOV of
standby pump got open.

Note:
Coordinate with chemical section for sampling and chemical dosing. Start Dosing pumps
as per requirement and adjust the dosing rate as per instructions of the Chemist.

6.2.1.1 If routine changeover of the pump to be performed,

 Remove the pump from Auto, the pump discharge MOV will
remain in open position.
 Start the respective pump from DCS.
 Check the pump discharge pressure is normal.
 Check for any abnormality in the field.
 Monitor pump/motor bearing and winding temperatures.
 If the pump is running normal stop the other pump from the
DCS and select standby.

6.2.1.2 HP Feed water pump will trip automatically If:

 DA level < 20 %.
 HP Feed water pump bearing temperature > 100 oC.
 HP Feed water pump motor winding temperature > 150 oC.
 HP Feed water pump motor bearing temperature > 135 oC.
 HP feed water pump running and suction MOV closed.
 Suction DP>1500mmH2O
6.2.1.3 Standby HP Feed water pump will start on Auto IF
 Running pump stopped/tripped.
 HP Feed water header pressure < 116 bar.

Note:
Coordinate with chemical section for sampling and chemical dosing. Start Dosing pumps
as per requirement and adjust the dosing rate as per instructions of the Chemist.

6.3. SHUTDOWN

6.3.1 HP Feed water pumps shutdown

 Ensure that the HP Feed water pump is no more required.
Prepared By: Shift Manager
Nov-2018
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Revision:0 Approved By: General Manager
 1x22 MW
Operation Department
Cogeneration
Chanar Energy DOC #: CEL/OPS/SOP-04
Limited
Feed Water System
 Remove the standby pump from Auto.
 Give stop command to the respective pump from DCS.
 Check that the respective pump shuts down.
 Check that pump discharge MOV closed on AUTO.
 Stop phosphate-dosing pump if running.
.

7.SUPPLEMENTAL ACTIONS

NA

8.APPENDICES

8.1 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.

8.1 APPENDIX-I

PRE STARTS CHECK LIST FOR VALVES LINE UP

FREQUENCY

 After cancellation of safety document.

 If the Plant is under shut down or stand by for more than 48 hours.

NOTE
The valve type will determine the required position. If it is a manual valve, the position
will either be designated as open or close. If it were a Motor-Operated valve, the
position would reflect both the control status and the valve position (e.g. auto open,

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 1x22 MW
Operation Department
Cogeneration
Chanar Energy DOC #: CEL/OPS/SOP-04
Limited
Feed Water System

auto close, manual open, or manual close.

SR. DESCRIPTION STATUS

NO.
HP system isolation valve check list
1 HP attemperator isolation valve OPEN
2 HP feed water line drain valve CLOSE
3 HP drum LCV upstream valve OPEN
4 HP drum LCV downstream valve OPEN
5 HP feed water sampling valve OPEN
6 HP economizer vent valve CLOSE
7 Phosphate dosing valve OPEN
9 HP drum IBD valve OPEN
10 HP drum CBD valve OPEN
11 HP saturated steam sampling valve OPEN
12 HP drum outlet steam line vent valve CLOSE
13 HP drum nitrogen blanketing valve CLOSE
14 LTSH header drain CLOSE
15 LTSH out header vent CLOSE
16 LTSH outlet drain CLOSE
17 RSH outlet header vent CLOSE
18 FSH outlet header vent CLOSE
19 Main steam line drain CLOSE
20 Main steam line sampling valve CLOSE
HP feed water pump "A" suction line drain CLOSE
21
valve
HP feed water pump "A" discharge line CLOSE
22
drain valve

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Nov-2018
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Revision:0 Approved By: General Manager
 1x22 MW
Operation Department
Cogeneration
Chanar Energy DOC #: CEL/OPS/SOP-04
Limited
Feed Water System

HP feed water pump "A" recirculation line OPEN

23
valve
HP feed water pump "B" suction line drain CLOSE
24
valve
HP feed water pump "B" discharge line CLOSE
25
drain valve
HP feed water pump "B" recirculation line OPEN
26
valve
HP feed water pump "C" suction line drain CLOSE
27
valve
HP feed water pump "C" discharge line CLOSE
28
drain valve
HP feed water pump "C" recirculation line OPEN
29
valve

SR.
DESCRIPTION STATUS
#
DA system isolation valve list
1 Condensate line drain valve CLOSE
2 Condensate line vent valve CLOSE
3 DA drum LCV upstream valve OPEN
4 DA drum LCV downstream valve OPEN
5 DA drum LCV by pass valve CLOSE
8 DA drum water sampling valve OPEN
9 Isolation valve to HP feed water pumps OPEN
10 DA chemical dosing valve OPEN

Prepared By: Shift Manager

Nov-2018
Page 8 of 11
Revision:0 Approved By: General Manager
 1x22 MW
Operation Department
Cogeneration
Chanar Energy DOC #: CEL/OPS/SOP-04
Limited
Feed Water System
8.2 APPENDIX-II

PRE STARTS CHECK LIST FOR INSTRUMENTATION

FREQUENCY

 After cancellation of safety document.

 If the Plant is under shut down or stand by for more than 48 hours.

NOTE
Verify that following instruments are in place, lined up and their cables connected.

SR DESCRIPTION STATUS
NO.
HP System Instrumentation
1 HP drum feed water flow Normal
2 HP feed water temp.  Normal
3 HP feed water press.  Normal
4 Press. After HP feed water CV  Normal
5 HP economizer inlet temp.  Normal
6 HP economizer outlet temp.  Normal
7 HP drum press.  Normal
8 HP drum level  Normal
9 HP main steam temp.  Normal
10 HP main steam press.  Normal
11 HP main steam flow  Normal
DA System Instrumentation
1 condensate water pressure  Normal
2 condensate water temperature  Normal
3 DA drum inlet flow  Normal
4 DA drum inlet pressure  Normal
5 DA drum inlet temperature  Normal
6 DA pressure  Normal
7 DA drum level  Normal

8.3 APPENDIX-III

 After cancellation of safety document.

 If the Plant is under shut down or stand by for more than 48 hours.

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Nov-2018
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Revision:0 Approved By: General Manager
 1x22 MW
Operation Department
Cogeneration
Chanar Energy DOC #: CEL/OPS/SOP-04
Limited
Feed Water System
PRE STARTS CHECK LIST FOR ELECTRICAL DISTRIBUTION

NOTE

Verify that following circuit breakers are RACKED IN, switched ON and their controls
selected on REMOTE

SR. DESCRIPTION LOCATION

#
HP Electrical System
1 HP feed water line MOV energize
2 SHs, drain MOVs energize
3 HP feed water pump"A" outlet MOV energize
4 HP feed water pump"A" outlet bypass
MOV
5 HP feed water pump"A" energize
6 HP feed water pump"B" outlet MOV energize
7 HP feed water pump"B" outlet bypass energize
MOV
8 HP feed water pump"B" energize
9 HP feed water pump"C" outlet MOV energize
10 HP feed water pump"C" outlet bypass energize
MOV
11 HP feed water pump"C" energize
DA Electrical System
1 DA inlet MOV Energize

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Nov-2018
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