THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' (
Procedure 1x15 MW Power
Plant

STANDARD OPERATING PROCEDURE

FOR 1X 15 MW POWER PLANT WITH 5 NO. WHRB

AT JK LAKHSMI CEMENT,
 SIROHI
 

The plant has 6 boilers operating on the waste heat from the Cement Kiln.

1. 3 Nos
Nos.. PH
PH B
Boi
oile
lers
rs heate
heated
db by
y the
the exi
exitt gas
gases
es from
from th
the
e pre
prehea
heate
terr il
ilns
ns 1!"!
1!"!3
3
". 3 Nos
Nos.. #$C
#$C Boi
Boile
lers
rs heate
heated
d by
by exi
exitt gas
gases
es from
from %rat
%rate
e Cool
Cooler
er Ki
Kiln
lns
s 1!"
1!"

PH &1 1".'(' TPH

PH ) " "3.* TPH

PH ) 3 "1.+6' TPH

#$C&1# ,.3,* TPH

#$C&1B 6.' TPH

#$C&" 1*.""* TPH

T-rbine iemens mae 1'/0

%enerator TP mae 1'/0

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THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' 0
Procedure 1x15 MW Power
Plant

STANDARD PROCEDURE
FOR 
 DAMPER OPERATION

DAMPER OPERATION
OPERATION DURING WHRB START UP

 2ns-re that waste heat gas is aailable at re4-ired temperat-re with

re4-ired 4-antity.
 0H5B by pass damper is open.
 Boiler dr-m leel is maintained at operating leel  '*78
 5e9ir9-lation p-mp is in operation and re9ir9-lation flow is established at
re4-isite al-e
 The gas :!; damper are open 9lose type whereas the bypass damper will
be reg-lating type and 9ontrolled by CPP;C. The /otori<ed ampers also
hae end portion limit swit9hes whi9h indi9ate open!9lose position of
dampers.
 %as bypass damper will be opened!9losed step by step and 9ontrolled by
CPP;C.
 :n9rease in 0H5B inlet gas temperat-re and draft a9ross boiler will ens-re
the fl-e gas flow thro-gh 0H5B.
 Che9 boiler inlet fl-e
fl-e gas parameter lie
lie fl-e gas temperat-re = draft.

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THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' 1
Procedure 1x15 MW Power
Plant

STANDARD START UP AND SHUT DOWN PROCEDURE

PROCEDURE FOR WHRB

1X 15 MW WHRB BASE POWER PLANT

START UP OF WHRB

1. 2ns
2ns-r
-re
e th
that

 Normal operating leel of water is maintained in boiler.

 #ll the ents are open.
 #ll the boiler drains are 9losed
 tart -p ent is f-lly open.

>l-e gas is aailable with re4-isite temperat-re and flowing thro-gh
the 0H5B bye& pass line
 5e9ir9-lation p-mp is in operation and re9ir9-lation
r e9ir9-lation flow is established
at re4-isite al-e.
 Hammering system of PH Boilers is in operating 9ondition. Before
operating the hammering system ens-re that all the hammers are free
to rotate.

". tart CC?s

CC?s and 5#@?s
5#@?s of the
the 9orresponding
9orresponding boiler
boiler and obsere
obsere that
that Boiler
Boiler
AN Permissie is generated. #lso ens-re the Boiler is not tripped. Hen9e
the damper operation will start a-tomati9ally.

3. #fter Boiler
Boiler AN Permissi
Permissie
e the damper
damper operation
operation is as
as follows
follows

a8 0H5B fl-e gas iinlet

nlet damper will be opened.
opened.

b8 0H5B
0H5B o-tlet
o-tlet damp
damper
er will
will be o
open
pened.
ed.

98 Close
Close Bypass
Bypass damper
damper is steps
steps

,. Absere
Absere that amper
amper %ro
%ro-p
-p 5eady signal
signal is generated
generated on C
C -pon
s-99essf-l 9ompletion of damper operation.

'. #s the bypass

bypass damper
damper is partially
partially 9losed
9losed gas
gas starts
starts flowi
flowing
ng thro-gh
thro-gh
0H5B.

6. Control
Control the gas flow thro-gh
thro-gh 0H5B
0H5B by 9losing
9losing  step
step wise8
wise8 bypass
bypass damper
damper
in s-9h a way that in9rease in /ain
/ain steam temperat-re does not in9rease
more that 3 deg C per min-te.

(. ee that
that 0H5B
0H5B star
starts
ts stea
steamin
ming.
g.

P$e)a$e* +,- T%e$ma. limite* Po/e$ Division

 

THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' 2
Procedure 1x15 MW Power
Plant

+. Close ents at dr-m press-re at " g!9m".

. tart one B>P if re4-ired and maintain dr-m leel

1*. Charge /ain steam line at 1" to 1, g!9m" and temp at 3** deg C if 1st
boiler is started8.
started8. Apen the main steam line when normal operating press-re
and temp are a9hieed for 9onne9ting with the main steam header.

11. %rad-ally 9lose bye&pass damper and 9lose start -p ents f-lly as steam
demand is in9reased.

1". tart HP = ;P dosing p-mp.

SHUT DOWN PROCEDURE OF WHRB

>ollow below mentioned steps for stopping of 0H5B

1. :nform DK;C 9ontrol

9ontrol room
room for
for stoppa
stoppage
ge of 0H5B

". lowly
lowly operate
operate bypass
bypass damper
damper for by passin
passing
g fl-e gas from 0H5B

3. Absere
Absere that
that steam
steam generation
generation is de9reas
de9reasing
ing

,. 5ed-
5ed-9e
9e loa
load
d iin
n T%
T%

'. An9e steam generation

generation be9omes
be9omes <ero
<ero 9lose
9lose /@

6. Apen bypas
bypass
s damp
damper
er f-lly.
f-lly.

(. Close fl-e
fl-e gas o-tlet
o-tlet damper a
and
nd s-bse4-en
s-bse4-ently
tly 9lose
9lose inlet
inlet damper
damper

+. /a
/ain
inta
tain
in dr
dr-m
-m lee
leell
. Kee
Keep
p 5C p-m
p-mp
p operati
operation
on for ff-rt
-rther
her on
one
e 1 hr.

1*. top hammering system after 1 hr of stoppage of boiler

1*. top HP dosing

dosing p-mp

P$e)a$e* +,- T%e$ma. limite* Po/e$ Division

 

THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' 3
Procedure 1x15 MW Power
Plant

STANDARD START UP AND SHUT DOWN

PROCEDURE FOR

TOTAL POWER PLANT

START UP PROCEDURE OF POWER PLANT

.
 >ollow below mentioned
mentioned steps for start -p of power plant.

1. P-t tt-rb
-rbine
ine on Barr
Barring
ing gear
gear by star
startin
ting
g #AP
". tart C2P on re9ir9-lati
re9ir9-lation
on mod
mode
e and maint
maintain
ain CT leel.
3. tart PH" and
and #$C"
#$C" as per start
start pro9ed-
pro9ed-re
re of 0H5B
,. Charge steam
steam line
line and heat
heat -p line
line -p to t-
t-rbine
rbine inlet
inlet by opening
opening warm
warm -p
ent line and drain lines.
'. P-ll a9--m
a9--m in
in 9ondenser
9ondenser by tain
taing
g hogger eEe9tor
eEe9tor first
first and m
mainta
aintain
in
a9--m by taing seri9e eEe9tor in line.
6. An9e re4-isi
re4-isite
te temperat-re
temperat-re  3", deg C8 is a9hieed
a9hieed roll the
the t-rbine
t-rbine as
per t-rbine start-p pro9ed-re.
(. 0hile steam
steam line
line is 9harged
9harged with
with the steam
steam from
from PH an
and
d #$C boilers
boilers
mae ready to start other 0H5B . Please
 Please note that with only PH1 and 
 AQC1 alone, turbine can not be loaded. So it is advisable tto
o have at 
turbine 8
least one more WHRB ready beore synchroni!in" the turbine8
+. yn
yn9hr
9hroni
oni<e
<e T% with
with two
two 0H5
0H5B?s
B?s in
in line.
line.
. %ra
%rad-a
d-ally
lly in9rea
in9rease
se load
load in
in T
T%.
%.
1*. tart 9ooling tower fans as per re4-irement.
11. -bse4-ently tae other 0H5B in line one by one.
1". tabili<e the power plant and note down all the parameter.

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THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' 4
Procedure 1x15 MW Power
Plant

SHUT DOWN PROCEDURE OF POWER PLANT

>ollow below mentioned steps for taing sh-t down of power plant

1. Tae sh-t
sh-t down of
of 0H5B as
as per standar
standard
d pro9ed-re
pro9ed-re of 0H5B
0H5B sh-t d
down.
own.

-ring sh-t down red-9e load and maintain t-rbine inlet steam press-re.

". -bse4-entl
-bse4-ently
y tae sh-t
sh-t down of
of other 0H5B
0H5B one by one followi
following
ng aboe

mentioned step.

3. #99ordingly
#99ordingly red
red-9e
-9e load
load to T%. -ring
-ring red-9tio
red-9tion
n of load maintain
maintain steam
steam

press-re by opening start -p ents of 0H5Bs.

,. Ap
Apen
en gen
genera
erato
torr brea
breae
er.
r.

'. 2ns-re that l-be oil press-re

press-re is maintained.
maintained.

6. 2ns-re barring
barring gear a-to start at 1'*rpm speed of T%.

(. Kee
Keep
p C2P in o
oper
perati
ation
on fo
forr another
another one
one ho-r.
ho-r.

+. Keep T%
T% on barring
barring gear till
till the bearing
bearing tem
temperat-
perat-re
re is aro-nd
aro-nd ,* deg C.
C.

P$e)a$e* +,- T%e$ma. limite* Po/e$ Division

 

THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' 5
Procedure 1x15 MW Power
Plant

EMERGENCIES

IN

1X 15 MW WHRB BASE POWER PLANT

P$e)a$e* +,- T%e$ma. limite* Po/e$ Division

 

THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' 6
Procedure 1x15 MW Power
Plant

EMERGENCIES IN 15 MW POWER PLANT

>ollowing emergen9ies are enisaged d-ring operation of 1' /0 power plant.

1. Stu
Stuck
ck u
u
 !" F#u
F#u$
$ %&
%&'
' (&)$
(&)$*.
*.

+. T*
T*
-%
-% !" R$
R$c*
c*cu#
cu#&t
&t!-
!- u)
u).
.

. T*
T*
-%
-% !" B!
B!#$*
#$* "$$(
"$$( u).
u).

/. S0$&*-%
S0$&*-% !" D*&% c0&-
c0&- c!-$
c!-$2!*
2!* S0$&*
S0$&* -.

5. I-c*$&'$
I-c*$&'$ - "#u$
"#u$ %&' t$)$
t$)$*&tu*
*&tu*$
$ 3$2!-(
3$2!-( /44 ($%
($% C.

. T*
T*
-%
-% !" &'0 Sc*
Sc*$6
$67P&
7P&-
- c!-$2
c!-$2!*.
!*.

8. T*
T*
-%
-% 7 't!
't!&
&%$
%$ !" WHR
WHR B!#$
B!#$*'.
*'.

9. T*
T*

-%
-% !" k
k#-
#-

:. T*-%
T*-% !" tu*3-
tu*3-$
$ &-( &## WHRB'
WHRB' &*
&*$
$ - '
'$*
$*c$.
c$.

P$e)a$e* +,- T%e$ma. limite* Po/e$ Division

 

THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' 7
Procedure 1x15 MW Power
Plant

1. Stuck u !" F#u$ %&' (&)$*

Tae following a9tions while fl-e gas damper!s are st-9 -p

 Aperate damper man-ally as per se4-en9e mentioned in D&)$*

O$*&t!- P*!c$(u*$

 Boiler 9an be ept in operation een by operating the dampers man-ally.

 -ring sh-t down please stop! 9lose damper as per the se4-en9e
mentioned in damper operation pro9ed-re.

+. T*-% !" R$c*cu#&t!-

R$c*cu#&t!- u).

Tae following a9tions are to be taen while 5e9ir9-lation p-mp trips

 5C p-mp shall trip on low dr-m leel and ele9tri9al fa-lt.

 :f the p-mp trips on ele9tri9al fa-lt restart stand by p-mp.  Normal
dr-m leel ens-res that 5C p-mp tripped on ele9tri9al fa-lt8
 :f there is low dr-m leel try to maintain dr-m leel as early as possible.
 :f dr-m leel 9an not be maintained within 1* min-tes by pass fl-e gas to
tae sh-t down of the boiler.
 -ring bypassing the se4-en9e of damper operation shall be as per the
damper operating pro9ed-re.

. T*-% !" B!#$*

B!#$* "$$( u)

Boiler feed p-mp may trip d-e to low deaerator leel or d-e to any ele9tri9al
fa-lt

:f B>P trips on ele9tri9al fa-lt start stand by B>P immediately within '
min-tes8.

:f stand by 9an not be started d-e to any reason follow the steps to tae sh-t
down of all the boilers

 Apen fl-e gas by pass damper.

 Close 0H5B o-tlet damper.
 Close inlet damper.

P$e)a$e* +,- T%e$ma. limite* Po/e$ Division

 

THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' ('
Procedure 1x15 MW Power
Plant

 :solate main steam line ales.

/. S0$&*-% !" D*&% c0&- S0$&* -

 :nform Cement plant 9ontrol room.

 tart by passing fl-e gas and a99ordingly red-9e load in T%.
 An9e fl-e gas is totally by passed repla9e shear pin.
 An9e the rag 9hain feeder is operatable start taing fl-e gas in 0H5B as
per 0H5B start -p pro9ed-re.
 :n9rease load in T%.

5. I-c*$&'$ - "#u$ %&' t$)$*&tu*$ 3$2!-( /44 ($% C

By in9reasing fl-e gas temperat-re / temp will in9rease beyond 3"' deg C.

 Apen by pass damper partially and see that /ain steam temperat-re is
-nder 9ontrol and 0H5B steam generation has red-9ed.
 e9rease T% load.
 :nform DK;C 9ontrol room.
 An9e >l-e gas temp is within ,** deg C grad-ally 9lose the by pass
damper.
 ee that boiler load has again in9reased in9rease T% load and normali<e.

. T*-% !" &'0 'c*$6 c!-$2!*

 :nform DK;C 9ontrol room as maintenan9e of s9rew!pan 9oneyor is in

9-stomer?s s9ope.
 :> the same is not attended within 1* min-tes by pass fl-e gas from
0H5B following the damper operating se4-en9e.

8. T*-% 7 't!&%$ !" WHRB

 :nform DK;C 9ontrol room and grad-ally de9rease load in T%.

 2ns-re that 0H5B fl-e gas by passing has been done as per damper
operation pro9ed-re.

P$e)a$e* +,- T%e$ma. limite* Po/e$ Division

 

THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' ((
Procedure 1x15 MW Power
Plant

9. T*-% !" k#-

 An9e iln is tripped! stopped 9orresponding Boiler is re4-ired to be

stopped.
 top the Boiler as per Boiler h-t down pro9ed-re mentioned aboe.
 5ed-9e T% load grad-ally. #t 1.' /0 load open the generator breaer.
 top t-rbine as per normal sh-t down pro9ed-re.

:. T*-% !" tu*3-$ &-( &## WHRB'

WHRB' &*$ - '$*c$
'$*c$

 /aintain dr-m press-re by opening start -p ents of all the 0H5B

 :nform DK;C 9ontrol room.
 By pass fl-e gas from 0H5Bs one by one


Tae sh-t down of all 0H5Bs one by one as per sh-t down pro9ed-re.
 /aintain dr-m leel all the time.

P$e)a$e* +,- T%e$ma. limite* Po/e$ Division

 

THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' (0
Procedure 1x15 MW Power
Plant

D!' AND D!-;t'

FOR

1X 15 MW WHRB BASE POWER PLANT

IMPORTANT D!' AND D!-;t' DURING PLANT OPERATION

OPERATION

D!'

1. %o thro-gh
thro-gh all APs
APs in detai
details
ls and eep
eep se4-en9e
se4-en9e of dampers
dampers operat
operation
ion in
mind.

". o as in
in 9ase
9ase of any do-bts
do-bts to
to yo-r seniors
seniors before
before any
any operation.
operation.

3. o note all
all parameter
parameter of 0H5Bs and
and T% areas
areas on reg-la
reg-larr basis.
basis.

,. o tae
tae safety
safety meas-res
meas-res while worin
woring
g in power
power plant.
plant.

D!-;t'

1. o not 9arry
9arry o-t
o-t any of the
the operation
operation in
in h-rry and
and with o-t -nderstandi
-nderstanding
ng
the reason for operation.

". o not do any mainte

maintenan9
nan9e
e a9tiities
a9tiities witho-t
witho-t 0or permit
permit an
and
d informing
informing
DK;C CC5.
3. o not allow
allow any
any -na-thori<e
-na-thori<ed
d person to
to perform
perform plan
plantt operations
operations from
from
C.
,. o not by pass any
any prote9tion
prote9tion and
and interlo9
interlo9 of the power
power plant
plant
'. o no
nott hesitat
hesitate
e to as in
in 9ase
9ase of do-bts
do-bts..

P$e)a$e* +,- T%e$ma. limite* Po/e$ Division

 

THERMAX LIMITED POWER DIVISION

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!L"# Si$o%i# Raast%an Standard Operating ' (1
Procedure 1x15 MW Power
Plant

STEAM T8R9INE :ENERA

:ENERATOR
TOR ; (NO< =>REE
=>REE S8PPL
S8PPL?# ERE"TION
ERE"TION AND
"OMMISSIONIN: 9? "8STOMER@

Parameter Unit Value

Power at generator terminal (Approx) kW 15000

Main Steam Pressure at Turbine inlet Ata   15

Main Steam Temperature at Turbine inlet °C   324.3

Main S
Stteam l
low a
att Turbine in
inlet iin
n!lu"ing au
auxiliaries TP#   72

$x%aust steam Pressure Ata   0.2

Cooling water &nlet Temperature °C   33

Cooling water outlet Temperature °C   42

P$e)a$e* +,- T%e$ma. limite* Po/e$ Division