STANDARD OPERATING PROCEDURE

Jaypee Nigrie Super Thermal Power Plant

2 X 660 MW IPP
SOP FOR CONDENSER FLOOD TEST
Document No.: PMPL/SOP/31 Revision No.: 01
Effective Date: Page 1 of 6
Revision Date:

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Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR CONDENSER FLOOD TEST
Document No.: PMPL/SOP/31 Revision No.: 01
Effective Date: Page 2 of 6
Revision Date:

STANDARD OPERATING
PROCEDURE
FOR

FLOOD TEST OF CONDENSER

Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR CONDENSER FLOOD TEST
Document No.: PMPL/SOP/31 Revision No.: 01
Effective Date: Page 3 of 6
Revision Date:

List of Contents

1. Objective
2. Scope
3. Responsibility
4. Safety Ppe’s
5. Safety Precaution During operation
6. Brief description of the system
7. Operating Procedure
8. Abbreviations / Notations

References

1. Objective:
This SOP is for Smooth Operation of Condenser Flood Test.

Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR CONDENSER FLOOD TEST
Document No.: PMPL/SOP/31 Revision No.: 01
Effective Date: Page 4 of 6
Revision Date:

2. Scope:
This SOP is applicable for Condenser Flood Test.

3. Responsibility :
Unit Control Engineer, Field Engineer and Desk Engineer

4. Safety PPE’s:
Ear Plugs, Safety Goggles, Hand Gloves, etc.

5. Safety Precaution During operation

Ensure no permit to work is pending on regarding this system
by checking with EE/FE.
6. Brief description of the system:

Condenser steam side water filling test is commonly referred to as flood

test. The purpose of the condenser flood test is twofold.
1. To check for any presence of air inleakge points in the no-
load vacuum system after a major overhaul or maintenance
work in the vacuum system.
2. To check for condenser tube leaks.
The condenser is double shell, single flow, dual back pressure surface
condenser all welded construction with stainless steel bellows expansion
joint used to connect the turbine exhaust cylinder and the condenser.
The condenser is rigidly supported.

7. Operating Procedure

If the condenser flood test is carried out for the limited purpose of
checking tube leaks, all the valves connected to condenser shell are to
be kept closed.
In rare cases, if the flood test is carried out for checking all the lines
connected to the condenser shell, then, ensure that all lines

Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR CONDENSER FLOOD TEST
Document No.: PMPL/SOP/31 Revision No.: 01
Effective Date: Page 5 of 6
Revision Date:

connected to the condenser are cooled down sufficiently and isolation

MIV/MOV and control valves are open.
Ensure all PTW relating to condenser shell side, pipes connecting to
shell side, CTP pumps and its discharge line, Chemical dosing system
etc are cancelled.
1. Ensure the condenser pit dewatering pumps are available.
2. Close CEP suction valves.
3. Ensure all the manholes on the condenser shell are boxed up.
4. Water box manholes are open. Ensure the drying of tubes by air
blowing is completed.
5. Ensure suitable temporary arrangement of a transparent tube to
check level is done. The temporary tube is connected to the vent of the
level gauge.
6. Ensure sufficient quantity of DM water is available in CST and DM
streams are available for further make up.
7. Inform chemist and ensure that chemical dosing system is ready with
sufficient chemical in dosing tanks.
8. Open the CTP recirculation. Close the individual filling valves of
Hotwell, Deaerator, Condensate line. Open the hot well makeup CV
MIV’s.
9. Start the CTP and open the discharge valve up to 50%.
10.Slowly open the hot well filling control valve and as flow is
established ,throttle the recirculation to close.
11.Open the dosing MIV’s. Inform chemist to start Ammonia and
hydrazine dosing so as to get 8.5 to 9.5 Ph and 50 PPM residual
hydrazine.
12.Fill the condenser shell. The filling is to be done up to 300mm above
the Condenser neck bellow.
13.Ensure strictly that the filling doesn’t go beyond the said level.

Standard Operating Procedure

 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR CONDENSER FLOOD TEST
Document No.: PMPL/SOP/31 Revision No.: 01
Effective Date: Page 6 of 6
Revision Date:

14.Inform MM on completion of filling for tube sheet inspection inside

water box.
15.Also as per the scope of the test, check all the lines (valve flanges,
glands, weld joints, drain valve passing etc) connected to the condenser
shell/flash tank.
16.Once cleared by MM, open the hotwell draining valve and drain the
hotwell upto NWL.

8. Abbreviations / Notations

1. SOP: Standard Operating Procedure

2. UCE: Unit Control Engineer
3. DE: Desk Engineer
4. FE: Field Engineer
5. DCS: Distributed Control System
6. EE: Electrical Shift Engineer

References
1. Turbine O & M manual
2. Catalogue of Turbine interlock & protection
3. Turbine P & I Drawing

Standard Operating Procedure