GPPC POWER PLANT,PIPAVAV

2X351MW Combined Cycle Power Plant

POMSP
L SOP
001
ECP Start up and shutdown SOP
GPPC POMSP
L
Revision Date Clau
Issue No Issue Date Revision
06.02.2018 se Page 1 of 5
001 Rev# 01

1.0 PURPOSE:

The purpose of this document is to explain the safe and effective Operation of the
electro chlorination plant.

2.0 RESPONSIBILITY:

Shift Manager is responsible for the execution of this procedure.

Operation Manager is responsible for maintenance of this procedure.

3.0 SYSTEM DESCRIPTION:

The Electro chlorination plant is designed to prevent bio fouling in the condenser,
cooling tower and other facilities like Seawater intake, Pre-treatment Plant, CW
system and Potable water system. Sodium hypochlorite solution is used for the
chlorination / disinfection of the seawater circuit to prevent bio fouling growth of
marine organisms in the seawater facilities.

4.0 START UP PROCEDURE:

1. Start SWRO supply pump any one out of three (9GDA01AP001,

9GDA02AP001, 9GDA03AE001).

2. If SWRO system in running then open the ECP line inlet valve near MOV
(9GCB01AA051).

3. If SWRO system not in running condition then take any two PSF in rinse
mode with 60-70 m3/hr flow.

4. Open inlet valve (XSDV-001).

5. Open the Storage tank inlet valve (XSDV) and start blower.

6. Open the manual valves of electrolyzer Inlet and outlet valve.

7. The sea water fed to the electro chlorination plant at a pressure of 4.0 – 5.0
kg/cm2.
 GPPC POWER PLANT,PIPAVAV
2X351MW Combined Cycle Power Plant
POMSP
L SOP
001
ECP Start up and shutdown SOP
GPPC POMSP
L
Revision Date Clau
Issue No Issue Date Revision
06.02.2018 se Page 2 of 5
001 Rev# 01

8. The high pressure may control by self-actuated pressure control provided at

seawater supply line which is control the down steam pressure in the range of
2.5 to 3.5 kg/cm2.

9. If the seawater supply pressure is ≤2.5 kg/cm 2, then the water is pumped by
means of seawater booster pumps (1 operating + 1 standby) to self-cleaning
filters to maintain pressure.

10. Ensure the service water line pressure near ECP plant above 3.00 kg/cm 2.

11. Open electrolyzer Inlet valve (XSDV002 for steam # A, XSDV003 for stream
# B, XSDV004for stream # C) and FCV (FCV001 for steam # A, FCV002 for
steam # B, FCV003 for steam # C) valve.

12. Establish the 27 m³/hr flow & set the flow valve in PLC SP box in auto mode
or give % valve in OP box in manual mode of respective stream.

13. Give the start command to rectifier from PLC after ensuring the following
steps.

A. Ensure the amp. Booster knob in zero position.

B. Charge the rectifier from electric panel
C. Start the blower.
D. Select the remote mode from rectifier panel.

14. Ensure all the starting parameters (feed flow, inlet pressure, Temp,) are well
within limits.

15. Increase the DC current in steps of 50 to 100 amps up to 2800 amps by

entering % Value in OP box in manual mode. Rectifier current can be
adjusted by the operator for controlling hypochlorite solution concentration by
potentiometer provided in the panel or by setting the value through PLC
panel. Ensure D.C. current is stable & after 30 mins sample to be taken.

5.0 SHUT DOWN PROCEDURE:

1. Decrease the DC current in steps of 50 to 100 amps up to zero amps by

entering % Value in OP box in manual mode.

2. Stop the rectifier as per following stapes.

A Ensure the amp. booster knob in zero position.
 GPPC POWER PLANT,PIPAVAV
2X351MW Combined Cycle Power Plant
POMSP
L SOP
001
ECP Start up and shutdown SOP
GPPC POMSP
L
Revision Date Clau
Issue No Issue Date Revision
06.02.2018 se Page 3 of 5
001 Rev# 01

B Stop the blower and fan.

C Cut the power supply from the electric panel by tripping breaker.

3. Ensure the storage tank blower in running condition for half an hour after
stopping the rectifier.

4. Flush the system with sea water to bring down temperature to room
temperature.

5. Stop the RO supply pump OR inlet vale near MOV 9GCB01AA051) which is
provided at seawater supply line.

6. Open the service water main isolation valve near the Hypo storage tank.

7. Open the electrolizer service water flushing inlet and outlet / drain valve and
let flush the system up to conductivity at both end are same.

8. Stop the service water pump.

9. Isolate the system.

6.0 ALARMS & TRIPS:

The following conditions are incorporated towards automatic stop / trip of the
individual stream of electrolysers and its associated equipment’s
.
 High High seawater inlet pressure
 High seawater supply pressure
 Low seawater flow at the inlet of Electrolyser stream
 High differential pressure across electrolyser stream
 High High solution temperature at the outlet of Electrolyzer stream
 Seawater booster pumps trip
 Low flow on the blower discharge header line occurs continuously.
 High High Level in hypochlorite storage cum degassing tanks.
 Loss of power, Transformer trip, Rectifier Failure.
 The following conditions are incorporated towards automatic shutdown
of the complete plant.
 H2 is 2.0% near hypochlorite storage cum degassing tanks and
Electrolysers.
 Motor failure / stop of both the Air dilution blowers
 Emergency plant shutdown by push button.
 GPPC POWER PLANT,PIPAVAV
2X351MW Combined Cycle Power Plant
POMSP
L SOP
001
ECP Start up and shutdown SOP
GPPC POMSP
L
Revision Date Clau
Issue No Issue Date Revision
06.02.2018 se Page 4 of 5
001 Rev# 01

7.0 PROCESS CONTROL & INTERLOCKS:

 Pressure indicator transmitter provided at the seawater inlet line will

deliver alarm in case of high high seawater supply pressure (around
5.0 Kg/cm2.g) and trip the running electrolysers and close the inlet
shutdown valve XSDV 001.
 Differential pressure transmitter provided across the self-cleaning
strainers will start backwashing at high differential pressure and deliver
alarm in case of high high differential Pressure across the strainers.

 Pressure indicator transmitter provided at the each seawater booster

pump discharge line will continuously monitor the seawater booster
pump discharge pressure.

 Standby seawater booster pump starts in case of running pump trips.

 The flow control station provided at the inlet of each Electrolyzer

stream will control seawater flow through Electrolysers at a pre-set
value. In case of high flow, alarm will be delivered.

 Flow switch provided at the inlet of each Electrolyzer stream will deliver
alarm and trip the respective Electrolyzer stream in case of low flow
and close the respective upstream ON-OFF valves with time delay.

 Differential pressure indicator transmitter provided across each

Electrolyzer stream will deliver alarm and trip the respective
Electrolyzer stream in case of high differential pressure across the
Electrolyzer stream and close the respective upstream ON-OFF valves
with time delay.

 Temperature indicator transmitter provided at the common seawater

supply header after strainers will deliver alarm in case of high seawater
temperature and trip the running Electrolyzer streams, seawater
booster pumps and close the XSDV 001 valve.

 Temperature indicator transmitter provided at the outlet of each

Electrolyzer stream will deliver alarm in case of higher temperature
than pre-set value and trip the respective Electrolyzer stream and close
the respective upstream ON-OFF valves with time delay.
 GPPC POWER PLANT,PIPAVAV
2X351MW Combined Cycle Power Plant
POMSP
L SOP
001
ECP Start up and shutdown SOP
GPPC POMSP
L
Revision Date Clau
Issue No Issue Date Revision
06.02.2018 se Page 5 of 5
001 Rev# 01

 Flow transmitter provided at the common discharge header of dilution

blowers (B-1001 A/B & B-1002 A/B) will continuously monitor the
airflow. It will deliver alarm in case of low flow and start the standby
dilution air blower and trip the complete plant in case of low airflow
persists.

 Spare blowers will automatically start when running blower trips.

 Hydrogen detector provided near the electrolyser unit and hypochlorite

storage cum degassing tank area, ensure that the hydrogen
concentration in the atmosphere does not cross-allowable limits (25%
of LEL). If the pre-set value is reached, the whole plant will shut down
automatically.

 Flow control station provided at each sets of hypochlorite dosing pump

common discharge line will control the dosing flow continuously as per
pre-set value.

 Flow transmitters provided at each sets of hypochlorite dosing pump

common discharge line will deliver alarm in case of low hypochlorite
flow or high hypochlorite flow. It will trip the respective running pump in
case of low low hypochlorite flow.

 In case of automatic shutdown of the unit, a timer will delay the

shutdown of the air dilution blowers.