INTEGRATED RISK MANAGEMENT SYSTEM PROCEDURE || SOP ON CONDENSER FLOOD TEST MAAMBA COLLIERIES LIMITED SOP-TPP -TO- 03 13.08.2020 [/Rev: | 1 LY. Phi 1.0 Purpose This Standard Operation Procedure (SOP) provides instructions for the condenser flood test, The instructions also address safety and health concerns during condenser flood test. 2.0 Scope of application This procedure applies to all activities to be carried out during condenser flood test. 3.0 Responsible person(s) a) Shift charge engineer b) Turbine DCS operator ©) Turbine field operator d) Operation head ) Maintenance head ) Turbine maintenance engineer 9) SHEQ Manager 4.0 Required Personal Protective Equipment (PPE) ‘Safety during the condenser flood test includes general safety. The following are the PPEs to be used during boiler Hydro test. a) Safety helmet b) Safety shoes ©) — Hand Gloves d) Nose mask/Respirator e) Safety Googles f) Safety belt 5.0 Condenser Technical Parameters [ Condenser type = [Surface Cooling area 11060m* Cooling water temperature 330C Cooling water pressure =| 0.4 MPa (g) Cooling water flow circuit | 20500TPH ‘Steam pressure 9.8Kpa(a) _ Steam flow 353TPH 6.0 Condenser test procedure Condenser flood test to be carried out by water fil test. Under this all the equipment and systems coming in contact with condenser are filled with DM water and leaks are identified. Then the leakage points are arrested to prevent the air ingress while vacuum is raised.x CONDENSER FLOOD TEST SOP-TPP-T0-03, Revision: 1 | Page 20f4 Pre checks + Ensure availability of OM water (around 220MT) for Condenser Flood Test. Ensure the turbine casing metal temperatures are below 50°C. Ensure availability of proper illumination around the equipment in the test area. Ensure availability of dewatering pump for dewatering pit. Locking of the condenser springs before starting water fill test so as to arrest the spring action. * Condenser hood manholes are kept open for water level checking. * Locking of all the hangers of drain flash tanks and connected pipe Lines in vacuum system. * Ensure CW pumps are not in service and condenser water box is empty. PROCEDURE DETAILS © Start filing water in the system gradually. 0 Release the air of LP Heaters, HP Heater, Drain cooler and Gland steam condenser by ‘opening their vent valves during filling. ‘© Check for leakages in the system after every 1-meter rise in water level Drain up to just below the leak observed and attend the same. © Repeat the above process and continue checking and attending to the leakages as in above steps till the water level filed is 300mm above the condenser and LP cylinder weld joint. ©. Further check the leakages up to 1 meter above tube nest (water level should be at least 0.5 meter below the LP blades) and maintain this level during this test (at least 12 hrs.). ©. Drain the system and attend all leakages (which were not attended earlier). ©. After the completion of leak test, clean hot well and release the jack bolts of condenser springs © During flood test the condenser water box shall be inspected to identify the tube leaks. © Condenser Flood Test is completed after satisfactorily attending to all the identified leakages. 7.0 References > Condenser manual, > Pa&lds 8.0 RECORDS Sl.No. | Record No. Records, 4 ‘Turbine DCS operator log book. 2 Turbine field operator log book - 3 Shift charge engineer log book. 9.0 REVISION HISTORY DATE REV | CHANGES, NAME 13.08.2020 | 1 | New SOP A.Livingston I Bie anal ‘APPROVAL SIGNATURES il PREPARED BY | G.J Mohana Babu | TITLE | Operation Incharge | SIGN oq AUTHORISED BY | B. Laxmi Prasad TITLE | Head O&M SIGN APPROVED BY | Yotham Phiri TITLE | SHEQ Manager SIGN Page 20f2