DEPARTMENT: Operation Department

PLANT:(IPP)

WORK INSTRUCTION TITLE: STANDARD OPERATING PROCEDURE OF APH

DATE:06.07.2021 PAGES 1 of 13
VER.NO: 03 REV.NO : 00 WI- IPP/BTG/OPR/005

ISO ISO ISO ISO

Manageme ISO 9001:2015
14001:2015 45001:2018 50001:2018 55001:2014
nt Standard QMS
EMS OHSMS EnMS AMS
Operation
Operation Operation
Element Operation Operation Planning
Planning Planning
Name Control Planning & Control
& Control & Control
& Control
Element
8.1 8.1 8.1
Number 8.1 8.1

Table of Contents
1) PURPOSE.......................................................................................................................................................2
2) SCOPE............................................................................................................................................................2
3) REFERENCE..................................................................................................................................................2
4) ANNEXURE...................................................................................................................................................2
5) DISTRIBUTION.............................................................................................................................................2
6) AMENDMENT HISTORY.............................................................................................................................2
7) ACTIVITY CHARACTERISTICS:................................................................................................................3
8) RESPONSIBILITY.........................................................................................................................................3
9) DEFINITION..................................................................................................................................................3
10) SAFETY TABLE........................................................................................................................................3
11.1.0 EQUIPMENT DETAILS OFAPH...........................................................................................................5
11.1.1 Power Supply of APH..............................................................................................................................5
11.1.2 Starting Procedure of APH:.....................................................................................................................5
11.1.3 Start Permissive:......................................................................................................................................5
11.1.4 Pre start:...................................................................................................................................................6
11.1.5 Taking APH in service with running Boiler:............................................................................................7
11.1.6 Post start of APH.....................................................................................................................................8
11.1.7 Stopping Procedure of APH.....................................................................................................................8
11.1.8 Tripping Condition of APH.....................................................................................................................8
11.1.9 Post action of tripping of both APH.........................................................................................................9
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WORK INSTRUCTION TITLE: STANDARD OPERATING PROCEDURE OF APH

DATE:06.07.2021 PAGES 2 of 13
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11.2.0 APH Damper Interlocks...........................................................................................................................9

11.2.1 Isolation procedure /safety aspects (PTW) for APH:...............................................................................9
11.2.2 Emergency Procedure............................................................................................................................11
11.2.3 SCHEMATIC DIAGRAM:...................................................................................................................12
12.0 EMS CONSIDERATION:.........................................................................................................................13
13.0 OHSMS IMPLEMENTATION:................................................................................................................13
14.0 QMS CONSIDERATION:........................................................................................................................13
15.0 RECORDS:....................................................................................................Error! Bookmark not defined.

1) PURPOSE
Operate the Equipment by Standard Operating Procedure
2) SCOPE
This Procedure is applicable for Unit 1, 2, 3 & 4
3) REFERENCE
O & M Manual
4) ANNEXURE
NIL
5) DISTRIBUTION
DCS Engineer, Shift in charge, HOD Operation,MR and DCIC.
6) AMENDMENT HISTORY
S No Amendment Description Page Number(s) Current Ver. Current Rev. NoIssue Date
No.
1. SI system is change by SAP 8 00 01 12.06.2015
System.
7) ACTIVITY CHARACTERISTICS:

REVIEW
INPUTS OUTPUTS EFFICIENCY EFFECTIVENESS
FREQUENCY
All Safety PPE’s in place Normal Proper loading Smooth operation of One Year
operation with of APH at APH with reduced
normal permissible breakdown
generation of air operation limits

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WORK INSTRUCTION TITLE: STANDARD OPERATING PROCEDURE OF APH

DATE:06.07.2021 PAGES 3 of 13
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8) RESPONSIBILITY
Operator, DCS Engineer, Shift In charge/ HOD.

9) DEFINITION
Operate the equipment’s safely.

10) SAFETY TABLE

Ear Respirato PVC Safety Safety Safety

Job Safety Safety
muff r/ Dust gloves Goggle Belt Shoes
description/ Helmet uniform/
Mask

BOILER Y X Y Y Y Y Y Y
COOLING
11.1.0 EQUIPMENT DETAILS OFAPH
No. Description
APH:-Name-Ljungstrom Tri-sector Air Preheater; Quantity: 02 for each boiler; Rotor in-
1
side radius: R5413 mm;
Total heating area: Hot end layer: Depth: 1000mm Thickness: 0.8mm
2 Hot intermediate layer: Depth: 675mm Thickness: 0.8mm
Cold end layer: Depth: 305mm Thickness: 1.2mm
3 Rotating speed: 1.2 r/min (under drive),when pneumatic : 0.7 r/min
4 Speed Reducer: Type: SGW-100E; Ratio:128.2; Rated output Torque: 12500N-m;
Main motor: type: Y180M-4B3; power: 18.5kW, Rotating speed: 1470 r/min, Main mo-
tor voltage: 415 V, Motor rating current: 33A,
5
Pneumatic motor: type: HHFM, power: 11.3kW, Rotating speed: 750 r/min Pressure of
air supply source: 0.62 MPa; 2.69m3/min.
Guide Bearing: Two way spherical Roller thrust Bearing Type: SKF 23072CCK/W33
6
Support Bearing: Spherical Roller Thrust Bearing Type: SKF 294/530EM
Oil pump :- Type: Screw Pump; Model: 3GR25*4-0.8/1.0, Outlet pressure: 0.5 MPa
7
Oil pump motor:-Type Model: Y802-4B3, 0.75kw; Rotating speed: 1410 r/min
Filter :- Type Model: SXU-A63; Blockage alarm pressure: 0.35 Mpa, Filter accuracy:
8
50µm
Cooler :-Type Model: GLC1-0.8, Heater exchanging area: 0.4m2,Cooling water flow: 1-
9
3 m3/h,Cooling water temperature: ≤32°C,
10 Oil used:
Guide Bearing /Support Bearing– ISO VG680; Gear Box: ISO VG 220: Hydraulic coup-
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WORK INSTRUCTION TITLE: STANDARD OPERATING PROCEDURE OF APH

DATE:06.07.2021 PAGES 4 of 13
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ling- ISO VG32; Oil cup- Lithium base grease;

11 Sootblower: Cold End: Medium: steam:1-1.37Mpa Compressed air: 1-1.25Mpa
11.1.1 Power Supply of APH
No. Description Feeder no
1 APH A main motor- NE MCC * 6F2
2 APH B main motor- NE MCC *10F4
3 APH-A S/B LOP-1 *12R3
4 APH-A S/B LOP-2 *11R2
5 APH-A G/B LOP-1 *6R1
6 APH-A G/B LOP-2 *6F1
7 APH-B S/B LOP-1 *12R4
8 APH-B S/B LOP-2 *12R2
9 APH-B G/B LOP-1 *8F1
10 APH-B G/B LOP-2 *11R1
11 APH-A motor for soot blower *12R5
12 APH-B motor for soot blower *12R6

11.1.2 Starting Procedure of APH:

11.1.3 Start Permissive:
No. Description
1 Support Bearing temperature not high(<50˚C)
2 Guide Bearing Temperature not high (<60˚C)
Air motor Interlock Start
1 Main motor trips, Air motor will pick up if in standby with a time delay of 30 seconds

11.1.4 Pre start:

S No. Description Responsibility
Pre Start
Work permit on various boiler areas such as furnace, APH, ID fans, ESP, Desk Engineer
1 flue gas ducts, dampers etc. are closed and men, material are removed from / Field Engin-
these areas. eer
2 ACW cooling water system is in running condition. Field Engineer
3 Firefighting water available for Boiler and APH. Field Engineer
4 APH soot blowing system available. (Either air / steam) Desk Engineer

5 Desk Engineer
Ensure 415 V power supply is available to APH drive motor.

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WORK INSTRUCTION TITLE: STANDARD OPERATING PROCEDURE OF APH

DATE:06.07.2021 PAGES 5 of 13
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6 Field Engineer
Charge local pressure, temperature, flow, level gauges and transmitters.
Use of PPEs, electrical gloves, shoes, voltage detector, arc suit ,proper insu-
7 Field Engineer
lation/earthing, PTW(SI)system, SOPs displayed, awareness, LOTO system.
Check oil level in APH guide bearing and support bearing by dip stick and if
8 necessary top up with the correct oil to bring the level normal and check oil Field Engineer
level of main gear box.

9 Establish ACW cooling water supply through guide bearing and support Field Engineer
bearing oil coolers (water pressure >0.5 MPa).

10 Open the suction and discharge valves of the guide bearing lube oil pump Field Engineer
for the APH to be taken in service.

11 Open the suction and discharge valves of the support bearing lube oil pump Field Engineer
for the APH to be taken in service.
Field Engineer
12 /Desk Engin-
Ensure that APH flue gas inlet dampers/ outlet dampers are open. eer
Field Engineer
13 /Desk Engin-
Ensure APH secondary air inlet/outlet dampers are open. eer
Field Engineer
14 /Desk Engin-
Ensure that APH primary air inlet/outlet dampers are open. eer
Ensure that all the dampers for the other APH (which is not in service) are
15 Desk Engineer
closed.
Field Engin-
16 Start guide bearing lube oil pump and ensure that the bearing oil temperature eer/ Desk En-
is <60°C, oil pressure 0.4 - 0.5 MPa. gineer
Field Engin-
Start support bearing lube oil pump and ensure that the bearing oil temperat-
17 eer/ Desk En-
ure is <50 °C, oil pressure 0.4 - 0.5 MPa.
gineer

18 Check all the permissive for the APH to be started are available. Desk Engineer

Line up air motor and start APH on air motor and ensure smooth running of
19 Field Engineer
APH from local (0.4 ~ 0.5 rpm) for emergency trial run and then stop.

20 Start APH electric Main motor Desk Engineer

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11.1.5 Taking APH in service with running Boiler:

After work completion and PTW closer start APH with all manhole open (all related
1. dampers will be close as earlier to check any seal rubbing and observe any hunting in cur-
rent.
After work completion and PTW closer start APH with all manhole open (all related
2. dampers will be close as earlier to check any seal rubbing and observe any hunting in cur-
rent.
3. Keep APH in running condition till APH current get stabilize.
4. Close all manholes
Charge secondary air gradually by opening APH inlet SA damper and APH Hot SA outlet
5.
damper
Charge Primary air gradually by opening APH Cold PA inlet damper, keep HOT PA O/L
6. damper in close condition. While charging PA air monitor PA header pressure of running
Fan, maintain PA header above 7.0 KPa
7. Monitor APH running parameter (current, Hot secondary & Hot primary temp)
8. Gradually open APH Flue gas outlet damper.
9. Monitor APH I/L and O/L temp increasing trend and wait till it gets stabilize.
After stabilization of temp open any one I/L flue gas damper to 5-10% wait till APH para-
10.
meter stabilization then increase damper opening gradually
In Parallel gradually by keeping watch on hot secondary temp. If temp is in increasing trend
11.
increase secondary air damper and flue gas damper opening gradually.
12. Same way charge Hot PA damper by keeping track on hot PA temp
100% Hot PA and hot secondary air damper opening activity to be completed till APH out-
13.
let temp reaches to 100 °c.
Start ID and FD fan of related pass, fan loading to be done by keeping watch on APH O/L
14. temp and APH current hunting. If any increase in hunting observed decrease ID fan
loading/increase FD fan loading.
By monitoring APH ampere and APH O/L temp (less than 120°C) balance ID and FD fan
15.
loading.

11.1.6 Post start of APH

S.No. Description
After boiler light-up ensure continuous soot blowing is done until oil sup- Desk Engin-
1 port withdrawn, check from local. eer/ Field En-
gineer

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2 Soot blower steam press and temp has to be normal (0.8 Mpa&>250 °C) Desk Engineer
3 Note the parameters of lube oil motor. Field Engineer
With the same sequence other APH can be taken in service as per require-
4 Desk Engineer
ment

11.1.7 Stopping Procedure of APH

S.No. Description Responsibility
Stopping of one APH(e.g. APH-A)
1 Reduce Load to approx. 150 MW by stopping upper two mills Desk Engineer
Reduce vane position to minimum of FDF A & IDF A, simultaneously In-
2 Desk Engineer
crease vane position of FDF B & IDF B to maintain furnace pressure.
3 Stop FD fan A Desk Engineer
4 Stop ID Fan A& stop PA fan A. Desk Engineer
5 Stop APH A & Isolate the flue gas path Desk Engineer
Stopping of both APHs
1 stop both APHs when flue gas temperature <120 °C Desk Engineer

11.1.8 Tripping Condition of APH

No. Description
1 If Motor Protection Acted (Over load current & Over load)
5.1 Post action of Tripping of one APH (e.g. APH A) other APH running:

No. Description
If Motor Protection Acted and main motor trips, Air motor must pick up in 30secs. If Air
motor does not pick-up following actions take place:
1 Corresponding ID,FD and PA fan trip
2 If load>150MW runback will be initiated
APH SA inlet/outlet damper, APH PA inlet/outlet damper, APH Flue Gas inlet/outlet
3
dampers would close in auto.

11.1.9 Post action of tripping of both APH

No. Description
If both APH main and auxiliary motor trip, Boiler will trip under MFT (time Delay
1
=30sec)

11.2.0 APH Damper Interlocks

No. Description
Primary Air inlet/outlet damper
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1 Opens when both APH stop (delay =15s)

2 Opens in auto when APH start
3 Closes when APH trip (delay = 8sec)
Secondary air inlet/outlet damper
1 Opens when both APH stop
2 Opens in auto when APH starts in auto (delay = 15sec)
3 Closes when APH trip
Flue gas inlet/outlet damper
1 Opens in auto when both APH stop (delay = 15sec)
2 Opens in auto when APH start
3 Closes when APH tripped.

11.2.1 Isolation procedure /safety aspects (PTW) for APH:

No. Description Responsibility
APH and lubrication system isolation (when unit running)
1 Electrical Isolation
1.1 APH main motor breaker racked out and tagged. Field Engineer
1.2 APH soot blower breaker off. Field Engineer
1.3 APH guide and support bearing lubricating oil pumps rack out. Field Engineer
2 Mechanical isolation
2.1 APH soot blower steam/air side isolation. Field Engineer
Close inlet/outlet MIV of Guide bearing and support bearing oil
2.2 Field Engineer
system and isolate using mechanical LOTO.
Close service water inlet and outlet valve of lubricating oil cooler
2.3 Field Engineer
and isolate using Mechanical LOTO.
When APH has stopped and ensure from local that the dampers
2.4 Field Engineer
have been closed, then isolate the same using mechanical LOTO.
2.5 Close air valve for APH air motor and isolate using mechanical
Field Engineer
LOTO.
3 DCS isolation
3.1 Stop APH motor and keep in operation disable mode Desk Engineer
Once motor is stopped both air side and gas side dampers would
3.2 close in auto, ensure the same. Upon confirming the same switch Desk Engineer
off the module.
APH and lubrication system isolation( unit shut down) :-
1 Electrical Isolation
1.1 APH soot blowing power supply OFF. Field Engineer
For maintenance activity, before welding the rotor, the rotor
1.2 Field Engineer
grounding to prevent burning of air preheater bearings.
1.3 APH main motor, Auxiliary motor and both ID fan, FD fan, PA fan Field Engineer
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WORK INSTRUCTION TITLE: STANDARD OPERATING PROCEDURE OF APH

DATE:06.07.2021 PAGES 9 of 13
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stopped and breaker in racked out condition

1.4 APH guide and support bearing lubricating oil pumps rack out. Field Engineer
2 Mechanical Isolation
APH water washing and firefighting water supply closed and
2.1 Field Engineer
tagged.
2.2 APH soot blower steam/air side isolation. Field Engineer
Close inlet MIV of Guide bearing and support bearing oil system
2.3 Field Engineer
and isolate using mechanical LOTO.
Close inlet and outlet valve of lubricating oil cooler and isolate us-
2.4 Field Engineer
ing Mechanical LOTO.
When APH has stopped and check from local whether dampers are
2.5 in closed condition or not, if closed isolate the same using mechan- Field Engineer
ical LOTO.
Close air valve for APH air motor and isolate using mechanical
2.6 Field Engineer
LOTO.
3 DCS isolation
Both ID, FD and PA Fan Stopped condition and put in operation
3.1 Desk Engineer
disable.
Before stopping the running motor, remove the other motor from
3.2 Desk Engineer
standby. Once stopped put both in operation disable mode
Once motor is stopped both air side and gas side dampers would
3.3 close in auto, ensure the same. Upon confirming the same switch Desk Engineer
off the MCB.
Note Follow SAP system to issue PTW, isolation and normalisation

11.2.2 Emergency Procedure

SNO. Description
I Fire in APH
Cause: - A) Due to incomplete combustion of oil (LDO/HFO) and unburnt carbon accumu-
lation on APH heating elements may cause fire.
1
B) Due to low speed 1 rpm and availability of hot air may cause fire in the APH.
C) Due to unscheduled soot blowing during light up and normal.
2 Operator Action :-
I) Watch flue gas inlet and outlet temperature in start up to get first fire signs.
II) If the temperature continuously rises and there is fire, close flue gas inlet dampers but
keep APH running to avoid uneven expansion of APH. Confirm from local that APH is ro-
tating.
III) Open fire fighting water nozzle to extinguish the flame. Water washing lines of APH
must be open. Ensure that hopper ash conveying valve is closed & ash water drain valve to
atmosphere is open.
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IV) If fire was extinguished completely & temp of flue gas inlet & outlet is < 150 °C.Stop
APH
V) Check radial seal, axial seal and circumferential Bypass seal.
After light up of boiler, APH soot blowing to be carried out to avoid fire in APH. Soot
Note: blower pressure and temperature must be normal (0.8Mpa / more than 250 °C), ensure from
local that APH soot blowing is operating.
II. Ash accumulation near APH guide bearing and support bearing
Clear the ash accumulation near APH guide bearing and Support bearing to avoid bearing
1
damage.
APH current started hunting due to ash entry into bearings, if current hunting is more than
2
20A and abnormal sound observed; Stop Air Preheater and inspect the bearings .

11.2.3 SCHEMATIC DIAGRAM:

Isolation:

Sl.no Isolation Check list Location Tag no Remarks

1 Check APH stopped 18m
2 Check APH Main motor stopped 18m  Unit-1
Check APH Main motor power supply 0m
3 isolated  Unit-1
Check APH air motor stopped and air supply 18m
4 valve closed  Unit-1
22m  (For
5 Check APH inlet flue gas damper closed APH1A)
Check APH inlet flue gas damper power 0m
6 supply isolated.
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Check Respective ID fan stopped and HT 0m

7 breaker racked out  (IDF-1A)
Check Respective ID fan HT breaker racked
8 out
Check respective ID fan suction, discharge 0m
7 gate and ID fan suction damper closed.   (IDF-1A)
Check respective ID fan suction, discharge
gate power supply isolated.
Check respective ID fan suction damper IA
isolated.
Check APH outlet sec air damper closed and 22m
8 power supply isolated  (APH-1A)
Check Respective pass FD fan stopped and 6.9m
9 HT breaker racked out  (FDF-1A)
Check FD fan discharge damper closed and 0m
10 power supply isolated  (FDF-1A)
Check FD fan discharge interconnection 0m
11 damper closed and power supply isolated
0m
12 Check SCAPH steam supply is cut off (Unit-1)
Check Respective PA fan stopped and HT 0m
13 breaker racked out  (PAF-1A)
Check PA fan discharge damper closed and 0m
14 power supply isolated  (PAF-1A)
Check APH outlet HOT PA damper closed 13m
15 and power supply isolated  (APH-1A)
Check PA fan discharge interconnection 0m
16 damper closed and power supply isolated  (unit-1)
17 Check Fire water isolation valve closed 22m
18 Soot blower steam supply valve closed 22m,80m   (unit-1)
19 Soot blower power supply isolated 22m,80m   (unit-1)
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20 APH washing water supply line isolated 13m  (unit-1)

Normalization:

Locatio Tag no
Sl.no Normalization Check list n Remark
APH motor-1 power supply module normalized and
1 put in remote  18m 11HLD04XG
APH motor-2 power supply module normalized and
2 put in remote  18m  11HLD05XG
 1APHN1,
1APHA1,1APHB
3 APH air motor air supply valve open  18m 1
APH inlet flue gas damper power supply normalized  11HNA10AA00
4 and put in remote  22m 3A,B,C,D
 10HNC10AN00
Respective pass ID fan HT breaker racked in, control 1/10HNC20AN0
5 supply on and put in remote  6.9m 01
 10HNA10AA00
1A/B,
10HNA30AA001
ID fan suction, discharge and interconnection damper 10HNA10AA002
6 power supply normalized and put in remote.  0m A
APH outlet sec air damper power supply normalized  11HLA10AA00
7 and put in remote  22m 2A,B
Respective pass FD fan HT breaker racked in, control
8 supply on and put in remote  6.9m  10HLB10AN001
FD fan discharge damper power supply normalized  10HLA10AA00
9 and put in remote  03 1B
FD fan discharge interconnecting damper power  10HLA50AA00
10 supply normalized and put in remote  0m 1
1SAPHA1,1SAP
HA4, 1SAPHB4,
1SAPHB1
11 SCAPH steam supply MIV normalized  6.9m
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Respective PA fan HT breaker racked in, control

12 supply on and put in remote  6.9m  10HLB30AN001
PA fan discharge damper power supply normalized  10HLA30AA00
13 and put in remote  0m 1
APH outlet HOT PA damper power supply  10HLA30AA00
14 normalized and put in remote  13m 2
PA fan discharge interconnection damper power  10HLA60AA00
15 supply normalized  0m 1
16 Fire water isolation valve remains closed  22m
 11HCB20AA00
2
 22m,80
17 Soot blower steam supply valve opened m 10HCB15AA002
 11HCB20AA00
2

18 Soot blower power supply normalized  13.7m 10HCB15AA002

 1APHA6,1APH
A7
1APHB6,1APHB
19 APH washing water supply line remains isolated  13m 7
20 LOTO tags removed

12.0 RECORDS:
Field Logbook, Field Engineer Checklist, Desk Logbook.

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