DOC NO:

OPGS POWER GUJARAT PVT LTD

OPGS-0-BLR-OPN-19-29-00
2X150 MW THERMAL POWER PLANT
SOP FOR CLOSED CIRCULATING COOLING
DOC TITLE REV NO 0 DATE 03-03-2017
WATER SYSTEM

CLOSED CIRCULATING COOLING

WATER SYSTEM (CCCW)

PREPARED BY APPROVED BY

DATE DATE

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-29-00
2X150 MW THERMAL POWER PLANT
SOP FOR CLOSED CIRCULATING COOLING
DOC TITLE REV NO 0 DATE 03-03-2017
WATER SYSTEM

Applicable Elements of Standard:

ISO 14001(2004) 4.4.4.6 Operational control.
OHSAS 18001 (2007) 4.4.6 Operational control.

1. OBJECTIVE
This procedure covers all the operational activities related to starting & operating closed circulating
cooling water system, which are carried out by operation personnel who are responsible for
improving efficiency of the plant.

2. DESCRIPTION
In a power plant every rotating equipment’s are supported by bearings which will produce
enormous amount of heat. That heat has to be removed for proper working of the bearing as well as
rotating equipment. For removal of heat in this plant we use demineralized water. The water is
circulated in a closed loop to the coolers of the equipment’s in that cooler the heat from the bearing
is transferred to the lubrication oil which in turn rejects heat to the water in coolers. Once the water
gained the heat it will reject that in cooling fan water bundles and recirculated through pumps.

In this plant 2no’s of CCCW pumps provided with 1 no’s of strainer for each pump is used. Along
with that for treating DM water we have chemical dosing system and also make up water tank at
boiler 35 metre level. We provided 40 no’s of cooling fans for heat rejection.

3. REFERENCE DOCUMENT
1. Scheme of closed circulating cooling water system, Drawing no: - 1-9336-100-012.
2. P&ID diagram of boiler cooling water system: - 0-00-303-31084.
3. P&ID diagram of main oil cooler: - 2-131-00-90108.
4. P&ID diagram of boiler feed water cooling pump: - HY-DG-1-18000-56941.
5. Fan data sheet by GEM equipment’s ltd. drawing no: - X01322.

4. SAFETY PRECAUTIONS
1. Hazard Identification and risk assessment of the activity shall be made available to the operator.
2. Only authorized person is allowed to operate the equipment.
3. All the access to the equipment shall be kept clear.
4. All the persons operating the equipment shall be provided with the proper training.
5. All the guards and coverings of the equipment shall be covered.
6. No flammable material or oil shall be scattered or spilled around the equipment.
7. Field operator should wear the relevant personal protective equipment like boiler suit, safety
shoes, helmet, safety hand gloves, safety goggle and others.

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-29-00
2X150 MW THERMAL POWER PLANT
SOP FOR CLOSED CIRCULATING COOLING
DOC TITLE REV NO 0 DATE 03-03-2017
WATER SYSTEM

5. TECHNICAL SPECIFICATION
5.1 PUMP
MAKE M/s. KSB PUMP LTD
FLOW 683 m3 / hr
HEAD 45 m
POWER 132 / 45
SPEED 1450 rpm
PHASE ANGLE 390

5.2 MOTOR
MAKE M/s. SIEMENS
PHASE 3 phase induction motor
FRAME 315 M
INS CL F
EFFICIENCY 95%
PROTECTION IP 55
DUTY S1
FREQUENCY 50 Hz
VOLTAGE 415
POWER 132 KW
CURRENT 230
SPEED 1485 rpm
AMB 50 ⁰C
ROTOR KL16
DE BRG 6319C3
NDE BRG 6319C3

5.3 FAN MOTOR

CURRENT 13 Amps
POWER 5.5 KW
SPEED 720 rpm
TEMPERATURE 50 ⁰C
POWER FACTOR 0.72
FREQUENCY 50 Hz
DUTY S1
INS CL F
VOLTAGE 415

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-29-00
2X150 MW THERMAL POWER PLANT
SOP FOR CLOSED CIRCULATING COOLING
DOC TITLE REV NO 0 DATE 03-03-2017
WATER SYSTEM
DRIVE END BRG 6309C3
NON DRIVE END BRG 6309C3

5.4 FAN
FAN MODEL C6/2.00 FB6
FAN DIAMETER 2000MM
VOLUME AIR FLOW 85500 cu.m/hr.
SPEED 720 rpm
STATIC PRESSURE 15 mmwc
AIR DENSITY 1.1 kg/cu.m
VELOCITY PRESSURE 34.35 pascal
PITCH ANGEL (TIP) 11.3 degree
FAN SHAFT POWER 5.07kw
TIP CLEARANCE 20mm
GD2 VALUE 13kg.cu.m
BLADE NATURAL FREQUENCY .76hz
STATIC EFFICIENCY 68.99 %

6. PRECHECKS
Following Engineer checks required before starting the Equipment.

6.1 FIELD ENGINEER CHECKS

1. Check all permits issued related works are completed for the equipment’s.
2. Check all safety and firefighting equipment are in line.
3. Ensure cleanliness of the area for combustible materials are removed properly.
4. Check oil level in pump bearing.
5. Check all the TG, PG, TE, PS, LS are properly fixed.
6. Check fans blades are fixed properly and bolted tightly.
7. No loose materials should be present in fan bundles.
8. Motor double earthing to be checked and motor terminal cover to be closed.
9. Check motor push button is released.
6.2 SWITCH GEAR ENGINEER CHECKS
1. Check all the permits issued for the equipment are returned.
2. Check 0.4 kv feeder proper rack in and circuit breaker healthiness, spring charging condition, trip
circuit healthy, rated bus voltage.
3. If above conditions ok give clearance to the control room engineer.

6.3 CONTROL ROOM ENGINEER CHECKS

1. All permit clearance to be checked.
2. Before starting the pump outlet should be closed condition.
3. Check all RTD values whether it shows nearby ambient temperature in DCS.
4. Check all TE transmitters are lined up or not in local.

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-29-00
2X150 MW THERMAL POWER PLANT
SOP FOR CLOSED CIRCULATING COOLING
DOC TITLE REV NO 0 DATE 03-03-2017
WATER SYSTEM
7. PERMISSIVE
Not applicable.

8. PROTECTION AND INTERLOCK

1. Pump discharge header pressure low alarm -3.5 ksc.
2. Pump discharge header pressure high alarm - 5.5 ksc.
3. Expansion tank level low alarm - 525 mmwc.
4. Expansion tank level high alarm - 1375 mmwc.
5. Fin Fan inlet temperature high alarm - 50 deg C.
6. Fin Fan outlet temperature high alarm - 46 deg C.

9. STARTING PROCEDURE
1. Back fill the CCCW system using DM filling pump.
2. Initial filling line isolation valve is given near turbine control oil pump skid.
3. Open all drains and vents. Slowly charge the lines in both boiler and turbine side.
4. Respective field engineers should take responsibility for opening and closing of drains and vents.
5. As constant laminar flow exists in drain close the drains one by one and top most vent is situated
in boiler 35M over window. Wait till water reaches there and air should be vented properly.
6. Fill the expansion tank also for water makeup.
7. Once system is filled with water clearance should be given by both turbine and boiler field
engineer to control room engineer.
8. Control room engineer should inform chemist to maintain water parameter with the help of
dosing system.
9. Get clearance from switch gear room and turbine field engineer.
10. Check once air is released in pump suction by opening strainer vent.
11. Close pump discharge valve.
12. Check the suction pressure (4 ksc) and suction valve should be open.
13. Give start command from desk. After started slowly open the discharge valve till the valve is
opened fully. Check the discharge pressure (7 ksc).
14. Once again open the lowest drain and highest vent for air removal once checked close it.
15. SWGR engineer should note starting current, no load current, voltage drop and breaker spring
charge condition.
16. Start the fan after getting clearance from switch gear and local engineer. Once started check for
abnormal noise, vibration and direction of rotation. Note down the current, voltage.
17. When the outlet temperature raised switch ON more no’s of fan.

9.1 STARTING OF ANOTHER PUMP (PUMP B)

Not applicable.

9.2 PUTTING PUMP, A & B AUTO

Not applicable.
Page 5 of 7
 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-29-00
2X150 MW THERMAL POWER PLANT
SOP FOR CLOSED CIRCULATING COOLING
DOC TITLE REV NO 0 DATE 03-03-2017
WATER SYSTEM

10. SHUTDOWN PROCEDURE

1. Check all the fans are switch off.
2. Close discharge valve.
3. Inform to local and switch gear engineer and give stop command from desk.
4. Press the emergency push button of the pumps.
5. Close the pump suction valve.
6. Fill the expansion tank to its normal level.
7. For draining of the system first open all the vents then open the lowest drain after sometimes
open all the drain.
8. Once system is drained completely close all drain and vents.
9. Inform to maintenance engineer to carry out any defects jobs.

11. CHANGEOVER PROCEDURE

1. Close the discharge isolation valve and open the suction valve.
2. After getting clearance from field and switch gear engineer start the pump.
3. Slowly open the discharge isolation valve fully. Check the discharge pressure must be 7 ksc
4. Close the pump discharge valve and Stop the pump which we want to stop.
5. Inform to maintenance engineer to carry out any defects jobs.

12. STANDBY OPERATION PROCEDURE

1. Keep the discharge and suction valve of the standby pump in open condition.
2. Release the emergency push button.
3. When the discharge header pressure decreased below ≤ 3.5 ksc. Another pump will start
automatically.

13. CONCLUSION
The purpose of this procedure is for proper understanding about the interlock and protection of the
CCCW system and its safe operation.

14. RECORD
Turbine desk log book.
Turbine local log book.
Switch gear log book.

15. AMENDMENT HISTORY

PREVIOUS
PRESENT
CONDITION PREVIOUS REV. CURRENT REV. NO
S.NO CONDITION
(BEFORE THIS NO.& ISSUE DATE & ISSUE DATE
(REASON MADE)
REVISION)
1.

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-29-00
2X150 MW THERMAL POWER PLANT
SOP FOR CLOSED CIRCULATING COOLING
DOC TITLE REV NO 0 DATE 03-03-2017
WATER SYSTEM
2.

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