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BHARAT ALUMINIUM
COMAPNY LIMITED
IMS MANAGEMENT SYSTEM AUXILIARY HEADER ISOLATION AND
CHARGING
STANDARD OPERATING
PROCEDURE
STANDARDS ISO : 9001 ISO : 14001 OHSAS : 18001 ISO : 50001
CONTROL OF
OPERATIONAL
Element Name: PRODUCTION & SERVICE OPERATIONAL CONTROL OPERATIONAL CONTROL
CONTROL
PROVISION
Element Number: 7.5.1 4.4.6 4.4.6 4.5.5
MR OFFICE USE ONLY
FORMAT NO. – IMS 10 FORMAT REVISION NO.: 00 FORMAT VERSION NO.: 00 FORMAT REVISION DATE : 12.06.15
Rev. No. 00 Version No. 00 Date of Preparation: 23/03/2016 Pages: 1 of 8
SOP No: BALCO/POWER/CPP2/OPN/MP/IMS/DOC/010-AUXHDR

1. SCOPE: APPLICABLE FOR ALL FOUR UNITS

2.OBJECTIVES:
 To isolate and normalize auxiliary header without any damage to equipment
 To enable maintenance activity to be carried out in safest manner
3.REQUIRED Knowledge of operations
COMPETENCIES
Knowledge of EnMS
Knowledge of safety

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INPUTS REFERENCE/RECORD PPE OUTPUTS EFFICIENCY EFFECTIVENESS REVIEW

1. Steam Desk engineer log book 1. Safety shoes 1.Proper Time for isolation and 1.No Half yearly
BALCO/POWER/CPP2/OPN/MP/IMS 2 .Safety Helmet isolation of normalisation < 30 min abnormalities review by Shift
/DEL-01,02,03,04 Auxillary after Steam In Charges &
3. Hand Gloves
Field engineer log book header charging. approved by
BALCO/POWER/CPP2/OPN/MP/IMS 4. Dust Masks Head CPP 2
2. Proper 2. Isolation
/FEL-01,02,03,04 5. Ear Plug charging of without lene
Shift charge log book 6.Goggles auxillary hammering
BALCO/POWER/CPP2/OPN/MP/ header
IMS/SEL
4. RESPONSIBILITY MATRIX:
1. Monitoring:- Shift In charge , Desk charge engineer
2. Isolation and Normalization :- Field Charge Engineer
5.DISTRIBUTION LIST:
Places where
Ver. No of No of copies distributed
SOP W. I . NO Reference Rev. No
No pages distributed (Location of
documents)
Control Room & soft copy
auxiliary header BALCO/POWER/CPP2/OPN/ Turbine Operation available in Library &
00 00 08 03
isolation and charging MP/IMS/DOC/010-SCP manual WE CONNECT(DMS
PORTAL)

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HEALTH,SAFETY,
STEP ENVIRONMENT
ACTIONS/OUTCOMES AND QUALITY
MESSAGES

Safety Safety Ear Dust Gloves Safety Safety Safety Belt

Helmet Shoes Muffs Mask/Respirator Goggles Jacket
Safety
SAFETY PPE’s PPE

Usage
√ √ √ √ √ √ √ X

TECHNICAL SPECIFICATIONS
SAFETY:
Designed Pr. 10 Kg/cm 2
There should be
Design Temp 400 oC no steam
Steam Pressure 6Kg/cm2 leakage
Stream Temperature 250-275 oC
1. PRE-CHECKS
BEFORE ISOLATION
HEALTH:
1. Ensure that turbine gland steam of all units is charged from Main steam of respective units. (DE) (EnMS) Ensure proper
2. HFO Atomizing steam is charged from CRH in any one unit from U#1 and U#2 and any one unit from U#3 lighting
and U#4. (FE) arrangement
3. All units mill inerting steam line is in isolated condition. (FE)

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4. Ensure that in U#1 ejector is not in service and is in isolated condition. (FE)
5. Ensure that all units SCAPH is in isolated condition.(FE)
6. Ensure that pegging steam line is in isolated condition in all units. (FE)
7. Ensure that auxiliary to 3rd extraction line is in isolated condition.(FE)
2. Isolation
procedure
1. Monitoring the gland steam pressure close the auxiliary steam to gland steam isolation valve (turbine 9m) in
all units. (DE)
2. Monitoring the HFO atomising steam temperature and pressure isolate the Auxiliary steam to FOPH line
isolation valve in U#1 D/A floor. (FE) (EnMS)
3. Open drain line after I/V and drain in U#1 boiler 0m atomising line.(FE)
4. Isolate auxiliary steam header to gland steam header isolation valve in U#1 D/A floor and open drains.(FE)
5. Crack open auxiliary steam header drains in between U# 2 and 3 and 3 and 4. (FE)
6. Crack open auxiliary header drain in U#1 near FOPH line.(FE)
7. Close the 3rd extraction to auxiliary line I/V in all units and open the drain after isolation V/V.(FE)
8. During isolation if hammering is observed increase the opening of drains. (FE)
9. Open the drains fully and monitor the auxiliary header temperature.(FE)
10. After the header temperature comes down to room temperature issue PTW for maintenance activity.(FE)

SAFETY:
1. There should
be no steam
leakage

HEALTH:
Ensure proper
lighting
3rd extraction to auxiliary Drain to condenser Drain to arrangement
header atmosphere

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3.Normalisation
Procedure

1. Ensure the all PTW are surrendered. (DE)

2. Ensure that auxiliary header drains are in open condition. (DE)
3. Crack open 3rd extraction to auxiliary line manual I/V to warm up the Auxiliary header. (DE)

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4. Monitor the temperature of auxiliary header. (DE) (EnMS)

5. Once temperature rises to 100 degrees slowly charge 3rd extraction to auxiliary in any one unit. (FE)(EnMS)
6. Close the drains and monitor the temperature and pressure of Auxiliary header.(FE)
7. Charge 3rd extraction to auxiliary from all other units by opening the manual I/V.(FE)
8. If any steam leakage is observed isolate the header immediately and inform to MMD.(FE)
9. Charge gland steam header and auxiliary steam to FOPH as per requirement. (DE)

ABNORMALITY TREATMENT
ABNORMALITIES REASON CORRECTIVE ACTION
Leakage from Auxiliary header Condensate deposition Drain Auxiliary header line properly
while charging
4. Cross Glands and gaskets of isolation Inform boiler MMD to resolve the
Reference valves are damaged problem
Line hammering Condensate deposition Drain the line before charging the
steam
Low auxiliary header temperature Auxiliary steam temperature is low Open the auxiliary header drains
5. OH&S, EMS, after charging near U#1 in D/A floor
SAFETY, ENMS &
PRECAUTIONS

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1. Boiler operation manual

2. Child reference no (check list): BALCO/POWER/CPP2/OPN/MP/CHK-60

5.1 OH&S CONSIDERATION (HIRADeC & Risk No. to be linked)

1. Be careful of leakage of steam.
2. In case of contact with heat report to control room.
3. Arrange for first aid as required.
Related HIRADC: BALCO/POWER/CPP2/OPN/MP/OHSAS/DOC/002-05 (5.10)

RISK NO: 110.

5.2 EMS CONSIDERTAION (Aspect No. to be linked)
1.. During charging and isolation ensure that the drains are opened to avoid hammering
2. Monitor for any leakage of steam. In case of leakage:
a) Report immediately to the control room.
b) Remove men and material if the leakage is very high.
c) If necessary issue permit to arrest the leakage
As emergency required stop the process
E-Aspect : BALCO/POWER/CPP2/OPN/MP/EMS/DOC/001A,001B,002,003,004

E-ASPECT NO: 2,7,11,13,19,34.

5.3 SAFETY CONSIDERATION :

Before charging the line please that condensate is removed completely from the drain & monitor the drain
temperature.

5.4 EnMS CONSIDERATION:

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Close SCAPH drain isolation valve once required APH outlet temp reaches.

5.5 PRECAUTIONS :
Ensure FD fan is running Before charging steam, to avoid over heating of SCAPH
REVISION PAGE
CHANGE EFFECTED DATE OF CHANGE
NUMBER NUMBERS
00 All pages Revision as per process requirement 23.03.2016

APPROVAL SIGNATURES RECORD

REVIEWER ROLE POSITION TITLE INITIAL AND SURNAME DATE SIGNATURE

Document Owner Operation Head R K Sharma

Reviewer 1 Shift In charge Dipankar Basu

Reviewer 2 Operation In charge R Sendhil Kumar

Prepared By Operation Engineer P Gowtham Pruthvi

APPROVED BY: SBU Head R K Dhancholia

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