DOC NO:

OPGS POWER GUJARAT PVT LTD

OPGS-0-BLR-OPN-19-26-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR DM INITIAL FILLING PUMP REV NO 0 DATE 03-03-2017

DM INITIAL FILLING PUMP

PREPARED BY APPROVED BY

DATE DATE

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-26-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR DM INITIAL FILLING PUMP REV NO 0 DATE 03-03-2017

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 of DM initial
filling water system, which are carried out by operation personnel who are responsible for improving
efficiency of the plant.

2. DESCRIPTION
In every power plant before light up boiler and some other systems like deaerator initial filling, hot
well filling, vacuum breaker filling, adiabatic system, APH water washing line, dosing system, valve
gland sealing, ejector syphon have to be filled with DM water up to their operating normal level. For
this we incorporated DM initial filling system.
In this plant DM initial filling system consists of 3 no’s of DM tank of 500 cu.m capacity with 2 no’s
of DM initial fill pump.

3. REFERENCE DOCUMENT
1. P&ID diagram of plant water system diagram no: - 1-9336-100-013.
2. P&ID diagram of APH firefighting and water washing system: - 2-00-305-31467.
3. P&ID diagram of steam and water circuit of boiler: - 0-00-047-47954.

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.

5. TECHNICAL SPECIFICATION
5.1 PUMP
Make ksb
Quantity 100 m3/hr
Head 75 m
Speed 2900 rpm
Power 30 kw
Phase angle 243mm

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-26-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR DM INITIAL FILLING PUMP REV NO 0 DATE 03-03-2017

5.2 MOTOR
Phase 3 phase induction motor
kw 30
Voltage 415
Speed 2950rpm
Current 52 amps
insulation class F
Duty S1
IP 55
Frame N0200L
Efficiency 91.5%(full load)
Frequency 50Hz
Temperature 50 deg C
Make Crompton Greaves
Drive end bearing 6312-2RS
Non drive end 6212-2RS

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 the DM tank water level.
6. Check all the TG, PG, LT are properly fixed.
7. Motor double earthing to be checked and motor terminal cover to be closed.
8. 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 PT, LT transmitters are lined up or not in local.

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-26-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR DM INITIAL FILLING PUMP REV NO 0 DATE 03-03-2017
7. PERMISSIVE
Not applicable.

8. PROTECTION
Not applicable.

9. STARTING PROCEDURE
1. Note down the DM tank level.
2. Check all the tapping from the DM initial filling line are closed.
3. Open suction valve and close the discharge valve of the pump.
4. Check the interconnecting isolation valve between DM initial filling header and DM make up
header. Keep open the valve according to the requirement or else close it.
5. Release the emergency push button of the pump.
6. Check for the suction pressure >0.5 ksc.
7. Remove the air by venting it via pressure tapping.
8. Inform to local and switch gear engineer and start the pump.
9. Check for direction, vibration and sound.
10. Slowly open the discharge valve up to 50% and maintain 7.0 ksc pressure at the outlet.
11. Throttle recirculation valve and keep open 25%.
12. SWGR engineer should note starting current, running current.

9.1 STARTING OF ANOTHER PUMP (PUMP B)

1. During initial filling we need to fill large quantity of water at that time we can start the second
pump.
2. Start the second pump as following the steps said in starting procedure.

9.2 PUTTING PUMP, A & B AUTO

1. Keep open the pump suction fully and discharge valve up to 50%.
2. Put the standby pump in AUTO mode using selection switch

10. SHUTDOWN PROCEDURE

1. When filling is not necessary inform to local and switch gear engineer then give stop command.
2. Keep the discharge and suction in open for standby or close it whether when we are giving it for
any maintenance job.
3. Note the DM tank level.

11. CHANGEOVER PROCEDURE

1. Start the second pump as said in starting procedure.
2. Give Stop command for the pump which we want to stop.
3. Inform to local and switch gear engineer.

Page 4 of 5
 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-26-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR DM INITIAL FILLING PUMP REV NO 0 DATE 03-03-2017
12. STANDBY OPERATION PROCEDURE
1. Open discharge and suction valve of the pumps.
2. Release the emergency push buttons.
3. Open pump pop up window and put the pump in auto mode.

13. CONCLUSION
The purpose of this procedure is for proper understanding of safe operation of DM initial filling
system.

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.
2.

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