19 SOP For CEP

DB POWER LIMITED, RAIGARH
2 X 600 MW Power Plant

SOP for CONDENSATE EXTRACTION DB / SOP / CEP
PUMP
Issue No: Issue Date: Revision: 01 Revision Date: File no: Page 1 of 8
19/10/2013 22/11/2013
WORK INSTRUCTIONS
FOR
CONDENSATE EXTRACTION PUMP

[DB / SOP / CEP]
Prepared by: Reviewed by: Approved by:
FEEDBACK POWER O&M Signature: Signature:

Name: P.K. SAHA Name:
Designation: HOD Operations, DBPL Designation:

PUMP
19/10/2013 22/11/2013
Amendment Record
Amendment Amendment Nature of Change ACK No.

Date
Rev Page
No. No.
01 4,5,6 22/11/2013 Modified as per comments given by DBPL


PUMP
19/10/2013 22/11/2013
1.0 Purpose:
This Procedure is intended to provide guidance and instructions for carrying out the CEP Start-up
Operation.
2.0 Responsibility:
1. All the personnel involved in carrying out /supervising the above activities are required to ensure
implementation of this procedure.
2. In the event of any changes required in the procedure such changes may be requested with Site
in charge, who would take appropriate action with approval from respective departmental heads.
3.0 SAFETY AND ENVIRONMENTAL MEASURES/ CHECKS:
1. Ensure coupling guard of all the pumps are properly fixed.

2. Ensure proper earthing connections of motor.
3. Work area should be clean & no oil, grease splitting should be there.
4. Safety signs should be marked wherever required.
5. Ensure that there is extra cover for motor, to prevent motor from free falling water, is properly
fixed.
6. Ensure no oil leak at CEP bearings area. If oil leak is there, collect in suitable container and
transfer to the empty barrels and keep that barrel at waste oil storage yard.
7. If any fire / smoke due to oil leak, put off the fire and stop the equipment and start the
standby one.
4.0 CHECKLIST:
1. Ensure Work permits on CEP and the condensate system are closed and men, material are
removed from these areas.
2. Ensure Hot well level is normal.
3. Ensure sealing water line will charge from condensate transfer pump discharge line.
4. Ensure bearing cooling water charged (DMCW Pump should be running) and bearing oil level is
normal.
5. Ensure manual isolation valves upstream and downstream of the Re-circulation control valve are
open.
6. Recirculation Control Valve should be in Manual mode and fully open condition.


PUMP
19/10/2013 22/11/2013
7. Ensure suction valve of CEP is open.

8. Ensure Canister Vent Valve (Vacuum Balancing) is in open condition.
9. All the local gauges are mounted properly and are charged.
10. Hot well make up water line is available & CST level normal.
11. Ensure all the CEP discharge valves are in closed condition.
12. Ensure Deaerator level control station isolating valves are open.
13. Following air vents between CEP discharge line and Deaerator should be open.
14. Ensure the condensate flow path for all the LP Heaters and GSC are through.
15. Ensure manual isolating valves of LP Turbine hood spray; LP Bypass etc. are closed.
16. Rack in the breaker and put it in remote position.
17. Release the Local Emergency Stop Push Button (EPB).
6.0 START PERMISSIVES:
1. Suction valve in OPEN condition

2. Hot well level not Low > -100 mm
3. Canister Vent ( Vacuum Balancing) valve in OPEN condition
4. Switchgear supply available
5. Switchgear supply not disturbed
6. EPB not operated
7. MTR not operated
8. Recirculation valve 40% OPEN
9. Breaker not in TEST position
10. Motor winding temp not V. High < 1250C
11. Motor bearing temp not V. High < 900C
12. Thrust bearing temp not V. High < 900C
13. Discharge valve in CLOSED condition
14. Discharge vent open condition
15. Vibration not high
Start CEP
Post Start:
1. Observe that Equalising Valve opens and then the Discharge valve opens fully in auto if not
open it manually
2. Observe for any abnormal sound from Motor & Pump.


PUMP
19/10/2013 22/11/2013
3. Observe for the bearing temperatures and bearing vibrations of Motor and Pump.
4. Check that pump suction strainer differential pressure is ok.
5. Check that no water leakage is present in condensate water line.
6. Check the discharge pressure and flow of CEP.
7. Close all the condensate line vents after proper venting.
8. Put the Condensate Re-Circulation CV in Auto mode.
9. Ensure pump discharge valve is in full open condition
10. Check the motor winding, bearing temperature and vibration is normal.
11. Check any abnormal sound, any leakage
12. Make ready for second pump, put 2nd pump on auto standby mode
7.0 NORMAL OPERATING PARAMETERS:
Parameter Value
CEP discharge pressure. kg/cm²
Hot well level Normal %
Header pressure kg/cm²
CEP motor winding temp < Deg C
CEP motor bearing temp < Deg C
CEP bearing vibration.
CEP thrust bearing temp < Deg C
Suction strainer DP < kg/cm²
8.0 Stopping Procedure of CEP:
1. Plant load got reduced below 300MW.

2. Open pump recirculation valve and maintain the flow.
3. Stop the pump
4. Close the Recirculation valve and maintain the flow through one pump
5. Close pump suction & discharge MOV, first close Discharge, then suction MOV
6. Rack out the motor breaker & tag with PTW no.
7. Close all valves tightly as MOVs before and after D/A level control V/V
8. Stop motor cooling water
9. Stop bearing cooling water
10. Sealing water to the Pump should be stopped.
11. Dosing line for condensate water is to be closed


PUMP
19/10/2013 22/11/2013
12. Open all drains of condensate line i.e. CEP discharge drain, Dearator level control station drain,
LPH drain (water side).
ITEM SOURCE BREAKER PROTECTION ALARM TRIP CHEC

KED
STAT
US
CEP
1. Suction valve not OPEN.
2. Discharge press Low < 20 kg/cm2 with
10 sec delay
3. CEP flow V. Low. < 300 T/hr < 200 T/hr
4. Hot well level V. Low -1030mm
5. Motor winding temp V. High > 1200C > 1350C
6. Motor bearing temp V. High > 800C >900C
7. Motor bearing vibration V. High >11 mm/sec > 18 mm/sec
8. Thrust bearing temp V. High > 950C > 1050C
9. Pump bearing vibration V. High >11 mm/sec > 18 mm/sec
10. Electrical Protection operated
a) MTR operated
b) EPB operated
11. Thrust bearing oil temp 90 0C
12. CEP ON & discharge valve not
open 35 sec delay.
Isolation procedure for CEP for long Shutdown:
1. Reduce the load on the pump by reducing the opening of D/A LEVEL CTRL V/V and open its
recirculation valve
2. Release interlock of the standby pump (if interlock Put in)
3. Stop the Pump. Issue PTW and follow SI system.
4. Put off power supply to the MOV disable the pump from DCS.
5. Close pump suction & discharge MOV, first close Discharge MOV and then suction MOV disable
the MOV from DCS
6. Motor Breaker DC off, local Rack out and tagged with PTW no.
7. Close Pump recirculation valves


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19/10/2013 22/11/2013
8. close the Canister Vent ( vacuum balancing ) valve

9. close the motor & bearing cooling line valve if temp< 40°C
10. Close the sealing line to CEP from CT pump.
11. Close dosing line for condensate line which is at the inlet of GSC. Open drains provided at D/A
level control station, LPH drains (water side).
When one CEP is running then isolation procedure for 2nd CEP
Electrical-
1. Electrical- stopped & disable from DCS
2. Selector switch OFF
3. Breaker rack-out
4. Earth switch close
5. DC supply OFF
6. Tagged with PTW NO.
Mechanical-
1. Close discharge MOV
2. Close suction MOV
3. Close Canister Vent (vacuum balancing) line
4. Close sealing water valve(near the pump discharge and on common header)
5. Close motor cooling water
6. Close bearing cooling water
7. Make disable from DCS & MOV to be made OFF if required ( long S/D)
CEP Changeover
1. Ensure the any permit, men and material are removed from CEP area
2. Confirm the Permissive
3. Check the sealing and cooling line of CEP
4. Since one CEP is in service discharge header is full of water. No need to open vent and drain
5. Check vacuum line is in open condition
6. Check the oil level of CEP bearing. It’s must be above normal. (>50 %)
7. Start CEP
8. Observe the Discharge valve opens fully in auto if not open it manually
9. Observe vibration and Bearing Temp. it must be normal.
10. Stop CEP which is to be stopped.


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19/10/2013 22/11/2013
11. Keep the pump on standby or isolate for maintenance.
Emergency operation Of CEP

Cause:
1. Motor protection relay operates or disturbance in the supply module (Fuse blown off)
2. Hot well level low low < 200mm ( Alarms low <600 mm )
3. 415 V Aux. supply failure
4. Motor bearing temp. high
Effect:
1.Dearator level will fall
2.Hot well level will rise.
3.Condenser vacuum will fall
4.Unit has to be tripped unless the CEPs can be restored immediately
5.If one CEP has tripped see that the stand by CEP has started on auto or not ,
if not start it manual
6. If the CEP have found tripped on Hot well level low low, build up the hot well level quickly and
reset the hot well level low low and start CEP immediately
7. Reduce the unit load if stand by CEP is not available to control the Dearator level and rectify the
problem in the CEP which has tripped
8. Stand by CEP will start on auto on operating CEP discharge header pressure low.


19 SOP For CEP

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DB POWER LIMITED, RAIGARH

2 X 600 MW Power Plant

CONDENSATE EXTRACTION PUMP

Prepared by: Reviewed by: Approved by:

FEEDBACK POWER O&M Signature: Signature:

2 X 600 MW Power Plant

Amendment Amendment Nature of Change ACK No.

Prepared by: Reviewed by: Approved by:

FEEDBACK POWER O&M Signature: Signature:

2 X 600 MW Power Plant

3.0 SAFETY AND ENVIRONMENTAL MEASURES/ CHECKS:

1. Ensure coupling guard of all the pumps are properly fixed.

Prepared by: Reviewed by: Approved by:

FEEDBACK POWER O&M Signature: Signature:

2 X 600 MW Power Plant

7. Ensure suction valve of CEP is open.

6.0 START PERMISSIVES:

1. Suction valve in OPEN condition

Prepared by: Reviewed by: Approved by:

FEEDBACK POWER O&M Signature: Signature:

2 X 600 MW Power Plant

7.0 NORMAL OPERATING PARAMETERS:

8.0 Stopping Procedure of CEP:

1. Plant load got reduced below 300MW.

Prepared by: Reviewed by: Approved by:

FEEDBACK POWER O&M Signature: Signature:

2 X 600 MW Power Plant

ITEM SOURCE BREAKER PROTECTION ALARM TRIP CHEC

Isolation procedure for CEP for long Shutdown:

Prepared by: Reviewed by: Approved by:

FEEDBACK POWER O&M Signature: Signature:

2 X 600 MW Power Plant

8. close the Canister Vent ( vacuum balancing ) valve

Prepared by: Reviewed by: Approved by:

FEEDBACK POWER O&M Signature: Signature:

2 X 600 MW Power Plant

11. Keep the pump on standby or isolate for maintenance.

Emergency operation Of CEP

Prepared by: Reviewed by: Approved by:

FEEDBACK POWER O&M Signature: Signature:

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