DOCUMENT CODE REV. # 01 REV.

DATE 25-09-21 PAGE 1 of 6

EMERGENCY RESPONSE PROCEDURE FOR

MAIN PLANT
LOSS OF EXTRACTION STEAM SYSTEM

Title: Work procedure for Loss of extraction Steam System

Scope: This procedure will cover all the actions to be taken during the Loss of Extraction Steam system.

Type: Routine Procedure with Low Risk

Table of Contents

Chapters Description

1.0 Safety Requirements/ Precautions

2.0 Prerequisite
3.0 Safe Operating Limits
4.0 Action Against Deviations
5.0 Alarm & Trip Limits
6.0 Procedure & Responsibilities
7.0 Emergency Handling
8.0 Routine Check Sheet
9.0 Reference Document
10.0 Record
11.0 Distribution List

ROUTE PREPARED BY REVIEWED BY APPROVED BY

Name Tariq Iqbal Hafiz M Ishaq Muhammad Shakeel Khan
Date 25-09-21 26-09-21 26-09-21
Desig./Sign. SM SM OM
 DOCUMENT CODE REV. # 01 REV. DATE 25-09-21 PAGE 2 of 6

EMERGENCY RESPONSE PROCEDURE FOR

MAIN PLANT
LOSS OF EXTRACTION STEAM SYSTEM

Record for Change:

Rev. Page Chapter Section

Sr. Date Description of Change
No. No. No. No.

1. --- --- --- ---

2.

3.

4.

5.

ROUTE PREPARED BY REVIEWED BY APPROVED BY

Name Tariq Iqbal Hafiz M Ishaq Muhammad Shakeel Khan
Date 25-09-21 26-09-21 26-09-21
Desig./Sign. SM SM OM
 DOCUMENT CODE REV. # 01 REV. DATE 25-09-21 PAGE 3 of 6

EMERGENCY RESPONSE PROCEDURE FOR

MAIN PLANT
LOSS OF EXTRACTION STEAM SYSTEM

1.1 Safety Precautions:

1.2 Use mandatory PPEs.
1.3 Use right type of gloves as per job requirement.
1.4 All F-Keys & other material are placed at their proper places for easy access.
1.5 Walkie Talkie Set should be available to all the shift personnel for better communication.
1.6 Ensure clear tagging of equipment in field.
1.7 Think and analyze before commencement of any job.
2.0 Pre-Requisites:

2.1 All permits are cancelled.

2.2 Ensure that all motors breaker are racked in.

2.3 Extraction steam controller in service.

3.0 Safe Operating Limits:

Parameter SOL

Extraction steam pressure 2.2 ~ 2.8 bar

Extraction steam temperature 150 0C
Extraction Overflow temperature 170 0C

4.0 Actions Against Deviations:

4.1 LP header supply loss

Reason Consequence Actions

 ST tripping or De- Steam supply from LP

 Manage steam flow through
Synch resulting header consumers will
Second ST extraction (if in
Loss of extraction loss as below,
Normal Range service)
 PRDS on  DA heating steam
2.5 bar  Charge LP header from
manual/unavailable supply
PRDS-1/2 accordingly.
 Pneumatic NRV air  SCAPH Steam supply
 Connect air supply pipe if
supply loss  Sugar Mill Steam
dismantled
Supply

ROUTE PREPARED BY REVIEWED BY APPROVED BY

Name Tariq Iqbal Hafiz M Ishaq Muhammad Shakeel Khan
Date 25-09-21 26-09-21 26-09-21
Desig./Sign. SM SM OM
 DOCUMENT CODE REV. # 01 REV. DATE 25-09-21 PAGE 4 of 6

EMERGENCY RESPONSE PROCEDURE FOR

MAIN PLANT
LOSS OF EXTRACTION STEAM SYSTEM

5.0 Alarms & Trips:

Indication Alarm Trip Effect

Extraction steam E1 pressure 3.8barg Steam turbine will trip
0
Extraction Steam overflow temp 240 C 250 0C Steam turbine will trip

6.0 Procedure & Responsibilities:

Sr# Actions Responsibility

1 Turbine extraction controller Auto maintain extraction steam pressure as per given CRS
set point
2 Extraction controller will trip in case of ST d-synch or trip. CRS

3 Extraction line to LP header pneumatic NRV air supply loss will result closing of CRS/FO
NRV
3 Loss of extraction resulting LP header steam supply loss. CRS

LP header steam consumers supply will not be available as below,

4  DA heating steam supply FO/CRS
 SCAPH Steam supply
 Sugar Mill Steam Supply

5 Manage steam flow through second unit extraction (if in service) CRS

Charge LP header from PRDS-1 or 2 as per consumer load,

6 FO/CRS
PRDS-1 design to fulfill sugar mill requirements
PRDS-2 design to fulfill plant requirements
7 Carefully observe line hammering during LP header charging by opening MOV and FO/CRS
ensure its drains are already open.

ROUTE PREPARED BY REVIEWED BY APPROVED BY

Name Tariq Iqbal Hafiz M Ishaq Muhammad Shakeel Khan
Date 25-09-21 26-09-21 26-09-21
Desig./Sign. SM SM OM
 DOCUMENT CODE REV. # 01 REV. DATE 25-09-21 PAGE 5 of 6

EMERGENCY RESPONSE PROCEDURE FOR

MAIN PLANT
LOSS OF EXTRACTION STEAM SYSTEM

7.0 Emergency Handling:

7.1 Total Power failure

Sr. Action Responsibility
#

1 Both STs will trip, resulting loss of extraction supply, try to reset the
protections and restart the unit, prepare PRDS-1/2 for recharging of LP FO/ CRS
header

8.0 Routine Check Sheet

Sr. No Description Units Normal Range Value Remarks

1 Extraction Steam Pressure bar
0
2 Extraction Steam C
temperature
0
3 Extraction over flow C
temperature
4 Any abnormality

9.0 Reference Documents:

9.1 Operation and Maintenance Manual by Siemens

9.2 P&ID

10.0 Records:

10.1 Shift Engineer’s Log Book

10.2 Area Operator’s Log Book
10.3 Area Log Sheet

11.0 Distribution List:

Original : OM / Section Head

Copy # 1 : Central Control Room

ROUTE PREPARED BY REVIEWED BY APPROVED BY

Name Tariq Iqbal Hafiz M Ishaq Muhammad Shakeel Khan
Date 25-09-21 26-09-21 26-09-21
Desig./Sign. SM SM OM