STEAM TURBINE STANDARD OPERATING PROCEDURE

Steam Turbine standard operating procedures (SOPs)


Lube oil system operation


Pre-checks


• Ensure lube oil tank level is normal • Ensure lube oil pumps are healthy to operate


• Ensure lube filter & cooler are in service


• Ensure lube oil inlet and outlet valve provided at


filters & coolers are open Ensure cooling water inlet & outlet valves


provided for oil coolers are in closed condition
• Ensure suction & discharge valve of the pumps are in opened condition


Operation


. Start the oil pump (AOP)


• Ensure no abnormal sound & vibrations . Observe the discharge pressure


• Ensure header pressure is normal, if not adjust


with PRV or recirculation valve . Check the oil filter DP, if high change over the


filter


. Check overhead oil tank is getting filling
• Ensure lub oil is supplying to each bearing & adjust the oil pressure to each bearing as per


desired requirement . Maintain the oil temperature by adjusting


cooling water inlet & outlet valves.


Note: Keep open cooling water inlet valve 100% open & adjust the temperature by adjusting outlet valve


• Ensure the over head oil tank is full Keep stand by lube oil pump & EOP ready


Barring gear operation


• Ensure lube oil system is in service and oil is circulating at the bearings at a desired pressure


• Ensure barring gear motor is healthy to start & its all interlocks are in place


Engage the barring gear clutch . Start the barring gear motor


Observe the rotor is rotating at barring speed without increase in bearing vibrations & temperature


• Ensure there is no any abnormal sound
Cooling water system operation Pre-checks


• Ensure the cooling tower level is normal • Ensure cooling water pump is healthy to operate


& their protections & interlocks are in place


• Ensure cooling water pump (MCWP) suction


valve is open & discharge valve is closed


• Ensure all the field instruments are healthy & inline


• Ensure surface condenser inlet & outlet cooling


water line valves are open • Ensure Condenser water box vents are open


• Ensure cooling tower inlet cooling water line


valves are open


Operation


• Start the pump from DCS at 70% RPM


Open the discharge valve slowly • Observe discharge pressure is increasing


gradually


• Ensure the pump's vibration & bearing


temperatures are normal • After venting air from condenser water box


close the vent valves ⚫ Observe cooling water is falling in cooling water


• Increase the pump's speed as per requirement ⚫ Note down cooling water inlet & outlet water


temperature of condenser


. Start cooling tower fans one by one as per


requirement




Condensate system operation


• Ensure the hot well level is adequate. Otherwise make the hot well level with DM water


• Ensure the CEP is healthy & its all interlocks are in place


• Ensure pump's suction & discharge valves are open


• Ensure ejector & gland sealing steam condenser inlet & outlet cooling water line valves are open . Start the pump, ensure the water will flow from


ejector & Gland steam condenser (GSC)


• Ensure gland steam outlet control valve to deaerator is close & cooling water is recirculating through recirculating control valve
• If the hot well level increases, then GSC discharge valve can be opened


. Once the Turbine comes into line,GSC outlet control valve should be kept in auto mode to maintain hot well level


• Vacuum pulling & Vacuum killing


• Pre-checks


• Ensure auxiliary steam is available at desired pressure and temperature . Ensure vacuum breaker valve fitted on steam


condenser is closed • Ensure cooling water is circulating in the condenser and the turbine gland is charged fully


at 0.1 kg/cm2


• Ensure live steam line to ejector steam lines


drain are kept open • Ensure Hogger & main ejectors steam and air


valves are in closed condition


Vacuum pulling through hogger ejector


⚫ Charge the main steam line to ejector steam &


temperature control valve


• Ensure the rated pressure (10 kg/cm2) and temperature (220 deg C) for ejector vacuum pulling


. Once the rated parameters are reached open the steam valve of starting or hogger ejector . Observe the steam is vented to the atmosphere


⚫ Then open the ejector airline valve


• Observe vacuum inside the condenser increasing slowly and will reach 60 to 70% of rated vacuum within 20 minutes


SOP to put main ejector into line


• Ensure CEP is running


• Ensure cooling water inlet and outlet valves of


main ejector which is to be taken into line . Vent out air from water box of the ejector


• Then open the drain valve of inter condenser and after condenser of ejector


. Open the steam valve of after condenser ejector • Open the steam valve of inter condenser ejector


. Observe the condensate is drained out from both the condensers


Slowly open the air valve & observe the vacuum


is increasing


• When vacuum reaches rated, then stop the hogger or starting ejector
Vacuum killing or Taking out of main ejector


. Close the air valve of the ejector


. Close the steam valve of inter condenser


. Close the steam valve of after condenser


. Close the drain valves of after & inter condensers


. Close the cooling water inlet & outlet valve once the ejector is cooled

SLOP BOILER OPERATING PROCEDURE

SLOP FIRED BOILER STARTING PROCEDURE:-

Pre-checks



• Ensure DM water storage tank, feed tank & Deaerator level are normal


• Ensure availability of start up fuel (wood) & main fuel (coal) and power supply with DG backup


• Ensure maintenance & trial runs (healthiness) of all equipment including fuel handling, ash handling/ auxiliaries, motorized valves, actuators, control valves and PRDS controls are completed successfully


• Ensure that all interlocks / protection and controls are checked & taken in line.


• Ensure expansion pointers are cleaned & tramps


are in good condition.


• Ensure Boiler manholes and flue gas path system manholes are boxed up.


• Ensure availability of chemical dosing system and


readiness of drum level gauge glass with


illuminator assembly.


• Ensure availability of cooling water, instrument air and service air.


• Ensure Coal bunker is filled with required level


. Ensure all rotary air lock valves of evaporator, economizer & bag filters are open


• Ensure healthiness of all dampers and keep them


in open/close marked positions as per requirement • Open all air releases/vent valves in boiler drum and open super heater header drains and its vent valves.


• Ensure all boiler bottom ring header drains, blow down valves and main steam stop valves including its bypass valves are closed.


• Ensure Boiler feed pump's bearings oil level normal, minimum recirculation, balancing leak off valves & suction valves are open, cooling water pressure normal.


Boiler start up


. Start the ACW pump, Instrument Air & Service Air Compressor


• Start BFP from control room. Ensure suction pressure, balancing pressure & discharge pressure normal. Bearing temperature & Vibrations normal. Ensure motor draws current normal & sound normal. Shut the BFP immediately if any abnormal condition and check thoroughly before restart.


. Start water filling the boiler drum through 30% control valve and maintain the drum level up to 30%.


. Start the Ash handling plant prior to light up the Boiler. Then start all hoppers RAV.


• Ensure bag filter main damper is closed & bypass damper is open


. Maintain the drum level about 40%.


• Drum vent, super heater vent and main steam line


drain should be kept open.


. Start wood firing by spraying small quantity of diesel & slowly raise the furnace temperature


• At furnace temperature > 150 deg C start ID & FD fans at minimum speed


⚫ Close drum air vent at 2.5 kg/cm2


⚫ At 3 kg/cm2, gibe blow down to CBD, IBD & bottom headers one by one for 30 sec to 45 seconds


• At pressure > 4 kg/cm2, open start up vent 10% initially & close the top header drain valves & go on increasing the pressure


• At furnace temperature around 250 deg C, start coal feeding by starting SA fan


• Now slowly increase fuel feeding & FD air


• When boiler pressure reaches 6 kg/cm2 & 150 deg C, charge the main steam line. Before charging the main steam line, open all the drains at 100% and warm up vents at minimum opening and then open the MSSV bypass valve.
• Start HP & LP dosing and maintain recommended drum water parameters of boiler. Keep the CBD at minimum opening to maintain recommended residual PO4 & conductivity of drum water


. Check & record thermal expansion of boiler pressure parts and record the bearings temperature & vibrations of auxiliary equipment's associated with Boiler


. After ensured all condensate removed & color less steam comes through drains, keep all the drains in crack position, then open main steam stop valve and close the bypass steam valve


⚫ At Boiler pressure 9 kg/cm2 & temperature 180 deg C, charge Deaerator & SCAPH through PRDSH


. At flue gas temperature > 180 deg C take bag filter into line


• Observe seal air pressure, conveying air vessel pressure of AHP is normal.


Slop firing:


• Ensure sufficient quantity of slop with required brix is available in slop tank


• Ensure tank coil heater & steam tracing lines are charged & tank slop temperature is 70 to 80 deg C • Ensure slop pumps are healthy & agitator is


running condition


• After ensuring above all are normal, start slop transfer pumps & keep slop in recirculation mode for at least 2 to 3 hours before taking into boiler


. As the Boiler reaches 50 to 60% of MCR & furnace temperature is 450 to 500 deg C open the atomizing steam line, slowly introduce the slop into furnace by opening SOV


• Note: Before introducing slop into nozzle, keep open the steam connection line provided with respective nozzle.


• Quantity of slop fired at MCR is 3.91 TPH & slop quantity should be reduced as the load demand reduces


• Always maintain 20 to 25% supporting fuel on heat


basis. Never start the Boiler with slop


⚫ During slop firing ensure supplement fuel is supplying continuously to avoid clinker


• The soot blowers provided in economizer, evaporators are operated once in a shift & wall blowers twice in a shift