KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
Power from knowledge
Issue No: 1
Issue Date:
KMPCL / Opr. / LP
HEATER/ 01
SOP FOR LP HEATERS
Revision: 0
Revision Date:
File no:
Standard Operating Instruction
FOR
LP HEATERS
STANDARD OPERATING PROCEDURE FOR LP HEATERS
Prepared by:
Reviewed by:
Approved by:
Signature:
Name: Abinash Mishra
Designation: Assistant Manager
Signature:
Name:
Designation:
Signature:
Name:
Designation:
Page 1 of 9
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
Power from knowledge
Issue No: 1
Issue Date:
KMPCL / Opr. / LP
HEATER/ 01
SOP FOR LP HEATERS
Revision: 0
Revision Date:
Page 2 of 9
File no:
OBJECTIVE: For Smooth Operation of LP HEATERS
SCOPE: This SOP is applicable for LP HEATERS.
INTRODUCTION:
LP HEATERS
LP feed water heaters is an important equipment in regenerative system of power plant it uses steam extraction
of the steam turbine to heat boiler feed water and reach the required feed temperature, so as to increase thermal
efficiency and ensure unit output.
LP heater system of this unit adopts single series, horizontal large bypass arrangement, includes 4 LP heaters( LP
heater #5 #6 #7&8). Each LP heaters consists of 3 zones, Desuperheating, condensing and drain cooling.
LP heaters Technical Data:ITEM
Unit
LP heater-5
LP heater-6
LP heater-7,8
THE NUMBER OF EACH UNIT EQIPMENT
1
1
1
Type
Single horizontal type
Heat-transfer area
m2
1050
1050
600
Design temperature of the shell side
°C
260
200
150
Design pressure of the shell side
MPa
0.6
0.6
0.6
Design temperature of the tube side
ºC
170
150
150
Design pressure of the tube side
MPa
4
4
4
Difference of upper end
°C
2.8
2.8
2.8
Difference of lower end
°C
5.6
5.6
5.6
Prepared by:
Reviewed by:
Approved by:
Signature:
Name: Abinash Mishra
Designation: Assistant Manager
Signature:
Name:
Designation:
Signature:
Name:
Designation:
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
Power from knowledge
Issue No: 1
S No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Issue Date:
KMPCL / Opr. / LP
HEATER/ 01
SOP FOR LP HEATERS
Revision: 0
Revision Date:
File no:
PRECHECKS AND ACTION BY FIELD ENGINEER
Description
Ok
Not
Ok
Work permit on various LP heaters, drip valves, level gauges,
water side valves, NRVs, etc., cancelled and men, material
□
□
removed from these areas.
The unit is synchronised and LP/LP bypass valves are closed.
□
□
The instrument air is charged to various drip valves and
valves are checked for the operation on auto.
□
□
All the pressure gauges, local level gauges, root valves and
□
□
various instrument impulses lines are charged or in service.
The 415 V power to various motorised valves is available.
Check that LPH-7A, 8A, 7B, 8B condensate inlet/outlet
valves are in open condition and bypass valve is in closed
condition.
Ensure all the shell side heater vents drain are in open
condition.
Check that all the isolating valves of the LP heater level
controllers are full open for all the heaters.
Charge the local level gauges for all the LP heaters.
Check that LPH-6 condensate inlet/outlet valves are in open
condition and bypass valve close.
LP HEATERS normal & emergency drain to flash tank
manual valve should be open .
□
□
□
□
□
□
□
□
□
□
Prepared by:
Reviewed by:
Approved by:
Signature:
Name: Abinash Mishra
Designation: Assistant Manager
Signature:
Name:
Designation:
Signature:
Name:
Designation:
Page 3 of 9
Remarks
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
Power from knowledge
Issue No: 1
Issue Date:
SOP FOR LP HEATERS
Revision: 0
Revision Date:
esEcSriK
ptE
ioN
nGINEER
PSRN
EoCH ECKS AND ACTION BYDD
S N1 o8.
1.
While making normal draiD
n e&scermipetrigoenncy drain valve in auto.
Check that Emergency control
valve set point is 10 or 20 mm
W
higohrkerptehram
nintornmvaalrdiorauisnLcPonhteraotlevrsa,lvder.ipSovatlhvaets,lelvevelelcognautrgoels,
w
anterbsyidneovrm
alavles,
RV
sn,tertocl.,vcaalvnec.elled and men, material
do
dth
raNin
co
r
e
m
o
ve
d
fr
o
m
e
e
s.perature after LPH-7A, 8A, 7B, 8B
19. C h e ck t he c o nd en s ataerteeam
2.
anhde L
mPp/eLrPatbuyrepasshsovualdlvgesraadrueacllyosed.
T
uP
niH
t i6s saynndchLrPoH
nis5edThaendteL
increase.
32 .0. The instrument a ir i s ch a rg ed t o v arious drip valves and valves
Close the heater v e n ts fr o m lo c al .
are checked for the operation on auto.
All the pressure gauges, local level gauges, root valves and
4.
various instrument impulses lines are charged or in service.
5.
The 415 V power to various motorised valves is available.
6.
7.
8.
9.
11.
Check that LPH-6 condensate inlet/outlet valves are in open
condition and bypass valve close.
14.
15.
16.
17.
Ok
Not Ok
Remarks
Ok
Not Ok
Remarks
□
□
□
□
□
□
□
□
□
□
Charge the local level gauges for all the LP heaters.
For LPH 7A, 8A and LPH 7B, 8B put the normal drain valve
control switch to control mode. The valve starts modulating to
maintain the LP heater level.
13.
Page 4 of 9
File no:
Check that LPH-7A, 8A, 7B, 8B condensate inlet/outlet valves
are in open condition and bypass valve is in closed condition.
Ensure the entire shell side heater vents drain are in open
condition.
Check that all the isolating valves of the LP heater level
controllers are full open for all the heaters.
10.
12.
KMPCL / Opr. / LP
HEATER/ 01
Open the extraction steam isolating valve to LPH6.
Open MOV after NRV & after MOV temperature is almost
same.
Put the normal drain valve control switch to auto mode. The
valve starts modulating to maintain the LP heater level.
Check the condensate inlet / Outlet valves for the LPH5 are
open and bypass valve closed.
Open the extraction steam isolation valve to LPH5
Put the normal drain valve control switch to auto mode. The
valve starts modulating to maintain the LP heater level.
Prepared by:
Reviewed by:
Approved by:
Signature:
Name: Abinash Mishra
Designation: Assistant Manager
Signature:
Name:
Designation:
Signature:
Name:
Designation:
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
Power from knowledge
Issue No: 1
Issue Date:
KMPCL / Opr. / LP
HEATER/ 01
SOP FOR LP HEATERS
Revision: 0
Revision Date:
File no:
Page 5 of 9
OPERATING PROCEDURE –
Sr.
No.
RESPONSIBILITY
UCE DE FE EE
Description
1.
The unit load is around5 % with both set of auxiliaries running.(30Mw).
2.
Work permit on various LP heaters, drip valves, level gauges, water side
valves, NRVs, etc., cancelled and men, material removed from these areas.
3.
4.
5.
6.
7.
8.
9.
10.
The unit is synchronised and LP/LP bypass valves are closed.
The instrument air is charged to various drip valves and valves are checked
for the operation on auto.
All the pressure gauges, local level gauges, root valves and various
instrument impulses lines are charged or in service.
The 415 V power to various motorised valves is available.
Check that LPH-7A, 8A, 7B, 8B condensate inlet/outlet valves are in open
condition and bypass valve is in closed condition.
Ensure all the shell side heater vents drain are in open condition.
Check that all the isolating valves of the LP heater level controllers are full
open for all the heaters.
Charge the local level gauges for all the LP heaters.
11. For LPH 7A, 8A and LPH 7B, 8B put the normal drain valve control switch
to control mode. The valve starts modulating to maintain the LP heater level.
Prepared by:
Reviewed by:
Approved by:
Signature:
Name: Abinash Mishra
Designation: Assistant Manager
Signature:
Name:
Designation:
Signature:
Name:
Designation:
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
Power from knowledge
Issue No: 1
Issue Date:
KMPCL / Opr. / LP
HEATER/ 01
SOP FOR LP HEATERS
Revision: 0
Revision Date:
File no:
Page 6 of 9
12. Check that LPH-6 condensate inlet/outlet valves are in open condition and
bypass valve close.
13.
Open the extraction steam isolating valve to LPH6.
14.
Open MOV after NRV & after MOV temperature is almost same.
15. Put the normal drain valve control switch to auto mode. The valve starts
modulating to maintain the LP heater level.
16. Check the condensate inlet / Outlet valves for the LPH5 are open and bypass
valve closed.
17.
Open the extraction steam isolation valve to LPH5
18 Put the normal drain valve control switch to auto mode. The valve starts
modulating to maintain the LP heater level.
19. While making normal drain & emergency drain valve in auto. Check that
Emergency control valve set point is 10 or 20 mm higher than normal drain
control valve. So that level control done by normal drain control valve.
20. Check the condensate temperature after LPH-7A, 8A, 7B, 8B and LPH 6 and
LPH 5 The temperature should gradually increase.
21. Close the heater vents from local.
Prepared by:
Reviewed by:
Approved by:
Signature:
Name: Abinash Mishra
Designation: Assistant Manager
Signature:
Name:
Designation:
Signature:
Name:
Designation:
√
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant
Power from knowledge
Issue No: 1
KMPCL / Opr. / LP
HEATER/ 01
SOP FOR LP HEATERS
Issue Date:
Revision: 0
Revision Date:
Page 7 of 9
File no:
PLANNED SHUTDOWN :
1.
1
2.
√
Close extraction check valve.
Close extraction MOV
3.
Close inlet and outlet valves of condensate water of respective LPH.
2
4. Before taking LPH out from service ensure LPH bypass MOV (water side) is
3 open.
5.
Close extraction check valve.
4
EMERGENCY SHUT DOWN:
1
2
3
√
Causes:
Heater drain control valves are not operating properly so should be checked
from local.
Due to tube leakage, condensate may enter the LPH & increase the level.
Effect:
If level goes to HH then water can go to turbine through NRV (if they are
passing) which leads to turbine blade erosion.
Action:
Heater emergency drain valve should be opened fully .If still level is going high,
the corresponding LPH will be bypassed from steam & water side automatically
(water side bypass valve will be open in auto).
Important Note: -
References: KMPCL LP heater EOM Manual.
P&ID of LP heater.
DCS logics
Prepared by:
Reviewed by:
Approved by:
Signature:
Name: Abinash Mishra
Designation: Assistant Manager
Signature:
Name:
Designation:
Signature:
Name:
Designation:
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