BOP Operating Manual 2011-12
BOP Operating Manual 2011-12
BOP Operating Manual 2011-12
FOR
BOP MANUAL
1
PREFACE
S L BANGOTRA
PUM, PNC-CPP
2
BOP Operating Manual
3
BOP Operating Manual
Updation/Issue Record
4
INDEX
EQUIPMENT DESCRIPTION, SPECIFICATIONS
PAGE NO
& OPERATING PROCEDURES :
4 Deaerator
7 PRDS
8 Auxiliary Boiler
5
GENERAL DESCRIPTION OF BOP AREA
The BOP area of Captive power plant to Naptha Cracker Complex includes
SHP BFPs, MP BFPs, Deaerator Feed pumps, Deaerators, Condensate
storage tanks, Auxiliary Boiler & PRDS.
Super High pressure Boiler feed pumps (3 Turbo driven & 2 Motor driven)
supply feedwater to Utility boilers, HRSGs & Naptha cracker complex. The
specifications are as follow:
No. of stages 10
6
Radial(Sleeve) & Thrust(Tilting pad
Bearing type
type)
Oil viscosity ISO grade VG 46
Total cooling water requirement, m3/hr
(Seal jacket/Seal heat exchanger/Lube oil 24.2 at 5.6 ksc
system/Motor
Max allowable noise 85 dBA @ 1m
START UP PROCEDURE:
9
INTERLOCK TABLE :
10
MP BOILER FEED PUMPs (52P 506/507) :
Medium pressure Boiler feed pumps (2 Motor driven) supply feed water to
Naptha cracker complex (LLDPE). The specifications are as follow:
Quantity 2 ( MD)
No. of stages 7
11
OPERATING PROCEDURE FOR MP BFP (MOTOR DRIVE):
START UP PROCEDURE:
12
6. Slowly open the motorized integral bypass valve (3016/3030) on the
discharge line.
7. Slowly open the main motorized Discharge valve (3015/3029)
keeping in watch of the discharge pressure.
8. Check for any flange/tapping leakages from pump & its associated
pipings
9. Record all the critical parameters in the Field Log book at regular
intervals.
INTERLOCK TABLE :
13
DEAERATOR FEED PUMPS (52P-510/511/512) :
Quantity 3 ( MD)
No. of stages 1
14
Total cooling water requirement, m3/hr
(Seal jacket/Seal heat exchanger/Lube oil
system/Motor
Max allowable noise 85 dBA @ 1m
START UP PROCEDURE:
INTERLOCK TABLE :
16
DEAERATOR (52-V-501/502):
Function:
The presence of certain gases like O2, Co2, Ammonia dissolved in water is
harmful because of their corrosive attack, particularly at elevated
temperature. Thus in modern high pressure boilers, to prevent internal
corrosion, the feed water should be free of all dissolved gases especially O2.
This is achieved by embodying into the freed system a Deaerating Unit.
Apart from deaeration, it also serves following functions:
1. Heating incoming feed water.
2. To act as reservoir to provide a sudden or instantaneous demand.
Principle of Deaeration :
Quantity 2
17
Heating steam flow rate required at
27.15 85.92
given pressure & temp.
Drains into Deaerator :
18
Material of tray SA240 TP304
Supports for feed water storage tanks Sliding type - 4 Fixed type -1
Guaranteed Performance :
Oxygen content in feed water at
0.005
deaerator outlet (ppm)
CO2 content in feed water at deaerator
Nil
outlet (ppm)
START UP PROCEDURE:
START UP PROCEDURE:
START UP PROCEDURE:
INTERLOCK TABLE :
24
CONDENSATE STORAGE TANKS (52T-001/002) :
Quantity 2
Capacity, m3 100
Fluid handled DM water
START UP PROCEDURE:
26
STEAM NETWORK (CPP):
In CPP complex four types of Steam are produced i.e. SHP, HP, MP, and
LP. These steams are utilized in CPP & Naptha Cracker Complex for
different purposes like heating, for Turbo driven equipments etc.
Different steams parameters, Connections & their purposes are as
follow:
SHP STEAM :
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HP STEAM :
SHP/HP PRDS-1 8
SHP/HP PRDS-2 6
STG-1/2/3 Extraction 12 each
Spray water from SHP BFP Discharge header 1
28
MP STEAM:
HP/MP PRDS-1 20
HP/MP PRDS-2 10
STG-1/2/3 Extraction 10 each
FD-TD 1/2 Outlet 12 each
Spray water from SHP BFP Bleed header 1
MP/LP PRDS 6
Atomization & soot blowing for UB-1/2 4 each
Soot blowing for HRSG 1/2/3/4/5 6 each
NCU 42
29
LP STEAM :
MP/LP PRDS 16
SHP BFP TD 1/2/3 Exhaust 12 each
FO TD 1/2 Exhaust 6 each
MOP TD 1/2/3(STG) Exhaust 6 each
Spray water from SHP BFP Bleed header 1
30
PRDS UNITS: PRDS (Pressure Reducing Desuperheating Station) is
used to reduce the pressure & temperature of the steam as per our
process requirement. It consists of a pressure control valve to reduce
pressure & a temperature control valve to reduce temperature by the
introduction of DM water spray. The spray for various PRDS is taken
from BFP discharge header, BFP bleed header & DFP discharge spray.
31
LP PROCESS STEAM LINE TO CPP
DS-1 SHP BFP Bleed header
B/L
START UP PROCEDURE:
1. Take clearance from the panel operator for charging the system.
2. Make LOCAL/REMOTE mode selection from DCS or LOCAL.
3. Ensure all drains in SHP to HP PRDS-1/2 in steam side are open.
4. Slowly open the Motorised valve (0906/0907) on the SHP to HP
PRDS-1/2 steam line.
5. Slowly open the Pressure control valve CV-0926/0920 & charge
the system to maintain the requisite pressure.
6. Ensure all drains in SHP to HP PRDS-1/2 in steam side are closed
after proper removal of condensate from lines.
7. Open the isolation valves 902/909 upstream & 946/948
downstream of temperature control valves CV 901/910of spray
water from SHP BFP Discharge header.
8. Now charge the spray water from SHP BFP Discharge header by
slowly opening the Temp. Control valve CV 901/910 & maintain
the required temperature.
32
9. Put the pressure & Temperature control valves in AUTO as per
requirement.
10.Check for any abnormal noise & Vibration level of pipelines.
11.Check for any flange/tapping leakages from its associated pipings.
12.Record all the critical parameters in the Field Log book at regular
intervals.
Operating procedure for HP TO MP PRDS UNITS 1/2:
START UP PROCEDURE:
1. Take clearance from the panel operator for charging the system.
2. Make LOCAL/REMOTE mode selection from DCS or LOCAL.
3. Ensure all drains in HP to MP PRDS-1/2 in steam side are open.
4. Slowly open the Motorised valve (1022A/1001A) on the HP to MP
PRDS-1/2 steam line.
5. Slowly open the Pressure control valve CV-1007/1002 & charge
the system to maintain the requisite pressure.
6. Ensure all drains in HP to MP PRDS-1/2 in steam side are closed
after proper removal of condensate from lines.
7. Open the isolation valves 1010/1005 upstream & 1052/1054
downstream of temperature control valves CV 1009/1004 of spray
water from SHP BFP bleed header.
8. Now charge the spray water from SHP BFP bleed header by
slowly opening the Temp. Control valve CV 1009/1004& maintain
the required temperature.
9. Put the pressure & Temperature control valves in AUTO as per
requirement.
10.Check for any abnormal noise & Vibration level of pipelines.
11.Check for any flange/tapping leakages from its associated pipings.
33
12.Record all the critical parameters in the Field Log book at regular
intervals.
START UP PROCEDURE:
1. Take clearance from the panel operator for charging the system.
2. Make LOCAL/REMOTE mode selection from DCS or LOCAL.
3. Ensure all drains in HP to MP PRDS-1/2 in steam side are open.
4. Slowly open the Motorised valve (1605) on the MP to LP PRDS-
1/2 steam line.
5. Slowly open the Pressure control valve CV-1606 charge the system
to maintain the requisite pressure.
6. Ensure all drains in MP to LP PRDS-1/2 in steam side are closed
after proper removal of condensate from lines.
7. Open the isolation valves 1634 upstream & downstream of
temperature control valves CV 1624 of spray water from SHP BFP
bleed header.
8. Now charge the spray water from SHP BFP bleed header by slowly
opening the Temp. Control valve CV 1624 & maintain the required
temperature.
9. Put the pressure & Temperature control valves in AUTO as per
requirement.
10.Check for any abnormal noise & Vibration level of pipelines.
11.Check for any flange/tapping leakages from its associated pipings.
34
12.Record all the critical parameters in the Field Log book at regular
intervals.
START UP PROCEDURE:
1. Take clearance from the panel operator for charging the system.
2. Make LOCAL/REMOTE mode selection from DCS or LOCAL.
3. Ensure all drains in SHP bypass to condenser PRDS-1/2/3 in
steam side are open.
4. Slowly open the isolation valve (793/797/799) on the SHP bypass to
condenser PRDS-1/2/3 in steam side line.
5. Slowly open the Pressure control valve CV-704/705/706 charge the
system to maintain the requisite pressure.
6. Ensure all drains in SHP bypass to condenser PRDS-1/2 in steam
side are closed after proper removal of condensate from lines.
7. Open the isolation valves 708/711/714 upstream & downstream
778/779/780 of temperature control valves CV 704/705/706 of
spray water from DFP discharge header.
8. Now charge the spray water from DFP discharge header by slowly
opening the Temp. Control valve CV 704/705/706 & maintain the
required temperature.
9. Put the pressure & Temperature control valves in AUTO as per
requirement.
35
10.Check for any abnormal noise & Vibration level of pipelines.
11.Check for any flange/tapping leakages from its associated pipings.
12.Record all the critical parameters in the Field Log book at regular
intervals.
START UP PROCEDURE:
1. Take clearance from the panel operator for charging the system.
2. Make LOCAL/REMOTE mode selection from DCS or LOCAL
3. Ensure all drains in LP excess steam to condensor PRDS-1/2/3 in
steam side are open.
4. Slowly open the isolation valve (1582/1584/1586) on the LP excess
steam to condensor PRDS-1/2/3 in steam side line.
5. Slowly open the Pressure control valve CV-1501/1503/1505 charge
the system to maintain the requisite pressure.
6. Ensure all drains in LP excess steam to condensor PRDS-1/2/3 in
steam side are closed after proper removal of condensate from
lines.
7. Open the isolation valves 1511/1514/1517 upstream of
temperature control valves CV 1512/1515/1518 of spray water
from CEP Discharge 1/2/3.
8. Now charge the spray water from spray water from CEP
Discharge 1/2/3 by slowly opening the Temp. control valve CV
1512/1515/1518 & maintain the required temperature.
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9. Put the pressure & Temperature control valves in AUTO as per
requirement.
10.Check for any abnormal noise & Vibration level of pipelines.
11.Check for any flange/tapping leakages from its associated pipings.
12.Record all the critical parameters in the Field Log book at regular
intervals.
START UP PROCEDURE:
1. Take clearence from the panel operator for charging the system.
2. Make LOCAL/REMOTE mode selection from DCS or LOCAL.
3. Ensure all drains in HP steam to GT steam injection PRDS-
1/2/3/4/5 in steam side are open.
4. Slowly open the isolation valve (1201/1209/1217/1349/1319) on the
HP steam to GT steam injection PRDS-1/2/3/4/5 in steam side
line.
5. Open the isolation valves 1202/1210/1218/1312/1320 upstream &
downstream 1204/1212/1220/1314/1322 of pressure control valves
CV 1203/1211/1219/1313/1321 of HP steam to GT steam injection
PRDS-1/2/3/4/5 in steam side line.
6. Slowly open the Pressure control valve CV-
1203/1211/1219/1313/1321 charge the system to maintain the
requisite pressure.
7. Ensure all drains in HP steam to GT steam injection PRDS-
1/2/3/4/5 in steam side are closed after proper removal of
condensate from lines.
37
8. Open the isolation valves 1206/1214/1222/1316/1324 upstream &
downstream 1260/1262/1264/1323/1327 of temperature control
valves CV 1207/1215/1223/1317/1325 of spray water from SHP
BFP bleed header .
9. Now charge the spray water from SHP BFP bleed header by
slowly opening the Temp. control valve CV
1207/1215/1223/1317/1325 & maintain the required temperature.
10.Put the pressure & Temperature control valves in AUTO as per
requirement.
11.Check for any abnormal noise & Vibration level of pipelines.
12.Check for any flange/tapping leakages from its associated pipings.
13.Record all the critical parameters in the Field Log book at regular
intervals.
START UP PROCEDURE:
1. Take clearence from the panel operator for charging the system.
2. Make LOCAL/REMOTE mode selection from DCS or LOCAL.
3. Ensure all drains in HP steam to STG Aux. PRDS-1/2 in steam
side are open.
4. Open the isolation valves 1343/1390 upstream & downstream
1344/1391 of pressure control valves CV 1311/1323 of HP steam to
STG Aux. PRDS-1/2 in steam side line.
5. Slowly open the Pressure control valve CV-1311/1323 charge the
system to maintain the requisite pressure.
6. Ensure all drains in HP steam to STG Aux. PRDS-1/2 in steam
side are closed after proper removal of condensate from lines.
38
7. Open the isolation valves 1301/1393 upstream & downstream
1328/1329 of temperature control valves CV 1308/1315 of spray
water from SHP BFP bleed header.
8. Now charge the spray water from SHP BFP bleed header by
slowly opening the Temp. Control valve CV 1308/1315 & maintain
the required temperature.
9. Put the pressure & Temperature control valves in AUTO as per
requirement.
10.Check for any abnormal noise & Vibration level of pipelines.
11.Check for any flange/tapping leakages from its associated pipings.
12.Record all the critical parameters in the Field Log book at regular
intervals.
START UP PROCEDURE:
1. Take clearance from the panel operator for charging the system.
2. Make LOCAL/REMOTE mode selection from DCS or LOCAL.
3. Ensure all drains in SHP BFP bleed header in water side are
closed/ blinded.
4. Open the isolation valves 1418 upstream of temperature control
valves CV 1419 of spray water from SHP BFP bleed header.
5. Now charge the spray water from SHP BFP bleed header by
slowly opening the Temp. Control valve CV 1419 & maintain the
required temperature.
6. Put Temperature control valve in AUTO as per requirement.
7. Check for any abnormal noise & Vibration level of pipelines.
8. Check for any flange/tapping leakages from its associated pipings.
39
9. Record all the critical parameters in the Field Log book at regular
intervals.
START UP PROCEDURE:
1. Take clearance from the panel operator for charging the system.
2. Make LOCAL/REMOTE mode selection from DCS or LOCAL.
3. Ensure all drains in SHP BFP bleed header in water side are
closed/ blinded.
4. Open the isolation valves 1631 upstream of temperature control
valves CV 1626 of spray water from SHP BFP bleed header.
5. Now charge the spray water from SHP BFP bleed header by
slowly opening the Temp. Control valve CV 1626 & maintain the
required temperature.
6. Put Temperature control valve in AUTO as per requirement.
7. Check for any abnormal noise & Vibration level of pipelines.
8. Check for any flange/tapping leakages from its associated pipings.
9. Record all the critical parameters in the Field Log book at regular
intervals.
40
PRE START CHECKS:
START UP PROCEDURE:
1. Take clearance from the panel operator for charging the system.
2. Make LOCAL/REMOTE mode selection from DCS or LOCAL.
3. Ensure all drains in SHP BFP bleed header in water side are
closed/ blinded.
4. Open the isolation valves 1040 upstream of temperature control
valves CV 1020 of spray water from SHP BFP bleed header.
5. Now charge the spray water from SHP BFP bleed header by
slowly opening the Temp. Control valve CV 1020 & maintain the
required temperature.
6. Put Temperature control valve in AUTO as per requirement.
7. Check for any abnormal noise & Vibration level of pipelines.
8. Check for any flange/tapping leakages from its associated pipings.
9. Record all the critical parameters in the Field Log book at regular
intervals.
41
AUXILIARY BOILER: Auxiliary boiler is used to supply LP steam for
the VAM (Vapour Absorption Machine) system. The auxiliary boiler
outlet is Low pressure steam which is connected to LP header. Only
during initial start up of VAM system subjected to MP/LP PRDS
availability the LP steam requirement is met by Auxiliary boiler. In
normal circumstances, the LP steam requirement for VAM system is
met by MP/LP PRDS. The specifications are as follow:
MAKE : ENERGYPACK
CAPACITY 10 T/Hr
PRESSURE 9 Kg/cm2
FD FAN 1 NO.
2 NO.s
HSD PUMPS
2 NO.s
BOILER FEED PUMPS
Fuel HSD/LDO
START UP PROCEDURE:
45