Final Manual Vivek PDF

HPCL-Mittal Energy Limited
Guru Gobind Singh Refinery, Bathinda

Captive Power Plant Operating Manual
9112-575-OPR-701-00002
O&M By:
STEAG ENERGY SERVICES (I) PVT LTD
Mona Nanoty Ashish Srivastava Siddiqui MD Ghazunfer Ali

Amit Kumar K. V. Rao
02 31-Jan-2019 IFI /Ayush Kumar
(HMEL) (STEAG) (STEAG) (HMEL)
(STEAG)
Abhik Das Amit Kumar Ashish Srivastava S. Nath Siddiqui MD Ghazunfer Ali
01 15-Dec-2017 IFI (STEAG) (HMEL) (STEAG) (STEAG) (HMEL)
Amit Kumar Suneel Jain Ashish Srivastava Rajiv Dhenge Siddiqui MD Ghazunfer Ali
00 11-June-2011 IFI (STEAG) (HMEL) (STEAG) (STEAG) (HMEL)
REV ISSUE DATE STATUS PREPARED REVIEWED CHECKED APPROVED CONCURRED

This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of HPCL-MITTAL ENERGY LTD. The
copyright of this document is vested in HPCL-MITTAL ENERGY LTD. All rights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system
or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owner.
Revision 02
Issue Date 31-Jan-2019
Captive Power Plant Operating Manual Next Review 30-Jan-2022
9112-575-OPR-701-00002 Page 1 of 5
INDEX
CHAPTER - 1 GENERAL
1.1 INTRODUCTION
1.2 PLANT CAPACITY
1.3 OBJECTIVE OF THE UNIT
1.4 BATTERY LIMIT CONDITIONS
CHAPTER - 2 PROCESS DESCRIPTION

2.1 INTRODUCTION
2.2 DETAIL PROCESS DESCRIPTION
CHAPTER - 3 UTILITIES, CHEMICALS AND EFFLUENTS

3.1 UTILITIES INTRODUCTION
3.2 UTILITIES SPECIFICATION
3.3 UTILITIES CONSUMPTION
3.4 UTILITIES B/L CONDITIONS
3.5 CHEMICAL CONSUMPTION AND SUMMARY
3.6 WASTE EFFLUENTS / BLOW DOWN
3.7 EFFLUENT TREATMENT
CHAPTER - 4 OPERATING VARIABLES

4.1 NORMAL OPERATING PARAMETER WITH ALARM SP’s
CHAPTER - 5 PREPARATIONS FOR START-UP

5.1 PLANT CHECKING
5.2 EQUIPMENT INSPECTION
5.3 PIPING INSPECTION
5.4 SUPPORTING SYSTEM
5.5 ELECTRICAL AND INSTRUMENTATION
5.6 CHEMICAL INVENTORY
5.7 PAVED AREA
Template No. Copyrights HMEL– All rights reserved

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5.8 AREA LIGHTING

5.9 PUBLIC ADDRESS SYSTEM
5.10 STRUCTURAL INSPECTION
5.11 FIRE AND SAFETY
5.12 UTILITY COMMISSIONING
5.13 PRE-COMMISSIONING ACTIVITIES
CHAPTER - 6 COMMISSIONING & START-UP PROCEDURES

6.1 INTRODUCTION
6.2 CPP COMMISSIONING AND START UP
CHAPTER - 7 NORMAL SHUTDOWN PROCEDURES

7.1 NORMAL SHUTDOWN
CHAPTER - 8 EMERGENCY SHUTDOWN PROCEDURES

8.1 EMERGENCY WITHIN CPP
8.2 EMERGENCY DUE TO UTILITIES FOR CPP
CHAPTER – 9 NORMAL OPERATION OF THE UNIT

9.1 INTRODUCTION
9.2 SUMMARY OF OPERATING CONDITIONS
9.3 CONTROL PHILOSOPHY OF THE PROCESS
9.4 OPERATING PARAMETERS
9.5 TROUBLESHOOTING
CHAPTER – 10 PROCESS INTERLOCKS & PSV SCHEDULE

10.1 LIST OF INTERLOCKS
10.2 PSV SCHEDULE

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CHAPTER – 11 HAZARDS, SAFETY & COMMUNICATION

11.1 INTRODUCTION
11.2 SAFETY WARNING
11.3 SAFETY OF PERSONNEL
11.4 HAZARD DURING STARTUP/SHUTDOWN AND PRECAUTION
11.5 WORK PERMIT PROCEDURE
11.6 FIRST AID
11.7 HAZARD SOURCE TO THE ENVIRONMENT
11.8 WASTE DISPOSAL
11.9 COMMUNICATION SYSTEM
CHAPTER – 12 CATALYST SPECIFICATION AND SPECIAL PROCEDURES

NOT APPLICATION FOR CPP
CHAPTER – 13 MAJOR EQUIPMENTS AND THEIR OPERATION
CHAPTER – 14 MATERIAL SAFETY DATASHEETS
CHAPTER – 15 FIRE FIGHTING FACILITIES
15.1 INTRODUCTION
15.2 FIRE FIGHTING SYSTEM – DESIGN BASIS
15.3 USE OF LIFE SAVING DEVICE
CHAPTER – 16 CONSEQUENCES DUE TO UPSETS IN OUTGOING B/L STREAMS

16.1 CONSEQUENCES DUE TO UPSETS IN OUTGOING B/L STREAMS
CHAPTER – 17 EQUIPMENT DATASHEETS

17.1 EQUIPMENT LIST OF CPP

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CHAPTER – 18 EQUIPMENT HANDOVER PROCEDURES
CHAPTER – 19 BLIND LISTS
CHAPTER – 20 CHECK LIST

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CHAPTER-1
GENERAL
1.1 INTRODUCTION
HPCL-MITTAL ENERGY LIMITED (HMEL) setup a 11.25 MMTPA refinery at Bathinda, in the state of
Punjab, India for producing transport fuels of EURO IV specifications. Engineers India Limited (EIL)
has been retained by HMEL as PMC for the entire complex and for the preparation of the Basic
Design & Engineering Package for all open art units including Captive Power Plant (CPP). M/s BHEL
is awarded as a Vendor for the complete CPP as an Lump sum Turnkey Contractor (LSTK)
The CPP unit consists of the following main processing sections:
1. Steam Generating Units – Utility Boilers, Heat Recovery Steam Generator (HRSGs) &
Circulating Fluidized bed combustion Boilers
The main objective of this section is to generate steam from Feed water at Operating
Parameter (108 Kg/cm2 g, 508 ºC) for Power Generation at Steam Turbine end and also
providing 3 level of steam i.e. HP steam level (40 Kg/cm2 g, 390 ºC), MP steam level (12.5
Kg/cm2 g, 280 ºC) and LP steam level (4.5 Kg/cm2 g, 170 ºC) for different Processes of
Refinery.
2. Power Generating Units – Gas Turbine and Steam Turbine

The main objective of this section is to generate Power from steam at steam Turbine
Generator end (35 MW X 2 + 32 MW X 1) and also from Gas Turbine Unit (34.5 MW X 2). 02
nos. of STG is with double control extraction type while 01 nos. STG is Back pressure type.
Extraction and back pressure level of steam is equivalent to the Refinery demand steam
Level. CPP also include one DG set unit (2.8 MW capacity @ 6.6 KV level) which is act as a
standby source of Power during Blackout condition of Refinery.

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3. Boiler Feed water Deaeration – Deaerator

The main objective of this section is to ensure proper Deaeration of Boiler feed water
before feeding to steam generator and BFW is supplied to the process units for steam
generation, BFW shall be exported from CPP to process units at HP level.
The Key features of the unit are as follows:
 CPP is design to produce steam and power as per the full capacity demand of Refinery
i.e. 11.25 MMTPA crude processing capacity

 CPP is design to cater the continuous supply of steam supply for 30 minutes by
running single Utility Boiler on full load during the time of complete power Blackout
which ensures that steam supply for safe Refinery shutdown.
1.2 PLANT CAPACITY

CPP CAPACITY TABLE
UNIT MCR TOTAL UNIT TOTAL

UO TOTAL RUNNING
SOURCE CAPACITY MCR OPERATING OPERATING
M UNITS UNITS
CAPCITY CONDITION CONDITION
STEAM
UTILITY BOILER TPH 4 240 960 3 226.26 678.78
HRSG TPH 2 110 220 2 110 220
CFBC TPH 2 300 600 2 300 600
TOTAL 1780 1498.78
POWER
GAS TURBINE MW 2 34.5 69 2 31.95 63.9
STEAM TURBINE
MW 2 35 70 2 35 70
CONDENSING TYPE
STEAM TURBINE
MW 1 32 32 1 30.4 30.4
BACKPRESSURE TYPE
TOTAL 171 164.3

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TURNDOWN CAPABILITY
 30% of MCR on ACC, 50% on STC @ ≥ 505 deg C.

 Between 30% to 50% steam temperature can be go up to 500 Deg
1.3 OBJECTIVE OF UNIT

• To ensure uninterrupted supply of Process steams (HP, MP and LP type), Feed water &
Electrical Power for all Refinery unit processes at define Quality level and rated state.
• To ensure that the Process steam supply is as per define Quality
• To ensure that CPP reliably supply steam and power to Refinery for all refinery mode of
operation

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1.4 BATTERY LIMIT CONDITION:

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b) Battery Limit condition at CPP
Steam level Units Min. Normal Max. Mech. Design.
HP Steam
2
Pressure Kg/cm g 36.0 38.0 39.0 40.0
Temperature oC 370 380 390 400

MP Steam
2
Pressure Kg/cm g 10.0 11.3 11.5 12.5
LP Steam
2
Pressure Kg/cm g 3.8 4.4 4.7 5.5

Boiler Feed Water (HP Level), AT CPP B/L
Pressure Kg/cm2g 47 52 58 71
o
Temperature C 120 120 135 155

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CHAPTER – 2
PROCESS DESCRIPTION
2.1 INTRODUCTION
The Process flow sequence, arrangement of process equipment, salient operating parameters, major
control schemes and heat and material balance for Captive Power Plant Unit is shown in the Heat
and Mass Balance Diagram (Drawing nos.: 2381-01-00835-Rev0-S01 & S02). Major Facilities provided
in the unit battery limit are:
- Gas Turbine Generator
- Steam Turbine Generator
- Utility Boiler
- Heat Recovery steam Generator
- CFBC Boiler
- Boiler Feed Pumps
- Gas Booster Compressor
- Deaerator
- Black Start DG set
- SS – 10 Substation
2.2 DETAIL PROCESS DESCRIPTION
2.2.1 DM Water system and Make up and Condensate Transfer system to Deaerator:
DM water from Utility @ 6.0 Kg/cm2 g enters to CPP Battery limit where it get distributed to
different location inside CPP as mentioned below:
a. DM water to Condensate collecting tank
b. DM water to LP dozing skid for Deaerator and Condensate storage tank
c. DM water to HP dozing system for UB and HRSG
Template No. Copyright HMEL– All rights reserved
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d. DM water to GT Compressor Water wash skid and Water Injection skid as make up
e. DM water to STG # 1 and 2 Initial filing to Condenser
f. DM water to VAM system
g. DM water to DG set house
h. DM water to make up surge vessel for each GT Atomizing Air Pre-cooling system
DM water enters the Condensate collecting tank (575-CST-00-001) as makeup water for Boilers. Rate
at which the DM water enters to CPP depends upon the Level controller installed on CST tank. There
are condensate supply headers coming from Refinery to Condensate storage tank. The Condensates
coming from refinery are:
 Pure Condensate

 Surface Condensate

 Condensate from Process
Common supply header for condensates from refinery to CST is provided with Flow Element (10-
FE1701) which measures the inlet flow of condensates from Refinery to CST. Each above mentioned
condensate header from Refinery complex coming to condensate storage tank is provided with
Motorized Operated valve (MOV). There is dedicated LP dozing skid (Ammonia) (Refer P&ID – 3-
38101-022770) for Condensate Storage tank which ensure that the Condensate before transferring to
Deaerator should have proper pH value.
Other inputs to Condensate storage tank are:
1. STG # 1 and 2 Hotwell condensate return.
2. BPTG GSC drain transfer through pumps (575-P-CF-006A/B)
3. BFPDT GSC drain transfer through Pumps (575-P-CF-010A/B)
Along with this there are online Analyzer and Sample station to monitor the Condensate Chemistry
before putting into Deaerator. List of Analyzer and SWAS associated with DM system are as below:
 DM water inlet header to CST – pH and Conductivity Analyzer

 Surface Condensate – Conductivity Analyzer
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 Pure condensate – HC Analyzer


 Condensate supply to Condensate transfer pump – pH analyzer

 Condensate to SWAS system – pH, Conductivity and HC analyzer
Two separate systems for transferring the condensate to Deaerator (575-DEA-00-001) are available.
1. Condensate through Condensate Transfer Pumps (575-P-CF-004A/B, 2 X 100% + TD-CTP,1 X100)
and LP Heater (575-LPH-00-001)
2. Condensate through MUH transfer pumps (575-P-CF-003A/B, 2 X 100%) and HRSG # 1 &2
MUH modules
Condensate pumped through system no. 1 is diverted to LP heater where the LP steam heats up the
condensate from ambient condition to max 100 deg C. While the for system no. 2, Condensate pump
by MUH is diver to HRSG WPH module where they get heated up to max 100 Deg C. Both systems are
diverted to Deaerator. LP steam is used as pegging steam in Deaerator.
LP heater drain is provided with LP header collecting tank and the transfer pump facilities to transfer
LP steam condensate back to Deaerator.
LP steam to Deaerator is control through Pressure control valve (10-PV1407) which maintain the
Deaerator Pressure at 2.37 Kg/cm2. The supply header of LP steam to Deaerator also consists of
tapping for LP steam vented from each Boiler CBD vessels. Deaerator water once Deaerator is stored
feed water storage tank (575-W-00-001). LP steam from LP steam supply header to Deaerator is
tapped off for initial heating of Feed water storage tank during Plant start up or initial startup.
DM water is used as make up water for each GT Atomizing Air Pre-cooler system. Normally Atomizing
air Pre-cooler system consist of DM water which cools Atomizing air going for Fuel atomizing through
DM water in AA Pre-cooler. The heated DM water then cooled in Water to Water Heat Exchanger
(W2W HE) (01 nos.) using ACW supply water. The cooled DM water get collected in DM water surge

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tank where additional fresh DM water is intake as make up.

Refer P&IDs: 1-381-01-03148-S01 and 1-381-01-03146-S01
2.2.2 Feed water from Deaerator to Individual Boiler Drum including Export BFW system:
Feed water stored in Feed water storage tank is common for entire CPP. Separate header are
provided to supply feed water to HRSG Feed water pumps (575-P-CF-007A/B/C) and UB feed water
pumps (575-P-CF-008A/B/C/D) along with Export feed water pumps (575-P-CF-009A/B) which transfer
feed water to Refinery complex. Refer P&IDs: 1-381-01-03149-S01/02/03
2.2.2.1 Feed water to Utility Boilers
Feed water from Deaerator is supplied to UB Feed water pumps (BFP, 04 nos., 3W + 1S) through
Common supply header. A Tapping for Boiler feed water supplied to each UB is given from common
discharge header. The supply header for each UB will pass through Feed regulating Station (FRS). FRS
for each Boiler consist of 1 X 30% Feed regulating Control valve (06-FV1844C, 07-FV1845C, 08-
FV1846C, 09-FV1847C) and 2 X 100% Feed regulating control valve (06-FV1844A/B, 07-FV1845A/B, 08-
FV1846A/B, 09-FV1847A/B) in parallel. The control of command to each of 3 controlling element is a
part of Drum level controller as discuss in control Philosophy chapter no. 09. Feed water after passing
through FRS goes to Economizer tube bundle arrangement in each Boiler. In Economizer, the exhaust
Flue gas from UB Furnace exchange heat with Feed water. Feed water inlet temperature at Eco inlet is
125 ⁰C while the Feed water outlet temperature will be in the range of 170 ⁰C. The heated feed water
thereafter enter the Boiler steam drum.
For Each UB, Feed water supply header is provided with a tapping for sample system. Sampling station
measure Silica, pH and conductivity through online analyzer after cooling the sample using ACW
cooling water. In the Feed water supply header to each UB before FRS, a 2” tapping is taken for spray
attemperator system. The control part is detailed in the section of control philosophy.

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2.2.2.2 Feed water to HRSG

Feed water from Deaerator is supplied to HRSG Feed water pumps (BFP, 03 nos., 2W + 1S) through
Common supply header. A Tapping for Boiler feed water supplied to each HRSG is given from common
discharge header. The supply header for each HRSG will pass through Feed regulating Station (FRS).
FRS for each Boiler consist of 1 X 30% Feed regulating Control valve (04/05-FV1816C) and 2 X 100%
Feed regulating control valve (04-FV1816A/B, 05-FV1816A/B) in parallel. The control of command to
each of 3 controlling element is a part of Drum level controller as discuss in control Philosophy
chapter no.09.
Feed water after passing through FRS goes to MUH/WPH Module of HRSG. Inlet and outlet of MUH
module is provided with MOV with a provision of Bypass MOV as well for Bypassing MUH module of
HRSG. In MUH module, the exhaust Flue gas from HRSG exchange heat with Feed water. Feed water
inlet temperature at Eco inlet is 125 ⁰C while the outlet temperature will be in the range of 295 ⁰C.
The heated feed water thereafter enter the HRSG steam drum.
For Each HRSG, Feed water supply header is provided with a tapping for sample system. Sampling
station measure Silica, pH and conductivity through online analyzer after cooling the sample using
ACW cooling water. In the Feed water supply header to each HRSG before FRS, a 2” tapping is taken
for spray attemperator system. The control part is detailed in the section of control philosophy.
2.2.2.3 Feed water to Refinery
Feed water from Deaerator is supplied to Export Feed water pumps (02 nos., 1W + 1S) through
Common supply header. Flow Element (10-FE1861) is provided to measure the Export Feed water to
Refinery. All Interlock and control related to UB Feed water system are part of DCS controls.
2.2.3 Off Base HSD Fuel system:

Refer P&ID no: 1-381-01-03138-S01 to S06

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2.2.3.1 HSD from Refinery to HSD day tank in CPP

HSD from Refinery is coming from FCCPU down run to CPP tank (575-T-00-502).
Capacity of each HSD tank in CPP is 200 m3 with fixed roof cone type.
2.2.3.2 HSD Centrifuge system
Normally storage HSD tank is lineup for Centrifuge system for HSD. HSD centrifuge skid pumps suck
the HSD/LCO from centrifuge common header which get HSD/LCO from storage tank outgoing header.
Clean HSD/LCO is supplied to respective HSD/LCO Tank-1 as per requirement. Centrifuge skid is a PLC
mounted skid (only indication are available to DCS) so operation of Centrifuge is done from field only.
Centrifuge skid consist of Centrifuge forwarding pumps (03 nos. each for individual centrifuge), Supply
header suction strainer, 3 way solenoid operate valve, Mechanical preset flow regulation valve to
control the flow rate of HSD to centrifuge, Centrifuge (03 nos., 2W +
1S, 15 m3/hr, Discharge Pressure: 15 mlc), Sludge tank (575-T-00-008) and Sludge transfer
Diaphragm pumps to nearest drain header.
Discharge common header from centrifuge back to clean tank. In each centrifuge discharge header
there is Pressure Switch (PSL-6611/6620/6625) which command 3 way valve SOV (SOV-
6611/6620/6625) to divert the HSD back to raw water tank as it indicate water seal breakage.
Sludge tank transfer diaphragm pump when kept in AUTO mode will start and stop based on the
Level high and low signal from Level switch (LSH6616 and LSL6615 respectively).
2.2.3.3 HSD supply system to GTG
Clean HSD tank is normally lineup for GT forwarding skid Pump. All valves associated with header line
are kept open and HSD from clean tank get lineup through HSD common suction header for GT # 1
and 2 HSD forwarding system. Each GT is provided with separated forwarding pump system which
consist of suction duplex filter (100 micron) with Differential pressure transmitter, GT Forwarding
Pumps (02 nos., 1W + 1S), Accumulator, Long and short recirculation Control valves, Fine duplex filters
(25 micron, reusable), Fine Duplex filters (6 micron, disposable), Flow transmitter up to 3 way
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valve. HSD is pumped by Forwarding pump up to 3 way valve, beyond which the opening of 3 way
valve decide the usage of fuel i.e. either HSD or LCO to be selected for GT operation. Normally HSD is
used only during GT start up and during Fuel change over, rest LCO will be used. Opening of 3 way
valve to particular fuel depends purely on operating condition and philosophy which is govern
through Mark VI controller.
2.2.4 Off Base LCO Fuel system:

Refer P&ID no: 1-381-01-03139-S01 to S012
2.2.4.1 LCO from Refinery to LCO day tank in CPP
LCO from Refinery is coming from FCCPU down run to CPP Day tank (575-T-00-509/512). LCO tanks
are used to supply LCO for GT, HRSG and UB operation. At any instant of time one out of two LCO tank
is lineup for GT while another LCO tank will be lineup for UB and HRSG Operation. LCO from Refinery
can be taken into either or both the LCO tank at a time. Capacity of each LCO tank in CPP is 2200 m3
with Floating roof type.
2.2.4.2 LCO forwarding system for GTG
Any one LCO tank is normally lineup for GT forwarding skid Pump. All valves associated with header
line are kept open and LCO from tank get lineup through LCO common suction header for GT # 1 and
2. LCO from common header through Suction Duplex filter (100 micron) reaches inlet to the LCO
forwarding pumps (03 nos., 2W + 1S, 01 for each GT). LCO forwarding skid for both the GTs are
common. One pump is capable to delivery 100% requirement of LCO for one GT. In the Pump
discharge header, the LCO divider is provided which divide the LCO flow to GT # 1 and 2. In each LCO
supply header after forwarding pumps contain Accumulator, Main Pressure control valve and
recirculation header Control valves, Fine duplex filters (25 micron, reusable), Fine Duplex filters (6
micron, disposable), Flow transmitter up to 3 way valve, Vanadium Inhibitor skid with connection to
supply header and Motorized Operated valve.
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After 3 way valve, for liquid supply fuel header to GT, a vanadium inhibitor skid is installed which
includes metering tank (9-T-48C), Vanadium Inhibitor forwarding Pump (02 nos., 1W+1S, P-506A/B),
Accumulator in forwarding header, Flow element (FT-6728/6754). There is one unloading pump (9-P-
49C) for unloading the Vanadium solution into Vanadium inhibitor solution metering tank. Vanadium
Inhibitor skid will be in operation only during LCO firing selection for GT operation. For HSD it is not
envisage.
Refer P&ID no: 1-381-01-03138-S01 to S06
2.2.4.3 LCO forwarding system for HRSG
Any one LCO tank is normally lineup for HRSG and UB forwarding skid Pump. All valves associated with
header line are kept open and LCO from tank get lineup through LCO common suction header for UB
and HRSG. LCO from common header through Suction Duplex filter (100 micron) reaches inlet to the
LCO forwarding pumps (03 nos., 2W + 1S, 01 for each HRSG). LCO forwarding skid for both the HRSG
are common. Each pump is capable to delivery 100% full load requirement of LCO for each HRSG.
From pump discharge common header, LCO is forward to HRSG through Accumulator and
recirculation header with Control valve.
2.2.4.4 LCO forwarding system for UB
LCO forwarding pumps (03 nos., 2W + 1S, 01 for two UBs). LCO forwarding skid for common for all the
UBs. Each pump is capable to delivery 100% full load requirement of LCO for 02 nos. of UB. From
pump discharge common header, LCO is forward to UB through Accumulators (02 nos.) and
2.2.4.5 HSD/LCO drain system

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HSD/LCO drain system consists of following:

a. HSD/LCO drain tank for GT # 1 (575-T-00-503)
b. HSD/LCO drain tank for GT # 2 (575-T-00-504)
c. HSD/LCO drain tank for UB # 1 and 2 (575-T-00-505)
d. HSD/LCO drain tank for UB # 3 and 4 (575-T-00-506)
e. HSD/LCO drain tank near storage tank area (575-T-00-507)
All HSD and LCO related Off Base system drains are collected into the above mentioned drain tanks.
From which the submersible pump immersed in each tanks pump the drain to CPP common slope
header, which in turn divert all the drain to Refinery slope header including FG condensate drain from
CPP.
2.2.5 Off Base Naphtha Fuel system:

Refer P&ID no: 1-381-01-06325- 1to7 & 1-381-006326- 1to5
2.2.5.1 Naphtha forwarding system for GTG
Naphtha tank is normally lineup for GT forwarding skid Pump. All valves associated with header line
are kept open and Naphtha from tank get lineup through Naphtha common suction header for GT # 1
and 2. Naphtha from common header through Suction Duplex filter (100 micron) reaches inlet to the
Naphtha forwarding pumps (03 nos., 2W + 1S, 01 for each GT). Naphtha forwarding skid for both the
GTs are common. One pump is capable to delivery 100% requirement of Naphtha for one GT. In the
Pump discharge header, the Naphtha divider is provided which divide the Naphtha flow to GT # 1 and
2. In each Naphtha supply header after forwarding pumps contain Accumulator, Main Pressure
control valve and recirculation header Control valves, Fine duplex filters (25 micron, reusable), Fine
Duplex filters (6 micron, disposable), Flow transmitter up to 3 way valve, Vanadium Inhibitor skid with
connection to supply header and Motorized Operated valve.
2.2.5.2 Naphtha forwarding system for HRSG/UB
Naphtha tank is normally lineup for HRSG/UB forwarding skid Pump. All valves associated with
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header line are kept open and Naphtha from tank get lineup through Naphtha common suction
header for HRSG/UB. Naphtha from common header through Suction Duplex filter (100 micron)
reaches inlet to the Naphtha forwarding pumps (03 nos., 2W + 1S, 01 for each HRSG/UB). Naphtha
forwarding skid for the HRSG/UB are common. From pump discharge common header, Naphtha is
forward to HRSG/UB through Main Control valve Accumulator and recirculation header, individual
isolation valve at control station for HRSG & UB Naphtha Header.
2.2.5.3 Off base Naphtha drain system
Naphtha drain system consists of following:

a. FG drain tank near GBC area (575-T-00-521)
b. FG drain tank for GT # 1 (575-T-00-523)
c. FG drain tank for GT # 2 (575-T-00-522)
All Naphtha related Offbase system drains are collected into the above mentioned drain tanks. From
which the submersible pump immersed in each tanks pump the drain to CPP common slope header,
which in turn divert all the drain to Refinery slope header including FG condensate drain from CPP.
Also all the flares collected from each drain tank are diverted to Refinery Flare Header.
2.2.6 Utility Boilers (4 nos., 3W + 1S, 240 TPH MCR rating)
Each UBs for CPP are design to operate at MCR condition of 240 TPH, 107.5 Kg/cm2g @ 508 ⁰C and
Inlet Feed water temperature at 125.6 ⁰C. The same UB can operate a peak demand of 265 TPH with
same steam and Feed water parameter. Each UB consist of 08 nos. of low NOx Burners which are
mounted on Front wall for UB. UB for CPP can be designated as water cooled, Natural circulation type,
Forced draft, Bottom support, Bi-drum type Boilers. Normally LCO/ Naphtha is used as a Main Fuel for
Firing and RFG can be used at a secondary fuel. All Burners of UB are capable to fire both the fuels but
only one fuel at a time in each Burner. However the boiler is design and control to fire both the fuel at
a time but in different set of burners. BMS (Burner Management system) is provided to Safe guard the
boiler from Fuel related Hazards and ensure that if any abnormality occurs which impact the Boiler
Operation; BMS will safety Turn off the Boiler operation. It is must as per NFPA requirements.

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Controls of each UB are divided into two separate control system namely DCS and BMS. BMS will take
care for safety related issues of Boiler while DCS controller system is used to control and operate the
Boiler normal Operations. Each UB is having associated Auxiliaries and integral system to support the
normal Boiler Operations. Refer P&ID no. 0-00-047-47817, 2-97-288-90441, 1-00-056-10442, 1-00-
056-10443.
UB integral system consists of:
a. Steam and water drums
b. Water wall Tubes
c. Superheater (Primary and Secondary)
d. Economizer
e. CBD/IBD vessel
f. Burners
g. Steam and Water sampling station and SWAS system
h. Spray attemperator for SHs
i. Steam Drum mounted safety valves (02 nos.) and SH header mounted safety valve (01 nos.)
j. Drain headers
k. Start up vent and Main steam stop valve (MSSV)
a. FD fan with IGV

b. Air and Flue gas ducts
c. Scanner air fans
d. Regenerative type of Air Preheater (RAPH)
e. Steam condensate type Air preheater (SCAPH)
f. Soot Blowers
g. Stack / Chimney
h. Fuel supply mounted skids
i. HP dozing skid

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The Feed water Pumped by Boiler Feed water pumps enter the steam drum through Feed regulating
station designated for each Boiler. Each FRS station consist of 1 X 30% Feed regulating Control valve
(06-FV1844C, 07-FV1845C, 08-FV1846C, 09-FV1847C) and 2 X 100% Feed regulating control valve (06-
FV1844A/B, 07-FV1845A/B, 08-FV1846A/B, 09-FV1847A/B) in parallel. The feed water from the steam
drum enter to water wall tubes and Evaporator tubes through Natural Circulation because of the
density difference between feedwater and steam generated. The heat required to convert the feed
water to steam is provided by burning of Fuel inside Furnace. The saturated steam rises up inside the
tube and gets collected back into steam drum. From steam drum the saturated steam taken out and
passes to Super heater I and II coils hanging in Furnace and convection zone respectively of boiler
from where the saturated steam pick up the heat from Flue gas and get converted into superheater
steam. The superheated steam is collected into superheater header and flow to Boiler Main steam
stop valve to VHP common header.
UB feed water and steam chemistry is continuous monitored using online analyzer and taking regular
sample at sampling station. Each UB are assigned with feedwater, Blow down, Saturated and
Superheater steam sampling station with necessary analyzer. Samples are cooled to 25 ⁰C using ACW
cooling water before passing to analyzer. The decision to doze HP dozing chemical (Tri Sodium
Phosphate solution) to boiler depends upon the value of analyzer and sample results. HP dozing
chemical are added at prerequisite time directly into steam drum through HP dozing skid. The rate of
the chemical dozing is regulated and adjusted by changing the stroke of HP dozing pumps (2 X 100%).
Each UB is assigned with dedicated HP dozing pumps with common metering and solution preparation
tank. Refer P&ID no. 1-38101-03198-S01. Steam drum is also provide with MOVs for CBD and IBD
operation, which allows to drain the feedwater cum saturated steam from steam drum thus removing
the sludge formed due to chemical reaction between HP dozed chemical and feedwater.
For each UB, the air and Flue gas consist of FD fan (01 nos., Dual drive (steam and Motor with high
speed coupling for changeover), Dampers, Scanner fans, Wind box for Burner, Exhaust duct and stack.
FD fan installed for UB supply atmospheric air to UB for Fuel combustion. The rate of air flow is
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regulated by the Inlet Guide vane (IGV) installed at inlet of FD fan which receive inputs from Air/Fuel
combustion controller. Air before entering to Wind box area is passed through SCAPH and RAPH which
increase the Air temperature at inlet of Furnace by gaining heat from Exhaust Flue gas from furnace.
Necessary dampers at inlet and bypass of RAPH and SCAPH are given to isolate the APH as a
when required depending upon the need of operation condition. Heat air get collected in wind box
from where the Air get distributed as per the opening and closing of Combustion air damper installed
on each Burner. The control of the combustion damper is regulated through BMS. IT is basically an
Open/Close type of dampers. There are a set of manual operated damper called Primary and
secondary air dampers to regulate the flow and flame length and intensity for each burner. The
Damper positions are manually adjusted during commissiong and need not required frequent
intervention during normal operation once set.
The fuel and air are mixed and ignited inside the Burner and Flue gas generated is then passes
through different heat transfer zone of furnace. The hot flue gas from furnace first passes to Primary
SH and then to Secondary superheater. After superheater the next heat transfer zone is Economizer
where feed water before entering the steam drum get heater just below the saturation temperature
at the given pressure through flue gas. Flue gas there after enters into RAPH. RAPH is regenerative
type rotary APH where Hot flue gas transfer heat to Combustion air from FD fan. After RAPH the flue
gas which will be at the temperature range of 160-140 ⁰C enter into stack installed inside the RCC
chimney. Stack is equipped with stack monitoring devices like Sox, NOx, SPM, CO and HC analyzer
which is also one of the mandatory required of State Pollution control board (PPCB).
All Feed water headers and steam header drain are collected into Water and steam drain header from
where the drain are diverted to IBD vessel. Interconnection is provided between Water drain header
and Steam header with a provision of Initial filling line for Boiler and Hydro test pressure connection
provision.
From SH I outlet header a tapping of 2” is taken for Soot blower (SB) Operation. Each UB consist of
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total 15 nos. of SB out of which 10 nos. are LRSB type installed in Furnace and SH zone, 04 nos. are of
Rotary type installed in Economizer zone and 01 nos. is Air heated type SB installed in RAPH. The
drains of SB are diverted back to IBD vessel.
Steam drum Level is mounted with 02 nos. of safety valve (06/07/08/09-SV1 and SV2, set at Pressure
124 and 127 Kg/cm2 g respectively) while one more addition safety valve (06/07/08/09-SV3 set a
pressure 116 Kg/cm2 g) is mounted on SH – II Outlet header.
In furnace, combustion Fuel with Air occurs with the help of Burner and atomizing air and Pilot gas
burners. Air and fuel is ignited inside the furnace after proper atomization using atomizing air from
atomizing air compressor. 8 nos. of low NOx burners are used to ignite the fuel. Normal LCO/Naphtha is
used as fuel for normal operation while RFG is a standby fuel. Each Burner is capable to burn both fuel
but only one fuel at a time in each burner. However BMS permit to use both fuel simultaneously in
boiler during normal operation. BMS system is used as safety manager for safe guarding the Boiler
during any emergency or abnormality.
Fuel supply to each burner is regulated by the common supply header control valve which operates
based on the demand signal from DCS. Similarly Air flow is regulated by IGV installed at inlet of FD fan
which regulate the supply of Air to Boiler as per demand.
The Generated Main steam temperature is controlled using spary attemperator system. The steam
temperature is controlled by spraying the Boiler Feed water directly into the steam path. Spray water
is tapped from the Boiler feed water supply header to Boiler. The spray station is provided with a main
pneumatic operated spray control valve (06/07/08/09-TCV8732A) and Standby pneumatic operated
spray control valve (06/07/08/09-TCV8732B).
Soot blower is provided to remove the soot deposited on heat transfer area from Fuel gas side by
purging the high pressure and temperature steam at regular interval Steam supply to Soot Blower is SH
steam tapping taken from SH – I steam outlet header before des-superheating station.

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The Fuel gas from furnace is diverted to different heat transfer zone like SH – II, SH – I, Economizer,
RAPH and SCAPH before exhausting into atmosphere through chimney at a safe height of 100 m from
ground level.
2.2.7 Heat Recovery steam generator (HRSG, 2 nos.)
Each HRSG for CPP are design to operate at MCR condition of 110 TPH, 107 Kg/cm2g @ 508 ⁰C and
Feed water temperature at 125 ⁰C. HRSG is design with supplementary firing provision to cater the
rated steam parameters. Each HRSG consist of total 19 nos of Fuel firing duct low NOx type Burners
with each Burner capable to handle only one kind of fuel (12 nos. for LCO/Naphtha and 07 nos. for
RFG). HRSG can be designated as Natural circulation type, Supplementary Fired, top support, single
drum type Boilers. Normally LCO/Naphtha is used as a Main Fuel for Firing and RFG can be used as a
secondary fuel. Both Naphtha/LCO and RFG burners are capable to operate individual and generate
rated steam. HRSG is with combination fuel firing provision. BMS (Burner Management system) is
provided to Safe guard the boilers from Fuel related Hazards and ensure that if any abnormality
occurs which impacts the Boiler Operation; BMS will safety Turn off the Boiler operation.
Controls of each HRSG are divided into two separate control system namely DCS and BMS. BMS will
take care for safety related issues of Boiler while DCS controller system is used to control and operate
the Boiler normal Operations. Few of the common control system related to Boilers are mentioned
below with the control system controlling the same are also mentioned:
a. Steam drum Level Controller – DCS based
b. Combustion controller – DCS based
c. Boiler Load controller – DCS based
d. Steam Temperature controller – DCS based
e. Augmenting Fan damper control – DCS
f. Burner Management system control and safety – BMS
Each HRSG is having associated Auxiliaries and integral system to support the normal Boiler
Operations. Refer P&ID no. 0-24-400-80706, 3-97-400-86770, and 0-00-056-51135 HRSG integral
system consists of:
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a. Steam drum
b. Superheater, Evaporator, Economizer and MUH modules
c. CBD/IBD vessel
d. Burners (RFG and LCO/ Naphtha)
e. Steam and Water sampling station and SWAS system
f. Spray attemperator for SHs
g. Safety valves (03 nos.)
h. Drain headers
i. Start up vent and Main steam stop valve (MSSV)
a. Augmenting air fans with IGV

b. Seal and Scanner air fans
c. Air and Flue gas ducts
d. Scanner air fans
e. Soot Blowers
f. Chimney
g. Fuel supply mounted skids
h. HP dozing skid
The Feedwater Pumped by HRSG Feed water pumps enter the steam drum through Feed regulating
(04/05-FV1816C) and 2 X 100% Feed regulating control valve (04/05-FV1816A/B) in parallel. The
controls of this CV are in steam drum level controllers which regulate the flow of feed water to steam
drum. The feed water from the steam drum enters to Modules through Natural Circulation because of
the density difference between feedwater and steam generated. The heat required to convert the
feedwater to steam is provided by burning the Fuel in duct burner zone with the help of exhaust Flue
gas from Gas Turbine. The saturated steam rises up inside the module and gets collected back into
steam drum. From steam drum the saturated steam taken out and passes to Super heater I and II coils
hanging in as a first 4 modules in flue gas path HRSG from where the saturated steam pick up
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the heat from Flue gas and get converted into superheater steam. The superheated steam is collected
into superheater header and flow to Boiler Main steam stop valve to VHP common header. HRSG feed
water and steam chemistry is continuous monitored using online analyzer and taking regular sample
at sampling station. Each HRSG are assigned with feedwater, Blow down, Saturated and Superheater
steam sampling station with necessary analyzer. Samples are cooled to 25 ⁰C using ACW cooling water
before passing to analyzer. The decision to doze HP dozing chemical (Tri Sodium Phosphate solution)
to boiler depends upon the value of analyzer and sample results. HP dozing chemical are added at
prerequisite time directly into steam drum through HP dozing skid. The rate of the chemical dozing is
regulated and adjusted by changing the stroke of HP dozing pumps (2 X 100%). Each HRSG is assigned
with dedicated HP dozing skid consisting of dozing pumps with metering and solution preparation
tank. Refer P&ID no. 2-80-219-80157. Steam drum is also provide with MOVs for CBD and IBD
For each HRSG, the Flue gas consist of Inlet duct with duct burners after Guillotine Dampers, Scanner
fans, Augmenting air fans, Seal air fans and Exhaust chimney. The Exhaust gases from GT are diverted
to HRSG through Diverter and Guillotine dampers. Both Dampers logic are in GT control. Once HRSG
healthy signal is available, first Guillotine damper open command is generated and once the Guillotine
damper open feedback healthy signal received, Diverter damper is command to open which allow GT
exhaust gas to divert through HRSG modules. Refer Control scheme no 3-36502-69008 for Guillotine
and Diverter damper controls. The Flue gas first passes through duct burner zone where LCO/
Naphtha and RFG burners are installed which burn the fuel injected into system with the help of Flue
gas from GT.
NOTE: HRSG is not installed with FD fan for fuel firing. Augmenting Air fan is used only for Naphtha
/LCO fuel firing
The high temperature flue gas then passes over the Water filled Modules hanging in the flue gas path
where the actual heat transfer occur between Flue gas and water through module tubes with
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extended fins for effective heat transfer area. There are total 54 nos. of Module and its arrangement
is as below:
Module arrangement details for HRSG
In line with Flue gas path

Row of Tube
Type of Module
tubes type
Evaporator 2 Bare
Superheater - 2 2 Bare
Evaporator 23 Fins
Economizer 20 Fins
Water preheater / MUH 5 Fins
The flue gases after WPH/MUH module enter into steel chimney. Chimney is equipped with stack
monitoring devices like Sox, NOx, SPM, CO and HC analyzer which is also one of the mandatory
required of State Pollution control board (PPCB).
provision.
From SH I inlet header a tapping of 2” is taken for Soot blower (SB) Operation. Each HRSG consist of
total 16 nos. of rotary type of SBs. The drains of SB are diverted to IBD tanks for HRSG. The pressure
control valve (04/05-PCV8174) in the upstream of SB supply header regulates the steam supply by
getting the pressure signal from pressure transmitter (04/05-PT8174) in the downstream pressure of
PCV.
2.2.8 Gas Turbine

2 nos. of Gas Turbine installed having model series MS6001, category – B, Model no. PG6581B uses
for power generation. GT base load (design load) data are 34.5 MW @ 40 ⁰C ambient condition @ Template
No. Copyright HMEL– All rights reserved
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5163 rated rpm with HSD as a main fuel and LCO/Naphtha/RFG as secondary fuel. Gas Turbine (GT) is
equipped with GT driven Air compressor having compressor ratio of 12 with 17 stages of axial flow
design. GT is equipped with flowing accessories as well:
 Diesel Engine for start up

 Accessory gear Box

 Water injection system for NOx control

 Water wash skid

 Starting means

 Evaporator

 Variable inlet guide vanes

 CO2 gas detector system

 F&G system

 Vent blowers and fans for AGB compartment, Turbine compartment, Load compartment.
The combustion zone is a reverse flow type which includes 10 combustion chamber having following
components; liners, flow sleeves, transition piece and cross fire tubes. Flame detectors, cross fire
tubes, fuel nozzles and spark plugs igniters are also part of combustion zone. In reverse flow
arrangement high pressure air from the compressor discharge is directed around the transition piece
and into the annular space that surround each of the 10 combustion chamber liners. Compressor air
flow radials inwards through small holes in the liner wall and impinge against the rings that are brazed
to the inner wall. The air then flow right towards the liner discharge end and form a film of air that
shields the liner wall from the hot combustion gases.
The compressed air enters the reaction zone of combustion chamber through fuel nozzle swirl tip and
through metering holes in both the cap and liner. The hot combustion gas from reaction zone passes
through thermal soaking zone and then to dilution zone where additional air is mixed with
combustion gases. Along the length of combustion liner and liner cap an opening are provided whose
function is provide a film of air for cooling the wall of liner and cap.

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Spark Plug provided is of two in number and installed in adjacent combustion chamber. Spark plug is
high voltage type, retractable type. The main spark ignites fuel in combustion chamber and remaining
chamber fuel get ignited through cross fire tubes which connect reaction zone of all 10 nos of
combustion chamber. For sensing the flame inside combustion chamber an UV type flame detector is
installed on two adjacent combustion chambers. If the flame washes out is sense by any one out of
two sensors, only an annunciation is given back to operator for corrective action.
Each combustion zone is equipped with fuel nozzle capable to ignite both gas as well as Liquid fuel. GT
supplied at our end is design for Refinery Gas as gaseous fuel while HSD/LCO/ Naphtha fuel as liquid
fuel. Gaseous fuel is directly admitted into combustion zone while liquid fuel is ignited through proper
atomizing air in the nozzle swirl chamber. Transition piece divert the hot gases from combustion zone
to turbine section.
Turbine section of GT is provided with 3 stages, each stage consist of one set of stationary blades and
one set of moving blades. Moving blades are mounted on rotor while stationary blades are mounted
on turbine casing. Exhaust of turbine zone consists of exhaust frame, exhaust diffuser, nozzle and
shrouds. Turbine rotor must be cooled to maintain reasonable operating temperature and therefore,
cooling is provided by means of positive flow of cool air radially outward through a space between
wheel and buckets and the stator into the main gas stream. This area is called wheel space. The
exhaust gas from turbine outlet is diverted to exhaust diffuser where partial velocity energy is
recovered as pressure energy. From exhaust diffuser, the hot gases is divert to exhaust plenum which
is turn divert the flue gas either to open atmosphere is GT is selected for Open cycle operation or
towards HRSG inlet zone if GT is selected for Close cycle operation.
The control inside the GT is controlled by Mark VI controllers which regulates the Temperature and
load on turbine by regulating the fuel and air flow to GT. Details of GT controller are discuss in details
in chapter 9.

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2.2.9 Steam Turbine
Steam Turbine installed at CPP is of BHEL make, model no. EEHNK 50/56-3, 2 nos. total with Maximum
power output capacity of 35 MW each with double extraction cum condensing type, Generator couple
with gear box, Speed: 6300 rpm rated, Economical rating – 33.15 MW, Inlet steam condition:
Pressure: 106 Kg/cm2 g, Temperature – 505 ⁰C, Exhaust pressure – 0.08 Kg/cm2 (a) with horizontal
split single casing, 17 stages
Other Auxiliaries with STG are:

 Gear box

 High speed and low speed coupling

 Lube oil system with MLOP, ALOP, JOP and EOP with overhead tank facility, Centrifuge and
vapour extraction fan on MOT top

 Vibration monitoring system – Bentley Nevada

 Surface condenser with Hotwell

 Condensate extraction pump

 Hogger Air ejector with condenser

 Primary and secondary steam ejector with condenser

 Gland steam ejector with condenser

 Drain and vacuum system

 Control valve and servo motor with E/H amplifier and governor for steam regulation at Inlet,
HP and MP extraction state
The high pressure steam from VHP header is diverted to STG. The main supply line to STG is provided
with necessary drain and startup vent used during initial startup and heating of line. Steam Inlet to
STG is stop by Emergency Stop valve (ESV) which is open/close type of Hydraulic operated valve.
Steam to Turbine enter from two separated header each having ESV installed.
Steam from ESV enters in Main control valve chest section which ensures no steam flow to
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downstream of control valve till there is opening of CV. Main control is provided with servo motor
which regulate the stroke of CV as per demand generation from EHTC (Governor system) of turbine.
Steam enter to rotor area is regulated with set of nozzle fitted below the each 5 set of control valve.
The governing philosophy adopted here is called Nozzle governing which allow the steam to enter the
turbine blade area at particular location. STG is provided with 17 stages, each having one set of fixed
blades and one set of moving blades. Each stage of STG is principally reaction type only inlet nozzle is
Impulse type. The pressure inside HP wheel chamber will be 61.34 Kg/cm2 (a). This parameter need to
keep monitor continuously, any increase in pressure is a sign of Blade deposition.
After doing the work on the moving blade, steam is exhaust in surface condenser which is at a
pressure less than atm. i.e. at 0.08 Kg/cm2 (a) which is equivalent to -0.92 Kg/cm2 g. Here the cooling
water cools the steam and thus condense into water. The condense steam get collected inside Hotwell
from where the Condensate extraction pump suck the condensate and divert back to Deaerator
through CST.
Here steam turbine is provided with 2 extraction point at certain stage. The first extraction point is
called HP extraction point which is provided with a regulating control valve and servo motor which
operates based on command from EHTC. More opening of HP extraction CV mean, lesser HP steam
flow to process. The steam parameter at HP extraction point is 40 Kg/cm2 g and 400 ⁰C. The second
extraction point is called MP extraction point which is provided with a regulating control valve and
servo motor which operates based on command from EHTC. More opening of MP extraction CV mean,
lesser MP steam flow to process. The steam parameter at MP extraction point is 12 Kg/cm2 g and 260
⁰C. The remaining steam work in last few stages of Turbine after MP extraction before condensing to
Surface condenser.
The condensate collected in Hotwell due to condensing of exhaust steam in surface condenser by
cooling water is sucked by CEP which re-circulates the condensate back to Deaerator. The discharge of
CEP first goes to Hogger Ejector condenser, Primary and secondary Ejector condenser and finally to
Gland steam ejector condenser by which the steam used for ejection at respective station is
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condense to water and recirculated back to flash vessel drain of Surface condenser.
HP steam with letdown at a pressure of 14 Kg/cm2 g and 300 ⁰C is used as an auxiliary steam for
Ejector. Ejector primary function is to suck the Air and gases from surface condenser and creating
vacuum. During initial startup Hogger Ejector is used to pull vacuum up to -0.6 Kg/cm2 g, beyond
which the Primary and secondary air ejector pull out the condensable gases and air from the vacuum
ckt and create a vacuum pressure up to 0.08 Kg/cm2 (a). Gland steam is used to seal the Turbine HP
and LP side gland and labyrinth using MP steam but a very low pressure of 0.2 Kg/cm2 g (Max.).
Control of Gland steam control valve is briefly described in control philosophy chapter no. 9 of
operating manual.
Lube oil system of STG include Main oil Tank (MOT) of approx. 10000 ltrs of Oil capacity, Steam turbo
drive driven Main Lube oil Pump (MLOP), Aux. Motor driven Lube oil pump (ALOP) and an Emergency
Lube oil pump (ELOP). In order to maintain the quality of Lubricant, centrifuge is installed which keep
removing condensate and emulsion from lube oil. MOT of STG is also provided with Vapour extraction
fan which continuously removed the fumes generating by recirculated hot lube oil from MOT tank and
maintain the MOT pressure less than Atmospheric.
In additional feature of Lube oil system, Overhead Lube oil tank of capacity (1400 ltrs) is provided as a
last source of defense during complete blackout and failure of ELOP simultaneously. Lube oil pump by
MLOP is cooled first in Lube oil cooler (twin duplex type with Temperature control valve) and filter in
Lube oil filter chamber (Twin duplex type) before going to Turbine and generator bearing. Self-
regulating PRV is installed after Filter which reduces the pressure of Lube oil from 8-9 Kg/cm2 g to 3.0
Kg/cm2 g. Lube oil after reaching to bearing return back to MOT in return header through gravity.
Overhead lube oil is installed after self-regulating PRV in Lube oil supply header. Control operation of
Lube oil pumps on header pressure is details describe in Control philosophy chapter no. 9 of operating
manual.
A separate tap off from discharge of Lube oil pump common header before cooler is given for
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governing oil system. This oil is used to operate the Trip and Control valve actuator and servo motor
which in turn control the admission of steam inside each stage of Turbine. Detail of governing system
is discussed in chapter no. 9.
Bearing of STG is tilted pad type white metal bearing. The static load of STG is quite high to withstand
the starting torque which may result into bearing material damage during start up. In order to avoid
it, a reciprocating type Jacking oil pump is installed which suck the Oil from MOT or from Lube oil
header after filter and increase the pressure from 8 to more than 75 Kg/cm2 g. The jacking oil header
is supplied to bearing bottom to support the load of turbine during start up. A Pressure relief valve in
Jacking oil supply header ensure that pressure of header remains more than 75 Kg/cm2 g. Opening of
Pressure relief valve is diverted back to tank. Jacking oil pump is to be started manually at the time of
starting by Operator and which is a start permissive for Turbine Barring. STG cannot be put to barring
until healthy signal from jacking oil header pressure is activated.
Each turbine is provided with necessary casing drains at suitable location, which used to drain the
condensate from turbine. The drains are diverted back to flash vessel of Surface condenser. Steam
line drain are connected to Flash vessel of STG, where the drain steam get flashed and condense and
collected in Collection vessel which is further diverted to Main Blow down pit of CPP.
All control and operation of Turbine is through DCS installed EHTC Block which is nothing but a inbuilt
DCS Governor. It govern all the operating state of turbine and regulate the supply of steam at each
level thus maintaining a constant speed of 6300 rpm (Isochronous mode) or 6300 rpm ± 4% (Drop
mode). Detail of turbine governing and operation are made available in Chapter 9.
Turbine is couple Gear box through High speed coupling which reduce the speed from 6300 rpm to
3000 rpm through pinion gear arrangement. Output of gear box is couple with Generator which
produces power. Barring gear is mounted on Gear box with necessary gear arrangement and a
provision on hand ratchet is also provided which will be useful during Black out condition.

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2.2.10 Back Pressure Turbine Controller
Back pressure Steam Turbine installed at CPP is of BHEL make, model no. HNG 50/50-3, 01 nos. total
with Maximum power output capacity of 32 MW and back pressure of 6.0 Kg/cm2 g, Generator couple
with gear box, Speed: 5000 rpm rated, Economical rating – 30.15 MW, Inlet steam condition:
Pressure: 106 Kg/cm2 g, Temperature – 505 ⁰C, Exhaust pressure – 6.0 Kg/cm2 (a) with horizontal split
single casing, 19 stages

 Gear box


 Lube oil system with MLOP, ALOP, JOP and EOP with overhead tank facility, Centrifuge and
vapour extraction fan on MOT top




 Control valve and servo motor with E/H amplifier and governor for steam regulation at Inlet
The high pressure steam from VHP header is diverted to BPTG. The main supply line to BPTG is
provided with necessary drain and startup vent used during initial startup and heating of line. Steam
Inlet to BPTG is stop by Emergency Stop valve (ESV) which is open/close type of Hydraulic operated
valve. Steam to Turbine enter from two separated header each having ESV installed.
Steam enter to rotor area is regulated with nozzle fitted below the high pressure control valve. The
governing philosophy adopted here is called Nozzle governing which allow the steam to enter the
turbine blade area at particular location. BPTG is provided with 19 stages, each having one set of fixed
blades and one set of moving blades. Each stage of BPTG is principally reaction type only inlet
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nozzle is Impulse type. The pressure inside HP wheel chamber will be 74.2 Kg/cm2 (a). This parameter
need to keep monitor continuously, any increase in pressure is a sign of Blade deposition.
Ejector. Gland steam is used to seal the Turbine HP and LP side gland and labyrinth using MP steam
but a very low pressure of 0.2 Kg/cm2 g (Max.). Control of Gland steam control valve is briefly
described in control philosophy chapter no. 9 of operating manual.
Lube oil system of BPTG include Main oil Tank (MOT) of approx. 8000 ltrs of Oil capacity, Steam turbo
drive driven Main Lube oil Pump (MLOP), Aux. Motor driven Lube oil pump (ALOP) and an Emergency
Lube oil pump (ELOP). In order to maintain the quality of Lubricant, centrifuge is installed which keep
removing condensate and emulsion from lube oil. MOT of BPTG is also provided with Vapour
extraction fan which continuously removed the fumes generating by recirculated hot lube oil from
MOT tank and maintain the MOT pressure less than Atmospheric.
MLOP is cooled first in Lube oil cooler (twin duplex type with Temperature control 3 way valve) and
filter in Lube oil filter chamber (Twin duplex type) before going to Turbine and generator bearing. Self
Overhead lube oil is installed after self-regulating PRV in Lube oil supply header. Control operation of
manual.
which in turn control the admission of steam inside Turbine. Detail of governing system is discussed in
chapter no. 9.
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Bearing of BPTG is tilted pad type white metal bearing. The static load of BPTG is quite high to
withstand the starting torque which may result into bearing material damage during start up. In order
to avoid it, a reciprocating type Jacking oil pump is installed which suck the Oil from MOT or from Lube
oil header after filter and increase the pressure from 8 to more than 75 Kg/cm2 g. The jacking oil
header is supplied to bearing bottom to support the load of generator during start up. A Pressure
relief valve in Jacking oil supply header ensure that pressure of header remains more than 75 Kg/cm2
g. Opening of Pressure relief valve is diverted back to tank. Jacking oil pump is to be started manually
at the time of starting by Operator and which is a start permissive for Turbine Barring. BPTG cannot be
put to barring until healthy signal from jacking oil header pressure is activated.
condensate from turbine. The drains are diverted back to flash vessel of Surface condenser. Steam line
drain are connected to Flash vessel of BPTG, where the drain steam get flashed and condense and
collected in Collection vessel which is further diverted to Main Blow down pit of CPP.
All control and operation of Turbine is through DCS installed EHTC Block which is nothing but an
inbuilt DCS Governor. It govern all the operating state of turbine and regulate the supply of steam at
each level thus maintaining a constant speed of 5000rpm (Isochronous mode) or 5000 rpm ± 4% (Drop
mode). Detail of turbine governing and operation are made available in Chapter 9.
Turbine is coupled to Gear box through High speed coupling which reduce the speed from 5000 rpm
to 3000 rpm through pinion gear arrangement. Output of gear box is couple with Generator which
produces power. Barring gear is mounted on Gear box with necessary gear arrangement and a
provision on hand ratchet is also provided which will be useful during Black out condition.
2.2.11 Boiler Feed water Drive Turbine (BFP DT)
Back pressure type Steam Turbo drive for UB Boiler Feed pump installed at CPP is of BHEL make,
model no. NG 25/20-3, 01 nos. total with Maximum power output capacity of 1.8 MW and back
pressure of 12.0 Kg/cm2 g, couple with Utility Boiler feed pump through high speed gear box, Turbine

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Speed: 8800 rpm rated, Feed pump speed – 2980 rpm, Inlet steam condition: Pressure: 40 Kg/cm2 g,
Temperature – 405 ⁰C, Exhaust pressure – 12.0 Kg/cm2 (a)

 Gear box


 Lube oil system with MLOP, ALOP and EOP with overhead tank facility, Centrifuge and vapour
extraction fan on MOT top




 Control valve and servo motor with E/H amplifier and governor for steam regulation at Inlet
The high pressure steam from VHP header is diverted to BFP DT. The main supply line to BFP DT is
provided with necessary drain and startup vent used during initial startup and heating of line. Steam
Inlet to BFP DT is stop by Emergency Stop valve (ESV) which is open/close type of Hydraulic operated
valve. Steam to Turbine enter from two separated header each having ESV installed.
Steam enter to rotor area is regulated with set of nozzle fitted below the high pressure control valve.
The governing philosophy adopted here is called Nozzle governing which allow the steam to enter the
turbine blade area at particular location. BFP DT is provided with XX stages, each having one set of
fixed blades and one set of moving blades. Each stage of BFP DT is principally reaction type only inlet
nozzle is Impulse type. The pressure inside HP wheel chamber will be 18.093 Kg/cm2 (a). This
parameter need to keep monitor continuously, any increase in pressure is a sign of Blade deposition.
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Ejector. Gland steam is used to seal the Turbine HP and LP side gland and labyrinth using MP steam
but a very low pressure of 0.2 Kg/cm2 g (Max.). Control of Gland steam control valve is briefly
described in control philosophy chapter no. 9 of operating manual.
Lube oil system of BFP DT include Main oil Tank (MOT) of approx. 8000 ltrs of Oil capacity, Steam
turbo drive driven Main Lube oil Pump (MLOP), Aux. Motor driven Lube oil pump (ALOP) and an
Emergency Lube oil pump (ELOP). In order to maintain the quality of Lubricant, centrifuge is installed
which keep removing condensate and emulsion from lube oil. MOT of BFP DT is also provided with
Vapour extraction fan which continuously removed the fumes generating by recirculated hot lube oil
from MOT tank and maintain the MOT pressure less than Atmospheric.
MLOP is cooled first in Lube oil cooler (twin duplex type with Temperature control 3 way valve) and
filter in Lube oil filter chamber (Twin duplex type) before going to Turbine and generator bearing. Self
Overhead lube oil is installed after self regulating PRV in Lube oil supply header. Control operation of
manual.
which in turn control the admission of steam inside Turbine. Detail of governing system is discussed in
chapter no. 9.
condensate from turbine. The drains are diverted back to flash vessel of Surface condenser. Steam
line drain are connected to Flash vessel of BFP DT, where the drain steam get flashed and condense
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and collected in Collection vessel which is further diverted to Main Blow down pit of CPP.
All control and operation of Turbine is through DCS installed EHTC Block which is nothing but an
inbuilt DCS Governor. Detail of turbine governing and operation are made available in Chapter 9.
Turbine is couple Gear box through High speed coupling which reduce the speed from 8800 rpm to
2980 rpm through pinion gear arrangement. Output of gear box is couple with Boiler feed pump.
Barring gear is mounted on Gear box with necessary gear arrangement and a provision on hand
ratchet is also provided which will be useful during Black out condition.
2.2.12 Cooling Water system:
Cooling water system in CPP consist of Main Cooling tower with 6 cells (5W+1S), Main Cooling water
Pumps (02 nos., 1W+1S, 575-P-VT-552/553), Side stream filters and Pumps and Auxiliary cooling water
pumps (03 nos., 2W+1S, 575-PT/PA-VT-572A/573A/574A). Cooling water as Raw Water from RWTP
adds into cooling tower forebay as makeup water. Cooling tower is an Induce draft Counter flow
direct contact type with 6 cells having an assembly of a Fan with Motor and Gear box for creating air
Induce draft in cell. Cooled water get collected into Forebay from where the Main
cooling tower pumps sucked the cooling water. Main cooling water pump are Vertical mounted which
supply the cooling water to STG surface condenser. The Hot water coming out of surface condenser
come back to cooling tower and gets distributed to each cell. The return header of cooling water also
consist the tapping for return supply header of ACW system. Refer P&ID no. 0-38101-00935-S01 for
cooling water system.
The design parameters for cooling tower are:
a. Hot water inlet Temperature: 45 ⁰C,
b. Cold water outlet Temperature: 33 ⁰C
c. Wet Bulb temperature of Inlet air: 28.2 ⁰C
d. Range: 12 ⁰C
e. Approach: 4.8 ⁰C
f. COC : 4
g. Cooling Tower Make requirements: 9858 m3/hr
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h. Blow down: 61 m3/hr

i. Make Up water requirement: 320 m3/hr
j. Drift Loss: 20 m3/hr
Cooling tower forebay consist of Level Transmitter (10-LT4767). The makeup water coming as Raw
water from Refinery to Cold water channel / Forebay of CPP cooling tower is having ON/OFF type SOV
(10-UV4777). On Normal level signal from Level transmitter, the Makeup Line SOV open and on High
level it closed. Cooling tower is facilitated with CT Overflow provision by draining it to Storm water
drain. CT cooling water can also be drain to storm water system through drain pump (01 nos., 575-P-
00-567). Cooling tower is also equipped with online analyzer for monitoring the cooling water
parameter like HC and H2S along with the pH analyzer installed in discharge common header to
Condenser.
A dedicated cooling water treatment is envisaged for CPP cooling water. The system consists of:
1. Scale and Corrosion Inhibitor Dozing tank with Pumps (2 X 100%)
2. Bio-Dispersant Dozing tank with Pumps (2 X 100%)
3. Polymeric Dispersant dozing tank with Pumps (2 X 100%)
4. Non Oxidizing Biocide Chemical drum (Carbouy) – Slug dozed once in 15 days
5. Oxidizing Biocide Chemical Drum (Carbouy) – Slug dozed once in 15 days
Side stream filter arrangement installed is used to remove dirt from the cooling water. SSF pumps (02
nos., 2 X 100%) are installed to pump the cooling water to Side stream filters (575-SSF-00-568A/B, 2 X
100%) with having Air blowers (575-P-00-569A/B, 2 X 100%). Drain from the side stream filters are
diverted to Storm water while the clean cooling water is return back to Forebay. The capacity of SSF is
3% of Circulation water capacity.
2.2.13 Auxiliary Cooling water system
Auxiliary cooling water system for CPP consist of ACW cooling water pumps (03 nos., 2W+1S, 575-P-
VT-572B/573B/574B) and distribution header for ACW supply to CPP Auxiliaries. ACW system is
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backed up by the FRP cooling water system which is used only during Black out for GT start up. FRP
Cooling water system consist of two FRP cooling tower cell with Fan (02 nos., 575-P-00-580B) and FRP
cooling water Pump (01 nos., 575-P-00-582B). Refer P&ID no. 0-038101-00936-S01/02. ACW cooling
water Pumps are vertically mounted in same forebay of Cooling Tower. ACW pump discharge common
header is divided into 04 major areas which are:
a. ACW to cooling water pump area for GB, Turbo drive and gland seal cooling
b. ACW to STG and BPTG Auxiliaries along with LP drain pump and Sample coolers for UBs
c. ACW to all Boiler Feed pumps, TD-CTP, Blow down pumps sealing and cooling
d. ACW to GT and HRSG auxiliaries including GBC, Air compressor and HP nitrogen compressors.
e. ACW blow down to RO plant (Refinery) and ACW as alternative of Service water for all UB and
HRSG boilers CBD vessel steam inching
ACW supply header to GT consists of ON/OFF SOV (10-UV4827). The SOV normally remain in open
condition but will get closed on sensing Black out condition from ECS. A direct signal is incorporate to
cut the supply of ACW to GT area. This is done because after blackout is sensed, the ACW pump will
be tripped condition and FRP cooling tower Pumps and fan is used to charge the ACW system for GT
start up. The supply for FRP cooling tower fan and pumps are from Black start DG set. This ensures
that during Black out, FRP cooling tower system provide necessary ACW for any one GT start up. Once
plant get normalized and ACW pump started and header get charged, SOV can be energized to Open
to ensure ACW from ACW pumps and thus stopping the FRP cooling water system.
FRP cooling Tower basin make up is coming from raw water supply coming from Refinery (tapped
before Main cooling tower make SOV 10-UV4777).
2.2.14 Atomizing Air compressor system and Emergency IA system

Internal CPP Atomizing air system is design to cater the following:
a. Atomizing air for Boilers
b. IA and AA, PA for CPP operation i.e. 30 min operation of one survive UB during Black out
Operation
In order to meet the first requirements Atomizing Air compressor is used to provide the Atomizing Air
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for Naphtha/LCO fuel atomization in HRSG and UB boilers. CPP is equipped with dedicated Atomizing
Air compressor (03 nos., 03 X 50%, Centrifugal type, Discharge Pressure: 7 Kg/cm2 g, 4600 Nm3/hr).
The Discharge of the Atomizing air compressor is collected into Surge air receiver (Capacity 20 m3).
From the receiver the Atomizing air is directly supplied to each UB and HRSG.
In order to cater the second demand, from the Atomizing air supply header to UB and HRSG a tapping
of 2” is taken for Plant Air utilization in CPP. This will cater the need of Plant air demand during
blackout condition. From the Atomizing air compressor receiver tank, a connection for Air booster
Compressor (01 nos., Reciprocating type, 500 Nm3/hr @ 30 Kg/cm2 g) is taken. This air booster
compressor sucked the pressurized air at 7 Kg/cm2 g and discharge at 30 Kg/cm2 g. The discharge
header from the Air booster compressor fills 03 nos. of receiver tank each of capacity 22 m3. Out of 03
nos. of receiver tank, 02 nos. are used to store the Pressurized atomizing air at 30 kg/cm2 g. This
stored atomizing air will be used only during Black out condition for 01 nos. of survive UB Boiler
operation demand. Necessary NRV is kept in the supply header to Atomizing air to UB to ensure that
no reverse flow occur during black out. The Atomizing air from both the receiver are combined and
then pass through Self-regulating pre-set Pressure reducing Control valve (PRV) thus reducing the
atomizing air pressure from 30 Kg/cm2 g back to 7 Kg/cm2 g.
Another 01 receiver which received Air from Air booster compressor is used to cater the IA demand of
CPP during black out or non-availability of IA from Refinery. Atomizing Air stored in the receiver is first
passes through self-regulation de-Pressure station (PVRV) which reduces the pressure to 5-6 Kg/cm2
g. The atomizing air then diverted to Air Drier which removes moisture and thus converts atomizing
air to Instrument air to meet exact IA pressure demand. The IA from this system is than connected to
main IA supply header of CPP through appropriate NRV installed near tapped off. Also Main IA supply
header of CPP consists of NRV at B/L which avoid IA back to IA header of refinery during refinery black
out condition.
2.2.15 Blow Down system

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Blow Down system of CPP comprises of Blow down vessels for each Boilers, STGs, BPTG and Deaerator
/ LP heaters/BFP DT, blow down collecting Pits, Blow down Transfer pumps from Pit to transfer
header to Refinery RO Plant. Refer P&ID no. 2-381-01-00862-S01/S02/S03/S04 and 0-24-400-80706
Blow down from each Boiler is collected in respective boiler CBD and IBD vessel. CBD being given from
steam drum having High Pressure steam, in CBD vessel the high temperature saturated water/steam
get flashed from which the steam get collected on CBD vessel top and taken out by diverted back to
Deaerator as LP steam. The Flash condensate in CBD vessel is diverted to IBD vessel. IBD vessel is
Open to atmosphere. Other Boiler Steam and water circuit header drain are also diverted to IBD
vessel. A Provision of service water / CT Blow down water are provided in IBD vessel for quick
Quenching of flash condensate.
The cool condensate i.e. Blow down from IBD is forwarded to UB # 1 and 2, UB # 3 and 4 and HRSG
Blow down Pit respectively through gravity having siphon arrangement. The Blow down collected in
each pit is pumped by Blow down transfer pumps (02 X 100%) for each tank to Main blow down
transfer pit.
Similarly drains from STG # 1, STG # 2, BPTG and LP heater/BFP DT/Deaerator are routed to their
respective flash vessel. Each Flash vessel is provided with quick quenching arrangement as mentioned
above for UBs. Drain from STG # 1, STG # 2 and BPTG flash vessel are commonly routed to STG blow
down pit from where the Blow down transfer pump, pumped the BD to Main blow down pit. While
the drain from LP heater/BFP DT/Deaerator is directly routed to Main blow down pit. All CPP boiler
and steam blow down are finally collected in Main Blow down pit from where the Main Blow down pit
transfer pumps, pushes the BD to Refinery RO plant.
2.2.16 HP Nitrogen system
HP nitrogen system is used to cater the demand of Nitrogen requirement at 26 – 30 Kg/cm2 g

pressure (higher than the FG pressure after GBC outlet) for GT supply Fuel Gas (FG) header purging
after GBC outlet. As the Fuel gas supply from Refinery is “High Hydrogen Fuel Gas”, it is not
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recommended to start the GT on FG and also requires an inert gas purging system to separate “high
hydrogen fuel gas” from compressor discharge hot air for safe operation of the Gas Turbine. Nitrogen
coming from Refinery is bone dry type. Nitrogen for HP nitrogen is tapped from Nitrogen supply
header for CPP. Two no. of Gas booster compressors (2 X 100%) compressed the nitrogen from 7
Kg/cm2 g to 40.5 Kg/cm2 g and stored in 4 nos. of receiver tank in parallel operation each of capacity
of 25 m3. The HP Nitrogen is then depressurized in a set of self-regulating Pressure reducing valve (04
nos. in parallel) for each GT supply header. The set of each PVRV are being monitored by checking the
downstream header pressure to GT. The depressurized HP nitrogen is than passed to GT area which is
then connected to FG supply header inside GT B/L.
The Design basis for the HP nitrogen system is that both the Gas Turbine will run on Fuel gas. Quantity
of HP nitrogen system is consider keeping in mind that during normal operation of GT on fuel gas at
any instant of time, only one GT will trip. Tripping of both GT is considered as a remote possibility,
hence not considered during design stage of HP nitrogen system. Also the trip of GT is consider to
infrequent and hence for design basis of HP nitrogen system one trip per week for GT is considered.
Based on the above basis the maximum quantity required of HP nitrogen is 160 Sm3. These include
the Total Quantity of Nitrogen required during normal operation of GT, Trip purging of one GT, False
start purging of tripped GT, Nitrogen required during changeover from Liquid to Gas and at the same
movement second running GT trips which sums up to 160 Sm3. Refer Sizing criteria Document no.
PEMC – 1955 for detail calculation. The control of HP nitrogen system is from Local Control panel
mounted PLC with signal indication to DCS for monitoring through MODBUS communication. Refer
P&ID no. 2-38101-00875-S01/S02/S03
2.2.17 Off base FG/RG supply system
Fuel gas (FG) / Refinery Gas (RG) received from Refinery to CPP B/L. Flow element (FE-6801) measure
the inlet quantity of FG from Refinery to CPP. RFG inside the CPP gets distributed for GT area, UB area
and HRSG area as a separate header. Before the distribution at the inlet of RFG Main supply header
installed an ON/OFF type SOV (ESD 6802). This valve will be operated during Long Shutdown of FG
system or Emergency of complete CPP and will be done by Operator from DCS. Refer P&ID
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no. 1-38101-03142-S01 to S09. Two numbers of RFG heaters are installed in order to avoid
condensing of RFG. It raises the temperature of RFG upto 60 deg cel & it is designed for temperature
of 100 deg cel
2.2.17.1 Off base FG/RG for GT system
FG supply to GT consist of Gas scrubbers and Gas Booster compressor which are common to both the
GTs, FG Filtration and separation skid i.e. Gas conditioning skid which is separate for both GTs, and
common system like Nitrogen supply header for FG header purging and Flare system . FG to GTGs can
be stopped by closing the Main supply header ON/OFF type SOV (ESD 6804). FG for GT first enters in
to Gas scrubbers (V-11/12, 2 nos., 2 X 50%). FSV are connected to common flare header going to FG
condensate tank. FG from FG scrubber combine and inlet to GBC (02 nos., 2 X 50%) where the
Pressure of FG get boosted from 10 Kg/cm2 g @ 40-60 ⁰C to 20-24 Kg/cm2 g @ 120 – 145 ⁰C. Inlet
common header gets split into separate branch for each GBC. One GBC is capable to deliver the FG for
only one GT full load operation. From GBC the FG gets separated for GT # 1 and 2.
In each GT supply line after GBC, FG filtration and separator skids (V-12/13 and V-15/16, 02 nos. each,
2 X 100%) are installed which further removes the condensate from pressurized and high temperature
FG before entering into GT Burners. Each Filtration and separation skid consists of Filter and separator
chamber with drain collecting vessel for each. Filter chamber is installed with FSV (FSV6819A/6820A
and FSV6837A/6838A) and Separator chamber consist of FSV (FSV6819B/6820B and
FSV6837B/6838B) along with ON/OFF operated SOV (BDV6829/6830 and 6839/6840) for Flaring the
FG to flare header inside CPP.
FG from the each skid for each GT enter to FG supply header in which one ESD valve (ESD6832/6848)
is installed with SOV and one ESD valve (ESD/BDV6833/6849) is installed in FG flare header branch
from supply header. On any fire signal from GTG area through Mark VI will result in Opening of Flare
BDV and closing of Supply header ESD in order to stop the further FG supply to GTG. After this another
BDV valve with SOV operated (SOV6869/6870) is installed which operate as per the Nitrogen Purge
Logic command from Mark VI. FG than passes through Flow element (FE6831/6847) before
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entering into GT B/L. Nitrogen and Flare system are connected to the GT FG supply system at required
location for respective Purging and Flaring process.
2.2.17.2 Off base FG/RG for UB system
FG supply to UB consist of Gas scrubbers (02 nos., 2 X 50%, each capable to delivery full load FG
quantity for 02 nos. of UB, Pressure regulating station for each Utility Boilers and common system like
Nitrogen supply header for FG header purging and Flare system . FG to UB can be stopped by closing
the Main supply header ON/OFF type SOV (ESD6862) FG KOD condensate level is maintained by Level
control valve which operates on ON/OFF SOV installed on top to Open and close operation during
level high and level low signal from Level transmitter (1of 2 for each KOD). FSV are connected to
common flare header going to FG condensate tank. FG from scrubber combines and then separated
to FG supply header for each UB. For each UB there is Pressure control station which consists of 02
nos. of each 100% capacity Pressure control valve (PCV6870A/B, 6871A/B, 6872A/B, 6873A/B) and 01
nos of 30% Pressure control valve (PCV6870C, 6871C, 6872C, 6873C) all in parallel operation.
Operation from 30% to 100% and vice versa is done as per the demand of FG on each UB. FG
thereafter enters to individual Boiler burner. Control philosophy of PCV are detail describe in control
philosophy chapter no. 9.
2.2.17.3 Off base FG/RG for HRSG system
FG supply to HRSG consist of Gas scrubbers (01 nos., 1 X 100%, capable to delivery full load FG
quantity for both HRSGs, Pressure regulating station for each HRSG and common system like Nitrogen
supply header for FG header purging and Flare system . FG to HRSG can be stopped by closing the
Main supply header ON/OFF type SOV (ESD6852). FG to HRSG first bifurcated in to Gas scrubbers (V-
17). FSV are connected to common flare header going to FG condensate tank. FG from scrubber then
separated to FG supply header for each HRSG.
For each HRSG there is Pressure control station which consists of 01 nos. of 100% capacity Pressure
control valve (PCV6860A, 6886A) and 01 nos of 30% Pressure control valve (PCV6860B, 6886B) in
parallel operation. Operation from 30% to 100% and vice versa is done as per the demand of FG on

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each HRSG. FG thereafter enters to individual Boiler burner. Control philosophy of PCV are detail
describe in control philosophy chapter no. 9.
2.2.17.4 Off base FG/RG Flare and Slope system

FG Flare and drain system consists of following:
All FG related Offbase system drains are collected into the above mentioned drain tanks. From which
the submersible pump immersed in each tanks pump the drain to CPP common slope header, which
in turn divert all the drain to Refinery slope header including FG condensate drain from CPP. Also all
the flares collected from each drain tank are diverted to Refinery Flare Header.
In FG drain tank near GBC area, FG drain from main supply header in CPP along with GTGs Gas
scrubbers, Naphtha tank drain, Naphtha fwd skid drain for GT and HRSG, UB’s(when on Naphtha fuel)
liquid fuel line drain and GBC drain and flare are connected. While in FG drain tank for GT # 1 area,
RFG Heater drain, GT-1Naphtha supply line drain along with filtration skid drain , all drain from UBs
internal along with UB scrubber drain and Flare, HRSG scrubber drain and flare, HRSG # 1 FG/Naphtha
drain, GT # 1 FG supply header drain and flare along with GT # 1 filtration skid drain and flare are
connected. For FG drain tank for GT # 2, GT-2 Naphtha supply line drain along with filtration skid
drain, GT # 2 RFG filtration skid drain and vent, GT # 2 supply header flare, HRSG # 2 drain are
connected. Submersible pump installed in each drain tank pumped the FG condensate to CPP
common slope header which in turn connected to Refinery Slope header which divert slope to
Refinery dry slope tank. While all flare in each drain tank are connected to a common header which in
turn connect to Refinery Flare header.
2.2.18 Instrument Air (IA) system
2” Instrument Air (IA) header supplies IA from Refinery to CPP. The header is provided with isolation
valve and a spectacle blind. Flow transmitter (10-FT5004), Pressure transmitter (10-PT5001), Local
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pressure gauge (10-PG5002) and Thermocouple for temperature measurement (10-TE5003) are
installed in supplied header of IA to CPP inside CPP B/L. IA header is provided with NRV which prevent
the back flow of IA from CPP Air booster compressor during Blackout condition. Various Instrument air
tapping are connected from/to this header at various locations for IA supply. One of the inputs to IA
header is IA from Air booster compressor located in CPP which supply IA to CPP Operation during black
out condition. The supply header of 2” is connected to IA supply header inside CPP with NRV which
stop IA coming back to Air booster compressor area. IA is use as motive force for pneumatically
operated control valves and other instruments operation.
2.2.19 Plant Air (PA) system
2" plant air (PA) header supplies plant air from Refinery to CPP. The header is provided with Isolation
valves with spectacle blinds. Flow transmitter (10-FT5010), Local pressure gauge (10-PG5008) and
Thermocouple for temperature measurement (10-TE5009) are installed in supplied header of PA to
CPP inside CPP B/L. In PA header for CPP, a 2” tapping with isolation valve is connected from
Atomizing Air compressor header to UB as a backup source. Normally the isolation valve remains in
closed position. From main PA header no. of trappings is at different location for PA utility inside CPP.
PA is use as motive force cleaning and cooling purpose inside CPP.
2.2.20 Service water system
A 6” supply header of service water from Refinery enters to CPP B/L. It is provided with an isolation
valve and a spectacle blind at battery limit. Flow transmitter (10-FT4906) and Pressure transmitter
(10-PT4907) are installed on supply header for monitoring. The service water header supplies service
water to various location inside CPP for the purpose line CBD steam quenching in Boilers, Near Fuel
tank area, At STG floor, Near Cooling tower area. Service water connections have been provided to
eye wash and safety shower location as well. Service water is required mainly for cleaning and
washing.
2.2.21 Potable water system

A 4” Potable water supply from refinery is coming to CPP at CPP B/L. Block valve and a spectacle blind
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have been provided at the battery limit for positive isolation. Pressure transmitter (10-PT4908), local
pressure (10-PG4909) and Temperature (10-TG4910) gauges are also mounted on potable supply
header inside CPP. Potable water is then tapped off at location near CT area, GT area and STG hall.
Potable water is used for drinking and other human biological requirement utilities.
2.2.22 Nitrogen system
4” supply header of Nitrogen from Refinery enters to CPP at CPP B/L. Nitrogen supply header consist
of double isolation valve with spectacle blind. Flow transmitter (10-FT5011), Pressure transmitter (10-
PT5007), Pressure gauge (10-PG5005) and Temperature gauge (10-TG5006) are the instrumentation
installed in supply header of Nitrogen for monitoring. Nitrogen inside CPP mainly consumed in GT and
its auxiliaries purging, Boiler preservation, LCO tank, GBC skids, and LP hydrazine dozing skid flare
header swipping. Nitrogen is majorly used as a Purge gas for FG header system inside CPP. A 2”
tapping is taken from Nitrogen supply header as in inlet to Nitrogen HP compressor. This compressor
boost the nitrogen pressure from 7.0 Kg/cm2 g to 42 Kg/cm2 g and stored in Nitrogen receiver. This
pressurized nitrogen is used to purge the FG header to GTGs are GBC discharge. Refer point 2.2.16 for
details about HP nitrogen system
2.2.23 Fire Hydrant System
Fire hydrant system consists of an Outer peripheral ring header which has 8 different input output
connection at different location. A 24” ring header on the outer peripheral of CPP unit forms a ring
header type of arrangement to which from 8 different locations, a header is connected for input and
output of fire hydrant from refinery.
Internal fire hydrant distribution is also a closed loop type. A tapping off from the main ring header is
taken at various suitable locations around the critical area like Fuel tankages area, Boiler area, Gas
turbine area, Transformer area and reconnected back to the ring header forming a closed loop cycle.
Necessary Butterfly valve, Gate valves, Air release valve, Water monitor, water cum foam monitor, T
strainers, Globe valves, Hose reel box, Deluge valve housing, Foam inlet breeching connection, Hose
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reel are provided at suitable location. Refer drawing no. 14-4833-0 Rev 05 of M/s Kidde India Limited
for complete layout of Hydrant system.
2.2.24 Storm Water system
Storm water drain of CPP unit starts from North east corner near tankages area with two separate
stream of storm water drain – one running from North to west while one running from East to South.
Both channels are connected back before connecting it to refinery main drain channel at south west
corner of CPP unit. Drain from Fuel tankages area, Gas Turbine area and GT generator area are
connected to stream running from North to west while drain from Cooling water area, UB area, STG
generator area and LT distribution transformer area are connected to stream running from East to
South. Refer drawing no. 0-38142-01713 Rev 00 for detail layout of drain system of CPP.
2.2.25 Oily Water Sever (OWS) system
OWS system for CPP is design as underground buried line of size 6”. OWS from different location
inside CPP are connected to Plant OWS line laid on the South East side of CPP unit. OWS from Fuel
tankages area, GT area, Fuel pump house area are connected to Plant OWS line in the East side of CPP
unit while the OWS from Turbine generator area and Boiler Area are connected to Plant OWS line in
South side of CPP unit. Necessary Funnel, Seal Manholes, etc are provided at suitable location inside
CPP area. OWS from CPP area is diverted back to Plant OWS common header through Plant OWS line.
OWS from CPP is taken out from south west side of CPP unit. Refer drawing no. 0-38142-01836 Rev 02
for detail layout of OWS system for CPP.
2.2.26 Distributed Control System (DCS)

DCS system is supplied by M/s BHEL, Technology collaboration with M/s Metso, USA, name of DCS is
maxDNA. Function on DCS is to ensure that all the plant control is within the specified limit as per the
operator requirement. All logics and auto control loops are uploaded in DCS which control the
process of plant as per demand. DCS is basically a Window based system, which allows Operator to
interface and control with the system by sitting at one common place. DCS control include all the
control of BOP equipments, Boiler load & pressure control, Fuel and Air control, Temperature and

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level control, STG Governing control, Pressure and temperature control, etc. The complete CPP system
except Gas Turbine and Boiler BMS system is control on the common platform of DCS. DCS is provided
with a HMI called Operator Consoles which are placed in Operator control room. Total 16 nos of
Operator console are installed in Control room. Rest Engineering console are placed in Engineering
Control room.
Communication channel of DCS is through either hardwire or through Ethernet Modbus with
redundancy features. All Critical signal to/from ESC/SCAP/Mark VI and BMS controller is through
hardwire while communication and data concentrator signals are through modbus linkage. The speed
on modbus communication is 100 MBPS. Refer below schematic for communication network of DCS.
There is also an OPC communication channel between Refinery and CPP control room for exchanging
the real time data
Total there are 66 nos. control panels for DCS controller. Out of which 16 nos. are for Turbines, 5 nos.
for Boiler Soot blower panel and rest 45 are for BOP and Auxiliaries unit of CPP which include Boiler
and HRSG control as well. The entire analog input signal to DCS from Fuel area is provided with Barrier
protection. All panels controller called Digital processing units (DPU) are with dual redundancy and
having a bump less transfer feature during failure of communication from one set of controller. There
is a continuous communication between the primary and slave controller during normal operation
through Bus link channel. Failure of one controller will immediately alarm on DCS indicating the
source and panel location for ease in identification.
Over and above there are few additional systems which are a part of DCS are:
 Alarm Information and Management system (AIMS)

 Sequence of Event station (SOE station)

 Mark VI – OWS

 BMS – OWS

 ECS – OWS

 CCTV – OWS

 Color Printers

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2.2.27 BMS system
Burner Management system (BMS) is nothing but a safety manager system installed to safe guard the
Boiler and ensure smooth, quick and safe shut down of boiler due to any abnormalities beyond the
DCS control. BMS design Philosophy is Triple Modular Redundancy (TMR) based which is the latest
operated and universally acceptance Philosophy.
BMS is supplied by M/s BHEL but the detail engineering and supplier is M/s Honey well (India), Pune.
All UB and HRSG are provided with BMS system. The function of BMS is only to ensure safe start up
and shutdown of Boiler burners. There are total 56 panels of BMS out of which 10 panels for each UB
boilers i.e. total 40 panels for all 4 nos. of UB and 8 panels for each HRSG i.e. total 16 panels for both
HRSGs.
All the communication to BMS from either directly from field as analog input or through digital input
from field or through DCS/ESC/SCAP is through hard wire contact only. Communication to BMS cannot
be possible through Modbus communication. However all signal except few critical signal from BMS
can be communicated to DCS through modbus communication channel. All Interlocks and critical
signal back to field is also through Hardwire. Here BMS is master control while DCS and other
controller are acting as slave. All Operation related to any boiler burners are through BMS only.
Start/stop operation of Burner is through BMS
2.2.28 Electrical Power Distribution system
Electrical power distribution is done in CPP through CPP substation SS – 10 where all generating
Power units and distribution feeders are placed and operator. The Power distribution inside Refinery
is done at 33 KV level. The generating Power is at 11 KV level while PSEB (grid) power is at 220 KV
level. PSEB is only the backup source available for refinery when any one out of 5 generating m/c
inside CPP is out of service, while CPP is capable enough to deliver the complete power requirement
of refinery without importing. There is no exporting provision is made inside the 220 KV switch yard.
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Major equipments in Electrical power distribution are:
a. Turbine Generator (48 – 50 MVA, 3 phase machine for each Turbine drives, 05 nos., 11 KV, 0.8
pf, 50 Hz)
b. 11/33 KV step up transformer (50 MVA rating, 5 nos., each for each generator)
c. 33 KV GIS panels (Gas insulated switch gear)
d. 33/6.6 KV step down transformers (4 nos., 25/31.5 MVA)

e. 6.6 HT switch gear (3 bus bar with couplers)
f. 6.6/0.415 KV step down transformer (12 nos., 2.5 MVA)
g. 415 LT switch gear (6 nos. of PMCC)
h. 220/33 KV step down transformer (2 nos., 50 MVA) at switch yard
Details of 33 KV Power distributions:
 From CPP substation, the 33 KV is distributed to all Refinery substations and from the
corresponding substation’s auxiliary Transformers are stepping down to 6.6 KV and 415 V
respectively. All the substations are individually equipped with DC battery chargers and
Battery bank for control supply and protection relays.

 All plant feeder circuit breakers can be opened or closed from the ECS console in the CCB with
circuit breaker status indicated on MMI of ECS. In addition, feeder current, MW, MVAR, PF and
feeder status is also transmitted and can be displayed on the ECS panel.

 During operational switching, indication on ECS is used to check that synchronism exists
between bus bars before circuit breakers can be closed. Synchronizing is also required
whenever the bus sectionalize is about to be closed following operating procedures after an
outage.
Details of 6.6 KV Power distributions:
 The 6.6 kV switchboards normally operate with both incoming circuit breakers closed and the
bus sectionalizer breakers opened (secondary selective configurations). Status of all breakers
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is indicated on the ECS.
 6.6 KV power distribution is used to supply HT power to all CPP HT drives. It also supplies
power for LT distribution Transformer for LT switch gear

 3 bus bars with bus coupler arrangement is used for HT power distribution and feeding

 The incoming circuit breaker opens automatically when there is a fault or sustained under
voltage on primary side of the breaker and the bus sectionalizer is closed and power to the bus
is restored automatically. When the cause of under voltage is a fault on the switchgear bus
bar, above transfer is blocked to safeguard the network.

 A additional source of 2.8 MW Black start DG set is used to feed the Power during Black out
condition through Emergency bus bar of 6.6 KV (10HV201)
Details of 0.415 KV Power distributions:
 6 nos. Of PMCC is used to supply the LT power distribution inside CPP through the individual
equipment MCC.

 A transformer feeder trip results from a fault on the medium voltage feeder, the transformer
or the 415V switchboard, Switchgear protection relays identify the fault by means of a flag or a
light emitting diode (LED). Each transformer feeder trip will be registered on the substation
annunciator panel and individual alarm annunciation on the ECS in the CCB.

 Lighting transformer (10 nos.) are a part of LT Power distribution network

 A back up source of 2 nos. Of Battery bank with 220 V DCDB and 220 V AC UPS and ACDB is
used to provide control supply power to all SWGR and ECS/SCAP panels including DCS and

BMS
Synchronization control and Annunciation panel (SCAP):

SCAP Panel Performs the following functions;
 Auto/Manual Synchronization of all Incomers and Bus couplers of 33 KV switchboard.

 Voltage and Frequency control of all Generators

 All 33 KV breakers operation
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 Generators Excitation control


 All type of Generator controls required for synchronization/control of Generators.

 Temperature scanners for Generators

 Breaker operation of 6.6 KV/415 V

 Maintaining and Controlling the Grid supply.
Electrical Control systems (ECS):

ECS is having the overall control on Electrical system and it performs the following functions;
 By ECS we can view the overall electrical schematic status

 Overall electrical system can be controlled including the electrical load sharing and electrical
load shedding system

 Synchronization of all Incomers with all type of controls

 Operation of all switchgear breakers

 Black out operation can be carried out in ECS

 Voltage and Frequency control of all Generators

 maintaining and controlling the Grid supply.
Power system Operating Philosophy:

1. Normal Operation:
In normal operation
 Bus -1A, 2A of 33 kV GIS switchboard is fed from Grid.

 Bus -2A, 2B of 33 kV GIS switchboard is fed from Generators.

2. Black start Condition:
The plant will be started manually with power supply from 6.6 kV DG set. During Black start
 Black start of one GTG is envisaged.

 All HEML loads will be isolated.

 All non-process and non-critical loads of BHEL shall be isolated, except for DC, UPS and
ELDB-AC.
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 Process loads required or not required will be controlled from DCS



3. EMERGENCY CONDITION (Blackout Condition):
During Emergency one of the three running boilers is to be sustained. This is needed for
delivering process steam to refinery for its safe shutdown. The boiler to be sustained is pre-
selected at DCS and the signal shall be made available at ECS for controls as required. The pre-
selected boiler will sustain without any emergency DG support. Necessary provisions for drives
are envisaged (like Steam turbine drives, Accumulators etc)
In emergency condition, DG will start automatically to fed below loads
 HMEL Emergency loads

 Emergency shutdown loads of GTG, STG, BPTG

 Emergency plant loads like DC, UPS, AC emergency lighting.
DCS and ECS system issue trip commands for non-process/non motor loads as required to
isolate non-emergency non process loads during single boiler sustenance.
2.2.29 Blackout operation Philosophy
CPP is design to take care of Blackout operation. Capacity Installation of Power generation and steam
generation is enough to meet the 11 MMTPA requirements of Refinery. But considering the worst
condition of complete blackout i.e. failure of all power generating equipment and non-availability of
PSEB power, CPP is design to operate one Utility Boiler for next 30 min of operation during blackout
which cater the needs of Refinery as well as CPP steam demand for safe shutdown of refinery units.
Operating Philosophy of CPP during Power blackout conditions are mentioned below:
Sr.
Logic for running UB Logic for Tripped UB
no.
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The FD fan running with HT drive will be

The Bearing of FD fans are envisaged with automatically tripped. If more than one UB is
sump oil Lubrication with water cooling for 30 operating with steam turbine driven FD fan, then
1 min. Hence during Utility Boiler black out the UB to be tripped under blackout condition
operation the lube oil system of steam turbine has to be selected by operator. On the receipt of
driven FD fan will sustain for 30 min even black out condition signal, these selected UBs
without forced lubrication system are tripped. The associated FD fans and its lube
oil pumps will be tripped
The RAPH will continue to run with air motor
instead of main motor for 30 min. The AH lube
The AH will continue to run with Air motor for
oil pump will be tripped and the AH system is
predetermined time. The AH lube oil pump and
2 design to sustain the operation for 30 min
AH soot blower motor will also be
(during the blackout operation) without forced
tripped/stopped
lube oil system. AH SB motor if operating will
be tripped
The scanner air fan running with AC drive will The scanner air fan of the tripped boiler running
be tripped and DC scanner air fan will be with AC drive will be tripped and DC scanner air
3
started automatically and continue to run for fan will be automatically started and continue to
30 min run for pre-determined time
The Open close Motorized dampers actuators the motorized damper actuators in Air and flue
4 in air and flue gas path will be retained in the gas path will be retained in the existing position
existing position for the tripped boilers
The secondary air dampers, pneumatic power
The secondary air dampers, pneumatic power
cylinder will operate as per the logic envisaged
5 cylinder will operate as per the logic envisaged
in the BMS powered from UPS supply for the
in the BMS powered from UPS supply
tripped boilers
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Under blackout condition, the pneumatically

operated feed control valve in feed control
The MOV for Economizer inlet (XX-GTV-MOV- station of individual boiler has to be closed by
6
8757) will continue to be in open condition operator from DCS. In addition to this the
motorized economizer inlet valve (XX-GTV-MOV-
8757) has to be close manually if required
The drum continuous drain motorized inching The drum drain to CBD tank has to be isolated
valve (XX-ANV-MOV-8759) will be retained in either by closing the manual isolation valve (B50)
7
the previous position when the normal supply or by manually closing the motorized inching
fails valve (XX-ANV-MOV-8759)
Normally the drum emergency drain motorized
The drum emergency drain motorized isolation isolation valve (XX-GLV-MOV-8760) and (XX-GLV-
valve (XX-GLV-MOV-8760) and (XX- GLV-MOV- MOV-8761) will be in closed condition. Under
8
8761) will be retained in the previous position power blackout condition if this valve remains in
when the normal supply fails open position, then this valve has to be manually
closed.
The SOV for SH spray common block valve (XX-
The SOV for SH spray common block valve (XX-
GLV-CBV-8753) will be in open position during
GLV-CBV-8753) will be in close hence the
boiler operation to ensure spray. The spray
9 motorized isolation valve (XX-GLV-TCV-8732) or
control valve which was in service (XX-GLV-
(GLV-TCV-8766) on the upstream of SH spray
TCV-8732) or (XX-GLV-TCV-8766) will continue
control valves (SD1) need not be closed.
to be in service
The motorized SH start up vent isolation valve The motorized SH start up vent isolation valve
10 (XX-GLV-MOV-8762) and (XX-GLV-MOV-8763) (XX-GLV-MOV-8762) and (XX-GLV-MOV-8763) of
of the running UB will be in closed position the tripped UBs will be in previous position
The motorized main steam stop valve (XX- The motorized main steam stop valve (XX-GTV-
11 GTV-MOV-8764) of the running UB will MOV-8764) of the tripped UB need not be closed
continue to be in open position under power blackout condition as the back flow
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of steam to tripped UB is prevented by the NRV
In case if SB is in operation, the advance SB in

The advance SB of the tripped UB in the event of
the event of Power blackout condition need
power blackout condition need not be retracted
not be retracted to home position
to home position immediately. The LRSB will be
immediately. The blower overrun will be
manually retracted.
monitored and the Pneumatically operated SB
pressure reducing valve will be command to
close to minimum position from DCS for
12 minimum SB steam pressure for operating
boiler, so that the lance tube of SB can be
safely cooled with the low pressure steam.
The LRSB will be manually retracted.
SB steam PRV inlet MOV (S59) need not be
Hence the SB steam PRV inlet MOV (S59) need
closed immediately for the tripped boilers under
not be closed immediately under Power
Power blackout condition. They can be manually
blackout condition. They can be manually
closed
closed
All the pneumatically open close and All the pneumatically open close and regulating
regulating valves of the running UB will valves of the tripped UB will go to the boiler trip
13 continue to operate as per the logics and position as per the logics and controls envisaged
controls envisaged in BMS and DCS system in BMS and DCS system powered from UPS
powered from UPS supply supply
UV4827 in ACW header for GT black start UV4827 in ACW header for GT black start should
14
should be closed during Blackout sensing be closed during Blackout sensing
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CHAPTER – 3
UTILITIES, CHEMICALS AND EFFLUENTS
3.1 UTILITY INTRODUCTION
The utility systems are basically divided into two categories:

1. Utility coming to CPP
2. Utility going outside from CPP
List of Utilities coming to CPP B/L are:

 Instrument Air (AI)

 Plant Air (AP)

 Nitrogen Gas (IG)

 Service Water (WS)

 DM Water (WDM)

 Potable water (WP)

 HSD/LCO/Naphtha Fuel (FO)

 Fuel Gas (FG)

 Fire hydrants (FH)

 Pure Condensate (CL)

 Surface Condensate (CL)

 Process Condensate (CL)

 Raw Water as make up water for CT (WR)
List of Utilities going from CPP to Refinery are:
 Boiler water Blow down (BD)

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 Cooling water Blow down (BD)


 Flare system (FL)

 Oily Water Sewer (OWS)

 Slope system (GS)
3.2 UTILITIES SPECIFICATION
a) List of Utilities coming to CPP
3.2.1 INSTRUMENT AIR SYSTEM

Refer P&ID No. 2-38101-00860-S01 Rev 05
2” Instrument Air (IA) header supplies IA from Refinery to CPP. The header is provided with isolation
valve and a spectacle blind. Flow transmitter (10-FT5004), Pressure transmitter (10-PT5001), Local
pressure gauge (10-PG5002) and Thermocouple for temperature measurement (10-TE5003) are
installed in supplied header of IA to CPP inside CPP B/L. IA header is provided with NRV which
prevent the back flow of IA from CPP Air booster compressor during Blackout condition. Various
Instrument air tapping are connected from/to this header at various locations for IA supply. One of
the inputs to IA header is IA from Air booster compressor located in CPP which supply IA to CPP
Operation during black out condition. The supply header of 2” is connected to IA supply header inside
CPP with NRV which stop IA coming back to Air booster compressor area. IA is use as motive force for
pneumatically operated control valves and other instruments operation.
3.2.2 PLANT AIR SYSTEM

Refer P&ID No. 2-38101-00860-S01 Rev 05
2" plant air (PA) header supplies plant air from Refinery to CPP. The header is provided with Isolation
valves with spectacle blinds. Flow transmitter (10-FT5010), Local pressure gauge (10-PG5008) and
Thermocouple for temperature measurement (10-TE5009) are installed in supplied header of PA to
CPP inside CPP B/L. In PA header for CPP, a 2” tapping with isolation valve is connected from
Atomizing Air compressor header to UB as a backup source. Normally the isolation

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valve remains in closed position. From main PA header no. of trappings is at different location for PA
utility inside CPP. PA is use as motive force cleaning and cooling purpose inside CPP.
3.2.3 NITROGEN SUPPLY SYSTEM

Refer P&ID No. 2-38101-00860-S02 Rev 05
4” supply header of Nitrogen from Refinery enters to CPP at CPP B/L. Nitrogen supply header consist
of double isolation valve with spectacle blind. Flow transmitter (10-FT5011), Pressure transmitter
(10-PT5007), Pressure gauge (10-PG5005) and Temperature gauge (10-TG5006) are the
instrumentation installed in supply header of Nitrogen for monitoring. Nitrogen inside CPP mainly
consumed in GT and its auxiliaries purging, Boiler preservation, LCO tank, GBC skids, and LP hydrazine
dozing skid. Nitrogen is majorly used as a Purge gas for FG header system inside CPP. A 2” tapping is
taken from Nitrogen supply header as in inlet to Nitrogen HP compressor. This compressor boost the
nitrogen pressure from 7.0 Kg/cm2 g to 42 Kg/cm2 g and stored in Nitrogen receiver. This pressurized
nitrogen is used to purge the FG header to GTGs are GBC discharge. Refer P&ID no. 2-38101-00875-
S01/S02/S03-Rev02 for the details of HP nitrogen system.
3.2.4 SERVICE WATER SYSTEM

Refer P&ID No. 1-38101-03196 Rev 05
A 6” supply header of service water from Refinery enters to CPP B/L. It is provided with an isolation
valve and a spectacle blind at battery limit. Flow transmitter (10-FT4906) and Pressure transmitter
(10-PT4907) are installed on supply header for monitoring. The service water header supplies service
water to various location inside CPP for the purpose line CBD steam quenching in Boilers, Near Fuel
tank area, for HSD centrifuge, At STG floor, Near Cooling tower area. Service water connections have
been provided to eye wash and safety shower location as well. Service water is required mainly for
cleaning and washing.
3.2.5 DM WATER SYSTEM

Refer P&ID No. 1-38101-03196 Rev 05

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An 18" supply header of DM water from RO/DM plant of Refinery comes to CPP B/L. DM water
header inside CPP B/L is provided with two isolation valve with spectacle blind. DM water is one of
the most critical and crucial Utility requirement for CPP without which CPP cannot operate. DM water
inside CPP is preliminary used in Boilers as Boiler Feed water after passing through Deaeration
process. Before going to Deaeration process the DM water along with other Refinery condensate like
Pure, clean and Process condensate are collected in a storage tank called Condensate storage tank
(CST) inside CPP. DM water before taking into Deaerator, is treated with LP dozing chemical named
Morpholine which boost the pH of DM. This chemical is directly doze in to CST through LP dozing
pumps. DM water to CST is through 18” header and provide with Flow Element (10-FE1702),
Temperature (10-TE1703) and Pressure transmitter (10-PT1703), Temperature (10-TI1704) and
Pressure gauge (10-PG1704) and online SWAS analyzers which monitor pH (10-AE1750) and
Conductivity (10-AE1751).
DM water inside CPP is also utilized at different locations like, LP dozing skids for CST and Deaerator
as chemical preparation medium, GTG Atomizing Air cooler system make up, GT water wash skid,
GTG water injection skid, STG Condenser initial filling and HP dozing skid of all boilers.
3.2.6 POTABLE WATER SYSTEM

Refer P&ID No. 1-38101-03196 Rev 05
A 4” Potable water supply from refinery is coming to CPP at CPP B/L. Block valve and a spectacle blind
have been provided at the battery limit for positive isolation. Pressure transmitter (10-PT4908), local
pressure (10-PG4909) and Temperature (10-TG4910) gauges are also mounted on potable supply
header inside CPP. Potable water is then tapped off at location near CT area, GT area and STG hall.
Potable water is used for drinking and other human biological requirement utilities.
3.2.7 HSD/LCO/Naphtha FUEL SUPPLY SYSTEM

Refer P&ID No. 1-38101-03138-S01 to S06 for HSD Fuel system and
Refer P&ID no. 1-38101-03139-S01 to S12 for LCO fuel system

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Refer P&ID no: 1-381-01-06325- 1to7 & 1-381-006326- 1to5 for Naphtha fuel system
HSD to CPP received from HSD supply header from Refinery. HSD from refinery is coming from Finish
Product tankages area through an 4/8” supply header. The header from refinery enters inside CPP
B/L with Isolation valve and spectacle blind provision. Flow Element (10-FE6601) along with Pressure
(10-PT6602) and Temperature (10-TI6602) transmitter and Local pressure (10-PG6601) and
Temperature (10-TI6601) gauge are mounted on supply header of HSD inside CPP B/L. HSD from
refinery is diverted to HSD tank in CPP which is Floating roof type of storage tank of capacity 200 m3
each. The stored HSD is than centrifuge through centrifuge system and then return back to HSD Tank
for CPP internal usage. Necessary arrangement is made to line up day oil tank with centrifuge system
and clean HSD return to HSD oil tank. All CPP users are connected to HSD oil tank through forwarding
pumps. HSD normally is used as startup fuel for EDG, Diesel engine, GT as well as changeover fuel for
GT. HSD can also be used as substitute fuel in UB and HRSG firing. A line from LCO supply header
from refinery is connected to HSD refinery supply header for initial filling during commissioning and
using LCO tank as a HSD storage tank.
LCO to CPP received from LCO supply header from Refinery. LCO from refinery is coming from FCC PC
CPP Fuel storage tankages through an 8/12” supply header. The header from refinery enters inside
CPP B/L with Isolation valve and spectacle blind provision. Flow Element (10-FE6701) along with
Pressure (10-PT6702) and Temperature (10-TI6702) transmitter and Local pressure (10-PG6701) and
Temperature (10-TI6701) gauge are mounted on supply header of LCO inside CPP B/L. LCO from
refinery is diverted to any one of the two day oil LCO tank or both LCO tank in CPP which is Fixed roof
type storage tank with 2200 m3 capacity each. A line from LCO supply header from refinery is
connected to LCO refinery supply header for initial filling during commissioning and using LCO tank as
a LCO storage tank. LCO in CPP is consumed by Gas Turbine as substitute fuel of FG and in UB and
HRSG as primary fuel. At any movement of time, one LCO tank is lineup for GTGs and another LCO
tank is line up with UB and HRSG forwarding Pumps. Provision of interchanging the LCO tank as well
as Operation with single LCO tank is possible. All return headers from all end user are diverted back
to their respective LCO tanks. Provision of interchanging and mixing of return header is also possible.

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Provision of HSD and LCO system drain are provided at necessary location by collecting the HSD/LCO
drain from tank area to end user area. All drain are collected in 5 nos. of HSD/LCO drain collecting
vessel located in areas like GT # 1, GT # 2, GBC, UB # 1 and 2 and UB # 3 and 4. The drain are finally
collected and diverted to CPP slope header which in turn connected to refinery slope header.
Naphtha to CPP received from Naphtha supply header from Refinery. Naphtha from refinery is
coming from Finish Product tankages area through an 4” supply header. The header from refinery
enters inside CPP B/L with Isolation valve and spectacle blind provision. Flow Element (10-FE9625)
along with Pressure (10-PT9626) and Temperature (10-9627) transmitter are mounted on supply
header of Naphtha inside CPP B/L. Naphtha from refinery is diverted to Naphtha tank in CPP which is
Floating roof type of storage tank of capacity 200 m3 each. All CPP users are connected to Naphtha
oil tank through forwarding pumps. Naphtha normally is used as fuel for Naphtha can also be used as
substitute fuel in UB and HRSG firing.
Provision of Naphtha system drain are provided at necessary location. All drain are collected in 3 nos.
of RFG drain collecting vessel located in areas like GT # 1, GT # 2, GBC. The drain are finally collected
and diverted to CPP slope header which in turn connected to refinery slope header.
3.2.8 FUEL GAS (FG) SUPPLY SYSTEM

Refer P&ID No. 1-38101-03142-S01 to S09
FG to CPP received from FG supply header from Refinery. FG from refinery is coming from FG treating
unit through 24/20” supply header. The header from refinery enters inside CPP B/L with Isolation
valve and spectacle blind provision. Flow Element (10-FE6801) along with Pressure (10-PT6801) and
Temperature (10-TI6801) transmitter and Local pressure (10-PG6802) and Temperature (10-TI6802)
gauge are mounted on supply header of FG inside CPP B/L. FG supply header to CPP is also provide
with Shutoff valve (10-ESD6802) which is a SOV mounted. FG in CPP is mainly consumed by GT as
Primary fuel and also by UB and HRSG as a substitute fuel. FG from refinery is diverted to Gas Turbine
Scrubbers, UB Scrubbers and HRSG Scrubber from Main supply header. Each end user header is
provided with ESD with SOV mounted valve which trip on High–High Level of gas scrubbers.

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Provision of draining the FG condensate into slope and Flare header are also provided at necessary
location like GBC area, GT # 1 and GT # 2 area. All drain from header and processing skid drains are
collected into respective drain vessel, from where the condensate is diverted to Slope header of CPP
which is further connected to Refinery Slope header, while FG flare is diverted Flare header for CPP
which is further connected to Refinery Flare header. Provisions of Nitrogen tapping at necessary
location are made to ensure Purging of headers during normal as well as shutdown operation of FG.
3.2.9 FIRE HYDRANT WATER SYSTEM
Refer drawing no. 14-4833-0 Rev 05 of M/s Kidde India Limited for complete layout of Hydrant
system.
connection at different location. A 24” ring header on the outer peripheral of CPP unit forms a ring
header type of arrangement to which from 8 different locations, a header is connected for input and
output of fire hydrant from refinery.
Internal fire hydrant distribution is also a closed loop type. A tapping off from the main ring header is
taken at various suitable locations around the critical area like Fuel tankages area, Boiler area, Gas
turbine area, Transformer area and reconnected back to the ring header forming a closed loop cycle.
Necessary Butterfly valve, Gate valves, Air release valve, Water monitor, water cum foam monitor, T
strainers, Globe valves, Hose reel box, Deluge valve housing, Foam inlet breeching connection, Hose
reel are provided at suitable location. Refer drawing no. 14-4833-0 Rev 05 of M/s Kidde India Limited
for complete layout of Hydrant system.

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3.2.10 PURE CONDENSATE SUPPLY SYSTEM

Refer P&ID No. 1-38101-03148 Rev04
A 14” header supplies pure condensate from Refinery to CPP. Pure condensate from Refinery is
coming from DCU, NHT/CCR unit and SRU unit. Pure condensate header from refinery is also going to
RO/DM unit. Pure condensate from refinery to CPP header is provided with MOV operated isolation
valve and NRV. The Pure condensate header is further connected to Process condensate header which
in turn connects to Condensate storage tank (CST) inside CPP. Online analyzer like HC (10-AE1502) is
provided to constantly monitor the quality of pure condensate.
3.2.11 SURFACE CONDENSATE SYSTEM

Refer P&ID No. 1-38101-03148 Rev04
A 16” header supplies Surface condensate from Refinery to CPP. Surface condensate from Refinery is
coming from DCU, NHT/CCR, DHDT, FCC PU and VGO HT units and same is also forwarded to RO/DM
units as well. Surface condensate header inside CPP is provided with MOV operated isolation valve
and NRV. The Surface condensate header is further connected to Process condensate header which in
turn connects to Condensate storage tank (CST) inside CPP. Online analyzer like Conductivity analyzer
(10-AE1501) is provided to constantly monitor the quality of Surface condensate.
3.2.12 PROCESS CONDENSATE SYSTEM

Refer P&ID No. 1-38101-03148 Rev04
A 16” header supplies Process condensate from Refinery to CPP. Process condensate from Refinery is
coming from RO/DM unit of Refinery. Process condensate header inside CPP is provided with Manual
Isolation valve along with MOV operated isolation valve and NRV. The Process condensate header is
further connected to Pure and Surface condensate headers which in turn connect to Condensate
storage tank (CST) inside CPP. The common header is provided with Flow element (10-FE1701),
Pressure (10-PT1701) and Temperature (10-TI1701) transmitter and Pressure (10-PG1702) and
Temperature (10-TG1702) gauges.

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3.2.13 RAW WATER SUPPLY SYSTEM

Refer P&ID No. 0-38101-00935-S01 Rev05
A 10” supply header supplies Raw Water from Refinery to CPP. Raw Water from Refinery is coming
from RO/DM unit of Refinery. Raw Water header inside CPP is provided with Manual Isolation valve
with spectacle blind and ON/OFF valve (10-UV4777). Raw water inside CPP is used as Make up water
for CPP Cooling Tower. A tapping for GT FRP CT make up, AC ventilation, GT APU Evaporative cooling
water are provided from the supply header of raw water inside CPP.
b) List of Utilities going from CPP
3.2.1 BOILER BLOW DOWN SYSTEM

Refer P&ID No. 2-38101-00862-S04 Rev03
A 6” header is used to divert the Boiler Blow down back to RO/DM Plant. All boilers IBD drain including
STG, BPTG, RFG Heater LP steam Condensate drain and BFP DT drains is collected in Main blow down
pit for CPP from where the Blow down transfer pumps, is used to pump the drain back to RO/DM unit
of Refinery. The discharge header at CPP B/L consists of two isolation valve with one spectacle blind.
Flow transmitter (10-FE1957), Pressure (10-PI1959) and Temperature (10-TI1958) transmitters,
Pressure (10-PI1960) and Temperature (10-TI1960) gauges are also provided in discharge header inside
CPP B/L.

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3.2.2 COOLING WATER BLOW DOWN SYSTEM

Refer P&ID No. 0-38101-00936-S01 Rev06
A 6” header is used to divert the Cooling tower Blow down back to RO/DM Plant. A tapping from ACW
Pump discharge common header is taken for CT blow down. In the blow down header from CPP to
RO/DM, a Flow control valve (10-FCV4815) is provided which takes an input from Flow element (10-
FE4807) fitted in upstream of FCV. Operator will set a set point for controller and PID will maintain a
zero error signal based on which the action of CV is decided. From the FCV downstream header inside
CPP, a tapping is taken from header for Boiler CBD vessel, STG & BPTG vessel quenching. It is a
alternative source of water for quenching with respect to service water.
3.2.3 FLARE SYSTEM
A 10” flare header from CPP is connected to Refinery Flare header. All the FG condensate vessels (03
nos.) flare located at different location in CPP, are collected in combine flare header inside CPP. Flare
header of CPP consist of double isolation valve with one spectacle blind.
3.2.4 OILY WATER SEVER (OWS) SYSTEM

Refer drawing no. 0-38142-01836 Rev 02 for detail layout of OWS system for CPP.
OWS system for CPP is design as underground buried line of size 6”. OWS from different location
inside CPP are connected to Plant OWS line laid on the South East side of CPP unit. OWS from Fuel
tankages area, GT area, Fuel pump house area are connected to Plant OWS line in the East side of CPP
unit while the OWS from Turbine generator area and Boiler Area are connected to Plant OWS line in
South side of CPP unit. Necessary Funnel, Seal Manholes, etc are provided at suitable location inside
CPP area. OWS from CPP area is diverted back to Plant OWS common header through Plant OWS line.
OWS from CPP is taken out from south west side of CPP unit.

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3.2.5 SLOPE SYSTEM
A 6” slope header supply slope generate from different location inside CPP to Slope header of Refinery.
The entire slope from CPP is going to Dry slope tank area in refinery. All HSD/LCO drain tanks (05 nos.)
and FG/Naphtha drain tanks (03 nos.) submersible pumps are used to pump the drain/slope collected
inside the vessel to common CPP slope header. The common slope header is further connected to
Refinery Slope header at CPP B/L. slope header inside CPP is provided with double isolation valve with
spectacle blind and NRV.
3.2.6 STORM WATER DRAIN SYSTEM
Storm water drain of CPP unit starts from North east corner near tankages area with two separate
stream of storm water drain – one running from North to west while one running from East to South.
Both channels are connected back before connecting it to refinery main drain channel at south west
corner of CPP unit. Drain from Fuel tankages area, Gas Turbine area and GT generator area are
connected to stream running from North to west while drain from Cooling water area, UB area, STG
generator area and LT distribution transformer area are connected to stream running from East to
South. Refer drawing no. 0-38142-01713 Rev 00 for detail layout of drain system of CPP.
3.3 UTILITY CONSUMPTION

UTILITY CONDITION AND CONSUMPTION DETAILS FOR CPP
DETAILS OF UTILITIES GOING OUT FROM CPP
Pressure Temperature Flow
Nor Max Min Design Nor Max Min Design Nor Max Min Design
Kg/cm2 g ⁰C TPH
HP STEAM 39 39 34 41 380 380 340 390 219 219 20 -
MP STEAM 12 12 10 14 245 245 179 300 387 396 85 -
LP STEAM 5 5.5 3.5 6.5 170 170 126.8 190 96 106.7 85 -
BFW 55 59 48 70 125.6 135 125.6 155 253.6 280 253.6 -
SLOPE - 5 5 7 - - - 60 - - - 40

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OWS - - - - - - - - - - - -
FLARE - - - - - - - - - - - -
BOILER BLOW
DOWN 4 5 3 10 60 60 60 100 30 70 15 -
COOLING TOWER
BLOW DOWN 3 - - - 33 - - 65 11 61 11 -
DETAILS OF UTILITIES COMING TO CPP

Pressure Temperature Flow
Nor Max Min Design Nor Max Min Design Nor Max Min Design
Kg/cm2 g ⁰C m3/hr
INSTRUMENT AIR 6 6.5 4.5 9 Amb Amb Amb 65 335* 571* - -
PLANT AIR 6.5 7 4 9 Amb Amb Amb 65 - 100* - -
NITROGEN 6 7 5 9 Amb Amb Amb 65 13* 1000* - -
HSD 12 13 11 19 - - - 65 50-100 - - -
LCO 12 13 11 14 30 46.1 1 65 182 200 60
FUEL GAS 10.5 11 10 15 50 60 40 100 112114* 125370* 1229* 135370*
DM WATER 6 - 3.5 10 Amb Amb Amb 65 983 996 - -
SERVICE WATER 5 - 10 Amb Amb Amb 65 - 150* - -
POTABLE WATER - - 2.5 - Amb Amb Amb 65 40 - - -
RAW WATER 4 5.2 - 8 Amb Amb Amb 65 319 - - -
PROCESS
CONDENSATE 4.5 7 - 10 59 100 - 185 435** 650** - -
SURFACE
CONDENSATE 4 4.5 3.5 13 55 55 45 125 - - - -
PURE
CONDENSATE 4 4.5 3.5 13 100 100 90 125 - - - -
3.4 UTILITY B/L CONDITION
Refer above table for Utility condition
3.5 CHEMICAL CONSUMPTION AND SUMMARY
The Chemical used for CPP Operation are basically divided into broadly 3 categories:
1. Chemical for Boiler Feed water

Treatment 1.1. HP dozing chemicals

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1.2. LP dozing chemicals

1.2.1. CyloHexa Amine Dozing in Deaerator
1.2.2. Hydrazine Dozing in Deaerator
1.2.3. Morpholine Dozing in Condensate Storage tank
2. Chemical for Raw Water treatment
2.1. Scale and Corrosion Inhibitor skid
2.2. Bio dispersant Dozing Skid
2.3. Polymeric Dispersant skid
2.4. Non-Oxidizing Biocide chemical drum (Carbuoy)
2.5. Oxidizing Biocide chemical Drum (Carbuoy)
3. Chemical for LCO fuel treatment for GT operation
3.1. Vanadium/Naphtha Additive(ER-517) Inhibitor dozing skid for each GT
1.1. HP dosing details:
CHEMICAL Tri-sodium phosphate (Na3PO4.12H2O)

99% by weight, commercial grade
Dosing Concentration 2 % as Na3PO4.12H2O
Dosing rate (Max) 45 to 50 litres per hour***
Dosing pump capacity 100 litres per hour
Dosing tank capacity 1000 litres
Dosing tank material MSRL or SS
1.2. LP dosing details:
CHEMICAL Hydrazine hydrate [N2H4.H2O] 80 % by weight, commercial grade

Dosing concentration 0.5% (as N2H4.H2O)
Dosing rate 3 to 4 litres per hour

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Dosing pump capacity 10 litres per hour

Dosing tank material MS epoxy coated or SS
CHEMICAL Cyclohexaylamine Solution 25% by weight, commercial grade, Sp.

Gr
Dosing concentration Concentration of dosing solution 0.5 to 1 %
Dosing rate 5 to 10 lph*
Dosing pump capacity 10 litres per hour**
Dosing tank material MS epoxy coated or SS
Hydrazine & Cyclohexaylamine solution are prepared in
seperate tank and dosed
Note 1: The finer adjustments of both LP and HP dosing have to be made based on the chemical
analysis of Cyclohexaylamine, hydrazine and phosphate during normal running of the boiler.
Note 2: Cyclohexaylamine solution also has to be taken as a 0.5 to 1% solution and dosed along with
hydrazine. The solution dosing rate has to be fine-tuned based on the chemical analysis of hydrazine
and Cyclohexaylamine in the condensate / feed water samples.
NOTE 3:
* concentrated Cyclohexaylamine (25 % by wt) of 5 to 10 litre and 2 to 4 litre of Hydrazine (80%

N2H4H2O) taken and diluted to about 250 litres in L.P dosing tank. The dosing rate of Cyclohexaylamine
and N2H4 has to be fine tuned, based on measurement of N2H4 in feedwater (0.02 to 0.04 ppm as
N2H4) and 0.5 ppm NH3 in condensate

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**Continuous addition of Cyclohexaylamine may not be required due to possible decomposition of

hydrazine to Cyclohexaylamine and hence Cyclohexaylamine dosing will be decided based on analytical
measurement of Cyclohexaylamine and hydrazine. Hence consumption of Cyclohexaylamine per month is
not given.
***The higher dosing rate of TSP 50 LPH is given, considering the extreme case of higher level
residual phosphate , 20 ppm as PO4 and emergency boiler operation with higher and design blow
down rate of 5 %. But during normal operation of the boiler, the Phosphate (residual) level in Boiler
drum will be maintained 5 - 10 ppm and blow down rate will be less than 2 % and hence during
normal operation, the TSP dosing rate will come down to 10 litre / hr. (TSP concentration in the
dosing tank must be 2% on Na3PO4.12H2O) Hence consumption will come down and the dosing rate
and consumption have to be based on analysis.
2. Cooling Tower Treatment scheme:
Cooling Water treatment facilities including side stream filters, anti-scalant, biological control &
other dosing systems as per requirement. Dosing of the closed cooling water system is envisaged to
control Scaling, Microbiological Growth and Material Deposition. The quality of make-up water for
condenser cooling water system is considered as per the inputs provided by HMEL/EIL during
contract stage. As per the calculations the Langlier Saturation Index (LSI) is (+0.2 to +0.5) i.e. there is
a tendency for scaling. A proper dosing program for scale and corrosion inhibition will be provided.
The following treatment is considered for the cooling water system:
(a) Scale & Corrosion Inhibition:

Base Chemical: Zinc Organophosphonate (HEDP)
Dosing : Continous
Dosing Rate : @ 40 ppm of blowdown
(b) Bio Dispersant:

Base Chemical: Vendor Specific
Dosing : Continous
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(c) Polymeric Dispersant:

Base Chemical: Vendor Specific
Dosing : Continous
(d) Biocide (Oxidising):

Base Chemical: Sodium Hypo-chloride
Dosing : Slug Dosing (Once in 15 Days)
Dosing Rate : 30 ppm of holdup
(e) Biocide (Non-Oxidising):

Base Chemical: Quatenary Ammonium Salts (Quats)
Dosing : Slug Dosing (Once in 15 Days)
Dosing Rate : 30 ppm of holdup
Please find attached a file for the CW dosing arrangement.
FRP day storage tanks, dosing/metering pumps, piping up to cooling tower cold water channel etc
will be provided for the continuous dosing chemicals. Slug dosing equipment (as required) will be
provided. Personal Protection Equipment gloves, Helmets etc (as required) will also be provided.

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3. Vanadium Inhibitor for GT LCO firing
3.7 WASTE EFFLUENTS / BLOW DOWN SYSTEMS

Refer 3.2 point (b) for details of Waste Effluents and Blow down system of CPP
3.8 EFFLUENT SUMMARY

Not Applicable

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CHAPTER – 4
OPERATING VARIABLES
1. Prefix the Tag no. as below for mentioned equipment
01 – STG # 1
02 – STG # 2
03 – BPTG
04 – HRSG # 1
05 – HRSG # 2
06 – UB # 1
07 – UB # 2
08 – UB # 3
09 – UB # 4
10 – BOP
11 – BFP DT
12 - GBC # 1
13– GBC # 2
4.1 NORMAL OPERATING PARAMETER WITH ALARM SP’s
SET POINT Dead

Band TIME
TAG No DESCRIPTION STATUS ALM
ALARM VALUE DELAY SOE
SEV
TRIP UNIT (SEC)
FAH6601 HSD OIL TANK I/L FLOW HI HIGH 110 M3/hr 5 10 4 0
LAH6604 NAPHTHA LEVEL HI HIGH 85 % 5 10 5 0
LAH6607 HSD OIL TANK 2 LEVEL HI HIGH 80 % 5 10 5 0
07PAH8840 UB 2 IGNITOR AIR HDR PR HI HIGH 8 Kg/cm2 0.5 15 3 0
06PAH8841 UB1 PR AT IGNR GAS HDR HI HIGH 3.2 Kg/cm2 0.2 15 4 0
08PAH8838 UB3 PR AT IGNR GAS HDR HI HIGH 2 Kg/cm2 0.2 15 4 1
04DPAH7717 HR1 LCO STNR DP HI HIGH 0.3 Kg/cm2 0.02 15 4 1
07PAH8809 UB2 PR AT RFG HDR HI HIGH 3.5 Kg/cm2 0.2 15 4 1
04PAH7708 HR1 RFG PR AFT FCV HI HIGH 2 Kg/cm2 0.1 15 5 1
04PAH7722 HR1 LCO PR AFT FCV HI HIGH 7.5 Kg/cm2 0.5 15 4 1
04PAH7727 HR1 ATM AIR PR HI HIGH 5.75 Kg/cm2 0.25 15 5 1
05DPAH7717 HR2 LCO STNR DP HI HIGH 0.3 Kg/cm2 0.02 15 4 1
05PAH7708 HR1 RFG PR AFT FCV HI HIGH 2 Kg/cm2 0.1 15 5 1

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05PAH7722 HR2 LCO PR AFT FCV HI HIGH 7.5 Kg/cm2 0.5 15 4 1

05PAH7727 HR2 ATM AIR PR HI HIGH 5.75 Kg/cm2 0.25 15 5 1
GT1 HSD 6 MICRON FILTER DP
0.8 Kg/cm2 0.05 15 4 1
DPAH6636 HI HIGH
DPAH6642 GT 2 100 MICRON FILTER DP HI HIGH 0.1 Kg/cm2 0.005 15 4 1
0.9 Kg/cm2 0.05 15 4 1
DPAH6649 HI HIGH
0.8 Kg/cm2 0.05 15 4 1
DPAH6650 HI HIGH
PAH6602 HSD TNK I/L PR HI HIGH 3 Kg/cm2 0.15 15 4 1
10PAH6933 GT2 HP N2 PCV O/L PR HI HIGH 31 Kg/cm2 1 15 4 1
0.8 Kg/cm2 0.05 15 4 1
DPAH6635 HI HIGH
DPAH6628 GT 2 100 MICRON FILTER DP HI HIGH 0.1 Kg/cm2 0.005 15 4 1
10DPAH6610 HSD CENTRIFUGE I/L DP HI HIGH 0.1 Kg/cm2 0.01 15 4 1
10PAH6927 GT1 HP N2 PCV O/L PR HI HIGH 31 Kg/cm2 1 15 5 1
09PAH8838 UB4 PR AT IGNR GAS HDR PR HI HIGH 2 Kg/cm2 0.2 15 4 1
TAH6602 HSD TNK I/L TEMP HI HIGH 55 Deg C 1 30 4 1
FAL6601 HSD OIL TANK I/L FLOW LO LOW 30 M3/hr 2 10 4 0
LAL6604 NAPHTHA LEVEL LO LOW 30 % 5 10 5 0
LAL6607 HSD OIL TANK 2 LEVEL LO LOW 30 % 5 10 5 0
07PAL8840 UB 2 IGNITOR AIR HDR PR LO LOW 3.5 Kg/cm2 0.5 15 3 0
06PAL8841 UB1 PR AT IGNR GAS HDR LO LOW 1.5 Kg/cm2 0.2 15 4 0
UB1 HSD HDR PR AFT HSD
3 Kg/cm2 0.2 15 5 1
06PAL8908 FCV(L) LOW
07PAL8908 UB2 HSD HDR PR AT HSD FCV LOW 3 Kg/cm2 0.2 15 4 1
07PAL8809 UB2 PR AT RFG HDR LO LOW 0.28 Kg/cm2 0.02 15 4 1
05PAL7715 HR2 SCNR FAN O/L AIR PR LO LOW 250 mmwc 5 30 4 1
04PAL7708 HR1 RFG PR AFT FCV LO LOW 0.08 Kg/cm2 0.002 15 5 1
04PAL7715 HR1 SCNR FAN O/L AIR PR LO LOW 250 mmwc 5 30 5 1
04PAL7722 HR1 LCO PR AFT FCV LO LOW 2 Kg/cm2 0.01 15 4 1
04PAL7727 HR1 ATM AIR PR LO LOW 4.5 Kg/cm2 0.2 15 5 1

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04PAL7731 HR1 AUG AIR FAN O/L PR LO LOW 250 mmwc 5 30 4 1

04PAL7733 HR1 SEAL AIR FAN O/L PR LO LOW 340 mmwc 10 30 4 1
05PAL7708 HR1 RFG PR AFT FCV LO LOW 0.08 Kg/cm2 0.002 15 5 1
05PAL7722 HR1 LCO PR AFT FCV LO LOW 2 Kg/cm2 0.01 15 4 1
05PAL7727 HR2 ATM AIR PR LO LOW 3.5 Kg/cm2 0.2 15 5 1
05PAL7731 HR2 AUG AIR FAN O/L PR LO LOW 250 mmwc 5 30 4 1
05PAL7733 HR2 SEAL AIR FAN O/L PR LO LOW 340 mmwc 10 30 4 1
HSD FWD SKID SUCTION HDR PR
0.3 Kg/cm2 0.015 15 5 1
PAL6609B LO LOW
PAL6602 HSD TNK I/L PR LO LOW 0.5 Kg/cm2 0.025 15 4 1
PAL6608A HSD TANK -1 & 2 O/L HDR PR LO LOW 0.28 Kg/cm2 0.01 15 5 1
HSD TANK -1 & 2 O/L HDR PR
0.28 Kg/cm2 0.01 15 5 1
PAL6608B LO LOW
0.28 Kg/cm2 0.01 15 5 1
PAL6608C LO LOW
0.3 Kg/cm2 0.015 15 5 1
PAL6609A LO LOW
10PAL6933 GT2 HP N2 PCV O/L PR LO LOW 25.3 Kg/cm2 1 15 4 1
0.3 Kg/cm2 0.015 15 5 1
PAL6609C LO LOW
PAL6633 GT1 HSD PMP DICH PR LO LOW 6.5 Kg/cm2 0.25 15 4 1
PAL6637 HSD HDR PR TO GT-1 LO LOW 2.3 Kg/cm2 0.12 15 4 1
PAL6645 GT2 HSD PMP DICH PR LO LOW 6.5 Kg/cm2 0.25 15 4 1
PAL6652 HSD HDR PR TO GT-2 LO LOW 2.3 Kg/cm2 0.12 15 4 1
09PAL8841 UB4 PR AT IGNR GAS HDR PR LO LOW 1.5 Kg/cm2 0.2 15 4 1
3 Kg/cm2 0.2 15 5 1
3 Kg/cm2 0.2 15 5 1
10PAL6927 GT1 HP N2 PCV O/L PR LO LOW 25.5 Kg/cm2 1 15 4 1
TAL6602 HSD TNK I/L TEMP LO LOW 10 Deg C 0.5 30 4 1
VERY
NAPHTHA LEVEL HH 90 % 2 10 4 0
LAHH6604 HIGH
VERY
HSD OIL TANK 2 LEVEL HH 90 % 2 10 4 0
LAHH6607 HIGH
07PAHH8806 VERY
UB2 RFG HRD PR HH 4.5 Kg/cm2 0.2 15 4 1
A HIGH
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07PAHH8806 VERY
B HIGH
07PAHH8806 VERY
C HIGH
06PAHH8806 VERY
C HIGH
08PAHH8806 VERY
A HIGH
08PAHH8806 VERY
B HIGH
08PAHH8806 VERY
C HIGH
VERY
HR1 RFG PR AFT FCV HIHI 2.2 Kg/cm2 0.1 15 4 1
04PAHH7708 HIGH
VERY
05PAHH7708 HIGH
06PAHH8806 VERY
A HIGH
06PAHH8806 VERY
B HIGH
09PAHH8806 VERY
A HIGH
09PAHH8806 VERY
B HIGH
09PAHH8806 VERY
C HIGH
VERY
HP N2 RECEIVER 1 PR HH 44 Kg/cm2 1.5 15 5 1
10PAHH6908 HIGH
VERY
10PAHH6912 HIGH
VERY
10PAHH6916 HIGH
VERY
10PAHH6920 HIGH
LALL6604 NAPHTHA LEVEL LL VERY LOW 20 % 2 10 4 0
LALL6607 HSD OIL TANK 2 LEVEL LL VERY LOW 20 % 2 10 4 0
04PALL7708 HR1 RFG PRAFT FCV LL VERY LOW 0.05 Kg/cm2 0.002 15 4 1
05PALL7708 HR1 RFG PRAFT FCV LL VERYLOW 0.05 Kg/cm2 0.002 15 4 1
0.2 Kg/cm2 0.01 15 4 1
PALL6609B LL VERY LOW
0.2 Kg/cm2 0.01 15 4 1
PALL6608A LL VERY LOW
0.2 Kg/cm2 0.01 15 4 1
PALL6608C HSD TANK -1 & 2 O/L HDR PR LL VERY LOW 0.2 Kg/cm2 0.01 15 4 1
0.2 Kg/cm2 0.01 15 4 1
0.2 Kg/cm2 0.01 15 4 1
PALL6609C LL VERY LOW

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10PALL6908 HP N2 RECEIVER 1 PR LL VERY LOW 36 Kg/cm2 1.5 15 5 1

07PAHH8806 VERY
A HIGH
07PAHH8806 VERY
B HIGH
07PAHH8806 VERY
C HIGH
06PAHH8806 VERY
C HIGH
08PAHH8806 VERY
A HIGH
08PAHH8806 VERY
B HIGH
08PAHH8806 VERY
C HIGH
VERY
04PAHH7708 HIGH
VERY
05PAHH7708 HIGH
06PAHH8806 VERY
A HIGH
06PAHH8806 VERY
B HIGH
09PAHH8806 VERY
A HIGH
09PAHH8806 VERY
B HIGH
09PAHH8806 VERY
C HIGH
0.2 Kg/cm2 0.01 15 4 1
0.2 Kg/cm2 0.01 15 4 1
GBC 2 GEAR BOX THRUST BRG
100 °C 1 15 5 0
02TAH7316 TEMP HI HIGH
100 °C 1 15 5 0
100 °C 1 15 5 0
100 °C 1 15 5 0
GBC 2 MOTOR WINDING TEMP
90 °C 0.9 15 5 0
02TAH7332A HI HIGH
02TAH7332B GBC 2 MOTOR WINDING TEMP HIGH 90 °C 0.9 15 5 0
Revision 02
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HI
90 °C 0.9 15 5 0
02TAH7332C HI HIGH
90 °C 0.9 15 5 0
02TAH7332D HI HIGH
90 °C 0.9 15 5 0
02TAH7332E HI HIGH
90 °C 0.9 15 5 0
02TAH7332F HI HIGH
GBC 2 GEAR BOX THRUST
±0.5 mm 0.02 15 5 0
02ZAH7301A POSITION HI HIGH
GBC 2 GEAR BOX THRUST
±0.5 mm 0.02 15 5 0
02ZAH7301B POSITION HI HIGH
02ZAH7302A GBC 2 AXIAL POSITION HI HIGH ±0.5 mm 0.02 15 5 0
02ZAH7302B GBC 2 AXIAL POSITION HI HIGH ±0.5 mm 0.02 15 5 0
GBC 2 GEAR BOX LSS SFT DE VIB
75 micron 0.02 15 5 0
02VAH7301A HI HIGH
GBC 2 GEAR BOX LSS SFT DE VIB
75 micron 0.02 15 5 0
02VAH7301B HI HIGH
02VAH7306A GBC 2 (NDE SIDE) JB VIB HI HIGH 75 micron 0.02 15 5 0
02VAH7306B GBC 2 (NDE SIDE) JB VIB HI HIGH 75 micron 0.02 15 5 0
GBC 2 GEAR BOX TURBINE NDE
75 micron 0.02 15 5 0
02VAH7302A VIB(LSS)HI HIGH
GBC 2 GEAR BOX TURBINE NDE
75 micron 0.02 15 5 0
02VAH7302B VIB(LSS)HI HIGH
GBC 2 GEAR BOX HSS SFT DE VIB
75 micron 0.02 15 5 0
02VAH7303A HI HIGH
75 micron 0.02 15 5 0
02VAH7303B HI HIGH
75 micron 0.02 15 5 0
02VAH7304A HI HIGH
75 micron 0.02 15 5 0
02VAH7304B HI HIGH
02VAH7305A GBC 2 (DE SIDE) JB VIB HI HIGH 75 micron 0.02 15 5 0
02VAH7305B GBC 2 (DE SIDE) JB VIB HI HIGH 75 micron 0.02 15 5 0
GBC 2 MOTOR BRG NDE TEMP
90 °C 0.8 15 5 0
02TAH7310 HI HIGH
02TAH7311 GBC 2 MOTOR BRG DE TEMP HI HIGH 80 °C 0.8 15 5 0
COMP2 OVERHEAD LO TANK
70 % 0.5 0 3 0
02LAH7304 LVL Hi HIGH
GBC area 10m3 FG COND TNK
70 % 0.5 15 3 0
LAH6876 LVL HI HIGH
GT2 area 10m3 FG COND TNK
70 % 0.5 15 3 0
LAH6881 LVL HI HIGH
70 % 0.5 15 3 0
LAH6882 LVL HI HIGH
70 % 0.5 15 3 0
LAH6884 LVL HI HIGH

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70 % 0.5 15 3 0
LAH6885 LVL HI HIGH
GT 1 SEPARATOR 1 DRN COLL
70 % 0.5 15 3 0
LCAH6821 LVL HI HIGH
70 % 0.5 15 3 0
70 % 0.5 15 3 0
70 % 0.5 15 3 0
70 % 0.5 15 3 0
70 % 0.5 15 3 0
70 % 0.5 15 3 0
70 % 0.5 15 3 0
LAH6863F UB GAS SCRBR2 LVL HI HIGH 70 % 0.5 15 3 0
70 % 0.5 15 3 0
LAH6875 LVL HI HIGH
LAH6805B GBC GAS SCRBR1 LVL HI HIGH 70 % 0.5 15 5 0
LAH6814B GBC GAS SCRBR 2 LVL HI HIGH 70 % 0.5 15 5 0
LAH6854B HRSG GAS SCRBR1 LVL HI HIGH 70 % 0.5 15 4 0
LAH6854C HRSG GAS SCRBR1 LVL HI HIGH 70 % 0.5 15 4 0
LAH6863B UB GAS SCRBR1 LVL HI HIGH 70 % 0.5 15 3 0
LAH6863C UB GAS SCRBR1 LVL HI HIGH 70 % 0.5 15 3 0
LAH6863E UB GAS SCRBR2 LVL HI HIGH 70 % 0.5 15 3 0
02PDAH7003
0.8 kg/cm2 0.02 15 3 0
A GBC 2 DP BAL GAS&SEAL GAS HI HIGH
02PDAH7003
0.8 kg/cm2 0.02 15 3 0
B GBC 2 DP BAL GAS&SEAL GAS HI HIGH
02PDAH7005 GBC 2 SEAL GAS FILT DP HI HIGH 0.5 kg/cm2 0.02 15 3 0
02PDAH7018 GBC N2 SUPLY FILTER DP HI HIGH 0.5 kg/cm2 0.02 15 3 0
02PDAH7310 GBC 2 DP ACR LO DUP FLTR HI HIGH 1.0 kg/cm2 0.02 15 3 0
02PAH7012C GBC 2 PRI SEAL LEAK PR HI HIGH 2.0 kg/cm2 0.05 15 5 0
02PAH7013C GBC 2 PRI SEAL LEAK PR HI HIGH 2.0 kg/cm2 0.05 15 5 0
02PAH7202 GBC2 GAS SUC PR HI HIGH 8.5 kg/cm2 0.2 15 3 0
DP ACROSS SEPERATOR FOR GT-
0.5 kg/cm2 0.01 15 3 0
DPAH6809 1 HI HIGH
DP ACROSS SEPERATOR FOR GT-
0.5 kg/cm2 0.01 15 3 0
DPAH6820 2 HI HIGH
PAH6872 SCRBR 1&2 O/L PR->UB3 HI HIGH 4.2 kg/cm2 0.1 15 3 0
PAH6887 GAS SCRBR O/L PR HRSG2 HI HIGH 8 kg/cm2 0.2 15 3 0

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PAH6861 GAS SCRBR O/L PR HRSG1 HI HIGH 8 kg/cm2 0.2 15 3 0

02TAH7204 GBC-2 RFG O/L TEMP HI HIGH 160 °C 1 15 3 0
02TAH7302 GBC 2 LO TNK TMP HI HIGH 60 °C 0.5 15 3 0
02FAL7201A GBC 2 RFG I/L FLOW LO LOW 7000 M3/Hr 10 15 5 0
02LAL7302 GBC 2 LO MAIN TNK LVL LO LOW 20 % 0.5 15 5 0
COMP2 OVERHEAD LO TANK
30 % 0.5 0 3 0
02LAL7304 LVL Lo LOW
30 % 0.5 15 3 0
LAL6876 LVL LO LOW
30 % 0.5 15 3 0
LAL6881 LVL LO LOW
30 % 0.5 15 3 0
LAL6882 LVL LO LOW
30 % 0.5 15 3 0
LAL6884 LVL LO LOW
30 % 0.5 15 3 0
LAL6885 LVL LO LOW
20 % 0.5 15 3 0
LCAL6821 LVL LO LOW
20 % 0.5 15 3 0
LCAL6823 LVL LO LOW
20 % 0.5 15 3 0
LCAL6825 LVL LO LOW
20 % 0.5 15 3 0
LCAL6826 LVL LO LOW
20 % 0.5 15 3 0
LCAL6836 LVL LO LOW
20 % 0.5 15 3 0
LCAL6841 LVL LO LOW
20 % 0.5 15 3 0
LCAL6844 LVL LO LOW
20 % 0.5 15 3 0
LCAL6846 LVL LO LOW
LAL6863F UB GAS SCRBR2 LVL LO LOW 30 % 0.5 15 3 0
30 % 0.5 15 3 0
LAL6875 LVL LO LOW
LAL6805B GBC GAS SCRBR1 LVL LO LOW 30 % 0.5 15 3 0
LAL6814B GBC GAS SCRBR 2 LVL LO LOW 30 % 0.5 15 3 0
LAL6854B HR GAS SCRBR1 LVL LO LOW 30 % 0.5 15 3 0
LAL6854C HR GAS SCRBR1 LVL LO LOW 30 % 0.5 15 3 0
LAL6863B UB GAS SCRBR1 LVL LO LOW 30 % 0.5 15 3 0
LAL6863C UB GAS SCRBR1 LVL LO LOW 30 % 0.5 15 3 0
LAL6863E UB GAS SCRBR2 LVL LO LOW 30 % 0.5 15 3 0

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02PAL7020 N2 FOR SEC SEAL HDR PR LO LOW 0.5 kg/cm2 0.02 0 3 0

INST AIR FOR BARRIER SEAL HDR
1 kg/cm2 0.02 15 3 0
02PAL7021 PR LO LOW
02PAL7202 GBC2 GAS SUC PR LO LOW 6.5 kg/cm2 0.15 15 3 0
02PAL7308 GBC-2 LOP DICH PR LO LOW 6.5 kg/cm2 0.2 15 5 0
02PAL7312C GBC-2 LO HDR PR LO LOW 2.3 kg/cm2 0.05 15 5 0
PAL6865C FG SCRBR O/L PR TO GBC LO LOW 9.5 kg/cm2 0.1 15 3 0
PAL6887 GAS SCRBR O/L PR HRSG2 LO LOW 4 kg/cm2 0.1 15 3 0
PAL6801 Battery limit RFG pressure Lo LOW 9 kg/cm2 0.5 15 3 0
PAL6834 FG PR AT GT1 I/L LO LOW 18 kg/cm2 0.5 15 5 0
PAL6850 FG PR AT GT2 I/L LO LOW 18 kg/cm2 0.5 15 5 0
PAL6865A FG SCRBR O/L PR TO GBC LO LOW 9.5 kg/cm2 0.1 15 5 0
PAL6865B FG SCRBR O/L PR TO GBC LO LOW 9.5 kg/cm2 0.1 15 5 0
PAL6861 GAS SCRBR O/L PR HRSG1 LO LOW 4 kg/cm2 0.1 15 3 0
PAL6870 SCRBR 1&2 O/L PR->UB1 LO LOW 1 kg/cm2 0.02 0 3 0
PAL6871 SCRBR 1&2 O/L PR->UB2 LO LOW 1 kg/cm2 0.02 0 3 0
LAHH6805A GBC GAS SCRBR1 LVL HH V HIGH 90 % 0.5 0 4 0
90 % 0.5 0 4 0
LAHH6876 LVL HH V HIGH
90 % 0.5 0 4 0
90 % 0.5 0 4 0
LAHH6863F UB GAS SCRBR2 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6805B GBC GAS SCRBR1 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6805C GBC GAS SCRBR1 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6814A GBC GAS SCRBR 2 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6814B GBC GAS SCRBR 2 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6814C GBC GAS SCRBR 2 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6854A HRSG GAS SCRBR1 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6854B HRSG GAS SCRBR1 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6854C HRSG GAS SCRBR1 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6863A UB GAS SCRBR1 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6863B UB GAS SCRBR1 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6863C UB GAS SCRBR1 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6863D UB GAS SCRBR2 LVL HH V HIGH 90 % 0.5 15 4 0
LAHH6863E UB GAS SCRBR2 LVL HH V HIGH 90 % 0.5 15 4 0
02PAHH7012
3.0 kg/cm2 0.05 0 4 0
A GBC 2PRI SEAL LEAK PR HH V HIGH
02PAHH7012
3.0 kg/cm2 0.05 0 4 0
B GBC 2 PRI SEAL LEAK PR HH V HIGH
Revision 02
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02PAHH7012
3.0 kg/cm2 0.05 0 4 0
C GBC 2 PRI SEAL LEAK PR HH V HIGH
02PAHH7013
3.0 kg/cm2 0.05 0 4 0
A GBC 2 PRI SEAL LEAK PR HH V HIGH
02PAHH7013
3.0 kg/cm2 0.05 0 4 0
B GBC 2 PRI SEAL LEAK PR HH V HIGH
02PAHH7013
3.0 kg/cm2 0.05 0 4 0
C GBC 2 PRI SEAL LEAK PR HH V HIGH
PAHH6872 SCRBR 1&2 O/L PR->UB3 HH V HIGH 4.6 kg/cm2 0.1 0 4 0
LALL6805A GBC GAS SCRBR1 LVL LL V LOW 20 % 0.5 0 3 0
20 % 0.5 0 4 0
LALL6876 LVL LL V LOW
20 % 0.5 0 4 0
20 % 0.5 0 4 0
LALL6814A GBC GAS SCRBR 2 LVL LL V LOW 20 % 0.5 15 3 0
LALL6854A HRSG GAS SCRBR1 LVL LL V LOW 20 % 0.5 15 3 0
LALL6863A UB GAS SCRBR1 LVL LL V LOW 20 % 0.5 15 3 0
LALL6863D UB GAS SCRBR2 LVL LL V LOW 20 % 0.5 15 3 0
GBC 2 GEAR BOX TRUST BRG
110 °C 1 0 4 0
02TAHH7316 TEMP HH V HIGH
110 °C 1 0 4 0
110 °C 1 0 4 0
110 °C 1 0 4 0
02TAHH7332 GBC 2 MOTOR WINDING TEMP
100 °C 1 0 4 0
A HH V HIGH
100 °C 1 0 4 0
B HH V HIGH
100 °C 1 0 4 0
C HH V HIGH
100 °C 1 0 4 0
D HH V HIGH
100 °C 1 0 4 0
E HH V HIGH
100 °C 1 0 4 0
F HH V HIGH
02ZAHH7301 GBC 2 GEAR BOX THRUST
±0.7 mm 0.02 0 4 0
A POSITION HH V HIGH
02ZAHH7301 GBC 2 GEAR BOX THRUST
±0.7 mm 0.02 0 4 0
B POSITION HH V HIGH
02ZAHH7302 GBC 2 AXIAL POSITION HH V HIGH ±0.7 mm 0.02 0 4 0
Revision 02
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A
02ZAHH7302
±0.7 mm 0.02 0 4 0
B GBC 2 AXIAL POSITION HH V HIGH
02VAHH7301 GBC 2 GEAR BOX LSS SFT DE VIB
120 micron 0.02 0 4 0
A HH V HIGH
02VAHH7301 GBC 2 GEAR BOX LSS SFT DE VIB
120 micron 0.02 0 4 0
B HH V HIGH
02VAHH7302 GBC 2 GEAR BOX TURBINE NDE
120 micron 0.02 0 4 0
A VIB(LSS)HH V HIGH
02VAHH7302 GBC 2 GEAR BOX TURBINE NDE
120 micron 0.02 0 4 0
B VIB(LSS)HH V HIGH
02VAHH7303 GBC 2 GEAR BOX HSS SFT DE VIB
120 micron 0.02 0 4 0
A HH V HIGH
120 micron 0.02 0 4 0
B HH V HIGH
120 micron 0.02 0 4 0
A HH V HIGH
120 micron 0.02 0 4 0
B HH V HIGH
02VAHH730 GBC 2 (DE SIDE) JB VIB HH V HIGH 120 micron 0.02 0 4 0
02VAHH7305
120 micron 0.02 0 4 0
B GBC 2 (DE SIDE) JB VIB HH V HIGH
02VAHH7306
120 micron 0.02 0 4 0
A GBC 2 (NDE SIDE) JB VIB HH V HIGH
02VAHH7306
120 micron 0.02 0 4 0
B GBC 2 (NDE SIDE) JB VIB HH V HIGH
GBC 2 MOTOR BRG NDE TEMP
100 °C 1 0 4 0
02TAHH7310 HH V HIGH
02TAHH7311 GBC 2 MOTOR BRG DE TEMP HH V HIGH 100 °C 1 0 4 0
02FALL7201B GBC 2 RFG I/L FLOW V LO V LOW 6500 M3/Hr 10 0 4 0
02PALL7312A GBC-2 LO HDR PR LL V LOW 1 kg/cm2 0.05 0 4 0
02PALL7312B GBC-2 LO HDR PR LL V LOW 1 kg/cm2 0.05 0 4 0
02PALL7312C GBC-2 LO HDR PR LL V LOW 1 kg/cm2 0.05 0 4 0
9.5 1 10 3 1
04AIH8168 HR1 MAIN STEAM PH Hi HIGH
HR1 MAIN STEAM
6 µS/cm 1 10 3 1
04AIH8167 CONDUCTIVITY Hi HIGH
04AIH8169 HR1 MAIN STEAM SILICA Hi HIGH 20 ppb 1 10 3 1

HR1 DRUM WATER
20 µS/cm 1 10 3 1
04AIH8165 CONDUCTIVITY HIGH
HR1 FEED WATER
04AIH8162 6 µS/cm 1 10 3 1
CONDUCTIVITY HIGH
04AIH8164 HR1 FEED WATER SILICA HIGH 20 ppb 1 10 3 1
04AIH8166 10.1 1 10 3 1
HR1 DRUM WATER PH Hi HIGH
HR1 HP Dosing METERING TNK
04LIH8203 90 % 2 10 3 1
LVL Hi HIGH

Revision 02
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HR1 FLUE GAS TEMP AFTER

04TAH7609 865 °C 1 30 5 1
DUCT BNR Hi HIGH
04TAH7612 865 °C 1 30 5 1
DUCT BNR Hi HIGH
04TAH7610 865 °C 1 30 5 1
DUCT BNR Hi HIGH
04TAH7613 865 °C 1 30 5 1
DUCT BNR Hi HIGH
04TAH8130 HR1 DESH I/L TEMP Hi HIGH 505 °C 1 30 5 1
04AIH8163 HR1 FEED WATER PH Hi HIGH 9.2 1 3 1

04TAH7608 865 °C 1 30 5 1
DUCT BNR Hi HIGH
04TAH7611 865 °C 1 30 5 1
DUCT BNR Hi HIGH
04TAH8134 HR1 Main Steam Temp Hi HIGH 513 °C 1 30 5 1
100 mm 5 10 5 1
04LAH8109 HR1 DRUM LEVEL Hi HIGH
108 Kg/Cm2 1 15 3 1
04PAH8137 HR1 MAIN STEAM PR Hi HIGH
04TAH8106 HR1 ECO O/L TEMP HIGH 300 °C 1 30 3 1
8.5 1 3 1
04AIL8168 HR1 MAIN STEAM PH Lo LOW
04AIL8166 HR1 DRUM WATER PH Lo LOW 9.1 1 3 1
04LILO8203 20 % 2 10 3 1
LVL Lo LOW
8.8 1 3 1
04AIL8163 HR1 FEED WATER PH Lo LOW
450 °C 1 30 3 1
04TAL8134 HR1 Main Steam Temp Lo LOW
04LAL8109 HR1 DRUM LEVEL LO LOW -100 mm 5 10 5 1
04TAL8144 HR1 SOOT BLOWER TEMP Lo LOW 250 °C 1 30 3 1
04PAL8137 HR1 MAIN STEAM PR Lo LOW 105 Kg/Cm2 1 15 3 1

VERY
175 mm 2 mm 4 1
04LAHH8109 HR1 DRUM LEVEL HH HIGH
9.5 1 10 3 1
05AIH8168 HR2 MAIN STEAM PH Hi HIGH
HR2 MAIN STEAM
6 µS/cm 1 10 3 1
05AIH8167 CONDUCTIVITY Hi HIGH
20 ppb 1 10 3 1
05AIH8169 HR2 MAIN STEAM SILICA Hi HIGH
HR2 DRUM WATER
20 µS/cm 1 10 3 1
05AIH8165 CONDUCTIVITY HIGH
HR2 FEED WATER
05AIH8162 6 µS/cm 1 10 3 1
CONDUCTIVITY HIGH
05AIH8164 20 ppb 1 10 3 1
HR2 FEED WATER SILICA HIGH

Revision 02
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05AIH8166 HR2 DRUM WATER PH Hi HIGH 10.1 1 10 3 1

05LIH8203 90 % 2 10 3 1
LVL Hi HIGH
05TAH7609 865 °C 1 30 5 1
DUCT BNR Hi HIGH
05TAH7612 865 °C 1 30 5 1
DUCT BNR Hi HIGH
05TAH7610 865 °C 1 30 5 1
DUCT BNR Hi HIGH
05TAH7613 865 °C 1 30 5 1
DUCT BNR Hi HIGH
505 °C 1 30 5 1
05TAH8130 HR2 DESH I/L TEMP Hi HIGH
9.2 1 3 1
05AIH8163 HR2 FEED WATER PH Hi HIGH
05TAH7608 865 °C 1 30 5 1
DUCT BNR Hi HIGH
05TAH7611 865 °C 1 30 5 1
DUCT BNR Hi HIGH
513 °C 1 30 5 1
05TAH8134 HR2 Main Steam Temp Hi HIGH
05LAH8109 HR2 DRUM LEVEL Hi HIGH 100 mm 5 10 5 1
05PAH8137 HR2 MAIN STEAM PR Hi HIGH 108 Kg/Cm2 1 15 3 1
05TAH8106 HR2 ECO O/L TEMP HIGH 300 °C 1 30 3 1
05AIL8168 HR2 MAIN STEAM PH Lo LOW 8.5 1 3 1
05AIL8166 9.1 1 3 1
HR2 DRUM WATER PH Lo LOW
05LILO8203 20 % 2 10 3 1
LVL Lo LOW
05AIL8163 HR2 FEED WATER PH Lo LOW 8.8 1 3 1
450 °C 1 30 3 1
05TAL8134 HR2 Main Steam Temp Lo LOW
-100 mm 5 10 5 1
05LAL8109 HR2 DRUM LEVEL LO LOW
05TAL8144 HR2 SOOT BLOWER TEMP Lo LOW 250 °C 1 30 3 1
105 Kg/Cm2 1 15 3 1
05PAL8137 HR2 MAIN STEAM PR Lo LOW
VERY
175 mm 2 mm 4 1
05LAHH8109 HR2 DRUM LEVEL HH HIGH
05LALL8109 HR2 DRUM LEVEL LL VERY LOW -505 mm 2 mm 4 1

UB1 MDFD MOTOR NDE BRG
95 ⁰C 1 0 5
06TI8661Hi TMP HI HIGH
UB1 MDFD MOTOR DE BRG TMP
95 ⁰C 1 0 5
06TI8663Hi HI HIGH
UB1 FDF MOTOR SIDE BRG TMP
95 ⁰C 1 0 5
06TI8664Hi HI HIGH

Revision 02
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06TI8665Hi UB1 FDF TURB. SIDE BRG TMP HI HIGH 95 ⁰C 1 0 5
95 ⁰C 1 0 5
06TI8662AHi UB1 MDFDF WDG TMP HI HIGH
95 ⁰C 1 0 5
06TI8662BHi UB1 MDFDF WDG TMP HI HIGH
06TI8662CHi UB1 MDFDF WDG TMP HI HIGH 95 ⁰C 1 0 5
06TI8662DHi UB1 MDFDF WDG TMP HI HIGH 95 ⁰C 1 0 5
95 ⁰C 1 0 5
06TI8662EHi UB1 MDFDF WDG TMP HI HIGH
06TI8662FHi UB1 MDFDF WDG TMP HI HIGH 95 ⁰C 1 0 5

06HLV10CP1
1.5 Kg/cm2 0.03 0 5
01Hi UB1 MDFDF LO PR HI HIGH
06HLV10CP1
0.5 Kg/cm2 0.1 15 1
02Hi UB1 MDFDF LO DP HI HIGH
06HLV10CL10 UB1 MDFDF LUBEOIL TANK LVL
70 % 5 15 3
1Hi HI HIGH
06TDFDFLOPr
1.8 Kg/cm2 0.036 15 3
1Hi UB1 TDFDF LO PR HI HIGH
06TDFDFLOPr
1.8 Kg/cm2 0.036 15 3
2Hi UB1 TDFDF LO PR HI HIGH
315 mmwc 6.3 15 5
06PI8673_Hi UB1 FURNACE PR HI HIGH
UB1 SCANNER SUCTION FILTER
15 mmwc 0.3 15 1
06PDSH8687 DP HI HIGH
06AI8738_hig
10.1 1 30 1
h UB1 pH FOR DRUM WATER HI HIGH
200 MM 5 0 5
06LAH8711 UB1 DRUM LVL1 HI HIGH
06LAH8712 UB1 DRUM LVL2 HI HIGH 200 MM 5 0 5
200 MM 5 0 5
06LAH8713 UB1 DRUM LVL3 HI HIGH
06DrumLevel UB1 DRUM LEVEL ACTUAL HI HIGH 200 MM 5 0 5
06TAH8732A UB1 MAIN STEAM TEMP HI HIGH 513 ⁰C 5.13 30 3
110 Kg/cm2 2.2 15 3

06PAH8729 UB1 MAIN STEAM PRESSURE HI HIGH
40 Kg/cm2 0.8 15 3
06PAH8744 UB1 SB STEAM PR. AFTER PCV HI HIGH
06TAH8664_ UB1 FDF MOTOR SIDE BRG TMP
95 ⁰C 1 0 5
RTD1 HI HIGH
06TAH8665_
95 ⁰C 1 0 5
RTD2 UB1 FDF TURB. SIDE BRG TMP HI HIGH
UB1 FDF DRV TURB GB BRG TMP
105 ⁰C 1.05 0 5
06TAH8669 HI HIGH
105 ⁰C 1.05 0 5
06TAH8670 HI HIGH
105 ⁰C 1.05 0 5
06TAH8671 HI HIGH

Revision 02
9112-575-OPR-701-00002 Page 15 of 92

105 ⁰C 1.05 0 5
06TAH8672 HI HIGH
105 ⁰C 1.05 0 5
06TAH8673 HI HIGH
105 ⁰C 1.05 0 5
06TAH8668A HI HIGH
06TDFDSpee
5200 RPM 0 5
dHi UB1 FDF DRV TURB SPEED HI HIGH
UB1 FDF DRV TURB DE BRG TMP
105 ⁰C 1.05 0 5
06TAH8666A HI HIGH
UB1 FDF DRV TURB NDE BRG
105 ⁰C 1.05 0 5
06TAH8667 TMP HI HIGH
57506AIHLM UB1 REGEN APH MAIN MOTOR
7 AMP 3 --
152 CURRENT HI HIGH
06AIH8735 UB1 SILICA FOR MAIN STEAM HI HIGH 20 ppb 1 30 1

UB1 MAIN STEAM
6 µs/cm 1 30 1
06AIH8737 CONDUCTIVITY HI HIGH
UB1 DRUM WATER
200 µs/cm 1 30 1
06AIH8739 CONDUCTIVITY HI HIGH
06AIH8736 UB1 pH FOR MAIN STEAM HI HIGH 9.5 1 30 1
06LAH8714 UB1 EDLI LEVEL HI HIGH 100 % 5 0 5

UB1 APH SUPT BERG COLD END
80 ⁰C 0.8 15 3
06TAH5351B TEMP HI HIGH
UB1 APH SUPT BERG HOT END
80 ⁰C 0.8 30 3
06TAH5351A TEMP HI HIGH
06TAH8705 UB1 TEMP AT ECO. O/L HI HIGH 300 ⁰C 3.008 30 3

UB1 PLATEN SH METAL TEMP-01
485 ⁰C 4.85 30 3
06TAH8719A HI HIGH
485 ⁰C 4.85 30 3
06TAH8719B HI HIGH
485 ⁰C 4.85 30 3
06TAH8719C HI HIGH
485 ⁰C 4.85 30 3
06TAH8719D HI HIGH
485 ⁰C 4.85 30 3
06TAH8719E HI HIGH
485 ⁰C 4.85 30 3
06TAH8719F HI HIGH
485 ⁰C 4.85 30 3
06TAH8719G HI HIGH
485 ⁰C 4.85 30 3
06TAH8719H HI HIGH
485 ⁰C 4.85 30 3
06TAH8719I HI HIGH
485 ⁰C 4.85 30 3
06TAH8719J HI HIGH
485 ⁰C 4.85 30 3
06TAH8719K HI HIGH

Revision 02
9112-575-OPR-701-00002 Page 16 of 92

485 ⁰C 4.85 30 3
06TAH8719L HI HIGH
485 ⁰C 4.85 30 3
06TAH8719M HI HIGH
485 ⁰C 4.85 30 3
06TAH8719N HI HIGH
485 ⁰C 4.85 30 3
06TAH8719O HI HIGH
UB1 FINAL SH METAL TEMP-01
573 ⁰C 5.73 30 3
06TAH8726A HI HIGH
573 ⁰C 5.73 30 3
06TAH8726B HI HIGH
573 ⁰C 5.73 30 3
06TAH8726C HI HIGH
573 ⁰C 5.73 30 3
06TAH8726D HI HIGH
573 ⁰C 5.73 30 3
06TAH8726E HI HIGH
573 ⁰C 5.73 30 3
06TAH8726F HI HIGH
573 ⁰C 5.73 30 3
06TAH8726G HI HIGH
573 ⁰C 5.73 30 3
06TAH8726H HI HIGH
573 ⁰C 5.73 30 3
06TAH8726I HI HIGH
573 ⁰C 5.73 30 3
06TAH8726J HI HIGH
573 ⁰C 5.73 30 3
06TAH8726K HI HIGH
UB1 DRUM MTM
330 ⁰C 3.3 30 3
06TAH8746 (RIGHT)BOTTOM HI HIGH
UB1 DRUM MTM
330 ⁰C 3.3 30 3
06TAH8726M (LEFT)BOTTOM HI HIGH
06TAH8726L UB1 DRUM MTM (RIGHT)TOP HI HIGH 330 ⁰C 3.3 30 3 --
06TAH8726R UB1 DRUM MTM (LEFT)TOP HI HIGH 330 ⁰C 3.3 30 3 --

UB1 FDF DRV TURB LO TNK LVL
90 % 5 30 3 --
06TDLOLvlHi HI HIGH
06TDLOClrTm UB1 FDF DRV TURB LO TMP AFT
70 ⁰C 0.7 0 5
pHi COOLER HI HIGH
UB1 FDF DRV TURB LO FILT DP
0.6 kg/cm2 0.012 15 1
06TDLODPHi HI HIGH
315 ⁰C 3.15 30 3
06TAH5352 UB1 FLUE GAS O/L TEMP-1 HI HIGH
315 ⁰C 3.15 30 3
315 ⁰C 3.15 30 3
06TAH5355 UB1 FLUE GAS O/L TEMP-4 HI HIGH 315 ⁰C 3.15 30 3

Revision 02
9112-575-OPR-701-00002 Page 17 of 92
315 ⁰C 3.15 30 3
06TAH5357 UB1 SEC AIR O/L TEMP-1 HI HIGH
315 ⁰C 3.15 30 3
06TAH5359 UB1 SEC AIR O/L TEMP-3 HI HIGH 315 ⁰C 3.15 30 3
315 ⁰C 3.15 0 3
06PAH8672 1 UB1 FURNACE PR-1 HI HIGH 315 MMWC 6.3 0 5
315 MMWC 6.3 0 5

06PAH8672 3 UB1 FURNACE PR-3 HI HIGH
06HLV10CP1
0.6 Kg/cm2 0.012 0 5
01Lo UB1 MDFDF LO PR LO LOW
30 % 5 0 3
1Lo LO LOW
06TDFDFLOPr
1 Kg/cm2 0.01 0 5
1Lo UB1 TDFDF LO PR LO LOW
06TDFDFLOPr
1 Kg/cm2 0.01 0 5
2Lo UB1 TDFDF LO PR LO LOW
06AI8738_LO
9.1 1 30 1
W UB1 pH FOR DRUM WATER LO LOW
-150 % 5 0 5
06LAL8711 UB1 DRUM LVL1 LO LOW
06LAL8712 UB1 DRUM LVL2 LO LOW -150 % 5 0 5
-150 % 5 0 5
06LAL8713 UB1 DRUM LVL3 LO LOW
06DrumLevel UB1 DRUM LEVEL ACTUAL LO LOW -100 % 5 0 5

06FAL8669A_
120 TPH 6 0 5
Flow UB1 COMBUSTION AIR FLOW LO LOW
06FAL8669B_
120 TPH 6 0 5
06FAL8669C_
120 TPH 6 0 5
06UBAirFlow
120 TPH 6 0 5
Act Lo UB1 AIR FLOW ACTUAL LO LOW
06TAL8732A UB1 MAIN STEAM TEMP LO LOW 480 ⁰C 4.8 30 3
100 Kg/cm2 2 15 3
06PAL8729 UB1 MAIN STEAM PRESSURE LO LOW
06TDFDSpee
4950 RPM 15 3
dLo UB1 FDF DRV TURB SPEED LO LOW
UB1 TEMP AT LRSB SB DRAIN
220 ⁰C 2.2 30 1
06TAL8751 LINE LO LOW
UB1 TEMP AT RAPH SB DRAIN
220 ⁰C 2.2 30 1
06TAL8749 LINE LO LOW

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06AIL8736 UB1 pH FOR MAIN STEAM LO LOW 8.5 1 30 1
-150 % 5 0 5
06LAL8714 UB1 EDLI LEVEL LO LOW
30 % 5 10 3
06TDLOLvlLo LO LOW
UB1 SCANNER DISCHARGE TO
150 mmwc 3 15 3
06PDAL8688 FURNACE DP LO LOW
105 ⁰C 1.05 0 4
06TI8661VHi TMP HI HI V HIGH
105 ⁰C 1.05 0 4
06TI8663VHi HI HI V HIGH
105 ⁰C 1.05 0 4
06TI8664VHi HI HI V HIGH
UB1 FDF TURB. SIDE BRG TMP HI
105 ⁰C 1.05 0 4
06TI8665VHi HI V HIGH
06HLV10CP1
2.2 Kg/cm2 0.044 0 4
01VHi UB1 MDFDF LO PR HI HI V HIGH
06TI8662AVH
105 1.05 0 4
i UB1 MDFDF WDG TMP HI HI V HIGH
06TI8662BVH
105 ⁰C 1.05 0 4
06TI8662CVH
105 ⁰C 1.05 0 4
06TI8662DVH
105 ⁰C 1.05 0 4
06TI8662EVH
105 ⁰C 1.05 0 4
105 ⁰C 1.05 0 4
06TI8662FVHi UB1 MDFDF WDG TMP HI HI V HIGH
450 % 5 0 4
06LAHH8711 UB1 DRUM LVL1 V HI V HIGH
06LAHH8712 UB1 DRUM LVL2 V HI V HIGH 450 % 5 0 4
06DrumLevel UB1 DRUM LEVEL ACTUAL HI HI V HIGH 450 % 5 0 4 ,--

06TAHH8664 UB1 FDF MOTOR SIDE BRG TMP
105 ⁰C 1.05 0 4
_RTD1 HI HI V HIGH
06TAHH8665 UB1 FDF TURB. SIDE BRG TMP HI
105 ⁰C 1.05 0 4
_RTD2 HI V HIGH
115 ⁰C 1.15 0 4
06TAHH8669 HIHI V HIGH
115 ⁰C 1.15 0 4
115 ⁰C 1.15 0 4
115 ⁰C 1.15 0 4
115 ⁰C 1.15 0 4

Revision 02
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06TAHH8668 UB1 FDF DRV TURB GB BRG TMP

115 ⁰C 1.15 0 4
A HIHI V HIGH
06TDFDSpee
5600 RPM 0 4
dVHi UB1 FDF DRV TURB SPEED HI HI V HIGH
06TAHH8666 UB1 FDF DRV TURB DE BRG TMP
125 ⁰C 1.25 0 4
A HI HI V HIGH
125 ⁰C 1.25 0 4
06TAHH8667 TMP HI HI V HIGH
90 % 5 0 4
1VHi HI HI V HIGH
06PAHH8672
350 MMWC 7 0 4
1 UB1 FURNACE PR-1 HI HI V HIGH
06PAHH8672
350 MMWC 7 0 4
06PAHH8672
350 MMWC 7 0 4
75 ⁰C 0.75 0 4
pVHi COOLER HI HI V HIGH
20 % 5 30 4
1VLo LO LO V LOW
06TDFDFLOPr
0.6 Kg/cm2 0.012 0 4
1VLo UB1 TDFDF LO PR V LO V LOW
06TDFDFLOPr
0.6 Kg/cm2 0.012 0 4
2VLo UB1 TDFDF LO PR V LO V LOW
06LALL8711 UB1 DRUM LVL1 V LO V LOW -250 % 5 0 4
-250 % 5 0 4
06LALL8713 UB1 DRUM LVL3 V LO V LOW
-250 % 5 0 4 --
06DrumLevel UB1 DRUM LEVEL ACTUAL LO LO V LOW
06FALL8669A UB1 COMBUSTION AIR FLOW LO
78 TPH 3.9 0 4
_Flow LO V LOW
06HLV10CP1
0.2 Kg/cm2 0.004 0 4
01V Lo UB1 MDFDF LO PR LO LO V LOW
06FALL8669B UB1 COMBUSTION AIR FLOW LO
78 TPH 3.9 0 4
_Flow LO V LOW
06FALL8669C UB1 COMBUSTION AIR FLOW LO
78 TPH 3.9 0 4
_Flow LO V LOW
07TI8661Hi HIGH 95 ⁰C 1 0 5
TMP HI
07TI8663Hi HIGH 95 ⁰C 1 0 5
HI
07TI8664Hi HIGH 95 ⁰C 1 0 5
HI
07TI8662AHi UB2 MDFDF WDG TMP HI HIGH 95 ⁰C 1 0 5
07TI8662BHi UB2 MDFDF WDG TMP HI HIGH 95 ⁰C 1 0 5

Revision 02
9112-575-OPR-701-00002 Page 20 of 92
07TI8662EHi UB2 MDFDF WDG TMP HI HIGH 95 ⁰C 1 0 5

07HLV10CP1
UB2 MDFDF LO PR HI HIGH 1.5 Kg/cm2 0.03 0 5
01Hi
07HLV10CP1
UB2 MDFDF LO DP HI HIGH 0.5 Kg/cm2 0.1 15 1
02Hi
HIGH 70 % 5 15 3
1Hi HI
07TDFDFLOPr
UB2 TDFDF LO PR HI HIGH 1.8 Kg/cm2 0.036 15 3
1Hi
07TDFDFLOPr
2Hi
07PI8673_Hi UB2 FURNACE PR HI HIGH 315 mmwc 6.3 15 5
07PDSH8687 HIGH 15 mmwc 0.3 15 1
DP HI
07AI8738_hig
UB2 pH FOR DRUM WATER HI HIGH 10.1 1 30 1
h
07PAH8729 UB2 MAIN STEAM PRESSURE HI HIGH 110 Kg/cm2 2.2 15 3
07PAH8744 UB2 SB STEAM PR. AFTER PCV HI HIGH 40 Kg/cm2 0.8 15 3

HIGH 95 ⁰C 1 0 5
RTD1 HI
07TAH8665_
UB2 FDF TURB. SIDE BRG TMP HI HIGH 95 ⁰C 1 0 5
RTD2
07TAH8669 HIGH 105 ⁰C 1.05 0 5
HI
07TAH8670 HIGH 105 ⁰C 1.05 0 5
HI
07TAH8671 HIGH 105 ⁰C 1.05 0 5
HI
07TAH8672 HIGH 105 ⁰C 1.05 0 5
HI
07TAH8673 HIGH 105 ⁰C 1.05 0 5
HI
07TAH8668A HIGH 105 ⁰C 1.05 0 5
HI
Revision 02
9112-575-OPR-701-00002 Page 21 of 92
07TDFDSpee
UB2 FDF DRV TURB SPEED HI HIGH 5200 RPM 0 5
dHi
07TAH8666A HIGH 105 ⁰C 1.05 0 5
HI
07TAH8667 HIGH 105 ⁰C 1.05 0 5
TMP HI
HIGH 7 AMP 3 --
152 CURRENT HI
UB2 MAIN STEAM
07AIH8737 HIGH 6 µs/cm 1 30 1
CONDUCTIVITY HI
UB2 DRUM WATER
07AIH8739 HIGH 200 µs/cm 1 30 1
CONDUCTIVITY HI

07TAH5351B HIGH 80 ⁰C 0.8 15 3
TEMP HI
07TAH5351A HIGH 80 ⁰C 0.8 30 3
TEMP HI
07TAH8719A HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719B HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719C HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719D HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719E HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719F HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719G HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719H HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719I HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719J HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719K HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719L HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719M HIGH 485 ⁰C 4.85 30 3
HI
07TAH8719N HIGH 485 ⁰C 4.85 30 3
HI

Revision 02
9112-575-OPR-701-00002 Page 22 of 92

07TAH8719O HIGH 485 ⁰C 4.85 30 3
HI
07TAH8726A HIGH 573 ⁰C 5.73 30 3
HI
07TAH8726B HIGH 573 ⁰C 5.73 30 3
HI
07TAH8726C HIGH 573 ⁰C 5.73 30 3
HI
07TAH8726D HIGH 573 ⁰C 5.73 30 3
HI
07TAH8726E HIGH 573 ⁰C 5.73 30 3
HI
07TAH8726F HIGH 573 ⁰C 5.73 30 3
HI
07TAH8726G HIGH 573 ⁰C 5.73 30 3
HI
07TAH8726H HIGH 573 ⁰C 5.73 30 3
HI
07TAH8726I HIGH 573 ⁰C 5.73 30 3
HI
07TAH8726J HIGH 573 ⁰C 5.73 30 3
HI
07TAH8726K HIGH 573 ⁰C 5.73 30 3
HI
UB2 DRUM MTM
07TAH8746 HIGH 330 ⁰C 3.3 30 3
(RIGHT)BOTTOM HI
UB2 DRUM MTM
07TAH8726M HIGH 330 ⁰C 3.3 30 3
(LEFT)BOTTOM HI

07TDLOLvlHi HIGH 90 % 5 30 3 --
HI
HIGH 70 ⁰C 0.7 0 5
pHi COOLER HI
07TDLODPHi HIGH 0.6 kg/cm2 0.012 15 1
HI

Revision 02
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07HLV10CP1
UB2 MDFDF LO PR LO LOW 0.6 Kg/cm2 0.012 0 5
01Lo
LOW 30 % 5 0 3
1Lo LO
07TDFDFLOPr
UB2 TDFDF LO PR LO LOW 1 Kg/cm2 0.01 0 5
1Lo
07TDFDFLOPr
2Lo
07AI8738_LO
UB2 pH FOR DRUM WATER LO LOW 9.1 1 30 1
W

07FAL8669A_
UB2 COMBUSTION AIR FLOW LO LOW 120 TPH 6 0 5
Flow
07FAL8669B_
Flow
07FAL8669C_
Flow
07UBAirFlow
UB2 AIR FLOW ACTUAL LO LOW 120 TPH 6 0 5
Act Lo
07PAL8729 UB2 MAIN STEAM PRESSURE LO LOW 100 Kg/cm2 2 15 3

07TDFDSpee
UB2 FDF DRV TURB SPEED LO LOW 4950 RPM 15 3
dLo
07TAL8751 LOW 220 ⁰C 2.2 30 1
LINE LO
07TAL8749 LOW 220 ⁰C 2.2 30 1
LINE LO
07LAL8714 UB2 EDLI LEVEL LO LOW -150 % 5 0 5

07TDLOLvlLo LOW 30 % 5 10 3
LO

Revision 02
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07PDAL8688 LOW 150 mmwc 3 15 3
FURNACE DP LO
07TI8661VHi V HIGH 105 ⁰C 1.05 0 4
TMP HI HI
07TI8663VHi V HIGH 105 ⁰C 1.05 0 4
HI HI
07TI8664VHi V HIGH 105 ⁰C 1.05 0 4
HI HI
07TI8665VHi V HIGH 105 ⁰C 1.05 0 4
HI
07HLV10CP1
UB2 MDFDF LO PR HI HI V HIGH 2.2 Kg/cm2 0.044 0 4
01VHi
07TI8662AVH
UB2 MDFDF WDG TMP HI HI V HIGH 105 1.05 0 4
i
07TI8662BVH
UB2 MDFDF WDG TMP HI HI V HIGH 105 ⁰C 1.05 0 4
i
07TI8662CVH
i
07TI8662DVH
i
07TI8662EVH
i
07TI8662FVHi UB2 MDFDF WDG TMP HI HI V HIGH 105 ⁰C 1.05 0 4

V HIGH 105 ⁰C 1.05 0 4
_RTD1 HI HI
V HIGH 105 ⁰C 1.05 0 4
_RTD2 HI
07TAHH8669 V HIGH 115 ⁰C 1.15 0 4
HIHI
07TAHH8670 V HIGH 115 ⁰C 1.15 0 4
HIHI
07TAHH8671 V HIGH 115 ⁰C 1.15 0 4
HIHI
07TAHH8672 V HIGH 115 ⁰C 1.15 0 4
HIHI
07TAHH8673 V HIGH 115 ⁰C 1.15 0 4
HIHI
V HIGH 115 ⁰C 1.15 0 4
A HIHI
07TDFDSpee
UB2 FDF DRV TURB SPEED HI HI V HIGH 5600 RPM 0 4
dVHi
V HIGH 125 ⁰C 1.25 0 4
A HI HI

Revision 02
9112-575-OPR-701-00002 Page 25 of 92

07TAHH8667 V HIGH 125 ⁰C 1.25 0 4
TMP HI HI
V HIGH 90 % 5 0 4
1VHi HI HI
07PAHH8672
UB2 FURNACE PR-1 HI HI V HIGH 350 MMWC 7 0 4
1
07PAHH8672
2
07PAHH8672
3
V HIGH 75 ⁰C 0.75 0 4
pVHi COOLER HI HI
V LOW 20 % 5 30 4
1VLo LO LO
07TDFDFLOPr
UB2 TDFDF LO PR V LO V LOW 0.6 Kg/cm2 0.012 0 4
1VLo
07TDFDFLOPr
2VLo
07DrumLevel UB2 DRUM LEVEL ACTUAL LO LO V LOW -250 % 5 0 4 --

V LOW 78 TPH 3.9 0 4
_Flow LO
07HLV10CP1
UB2 MDFDF LO PR LO LO V LOW 0.2 Kg/cm2 0.004 0 4
01V Lo
V LOW 78 TPH 3.9 0 4
_Flow LO
V LOW 78 TPH 3.9 0 4
_Flow LO
08TI8661Hi HIGH 95 ⁰C 1 0 5
TMP HI
08TI8663Hi HIGH 95 ⁰C 1 0 5
HI
08TI8664Hi HIGH 95 ⁰C 1 0 5
HI

Revision 02
9112-575-OPR-701-00002 Page 26 of 92

08HLV10CP1
01Hi
08HLV10CP1
UB3 MDFDF LO DP HI HIGH 0.5 Kg/cm2 0.1 15 1
02Hi
HIGH 70 % 5 15 3
1Hi HI
08TDFDFLOPr
1Hi
08TDFDFLOPr
2Hi
08PDSH8687 HIGH 15 mmwc 0.3 15 1
DP HI
08AI8738_hig
h

HIGH 95 ⁰C 1 0 5
RTD1 HI
08TAH8665_
RTD2
08TAH8669 HIGH 105 ⁰C 1.05 0 5
HI
08TAH8670 HIGH 105 ⁰C 1.05 0 5
HI
08TAH8671 HIGH 105 ⁰C 1.05 0 5
HI
08TAH8672 HIGH 105 ⁰C 1.05 0 5
HI
08TAH8673 HIGH 105 ⁰C 1.05 0 5
HI
08TAH8668A HIGH 105 ⁰C 1.05 0 5
HI
08TDFDSpee
dHi
08TAH8666A HIGH 105 ⁰C 1.05 0 5
HI

Revision 02
9112-575-OPR-701-00002 Page 27 of 92

08TAH8667 HIGH 105 ⁰C 1.05 0 5
TMP HI
HIGH 7 AMP 3 --
152 CURRENT HI
UB3 MAIN STEAM
08AIH8737 HIGH 6 µs/cm 1 30 1
CONDUCTIVITY HI
UB3 DRUM WATER
08AIH8739 HIGH 200 µs/cm 1 30 1
CONDUCTIVITY HI

08TAH5351B HIGH 80 ⁰C 0.8 15 3
TEMP HI
08TAH5351A HIGH 80 ⁰C 0.8 30 3
TEMP HI
08TAH8719A HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719B HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719C HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719D HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719E HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719F HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719G HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719H HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719I HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719J HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719K HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719L HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719M HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719N HIGH 485 ⁰C 4.85 30 3
HI
08TAH8719O HIGH 485 ⁰C 4.85 30 3
HI
08TAH8726A HIGH 573 ⁰C 5.73 30 3
HI

Revision 02
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08TAH8726B HIGH 573 ⁰C 5.73 30 3
HI
08TAH8726C HIGH 573 ⁰C 5.73 30 3
HI
08TAH8726D HIGH 573 ⁰C 5.73 30 3
HI
08TAH8726E HIGH 573 ⁰C 5.73 30 3
HI
08TAH8726F HIGH 573 ⁰C 5.73 30 3
HI
08TAH8726G HIGH 573 ⁰C 5.73 30 3
HI
08TAH8726H HIGH 573 ⁰C 5.73 30 3
HI
08TAH8726I HIGH 573 ⁰C 5.73 30 3
HI
08TAH8726J HIGH 573 ⁰C 5.73 30 3
HI
08TAH8726K HIGH 573 ⁰C 5.73 30 3
HI
UB3 DRUM MTM
08TAH8746 HIGH 330 ⁰C 3.3 30 3
(RIGHT)BOTTOM HI
UB3 DRUM MTM
08TAH8726M HIGH 330 ⁰C 3.3 30 3
(LEFT)BOTTOM HI

08TDLOLvlHi HIGH 90 % 5 30 3 --
HI
HIGH 70 ⁰C 0.7 0 5
pHi COOLER HI
08TDLODPHi HIGH 0.6 kg/cm2 0.012 15 1
HI

Revision 02
9112-575-OPR-701-00002 Page 29 of 92

08HLV10CP1
01Lo
LOW 30 % 5 0 3
1Lo LO
08TDFDFLOPr
1Lo
08TDFDFLOPr
2Lo
08AI8738_LO
W

08FAL8669A_
Flow
08FAL8669B_
Flow
08FAL8669C_
Flow
08UBAirFlow
Act Lo

08TDFDSpee
dLo
08TAL8751 LOW 220 ⁰C 2.2 30 1
LINE LO
08TAL8749 LOW 220 ⁰C 2.2 30 1
LINE LO

08TDLOLvlLo LOW 30 % 5 10 3
LO
08PDAL8688 LOW 150 mmwc 3 15 3
FURNACE DP LO
08TI8661VHi V HIGH 105 ⁰C 1.05 0 4
TMP HI HI
08TI8663VHi UB3 MDFD MOTOR DE BRG TMP V HIGH 105 ⁰C 1.05 0 4

Revision 02
9112-575-OPR-701-00002 Page 30 of 92
HI HI

08TI8664VHi V HIGH 105 ⁰C 1.05 0 4
HI HI
08TI8665VHi V HIGH 105 ⁰C 1.05 0 4
HI
08HLV10CP1
01VHi
08TI8662AVH
UB3 MDFDF WDG TMP HI HI V HIGH 105 1.05 0 4
i
08TI8662BVH
i
08TI8662CVH
i
08TI8662DVH
i
08TI8662EVH
i

V HIGH 105 ⁰C 1.05 0 4
_RTD1 HI HI
V HIGH 105 ⁰C 1.05 0 4
_RTD2 HI
08TAHH8669 V HIGH 115 ⁰C 1.15 0 4
HIHI
08TAHH8670 V HIGH 115 ⁰C 1.15 0 4
HIHI
08TAHH8671 V HIGH 115 ⁰C 1.15 0 4
HIHI
08TAHH8672 V HIGH 115 ⁰C 1.15 0 4
HIHI
08TAHH8673 V HIGH 115 ⁰C 1.15 0 4
HIHI
V HIGH 115 ⁰C 1.15 0 4
A HIHI
08TDFDSpee
dVHi
V HIGH 125 ⁰C 1.25 0 4
A HI HI
08TAHH8667 V HIGH 125 ⁰C 1.25 0 4
TMP HI HI
V HIGH 90 % 5 0 4
1VHi HI HI

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08PAHH8672
1
08PAHH8672
2
08PAHH8672
3
V HIGH 75 ⁰C 0.75 0 4
pVHi COOLER HI HI
V LOW 20 % 5 30 4
1VLo LO LO
08TDFDFLOPr
1VLo
08TDFDFLOPr
2VLo

V LOW 78 TPH 3.9 0 4
_Flow LO
08HLV10CP1
01V Lo
V LOW 78 TPH 3.9 0 4
_Flow LO
V LOW 78 TPH 3.9 0 4
_Flow LO
09TI8661Hi
TMP HI
HIGH 95 ⁰C 1 0 5
09TI8663Hi
HI
HIGH 95 ⁰C 1 0 5
09TI8664Hi
HI
HIGH 95 ⁰C 1 0 5
09HLV10CP1
01Hi
09HLV10CP1 UB4 MDFDF LO DP HI HIGH 0.5 Kg/cm2 0.1 15 1
Revision 02
9112-575-OPR-701-00002 Page 32 of 92
02Hi

1Hi HI
HIGH 70 % 5 15 3
09TDFDFLOPr
1Hi
09TDFDFLOPr
2Hi
09PDSH8687
DP HI
HIGH 15 mmwc 0.3 15 1
09AI8738_hig
h
RTD1 HI
HIGH 95 ⁰C 1 0 5
09TAH8665_
RTD2
09TAH8669
HI
HIGH 105 ⁰C 1.05 0 5
09TAH8670
HI
HIGH 105 ⁰C 1.05 0 5
09TAH8671
HI
HIGH 105 ⁰C 1.05 0 5
09TAH8672
HI
HIGH 105 ⁰C 1.05 0 5
09TAH8673
HI
HIGH 105 ⁰C 1.05 0 5
09TAH8668A
HI
HIGH 105 ⁰C 1.05 0 5
09TDFDSpee
dHi
09TAH8666A
HI
HIGH 105 ⁰C 1.05 0 5
09TAH8667
TMP HI
HIGH 105 ⁰C 1.05 0 5
152 CURRENT HI
HIGH 7 AMP 3 --

Revision 02
9112-575-OPR-701-00002 Page 33 of 92

UB4 MAIN STEAM
09AIH8737
CONDUCTIVITY HI
HIGH 6 µs/cm 1 30 1
UB4 DRUM WATER
09AIH8739
CONDUCTIVITY HI
HIGH 200 µs/cm 1 30 1
09TAH5351B
TEMP HI
HIGH 80 ⁰C 0.8 15 3
09TAH5351A
TEMP HI
HIGH 80 ⁰C 0.8 30 3
09TAH8719A
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719B
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719C
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719D
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719E
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719F
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719G
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719H
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719I
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719J
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719K
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719L
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719M
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719N
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8719O
HI
HIGH 485 ⁰C 4.85 30 3
09TAH8726A
HI
HIGH 573 ⁰C 5.73 30 3
09TAH8726B
HI
HIGH 573 ⁰C 5.73 30 3
09TAH8726C
HI
HIGH 573 ⁰C 5.73 30 3

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09TAH8726D
HI
HIGH 573 ⁰C 5.73 30 3
09TAH8726E
HI
HIGH 573 ⁰C 5.73 30 3
09TAH8726F
HI
HIGH 573 ⁰C 5.73 30 3
09TAH8726G
HI
HIGH 573 ⁰C 5.73 30 3
09TAH8726H
HI
HIGH 573 ⁰C 5.73 30 3
09TAH8726I
HI
HIGH 573 ⁰C 5.73 30 3
09TAH8726J
HI
HIGH 573 ⁰C 5.73 30 3
09TAH8726K
HI
HIGH 573 ⁰C 5.73 30 3
UB4 DRUM MTM
09TAH8746
(RIGHT)BOTTOM HI
HIGH 330 ⁰C 3.3 30 3
UB4 DRUM MTM
09TAH8726M
(LEFT)BOTTOM HI
HIGH 330 ⁰C 3.3 30 3
09TDLOLvlHi
HI
HIGH 90 % 5 30 3 --
pHi COOLER HI
HIGH 70 ⁰C 0.7 0 5
09TDLODPHi
HI
HIGH 0.6 kg/cm2 0.012 15 1

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09HLV10CP1
01Lo
1Lo LO
LOW 30 % 5 0 3
09TDFDFLOPr
1Lo
09TDFDFLOPr
2Lo
09AI8738_LO
W
09FAL8669A_
Flow
09FAL8669B_
Flow
09FAL8669C_
Flow
09UBAirFlow
Act Lo
09TDFDSpee
dLo
09TAL8751
LINE LO
LOW 220 ⁰C 2.2 30 1
09TAL8749
LINE LO
LOW 220 ⁰C 2.2 30 1
09TDLOLvlLo
LO
LOW 30 % 5 10 3
09PDAL8688
FURNACE DP LO
LOW 150 mmwc 3 15 3
09TI8661VHi
TMP HI HI
V HIGH 105 ⁰C 1.05 0 4
09TI8663VHi
HI HI
V HIGH 105 ⁰C 1.05 0 4
09TI8664VHi
HI HI
V HIGH 105 ⁰C 1.05 0 4

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09TI8665VHi
HI
V HIGH 105 ⁰C 1.05 0 4
09HLV10CP1
01VHi
09TI8662AVH
i
09TI8662BVH
i
09TI8662CVH
i
09TI8662DVH
i
09TI8662EVH
i
_RTD1 HI HI
V HIGH 105 ⁰C 1.05 0 4
_RTD2 HI
V HIGH 105 ⁰C 1.05 0 4
09TAHH8669
HIHI
V HIGH 115 ⁰C 1.15 0 4
09TAHH8670
HIHI
V HIGH 115 ⁰C 1.15 0 4
09TAHH8671
HIHI
V HIGH 115 ⁰C 1.15 0 4
09TAHH8672
HIHI
V HIGH 115 ⁰C 1.15 0 4
09TAHH8673
HIHI
V HIGH 115 ⁰C 1.15 0 4
A HIHI
V HIGH 115 ⁰C 1.15 0 4
09TDFDSpee
dVHi
A HI HI
V HIGH 125 ⁰C 1.25 0 4
09TAHH8667
TMP HI HI
V HIGH 125 ⁰C 1.25 0 4
1VHi HI HI
V HIGH 90 % 5 0 4
09PAHH8672
1
09PAHH8672
2

Revision 02
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09PAHH8672
3
pVHi COOLER HI HI
V HIGH 75 ⁰C 0.75 0 4
1VLo LO LO
V LOW 20 % 5 30 4
09TDFDFLOPr
1VLo
09TDFDFLOPr
2VLo
_Flow LO
V LOW 78 TPH 3.9 0 4
09HLV10CP1
01V Lo
_Flow LO
V LOW 78 TPH 3.9 0 4
_Flow LO
V LOW 78 TPH 3.9 0 4
520 °C 5.2 30 3
01TAH3101 VHP STEAM TO STG1 TEMP HI HIGH
520 °C 5.2 30 3
02TAH3101 VHP STEAM TO STG2 TEMP HI HIGH
03TAH3601 VHP STEAM TO STG3 TEMP HI HIGH 520 °C 5.2 30 3

HP STEAM I/L TEMP. TO TD BFP
390 °C 3.9 30 3
10TAH4101 HI HIGH
STG HP EXTN TEMP AFT ATTEM
385 °C 3.85 30 1
10TAH1202 HI HIGH
MP STEAM TEMP. AFTER PRDS
280 °C 2.55 30 1
10TAH1207 HI HIGH
MPDT EXHAUST AFT. DSH
280 °C 2.55 30 1
TD MOP LP EXHAUST AFT. DSH
180 °C 1.8 30 1
TD FD LP EXHAUST AFTER DSH
180 °C 1.8 30 1
STG MP EXTN TEMP AFT ATTEM
280 °C 2.6 30 1
10TAH1302 HI HIGH
180 °C 1.8 30 1
10TAH1309 LP PRDS O/L AFT. DSH TEMP HI HIGH
BPTG LP EXHAUST TEMP AFT
180 °C 1.8 30 1
10TAH1402 ATTEM HI HIGH
LP STEAM TO AIR COND SYS AFT
143 °C 1.4 30 1
10TAH1415 DESH TEMP HI HIGH

Revision 02
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LP STEAM HDR TMP AFT

190 °C 1.9 30 1
10TAH1421 BLENDING HI HIGH
10TAH1305 MP STM TO REFINERY TEMP HI HIGH 280 °C 2.6 30 1
10PAH4113A TD BFP MP Exhaust PR HI HIGH 13.3 Kg/Cm2 0.3 0 5
10PAH4113B TD BFP MP Exhaust PR HI HIGH 13.3 Kg/Cm2 0.3 0 5
10PAH4113C TD BFP MP Exhaust PR HI HIGH 13.3 Kg/Cm2 0.3 0 5
112 Kg/Cm2 2.2 15 3

01PAH3102 VHP STEAM TO STG1 PR. HI HIGH
112 Kg/Cm2 2.2 15 3
112 Kg/Cm2 2.2 15 3
10PAH4101 HP STM I/L TO TD BFP PR HI HIGH 40 Kg/Cm2 0.8 15 3
10PAH1112 VHP HDR PR HI HIGH 115 Kg/Cm2 2.3 15 3
10PAH1113 HP STM HDR AFT PRDS PR HI HIGH 40 Kg/Cm2 0.8 15 1
10PAH1407 FEED WTR STG TANK PR HI HIGH 2.6 Kg/Cm2 0.1 15 3
190 °C 1.9 30 3
10TAH1406 LP STM TO REFINERY TEMP HI HIGH
1.6 Kg/Cm2 0.0 15 1
10PAH1410 LP STM PR. TO LP HEATER HI HIGH
10TAH1115 HP STEAM TEMP. AFTER PRDS HI HIGH 390 °C 3.9 30 1

10FI1204_Flo
218 m3/hr 11.0 10 1
w HP STM TO REFINERY FLOW HI HIGH
390 °C 3.9 30 3
10TAH1204 HP STM TO REFINERY TEMP HI HIGH
01TAL3101 VHP STEAM TO STG1 TEMP LO LOW 495 °C 4.95 30 3

HP Steam I/L TEMP. TO TD BFP
340 °C 3.4 30 3
10TAL4101 LO LOW
HP STEAM TEMP. AFTER PRDS
340 °C 3.4 30 1
10TAL1115 LO LOW
STG HP EXTN TEMP AFT ATTEM
375 °C 3.8 30 1
10TAL1202 LO LOW
MP STEAM TEMP. AFTER PRDS
240 °C 2.45 30 1
10TAL1207 LO LOW
MPDT EXHAUST AFT. DSH TEMP
240 °C 2.4 30 1
10TAL1219 LO LOW
TD MOP LP EXHAUST AFT. DSH
160 °C 1.6 30 1
10TAL1254 TEMP LO LOW
TD FD LP EXHAUST AFTER DSH
170 °C 1.7 30 1
10TAL1271 TEMP LO LOW

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STG MP EXTN TEMP AFT ATTEM

240 °C 2.4 30 1
10TAL1302 LO LOW
10TAL1309 LP PRDS O/L AFT. DSH TEMP LO LOW 170 °C 1.7 30 1

BPTG LP EXHAUST TEMP AFT
160 °C 1.6 30 1
10TAL1402 ATTEM LO LOW
LP STEAM TO AIR COND SYS AFT
123 °C 1.2 30 1
10TAL1415 DESH TEMP LO LOW
LP Steam HDR TMP AFT
170 °C 1.7 30 1
10TAL1421 Blending LO LOW
10PAL4113A TD BFP MP Exhaust PR LO LOW 10.7 Kg/Cm2 0.2 0 5
10PAL4113B TD BFP MP Exhaust PR LO LOW 10.7 Kg/Cm2 0.2 0 5
10.7 Kg/Cm2 0.2 0 5

10PAL4113C TD BFP MP Exhaust PR LO LOW
100 Kg/Cm2 2 15 3
01PAL3102 VHP STEAM TO STG1 PR. LO LOW
02PAL3102 VHP STEAM TO STG2 PR. LO LOW 100 Kg/Cm2 2 15 3
03PAL3602 VHP STEAM TO STG3 PR. LO LOW 100 Kg/Cm2 2 15 3
10PAL4101 HP STM I/L TO TD BFP PR LO LOW 35 Kg/Cm2 0.7 15 3
10PAL1112 VHP HDR PR LO LOW 100 Kg/Cm2 2 15 3
45 Kg/Cm2 0.9 15 1
10PAL1114 VHP BFP SPRY WTR LINE PR LOW
12 Kg/Cm2 0.24 15 3
10PAL1118 HP STM TO AUX.STM HDR PR LO LOW
STG HP EXTRACTION
ATTEMPERATION LINE AFT. PCV 45 Kg/Cm2 0.9 15 1
10PAL1201 PR. LO LOW
MP PRDS ATTEMPERATION LINE
18 Kg/Cm2 0.36 15 1
10PAL1208 AFT. PCV PR. LO LOW
MPDT O/L ATTEMPERATION
18 Kg/Cm2 0.4 15 1
10PAL1220 LINE AFT. PCV PR. LO LOW
TD MOP O/L ATTEMPERATION
10 Kg/Cm2 0.2 15 1
TD FD O/L ATTEMPERATION
10 Kg/Cm2 0.2 15 1
LP PRDS O/L ATTEMPERATION
10 Kg/Cm2 0.2 15 1
10PAL1308 AFT. PCV PR. LO LOW
BPTG LP EXHAUST
ATTEMPERATION LINE AFT. PCV 10 Kg/Cm2 0.2 15 1
10PAL1401 PR. LO LOW
10PAL1407 FEED WTR STG TANK PR LO LOW 2.2 Kg/Cm2 0.04 15 3
1 Kg/Cm2 0.02 15 1
10PAL1410 LP STM PR. TO LP HEATER LO LOW
LP STM HDR TO AIR COND SYS
2.5 Kg/Cm2 0.05 15 1
10PAL1414 PR LOW
10TAL1406 LP STM TO REFINERY TEMP LO LOW 170 °C 1.7 30 1

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10TAL1204 HP STM TO REFINERY TEMP LO LOW 340 °C 3.4 30 1
240 °C 2.5 30
10TAL1305 MP STM TO REFINERY TEMP LO LOW
AIR COND SYS DS SPRY PR AFT
5 Kg/Cm2 0.1 15 1
10PAL1419 PCV LO LOW
01TAHH3101 VHP STEAM TO STG1 TEMP HH V HIGH 530 °C 5.3 30 3
530 °C 5.3 30 3
02TAHH3101 VHP STEAM TO STG2 TEMP HH V HIGH
530 °C 5.30 30 3
03TAHH3601 VHP STEAM TO STG3 TEMP HH V HIGH
10PAHH4113
15.6 Kg/Cm2 4
A TD BFP MP Exhaust PR HH V HIGH
10PAHH4113
15.6 Kg/Cm2 4
B TD BFP MP Exhaust PR HH V HIGH
10PAHH4113
15.6 Kg/Cm2 4
C TD BFP MP Exhaust PR HH V HIGH
116 Kg/Cm2 2.32 15 3
01PAHH3102 VHP STEAM TO STG1 PR. HH V HIGH
02PAHH3102 VHP STEAM TO STG2 PR. HH V HIGH 116 Kg/Cm2 2.32 15 3
03PAHH3602 VHP STEAM TO STG3 PR. HH V HIGH 116 Kg/Cm2 2.32 15 3
480 °C 4.8 30 3
01TALL3101 VHP STEAM TO STG1 TEMP LL V LOW
480 °C 4.8 30 3
02TALL3101 VHP STEAM TO STG2 TEMP LL V LOW
03TALL3601 VHP STEAM TO STG3 TEMP LL V LOW 480 °C 4.80 30 3
10PALL4113A TD BFP MP Exhaust PR LL V LOW 9.5 Kg/Cm2 4
10PALL4113B TD BFP MP Exhaust PR LL V LOW 9.5 Kg/Cm2 4
10PALL4113C TD BFP MP Exhaust PR LL V LOW 9.5 Kg/Cm2 4
95 Kg/Cm2 1.9 15 3
01PALL3102 VHP STEAM TO STG1 PR. LL V LOW
95 Kg/Cm2 1.9 15 3
02PALL3102 VHP STEAM TO STG2 PR. LL V LOW
HIGH 80 °C 0.8 0 5
10TAH1751A CTPA MOTOR BRG DE TEMP HI
10TAH1752B CTPB MOTOR BRG NDE TEMP HI HIGH 80 °C 0.8 0 5
10TAH1751B CTPB MOTOR BRG DE TEMP HI HIGH 80 °C 0.8 0 5
10TAH1752A CTPA MOTOR BRG NDE TEMP HI HIGH 80 °C 0.8 0 5
HIGH 120 °C 1.2 0 5

10TAH1753A CTPA MOTOR WDG TEMP01 HI
HIGH 120 °C 1.2 0 5
10TAH1753B CTPB MOTOR WDG TEMP01 HI
10TAH1754A CTPA MOTOR WDG TEMP02 HI HIGH 120 °C 1.2 0 5
HIGH 120 °C 1.2 0 5


Revision 02
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HIGH 120 °C 1.2 0 5

HIGH 120 °C 1.2 0 5
HIGH 120 °C 1.2 0 5
10TAH1756B CTPB MOTOR WDG TEMP04 HI HIGH 120 °C 1.2 0 5
10TAH1757B CTPB MOTOR WDG TEMP05 HI HIGH 120 °C 1.2 0 5
HIGH 120 °C 1.2 0 5

HRSG BFPB THRUST BRG TEMP1
HIGH 80 °C 0.8 0 5
10TAH2114B HI
HRSG BFPB THRUST BRG TEMP2
HIGH 80 °C 0.8 0 5
10TAH2115B HI
HIGH 80 °C 0.8 0 5
10TAH2116B HRSG BFP-B NDE BRG TEMP HI
HIGH 80 °C 0.8 0 5
10TAH2117B HRSG BFP-B DE BRG TEMP HI
HR-BFPB MOTOR BRG DE TEMP
HIGH 80 °C 0.8 0 5
10TAH2118B HI
HR-BFPB MOTOR BRG NDE
HIGH 80 °C 0.8 0 5
10TAH2119B TEMP HI
HRSG BFPB MOTOR WDG
HIGH 120 °C 1.2 0 5
10TAH2120B TEMP01 HI
HRSG BFPB MOTOR WDG
HIGH 120 °C 1.2 0 5
HRSG BFPB MOTOR WDG
HIGH 120 °C 1.2 0 5
HRSG BFPB MOTOR WDG
HIGH 120 °C 1.2 0 5
HRSG BFPB MOTOR WDG
HIGH 120 °C 1.2 0 5
HRSG BFPB MOTOR WDG
HIGH 120 °C 1.2 0 5
UB BFP B PMP THRUST BRG
HIGH 80 °C 0.8 0 5
10TAH2311B TEMP1 HI
HIGH 80 °C 0.8 0 5
10TAH2312B TEMP2 HI
HIGH 80 °C 0.8 0 5
10TAH2313B TEMP 3 HI
HIGH 80 °C 0.8 0 5
10TAH2314B TEMP 4 HI
UB-BFPB PMP NDE BRG TEMP1
HIGH 80 °C 0.8 0 5
10TAH2315B HI
UB-BFPB PMP NDE BRG TEMP2
HIGH 80 °C 0.8 0 5
10TAH2316B HI

Revision 02
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HIGH 80 °C 0.8 0 5
10TAH2317B UB-BFPB PMP DE BRG TEMP1 HI
HIGH 80 °C 0.8 0 5
10TAH2318B UB-BFPB PMP DE BRG TEMP2 HI
UB-BFPB MOTOR DE BRG TEMP
HIGH 80 °C 0.8 0 5
10TAH2321B HI
UB-BFPB MOTOR NDE BRG
HIGH 80 °C 0.8 0 5
10TAH2322B TEMP HI
UB BFPB MOTOR WDG TEMP01
HIGH 120 °C 1.2 0 5
10TAH2323B HI
HIGH 120 °C 1.2 0 5
10TAH2324B HI
HIGH 120 °C 1.2 0 5
10TAH2325B HI
HIGH 120 °C 1.2 0 5
10TAH2326B HI
HIGH 120 °C 1.2 0 5
10TAH2327B HI
HIGH 120 °C 1.2 0 5
10TAH2328B HI
HIGH 80 °C 0.8 0 5
10TAH2609B EX-BFPB PMP NDE BRG TEMP HI
HIGH 80 °C 0.8 0 5
10TAH2611B EX-BFPB PMP DE BRG TEMP HI
EX-BFPB MOTOR BRG DE TEMP
HIGH 80 °C 0.8 0 5
10TAH2612B HI
EX-BFPB MOTOR BRG NDE TEMP
HIGH 80 °C 0.8 0 5
10TAH2613B HI
EXPORT BFPB MOTOR WDG
HIGH 120 °C 1.2 0 5
HIGH 120 °C 1.2 0 5
HIGH 120 °C 1.2 0 5
HIGH 120 °C 1.2 0 5
HIGH 120 °C 1.2 0 5
HIGH 120 °C 1.2 0 5
02LAH1603 STG2 COND LVL HI HIGH 70 % 3.5 30 3
HIGH 70 % 3.5 30 1
10LAH1710 LP HTR COND. COLL. TNK LVL HI
KG/CM
HIGH 6.5 0.13 15 1
10PAH2719B EXPORT BFP-B LO PR 2 HI 2
10DPAH2516 KG/CM
HIGH 0.5 0.01 0 3
A UB BFP-B LO FILTER DP HI 2
HIGH 500 MMWC 10 15 3
02DPAH1603 STG2 CEP-A SUC DP HI
HIGH 500 MMWC 10 15 3
02DPAH1604 STG-2 CEP-B SUC DP HI

Revision 02
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KG/CM
HIGH 11 0.22 15 3
10PAH1731 CTP DISCHARGE HDR. PR HI 2
KG/CM
HIGH 170 3.4 15 1
10PAH1840B UB BFP-B DISG PR HI 2
KG/CM
HIGH 65 1.3 15 1
10PAH1869B EXPORT BFP-B DISCH PR HI 2
10DPAH2208 KG/CM
HIGH 0.5 0.01 15 3
B HRSG BFPB LO FILTER DP HI 2
KG/CM
HIGH 0.5 0.01 15 3
10DPAH1725 COND TRF PMP-A SUC DP HI 2
KG/CM
HIGH 0.5 0.01 15 3
10DPAH1726 COND TRF PMP-B SUC DP HI 2
02LAH1612 STG2 GSC LEVEL HI HIGH 70 % 3.5 30 3

EXPORT BFP-B BAL LEAK-OFF PR KG/CM
HIGH 7.5 0.15 15 1
10PAH1867B HI 2
10DPAH2716 KG/CM
HIGH 0.5 0.1 15 5
B EXPORT BFP-B LO FILTER DP HI 2
KG/CM
HIGH 0.2 0.004 15 3
10DPAH1737 LPH DRN TP-A SUC DP HI 2
KG/CM
HIGH 0.2 0.004 15 3
10DPAH1738 LPH DRN TP-B SUC DP HI 2
KG/CM
HIGH 7.5 0.15 15 1
10PAH1836B UB BFP-B BAL. LEAK-OFF PR HI 2
10FAH1701_F
HIGH 447 TPH 22.3 10 3
low COND RTN->CST FLO HI
10FAH1702_F DM WTR FLOW TO COND STG
HIGH 800 TPH 50 10 1
low TANK HI
575AIPM004 COND TRFR PMP-A MOTOR
HIGH 32 AMP 0 0 5
A CURRENT HI
575AIPM004 COND TRFR PMP-B MOTOR
HIGH 32 AMP 0 0 5
B CURRENT HI
575AIPM009
HIGH 165 AMP 0 0 5
B UB BFP-B MOTOR CURRENT HI
575AIPM008 EXPORT BFP-B MOTOR
HIGH 80 AMP 0 0 5
B CURRENT HI
575AIPM007 HRSG BFP-B MOTOR CURRENT
HIGH 88 AMP 0 0 5
B HI
10LAH1702 COND STG TNK LVL HI HIGH 70 % 3.5 30 3
HIGH 2700 MM 135 30 3

10LAH1801A FEED WTR STG TNK LVL HI
HIGH 2700 MM 135 30 3
10LAH1801B FEED WTR STG TNK LVL HI
10DPAH1831 KG/CM
HIGH 0.15 0.003 15 3
B UBBFPB SUC DP HI 2
KG/CM
HIGH 160 3.2 15 3
10PAH1812B HRSG BFPB DISG PR HI 2
KG/CM
HIGH 65 1.3 15 3
10PAH1871B EXPORT BFPB DISG PR HI 2
KG/CM
HIGH 2.6 0.05 15 3
10PAH2211B HRSG BFPB LO DISH HDR PR HI 2

Revision 02
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10DPAH1804 KG/CM
HIGH 0.15 0.003 15 3
B HRSG'S BFPB SUC DP HI 2
10DPAH1862 KG/CM
HIGH 0.15 0.003 15 3
B EXBFPB SUC DP HI 2
10DEALVLHI DEA LEVEL HIGH HIGH 2700 MM 135 30 3
10CSTLVLHI COND STRG TNK LVL HIGH HIGH 70 % 3.5 30 3

KG/CM
HIGH 8 15 1
10PAH1808B HRSG BFP-B BAL LEAK-OFF PR HI 2 0.16
COND RTN TO COND STG TANK KG/CM
HIGH 8 15 1
10PAH1701 PR HI 2 0.16
02LAL1603 STG2 COND LVL LO LOW 30 % 1.5 0 5
10LAL1710 LP HTR COND. COLL. TNK LVL LO LOW 30 % 1.5 0 5

KG/CM
LOW 1.4 0 5
10PAL1802B HRSG BFPB SUC PR LO 2 0.028
KG/CM
LOW 6.5 0 5
02PAL1609 STG2 CEP DISG HDR PR LO 2 0.13
DM WTR->COND STG TANK PR KG/CM
LOW 2 15 3
10PAL1703 LO 2 0.04
KG/CM
LOW 7 0 5
10PAL1731 CTP DISCHARGE HDR. PR LO 2 0.14
KG/CM
LOW 54 0 5
10PAL1869B EXPORT BFP-B DISCH PR LO 2 1.08
LOW 30 % 30 1
02LAL1612 STG2 GSC LEVEL LO 1.5
KG/CM
LOW 1.4 0 5
10PAL1833B UB BFP-B Suction PR LO 2 0.028
KG/CM
LOW 1.4 0 5
10PAL1864B EXPORT BFP-B SUCTION PR LO 2 0.028
KG/CM
LOW 138 0 5
10PAL1838B UB BFP-B DISCH PR LO 2 2.76
10FAL1701_F KG/CM
LOW 40 10 1
low COND RTN->CST FLO LO 2 2
10FAL1702_F DM WTR FLOW TO COND STG
LOW 200 TPH 10 1
low TANK LO 10
10LAL2202B HRSG BFPB LO TNK LVL LO LOW 30 % 1.5 0 5
10LAL1702 COND STG TNK LVL LO LOW 30 % 1.5 0 5
LOW 2000 MM 0 5
10LAL1801A FEED WTR STG TNK LVL LO 100
10LAL1801B FEED WTR STG TNK LVL LO LOW 2000 MM 100 0 5
10LAL2502A UB BFPB LO TNK LVL LO LOW 30 % 1.5 0 5
LOW 30 % 0 5
10LAL2702B EXPORT BFPB LO TNK LVL LO 1.5
COND RTN COND STG TANK PR KG/CM
LOW 3.5 15 1
10PAL1701 LO 2 0.07
LOW 7 KG/CM 0 5
10PAL1743 LPH DRN TP DISH HDR PR LO 0.14
Revision 02
9112-575-OPR-701-00002 Page 45 of 92
KG/CM
LOW 1.6 0 5
10PAL2211B HRSG BFPB LO DISH HDR PR LO 2 0.032
KG/CM
LOW 1.8 0 5
10PAL2519A UB BFPB LO DISH HDR PR LO 2 0.036
10DEALVLLO DEA LVL LOW LOW 2000 MM 100 0 5
10CSTLVLLO COND STRG TNK LVL LOW LOW 30 % 1.5 0 5

KG/CM
LOW 2 0 5
10PAL2719B EXPORT BFP-B LO PR 2 LO 2 0.04
KG/CM
LOW 134 0 5
10PAL1810B HRSG BFPB DISG PR LO 2 2.6
10TAHH1751 VERY
90 °C 0.9 0 4
A CTPA MOTOR BRG DE TEMP HH HIGH
10TAHH1752 CTPB MOTOR BRG NDE TEMP VERY
90 °C 0.9 0 4
B HH HIGH
10TAHH1751 VERY
90 °C 0.9 0 4
B CTPB MOTOR BRG DE TEMP HH HIGH
10TAHH1752 CTPA MOTOR BRG NDE TEMP VERY
90 °C 0.9 0 4
A HH HIGH
10TAHH1753 VERY
130 °C 1.3 0 4
A CTPA MOTOR WDG TEMP01 HH HIGH
10TAHH1753 VERY
130 °C 1.3 0 4
B CTPB MOTOR WDG TEMP01 HH HIGH
10TAHH1754 VERY
130 °C 1.3 0 4
10TAHH1754 VERY
130 °C 1.3 0 4
10TAHH1755 VERY
130 °C 1.3 0 4
10TAHH1755 VERY
130 °C 1.3 0 4
10TAHH1756 VERY
130 °C 1.3 0 4
10TAHH1756 VERY
130 °C 1.3 0 4
10TAHH1757 VERY
130 °C 1.3 0 4
10TAHH1757 VERY
130 °C 1.3 0 4
10TAHH1758 VERY
130 °C 1.3 0 4
10TAHH1758 VERY
130 °C 1.3 0 4
10TAHH2114 HRSG BFPB THRUST BRG TEMP1 VERY
90 °C 0.9 0 4
B HH HIGH
10TAHH2115 HRSG BFPB THRUST BRG VERY
90 °C 0.9 0 4
B TEMP2HH HIGH
10TAHH2116 VERY
90 °C 0.9 0 4
B HRSG BFP-B NDE BRG TEMP HH HIGH
10TAHH2117 VERY
90 °C 0.9 0 4
B HRSG BFP-B DE BRG TEMP HH HIGH
Revision 02
9112-575-OPR-701-00002 Page 46 of 92
10TAHH2118 HR-BFPB MOTOR BRG DE TEMP VERY

90 °C 0.9 0 4
B HH HIGH
10TAHH2119 HR-BFPB MOTOR BRG NDE VERY
90 °C 0.9 0 4
B TEMP HH HIGH
10TAHH2120 HRSG BFPB MOTOR WDG VERY
130 °C 1.3 0 4
B TEMP01 HH HIGH
130 °C 1.3 0 4
B TEMP02 HH HIGH
130 °C 1.3 0 4
B TEMP03 HH HIGH
130 °C 1.3 0 4
B TEMP04 HH HIGH
130 °C 1.3 0 4
B TEMP05 HH HIGH
130 °C 1.3 0 4
B TEMP06 HH HIGH
10TAHH2311 UB BFP B PMP THRUST BRG VERY
90 °C 0.9 0 4
B TEMP1 HH HIGH
90 °C 0.9 0 4
B TEMP 2 HH HIGH
90 °C 0.9 0 4
B TEMP 3 HH HIGH
90 °C 0.9 0 4
B TEMP 4 HH HIGH
10TAHH2315 UB-BFPB PMP NDE BRG TEMP1 VERY
90 °C 0.9 0 4
B HH HIGH
10TAHH2316 UB-BFPB PMP NDE BRG TEMP2 VERY
90 °C 0.9 0 4
B HH HIGH
10TAHH2317 UB-BFPB PMP DE BRG TEMP1 VERY
90 °C 0.9 0 4
B HH HIGH
10TAHH2318 UB-BFPB PMP DE BRG TEMP2 VERY
90 °C 0.9 0 4
B HH HIGH
10TAHH2321 UB-BFPB MOTOR DE BRG TEMP VERY
90 °C 0.9 0 4
B HH HIGH
10TAHH2322 UB-BFPB MOTOR NDE BRG VERY
90 °C 0.9 0 4
B TEMP HH HIGH
10TAHH2323 UB BFPB MOTOR WDG TEMP01 VERY
130 °C 1.3 0 4
B HH HIGH
130 °C 1.3 0 4
B HH HIGH
130 °C 1.3 0 4
B HH HIGH
130 °C 1.3 0 4
B HH HIGH
130 °C 1.3 0 4
B HH HIGH
130 °C 1.3 0 4
B HH HIGH
10TAHH2609 EX-BFPB PMP NDE BRG TEMP VERY
90 °C 0.9 0 4
B HH HIGH

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10TAHH2611 VERY
90 °C 0.9 0 4
B EX-BFPB PMP DE BRG TEMP HH HIGH
10TAHH2612 EX-BFPB MOTOR BRG DE TEMP VERY
90 °C 0.9 0 4
B HH HIGH
10TAHH2613 EX-BFPB MOTOR BRG NDE TEMP VERY
90 °C 0.9 0 4
B HH HIGH
10TAHH2614 EXPORT BFPB MOTOR WDG VERY
130 °C 1.3 0 4
B TEMP01 HH HIGH
130 °C 1.3 0 4
B TEMP02 HH HIGH
130 °C 1.3 0 4
B TEMP03 HH HIGH
130 °C 1.3 0 4
B TEMP04 HH HIGH
130 °C 1.3 0 4
B TEMP05 HH HIGH
130 °C 1.3 0 4
B TEMP06 HH HIGH
VERY
80 % 0.8 30 3
02LAHH1603 STG2 COND LVL HH HIGH
VERY
80 % 0.8 30 3
10LAHH1710 LP HTR COND. COLL. TNK LVL HH HIGH
10DPAHH220 VERY KG/CM
0.8 0 4
8B HRSG BFPB LO FILTER DP HH HIGH 2 0.16
0.8 0 4
6A UB BFP-B LO FILTER DP HH HIGH 2 0.16
0.8 0 4
6B EXPORT BFP-B LO FILTER DP HH HIGH 2 0.16
575AIPM004 COND TRFR PMP-A MOTOR VERY
35 AMP 0 4
A CURRENT HH HIGH 0
575AIPM004 COND TRFR PMP-B MOTOR VERY
35 AMP 0 4
B CURRENT HH HIGH 0
575AIPM009 VERY
171 AMP 0 4
B UB BFP-B MOTOR CURRENT HH HIGH 0
575AIPM008 EXPORT BFP-B MOTOR VERY
86 AMP 0 4
B CURRENT HH HIGH 0
575AIPM007 HRSG BFP-B MOTOR CURRENT VERY
93 AMP 0 4
B HH HIGH 0
VERY
80 AMP 30 3
10LAHH1702 COND STG TNK LVL HH HIGH 4
10LAHH1801 VERY
3000 MM 30 3
A FEED WTR STG TNK LVL HH HIGH 150
10LAHH1801 VERY
3000 MM 30 3
B FEED WTR STG TNK LVL HH HIGH 150
VERY
80 % 30 3
10CSTLVLVHI COND STRG TANK LVL V.HIGH HIGH 4
KG/CM
VERY LOW 2 0 4
10EXBLOPRLL EXBFP-B LO PR LL_ALM 2 1.25
VERY LOW 20 % 0 4
10LALL2202B HRSG BFPB LO TNK LVL LL 1
10LALL1702 COND STG TNK LVL LL VERY LOW 20 % 1 0 4

Revision 02
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VERY LOW 20 % 0 4
10LALL1710 LP HTR COND. COLL. TNK LVL LL 1
VERY LOW 300 MM 0 4
10LALL1801A FEED WTR STG TNK LVL LL 15
VERY LOW 300 MM 0 4
10LALL1801B FEED WTR STG TNK LVL LL 15
10LALL2502A UB BFPB LO TNK LVL LL VERY LOW 20 % 1 0 4
10LALL2702B EXPORT BFPB LO TNK LVL LL VERY LOW 25 % 1.25 0 4

KG/CM
VERY LOW 101 0 4
10PALL1810B HRSG BFPB DISG PR LL 2 2
KG/CM
VERY LOW 2.2 0 4
02PALL1609 STG 2 CEP DISG HDR PR LL 2 0.11
KG/CM
VERY LOW 0.8 0 4
10PALL2212B HRSG BFPB LO DISH HDR PR LL 2 0.04
KG/CM
VERY LOW 1.6 0 4
10PALL2520A UB BFPB LO DISH HDR PR LL 2 0.08
10DEALVLLOL
VERY LOW 300 MM 0 4
O DEA LVL V.LOW 15
KG/CM
VERY LOW 20 0 4
10CSTLVLVLO COND STRG TANK LVL V.LOW 2 1
KG/CM
VERY LOW 1.6 0 4
10PAL2720B EXPORT BFP-B LO PR 3 LL 2 0.08
KG/CM
VERY LOW 1.2 0 4
10PALL1833B UB BFP-B Suction PR LL 2 0.06
KG/CM
VERY LOW 1.2 0 4
10PALL1864B EXPORT BFP-B SUCTION PR LL 2 0.06
KG/CM
VERY LOW 1.2 0 4
10PALL1802B HRSG BFP-B SUC PR LL 2 0.06
KG/CM
VERY LOW 128 0 4
10PALL1838B UB BFP-B DISCH PR LL 2 6.4
HRSG BFPC THRUST BRG TEMP
HIGH 80 °C
10TAH2114C HI 0.8 0 5
HRSG BFPC THRUST BRG TEMP
HIGH 80 °C
10TAH2115C HI 0.8 0 5
10TAH2116C HR-BFPC PMP NDE BRG TEMP HI HIGH 80 °C 0.8 0 5

HIGH 80 °C
10TAH2117C HR-BFPC PMP DE BRG TEMP HI 0.8 0 5
HR-BFPC MOTOR DE BRG TEMP
HIGH 80 °C
10TAH2118C HI 0.8 0 5
HR-BFPC MOTOR NDE BRG
HIGH 80 °C
10TAH2119C TEMP HI 0.8 0 5
HRSG BFPC MOTOR WDG
HIGH 120 °C
10TAH2120C TEMP01 HI 1.2 0 5
HRSG BFPC MOTOR WDG
HIGH 120 °C
10TAH2121C TEMP02 HI 1.2 0 5
HRSG BFPC MOTOR WDG
HIGH 120 °C
10TAH2122C TEMP03 HI 1.2 0 5
HRSG BFPC MOTOR WDG
HIGH 120 °C
10TAH2123C TEMP04 HI 1.2 0 5

Revision 02
9112-575-OPR-701-00002 Page 49 of 92
HRSG BFPC MOTOR WDG

HIGH 120 °C
10TAH2124C TEMP05 HI 1.2 0 5
HRSG BFPC MOTOR WDG
HIGH 120 °C
10TAH2125C TEMP06 HI 1.2 0 5
HRSG BFPC MOTOR WDG
HIGH 120 °C
10TAH2126C TEMP07 HI 1.2 0 5
HRSG BFPC MOTOR WDG
HIGH 120 °C
10TAH2127C TEMP08 HI 1.2 0 5
HRSG BFPC MOTOR WDG
HIGH 120 °C
10TAH2128C TEMP09 HI 1.2 0 5
HRSG BFPC MOTOR WDG
HIGH 120 °C
10TAH2129C TEMP10 HI 1.2 0 5
HRSG BFPC MOTOR WDG
HIGH 120 °C
10TAH2130C TEMP11 HI 1.2 0 5
HRSG BFPC MOTOR WDG
HIGH 120 °C
10TAH2131C TEMP12 HI 1.2 0 5
HIGH 80 °C
10TAH2255C HRSG BFPC GB BRG TEMP HI 0.8 0 5
HIGH 80 °C
HIGH 80 °C
10TAH2258C HRSG BFPC GB BRG TEMP HI HIGH 80 °C 0.8 0 5

HIGH 80 °C
HIGH 80 °C
HIGH 80 °C

UB BFPC PMP THRUST BRG
HIGH 80 °C
10TAH2311C TEMP1 HI 0.8 0 5
HIGH 80 °C
10TAH2312C TEMP2 HI 0.8 0 5
HIGH 80 °C
10TAH2313C TEMP3 HI 0.8 0 5
HIGH 80 °C
10TAH2314C TEMP4 HI 0.8 0 5
UB-BFPC PMP NDE BRG TEMP1
HIGH 80 °C
10TAH2315C HI 0.8 0 5
UB-BFPC PMP NDE BRG TEMP2
HIGH 80 °C
10TAH2316C HI 0.8 0 5
10TAH2317C UB-BFPC PMP DE BRG TEMP1 HI HIGH 80 °C 0.8 0 5

HIGH 80 °C
10TAH2318C UB-BFPC PMP DE BRG TEMP2 HI 0.8 0 5
UB-BFPC MOTOR DE BRG TEMP
HIGH 80 °C
10TAH2321C HI 0.8 0 5
Revision 02
9112-575-OPR-701-00002 Page 50 of 92
UB-BFPC MOTOR NDE BRG.

HIGH 80 °C
10TAH2322C TEMP HI 0.8 0 5
UB BFPC MOTOR WDG TEMP01
HIGH 120 °C
10TAH2323C HI 1.2 0 5
HIGH 120 °C
10TAH2324C HI 1.2 0 5
HIGH 120 °C
10TAH2325C HI 1.2 0 5
HIGH 120 °C
10TAH2326C HI 1.2 0 5
HIGH 120 °C
10TAH2327C HI 1.2 0 5
HIGH 120 °C
10TAH2328C HI 1.2 0 5
HIGH 120 °C
10TAH2329C HI 1.2 0 5
HIGH 120 °C
10TAH2330C HI 1.2 0 5
HIGH 120 °C
10TAH2331C HI 1.2 0 5
HIGH 120 °C
10TAH2332C HI 1.2 0 5
HIGH 120 °C
10TAH2333C HI 1.2 0 5
HIGH 120 °C
10TAH2334C HI 1.2 0 5
HIGH 6.1 MTR
10LAH4767_1 COLD WTR SUMP LVL HI 0.3 30 1
HIGH 80 °C
10LAH1921 HRSG AREA BD PIT LVL HI 4 30 1
HIGH 80 °C
10LAH1926 STG BD PIT LVL HI 4 30 1
10LAH1931 UB1&2 BD PIT LVL HI HIGH 80 °C 4 30 1
10LAH1936 UB3&4 BD PIT LVL HI HIGH 80 °C 4 30 1

HIGH 80 °C
10LAH1956 MAIN BD COLL PIT LVL HI 4 30 1
10LAH4767 COLD WTR SUMP LVL HI HIGH 6.1 MTR 0.25 30 1

KG/CM
HIGH 160
10PAH1812C HRSG BFPC DISG PR HI 2 3.2 15 1
KG/CM
HIGH 2.8
10PAH2211C HRSG BFPC LO DISH HDR PR HI 2 0.05 15 1
10DPAH2208 KG/CM
HIGH 0.5
C HRSG BFPC LUBE OIL DP HI 2 0.01 0 3
KG/CM
HIGH 6
10PAH2519B UB BFPC LO DISH HDR PR HI 2 0.12 15 1
10DPAH1804 KG/CM
HIGH 0.15
C HRSG'S BFPC SUC DP HI 2 0.003 15 3
10DPAH1831 KG/CM
HIGH 0.15
C UBBFP C SUC DP HI 2 0.003 15 3

Revision 02
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06LAH1906 UB1 IBD TANK LEVEL HI HIGH 80 % 4 30 1

HIGH 80 % 30
07LAH1906 UB2 IBD TANK LEVEL HI 4 1
HIGH 80 % 30
08LAH1906 UB3 IBD TANK LEVEL HI 4 1
09LAH1906 UB4 IBD TANK LEVEL HI HIGH 80 % 4 30 1
06LAH1902 UB1 CBD TANK LEVEL HI HIGH 80 % 4 30 1

HIGH 80 % 30
07LAH1902 UB2 CBD TANK LEVEL HI 4 1

HIGH 60 % 30
06TAH1908 UB1 IBD TANK TEMP HI 0.6 1
07TAH1908 UB2 IBD TANK TEMP HI HIGH 60 % 0.6 30 1
08TAH1908 UB3 IBD TANK TEMP HI HIGH 60 % 0.6 30 1

HIGH 60 % 30
09TAH1908 UB4 IBD TANK TEMP HI 0.6 1
HIGH 70 % 30
01LAH1911 STG1 FLASH TANK LEVEL HI 3.5 1
02AH1911 STG2 FLASH TANK LEVEL HI HIGH 70 % 3.5 30 1

HIGH 70 % 30
03LAH1911 BPTG FLASH TANK LEVEL HI 3.5 1
01TAH1911 STG1 FLASH TANK TEMP HI HIGH 70 % 0.6 30 1
02TAH1911 STG2 FLASH TANK TEMP HI HIGH 70 % 0.6 30 1

HIGH 70 % 30
03TAH1911 BPTG FLASH TANK TEMP HI 0.6 1
HIGH 70 % 30
10LAH1951 DEA FLASH TANK LEVEL HI 3.5 1
HRSG AREA BD PIT PMP DISCH KG/CM
HIGH 4.5 15
10PAH1922 PR HI 2 0.09 1
STG AREA BD PIT PMP DISCH PR KG/CM
HIGH 4.5 15
10PAH1927 HI 2 0.09 1
KG/CM
HIGH 4.5 15
10PAH1932 UB1&2 BD PIT PMP DISCH PR HI 2 0.09 1
KG/CM
HIGH 4.5 15
10PAH1937 UB3&4 BD PIT PMP DISCH PR HI 2 0.09 1
10DPAH2516 KG/CM
HIGH 0.5 0
B UB BFP-C LO FILTER DP HI 2 0.01 5
KG/CM
HIGH 8 15
10PAH1808C HRSG BFP-C BAL LEAK-OFF PR HI 2 0.16 3
KG/CM
HIGH 7.5 15
10PAH1836C UB BFP-C BAL LEAK-OFF PR HI 2 0.15 3
DM WTR SUPPLY TO COND KG/CM
HIGH 7 15
10PAH4902 TANK PR HI 2 0.12 3

Revision 02
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10DPAH4769 SIDE STREAM FLTR-A DP HI HIGH 8000 MMWC 160 15 1

HIGH 8000 MMWC 15
10DPAH4773 SIDE STREAM FLTR-B DP HI 160 1
HIGH 36 °C 30
10TAH4710 CW PMP DISCH HDR. TEMP HI 0.36 3
575AIPM008
HIGH 165 AMP 0
CHI UB'S VHP BFP-C CUR HI 0 5
575AIPM007
HIGH 88 AMP 0
CHI HRSG'S VHP BFP-C CUR HI 0 5
LOW 30 % 30
10LAL1951 DEA FLASH TANK LEVEL LO 1.5 1
10LAL4767_1 COLD WTR SUMP LVL LO LOW 5 MTR 0.25 30 5
10LAL1921 HRSG AREA BD PIT LVL LO LOW 25 % 1.25 30 3

LOW 25 %
10LAL1926 STG BD PIT LVL LO 1.25 30 3
LOW 25 %
10LAL1931 UB1&2 BD PIT LVL LO 1.25 30 3
LOW 25 %
10LAL1936 UB3&4 BD PIT LVL LO 1.25 30 3
10LAL1956 MAIN BD COLL PIT LVL LO LOW 25 % 1.25 30 3
10LAL4754 C.T FAN1 GB LVL LO LOW 40 % 2 0 5

LOW 40 %
10LAL4757 C.T FAN4 GB LVL LO 2 0 5
LOW 40 %
10LAL4758 C.T FAN5 GB LVL LO 2 0 5
10LAL4767 COLD WTR SUMP LVL LO LOW 5 MTR 0.3 30 5
10LAL2202C HRSG BFPC LO TNK LVL LO LOW 30 % 1.5 0 5
10LAL2502B UB BFPC LO TNK LVL LO LOW 30 % 1.5 0 5

KG/CM
LOW 1.2
10PAL2211C HRSG BFPC LO DISH HDR PR LO 2 0.02 0 5
KG/CM
LOW 134
10PAL1810C HRSG BFPC DISG PR LO 2 2.6 0 5
KG/CM
LOW 1.4
10PAL1802C HRSG BFPC SUC PR LO 2 0.02 0 5
KG/CM
LOW 2
10PAL2519B UB BFPC LO DISH HDR PR LO 2 0.04 0 5
KG/CM
LOW 1.7
10PAL4705 CW PMP DISG HDR PR LO 2 0.03 0 5
06LAL1906 UB1 IBD TANK LEVEL LO LOW 20 % 1 30 1

LOW 20 % 30
07LAL1906 UB2 IBD TANK LEVEL LO 1 1
Revision 02
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08LAL1906 UB3 IBD TANK LEVEL LO LOW 20 % 1 30 1

LOW 20 % 30
09LAL1906 UB4 IBD TANK LEVEL LO 1 1
LOW 20 % 30
06LAL1902 UB1 CBD TANK LEVEL LO 1 1
07LAL1902 UB2 CBD TANK LEVEL LO LOW 20 % 1 30 1
08LAL1902 UB3 CBD TANK LEVEL LO LOW 20 % 1 30 1

LOW 20 % 30
09LAL1902 UB4 CBD TANK LEVEL LO 1 1
01LAL1911 STG1 FLASH TANK LEVEL LO LOW 30 % 1.5 30 1
02LAL1911 STG2 FLASH TANK LEVEL LO LOW 30 % 1.5 30 1

LOW 30 % 30
03LAL1911 BPTG FLASH TANK LEVEL LO 1.5 1
10LAL1951 DEA FLASH TANK LEVEL LO LOW 30 % 1.5 30 1

HRSG AREA BD PIT PMP DISCH KG/CM
LOW 2.5 15
10PAL1922 PR LO 2 0.05 1
STG AREA BD PIT PMP DISCH PR KG/CM
LOW 2.5 15
10PAL1927 LO 2 0.05 1
KG/CM
LOW 2.5 15
10PAL1932 UB1&2 BD PIT PMP DISCH PR LO 2 0.05 1
KG/CM
LOW 2.5 15
10PAL1937 UB3&4 BD PIT PMP DISCH PR LO 2 0.05 1
KG/CM
LOW 1.4 0
10PAL1833C UB BFP-C SUC PR LO 2 0.02 5
KG/CM
LOW 138 0
10PAL1838C UB BFP-C DISCH PR LO 2 2.7 5
DM WTR SUPPLY TO COND KG/CM
LOW 2 15
10PAL4902 TANK PR LO 2 0.05 3
KG/CM
LOW 3 15
10PAL4907 SERVICE WTR B/L SUPPLY PR LO 2 0.06 1
KG/CM
LOW 2.5 15
10PAL4908 B/L PORTABLE WTR PR LO 2 0.05 1
10TAHH2114 HRSG BFPC THRUST BRG TEMP
VHIGH 90 °C
C HH 0.9 0 4
10TAHH2115 HRSG BFPC THRUST BRG TEMP
VHIGH 90 °C
C HH 0.9 0 4
10TAHH2116 HR-BFPC PMP NDE BRG TEMP
VHIGH 90 °C
C HH 0.9 0 4
10TAHH2117
VHIGH 90 °C
C HR-BFPC PMP DE BRG TEMP HH 0.9 0 4
10TAHH2118 HR-BFPC MOTOR DE BRG TEMP
VHIGH 90 °C
C HH 0.9 0 4
10TAHH2119 HR-BFPC MOTOR NDE BRG
VHIGH 90 °C
C TEMP HH 0.9 0 4
10TAHH2120 HRSG BFPC MOTOR WDG
VHIGH 130 °C
C TEMP01 HH 1.3 0 4

Revision 02
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VHIGH 130 °C
C TEMP02 HH 1.3 0 4
VHIGH 130 °C
C TEMP03 HH 1.3 0 4
VHIGH 130 °C
C TEMP04 HH 1.3 0 4
VHIGH 130 °C
C TEMP05 HH 1.3 0 4
VHIGH 130 °C
C TEMP06 HH 1.3 0 4
VHIGH 130 °C
C TEMP07 HH 1.3 0 4
VHIGH 130 °C
C TEMP08 HH 1.3 0 4
VHIGH 130 °C
C TEMP09 HH 1.3 0 4
VHIGH 130 °C
C TEMP10 HH 1.3 0 4
VHIGH 130 °C
C TEMP11 HH 1.3 0 4
VHIGH 130 °C
C TEMP12 HH 1.3 0 4
10TAHH2255
VHIGH 90 °C
C HRSG BFPC GB BRG TEMP HH 0.9 0 4
10TAHH2256
VHIGH 90 °C
10TAHH2257
VHIGH 90 °C
10TAHH2258
VHIGH 90 °C
10TAHH2259
VHIGH 90 °C
10TAHH2260
VHIGH 90 °C
10TAHH2261
VHIGH 90 °C
10TAHH2262
VHIGH 90 °C
10TAHH2263
VHIGH 90 °C
10TAHH2264
VHIGH 90 °C
10TAHH2311 UB BFPC PMP THRUST BRG
VHIGH 90 °C
C TEMP1 HH 0.9 0 4
VHIGH 90 °C
C TEMP2 HH 0.9 0 4
VHIGH 90 °C
C TEMP3 HH 0.9 0 4
VHIGH 90 °C
C TEMP4 HH 0.9 0 4

Revision 02
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10TAHH2315 UB-BFPC PMP NDE BRG TEMP1

VHIGH 90 °C
C HH 0.9 0 4
10TAHH2316 UB-BFPC PMP NDE BRG TEMP2
VHIGH 90 °C
C HH 0.9 0 4
10TAHH2317 UB-BFPC PMP DE BRG TEMP1
VHIGH 90 °C
C HH 0.9 0 4
10TAHH2318 UB-BFPC PMP DE BRG TEMP2
VHIGH 90 °C
C HH 0.9 0 4
10TAHH2321 UB-BFPC MOTOR DE BRG TEMP
VHIGH 90 °C
C HH 0.9 0 4
10TAHH2322 UB-BFPC MOTOR NDE BRG.
VHIGH 90 °C
C TEMP HH 0.9 0 4
10TAHH2323 UB BFPC MOTOR WDG TEMP01
VHIGH 130 °C
C HH 1.3 0 4
VHIGH 130 °C
C HH 1.3 0 4
VHIGH 130 °C
C HH 1.3 0 4
VHIGH 130 °C
C HH 1.3 0 4
VHIGH 130 °C
C HH 1.3 0 4
VHIGH 130 °C
C HH 1.3 0 4
VHIGH 130 °C
C HH 1.3 0 4
VHIGH 130 °C
C HH 1.3 0 4
VHIGH 130 °C
C HH 1.3 0 4
VHIGH 130 °C
C HH 1.3 0 4
VHIGH 130 °C
C HH 1.3 0 4
VHIGH 130 °C
C HH 1.3 0 4
10LAHH4767
VHIGH 6.5 MTR
_1 COLD WTR SUMP LVL HH 0.32 30 3
10LAHH1926 STG BD PIT LVL HH VHIGH 85 % 4.25 30 1
10LAHH1931 UB1&2 BD PIT LVL HH VHIGH 85 % 4.25 30 1
10LAHH1936 UB3&4 BD PIT LVL HH VHIGH 85 % 4.25 30 1

VHIGH 85 %
10LAHH1956 MAIN BD COLL PIT LVL HH 4.25 30 1
VHIGH 6.5 MTR
10LAHH4767 COLD WTR SUMP LVL HH 0 0 3
10DPAHH220 KG/CM
VHIGH 0.8 0
8C HRSG BFPC LUBE OIL DP HH 2 0 4
10DPAHH251 KG/CM
VHIGH 0.8 0
6B UB BFP-C LO FILTER DP HH 2 0 4

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575AIPM008
VHIGH 171 AMP 0
CHH UB BFP-C CUR HH 0 4
575AIPM007
VHIGH 93 AMP 0
CHH HRSG BFP-C CUR HH 0 4
10LALL4767_
VLOW 3.5 MTR
1 COLD WTR SUMP LVL LL 0 0 4
10LALL1921 HRSG AREA BD PIT LVL LL VLOW 20 % 1 0 4

VLOW 20 %
10LALL1926 STG BD PIT LVL LL 1 0 4
10LALL1931 UB1&2 BD PIT LVL LL VLOW 20 % 1 0 4
10LALL1936 UB3&4 BD PIT LVL LL VLOW 20 % 1 0 4

VLOW 20 %
10LALL1956 MAIN BD COLL PIT LVL LL 1 0 4
VLOW 20 %
10LALL4754 C.T FAN1 GB LVL LL 0 0 4
VLOW 20 %
10LALL4755 C.T FAN2 GB LVL LL 0 0 4
10LALL4756 C.T FAN3 GB LVL LL VLOW 20 % 0 0 4

VLOW 3.5 MTR
10LALL4767 COLD WTR SUMP LVL LL 0.32 30 4
VLOW 20 %
10LALL2202C HRSG BFPC LO TNK LVL LL 1 0 4
10LALL2502B UB BFPC LO TNK LVL LL VLOW 20 % 1 0 4

KG/CM
VLOW 0.8
10PALL2212C HRSG BFPC LO DISH HDR PR LL 2 0 0 4
KG/CM
VLOW 101
10PALL1810C HRSG BFPC DISG PR LL 2 0 0 4
KG/CM
VLOW 1.6
10PALL2520B UB BFPC LO DISH HDR PR LL 2 0 0 4
KG/CM
VLOW 1
10PALL4705 CW PMP DISG HDR PR LL 2 0 0 4
KG/CM
VLOW 1.2 0
10PALL1833C UB BFP-C SUC PR LL 2 0 4
KG/CM
VLOW 1.2 0
10PALL1802C HRSG BFPC SUC PR LL 2 0.02 4
HIGH 80 °C 0.8
10TAH2257B HRSG BFPB GB BRG TEMP HI 0 5
HIGH 80 °C 0.8
10TAH2256B HRSG BFPB GB BRG TEMP HI HIGH 80 °C 0.8 0 5

HIGH 80 °C 0.8

Revision 02
9112-575-OPR-701-00002 Page 57 of 92

HIGH 80 °C 0.8
HIGH 80 °C 0.8

HIGH 80 °C 0.8
UB BFPD PMP THRUST BRG
HIGH 80 °C 0.8
10TAH2311D TEMP1 HI 0 5
HIGH 80 °C 0.8
HIGH 80 °C 0.8
HIGH 80 °C 0.8
UB-BFPD PMP NDE BRG TEMP1
HIGH 80 °C 0.8
10TAH2315D HI 0 5
UB-BFPD PMP NDE BRG TEMP2
HIGH 80 °C 0.8
10TAH2316D HI 0 5
HIGH 80 °C 0.8
10TAH2317D UB-BFPD PMP DE BRG TEMP1 HI 0 5
10TAH2318D UB-BFPD PMP DE BRG TEMP2 HI HIGH 80 °C 0.8 0 5

UB-BFPD MOTOR DE BRG TEMP
HIGH 80 °C 0.8
10TAH2321D HI 0 5
UB-BFPD MOTOR NDE BRG
HIGH 80 °C 0.8
10TAH2322D TEMP HI 0 5
UB BFPD MOTOR WDG TEMP01
HIGH 120 °C 1.2
10TAH2323D HI 0 5
HIGH 120 °C 1.2
10TAH2324D HI 0 5
HIGH 120 °C 1.2
10TAH2325D HI 0 5
HIGH 120 °C 1.2
10TAH2326D HI 0 5
HIGH 120 °C 1.2
10TAH2327D HI 0 5
HIGH 120 °C 1.2
10TAH2328D HI 0 5
HIGH 120 °C 1.2
10TAH2329D HI 0 5
HIGH 120 °C 1.2
10TAH2330D HI 0 5
HIGH 120 °C 1.2
10TAH2331D HI 0 5
HIGH 120 °C 1.2
10TAH2332D HI 0 5

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HIGH 120 °C 1.2
10TAH2333D HI 0 5
HIGH 120 °C 1.2
10TAH2334D HI 0 5
10TAH4890B ACW-B(MD)PMP BRG TEMP HI HIGH 80 °C 0.8 0 5

HIGH 80 °C 0.8
10TAH4890C ACW-C(MD)PMP BRG TEMP HI 0 5
HIGH 80 °C 0.8
10TAH4891B ACW-B MOTOR DE BRG TEMP HI 0 5
HIGH 80 °C 0.8
10TAH4891C ACW-C MOTOR DE BRG TEMP HI 0 5
ACW-B MOTOR NDE BRG TEMP
HIGH 80 °C 0.8
10TAH4892B HI 0 5
ACW-C MOTOR NDE BRG TEMP
HIGH 80 °C 0.8
10TAH4892C HI 0 5
ACWPB(MD)MOTOR WDG TEMP
HIGH 130 °C 1.3
10TAH4893B HI 0 5
ACWPC(MD)MOTOR WDG TEMP
HIGH 130 °C 1.3
10TAH4893C HI 0 5
HIGH 130 °C 1.3
10TAH4894B HI 0 5
HIGH 130 °C 1.3
10TAH4894C HI 0 5
HIGH 130 °C 1.3
10TAH4895B HI 0 5
HIGH 130 °C 1.3
10TAH4895C HI 0 5
HIGH 130 °C 1.3
10TAH4896B HI 0 5
HIGH 130 °C 1.3
10TAH4896C HI 0 5
HIGH 130 °C 1.3
10TAH4897B HI 0 5
HIGH 130 °C 1.3
10TAH4897C HI 0 5
HIGH 130 °C 1.3
10TAH4898B HI 0 5
HIGH 130 °C 1.3
10TAH4898C HI 0 5
575TAHPM58 CW PMP A MOTOR WDG TMP01
HIGH 120 °C 1.2
0A01 HI 0 5
HIGH 120 °C 1.2
0A02 HI 0 5
HIGH 120 °C 1.2
0A03 HI 0 5
HIGH 120 °C 1.2
0A04 HI 0 5
HIGH 120 °C 1.2
0A05 HI 0 5
HIGH 120 °C 1.2
0A06 HI 0 5

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575TAHPM58
HIGH 80 °C 0.8
0A07 CW PMP A PUMP BRG TMP HI 0 5
575TAHPM58 CW PMP A MOTOR DE BRG TMP
HIGH 80 °C 0.8
0A08 HI 0 5
575TAHPM58 CW PMP A MOTOR NDE BRG
HIGH 80 °C 0.8
0A09 TMP HI 0 5
10LAH4825 GT-1 DMCW SURGE PIPE LVL HI HIGH 90 °C 0.9 30 3

HIGH 90 °C 0.9
10LAH4858 GT-2 DMCW SURGE PIPE LVL HI 30 3
10LAH4871 FRP COOLING TOWER LVL HI HIGH 90 °C 0.9 30 3

KG/CM
HIGH 7.5 0.02
10PAH1836D UB BFPD BAL LEAKOFF PR HI 2 15 3
KG/CM
HIGH 6 0.12
10PAH2519C UB BFPD LO DISH HDR PR HI 2 15 3
10DPAH1831 KG/CM
HIGH 0.15 0.003
D UBBFPD SUC DP HI 2 15 3
KG/CM
HIGH 0.2 0.004
10DPAH4827 GT-1 DMCW PMP-A SUC. DP HI 2 15 3
KG/CM
HIGH 0.2 0.004
10DPAH4872 GT-2 DMCW PMP-B SUC. DP HI 2 15 3
KG/CM
HIGH 0.2 0.004
10DPI4841 FRP CW PMP SUC DP HI 2 15 3
10DPAH2516 KG/CM
HIGH 0.5 0.01
C UB BFP-D LO FILTER DP HI 2 15 5
KG/CM
HIGH 0.2 0.004
10DPAH4831 GT-1 DMCW PMP-B SUC. DP HI 2 15 3
KG/CM
HIGH 0.2 0.004
10DPAH4859 GT-2 DMCW PMP-A SUC. DP HI 2 15 3
KG/CM
HIGH 8 0.016
10PAH5007 B/L N2 SUPPLY PR HI 2 15 1
B/L INSTRUMENT AIR SUPPLY PR KG/CM
HIGH 7 0.14
10PAH5001 HI 2 15 1
575AIPM574
HIGH 36 AMP 0
A AUX.CW PMP-3 CUR HI 0 5
575AIPM573
HIGH 36 AMP 0
A AUX.CW PMP-2 CUR HI 0 5
575AIPM580
HIGH 100 AMP 0
A FRP CW PMP CUR HI 0 5
575AIPM008
HIGH 165 AMP 0
D UB'S VHP BFP-D CUR HI 0 5
HYDRAZINE DOSING TO DEA
LOW 30 % 1.5
10LAL2002 METERING TNK LVL LO 0 4
10LAL4825 GT-1 DMCW SURGE PIPE LVL LO LOW 17 % 0.85 0 5

LOW 17 % 0.85
10LAL4858 GT-2 DMCW SURGE PIPE LVL LO 0 5
LOW 80 % 4
10LAL4871 FRP COOLING TOWER LVL LO 0 5
AMMONIA DOSING TO DEA
LOW 30 % 1.5

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TSP DOSING TO UB'S METERING

LOW 30 % 1.5
10LAL5202 TNK LVL LO 0 5
AMMONIA DOSING TO CST
LOW 30 % 1.5
10LAL2502C UB BFPD LO TNK LVL LO LOW 30 % 1.5 0 5

KG/CM
LOW 138 2.76
10PAL1838D UB BFPD DISG PR LO 2 15 5
KG/CM
LOW 2 0.04
10PAL2519C UB BFPD LO DISH HDR PR LO 2 0 5
KG/CM
LOW 4
10PAL4805 ACW PMP DISG HDR PR LO 2 0.08 0 5
GT-1 DMCW PUMP DISC HDR. KG/CM
LOW 1.2
10PAL4830 PR. LO 2 0.02 15 5
GT-2 DMCW PUMP DISC HDR. KG/CM
LOW 1.2
10PAL4862 PR. LO 2 0.02 15 5
KG/CM
LOW 1.4 0 5
10PAL1833D UB BFP-D SUC PR LO 2 0.03
KG/CM
LOW 5 15 3
10PAL5007 B/L N2 SUPPLY PR LO 2 0.1
B/L INSTRUMENT AIR SUPPLY PR KG/CM
LOW 4.5 15 3
10PAL5001 LO 2 0.1
10TAHH2257 VERY
90 °C
B HRSG BFPB GB BRG TEMP HH HIGH 0.9 0 4
10TAHH2255 VERY
90 °C
10TAHH2256 VERY
90 °C
10TAHH2258 VERY
90 °C
10TAHH2259 VERY
90 °C
10TAHH2260 VERY
90 °C
10TAHH2261 VERY
90 °C
10TAHH2262 VERY
90 °C
10TAHH2263 VERY
90 °C
10TAHH2264 VERY
90 °C
10TAHH2311 UB BFPD PMP THRUST BRG VERY
90 °C
D TEMP1 HH HIGH 0.9 0 4
90 °C
90 °C
90 °C
VERY 90 °C
10TAHH2315 UB-BFPD PMP NDE BRG TEMP1 0.9 0 4
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D HH HIGH
10TAHH2316 UB-BFPD PMP NDE BRG TEMP2 VERY

90 °C
D HH HIGH 0.9 0 4
10TAHH2317 UB-BFPD PMP DE BRG TEMP1 VERY
90 °C
D HH HIGH 0.9 0 4
10TAHH2318 UB-BFPD PMP DE BRG TEMP2 VERY
90 °C
D HH HIGH 0.9 0 4
10TAHH2321 UB-BFPD MOTOR DE BRG TEMP VERY
90 °C
D HH HIGH 0.9 0 4
10TAHH2322 UB-BFPD MOTOR NDE BRG VERY
90 °C
D TEMP HH HIGH 0.9 0 4
10TAHH2323 UB BFPD MOTOR WDG TEMP01 VERY
130 °C
D HH HIGH 1.3 0 4
130 °C
D HH HIGH 1.3 0 4
130 °C
D HH HIGH 1.3 0 4
130 °C
D HH HIGH 1.3 0 4
130 °C
D HH HIGH 1.3 0 4
130 °C
D HH HIGH 1.3 0 4
130 °C
D HH HIGH 1.3 0 4
130 °C
D HH HIGH 1.3 0 4
130 °C
D HH HIGH 1.3 0 4
130 °C
D HH HIGH 1.3 0 4
130 °C
D HH HIGH 1.3 0 4
130 °C
D HH HIGH 1.3 0 4
10TAHH4890 VERY
90 °C
B ACW-B(MD)PMP BRG TEMP HH HIGH 0.9 0 4
10TAHH4890 VERY
90 °C
C ACW-C(MD)PMP BRG TEMP HH HIGH 0.9 0 4
10TAHH4891 ACW-B MOTOR DE BRG TEMP VERY
90 °C
B HH HIGH 0.9 0 4
10TAHH4891 ACW-C MOTOR DE BRG TEMP VERY
90 °C
C HH HIGH 0.9 0 4
10TAHH4892 ACW-B MOTOR NDE BRG TEMP VERY
90 °C
B HH HIGH 0.9 0 4
10TAHH4892 ACW-C MOTOR NDE BRG TEMP VERY
90 °C
C HH HIGH 0.9 0 4
10TAHH4893 ACWPB(MD)MOTOR WDG TEMP VERY
135 °C
B HH HIGH 1.35 0 4
VERY 135 °C
10TAHH4893 ACWPC(MD)MOTOR WDG TEMP 1.35 0 4
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C HH HIGH

135 °C
B HH HIGH 1.35 0 4
10TAHH4894 ACWPC(MD)MOTOR WDG TEMP VERY
135 °C
C HH HIGH 1.35 0 4
135 °C
B HH HIGH 1.35 0 4
135 °C
C HH HIGH 1.35 0 4
135 °C
B HH HIGH 1.35 0 4
135 °C
C HH HIGH 1.35 0 4
135 °C
B HH HIGH 1.35 0 4
135 °C
C HH HIGH 1.35 0 4
135 °C
B HH HIGH 1.35 0 4
135 °C
C HH HIGH 1.35 0 4
575TAHHPM CW PMP A MOTOR WDG TMP01 VERY
130 °C
580A01 HH HIGH 1.3 0 4
130 °C
580A02 HH HIGH 1.3 0 4
575TAHHPM VERY
130 °C
580A03 CW PMP WDG A TMP03 HH HIGH 1.3 0 4
130 °C
580A04 HH HIGH 1.3 0 4
130 °C
580A05 HH HIGH 1.3 0 4
130 °C
580A06 HH HIGH 1.3 0 4
575TAHHPM VERY
90 °C
580A07 CW PMP A PUMP BRG TMP HH HIGH 0.9 0 4
575TAHHPM CW PMP A MOTOR DE BRG TMP VERY
90 °C
580A08 HH HIGH 0.9 0 4
575TAHHPM CW PMP A MOTOR NDE BRG VERY
90 °C
580A09 TMP HH HIGH 0.9 0 4
0.8
6C UB BFP-D LO FILTER DP HH HIGH 2 0.015 0 4
575AIPM574 VERY
38 AMP
A AUX.CW PMP-3 CUR HH HIGH 0 0 4
575AIPM573 VERY
38 AMP
A AUX.CW PMP-2 CUR HH HIGH 0 0 4
575AIPM580 VERY
120 AMP
A FRP CW PMP CUR HH HIGH 0 0 4
575AIPM008 VERY
171 AMP
D UB'S VHP BFP-D CUR HH HIGH 0 0 4
VERY LOW 20 % 1 0 4
10LALL2002 HYDRAZINE DOSING TO DEA
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METERING TNK LVL LL
10LALL4825 GT-1 DMCW SURGE PIPE LVL LL VERY LOW 20 % 1 0 4
10LALL4858 GT-2 DMCW SURGE PIPE LVL LL VERY LOW 20 % 1 0 4
10LALL4870 FRP COOLING TOWER LVL LL VERY LOW 20 % 1 0 4

AMMONIA DOSING TO DEA
VERY LOW 20 % 1 0 4
10LALL5102 METERING TNK LVL LL
TSP DOSING TO UB'S METERING
VERY LOW 20 % 1 0 4
10LALL5202 TNK LVL LL
AMMONIA DOSING TO CST
VERY LOW 20 % 1 0 4
10LALL5302 METERING TNK LVL LL
VERY LOW 20 % 1 0 4
10LALL2502C UB BFPD LO TNK LVL LL
KG/CM
VERY LOW 128 2.56 0 4
10PALL1838D UB BFPD DISG PR LL 2
KG/CM
VERY LOW 1.6 0.032 0 4
10PALL2520C UC BFPD LO DISH HDR PR LL 2
KG/CM
VERY LOW 3.8 0.1 0 4
10PALL4805 ACW PMP DISG HDR PR LL 2
HRSG BFPB MOTOR WDG TEMP
HIGH 120 ˚C 1.2 0 4
10TAH2126B HI
HIGH 120 ˚C 1.2 0 4
10TAH2127B HI
HIGH 120 ˚C 1.2 0 4
10TAH2128B HI
HIGH 120 ˚C 1.2 0 4
10TAH2129B HI
HIGH 120 ˚C 1.2 0 4
10TAH2130B HI
HIGH 120 ˚C 1.2 0 4
10TAH2131B HI
10TAH2329B UB BFPB MOTOR WDG TEMP HI HIGH 120 ˚C 1.2 0 4
HIGH 120 ˚C 1.2 0 4

10TAH2331B UB BFPB MOTOR WDG TEMP HI
HIGH 120 ˚C 1.2 0 4
HIGH 120 ˚C 1.2 0 4

HIGH 120 ˚C 1.2 0 4
10TAH2620B TEMP HI
HIGH 120 ˚C 1.2 0 4
10TAH2621B TEMP HI
HIGH 120 ˚C 1.2 0 4
10TAH2622B TEMP HI
HIGH 120 ˚C 1.2 0 4
10TAH2623B EXPORT BFPB MOTOR WDG
Revision 02
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TEMP HI

HIGH 120 ˚C 1.2 0 4
10TAH2624B TEMP HI
HIGH 120 ˚C 1.2 0 4
10TAH2625B TEMP HI
10PAH5502 SURGE AIR RECVR PR HI HIGH 10 Kg/Cm2 0.2 15 4
10PAH5505 ATOMOZING AIR RECVR-1 PR HI HIGH 32 Kg/Cm2 0.6 15 1
ATOMOZING AIR RECVR-2 PR HI HIGH 32 Kg/Cm2 0.6 15 1

10PAH5508
10PAH5514 INST AIR RECVR PR HI HIGH 32 Kg/Cm2 0.6 15 1

HP NITROGEN SYSTEM HDR PR
HIGH 42 Kg/Cm2 0.8 15 1
10PAH6904 HI
HIGH 42 Kg/Cm2 0.8 15 1
10PAH6905 HI
04HAZ1_GT1
HIGH 20 %LEL 5 3
HI GT-1 HAZ. GAS DETECTOR1 HI
04HAZ2_GT1
HIGH 20 %LEL 5 3
04HAZ3_GT1
HIGH 40 %LEL 5 3
04HAZ4_GT1
HIGH 40 %LEL 5 3
05HAZ1_GT2
HIGH 20 %LEL 5 3
05HAZ2_GT2
HIGH 20 %LEL 5 3
05HAZ3_GT2
HIGH 40 %LEL 5 3
05HAZ4_GT2
HIGH 40 %LEL 5 3
10PAL5502 SURGE AIR RECVR PR LO LOW 6 Kg/Cm2 0.12 15 3
10PAL5505 ATOMOZING AIR RECVR-1 PR LO LOW 26 Kg/Cm2 0.5 15 3
10PAL5508 ATOMOZING AIR RECVR-2 PR LO LOW 26 Kg/Cm2 0.5 15 3

INST AIR RECVR PR LO LOW 26 Kg/Cm2 0.5
10PAL5514 15 3
HP NITROGEN SYSTEM HDR LOW 38 Kg/Cm2 0.75
10PAL6904 15 5
LOW 38 Kg/Cm2 0.75
10PAL6905 LO 15 5
10TAHH2126 HRSG BFPB MOTOR WDG TEMP VERY
130 ˚C 1.3
B HH HIGH 0 4
130 ˚C 1.3
B HH HIGH 0 4
130 ˚C 1.3
B HH HIGH 0 4

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130 ˚C 1.3
B HH HIGH 0 4
130 ˚C 1.3
B HH HIGH 0 4
130 ˚C 1.3
B HH HIGH 0 4
10TAHH2329 VERY
130 ˚C 1.3
B UB BFPB MOTOR WDG TEMP HH HIGH 0 4
10TAHH2330 VERY
130 ˚C 1.3
10TAHH2331 VERY
130 ˚C 1.3
10TAHH2332 VERY
130 ˚C 1.3
10TAHH2333 VERY
130 ˚C 1.3
10TAHH2334 VERY
130 ˚C 1.3
130 ˚C 1.3
B TEMP HH HIGH 0 4
130 ˚C 1.3
B TEMP HH HIGH 0 4
130 ˚C 1.3
B TEMP HH HIGH 0 4
130 ˚C 1.3
B TEMP HH HIGH 0 4
130 ˚C 1.3
B TEMP HH HIGH 0 4
130 ˚C 1.3
B TEMP HH HIGH 0 4
HP NITROGEN SYSTEM HDR PR VERY
44 Kg/Cm2 0.88
10PAHH6906 HH HIGH 15 3
04HAZ1_GT1 VERY
60 %LEL
HH GT-1 HAZ. GAS DETECTOR1 HH HIGH 5 3
04HAZ2_GT1 VERY
60 %LEL
04HAZ3_GT1 VERY
60 %LEL
04HAZ4_GT1 VERY
60 %LEL
05HAZ1_GT2 VERY
60 %LEL
05HAZ2_GT2 VERY
60 %LEL
05HAZ3_GT2 VERY
60 %LEL
05HAZ4_GT2 VERY
60 %LEL
1-STAGE COMPRESSOR SUCTION
HIGH NA 150 °C 1.5 0 0
TAH401 TEMPERATURE HI 5

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1-STAGE COMPRESSOR SUCTION KG/CM

HIGH NA 15 0.3 0 0
PAH401 PRESSURE HI 2 5
HIGH NA 130 °C 1.3 0 0
2-STAGE COMPRESSOR SUCTION KG/CM
HIGH NA 25 0.5 0 0
PAH402 PRESSURE HI 2 5
HIGH NA 120 °C 1.2 0 0
LAH6903 GAS SCRUBBER LEVEL HI HIGH 225 MM 5 0

VERY
275 MM 0
LAHH6903 GAS SCRUBBER LEVEL HH HIGH 4
LOW 125 MM 0
LAL6903 GAS SCRUBBER LEVEL LO 5
LALL6903 GAS SCRUBBER LEVEL LL VERY LOW 75 MM 4 0
HIGH 225 MM 0
LAH6905 GAS SCRUBBER LEVEL HI 5
VERY
275 MM 0
LAHH6905 GAS SCRUBBER LEVEL HH HIGH 4
LOW 125 MM 0
LAL6905 GAS SCRUBBER LEVEL LO 5
LALL6905 GAS SCRUBBER LEVEL LL VERY LOW 75 MM 4 0

LP STEAM TO STEAM HEATER-1 VERY KG/CM
5.5 0
PAH7343A PRESSURE HH HIGH 2 4
ATOMISING AIR COMPRESSOR MICRO
HIGH 0.85 NA 0 0 0
1VAH 1-STAGE VIBRATION HI N 5
HIGH 0.80 NA 0 0 0
HIGH 0.80 NA 0 0 0
ATOMISING AIR COMPRESSOR
HIGH 49 NA °C 0.49 0 0
1TAH LUBE OIL TEMPERATURE HI 5
LOW 38 NA °C 0.38 0 0
1TAL LUBE OIL TEMPERATURE LO 5
ATOMISING AIR COMPRESSOR KG/CM
2PAL LOW 1.27 NA 0.025 0 5 0
LUBE OIL PRESSURE LO 2
ATOMISING AIR COMPRESSOR VERY MICRO
NA 1.05 0 0 4 0
1VAHH 1-STAGE VIBRATION HH HIGH N
NA 1.00 0 0 4 0
NA 1.00 0 0 4 0
ATOMISING AIR COMPRESSOR VERY
NA 52 °C 0.52 0 4 0
1TAHH LUBE OIL TEMPERATURE HH HIGH
VERY LOW NA 35 °C 0.35 0 4 0
2TALL LUBE OIL TEMPERATURE LL
ATOMISING AIR COMPRESSOR KG/CM
VERY LOW NA 1.12 0.022 0 4 0
2PALL LUBE OIL PRESSURE LL 2
STG-1 MP EXTR HDR PRESSURE- HIGH 12.8 N/A 0.3 0
1PAH3123A 1 HI Kg/Cm2 5

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1PAH3123B 2 HI Kg/Cm2 5
1PAH3123C 3 HI Kg/Cm2 5
STG-1 HP EXTR HDR PRESSURE-1 HIGH 42 N/A 0.84 0
1PAH3113A HI Kg/Cm2 5
1PAH3113B HI Kg/Cm2 5
1PAH3113C HI Kg/Cm2 5
HIGH 6615 N/A RPM 0 0

1SE3502AHI STG-1 TURBINE SPEED-1 HI 5

1SE3502BHI STG-1 TURBINE SPEED-2 HI 5

1SE3502CHI STG-1 TURBINE SPEED-3 HI 5
HIGH -0.6 N/A -0.012 0

1PAH3172A STG-1 EXHAUST PRESSURE HI Kg/Cm2 5
HIGH -0.6 N/A -0.012 0

1PAH3172B STG-1 EXHAUST PRESSURE HI Kg/Cm2 5
HIGH -0.6 N/A -0.012 0

1PAH3172C STG-1 EXHAUST PRESSURE HI Kg/Cm2 5
HIGH 90 N/A 0.9 30

1TAH3173 STG-1 EXHAUST HOOD TEMP HI °C 1
HIGH 70 N/A 0.7

1TAH3206 STG-1 LO TANK TEMP HI °C 1
HIGH 1.5 N/A 0.0 15

1DPAH3209 STG-1 DP ACROSS LO FILTER HI Kg/Cm2 1
HIGH 1535 N/A mm 75.0 30

1LAH3202 STG-1 MAIN OIL TANK LVL HI 3
STG-1 THRUST BEARING METAL HIGH 95 N/A 0.95 0
1TAH3501 TEMP1(NON ACTIVE) HI °C 5
1TAH3502A TEMP2(NON ACTIVE) HI °C 5
1TAH3503 TEMP1(ACTIVE) HI °C 5
1TAH3504A TEMP2(ACTIVE) HI °C 5
STG-1 TURBINRE FRONT SHAFT HIGH 113 N/A Micron N/A 0
1VAH3501A VIBRATION HI 5
STG-1 TURBINRE FRONT SHAFT HIGH 113 N/A Micron 0
1VAH3501B VIBRATION HI 5
STG-1 TURBINE FRONT BEARING HIGH 95 N/A 0.95 0
1TAH3505 METAL TEMP1 HI °C 5
STG-1 TURBINE FRONT BEARING HIGH 95 N/A 0.95 0
1TAH3505A METAL TEMP 2 HI °C 5
Revision 02
9112-575-OPR-701-00002 Page 68 of 92
STG-1 TURBINE REAR BEARING HIGH 95 N/A 0.95 30

1TAH3506 METAL TEMP1 HI °C 5
STG-1 TURBINE REAR BEARING HIGH 95 N/A 0.95 30
1TAH3506A METAL TEMP 2 HI °C 5
STG-1 TURBINRE REAR SHAFT HIGH 113 N/A Micron N/A 0
STG-1 TURBINRE REAR SHAFT HIGH 113 N/A Micron 0
STG-1 G/B HSS FRONT BEARING HIGH 113 N/A Micron 0
1VAH3503A VIB. HI 5
STG-1 G/B HSS FRONT BEARING HIGH 113 N/A Micron 0
1VAH3503B VIB. HI 5
STG-1 G/B HSS FRONT BEARING HIGH 95 N/A 0.95 0
1TAH3507 TEMP. HI °C 5
STG-1 G/B HSS REAR BEARING HIGH 113 N/A Micron N/A 0
1VAH3504A VIB. HI 5
STG-1 G/B HSS REAR BEARING HIGH 113 N/A Micron 0
1VAH3504B VIB. HI 5
STG-1 G/B HSS REAR BEARING HIGH 95 N/A 0.95 0
STG-1 G/B LSS FRONT BEARING HIGH 113 N/A Micron N/A 0
1VAH3503A VIB. HI 5
STG-1 G/B LSS FRONT BEARING HIGH 113 N/A Micron 0
1VAH3503B VIB. HI 5
STG-1 G/B LSS FRONT BEARING HIGH 95 N/A 0.95 0
STG-1 G/B LSS REAR BEARING HIGH 164 N/A Micron 0
1VAH3506A VIB. HI 5
STG-1 G/B LSS REAR BEARING HIGH 164 N/A Micron 0
1VAH3506B VIB. HI 5
STG-1 G/B LSS REAR BEARING HIGH 95 N/A 0.95 0
STG-1 G/B THRUST BEARING HIGH 95 N/A 0.95 0
1TAH3509 TEMP(NON-ACTIVE)HI °C 5
STG-1 G/B THRUST BEARING HIGH 95 N/A 0.95 0
1TAH3510 TEMP (ACTIVE)HI °C 5
STG-1 GENERATOR REAR SHAFT HIGH 164 N/A Micron N/A 0
1VAH3508A VIB HI 5
STG-1 GENERATOR REAR SHAFT HIGH 164 N/A Micron 0
1VAH3508B VIB HI 5
STG-1 GENERATOR REAR HIGH 95 N/A 0.95 0
1TAH3514 BRG.TEMP HI °C 5
STG-1 GENERATOR FRONT HIGH 164 N/A Micron N/A 0
1VAH3507A SHAFT VIB HI 5
STG-1 GENERATOR FRONT HIGH 164 N/A Micron 0
1VAH3507B SHAFT VIB HI 5
Revision 02
9112-575-OPR-701-00002 Page 69 of 92
STG-1 GENERATOR FRONT HIGH 115 N/A 0.95 0

1TAH3513 BRG.TEMP HI °C 5
STG-1 MP EXTR HDR PRESSURE- LOW 10.7 N/A 0.2 0
1PAL3123A 1LO Kg/Cm2 5
1PAL3123B 2LO Kg/Cm2 5
1PAL3123C 3LO Kg/Cm2 5
STG-1 HP EXTR HDR PRESSURE- LOW 38 N/A 0.76 0
1PAL3113A 1LO Kg/Cm2 5
1PAL3113B 2LO Kg/Cm2 5
1PAL3113C 3LO Kg/Cm2 5
LOW 5.5 N/A 0.11 0

1PAL3401A STG-1 CONTROL OIL PR LO Kg/Cm2 5
LOW 5.5 N/A 0.11 0

1PAL3401B STG-1 CONTROL OIL PR LO Kg/Cm2 5
LOW 5.5 N/A 0.11 0

1PAL3401C STG-1 CONTROL OIL PR LO Kg/Cm2 5
LOW 2.5 N/A 0.05 0

1PAL3402A STG-1 TRIP OIL PR LO Kg/Cm2 5
LOW 2.5 N/A 0.05 0

1PAL3402B STG-1 TRIP OIL PR LO Kg/Cm2 5
LOW 2.5 N/A 0.05 0

1PAL3402C STG-1 TRIP OIL PR LO Kg/Cm2 5
LOW 6.5 N/A 0.13 0

1PAL3206 STG-1 LO PUMP DISCH. PR LO Kg/Cm2 3
LOW 40 N/A 2
1TAL3206 STG-1 LO TANK TEMP LO °C 30 1
STG-1 LO OVRHEAD TANK LVL LOW 500 N/A mm 25
1LAL3207 LO 30 1
LOW 1435 N/A mm 70

1LAL3202 STG-1 MAIN OIL TANK LVL LO 30 1
LOW 1.5 N/A 0.03

1PAL3214A STG-1 LUBE OIL HDR. PR-1 LO Kg/Cm2 0 5
LOW 1.5 N/A 0.03

1PAL3214B STG-1 LUBE OIL HDR. PR-2 LO Kg/Cm2 0 5
LOW 1.5 N/A 0.03

1PAL3214C STG-1 LUBE OIL HDR. PR-3 LO Kg/Cm2 0 5
STG-1 MP EXTR HDR PRESSURE- VERY 15 N/A 0.3
1PAHH3123A 1 HH HIGH Kg/Cm2 0 4
1PAHH3123B 2 HH HIGH Kg/Cm2 0 4
1PAHH3123C 3 HH HIGH Kg/Cm2 0 4
Revision 02
9112-575-OPR-701-00002 Page 70 of 92
STG-1 HP EXTR HDR PRESSURE-1 VERY 49.1 N/A 0.98

1PAHH3113A HH HIGH Kg/Cm2 0 4
1PAHH3113B HH HIGH Kg/Cm2 0 4
1PAHH3113C HH HIGH Kg/Cm2 0 4
VERY
N/A 6930 RPM N/A
1SE3502AHH STG-1 TURBINE SPEED-1 HH HIGH 0 4
VERY
N/A 6930 RPM
1SE3502BHH STG-1 TURBINE SPEED-2 HH HIGH 0 4
VERY
N/A 6930 RPM
1SE3502CHH STG-1 TURBINE SPEED-3 HH HIGH 0 4
VERY
N/A -0.4 -0.08
1PAHH3172A STG-1 EXHAUST PRESSURE HH HIGH Kg/Cm2 0 4
VERY
N/A -0.4 -0.08
1PAHH3172B STG-1 EXHAUST PRESSURE HH HIGH Kg/Cm2 0 4
VERY
N/A -0.4 -0.08
1PAHH3172C STG-1 EXHAUST PRESSURE HH HIGH Kg/Cm2 0 4
STG-1 THRUST BEARING METAL VERY N/A 115 1.15
1TAHH3501 TEMP1(NON ACTIVE) HH HIGH °C 0 4
1TAHH3502A TEMP2(NON ACTIVE) HH HIGH °C 0 4
1TAHH3503 TEMP1(ACTIVE) HH HIGH °C 0 4
1TAHH3504A TEMP2(ACTIVE) HH HIGH °C 0 4
STG-1 TURBINRE FRONT SHAFT VERY N/A 166 Micron N/A
1VAHH3501A VIBRATION HH HIGH 0 4
STG-1 TURBINRE FRONT SHAFT VERY N/A 166 Micron
1VAHH3501B VIBRATION HH HIGH 0 4
STG-1 TURBINE FRONT BEARING VERY N/A 115 1.15
1TAHH3505 METAL TEMP1 HH HIGH °C 0 4
STG-1 TURBINE FRONT BEARING VERY N/A 115 1.15
1TAHH3505A METAL TEMP2HH HIGH °C 0 4
STG-1 TURBINE REAR BEARING VERY N/A 115 1.15
1TAHH3506 METAL TEMP1 HH HIGH °C 0 4
STG-1 TURBINE REAR BEARING VERY N/A 115 1.15
1TAHH3506A METAL TEMP2HH HIGH °C 0 4
STG-1 TURBINRE REAR SHAFT VERY N/A 166 Micron N/A
STG-1 TURBINRE REAR SHAFT VERY N/A 166 Micron
STG-1 G/B HSS FRONT BEARING VERY N/A 166 Micron
1VAHH3503A VIB. HH HIGH 0 4
STG-1 G/B HSS FRONT BEARING VERY N/A 166 Micron
1VAHH3503B VIB. HH HIGH 0 4
Revision 02
9112-575-OPR-701-00002 Page 71 of 92
STG-1 G/B HSS FRONT BEARING VERY N/A 115 1.15

1TAHH3507 TEMP. HH HIGH °C 0 4
STG-1 G/B HSS REAR BEARING VERY N/A 166
STG-1 G/B HSS REAR BEARING VERY N/A 166
STG-1 G/B HSS REAR BEARING VERY N/A 115 1.15
STG-1 G/B LSS FRONT BEARING VERY N/A 166 Micron N/A
STG-1 G/B LSS FRONT BEARING VERY N/A 166 Micron
STG-1 G/B LSS FRONT BEARING VERY N/A 115 1.15
STG-1 G/B LSS REAR BEARING VERY N/A 240 Micron N/A
STG-1 G/B LSS REAR BEARING VERY N/A 240 Micron
STG-1 G/B LSS REAR BEARING VERY N/A 115 1.15
STG-1 G/B THRUST BEARING VERY N/A 115 1.15
1TAHH3509 TEMP(NON-ACTIVE)HH HIGH °C 0 4
STG-1 G/B THRUST BEARING VERY N/A 115 1.15
1TAHH3510 TEMP(ACTIVE)HH HIGH °C 0 4
STG-1 GENERATOR REAR SHAFT VERY N/A 240 Micron
1VAHH3508A VIB HH HIGH 0 4
STG-1 GENERATOR REAR SHAFT VERY N/A 240 Micron
1VAHH3508B VIB HH HIGH 0 4
STG-1 GENERATOR REAR VERY N/A 115 1.15
1TAHH3514 BRG.TEMP HH HIGH °C 0 4
STG-1 GENERATOR FRONT VERY N/A 240 Micron N/A
1VAHH3507A SHAFT VIB HH HIGH 0 4
STG-1 GENERATOR FRONT VERY N/A 240 Micron
1VAHH3507B SHAFT VIB HH HIGH 0 4
STG-1 GENERATOR FRONT VERY N/A 115 1.15
1TAHH3513 BRG.TEMP HH HIGH °C 0 4
STG-1 MP EXTR HDR PRESSURE- VERY LOW N/A 9.6 0.192
1PALL3123A 1 LL Kg/Cm2 0 4
1PALL3123B 2 LL Kg/Cm2 0 4
1PALL3123C 3 LL Kg/Cm2 0 4
STG-1 HP EXTR HDR PRESSURE-1 VERY LOW N/A 34.1 0.682
1PALL3113A LL Kg/Cm2 0 4
1PALL3113B LL Kg/Cm2 0 4
Revision 02
9112-575-OPR-701-00002 Page 72 of 92

1PALL3113C LL Kg/Cm2 0 4
VERY LOW N/A 4.5 0.09

1PALL3401A STG-1 CONTROL OIL PR LL Kg/Cm2 0 4

1PALL3401B STG-1 CONTROL OIL PR LL Kg/Cm2 0 4

1PALL3401C STG-1 CONTROL OIL PR LL Kg/Cm2 0 4
VERY LOW N/A 2 0.04

1PALL3402A STG-1 TRIP OIL PR LL Kg/Cm2 0 4
VERY LOW N/A 2 0.04

1PALL3402B STG-1 TRIP OIL PR LL Kg/Cm2 0 4
VERY LOW N/A 2 0.04

1PALL3402C STG-1 TRIP OIL PR LL Kg/Cm2 0 4
VERY LOW 900 N/A 45

1LALL3202 STG-1 MAIN OIL TANK LVL LL mm 30 3

1PALL3214A STG-1 LUBE OIL HDR. PR-1 LL Kg/Cm2 0 4

1PALL3214B STG-1 LUBE OIL HDR. PR-2 LL Kg/Cm2 0 4
STG-2 MP EXTR HDR PRESSURE- HIGH 12.8 Kg/Cm2 0.3 0
2PAH3123A 1 HI 5
2PAH3123B 2 HI 5
2PAH3123C 3 HI 5
STG-2 HP EXTR HDR PRESSURE-1 HIGH 42 Kg/Cm2 0.84 0
2PAH3113A HI 5
2PAH3113B HI 5
2PAH3113C HI 5
HIGH 6615 RPM 0 0

2SE3502AHI STG-2 TURBINE SPEED-1 HI 5
HIGH 6615 RPM 0 0

2SE3502BHI STG-2 TURBINE SPEED-2 HI 5
HIGH 6615 RPM 0 0

2SE3502CHI STG-2 TURBINE SPEED-3 HI 5
HIGH -0.6 Kg/Cm2 -0.012 0

2PAH3172A STG-2 EXHAUST PRESSURE HI 5
HIGH -0.6 Kg/Cm2 -0.012 0

2PAH3172B STG-2 EXHAUST PRESSURE HI 5
HIGH -0.6 Kg/Cm2 -0.012 0

2PAH3172C STG-2 EXHAUST PRESSURE HI 5
HIGH 90 °C 0.9 30
2TAH3173 STG-2 EXHAUST HOOD TEMP HI 1
Revision 02
9112-575-OPR-701-00002 Page 73 of 92
HIGH 70 °C 0.7
2TAH3206 STG-2 LO TANK TEMP HI 1
HIGH 1.5 Kg/Cm2 0.0 15

2DPAH3209 STG-2 DP ACROSS LO FILTER HI 1
HIGH 1535 mm 75.0 30

2LAH3202 STG-2 MAIN OIL TANK LVL HI 3
STG-2 THRUST BEARING METAL HIGH 95 °C 0.95 0
2TAH3501 TEMP1(NON ACTIVE) HI 5
2TAH3502A TEMP2(NON ACTIVE) HI 5
2TAH3503 TEMP1(ACTIVE) HI 5
2TAH3504A TEMP2(ACTIVE) HI 5
STG-2 TURBINRE FRONT SHAFT HIGH 113 Micron 0
STG-2 TURBINRE FRONT SHAFT HIGH 113 Micron 0
STG-2 TURBINE FRONT BEARING HIGH 95 °C 0.95 0
2TAH3505 METAL TEMP1 HI 5
STG-2 TURBINE FRONT BEARING HIGH 95 °C 0.95 0
2TAH3505A METAL TEMP 2 HI 5
STG-2 TURBINE REAR BEARING HIGH 95 °C 0.95 30
2TAH3506 METAL TEMP1 HI 5
STG-2 TURBINE REAR BEARING HIGH 95 °C 0.95 30
2TAH3506A METAL TEMP 2 HI 5
STG-2 TURBINRE REAR SHAFT HIGH 113 Micron 0
STG-2 TURBINRE REAR SHAFT HIGH 113 Micron 0
STG-2 G/B HSS FRONT BEARING HIGH 113 Micron 0
2VAH3503A VIB. HI 5
STG-2 G/B HSS FRONT BEARING HIGH 113 Micron 0
2VAH3503B VIB. HI 5
STG-2 G/B HSS FRONT BEARING HIGH 95 °C 0.95 0
2TAH3507 TEMP. HI 5
STG-2 G/B HSS REAR BEARING HIGH 113 Micron 0
2VAH3504A VIB. HI 5
STG-2 G/B HSS REAR BEARING HIGH 113 Micron 0
2VAH3504B VIB. HI 5
STG-2 G/B HSS REAR BEARING HIGH 95 °C 0.95 0
2TAH3508 TEMP. HI 5
STG-2 G/B LSS FRONT BEARING HIGH 113 Micron 0
2VAH3503A VIB. HI 5
STG-2 G/B LSS FRONT BEARING HIGH 113 Micron 0
2VAH3503B VIB. HI 5
Revision 02
9112-575-OPR-701-00002 Page 74 of 92
STG-2 G/B LSS FRONT BEARING HIGH 95 °C 0.95 0

2TAH3507 TEMP. HI 5
STG-2 G/B LSS REAR BEARING HIGH 164 Micron 0
2VAH3506A VIB. HI 5
STG-2 G/B LSS REAR BEARING HIGH 164 Micron 0
2VAH3506B VIB. HI 5
STG-2 G/B LSS REAR BEARING HIGH 95 °C 0.95 0
2TAH3512 TEMP. HI 5
STG-2 G/B THRUST BEARING HIGH 95 °C 0.95 0
2TAH3509 TEMP(NON-ACTIVE)HI 5
STG-2 G/B THRUST BEARING HIGH 95 °C 0.95 0
2TAH3510 TEMP (ACTIVE)HI 5
STG-2 GENERATOR REAR SHAFT HIGH 164 Micron 0
2VAH3508A VIB HI 5
STG-2 GENERATOR REAR SHAFT HIGH 164 Micron 0
2VAH3508B VIB HI 5
STG-2 GENERATOR REAR HIGH 95 °C 0.95 0
2TAH3514 BRG.TEMP HI 5
STG-2 GENERATOR FRONT HIGH 164 Micron 0
2VAH3507A SHAFT VIB HI 5
STG-2 GENERATOR FRONT HIGH 164 Micron 0
2VAH3507B SHAFT VIB HI 5
STG-2 GENERATOR FRONT HIGH 115 °C 0.95 0
2TAH3513 BRG.TEMP HI 5
STG-2 MP EXTR HDR PRESSURE- LOW 10.7 Kg/Cm2 0.2 0
2PAL3123A 1LO 5
2PAL3123B 2LO 5
2PAL3123C 3LO 5
STG-2 HP EXTR HDR PRESSURE- LOW 38 Kg/Cm2 0.76 0
2PAL3113A 1LO 5
2PAL3113B 2LO 5
2PAL3113C 3LO 5
LOW 5.5 Kg/Cm2 0.11 0

2PAL3401A STG-2 CONTROL OIL PR LO 5
LOW 5.5 Kg/Cm2 0.11 0

2PAL3401B STG-2 CONTROL OIL PR LO 5
LOW 5.5 Kg/Cm2 0.11 0

2PAL3401C STG-2 CONTROL OIL PR LO 5
LOW 2.5 Kg/Cm2 0.05 0

2PAL3402A STG-2 TRIP OIL PR LO 5
LOW 2.5 Kg/Cm2 0.05 0

2PAL3402B STG-2 TRIP OIL PR LO 5
Revision 02
9112-575-OPR-701-00002 Page 75 of 92
LOW 2.5 Kg/Cm2 0.05 0

2PAL3402C STG-2 TRIP OIL PR LO 5
LOW 6.5 Kg/Cm2 0.13 0

2PAL3206 STG-2 LO PUMP DISCH. PR LO 3
LOW 40 °C 2
2TAL3206 STG-2 LO TANK TEMP LO 30 1
STG-2 LO OVRHEAD TANK LVL LOW 500 mm 25
2LAL3207 LO 30 1
LOW 1435 mm 70
2LAL3202 STG-2 MAIN OIL TANK LVL LO 30 1
LOW 1.5 Kg/Cm2 0.03

2PAL3214A STG-2 LUBE OIL HDR. PR-1 LO 0 5
LOW 1.5 Kg/Cm2 0.03

2PAL3214B STG-2 LUBE OIL HDR. PR-2 LO 0 5
LOW 1.5 Kg/Cm2 0.03

2PAL3214C STG-2 LUBE OIL HDR. PR-3 LO 0 5
STG-2 MP EXTR HDR PRESSURE- VERY 15 Kg/Cm2 0.3
2PAHH3123A 1 HH HIGH 0 4
2PAHH3123B 2 HH HIGH 0 4
2PAHH3123C 3 HH HIGH 0 4
STG-2 HP EXTR HDR PRESSURE-1 VERY 49.1 Kg/Cm2 0.98
2PAHH3113A HH HIGH 0 4
2PAHH3113B HH HIGH 0 4
2PAHH3113C HH HIGH 0 4
VERY
6930 RPM
2SE3502AHH STG-2 TURBINE SPEED-1 HH HIGH 0 4
VERY
6930 RPM
2SE3502BHH STG-2 TURBINE SPEED-2 HH HIGH 0 4
VERY
6930 RPM
2SE3502CHH STG-2 TURBINE SPEED-3 HH HIGH 0 4
VERY
-0.4 Kg/Cm2 -0.08
2PAHH3172A STG-2 EXHAUST PRESSURE HH HIGH 0 4
VERY
-0.4 Kg/Cm2 -0.08
2PAHH3172B STG-2 EXHAUST PRESSURE HH HIGH 0 4
VERY
-0.4 Kg/Cm2 -0.08
2PAHH3172C STG-2 EXHAUST PRESSURE HH HIGH 0 4
STG-2 THRUST BEARING METAL VERY 115 °C 1.15
2TAHH3501 TEMP1(NON ACTIVE) HH HIGH 0 4
2TAHH3502A TEMP2(NON ACTIVE) HH HIGH 0 4
2TAHH3503 TEMP1(ACTIVE) HH HIGH 0 4
Revision 02
9112-575-OPR-701-00002 Page 76 of 92

2TAHH3504A TEMP2(ACTIVE) HH HIGH 0 4
STG-2 TURBINRE FRONT SHAFT VERY 166 Micron
STG-2 TURBINRE FRONT SHAFT VERY 166 Micron
STG-2 TURBINE FRONT BEARING VERY 115 °C 1.15
2TAHH3505 METAL TEMP1 HH HIGH 0 4
STG-2 TURBINE FRONT BEARING VERY 115 °C 1.15
2TAHH3505A METAL TEMP2HH HIGH 0 4
STG-2 TURBINE REAR BEARING VERY 115 °C 1.15
2TAHH3506 METAL TEMP1 HH HIGH 0 4
STG-2 TURBINE REAR BEARING VERY 115 °C 1.15
2TAHH3506A METAL TEMP2HH HIGH 0 4
STG-2 TURBINRE REAR SHAFT VERY 166 Micron
STG-2 TURBINRE REAR SHAFT VERY 166 Micron
STG-2 G/B HSS FRONT BEARING VERY 166 Micron
STG-2 G/B HSS FRONT BEARING VERY 166 Micron
STG-2 G/B HSS FRONT BEARING VERY 115 °C 1.15
2TAHH3507 TEMP. HH HIGH 0 4
STG-2 G/B HSS REAR BEARING VERY 166 Micron
STG-2 G/B HSS REAR BEARING VERY 166 Micron
STG-2 G/B HSS REAR BEARING VERY 115 °C
STG-2 G/B LSS FRONT BEARING VERY 166 Micron
STG-2 G/B LSS FRONT BEARING VERY 166 Micron
STG-2 G/B LSS FRONT BEARING VERY 115 °C
STG-2 G/B LSS REAR BEARING VERY 240 Micron
STG-2 G/B LSS REAR BEARING VERY 240 Micron
STG-2 G/B LSS REAR BEARING VERY 115 °C 1.15
STG-2 G/B THRUST BEARING VERY 115 °C 1.15
2TAHH3509 TEMP(NON-ACTIVE)HH HIGH 0 4
STG-2 G/B THRUST BEARING VERY 115 °C 1.15
2TAHH3510 TEMP(ACTIVE)HH HIGH 0 4
Revision 02
9112-575-OPR-701-00002 Page 77 of 92
STG-2 GENERATOR REAR SHAFT VERY 240 Micron

2VAHH3508A VIB HH HIGH 0 4
STG-2 GENERATOR REAR SHAFT VERY 240 Micron
2VAHH3508B VIB HH HIGH 0 4
STG-2 GENERATOR REAR VERY 115 °C 1.15
2TAHH3514 BRG.TEMP HH HIGH 0 4
STG-2 GENERATOR FRONT VERY 240 Micron
2VAHH3507A SHAFT VIB HH HIGH 0 4
STG-2 GENERATOR FRONT VERY 240 Micron
2VAHH3507B SHAFT VIB HH HIGH 0 4
STG-2 GENERATOR FRONT VERY 115 °C 1.15
2TAHH3513 BRG.TEMP HH HIGH 0 4
STG-2 MP EXTR HDR PRESSURE- VERY LOW 9.6 Kg/Cm2 0.192
2PALL3123A 1 LL 0 4
2PALL3123B 2 LL 0 4
2PALL3123C 3 LL 0 4
STG-2 HP EXTR HDR PRESSURE-1 VERY LOW 34.1 Kg/Cm2 0.682
2PALL3113A LL 0 4
2PALL3113B LL 0 4
2PALL3113C LL 0 4
VERY LOW 4.5 Kg/Cm2 0.09

2PALL3401A STG-2 CONTROL OIL PR LL 0 4

2PALL3401B STG-2 CONTROL OIL PR LL 0 4

2PALL3401C STG-2 CONTROL OIL PR LL 0 4
VERY LOW 2 Kg/Cm2 0.04

2PALL3402A STG-2 TRIP OIL PR LL 0 4

2PALL3402B STG-2 TRIP OIL PR LL 0 4

2PALL3402C STG-2 TRIP OIL PR LL 0 4
VERY LOW 900 mm 45

2LALL3202 STG-2 MAIN OIL TANK LVL LL 30 3

2PALL3214A STG-2 LUBE OIL HDR. PR-1 LL 0 4

2PALL3214B STG-2 LUBE OIL HDR. PR-2 LL 0 4
3TAH3704A BPTG L.O. TEMP AFTER COOLER HIGH 55 °C 0.55 30 1

HI
3TAH3704B BPTG L.O. TEMP AFTER COOLER HIGH 55 °C 0.55 30 1
HI
Revision 02
9112-575-OPR-701-00002 Page 78 of 92
3SE4002AHI HIGH 5250 RPM 0 5

BPTG TURBINE SPEED-1 HI
3SE4002BHI HIGH 5250 RPM 0 5

3SE4002CHI HIGH 5250 RPM 0 5

3PAH3606A HIGH 5.6 Kg/Cm2 0.112 0 5

BPTG EXHAUST PRESSURE HI
3PAH3606B HIGH 5.6 Kg/Cm2 0.112 0 5

3PAH3606C HIGH 5.6 Kg/Cm2 0.112 0 5

3PAH3602 HIGH 112 Kg/Cm2 2.24 15 1

BPTG INLET STEAM PRESSURE HI
3DPAH3709 HIGH 1.5 Kg/Cm2 0.03 15 1

BPTG DP ACROSS LO FILTER HI
3LAH3702 HIGH 1535 76.75 30 1

BPTG MAIN OIL TANK LVL HI MM
3TAH3706 HIGH 70 °C 0.7 30 3

BPTG L.O TANK TEMP HI
3TAH3702 BPTG L.O TEMP. BEF COOLERS HIGH 45 °C 0.45 30 1

HI
3TAH3601 HIGH 520 °C 5.2 30 1
BPTG INLET STEAM TEMP HI
3TAH4011 BPTG GEAR BOX LSS FRONT BRG HIGH 120 °C 1.2 0 5
TEMP HI
3TAH4001 BPTG TURBINE THRUST BRG HIGH 95 °C 0.95 0 5

METAL TEMP NON-ACTIVE HI

METAL TEMP ACTIVE HI
3TAH4005 BPTG TURBINE FRONT BRG HIGH 95 °C 0.95 0 5

METAL TEMP-1 HI
3TAH4005A BPTG TURBINE FRONT BRG HIGH 95 °C 0.95 0 5

METAL TEMP-2 HI
3TAH4007 BPTG GEAR BOX HSS FRONT BRG HIGH 120 °C 1.2 0 5
TEMP HI
3TAH4009 BPTG GEAR BOX LSS THRUST HIGH 120 °C 1.2 0 5

BRG TEMP HI
3TAH4013 BPTG GENERATOR FRONT BRG HIGH 95 °C 0.95 0 5

METAL TEMP HI
3TAH4006A BPTG TURBINE REAR BRG HIGH 95 °C 0.95 0 5

METAL TEMP-2 HI
3TAH4012 BPTG GEAR BOX LSS REAR BRG HIGH 120 °C 1.2 0 5
TEMP HI
3TAH4014 BPTG GENERATOR REAR BRG HIGH 95 °C 0.95 0 5
METAL TEMP HI
Revision 02
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METAL TEMP NON-ACTIVE HI
3TAH4010 BPTG GEAR BOX LSS THRUST HIGH 120 °C 1.2 0 5

BRG TEMP HI

METAL TEMP ACTIVE HI
3TAH4006 BPTG TURBINE REAR BRG HIGH 95 °C 0.95 0 5

METAL TEMP-1 HI
3TAH4008 BPTG GEAR BOX HSS REAR BRG HIGH 120 °C 1.2 0 5
TEMP HI
3VAH4001A BPTG TURBINE FRONT SHAFT HIGH 127 MICRO 0 5

VIB HI N
3VAH4002A BPTG TURBINE REAR SHAFT VIB HIGH 127 MICRO 0 5
HI N
3VAH4003A BPTG GEAR BOX HSS FRONT VIB HIGH 66 MICRO 0 5
HI N
3VAH4004A BPTG GEAR BOX HSS REAR VIB HIGH 66 MICRO 0 5
HI N
3VAH4005A BPTG GEAR BOX LSS FRONT VIB HIGH 86 MICRO 0 5
HI N
MICRO
3VAH4006A HIGH 86 0 5
BPTG GEAR BOX LSS REAR VIB HI N
3VAH4007A BPTG GENERATOR FRONT SHAFT HIGH 164 MICRO 0 5

VIB HI N
3VAHH4007A BPTG GENERATOR FRONT SHAFT HIGH 240 MICRO 0 4
VIB HI N
3VAH4008A BPTG GENERATOR REAR SHAFT HIGH 164 MICRO 0 5
VIB HI N
3VAHH4008A BPTG GENERATOR REAR SHAFT HIGH 240 MICRO 0 4
VIB HI N
3VAH4001B BPTG TURBINE FRONT SHAFT HIGH 127 MICRO 0 5
VIB HI N
3VAH4002B BPTG TURBINE REAR SHAFT VIB HIGH 127 MICRO 0 5
HI N
3VAH4003B BPTG GEAR BOX HSS FRONT VIB HIGH 66 MICRO 0 5
HI N
3VAH4004B BPTG GEAR BOX HSS REAR VIB HIGH 66 MICRO 0 5
HI N
3VAH4005B BPTG GEAR BOX LSS FRONT VIB HIGH 86 MICRO 0 5
HI N
MICRO
3VAH4006B HIGH 86 0 5
BPTG GEAR BOX LSS REAR VIB HI N
3VAH4007B BPTG GENERATOR FRONT SHAFT HIGH 164 MICRO 0 5

VIB HI N
3VAH4008B BPTG GENERATOR REAR SHAFT HIGH 164 MICRO 0 5
VIB HI N
Revision 02
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3ZAH4001A HIGH 0.5 MM 0 5

BPTG AXIAL DISP HI
3ZAH4001B HIGH 0.5 MM 0 5

BPTG AXIAL DISP HI
3PAL3901A LOW 5.5 Kg/Cm2 0.11 0 5

BPTG CONTROL OIL PR LO
3PAL3901B LOW 5.5 Kg/Cm2 0.11 0 5

3PAL3901C LOW 5.5 Kg/Cm2 0.11 0 5

3PAL3902A LOW 2.5 Kg/Cm2 0.05 0 5

BPTG TRIP OIL PR LO
3PAL3902B LOW 2.5 Kg/Cm2 0.05 0 5

BPTG TRIP OIL PR LO
3PAL3902C LOW 2.5 Kg/Cm2 0.05 0 5

BPTG TRIP OIL PR LO
3PAL3714A LOW 1.5 Kg/Cm2 0.03 0 5

BPTG LUBE OIL HDR. PR-1 LO
3PAL3714B LOW 1.5 Kg/Cm2 0.03 0 5

3PAL3714C LOW 1.5 Kg/Cm2 0.03 0 5

3PAL3606A LOW 4.4 Kg/Cm2 0.088 0 5

BPTG EXHAUST PRESSURE LO
3PAL3606B LOW 4.4 Kg/Cm2 0.088 0 5

3PAL3606C LOW 4.4 Kg/Cm2 0.088 0 5

3PAL3602 BPTG INLET STEAM PRESSURE LOW 100 Kg/Cm2 2 15 1

LO
3LAL3702 LOW 1435 71.75 30 1

BPTG MAIN OIL TANK LVL LO MM
3LAL3707 BPTG L.O OVRHEAD TANK LVL LOW 500 25 30 3

LO MM
3TAL3706 LOW 40 °C 0.4 30 3

BPTG L.O TANK TEMP LO
3PAL3706 LOW 6.5 Kg/Cm2 0.13 0 5

BPTG L.O PUMP DISCR PR LO
3TAL3601 LOW 495 °C 4.95 30 1

BPTG INLET STEAM TEMP LO
3ZAL4001A LOW -0.5 MM 0 5

BPTG AXIAL DISP LO
3ZAL4001B LOW -0.5 MM 0 5

BPTG AXIAL DISP LO
VERY
3SE4002AHH 5500 RPM 0 4
BPTG TURBINE SPEED-1 HH HIGH
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VERY
3SE4002BHH 5500 RPM 0 4
VERY
3SE4002CHH 5500 RPM 0 4
VERY
3PAHH3606A 6.6 Kg/Cm2 0.132 0 4
BPTG EXHAUST PRESSURE HH HIGH
VERY
3PAHH3606B 6.6 Kg/Cm2 0.132 0 4
VERY
3PAHH3606C 6.6 Kg/Cm2 0.132 0 4
3PAHH3602 BPTG INLET STEAM PRESSURE VERY 116 Kg/Cm2 2.32 15 3

HH HIGH
VERY
3TAHH3601 530 °C 5.3 30 1
BPTG INLET STEAM TEMP HH HIGH
3TAHH4011 BPTG GEAR BOX LSS FRONT BRG VERY 125 °C 1.25 0 4
TEMP HH HIGH
3TAHH4001 BPTG TURBINE THRUST BRG VERY 115 °C 1.15 0 4
METAL TEMP NON-ACTIVE HH HIGH
METAL TEMP ACTIVE HH HIGH
3TAHH4005 BPTG TURBINE FRONT BRG VERY 115 °C 1.15 0 4
METAL TEMP-1 HH HIGH
3TAHH4005A BPTG TURBINE FRONT BRG VERY 115 °C 1.15 0 4
3TAHH4007 BPTG GEAR BOX HSS FRONT BRG VERY 125 °C 1.25 0 4
TEMP HH HIGH
3TAHH4009 BPTG GEAR BOX LSS THRUST VERY 125 °C 1.25 0 4
BRG TEMP HH HIGH
3TAHH4013 BPTG GENERATOR FRONT BRG VERY 115 °C 1.15 0 4
METAL TEMP HH HIGH
3TAHH4006A BPTG TURBINE REAR BRG VERY 115 °C 1.15 0 4
3TAHH4012 BPTG GEAR BOX LSS REAR BRG VERY 125 °C 1.25 0 4
TEMP HH HIGH
3TAHH4014 BPTG GENERATOR REAR BRG VERY 115 °C 1.15 0 4
METAL TEMP HH HIGH
METAL TEMP NON-ACTIVE HH HIGH
3TAHH4010 BPTG GEAR BOX LSS THRUST VERY 125 °C 1.25 0 4
BRG TEMP HH HIGH
METAL TEMP ACTIVE HH HIGH
3TAHH4006 BPTG TURBINE REAR BRG VERY 115 °C 1.15 0 4
3TAHH4008 BPTG GEAR BOX HSS REAR BRG VERY 125 °C 1.25 0 4
TEMP HH HIGH
Revision 02
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3VAHH4001A BPTG TURBINE FRONT SHAFT VERY 185 MICRO 0 4

VIB HH HIGH N
3VAHH4002A BPTG TURBINE REAR SHAFT VIB VERY 185 MICRO 0 4
HH HIGH N
3VAHH4003A BPTG GEAR BOX HSS FRONT VIB VERY 124 MICRO 0 4
HH HIGH N
3VAHH4004A BPTG GEAR BOX HSS REAR VIB VERY 124 MICRO 0 4
HH HIGH N
3VAHH4005A BPTG GEAR BOX LSS FRONT VIB VERY 160 MICRO 0 4
HH HIGH N
3VAHH4006A BPTG GEAR BOX LSS REAR VIB VERY 160 MICRO 0 4
HH HIGH N
3VAHH4001B BPTG TURBINE FRONT SHAFT VERY 185 MICRO 0 4
VIB HH HIGH N
3VAHH4002B BPTG TURBINE REAR SHAFT VIB VERY 185 MICRO 0 4
HH HIGH N
3VAHH4003B BPTG GEAR BOX HSS FRONT VIB VERY 124 MICRO 0 4
HH HIGH N
3VAHH4004B BPTG GEAR BOX HSS REAR VIB VERY 124 MICRO 0 4
HH HIGH N
3VAHH4005B BPTG GEAR BOX LSS FRONT VIB VERY 160 MICRO 0 4
HH HIGH N
3VAHH4006B BPTG GEAR BOX LSS REAR VIB VERY 160 MICRO 0 4
HH HIGH N
3VAHH4007B BPTG GENERATOR FRONT SHAFT VERY 240 MICRO 0 4
VIB HH HIGH N
3VAHH4008B BPTG GENERATOR REAR SHAFT VERY 240 MICRO 0 4
VIB HH HIGH N
VERY
3ZAHH4001A 0.7 MM 0 4
BPTG AXIAL DISP HH HIGH
VERY
3ZAHH4001B 0.7 MM 0 4
BPTG AXIAL DISP HH HIGH
3PALL3901A VERY LOW 4.5 Kg/Cm2 0.09 0 4

BPTG CONTROL OIL PR LL
3PALL3901B VERY LOW 4.5 Kg/Cm2 0.09 0 4

3PALL3901C VERY LOW 4.5 Kg/Cm2 0.09 0 4

3PALL3902A VERY LOW 2 Kg/Cm2 0.04 0 4

BPTG TRIP OIL PR LL
3PALL3902B VERY LOW 2 Kg/Cm2 0.04 0 4

BPTG TRIP OIL PR LL
3PALL3902C VERY LOW 2 Kg/Cm2 0.04 0 4

BPTG TRIP OIL PR LL
3PALL3714A VERY LOW 1 Kg/Cm2 0.02 0 4

BPTG LUBE OIL HDR. PR-1 LL
Revision 02
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3PALL3714B VERY LOW 1 Kg/Cm2 0.02 0 4

3PALL3714C VERY LOW 1 Kg/Cm2 0.02 0 4

3PALL3606A VERY LOW 3.9 Kg/Cm2 0.078 0 4

BPTG EXHAUST PRESSURE LL
3PALL3606B VERY LOW 3.9 Kg/Cm2 0.078 0 4

3PALL3606C VERY LOW 3.9 Kg/Cm2 0.078 0 4

3PALL3602 VERY LOW 95 Kg/Cm2 1.9 15 3

BPTG INLET STEAM PRESSURE LL
3LALL3702 VERY LOW 900 45 30 3

BPTG MAIN OIL TANK LVL LL MM
3TALL3601 VERY LOW 480 °C 4.85 30 3

BPTG INLET STEAM TEMP LL
3ZALL4001A VERY LOW -0.7 MM 0 4

BPTG AXIAL DISP LL
HIGH 70 0.7 30 1
11TAH4202 TDBFP LO TANK TEMP HI °C
HIGH 50 0.5 30 1
11TAH4206A TDBFP L.O TEMP AFT COOLER HI °C
HIGH 50 0.5 30 1
11TAH4206B TDBFP L.O TEMP AFT COOLER HI °C
HIGH 9450 0 5
11SAH4502A TD BFP TURBINE SPEED HI RPM
HIGH 9450 0 5
11SAH4502B TD BFP TURBINE SPEED HI RPM
HIGH 9450 RPM 0 5

11SAH4502C TD BFP TURBINE SPEED HI
HIGH 13.3 0.266 0 5

11PAH4113A TDBFP EXHAUST PRESSURE HI Kg/Cm2
HIGH 13.3 0.266 0 5

11PAH4113B TDBFP EXHAUST PRESSURE HI Kg/Cm2
HIGH 13.3 0.266 0 5

11PAH4113C TDBFP EXHAUST PRESSURE HI Kg/Cm2
TD BFP TURBINE FRONT SHAFT HIGH 94 Micron 0 5
11VAH4501A VIB HI
TD BFP TURBINE REAR SHAFT HIGH 94 Micron 0 5
11VAH4502A VIB HI
TD BFP GEAR BOX FRONT HSS HIGH 94 Micron 0 5
11VAH4503A VIB HI
TD BFP GEAR BOX REAR HSS VIB HIGH 94 Micron 0 5
11VAH4504A HI
TD BFP GEAR BOX FRONT LSS HIGH 94 Micron 0 5
11VAH4505A VIB HI
Revision 02
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TD BFP GEAR BOX REAR LSS VIB HIGH 94 Micron 0 5

11VAH4506A HI
TD BFP TURBINE FRONT SHAFT HIGH 94 Micron 0 5
11VAH4501B VIB HI
TD BFP TURBINE REAR SHAFT HIGH 94 Micron 0 5
11VAH4502B VIB HI
TD BFP GEAR BOX FRONT HSS HIGH 94 Micron 0 5
11VAH4503B VIB HI
TD BFP GEAR BOX REAR HSS VIB HIGH 94 Micron 0 5
11VAH4504B HI
TD BFP GEAR BOX FRONT LSS HIGH 94 Micron 0 5
11VAH4505B VIB HI
TD BFP GEAR BOX REAR LSS VIB HIGH 94 Micron 0 5
11VAH4506B HI
HIGH +0.5 0 5
11ZAH4501A TD BFP TURBINE AXIAL DISP HI mm
HIGH +0.5 0 5
11ZAH4501B TD BFP TURBINE AXIAL DISP HI mm
TD BFP GEAR BOX FRONT LSS HIGH 90 0.9 0 5
11TAH4511 BRG TEMP HI °C
TD BFP THRUST BRG METAL HIGH 95 0.95 0 5
11TAH4501 TEMP NON-ACTIVE HI °C
11TAH4503 TEMP ACTIVE HI °C
TD BFP FRONT BRG METAL HIGH 95 0.95 0 5
11TAH4505 TEMP HI °C
TD BFP GEAR BOX FRONT HSS HIGH 90 0.9 0 5
TD BFP GEAR BOX REAR LSS HIGH 90 0.9 0 5
11TAH4509 THRUST BRG TEMP HI °C
TD BFP GEAR BOX REAR LSS HIGH 90 0.9 0 5
11TAH4502 TEMP NON-ACTIVE HI °C
TD BFP GEAR BOX REAR (LSS) HIGH 90 0.9 0 5
11TAH4504 TEMP ACTIVE HI °C
TD BFP TURBINE REAR BRG HIGH 95 0.95 0 5
11TAH4506 METAL TEMP HI °C
TD BFP GEAR BOX REAR HSST HIGH 90 0.9 0 5
HIGH 1.5 0.03 15 1
11DPAH4209 TDBFP DP ACROSS LO FILTER HI Kg/Cm2
HIGH 1563 75 30 1
11LAH4202 TDBFP MAIN OIL TANK LVL HI mm
Revision 02
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HIGH 390 3.9 30 1

11TAH4101 TD BFP HP Steam I/L TEMP HI °C
LOW 40 0.4 30 3
11TAL4202 TDBFP LO TANK TEMP LO °C
LOW 6.5 0.13 0 3

11PAL4206 TDBFP LO PUMP DISCR PR LO Kg/Cm2
LOW 5.5 0.11 0 5

11PAL4401A TDBFP CONTROL OIL PR LO Kg/Cm2
LOW 5.5 0.11 0 5

11PAL4401B TDBFP CONTROL OIL PR LO Kg/Cm2
LOW 5.5 0.11 0 5

11PAL4401C TDBFP CONTROL OIL PR LO Kg/Cm2
LOW 2.5 0.05 0 5

11PAL4402A TDBFP TRIP OIL PR LO Kg/Cm2
LOW 2.5 0.05 0 5

11PAL4402B TDBFP TRIP OIL PR LO Kg/Cm2
LOW 2.5 0.1 0 5

11PAL4402C TDBFP TRIP OIL PR LO Kg/Cm2
LOW 10.7 0.214 0 5

11PAL4113A TDBFP EXHAUST PRESSURE LO Kg/Cm2
LOW 10.7 0.214 0 5

11PAL4113B TDBFP EXHAUST PRESSURE LO Kg/Cm2
LOW 10.7 0.214 0 5

11PAL4113C TDBFP EXHAUST PRESSURE LO Kg/Cm2
LOW 1.5 0.03 0 5

11PAL4216A TD BFP L.O HEADER PR-1 LO Kg/Cm2
LOW 1.5 0.03 0 5

11PAL4216B TD BFP L.O HEADER PR-2 LO Kg/Cm2
LOW 1.5 0.03 0 5

11PAL4216C TD BFP L.O HEADER PR-3 LO Kg/Cm2
LOW -0.5 0 5
11ZAL4501A TD BFP TURBINE AXIAL DISP LO mm
LOW -0.5 0 5
11ZAL4501B TD BFP TURBINE AXIAL DISP LO mm
TDBFP LO OVERHEAD TANK LVL LOW 500 25 30 3
11LAL4204 LO mm
LOW 1463 70 30 1
11LAL4202 TDBFP MAIN OIL TANK LVL LO mm
LOW 340 3.4 30 3

11TAHH4101 TD BFP HP Steam I/L TEMP LO °C
11SAHH4502 VERY 9900 0 4
A TD BFP TURBINE SPEED HH HIGH RPM
11SAHH4502 VERY 9900 RPM 0 4
B TD BFP TURBINE SPEED HH HIGH
11SAHH4502 VERY 9900 0 4
C TD BFP TURBINE SPEED HH HIGH RPM
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11PAHH4113 VERY 15.6 0.312 0 4

A TDBFP EXHAUST PRESSURE HH HIGH Kg/Cm2
11PAHH4113 VERY 15.6 0.312 0 4
B TDBFP EXHAUST PRESSURE HH HIGH Kg/Cm2
11PAHH4113 VERY 15.6 0.312 0 4
C TDBFP EXHAUST PRESSURE HH HIGH Kg/Cm2
11VAHH4501 TD BFP TURBINE FRONT SHAFT VERY 139 Micron 0 4
A VIB HH HIGH
11VAHH4502 TD BFP TURBINE REAR SHAFT VERY 139 Micron 0 4
A VIB HH HIGH
11VAHH4503 TD BFP GEAR BOX HSS FRONT VERY 139 Micron 0 4
A VIB HH HIGH
11VAHH4504 TD BFP GEAR BOX REAR HSS VIB VERY 139 Micron 0 4
A HH HIGH
11VAHH4505 TD BFP GEAR BOX FRONT LSS VERY 139 Micron 0 4
A VIB HH HIGH
11VAHH4506 TD BFP GEAR BOX REAR LSS VIB VERY 139 Micron 0 4
A HH HIGH
11VAHH4501 TD BFP TURBINE FRONT SHAFT VERY 139 Micron 0 4
B VIB HH HIGH
11VAHH4502 TD BFP TURBINE REAR SHAFT VERY 139 Micron 0 4
B VIB HH HIGH
11VAHH4503 TD BFP GEAR BOX FRONT HSS VERY 139 Micron 0 4
B VIB HH HIGH
11VAHH4504 TD BFP GEAR BOX REAR HSS VIB VERY 139 Micron 0 4
B HH HIGH
11VAHH4505 TD BFP GEAR BOX FRONT LSS VERY 139 Micron 0 4
B VIB HH HIGH
11VAHH4506 TD BFP GEAR BOX REAR LSS VIB VERY 139 Micron 0 4
B HH HIGH
11ZAHH4501 VERY +0.7 0 4
A TD BFP TURBINE AXIAL DISP HH HIGH mm
11ZAHH4501 VERY +0.7 0 4
B TD BFP TURBINE AXIAL DISP HH HIGH mm
TD BFP GEAR BOX FRONT LSS VERY 100 1 0 4
11TAHH4511 BRG TEMP HH HIGH °C
TD BFP THRUST BRG METAL VERY 115 1.15 0 4
11TAHH4501 TEMP NON-ACTIVE HH HIGH °C
11TAHH4503 TEMP ACTIVE HH HIGH °C
TD BFP FRONT BRG METAL VERY 115 1.15 0 4
11TAHH4505 TEMP HH HIGH °C
TD BFP GEAR BOX FRONT HSS VERY 100 1 0 4
TD BFP GEAR BOX REAR LSS VERY 100 1 0 4
11TAHH4509 THRUST BRG TEMP HH HIGH °C
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TD BFP GEAR BOX REAR LSS VERY 100 1 0 4

11TAHH4502 TEMP NON-ACTIVE HH HIGH °C
TD BFP GEAR BOX REAR (LSS) VERY 100 1 0 4
11TAHH4504 TEMP ACTIVE HH HIGH °C
TD BFP REAR BRG METAL TEMP VERY 115 1.15 0 4
11TAHH4506 HH HIGH °C
TD BFP GEAR BOX REAR HSST VERY 100 1 0 4
VERY LOW 4.5 0.09 0 4

11PALL4401A TDBFP CONTROL OIL PR LL Kg/Cm2
VERY LOW 4.5 0.09 0 4

11PALL4401B TDBFP CONTROL OIL PR LL Kg/Cm2
VERY LOW 4.5 0.09 0 4

11PALL4401C TDBFP CONTROL OIL PR LL Kg/Cm2
VERY LOW 2 0.04 0 4

11PALL4402A TDBFP TRIP OIL PR LL Kg/Cm2
VERY LOW 2 0.04 0 4

11PALL4402B TDBFP TRIP OIL PR LL Kg/Cm2
VERY LOW 2 0.04 0 4

11PALL4402C TDBFP TRIP OIL PR LL Kg/Cm2
VERY LOW 9.5 0.19 0 4

11PALL4113A TDBFP EXHAUST PRESSURE LL Kg/Cm2
VERY LOW 9.5 0.19 0 4

11PALL4113B TDBFP EXHAUST PRESSURE LL Kg/Cm2
VERY LOW 9.5 0.19 0 4

11PALL4113C TDBFP EXHAUST PRESSURE LL Kg/Cm2
VERY LOW 1 0.02 0 4

11PALL4216A TD BFP L.O HEADER PR-1 LL Kg/Cm2
VERY LOW 1 0.02 0 4

11PALL4216B TD BFP L.O HEADER PR-2 LL Kg/Cm2
VERY LOW 1 0.02 0 4

11PALL4216C TD BFP L.O HEADER PR-3 LL Kg/Cm2
VERY LOW -0.7 0 4

11ZALL4501A TD BFP TURBINE AXIAL DISP LL mm
VERY LOW -0.7 mm 0 4

11ZALL4501B TD BFP TURBINE AXIAL DISP LL
Not
HIGH 51 N/A Hz applic 0 5 N/A
1Freq_Hi STG-1 Generator Frequency HI able
HIGH 6615 N/A RPM 0 5 N/A

1SAH3501A STG-1 SPEED SIGNAL CH-1 HI

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1SAH3501B STG-1 SPEED SIGNAL CH-2 HI

1SAH3501C STG-1 SPEED SIGNAL CH-3 HI
HIGH 42 N/A Kg/Cm2 0.84 0 5 N/A

1PAH3112A STG-1 HP Extraction Pr.-1 HI
HIGH 42 N/A Kg/Cm2 0.84 0 5 N/A

1PAH3112B STG-1 HP Extraction Pr.-2 HI
HIGH 42 N/A Kg/Cm2 0.84 0 5 N/A

1PAH3112C STG-1 HP Extraction Pr.-3 HI
HIGH 12.8 N/A Kg/Cm2 0.256 0 5 N/A

1PAH3122A STG-1 MP Extraction Pr.-1 HI
HIGH 12.8 N/A Kg/Cm2 0.256 0 5 N/A

1PAH3122B STG-1 MP Extraction Pr.-2 HI
HIGH 12.8 N/A Kg/Cm2 0.256 0 5 N/A

1PAH3122C STG-1 MP Extraction Pr.-3 HI
HIGH 112 N/A Kg/Cm2 2.24 15 1 N/A

1PAH3101 STG-1 VHP Steam I/L Pr. HI
Not
1TURB_SPDM HIGH 6615 N/A RPM applic 0 N/A
V3_HI STG-1 TURB_SPDMV3_HI able 5
1EXTR1PR_CT HIGH 95 N/A % 0 N/A
RLR HI STG-1 EXTR1 PR CTRLR HI 3
1EXTR1_PR_L HIGH 95 N/A % 0 N/A
IMIT HI STG-1 EXTR1 PR LIMIT HI 3
1EXTR2PR_CT HIGH 95 N/A % 0 N/A
RLR HI STG-1 EXTR2 PR CTRLR HI 3
1EXTR2_PR_L HIGH 95 N/A % 0 N/A
IMIT HI STG-1 EXTR2 PR LIMIT HI 3
LOW 48.5 N/A Hz 0 5 N/A

1Freq_Lo STG-1 Generator Frequency LO
LOW 38 N/A Kg/Cm2 0.76 0 5 N/A

1PAL3112A STG-1 HP Extraction Pr.-1 LO
LOW 38 N/A Kg/Cm2 0.76 0 5 N/A

1PAL3112B STG-1 HP Extraction Pr.-2 LO
LOW 38 N/A Kg/Cm2 0.76 0 5 N/A

1PAL3112C STG-1 HP Extraction Pr.-3 LO
LOW 10.7 N/A Kg/Cm2 0.214 0 5 N/A

1PAL3122A STG-1 MP Extraction Pr.-1 LO
LOW 10.7 N/A Kg/Cm2 0.214 0 5 N/A

1PAL3122B STG-1 MP Extraction Pr.-2 LO
LOW 10.7 N/A Kg/Cm2 0.214 0 5 N/A

1PAL3122C STG-1 MP Extraction Pr.-3 LO
LOW 100 N/A Kg/Cm2 2 15 1 N/A

1PAL3101 STG-1 VHP Steam I/L Pr. LO

Revision 02
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Not
VERY
51.5 N/A Hz applic 0 4 N/A
HIGH
1Freq_HH STG-1 Generator Frequency HH able
VERY
6930 N/A RPM 0 4 N/A
1SAHH3501A STG-1 SPEED SIGNAL CH-1 HIHI HIGH
VERY
6930 N/A RPM 0 4 N/A
1SAHH3501B STG-1 SPEED SIGNAL CH-2 HIHI HIGH
VERY
6930 N/A RPM 0 4 N/A
1SAHH3501C STG-1 SPEED SIGNAL CH-3 HIHI HIGH
VERY
49.1 N/A Kg/Cm2 0.982 0 4 N/A
1PAHH3112A STG-1 HP Extraction Pr.-1 HH HIGH
VERY
49.1 N/A Kg/Cm2 0.982 0 4 N/A
1PAHH3112B STG-1 HP Extraction Pr.-2 HH HIGH
VERY
49.1 N/A Kg/Cm2 0.982 0 4 N/A
1PAHH3112C STG-1 HP Extraction Pr.-3 HH HIGH
VERY
15 N/A Kg/Cm2 0.3 0 4 N/A
1PAHH3122A STG-1 MP Extraction Pr.-1 HH HIGH
VERY
15 N/A Kg/Cm2 0.3 0 4 N/A
1PAHH3122B STG-1 MP Extraction Pr.-2 HH HIGH
VERY
15 N/A Kg/Cm2 0.3 0 4 N/A
1PAHH3122C STG-1 MP Extraction Pr.-3 HH HIGH
VERY
116 N/A Kg/Cm2 2.32 15 3 N/A
1PAHH3101 STG-1 VHP Steam I/L Pr. HH HIGH
VERY LOW 47.5 N/A Hz N/A 0 4 N/A
1Freq_LL STG-1 Generator Frequency LL
VERY LOW 34.1 N/A Kg/Cm2 0.682 0 4 N/A

1PALL3112A STG-1 HP Extraction Pr.-1 LL

1PALL3112B STG-1 HP Extraction Pr.-2 LL

1PALL3112C STG-1 HP Extraction Pr.-3 LL

1PALL3122A STG-1 MP Extraction Pr.-1 LL

1PALL3122B STG-1 MP Extraction Pr.-2 LL

1PALL3122C STG-1 MP Extraction Pr.-3 LL
VERY LOW 95 N/A Kg/Cm2 1.9 15 3 N/A

1PALL3101 STG-1 VHP Steam I/L Pr. LL
TAG NEEDS Not
TO BE HIGH 90 N/A % applic 0 3 N/A
CREATED STG-1 HPCV OPENING HIGH able
1TURB_SPDM VERY 6930 RPM 0 N/A
V3_HH STG-1 TURB SPDMV3 HH HIGH 4
HIGH 51 Hz 0 5
2Freq_Hi STG-2 Generator Frequency HI

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HIGH 6615 0 5
2SAH3501A STG-2 SPEED SIGNAL CH-1 HI RPM
HIGH 6615 0 5
2SAH3501B STG-2 SPEED SIGNAL CH-2 HI RPM
HIGH 6615 0 5
2SAH3501C STG-2 SPEED SIGNAL CH-3 HI RPM
HIGH 42 Kg/Cm2 0.84 0 5

2PAH3112A STG-2 HP Extraction Pr.-1 HI
HIGH 42 Kg/Cm2 0.84 0 5

2PAH3112B STG-2 HP Extraction Pr.-2 HI
HIGH 42 Kg/Cm2 0.84 0 5

2PAH3112C STG-2 HP Extraction Pr.-3 HI
HIGH 12.8 Kg/Cm2 0.256 0 5

2PAH3122A STG-2 MP Extraction Pr.-1 HI
HIGH 12.8 Kg/Cm2 0.256 0 5

2PAH3122B STG-2 MP Extraction Pr.-2 HI
HIGH 12.8 Kg/Cm2 0.256 0 5

2PAH3122C STG-2 MP Extraction Pr.-3 HI
HIGH 112 Kg/Cm2 2.24 15 1

2PAH3101 STG-2 VHP Steam I/L Pr. HI
2TURB_SPDM HIGH 6615 0
V3_HI STG-2TURB_SPDMV3_HI RPM 5
2EXTR1PR_CT HIGH 95 0
RLR HI STG-2 EXTR1 PR CTRLR HI % 3
2EXTR1_PR_L HIGH 95 0
IMIT HI STG-2 EXTR1 PR LIMIT HI % 3
2EXTR2PR_CT HIGH 95 0
RLR HI STG-2 EXTR2 PR CTRLR HI % 3
2EXTR2_PR_L HIGH 95 0
IMIT HI STG-2 EXTR2 PR LIMIT HI % 3
LOW 48.5 Hz 0 5
2Freq_Lo STG-2 Generator Frequency LO
LOW 38 Kg/Cm2 0.76 0 5

2PAL3112A STG-2 HP Extraction Pr.-1 LO
LOW 38 Kg/Cm2 0.76 0 5

2PAL3112B STG-2 HP Extraction Pr.-2 LO
LOW 38 Kg/Cm2 0.76 0 5

2PAL3112C STG-2 HP Extraction Pr.-3 LO
LOW 10.7 Kg/Cm2 0.214 0 5

2PAL3122A STG-2 MP Extraction Pr.-1 LO
LOW 10.7 Kg/Cm2 0.214 0 5

2PAL3122B STG-2 MP Extraction Pr.-2 LO
LOW 10.7 Kg/Cm2 0.214 0 5

2PAL3122C STG-2 MP Extraction Pr.-3 LO
LOW 100 Kg/Cm2 2 15 1

2PAL3101 STG-2 VHP Steam I/L Pr. LO
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VERY
51.5 Hz 0 4
2Freq_HH STG-2 Generator Frequency HH HIGH
VERY
6930 0 4
2SAHH3501A STG-2 SPEED SIGNAL CH-1 HIHI HIGH RPM
VERY
6930 0 4
2SAHH3501B STG-2 SPEED SIGNAL CH-2 HIHI HIGH RPM
VERY
6930 0 4
2SAHH3501C STG-2 SPEED SIGNAL CH-3 HIHI HIGH RPM
VERY
49.1 Kg/Cm2 0.982 0 4
2PAHH3112A STG-2 HP Extraction Pr.-1 HH HIGH
VERY
49.1 Kg/Cm2 0.982 0 4
2PAHH3112B STG-2 HP Extraction Pr.-2 HH HIGH
VERY
49.1 Kg/Cm2 0.982 0 4
2PAHH3112C STG-2 HP Extraction Pr.-3 HH HIGH
VERY
15 Kg/Cm2 0.3 0 4
2PAHH3122A STG-2 MP Extraction Pr.-1 HH HIGH
VERY
15 Kg/Cm2 0.3 0 4
2PAHH3122B STG-2 MP Extraction Pr.-2 HH HIGH
VERY
15 Kg/Cm2 0.3 0 4
2PAHH3122C STG-2 MP Extraction Pr.-3 HH HIGH
VERY
116 Kg/Cm2 2.32 15 3
2PAHH3101 STG-2 VHP Steam I/L Pr. HH HIGH
VERY LOW 47.5 Hz 0 4

2Freq_LL STG-2 Generator Frequency LL
VERY LOW 34.1 Kg/Cm2 0.682 0 4

2PALL3112A STG-2 HP Extraction Pr.-1 LL
VERY LOW 34.1 Kg/Cm2 0.682 0 4

2PALL3112B STG-2 HP Extraction Pr.-2 LL
VERY LOW 34.1 Kg/Cm2 0.682 0 4

2PALL3112C STG-2 HP Extraction Pr.-3 LL
VERY LOW 9.6 Kg/Cm2 0.192 0 4

2PALL3122A STG-2 MP Extraction Pr.-1 LL
VERY LOW 9.6 Kg/Cm2 0.192 0 4

2PALL3122B STG-2 MP Extraction Pr.-2 LL
VERY LOW 9.6 Kg/Cm2 0.192 0 4

2PALL3122C STG-2 MP Extraction Pr.-3 LL
VERY LOW 95 Kg/Cm2 1.9 15 3

2PALL3101 STG-2 VHP Steam I/L Pr. LL
TAG NEEDS
TO BE 90 0 3
CREATED STG-2 HPCV OPENING HIGH %
2TURB_SPDM 6930 0
V3_HH STG-2 TURB_SPDMV3_HH RPM 5
HIGH 5250 RPM 0 5

3SAH4001A BPTG Turbine speed HI

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HIGH 5250 RPM 0 5

3SAH4001B BPTG Turbine speed HI
HIGH 5250 RPM 0 5

3SAH4001C BPTG Turbine speed HI
3Spd_Ref_TD HIGH 8800 RPM 0 5
_Nrtd HI BPTG Speed Ref HI
3Freq_Actual HIGH 51 Hz 0 5
_HI BPTG Generator Frequency HI
TAG NEEDS
TO BE HIGH 90 % 0 4
CREATED BPTG HPCV OPENING HIGH
3Freq_Actual LOW 48.5 Hz 0 5
_LO BPTG Generator Frequency LO
VERY
5500 RPM 0 4
3SAHH4001A BPTG Turbine speed HH HIGH
VERY
5500 RPM 0 4
3SAHH4001B BPTG Turbine speed HH HIGH
VERY
5500 RPM 0 4
3SAHH4001C BPTG Turbine speed HH HIGH
3Freq_Actual VERY LOW 51.5 Hz 0 4
_HH BPTG Generator Frequency HH
3Freq_Actual VERY 47.5 Hz 0 4
_LL BPTG Generator Frequency LL HIGH

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CHAPTER - 5
PREPARATIONS FOR START-UP (PRE-COMMISIONING)
5.1 PLANT CHECKING

5.2 EQUIPMENT INSPECTION
5.3 PIPING INSPECTION
5.4 SUPPORTING SYSTEM INSPECTION
5.5 INSTRUMENTATION INSPECTION
5.6 CHEMICAL INVENTORY
5.7 PAVED AREA
5.8 AREA LIGHTING
5.9 PUBLIC ADDRESS SYSTEM
5.10 STRUCTURAL
5.11 FIRE AND SAFETY
5.12 UTILITY COMMISSIONING
5.13 PRE COMMISSIONING ACTIVITIES

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5.1 PLANT CHECKING:

As the new unit nears completion, there is a large amount of preparatory work, which should
be performed by the operating crew. A planned check of the unit will not only set the
foundation of a smooth start-up, but will also provide a firm basis for acquainting operators
with the equipment. Start-up is a critical period and the operator must know exactly the
operation of all equipments.
Some of the pre-commissioning works can be carried out simultaneously along with
construction. But, care in the organization of this work is necessary so that it will not interfere
with construction work. It is most important to plan schedule and record with checklists and
test schedules all the preliminary operation and to co-ordinate the construction program.
Once contractor completes work, sections of the unit should be checked out by both HMEL
and EIL personnel in those areas. Immediately punch lists that indicate the deviations from the
EIL design specifications, should be written following inspection of those areas, and distributed
to the contractor. In this manner mistakes in construction can be found and corrected early.
Captive power plant includes number of segments, like wise; Utility boilers, Gas turbines,
HRSG’s, STG’s (condensing with extraction & back pressure), Condensate storage & transfer
unit, Deaerator and Boiler feed water pumps, Chemical dosing system, CBD/IBD System,
Cooling tower, Gas booster compressor skid, Nitrogen booster compressor skid, Fuel storage
& forwarding skid, Atomizing air compressor/ emergency air back up.EDG & Electrical
substation .
Inspection of the CPP plant can be basically divided into the following sub sections:
 Equipments

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 Piping

 Supporting systems (pumps, Vessels, Exchangers, Heaters, Blowers, Fans, compressors
etc)

 Instrumentation / Electrical system

 Chemicals Inventory
5.2 EQUIPMENT INSPECTION:

The actual installations must be compared against the drawings to assure that the
Equipment will function as intended. The equipment internals must confirm exactly to the
design specifications. Ensure adequate lighting and proper approach for the people to work
on equipment. Follow the vendor’s instruction before opening any equipment for
inspection. While going for first start up or subsequent operations always follow vendor’s
instruction and standard operating procedures.
Attention must be paid to the following details:
Review design specifications of equipment with the vendor drawings

Verify that all plate information on the Equipment is correct.
Inspect thoroughly equipment parts, instrumentations (TG’S, PG’S, Flow elements, vibration
monitoring) PSV’S, ERV’S, Equipment protection system, and electrical system etc.
Readiness of upstream & downstream systems of equipment must be ensured prior to any
startup operation activity.
ALL INSPECTIONS SHOULD BE CARRIED OUT USING THE STANDARD “PRE START-
UP SAFETY REVIEW”. EACH SYSTEM OR MAJOR PIECE OF EQUIPMENT SHOULD
HAVE ITS OWN PSSR.
5.3 PIPING INSPECTION:

The unit must be constructed in accordance with Piping and Instrumentation Diagrams

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(P&ID's), including all details, elevations, dimensions, arrangements, and other notes on the
P&ID's. One must be able to startup, shutdown and conduct normal operations on the unit as
envisioned in the licensor design. Alternative flow schemes & system isolation for maintenance
without or minimum operation disturbances may have been incorporated into the unit's
design. Also, piping for special procedures such as blowing, flushing, dry-out, special materials
preparation, regeneration and back flushing, and the unit should be able to operate in all of
these modes with piping as designed and constructed.
Check that adequate means of measuring flows, pressures, and temperatures, and sampling
of all process streams has been provided.
The following items must be checked to ensure conformity to the design specifications:
1. Flanges: rating, facing, and metallurgy; type (typically, 2" and smaller are socket weld, 2½"
and larger are weld neck flanges).
2. Gaskets: type; metallurgy (materials of retainer, jackets, winding, filler, etc.); thickness, ring
size, etc.
3. Fittings, connections and couplings: rating and metallurgy.
4. Valves: rating and metallurgy (body, trim, seats, etc.); packing; seat inserts; bonnet gaskets;
grease seals; socket-weld or flange type, rating and facing; installed in correct direction of
flow; lubricant provisions; gear operators; extended bonnets; stops; ease of operation.
5. Bolting: stud or machine bolts; bolt and nut metallurgy; bolt size.
6. Pipe: metallurgy, thickness; seamed or seamless; lining.
7. Tubing: size and thickness; metallurgy; seamed or seamless.
8. Gauge glasses:
− Through-view types should have rear-mounted lights.
− Design pressure and temperature.
− Special materials of construction.
− Drains to safe location.
− Visible from grade (or platform, if required).

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9. Pressure relief valves:

Size and Type pilot operated, balanced, Metallurgy of nozzle, disc, spring, Lever requirement,
Inlet/outlet flange material, facing and rating. Set pressure - must be bench tested,
Inlet/outlet block valves car-sealed open; valve stems installed in horizontal or below.
10. General:
a. Utility systems within the battery limit should follow all relevant pipe class specifications
in the same detail required for process lines.
a. Package systems (GTG’S, STG’S, etc.) shown on the EIL P&ID should follow all relevant
pipe class specifications in the same detail required for other process lines.
b. Expansion: review the physical installation to ensure that no expansion problems will
occur when the unit gets hot and charged.
c. Rotating equipment will not be pulled out of alignment.
d. Sufficient expansion loops have been provided on long hot lines.
e. Pipe shoes are free to move in one direction, and are resting on supports of sufficient size
that the shoe will not fall off the support.
f. High point vents and low point drains should be installed where necessary.
g. Spectacle blinds should be provided where required.
h. Car-sealed valves should be locked in proper position.
i. Spring hangers should have locking pins removed (after hydro testing) and necessary
adjustments should be made for hot/cold position after startup.
j. All the isolation valves and control valves are installed correctly; special attention should
be given for flow direction of globe valves, check valves and control valves
k. Do not install flow orifices till the flushing activity is completed
l. Check for proper thickness and completion of insulation as specified in P&ID. Check for
heat tracing / painting etc.
m. Check for adequacy of piping vents and drains. Wherever necessary, also check for safe
approach for operating and maintaining such valves, especially in columns over head
lines.

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5.4. SUPPORTING SYSTEM:

Pumps, vessels, compressors, turbines, blower, exchangers, heaters, fans & fuel system are the
major equipments which require thorough inspection prior to any start up activity.
PUMPS:
Centrifugal Pumps
The design specifications should be reviewed against the pump curves and data given by the
vendor to confirm agreement on the following:
a. Head and capacity.
b. Pressure and temperature rating.
c. Speed.
d. NPSH requirement.
e. Pump type, materials of construction, flange ratings, seals, bearings, number of stages,
lubrication and cooling systems, etc.
f. Type of driver. Direction of rotation mark at both ends.
g. Balancing lines for multistage pumps must have flanged joints (not unions).
Reciprocating Pumps
The vendor information should be checked against the specifications to verify agreement on the
following:
1. Head and capacity (minimum, normal, maximum).
2. Materials of construction (body/glands, plungers, diaphragms, packing, internal check

valves).
3. Cooling/lubrication systems.
4. Pressure, temperature ratings.
5. Relief valve setting must be bench tested.
6. Pump speed and stroke.
7. Pulsation suppression devices, if required.

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The following items should be checked for all pumps:

1. Piping to be arranged to permit removal or replacement of pump and driver.
2. Piping independently supported from pump; pump will not be pulled out of alignment when
lines get hot; no vapor pockets in piping.
3. Suction strainer easily removed for cleaning; strainers fit well so no bypassing can occur;
strainers have been installed.
4. Discharge pressure gauge readable from discharge block valve.
5. Suction/discharge valves easily accessible and operable, and near to the pump. Accessibility of
auxiliary piping and controls.
6. Check that NPSH requirements have been met.
7. Base plate grouting complete.
8. Minimum flow bypasses (with restriction orifice), if required.
9. Lubrication and cooling systems operate correctly.
10. Adequate means for venting and draining the pump casing are available.
11. Pumps and drivers are aligned correctly.
12. Check valves are of proper type and installed in the correct direction.
13. All drains from pumps and associated piping and instrumentation should be routed to a safe
location.
14. Verify that bearings and shafts have been cleaned prior to final lubrication.
15. PSV’s provided are as per documents specification and their test report.
16. Steam tracing and insulation provided on suction/discharge lines, pump casing, and process
seal flush lines, as required.
VESSELS, TANKS:
External Inspection
1. Man ways and nozzles: location, size, flange rating and finish, metallurgy, with proper
gaskets, nuts and bolts.

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2. The vessel should be clean (free from trash) and should not have excessive mill scale.
3. Ladders and platforms: correctly positioned, secure and free to expand.
4. Vessel elevation & grounded correctly.
5. Valves and instrumentation: easily accessible from grade or platform.
6. Adequate supports and guides for all connecting lines.
7. Level and pressure instrument connections drain to a safe location.
8. Vents to atmosphere or blow down provided as specified.
9. Relief valves have been bench tested.
10. Fireproofing of structure and supports is complete.
11. Level glass floats center positioned correctly, and are readable from grade or platform.
Internal Inspection
1. Vortex breakers: type, size, and orientation.
2. Baffles: size, type, orientation, levelness.
3. Instrument nozzles: location, orientation, cleanliness, thermo well length and metallurgy.
4. Inlet distributors: type, size, orientation, levelness, freedom to expand, wetted area.
5. Internal ladders and other devices: location, size, orientation, properly secured.
FUEL SYSTEM:
1. Fuel lines have battery limit block valves that are remote from the heater and easily
accessible. Fuel oil piping and its steam tracing are arranged such that no dead legs or
pockets are formed. Fuel lines to burners can be easily disconnected from burners for
burner removal. All fuel lines have been leak tested.
2. Fuel oil lines at burner valves are correctly piped with steam crossovers. All steam lines
have adequate traps and condensate drains.
3. Shutdown solenoids for fuel shutoff valves have been set properly.
4. Fuel oil circulating lines are provided.

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HEAT EXCHANGERS:
The design specifications should be reviewed with the vendor drawings to check:
1. Metallurgy of shell, tubes, tube sheet, channel cover, baffle, header box, etc.
2. Tube size and thickness: number of shell and tube passes and direction of flowing
streams; max/min allowable velocities.
3. Design temperature, pressure and pressure-drop ratings.
4. Nozzle size, flange type, rating, facing and metallurgy; vent and drain connections.
5. Design differential pressure between shell and tube sides of the exchanger.
In the field the following items should be checked:-

1. Name plate verifies specifications.
2. Flange size, rating, facing and gaskets.
3. Insulation for heat retention and personnel protection.
4. Exchanger properly grounded.
Tubular exchanger
a. Elevation
b. Slot length of sliding plates adequate for expansion. Exchanger should not be tied
down at both ends. Check that sliding ends of multi-shell exchangers make sense with
regard to expansion of exchangers and connecting pipe.
c. Piping symmetry for parallel exchangers.
d. Non-condensable vents in steam service or in totally condensing systems.
e. Water coolers; inlet at bottom of exchangers; inlet/outlet block valves with a thermal
relief valve inside the outlet block valve; vent and drain connections inside the block
valves.
f. Witness a shell/tube differential pressure test, if possible (especially important in

feed/effluent exchangers). When leak testing piping and equipment, ensure that the
design shell/tube differential pressure is not exceeded.

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5.5. ELECTRICAL AND INSTRUMENTATION:

All personnel on site should check to ensure that the electrical and instrumentation are provided as
specified; that it is functional; and that a minimum problems will occur when the unit is
commissioned. Some of the basic items which must be checked include the following:
1. Motor fixing and proper coupled with driven unit
2. Motor No load test run and vibration analysis report acceptance
3. Motor cable lugging and IPOD testing
4. Motor Earthing
5. Electrical Panel testing and earthing
6. Protection and control logic relay setting
7. Cable glanding and scheduling as per cable list
8. Cable laying and termination
9. Control system line up with backup power source
10. Instrument type, range, and size.
11. Materials of construction and rating of instrument, accessories, and connecting piping, flanges,
and valves.
12. Accessibility of instrument for routine checks and maintenance; rigidly mounted.
13. Installation according to correct drawing details.
14. Accessories (pulsation dampeners, filter/regulators, diaphragm seals, excess flow checks, seal
pots).
15. Location of local indicators so they are readable from grade platform or controller assembly, as
required.
16. Process requirements of flow, temperature, pressure, differential pressure, specific gravity, etc.
17. Controller type, number of modes, chart type, range, cascades.

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18. Power requirements of voltage, frequency; emergency power supply and connections.
19. Calibration of controllers, transmitters, analyzers, special instrumentation.
20. Control valve, block and bypass valve sizes for control valve assemblies.
21. All instruments properly identified.
22. All motors properly identified? This should include substation location of circuit breaker as well.
23. All instrument/electrical junction boxes properly identified.
5.6. CHEMICAL INVENTORY

It must be verified that the proper type and quantity of chemicals (such as Ammonia, Hydrazine, Tri
sodium phosphate for boilers & cooling water conditioning chemicals) are on site and stored properly.
5.7 PAVED AREA:

As and when the area paving is completed along with the respective underground system,
check for the following.
a. Proper grading of the area.
b. The surface finish should not be slippery. At the same time it should be conducive to safe
and efficient operation.
c. The construction group should check that there is no stagnation of water by actually pouring
some water on the surface and confirming that it smoothly flows to the underground pipe.
5.8 AREA LIGHTING:

Check the area lighting with respect to following.
a. The area lighting and electrical fixtures are suitable for the unit as defined by hazardous
area specification.

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b. The height of fixture does not hamper safe movement of operation personnel and for
safely carrying out maintenance work.
c. Adequacy of area lighting especially around the emergency exit area.
d. Automatic switch over to emergency lighting, during power failure.
5.9 PUBLIC ADDRESS SYSTEM:

a. Proper audibility of the message when received by the field operator. This must be
checked when sufficient numbers of rotary equipments are in operation in the unit.
b. Adequacy of public address system, keeping in mind the emergency operations, which will
have to be done by field operator.
c. Proper training should be given to both the field operator and control room operator for
effective communication through public address system.
5.10 STRUCTURAL INSPECTION:

Special attention should be given to the following points with regard to the structural.
a. The alignment and grouting is complete.
b. Fire proofing is done as required by detailed engineering.
c. Adequacy of hand rails in normal movement area and at higher elevations.
d. Proper completion of cages for the entire monkey ladders
e. All the gratings are properly erected and are not slippery. Safe movement of the personnel
should be ensured while working on the gratings.
f. Staircase steps are properly spaced. Whenever possible, platforms at the higher elevations
should be interconnected so as to ensure the effective movement of operating crew.

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5.11 FIRE AND SAFETY:

The fire team along with the operation team of the unit should make a visit to the plant and
identify the location of the fire extinguishers as well as the type of fire extinguisher. The
following things should be kept in mind while deciding the same:
a. The operator is not required to move long distances more than about 10 meter to the
nearest fire extinguisher. These needs are to confirm statutory requirements dictated by
statutory regulators.
b. Usefulness of the fire extinguisher, i. e. its physical placement in the plant, its approximate
weight etc. The fire and safety group will also periodically check this.
c. All the operating and maintenance personnel are given periodic fire fighting training and
they are completely familiar with the method of using every type of fire extinguisher.
d. All the operating and maintenance personnel are fully aware of the fire incident reporting
procedure, their roles in case of a disaster and awareness of where to assemble in case of
disaster.
e. With respect to safety the following points need to be checked by the operations in charge
as well as safety in charge:
1. All the exit routes are clearly identified, marked and are not blocked by any equipment or
piping etc.
2. The safety showers are in position and are operable.
3. All operating and maintenance personnel should be educated on the various hazards
associated with unit. Wherever necessary written instructions should be given. At the
strategic locations in the plant, safety signboards should be displayed.
4. All the operating and maintenance personnel should be compelled to wear mandatory
PPEs.
5. Specific safety equipments such as gas masks and canisters should be available handy in
required areas in the plant.
6. The first aid boxes along with necessary fixtures should be available round the clock for all
the plant personnel at specific location.

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7. In addition to the above, safety audit must be carried out by PSSR audit team in the plant
area, approximately one month before start up of the unit to identify any safety aspect
overlooked & recommended points are to be liquidated at least A category points.
8. All the work permits necessary to carry out cold work and hot work, excavation and vessel
entry should be made ready sufficiently in advance so as to implement the same at the
appropriate time.
5.12. UTILITY COMMISSIONING

The preparation of the unit for startup must start as soon as construction of the various sections of
the unit is completed. Careful attention to detail will assure that a smooth startup can be conducted
and a safe operation is achieved. Prior to start of pre-commissioning activities of main equipments like
Boilers, STG and GTG, it is must that the Common Utilities inside CPP should be completed and
commissioned. These Utilities are common distributed system for all the major equipment which is
required to be kept in ready for use condition before commencing the actual commissioning of main
equipments.
Common Utilities falling under CPP are basically divided into broadly two category:
(a) Utilities from Refinery
(b) Utilities to Refinery
(A) Utilities from Refinery are listed below as:
 Instrument Air (AI)

 Plant Air (AP)

 Nitrogen Gas (IG)

 Service Water (WS)

 DM Water (WDM)

 Potable water (WP)

 HSD/LCO Fuel (FO)

 Fuel Gas (FG)

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 Fire hydrants (FH)


 Pure Condensate (CL)

 Surface Condensate (CL)

 Process Condensate (CL)

 Raw Water as make up water for CT (WR)

 33 KV power from 220 KV substation

(B) Utilities to Refinery are listed below as:
 Boiler water Blow down (BD)

 Cooling water Blow down (BD)

 Flare system (FL)

 Oily Water Sewer (OWS)

 Slope system (GS)

 33 KV power distribution to Refinery Substations
Commissioning of all the above system within the CPP as well outside the CPP is must before
commencing the Pre-Commissioning or commissioning of major equipments. Commissioning of all
Process Utilities should follow pre-commissioning activities like: Hydro testing, Line/header Flushing,
Leak test, etc. All the above mentioned pre-commissioning activities are mentioned in details in below
section.
The important part of the Utilities commissioning is it’s also include Non P&ID process like; Electrical
and Instrumentations. Electrical system includes: 220 KV switch yard, 33 KV GIS, 6.6 and .415 KV
switch gear, LT MCCs, Station Trafo and LT distribution trafo, Motors solo run, Motor no load vibration
testing, IPOD test, Megger testing, Earthing testing, Protection and control Relay testing and checking
and approval.
Instrument system include: DCS, BMS and Field instrumentation calibration, cabling, loop testing,
tuning and SAT. All instruments should be checked as soon as possible so that any malfunctions or

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other faults can be detected early. The instrument checkout should include the following items:
1. Pressure test of instrument air lines
2. Control valve action and calibration
3. Positioner calibration
4. Board calibration and loop check
5. Thermocouple calibration and identification
6. Level instrument calibration
7. Thermometers, pressure gauges, etc.
All orifice plate bores should be measured, recorded and compared with required sizes. The orifice
plates should also be checked to see if they were counter-bored wherever required. After hydro
testing and water flushing have been completed, the orifice plates can be installed. Loop & functional
checking must be completed prior to start the unit.
5.13 PRE-COMMISSIONING ACTIVITIES:

5.13.1. HYDROTEST
This procedure defines the requirement and procedure of hydrostatic testing of pressure parts after
assembly of all the components subjected to high pressure / temperature operation. Ensure the
following works are completed before hydrostatic testing.
o All pressure parts erection completed
o All attachments welded to pressure parts.
o Radiography and other non-destructive examination for pressure parts.
o Stress relieving (if req.) and repairs (if any).
o Permanent supports, spring hangers are provided and temporary supports removed.
o Piping for water filling & draining
o Isolation valves provided on all drains, vents, instrument tapping points.
o Installation of gags or hydrostatic test plugs for safety valves
o Drum inside is cleaned and the manholes are boxed up with proper gaskets
o Adequate feed water for initial flushing and hydrostatic tests.

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 All facilities required for carrying out the hydrostatic testing like temporary piping, filling pumps
and adequate pressure / capacity -testing pumps shall be made ready. The test pumps
discharge shall be connected to any drain, preferably the MSL drain before boiler stop valve.

 Pressure gauges shall be of indicating type and preferably have dials 12'' to the available range
nearest to twice the operating pressure. All pressure gauges used for hydrostatic test shall be
calibrated with dead weight tester prior to test and stamped. All test records shall be
maintained. Minimum 3nos. pressure gauges are required for hydrostatic test, one to be
connected to steam drum, one steam outlet header and third one on testing pump (before NRV
). The pressure gauge used on pump shall preferably be of snubber type.

 Water used for hydrostatic test shall confirm to be mineralized / deaerated water having pH
Value between 8.5 to 9.0. Addition of oxygen scavenger like hydrazine up to 500 ppm to avoid
any possible corrosion in - drainable super heater is recommended.

 Test water and the metal temperature should be ambient air dew point to prevent condensate
formation on the pressure parts being tested, which interferes with the detection of small
leaks. Test water should remain below 50 deg C for close / safe inspection. Water and the
temperature should be above 21 deg C to avoid brittle fracture temperatures.

 Test pressure (usually 1.5 times the design pressure for new boiler) shall be as specified in
pressure part assembly drawing. The pressure shall be under proper control, so that actual
pressure is never exceeded by more than six (6) percent of test pressure

 For Gaseous system – First Hydrotest after erection should be at 1.3 times the design pressure

 Since 3 gauges are used, the pressure gauge attached to the steam drum shall be used as
official gauge for the test.
Test Procedure
 All valves provided on the drain and instrument isolation valves shall be closed

 Vent valves shall be kept open to purge the air pocket while filling pump and closed after the air
pockets are purged.

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 Before applying pressure, the unit shall be examined to see that all valves & gaskets joint are
tight and no leakages are observed

 The pressure shall be gradually raised to the test pressure with the help of test pump. The relief
valve provided on the leak off line of the pump shall be operated to control the rate of raise of
pressure. After raising the boiler pressure to test value the isolation valve at unit inlet shall be
closed.

 The unit shall be held under pressure for maximum 10 minutes. Quick, but thorough inspection
for leakages/ sweating shall be carried out during these 10 minutes. The pressure shall be then
reduced to maximum allowable working pressure & maintained allowable working pressure &
maintained at that pressure while the unit is carefully examined for leakage.
Acceptance Criteria:
 Leaks through welds, casting, forgings, plate, pipe & tubes excluding gasket joints or mechanical
seal are not acceptable. Slight seepage at the test pressure is permitted at gasket joints &
mechanical seals

 The test data shall be recorded jointly by the parties conducting the test. The records shall
include the date / time of testing, the duration of test, the sequence / duration of rise and drop
of pressure in the circuit involved in test, details of pressure gauges and other equipments
used, ambient temperature and any abnormalities observed during the test.
NOTE: For Pressure piping and pressure parts of Boilers, hydrotest to be confronted in front of Local
IBR authority and necessary report duly signed by IBR authority to be attached as main document for
each test packs for all systems.
Repairs:
 Any leaks in the welded connections shall be repaired with approved weld repairs procedure
and the applicable boiler pressure vessel code

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 Any unaccepted leaks in gasket joints mechanical seals shall be regasketed or resealed.

 After all the repairs have been carried out, hydraulic test shall be repeated in accordance with
the above said procedures.
Draining:
 It is recommended to keep the boiler under wet preservation with the hydrazine concentration
around 200PPM, as the boiler hydro test to boiler light up duration may be number of days. If
required, boiler can be drained for any erection related jobs.
5.13.2 LINE FLUSHING
The purpose of carrying out flushing is to remove foreign matter, mill scale, dirt etc. resulting out of
manufacturing, storing, fabrication & erection of boiler, vessel & piping. Such deposits in the piping walls
sometimes restrict flow through the pipes/tubes causing, over heating and pressure/flow fluctuations and
even failure.
Pre-requisites are:
 Mechanical completion of piping including supports


 Identify the piping system to be flushed, e.g. flushing is carried out for oil piping, atomizing
media piping, pneumatic air piping, steam piping, boiler feed water piping etc.

 Check for adequate illumination and personnel safety in and around the piping flushed.

 Check for adequate supports and expansion loops, as per piping drawings. Supports are to be
completed before starting of flushing activities. If temporary supports are required, they should
be provided as reactive forces resulting from flushing/blowing off media are more than normal
conditions.

 All connected equipment must be adequately vented. The following is a guideline for flushing:


a. Orifice plates must not be installed prior to flushing.
b. Control valves should be removed.

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c. All instrument impulse lines should be isolated or disconnected.

d. All pump suction and discharge piping should be flushed while disconnected.
e. The steam supply and exhaust piping to and from turbines are cleaned by blowing them
while disconnected. Blowing completion criteria based on target plates condition.
f. When flushing through lines regulate the flow of flushing medium at the source and not at
the outlet of the lines being flushed. For example, water from a column, should be
regulated at the column; and steam, at the valve on the steam supply to the line being
blown.
g. Flush through all vents and drains.
h. Where possible flush downwards or horizontally.
i. Always flush through the upstream isolation valves on control loops, before flushing
through the bypass valves into the downstream control valve piping.
j. For steam systems, flush thoroughly the dirt leg drains and steam trap bypasses before
placing the steam trap in service.
k. Disconnect the lines into and out of exchangers, and then flush the lines thoroughly before
reconnecting and flushing through the exchangers.
l. Upon completion of line flushing of a system, carefully check that all temporary lines are
disconnected, control valves reinstalled, and pump alignments are normal. All lines are
properly supported wherever required, line flanges are electrically bonded to avoid static
charges etc. and permanent gaskets are installed.
Procedure:
 Connect flushing media to the starting point of piping


 Check for flushing media isolating valve in good working order.

 Remove all strainer, NRV plug/internals, control valves (provided spool pieces in place of
PCV/FCV, orifice plate/flow nozzle.

 Isolate/remove instruments, e.g. temperature gauges, pressure switches, flow meters.


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 Cordon off the area where flushing is to be done and preferably post a personnel for vigilance.
As a safety measure, install signboards to caution the working personnel

 Piping will be flushed with DM water with pH of 8.5 containing 0.05% SNID detergent by
installing a temporary flushing pump and a closed loop connected to Deaerator.

 Instrument air lines shall be flushed with air only

 LDO lines shall be flushed with water, then with air and finally with water circulation.

 Acceptance: Color of the flushed water.

 After completing the flushing activities, replace the NRV internals /control valves etc. which
has been removed during flushing operation.

 Mark the P&ID and sign against the line as a record

 Prepare the protocols.
Safety Precaution:
 Clear out/cordon off area where flushing is to be carried out as live pressurized steam is to be
flushed out through the system end point.

 Please make available plenty of safety gears, e.g. asbestos hand gloves, ear muffs, transparent
eye protective goggles, and first aid kit.
NOTE: - If controls valves, isolating valves are to be kept in online position during steam flushing, keep
them in 100% open position to avoid damage to seat of the valves or accumulation of dirt.
5.13.3. STEAM BLOWING
Steam blowing is carried out for removing foreign particles like rust, dirt scale and welding burr from
the steam system to prevent any impact damage to steam driven equipments at consumer end.
Pre-requisites are:
 The following activities need to be complied at site

 Completion of temporary exhaust piping including reaction supports.

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 Removal of internals of NRV & FLOW NOZZLE on pipe line to be blown.


 Operability of boiler stop valve.

 Readiness of boiler for operation.

 Readiness of start up vent for operation

 Readiness of instrumentation, namely drum level transmitter, pressure indicators, pressure
transmitter, direct level gauge and necessary instrumentation for safe boiler operation.

 Readiness of feed water system and feed water pump & DM supply.

 Availability of qualified boiler operators and engineer’s staff.

 Adequate safety equipments and first aid kit for operating personnel for protection against high
noise level and hot surfaces.

 Equipment start-up sequence with all the safety protections for all the equipments.

 Healthiness of all the boiler safety interlock like drum level very low, furnace pressure high,
steam temperature high, equipments trip interlock etc.

 Control valve readiness for boiler level control, deaerator level control etc.

 Motorized valves.

 Blow down tank level control system.

 Temperature gauges and transmitters.

 Draft gauges and transmitters

 Controllers and other panel instruments

 Annunciators.

 Check the newly erected line & temporary blowing line in all respect along with line supports &
target blowing assembly.

 Check the extent of removal of foreign particles, target plates are installed near the exit of
temporary exhaust pipe. Target plates are rectangular plates of soft material like aluminum or
brass, which would get impingement by articles blowing off with steam. The target plates are
mirror finish on one face and fitted on a rigid M.S mounting with the machined face, facing the
blowing steam.

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 When the impingement noticed on target plates are within the limits, steam blowing is declared
as complete. (Specified at the end of document)
Procedure for Steam Blowing:
 Fill boiler with specified quality feed water to NWL


 Light up the boiler as per cold start up procedure, ensuring that the boiler stop valve is fully
closed. Also ensure drain valve before stop valve is kept open to remove condensate from main
steam line.

 Raise the boiler pressure gradually to 20 - 30 kg/cm2 controlling fuel firing / modulating the
start up vent as required.

 Crack open boiler stop valve bypass valve on main steam line so that a little steam begin to flow
out of the exhaust pipe.

 Maintain pressure as specified in above point

 After ensuring that entire main piping is hot and no condensate is left over in the pipe prepare
for blowing steam.

 Prior to blow off, clear the working personnel from blowing area.

 Just before starting the steam blow, reduce drum level to 15% and stop firing burner.

 Throttle the start up vent quickly. Open quick acting blow off valve to release steam from main
line into atmosphere.

 When boiler pressure drops to about 10 kg/cm2, close stop valve. So that by time the valve is
fully closed, the boiler pressure settles down. During blow keep watch on the color of steam
exhausted in atmosphere. If exhausted steam is brownish it means some derbies are coming
out with it. Pure superheater steam will be Colorless

 Check for line & support healthiness; then rest of the blows to be carried at 40 – 50 kg/cm2 &
steam temperature should be minimum 400°C. Hammering can be done on exposed steam pipe
to loosen scale faster

 Follow earlier above mentioned steps until three clear target plates are obtained as desired.

 Protocol to be filled

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 Temporary blowing line should be removed
Notes:-
1) Target plates are fitted towards the end of steam blowing cycles. Plates are fitted before
starting blow with blow sequence number clearly punched on them for comparison and record.
One target plate with initial impingement & three target plate with final should be preserved
for record purpose.
2) It is suggested to do the steam blowing (Around 3-4 blows; pressure rise to be done as per
pressure rising curve) in the first half and soaking in second half time to be left for cooling the
steam line to dislodge the scale/deposits from the piping. Again repeat blows in afternoon till
three consecutive acceptable target plates are observed.
Precautions:
1. In the puffing method of steam blowing, the water level in the drum swings beyond visible
limits at the start, during and at the end of blowing. During steam blowing there are chances of
water carry over to steam lines and low temperature superheater. This can possibly be
minimized by keeping the water level in drum to the lowest visible limit at the start of blow. It is
recommended that the water feeding to drum may be started when the drum level starts falling
towards end of the blow and drum level is to be brought to normal level for subsequent light up
of boiler.
2. The time for opening as well as closing of the electrical operated temporary valve should be as
short as possible to match the pressure drops in drum. Arrangements should exist in control
room for simultaneous opening / closing of the temporary valves.
3. The boiler pressure during blowing out operation should be kept within the design pressure of
related piping, temporary piping, fittings and flanges.
4. Water level in drum will be subjected to a very high degree of fluctuation. Special care is to be
given to this aspect.

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5. Sufficient storage of demineralised water shall be ensured and the rate of make-up water to
feed tank is to be matched taking into account the capacity of feed tank.
6. Internal boiler water treatment to be carried out as per desired parameters.
7. Communication between operating levels and control room, necessary instruments and
controls and boiler protections should be ensured before steam blowing.
8. Hot tightening of flange studs/bolts is to be done wherever such connections have been made
at 5 Kg/Cm2.
9. All the drains of connecting piping are to be left open to atmosphere and not to be connected
to drain vessels, to ensure proper draining.
10. After completion of steam blowing, permanent drain piping can be routed and TIG welding
adopted to avoid welding slag not to create subsequent problems in draining the system during
operation.
Results:
The target plate should be free of indentations or markings to the extent possible. At least one target
plate at the initial blow off operation should be kept as base for comparison and arrive at a conclusion.
The indentations must be reduced to at least 20% of the initial reference plate. No Indentation of dia
2
0.8 mm may be seen on the plate. Number of indentation of dia 0.4 mm may not exceeding 2/inch in
2
number. Number of indentation of dia 0.2 mm may not exceeding 10/inch in number. These are a few
guidelines for declaring the Steam Blowing operation is completed successfully.
Record keeping format:

Header Details:
Design Pressure:
Design Temperature
Service:
No. of Date Time Press Temp. Duration Target plate Time for Remarks

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Blows (Bar) (⁰C) of blow details soaking

(Min) (Min)
1.
2.
5.13.4. CARD BOARD BLASTING
All pneumatic and Gas piping are pre-commissioned as per card board blasting technique. In this
process, the pipe which is to be flushed is pressurized at suitable pressure (as per recommendation and
design). At the end of pipe connection one isolation valve is provided with is normally kept closed
during pressurization. A hard cardboard with white paper on it is fixed at the outlet of isolation valve.
The distance between isolation valve outlet and cardboard should not be greater than 3 ft. Once the
above system are in place, the isolation valve should be open manual as fast as possible by which the
high pressure jet get impingement on Hard cardboard. The amount of debris and sludge deposited on
cardboard and white paper help to judge the completion of Card board blasting. Normally it is
recommended to installed cardboard only after initial one or two blow is given to header by
pressurizing the header and venting the high pressure air into open atmosphere.
Due to sudden increase in pressure, the pressure jerks removes out the sludge and welding and piping
debris from pipe and the resultant high velocity ensure to dropping of debris inside pipe. The cycle to
be repeated until ensures that the impression on cardboard is under satisfactorily level.
5.13.5. LEAK TEST
The purpose of this procedure is to outline the system used to conduct leak test of air/gas path. This is
to be followed for leak tests of air/gas path i.e. FD fan outlet ducts/wind box, boiler
furnace/Economizer inlet duct/Economizer outlet ducts, steam coil air pre heater, and flue gas inlet
duct to chimney. Hence, the above area will be pressurized.

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Procedure:
 Check that erection of boiler, economizer, and connecting air & flue gas ducts which are to be
tested for leakage are completed (including supports).

 All temporary attachments to the ducts/furnace/economizer/SCAPH which cause leak is
removed at later stage. No welding should be carried out after leak test is over except repairs.

 Ensure FD fan is in operating condition ,inlet guide vanes are free to operate, and dampers on
flue gas inlet ducts near chimney is in operating condition(if provided).

 Ensure that insulation or cladding is not done on ducts/economizer casing. The same applies to
the boiler casing also.

 Ensure that all draught gauges, pressure switches in air/flue gas path are isolated except
draught gauge for FD fan outlet and furnace draught

 Ensures that all the possible air leakage openings like burner openings, access door, peepholes
are closed for the tests.

 Fill the boiler with specified quality feed water up to NWL in steam drum. Ensure that all the
drains are kept closed and vents in open condition.

 Close boiler furnace door quickly. Set FD fan IGV to close position and start FD fan. Open the FD
fan damper gradually to the required opening for pressuring the system up to max 700 mmWC
in the furnace.

 Keep the boiler and complete system pressurized for the shortest possible time and quickly
inspect the system for leakage

 In case of large units, kerosene/lime test is acceptable for flue, ducts and casings.
Repairs:
 In the event of any leakage in casings, smoke will start leaking out from it. Mark the place of
leakage and repair them after stopping FD fan and depressurizing the system. A special lookout
at the corners, bolted joints, and instrument tapping is necessary during the testing. Use soap
solution for confirmation.

 Repeat the test after repairs (if any) to ensure no leakage remains and ensure that packages are
airtight.

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 The furnace and ducting is cleared for further process.
Leak test is also applicable to Vacuum system of STG condenser where, vacuum is pulled through
installed ejector system. The vacuum drop rate should be as low as 0.01 Kg/cm2 g per hour. Any
susceptible leak point should be immediately attended if possible otherwise marked and noted for
necessary action during de-pressurized state.
In case of flange joint for piping especially carrying Hydrocarbon Gaseous, IA/PA and nitrogen header -
a foam/soap test is advisable. All Flange joints, Valve glands, piping tapped off points, etc are poured
externally with Soap/foam solution and check for any leakage. This is done after hydro testing of piping
is completed and piping is reinstated as per design. Normally Inert gas like Nitrogen or PA is used to
pressurize the piping. All leakages to be immediately attended and retested before taking into service.
5.13.6. CHEMICAL CLEANING / ALKALI BOIL OUT
Chemical cleaning also called as Alkali Boil out is process to clean and passivate the steam generating
surfaces of steam generator prior to its regular operation. This operation shall include the following:
 Economizer
  Drum
 Water walls and associated headers
By carrying out alkali flushing and water rinsing loose rust, debris, oil and grease, if any, left in the
boiler are removed. Then evaporating surfaces and other heating surfaces are subjected to acid
cleaning for the removal of mill scale and rust. The acid pickled surface is passivated for the formation
of magnetite layer. Both the acid cleaning and passivation processes are completed in a single step.
Provisional requirement for Alkali Boil out process are:
1. Circulating Pump with necessary standby unit. Capacity of pump and head should be the
technical requirement for circulation chemical at prescribes rate and necessary head to pump
the chemical at max height location.

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2. Acid Transfer pumps to divert the chemical to nearby blow down pit.
3. Pipeline and valves as per finalized scheme
4. Mixing tank, where fresh DM and chemical solution is prepared
5. Acid storage tank to handle acid dozing
6. Acid transfer Pump for safe and control transfer of acid from acid tanker to acid storage tank
is to be ensured.
7. Suitable neutralizing pit (for effluent treatment) shall be made available for this activity.
Volume of this pit may be preferably 1.1 - 1.3 times the maximum holding capacity of Steam
generating unit.
8. Adequate quantity of DM water as per specification shall be made available.
9. Adequate quantity of required chemicals shall be made available.
10. Other requirements – Express Lab. for chemical analysis, pressure & temperature gauges -
shall be made available.
11. Provisions should be made at the following locations for the measurement of temperature.
a. Two locations in the drum (left & right) for the measurement of boiler water temperature.
Long thermocouples of around 1500 mm length shall be installed directly in the spare /
unused stubs in the drum.
b. Water wall metal temperature measurements at two locations.
12. Penning type temporary thermocouples are to be provided at the temp. measurement points
on the water walls.
13. Provision has to be made for monitoring the temperatures at the control room.
14. Temporary sample cooler along with cooling water connection for collecting samples has to
be installed.
15. To get representative samples of the process solution, sampling points with sample coolers
are to be provided at the following locations:
a. Drum water sample to be drawn from CBD sampling line and from a spare tapping point in
water side through the permanent saturated steam sampling line.
b. Two numbers of sampling point is to be provided from bottom ring header drain lines.

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16. Temporary drum level gauge (tell-tale lamp indication) shall be arranged.
17. Flood lights / Telephones/ Walkie-talkie to be made available.
18. For effluent treatment, compressed air facility and suitable perforated carbon steel /
polythene tubing arrangement shall be made available.
19. A temporary pressure gauge of 0 to 10 kg/cm2 shall be arranged in the drum for monitoring
the pressure in the drum during acid cleaning.
20. Drum internals in drum are to be installed.
21. Water wall tube test coupons are to be placed at two ends inside the drum.
22. Boiler shall be ready for operation with necessary protections, as per O&M instructions and
mutual agreement at site between BHEL and GGSR Engineers.
23. All tapping & sampling root valve shall be closed except the following:
a. Local drum pr. measurement.
b. Local drum level measurement.
c. CBD sampling line.
d. One spare tapping of drum for sampling.
24. Local drum level gauge glass shall be ready with illumination, if any.
25. Drum level indication in control room shall be made available.
26. Provision for measurement of expansion of boiler shall be made available.
27. Indication of drum metal and other metal temperatures shall be made available in the control
room.
28. Data logger at the control room should be made available to record the boiler parameters
periodically.
Details of Chemical cleaning / Alkali boil process as per BHEL standards are mentioned as below:
SPECIFICATION OF CHEMICALS & QUANTITY

NAME OF CHEMICALS Qty./Each Boiler
a. Tri Sodium Phosphate (Purity, as P2O5 :17.5% min), IS:573-1985 100 kgs

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b. Disodium Hydrogen Phosphate (99 % purity), IS : 566-1984 50 kgs

c. Ammoniated EDTA, 40% wt/wt as active EDTA
Ammoniated solution pH = 9.5 to 9.8
(EDTA: Ethylene diamine tetra acetic acid) Sp. gravity: 1.18 14 tons
d. Ammonia solution (20% Min as NH3, Sp gravity 0.91), IS : 799 - 1990 600 litres
e. Hydrazine Hydrate (80% Min. concentration), IS: 12086-1991 500 litres
f. Bhelmax 180 kgs
g. Bhelsol 180 litres
ALKALI BOIL OUT / CHEMICAL CLEANING PROCESS STEPS:

(A) ALKALI FLUSHING:
 The requisite quantities of Tri-sodium Phosphate (TSP) & Di Sodium Hydrogen Phosphate to
be added to the mixing tank along with DM Water and the solution will be thoroughly
mixed by recirculation so that final solution in the Boiler contains 0.1 % TSP and 0.05 % DSP.
The solution will be injected into the boiler through the bottom ring header drains and
economiser drain operating the chemical filling pump. Further DM water will be taken in
the boiler up to normal level.
 Light up boiler as per O&M instructions and gradually raise the boiler water temperature
to 130 ⁰C – 140 ⁰C. Trip the boiler and keep the fans running for cooling.

 Drain the boiler at 95 ⁰C to the plant water disposal system, by keeping open the drain
valves fully (without any throttling). The drain solution will be diluted with plenty of service
water.

(B) HOT WATER RINSE
 Once the draining is completed, refill the boiler with demineralised water. Light up the
boiler and gradually raise the boiler water temperature to 130 ⁰C – 140 ⁰C. Trip the boiler
and keep the FD fan running for cooling.

 Drain the boiler at 95 ⁰C to the plant’s water disposal system by keeping open the drain
valves fully (without throttling).

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(C) COLD WATER RINSE
 Cold water rinses will be done by filling and dumping method. During these steps, draining
will be done to the plant’s water disposal system. The pH and PO4 will be monitored during
draining of each cold water rinse stage.

 The pH and PO4 are to be reduced to a level below 7.5 and 10 ppm respectively.

 Flush all sampling and blow down lines. Check all temperature / pressure measurements
relevant to the process for monitoring at UCB and ensure their reliability
(D) ACID CLEANING & PASSIVATION
 Acid cleaning is carried out by adopting soaking technique using a single fill of mixture of
chemical solutions containing EDTA, inhibitor, ammonia and hydrazine in DM water. Boiler
is fired and the temperature raise to 140 ⁰C and subsequently cooled. The removal of
deposit constituents and subsequent passivation of the metal surfaces will occur during this
single step.

 Keep ready the required quantity of ammoniated EDTA (40% wt/wt) solution.

 Keep ready the inhibitor “BHELMAX” & “BHELSOL” for addition in the mixing tank.

 Keep all the boiler blow down valves shut and drum vent valves & start up vent open during
boiler filling.

 Take 20 m3 of DM water in the mixing tank. Start the temporary chemical fill pump and put
the DM water under recirculation. Start transferring the mixture of Ammoniated EDTA (40%
wt/wt) solution, inhibitors and Hydrazine Hydrate to the mixing tank. Re-circulate till all the
chemicals get uniformly mixed up. With this, one batch of EDTA chemical solution is ready
for filling into the boiler.

 The approx. quantities of various chemicals that are to be mixed per batch of 20 m3 is given
below:

1. EDTA ammoniated (40 %) concentrate: 2 to 3 m3
2. BHELMAX : 30 kgs
3. BHELSOL : 30 lit
4. N2H4.H2O (80%) : 30 litres

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 Ammonia will be added if required to adjust the pH between 9.2 to 9.5. DM water will be
used to make up to 20 m3.

 Starts filling this solution into the boiler through LP drain header fill line from temporary
chemical fill pump.

 Repeat the preparation of chemical solution and batch filling as explained in point No.
5.4.6 till water level in the drum reaches the center line of the gauge glass. The
composition of the filling solution shall be as below:
EDTA content : 3 - 4% W/v
Hydrazine : 1000 ppm.
pH : 9.2 to 9.5
 Fire the boiler and gradually raise the temperature of the Boiler water following the
precautions as detailed out for hot water rinsing.

 The drum and super heater vents are to be closed when steaming starts, say at 1 Kg/cm2 in
the drum & SH start up vent remains open.

 Note the time at which the temperature of boiler water reaches 110 ⁰C.

 Continue raising the temperature of boiler water to a saturation temperature of 140 ⁰C.

 Once the temperature of boiler water reaches 140 ⁰C, control the firing rate in such a way
that the boiler water temperature is maintained at 140 to 145 ⁰C, for approx. 4 hours.

 Then trip the boiler. Continue running the FD fan to bring down the boiler water
temperature. In case it appears that the results of iron concentration may not level out
when temp is expected to be 110 ⁰C, FD fan shall be stopped, suitably, during the cooling
down phase & boiler shall be boxed up and kept in this condition to achieve the EDTA
contact period of 8 hours with temperature exceeding 110 ⁰C.

 Samples have to be taken every 30 minutes from the sampling points at locations given as
per point 15, from the time on when the temperature in the system has reached 110 ⁰C and
analysed for pH, EDTA concentration and iron content.

 Boiler water temperature & Water Wall metal temperature at the locations indicated as per
point 15 are to be measured and logged.

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 During the boiler operation extreme care has to be taken towards drum level control so
that no process solution enters the superheater. In case the level in the boiler drum
becomes too low, adequate make-up of process solution has to be made, injecting the
process solution from the mixing tank into the drum. Hence, some reserve process solution
has to be kept ready always during the boiler operation until the end.

 Cleaning process is to be continued till iron concentration in three consecutive samples
show equilibrium status. When the iron concentration in the cleaning solution is constant, it
indicates that all the oxides have been dissolved. However, a minimum EDTA contact period
of 6 hours from the time of attaining the required temperature (110 ⁰C) shall be allowed. If
the iron concentration values do not level out and attain equilibrium status, regardless of
analytical results, the EDTA contact period with temperature exceeding 110 ⁰C shall not be
allowed for more than 8 hours (approx).

 After completion of pickling process as above, the system shall be allowed to cool with the
FD fan in operation. Open the drum air vents when the pressure reaches to 1 Kg/cm2.

 When the temperature comes down to 95 ⁰C, all drain valves shall be opened and the
system drained completely in hot condition to the effluent pit.

(E) TREATED DM WATER RINSE
 Prepare a blended solution of Ammonia and Hydrazine with calculated quantities in the
mixing tank in order to achieve a solution pH of 9.0 to 9.5 and Hydrazine content of 50 ppm
in the DM water being filled in the boiler.

 Fill the boiler with the above treated DM water through LP drains as practiced earlier, up to
just above the center of gauge glass.

 Fire the boiler to raise temperature to 120 ⁰C and then shut down the boiler. Allow the
boiler to cool down to 95 ⁰C.

 Drain the boiler to the effluent pit and allow the system for natural aeration.

 Open the drum for inspection. Manually clean the drum, if required.

 Back flush the SH with the above treated DM water.

(F) CHEMICAL CLEANING WASTE TREATMENT & DISPOSAL

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 The organic spent EDTA chemical solution after the cleaning process is drained into a pit.
The pH of the effluent will be in the range of 8.5 to 9.0 and hence no treatment for pH
adjustment is required, as it would meet the pH requirement for disposal.
 Compressed air shall be used to destroy the residual Hydrazine & organics and the effluent
shall be disposed after aeration for 15 days approx. (The organic chemical is completely bio-
degradable). This effluent may be disposed to plant disposal system after ensuring residual
Hydrazine & pH etc. using a temporary pump.

(G) COMPLETION CRITERIA AT A GLANCE
 COLD DM WATER RINSING:
The pH and PO4 will be measured in the drain water. The pH and PO4 are to be reduced
to a level below 7.5 and 10 ppm respectively.
 ACID CLEANING & PASSIVATION
Cleaning process is to be continued till iron concentration in three consecutive samples

show equilibrium status. When the iron concentration in the cleaning solution is
constant; it indicates that all the oxides have been dissolved. However, a minimum
EDTA contact period of 6 hours from the time of attaining the required temperature
(1100C) shall be allowed.
 If the iron concentration values do not level out and attain equilibrium status, regardless of
analytical results, the EDTA contact time at >110 ⁰C shall not be allowed for more than 8
hours from the time of attaining the required temperature (110 ⁰C).

 The pickling process will be declared completed once the EDTA strength and iron
concentration level out and reach equilibrium.

(H) SAFETY PRECAUTION
 Effectiveness of inhibitor should have been checked.

 Temperature limitations specified for various steps should not be exceeded.

 Drum safety valves shall be protected by installing hydrostatic plug.

 All the tapping points from drum shall be isolated.

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 If the boiler light up after chemical cleaning cannot be done within 4 weeks, the system
should be suitably preserved.

 Prior to Acid cleaning, ensure availability of the following:
o One Ambulance / Car for emergency and Fire tenders

o Proper lighting and communication system o PPEs &
First Aid kit
o Cordoning & signage
 Safety shower shall be provided
(I) WATER VOLUME OF BOILER

System Volume in M3
Economiser 7
Circulating System including drums, boiler bank, headers, pipes, water wall tubes 90
Superheater 13
Refer below the detail schematic of Alkali Boil temporary piping, permanent piping and arrangement
schematic for UB and HRSG

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5.13.7. REFRACTORY DRY OUT
Refractory dry process commence immediately after the Alkali boil out process for Boilers. In this
process the patch up refractory installed near Burner area, Drum area and near peep holes area is
required to be cure before taking the boiler in to continuous operation. Refractory process can also be
clubbed together with Alkali boil out process if the content of refractory inside the boiler is less. For the
Boiler at CPP, no separate procedure is made to refractory dry out. The only precaution required to be
taken is that the necessary curing time (minimum 1 day) is must for refractory at elevated temperature
say above 600 ⁰C of flue gas or 160 ⁰C refractory temperatures. For smaller quantity of refractory like
our boiler, same can be achieved in parallel with Alkali Boil out process where DM water is heated up
to 110 ⁰C before rinsing.
5.13.8. VESSEL INSPECTION
Inspection of the vessels can be undertaken as soon as the EIL person arrives on site. The actual
arrangement of lines, vessels, pumps, etc., must conform to the Piping and Instrumentation (P&ID)
drawing. As soon as construction is completed, and if possible even before, the unit must be carefully
checked against the P&ID and the appropriate UOP specifications. Ensure the following before giving
final clearance for vessel closure:
 Vessel is hydrotest as per the EIL standards

 Vessel all nozzle, piping and drains are thoroughly connected to their respective location

 All field instrumentation are ready to be mounted

 Calibration record of tank is prepared by contractor and handed over to EIL. Same should
also be approved before closing the vessel

 Vessel closure report duly sign by EIL/Contractor/Inspection/QA-QC dept.

 Vessel thoroughly clean and free from any debris

 Necessary statutory clearance received (CCOE for Fuel tanks, IBR for Pressure vessels,
Factory and safety directorate for Pressurized air vessels)

 Name plate stamped on Vessel

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 Fuel handle MSDS with technical details of tanks and statutory clearance certificate no., date
and expiry date to be mentioned in a separate board and installed near tank

 Fire hazard – Diamond painted

 Proper painting as per spec (Inside and outside completed)

 Tag no. painted on tank

 Insulation completed on tank

 All nozzle connected with associated piping or blinded with spectacle blind and isolation
valve

 Vessel Protocol duly filled and signs off by EIL/Contractor/Inspection/QA-QC dept.
Once the above mentioned points are inspected, checked and agreed upon, the final closure report
of vessel can be sign off. Vessel can now declared as ready for operation.
5.13.9. PURGING, INERTING AND PRESERVATION
Once the boiler is chemically cleaned and a uniform magnetite layer (Grey in colour) is observed during
the drum inspection and if boiler is not be started off for further commissioning process like steam
blowing, Boiler is required to kept under preservation. In case that the boiler is shut down, provisions
have to be made against standstill corrosions. There are in general two different preservation
methods, the wet and the dry method. Which method will be chosen depends from the local and
actual requirements, as there are:
- duration of the shut down
- local climatic conditions
- necessity of short term start up
- availability of chemicals and technical gases
- environmental aspects
Wet preservation
The wet preservation is applied for operation breaks of uncertain duration and if the boiler must
remain ready for operation. The chemicals should usually be added into the feed water tank, but in
case, that another boiler which is connected to the same feed water tank remains in operation, there

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are additional temporary arrangements for mixing, dosing and filling required. The conditioned water
in the boiler should be circulated at least once per week, if the plant has no circulating system (also no
opportunity to connect a temporary one), every week approximately 10% of the water content should
be renewed and the water properties should be monitored carefully and continuously. Before the
boiler is taken out of operation, the alkalinity of the boiler water has to be increased up to a pH-value
of 10.5. As soon as the boiler has been shut down, the boiler inclusive the superheater is filled with
alkaline feed water containing hydrazine (Levoxin) up to the overflow. The amount of Levoxin depends
from the scheduled shut down time and can be calculated by means of the values of the following
table:
Shut down time Hydrazine (Levoxin) content in Addition to 15% hydrazine

conservation solution mg N2H4/1 (Levoxin) solution g/m3
Weekend 15 100
1 week 20 - 50 140 - 350
1 month 100 - 200 700 - 1400
More than one month 200 - 500 1400 - 3500
It is advisable to remain the boiler additional under nitrogen pressure to avoid corrosion especially on
the water surface. The usage of hydrazine (Levoxin) needs care because the solutions with hydrazine
are said to have a cancer producing effect. The preservation water is strongly alkaline and contains still
large amount of hydrazine which is readily absorbing oxygen. The draining of such preservation water
needs care that it is not charged into public waters without treatment. Preservation water shall only be
drained and guided into public waters having been neutralized to a pH-value of approximately 7.The
hydrazine content has to be reduced to a “not detectable” value.
Dry preservation
The dry preservation is applied for a longer shut down of the plant, if a short term start up is not
necessary or a wet preservation is not possible because of any reason. At first the boiler has to be
emptied completely at a pressure of about 7 -8 bar and the steam has to be let off. The FD fan has to
be switched off in time to avoid, that the boiler cools down too quickly. All valves have to be opened

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so, that all residual moisture and steam may evaporate by the sensible heat in the boiler. It is advisable
for safety to flange all connecting tubes blind after the boiler is emptied. The next step is to avoid, that
humidity can enter the boilers pipe work again. Therefore are two methods recommendable:
1. Dry preservation with Hygroscopic Chemicals (Silica gel)
Once the boiler has been cleaned Silica gel in small perforated bags is to be brought into the upper
drum at amounts of 200 g/ m3 air space. After completion of the saturation process the Silica gel
changers it´s colour from blue to red. It can be used again after drying at 120 deg C. The boiler must
then be airtight sealed!
2. Dry preservation with Nitrogen
To preserve the boiler with Nitrogen, it is sufficient to rinse the boiler with about 5-fold of its volume
with nitrogen from the top (expulsion of air). Subsequently the low-lying valves (outlets) have to be
closed and the nitrogen pressure has to be adjusted above 10 mbar.
Keep the system hot during shut down
By means of a HP steam line, connected to the lower drum; it is possible to keep the boiler hot and
partly pressurised. This method is applied for a short shut down of the boiler. In this case it is suitable
to blow steam by means of the existing HP preservation steam line into the lower drum. The advantage
of this method is that the boiler can be re-started at any time from warm or hot condition.
Preconditions therefore are that at least one other boiler remains in operation and no maintenance
and/or inspection works at the boiler water steam and flue gas system are scheduled during shut
down. The boiler will shut down with the normal water level in the drum. The main steam gate valve at
boiler outlet will be closed and a pressure less than the pressure in the HP header will be maintained in
the boiler. The manual valve in the heating line in front of the lower drum has to be opened carefully
step by step until the pressure in the boiler starts to increase again. The system will be balanced now
by opening of the start up valve for a certain percentage (less than 10 %!). By means of this it will
ensured, that there is a certain steam flow in all parts of the boiler and no condensate will develop.

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Please note: So higher the pressure in the system is so higher will be the steam consumption of the
boiler and so shorter is the time for restarting the unit. At least a pressure of about 2 bar should
maintained all the time. In case, that the pressure is less than 10 bar, the manual drains should be
open shortly before restart of the boiler. Please watch the drum level and keep it manually constant!
Deaerator tank preservation
 Deaerator tank is made of carbon steel & must also be protected during a shut-down period.

 Dry completely the Deaerator tank after drainage. The tank can then be kept dry by installing
silica gel, approx. 20 kg & to close tightly the tank

 Nitrogen blanketing can also be done.

 Chemicals like ammonia & hydrazine can also be added as describe above.
Steam Piping Preservation
 The easiest solution is nitrogen filling of the piping during shut down of the boiler, when the
pressure is still above atmosphere

 If the boiler is stopped without precaution it is possible to fill the steam piping with nitrogen
while alternating pressurising & depressurising until the oxygen content in nitrogen is less than
1%.

 It is recommended to check periodically the oxygen content in the nitrogen.

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CHAPTER – 6
COMMISSIONING AND START UP PROCEDURE
6.1 INTRODUCTION
Startup and normal operating procedures are described in this section. Startup and shutdown are
the most critical periods in operation. It is then that the hazardous possibilities for fire and explosion
are greatest. The hazards encountered most frequently in start up and shut down of units are
accidental mixing of air and hydrocarbons and contacting of water with hot oil. Other hazards
primarily associated with startup are pressure, vacuum and thermal and mechanical shocks. These
can result in fires, explosions, destructive pressure surges and other damages to unit as well as
injury to personnel.
Fires occur when oxygen and fuel vapor or mists are mixed in flammable proportions and come in
contact with an ignition. They may run out of control or touch off devastating explosion. Pressure
surge from unplanned mixing of water and hot oil may cause damage of equipment and/or loss of
valuable production. Extensive, costly down time on process unit may result. Fires usually follow if
the explosion bursts lines or vessels.
Preparation for start-up begins with a complete review of the startup procedure by the operating
crew. Activities of CPP should be coordinated with other units, and utilities section. The main
objectives of the start-up procedure are:
 To provide a safe and reliable way of getting the unit on stream.


 To protect the high pressure, high temperature equipment during the critical period of
initial pressuring and heating up.
A successful start-up of the unit requires that the unit be clean and the equipment perform reliably.
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Pre-start-up activities usually include hydrostatic testing of Boilers, Alkali Boil out and steam blowing
of Boiler pressure parts, flushing of fuel and air lines, installation of burners, Boiler refractory dry
out, Inspection and testing of all associated rotary and static equipments including BMS and DCS
system. The boiler internal checking to be supervised and inspected thoroughly to ensure to meet
specifications after alkali boils out and refractory dry out process. The pre-start-up activities and
overall start-up critical path should be carefully planned.
Each system should have already completed a thorough Pre Startup Safety Review (PSSR). Each
system should also have completed all pre-commissioning procedures before starting these
procedures.
6.2 COMMISSIONING OF CPP

Commissioning of CPP is basically done as equipment wise. Major equipment inside CPP are Utility
Boilers (UB, 4 nos.), Steam Turbine with Generators (3 nos.), Gas turbine with Generators (2 nos.),
Heat recovery steam generators (HRSG, 2 nos.). Each major equipment required some or other kind
of Utilities and common Balance of Plant. It is must that the required BOP and utilities are made
available up to individual major equipment B/L so that the process of commissioning of Major
equipments progress smoothly without hick ups. Commissioning of Utilities inside CPP and BOP is
thereby firstly discussed in brief before going to the Major equipment commissioning.
6.2.1. COMMISSIONING OF UTILITIES

Commissioning of Utilities is basically divided based on the type of Utilities made available from
refinery to CPP B/L. These Utilities from refinery is must for the Commissioning of BOP and major
equipment inside CPP. Common Utilities inside CPP is required to first commission before going for
the Major equipment commissioning. The requirement of any common Utilities within the CPP for
each major equipment is different and the requirement at the time of commissioning is different.
Details pertaining to the requirements of all utility for all major equipments are mentioned during
the initial assumption made before starting of commissioning. Here we assumed that all Utilities are
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made available up to CPP B/L and Pre-commissioning activities inside CPP is complete before going
for Commissioning.
6.2.1.1. COMMISSIONING OF DM SYSTEM
DM water is made available to CPP from RO/DM plant of Refinery. An 18” supply header from
refinery supply DM inside CPP. Points to be ensured before commissioning of DM are:
 Format IV is accepted with exception of C category points

 Pre-commissioning activity is completed and necessary isolation valves with drain and
vents are provided on the header at suitable location.

 All instrument and piping are reinstated and no temporary arrangements are available on
header.

 Inform concerned department for Commissioning of CPP header
Once above point are ensured, first closed all near unit isolation valve and open suitable vent valve on
header. Open isolation valve with spectacle blind in CPP B/L and charge the header by venting air into
atmosphere. Open isolation valve at each end user connection and check the flow of DM. There
should not be any air trapped inside the header. Closed the vent valve on header once continuous
flow of DM is made available at a pressure > 3 Kg/cm2 g. Check the header pressure and temperature
including Flow. Header pressure of DM inside CPP should be 5-6 Kg/cm2 g minimum and there should
not be any hunting in pressure gauge reading. Take a DM water sample from any drain or vent
location and check the quality of DM before using it for actual process. Once quality is ensured, DM
water is said to be commissioned inside CPP.
6.2.1.2. COMMISSIONING OF PA/IA SYSTEM
IA and PA are being supplied from Refinery to CPP through the 2” header for each. Points to be
ensured before commissioning of IA/PA system are:


 All instrument and piping are reinstated and no temporary arrangements are available on
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header.
Once above point are ensured, first closed all near unit isolation valve and open suitable vent valve on
header. Open isolation valve with spectacle blind in CPP B/L and charge the header by venting air into
atmosphere. Open isolation valve at each end user connection and check the flow of IA/PA. Closed the
vent valve on header at a pressure > 3 Kg/cm2 g. Check the header pressure, temperature and Flow.
Header pressure of IA/PA inside CPP should be 6 – 6.5 Kg/cm2 g each. Also inspect physically the joints
on header and nearby any fitting for any leakage. Provide holdtite if any leakage is observed.
6.2.1.3. COMMISSIONING OF FIRE HYDRANT SYSTEM

Refer Drawing no. 14-4833-0_Rev05 (Kinde Drawing)
Fire hydrant system consists of outer ring header of 20” on CPP B/L and further distribution of
Fire hydrant network at different location inside CPP. Fire hydrant ring header is connected with 8
nos. of tapping for close loop circulation of fire water for CPP. At 8 different locations, tapping is taken
for charging and discharging the fire hydrant network. Points to be ensured before commissioning of
Fire hydrant system are:


header.

Once above point are ensured, open isolation valve with spectacle blind at a defined location out of 8
locations at CPP B/L and charge the header by opening necessary vents and deluge valve into
atmosphere. Also open another tapping point out of 8 where the fire hydrant system completes its
cycle. Once the header pressure is equivalent to Refinery supply header pressure, start opening all
other tapings for ring header after ensuring outside header charging. Once the fire hydrant ring
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header is charged, open necessary connection at each equipment end as per the requirement for
charging fire hydrant inside the each section like Boilers, Tankages area, STG area, Fuel pump house
area, Control room, Transformer area, etc. Always ensure that Fire hydrant pressure at each
equipment area should be > 8-9 Kg/cm2 g.
6.2.1.4. COMMISSIONING OF OWS SYSTEM

Refer Drawing no.:
OWS system (Oily water sever system) from each equipment inside CPP collect OWS and then
connect to Refinery OWS header at suitable location. OWS from CPP is going to ETP unit inside
Refinery for further treatment. Points to be ensured before commissioning of OWS system are:


header.


 Ensure the connectivity of header layout and proper vent station installation

 Ensure the pipe leakage by flushing the header with Water or steam and ensuring no
blockage inside the header.

 Ensure pipe laid U/G are as per the specified slope
Once above point are ensured, OWS system is consider to be commissioned. Any draining of
Hydrocarbons, effluents and condensate to OWS system should be smoothly routed to ETP without
any overflow or blockage.
6.2.1.5. COMMISSIONING OF NITROGEN SYSTEM
Nitrogen from Refinery is supplied to CPP through 4” header at CPP B/L. Nitrogen is normally
used only for GT FG line purging and for Boiler preservation. However the Nitrogen supplied pressure
from refinery is not sufficient enough for GT purging so a separate HP nitrogen system is installed
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within CPP to boost the nitrogen pressure for GT purging. Refer Comm. Activity no. 6.2.2.11. Points to
be ensured before commissioning of Nitrogen system are:


header.

 Inform concerned department for Commissioning of CPP N2 header
Nitrogen charging is initialized by opening isolation valve and spectacle blind on header. Before that
one should ensure that, all drain and end user connection are in closed condition and high header
vents are in open condition. Charge the nitrogen and measure the LEL level at vent station. Oxygen
content in vent should be ZERO. Check the header pressure (5-7 Kg/cm2 g).
6.2.1.6. COMMISSIONING OF SERVICE WATER SYSTEM
Service water from Refinery is coming from RWTP by a supply header of 6” at CPP B/L. Service
water is going to the area like CT, Fuel area, STG area, Aux CW area, etc. Out of which some uses are
Intermittent. Points to be ensured before commissioning of Service water system are:


header.

Once above point are ensured, open isolation valve with spectacle blind at CPP B/L and charge the
header by venting air into atmosphere. Closed the vent valve on header once continuous flow of DM?
is made available at a pressure > 3 Kg/cm2 g. Header pressure and temperature of service water
inside CPP should be 5 Kg/cm2 g and Ambient Deg C respectively. Ensure the continuous flow at each
user end for system to be declared commissioned inside CPP.
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6.2.1.7. COMMISSIONING OF CONDENSATE SYSTEM FROM REFINERY
Condensate from Refinery is coming to CPP B/L in three different forms from 3 different
locations through the supply header; 16” Process condensate from RO/DM, 16” Surface condensate
from Refinery and 14” Pure condensate from Refinery. Each header is equipped with Motorized
Isolation valve and NRV in downstream of the valve. A common header collecting all 3 streams are
connected to CST inside CPP. Points to be ensured before commissioning of Service water system are:
 Format VI is accepted with exception of C category points


header.

Once above point are ensured, commissioned each header as below:
6.2.1.7.1 PROCESS CONDENSATE
Open the Manual isolation valve and Motorized isolation valve at CPP B/L and charge the header up to
CST. Ensure that the CST is ready to take Condensate and Isolation near tank is in closed condition.
Take a sample from the header for checking the quality parameters. Once the quality parameter falls
within acceptable operating range, open the isolation valve near tank area for filling the CST. Ensure
that the header pressure is 4.5 Kg/cm2 g and Temp 50 Deg C through Field instrumentation. Also
ensure that NRV are fitted in corrected direction to ensure no Flow of process condensate to Pure and
surface condensate header.
6.2.1.7.2 SURFACE CONDENSATE
Open the Motorized isolation valve at CPP B/L and mix the surface condensate coming from refinery
with the already charged Process condensate from RO/DM unit. Before opening the isolation valve,
ensure from the Refinery Lab about the quality parameter. Any deviation in parameter should be
immediately inform to Utilities and close the isolation valve at CPP B/L till the concurrence to retake
received from Utility.

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6.2.1.7.3 PURE CONDENSATE
Open the Motorized isolation valve at CPP B/L and mix the pure condensate coming from refinery
with the already charged Process condensate from RO/DM unit and surface condensate from
Refinery. Before opening the isolation valve, ensure from the Refinery Lab about the quality
parameter. Any deviation in parameter should be immediately inform to Utilities and close the
isolation valve at CPP B/L till the concurrence to retake received from Utility.
6.2.1.8. COMMISSIONING OF STORM WATER DRAIN SYSTEM

Refer drawing no.: 0-31842-01713_Rev00 as Layout of drain inside CPP B/L
Storm water channel inside CPP should be appropriately connected at suitable location with
Refinery main channel. All inside CPP storm and drain are connected to main storm channel on either
side of CPP and further connected to refinery main channel. Points to be ensured before
commissioning of OWS system are:



 Ensure storm water culvert is properly design to accommodate the quantity of storm
water to be handled.

 Storm water channel should be free from any debris.
Once above point are ensured, storm water system is consider to be commissioned.
6.2.2. COMMISSIONING OF BOP

BOP of CPP is facility which is exclusive within the scope of CPP but commonly distributed among
all the major equipment of CPP. Any facility outside the perview of Major equipment are consider at
BOP and it is must to commissioned the BOP system before initializing the commissioning of major
CPP equipments. BOP of CPP are divided into category of process it handles and it is as per below.
However one should remember that, all BOP is not must to commission a given Boiler/STG/GT. The
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requirement of BOP and Utilities are mentioned during the starting of Commissioning of all major
equipments.
6.2.2.1 COMMISSIONING OF CONDENSATE SYSTEM
Condensate system inside CPP includes CST, Condensate transfer system through LP heater,
MUH transfer system through HRSG WPH modules and Deaerator along with Dozing skid for CST and
Deaerator. The entire process of Commissioning is basically divided into two separate channels:
Channel A include: CST, Condensate transfer pumps and header, LP heater, Deaerator
Channel B include: MUH transfer pumps, MUH header to HRSG and to Deaerator.
Points to be ensured before commissioning of any channel system are:

 Pre-commissioning activity is completed and necessary isolation valves with drain and vents
are provided on the header at suitable location.

 Pumps are installed, Solo run done and DCS configuration complete and trail taken

 All Instrumentation work is installed, check and hookup with DCS.

 All Utilities are available to charge and commissioned the system
Channel A:
 Fill the CST with DM water from DM water header. As refinery condensate is not available
during first filling, DM water is used to fill Condensate.

 Before filling the DM water inside CST, ensure that Seal pot facility, CO2 absorber and Level
transmitter are installed on tank.

 All Nozzle connection should be closed and blinded on downstream side.

 Filled the tank up to the required height with DM water.

 Ensure that LP dozing skid is commissioned and ready for dozing for CST.

 Doze the LP dozing chemical – namely Morphiline through LP dozing skid to boost the pH of
DM.

 Take the sample for Laboratory inspection. Online analyzer like pH, Conductivity and HC are
installed as a part of SWAS system.

 Once parameter is within the acceptable range, open the suction valve near tank to fill the
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suction header up to Condensate transfer pump (CTP) isolation valve near CTP.
 Keep the CTP discharge MOV in closed condition and ARC valve in open condition before
starting any one of the two CT Pumps from DCS or Local PB. Also ensure that CTP inlet strainer
is not chocked by ensuring DPT across filter below 0.3 Kg/cm2 g.

 Start the Pump and kept it under observation for next 10 min of operation. Ensure that
Vibration is within acceptable limit and leakage of Oil to be negligible. Also check the motor
current amperage for avoiding overloading of motor.
Once the pump running is ensure as normal, open the discharge Equalizing MOV and after
header charging, open discharge MOV.
 Open suction MOV and discharge isolation valve of LP heater from condensate side, while keep
the LP heater Bypass MOV in closed position.
 Always charge the heater first from condensate side and then put LP steam into shell side.
 Open the Level control valve (LV1802) by putting it in to manual and give command from DCS
to ensure flow inside system. Always ensure that Deaerator side system is ready and its vent
and PSV are installed.

 Put LV1802 in Auto mode which gets input from Feed water storage tank. Fill the Deaerator up
to 50 – 60%.

 Always during first fill of Deaerator, charge condensate system before going to charge LP
steam for heating.

 Doze the LP Dozing chemical to Deaerator to maintained necessary pH and to remove oxygen
from Feed water before opening the suction isolation valve near Deaerator for feed water
pumps

 Online O2 analyzer is installed to continuous monitor the dissolve Oxygen level inside
Deaerator. The KPI set is < 7 ppb

 Put another CTP pump in Auto changeover mode (ACO) in DCS
Channel B:
 Open the suction valve near tank to fill the suction header up to MUH transfer pumps up to
Pump suction isolation valve.
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Keep the MUH transfer pump discharge M O V in closed condition and ARC valve in open
condition before starting any one of the two MUH Pumps from DCS or Local PB. Also ensure
that MUH pump inlet strainer is not chocked by ensuring DPT across filter below 0.3 Kg/cm2 g.
 Start any one Pump and keep it under observation for next 10 min of operation. Ensure that
Vibration is within acceptable limit and leakage of Oil to be negligible. Also check the motor
current amperage for avoiding overloading of motor.

 Once the pump running is ensure as normal, open the discharge Equalizing MOV and after
header charging, open discharge MOV.

 Divert the MUH into any of 2 HRSG as per the demand. Always ensure that the WPH of any
HRSG to charge based on the Exhaust flue gas temperature after WHP. If the temperature of
flue gas is coming down drastically, it is not advisable to charge WHP from condensate side.

 Open the FCV and WHP inlet and outlet suction MOV and closed bypass MOV to charge WHP
from condensate side.

 Open the isolation valve at Deaerator end to divert MUH from HRSG to Deaerator.

 The rate at which the MUH coming to Deaerator doesn’t depend upon the Deaerator level, but
it depends upon the set point given for FCV at inlet to WHP for each HRSG. Level for Deaerator
is basically control by LV1802 installed in CST pump discharge header side while pressure in
Deaerator is maintained by PCV on LP steam header side to Deaerator.

 Put another MUH pump in Auto change over mode (ACO) in DCS

 Condensate system now said to be commissioned from both the channels

 Ammonia /hydrazine dosing system must be ready, because in the beginning due to
unavailability of steam, only means of Deaeration is chemical Deaeration; therefore extra
dosing of hydrazine is required. Also sample frequency may increase to analyze residual
hydrazine at Deaerator outlet.

 Also ensure that all instrumentations are connected and line up with DCS and put in operation
mode as per Operating Philosophy.

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 As during start up, LP steam is not available, so Deaerator filling will be done without LP steam
charging. Once LP steam is available charge the LP steam to Deaerator as per below procedure:


1. Put the LP steam supply header in heating mode by opening all drain valve, open LP steam
supply header isolation valve bypass isolation valve and keep open the Pressure control
valve (10PV1407) bypass manual isolation valve in open condition.
2. Once the line is heated up to temperature above 125 ⁰C, first open the LP steam supply
header isolation valve (10GTV1431) on LP steam common header and closed its bypass
regulation valve.
3. Open the LP steam supply header isolation valve (10GTV1443) for feedwater storage tank
heating.
4. Once the feedwater temperature reaches ≥75 ⁰C, open the MOV of Deaerator. Always
ensure that before opening the MOV, MUH and condensate system are line up and in ON
condition up to Deaerator.
5. Put PV1407 in AUTO mode and close its bypass isolation valve. Care must be taken to
avoid sudden rise in pressure of Deaerator.

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6.2.2.2 COMMISSIONING OF BOILER FEED WATER SYSTEM
Once the Deaerator is charge and filled with feedwater, Boiler Feed pumps (BFPs) and Boiler
feed water (BFW) system can be commissioned. First Boiler feed water pumps for UB, HRSG
and Export BFW are required to be commissioned.
Boiler Feed water commissioning:
 Ensure that Pump is ready in all aspect and Format IV /Equipment Protocol is
closed/acceptable for the system.

 Ensure that Pump suction and discharge MOV in closed condition along with Balance leak off
and ARC valve to Deaerator in closed condition.

 Identify the Pump which is to be lineup for Commissioning. If all 9 pumps are ready in all
aspect, then the below points can be applicable to all 9 pumps for their individual
commissioning

 Open the suction header isolation valve dedicated for the Individual pumps

 Check the filter DP. It should be less than <0.5 Kg/cm2 g

 Open the ARC and balancing leak off line isolation valve at pump as well as on Deaerator side
to ensure the flow of feedwater.

 Before starting the MD BFP, ensure that Lube oil system is line up as per following below
listed points:

a. No Lube oil tank level Alarm available
b. DP across Lube oil filter (HLV-10-CP-102) should not be high
c. No leakage in Lube oil supply system
 After ensuring the above condition, first start the ALOP from local control panel.

 Ensure that Lube oil discharge header should be greater than 0.8 Kg/cm2 g. Before giving start
command to Motor for BFP, ensure that its shaft driven Lube oil pump is properly line up.

 After ensuring the same, following below listed permissive needed to be check before giving
ON command to MD driven BFPs (575PCF008B/C/D):

a. Discharge MOVs (10-MOV-18158A/18172A/18186A) and its bypass MOV (10-MOV-

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18158B/18172B/18186B) are in closed position
b. Pump ARC discharge header isolation valve (10-GTV-18156/18170/18184) at pump end

and isolation valve (10-GTV-1818/1822/1826) at Deaerator end should be in open
position and key pad locked.
c. Similarly balancing leak off line isolation valve (10-GTV-18152/18166/18180) near

pump end and isolation valve (10-GTV-1820/1824/1828) at Deaerator end should be
in open position and keypad locked.
d. Suction valve (10-GTV-18145/18159/18173) for pump should be in open condition and

its open feedback to be healthy for DCS. Open feedback ON is a permissive for pump
start command
 On ensuring the readiness of above, Start BFP from DCS or from local PB.

 Check and monitor the vibration level, lube oil leakage and mechanical seal leakage. The
entire thing should be zero to bare minimum.

 Kept running the pump till another 15 – 30 minutes and keep checking the bearing
temperature of Motor and pumps and pump balance leak off pressure. It should be less than
80 ⁰C and 4.5 Kg/cm2 g respectively.

 Once the above points are acceptable the BFP is said to be commissioned.

 Repeat the process of all other BFPs as stated above.
Boiler Feed water system commissioning:
 BFP discharge MOV and its bypass MOV are in closed condition and kept in Manual mode.
Boiler steam drum is ready to take BFW and all high header vents in open condition including
drum vents.

 Discharge common header is lineup for required UB/HRSG operation based on the operation
requirement.

 All Boiler and HRSG, Feed regulating station (FRS) CVs are in closed position along with the
isolation valve for each boiler spray attemperator system.

 Boiler B/L MOV along with its bypass MOV should be closed position.

 Interconnection between UB and HRSG should be closed until specific requirement is raise to
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open the isolation valve.

 Once above points are ensured, put the pump discharge MOV and its bypass in AUTO mode.

 On keeping into AUTO mode, as pump in running condition, the discharge header PT signal
open the bypass MOV which in turn open main MOV as per the Logic.

 Complete BFW header will get filled including spray water header

 Open the Inlet and outlet isolation valve of FRS CVs after ensuring the CV position at 0 and in
Manual operation mode.

 Slowly open 30% CV in manual mode from DCS to charge the downstream header after
ensuring that Boiler B/L MOVs are in closed condition.

 Open first bypass MOV to fill the header and vent air from header. Thereafter once header is
complete filled and level inside drum is building up, open the Main MOV for faster filling.

 Filled the steam drum up to required level by adjusting the flow rate for BFW with 30% CV.
6.2.2.3 COMMISSIONING OF ATOMIZING AIR SYSTEM
Atomizing air compressor system consists of 3 nos. of atomizing air compressor, receivers and
piping up to UB and HRSG B/L. Commissioning of Atm air system is basically divided into two
parts: Comm. Of Atm air compressor and Comm. Of Atm air piping and receiver.
A. Commissioning of Atomizing Air compressors:
 Before commissioning the Atm air compressor, first ensure that the Compressor is ready for
start from all the aspects. CW system is line up and commissioned, Lube oil system of
Compressor is ready and in operation, receiver tank and associated piping are ready. Format VI
/ Equipment protocol are ready and signed off.

 Start the Lube oil system by starting lube oil pump. The Lube oil pressure should be > 1.5
Kg/cm2.

 Line up CW to lube oil cooler and Atm air compressor air cooler for cooling.

 Keep the discharge valve open to atmosphere

 Check inlet air ducting to ensure no water is present. If present, drain until dry.

 Start the Compressor through local PLC

 Check the healthiness of Compressor by checking its vibration and sound level. Also check the
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Lube oil spillage.
 Before diverting the Atm air to receiver, check that the receiver is ready in all aspect. PSV are
placed and its inlet filled line header isolation valve in open condition while outlet header
isolation valve in closed condition.

 Divert the atomizing air compressor discharge to receiver by closing the vent valve through
local PLC.

 Filled the receiver at necessary pressure. PLC for controlling the atomizing air compressor is
program to unload the compressor at a preset pressure of 7 Kg/cm2 g.

 Drain condensate from low points.

 Once receiver is filled, open the atomizing supply header to UB after ensuring that Atm air
tapping to Plant air header is in closed condition along with each boiler B/L isolation valve.

 Charge the atomizing air up to individual boiler B/L. Further charging of atomizing air to
individual boiler depends upon the fuel selected for firing. Charging downstream the boiler is
done as part of Boiler commissioning and startup activities.

6.2.2.4 COMMISSIONING OF HSD FUEL SYSTEM
HSD tankages inside CPP should be first filled from refinery. HSD system commissioning is
divided basically into 3 parts: a. HSD from refinery to HSD storage tank of CPP, b. HSD to
centrifuge system and c. HSD to GTGs.
A. HSD from Refinery: (HSD from CPP B/L to HSD storage tank)
 HSD from Refinery is coming from finish product tankages area through a common supply
header. Here we assumed that the HSD header from refinery up to CPP B/L is already
commissioned and header is charged with HSD.

 Before taking the HSD inside CPP B/L ensure that below listed points are completed in all
aspects:

1. HSD tankages and header are ready inside CPP B/L for charging HSD. Format VI is
closed and acceptable to all
2. All safety equipments and system are in place and commissioned.
3. PSSR done for the system
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4. OWS system, Earthing and lighting arrestor system, Foam spray hydrant system, Fire
hydrant system, service water system, Potable water system and Safety shower
system are in place and ready to use.
5. Necessary Legal compliance of CCOE is taken before taking HSD inside tankages.
 Once the above system are ensure, HSD tank is ready to take HSD from refinery supply header

 Communicate to Refinery concerned person to line up the HSD for CPP tankages and ensure
that HSD at required pressure is made available up to CPP B/L

 Kept all nozzles isolation valve i.e. incoming and outgoing line isolation valve in closed
condition.

 Remove spectacle blind at CPP B/L supply header and open both the isolation valves.

 Also ensure that the line coming from LCO to HSD tank interconnection isolation valve in
closed position.

 Normally HSD day tank (575-T-00-502) are lineup for intake for refinery HSD to CPP. HSD from
refinery is not consider as clean fuel so before charging the HSD to GT system, it should be
clean by passing through HSD centrifuge system installed inside CPP.

 Manually open the level control valve (LV6606) to charge downstream supply header for tank


 Remove the spectacle blind and open both inlet line isolation valves for HSD supply header for
HSD Tank.

 Adjust the flow rate of HSD supply, by opening the LV6606, once sufficient level inside tank is
built up and Radar and level transmitter start showing the value put LV6606 in AUTO mode
with set point.

 At a preset point, LV will get closed and stop HSD flow inside HSD tank. UV 6607 is also
installed to safeguard the tank from overflowing by closing on high high tank level signal.

 Always ensure that the Naphtha tank inlet header isolation valve and spectacle are in closed
position.
B. HSD to HSD centrifuge system:
 Once the HSD Tank is filled with HSD, as said earlier, the HSD required to be cleaned from
sludge and emulsion by passing it through HSD centrifuge skid.
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 Normally 2 out of 3 nos. of centrifuge system remain in operation for cleaning HSD as a clean
fuel for GTGs

 HSD tank outlet header is lineup for HSD centrifuge suction header and to GTG forwarding
pump suction header.

 HSD through gravity enter into centrifuge pump inlet isolation valve through common suction
duplex filter. DP across filter should be < 0.1 Kg/cm2g

 Open the pump inlet isolation valve to allow HSD inside centrifuge pumps.

 Start the pump from local Centrifuge skid PLC.

 First fill the centrifuge with water for necessary water seal.

 Open the discharge header isolation valve to divert HSD to centrifuge skid. Mechanical flow
regulator regulates the flow of HSD to centrifuge.

 At centrifuge outlet, a pressure switch is installed to divert the HSD back to tank indicating the
failure of water seal.

 The clean HSD from centrifuge is collected in common header and diverted to HSD tank.

 Centrifuge system remain in operation always.

 Centrifuge system is provided with sludge tank removal pump which remove the sludge
collected in sludge tank by pumping it to nearby OWS header.
C. HSD to GT forwarding skid:
 HSD from tank is normally line up for GTG. Once required level is filled inside tank, HSD
can be charge for GTG operation

 HSD tank outlet headers is normally open to GT forwarding pump suction common header
from where the individual GT forwarding pump sucked the HSD.

 HSD from GTG suction common header is sucked by GTG forwarding pump through 100
micron suction filter. Any one filter chamber remains in service while other will remain in hot
standby mode.

 HSD from suction header is charge to any one chamber of duplex filter be keeping 3 way valve
in open direction for the filter and keeping its vent valve in open condition.

 Once the HSD continuous flow start coming out from vent, close the vent and open its
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balancing line valve to fill the second standby chamber by keeping its vent valve open.
 Close the balancing line valve once it is ensure that HSD continuous flow is available from vent
valve.

 Once it is done, it is said that duplex filter is commissioned and ready to operate.

 Open the inline duplex filter chamber outlet isolation valve to further fill the downstream
HSD header up to individual pump suction isolation valve.

 Open the any one pump inlet suction isolation valve and ARC discharge valve. Ensure that the
return of ARC is going back to HSD tank. Return header from GTG should be diverted back to

HSD Tank. Provision is available to divert the Naphtha tank, but normally the valves are kept in
closed locked/blind position.

 Start the pump from DCS or from local PB after ensuring its healthiness on field.

 Keep running the pump till another 15 min. and check the vibration and temperature level.
Both should be within the operational acceptance level.

 Open the running pump discharge valve only after ensuring that the Main CV
(10PV6639A/6653A) are kept closed in manual mode and its bypass isolation valve is kept
cracked open to fill the downstream header

 Once the flow is ensured in downstream header, open the CV bypass isolation valve further for
faster filling.

 Repeat the step as mentioned earlier for filling the 25 micron and 6 micron duplex filter.

 Open the 6 micron duplex filter discharge valve to fill the HSD supply header up to 3 way valve
downstream isolation valve.

 Before opening the same, ensure that 3 way valve is lineup for HSD and downstream system
up to GT inlet flange.

 Open the isolation valve in downstream of 3 way valve to charge the HSD for GT. Further inlet
charging of HSD inside GTG is in the scope of GT commissioning and start up.
6.2.2.5 COMMISSIONING OF LCO FUEL SYSTEM

LCO tankages inside CPP should be first filled from refinery. LCO system commissioning is

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divided basically into 4 parts: a. LCO from refinery to LCO storage tank of CPP, b. LCO system
for GTG system, c. LCO to UB and d. LCO to HRSG.
A. LCO from Refinery: (LCO from CPP B/L to LCO storage tank)
 LCO from Refinery is coming from FCCPC and DHDT unit storage tankages through a common
supply header. Here we assumed that the LCO header from refinery up to CPP B/L is already
commissioned and header is charged with LCO.

 Before taking the LCO inside CPP B/L ensure that below listed points are completed in all
aspects:

1. LCO tankages and header are ready inside CPP B/L for charging LCO. Format VI is
closed and acceptable to all
5. Necessary Legal compliance of CCOE is taken before taking LCO inside tankages.
 Once the above systems are complete, LCO tank is ready to take LCO from refinery supply
header

 Communicate to Refinery concerned person to line up the LCO for CPP tankages and ensure
that LCO at required pressure is made available up to CPP B/L

 Kept all nozzles isolation valve i.e. outgoing line isolation valve in closed condition for both the
tankages for filling.

 Open both the isolation valve and remove spectacle blind at CPP B/L supply header.

 Also ensure that the line coming from LCO to LCO tank interconnection isolation valve in
closed position.

 Any out of 2 LCO day tank can be lineup for intake for refinery LCO to CPP. Normally LCO tank

– 1 (575-T-00-509) is lineup for GTG while LCO tank -2 (575-T-00-510) is lineup for UB and
HRSG system. Filling of any LCO tank is purely depends upon the level inside the LCO tank and

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the demand generate from the running unit inside CPP.
 Here initial fill of tank are consider to be parallel so both the tankages will be lineup for filling
LCO.

 Kept the Level control valve (LV6701 and 6705) and SOV (UV6704 / UV6711) in closed and
open mode respectively by putting it in to manual operation mode while keep open the LV
bypass isolation valve to charge the downstream supply header for tankages.

 First remove the spectacle blind and open both inlet line isolation valves for LCO supply header
at CPP B/L to charge the LCO inside CPP.

 Open spectacle blind and isolation valve near tankages before opening the isolation valve
downstream of LV for filing the header to each tank.

 Open the LV downstream isolation valve to start filling the LCO through bypass isolation valve.

 Take the Level control valve in operation by manual opening up to certain percentage and
closing its bypass isolation valve. Put the LV in AUTO mode by providing operator set point for
Level transmitter PID. Also put UV in AUTO mode through DCS. It will shut off when the levels
inside the tankages reach High High level.

 Fill the tankages up to present mark. Once filled, closed the isolation valve in downstream of
LV and thereafter at CPP B/L and parallel inform the refinery concerned person for closing the
LCO intake inside CPP.
B. LCO to GTG Forwarding skid:-
 As LCO tank # 1 is lineup for GT usage, all necessary interconnection valve for LCO tank #
2should be closed and lock out while LCO from tank # 1 to be lineup for GT only and not to UB
and HRSG by locking closed the isolation valve at interconnection header

 Open the Isolation valve with spectacle blind near tank # 1 to charge the LCO for GT

 Charge the common suction filter (100 micron) for GTGs

 Charge the pump by opening suction valve of the pump

 Ensure following before starting of GTG forwarding pump. One pump is capable to delivery
100% Rated quantity fuel for each GT

1. Discharge valve closed

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2. ARC isolation valve open and connected to recirculation
3. Other pumps are in hot standby mode with suction and discharge isolation valve in
open condition
 Start the Pump either from DCS or from local PB

 Open pump discharge header to charge the downstream common header of GTG. A tapping
for GT # 2 is taken out from common header. Ensure that further downstream of LCO to GT
should be done base on requirement. If both GT to be charged with LCO second standby pump
to be started.

 Take accumulator into service by opening the isolation valve after ensuring sufficient nitrogen
pressure.

 Open the Main control valve (PV6728A/PV6744A) isolation valve and its bypass keeping CV in
closed position from DCS.

 Filled the recirculation header by opening isolation valve

 Open recirculation header CV (PV6728B/PV6744B) Isolation valve and its bypass to fill the
downstream of recirculation header back to tank # 1

 Ensure that recirculation header for GT is line up back to tank # 1 by closing necessary
isolation valve on common distribution header and locking it.

 Charge the 25 micron duplex filter and 6 micron duplex filter with LCO and keep the standby
filter in hot standby mode.

 Open mass flow meter (FT6726/FT6742) bypass isolation valve to charge the LCO up to 3 way
valve.

 Open the 3 way valve as per Mark VI logic to ensure either of HSD or LCO goes to GT for firing
when selected for Liquid fuel option

 In case of LCO firing selected, ensure that vanadium inhibitor system is ready as per below
points:

1. Solution preparation tank level should be normal
2. Vanadium/(ER-517) dozing pump ready to operate
 Charge the vanadium/(ER-517) solution from tank to selected pump by opening pump suction valve.

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9112-575-OPR-701-00002 Page 23 of 90
 Start the vanadium dozing pump keeping discharge valve in open condition

 Charge the downstream header up to LCO header tapping point by opening Flow meter
bypass isolation valve.

 Once header is charged, Put another vanadium dozing pump in Auto standby mode

 Take FT in service by opening its isolation valve and closing its bypass isolation valve.

 Once vanadium system is in service, LCO can be taken into the GT by opening the isolation
valve at GT Battery limit.

 Take LCO header flow meter in service by opening the isolation valve and closing its bypass
isolation valve.

 Manually open the CV from DCS and close its bypass valve

 Put CV in Auto operation mode and maintain the LCO header pressure to GT at 3.3 Kg/cm2 g

 Put on the second pump if requirement of second GT is envisage.
C LCO to UB
 As LCO tank # 2 is lineup for UB and HRSG usage, all necessary interconnection valve for LCO
tank # 1 should be closed and lock out while LCO from tank # 2 to be lineup for UB and HRSG
only and not to GT locking closed the isolation valve at interconnection header

 Open the Isolation valve with spectacle blind near tank # 2 to charge the LCO for UB

 Charge the suction filter (100 micron) for UBs

 Charge the pump by opening suction valve of the pump for UB

 Ensure following before starting of UB forwarding pump. One pump is capable to delivery 2 X
100% MCR quantity fuel for UB

3. Other pumps are in hot standby mode with suction and discharge isolation valve
in open condition
 Start the Pump either from DCS or from local PB. MD forwarding pump is preferred during
commissioning while during normal start up one MD and one TD pumps will be always in
service.
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 Take both accumulators into service by opening the isolation valve after ensuring sufficient
nitrogen pressure.

 Open the recirculation control valve (PCV6778/ 6778A & PCV 6778B) isolation valve and its
bypass keeping CV in closed position from DCS.

 Filled the recirculation header. Ensure that recirculation header for UB is line up back to tank

# 2 by closing necessary isolation valve on common distribution header and locking it.

 Open the isolation valve of LCO supply header to each UB at UB B/L for charging LCO inside
UB B/L.

 Take recirculation header into service by putting the CV in Auto mode by ensuring that the UB
LCO inlet pressure is at 17.0 Kg/cm2 g
D. LCO to HRSG
 As LCO tank # 2 is lineup for UB and HRSG usage, all necessary interconnection valve for LCO
tank # 1 should be closed and lock out while LCO from tank # 2 to be lineup for UB and HRSG
only and not to GT locking closed the isolation valve at interconnection header

 Open the Isolation valve with spectacle blind near tank # 2 to charge the LCO for HRSG

 Charge the suction filter (100 micron) for HRSG

 Charge the pump by opening suction valve of the pump for HRSG
 Ensure following before starting of UB forwarding pump. One pump is capable to delivery 1 X
100% MCR quantity fuel for HRSG

3. Other pumps are in hot standby mode with suction and discharge isolation valve
in open condition
 Start the Pump either from DCS or from local PB.

 Open pump discharge header to charge the downstream common header of HRSG

 Take accumulator into service by opening the isolation valve after ensuring sufficient nitrogen
pressure.

 Open the recirculation control valve (PV6771) isolation valve and its bypass keeping CV in
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9112-575-OPR-701-00002 Page 25 of 90
closed position from DCS.
 Filled the recirculation header. Ensure that recirculation header for HRSG is line up back to
tank # 2 by closing necessary isolation valve on common distribution header and locking it.

 Open the isolation valve of LCO supply header to each HRSG at HRSG B/L for charging LCO
inside HRSG B/L.

 Take recirculation header into service by putting the CV in Auto mode by ensuring that the
HRSG LCO inlet pressure is at 12.0 Kg/cm2 g
E. HSD/LCO drain tank system
 HSD/LCO drain tank system consist of 5 nos. of drain tanks located at different location like:

1. HSD/LCO drain tank near GT # 1 (575-T-00-503)
2. HSD/LCO drain tank near GT # 2 (575-T-00-504)
3. HSD/LCO drain tank for UB # 1 and 2 (575-T-00-505)
4. HSD/LCO drain tank for UB # 3 and 4 (575-T-00-506)
5. HSD/LCO drain tank near tankages area (575-T-00-507)
 Each HSD/LCO Offbase drain + GT integral + UB and HRSG integral drains are connected to
suitable nearby drain tank

 The collected false drains are pumped back to refinery slope header via CPP common header
through installed submersible pumps

 Pump discharge and suction isolation valve will remain in Open condition and pump will be
start/stop based on the level inside the drain tanks.

 Always ensure that the HSD/LCO drain system should be in place and ready for start up before
introducing any Hydrocarbon inside CPP units.
6.2.2.6 COMMISSIONING OF NAPHTHA FUEL SYSTEM
Naphtha tankages inside CPP should be first filled from refinery. Naphtha system
commissioning is divided basically into 3 parts: a. Naphtha from refinery to Naphtha storage

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tank of CPP, b. Naphtha to GTGs and c. Naphtha to UB/HRSG

A. Naphtha from Refinery: (Naphtha from CPP B/L to Naphtha storage tank)
 Naphtha from Refinery is coming from finish product tankages area through a common supply
header. Here we assumed that the Naphtha header from refinery up to CPP B/L is already
commissioned and header is charged with Naphtha.

 Before taking the Naphtha inside CPP B/L ensure that below listed points are completed in all
aspects:

1. Naphtha tankages and header are ready inside CPP B/L for charging Naphtha.
Format VI is closed and acceptable to all
5. Necessary Legal compliance of CCOE is taken before taking Naphtha inside tankages.
 Once the above system are ensure, Naphtha tank is ready to take Naphtha from refinery.

 Communicate to Refinery concerned person to line up the Naphtha for CPP tankages and
ensure that Naphtha at required pressure is made available up to CPP B/L

 Kept all nozzles isolation valve i.e. incoming and outgoing line isolation valve in closed
condition.

 Remove spectacle blind at CPP B/L supply header and open both the isolation valve.

 Normally Naphtha tank (575-T-00-501) are lineup for intake for refinery Naphtha to CPP.

 Manually open the level control valve (LV6605B) to charge downstream supply header for
Naphtha tank

 Remove the spectacle blind and open both inlet line isolation valves for Naphtha supply header
for Naphtha tank.

 Adjust the flow rate of Naphtha supply, by opening the LV6605B, once sufficient level inside
tank is built up and Radar and level transmitter start showing the value put LV6605B in AUTO
mode with set point.

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 At a preset point, LV will get closed and stop Naphtha flow inside Naphtha tank. UV 6604B is
also installed to safeguard the tank from overflowing by closing on high high tank level signal.


 Always ensure that the HSD tank inlet header isolation valve and spectacle are in closed
position.
B. Naphtha to GT forwarding skid:
 Naphtha from tank is normally line up for GTG. Once required level is filled inside tank, Naphtha
can be charge for GTG operation

 Naphtha tank outlet headers is normally open to GT forwarding pump suction common header
from where the GT forwarding pump sucked the Naphtha.

 Naphtha from GTG suction common header is sucked by GTG forwarding pump through 100
micron suction filter. Any one filter chamber remains in service while other will remain in hot
standby mode.

 Naphtha from suction header is charge to any one chamber of duplex filter be keeping 3 way
valve in open direction for the filter and keeping its vent valve in open condition.

 Once the Naphtha continuous flow start coming out from vent, close the vent and open its
balancing line valve to fill the second standby chamber by keeping its vent valve open.

 Close the balancing line valve once it is ensure that Naphtha continuous flow is available from
vent valve.


 Open the inline duplex filter chamber outlet isolation valve to further fill the downstream
Naphtha header up to individual pump suction isolation valve.

 Open the any one pump inlet suction isolation valve and ARC discharge valve. Ensure that the
return of ARC is going back to Naphtha tank. Return header from GTG should be diverted back
to Naphtha Tank.


 Keep running the pump till another 15 min. and check the vibration and temperature level.
Both should be within the operational acceptance level.
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 Open the running pump discharge valve only after ensuring that the Main CV (6728C/6744C)
are kept closed in manual mode and its bypass isolation valve is kept cracked open to fill the
downstream header

faster filling.

 Repeat the step as mentioned earlier for filling the 25 micron and 6 micron duplex filter.

 Open the 6 micron duplex filter discharge valve to fill the Naphtha supply header up to 3 way
valve.

 Before opening the same, ensure that 3 way valve is lineup for HSD and downstream system
up to GT inlet flange.
C. Naphtha to HRSG/UB forwarding skid:
 Naphtha from tank is normally line up for HRSG/UB. Once required level is filled inside tank,
Naphtha can be charge for HRSG/UB burner operation

 Naphtha tank outlet headers is normally open to HRSG/UB Naphtha forwarding pump suction
common header from where the HRSG/UB Naphtha forwarding pump sucked the Naphtha.


 Naphtha from HRSG/UB suction common header is sucked by HRSG/UB forwarding pump
through 100 micron suction filter. Any one filter chamber remains in service while other will
remain in hot standby mode.

 Naphtha from suction header is charge to any one chamber of duplex filter be keeping 3 way
valve in open direction for the filter and keeping its vent valve in open condition.

 Once the Naphtha continuous flow start coming out from vent, close the vent and open its
balancing line valve to fill the second standby chamber by keeping its vent valve open.

 Close the balancing line valve once it is ensure that Naphtha continuous flow is available from
vent valve.


 Open the inline duplex filter chamber outlet isolation valve to further fill the downstream Naphtha
header up to individual pump suction isolation valve.
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 Open the any one pump inlet suction isolation valve and ARC, Balance Leak off valve. Ensure
that the return of ARC, Balance leak off is going back to Naphtha tank. Return header from
HRSG/UB control station should be diverted back to Naphtha Tank.


 Keep running the pump till another 15 min. and check the vibration and temperature level.
Both should be within the operational acceptance level.

 Open the running pump discharge valve only after ensuring that the Main CV (PV9714) are
kept closed in manual mode and its bypass isolation valve is kept cracked open to fill the
downstream header

faster filling.

D. Naphtha drain system
 FG drain tank system consist of 03 nos. of drain tanks located at different location like:

1. FG drain tank near GBC area (575-T-00-521)
2. FG drain tank near GT # 2 (575-T-00-522)
 Each Naphtha Offbase drain + GT integral + UB and HRSG integral drains are connected to
suitable nearby drain tank



 Also ensure that the FG flare vent from each drain tank are collected to common flare header
which in turn connect to refinery flare header
6.2.2.6 COMMISSIONING OF FG FUEL SYSTEM

FG system commissioning is divided basically into 4 parts: a. FG system for RFG Heater, b. FG system
for GTG system, c. FG to UB and d. FG to HRSG.
A. FG to RFG Heater

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 FG from Refinery is coming from FCCPC and DHDT unit through a common supply header.
Here we assumed that the FG header from refinery up to CPP B/L is already commissioned

and header is charged with FG up to CPP B/L.

 Before taking the FG inside CPP B/L ensure that below listed points are completed in all
aspects:

1. FG header is ready inside CPP B/L for charging FG. Format VI is closed and approved
4. OWS system, Earthing and lighting arrestor system, F&G system, Fire hydrant system,
service water system, Potable water system and Safety shower system are in place and
ready to use.
5. Nitrogen is available on continuous basis and Nitrogen system is commissioned inside
CPP unit
6. HP Nitrogen system is commissioned inside CPP and HP Nitrogen receiver are filled at
required pressure
7. FG condensate system are ready to be used
8. FG Flare system is also ready to be used inside CPP B/L and Refinery side flare header is
ready to take CPP Flare.
9. Ensure that FG header inside CPP is charged with Nitrogen at a pressure > 5.0 Kg/cm2
g and ensure that no pressure drop occur inside the system
 Once the above systems are ensure, FG is ready to take inside CPP from refinery supply header


 Communicate to Refinery concerned person for FG commissioning inside CPP and ensure that
FG at required pressure (10-11 Kg/cm2 g) is made available up to CPP B/L

 Ensure that header drains are connected properly to their respective drain tanks and FG
supply flare connection are connected to necessary flare header.

 Ensure that FG supply header to CPP ESD valve (ESD6802) is in close position

 Ensure that FG supply header to GT, UB and HRSG header ESD valve (ESD6804, ESD6852 and
ESD6862 respectively) are in close position

 Open both the isolation valve and remove spectacle blind at CPP B/L supply header.
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 Open ESD6802 either from DCS or from Local field operation after ensuring that line up of FG

downstream inside CPP.
Ensure following system readiness before putting FG inside RFG Heater:-

 Service water header root valve GTV-6998F in open condition.

 Service water TCV-6997 upstream GTV-6998B & downstream valve GTV-6998A should
 be open condition & Bypass Valve GLV-6987 in close condition.
  Nitrogen root Valve GTV-6984A in open condition.
 Instrument Air root valve GTV-6985A in open condition.
STEAM CONDENSATE SYSTEM
 Ensure Heater-1 Ball Float Trap System GTV-6972A & GTV-6973A line up to
flash tank.

 Ensure Heater-2 Ball Float Trap System GTV-6972B & GTV-6973B line up to
 flash tank.
  Gas Heater Flash Tank LT-6935 should be line up.
  Gas Heater Flash Tank local drain GTV-6989 should be close condition.
  Gas heater CTP –A 575-P-545A should be energized condition.
 Gas heater CTP –B 575-P-545B should be energized condition.

 Gas heater CTP –A 575-P-545A Suction valve GTV-6990A & Discharge GTV-
6990D should be open condition.

 Gas heater CTP –B 575-P-545B Suction valve GTV-6990B & Discharge GTV-
 6991D should be open condition.
 Ensure That Pump-A&B lube oil cup should be filled up.
SCRUBBER CHARGING
  Ensure RFG Heater system Inlet line (GTV 6902) in close Condition.
  Ensure RFG Heater system outlet line (GTV-6999C) in close Condition.
  Ensure RFG Heater system bypass valve (GLV-6901) in open condition.
  Ensure N2 line valve (GTV-6996B) in close condition.
 Monitor RFG Heater inlet line TE-6945 & PT-6946 reading show in DCS system.

 Open Scrubber Inlet valve (GTV-6903) & Outlet valve(GTV-6933) should be in
 closed condition.
  Ensure Scrubber Inlet strainer (STR-6904) in right direction.
  Ensure Scrubber inlet line PG-6901 & TG-6902 should be line up.
 Ensure Scrubber inlet line & outlet line in deblinding condition.

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 Ensure N2 line isolation valve GTV-6906 to scrubber in close condition.

 Ensure Scrubber Level transmitter LT-6903 & LT-6905 line up in field as well as
 DCS.
  Ensure Scrubber N2 line GTV-6922 in close condition.
  Ensure healthiness of Scrubber Condensate Drain valve UV-6929
  Ensure Scrubber PG-7304 & Scrubber Outlet line PG-6906 & TG-6907 is line-up.
  Ensure Scrubber PSV-6977 & PSV-6978 is line-up.
 Ensure Scrubber vent UV-6911 & manual valve GTV-6908 in close condition.
RFG HEATER 1&2 GAS CHARGING

  Open Heater-1 Inlet Valve GTV-6939A & Outlet Valve GTV-6951A .
  Ensure Heater-1&2 Bypass valve GLV-6934 in close condition.
 Open scrubber outlet valve GTV-6933

 Ensure Heater-1 inlet TE-6913,PG-6914,TG-6915 & outlet TE-6917,PG-6918,TG-
 6919 is line-up.
 Ensure Heater-1 Gas PSV-6981A & PSV-6982A are line up.

 Ensure Heater-1 Gas vent UV-6949A & manual vent GTV-6946A in close
 condition.
  Ensure Heater-1 N2 line Valve GTV-6941A in close condition.
 Open Heater-2 Inlet Valve GTV-6939B & Outlet Valve GTV-6951B

 Ensure Heater-2 inlet TE-6922,PG-6923,TG-6924 & outlet TE-6926,PG-6927,TG-
 6928 is line up.
 Ensure Heater-2 Gas PSV-6981B & PSV-6982B is line up.

 Ensure Heater-2 Gas vent UV-6949B & Manual vent GTV-6946B in close
 condition.
 Ensure Heater-2 N2 line Valve GTV-6941B in close condition.

 Ensure Heater-2 Gas vent UV-6949B & Manual vent GTV-6946B in close
 condition.
 Ensure Heater-2 N2 line Valve GTV-6941B in close condition.
  Heater-1 Gas Drain upstream & Downstream Valve in close condition.

 Heater-2 Gas Drain upstream & Downstream Valve in close condition.

 Gas Condensate to Gas condensate pit Valve GTV-6998D & GTV-6998E in open
condition.
RFG HEATER 1 & 2 LP STEAM CHARGING

  Open LP STEAM root valve GTV-7355A & B
 Ensure FT-6944 should be in line.
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  Ensure LP STEAM trap in open condition during initial charging.

  Open Heater-1 LP STEAM TCV-6919 upstream and downstream valves
  Make sure that by pass valve GLV6999A is in closed condition
  Open Heater-2 LP STEAM TCV-6928 upstream and downstream valves
  Make sure that by pass valve GLV6999A is in closed condition
  Ensure Heater-1 LP STEAM PSV-6978A & PSV-6979A should be line up.
 Ensure Heater-2 LP STEAM PSV-6978B & PSV-6979B should be line up.

B. FG to GTGs

 Open ESD6804 which allow the FG to charge the FG supply header for GTGs.

 Open any one gas scrubbers (V-11 or V-12) inlet isolation valve after opening the spectacle
blind on downstream of valve to charge the gas scrubbers. One Gas scrubber is enough to
cater the need for one GT full load operation

 Keep gas scrubbers manual vent valve in open condition to vent the nitrogen by displacing the

FG

 Check the FG in flare before closing the manual vent valve on gas scrubber using Portable FG
online detector

 Provide spectacle blind in vent valve downstream header for both gas scrubbers

 Check the opening of BDV6810 and 6811 on both gas scrubber by manually opening the BDV
SOVs from DCS

 Ensure that FSV6808A/B or FSV6809A/B are in operation and its upstream and downstream
valve are in open condition and lock open.

 Ensure that gas scrubbers drain connection level control valve (LCV6805 and 6814) are in
service and drain are routed to appropriate drain tank collection vessel

 Open gas scrubbers outlet isolation valve after opening the spectacle blind in the downstream
supply header

 Ensure that the pressure and temperature at the inlet of Gas booster compressor is normal
through PT6865A/B/C, PG6807 and TI6804 respectively

 Ensure following system readiness before putting FG inside GBC:

o Ensure that Lube oil system is ready of GBC and Oil pressure for both GBC are adequate
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o Ensure that Instrument air and nitrogen are available for GBC
o Ensure that Aux Cooling water system is charge for GBC lube oil and bypass cooler
o Ensure that Nitrogen is filled inside GBC and seal gas is also charge with Nitrogen
o Ensure that no alarm and interlock exist for GBC
o Ensure that all vents are properly route to flare header
o Ensure that all drain are connected to nearby condensate tank
o Ensure that GBC FG side inlet and outlet discharge isolation valve are in closed condition
o Ensure that Vibration measuring device of M/s Bentley Nevada System are in place and
no alarm exist
o Ensure that all interlock and protection are check and found ok
o Ensure that bypass CV in FG discharge header of GBC are in open condition (100%
opening) and SOV is de-energized condition
 After ensuring the above system healthiness, start the any one GBC from local control panel PB
or from DCS with nitrogen inside the casing. One GBC is capable to provide MCR condition FG
for one GT.

 Check the leakages from HP and LP gland seal by checking the differential pressure across the
seal gas (PDT70003A/B, PDG7002)

 Ensure that pressure of Nitrogen (PT7013A/B/C and PT7012A/B/C) in seal gas vent lines are
not high

 Open GBC FG inlet manual isolation valve

 Open GBC FG inlet Flow control valve in manual operation to charge GBC

 Check the vent for any trace of FG and venting of nitrogen from GBC after a keeping
compressor in recycle / bypass mode




 Check the discharge header pressure (PT7205A/B, PG7204) and temperature (TG7203 and
TI7204) i.e. <23 Kg/cm2 g and <145 ⁰C

 After ensuring the readiness of GBC, open the discharge isolation valve of GBC to charge the
pressurized FG in FG Gas conditioning skid (GCS) also known as filtration and separation skid

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 From GBC common discharge header, a bifurcation of FG to GTGs are done before GCS

 Open both manual isolation valve along with spectacle blind to charge the FG inside GCS. For
each GTG, 2 X 100% capacity GCS are installed.

 Keep GCS manual vent valve in cracked open condition to vent the nitrogen

online detector


 Check the opening of BDV6829 or 6830 and BDV6839 or 6840 on GCS for both GTGs manually
opening the BDV SOVs from DCS

 Ensure that FSV6819A/B or FS6820A/B for GT # 1 and FSV6837A/B or FSV6838A/B are in
operation and its upstream and downstream valve are in open condition and lock open.

 Ensure that both GCS drain connection tank level control valve LCV6821/6823 or
LCV6826/6825 for GT # 1 LCV6841/6836 or LCV6844/6846 and are in service and drain are
routed to appropriate drain tank collection vessel

 Open both GCS isolation valve after opening the spectacle blind in the downstream supply
header

 Open ESD6832 and close ESD6833 from Mark VI controller for GT # 1 and open ESD6848 and
close ESD6849 from Mark VI controller for GT # 2

 Open ESD6869 and open ESD6870 to charge the FG up to GT # 1 and 2 respective inlet flange,

 Ensure that the FG at the inlet of GTG are at normal pressure (PT6834 – 20.3 Kg/cm2 g) and
normal temperature (TE6809 – 130 ⁰C)

 Put all control valve in Auto operation mode after charging the FG inside GTGs. FG is now said
to be commissioning for GTGs
C. FG to HRSG
 After ensuring the availability of FG inside CPP B/L by opening ESD6802 inside CPP, for charging
FG for HRSG burners, open ESD6852 and its upstream isolation valve to charge FG inside HRSG
Offbase FG system

 Open any one gas scrubbers (V-17) inlet isolation valve after opening the spectacle blind on

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downstream of valve to charge the gas scrubbers.


FG

online detector


 Check the opening of BDV6859 on gas scrubber by manually opening the BDV SOVs from DCS

 Ensure that FSV6853A/B are in operation and its upstream and downstream valve are in open
condition and lock open.

 Ensure that gas scrubber drain connection level control valve (LCV6854) is in service and drain
are routed to appropriate drain tank collection vessel

supply header

 Ensure that the pressure and temperature at the Outlet of gas scrubber is normal through
PI68634/6835/6857 and TI6816/6817/6829

 Open any one out of two Pressure control valve PCV6860A/B for HRSG # 1 and PCV6886A/B for
HRSG # 2

 Open Individual HRSG B/L isolation valve along with spectacle blind to charge the FG inside

HRSG B/L

 Ensure that pressure PT6861, PG6836 and PT6887, PG6858 = 6.0 Kg/cm2 g and temperature
TI6818 and TI6830 = 40 ⁰C at inlet of HRSG # 1 and 2 respectively through PCV

 Put PCV in auto mode once HRSG is fired inside burners
C FG to UB
 After ensuring the availability of FG inside CPP B/L by opening ESD6802 inside CPP, for charging
FG for UB burners, open ESD6862 and its upstream isolation valve to charge FG inside UB
Offbase FG system

 Open any one gas scrubbers (V-18 or V-19) inlet isolation valve after opening the spectacle blind
on downstream of valve to charge the gas scrubbers. One gas scrubber is capable to delivery

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two UB MCR condition.


FG

online detector


 Check the opening of BDV6868A/B on each gas scrubber by manually opening the BDV SOVs
from DCS

 Ensure that FSV6869A/B or FSV6869C/D are in operation and its upstream and downstream
valve are in open condition and lock open.

 Ensure that gas scrubber drain connection level control valve (LCV6863A or LCV6863D) is in
service and drain are routed to appropriate drain tank collection vessel

supply header

 Ensure that the pressure and temperature at the Outlet of gas scrubber is normal through
PI6841/6842/6844/6847/6849 and TI6820/6821/6823/6825/6827

 Open first 30% CV (PCV6870C for UB # 1, PCV6871C for UB # 2, PCV6872C for UB # 3 and
PCV6872/C for UB # 4) to charge the FG inside UB

 Open Individual UB B/L isolation valve along with spectacle blind to charge the FG inside UB B/L

 Ensure that pressure PT6870, PG6843 for UB # 1, PT6871, PG6845 for UB # 2, PT6872, PG6848
for UB # 3, PT6873, PG6850 for UB # 4 = 3.0 Kg/cm2 g and temperature TI6822 for UB # 1, TI6824
for UB # 2, TI6826 for UB # 3, TI6828 for UB # 4 = 40 ⁰C

 Put PCV in auto mode once HRSG is fired inside burners

D. FG drain tank system
 FG drain tank system consist of 03 nos. of drain tanks located at different location like:

1. FG drain tank near GBC area (575-T-00-521)
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 Each FG Offbase drain + GT integral + UB and HRSG integral drains are connected to suitable
nearby drain tank



 Always ensure that the FG drain system should be in place and ready for start up before
introducing any Hydrocarbon inside CPP units.

 Also ensure that the FG flare vent from each drain tank are collected to common flare header
which in turn connect to refinery flare header

6.2.2.7 COMMISSIONING OF BOILER BLOW DOWN SYSTEM

 Blow down system in CPP consist of 5 nos. of Blow down pit with submersible pumps for
pumping the boiler blow down to Refinery RO/DM for necessary treatment. List of blowdown
pits are as below:

1. HRSG blow down pit
2. UB # 1 and 2 Blow down pit
3. UB # 3 and 4 Blow down pit
4. LP heater flash collection blow down pit
5. Main blow down pit
6. STGs and BPTG flash collection blow down pit
 Drain from CBD/IDB vessel is diverted to their respective Blow down vessel for each UB and
HRSG. LP heater flash line is collected to flash vessel through which drain is collected to blow
down pit

 For commissioning of Blow down system, first ensure that the system is ready in all aspect;
Format VI is completed for complete system and can be commissioned up from individual main
equipment B/L isolation valve to refinery CPP B/L.

 All drain collected in above 5 pits are pumped through their respective submersible pumps to
Main blow pit

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 From Main blow down pit, the submersible pumps used to divert the drain back to RO/DM
plant. Ensure that Pump discharge and suction isolation valve will remain in Open condition and
pump will be start/stop based on the level inside the drain tanks.
6.2.2.8 COMMISSIONING OF EMERGENCY IA/PA SYSTEM
 For commissioning of IA/PA system, first ensure that the system is ready in all aspect, Format
IV is completed for complete system and can be commissioned up to individual main
equipment B/L isolation valve.

 Ensure following before starting the Atomizing air compressor:

1. CW system charge and commissioned for Atm air compressor system
2. Atomizing air compressor PLC commissioned
3. Atomizing air compressor receiver and header is ready for commissioning
4. Lube oil system readiness for atomizing air compressor ensure
5. Lube oil system is in operation
6. PLC interface with DCS is already done.
7. Electrical wiring completed and tested and ready to start the drive
 Once above thing are ensure, start the atomizing air compressor from local PLC

 Check all vibration level, leakages of oil and temperature reading for next 30 min after
opening the main discharge valve

 Fill the receiver downstream up to required pressure

 Charge the header and ensure that Atomizing air is available for UB and HRSG B/L

 Start Booster air compressor once surge air receiver is filled and charge

 Fill the IA & atomizing air receiver tank

 Charge the IA drier system and take the drier system in to service before charging IA to
Common IA header inside CPP

 Ensure that PRV installed working properly by checking downstream IA header pressure.
6.2.2.9 COMMISSIONING OF COOLING WATER SYSTEM

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 Cooling water system commissioning commence once the below following system are ready:

1. Raw water supply header to CPP inside CPP B/L is ready to use.
2. Cooling tower cell and forebay are ready to use
3. All vertical pumps and cell sluice gate valve is installed and in operation
4. CW supply header to ACW supply header interconnection and its MOV4701 is ready.
5. CT Fan with Motor ready to use
6. All instrument hook up DCS and PLC system
7. Side stream filter system ready to be use
8. ACW and CW supply and return header are ready to be use. Initial it is advisable to drain
the return header back to storm water channel to remove all dirts and debris lying inside
header (especially for U/G piping)
9. Ensure the header is passivated properly and ready to use

10. CT chemical treatment system ready to be use
11. Ensure that electrical and instrument work is complete for CW system
12. Format IV release and approved
 Fill the Cooling water cell with Raw water from refinery

 Fill the necessary height of Cooling tower forebay and check the quality of parameter before
charging the Raw water for CPP equipment

 Open the CW pump sluice gate valve to filled the sump for vertical mounted pumps

 Start the CW pump from DCS or from local PB

 Filled the header by opening the CW discharge isolation valve.

 Open the CW supply and return header to each STG to charge Cooling water system of STG

 Divert the return CW header back to sump through cooling fan only once ensure that no
debris are coming back from the system.

 Take regular sample of return header and keep make up water incomer in service to maintain
sump level at normal state

 Make up the Chemical as per the requirement of vendors or based on the sample reading and
recommendation from TS to maintain pH and necessary COC.

 If COC exceed the design limit, provide blowdown and divert the drain CPP CT cooling water

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back to RO/DM unit for recycling.
 Ensure that CW system to charge only when STG to be taken is operation, otherwise ACW
system is remain in continuous operation for all other equipment cooling

 Start the CT fans as per the requirement to maintain the Inlet CW temperature at 32 ⁰C with
Delta temperature of 11 ⁰C

 Start SSF system to ensure the all dirts are removed from CT water


6.2.2.10 COMMISSIONING OF AUX COOLING WATER SYSTEM

 Aux Cooling water system commissioning commence once the below following system are
ready:

1. CT is ready as per CW requirement.
2. All instrument hook up DCS and PLC system
3. Side stream filter system ready to be use
4. ACW piping header up to each equipment isolation valve is ready
5. CW supply header to ACW supply header interconnection its MOV 4701 is ready.
6. Ensure the header is passivated properly and ready to use
7. Ensure that electrical and instrument work is complete for ACW system
8. Format IV release and approved
 Open the ACW pump sluice gate valve to filled the sump for vertical mounted pumps

 Start the ACW pump from DCS or from local PB

 Filled the ACW header by opening the ACW discharge MOV.

 Open the ACW supply and return header to each equipment to check the flow and ensure
commissioning of system

 Divert the return ACW return header to CW return header and back to sump through cooling
fan only once ensure that no debris are coming back from the system.

 If COC exceed the design limit, provide blowdown and divert the drain CPP CT cooling water
back to RO/DM unit for recycling by opening the CV in the header from ACW pump common
discharge header.

 Blow down water can be routed back to RO/DM unit or can be use in IBD flash vessel as
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quenching media
6.2.2.11 COMMISSIONING OF HP NITROGEN SYSTEM

 Ensure that Nitrogen header inside CPP is completed and Format IV is approved.

 Ensure that nitrogen is available at CPP Refinery B/L

 Open the isolation valve with spectacle blind to charge the Nitrogen header inside CPP

 Open the Nitrogen supply isolation valve to HP nitrogen compressor inlet

 Ensure the following before starting HP nitrogen compressor:

1. Nitrogen is available at suction at a pressure of min 3.5 Kg/cm2 g
2. Nitrogen should be continuously available at Compressor inlet
3. ACW system charge for Nitrogen compressor coolers
4. Nitrogen compressor – Local PLC commissioned and necessary communication given back
to DCS for monitoring
5. Motor solo run completed
6. Lube oil system readiness for compressor
7. All interlocks and protection check for compressor through local PLC operation
8. HP Nitrogen receivers along with header are ready and connected properly to FG header
to GT for purging.
 Start the Nitrogen compressor from local PLC

 Filled the nitrogen inside receiver along with header by isolation the header near connection
point by closing the isolation valve with spectacle blind

 Check the pressure of the system and ensure no passing of PSV and leakage of gas from
system when kept under hold for 1 hour

 Attend the leakage if any

 Ensure all PRV installed for GTG are connected and ready for operation

 Once no leakage identified filled the header and receiver upto 42 Kg/cm2 g and thereafter put
the compressor in AUTO mode operation to start and stop at 34 and 42 Kg/cm2 g
respectively.

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6.2.3. COMMISSIONING OF ELECTRICAL SYSTEM

Electrical system consist of all Power generating Turbine Generator, Step up and step down
transformers, 220 KV switch yards, Circuit breakers, Bus couplers, Isolators, Relays, 33 KV GIS, 6.6 KW
SWGR, 415 V SWGR, Black start DG set, AVR for Generator control, Capacitor bank for PF
improvement, Battery bank, DCDB, AC UPS, ACDB, Lighting transformers, plant lighting, HT and LT
motors, PMCC and MCC, MOV and earthing system, ECS and SCAP
Commissioning of Electrical system is done parallel with the major equipment like GT and STG.
However the sequences of commissioning of Electrical system are as follow:
1. Plant earthing network
2. Battery bank and DCDB
3. AC UPS and ACDB
4. 220 KV switch yard along with 220/33 KV Trafo
5. 33 KV GIS with SCAP
6. 33 KV outgoing breaker to Refinery S/S
7. 33/11 KV – step down Trafo for CPP Auxiliary power – Station Trafo
8. 6.6 KV SWGR
9. 6.6/0.415 KV – stepdown Trafo – Distribution Trafo
10. 415 V - PMCC and MCC
11. All power generating unit – Generator
12. Step up Generator Trafo
13. Black start DG set
Commissioning of electrical system mentioned from point 1 to 10 is to be done before actual main
equipment commissioning in CPP as motor and drives are required to run boilers and STG. STG
generator along with step up Trafo and Black Start DG set can be commissioned in parallel with main
equipment commissioning.

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6.2.4. COMMISSIONING OF DCS AND BMS SYSTEM

DCS and BMS system are the Instrumentation system used to control plant operation and use for
safety shutdown of Boiler burners respectively. Commissioning activities of DCS and BMS include:
1. Testing of Panels and relays
2. Checking of all hooking up of cables to field instrumentation and getting input from field
as well
3. Checking the Power disturbance system, Power protection system and backup power
system to ensure availability of DCS and BMS system
4. Ensure the communication between DCS and Console monitor for operator
5. Ensure other systems like AIMS, PLC Max link connectors, Annuciator, Data
connectrator, ECS, SCAP, etc are ready and configure
6. Ensure the communication network establish between all system through MODBUS with
redundancy
7. Check the loop testing of each Controlling elements from DCS/BMS through field
operation
8. Ensuring cabling done for the same
9. Trial testing of system before commissioning
10. Simulation trial and tuning of PIDs simulation to be completed
11. Check for the DCS controller loading and 40% redundancy availability after SAT
12. Operate the system through DCS communication channel during commissioning
13. Start submitting the system based on the process stream requirement from DCS/BMS
14. Check all interlocks, setting, Control loops, logics for all process and non-process
system for CPP

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6.2.5. COMMISSIONING AND START UP OF UTILITY BOILERS

Before going to start the UB for continuous steam production following below mentioned things t o
be ensure first for completion:
PRE-REQUISTE CONDITIONS:
 All Format IV activities like Alkali Boil out, Steam blowing, Refractory dry out, Burner testing
and alignment, etc are complete for the given boiler and Format IV is approved

 PSSR done for Boiler and all the A and B category points are liquidated

 All Utilities associated for Boilers like; Atomizing air compressor, Blow down system, Off base
Fuel system, Nitrogen system, ACW system, Flare header system, OWS system are available or
connected for the continuous usage at Boiler B/L

 IBR clearance to operate the boiler on continuous basis is received (provisional orders is also
acceptable if SVF is not done)

 All Field instrument and drives loop checking and trial run done from DCS/BMS system

 All Safety related issues are close and necessary fire hydrant system are commissioned

 All Equipments like FD fan, Scanner cooling fan, RAPH are free of Maintenance, lined up
properly and in operation.

 All PSVs and PVRV’s are calibrated and in lined up condition and car sealed as mentioned
above.

 All Instruments and analyzers are in lined up condition and working well.

 Sample coolers are in lined up condition

 All Manual valves are in the desired position and UV’s and Control Valves are stroke tested
and getting operated as required.

 Boiler is ready in all aspect and ready to intake DM/BFW for start up

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STARTING SEQUENCE:
1. Boiler feed water line up and drum filling and steam circuit line up
Very first step in Boiler lit up is filled the Boiler with BFW or fresh DM. It is normally recommended to
use BFW from Deaerator through Boiler Feed pump. Step for Boiler filling are as below:
 Ensure that BFW pump is started and BFW is lineup up to FRS station CV. Check the pressure at
FRS inlet as 125.7 kg/cm2 (144.2 kg/cm2 - Max) through pressure transmitter (PT1842) or
pressure gauge (PT1841).

 Ensure that BFW temperature is ambient condition during first lit up of Boiler inside CPP. Once
LP steam is available for Deaerator and LP heater, the BFW temperature should be 125.6 ⁰C

 Ensure that steam drum vents, Eco outlet header vents and SH – I and II high vents are in open
condition before opening the Eco inlet MOV (GTV-MOV-8757)

 Ensure that all BFW header and steam header drains are in open condition and line up to their
respective drain header which in turn line up to IBD vessel

 First open 30% CV (FCV1844C/1845C/1846C/1847C) to filled the header up to MOV

 Open the bypass MOV (GTV-MOV-8758) first before opening main MOV

 Start filling the steam drum. Check the drum level through level transmitter (LT8711/8712/8713)
and through Local level gauge(LI8716/8715) and also through EWLI (LS8717/8714)


 Fill the drum level up to required height depending up on the requirement of filling SHs. SHs can
be either filled through BFW spray nozzle and keeping MSSV (GTV-MOV-8764) in closed condition
or can be filled through filling the drum up to maximum level and there after filling the SHs. In
both cases SH is required to keep filled with water before firing.

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 Once SH is filled and ensure that the BFW is coming out from vent and the pressure inside the
drum reaches up to 3-4 Kg/cm2 g, close the vent valves and also start closing drain valve.

 In case SH is filled through drum, drains out the drum BFW through CBD /IBD MOVs and kept the
drum level at 40%. Always ensure that drain to done inside Boiler drum only after closing its
vent valve.

 Close 30% FRS CV and keep steady state of drum level inside boiler.

 Once the above state is achieve, BFW is consider to charged inside Boiler

 Keep Main steam stop valve (GLVMOV8765) and its bypass MOV (GLVMOV8757) in closed
position

 Ensure that start vent MOVs (RGVMOV8763 and GLVMOV8762) are in close position

 Ensure that PSV (ERVPCV8752) in operation by ensuring that its upstream manual isolation valve
is in open condition

 Ensure that Steam line to SB MOV (GLVMOV8756) is in close position and all SBs are in local mode
and outside the boilers.

 Ensure that SB system is ready to start up
2. Air and Flue gas path line up and starting
Next system to line up is Air and Flue gas path system of Boiler. It consist of FD fan with dual drives,
IGV dampers, SCAP and its dampers, RAPH and its dampers, Burner wind box and its controlling
dampers, Boiler furnace, Stack and chimneys. All the above mentioned equipments along with
associated ducting and expansion bellows are erected and complete, leak test done and approved and
ready to charge. Steps involve are:
 Check to be made before starting FD fan are:

1. IGV (FCV8669-A) is in closed position
2. Lube oil system line up
3. ACW system for Lube oil cooling available and line up
4. HT power available
5. No trip on drive exist

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6. SCAPH inlet (LM004) and outlet (LM005) MOV type damper in closed position and its bypass
MOV type damper (LM006) in open condition
7. RAPH bypass damper (Pneumatic type) (LM003) is in close condition
8. Scanner fan ready to start
9. Burner wind box damper (LM007-014) are in close condition while secondary manual air
damper (LM-015 to 022) are in open condition
10. Stack analyzer in operation
 Start the FD fan after ensuring above points

 Check the pressure, temperature and flow of air through PT8671, TE8670-1/2/3 and FT8669-
1/2/3

 Ensure that furnace pressure is not high (PT8672-1/2/3 and PT8673)

 Start the Scanner air fan (AC drive) and ensure no differential pressure alarm exist (PDT8688)

 Check the furnace pressure at various location through local PG installed in flue gas path of
boiler (PPP8609, 8611, 8614, 8680)

 Ensure that no leakage exist from any of the joints and expansion bellow

 If steam is available for SCAPH operation, line up SCAPH from steam as well as Air side by opening
necessary dampers. Always charge first air to SCAPH before charging LP steam to SCAPH.

 Start RAPH on motor drive and line up SCAPH by opening its inlet (LM004) and outlet (LM005)
MOV type damper and keep closing its bypass damper

 Once above is check, air and flue gas path system is said to be ready
3. Fuel system line up
The last thing to be lineup for UB lit up is Fuel system. Normally LCO is used as fuel for UB start up.
LCO is available up to Boiler B/L isolation valve (GTV-L021) at a pressure of 17 Kg/cm2 g and Temp -
ambient condition. Before charging LCO inside Boiler ensure the

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below mentioned points for safe start up:

 Atomizing air is available at Boiler B/L at a pressure of 6.0 Kg/cm2 g

 LPG gas bottleis available or tapping from RFG header connected to Pilot fuel header

 In case of FG, FG should be available up to boiler B/L at a pressure of 1.5 – 4.0 Kg/cm2 g

 In case of FG, Nitrogen should be available at a pressure of Min 2.0 Kg/cm2 g which will also
act as an start permissive for FG firing

 Ensure that all main fuel line SOV and all Burner SOV are in closed condition and feedback of
the same is coming back to BMS which will act as a permissive for next command.
First Burner Start up sequence:
 First charge atomizing air inside Boiler by opening Boiler B/L isolation valve.

 Ensure that the pressure is greater than 2.5 Kg/cm2 g through PT8902-1/2/3 and PI890

 Before taking fuel inside the boiler, ensure that, following drives are in running condition and
its standby are kept in ACO mode:

o MD/ TD FD fan (>30 % BMCR flow)
o Feed water pumps

o Scanner air fan

 Ensure that scavenging of the Burner is completed by checking that no scavenging alarm exists.
This in only possible if any of the burner trip during previous boiler running state. In case of
planned shutdown scavenging cycle will automatically commence for 300 sec to ensure no un-
burnt fuel inside furnace. Details of scavenging process are explained as below process during
Burner shutdown process.

 Also ensure that before starting the boiler burner, the initial Boiler trip or MFT command
should be reset and boiler should be ready to start the burners. The necessary pre-requisite for
No Boiler trip command are:

o No emergency trip PB pressed (both from MMI and local control panel)
o DCS Control supply available (2oo3 logic)
o Air flow > 30% (2oo3 logic – FT8869-1/2/3)
o Drum level not very low (2oo3 logic – two Level transmitter signal and one EWLI signal)
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o Furnace pressure not very high (2oo3 logic – PT8672-1/2/3)

o FD fan running MCC feedback (2oo3 logic)
o Drum level not very high (2oo3 logic – two Level transmitter signal and one EWLI
signal)
o RAPH ON feedback from motor (2oo3 logic)
o 110 V AC available for SOV operation (2oo3 logic)
o Loss of all Fuel trip
o Unit flame failure trip
 Once the above conditions are OK, Boiler is ready to start for fuel firing i.e. no boiler trip or
MFT (main fuel trip) exist

 Next step is to purge the Boiler furnace before any start up or after every boiler trip

 Necessary pre-requisite condition for purging are:
o LCO/Naphtha Trip valve (GLVSOV100) close feedback healthy
o FG Trip valve (BLVSOV015) close feedback healthy
o FG vent valve (BLVSOV016) open feedback healthy
o All LCO/Naphtha nozzle valve (BLVSOV060-067) close feedback healthy
o All FG nozzle valve (BLVSOV076-083 and BLVSOV084-091) close feedback healthy
o All UV and IR scanner show no flame
o Ignitor gas trip valve (IG40) close feedback healthy
o Ignitor gas vent valve (IG39) open feedback healthy
o No boiler trip / MFT exist
o All Burner Secondary Air dampers (LM007-014) Open feedback healthy
o Air Flow >30% of BMCR rating
 If all of the above conditions are healthy, Purge ready signal is gets activated at HMI/console.

 Press Purge start PB from HMI or local control panel to start the purging

 Purge cycle will persist for next 5 min. Within that duration if any of the above signal
healthiness goes out, Purge will stop and a Boiler Trip signal will generate. Operator to reset
the trip and repeat the purging process as mentioned above.
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First Burner lit up on LCO/Naphtha fuel:

 Ensure that LCO/Naphtha inlet pressure before CV is healthy (> 17.0 Kg/cm2 g) before opening MFT

 Kept LCO/Naphtha header CV (FCV8907A) and its bypass isolation valve (L025) in closed
position and in manual condition.

 Select the LCO/Naphtha /FG Fuel for any burner i.e. at each burner level, fuel selection
provision is provided. Either selects LCO/Naphtha /FG for a given burner. Any one fuel can be
selected for burner at any given movement of time.

 Once any burner is selected for any fuel, its associated Main Fuel Trip valve can be command
to open from MMI or from local control panel.

 Pressed LCO/Naphtha trip valve PB open command from MMI or local control panel to open
LCO/Naphtha trip valve (GLVSOV100)

 Also Open LPG /FG Ignitor fuel header isolation valve IG31 manually and charge the Igniter fuel
header. LPG/FG Ignitor header should not be less than 1.2 and high than 2.0 Kg/cm2 g which
can be sense by PT8841 and PG8836 installed before main header SOV (IG40)

 Open IG40 from BMS by pressing Ignitor trip valve open PB from MMI or from local control
panel.

 On satisfying the above mentioned condition, Ignitor Trip valve open commands execute to
open IG40. After a delay of 60 sec the vent valve IG39 is commanded to close.

 This ensure that Ignitor gas is charge up to all Burners for boiler

 If any other burners either on LCO/Naphtha or FG are in service Ignitor system is said to be
service for complete boiler and the above mentioned steps are not required to be performed
for any other burner start up once any one burner is in service for given boiler.

 Open the FCV from DCS in manual mode of operation to charge the downstream header of
Boiler up to burners.

 Ensure that the downstream pressure (PT8911) should be healthy i.e. >2.5 Kg/cm2 g

 Pressed PB start for selected burner on FG from MMI or from local control panel
 Once ready to permit is achieved, Ignitor Trip valve in open condition and start PB is pressed,
selected Burner start time logic is activated for next 20 sec of operation.
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 Once the Burner start time is activated for selected burner, the timer remains active for next
20 sec in which both Igniter flame to proven and main flame also required to be proven
otherwise, burner is declared as unsuccessful start and if for the boiler if it is first burner than
it will result into MFT command for complete boiler and thus the process of restarting to be
done from purging cycle.

 MFT will occur base on either Loss of all Fuel trip logic or based on Flame failure trip logic

 If Ignitor flame get proven for a selected burner within 10 sec after start PB pressed for

Burner, the command to open selected burner Atomizing SOV valve and LCO/Naphtha nozzle
valve

 Once the Atomizing air nozzle valve and LCO/Naphtha nozzle valve open for the selected
burner, the healthy feedback of IR scanner flame should come back to BMS within remaining
10 sec of operation. If the flame fault occurs, Burner is declared as trip and if the burner is first
burner for the boiler, Boiler is declared as trip on all Flame failure loss or main fuel trip loss
logic as mentioned above.

 If the IR scanner shows the existence of flame within the remaining 20 sec, Burner is declared
as ON burner.

 Any flame failure even during the running of burner while result into burner trip signal.

 Repeat the same process of selecting fuel and starting the burner of LCO/NAPHTHA fuel for
other burners as well

 Similarly during Ignitor firing, the Secondary air damper (SAD) (LM007-1/2 to LM014-1/2) for
each burner will remain in open position.

 SAD will close to zero on following cases:
o MFT exist
o HSD or FG nozzle valve in close condition
o SAD close command from MMI
First Burner lit up on FG fuel:
 Ensure that FG inlet pressure before CV is healthy (> 4.5 Kg/cm2 g) before opening MFT valve
(BLVSOV015) for FG
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 Kept FG header CV (FCV8803A/B), its bypass isolation valve (FG35) in closed position and in
manual condition along with its self regulating PRV (LM-301A) in operation mode

 Select the FG Fuel for any burner i.e. at each burner level, fuel selection provision is provided.
Either selects LCO/NAPHTHA or FG for a given burner. Any one fuel can be selected for burner
at any given movement of time.

 Once any burner is selected for any fuel, its associated Main Fuel Trip valve can be command
to open from MMI or from local control panel.

 Pressed FG trip valve PB open command from MMI or local control panel to open FG trip valve

 Also Open LPG / Ignitor fuel header isolation valve IG31 manually and charge the Igniter fuel
header. Ignitor header should not be less than 1.2 and high than 2.0 Kg/cm2 g which can be
sense by PT8841 and PG8836 installed before main header SOV (IG40)

 Open IG40 from BMS by pressing Ignitor trip valve open PB from MMI or from local control
panel. This ensure that Ignitor gas is charge up to all Burners for boiler

 If any other burners either on LCO/NAPHTHA or FG are in service Ignitor system is said to be
service for complete boiler and the above mentioned steps are not required to be performed
for any other burner start up once any one burner is in service for given boiler.

 Pressed PB start for selected burner on FG from MMI or from local control panel

 Once ready to permit is achieved, Ignitor Trip valve in open condition and start PB is pressed,
selected Burner start time logic is activated for next 20 sec of operation.

 Once the Burner start time is activated for selected burner, the timer remains active for next
20 sec in which both Ignitor flame to proven and main flame also required to be proven
otherwise, burner is declared as unsuccessful start and if for the boiler if it is first burner than
it will result into MFT command for complete boiler and thus the process of restarting to be
done from purging cycle.

 MFT will occur base on either Loss of all Fuel trip logic or based on Flame failure trip logic

 If Ignitor flame get proven for a selected burner within 10 sec after start PB pressed for

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Burner, the command to open selected burner FG burner side valve and FG header side valve
as per below logic. First FG burner side will open which in turn command to FG header side
valve to open.
 Once the above condition are satisfied, first FG burner side valve open which open signal is
input to open FG header side valve. FG header side valve is basically a 3 way valve, which is
state in Open condition when FG is allow to go into burner else state close and thus FG is vent
to flare header.

 Healthy feedback of UV scanner flame should come back to BMS within remaining 10 sec of
operation. If the flame fault occurs, Burner is declared as trip and if the burner is first burner
for the boiler, Boiler is declared as trip on all Flame failure loss or main fuel trip loss logic as
mentioned above.

 If the UV scanner shows the existence of flame within the remaining 20 sec, Burner is
declared as ON burner.

 Any flame failure (IR or UV) even during the running of burner while result into burner trip
signal.

 Similarly during Ignitor firing, the Secondary air damper (SAD) (LM007-1/2 to LM014-1/2) for
each burner will remain in open position.

 SAD will close to zero on following cases:
o MFT exist
o HSD or FG nozzle valve in close condition
o SAD close command from MMI
 FG flow control PRV is sufficient enough to cater the need for one burner. In order to increase
the load on FG, FCV8803-A/B to be taken into service and put the system in AUTO mode once
sufficient load on FG is taken.

 Repeat the same process of selecting fuel and starting the burner of FG fuel for other burners
as per requirements
Scavenging Process:
 Scavenging of burner is done in following condition only:

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o Burner running on LCO/Naphtha as fuel

o Burner is manually stopped
 In case if burner trip occurred, scavenging to be done manually through local control panel or
through MMI before restarting. Until scavenging is not done, burner cannot be restarted
either on LCO/Naphtha or FG fuel

 In case of FG firing no scavenging is envisage

 During scavenging process, Ignitor system is again activate to burn the scavenge fuel.

 Scavenging valve (BLVSOV092-099) open to allow atomizing air to pass through LCO/NAPHTHA
lance and thus do the scavenging process

 Simultaneously a command to operate Ignitor system for a burner is also activated.

 Scavenging will last for 300 sec where Ignitor flame will continuous sense the scavenging
process. Any flame failure by Ignitor scanner will lead to false scavenging and thus manual
scavenging process to be followed for burner.
Changeover of Fuel inside Burner:
 Fuel change over from LCO/Naphtha to FG and FG to LCO/Naphtha is possible in all burners

 In case of LCO/Naphtha to FG fuel change over, LCO/Naphtha burner to planned stop, ensure
scavenging before selecting FG as fuel for burner

 Similarly in case of FG to LCO/Naphtha change over, stopped the Burner on FG and
selected LCO/Naphtha fuel. No scavenging is required in case of FG fuel firing change over.
Commissioning after Burner startup:
 Once the Burner are taken in service, Open start up vent MOVs to vent out the steam from
header and SH zone

 Close Superheater all drains when drum pressure reaches to 5-10 Kg/cm2 g

 Increase the load on Boiler by taking more burner in service

 Once the Boiler load is above the 30% MCR condition, start up control drives in AUTO mode:
o Feed regulating CVs
o FD fan IGV
o FG and LCO/NAPHTHA fuel FCV

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o ERV of main steam line
 Select the mode of operation for loading the boiler i.e. either pressure control mode or load
control mode once the boiler crosses the 30% MCR condition

 Take RAPH in service and remove SCAPH from the service by closing its inlet and outlet damper
and opening SCAPH bypass damper

 Increase the load on boiler for Safety valve floating. Check the SV floating in front of IBR
inspector

 Mark the set point of opening and closing pressure value on safety valve for future reference

 Reduce the boiler load.

 Open first MSSV bypass MOV to heat up the downstream VHP header. Ensure that drains of
VHP header are in open condition

 Heat the VHP header up to 400 deg C and a pressure of say 35-40 Kg/cm2 g by crack closing
the VHP header drain valve

  Open MSSV MOV of boiler to charge VHP header
  Close start up vent MOVs
 Boiler is declared as commissioned and can be operated based on requirements
6.2.6. COMMISSIONING AND START UP OF GAS TURBINE

 All Format IV activities like Burner testing and alignment, Lube oil flushing, starting means
precommissioning, Fuel piping and drain system readiness, etc are complete for the given GT
and Format IV is approved

 PSSR done for GT and all the A and B category points are liquidated

 All Utilities associated for GT like; Atomizing air compressor, Fuel drain system, Off base Fuel
system, Nitrogen system, ACW system, Flare header system, OWS system, Slope, Fire hydrant
system, DCS, Mark VI controller, GT Generator, ECS and SCAP, etc are available or connected
for the continuous usage at GT B/L

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 All Field instrument and drives loop checking and trial run done from DCS/Mark VI/ECS/SCAP
system


 Equipments like fans, etc are free of Maintenance, lined up properly and in operation.

above.




 GT is ready in all aspect and ready to intake all Utilities from its B/L flange for start up

 Perquisite condition is to select any one Fuel for Start up of GT. Normally HSD is selected as
fuel for GT start up.

 Prior to startup or following major maintenance work, it is essential to check all support
systems, power sources and control devices for proper condition. These checks are dependent
on individual station procedures requirements, but may include such areas as drain valves
closed, power breakers in the on position, supply/isolation valves open, controls in


 Start/operation positions, any tagged out equipment returned to normal state, all safety
equipment in place.
The following is a list of important checks to be made on a new or newly overhauled turbine with
OPERATION SELECTOR in various modes.
CAUTION
Where an electric motor is used as the starting means, refer to the Control Specifications in regard to
maximum operating time.

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“Crank”
1. Listen for rubbing noises in the turbine compartment

2. Check for unusual vibration.
3. Inspect for water system leakage.
“Fire”
1. Bleed fuel oil filters, if appropriate, and then check entire fuel system and the area
immediately around the fuel nozzle for leaks. In particular, check for leaks at the following
points;
Turbine Compartment
a. Fuel piping/tubing to fuel nozzle
b. Fuel check valves
c. Atomizing air manifold and associated piping (when used)
d. Gas manifold and associated piping (when used)
Accessory Compartment
a. Flow divider if used
b. Fuel and water pumps
c. Filter covers and drains
Caution
Where an electric motor is used as the starting means, refer to the Control Specifications in regard
to maximum operating time
2. Monitor the turbine control panel readings for unusual exhaust thermocouple temperature,
wheel space temperature, lube oil drain temperature, highest to lowest exhaust temperature
spreads and ‘hot spots” i.e. combustion chambers burning hotter than all the others.
3. Listen for unusual noises and rubbing.
4. Monitor for excessive vibration.

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“Automatic, Remote”
Permit the gas turbine to operate for 30 to 60 minute period in a full speed, no load condition.
Record all data for further comparison & investigation.
1. Continue monitoring for unusual rubbing noises & shutdown immediately if noise persists.
2. Monitor the lube oil tank, header & bearing drain temperatures continually during the
heating period. Adjust the VTRs if required.
3. Perform a thorough vibration check. It is suggested that horizontal, vertical & axial data be
recorded for the:
 All accessible bearing covers on the turbine

 Turbine forward compressor casing

 Turbine support legs

 Reduction gear (when used) forward & aft sides, gear & pinion.

 Bearing covers on the load equipment

4. Check & record wheel space, exhaust & control thermocouples for proper indication on the
CRT.
5. Check flame detector operation.
STARTING SEQUENCE:
Very first step in GT commissioning is the starting of Lube oil system. Ensure that Mark VI controller is
ready in all aspect and GT HMI is ready for operation. Also ensure that all Utilities are available and
commissioned for GT like; DM water system for AA cooler, ACW system including FRP CT system,
Electrical system 125 V, 220 AC UPS, GT MCC, etc. Provisions are provided in GT HMI to start the GT
on different mode of operation like; Crank mode, Fire mode, Auto mode.
Each Mode can be used to start the GT. Function of each mode is to take GT from standstill position to
FSNL in sequence following the startup curve. Normally the GT is first selected for crank mode and
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then put it into AUTO mode so that GT goes up to FSNL following start up curve.
GENERAL
Starting the gas turbine involves proper sequencing of command signals to the accessories, starting
device & fuel control system. Since a safe & successful start up depends on proper functioning of
almost all of the gas turbine equipment, it is important to verify the state of selected devices in
sequence. Much of the control logic circuitry is associated not only with actuating control devices, but
enabling protective circuits & obtaining permissive conditions before proceeding. Reference to the
control sequence programme is necessary for complete understanding of all the logic functions
included for the particular equipment provided with a gas turbine. The operating sequences of the
Control specifications are written to explain significant functions which pertain to a specific gas
turbine.
A block diagram of all SPEED TRONIC circuits which can interplay to control start-up, is shown in
Figure SECFR-1. Detailed descriptions are found in the SPEED TRONIC panel information included in
this manual & on the control sequence programme. Utilize figure SECFR-2, a plot of a typical start up,
to aid in understanding the sequences described here.
Start up & shutdown cycle improvements have been included to reduce low cycle fatigue of hot gas
path parts.
SPEED DETECTORS
An important part of the startup/ shut down sequence control of the turbine is proper speed sensing.
This is necessary for the logic sequences in startup & shut down of the gas turbine. The following
speed detectors & speed relays are used: L14HR Zero-Speed Detector, L14HM Minimum-Speed Relay
Detector, L14HA Accelerating Relay Speed Detector & L14HS High Speed Relay (some units use-a
L14HF fired shutdown relay).
The zero speed detector, L14HR, provides the signal when turbine shaft starts rotating. If speed is
below L14HR, permissive logic initiates clutch engagement & the cranking sequence for the turbine.
During the shutdown cycle this speed detector provides the signal to permit the ratchet gear, or

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turning device, to be placed in service in the automatic cool down logic sequence of the turbine. The
minimum speed detector L14HM indicates that the turbine has reached the minimum firing speed &
initiates the purge (if required) prior to ignition. The drop out of the L14HM minimum speed relay
provides several permissive functions in the restarting of the gas turbine after shutdown.
The acceleration speed relay L14HA pickup indicates that the turbine has reached approximately 40 to
50n percent in the acceleration cycle. The high speed sensor L14HS pickup indicates that the turbine is
at operating speed, & that the accelerating sequence is complete. With this signal the inlet guide
vanes are actuated unless the unit is equipped for modulation. See the inlet guide Vane section.
The L14HS dropout speed is used to close unmodulated inlet guide vanes upon turbine shutdown.
During a normal shut down the digital set point will countdown to minimum, the generator breaker
will open on reverse power & FSR will ramp to minimum. Flame will be maintained to shut down
speed where L14HA (or L14HF) will then drop out & drive FSR to zero.
The settings of the speed are programmed in the computer as PROM constants & are listed in the
Control Specifications.
START UP CONTROL
The start up control operates as an open loop control in the use of preset levels of the fuel command
signal, FSR. The levels set are “FIRE”, “WARMUP” & “ACCELERATION LIMIT”. The control specifications
provide proper settings calculated for the fuel anticipated. The FSR levels must be set in the SPEED
TRONIC start up control.
Start up control FSR signals operate through the minimum vale gate to insure that speed control &
temp control can limit FSR if required. During the starting sequence, rates of increase in speed &
exhaust temp are restricted to protect the turbine parts from excessive mechanical & thermal
stresses. The rates of acceleration & temp rise are controlled in dependently by the closed loops of
the speed & temp control systems. The rate limits operate through the SPEED TRONIC control circuits
discussed in those control systems.

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The fuel command signals are generated by the SPEED TRONIC start up software. See the turbine
control sequence programme. In addition to three startup levels, the software sets maximum & min
FSR & provides for manual control of FSR. Pressing the switches for “MANUAL CONTROL” & “FSR GAG
RAISE OR LOWER” allows manual adjustment of FSR setting between FSRMIN & FSRMAX.
While the turbine is at rest, electronic checks are made of the stop/speed ratio vale, the gas control
valve, the accessories & the voltage supplies. At this time the operator display will be normal & the
“SHUTDOWN STATUS” will be displayed on the CRT. Activating the master operation switch L43 from
“OFF” to an operating mode will activate the ready circuit. If all protective circuits & trip latches are
permissive the start up status “READY TO START” messages will be displayed & indicates the turbine
will accept a start signal. Depressing the “START” master control switch (LIS) will introduce the start
signal to the panel.
The start signal energizes the Master Control & protection circuits (the “L4” circuit) & starts the
necessary auxiliary equipment. The “L4” circuit permits pressurization of the trip oil system &
engaging of the starting clutch. With the “L4” circuit permissive & the starting clutch engaged, the
starting device starts turning. Start up status message “STARTING” will be displayed on the CRT. See
point “A” on figure SECFR-2.
Once the turbine crosses zero speed, the L14HR signal drops & de-energizes starting clutch, solenoid
20CS. The clutch then requires torque from the starting device to maintain engagement. The turbine
speed relay L14HM indicates that the turbine is turning at the speed required for proper ignition i n
the combustors. Gas turbine unit have a purge timer, L2TV. A purge time is set to force about four
changes of exhaust duct air to ensure no combustible m9ixture is in the exhaust. The setting for L2TV
is given in the control specifications. The starting means will hold speed limit L2TV, which was started
with the L14HM signal, has completed its cycle.
The L14HM signal on completion of purge timer cycle enables fuel flow, sets firing level FSR, &
initiates the firing timer L2F-see point “B” on figure SECFR-2. When the flame detector output signals
indicate flame is established in the combustors, the warm up timer L2W starts & the fuel command is
set to the “WARMUP” FSR level. The warm up time is provided to minimize the thermal stresses
during initial part of the start up.

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If flame is not established by the end of the L2F timer, the unit can be given another start signal but
firing will be delayed by the L2TV timer to avoid fuel accumulation in successive attempts. This occurs
even on units not requiring initial L2TV purge.
At the completion of the warm up period, start up control increases FSR exponentially to the
acceleration setting for “TURBINE ACCEL REFRENE INCREMENT RATE”. See point “C” on fig SECFR-2. As
fuel is increased, the turbine begins the acceleration phase of start up. The clutch is held in position as
long as the starting device provides torque to the gas turbine. When the turbine over runs the Starting
device, the clutch will be thrown out,. Speed relay L14HA indicates the turbine is accelerating
The start up control software establishes FSR signals during start which must not be exceeded. Other
control circuits are also able to reduce & modulate FSR to perform their control functions. In the
acceleration phase of start-up it is possible to reach the temp control limit, temp rate limit, low speed
stops, or shaft acceleration rate limits. The speed & temp control system will not permit these values
to be exceeded by controlling FSR as required. Control panel display will show which parameter is
limiting or controlling.
CONTROL MODE DISPALY & OPERTAING CONDITION

Display Condition
STARTUP Start up program
ACCEL Acceleration control
DROOP SPEED Speed control
TEMP Temperature control
The start up cycle has been designed to moderate the highest firing temp produced during
acceleration. This is done by programming a slow exponential rise in FSR (120 sec time constant
normally) to a somewhat reduced ACCEL FSR setting. The acceleration rate control limit setting on the
speed control circuit is reduced during start up to over ride the rise in FSR during acceleration. It also
aids smooth transition to speed control at the end of the startup sequence. The startup

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sequence time is extended to an optimum time to minimize strains produced on the hot gas path
parts in mid-acceleration cycle.
The minimum FSR limit on the start up control prevents the speed & the start up circuit from driving.
The FSR below the value which would cause flameout during a transient condition. For example, with
a sudden rejection of load on the turbine, the speed control system loop would drive the FSR voltage
to no less than the minimum FSR setting, without which a flameout would probably occur. Since the
minimum fuel FSR circuit does not connect to the temp amplifier, the temp control system is capable
of driving the FSR to zero to prevent excessive temp in the turbine.
The acceleration phase of startup ends when complete sequence is reached, (see point “D” on figure
SECFR-2). The turbine speed is controlled by FSR & the auxiliary pumps have been shut down.
Refer to figure SECFR-1 through SECFR-3 for starting sequence & control description.
Loading Characteristics
GENERAL
Once the unit has been synchronized either manually or automatically it can be loaded by several
loading sequences. For instance, a unit can be loaded manually or automatically up to a temp control
limit, or a output load limit. Units operating under isochronous control will accept existing load or be
limited by temp control. More detail on the actual control panel features are described in the
operation section.
SYNCHRONIZING
Automatic synchronizing is accomplished sing a microprocessor based synchronizing circuit. The

circuit inputs are transmitted through an interface module. Te interface module contains an isolation
transformer for the generator & line input signals & the breaker closing relay. The synchronizing
software is part of the SPEEDTRONIC mark V control system.
For synchronizing, the unit is brought to 100.3% of rated speed. If the system frequency has varied
enough to cause an unacceptably high slip frequency a speed matching circuit in the synchronizer will
adjust the turbine governor to reduce the slip frequency & permit synchronizing.
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For added protection a synchro check relay is provided. It is used in series with both the auto
synchronizing relay & the manual breaker close switch to prevent large out-of-phase breaker closures.
FULL SPEED NO LOAD
The reason that “Full Speed, No load” adjustment is important is that it actually calibrates speed with
the called for speed using the digital set point. The 100.3% will cause an increase in fuel command
necessary to raise the speed 0.3% above synchronous grid frequency. It is essential that the generator
& system frequency be matched within 0.33Hz to synchronize quickly with the synchronizing relay.
“Full Speed-No-Load” therefore is an important setting to assure proper speed for synchronizing.
LOAD CONTROL
Speed load control increases fuel through the digital set point to maintain output value. Most units
have three values of output control: reference to the control specifications for settings is required.
a. Spinning reserve- once the generator breaker is closed, the turbine will load to this setting.
b. Preselected Load- the required load is first selected by inputting the data on the main screen,
then by selecting the PRESELECT option on the main display; the load is varied to the
preselected load.
c. Load limit- this load is not selectable, but is a calculated load limit beyond which the unit is
not permitted to operate. It is normally the material limit for the gas turbine generator.
MANUAL LOAD
The operator may increase or decrease load using switches 70R4/CS between no-load & base temp
control line. The loading is accomplished by raising or lowering the digital set point.

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ISOCHRONOUS CONTROL
In this control mode the unit output is a function of system demand. When selected, this control
mode maintains a constant speed.
TEMPERTAURE CONTROL
Temp control is initiated by the switch 43bp. In this mode of control load is increased automatically
until a temp control limit is reached. Load is then held at a constant firing temp as more fully
described in the temp control text. Turbine output in this mode of control is a function of ambient
temp.
Note: Manual load control is provided for full convenient rapid adjustment of load. It is not intended
to be used to raise load to rated output without interruption. Frequent use of manual set point
control to reach rate load more rapidly than the automatic cycle can reduce hot gas path parts life.
Similarly excessive use of “Fast start” can also reduce hot gas path parts life.
6.2.7. COMMISSIONING AND START UP OF HRSG

Before going to start the HRSG for continuous steam production following below mentioned things to
be ensure first for completion:
 All Format IV activities like Alkali Boil out, Steam blowing, Refractory dry out, Burner testing
and alignment, etc are complete for the given boiler and Format IV is approved

 PSSR done for HRSG and all the A and B category points are liquidated

 All Utilities associated for Boilers like; Atomizing air compressor, Blow down system, Off base
Fuel system, Nitrogen system, ACW system, Flare header system, OWS system, Slope, Fire
hydrant system, etc are available or connected for the continuous usage at Boiler B/L

 IBR clearance to operate the boiler on continuous basis is received (provisional orders is also
acceptable if SVF is not done)

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

above.




 HRSG is ready in all aspect and ready to intake DM/BFW for start up

 Ensure that GT in running on in the range of 50% loading to base load @ 40 ⁰C ambient
temperature condition
STARTING SEQUENCE:
1. Boiler feed water line up and drum filling and steam circuit line up
Very first step in HRSG lit up is filled the Boiler with BFW or fresh DM. It is normally recommended to
use BFW from Deaerator through Boiler Feed pump. Step for Boiler filling are as below:
 Ensure that BFW pump is started and BFW is lineup up to FRS station CV. Check the pressure at
FRS inlet as 130 kg/cm2 through pressure transmitter (PT1813) or pressure gauge (PT1814).

 Ensure that BFW temperature is ambient condition during first lit up of Boiler inside CPP. Once
LP steam is available for Deaerator and LP heater, the BFW temperature should be 125.6 ⁰C

 Ensure that vents at Eco inlet and Outlet, steam drum, Main steam header vent, etc high vents
are in open condition before opening the Eco inlet MOV (GTV-MOV-8757)

 Ensure that all BFW header, steam drum and HRSG Modules, and steam header drains are in
open condition and line up to their respective drain header which in turn line up to IBD vessel

 First open 30% CV (FCV1816C) to filled the header up to MOV

 Open the bypass MOV (FW012A) first before opening main MOV (FW012)

 Start filling the steam drum. Check the drum level through level transmitter (LT8109/8107/8108)
and through Local level gauge(BW039/027) and also through EWLI (EWLI8145)
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 Fill the drum level up to required height depending up on the requirement of filling SHs. SHs can
be either filled through BFW spray nozzle and keeping MSSV (MS036) in closed condition or can
be filled through filling the drum up to maximum level and there after filling the SHs. In both cases
SH is required to keep filled with water before firing.

 Once SH is filled and ensure that the BFW is coming out from vent and the pressure inside the
drum reaches up to 3-4 Kg/cm2 g, close the vent valves and also start closing drain valve.

 In case SH is filled through drum, drains out the drum BFW through CBD /IBD MOVs and kept the
drum level at 40%. Always ensure that drain to done inside Boiler drum only after closing its
vent valve.

 Close 30% FRS CV and keep steady state of drum level inside boiler.

 Once the above state is achieve, BFW is consider to charged inside Boiler

 Keep Main steam stop valve (MS036) and its bypass MOV (MS036A) in closed position

 Ensure that start vent MOVs (MS028 and MS029) are in close position

 Ensure that Steam line to SB MOV (SB004) is in close position and all SBs are in local mode and
outside the boilers.

 Ensure that SB system is ready to start up
2. Air and Flue gas path line up and starting
Next system to line up is Air and Flue gas path system of Boiler. It consists of GT exhaust ducting,
Diverter and Guillotine damper, Open bypass stack, HRSG inlet plenum and burner zone and Chimney.
All the above mentioned equipments along with associated ducting and expansion bellows are
erected and complete, leak test done and approved and ready to charge. Steps involve are:
 Start Augmenting air fan, Seal air fan and Scanner air fan from DCS.

 Ensure that the pressure is normal i.e. PT7730 for Augmenting air, PT7733 for Seal air and
PT7714 for scanner air at 400 mmWC, 360 mmWC, 250 mmWC respectively.

 Ensure that the flue gas pressure at the inlet of HRSG from GT is normal through PT7601 i.e. XX
mmWC

 Ensure that the Flue gas temperature at the inlet of HRSG from GT is normal through TE7608 to
TE7613 i.e. XX ⁰C
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 Ensure that no leakage exist from any of the joints and expansion bellow

 Once above is check, air and flue gas path system is said to be ready

 Line up HRSG to check the below necessary condition / permissive to take HRSG into service
are: o GT running at load (>50%)

o HRSG drum level not low (DSC signal i.e. 2oo3 logic on LT8107/8108/8109)
o HRSG drum level not high (DSC signal i.e. 2oo3 logic on LT8107/8108/8109)
o HRSG trip signal doesn’t exist

o Diverter damper is in closed condition.

 Once the above readiness are ensure, HRSG is said to healthy

 Open Guillotine damper after getting signal of HRSG Healthy from DCS.

 Open feedback of Guillotine damper along with GT operation mode selection i.e. Combine cycle
signal to open diverter damper if diverter damper RTS is activated.

 Once both dampers are in open condition, GT flue gas is say to line up for HRSG.
3. Fuel system line up
The last thing to be lineup for HRSG lit up is Fuel system. Normally FG is used as fuel for HRSG start up
but LCO/Naphth a can be used if FG is not available. LCO/Napht ha is available up to Boiler B/L
isolation valve (GTVHOV7701) at a pressure of 12 Kg/cm2 g and Temp - ambient condition. Before
charging FG inside Boiler ensure the below mentioned points for safe start up:
 Atomizing air is available at Boiler B/L at a pressure of 7.0 Kg/cm2 g

 LPG gas bottle/ tapping from RFG header is available and connected to Pilot fuel header

 In case of FG, FG should be available up to boiler B/L at a pressure of 4.5-6.0 Kg/cm2 g

 In case of FG, Nitrogen should be available at a pressure of Min 2.0 Kg/cm2 g which will
also act as an start permissive for FG firing

 Ensure that all main fuel line SOV and all Burner SOV are in closed condition and feedback of
the same is coming back to BMS which will act as a permissive for next command.
First Burner Start up sequence:
 First charge atomizing air inside Boiler by opening Boiler B/L isolation valve (GTVHOV7714)
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 Ensure that the pressure is greater than 3.25 Kg/cm2 g through PT7726/7727 and PI7725

 Before taking LCO/N aphth a fuel inside the HRSG, ensure that, following drives are in running
condition and its standby are kept in ACO mode:

o Augmenting Air fans

o HRSG Feed water pumps
o Scanner air fan

o Seal air fan

 Necessary condition / External permissive to take HRSG into service are:
o GT running at load (>50%)
o Diverter damper 100% open towards HRSG
o HRSG drum level not low (DSC signal i.e. 2oo3 logic on LT8107/8108/8109)
o HRSG drum level not high (DSC signal i.e. 2oo3 logic on LT8107/8108/8109)
o HRSG trip signal doesn’t exist
 Also Ensure that scavenging of the Burner is completed by checking that no scavenging alarm
exists. This in only possible if any of the burner trip during previous boiler running state. In
case of planned shutdown scavenging cycle will automatically commence for 300 sec to ensure
no un-burnt fuel inside furnace. Details of scavenging process are explained as below process
during Burner shutdown process.

 Next step in HRSG burner lit up is the fuel selection. Either LCO/N aphtha or FG or combination mode
or no supplementary firing mode can be selected before starting up the HRSG.

 If combination firing is selected, Open both LCO/Naphth a and FG supply header main manual
isolation valve along with Atomizing air manual isolation valve as mentioned below:

o Open Atomizing air Manual isolation valve (GTVHOV7714) after ensuring sufficient Atm
air pressure at upstream header. Once valve is open, atomizing air is charge up to all
LCO/Naphth a burner inlet isolation valve (GLVHOV7733 to 7742). Ensure that the
atomizing header pressure is not low or high through pressure transmitter
(PT7726/7727) and PG7725 i.e. >3.25 Kg/cm2 g and <8.0 Kg/cm2 g

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o Open LCO/N aphtha supply header manual isolation valve (GTVHOV7701) and charge
the LCO/Naphtha up to MTV (GLVPNM7733) after ensuring it in closed position. Ensure
that the LCO/Napht ha pressure is normal through Pressure transmitter (PT7718) and
PG7716 i.e. <12 kg/cm2 g. Also ensure that the pressure across the inlet filter <0.3
Kg/cm2 g through DPT7717
o Open FG supply header manual isolation valve (BLVHOV7701) and charge the FG up to
FG MTV (BLVPNM7701) after ensuring it in closed position. Ensure that the FG pressure
is normal through Pressure transmitter (PT7702/03) and PG7701 i.e. >2.0 and <6.5
kg/cm2 g.
 Necessary pre-requisite condition for purging are:
o No Burner trip channel
o Ignitor MTV closed (BLVPNM7712)
o LCO/N aphtha MTV closed (GLVPNM7733)
o FG MTV closed (BLVPNM7701)
o All LCO/N aphtha scavenging valve (GLVPNM7760 to 7771) are closed
o All LCO/Naphtha Burner trip valve (BTV) closed (GLVPNM7736 to 7747)
o All FG Burner trip valve closed (BLVPNM7705 to 7711)
o Scanner air fan pressure OK (PT7714) i.e. > 200 mmWC
o All LCO/NAPHTHA atomization air valve closed (GLVPNM7748 to 7759)
o All scanners show no flame
o LCO/N aphtha pressure OK (PT7718) i.e. >XX Kg/cm2 g
o Augmenting air pressure OK (PT7730) i.e. 400 mmWC
o Fuel firing mode selected
o FG pressure OK (PT7702) i.e. >2.0 Kg/cm2 g
 Once above condition are satisfied, HRSG can be purged through GT exhaust flue gas

 Pressed Purge start PB from remote or from local burner control panel. A cycle time of 3
minute is initiated which indicate purge under progress. After 3 min on successful completion
of Purge, a command feedback signal of purge completed /no MFT received.

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First Burner lit up on LCO/Naphtha fuel:
 Ensure that HRSG is selected for LCO/Naphtha or combination firing mode and HRSG purge
is completed. No HRSG trip exists and HRSG healthy signal is generated as mentioned
above.

 Once above condition are satisfied, any one burner out of 12 nos is ready to be started.

 Prior to give start command to selected burner, put any one out of two LCO/Naphtha fuel
control valves (FCV7721 – 30% CV and FCV7720 – 100%) in minimum position manually

 Start any one LCO/Naphtha burner out of 12 burners by pressing start button for the burner.

 Once the start command is given to selected burner on LCO/Naphtha the below
mentioned sequence of operation execute to get the burner ON command. Sequence
of operation is:

1. Ignitor MTV open
2. Ignitor BTV open for selected burner
3. Ignitor flame comes
4. LCO/Naphtha MTV open
5. Atomizing BTV open for selected burner
6. LCO/Naphtha Selected burner BTV open
7. Main flame comes
8. Ignitor stop
 Complete cycle is open on sequence. Details of the sequence as per logic are given in details
as below:

o Pressing PB start for selected burner first result into first opening of Ignitor MTV valve.
o Ignitor MTV open feedback will command to close Ignitor Vent valve.

o Ignitor MTV open feedback signal opens selected burner Ignitor BTV valve
(GLVSOV7714 to 7732) for LCO/Naphtha system

o Within 10 sec of time elapsed, Ignitor flame need to be sense by Ignitor sensor and the
pulse of the same should be signal back to BMS for ensuring the Ignitor ON for
LCO/Naphtha fuel for selected burner

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o If the Ignitor flame wash out after 10 sec of command, Burner is declared as trip burner
o If this is very first burner in HRSG, than this further result into Ignitor MTV trip and
hence MFT thus result into all fuel MTV close and the process of purging to be started
after resetting the HRSG trip
o In case if any other burner is in ON condition, it will not result in to Ignitor MTV trip
o LCO/Naphtha Ignitor ON command for selected burner will result into the
LCO/Naphtha BTV ready command for selected burner.
o LCO/Naphtha BTV ready command for any one burner result into command to Open
LCO/Naphtha MTV (GLVPNM7733). In case of first burner startup on LCO/Naphtha,
selected burner BTV ready command will result into opening command of
LCO/Naphtha MTV.
o Open LCO/Naphtha MTV healthy feedback first result into open command for selected
burner Atomizing valve (GLVPNM7748 to 7759)
o Healthy open feedback of atomizing BTV valve result into open command to LCO/Naphtha
Selected burner BTV (GLNPNM7736 to 7747)
o Opening of selected burner LCO/NAPHTHA BTV valve along with atomizing valve will
result in to the Flame inside the furnace which is sense by IR flame scanner.
o Healthy continuous pulse as an feedback to BMS along with LCO/NAPHTHA BTV open
feedback command for selected burner result into LCO/NAPHTHA burner ON signal
which is turn generate a signal of “Any Burner in service” which help to keep active the
“No Burner trip channel command which in turn help to keep active the No MFT signal
for boiler
o Ignitor pulse will exist only of 20 sec of operation after which selected burner Ignitor
BTV valve will close which result into loss of LCO/NAPHTHA Ignitor BTV ready command
which in turn result into closing of Ignitor MTV valve close command.
o Ignitor MTV need to be taken in service during each burner lit up irrespective of fuel
selected.

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First Burner lit up on FG fuel:
 Ensure that HRSG is selected for FG or combination firing mode and HRSG purge is completed.
No HRSG trip exists and HRSG healthy signal is generated as mentioned above.

 once above condition are satisfied, any one burner out of 07 nos is ready to be started.

 Necessary condition for starting up FG burners are:
o Combination or FG firing selected
o No MFT exist
o FG pressure OK (PT7702) i.e. >2.4 Kg/cm2 g
 prior to give start command to selected burner, put any one out of two FG fuel control valves
(FCV7706 – 30% CV and FCV7705 – 100%) in minimum position manually

 Start any one FG burner out of 07 burners by pressing start button for the burner.

 Once the start command is given to selected burner on FG the below mentioned sequence of
operation execute to get the burner ON command. Sequence of operation is:

1. Ignitor MTV open
2. Ignitor BTV open for selected valve
3. Ignitor flame comes
4. FG MTV open
5. FG Selected burner BTV open
6. Main flame comes
7. Ignitor stop
 Complete cycle is open on sequence. Details of the sequence as per logic are given in details
as below:

o Pressing PB start for selected burner first result into FG Ignitor MTV open command
o Ignitor MTV open feedback will command to close Ignitor Vent valve.
o Ignitor MTV open feedback signal along with a signal of Ignitor BTV ready of selected
burner; opens selected burner Ignitor BTV valve (GLVSOV7714 to 7732) for FG system
o Within 10 sec of time elapsed, Ignitor flame need to be sense by Ignitor sensor and the
pulse of the same should be signal back to BMS for ensuring the Ignitor ON for FG fuel
for selected burner
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o If the Ignitor flame wash out after 10 sec of command, Burner is declared as trip burner
o If this is very first burner in HRSG, than this further result into Ignitor MTV trip and
hence MFT thus result into all fuel MTV close and the process of purging to be started
after resetting the HRSG trip
o In case if any other burner is in ON condition, it will not result in to Ignitor MTV trip
o FG Ignitor ON command for selected burner will result into the FG BTV ready command
for selected burner.
o FG BTV ready command for any one burner result into command to Open FG MTV
(BLVPNM7701). In case of first burner startup on FG, selected burner BTV ready
command will result into opening command of FG MTV.
o Open FG MTV command simultaneously command to close FG vent valve

(BLVPNM7704)
o Open FG MTV healthy feedback first result into open command for selected burner FG
BTV (BLVPNM7705 to 7711)
o If any of the above case is not healthy will not command to FG BTV for selected burner
which result into Ignitor time elapsed activation and thus result into burner trip or even
boiler trip (if first burner)
o Opening of selected burner FG BTV valve will result in to the Flame inside the furnace
which is sense by UV flame scanner.
o Healthy continuous pulse as an feedback to BMS along with FG BTV open feedback
command for selected burner result into FG burner ON signal which is turn generate a
signal of “Any Burner in service” which help to keep active the “No Burner trip channel
command which in turn help to keep active the No MFT signal for boiler
o Ignitor pulse will exist only of 20 sec of operation after which selected burner Ignitor
BTV valve will close which result into loss of FG Ignitor BTV ready command which in
turn result into closing of Ignitor MTV valve close command.

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o Ignitor MTV need to be taken in service during each burner lit up irrespective of fuel
selected.
 This end the process of lit up of any burner of FG for HRSG
Scavenging Process:
 Scavenging of burner is done in following condition

only: o Burner running on LCO/NAPHTHA as fuel

o Burner is manually stopped

 in case if burner trip occurred, scavenging to be done manually through local control panel or
through MMI before restarting. Until scavenging is not done, burner cannot be restarted
either on LCO/NAPHTHA or FG fuel

 In case of FG firing no scavenging is envisage

 during scavenging process, Ignitor system is again activate to burn the scavenge fuel. The
logical operation of scavenging are as follow:

o Pressed selected burner running on LCO/NAPHTHA fuel stop command PB. Command
will exist for next 75 sec within which the process of scavenging to be complete. The
cycle for scavenging took 60 sec for completion.

o Sequence of step are:

1. Closing of Selected burner BTV valve
2. Opening of scavenging valve (GLVPNM7760 to 7771) for selected burner.
3. Closing of scavenging valve (GLVPNM7760 to 7771) for selected burner after 60

sec of operation.
4. Closing of atomizing BTV for selected burner after another 15 sec
o Once the above cycle is completed the burner is declared as scavenged and ready to
next start up. In case on trip burner, scavenging process to be manually done from local
control panel
Commissioning after Burner startup:
 Once the Burner are taken in service, Open start up vent MOVs to vent out the steam from
header and SH zone
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 Close Superheater all drains when drum pressure reaches to 5-10 Kg/cm2 g

 Increase the load on Boiler by taking more burner in service

 Once the Boiler load is above the 30% MCR condition, start up control drives in AUTO mode:
o Feed regulating CVs
o FD fan IGV
o FG and LCO/NAPHTHA fuel FCV
 Select the mode of operation for loading the boiler i.e. either pressure control mode or load
control mode once the boiler crosses the 30% MCR condition

 Increase the load on boiler for Safety valve floating. Check the SV floating in front of IBR
Inspector

 Mark the set point of opening and closing pressure value on safety valve for future reference

 reduce the boiler load and open start up vent MOVs to vent out the steam

 Open first MSSV bypass MOV to heat up the downstream VHP header. Ensure that drains of
VHP header are in open condition

 Heat the VHP header up to 400 deg C and a pressure of say 35-40 Kg/cm2 g by crack closing
the VHP header drain valve

  Open MSSV MOV of boiler to charge VHP header
 Close start up vent MOVs

 Boiler is declared as commissioned and can be operated based on requirements
6.2.8. COMMISSIONING OF STEAM HEADERS AND PRDS SYSTEM

Once the UB and HRSG are ready for continuous steam supply, very next step before diverting steam
for STG and BPTG are to commissioning the steam header inside CPP unit. Commissioning of steam
header include the process of steam blowing. Refer in detail the process of steam blowing 5.13.3. The
same process is to be adopted for the entire steam header inside as well as outside the CPP B/L.

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Special care to be taken in steam blowing operation especially during blowing of steam header which
is used for steam generating drives like Steam turbines and Auxiliary steam driven turbo drives.
6.2.9. COMMISSIONING AND START UP OF STG

 All Format IV activities like Steam blowing of piping, Vacuum checking and leak testing,
Condenser Inspection and cleaning, Lube oil flushing, Turbine Alignment and fixing, etc are
complete for the STG and Format IV is approved

 PSSR done for STG and all the A and B category points are liquidated

 All Utilities associated for STG like; Cooling water system, PA/IA system, Blow down system,
Fire hydrant system, Service and potable water system, OWS system, etc are available or
connected for the continuous usage at Boiler B/L



 Equipments like fans, etc. are free of Maintenance, lined up properly and in operation.

above.




 STG is ready in all aspect and ready to intake steam for start up

 STG servo valve are check, calibrated and put in DCS controlled. DCS controller is ON and STG
can be run from DCS HMI

 STG electrical system like Generator and its protection, Transformer and 33 KV GIS system are
ready along with ECS and SCAP for synchronization of STG

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STARTING SEQUENCE:
Lube Oil system readiness and start up
 The very first activities in starting up the STG is to start the Lube oil system

 Aux LOP (MD) is started after ensuring that sufficient Oil level is maintained inside Main oil
tank (MOT)

 filled the entire header including Governing and control ckt along with Overhead tank

 Make up the required level in MOT by pouring additional Lube oil into system

 Circulate the lube oil and check the return lube oil flow from flow glass to ensure sufficient
flow of Lube oil.

 maintained the flow and pressure of lube oil at each point as per requirement by adjusting
the needle valve or using fixed orifice.

 Ensure that there is no oil spillage or leakage from bearing or any other joints from the system

 Check the interlock by simulating the system through DCS

 Once the ALOP is running and normal Lube oil pressure is received, Jacking oil pump can be
started

 JOP is normally used during barring operation of STG. JOP is normally take its suction from
ALOP pump discharge header after filters

 Ensure that JOP develop pressure as required

 Healthily ON command of JOP is start permissive of STG barring motor

 Start STG barring motor and put STG in barring mode.

 Charge ACW to lube oil cooler once temperature of Lube start increasing beyond 60 ⁰C in

MOT

 Ensure that the Lube oil temperature after cooler should be in the range of 40 – 45 ⁰C

 Start Lube oil centrifuge system along with MOT vapor extraction fan so that the tank will
remain in vacuum and all fumes coming due to heated lube oil is extracted out by fans

 Ensure no ∆P across the Lube oil filter

 also ensure that Emergency Lube oil pump (EOP) is available with battery back up

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 Reset the turbine Trip SOV from HMI to allow Control oil enter the control circuit
Cooling Water system commissioning and start up:
 Next step after lube oil starting is charging of Main CW to Condenser and Generator cooler

 Ensure that Cooling tower is ready and filled with treated raw water, CW pump is ready, CT
Fan and CT piping are ready

 Ensure that the CW return is connected back to cooling tower sump and CW dozing systems
are in place.

 Start any 1 out of 2 cooling water pump by putting its discharge valve in closed condition and
check out the readiness of CW Pump

 Open slowly the discharge valve to filled the CW U/G piping

 Open selected STG CW inlet and outlet isolation valve of Condenser to charge CW to STG

 Ensure that return is connected back to CW system

 Also ensure that CW parameter are maintain by dozing necessary chemical at regular interval
based on the same taken during each day for lab inspection

 also ensure that CT blowdown is routed back to RWTP
Condenser filling with DM water and commissioning of Condensate header to Deaerator
 during first startup of STG, it is must to fill the condenser with fresh DM water make up. DM is
tapped off from DM supply header to fill the condenser and same is used as seal water for
vacuum ckt valves

 filled the required level of Hotwell of STG

 Start any one out of two Condensate Extraction pump (CEPs) and put the recirculation as well
as STG condensate main Control valve in AUTO mode to ensure that the Hotwell level is
maintained

 Regulate the flow of Hotwell to Condensate storage tank (CST) by putting the Hotwell level
controller in AUTO mode and thus diverting excess DM to CST

 keep running the circuit till the necessary quantity of steam start condensing in STG after STG
Rolling

 Ensure that STG condensate to CST is header is ready by ensuring that CEP discharge is route
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Through Steam Ejector and Gland steam condenser coolers system

Aux. Steam charging and vacuum pulling
 Aux steam is required in STG for vacuum pulling through steam Ejector and for gland sealing
during rolling and initial turbine loading.

 Charge HP/MP PRDS for Aux steam charging for given STG by opening the isolation valve of
PRDS station

 Ensure that Aux steam is open to the required STG only and same PRDS is used for all 3 STG in

CPP

 First charge the Aux steam to Hogger ejector of by opening the Inlet steam line to Ejector.
Hogger Ejector vent is open to atmosphere

 Open the isolation valve of Air line coming from condenser to Hogger ejector. This will start
pulling air and non-condensable gases from condenser and thus creating a vacuum inside
condenser

 Hogger ejector can pulled vacuum up to 0.65 bar (a), beyond which the vacuum pulling will be
accomplished using main ejector system

 Prior to taking main ejector into system, charge the Aux steam for Gland sealing through
Gland sealing ejector

 Ensure that Gland sealing ejector drain are connected to drain collecting tank which in turn
connected to CST tank through drain transfer pumps

 On level high in Gland condenser collection tank, the pump will start in AUTO mode to pump
the condensate to CST.

 Maintain the Gland steam pressure through PCV. Normal pressure of Gland sealing is 0.1 -0.2
Kg/cm2 g

 Once gland sealing is started, another 0.05 to 0.1 bar a pressure in vacuum is achieved.
Beyond which the vacuum need to pulled through main steam ejector

 Each STG is provide with 2 X 100 steam ejector out of which each ejector set is provided with
primary and secondary ejector arrangement

 Aux steam is charge first into primary ejector. Each ejector is provided with Ejector condenser
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which is used to condense the Steam and gases from condenser using CEP discharge
condensate
 Open isolation valve in Air line from condenser to start pulling air and condensable gases
from STG condenser.

 A connection from Primary ejector condenser is given to secondary ejector as inlet of air
system which is further vented to atmosphere after condensing into secondary ejector
condenser.

 Once both ejector are in service, the maximum vacuum can be pulled in 0.99 bar a

 Normally the acceptable range of good vacuum pulling is 0.96 to 0.98 bar a

 Once the above vacuum is pulled stopped Hogger ejector by first closing air line isolation valve
and then the steam supply header isolation valve
Steam Charging, STG rolling and FSNL:
 Once the vacuum is pulled, steam can now be charge inside STG. For that, first heat the
Supply header line of main steam line to STG

 Open main range valve bypass isolation valve MOV to start heating the main steam line

 Ensure the flow of steam through main steam supply header to STG by opening the necessary
drain valve in supply header.

 Open warm up line MOV (before inlet of ESV) to have sufficient flow of steam for heating

 Once the header temperature reaches above 400 ⁰C, open the main range valve and filled the
steam in complete header

 Warm up MOV will remain in open state and vent the steam from main header

 Reset the Governor and put the governor in AUTO mode. Select the mode of start up from HMI
i.e. Cold, Hot or Warm. Any one mode can be selected at a time. Selection of mode is purely
depends upon the duration of stoppage and Turbine temperature. If duration is ≤20 it is said to
be hot startup, if duration of stoppage is ≤40 and ≥250 hrs it is said to be warm startup and if
duration is ≥250 hrs it is said to be cold start up.

 All three start up curves are empirically define in governor and based on Operator selection
mode the turbine governor will ramped the STG as per curve path.
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 Pressed Start button on DCS HMI or from TCP, so that the governor will start opening the ESV
and thus start the turning rolling.

 Once ESV open thus steam will come into turbine chest. Heat the turbine chest for pre-
describe time i.e. Cold start up – 20 min, Warm start up – 14 min and Hot start up – 6 min

 Once the turbine chest is heated, open the Main CV through governor which allows the main
steam to enter into Turbine. During start up Normal extraction CV remains in Open condition,
so all steam is allowed to condense into condenser. Thus steam coming to condenser will work
on turbine blade thus result into turbine rolling at certain rpm.

 At prescribe speed, Barring will be automatically latch out and turbine start rolling at higher
speed

 The governor will follow the Turbine start up curve and mode of selection of start i.e. Cold,
Warm or Hot as selected by operator.

 The duration to for turbine to reach FSNL depends upon the mode of selection for STG for start
up. If hot start up – 16 min is required for turbine to reach FSNL, In warm up mode – 30 min
and in cold mode – 100 min.

 Main Control valve opening will be accordingly regulating the flow of steam to turbine through
governor.

 At FSNL, i.e. 95% of rated speed, the governor will stop ramping the STG speed. Further 5%
increase in speed is done through manual intervention by opening the CV through HMI by
giving new set point to governor controller

 STG is now in the state of FSNL (full speed no load condition)

 Check the vibration and Temperature level of Turbine, Load gear and Generator. All should be
in acceptable range.

 Close the warm up MOV and kept open the header drains
STG synchronization and Loading:
 Check the healthiness of Generator, Transformer and 33 KV GIS grid side. Ensure that Line
circuit breaker for STG are in open condition

 Ensure that AVR is commissioned and check and all protection and interlock are checked
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 Synchronized the STG either at 33 KV level or directly through grid i.e. at 220 KV level. If STG
synchronized at 33 KV level refinery load frequency is equal to STG frequency and if STG
synchronized with grid than grid frequency is equal to STG frequency.

 Once system frequency, Voltage and PF is matching with the STG generated frequency, Close
the circuit breaker and immediately load the STG to minimum loading of 5 MW to avoid
reverse powering

 STG is now said synchronized
STG extraction pulling:
 After certain load on STG as prescribe in loading curve of STG, STG is required to load before
taking any extraction from STG.

 Ensure that QC NRV is in open condition by energizing the SOVs

 Keep open the HP and MP extraction header MOV

 To have the Steam extraction, it is always to be ensure that the downstream header pressure
is always less than the set point given to HP or MP Governor. So reduce down the downstream
header pressure by regulating PRDS set point and once the header pressure is less than the
STG extraction pressure, a flow in established from STG to extraction header

 HP and MP extraction pressure transmitter are used to control the opening on HP and MP CV
along with speed controller in cascade mode.

 In normal operation at fixed load set point to STG, HP and MP extraction pressure gives the set
point to HP and MP CV governor for opening and closing.

 Kept the STG in droop mode with 4% max droop selection if STG is running in Synchronized
mode
PG test of STG and OST test of STG:
 Increase the load on STG up to maximum loading i.e. 35 MW,

 Reduce the load on STG and take maximum HP and MP extraction respectively

 Take the STG load up to Performance guaranteed stage with HP and MP extraction opening as
per performance guaranteed condition. Take out the reading and note it for future reference.

 Run the STG for next 4 hours in same mode and sign off the final closure of contract
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 Reduce load to minimum 5 MW and take out the extraction


 Open circuit breaker and keep turbine of FSNL.

 Now manually increase the speed on STG by opening the main control valve.

 Take the turbine very slowly upto 1.1% of rated speed i.e. 6930 rpm which is trip set point for
over speed tripping. Over speed tripping will be activated at this point. Note the value of exact
tripping and if deviation is higher than 1% adjust the setting and repeat the process

 OST can be also done before PG testing.

 STG in now declared commissioned
6.2.10. COMMISSIONING AND START UP OF BPTG

 All Format IV activities like Steam blowing of piping, Vacuum checking and leak testing,
Condenser Inspection and cleaning, Lube oil flushing, Turbine Alignment and fixing, etc are
complete for the BPTG and Format IV is approved

 PSSR done for BPTG and all the A and B category points are liquidated

 All Utilities associated for BPTG like; PA/IA system, Blow down system, Fire hydrant system,
Service and potable water system, OWS system, etc are available or connected for the
continuous usage at Boiler B/L




above.




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 BPTG is ready in all aspect and ready to intake steam for start up

 BPTG servo valve are check, calibrated and put in DCS controlled. DCS controller is ON and
BPTG can be run from DCS HMI

 BPTG electrical system like Generator and its protection, Transformer and 33 KV GIS system
are ready along with ECS and SCAP for synchronization of BPTG
STARTING SEQUENCE:
Lube Oil system readiness and start up
 The very first activities in starting up the BPTG is to start the Lube oil system

 Aux LOP (MD) is started after ensuring that sufficient Oil level is maintained inside Main oil
tank (MOT)

 Filled the entire header including Governing and control ckt along with Overhead tank

 Make up the required level in MOT by pouring additional Lube oil into system

 Circulate the lube oil and check the return lube oil flow from flow glass to ensure sufficient
flow of Lube oil.

 Maintained the flow and pressure of lube oil at each point as per requirement by adjusting
the needle valve or using fixed orifice.

 Ensure that there is no oil spillage or leakage from bearing or any other joints from the system

 Check the interlock by simulating the system through DCS

 Once the ALOP is running and normal Lube oil pressure is received, Jacking oil pump can be
started

 JOP is normally used during barring operation of BPTG. JOP is normally take its suction from
ALOP pump discharge header after filters

 Ensure that JOP develop pressure as required

 Healthily ON command of JOP is start permissive of BPTG barring motor

 Start BPTG barring motor and put BPTG in barring mode.

 Charge ACW to Lube oil cooler once temperature of Lube start increasing beyond 60 ⁰C in
MOT
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 Ensure that the Lube oil temperature after cooler should be in the range of 40 – 45 ⁰C

 Start Lube oil centrifuge system along with MOT vapour extraction fan so that the tank will
remain in vacuum and all fumes coming due to heated lube oil is extracted out by fans

 Ensure no ∆P across the Lube oil filter

 Also ensure that Emergency Lube oil pump (EOP) is available with battery back up

 Reset the turbine Trip SOV from HMI to allow Control oil enter the control circuit
Aux. Steam charging and gland sealing
 Aux steam is required in BPTG gland sealing only

 Charge HP/MP PRDS for Aux steam charging for given BPTG by opening the isolation valve of
PRDS station

 Ensure that Aux steam is open to the required BPTG only and same PRDS is used for all 3
BPTG in CPP

 Ensure that Gland sealing ejector drain are connected to drain collecting tank which in turn
connected to CST tank through drain transfer pumps

 On level high in Gland condenser collection tank, the pump will start in AUTO mode to pump
the condensate to CST.

 Maintain the Gland steam pressure through PCV. Normal pressure of Gland sealing is 0.1 -0.2
Kg/cm2 g
Steam Charging, BPTG rolling and FSNL:
 Once the vacuum is pulled, steam can now be charge inside BPTG. For that, first heat the
Supply header line of main steam line to BPTG

 Open main range valve bypass isolation valve MOV to start heating the main steam line

 Ensure the flow of steam through main steam supply header to BPTG by opening the
necessary drain valve in supply header.

 Open warm up line MOV (before inlet of ESV) to have sufficient flow of steam for heating

 Once the header temperature reaches above 400 ⁰C, open the main range valve and filled the
steam in complete header

 Warm up MOV will remain in open state and vent the steam from main header

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 Reset the Governor and put the governor in AUTO mode. Select the mode of start up from HMI
i.e. Cold, Hot or Warm. Any one mode can be selected at a time. Selection of mode is purely
depends upon the duration of stoppage and Turbine temperature. If duration is ≤20 it is said
to be hot startup, if duration of stoppage is ≤40 and ≥250 hrs it is said to be warm startup and
if duration is ≥250 hrs it is said to be cold start up.

 All three start up curves are empirically define in governor and based on Operator selection
mode the turbine governor will ramped the BPTG as per curve path.

 Ensure the back pressure i.e. exhaust pressure system is also line up before taking steam.
Kept open QC NRV by energizing SOV and kept open LP exhaust MOV

 Pressed Start button on DCS HMI or from TCP, so that the governor will start opening the ESV
and thus start the turning rolling

 Once ESV open thus steam will come into turbine chest. Heat the turbine chest for pre-
describe time i.e. Cold startup – 25 min, Warm startup – 15 min and Hot start up – 7 min

 Once the turbine chest is heated, open the Main CV through governor which allows the main
steam to enter into Turbine.

 At prescribe speed, Barring will be automatically latch out and turbine start rolling at higher
speed

 The governor will follow the Turbine start up curve and mode of selection of start i.e. Cold,
Warm or Hot as selected by operator.

 The duration to for turbine to reach FSNL depends upon the mode of selection for BPTG for
start up. If hot start up – 16 min is required for turbine to reach FSNL, In warm up mode – 40
min and in cold mode – 120 min.

 Main Control valve opening will be accordingly regulating the flow of steam to turbine through
governor.

 At FSNL, i.e. 95% of rated speed, the governor will stop ramping the BPTG speed. Further 5%
increase in speed is done through manual intervention by opening the CV through HMI by
giving new set point to governor controller

 BPTG is now in the state of FSNL (full speed no load condition)
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 Check the vibration and Temperature level of Turbine, Load gear and Generator. All should be
in acceptable range.

 Close the warm up MOV and kept open the header drains
BPTG synchronization and Loading:
 Check the healthiness of Generator, Transformer and 33 KV GIS grid side. Ensure that Line
circuit breaker for BPTG are in open condition

 Ensure that AVR is commissioned and check and all protection and interlock are checked

 synchronized the BPTG either at 33 KV level or directly through grid i.e. at 220 KV level. If BPTG
synchronized at 33 KV level refinery load frequency is equal to BPTG frequency and if BPTG
synchronized with grid than grid frequency is equal to BPTG frequency.

 once system frequency, Voltage and PF is matching with the BPTG generated frequency, Close
the circuit breaker and immediately load the BPTG to minimum loading of 5 MW to avoid
reverse powering

 BPTG is now said synchronized

 BPTG governing control is through back pressure header pressure. LP header pressure
regulates the Main control valve opening thus floating the load on BPTG.

 Governor of BPTG received LP header pressure signal which will regulate the position of CV.

 BPTG will always operate on back pressure mode and load on BPTG varies base on the steam
inlet flow.
PG test of BPTG and OST test of BPTG:
 Increase the load on BPTG up to maximum loading i.e. 32 MW,

 Run the BPTG for next 4 hours in same mode and sign off the final closure of contract

 Reduce load to minimum 5 MW and take out the extraction

 Open circuit breaker and keep turbine of FSNL.

 Now manually increase the speed on BPTG by opening the main control valve.

 Take the turbine very slowly up to 1.1% of rated speed i.e. 5500 rpm which is trip set point for
over speed tripping. Over speed tripping will be activated at this point. Note the value of exact
tripping and if deviation is higher than 1% adjust the setting and repeat the process
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 OST can be also done before PG testing.


 BPTG in now declared commissioned

Revision 02
Captive Power Plant Operating Manual Next Review 30-Dec-2022
9112-575-OPR-701-00002 Page 1 of 9
CHAPTER – 7
NORMAL SHUT DOWN PROCEDURE
Shut down of captive power plant involves various steps as we are not only supplying power to entire
refinery complex but also supplying steam at various levels (HP/MP/LP) & HP-BFW for various refinery
units. Therefore stopping of CPP involves good planning and complete coordination with other part of
refinery; accordingly refinery reduce the load of individual units and step wise CPP will stop individual
equipment along with associated utilities. This can be done in such a synchronize manner so that none
of the refinery units should face any difficulty with respect to power & steam as well. As per normal
operation philosophy of CPP following units are in operation:
 GAS TURBINE (2Nos)

 Heat recovery steam generation (2Nos)

 STG # 1 & 2

 BPTG

 Utility boiler (4Nos)
 CFBC
POWER GENERATION:
 GAS TURBINES (2Nos.) : 69.0 MW (34.5*2)

 STG # 1(DOUBLE EXT/COND) : 33.15 MW (35.0 MW max)
 STG # 2(DOUBLE EXT/COND) : 33.15 MW (35.0 MW max)
 BPTG : 30.10 MW (32.0 MW max)
 TOTAL POWER GENERATION : 165.4 MW
 TOTAL POWER CONSUMPTION : 153.6 MW (Including CPP)

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 CPP INTERNAL CONSUMPTION : 12.0 MW (Aprrox)

 POWER AVAILABLE TO REFINERY: 142.0 MW (Aprrox)
STEAM GENERATION:
 To meet refinery steam demand CPP have following configuration:
 HRSG (2Nos.) : 220 T/ hr (VHP) (110*2)
 UTILITY BOILER : 904 T/ hr (VHP) (226*4)
 CFBC : 600T/hr(VHP) (300*2)
TOTAL STEAM GENRATION : 1724 T/ hr (VHP)
TOTAL STEAM CONSUMPTION (CPP):
 VHP STEAM CONSUMPTION : 898 T/ hr

 HP STEAM CONSUMPTION : 108 T/ hr
 MP STEAM CONSUMPTION : 16.0 T/ hr
 LP STEAM CONSUMPTION : 150 T/ hr
STEAM AVAILABLE TO REFINERY:

 HP-STEAM : 219 T/ hr

 MP-STEAM : 387 T/ hr
 LP-STEAM : 96.0 T/ hr
 VHP-BFW : 253 T/ hr
Stopping of any of the unit of captive power plant leads to either power and steam shortage as well.
Therefore any shut down must be planned properly in close coordination with other refinery units.
As per planned schedule refinery will release load and same manner stopping of CPP units can be
done. Before stopping any of power or steam generating unit one thing must be kept as prime
importance that in any case refinery should not face any problem regarding power or steam
limitations for their normal shut down procedures.

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We here will discuss the basic step of stopping the major steam and power generating equipments of
CPP. Sequence of stopping of major equipment purely depends upon the steam and power
requirement of Refinery at a given movement of time and also based on the availability of Fuel and
DM water for CPP operation. Sequence will be purely judgmental and based on requirement of
refinery and availability of CPP equipments at a given instance. Stopping of various major steam and
power generating equipments of captive power plant can be done as per their standard procedures as
mentioned below
1. STG (Double Extraction/condensing) shutdown:
Shut down of any one STG will result into power loss as well as HP & MP level steam extraction loss.
Power loss: 35 MW, HP Steam loss: 158 t/hr & MP Steam loss: 164 t/hr
 Adjust the load on Boiler to meet the amount of steam required in this case

 Ensure PRDS VHP-HP (10-PV-1113A or B) & HP-MP (10-PV-1205A or B) & VHP-MP (10-
PV-1321A or B) operates to maintain normal HP & MP level of steam demand as
extractions from STG not available.

 before start the unloading of STG (575-MT-00-001 or 2) confirm that FE/FS are available
in field near local control panel

 From ECS select “Droop” mode of operation for turbine planned for shut down.

 Confirm in ECS power generator load controller in “AUTO”.

 slowly reduce MP & HP extraction and finally close extraction.

 Start unloading of STG, once load reach up to 10% of rated (3.4 MW) select “LOCAL” at
SCAP, press circuit breaker control switch to “OPEN”, confirm from ECS.

 Reduce the turbine speed up to 1200 rpm from control panel.

 Trip the turbine & ensure speed drop to zero on control panel.

 When the turbine rotor speed reaches zero indicated at turbine control panel confirm
turning device has started on auto and turbine is rotating at 8-15 rev/min.

 Isolate VHP steam line to STG; close fully 01-GTV-1102/1102A, 01-GTV-MOV-1103.

 Open TTV condensate drains.
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 Close vacuum ejector (575-EJ-01-021) vapor supply isolation valve.


 Close hogging ejector (575-EJ-01-001) vapor supply isolation valve.

 Isolate MP steam line to vacuum ejectors.

 Put condenser level controller (LCV-1601A) in Manual mode. Stop condensate extraction
pump (575-PM-01-001A/B) and isolate the pump.

 Isolate turbine sealing steam and gland steam condenser system.

0
 When turbine bearing metal temperature reaches below 60 c stop turbine turning device.

 Put AOP/EOP hand switch on manual & then stop main oil pump.

 Instruct E/M to isolate 575-MT-00-001 generator breaker rack out and apply LOTO.

 Also ensure isolation of electrical supply to following equipments and apply LOTO.

 Auxiliary oil pump motor(575-01-P-402)

 Emergency oil pump motor (575-01-P-403)

 Jack oil pump motor & turning device motor

 Condensate extraction pumps motor

 Lube oil heater.

 STG is now ready for maintenance. Hand over the equipment to maintenance with valid
work permit after the required isolation is carried out.




2. BPTG shutdown:
Tripping of BPTG will result in loss of Power as well as disturbance in LP steam level.
Power loss: 32 MW, LP Steam loss: 194 TPH
 Adjust the load on Boiler to meet the amount of steam required in this case

 Ensure PRDS VHP-HP, HP-MP, & MP-LP operates to maintain normal HP & MP & LP level
of steam demand as exhaust from BPTG is not available.

 Before start the unloading of BPTG (575-MT-00-003) confirm that FE/FS are available in
field near local control panel

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 From ECS select “Droop” mode of operation for turbine planned for shut down.

 Confirm in ECS power generator load controller in “AUTO”.

 Start unloading of BPTG, once load reach up to 10% of rated (3.2 MW) select “LOCAL” at

 Reduce the turbine speed up to 1200 rpm from control panel.

 Trip the turbine & ensure speed drop to zero on control panel.

 When the turbine rotor speed reaches zero indicated at turbine control panel confirm
turning device has started on auto and turbine is rotating at 8-15 rev/min.

 Isolate VHP steam line to STG; close fully 03-GTV-MOV-1103/1103A,

 Open TTV condensate drains.

 Isolate turbine sealing steam and gland steam condenser system.

0
 When turbine bearing metal temperature reaches below 60 c stop turbine turning device.

 Put AOP/EOP hand switch on manual & then stop main oil pump.

 Instruct E/M to isolate 575-MT-00-001 generator breaker rack out and apply LOTO.

 Also ensure isolation of electrical supply to following equipments and apply LOTO.

 Auxiliary oil pump motor(575-03-P-402)

 Emergency oil pump motor (575-03-P-403)

 Jack oil pump motor & turning device motor

 Lube oil heater.

 STG is now ready for maintenance. Hand over the equipment to maintenance with valid
work permit after the required isolation is carried out.




3. Utility boiler shutdown:
Shut down of one UB will lead to a loss of 240 TPH of MCR steam generation, however no shedding of
steam in any unit is required as shortfall of the steam is taken care by power shedding. Steps to be
taken during shut down of utility boiler as follows:

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 Once Boiler is decided to stop for any reasons, first ensure that Boiler is taken out of
Master pressure control mode, keep running in load control mode.

 Start reducing the load by reducing the Load control set point for Boiler & Increase the
load on another two running UB to take to MCR condition

 Repeat the process till the Boiler load reduces up to 30% of MCR. Below this value it is not
recommended to run the boiler in AUTO control mode

 After 30 % of boiler load reduction take out the boiler from load control mode of
operation to Manual mode of operation

 For taking out the boiler from AUTO control mode, first put boiler fuel controller for
running fuels in manual mode, by selecting the control valve for HSD/LCO fuel supply CV
(FCV-8907A) & Fuel gas control valves (FCV-8803A/B) and putting it to manual mode.

 Then take FD fan air controller into Manual mode by selecting the controlling element
(i.e. FD fan IGV, 575-06-FCV-8669A) and putting to manual.

 Once Air and Fuel is out into manual mode, Boiler load demand is said to be out of service
and boiler is said to be in Manual mode of operation.

 Keep reducing the steam demand of Boiler by cutting down the burners from the boiler
running on Naphtha/LCO and FG respectively.

 Boiler Operation need to keep on ensuring that reduction of boiler load should not impact
the steam and power demand of refinery from CPP

 Decrease in steam load will leads to Boiler drum level controller element to go from 3
element control to single element control on reduction of steam load to <30% of MCR of
boiler

 Ensure that the drum level in boiler is remain in AUTO operation even working in single
element control.

 Open start up vent valve MOVs (GLV-MOV-8762 and RGV-MOV8763) to vent the below
rated steam to atmosphere without putting into the VHP header.

 Close the Main steam stop valve (MSSV, GTV-MOV-8764) of the boiler to ensure the
positive isolation of Boiler from VHP header.

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 After stopping last burner of boiler, TSP dozing stopped.


 Keep running the FD fan for at least 10 minutes to purge out boiler with minimum air flow
of 30% of MCR.

 Stop other boiler auxiliaries like scanner fan & allow natural cooling to occur through
Chimney draft.

 Ensure the feed water supply to maintain drum level.

2
 Open all air vents of boiler at 2.5Kg/Cm pressure to avoid any chances of vacuum
formation and failure of pressure parts on shrinking / Implosion.

 After cooling down of furnace Positive isolate the Fuel supply header of Boiler from the
main header and closed all the main isolation valve of fuel to boiler before giving boiler for
Maintenance.




4. Gas Turbine shutdown:
Shut down of one GT will lead to a power loss of 34.5 MW and also a loss of 110 TPH of steam
generation from HRSG. GT tripping means HRSG forced tripping. Steps to be taken are:
 Stop supplementary firing for HRSG and Shut down the HRSG and keep GT to run in open
cycle mode of operation. Line up GT exhaust to bypass stack, close DD towards HRSG.

 Ramp up the running HRSG/UB, load to 100% to overcome some deficit of steam
demand. Rest will be taken care by tripping of ISBL units

 From ECS select “Droop” mode of operation for GTG planned for shut down.

 Start unloading of GTG, once load reach up to 10% of rated (3.4 MW) select “LOCAL” at

 Once generator breaker opens FSNL will be displayed on GTG panel.

 Give stop command from mark-6 panel.

 After 95% speed of machine ensures starting of AOP/AHOP.

 Once speed display reaches to zero Ratcheting will start automatically.

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0
 Ensure shaft movement 47 after each 3 minutes.

 AOP will run till complete cool down cycle.

0
 Ratcheting can be stopped once wheel space temperature comes down below 100 c.




5. HRSG shutdown:
Shut down of HRSG will result into GT open cycle mode operation. This will not result into power
shortage but definitely a shortfall of 110 TPH of steam in CPP. Step to taken are:
 Once HRSG is decided to stop for any reasons, first ensure that HRSG is taken out of
Master pressure control mode, keep running in load control mode. Increase the load on
running HRSG/UB to MCR condition

 Reduce the load in step of 2.5% per minute for load down to 50% MCR. Reduce
supplementary firing accordingly.

 After 50 % of boiler load reduction take out the boiler from load control mode of
operation to Manual mode of operation

 For that first put boiler fuel controller for running fuels in manual mode, by selecting the
control valve for Naphtha/LCO fuel supply FCV (04-GLV-PNM-7734/7735) & Fuel gas
control valves (04-FCV-PNM-7702/7703) and putting it to manual mode.

 Keep reducing the steam demand of Boiler by cutting down the burners from the HRSG
running on HSD/LCO or FG respectively.

 Reduce the load gradually below 50% MCR, 10% per minute with one minute hold up time
for every 10% load reduction.

 Do not start closing of diverter damper towards HRSG until supplementary firing is fully
shut down.

 Decrease in steam load will leads to HRSG drum level controller element to go from 3
element control to single element control on reduction of steam load to <30% of MCR .

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 Ensure that the drum level in HRSG is remain in AUTO operation even working in single
element control.

 Open start up vent valve MOVs (MS-028 & MS-029) to vent the below rated steam to
atmosphere without putting into the VHP header.

 Close the Main steam stop valve (MSSV, MS-036) of the boiler to ensure the positive
isolation of Boiler from VHP header.

 After stopping supplementary firing slowly operate diverter damper towards bypass stack
which intern closing Gas turbine exhaust towards HRSG.

 After complete closing of diverter damper towards HRSG & line up towards bypass
exhaust stop TSP dozing, close start up vent.

 Isolate MUH system to avoid cold end corrosion in stack

 Ensure minimum BFW flow to HRSG drum to avoid starvation of tubes by maintaining
drum level through the FRS 30% CV.

 Do not stop seal air fan & scanner fan & allow natural cooling to occur through Chimney
draft.

2
 Open all air vents of boiler at 2.5Kg/Cm pressure to avoid any chances of vacuum
formation and failure of pressure parts on shrinking / Implosion.

 After cooling down of furnace Positive isolate the Fuel supply header of HRSG from the
main header and closed all the main isolation valve of fuel to boiler before giving boiler for
Maintenance.

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CHAPTER – 08
EMERGENCY SHUTDOWN PROCEDURE
When the safe routing operation is interrupted emergency procedures are sometimes required to
overcome the potential hazards. If continuation of unit operations on limited basis is impractical the
unit must be shut down as safely as possible.
The emergency procedures attempt to overcome the hazard of a quick shut down. Emergency can
result from equipment failure and from interruption of utilities. Certain features have been designed
into the plant to minimize the likelihood of emergencies. These includes spare pumps, exchangers
etc. Operators should be thoroughly familiar with emergency procedures and understand the reasons
for each work. Good judgment must be exercised as no written procedure can completely cover all
details or problems that can arise in an emergency. Judgment is more likely to be exact if prior
thought and planning have been made. As during emergency there is no time, emergency procedure
must be learnt beforehand.
Various Emergencies and the steps to be taken during various emergencies are given in details as
below. Emergencies are broadly classified into two main categories:
 Emergency within CPP due to equipment or process problem

 Emergency from Utilities
Each of the above mentioned category consist in details further level of Emergencies as describe
below
8.1. EMERGENCY WITHIN CPP DUE TO EQUIPMENT / PROCESS PROBLEM:

8.1.1 STG trip/failure/shutdown

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Tripping of any one STG will result into power loss as well as HP and MP level steam extraction loss.
PSEB power of 35 MW is capable to take care of single STG trip. Step to be taken are:
 Importing Power from PSEB without activating LSS (until Frequency of system remain healthy)

 If frequency drops, LSS to activated

 Reduce the load on Boiler equal to the amount of steam condensing during STG running

 Ensure PRDS operates before loading STG # 2 to meet the demand of refinery of HP/MP steam.

 Ensure PSEB take all load without overloading the CPP m/c. However the limiter to be fixed
for importing the power from PSEB to avoid crossing Maximum Demand condition (MD).

 Check the reasons for STG tripping before restarting the turbine

 Stop CEP of tripped STG if problem is acute

 Ensure MOP/ALOP in operation and STG taken on barring

 Reduce CW pump flow by opening through CT Riser valve to avoid high inlet pressure in
running STG condenser

 Restart the STG once fault rectified
8.1.2 BPTG trip/failure/shutdown

Tripping of BPTG will result in loss of Power as well as disturbance in LP steam level. PSEB power of
35 MW is capable to take care of power loss due to BPTG trip. Step to be taken are:
 Importing Power from PSEB without activating LSS (until Frequency of system remain healthy)

 Ensure PRDS operates to take care of LP header pressure fluctuation

 Ensure PSEB take all load without overloading the CPP m/c. However the limiter to be fixed
for importing the power from PSEB to avoid crossing Maximum Demand condition (MD).

 Check the fault, removed it before re-starting the BPTG
8.1.3 UB tripped / Failure/ shutdown
Tripping of one UB will lead to a loss of 240 TPH of MCR steam generation, this may result into steam
based load shedding by STG at CPP level and thus the power shedding at refinery level. However no
shedding of steam in any unit is required as shortfall of the steam is taken care by power shedding.

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Here even though PSEB is available or not, steam based power shedding is required at CPP level to
reduce down the STG load to matching the Refinery steam demand. Shortfall in power to taken care
by PSEB (if available, other LSS) and steam shortfall is taken care by steam base power shedding of
STG in CPP only. Steps to be taken during such emergency are
 Load on STG to throw to predetermined level keeping extraction at predetermined level

 Power shedding to be immediately taken care by PSEB power

 PRDS to be quickly operated to ensure the HP/MP/LP header pressure and thus VPH header
pressure due to Boiler trip and thus STG reduce load

 Increase the load on another running UB’s to take to MCR condition,

 Stop FD fan after 10-15 min of operation and ensuring that no fuel exist inside tripped UB.
This is done to avoid faster cooling of furnace and simultaneously avoid low air inside furnace
after tripping to avoid firing

 Ensure scanner fan is running

 Ensure all trip valve of fuel is closed and Burner retract back to normal position

 Ensure minimum drum level (>30%) to avoid starvation of boiler tubes during tripping boiler
by taking FRS control in manual operation

 Open drain of SH header (if trip period is greater than 30 mins). If trip is lesser than the
period mentioned or the pressure inside boiler is >7-10 Kg/cm2 g, restart the boiler

 Check all the faults level and rectify the problem before re-starting

 Inform to SS for the event and ask refinery unit to reduce down the steam load as much as
possibility can to avoid loss in header pressure

 Give priority to VHP steam header pressure inside CPP

 Stop UB LCO pump and put in to ACO mode of operation
8.1.4 GT tripped/failure/shutdown
Tripping of one GT will lead to a power loss of 34.5 MW and also a loss of 110 TPH of steam
generation from HRSG. GT tripping means HRSG forced tripping. Power loss of 34.5 MW can be back
up with PSEB. Steam loss to be ramped up by UB loading and steam shedding at ISBL units like DHDT

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and VGO HT tripping. Steps to be taken are:

 PSEB to take the load (if available)

 PSEB if not available, LSS to be activated

 Steam shedding at ISBL unit like VGO HT and DHDT to cater the need of shortfall steam
demand

 Ramp up the UB running load to 100% to overcome some deficit of steam demand. Rest will
be taken care by tripping of ISBL units

 Ensure operation of PRDS to avoid fluctuation of Steam header to refinery

 Check the problem inside GT, rectify and reset the trip GT before re-starting

 Ensure the FG header pressure doesn’t fluctuate more and flare is not disturbed too much.

 Ensure minimum HRSG drum level to avoid starvation in tubes

 Ensure all MFT trip exists for HRSG burner.

 Stop augmenting air fan, but do not stop seal air and scanner air fan for tripped HRSG

 Restart the GT in open cycle mode

 After loading GT, take HRSG into service after following proper startup sequence
8.1.5 HRSG tripped/failure/shutdown
Tripping HRSG only will result into GT open cycle mode operation. This will not result into power
shortage but definitely a shortfall of 110 TPH of steam in CPP. This result into steam based power
shedding at CPP. No steam shedding at Refinery level is envisaged. Steam based Power shedding at
CPP will result into power shedding at refinery level. Step to taken are:
 Ensure GT operate at full load in open cycle mode

 Ensure minimum BFW flow to HRSG drum to avoid starvation of tubes by manually opening
the FRS 30% CV to minimum position

 Ensure no Fuel in Boiler burners and MFT SOV are in closed position

 Isolate MUH system to avoid cold end corrosion in stack

 Shed the power at STG level by shedding steam supply to STG

 Increase the load on running UB to MCR condition

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 Shed the load inside refinery due to steam based power shedding at CPP if PSEB is not
available otherwise extract addition power from PSEB as per requirements.

 Check the faults, rectify and reset the boiler before re-starting.
8.1.6 DCS failure / BMS failure
DCS/ BMS failure result into the failure of control system inside CPP. As there are total 15 DPU for
BOP, 5 DPU for STG controller, 4 DPU for GT mark VI control along with separate BMS system,
chances of failure of complete DCS is very rare. In case if any one DPU fails, each panel is provided
with redundant DPU backup which automatically taken into service. The changeover of DPU is bump
less. Step to be taken are:
 Ensure DPU trip through proper checking of annunciation at DCS level

 Ensure that redundant DPU take over the system

 Check the complete association system related of failure DPU panel

 Check all the controller associated with failed DPU panel and ensure working normal. Check
by taking controller in manual and again putting in to AUTO

 Check console monitor system healthiness

 If failure is more predominant, stop the Boiler, STG , BPTG and GTGs through their local PB /
Emergency push button

 Inform to Shift SS immediately, along with concerned Instrument Engineer for rectification

 Never open panel back end until unless power work permit is given or necessary emergency
approval taken for the same from HOD.

 In case on BMS failure, check the system which gets impacted by failure. In BMS the
controller is off TMR type so the redundant module should take care of failure.
8.1.7 SWGR failure
Switch gear system failure can be at 33 KV GIS panel, 6.6 KV HT panels or at 415 V LT panels, the
consequence depends upon the level of failure at what mode.
8.1.7.1. 33 KV GIS failure

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Failure of 33 KV GIS will result into complete Refinery power distribution network failure which will
result into complete refinery shut down and power blackout. Even after availability of CPP power
generating source, the Power will not be able to distribute to refinery as well as CPP internal due to
unavailability of 33 KBV GIS system. Chance of failure of complete 33 KV GIS is very less as the
complete system is design as ring header type with bus coupler and ICT provision to isolate the faulty
bus from main bus and thus avoid the failure of 33 KV GIS. Steps to be taken are:
 Trip all STG, BPTG and GT

 Trip all UB and HRSG

 Start Black start DG set, power the CPP using the Emergency Bus bar (10HV201)

 Check the problem, rectified, reset and start the 33 KV power distribution either from PSEB
power or from GT power after starting GT
8.1.7.2. 6.6 KV HT SWGR panel failure
6.6 KV HT switch gear is used to supply HT power to CPP internal drives as well as provide power
supply to LT distribution transformer and thus the LT panels. Failure of HT system will result into
tripping of HT drives inside CPP which result into part or complete tripping of CPP major equipments
except GTGs. However GT will trip due to unavailability of ACW for cooling. Black start DG set can also
be not started as failure is at 6.6 KV level. However the 6.6 KV bus bar is divided into three bus with
appropriate bus couplers. Chances of failure of all at a time is very less.
8.1.7.3. 415 V LT SWGR panel failure
415 V LT switch gear is used to supply LT power to CPP internal drives as well as provide power AC
UPS system for DCS. Failure of LT system will result into tripping of LT drives inside CPP which result
into part or complete tripping of CPP major equipments. Black start DG set also cannot be started as
failure is at 415 V level. However the 415 V bus bar is divided into 6 PMCC which is further divided
into equipment specific MCC with appropriate bus couplers. Chances of failure of all PMCC at a time
is very less.

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8.1.8 HSD/LCO/Naphtha tankages failure
Failure of HSD/LCO/Naphtha tankages will result into reduction in bulk storage capacity of CPP liquid
fuel. HSD being not a continuous usage fuel and HSD is only used during GT start up or during fuel
change over time in GTGs, the maximum consumption of GT is 24 m3/hr and a tank having capacity of
200 m3, the survival time is 8 hours of operation.
In case of LCO, failure of one LCO tank will result in reduction of storage time by one day. One tank is
capable to deliver the full load operation LCO i.e. 97 m3/hr of LCO for 22 hours of day operation.
Beyond which the plant need to be tripped. This is considering when no FG/Naphtha is available as an
alternative fuel for firing in CPP. If FG is available, the duration of backup will increase from 22 hours
depending the load taken on FG firing. Provision of FG firing is available in all equipments and all
equipment can run at MCR condition with FG as well as LCO fuel.
In case of failure of Naphtha tank, nothing much will be affected because Naphtha is used as a
substitute of LCO/FG. When no FG/LCO is available as an alternative fuel for firing in CPP, Run GTGs in
HSD and take burner in HRSG/UB in Naphtha.
8.1.9 Deaerator nozzle failure
Single Deaerator of holding capacity of 420 m3 of Feed water at normal level is available at CPP. The
holding period provide the back up of 20 min to operate the CPP at full load, after which the BFW will
trip result into complete CPP trip.
Also the spray nozzle is common in Deaerator. Failure/damage of nozzle, poor Deaeration will result
and thus increase the chance of higher oxygen content inside BFW which hamper tube life. Shutting
down of Deaerator will result into complete CPP stoppage.
8.1.10 Power Blackout
Power blackout occur when all 6 source of power generating units i.e. 5 CPP generator and 1 PSEB
grid power is not available. This result into complete refinery blackout condition. Step to be taken
during the situation are:
 Ensure that one survive UB keep running at full load operation for safe refinery shutdown

 All TD units like, UB FD fan, UB LCO TD, ACW TD, BFP DT unit cater the need of only one
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running boiler
 Ensure that the HP/MP/LP steam header pressure inside CPP is maintain to avoid tripping of
running TD units

 Ensure steam is available at refinery unit at required pressure.

 Communicate to SS for steam shedding in refinery units and maintain header pressure

 Ensure start of BSDG set on power failure sensing

 Start the GT through supplying BSDG power and starting diesel engine

 Start FRP cooling tower to supply ACW water to GT

 Ensure PA / IA availability from refinery. Normally IA pressure should go to <3.5 Kg/cm2 g after
20-25 min of operation after blackout. However Emergency IA back up is available inside CPP
to cater the IA need of CPP only.

 Start GT and synchronized with 33 KV grid to supply power to CPP aux as well to critical
drives in refinery
There are other Emergency like failure of both STG, failure of GT and STG simultaneously, failure of all
3 UBs, failure of STG and BPTG, failure of both GT, etc. All this cases are details studied in finalizing
the LSS. Refer the LSS final document for detail. However the level of emergency at equipment level is
same as mentioned above for individual equipment failure.
8.2. Emergency from Utilities

8.2.1. DM water unavailability
DM water to CPP is coming from RO/DM unit of refinery. The capacity of DM supply to CPP is limited
to size of DM supply header of 18” (1000 TPH – Max.). Failure of DM transfer to CPP will result into
CPP tripping with 20 minute of operation at full load due to Deaerator feed storage tank empty out.
However the back up of approximately 650 TPH of refinery condensate from RO/DM unit is also
available. Step to be taken are:
 Ensure Deaerator level set point to be increase to ensure accommodation of make-up water
to maximum level (80%) of Deaerator

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 Ensure that CST tank level is normal and condensate make up fill the tank at full capacity.

 Check the rate at which the refinery condensate filled the CST tank and rate at which the
steam is generated and BFW is sent to refinery. At full load operation of CPP and at full load
incoming condensate rate, CPP can successfully survive for 1 hour of operation.

 Inform the SS and Utility team to provide DM to CPP.

 Inform Utility FS to divert maximum allowable Condensate to CPP through condensate header

 Inform SS to reduce down the steam and BFW rate in refinery (if possible)

 Start providing DM through any other source with a shortest possible time
8.2.2. P A /IA unavailability
PA/IA to CPP is coming from IA unit of refinery. The capacity of IA supply to CPP is limited to size of IA
supply header of 2” (571 Nm3/hr – Max.). Failure of IA to CPP will result into complete CPP tripping.
However the back up of Emergency IA system is available at CPP end having a capacity of 451 Nm3/hr
IA generation which is sufficient to cater the need of CPP operation. Step to be taken are:
 Ensure the Emergency IA system is always in ready to start mode of operation and IA receiver
is filled at 30 Kg/cm2 g to cater the need of IA inside CPP for max 30 min if Emergency IA does
not start.

 Ensure that Emergency IA start and cater CPP demand
8.2.3. N it r o g e n Unavailability
Nitrogen to CPP is coming from Nitrogen unit of refinery. The capacity of IA supply to CPP is limited to
size of Nitrogen supply header of 4” (1000 Nm3/hr – Max.). Failure of nitrogen to CPP will not directly
result into tripping of Gas Turbine if running on FG. However if HP nitrogen system is not available for
longer duration of time, the GT running on FG is required to tripped due to low HP nitrogen header
pressure to GTG. As HP nitrogen system take input from refinery Nitrogen, and as GTG running of FG
continuously consume HP nitrogen, prolong failure of nitrogen back up will result into forced tripping
of GT running on FG. Also if any GT to be started or taken on load using FG required a larger content
of FG for purging which again increase the consumption rate of HP nitrogen

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and ultimately will result into forced tripping of GT.
Also UB and HRSG burner running on FG required FG as a purging source during burner stoppage.
Also nitrogen pressure is a start permissive for FG firing in any unit. Low pressure will not allow the
unit to fired on FG. Steps to be taken are:
 Ensure that HP Nitrogen system is always in ready to start mode of operation and the
receivers are filled at 42 Kg/cm2 g to cater the need of HP nitrogen for GT operation.

 Ensure that nitrogen is always available at required pressure for purging in burner.
8.2.4. HSD/LCO/Naphtha fuel unavailability
Unavailability of HSD and LCO and Naphtha will not impact too much if the duration is less than 12 to
24 hours of operation. Prolong unavailability will result into forced outage of power and steam
generating equipment at CPP. However all equipment inside CPP are design for dual fuel operation at
MCR condition. So backup of FG as fuel is always available in case of prolong outage of
HSD/LCO/Naphtha fuel from refinery. However FG pressure is of critical importance and one need to
ensure that FG header pressure at CPP B/L is maintained.

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CHAPTER – 9
NORMAL OPERATION OF THE UNIT
9.1 INTRODUCTION
After the unit has been started up and lined out, the focus shifts to reaching and maintaining a state
of optimum operation. This state of optimum operation can be achieved by establishing a few general
operating rules and being aware of potential problems which can occur. First, a means of judging
performance must be defined.
Secondly, a list of operating variables is established. Using these operating variables, an approach to
Operating the unit is outlined with respect to the performance indicators. This procedure establishes
a logical method for operating the plant, increasing yields and ensuring longer operating cycles.
9.2 SUMMARY OF OPERATING CONDITION

Conditions of Plant during normal steady state operation are as below:
 Utility Boiler # 1 Load – 226 TPH @ 107.5 Kg/cm2 g and 508 :C



 Utility Boiler # 4 Load – Under hot standby

 GT # 1 - 34.5 MW @ ambient condition

 GT # 2 – 34.5 MW @ ambient condition

 HRSG # 1 Load – 110 TPH @ 108.5 Kg/cm2 g and 508 :C

 HRSG # 2 Load – 110 TPH @ 108.5 Kg/cm2 g and 508 :C

 STG # 1 – 33.15 MW Load with 158.4 TPH of HP steam extraction and 164.7 TPH of MP steam
extraction

 STG # 2 – 33.15 MW Load with 158.4 TPH of HP steam extraction and 164.7 TPH of MP steam
extraction

 BPTG – 30.1 MW with 194.5 TPH of LP steam exhaust

 All Turbo drive unit are in operation

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9.3 CONTROL PHILOSOPHY

Control Philosophy of the plant is divided basically into Major Equipment and Utilities as describe in
details as below:
9.3.1. DM Water system and Make up and Condensate Transfer system to Deaerator:
DM water enters the Condensate collecting tank (575-CST-00-001) as makeup water for Boilers. Flow
Orifice (10-FE1702) is used to measure the flow of DM water to CST. Rate at which the DM water
enters to CPP depends upon the Level controller installed on CST tank. The Level transmitter (10-
LT1701) controls the DM water inlet to CPP through Level Control valve (10-LV1701). There are
condensate supply headers coming from Refinery to Condensate storage tank. The Condensates
coming from refinery are:
 Pure Condensate

 Surface Condensate

 Condensate from Process
Each above mentioned condensate header from Refinery complex coming to condensate storage tank
is provided with Motorized Operated valve (MOV). The logic behind putting the MOV is to close the
MOV on level high of condensate storage tank. Level transmitter (10-LT1701) is used to command the
MOV for closing on level high.
Other inputs to Condensate storage tank are:
1. STG # 1 and 2 Hotwell condensate return
2. BPTG GSC drain transfer through pumps (575-P-CF-006A/B)
3. BFPDT GSC drain transfer through Pumps (575-P-CF-010A/B)
Transfer pumps mentioned above for transferring Condensate from BPTG and BFPDT drain tank
having common Interlocks and controller as below are:
a. Pump Selection for Auto Change over (ACO) and A/M mode of Operation
b. Running Pump tripping on BPTG GSC drain collection tank (575-3-T-EE-401) level Low Low (10-
LT1706)
c. Running Pump tripping on BFPDT drain collection tank (575-3-T-EE-402) level Low Low (10-
LT1746)

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d. BPTG pump Discharge common header pressure low (10-PT1708) to auto-start of standby
pump.
e. BFPDT Pump Discharge common header pressure low (10-PT1749) to change over the Pump and
trip the running pump after time delay
Two separate systems for transferring the condensate to Deaerator (575-DEA-00-001) are available.
1. Condensate through Condensate Transfer Pumps (TD-CTP, 575-P-CF-004A/B, 3 X 100%) and
LP heater (575-LPH-00-001)
2. Condensate through MUH transfer pumps (575-P-CF-003A/B, 2 X 100%) and HRSG # 1 and 2
MUH modules Both system of condensate transfer is provided with common Interlock and
controllers for Pumps. All 04 pumps inlet is provide with Manual Operated gate valve (10-
GTV1729/1730/1768/1769) with Open Limit switch (10-ZSH1729/1730/1768/1769). Healthiness of
the Limit switch is the start permissive for all respective pumps. Along with this start permissive one
additional start permissive for pumps is the CST tank Level not Low (10-LT1702). Also
Other Interlocks and controller of the Pumps are:
b. Running Pump tripping on CST tank level Low Low (10-LT1702)
c. Discharge common header pressure low (10-PT1731/1719) to auto-start of standby pump.
LP heater drain tank condensate is transfer through LP heater drain transfer pumps (575-P-CF-
005A/B). The rate at which the condensate transfer by LP heater drain transfer pumps is being
regulated by Level control valve (10-LV1710) which is kept in discharge of transfer pumps common
header to Deaerator and the level of the drain tank is maintained accordingly. Other Interlocks and
controller of the Pumps are:
b. Running Pump tripping on LP heater drain collecting tank level Low Low (10-LT1710)
c. Discharge common header pressure low (10-PT1743) to auto-start of standby pump.
d. Start permissive of Pumps on suction header manual operated gate valve open limit switch
(10-ZSH1797/1798)
LP steam flow to Deaerator is control through Pressure control valve (10-PV1407) which maintains
the Deaerator Pressure at 2.37 Kg/cm2 a. LP steam from LP steam supply header to Deaerator is
tapped off for initial heating of Feed water storage tank during Plant start up or initial start up. The

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level in Deaerator/Feed water storage tank is normally maintained through Level transmitter (10-
LT1802) which controls the supply of Condensate transfer through condensate transfer pumps and LP
heater using level control valve (10-LV1802).
Other logics which maintain the Feed water storage tank Level are as below:
1. 2oo3 logic of Level transmitter (10-LT1801A/B and 10-LT1802) to command feed water
storage tank Overflow MOV (10-LV1801) to open on level above 50mm high level.
2. 2oo3 logic of Level transmitter (10-LT1801A/B and 10-LT1802) to command feed water
storage tank Overflow MOV (10-LV1801) to close on level below 50mm high level.
3. 2oo3 logic of Level transmitter (10-LT1801A/B and 10-LT1802) to command LP steam supply
header MOV (10-GTV-MOV1441) to close on level High High.
4. 2oo3 logic of Level transmitter (10-LT1801A/B and 10-LT1802) to command all Boiler Feed
Pumps (09 nos.) to trip on level Low Low
DM water used for CFBC Deaerator is given from tapping of discharge line of CTP after LP Heater.
DM water used for GT AA Cooler flow rate is control through Level transmitter (10-LT4825/4858)
installed on surge tank which in turn command the ON/OFF SOV (10-UV4887A/4888A) installed in
DM water supply header to surge tank. The DM forwarding pumps (02 nos., 2 X 100%, 575-P-00-
578B/579B/580B/581B) are installed to pumped the DM water from sludge tank to AA Pre-cooler.
Thus DM water keeps circulating in closed cycle.
DM forwarding Pumps Interlock and Control are:
b. Running Pump tripping on DM surge tank level Low Low (10-LT4825/4858)
c. Auto-start of standby pump of Pump on common discharge header pressure low (10-
PT4830/4862)
The control of entire DM water and Condensate system as mentioned above is a part of DCS
controller system. Refer P&IDs: 1-381-01-03148-S01 and 1-381-01-03146-S01
9.3.2 Feed water from Deaerator to Individual Boiler Drum including Export BFW system:
Feed water stored in Feed water storage tank is common for entire CPP. Separate header are
provided to supply feed water to HRSG Feed water pumps (575-P-CF-007A/B/C) and UB feed water
pumps (575-P-CF-008A/B/C/D) along with Export feed water pumps (575-P-CF-009A/B) which

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transfer feed water to Refinery complex. Refer P&IDs: 1-381-01-03149-

S01/02/03 9.3.2.1 Feed water to Utility Boilers
Feed water from Deaerator is supplied to UB Feed water pumps (BFP, 04 nos., 3W + 1S) through
Common supply header. Supply header for each UB BFP is provided with the Hand Operated Gate
valve with Open Limit switch (10-ZSH18131/18145/18159/18173). This will act as a start permissive
for Pump. Healthiness of the limit switch will allowed the Operator to start the Pump. UB Feed Pumps
Interlock and Control are:
d. Pump Selection for Auto Change over (ACO) and A/M mode of Operation
e. Running Pump tripping on Feed water storage tank level Low Low 2oo3 logic of Level
transmitter (10-LT1801A/B and 10-LT1802)
f. Discharge common header pressure low (10-PT1841) to auto-start of standby pump
On the discharge end of each UB BFPs there is Motorized valve (10-MOV18144A/18158/18172/18186)

with Integral Bypass MOV valve (10-MOV18144B/18158B/18172B/18186B) with Open and closed Limit
switches. The Logic to Operate the MOV is as below:
a. In case of MOV kept in Manual Mode, Operator has to give command to Open the MOV
b. In case of MOV in AUTO mode, during Pump start up, both MOV are in closed position and in
AUTO mode. Once the pump started, in the discharge header before discharge MOV there is Pressure
transmitter (10-PT1840A/B/C/D) which on sensing high pressure opens first the bypass integral MOV.
On getting the bypass integral MOV open feedback through Limit switch (10-
ZSO18144B/18158B/18172B/18186B) which in turn commands the Main MOV in discharge header to
Open. On getting the Open feedback of main MOV open through Limit switch (10-
ZSO18144A/18158/18172/18186), which in turn commands to Closed the Integral bypass MOV. Thus
during normal operation, Main MOV remain open and Integral bypass MOV remain in closed Position.
Similarly once the pump is stop, Operator should close the Main MOV through DCS.
FRS for each Boiler consist of 1 X 30% Feed regulating Control valve (06-FV1844C, 07-FV1845C, 08-
FV1846C, 09-FV1847C) and 2 X 100% Feed regulating control valve (06-FV1844A/B, 07-FV1845A/B, 08-
FV1846A/B, 09-FV1847A/B) in parallel. The control of command to each of 3 controlling element is

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a part of Drum level controller as discuss in 9.3.5.1 as below
In the Feed water supply header to each UB before FRS, a 2” tapping is taken for spray attemperator
system. The control part is detailed in the section 9.3.5.3. All Interlock and control related to UB Feed
water system are part of DCS controls.
9.3.2.2 Feed water to HRSG
Feed water from Deaerator is supplied to HRSG Feed water pumps (BFP, 03 nos., 2W + 1S) through
Common supply header. Supply header for each HRSG BFP is provided with the Hand Operated Gate
valve with Open Limit switch (10-ZSH1839/1854/1868). This will act as a start permissive for Pump.
Healthiness of the limit switch will allowed the Operator to start the Pump. HRSG Feed Pumps
b. Running Pump tripping on Feed water storage tank level Low Low 2oo3 logic of Level
c. Discharge common header pressure low (10-PT1813) to auto-start of standby pump
On the discharge end of each UB BFPs there is Motorized valve (10-MOV1853A/1867A/1881A) with
Integral Bypass MOV valve (10- MOV1853B/1867B/1881B) with Open and closed Limit switches. The
Logic to Operate the MOV is as below:
On getting the bypass integral MOV open feedback through Limit switch (10-ZSO1853B/1867B/1881B)
which in turn commands the Main MOV in discharge header to Open. On getting the Open feedback
of main MOV open through Limit switch (10-ZSO1853A/1867A/1881A), which in turn commands to
closed the Integral bypass MOV. Thus during normal operation, Main MOV remain open and Integral
bypass MOV remain in closed Position. Similarly once the pump is stop, Operator should close the
Main MOV through DCS.
FRS for each Boiler consist of 1 X 30% Feed regulating Control valve (04/05-FV1816C) and 2 X 100%

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Feed regulating control valve (04-FV1816A/B, 05-FV1816A/B) in parallel. The control of command to
each of 3 controlling element is a part of Drum level controller as discuss in 9.3.6.1
In the Feed water supply header to each UB before FRS, a 2” tapping is taken for spray attemperator
system. The control part is detailed in the section 9.3.6.3. All Interlock and control related to UB Feed
9.3.2.3 Feed water to Refinery
Feed water from Deaerator is supplied to Export Feed water pumps (02 nos., 1W + 1S) through
Common supply header. Supply header for each Export BFP is provided with the Hand Operated Gate
valve with Open Limit switch (10-ZSH18271/18286). This will act as a start permissive for Pump.
Healthiness of the limit switch will allowed the Operator to start the Pump. Export Feed Pumps
b. Running Pump tripping on Feed water storage tank level Low Low 2oo3 logic of Level
c. Discharge common header pressure low (10-PT1874) to auto-start of standby pump
On the discharge end of each Export BFPs there is Motorized valve (10-MOV18285A/18299A) with
Integral Bypass MOV valve (10- MOV18285B/18299B) with Open and closed Limit switches. The Logic
to Operate the MOV is as below:
On getting the bypass integral MOV open feedback through Limit switch (10-ZSO18285A/18299A)
which in turn commands the Main MOV in discharge header to Open. On getting the Open feedback
of main MOV open through Limit switch (10-ZSO18285A/18299A), which in turn commands to closed
the Integral bypass MOV. Thus during normal operation, Main MOV remain open and Integral bypass
MOV remain in closed Position. Similarly once the pump is stop, Operator should close the Main MOV
through DCS.

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Opening of Main MOV filled the common Discharge header to Refinery. Flow Element (10-FE1861) is
provided to measure the Export Feed water to Refinery. All Interlock and control related to UB Feed
9.3.3 Off Base HSD Fuel system:
Refer P&ID no: 1-381-01-03138-S01 to S06
9.3.3.1 HSD from Refinery to HSD day tank in CPP
HSD from Refinery to CPP is received in HSD tank. HSD tanks are fitted with two no. of Level
transmitter (LT 6613/6607) along with the Radar Transmitter (LT6606). The flow of HSD from refinery
to each tank is regulated by Level control valve (LV6606) which regulate through the signal coming
from Radar transmitter. In case on Tank Level High High signal from Level transmitter (LT6607), the
Solenoid Operated valve (SOV, UV6607) in supply header to tank 502 respectively will closed.
9.3.3.2 HSD supply system to GTG
Clean HSD from HSD tank is lineup for GT firing. Dedicated HSD forwarding pump for each GT is used
to pump HSD.
HSD forwarding pumps for GTs (58-P-14C/15C/21C/22C) operating Logics are as below:
b. HSD forwarding Pump trips on Low Low tank level through Pressure transmitter
(PT6609A/B/C 2oo3 Logic)
c. Auto-start of standby HSD forwarding Pump on low common discharge header Pressure
transmitter(PT6633/6645)
d. Pressure transmitter (PT6637/6652) is a start permissive for GT on HSD. This signal is Hardwire to
Mark VI controller of GT for deciding of HSD fuel as a start up fuel or changeover fuel. Unhealthiness
of PT results into either false start or tripping of GT. 3 way valve will get the command to change over
from LCO to HSD only if the PT signal is healthy.
e. Pressure transmitter (PT6639/6653) regulates the HSD supply pressure by splitting the demand for
Main Pressure Control valve (PV6639A/6653A) and Recirculation Pressure control valve
(PV6639B/6653B). The action of both the control valve is reverse. On increase in demand, main
control valve will open and simultaneously recirculation control valve will close. However in order to
have minimum flow to recirculation header, recirculation control valve should kept locked open at

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minimum position (say – 20%). Both control valve should operate in such a matter that at all the time
the pressure at the inlet of 3 way valve should be always greater than 3.5 Kg/cm2 g
9.3.3.3 HSD Centrifuge system
Normally storage HSD tank is lineup for Centrifuge system for HSD. Operation of Centrifuge for HSD to
be done from field only. Centrifuge forwarding pumps (03 nos., 2W + 1S, 15 m3/hr, Discharge
Pressure: 15 mlc) to be start from local PLC. Discharge common header from centrifuge back to HSD
Tank . In each centrifuge discharge header there is Pressure Switch (PSL-6611/6620/6625) which
command 3 way valve SOV (SOV- 6611/6620/6625) to divert the HSD back to HSD tank as it indicate
water seal breakage.
Sludge tank transfer diaphragm pump when kept in AUTO mode will start and stop based on the Level
high and low signal from Level switch (LSH6616 and LSL6615 respectively). All Interlock and control
related to HSD fuel supply system are part of DCS controls.
9.3.4 Off Base LCO Fuel system:

Refer P&ID no: 1-381-01-03139-S01 to S012
9.3.4.1 LCO from Refinery to LCO day tank in CPP

LCO from Refinery is coming from FCCPU down run to CPP Day tank (575-T-00-509/512). LCO tanks
are used to supply LCO for GT, HRSG and UB operation. At any instant of time one out of two LCO tank
is lineup for GT while another LCO tank will be lineup for UB and HRSG Operation. LCO from Refinery
can be taken into either or both the LCO tank at a time. Capacity of each LCO tank in CPP is 2200 m3
with Floating roof type. Each LCO tank is fitted with two no. of Level transmitter (LT6704/6707 for
tank 509 and LT 6709/6711 for tank 510) along with the Radar Transmitter (LT6709/6710). The flow of
LCO from refinery to each tank is regulated by Level control valve (LV6701/6705) which regulate
through the signal coming from Radar transmitter. In case on Tank Level High High signal from Level
transmitter (LT6704/6711), the Solenoid Operated valve (SOV, UV6701/6705) in supply header to tank
509/510 respectively will closed.
9.3.4.2 LCO forwarding system for GTG
Any one LCO tank is normally lineup for GT forwarding skid Pump. All valves associated with header
line are kept open and LCO from tank get lineup through LCO common suction header for GT # 1 and

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2. LCO from common header through Suction Duplex filter (100 micron) reaches inlet to the LCO
forwarding pumps (03 nos., 2W + 1S, 01 for each GT). LCO forwarding skid for both the GTs are
common. One pump is capable to delivery 100% requirement of LCO for one GT. In the Pump
discharge header, the LCO divider is provided which divide the LCO flow to GT # 1 and 2. In each LCO
supply header after forwarding pumps contain Accumulator, Main Pressure control valve and
recirculation header Control valves, Fine duplex filters (25 micron, reusable), Fine Duplex filters (6
micron, disposable), Flow transmitter up to 3 way valve, Vanadium Inhibitor skid with connection to
supply header and Motorized Operated valve.
LCO forwarding pumps for GTs (P-502A/B/C) operating Logics are as below:
b. LCO forwarding Pump trips on Low Low tank level through Pressure transmitter
c. Auto-start of standby pump on low common discharge header Pressure transmitter (PT6721)
d. Pressure transmitter (PT6727/6743) is a start permissive for GT on LCO. This signal is Hardwire
to Mark VI controller of GT for deciding of LCO fuel as a changeover fuel. Unhealthiness of PT disables
Mark VI to changeover from HSD to LCO. 3 way valve will get the command to change over from HSD
to LCO only if the PT signal is healthy.
e. Start permissive for LCO forwarding pump is the non activation signal of vanadium inhibitor
flow (FAL-6728/6754).
f. Pressure transmitter (PT6728/6744) regulates the LCO supply pressure by splitting the
demand for Main Pressure Control valve (PV6728A/6744A) and Recirculation Pressure control valve
(PV6728B/6744B). The action of both the control valve is reverse. On increase in demand, main
control valve should open and simultaneously recirculation control valve should close. However in
order to have minimum flow to recirculation header, recirculation control valve should kept locked
open at minimum position (say – 5%) and similarly the recirculation control valve should be kept
locked closed at Maximum position (say – 20%). Both control valves should operate in such a matter
that at all the time the pressure at the inlet of 3 way valve should be always greater than 3.5 Kg/cm2
For each there is dedicated Vanadium/Naphtha Additive Inhibitor skid which includes

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metering tank (9-T-48C), Vanadium/Naphtha Additive Inhibitor forwarding Pump (02 nos., 1W+1S, P-
506A/B), Accumulator in forwarding header, Flow element (FT-6728/6754). There is one unloading
pump (9-P-49C) for unloading the Vanadium/Naphtha Additive solution into Vanadium/Naphtha
Additive inhibitor solution metering tank.
Vanadium Inhibitor forwarding pumps for each GTs (P-506A/B) operating Logics are as below:
b. Vanadium/Naphtha Additive forwarding Pump trips on Low Low tank level through Level Switch
(LSLL6724/6750) and also command to Mark VI to change over the GT from LCO to HSD
c. Auto-start of standby pump of Pump on low flow signal (FAL-6728/6754)
d. Pumps are provided with Variable frequency drive, which regulates the flow of
vanadium/Naphtha Additive solution to LCO/Naphtha header based on the actual LCO flow to
GT.
e. Refer P&ID no: 1-381-01-03138-S01 to S06
MOV (MOV-6729/6755) installed near GT inlet is operated to close on any fire signal in GT area
through Mark VI. This ensures the 100% isolation of supply fuel to GT thus avoid hazard. All control
relate to vanadium/Naphtha Additive inhibitor skid is a part of local PLC.
9.3.4.3 LCO forwarding system for HRSG
LCO forwarding pumps (03 nos., 2W + 1S, 01 for each HRSG). LCO forwarding skid for both the HRSG
are common. Each pump is capable to delivery 100% full load requirement of LCO for each HRSG.
From pump discharge common header, LCO is forward to HRSG through Accumulator and
LCO forwarding pumps for HRSGs (P-513A/B/C) operating Logics are as below:

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c. Auto-start of selected LCO forwarding pump for HRSG on low discharge header pressure
(PT6770)
d. Recirculation header control valve (PCV6771) control the Pressure in the supply header to
HRSG by passing the excess LCO flow back to tank using the Pressure transmitter signal
(PT6771). Set point for the control valve is 10.0 Kg/cm2 g
9.3.4.4 LCO forwarding system for UB
LCO forwarding pumps (03 nos., 2W + 1S, 01 for two UBs). LCO forwarding skid for common for all the
UBs. Each pump is capable to delivery 100% full load requirement of LCO for 02 nos. of UB. From
pump discharge common header, LCO is forward to UB through Accumulators (02 nos.) and
LCO forwarding pumps for UBs (P-515A/B/C) operating Logics are as below:
c. Auto-start of of selected LCO forwarding pump for UB on low discharge header pressure
(PT6774)
d. Recirculation header control valve (PCV6778/ 6778A & PCV 6778B) control the Pressure in
the supply header to UB by passing the excess LCO flow back to tank using the Pressure transmitter
signal (PT6771). Set point for the control valve is 18.0 Kg/cm2 g
9.3.4.5 HSD/LCO drain system
HSD/LCO drain system consists of following:
a. HSD/LCO drain tank for GT # 1 (575-T-00-503)
b. HSD/LCO drain tank for GT # 2 (575-T-00-504)
c. HSD/LCO drain tank for UB # 1 and 2 (575-T-00-505)
d. HSD/LCO drain tank for UB # 3 and 4 (575-T-00-506)
e. HSD/LCO drain tank near storage tank area (575-T-00-507)

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All HSD and LCO related Offbase system drains are collected into the above mentioned drain tanks.
header, which in turn divert all the drain to Refinery slope header including FG condensate drain from
CPP.
In HSD/LCO drain tank near storage tank area, all drain from 04 nos. storage tank inside CPP is
diverted. All the drains in Fuel tank area of CPP are diverted to HSD/LCO drain tank along with the
HSD and LCO forwarding skid drain for UB and HRSG. In HSD/LCO drain tank near GT # 1 and 2 area, all
drain from HSD and LCO forwarding header up to GT # 1 and 2 battery limit respectively are diverted
along with the HRSG # 1 and 2 inside B/L drain as well in respective GT # 1 and GT # 2
HSD/LCO drain tanks. In HSD/LCO drain tank for UB # 1 and 2, all drain of generated inside UB # 1 and
UB # 2 battery limit for both the fuel are diverted to the tank and similarly all drain generated inside
B/L of UB # 3 and 4 are diverted to HSD/LCO drain tank for UB # 3 and 4. From each of above HSD/LCO
drain tank in CPP, a submersible pump provide in each tank pumped the drain to CPP common slope
header and thus to Refinery Slope header.
HSD/LCO drain tank submersible Pumps (G-507A/B, G-512A/B, G-517A/B, G-518A/B, G-519A/B)
Operating Logics are as below:
b. Each HSD/LCO drain tank consist (02 nos.,1W+1S)
c. Pump start stop in AUTO and Operator has a facility of select the master and slave pump.
d. Master selected Pump start on High level signal from level transmitter
(LT6733/6758/6768/6798/6727). It remains in operation till the level inside the tank reaches to Low
level with is sense by same transmitter as mentioned above. On reaching the low level, the AUTO
started master pump stop and remain in active state for next cycle.
e. During the operation of master pump, if in any abnormal case, the pump trips than on sensing
the trip signal the slave pump started in kept in AUTO mode. It will run till level reached to Low value
as sense by same trasnmitter. On reaching the low level, the slave pump stop and now act as master
pump for next cycle operation until interface by Operator.
f. During normal operation if the level inside the tank keeps on increases even after master

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pump in operation, than after level high high the slave pump will also start. The slave pump will stop
only when level inside the tank reaches Low low value while the master pump stop on level low value
as sense by the above mentioned transmitter.
All Interlock and control related to LCO fuel supply system are part of DCS controls. Also all PSVs drain
diverted in nearby OWS header.
9.3.5 Off Base Naphtha Fuel system:
Refer P&ID no: 1-381-01-06325- 1to7 & 1-381-006326-1to5

9.3.5.1 Naphtha from Refinery to Naphtha day tank in CPP
Naphtha from Refinery to CPP is received in Naphtha tank. Naphtha tanks are fitted with two no. of
Level transmitter (LT 6603/6604) along with the Radar Transmitter (LT6605).The flow of HSD from
refinery to each tank is regulated by Level control valve (LV6605B) which regulate through the signal
coming from Radar transmitter. In case on Tank Level High High signal from Level transmitter (LT6607),
the Solenoid Operated valve (SOV, UV6604B) in supply header to tank 501 respectively will closed.
9.3.5.2 Naphtha forwarding system for GTG
Any Naphtha is normally lineup for GT forwarding skid Pump. All valves associated with header line
are kept open and Naphtha from tank get lineup through Naphtha common suction header for GT # 1
and 2. Naphtha from common header through Suction Duplex filter (100 micron) reaches inlet to the
Naphtha forwarding pumps (03 nos., 2W + 1S, 01 for each GT). Naphtha forwarding skid for both the
GTs are common. One pump is capable to delivery 100% requirement of Naphtha for one GT. In the
Pump discharge header, the Naphtha divider is provided which divide the Naphtha flow to GT # 1 and
2. In each Naphtha supply header after forwarding pumps contain Accumulator, Main Pressure
control valve, Fine duplex filters (25 micron, reusable), Fine Duplex filters (6 micron, disposable), Flow
transmitter up to 3 way valve, Vanadium/Naphtha Additive Inhibitor skid with connection to supply
header and Motorized Operated valve.
Naphtha forwarding pumps for GTs (P-9601A/B/C) operating Logics are as
below:
b. Naphtha forwarding Pump trips on Low Low tank level through Pressure transmitter
c. Auto-start of standby pump on low common discharge header Pressure transmitter (PT9614)

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d. Pressure transmitter (PT6727/6743) is a start permissive for GT on Naphtha. This signal is

Hardwire to Mark VI controller of GT for deciding of Naphtha fuel as a changeover fuel. Unhealthiness
of PT disables Mark VI to changeover from HSD to Naphtha. 3 way valve will get the command to
change over from HSD to Naphtha only if the PT signal is healthy.
e. Start permissive for Naphtha forwarding pump is the non activation signal of
vanadium/Naphtha Additive inhibitor flow (FAL-6728/6754).
f. pressure transmitter (PT6728/6744) regulates the Naphtha supply pressure by splitting the
demand for Main Pressure Control valve (PV6728C/6744C) through recirculation line. Main
control valves should operate in such a matter that at all the time the pressure at the inlet of 3
way valve should be always greater than 3.8 Kg/cm2
For each there is dedicated Vanadium/Naphtha Additive Inhibitor skid which includes
metering tank (9-T-48C), Vanadium/Naphtha Additive Inhibitor forwarding Pump (02 nos., 1W+1S, P-
506A/B), Accumulator in forwarding header, Flow element (FT-6728/6754). There is one unloading
pump (9-P-49C) for unloading the Vanadium/Naphtha Additive solution into Vanadium/Naphtha
Additive inhibitor solution metering tank.
Vanadium Inhibitor forwarding pumps for each GTs (P-506A/B) operating Logics are as below:
b. Vanadium/Naphtha Additive forwarding Pump trips on Low Low tank level through Level Switch
(LSLL6724/6750) and also command to Mark VI to change over the GT from Naphtha to HSD
c. Auto-start of standby pump of Pump on low flow signal (FAL-6728/6754)
d. Pumps are provided with Variable frequency drive, which regulates the flow of
vanadium/Naphtha Additive solution to LCO/Naphtha header based on the actual Naphtha flow
to GT.
e. Refer P&ID no: 1-381-01-03138-S01 to S06 MOV (MOV-6729/6755) installed near GT inlet is
operated to close on any fire signal in GT area through Mark VI. This ensures the 100% isolation of
supply fuel to GT thus avoid hazard. All control relate to vanadium/Naphtha Additive inhibitor skid is a
part of local PLC.
9.3.5.3 Naphtha forwarding system for HRSG/UB
Naphtha tank is normally lineup for HRSG/UB forwarding skid Pump. All valves associated with
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header line are kept open and Naphtha from tank get lineup through Naphtha common suction
header for HRSG/UB. Naphtha from common header through Suction Duplex filter (100 micron)
reaches inlet to the Naphtha forwarding pumps (03 nos., 2W + 1S, 01 for HRSG/UB). Naphtha
forwarding skid for the HRSG/UB are common. From pump discharge common header, Naphtha is
forward to HRSG/UB through Accumulator and Main Control valve, recirculation header, individual
isolation valve at control station for HRSG & UB Naphtha Header.
Naphtha forwarding pumps for UBs/HRSGs (P-9701/2/3) operating Logics are as below:
b. Naphtha forwarding Pump trips on Low Low tank level through Pressure transmitter (PT-
9619-A/B/C 2oo3 Logic)
c. Auto-start of selected Naphtha forwarding pump for UB/HRSGs on low discharge header
pressure (PAL9711)
d. Main control valve (PV-9714) control the Pressure in the supply header to UB/HRSGs .Set point
for the control valve is 17.0/12.0 Kg/cm2 g for UB/HRSGs respectively.
9.3.5.4 Off base Naphtha drain system
Naphtha drain system consists of following:
All Naphtha related Offbase system drains are collected into the above mentioned drain tanks.
header, which in turn divert all the drain to Refinery slope header including FG condensate drain
from CPP. Also all the flares collected from each drain tank are diverted to Refinery Flare Header.
9.3.5 UB and its DCS and BMS Controllers
Each UB for CPP are design to operate at MCR condition of 240 TPH, 107.5 Kg/cm2g @ 508 :C and
Feed water temperature at 125.6 :C. The same UB can operate a peak demand of 265 TPH with same

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steam and Feed water parameter. Each UB consist of 08 nos. of low NOx Burners which are mounted
on Front wall for UB. UB for CPP can be designated as water cooled, Natural circulation type, Forced
draft, Bottom support, Bi-drum type Boilers. Normally LCO is used as a Main Fuel for Firing and
RFG/Naphtha can be used at a secondary fuel. All Burners of UB are capable to fire both the fuels but
only one fuel at a time in each Burner. However the boiler is design and control to fire both the fuel at
a time but in different set of burners. BMS (Burner Management system) is provided to Safe guard the
boiler from Fuel related Hazards and ensure that if any abnormality occurs which impact the Boiler
Operation; BMS will safety Turn off the Boiler operation. It is must as per NFPA requirements.
Controls of each UB are divided into two separate control system namely DCS and BMS. BMS will take
care for safety related issues of Boiler while DCS controller system is used to control and operate the
Boiler normal Operations. Few of the common control system related to Boilers are mentioned below
with the control system controlling the same are also mentioned:
b. Combustion Air and Fuel (both Fuels) controller – DCS based
c. Steam Temperature controller – DCS based
d. Master header Pressure controller – DCS
e. Air heater controls – DCS
f. Boiler Auxiliary system control – DCS/PLC
g. Burner Management system control and safety – BMS
Each UB is having associated Auxiliaries and integral system to support the normal Boiler Operations.
Refer P&ID no. 0-00-047-47817, 2-97-288-90441, 1-00-056-10442, 1-00-056-10443.
UB integral system consists of:
a. Steam and water drums
b. Water wall Tubes
c. Superheater (Primary and Secondary)
d. Economizer
e. CBD/IBD vessel

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f. Burners
g. Steam and Water sampling station and SWAS system
h. Spray attemperator for SHs
i. Steam Drum mounted safety valves (02 nos.) and SH header mounted safety valve (01 nos.)
j. Drain headers
k. Start up vent and Main steam stop valve (MSSV)
a. FD fan with IGV

b. Air and Flue gas ducts
c. Scanner air fans
d. Regenerative type of Air Preheater (RAPH)
e. Steam condensate type Air preheater (SCAPH)
f. Soot Blowers
g. Stack / Chimney
h. Fuel supply mounted skids
i. HP dozing skid
The Feedwater Pumped by Boiler Feed water pumps enter the steam drum through Feed regulating
(06-FV1844C, 07-FV1845C, 08-FV1846C, 09-FV1847C) and 2 X 100% Feed regulating control valve (06-
FV1844A/B, 07-FV1845A/B, 08-FV1846A/B, 09-FV1847A/B) in parallel. The controls of this CV are in
steam drum level controllers which regulate the flow of feed water to steam drum. The feed water
from the steam drum enter to water wall tubes and Evaporator tubes through Natural Circulation
because of the density difference between feedwater and steam generated. The heat required to
convert the feedwater to steam is provided by burning of Fuel inside Furnace. The saturated steam
rises up inside the tube and gets collected back into steam drum. From steam drum the saturated
steam taken out and passes to Super heater I and II coils hanging in Furnace and convection zone
respectively of boiler from where the saturated steam pick up the heat from Flue gas and get

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converted into superheater steam. The superheated steam is collected into superheater header and
flow to Boiler Main steam stop valve to VHP common header.
UB feed water and steam chemistry is continuous monitored using online analyzer and taking regular
sample at sampling station. Each UB are assigned with feedwater, Blow down, Saturated and
Superheater steam sampling station with necessary analyzer. Samples are cooled to 25 :C using ACW
cooling water before passing to analyzer. The decision to doze HP dozing chemical (Tri Sodium
Each UB is assigned with dedicated HP dozing pumps with common metering and solution preparation
tank. Refer P&ID no. 1-38101-03198-S01. Steam drum is also provide with MOVs for CBD and IBD
For each UB, the air and Flue gas consist of FD fan (01 nos., Dual drive (steam and Motor with high
speed coupling for changeover), Dampers, Scanner fans, Wind box for Burner, Exhaust duct and stack.
FD fan installed for UB supply atmospheric air to UB for Fuel combustion. The rate of air flow is
regulated by the Inlet Guide vane (IGV) installed at inlet of FD fan which receive inputs from Air/Fuel
combustion controller. Air before entering to Wind box area is passed through SCAPH and RAPH which
increase the Air temperature at inlet of Furnace by gaining heat from Exhaust Flue gas from furnace.
Necessary dampers at inlet and bypass of RAPH and SCAPH are given to isolate the APH as a when
required depending upon the need of operation condition. Heat air get collected in wind box from
where the Air get distributed as per the opening and closing of Combustion air damper installed on
each Burner. The control of the combustion damper is regulated through BMS. It is basically an
Open/Close type of dampers. There are a set of manual operated damper called Primary and
secondary air dampers to regulate the flow and flame length and intensity for each burner. The
Damper positions are manually adjusted during commissiong and need not required frequent

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intervention during normal operation once set.
The fuel and air are mixed and ignited inside the Burner and Flue gas generated is then passes through
different heat transfer zone of furnace. The hot flue gas from furnace first passes to Primary SH and
then to Secondary superheater. After superheater the next heat transfer zone is Economizer where
feed water before entering the steam drum get heater just below the saturation temperature at the
given pressure through flue gas. Flue gas there after enters into RAPH. RAPH is regenerative type
rotary APH where Hot flue gas transfer heat to Combustion air from FD fan. After RAPH the flue gas
which will be at the temperature range of 160-140 :C enter into stack installed inside the RCC
chimney. Stack is equipped with stack monitoring devices like Sox, NOx, SPM, CO and HC analyzer
which is also one of the mandatory required of State Pollution control board (PPCB).
provision.
From SH I outlet header a tapping of 2” is taken for Soot blower (SB) Operation. Each UB consist of
total 15 nos. of SB out of which 10 nos. are LRSB type installed in Furnace and SH zone, 04 nos. are of
Rotary type installed in Economizer zone and 01 nos. is Air heated type SB installed in RAPH. The
drains of SB are diverted back to IBD vessel with Temperature control valve (TCV8749/8751) which
operates line temperature (TE8749/8751). There is another pressure control valve (PCV8744A) in the
upstream of SB supply header which regulate the SB steam supply header pressure greater than 30
Kg/cm2 g. Pressure transmitter (PT8744) is used to sense the downstream pressure of CV and thus
regulate the PCV through PID. Operate can set a set point of Pressure for SB. The block is also used
during blackout condition when activated through SB MCC command to PCV to maintain 30 Kg/cm2 g
pressure minimum.

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9.3.5.1 Steam drum Level controller
Steam drum Level is basically a DCS based controller. UB steam drum consist of 03 nos. of Level
Transmitter (06/07/08/09-LT8711/8712/8713), 02 nos. of Electronic Water level indicator switch and
Transmitter (EWLI, 06/07/08/09-LS8717 and LT8714), Local Level gauge, Pressure Gauge
(06/07/08/09-PG8707), 03 nos. of Pressure Transmitter (06/07/08/09-PT8708/8709/8710), 02 nos. of
safety valve (06/07/08/09-SV1 and SV2, set at Pressure 124 and 127 Kg/cm2 g respectively). Steam
drum level controller act as a single element controller or a three element controller which maintain
the steam drum level as preset level at all the time during all stages of Boiler operation.
Before taking steam drum level controller into action, operator need to ensure that the all 03 nos. of
Feed regulating station CV are in AUTO operation mode and at 0% opening feedback. During start up
of boiler normally, steam drum level controller is kept in single element control in which the level
inside the drum is regulated directly by opening of Feed water control valve (30%, 06-FV1844C, 07-
FV1845C, 08-FV1846C and 09-FV1847C) through PID controller. 03 nos. of Level transmitter analog
signal goes to MVAS (Mid value Average selector) block which gives a single output as a signal which
gets Pressure and Temperature compensated and thereafter in Compensation block. The Output from
compensation block gets referred with SP set by the Operator in Difference block. The error signal out
of the difference block is act as an input for single element PID controller, which command the 30% CV
to open/close based on the input error signal to PID.
In three Element controllers, the level inside the drum is maintained not only through Level
transmitters but also through the signal of Feed water flow transmitter (06/07/08/09-FE1831) and
steam flow transmitter (06/07/08/09-FT1111) as a Feedback and feed forward signal respectively for
controller. The error signal from difference block enters to 3 element PID from which the PID signal
get summed with steam flow signal (which is already pressure and temperature compensated in
compensation block) as feed forwarded. The output from the summation block is compared with the
Feed water flow signal in another PID as a feedback signal. The output of PID is send as command to
both the 100% control valve (The command can be either going to only one controlling element or

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two both control valve as split command depends up on SAT configuration. Normally both 100 %
Control valve will be remain in operation and in AUTO mode.
Switching of single element to three element control is to be done by Operator but the vice versa
operation will be done in AUTO. Permissive for switching from single to three element are feed water
and steam flow > 30% of MCR condition of UB. Refer the control scheme document no. 4-97-096-
92497 for details.
9.3.5.2 Combustion controller
The combustion control system comprises of Fuel flow control system and Air flow control system. The
combustion control system has been designed to take care of the special design requirements of multi-
fuel firing. The boiler is capable of firing 100% gas, and 100% High speed Diesel oil (HSD) or Light Cycle
Oil (LCO). These fuels can be fired independently or in combination in the boiler. Burner’s can be
started and fired either by LCO/HSD or fuel gas. Combination firing is not allowed in the individual
burners, the combustion control shall be put in Auto in the control range of 30 -100% MCR
Fuel Flow controller: In Fuel flow controller the demand signal either in the form of steam header
pressure or the boiler load depending upon the selection made by Operator, goes to Fuel ratio
computation block. In Fuel ratio computation block, the counting of burners running on FG and
HSD/LCO are done individually and both are summed together to get the total no. of burners in
operation. Now the FG ratio is calculated based on the no. of burner of FG divided total no. of Burner in
Operations. Similarly the HSD/LCO fuel ratio is calculated by dividing the no. of burner on HSD/LCO to
total no. running Burners in boiler. Now this calculated fuel ratio are multiplied with the total demand
signal. The total demand signal are not split or divided, but the total demand signal from Boiler load
controller PID after selection which are diverted to both the multiplication block. The output from the
Multiplication block for both the fuels enter the fuel control PID in which the actual flow measurement
signal from field are compared. Flow element (06/07/08/09-FT8803) is used for Fuel gas to Boilers and
Mass Flow meter (06/07/08/09-FM8907) is used for HSD/LCO fuel measurement to Boilers. The
demand signal from the Fuel control PID. In case of FG flow Pressure

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compensation is applied to the flow transmitter output, from the signal from pressure transmitter
(06/07/08/09-PT8801) with a facility to remove this from the circuit by the engineer. The Fuel flow
controller output is fed to 0-25% flow control valve and 25-100% Flow control valve operating in split
range mode. In case of FG demand, the output from FG fuel controller PID is feed to 0-25% flow control
valve (06/07/08/09-FCV8803A) & 25-100% flow control valve (06/07/08/09-FCV8803B) while in case of
HSD/LCO fuel, the output from HSD/LCO fuel controller PID is feed to Feed control valve (06/07/08/09-
FCV8907A). Refer control scheme 4-97-096-92497-S08 for details. Auto/manual selection provision is
provided for all controlling element.
There is also a provision for Operator to Operate the fuel supply control valve in pressure control
mode. This is normally done during start up of Boilers where the inlet pressure of fuel to Boilers is used
to regulate the position of CV. The Pressure transmitter (06/07/08/09-PT8908 for HSD/LCO fuel and
06/07/08/09-PT8809) for FG fuel ) in the downstream of fuel supply CV regulate the fuel rate going to
Boiler. The set point is set for by an Operator depending upon the fuel demand during start up which
ensure that the Burner flame sustained and any additional requirement of fuel can be pre - adjusted
during lit of another burner.
There is an additional Burner safety logic inbuilt to protect the Burner from Overloading. When the
differential load between burners exceeds, the condition is alarmed, for the operator to take remedial
steps. The further increase of boiler load is blocked in the Master pressure control loop, till this
condition is cleared by the operator. The burner differential load condition is computed as follows-
a. The quantity of each fuel fired is measured. The calorific flue flow is computed as be Q FG and
QHSD.
b. The heat input in each of the burner for the fuel fired is QFG/NFG and QHSD/NHSD, where NFG
and NHSD are the no. of Fuel gas and Naphtha/LCO burner ON respectively. (Contact from BMS Fuel
nozzle valves open)
c. A computation circuit calculates the differential heat loading. When the differential heat load

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between any two burners is greater than X%, alarm is generated till this condition is cleared by the
operator. This is to ensure that the all burners fire same quantum of fuel, as air distribution in all the
burners are same and in no case one burner get exceed loading as compared to other. It also help to
safe guard the burner operation running on part load as during any increase in demand, any additional
requirement of Burner should not be drive through running burner by excess loading.
The heat load in each burner is computed. When the burner heat load capacity is exceeded, alarm shall
be generated and further increase in boiler load is blocked by blocking the demand generated by Boiler
load controller till this condition is cleared by the operator.
Air Demand Controller: In case of Air demand controller, the same demand signal generated from
Boiler load controller PID is imputed to calculate the Combustion Air demand. System is design to
ensure that the Air/Flue mixture inside the Furnace should always being air rich thus ensuring safe
combustion inside the furnace. This is being done by two ways (i) with O2 steam flow controller as back
up controller and (ii) by putting manual bias in demand signal to Air flow controller PID and both
control are kept in series to ensure that if any movement of time if one control malfunction, second
control being in series rectify the demand of air and thus ensuring Air rich mixture in furnace.
The demand signal from Boiler load controller is compute with the signal of any burner “ON” on FG and
HSD/LCO separately. Both the outputs are compared and the higher value is selected to generate Air
demand signal. The generate air demand signal is enter to computed block which has input from O2
analyzer (AT8678) signal PID installed in Flue gas path after RAPH. The signal of O2 analyzer is having
the backup controller as steam flow signal. This is done to ensure that if any movement of time if O2
analyzer fails or malfunction, actual steam flow is compute to generate the air demand requirement
for complete enrich combustion. The Steam flow signal from Boiler is computed with the signal of any
burner “ON” on FG and HSD/LCO separately. Both the output are compared and the higher value is
selected which input to PID in which the actual Flue gas exhaust O2 analyzer (After RAPH) act as a
another input signal. The PID output is input to the computation block in which the generate air
demand signal also comes as another signal. The air demand output signal is also

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compared with the Min air requirement Block (min 30% MCR air demand) which is one of the interlock
for Boiler. Any demand less than 30% is locked and the signal of minimum air flow goes as demand to
Air demand controller PID. The demand signal before entering to air demand controller PID passes
through a Bias Block in which operate add or subtract the demand quantity by incorpating BIAS value.
The demand with BIAS enter to air demand controller PID where Actual air flow is the another signal to
PID. Actual air flow is measured using venture type flow meter (06/07/08/09-FT8669-1/2/3) which get
Temperature compensated using temperature transmitter signal (06/07/08/09-TE8670-1/2/3)
respectively. The flow is linearised by means of square root extractor. And after that selection is done
by Mid Value Auto Selection (MVAS). The demand signal will be applied to the FD fan pneumatically
operated inlet control vanes (IGV) which regulate airflow. IGV is provided with the facility of
auto/manual selection and operation. Position indication for FD fan A inlet control damper (ZI8669A) is
provided as feedback to DCS. The control system is also interfaced with FD fan interlocking system
implemented in DCS, for overriding controls viz. FD fan inlet control damper full open/full close.
9.3.5.3 Boiler load controller
Loading on the Boiler is done by increase in demand of steam or by fluctuation of Pressure of steam
from Boilers. Individual Boiler Loading can be control by two fundamental methodologies:
a. Load control
b. Pressure control
In Load control mode, the steam demand is the driving signal for loading the boiler. The MCR rating of
the boiler i.e. 240 TPH of steam generation is equivalent to 100% loading demand of UB. Operator set
the demand signal for the Boiler. This demand signal control the rate of Flow of Fuel and Air into
system into which generate steam. The driving parameter for the Boiler is steam flow rather than
steam pressure and steam temperature. Boiler will try to generate the demanded quantity of steam
without checking the other steam parameters. Normally if operated smoothly the other steam
parameter i.e. pressure and temperature will follow the demand signal and try to maintain the
condition as per operating condition requirements. But operator does not have any cont rol on both
the steam parameters. This control is normally used for the faster response from the Boiler. Flow

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controller being the faster PID controller as compared to Pressure and temperature controller, the
response of boiler with respect to deviation/error signal from controller is faster responded by the
boiler Auto Control logics cycle. In Steam demand controller / Load controller, the actual steam
demand signal from FE in the discharge main steam header gives an input signal which is compared
with Operator set point in the steam controller PID. The error signal generated from PID is the input to
the Fuel and Air controller demand signal / Combustion controller PIDs. Refer the details of
Combustion controller 2.2.5.2
In Pressure control mode for Boiler load controller, the steam header discharge pressure is the driving
signal which maintained and regulates the supply rate of Fuel and air to Boilers. Here the steam
pressure is given the top priority. All Boiler Auto control logic and combustion controller will be driven
by steam header pressure. The Pressure sensing point is in the Main steam header for each Boiler and
normally 2oo3 mode is used. Boiler MCR condition i.e. 107.5 Kg/cm2 g is the reference point and
equivalent to 100% steam pressure demand. Operator gives and set the set point for the boiler to
operate. The set point may be in terms of % demand or a direct pressure value. In our case it is direct
pressure value which is being set by operator. Boiler once set in pressure control mode will try to
maintain the set header pressure irrespective of steam quantity generation. Any sudden fluctuation in
demand will indirectly reduce the header pressure which in turn regulates the fuel and air flow to
furnace. The response time being slow as compared to Load controller, it is normally not
recommended to put boiler in pressure control mode for fluctuating load demand, especially for
process type industries. The actual pressure measured in Main steam header for each boiler is inputted
along with the set point and both are compared in steam pressure controller PID. The error signal
generated from PID is the input to the Fuel and Air controller demand signal / Combustion controller
PIDs. Refer the details of Combustion controller 2.2.5.2
Operator has a provision of selector switch for selecting the Boiler load control methodology.
Operator can selected each boiler control mode operation from DCS.

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The above two methodology are for the normal mode of each Boiler operation. In our case as there are
6 nos. of steam generating unit and output from each boilers are connected to common VHP header
from where the distribution of VHP steam inside CPP is done. So all 6 nos. of Boilers in CPP are said to
be in Parallel operation. In order to regulate the controls of all 6 nos. of boilers with a single demand
signal, the master pressure controller system is used. In Master pressure controller, the VHP steam
header pressure normally 2oo3 is a demand signal for all boilers loading. The 2oo3 signal from MVAS
system enters to Master pressure control PID where it is compared with demand signal set by
Operator. Normally the demand signal is the operating condition of VHP steam header (107 Kg/cm2 g).
This demand signal from Master pressure controller is calculated with the all boiler steam flow
summation block, and thereafter the demand for each Boiler is output to each boilers with a provision
block of manual Bias. The output from the Bias block is goes to A/M selector block. If the block is
selected in Auto mode, and the individual boiler is selected for load control mode than the master
pressure command is the driving command for Fuel and air flow regulation for Boiler. So before putting
the boilers in master pressure control mode, it is must that the operator put each boiler in Load control
mode and then put the control in Auto mode. Once put into Auto mode, master pressure signal with
bias will load the boiler based on the actual VHP steam header pressure. Loading of boiler will be done
based on the steam flow during selection of master pressure control. Thus this system allowed loading
the each Boiler equally. Operator has a provision to remove an individual boiler out of master pressure
controller by putting the boiler in Manual load or pressure control mode. The complete Boiler load
controller including master pressure controller are control through DCS. Refer document no. 3-381-21-
01894.
9.3.5.4 Steam Temperature Controller
The steam temperature controller is used to control the super heated steam temperature after Platen
SH (SH – I) before entering into Convection SH (SH – II). The steam temperature is controlled by
spraying the Boiler Feed water directly into the steam path. Spray water is tapped from the Boiler
feed water supply header to Boiler. The spray station is provided with a main pneumatic operated
spray control valve (06/07/08/09-TCV8732A) and Standby pneumatic operated spray control valve

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(06/07/08/09-TCV8732B). In case the main valve is taken for maintenance, the Standby valve can be
used for remote manual control of the de-superheating spray. In the automatic mode, SH spray water
valve is controlled by a cascade control. The Main steam heater temperature is measured by three
temperature sensors (06/07/08/09-TE8732/1/23) and steam temperature after de-superheater (desh)
outlet temperature is measured by three temperature sensors (06/07/08/09-TE8725/1/23). Each TE
output goes to MVAS. Under normal conditions, SH outlet temperature the primary control variable is
in the outer loop of the cascade control for each valve. SH desh outlet temperature an index of the
immediate effect of spray valve operation is in the inner loop.
The outer loop PID controller receives an error signal equal to the deviation of SH outlet temperature
set point and measured final SH outlet temperature. The SH outlet temperature set point is
programmed as function of unit steam flow or manually set. The outer loop controller establishes a
set point for the SH desh outlet temperature. To this set point, steam flow feed forward signal is
added as feed-forward control signal. This modified set point is compared to the measured de-super
heater outlet temperature and the resulting error is used to position the SH spray control valve.
Auto/manual station is provided for auto/manual selection and operation of pneumatic operated
spray control valve. Interlocks are provided to close the SH spray valves at loads less than 20% MCR.
On Boiler Trip condition, the feedwater inlet supply line SOV (09/07/08/09-GLVCBV8753) get closed.
Refer P&ID no. 0-00-047-47817
9.3.5.5 BMS Controller
BMS is called Burner Management system which protects the Boiler/Burner during emergency or
abnormal Boiler condition. It is nothing but a safety manager system which is PLC based, installed to
safe guard the Boiler and ensure smooth, quick and safe shut down of boiler due to any abnormalities
beyond the DCS control. BMS design Philosophy is Triple Modular Redundancy (TMR) based which is
the latest operated and universally acceptance Philosophy.
All UB and HRSG are provided with BMS system. All the communication to BMS from either directly
from field as analog input or through digital input from field or through DCS/ESC/SCAP is through

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hard wire contact only. Communication to BMS cannot be possible through Modbus communication.
However all signal except few critical signal from BMS can be communicated to DCS through modbus
communication channel. All Interlocks and critical signal back to field is also through Hardwire. BMS is
master control while DCS and other controller are acting as slave. All Operation related to any boiler
burners are through BMS only. Start/stop operation of Burner is through BMS.
All Logic, start permissive, safety interlocks, etc are programmed in BMS by which the Boiler burner
will operate. Any abnormality in Operation will be sense by the Instrument which acts to stop / trip
the burner immediately without any time backlog. The response time of BMS is in Milli second
because the system is design to safe guard the Assets during abnormality without human interface.
Being PLC controlled and most of signal especially for operation is configured hardwire the time cycle
for command exertion was very less. All Burner start / stop sequence is from BMS HMI while the rate
of flow of fuel are under DCS controller.
BMS is provided with DPU with Quadra redundancy. All DPU are in service but at any movement of
time only one DPU is master rest all 3 are slave. Failure of master will not lead to failure of controller
but result into bump less transfer to another DPU in fraction of second. There is no loss of DATA
during the process and Inbuilt RAM of DPU is sufficient to continuous the process without over
loading. Similar to DCS system, BMS panels are provide with Analog input and output cards and
channels, DI/DO cards and other necessary system like – Interposing relays, Barriers, Channel
communicator, Back plane controller, annunciator, etc with necessary wiring and cables. Analog
inputs/ Output are of 08 channel card while DI/DO is 16 channel card. The power source to BMS panel
is through 220 V AC supply.
9.3.5.6 Soot Blower controller
Steam supply to Soot Blower is SH steam tapping taken from SH – I steam outlet header before des-
superheating station. Steam flow to SB is regulated by Pressure regulating valve (06/07/08/09-
PRV8744A) which get signal from the downstream header mounted Pressure transmitter

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(06/07/08/09-PT8744). The actual downstream pressure is compared with set point set by operator in
PID and the error signal is position demand signal for PRV. Power black condition is interlocked from
SBMCC to soot blower pressure reducing valve and the valve is regulated for maintaining a minimum
pressure. There are two more Temperature Control valve (06/07/08/09-TCV8749 and 8751) in the
downstream drain header for AH zone and Boiler zone respectively. Control signal to both TCV are
from the Temperature element (TE849 and TE8751). On low temperature (220 :C) the TE command to
open TCV and on temperature (310 :C) the TCV are command to close. This is how the heating is done
in SB line. Refer P&ID no. 0-00-047-74817. Starts permissive for SB operation from DCS are:
a. Header temperature >310 :C
b. Flow of steam in SB header > 5 TPH
c. Header pressure greater than 18 Kg/cm2 g.
9.3.5.7 Air Heater cold end Temperature Controller
Air Heater cold end temperature control is provided to maintain the average cold end end temperature
(ACET) of Air heater above acid due point to avoid corrosion of AH cold end elements by adjusting the
temperature of air at AH inlet. This is done by either varying the steam flow to SCAPH or regulating AH
air Bypass damper (575-06/07/08/09-LM-003)
SCAPH Operation:
a. SCAPH will operate normally to attain required Average cold end temperature (ACET) for RAPH.
b. For this, SCAPH main line damper 575-06/07/08/09-LM-006 is to be closed and SCAPH inlet and
outlet dampers 575-06/07/08/09-LM-004 and LM-005 are to be opened.
c. Air heater bypass to be isolated by closing AH bypass damper when SCAPH is in operation.
d. The AH Secondary air inlet temperature (06/07/08/09-TE8668) and AH Flue Gas outlet
temperature (06/07/08/09-TE8679) is measured and averaged. The average temperature is compared
with the set point of 96 :C. The error signal has a proportional and integral action in the SCAPH steam
temperature controller. This controller output is the position demand signal for the SCAPH steam
temperature control valves. (Main & standby TCV 8668A/B) for the control of steam flow through the
valve.

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e. Auto/manual station is provided for auto/manual selection and operation. Position indication
(ZI8668A/B) is provided for the main & standby SCAPH Steam temperature control valves.
Note:
When ACET is not attained even when steam flow control valve is fully open, it indicates inadequate
steam supply and in this case SCAPH is to be removed from service and Air heater bypass is to be put
into operation.
Air heater bypass Operation:

a. Air heater bypass to operate when steam supply for SCAPH is not available (Operator Selection)
b. SCAPH is to be isolated by closing SCAPH inlet and outlet dampers and closing SCAPH steam
supply CV.
c. Average cold end temperature of Air heater is maintained as 96 :C by keeping SCAPH main line
damper (575-06/07/08/09-LM-006) open & the controller output is the position demand signal AH
bypass regulating damper.
d. Auto/manual station is provided for auto/manual selection and operation. Position indication
(ZI8668C) is provided for the SCAPH Steam temperature control valve.
Note:
Change over from Air heater bypass to SCAPH is to be done manually by the operator based
on availability of steam.
9.3.6 HRSG controller
Each HRSG for CPP are design to operate at MCR condition of 110 TPH, 107 Kg/cm2g @ 508 :C and
Feed water temperature at 125 :C. HRSG is design with supplementary firing provision to cater the
rated steam parameters. Each HRSG consist of total 19 nos of Fuel firing duct low NOx type Burners
with each Burner capable to handle only one kind of fuel (12 nos. for LCO/HSD and 07 nos. for FG/RG).
HRSG can be designated as Natural circulation type, Supplementary Fired, top support, single drum
type Boilers. Normally Naphtha/LCO is used as a Main Fuel for Firing and FG/RG can be used

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secondary fuel. Both Naphtha/LCO and FG/RG burners are capable to operate individual and generate
rated steam. HRSG is with combination fuel firing provision. BMS (Burner Management system) is
provided to Safe guard the boilers from Fuel related Hazards and ensure that if any abnormality
occurs which impacts the Boiler Operation; BMS will safety Turn off the Boiler operation.
Controls of each HRSG are divided into two separate control system namely DCS and BMS. BMS will
take care for safety related issues of Boiler while DCS controller system is used to control and operate
the Boiler normal Operations. Few of the common control system related to Boilers are mentioned
below with the control system controlling the same are also mentioned:
b. Combustion controller – DCS based
c. Boiler Load controller – DCS based
d. Steam Temperature controller – DCS based
e. Augmenting Fan damper control – DCS
f. Burner Management system control and safety – BMS
Each HRSG is having associated Auxiliaries and integral system to support the normal Boiler
Operations. Refer P&ID no. 0-24-400-80706, 3-97-400-86770, and 0-00-056-51135 HRSG integral
system consists of:
a. Steam drum
b. Superheater, Evaporator, Economizer and MUH modules
c. CBD/IBD vessel
d. Burners (FG and LCO)
e. Steam and Water sampling station and SWAS system
f. Spray attemperator for SHs
g. Safety valves (03 nos.)
h. Drain headers
i. Start up vent and Main steam stop valve (MSSV)
While HRSG Auxiliary consists of:

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a. Augmenting air fans with IGV

b. Seal and Scanner air fans
c. Air and Flue gas ducts
d. Scanner air fans
e. Soot Blowers
f. Chimney
g. Fuel supply mounted skids
h. HP dozing skid
The Feedwater Pumped by HRSG Feed water pumps enter the steam drum through Feed regulating
(04/05-FV1816C) and 2 X 100% Feed regulating control valve (04/05-FV1816A/B) in parallel. The
controls of this CV are in steam drum level controllers which regulate the flow of feed water to steam
drum. The feed water from the steam drum enters to Modules through Natural Circulation because of
the density difference between feedwater and steam generated. The heat required to convert the
feedwater to steam is provided by burning the Fuel in duct burner zone with the help of exhaust Flue
gas from Gas Turbine. The saturated steam rises up inside the module and gets collected back into
steam drum. From steam drum the saturated steam taken out and passes to Super heater I and II coils
hanging in as a first 4 modules in flue gas path HRSG from where the saturated steam pick up the heat
from Flue gas and get converted into superheater steam. The superheated steam is collected into
superheater header and flow to Boiler Main steam stop valve to VHP common header.
HRSG feed water and steam chemistry is continuous monitored using online analyzer and taking
regular sample at sampling station. Each HRSG are assigned with feedwater, Blow down, Saturated
and Superheater steam sampling station with necessary analyzer. Samples are cooled to 25 :C using
ACW cooling water before passing to analyzer. The decision to doze HP dozing chemical (Tri Sodium

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Each HRSG is assigned with dedicated HP dozing skid consisting of dozing pumps with metering and
solution preparation tank. Refer P&ID no. 2-80-219-80157. Steam drum is also provide with MOVs for
CBD and IBD operation, which allows to drain the feedwater cum saturated steam from steam drum
thus removing the sludge formed due to chemical reaction between HP dozed chemical and
feedwater.
For each HRSG, the Flue gas consist of Inlet duct with duct burners after Guillotine Dampers, Scanner
fans, Augmenting air fans, Seal air fans and Exhaust chimney. The Exhaust gases from GT are diverted
to HRSG through Diverter and Guillotine dampers. Both Dampers logic are in GT control. Once HRSG
healthy signal is available, first Guillotine damper open command is generated and once the Guillotine
damper open feedback healthy signal received, Diverter damper is command to open which allow GT
exhaust gas to divert through HRSG modules. Refer Control scheme no 3-36502-69008 for Guillotine
and Diverter damper controls. The Flue gas first passes through duct burner zone where LCO and FG
burners are installed which burn the fuel injected into system with the help of Flue gas from GT.
NOTE: HRSG is not installed with FD fan for fuel firing. Augmenting Air fan is used only for
Naphtha/LCO fuel firing.The high temperature flue gas then passes over the Water filled Modules
hanging in the flue gas path where the actual heat transfer occur between Flue gas and water through
module tubes with extended fins for effective heat transfer area. There are total 54 nos. of Module
and its arrangement is as below:
Module arrangement details for HRSG

In line with Flue gas path
Row of Tube
Type of Module
tubes type
Evaporator 2 Bare

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Evaporator 23 Fins
Economizer 20 Fins
Water preheater / MUH 5 Fins
The flue gases after WPH/MUH module enter into steel chimney. Chimney is equipped with stack
monitoring devices like Sox, NOx, SPM, CO and HC analyzer which is also one of the mandatory
required of State Pollution control board (PPCB).
provision.
From SH I inlet header a tapping of 2” is taken for Soot blower (SB) Operation. Each HRSG consist of
total 16 nos. of rotoary type of SBs. The drains of SB are diverted to IBD tanks for HRSG. The p ressure
control valve (04/05-PCV8174) in the upstream of SB supply header regulates the steam supply by
getting the pressure signal from pressure transmitter (04/05-PT8174) in the downstream pressure of
PCV.
9.3.6.1 Steam drum Level controller
Steam drum Level is basically a DCS based controller. HRSG steam drum consist of 03 nos. of Level
Transmitter (04/05-LT8107/8108/8109), 02 nos. of Electronic Water level indicator switch and
Transmitter (EWLI, 04/05-LI8145), Local Level gauge, Pressure Gauge (04/05-PI8111), Pressure
Transmitter (04/05-PT8110), 02 nos. of safety valve (04/05-BW051 and BW063 set at Pressure
132/135 .9Kg/cm2 g respectively). Steam drum level controller act as a single element controller or a
three element controller which maintain the steam drum level as preset level at all the time during all
stages of Boiler operation.
Before taking steam drum level controller into action, operator need to ensure that the all 03 nos. of

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Feed regulating station CV are in AUTO operation mode and at 0% opening feedback. During start up
of boiler normally, steam drum level controller is kept in single element control in which the level
inside the drum is regulated directly by opening of Feed water of 30 % control valve. 03 nos. of Level
transmitter analog signal goes to MVAS (Mid value Average selector) block which gives a single output
as a signal which gets Pressure compensated thereafter in Compensation block. The Output from
compensation block gets referred with SP set by the Operator in Difference block. The error signal out
of the difference block is act as an input for single element PID controller, which command the 30% CV
to open/close based on the input error signal to PID.
In three Element controllers, the level inside the drum is maintained not only through Level
transmitters but also through the signal of Feed water flow transmitter (04/05-FE8101) and steam
flow transmitter (04/05-FT8139) as a Feedback and feed forward signal respectively for controller. The
error signal from difference block enters to 3 element PID from which the PID signal get summed with
steam flow signal (which is already pressure and temperature compensated in compensation block) as
feed forwarded. The output from the summation block is compared with the Feed water flow signal in
another PID as a feedback signal. The output of PID is send as command to both the 100% control
valve (The command can be either going to only one controlling element or two both control valve as
split command depends up on SAT configuration. Normally both 100 % Control valve will be remain in
operation and in AUTO mode.
Switching of single element to three element control is to be done by Operator but the vice versa
operation will be done in AUTO. Permissive for switching from single to three element are feed water
and steam flow > 30% of MCR condition of UB. Refer the control scheme document no. 3-97-400-
87014 for details.
9.3.6.2 Combustion controller
For HRSG the combustion control system comprises only of Fuel flow control. The Air/Flue gas coming
from GT exhaust is not having any control in scope of HRSG. However, minimum air flow is required as

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a start permissive for HRSG to be put into operation. HRSG can operate in supplementary firing mode
operation in order to delivery the rated output of steam with a minimum GT loading of >40%. HRSG is
capable of either firing 100% gas or 100% Naphtha or Light Cycle Oil (LCO) and combination of both
Fuel at time to get rated output of steam.
Fuel Flow controller: In Fuel flow controller the steam demand signal either in the form of steam
header pressure or the boiler load depending upon the selection made by Operator, goes to Fuel ratio
computation block. In Fuel ratio computation block, the counting of burners running on FG and
NAPHTHA/LCO are done individually and both are summed together to get the total no. of burners in
operation. Now the FG ratio is calculated based on the no. of burner of FG divided total no. of Burner in
Operations. Similarly the NAPHTHA/LCO fuel ratio is calculated by dividing the no. of burner on
NAPHTHA/LCO to total no. running Burners in boiler. Now this calculated fuel ratio are multiplied with
the total demand signal. The total demand signal are not split or divided, but the total demand signal
from Boiler load controller PID after selection which are diverted to both the multiplication block. The
output from the Multiplication block for both the fuels enter the fuel control PID in which the actual
flow measurement signal from field are compared. Flow element (04/05-FT7704) is used for Fuel gas to
Boilers and Mass Flow meter (04/05-FM7719) is used for NAPHTHA/LCO fuel measurement to Boilers.
The demand signal from the Fuel control PID. In case of FG flow Pressure compensation is applied to
the flow transmitter output, from the signal from pressure transmitter (04/05-PT7703) with a facility to
remove this from the circuit by the engineer. The Fuel flow controller output in both type of fuel is feed
to 0-30% flow control valve (04/05-FCV7706 in FG and 04/05-FCV7721 in NAPHTHA/LCO) & 25-100%
flow control valve (04/05-FCV7705 in FG and 04/05-FCV7720 in NAPHTHA/LCO). Refer control scheme
3-97-400-87018 for details. Auto/manual selection provision is provided for all controlling element.
There is also a provision for Operator to operate the fuel supply control valve in pressure control mode.
This is normally done during start up of Boilers where the inlet pressure of fuel to Boilers is used to
regulate the position of CV. The Pressure transmitter (04/05-PT7722 for NAPHTHA/LCO fuel and 04/05-
PT7707 for FG fuel) in the downstream of fuel supply CV regulate the fuel rate.

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The set point is set for by an Operator depending upon the fuel demand during start up which ensure
that the Burner flame sustained and any additional requirement of fuel can be pre-adjusted during lit
of another burner.
There are two additional Burner safety logic inbuilt to protect the Burner from Overloading. (A) When
the differential load between burners exceeds X%, the condition is alarmed, for the operator to take
remedial steps. The further increase of boiler load is blocked in the Master pressure control loop, till
this condition is cleared by the operator. The burner differential load condition is computed as follows-
a. The quantity of each fuel fired is measured. The calorific flue flow is computed as be QFG and
QHSD.
b. The heat input in each of the burner for the fuel fired is QFG/NFG and QHSD/NHSD, where NFG
and NHSD are the no. of Fuel gas and NAPHTHA/LCO burner ON respectively. (Contact from BMS Fuel
nozzle valves open)
c. A computation circuit calculates the differential heat loading. When the differential heat load
between any two burners is greater than X%, alarm is generated till this condition is cleared by the
operator. This is to ensure that the all burners fire same quantum of fuel, as air distribution in all the
burners are same and in no case one burner get exceed loading as compared to other. It also help to
safe guard the burner operation running on part load as during any increase in demand, any additional
requirement of Burner should not be drive through running burner by excess loading.
The heat load in each burner is computed. When the burner heat load capacity is exceeded, alarm shall
be generated and further increase in boiler load is blocked by blocking the demand generated by Boiler
load controller till this condition is cleared by the operator.
(B) When the Temperature elements installed in Flue gas path of Duct Burner zone (06 nos., 04/05-
TE7608 to 7613) and on material skin of Superheater modules (12 nos., 06 nos on each SH module,
04/05-TE8118 to 8129), exceeds the preset safe limit, the fuel control valve based on the same logic of
Fuel ratio calculation block will try to reduce the 10% fuel flow to HRSG by closing the Control valve in

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same ratio as demand. The system then waits for 60 sec to check the Temperature. The cycle will
repeated till the exceed temperature comes below the safe limiting value. During this run down
operation, any increase demand in fuel flow is override. Operator will get an alarm once this operation
is activated.
In HRSG being no FD / ID fans, no air control is required. The only fan which required controls is
Augmenting Air fans. Refer 2.2.6.6 for augmenting air fan controls.
9.3.6.3 Boiler Load controller
Loading on the Boiler is done by increase in demand of steam or by fluctuation of Pressure of steam
from Boilers. Individual Boiler Loading can be control by two fundamental methodologies:
a. Load control
b. Pressure control
NOTE: HRSG normally operate on steam header Pressure control mode only as the load on the HRSG is
depends upon the GT loading. In this case pressure control mode sis best suited. However Load control
mode can also feasible but required Operator attention.
In Load control mode, the steam demand is the driving signal for loading the boiler. The MCR rating of
the boiler i.e. 110 TPH of steam generation is equivalent to 100% loading demand of HRSG. Operator
set the demand signal for the Boiler. This demand signal control the rate of Flow of Fuel into system
into which generates steam. In Steam demand controller / Load controller, the actual steam demand
signal from Flow Transmitter (04/05-FE8139) in the discharge main steam header gives an input signal
which is compared with Operator set point in the steam controller PID. The error signal generated from
PID is the input to the Fuel and Air controller demand signal / Combustion controller PIDs. Refer the
details of Combustion controller 2.2.6.2.
In Pressure control mode for Boiler load controller, the steam header discharge pressure is the driving
signal which maintained and regulates the supply rate of Fuel Boilers. The Pressure is sense by

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Pressure transmitter (04/05-PT8136) in the Main steam header for each Boiler. Operator set the set
point for the boiler to operate. The set point may be in terms of % demand or a direct pressure value.
In our case it is direct pressure value which is being set by operator. Boiler once set in pressure control
mode will try to maintain the set header pressure irrespective of steam quantity generation. Any
sudden fluctuation in demand will indirectly reduce the header pressure which in turn regulates the
fuel and air flow to furnace. Even though the response time of pressure controller being slow as
compared to Load controller, it is normally advisable to run the HRSG on Load control mode as HRSG
depends upon GT flue gas exhaust quantity. If HRSG operate on Load control mode, chances of
overheating as well as unburnt Fuel in flue gas path are always there especially during GT part load
operation and HRSG on full load operation. That is why the additional burner safety point (B) in 2.2.6.2
is kept to control the skin temperature of pressure parts to avoid overheating. The actual pressure
measured in Main steam header for each boiler is inputted along with the set point and both are
compared in steam pressure controller PID. The error signal generated from PID is the input to the Fuel
and Air controller demand signal / Combustion controller PIDs. Refer the details of Combustion
controller 2.2.5.2
Operator has a provision of selector switch for selecting the Boiler load control methodology. Operator
can selected each boiler control mode operation from DCS. Over and above as discuss in 2.2.5.3,
master pressure controller is encompassing the HRSG boiler load control. Refer 2.2.5.3 for details and
document no. 3-381-21-01894 for Master pressure control.
9.3.6.4 Steam Temperature Controller
The steam temperature controller is used to control the super heated steam temperature after Platen
SH (SH – I) before entering into Convection SH (SH – II). The steam temperature is controlled by
spraying the Boiler Feed water directly into the steam path. Spray water is tapped from the Boiler
feed water supply header to Boiler. The spray station is provided with a main pneumatic operated
spray control valve (04/05-TCV8153). In the automatic mode, SH spray water valve is controlled by a
cascade control. The Main steam heater temperature is measured by Temperature Element (04/05-

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TE8133) and steam temperature after de-superheater (desh) outlet temperature is measured by
temperature sensors (04/05-TE8131). Under normal conditions, SH outlet temperature the primary
control variable is in the outer loop of the cascade control for each valve. SH desh outlet temperature
an index of the immediate effect of spray valve operation is in the inner loop.
The outer loop PID controller generate an error signal equal to the deviation of SH outlet temperature
set point and measured final SH outlet temperature. The outer loop controller establishes a set point
for the SH desh outlet temperature PID which is compared with actual outlet desh temperature. The
error signal from inner PID is used to position the SH spray control valve. Auto/manual station is
provided for auto/manual selection and operation of pneumatic operated spray control valve. On
Boiler Trip condition, the feedwater inlet supply line SOV (04/05-94SOVSW009) gets closed. Refer
P&ID no. 0-24-400-80706
9.3.6.5 BMS Controller

BMS controller is similar to UB BMS controller. Refer point no. 9.3.5.5.
9.3.6.6 Augmenting Fan Damper controller
Augmenting Air Fan is used to provide additional Air during NAPHTHA/LCO firing only. It is also a
permissive for HRSG healthiness signal. Before taking HRSG into service, Augmenting air fan should be
started and its inlet air damper should be kept at minimum position i.e. 5%. Normally, augmenting air
fan damper positioned to 5% opening on starting of Augmenting air fan. A decision is used to select
the position of Augmenting air damper based on fuel selected for supplementary firing. If HRSG is
fired only with FG or without firing, augmenting fan damper will position to 5% but when
NAPHTHA/LCO is selected as fuel for firing the augmenting air damper position to 80%.
9.3.7 Gas Turbine Controller

9.3.7.1 Starting / Shutdown system Controller

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Starting the gas turbine involves proper sequencing of command signals to the accessories, starting
device & fuel control system. Since a safe & successful start up depends on proper functioning of
almost all of the gas turbine equipment, it is important to verify the state of selected devices in
sequence. Much of the control logic circuitry is associated not only with actuating control devices, but
enabling protective circuits & obtaining permissive conditions before proceeding. Reference to the
control sequence programme is necessary for complete understanding of all the logic functions
included for the particular equipment provided with a gas turbine. The operating sequences of the
Control specifications are written to explain significant functions which pertain to a specific gas
turbine.
A block diagram of all SPEED TRONIC circuits which can interplay to control start-up, is shown in Figure
SECFR-1. Detailed descriptions are found in the SPEED TRONIC panel information included in this
manual & on the control sequence programme. Utilize figure SECFR-2, a plot of a typical start up, to aid
in understanding the sequences described here. Start up & shutdown cycle improvements have been
included to reduce low cycle fatigue of hot gas path parts.
9.3.7.1.1. Speed detectors
An important part of the startup/ shut down sequence control of the turbine is proper speed sensing.
This is necessary for the logic sequences in startup & shut down of the gas turbine. The following speed
detectors & speed relays are used: L14HR Zero-Speed Detector, L14HM Minimum-Speed Relay
Detector, L14HA Accelerating Relay Speed Detector & L14HS High Speed Relay (some units use-a L14HF
fired shutdown relay).
o The zero speed detector, L14HR, provides the signal when turbine shaft starts rotating. If speed
is below L14HR, permissive logic initiates clutch engagement & the cranking sequence for the turbine.
During the shutdown cycle this speed detector provides the signal to permit the ratchet gear, or
turning device, to be placed in service in the automatic cool down logic sequence of the turbine. The
minimum speed detector L14HM indicates that the turbine has reached the minimum firing speed &

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initiates the purge (if required) prior to ignition. The drop out of the L14HM minimum speed relay
provides several permissive functions in the restarting of the gas turbine after shutdown.
o The acceleration speed relay L14HA pickup indicates that the turbine has reached
approximately 40 to 50n percent in the acceleration cycle. The high speed sensor L14HS pickup
indicates that the turbine is at operating speed, & that the accelerating sequence is complete. With
this signal the inlet guide vanes are actuated unless the unit is equipped for modulation. See the inlet
guide Vane section.
o The L14HS dropout speed is used to close unmodulated inlet guide vanes upon turbine
shutdown. During a normal shut down the digital set point will countdown to minimum, the generator
breaker will open on reverse power & FSR will ramp to minimum. Flame will be maintained to shut
down speed where L14HA (or L14HF) will then drop out & drive FSR to zero.
o The settings of the speed are programmed in the computer as PROM constants & are listed in
the Control Specifications.
9.3.7.1.2. Start up controls
 The start up control operates as an open loop control in the use of preset levels of the fuel
command signal, FSR. The levels set are “FIRE”, “WARMUP” & “ACCELERATION LIMIT”. The control
specifications provide proper settings calculated for the fuel anticipated. The FSR levels must be set in
the SPEED TRONIC start up control.

 Start up control FSR signals operate through the minimum vale gate to insure that speed
control & temp control can limit FSR if required. During the starting sequence, rates of increase in
speed & exhaust temp are restricted to protect the turbine parts from excessive mechanical & thermal
stresses. The rates of acceleration & temp rise are controlled in dependently by the closed loops of the
speed & temp control systems. The rate limits operate through the SPEED TRONIC control circuits
discussed in those control systems.

 The fuel command signals are generated by the SPEED TRONIC start up software. See the
turbine control sequence programme. In addition to three start up levels, the software sets maximum

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& min FSR & provides for manual control of FSR. Pressing the switches for “MANUAL CONTROL” & “FSR
GAG RAISE OR LOWER” allows manual adjustment of FSR setting between FSRMIN & FSRMAX.
 While the turbine is at rest, electronic checks are made of the stop/speed ratio vale, the gas
control valve, the accessories & the voltage supplies. At this time the operator display will be normal &
the “SHUTDOWN STATUS” will be displayed on the CRT. Activating the master operation switch L43
from “OFF” to an operating mode will activate the ready circuit. If all protective circuits & trip latches
are permissive the start up status “READY TO START” messages will be displayed & indicates the
turbine will accept a start signal. Depressing the “START” master control switch (LIS) will introduce the
start signal to the panel.

 The start signal energizes the Master Control & protection circuits (the “L$” circuit) & starts the
necessary auxiliary equipment. The “L4” circuit permits pressurization of the trip oil system & engaging
of the starting clutch. With the “L4” circuit permissive & the starting clutch engaged, the starting device
starts turning. Start up status message “STARTING” will be displayed on the CRT. See point “A”
on figure SECFR-2.
 Once the turbine crosses zero speed, the L14HR signal drops & deenergizes starting clutch,
solenoid 20CS. The clutch then requires torque from the starting device to maintain engagement. The
turbine speed relay L14HM indicates that the turbine is turning at the speed required for prop er
ignition in the combustors. Gas turbine unit have a purge timer, L2TV. A purge time is set to force
about four changes of exhaust duct air to ensure no combustible m9ixture is in the exhaust. The setting
for L2TV is given in the control specifications. The starting means will hold speed limit L2TV, which was
started with the L14HM signal, has completed its cycle.

 The L14HM signal on completion of purge timer cycle enables fuel flow, sets firing level FSR, &
initiates the firing timer L2F-see point “B” on figure SECFR-2. When the flame detector output signals
indicate flame is established in the combustors, the warm up timer L2W starts & the fuel command is
set to the “WARMUP” FSR level. The warm up time is provided to minimize the thermal stresses during
initial part of the start up.

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 If flame is not established by the end of the L2F timer, the unit can be given another start signal
but firing will be delayed by the L2TV timer to avoid fuel accumulation in successive attempts. This
occurs even on units not requiring initial L2TV purge.

 At the completion of the warm up period, start up control increases FSR exponentially to the
acceleration setting for “TURBINE ACCEL REFRENE INCREMENT RATE”. See point “C” on fig SECFR-2. As
fuel is increased, the turbine begins the acceleration phase of start up. The clutch is held in position as
long as the starting device provides torque to the gas turbine. When the turbine over runs the Starting
device, the clutch will be thrown out,. Speed relay L14HA indicates the turbine is accelerating

 The start up control software establishes FSR signals during start which must not be exceeded.
Other control circuits are also able to reduce & modulate FSR to perform their control functions. In the
acceleration phase of start-up it is possible to reach the temp control limit, temp rate limit, low speed
stops, or shaft acceleration rate limits. The speed & temp control system will not permit these values to
be exceeded by controlling FSR as required. Control panel display will show which parameter is limiting
or controlling.

 CONTROL MODE DISPALY & OPERTAING CONDITION
Display Condition
STARTUP Start up program
ACCEL Acceleration control
DROOP SPEED Speed control
TEMP Temperature control
 The start up cycle has been designed to moderate the highest firing temp produced during
acceleration. This is done by programming a slow exponential rise in FSR (120 sec time constant
normally) to a somewhat reduced ACCEL FSR setting. The acceleration rate control limit setting on the
speed control circuit is reduced during start up to over ride the rise in FSR during acceleration. It also
aids smooth transition to speed control at the end of the startup sequence. The startup sequence time
is extended to an optimum time to minimize strains produced on the hot gas path parts in mid-
acceleration cycle.

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 The minimum FSR limit on the start up control prevents the speed & the start up circuit from
driving. The FSR below the value which would cause flameout during a transient condition. For
example, with a sudden rejection of load on the turbine, the speed control system loop would drive the
FSR voltage to no less than the minimum FSR setting, without which a flameout would probably occur.
Since the minimum fuel FSR circuit does not connect to the temp amplifier, the temp control system is
capable of driving the FSR to zero to prevent excessive temp in the turbine.

 The acceleration phase of startup ends when complete sequence is reached, (see point “D” on
figure SECFR-2). The turbine speed is controlled by FSR & the auxiliary pumps have been shut down.

 Refer to figure SECFR-1 through SECFR-3 for starting sequence & control description.
9.3.7.1.3. Fired shutdown
 A normal shutdown is initiated by electing the STOP switch on the Master Control Selector. This
will produce a L94X signal. If the generator breaker is closed when the stop signal is initiated, the digital
set point is counted down to reduce FSR & load at the normal rate until the reverse power relay
operates to open the generator breaker. When this occurs, FSR will be ramped to MIN. The MIN setting
should be adjusted to allow the turbine to coast down to the L14HA (or L14HF) drop out setting at 40-
50% in 3 to 4 minutes. When L14HA drops out, fuel is shut off by clamping FSR to zero & tripping the
stop valve closed.

 During coast down on units having motor driven atomizing air booster compressors, the
booster is started at L14HS drop out to prevent exhaust smoke down to shut off. Units not having
motor driven boosters may require higher fuel shut off adjustment to avoid smoke.

 Fired shut down is an improvement over the former fuel shut off at L14HS drop out where at
higher-speed the firing temp is higher & decays more rapidly. By holding flame until lower speed
(approximately 40%) there is a significant reduction in the strain developed on the hot gas path parts
at the time of fuel shut off.

 See figure SECFR-4 for a typical shut down curve.

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9.3.7.3 Exhaust Temperature Controller

9.3.7.3.1. General
A temp control system is required, to control fuel flow to the gas turbine to maintain operating temp
within design thermal stress limitations of turbine parts. The highest temp attained in the gas turbine
occurs in the combustion chambers & that the gas temp occurs at the turbine inlet. This temp must be
limited y the control system. The temp control system is designed to measure & control turbine
exhaust temp because it is impractical to measure temp in the combustion chambers or at the turbine
inlet directly. This indirect control of turbine inlet Temp, called firing (combustion reference) temp, is
possible through known turbine performance relationships. The exhaust temp alone does not fully
determine firing temp: another dependent parameter is also required.
From thermodynamic relationships, gas turbine cycle performance calculations & known site
conditions, firing temp can be determined as a function of exhaust temp & pressure ratio across the
turbine. The latter is determined from the measured compressor discharge pressure (CPD). Firing temp
is also determined as a function of exhaust temp & fuel consumption which is proportional to the fuel
command Fuel Stroke Reference (FSR).
These relationships are shown on figure TCFR-1. The lines of constant firing temp are used in the
control system to limit gas turbine operating temp. Compressor discharge pressure is measure by 96CD
pressure transducer. Some applications use redundant 96CD transducers to ensure reliable compressor
discharge measurement.
9.3.7.3.2. Exhaust Temperature Control
The temperature control software determines the cold junction compensated thermocouple readings,
selects the temp control set point value, calculates the control set point value, calculates the medium

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exhaust temp value, compares the set point & median temp & generates a fuel stroke reference (FSR)
signal to the analogue control system to regulate exhaust temp.
9.3.7.3.3. Cold Junction scan
There are 18 exhaust temperature thermocouples in a fr-6 Unit. These are brought into the control
panel via the Isothermal modules TCM, where they are conditioned & divided among the three
controllers RST: e.g. for instance TC#1 to R, TC#2 to S, Tc#3 to T, TC#4 to R etc. All other non -critical
thermocouple signals are sent to C.
An additional thermocouple junction is created where the thermocouple wires are connected to the
terminals on the isothermal module. A voltage, that is a function of the temp at the connection points
& in opposition to the signal generated by the thermocouple, is generated at this junction. An RTD is
mounted on the isothermal module to measure this “cold junction” or connection point temp. These
RTD’s are scanned with the thermocouples as part of the analogue-input-scan program & the data is
stored in the analogue-input-data memory. The thermocouple data is also influenced by offsets in the
thermocouple amplifier & the analogue to digital conversion amplifier. An input is shorted on the
isothermal modules, the shorted inputs are scanned during the analogue input scan program & the
resulting data stored in the analogue input data memory. The cold junction scan program (figure TCFR-
2) operates on the cold junction temp RTD data & the amplifier zero offset shorted input data. The
results, which represent a sum of the two effects, are stored in the compensation data memory use in
the cold junction compensation program.
9.3.7.3.4. Cold Junction Compensation
The thermocouple data, scanned & stored by the analogue input scan program, is corrected for cold
junction effect & amplifier offset, by cold junction compensation program figure TCFR-3. As determined
by the analogue input address table, data from the analogue input data table & the compensation data
tables are read by the cold junction compensation program, where thermocouple

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data is corrected by adding the compensation value. These results are stored in the computer memory.
9.3.7.3.5. Temperature Reference select
The exhaust temp control function selects control set points to allow gas turbine operation at various
firing temperatures. Temp reference selection is accomplished in the sequencing software (see the
turbine control sequence programme diagram). Typical input logic signals used are “Base select”, “Peak
Select”, & “Combined Cycle Select”. For example, the “Base Select” signal determines operation at
base firing temp. The appropriate set of constants are selected & used in the algorithm for calculation
of the temp reference set point.
9.3.7.3.6. Temperature Control reference
The purpose of the exhaust temp control & protection system is to control the fuel flow t o the gas
turbine thus maintaining operating temp within the design thermal stress limitations of the turbine
parts. This system measures & controls turbine exhaust temp since it is impractical to directly measure
combustion chamber temp. Temp control is designed to over ride any other control demand for
increased fuel low (FSRT)
The speed tronic computes the gas turbine exhaust temp control reference. He exhaust temp is
controlled as a function of compressor discharge pressure, CPD. Dry low NOx units may require the
control curve to be broken in to two or three temp control curves. This allows firing temp to be limited
by a lineraized function of exhaust temp & CPD. A “backup” curve (secondary curve), is also a lineraized
function of fuel stroke reference, FSR or gas turbine output, DWATT which limits firing temp.
The secondary curve is offset above the primary curve by TTKRX2. This enables that the backup temp
control curve does not interface with the primary gas turbine exhaust temp control based on CPD. In
the event of a compressor discharge pressure transducer failure as detected by L3TFLT, the constant

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TTLRX2 is subtracted from the secondary curve. This back up curve now becomes the control curve for
gas turbine exhaust temp.
The exhaust turbine exhaust temp control reference, TTRX is computed as the minimum select among
TTRXP, TTRXS & TTKn_1 & will not exceed the ramp rates (Slope) TTRXR1 & TTRXR2 during transients.
The typical rate limit is 5 Deg F per second.
9.3.7.3.7. Temperature control reference and CPD signal Fault
Temp reference is reduced if compressor discharge pressure signal is less than a calculated operating
speed momentum. This failure is armed as “CPD signal low”. This failure reduces FSR BIAS by constant
TTKRX2 (fig TCFR-4) to permit operation at approximately rated firing temp till the fault is cleared. This
feature is shown on fig TCFR-7.
9.3.7.3.8. Temperature control reference speed Bias
On two shaft gas turbines, fuel temp reference is increased by 7 Deg F for each percent HP set speed
below 100% ratted. This features allows LP governor speed control to increase exhaust temp above
that set by inlet guide vanes & nozzles over an HP speed operating range of 95 to 100%. This feature is
shown on fig TCFR-8.
9.3.7.3.9. Temperature feedback
The temp control fuel stroke reference algorithm compares the exhaust temp control set point with
the measured gas turbine exhaust temp as obtained from thermocouples mounted in the exhaust
plenum. These thermocouples are scanned & the signals are accessed by RST as well as C processor.
The exhaust temp vector algorithm (fig TCFR-5) reads the exhaust thermocouple temp values & sorts
them from the highest to lowest into TTXD2_n array. These signals (TTXD2_n) are used in the
combustion monitor algorithm as well as in the temp control system exhaust average algorithm. Each
value is looked at & all thermocouple signals below the constant TTKXCO which are considered low, or
from a controller to which communications are lost, are rejected from the averaging. The remaining

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ones are looked at again, & the highest & lowest are rejected. The remaining ones are averaged in the
algorithm which calculates the exhaust temp median feedback, TTXM.
The TTXM value is used as the feedback for the exhaust temp comparator. This calculated feedback is
used because its value is not affected by extremes values that may be the result of faulty
instrumentation.
9.3.7.3.10. Temperature control FSR
The temp control fuel stroke reference algorithm in RST compares the exhaust temp control set point
(calculated in the temp control reference algorithm) TTRXB to TTXM value to determine the temp
error. The software program converts the temp error to a fuel stroke reference signal, FSRT.
Should one of the communication links fail between one of the controllers & C, the controller affected
will freeze the value of TTXM at the last healthy sample & compare it with the current sample of TTXM
of the controller. This prevents large changes in the feedback signal. When the link becomes healthy
again there is a fixed rate of correction to prevent sudden bumps in the system.
With three FSRT values most errors can be removed to give reliable gas turbine operation. This is true
also with each controller doing the same calculations for TTXC & TTXM.
9.3.7.4 IGV control
Variable inlet guide vanes (VIGV) are installed on the Gas Turbine to provide compressor pulsation
protection during start up & shut down & also to be used during operation under partial load
conditions for maximizing the exhaust temperatures. The variable inlet guide vane actuator is a
hydraulically operated assembly having a closed feedback control loop to control the guide vanes
angle. The vanes are automatically positioned within their operating range in response either to the
control system exhaust temperature limits for normal loaded operation, or to the control system
pulsation protection limits during the start-up & shut down sequences

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The modulated inlet guide vane actuating system includes the following components: servo-valve
90TV-1, position sensors (LVDT) 96TV-1 & 96TV-2 & hydraulic dump valve VH3-1.
When the inlet guide vane trip solenoid 20TV-1 (located in the trip oil circuit) is energized, its drain
ports are blocked. This allows the trip oil pressure to build up & operate the dump valve VH3-1.
Actuation of the dump valve allows hydraulic oil to flow through servo-valve 90TV-1. Control of 90TV-1
will port hydraulic oil to the hydraulic cylinder & operate the variable inlet guide vanes.
The inlet guide vanes are automatically positioned during start-up & a shut down sequence to avoid
gas turbine compressor pulsation. The pulsation limit is expressed as a function of IGV angle &
corrected speed, shown by the broken line on figure MIGVCR-2. Corrected speed is a compressor
design parameter that is a function of the actual running speed of the compressor & the inlet air
temperature. The control system utilizes the measured variables of turbine speed & ambient
temperature to determine the required IGV angle & automatically position the IGVs at the required
angle. This control curve is shown on figure MIGVCR-2. Note that the control curve is set to avoid
operating the compressor at an IGV angle which would result in negative pressure at the 5th stage
extraction (air used for bearing seals).
For applications such as a regenerative cycle or where a heat recovery system (boiler) is installed in the
gas turbine exhaust, it is desirable to maximize the exhaust temperature. The control program for such
turbines includes an exhaust temperature control which automatically holds the IGV at a minimum
angle during part-load operations. An operator selectable soft switch is provided to permit selection of
this mode of operation.
During a normal start-up, the inlet guide vanes are held in the full-closed position (see the Control
Specifications for settings) until the proper temperature corrected speed is reached. Ta this time, the
inlet guide vanes will begin to open. The schedule is shown on figure MIGVCR-2. During full speed
operation & with less than 20% load, the inlet guide vanes remain in the minimum full speed angle.

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The 11th stage compressor bleed valves, which must operate in conjunction with the guide vanes to
maintain adequate compressor surge margin, will be closed after breaker closure.
For normal shutdown, inlet guide vane actuation is the reverse of the startup sequence, the 11th stage
compressor bleed valves will open when the generator breaker is opened & will ramp to the full closed
position as a function of the turbine corrected speed.
In the event of a turbine trip also the 11th stage compressor bleed valves will open & the inlet guide
vanes will ramp to the full closed position.
When the “IGV TEMPERATURE CONTROL” mode is “OFF” the IGV angle reference is calculated using
the simple cycle curve. The guide vanes are held at the minimum full speed angle until the simple cycle
IGV exhaust temp set point CSKGVSSR is reached. (This temp control set point is programmed in the
software at approx 300 Deg F (167 Deg C) below the base temperature control set point). With increase
in the load the exhaust temp increases. A value computed as the product of constant CSKGVTP & the
difference between the actual mean exhaust temps TTXM & CSKGVSSR is added to the minimum angle.
This increased VIGV angle reference causing the VIGVs to open till the maximum angle. This sets a min
load which the unit must reach before the VIGVs are allowed to open. This si necessary to avoid
combustion resonance & must not be changed.
For applications which require exhaust temp control operation, the “IGV TEMP CONTROL” is switched
“ON” using the operator selectable soft switch. In this mode the guide vanes remain at the minimum
full speed angle until the base load exhaust temp limit is reached. With further increase in load & the
resultant increase of exhaust temperatures, the VIGV angle reference increases, thus opening the
VIGVs in order to maintain the exhaust temp at this limit until the VIGVs are fully open. At this point
the exhaust temp control reverts to fuel modulation. In order to keep the fuel control & IGV control
from trying to act simultaneously, a fuel control bias is added to keep the fuel line slightly above the
VIGV line. This bias is the product of constant CSKGVBG & the difference between the max VIGV angle
(constant CSKGVMAX) & the VIGV reference CSRGV. This bias becomes zero when the VIGVs are fully
open & the fuel temp control takes over.

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The operator can activate or deactivate the IGV temp control made at any time via the panel soft
selector switch. The control system will automatically re-program the VIGVs to the correct position at a
controlled rate.
Manual open/close soft switches are provided on the manual control display to allow the operator to
manually position the IGV between the min full speed angle & full open. This control should only be
used in special circumstances to limit the travel (amount opened) of the IGV. The manual control is
limited to command an IGV angle which is less than that being called for by the automatic control
system. In normal operations the manual control is set at full open.
The guide vane protection system will trip solenoid valve 20TV-1, initiate a fast normal shutdown &
annunciate under the following conditions:
1. Low hydraulic supply pressure
2. VIGV position feedback (from LVDTs) does not match the position reference computed by the
control system
Should the inlet guide vane system be tripped under & one of the above conditions, the control
sequencing is programmed to inhibit any further attempts to restart the turbine until the cause of for
the trip is identified & estimated.
The primary IGV fault signals are generated by the “IGV NOT FOLLOWING CSRGV” algorithm
(L86GVTV2) & are as below:
- This algorithm compares the difference between the VIGV position feedback CSGV & the
reference signal CSRGV to generate alarm signal, L86GVA if the IGV is not following the reference
within the value of LK*^GVA1 for time duration more than LK86GVA2 (Refer control specifications
Settings for values)
- During part speed operation, a trip signal L86GVT is generated if the VIGV position feedback
CSGV does not agree with the part speed reference CSRGVPS within the value of LK86GVT1 for
duration more than LK86GVT2 will alarm & trip the turbine if the VIGV feedback CSGV falls below
minimum full speed angle LK41GVTX. Either of these conditions generates a trip signal L41GVT which

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de-energizes the trip solenoid valve 20TV-1 leading to tripping of the gas turbine with an annunciated
alarm.
9.3.7.5 Gas Fuel control
Fuel gas is controlled with the fuel gas stop/ratio & control valve assembly. Two valves are combined in
this assembly as shown in figure 1. Both are servo controlled by electrical signals from the Mark-V
control panel & actuated by single acting hydraulic cylinders moving against spring loaded plugs. It is
the gas control valve that controls the desired fuel flow in response to the command voltage, FSR. To
enable it to do this in a predictable way, the stop/ ratio valve is designed to maintain a predetermined
pressure, P2 at its inlet. Other system features, as discussed here, are provided for reliability of
operation & protection against malfunctions
The fuel gas control system contains the following components: gas strainer, gas supply pressure
switch 63FG-3, stop/ratio valve assembly, three redundant fuel gas pressure transducers 96FG-2A, 2B
& 2C, fuel vent solenoid valve 20VG-1, control valve assembly, four LVDT’s ( Linear Variable
Differential Transformers) 96GC-1, 2 & 96SR-1, 2, two servo valves 90SR-1 & 65GC-1, dump valve, three
pressure gauges & SPEEDTRONIC software. Refer to Figure 2, where all components are shown
interconnected schematically. A functional explanation of each part or subsystem is contained in
subsequent paragraphs. For more detail on the electro hydraulic circuits see SPEEDTRONIC system text
& control sequence program diagrams furnished to the site.
The position of the gas control valve plug is intended to be proportional to FSR, which represents the
called for fuel. When the turbine is to run on gas fuel, the permissives must be “true”. This enables the
GCV to open. The stroke of the valve will then be proportional to FSR. FSR goes through the fuel splitter
(discussed in the dual fuel section, if applicable) & becomes FSR2, which is then conditioned for offset
& gain. This signal (FSROUT) commands the gas FSR2, control valve position. The gas control valve stem
position is sensed by the output of a linear variable differential transducer (LVDT), rectified & fed back
to an operational amplifier. There are two LVDT’s. The highest output among these two is

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selected & is compared to the FSROUT input signal at the summing junction. If the feedback is in error
with FSROUT, the operational amplifier will increase the signal to the hydraulic servo valve to drive the
gas control valve in a direction to decrease the error. In this way, the desired relationship between
position & FSR is maintained & the control valve meters the correct gas fuel (see figure 3).
Actuation of the spring-loaded gas control valve is by a hydraulic cylinder controlled by the electro-
hydraulic servo valve.
The plug in the gas control valve is contoured to provide the proper flow area in relation to valve
stroke. The gas control valve uses a skirted valve disc & venture seat to obtain adequate pressure
recovery, high-pressure recovery occurs at overall valve pressure ratios substantially less than the
critical pressure ratio. The net result is that flow through the control valve is independent of valve
pressure drop. Gas flow is a function of valve inlet pressure, P2 & valve area only. An open or a short
circuit in one of the servo coils or bad signal to one does not cause a trip. The GCV has two LVDTs & can
run correctly on one.
The position control loop is shown on Fig 4. Two LVDTs, 96GC-1 & 2, are used for position sensing.
Their feedback signals go through the SPEEDTRONIC where two independent transformers & a
discriminator circuit demodulate the LVDT AC output to give DC feedback signals acceptable for use by
the position control. The highest signal is diode gated & proportioned by an amplifier to the correct
valve stroke calibration. See figure 4 for a typical calibration curve.
It is this DC signal which is fed back & compared to FSR in the Mark-V. for stable control, the amplifier
error is properly proportioned by a berg jumper, to command the integrating amplifier which drives the
servo valve, 65GC. When the LVDT feedback equals the FSR input signal the servo-drive amplifier
summing junction is satisfied.
The control specifications give the correct position loop settings for a specific turbine.

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The servo valves are furnished with a mechanical null offset bias to cause the gas control valve or
stop/ratio to go the zero stroke position on zero voltage or an open circuiting f both servo valve coils.
During calibration, checks should be made to ensure that this happens.
The stop/ratio valve is a dual-function valve. It serves as a stop valve & is therefore an integral part of
the protection system. Any emergency trip or normal shutdown will trip the value to its closed
position, shutting of gas fuel flow to the turbine. This is done either by dumping hydraulic oil from the
SRV hydraulic cylinder or driving the position control closed electrically. The valve also serves as a
pressure regulating valve to hold a known fuel gas pressure ahead of the gas control valve & because
of these dual functions the valve is sometimes called a stop/speed ratio valve.
The stop/speed ratio valve has two control loops. There is a position control loop similar to that for
the gas control valve & there is a pressure control loop (see fig 5). Fuel gas pressure P2 at the inlet to
the gas control valve is controlled by the pressure loop as a function of turbine speed. This is done by
proportioning the turbine speed signal TNH & comparing it with the pressure feedback signal from
transducer 96FG in software (see fig 6). Any error between signals causes the amplifier to generate a
control signal to reposition the valve. The valve will be modulated continuously to hold this pressure.
The pressure control signals commands a servo drive amplifier to control the ratio valve position loop
in the same way the gas control valve drives its position loop in response to FSR.
The stop/ratio valve provides a shut off of the fuel gas flow when required by either normal operation
or emergency conditions. A hydraulic trip dump relay valve is located between the electro hydraulic
servo valve, 90SR & the hydraulic cylinder. This dump relay valve is operated by the low pressure
control trip oil system (OLT). When the trip is at normal pressure, the dump valve is maintained in a
position that allows the electro hydraulic servo valve 90SR to control the cylinder position. When the
trip pressure is low ( as in the case of normal or emergency shutdown), to dump valve spring shifts a
spool to a position which dumps high pressure hydraulic oil in the stop/ speed ratio valve actuating

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cylinder to the lube oil reservoir. The closing spring, stop the valves plug. Instantly shuts the valve,
there by shutting off fuel gas flow to the turbine combustors.
In addition to being displayed, the feedback signals & the control signals of both valves are compared
to normal operating limits & if the should go outside of these limits, there will be alarms generated.
The following are some typical alarms:
- L3GRVA_ALM------------- Stop/Speed ratio valve not tracking-Alarm
- L3GRVAT_ALM----------- Stop/Speed ratio valve not tracking-Trip
- L3GRVFLT------------------ Gas ratio valve position servo trouble
- L3GCVA_ALM------------- Gas control Valve not following- Alarm
- L86GCVT_ ALM----------- Gas control Valve not following- Trip
- L3GCVFLT------------------ Gas control valve servo trouble.
- L3GFIVP--------------------- Gas fuel inter valve pressure trouble
The servo valves are furnished with a mechanical null offset bias to cause the gas control valve or
speed ratio valve to go the zero stroke position (fail-safe condition) should the servo valve coil signals
or power is lost. During a trip or no run condition, a positive voltage bias is placed on the servo coils,
holding them in the position calling for the valve to be closed.
9.3.7.6 High Hydrogen gas control
Turbines that are designed to operate on high hydrogen gas fuels (like refinery gas) are required with
controls to provide the following features:
1. Inert purge of the gas fuel lines when GT is shutdown or is operating on Liquid Fuel.
2. Pre-start purge while starting the unit on distillate ( Start-up on High Hydrogen Gas is
prohibited)
3. Inert purge of the gas fuel lines prior to transferring to High Hydrogen Gas
4. Transfer to High Hydrogen Gas
5. Inert purge of the gas fuel lines after transferring off High Hydrogen Gas
6. Inert purge of the gas fuel lines after trip even when operating with High Hydrogen Gas

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The software diagram for the fuel selection is shown in Control Sequence Program.
INERT PURGE TEST
Inert purge test can be done during GT shutdown condition (recommended) or Liquid Fuel mode of
operation with no High Hydrogen Gas (96FG-16A, B<50 psig) present upstream of VS4-11. When the
inert purge test is activated by operator, following sequence shall be followed automatically. Inert
Purge Sequence:
1. Open VAH1-8 & close VA13-32, verify N2 pressure with 96HPG-1, 63HPG-1A, B.
2. Confirm N2 pressure is within the range as mentioned in device summary & no N2 pressure
Low alarm
3. Close VA13-13 & VA13-14: open VAH1-2.
4. Confirm VA13-13 & VA13-14 closed (by 33PG-13C & 33PG-14C), then open VAH1-1 & VAH1-3
staggered 3 secs apart.
5. After 3 sec of VAH1-3 open command, open VA13-15 % VA13-20.
6. Start inert purge timer.
7. Successful completion of purge s indicated when TMR DP transmitter (1 no.)/ switches (2 nos.)
96HPGD’s & 63HPGD’s are more than 5 psid for the duration of the purge (60 secs). If any 2 of 3 TMR
HPGD’s is less than 5 psid for 20 secs, continue purge for 90 secs. Abort purge if still not successful.
8. At the end of successful inert purge, close VA13-20, VA13-15, VAH1-1, VAH1-2 & VAH1-3 (vent
valves shall be closed first, then N2 purge valves).
9. Open VA13-13 & VA13-14, if GT is in liquid fuel with no High Hydrogen Gas (96FG-16A, B<50
psig) present upstream of VS4-11.
PRE- START PURGE

Gas turbine start up shall occur on distillate only.
GT Start Permissive:

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At GT start, if high hydrogen gas is present upstream of VS4-11, a pre-start N2 purge needs to be
completed before the GT is allowed to continue its start-up. The steps are as follows:
1. If PT 96FG-16A, B>50 Psig, steps 1-7 of Inert purge sequence as detailed above to be followed.
2. At the end of successful inert purge, close VA13-20, VA13-15, VAH1-2 & VAH1-3 (vent valves
shall be closed first, then N2 purge valves). VAH1-1 shall be kept open to block the P1 cavity between
VS4-11 & VSR-11.
100% LIQUID FUEL MODE

GT startup & shutdown shall occur on distillate fuel only. During unavailability of High Hydrogen Gas,
the unit is allowed to run on distillate only modes.
There are two possible scenarios under this mode:
a) 100% Liquid Fuel Mode- High Hydrogen Gas NOT present upstream of VS4-11
b) 100% Liquid Fuel Mode – High Hydrogen Gas present upstream of VS4-11
The above diagram shows the fuel system valve status during the Liquid Fuel mode above 95% speed,
when High Hydrogen Gas fuel is not present upstream of VS4-11. Key events:
1. At 95% GT speed, VA13-13 & VA13-14 are opened, VA13-15 closed to allow compressor
discharge purge air to the High Hydrogen Gas nozzles.
2. Vent valves VA13-20 & VA13-22 are open
3. If PT 96FG-16A, B<50 Psig, N2 block of P1 cavity is not required
4. Close VAH1-8 & open VA13-32 vent to prevent contamination of upstream N2 system.
During this mode, if High Hydrogen Gas pressure indicated by 96FG-16A, B>50 Psig, the actions
described in the next mode shall be initiated. The above diagram shows the fuel system status during
Liquid Fuel operation when High Hydrogen Gas pressure is detected at the inlet of the VS4-11 valves.

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Key Events:
1. If PT 96FG-16A,B indicate>50 Psig, N2 block of P1 cavity is required

2. Steps 1-7 of Inert purge sequence as detailed in sections above to be followed
3. At the end of successful inert purge, close VA13-20, VA13-15, VAH1-2 & VAH1-3 (vent valves
shall be closed first, then N2 purge valves). VAH1-1 shall be kept open to block the P1 cavity between
VS4-11 & VSR-11.
4. Loss of N2 pressure in the P1 cavity, as indicated by pressure transducer 96HPG-1 & pressure
switches 63HPG-1A, B, will trigger Low alarm at 63HPG-1A set point & will triggered fired shutdown at
63HPG-1B set point. During the fired shutdown, if there is high pressure in P2 cavity, as indicated by
96FG-12A, B, C>50 Psig a trip to prevent mixing air with High Hydrogen Gas fuel.
The above diagram shows the Fuel system status during purge mode prior to transfer to High
Hydrogen Gas.
Key Events:
 The following are the permissive for this mode
1. GT load greater than the value specified in control specification
2. Distillate fuel in operation
3. High Hydrogen Gas temp FT-G1-14A, B, 15A is in the range as mentioned in Device summary
4. High Hydrogen Gas pressure 96 FG-16A, 16B is in the range as mentioned in Device summary
 Once fuel transfer to High Hydrogen Gas is selected, initiate Inert purge sequence as detailed
in sections above. Only steps 2-7 to be followed.

 N2 supply pressure is monitored by pressure instrumentation 96HPG1, 63HPG-1A, and 1B. If N2
pressure drops below Low set point, it triggers an action (with the time delay of 3 secs) to abort the
purge & the transfer is inhibited.

 Upon successful purge completion, close VA13-20, VA13-22, Vah1-1, and VAH1-2 & VAH13-15.
VAH1-3 should be left open to create a N2 block in the CPD purge cavity between VA13-13 & VA13-14.

 Now the system is ready for transfer to High Hydrogen Gas.

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TRANSFER TO HIGH HYDROGEN GAS MODE
Co-fire mode (mixed fuel operation) is not allowed for high hydrogen gas. The operator should be able
to select High Hydrogen Gas operation to transfer to 100% high Hydrogen Gas Permissive for this
mode are:
 Successful inert purge determined by logics in previous step

 GT load limit: DWATT as mentioned in control specification

 High Hydrogen Gas temp limits: FT-G1-14A, B, 15A as mentioned in device summary

 High hydrogen gas supply pressure limits: 96FG-16A, B as mentioned in device summary

 N2 block I CPD purge cavity: indicated by 96PG-12, 63PG-12A, B, no N2 alarm

 Unit operating on Distillate
The transfer sequence will go through following modes to reach 100% High hydrogen gas Mode:
 High hydrogen gas manifold Pre-fill mode

 Transfer Mode
Upon meeting all the permissive listed above, transfer to High Hydrogen sequencing should start.
 Close vent valves VA13-20 & VA13-22

 Open High hydrogen gas aux stop valve VS4-11

 Open SRV to maintain P2 pressure set point

 VGC-11 shall open to 10% stroke for 10 sec to pre-fill manifold with High Hydrogen Gas
(Monitoring & field tuning is required. Recommended to adjust the valve stroke to match the pre -fill
time 8-10 sec).

Transfer Mode:

 Once pre-fill mode is complete, GT shall reach 100% High Hydrogen Gas mode in 60 secs

 VGC-11 opens from its prefill position & starts ramping up.

 The rate of valve opening is controlled by the normal fuel transfer rate.

 No steady state point is allowed below 10% stroke of the valve.

 Abort transfer & go to 100% liquid Fuel on failure of reaching 100% High Hydrogen Gas mode in
60secs

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In this mode GT may operate from FSNL to base load. But to transfer back to Liquid fuel, it shall be
above transfer permissible load as mentioned in control specifications.
The inert purge mode should start automatically as part of transfer off High Hydrogen Gas sequencing
once the appropriate permissive is met. The permissive for this mode include allowable transfer GT
load.
To mitigate risk of load or/ and exhaust temp spike during High hydrogen Gas manifold N2 purge due
to unaccounted fuel being added to the combustor, the HPG2 purge should begin when High Hydrogen
Gas split reaches 10% (FX1=10%) before transfer to Liquid Fuel is complete. Open VAH1-2 valve to
initiate HPG-2 purge. The above plot describes the valve sequencing strategy.
The above diagram shows the fuel system status during inert purge mode during transfer to Liquid
Fuel.
Key Events:
 During fuel transfer sequence, open VAH1-2 at high hydrogen gas split (FX1) is at 10% to purge
the High Hydrogen Gas manifold.

 Once VGC-11, VSR-11 & VSR-11 are closed, (GT transferred to Liquid Fuel) open VAH-1. (VAH1-
3 is already open to block CPD cavity during High Hydrogen Gas operation)

 3 secs after VAH1-1 command, open VA13-15, VA13-22 & VA13-290

 Start inert purge timer.

 Successful completion of purge is indicated by TMR DP transmitter (1 no.)/switches (2 nos.)
96HPGD’s & 63HPGD’s are more than 5 psid for the duration of the purge (60 secs). If any 2 of 3 TMR
HPGD’s is less than 5 psid for 20 secs, continue purge for 90 secs. Abort purge if still not successful.

 N2 supply pressure is monitored by pressure instumentaion96HPG1, 63HPG-1A, 1B. if N2
pressure drops below Low set point, (with the time delay of 3 secs), a TRIP is initiated.

 If purge is unsuccessful, the machine is tripped & the unit is locked out. Successful inert purge is
a permissive to restart the unit.

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 Upon successful purge completion, close VA13-20, VAH1-2, VAH1-3 & VAH13-15 & open VA
13-13 & 13-22 will remain open to keep P1 cavity blocked with N2 & P2 cavity vented.
TRIP EVENT
If unit trips while operating on 100% Liquid Fuel with Hydrogen Gas present or High Hydrogen Gas
mode, trip event is followed by inert purge. If N2 purge fails during trip (as indicated by 96 HPGD<LL
set point) unit is locked out. Successful inert [purge is a permissive to restart the unit.
Trip from 100% Liquid Fuel Mode:
If operating on 100% Liquid Fuel & GT trips, no purge is needed.
During any GT trip on High Hydrogen Gas, the closure of VGC-11 should trigger opening of N2 valves
VAH1-1 & VAH1-2 (VAH1-3 is already open to block CPD cavity during high hydrogen gas operation). 3
secs after opening VAH1-1, open valves VA13-20, VA13-22 & VA13-15 to carry out inert purging of high
hydrogen gas manifold, P1 cavities & CPD cavity & vent P2 cavity.
The purge should last 60 secs. If inert purge fails, during restart selection of “FIRE/AUTO/REMOTE”
mode commands from <HM1> screen is inhibited. Only “CRANK” mode can be selected. Once at Crank
speed (>24% speed, L14HM=1) the operator can select “INERT PURGE TEST” push button & a purge of
all the purge legs is performed. This purge test must be successful to allow the operator to select
“FIRE/AUTO/REMOTE” mode commands from <HM1? Screen to continue the startup.
LOAD REJECTION
Fuel nozzle passages on this application are sized such that the GT can achieve a load to FSNL on load
rejection on 100% high hydrogen gas.
Following strategy would be followed for start point & end point of load rejection
 Liquid fuel to high hydrogen gas transfer mode-load reject to FSNL liquid fuel operation

 100% High Hydrogen Gas operational mode-load reject to FSNL high hydrogen gas operation

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Load rejection from liquid fuel is treated similar to original liquid fuel unit. For load rejection event
from 100% high hydrogen gas operation, the strategy is to go to FSNL high hydrogen gas & stay on high
hydrogen gas. After the load rejection event, GT can load back up on High Hydrogen Gas or load to
permissible transfer load & transfer to liquid fuel. If the operator decides to shut down the GT instead
of loading on High Hydrogen Gas or in the event of unit unable to load back or load to permissible
transfer load, the controls should initiate a trip when the turbine speed drops to L14HS=0, 94% speed.
Alternatively, unit can trip instantaneously.
If load rejection happens during a fuel transfer-gas turbine should transfer to 100% liquid fuel mode &
recover speed.
SOV CLOSURE AND VENTING REQUIREMENTS
Any of the following events results in immediate closure of the SSOV (VS4-11) & opening of the vent
valve (VA13-20) to remove fuel pressure from the piping cavity between the SSOV (VS$-11) & the stop
speed ratio valve (VSR-11).
 Fire detected in the gas turbine enclosure of gas valve module.

 E-stop initiated

 High-High LEL alarm

 Loss if inert gas pressure block in the P1 pressure cavity during back up fuel use when gas fuel
pressure is equal to or greater than 50 psig as sensed by instruments PT-96FG-16A, -16B.

 Loss of ventilation in fuel gas module during High Hydrogen GAS operation, sensed by TMR
ventilation pressure switches.
9.3.7.7LCO/Naphtha control
The liquid fuel oil control system consists of fuel handling components & electrical control
components. The fuel handling components are primary fuel oil filter/strainer (low pressure), fuel oil
stop valve VS1-1, fuel pump PF1-1, fuel bypass valve assembly VC3-1, fuel pump pressure relief valve

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VR4-1, secondary fuel oil filter F2-1 (high pressure), flow divider FD1, combined selector
valve/pressure gauge assembly, check valves VCK1-1 to 10 & false start drain valves VA17-1, 2 & 5.
The electrical control components are liquid fuel pressure switch (up stream) 63 FL-2, fuel oil stop
valve limit switch 33FL, fuel pump clutch solenoid 20CF, liquid fuel pump bypass valve servo valve
65FP, flow divider speed pickups 77FD-1, 2 & 3.
The fuel stop valve is an emergency valve operated from the protection system of the turbine. This
stop valve is a two-position valve either fully open or fully closed, with a venture disc & valve seat.
When the turbine is shut down in the normal sequence or by emergency trip or over-speed trip
operation, the fuel oil stop valve will fully close within 0.5 seconds total elapsed time. For normal
startup & shut down sequence operation & for electrical trip from the control panel, electro-hydraulic
trip solenoid valve 20FL-1 & hydraulic trip valve VH4-1 shut off the hydraulic oil flow to the fuel oil stop
valve hydraulic cylinder. The spring in the fuel oil stop valve then over comes the oil pressure & closes
the valve.
The main fuel pump is a timing gear, screw type pump which is driven directly from the turbine driven
accessory gear. Its speed is directly proportional to turbine speed. Fuel pump discharge flow at any
given turbine speed is greater than the turbine combustion requirement. The excess fuel is re-
circulated back to the fuel pump inlet through the bypass valve, VC3. The pump has the desirable
feature of having its bearings located externally from fuel. The bearings therefore do not rely on the
fuel oil for lubrication. They are lubricated using sump lubrication for units operating with HSD only &
from external lube oil system fro units operating with Naphtha along with HSD.
Fuel flow to the turbine combustion system is the difference between the fuel pump flow & the bypass
flow. Fuel flow from the fuel pump to the turbine is controlled by modulation of the bypass control
valve position by means of an electro hydraulic servo system in response to a control signal from the
mark-V control panel. The bypass control valve is fitted with a single acting hydraulic cylinder, a return
spring & a servo valve 65FP-1.

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VR4, the main fuel pump discharge relief value, is located in a loop between the discharge & inlet of
the pump. The valve prevents the fuel oil pressure from getting high enough to rupture any lines in the
event when the flow divider stops rotating. The relief setting for this valve is specified in the device
summary drawing
The flow divider equally distributes input fuel flow to the individual combustion nozzles. It is a
freewheeling flow device consisting if gear pumps elements in a circular arrangement having a
common inlet with a single timing gear. This timing gear serves to maintain true synchronous speed of
each pumping element with all other elements.
The speed of the flow divider pumping elements is directly proportional to the fuel flow through the
flow divider. The flow divider is fitted with three magnetic pick up assemblies that monitor flow divider
speed & produce the feedback signal in the outer (primary) loop of the fuel system control loop.
A multi position selector valve located at the output of the flow divider facilities monitoring selected
fuel oil pressure values on a 0 to 1500 PSI pressure gauge. The pressures at each of the fuel nozzles &
the fuel pump outlet pressure can be measured.
Spring loaded check valves are located in each line between the flow divider & the fuel nozzles. The
check valves perform two functions:
1. Prevent fuel oil from entering the turbine under the condition where the fuel pump bypass
valve is fully open, the fuel forwarding system is on, & the fuel stop valve either leaks or is open
(regardless of turbine speed or whether the fuel pump clutch is energized or de-energized)
2. Prevent back flow of combustion gases from the combustion chamber through fuel nozzles &
liquid fuel system which would push the fuel oil in the fuel lines back towards the fuel oi l supply. Such
& occurrence would cause problems during subsequent startups on liquid fuel since there would be
very little liquid fuel in the fuel system.

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The false start drain valves are normally open spring loaded valves which are closed by compressor
discharge pressure. In the event of an unsuccessful start, fuel oil in the combustion wrapper & exhaust
frame is drained through the false start drain valves. During a normal start up, these valves will close as
the turbine accelerates & compressor discharge pressure increases.
The fuel pump clutch solenoid electrically positions the fuel pump clutch to allow the accessory gear to
drive the feel pump. It operates on “flux through disc” principle with all forces acting within the clutch
itself. The end plate acts as the armature of the magnetic circuit. It automatically takes up for disc wear
eliminating adjustment. The clutch, however, must be locked end wise to the shaft.
Electro-hydraulic valve that controls the position of the fuel pump bypass valve. When the turbine is
shut down or in tripped condition this servo valve is electrically positioned to fully open the bypass
valve. The valve has three independent coils. Each coil is driven by one of the three controllers (R,S & T)
to provide redundancy in the electrical circuit.
These are non-contacting magnetic pickups which generate a pulse signal at a frequency proportional
to flow divider speed which in turn is proportional to fuel flow delivered to the combustion chambers.
This switch monitors the liquid fuel oil inlet pressure to the pump. If fuel pressure falls below the safe
NPSH requirement of the fuel pump for duration of more than five seconds the fuel pump clutch is de -
energized. This protects the fuel pump against damage due to operating with low suction pressure &
also avoids inadvertent trips due to transient reduction in fuel pressure.
Limit switch 33FL-1 indicates the close position of stop valve. An alarm is annunciated if the stop valve
is closed after the start of firing sequence. The control system also checks that the valve is closed at the
initiation of start. On initiation of the firing sequence of the Gas-Turbine during startup the control
system commands the stop valve to open condition.

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When the turbine is run on liquid fuel, the control system check the permissive (L4 & L33FL1C) & holds
FSR to zero unless they are “true”. Other permissive come from 63FL & the master protective system
& control the opening & closing of the fuel oil stop valve, energizing the fuel pump clutch (20CF) to
drive the fuel pump.
The FSR signal from the controlling system goes through the fuel splitter on dual fuel machines (see
dual Fuel) & becomes FSR1. The FSR1 signal will be multiplied by speed (TNH), so that fuel flow
becomes a function of speed. This enables the control system to have better fuel control & resolution
at the lower, more critical speeds where the air flow is less. This resultant signal (FQROUT) becomes
the reference for fuel flow. At full speed FOROUT will be equal to FSR.
When the gas turbine is given a start signal the liquid fuel oil system is present in the following state:
 The fuel stop valve is shut since 20FL has not energized to open the stop valve. FSR1 (liquid fuel
control voltage) fed in to the fuel control software, is held at zero. This causes the control panel
circuitry to drive the fuel oil bypass valve servo 65FP to a position so that the bypass valve is held at
fully open position.

 The flow divider is not rotating as there is no fuel flow; therefore, the speed pickups 77FD-1, -
2, & -3 indicates zero fuel flow to the control system.

 The false start drain valves are open until the compressor discharge pressure is high enough to
close the valves.

The liquid fuel oil control system remains in this state until the turbine reaches firing speed. At firing
speed (reached after the starting means has held the gas turbine at cranking speed until the purge
timer K2TV has completed) the liquid fuel system components follow the following sequence:

 Solenoid valve 20FL is energized to open the liquid fuel stop valve. The fuel stop valve limit
switch 33FL detects the full open position of the liquid fuel stop valve. This allows the fuel pump clutch
solenoid 20CF to energize. The fuel pump is now engaged to the accessory gear shifts & starts pumping
fuel through the bypass value.

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 The FSR1 which was clamped to zero is reset to the firing FSR value (this value is detailed in the
Control Specifications). This FSR signal & turbine speed signal TNH combine in a multiplier block in the
liquid fuel flow command algorithm & establish the desired rate of fuel flow in to the turbine (FQROUT)


 The increased value of FQROUT results in the liquid fuel bypass valve being commanded to start
closing. This increases the fuel pump discharge pressure. When this pressure has increased to a
pressure high enough to overcome the friction in the flow divider & the check valves cracking pressure,
the fuel will begin to flow into the combustion chambers.

 As the fuel starts flowing in to the combustion chambers, the speed sensors 77Fd-1, 2, & 3 send
a signal to the TCQA card which is read as the fuel flow rate signal by the control system. When the fuel
flow rate is equal to the called for fuel flow rate , the servo valve 65FP is moved to the null position &
the liquid fuel bypass valve remains “stationary”

 Once flame has been established in the combustion chambers, FSR1 is lowered to the warm-up

level.

 During the initial firing of the gas turbine the control software monitors the fuel flow rate in to
the combustion chamber. If a preset flow rate is exceeded for more than two seconds continuously it
will cause the turbine to tri on “EXCESSIVE STARTUP FUEL FLOW”. This protection is disabled after
completion of warm-up time (L2WX).

 Upon completion of the warm-up period, the FSR1 is increased to accelerate the turbine to
operating speed. The fuel control system adjusts fuel flow to meet the commanded fuel flow (a
function of FSR1 & TNH). As the turbine is accelerated, the false start drain valve closes due to
increased compressor discharge pressure.

 After attaining Full Speed the commanded fuel flow becomes a function of FSr1 only.
When a shutdown command is given FSr1 is slowly ramped down to minimum FSR value & leading to
direction of the turbine. When L14HA speed relay drops out, the liquid fuel system goes into the trip
state, & the liquid fuel stop valve closes. At the same time FSR is reset to zero, the bypass valve servo
65FP is electrically driven to such a position where the hydraulic oil moves the liquid fuel bypass valve

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to fully open condition. This tops fuel flow into the turbine so the flow divider wills top rotating as
sensed by the magnetic speed pickups 77FD-1, 2 & 3. As the turbine decelerates further, the false start
drain valves will open. The fuel oil control system will remain in this sate until the turbine is ready to
fire during the next startup.
9.3.7.8 Dual Fuel control
Turbines that are designed to operate on liquid & gaseous fuel are equipped with controls top
provide the following features:
 Transfer from one fuel to the other on command

 Allowable time for filling of the type fuel to which turbine operation is being transferred

 Mixed fuel operation

 Operation of liquid fuel nozzle purge when operating totally on gas fuel

 Operation of gas fuel nozzle purge when operating totally on liquid fuel for some frame
sizes The software diagram for the fuel splitter is shown in the fig DFFR-3.
If the unit is running on-liquid & the <I> command pushbutton is pressed to select gas, the
following sequence of events will take place: (refer to Figure DFFR)
 FSR 1 will remain at its initial value but FSR2 will step to a value slightly greater than zero.
This will open the gas control valve slightly to bleed down the intervalve volume, P2. This is done in
case a high pressure has been entrapped. The presence of a higher pressure than that required by
the sped ratio controller would cause slow response in initiating gas flow.

 After a time delay, typically thirty seconds, to bleed down P2 & fill the gas supply line, tile
software program ramps the fuel commands at a arte programmed as a PROM constant to
complete fuel transfer in thirty seconds.

 As the transfer progresses, FSR1 will be reduced & FSR2 will increase at the programmed ramp

rate

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 When the transfer is complete, a logic signal, L84TG (Total Gas), will disengage the fuel pump
clutch 20CF, close the fuel oil stop valve by deenergizing the liquid fuel dump valve 20FL & initiate
the purge sequence.
Transfer from gas to liquid is essentially the same sequence as previously described except that gas &
liquid fuel commands are interchanged. For instance, at the beginning of a transfer, FSR2 remains at its
initial value, but FSR1 steps to a value slightly greater than zero. This will command a small liquid fuel
flow. If there has been any fuel leakage past the check valves, this will find the liquid fuel piping &
avoid any delay in delivery at the beginning of the FSR1 increase. The rest of the sequence is the same
as liquid-to-gas.
The gas turbine burns natural gas or fuel oil. The fuel purge system supplies air to the inactive fuel
nozzles to prevent fuel accumulation & combustion back flow in the associated gas turbine fuel piping.
When burning natural gas, the fuel purge system supplies purging air to the fuel oil passage of dual fuel
nozzles. When burning oil the fuel purge system supplies purging air to the gas turbine natural gas
manifold.
When transfer from gas to liquid is completed, gas fuel system purge valves VA 13-1 & -2 are opened
by energizing 20PG-1 & 20PG-2. The signal to energize 20PG-1 & -2 also closes gas vent solenoid valve
20VG-2 to prevent venting of the volume between the purge valves. Limit switches 33PG-1 & -2 on the
purge valves indicate that the valves are closed & permit transfer from liquid to gas when both purge
valves are closed & the intervolume pressure switch 63PG-1 indicates low pressure. Limit switches
33PG-2 & -4 indicate that the purge valves are open & used to determine valve fault.
To prevent chocking of the liquid fuel nozzles while operating oil gas fuel, some atomizing air is
diverted through the liquid fuel nozzles. See fig DFFR-2. The following sequence of events occurs when
transfer from liquid to gas is complete. The atomizing air bypass valve VA18 is opened by energizing
20AA. This results in a purge pressure ratio across the compressor of 1.1. After a time delay which

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permits reaching steady state purge compressor ratio, purge valve VA 19-1 is then transferred
because of the energizing of solenoid valve 20PL-1. This results in a flow of air through the liquid fuel
nozzles. The time delay is needed to reduce the load spike which occurs when purge air displaces the
liquid fuel nozzle into the combustion chamber.
Units may be operated on a mixture of liquid & gas fuel is permitted. Operation on a selected mixture
is obtained by electing the mix command push button & setting the command set point FX1_CMD to
the desired liquid fuel fraction. Limits on the fuel mixture are required to insure proper fuel
combustion, gas fuel distribution, gas nozzle flow velocities. Percentage of gas flow must b increased as
load is decreased to maintain the minimum pressure ratio.
As stated before FSR is divided into two signals to provide dual fuel operation. The two signals are FSR1
& FSR2. Typically FSR1 is for liquid & FSR2 for gas. See figure DFFR-3. FSR is multiplied by the desired
fuel mix ratio, FX1 to produce an FSR1 signal. FSR1 is then subtracted from the FSR signal to give FSR2;
that becomes the control signal for the secondary fuel.
9.3.7.9 Load control

9.3.7.9.1. General
Once the unit has been synchronized either manually or automatically it can be loaded by several
loading sequences. For instance, a unit can be loaded manually or automatically up to a temp control
limit, or a output load limit. Units operating under isochronous control will accept existing load or be
limited by temp control. More detail on the actual control panel features are described in the
operation section.
9.3.7.9.2. Synchronizing
Automatic synchronizing is accomplished sing a microprocessor based synchronizing circuit. The circuit
inputs are transmitted through an interface module. Te interface module contains an isolation

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transformer for the generator & line input signals & the breaker closing relay. The synchronizing
software is part of the SPEEDTRONIC mark V control system.
For synchronizing, the unit is brought to 100.3% of rated speed. If the system frequency has varied
enough to cause an unacceptably high slip frequency a speed matching circuit in the synchronizer will
adjust the turbine governor to reduce the slip frequency & permit synchronizing. For added protection
a synchro check relay is provided. It is used in series with both the auto synchronizing relay & the
manual breaker close switch to prevent large out-of-phase breaker closures.
9.3.7.9.3. FSNL (Full speed no load)
The reason that “Full Speed, No load” adjustment is important is that it actually calibrates speed with
the called for speed using the digital set point. The 100.3% will cause an increase in fuel command
necessary to raise the speed 0.3% above synchronous grid frequency. It is essential that the generator
& system frequency be matched within 0.33Hz to synchronize quickly with the synchronizing relay.
“Full Speed-No-Load” therefore is an important setting to assure proper speed for synchronizing.
9.3.7.9.4. Load control
Speed load control increases fuel through the digital set point to maintain output value. Most units
have three values of output control: reference to the control specifications for settings is required.
a. Spinning reserve- once the generator breaker is closed, the turbine will load to this setting.
b. Preselected Load- the required load is first selected by inputting the data on the main screen,
then by selecting the PRESELECT option on the main display; the load is varied to the preselected load.
c. Load limit- this load is not selectable, but is a calculated load limit beyond which the unit is not
permitted to operate. It is normally the material limit for the gas turbine generator.
9.3.7.9.4.1. Manual mode
The operator may increase or decrease load using switches 70R4/CS between no-load & base temp
control line. The loading is accomplished by raising or lowering the digital set point.
9.3.7.9.4.2. Isochronous mode

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In this control mode the unit output is a function of system demand. When selected, this control
mode maintains a constant speed.
9.3.7.9.4.3. Temperature control
Temp control is initiated by the switch 43bp. In this mode of control load is increased automatically
until a temp control limit is reached. Load is then held at a constant firing temp as more fully described
in the temp control text. Turbine output in this mode of control is a function of ambient temp.
Note: Manual load control is provided for full convenient rapid adjustment of load. It is not intended
to be used to raise load to rated output without interruption. Frequent use of manual set point
control to reach rate load more rapidly than the automatic cycle can reduce hot gas path parts life.
Similarly excessive use of “Fast start” can also reduce hot gas path parts life.
9.3.7.10 Water Injection skid controller
The water injection control system provides the necessary flow of water to the gas turbine
combustion system for the following reasons:
 In order to meet the current statutory regulations w.r.t. limiting the quantum of the
emissions of nitrogen oxides (NOx) in the exhaust stream.

 On some units is used for power augmentation.
Certain regulations not only require meeting the emission levels, but also require the continuous
monitoring of exhaust gas composition to verify that the regulations are being met. The major portion
of the water injection system is located on an off-base skid (shown in the System Schematic). The
system schedules water flow to the turbine combustors as a function of total fuel flow and, if required,
ambient temperature. The required water to fuel ratio must be established through the field
compliance test of each unit as per the current statutory regulations. The final control schedule is
calculated in <RST> controller software algorithms.
The primary components of the system are as follows:

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 Electric motor-driven centrifugal water pump(s) 88WN(s). The pump(s) is protected from low
water pressure by pressure switches 63WN-1 & 2, located in the pump suction and discharge
respectively.

 A five-micron filter at the pump discharge to prevent foreign object contamination of control
devices and water injection nozzles.

 Flow meter FM1 which provides electrical feedback signals proportional to water flow to the
gas turbine control system.

 Water injection system stop valve VS2- 1, controlled by solenoid operated valve 20WN- 1.

 The water injection control valve VC4-l and its actuator are controlled by direct digital pulses
from controllers RST. This assembly controls the flow of water to the water injection manifold on the
gas turbine. LVDT 96WN provides position feedback in order to assure valve position accuracy and
used as a backup feedback to flow measurement in case flow meter is bypassed for maintenance.

 Injection manifold on turbine base and water injection nozzles which distribute an even flow of
water to the combustors over the required flow range. The manifold distributes the flow equally to the
flow proportioning valves VWP1-l to VWP1-10. These valves provide a high flow resistance at low flows
in order to evenly distribute the water flow at start-up and low flows.
Controllers RST position the control valve actuator for required water flow. In case of continuous
monitoring of exhaust emissions it is possible for a few successive oneminute data points to fall below
the required water-to-fuel ratio without causing a noncompliance condition over the sixty minute
averaging interval. In such a case, a local alarm will alert the operator so that corrective action may be
taken to prevent a non-compliance situation from occurring. A combustion monitor function in the
control panel will detect any abnormal operation of the water injection system which may extinguish
the flame in one or more combustion cans. The monitor will give a combustion alarm upon detection
of an abnormal exhaust temperature pattern. Controller software contains constants which will detect
loss of feedback from the flow meter and control valve LVDT, respectively. Loss of either feedback path
is annunciated on the turbine control panel.

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Several water system alarm and shutoff conditions are detected by the controllers <RST>.
 A “WATER SYSTEM TROUBLE” signal is annunciated on the turbine control panel if problems in
the feedback or fuel flow measurement circuits are detected.

 A “WATER SYSTEM SHUTDOWN” signal and trip of the water injection system occur due to any
of the following conditions:
1. Low water injection pump suction or discharge pressure, as sensed by pressure switches 63WN
2. Fuel flow to the turbine is cut back very rapidly. This is observed by sensing the rate of
decrease in FSR, and the water is shut off in order to prevent flameout in any of the combustors.
3. Combustion alarm generated from the combustion monitor function.
Each of the above trip conditions will trip the water injection system only if the condition exists for
duration more than a set time period (Refer Control Specifications for Values). This prevents water
injection system trips due to transient conditions.

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9.3.8 GBC controller

9.3.8.1. Fuel Gas Anti Surge controller
GBC consist of FG inlet Flow control valve (HV7201) and the SOV operated Anti surge Control valve
(UV7201). During start up, HV7201 is at 0% opening while anti surge valve is at 100% opening. During
normal running the GBC outlet discharge pressure is the regulating parameter. The actual discharge
header pressure (PT7205A/B – ½ logic) output signal is compensate with Actual suction flow measured
through FT7201A/B (1/2 Logic) and same is compared with operator flow SP in FIC7201B. The error
signal will regulate the position of anti surge valve (UV7201). Inlet flow CV HV7201 is manually
operated to ensure that FE7201 measured the minimum flow. At low value of FE7201, GBC will trip.
9.3.8.2. Lube oil system controller
In Lube oil system of GBC, drive list consist of 2 nos of Motor driven Lube oil pump. Any one Lube oil
pump is started and standby is kept in ACO mode. ACO selected LOP will start in Auto if lube oil
pressure of header reduce to XX Kg/cm2 g through PT7312D
9.3.8.3. Primary seal gas controller
Primary seal gas is nothing but sealing of GBC LP and HP gland through the same process gas. The
tapping of Gas is taken from both inlet and outlet header of GBC. Even Nitrogen is also connected to
the seal gas header. Normally during startup as no discharge is available, seal gas is normally taken
from GBC inlet FG line or from nitrogen header. In normal running condition, the GBC discharge is
lineup for sealing. Seal gas filter skid is equipped with one control valve PDCV7003, which get an input
from 2 differential pressure transmitter PDT7003A/B. These differential transmitters sense the
pressure from HP and LP side gland and compared the same with the Operator SP in PDIC7003 PI
controller. The output of the controller is command to operate the PDCV7003 control valve.
Controller action is reverse.

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9.3.9 Steam Turbine Controller

9.3.9.1. Load / Speed / Frequency / Extraction Controller
Steam Turbine is one the most critical high speed rotating device which required to be controlled
through very precise controlling mechanism, said Governor. Governor includes EHTC control block,
Servo motor / Mechanism, Amplifier, Control valve mechanism. Governing scheme equipment details
for STG are mentioned as below
The Turbo Generator set is equipped with Electro-hydraulic governing system. The governing system is
simple and easy to operate and maintain. The Electro hydraulic governor maintains the speed of turbo-
generator set constant according to the droop characteristic. Simultaneously the extraction steam
pressures in two extraction lines are also maintained by the governing system. Additionally Turbine
governing system incorporates protective device to protect the turbine during adverse operating
conditions such as over-speed, rotor axial shift, low lubricating oil pressure etc. For control purpose
single casing condensing turbine with two controlled extractions has been divided internally with
steam glands in three parts, namely
HP part (0001)
IP part (0002)
LP Part (0003)
In each part of the turbine steam flow is regulated by a set of steam control valves (0801, 0802A&B &
0803A&B).The amount of opening of each valve is controlled by the hydraulic signal (secondary oil
pressure) generated by speed governor and extraction pressure controllers through I/H converter.
Speed governor acts in such a way that the change in amount of steam flow through HP,IP& LP parts
of turbine is same. This does not affect the steam flow through extractions.
Extraction pressure controller-I acts in such a way that upon decrease in extraction pressure-I, HP
control valves open more and IP & LP control valves move in close direction. Valve movements through
changes in secondary oil pressures are designed such that the increase in power in HP part of

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the turbine is equal to the decrease in power in IP& LP part of turbine. This arrangement does not
affect the total power developed by the turbine. Similarly, upon increase in extraction pressure-I, HP
control valves move in close direction and IP & LP control valves move in open direction. On the similar
lines, extraction pressure controller-II acts in such a way that upon decrease in extraction pressure -II,
HP&IP control valves open more and LP control valve move in close direction. Valve movements
through change in secondary oil pressure is designed such that the increase in power in HP&IP parts of
the turbine is equal to decrease in power in LP part of the turbine. This arrangement does not affect
the total power developed by the turbine. Similarly upon increase in extraction pressure, HP&IP control
valves move in close direction and LP control valves move in open direction. Output of speed governor
and extraction pressure controller is coordinated in ratio module in electronic governor.
ELECTROHYDRAULIC TURBINE CONTROLLER (Control cubicle)
The Electro-hydraulic turbine controller is designed to control the speed, electrical power and
extraction pressure. The following functional/control loops are incorporated in the controller:
-Speed acquisition
-Speed reference
-Speed controller
-Extraction pressure (I&II) control
-Binary emergency stop valve control
-Interlock functions
-Power supply.
For details of electronic control system refer EHTC block diagram.
ELECTROHYDRAULC CONVERTERS (1800A, B & C): The Electro-hydraulic converters are connecting link
between electronic and hydraulic parts of Electro-hydraulic governing system. The output signal of
electronic governor is fed to the torque motor of Electro-hydraulic converter (I/H). Torque motor

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positions the control slide, which in turn builds up the secondary oil pressure proportional to the
signal. This secondary oil pressure is transmitted to the control valve actuator.
EMERGENCY STOP VALVE (2301) AND SOLENOID VALVES (2220, 2221A&B): The emergency stop valve
(2301) is of quick closing type. ESV consists of a spring-loaded piston and a piston disk, which is
connected to the valve cone through a spindle. The emergency stop valve is actuated by means of
solenoid valves (2220, 2221A&B) and a control circuit built in the electronic control cubicle. The logic
and interlocking part permits the sequential opening and closing of emergency stop valve only when
the control valve (0801) of the turbine is closed. When solenoid valves are energized, the start-up oil
pressure builds up. The pistons of emergency stop valve actuator compress the spring and forms oil
tight with the piston disk. Pressure transmitter PT (3404) initiate the signal and through the logic de-
energizes the solenoid valve (2220) thereby trip oil pressure builds up below the piston disc. Next
solenoid valve (2221A&B) is de-energized upon initiation of PT (3406), the oil in the space above the
piston of emergency stop valve (2301) is allowed to pass to the drain via orifice (5610). The resulting
pressure difference across the piston and the piston disk causes the piston with piston disk to be
moved to the opening end position with the spring compressed. The end position is indicated by means
of signal lamp. Upon complete opening of ESV (2301), solenoid valve (2221A&B) is de energized and
ESV (2301) opens. The opening and closing speeds of emergency stop valves can be set accurately with
the aid of adjustable orifices (5610) in the oil drain lines of the solenoid valves.
CONTROL VALVE ACTUATORS (SERVOMOTORS) (1910, 1911 A & B & 1912): Control valve actuators
(1910, 1911A&B & 1912A&B) position the control valves (0801, 0802A&B, 0803A&B) corresponding to
the effective secondary oil pressures generated by hydraulic amplifier. Control valve actuator
(Servomotor) mainly consists of a pilot valve; a power cylinder and a feed back system. Upon change in
secondary oil pressure, pilot valve provides oil passages to and from power cylinder. The movement of
power piston is transmitted to the control valves through levers. The feed back lever resets the pilot
valve to its neutral position once the power piston occupies new position corresponding to changed

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secondary oil pressure. The system is such that the increase in secondary oil pressure causes the
control valves to open. Hence interruption of secondary oil pressure causes the control valves to close.
DAMPING DEVICE (5620): Damping device (5620) damps out the quick oscillations in secondary oil
pressure generated by hydraulic amplifier; this helps in improving the stability of the governing system
TESTER (2309) FOR EMERGENCY STOP VALVE: Testing device (2309) is provided to check the proper
functioning of emergency stop valve (2301) during normal operation of turbine. If the testing device is
operated, it will admit the pressure oil to the space behind the test piston of emergency stop valve,
which will then be pushed against the piston and move the piston and valve spindle towards the closed
position (partial closing).
REMOTE ENGAGEMENT OF HAND TRIP VALVE: Hand trip valve (2250) can be put into operation
remotely with the help of a control switch, i.e. a pressure transmitter (PT 3407) and a solenoid valve
(1050). As soon as control switch is pressed, solenoid valve (1050) gets energized and oil flows into
hand trip valve (2250) and reset the trip lever. Soon after trip oil pressure is built up, solenoid valve
gets de-energized through the pressure transmitter (PT 3407).
HAND TRIP VALVE (2250): Whenever the turbine is to be tripped, the governing oil pressure (trip oil
line after hand operated valve) is drained by hand trip valve. Thus pressure in front of stop valve
piston disc and secondary oil pressure falls, resulting in closure of stop valve and control valves. The
hand trip valve (2250) is operated either manually or by loss of source oil pressure
NON RETURN EXTRACTION STEAM VALVE (2350A&B): In the extraction steam line, non-return quick
closing flap valve has been provided, which prevents reverse flow of steam into the turbine. Also at
turbine trip, its actuator, which in turn acts at the loss of trip oil pressure, closes non-return valve,
change over valve (5400A&B) helps in quick draining of oil from non-return valve actuator.

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TRIP SOLENOID VALVE (2222): Trip solenoid valve facilitates the tripping of turbine from remote place
such as control room through push button. Whenever the solenoid valve is energized, it interrupts the
oil supply to trip oil circuit and simultaneously de-pressurizes the trip oil circuit. Solenoid valve is also
energized by any one of the signals initiated by limit value monitoring devices or upon generator faults
DUPLEX FILTER (4520): The Duplex filter with 225 lpm 20 micron filtration is consist of filter head with
change over valve and two filter bowls which are removable for maintenance. The change over
mechanism facilitates redirection of fluid stream from the dirty to clean filter housing without
reduction in flow. The arrangement also provided with a maintenance indicator, which monitors the
degree of clogging of the filter elements. Arrows indicate which filter bowl is in operation. Closing of
both filter bowls simultaneously not possible
GOVERNING CONTROLS:
STG controlling can be broadly divided into three categories:
1. EXTRACTION PRESSURE CONTROL
Turbine governing system is capable of meeting HP and MP extraction steam demands at constant
pressure while generating desired electricity. This is achieved with the help of HP and MP extraction
pressure control system. The HP extraction pressure control system work similarly in the following way;
PT3112A/B sense the HP steam extraction pressure (Process value) and give feed back to EHTC
governor. This process value is compared with extraction pressure set point register in extraction
pressure summer unit. (Extraction pressure set point register output can be varied from operator
control panel through raise/lower push button). Error signal from extraction pressure summer unit is
transmitted to a Minimum value selector. Second input to Minimum selector unit is from HP extraction
limiter controller. (HP Extraction limiter output can be varied from operator control panel though
raise/lower push button). Minimum value out of two is selected as output signal for HP extraction
controller O/P. Similar logic is applicable for MP extraction system as well.

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2. SPEED/LOAD CONTROL:
Turbine can be operated either on speed control mode or on load control mode. When operating
independently (When machine is not connected with utility), STG will work on speed corrector control
mode. Speed Reference setter block gives signal to speed reference time dependent which is having a
selection switch for Cold, warn and hot start curves. Input to the Speed reference setter block is
manual selection of speed set point, Auto run selection or through speed synchronizer raise lower
button. Output of Speed ref. time dependent block comes to Speed controller as one of the input
speed signal. Proximity sensor provided for speed measurement provides the actual speed of the
turbine to Speed controller. Difference between the speed set point and actual speed is directed to a
summation block. Second input to the summation block is signal from the load controller. In load
controller Actual load is compared with Load reference time dependent block signal. Input to the load
ref. time dependent block is output from Minimum selector block which is having the input for Load
limit set by operator and Load reference from synchronizer. Another input to load controller is
Frequency controller signal. Input to frequency controller is error signal from actual frequency to
reference frequency set by operator.
As long as the load set point is higher than the speed error signal, whenever turbine speed goes below
the set point, speed raise action will be active on governor control valves. Whenever load set point is
lower than the speed error signal, turbine governor will not be able to pick up the speed to the set
point value when speed of the turbine decreases. Then load set point has to be increased to maximum
to activate turbine speed control.
Finally for the position of all Control valve, Main as well Extraction control valves, the HP/MP valve
ratio setter block is provided which get input from minimum block selector having input from Load and
speed controller along with the HP and MP extraction controller output signal. HP/MP valve ratio setter
block provide analog signal to I/H governor after considering valve characteristics compensation.

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3. INLET STEAM PRESSURE CONTROL:
Inlet steam pressure limiter has been configured for our turbine. If the inlet steam pressure drops
below the set point, inlet steam pressure limiter will restrict the opening of control valve. While doing
so, normal speed and load of the turbine will also be maintained unless the inlet steam pressure drops
further to below the set point. If the inlet steam pressure further decreases, priority will be shifted to
maintaining inlet steam pressure sacrificing turbine speed/load.
9.3.9.2. Lube Oil controller
In Lube oil system of STG, drive list consist of one Motor driven Aux Lube oil pump, Steam drive driven
MLOP and one DC drive driven EOP pump. In addition to this there are Jacking oil pump and barring
motor drive. During start up normally based on the availability of steam or power, either ALOP or
MLOP is started. Simaltenuosuly start JOP. Healthy signal of JOP is start permissive for

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barring motor starting. Start barring motor and put STG on barring mode. ALOP and EOP to kept in
ACO mode of operation to start on AUTO mode. ALOP and EOP will start if the Lube oil pressure fall
below 4.2 and 0.8 Kg/cm2 g through PT3206 and PT3214A respectively.
9.3.9.3. Auxiliary Steam controller

Aux steam in STG is used for two main purposes:
1. Gland sealing
2. Vacuum pulling
Control of Aux steam is applicable only in Gland sealing where the pressure at inlet of HP and LP gland
of STG to be maintained in the range of 0.1 to 0.2 Kg/cm2 g. Aux steam at a pressure of 11 bar a and
350 :C enter the STG inlet. The main control valve PCV3131A and the drain control valve PCV3131B is
used to maintain the STG gland steam pressure. The action of both control valves are in direct and
reverse respectively. Normally the main control valve is in 0% position while the drain control valve is
in 100% opening. When the Operator provide the set point the error signal between SP and actual
valve is generated from PI controller which command main control valve to open and simultaneously
command drain control valve to close.
9.3.9.4. Hotwell Level Controller
The function of Hotwell level controller is to maintained the Hotwell level through two control valves
action; one in direct control mode while one in reverse control mode. Direct control mode CV is the
CV (LCV1601A) which discharges the STG condensate to Deaerator while reverse control mode CV
(LC1601B) recirculates the condensate back to Hotwell. Level transmitter signal from LT1601 is
compared with the Operator SP given in LIC PI controller. The error signal is split for both the control
valve. Normally the main control valve is in 0% position while the drain control valve is in 100%
opening. When the Operator provide the set point the error signal between SP and actual valve is
generated from PI controller which command main control valve to open and simultaneously
command drain control valve to close thus maintaining the hotwell level in condenser.

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9.3.10. Back Pressure Turbine Controller

9.3.10.1. Load / Speed / Frequency / Extraction Controller
The Back pressure turbine is equipped with Electro-hydraulic governing system. The system offers the
advantages of electronic methods for measurement and signal processing and use of hydraulic devices
for control of large positioning drives. The advantages of this combination are better integration
capability, high quality steady state and dynamic response and facility for implementation of
complicated functions. The signal processing, control function and interlocks are incorporated in the
electronic control cubicle, which is placed in the control room. An Electro-hydraulic converter provides
the link between electronic section and the hydraulic section. The other features of BPTG governing
systems are a quick closing stop valve, over speed protection, rotor axial motion protection, manual
trip, remote solenoid trip and remote engagement of trip lever.
SPEED CONTROL: The speed transmitters sense the turbine speed digitally and feed the actual speed
signal to speed controller. The speed controller can be programmed for droop mode or isochronous
mode depending on requirements. The speed controller gives output signal to Electro-hydraulic
converters through ratio modules. The Electro-hydraulic converters convert the electrical signal into
hydraulic signal (secondary oil pressure).
OIL SUPPLY TO THE GOVERNING SYSTEM: The supply of oil to the governing system is at 8 bar from the
main oil pump which is driven by electrical motor.
ELECTRONIC CONTROLLER: The speed transmitters (SE3901 A,B&C) sense the turbine speed digitally
and feed the actual speed signal to speed controller. The speed controller can be programmed for
droop mode or isochronous mode depending on requirements. The speed controller gives output
signal to Electro-hydraulic converter (1800). The Electro-hydraulic converters convert the electrical
signal into hydraulic signal (secondary oil pressure).

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ELECTROHYDRAULIC CONVERTORS (1800): The output signal of the electronic governor is converted
into a proportional signal pressure (secondary oil pressure) in the converter (1800). The converter
consists of an electrical amplifier, an Electro-hydraulic converter and a hydraulic pressure sensor which
feeds the hydraulic output signal back to the input of the electrical amplifier.
CONTROL VALVE ACTUATORS (1910): Control valve actuators (1910 & 1911) position the control valves
(0801) corresponding to the secondary oil pressures generated by hydraulic amplifier. Control valve
actuator (Servomotor) mainly consists of a pilot valve, a power cylinder and a feed back system. Upon
change in secondary oil pressure, pilot valve provides oil passages to and from power cylinder. The
movement of power piston is transmitted to the control valves through levers. The feed back lever
resets the pilot valve to its neutral position once the power piston occupies new position
corresponding to changed secondary oil pressure. The system is such that the increase in secondary oil
pressure causes the control valves to open. Hence interruption of secondary oil pressure causes the
control valves to close.
EMERGENCY STOP VALVE (2301) AND SOLENOID VALVES (2220 2221): The emergency stop valve (2301)
is of quick closing type. The valve is actuated by means of a starting device. The stop valve consists of a
spring-loaded piston and piston disc, which is connected to the valve cone through a spindle. The
emergency stop valve is actuated by means of solenoid valves (2220, 2221) and a control circuit built in
the electronic control cubicle. The logic and interlocking part permits the opening of emergency stop
valve only when the control valve (0801) of the turbine is closed. When solenoid valves are energized,
the start-up oil pressure builds up. The piston of emergency stop valve actuator compresses the spring
and forms oil tight joint with the piston disk. Pressure transmitter PT(3903) initiates the signal and
through the logic de-energizes the solenoid valve (2220) thereby trip oil pressure builds up below the
piston disc. As soon as the solenoid valve (2221) is de-energized upon initiation of PT (3904), the oil in
the space above the piston of emergency stop valve is allowed to pass to the drain via orifices
(5610A&B). The resulting pressure difference across the piston and the piston disk causes the piston
with piston disk to be moved to the opening end position with the spring

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compressed. The end position is indicated by means of signal lamp. The opening and closing speeds of
emergency stop valve can be set accurately with the aid of adjustable orifices (5610A&B) in the oil
drain lines of the solenoid valves.
START PERMISSIVE TO GOVERNOR: Once the stop valve is opened, the limit switch (ZAH 3902) on the
stop valve sends a signal to the governor through the interlock logic for permitting it to give the signal
to open the control valves.
TESTER (2309) FOR EMERGENCY STOP VALVE: Testing device (2309) is provided to check the proper
functioning of emergency stop valve (2301) during normal operation of turbine. If the testing device is
operated, it will admit the pressure oil to the space behind the test piston of emergency stop valve,
which will then be pushed against the piston and move the piston and valve spindle towards the closed
position (partial closing).
REMOTE ENGAGEMENT OF HAND TRIP VALVE: Hand trip valve (2250) can be put into operation
remotely with the help of a control switch, i.e. a pressure transmitter (PT 3905) and a solenoid valve
(1050). As soon as control switch is pressed, solenoid valve (1050) gets energized and oil flows into
hand trip valve (2250) and reset the trip lever. Soon after trip oil pressure is built up, solenoid valve
gets de-energized through the pressure transmitter (PT 3905).
HAND TRIP VALVE (2250): Whenever the turbine is to be tripped, the governing oil pressure (trip oil
line after hand operated valve) is drained by hand trip valve. Thus pressure in front of stop valve
piston disc and secondary oil pressure falls, resulting in closure of stop valve and control valves. The
hand trip valve (2250) is operated either manually or by loss of source oil pressure.
DAMPING DEVICE (5620): Damping device (5620) damps out the quick oscillations in secondary oil
pressure generated by hydraulic amplifier. This helps in improving the stability of the governing
system.

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SOLENOID VALVE (2222): Solenoid valves (2222), when energized one of them or both, interrupts the
oil supply to trip oil circuit and simultaneously depressurizes the trip oil circuit, thereby tripping the
turbine. Solenoid valve can be energized from control room with the push buttons or by trip logic in
association with limit value monitoring circuit
DUPLEX FILTER (4520): The Duplex filter with 225 lpm 20 micron filtration is consist of filter head with
change over valve and two filter bowls which are removable for maintenance. The change over
mechanism facilitates redirection of fluid stream from the dirty to clean filter housing without
reduction in flow. The arrangement also provided with a maintenance indicator, which monitors the
degree of clogging of the filter elements. Arrows indicate which filter bowl is in operation. Closing of
both filter bowls simultaneously not possible
GOVERNING CONTROLS:
STG controlling can be broadly divided into three categories:
1. BACK PRESSURE CONTROL
BPTG governing system is capable of meeting LP exhaust (back pressure) steam demands while
generating desired electricity. In back pressure controller, PT3607A/B sense the LP steam header
pressure (Process value) and give feed back to EHTC governor. This process value is compared with
back pressure set point register in back pressure controller. Reference back pressure input to controller
is from back pressure reference time dependent block which in turn get input from manual raise/lower
push button. Output of back pressure controller is feed to Min value selector which in turn generate
analog signal for I/H governor.
2. SPEED/LOAD CONTROL:
BPTG can be operated either on speed control mode or on back pressure control mode. When
operating independently (When machine is not connected with utility), STG will work on speed
corrector control mode. Speed Reference setter block gives signal to speed reference time dependent

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which is having a selection switch for Cold, warn and hot start curves. Input to the Speed reference
setter block is manual selection of speed set point, Auto run selection or through speed synchronizer
raise lower button. Output of Speed ref. time dependent block comes to Speed controller as one of the
input speed signal. Proximity sensor provided for speed measurement provides the actual speed of the
turbine to Speed controller. Difference between the speed set point and actual speed is directed to a
summation block. Second input to the summation block is signal from the load controller. In load
controller Actual load is compared with Load reference time dependent block signal. Input to the load
ref. time dependent block is output from Minimum selector block which is having the input for Load
limit set by operator and Load reference from synchronizer. Another input to load controller is
Frequency controller signal. Input to frequency controller is error signal from actual frequency to
reference frequency set by operator.
As long as the load set point is higher than the speed error signal, whenever turbine speed goes below
the set point, speed raise action will be active on governor control valves. Whenever load set point is
lower than the speed error signal, turbine governor will not be able to pick up the speed to the set
point value when speed of the turbine decreases. Then load set point has to be increased to maximum
to activate turbine speed control.
Finally for the position of all Control valve, Main as well Extraction control valves, the HP/MP valve
ratio setter block is provided which get input from minimum block selector having input from Load and
speed controller along with the HP and MP extraction controller output signal. HP/MP valve ratio
setter block provide analog signal to I/H governor after considering valve characteristics compensation.

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3. INLET STEAM PRESSURE CONTROL:
Inlet steam pressure limiter has been configured for our turbine. If the inlet steam pressure drops
below the set point, inlet steam pressure limiter will restrict the opening of control valve. While doing
so, normal speed and load of the turbine will also be maintained unless the inlet steam pressure drops
further to below the set point. If the inlet steam pressure further decreases, priority will be shifted to
maintaining inlet steam pressure sacrificing turbine speed/load.
9.3.11. Cooling Water system for STG with Condensing type:
Cooling water system in CPP consist of Main Cooling tower with 6 cells (5W+1S), Main Cooling water
Pumps (02 nos., 1W+1S, 575-P-VT-552/553), Side stream filters and Pumps and Auxiliary cooling
water pumps (03 nos., 2W+1S, 575-PT/PA-VT-572A/573A/574A). Cooling water as Raw Water from
RWTP adds into cooling tower forebay as makeup water. Cooling tower is a Induce draft Counter flow

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direct contact type with 6 cells having an assembly of a Fan with Motor and Gear box for creating a air
Induce draft in cell. Cooled water get collected into Forebay from where the Main cooling tower
pumps sucked the cooling water. Main cooling water pump are Vertical mounted which supply the
cooling water to STG surface condenser. The Hot water coming out of surface condenser come back to
cooling tower and gets distributed to each cell. The return header of cooling water also consist the
tapping for return supply header of ACW system. Refer P&ID no. 0-38101-00935-S01 for Cooling water
system.
The design parameters for cooling tower are:
a. Hot water inlet Temperature: 45 :C,
b. Cold water outlet Temperature: 33 :C
c. Wet Bulb temperature of Inlet air: 28.2 :C
d. Range: 12 :C
e. Approach: 4.8 :C
f. COC : 4
g. Cooling Tower Make requirements: 9858 m3/hr
h. Blow down: 61 m3/hr
i. Make Up water requirement: 320 m3/hr
j. Drift Loss: 20 m3/hr
Cooling tower forebay consist of Level Transmitter (10-LT4767). The makeup water coming as Raw
water from Refinery to Cold water channel / Forebay of CPP cooling tower is having ON/OFF type SOV
(10-UV4777). On Normal level signal from Level transmitter, the Makeup Line SOV open and on High
level it closed.
Main cooling water pumps for STG (575-P-VT-552/554) and Side Stream Filter Pumps (10-P-VT-
563/565) operating Logics are as below:
b. Start permissive for Pumps are:

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1. Cooling water forebay Level not low (10-LT4767)

2. Pump not in reverse rotation (10-RRI101/102)
c. MCW pump trip on low low CW forebay Level
d. Start command to MCW result into opening of discharge MOV (10-BV-MOV4708/4704) to

10% filling discharge header.
e. Normalizing the common discharge header pressure (10-PT4705) command discharge MOV
of running pump to open fully (100%)
f. Low discharge header pressure result to ACO of CWP (if selected)
CT fan Trips due to Low Low Gear Box Lube oil level and on vibration high high. Flow to Condenser is
measure in the return header through Flow Element (10-FE4739). Cooling tower is facilitated with CT
Overflow provision by draining it to Storm water drain. CT cooling water can also be drain to storm
water system through drain pump (01 nos., 575-P-00-567). Cooling tower is also equipped with online
analyzer for monitoring the cooling water parameter like HC and H2S along with the pH analyzer
installed in discharge common header to Condenser.
A dedicated cooling water treatment is envisaged for CPP cooling water. The system consists of:
1. Scale and Corrosion Inhibitor Dozing tank with Pumps (2 X 100%)
2. Bio-Dispersant Dozing tank with Pumps (2 X 100%)
3. Polymeric Dispersant dozing tank with Pumps (2 X 100%)
4. Non Oxidizing Biocide Chemical drum (Carbouy) – Slug dozed once in 15 days
5. Oxidizing Biocide Chemical Drum (Carbouy) – Slug dozed once in 15 days
Side stream filter arrangement installed is used to remove dirt from the cooling water. SSF pumps
(02 nos., 2 X 100%) are installed to pump the cooling water to Side stream filters (575-SSF-00-
568A/B, 2 X 100%) with having Air blowers (575-P-00-569A/B, 2 X 100%). Drain from the side stream
filters are diverted to Storm water while the clean cooling water is return back to Forebay. The
capacity of SSF is 3% of Circulation water capacity.

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9.3.12. Auxiliary Cooling water system
Auxiliary cooling water system for CPP consist of ACW cooling water pumps (03 nos., 2W+1S, 575-P-
VT-572B/573B/574B) and distribution header for ACW supply to CPP Auxiliaries. ACW system is
backed up by the FRP cooling water system which is used only during Black out for GT start up. FRP
Cooling water system consist of Single FRP cooling tower cell with Fan (01 nos., 575-P-00-580B) and
FRP cooling water Pump (01 nos., 575-P-00-582B). Refer P&ID no. 0-038101-00936-S01/02.
ACW cooling water Pumps are vertically mounted in same forebay of Cooling Tower. ACW pump
discharge common header is divided into 04 major areas which are:
a. ACW to Cooling water pump area for GB, Turbo drive and gland seal cooling
b. ACW to STG and BPTG Auxiliaries along with LP drain pump and Sample coolers for UBs
c. ACW to all Boiler Feed pumps, Blow down pumps sealing and cooling
d. ACW to GT and HRSG auxiliaries including GBC, Air compressor and HP nitrogen compressors.
e. ACW blow down to RO plant (Refinery) and ACW as alternative of Service water for all UB and
HRSG boilers CBD vessel steam inching
ACW supply header to GT consists of ON/OFF SOV (10-UV4827). The SOV normally remain in open
condition but will get closed on sensing Black out condition from ECS. A direct signal is incorporate to
cut the supply of ACW to GT area. This is done because after blackout is sensed, the ACW pump will
be tripped condition and FRP cooling tower Pumps and fan is used to charge the ACW system for GT
start up. The supply for FRP cooling tower fan and pumps are from Black start DG set. This ensures
that during Black out, FRP cooling tower system provide necessary ACW for any one GT start up. Once
plant get normalized and ACW pump started and header get charged, SOV can be energized to Open
to ensure ACW from ACW pumps and thus stopping the FRP cooling water system.
Aux. cooling water pumps operating Logics are as below:


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b. Start permissive for Pumps are:

1. Cooling water forebay Level not low (10-LT4767)
2. Pump not in reverse rotation (10-RRI 4804/4872/4809)
c. ACW running pump tripping on CT basin level low low (10-LT4767)
d. Start command to ACW result into opening of discharge MOV (10-BV-MOV4803/4806/4809)

to 10% for filling discharge header.
e. Normalizing the common discharge header pressure (10-PT4805) command discharge MOV of
running pump to open fully (100%)
f. ACW pump ACO on low discharge header pressure (10-PT4805)
ACW is blow down to RO plant return header (Refinery) through Flow control valve (10-FCV4815)
which get the command from Flow element (10-FE4807) installed in Blow down header to RO plant
(upstream of FCV).
FRP cooling Tower basin make up is coming from raw water supply coming from Refinery (tapped
before Main cooling tower make SOV (10-UV4777). FRP cooling Tower basin consists of two no. of
Level transmitter (10-LT4871 and 10-LT4870). Level transmitter (10-LT4781) is used to command
ON/OFF SOV installed in raw water make up line to FRP cooling tower while another level transmitter
(10-LT4870) is used to Trip the FRP cooling water pump on low low level.
9.3.13. Atomizing Air compressor system and Emergency IA system

Internal CPP Atomizing air system is design to cater the following:
a. Atomizing air for Boilers
b. IA and PA for CPP operation i.e. 30 min operation of one survive UB during Black out
Operation.
In order to meet the first requirements Atomizing Air compressor is used to provide the Atomizing Air
for NAPHTHA/LCO fuel atomization in HRSG and UB boilers. CPP is equipped with dedicated Atomizing
Air compressor (03 nos., 03 X 50%, Centrifugal type, Disch. Pr.: 7 Kg/cm2 g, 4600 Nm3/hr). The
Discharge

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of the Atomizing air compressor is collected into Receiver (Capacity 20 m3). From the receiver the
Atomizing air is directly supplied to each UB and HRSG B/L with a pressure drop of 1 Kg/cm2 g as
consider.
In order to cater the second demand, from the Atomizing air supply header to UB and HRSG a tapping
of 2” is taken for Plant Air utilization in CPP. This will cater the need of Plant air demand during
blackout condition. From the Atomizing air compressor reciver tank, a connection for Air booster
Compressor (01 nos., Reciprocating type, 500 Nm3/hr @ 30 Kg/cm2 g) is taken. This air booster
compressor sucked the pressurized air at 7 Kg/cm2 g and discharge at 30 Kg/cm2 g. The discharge
header from the Air booster compressor fills 03 nos. of receiver tank each of capacity 22 m3. Out of
03 nos. of receiver tank, 02 nos. are used to stored the Pressurized atomizing air at 30 kg/cm2 g. This
stored atomizing air will be used only during Black out condition for 01 nos. of survive UB Boiler
operation demand. Necessary NRV is kept in the supply header to Atomizing air to UB to ensure that
no reverse flow occur during black out. The Atomizing air from both the receiver are combined and
then pass through Self regulating pre-set Pressure reducing Control valve (PVRV) thus reducing the
atomizing air pressure from 30 Kg/cm2 g back to 7 Kg/cm2 g.
Another 01 receiver which received Air from Air booster compressor is used to cater the IA demand of
CPP during black out or non availability of IA from Refinery. Atomizing Air stored in the receiver is first
passes through self regulation de-Pressure station (PVRV) which reduces the pressure to 7 Kg/cm2 g.
The atomizing then diverted to Air Drier which removes moisture and thus converts atomizing air to
Instrument air. This instrument air is then again passes through self regulated de-pressurized station
(PVRV) to meet exact IA pressure demand. The IA from this system is than connected to main IA
supply header of CPP through appropriate NRV installed near tapped off. Also Main IA supply header
of CPP consists of NRV at B/L which avoid IA back to IA header of refinery during refinery black out
condition.
9.3.14. Blow Down system

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Blow Down system of CPP comprises of Blow down vessels for each Boilers, STGs, BPTG and Deaerator
/ LP heaters/BFP DT, blow down collecting Pits, Blow down Transfer pumps from Pit to Boiler BD
transfer header to Refinery RO Plant. Refer P&ID no. 2-381-01-00862-S01/S02/S03/S04 and 0-24-400-
80706
Blow down from each Boiler is collected in respective boiler CBD and IBD vessel. CBD being given from
steam drum having High Pressure steam, in CBD vessel the high temperature saturated water/steam
get flashed from which the steam get collected on CBD vessel top and taken out by diverted back to
Deaerator as LP steam. The Flash condensate in CBD vessel is diverted to IBD vessel through Level
control valve (06/07/08/09-LCV1901) for UBs and (04/05-SPT1818) for HRSGs which get command
from Level transmitter (06/07/08/09-LT1902) for UBs and (04/05-LT8160) installed on CBD vessel. IBD
vessel is Open to atmosphere. Other Boiler Steam and water circuit header drain are also diverted to
IBD vessel. A Provision of service water / CT Blow down water are provided in IBD vessel for quick
Quenching of flash condensate. The rate at which the quench water enter IBD depends upon the level
inside IBD vessel which is sensed by Level Transmitter (06/07/08/09-LT1906) for UBs and (04/05-
LTXXXX) which operate the Temperature Control valve (06/07/08/09-TCV1908) installed in supply
header to each IBD vessel.
The cool condensate i.e. Blow down from IBD is forwarded to UB # 1 and 2, UB # 3 and 4 and HRSG
Blow down Pit respectively through gravity having siphon arrangement. The Blow down collected in
each pit is pumped by Blow down transfer pumps (02 X 100%) for each tank to Main blow down
transfer pit.
Similarly drains from STG # 1, STG # 2, BPTG and LP heater/BFP DT/Deaerator are routed to their
respective flash vessel. Each Flash vessel is provided with quick quenching arrangement as mentioned
above for UBs. Drain from STG # 1, STG # 2 and BPTG flash vessel are commonly routed to STG blow
down pit from where the Blow down transfer pump, pumped the BD to Main blow down pit. While
the drain from LP heater/BFP DT/Deaerator is directly routed to Main blow down pit. All CPP boiler

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and steam blow down are finally collected in Main Blow down pit from where the Main Blow down
pit transfer pumps, pushes the BD to Refinery RO plant.
All blow down transfer pumps (575-P-CF-351A/B for HRSG pit, 575-P-CF-352A/B for UB # 1 and 2 pit,
575-P-CF-353A/B for UB # 3 and 4 pit, 575-P-CF-354A/B for STG pit and 575-P-CF-355A/B for Main BD
pit, 2 X 100% each) Operating Logics are as below:
b. Each Blow down pit consist of 02 nos. of BD transfer pumps (1W+1S)
c. Pump start/stop in AUTO and Operator has a facility of select the master and slave pump.
d. Master selected Pump start on High level signal from level transmitter (10-
LT1921/1926/1931/1936/1956). It remains in operation till the level inside the pit reaches to Low level
with is sense by same transmitter as mentioned above. On reaching the low level, the AUTO started
master pump stop and remain in active state for next cycle.
e. During the operation of master pump, if in any abnormal case (say the pump trips) than on
sensing the trip signal the slave pump started if kept in AUTO mode. It will run till level reached to Low
value as sense by same trasnmitter. On reaching the low level, the slave pump stop and now act as
master pump for next cycle operation until interface by Operator.
f. During normal operation if the level inside the pit keeps on increases even after master pump
in operation, than after level high high the slave pump will also start. The slave pump will stop only
when level inside the pit reaches Low low value while the master pump stop on level low value as
sense by the above mentioned transmitter.
9.3.15. HP Nitrogen system
HP nitrogen system is used to cater the demand of Nitrogen requirement at 26 – 30 Kg/cm2 g

pressure (higher than the FG pressure after GBC outlet) for GT supply Fuel Gas (FG) header purging
after GBC outlet. As the Fuel gas supply from Refinery is “High Hydrogen Fuel Gas”, it is not
recommended to start the GT on FG and also requires an inert gas purging system to separate “high
hydrogen fuel gas” from compressor discharge hot air for safe operation of the Gas Turbine.

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Nitrogen coming from Refinery is bone dry type. Nitrogen for HP nitrogen is tapped from Nitrogen
supply header for CPP. Two no. of Gas booster compressors (2 X 100%) compressed the nitrogen from
7 Kg/cm2 g to 40.5 Kg/cm2 g and stored in 4 nos. of receiver tank in parallel operation each of
capacity of 25 m3. The HP Nitrogen is than depressurized in a set of self regulating Pressure reducing
valve (04 nos. in parallel) for each GT supply header. The set of each PVRV are being monitored by
checking the downstream header pressure to GT. The depressurized HP nitrogen is than passed to GT
area which is then connected to FG supply header inside GT B/L.
The Design basis for the HP nitrogen system is that both the Gas Turbine will run on Fuel gas. Quantity
of HP nitrogen system is consider keeping in mind that during normal operation of GT on fuel gas at
any instant of time, only one GT will trip. Tripping of both GT is considered as a remote possibility,
hence not considered during design stage of HP nitrogen system. Also the trip of GT is consider to
infrequent and hence for design basis of HP nitrogen system one trip per week for GT is considered.
Based on the above basis the maximum quantity required of HP nitrogen is 160 Sm3. These include
the Total Quantity of Nitrogen required during normal operation of GT, Trip purging of one GT, False
start purging of tripped GT, Nitrogen required during changeover from Liquid to Gas and at the same
movement second running GT trips which sums up to 160 Sm3. Refer Sizing criteria Document no.
PEMC – 1955 for detail calculation. The control of HP nitrogen system is from Local Control panel
mounted PLC with signal indication to DCS for monitoring through MODBUS communication. Refer
P&ID no. 2-38101-00875-S01/S02/S03
9.3.16. Offbase FG/RG supply system
Fuel gas (FG) / Refinery Gas (RG) received from Refinery to CPP B/L. Flow element (FE-6801) measure
the inlet quantity of FG from Refinery to CPP. FG inside the CPP gets distributed for GT area, UB area
and HRSG area as a separate header. Before the distribution at the inlet of FG Main supply header
installed an ON/OFF type SOV (ESD 6802). This valve will be operated during Long Shutdown of FG
system or Emergency of complete CPP and will be done by Operator from DCS. Refer P&ID no. 1-
38101-03142-S01 to S09

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9.3.16.1. Offbase FG/RG for GT system
FG supply to GT consist of Gas scrubbers and Gas Booster compressor which are common to both the
GTs, FG Filtration and separation skid i.e. Gas conditioning skid which is separate for both GTs, and
common system like Nitrogen supply header for FG header purging and Flare system . FG to GTGs can
be stopped by closing the Main supply header ON/OFF type SOV (ESD 6804). FG for GT first enters in
to Gas scrubbers (V-11/12, 2 nos., 2 X 50%). Gas scrubber also commonly known as Knock out drum
(KOD) consist of Level transmitters (03 nos. in each KOD vessel, LT6805A/B/C and LT6814A/B/C), Flare
header supply SOV (BDV6810/6811), FG KOD condensate Level control valve (LCV6805/6814) and 02
nos of Flare safety valve (FSV) (FSV6808A/B and FSV6809A/B).
GT FG KOD condensate level is maintained by Level control valve which operates on ON/OFF SOV
installed on top to Open and close operation during level high and level low signal from Level
transmitter (1oo2 for each KOD). Level high high in any of KOD result into closing of Main FG supply
header ESD (ESD 6804) and ESD installed in FG supply header to GT # 1 and 2 (ESD 6832 and ESD 6848
respectively) and Opening of Flare header SOV in supply header to GT # 1 and 2 (BDV 6833 and 6849
respectively). FSV are connected to common flare header going to FG condensate tank. FG from FG
scrubber combine and inlet to GBC (02 nos., 2 X 50%) where the Pressure of FG get boosted from 10
Kg/cm2 g @ 40-60 :C to 20-24 Kg/cm2 g @ 120 – 145 :C. Inlet common header gets split into separate
branch for each GBC. One GBC is capable to deliver the FG for only one GT full load operation. From
GBC the FG gets separated for GT # 1 and 2.
In each GT supply line after GBC, FG filtration and separator skids (V-12/13 and V-15/16, 02 nos. each,
2 X 100%) are installed which further removes the condensate from pressurized and high temperature
FG before entering into GT Burners. Each Filtration and separation skid consists of Filter and separator
chamber with drain collecting vessel for each. Filter chamber is installed with FSV (FSV6819A/6820A
and FSV6837A/6838A) and Separator chamber consist of FSV (FSV6819B/6820B and FSV6837B/6838B)
along with ON/OFF operated SOV (BDV6829/6830 and 6839/6840) for Flaring the FG to flare header
inside CPP. Each drain collector vessel consist of Level transmitter

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(LT6821/6823/6826/6825 and LT6836/6841/6844/6846) which command to open the Level control

valve (LCV6821/6823/6826/6825 and LCV6836/6841/6844/6846) installed in respective drain
collector vessel to drain the FG condensate to nearby FG condensate storage tank. LCV operate as
ON/OFF through installed SOV on top for Open and closed operation on level high and low
respectively in each of the drain collector vessel for each filtration and separation skid.
FG from the each skid for each GT enter to FG supply header in which one ESD valve (ESD6832/6848)
is installed with SOV and one ESD valve (ESD/BDV6833/6849) is installed in FG flare header branch
from supply header. On any fire signal from GTG area through Mark VI will result in Opening of Flare
BDV and closing of Supply header ESD in order to stop the further FG supply to GTG. After this another
BDV valve with SOV operated (SOV6869/6870) is installed which operate as per the Nitrogen Purge
Logic command from Mark VI. FG than passes through Flow element (FE6831/6847) before entering
into GT B/L. Nitrogen and Flare system are connected to the GT FG supply system at required location
for respective Purging and Flaring process.
9.3.16.2. Offbase FG/RG for UB system
FG supply to UB consist of Gas scrubbers (02 nos., 2 X 50%, each capable to delivery full load FG
quantity for 02 nos. of UB, Pressure regulating station for each Utility Boilers and common system like
Nitrogen supply header for FG header purging and Flare system . FG to UB can be stopped by closing
the Main supply header ON/OFF type SOV (ESD6862). FG for UB first bifurcated in to Gas scrubbers (V-
18/19) which each consist of Level transmitters (03 nos., LT6863A/B/C and LT6863D/E/F), Flare
header supply SOV (BDV6868A/B), FG KOD condensate Level control valve (LCV6863A/D) and 02 nos
of Flare safety valve (FSV) (FSV6869A/B/C/D).
UB FG KOD condensate level is maintained by Level control valve which operates on ON/OFF SOV
transmitter (1oo2 for each KOD). FSV are connected to common flare header going to FG condensate
tank. FG from scrubber combines and then separated to FG supply header for each UB. For each UB

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there is Pressure control station which consists of 02 nos. of each 100% capacity Pressure control
valve (PCV6870A/B, 6871A/B, 6872A/B, 6873A/B) and 01 nos of 30% Pressure control valve
(PCV6870C, 6871C, 6872C, 6873C) all in parallel operation. Each control valve get command from the
downstream pressure transmitter (PT6870/6871/6872/6873). Operation from 30% to 100% and vice
versa is done as per the demand of FG on each UB. FG thereafter enters to individual Boiler B/L.
9.3.16.3. Offbase FG/RG for HRSG system
FG supply to HRSG consist of Gas scrubbers (01 nos., 1 X 100%, capable to delivery full load FG
quantity for both HRSGs, Pressure regulating station for each HRSG and common system like Nitrogen
supply header for FG header purging and Flare system . FG to HRSG can be stopped by closing the
Main supply header ON/OFF type SOV (ESD6852). FG to HRSG first bifurcated in to Gas scrubbers (V-
17) which consist of Level transmitters (03 nos., LT6854A/B/C), Flare header supply SOV (BDV6859),
FG KOD condensate Level control valve (LCV6854) and 02 nos of Flare safety valve (FSV) (FSV6853A/B).
HRSG FG KOD condensate level is maintained by Level control valve which operates on ON/OFF SOV
transmitter (1oo2 for each KOD). FSV are connected to common flare header going to FG condensate
tank. FG from scrubber then separated to FG supply header for each HRSG. For each HRSG there is
Pressure control station which consists of 01 nos. of 100% capacity Pressure control valve (PCV6860A,
6886A) and 01 nos of 30% Pressure control valve (PCV6860B, 6886B) in parallel operation. Each
control valve gets command from the downstream pressure transmitter (PT6861/6887). Operation
from 30% to 100% and vice versa is done as per the demand of FG on each HRSG. FG thereafter enters
to individual Boiler B/L.
9.3.16.4. Offbase FG/RG Flare and Slope system

FG Flare and drain system consists of following:

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All FG related Offbase system drains are collected into the above mentioned drain tanks. From which
the submersible pump immersed in each tanks pump the drain to CPP common slope header, which
in turn divert all the drain to Refinery slope header including FG condensate drain from CPP. Also all
the flares collected from each drain tank are diverted to Refinery Flare Header.
In FG drain tank near GBC area, FG drain from main supply header in CPP along with GTGs Gas
scrubbers and GBC drain and flare are connected. While in FG drain tank for GT # 1 area, all drain from
UBs internal along with UB scrubber drain and Flare, HRSG scrubber drain and flare, HRSG # 1 drain,
GT # 1 supply header drain and flare along with GT # 1 filtration skid drain and flare are connected. For
FG drain tank for GT # 2, GT # 2 filtration skid drain and vent, GT # 2 supply header flare, HRSG # 2
drain are connected. Submersible pump installed in each drain tank pumped the FG condensate to
CPP common slope header which in turn connected to Refinery Slope header which divert slope to
Refinery dry slope tank. While all flare in each drain tank are connected to a common header which in
turn connect to Refinery Flare header.
FG drain tank submersible Pumps (PM-524A/B, PM-525A/B, PM-526A/B) Operating Logics are as
below:
g. Pump Selection for Auto Change over (ACO) and A/M mode of Operation
h. Each FG drain tank consist (02 nos.,1W+1S)
i. Pump start stop in AUTO and Operator has a facility of select the master and slave pump.
j. Master selected Pump start on High level signal from level transmitter (LT6875/6881/6884). It
remains in operation till the level inside the tank reaches to Low level with is sense by same
transmitter as mentioned above. On reaching the low level, the AUTO started master pump stop and
remain in active state for next cycle.
k. During the operation of master pump, if in any abnormal case, the pump trips than on sensing
the trip signal the slave pump started in kept in AUTO mode. It will run till level reached to Low value
as sense by same trasnmitter. On reaching the low level, the slave pump stop and now act as master
pump for next cycle operation until interface by Operator.

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l. During normal operation if the level inside the tank keeps on increases even after master
pump in operation, than after level high high the slave pump will also start. The slave pump will stop
only when level inside the tank reaches Low low value while the master pump stop on level low value
as sense by the above mentioned transmitter.
All Interlock and control related to LCO fuel supply system are part of DCS controls. Also all PSVs
drain diverted in nearby OWS header.
9.4. OPERATING PARAMETERS

Refer chapter no. 4 for details
9.5. TROUBLE SHOOTING

Trouble shooting of CPP is defined based on equipment related trouble shooting. Some general plant
related trouble shooting is also mentioned in last
Sr.
Problem Operating condition Possible cause of problem Recommended action
No.
UTILITY BOILERS AND HRSG
Sludge, scale deposition Check for pressure drop and
on tube side while debris temperature difference of inlet
deposition on Fluid side and outlet streams.
Ensure the upstream pressure
Increased pressure and temperature of Cooling
Exchanger drop across Insufficient flow at
1 media is as per design condition.
fouling exchanger. Poor heat required pressure Rectify or inform concerned unit
transfer. for any deviation
Inadequate dozing of
Online chemical resulting
into scale deposition
Burner firing Increase in Pressure Water/Condensate in Ensure that NAPHTHA/LCO used
2
problem / of Fuel and Atomizing NAPHTHA/LCO Fuel. for firing should be free from any
Flame air header to burner. Improper condensate H20 content. Sample the fuel
instability Scanner flame removal every shift. Ensure that the
Intensity flickering during initial charging of condensate pot and sludge is
header removed on regular basis from
tankages

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Insufficient Atomizing of Ensure proper differential

Heavier fuel particles by pressure between fuel and
air due to lack of Pressure Atomizing air for sufficient
differential atomization.
Ensure Fuel used for CPP should
Heavier Hydrocarbon be as per design. Any deviation in
content in fuel composition to be intimated in
advance for corrective actions
Sludge deposition on
Metal content should be well
Back fire in Burner result into Higher percentage of
3 within the design criteria for
Burner increase in pressure Metals like Vanadium,
given fuel. No deviation is
of Burner tip Sodium, Nickel
accepted
Adequate temperature cum
Improper temperature of viscosity to be maintained for
fuel which result in higher fuel for complete atomization.
viscosity Higher viscosity may result into
improper atomization.
Condensate carry over in Proper functioning of KOD /
Fuel especially for RG/FG Scrubber to be ensured.
Metal content should be well
Higher Metal content Fuel within the design criteria for
used for firing given fuel. No deviation is
accepted
Ensure 100% reliable Operation
Inadequate soot blowing
of soot blowers during shift
Chocking of in SH, Eco and APH area
operation.
Downstream heat
Ensure that Air requirement
Higher exchange area like
should be 5-10% more than that
4 Furnace superheaters,
of Stoichiometric air requirement
pressure Economizers and APH Insufficient Air for
for Oil fired boiler. Logic of
area from Flue gas combustion
combustion control should take
path side
care of sufficient Oxygen content
at Eco Outlet (1.5 – 2% O2)
Poor Operating condition
during start up like Sudden Follow Boiler start up curve and
fluctuation of load or Cold loading curve as recommended
by Manufacture
Water inside Water wall

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and SH tubes during start

up
Remove soot, scale deposit from

Inadequate cleaning at heat transfer area on flue gas
regular interval path during annual shutdown of
boilers
Provide CBD after dozing the

chemical. If proper still persist –
Disturbed Drum level Trace of Oil or even provide EBD by reducing the
indication showing Hydrocarbon in Boiler load on Boiler. Excess spillage
Foaming
5 false reading Feed water required Boiler shutdown and
inside drum
adequate cleaning as Alkali boil
out in extreme cases.
Unable to maintain High concentration of solid

Same as above
Boiler pH (TDS) in BFW
Operating below the

design pressure,
demanding more steam Same as suggested for Foaming
than the boiler is capable
Deposition in SH
Priming in of.
6 tubes from steam
Boiler
side
Sudden fluctuation in
Avoid during Operation of Boilers
boiler loading

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Ensure proper tuning of Boiler

Higher water level in drum feed water CV opening with
Drum level
Deposition of harder
Ensure steam drum internal
scale on steam side of Drum internal damage
functionally OK
SH tubes
Poor BFW chemistry Ensure Silica content < 0.01 ppm

7 Carry over Poor Heat transfer
having higher silica and Na and Na – Nil in saturated steam
from SH tubes
content sample
Sudden fluctuation in
Failure of SH tubes Avoid during Operation of Boilers
Boiler loading
Give sufficient blow down at

Higher Turbine
regular interval as per the
integral pressure and Inadequate Blow down in
recommendation of supplier and
Turbine related boilers
also on the base of last CBD
problems
sample analysis
Higher Flue Poor heat transfer inside Ensure that the all operating
gas Uneven expansion of boiler result into more condition during boiler operation
8
temperature Boilers Heat duty demand by are well within the design
in Furnace controller condition. Clean the Heat transfer
area from Flue gas side
with Online chemical treatment or
during shutdown. Ensure the BFW
chemistry is also as per
recommendation so as no scaling
or pitting occur inside water wall
tube of boiler

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Tube failure due to

prolong expose to Same as above
higher temperature
Furnace disturbance
Same as above
and heat loss
STEAM TURBINE
• Stop turbine immediately even
• Suspected damage. e.g. when accuracy of readings is
Loud noises, high wall broken blades or metal to doubtful.
temperatures, high metal rubbing. • Check whether increased
casing differential
• Clearances eliminated by vibration is maintained after load
temperatures, high
casing distortion is reduced and when running
differential expansion • Axial clearances down.
and bearing metal eliminated. • Measure the time taken to run
temperatures.
• Bearing damage. down and listen for noises during
this period.
Low frequency
vibration. Vibration • Reduce turbine load
frequency less than immediately until vibration
Unstable running due to
the rotational decreases.
self excited vibration.
1 Vibration frequency. Irregular • Examine vibration. Load turbine
point trace from slowly to stability limit.
recording instrument
• Examine magnitude and
direction of vibration
• Check for radial run outs of
Increased vibration at
couplings and centering rabbets.
rated speed / Change in shaft system
• Check for axial run outs of
Increased vibration balance due to rotor
coupling faces.
over entire load condition induced by
• Check alignment
range under steady eccentric coupling
• Dynamically rebalance the
state operation
turbine (except if coupling bolts
are not tight and alignment
unsatisfactory).
Increased vibration • Permanent shaft • Measure radial run outs of

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above normal values distortion due to slipping shaft.

including when of shrink fits and/or metal • Inspect blade
passing through to metal rubbing. • Do dynamic rebalancing.
critical speed ranges • Blade damage.
• Bearing loading too low.

Vibration is related to • Excessive bearing Increase bearing loading by
load and valve lift clearances. changing the alignment.
Vibration related to Change oil temperature.

Changes in damping
lubricating oil Maintain Turbine inlet Lube oil
temperature properties due to changes temperature in the range of 38 –
changes. in oil viscosity. 45 :C
• Shut down turbine immediately

• Inadequate oil supply. to prevent
• Dirt consequential damage.
Rapid rise of one or • Tilting of bearings. • Check oil pressures and
more bearing metal • Excessive thrust flow restricted settings.
temperatures. • Fault in oil temperature • Check bearing installation
control system. • Clarify cause of
Higher Bearing • Fault in cooling water excessive thrust.
2 Temperature supply (Reduced pressure  Check Lube oil cooler
and increased performance.
temperature).  Check and correct
• Fouling of oil cooler. alignment
 Misalignment
Uneven High positive and • Too fast a turbine rolling. Do the rolling, loading and
3 differential negative differential • Sudden loading / unloading as per manufacturer’s
Expansion expansion. unloading of the turbine. recommendations.

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• Check free movement of

• Turbine control
hydraulic control elements.
malfunction.
• Check for leaks in control
Over speed trip • Leak in turbine control
valves.
operated. valves.
• Check extraction check valve
Mal function • Extraction check valves
position. Check actuator
4 of Protective fail to close
operation.
device
• Loss of condenser
• Identify the cause of condenser
vacuum.
• Fault in circulation water vacuum loss.
Low vacuum trip supply. • Check circulating water
operated. pump for normal operation.
• Faulty ejectors.
• Leakage through rupture • Rectify the ejector nozzles.
disc. • Rectify the rupture disc
• Oil contamination. • Examine oil samples.

Air release property • High water content • Operate the filtration
5 Oil system in oil. unit continuously.
more than the faults • Improper sealant. • Check sealant used. Do not
specified limit value. . • Oil mixed with too use any sealant containing
much anti foam silicon.

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In lubricating oil
Filter/cooler not filled and Ensure proper air venting from
system when oil
vented before change the stand by filter/ cooler before
filter/oil cooler
Low oil over. change over.
6 change over.
pressure.
High differential
Change over filter properly and
pressure across oil Filter fouled.
clean filters.
filter.
High oil temperature
Check the position of cooling
during rated speed No flow of cooling water
water isolation valves. Open if
operation after start through oil cooler.
closed or throttled
up.
• Oil cooler not vented on
oil side or cooling water
High oil side. • Check vents.
7 High oil temperature
temperatures. • Cooling water inlet • Change over oil cooler.
during start up
temperature too high. • Clean fouled oil cooler
• Oil cooler fouled on
cooling water side.
during shut down of Oil heater not switched off Switch off oil heater
STG unit
GAS TURBINE
Loud noises, high wall • Suspected damage. e.g. • Stop turbine immediately even
temperatures, high broken blades or metal to when accuracy of readings is
casing differential metal rubbing. doubtful.
1 Vibration
temperatures, high • Clearances eliminated by • Check whether increased
differential expansion casing distortion vibration is maintained after load
and bearing metal • Axial clearances is reduced and when running
temperatures. eliminated down.
• Measure the time taken to run
down and listen for noises during
this period.
Low frequency
vibration. Vibration • Reduce turbine load
frequency less than immediately until vibration
the rotational Unstable running due to self decreases.
frequency. Irregular excited vibration. • Examine vibration. Load turbine
point trace from slowly to stability limit.

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coupling faces.
• Check alignment
state operation
unsatisfactory).
Increased vibration • Permanent shaft
• Measure radial run outs of
above normal values distortion due to slipping
shaft.
including when of shrink fits and/or metal
• Inspect blade
passing through to metal rubbing.
• Do dynamic rebalancing.
Vibration is related to Increase bearing loading by
• Excessive bearing
load and valve lift changing the alignment.
clearances.
Changes in damping
properties due to changes
temperature temperature in the range of 38 –
in oil viscosity.
changes. 45C
• Shut down turbine immediately
to prevent consequential
• Inadequate oil supply. damage.
Higher Bearing Rapid rise of one or • Dirt • Check oil pressures and flow
2 Temperature more bearing metal • Tilting of bearings. restricted settings.
temperatures.
• Excessive thrust • Check bearing installation
• Clarify cause of excessive
thrust.
• Fault in oil temperature

Rapid rise of all
control system.
bearing metal
• Fault in cooling water  Check Lube oil cooler
temperatures.
supply (Reduced pressure performance.
and increased  Check and correct
temperature). alignment
• Fouling of oil cooler.
 Misalignment.

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• Check free movement of

• Turbine control
hydraulic control elements.
malfunction.
• Check for leaks in control
Over speed trip • Leak in turbine control
valves.
operated. valves.
• Check extraction check valve
• Extraction check valves
position. Check actuator
fail to close
operation.
• Check thrust bearing metal
• Excessive play in thrust temperature.
Thrust bearing trip bearing. • Inspect bearing for wear out.
Mal function responded. • False response of thrust • Check the thrust bearing trip
3 of Protective bearing trip mechanism, particularly the
device latching edges
• Fault in nozzle of burners
• Fault in Temperature
• Identify the cause of Burner
sensor
damage
High Spread • Fault in Turbine blade
• Check compressor discharge
temperature or and nozzle
pressure and temperature
excess exhaust • high Ambient
• Rectify the nozzles.
pressure trip temperature
• Rectify the turbine blade and
High compressor discharge nozzle clearance
pressure
 Mal fn of heat and fire

 Check the sensor and replace
sensor simaltenuously in
with new one if found faulty
one compartment
 High temperature in load  Ensure monitoring of exhaust
CO2 and fire trip fan operation
and turbine compartment
operated  Ensure CO2 cylinder inergen
due to tripping of exhaust
system operation during fire
fan
signal
 Fire inside the
compartment
Oil system Air release property • Oil contamination. • Examine oil samples.
4
faults more than the • High water content in oil. • Operate the filtration unit
specified limit value. • Improper sealant. continuously.
• Oil mixed with too much • Check sealant used. Do not use
anti foam additives. any sealant containing silicon.
• Consult the oil supplier.

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In lubricating oil
system when oil
vented before change the stand by filter/ cooler before
filter/oil cooler
Low oil over. change over.
5 change over.
pressure.
High differential
Change over filter properly and
pressure across oil Filter fouled.
clean filters.
filter.
closed or throttled
up.
during start up
cooling water side.
STG unit
 Ensure proper flow of
Lubrication to each bearing at
right temperature
 Excessive Axial thrust
 Check the assembly of bearing
 Incorrect lubrication
Bearing before starting
7 Failure of M/C  Improper assembly
Damage  Check the differential expansion
 Improper loading of
and follow the curve during
machine
startup and shutdown
 Check loading of bearing and
alignment
 Check the alignment
 Misalignment and
 Ensure proper sealing of
vibrations
bearing and use centifuge to
Damage of oil Oil leakage from  Dirt in oil
8 remove out the dirt from lube oil
seal ring bearing and spillage  Improper oil clearance
 Ensure filter screen operation in
 Insufficient oil pressure
service
 Improper assembly
 Ensure lube oil pressure

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 Check clearance and replace the

High amount of oil Excessive internal seal
seal if clearance is above
spillage from bearing clearances
acceptable range
High Axial High axial
9  Instrument fault  Replace faulty instrumentation
Thrust displacement
 Incorrect loading
High axial lube oil  Check alignment and assembly
 Incorrect assembly of
temperature of coupling loading
coupling
 Check exhaust plenum leakages
Low exhaust  Internal leakages are at each Overhaul or MI. Replace
pressure at Low exhaust pressure high below if found damage
10 Result into GT
constant  Drastic change in  Gas composition to monitor on
tripping
speed composition of gas regular basis based on fuel
composition changes
 Ensure sufficient gas at suction
during start up i.e. low speed
flow by recirculating or bleeding
 Insufficient gas at to atmosphere
suction  Ensure proper bleeding valve
 High internal leakages operation during start up and
High vibration during
 Blockage in anti surge shutdown
Surging of start up and
11 valve  Ensure air filter is not chocked
compressor shutdown which
 Suction strainer choking and DP across filter is normal by
result into GT tripping  Malfunctioning of anti purging regularly through high
surge System pressure air or by replacing
 Improper loading chocked filter
 Ensure uniform loading of
compressor by proper opening of
IGV
ROTARY COMPRESSOR – GBC, Atomizing Air Compressor
• Stop Compressor immediately
Loud noises, high wall • Suspected damage. e.g. even when accuracy of readings
temperatures, high broken blades or metal to is doubtful.
metal rubbing.
casing differential • Clearances eliminated by • Check whether increased
1 Vibration temperatures, high casing distortion vibration is maintained after load
differential expansion • Axial clearances is reduced and when running
and bearing metal eliminated. down.
temperatures. • Measure the time taken to run
• Bearing damage.
down and listen for noises during
this period.

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Low frequency
• Reduce compressor load
vibration. Vibration
immediately until vibration
frequency less than
Unstable running due to decreases.
the rotational
self excited vibration. • Examine vibration. Load
frequency. Irregular
compressor slowly to stability
point trace from
limit.
coupling faces.
• Check alignment
state operation
unsatisfactory).
Increased vibration • Permanent shaft
• Measure radial run outs of
above normal values distortion due to slipping
shaft.
including when of shrink fits and/or metal
• Inspect blade
passing through to metal rubbing.
• Do dynamic rebalancing.
Vibration is related to • Excessive bearing Increase bearing loading by
load and valve lift clearances. changing the alignment.
Changes in damping
properties due to changes
temperature temperature in the range of 38 –
in oil viscosity.
changes. 45 :C
• Oil contamination. • Examine oil samples.
• High water content in • Operate the filtration unit
Air release property
Oil system oil. continuously.
2 more than the
faults • Improper sealant. • Check sealant used. Do not use
specified limit value.
• Oil mixed with too much any sealant containing silicon.
anti foam additives. • Consult the oil supplier.
In lubricating oil
system when oil
Low oil vented before change the stand by filter/ cooler before
3 filter/oil cooler
pressure. over. change over.
change over.

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closed or throttled
up.
during start up
cooling water side.
STG unit
 Mal function of anti
Overloading
surge valve
and tripping  Same as mentioned in surge
5 Surging problem  Compressor operating
on high protection for GT
on the load below anti
vibration
surge line
RECIPROCATING AIR / NITROGEN COMPRESSORS
 Valve damage  Replace damage valve and
 Poor heat transfer in clean regularly the valve seat and
Inter and after coolers spring for proper functioning
 High ambient air  Clean the HE and back wash
condition regularly
High discharge  Insufficient cooling  Ensure cool air pressurized air
Loss of rated temperature water supply room condition
1
flow  HE fouling  Ensure proper cooling water
 Increase clearance supply
between piston and  Ensure proper clearance
cylinder between piston and cylinder
 Chocked suction  Clean suction filter regularly
 Flange joint failure and Remove and replace the flange
Leakages
leakage joint gasket to arrest leakage
 Leak HEs
Liquid in Low fluid outlet  Improper drier operation
2
discharge temperature result into moisture
condensation

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CHAPTER - 10
PROCESS INTERLOCKS AND PSV SCHEDULES
10.1 LIST OF INTERLOCKS

10.2 PSV SCHEDULE

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10.1. LIST OF INTERLOCKS:

UNIT Sr. INTERLOCK INTERLOCK DESCRIPTION ALARM TRIP
DESCRIPTION no. NO.
Condensate 1 I-16 LT-1702(LAN) for 575-CST-00-001 (All Pump
storage tank start permissive)
2 I-17A ZSH-GTV-1729 (MUH-003A) suction valve
open, pump start permissive.
3 I-17B ZSH-GTV-1730 (MUH-003B) suction valve
4 I-18 LT-1702(LALL) for 575-CST-00-001(Trip all
running pump)
5 I-19 PT-1719(PAL), Start MUH-standby pp. on low
header pressure & trip running pump after
delay.
6 I-20A ZSH-GTV-1767 (CST-004A) suction valve
7 I-20B ZSH-GTV-1768 (CST-004B) suction valve
8 I-21 PT-1731(PAL), Start CST-standby pp. on low
header pressure & trip running pump after
delay.
Condensate 9 I-30 LT 1701(LAHH) close LCV-1701(M/U),
storage tank MOVGTV-1704/17125/17127 in condensate
return line from process to CST.
LP Heater 10 I-22 LT-1710(LAN) for( 005 A/B Pump start
drain transfer permissive)
pump 11 I-23A ZSH-GTV-1797 (P-005A) suction valve open,
pump start permissive.

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12 I-23B ZSH-GTV-1798 (P-005B) suction valve open,

13 I-24 LT-1710 (LALL) Trip LP Heater Drain Transfer
pp (005A/B)
14 I-25 PT-1743(PAL) or LAHH-1710 Start LP Heater
Drain Transfer standby pp. on low header
pressure or condensate collection tank level
high- high & trip running pump after delay.
15 I-07 On heater level high-high close 10-GTV-1444
(LP steam inlet to heater)
BPTG GSC 16 I-26 LT-1706(LAH) BPTG-CCTP-(006A/B) Start
drain cond. permissive.
Collection 17 I-28 LT-1706(LAL) BPTG-CCTP-(006A/B) Stop
transfer permissive.
pump. 18 I-27A ZSH-GTV-1723 (P-006A) suction valve open,
20 I-29 PT-1708(PAL) Start BPTG-CCTP standby pp.
on low header pressure & trip running pump
after delay.
BFPTD GSC 21 I-31 LT-1746(LAH) BFPTD-CCTP-(010A/B) Start
drain cond. permissive.
Collection 22 I-32A ZSH-GTV-17129 (P-010A) suction valve open,
transfer pp. pump start permissive.
24 I-33 LT-1746(LAL) BFPTD-CCTP-(010A/B) Stop
permissive.
25 I-34 PT-1749(PAL) Start BFPTD-CCTP standby pp.

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9112-575-OPR-701-00002 Page 4 of 43
on low header pressure & trip running pump

after delay.
Deaerator 26 I-35 10-LT-1801(LALL), Trip all Boiler Feed Water
pump (007A/B/C,008A/B/C/D, 009A/B)
27 I-36 10-LT-1801(LAN), start permissive for all BFW
pump
28 I-43 10-LT-1801(LAH)50mm above high level, 50mm
open over flow valve 10-UV1800
29 I-44 10-LT-1801(LAL) 50mm below high level, 50mm
close over flow valve 10-UV1800
30 I-45 10-LT-1801(LAHH) close LP steam inlet valve
to deaerator 10MOV-GTV-1441
Boiler feed 31 I-37-A/B/C 10-ZSH-1839/1854/1868, (PP suction valve
pump open limit switch) start permissive for (P-007
A/B/C).
32 I-38- 10-ZSH-18131/18145/18159/18173, (PP
A/B/C/D suction valve open limit switch) start
permissive for (P-008 A/B/C/D).
33 I-39-A/B 10-ZSH-18271/18286, (PP suction valve open
limit switch) start permissive for (P-009A/B).
34 I-40 10-PT-1813(PAL)auto start of stand by
BFWP(HRSG)
35 I-41 10-PT-1813(PAL) auto start of stand by
BFWP(UB’S)
36 I-42 10-PT-1813(PAL) auto start of stand by
BFWP(Refinery)
BFWP-HRSG 37 I-46A 10-PT-1812A(PAH) or pump start, open
bypass valve of main discharge valve(10-
MOV-GTV-1853B)
38 I-47A 10-ZAH-1853B open limit switch, open main

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disch. valve.10-MOV-GTV-1853A
39 I-46B 10-PT-1812B(PAH) or pump start, open

MOV-GTV-1867B)
40 I-47B 10-ZAH-1867B open limit switch, open main
discharge valve. 10-MOV-GTV-1867A
41 I-46C 10-PT-1812C(PAH) or pump start, open
MOV-GTV-1881B)
42 I-47C 10-ZAH-1881B open limit switch, open main
BFWP-UB 43 I-48A 10-PT-1840A(PAH) or pump start, open
MOV-GTV-18144B)
MOV-GTV-18158B)
47 I-48C 10-PT-1840C(PAH) or pump start, open
MOV-GTV-18172B)
48 I-49C 10-ZAH-18172B open limit switch, open main
49 I-48D 10-PT-1840D(PAH) or pump start, open
MOV-GTV-18186B)

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50 I-49D 10-ZAH-18186B open limit switch, open main

BFWP- 51 I-50A 10-PT-1871A(PAH) or pump start, open
REFINERY bypass valve of main discharge valve(10-
MOV-GTV-18285B)
MOV-GTV-18299B)
BFWP-TD 55 11-PT-4216A/B/C, L.O. header pressure very 1.0kg/cm2
low (2oo3)
56 11-PT-4113A/B/C, Exhaust pressure very high 16.6 ata
(2oo3)
57 11-PT-4113A/B/C, Exhaust pressure very low 10.5 ata
(2oo3)
58 11-PT-4401A/B/C , Control oil press. very low 4.5 kg/cm
(2oo3)
59 11-PT-4402A/B/C , Trip oil press. Very. low 2.0 kg/cm2
(2oo3)
60 11-SAHH-4501(EHTC), Turbine speed very. 9900 rpm
High
61 11-SAHH-4505(OSP), Turbine over speed 9900 rpm
very. High
62 11-ZSHH-4501A & B(TSIM), Axial displ. v. high ± 0.7mm
63 11-VSHH-4501 to 4504A & B (TSIM) turbine & 139 µ
gear box HSS shaft vibration very high,
64 11-VSHH-4505 to 4506A & B(TSIM) Gear box 240 µ

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LSS shaft vibration very high,
65 11-TSHH-4501 to 4512(TSIM) turbine & gear 115 deg c

box bearing temp.very high,
66 11-E.P.B. 1 &2(DCS-MMI)Emergency push OPTD
button
67 11-LT-4204, over head oil tank level TRIP RESET
ok.(OPTD),
68 11-7-P.B(DCS-MMI) turbine trip reset(OPTD), TRIP RESET
CBD & IBD 69
system
Blow down 70 I-61 10-LT-1921(LAH) start pump
transfer 71 I-62 10-LT-1921(LAL) stop pump
pump HRSG 72 I-63 10-LT-1921(LAHH) start stand by pump
73 I-64 10-LT-1921(LALL) stop both pump
pump STG 76 I-67 10-LT-1926(LAHH) start stand by pump
hall area 77 I-68 10-LT-1926(LALL) stop both pump
pump UB # 1 80 I-71 10-LT-1931(LAHH) start stand by pump
&2 81 I-72 10-LT-1931(LALL) stop both pump
pump UB # 3 84 I-75 10-LT-1936(LAHH) start stand by pump
&4 85 I-76 10-LT-1936(LALL) stop both pump
B/D transfer 86 I-77 10-LT-1956(LAH) start pump
pp. LP heater 87 I-78 10-LT-1956(LAL) stop pump
vent flash 88 I-79 10-LT-1956(LAHH) start stand by pump
tank 89 I-80 10-LT-1956(LALL) stop both pump

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90
CHEMICAL 91
DOSING SKID
NH3 dosing 92 I-20 LAL-5102 for 575-T-390B, Trip running pump
skid
Deaerator
O/L
NH3 dosing 93 I-22 LAL-5302 for 575-T-398B, Trip running pump
skid Cond.
Storage tank
I/L
HYDRAZINE 94 I-19 LAL-2002 for 575-T-386B, Trip running pump
dosing skid
Deaerator
O/L
TSP dosing 95 I-21 LAL-5202 for 575-T-394B, Trip running
pump # UB pumps
TSP dosing 96 I-3201 LAL-8203 for 575-T--, Trip running pumps
pump # HRSG
Cooling 97 I-101 10-LAN-4767 & 10-LAH-4767, at normal level
tower make open # 10-UV-4777 and at high level close #
up 10-UV-4777.
98 I-102 10-LAN-4767, normal, start permissive for
condenser cooling water pumps/SSF pumps,
and open discharge MOV by 10 %
99 I-110/I-119 10-RR1-101, 10-RR1-102, pump not in
reverse rotation, start condenser cooling
water pumps & open disch. MOV by 10%
100 I-103 10-PAN-4705, CW. Header pressure normal,
open MOV fully

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101 I-105 10-PAL-4705, CW. Header pressure low,

closes MOV fully & trip CW pump.
102 I-104 10-LALL-4767, CT sump level low, trip
condenser cooling water pumps/SSF pumps,
and close discharge MOV of CW pump.
103 I-105 10-PAL-4705, CW. Header pressure low, auto
start stand by pump and open discharge
valve.
Cooling 104 I-106 to 111 10-LALL-4754-4759, oil level in fan gear box
tower fan low, trip respective cooling water fan.
105 I-112 to 117 10-VAHH-4760-4765, fan vibration high, trip
respective cooling water fan.
ACW transfer 106 I-102 10-LAN-4767, sump level normal, start
pump permissive for ACW pump, and open
discharge MOV by 10 %
107 I- 10-RR1-4804/4872/4809, pumps not in
134/135/13 reverse rotation, starts ACW pumps & open
6 disch. MOV by 10%
108 I-132 10-PAN-4805, ACW. Header pressure normal,
open MOV fully.
109 I-133 10-PAL-4805, ACW. Header pressure low,
closes MOV fully & trip ACW pump with time
delay.
110 I-104 10-LALL-4767, CT sump level low, trip ACW
pumps and close discharge MOV of ACW
pump.
111 I-133 10-PAL-4705, ACW. Header pressure low,
auto start stand by pump and open discharge
valve.
Surge pipe 112 I-126 LAH-4825, level high, close 10-UV-4887a

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make-up 113 I-126 LAH-4825, level low, open 10-UV-4887a

GT # 1
DM water 114 I-127 10-LALL-4825, water level in surge pipe low-
pumps GT # 1 low, trip working DM water pump.
115 I-128 10-PAL-4830, Disch. Header pressure low,
auto start stand by DM water pump and trip
working pump with time delay.
Surge pipe 116 I-129 LAH-4858, level high, close 10-UV-4888a
make-up 117 I-129 LAH-4858, level low, open 10-UV-4888a
GT # 2
DM water 118 I-130 10-LALL-4858, water level in surge pipe low-
pumps GT # 2 low, trip working DM water pump.
119 I-131 10-PAL-4862, Disch. Header pressure low,
auto start stand by DM water pump and trip
working pump with time delay.
FRP C.W. 120 I-132 LAL-4871(FRP-CT level low) open make up(
trans. pump 10-UV-4890d)
121 I-132 LAH-4871(FRP-CT level high) close make up(
10-UV-4890d)
122 I-133 LALL-4670(FRP-CT level low- low, trip FRP-CT
pump(00-580b)
123 I-137 UV-4827(Black out condition), close UV-4827
HSD storage 124 I-151 LAHH-6604(Tank # 1) level high-high, close
tank filling valve (UV-6604)
125 I-152 LAHH-6607(Tank # 2) level high-high, close
filling valve (UV-6607)
HSD 126 I-153 PALL-6608A/B/C (2OO3)(Raw HSD tank level
centrifuge low-low) or PAHH-6609(HSD clean oil tank
skid level high-high) trip running centrifuge &
unloading pump on centrifuge skid.

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127 I- Water seal breakage of centrifuge # 1,2,3-

154/154/15 PAL6611/6620/6625 centrifuge downstream
5 pressure low, divert HSD oil back to HSD raw
oil tank.
HSD 128 I-158 PALL-6609A/B/C(2OO3), HSD clean oil tank
forwarding level low-low, trip running forwarding pump.
pumps # GT # 129 I-158 PAL-6633(Forwarding pump discharge
1 pressure low) start standby pump(tripping of
running pump due to level low-low in
tank/fire in GT, will override starting of stand
by pump. Running pump
shall be tripped manually.
130 I-158 Fire signal from GT # 2, to trip running
forwarding pump.
HSD pressure 131 I-159 PAL-6637(Non activation of this gives start
at inlet of 3- permissive for GT to start on HSD.(upstream
way valve for of 3-way valve), MARK-6
GT # 1
LCO to HSD 132 Control loop 1-PV-6639A, Changeover signal from MARK-6
changeover description from LCO to HSD, %age opening of main PCV
logic of GT # C-1 ramped up to required %age directly by DCS,
1 bypassing PIC-6639, based on load on GT.
(PV-6639A) 133 2-Estimated required % opening of control
valve at full load of GT, while changeover is
75%
134 3- Estimated required % opening of control
valve at FSNL of GT, while changeover is 33%.
valve at intermittent loads of GT, while
changeover will be in between 33% to 75%,

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depending on GT load.
136 5-After 1 minute of changeover control of

PCV will again transfer to PIC-6639A.
Bypass 137 Control loop 1-PV-6639B, provided to maintain HSD
control valve( description pressure at inlet of GT during startup &
PV-6639B) C-1 change over from HSD to LCO mode.
138 2-Bypass control valve PV-6639B kept 20%
open continuous as long recirculation flow
@3.5m3/hr. It will put PV-6639A in action,
maintaining pressure at GT inlet within limit,
ensuring smooth startup of GT on HSD
fuel/changeover to HSD.
HSD 139 I-161 PALL-6609A/B/C(2OO3), HSD clean oil tank
forwarding level low-low, trip running forwarding pump.
pumps # GT # 140 I-161 PAL-6645(Forwarding pump discharge
2 pressure low) start standby pump(tripping of
by pump .running pump shall be tripped
manually.
141 I-161 Fire signal from GT # 2, to trip running
forwarding pump.
HSD pressure 142 I-162 PAL-6652(Non activation of this gives start
at inlet of 3- permissive for GT to start on HSD.(upstream
GT # 2
LCO to HSD 143 Control loop 1-PV-6653A, Changeover signal from MARK-6
changeover description from LCO to HSD, %age opening of main PCV
logic of GT # C-2 ramped up to required %age directly by DCS,

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2 ( bypassing PIC-6653, based on load on GT.

PV-6653A)
144 2-Estimated required % opening of control

75%
Bypass 148 Control loop 1-PV-6653B, provided to maintain HSD
control valve description pressure at inlet of GT during startup &
(PV-6653B) C-2 change over from HSD to LCO mode.
149 2-Bypass control valve PV-6653B kept 20%
@3.5m3/hr. It will put PV-6639A in action,
ensuring smooth startup of GT on HSD
fuel/changeover to HSD.
LCO storage 150 I-171 LAHH-6704(Tank # 1) level high-high, close
tank filling valve (UV-6704)
151 I-172 LAHH-6711(Tank # 2) level high-high, close
filling valve (UV-6711)
LCO 152 I-173 PALL-6704A/6704B/6704C (2OO3), LCO clean
forwarding oil tank level low-low, trip running forwarding
pumps # GT # pump

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1 153 I-173 PAL-6721(Forwarding pump discharge 6.0kg/cm2

pressure low) start standby pump(tripping of
by pump. Running pump shall be tripped
manually.PAL-6712/6715/6717 used to
identify faulty pump & same will be stopped
manually.
LCO pressure 154 I-174 PAL-6727 Non activation of this gives start 2.3kg/cm2
at inlet of 3- permissive for GT to start on LCO.(upstream
GT # 1
Trip valve 155 I-175 MOV-6729, on fire signal in GT area, close
near GT #1 MOV-6729.MARK-6
Vanadium 156 I-176 LALL-6724(Tank level low-low) signal to
inhibitor MARK-6 for change over to HSD & trip
dosing pump running dosing pump.
for GT # 1
Vanadium 157 I-177 FAL-6728 (VD-Flow low-low), start stand by 0.05 LPH
inhibitor pump, auto signal to MARK-6 for change over
dosing pump of GT from LCO to HSD, if S/B pump does not
for GT # 1 come in to operation in pre set time. If FAL is
still activated after pre set time over running
dosing pp switched of manually after C/O
from LCO to HSD. Non activation of
FAL-6728 is start permissive for LCO FWD
pump,if GT is to be run on LCO oil.
2.0 m3 158 I-178 LAH-6733 Start selected drain pump as per
HSD/LCO level high & and start S/B pump in case of
drain tank working pump trips or LAHH-6733.LAL-6733,
area near GT trip running S/B pump and LALL-6733, trip

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9112-575-OPR-701-00002 Page 15 of 43
#1 running pump
HSD to LCO 159 Control loop 1-PV-6728A, Change over signal from MARK-
changeover description 6 from HSD to LCO, %age opening of main
logic of GT # C-3 PCV ramped up to required % age directly by
1 DCS, bypassing PIC-6728, based on load on
(PV-6728A) GT in 5 sec..
75%
Bypass 164 Control loop 1-PV-6728B, provided to maintain LCO
165 2-Bypass control valve PV-6728 B kept 20%
@3.5m3/hr. It will put PV-6728 A in action,
ensuring smooth startup of GT on LCO
fuel/changeover to LCO.
LCO pressure 166 I-179 PAL-6743 Non activation of this gives start
at inlet of 3- permissive for GT to start on LCO.(upstream

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GT # 2
Trip valve 167 I-180 MOV-6755, on fire signal in GT area, close

near GT # 2 MOV-6755.MARK-6
Vanadium 168 I-181 LALL-6750(Tank level low-low) signal to
inhibitor MARK-6 for change over to HSD & trip
dosing pump running dosing pump.
for GT # 2
Vanadium 169 I-182 FAL-6754(VD-Flow low-low), start stand by
inhibitor pump, auto signal to MARK-6 for change over
dosing pump of GT from LCO to HSD, if S/B pump does not
for GT # 2 come in to operation in pre set time. If FAL is
still activated after pre set time over running
dosing pp switched of manually after C/O
from LCO to HSD. Non activation of
FAL-6754, is start permissive forlco fwd
pump, if GT # 2 is to be run on LCO oil.
area near GT trip running S/B pump and LALL-6758, trip
#2 running pump
HSD to LCO 171 Control loop 1-PV-6744A, Change over signal from MARK-
changeover description 6 from HSD to LCO, %age opening of main
logic of GT # C-4 PCV ramped up to required % age directly by
2 DCS, bypassing PIC-6744, based on load on
(PV-6744A) GT.
75%

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Bypass 176 Control loop 1-PV-6744B, provided to maintain LCO
177 2-Bypass control valve PV-6744 B kept 20%
@3.5m3/hr. It will put PV-6744 A in action,
ensuring smooth startup of GT on LCO
fuel/changeover to LCO.
LCO 178 I-184 PALL-6703A/B/C (2OO3), LCO oil tank level
forwarding low-low, trip running forwarding pump.
pumps for 179 PAL-6770 (Forwarding pump discharge
HRSG’S pressure low) start standby pump(tripping of
running pump due to level low-low in tank
will override starting of stand by pump due to
low pressure.
180 PAL-6779/6768/6769 used to identify faulty
pump, same will be tripped manually.
LCO 181 I-185 PALL-6703A/B/C (2OO3), LCO oil tank level
forwarding low-low, trip running forwarding pump.

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pumps for 182 PAL-6774(Forwarding pump discharge

Utility pressure low) start standby pump(tripping of
Boiler’s running pump due to level low-low in tank
will override starting of stand by pump due to
low pressure.
183 PAL-6777/6776/6773 used to identify faulty
pump, same will be tripped manually.
2.0 m3 LCO 184 I-186 LAH-6768 Start selected drain pump as per
drain tank level high & and start S/B pump in case of
area near UB working pump trips or LAHH-6768.LAL-6758,
#1&2 trip running S/B pump and LALL-6768, trip
running pump
2.0 m3 LCO 185 I-187 LAH-6798 Start selected drain pump as per
drain tank level high & and start S/B pump in case of
area near UB working pump trips or LAHH-6798.LAL-6758,
#1&2 trip running S/B pump and LALL-6798, trip
running pump
area near trip running S/B pump and LALL-6727, trip
storage tank running pump
area
STG-(2 X 36 187 01-PT-3214 A/B/C, L.O. header pressure very 1.0kg/cm2
MW) low (2oo3)
188 01-PT-3172 A/B/C, Exhaust pressure very 0.3 ata
high (2oo3)
189 01-PT-3113 A/B/C, Ext.-1 to HP header 50 ata (2oo3)
press.v.high
190 01-PT-3113 A/B/C, Ext.-1 to HP header press. 35.1 ata

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v.low (2oo3)
191 01-PT-3123 A/B/C, Ext.-2 to MP header 16 ata (2oo3)
press.V.high
192 01-PT-3123 A/B/C, Ext.-2 to MP header 10.6 ata
press.v.low (2oo3)
193 01-PT-3401A/B/C, Control oil press. v. low 4.5 kg/cm2
(2oo3)
194 01-PT-3402A/B/C , Trip oil press. V. low 2.0 kg/cm2
(2oo3)
195 01-GRP-86GB (GRP), Generator trip 86GB, OPTD
196 01-SAHH-3501(EHTC), Turbine speed v. high 6930 rpm
197 01-SAHH-3502(OSP), Turbine over speed v. 6930 rpm
high
198 01-ZSHH-3501A & B(TSIM), Axial displ. v. high ±0.7mm
199 01-VSHH-3501 to 3502 A & B, 3505 to 3506 A 166 µ
& B turbine & gear box HSS shaft vibration
very high,
200 01-VSHH-3503 to 3504 A & B,3507 to 3508 A 240 µ
& B gear box LSS & Generator shaft vibrn
very high,
201 01-TSHH-3101 to 3114(TSIM) turbine ,gear 115 deg c
box & generator bearing temperature very
high,
202 E.P.B. 1 &2 (DCS-MMI)Emergency push (OPTD)
button
203 01-DPT-3209, over head oil tank level TRIP RESET
ok.(OPTD),
204 P.B(DCS-MMI) turbine trip reset(OPTD), TRIP RESET
Condenser 205
interlocks 206 I-11 01-LAN-1603 (Start permissive for CEP-

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001A/B)
207 I-12 01-PAL-1621/1622(Discharge press.low)Auto
start of standby CEP-001A or 001B
208 I-13 01-LALL-1603(Trip working cond. Extraction
pump)
209 I-14 01-LAH-1603 (Start stand by cond.Extraction
pump)
210
211
212
BPTG 213 03-PT-3714 A/B/C, L.O. header pressure very 1.0kg/cm2
low (2oo3)
214 03-PT-3606 A/B/C, Exhaust pressure very 7.6 ata
high (2oo3)
215 03-PT-3606 A/B/C, Exhaust pressure very low 4.9 ata
(2oo3)
216 03-PT-3901A/B/C , Control oil press. very low 4.5 kg/cm2
(2oo3)
217 03-PT-3902A/B/C , Trip oil press. Very. low 2.0 kg/cm2
(2oo3)
218 03-GRP-86GB, Generator trip 86GB OPTD
219 03-SAHH-4001(EHTC), Turbine speed very. 5500 rpm
High
220 03-SAHH-4002(OSP), Turbine over speed 5500 rpm
very. High
221 03-ZSHH-4001A & B(TSIM), Axial displ. v. high ± 0.7mm
222 03-VSHH-4001 to 4004A & B (TSIM) turbine & 185 µ
gear box HSS shaft vibration very high,
223 03-VSHH-4005 to 4008 A & B(TSIM) Gear 240 µ
box/Generator LSS shaft vibration very high,

Revision 02
9112-575-OPR-701-00002 Page 21 of 43
224 03-TSHH-4001 to 4014 (TSIM) turbine/gear 115 deg c

box & gear box bearing temp.very high,
225 03-E.P.B. 1 &2(DCS-MMI)Emergency push OPTD
button
226 03-LT-3707, over head oil tank level TRIP RESET
ok.(OPTD),
227 03-P.B(DCS-MMI) turbine trip reset(OPTD), TRIP RESET
228
HRSG 229 Drum level LT-8107/8108/8109 (2OO3) Drum level low -100mm -505mm
230 LT-8107/8108/8109 (2OO3) Drum level high +100mm +175mm
231 EWLI-8170, Cond. Level switch for drum level -100mm -505mm
low
232 EWLI-8170, Cond. Level switch for drum level +100mm +175mm
high
0 0
233 SH-1 Metal TE- 8118 / 8119 / 8120 / 8121 / 8122 /8123 THA-580 C, THHT-595 C
temp.
0 0
234 SH-2 Metal TE-8124 /8125 / 8126 / 8127 / 8128 / 8129 THA-590 C, THHT-605 C
temp.
235 Drum PT-8110, PLA (low) / PHA (high) 115.5/118.5kg/
pressure cm2
236 Drum TE-8112/8113/8114/8115 328 deg c
temperature
237 Main steam TET-8133/8134 TLA(low)/ THA(high) 450/513 deg c
temp.
238 Main steam PT-8136 / 8137 PLA (low) / PHA (high) 105/108
press. kg/cm2
239 Fuel gas PT-7708 PLA (low) / PHA (high) 0.08/1.6
press.after kg/cm2
C/V
240 LCO/HSD PT-7722 PLA (low) / PHA (high) 2.0/11.0

Revision 02
9112-575-OPR-701-00002 Page 22 of 43
press. After kg/cm2

C/V
241 Atomising PT-7727 PLA (low) 3.5 kg/cm2
air pressure
242 DP across DPT-7717 PAH (high) 0.3 kg/cm2
strainer
243 Augm. Air PT-7731 PLA (low) 250 mmwc
press. At
inlet
244 Seal air PT-7733 PLA (low) 360 mmwc
pressure at
inlet
245 Scanner air PT-7715 PLA (low) 250 mmwc
press. At
inlet
246 Feed water AT-8163 (LOW / HIGH) 8.8/10.0
PH
247 Feed water AT-8162 (HIGH) 0.5µs/cm
conductivity
248 Feed water AT-8164 (HIGH) 0.03 ppm
silica
249 Drum water AT-8165 (HIGH) 210 µs/cm
conductivity
250 Drum water AT-8166 (LOW / HIGH) 8.5 / 11.0
PH
251 Main steam AT-8168 (LOW /HIGH) 8.0 / 10.0
PH
252 Main steam AT-8167 (HIGH) 0.3 µs/cm
conductivity
253 Main steam AT-8169 (HIGH) 0.04 ppm

Revision 02
9112-575-OPR-701-00002 Page 23 of 43
silica
HP Nitogen 254
booster
compressor
Gas Booster 255 Lube oil PT-7312 A/B/C(2OO3) 1.0 kg/cm2
compressor header
pressure low
256 Primary seal PT-7012 A/B/C (2OO3)
gas to vent
pressure
very high
257 Primary seal PT-7013 A/B/C (2OO3)
gas to vent
pressure
very high
258 Shaft vib'n
of
GB/Comp.v
high
259 Axial disp.
Of
GB/Comp.v
high
260 Brg. Temp of
GB/Motor/C
omp very
high
261 Thrust Brg.
Temp of
GB/Comp

Revision 02
9112-575-OPR-701-00002 Page 24 of 43
very high
262 Motor wind.

Temp very
high
263 Inst. Air to
barrier seal
pressure low
264
Off Base 265 I-201 LAHH-6805 A/B/C & LAHH-6814 A/B/C
Refinery Gas (2OO3), Level high high in knock out drum
system close in auto, ESD-6804, ESD-
6832 / 6848
266 Fire in GT # close ESD-6832,open BDV-6833
1,
267 Fire in GT # close ESD-6848,open BDV-6849
2,
268 Shut down / Close remote manually ESD-6804/6832/6848
Emergency and open remote manually BDV-
of GT 6810/6811,6829/6830/
6839/6840/6833/6849
269 I-202 (LCV- LAH-6805B/C,LAL-6805B/C, Open & close
6805) LCV-6805
6814) LCV-6814
6854) LCV-6854
6863A) LCV-6863A
273 I-204 (LCV- LAH-6863E/F,LAL-6863E/F, Open & close LCV-
6863D) 6863D

Revision 02
9112-575-OPR-701-00002 Page 25 of 43
274 I-205 (in Close remote manually ESD-6852 and open case of
long remote manually BDV-6859
Shut down /
Emergency
of HRSG's)
275 I-206 (in Close remote manually ESD-6862 and open case of
long remote manually BDV-6868A/B
Shut down /
Emergency
of UB's)
276 I-207 (in Close remote manually ESD-
case of long 6804/6832/6848/6852/ 6862 and open
Shut down / remote manually BDV-6810/6811/
Emergency 6829/6830/6839/6840/6833/68496859/6868
of Complete A/6868B
plant)
277 I-208 (LCV- LAH-6875 Start selected drain pump as per
6875)level high & and start S/B pump in case of working

pump trips & LAH still persist or LAHH-
6875.LAL-6875, trip running S/B pump and
LALL-6875, trip running pump

pump trips or LAHH-6881.LAL-6881, trip
running S/B pump and LALL-6881, trip running
pump

pump trips or LAHH-6884.LAL-6884, trip
running S/B pump and LALL-6884, trip running
pump

Revision 02
9112-575-OPR-701-00002 Page 26 of 43
GAS TURBINE 280 Low lube oil pressure

281 Lube oil temperature hi-hi
282 High vibration
283 High spread
284 Flame detector failure
285 Fire in gas turbine
286 Exhaust press hi-hi
287 turbine inlet air filter dp hi-hi
288 Exhaust temp hi-hi
289 Exhaust frame cooling pre lo-lo
290 liquid trip oil pr lo
291 gas trip oil press lo
292 IGV TRIP
293 Generator protection trip
294 Control system fault
295 Comp Bleed valve trouble
296 High warren pump temp
297 High bearing temp
UTILITY 298 Fuel gas header pressure very low
BOILER 299 Fuel gas header pressure very high
300 HSD/LCO header pressure very low
301 Atomizing air pressure very low
302 Both scanner fan fails to start
303 Loss of 110V AC or FD-Fan off and scanner
emergency damper not open
304 FD fan off
305 Drum level very low
306 Drum level very high
307 Air flow < 30%
308 Flame failure trip

Revision 02
9112-575-OPR-701-00002 Page 27 of 43
309 Furnace pressure very high

310 Loss of all fuel trip
311 Air pre-heater trip
312 Emergency trip PB operated
313 110V AC UPS power supply solenoid) not
available

Revision 02
9112-575-OPR-701-00002 Page 28 of 43
10.2. PSV SCHEDULES:

Specifications details
Sr. Equipment Set point Relieving
Unit Equipment Description Reference PID
no. Tag no. (Kg/cm2 capacity
a) (Kg/hr)
1 HRSG # 1 04SB015 PSV for MS line to SB 02440080706
2 HRSG # 2 05SB015 PSV for MS line to SB 02440080706
3 HRSG # 1 04MS015 PSV in Superheater MS line 02440080706 117.4
4 HRSG # 2 05MS015 PSV in Superheater MS line 02440080706 117.4
5 HRSG # 1 04BW051 Steam drum safety valve1 02440080706 132
6 HRSG # 1 04BW063 Steam drum safety valve2 02440080706 135.9
7 HRSG # 2 05BW051 Steam drum safety valve1 02440080706 132
8 HRSG # 2 05BW063 Steam drum safety valve2 02440080706 135.9
9 HRSG # 1 04BDS004 CBD tank PSV 02440080706 5.00
10 HRSG # 2 05BDS004 CBD tank PSV 02440080706 5.00
11 HRSG # 1 04WPH004 WPH supply line PSV
12 HRSG # 2 05WPH004 WPH supply line PSV
13 UB # 1 06SV1 Steam drum safety valve1 '00004747817 125 99412
14 UB # 1 06SV2 Steam drum safety valve2 '00004747817 128.7 99412
21 UB # 1 06SV3 PSV in Superheater MS line '00004747817 117.1 73720

Revision 02
9112-575-OPR-701-00002 Page 29 of 43

25 UB # 1 06SV5 SB supply line safety valve '00004747817 41
29 VHP Steam 10PSV1115A VHP/HP PRDS 13810103143 43.3
30 VHP Steam 10PSV1115B VHP/HP PRDS 13810103143 44.3
31 VHP Steam 10PSV1115C VHP/HP PRDS 13810103143 44.3
32 HP steam 01PSV3115A HP extraction line PSV for STG # 1 13810103156 47.3
33 HP steam 01PSV3115B HP extraction line PSV for STG # 1 13810103156 47.6
34 HP steam 02PSV3115A HP extraction line PSV for STG # 2 13810103156 47.3
35 HP steam 02PSV3115B HP extraction line PSV for STG # 2 13810103156 47.6
36 MP steam 01PSV3125A MP extraction line PSV for STG # 1 13810103156 15.1
37 MP steam 01PSV3125B MP extraction line PSV for STG # 1 13810103156 15.4
38 MP steam 02PSV3125A MP extraction line PSV for STG # 2 13810103156 15.1
39 MP steam 02PSV3125B MP extraction line PSV for STG # 2 13810103156 15.4
40 HP steam 10PSV1207A HP/MP PRDS PSV 1 13810103144 13.4
41 HP steam 10PSV1207B HP/MP PRDS PSV 2 13810103144 13.7
42 HP steam 10PSV1207C HP/MP PRDS PSV 3 13810103144 14
43 HP steam 10PSV1207D HP/MP PRDS PSV 4 13810103144 14
TD ACW pump exhaust MP steam
44 HP steam 10PSV1217A 13810103144 14
PSV 1
TD ACW pump exhaust MP steam
45 HP steam 10PSV1217B 13810103144 14.3
PSV 2
TD UB LCO Fwd pump exhaust MP
46 HP steam 10PSV1213A 13810103144 14.3
steam
TD UB LCO Fwd pump exhaust MP
47 HP steam 10PSV1213B 13810103144 14.3
steam
48 HP steam 10PSV1244A STG # 1 MOP exhaust LP steam 13810103144 7
49 HP steam 10PSV1244B STG # 1 MOP exhaust LP steam 13810103144 7

Revision 02
9112-575-OPR-701-00002 Page 30 of 43
50 HP steam 10PSV1248A STG # 2 MOP exhaust LP steam 13810103144 7

51 HP steam 10PSV1248B STG # 2 MOP exhaust LP steam 13810103144 7
52 HP steam 10PSV1252A BPTG MOP exhaust LP steam 13810103144 7
53 HP steam 10PSV1252B BPTG MOP exhaust LP steam 13810103144 7
54 HP steam 11PSV4301A BFPDT MOP exhaust LP steam 13810103144 7
55 HP steam 11PSV4301B BFPDT MOP exhaust LP steam 13810103144 7
56 HP steam 10PSV1258A UB # 1 FD fan exhaust LP steam 13810103144 7
57 HP steam 10PSV1258B UB # 1 FD fan exhaust LP steam 13810103144 7.3
64 HP steam 10PSV1119A Aux.SM steam header 13810103144 15
65 HP steam 10PSV1119B Aux.SM steam header 13810103144 15.3
66 MP steam 10PSV1307A MP/LP PRDS PSV 1 13810103145 6
67 MP steam 10PSV1307B MP/LP PRDS PSV 2 13810103145 6.3
68 MP steam 10PSV1307C MP/LP PRDS PSV 3 13810103145 6.3
69 MP steam 10PSV1307D MP/LP PRDS PSV 4 13810103145 6.4
70 MP steam 10PSV1307E MP/LP PRDS PSV 5 13810103145 6.4
71 MP steam 10PSV1307F MP/LP PRDS PSV 6 13810103145 6.3
72 LP Steam 10PSV1402A BPTG exhaust LP steam PSV 1 13810103146 7.2
73 LP Steam 10PSV1402B BPTG exhaust LP steam PSV 2 13810103146 7.5
LP blending valve exhaust LP
74 LP Steam 10PSV1420A 13810103146 7.2
steam PSV 1
LP blending valve exhaust LP
75 LP Steam 10PSV1420B 13810103146 7.5
steam PSV 2
76 LP Steam 10PSV1412 LP heater steam side PSV 13810103146 4
77 LP Steam PSV # 1 on D/A 13810103146 4.15

Revision 02
9112-575-OPR-701-00002 Page 31 of 43
78 LP Steam PSV # 2 on D/A 13810103146 4.15

79 Air Ejector PSV ON I/A CONDENSOR(STG-1) 13810103147 16
PSV ON SURFACE CONDENSOR-
83 Condensor PSV1651 13810103147 0.1
STG1
PSV ON SURFACE CONDENSOR-
84 Condensor PSV1652 13810103147 0.1
STG2
85 MP steam 11PSV4111A BFPDT Back Pressure 13810103147 14.7
86 MP steam 11PSV4111B BFPDT Back Pressure 13810103147 15
TSV in ACW disch from water to
87 ACW 10TSV4803 '03810100936 7
water Heat exchanger for GT # 1
88 TSV in DM water supply header to
ACW 10TSV4823 '03810100936 7
DM pump for GT # 1
89 TSV in DM water Outlet line from
ACW 10TSV4839 '03810100936 7
Atm air precooler for GT # 1
90 TSV in ACW disch from water to
ACW 10TSV4848 '03810100936 7
water Heat exchanger for GT # 2
91 TSV in DM water supply header to
ACW 10TSV4853 '03810100936 7
DM pump for GT # 2
92 TSV in DM water Outlet line from
ACW 10TSV4866 '03810100936 7
Atm air precooler for GT # 1
93 TSV in inlet header of HSD coming
Off base HSD 10TSV6601 13810103138 18
from refinery to tank # 1
94 TSV in inlet header of HSD coming
Off base HSD 10TSV6602 13810103138 18
from refinery to tank # 2
95 Off base HSD 10TSV6637 TSV in HSD supply header from 13810103138 18

Revision 02
9112-575-OPR-701-00002 Page 32 of 43
refinery
TSV in HSD return header to tank
96 Off base HSD 10TSV6603 13810103138 13.5
#1
TSV in HSD suction common
97 Off base HSD 10TSV6604 13810103138 3.5
header for tank # 1
98 TSV in HSD return header to tank
Off base HSD 10TSV6605 13810103138 13.5
#2
99 TSV in HSD suction common
Off base HSD 10TSV6606 13810103138 3.5
header for tank # 1
100 TSV in common header for HSD
Off base HSD 10TSV6607 13810103138 3.5
supply to centrifuge system
101 TSV in return header common
Off base HSD 10TSV6608 13810103138 13.5
from GTs
102 TSV in common header for HSD
Off base HSD 10TSV6609 13810103138 3.5
supply to GTs
Off base HSD 10TSV6610 13810103138 3.5
from centrifuge
Off base HSD 10TSV6611 13810103138 3.5
from centrifuge disch
105 TSV in HSD suction header for GT
Off base HSD 10TSV6634 13810103138 3.5
#1
106 TSV in 100 micron suction filter
Off base HSD 10TSV6613 13810103138 3.5
9G12C for GT # 1
Off base HSD 10TSV6614 13810103138 3.5
9G13C for GT # 1
108 TSV in HSD Recirculation header
Off base HSD 10TSV6612 13810103138 13.5
for GT # 1
109 TSV in 25 micron twin filter
Off base HSD 10TSV6615 13810103138 13.5
(9X22C) for GT # 1
110 Off base HSD 10TSV6616 TSV in 25 micron twin filter 13810103138 13.5

Revision 02
9112-575-OPR-701-00002 Page 33 of 43
(9X22C) for GT # 1
111 TSV in 6 micron twin filter (9X23C)
Off base HSD 10TSV6617 13810103138 13.5
for GT # 1
Off base HSD 10TSV6618 13810103138 13.5
for GT # 1
113 TSV in ARC line to return header
Off base HSD 10TSV6619 13810103138 13.5
for HSD fwd pumps for GT # 1
114 TSV in HSD Disch header after
Off base HSD 10TSV6621 13810103138 13.5
accumulator for GT # 1
115 TSV in HSD header to GT # 1
Off base HSD 10TSV6622 13810103138 13.5
before 3 way valve
116 TSV in HSD suction header for GT
Off base HSD 10TSV6631 13810103138 3.5
#2
Off base HSD 10TSV6624 13810103138 3.5
9G12C for GT # 2
Off base HSD 10TSV6625 13810103138 3.5
9G13C for GT # 2
119 TSV in HSD Recirculation header
Off base HSD 10TSV6632 13810103138 13.5
for GT # 2
Off base HSD 10TSV6627 13810103138 13.5
(9X22C) for GT # 2
Off base HSD 10TSV6628 13810103138 13.5
(9X22C) for GT # 2
Off base HSD 10TSV6629 13810103138 13.5
for GT # 2
Off base HSD 10TSV6630 13810103138 13.5
for GT # 2
124 TSV in ARC line to return header
Off base HSD 10TSV6623 13810103138 13.5
for HSD fwd pumps for GT # 2
125 Off base HSD 10TSV6626 TSV in HSD Disch header after 13810103138 13.5

Revision 02
9112-575-OPR-701-00002 Page 34 of 43
accumulator for GT # 2
126 TSV in HSD header to GT # 2
Off base HSD 10TSV6633 13810103138 13.5
before 3 way valve
127 10GT2PSV67 PSV in ntirogen supply header to
Off base LCO 13810103139 2
80 LCO tank
128 10GT2VRV6 Vacuum relief valve for LCO tank # -25
Off base LCO 13810103139
782 1 mmWC g
129 10GT2VRV6 Pressure relief valve for LCO tank 75
783 #1 mmWC g
130 10GT2VRV6 Vacuum relief valve for LCO tank # -25
788 2 mmWC g
131 10GT2VRV6 Pressure relief valve for LCO tank 75
789 #2 mmWC g
132 TSV in LCO supply header from
Off base LCO 10TSV6761 13810103139 13.5
refinery to tankages
Off base LCO 10TSV6701 13810103139 13.5
refinery to tank # 1
Off base LCO 10TSV6702 13810103139 13.5
refinery to tank # 2
135 Off base LCO 10TSV6703 TSV in return header to tank # 1 13810103139 17.5
136 TSV in suction header from tank #
Off base LCO 10TSV6704 13810103139 3.5
1
137 Off base LCO 10TSV6705 TSV in return header to tank # 2 13810103139 17.5
138 TSV in suction header from tank #
Off base LCO 10TSV6706 13810103139 3.5
2
139 TSV in common suction header for
Off base LCO 10TSV6707 13810103139 3.5
LCO pump for UB and HRSG
140 TSV in LCO return header from
Off base LCO 10TSV6708 13810103139 13.5
GTs
141 Off base LCO 10TSV6709 TSV in common suction header for 13810103139 3.5

Revision 02
9112-575-OPR-701-00002 Page 35 of 43
LCO pump for GTs

142 TSV in recirculation header of LCO
Off base LCO 10TSV6710 13810103139 13.5
for GT # 1
143 TSV in ARC header for LCO fwd
Off base LCO 10TSV6711 13810103139 13.5
pump for GTs
144 TSV in 100 micron suction twin
Off base LCO 10TSV6713 13810103139 3.5
filters for GTs
145 TSV in 100 micron suction twin
Off base LCO 10TSV6714 13810103139 3.5
filters for GTs
146 TSV in LCO disch header for GT # 1
Off base LCO 10TSV6715 13810103139 13.5
after accumulator
147 TSV in 25 micron twin filters
Off base LCO 10TSV6716 13810103139 13.5
(M504A) for GT # 1
Off base LCO 10TSV6717 13810103139 13.5
(M504B) for GT # 1
Off base LCO 10TSV6718 13810103139 13.5
(M505A) for GT # 1
Off base LCO 10TSV6719 13810103139 13.5
(M505B) for GT # 1
151 TSV in LCO supply header for GT #
Off base LCO 10TSV6720 13810103139 15.5
1 before 3 way valve
152 TSV in liquid fuel supply header
Off base LCO 10TSV6722 13810103139 15.5
for GT # 1 after 3 way valve
153 Vanadium Inhibitor pump # 1
Off base LCO PSV6725 13810103139 7
disch header PSV for GT # 1
Off base LCO PSV6730 13810103139 7
155 TSV in recirculation header of LCO
Off base LCO 10TSV6723 13810103139 13.5
for GT # 2
156 Off base LCO 10TSV6724 TSV in LCO disch header for GT # 2 13810103139 13.5

Revision 02
9112-575-OPR-701-00002 Page 36 of 43
after accumulator
Off base LCO 10TSV6725 13810103139 13.5
(G509A) for GT # 2
Off base LCO 10TSV6726 13810103139 13.5
(G509B) for GT # 2
Off base LCO 10TSV6727 13810103139 13.5
(G510A) for GT # 2
Off base LCO 10TSV6728 13810103139 13.5
(G510B) for GT # 2
161 TSV in LCO supply header for GT #
Off base LCO 10TSV6729 13810103139 15.5
2 before 3 way valve
162 TSV in liquid fuel supply header
Off base LCO 10TSV6730 13810103139 15.5
for GT # 2 after 3 way valve
Off base LCO PSV6747 13810103139 7
Off base LCO PSV6751 13810103139 7
165 TSV in LCO recirculation header
Off base LCO 10TSV6731 13810103139 17.5
for HRSGs
166 TSV in 100 micron twin filter for
Off base LCO 10TSV6732 13810103139 3.5
HRSG fwd pumps
Off base LCO 10TSV6733 13810103139 3.5
HRSG fwd pumps
168 TSV in LCO supply header to HRSG
Off base LCO 10TSV6734 13810103139 17.5
after accumulator
169 TSV in LCO fwd pump # 2 disch
Off base LCO 10TSV6791 13810103139 17.5
header for HRSG
Off base LCO 10TSV6792 13810103139 17.5
header for HRSG
171 Off base LCO 10TSV6793 TSV in LCO fwd pump # 1 disch 13810103139 17.5

Revision 02
9112-575-OPR-701-00002 Page 37 of 43
header for HRSG

172 TSV in LCO recirculation header
Off base LCO 10TSV6735 13810103139 22
for UB
Off base LCO 10TSV6736 13810103139 3.5
UB fwd pumps
Off base LCO 10TSV6737 13810103139 3.5
UB fwd pumps
Off base LCO 10TSV6794 13810103139 22
header for UB
Off base LCO 10TSV6795 13810103139 22
header for UB
Off base LCO 10TSV6796 13810103139 22
header for UB
178 TSV in LCO common disch header
Off base LCO 10TSV6758 13810103139 22
for UB
179 FSV in Gas scurbber / KOD # 2 for
Off base FG 10FSV6808A 13810103142 15
GTs
Off base FG 10FSV6808B 13810103142 15
GTs
Off base FG 10FSV6809A 13810103142 15
GTs
Off base FG 10FSV6809B 13810103142 15
GTs
183 Off base FG 10FSV6819A FSV in FG seperator # 1 for GT # 1 13810103142 24
184 Off base FG 10FSV6819B FSV in FG seperator # 1 for GT # 1 13810103142 24

Revision 02
9112-575-OPR-701-00002 Page 38 of 43

FSV in FG scrubber / KOD for
194 Off base FG 10FSV6853A 13810103142 15
HRSGs
FSV in FG scrubber / KOD for
195 Off base FG 10FSV6853B 13810103142 15
HRSGs
FSV in FG scrubber / KOD # 1 for
196 Off base FG 10FSV6869A 13810103142 15
UB
197 Off base FG 10FSV6869B 13810103142 15
UB
198 Off base FG 10FSV6869C 13810103142 15
UB
199 Off base FG 10FSV6869D 13810103142 15
UB
200 Emerg IA 10PSV5501A PSV in Surge receiver 23810100876 12
201 Emerg IA 10PSV5501B PSV in Surge receiver 23810100876 12
202 Emerg IA 10PSV5504A PSV in Atomizing air receiver # 1 23810100876 35
203 Emerg IA 10PSV5504B PSV in Atomizing air receiver # 1 23810100876 35
204 Emerg IA 10PSV5507A PSV in Atomizing air receiver # 2 23810100876 35
205 Emerg IA 10PSV5507B PSV in Atomizing air receiver # 2 23810100876 35
PSV in Atm air supply from
206 Emerg IA 10PSV5512A 23810100876 12
Emergency air system for boilers
PSV in Atm air supply from
207 Emerg IA 10PSV5512B 23810100876 12
Emergency air system for boilers
208 Emerg IA 10PSV5513A PSV in Instrument air receiver 23810100876 35
209 Emerg IA 10PSV5513B PSV in Instrument air receiver 23810100876 35
PSV in Instrument air supply
210 Emerg IA 10PSV5517A 23810100876 12
header from emergency air
PSV in Instrument air supply
211 Emerg IA 10PSV5517B 23810100876 12
header from emergency air
212 HP Nitrogen 10PSV6903 PSV in nitrogen supply header 23810100875 9

Revision 02
9112-575-OPR-701-00002 Page 39 of 43
from refinery to compressor

213 HP Nitrogen 10PSV6907A PSV in HP nitrogen receiver # 1 23810100875 47
214 HP Nitrogen 10PSV6907B PSV in HP nitrogen receiver # 1 23810100875 47
PSV in HP nitrogen supply header
221 HP Nitrogen 10PSV6928 23810100875 38.5
after PSV to GT # 1
PSV in HP nitrogen supply header
222 HP Nitrogen 10PSV6934 23810100875 38.5
after PSV to GT # 2
223 Blowdown PSV on CBD tank for UB # 1 23810100862
HP dozing PSV in HP dozing pump # 1 disch.
227 10PSV5204 13810103198
for UB header for UB # 1
228 10PSV5205 13810103198
229 10PSV5209 13810103198
230 10PSV5211 13810103198
231 10PSV5213 13810103198
HP dozing PSV in HP dozing pump # 2 disch
232 10PSV5215 13810103198
233 HP dozing 10PSV5217 PSV in HP dozing pump # 1 disch 13810103198

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HP dozing PSV in HP dozing pump # 2 disch
234 10PSV5219 13810103198
LP dozing PSV in LP dozing (hydrazine) fwd
235 10PSV2004 33810102768 6 atm (a)
(hydrazine) pump # 1
LP dozing PSV in LP dozing (hydrazine) fwd
236 10PSV2004 33810102768 6 atm (a)
(hydrazine) pump # 2
LP dozing PSV in LP dozing (Ammonia) fwd
237 10PSV5104 33810102769 5 atm (a)
(Ammonia) pump # 1 for Deaerator
LP dozing PSV in LP dozing (Ammonia) fwd
238 10PSV5105 33810102769 5 atm (a)
(Ammonia) pump # 2 for Deaerator
PSV in LP dozing (Ammonia) fwd
LP dozing
239 10PSV5304 pump # 1 for Condensate storage 33810102770 6 atm (a)
(Ammonia)
tank
PSV in LP dozing (Ammonia) fwd
LP dozing
240 10PSV5305 pump # 2 for Condensate storage 33810102770 6 atm (a)
(Ammonia)
tank
PSV in Main oil tank for GBC of GT
241 GBC 04PSV7301 '03360032072
#1
242 GBC 04PSV7302 '03360032072
#1
243 GBC 05PSV7301 '03360032072
#2
244 GBC 05PSV7302 '03360032072
#2
TSV in CW return line of bypass
245 GBC 04TSV7101 33360034029 8
cooler of GBC for GT # 1
TSV in CW return line of Lube oil
246 GBC 04TSV7102 33360034029 8
247 GBC 04TSV7103 TSV in CW return line of Lube oil 33360034029 8

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TSV in CW return line of bypass
248 GBC 05TSV7101 33360034029 8
249 GBC 05TSV7102 33360034029 8
250 GBC 05TSV7103 33360034029 8
PSV in Jacking oil supply header
251 STG # 1 01PSV3301 23170082363 96
for STG # 1
PSV (Relief valve) in Jacking oil
252 STG # 1 01PSV3302 23170082363 86
supply header of STG # 1
253 STG # 2 02PSV3301 23170082363 96
for STG # 2
254 STG # 2 02PSV3302 23170082363 86
supply header of STG # 2
PSV on surface condenser of STG
255 STG # 1 01PSV1651 13810103147 1.1
#1
PSV on Primary Ejector condenser
256 STG # 1 01PSV 13810103147
system # 1 of STG # 1
257 STG # 1 13810103147
PSV on Gland steam condenser of
258 STG # 1 13810103147
STG # 1
PSV on surface condenser of STG
259 STG # 2 02PSV1651 13810103147 1.1
#2
260 STG # 2 01PSV 13810103147
261 STG # 2 13810103147
262 STG # 2 PSV on Gland steam condenser of 13810103147

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STG # 2
263 BPTG 03PSV3801 23170082663 77
for BPTG
264 BPTG 03PSV3802 23170082663 70
supply header of BPTG
TD UB BFP exhaust MP steam PSV
265 BFPDT 11PSV4111A 13170082561 15.7
1
TD UB BFP exhaust MP steam PSV
266 BFPDT 11PSV4111B 13170082561 16
2
267 BFPDT 11PSV4301A BFP TD MOP exhaust LP steam 23170082564 7.3
268 BFPDT 11PSV4301B BFP TD MOP exhaust LP steam 23170082564 7
269 10-PSV-1322A VHP-MP PRDS MP exhaust leg-A 13.4 kg/cm2
270 10-PSV-1322B VHP-MP PRDS MP exhaust leg-A 14 kg/cm2
271 VHP-MP PRDS 10-PSV-1326A VHP-MP PRDS MP exhaust leg-B 14 kg/cm2

272 10-PSV-1326B VHP-MP PRDS MP exhaust leg-B 13.4 kg/cm2
273 10-PSV-1326C VHP-MP PRDS MP exhaust leg-B 13.4 kg/cm2
274 10-PSV-1322C VHP-MP PRDS MP exhaust leg-A 14 kg/cm2
275 575—TSV-9661A Pump seal pot cooling water outlet 6.0 kg/cm2
276 575—TSV-9661B Pump seal pot cooling water outlet 6.0 kg/cm2
277 575—TSV-9661C Pump seal pot cooling water outlet 6.0 kg/cm2
278 575—TSV-9659A Suction filter A TSV 3.43 bar
279 GT Naphtha 575—TSV-9659B Suction filter B TSV 3.43 bar

280 575-TSV-9657 GT Naphtha pump skid suction line 3.5kg/cm2
281 575-TSV-9658 GT Naphtha pump skid recirculation 15.5kg/cm2
15.5kg/cm2
282 575-TSV-9608A GT-1 Naptha line PCV U/S TSV 9608A
15.5kg/cm2
283
575-TSV-9608B GT-2 Naptha line PCV U/S TSV 9608B
Pump De seal pot cooling water

284 HRSG Naphtha 575-TSV-9745A outlet line Tsv 6.0 kg/cm2

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Pump Nde seal pot cooling water

285 575-TSV-9745B outlet line Tsv 6.0 kg/cm2
286 575-TSV-9701 Pump balance leak-off Tsv 3.92 bar
Pump De seal pot cooling water

287 575-TSV-9745C outlet line Tsv 6.0 kg/cm2
Pump Nde seal pot cooling water

288 575-TSV-9745D outlet line Tsv 6.0 kg/cm2
289 575—TSV-9702 Pump balance leak-off Tsv 3.92 bar
290 Pump De seal pot cooling water

575-TSV-9745E outlet line Tsv 6.0 kg/cm2
HRSG Naphtha
300 Pump Nde seal pot cooling water
575-TSV-9745F outlet line Tsv 6.0 kg/cm2
301
575—TSV-9703 Pump balance leak-off Tsv 3.92 bar
302
575-TSV-9744A Suction filter-A TSV 3.5 bar
303
575-TSV-9744B Suction filter-B TSV 3.5 bar
304
575—TSV-9738 Naphtha pump skid suction line TSV 3.5kg/cm2
305 Naphtha pump skid recirculation

575—TSV-9739 line TSV 17.5kg/cm2
17.5kg/cm2
306 HRSG Naphtha HRSG Naphtha control station
575-TSV-9743

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CHAPTER - 11
HAZARD, SAFETY AND COMMUNICATION
11.1 INTRODUCTION
Safety of personnel and equipment is very important. Ignorance of the details of the unit or the
techniques of safe and efficient operation reduces the margin of safety of personnel and subjects the
equipment to more hazardous conditions. All the operating and maintenance crew therefore must be
fully familiar with the equipment and materials being handled in the unit, and recognize the hazards
involved in handling them and the measures taken to ensure safe operations.
Since the unit handles with one of the most potential source of fire and explosion, Fuel Gas, HSD,
LCO, LPG, and chemical like Ammonia, Hydrazine, Tri Sodium Phosphate, Vanadium corrosion
inhibitor and of course STEAM handling therefore adherence of safety rules should be given uphill
importance.
11.2 SAFETY WARNINGS

Before to start the job the operator must know very well the features, the position, the functioning of
the equipment and its commands on which he is preparing to intervene.
The zones in which the operator is working must be maintained clean and clear because areas and
environments in disorder favor the accidents.
All maintenance activities mu st be performed after the equipment shut -down and without voltage.
The people not directly involved in the activities must not enter in the working area. The repairing on
electrical/control panels must be carried out without voltage and with emergency pushbutton
inserted. The people not directly involved in the activities must not enter in the working area.
Before the equipment start-up all electrical/control panels, safety devices, guards must be

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restored as at the beginning. Don't put objects or tools so as not to block the view of the zones and of
the safety devices.
Extraneous and/ or inexperienced people must not enter in the hazardous zones. The activities of set-
up and tuning to be performed with the equipment in operation must be carried out by skilled
personnel.
11.3 SAFETY OF PERSONNEL

General safety rules which shall be practiced and enforces for all personnel who enter the unit are
summarized below:
A. Safety helmets and shoes shall be worn by all personnel at all times in the plant. They may
be removed when inside rooms or buildings which do not have overhead or other hazards.
B. Smoking shall be permitted only in specified areas which are declared as non-hazardous and
are pressurized through a ventilation system. Failure of the ventilation system automatically
cancels the smoking privilege until the system is repaired, inspected and authorized
operation.
C. Each employees assigned to work in the unit shall know where the safety and fire suppression
equipment is located and how to operate this equipment.
D. Safety glasses, goggles or face shields shall be worn while performing work which could result
in eye or face injury.
E. PVC suits, gloves, gum shoes to be used wherever applicable.
F. Safety belt & full body harness to be used wherever applicable for working at height.
G. Operations personnel golden rule
H. The GGSR APM should be consulted as needed for details on safety policies and procedures.
Do not open or close any valve without first determining the effect.
Note: - Treat each piece of equipment or piping as if it is under pressure.

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11.4 HAZARDS DURING START UP / SHUT DOWN AND PRECAUTION

Start up and shut down of units in the most critical period during which there is a possibility of
leakages / fires. All necessary precautions should to be taken by all operating personnel for smooth
and safe start-up and shutdown activity. The various types of hazards are given below.
 During fuel gas backup in the unit, all the vents should be kept closed.

 Liquid draining should not be left unattended. Any leak during start up leads to fire.
Therefore
Before gas back up, withdraw all the hot / fire permits.
 Fire water hose to be laid


 Ensure that all the OWS manholes are properly covered otherwise any gas pocket is the
channel may cause fire / explosion at some other end outside battery area.

 During hot oil circulation, exchanger flanges / cover flanges are likely to leak cause fire.
Hot Circulation should be done gradually and carefully as per procedure
STEAM GENERATOR HAZARDS
This paragraph draws-up a list of hazards related to the operation of a steam generator.
 Hazards due to fluids under pressure and temperature.


 Blow-downs and/or drains necessary for cleaning, inspection and maintenance activities.
Hazards due to pressure equipment internal inspection activities

 Hazards due to normal operation such as: Filling and/or emptying activities o f pressure
equipment

 Not perfect efficiency of the protection devices and of the safety accessories

 Hazards due to fire of external origin

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HAZARDS DUE TO PRESSURIZED FLUIDS
The fluid (water and/or steam) contained inside of the pressure parts of a steam g enerator, has
pressure values higher than the atmospheric pressure.
The opening of vent/drain valves must be carried out with caution verifying that:
 The discharge piping goes to a safe location


 The piping is strongly anchored and it is able to bear the forces due to the passage at high
velocity of the pressurized fluid.
For these reasons verify the state of anchors and/or supports of the safety valves discharge piping;
furthermore verify also:
 The discharge piping of safety accessories are free of obstructions

 No blockage is present in drainages of this piping
To verify the operation of valves, safety valves and for the maintenance activities to be carried out
periodically refer to the instructi ons of the boiler auxiliary equipment manufacturers.
In the case of searching a leakage in the system, it is very important to remind that the superheated
steam is invisible. A superheated steam leakage is only visible at a certain distance from the actual
point of escape. Pay attention not to walk through the steam blow (invisible and at high velocity)
when searching the leak since it can cause grave burns
The leaks of saturated steam are dangerous but their detection is easier, since the plume is visible at
the point of escape. Each zone of steam leakage must be inaccessible for the people not involved in
the repairing until the work has been completed.
HAZARDS DUE TO INTERNAL INSPECTIONS
To allow the internal inspection of pressure equipment, suitable openings are provided to enable the
entrance inside to proceed with the necessary inspections in safe conditions.

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Before to proceeding for inspection it is necessary to verify that the equipm ent has been
depressurized in addition to the precautions listed below.
In CPP our major concern for Boilers /HRSG it will be necessary to inspect the conditions of the
internal surfaces of the combustion chamber and the flue gas ducts.
 Never enter into a vessel, in particular into a steam drum, if any water and steam valves are
open. Be sure that the drain and continuous blow down valves are closed; there is the
possibility that steam and hot water go up to steam drum by means of the draining pipes.


 Before entering any vessel, each piece of piping will need to be isolated away from the
vessel via a blind or blank.

 Never enter into a "confined space" if it is not cold, purged from toxic or combustible gas;
the vessel must be flushed in an appropriate way paying attention that the access door
remain open. It is recommended that a "buddy system" is used when entering in a confined
space. This means that there is always a person outside the confined space while someone
is inside. If a trouble occurs, the outside person must take any action to get the inside
person out of the confined space.

 By means of a portable oxygen meter it shall be verified that the oxygen content is
sufficient to allow the entering of the personnel. In order to assure that, during the
inspection/works, safe working conditions are maintained repeat this check periodically.

 Inside a confined space use low voltage electrical power and with correct earthling. The
lights have to be of explosion proof type .

 Never use, inside confined spaces, toxic fluids.
HAZARDS FOR SAFETY AND HEALTH
Chemical Compounds
To assure a suitable protection against corrosion feed water and boiler water are properly added of
chemical additives.

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Chemicals compound, if not correctly handled, can be dangerous for personnel safety.
For the correct use and handling refer to the safety data sheets of each product sent by the supplier
along with the products themselves.
It is forbidden to mix chemicals of different type; u se clean containers and without residuals. The use
of glasses, gloves and aprons will be integral part of the operating procedures prepared by plant
manager.
Specific procedures for the containment of the eventual leakage and for its removing will be prepared
for each product.
Potential dangerous substances and material are:
Tri-sodium phosphate (Na3PO4) [1 ] Source: Chemical dosing skid
Nitrogen (N2) [2] Source: Boiler preservation/GT-sealing

Ammonia [1] Source: Chemical dosing skid
Hydrazine [1] Source: Chemical dosing skid
Vanadium corrosion inhibitor Source: LCO additive for GTG’s
Nitrogen is not toxic, but may be dangerous for the personnel if it substitute the oxygen. For this
reason it will be necessary to ventilate the plant parts purged with N2 before the personnel entering.
Breathing Hazards
 Avoid breathing Hydrazine vapor. When handling these substances, ensure there is adequate
ventilation in the area. Carefully follow the manufacturer's user instructions.

 Inhalation of tri-sodium phosphate may cause sore throat, coughing and shortness of breath.
Ingestion of tri-sodium phosphate could result in symptoms of abdominal pain and diarrhea. In
all instances, move the victim to fresh air. Seek medical attention if symptoms persist.


 Inhalation of Ammonia causes respiration disturbance, in higher concentration severe problem
may occur.

 Avoid breathing Nitrogen, because it will not allow respiration.

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 Usually Nitrogen can be used for boiler preservation.


 Purge steam drum from Nitrogen keeping opened both the man -ways for at least one day. In
order to increase the ventilation it is a good provision the use of air movers.

 Before entering into a confined space, it is suggested to perform a test, by means an oxygen
analyzer, to verify that the oxygen content is 20,5+21% vol.
Skin And Eyes Irritation

Skin and eye irritation can be caused from the chemicals dosed in the Boilers system.
Here below are listed the actions that must be undertaken in case of use of typical chemicals, as
Hydrazine, Ammonia and Tri-sodium phosphate.
 Hydrazine, usually used as oxygen scavenger, is corrosive to the eyes and skin. Wear goggles;
face shield and rubber gloves when handling this substance. In case of contact, immediately
flush with water for 15 minutes and seek medical attention. Remove contaminated
clothing and wash before re-use. Do not take internally. Keep the container closed when not in
useand away from heat, potential sparks and open flames.
 Tri-sodium phosphate, usually injected in the steam drum, in case of contact with the skin will
cause inflammation. Contact with the skin causes inflammation andpain. Gloves and goggles
must be worn. If there is contact with the skin, remove contaminated clothing and flush the
skin with water. For contact with the eyes, flush with large volumes of water and, if necessary,
seek medical attention.
 Ammonia, Exposure to high levels of ammonia can cause irritation and serious burns on the
skin and in the mouth, throat, lungs, and eyes. At very high levels, ammonia can even cause
death. Lung damage and death may occur after exposure to very high concentrations of
ammonia. Some people with asthma may be more sensitive to breathing ammonia than
others. Swallowing concentrated solutions of ammonia can cause burns in your mouth, throat,
and stomach. Splashing ammonia into your eyes can cause burns and even blindness.

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 Mg based vanadium corrosion inhibitor, used in gas turbines to control vanadium. Avoid skin
& eye contact. Wash contaminated area with soap and water.
Presence of High Temperature Fluids
The most common hazard around the steam generator is the high temperatures of the system. To
minimize the risk of burns it is recommended to wear Long pants, shirts with long sleeves and Leather
works gloves etc. Keep in mind that some of the equipment will retain heat for an extended time after
the plant is shut-down.
Plant manager will prepare dedicated procedures to make inaccessible, temporarily, the high
temperature equipment occasionally without insulation that are present in working areas. As example
it is possible to remind the areas in which are present:
 Valves or pipes with insulation removed for maintenance

 Any casing hot spots should be barricaded.

 Even if from a process point of view the insulation of some hot equipment and piping may not
be required or not economically justified, the insulation is necessary for personnel protection
in particular in those areas where more frequently the presence of the operators is requested.


 It is necessary to check very well the integrity of the insulation and carried out the periodic
maintenance in order to maintain its efficiency in the time.

 It is important to remind that a damaged insulation is more dangerous than a lacking insulation
because deceptively it makes to believe to the operators they are protected.
Hot Burns
Although an accidental contact with hot metal surfaces is not expected because insulation is widely
used in the boiler, if an unprotected contact with the skin happens provide to wash with cold water
for a minimum of 15 minutes. Seek medical attention if symptoms persist. If a steam leak is
suspected, great care must be taken during investigation as the steam will not be visible and cause
severe injury if in contact with unprotected skin. Suitable protective overalls,

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gloves, facemask must be worn to protect against possible contact. Contact with steam will require
immediate medical attention.
Trips And Falls
Access for inspection of the boiler steam drums and flue stack is via ladders, which necessitate
caution during use.
Care must be taken by personnel who might be working in the vicinity of the Forced Draft Fan drive
shafts.
Coupling guards must not be removed unless the relevant fan has been electrically isolated. Any oil
leaks that may occur from the Forced Draft Fans, Boiler Feed Water Pumps or any other equipment
relevant to Boilers, must be cleaned-up as soon as possible, to obviate the possibility of persons losing
their footing. Good housekeeping is to be maintained at all times.
Hearing Damage
In Boilers area, there are normally in operations Forced Draft Fans, Burners and Boiler Feed Water
Pumps. When the noise level exceeds 85 dBA attention must be given to prevailing Health and Safety
Legislation, to limit the exposure of plant operating personnel to the noise. The usual approach is to
control exposure time to the noise or to adopt opportune dev ices to reduce the emitted sound. It is
understood that when the sound pressure level in the working area is:
 Lower than 70 dB (A) No particular measure is necessary

 Higher than 70 dB (A) Protection measure against noise must be supplied to personnel
permanently working in the plant.

 Lower than 85 dB (A) No particular measurement is foreseen for occasional visitors staying in
the plant for a short period.

 Higher than 85 dB(A) The plant must be classified as a noise hazardous area and therefore a
permanent visible warning must be installed at each entrance to alert the personnel entering
the plant, even for a short period, about the need to wear ear protections.

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 Higher than 105 dB (A) Special ear protections adequate for this noise level and spectral
composition shall be provided and a special warning shall be placed at each entrance.It is
essential to make sure that the noise propagated does not create too high noise level in the
surrounding environment.
Incorrect maneuver during operation

 All maneuvers made during operation, start - up and shutdown should be carried
out following the instructions shown in this manual.

In
particular the operator must follow the start-up curves.

The plant manager has to assure himself that the personnel has a good knowledge of the operating

procedures.
For this reason the plant manager will define a periodic training program in order to assure the good
knowledge of the procedures by the operating and maintenance personnel . The training course will be
repeated if plant modifications and/or equipment substitutions are made.
MECHANICAL HAZARDS
Rotating Machinery
During the use of the machines always refer to the relevant instruction manuals. It is
recommended:
 Check frequently the correct installation of safety devices like guards etc.

 Never operate on moving parts

 Never carry out any maintenance activity if the equipment is not in safe conditions.

 The operating personnel must wear adequate accident -prevention clothes (helmet, gloves
etc.). The clothes must not have fluttering parts that can get entangled in moving parts.

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 Abnormal vibration and/or overheating must be immediately notified and the machine has to
be put out of service for check and /or repairing.
Electrical Hazards
 The terminals on the machines must be always protected in their boxes


 Never allow to open on electrical parts if electrical power is present.

 Never allow to restore the electrical power without the confirmation that nobody is still
working on that equipment.
11.5 WORK PERMIT PROCEDURE

A work permit system must be issued by the appropriate operations group before commencing any
Maintenance work affecting the operation of the unit. The work permit is issued for “Hot”
And “Cold” work. The “Hot” work permit must include as a minimum, a precise description and
mode of execution of “Hot” works, the equipment to be used, the expected time which “Hot”
works is scheduled to start and expected completion, an exact location of the “Hot “ works and
precautions to be taken.
Unit areas are generally identified as hazardous areas as far as the threat of fire is concerned.
Therefore, in order to carryout works within these areas, a written work permit is required. The
work permit, when approved, indicates that a specific work can be carried out in safe conditions
provided that all safety precautions are observed.
a) Permits for HOT-Work

Permits of hot works are required for any work :-
 Electric and gas welding

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 Hot work.

 Confined space entry.

 Radiation source work.

 Vehicle /Equipment entry.

 Work on equipment in service.

 Fresh air equipment in Hazardous service.



b) Permits for Cold-Work
Permits for cold-work are required for any work not involving the use of a local ignition source.
Typical examples of cold-work are:
 Disconnecting of lines for the insertion of blinds etc. − Opening of any equipment such as
 vessels, filters, etc.
 Electrical work.
 Excavation work.(Manual)
c) Confined Space entry permits
Entry permits are required for entering enclosed spaces such as vessels, sewer, pits, trenches, etc.
The use of any tool or machinery, which could provide a source of ignition, is forbidden. Also, prior
to entry it should be ensured that area is well ventilated and the oxygen content in air is about 21%
by volume. Fresh air flow is to be ensured in the enclosed space throughout the duration of work.
A gas test for H2S and flammable gases should also be performed before entry.
A person should also be on alert outside the enclosed space for rescue in case of emergency.
Procedure for carrying out work and rescue plan shall be formulated before commencement of
work.
d) Guidelines for release of permits
 The equipment item, on which works have to be carried out, shall be clearly indicated. During
the shutdown of any system, permits covering the whole section with above mentioned item
shall be issued, if possible. The type of work permitted shall be clearlyindicated.

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 The date and the period of validity of the permit shall also be indicated. If the work does not
yet over within the period of validity of the permit, the permit can be extended provided
that, at each start of the works the safety conditions are checked again and signed by the
operator in-charge and by safety officer. Beyond this extended period, a next permit will have
to be issued. The explosiveness test and the check of toxic gases shall be performed always at
the last moment before each start of the work and subsequently every time the work is
resumed or whenever doubts arise.

 The validity of the permit can be cancelled at any moment by the operator or by safety
officer; in case they deem that the conditions are not safe.

 The conditions to be complied with shall include special precautions, such as the use of
protective clothing, breathing apparatus, safety equipment and the tools to be used etc.

 No one shall be allowed to enter the vessel or other enclosed spaces without suitable
protective clothing and until the vessels or the enclosed spaces become safe for entry by
means of proper isolation, proper ventilation and suitable check of the atmosphere inside
and availability of rescue person outside the enclosed equipment.

 For any kind of work availability of Escape Route to be checked as it is most important thing in
case of emergency situation.
If welding or hot work is to be done ensure that:-

 Fire fighting system is ready

 Close the neighboring surface drains with wet gunny bags

 Keep water flowing in the neighboring area to cool down any spark.

 Responsible operation supervisor should be present at the place of hot work till the first
torch is lighted.

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11.6 FIRST AID
In addition of what foreseen by the provisions of the law regard safety the following safety kits have
to be available on site:
 Eyes washer: Even if small quantities of chemical enter in the eyes, they must be washed
immediately with a lot of water at least for 15 minutes.

 Safety shower : In the area where the chemicals are handled, an easily accessible shower
must be present.

 First Aid Kit: If some small injury happen, then first aid kit is present at proper location.

 Safety inspections: Verify periodically that all safety equipments are always in good
conditions. Signs indicating their operation must be placed near each water source and
shower.
11.7 HAZARD SOURCES TO THE ENVIRONMENT
The most significant potential environmental hazard from Boilers is the release of gas from the fuel
gas lines. Waste management during routine maintenance and shutdowns is another potential hazard
to be considered.
11.8 WASTE DISPOSAL

The generated waste i.e.: lubricating oil/grease, water discharged after boiler boil-out etc are
properly disposed in accordance with local rules for environment protection.
11.9 COMMUNICATION SYSTEM

Proposed public address system and walky talky sets detailed information Awaited.

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CHAPTER – 12
CATALYST SPECIFICATION AND SPECIAL PROCEDURES
 No catalyst is used in CPP.

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9112-575-OPR-701-00002 Page 1 of 3
CHAPTER – 13
MAJOR EQUIPMENTS AND THEIR OPERATIONS
Refer Normal Standard Operating Procedure for all equipment and process and their operation
details
1 9112-575-OPR-704-00001 SOP OF FOR GAS TURBINE NORMAL START-UP/SHUTDOWN
2 9112-575-OPR-704-00002 NORMAL SOP OF CPP GTG FIRE FIGHTING SYSTEM
3 9112-575-OPR-704-00003 SOP FOR GT WATER WASH SYSTEM OFFLINE/ONLINE
4 9112-575-OPR-704-00004 SOP FOR CPP FOR GT FUEL CHANFEOVER AND MIX FUEL OPERATION
5 9112-575-OPR-704-00005 "NORMAL SOP OF CPP FOR HRSG START-UP/SHUTDOWN & SUPPLEMENTARY

FIRING"
6 9112-575-OPR-704-00006 NORMAL SOP OF CPP FOR HRSG HYDRO TEST
7 9112-575-OPR-704-00007 SOP OF CPP FOR UTILITY BOILER STARTUP AND SHUTDOWN
8 9112-575-OPR-704-00008 SOP OF CPP FOR SLOP OIL AND GAS CONDENSATE TRANFER
9 9112-575-OPR-704-00009 NORMAL SOP OF CPP FOR UTILITY BOILER HYDRO TEST
10 9112-575-OPR-704-00010 SOP FOR UB/HRSG SAFETY VALVE FLOATING
11 9112-575-OPR-704-00011 SOP OF CPP FOR STG START UP/SHUTDOWN/SYNCHRONIZATION
12 9112-575-OPR-704-00012 SOP OF CPP FOR BPTG START-UP / SHUTDOWN / SYNCHRONIZATION
13 9112-575-OPR-704-00013 NORMAL SOP OF CPP FOR TURBINE DRIVEN ACW PUMP

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14 9112-575-OPR-704-00014 SOP OF START UP / SHUTDOWN OF UB TD LOC FORWARDING PUMP
15 9112-575-OPR-704-00015 SOP FOR CPP FOR UTILITY BOILERS TD FD
16 9112-575-OPR-704-00016 "SOP FOR STRAT - UP / SHUTDOWN OF TD - MOP OF STEAM TURBINE GENETATOTRS

(STGS)"
17 9112-575-OPR-704-00017 SOP OF CPP FOR STEAM HEADER CHARGING
18 9112-575-OPR-704-00018 "SOP FOR DETERMINING GENERATORS CAPABILITY FOR FAST LOAD SHEDDING
,GUIDELINE AND GUIDELINE FOR UNDER FREQUENCY LOAD SHEDDING"
19 9112-575-OPR-704-00019 NORMAL SOP OF CPP FOR FILTER CHANGE OVER
20 9112-575-OPR-704-00020 "NORMAL SOP FOR HSD & LCO FUELS FOR RECEIPT AND STOCK CALCULATIONS"
21 9112-575-OPR-704-00021 "SOP OF CPP FOR ATOMIZING AND BOOSTER AIR COMPRESSOR STARTUP /
SHUTDOWN"
22 9112-575-OPR-704-00022 SOP OF CPP FOR AUXILIARY COOLING WATER SYSTEM
23 9112-575-OPR-704-00023 SOP OF CPP FOR SSF SYSTEM
24 9112-575-OPR-704-00024 NORMAL SOP OF CPP FOR AIR CONDITIONING SYSTEM
25 9112-575-OPR-704-00025 "NORMAL SOP OF CPP FOR HP NITROGEN COMPRESSOR STRAT UP AND

SHUTDOWN"
26 9112-575-OPR-704-00026 SOP OF CPP FOR GAS BOOSTER COMPRESSOR START-UP AND SHUTDOWN
27 9112-575-OPR-704-00027 SOP OF CPP FOR BLACK START DIESEL GENERATOR START-UP/SHUTDOWN
28 9112-575-OPR-704-00028 SOP OF CPP FOR COOLING TOWER OPERATION
29 9112-575-OPR-704-00029 "NORMAL SOP OF CPP FOR DEAERATOR LP HEATER, EXPORT FEED WATER PUMPS &
BEP-S"
30 9112-575-OPR-704-00030 EMERGENCY SOP OF CPP FOR STATION BLACKOUT
31 9112-575-OPR-704-00031 NORMAL SOP OF CPP PLANT EQUIPEMENT CHANGEOVER

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32 9112-575-OPR-704-00032 SOP FOR DM WATER AND RETURN CONDENSATE SUPPLY FAILURE
33 9112-575-OPR-704-00033 "EMERGENCY SOP OF CPP FOR RFG PRESSURE DISTURBANCE DUE TO RFG SUPPLY
NOT AVAILABLE FORM DCU/FCCU"
34 9112-575-OPR-704-00034 NORMAL SOP OF CPP FOR RFG SYSTEM CHARGING
35 9112-575-OPR-704-00035 EMERGENCY SOP OF CPP FOR REFINERY INSTRUMENT AIR SUPPLY FAILURE
36 9112-575-OPR-704-00036 SOP FOR TD MOP OF TD BFP
37 9112-575-OPR-704-00037 "NORMAL SOP OF CPP FOR HANDING OVER OF EQUIPMENT/VESSEL TO

MAINTENANCE"
38 9112-575-OPR-704-00038 SOP OF LIQUIDD FUEL STORAGE TANK OPERATION
39 9112-575-OPR-704-00039 SOP OF CPP FOR FUEL FORWARDING SYSTEM FOR UB
40 9112-575-OPR-704-00040 "SOP OF CPP FOR HRSG LIQUID FUEL SUPPLEMENTARY FIRING FORWARDING
SYSTEM"
41 9112-575-OPR-704-00041 "NORMAL SOP OF CPP FOR GAS TURBINE HSD/LCO/NAPHTHA OFF BASE FUEL
SYSTEM"
42 9112-575-OPR-704-00042 "SOP FOR CPP OPERATING PHILOSOPHY IN NORMAL OPERATIONS & EMERGENCY
HANDLING"
43 9112-575-OPR-704-00043 EMERGENCY SOP OF CPP FOR STEAM LOAD SHEDDING
44 9112-575-OPR-704-00044 "EMERGENCY SOP OF CPP FOR MONITORING AND CONTROL DURING MAX
DNA(DCS)"
45 9112-575-OPR-704-00045 SOP OF CPP FOR LCO TANK CLEANING
46 9112-575-OPR-704-00056 NORMAL SOP OF CPP FOR EQUIPMENT PRESERVATION
47 9112-575-OPR-704-00105 SOP OF CPP FOR NAPHTHA FIRING IN UTILITY

BOILER
48 9112-575-OPR-704-00108 NORMAL SOP OF CPP FOR PRDS OPERATION

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CHAPTER – 14
List of chemicals used in CPP
S. No. Name of the Chemical

1 Indion 3591– Sodium silicate formulation-VII
2 Indion 7079 – Bio-Dispersant
3 Indion 7240 - Corrosion Inhibitor
4 Indion 7241 – Corrosion formulation -2-Zinc
5 Indion 7243 – Pyrophosphate Formulation
6 Indion 7244 – Copper Inhibitor
7 Indion 7245 – Polymeric Dispersant
8 Indion 7246 – SHMP Powder
9 Indion 7247 – DOSS Product
10 Indion 7248 - Anti Scalent
th
11 Indion 7249 – Corrosion formulation -4 -PBTC
12 Indion 7250 –Polymeric Dispersant
13 Indion 7271 –Sodium Chlorite
14 Indion 7280 – Non oxidizing Biocide - QUAT
15 Indion 7281 - Non oxidizing Biocide - DBNPA
16 Indion 7590- Soda Ash
17 Tri Sodium Phosphate
18 Hydrazine Hydrate
19 Morpholine
20 Sulphuric Acid
21 Sodium Hypochlorite
22 TCCA (Trichloroisocyanuric Acid) Tablets
23 Cyclohexylamine
24 Light Cycle Oil
25 High Speed Diesel
26 Refinery Fuel Gas
27 ZOK-27
28 Liquid Petroleum Gas
29 Anthracite
30 Alumina Balls (Dryers)
31 Carbon Di Oxide
32 Lithium Bromide
33 Naphtha
34 Naptha additive Lube Improver Liquid
 Template No. Copyrights HMEL– All rights reserved

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Some of the major MSDS are as follows:-

14.1 MSDS for Morphiline
1. Identification
Product Name - MORPHOLINE
2. Hazard(s) identification
Classification
This chemical is considered hazardous by the -2012 OSHA Hazard Communication

Standard. Hazard Statements
 Harmful if swallowed

 Causes skin irritation

 Causes serious eye irritation

 May cause an allergic.

 Harmful if Inhaled

 Flammable liquid and vapour
Precautionary Statements
 Prevention

 Wash face, hands and any exposed skin thoroughly after handling.

 Do not eat, drink or smoke when using this product.

 Wear protective gloves/protective clothing/eye protection/face protection.

 Avoid breathing dust/fume/gas/mist/vapors/spray

 Contaminated work clothing should not be allowed out of the workplace

 Keep away from heat, hot surfaces, sparks, open flames and other ignition sources. No smoking.
Skin
IF ON SKIN: Wash with plenty of soap and water.Take off contaminated clothing and wash before reuse

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If skin irritation or rash occurs: Get medical advice/attention
Eyes
IF IN EYES: Rinse cautiously with water for several minutes. Remove Contact lenses, if present and easy to do.
Continue rinsing If eye irritation persists: Get medical advice/attention.
Ingestion
Do not induce vomiting. Never give anything by mouth to an unconscious person. Rinse mouth with water.
Consult a physician.
Disposal
Dispose of contents/container to an approved waste disposal plant.
3. Composition / information on ingredients
 Morpholine , purity->99 %
 Flash Point - 38
 Method - closed cup
 Auto ignition Temperature –No data available

 Explosion Limits
 Upper - 10.8% V/V
 Lower - 1.8% V/V
 Sensitivity to Mechanical Impact –

 No information available

 Sensitivity to Static Discharge –


 Specific Hazards Arising from the Chemical-

 Combustible .

 Hazardous Combustion Products- Carbon Oxides, Nitrogen Oxides

 Protective Equipment and Precautions for Firefighter
As in any fire, wear self-contained breathing apparatus pressure-demand, (approved or equivalent) and full
protective gear.

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4. First-aid measures
 Eye Contact- Rinse immediately with plenty of water, also under theEyelids, for at least 15 minutes
Obtain medical attention.

 Skin Contact- Wash off immediately with plenty of water for at least 15 Minutes. Obtain medical
attention.
 Inhalation - Remove from exposure, lie down. Move to fresh air. If
 Breathing is difficult, give oxygen. If not breathing, give artificial respiration Obtain medical attention.

 Ingestion - Clean mouth with water. Do not induce vomiting. Obtain Medical attention.

 Most important symptoms/effects -May cause allergic skin reaction. Symptoms of allergic reaction may
include rash, itching, swelling, trouble breathing, tingling of the hands and feet, dizziness, light
headedness, chest pain, muscle pain or flushing.


5. Fire-fighting measures
Suitable Extinguishing Media-Use extinguishing measures that are appropriate to local circumstances and the
surrounding environment.
6. Accidental release measures
Personal Precautions-Use personal protective equipment. Ensure adequate ventilation. Avoid breathing
Vapours, Mist or gas.
Environmental Precautions –Should not be released into the environment.
Methods for Containment and Cleanup -
Soak up with inert absorbent material and dispose of as hazardous waste. Keep in suitable, closed containers for
disposal. Sweep up or vacuum up spillage and collect in suitable container for disposal. Do not let this chemical
enter the environment.
7. Handling and storage
Handling -Avoid contact with skin and eyes. Avoid inhalation of vapour or mist. Storage -Keep in a dry, cool and
well-ventilated place. Keep container tightly closed. Containers which are opened must be resealed.
8. Exposure controls / personal protection

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Exposure Guidelines This product is very hazardous with occupational exposure

limits Established by the region specific regulatory bodies.
9. Physical and chemical properties
 Physical State Appearance - Colourless Oily liquid

 Flammability-No data available

 Instability-Stable under Conditions recommended.

 Physical hazards-N/A

 Engineering Measures- Ensure adequate ventilation, especially in confined areas. Ensure that eyewash
stations and safety showers are close to the workstation location.

 Personal Protective Equipment

 Eye/face Protection- Wear appropriate protective eyeglasses or chemical safety goggles as described by
OSHA's eye and face protection regulations

 Skin and body protection - Wear appropriate protective gloves and clothing to prevent skin exposure.

 Respiratory Protection

 Follow the OSHA respirator regulations

 Use a approved respirator if exposure limits are exceeded or if irritation or other symptoms are
experienced.

 Hygiene Measures -Handle in accordance with good industrial hygiene and safety practice

 Morpholine

 Odour - Weak ammonia like

 Odour Threshold -No information available
 pH - No data available
 Melting Point/Range- - 5°C / 23°F

 Boiling Point/Range -126-129 °C / 264 °F

 Flash Point -38

 Evaporation Rate –No data available

 Flammability (solid, gas) -No information available

 Flammability or explosive limits

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 Upper- 10.8 % V/V


 Lower -1.8 % V/V

 Vapour Pressure- 6mmHg (20°C)

 Vapour Density- Not data available

 Relative Density – 1.01

 Solubility- No information available

 Partition coefficient -No data available


 Decomposition temperature -No information available

 Viscosity -No data available

 Molecular Formula- C4H9NO

 Molecular Weight – 87.1

 Corrosivity- Highly corrosive

10. Stability and reactivity
 Reactive Hazard -None known, based on information available

 Stability - Stable under recommended conditions.

 Conditions to Avoid- Heat, flames & Sparks .

 Incompatible Materials - Strong oxidizing agents.

 Hazardous Decomposition Products - No data available

 Hazardous Polymerization - Hazardous polymerization does not occur.

 Hazardous Reactions - None under normal processing.

11. Toxicological information
 Acute Toxicity

 Product Information

 Component Information
Toxicologically Synergistic Products -No information available
Delayed and immediate effects as well as chronic effects from short and long-term exposure Irritation -Irritating
to eyes and skin

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Sensitization -May cause sensitization by skin contact

Mutagenic Effects -No information available
Reproductive Effects- No information available.
12. Ecological information
Ecotoxicity-Do not empty into drains.
Persistence and Degradability -Soluble in water Persistence is unlikely based on information available.
Bioaccumulation/ Accumulation - No information available.
Mobility -Will likely be mobile in the environment due to its water solubility.
14.2 MSDS for Hydrazine:

1. Identification
Product Name - HYDRAZINE HYDRATE
Classification


 Causes skin irritation


 May cause an allergic.


 Flammable liquid and vapour
Prevention

 Do not eat, drink or smoke when using this product.


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 Avoid breathing dust/fume/gas/mist/vapors/spray



 Keep away from heat, hot surfaces, sparks, open flames and other ignition sources.
No smoking.
Skin
IF ON SKIN: Wash with plenty of soap and water.Take off contaminated clothing and wash before reuse If skin
irritation or rash occurs: Get medical advice/attention
Eyes
Ingestion
Disposal
Dispose of contents/container to an approved waste disposal plant
3. Composition /information on ingredients
 Flash Point - None upto boiling point
 Auto ignition Temperature- No information available

 Explosion Limits- No information available

 Upper Limit- 100% Hydrazine

 Lower Limit- 4.7% Hydrazine





 Specific Hazards Arising from the Chemical- Combustible.

 Hazardous Combustion Products-Not available
Protective Equipment and Precautions for Firefighter

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protective gear.
Eye Contact- Rinse immediately with plenty of water, also under the Eyelids, for at least 15 minutes Obtain
medical attention.
Skin Contact- Wash off immediately with plenty of water for at least 15 Minutes. Obtain medical attention.
Inhalation - Remove from exposure, lie down. Move to fresh air. If Breathing is difficult, give oxygen. If not
breathing, give artificial respiration Obtain medical attention.
Ingestion - Clean mouth with water. Do not induce vomiting. Obtain Medical attention.
Most important symptoms/effects - May cause allergic skin reaction. Symptoms of allergic reaction may include
rash, itching, swelling, trouble breathing, tingling of the hands and feet, dizziness, light headedness, chest pain,
muscle pain or flushing.
Suitable Extinguishing Media- Use extinguishing measures that are appropriate to local Circumstances and the
surrounding environment.
Personal Precautions- Use personal protective equipment. Ensure adequate ventilation. Avoid breathing
Environmental Precautions –Should not be released into the environment.
Methods for Containment and Cleanup -Soak up with inert absorbent material and dispose of as hazardous
waste. Keep in suitable, closed containers for disposal.
Sweep up or vacuum up spillage and collect in suitable container for disposal. Do not let this chemical enter the
environment.

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Exposure Guidelines This product is very hazardous with occupational exposure limits established by the region
specific regulatory bodies.
 Physical State Appearance - Liquid










experienced.


 Hydrazine Hydrate

 Odour – Ammonia like

 Odour Threshold - No data available

 pH - 10.7 (Basic)

 Melting Point/Range- 2°C / 35°F

 Boiling Point/Range -114°C / 237°F

 Flash Point –None upto boiling point


 Flammability (solid, gas)- Not Flammable

 Flammability or explosive limits- No data available

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 Vapour Pressure- 10mmHg (20°C)


 Vapour Density- 1.1

 Relative Density –1.02

 Solubility- Complete

 Dist.Water/Oil coefficient -0.2



 Viscosity -No data available

 Molecular Formula- N2H4

 Molecular Weight – 32.05 g/mole

 Corrosivity- Non corrosive in presence of glass




 Conditions to Avoid- Heat, flames & Sparks.


 Hazardous Decomposition Products – Hydrogen decomposition temperature >250°C

 Hazardous Polymerization -Polymerization does not occur.

 Hazardous Reactions - None under normal processing.




to eyes and skin

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12. Ecological information
Ecotoxicity-Do not empty into drains.
Persistence and Degradability -Soluble in water Persistence is unlikely based on information available.
14.3 MSDS for Sulphuric acid
1. Identification
Product Name – Sulphuric acid
Classification-This chemical is considered hazardous by the -2012 OSHA Hazard Communication Standard.
Hazard Statements

 Hazardous in case of skin contact


 Highly Corrosive


 Liquid or spray mist can cause tissue damage
Prevention

 Do not eat, drink when using this product.


 Avoid breathing fume/gas/mist/vapors/spray


 Keep away from heat, hot surfaces, sparks, open flames and other ignition sources.

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Skin
IF ON SKIN: Wash with plenty of soap and water at least 15 minutes.Take off contaminated clothing and wash
before reuse If skin irritation or rash occurs: Get medical advice/attention
Eyes
IF IN EYES: Rinse cautiously with water for at least 15 minutes. Remove Contact lenses, if present and easy to do.
Continue rinsingIf eye irritation persists: Get medical advice/attention immediately.
Ingestion
Disposal
Dispose of contents/container to an approved waste disposal plant or dry sand, earth. It may also be
neutralized.
 Sulphuric acid purity- 98 %
 Flash Point - No data available
 Method - No data available

 Upper - No data available
 Lower - No data available




 Specific Hazards Arising from the Chemical-

 Non Combustible but many reactions can cause fire and explosions.
 Hazardous Combustion Products- Release of toxic gases like Oxides of sulphur.

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Protective Equipment and Precautions for Firefighter
protective gear.
medical attention.
Skin Contact- Wash off immediately with plenty of water for at least Minutes. Obtain medical attention.
breathing, give artificial respiration Obtain medical attention. Ingestion - Clean mouth with water. Do not induce
vomiting. Obtain Medical attention.
Most important symptoms/effects -May cause allergic skin reaction. Symptoms of allergic reaction may include
Use extinguishing measures that are appropriate to local Circumstances and the surrounding environment Non
flammable. Oxidising agent may assist combustion.
Environmental Precautions –Take care to avoid the contamination of water courses and drains. Inform
appropriate authority in case of accidental contamination of watercourses
Methods for Containment and Cleanup - Spill away small spillage with copious quantity of water. Contain large
spillage with sand or earth as necessary. Neutralize cautiously with soda ash or lime (risk of heat generation and
splashing acid) and Recover for disposal.

Handling - Avoid contact with skin and eyes. Provide adequate ventilation, Wear full PPe’s, Avoid inhalation of
high concentration of mist.

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Storage - Keep in a dry, cool and well-ventilated place. Keep container tightly closed. Containers which are
opened must be resealed.

 Physical State Appearance – Liquid (Thick Oily liquid)










experienced.


 Sulphuric Acid

 Odour - Odourless

 Odour Threshold -No information available


 Boiling Point/Range -337°C / 639 °F

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 Flash Point –Non flammable



 Flammability (solid, gas) -Non-flammable

 Vapour Pressure- 0.001mmHg (20°C)

 Vapour Density- Not data available


 Solubility- Easily soluble in cold water




 Viscosity -26.7cP (20°C)

 Molecular Formula- H2SO4

 Molecular Weight – 98.07

 Corrosivity- Highly corrosive




 Conditions to Avoid- High temperatures .

Hazardous Reactions/Decomposition Products Sulphur dioxide, sulphur trioxide and hydrogen gases evolved.


Delayed and immediate effects as well as chronic effects from short and long-term
exposure Irritation -Irritating to eyes and skin

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14.4 MSDS for Sodium Hypochlorite

1. Identification
Product Name – Sodium Hypochlorite
Classification




 Corrosive


 Prevention






Skin
IF ON SKIN: Wash with plenty of soap and water at least 15 minutes. Take off contaminated clothing and wash
before reuse,If skin irritation or rash occurs: Get medical advice/attention

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Eyes
Continue rinsing If eye irritation persists: Get medical advice/attention immediately.
Ingestion
Disposal
neutralized.
 Sodium Hypochlorite purity- 10 %

 Sensitivity to Mechanical Impact – No information available

 Sensitivity to Static Discharge –No information available

 Specific Hazards Arising from the Chemical- Non Combustible .
protective gear.
medical attention.

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Inhalation - Remove from exposure, lie down. Move to fresh air. If Breathing is difficult, give oxygen. If
not breathing, give artificial respiration Obtain medical attention.
Personal Precautions-
Use personal protective equipment. Ensure adequate ventilation. Avoid breathing Vapours, Mist or gas.
Environmental Precautions –
Take care to avoid the contamination of water courses and drains. Inform appropriate authority in case of
accidental contamination of watercourses
Methods for Containment and Cleanup –
Spill away small spillage with copious quantity of water. Contain large spillage with sand or earth as necessary.
Physical and chemical properties
Physical State Appearance – Liquid

Flammability-Non flammable

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







experienced.


 Sodium Hypochlorite

 Odour - Odourless

 Odour Threshold –slightly chlorine like


 Boiling Point/Range -101°C / 214°F

 Flash Point –Non flammable


 Flammability (solid, gas) -Non-flammable

 Vapour Pressure- 6.6mmHg (50°C)

 Vapour Density- 0.62


 Solubility- Easily soluble in cold water



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Decomposition temperature -No information available


Viscosity –No data available

Molecular Formula- NaOCl

Molecular Weight – 74.45

Corrosivity- Highly corrosive in presence of aluminium

Stability and reactivity
Reactive Hazard -None known, based on information available
Stability - Stable under recommended conditions.
Conditions to avoid- High temperatures.
Incompatible Materials - Strong oxidizing agents.
Hazardous Reactions/Decomposition Products –Emits toxic fumes of chlorine when heated to decomposition.
Toxicological information
Acute Toxicity

Product Information

Component Information
to eyes and skin
14.5 MSDS for Tri Chloro Isocyanuric acid

1. Identification
Product Name – Tri Chloro Isocyanuric acid
Hazard(s) identification
Classification
This chemical is considered hazardous by the -2012 OSHA Hazard Communication Standard.

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Hazard Statements



 Corrosive


Prevention





Skin
IF ON SKIN: Wash with plenty of soap and water at least 15 minutes.Take off contaminated clothing and wash
before reuseIf skin irritation or rash occurs: Get medical advice/attention
Eyes
Continue rinsing If eye irritation persists: Get medical advice/attention immediately
Ingestion
Disposal
neutralized.

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 Sodium Hypochlorite purity- 10 %


 Sensitivity to Mechanical Impact –No information available

 Sensitivity to Static Discharge –No information available

 Specific Hazards Arising from the Chemical- Non Combustible .
protective gear.
medical attention.

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Environmental Precautions –Take care to avoid the contamination of water courses and drains.Inform
appropriate authority in case of accidental contamination of watercourses
Methods for Containment and Cleanup - Spill away small spillage with copious quantity of water. Contain large
spillage with sand or earth as necessary.

Flammability-Non flammable

Instability-Stable under Conditions recommended.

Physical hazards-N/A

Engineering Measures- Ensure adequate ventilation, especially in confined areas. Ensure that eyewash

Personal Protective Equipment

Eye/face Protection- Wear appropriate protective eyeglasses or chemical safety goggles as described by

Skin and body protection - Wear appropriate protective gloves and clothing to prevent skin exposure.

Respiratory Protection

Follow the OSHA respirator regulations

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Use a approved respirator if exposure limits are exceeded or if irritation or other symptoms are
experienced.

Hygiene Measures -Handle in accordance with good industrial hygiene and safety practice

Odour - Odour of chlorine

Odour Threshold –Not available

pH - 2.8

Melting Point/Range- - 247°C / 477°F

Boiling Point/Range -Decomposes

Flash Point –Non flammable

Evaporation Rate –No data available

Flammability (solid, gas) -Non-flammable

Vapour Pressure- No data available

Vapour Density- 0.62

Relative Density – 2.1

Solubility- Sparingly soluble in water

Partition coefficient -No data available

Auto ignition Temperature –No data available


Viscosity –No data available

Molecular Formula- C3Cl3N3O3

Molecular Weight – 232.40g/mol

Corrosivity- Highly corrosive in presence of aluminium

Reactive Hazard –Contact with acid liberates fumes

Stability - Stable under recommended conditions.

Conditions to avoid- High temperatures.

Incompatible Materials - Strong oxidizing agents.

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Hazardous Reactions/Decomposition Products –Emits toxic fumes of chlorine when heated to

decomposition.

Acute Toxicity



Toxicologically Synergistic Products -No information available

Delayed and immediate effects as well as chronic effects from short and long-term exposure Irritation -
Irritating to eyes and skin

Sensitization -May cause sensitization by skin contact

Mutagenic Effects -No information available

Reproductive Effects- No information available.
14.6 MSDS for CYLOHEXYLAMINE

1. Identification
Product Name - CYLOHEXYLAMINE
Hazard(s) identification
Classification
Hazard Statements
 Harmful if swallowed

 Causes skin irritation

 Causes serious eye irritation

 May cause an allergic.

 Harmful if Inhaled

 Flammable liquid and vapour
Prevention

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 Wash face, hands and any exposed skin thoroughly after handling.

 Do not eat, drink or smoke when using this product.

 Wear protective gloves/protective clothing/eye protection/face protection.

 Avoid breathing dust/fume/gas/mist/vapors/spray

 Contaminated work clothing should not be allowed out of the workplace

 Keep away from heat, hot surfaces, sparks, open flames and other ignition sources.
Skin
IF ON SKIN: Wash with plenty of soap and water take off contaminated clothing and wash before reuse.
Eyes
Ingestion
Disposal
 Flash Point - 31°C
 Auto ignition Temperature-293°C

 Explosion Limits- No information available

 Sensitivity to Mechanical Impact –

 No information available

 Sensitivity to Static Discharge –

 No information available

 Specific Hazards Arising from the Chemical- Combustible.

 Hazardous Combustion Products-CarbonMonoOxides,Carbon Dioxide

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protective gear.
medical attention.
Most important symptoms/effects - May cause allergic skin reaction. Symptoms of allergic reaction may include
Suitable Extinguishing Media-
Use extinguishing measures that are appropriate to local
Circumstances and the surrounding environment.
 Personal Precautions- Use personal protective equipment. Ensure adequate ventilation. Avoid
breathing Vapours, Mist or gas.
 Environmental Precautions –Should not be released into the environment.

 Methods for Containment and Cleanup -Soak up with inert absorbent material and dispose of as
hazardous waste. Keep in suitable, closed containers for disposal. Sweep up or vacuum up spillage and
collect in suitable container for disposal. Do not let this chemical enter the environment.

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Exposure Guidelines This product is very hazardous with occupational exposure limits
Established by the region specific regulatory bodies.
c. Physical and chemical properties
Physical State Appearance - Liquid

Flammability-No data available







Respiratory Protection

Follow the OSHA respirator regulations

experienced.


Cyclohexylamine

Odour – Strong fishy amine odour

Odour Threshold -26 PPm
 pH - 11 (Basic)
 Melting Point/Range- -17°C / 0.1°F

 Boiling Point/Range -134.5°C / 274.1 °F

 Flash Point -31°C

 Evaporation Rate –No data available

 Flammability (solid, gas) -Flammable

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Flammability or explosive limits- No data available


Vapour Pressure- 11mmHg (20°C)

Vapour Density- Not data available

Relative Density – 0.8647

Solubility- No information available

Dist.Water/Oil coefficient -1.5

Auto ignition Temperature –No data available


Viscosity -No data available

Molecular Formula- C6H13N

Molecular Weight – 99.17

Corrosivity- Non corrosive in presence of glass

c. Stability and reactivity
Reactive Hazard -None known, based on information available


Conditions to Avoid- Heat, flames & Sparks.


Hazardous Decomposition Products – CO and CO2

Hazardous Polymerization -Polymerization does not occur.

Hazardous Reactions - None under normal processing.

d. Toxicological information
Acute Toxicity


Delayed and immediate effects as well as chronic effects from short and long-term exposure Irritation -Irritating to
eyes and skin

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Reproductive Effects- No information available
14.7 MSDS for Naptha additive Turbotect ER-517

1. Identification
Product Name – Naptha additive Turbotect ER-517
d. Hazard(s) identification
Classification

 Harmful if swallowed

 Hazardous in case of skin contact

 Causes serious eye irritation

 Corrosive

 Harmful if Inhaled

 Liquid or spray mist can cause tissue damage
Prevention
 Wash face, hands and any exposed skin thoroughly after handling.

 Do not eat, drink when using this product.

 Wear protective gloves/protective clothing/eye protection/face protection.

 Avoid breathing fume/gas/mist/vapors/spray

 Contaminated work clothing should not be allowed out of the workplace

 Keep away from heat, hot surfaces, sparks, open flames and other ignition sources.
Skin-IF ON SKIN: Wash with plenty of soap and water at least 15 minutes.Take off contaminated clothing and wash

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Eyes-IF IN EYES: Rinse cautiously with water for at least 15 minutes. Remove Contact lenses, if present and easy to
do. Continue rinsing If eye irritation persists: Get medical advice/attention immediately. Ingestion
Disposal
Dispose of contents/container to an approved waste disposal plant or dry sand, earth. It may also be neutralized.
 Flash Point - >200°C
 Method - Closed cups
 Auto ignition Temperature –No determined

 Explosion Limits
 Sensitivity to Mechanical Impact –No information available

 Sensitivity to Static Discharge –No information available

 Specific Hazards Arising from the Chemical- Combustible.

 Hazardous Combustion Products- Release of toxic gases
protective gear.
medical attention.
Inhalation - Remove from exposure, lie down. Move to fresh air. Breathing is difficult, give oxygen. If not


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g. Accidental release measures

Spill away small spillage with copious quantity of water.Contain large spillage with sand or earth as necessary.
Storage - Keep in a dry, cool and well-ventilated place. Keep container tightly closed. Containers which are opened
must be resealed.
Exposure Guidelines- This product is very hazardous with occupational exposure limits established by the region
b. Physical and chemical properties

Flammability-Not applicable



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 Engineering Measures- Ensure adequate ventilation, especially in confined areas. Ensure that eyewash


 Personal Protective Equipment

 Eye/face Protection- Wear appropriate protective eyeglasses or chemical safety goggles as described by

 Skin and body protection - Wear appropriate protective gloves and clothing to prevent skin exposure.

 Respiratory Protection

 Follow the OSHA respirator regulations

 Use a approved respirator if exposure limits are exceeded or if irritation or other symptoms are
experienced.

 Hygiene Measures -Handle in accordance with good industrial hygiene and safety practice

 Naptha additive Turbotect ER517

 Odour – Soapy, fatty

 Odour Threshold –Not available
 pH - 7.2-7.5
 Melting Point/Range- - 0°C

 Boiling Point/Range ->200°C/760mmHg

 Flash Point –190°C PMCC

 Evaporation Rate –No data available

 Flammability (solid, gas) -flammable

 Vapour Pressure- 3mbar

 Vapour Density- No data available

 Relative Density – 0.89-0.92

 Solubility- Miscible with water

 Partition coefficient –log Pow :< 3

 Auto ignition Temperature –No data available

 Decomposition temperature -No information available

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Viscosity –20-50 cSt@ 20°C


Molecular Formula- Not relevant

Molecular Weight – No data available

Corrosivity- Highly corrosive

e. Stability and reactivity
Reactive Hazard –Contact with acid liberates fumes


Conditions to avoid- High temperatures.


Hazardous Reactions/Decomposition Products –Product is self ignite when soaked into porous material.
Product stable under normal condition.

f. Toxicological information
Acute Toxicity


eyes and skin
14.8 MSDS for NAPTHA

1. Identification
Product Name - NAPTHA
Classification

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Hazard Statements
 Harmful if swallowed

 Causes skin irritation

 Causes serious eye irritation

 May cause an allergic.

 Harmful if Inhaled

 Flammable liquid and vapour
 Prevention

 Wash face, hands and any exposed skin thoroughly after handling.

 Do not eat, drink or smoke when using this product.

 Wear protective gloves/protective clothing/eye protection/face protection.

 Avoid breathing dust/fume/gas/mist/vapors/spray

 Contaminated work clothing should not be allowed out of the workplace

 Keep away from heat, hot surfaces, sparks, open flames and other ignition sources.
No smoking.
Skin
IF ON SKIN: Wash with plenty of soap and water.Take off contaminated clothing and wash before reuse
Eyes
Ingestion
Disposal

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 Flash Point - 10°C
 Auto ignition Temperature –232°C (449°F)

 Explosion Limits
 Upper - 1.4% V/V
 Lower - 12.6% V/V
 Sensitivity to Mechanical Impact –No information available

 Sensitivity to Static Discharge –No information available

 Specific Hazards Arising from the Chemical- Combustible .

 Hazardous Combustion Products- Not available
protective gear.
medical attention.
d. Fire-fighting measures
circumstances and the surrounding environment.

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f. Accidental release measures

Should not be released into the environment.
Soak up with inert absorbent material and dispose of as hazardous waste. Keep in suitable, closed containers for
disposal.
Sweep up or vacuum up spillage and collect in suitable container for disposal. Do not let this chemical enter the
environment.
Handling -Avoid contact with skin and eyes. Avoid inhalation of vapour or mist.
Storage -Keep in a dry, cool and well-ventilated place. Keep container tightly closed. Containers which are opened
must be resealed.
Exposure Guidelines This product is very hazardous with occupational exposure limits
Established by the region specific regulatory bodies.
g. Physical and chemical properties
Physical State Appearance - Liquid

Flammability-Flammable







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 Respiratory Protection

 Follow the OSHA respirator regulations

 Use a approved respirator if exposure limits are exceeded or if irritation or other symptoms are
experienced.

 Hygiene Measures -Handle in accordance with good industrial hygiene and safety practice

 Naptha-

 Odour - Petroleum odour (Slight)

 Odour Threshold -No information available
 pH - No data available
 Melting Point/Range- -73°C / -99.4°F

 Boiling Point/Range- 86°C / 186°F

 Flash Point -10°C

 Evaporation Rate –No data available

 Flammability (solid, gas) -No information available

 Flammability or explosive limits

 Upper- 1.4 % V/V

 Lower -12.6 % V/V

 Vapour Pressure- 1.4Kpa (20°C)

 Vapour Density- 3.8

 Relative Density – 0.75

 Solubility- Easily soluble in aromatic compounds

 Partition coefficient -No data available

 Auto ignition Temperature –No data available

 Decomposition temperature -No information available

 Viscosity -No data available

 Molecular Formula- No data available

 Molecular Weight – No data available

 Corrosivity- Highly corrosive

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e. Stability and reactivity



Conditions to Avoid- Heat, flames & Sparks.


Hazardous Decomposition Products - No data available

Hazardous Polymerization - Hazardous polymerization does not occur.


f. Toxicological information
Acute Toxicity


eyes and skin
14.9 MSDS for Lithium bromide

1. Identification
Product Name -- Lithium bromide
Synonyms -- Lithium mono-bromide
Classification
Hazard Statements
 Harmful if swallowed

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 Causes skin irritation


 Causes serious eye irritation

 May cause an allergic.
Prevention
 Wash face, hands and any exposed skin thoroughly after handling.

 Do not eat, drink or smoke when using this product.

 Wear protective gloves/protective clothing/eye protection/face protection.

 Avoid breathing dust/fume/gas/mist/vapors/spray

 Contaminated work clothing should not be allowed out of the workplace
Skin
IF ON SKIN: Wash with plenty of soap and water. Take off contaminated clothing and wash before reuse If skin
irritation or rash occurs: Get medical advice/attention
Eyes
Ingestion
IF SWALLOWED: Call a POISON CENTER or doctor/physician if you feel unwell Rinse mouth.
Disposal
j. Composition / information on ingredients
Lithium bromide (LiBr) ,purity->95%

Lithium bromide 50 – 65, Water 50 – 35
 Flash Point - No information available
 Method - No information available
 Auto ignition Temperature -Not applicable

 Explosion Limits


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 Sensitivity to Mechanical Impact –No information available

 Sensitivity to Static Discharge –No information available

 Specific Hazards Arising from the Chemical-Non-combustible .

 Hazardous Combustion Products- Hydrogen halides, highly corrosive.
protective gear.
medical attention.
Ingestion - Clean mouth with water. Do not induce vomiting. Obtain medical attention.
muscle pain or flushing
c. Fire-fighting measures
Use extinguishing measures that are appropriate to local Circumstances and the surrounding environment.
d. Accidental release measures

Use personal protective equipment. Ensure adequate ventilation.
Should not be released into the environment.

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Avoid dust formation. Sweep up or vacuum up spillage and Collect in suitable container for-disposal. Do not let
thisChemical enter the environment.

Handling -Avoid contact with skin and eyes. Do not breathe dust. Do not ingest. Wash hands before breaks and
immediately after handling the product.
Storage -Keep in a dry, cool and well-ventilated place. Keep container tightly closed.
Exposure Guidelines This product does not contain any hazardous materials with occupational exposure
limits Established by the region specific regulatory bodies.
e. Physical and chemical properties
Physical State Appearance ----Powder Solid Beige

Flammability-0

Instability-1






Respiratory Protection- Follow the OSHA respirator regulations

experienced.


Lithium bromide

Odor - Odorless

Odor Threshold -No information available

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pH -7

Melting Point/Range- 550 °C / 1022 °F

Boiling Point/Range -1265 °C / 2309 °F

Flash Point -No information available

Evaporation Rate -Not applicable

Flammability (solid,gas) -No information available

Flammability or explosive limits

Upper- No data available

Lower -No data available

Vapor Pressure- No information available

Vapor Density- Not applicable

Relative Density -3.460

Solubility---- No information available

Partition coefficient; n-octanol/water -No data available

Auto ignition Temperature -Not applicable


Viscosity -Not applicable

Molecular Formula- Br Li

Molecular Weight - 86.84

CORROSIVITY- HIGHLY CORROSIVE DUE TO FORMATION OF HYDROGEN BROMIDE.

f. Stability and reactivity

Stability -Stable under normal conditions. Hygroscopic.

Conditions to Avoid- Avoid dust formation. Incompatible products. Exposure to moist air or water.

Incompatible Materials - Strong oxidizing agents, Strong acids

Hazardous Decomposition Products - Hydrogen halides hydrogen bromide

Hazardous Polymerization - Hazardous polymerization does not occur.


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e. Toxicological information
Acute Toxicity


eyes and skin
14.10. MSDS for LPG

1. PRODUCT AND COMPANY DETAILS
Product name Commercial Propane
Other names LPG, LP Gas, Liquefied Petroleum Gas
Use As fuel in domestic, commercial and industrial

applications 2. HAZARDS IDENTIFICATION
Commercial Propane as supplied by A gas National contains less than 0.1% of 1, 3 Butadiene and is not classified
as hazardous according to criteria of Work safe .
3. COMPOSITION/INFORMATION ON INGREDIENTS
Chemical Entity CAS Number Proportion
Propane [74-98-6] 25-99%
Propane [115-07-1] 0-60%
Butane [106-97-8] 0-7.5%
Butane [106-98-9] 0-2%
Ethyl Mercaptan (Odorant) [75-08-1] 25mg/kg
NOTICE

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Agas National believes that information given herein is accurate and reliable at the date of compilation, and
conforms to the guidelines of Worksafe Australia for the preparation of MSDS, but no warranty, express or
implied, is made. While the MSDS provides adequate information for most users, an MSDS is not a substitute for
expert advice on development of engineering and safe handling practices.
4. FIRST AID MEASURES
Swallowed- Due to high volatility of product, this is not likely to occur.
Eyes- Hold eyes open and continuously wash with clean water while seeking urgent
medical attention. Eye wash bottles containing sterile water or normal saline solution should be kept readily
available.
Skin- Immediately wash affected areas with plenty of water at room temperature to
overcome frostbite. Do not use iced water. Warm up gently. In hot conditions, cover with damp sheet to prevent
too rapid heating up of affected area. Seek urgent medical attention. Inhaled-Material Safety Data Sheet (MSDS)
Commercial Propane Issue 25 - May 2007 Page 2 of 5
Remove patient to fresh air and allow to rest. If patient is unconscious and breathing, place them in the coma
position, check airway and observe. If patient is not breathing, clear airway and apply mouth to mouth
resuscitation. If patient is not breathing and does not have a pulse, commence cardio pulmonary resuscitation.
Seek urgent medical attention.
Advice to doctor -Treat symptomatically.
g. FIRE FIGHTING MEASURES
Fire/explosionhazard-

Evacuate area, remove ignition sources.

Cut off gas supply if safe to do so - do not endanger life.

Do not extinguish fire - allow gas to burn out.

Use water to keep vessel(s) cool.
Note: If ignition has occurred and water is not available, the tank metal may weaken from the heat and may result
in an explosion.The area should be evacuated immediately. From a safe location, notify emergency services.
Combustion products- Carbon dioxide, water vapour, traces of carbon monoxide and nitrogen oxides.

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Fumes, smoke, carbon monoxide and aldehydes can be formed during incomplete combustion. Fire fighters may
need self contained breathing apparatus.
j. ACCIDENTAL RELEASE MEASURES
Spills and disposal Move people away and upwind from spill.

Shut off supply of gas if it is safe to do so.

Eliminate sources of ignition e.g. power supply, matches, non-intrinsically safe communication equipment.

Ventilate area.

Remove leaking cylinder to open air.

Avoid breathing vapour and contact with liquid or vapour. Disperse vapour with water spray.
Note: Vapour is heavier than air and will settle at the lowest point e.g. ditches, drains and water courses.
Contact Agas National if disposal of material is required.
7. HANDLING AND STORAGE
Store in approved areas as defined by current issue of AS1596.
Comply with the current issue of the Australian Code for the Transportation of Dangerous Goods by Road and Rail,
and with the relevant Dangerous Goods Legislation in each State or Territory.
Store containers in an upright position (even when empty); keep away from heat sources; do not drop; keep
valves closed when not in use.
Ensure dust and rain caps are fitted at all times.
Store away from oxidizing substances e.g. pool chlorine. Store in well ventilated area.
8. EXPOSURE CONTROLS/PERSONAL PROTECTION
Propane is an asphyxiant – NOHSC Exposure Standard
Propylene is an asphyxiant – NOHSC Exposure Standard
Butane – ES-TWA 800 ppm
Engineering controls -Ignition sources No Smoking. No Flames.
Follow procedures to avoid static discharges.
Use only intrinsically safe communication equipment (e.g. mobile phones and pagers). Use non-spark generating
tools and flameproof (intrinsically safe) equipment.
Ventilation- Maintain adequate ventilation.

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LP Gas appliances can be hazardous when used in a poorly ventilated room. Usage- In
applications other than as a forklift cylinder, all cylinders should be used in the upright
position.
Use only equipment approved for LP Gas installations and install in accordance with AS1596 and
AS5601. Personal protection
Thermally insulated gloves and either goggles or close fitting protective glasses with side visors are recommended
when handling liquid.
Long sleeved shirts and long trousers made from natural materials should be worn when handling.
If personnel are required to work in areas where the concentration of LP Gas may be above the exposure standard
respiratory protection should be used. This should be a supplied air facemask or self contained breathing
apparatus complying with AS1715 and AS1716.
9. PHYSICAL AND CHEMICAL PROPERTIES
Physical description/properties
 Appearance Colorless, odourless gas supplied in compressed liquid form in a pressure container. A
strong and distinctive odour is added to assist in the early detection of even minor leaks.
 Boiling Point -42°C Flash Point -104°C
 Vapour Pressure (at 40°C)
 1530 kPa Max Flammability Limits 2.4% to 9.6% in air (v/v)
 Solubility in Water (at 20°C)

 <200ppm Auto ignition Temperature 494°C to 549°C
Specific Gravity Liquid 0.51

(water = 1)Specific Gravity Gas 1.52 (air = 1)


d. STABILITY AND REACTIVITY
Stable under normal ambient conditions of storage and use. Avoid heat sources.
Can react violently with oxidizing agents - chlorine, pool chlorine or nitric acid.
11. TOXICOLOGICAL INFORMATION
Health effects from acute exposure

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Swallowed-Due to high volatility of product, this is not likely to occur.

Eyes-Liquid will cause severe damage. Vapour will cause irritation.
Skin-Vaporizing liquid or liquid contact can result in cold contact burns. Inhaled- May cause light-headedness,
dizziness and drowsiness. Excessive exposure may cause unconsciousness or even death, due to asphyxiation
(refers to vapour not liquid).
Health effects from chronic exposure
No chronic systemic effects reported from industrial exposures.
Carcinogenicity No known effect
Mutagenicity No known effect
Teratogenicity No known effect
12. ECOLOGICAL INFORMATION
Liquid propane will vaporize rapidly when released to atmosphere.
Commercial Propane consists of hydrocarbons that photo chemically decompose under atmospheric conditions.
(C) DISPOSAL CONSIDERATIONS
Contact Agas National if disposal of LP Gas is required.

LP Gas cylinders should be returned to the owning organization stamped on the cylinder when no longer
required.

Small customer owned cylinders should be made safe at a Gas Cylinder Test Station before disposal. Check
with local Council re acceptance for disposal to landfill. Do not incinerate LP Gas cylinders.

(D) TRANSPORT INFORMATION
Transport information UN number UN 1978 Shipping name Propane
Cylinders must be secured in an upright position for transport.
15. REGULATORY INFORMATION
Poisons schedule number – none allocated.
LP Gas is a prescribed Dangerous Good and its storage and handling is covered by various pieces of legislation in
allStates.
The installation of LP Gas equipment must be performed only by appropriately licensed or authorized persons.

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14.11. MSDS for ZOK

c. Identification
Product Name – Zok-27
Classification
Hazard Statements
 Harmful if swallowed
 Hazardous in case of skin contact
 Causes serious eye irritation
 Corrosive
 Harmful if Inhaled
Liquid or spray mist can cause tissue damage
Prevention
  Wash face, hands and any exposed skin thoroughly after handling.
  Do not eat, drink when using this product.
  Wear protective gloves/protective clothing/eye protection/face protection.
  Avoid breathing fume/gas/mist/vapors/spray
  Contaminated work clothing should not be allowed out of the workplace
 Keep away from heat, hot surfaces, sparks, open flames and other ignition sources.
Skin
IF ON SKIN: Wash with plenty of soap and water at least 15 minutes. Take off contaminated clothing and wash
Eyes
Continue rinsing If eye irritation persists: Get medical advice/attention immediately.
Ingestion
Disposal
neutralized.

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 Flash Point - >100°C

 Method - Closed cups
  Auto ignition Temperature –No relevant
 Explosion Limits
 Sensitivity to Mechanical Impact –No information available
 Sensitivity to Static Discharge –No information available
Specific Hazards Arising from the Chemical- Combustible .
 Hazardous Combustion Products- Release of toxic gases like CO and CO2.
Protective Equipment and Precautions for Firefighter

protective
 gear.
p First-aid measures
medical attention.
Circumstances and the surrounding environment Non flammable. Oxidising agent may assist combustion.
p Accidental release measures
Spill away small spillage with copious quantity of water. Contain large spillage with sand or earth as necessary.

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Exposure Guidelines- This product is very hazardous with occupational exposure limits established by the region
 Physical State Appearance – Liquid
 Flammability-Not applicable
 Instability-Stable under Conditions recommended.

 stations and safety showers are close to the workstation location.

 OSHA's eye and face protection regulations
 Skin and body protection - Wear appropriate protective gloves and clothing to prevent skin exposure.
Respiratory Protection- Follow the OSHA respirator regulations

 experienced.
 Hygiene Measures -Handle in accordance with good industrial hygiene and safety practice
 ZOK-27
 Odour - Characteristics
 Odour Threshold –Not available
 pH - 7.2-7.5
 Melting Point/Range- - 0°C
 Boiling Point/Range -100°C/760mmHg
 Flash Point –>100°C PMCC
 Evaporation Rate –No data available
 Flammability (solid, gas) -Non-flammable
 Vapour Pressure- No data available
 Vapour Density- No data available
 Relative Density – 1.01
 Solubility- Miscible with water
Partition coefficient –log Pow :< 3

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 Auto ignition Temperature –No data available

 Decomposition temperature -No information available
 Viscosity –22.26 cSt@ 20°C
 Molecular Formula- Not relevant
 Molecular Weight – No data available
Corrosivity- Highly corrosive

 Reactive Hazard –Contact with acid liberates fumes
 Stability - Stable under recommended conditions.
 Conditions to avoid- High temperatures.

Hazardous Reactions/Decomposition Products –Emits toxic fumes of chlorine when heated to
decomposition.

 Acute Toxicity
 Product Information
to eyes and skin
14.12. MSDS for HSD
Chemical identity
 Chemical name: Diesel Oil
 Chemical classification: Flammable liquid
 Synonyms: Automotive Diesel Oil
Trade name: HSD
 Formula Range: C13 - C18 C.A.S. NO.68476-30-2. U.N.NO. 1202
 Shipping name: HSD

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  Codes/Label:. Hazchem code class 3

  Hazardous waste : N.A.
 Hazardous ingredients- C.A.S.NO.
Diesel 68476-30-2
Benzene Trace 71-43-2
Naphthalene Trace 91-20-3
Sulphur Trace 7704-34-9
Diesel is complex mixture of hydrocarbons .It’s exact composition depends on the source of crude oil
from which it is produced and the refining methods used

Physical and chemical data
 Boiling point/Range (deg.C): 215 - 376.
 Physical state: Liquid. Appearance: yellowish brown
 Melting/freezing point (deg.C): N. A.
 Vapour pressure: 2.12 to 26mm Hg at 21 deg C.
 Odour: Perceptible odour
 Vapour density: N.A.
 Solubility in water @ 30 deg.C: Insoluble Specific gravity: 0.86 - 0.90at 20 deg C
Others: Pour Point: 6 - 18 deg. C.

Fire and explosion Hazard data
 Flammability: Yes LEL: 0.6% Flash point (deg C) : 32 (OC) TDG
 Flammability: class 3 . UEL: 6% Flash point (deg C) : N.A. (CC)
  Auto Ignition Temp : 225 deg. C
  Explosion sensitivity to impact: not sensitive to Mechanical Impact.
  Explosion sensitivity to static electricity: For vapors sensitivity exist
  Hazardous Combustion Products: carbon monoxide, Nitrogen oxide. and other aromatic hydrocarbons
  Hazardous Polymerization: N.A.
  Combustible liquid: Yes
  Explosive material: Yes
  Corrosive material: No
  Flammable material : yes
  Oxidizer: N.A.
  Pyrophoric material: N.A.
 Organic peroxide: N.A.

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4. Reactivity data
Chemical stability: Stable

Incompatibility with other material: oxidizers such Peroxides, Nitric acid and Perchorates
Hazardous reaction products: on fire it will liberate some amount of carbon monoxide, sulphur dioxide Nitrogen
oxide. and other aromatic hydrocarbon.
5. Health Hazard data
 Routes of entry: Inhalation, Skin absorption ,ingestion

 Effects of Exposure / symptoms: excessive inhalation Vapors cause rapid breathing, excitability,
staggering, headache, fatigue, nausea and vomiting, dizziness, drowsiness, narcosis
convulsions, coma,
 Skin Contact: Skin-dryness, cracking, irritation eyes watering, stinging and inflammation.
 Emergency treatment: In case of eye or Skin contact, flush with plenty of water. Remove soaked clothing.
in case of excessive inhalation move the victim to fresh air, obtain medical assistance
 L.D50 (Oral-Rat) : > 5g/kg L.C 50: (rat 4hrs) 5g/m3
  Permissible Exposure limit: N.A.
  Odour threshold: N.A.
  TLV (ACGIH) : 800 ppm
 STEL: N.A.
 NFPA Hazard signals: Health-1 Flammability-2 Reactivity/Stability-0 Special-
& Preventive measures
Personal Protective equipment: Canister type gas mask. PVC or Rubber. Goggles giving complete
protection to eyes. Eye wash fountain with safetyshower.

Handling and storage precautions: Do not expose to heat and naked lights, keep containers and valves
closed when not in use.

& Emergency and first aid measures
 Fire extinguishing media: Foam, Carbon dioxide, Dry Chemical Powder. Water may be used to cool fire-
 exposed containers.
 Special procedure: Shut off leak, if safe to do so, .Keep non-involved people away from spill site.
Eliminate all sources of ignition.

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  Unusual hazards: it will spread along the ground and collect in sewers
 Exposure:
 Skin contact ; in case of contact with Skin flush with fresh water, remove containment clothing,

 Inhalation: in case of excessive inhalation move the victim to fresh air, If problem in breathing give
 artificial respiration; give oxygen. obtain medical assistance
  Ingestion: Give water to conscious victim to drink; do not induce vomiting.
 Antidotes/Dosages: N.A.
Spills:
Steps to be taken Shut off leak, if safe to do so, .Keep non-involved people away from spill site. Eliminate all
sources of ignition. Prevent spill entering in to sewers, for Major spillage contact Emergency services
14.13. MSDS for INDION 3591
1. IDENTIFICATION OF CHEMICAL
Chemical Product Name: INDION 3591
2. HAZARDOUS INGREDIENT
Sodium Silicate: 30.00%
3. HAZARD IDENTIFICATION
May cause irritation to eyes and skin. Harmful if swallowed.
4. FIRST AID MEASURES
Inhalation : Mist may cause irritation to respiratory system.

Skin Contact : Wash immediately with soap and water. Seek medical attention.
Eye Contact : Flush immediately with plenty of running water, seek
medical attention.
Ingestion : Rinse mouth with water. Do not induce vomiting, Seek medical attention.
5. FIRE AND EXPLOSION DATA

The product is in aqueous system, it is not a fire hazard, after water is evaporated dry solid may
burn – Use extinguishing media appropriate for surrounding fire.
6. ACCIDENT RELEASE MEASURES

Personal Precautions : Wear Suitable protective clothing, gloves and safety goggles.
Environmental Precautions : Prevent from entering sewers or the immediate environment.
Methods for cleaning up

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Mop up liquid and place waste disposal container.
On soil : Absorb onto inert material and dispose of according to

Special Waste Regulations.
On water : None
7. HANDLING AND STORAGE
Handling : Do not breathe vapors. Avoid contact with skin and eyes.
Storage : Keep container tightly closed. Store in cool, well-ventilated
area.
8. EXPOSURE CONTROLS/PERSONAL PROTECTION
Skin Protection : Use impervious gloves and clean body covering clothing.
Eye Protection : Use safety glasses, where contact with eyes is likely, use chemical
goggles. Use a face shield as needed.
Hand Protection : Wash hands with soap before eating / drinking.
9. TYPICAL PHYSICAL DATA AND CHEMICAL PROPERTIES
Specific Gravity : Not Applicable

pH of 1% solution : 8.0 - 11.0
Appearance : Colorless to Pale Yellow Hazy Liquid.
Odor : None
Solubility in Water : Freely soluble
10. STABILITY AND REACTIVITY
Stability : Stable under normal conditions.

Conditions to avoid : Keep away from heat.
Material to avoid : Strong acids.
Hazardous decomposition products.: If the solution is evaporated to dryness, the
resulting solid may decompose if heated at high temperature.
11. TOXICOLOGICAL INFORMATION

Harmful if inhaled. Prolonged or repeated exposure may cause allergic reaction. The LD
value of the active ingredient is not available.
12. ECOLOGICAL INFORMATION
Do not allow to enter drinking water supplies or Sources/waste water or soil. No other
adverse ecological effects observed with this product.
13. DISPOSAL CONSIDERATIONS

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Disposal in sewage lines is strictly prohibited. Flush the aqueous solution with water. Mop up the
area and dispose it as non hazardous waste. Treat in consultation with approved industrial waste
treatment industry personnel. Refer to applicable local, state and federal regulations as well as
industry standards.
14. TRANSPORTATION INFORMATION
Ensure absence of damage and leaks in containers, and stack such that there is no impact,
tumbling, drop and crack. Ensure there is no collapsing load. Follow relevant regulations
for transportation.

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CHAPTER – 15
FIRE FIGHTING FACILITIES
15.1 INTRODUCTION
connection at different location. A 24” ring header on the outer peripheral of CPP unit forms a
ring header type of arrangement to which from 8 different locations, a header is connected for
input and output of fire hydrant from refinery.
Internal fire hydrant distribution is also a closed loop type. A tapping off from the main ring
header is taken at various suitable locations around the critical area like Fuel tankages area, Boiler
area, Gas turbine area, Transformer area and reconnected back to the ring header forming a
closed loop cycle. Necessary Butterfly valve, Gate valves, Air release valve, Water monitor, water
cum foam monitor, T strainers, Globe valves, Hose reel box, Deluge valve housing, Foam inlet
breeching connection, Hose reel are provided at suitable location.
The operating personnel should be fully conversant with Fire Fighting system provided in the unit.
All of them should have adequate fire fighting training and will serve as an auxiliary Fire Squad in
the event of a fire breakout. It will be the primary responsibility of unit personnel to fight the fire at
the very initial stage and, at the least, localize it.
Major Fire fighting facilities provided in the unit comprise the following:
A. Fire Water System
Water is most important fire fighting medium. Water is used for fire extinguishment, control,

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equipment cooling & exposure protection of equipment/personnel from heat radiation. Fire
network must be ready in all respect to avoid any hazard. An elaborate fire water distribution
network is provided around unit. Fire Water Hydrants/Monitors are provided around unit, which
give coverage to most of equipment.
B. Foam System
For containing large Hydrocarbon fires, foam systems are useful. They have inherent blanketing
ability, heat resistance and security against burn back. Low expansion foam is used for
hydrocarbon oil fire. Foam can be applied over burning oil pool with the help of foam
tenders/foam delivery system.
Each HSD, Naphtha and LCO tank in CPP is provided with Foam system arrangement. A foam
tender from Refinery fire station need to be connected to have foaming inside the tank during the
case of fire. Each tank is provided with separate spray and foam nozzle connection with are
extended outside the tank dyke area. Refer HSD,Naphtha and LCO tank GA drawings in details for
arrangement of foam system for HSD/LCO/Naphtha tankages in CPP.
C. Portable Fire Extinguishers
Fire should be killed at the incipient stage. Portable fire extinguishers are very useful in fighting
small fires. All extinguishers in the unit must be located in specified places only. The operating
crew should be acquainted with exact location of the extinguishers. They also must know most
suitable type, which, when and how to use an extinguisher. For example, electrical fires should be
put out with CO2 or dry powder extinguishers; water and foam should not be used. The used
extinguishers should be checked and restored by fire station personnel.
D. Fire Signal
Break Glasses have been provided at strategic locations of unit to see fire alarm in fire station. If a
fire is sighted, glass of window should be smashed, causing fire alarm switch to actuate. This is an
emergency call & should be periodically tested for proper functioning.
E. Steam Smothering
LP Steam hose connections have been provided at every convenient point inside unit. Steam
lances of standard 15M length can be fitted with these hose stations. Where ever hydrocarbon
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leakage is detected which is likely to catch fire, Steam blanketing may be done. Apart from diluting
combustible hydrocarbons, steam prevents atmospheric oxygen from taking part in combustion,
thus help in extinguishing fire. However, steam should never be applied on large pool of
hydrocarbon fire. Direct application of steam on burning oil may result in spillage of burning
hydrocarbon & spread of fire. Similarly use of fire water on hot oil surfaces may cause sputtering &
spread of fire.
F. Carbon dioxide Cylinder
Carbon dioxide Cylinder have been provided at strategic locations in CPP(GTGs, STGs, SS-10
Substation). electrical fires should be put out with CO2 or dry powder extinguisher. In GTGs, STGs
Fire detector is already installed inside compartment and generator, if fire is sighted Carbon
dioxide Cylinder releases Carbon dioxide automatically. In SS -10 Substation Carbon dioxide
Cylinder has been kept to extinguish the fire.
15.2 DESIGN BASIS
15.2.1 USE OF LIFE SAVING DEVICE

Safety of the personnel should be the prime concern. Life saving device is to be used for
personnel protection. Important lives saving devices which are required to be used are given
below:

Head protection: - Safety helmets shall be worn by all personnel at all times in the plant for
protection of the head. They may be removed when inside rooms or buildings
which do not have overhead or other hazards.


Eye and face protection: - Safety glasses, goggles or face shields shall be worn
while performing work, which could result in eye or face injury.

Hand Protection: - Proper hand protective gloves should be worn.



Foot protection: - Safety shoes are to be worn for foot protection.

Ear protection: - Whenever personnel are required to be work in noisy areas proper ear
Revision 02
9112-575-OPR-701-00002 Page 4 of 4
protection device such as ear plug etc, is to be used.


Breathing apparatus: - Whenever persons are required to work or enter an area of high
toxic/aromatic/hydrocarbon vapor concentration, wear appropriate respiratory protection,
such as self-contained breathing apparatus or an air mask with an external air supply.

Body Protection :- Coverall are to be worn for body protection.
Details for the Fire hydrant facilities within the preview of CPP B/L are mentioned in details as
below:
 FIRE WATER SPRINKLERS / SPARY SYSTEM


 FIRE WATER HYDRANTS AND MONITORS

 FIRE EXTINGUISHER AND HOSE REEL

 FIRE EXTINGUISHER SYSTEM

 FIRE ALARM SYSTEM

 ATTACHMENTS
Refer drawing no. 14-4833-0 Rev 05 of M/s Kidde India Limited for complete layout of Hydrant system

Revision 02
9112-575-OPR-701-00002 Page 1 of 10
CHAPTER – 16
CONSEQUENCE DUE TO UPSET IN OUTGOING B/L STREAMS
CPP is catering the continuous un-interrupted steam and power demand of Refinery. In addition to
steam and power, CPP also provide the Boiler Feed Water (BFW) to refinery for their waste heat
recovery boilers. Details of the each Utility with demand and the detail consequence due to
abnormality in any of the Utility are explained in details as below:
STEAM:
Steam inside CPP is consumed at various units at various levels. The steam from CPP to refinery is
classified based on the Pressure rating and it is broadly divided into 3 Levels, which are:
 HP steam

 MP steam

 LP steam
Refer the Battery limit condition of all Utilities from CPP to Refinery at other units B/L. It also
mentioned the Max and Min state as well as design state condition of pressure and temperature. This
upper and lower range is of utmost important for complete CPP process, because based on this the set
point is given to the controller to maintain the HP, MP and LP header pressure at all refinery load
irrespective on any condition. This is also a one of the most important KPI for CPP Operation team.

Revision 02
9112-575-OPR-701-00002 Page 2 of 10
Utilities Units Min. Normal Max. Mech. Design.
HP Steam
2
Pressure Kg/cm g 36.0 38.0 39.0 40.0
Temperature C
o 370 380 390 400
MP Steam
2
Pressure Kg/cm g 10 11.3 11.5 12.5
Temperature C
o 245 260 280 300
LP Steam
2
Pressure Kg/cm g 3.8 4.4 4.7 5.5

Boiler Feed Water
Pressure Kg/cm2g 47 52 58 71
Any deviation will definitely lead to either process disturbance, Plant disturbance and even may lead
to critical Turbine drives tripping on low and high HP header pressure.
Details of steam consumption at each level is very important to be know before going into the
discussion of their consequence.
HP STEAM REQUIREMENT (TPH)

m
H
n
n
d
P
e
T
a
r
t
t
t
t
f
I
,
i
V
C
e
a
V
s
e
a
-
I
s
C
e
a
-
s
UNITS Capacity, Net Steam Consumption, TPH

-
I
I
I
MMTPA Continuous Intermitte- Gen.

Demand nt demand TPH Case-1 Case-2 Case-3 Case-4 Case-5 Case-6
TPH TPH
CDU/VDU 9.0 - - - - - - - - -
NHT/NSU 0.942 16.4 - - 16.4 16.4 - - 16.4 16.4
ISOM 0.322 7.4 - - 7.4 7.4 - - 7.4 7.4
CCR 0.5 15.1 - 12 3.1 3.1 - - 3.1 3.1
HGU 2x44 108.2 16.0 175. -66.8 - -66.8 -66.8 - -66.8
KTPA 0
Revision 02
HPCL-Mittal Energy Limited 31-Jan-
Issue Date 2019
Captive Power Plant Operating Manual 30-Jan-
Next Review 2022
9112-575-OPR-701-00002 Page 3 of 10
DHDT 4.14 33.7 - - 33.7 - 33.7 33.7 - 33.7

DCU 2.9 33.1 8.2 - 33.1 33.1 - 33.1 - 33.1
VGO HDT 2.9 51.02 - - 51.02 - 51.02 51.02 - 51.0
2
FCCU 2.22 249 - 130 119 - 119 - 119 -
PP 440 KTA 1.0 - - 1.0 1.0 - 1.0 1.0 1.0
S-Block 600 TPD - - - - -
Utilities & - - - - - -
Offsites
NET TOTAL 197.9 61.0 136.9 52.02 146.9 78.9
2
With 10% Margin 217.0 67.0 150.0 57.0 161.6 86.8
MP STEAM REQUIREMENT (TPH)
e
a
s
UNITS Capacity, continuous intermittent Gen. Net Steam Consumption, TPH
V
-
C
I
I
I
e
a
s
C
-
e
a
s
-
I
I
V
C
e
a
s
-
I
MMTPA demand demand TPH
case-1 case-2 case-3 case-4 case-5 case-6

CDU/VDU 9.0 97.11 18.0 10.8 86.3 86.3 - 86.3 - 86.3
9.1
NHT/NSU 0.942 22.0 - - 22.0 22.0 - - 22.0 22.0
ISOM 0.322 28.4 - - 28.4 28.4 - - 28.4 28.4
CCR 0.5 2.5 9.1 - 2.5 2.5 - - 2.5 2.5
20.0
HGU 2x44 1.0 - 15.5 -13.0 - -13 -13 - -13.0
KTPA
DHDT 4.14 2.5 9.1 4.5 -2.0 - -2.0 -2.0 - -2.0
DCU 2.9 41.0 9.1 12.2 28.8 28.8 - 28.8 - 28.8

(Note
-2)
VGO HDT 2.9 5.9 9.1 21.7 -15.8 - -15.8 -15.8 - -15.8
FCCU 2.22 84.37 9.1 - 84.37 - 84.37 - 84.37 -
PP 440 KTA - - - - - - - - -
FG/LPGTU - - - - - - - - -
SRU-Block 600 TPD 84.2 18.74 65.5 65.5 65.5 65.5 - 65.5
Utilities & 25.0 25.0 25.0 25.0 25.0 25.0 25.0
Offsites

Revision 02
9112-575-OPR-701-00002 Page 4 of 10
Soot 9.1 9.1 9.1 9.1 9.1 9.1 9.1

blower
(Note-3)
NET TOTAL 321.2 267.6 153.2 183.9 171.4 214.8

With 10% Margin 353.0 294.0 169.0 203.0 186.0 237.0
Notes :
Two soot blowers operating in one unit at any one time each consuming 4.5 T/Hr of MP
steam is considered
50 % of steam generation considered
Two soot blowers steam requirements are considered in continuous normal operation.
LP STEAM REQUIREMENT (TPH)
UNITS Capacity, Continuous Intermittent Net Steam Consumption, TPH

Demand, demand, Generation,
TPH TPH TPH
MMTPA
Case-I Case-II Case-III Case-IV Case-V Case-VI

CDU/VDU 9.0 6.0 22.0 4.5 1.5 1.5 - 1.5 - 1.5
NHT/NSU/ 0.942 3.0 0.9 8.0 -5.0 -5.0 - - -5.0 -5.0
HRU
ISOM 0.322 1.0 - - 1.0 1.0 - - 1.0 1.0
CCR 0.5 1.0 20.0 1.6 -0.6 -0.6 - - -0.6 -0.6
(Note-1)
HGU 2x44 KTPA 0.9 6.9 - 0.9 - 0.9 0.9 - 0.9
DHDT 4.14 5.5 5.5 3.0 2.5 - 2.5 2.5 - 2.5
(Note-1)
DCU 2.9 2.0 14.0 1.6 0.4 0.4 - 0.4 - 0.4
(Note-2)
VGO HDT 2.9 30.3 8.0 9.5 20.8 - 20.8 20.8 - 20.8
(Note-1)
FCCU 2.22 59.6 2.5 23.1 36.5 - 36.5 36.5 36.5 -
(Note-1)
PP 440 KTA - - - - - - -
FG/LPG TU 1.5 1.5 1.5 1.5 1.5 1.5 1.5
SRU- Block 600 TPD - - - - - - -
Utilities & 20 20 20 20 20 20 20
Offsites
Template No. CopyrightsHMEL– All rights reserved

Revision 02
9112-575-OPR-701-00002 Page 5 of 10
NET TOTAL 79.5 18.8 82.2 84.1 53.4 43.0

With 10% Margin 88.0 21.0 90.0 92.5 65.0 47.3
Notes :
5. Snuffing steam requirement for heaters
6. Winterizing steam requirement.
Here the details are provided with 6 different cases consider during the design stage for CPP. This will
help to identify the maximum demand of steam at each level during various conditions. Base on the
above the final consumption details for 9 MMTPA refinery productions are mentioned below:
Total Steam Requirements
Case Description HP MP LP Total
steam steam steam steam
TPH TPH TPH TPH
All units operating normally (excluding
Case-I 217.0 353.0 88.0 658.0
CPP)
Block shut down of VGOHDT, DHT, HGU &
Case-II FCC 67.0 294.0 21.0 382.0
Block shut down of CDU/VDU, MSB, DCU

Case-III & PP 150.0 169.0 90.0 409.0
FCC, MS Block, PP DOWN other units
Case-IV running normal 57.0 203.0 92.5 352.5
CDU/VDU,DCU,DHDT,VGOHDT, HGU &
Case-V SRU down, other units running normal 161.6 186.0 65.0 411.6
Case-VI Only FCC down 86.8 237.0 47.3 371.1

CPP DESIGN BASIS 219.0 387.0 96.0 702
Looking into the details in above mentioned tables as well as previous tables, it was found that during
tripping or force shutting down the various units will result in requirement of Intermediate steam. The
Intermediate steam requirement is over and above the steam requirement of Units. Many Units like
HGU, FCCU, SRU, MS block are also generating the steam at different level through their waste heat
recovery boilers. Tripping of that unit will result into increase in steam demand to CPP.
Major consequences which lead to Outgoing stream abnormality are mentioned in brief as below:

Revision 02
9112-575-OPR-701-00002 Page 6 of 10
 Tripping of one or more steam generating unit inside CPP


 Tripping of STG, BPTG – as all are extraction or back pressure type units

 Tripping of GT which result into forced tripping of HRSG unit
Details cases of Tripping of one or more critical units inside CPP and their consequence of steam and
power demand as well as mitigation plan to avoid complete refinery is discuss and freeze in “LOAD
SHEDDING SCHEME (LSS)”. Refer Below mentioned attached which summarized the cases of CPP
equipment tripping viz a viz shortfall of steam and power and their consequence which results into
tripping of individual unit or part load shedding of unit to avoid complete refinery tripping.
The major havoc occurs because on outgoing Utilities disturbance from CPP are summarized as below:
 Tripping of critical drives inside ISBL unit due to High and low Header pressure of steam

 Tripping of critical drives inside ISBL unit due to high back pressure on exhaust side of TD unit
of critical drives

 Tripping of steam generating unit because of non-availability of power resulting into increase
demand of steam from CPP

 Tripping of complete Unit as a result of LSS

 Tripping of one unit because of either tripping of upstream or downstream unit (Capacity /
Feed constrain)
POWER
CPP is design to supply un-interrupted power demand by generating necessary power at CPP end
through various Turbine drives and distribute the same to all refinery substation for their need without
importing any power from PSEB at 9 MMTPA refinery capacities.
Power demand of each unit inside refinery is different at different load including CPP. CPP auxiliary
power varies based on the load on CPP. Refer below table for details of Power load of each unit during
full load operation of refinery.

Revision 02
9112-575-OPR-701-00002 Page 7 of 10
POWER REQUIREMENT (KW)
UNITS Capacity Intermitt- Net Power Consumption, KW

Continuous ent
Demand demand Case-I Case-II Case-III Case-IV Case-V Case-VI
MMTPA
CDU/VDU 9.0 11482 11482 11482 - 11482 - 11482

NHT/NSU 0.942 2256 2256 2256 - - 2256 2256
ISOM 0.322 2269 817 2269 2269 - - 2269 2269
CCR 0.5 5637 5637 5637 - - 5637 5637
HGU 2x44 2800 2800 - 2800 2800 - 2800
KTPA
DHDT 4.14 10209 10209 - 10209 10209 - 10209
DCU 2.9 7320 7320 7320 - 7320 - 7320
VGO HDT 2.9 12935 12935 - 12935 12935 - 12935
FCCU 2.22 6424 6424 - 6424 - 6424 -
PP 440 KTA 26760 26760 26760 - - 26760 26760
FGTU 200 200 200 200 200 200 200
LPGTU 200 200 200 200 200 200 200
SRU- Block 600 TPD 8855 8855 8855 8855 8855 - 8855
Utilities & 44009 44009 44009 44009 44009 44009 44009
Offsites
Total (excluding CPP) 141356 141356 108988 85632 98010 87755 134932
With 10 % margin 155491 155491 119886 94195 107811 96530 148425
Same 6 cases are considered as what consider during steam demand requirement calculation.
Major consequences which lead to Power abnormality are mentioned in brief as below:
 Tripping of one or more steam generating unit inside CPP

 Tripping of STG, BPTG

 Tripping of GT which also result into forced tripping of HRSG unit
Details cases of Tripping of one or more critical units inside CPP and their consequence of power
demand as well as mitigation plan to avoid complete refinery is discuss and freeze in “LOAD SHEDDING
SCHEME (LSS)”. Refer Below mentioned attached which summarized the cases of CPP

Revision 02
9112-575-OPR-701-00002 Page 8 of 10
equipment tripping viz a viz shortfall of steam and power and their consequence which results into
tripping of individual unit or part load shedding of unit to avoid complete refinery tripping.
The major havoc occurs because on Power disturbance from CPP are summarized as below:
 Tripping of critical drives inside ISBL unit due to Power shortfall

 Tripping of complete Unit as a result of LSS

 Tripping of one unit because of either tripping of upstream or downstream unit (Capacity /
Feed constrain)

 Tripping of steam generating unit because of non-availability of power resulting into increase
PSEB power is available but only act as a source of buffer power during tripping or non-availability of
one Power generating unit. Maximum Import drawn from PSED is limited to 35 MW only. Tripping of
two power generating unit inside CPP will definitely lead to LSS activation.
BOILER FEED WATER
Boiler Feed water (BFW) is supplied from CPP after Deaeration process through 2 nos. of Export
BFW Pumps (1 X 100%) with a capacity of 253 m3/hr. BFW is used inside refinery for basically below
mentioned principle purposes as:
Boiler feed water for waste heat recovery boilers
Spray water for Desuperheater station
Direct water quenching for critical process (Intermediate requirements)
Boiler feed water requirements of various process units, which will be supplied from CPP are as below:
Continuous Intermittent demand
UNIT Level TOTAL
Demand Rate Duration Type
CDU MP 20.0 41 Note-1 20.0

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9112-575-OPR-701-00002 Page 9 of 10
VGO HDT/ DHDT MP 35 35.0
FCCU HP 110 110.0
HP 0.5 0.5
DCU
MP 25.6 35 Note-2 25.6
HP 26.0 26.0
MS BLOCK
MP 4.0 18.7 Note-3 4.0
HP 136.5
MP 84.6 (Note-4)
Total
LP NIL
Total ( HP+MP) = 221 (Note-5)
Notes :
Intermittent BFW requirement is in case of DCU shut down.
Intermittent requirement for OVHD water wash
Intermittent BFW requirement for caustic dilution in ISOM.
From CPP only HP level BFW is exported to all process units, any other level steam
requirement shall be met by pressure reduction within process units B/L.
CPP is designed for 253.6 TPH of HP BFW.
BFW going to refinery should also meet the below quality norms. This is of prime importance as the
BFW usage is directly into high heat flux zone or directly into process fluid. So any contamination in
BFW will adversely impact the quality standards of process fluid or even lead to BFW related problems
in Waste heat recovery boilers.
Recommended BFW Quality:
SL. No. Description Unit Range
1 pH - 8.5 – 9.5
2 Conductivity at 25 deg.C Micro mhos/cm <0.2

Revision 02
9112-575-OPR-701-00002 Page 10 of 10
3 Total Silica SiO2 (max) ppm 0.02

4 Total Hardness (ppm of CaCO3) ppm Nil
5 Dissolved Oxygen (max) ppm 0.005
6 Total Iron as Fe (max) ppm <0.03
7 Total copper as Cu (max) ppm 0.005
8 Oil content ppm <0.5
9 KMnO4 at 100 deg. C ppm <0.5
Major consequences which lead to BFW related abnormality are mentioned in brief as below:
 Tripping of BFW pump inside CPP

 Deaerator performance detoriation
The major havoc occurs because of BFW disturbance from CPP are summarized as below:
 Tripping of steam generating unit because of non-availability of BFW resulting into increase

 Process disturbance result into non availability of sufficient quantity of BFW for De-
superheating stations

 Process quality detoriation result of poor quality of BFW for quenching and Spray water

 Process equipment failure due to poor quality of BFW for process

Revision 02
9112-575-OPR-701-00002 Page 1 of 10
CHAPTER – 17
EQUIPMENT DATA SHEET
List of the equipment available in CPP and their data sheet is attached as annexure for ready
reference as below:
CPP EQUIPMENT LIST
Category Equipment no. Quantity Annexure
Tankages
Condensate storage tank 575-CST-00-001 1 Tank_Annexure - 1
Feed water storage tank 575-W-00-001 1 Tank_Annexure - 2
Ammonia dosing Tank for CST 575-T-398B 1 Tank_Annexure - 3
Solution preparation tank for CST 575-T-398A 1 Tank_Annexure - 4
Ammonia dosing Tank for Deaerator 575-T-390B 1 Tank_Annexure - 5
Solution preperation tank for Deareator 575-T-390A 1 Tank_Annexure - 6
Hydrazine dosing Tank for Deaerator 575-T-386B 1 Tank_Annexure - 7
Solution preperation tank for Deareator 575-T-386A 1 Tank_Annexure - 8
TSP dosing tank for Utility boiler 575-T-394B 1 Tank_Annexure - 9
TSP dosing tank for HRSGs 2 Tank_Annexure - 10
Chemical prepration tank for UB 575-T-394A 1 Tank_Annexure - 11
Chemical prepration tank for HRSG 2 Tank_Annexure - 12
HSD storage tank 575-T-00-502 1 Tank_Annexure - 13
Naphtha storage tank 575-T-00-501 1
LCO storage tank 575-T-00-509/510 2 Tank_Annexure - 14
Atm air Surge air Reciever tank 575-AR-AS-640 1 Tank_Annexure - 15
Atomizing Air Reciever tank 575-AR-AS-641 2 Tank_Annexure - 16
Instrument Air Reciever tank 575-AR-AS-642 1 Tank_Annexure - 17
HP Nitrogen Reciever tanks 575-AR-AS-643 4 Tank_Annexure - 18
LP heater Condensate collection tank 575-LPHCCT-00-001 1 Tank_Annexure - 19
BFPDT-GSC Drain condensate collection 575-03-T-EE-402 1 Tank_Annexure - 20

Revision 02
9112-575-OPR-701-00002 Page 2 of 10
BPTG-GSC Drain condensate collection 575-03-T-EE-401 1 Tank_Annexure - 21

tank
STG # 1 Lube oil Mail oil tank 575-01-T-501 1 Tank_Annexure - 22
STG # 1 Overhead Lube oil tank 575-01-T-402 1 Tank_Annexure - 23
STG # 2 Lube oil Mail oil tank 575-02-T-501 1 Tank_Annexure - 24
STG # 2 Overhead Lube oil tank 575-02-T-402 1 Tank_Annexure - 25
BPTG Lube oil tank 575-03-T-401 1 Tank_Annexure - 26
BPTG Overhead lube oil tank 575-03-T-402 1 Tank_Annexure - 27
BFP DT Lube oil tank 575-11-T-401 1 Tank_Annexure - 28
BFP DT Overhead lube oil tank 575-11-T-402 1 Tank_Annexure - 29
HSD/LCO drain tank near GT # 1 575-T-00-503 1 Tank_Annexure - 30
HSD/LCO drain tank near GT # 2 575-T-00-504 1 Tank_Annexure - 31
HSD/LCO drain tank near storage tank area 575-T-00-507 1 Tank_Annexure - 32
HSD/LCO drain tank for UB # 1 and 2 575-T-00-505 1 Tank_Annexure - 33
HSD/LCO drain tank for UB # 3 and 4 575-T-00-506 1 Tank_Annexure - 34
HSD centifuge sludge tank 575-T-00-508 1 Tank_Annexure - 35
FG condensate drain tank near GBC 575-T-00-521 1 Tank_Annexure - 36
FG condensate drain tank near GT # 1 575-T-00-523 1 Tank_Annexure - 37
FG condensate drain tank near GT # 2 575-T-00-522 1 Tank_Annexure - 38
GBC lube oil tank 575-T-00-408 1 Tank_Annexure - 39
GBC Lube oil over head tank 575-T-00-409 1 Tank_Annexure - 40
GT # 1 Lube oil tank 1 Tank_Annexure - 41
GT # 2 Lube oil tank 1 Tank_Annexure - 42
HRSG Area Blow down pit tank 1 Tank_Annexure - 43
UB # 1 and 2 area blow down pit tank 1 Tank_Annexure - 44
UB # 3 and 4 area blow down pit tank 1 Tank_Annexure - 45
STG area blow down pit tank 1 Tank_Annexure - 46
Main blow down pit tank 1 Tank_Annexure - 47
Vanadium Inhibitor solution Preperation 9-T-48C 2 Tank_Annexure - 48
tank
GT Detergent tank for Water wash skid 2 Tank_Annexure - 49
GT Water wash skid tank 2 Tank_Annexure - 50
TOTAL>>>>> 61

Revision 02
9112-575-OPR-701-00002 Page 3 of 10
Pumps
STG Lube oil pump - DT driven 575-01/02-P-401 2 Pump_Annexure - 1
STG Lube oil pump - MD driven 575-01/02-P-402 2 Pump_Annexure - 2
STG Emergency Lube oil pump 575-01/02-P-403 2 Pump_Annexure - 3
STG Jacking oil pump 575-01/02-P-404 2 Pump_Annexure - 4
Condensate extraction pumps 575-PCF-01/02- 4 Pump_Annexure - 5
001A/B
BPTG Lube oil pump - DT driven 575-03-P-401 1 Pump_Annexure - 6
BPTG Lube oil pump - MD driven 575-03-P-402 1 Pump_Annexure - 7
BPTG Emergency Lube oil pump 575-03-P-403 1 Pump_Annexure - 8
BPTG Jacking oil pump 575-03-P-404 1 Pump_Annexure - 9
BFP DT Lube oil pump - DT driven 575-11-P-401 1 Pump_Annexure - 10
BFP DT Lube oil pump - MD driven 575-11-P-402 1 Pump_Annexure - 11
BFP DT Emergency Lube oil pump 575-11-P-403 1 Pump_Annexure - 12
BFP DT Jacking oil pump 575-11-P-404 1 Pump_Annexure - 13
Condensate Transfer pump 575-P-CF-004A/B 2 Pump_Annexure - 14
MUH condensate Transfer Pump 575-P-CF-003A/B 2 Pump_Annexure - 15
LP header drain transfer pump 575-P-CF-005A/B 2 Pump_Annexure - 16
BPTG GSC collection transfer pump 575-P-CF-006A/B 2 Pump_Annexure - 17
BFP TD GSC drain collection transfer 575-P-CF-010A/B 2 Pump_Annexure - 18
pump
HRSG Feed water pumps 575-P-CF-007A/B/C 3 Pump_Annexure - 19
UB Feed water pumps 575-P-CF- 4 Pump_Annexure - 20
008A/B/C/D
Export BFW water pumps 575-P-CF-009A/B 2 Pump_Annexure - 21
Main Cooling water pumps 575-P-VT-552/554 2 Pump_Annexure - 22
Aux. CW Pumps 575-P-VT- 3 Pump_Annexure - 23
572B/573B/574B
Side stream filter pumps 575-P-VT-563/565 2 Pump_Annexure - 24
FRP cooling tower pump 575-P-00-562B 1 Pump_Annexure - 25
DM cooling water pump for GT AA cooler 575-P-00- 4 Pump_Annexure - 26
578B/579B/580B/
581B
HSD centifuge pumps 3 Pump_Annexure - 27

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9112-575-OPR-701-00002 Page 4 of 10
HSD centifuge sludge pumps 2 Pump_Annexure - 28

HSD forwarding pump for GT # 1 58-P-14C/15C 2 Pump_Annexure - 29
HSD forwarding pump for GT # 2 58-P-21C/22C 2 Pump_Annexure - 30
Naphtha forwarding pump for GTs 575-P-9601/2/3 3
Naphtha forwarding pump for HRGSs/UBs 575-P-9701/2/3 3
LCO forwarding pump for GTG P-502A/B/C 3 Pump_Annexure - 31
Vanadium Inhibitor Dozing pump for GT # P-506A/B 2 Pump_Annexure - 32
1
Submersible pump in HSD/LCO drain tank MG-507A/B 2 Pump_Annexure - 33
for GT # 1
Vanadium Inhibitor Dozing pump for GT # P-511A/B 2 Pump_Annexure - 34
2
for GT # 2
LCO forwarding pump for HRSG P-513A/B/C 3 Pump_Annexure - 36
LCO forwarding pump for UB P-515A/B/C 3 Pump_Annexure - 37
Submersible pump in HSD/LCO drain tank for MG-517A/B 2 Pump_Annexure - 38
UB # 1 & 2
for UB # 3 & 4
near Pit
Submersible pump in FG cond. Drain tank P-524A/B 2 Pump_Annexure - 41
near GBC
near GT # 2
near GT # 1
GBC Lube oil pumps 575-P-01/02-408A/B 4 Pump_Annexure - 44
GT ALOP 88QA-1 2 Pump_Annexure - 45
GT ELOP 88QE-1 2 Pump_Annexure - 46
GT MD hydraulic Pump 88HQ-1 2 Pump_Annexure - 47
GT Water Injection forwarding pump 88WN-1 2 Pump_Annexure - 48
UB HP dozing Pumps 575-P- 8 Pump_Annexure - 49
395A/B/C/D/E/F/G/H
LP Dozing pumps - Deareator Hydrazing 575-P-388A/B 2 Pump_Annexure - 50
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9112-575-OPR-701-00002 Page 5 of 10
LP Dozing pumps - Deareator Ammonia 575-P-392A/B 2 Pump_Annexure - 51

LP Dozing pumps - CST Ammonia 575-P-400A/B 2 Pump_Annexure - 52
HRSG HP Dozing pumps44 4 Pump_Annexure - 53
HRSG # 1 and 2 Blowdown pit pumps 575-P-CF-351A/B 2 Pump_Annexure – 54
UB # 1 and 2 Blowdown pit pumps 575 -P-CF -353A/B 2 Pump_Annexure – 5 5
UB # 3 and 4 Blowdown pit pumps 575 -P-CF -354A/B 2 Pump_Annexure – 5 6
STG area blowdown pit pumps 575 -P-CF -352A/B 2 Pump_Annexure – 5 7
Main Blow down pit pumps 575-P-CF-355A/B 2 Pump_Annexure – 58
TOTAL>>>>> 133
Vessels
CBD vessel for HRSG 2 Vessel_Annexure - 1
IBD vessel for HRSG 2 Vessel_Annexure - 2
CBD vessel for UB 575-CBD- 4 Vessel_Annexure - 3
06/07/08/09-001
IBD vessel for UB 575-IBD- 4 Vessel_Annexure - 4
06/07/08/09-001
Gas scrubber for GT V-11/12 2 Vessel_Annexure - 5
Gas scrubber for HRSG V-17 1 Vessel_Annexure - 6
Gas scrubber for UB V-18/19 2 Vessel_Annexure - 7
Flash Vessel for STG - 1 1 Vessel_Annexure - 8
Flash Vessel for STG - 2 1 Vessel_Annexure - 9
Flash Vessel for BPTG 1 Vessel_Annexure - 10
Flash vessel for LP heater 1 Vessel_Annexure - 11
TOTAL>>>>> 21
Fans
UB FD fan 4 Fan_Annexure - 1
UB # scanner air fans 2 Fan_Annexure - 2
Augmenting Air fan for HRSG 4 Fan_Annexure - 6
Seal air fan for HRSG 4 Fan_Annexure - 7
Scanner air fan for HRSG 4 Fan_Annexure - 8
STG vapour extraction fan 575-01/02-K-401 4 Fan_Annexure - 9

Revision 02
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9112-575-OPR-701-00002 Page 6 of 10
BPTG vapour extraction fan 575-03-K-401 2 Fan_Annexure - 10

BFP DT vapour extraction fan 5751-K-403 2 Fan_Annexure - 11
CT Fans 6 Fan_Annexure - 12
SSF Air blower 575-P-00-569A/B 2 Fan_Annexure - 13
Roof mounted vent fan for Acc GB 88BA-1,2 4 Fan_Annexure - 14
Roof mounted vent fan for Turbine 88BT-1,2 4 Fan_Annexure - 15
compartment
Roof mounted vent fan for Load gear 88VG-1,2 4 Fan_Annexure - 16
compartment
TOTAL>>>>> 52
Equipment
UB 4 Equip_Annexure - 1
SCAPH for UB 4 Equip_Annexure - 2
RAPH for UB 4 Equip_Annexure - 3
HRSG 2 Equip_Annexure - 4
STG 575-MT-00-001/002 2 Equip_Annexure - 5
BPTG 575-MT-00-003 1 Equip_Annexure - 6
BFP DT 575-MT-00-004 1 Equip_Annexure - 7
TD for UB LCO ST-515C 1 Equip_Annexure - 8
TD for UB FD fan 4 Equip_Annexure - 9
TD for STG MOP 575-01/02-DT-401 2 Equip_Annexure - 10
TD for BPTG MOP 575-03-DT-401 1 Equip_Annexure - 11
TD for BFP DT MOP 1 Equip_Annexure - 12
TD for ACW Pump 1 Equip_Annexure - 13
Deaerator 575-DEA-00-001 1 Equip_Annexure - 14
LP heater 575-LPH-00-001 1 Equip_Annexure - 15
VAM 1 Equip_Annexure - 16
STG drive Gear box 575-01/02-GB-401 2 Equip_Annexure - 17
STG generator 575-01/02-STG-401 2 Equip_Annexure - 18
STG gland steam Ejector 575-EJ-00-006/007 4 Equip_Annexure - 19
STG lube oil filters 575-01/02-G- 4 Equip_Annexure - 20
401/402
STG oil centifuge 575-01/02-ME-401 2 Equip_Annexure - 21
STG barring gear motor 575-01/02-TGM-401 2 Equip_Annexure - 22

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9112-575-OPR-701-00002 Page 7 of 10
STG Primary air Ejector 575-EJ-01/02-002A/B 4 Equip_Annexure - 23

STG Secondary air Ejector 575-EJ-01/02-003A/B 4 Equip_Annexure - 24
STG Hogger Ejector 575-EJ-01/02-001 2 Equip_Annexure - 25
BPTG Gear box 575-03-GB-401 1 Equip_Annexure - 26
BPTG generator 575-03-STG-401 1 Equip_Annexure - 27
BPTG gland steam Ejector 575-03-EJ-401/402 2 Equip_Annexure - 28
BPTG lube oil filters 575-03-G-401/402 2 Equip_Annexure - 29
BPTG oil centifuge 575-03-ME-403 1 Equip_Annexure - 30
BPTG barring gear motor 575-03-TGM-401 1 Equip_Annexure - 31
BFP DT gland steam Ejector 575-11-EJ-401/402 2 Equip_Annexure - 32
BFP DT lube oil filters 575-11-G-401/402 2 Equip_Annexure - 33
BFP DT oil centifuge 575-11-ME-401 1 Equip_Annexure - 34
BFP DT Gear box 575-11-GB-401 1 Equip_Annexure - 35
Cooling Tower 575-CT-00-561 1 Equip_Annexure - 36
Side stream filters 575-SSF-00-568A/B 2 Equip_Annexure - 37
FRP Cooling tower 1 Equip_Annexure - 38
HSD centifuge 10-M-06B/07B/08B 3 Equip_Annexure - 39
HSD 100 micron filter for GT # 1 9-C-12C/13C 2 Equip_Annexure - 40
Naphtha 100 micron filter for GTs 575-G-9601/2 2
Accumulator in HSD header to GT # 1 58-M-16C 1 Equip_Annexure - 41
Accumulator in Naphtha header to GT # 1 575-LZ-9601 1
HSD 100 micron filter for GT # 2 9-G-12C/13C 2 Equip_Annexure - 44
Accumulator in HSD header to GT # 2 58-M-23C 1 Equip_Annexure - 45
Accumulator in Naphtha header to GT # 2 575-LZ-9602 1
HSD 25 micron filter for GT # 2 9-M-24C/25C 2 Equip_Annexure - 46
HSD 06 micron filter for GT # 2 9-FL-26C/27C 2 Equip_Annexure - 47
LCO 100 micron filter for GTG 2 Equip_Annexure - 48
Accumulator in LCO header to GT # 1 M-503 1 Equip_Annexure - 49
LCO 25 micron filter for GT # 1 M-504A/504B 2 Equip_Annexure - 50
LCO 06 micron filter for GT # 1 M-505A/505B 2 Equip_Annexure - 51
Vanadium Inhibitor skid accumulator 9-V-53C 2 Equip_Annexure - 52
Accumulator in LCO header to GT # 2 M-508 1 Equip_Annexure - 53
LCO 25 micron filter for GT # 2 M-509A/B 2 Equip_Annexure - 54
LCO 06 micron filter for GT # 2 M-510A/B 2 Equip_Annexure - 55
LCO 100 micron filter for HRSG 2 Equip_Annexure - 56
Template No. CopyrightsHMEL– All rights reserved
Revision 02
9112-575-OPR-701-00002 Page 8 of 10
Accumulator in LCO header to HRSG M-514 1 Equip_Annexure - 57

Accumulator in Naphtha header to HRSGs 575-LZ-9701 1
LCO 100 micron filter for UB 2 Equip_Annexure - 58
Accumulator in LCO header to UB M-516A/B 2 Equip_Annexure - 59
GCS for GT # 1 V-13/14 2 Equip_Annexure - 60
GCS for GT # 2 V-15/16 2 Equip_Annexure - 61
Gas Booster compressor 575-K-01/02-403 2 Equip_Annexure - 62
Seal gas filter 575-G-01/02-401 4 Equip_Annexure - 63
Nitrogen gas filter 575-G-01/02-402 4 Equip_Annexure - 64
GBC Lube oil filter 575-G-01/02-408A/B 4 Equip_Annexure - 65
Accumulator in Lube oil line for GBC 575-V-01/02-408A/B 4 Equip_Annexure - 66
GBC Gear box 575-KG-01/02-408 2 Equip_Annexure - 67
Motor for GBC 575-KM-01/02-408 2 Equip_Annexure - 68
Gas Turbines 2 Equip_Annexure - 69
GT Lube oil filter F5U 4 Equip_Annexure - 70
Accesory Gear box for GT (Lube oil gear 2 Equip_Annexure - 71
pump, Hydraulic pump, AA compressor,
Liquid Fuel Pump
Diesel Engine for GT 2 Equip_Annexure - 72
GT Lube Oil Mist Seperator 88QV-1/2 4 Equip_Annexure - 73
GT Diesel engine starter 88DS-1 2 Equip_Annexure - 74
GT IGV HM3-1 2 Equip_Annexure - 75
GT Liquid fuel Flow divider FD1 2 Equip_Annexure - 76
GT Liquid fuel Flow divider magnetic pick 77FD-1,2,3 2 Equip_Annexure - 77
up speed
GT Motor driven Booster AA compressor CA2-1 2 Equip_Annexure - 78
Atomizing Air Compressor 3 Equip_Annexure - 79
IA Booster air Compressor 1 Equip_Annexure - 80
HP Nitrogen Booster compressor 2 Equip_Annexure - 81
GT Generator 2 Equip_Annexure - 82
33/6.6 KV Station Trafo 4 Equip_Annexure - 83
6.6/.415 KV Distribution Trafo 12 Equip_Annexure - 84
33 KV GIS 62 Equip_Annexure - 85
6.6 KV SWGR 89 Equip_Annexure - 86

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9112-575-OPR-701-00002 Page 9 of 10
415 V SWGR 316 Equip_Annexure - 87

Battery Bank and DCDB 1 Equip_Annexure - 88
AC UPS and ACDB 1 Equip_Annexure - 89
Lighting Trafo 10 Equip_Annexure - 90
Black start DG set 1 Equip_Annexure - 91
DCS 66 Equip_Annexure - 92
BMS 55 Equip_Annexure - 93
SCAP 12 Equip_Annexure - 94
ECS Equip_Annexure - 95
TOTAL>>>>> 800
Heat Exchangers / Coolers
Sample cooler for Sat steam, HRSG 2 HE_Annexure - 1
Sample cooler for BFW, HRSG 2 HE_Annexure - 2
Sample cooler for SH steam, HRSG 2 HE_Annexure - 3
Sample cooler for CBD, HRSG 2 HE_Annexure - 4
Sample cooler for Sat steam, UB 2 HE_Annexure - 5
Sample cooler for BFW, UB 2 HE_Annexure - 6
Sample cooler for SH steam, UB 2 HE_Annexure - 7
Sample cooler for CBD, UB 2 HE_Annexure - 8
STG Gland steam condenser 575-EE-00-009 / 575- 2 HE_Annexure - 9
EE-01/02-004
STG twin duplex Lube oil cooler 575-01/02-E-402/403 4 HE_Annexure - 10
Surface condenser 575-01/02-E-401 2 HE_Annexure - 11

STG Primary air ejector condenser 575-EE-00-002A/B 4 HE_Annexure - 12
STG secondary air ejector condenser 575-EE-00-003A/B 4 HE_Annexure - 13
BPTG Gland steam condenser 575-03-EE-401 1 HE_Annexure - 14
BPTG twin duplex Lube oil cooler 575-03-E-402/403 2 HE_Annexure - 15
BFP DT Gland steam condenser 575-11-EE-401 1 HE_Annexure - 16
BFP DT twin duplex Lube oil cooler 575-11-E-402/403 2 HE_Annexure - 17
GT Atomizing Air cooler 2 HE_Annexure - 18
GBC Lube oil cooler 575-E-01/02-408A/B 4 HE_Annexure - 19
GBC bypass cooler 575-E-01/02-404 2 HE_Annexure - 20
GT Lube oil cooler 4 HE_Annexure - 21
Water to Water HE 2 HE_Annexure - 22
Revision 02
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TOTAL>>>>> 52

Revision 02
9112-575-OPR-701-00002 Page 1 of 3
CHAPTER – 18
EQUIPMENT HANDOVER PROCEDURE
18.1 PREPARATION OF EQUIPMENT FOR MAINTENANCE
18.1.1 Process Equipment: Towers, Vessels, Pumps etc.
Before opening any equipment, it should be purged to render the internal atmosphere
non-explosive and breathable. Operations to be carried out are: -
 Isolation with valves and blinds.


 Draining and depressurization.

 Replacement of vapors or gas by steam, water or inert gas.

 Take care about instrument tapping.

 Washing of towers and vessels with water.

 Ventilation of equipment.

 Opening of top manhole.

 Entry blinds are installed in entry is required.

 Testing of inside atmosphere with explosive meter if required.

 Complete opening if inside atmosphere is satisfactory.

 Analyze the atmosphere inside for O2 content and any poisonous gas.

 Any pump /compressor/fan/blowers etc must be de-energized and tagged properly
prior to hand over to the maintenance person.

 In case of pumps drain out and flushing to be done. Wait for cooling down of
equipment before start maintenance operations.

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9112-575-OPR-701-00002 Page 2 of 3
Note: Open a vent on the upper part of the vessel to allow gases to escape during filling and to
allow air inside the vessel during draining. Avoid any spillage on open ground area; all
disposals should be routed to designated area. Ensure proper ventilation inside the vessel by
opening all manholes. For fuel gas handling equipments, purge them with N 2 gas In case of
N2 purging properly barricade the area for entry and provide display sign boards.
18.1.2 Precautions before Handing Over Equipment
Following items should be checked by a responsible operating supervisor before the equipment is
handed over for maintenance after it has been purged.
 Ascertain that equipment is isolated by proper valves and blinds.


 Ascertain that there is no pressure in the lines, vessels and equipment.

 Purge the system with N2 first and later by air and check for O2 content at vent and drain to
ensure that the vessel is full of air.

 Provide tags on the various blinds to avoid mistakes. Maintain a register for blinds.

 Keep the surrounding area cleaned up.

 Get explosive meter test done in vessels, lines, equipment and surrounding areas.
If welding or hot work is to be done, also:

 Keeps fire fighting devices ready for use.

 Close the neighboring surface drains with wet gunny bags.

 Keep water flowing in the neighboring area to cool down any spark bits etc.

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9112-575-OPR-701-00002 Page 3 of 3
18.1.3 Preparation of Work Order Permit:
After the above operations have been made, a safety permit should be issued for carrying out the
work. A responsible operating supervisor should be personally present at the place of hot work till
the first torch is lighted. Hot work should be immediately suspended if instructed by the
supervisor or on detecting any unsafe condition. When people have to enter a vessel for
inspection or other work, one person should stand outside near the man hole of the vessel for
any help needed by the persons working inside. The person entering the vessel should have tied
on his waist a rope to enable pulling him out in case of urgency. Detail procedure for preparation
for vessel entry is given in next sub-section.

Revision 02
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CHAPTER – 19
BLIND LIST
BLIND LIST
Sr. System P&ID Sheet Line Line no. Type of Normal Remarks
no. Name size and Blind Position
details
1 FG Fuel 10005610442 1/1 20" 20" FG Spectacle Open

system 575 8881 Blind
A1A
2 Nitrogen 10005610442 1/1 3" 3" N2 575 Spectacle Open

system 8881 A1A Blind
3 HSD/LCO 10005610443 1/1 3" 3" FO 575 Spectacle Open

fuel system 8901 A1A Blind
4 Fuel Gas 00005651135 1/1 6" 6" FG 575 Spectacle Close

system 7701 12C Blind
5 HSD/LCO 00005651135 1/1 1.5" 1.5" FO Spectacle Close

fuel system 575 7703 Blind
12C
6 VHP steam 1381 0103143 1/1 10" 10" End Blind Close Future tapping for 3rd
HRSG
7 HP steam 1381 0103144 1/2 16" 16" SH Spectacle Open

575 1206 Blind
D2A IH

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8 HP steam 1381 0103144 1/2 16" 16" SH End Blind Close Header drain between
575 1206 valve no. 10-GTV-1215A
D2A IH and 1214A
9 BFW for 1381 0103144 1/2 3" 3"WB 575 End Blind Close 10-TV1207 TCV upsteam
spary water 1241 F2A header drain valve end
IH blind
10 BFW for 1381 0103144 1/2 3" 3"WB 575 End Blind Close 10-TV1207 TCV
spray water 1241 F2A downstream header
IH drain valve end blind
11 BFW for 1381 0103144 1/2 1" 1"WB 575 End Blind Close 10-PV1220 PCV
spray water 1240 F2A Upstream header drain
IH valve end blind
IH valve end blind
IH valve end blind
17 HP steam 1381 0103145 2/2 3" 3" HP 575 End Blind Close 10-PV1118 PCV
1297 D2A upstream header drain
IH valve end blind

Revision 02
9112-575-OPR-701-00002 Page 3 of 34
18 HP steam 1381 0103145 1/1 3" 3" HP 575 End Blind Close 10-PV1118 PCV
1297 D2A downstream header
spray water 1269 F2A upstream header drain
IH valve end blind
IH valve end blind
spray water 1269 F2A downsteam header drain
IH valve end blind
23 BFW for 1381 0103145 1/1 11/2" 11/2"WB End Blind Close 10-PV1270 PCV upsteam
spary water 575 1296 header drain valve end
F2A IH blind
24 BFW for 1381 0103145 1/1 11/2" 11/2"WB End Blind Close 10-PV1270 PCV
spary water 575 1296 downstream header
F2A IH drain valve end blind
25 BFW for 1381 0103145 1/1 11/2" 11/2"WB End Blind Close 10-TV1271 TCV upsteam
spray water 575 1296 header drain valve end
F2A IH blind
26 BFW for 1381 0103145 1/1 11/2" 11/2"WB End Blind Close 10-TV1271 TCV
spray water 575 1296 downstream header
27 BFW for 1381 0103145 1/1 2" 2" WB 575 End Blind Close 10-PV1301 PCV
IH valve end blind

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29 MP steam 1381 0103145 1/1 32" 32" SM Spectacle Open

575 1305 Blind
B2A IH
30 MP steam 1381 0103145 1/1 32" 32" SM End Blind Close Header drain between
575 1305 valve no. 10-GTV-1319A
B2A IH and 1318A
IH valve end blind
33 BFW for 13810103145 1/1 3" 3" WB 575 End Blind Close 10-TV1309 TCV
IH valve end blind
34 BFW for 13810103145 1/1 3" 3" WB 575 End Blind Close 10-TV1309 TCV
35 LP steam 13810103146 1/1 24" 24"SL 575 Spectacle Open

1412 Blind
A22A IH
36 LP steam 1381 0103146 1/1 24" 24"SL 575 End Blind Close Header drain between
1412 valve no. 10-GTV-1428
A22A IH and 1429
spray water 575 1411 upstream header drain
F2A IH valve end blind

Revision 02
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spray water 575 1411 upstream header drain
41 LP steam 1381 0103146 1/1 4" 4" SL 575 End Blind Close 10-PV1411 PCV
1481 upstream header drain
A22A IH valve end blind
1481 downstream header
A22A IH drain valve end blind
IH valve end blind
IH valve end blind

Revision 02
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51 Process 1381 0103148 1/1 16" 16" CL 575 Spectacle Open

condensate 1732 A3K Blind
52 MUH 1381 0103148 1/1 6" 10" CL 575 End Blind Close Connection for Future
condensate 1735 A1A MUH Pump for HRSG # 3
53 Deaerator 1381 0103149 1/3 3/4" 3/4" WB End Blind Close Sampling line for
Sample 575 1826 deaerator for SWAS
A1A
54 Condensate 1381 0103149 1/3 3/4" 3/4" CL End Blind Close Sampling line for CST for
storage 575 1742 SWAS
tank A3K
55 Boiler Feed 1381 0103149 1/3 10" 10" WB End Blind Close Future tapping for HRSG
water 575 1807 #3
A1A IH
56 Boiler Feed 1381 0103149 1/3 6" 6" WB 575 End Blind Close 04-FV1816A FCV
water 1819 F2A upstream header drain
IH valve end blind
water 1819 F2A downstream header
58 Boiler Feed 1381 0103149 1/3 6" 6" WB 575 End Blind Close 04-FV1816B FCV

Revision 02
9112-575-OPR-701-00002 Page 7 of 34
IH valve end blind
60 Boiler Feed 1381 0103149 1/3 6" 6" WB 575 End Blind Close 04-FV1816C FCV
IH valve end blind
61 Boiler Feed 1381 0103149 1/3 6" 6" WB 575 End Blind Close 04-FV1816c FCV
IH valve end blind
IH valve end blind
66 Boiler Feed 1381 0103149 1/3 6" 6" WB 575 End Blind Close 05-FV1816C FCV
IH valve end blind
67 Boiler Feed 1381 0103149 1/3 6" 6" WB 575 End Blind Close 05-FV1816c FCV
68 Boiler Feed 1381 01 2/3 12" 22" WB End Blind Close Future connection valve

Revision 02
9112-575-OPR-701-00002 Page 8 of 34
water 03149 575 1802 end blind

A1A IH
69 Boiler Feed 1381 0103149 2/3 10" 10" WB End Blind Close 06-FV1844A FCV
water 575 1848 upstream header drain
water 575 1848 downstream header
71 Boiler Feed 1381 0103149 2/3 10" 10" WB End Blind Close 06-FV1844B FCV
73 Boiler Feed 1381 0103149 2/3 10" 10" WB End Blind Close 06-FV1844C FCV

Revision 02
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water 575 1854 upsteam header drain

Revision 02
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93 Boiler Feed 1381 0103149 3/3 10" 10" WB End Blind Close
water 575 1879
F2A IH
94 Cooling 0381 0100935 1/1 10" 10" WR Spectacle Open

water make 575 4718 Blind
up A3A
95 CT 0381 0100936 1/1 6" 6" BD 575 Spectacle Open

Blowdown 4806b Blind
A91A
96 ACW 0381 0100936 1/2 12" 12" WCS Spectacle Close Future for GT # 3
575 4809a Blind
A91A
97 ACW 0381 0100936 1/2 12" 12" WCR Spectacle Close Future for GT # 3
575 4810a Blind
A91A

Revision 02
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98 ACW 0381 0100936 1/2 12" 12" WCS Spectacle Close Future for GT # 3 - FRP
575 4879 Blind CT supply
A91A
99 ACW 0381 0100936 1/2 12" 12" WCR Spectacle Close Future for GT # 3 - FRP
575 4892a Blind CT return
A91A
100 HSD 1381 0103138 1/6 8" 8" FO 575 Spectacle Open BLV66001 downstream
66001 Blind
A1A
101 HSD 1381 0103138 1/6 8" 8" FO 575 Spectacle close HSD through LCO header
67012 Blind
A1A
102 HSD 1381 0103138 1/6 8" 8" FO 575 End Blind Close LV6605 LCV upsteam
66002 header drain valve end
A1A blind
103 HSD 1381 0103138 1/6 8" 8" FO 575 End Blind Close LV6605 LCV downstream
A1A blind
104 HSD 1381 0103138 1/6 8" 8" FO 575 End Blind Close Drain valve end blind
66002 after NRV
A1A
105 HSD 1381 0103138 1/6 8" 8" FO 575 Spectacle close Near tank # 1 valve
66002 Blind 66008
A1A
106 HSD 1381 0103138 1/6 8" 8" FO 575 End Blind Close LV6606 LCV upsteam

Revision 02
9112-575-OPR-701-00002 Page 12 of 34
A1A blind
107 HSD 1381 0103138 1/6 8" 8" FO 575 End Blind Close LV6606 LCV downstream
A1A blind
108 HSD 1381 0103138 1/6 8" 8" FO 575 End Blind Close Drain valve end blind
66001 after NRV
A1A
109 HSD 1381 0103138 1/6 8" End Blind Close Spare Inlet valve End
blind on Tank 502
110 HSD 1381 0103138 1/6 8" End Blind Close Spare recirculation valve
End blind on Tank 502
111 HSD 1381 0103138 1/6 8" 8" FO 575 Spectacle Close Near tank # 2 valve
66001 Blind 66011
A1A
112 HSD 1381 0103138 1/6 6" 6" FO 575 Spectacle Open
66013 Blind
A1A
66014 Blind
A1A
114 HSD 1381 0103138 1/6 6" 6" FO 575 Spectacle close BLV66012 upstream
66004 Blind
A1A
66034 Blind
A1A
66011 Blind
A1A

Revision 02
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66017 Blind
A1A
66019 Blind
A1A
66021 Blind
A1A
120 HSD 1381 0103138 1/6 6" 6" FO 575 End Blind Close Header drain
66024
A1A
121 HSD 1381 0103138 1/6 6" 6" FO 575 End Blind Close Header drain
66026
A1A
66027 Blind
A1A
123 HSD 1381 0103138 3/6 3" 3" FO 575 End Blind Close FT6638 Upstream
A1A blind
124 HSD 1381 01 3/6 3" 3" FO 575 End Blind Close FT6638 downstream
03138 66051 header drain valve end
A1A blind

03138 66028 Blind
A1A
126 HSD 1381 01 6/6 3" 3" FO 575 End Blind Close FT6651 Upstream
A1A blind

Revision 02
9112-575-OPR-701-00002 Page 14 of 34
127 HSD 1381 01 6/6 3" 3" FO 575 End Blind Close FT6651 downstream
A1A blind
128 LCO 1381 01 1/12 12" 12" FO Spectacle Open

03139 575 67001 Blind
A1A
129 LCO 1381 01 1/12 12" 12" FO End Blind Close Drain valve end blind
03139 575 67001 between two isolation
A1A valve
130 LCO 1381 01 1/12 12" 12" FO End Blind Close LV6701 LCV upstream
03139 575 67002 drain valve end blind
A1A
131 LCO 1381 01 1/12 12" 12" FO End Blind Close LV6701 LCV downstream
A1A
03139 575 67002 after NRV
A1A
133 LCO 1381 01 1/12 12" 12" FO Spectacle Open Near tank # 1 valve
03139 575 67002 Blind 67008
A1A
134 LCO 1381 01 1/12 12" End Blind Close Spare Inlet valve End
03139 blind on Tank 509
135 LCO 1381 01 1/12 12" End Blind Close Spare recirculation valve
03139 End blind on Tank 509
136 LCO 1381 01 1/12 12" 12" FO End Blind Close LV6705 LCV upstream
A1A
137 LCO 1381 01 1/12 12" 12" FO End Blind Close LV6705 LCV downstream

Revision 02
9112-575-OPR-701-00002 Page 15 of 34
A1A
03139 575 67003 after NRV
A1A
139 LCO 1381 01 1/12 12" 12" FO Spectacle Close Near tank # 2 valve
03139 575 67003 Blind 67014
A1A
140 LCO 1381 01 1/12 12" End Blind Close Spare Inlet valve End
03139 blind on Tank 510
141 LCO 1381 01 1/12 12" End Blind Close Spare recirculation valve
03139 End blind on Tank 510

03139 575 67006 Blind
A1A
143 LCO 1381 01 1/12 3" 3" FO 575 Spectacle Open

03139 67008 Blind
A1A

03139 67023 Blind
A1A

03139 67004 Blind
A1A
146 LCO 1381 01 1/12 6" 6" FO 575 End Blind Close Header drain valve end
03139 32024 blind
A1A
03139 67158 blind
A1A

Revision 02
9112-575-OPR-701-00002 Page 16 of 34
03139 67029 blind
A1A

03139 575 67014 Blind
A1A

03139 67015 Blind
A1A

03139 67013 Blind
A1A

03139 67011 Blind
A1A
153 LCO 1381 01 3/12 3" 3" FO 575 End Blind Close FT6726 upstream drain
03139 67054 valve end blind
A1K
154 LCO 1381 01 3/12 3" 3" FO 575 End Blind Close FT6726 downstream
03139 67054 drain valve end blind
A1K
155 LCO 1381 01 4/12 1/2" 1/2" HIT End Blind Close FT6728 upstream drain
03139 575 67075 valve end blind
A1K
156 LCO 1381 01 4/12 1/2" 1/2" HIT End Blind Close FT6728 downstream
A1K
157 LCO 1381 01 4/12 2" End Blind Close Spare connection on
03139 tank 503

Revision 02
9112-575-OPR-701-00002 Page 17 of 34
03139 tank 503
159 LCO 1381 01 5/12 3" 3" FO 575 End Blind Close FT6742 upstream drain
03139 67084 valve end blind
A1K
160 LCO 1381 01 5/12 3" 3" FO 575 End Blind Close FT6742 downstream
03139 67084 drain valve end blind
A1K
161 LCO 1381 01 5/12 2" 2" OWS Spectacle Open

03139 575 67066 Blind
A1K

03139 575 67068 Blind
A1K
163 LCO 1381 01 6/12 1/2" 1/2" HIT End Blind Close FT6754 upstream drain
03139 575 67098 valve end blind
A1K
164 LCO 1381 01 6/12 1/2" 1/2" HIT End Blind Close FT6754 downstream
A1K
03139 tank 504
03139 tank 504

03139 575 67101 Blind
A1K

03139 575 67103 Blind
A1K

Revision 02
9112-575-OPR-701-00002 Page 18 of 34
03139 tank 505
03139 tank 505

03139 575 67068 Blind
A1K
03139 tank 506
03139 tank 506

03139 575 67160 Blind
A1K
03139 tank 507
03139 tank 507

03139 575 31014 Blind
A1K

03139 575 31012 Blind
A1K

03139 575 67008 Blind
A1K

03139 575 67015 Blind

Revision 02
9112-575-OPR-701-00002 Page 19 of 34
A1K

03139 575 67056 Blind
A1K
182 FG 1381 01 1/9 20" 20" FG Spectacle Open

03142 575 6801 Blind
A1A
183 FG 1381 01 1/9 Spectacle Open N2 connection to FG

03142 Blind header
184 FG 1381 01 1/9 20" 20" FG End Blind Close Header drain valve end
03142 575 6801 blind
A1A
185 FG 1381 01 1/9 8" Spectacle Open V11 inlet

03142 Blind
186 FG 1381 01 1/9 8" Spectacle Open V11 Outlet

03142 Blind
187 FG 1381 01 1/9 1" Spectacle Open V11 vent line to Flare
03142 Blind
188 FG 1381 01 1/9 1" Spectacle Open V11 vent to BDV 6810
03142 Blind
189 FG 1381 01 1/9 2" 2" GC 575 End Blind Close LV6805 LCV upsteam
03142 6809 A1A drain valve end blind
190 FG 1381 01 1/9 2" 2" GC 575 End Blind Close LV6805 LCV downsteam
191 FG 1381 01 1/9 2" Spectacle Open Nitrogen connection

03142 Blind header for GT Gas
scrubber Purging

03142 Blind

Revision 02
9112-575-OPR-701-00002 Page 20 of 34

03142 Blind
03142 Blind
03142 Blind
198 FG 1381 01 2/9 8" 8" FG 575 Spectacle Open

03142 6810 A1A Blind

03142 6811 A1A Blind

03142 6812 A1A Blind

03142 Blind

03142 Blind
203 FG 1381 01 2/9 1" Spectacle Close V13 vent to flare

03142 Blind
204 FG 1381 01 2/9 1" Spectacle Open V13 vent to BDV6829

03142 Blind

Revision 02
9112-575-OPR-701-00002 Page 21 of 34

03142 Blind

03142 Blind

03142 Blind

03142 Blind

03142 Blind header for GT filteration
skid Purging
218 FG 1381 01 2/9 1" 1" N26862 Spectacle Open Nitrogen conn after
03142 A1A Blind filteration skid
219 FG 1381 01 2/9 8" 8" FG 575 End Blind Close FE6831 upstream header

Revision 02
9112-575-OPR-701-00002 Page 22 of 34
220 FG 1381 01 2/9 8" 8" FG 575 End Blind Close FE6831 downstream
03142 6815 A1A header drain valve end
blind

03142 Blind

03142 Blind
03142 Blind
03142 Blind

03142 Blind

03142 Blind

03142 Blind

03142 Blind

Revision 02
9112-575-OPR-701-00002 Page 23 of 34

03142 Blind header for GT filteration
skid Purging
238 FG 1381 01 3/9 1" 1" N26864 Spectacle Open Nitrogen conn after
03142 A1A Blind filteration skid
239 FG 1381 01 3/9 8" 8" FG 575 End Blind Close FE6847 upstream header
240 FG 1381 01 3/9 8" 8" FG 575 End Blind Close FE6847 downstream
03142 6815 A1A header drain valve end
blind
241 FG 1381 01 4/9 6" Spectacle Open V17 Inlet

03142 Blind

03142 Blind
243 FG 1381 01 4/9 1" Spectacle Open Nitrogen conn for V17
03142 Blind scrubber

Revision 02
9112-575-OPR-701-00002 Page 24 of 34
03142 6826 A1A Blind

03142 6825 A1A Blind
248 FG 1381 01 4/9 6" 6" FG 575 End Blind Close PCV6860A upstream
249 FG 1381 01 4/9 6" 6" FG 575 End Blind Close PCV6860A downstream
250 FG 1381 01 4/9 6" 6" FG 575 End Blind Close PCV6860B upstream
251 FG 1381 01 4/9 6" 6" FG 575 End Blind Close PCV6860B downstream
256 FG 1381 01 4/9 1" Spectacle Close V17 vent to flare header
03142 Blind

03142 Blind

03142 Blind

03142 Blind

Revision 02
9112-575-OPR-701-00002 Page 25 of 34
03142 Blind
261 FG 1381 01 5/9 1" Spectacle Open V18 vent to BDV6868A

03142 Blind
262 FG 1381 01 5/9 2" 2" GC 575 End Blind Close LV6863A LCV upsteam
263 FG 1381 01 5/9 2" 2" GC 575 End Blind Close LV6863A LCV
03142 6844 A1A downsteam drain valve
end blind

03142 Blind

03142 Blind
03142 Blind
267 FG 1381 01 5/9 1" Spectacle Open V19 vent to BDV6868A

03142 Blind
268 FG 1381 01 5/9 2" 2" GC 575 End Blind Close LV6863D LCV upsteam
269 FG 1381 01 5/9 2" 2" GC 575 End Blind Close LV6863D LCV
03142 6844 A1A downsteam drain valve
end blind

03142 6836 A1A Blind

03142 6838 A1A Blind

Revision 02
9112-575-OPR-701-00002 Page 26 of 34
276 FG 1381 01 5/9 6" 6" FG 575 End Blind Close PCV6870C upstream
277 FG 1381 01 5/9 6" 6" FG 575 End Blind Close PCV6870C downstream

03142 6847 A1A Blind

03142 6850 A1A Blind

Revision 02
9112-575-OPR-701-00002 Page 27 of 34
298 FG 1381 01 7/9 8" 8" FL 575 Spectacle Open

03142 6885 A1A Blind
299 FG 1381 01 7/9 Spectacle Open Nitrogen conn to Flare

03142 Blind header
300 FG 1381 01 7/9 2" 2" GC 575 Spectacle Open

03142 6807 A1A Blind

Revision 02
9112-575-OPR-701-00002 Page 28 of 34

03142 6809 A1A Blind

03142 6859 A1A Blind
303 FG 1381 01 7/9 4" End Blind Close spare connection on

03142 tank 521

03142 tank 521

03142 tank 521

03142 tank 521

03142 tank 521
308 FG 1381 01 7/9 6" 6" GC 575 End Blind Close

03142 6860 A1A
309 FG 1381 01 7/9 2" 2" N2 575 Spectacle Open Nitrogen conn to tank
03142 6842 A1A Blind 521

03142 6866 A1A Blind

03142 Blind header

03142 6822 A1A Blind

03142 6857 A1A Blind

03142 tank 522

Revision 02
9112-575-OPR-701-00002 Page 29 of 34

03142 tank 522

03142 tank 522
03142 6855 A1A Blind 522

03142 6867 A1A Blind

03142 6844 A1A Blind

03142 6831 A1A Blind

03142 6817 A1A Blind

03142 6872 A1A Blind
323 FG 1381 01 9/9 8" 8" FL 575 Spectacle Open Between isolation valves
03142 6872 A1A Blind

03142 tank 523

03142 tank 523

03142 tank 523
03142 6843 A1A Blind 523

03142 Blind header

Revision 02
9112-575-OPR-701-00002 Page 30 of 34
329 Instrument 2381 01 1/2 2" 2" AI 575 Spectacle Open

Air 00860 5001 A3A Blind
330 Plant Air 2381 01 1/2 2" 2" AP 575 Spectacle Open
00860 5015 A3A Blind
331 Nitrogen 2381 01 2/2 4" 4"IG 575 Spectacle Open

00860 5007 A3A Blind
332 DM water 1381 01 1/1 18" 18" WDM Spectacle Open

03196 575 4901 Blind
A3K
333 Potable 1381 01 1/1 4" 4" WP 575 Spectacle Open

water 03196 4919 J2A Blind
334 Service 1381 01 1/1 6" 6" WS 575 Spectacle Open

water 03196 4914 A3A Blind
335 Atomizing 2381 01 1/2 8" End Blind Close Spare on 20m3 receiver
Air 00876
336 Atomizing 2381 01 1/2 1/2" End Blind Close Spare on 20m3 receiver
Air 00876
337 Atomizing 2381 01 1/2 3/4" End Blind Close Spare on 20m3 receiver
Air 00876
338 Atomizing 2381 01 1/2 4" End Blind Close Spare on 22 m3 receiver
Air 00876
339 Atomizing 2381 01 1/2 1/2" End Blind Close Spare on 22 m3 receiver
Air 00876
Air 00876
Air 00876

Revision 02
9112-575-OPR-701-00002 Page 31 of 34
Air 00876
Air 00876
Air 00876 - IA
Air 00876 - IA
Air 00876 - IA
347 HP 2381 01 1/3 3" End Blind Close Spare on 25 m3 receiver

Nitrogen 00875 tank # 1
system
348 HP 2381 01 1/3 1/2" End Blind Close Spare on 25 m3 receiver

system

system

system

system

system


Revision 02
9112-575-OPR-701-00002 Page 32 of 34

system

system

system

system

system
359 Blow down 2381 01 4/4 6" 6" BD 575 Spectacle Open
00862 1952 A1A Blind
360 Naphtha 1381 01 06325 1/7 3/4 " 4"-FO-575- Spectacle Close Battery limit BLV9603
9601-A1A Blind upsteam header drain
valve end blind
361 Naphtha 1381 01 06325 1/7 3/4 " 4"-FO-575- End Blind Close LV6605B LCV upsteam
9601-A1A header drain valve end
blind
362 Naphtha 1381 01 06325 1/7 3/4 " 4"-FO-575- End Blind Close LV6605B LCV upsteam
9601-A1A header drain valve end
blind
363 Naphtha 1381 01 06325 1/7 1" 4"-FO-575- End Blind Close BLV66052 upstream
9601-A1A Inlet header drain
valve end blind
364 Naphtha 1381 01 06325 1/7 1" 4"-FO-575- End Blind Close BLV66054 upstream
9613-A1K Recirculation header
drain valve end blind
365 Naphtha 1381 01 06325 1/7 6" 4"-FO-575- Spectacle Close BLV9616 upstream
9604-A1K Blind Common Recirculation
header future tap off.

Revision 02
9112-575-OPR-701-00002 Page 33 of 34
366 Naphtha 1381 01 06325 1/7 4" 4"-FO-575- Spectacle Close BLV9616 upstream
9604-A1K Blind Common discharge
header future Naphtha
storage tank
367 GT-Naphtha 1381 01 06325 1/7 3/4 “ 6"-FO-575- Spectacle Open BLV9619 upstream
9605-A1K Blind Common discharge
header for GT-Naphtha
skid.
368 GT-Naphtha 1381 01 06325 1/7 3/4 “ 6"-FO-575- End Blind Close GT-Naphtha skid
9607-A1K discharge header drain
valve end blind
369 GT-1 1381 01 06325 2/7 3/4 “ 4"-FO-575- End Blind Close PV6728C downstream
Naphtha 9608-A1K header drain valve end
blind
370 GT-1 1381 01 06325 2/7 3/4 “ 4"-FO-575- End Blind Close PV6728C upstream
Naphtha 9608-A1K header drain valve end
blind
371 GT-1 1381 01 06325 2/7 3/4 “ 4"-FO-575- End Blind Close NRV-9648A downstream
Naphtha 9608-A1K header sample drain valve
end blind
372 GT-1 1381 01 06325 2/7 3/4 “ 4"-FO-575- End Blind Close NRV-9651A downstream
Naphtha 67044-A1A header sample drain valve
end blind
GT-2 1381 01 06325 2/7 3/4 “ 4"-FO-575- End Blind Close PV6744C downstream
373 Naphtha 9609-A1K header drain valve end
blind
GT-2 1381 01 06325 2/7 3/4 “ 4"-FO-575- End Blind Close PV6744C upstream
374 Naphtha 9609-A1K header drain valve end
blind
375 GT-2 1381 01 06325 2/7 3/4 “ 4"-FO-575- End Blind Close NRV-9648B downstream
Naphtha 9609-A1K header sample drain valve
end blind
376 GT-2 1381 01 06325 2/7 3/4 “ 4"-FO-575- End Blind Close NRV-9651B downstream
end blind
377 HRSG- 138 01 06326 1/7 4“ 6"-FO-575- Spectacle Open BLV9701 downstream
Naphtha 9606-A1A Blind discharge header for
HRSG-Naphtha skid.
HRSG 1381 01 06326 2/5 3/4 “ 4"-FO-575- End Blind Close PV9714 upstream
378 Naphtha 9702-A1A header drain valve end
blind

Revision 02
9112-575-OPR-701-00002 Page 34 of 34
HRSG 1381 01 06326 2/5 3/4 “ 4"-FO-575- End Blind Close PV9714 downstream
379 Naphtha 9702-A1A header drain valve end
blind
380 HRSG 1381 01 06326 2/5 3/4 “ 4"-FO-575- End Blind Close NRV-9732 downstream
381 HRSG 1381 01 06326 2/5 3/4 “ 4"-FO-575- End Blind Close NRV-9735 downstream
end blind
382 HRSG 1381 01 06326 1/5 3/4 “ 4"-FO-575- End Blind Close NRV-9721 upstream
end blind
383 HRSG 1381 01 06326 1/5 3/4 “ 4"-FO-575- End Blind Close BLV-9701 upstream
Naphtha 9706-A1A header drain valve end
blind

Revision 02
Issue Date 31-Jan -2019
9112-575-OPR-701-00002 Page 1 of 3
CHAPTER – 20
CHECKLIST
Check list of CPP include – Checklist based on SOP. All SOP is affixed with associated checklist. Go through
these document for equipment wise startup/ shutdown procedure and checklist.
Sl NO HMEL Document ID Description
1 9112-575-OPR-704-00001 SOP OF FOR GAS TURBINE NORMAL START-UP/SHUTDOWN
2 9112-575-OPR-704-00002 NORMAL SOP OF CPP GTG FIRE FIGHTING SYSTEM
3 9112-575-OPR-704-00003 SOP FOR GT WATER WASH SYSTEM OFFLINE/ONLINE
SOP FOR CPP FOR GT FUEL CHANFEOVER AND MIX FUEL

4 9112-575-OPR-704-00004
OPERATION
"NORMAL SOP OF CPP FOR HRSG START-UP/SHUTDOWN &

5 9112-575-OPR-704-00005
SUPPLEMENTARY FIRING"
6 9112-575-OPR-704-00006 NORMAL SOP OF CPP FOR HRSG HYDRO TEST
7 9112-575-OPR-704-00007 SOP OF CPP FOR UTILITY BOILER STARTUP AND SHUTDOWN
8 9112-575-OPR-704-00008 SOP OF CPP FOR SLOP OIL AND GAS CONDENSATE TRANFER
9 9112-575-OPR-704-00009 NORMAL SOP OF CPP FOR UTILITY BOILER HYDRO TEST
10 9112-575-OPR-704-00010 SOP FOR UB/HRSG SAFETY VALVE FLOATING
SOP OF CPP FOR STG START

11 9112-575-OPR-704-00011
UP/SHUTDOWN/SYNCHRONIZATION
SOP OF CPP FOR BPTG START-UP / SHUTDOWN /
12 9112-575-OPR-704-00012
SYNCHRONIZATION
13 9112-575-OPR-704-00013 NORMAL SOP OF CPP FOR TURBINE DRIVEN ACW PUMP
SOP OF START UP / SHUTDOWN OF UB TD LOC

14 9112-575-OPR-704-00014
FORWARDING PUMP

Revision 02
9112-575-OPR-701-00002 Page 2 of 3
15 9112-575-OPR-704-00015 SOP FOR CPP FOR UTILITY BOILERS TD FD
"SOP FOR STRAT - UP / SHUTDOWN OF TD - MOP OF

16 9112-575-OPR-704-00016
STEAM TURBINE GENETATOTRS (STGS)"
17 9112-575-OPR-704-00017 SOP OF CPP FOR STEAM HEADER CHARGING
"SOP FOR DETERMINING GENERATORS CAPABILITY FOR

18 9112-575-OPR-704-00018 FAST LOAD SHEDDING ,GUIDELINE AND GUIDELINE FOR
UNDER FREQUENCY LOAD SHEDDING"
19 9112-575-OPR-704-00019 NORMAL SOP OF CPP FOR FILTER CHANGE OVER
"NORMAL SOP FOR HSD & LCO FUELS FOR RECEIPT AND
20 9112-575-OPR-704-00020
STOCK CALCULATIONS"
"SOP OF CPP FOR ATOMIZING AND BOOSTER AIR
21 9112-575-OPR-704-00021
COMPRESSOR STARTUP / SHUTDOWN"
22 9112-575-OPR-704-00022 SOP OF CPP FOR AUXILIARY COOLING WATER SYSTEM
23 9112-575-OPR-704-00023 SOP OF CPP FOR SSF SYSTEM
24 9112-575-OPR-704-00024 NORMAL SOP OF CPP FOR AIR CONDITIONING SYSTEM
"NORMAL SOP OF CPP FOR HP NITROGEN COMPRESSOR

25 9112-575-OPR-704-00025
STRAT UP AND SHUTDOWN"
SOP OF CPP FOR GAS BOOSTER COMPRESSOR START-UP

26 9112-575-OPR-704-00026
AND SHUTDOWN
SOP OF CPP FOR BLACK START DIESEL GENERATOR START-
27 9112-575-OPR-704-00027
UP/SHUTDOWN
28 9112-575-OPR-704-00028 SOP OF CPP FOR COOLING TOWER OPERATION
"NORMAL SOP OF CPP FOR DEAERATOR LP HEATER,

29 9112-575-OPR-704-00029
EXPORT FEED WATER PUMPS & BEP-S"
30 9112-575-OPR-704-00030 EMERGENCY SOP OF CPP FOR STATION BLACKOUT
31 9112-575-OPR-704-00031 NORMAL SOP OF CPP PLANT EQUIPEMENT CHANGEOVER

Revision 02
9112-575-OPR-701-00002 Page 3 of 3
SOP FOR DM WATER AND RETURN CONDENSATE SUPPLY

32 9112-575-OPR-704-00032
FAILURE
"EMERGENCY SOP OF CPP FOR RFG PRESSURE
33 9112-575-OPR-704-00033 DISTURBANCE DUE TO RFG SUPPLY NOT AVAILABLE FORM
DCU/FCCU"
34 9112-575-OPR-704-00034 NORMAL SOP OF CPP FOR RFG SYSTEM CHARGING
EMERGENCY SOP OF CPP FOR REFINERY INSTRUMENT AIR

35 9112-575-OPR-704-00035
SUPPLY FAILURE
36 9112-575-OPR-704-00036 SOP FOR TD MOP OF TD BFP
"NORMAL SOP OF CPP FOR HANDING OVER OF

37 9112-575-OPR-704-00037
EQUIPMENT/VESSEL TO MAINTENANCE"
38 9112-575-OPR-704-00038 SOP OF LIQUIDD FUEL STORAGE TANK OPERATION
39 9112-575-OPR-704-00039 SOP OF CPP FOR FUEL FORWARDING SYSTEM FOR UB
"SOP OF CPP FOR HRSG LIQUID FUEL SUPPLEMENTARY

40 9112-575-OPR-704-00040
FIRING FORWARDING SYSTEM"
"NORMAL SOP OF CPP FOR GAS TURBINE

41 9112-575-OPR-704-00041
HSD/LCO/NAPHTHA OFF BASE FUEL SYSTEM"
"SOP FOR CPP OPERATING PHILOSOPHY IN
NORMAL
42 9112-575-OPR-704-00042
OPERATIONS & EMERGENCY HANDLING"
43 9112-575-OPR-704-00043 EMERGENCY SOP OF CPP FOR STEAM LOAD SHEDDING
"EMERGENCY SOP OF CPP FOR MONITORING AND

44 9112-575-OPR-704-00044
CONTROL DURING MAX DNA(DCS)"
45 9112-575-OPR-704-00045 SOP OF CPP FOR LCO TANK CLEANING
46 9112-575-OPR-704-00056 NORMAL SOP OF CPP FOR EQUIPMENT PRESERVATION
SOP OF CPP FOR NAPHTHA FIRING IN UTILITY

47 9112-575-OPR-704-00105
BOILER
48 9112-575-OPR-704-00108 NORMAL SOP OF CPP FOR PRDS OPERATION

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HPCL-Mittal Energy Limited

Guru Gobind Singh Refinery, Bathinda

STEAG ENERGY SERVICES (I) PVT LTD

Mona Nanoty Ashish Srivastava Siddiqui MD Ghazunfer Ali

REV ISSUE DATE STATUS PREPARED REVIEWED CHECKED APPROVED CONCURRED

CHAPTER - 2 PROCESS DESCRIPTION

CHAPTER - 3 UTILITIES, CHEMICALS AND EFFLUENTS

CHAPTER - 4 OPERATING VARIABLES

CHAPTER - 5 PREPARATIONS FOR START-UP

Template No. Copyrights HMEL– All rights reserved

5.8 AREA LIGHTING

CHAPTER - 6 COMMISSIONING & START-UP PROCEDURES

CHAPTER - 7 NORMAL SHUTDOWN PROCEDURES

CHAPTER - 8 EMERGENCY SHUTDOWN PROCEDURES

CHAPTER – 9 NORMAL OPERATION OF THE UNIT

CHAPTER – 10 PROCESS INTERLOCKS & PSV SCHEDULE

Template No. Copyrights HMEL– All rights reserved

CHAPTER – 11 HAZARDS, SAFETY & COMMUNICATION

CHAPTER – 12 CATALYST SPECIFICATION AND SPECIAL PROCEDURES

CHAPTER – 13 MAJOR EQUIPMENTS AND THEIR OPERATION

CHAPTER – 14 MATERIAL SAFETY DATASHEETS

CHAPTER – 15 FIRE FIGHTING FACILITIES

CHAPTER – 16 CONSEQUENCES DUE TO UPSETS IN OUTGOING B/L STREAMS

CHAPTER – 17 EQUIPMENT DATASHEETS

Template No. Copyrights HMEL– All rights reserved

CHAPTER – 18 EQUIPMENT HANDOVER PROCEDURES

CHAPTER – 19 BLIND LISTS

CHAPTER – 20 CHECK LIST

Template No. Copyrights HMEL– All rights reserved

The CPP unit consists of the following main processing sections:

2. Power Generating Units – Gas Turbine and Steam Turbine

Template No. Copyrights HMEL– All rights reserved

3. Boiler Feed water Deaeration – Deaerator

The Key features of the unit are as follows:

1.2 PLANT CAPACITY

UNIT MCR TOTAL UNIT TOTAL

Template No. Copyrights HMEL– All rights reserved

1.3 OBJECTIVE OF UNIT

Template No. Copyrights HMEL– All rights reserved

1.4 BATTERY LIMIT CONDITION:

Template No. Copyrights HMEL– All rights reserved

b) Battery Limit condition at CPP

Steam level Units Min. Normal Max. Mech. Design.

Temperature oC 370 380 390 400

Temperature oC 165 170 180 190

Template No. Copyrights HMEL– All rights reserved

2.2 DETAIL PROCESS DESCRIPTION

 Pure condensate – HC Analyzer

Template No. Copyright HMEL– All rights reserved

tank where additional fresh DM water is intake as make up.

2.2.2.1 Feed water to Utility Boilers

Template No. Copyright HMEL– All rights reserved

2.2.2.2 Feed water to HRSG

2.2.2.3 Feed water to Refinery

2.2.3 Off Base HSD Fuel system:

Template No. Copyright HMEL– All rights reserved

2.2.3.1 HSD from Refinery to HSD day tank in CPP