SOP For Compressed Air System

SOP FOR COMPRESSED AIR SYSTEM
DOC. # SEPCOIII-HBS-OPR-SOP-20 Issue # 00 Issue Date: 25-05-2019
Standard Operating Procedure for

Compressed Air System
Copyright
The copyright of this procedure, together with all confidential information contained herein is the
sole property of SEPCOIII Haveli Bahadur Shah 1230 MW Combined Cycle Power Plant.
It may be copied in full or in parts only by the Management / personnel and only for the purpose of
Company related activities. Disclosure and copying of any information contained within this
procedure to any person (s) outside the employee of company without written
permission/authorization of the Management Representative or Plant Manager is strictly prohibited.
Drafted By: _________________________ 18th April, 2019

Operation Manager
Reviewed: _________________________ 14th MAY, 2019

Sr. Consultant
Approved By: _________________________ 25th May, 2019

Plant Manager
Page 1 of 14
Page 2 of 14
Amendment Sheet
Section Amendment
Date Revision # Amendment Detail Signatures
Affected Approved by
Page 3 of 14
Table of Contents
1.0 SCOPE & PURPOSE.............................................................................................................4

2.0 REFERENCES......................................................................................................................4
3.0 PREREQUISITE....................................................................................................................4
4.0 GENERAL PRECAUTION AND LIMITATION.............................................................................5
5.0 SPECIAL TOOLS, MATERIAL AND EQUIPMENT.......................................................................5
6.0 PROCEDURE.......................................................................................................................6
7.0 SUPPLEMENTAL ACTION.....................................................................................................8
8.0 APPENDICES......................................................................................................................8
Page 4 of 14
1.0 SCOPE & PURPOSE
This operating procedure describes the standard and reliable operating guidelines to safely start
the Compressed Air System leading to its normal operation resulting in the optimum
performance within specified operating limits. This procedure also covers the shutdown of the
Compressed Air System.
2.0 REFERENCES
 P&ID # 33-F09221S-J1101-01
 Vendor Technical Manuals
 Operation and Maintenance Manual for Compressed Air System
3.0 PREREQUISITE
 All PTW cancelled and de-isolations have been done.

 General Safety Checks have been carried out.
 Closed cooling water system is in operation.
 System valves lined up as per APPENDIX-I
 System Instruments checked as per APPENDIX-II
 Electrical Distribution System status is as per APPENDIX-III
 The 11 kV and 400 V electrical systems are in operation for providing the electrical energy
required for starting and sustaining the normal operations of the relevant electrical
equipment.
 Compressors oil level is normal.
CAUTION
Before start-up of 1st air compressor, check the system to verify that conditions are normal
and Compressor Enclosure doors are intact.
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4.0 GENERAL PRECAUTION AND LIMITATION
The following precautions and limitations apply specifically to the operation of the
Compressed Air System.
 Prior to start pressurizing the system, make sure that the Air receivers manholes covers
are properly closed.
 Exposed parts of all rotary equipments must be guarded properly.
 All personnel handling the system should be familiar with the following:
 Equipment Operating Procedures
 Evacuation Procedures in emergency circumstances
 Leak/Spill Emergency Response Procedures
 First Aid and Rescue Procedures
 Location and use of Fire Fighting Equipment
 Proper Use of Protective Clothing
 Proper Use of Breathing Apparatus
 Location of safety showers and eyewash stations
 Prearranged Procedures for Emergency Medical Care
CAUTION
In addition to the items listed above, it is duty of every person who may be concerned
with work on or adjacent system to make themselves conversant with safety rules and
requirement relating to any activities with which they an involvement. It remains the
responsibility of all employees to take reasonable care for health and safety for
themselves, their colleagues and the general public who may be affected by their acts or
omissions.
5.0 SPECIAL TOOLS, MATERIAL AND EQUIPMENT
Required PPEs – unique task related

Number PPE
1 PPE’s for routine operations like safety shoes, helmet, safety glasses
2 Hearing protection (Ear plugs/Muffs) required.
Tools and Test Equipment

Number Tool Description Meter & Test Equipment ID
1 Flash Light N/A
2 Radio
Page 6 of 14
Materials, Chemicals and Reagents

Number Chemical/Material Description MSDS
CAUTION
Immediately following start-up, check the system to verify that conditions are normal.
Abnormal conditions, alarms or malfunctions are to be investigated and corrected as soon
as possible.
CAUTION
Particular attention should be given to normal operating conditions of the Compressed Air
System, its equipment, and components to detect variations from their normal conditions
and function. Abnormal conditions, alarms or malfunctions are to be investigated and
corrected as soon as possible.
6.0 PROCEDURE
This procedure consists of two main steps:

6.1 STARTUP
6.2 SHUTDOWN
6.1 STARTUP
6.1.1 Ensure all the valves are aligned as per Appendix-I of this procedure.
6.1.2 Ensure all the instruments are aligned as per Appendix-II of this procedure.
6.1.3 Ensure all the breakers are in their appropriate position as per Appendix-III of
this procedure.
6.1.4 Ensure all the drain and vent valves in the system are in closed position as per
Appendix-1 of this procedure.
6.1.5 Select both Air compressors on auto/remote and Make sure Emergency Push
Buttons are in the released condition.
6.1.6 Adjust the priority of the Air compressor by adjusting the load and unload set
point from local.
6.1.7 Lead compressor set points loading at 7.5 bar and unloading at 9.0 bar. Lag
compressor set points loading at 7.4 bar and unloading at 9.0 bar.
6.1.8 Select Auto/remote of the Lead Air compressor from local.
6.1.9 Select Auto /remote of the Lag Air compressor from local.
6.1.10 Give start command to the Lead Air compressor from CCR DCS.
6.1.11 Check that the Air compressor has started, the compressor will run unload for
warm up period of 15 seconds.
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6.1.12 Check the Air compressor discharge pressure is normal and maintaining the
pressure set point by loading/ unloading.
6.1.13 Check for any abnormality in the field.
6.1.14 Give start command to the lag Air compressor from CCR DCS.
6.1.15 Check that the Air compressor has started; the compressor will stop when
system pressure rises upto Compressor offline pressure.
6.1.16 Crack Open Service Air Receiver inlet valve, when Service Air system pressure
become normal wide open Service Air Receiver Inlet valve.
6.1.17 Ensure Air Dryers are selected Auto/remote from local.
6.1.18 Give start command to the respective Air Dryer from CCR DCS.
6.1.19 Make sure that the Dryer outlet MOV has opened.
6.1.20 Verify that the Air dryer is now in operation, one tower on drying and the
other on regeneration. Regeneration cycle is as follows,
 Blow –off and regeneration 195s.
 Pressurizing 55s
 Adsorbing195s.
 Adsorbing55s.
6.1.21 Crack Open by pass valve of Instrument Air Receiver inlet valve, when
Instrument Air system pressure become normal full open Instrument Air
Receiver Inlet valve.
6.1.22 Make sure that the system pressure is normal.
6.1.23 If routine change over of the Air compressor to be performed, suppose Air
compressor # A is in service and B on Auto.
 Give start command to compressor # B form CCR DCS AND Make sure
that the Air compressor # B has started normally.
 After confirming all parameters are normal then stop air compressor
#A and put on standby.
6.1.24 If routine change over of the Air Dryer to be performed

 Make sure that the Standby Air Dryer is selected on Auto.
 Make sure that the Air Dryer Outlet manual isolation valve is in open
position.
 Give start command to the Standby Air Dryer from CCR DCS.
 Check that the Inlet MOV has opened.
 Verify that the Air dryer is now in operation, one tower on drying and
the other on regeneration.
 If the dryer is running without any abnormality Give stop command to
the Air Dryer to be taken out of service.
 Check the Air Dryer Inlet MOV has closed.
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Page 9 of 14
6.2 SHUTDOWN
6.2.1 Make sure that the Instrument and Service Air are no more required.
6.2.2 Put off the standby position of standby air dryer.
6.2.3 Give stop command to the running Air Dryer.
6.2.4 Check that the Inlet MOV of Air Dryer has closed.
6.2.5 Put off the standby position of standby air compressor.
6.2.6 Give stop command to the running Air Compressor from CCR DCS.
6.2.7 Push Emergency Stop Push Buttons of both Air compressors from local.
7.0 SUPPLEMENTAL ACTION
N/A
8.0 APPENDICES
8.1 APPENDIX-1 Pre start checklist for valves line up.

8.2 APPENDIX-2 Pre start checklist for instrumentation.
8.3 APPENDIX-3 Pre start checklist for Electrical distribution.
APPENDIX-I
PRE START VALVE LINE UP CHECK LIST

S. No KKS DESCRIPTION STATUS
1 00QEA11AA001 Air Compressor-A Discharge Valve OPEN
2 00QEA12AA001 Air Compressor-B Discharge Valve OPEN
3 00QFA31AA001 Instrument Air Receiver #A Inlet Valve OPEN
4 00QFA32AA001 Instrument Air Receiver #B Inlet Valve OPEN
5 00QFB31AA001 Instrument Air Receiver #A Outlet Valve OPEN
6 00QFB32AA001 Instrument Air Receiver #B Outlet Valve OPEN
7 00QFA10AA001 Instrument Air Dryer-A Inlet Valve OPEN
8 00QFA10AA002 Instrument Air Dryer-A Outlet MOV CLOSE
9 00QFA20AA001 Instrument Air Dryer-B Inlet Valve OPEN
10 00QFA20AA002 Instrument Air Dryer-B Outlet MOV CLOSE
11 00QFB10AA001 Instrument air supply common header valve OPEN
12 00QFB11AA001 Gas booster and conditioning system zone OPEN
13 00QFB20AA001 Common air supply valve for HRSGs and GTs CA OPEN
system zone.
14 00QFB21AA001 Gas fuel conditioning skid of GTs air supply valve OPEN
15 11QFB 12AA001 HRSG 1 Instrument air supply valve OPEN
16 12QFB 13AA001 HRSG 2 Instrument air supply valve OPEN
17 00QFB20AA001 Common air supply valve for GTs CA system OPEN
18 11QFB10AA001 GT 1CA system common air supply valve OPEN
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19 11QFB10AA002 GT 1CA system air supply valve OPEN

20 11QFB10AA003 GT 1CA system air supply valve OPEN
21 12QFB10AA001 GT 2CA system common air supply valve OPEN
22 12QFB10AA002 GT 2CA system air supply valve
23 12QFB10AA003 GT 2CA system air supply valve
24 00QFB22AA002 GT 1/2 CA system interconnection air supply valve OPEN
25 00QFB14AA001 Water treatment area air supply valve OPEN
26 10QFB15AA001 To ST hall air supply valve OPEN
27 00QEA20AA001 Service air MOV upstream isolation valve OPEN
28 00QEA20AA002 Service air MOV CLOSE
29 00QEA20AA003 Service air MOV downstream isolation valve OPEN
30 00QEA 20AA005 Service air receiver inlet valve OPEN
31 00QEB10AA001 Service air receiver outlet valve OPEN
32 00QEB11AA001 Workshop area air supply OPEN
33 00QEB12AA001 Common service air supply valve to gas compressor OPEN
and H2 plant.
34 00QEB12AA002 Gas booster and conditioning system zone service OPEN
air supply valve
35 00QEB12AA003 H2 Generation system zone service air supply valve OPEN
36 00QEB20AA001 Common service air supply valve to Fuel gas OPEN
conditioning skid, HRSGs and GTs hall.
37 00QEB21AA001 Fuel gas conditioning service air supply valve OPEN
38 11QEB13AA001 HRSG 1 Service air header pipe OPEN
39 12QEB14AA001 HRSG 2 Service air header pipe OPEN
40 00QEB22AA001 GTs Hall service air supply valve OPEN
41 12QEB10AA001 GT 2 CA system service air supply valve OPEN
42 11QEB10AA001 GT 1 CA system service air supply valve OPEN
43 11QEB10AA001 GT 1/2 CA system service air interconnection supply OPEN
valve
44 10QEB16AA001 To ST hall service air supply valve OPEN
45 10QEB17AA001 To Fuel unloading and forwarding area service air OPEN
supply valve
46 00QEA12AA401 Air Compressor-B Discharge line drain valve CLOSE
47 00QEA11AA401 Air Compressor-A Discharge line drain valve CLOSE
48 00QFA31AA409 Air receiver # A inlet header drain valve CLOSE
49 00QFB31AA401 Air receiver # A outlet header drain valve CLOSE
50 00QFA31AA401 Air receiver # A drain trap upstream valve OPEN
51 00QFA31AA403 Air receiver # A drain trap bypass valve CLOSE
52 00QFA32AA409 Air receiver # B inlet header drain valve CLOSE
53 00QFB32AA401 Air receiver # B outlet header drain valve CLOSE
54 00QFA32AA401 Air receiver # B drain trap upstream valve OPEN
55 00QFA32AA403 Air receiver # B drain trap bypass valve CLOSE
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56 00QFB11AA401 Gas booster and conditioning system line drain valve CLOSE
57 00QFB11AA501 Gas booster and conditioning system line vent valve CLOSE
58 00QFB21AA401 Fuel gas conditioning skid supply line drain valve CLOSE
59 00QFB21AA501 Fuel gas conditioning skid supply line vent valve CLOSE
60 11QFB12AA401 HRSG 1 Instrument air supply line drain valve CLOSE
61 11QFB12AA501 HRSG 1 Instrument air supply line vent valve CLOSE
65 12QFB13AA501 HRSG 2 Instrument air supply line vent valve CLOSE
68 00QFB22AA401 GT CA system common header air supply line drain CLOSE
valve
69 00QFB22AA501 GT CA system common header air supply line vent CLOSE
valve
72 00QFB10AA402 ST hall air supply line drain valve CLOSE
73 00QFB10AA501 ST hall air supply line vent valve CLOSE
74 00QFB14AA401 Water treatment area air supply line drain valve CLOSE
75 00QFB14AA401 Water treatment area air supply line vent valve CLOSE
76 10QFB15AA401 ST hall common air supply line drain valve CLOSE
83 00QEA20AA409 Service air common header drain valve CLOSE
84 00QEA20AA401 Service air receiver drain trap upstream valve CLOSE
85 00QEA20AA403 Service air receiver drain trap bypass valve CLOSE
86 00QEB10AA401 Service air receiver discharge pipe drain valve CLOSE
87 00QEB10AA402 Service air receiver discharge pipe drain valve CLOSE
88 00QEB11AA401 Workshop area service air supply drain valve CLOSE
89 00QEB11AA501 Workshop area service air supply vent valve CLOSE
90 00QEB12AA401 H2 Generation system service air supply line drain CLOSE
valve
91 00QEB12AA501 H2 Generation system service air supply line vent CLOSE
valve
92 00QEB21AA401 Fuel gas conditioning skid service air supply line CLOSE
drain valve
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93 00QEB21AA501 Fuel gas conditioning skid service air supply line vent CLOSE
valve
94 00QEB20AA401 HRSG Common service air supply drain valve CLOSE
95 11QEB13AA002 HRSG 1 service air supply valve OPEN
96 11QEB13AA003 HRSG 1service air supply valve OPEN
99 11QEB30AA401 HRSG 1 common service air supply line drain valve CLOSE
100 11QEB30AA501 HRSG 1 common service air supply line vent valve CLOSE
101 11QEB13AA402 HRSG 1 service air supply line drain valve CLOSE
102 11QEB13AA403 HRSG 1 service air supply line drain valve CLOSE
103 12QEB14AA401 HRSG 2Common service air supply drain valve CLOSE
104 12QEB14AA501 HRSG 2Common service air supply drain valve CLOSE
107 12QEB22AA501 GTs CA system common header service air supply CLOSE
line vent valve
108 12QEB22AA401 GTs CA system common header service air supply CLOSE
line drain valve
109 11QEB10AA002 GT 1 CA system service air supply line valve OPEN
113 11QEB10AA402 GT 1 CA system service air supply line drain valve CLOSE
114 12QEB10AA402 GT 2 CA system service air supply line drain valve CLOSE
115 10QEB16AA401 ST hall service air common supply line drain valve CLOSE
116 10QEB16AA002 ST hall service air supply line valve OPEN
120 10QEB16AA402 ST hall service air supply line drain valve CLOSE
126 10QEB16AA501 ST hall service air supply line vent valve CLOSE
127 10QEB16AA502 ST hall service air supply line vent valve CLOSE
128 00QEB17AA401 Fuel unloading and forwarding area service air CLOSE
supply line drain valve
129 00QEB17AA501 Fuel unloading and forwarding area service air CLOSE
supply line vent valve
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APPENDIX II
PRE START INSTRUMENT CHECK LIST

S. No KKS DESCRIPTION
1 00QEA10CP101 Instrument Air Compressors common discharge header
pressure transmitter
pressure indicator
4 00QFA30CP101 After dryer Instrument Air common discharge header
pressure indicator
7 00QFA31CP501 Instrument Air Receiver Pressure A indicator
8 00QFA32CP501 Instrument Air Receiver Pressure B indicator
9 00QFB10CP101 After Instrument Air receiver common discharge header
pressure indicator
12 00QEA20CP501 Service Air Receiver Pressure indicator
13 00QEA10CP101 Service Air common discharge header Pressure transmitter
14 00QEA10CP501 Service Air common discharge header Pressure indicator
APPENDIX-III
PRE START ELECTRICAL DISTRIBUTION CHECKS LIST

S. No Description Status
1 Instrument Air Compressor-A Breaker ON
2 Instrument Air Compressor-B Breaker ON
3 Instrument Air Dryer-A Breaker ON
4 Instrument Air Dryer-B Breaker ON
6 Service Air Receiver inlet MOV Breaker ON
7 Instrument Air Dryer-A outlet MOV Breaker ON
8 Instrument Air Dryer-B outlet MOV Breaker ON
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SOP For Compressed Air System

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SOP FOR COMPRESSED AIR SYSTEM

DOC. # SEPCOIII-HBS-OPR-SOP-20 Issue # 00 Issue Date: 25-05-2019

Standard Operating Procedure for

Drafted By: _________________________ 18th April, 2019

Reviewed: _________________________ 14th MAY, 2019

Approved By: _________________________ 25th May, 2019

1.0 SCOPE & PURPOSE.............................................................................................................4

1.0 SCOPE & PURPOSE

 All PTW cancelled and de-isolations have been done.

4.0 GENERAL PRECAUTION AND LIMITATION

5.0 SPECIAL TOOLS, MATERIAL AND EQUIPMENT

Required PPEs – unique task related

Tools and Test Equipment

Materials, Chemicals and Reagents

This procedure consists of two main steps:

6.1.22 Make sure that the system pressure is normal.

6.1.24 If routine change over of the Air Dryer to be performed

7.0 SUPPLEMENTAL ACTION

8.1 APPENDIX-1 Pre start checklist for valves line up.

PRE START VALVE LINE UP CHECK LIST

19 11QFB10AA002 GT 1CA system air supply valve OPEN

PRE START INSTRUMENT CHECK LIST

PRE START ELECTRICAL DISTRIBUTION CHECKS LIST

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