STANDARD OPERATING PROCEDURE

Jaypee Nigrie Super Thermal Power Plant

2 X 660 MW IPP
SOP FOR BCP Flushing
Revision No.: 00
Document No.: PMPL/SOP/54 Effective Date: Page 1 of 7
Revision Date:

STANDARD OPERATING
PROCEDURE
FOR

BCP FLUSHING

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (Jaypee): Approved by (Jaypee):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR BCP Flushing
Revision No.: 00
Document No.: PMPL/SOP/54 Effective Date: Page 2 of 7
Revision Date:

List of Contents

1. Objective
2. Scope
3. Introduction
4. Technical Data
5. Responsibility
6. Safety Precaution During operation
7. Safety Ppe’s
8. Special Tools/ Equipments
9. Pre checks And Action By Field Engineer
10.Operating Procedure
11.Abbreviations / Notations

References

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (Jaypee): Approved by (Jaypee):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR BCP Flushing
Revision No.: 00
Document No.: PMPL/SOP/54 Effective Date: Page 3 of 7
Revision Date:

1. Objective
For Smooth Operation of Boiler Circulation Pump.

2. Scope
This SOP is applicable for 01 No. of BCP.

3. Introduction
Boiler Water Circulation Pump used in high capacity boiler (super critical or
sub critical), it assisted the circulation of water to overcome friction losses in
pipe lines.

4. BCP Technical Data

Pump Data

Manufacturer Torishima Pump MFG Co., LTD.

Type & Size HLAV 250-570/1K
Spherical Casing, Centrifugal closed
Type
impeller
Number of Pump 1 set/unit
Design Pressure 284 kg/cm2
Design Temperature 359°C
Test Pressure 434.4 kg/cm2g
Operating temperature 287.3°C
Pump Design Capacity 890 m3/h
Total Head 110 m
Min. flow 100 m3/h
Pump Speed 1465 rpm
Suction Pressure at rated capacity 89.6 kg/cm2g
Discharge Pressure at rated capacity 97.1 kg/cm2g

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (Jaypee): Approved by (Jaypee):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR BCP Flushing
Revision No.: 00
Document No.: PMPL/SOP/54 Effective Date: Page 4 of 7
Revision Date:

Max. discharge pressure 289.6 kg/cm2g (Design Pressure)

Motor Data
Type HLV55/4EV38-335
Nominal rating 380 kw
Frequency 50 Hz
Voltage 3300 V
Nominal Current 92.1 A
Starting current 599 A
Motor trip temperature 65°C
Motor alarm temperature 60°C
Motor Cooler
Type Shell & Tube
Design conditions of Primary side
Cooled medium Boiler Water
Design temperature 90°C
Design pressure 289.6 kg/cm2g
Hydraulic test pressure 434.4 kg/cm2g
Design conditions of Secondary side
Cooled medium Cooling Water (Clean Water)
Design temperature 57°C
Design pressure 10 kg/cm2g
Hydraulic test pressure 15 kg/cm2g
Purge Cooler
Type Shell & Tube
Design conditions of Primary side
Cooled medium Boiler Water
Design temperature 359°C
Design pressure 339.56 kg/cm2g
Hydraulic test pressure 509.34 kg/cm2g
Design conditions of Secondary side
Cooled medium Cooling Water (Clean Water)
Design temperature 57°C
Design pressure 10 kg/cm2g
Hydraulic test pressure 15 kg/cm2g

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (Jaypee): Approved by (Jaypee):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR BCP Flushing
Revision No.: 00
Document No.: PMPL/SOP/54 Effective Date: Page 5 of 7
Revision Date:

Liquid Data
Liquid Temperature 287.3°C
Chemical Composition Boiler Water

5. Responsibility
Unit Control Engineer, Field Engineer and Desk Engineer.

6. Safety Precautions
Ensure no permit to work is pending on regarding this system by checking
with EE/MRSE.

7. Safety PPE’s: Ear Plugs, Safety Goggles, Hand Gloves, etc.

8. Special Tools/ Equipments: Nil

9. Pre checks And Action By Field Engineer

S No Description Ok Not Ok Remarks

1. No PTW is pending
Ensure that adequate quantity of DM water is
2.
available
3. Ensure one CCCW pump in service
Heat barrier CCCW inlet and outlet valves are
4.
open
Purge cooler inlet line valves and outlet valves are
5.
open
6. Ensure CCCW flow in return line view glass
Check that all the drains and vents in the systems
7.
are open
Check that the suction and discharge valves of
8.
BCP are open

10. Operating Procedure

Sl. No Description Ok Not Ok Remarks

1 Ensure all the pre start checks are satisfied
2 Line up the system as follows
3 Open CEP to BCP filling line MIV

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Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

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 STANDARD OPERATING PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SOP FOR BCP Flushing
Revision No.: 00
Document No.: PMPL/SOP/54 Effective Date: Page 6 of 7
Revision Date:

4 Close BFP to BCP filling line MIV and MOV

5 Open CEP line MIV near the BCP pump
6 Open inlet and outlet MIV’s of strainer
Open outlet MIV’s of heat barrier cooler and both
7
MIV’s at BCP motor bottom side
8 Open the drain MIV’s for flushing.
Start the condensate transfer pump and fill the
9
CEP discharge header through CEP priming line
10 When header is fully filled see that water is coming
from all the drains and vents of BCP cooling
system
11 Close all the drains in the system except flushing
drain MIV
12 Continuously monitor the pressure and
temperature of the system
13 Maintain the flushing flow about 5 lit/minute
14 Take the DM water sample and check the
conductivity after every 1 hour
15 When flushing water conductivity reaches to 0.6
µs/cm close all the open drains and stop the
flushing

11. Abbreviations / Notations

1. SOP: Standard Operating Procedure

2. UCE: Unit Control Engineer
3. DE: Desk Engineer
4. FE: Field Engineer
5. DCS: Distributed Control System
6. EE: Electrical Shift Engineer
7. MFT: Main Fuel Trip.
8. RB: Run Back

References
1. Torishima BCP O & M manual
2. Catalogue of boiler interlock & protection
3. BCP P & I Drawing
4. P & I for BCP Cooling system

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (Jaypee): Approved by (Jaypee):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head