A Desal SOP

Effective
Oct 2002
Q.E.W.C
Issued Date Revision Issued By

May 2003
Production/Operation
Page 1 of 320
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May 2003
RAF-A DESALINATION STANDARD OPERATION PROCEDURES

PART-D1 DISTILLERS
Page 2 of 320
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May 2003
TO VIEW ANY SOP CLICK ON ITS PAGE NUMBER. TITLE: DISTILLERS Serial no. 1 2 3 4
SOP No. D1-001 D1-002 D1-003 D1-004
DESCRIPTION INTER TRIP TEST SEQUENCE SEA WATER RECEIVING STARTING OF BRINE BLOWDOWN PUMP STARTING OF BRINE RECIRCULATION PUMP COOLING SEAWATER SUPPLY TO EJECTOR CONDENSERS WARMING UP OF EJECTOR STEAM LINE
Page No. 23 24 26 27
DI-005
29
D1-006
30
D1-007
VACUUM RAISING BY HOGGING EJECTOR.
31
D1-008
EJECTOR SWITCHING
32
D1-009
WARMINGUP OF BRINE HEATER STEAM LINE STEAM ADMISSION & STARTING OF CONDENSATE PUMP
33
10
D1-010
34
Page 3 of 320
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11 12 13 14 D1-011 D1-012 D1-013 D1-014

May 2003
Production/Operation 36 37 38 39
STARTING ANTISCALE & ANTIFOAM DOSING STARTING OF DISTILLATE EXTRACTION PUMP STARTING OF SECOND BRINE RECIRCULATION PUMP LOADING UP & STABILISATION
15
DI-015
STARTING OF HIGH PURITY DISTILLATE PUMP
40
16
D1-016
STARTING OF SEAWATER RECIRCULATION PUMP DISTILLER SHUTDOWN PROCEDURE PREPARATIONS LOAD REDUCTION
41
17
D1-017
42
18
D1-018
43
19
D1-019
DUMPING OF DISTILLATE & CUTTING OF STEAM

COLD CIRCULATION & SEALING OF PLANT VACUUM STOPPING COLD CIRCULATION & STARTING DRAINING STOPPING SEAWATER FLOW TO HJS
44
20
D1-020
45
21
D1-021
46
22
D1-022
47
23
D1-023
EMERGENCY SITUATIONS
48
Page 4 of 320
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24 25 26 27 D1-024 D1-025 D1-026 D1-027

May 2003
Production/Operation 49 51 52 54
SEAWATER SUPPLY FAILURE STEAM SUPPLY FAILURE INSTRUMENT AIR SUPPLY FAILURE TWO BRINE RECIRCULATION PUMPS TRIP
28
DI-028
TWO BRINE BLOWDOWN PUMPS TRIP TWO CONDENSATE OR DISTILLATE PUMPS FAILURE UNIT POWER SUPPLY FAILURE
55
29
D1-029
56
30
D1-030
57
31
D1-031
BLACKOUT
58
32
D1-032
OPERATIONAL CHECKS
59
33
D1-033
OPERATION OF EJECTORS AT PHASE I & III
60
34
D1-034
OPERATION OF EJECTORS AT PHASE II
65
35
D1-035
OPERATION OF EJECTORS AT PHASE IV
70
36
D1-036
OPERATION OF EJECTORS AT PHASE V
75
Page 5 of 320
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37 38 39 D1-037 D1-038 D1-039

May 2003
OPERATION OF CO2 RECOVERY SYSTEM IN PHASE I, II, & III STARTUP OPERATION OF CO2 RECOVERY SYSTEM IN PHASE I, II, & III SHUTDOWN OPERATION OF TAPROGGE SYSTEM PROCEDURE FOR FLUSHING WITH DISTILLATE WATER HEAT REJECTION SECTION FILLING METHOD FOR PHASE I, II, III, IV & V
80 81 82
40
DI-040
90
41
D1-041
91
42
D1-042
STARTING FLUSHING CIRCULATION FLUSHING OF HEAT RECOVERY & HEAT INPUT SECTIONS FILLING METHOD FOR PHASE V AND CIRCULATION FOR FLUSHING TUBE LEAK DETECTION HEAT REJECT SECTION TUBE LEAK DETECTION HEAT RECOVERY SECTION HYDROSTATIC TEST FOR TUBE LEAKS TUBE LEAK DETECTION IN PHASE II- HEAT REJECT SECTION TUBE LEAK DETECTION HEAT RECOVERY SECTION TUBE LEAK DETECTION HEAT REJECT SECTION PHASE IV
93
43
D1-043
94
44
D1-044
95
45
D1-045
97
46
D1-046
101
47
D1-047
102
48
D1-048
104
49
D1-049
105
Page 6 of 320
Effective
Oct 2002
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50 51 52 D1-050 D1-051 D1-052

May 2003
Production/Operation 107 108 109
TUBE LEAK DETECTION IN PHASE IV HEAT RECOVERY SECTION TUBE LEAK DETECTION IN PHASE V HEAT RECOVERY SECTION TUBE LEAK DETECTION IN PHASE V HEAT REJECT SECTION TUBE LEAK DETECTION IN BRINE HEATE IN ALL PHASES ACID CLEANING PROCEDURE - FILLING WITH SEAWATER ACID CLEANING PROCEDURE PREPARATION ACID CLEANING PROCEDURE STARTING CIRCULATION ACID CLEANING PROCEDURE WARMING UP
53
DI-053
111
54
D1-054
113
55
D1-055
114
56
D1-056
116
57
D1-057
117
58
D1-058
ACID CLEANING PROCEDURE ACID CHARGING ACID CLEANING PROCEDURE FLUSHING WITH SEA WATER ACID CLEANING PROCEDURE DRAINING
118
59
D1-059
119
60
D1-060
120
61
D1-061
BASIC ISOLATIONS FOR SPECIFIC PERMITS
121
62
D1-062
DISTILLER OVERHAUL PERMITS
134
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May 2003

PART-D2 BOILERS & DEAERATORS
Page 8 of 320
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63 64 65 GENERAL D2-001 D2- 002

May 2003
Production/Operation 138 141 143
WATER QUALITY OF H.P.MAKEUP AND CONDENSATE AND BOILER WATER STARTUP OF DEAERATOR SHUTDOWN OF DEAERATOR
66
D2-003
WHB PRESTARTUP CONDITIONS
144
67
D2-004
WHB STARTUP
145
68
D2-005
WHB SUPPLEMENTARY GAS FIRING
147
69
D2-006
WHB SHUTDOWN PROCEDURES
148
70
D2-007
AUX BOILER PRESTART CHECKS
149
71
D2-008
AUX BOILER STARTUP ON GAS
150
72
D2-009
AUX BOILER PRESTARTUP CHECKS FOR OIL
152
73
D2-010
AUX BOILER STARTUP ON OIL AUX BOILER FUEL CHANGEOVER FROM GAS TO OIL AUX BOILER FUEL CHANGEOVER FROM OIL TO GAS
153
74
D2-011
155
75
D2-012
156
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77 78 D2-013 D2- 014

May 2003
AUX BOILER SHUTDOWN PROCEDURE AUX BOILER PROCEDURE
157 158
79
D2-015
WHB WATER WEDGING PROCEDURE
159
80
D2-016
WHB DEWATERWEDGING PROCEDURE
160
81
D2-017
AUX BOILER WATER WEDGING PROCEDURE
161
82
D2-018
AUX BOILER DEWATERWEDGING PROCEDURE
162
83
D2-019
PTW & WHB PRESSURE PARTS
163
84
D2-020
PTW & WHB NON PRESSURE PARTS
164
85
D2-021
PTW & WHB FUEL GAS SYSTEM HIGH RISK SANCTION FOR WORK AT THE BOILER MECHANICAL & ELECTRICAL ISOLATIONS
165
86
D2-022
166
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May 2003

PART- D3 COMMON SERVICES
Page 11 of 320
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May 2003
87 88 89
GENERAL D3-001 D3-002
OPERATIONAL PROCEDURE COMPRESSED AIR SYSTEM COMPRESSOR STARTUP PROCEDURE COMPRESSOR SHUTDOWN PROCEDURE
169 170 172
90
D3-003
ISOLATION FOR PTW
173
91
D3-004
AIR DRIER OPERATION
174
92
D3-005
INDUSTRIAL WATER SYSTEM PROCEDURE FOR CHANGEOVER OF BOOSTER PUMP ISOLATION FOR PTW
176
93
D3-006
177
94
D3-007
179
95
D3-008
MAKEUP WATER SYSTEM
181
96
D3-009
BEARING COOLING WATER SYSTEM
185
Page 12 of 320
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May 2003

PART- D4 FIRE FIGHTING
Page 13 of 320
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May 2003
97 98 99
D4-001 D4-002 D4-003
ELECTRIC FIRE PUMPS A & B DIESEL FIRE PUMPS A & B ELECTRIC FIRE PUMP C
187 189 192
100
D4-004
DIESEL FIRE PUMP C FIRE MAIN PRSSURE SUSTAINING PUMPS A1, A2, B1 & B2 DELUGE SYSTEM TANK FARM
194
101
D4-005
196
102
D4-006
198
103
D4-007
SPRINKLER FIRE ALARM
200
104
D4-008
FIRE HYDRANTS SAMPLE OF H-1, H-17 & H- 27
202
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May 2003

PART- D5 BOP
Page 15 of 320
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May 2003
105 106 107 108
GENERAL D5-001 D5-002 D5-003
SEA WATER PUMPS OPERATIONS PRESTART CHECHS STARTING OF S.W.PUMP AT SWPH A STARTING OF S.W.PUMP AT SWPH B STARTING OF S.W.PUMP AT SWPH C
204 205 206 207
109
D5-004
S W PUMPS RUNNING CHECKS
208
110
D5-005
S W PUMP SHUTDOWN
209
111
D5-006
GT C.W PUMPS A & B
210
112
D5-007
BAND SCREENS A , B , C, D, & E
213
113
D5-008
WASHWATER PUMPS A & B
215
114
D5-009
BAND SCREENS & WASHWATER PUMPS F , G & H
217
115
D5-010
BAND SCREENS 2A & 2B CUMBERLAND ELECTROCHLORINATION STREAMS 1, 2 ,3 & 4 ELECTROCHLORINATION G , H & J
219
116 117
D5-011 D5-012
221 225
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118 D5-013

May 2003
ELECTROCHLORINATION K & L
227
119
D5-014
SCHEDULED CHANGEOVER OF EQUIPMENTS
230
120
D5-015
STARTUP OF RECARBONATION (DTP)
232
121
D5-016
STARTUP OF CO2 COMPRESSOR SYSTEM
233
122
D5-017
STARTUP CHLORINATION PLANT
234
123
D5-018
LIMESTONE FILTERS
235
124
D5-019
RECARBONATION PLANT SHUTDOWN
236
125
D5-020
ELECTROCHLORINATION PLANT SHUTDOWN
237
126
D5-021
FORWARDING PUMPS STARTUP
238
127
D5-022
FORWARDING PUMPS SHUTDOWN
239
Page 17 of 320
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May 2003

PART-D6 ELECTRICAL ISOLATIONS
128
GENERAL GENERAL GUIDE LINES Page 18 of 320
240
Effective
Oct 2002
Q.E.W.C
129 130 131 132 133 134

May 2003
Production/Operation 241 242 243 244 245 247
GENERAL GENERAL GUIDE LINES D6-001 D6-002 D6-003 D6-004 D6-005 ISOLATION OF 6.6KV VCB DEISOLATION OF 6.6KV VCB ISIOLATION OF 6.6KV DEISOLATION OF 6.6KV ISOLATION OF 415V ACB FOR WORK ON PUMP
135
D6-006
ISOLATION OF 415V ACB FOR WORK ON MOTOR ISOLATION OF 415V ACB FOR WORK ON MOTOR STARTER STARTER DEISOLATION OF 415V ACB AFTER WORK ON MOTOR ISOLATION OF 415V ACB AT STATION AUX BOARDS ISOLATION OF 415V ACB AT STATION AUX BOARDS FOR WORK ON MOTOR STARTER DEISOLATION OF 415V ACB AFTER WOPRK ON MOTOR STARTER SUPPLY CHANGING OVER FOR 415V DISTILLER BOARDS SUPPLY CHANGING OVER & RELEASING THE INCOMER AT PHASE I ,II, & III
248
136
D6-007
249
137
D6-008
250
138
D6-009
252
139
D6-010
253
140
D6-011
254
141
D6-012
255
142
D6-013
256
Page 19 of 320
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143 144 145 146 147 D6-014 D6-015 D6-016 D6-017 D6-018

May 2003
Production/Operation 264 265 273 274 275
NORMALISING THE INCOMING SUPPLY IN 415V DISTILLER BOARD SUPPLY CHANGING OVER & RELEASING THE INCOMER IN PHASSE - IV NORMALISING THE INCOMING SUPPLY IN PHASE IV 415V DISTILLER BOARDS SUPPLY CHANGING OVER IN DISTILLER BOARDS 13 & 14 SUPPLY CHANGING OVER IN STATION AUXILIARY BOARDS 7A, 7B, 8A & 8B NORMALISING THE INCOMING SUPPLY IN 415V STATION AUX BOARDS RELEASING OF 415V DISTILLER BOARDS FOR ANNUAL OVERHAUL RELEASING OF 415V DISTILLER BOARDS AT PHASE I, II, III & IV ELECTRICAL ISOLATION FOR OVERHAUL PERMIT OF DISTILLER -13 ELECTRICAL ISOLATION FOR OVERHAUL PERMIT OF DISTILLER -14 TAKING DISTILLER TRANSFORMER IN SERVICE AFTER COMPLETION OF MAINTENANCE ON TXR, OCB, & ACB INTERTRIP TEST SEQUENCE
148
D6-019
276
149
D6-020
277
150
D6-021
278
151
D6-022
279
152
D6-023
280
153
D6-024
282
154
D6-025
284
Page 20 of 320
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May 2003

PART-D7 EMERGENCY CONTINGENCY PROCEDURE
Page 21 of 320
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155 D7-001 BLACK OUT

May 2003
287
156
D7-002
OIL SLICK CONTINGENCY PLAN
289
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May 2003

PART-D1 DISTILLERS
Page 23 of 320
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SOP No

May 2003
TITLE: DISTILLERS
D1-001
ACTIVITY REFERENCE RESPONSIBILITY COMMUNICATION
DISTILLER START-UP PROCEDURE

DSCE/PERMIT ENGINEER/SUPERVISOR/DIST
Location OPERATION Field CCR/DCR
INTERTRIP TEST SEQUENCE
Prior to start-up, the following items are to be checked and confirmed. Piping connections are tightened, all related drain valves are closed and hogging ejector vapour suction valve is opened. Strainers are cleaned where applicable. Pump lubrication is adequate, cooling/flushing/sealing water is in service and pumps suction valves are opened. Instrument air is in service and control valves opening position match to controller output. All control valves are closed and their isolation valves are opened and the bypass valve is closed. All instrument devices are available and functioning. The chemicals are prepared in local day tanks and power supply for the mixer motors are turned ON at their circuit breakers. The 6.6 kV and 415V electrical supplies to the electrical equipment are available and the selectors on their circuit breakers are positioned in control room. Steam and seawater supplies are ready for service.
Page 24 of 320
* *
* *
* *
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Oct 2002
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SOP No

May 2003
TITLE: DISTILLERS
D1-002
ACTIVITY REFERENCE RESPONSIBILITY COMMUNICATION OPERATION
CCR/DCR/LOCAL DIST SPERVISORS CCR/DCR

Location Field CCR/DCR
Seawater Receiving Confirm that, all heat reject section water boxes vent isolation valves are opened and all drain isolation valves are closed. Open seawater reject TCV(SW-19FCV-102A/SW-2TCV005/SW-19FCV1002A/TCV104/QL-FV-604) by 15% for Phase I & III, also open seawater reject TCV by 15% for Phase II, IV & V. Gradually, open the S W main isolation valve (SW1/VSW-1/SW-1/SW-1/QL-MV-600) of the seawater inlet up to 25% (at Phase IV & V it is motorized valve, except distiller No. 10). When water boxes venting are completed and seawater to reject pressure indicator goes up to 2.7 barg or higher and becomes stable, gradually open seawater main isolation valve(SW-1/VSW-1/SW-1/SW-1/QL-MV-600)100%, then maintain the reject flow as required by TCV(SW-19FCV102A/SW-2TCV-005/SW-19FCV1002A/TCV104/QL-FV604) and close vent isolation valves of water boxes. Start Fe SO4 dosing at Phase IV. To start shell filling, confirm that hogging ejector vapour suction isolation valve (VA-11/VAE-1/VA-11/VA-11/LQPage 25 of 320 *
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Oct 2002
Q.E.W.C

May 2003
XV-793) is opened, and seawater make-up FCV(SW22,FCV012/VFW2,FCV-502/SW-22,FCV-012/FCV104/QL-V-619) isolation valves (U/S: SW-21/VFW-1/SW21/SW-2/QL-V-630 & D/S: -/VFW-3/-/QL-V-629) are opened and bypass isolation valve (SW-24/VFW-4/SW24/SW-4/QL-V-631) is closed. Open seawater make-up FCV (SW22,FCV012/VFW2,FCV-502/SW-22,FCV-012/FCV-104/ QL-V-619)as required to adjust the last stage level to the normal working level. At Phase IV, adjust seawater deaerator level by opening seawater make-up FCV(SW22,FCV012/VFW2,FCV-502/SW-22,FCV-012/FCV-104/ QL-V-619), and then adjust the last stage level by opening deaerator LCV(LCV-106). Start Na2 SO3 dosing at Phase IV; the dosing is in seawater make-up outlet line from seawater deaerator.
Page 26 of 320
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May 2003
TITLE: DISTILLERS SOP No
D1-003
CCR/DCR/LOCAL DIST SUPERVISORS CCR / DCR

Starting of Brine Blowdown Pump Confirm that: - BlowdownLCV(BD-8,LCV-001/VBD-8,LCV352/BD-8,LCV-001/LCV-103/QN-LV-752) isolation valves (U/S: BD-7/VBD-7/BD-7/BD85/QN-V-609& D/S: BD-8/VBD-8/BD-8/-/QN-V610) are opened and bypass isolation valve(BD10/VBD-10/BD-10/B-86/QN-V-611) is closed. - Blowdown pump suction isolation valve(BD-1,BD2/VBD-1,VBD-2/BD-1,BD-2/B-79,B-80/QN-V600,QN-V-605) and casing with suction vent isolation valves are opened. - Sealing/flushing water is in service.
Page 27 of 320
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May 2003
Production/Operation * *
Open Blow down discharge isolation valve(BD-5,BD6/VBD-5,VBD-6/BD-5,BD-6/B-81,B-82/QN-V-603,QNV-608) of blowdown pump upto 20% to fill up discharge line with seawater and open discharge vent isolation valve and then close the pump discharge isolation valve(BD5,BD-6/VBD-5,VBD-6/BD-5,BD-6/B-81,B-82/QN-V603,QN-V-608). When last stage level rises up to 80%, release E.P.B. Emergency Push Button then start the pump. Check the discharge pressure, and then open the discharge isolation valve (BD-5,BD-6/VBD-5,VBD-6/BD-5,BD-6/B81,B-82/QN-V-603,QN-V-608) and close the discharge vent isolation valve. Check the electric current, and make sure that there is no abnormal noise or vibration from the pump. Adjust FCV (seawater make-up) (SW22,FCV012/VFW2,FCV-502/SW-22,FCV-012/FCV-104/ QL-V-619) & LCV (BD-8,LCV-001/VBD-8,LCV352/BD-8,LCV-001/LCV-103/QN-LV-52)to keep last stage level around 90% and seawater make-up flow around 1000 t/hr. Open the discharge isolation valve (BD-5,BD-6/VBD5,VBD-6/BD-5,BD-6/B-81,B-82/QN-V-603,QN-V-608). of the other pump to make it in standby position for emergency auto changeover.
* * *
D1-004
CCR/DCR/LOCAL DIST SUPERVISORS CCR/DCR
Page 28 of 320
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Q.E.W.C
OPERATION

May 2003
Starting of One Brine Recirculation Pump & Establishing of Cold Circulation Confirm that: - Brine Pump suction isolation (B-3,B4/VBR1,VBR2/B-3,B4/B-1,B-2/QM-MV-600,QMMV604)valve is opened. - Suction(V-28,29/VVA-16,17/VA-28,29/B-V-4,8/ QQV-601,603), casing(Ph-1~4 N/A//QQV-600,602 ) and discharge (BD-52,53/N/A/BD-52,53/B-V1,2,5,6/QM-V-658,659,660 )vent valves are opened. - Sealing/flushing/cooling water is in service. - Oil level for thrust bearing and motor bearing, where applicable, are normal. - Opening & closing sequence of Brine pump discharge motorised valves (B-7/VBR-5/B-7/B3/QM-MV603 & B-8/VBR-6/B-8/B-4/QM-MV607). - Taprogge ball strainers are in backwash position. - Open emergency blowdown isolation valve (B9/VEB-1/B-9/B-7/--) or discharge motorised valve(B-7/VBR-5/B-7/B-3/QM-MV603 & B8/VBR-6/B-8/B-4/QM-MV-607). and FCV (recirculating brine at Phase I to IV) (B14,FCV-001/VBR-7,FCV-503/B-14FCV-107) up to 30% to fill up the discharge line with seawater, and then close the valves. Open vent isolation valves and close drain isolation valves of water boxes for heat recovery section and brine heater. Get clearance from the generation to start the brine recirculation pump. Open FCV (B-14,FCV-001/VBR-7,FCV-503/B-14FCVPage 29 of 320 * * * * * * * *
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May 2003
Production/Operation * * * *
107/QM-FV-666)(Isolation Valves U/S:B-13/NA/B13/NA/NA & D/S:B-15/NA/B-15/NA/NA)15%, release E.P.B. then start BRP-B and then open discharge motorised valve 100% for priming the water boxes. At Phase V the priming will be by the discharge motorised valve, and after priming the water boxes, open the motorised valve(B-7/VBR-5/B-7/B-3/QM-MV603 & B8/VBR-6/B-8/B-4/QM-MV-607). 100% and adjust the flow by FCV FCV (B-14,FCV-001/VBR-7,FCV-503/B14FCV-107/QM-FV-666). Check the discharge pressure and electric current, and make sure that there is no abnormal noise and vibration from the pump. Vent the discharge line, and keep the pump running under close observation. Open self-flushing isolation valve and isolate the industrial water at Phase IV. Close the water box vent valves after venting is completed. Adjust recirculating brine flow while maintaining first and last stage level. Start debris separator system at Phase I, III & V. Start Na2SO3 dosing at Phase I & III; the dosing is in the common discharge line of the brine recirculation pumps.
Page 30 of 320
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May 2003
D1-005

Cooling Seawater Supply to Ejector Condensers Open the cooling seawater main isolation valve (SW2/SW-7/SW-2/SW-8/QLV-618). Check seawater to vent condenser C/V (SW-6), its by-pass (SW-5) & Isolation Valves (U/S: SW-3, D/S: S/W-4) at Phase I & III. Confirm that seawater flow is established to each condenser and seawater pressure and the flow are normal.
* * *
Page 31 of 320
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May 2003
D1-006
CCR/DCR/LOCAL DIST SUPERVISOR CCR/DCR

Warming-Up of Ejector Steam Line Confirm that: - Steam trap isolation valves are closed. - Steam drain valves are opened. - Steam isolation valve (S-15/VHS-11/S-15/S10,11/--)(S-16/VHS-12/S-16/S-14,15/--) to each ejector is closed. Drain the accumulated water in vapour lines where applicable. Open steam to ejectors main isolation valve (S-13/S-13/LQ-MV-630) around 10% (at Phase I, III & V). Open the isolation valves (VHS-8/S-7,S-8) of PCV
Page 32 of 320
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May 2003
Production/Operation * * *
(VHS-7/PCV-101) (to ejectors) and close the bypass(VHS9/S-9) valve of PCV(VHS-7/PCV-101), and then open PCV(VHS-7/PCV-101) around 10% (at Phase II & IV). Open the equalising isolation valve of the steam unit isolation valve (U/S: S-8 (MOV)/VHS-1A/S-8 (MOV) /S1/LQ-MV-603, S-9/VHS-1B/S-9/S-3/NA. D/S:S12/A(MOV)/S-12/S-2/NA ) step by step, observing steam drainage. When water draining is reduced, open the trap isolation valves, and when steam draining is finished completely, close the drain bypass isolation valves. Open the steam unit isolation valve (S-8&9/S4002/S8&9/S-252/LQ-V-600) and then close the equalising isolation valve of steam unit isol. V/v(S-8&9/S4002/S8&9/S-252/LQ-V-600).
D1-007
CCR/DCR/DIST LOCAL SUPERVISORS CCR/DCR

Page 33 of 320
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Vacuum Raising by Hogging Ejector

May 2003
Confirm that: - All vent valves, drain valves, sampling valves connected to vacuum zone are closed. - Pump casing drain valves are closed. - Service ejectors are isolated. - Line up stage No. 1 & 2 vapour line to vent condenser at Phase I & III. Slightly open the hogging ejector steam isolation valve (S14/VHS-10/S-14/S-12/LQ-XV-777) to warm up the ejector, and when white smoke exhaust begins, slowly open the isolation valve to full open position. Confirm that pressure indicators go down to lower than 450 mbarA for the first 30 min, when the pressure indicator drops to 200 mbarA, switch over the ejector to service ejectors.
Line diagram of ' VACUUM SYSTEM '
* * * *
* *
D1-008
CCR/DCR/DIST LOCAL SUPERVISORS CCRDCR

Ejector Switching
Page 34 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
Confirm that each ejector exhaust isolation valves(VA14/NA/VA-14/VA-9/NA , VA-18/NA/VA-18/VA-14/NA, VA-22/NA/VA-22/NA/N/A ,VA-22/NA/VA-22/NA/NA) are opened. Close the hogging ejector vapour suction isolation valve (VA-11/VAE-1/VA-11/VA-11/LQ-XV-793) and then the steam isolation valve (S-14/VHS-10/S-14/S-12/LQ-XV777). Slowly open the steam isolation valve of the secondary ejector(S-17/VHS-11/S-17/S-13/LQ-XV-783, OR S18/VHS-12/S-18/S-14/LQ-XV-785) to full open position. Then open the vapour suction isolation valve(VA-16/VAE4/VA-16/VA-12/LQ-XV-798 OR VA-17/VAE-5/VA17/VA-13/LQ-XV-800) of the secondary ejector. Slowly open the steam isolation valve (S-15/VHS-11/S15/S-10/LQ-XV-779 OR S-16/VHS-12/S-16/S-11/LQXV-781)of the primary ejector to full open position. Then open the vapour suction isolation valve(VA-12/VAE2/VA-12/VA-7/LQ-XV-794 OR VA-13/VA-3/VA13/VA8/LQ-XV-796) of the primary ejector (at Phase I & III there are three stages service ejector). For more details refer to Operation of Venting System section. Confirm that pressure drop down approximately 30 mbar per 10 min, until reach 100 mbarA.
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D1-009
ACTIVITY

Page 35 of 320
Effective
Oct 2002
Q.E.W.C
REFERENCE RESPONSIBILITY COMMUNICATION OPERATION

May 2003

Warming-Up of Brine Heater Steam Line Confirm that: - Steam drain valves are opened. - PCV(s) (to brine heater) (S-10,TCV-071/VHS2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679) is closed. Slowly open the equalising valve(s) of PCV) (S-10,TCV071/VHS-2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679)up-stream isolation valve (S-8/VHS-1A,VHS-1B/S-8/S1,S3/LQMV603), when drain become hot, open the isolation valves of steam traps. As the steam exhaust from the drain valves becomes stronger, close the steam drain valves, and confirm that steam traps are functioning. Open PCV(S-10,TCV-071/VHS-2,TCV-004A; VHS2,TCV-004B/S-10,TCV-071/PCV-102A,PCV-102B/LQTV-679) up-stream isolation valve(s(S-8/VHS-1A,VHS-1B/S8/S1,S3/LQ-MV603), (motorised valve at Phase I, III & V), and close the equalising valve(s). Open PCV(S-10,TCV-071/VHS-2,TCV-004A; VHS2,TCV-004B/S-10,TCV-071/PCV-102A,PCV-102B/LQTV-679) Steam PCV down stream isolation valve(s) (S12/VHS-3,VHS-4/S-12/S-2,S-4/--) (motorised valve at Phase II & IV), and the steam trap isolation valves (at Phase V there is no down stream isolation valve).
Page 36 of 320
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Q.E.W.C

May 2003
D1-010

Steam Admission & Starting of Condensate Pump Line diagram of ' STEAM & CONDENSATE ' Confirm that: - Cooling water header isolation valve (HM-6/VCH19/HM-6/O-HM-287/LT-V-625) to the desuperheater is opened (H.P. make-up at Phase I to IV and condensate at Phase V), and isolation valves (U/S:C-16/VCH-15C-16/C-11LT-V-622 &D/S:C-18/VCH-17/C-18/C-12/LT-V-623)of LP. Steam TCV(C-17*TCV-073/VCH-16*TCV-009/C17/TCV-073/TCV-101/LT-TV-814), LCV(C11*LCV-003/VCH-8*LCV-354/C-11/LCV-003/ LCV-101/LT-LV-822) (brine heater), and CRV(C9/VCH-11/C-9/CRV-103-B/LT-XV-841) (condensate) are opened. - Brine heater vent to atmosphere valve is opened (at Phase V, vent line connected to seawater
Page 37 of 320
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Q.E.W.C

May 2003
deaerator vent header at start up only). - B.H LCV (C-11*LCV-003/VCH-8*LCV-354/C11/LCV-003/ LCV-101/LT-LV-822)(U/S:C10/VCH-7/C-10/C-7/LT-V-610)(D/S:C-12/VCH9/C-12/C-8/LT-V-611)(BY-PASSV/V:C-13/VCH10/C-13/C-9/LT-V-612)& TCV (C-17*TCV073/VCH-16*TCV-009/C-17/TCV-073/TCV101/LT-TV-814)are closed, and Condensate CRV(C-9/VCH-11/C-9/CRV-103-B/LT-XV-841) is in dump position. - Open LP. Steam TCV(C-17*TCV-073/VCH16*TCV-009/C-17/TCV-073/TCV-101/LT-TV814) up to 10% and PCV(S-10,TCV-071/VHS2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679) step by step and atomising steam to desuperheater at Phase V only.
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To start the condensate pump, confirm that: - Pump suction valves(C-1/VCH-1/C-1/C-1/LT-V600 &C-2VCH-2/C-2/C-2/LT-V-605), vent valves & Dump V/V(C-8//C-8/NA/LT-V-627) are opened. - Sealing/flushing/cooling water is in service. - Bearing oil level is normal at Phase IV & V.
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* *
Fill up the pump casing. Start the pump, and then open the discharge valve (C5/VCH-5/C-5/C-5/LT-V-603) OR(C-6VCH-6/C-6/C-6LTV-608) very slowly . Check discharge pressure and electric current, and vent the discharge line. Open the discharge valve(C-5/VCH-5/C-5/C-5/LT-V-603) OR(C-6VCH-6/C-6/C-6LT-V-608) of the other pump to make it in standby position for emergency auto changeover. Adjust the level of the brine heater by LCV(C-11*LCVPage 38 of 320
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May 2003
003/VCH-8*LCV-354/C-11/LCV-003/ LCV-101/LT-LV822). Continuous Load Up Increase steam supply to the brine heater step by step, at the same time increase the brine recirculation rate. Confirm that: - Brine temperature rising rate must be less than 20 o C per hour (to prevent the thermal damage to the B. H. tubes). - Brine pressure at the brine heater inlet must be higher than the saturated vapour pressure at its temperature (to prevent flashing in the tube, which will cause scale formation and hammering). When condensate conductivity drops down to 2.5 S/cm, retain(V/V.NO:C-11/VCH-12/C-11/CRV-103-A/LT-XV840) the condensate to the condensate header (V/V. NO:C-22/VCH-12/C-14/C-22/LT-XV-614) and to desuperheating system (V/V. NO:-C-20/VCH14/C-20/C-10/LT-V-620)
D1-011 Page 39 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
LOCAL DIST SUPERVISOR CCR/DCR

Starting Antiscale & Antifoam Dosing Line diagram of ' ANTI SCALE & ANTI FOAM ' Confirm that: - Tanks are filled with chemical and they have proper concentration. - All valves in suction and discharge are opened. - Suction strainers are cleaned. - Accumulator gas pressure is adequate. Open the accumulator isolation valves, and open the accumulator drain valves to vent the pumps casing then close them. Start the chemical dosing pumps. Check the discharge pressure and the electric current. Adjust the pumps stroke dial according to the lab instruction.
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D1-012 Page 40 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
CCR/DCR/LOCAL DIST SUPERVISORS CCR/DCR/TCC

Starting of Distillate Extraction Pump Line diagram of ' DISTILLATE ' Confirm that: - The pump suction isolation valves(DP-1/VDM1/DP-2/DP-2/QQ-V-600 &DP-2/VDM-2/DP-2/DP2QQ-V-604) and casing vent isolation valve is opened. - Sealing/flushing water is in service. - The pump casing is filled up with water by checking temperature of pump casing. - The isolation valves(U/P:DP-10/VDM-7/DP10/DP-7/QQ-V-780&D/S:DP-12/VDM-9/DP12/DP-8/QQ-V-781) of LCV (DP-11*LCV002/VDM8*LCV-353/DP-11*LCV-002/LCV104/QQ-LV-702)and CRV (DP-8/VDM-12/DP8/CRV-101-B/QQ-XV-719) (distillate) are opened - Distillate LCV(DP-11*LCV-002/VDM8*LCV353/DP-11*LCV-002/LCV-104/QQ-LV702)Distillate Retain C/V(VDM-11/CRV-101A/QQ-XV-718)andC/V By-pass (DP-13/VDM10DP-13/DP-9/QQ-V-782) are closed and Distillate dump CRV(DP-8/VDM-12/DP-8/CRV101-B/QQ-XV-719)Iso. V/v.(DP-7,DP-9/ TAG No. N/A/DP-7/N/A/QQ-V-637) is in dump position. When the distillate level comes up, release the E.P.B., and then start the distillate extraction pump.
Page 41 of 320
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Q.E.W.C

May 2003
Close casing vent valve, check the discharge pressure and electric current then o pen discharge isolation valve(DP-5,DP-6/VDM-5,VDM6/DP-5,DP-6/DP-5,DP-6/QQ-V-603,QQ-V-607) and vent discharge line. Open the discharge valve (DP-5,DP-6/VDM-5,VDM6/DP-5,DP-6/DP-5,DP-6/QQ-V-603,QQ-V-607) and casing vent valve of the other pump to make it in standby position for emergency auto changeover. Open LCV(DP-11*LCV-002/VDM8*LCV-353/DP11*LCV-002/LCV-104/QQ-LV-702), and adjust the distillate level to the working level. When distillate conductivity goes down to acceptable limit, retain the distillate to the distillate header.V/V.NOS:(VDM-13/DP-26/DP-105/QQ-V-608) OR (DP-25/DP106)Iso. V/v Sleeper way (DP-14/DP-13/DP-14/NA/NA).
D1-013

Starting of Second Brine Recirculation Pump When the top brine temperature reach 102 oC, start preparation for starting BRP-A.
Page 42 of 320 *
Effective
Oct 2002
Q.E.W.C

May 2003
Confirm that: - Pump suction isolation valve (B-3/VBR-1/B-3/B1/QM-MV-600) is opened. - Suction, (V-28,29/VVA-16,17/VA-28,29/B-V-4,8/QQ-V601,603 ), casing (Ph-1~4 N/A// QQ-V-600,602) and discharge vent valves (BD-52,53/N/A/BD-52,53/B-V1,2,5,6/QM-V-658,660 ) are opened. - Sealing/flushing/cooling water is in service. Oil level for thrust bearing and motor bearing where applicable is normal. Get clearance from the generation to start the brine recirculation pump. Release E.P.B. and then start the pump, close the casing vent valve and open motorised discharge valve(B-7/VBR5/B-7/B-3/QM-MV-603). Check the discharge pressure and electric current, and make sure that there is no abnormal noise and vibration from the pump.
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D1-014

Page 43 of 320
Effective
Oct 2002
Q.E.W.C
Loading Up & Stabilisation

May 2003
Continuously increase the output of PCV(S-10,TCV071/VHS-2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679) (steam to brine heater) with the corresponding value of brine flow, until reaching the target values. Once the target condition is achieved, all interlocks to be restored where applicable and controllers to be put on auto mode. After the process is stabilised, start taprogge system. Line up CO2 vent gas to compressor at Phase I, II, III & V.
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D1-015
Page 44 of 320
Effective
Oct 2002
Q.E.W.C
OPERATION

May 2003
Starting of High Purity Distillate Pump After the process is stabilised, start preparation for starting the H.P. distillate pump. Confirm that: - The pumps suction isolation valves(HD-1/VDH1/HD-1/HD-1/QQ-V-615),(HD-2/VDH-2/HD2/HD-2/QQ-V-618)&(HD-3/VDH-3/HD-3/HD3/QQ-V-610) are opened. - Sealing/flushing water is in service. - Isolation valves(U/S:NA/VDH-10/NA/HD-10/QQV-621)(D/S:NA/VDH-12/NA/NA/QQ-V-622) of CRV (HD-13/VDH-11/HD-13/NA/QQ-FV-734)for H.P. Distillate are opened and CRV(HD-14/VDH14/HD-14/CRV-101-B/QQ-XV-788) is in dump position. Though the selection of the pump to operate depends on the demand of H.P. distillate. It is recommended at start up to run each pump for 10 minutes to replace the water stored in suction piping and pump casing. This operation is effective to reduce the conductivity quickly. Select the flow transmitter according to pump selection at Phase IV. Start the pump and open the discharge valve(HD-7/VDH7/HD-7/HD-4/QQ-V-617)OR(HD-8/VDH-8/HD-8/HD5/QQ-V-620)OR(HD-9/VDH-9/HD-9/HD-6/QQ-V-612). Vent the discharge line completely during suction water replacing. Check the electric current. When H.P. distillate conductivity drops down to less than 2.5 S/cm, you can retain(V/V NO:HD-16/VDH-15/HD-16/CRV102-A/QQ-XV-788) it to the H.P. distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD-17/HD-51/QQ-V-641)
Page 45 of 320
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Q.E.W.C
SOP No

May 2003
TITLE: DISTILLERS
D1-016

Starting of Seawater Recycle Pump To control seawater inlet temperature during winter, seawater recycle pump is put in service. Confirm that: - Pump suction valve(SW-38/VSW-3/SW-38/SW5/QL-V-610),discharge valve (SW-15/NA/SW15/SW-7/NA) and casing vent valve(SW-V-1/VVA-9/SW-V-1/SW-V-2/N/A ) are opened. - Sealing/flushing water is in service. - The pump casing is filled up with seawater. - The isolation valve (SW-18/NA/SW18/TagNo.NA/NA)of seawater reject TCVB (SW26*FCV-1002-B/NA/SW-26*FCV-1002B/NA/NA)and down stream isolation valve(SW17/VSW-6/SW-17/SW-7/QL-V-620) of seawater recycle TCV(SW-16*TCV-066/VSW-5*HI010/SW-16/TCV-066/TCV-103/QL-TV-605) are opened at Phase I & III. - Bearing oil level is normal at Phase IV. Get clearance from the generation to start the pump at Phase IV only. If S.W.Recycle flow become less than 2500 m3/hr (phase-iv) pump to be stopped as
Page 46 of 320
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Effective
Oct 2002
Q.E.W.C

May 2003
recommended by manufacturer. Release E.P.B. and start the pump. Check the discharge pressure and electric current, and make sure that there is no abnormal noise and vibration from the pump. Adjust the seawater flow by opening seawater recycle TCV(SW-16*TCV-066/VSW-5*HI-010/SW-16/TCV066/TCV-103/QL-TV-605). Close seawater reject TCVA (SW-19*FCV-1002-A/ SW-19*FCV1002-A) and open TCVB (SW-26*FCV-1002-B/ SW-26*FCV1002-B) at Phase I & III.
D1-017
DISTILLER SHUTDOWN PROCEDURE

Preparations for Shutdown The normal shutdown should be carried out according to the guidelines provided in this section. Stop the operation of ball tube cleaning system and set it for ball collection and inform lab. Turn CRV (H.P. Distillate) (HD-14/VDH-14/HD-14/CRV101-B/QQ-XV-788) to dump position if it is on retaining position. Stop H.P. distillate pump, and Isolate the header (ISO.V/V. NO:HD-17/TagNo. NA/HD-17/HD-51/QQ-V641).
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Q.E.W.C
controllers to be put on manual mode.

May 2003
Interlocks to be cancelled where applicable and the
D1-018
CCR/DCR/DIST LOCAL SUPERVISORS CCR/DCR

Load Reduction Reduce brine recirculation flow and steam supply by closing FCV(B-14,FCV-001/VBR-7,FCV-503/B-14FCV107/QM-FV-666) & PCV (S-10,TCV-071/VHS-2,TCV004A; VHS-2,TCV-004B/S-10,TCV-071/PCV102A,PCV-102B/LQ-TV-679) step by step. Brine top temperature reducing rate must be kept less than 20 oC/hr, and brine recirculation flow should be decreased in a way so that first stage brine level be constant.
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Q.E.W.C

May 2003
When top brine temperature is reduced to 102 oC, shut down BRP-A by following normal procedure. Close CO2 vent gas isolation valve(CO-1001A,B/CO1001C,D,E,F/CO1001G,H/N/A//QG-V-635) to the CO2 recovery system. Turn CRV (condensate) (C-9/VCH-11/C-9/CRV-103B/LT-XV-841 to dump position when conductivity of condensate increases, then close LCV (brine heater) (C11*LCV-003/VCH-8*LCV-354/C-11/LCV-003/ LCV101/LT-LV-822), and line up the cooling water to desuperheater (HM-6/VCH-19/HM-6/O-HM-287/LT-V625) from the H.P. make-up header (from condensate header at Phase V), then isolate condensate header (V/V. NO:-C-22/VCH-12/C-14/C-22/LT-XV-614) .
D1-019
CCR/DCR/LOCAL SUPERVISORS CCR/DCR

Page 49 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
Dumping of Distillate & Cutting of Steam When distillate conductivity increases, turn CRV (distillate) CRV(DP-8/VDM-12/DP-8/CRV-101-B/QQXV-719)Iso. V/v.(DP-7,DP-9/ TAG No. N/A/DP7/N/A/QQ-V-637) to dump position and isolate distillate header.V/V.NOS:-(VDM-13/DP-26/DP-105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP-14/DP13/DP-14/NA/NA).. Stop seawater recycle pump if it is running. When brine recirculation temperature become lower than 60 oC, cut steam to brine heater, then close isolation valves (up-stream isolation valve()s(S-8/VHS-1A,VHS-1B/S8/S1,S3/LQ-MV603)down stream(S-12/VHS-3,VHS-4/S12/S-2,S-4/--), of PCV(s)(S-10,TCV-071/VHS-2,TCV004A; VHS-2,TCV-004B/S-10,TCV-071/PCV102A,PCV-102B/LQ-TV-679) and stop the chemical dosing pumps. Close TCV (C-17*TCV-073/VCH-16*TCV-009/C17/TCV-073/TCV-101/LT-TV-814) Cooling water header isolation valve (HM-6/VCH-19/HM-6/O-HM-287/LT-V625) and TCVs isolation valves(U/S:C-16/VCH-15C16/C-11LT-V-622 &D/S:C-18/VCH-17/C-18/C-12/LT-V623) ( Isolate H.P. make-up header in Phase1- 4 and in Phase V isolate condensate header). Stop condensate pump at brine heater shell level around 55%. When distillate flow falls down, close LCV (distillate) (DP-11*LCV-002/VDM8*LCV-353/DP-11*LCV002/LCV-104/QQ-LV-702), then stop distillate extraction pump. Slowly decrease the flow of the seawater make-up.
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Page 50 of 320
Effective
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Q.E.W.C

May 2003
D1-020

Cold Circulation & Sealing of Plant Vacuum Keep the recirculation until top brine temperature and bottom brine temperature become equal to seawater makeup temperature. Seal plant vacuum and then close the steam isolation valves of the ejectors(S-15,17,19,16,18,20/VHS11A,11B/S-15,17,19,16,18,20/S-10,S13,S-11,S-14/LQXV-779,783,781,785). Close steam to ejector PCV(VHS-7/PCV-101) and its isolation valves at Phase II & IV, and close the ejector steam main isolation valve(VHS-8/S-7,S-8). Close steam to ejector main isolation valve at Phase I, III & V. steam to ejectors main isolation valve (S-13/S-13/LQ-MV-630) Close the steam unit valve (S-8&9/S4002/S-8&9/S252/LQ-V-600), confirm that its equalizers valve is completely closed.
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Page 51 of 320
Effective
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Q.E.W.C

May 2003
D1-021

Stopping of Cold Circulation & Starting of Draining Release plant vacuum by slowly opening the suction valve (VA-11/VAE-1/VA-11/VA-11/LQ-XV-793)of hogging ejector to full open position. Stop debris separator at Phase I, III & V. Stop feeding seawater make-up. Stop Na2 SO3 dosing. Close the discharge motorised valve of BRP-B(B-8/VBR6/B-8/B-4/Q-M-MV-607) and stop the pump. Open the vent valves and the drain valves of the water boxes of HRS and brine heater, avoid overflow. Close LCV (brine blowdown) (BD-8,LCV-001/VBD8,LCV-352/BD-8,LCV-001/LCV-103/QN-LV-52)when shell level is minimum, and stop brine blowdown pump. Open blowdown LCV ((BD-8,LCV-001/VBD-8,LCV352/BD-8,LCV-001/LCV-103/QN-LV-752)and its bypass isolation valve(BD-10/VBD-10/BD-10/B-86/QN-V-611),
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May 2003
also open all drain valves related to brine shell for natural draining. Open emergency blowdown valve (B-9/VEB-1/B-9/B-7/--) for faster draining of water boxes and tube bundles at Phase I to IV. Drain out distillate channel, if it is required.
D1-022

Stopping of Seawater Flow to HJS Close the cooling seawater main isolation valve (SW2/SW-7/SW-2/SW-8/QLV-618) to ejector condensers. Close the seawater main isolation valve (motorised valve at Phase IV & V (SW-1/VSW-1/SW-1/SW-1/QL-MV600), and stop Fe SO4 dosing at Phase IV. Open the vent valves and the drain valves of the water boxes of HJS, avoid overflow.
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Effective
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Q.E.W.C

May 2003
D1-023
CCR/DCR/LOCAL DIST SUPERVISORS DSCE/PERMIT ENGINEER/CCR/DCR
Plant emergency can be classified in to two categories depending on the status of the brine recirculating pumps during the emergency. The first one is that one of the pumps can be operated, in this case the load should be reduced, then the plant should be put in cold running. The second one is that the pump can not be operated in this case the plant should be shut down completely.
Page 54 of 320
Effective
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Q.E.W.C

May 2003
D1-024
DSCE/PERMIT ENGINEER/CCR/DCR/LOCAL DIST SUPERVISORS CCR/DCR

Seawater Supply Failure When interlock is cancelled or not available, plant will continue to run in case of seawater supply failure. Cut steam to ejectors (S-15,17,19,16,18,20/VHS11A,11B/S-15,17,19,16,18,20/S-10,S13,S-11,S-14/LQXV-779,783,781,785). , open the water boxes vent valves of the heat reject section and stop seawater recycle pump, if it is running. Cut steam to brine heater PCV (S-10,TCV-071/VHSPage 55 of 320 * * * *
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May 2003
Production/Operation * * * *
2,TCV-004A; VHS-2,TCV-004B/S-10,TCV-071/PCV102A,PCV-102B/LQ-TV-679) , close ejectors vapour section isolation valves(VA-12,VA13/VAE-2,VAE-3/VA12,VA13/VA-7,VA-8,LQ-XV-794,LQ-XV-796), isolate the main steam supply line (S-8&9/S4002/S-8&9/S252/LQ-V-600), and then depressurise it. Close the seawater main isolation valve (SW-1/VSW1/SW-1/SW-1/QL-MV-600), and close the cooling seawater to ejector condensers isolation valve (SW-2/SW7/SW-2/SW-8/QLV-618). . Close LCV (condensate) (C-11*LCV-003/VCH-8*LCV354/C-11/LCV-003/ LCV-101/LT-LV-822)(U/S:C10/VCH-7/C-10/C-7/LT-V-610) & TCV (cooling water to super heater) (C-17*TCV-073/VCH-16*TCV-009/C17/TCV-073/TCV-101/LT-TV-814). Turn CRV (C9/VCH-11/C-9/CRV-103-B/LT-XV-841) to dump position and stop condensate pump and isolate the headers (V/V. NO:-C-22/VCH-21/C-22/ Tag No N/A /LT-XV-614) . Brine shell level to be maintained by stopping brine blowdown pump and keeping the plant run in closed circulation. Turn CRV (HD-14/VDH-14/HD-14/CRV-101-B/QQ-XV788) to dump position of H.P. distillate. Stop the operation of ball tube cleaning system and set it for ball collection. Reduce the brine recirculation flow then shut down one brine recirculation pump. Turn CRV CRV(DP-8/VDM-12/DP-8/CRV-101-B/QQXV-719)Iso. V/v.(DP-7,DP-9/ TAG No. N/A/DP7/N/A/QQ-V-637) to dump position of distillate when conductivity becomes high. Close LCV (distillate) (DP-11*LCV-002/VDM8*LCV353/DP-11*LCV-002/LCV-104/QQ-LV-702),and stop distillate extraction & H.P. distillate pumps, then isolate the headers V/V.NOS:-(VDM-13/DP-26/DP-105/QQ-VPage 56 of 320
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Effective
Oct 2002
Q.E.W.C

May 2003
608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP14/DP-13/DP-14/NA/NA) H.P. distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD-17/HD-51/QQ-V-641) .. Follow normal shutdown completion work.
D1-025 Page 57 of 320
Effective
Oct 2002
Q.E.W.C

May 2003

Steam Supply Failure Isolate the main steam supply line (S-8&9/S4002/S8&9/S-252,254,256,258/LQ-V-600),, close ejectors steam isolation valves(S-15,17,19,16,18,20/VHS-11A,11B/S15,17,19,16,18,20/S-10,S13,S-11,S-14/LQ-XV779,783,781,785). and the vapour section isolation valves(VA-12,VA13/VAE-2,VAE-3/VA-12,VA13/VA7,VA-8,LQ-XV-794,LQ-XV-796),, and then depressurise the isolated sections. Close LCV (condensate) (C-11*LCV-003/VCH-8*LCV354/C-11/LCV-003/ LCV-101/LT-LV-822)(U/S:C10/VCH-7/C-10/C-7/LT-V-610)& TCV (cooling water to super heater) (C-17*TCV-073/VCH-16*TCV-009/C17/TCV-073/TCV-101/LT-TV-814), turn CRV (C-9/VCH11/C-9/CRV-103-B/LT-XV-841) to dump position, and stop condensate pump and isolate the headers(V/V. NO:C-22/VCH-21/C-22/ Tag No N/A /LT-XV-614). Turn H.P CRV (HD-14/VDH-14/HD-14/CRV-101-B/QQXV-788) to dump position of H.P. distillate. Stop the operation of ball tube cleaning system, and set it for ball collection. Reduce the brine recirculation flow and proceed to shut down one brine recirculation pump. Turn Dist. CRV (DP-8/VDM-12/DP-8/CRV-101-B/QQXV-719) to dump position of distillate when conductivity
Page 58 of 320
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Effective
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Q.E.W.C

May 2003
becomes high. Close LCV (distillate) (DP-11*LCV-002/VDM8*LCV353/DP-11*LCV-002/LCV-104/QQ-LV-702),and stop distillate extraction & H.P. distillate pumps, then isolate the headers distillate header.V/V.NOS:-(VDM-13/DP26/DP-105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP-14/DP-13/DP-14/NA/NA).& H.P. distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD17/HD-51/QQ-V-641) Keep the plant on cold circulation or follow normal shut down completion work.
D1-026
DSCE/PERMIT ENGINEER/CCR/DCR/DIST SUPERVISORS CCR/DCR

Instrument Air Supply Failure In case of instrument air supply failure, each control valve will performs in accordance with fail safe operation as shown below. Plant can no more be kept on continuous operation.
Fail safe operation of control valves are as following: TCV (cooling water to desuper heater) (HM-6/VCHPage 59 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
19/HM-6/O-HM-287/LT-V-625) full open. TCV (SEAWATER RECIRCULATION) TCV(SW16*TCV-066/VSW-5*HI-010/SW-16/TCV-066/TCV103/QL-TV-605) CLOSE TO MINIMUM FLOW. TCV (SEAWATER TO REJECT) (SW-19FCV102A/SW-2TCV-005/SW-19FCV1002A/TCV104/QLFV-604) LOCKED & TAGGED. LCV (condensate) (C-11*LCV-003/VCH-8*LCV-354/C11/LCV-003/ LCV-101/LT-LV-822)(U/S:C-10/VCH-7/C10/C-7/LT-V-610) locked & tagged. LCV (brine blowdown) (BD-8,LCV-001/VBD-8,LCV352/BD-8,LCV-001/LCV-103/QN-LV-52)locked & tagged. LCV (distillate) (DP-11*LCV-002/VDM8*LCV-353/DP11*LCV-002/LCV-104/QQ-LV-702),locked & tagged. LCV (S/W M/U from deaerator to last stage) (LCV106)full open at Phase IV PCV (steam to ejector)(VHS-7/PCV-101) full close at Phase II & IV. PCV (steam to brine heater) PCV (S-10,TCV-071/VHS2,TCV-004A; VHS-2,TCV-004B/S-10,TCV-071/PCV102A,PCV-102B/LQ-TV-679) full close. FCV (SW-22,FCV012/VFW2,FCV-502/SW-22,FCV012/FCV-104/QL-V-619) (seawater make up) full close. FCV (brine recirculation) FCV(B-14,FCV-001/VBR7,FCV-503/B-14FCV-107/QM-FV-666) locked & tagged. CRV (distillate) (DP-8/VDM-12/DP-8/CRV-101-B/QQXV-719) dump. CRV (H.P. distillate) (HD-14/VDH-14/HD-14/CRV-101B/QQ-XV-788) dump. CRV (C-9/VCH-11/C-9/CRV-103-B/LT-XV-841) (condensate) dump. Isolate the steam line to brine heater PCV(S-10,TCV071/VHS-2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679) up-stream isolation valve(s(S-8/VHS-1A,VHS-1B/S-8/S1,S3/LQ-MV603), Steam PCV down stream isolation valve(s) (S-12/VHSPage 60 of 320
* * *
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Effective
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Q.E.W.C

May 2003
3,VHS-4/S-12/S-2,S-4/--) . Stop the operation of ball tube cleaning system, and set it for ball collection. Keep the brine recirculation with one BRP by adjusting brine FCV (B-14,FCV-001/VBR-7,FCV-503/B-14FCV107/QM-FV-666) manually or by its bypass isolation valve(B-16/NA/B-16/NA/NA) if available, and keep ejectors system in service for cooling down the recirculating brine (at Phase II & IV maintain steam to ejector through PCV bypass line)(VHS-9/S-9). Maintain Brine shell level by adjusting blowdown LCV (BD-8,LCV-001/VBD-8,LCV-352/BD-8,LCV-001/LCV103/QN-LV-52) and seawater make-up FCV (SW-22,FCV012/VFW2,FCV502/SW-22,FCV-012/FCV-104/ QL-V-619) manually or by adjusting their bypass isolation valve(SW-24/VFW4/SW-24/SW-4/QL-V-631). Stop seawater recycle pump if it is running, and stop condensate pump, H. P. distillate pump and distillate extraction pump then isolate the headers Condensate Header(V/V. NO:-C-22/VCH-21/C-22/ Tag No N/A /LTXV-614) H.P. distillate header (ISO.V/V. NO:HD17/TagNo. NA/HD-17/HD-51/QQ-V-641) distillate header.V/V.NOS:-(VDM-13/DP-26/DP-105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP-14/DP13/DP-14/NA/NA).. After performing the above, follow normal shutdown completion work. After the instrument air supply restoration, all control valves should be checked for full operations.
Page 61 of 320
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Q.E.W.C

May 2003
D1-027
DSCE/PERMIT ENGINEER/CCR/DCR/DIST LOCAL SUPERVISORS CCR/DCR

Page 62 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
Two Brine Recirculation Pumps Trip When interlock is cancelled or not available, the other pumps will continue to run in case of two BRPs trip. Isolate the steam line to brine heater PCV(S-10,TCV071/VHS-2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679) up-stream isolation valve(s(S-8/VHS-1A,VHS-1B/S-8/S1,S3/LQ-MV603), Steam PCV down stream isolation valve(s) (S-12/VHS3,VHS-4/S-12/S-2,S-4/--). - Open the water boxes vent valves of heat recovery section and close discharge motorised valves of BRPs(B-7/VBR-5/B-7/B-3/QM-MV603 & B8/VBR-6/B-8/B-4/QM-MV-607). . Stop the ball tube cleaning system, if it is running. Isolate the main steam supply line (S-8&9/S4002/S-8&9/S252/LQ-V-600),, close ejectors steam isolation valves(S15,17,19,16,18,20/VHS-11A,11B/S-15,17,19,16,18,20/S10,S13,S-11,S-14/LQ-XV-779,783,781,785). and the vapour section isolation valves(VA-12,VA13/VAE2,VAE-3/VA-12,VA13/VA-7,VA-8,LQ-XV-794,LQ-XV796),, and then depressurise the isolated sections.. Close LCV (condensate) (C-11*LCV-003/VCH-8*LCV354/C-11/LCV-003/ LCV-101/LT-LV-822)(U/S:C10/VCH-7/C-10/C-7/LT-V-610) & TCV (cooling water to desuper heater) (HM-6/VCH-19/HM-6/O-HM-287/LT-V625), turn CRV (C-9/VCH-11/C-9/CRV-103-B/LT-XV841) to dump position, and stop condensate pump then isolate the headers(V/V. NO:-C-22/VCH-21/C-22/ Tag No N/A /LT-XV-614). Turn CRV to dump position of distillate (DP-8/VDM12/DP-8/CRV-101-B/QQ-XV-719) and H.P. distillate (HD-14/VDH-14/HD-14/CRV-101-B/QQ-XV-788). Close LCV (distillate) (DP-11*LCV-002/VDM8*LCV353/DP-11*LCV-002/LCV-104/QQ-LV-702), and stop distillate extraction & H.P. distillate pumps then isolate the headers distillate header.V/V.NOS:-(VDM-13/DP-26/DPPage 63 of 320
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Effective
Oct 2002
Q.E.W.C

May 2003
105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP-14/DP-13/DP-14/NA/NA). H.P. distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD-17/HD-51/QQ-V641). Close LCV (blowdown) (BD-8,LCV-001/VBD-8,LCV352/BD-8,LCV-001/LCV-103/QN-LV-52)and stop brine blowdown pump. Make sure to leave the level in the brine shell at the working level. After performing the above, follow normal shutdown and complete the work.
D1-028
DSCE/PERMIT ENGINEER/CCR/DCR/DIST LOCAL SUPERVISORS CCR/DCR

Page 64 of 320
Effective
Oct 2002
Q.E.W.C
Two Brine Blowdown Pumps Failure

May 2003
Open emergency blowdown isolation valve (B-9/VEB-1/B9/B-7/--) and continue on-load operation. Attention to be paid to the brine recirculation pump motor load. Operating under this condition should not be for long time, because of abnormal brine blowdown; the concentration of brine will increase with the time.
D1-029

Page 65 of 320
Effective
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Q.E.W.C

May 2003
Two Condensate or Distillate Extraction Pumps Failure Load-down followed by cold run is to be applied.
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D1-030

Page 66 of 320
Effective
Oct 2002
Q.E.W.C
Unit Power Supply Failure

May 2003
Unit power supply failure will cause BRP-A and all 415V pumps to trip and the motorised valves will not function. If the power supply cant be restored immediately, plant to be de-loaded and put on cold circulation with BRP-B. Cut steam to brine heater PCV (S-10,TCV-071/VHS2,TCV-004A; VHS-2,TCV-004B/S-10,TCV-071/PCV102A,PCV-102B/LQ-TV-679) and isolate the steam to brine heater line. - Close discharge valve of BRP-A (B-7/VBR-5/B7/B-3/QM-MV603 )manually. Isolate all headers; distillate header.V/V.NOS:-(VDM13/DP-26/DP-105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP-14/DP-13/DP-14/NA/NA); H.P. distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD17/HD-51/QQ-V-641);Condensate Header (V/V. NO:-C22/VCH-21/C-22/ Tag No N/A /LT-XV-614).. Keep circulation with BRP-B and maintain the last stage brine level through emergency blowdown line (B-9/VEB1/B-9/B-7/--) and blowdown LCV (BD-8,LCV-001/VBD8,LCV-352/BD-8,LCV-001/LCV-103/QN-LV-52). When circulated brine temperature becomes close to seawater temperature, seal plant vacuum or follow normal shutdown completion work.
* * *
* *
D1-031
ACTIVITY
Page 67 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
DSCE/PERMIT ENGINEER/CCR/DCR/LOCAL DIST SUPERVIOSRS CCR/DCR

Blackout
Isolate the steam line to brine heater PCV(S-10,TCV071/VHS-2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679) up-stream isolation valve(s(S-8/VHS-1A,VHS-1B/S-8/S1,S3/LQ-MV603), Steam PCV down stream isolation valve(s) (S-12/VHS3,VHS-4/S-12/S-2,S-4/--). - Fully open the water boxes vent valves and close discharge motorised valves of BRPs (B-7/VBR5/B-7/B-3/QM-MV603 & B-8/VBR-6/B-8/B4/QM-MV-607). . Isolate the main steam supply line (S-8&9/S4002/S8&9/S-252/LQ-V-600),, close ejectors steam isolation valves(S-15,17,19,16,18,20/VHS-11A,11B/S15,17,19,16,18,20/S-10,S13,S-11,S-14/LQ-XV779,783,781,785). and the vapour section isolation valves(VA-12,VA13/VAE-2,VAE-3/VA-12,VA13/VA7,VA-8,LQ-XV-794,LQ-XV-796),, and then depressurise the isolated sections. Close the seawater main isolation valve(SW-1/VSW1/SW-1/SW-1/QL-MV-600), and close the cooling seawater to ejector condensers isolation valve(SW2,3,6,4,5,8/SW-7,VSW-8&9,VSW-11/SW-2,3,6,4,5,8/ SW-8,9,10,11/QL-W-618,QL-W-616). Isolate all headers distillate header.V/V.NOS:-(VDM13/DP-26/DP-105/QQ-V-608) OR (DP-25/DP-106)Iso.
Page 68 of 320 * * * * * *
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May 2003
V/v Sleeper way (DP-14/DP-13/DP-14/NA/NA). H.P. distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD17/HD-51/QQ-V-641)Condensate Header(V/V. NO:-C22/VCH-21/C-22/ Tag No N/A /LT-XV-614) . Shutdown completion work is to follow to keep the plant ready for start up.
D1-032
Operational Checks
CCR/DCR SUPERVISORS/ OPERATORS CCR/DCR

Local and CCR/DCR indicators are to be regularly read and their indication values are to be recorded on the log form. Rotating machines are to be checked for the following items: - Suction and discharge pressure. - Electric current. - Flow rate.
Page 69 of 320
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* * *
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Q.E.W.C
-

May 2003
Production/Operation * * * * * * * * * * *
Bearing temperature and noise. Shaft seal. Vibration. Lubricant colour and level. Gas pressure in the accumulator for reciprocating pumps to be checked regularly. Strainers to be changed over and cleaned once a week where applicable. Chemical level of the local day tanks to be checked at regular intervals. Chemical dosing rate should be checked and adjusted as process requirement. All instruments should be checked regularly. Plant to be checked frequently for symptom of leakage The site to be kept clean at all the time.
D1-033
Operation of Venting System
DIST LOCAL SUPERVISORS CCR

Operating of Ejectors at Phase I & III Starting Hogger Ejector Make sure all vapour valves(VA-1,2,3,4,5,6,7,8,11/ VA1,2,3,4,6,7,8,11)of the distiller connected to venting system are in open position and service ejectors (VA-12/VAPage 70 of 320 *
Effective
Oct 2002
Q.E.W.C

May 2003
12)OR VA-13/ VA13)(VA-16/VA-16) OR VA-17/VA-17) are isolated and ensure sufficient sea water flow to surface condensers by opening inlet and outlet valves (SW-8/SW/8)&(SW-10/SW-10)(SW-11/SW-11)(SW-12/SW-12) Line up stage No. 1 & 2 vapour line (Tag No. N/A)to pre-condenser. Open steam isolation valve(S-14/S-14) to hogger ejector. Open vapour isolation valve (VA-11/VA-11)to hogger ejector.
D1-033
DIST LOCAL SUPERVISORS CCR

Page 71 of 320
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May 2003
Changing Over from Hogger to Service Ejectors Set-A Close vapour isolation valve to hogger ejector(VA-11/ /VA-11) Close steam isolation valve to hogger ejector(S14/ S-14). Put tertiary ejector-A in service by opening steam isolation valve (S-19 /S-19/ then vapour isolation valve (VA-20/VA-20). Put secondary ejector-A in service by opening steam isolation valve(S-17/S-17) then vapour isolation valve(VA16/ VA-16 ) Put primary ejector-A in service by opening steam isolation valve(S-15/ S-15) then vapour isolation valve(VA-12/ VA-14). Change over stage No. 1 & 2 vapour line(Tag No. N/A) from pre-condenser to inter condenser-A.
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D1-033
ACTIVITY REFERENCE RESPONSIBILITY
DIST LOCAL SUPERVIOSRS Page 72 of 320
Effective
Oct 2002
Q.E.W.C
COMMUNICATION OPERATION

May 2003
CCR
Changing Over from Service Ejectors Set-A to Set-B

*
Put tertiary ejector-B in service by opening steam isolation valve(S-20/S-20) & discharge valve (VA-23/VA-23/) then opening vapour isolation valve(VA-21/ /VA-21) then stop tertiary ejector-A by closing vapour isolation valve(VA-20/VAE-20) then closing steam isolation valve(S-19/ S-19) Put secondary ejector-B in service and Stop secondary ejector-A . Put primary ejector-B in service and stop primary ejectorA.
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D1-033
ACTIVITY REFERENCE
Page 73 of 320
Effective
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Q.E.W.C
RESPONSIBILITY COMMUNICATION OPERATION

May 2003

Stopping Service Ejector & Sealing the Plant Vacuum Stop primary ejector by closing vapour isolation valve (VA-12,13/VA-12,13) then close steam isolation valve(S15,16/S-15,16). Stop secondary ejector. Stop tertiary ejector. Change over stage No. 1 & 2 vapour line(Tag No. N/A ) to pre-condenser.
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D1-033
ACTIVITY

Page 74 of 320
Effective
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Q.E.W.C

May 2003
LOCAL DIST SUPERVISOR CCR

Releasing Plant Vacuum Release plant vacuum by slowly opening the vapour suction isolation valve(VA-11/VA-11) of the hogging ejector.
D1-034 Page 75 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
Operating of Ejectors at Phase II

Operating of Ejectors at Phase - II Starting Hogger Ejector Make sure all vapour valves(,VAE2,VAE3,VAE4)of the distiller connected to venting system are in open position and service ejectors(VAE-2 ,VAE3)are isolated. Open steam isolation valve to hogger (VHS-10)ejector. Open vapour isolation valve(VAE-1) to hogger ejector.
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D1-034 Page 76 of 320
Effective
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May 2003

Changing Over from Hogger to Service Ejectors Set-A Close vapour isolation valve to hogger (VAE-1)ejector and then close steam isolation valve (VHS-10)to hogger ejector. Establish sea water flow to the condensers by opening Inlet valves(VSW-8/9,VSW-11/12) Put secondary ejector-A in service by opening vapour outlet isolation valve(N/A), then steam isolation valve(VHS-11) and then vapour isolation valve(VAE-4) to inter condenser-A. Put primary ejector-A in service by opening steam isolation valve(VHS-11) and then vapour isolation valve to pre-condenser-A.(VAE-2) Line up after condenser level control float valve (VAE8,10) to inter condenser-A. Line up Pre-condenser-A shell drain (VAE-20,24,26) connected to last stage brine shell.
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Page 77 of 320
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SOP No

May 2003
TITLE: DISTILLERS
D1-034

Changing Over from Service Ejectors Set-A to Set-B Confirm that S/W is lined up to condensers set-B. Seal the vacuum by closing vapour isolation valves of pre-condenser-A(VAE-2) and inter condenser-A(VAE-4) then close steam isolation valves.(VHS-11,VHS-11) Close after condenser shell drain line to inter condenserA isolation valve(VAE-8,10) and close pre-condenser-A shell drain to last stage brine shell isolation valve(VAE20,24,26). Put secondary ejector-B in service by opening vapour outlet isolation valve(N/A), then steam isolation valve(VHS-12,VHS-12) and then vapour to inter condenser-B isolation valve(VAE-5). Open after condenser shell drain to inter condenser-B isolation valve(VAE-9,11) and line up Pre-condenser-B shell drain (VAE21,25,27)connected to last stage brine shell.
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Page 78 of 320
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May 2003
D1-034

Stopping Service Ejector & Sealing the Plant Vacuum Seal the vacuum by closing vapour isolation valves of pre-condenser(VAE-2,3) and inter condenser(VAE4,5) then close steam isolation valves(VHS-11,11,VHS-12,12). Close after condenser shell drain line to inter condenser isolation valve(VAE8,10,VAE-9,11) and close precondenser shell drain to last stage brine shell isolation valve(VAE-20,24,26,VAE21,25,27).
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Page 79 of 320
Effective
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May 2003
D1-034

Releasing Plant Vacuum Release plant vacuum by slowly opening the suction isolation valve of the hogging ejector(VAE-1).
Page 80 of 320
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Oct 2002
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May 2003
D1-035
LOCAL DIST SUPERVISOR DCR

Operation of Ejectors at Phase IV Starting Hogger Ejector Make sure all vapour valves (V-5,51) of the distiller connected to venting system are in open position and service ejectors (V-7,8712,13) are isolated. Open steam isolation valve (S-12) to hogger ejector. Open vapour isolation valve(VA-11) to hogger ejector.
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Page 81 of 320
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May 2003
D1-035

Changing Over from Hogger to Service Ejectors Set- A Open all ejector outlet vapour isolation valves (VA9,10,14,15). Establish sea water flow in contact condensors by opening inlet valves (SW-9/SW-10/SW-11) Close vapour isolation valve (VA-11) to hogger ejector and then close steam isolation valve (S-12) to hogger ejector. Put secondary ejector-A in service by opening steam isolation valve (S-13) then open vapour isolation valve(VA-12). Put primary ejector-A in service by opening steam isolation valve(S-10) then open vapour line isolation valve(VA-7).
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Page 82 of 320
Effective
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Q.E.W.C

May 2003
D1035

Changing Over from Service Ejectors Set-A to Set-B Put secondary ejector-B in service by opening steam isolation valve (S-14)then opening vapour isolation valve(VA-13).Stop secondary ejector-A by closing vapour isolation valve(VA-12) then closing steam isolation valve(S-13). Put primary ejector-B in service and stop primary ejectorA.
Page 83 of 320
Effective
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Q.E.W.C

May 2003
D1-035

Stopping Service Ejector & Sealing the Plant Vacuum
Stop secondary ejector by closing vapour isolation valve(VA-12,VA13) then close steam isolation valve(S13,S-14). Stop primary ejector.
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Page 84 of 320
Effective
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Q.E.W.C

May 2003
D1-035

Releasing Plant Vacuum Release plant vacuum by slowly opening the suction isolation valve(VA-11) of the hogging ejector.
Page 85 of 320
Effective
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Q.E.W.C

May 2003
D1-036
DCR/LOCAL DIST SUPERVISORS DCR

Operating of Ejectors at Phase - V Line diagram of ' VACUUM SYSTEM ' Starting Hogger Ejector Make sure all vapour valves(QG-V-605,606,607,608,LQV-600 ) of the distiller connected to venting system are in open position and service ejectors are isolated. Open steam isolation valve(LQ-XV-777) to hogger ejector. Open vapour isolation valve(LQ-XV-793) to hogger
Page 86 of 320 * * *
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ejector.

May 2003
D1-036
DCR/LOCAL DIST SUPERVISOR DCR

Changing Over from Hogger to Service Ejectors Set-A Open all ejector vapour outlet isolation valves(LQ-V635,638,642,645) locally. Establish sea water to suface condensers by opening valves QLV-616 &QLV-617 Close vapour isolation valve(LQ-XV-793) to hogger ejector and then close steam isolation valve(LQ-XV-777) to hogger ejector. Put secondary ejector-A in service by opening steam
Page 87 of 320 * * * *
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May 2003
isolation valve(LQ-XV-783) then open vapour isolation valve(LQ-XV-798). Put primary ejector-A in service by opening steam isolation valve(LQ-XV-779) then open vapour isolation valve(LQ-XV-794).
D1-036
DCR SUPERVISOR FIELD

Changing Over from Service Ejectors Set-A to Set-B Put secondary ejector-B in service by opening steam isolation valve(LQ-XV-785) then open vapour isolation
Page 88 of 320
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May 2003
valve(LQ-XV-800), and then stop secondary ejector-A by closing vapour isolation valve(LQ-XV-798) then close steam isolation valve(LQ-XV-783). Put primary ejector-B in service and then stop primary ejector-A.
D1-036

Stopping Service Ejector and Sealing the Plant Vacuum Stop secondary ejector by closing vapour isolation
Page 89 of 320
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Oct 2002
Q.E.W.C
valve(LQ-XV-798,800) then valve(LQ-XV-783,785). Stop primary ejector. close

May 2003
steam
isolation
* *
D1-036

Releasing Plant Vacuum Release plant vacuum by slowly opening the suction
Page 90 of 320 *
Effective
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Q.E.W.C

May 2003
isolation valve(LQ-XV-793) of the hogging ejector.
D1-037
Operation of CO2 Recovery System at Phase I, II & III
Loca
Field C
CO2 Compressors
Page 91 of 320
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Start-Up

May 2003
Confirm that: - Sealing water isolation valve (DW1013A&1015A,/DW1013C,1015C,DW1013E,1015E/DW1013G,1015 G)is opened. - CO2 recirculating valve(C-101A/B//C-101C/D,E/F//C-101G/H) is closed. - Water separator drain(C-O-1003A,1003B,1046A,1046B//C-O1003C,1003D,1003E,1003F,1046C,1046D,1046E,1046F//C-O1003G,1003H,1046G,1046H) and vent valves(C-101A,101B/C101C,101D,101E, 101F /C-101G,101H)are closed. - Water separator L.C. float V/v and sealing water solenoid valve are de isolated. Line up CO2 from distiller. Open suction (C-101A,101B/C-101C,101D,101E, 101F /C-101G,101H) and discharge valves C-101A,101B/C-101C,101D,101E, 101F /C-101G,101H) of the CO2 compressor. Open sealing water solenoid valve and maintain flow at 4 T/hr. Start the CO2 compressor. Open CO2 recirculation valve(C-101A/B//C-101C/D,E/F//C-101G/H) and maintain flow as required. Open all relevant valves of the standby CO2 compressor and keep the standby selector switch on auto mode for emergency auto-change over.
* * * * * * * * * *
D1-038
Operation of CO2 Recovery System at Phase I, II & III
LOCAL DIST SUPERVISOR DCR / BOP SUPERVISOR
Page 92 of 320
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OPERATION

May 2003
Loca
Field C
Shutdown Keep the standby selector switch on manual mode. Stop the CO2 compressor. Isolate gas line from distiller venting system(CO-1001A&B/CO-1001C&D,CO1001E&F/CO-1001G&H). Close sealing water isolation valve and all relevant isolation valves and drain the system if required.
* * * *
D1-039
OPERATION OF TAPROGGE SYSTEM
LOCAL DIST SUPERVISOR Page 93 of 320
Effective
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Q.E.W.C

May 2003
CCR/DCR
Taprogge Operation ( Tube Cleaning System) The following are to be ensured before and during the operation of taprogge plant: The ball strainer is on opposite position. P across the ball strainer is normal. All control valves(B-11,B-12,B-19,B-20/VTR-5,VTR-6, VTR-10,VTR-11/ B-11,B-12,B-19,B-20/HCV-105,HCV106,HCV-107,HCV-108,HCV-109,OB-58/QW-MV601,604,607,612,615620) are available to the mode of selection and all indication lights for them are available on the panel. None of the control valves(B-11,B-12,B-19,B-20/VTR5,VTR-6, VTR-10,VTR-11/ B-11,B-12,B-19,B-20/HCV105,HCV-106,HCV-107,HCV-108,HCV-109,OB-58/ QWMV-601,604,607,612,615620) pass. All hand-operated isolation valves(B-10,B-22,B-23,,B21,B-17,B-18,BV-2,BV-3/ VTR-1,VTR2,VTR3,VTR9,VTR-12,VTR-13,VTR-14,VTR-15/ B-10,B-22,B-23,,B21,B-17,B-18,BV-2,BV-3/B-8,B-53,B-54,B-65,B-66,B-67, B-68,B-58,B-60,B-59,B-61B-62,BV-10,BV-11/QW-V600,602,605,608,609,610,611,613,614,616,617,618,619) are open.
* * * * *
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May 2003
ITLE: DISTILLERS SOP No
D1-039

Normal Operation of Taprogge System Select the mode of operation: either auto or manual. Select the type of cleaning cycle: either through recovery stages with brine heater or brine heater only (except Phase I & III). Place ball catcher on catching position. Make one ball circulating pump standby (except Phase I, II & III). Line up the pipelines as per requirement of the system. Box up the vessel with the required numbers of good balls by properly venting the vessel. Check all control valves(B-11,B-12,B-19,B-20/VTR5,VTR-6, VTR-10,VTR-11/ B-11,B-12,B-19,B-20/HCV105,HCV-106,HCV-107,HCV-108,HCV-109,OB-58/ QWMV-601,604,607,612,615620) are in shut position. Reset the alarm switch.
Page 95 of 320
* * * * * * * * *
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May 2003
In case of auto mode, press the auto start switch, and check that the pump has started and it is taking proper load, the control valves (B-11,B-12,B-19,B-20/VTR-5,VTR-6, VTR-10,VTR-11/ B-11,B-12,B-19,B-20/HCV-105,HCV106,HCV-107,HCV-108,HCV-109,OB-58/ QW-MV601,604,607,612,615620) are operating on time as per selection, and balls are releasing and returning as usual. Press the auto stop switch after releasing of the balls from the vessel (not required at Phase V).
In manual mode the pump needs to be started and control valves(B-11,B12,B-19,B-20/VTR-5,VTR-6, VTR-10,VTR-11/ B-11,B-12,B-19,B20/HCV-105,HCV-106,HCV-107,HCV-108,HCV-109,OB-58/ QW-MV601,604,607,612,615620) are opened or closed by pressing the open or close button for each valve.
D1-039
LOCAL SUPERVISOR DSCE/PERMIT ENGINEER

Checking of Taprogge Balls Daily, the balls are counted and checked for their suitability to keep them in circulation. New balls are used instead of the balls with following criteria: broken, undersize, soft, hard, heavy, damaged, oversize or lost shape.
Page 96 of 320
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May 2003
D1-039
LOCAL DIST SUPERVISOR
Ball Strainer Backwashing After ball collection, if the ball counting is considered good, backwash can be performed for the ball strainer. The backwash is done to clean the ball strainer from any debris, the ball strainer is put on backwash manually by hand operated valves(Tag No. N/A// Tag No. N/A// Tag No. N/A//Tag No. N/A ) during idle hour of the taprogge system (except Phase V). Also the backwash is performed when pressure differential
Page 97 of 320
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May 2003
across the ball strainer exceeds specified limit. Also when taprogge is not in operation, the ball strainer is generally kept on backwash position to keep the catchers clean by flushing out the debris.
D1-039
LOCAL DIST SUPERVISOR CCR/DCR/DSCE/PERMIT ENGINEER

Special Operation Cycles Beside the normal operation, there are special operations, which are performed when required. These operations are described below:
Page 98 of 320
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May 2003
D1-039
LOCAL DIST SUPERVISOR DSCE/PERMIT ENGINEER

Blank Cycle Whenever during routine checks the ball collection is poor, the system is put into service for collection cycle, in order to recover the lost balls. This operation is continued up to 3 to 4 times so as to recover most of the lost balls as practicable. Sometime on plant demand or due to any big leakage or fault/defect in the taprogge system, the operation is stopped
Page 99 of 320
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May 2003
quicker than normal time. In that case the system is put on collection cycle on manual and if necessary the collection cycle is shortened. Efforts should be made even in emergencies to stop the system on collection cycle.
D1-039
LOCAL DIST SUPERVISOR DSCE/PERMIT ENGINEER

Continuous Cycle In the continuous cycle, the system runs continuously without any stoppage unless it is programmed to stop or to discontinue. This operation is generally done when T across brine heater goes up and dose not come down to normal operating level, when steam consumption and G.O.R. is affected or when
Page 100 of 320
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May 2003
antiscale dosing system is out of service. This operation is carried out for several days. The continuous cycle of operation can be carried out through brine heater only (except in Phase I & III).
D1-039
LOCAL SUPERVISOR
Test Cycle Whenever the plant comes up from shutdown, test cycles are performed before normal cycles are operated. These test cycles are done to check for operationability of the system as well as successful nature of collection. For test cycles it is tested for both manual and auto cycles for sequence test and with a feed of
Page 101 of 320
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May 2003
Production/Operation *
400 balls. In case the collection is poor, the system is operated again and again to recover the lost balls so as to make the cycles successful. After the successful test cycle the ball strainer is put on backwash position for few minutes before starting the normal cycles on auto. In Phase V, the test cycles are carried out on manual only.
D1-040
PROCEDURE FOR FLUSHING WITH DISTILLATE WATER
CCR/DCR/LOCAL DIST SUPERVISOR CCR/DCR

Flushing of Heat Reject Section The distiller should be shut down to carry out flushing with distillate. The seawater main inlet isolation valve(SW-1/VSW1/SW-1/SW-1/QL-MV-600) should be closed, and the vent and drain isolation valves for the water boxes should be opened. When
Page 102 of 320
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May 2003
draining of the water boxes is completed, the drain isolation valves and seawater dump TCV(SW-19,FCV-1002A,SW26,1002B/SW-2,TCV-005/SW-19,FCV1002A,SW26,1002B/TCV-104/QL-FCV-604) should be closed with its isolation valve(SW-18/N/A//SW-18//Tag No. N/A//N/A).
*
After performing the previous steps, the distiller become ready to receive the distillate back flow from the distillate header by opening distillate header isolation valve (Tag No n/a/VDM13,DP-26&25/Tag no n/a//DP-105,DP106/QQ-V-608)(new/old), distillate retain control valve(DP-11,LCV-002/VDM-11/DP11,LCV-002/CRV101A/QQ-LV-718) and bypass isolation valve (DP-13/VDM-10/DP-13/DP-9/QQ-V-782) of distillate LCV(DP11,LCV-002/VDM8,LCV-353/DP-11,LCV-002/LCV-104/QQLV-702). According to the piping connection, there are several methods for filling the tubes and the water boxes of the heat reject section. The following illustrate these filling methods.
D1-041 PROCEDURE FOR FLUSHING WITH DISTILLATE WATER
Page 103 of 320
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OPERATION

May 2003
Filling Method at Phase I & III The filling of the tubes and water boxes of the heat reject section is done by using a hose, which connects between the distillate pumps common discharge line and seawater inlet line. Filling Method at Phase II The filling of the tubes and water boxes of the heat reject section is done by opening hogger ejector vapour isolation valve(VAE-1), seawater make-up bypass isolation valve (VFW-4) of FCV. Also suction (VDM-1)with discharge(VDM-5) isolation valves and bypass of non-return valve(Tag no N/A) of the distillate extraction pump-A should be opened to fill the distillate channel and overflow to the brine shells until the whole evaporator is filled. The water will enter into the reject line through the make-up bypass (VFW-4)line of FCV(VFW-2,FCV502). Filling Method at Phase IV
*
The filling of the tubes and water boxes of the heat reject section is done by opening interconnected line isolation valves(Tag no. N/A), between distillate pumps common disch. And seawater inlet line Filling Method at Phase V The filling of the tubes and water boxes of the heat reject section is done by closing the down stream(QQ-V-781) and bypass(QQ-V-782) isolation valves of distillate LCV (QQ-LV702) and opening of the distillate header isolation valve(QQ-V608), the distillate retain control valve(QQ-XV-718) and the distillate dump control valve(QQ-XV-719). The last isolation
Page 104 of 320 *
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May 2003
valve(QQ-V-637) in the dump line should be closed with seawater dump control valve(QL-FCV-604) and the isolation valve (QQ-V783)of the interconnected line between the dump line and seawater reject line should be open, to allow for distillate to flow to the seawater reject line and prime the tubes and water boxes.
ACTIVITY REFERENCE
Page 105 of 320
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RESPONSIBILITY COMMUNICATION

May 2003
Starting Flushing Circulation
After priming the tubes and water boxes of the heat reject section, the vent isolation valves are closed and the circulation is started for 30 minutes by using seawater recycle pump. In Phase I & III no circulation by the seawater recycle pump is performed, only filling by distillate and draining. This is done since circulation was found to cause cavitation in the seawater recycle pump. After the flushing with distillate is completed, and the tubes, water boxes and piping are drained, the heat rejection section is released for maintenance work.
ACTIVITY REFERENCE
Page 106 of 320
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May 2003

Flushing of Heat Recovery & Heat Input Sections To perform flushing with distillate, the distiller should be shut down and drained, after draining the drain isolation valves should be closed, the hogger ejector vapour isolation valve(VA11/VAE-1/VA-11/VA-11/LQ-XV-793) should be kept open for venting during filling the brine shells by distillate.
After performing the previous steps, the distiller become ready to receive the distillate back flow from the distillate header by opening distillate header isolation valve (TagNo.NA/VDM-13*DP26/DP-105/QQ-V608)(TagNo.NA/DP-25/DP-106/NA)(new/old), distillate retain control valve(DP-11,LCV-002/VDM-11/DP-11,LCV-002/CRV101A/QQLV-718) and bypass isolation valve (DP-13/VDM-10/DP-13/DP9/QQ-V-782) of distillate LCV(DP-11,LCV-002/VDM8,LCV-
353/DP-11,LCV-002/LCV-104/QQ-LV-702). .
According to the piping connections there are several methods for filling the brine shells for the different phases. These filling methods are illustrated in the following sections.
Page 107 of 320
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SOP No

May 2003
TITLE: DISTILLERS
CCR/LOCAL DIST SUPERVISORS DCR

Filling Method at Phase I & III The filling of the brine shells of evaporator via over flowing distillate channel is done by opening the suction and discharge isolation valves and lifting the weight of the lever for the non-return valve(DP-3/DP-3 OR DP-4/DP-4)of the discharge line of the distillate extraction pump. Filling Method at Phase II The method for filling the brine shells of the evaporator, to flush the tubes in the heat recovery section and the brine heater, is done by opening suction(VDM-1), discharge(VDM-5) and bypass(Tag no. N/A) of non-return valves (VDM-3) of the distillate extraction pump-A. Filling Method at Phase IV The filling of the brine shells of the evaporator is done by opening interconnected line isolation valve(TagNo.NA) between distillate extraction pump common discharge line and suction line.
*
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Filling Method at Phase V

May 2003
The filling of the brine shells of the evaporator is done by opening the suction (QQ-V-600,604)and discharge(QQ-V603,607) isolation valves and lifting the weight of the lever for the non-return valve(QQ-V-604 OR QQ-V-602) in the discharge line of the distillate extraction pump. Circulation For Flushing After filling the brine shell to sufficient level circulation is started with Brine pump B for 45 minutes and then with Brine PumpA for another 45 minutes. Distillate feed can be stopped when the level becomes stable after starting second Brine Pump.
Page 109 of 320
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May 2003
D1-045
TUBE LEAK DETECTION

Vacuum Test for Tube Leaks Vacuum test is carried out for the distillers in Phase I & III for the heat reject and recovery sections. It is applied because the foundation of the distiller can not stand the weight of the distiller when it is filled with water in case of a hydrostatic test. Tube Leak Detection in Heat Reject Section To perform the test, the distiller should be shut down, then drained and isolated. The isolation is performed as the following: Isolate the steam to brine heater by closing steam PCV (S10,TCV-071/VHS-2,TCV-004A; VHS-2,TCV-004B/S10,TCV-071/PCV-102A,PCV-102B/LQ-TV-679)and its up stream isolation motorised valve (S-8/VHS-1A,VHS1B/S-8/S1,S3/LQ-MV603), with its balance valve and down stream isolation valve (S-12/VHS-3,VHS-4/S-12/S2,S-4/--) with its balance valve, also the up and down stream bypass isolation valve(S-11/VHS-4/S-11/S-5/N/A)s with their balance valves.
Page 110 of 320
* * *
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May 2003
Close header isolation valves of the distillate (new & old) V/V.NOS:-(VDM-13/DP-26/DP-105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP-14/DP-13/DP14/NA/NA). , HP distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD-17/HD-51/QQ-V-641), condensate header (V/V. NO:-C-22/VCH-12/C-14/C-22/LT-XV-614)and HP makeup to desuperheater (HM-6/VCH-19/HM-6/O-HM287/LT-V-625). Stop seawater reject flow, close the seawater main isolation valve (SW-1/VSW-1/SW-1/SW-1/QL-MV600)and drain the water boxes of heat reject section. After completing draining of heat recovery water boxes, brine heater and brine shells, close all vent and drain isolation valves.
Close suction and discharge isolation valves of the brine recirculation( Brine Pump suction isolation)(B-4/VBR-2/B4B-2/QM-MV-604) (Brine pump discharge motorised valves) (B-7/VBR-5/B-7/B-3/QM-MV603 & B-8/VBR-6/B8/B-4/QM-MV-607)
* *
, blowdown,( Blowdown pump suction isolation valve)(BD-1,BD-2/VBD-1,VBD-2/BD-1,BD-2/B-79,B80/QN-V-600,QN-V-605) (Blow down discharge isolation valve)(BD-5,BD-6/VBD-5,VBD-6/BD-5,BD-6/B-81,B82/QN-V-603,QN-V-608) distillate,(Dist. suction isolation valves)(DP-1/VDM1/DP-2/DP-2/QQ-V-600 &DP-2/VDM-2/DP-2/DP-2QQV-604)(Dist. discharge isolation valve)(DP-5,DP-6/VDM5,VDM-6/DP-5,DP-6/DP-5,DP-6/QQ-V-603,QQ-V-607) seawater recycle Pump suction valve(SW-38/VSW-3/SW38/SW-5/QL-V-610),Discharge isol v/v( SW-15/VS5/SW-15/SW-7/N/A) - HP distillate pumps. The pumps suction isolation valves(HD-1/VDH-1/HD-1/HD-1/QQ-V615),(HD-2/VDH-2/HD-2/HD-2/QQ-V618)&(HD-3/VDH-3/HD-3/HD-3/QQ-V-610) discharge valve(HD-7/VDH-7/HD-7/HD-4/QQ-V617)OR(HD-8/VDH-8/HD-8/HD-5/QQ-VPage 111 of 320
* *
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-

May 2003
620)OR(HD-9/VDH-9/HD-9/HD-6/QQ-V-612). Also close all control valves Brine FCV (B-14,FCV001/VBR-7,FCV-503/B-14FCV-107/QM-FV666)(Isolation Valves U/S:B-13/NA/B-13/NA/NA & D/S:B-15/NA/B-15/NA/NA) BlowdownLCV(BD-8,LCV001/VBD-8,LCV-352/BD-8,LCV-001/LCV-103/QN-LV752) isolation valves (U/S: BD-7/VBD-7/BD-7/BD85/QN-V-609& D/S: BD-8/VBD-8/BD-8/-/QN-V-610) and bypass isolation valve(BD-10/VBD-10/BD-10/B86/QN-V-611) Dist.LCV-U/P:DP-10/VDM-7/DP-10/DP-7/QQ-V780&D/S:DP-12/VDM-9/DP-12/DP-8/QQ-V-781) of LCV (DP-11*LCV-002/VDM8*LCV-353/DP-11*LCV002/LCV-104/QQ-LV-702) SW Recirc TCV(SW-16*TCV-066/VSW-5*HI-010/SW16/TCV-066/TCV-103/QL-TV-605). down stream isolation valve(SW-17/VSW-6/SW-17/SW-7/QL-V-620), Up stream isol. V/V (Ph 1~ 5)N/A H.P Isolation valves(U/S:NA/VDH-10/NA/HD-10/QQ-V621)(D/S:NA/VDH-12/NA/NA/QQ-V-622) H.P C/V (HD13,HIC003,HIC002/VDH-11,FCV-506/HD13,HIC003,HIC002/N/A//QQ-FV-734) with their isolation valves, emergency blowdown isolation emergency blowdown isolation valve (B-9/VEB-1/B-9/B7/--) valve, stripping steam isolation valve (VA-24,N/A//VA-24/VA-5/ LQ-V-600)and taprogge system isolation valves (B-10,B22,B-23,,B-21,B-17,B-18,BV-2,BV-3/ VTR1,VTR2,VTR3,VTR-9,VTR-12,VTR-13,VTR-14,VTR-15/ B-10,B-22,B-23,,B-21,B-17,B-18,BV-2,BV-3/B-8,B-53,B54,B-65,B-66,B-67, B-68,B-58,B-60,B-59,B-61B-62,BV10,BV-11/QW-V600,602,605,608,609,610,611,613,614,616,617,618,619). Close All instrumentation, chemical dosing, vent and drain isolation valves.
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After completing the draining and the isolation, the vacuum is raised by starting hogger ejector till distiller vacuum comes to maximum. When the maximum vacuum is reached, the hogger could be stopped and the distiller vacuum is sealed, or the hogger could be kept in service, this depends on the situation. PTW can be issued to MMD to carry out vacuum test. After that the MMD will start tube leak detection. This is done through the manholes of the water box in the stage, which was determined earlier based on conductivity test. The MMD uses soap, paper or candle to find out the leaking tubes. Once the tubes are identified, they are plugged. On completion of the test, the vacuum may be released by opening the hogger ejector suction isolation valve. (VA-11/VAE1/VA-11/VA-11/LQ-XV-793)
D1-045
TUBE LEAK DETECTION
LOCAL DIST SUPERVISOR CCR/DCR Page 113 of 320
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OPERATION

May 2003
* * * *
Page 114 of 320
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May 2003
D1-046
TUBE LEAK DETECTION

Tube Leak Detection in Heat Recovery Section
The procedure to perform the test for the heat recovery section is similar to the procedure applied for the heat reject section, except that seawater reject flow can be kept in service, but seawater make-up line to be properly isolated. Also the MMD must fix a blind flange at the brine entry in the first stage shell. On completion of the test, the vacuum is released by opening the hogger ejector suction valve (VA-11/VAE-1/VA11/VA-11/LQ-XV-793), and removing the blind flange by MMD
Page 115 of 320
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from brine entry in the first stage shell.

May 2003
D1-047
TUBE LEAK DETECTION

Hydrostatic Test for Tube Leaks
Hydrostatic test is carried out for the distillers in Phase II, IV & V for tube leak detection at the heat reject and recovery sections. Tube Leak Detection in Phase II Tube Leak Detection in Heat Reject Section To perform the test, the distiller should be shut down, and then drained and isolated. The isolation is performed as the
Page 116 of 320
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following:

May 2003
Isolate the steam to brine heater by closing steam unit isolation valve (S-4002 and its balance valve, steam PCVs (A & B)(VHS2,TCV004A&B) to brine heater and their upstream isolation valve(VHS-1A&1B) and down-stream isolation motorised valves (VHS-3A&VHS-3B)with their balance valves. Close steam to ejectors main isolation valve(VHS-5) and steam to ejectors PCV (VHS-7)and its isolation valves(VHS6,VHS-8) with the bypass isolation valve(VHS-9), keep hogger ejector suction isolation valve. (VAE-1) open. Close header isolation valves of the HP distillate(Tag no.n/a), condensate(VCH-12,C-14) and HP make-up to desuperheater(VCH-19). After completing draining of heat recovery water boxes and brine heater, close suction and discharge isolation valves of the brine recirculation (VBR1,VBR2/VBR5,VBR6), blowdown (VBD1,VBD2/VBD5/VBD6), HP distillate(VDH1,VDH2VDH3/VDH-7,VDH8,VDH9) and seawater recycle pumps(VSW-3//N/A), also close their control valves(VBR7,FCV503)/(VBD8,LCV-352)/(VDH-11, FCV506) /(VSW5,HI-010) and the isolation valves(N/A//NA)/(VBD-7,VBD9)/(VDH-10,VDH12)/(N/A//VSW-6) of the control valves, emergency blowdown isolation valve(VEB-1), chemical dosing isolation valves and the taprogge system isolation valves(VTR-1,VTR7, VTR-14A,VTR-14B) Start filling the shells with seawater through seawater make-up FCV bypass(VFW-4) line, when distiller shells level comes up one foot below the rooftop stop seawater feeding. Stop seawater reject flow, close the seawater main isolation valve(VSW-1) and drain the water boxes of heat reject section. Also close seawater make-up FCV(VFW2,FCV-502) and its isolation valves(VFW-1,VFW-3) with the bypass isolation valve(VFW-4).
Page 117 of 320
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May 2003
The rest of the level to be filled with distillate by a back flow from distillate header through distillate pump-A NRV (VDM-3) bypass(Tag no. N/A) line. After completing the filling isolate the distillate pump-A NRV bypass(Tag no. N/A) line isolation valve if required. PTW can be issued to MMD to carry out the hydrostatic test. After that the MMD will start tube leak detection. This is done through the manholes of the water box in the stage, which was determined earlier based on conductivity test. Once the tubes are identified, they are plugged. On completion of the hydrotest the distiller should be drained.
D1-048
TUBE LEAK DETECTION

Tube Leak Detection in Heat Recovery Section
The procedure to perform the test for the heat recovery

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May 2003
section is similar to the procedure applied for the heat reject section, except that seawater reject flow can be kept in service, and seawater make-up line should be isolated after filling by seawater is completed. Note that in Phase II no need for fixing blind flange at brine heater outlet line to first stage brine shell.
D1-049
TUBE LEAK DETECTION

Page 119 of 320
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Q.E.W.C
Tube Leak Detection in Phase IV

May 2003
Tube Leak Detection in Heat Reject Section To perform the test, the distiller should be shut down, then drained and isolated. The isolation is performed as the following: Isolate the steam to brine heater by closing steam unit isolation valve(S-252,254,256,258) and its balance isolation valve, steam PCVs (A & B) to brine heater(PVV102A&B) and its up-stream isolation valve(S1,S-3)and down-stream isolation motorised valves(S-2,S4) and their balance isolation valves. Close steam to ejectors main isolation valve(S-6) and steam to ejectors PCV(PCV101) and its isolation valves(S7/S-8) with bypass isolation valve(S-9), keep hogger ejector suction isolation valve(V-11) open. Close header isolation valves of the HP distillate(HD-51), condensate (Tag no. N/A)and HP make-up to desuperheater(OHM-287). Stop seawater reject flow, close the seawater main isolation motorised valve (SW-1)and drain the water boxes of heat reject section. Also close seawater make-up FCV(FCV-104) and its isolation valve (SW-2//N/A)with the bypass isolation valve(SW-4). Also close seawater deaerator LCV (LCV-106)and stripping steam isolation valve(V-5). After completing draining of heat recovery water boxes, brine heater and brine shells, close suction and discharge isolation valves of the brine recirculation(B-1,B-2/B-3,B4), blowdown(B-79,B-80/B81,B-82), HP distillate(HD1,2,3/HD4,5,6) and seawater recycle pumps(SW-5/SW-7), also close their control valves(FCV107)/(LCV-103)//N/A/(TCV-103) with the isolation valves of the control valves(N/A//N/A)//(B85//N/A)//N/A//(N/A,SW-7), emergency blowdown isolation valve(B-7), chemical
Page 120 of 320
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May 2003
dosing isolation valves and the taprogge system isolation valves(B-8,B-53,B-54,B-65,B-66,B-67,B-68,) Close drain isolation valves, which are connected to shells. Keep open, for shells filling, the hogger ejector suction isolation valve (V-11)and the roof vent caps. Start filling the brine shells with distillate by a back flow from distillate header. Back flow distillate will fill the distillate channel and overflow to the shells until the whole evaporator is filled. After completing the filling close the roof vent caps. PTW can be issued to MMD to carry out hydrostatic test. After that the MMD will start tube leak detection. This is done through the manholes of the water box in the stage, which was determined earlier based on conductivity test. Once the tubes are identified, they are plugged. In completion of the hydrotest the distiller should be drained.
D1-050
ACTIVITY REFERENCE
TUBE LEAK DETECTION
Page 121 of 320
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May 2003

Tube Leak Detection in Phase IV Tube Leak Detection in Heat Recovery Section The procedure to perform the test for the heat recovery section is similar to the procedure applied for the heat reject section, except that seawater reject flow can be kept in service, and seawater make-up line to be properly isolated. Also the MMD must fix a blind flange at the brine heater outlet line to the first stage shell.
D1-051
ACTIVITY REFERENCE
TUBE LEAK DETECTION
Page 122 of 320
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May 2003

Tube Leak Detection in Phase V- Heat Recovery Section
The procedure to perform the test for the heat recovery section is similar to the procedure applied for the heat reject section, except that seawater reject flow can be kept in service, and seawater make-up line to be properly isolated. Also the MMD must fix a blind flange at the brine heater outlet line to the first stage shell.
D1-052
ACTIVITY REFERENCE
TUBE LEAK DETECTION
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May 2003

Tube Leak Detection in Phase - V in Heat Reject Section
To perform the test, the distiller should be shut down, then drained and isolated. The isolation is performed as the following: Isolate the steam to brine heater by closing steam unit isolation valve(LQ-V-600) and its balance isolation valve, steam PCV (LQ-TV-679)to brine heater and its up-stream isolation motorised valve(LQ-MV-603) with balance isolation valve. Close atomising steam to desuperheater isolation valve (LQ-V-610).
*
Close drain isolation valves, which are connected to shells. Keep open, for shells filling, the hogger ejector suction isolation valve(LQ-XV-793). Start filling the shells with distillate by a back flow from distillate header. Back flow distillate will fill the distillate channel and overflow to the shells until the whole evaporator is filled. PTW can be issued to MMD to carry out hydrostatic test. After that the MMD will start tube leak detection. This is done through the manholes of the water box in the stage, which was determined earlier based on conductivity test. Once the tubes are identified, they are plugged. In completion of the hydrotest the distiller should be drained.stage
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May 2003
D1-053 TUBE LEAK DETECTION

Page 125 of 320
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May 2003
Tube Leak Detection in Brine Heater for All Phases

To perform a hydrostatic test, the distiller should be shut down and drained. The steam line to the brine heater(S8&9/S4002/S-8&9/S-252/LQ-V-600) and condensate line to the desuperheater(C-20/VCH-14/C-20/HM-2/LT-V-620) should be isolated. Also condensate pumps suction valves(C-1/VCH-1/C1/C-1/LT-V-600 &C-2VCH-2/C-2/C-2/LT-V-605), with discharge isolation valve (C-5/VCH-5/C-5/C-5/LT-V-603) OR(C6VCH-6/C-6/C-6LT-V-608) should be closed and condensate header(C-22/VCH-12,C-14/C-22/Tag no. N/A//LT-XV-614) should be isolated. All instruments and drains isolation valves should be closed, and brine heater vent isolation valve(VA25,26/VVA-1/VA-26/V-1/QQ-V-604) should be opened. The methods to fill the brine heater shell for the different phases are as follow: At Phase I & III, the brine heater shell is filled by filling the condensate drum with industrial water until it flows to the brine heater shell and fill it to the top. At Phase II, the brine heater shell is filled by high purity make-up water from the desuperheater through the drain line(VHS-19), which is connected to the brine heater shell. At Phase IV, the brine heater shell can be filled by high purity make-up water from the desuperheater through the drain line(C-18), which is connected to the suction line of condensate pump. At Phase V, the brine heater shell can be filled by industrial water through a hose connection to the drain line(LT-V-630) of the level transmitter of the brine heater.
After filling, the MMD performs leak detection for the tubes through a manhole. Once the tube, which has a leak, is identified, it is plugged. On completion of the hydrostatic test, the
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brine heater shell is drained.

May 2003
D1-054
ACID CLEANING PROCEDURE
LOCAL DIST SUPERVISOR Page 127 of 320
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May 2003
Filling with Seawater
Open the main seawater supply isolation valve (O-SW13/S-26/SW-13/O-CH-230/QV-V-619) to acid cleaning system. Start priming the heat recovery and brine heater water boxes and tube bundles. After priming, close vent isolation valves of the water boxes. Pressurise the system and confirm that there is no leakage in the system. Fill the acid circulation tank with seawater up to 60%. Close the main seawater supply isolation valve(O-SW13/S-26/SW-13/O-CH-230/QV-V-619) to acid cleaning system.
* * * *
D1-055
ACTIVITY
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REFERENCE RESPONSIBILITY COMMUNICATION

May 2003

To perform the acid cleaning for distiller tubes, the acid cleaning system must be pressurised by seawater and checked for leakage and also the acid circulation with acid charging pumps should be tested. After completing the checking of the acid cleaning system the distiller to be shut down, then drained and performed the necessary isolation to issue PTW for MMD to fix blind flange at the brine entry in the first stage shell at Phase I & III, and at the brine heater outlet line to first stage shell at Phase II, IV & V also at Phase V there is provision for fixing blind flange before recirculating brine entry to water boxes of heat recovery section
* *
Preparation Confirm that suction (B3,B4/VBR1,VBR2/B3,B4/B1,B2/QM-MV-600,QM-MV604) and discharge valves (B-7/VBR-5/B-7/B-3/QMMV603 & B-8/VBR-6/B-8/B-4/QM-MV-607)for both brine recirculation pumps and isolation valve of emergency blowdown line valve (B-9/VEB-1/B-9/B-7/--) are isolated (at Phase V there is no emergency blowdown line), and the blind flange is fixed.
Close all isolation valves of the taprogge system isolation valves(B-10,12,17,18,22&23/ B-10,13,14,15&21/ BPage 129 of 320
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May 2003
0,12,17,18,23&24/ B-8,53,54,65,66,67&68/ 600,608,613,614,616 &617).
QW-V-
Close drain valves and keep vent valves open of water boxes at heat recovery section and brine heater for priming. Keep distillate in distillate channel for diluting in case of any leakage from tubes. Confirm that circulation pump and tank are ready for operation. Confirm that acid charging pump is ready for operation, and acid storage tank is filled with required amount of concentrated acid. Isolate all related instrument.
Page 130 of 320
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May 2003
D1-056
Starting Circulation Start acid circulation pump, and then slowly open the pump discharge isolation valve (O-SW-112 /SW-184/OSW-233/O-CH-167,253/QV-V-610) Keep 60% level at the circulation tank by adjusting tank inlet isolation valve ( O-SW-115/SW-185/O-SW-236/OCH-207/QV-V-651or 653). If more seawater is required, slowly open main seawater supply to acid cleaning system. Note that at Phase V, the acid circulation tank level is maintained by distillate or industrial water through a level control valve ( LCV-QQXV-953).
* *
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May 2003
D1-057
CCR/DCR/LOCAL DIST SUPERVISORS CCR/DCR/LOCAL

Warming-Up
Start charging the LP-steam to brine heater to warm-up the seawater circulation up to 55 oC. Periodically, drain the condensate in the brine heater to maintain the level in the brine heater shell and vent the water boxes of the heat recovery section and brine heater. When the seawater circulation reach 55 oC, stop steam charging to brine heater.
Page 132 of 320
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May 2003
D1-058

Acid Charging
Start acid charging by using acid charging pump. When circulation tank inlet and outlet pH becomes the same, approximately 1.3 pH, stop acid dosing pump. Periodically, vent the water boxes. Continue the circulation through the system until the lab gives an instruction to stop circulation.
* * * *
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May 2003
D1-059

Flushing with Seawater Open acid circulation drain line isolation valve ( O-SW113&114/V-AC-3/O-SW-234&234/O-CH-140/TAG NO. N/A), then open main seawater supply isolation valve (OSW-13/S-26/SW-13/O-CH-230/QV-V-619)to the acid cleaning system. Continue flushing by seawater until the lab gives an instruction to stop based on pH value.
*
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May 2003
TITLE: DISTILLERS SOP No ACTIVITY REFERENCE RESPONSIBILITY COMMUNICATION OPERATION Field CCR/DCR
D1-060

Location
Draining Close main seawater supply isolation valve (O-SW-13/S26/SW-13/O-CH-230/QV-V-619). Open vent and drain valves of water boxes of heat recovery section and brine heater. Flush the acid circulation tank if required, and drain the acid cleaning system.
* *
Page 135 of 320
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May 2003
D1-061
DSCE/PERMIT ENGINEER/LOCAL DIST SUPERVISOR CCR/DCR

Issue of Permits on Distillers Pumps or Motors MMD Permit on 415V Pumps Isolate the 415V power supply to pumps motor and Lock & Tag the isolator in Off position. Shut, chain and Lock & Tag suction and discharge valves of the pump:blowdown,( Blowdown pump suction isolation valve)(BD1,BD-2/VBD-1,VBD-2/BD-1,BD-2/B-79,B-80/QN-V600,QN-V-605) (Blow down discharge isolation
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May 2003
valve)(BD-5,BD-6/VBD-5,VBD-6/BD-5,BD-6/B-81,B82/QN-V-603,QN-V-608) distillate,(Dist. suction isolation valves)(DP-1/VDM1/DP-2/DP-2/QQ-V-600 &DP-2/VDM-2/DP-2/DP-2QQV-604)(Dist. discharge isolation valve)(DP-5,DP-6/VDM5,VDM-6/DP-5,DP-6/DP-5,DP-6/QQ-V-603,QQ-V-607) seawater recycle Pump suction valve(SW-38/VSW-3/SW38),Discharge isol v/v( SW-15/VS-5/SW-15) - HP distillate pumps. The pumps suction isolation valves(HD-1/VDH-1/HD-1/HD-1/QQ-V615),(HD-2/VDH-2/HD-2/HD-2/QQ-V618)&(HD-3/VDH-3/HD-3/HD-3/QQ-V-610) discharge valve(HD-7/VDH-7/HD-7/HD-4/QQ-V617)OR(HD-8/VDH-8/HD-8/HD-5/QQ-V620)OR(HD-9/VDH-9/HD-9/HD-6/QQ-V-612). - Condensate Pump suction valves(C-1/VCH-1/C1/C-1/LT-V-600 &C-2VCH-2/C-2/C-2/LT-V-605), the discharge valve (C-5/VCH-5/C-5/C-5/LT-V603) OR(C-6VCH-6/C-6/C-6LT-V-608) - Taprogge Pumps suction v/v(B-20/VTR-2/B-20/B59,B-60/QW-V-602,QW-V-605) Discharge V/V(B-21/VTR9/B21/B61,62/QW-MV-604,607) Close venting(V1,VA30,31,DP-1,DP2,HD4,5,6,VA35,36,BV3/VDM24,VVA17,VVA15,VVA14, VTR9/ V1,VA30,31,DP-1, DP-2,HD4,5,6,VA35,36, BV3/DPV2,4,BV-36,38,HDV1,2,3,BD-11,12,C14,15/QG-V-615,617,619,620,621,625,627,631,633,)and sealing water isolation valves(SW-45,SW-32,33,DP15,16,DW-16,17/VCW-12,VDM-24,VCW-10,11,VCW5,6,VCW1,2,3,4/ SW-45,SW-32,33,DP-15,16,DW-16,17/ B-6,7,HD13,14,15/QQ-V-743,670,671,673,674,680,683) of the pump.
EMD Permit on 415V Motors Isolate the 415V power supply to the motor and Lock & Tag the tray switch in Off position.
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EMD Permit on 415V Starters

May 2003
Isolate the 415V power supply, rack out motors starter and Lock & Tag the 415V power supply bus bar shutters.
D1-061
DSCE/PERMIT ENGINEER/LOCAL DIST SUPERVISOR CCR/DCR

MMD Permit on Brine Recirculation Pump Isolate the 6.6kV power supply to pumps motor and Lock & Tag the isolator in Off position. Isolate and Lock & Tag the 415V power supply to pumps discharge motorised valve (B-7/VBR-5/B-7/B3/QM-MV603 & B-8/VBR-6/B-8/B-4/QM-MV-607). Shut, chain and Lock & Tag suction (B-3,B4/VBR1,VBR2/B-3,B4/B-1,B-2/QM-MV-600,QMMV604) and discharge valves (B-7/VBR-5/B-7/B-3/QMMV603 & B-8/VBR-6/B-8/B-4/QM-MV-607) of the pump. Shut, chain and Lock & Tag barrel vent isolation valve (VA-28,29/VA-16,17/V-28&29/V-4&5/--/) where applicable. Close the sealing water isolation valves(SW34,35/VCW8,9/SW34,35/B-11,DP10/QQ-VPage 138 of 320 *
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660,661,663,664) of the pump. Precautions:

May 2003
Local Supervisor to check for passing of isolation valves. Permit holder to liaise with local Supervisor if any facility is required and to take extreme care during the work to not disturb the other running machine.
Permit holder is responsible for the safety of men and equipment.
Overhaul of Brine Recirculation Pump The following shows the steps that should be followed for issuing the overhaul permit for BRP of vertical borehole canister type, while the distiller is in partial operation. This work needs removing of the 6.6 kV motor to facilitate MMD work on the pump, for that G-SCE will rack out the 6.6 kV VCB, and will apply circuit earthling. Then he will issue EMD permit for removing the motor and he will give X-Lock & Tag key to D-SCE. Then D-SCE will perform the remaining isolations for the pump, which are mentioned previously. From the LOB, which contains these isolation keys, D-SCE will issue IMD permit to disconnect/reconnect BRPs instruments to facilitate MMD work on the pump, MMD permit to overhaul the pump and Civil permit for pump foundation, if it is required. Note: - If the suction or discharge valve of the pump is not holding, the distiller needs to be shut down to fix a blind flange for the passing valve.
Page 139 of 320
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May 2003
ITLE: DISTILLERS SOP No
D1-061
DSCE/PERMIT ENGINEER/LOCAL SUPERVISOR CCR/DCR

Issue of MMD Permit on Valves or Pipeline
The following is general steps for issuing permit to work on defective valve or leaking pipeline. Isolate the required section by closing the appropriate isolation valves. Depressurise and drain the section. Check for passing isolation valves. If there is passing valves make back isolations.
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May 2003
Chain and Lock & Tag the isolation valves. Isolate the power supply and Lock & Tag it for the motorised valves. Use the keys for issuing the permit.
* *
D1-061
Issue of Civil permit to Repair Cables Trench Concrete Precautions: Permit holder to take extreme care during work, because all cables in the trench are live. Permit holder should not allow any debris slip away in to
Page 141 of 320
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May 2003
the brine channel (if the work on the cable bridge). Area of work to be cordoned off with the rope and danger board to be displayed. Permit holder is responsible for cleaning the area after the work is finished. Permit holder is responsible for the safety of men and equipment.
D1-061
DSCE/PERMIT ENGINEER / LOCAL DIST SUPERVISOR
Issue of Permit for Fixing / Removing Blind Flange
The blind flange is fixed at brine entry in the first stage shell at Phase I & III before carrying out the vacuum test or acid
Page 142 of 320
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May 2003
cleaning. And it is fixed at brine entry line to first stage before carrying out the hydrostatic test or acid cleaning at Phase II, IV & V (hydrostatic test at Phase II for heat recovery section does not require fixing a blind flange), also at Phase V there is provision for fixing a blind flange before recirculating brine entry to water boxes of heat recovery section. The followings show the isolations required for fixing a blind flange. Isolate the 6.6 kV power supply to BRPs [A & B] and Lock & Tag the isolators in Off position. Isolate and Lock & Tag the 415V power supplies to BRP discharge motorised valves [A & B (B-7/VBR-5/B-7/B3/QM-MV603 & B-8/VBR-6/B-8/B-4/QM-MV-607). Isolate and Lock & Tag the 415V power supply to steam C/V upstream isolation motorised valve (S-8/S-8), (Phases I & III only). Shut, chain and Lock & Tag the following: steam C/V upstream valve (S-8/VHS-1A,VHS-1B/S-8/S1,S3/LQMV603), with bypass isolation valves (S-11/VHS-4/S11/S-5/NA) + their balance valves (at Phase I & III only), steam unit isolation valve (S-8&9/S4002/S-8&9/S252/LQ-V-600) + the balance valve (at Phases II, IV & V only), seawater make-up C/V upstream (U/S: SW21/VFW-1/SW-21/SW-2/QL-V-630 with bypass isolation valves (SW-24/VFW-4/SW-24/SW-4/QL-V-631), emergency blowdown isolation valve (B-9/VEB-1/B-9/B7/--) (not available at Phase V) and distillate headers isolation valves distillate header.V/V.NOS:-(VDM-13/DP26/DP-105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP-14/DP-13/DP-14/NA/NA).. The other isolation valves to be shut. After fixing the blind flange, the MMD will suspend the permit to allow the operation staff to start the preparation for hydrostatic, vacuum test or acid cleaning.
Page 143 of 320
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May 2003
D1-061
Vacuum Test at Phases I & III

Page 144 of 320
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May 2003
If the leak is in the heat reject section tubes, then reject flow to be stopped and seawater main isolation valve (SW-1/SW-1) should be shut, chained and locked & tagged in addition to the above isolations. In this case no need for fixing blind flange. When the test is completed the vacuum to be broken and then the permit to be reissued to remove the blind flange.
D1-061
LOCAL DIST SUPERVISOR CCR / DCR

Hydrostatic Test for HJS & HRS Tubes

Page 145 of 320
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May 2003
One distillate header isolation valve (VDM-13/DP-26/DP105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP14/DP-13/DP-14/NA/NA)..should be unlocked for filling the shell. At Phase II, fixing a blind is not required. Seawater makeup line should be locked & tagged after filling the plant shell. If the leak is in the heat reject section tubes then reject flow to be stopped and seawater main isolation valve (SW-1/VSW-1/SW1/SW-1/QL-MV-600) should be locked & tagged. At Phase II reject flow to be stopped after filling the plant shell. Also if the leak is in the heat reject section tubes, In this case no need for fixing blind flange. When the test is completed the distiller shell should be drained completely and then the permit to be reissued again to remove the blind flange.
D1-061
Page 146 of 320
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Acid Cleaning

May 2003
After fixing the blind flange, the MMD will suspend the permit to Remove the tag & Unlock the isolation valves of the steam to brine heater (S-8&9/S4002/S-8&9/S-252/LQ-V-600) to allow the operation staff to start the preparation for acid cleaning. When the acid cleaning is completed the plant should be drained completely and then the permit to be reissued again to remove the blind flange.
D1-061
Page 147 of 320
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May 2003
Hydrostatic Test for Brine Heater Tubes One distillate header isolation valve distillate headers isolation valves:-(VDM-13/DP-26/DP-105/QQ-V-608) OR (DP25/DP-106)Iso. V/v Sleeper way (DP-14/DP-13/DP14/NA/NA)..should be unlocked for filling the shell. At Phase II, fixing a blind is not required. Seawater make-up line should be locked & tagged after filling the plant shell. If the leak is in the heat reject section tubes then reject flow to be stopped and seawater main isolation valve (SW-1/VSW-1/SW-1/SW-1/QLMV-600) should be locked & tagged. At Phase II reject flow to be stopped after filling the plant shell. Also if the leak is in the heat reject section tubes, In this case no need for fixing blind flange. When the test is completed the distiller shell should be drained completely and then the permit to be reissued again to remove the blind flange. Hydrostatic Test for Brine Heater Tubes The following is general steps for issuing permit to carry out hydrostatic test for detecting leaking tubes in brine heater. There is no need for a blind flange for this test but the required isolations are similar to the above isolations.
*
At Phases I, III & V In addition to the above isolation, shut, chain and Lock & Tag the condensate header isolation valve (V/V. NO:-C-22/VCH-12,C14/ LT-XV-614) and HP make-up (condensate at Phase V) to desuperheater header isolation valve (HM-6/ HM-6/ LT-V625). The other isolation valves to be shut.
Page 148 of 320
* *
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Filling will be by industrial water. At Phases II & IV

May 2003
* *
In addition to the above isolation, shut, chain and Lock & Tag the condensate header isolation valve (V/V. NO:- VCH-12,C-14/C22/) . The other isolation valves to be shut. Filling will be by HP make-up water through desuper-heater (VCH-19/ O-HM-287).
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SOP No
TITLE: DISTILLERS

May 2003
D1-061
DSCE/PERMIT ENGINEER/DIST LOCAL SUPERVISOR CCRDCR

Issue of Permits to Release Distiller for Annual Overhaul The followings are main steps for releasing distiller and its board for annual overhaul: Shut down the distiller. Stop seawater flow in heat reject section. Drain the brine shells and the water boxes. Flush the tubes of heat reject section, heat recovery section and brine heater by distillate water. Shut, chain and Lock & Tag all header isolation valves distillate
header.V/V.NOS:-(VDM-13/DP-26/DP-105/QQ-V-608) OR (DP25/DP-106)Iso. V/v Sleeper way (DP-14/DP-13/DP-14/NA/NA). * * * * * * *
HP distillate header iso. v/v (ISO.V/V. NO:HD-17/TagNo. NA/HD-17/HD-51/QQ-V-641). the condensate header (V/V. NO:-C-22/VCH-12/C-14/C22/LT-XV-614) Kill the distiller board and rack out the incomer, bus-tie and all motor starters, then Lock & Tag their bus bar shutters. Give the G-SCE the 415V incomer ACB bus bar shutters Lock key and get from him the 6.6 kV OCB bus bar shutters X-Lock key and 6.6 kV VCBs bus bar shutters XLock keys. Use the keys for issuing the overhaul permits. Note:
Page 150 of 320
After cancellation of bus bar inspection permit, Lock & Tag the bus bar shutters of the big and small motor starters then issue their overhaul permits.
Effective
Oct 2002
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SOP No

May 2003
TITLE: DISTILLERS
D1-062
DISTILLER OVERHAUL PERMITS
DSCE/PERMIT ENGINEER
Location PRELIMINARY CHECKS Field CCR/DCR
The following is block permit system, which is being adopted at RAF-A to release a distiller and its board for annual overhauling. Phase IV will be used as an example to illustrate the block permit system. MMD Permit for Major Overhaul of Distiller (LOB1A/1) Points of Isolation:
6.6 kV power supply to BRP A, BRP B, SWRP and distiller transformer OCB isolated on generation permits and X-locked & tagged with this permit. 415V incomer and bus-tie ACBs racked out and bus bar shutters locked & tagged. Seawater main inlet iso. v/v (SW-1/VSW-1/SW-1/SW-1/QLMV-600), seawater to ejector condensers main iso v/v (SW2/SW-7/SW-2/SW-8/QLV-618)., steam unit iso v/v (S8&9/S4002/S-8&9/S-252/LQ-V-600) + balance v/v , condensate header iso. v/v (V/V. NO:-C-22/VCH-12/C14/C-22/LT-XV-614) , HP make-up to desuperheater header iso v/v (HMPage 151 of 320
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May 2003
6/VCH-19/HM-6/O-HM-287/LT-V-625), old and new distillate header iso v/vs:-(VDM-13/DP-26/DP-105/QQ-V608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP14/DP-13/DP-14/NA/NA). and HP distillate header iso. v/v (ISO.V/V. NO:HD-17/TagNo. NA/HD-17/HD-51/QQV-641)shut, chained and locked & tagged.
EMD Permit for Bus Bar & Starter Cubicles Inspection (LOB-2A/2) Points of Isolation: 6.6kV supply to distiller transformer OCB isolated on generation permit and X-locked & tagged with this permit. EMD Permit for Overhaul Incomer & Bus-Tie ACBs (LOB-2A/3) Points of Isolation: Both incomer and bus-tie ACBs racked out and bus bar shutters locked & tagged. EMD Permit for Overhaul 415V Big Motors & their Starters (LOB-6A/2) Points of Isolation: 415V supply ACBs racked out and bus bar shutters locked & tagged. EMD Permit for Overhaul 415V Small Motors & their Starters (LOB-7A/2) Points of Isolation: 415V supply ACBs racked out and bus bar shutters locked & tagged.
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IMD Permit for Disconnect / Reconnect BRP-A Instruments (LOB-3A/2) Points of Isolation: 6.6kV supply isolated on generation permit and X-locked & tagged with this permit. IMD Permit for Disconnect / Reconnect BRP-B Instruments (LOB-4A/2) Points of Isolation: 6.6kV supply isolated on generation permit and X-locked & tagged with this permit. IMD Permit for Disconnect / Reconnect SWRP Instruments (LOB-5A/2) Points of Isolation: 6.6kV supply isolated on generation permit and X-locked & tagged with this permit. IMD Permit for Major Overhaul of DCR & Field Instruments (LOB-1A/2) Points of Isolation: The distiller isolated on MMD overhaul permit and Xlocked & tagged with this permit. Civil Permit for Major Overhaul (LOB-1A/3) Points of Isolation:
Page 153 of 320
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The distiller isolated on MMD overhaul permit and Xlocked & tagged with this permit. General Precaution: Shells, tubes and water boxes of heat reject section, heat recovery section and brine heater are flushed with distillate and drained. Distillate channel filled for partition wall inspection. Permit holder to liaise with local area foreman if any facility is required. Permit holder is responsible for the safety of men and equipment. Permit holder is responsible for cleaning the area after the work is finished.
Page 154 of 320
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May 2003

PART-D2 BOILERS & DEAERATORS
Page 155 of 320
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CODE OF OPERATING PROCEDURES FOR BOILERS AND DEAERATORS CONTENTS
1.
General guidelines for water quality. High purity make up and condensate to the deaerator Boiler water
2.
Operation and shutdown procedures for deaerator W.H. Boiler Pre start up conditions.
3.
4.
W.H. Boiler start up and shutdown procedures
5.
Aux. Boiler startup and shutdown procedures
6.
Aux. Boiler start up and shut down procedures. Startup on fuel gas Startup on fuel oil Fuel changeover from gas to oil Fuel changeover from oil to gas
7.
General guidelines for boiler preservation - Boiler Water wedging procedure. - Boiler dewater wedging procedure.
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HIGH PURITY MAKEUP AND CONDENSATE

Ph Conductivity CO2 Copper Iron Oxygen : 5.6 : 2.2 uS / cm (max. 5uS / cm ) : 0.18 ppm : 0.01 ppm : 0.03 ppm : 0.02 ppm
BOILER WATER
Alkalinity : min. 50 ppm as CaCO3 max. 200 ppm as CaCO3 Silica as ppm in SiO2 TDS Iron Total hardness Phosphate Hydrazine Organic Matter : max 0.2 X alkalinity : max 1000 ppm : max 10 ppm : max 1 ppm as CaCO3 : max 25 ppm as P2O5 : max 0.2 to 0.5 ppm N2H4 : max 10 ppm KMnO4
Page 157 of 320
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SOP No

May 2003
TITLE: BOILERS & DEAERATORS
D2-001
STARTUP AND DEAERATOR
SHUTDOWN
PROCEDURES
FOR
LOCAL BOILER SUPERVISOR DSCE/PERMIT ENGINEER/CCR/DCR

PRE START CHECKS 1. 2. 3. 4. 5. Check instrument air supply is available and lined up. Check that bearing cooling water supply is available and lined up. Confirm all c/v are responding from CCR Confirm chemical dosing system is OK and tank is charged with chemicals. Confirm power supply is available to all electrical drives.
* * * * * *
START UP OF DEAERATOR Line diagram of ' DEAERATOR'

1. 2. 3. Start filling deaerator with H.P. make up by opening the make-up c/v bypass isoln. v/v(HM-5/2020/HM-5/HM-5/LTV-005). Open steam isoln. v/v(S-3/2005/S-3/83/LQV-001) on steam supply line. Start warming the deaerator slowly by opening the steam c/v by pass isoln. v/v (S-6/2021/S-6/S-6/LQV-003)and the warm up steam isoln. v/v(S-5/2004/S-5/S-5/LQV-002). When the deaerator level reaches normal working level, close the H.P. make up c/v BY pass isoln. v/v(HM-5/2020/HM-5/HM5/LTV-005). Page 158 of 320 * * * * * * *
4.
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5. 6.

May 2003
7. 8. 9. 10.
11.
12.
13.
When the deaerator drum pressure reaches 2.5 bar deisolate the steam c/v(S-4/PCV1100/S-4/PCV1100/PCV-054) and close the bypass V/v(HM-5/2020/HM-5/HM-5/LTV-005). and the warm up steam isoln v/vs(S-3/2005/S-3/83/LQV-001) Put the pressure controller on auto mode. Start the chemical dosing pump. Deisolate the H.P. Makeup c/v Upstream(HM-2/2007/HM-2/HM2/LTV-003) and downstream v/vs(HM-4/2007/HM-4/HM4/LTV-004). Keep the c/v(HM-3/LCV-1100/HM-3/LCV1100/LCV-061A) shut. Open the feed water pumps suction isoln v/vs(FW-2,FW3/2003B,2003B/FW-2,FW-3/FW-2,FW-3/LSV-001,LSV-002) and prime the pumps. Open the leak off line isoln v/vs(-/2011/2031//FW-4,FW-5/LSV008,LSV-009) and start one of the feed water pump and select the other on standby. Slowly open the feed water pump discharge isoln. v/v(FW-6,FW7/2008,2008/FW-6,FW-7/FW-6,FW-7/LSMV005,LSMV006) Check the feed water pump auto changeover. Deisolate the condensate c/v(C23,C25/2016, 2016/C23,C25/ C15,C17/LTV-003,LTV004) and put the level control(C-24/LCV1101/C-24/LCV-1101/LCV061B) on auto mode.
* * * * * * *
14. 15.
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TITLE: BOILERS & DEAERATORS SOP No
D2-002
STARTUP AND DEAERATOR
SHUTDOWN
PROCEDURES
FOR
SHUT DOWN OF DEAERATOR

CCR/DCR/ LOCAL BOILER SUPERVISORS DSCE/PERMIT ENGINEER/CCRDCR
1. 2.
Select the standby feed pump on manual. Close the disch. v/v(FW-6,FW7/2008,2008/FW-6,FW-7/FW-6,FW7/LSMV005,LSMV006 and stop the running
* * * * * * * * *
3. 4.
feed water pump. Put on manual the pressure controller. Close the steam c/v(S-4/PCV1100/S4/PCV1100/PCV-054) and close the all steam isoln. v/vs(S-6/2021/S-6/S-6/LQV-003)& (S5/2004/S-5/S-5/LQV-002).
5.
Close
the
condensate
isoln.
v/v(C-
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6. 7.
8.

May 2003
23,C25/2016,2016/C23,C25/C15,C17/LTV003,LTV4)
Put in manual the level controller Close the H.P. make up isoln. v/v(HM2/2007/HM-2/HM-2/LTV-003)&(HM4/2007/HM-4/HM-4/LTV-004).
Stop chemical dosing pump.
TITLE: BOILERS & DEAERATORS SOP No
D2-003
W.H. BOILER PRE START UP CONDITIONS

CCR/DCR/LOCAL BOILER SUPERVISOR DSCE/PERMIT ENGINEER/CC/DCR
1. 2. 3. 4.
Confirm that there are no permits in force. Inspect inside and around the boiler and confirm there are no abnormalities. Close and tightly shut all the casing doors. Confirm the boiler and bypass dampers are in shut down
Page 161 of 320
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5. 6. 7. 8. 9.

May 2003
position and CCR mimics are ok. Damper operation to be selected on hand at CCR [panel. Confirm Instrument air supply availability. Confirm all instrumentation is on line. Confirm all isolation and control v. /vs are in their normal position. Confirm cooling water supply and lubrication oil levels of pumps is normal. Confirm power supply to all electrical drives is restored. Stroke check all control valves and confirm responding normally from CCR. Confirm pumps and fans move freely. Confirm lab. Has charged service chemicals in the chemical tank and the dosing system is working O.K.
* * * * *
* *
10. 11.
* *
12. 13.
SOP
No
D2-004
W.H. BOILER
CCR/DCR/BOILER LOCAL SUPERVISORS CCR/DCR

Location
PRELIMINARY CHECKS Field LCR/MI
START - UP 1. If boiler is in water wedged condition, dewaterwedge the boiler 2. Line up Feed water up to the first isolation v/v(FWPage 162 of 320
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10//304//FW-10//FW-10). 3. Open economizer(FW-3,5,4,6/310(4Nos)/FW-3,5,4,6/FWV3,4,5,6) evaporator(FW-7,9,8,10/318(4Nos)/FW7,9,8,10/FW-7,8,9,10) steam line(SV1,2/308/SV1,2/SV12,13)and drum vent(SV3,4/323/SV3,4/SV14,15) valves. 4. Close and isolate the feed water LCV (FW11/LCV1300//LCV-1300//FW11/LCV-1300//LCV-1300) 5. Drain out completely the steam line upstream of steam NRV(S-21//201//S-21//S-19) 6. Take feed water (flow rate 20 to 30 t/h) by opening slightly the F.W. LCV Bypass isoln. v/v (FW-13//401//FW-13//FW13) 7. Close the economizer vent v/v(FW-3,5,4,6/310(4Nos)/FW3,5,4,6/FWV-3,4,5,6) when water starts flowing out. 8. Fill the boiler drum to about 10cm above normal working level and close the F.W. LCV bypass v/v(FW-13//401//FW13//FW-13) 9. Open Blr. Circulating pumps suction ( FW-16 & FW17//303A & 303B//FW-16 & FW-17// FW-16 & FW-17) and discharge ( FW-20 & FW-21//302A & 302B//FW-20 & FW-21// FW-20 & FW-21)V/V s and prime the pumps, delivery line and evaporator tubes. Then close the discharge V/V s( FW-20 & FW-21//302A & 302B//FW-20 & FW-21// FW-20 & FW-21) 10.Open the evaporator / economizer bypass v/v (FW-22 & FW 23// 332A & 332B// FW-22 & FW-23// FW-22 ). 11.Start one circulating pump and gradually open the discharge v/v. (FW-20 & FW-21// 302A & 302B// FW-16 & FW17//FW-16 & FW-17) Select the standby pump on auto 12.close the evaporator return line vent v/v(FW7,9,8,10/318(4Nos)/FW-7,9,8,10/FW-7,8,9,10) when water begins to flow out. 13.Confirm by Lab the boiler water is OK, if not drain out the boiler and repeat steps (6) to (13) 14.Start one purge air fan and select the other to auto. 15.Put Damper control selector switch to CCR, Drum level control on manual and internal set, combustion temp.
Page 163 of 320
* * * * * * * * * * * * * *
* *
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Control on manual and internal set. 16.Confirm GT is in normal operation and take clearance from Generation section to put boiler in service. 17.Open boiler damper by 15% to pressurize the boiler. 18.When the drum pressure raises to 3 bars close the drum(SV3&SV-4//323&--//SV-3&SV-4//SV-3&SV-4) and steam line vents. (SV1,2/308/SV1,2/SV12,13) 19.When boiler starts steaming deisolate the feed LCV(FW10//304//FW-10//FW-10)&(FW-12//304//FW-12//FW-12) and put the controller on auto. 20.Close the evaporator / economizer bypass isoln. v/v(Fw22&FW-23//332A&332B//FW-22&FW-23//FW-22) 21.When the drum pressure reaches 12 bar open the main steam MOV(S-1//601//S-1//S-1) by first opening the balance v/v.(S-1* Balance /601*Balance /S-1* Balance /S-1 *Balance) Confirm the steam NRV(S-21//201//S-21//S-19) is deisolated. 22.Boiler begins to feed steam to the system when drum pressure reaches 15 bars. 23.Open the boiler damper fully and close bypass damper as per steam requirement. 24.Start service chemical dosing as per lab. Instructions.
* *
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SOP No

May 2003
TITLE BOILERS & DEAERATORS
D2-005
ACTIVITY REFERENCE RESPONSIBILI TY COMMUNICATIO N
W.H. BOILER SUPPLEMENTARY GAS FIRING

CCR/DCR/LOCAL BOILER SUPERVISORS CCR/DCR
Location
OPERATION Field
CCR /DC R
If the boiler load is to be further increased after closing the bypass dampers fully, additional gas firing can be carried out to increase the combustion temperature. 1. Confirm that the Boiler damper full open and bypass damper full close mimic is available at local and CCR panels. 2. Check that LP & HP fuel gas isolation valves are open and filters are line up. 3. Open fuel gas isoln. v/v (G-35//701//G-35//G-35) at firing platform and pressurize the line upto the gas c/v (G-36//PCV-1300//G-36//PCV-1300) 4. Open gas isoln. v/vs. to pilot burners (G-45//706//G-45//G-45) and scanner burners(XT-1300,XT-1301,XT-1302,XT-1303,XT-1304,XT-1305,XT1306,XT-1307,XT-1308,XT-1309,XT-1310,XT-1311FORALL PHASES). 5. Open gas c/v (PCV-1300//PCV-1300//PCV-1300//PCV-1300)by about 25% from CCR. 6. Confirm ready to start is available at local panel and select Group A or B burners to ON. 7. Firing sequence will commence and proceeds as follows 0 to 60 sec. Purge 60th Sec Shut off v/v of pilot burners will open, 60 to 65 sec. Pilot burner ignition. 65 to 75 sec Settling time for pilot burners. 75 to 80 sec Main Burner ignition 80 to 90 sec Settling time for main burners. 8. Repeat the firing procedure for the other group of burners. 9. Open the gas isoln. v/vs of individual burners to obtain the required combustion temp. Page 165 of 320 Select the combustion temp. controller on auto with the required set point.
* * * * * * *
* * *
* * * * * * * *
* * *
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SOP No

May 2003
D2-006
W.H. BOILER SHUTDOWN PROCEDURES
CCR/DCR/BOILER LOCAL SUPERVISORS
Location PRELIMINARY CHECKS Field LCR/MI
1. Reduce the gas c/v (PCV-1300//PCV-1300//PCV1300//PCV-1300) opening and put off gas burners in group A and group B by closing the individual gas isoln. Valves. 2. At the local panel select group A and group B burner to off which will shutoff and ESV putting off the gas fi ring. 3. Close the gas c/v (PCV-1300//PCV-1300//PCV-1300//PCV1300) and gas isoln. v/v (G-35//701//G-35//G-35) at firing platform and open the downstream vent(GV-1/711/GV1/GV-3). 4. Reduce the boiler load by opening the bypass damper slowly, after bypass damper is fully open gradually close the boiler damper. 5. When the boiler stops steaming close the steam MOV (S1//601//S-1//S-1). 6. Open the evaporator Economizer bypass v/v (FW22&FW-23//332A&332B//FW-22&FW-23//FW-22&FW23) and isolate the Feed water c/v (FW-11/LCV1300//LCV-1300//FW-11/LCV-1300//FW-11/LCV1300).Maintain drum level through the bypass v/v (FW13//401//FW-13//FW-13) if required. 7. When the pressure drops to 3 bar open Drum vent v/v(SV3&SV-4//323&--//SV-3&SV-4//SV-3&SV-4) 8. Continue to run the Boiler circ. Pump and purge air fan if
Page 166 of 320
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the GT remains in service and the dampers are passing. 9. Confirm that the boiler and bypass damper mimics are ok. 10.If the pressure drops below 2 bars and the GT is shutdown and boiler circ. Pump and purge air fan may be stopped.
TITLE: AUXILIARY BOILER SOP No
D2-007
PRE-START CHECKS
DSCE/PERMIT ENGINEER/CCR/DCR/LOCAL BOILER SUPERVISORS CCR/DCR

Line diagram of ' AUX. BOILER' 1. Confirm that no PTW is in force. 2. Confirm power supply is restored to all the electrical drives. 3. Confirm that L/P and H/P gas is lined up and the pressure downstream of pressure reducer is normal. 4. Confirm that lab. has charged service chemical in the chemical dosing tank. 5. Confirm that the feed water line is pressurized upto the feed c/v (OFW9/LCV-301//LCV-301//LCV-301 upstream isoln. v/v (OFW10//1012//OFW101) and the steam line is
Page 167 of 320
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pressurized upto the steam MOV (OS-5/7//1001//OS51/56)
D2-008
STARTUP ON FUEL GAS
CCR/DCR/BOILER LOCAL SUPERVISORS CCR/DCR

Location
PRELIMINARY CHECKS Field CCR/DCR
Line diagram of ' FUEL GAS ' 1. Open the boiler drum vent (O-S-V-3/4&O-S-V1/2//323//O-S-V-1/2) and stream line vent(OSD4/1026/SD4). Deisolate stream NRV (OSD4//1002//OS-57/62) and keep the stream MOV balance v/v open(OS5/7 Balance//1001 balance//OS51/56 Balance). 2. Fill the boiler drum with feed water by opening the feed c/v bypass isoln. v/v (OFW13/14//1020//OFW198/203) upto normal working level. 3. Confirm by lab. That the boiler water is satisfactory.
Page 168 of 320
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4. Start F.D. Fan and Atomising air fan

May 2003
5. Line up the fuel gas line and pressurize the line upto the slam shutoff v/v (SSV) (OG15/16/XV801//06-321/326) 6. Confirm that Ready to Start is available at the local firing panel. 7. After taking clearance from the Control Room put the Gas burner switch to ON. This will initiate the firing sequences in the following order. 0 to 120 Sec. Furnace purge. 120 to 130 Sec. Ignition burner start 130 to 135 Sec Main gas burner start 8. With the main gas burner on, the drum pressure begins to increase. 9. Close the drum vent (O-S-V-3/4&O-S-V-1/2//323//O-S-V1/2) and stream line vent isoln. v/v(OSD4/1026/SD-4). when the drum pressure reaches 3 bars.
* *
* *
10.Open steam MOV (OS-5/7//1001//OS51~56) when drum pressure reaches 11 bars. Close the steam MOV balance v/v (OS-5/7 * Balance /1001* Balance /OS-51 ~ 56* Balance) 11.When boiler begins to steam deisolate the feed c/v (OFW9/LCV-301/LCV-301//LCV-301) and put drum level control on auto. 12.Increase / decrease the boiler load as per requirement by using the master controller selected to Auto internal, or set the boiler to maintain the steam header pressure on auto by selecting the master controller to Auto external
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May 2003
D2-009
STARTUP ON FUEL OIL
LOCAL BOILER SUPERVISORS CCR/DCR

Prestart checks 1. Confirm that the fuel oil day tank is having required level. 2. Confirm power supply is available for the fuel oil pumps. 3. Confirm Propane gas cylinders are available and full.
Page 170 of 320
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4. Confirm that the oil guns are inserted and the flexible hoses are connected and properly tightened. 5. Confirm that the propane cylinders are connected to the three way v/v(Phase1-OG 23/24//Phase VI-OG 297/302) 6. Confirm power supply is available to all other drives. 7. Confirm that chemical dosing tank is charged with services chemicals.
* * * *
D2-010
START UP
CCR/DCR/LOCAL BOILER SUPERVISORS CCR/DCR

1. Start F.D.Fan and Atomising air fan, 2. Start one fuel oil pump and put it on recirculation. 3. Open the manual oil isolation v/v(OFD 92/93,96/97,OFD 90/91,94/95// 1090,1091,1097,1098//OFO589/594,OFO606/611,OFO624/629,OFO618/6 23) before the oil gun. 4. Confirm ready to start is available. If not confirm that the oil supply
Page 171 of 320
*
*
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May 2003
pressure is o.k. , fuel oil c/v (PCV-302//PCV-302//PCV-302)position is right, both oil guns are properly coupled and manual oil v/vs (OFD92/93,96/97,OFD90/91,94/95// 1090,1091,1097,1098// OFO589/594, OFO606/611, OFO624/629,OFO618/623) are open. 5. After taking clearance from the control room, put the oil burner switch to ON 6. Firing sequence will get initiated in the following order. 0 to 120 sec Furnace Purge 120 to 130 sec. Ignition flame A & B will be on 130 to 145 Sec Ignition time for main oil burner, main burner A& B light on After 145 sec. Ignition flame A & B off and oil burner in operation light ON 7 Check the flame for combustion and confirm the stack is clear if not adjust the fuel / air ratio to attain proper combustion. 8 When the drum pressure is 3 bar close drum vent v/v (O-S-V3/4&O-S-V-1/2/323//O-S-V-1/2) 9 Confirm steam NRV (OSD4/1002//OS-57/62) is deisolated and steam MOV balance v/v (OS-5/7Balance/1001Balance/OS51~56Balance )is open. 10 When the drum pressure is 12 bar open steam MOV (OS5/7/1001//OS-51/56) and close balance v/v(OS5/7Balance/1001Balance/OS-51~56Balance)
* *
* * * *
11 When boiler begins to steam deisolate the feed c/v (OFW9/LCV301//LCV-301//LCV-301) and put drum level control on auto. 12 Increase / Decrease the boiler load as per the requirement by using the master controller selected to Auto Internal or set the boiler to maintain the steam header pressure on auto by selecting the master controller to Auto External
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May 2003
D2-011
FUEL CHANGEOVER FROM GAS TO OIL
CCR/DCR/BOILER LOCAL SUPERVISOR CCR/DCR

Page 173 of 320
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1. Reduce the boiler load to minimum 2. Insert and connect oil guns 3. Start one fuel oil pump on recirculation and keep the other on standby. 4 Oil burner ready to start will appear if Oil Guns are properly coupled. Fuel oil supply pressure is ok Fuel oil c/v (PCV-302//PCV-302//PCV-302) position is ok Manual valve (OFO-90/91,OFO-94/95/OFO589, 596/OFO-624,629) of both oil guns are open 5. Put the oil burner switch ON at the firing panel. 6. After 15 Sec. Time Delay the oil burner will ignite from the flame of gas burner. 7. After 15 sec. of dual firing Oil burner in operation indication will light on. 8. Put off gas burner switch and isolate gas line by gas isolation v/v (OG19/1056//06-291/296) 9. Check the burner flame and stack, adjust fuel-air ratio to attain proper combustion.
* * *
* * *
D2-012
FUEL CHANGEOVER FROM OIL TO GAS
CCR/DCR/BOILER LOCAL SUPERVISORS CCR/DCR Page 174 of 320
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OPERATION

May 2003
1. 2.
Reduce the boiler load to minimum. Open gas isoln. V/v (OG19//1056//06291/296) and pressurize the line upto the SSV (OG 15/16//XV801//06-321/326) Confirm (Gas burner ready to start) is available Switch the gas burner on Gas burner will ignite from the oil flame. When (gas burner in operation) indication lights on, put off the oil burner, purge the oil burner and isolate the manual v/vs (OFO-90/91,OFO-94/95/OFO-589, 596/OFO-624,629) Stop the oil pump and isolate the oil line. * *
3.
* *
4. 5. 6.
7.
D2-013
SHUT DOWN PROCEDURE.
CCR/DCR/LOCAL BOILER SUPERVISORS Page 175 of 320
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May 2003
CCR/DCR
Reduce the boiler load to minimum. Put OFF the gas / oil firing from local firing panel. In case of oil firing complete the oil gun purge sequence. Isolate the gas isolation v/v (OG19/1056//06-291/296)or close manual oil v/vs(OFO-90/91,OFO-94/95/OFO-589, 596/OFO-624,629) and stop oil pumps in case the boiler was on oil. Isolate the feed water line when the boiler stops steaming When the drum pressure drops to 12 bar close the steam MOV (OS-5/1001/OS51/56) When the drum pressure drops to 3 bars open the drum vent isoln. V/v (O-S-V-3/4&O-S-V-1/2//323//O-S-V-1/2) (If complete drum draining is required. Open the drum vent (O-SV-3/4&O-S-V-1/2/323//O-S-V-1/2) when Pressure is 5 bar begin draining for hot blow down) Shutdown F.D. fan and atomizing air fan.
* * * *
D2-014
ACTIVITY REFERENCE
BOILER PRESERVATION
Page 176 of 320
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May 2003
LOCAL BOILER SUPERVISOR CCR/DCR

If the boiler is shut down for upto two days it is preferable to fill the boiler drum upto the vent with boiler feed water. If the outage is from 2 days to 1 week the boiler drum is to be topped up with preservation chemicals. If the outage is expected to be for than a week the boiler has to be water wedged with the amount of preservation chemical proportional to the outage period.
TITLE:W.H.BOILER SOP No
D2-015
ACTIVITY REFERENCE
W.H.BOILER WATERWEDGING PROCEDURE
Page 177 of 320
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BOILER LOCAL SUPERVISOR CCR/DCR

1. 2. 3.
Hot blowdown the boiler when the drum pressure is 5 bars. Fill up the drum with fresh feed water.
Start one circulating pump and begin dosing the preservation chemicals 25.On completion of chemical dosing, fill the drum upto the steam line vent. (SV1,2/308/SV1,2/SV12,13) Close the vent after proper priming. Further pressurize the drum upto 4 bar by partially opening the feed v/v (FCVby-pass) (FW-13//401//FW-13//FW-13) Line up the pressure backup line from the deaerator if the deaerator is in-service or maintain the boiler drum at a pressure of 3 to 5 bar by opening the feed line from time to time
4.
5.
6.
TITLE: W.H.BOILER SOP No
D2-016
W.H.BOILER DEWATERWEDGING PROCEDURE.
BOILER LOCAL SUPERVISOR CCR/DCR Page 178 of 320
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OPERATION

May 2003
1. 2.
Close the pressure back-up line from deaerator isoln.V/v 26.Open drum (SV-3&SV-4//323&--//SV-3&SV4//SV-3&SV-4) and steam line vent v/vs(SV1,2/308/SV1,2/SV12,13) and begin draining to normal working level. Ensure evaporator/economizer bypass v/v (FW-22&FW23//332A&332B//FW-22&FW-23//FW22) is open. Start one circulation pump and one purge air fan. 27.Open boiler damper to about 15%, close the drum (SV-3&SV-4//323&--//SV-3&SV-4//SV-3&SV4) and steam vent w(SV1,2/308/SV1,2/SV12,13) when pressure reaches 2.5 bar, further pressurize the drum to 5 bar. Close the boiler damper and stop the boiler circ. Pump. Open the drum vent (SV-3&SV-4//323&--//SV-3&SV4//SV-3&SV-4) and begin Hot Blow down. Take fresh feed water upto NWL and start Circ. Pump for flushing. Drain the boiler empty and refill the boiler to NWL.
3. 4. 5.
* *
6. 7. 8. 9.
10. Check the boiler water quality by lab., if un-satisfactory repeat steps 8 & 9.
D2-017
ACTIVITY REFERENCE
AUX. BOILER WATERWEDGING PROCEDURE.
Page 179 of 320
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Q.E.W.C

May 2003

1. After shut down keep both fans running for cooling down the furnace. 2. Close feed (OFW10/11&OFW11/12//1012&1013//OFW101/106&OFW107/122) steam , gas isoln. V/vs (OG19//1056//O6-291/296) Close Steam MOV (OS5/7//1001//OS51/56) and NRV (OSD4//1002//OSD-57/62) 3. Start Hot blow down when the boiler drum pressure drops to 5 bars. Open drum vent (O-S-V-3/4&O-S-V-1/2//323//O-S-V-1/2) at 2.5 bar 4. Stop F.D and Atomising air fan. After draining completely, take fresh feed water and flush the boiler. 5. 6. Fill the drum upto NWL, start FD and Atom. Air fans and fire the boiler. Start dosing the preservation chemicals. When drum pressure is 5 bars cut the firing. If the FD and Atm. Air fan is not available or the fuel system is under PTW, fill the drum gradually. Simultaneously dose preservation chemicals
*
7.
D2-018
ACTIVITY REFERENCE
AUX. BOILER DE-WATERWEDGING PROCEDURE
Page 180 of 320
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May 2003

1. 2. 3. 4. 5. 6. 7.
Drain the boiler drum to NWL Start the FD and Atm. Fans and fire the boiler. Raise the drum pressure to 5 bar and cut gas firing.
* *
Hot blowdown the boiler. Take fresh feed water and flush the boiler. Fill the boiler again and get the boiler water sampled by lab.
* *
If boiler water is not satisfactory repeat steps 5 & 6
D2-019
PERMIT TO WORK ON W.H.B. PRESSURE PARTS
DSCE/PERMIT ENGINEER/LOCAL BOILER SUPERVISOR Page 181 of 320
Effective
Oct 2002
Q.E.W.C
COMMUNICATION PRELIMINARY CHECKS

May 2003
This permit is to be issued generally during the inspection or Overhaul of the gas turbine. Electrical isolations 415v supply to boiler damper motors. 415v supply to boiler circ. Pumps A and B. 415v supply to steam MOV. (S-1//601//S-1//S-1) Mechanical isolations: Steam maintenance isolation valve(--/--/--/OS225,226,227,228). Feed water first isolation valve. (FW-10//304//FW-10//FW-10) Fuel gas isolation valve (at firing platform) (G-35// 701//G-35//G35) Common drain to flash tank isolation valve (BD-19/20 // 314/306//BD-19/20//BD-14/18). Deaerator-waste heat boiler pressure back-up isolation valve. GT shut-down isolation cross Lock & Tag. Remarks: Hot blow-down the boiler at 5 bar.
* * *
* * * * *
D2-020
ACTIVITY REFERENCE
PERMIT TO WORK ON W.H.B. NON-PRESSURE PARTS
Page 182 of 320
Effective
Oct 2002
Q.E.W.C
RESPONSIBILITY COMMUNICATION

May 2003
DSCE/PERMIT ENGINEER/ BOILER LOCAL SUPERVISOR
This permit to be issued generally after the completion of pressure part Permit, but during GT inspection or overhaul. Electrical isolations 415v supply to boiler damper motors. 415v supply to purge air fans A and B. GT shut-down isolation cross Lock & Tag. Mechanical isolations: Fuel gas isolation valve (at firing platform) (G-35// 701//G-35//G35) .
* * *
Remarks: The boiler drum is to be water wedged
D2-021
ACTIVITY
PERMIT TO WORK ON W.H.B. FUEL GAS SYSTEM

Page 183 of 320
Effective
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Q.E.W.C

May 2003
DSCE/PERMIT ENGINEER/BOILER LOCAL SUPERVISOR
This permit is to be issued during GT overhaul or inspection and may be Issued at the same time when pressure part or nonpressure part permit is in force. Electrical isolations 415v supply to boiler damper motors.
Mechanical isolations: *
Fuel gas isolation (LP gas isolation at sleeper way(OG-655 /OG656 ~ 650/OG-661&662/OG819,820,821,822) and HP /LP cross connection valve(-/-/OG810,OG811/OG-861 ~ 864). GT shutdown isolation cross Lock & Tag.
Remarks:
The boiler drum may be water wedged. Down stream of gas isolation to be de-pressurized and vented.
TITLE: BOILER SOP No
D2-022
ACTIVITY
HIGH RISK SANCTION FOR WORK (AT AND AROUND

Page 184 of 320
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Q.E.W.C
THE BOILER).

May 2003
This permit to be issued generally with the boiler shut-down and as per the requirement in conjunction with other mechanical permits. Mechanical isolations: Isolate fuel gas at sleeper way and de-pressurize the gas line line down stream of isolation. Other mechanical isolations to be out depending upon the point of hot work. Remarks: The maintenance personnel should ensure that the area of hot work is gas free by getting it tested and certified by the laboratory. *
LOA for damper operation check and limit switch adjustment This LOA to be issued during GT outage and after completion of pressure part permit on the waster heat boiler. 415v supply to damper motors to be restored. LOA to be issued with GT shutdown isolation cross Lock & Tag.
Page 185 of 320
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Remarks:

May 2003
The boiler drum should be full or at normal working level. Both circulating pumps should be available to carry out the damper operation check. Ensure that no mechanical permit is in force on the boiler or bypass damper. This LOA to be issued at the end of the boiler maintenance outage and after all mechanical servicing of damper is completed.
LOA for electrical preventive maintenance of electrical drives. This LOA to be issued during GT inspection or overhaul and can be issued in conjunction with mechanical pressure part permit. Electrical isolation: * 415v supply to boiler damper motors. 415v supply to boiler circulating pumps A and B. 415v supply to purge air fans A and B 415v supply to steam motorized valve(S-1//601//S-1//S-1).
Page 186 of 320
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Q.E.W.C

May 2003

PART- D3 COMMON SERVICES
OPERATIONAL PROCEDURE.
COMPRESSED AIR SYSTEM: Page 187 of 320
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Q.E.W.C

May 2003
Compressed Air Requirement of RAF- (A) Desalination plant for Instruments Air Header (Ring) and Works air header (Single) obtains from three compressor houses, each Compressor house consist of two works air compressors, four instrument air Compressors, two works air receivers, four instrument air receivers, and three air dryers And cooling water system. Reciprocating compressors capacity = 190m3/h. Discharge pressure =8.0bar. Air receiver capacity =20m3
TITLE: COMMON SERVICES
Page 188 of 320
Effective
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Q.E.W.C
SOP No

May 2003
D3-001
COMPRESSOR START-UP PROCEDURE
LOCAL BOILER SUPERVISOR
1) Check the compressors air out let valve(I.A.Comp A= O-WA-3//B=OWA-4//C= ---//D= ---//E= ---//F= ---//G= OCA-652//H= O-CA-654//J= OCA-553//K= OCA-554//L=O-CA-555//M= OCA-556//.W.A.Comp. E= --//F= ---//C= O-WA-350//D= ---//Ph-4E=O-WA-318//Ph-4F=O-WA-320) . All outlet valves up to receiver should be in open position. 2) Check lubricating oil level in the crankcase (80%). 3) Check cooling water valves to after cooler (I.A.Comp A= O-CW-43&44// B= ----//C= ---// D=---// E= O-CW-219&220//F= O-CW-217&218//G= OCW-543&544//H= O-CW-545&546//J= O-CW-521&522//K= O-CW523&524//L= O-CW-525&526//M= O-CW-527&528// W.A.Comp.E= OCW-52&56// F= O-CW-43&44//C= O-CW-541&542//D= O-CW215&216//Ph4 E= O-CW-517&518// Ph4 F= O-CW-519&520) and cylinder jacket (I.A.Comp. A= ---// B= ---// C=O-DW-54&58// D= O-DW-53&57// E= O-DW-195&---// F= O-DW-194&197// G= ---&O-DW-550//H= O-DW551&452// J= OCW- ---&534// K= O-CA-535&OCW-536// L= OCW537&538// M= OCW-539&540//W.A.Comp. E= --&--//F= O-DW-51&--// C= O-CW-547&O-CW-548//D= --&O-DW-196// Ph4 E = OCW-529&530// Ph4 F= OCW-531&532) are open and confirm water flow is established. 4) Check automatic loader air supply is available. Page 189 of 320
* * * * *
* * *
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Oct 2002
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5) Set the position selector to hand position. 7) V-Belt of air compressor is in good tension. 8) Isol v/v from mechanical pilot v/v close.

May 2003
6) Release the (STOP) push button on local switch panel.
9) Push oil pressure reset button (reset time 40-second). 10) Start the compressor by pushing the start button at local panel. After starting confirm lube oil pressure 2.05~2.81bar. 11) Confirm vibration, noise, motor amps. And smell is normal. 12) Set the range selector to adequate position, compressor will take load after 40 second Under any condition compressor will start unloaded and will remain unloaded as long as selection is on (HAND) position. It will load whenever selector changed to any (RANGE) position. THERE ARE 5-RANGE SELECTOR FOR INSTRUMENT AIR COMPRESSOR AS: UNLOAD 6.9 Bar 7.1 bar 7.2 bar 7.5 bar LOAD 5.9 bar 6.1 bar 6.3 bar 6.5 bar
Hand Range-4 Range-3 Range-2 Range-1
THERE ARE 3-RANGE SELECTORS FOR WORKS AIR COMPRESSORS AS: Unload 6.5 bar 7.0 bar Load 6.0 bar 6.5 bar
Hand Range-2 Range-1
Page 190 of 320
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Q.E.W.C

May 2003
Page 191 of 320
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Oct 2002
Q.E.W.C
SOP No

May 2003
TITLE: COMMON SERVICES
D3-002
SHUT DOWN THE COMPRESSOR
LOCAL BOILER SUPERVISOR CCR/DCR

Following steps to be followed for shut down: 1) Set the Range selector switch to (HAND) position and push stop button, compressor will stop. 2) Close compressor discharge valve. (I.A.Comp A= O-WA-3//B=O-WA4//C= ---//D= ---//E= ---//F= ---//G= OCA-652//H= O-CA-654//J= OCA553//K= OCA-554//L=O-CA-555//M= OCA-556//.W.A.Comp. E= ---//F= --//C= O-WA-350//D= ---//Ph-4E=O-WA-318//Ph-4F=O-WA-320) . 3) Isolate compressor jacket cooling water supply v/v (I.A.Comp. A= ---// B= --// C=O-DW-54&58// D= O-DW-53&57// E= O-DW-195&---// F= O-DW194&197// G= ---&O-DW-550//H= O-DW-551&452// J= OCW- ---&534// K= O-CA-535&OCW-536// L= OCW-537&538// M= OCW539&540//W.A.Comp. E= --&--//F= O-DW-51&--// C= O-CW-547&O-CW548//D= --&O-DW-196// Ph4 E = OCW-529&530// Ph4 F= OCW-531&532) after 3.0 minutes.
* *
ALARM AND TRIPS:

a) Lubricating oil pressure low trip =0.37 bar g b) Cylinder cooling water flow low trip =8.3 I/h c) Cylinder jacket out let cooling water temp: high trip=65C d) Compressor air outlet temperature high trip=260C
ALARMS:
e) Separator outlet temperature high =45C f) Receiver water level high =0.2m g) Air dryer outlet pressure low =5.5bar h) Instrument air header pressure low =4.5bar. (Control room) I) Works air pressure low =5.0bar (control room) Page 192 of j) Comp: house fault =(control room) 320
Effective
Oct 2002
Q.E.W.C

May 2003
Page 193 of 320
TITLE: COMMON SERVICES SOP No
D3-003
Effective
Oct 2002
Q.E.W.C
Issued Date ISOLATION PERMIT TO WORK Revision Issued By

May 2003
DSCE/PERMIT ENGINEER/BOILER LOCAL SUPERVISOR
i) Air discharge valve(I.A.Comp A= O-WA-3//B=O-WA-4//C= ---//D= --//E= ---//F= ---//G= OCA-652//H= O-CA-654//J= OCA-553//K= OCA554//L=O-CA-555//M= OCA-556//.W.A.Comp. E= ---//F= ---//C= O-WA350//D= ---//Ph-4E=O-WA-318//Ph-4F=O-WA-320) . shut locked & tagged for any work in compressor. ii) Connected inlet valve for receiver ( I.A.Comp. A= O-CA-5// B= O-CA6// C= O-CA-7// D = O-CA-8// E= O-CA-206// F= O-CA-205// G= O-CA653// H= O-CA-655// J= OCA 557// K= OCA-558//L= OCA-559//M= OCA-560// W.A.Comp. E= O-WA-6// F= O-WA-5// C= ---// D= O-WA103// Ph4 E = OWA-319// Ph4 F = OWA-321) and interconnected valve(PH1,A&B= OCA-63//C&D=OCA35//E&F=OWA22//PH3,C&D=OWA-354// E&F=OCA-260// G&H=OCA656//PH4, E&F=OWA-324// J&K=OCA361//K&L=OCA362) to be isolated if work is in discharge valve (I.A.Comp A= O-WA-3//B=O-WA-4//C= ---//D= ---//E= ---//F= ---//G= OCA-652//H= O-CA-654//J= OCA-553//K= OCA-554//L=OCA-555//M= OCA-556//.W.A.Comp. E= ---//F= ---//C= O-WA-350//D= --//Ph-4E=O-WA-318//Ph-4F=O-WA-320) of compressor. iii) Receiver inlet( I.A.Comp. A= O-CA-5// B= O-CA-6// C= O-CA-7// D = O-CA-8// E= O-CA-206// F= O-CA-205// G= O-CA-653// H= O-CA-655// J= OCA 557// K= OCA-558//L= OCA-559//M= OCA-560// W.A.Comp. E= O-WA-6// F= O-WA-5// C= ---// D= O-WA-103// PH4 E = OWA-319// PH4 F = OWA-321) and out let Isol v/v (I.A.Comp. A= O-CA-7// B= OCA-8// C= O-CA-9// D = O-CA-10// E= O-CA-210// F= O-CA-209// G= OCA-662// H= O-CA-663// J= OCA 572// K= OCA-573//L= OCA-574//M= OCA-575// W.A.Comp. E= O-WA-10// F= O-WA-9// C= O-WA-355// D= Page 194 of 320 O-WA-105// Ph4 E = OWA-327// Ph4 F = OWA-38) shut Lock & Tag if work in receiver. Receiver to be drained.
* *
Effective
Oct 2002
Q.E.W.C

May 2003
D3-004
AIR DRYER OPERATION
BOILER LOCAL SUPERVISOR
Location PRELIMINARY CHECKS (ALL OPERATIONS FROM LOCAL) Field CCR/DCR
Air dryers are used for absorption of moisture in the instrument air by Alumina Absorbent to facilitate proper function of control valves. Operation of Dryer can be explained as follows (Ref; fig-1): Step-1 Flow-0~3.30 hrs i) Four way valve open for allowing inlet air to tower- (A) in absorption sequence. ii) PV-16 open. iii) Blower on and heating resistance- A (on) iv) PV-21 Close. Step-2 Cooling 3.30 ~4.00 hrs. i) Heating resistance- (A) OFF. Natural cooling operation in towerB starts (Regeneration). Step-3 Flow 4.00~5.45 hrs.
Page 195 of 320
* * * *
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May 2003
i) Blower (off) ii) PV-21 Open, allowing little quantity of dried air to tower-B to improve regeneration and cooling. Step-4 Flow 5.45~6.00 hrs (pressurization phase): i) PV-16 Close, tower-B pressurization starts. After 6hrs tower changeover occurs from A to B and absorbtion and regeneration takes Place in tower-B & A respectively with same process repeated automatically.
SHUT DOWN PROCEDURE: i) Put off main switch. ii) Close dryer inlet ( A= O-CA-13// B= O-CA-14// C= O-CA-15// D= O-CA-685// E= O-CA-215// F= O-CA-214// G = OCA-621// H= OCA-622// J= OCA-623) and outlet valve.( A= O-CA-34// B= O-CA-35// C= O-CA-36 // D=O-CA-686// E=O-CA-234// F=OCA-235// G = OCA-624// H= OCA-625// J= OCA-626) ISOLATION FOR PREMIT OF WORK: i) 415V Power supply off. And Tagged ii) Inlet( A= O-CA-13// B= O-CA-14// C= O-CA-15// D= O-CA685// E= O-CA-215// F= O-CA-214// G = OCA-621// H= OCA622// J= OCA-623) & outlet valve.( A= O-CA-34// B= O-CA-35// C= O-CA-36 // D=O-CA-686// E=O-CA-234// F=O-CA-235// G = OCA-624// H= OCA-625// J= OCA-626) Lock & Tag shut.
Page 196 of 320
Effective
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Q.E.W.C

May 2003
D3-005
INDUSTRIAL WATER SYSTEM
Location OPERATION (ALL OPERATIONS FROM LOCAL) Field CCR/DCR
* i) Level of overhead tank is maintained by industrial booster pumps, taking suction from High purity make up tanks. ii) Industrial water pump cuts in on auto when over head tank level reaches 45% and cuts off at 95% level. iii) Along with industrial booster pump caustic soda dosing pump starts on auto or manual to maintain PH around 8.0. iv) Before feeding to overhead tank it is cooled to 25~40c by industrial water coolers. V) There is provision for by-passing make up tanks & industrial coolers Page 197 of 320 * * * *
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control local & CCR.

May 2003
(phase-III Only) when booster pump takes suction from distillate header. v) Phase-1 over head tank sequence control at local only while phase-III * *
D3-006
PROCEDURE FOR CHANGEOVER OF BOOSTER PUMP
Phase-1 Booster Pump A to B and Caustic pump A to B: i) Change booster pump selector switch from A to B near makeup tank A&B ii) Select the control position selector of Booster pump A&B on local in MCC. iii) Select the control position selector of caustic pump-B on (Auto) (Always on Auto) in MCC. iv) Check suction valve for p/p-B (OHM-243) is open & pump is ready to start Page 198 of 320 * * * * * *
Effective
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Q.E.W.C
v) Prepare caustic p/p-B. 245) gradually.. vii) Confirm the Caustic pump-B started on Auto.

May 2003
vi) Start the booster pump-B from MCC and Open the Discharge V/v (OHM
viii) Stop booster p/p-A from MCC, check caustic pump-A also stopped. ix) Change control position selector of booster pump from (Local to (Auto) from MCC.
- Now booster pump-B will Start and Stop on (Auto) with tank level. Caustic pump-B will also start or stop Auto. - Changeover of booster pump-B to A and caustic pump B to A same as above.
D3-006
PROCEDURE FOR CHANGEOVER OF BOOSTER PUMP
CCR/LOCAL BOILER SUPERVISORS CCR/LOCAL

Change Over for Booster pump A to B and Caustic pump C to D Phase-III: i) Select the Auto / Manual switch of booster pump A&B on (Manual) in CCR panel ii) Select the control position selector of booster pump-B and caustic pump-D to control room in MCC. * Page 199 of 320 * *
Effective
Oct 2002
Q.E.W.C
pump-D also started. v) Stop booster pump-B if not required from CCR.

May 2003
iii) Make ready industrial booster pump-B and caustic pump-D. iv) Start booster pump-B from CCR after local clearance and confirm caustic * * *
vi) Change Auto / Manual selector of booster pump-B to (Manual) at CCR panel. - Now booster pump-B will start & stop on Auto along with caustic pump with over head tank level. - Changeover of booster pump B to A and caustic pump D to C same as above except caustic pump-C to be started on Manual from Remote at Motor. *
Page 200 of 320
Effective
Oct 2002
Q.E.W.C
SOP No
Issued Date
May 2003
Revision TITLE: COMMON SERVICES Issued By
D3-007
ACTIVITY REFERENCE
ISOLATION FOR PERMIT
RESPONSIBILITY DSCE/PERMIT ENGINEER/BOILER LOCAL SUPERVISOR COMMUNICATION Location OPERATION Field CCR/DCR
1) Industrial Water Overhead tank Tank inlet (Tag No. N/A) and outlet valves (Tag No. N/A) shut locked & tagged. ii) Tank drain valve(Tag No. N/A) open. * * * * *
2) Industrial Water Cooler i) Industrial water side inlet (Ph 1 A= O-HM238-// Ph 1 B= OHM-237// Ph 3 A= OHM-255// Ph 3 B= OHM- 254) & outlet valve (Ph 1 A=OHM236-// Ph 1 B= OHM-255// PPh 3 A= OHM-253// Ph 3 B= OHM- 252) shut locked & tagged. ii) Sea water side inlet(PH1 A=OSW-353//B= OSW-352//PH2 A=OSW366//B=OSW-365) and out let valve (PH1 A=OSW-355//B=OSW354//PH 2 A=OSW-364//B=OSW-363)shut locked & tagged.
* *
3) Booster Pump i) Suction (Ph1 A= OHM-240// Ph1 B= OHM-243// Ph3 A= ---// Ph3 B=O ODP-61) and discharge valve (Ph1 A= OHM-242// Ph1 B= OHM245// Ph3 A A= ---// Ph3 B= ---) shut locked & tagged. ii) 415V power supply off / locked & tagged.
Page 201 of 320
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May 2003
H.P.Makeup system consists on: Phase M.UP.Tanks Capacity Each

A, B C, D E, F G, H 550 m3 550 m3 550 m3 550 m3
No.of pumps
3 5 3 5
Chem. dosing system

Direct Direct Direct Pump
I II III IV
OPERATION;
i) Phase I, II & III area tank level is maintained manually while in phase IV it is Maintained by a level control valve-LCV-500. ii) Chemical (Morpholine) is injected in tank to increase the PH up to 8.5. iii) Normally Phase-IV make up system continuously remain in service with any one out of five pumps others are selected on (Auto). iv) For Phase I, II & III system, usually one phase remain in service and changed over weekly from one phase to other. v) Makeup pumps are feeding to common header and then supplied to deaerators.
Page 202 of 320
Effective
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May 2003
D3-008
MAKE-UP WATER SYSTEM
PRE-START CHECK: 1) Check all permit are cancelled. ii) If H.P. Makeup tanks are empty, tanks to be flushed and filled with H.P. distillate and quality to be confirmed by lab. (Conductivity < 5s/cm2) iii) Water temperature of tank is maintained around 75C. iv) If water quality not acceptable or temperature is low, drain the tank slightly and then over flow unit required quality is achieved. v) Power supply available for pump motor. vi) Bearing oil and cooling water are normal. vii) H.P.Distillate tank level sufficient to run the pump. viii) Ensure tank outlet (A= ---// B= ---// C= O-HD-51// D= O-HD-52// E= O-HD-81// F= O-HD-82// G= OHM-264// H= OHM-265) and pump suction valve ( 1= ---// 2= ---// 3= ---// 4= OHM-53// 5= OHM-56// 6= ---// 7= OHM62// 8= OHM-65// 9= OHM-83// 10= OHM-84// 11 = OHM-85//M= OHM270//N=OHM-271//P= OHM-272// Q= OHM-273// R= OHM-274) is open. ix) Pumps are started from CCR after giving clearance from local. Page 203 of 320 * * * * * * * * * * * *
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May 2003
x) After starting the pump, open the discharge valve ( 1= ---// 2 ---// 3= ---// 4= OHM-55// 5= OHM-58// 6= OHM-61// 7= OHM-64// 8= OHM-67// 9= --// 10= ----/ 11 = OHM-92//M= OHM-275//N=OHM-277//P= OHM-279// Q= OHM-281// R= OHM-283) slowly. xi) Inform lab. For chemical injection. xii) Check tank level ,If level comes down control room to be informed to increase the h.p.distillate flow.
D3-008
SHUT DOWN PROCEDURE: i) Close discharge valve ( 1= ---// 2 ---// 3= ---// 4= OHM-55// 5= OHM58// 6= OHM-61// 7= OHM-64// 8= OHM-67// 9= ---// 10= ----/ 11 = OHM-92//M= OHM-275//N=OHM-277//P= OHM-279// Q= OHM-281// R= OHM-283) of pump and inform CCR to stop the pump. ii) If the makeup water system not remain in service in any phase, close the tank inlet valve (A= ---// B= ---// C= O-HD-31// D= * * *
O-HD-32// E= O-HD-47// F= O-HD-48// G= OHM-261//H= OHM-263). Page 204 of 320
Effective
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May 2003
D3-008
ROUTINE CHECKS: i) Check motor amps. / noise / vibration. ii) Pump suction and discharge pressure. iii) Tank level, temperature and water quality. iv) Check chemical dosing system. Page 205 of 320 * * * * *
Effective
Oct 2002
Q.E.W.C
card to be issued if required.

May 2003
v) Leaks to checked for tank, pump and pipes. Defect
BEARING COOLING WATER SYSTEM

Cooling water requirement for compressors, boiler circulating pumps, boiler feed Pumps, sample coolers of boilers, condensate pumps (phase1~3), make up Pumps (phase1&3) is supplied by a closed cooling system from 3 cooling water plants Located at three compressor houses. Every cooling water plant consists of 2nos: cooling Water storage tanks, 3nos: of cooling water pumps and 2nos: of heat exchangers. Normally 2 pumps from phase-I, 1 pump from phase-III and2 pumps from phase-IV remain in service. Make up for losses in this closed system fed by industrial water System. The cooling water supply and return headers are having interconnection valves(Tag No. N/A) between the phases and can be opened whenever required. NOTE: In compressor house A&B separate coolers (2nos:) & 2nos: cooling water pumps have been provided for compressor after coolers in each compressor house.
BEARING COOLING WATER PUMP SPECIFICATION (Comp: house A&B)

Pressure. . . . . . . .. .. .. .. .. .. .. .. .. 3.4 bars Page 206 of 320
Effective
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Q.E.W.C
Capacity.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 19 m3 Pump trip at low level in tank .. .. .

May 2003
0.7m (alarm), 0.4m (trip)
Compressor house (C);

Pressure.. .. .. .. .. .. .. .. .. .. .. .. .. .. ..4.8bar Capacity .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 72 t/h Pump trip with low suction pressure-.0.1 bar
Page 207 of 320
SOP
No
TITLE: COMMON SERVICES Effective
Oct 2002
Q.E.W.C WATER SYSTEM BEARING COOLING

Revision Issued By
May 2003
D3-009
Issued Date
STARTING PROCEDURE OF BEARING COOLING PUMPS I) In compressor house A&B Pumps start/stop at local. * * * *
II) In compressor house-C start/stop from DCR/Local. III) Line up the tank out let to pump by opening tank outlet ( A= O-DW-1//B= O-DW-2//C= ---// D= O-DW-152// E= OCW-468// F= OCW-467) and pump inlet valves ( A= O-DW-4// B= O-DW-5// C= O-DW-6// D= O-DW-155// E= O-DW-154// F= ---// G= OCW462//H= OCW-469// J= OCW-470) IV) Establish S.W. flow to heat exchanger V) Check pump oil level. VI) Discharge valve (A= O-DW-8// B= O-DW-10// C= O-DW-12// D= ---// E= O-DW-158// F= ---// G= OCW471//H= OCW-472// J= OCW-473) position (close) VII) Local stop push button in released condition. VIII) Start the pump and physically check for noise and amps: for motor. IX) Slowly open pump discharge valve (A= O-DW-8// B= O-DW-10// C= ODW-12// D= ---// E= O-DW-158// F= ---// G= OCW471//H= OCW-472// J= OCW-473) and cooler c.w inlet (A= O-DW-13// B=O-DW-12-// C= OCW-207// D= ---// E= OCW-475//F= OCW-468) valve. X) To feed C.W to header open cooler out let valve ( A= O-DW-15// B=ODW-16-// C= O-CW-181// D= O-CW-176// E= OCW-447// F= OCW-474) carefully. Check during Running. I) Check tank level II) Pump amps and discharge pressure. III) Cooling water pressure, temperature and flow. Page 208 of 320
* * * * * * *
* * *
Effective
Oct 2002
Q.E.W.C

May 2003
STANDARD OPERATION PROCEDURES

PART- D4 FIRE FIGHTING
TITLE: FIRE FIGHTING SOP No
D4-001
ELECTRIC FIRE PUMPS A & B SWPH- (A)
OUTSTATION SUPERVISOR CCR(GEN)
Page 209 of 320
Effective
Oct 2002
Q.E.W.C
PRELIMINARY CHECKS & OPERATION

May 2003
Page 210 of 320
Effective
Oct 2002
Q.E.W.C
FREQUENCY OF TEST TYPE OF TEST INITIAL PLANT STATUS

May 2003
-WEEKLY-SUNDAY M / SHIFT -LOCAL, AUTO, C.CR. -STAND-BY.
Page 211 of 320
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Oct 2002
Q.E.W.C
ITEM NO. CHECKS

May 2003
REMARKS
(A) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
PRE-START CHECKS 415v Power supply Bearing oil level Pump disch. v/v (V-1220A,V-1220-B ) Re-circulation v/v(V1222-A,V-1222-B ) Air release v/v (V-1223A,V-1223-B ) on pump disch. Bearing cooling water system Selector switch position Inform C.C.R.Generation Local Panel isolator Panel alarms
Available. Normal. (Up to the mark) Close. Open. Open. Lined up. As required. Before start. On. Normal.
Page 212 of 320
Effective
Oct 2002
Q.E.W.C
(B) 1. 2. 3. 4. 5. 6.
START FROM LOCAL RUNNING CHECKS Motor load Discharge press. Panel alarm Bearing temp. Motor noise & vibration Leakage of mechanical seal & any other leakage. START ON AUTO (TEST) Selector switch Pressure switch isolation v/v (V-1225) Pump stop button Operate press. Switch test v/v (V-1226). (Drain v/v) Pump will start Panel alarm Press. Switch drain v/v (V1226) Press. Switch isolation v/v (V1225 ) Pump will stop by pushing the (stop) button. START & STOP FROM C.C.R. Selector switch Pump stop button Inform C.C.R.Generation to start & stop the pump. SHUT DOWN CONDITION Selector switch Re-circulation v/v(V-1222A,V-1222-B ) Pump disch. V/v. (V-1220-A, V-1220-B)

May 2003
Selector switch (local)/remote at motor. Normal. A=346 amps. Max.B=418 amps. Max. N/A.No press. Gauge. Pump running. Normal. (Physical check only). Normal. J/C to be raised as required.
(C) 1. 2. 3. 4. 5. 6. 7. 8. 9.
(Auto) close. Released. Will operate at 6.5 bar. After 30 secs./started. Auto running. Close. Open. Stop.
(Auto). Released. Start & stop from C.C.R.
(D) 1. 2. 3.
(Local) stand-by. Shut. Open.
Page 213 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
D4-002
DIESEL FIRE PUMPS A&B SWPH- (A)

Location
PRELIMINARY CHECKS & OPERATION Field CCR/DCR
FREQUENCY OF TEST TYPE OF TEST
-WEEKLY-SUNDAY M / SHIFT -LOCAL, AUTO, C.C.R.
INITIAL PLANT STATUS ITEM NO. (A) 1. 2. 3. 4. 5. CHECKS
-STAND-B REMARKS
PRE-START CHECKS Air compressor 415v Power Supply Compressor started selector Switch. Air receiver press. Gear box oil level Engine lube. Oil
Available Auto. Normal. A=14 to 17 bar. B=15 bar~16.5 bar Normal. (Up to the mark on dip stick). Normal. (Up to the mark in dip stick)
Page 214 of 320
Effective
Oct 2002
Q.E.W.C
6. 7. 8. 9. 10. 11. 12. 13. Engine jacket closed CCT. Cooling water thank level. Engine Cooling water system Air release v/v (V-1340-A ,V1340-B ) on pump disch. Engine fuel Inform C.C.R. Generation Pump discharge v/v (V-1330A,V-1330-B). Re-circulation v/v (V-1322A,V-1322-B ). Starter panel 240v Ac supply. Full.

May 2003
Lined up. Open. Available. Before start. Close. Open. Available (on).
14. 15. 16.
Panel isolator diesel fire pump. Panel alarms. Selector switch position.
(on). Normal. Section supply on (MAN (OR) AUTO) as required Selector switch hand.
(B)
START FROM LOCAL RUNNING CHECKS Engine Cooling water press. Engine Cooling temp. Engine R.P.M. Engine lub. Oil press. Discharge press. Noise & vibration Any leakage a. 0.6 bar. Normal. (Within green mark). Should not exceed 1530. Normal. (Within green mark). While pump on re-circulation 5 bar. Normal. J/C raised as required.
1. 2. 3. 4. 5. 6. 7.
Page 215 of 320
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Q.E.W.C
(C) 1. 2. 3. 4. 5. START ON (AUTO) TEST Pump starter selector switch Electric fire pump (Stop) button. Press. Switch isolation v/v(V-1325. Press. switch drain v/v (V1326 ). According to the sequence elect.fire pump (A) will be failed as the stop button (Press) condition & the diesel fire pump will take start after getting (Elect.fire pump failed) signal. Panel alarm. Pressure switch drain v/v. (V-1226) Pressure switch isolation v/v (V-1225) Starter panel selector switch. Push the stop button
START & STOP FROM C.C.R. Selector switch Inform C.C.R. Generation to start or stop the pump. SHUT DOWN CONDITION Selector switch Re-circulation v/v(V-1322A,V-1322-B ). Pump disc.Vv(V-1330-A,V1330-B).

May 2003
(Auto) (Pressed). Closed. Open. Elect. Fire pumps auto start failed & Diesel fire pump (APP After 20 sec) auto running.
6. 7. 8. 9. 10.
Diesel fire pump auto running. Closed. Open. Hand Stop.
(D) 1. 2.
Hand Start & Stop from CCR
(E) 1. 2. 3.
(Hand) stand-by Close Open
Page 216 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
D4-003
ELECTRIC FIRE PUMP(C)
OUTSTATION SUPERVISOR
Page 217 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
FREQUENCY OF TEST
-WEEKLY-SUNDAY M /SHIFT
TYPE OF TEST
- AUTO START/RELIABLELITY *
INITIAL PLANT STATUS
-AUTO STAND-BY.
ITEM NO.
CHECKS
REMARKS
Page 218 of 320
Effective
Oct 2002
Q.E.W.C
1. 2. 3. 4. 5. 6. 7. 8. (B) 1. 2. 3. 4. 5. START FROM LOCAL RUNNING CHECKS Motor load Amps. Disch.Press. Panel alarms. Noise & Vibration Stop pump after 5 mins. Running PRE-START CHECKS 415v Power supply Bearing oil level Air release v/v. on disch. Pump disch.v/v(V-1220). & Press Release v/v (V-1420). Bearing cooling water. Panel alarms. Selector switch position. Inform C.C.R.F/m. Gen.

May 2003
Available Up to normal mark. Open. Lined up. Available. Normal. As required. Before start. Selector switch local. Max. 385 amps. 9.5bar. Normal. Normal.
(C) 1. 2. 3. 4. 5.
START ON AUTO Selector switch Operate test v/v (V-1326 ) Press. Switch operate Panel alarm Check pump operation Stop pump START FROM C.C.R Selector switch Request C.C.R. F/m to start To stop
Auto. Open. 8.5 bar. Ring main press. Low. Will start. Local.
(D) 1. 2. 3.
Auto. Pump running. Local push stop button.
(E) 1. 2.
SHUT DOWN Selector switch Check line press.
Auto s/by. Normal.(9.0 to 10.5 bar).
Page 219 of 320
Effective
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Q.E.W.C
SOP No

May 2003
TITLE: FIRE FIGHTING
D4-004
DIESEL FIRE PUMP(C)

Location
REQUENCY OF TEST TYPE OF TEST INITIAL PLANT STATUS ITEM NO. (A) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. CHECKS
-WEEKLY-MONDAY M/ SHIFT -LOCAL, AUTO, C.C.R. -AUTO STAND-BY. REMARKS *
PRE-START CHECKS A.C.D.C. supply Gear box oil Lub.Oil Fuel oil Jacket water tank Cooling system Air release v/v(V-1520 ). Air receiver Pump disch. V/v (V-1219). & pressure release v/vs. Inform C.C.R. Supervisor (Gen.)
Available. Up to normal mark. Up to normal mark. 25 to 100%. Full. Available & lined up. Open. 180-240 PSI. On line. Before start.
Page 220 of 320
Effective
Oct 2002
Q.E.W.C
(B) 1. 2. 3. 4. 5. 6. 7. 8. (C) 1. 2. 3. 4. 5. 6. START FROM LOCAL RUNNING CHECKS Panel alarm Disch. Press. Engine C.W. press. Engine C.W.temp. R.P.M. Lub. Oil press. Noise & Vibration Stop pump after 30 mins. START ON AUTO 415V isolator of elect.F.P/p. . Test valve (V-1521 ). Press switch operate Panel alarm Pump will start after 20 secs. Stop pump

May 2003
Pump running. 9.5bar. 2.0bar. Normal. (Within green mark) Should not exceed 1470 Normal. (Within green mark) Normal.
* * * * * *
Selector switch (Auto) Off. Open. 8.5bar. Ring main press. Low. Pump running.
* * * *
(D) 1. 2. 3. (E) 1.
START FROM C.C.R 415V Isolator of elect: F.. P/P- Request C.C.R.F/m to start To stop SHUT DOWN Selector switch
Selector switch (Auto). Off. Pump running. Local push stop button.
* *
Auto s/by.
Page 221 of 320
Effective
Oct 2002
Q.E.W.C
SOP No ACTIVITY REFERENCE RESPONSIBILITY COMMUNICATION

May 2003
D4-005 FIRE MAIN PRESSURE SUSTAINING
PUMPS A1, A2, B1, B2-PHASES I & III
Location PRELIMINARY CHECKS & OPERATION Field CCR/DCR
FREQUENCY OF TEST
-WEEKLY CHANGE OVER-SUNDAY M/SHIFT TYPE OF TEST -AUTO CHANGE OVER/RELIBILITY INITIAL PLANT STATUS -AUTO STAND-BY
ITEM NO. (A) 1. 2. 3. 4. 5. 6.
CHECKS PRE-START CHECKS 415v Power supply Pump suction water Pump (stop) button Pump selector Local isolator (in SWPH-A-) Pumps suction v/v(O-FP-10,O-FP11,& disch. V/vs ( O-FP-16)
REMARKS
Available. Lined up. Released. As required On. Open.
* * * *
(B) 1. 2.
PUMP CHANGE OVER Operation set-up Selection of (B) set
A1/A2-B1/B2 By selector switch in C.C.R. (Gen.). Local isolator: ph-I & III (Open) in SWPH-A
* *
Page 222 of 320
Effective
Oct 2002
Q.E.W.C
(C) 1. 2. 3. 4. 5. (D) 1. 2. 3. AUTO TEST Pressure switch isol.V.(PV-01~04) Test v/v (PV-D-1 ~ 4 ). (Drainv/v.) Pump will start & check press.Test v/v. (PV-D-1 ~ 4 ). Press. Switch isol.V.(PV-01~04) RUNNING CHECKS Check pump operation Pump condition Pressure switch (PV-D-1 ~ 4 ).

May 2003
Close. Open. Pump cut in at 9.0 bar, Close. Open.
* * * *
Cut-in & cut-out intervals. Normal in running. Normal cut-out at 10.5bar.
* * *
(E) 1.
SHUT DOWN Selector switch
Change over A1/A2B1/B2 as needed on auto selection. CUT OUT 11 BAR 10.5BAR.
NOTE: CUT IN A1, A2 B1, B2
Page 223 of 320
Effective
Oct 2002
Q.E.W.C
SOP No

May 2003
D4-006
DELUGE SYSTEM- TANK FARM
OUTSTATION SUPERVISOR/GT SUPERVISOR/MMD CCR(GEN)

Location
FUEL OIL STORAGE TANKS A, B, C, D, E & F FREQUENCY OF TEST -MONTHLY-MONDAY M/SHIFT TYPE OF TEST -RELIABILITY. INITIAL PLANT STATUS STAND-BY. ATTENDANCE REQUIRED: MMD (FIRE), GT-SUPERVISOR & SWPH SUPERVISOR ITEM CHECKS REMARKS NO. (A) 1. 2. 3. 4 5. 6. PRE-START CHECKS Fire pump (C) electric or diesel. Fire main system press. Fire pumps (A) & (B). Sprinkler v/vs. (Deluge v/v.) Inform C.C.R. Gen. GT-supervisor operation personnel & Fire maint. Will be operating the procedure. 7. Water supply in pump suction chamber. Before operation. In presence of S.O.S. supervisor at fire pump. Available. Selected (auto) Normal-9.0 bar to 11.0 bar Normal. Close. * * * * *
Page 224 of 320
Effective
Oct 2002
Q.E.W.C
(B) DELUGE OPERATION

May 2003
Deluge v/v. to be operated one at a time on each tank for about 5 minutes. *
(C)
DURING OPEERATION CHECKS
1. 2.
Water spray Fire main system press.
Sufficient. 7.5 bar.
* *
(D) 1. 2. 3.
SHUT DOWN On completion of test When system press. Fire pump (C) Deluge v/v. closed. Normal (9.0 bar to 10.5 bar) Stop & selected (Auto). * * *
Page 225 of 320
Effective
Oct 2002
Q.E.W.C
SOP No ACTIVITY REFERENCE RESPONSIBILITY COMMUNICATION

May 2003
D4-007
SPRINKLER FIRE ALARM
OUTSTATION/BOILER & DISTILLER SUPERVISORS DCR/CCR(GEN)

Location
FREQUENCY OF TEST TYPE OF TEST INITIAL PLANT STATUS ITEM NO (A) 1. 2. 3. 4.
-WEEKLY-SATURDAY M/SHIFT -RELIABILITY. -STAND-BY. REMARKS Manual. Auto i/s. Normal. 9.5-100.5bar. CCR (Gen.), DCR & Phase III Boiler Supervisor * * * * *
CHECKS PRE-START CHECKS All fire pumps Fire main press.sus.P/p. System press. Information
(B)
1. 2. 3. 4. 5. 6.
OPERATION LUB. OIL STORE, CAFETERIA & CHEMICAL STORE (A) Inform CCR (Gen.) Operate test v/v.(Tag no N/A) Fire alarm will appear & Annunciate local. Inform CCR Gen. Operate test v/v. Alarm re-set
To accept & re-set alarm. Open. In CCR fire panel/local. Alarm accepted. Closed. By CCR Gen. & panel board clear.
* * * * * *
Page 226 of 320
Effective
Oct 2002
Q.E.W.C
(c) 1. 2. 3. CHEMICAL STORE (B) Inform Phase III Boiler Supervisor Operate test v/v. .(Tag no N/A) Alarm will appear & annunciate at local. 4. 5. 6. 7. (D) 1. 2. 3. 4. 5. 6. 7. Inform Boiler F/m. Operate test v/v(Tag no N/A) Alarm re-set Chiller fire panel CHEMICAL STORE (C) Inform DCR F/m. Operate test v/v.(Tag no N/A) . Alarm will appear & annunciate Inform DCR Supervisor Operate test v/v.(Tag no N/A). Alarm re-set Fire panel board in DCR

May 2003
To attend at Phase III chiller plant to accept & re-set the alarm Open. In chiller House (Phase III)/local.
* * * *
Alarm accepted. Closed. By Phase III boiler Supervisor Clear.
* To accept & re-set the alarm Open. In DCR fire panel/local. Alarm accepted. Closed. By DCR Supervisor Clear. * * * *
NOTE: On completion of tests when fire main press. Normal fire p/p (C) put back to (Auto)
Page 227 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
D4-008
FIRE HYDRANTS SAMPLE OF H-1, 17&27
OUTSTATION SUPERVISOR LABORATORY

REQUENCY OF TEST TYPE OF TEST \INITIAL PLANT STATUS
-WEEKLY MONDAY E SHIFT -CONDUCTIVITY STAND-BY. *
ITEM NO.
CHECKS
REMARKS
Page 228 of 320
Effective
Oct 2002
Q.E.W.C
(A) 1. (B) PRE-START CHECKS All fire pumps A, B &C RUNNING CHECKS Lub. Will collect water sample for test. CONCLUSION Local.

May 2003
Conductivity should not be more then 500/us/cm. If more then 500/us/cm the system should be flashed with fresh water as per D.S.C.E.
(C)
Page 229 of 320
Effective
Oct 2002
Q.E.W.C

May 2003

PART- D5 BOP
TITLE: BOP SOP No
D5-001 Page 230 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
SEA WATER PUMPS (OPERATIONS) OF SWPH A, B & C
OUTSTATION SUPERVISOR CCR

Location
CHECKS (A) PRE-START CHECKS 1 2 6.6KV Power Supply 415V Power Supply of the v/v (OSW1,2,3,4,5,6,7,202,308,309,310,311,312,V007-P,V-007-Q ,V-007-R ). cubicle hydraulic system P/ps. Thrust Bearing oil level Motor Bearing oil level Hydraulic oil level Bearing pre-flushing water & v/vs. Bearing pre-flushing header press Pre-flushing over head tank signal switch Oil pump operation switch Bearing cooling system & v/v Seal water system & v/vs
P/P HOUSES
REMARKS
Available Available * * * *
3 4 5 6 7 8 9 10 11
SWPH-A
Upto the mark 50% to 90% Available & lined up 1.5 bar (ON) (Auto)
* * * * * * *
SWPH-A SWPH-B
SWPH-C SWPH-C Page 231 of 320
Lined up & open Lined up & open
Effective
Oct 2002
Q.E.W.C
12 13 14 15 16 17 Pump disch. Air release v/v Pump Starter panel (alarm) of the disch.v/v S.W. system press. (2m Main) Pump Emergency stop button Hydraulic oil pump stop button V/v (OSW-1, 2,3,4,5,6,7,202,308,309,310,311,312,V007-P, V-007-Q, V-007-R). Cubicle hydraulic press. START OF THE PUMP (SWPH-A) Generation clearance from CCR One B. screen in Operation Pump starter panel (stop button) Start the pump Air from pump disc. Press crack open button Press (open) button
Issued Date Revision Issued By SWPH-C

May 2003
Production/Operation Open CloseIndication Below 2.7 bar * * * *
SWPHA&C SWPH-C SWPH-A SWPH-B SWPH-C
Release Release 85 to 125kg. 125 to 140 kg. 70 to 110 kg. O.K Manual in service Release Started Release Crack open Open full
B 1 2 3 4 5 6 7
* * * * * * *
Page 232 of 320
Effective
Oct 2002
Q.E.W.C
SOP No

May 2003
TITLE: BOP
D5-002
START UP THE PUMP (SWPH-B)
Location PRELIMINARY CHECKS & OPERATION Field CCR/DCR
CHECKS 1 2 3 4 5 6 7 8 9 10 11 SWP/P Selector Switch Disch v/v(OSW-308~312) operation switch Lamp test (panel signal) Alarm accept & re-set Disch. V/v (OSW-308~312) Generation Clearance Start the Pump (Local) Air from the pump disch. Discharge press Press. Crack open button of the disch v/v(OSW-308~312) Press disch. V/v (OSW-308~312) (open) button
REMARKS Local * Local O.K. Clear Close O.K. Started Released 4.5 to 5 bar Crack open Open full * * *
* * * * *
Page 233 of 320
Effective
Oct 2002
Q.E.W.C
SOP No

May 2003
TITLE: BOP
D5-003
START UP THE PUMP (SWPH-C)

1 2 3 4 5
Start one seal water pump along with filter from CCR Start hydraulic P/p (CCR) Start the pump (CCR computer) Discharge v/v (V-007-P, V-007-Q, V-007-R) Hydraulic pump (Auto)
Started Started
* *
Started * Open full For Auto operation * * *
Page 234 of 320
Effective
Oct 2002
Q.E.W.C
SOP No

May 2003
TITLE: BOP
D5-004
PUMPS (SWP/PS) RUNNING CHECKS
1 2
Air from pump disch. Motor SWPH-A SWPH-B SWPH-C
Released Normal, 146 (max) Normal, 153 (max.) Normal, 144 (max.) Should not exceed 72C 80C Not available Normal Normal Normal (Allowable) Normal Above 50%
* * * *
3 4 5 6 7 8 9 10
Thrust bearing temp. Thrust brg. Alarm set Thrust brg. Temp. high trip (SWPH-A, & B) Noise & Vibration Suction water level Leakage from the mech. Seal Thrust brg. Cooling water flow Thrust brg. Oil level & hydraulic oil level
* * * * * *
Page 235 of 320
Effective
Oct 2002
Q.E.W.C
SOP No

May 2003
TITLE: BOP
D5-005
SHUT DOWN THE (SWP/PS) PUMP
Inform CCR (desal)
For confirmation the system press above 2.7 bar. Closed *
Discharge v/v (OSW-1, 2,3,4,5,6,7,202,308,309,310,311,312,V007-P, V-007-Q, V-007-R). Stop the pump * SWPH-C: By pressing (stop) button either local or remote CCR
Stopped & selected on s/by. SWP/P (P.Q.R) is shut down & the disch v/v will start to close under the action of its counter weight closed.
Page 236 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
TITLE: BOP SOP No
D5-006
G.T. COOLING WATER PUMP (A) & (B)- SWPH (A)

Location
(A) 1 2 3 4
PUMP PRE-START CHECKS 415V Power supply Available * 415V Power supply of disch. V/v(V-1,V-2 ). Available Cubicle Pump brg. Oil level Up to the mark Disch. V/v ( V-1,V-2 ).cubicle hydraulic tank oil level & system press. Brg. Pre-flushing water Re-flushing water header press B. screen operations Pump disch. V/v ( V-1,V-2 ). Up to the mark * Available Above 1.5 bar One screen in service closed * * * * * *
5 6 7 8
Page 237 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
TITLE: BOP SOP No
D5-006
G.T. COOLING WATER PUMP (A) & (B)- SWPH (A)
B 1 2 3 4 5 6
START UP Pump stop button Pump Operation lever Inform CCR (Desal/Gen) Push (Start) button Push disch. V/v( V-1,V-2 ). crack open Push disch. V/v( V-1,V-2 ). Open RUNNING CHECKS Motor amps. Air venting Pump Bearing temp. Motor noise & vibration Thrust brg. Oil level & hydraulic oil level Max.225 amps. * Normal Normal, 78 (max) Normal Up to the mark 750% * * * * Released (ON) * For information Started Crack open Full open * * * * *
C 1 2 3 4 5
Page 238 of 320
Effective
Oct 2002
Q.E.W.C
6 Any leakage from mech. Seals & other

May 2003
J/C raised as required. *
TITLE: BOP SOP No
D5-006
G.T. COOLING WATER PUMP (A) & (B): SWPH (A)
D 1
SHUT DOWN THE PUMP Closed disch. V/v ( V-1,V-2 ) Closed * *
2 3
Push the stop button Pump operation lever
Stop * Open (off)
Page 239 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
TITLE: BOP SOP No
D5-007
BAND SCREEN-A TO E- SWPH (A)
A 1 2 3 4 5 6 7
PRE START CHECKS 415V Power supply of the screen Gear box oil level Wash water main isol. V/v ( OSW-8 ) Wash water header press Wash water to B. screen isolation v/v (OSW-44, 45,46,47,48). Pen-stocks (position) Panel alarm Available Up to the mark * Open Above 1.5 bar Open Open Clear * * * * * *
B 1 2 3
START UP THE SCREEN Screen operation selection Screen speed selection Lamp test alarm accept & re-set Manual Low speed * Clear Page 240 of 320 * *
Effective
Oct 2002
Q.E.W.C
4 Press screen (Start) button C 1 2 3 4 5 6 7 RUNNING CHECKS Screen motor amps. Wash water flow. Motor noise & vibration Screen sound Wash water drain channel Screen flushing nozzles Any leakage etc.
Issued Date Revision Issued By Started

May 2003
About 4 to 5 amps. Normal as required Normal
* * *
Normal Clear
* *
Clear J/C raised as required.
* *
D 1 2
SHUT DOWN THE SCREEN Press screen (Stop) button Screen operation selector Stopped (Auto) for auto operation * *
Page 241 of 320
Effective
Oct 2002
Q.E.W.C
SOP No

May 2003
TITLE: BOP
D5-008
WASH WATER PUMPS B & D- (SWPH)
A 1 2 3 4 5 B 1 2 3 C 1 2
PRE START CHECK 415V Power supply Starter panel switch Pump brg. Pre-flushing system Bearing pre-flushing over head tank level Pump disch v/v. (Tag no. N/A). STARTING THE PUMP Lamp test panel alarm accept & re-set Press the (Start) button Disch. V/v(Tag no. N/A). RUNNING CHECKS Motor amp. Pump brg. Temp. About 18 amp. Normal, by touch * * Clear Started Full open * * * Available (ON) Lined up Normal level > 50% Crack open * * * *
Page 242 of 320
Effective
Oct 2002
Q.E.W.C
3 4 Motor noise & vibration Any leakage of mech seal etc.
Issued Date Revision Issued By Normal J/C raised as required.

May 2003
D 1 2 3
SHUT DOWN THE PUMP Push stop button Pump disch. V/v (Tag no. N/A). Pump selected on Stopped * Close S/by * *
Page 243 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
TITLE: BOP SOP No
D5-009
BAND SCREEN & W.W. PUMP F, G & H. (SWPH-B)
A 1 2 3 4 5 6 7 8 9 B 1 2
PRE START CHECKS 415v Power supply of B. screen & W.W.P/p W.W.P/ps. Brg. Pre-flushing water Pump disch. (Auto) air vent v/v (V-381,382,383 ) Pump disch. Strainers inlet & outlet v/v (V02-1,03-1,02-2,03-2,02-3,03-3 ) . Wash water to screen inlet v/v ( V-22,-1,V-222,V-22-3 ) Grease condition of the screen W.W.Overhead tank signal Lub oil level of the screen cycle reducer gear box Pen-stock START UP THE SCREEN PLANT B. Screen switch W.W.P/p switch Manual Manual * * Available Lined up Open Open Open Normal (ON) Up to the mark Open * * * * * * * * *
Page 244 of 320
Effective
Oct 2002
Q.E.W.C
3 4 5 6 C 1 2 3 4 5 Screen speed selector switch Lamp test alarm accept & re-set Press wash water P/p (Start) button Press B. screen (Start) button RUNNING CHECKS Motor amps. Of the W.W.P/p Motor amps. Of the B. screen Pump motor noise & vibration Screen noise Any leakage etc.
Issued Date Revision Issued By Low speed * Clear * Started * Started *

May 2003
About 26 amps. * About 5 amps. * Normal Normal * J/C raised as required *
D 1 2 3
PLANT SHUT DOWN B. Screen (stop) button push W.W.P/p (stop) button push B. Screen & W.W.P/p operation selector switch Stopped * Stopped Auto for Auto operation *
Page 245 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
TITLE: BOP SOP No
D5-010
BAND SCREENS 2A & 2B (SWPH-C)
A 1 2 3 4 5 6 7
PRE START CHECK 415v Power supply of B. screen Screen cycle reducer gear box oil leak Screen wash water header main isol. V/v(OQL-V-30, Tag no N/A). Air system of the screen flushing v/vs. (0-NIV-007) Screen wash water header press. Grease condition of the screen driving chain Inlet & outlet sluice gates (pen-stock) Available * Up to the mark Open Available Normal visible Open * * * * * *
Page 246 of 320
Effective
Oct 2002
Q.E.W.C
B 1 2 3 4 START UP THE SCREEN B. Screen switch Screen emergency (stop) button Screen speed selector switch Wash water to B. screen flush iso. (Pneumatic) v/vs (MV-011, 012,013) operation selection Panel re-set button Press B. screen (Start) button RUNNING CHECKS Screen wash flushing pneumatic v/v (MV-011, 012,013) Screen driving motor amp. Screen Sound Motor gear box noise & vibration Screen wash water drain channel Any leakage etc. SHUT DOWN THE SCREEN PLANT Press (stop) button of the screen Screen wash water v/v (MV-011, 012,013) Screen operation selector

May 2003
Manual Release Low speed (1 Speed) Auto

st
* * * *
5 6 C 1 2 3 4 5 6 D
Pressed for re-set Started
* *
Open
* *
Normal Normal Clear J/C raised as required * * *
1 2
Stopped Closed
* * *
(Auto) for Auto operation
Page 247 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
TITLE: BOP SOP No D5-011
CUMBERLAND ELECTRCHLORINATION STREAMS (1,2,3,4) SWPH-A
Location OPERATION Field A 1 2 PRE-START CHECKS 415v Power supply Stream Cells vent v/v, vent through sample lines, ( V-45,V-46,V-46,V-47,V48 ). Cells (Acid) inlet & outlet v/v s (V19&V-21, V-25&V-27, V-31&V-33, V37&V-39) Cells outlet Hypo. Isolation v/v(V-20,26 ,V-32,38 ) Cells S.W inlet v/v (V-17,23 ,V-29,35 ) Cells drain v/v ( V-22,V-28,V-34,V-40 ) De-gasing tanks foam-flushing v/vs ( V69,V-70 ) De-gasing tanks drain v/v (V-60,V-62 ) De-gasing tanks drain v/v????????? Hypo. Injection v/vs. (near coarse screens :- V-64,V-65,V-66,V-67,V-68 ) Available Open * * * Shut * Shut Open Shut Open Open Shut Open * * * * * * * CCR/DCR
4 5 6 7 8 9 10
Page 248 of 320
Effective
Oct 2002
Q.E.W.C
11 12 13 S.W.headers main v/vs V-15, V-16 Cell inlet SW main isol. V/v . (V-17,23 ,V-29,35 ) (Diaphragm) S.W.flow
Issued Date Revision Issued By Open Open (slowly) 40 m3/hr.

May 2003
TITLE: BOP SOP No
D5-011
CUMBERLAND ELECTRONATION STREAMS (1,2,3,4) SWPH-A
B 1 2 3
START UP 415V Power Isolator of the rectifier Control panel alarm accept & re-set Amps. Increase to (full load) (ON) Clear 900 amps. * * *
C 1 2 3 4
RUNNING CHECKS Amps. & volts S.W.flow Vent v/v , ( V-45,V-46,V-46,V-47,V-48 ). Panel Alarm 900 amps. Volts 160 max. 40 m3/hr. Shut Clear * * * *
Page 249 of 320
Effective
Oct 2002
Q.E.W.C
5 6 Any leakage etc. Noise & vibration

May 2003
J/C raised as required Normal *
TITLE: BOP SOP No
D5-011
CUMBERLAND ELECTRONATION STREAMS (1,2,3,4) SWPH-A
OUTSATION SUPERVISOR
D 1 2 3
SHUT DOWN Load (amp.) reduce to Rectifiers panel power isolator Stream cell vent v/v , ( V-45,V-46,V-46,V47,V-48 ). S.W.flow reduce to Cells outlet v/v (V-20/V-26/V-32/V-38) Cells S.W.inlet v/v (V-17/V-23/V-29/V-35) Cells drain v/v ( V-22,V-28,V-34,V-40 ) Panel alarm FOR ACID WASH Minimum (OFF) Open * * * *
4 5 6 7 8
20m3/hr * Close * Close * Open S.W. flow low After 150 hrs. run Page 250 of 320 * *
Effective
Oct 2002
Q.E.W.C
9 10 11 12 Acid washing system
Issued Date Revision Issued By Lined up Open Close One hour * * * * Open & kept the stream s/by
May 2003
13
Cells (acid) inlet & outlet v/vs (V-19&V-21, V25&V-27, V-31&V-33, V-37&V-39) Cells vent, ( V-45,V-46,V-46,V-47,V-48 ). & drain v/vs , ( V-45,V-46,V-46,V-47,V-48 ). Acid p/p start & carry out (Acid) wash with acid strength 5% to 7%. After Acid wash cells flush with S.W. & drain Cells drain v/v , ( V-45,V-46,V-46,V-47,V-48 ). )& Vent v/v, ( V-45,V-46,V-46,V-47,V-48 ).
Page 251 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
TITLE: SOP No
BOP
D5-012
ELECTROCHLORINATORS G, H & J
A 1 2 3 4
PRE START CHECK 415V Power Supply S.W. supply Air vent ( Atm. Vent ) Available Available Open (air out & shut) * * * *
6 7
De-hydrogen drum inlet &outlet Open V/v (V-206-A,V-207-A,V-206B,V-207-B,V-206-C,V-207-C ) Cells & De-hydrogen drum drain Shut v/v (cells:-V-222A 1~ 8, V222B 1~8, V-222C 1~8 ; Drum:V-221A,V-221B,V-221C ) S.W. inlet v/v (cell) (V-205-A, Open 205-B, 205-C) De-hydrogen drains foam Open flushing v/v (V-217A,V217B,V-217C ) Page 252 of 320
* * * *
Effective
Oct 2002
Q.E.W.C
8 S.W. flow establish by opening the flow meter inlet v/v (V204A,V-204B,V-204C, V228,V-229,V-230 ) START UP THE PLAN

May 2003
Open & 57 m3/hr * *
B 1 2 3 4
* Control panel alarm lamp test accept & re-set 415V Power isolator of the rectifier Press ON button for start Amps. Increase slowly upto (on full load) RUNNING CHECKS S.W. Flow Amp. & Volts Noise & Vibration 57 m3/hr. 3400 amp. 40V max. Normal * * * * * OK & clear Close (ON) Started 3400 *
C 1 2 3 4 5 D 1 2 3
Any leakage of Cells & H2 drum J/c raised Hypo. Injecting SHUT DOWN Amps reduce to Push OFF button Zero Stopped Normal
* * *
S.W. Flow isol. V/v ( V203A,V- Close 203B)&cells inlet v/v . (V-205A, 205-B, 205-C) De-hydrogen drum outlet v/v (V- Close 207-A/B/C) & foam flush v/v (V-217A,V-217B,V-217C ) AC isolator of rectifier OFF
* * *
Page 253 of 320
Effective
Oct 2002
Q.E.W.C
6 Cells & H2 drum drain & vent v/vs (all) (cells:-V-222A 1~ 8, V-222B 1~8, V-222C 1~8 ; Drum:- V-221A,V-221B,V221C ) Flush (aII cells& H2 drum) & fill up with indl. Make up water. all drain
Issued Date Revision Issued By Open

May 2003
V/vs shut, s/by
TITLE: SOP No
BOP
D5-013
ELECTROCHLORINATORS (K & L) SWPH - C
CCR/OUTSTATION SUPERVISORS CCR

A 1 2
PRE START CHECKS 415V Power Supply S.W. Feeding System Available Lined up * *
Page 254 of 320
Effective
Oct 2002
Q.E.W.C
3 Vent v/vs (Atm. Vent from storage tanks.) Air purging fans 415V power supply Air purging fans emergency stop button Sodium hypochlorite storage tanks inlet & outlet v/vs.(V-071. ,V-026,V-072,V-037) Hypo. Storage tank drain v/v (V025, V-036 ) Storage tank outlet interconnected header v/v (V-027,V029 ) (inter connected header of E/chlori. House B & C) Hypo. Storage tanks level gauge isol. V/v (V-021,022,V023,024;V-032V-033,V-034,V035 ) (upper & lower) & drain shut. Hypo. Storage tanks (102) inlet inter connected v/v(V-070 ) Hypo. Header injecting points isol. V/v (V-038 ~ 045) (near S.W. inlet sluice gates ) Electrolizers drain v/vs (V-078 ~ 082 ,V-096 ~ 100 )all & acid inlet & outlet v/vs (V-090,V095;V-108,V-115 ) Hypo. Electrolizers outlet v/v (V-093,V-111) Electrolizers S.W. inlet v/v (V205-A, 205-B, 205-C) S.W. Flow START UP Air purging fan one start Control panel alarm lamp. Test accept & re-set 4 5 6
Issued Date Revision Issued By Open * Available Release Open * * * *

May 2003
7 8
Shut Shut
Open (L.G s drain shut)
* * *
10 11
Shut Open
12
Shut
* *
13 14 15 B 1 2
Open Open slowly 55m3/hr.
* *
* In service OK & clear * *
Page 255 of 320
Effective
Oct 2002
Q.E.W.C
3 4 5 6 C 1 2 3 4 5 6 7 Rectifier control selector switches Rectifier 415v Power isolator Push start button Amps. Increase to (full load) RUNNING CHECKS S.W. Flow Amps. & volts Hypo. Storage tank level Vent v/v of hypo. Injection header Noise of Vibration Control switch Any leakage etc.

May 2003
Manual / Current ON Started 2000 amps. * * *
55m3/hr. 2000A, 70 Volts Below high level alarm switch Shut Normal
* * * * * *
Manual to Auto for CCR Control J/c raise as required.
D 1 2 3 4 5 6
SHUTDOWN Amps Reduce to (From CCR control on Auto selection Control switch of rectifier Rectifier transformer isolation Electrolizers flush with SW Electrolizers SW inlet v/v (V205-A, 205-B, 205-C) Electrolizers outlet v/v (V093,V-111) Minimum Auto to manual OFF stopped 5 Close * Close Page 256 of 320 * * * * *
Effective
Oct 2002
Q.E.W.C
7 Eletrolizers all drain v/vs (V-078 ~ 082 ,V-096 ~ 100 )& hypo. Storage tank drain v/v.(V-071. ,V-026,V-072,V-037) Air purzing fan stop (after 30 minutes of shut down) ACID WASHING SYSTEM 9 10 Acid washing carry out by starting the Acid P/p with After carry out Acid Wash Electrolizers cells flush & kept fill with S.W. Panel alarms
Issued Date Revision Issued By Open * * Stopped

May 2003
* With clean the cells of Electrolizers Kept s/by * * 1. Generator low flow. 2. Tank level low 3. Fan low flow.
11
TITLE: BOP SOP No
D5-014
SCHEDULE CHANGE OVER
Page 257 of 320
Effective
Oct 2002
Q.E.W.C
PRELIMINARY CHECKS

May 2003
SCHEDULE CHANGE OVER / ROUTINE CHECK & TEST RUN, INSPECTION, OF STATION SWPH-A, B, C & ELECTROCHLORINATORS & FIRE PUMPS All routine DC veens to be operated twice in every shift Wash water p/p s B & D to be put in service for one hour in evening shift All available B. screens to be washed manually for one hour in evening shift SWP/ps J, K, L, M, N (running pumps or certain stopped P/ps) lab water filters of the p/ps bearing to be cleaned in light shift All stand-by (manual) B. screens to be washed in every shift SWPH-A & B (415v Switch rooms) 110V DC supply earth fault (- / +) polarity to be checked in m/shift G.T.C.W.P/ps (A) & (B) to be tested & one p/p to be put in service for 6 (six) hours approx. alternately in the morning shift E/Chlorination House- (B) E/Chlorinators (G, H, J) to be changed over along with SW Strainers (A & B) in m/shift Wash water p/ps-F, G, H Brg. Water strainers to be cleaned in m/shift SWPH- (A) & (B)-Drinking water coolers filters cartridges to be cleaned in E/shift SW intake channels lagoon inspection to be carried out in m/shift SWPH-C-Inst. Air compressor to be changed over in M/shift Sprinkler system fire alarm test of lub oil store, chemical stores A, B, C and cafeteria to be carried out in the M/shift Elect. & Diesel fire P/ps A & B set test (RUN) to be carried out in M/shift. Local/CCR (Gen.) Fire pressure sustaining p/ps to be changed over in cyclic order i.e. A1, to A2 to B1 to B2 to A1 in M/shift Elect. & Diesel Fire p/p (C) set test (RUN) to be carried out on hand & Auto mode from Local/CCR (Gen.) Cumberland E/chlorination streams 1,2,3,4 (Acid Wash) to be carried out every after 150 hour (RUN) approx. E/chlorinators (K/L) to be (Acid) washed approx-after 30 to 40 Days (RUN) E/chlorination streams 1,2,3,4 a set of full load test (RUN) reading to be taken after change over the stream once in a month DWP/ps (1 & 2) to be changed over 1st day of the month in N/shift SW 2m main (OSW-14,15,17,203,302,307,004,005,004,301) & G.T.C.W. main v/vs (OCW-3,4,6,7,28) pit inspection to be carried 1) 2) 3) 4) 5) 6) 1) 2) 3) 4) 5) 6) 1)
1) 2) 1) 1) 2) 1) 2)
Page 258 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
TITLE: BOP SOP No
D5-015
START UP OF RECARBONATION (DTP)
OUTSTATION SUPERVISOR DCR Page 259 of 320
Effective
Oct 2002
Q.E.W.C
OPERATION

May 2003
Location Field
CCR/DCR
Switch on all MCBS on 415V switchboard. Water shall be filled the all filters and pipes by Opening all the valves except return line motor valves. (DW-2135A, 2135-B, 2235-B, 2235-A). Close booster pump discharge valve (2107-A, 2107-B). Open return line motor valve (DW-2135-A, 2135-B, 2235-B, 2235(DW2135-A,2135-B,2235-B,2235-A). Open CO2 absorber outlet flow control valve (FCV-2001,2002 ) 50% manually from DCS. Crack open booster pump discharge valve. (2107-A, 2107-B). Start booster pump and gradually open until minimum flow value is close at 3300-m3/hr. flow. Establish distillate flow to 70% of header flow manually from DCS. Set distillate flow to cascade mode.
* * * * * * * *
TLE: BOP SOP No
D5-016
ACTIVITY REFERENCE
START UP OF CO2 COMPRESSOR SYSTEM
Page 260 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
DCR/OUTSTATION SUPERVISORS DCR

Open pressure control by-pass valve(CO-1036) (pressure control valve, PCV- 2001) on auto from DCS. Start CO2 compressor and evacuate two distillers vent gas. line. Open drain valves (CO-1032-A, 1032-B) at absorber inlet vent gas
* * * *
Gradually open vent gas flow control valve (FCV-2102, 2202) up to 40~50%. If gas is come out from drain then close drain valves.(CO-1032A&B)
* * *
Open level control valve (LCV-2101, 2201) manually from DCS so that absorber level Become (O) mm. Then set to automatic control. Start one CO2 compressor to evacuate distillers vent gas. Increase vent gas flow up to 370 nm3/hr.manually from DCS and to set auto. Fine adjustment shall be made so that hardness becomes 80 ppm.
TITLE: BOP SOP No
D5-017
ACTIVITY
START UP OF CHLORINATION PLANT

Page 261 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
OUTSTATION SUPERVISOR DCR

Air blower selector switch to auto. Booster pump selector switch to local. Dosing pump selector switch to auto. Start all blowers. Start booster pump.
* * *
* * *
Start trans/rectifier then seawater inlet valve (SW-4007-A, 4007-B, 4007-C) will open automatically, after 20 seconds, trans/rectifier will energize automatically. Adjust the seawater flow to 5.5 m3/hr.
* *
Dosing pump will be started automatically when the level of hydrogen tank becomes preset value.
TITLE: BOP SOP No
D5-018
ACTIVITY
LIMESTONE FILTERS
Page 262 of 320
Effective
Oct 2002
Q.E.W.C

May 2003

* Lime stone filter re-filling necessary when the limestone bed height Becomes low due to its dissolution. Wheel loader and limestone feeder Are used for this purpose. * * *
LIMESTONE FILTER BACK WASHING

The air supplied from air scour blower then backwashed by the mixture of air and fresh water makes the back washing. A periodic backwashing of the filters is necessary to remove the insoluble matters contains in the limestone and foreign matters trapped in the limestone bed and to prevent filters from clogging
TITLE: BOP SOP No
D5-019
ACTIVITY
RECORBONATION PLANT SHUTDOWN

Page 263 of 320
Effective
Oct 2002
Q.E.W.C

May 2003

Dist. booster pump discharge valve(2107-A, 2107-B). close. Stop Dist. booster pumps. Close Dist. supply and return isolation motor valve (supply: -DW2101-A, 2101-B, 2201-B, 2201-A & Return:- DW-2135-A,2135-B,2235B,2235-A). CO2 compressor as usual shutdown.
* * * *
TITLE: BOP SOP No
D5-020
Page 264 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
ELECTROCHLORINATION PLANT SHUTDOWN
Set point should be zero. Shut down of the trans/rectifier. This automatically allows a period of time 5 minutes, during which seawater is allowed to flush through the de-energized generator, associated tank, dosing pump and pipe work. After this seawater inlet valve (SW-4007-A, 4007-B, 4007-C) closed and dosing pump stop Automatically. Shutdown seawater booster pump. Shutdown air blower. If plant is shutdown for a prolonged period, i.e. more than two weeks cell module must drained and flush with fresh water.
* *
* * *
TITLE: BOP SOP No
D5-021 Page 265 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
FORWARDING PUMP HOUSE STARTING
OUTSTATION SUPERVISOR TCC

FORWARDING PUMP (A&B) STARTING PROCEDURE (LOCAL) Confirm 6.6kv & 415V supply. Suction and discharge header valves (V-1100/V-3,V-5,V-6,V-270,V271,V-272,V-708,V-709,V-716,V-717,V-710,V-711,V-718,V-719,V-712,V713,V-720,V-721,V-714,V-715,V-722,V-723 & V-732)open / reser. Level available. Pump suction valve (V-8,V-9,V-10,V-200,V-201; V-1109,V-1108 V1107,V-1106,V1105,V-1104)open. Pump discharge valve (V-11,V-12,V-13,V-202,V-203; V-1124,V1123,V-1122,V-1121,V-1120,V-1119 ) close. Pump casing primed. Cooling water solenoid valve auto. F/C actuator zero (O). Actuator position local. Cooling water primary valve (V-38,V-41,V-39,V-42,V-40,V-43,V227,V-229,V-228,V-230; D4-CW-1,D4-CW-4,D5-CW-1,D5-CW-4,D6-CW1,D6-CW-4,D7-CW-4,US3-CW-1,US3-CW-4,US4-CW-1,US4-CW-4)open. All secondary cooling system valves (V-22,V-32,V-24,V-34,V-23,V33,V-25,V-35,V-20,V-26,V211,V217,V213,V-219,V-212,V-218,V-214,V220,V209,V215 ; D-CW-18,D-CW-6,D-CW-20,D-CW-7,D-CW-22,D-CW9,D-CW-24,D-CW-1,D-CW-3,D-CW-10,US-CW-4,US-CW-18,US-CW6,US-CW-20,US-CW-7,US-CW-22,US-CW-9,US-CW-24,US-CW-1,USCW-3US-CW-10) open. Cooling water expansion tank level normal. Tank make up water supply valve (V-83,V-251,DM-12,DM-11)open. Start cooling water pump. Start forwarding pump. Open discharge valve . (V-11,V-12,V-13,V-202,V-203; V-1124,V1123,V-1122,V-1121,V-1120,V-1119 ) Confirm cooling water solenoid open. Page 266 of 320 * * * * * * * * * * * * * * * * *
Effective
Oct 2002
Q.E.W.C

May 2003
Pump load up by the actuator control gradually as required. And Confirm surge vessel systems.
TITLE: BOP SOP No
D5-022
FORWARDING PUMP HOUSE SHUTDOWN
OUTSTATION SUPERVISOR TCC

SHUTDOWN PROCEDURE:
F/C. actuator gradually bring down to zero.
* * *
Discharge valve close . . (V-11,V-12,V-13,V-202,V-203; V-1124,V- 1123,V-1122,V-1121,V1120,V-1119 ) Stop forwarding pump. Stop cooling water pump. Watch and confirm surge vessel systems.
* *
(If Doha Pump 02 nos. are in service actuator position should be kept open approximately 12% for avoiding the non-flow trip and change over procedure also as usual). Page 267 of 320
Effective
Oct 2002
Q.E.W.C

May 2003

PART - D6 ELECTRICAL ISOLATIONS
Page 268 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
ELECTRICAL ISOLATIONS GENERAL GUIDELINES 1. For mechanical P.T.Ws 6.6kv VCB isolator to be switched off and locked & tagged for brine pumps and s.w. r/c pumps (in phase-iv distillers.) 2. For mechanical P.T.Ws on pumps and drives 415v isolator or tray switch to be switched off and locked & tagged. 3. For electrical PTWs either 415v isolator or 415v isolator and tray switch to be switched off and locked & tagged as per the requirements of EMD. 4. For breaker maintenance breaker to be switched off, racked out and bus bar shutters to be shut and locked & tagged and caution boards to be placed.
Electrical Switching Procedures

Switching of 6.6 kV VCBs This section concerns the switching procedures in 6.6 kV vacuum circuit breaker. The switching procedures include isolation/de-isolation of vacuum circuit breaker for issuing permit for work on the pumps or on the motors if the circuit earth is not required.
Page 269 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
TITLE: ELECTRICAL ISOLATION PROCEDURES SOP No
D6-001
Isolation of 6.6 kV VCB
DSCE/PERMIT ENGINEER CCR/DCR

Switching for Phase I, II, III & IV Inform control room D-supervisor that the pump will be under PTW, and ask from him to stop the pump if it is running. Check that the VCB is opened by lamp indication and ammeter current. Press the emergency push button to Off position. Press the mechanical trip knob and turn the isolator to Off position. Lock & Tag the VCB isolator in Off position. Place a caution board. Use the key for issuing the permit.
* *
* * * *
Page 270 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
D6-002
De-Isolation of 6.6 kV VCB

Switching for Phase I, II, III & IV
Remove the tag & Unlock the VCB isolator. Press the mechanical trip knob and turn the isolator to ON position. Release the emergency pushbutton to ON position. Reset the protection relays, which have indication flag. Inform control room D-supervisor that the power for the pump is normalised.
* * * * *
Page 271 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
D6-003
Isolation of 6.6 kV VCB

SWITCHING FOR PHASE V
Inform control room D-supervisor that the pump will be under PTW, and ask from him to stop the pump if it is running. Check that the VCB is opened by lamp indication and ammeter current. Rack out the VCB by inserting the spindle in the provision hole and rotate the spindle in counter clockwise direction. Confirm that the feeder is not available by lamp indication in local panel. When the breaker is fully withdrawn, turn the rackin prevention lever at right bottom of the breaker by 90o and remove the key nearby. Place a caution board. Use the key for issuing the permit.
Page 272 of 320
Effective
Oct 2002
Q.E.W.C

May 2003
D6-004
De-Isolation of 6.6 kV VCB

SWITCHING FOR PHASE V
Insert the key in the provision Lock & Tag right bottom of the breaker and turn it, and confirm that the rack-in prevention lever is turned 90o. Rack in the VCB by inserting the spindle in the provision hole and rotate the spindle in clockwise direction. Confirm that the feeder is available by lamp indication in local panel. Reset the protection relays, which are fallen. Inform control room D-supervisor that the power for the pump is normalised.
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May 2003
415V POWER SUPPLY SYSTEM

This section concerns the switching procedures in 415V switchboards, which supply 415V power to distillers equipment. The switching procedures include isolation/de-isolation and racking out/in of the 415V ACBs, which include incomer, interconnector and motor starters. And it include changing over of the power supply to these 415V switchboards in case of releasing the incomer or its upstream 6.6kV OCB for maintenance. Also it includes the procedures to release the switchboard for bus bar inspection.
Page 274 of 320
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May 2003
D6-005
Isolation of 415V ACB for Work on Pump
Switching for Phase I, II, III & IV Confirm that the ACB is opened by lamp indication and ammeter current. Isolate the 415V power supply by turning the isolator to Off position. Lock & Tag the isolator in Off position. Place a caution board. Use the key for issuing the permit.
* * * * *
Page 275 of 320
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May 2003
D6-006
Isolation of 415V ACB for Work on Motor
Switching for Phase I, II, III & IV Confirm that the ACB is opened by lamp indication and ammeter current. Isolate the 415V power supply by turning the isolator to Off position where applicable. Turn the tray switch (isolating lever) to Off position, which will disconnect the breaker from the bus bar and from the outgoing terminals. Lock & Tag the tray switch in Off position. Place a caution board. Use the key for issuing the permit.
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Page 276 of 320
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May 2003
D6-007
Isolation of 415V ACB for Work on Motor Starter
Switching for Phase I, II, III & IV Confirm that the ACB is opened by lamp indication and ammeter current. Isolate the 415V power supply by turning the isolator to Off position. Turn the tray switch to Off position. Open the cubicle door. At the bottom of the breaker, turn the fixing pin to free the breaker from the cubicle. Pull the breaker to outside, it must be taken out of the cubicle, if the breaker is big, use a trolley. Lock & Tag the bus bar shutter. Close the cubicle door. Place a caution board. Use the key for issuing the permit.
* * * * * * * * * * *
Page 277 of 320
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May 2003
D6-008
Starter De-Isolation of 415V ACB After Work on Motor
Switching for Phase I, II, III & IV Open the cubicle door. Remove the tag & Unlock the bus bar shutter. Put the breaker inside the cubicle by using the trolley, if it is big. At the bottom of the breaker, turn the fixing pin to fix the breaker in the cubicle, otherwise the cubicle door cant be closed. Close the cubicle door. Turn the tray switch to ON position. Turn the isolator to ON position. Now the breaker is ready for closing.
* * * * * * * * * *
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May 2003
SWITCHING IN PHASE V At Phase V there are two types of ACBs for the motor starters. The ACBs of the big pumps, which are the seawater recycle, distillate extraction and blowdown pumps, are located in the 415V station aux. boards, whereas the ACBs of the small pumps are located in the 415V distiller boards. The switching procedures for the ACBs in distiller boards at Phase V are similar to the switching procedures at the other phases, whereas the switching procedures for the ACBs in station aux. boards are different.
Page 279 of 320
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May 2003
D6-009
Isolation of 415V ACB at Station Aux. Board
SWITCHING IN PHASE V
Confirm that the ACB is opened by lamp indication and ammeter current. Rack out the ACB by inserting the spindle in the provision hole and rotate the spindle in counter clockwise direction. Confirm that the feeder is not available by lamp indication in local panel. When the breaker is fully withdrawn, pull the rackin prevention button and Lock & Tag it. Place a caution board. Use the key for issuing the permit.
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Page 280 of 320
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May 2003
D6-010
Isolation of 415V ACB at Station Aux. Board for Work on Motor Starter
Confirm that the ACB is opened by lamp indication and ammeter current. Rack out the ACB by inserting the spindle in the provision hole and rotate the spindle in counter clockwise direction. Confirm that the feeder is not available by lamp indication in local panel. When the breaker is fully withdrawn, open the cubicle door. Pull the breaker to outside, it must be taken out of the cubicle by using trolley. Lock & Tag the bus bar shutter. Close the cubicle door. Place caution board. Use the key for issuing the permit.
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May 2003
D6-011
De-Isolation of 415V ACB After Work on Motor Starter
Open the cubicle door. Remove the tag & Unlock the bus bar shutter. Put the breaker inside the cubicle by using the trolley. Close the cubicle door. Rack in the ACB by inserting the spindle in the provision hole and rotate the spindle in clockwise direction. Confirm that the feeder is available by lamp indication in local panel. Now the breaker is ready for closing.
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May 2003
D6-012
SUPPLY CHANGING OVER FOR 415V DIST BOARDS
SUPPLY CHANGING OVER FOR 415V DISTILLER BOARDS This is done if there is a request for a routine maintenance work on the 415V incomer ACB. Also this is done if there is a request from G-SCE in case of a maintenance request for a work on the 6.6kV/415V distiller transformer or on the 6.6kV OCB. Put the interconnector ACB in test position and test the closing before starting supply changing over (at Phase I, II, III). Inform CCR/DCR and local supervisors about the proposed supply changing over, because the distiller is on production, If the supply changing over is done before the actuation time of the under voltage relay, the motor starters will not trip, otherwise all the starters should be started immediately.
Page 283 of 320
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May 2003
D6-013
Supply Changing Over & Releasing the Incomer at Phase I, II & III
DSCE/PERMIT ENGINEER CCR/DCR/GSCE

Rack in the interconnector 24-1 by inserting the spindle in the provision hole and rotate the spindle in clockwise direction, if it is racked out. In the 415V aux. boiler board 1/2, select position 4 with the selector switch. Open the incomer 52-1 and close the interconnector 24-1. Open the cubicle door of the incomer. Rack out the incomer 52-1 by inserting the spindle in the provision hole and rotate the spindle in counter clockwise direction. Pull the breaker to outside, it must be taken out of the cubicle by using trolley. Lock & Tag the bus bar shutters. Close the cubicle door. Place caution board. Use the key for issuing permit or hand it over to G-SCE.
DISTILLER BOARD 1
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* * *
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May 2003
D6-013
DISTILLER BOARD 2
Rack in the interconnector 24-2 if it is racked out. In the 415V aux. boiler board 1/2, select position 3 with the selector switch. Open the incomer 52-2 and close the interconnector 24-2. Open the cubicle door of the incomer. Rack out the incomer 52-2. Pull the breaker to outside, it must be taken out of the cubicle by using trolley. Lock & Tag the bus bar shutters. Close the cubicle door. Place caution board. Use the key for issuing permit or hand it over to G-SCE.
* * * * * * * *
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May 2003
D6-013
DSCE/PERMIT ENGINEER CCR

DISTILLER BOARD 3
Rack in the interconnector 24-3 if it is racked out. In the 415V aux. boiler board 1/2, rack in the interconnector 24-1/2 by rotating the spindle in clockwise direction, if it is racked out. And then select position 2 with the selector switch. Open the incomer 52-3, close the interconnector 24-3 and close the interconnector 24-1/2. Open the cubicle door of the incomer. Rack out the incomer 52-3. Pull the breaker to outside, it must be taken out of the cubicle by using trolley. Lock & Tag the bus bar shutters. Close the cubicle door. Place caution board. Use the key for issuing permit or hand it over to GSCE.
* *
* * * * * * * *
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May 2003
D6-013
DSCE/PERMIT ENGINEER CCR/GSCE

DISTILLER BOARD 4
Rack in the interconnector 24-4 if it is racked out. In the 415V aux. boiler board 3/4, rack in the interconnector 24-3/4 by rotating the spindle in clockwise direction, if it is racked out. And then select position 2 with the selector switch. Open the incomer 52-4, close the interconnector 24-4 and close the interconnector 24-3/4. Open the cubicle door of the incomer. Rack out the incomer 52-4. Pull the breaker to outside, it must be taken out of the cubicle by using trolley. Lock & Tag the bus bar shutters. Close the cubicle door. Place caution board. Use the key for issuing permit or hand it over to GSCE.
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* * * * * * * * *
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May 2003
D6-013

DISTILLER BOARD 5
Rack in the interconnector 24-5 if it is racked out. In the 415V aux. boiler board 3/4, select position 3 with the selector switch. Open the incomer 52-5 and close the interconnector 24-5. Open the cubicle door of the incomer. Rack out the incomer 52-5. Pull the breaker to outside, it must be taken out of the cubicle by using trolley. Lock & Tag the bus bar shutters. Close the cubicle door. Place caution board. Use the key for issuing permit or hand it over to GSCE.
* * *
* * * * * * * *
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May 2003
D6-013

DISTILLER BOARD 6
* * * * * *
* * * *
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May 2003
D6-013

DISTILLER BOARD 7
Rack in the interconnector 24-7 if it is racked out. In the 415V aux. boiler board 7/8, select position 2 with the selector switch. Open the incomer 52-7 and close the interconnector 24-7. Open the cubicle door of the incomer. Rack out the incomer 52-7. Pull the breaker to outside, it must be taken out of the cubicle by using trolley. Lock & Tag the bus bar shutters. Close the cubicle door. Place caution board. Use the key for issuing permit or hand it over to GSCE. Distiller Board 8
Page 290 of 320
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May 2003
Production/Operation * * * * * * * * * *
Page 291 of 320
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May 2003
D6-014
Normalising the Incoming Supply in 415v Dist Boards
NORMALISING THE INCOMING SUPPLY IN 415V DISTILLER BOARDS The following are general steps for normalising the 415V power supply through the incomer ACB in distiller board at Phase I, II & III: Open the cubicle door of the incomer. Remove the tag & Unlock the bus bar shutter. Put the breaker inside the cubicle by using the trolley. Close the cubicle door. Rack in the incomer by inserting the spindle in the provision hole and rotate the spindle in clockwise direction. Make appropriate selection in the aux. boiler board with the selector switch. Open the interconnector and close the incomer. Rack out the interconnector by inserting the spindle in the provision hole and rotate the spindle in counter clockwise direction.
Page 292 of 320
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May 2003
D6-015
SUPPLY CHANGING OVER & RELEASING THE INCOMER AT PHASE IV
DSCE/PERMIT ENGINEER DCR/GSCE

DISTILLER BOARD 9
Rack in the interconnector 52-9/B if it is racked out. Collect keys 8 and 10 from boards B and 10, then insert them in the locks of the block switch [g] at the interconnector 52-9/B panel. Open the incomer ACB 52-9 and then release the operation key 52-9, which is placed in the same bunch with the key 24. Insert key 24 in the Lock & Tag at block switch [f] at the incomer 52-9 panel, and then release key 4 from same block switch and insert it in the Lock & Tag at block switch [g] of interconnector 52-9/B panel. Release key 25, which is placed in the same bunch with the operation key 52-9/B. Insert the operation key 52-9/B in the Lock & Tag at 52-9/B panel. Close the interconnector ACB 52-9/B. Open the cubicle door of the incomer.
Page 293 of 320
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May 2003
Production/Operation * * * * *
Rack out the incomer 52-9. Pull the breaker to outside, it must be taken out of the cubicle by using trolley. Lock & Tag the bus bar shutters. Close the cubicle door. Place caution board. Use the key for issuing permit or hand it over to G-SCE.
Page 294 of 320
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May 2003
D6-015

DISTILLER BOARD 10
Rack in the interconnector 52-10/B if it is racked out. Collect keys 8 and 10 from boards B and 9, then insert them in the locks of the block switch [i] at the interconnector 52-10/B panel. Open the incomer ACB 52-10 and then release the operation key 52-10, which is placed in the same bunch with the key 26. Insert key 26 in the Lock & Tag at block switch [h] at the incomer 52-10 panel, and then release key 5 from same block switch and insert it in the Lock & Tag at block switch [i] of interconnector 52-10/B panel. Release key 27, which is placed in the same bunch with the operation key 52-10/B. Insert the operation key 52-10/B in the Lock & Tag at 52-10/B panel. Close the interconnector ACB 52-10/B. Open the cubicle door of the incomer. Rack out the incomer 52-10.
Page 295 of 320
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May 2003
Pull the breaker to outside, it must be taken out of the cubicle by using trolley. Lock & Tag the bus bar shutters. Close the cubicle door. Place caution board. Use the key for issuing permit or hand it over to GSCE.
* * * * *
Page 296 of 320
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Oct 2002
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May 2003
D6-015

DISTILLER BOARD 11
Rack in the interconnector 52-11/D if it is racked out. Collect keys 9 and 11 from boards D and 12, then insert them in the locks of the block switch [m] at the interconnector 52-11/D panel. Open the incomer ACB 52-11 and then release the operation key 52-11, which is placed in the same bunch with the key 28. Insert key 28 in the Lock & Tag at block switch [l] at the incomer 52-11 panel, and then release key 7 from same block switch and insert it in the Lock & Tag at block switch [m] of interconnector 52-11/D panel. Release key 29, which is placed in the same bunch with the operation key 52-11/D. Insert the operation key 52-11/D in the Lock & Tag at 52-11/D panel. Close the interconnector ACB 52-11/D. Open the cubicle door of the incomer.
Page 297 of 320
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May 2003
Production/Operation * * * * * *
Rack out the incomer 52-11. Pull the breaker to outside, it must be taken out of the cubicle by using trolley. Lock & Tag the bus bar shutters. Close the cubicle door. Place caution board. Use the key for issuing permit or hand it over to GSCE.
Page 298 of 320
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May 2003
D6-015

DISTILLER BOARD 12
Rack in the interconnector 52-12/D if it is racked out. Collect keys 9 and 11 from boards D and 11, then insert them in the locks of the block switch [o] at the interconnector 52-12/D panel. Open the incomer ACB 52-12 and then release the operation key 52-12, which is placed in the same bunch with the key 30. Insert key 30 in the Lock & Tag at block switch [n] at the incomer 52-12 panel, and then release key 6 from same block switch and insert it in the Lock & Tag at block switch [o] of interconnector 52-12/D panel. Release key 31, which is placed in the same bunch with the operation key 52-12/D. Insert the operation key 52-12/D in the Lock & Tag at 52-12/D panel. Close the interconnector ACB 52-12/D. Open the cubicle door of the incomer.
Page 299 of 320
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May 2003
Production/Operation * * * * *
Rack out the incomer 52-12. Pull the breaker to outside, it must be taken out of the cubicle by using trolley. Lock & Tag the bus bar shutters. Close the cubicle door. Place caution board. Use the key for issuing permit or hand it over to GSCE.
Page 300 of 320
Effective
Oct 2002
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May 2003
D6-016
NORMALISING THE INCOMING SUPPLY IN 415V DISTILLER BOARDS
DSCE/PERMIT ENGINEER DCR

SUPPLY CHANGING OVER & RELEASING THE INCOMER AT PHASE IV The following are general steps for normalising the 415V power supply through the incomer ACB in the distiller boards at Phase IV. Open the cubicle door of the incomer. Remove the tag & Unlock the bus bar shutter. Put the breaker inside the cubicle by using the trolley. Close the cubicle door. Rack in the incomer by inserting the spindle in the provision hole and rotate the spindle in clockwise direction. Open the interconnector and close the incomer by following the same steps of releasing the incomer but in reverse way. Rack out the interconnector by inserting the spindle in the provision hole and rotate the spindle in counter clockwise direction.
Page 301 of 320 *
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SOP No

May 2003
TITLE: ELECTRICAL ISOLATION PROCEDURES
D6-017
Supply Changing Over in Distiller Boards 13 & 14

Supply Changing Over at Phase V At Phase V each distiller board has two 415V incomer ACBs connected to another ACBs at the upstream in 415V station aux. board side. The following steps show the supply changing over between them and releasing of the incomers to the maintenance. Confirm that the standby incomer at station aux. board is in closed position. Open the service incomer ACB, then release and take out the operation key from breaker panel. Insert the operation key in the standby incomer panel and then close the incomer ACB. Open the service incomer ACB at station aux. board. Rack out both of the opened incomer ACBs. Open the cubicle doors of both of them. Take out both of ACBs from cubicle by using trolley. Lock & Tag the bus bar shutters for both of ACBs. Close the cubicle doors. Place caution boards. Use the keys for issuing the permit.
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* * * * * * * * *
Page 302 of 320
Effective
Oct 2002
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SOP No

May 2003
D6-018
Supply Changing Over in Station Aux. Boards 7A, 7B, 8A & 8B

Isolation of 415V ACB for Work on Motor Starter At Phase V each station aux. board has one 415V incomer ACB. Board A is connected to board B through 415V bus section ACB. Only two out of three breakers can be closed. The following steps show the supply changing over through the bus section to release the incomer for the maintenance. Open the required incomer ACB, then release and take out the operation key from breaker panel. Insert the operation key in the bus-tie panel and then close the bus section ACB. Rack out the incomer ACB. Open the cubicle door. Take out the incomer ACB from cubicle by using trolley. Lock & Tag the bus bar shutter of the incomer ACB. Close the cubicle door. Place caution board. Use the key for issuing permit or hand it over to GSCE.
Page 303 of 320 *
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Effective
Oct 2002
Q.E.W.C
SOP No

May 2003
D6-019
Normalising the Incoming Supply in 415V Station Aux. Boards

The following are general steps for normalising the 415V power supply through the incomer ACB in the station aux. boards. Open the cubicle door of the incomer. Remove the tag & Unlock the bus bar shutter. Put the breaker inside the cubicle by using the trolley. Close the cubicle door. Rack in the incomer by inserting the spindle in the provision hole and rotate the spindle in clockwise direction. Open the bus-tie ACB, then release and take out the operation key from breaker panel. Insert the operation key in the incomer panel and then close the incomer ACB. Rack out the bus-tie by inserting the spindle in the provision hole and rotate the spindle in counter clockwise direction.
* * * * *
* * *
Page 304 of 320
Effective
Oct 2002
Q.E.W.C
SOP No

May 2003
D6-020
Releasing of 415V Distiller Boards for Annual Overhaul
This can be done only during annual overhauling of the distiller, when no drive is running. Board overhauling include the following: 1234Bus bar & starter cubicles inspection. Overhaul of 415V ACB incomer. Overhaul of 415V ACB bus-tie. Overhaul of motor starters.
* * * *
Page 305 of 320
Effective
Oct 2002
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SOP No

May 2003
D6-021
Releasing of 415V Distiller Board at Phase I, II, III & IV

The following are general steps to release 415V distiller board for annual overhaul. All feeders to be switched off. Open the 415V incomer ACB. Rack out the 415V incomer ACB and Lock & Tag its bus bar shutter. Rack out the 415V bus-tie ACB and Lock & Tag its bus bar shutter. Rack out all 415V motor starters and Lock & Tag their bus bar shutters. Get from G-SCE, the 6.6kV OCB bus bar shutters locking key for bus bar inspection permit and hand over to G-SCE incomer ACB bus bar shutter locking key. Place caution board. Use the keys for issuing the permits.
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* *
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Page 306 of 320
Effective
Oct 2002
Q.E.W.C
SOP No

May 2003
D6-022
ELECTRICAL ISOLATION FOR OVERHAUL PERMIT OF DISTILLER 13

Releasing of 415V Distiller Board & Station Aux. Board at Phase V Both of station aux. boards 7A & 7B and distiller board 13 can be released after arranging the supply from the bus-tie for lighting and HVAC board B and Distiller 13/14 C/S board B. Kill the boards and Rack out the 415V incoming/bus section ACBs away from the cubicle at the boards with locking the bus bar shutters. Rack out the 415V motor starters away from the cubicle at the boards with locking the bus bar shutters. Get from G-SCE, the 6.6kV SF6 bus bar shutter locking key for bus bar inspection permit and hand over to G-SCE incomer ACB bus bar shutter locking key of the station aux. boards. Place caution board. Use the keys for issuing the permits.
*
* *
Page 307 of 320
Effective
Oct 2002
Q.E.W.C
SOP No

May 2003
D6-023 ELECTRICAL ISOLATION FOR OVERHAUL PERMIT OF DISTILLER 14

Releasing of 415V Distiller Board & Station Aux. Board at Phase V Both of station aux. board 8A and 8B cant be killed for bus bar inspection at same time, because this will make aux. boiler 14 to be out of service, for that one of them should be lived. Arrange the supply from the bus-tie for lighting and HVAC board A and Distiller 13/14 C/S board A. Kill the boards and Rack out the 415V incoming/bus section ACBs away from the cubicle at the boards with locking the bus bar shutter. Rack out the 415V motor starters away from the cubicle at the boards with locking the bus bar shutters. Get from G-SCE, the 6.6kV SF6 bus bar shutters locking key for bus bar inspection permit and hand over to G-SCE incomer ACB bus bar shutter locking key of the station aux. boards. Place caution board. Use the keys for issuing the permits. Notes:
Page 308 of 320 *
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-

May 2003
Before killing the distiller board, arrange temporary supply to the equipment that is related to another section in the desalination plant, if it is possible. All bus bar shutters should be unlocked for bus bar inspection. When permits on the bus bar inspection and overhauling of incomer and bus section ACBs are cancelled: rack in the breaker in the board cubicles and energise the board from the bus section to supply power to the equipment that related to another section in the desalination plant.
Page 309 of 320
Effective
Oct 2002
Q.E.W.C
SOP No

May 2003
D6-024
ACTIVITY
TAKING THE DISTILLER TRANSFORMER IN SERVICE AFTER COMPLETION OF MAINTENANCE ON TXR, OCB & ACB
REFERENCE RESPONSIBILITY COMMUNICATION OPERATION Field CCR/DCR

Location
Releasing of 415V Distiller Board & Station Aux. Board at Phase V When the supply from the distiller transformer 6.6kV OCB is ready, change the supply to the incomer ACB and carry out with G-SCE the INTERTRIP TEST between the distiller transformer 6.6 kV OCB and 415V distiller board incomer ACB. The intertrip test is carried out after every overhaul of the distiller transformer 6.6kV OCB and 415V distiller board incomer ACB to confirm that the interlocks, which are provided between them, are functioning properly. Intertrip test is strictly off load test; no drive should run in the distiller board during this test. During the test, G-SCE at 6.6kV board and D-SCE at 415V board should establish between them a direct contact through Radios.
Initial conditions At 6.6Kv unit boards: a) Unit Distiller Transformer OCB racked in service
Page 310 of 320
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May 2003
position, racked up and closed At 415V Distiller Board
b.1) All outgoing circuits isolators to be opened. b.2) Incoming transformer ACB racked into service position, bus tie ACB racked out.
Page 311 of 320
Effective
Oct 2002
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SOP No

May 2003
D6-025 INTERTRIP TEST SEQUENCE
DSCE/PERMIT ENGINEER DSCE/PERMIT ENGINEER/GSCE

Location
PRELIMINARY CHECKS Field LCR/MI
Releasing of 415V Distiller Board & Station Aux. Board at Phase V

*
trip. -
G-SCE: Close the 6.6 kV OCB. D-SCE: Close 415V incomer ACB. D-SCE: Check operation of ACB mechanical D-SCE: Close incomer ACB. EMD: Actuate restricted earth fault relay. G/D-SCE: Check that both of OCB & ACB are tripped , and then reset the trips. D-SCE: Try to close incomer ACB. Check no closing. G-SCE: Close 6.6 kV OCB. D-SCE: Close incomer ACB. G-SCE: Open 6.6 kV OCB. D-SCE: Check incomer ACB is tripped. G-SCE: Close 6.6 kV OCB. D-SCE: Close incomer ACB. And then rack out incomer ACB G/D-SCE: Check that both of OCB & ACB are tripped.
Page 312 of 320
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-

May 2003
G-SCE: Try to close 6.6 kV OCB. Check no closing. D-SCE: Rack in bus-tie ACB, check on-load closing operation, check mechanical trip operation and rack out. D-SCE: Rack in incomer ACB. G-SCE: Close 6.6 kV OCB. D-SCE: Close incomer ACB. After performing the above sequences the test is completed.
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May 2003

EMERGENCY CONTINGENCY PROCEDURE
Page 314 of 320
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May 2003
TITLE: EMERGENCY PROCEDURE SOP No
D7-001
BLACKOUT
GSCE/DSCE/PERMIT ENGINEER CCR(GEN)/CCR(DESALINATION)/DCR

RAS ABU FONTAS (A) POWER & WATER STATION

RESTORATION PROCEDURE AFTER A BLACKOUT
In the event of a complete system collapse and the bus bars at RAF-A becoming dead the following action should be taken: 1. Open all 132kv and 66kv circuit breakers, except the following: (Without reference to System Control should the fault be external to the Station bus bars). (a) (b) (c) (d) 2. 3 4. 5. 6. Bus Couplers and Bus Sections OCBs 132/66kv Interbus Transformers 1 & 2 OCBs. StationTransformers 1,2,3,5,6,7 & 8 132kv OCBs. BSGTx.20 132kv OCB C-2070. *
Open BSGTx.20 11kv ACB A-2010. Open Station Tx.4 11kv ACB A-1210 (6.6kv OCB A-880 to remain close). Open RAF-B 11kv Interconnector ACB A-3190. Open Stations Transformers 1,2,3,5,6,7 & 8 6.6kv OCBs. Confirm that415V Black Start Aux. Board is already energized by mean of one of the BSD auto-start operation. (if not, start a BSD and energize the B. S. Aux. Bd.). Page 315 of 320
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Q.E.W.C
7.

May 2003
Check that all 4 Nos. Station Lighting Boards are re-energized automatically via Emergency Lighting Diesels (ELDs). If not, carry out manual operation. 8. Inform General Manager, Production Manager, Operation Manager, Maintenance Manager, Planning Manager, Operation Section Heads, Planning & Maintenance Section Heads, Unit Heads and Maintenance Engineers over telephone at the earliest possible. 9. Start both BSG Ts, in turn, on gas, (at present oil firing is not available) and energize the 11kv B.S. Board using one machine (closing of BSG Gen. ACB on dead bar), second machine to be Left spinning. * 10. Restore BSATx.1 or 2 and shut down the running BSD. 11. Re-energize 132kv and 66kv bus bar via BSGTx.20 by closing 11kv ACB A-2010. (Permission must be taken from System Control prior to this operation). 12. Restore Station auxiliaries via all Station Transformers and give the BSG some load. (Priority gives to Seawater Pump House (A) Aux. Boards 1 & 2, for start-up of G. T. cooling water pumps). 13. Normalize Station Lighting Boards supply and shut down ELDs. 14. Prepare and run up one KWU m/c to full speed. (S.W. cooling system to be primed and nominal pressure should be established prior to start-up of this machine. 15. Inform System Control when the main generator attains full speed and await their instruction to synchronize. 16. Check and close RAF-B 11kv Interconnector ACB A-3190, if required by RAF-B. 17. Run-up other main generators, one by one, and restore Station generation and transmission system as required by System Control. 18. Re-start Desalination Plants. 19. Shut down at least one BSG for standby duty. *NOTE: Second BSG should be left spinning, with field breaker closeduntil complete system is back to normal. (415V B. S. Aux. Board supply must be restored within two minutes to prevent the BSG from tripping after subsequent (Black- out) during restoration period).
Page 316 of 320
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May 2003
TITLE: EMERGENCY PROCEDURE SOP No
D7-002
OIL SLICK CONTINGENCY PLAN
DSCE/PERMIT ENGINEER/OUTSTATION SUPERVISOR CCR/DCR

Ras Abu Fontas (a) Power & Water Station has a stone bundled lagoon around the mouth of the two intake channels (A) & (B) with an opening of about 10m wide through which most of the sea water flow to operate 14nos. Sea Water pumps to supply sea water for 12 nos. gas Turbines and 14 nos. Distillers. Each S.W. pumps has a capacity of about 10,000 T/Hr. at the discharge pressure of 2.5 to 3.0 bars. To operate 12 Distillers and 12 G.Ts the total number of S.W. pumps required during summer and winter are as follows: Summer Months: 13/14 Pumps Winter Months: 7/8 Pumps The design suction condition of sea water pumps at RAF (A) Station are flooded type where the low level alarm is set at 1750mm from the datum level and Sea water header pressure must be maintain between 2.5 to 3.0 bar. Seawater pumps will be shut down one at a time to maintain the above conditions. This contingency plan is prepared taking into account the period (summer/winter) and the type oil slick. OBJECTIVE: The objective is to assess the type and size of the oil slick in relation to plant Page 317 of 320
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May 2003
availability in a case by vase basis and to provide a Contingency plan to combat the oil spills in the event of significant contamination of our Seawater intake. Types of Spillage: Oil slick can be broadly divided into the following three main categories.
(A) (B) MINOR: MEDIUM:
(C)
MAJOR:
Tar balls (Active/ Inactive hydrocarbons) With no prior warning / information. Active hydrocarbon. There may or may not be any advance warning / information. Required quick and affective decision to be taken to minimize the loss of Power Station production. Active hydrocarbons. There will be adequate warning /information enabling extra staff and equipments to be mobilized and to face an imminent loss of power station.
SCOPE OF THE PLAN The scope of the Contingency plan is as under. Oil Slick Emergency (Major / Minor)
System Procedure & Equipment CONTINGENCY PLAN:
Man Power
Materials
(A) MINOR: Tar balls (active /Inactive) with no prior warning/ information. .
Page 318 of 320
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System Procedure: (i)

May 2003
No need to inform the higher management immediately, but head of Operations may be informed if required. All Band screens to be put in service on Manual. All available shift helpers and operators to be utilized as required at the Intake channels and at coarse screens to collect the Tar balls with the Supervision of S.W. pump house and F. pump house Supervisors. Change over the minimum required sea water pumps to one intake channel (either (A) or (B) so that to concentrate more effort in one channel, depending on the available man-power. Additional manpower to be arranged as required. * *
(ii) (iii)
(iv)
(v)
Materials & Equipments: As per schedule (A) plus oil absorbent materials, booms, pads, Forklift, Diesel powered oil skimmer & oil recovery unit, Floating tanks. (C) MAJOR- Active hydrocarbons.
There will be adequate warning/information of this enabling extra staff and Equipments to be mobilized and to face an imminent loss of power and water. System Procedure: (i) Inform Production Manager, Operation Manager, Maintenance Manager, Planning Manager, Operation Section Heads, Planning & Maintenance Section Heads, Unit Heads and Maintenance Engineers over telephone at the earliest possible. All Band screen to be put in service on (Manual) and lower the Penstocks, upstream of the Band screens, to 50%. Start the Black start G.Ts (If they are not in service). * (iv) Immediately take action to reduce inlet water flow by simultaneously shutting down the Distillers including stopping the Reject flow Sea Water pumps one by one. Page 319 of 320 *
(ii)
* * *
(iii)
Effective
Oct 2002
Q.E.W.C
(v)

May 2003
(a) Intensive sampling of distillate to monitor dissolved Hydrocarbons. (b) Seawater and distillate to be tested for hydrocarbons by authorized Dept. (e.g. Qatar University of Ministry of Public Health). (c) Shut down CO2 system, recarbonation and DTP Electro chlorinators if necessary. The seawater requirement for Gas Turbine cooling is about 11,000 to 12,000 t/hr. which is equal to one or two seawater pump capacity. So keep at least one or two seawater pumps in service in order to keep the Gas Turbines in service.
(vi)
* *
(vii) Arrange the available man-power along side the intake channel to pick up the floating oil as for as possible and to supply materials. (viii) Oil absorbent material to be placed upstream of the coarse screens and absorbent booms & pads to be placed at appropriate location. The diesel powered oil skimmer and oil recovery unit to be deployed in the common area of intake mouth (MMD)
Note: 2 nos. of Batteries of the following specifications to be kept stand-by for emergency use by Electrical section for operating the oil-skimmer with diesel pack & oil recovery unit. (1) Battery: 12V/60A (Delco) size: 20cm X 18cm X 17cm. (2) Battery: 12V/60A (Vega) size: 24cm X 19cm X17cm.
(ix)
Use high pressure water jets (Fire pump hydrant using sea water) to deflect the oil away at the intake entrance (Ops/MMD). Dispersant chemicals should not be used for any reason anywhere near the intake. Depending on the severity of the oil slick it may require a total shut down of the desalination Plants. But Gas Turbines can be maintained with at least one Sea Water pump.
(x)
(ix)
Page 320 of 320

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Issued Date Revision Issued By

Issued Date Revision Issued By

RAF-A DESALINATION STANDARD OPERATION PROCEDURES

Issued Date Revision Issued By

SOP No. D1-001 D1-002 D1-003 D1-004

VACUUM RAISING BY HOGGING EJECTOR.

Issued Date Revision Issued By

STARTING OF HIGH PURITY DISTILLATE PUMP

DUMPING OF DISTILLATE & CUTTING OF STEAM

Issued Date Revision Issued By

OPERATION OF EJECTORS AT PHASE I & III

OPERATION OF EJECTORS AT PHASE II

OPERATION OF EJECTORS AT PHASE IV

OPERATION OF EJECTORS AT PHASE V

Issued Date Revision Issued By

Issued Date Revision Issued By

Production/Operation 107 108 109

BASIC ISOLATIONS FOR SPECIFIC PERMITS

DISTILLER OVERHAUL PERMITS

Issued Date Revision Issued By

RAF-A DESALINATION STANDARD OPERATION PROCEDURES

Issued Date Revision Issued By

Production/Operation 138 141 143

WHB PRESTARTUP CONDITIONS

WHB SUPPLEMENTARY GAS FIRING

WHB SHUTDOWN PROCEDURES

AUX BOILER PRESTART CHECKS

AUX BOILER STARTUP ON GAS

AUX BOILER PRESTARTUP CHECKS FOR OIL

Issued Date Revision Issued By

AUX BOILER SHUTDOWN PROCEDURE AUX BOILER PROCEDURE

WHB WATER WEDGING PROCEDURE

WHB DEWATERWEDGING PROCEDURE

AUX BOILER WATER WEDGING PROCEDURE

AUX BOILER DEWATERWEDGING PROCEDURE

PTW & WHB PRESSURE PARTS

PTW & WHB NON PRESSURE PARTS

Issued Date Revision Issued By

RAF-A DESALINATION STANDARD OPERATION PROCEDURES

Issued Date Revision Issued By

GENERAL D3-001 D3-002

169 170 172

ISOLATION FOR PTW

AIR DRIER OPERATION

MAKEUP WATER SYSTEM

BEARING COOLING WATER SYSTEM

Issued Date Revision Issued By

RAF-A DESALINATION STANDARD OPERATION PROCEDURES

Issued Date Revision Issued By

D4-001 D4-002 D4-003

187 189 192

SPRINKLER FIRE ALARM

FIRE HYDRANTS SAMPLE OF H-1, H-17 & H- 27

Issued Date Revision Issued By

RAF-A DESALINATION STANDARD OPERATION PROCEDURES

Issued Date Revision Issued By

105 106 107 108

GENERAL D5-001 D5-002 D5-003

204 205 206 207

S W PUMPS RUNNING CHECKS

GT C.W PUMPS A & B

BAND SCREENS A , B , C, D, & E

WASHWATER PUMPS A & B