Sop HRSG

Bin Qasim Power Station II
560 MW Combined Cycle Power Plant,

Port Qasim, Karachi
Heat Recovery Steam Generator

KE-Gen-BQPSII-OPS-SOP-002
K-Electric - Generation – Bin Qasim Power Station – II , 560 MW CCPP Karachi
Document No. KE-Gen-BQPSII-OPS-SOP-002
Operation Department Level II
Revision Date 1st May, 2016
Heat Recovery Steam Generator Page Page 2 of 26
Authority Matrix
Name
Signature Date
Designation
Initiated/Author Abdul Rehman Shaikh

Manager Shif
Reviewed by QMR Zahid Faqir

DGM HSEQ
Syed Mehdi Ali

Reviewed by HOD
GM Operations
Tahir Ali Khan

Approved by
Director Plant
Revision History
Rev No. Author(s) Revision Date Description of Change (including reason for change)
00 Abd. Rehman 10th May, 2012 Original Issue
01 Abd. Rehman 1st Nov, 2013 Formatting
02 Abd. Rehman 31st May, 2015 Formatting
03 Abd. Rehman 1st May, 2016 CCR Check sheet attached
Distribution list
Original Hard Copy - 01
Photo Stated Controlled Copies – 03
Sof Copy at Share Folder
Next Review Date 30th April, 2018

This document is the intellectual property of Bin Qasim Power station II, 560 MW CCPP. Printed documents are uncontrolled,
if not stamped “Controlled” – verify current revision on the Network drive prior to use.
Index
1.PURPOSE..................................................................................................................................................3
2.REFERENCE...............................................................................................................................................3
3.PREREQUISITE...........................................................................................................................................3
4.GENERAL PRECAUTION AND LIMITATION.................................................................................................3
5.PROCEDURE..............................................................................................................................................4
6.DRUM WATER LEVEL CONTROLL.............................................................................................................10
7.BLOW DOWN………………………………………………………………………………………………………………………………………11
8. APPENDIX…………………………………………………………………………………………………………………………………..………12
1.0 PURPOSE
This operating procedure describes the required steps and the associated information to
safely perform HRSG system and components start up and shut down and operate these
systems and components under normal conditions and within specified operating limits.

2.0 REFRENCE
HRSG O&M Manual

HRSG PIDs
3.0 PREREQUISITE
0 Prior to starting HRSG System verify the following:-
• Safety Document(s) on HRSG System cancellation and de-isolation.

• General safety checks of the system.
• Feed Water System is in service.
• Condensate System is in service.
• Auxiliary Cooling Water System in service.
• Waste Water Drains System is ready and available for service
• Sample and Analysis System is ready and available for service
• HRSG Blow down System ready and available for service
• Chemical Feed System is ready and available for service
• Main Steam System is ready and available for service
• Gas Turbine is ready and available for service
• Instrument air is lined up to all pneumatically actuated valves and controllers.
• System valves lined up as per check list
• Electrical Distribution System is lined up as per check list
• System checks from operator station
• Chemical department informed about start up of HRSG
4.0 GENERAL PRECAUTIONS AND LIMITATION
All personnel working on the system should be familiar with the following: -
• Equipment Operating Procedures

• Evacuation Procedures
• Leak Emergency Response Procedures
• First Aid and Rescue Procedures
• Location and use of Fire Fighting Equipment
• Proper Use of PPEs
• Location and Use of Shut Off Valves
• Location of safety showers and eyewash stations
CAUTION
Maintaining proper steam drum level is very critical during startup and operation of
HRSG. High water levels can cause carry over and leave deposits in the super
heater, as well as possible water carryover into ST. A low low water level can result
in thermal damage to the evaporator tubes and will result in an automatic trip of GT

CAUTION
Thermal stresses are induced in HRSG during start up and shut down. The greater the
rate of thermal changes during these periods, the greater the stress. If ignored, these
stresses can cause fatigue and premature mechanical problems.
It is preferable to start the GT with HRSG temperatures as hot as possible. Hot starts
induce lower stresses in HRSG than cold starts.
The heat input to HRSG should be controlled by monitoring the rate at which the
saturation temperature rises in HP and LP drums. The rate of temperature increase
should be limited by:
• Releasing steam through start up vents or ST bypass valves.
• Controlling the rate at which heat enters the HRSG by Match
Mode/ GT loading or DD.
• During unit start up/shut down, HP/LP super heater vent valves
are opened to maintain steam flow through the respective tube
bundles. In no case shall the valves be operated at less than
10% OPEN. Doing so will cause excessive wear and erosion of
the valve seats promoting frequent repair.
• If HRSG has been drained due to maintenance, water must be
added to HRSG to establish drum levels prior to start up. When
filling the HRSG water circuits, the high point vents of the
economizers and steam drums must be opened to allow air to
escape. Once complete, the vents must be closed.
• When filling the HRSG, temperature differentials between the
fill water and tube metal temperatures should be minimized.
• HRSG super heater coils are not designed for ‘Dry Run’
operation. Steam flow through the coils must be established
prior to increase in GT exhaust temperature. Lack of steam
flow can result in short term overheating and subsequent tube
failure.
5.0 PROCEDURE
Operating the HRSG is mainly through the Human-Machine Interface (HMI) using the command
and automatic sequences like:
• Sealing fan in service

• Sealing butterfly valve opening and closing
• Damper closing
• HP feed water pump starting
• LP feed water pump starting

• Normal shut down etc.

• Operation phases.
• Alarms and trips.
• Special notes.
• Instructions.
5.1 HRSG Start-up Procedure
• Verify the lineup of HP and LP Feed water circuit as per checklist

• Verify that any one Damper sealing fan in service
Starting of HP Feed Water pump:
• Verify that Deaerator level is >900mm

• Pump Suction valve is open
• Recirculation motorized valve is open and on AUTO select.
• Verify that the respective feed water pump’s motorized outlet valve is on auto.
• Verify that 30% and 100% controller are closed.
• Ensure the water flow of CCW through oil cooler.
• Place control of the pump on Manual.
• Start respective pump from DCS using ‘Feed Water Pumps’ Screen.
• Verify respective Discharge Valve Open (ON DCS).
• Check for any abnormality.
Starting of LP Feed Water pump:
• Verify that Deaerator level is >800mm

• Pump Suction valve is open
• Recirculation motorized valve is open and on AUTO select.
• Verify that the respective feed water pump’s motorized outlet valve is on auto.
• Verify that the respective feed water pump’s Motorized outlet valve is on auto.
• Verify that pump discharge control v\v is on closed position.
• Place control of the pump on Manual.
• Start respective pump from DCS using ‘Feed Water Pumps’ Screen.
• Verify respective Discharge Valve Open (ON DCS).
• Check for any abnormality.
• Select the Second and LP Feed Water pump on Auto Mode and interlock on.
5.2 Start-up procedure
For HRSG starting up please refer to following:
• Cold start up: HRSG restart after shutting down 72 hours, boiler water temperature
1000C.
• Warm start up: HRSG restart from boxed up condition within 24 hours.
• Hot start up: HRSG restart from boxed up condition within 8 hours.
5.2.1 COLD/WARM START UP
• CHECK HRSG valves are line up as per checklist

• CHECK HP/LP drums level controllers are on MANUAL.
 HP Boiler Drum level control valves ALAB10AA001/ ALAB10AA002
 LP Boiler Drum level control valves ALAB50AA001
Maintain HP/LP Drum levels at -50 mm (for Cold Start Up).
CHECK following HP/LP Super heater drain valves is OPEN on MANUAL.
 HP Super heater drain MOV AHAH10AA103/104

 HP Super heater outlet drain MOV AHAH10AA102
 LP Super heater drain MOV AHAH50AA102/103
CHECK following HP/LP Super heater vent valves are OPEN on MANUAL.
 Check that HP super heater vent valve open AHAHH10AA101

 Check that LP super heater vent valve open AHAHH50AA101
CAUTION
Load on GT/ Opening of Diverter Damper will be increased according to HRSG Cold Start Up
guidelines.
5.2.1.1 Sliding pressure cold start -up
• Check boiler sealing fan in service position

• Check that gas turbine exhaust flue gas temperature is not > 450 0C.
• Open HP super-heater vent valve,
• Open main steam and bypass drain valve to drain all stored water out.
• Open boiler damper by 10%, the drum temperature difference should be controlled
strictly within 500C, if exceed stop pressure rising temporarily.
• Open the CBD of drums monitor strictly the drum water level changing, and water
level should not drop too fast.
• Periodic blow down should be done during normal operation, and monitor water level
strictly. The blow down times is lie on the water quality and the continuous blow down
frequency on the alkalinity of boiler water.
• Keep steam pressure as stable as possible, the pressure should not exceed the limit.

• OPEN HP Main steam line motorized warm up valve ALBA10AA102 with ALBA10AA101.
• OPEN LP Main steam line motorized warm up valve ALBB10AA112 with ALBB10AA111
MOV
• For hp bypass operation, following conditions should be met then operate the hp
bypass Superheated steam & flow of 15-20 T/hr
• For lp bypass operation, following conditions should be met then operate the lp
bypass Superheated steam & flow of 6 T/hr
CAUTION
During the operation of HP/LP bypass v/v keep monitoring the vacuum of condenser bypass
valve downstream temperature and temperature control valve opening
• As steam pressure up to 2 Mpa and temperature 3500C the steam turbine can be roll
up
• During turbine rolling, monitor steam temperature and pressure according turbine’s
requirement.
• The second HRSG start-up procedure is as same as that of the first one.
NOTE
For the latching the superheated steam from second boiler the steam temperature
difference compared to the neighbor’s is less than 20 0C and the pressure difference is less
than 0.05 Mpa.
5.2.1.2 Hot start up
Hot stat-up: HRSG restarting from boxed up condition within 8 hours, starting time in
50min. For unit shut down within 12 hours
 MAINTAIN HP/LP Drum levels at - 50 mm (for Hot Start up).
 CHECK HP/LP Super heater drain valves are on AUTO
 HP Super heater drain MOV AHAH10AA103/104
 HP Super heater outlet drain MOV AHAH10AA102
 LP Super heater drain MOV AHAH50AA102/103
CHECK following HP/LP Super heater vent valves is OPEN on MANUAL.
 Check that HP super heater vent valve open AHAHH10AA101

 Check that LP super heater vent valve open AHAHH50AA101
Open outlet valve to warm up pipeline, as main steam temperature reach up to cylinder
temperature and more than 2500C, warm up. As boiler main steam temperature is 80 0C~100C

higher than that of turbine casing, and has 50 C superheating degree, the steam turbine
0
rolling preconditions are reached and turbine can be roll up
• During turbine speed up and synchronizing, boiler should keep stable and steam
pressure and temperature forbid dropping.
• After unit parallel to grid, fully open the diverter with faster speed, and raise load to
what the casing temperature requested, and then raise temperature and pressure to
increase load till full load.
• Maintain chemical parameters of HRSG Feed Water, Saturated and Super-heated steam
through regular sampling and testing.
• Check for any leak on the flue gas duct, pressure parts, piping and valves.
• Verify HP/LP local drum levels with drums level appearing on DCS.
5.3 HRSG shut down procedure
5.3.1 Preparation prior to HRSG shut-down

• After receiving shut down command from shift charge, inform turbine, electrical,
chemical, gas turbine and all other post.
• A overall inspection should be made prior to boiler shut down, write down the existent
defectives into punch list so as to connect the maintenance group to repair.
• Correct the water level gauge to guarantee its veracity.
Shut down procedure

5.3.1.1 Shutdown any one HRSG While Running in Parallel

Make sure no any abnormality present.
• Reduce DD 10% from 100% which HRSG need to be Shutdown.
• Open 5% HP Bypass warm-up the Bypass line and then open to 10%.
• Check the HP Steam pressure Difference (> 2 bars) at the outlet of HRSG not near STG
inlet.
• Reduce DD from 90% to 80% and Open HP Bypass from 10% to 20% 5% by 5%.
• Maintain the Drum Levels and condenser level accordingly.
• Check the HRSG outlet pressure is > 2bars than header pressure.
• Make Sure the Steam temperature Difference should not be > 20 C.
• When the Difference is > 2 bars close the Latching MOV of Main Steam Header after
Bypass line.
• Maintain the Pressure on Bypass and reduce the HRSG DD 10% by 10% until Close
Completely.
• Reduce STG GV from 100% to 60 % from DEH Page or maintain Main Steam Pressure
between 55 to 60 Bars.
• While Reduce GV position or STG load please check the Diff expansion/ STG Vibration
and STG upper lower casing temperatures.
• Make Sure the Bypass also Close to 0% after DD Close to 0%.
• Make Sure Drum Levels Maintain at Normal Working levels.
• Close the HRSG outlet MOV for Proper Box-up.
• Increase the Drum Level of HP and LP Drums up to + 200mm and stop the HP and LP
Feed Water Pumps.
• Keep the Lube Oil System in service for HRSG HP Feed Water pumps.
5.3.1.2 Sliding pressure shut down

• Under the full load condition, reduce 15-20% rated load under nominal parameter.
• Slide parameter load reduction: lower boiler parameter, average slow down speed
0.03Mpa/Min, average temperature slow speed 30C/Min.
During slide shut down, the differential temperature between up and down drum wall
should keep less than 50C or slow down the speed of temperature deduction, and
meanwhile keep the degree of superheating more than 500C.
As the load lower down to 3MW, change over the turbine controller to synchronizer
and go on lower the load. As turbine change over to synchronizer control keep the
instant load stable for 3 Minute.
Go on lower the load by the speed 0.4MW per Min till to zero. Being informed that
turbine had been shut down, shut down the boiler.
• After boiler shut down fill water to drum slowly up to high level.
• Inform turbine operator to open de-super-heater a little bit and close it after 30
Minutes.
5.3.1.3 Constant pressure shut down

• Receiving shut down order from shift charge, inform turbine lower turbine load by 0.4
MW/Min, and close gas damper accordingly.
• Load reduction to zero, as being informed that the turbine had been shut down stop
boiler. During boiler shut down the parameter of pressure and temperature should
follow turbine requirement.
• After boiler shut down, inform turbine to open bypass system de-super-heater.
Attention should be paid that not to reduce the pressure too fast and close it after 30
Minutes.
• After boiler stop, fill water to drum up to high level.
(1) Water filling should be well-proportioned and uninterrupted, interrupted filling are not
allowed.
(2) Three or above panel water meter should be equipped and in correct indication condition.
If there is only one meter working, send one to check against local gauge. The local water
level meter should be well illuminated and can be seen clearly.
(3) When feed water pump in automatic control, monitor the variation of the drum level and
the outlet pressure of the pump. The control range can be too large, and the feed water flow
should match the steam flow. If the deviation is too large, switch to manual control and if
manual control can’t work change over the pump immediately.
6.0 Drum water level control
(1) Control object
According to feed water requirement in various boiler load to control the opening of the feed
water control valve to change the feed water flow rate and in turn to keep drum level equal
to setting value.
(2) Relative equipment
 Feed water control valve: (20% ~100%)

 Bypass control valve: (0 ~30%)
(3) Control function
(a) 0～30% load range

At this stage the single impulse control mode is adopted to control bypass valve opening to
keep drum level as setting value. The specific control procedure as following:
During boiler filling, set the valve at 10% opening to fill boiler. As water level reach the start-
up level, input single impulse water controller.
(b) 20% ～100% load range
Within this load range, the three impulses feed water control mode is adopt, which consist of
drum level, steam flow rate and feed water flow rate. It functions specifically as follow:
As steam output reach to 25%, Auto open main feed water control valve and close a little bit
its bypass valve. The opening time of main feed water control valve is 1 minute to prevent
water level too much turbulent or drum temperature too low. As changeover complete input
the three-impulse controller. Contrariwise, as steam output drop to 23% and below, changer
over from main control valve to bypass valve, and meanwhile feed water control changes over
from three-impulse controller to single impulse controller.
To ensure the control quality, the drum level need to be trimmed by saturated steam
pressure, and the steam flow rate to be trimmed by steam pressure and temperature.
7.0 Blow down
(1) Follow the blow-down regulation strictly. According the boiler water test result decide the
opening of the blow-down valve as well as the quantity.
(2) Periodic blow-down should be arranged at low load, and perform slowly to prevent
hammering.
(3) Pay attention to monitor the change of the feed-water and drum level during blowing
down and to keep normal level. Not allow opening two or above blow-down valves, the
duration for each opening should not be more than 30s.
(4) Follow the specific stipulation about blowing down in the safety regulation strictly

8.0 - Appendix
Appendix -1 HRSG Pre start valve line up
Appendix -2 HRSG Pre start valve line up CCR
Appendix – 3 LPFW pump change over check list

Appendix – 1
HRSG Pre start valve line up
Date: _______________ Time: _______________
S.N
Description Valve No. Yes No Sign
o
HRSG TOP
DEAERATOR SECTION
D/A VENTMOV ISOLATING VALVE LAA60AA206 OPEN

1.
D/A ALL PI AND PT ISO V/V OPEN
2.
DEMIN MAKEUP C.V UP/DOWN STREAM
LAA60AA210/11 OPEN
3. ISO VALVES
DEMIN MAKEUP C.V BYPASS ISO VALVE LAA60AA212 CLOSE

4.
COND. SUPPLY C.V UP/DOWN STREAM
LCA10AA207/8 OPEN
5. ISO VALVES
COND. SUPPLY C.V BYPASS ISO VALVE LCA10AA209 CLOSE

6.
COND. WATER HEATER OUTLET ISO
LCA10AA206 OPEN
7. VALVE
DEAERATOR TANK SECTION
ALL LEVEL GAUGES ISO VALVE OPEN

8.
ALL LOCAL VENT VALVE CLOSE
9.
ALL PI AND PT ISO VLAVE OPEN
10.
HEATING STEAM ISO VALVE LBG10AA215 CLOSE
11.
TANK CHEMICAL DOSING ISO VALVE LAA60AA205 OPEN
12.
LP DRUM
DRUM ALL LEVEL GAUGES ISO VALVE OPEN

13.
ALL LEVEL GAUGES LIGHTS ON
14.

LP SATURATED STEAM SAMPLING ISO

OPEN
15. VALVES
DRUM LOCAL VENT ISO VALVE HAD50AA203 CLOSE

16.
HAD50AA204
DRUM N2 SUPPLY ISO VALVE CLOSE
17.
DRUM ALL PI AND PT ISO VLAVE OPEN

18.
LP SUPER HEATER OUTLET HEADER
LP MAIN STEAM MOV ISO VALVE LBA50AA201 OPEN

19.
LP MAIN STEAM SAMPLING IS valve OPEN
20.
HEADER VENT ISO VALVE
CLOSE
21.
HEADER PI AND PT ISO VALVE OPEN

22.
HP DRUM
DRUM ALL LEVEL GAUGES ISO VALVE OPEN

23.
ALL LEVEL GAUGES LIGHTS ON
24.
DRUM ALL LOCAL VENT ISO VALVES HAD10AA204/2
CLOSE
25. 05
DRUM N2 SUPPLY ISO VALVES HAD10AA206/2

26. 07
DRUM ALL PI AND PT ISO V/V OPEN

27.
HP SATURATED STEAM SAMPLING ISO
OPEN
28. VALVES
HP DRUM CHEMICAL DOSING ISO VALVE OPEN

29.
HP SUPER HEATER OUTLET HEADER
HP MAIN STEAM MOV BYPASS MOV ISO

LBA10AA201 OPEN
30. VALVE
HP MAIN STEAM MOV ISO VALVE LBA10AA202 OPEN

31.
HP MAIN STEAM SAMPLING ISO VALVES OPEN
32.

HEADER VENT ISO VALVE

CLOSE
33.
HEADER PI AND PT ISO VALVE OPEN

34.
ATEMPERATOR C.V ISO VLAVES OPEN
35.
ATEMPERATOR C.V BYPASS ISO VALVE CLOSE
36.
VALVES PLATEFORM
LAB50AA207-
LP DRUM L.C.V UP/DOWN STREAM ISO 208 OPEN
37. VALVES
LP PUMPS RECIRCULATION COMMON ISO

LAA60AA208 OPEN
38. VLAVE
HP 30% C.V DOWN STREAM ISO VALVE LAB10AA208 OPEN

39.
HP 100% C.V DOWN STREAM ISO VALVE LAB10AA209 OPEN
40.
HP 30% AND 100% C.V BYPASS ISO VALVE LAB10AA207 CLOSE
41.
HP PUMPS DISCHARGE COMMAN LINE ISO
LAB10AA211 OPEN
42. VALVE
HP PUMPS RECIRCULATION COMMAN ISO

OPEN
43. VALVE
HRSG DRAINS
DEAERATOR SECTION
CONDENSATE WATER HEATER DRAIN ISO HAA60AA203-

CLOSE
44. VALVES 204
D/A I.B.D MOV ISO VLAVE LAA60AA202 OPEN

45.
D/A C.B.D MOV ISO VALVE LAA60AA201 OPEN
46.
D/A TANK SAMPLING ISO VALVE OPEN
47.
D/A E.B.D MOV ISO VALVE LAA60AA203 OPEN
48.
LP SECTION
HAC50AA201-
LP ECONOMIZER DRAIN ISO VALVES CLOSE
49. 202

LP I.B.D MOV ISO VALVE HAD50AA202 OPEN

50.
LP C.B.D MOV ISO VALVE HAD50AA201 OPEN
51.
LP DRUM SAMPLING ISO VALVE OPEN
52.
LP S.H OUT HDR DRAIN MOV ISO VALVE HAH50AA208 OPEN
53.
LP SUPERHEATER DRAIN MOV ISO VALVE HAH50AA209 OPEN
54.
HP SECTION
HAC10AA213-
HP ECONOMIZER-1 DRAIN ISO VALVES CLOSE
55. 216
HAC10AA217-
HP ECONOMIZER-2 DRAIN ISO VALVES CLOSE
56. 220
HP ECONOMIZER-3 DRAIN ISO VALVES HAC10AA221-

CLOSE
57. 224
HP I.B.D MOV ISO VALVE HAD10AA203 OPEN

58.
HP E.B.D MOV ISO VALVE HAD10AA201 OPEN
59.
HP C.B.D MOV ISO VALVE HAD10AA202 OPEN
60.
HP DRUM SAMPLING ISO VALVE OPEN
61.
HP SUPERHEATER DRAIN MOV’S ISO HAD10AA213-
OPEN
62. VALVES 214
HP S.H OUTLET HEADER DRAIN MOV ISO

HAD10AA212 OPEN
63. VALVE
LP FEED WATER PUMPS
LAA60AA209-
PUMPS SUCCOMMON LINE ISO V/V OPEN
64. 210
PUMP-1 SUCTION ISO VALVE LAB50AA201 OPEN

65.
PUMP-2 SUCTION ISO VALVE LAB50AA202 OPEN
66.
PUMP-1 C.B IS NORMAL AND ON REMOTE LAC50AP101 REMOTE
67.
68.
PUMP-1 RECIRCULATION ISO VLAVE LAB50AA205 OPEN
69.

PUMP-2 RECIRCULATION ISO VLAVE LAB50AA206 OPEN

70.
PUMP-1 SUC. / DIS. LINES PT,PI,FT ISO
OPEN
71. V/V

OPEN
72. V/V
LAB50AA303-
PUMP-1 SUC. FILTER DP SWITCH ISO V/V OPEN
73. 304
LAB50AA305-
PUMP-2 SUC. FILTER DP SWITCH ISO V/V OPEN
74. 306
HP FEED WATER PUMPS
LAA60AA211-
PUMPS SUCTION COMMON LINE ISO V/V
75. 212
PUMP-1 SUCTION ISO VALVE LAB10AA201

76.
PUMP-2 SUCTION ISO VALVE LAB10AA202
77.
PUMP-1 RECIRCULATION ISO V/V LAB10AA212
78.
PUMP-2 RECIRCULATION ISO V/V LAB10AA213
79.
80. V/V

81. V/V
LAB10AA303-
PUMP-1 SUC. FILTER DP SWITCH ISO V/V
82. 304
LAB10AA305-
PUMP-2 SUC. FILTER DP SWITCH ISO V/V
83. 306
PUMP-1 SUC. / DIS. SIDE CASING DRAIN

84. ISO V/V
PUMP-2 SUC. / DIS. SIDE CASING DRAIN

85. ISO V/V
PUMP-1 CCCW SUPPLY VALVE

86.
PUMP-2 CCCW SUPPLY VALVE
87.
PUMP-1 CCCW RETURN VALVE
88.

PUMP-2 CCCW RETURN VALVE

89.
CCCW FLOW FROM PUMPS IS NORMAL
90.
PUMPS BEARING OIL CUPS LEVEL IS
91. NORMAL
GENERAL CHECKS
HOUSE KEEPING IS NOMAL

92.
ALL SMALL VENT VALVES IN VENT BOX
93. ARE CLOSE
WATER/STEAM LEAKAGE FROM LP /HP

94. DRUMS
WATER/STEAM LEAKAGE FROM D/A

95.
ALL PSV’S ARE NORMAL (NO LEAKAGE)
96.
Field Operator Sig: ______________________ DGM Sig: _____________________
Appendix – 2
HRSG Pre start valve line up CCR
Date: _______________ Time: _______________
S.No Description Valve No. Yes No Sign
DEAERATOR SECTION
97.
D/A VENTMOV LCJ40AA102 OPEN
98.
D/A ALL PT AND LT VALUES ARE NORMAL OK

DEMIN MAKEUP C.V IS NORMAL AND ON

99.
LCA60AA001 AUTO
AUTO
100.
PRESSURE BALANCING MOV IS NORMAL LCJ40AA101 OPEN
COND. SUPPLY C.V IS NORMAL AND ON

101.
LCA10AA001 AUTO
AUTO
102.
D/A STEAM SUPPLY C.V ON MAN LBG10AA001 CLOSE
D/A STEAM SUPPLY C.V BYPASS MOV ON

103.
LBG10AA101 CLOSE
MAN
STARTUP STEAM FORM AUX. BOILER MOV

104.
LBG10AA103 CLOSE
ON MAN
COND. WATER HEATER INLET MOV (IF GT

105.
LAC10AA102 OPEN
ON GAS )
COND. WATER HEATER BYPASS MOV (IF

106.
LAC10AA101 CLOSE
GT ON GAS )
107.
D/A TANK C.B.D MOV IS NORMAL LAA60AA101 CLOSE
108.
D/A TANK E.B.D MOV IS NORMAL LAA60AA103 CLOSE
109.
D/A TANK I.B.D MOV IS NORMAL LAA60AA102 CLOSE
LP FEED WATER PUMPS
110.
PUMP-1 CB IS NORMAL AND ON REMOTE LAC50AP101 REMOTE
111.
PUMP-1 RECIRCULATION C.V IS NORMAL LAB50AA003 OPEN
PUMP-1 RECIRCULATION MOV IS NORMAL LAB50AA103 OPEN

112.
LAB50AA101
PUMP-1 DISCHARGE MOV IS NORMAL ON
113.
CLOSE
AUTO
LAC50AP102
114.
PUMP-2 CB IS NORMAL AND ON REMOTE REMOTE
115.

116.

117.
LAB50AA102 CLOSE
AUTO

118.
LP DRUM LEVEL C.V (L.C.V) IS NORMAL LAB50AA001 OK
119.
LP L.C.V BYPASS MOV IS NORMAL LAB50AA105 CLOSE
LP WATER PT,TT,FT VALUES ARE

120.
OK
NORMAL
LP DRUM AND SUPERHEATER
121.
ALL PT,LT,TT VALUES ARE NORMAL OK
D/A MAKEUP STEAM MOV IS NORMAL

122.
LBG10AA102 CLOSE
AND ON MAN
LP DRUM C.B.D MOV IS NORMAL

123.
HAD50AA101 CLOSE
124.
LP DRUM I.B.D MOV IS NORMAL HAD50AA102 CLOSE
LP S.H DRAIN MOV IN NORMAL AND ON

125.
HAH50AA103 OPEN
AUTO
LP S.H HEADER DRAIN MOV IS NORMAL

126.
HAH50AA102 OPEN
AND AUTO
LP S.H HEADER VENT MOV IS NORMAL

127.
HAH50AA101 CLOSE
AND MAN
LP MAIN STEAM O/L MOV IS NORMAL AND

128.
LBB10AA111 CLOSE
MAN
LP MAIN STEAM O/L BYPASS MOV IS

129.
LBB10AA112 CLOSE
NORMAL & MAN
HP FEED WATER PUMPS
PUMP-1 C.B IS NOMAL AND ON REMOTE LAC10AP101 REMOTE

130.

131.

132.

133.
LAB10AA101 CLOSE
AUTO

134.

135.


136.

137.
LAB10AA102 CLOSE
AUTO
30% L.C.V UPSTREAM MOV IS NORMAL ON

138.
LAB10AA106 OPEN
AUTO
30% L.C.V IS NORMAL LAB10AA002 CLOSE

139.
100% L.C.V UPSTREAM MOV IS NORMAL

140.
LAB10AA105 OPEN
ON AUTO
100% L.C.V IS NORMAL LAB10AA001 CLOSE

141.
HP WATER PT,TT,FT VALUES ARE

142.
OK
NORMAL
HP DRUM AND SUPERHEATER
143.
ALL PT,LT,TT VALUES ARE NORMAL OK
HP DRUM I.B.D MOV IS NORMAL HAD10AA103 CLOSE

144.
HP DRUM C.B.D MOV IS NORMAL HAD10AA102 CLOSE

145.
HP DRUM E.B.D MOV IS NORMAL HAD10AA101 CLOSE

146.
HP S.H DRAIN MOV A IS NORMAL ON

147.
HAH10AA104 OPEN
AUTO
HP S.H DRAIN MOV B IS NORMAL ON

148.
HAH10AA103 OPEN
AUTO
HP S.H HEADER DRAIN MOV IS NORMAL

149.
HAH10AA102 OPEN
ON AUTO
HP S.H HEADER VENT MOV IS NORMAL

150.
HAH10AA101 CLOSE
ON MAN
HP SPRAY WATER C.V IS NORMAL AND

151.
LAE10AA001 CLOSE
ON AUTO
HP SPRAY WATER MOV IS NORAMAL ON

152.
LAE10AA101 OPEN
MAN
HP MAIN STEAM O/L MOV IS NORMAL ON

153.
LBA10AA101 OPEN
MAN

HP M.S O/L BYPASS MOV IS NORMAL ON

154.
LBA10AA102 OPEN
MAN
GAS PATH
SEALING FAN-1 C.B IS NORMAL AND ON

155.
HNY10AN001 REMOTE
REMOTE
SEALING FAN-2 C.B IS NORMAL AND ON

156.
HNY10AN002 REMOTE
REMOTE
SELECTE
157.
ANY ONE SEALING FAN SELECTED
D
BOILER SIDE MOV IS NORMAL AND ON

158.
HNY10AA101 AUTO
AUTO
BYPASS SIDE MOV IS NORMAL AND ON

159.
HNY10AA102 AUTO
AUTO
160.
DAMPER POSITION FEED BACK IS NORMAL OK
161.
ALL TT AND PT ARE NORMAL OK
NO
162.
DAMPER NO OIL LEVEL LL ALARM
ALARM
DAMPER HYD. OIL PUMP-1 IS NORMAL ON

163.
HNY10AP001 AUTO
AUTO
DAMPER HYD. OIL PUMP-2 IS NORMAL ON

164.
HNY10AP002 AUTO
AUTO
165.
ANY ON OIL PUMP SELECTED SELECT
166.
DAMPER HYD. OIL FILTER DP IS NORMAL NORMAL
FW PUMP OIL SYSTEM
NO
167.
NO OIL PRESSURE LOW ALARM
ALARM
STANDB
168.
ONE OIL PUMP IS ON STANDY
Y
NO LIGHT FAULT ALARM ON FWP/P OIL NO

169. SKID ALARM

Field Operator Sig: ______________________ SM/DM Sig: _____________________
Appendix – 3
LPFW pump changeover check list
Date: _______________ Time: _______________
S.No Description Valve No. Yes No Signature
Deaerator main isolation valve AA209 and

1
AA209 / AA210
AA210 to LP pump suction open
LP pump suction isolation valve AA201 and

2
AA201 / AA202
AA202 open
3
Deaerator Level normal
4
Suction PI showing pressure
5
Oil cup level normal
6 LP pump recirculation line minimum flow

control v/v AA002 and AA003 On remote

position and open
LP pump recirculation line MOV AA103 and

7 AA104 On remote position and close
LP pump recirculation common header isolating

8 valve AA208 open
LP pump discharge MOV AA101 and AA102 on

9 Remote and open position
10
LP pump CB normal
11
Reset put lock
12
Put discharge valve on manual
13
Closed discharge valve and put on auto
14
Observe recirculation C/V opening
15
Ensure recirculation MOV is open
16
Check face plate alarm and reset
17
Start pump and check discharge valve opening
18
Check recirculation C/V closing
19
Closed initially running pump discharge valve
20
Ensure recirculation C/V valve open
21
Initial running pump select on manual and stop
22
Open discharge MOV and put on auto
23
Select stop pump and auto
24
Select lock for pump standby condition
_______________________________________________________________________________
_______________________________________________________________________________
Field Operator Sig: ______________________ DGM Sig: _____________________



Sop HRSG

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Sop HRSG

Caricato da

Copyright:

Formati disponibili

Bin Qasim Power Station II

560 MW Combined Cycle Power Plant,

Heat Recovery Steam Generator

Initiated/Author Abdul Rehman Shaikh

Reviewed by QMR Zahid Faqir

Syed Mehdi Ali

Tahir Ali Khan

Next Review Date 30th April, 2018

Next Review Date 30th April, 2018

HRSG O&M Manual

0 Prior to starting HRSG System verify the following:-

• Safety Document(s) on HRSG System cancellation and de-isolation.

4.0 GENERAL PRECAUTIONS AND LIMITATION

• Equipment Operating Procedures

Next Review Date 30th April, 2018

• Sealing fan in service

Next Review Date 30th April, 2018

• Normal shut down etc.

5.1 HRSG Start-up Procedure

• Verify the lineup of HP and LP Feed water circuit as per checklist

Starting of HP Feed Water pump:

• Verify that Deaerator level is >900mm

Starting of LP Feed Water pump:

• Verify that Deaerator level is >800mm

5.2 Start-up procedure

For HRSG starting up please refer to following:

5.2.1 COLD/WARM START UP

• CHECK HRSG valves are line up as per checklist

CHECK following HP/LP Super heater drain valves is OPEN on MANUAL.

 HP Super heater drain MOV AHAH10AA103/104

 LP Super heater drain MOV AHAH50AA102/103

 Check that HP super heater vent valve open AHAHH10AA101

5.2.1.1 Sliding pressure cold start -up

• Check boiler sealing fan in service position

Next Review Date 30th April, 2018

5.2.1.2 Hot start up

 LP Super heater drain MOV AHAH50AA102/103

CHECK following HP/LP Super heater vent valves is OPEN on MANUAL.

 Check that HP super heater vent valve open AHAHH10AA101

Next Review Date 30th April, 2018

rolling preconditions are reached and turbine can be roll up

5.3 HRSG shut down procedure

5.3.1 Preparation prior to HRSG shut-down

Shut down procedure

Next Review Date 30th April, 2018

5.3.1.1 Shutdown any one HRSG While Running in Parallel

5.3.1.2 Sliding pressure shut down

5.3.1.3 Constant pressure shut down

Next Review Date 30th April, 2018

6.0 Drum water level control

(1) Control object

(2) Relative equipment

 Feed water control valve: (20% ~100%)

(3) Control function

(a) 0～30% load range

Next Review Date 30th April, 2018

(b) 20% ～100% load range

7.0 Blow down

Next Review Date 30th April, 2018

Appendix -1 HRSG Pre start valve line up

Appendix -2 HRSG Pre start valve line up CCR

Appendix – 3 LPFW pump change over check list

Date: _ Time: _

Field Operator Sig: __ DGM Sig: _

Date: _ Time: _