08-SOP of ASH SLURRY PUMP

STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant

3 X 660 MW.
FIELD SOP FOR ASH SLURRY PUMP. PMPL
Document No.: Revision No.: 01
Effective Date: Page 1OF 7
PMPL/AHP/SOP/08 Revision Date:
ASH SLURRY PUMP

1. Description of the system:The Ash slurry sump has four separate compartments. In de-
ashing time the slurry from Bottom ash & Fly Ash from the three units are discharged into a RCC
collecting channel. This collecting channel is having sump isolation plug valves. Selected sump
compartment plug valve has to be opened. So that slurry can be transferred to selected
compartment.Each compartment of ash slurry sump is connected to two nos. ash slurry pumps
which are connected in series. Each Ash slurry series is connected to ash slurry discharge line.So
total four ash slurry lines are discharging the ash slurry to ash slurry pond. Cylinder operated
plate valves have been provided on the suction and the discharge sides of the ash slurry pumps
of each ash slurry lines.
TECHNICAL DETAILS:
APPLICATION ASH SLURRY DESPOSAL PUMP

MANUFACTURER SAM TURBO INDUSTRY PVT, LTD.
TYPE OF PUMP HORIZONTAL CENTRIFUGAL-CASING
NO. OF PUMP
OFFERED 08 Nos./4 set(3W+1S)
DESIGN
CAPACITY 830 M3/Hrs.
200KW(1 STAGE) & 180KW(2nd STAGE)
st
MOTOR RATING 1485RPM 2. Pre

checks and Action By Field Engineer:
1. No PTW is pending for ash slurry pump (Mech./Ele./Ins.)

2. Insure normal slurry sump level > 1.5mtr.
3. Pump breaker is in service, remote and lock out relay is reset.
4. Pump protections are in service and all parameters indication is healthy.
5. Slurry seal water pump header pressure >=15 bar and at least one seal water is under running
condition.
6. Slurry sump should be selected for required series by selection of plug valve.
7. Fluid coupling and gear box oil level normal.
8. Slurry seal water pump is in running condition.
9. Fluid coupling oil pump feeder healthy.
10. Pump should rotate freely by hand.
11. Motor bearing temperature and winding temperature should not be high.
Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):
Signature: Signature: Signature: Signature:
Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
3 X 660 MW.
12. Ensure mechanical system is healthy in field.

3. Operating Procedure:
1. Open fluid coupling oil pump cooling water line valve and ensure pressure showing healthy in field
and SCADA.(pressure >5.5kg/cm2).
2. Start fluid coupling oil pump and ensure oil flow switch, temp switch and DP switch ok.
3. Open BAHP slurry sump agitating valve of selected slurry group.
4. Open pump suction valve and ensure valve open feedback.


3 X 660 MW.
5. Open the seal water valve for the gland sealing/cooling and ensure seal water pressure switch is
healthy of all 02 pumps. ( 12.5 kg/cm2).
6. Set scoop of fluid coupling 0 %.

7. Give start command of stage #1 pump from SCADA and ensure pump running feedback.
8. Increase scoop of fluid coupling for increase slurry line pressure (> 1.5 bar).
9. Open discharge valve and ensure valve open feedback.
10. Increase scoop of fluid coupling and set line press. (> 1.5 bar).
11. Give start command of stage #2 pump from SCADA and ensure pump running feedback.
12. Maintain slurry sump level by adjusting scoop of fluid coupling ensure that fluid coupling scoop
should not be adjusted below 40%.
13. Now observe the vibration/temp of pump and motor bearing.
14. For any abnormalities, record it and inform to shift in charge/ operation in charge.


3 X 660 MW.
9. Tripping Condition:
1. MCC Disturbance.
2. Ash Slurry sump level below than 1.5 Mtr.
3. Seal water pressure below than 5.5 kg/cm2.
10. System Shutdown:
01. 1st stop the stage two pumps from SCADA and ensure stop feedback.
02. Adjust scoop of fluid coupling between 40-60%.
03. Close BAHP water valve of slurry sump agitation and ensure flushing completed.
04. Close suction valve and ensure close feedback of suction valve
05. Stop stage one pump and ensure stop feedback.
06. Close suction valve and ensure close feedback.
07. After stopping the slurry series operator must be ensure that slurry line raw flushing valve (Taping
from raw water line at suction line of each slurry groups) open w.r.t. running slurry group.
08. Ensure that slurry group discharge line flushing completed, then close raw water flushing valve.
09. Close seal water valve of the pump.
10. After ensuring that seal water press. Of the pump is not ok, then close discharge valve and ensure
close feedback of the valve.
11. Stop oil cooler pump and close the cooling water valve.
1. POINTS TO BE CHECKED BY OPERATOR IN EVERY SHIFT

 EQUIPMENT CLEANING
 PHYSICALLY VIBRATION CHECKING
 PHYSICALLY TEMPRATURE CHECKING
 OIL LEVEL AND GREASE CHECKING
2. CHECKING OF SYSTEM AFTER SHUT DOWN
 PHYSICALLY CHECK BOTTOM ASH HOPPER AFTER OPENING THE MAN
HOLE DOOR AS LIKE FOREIGN MATERIAL AFTER THAT CHECK THE
ROTATION OF CLINKER GRINDER IN FORWARD AND REVERSE DIRECTION.
 CHECK THE OIL LEVEL FREENESS.
 PHYSICALLY ALL VALVE CHECKING MANUALLY OPERATION THROUGH

PLC AS WELL.


3 X 660 MW.
 FIRST ENSURE SLURRY AND ASH WATER SUMP CLEANING AND THEN FILL
THE SUMP.
 CHECK THE SEAL PRESSURE OF ALL DOME VALVE PHYSICALLY.
 CHECK THE LINE VACUUM AND SHUT OFF VACUUM OF ALL PASSES.
 CHECK FLUIDIZING BLOWER AIR OF INDIVIDUAL HOPPER.
 CHECK THE PURZING OF BUFFER HOPPER AND SILO BAG FILTER.
 IF ANY PROBLEM OBSERVED IN EQUIPMENT THEN INFORM TO SHIFT IN

CHARGE/ OPERATION IN CHARGE IMMEDIATLY.



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STANDARD OPERATING PROCEDURE

PPGCL Super Thermal Power Plant

ASH SLURRY PUMP

APPLICATION ASH SLURRY DESPOSAL PUMP

MOTOR RATING 1485RPM 2. Pre

1. No PTW is pending for ash slurry pump (Mech./Ele./Ins.)

Name: Name: Name: Name:

12. Ensure mechanical system is healthy in field.

4. Open pump suction valve and ensure valve open feedback.

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

Name: Name: Name: Name:

6. Set scoop of fluid coupling 0 %.

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

Name: Name: Name: Name:

10. System Shutdown:

1. POINTS TO BE CHECKED BY OPERATOR IN EVERY SHIFT

 CHECK THE OIL LEVEL FREENESS.

 PHYSICALLY ALL VALVE CHECKING MANUALLY OPERATION THROUGH

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

Name: Name: Name: Name:

 CHECK THE SEAL PRESSURE OF ALL DOME VALVE PHYSICALLY.

 CHECK FLUIDIZING BLOWER AIR OF INDIVIDUAL HOPPER.

 CHECK THE PURZING OF BUFFER HOPPER AND SILO BAG FILTER.

 IF ANY PROBLEM OBSERVED IN EQUIPMENT THEN INFORM TO SHIFT IN

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

Name: Name: Name: Name:

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