KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL / CRITICAL/BOILER / BCP/

19

SOP FOR BOILER CIRCULATING PUMP (BCP)

Power from Knowledge
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 1 of 4

STANDARD OPERATING PROCEDURE FOR BOILER CIRCULATION PUMP (BCP)

OBJECTIVE: For Smooth Operation of Boiler Circulation Pump.

SCOPE: This SOP is applicable for 03 BCP.

INTRODUCTION: Boiler Water Circulation Pump used in high capacity boiler (super critical or sub critical),
it assisted the circulation of water to overcome friction losses in pipe lines.
In this power plant unit is designed on the basis that the boiler can operate in the full load only by using two
of three pumps. In order of flexibly, three pumps can be operate at same time. If only one pump put into
service, boiler load must decrease to 60 % of MCR. If continuous operating load is 60 % MCR, it is allowed
one pump in service. During light up, it is suggested that at least two pumps should be in service.
RESPONSIBILITY: Unit Control Engineer, Field Engineer and Desk Engineer.

SAFETY PRECAUTIONS:
 Ensure no permit to work is pending on this system.
 Use proper PPE where necessary.
 Ensure all Manual Call Points, Public Address System and Fire Alarms in working condition.
 Ensure housekeeping and proper area lighting.
 Ensure all electrical connections to be tight.
 Proper tools to be used for field operation.
 Leakages to be informed and barricading the same should be ensured.
 Area should be clear of any material.
 Ensure proper approach to instruments for maintenance.
 Ensure all measuring instruments working properly.

SPECIAL TOOLS/ EQUIPMENTS: NIL

OPERATING PROCEDURE –

RESPONSIBILITY
Sr. No. Description
UCE DE FE EE
PRE- START CHECKS:
1. All permits and cross permits have been returned. √ √ √
2. Area is clear of any other material. √

1|Page

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Subrata Kumar Mishra Name:
Designation: AM Designation: GM Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / CRITICAL/BOILER / BCP/
19

SOP FOR BOILER CIRCULATING PUMP (BCP)

Power from Knowledge
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 2 of 4

3. Power supply and control power supply available. √ √

4. All C & I instruments such as temperature gauge, pressure gauges,
√ √
DP transmitter & Flow meter of the BCP & Cooling water system
have been put into operation.
5. Check the CCCW pressure ≥ 0.7 Mpa and Low pressure cooling
√ √
water flow of the BCP’s motor cooler, heat barrier and purge
cooler is normal.
6. Drum water level should be normal ± 100mm. √ √ √
7. Left and right outlet valves of the BCP are fully opened. √ √
8. Temperature difference between the BCP housing and inlet header √
boiler water is less than 55 ° C
9. Check the Cavity water temperature <60 ° C √

NOTE
02 BCP are strictly prohibited to start at the same time
In case if BCP starts to fail in 5 sec, it should be stopped
immediately and start again after identifying the cause of failure

RESPONSIBILITY
Sr. No. Description
UCE DE FE EE
Cavity filling ,Flushing and Venting of BCP
1 Flush the heat barrier line and do the proper venting of the line. √
2 Flush the cavity filling line √
3 Cavity filling can be done from CEP OR BFP √
Drain valve of first strainer kept open to ensure purge cooler line √
4
and strainer get flushed
Than charge up to second strainer and open its drain and keep √
5
first strainer drain close
Flushed continued till water reaches following parameters:- √ √ √
PH › 6.5
6
Halogen (specially CI) ≤ 50 ppm
Solid content ≤ 5 PPM

2|Page

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Subrata Kumar Mishra Name:
Designation: AM Designation: GM Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / CRITICAL/BOILER / BCP/
19

SOP FOR BOILER CIRCULATING PUMP (BCP)

Power from Knowledge
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 3 of 4

7 Ensure pump vent open and line drain kept closed √

8 Start Cavity filling with a rate of 5 L/Min √ √
9 Do cavity air venting through pump vent √
10 Once cavity filled, ensure water comes through vent √
11 Stop cavity filling √
12 Do the venting of Motor cooler √
13 Do the venting of purge water cooler √
Do the priming and close all the drain and vent after priming of the √
14
pump
After closing all the drain and vent ,don’t touch the valve while √
15
pump is in service
START UP SEQUENCE :

1 Start the BCP

POST START UP CHECK

1 Ensure pump draws normal amps

2 Maintain the drum level since it will drop drastically, maintain
normal drum level
3 Check the inlet and outlet DP is normal
4 Check the low pressure cooling water Flow, Temperature &
Pressure
5 Check the BCP vibration is normal
6 Inspect BCP & Check for no leakage
SHUTDOWN SEQUENCE
HOT STATE OF BOILER
1 Shutdown the BCP
2 The outlet valve of BCP is open
3 The low pressure cooling water system of the BCP is maintained
the normal operation
4 Open the outlet and inlet bypass valve of BCP and drain valve of
the pump body
5 After BCP is shutdown, closely monitor the pump motor chamber
temperature to prevent damaging the motor coil insulation.
3|Page

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Subrata Kumar Mishra Name:
Designation: AM Designation: GM Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / CRITICAL/BOILER / BCP/
19

SOP FOR BOILER CIRCULATING PUMP (BCP)

Power from Knowledge
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 4 of 4

COLD STATE OF BOILER

1 When the boiler water temperature ≤150 ° C, Shutdown the BCP
2 The outlet valve of BCP is maintain to open
3 The low pressure cooling water system of the BCP is maintained
the normal operation and after shell temperature ≤ 80° C, stop the
low pressure cooling water
PROTECTIONS
1 Temperature of motor cavity>=66℃ {Temp. S/W}
2 Anyone outlet valve is not fully opened after pump running 60s
with 3 sec delay
3 Lost LP cooling water {Flow S/W } <287lit./min with 300 S delay
4 Differential pressure＜60kPa between inlet and outlet
INTERLOCK START-UP CONDITION OF THE BCP
1 The interlock of boiler circulation pump put into operation, if any
running pump tripped.
2 The interlock of boiler circulation pump put into operation, if
differential pressure＜148.3kPa between inlet and outlet of any
running pump with 3 sec delay

Do’s & Don’ts

 Do’s:
 Ensure adequate flow of cooling water for Motor Cooler and heat barrier.
 Test safety controls and devices on a periodic basis.
 Ensure local operators are adequately trained to assure safe and efficient operation.
 Inspect the equipment daily for proper operation, and/or adverse conditions.

4|Page

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Subrata Kumar Mishra Name:
Designation: AM Designation: GM Designation:
 KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL / CRITICAL/BOILER / BCP/
19

SOP FOR BOILER CIRCULATING PUMP (BCP)

Power from Knowledge
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 5 of 4

 Maintain a log of incidents and parameters that effect equipment operation.

 Allow only authorized person to work and attend any leakages.
 Regular maintenance and calibration of instruments to be ensured.

 Don’ts
 Avoid operating BCP without getting required motor cavity cooling water parameters.
 Avoid bypassing permissive/protection logics.
 Permit unqualified personnel to operate the equipment.

REFERENCE DOCUMENTS:
 Boiler Operation Manual

CURVES & CHARTS

 NA

ABBREVIATIONS / NOTATIONS:-
o SOP: Standard Operating Procedure
o UCE: Unit Control Engineer
o DE: Desk Engineer
o FE: Field Engineer
o DCS: Distributed Control System
o EE: Electrical Shift Engineer
o MFT: Main Fuel Trip.
o RB : Run Back

5|Page

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Bhupendra Sahu Name: Subrata Kumar Mishra Name:
Designation: AM Designation: GM Designation: