BOP Operating Manual 2011-12

OPERATING MANUAL
FOR
BOP MANUAL
DOCUMENT NO.: - PNC/PU/CPP/M/06
INDIAN OIL CORPORATION LTD

PANIPAT NAPHTHA CRACKER PROJECT
CAPTIVE POWER PLANT
PREPARED BY REVIEWED BY APPROVED BY

Sh S Kansal, Sh S L Bangotra, PUM Sh Baljeet Singh, SPUM
PUE
1
PREFACE
This manual contains information on the operation of

CPP Captive power plant at Panipat Naphtha Cracker. The
information has been prepared on the assumption that the
operating personnel have a basic knowledge of power system,
power plant engineering and operation.
It is an essential perquisite for satisfactory operation of

the power plant that the operating personnel are fully familiar
with the design of the power plant and receive thorough
training in operating the unit.
This write up does not replace any manual supplied

by M/S L&T.
It is hoped that user will go through it and will find

it helpful in achieving the safe operation of the Switch
Gear. Suggestions if any for upgrading this manual are always
welcomed and shall be revised accordingly.
S L BANGOTRA
PUM, PNC-CPP
2
BOP Operating Manual
Amendment / Updation Record
Sl Amendment Page Page Prepared By Reviewed by Approved by

No date no. revision
no.
1 00 1- Rev-0 Sh S Kansal, Sh S L Bangotra, Sh Baljeet Singh,
PUE PUM SPUM
3
BOP Operating Manual
Updation/Issue Record
S.No Date of List of recipient Prepared By Reviewed by Approved by

Updation
1 Sh S Kansal, Sh S L Bangotra, Sh Baljeet Singh, SPUM

PUE PUM
4
INDEX
EQUIPMENT DESCRIPTION, SPECIFICATIONS
PAGE NO
& OPERATING PROCEDURES :
1 SHP Boiler Feed Pumps
2 MP Boiler Feed Pumps
3 Deaerator Feed Pumps
4 Deaerator
5 Condensate storage tanks
6 Steam Network CPP
7 PRDS
8 Auxiliary Boiler
5
GENERAL DESCRIPTION OF BOP AREA
The BOP area of Captive power plant to Naptha Cracker Complex includes
SHP BFPs, MP BFPs, Deaerator Feed pumps, Deaerators, Condensate
storage tanks, Auxiliary Boiler & PRDS.
SHP BOILER FEED PUMPs (52P-501/502/503/504/505) :
Super High pressure Boiler feed pumps (3 Turbo driven & 2 Motor driven)
supply feedwater to Utility boilers, HRSGs & Naptha cracker complex. The
specifications are as follow:
Quantity 5 ( 3TD + 2MD)
Manufacturer KSB PUMPS LIMITED
Capacity, m3/hr Normal : 196 Rated : 286

Suction pressure, kg/cm2 (g) 4.1
Discharge pressure, kg/cm2 (g) 181.8
Differential Head, m 1895
Vapour pressure, kg/cm2 (A) 2.8
NPSH Required (m) 6.3
Full load speed(RPM) 3850
No. of stages 10
Pump driver Motor/Steam turbine
Rated BKW 2100
Min continuous flow, m3/hr 110

Pumping temperature (oC) 130.56
6
Radial(Sleeve) & Thrust(Tilting pad
Bearing type
type)
Oil viscosity ISO grade VG 46
Total cooling water requirement, m3/hr
(Seal jacket/Seal heat exchanger/Lube oil 24.2 at 5.6 ksc
system/Motor
Max allowable noise 85 dBA @ 1m
OPERATING PROCEDURE FOR SHP BFP (MOTOR DRIVE):
PRE STARTUP CHECKS:
1. Confirm that all Maintenance Work permit issued is Returned.

2. All men & unwanted material removed from the area.
3. Check coupling guard on feed pump.
4. Check oil level in oil cup for bearing lubrication.
5. Ensure CCW system for Motor/seal cooler is lined up i.e. suction &
discharge valve open.
6. Ensure both Deaerator level is normal (60%).
7. Ensure MOV's (2701/2702) from both Deaerators are open &
feedback healthy available on DCS.
8. Suction valve (2819/2901) of respective BFP in Closed condition.
9. Motorized Discharge valve (2823/2915) & its motorized integral
bypass valve (2824/2916) of respective BFP in Closed condition.
10.Ensure the opening of Drain & vent valves on discharge line.
11.Open suction valve (2819/2901) slowly for removing any air lock in
the pump.
12.After confirming that all air has been remove close the Drain & vent
valves on the delivery side of the pump.
13.Ensure suction DP (PDT 2802/2901) within limits.
14.Ensure Recirculation line isolating valves near Deaerator (2610/2613)
are open.
15.Ensure Balancing drum leak off line isolation valves near pump &
isolating valves near Deaerator (2665/2666) are open.
16.Ensure Bleed water for PRDS spray isolation valve (2834/2906) is
closed.
17.Check that all the instruments devices (PI,TI,PT,TT,FT,PDT) in pump
& pipings are taken in line & checked by simulation.
18.Ensure that all protections & interlocks are in service
7
START UP PROCEDURE:
1. Ensure electrical supply is available for motor.

3. Make LOCAL/REMOTE mode selection from DCS or LOCAL.
4. START required Boiler Feed pump (52-P-504/505).
5. Check for any abnormal noise, Vibration level & bearing
temperatures.
6. Slowly open the motorized integral bypass valve (2824/2916) on the
discharge line.
7. Slowly open the main motorized Discharge valve (2823/2915)
keeping in watch of the discharge pressure.
8. Now open Bleed water for PRDS spray isolation valve (2834/2906) as
per requirement.
9. Check for any flange/tapping leakages from pump & its associated
pipings.
10.Record all the critical parameters in the Field Log book at regular
intervals.
OPERATING PROCEDURE FOR SHP BFP (TURBO DRIVE):
PRE STARTUP CHECKS:

4. Ensure CCW system for Lube oil cooler & Motor/seal cooler is lined
up i.e. suction & discharge valve open.
5. Ensure that lube oil system is in service & lined up as per
requirements.
6. Ensure both Deaerator level is normal (60%).
7. Ensure MOV's (2701/2702) from both Deaerators are open &
8. Suction valve (2703/2719/2803) of respective BFP in Closed
condition.
9. Motorized Discharge valve (2717/2727/2817) & its motorized integral
bypass valve (2718/2828/2818) of respective BFP in Closed
condition.
8
11.Open suction valve (2703/2719/2803) slowly for removing any air
lock in the pump.
13.Ensure suction DP (PDT 2701/2702/2801) within limits.
14.Ensure Recirculation line isolating valves near Deaerator
(2601/2604/2607) are open.
15.Ensure Balancing drum leak off line isolation valves near pump &
isolating valves near Deaerator (2669/2668/2667) are open.
16.Ensure Bleed water for PRDS spray isolation valve
(22708/2724/2808) is closed.
17.Ensure that HP steam header is charged & HP steam stop valve in the
HP steam line is open.
18.Line up turbine drains. Check steam conditions are suitable for
rolling.
20.Ensure that all protections & interlocks are in service.
START UP PROCEDURE:

2. Take clearance from the panel operator for start up
3. Make LOCAL/REMOTE mode selection from DCS or LOCAL
4. Open the hydraulically operated stop valve at the turbine inlet, warm
up & start the turbine rolling.
5. Carry out the turbine rolling as per OEM's Cold start up guidelines.
6. Raise the speed to full rated speed and keep the turbine running at that
speed for the prescribed time.
7. Slowly open the motorized integral bypass valve (2718/2728/2818) on
the discharge line.
8. Slowly open the main motorized Discharge valve (2717/2727/2817)
temperatures.
10.Check for any flange/tapping leakages from pump & its associated
pipings
intervals.
9
INTERLOCK TABLE :
INTERLOCK NO. TAG NO. CONDITION ACTION

I-2501 LI2502 Low Low level in deaerator TRIP SHPBFP-1 52-P-501
storage tank-1 and OPEN TRIP SHPBFP-1 52-P-502
feedback of MOV 52-MOv-2701 TRIP SHPBFP-1 52-P-503
TRIP SHPBFP-1 52-P-504
I-2702 TI2705 High temperature differential TRIP RESPECTIVE SHP
TI2702 between suction & discharge of BFP
TI2704 BFP
TI2802
TI2804
TI2902
I-2603 LI2602 Low Low level in deaerator TRIP SHPBFP-1 52-P-501
feedback of MOV 52-MOv-2702 TRIP SHPBFP-1 52-P-503
I-2704 ZSO2703 Valve 52-GV-2703 Not open TRIP SHPBFP-1 52-P-501
I-2911 PI2903 Low pressure at outlet of SHP START standby

Feed water discharge header or SHP BFP
tripping of running BFP
10
MP BOILER FEED PUMPs (52P 506/507) :
Medium pressure Boiler feed pumps (2 Motor driven) supply feed water to
Naptha cracker complex (LLDPE). The specifications are as follow:
Quantity 2 ( MD)
Manufacturer SULZER PUMPS INDIA LIMITED
Capacity, m3/hr Normal : 24.61 Rated : 65

Suction pressure, kg/cm2 (g) 2.75
Differential Head, m 450
Vapour pressure, kg/cm2 (A) 2.75
NPSH Required (m) 2
No. of stages 7
Pump driver Motor
Rated BKW 132

15
Min continuous flow, m3/hr
Pumping temperature (oC) 130.56
Bearing type
type)
Oil viscosity ISO grade
(Seal jacket/Seal heat exchanger/Lube oil
system/Motor
11
OPERATING PROCEDURE FOR MP BFP (MOTOR DRIVE):
PRE STARTUP CHECKS:

4. Check oil level in oil cup for Bearing lubrication.
5. Ensure bearing oil/mechanical seal cooling water valves
(suction/discharge) are open.
6. Ensure Deaerator level is normal (60%).
7. Ensure MOV's (2701/2702/3001) from both Deaerators are open &
8. Suction valve (3003/3017) of respective BFP in Closed condition.
9. Motorized Discharge valve (3015/3029) & its motorized integral
bypass valve (3016/3030) of respective BFP in Closed condition.
11.Open suction valve (3003/3017) slowly for removing any air lock in
the pump.
13.Ensure suction DP (3001/3002) within limits.
14.Ensure Recirculation line isolation valves near pump (3053/3054) &
isolating valves near Deaerator (2616/2619) are open.
15.Ensure Balancing drum leak off line isolation valves near Deaerator
(2663/2664) are open.
16.Check that all the instruments devices (PI, TI, PT, TT, FT, PDT) in
pump & pipings are taken in line & checked by simulation.
START UP PROCEDURE:

2. Take clearance from the panel operator for start up
4. START required Boiler Feed pump (52-P-506/507).
temperatures.
12
6. Slowly open the motorized integral bypass valve (3016/3030) on the
discharge line.
7. Slowly open the main motorized Discharge valve (3015/3029)
pipings
9. Record all the critical parameters in the Field Log book at regular
intervals.
INTERLOCK TABLE :

I-2501 LI2502 Low Low level in Deaerator TRIP MP BFP-1 52-P-506
storage tank-1 and OPEN TRIP MP BFP-2 52-P-507
feedback of MOV 52-MOv-3001
I-2702 TI3002 High temperature differential TRIP MP BFP-1 52-P-506

TI3004 between suction & discharge of TRIP MP BFP-2 52-P-507
BFP
I-2603 LI2602 Low Low level in Deaerator TRIP MP BFP-1 52-P-506
storage tank-2 and OPEN TRIP MP BFP-2 52-P-507
feedback of MOV 52-MOv-3002
I-3009 ZSO3003 Valve 52-GV-3003 Not open TRIP MP BFP-1 52-P-506
I-3012 PI3005 Low pressure at outlet of MP START standby MP

Feed water discharge header or BFP
13
DEAERATOR FEED PUMPS (52P-510/511/512) :
Deaerator feed pumps (3 motor driven) take suction from Condensate

storage tanks and are used to feed condensate to the Deaerators through
Condensate preheater panels of HRSGs. Provision is provided to bypass
individual CPH panels & feed the condensate directly to Deaerator. The
specifications are as follow:
Quantity 3 ( MD)
Manufacturer SULZER PUMPS INDIA LIMITED
Capacity, m3/hr Normal : 560 Rated : 580

Liquid handled DM water
Suction pressure, kg/cm2 (A) 1.09
Differential Head (m) 130
Vapour pressure, kg/cm2 (A)
NPSH Required (m) 4.5
No. of stages 1
Pump driver Motor
Rated BKW 330

Pumping temperature (oC) 50
Bearing type
type)
Oil viscosity ISO grade
14
(Seal jacket/Seal heat exchanger/Lube oil
system/Motor
OPERATING PROCEDURE FOR DFP (MOTOR DRIVE):
PRE STARTUP CHECKS:

4. Check oil level in oil cup for bearing lubrication.
5. Ensure bearing oil/mechanical seal cooling water valves
(suction/discharge) are open.
6. Ensure that all the connected pipings to the DFP circuit are isolated as
per the procedures.
7. Ensure both Condensate storage tank level is normal (60%).
8. Suction valve (2303/2304/2305) of respective DFP in Closed
condition.
9. Motorised Discharge valve (2306/2307/2308) & its integral bypass
isolation valve (2360/2361/2362) of respective DFP in Closed
condition.
11.Open suction valve (2303/2304/2305) slowly for removing any air
lock in the pump.
13.Ensure suction DP (PDT 2301/2302/2303) within limits.
14.Ensure Motorised Discharge valve (2306/2307/2308) in open
condition.
15.Ensure Min. Recirculation line control valve (2426) & isolating valves
near CST tank (2371/2372) are open.
START UP PROCEDURE:
1. Ensure electrical supply is available for motor

2. Take clearance from the panel operator for start up.
15
4. START required Deaerator Feed pump (52-P-510/511/512).
temperatures.
6. Put the Min. Recirculation line control valve (2426) in AUTO as per
requirement.
pipings.
intervals.
INTERLOCK TABLE :
16
DEAERATOR (52-V-501/502):
Function:
The presence of certain gases like O2, Co2, Ammonia dissolved in water is
harmful because of their corrosive attack, particularly at elevated
temperature. Thus in modern high pressure boilers, to prevent internal
corrosion, the feed water should be free of all dissolved gases especially O2.
This is achieved by embodying into the freed system a Deaerating Unit.
Apart from deaeration, it also serves following functions:
1. Heating incoming feed water.
2. To act as reservoir to provide a sudden or instantaneous demand.
Principle of Deaeration :
a) Solubility of any gas dissolved in a liquid is directly proportional to the

partial pressure of the gas. This holds with in close limits for any gas, which
does not react chemically with the solvents.
b) Solubility of gases decrease with increases in solution temperature and or

decrease in pressure.
Quantity 2
Type of Deaerator feed water heater Spray cum tray type

Normal Maximum
Design conditions operation operation
Deaerator operating pressure kg/cm2 (A) 2.8 2.8
Deaerator operating temperature (oC) 130.55 130.55

Condensate pressure at the inlet of
2.3
Deaerator , kg/cm2 (g)
Condensate temperature (oC) 101.89 72.12
Condensate flow rate (TPH) 547.21 849.6
17
Heating steam flow rate required at
27.15 85.92
given pressure & temp.
Drains into Deaerator :
TPH kg/cm2 (A) o

C
SHP BFP recirculation flow per nozzle 110
MP BFP recirculation flow per nozzle 15 3.5 133
SHP BFP balance drum leak off flow 18 3.5 133
MP BFP balance drum leak off flow 5.7 3.5 133
Initial heating pipe provided in storage tank
Net water storage provided in Feed water storage tank :
Between NWL & LWL(m3) 359.737
Between LWL & LLWL(m3) 35.668

Between LLWL & Deaerator
36.071
bottom(m3)
Between NWL & HWL(m3) 94.571
Between HWL & HHWL(m3) 50.842
Between HHWL & Deaerator top(m3) 76.112
Total capacity 653.001
Sprayer Assembly details :
No. of sprayer assemblies 64
Sprayer assembly type Spring loaded staggered down
Manufacturer of sprayer assembly BHEL

Condensate flow through each sprayer
15
assembly (TPH)
Pressure drop under normal & max.
0.2
condensate flow kg/cm2
Material of sprayer assembly SS 316/384 trays
18
Material of tray SA240 TP304
Vent system details :
Deaerator vent steam flow(TPH) 0.75% of the inlet steam flow
No. of controlled vents & their size 4/2
No. of relief valves & capacity 4 (relieving capacity : 25TPH)
Deaerator feed water storage tanks :
No. of Manholes & size (mmxmm) 4/24
Supports for feed water storage tanks Sliding type - 4 Fixed type -1
Material of shell & dished ends SA516 Gr B
Material of steam pipes SA106 Gr B

Header : 12
Thickness of shell (mm)
FST : 16
Header : 12
Thickness of dished ends (mm)
FST : 16
Dimensions :
Tangent length (mm) 50610

Overall length included in dished ends Header : 9565
(mm) FST : 53190
Inside diameter. of storage tank 4000
Guaranteed Performance :
Oxygen content in feed water at
0.005
deaerator outlet (ppm)
CO2 content in feed water at deaerator
Nil
outlet (ppm)
Operating procedure for Deaerator filling (Through DM line)

(52-V-501/502):
PRE START CHECKS:

19
3. Ensure that other connected pipings to deaerator isolation valves
are isolated as per procedure.
4. Ensure DM water pump availability for make up.
5. Check Deaerator drain valves are closed.
6. Check Deaerator vent valves are open.
7. Ensure DM make up water line drains valve are closed.
8. Ensure Deaerator make up water from IOCL B/L Control
valve(on/off type) 2329 is open.
9. Ensure Deaerator make up water isolation valves (2560/2660)
near Deaerator are closed.
10.Check that all the instruments devices (LI, PI, TI, PT, TT, FT,
PDT) in Deaerator are taken in line & checked by simulation.
START UP PROCEDURE:

2. Start the DM transfer pump.
3. Open Deaerator make up water isolation valves (2560/2660) near
Deaerators.
4. Fill the Deaerator to the normal level (60%) as per the filling rate
curve.
5. Ensure the availability of Hydrazine dozing system before
consuming water from Deaerator.
6. Check for any flange/tapping leakages from pump & its
associated pipings.
intervals.
Operating Procedure for Deaerator Filling (Through DFPs)

(52-V-501/502):
PRE START CHECKS:

3. Ensure that other connected pipings to Deaerator isolation valves
5. Check Deaerator drain valves are closed.
20
6. Check Deaerator vent valves are open.
8. Ensure Deaerator make up water from IOCL B/L Control valve
(on/off type) 2329 is closed.
9. Ensure Deaerator make up water isolation valves (2560/2660)
near Deaerator are closed.
10.Ensure CST level is normal & DM make up control valves to CST
(2317/2319) in AUTO.
11.Ensure CPH circuit is Bypassed i.e. all isolation valves of CPH
circuit closed.
12.Ensure Deaerator 1&2 make up control valve from DFP discharge
(2424/2425) are closed.
13.Ensure Deaerator make up water isolation (condensate from
CPH) valves (2546/2646) near Deaerator are open.
14.Check that all the instruments devices (LI, PI,TI,PT,TT,FT,PDT)
in deaerator are taken in line & checked by simulation.
START UP PROCEDURE:

2. Start the Deaerator fill pump as per procedure.
3. Open Deaerator 1&2 make up control valve from DFP discharge
(2424/2425) slowly slowly.
4. Fill the deaerator to the normal level (60%) as per the filling rate
curve.
5. Put Deaerator 1&2 make up control valve from DFP discharge
(2424/2425) in AUTO as per requirement.
6. Ensure the availability of Hydrazine dozing system before
consuming water from deaerator.
associated pipings.
intervals.
Operating procedure for Deaerator pegging steam charging (52-V-

501/502):
PRE START CHECKS:

21
3. Ensure that other connected pipings to deaerator isolation valves
4. Ensure Deaerator is filled to the normal level (60%).
5. Ensure deaerator Overflow line valve is closed.
6. Deaerator vent valves are open.
7. Ensure the availability of steam with requisite parameters & the
pegging steam line from LP steam header is charged as per the
procedure.
8. Check that all the instruments devices (LI, PI,TI,PT,TT,FT,PDT)
in deaerator are taken in line & checked by simulation.
9. Ensure that all protections & interlocks are in service.
START UP PROCEDURE:

2. Open the drain valves in the upstream & downstream of pegging
steam line control valve (1406/1412) to Deaerators.
3. Open the manual bypass valve (1408/1414) of the pegging steam
control valve (1406/1412) to Deaerators.
4. Close the bypass valve (1408/1414) once the steam line temp.
reaches near the pegging steam temperatures.
5. Open the upstream & downstream isolation valves of the control
valves(1406/1412).
6. Open the isolation valve of the Deaerator-1/2 initial heating lines
(2591A/2691A) at the deaerator end.
7. Open the control valve (1406/1412) & charge steam slowly in the
deaerator.
8. Check the line for hammering. Open the vent valves on the line if
any to release the steam into atmosphere.
9. Close the vent valves/drain valves & charge pegging steam
towards deaerator.
10.Observe the pressure & temperature of the deaerator.
11.Visually observe the exhaust of non condensable gases from the
deaerator vents.
12.Throttle the vent valve as per requirement.
13.Check for the pegging steam balance line between deaerator.
Before charging the second deaerator with pegging steam, open
the isolation valves provided at two ends of the balancing line
between deaerators.
22
14.Put the control valves (1406/1412) in AUTO as per requirement.
15.Check for the Feed water balance line between deaerators. Before
charging the second deaerator with pegging steam, open the
isolation valves provided at two ends of the balancing line between
deaerators.
16.Check if the normal working level is maintained in deaerator
throughout the steam charging operation.
17.Continuously observe the pressure & temperature and adjust the
steam flow into the deaerator to avoid overpressurising.
18.Check for any flange/tapping leakages from pump & its
associated pipings.
intervals.
INTERLOCK TABLE :

High High level in deaerator OPEN MOV 52-MOV-2525
storage tank-1 (52-V-501)
High level in deaerator storage CLOSE MOV 52-MOV-2525
tank-1 (52-V-501)
Low Low level in deaerator TRIP SHPBFP-1 52-P-501
I-2501 LI2502 storage tank-1and OPEN TRIP SHPBFP-1 52-P-502
feedback of MOV 52-MOV-2701 TRIP SHPBFP-1 52-P-503
Low Low level in deaerator TRIP MPBFP-1 52-P-506
storage tank-1and OPEN TRIP MPBFP-1 52-P-507
feedback of MOV 52-MOV-3001
I-2702 TI2705 High temperature differential TRIP RESPECTIVE SHP
TI2702 between suction & discharge of BFP
TI2704 BFP
TI2802
TI2804
TI2902
TI3002 TRIP RESPECTIVE MP
TI3004 BFP
I-2603 LI2602 High High level in deaerator OPEN MOV 52-MOV-2625
storage tank-2 (52-V-502)
High level in deaerator storage CLOSE MOV 52-MOV-2625
tank-2 (52-V-502)
23
Low Low level in deaerator TRIP SHPBFP-1 52-P-501
feedback of MOV 52-MOV-2702 TRIP SHPBFP-1 52-P-503
Low Low level in deaerator TRIP MPBFP-1 52-P-506

storage tank-2and OPEN TRIP MPBFP-1 52-P-507
feedback of MOV 52-MOV-3002
I-2911 PI2903 Low pressure at outlet of SHP

Feed water discharge header or START standby SHP BFP
I-3012 PI3005 Low pressure at outlet of SHP
Feed water discharge header or START standby MP BFP
LI2502 High level in deaerator storage CLOSE 52 CV-2329
LI2602 tank -1 & deaerator storage tank- CLOSE 52 CV-2330
2 OPEN MOV 52 CV-2322
24
CONDENSATE STORAGE TANKS (52T-001/002) :
Condensate storage tank receives Polished condensate from Condensate

polishing unit (CPU), Turbine 1/2/3 condensate from CEP discharge &
make up water from DM plant. The condensate from Condensate
storage tank is feed to the Deaerator by Deaerator feed pumps (3 motor
driven). The specifications are as follow:
Quantity 2
Type Fixed roof
Capacity, m3 100
Fluid handled DM water
Storage temperature 46.65
Liquid specific gravity at storage temp. 1
Viscosity at storage temp.(CST) 0.58
Diameter (mm) 5000
Height (mm) 6750
Material of construction SS 304
Operating Procedure for CST Filling (52-V-501/502):
PRE START CHECKS:

3. Ensure that other connected pipings to CST isolation valves are
isolated as per procedure.
5. Check CST drain valves are closed.
6. Check CST vent valves are open.
25
8. Ensure Polished condensate line MOV-2322 closed.
9. Ensure Deaerator make up water from IOCL B/L Control valve
(on/off type) 2329 is closed.
10.Ensure Deaerator make up water isolation valves (2316/2313)
near CST are open.
11.Check that all the instruments devices (LI, PI, TI, PT, TT, FT,
PDT) in Deaerator are taken in line & checked by simulation.
START UP PROCEDURE:

2. Start the DM transfer pump.
3. Open upstream & downstream isolation valves of the DM make
up control valves (2317/2319) to CST.
4. Open the control valve (2317/2319) & charge water slowly in the
CST.
5. Fill the CST to the normal level (60%) as per the filling rate
curve.
6. Maintain required tank pressure as per the protocols by opening
the Nitrogen Control valve 2323.
7. Put CST level control valve (2317/2319) in AUTO as per
requirement.
8. Put Nitrogen pressure control valve 2323 in AUTO as per
requirement.
associated piping.
intervals.
26
STEAM NETWORK (CPP):
In CPP complex four types of Steam are produced i.e. SHP, HP, MP, and
LP. These steams are utilized in CPP & Naptha Cracker Complex for
different purposes like heating, for Turbo driven equipments etc.
Different steams parameters, Connections & their purposes are as
follow:
SHP STEAM :
Pressure ,kg/cm2 (A) 129.53
Temperature (oC) 525

Max. Flow (TPH)
265
Main Header size 20
HEADER INLET CONNECTIONS:
Utility Boiler 1 & 2 16 each

HRSG 1,2,3,4,5 8 each
HEADER OUTLET CONNECTIONS:
STG 1/2/3 20 each

SHP/HP PRDS -1 8
SHP/HP PRDS -2 6
NCU 20
Future IOCL units 16
SAFETY VALVE DETAILS:

3 safety valve in SHP header 135 ksc
Safety valve in PRDS 1 & 2 50 ksc
27
HP STEAM :

Max. Flow (TPH) 249.5
Main Header size 24
SHP/HP PRDS-1 8
SHP/HP PRDS-2 6
STG-1/2/3 Extraction 12 each
Spray water from SHP BFP Discharge header 1
SHP BFP 1/2/3 6 each

FO PUMP 1/2 4 each
Steam injection to GT-1/2/3/4/5 3 each
FD FAN 1/2 8 each
Fuel oil heater 3
Auxiliary steam header 3
HP/MP PRDS 1 14
HP/MP PRDS 2 14
NCU 28
MOP 1/2/3 (From STG extraction) 2 each

HP/MP PRDS 1 & 2 20.4 ksc
Discharge of SHP BFP & FOP 6.5 ksc
28
MP STEAM:

Main Header size 24
HP/MP PRDS-1 20
HP/MP PRDS-2 10
STG-1/2/3 Extraction 10 each
FD-TD 1/2 Outlet 12 each
Spray water from SHP BFP Bleed header 1
MP/LP PRDS 6
Atomization & soot blowing for UB-1/2 4 each
Soot blowing for HRSG 1/2/3/4/5 6 each
NCU 42
MP/LP PRDS 6.5 ksc
29
LP STEAM :

Main Header size 24
MP/LP PRDS 16
SHP BFP TD 1/2/3 Exhaust 12 each
FO TD 1/2 Exhaust 6 each
MOP TD 1/2/3(STG) Exhaust 6 each
Spray water from SHP BFP Bleed header 1
Pegging steam to Deaerator 1/2 30 each

UB 1/2 BFO Heater & SCAPH 8 each
Excess steam to condenser 1/2/3 14 each
Vapour absorption system 6
BFO Day tank 1/2 3 each
BFO Blending tank 3
Surge vessel 2
Steam tracing for HRSG &UB 4
Steam tracing for Pump & Strainer 4
Fuel gas heaters 8
NCU 20
To atmosphere through CV 16
30
PRDS UNITS: PRDS (Pressure Reducing Desuperheating Station) is
used to reduce the pressure & temperature of the steam as per our
process requirement. It consists of a pressure control valve to reduce
pressure & a temperature control valve to reduce temperature by the
introduction of DM water spray. The spray for various PRDS is taken
from BFP discharge header, BFP bleed header & DFP discharge spray.
NO. DESCRIPTION SPRAY SOURCE
SHP BFP Discharge header

PRDS-1 SHP/HP PRDS -1
PRDS-2 SHP BFP Bleed header

SHP/HP PRDS -2
PRDS-3 HP/MP PRDS -1 SHP BFP Bleed header
PRDS-4 HP/MP PRDS -2 SHP BFP Bleed header
PRDS-5 MP/LP PRDS SHP BFP Bleed header
SHP STEAM BYPASS TO

PRDS-6 DFP Discharge header
CONDENSOR-1/2/3
LP STEAM EXCESS DUMP TO

PRDS-7 CEP Discharge-1/2/3
CONDENSOR
HP STEAM TO GTG INJECTION-

PRDS-8 SHP BFP Bleed header
1/2/3/4/5
PRDS-9 HP STEAM TO STG AUX.(2) SHP BFP Bleed header
31
LP PROCESS STEAM LINE TO CPP
DS-1 SHP BFP Bleed header
B/L
MP PROCESS STEAM LINE TO CPP

B/L
HP PROCESS STEAM LINE TO CPP

B/L
Operating procedure for SHP TO HP PRDS UNITS 1/2:
PRE START CHECKS :

2. All men & unwanted material removed from the area
3. Ensure SHP steam availability with requisite parameters
(Pressure & Temp.)
4. Ensure availability of spray water from SHP BFP discharge
header with requisite parameters
5. Check that all the instruments devices(PI,TI,PT,TT,FT,PDT) in
pump & pipings are taken in line & checked by simulation
START UP PROCEDURE:
1. Take clearance from the panel operator for charging the system.
3. Ensure all drains in SHP to HP PRDS-1/2 in steam side are open.
4. Slowly open the Motorised valve (0906/0907) on the SHP to HP
PRDS-1/2 steam line.
5. Slowly open the Pressure control valve CV-0926/0920 & charge
the system to maintain the requisite pressure.
6. Ensure all drains in SHP to HP PRDS-1/2 in steam side are closed
after proper removal of condensate from lines.
7. Open the isolation valves 902/909 upstream & 946/948
downstream of temperature control valves CV 901/910of spray
water from SHP BFP Discharge header.
8. Now charge the spray water from SHP BFP Discharge header by
slowly opening the Temp. Control valve CV 901/910 & maintain
the required temperature.
32
9. Put the pressure & Temperature control valves in AUTO as per
requirement.
10.Check for any abnormal noise & Vibration level of pipelines.
11.Check for any flange/tapping leakages from its associated pipings.
intervals.
Operating procedure for HP TO MP PRDS UNITS 1/2:
PRE START CHECKS:

3. Ensure HP steam availability with requisite parameters (Pressure
& Temp).
4. Ensure availability of spray water from SHP BFP bleed header
with requisite parameters.
5. Check that all the instruments devices (PI,TI,PT,TT,FT,PDT) in
START UP PROCEDURE:
3. Ensure all drains in HP to MP PRDS-1/2 in steam side are open.
4. Slowly open the Motorised valve (1022A/1001A) on the HP to MP
PRDS-1/2 steam line.
5. Slowly open the Pressure control valve CV-1007/1002 & charge
6. Ensure all drains in HP to MP PRDS-1/2 in steam side are closed
7. Open the isolation valves 1010/1005 upstream & 1052/1054
downstream of temperature control valves CV 1009/1004 of spray
water from SHP BFP bleed header.
8. Now charge the spray water from SHP BFP bleed header by
slowly opening the Temp. Control valve CV 1009/1004& maintain
requirement.
33
intervals.
Operating procedure for MP TO LP PRDS UNITS :
PRE START CHECKS:

3. Ensure MP steam availability with requisite parameters (Pressure &
Temp).
4. Ensure availability of spray water from SHP BFP bleed header with
requisite parameters.
5. Check that all the instruments devices (PI, TI, PT, TT, FT, PDT) in
START UP PROCEDURE:
3. Ensure all drains in HP to MP PRDS-1/2 in steam side are open.
4. Slowly open the Motorised valve (1605) on the MP to LP PRDS-
1/2 steam line.
5. Slowly open the Pressure control valve CV-1606 charge the system
to maintain the requisite pressure.
6. Ensure all drains in MP to LP PRDS-1/2 in steam side are closed
7. Open the isolation valves 1634 upstream & downstream of
temperature control valves CV 1624 of spray water from SHP BFP
bleed header.
8. Now charge the spray water from SHP BFP bleed header by slowly
opening the Temp. Control valve CV 1624 & maintain the required
temperature.
requirement.
34
intervals.
Operating Procedure for SHP BYPASS TO CONDENSOR PRDS

UNITS (1/2/3):
PRE START CHECKS:

3. Ensure SHP steam availability with requisite parameters
(Pressure & Temp).
4. Ensure availability of spray water from DFP discharge header
START UP PROCEDURE:
3. Ensure all drains in SHP bypass to condenser PRDS-1/2/3 in
steam side are open.
4. Slowly open the isolation valve (793/797/799) on the SHP bypass to
condenser PRDS-1/2/3 in steam side line.
5. Slowly open the Pressure control valve CV-704/705/706 charge the
system to maintain the requisite pressure.
6. Ensure all drains in SHP bypass to condenser PRDS-1/2 in steam
side are closed after proper removal of condensate from lines.
7. Open the isolation valves 708/711/714 upstream & downstream
778/779/780 of temperature control valves CV 704/705/706 of
spray water from DFP discharge header.
8. Now charge the spray water from DFP discharge header by slowly
opening the Temp. Control valve CV 704/705/706 & maintain the
required temperature.
requirement.
35
intervals.
Operating Procedures for LP EXCESS DUMP TO CONDENSOR

PRDS UNITS (1/2/3) :
PRE START CHECKS:

3. Ensure LP steam availability with requisite parameters (Pressure
& Temp.)
4. Ensure availability of spray water from CEP Discharge 1/2/3 with
requisite parameters.
START UP PROCEDURE:
2. Make LOCAL/REMOTE mode selection from DCS or LOCAL
3. Ensure all drains in LP excess steam to condensor PRDS-1/2/3 in
steam side are open.
4. Slowly open the isolation valve (1582/1584/1586) on the LP excess
steam to condensor PRDS-1/2/3 in steam side line.
5. Slowly open the Pressure control valve CV-1501/1503/1505 charge
6. Ensure all drains in LP excess steam to condensor PRDS-1/2/3 in
steam side are closed after proper removal of condensate from
lines.
7. Open the isolation valves 1511/1514/1517 upstream of
temperature control valves CV 1512/1515/1518 of spray water
from CEP Discharge 1/2/3.
8. Now charge the spray water from spray water from CEP
Discharge 1/2/3 by slowly opening the Temp. control valve CV
1512/1515/1518 & maintain the required temperature.
36
requirement.
intervals.
Operating Procedures for HP STEAM TO GT STEAM INJECTION

PRDS UNITS(1/2/3/4/5) :
PRE START CHECKS:

& Temp.)
START UP PROCEDURE:
1. Take clearence from the panel operator for charging the system.
3. Ensure all drains in HP steam to GT steam injection PRDS-
1/2/3/4/5 in steam side are open.
4. Slowly open the isolation valve (1201/1209/1217/1349/1319) on the
HP steam to GT steam injection PRDS-1/2/3/4/5 in steam side
line.
5. Open the isolation valves 1202/1210/1218/1312/1320 upstream &
downstream 1204/1212/1220/1314/1322 of pressure control valves
CV 1203/1211/1219/1313/1321 of HP steam to GT steam injection
PRDS-1/2/3/4/5 in steam side line.
6. Slowly open the Pressure control valve CV-
1203/1211/1219/1313/1321 charge the system to maintain the
requisite pressure.
7. Ensure all drains in HP steam to GT steam injection PRDS-
1/2/3/4/5 in steam side are closed after proper removal of
condensate from lines.
37
8. Open the isolation valves 1206/1214/1222/1316/1324 upstream &
downstream 1260/1262/1264/1323/1327 of temperature control
valves CV 1207/1215/1223/1317/1325 of spray water from SHP
BFP bleed header .
slowly opening the Temp. control valve CV
1207/1215/1223/1317/1325 & maintain the required temperature.
10.Put the pressure & Temperature control valves in AUTO as per
requirement.
intervals.
Operating Procedures for HP STEAM TO STG AUXILIARIES PRDS

UNITS(1/2) :
PRE START CHECKS:

& Temp.)
START UP PROCEDURE:
1. Take clearence from the panel operator for charging the system.
3. Ensure all drains in HP steam to STG Aux. PRDS-1/2 in steam
side are open.
4. Open the isolation valves 1343/1390 upstream & downstream
1344/1391 of pressure control valves CV 1311/1323 of HP steam to
STG Aux. PRDS-1/2 in steam side line.
5. Slowly open the Pressure control valve CV-1311/1323 charge the
system to maintain the requisite pressure.
6. Ensure all drains in HP steam to STG Aux. PRDS-1/2 in steam
side are closed after proper removal of condensate from lines.
38
7. Open the isolation valves 1301/1393 upstream & downstream
1328/1329 of temperature control valves CV 1308/1315 of spray
water from SHP BFP bleed header.
slowly opening the Temp. Control valve CV 1308/1315 & maintain
requirement.
intervals.
Operating Procedures for LP PROCESS STEAM LINE AT CPP B/L DS

UNITS :
PRE START CHECKS:

3. Ensure LP steam availability with requisite parameters (Pressure
& Temp.)
START UP PROCEDURE:
3. Ensure all drains in SHP BFP bleed header in water side are
closed/ blinded.
4. Open the isolation valves 1418 upstream of temperature control
valves CV 1419 of spray water from SHP BFP bleed header.
slowly opening the Temp. Control valve CV 1419 & maintain the
6. Put Temperature control valve in AUTO as per requirement.
7. Check for any abnormal noise & Vibration level of pipelines.
8. Check for any flange/tapping leakages from its associated pipings.
39
intervals.
Operating Procedures for MP PROCESS STEAM LINE AT CPP B/L

DS UNITS :
PRE START CHECKS:

3. Ensure MP steam availability with requisite parameters (Pressure
& Temp.)
START UP PROCEDURE:
closed/ blinded.
intervals.
Operating Procedures for HP PROCESS STEAM LINE AT CPP B/L DS

UNITS :
40
PRE START CHECKS:

& Temp.)
START UP PROCEDURE:
closed/ blinded.
intervals.
41
AUXILIARY BOILER: Auxiliary boiler is used to supply LP steam for
the VAM (Vapour Absorption Machine) system. The auxiliary boiler
outlet is Low pressure steam which is connected to LP header. Only
during initial start up of VAM system subjected to MP/LP PRDS
availability the LP steam requirement is met by Auxiliary boiler. In
normal circumstances, the LP steam requirement for VAM system is
met by MP/LP PRDS. The specifications are as follow:
MAKE : ENERGYPACK
CAPACITY 10 T/Hr
PRESSURE 9 Kg/cm2
TEMPERATURE 185 Deg C
OIL SERVICE TANK (52T-201) 6.5 CU.M
WATER SERVICE TANK(52T-202) 5.0 CU.M
CHEMICAL TANK 100 LTRS
FD FAN 1 NO.
2 NO.s
HSD PUMPS
2 NO.s
BOILER FEED PUMPS
CHEMICAL TRANSFER PUMP 1 NO.
DRUM SAFETY VALVES WITH

2 NO.s (10.5KSC)
SILENCERS
BLOW DOWN PIT

42
CHIMNEY(MS CLADDING
22m height & 750mm dia
INSULATION UPTO 3m)
BURNER SPECIFICATIONS:
Burner model PA-45
Fuel HSD/LDO
Blower motor 30HP, 2900RPM
Blower capacity 13000 Nm3/hr
Heat output 8160000 Kcal/hr
Type Modulation spill fill return
Inlet fuel pressure 15 to 20 Ksc
Return fuel pressure 10 to 4 Ksc
Test pressure 30 Ksc
Year of manufacture 2007
Serial no. EB 07 1001
Make M/s Panchal Associates , Thane
BOILER FEED PUMP:

Manufacturer KSB
Type MOV 132/7
Flow 14.4 m3/hr
Power required 9.3KW 43
Head 130m
RPM 2900
OPERATING PROCEDURE FOR AUXILIARY BOILER:
PRE START CHECKS:

3. Ensure boiler is internally cleaned from loose scale & foreign
deposits.
4. Ensure boiler boxed up, all manholes secured with new packing
joints.
5. Ensure that DM water storage tank level is normal & BFP is lined
up.
6. Ensure FD fan is lined up.
7. Ensure Oil service tank has been filled with requisite amount of
HSD & HSD fuel oil pump is lined up.
8. Ensure the availability of chemicals for dozing & dozing pump
lined up.
START UP PROCEDURE:
1. Ensure electrical supply is available.

4. Start required Boiler Feed pump & fill the boiler shell with
required amount of DM water.
5. Start the FD fan & open the outlet damper slowly. Ensure the
availability of Forced draught at the burner front.
6. Start the HSD pump & ensure the flow of HSD Burner assembly.
7. Fire the boiler in LOW FIRE position by manual controls taking
into line the HSD burner assembly.
8. Keep open the air vent valve in the boiler shell side for steaming
purpose.
9. Continuously monitor the boiler water level form the level gauges
provided on the either side of the boiler.
10.Maintain normal working level of control valve in the boiler by
modulating the feed water control valve.
11.Maintain normal air box pressure of FD fan and modulate as per
requirement by regulating the fan.
44
12.Start the chemical dozing pumps as per requirement.
13.Close the boiler vent once the clear flow of steam with required
temperature & pressure (1.5 ksc) has been established.
14.Gradually increase the firing rate & raise the pressure. Boiler can
changed to AUTO controls i.e. HIGH FIRE after reaching
pressure half of the working pressure.
15.Ensure that the boiler has attained 75% of the rated steaming &
proceed to the next step of floating the safety valves as per
protocols.
16.Once the working pressure & temperature has been attained,
open the MSSV & release the steam for further applications.
17.Check for any abnormal noise, Vibration level.
18.Check for any flange/tapping leakages from boiler & its
associated pipings.
intervals.
45

BOP Operating Manual 2011-12

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OPERATING MANUAL

DOCUMENT NO.: - PNC/PU/CPP/M/06

INDIAN OIL CORPORATION LTD

PREPARED BY REVIEWED BY APPROVED BY

This manual contains information on the operation of

It is an essential perquisite for satisfactory operation of

This write up does not replace any manual supplied

It is hoped that user will go through it and will find

Amendment / Updation Record

Sl Amendment Page Page Prepared By Reviewed by Approved by

S.No Date of List of recipient Prepared By Reviewed by Approved by

1 Sh S Kansal, Sh S L Bangotra, Sh Baljeet Singh, SPUM

1 SHP Boiler Feed Pumps

2 MP Boiler Feed Pumps

3 Deaerator Feed Pumps

5 Condensate storage tanks

6 Steam Network CPP

SHP BOILER FEED PUMPs (52P-501/502/503/504/505) :

Quantity 5 ( 3TD + 2MD)

Manufacturer KSB PUMPS LIMITED

Capacity, m3/hr Normal : 196 Rated : 286

Discharge pressure, kg/cm2 (g) 181.8

Differential Head, m 1895

Vapour pressure, kg/cm2 (A) 2.8

NPSH Required (m) 6.3

Full load speed(RPM) 3850

Pump driver Motor/Steam turbine

Rated BKW 2100

Min continuous flow, m3/hr 110

OPERATING PROCEDURE FOR SHP BFP (MOTOR DRIVE):

PRE STARTUP CHECKS:

1. Confirm that all Maintenance Work permit issued is Returned.

1. Ensure electrical supply is available for motor.

OPERATING PROCEDURE FOR SHP BFP (TURBO DRIVE):

PRE STARTUP CHECKS:

1. Confirm that all Maintenance Work permit issued is Returned.

1. Ensure electrical supply is available for motor.

INTERLOCK NO. TAG NO. CONDITION ACTION

I-2704 ZSO2703 Valve 52-GV-2703 Not open TRIP SHPBFP-1 52-P-501

I-2705 ZSO2719 Valve 52-GV-2719 Not open TRIP SHPBFP-2 52-P-502

I-2806 ZSO2803 Valve 52-GV-2803 Not open TRIP SHPBFP-3 52-P-503

I-2807 ZSO2819 Valve 52-GV-2819 Not open TRIP SHPBFP-4 52-P-504

I-2908 ZSO2901 Valve 52-GV-2901 Not open TRIP SHPBFP-5 52-P-505

I-2911 PI2903 Low pressure at outlet of SHP START standby

Manufacturer SULZER PUMPS INDIA LIMITED

Capacity, m3/hr Normal : 24.61 Rated : 65

Discharge pressure, kg/cm2 (g) 44.816

Differential Head, m 450

Vapour pressure, kg/cm2 (A) 2.75

NPSH Required (m) 2

Full load speed(RPM) 2950

Pump driver Motor

Rated BKW 132

PRE STARTUP CHECKS:

1. Confirm that all Maintenance Work permit issued is Returned.

1. Ensure electrical supply is available for motor.

INTERLOCK NO. TAG NO. CONDITION ACTION

I-2702 TI3002 High temperature differential TRIP MP BFP-1 52-P-506

I-3009 ZSO3003 Valve 52-GV-3003 Not open TRIP MP BFP-1 52-P-506

I-3010 ZSO3017 Valve 52-GV-3017 Not open TRIP MP BFP-2 52-P-507

I-3012 PI3005 Low pressure at outlet of MP START standby MP

Deaerator feed pumps (3 motor driven) take suction from Condensate

Manufacturer SULZER PUMPS INDIA LIMITED

Capacity, m3/hr Normal : 560 Rated : 580