Jindal Power Limited

O.P.J.S.T.P.P, Tamnar, Raigarh

Commissioning Department

Project OPJSTPP (4X600 MW), Tamnar

Procedure LP Heaters
Purpose of Document For Execution/Information
Document No. JPL Reference No: Turbine/Comm./033

Prepared By - Reviewed By -
Rev No. 00
Dtd: Commissioning Commissioning Project

Name

Sign

Approved By :
HEAD – Steering Committee

Copy No:

Issued To:
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./033

Plant Area: Turbine

COMMISSIONING PROCEDURE FOR LP HEATERS

SLNO
LIST OF CONTENTS

1.0 PLANT DETAILS

2.0 OBJECTIVE

3.0 PROPOSAL

4.0 SERVICES REQUIRED

5.0 SAFETY PRECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STATE OF THE PLANT

8.0 METHOD

9.0 COMPLETION CRITERIA

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./033

Plant Area: Turbine

COMMISSIONING PROCEDURE FOR LP HEATERS

SL.NO STATUS

1.0 PLANT DETAILS

Regenerative Feed heating system of simhadri STPP consists of

one drain cooler, three LP Heaters one deaerator and four HP
Heaters.

The three LP Heaters draws bleeding steam from LP turbine and

heats up condensate after drain cooler in stages before feeding
to the deaerator. The condensed drain from the heaters is fed
back to the condensor through drain cooler.

The technical data are as follows.

Drain Cooler
1.1
Type : Shell and Tube

Shell side Tube side.

Medium Drain Condensate

Design Pressure 3 and Full 39 kg/cm2
Vacuum
Design Temperature 120 144 deg C
Test Pressure 4.5 58.5 kg/cm2
Test Temperature Ambient Ambient
Inlet Temperature 64.7 46.9 deg C
Outlet Temperature 51.7 48.7 deg C
No. of. Passes 1 1
No. of . Tubes 675
Surface are 145 m2

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./033

Plant Area: Turbine

COMMISSIONING PROCEDURE FOR LP HEATERS

STATUS
SL.NO
1.2 LP Heater 2

Type : Shell and Tube

Shell side Tube side.

Medium Steam & Drain Feed water

Design Pressure 3 and Full 39 kg/cm2
Vacuum
Design Temperature 155 152 deg C
Test Pressure 4.5 58.5 kg/cm2
Test Temperature Ambient Ambient
Inlet Temperature 126.7 61.89 deg C
Outlet Temperature 106.11 103.83 deg c
No. Of. Passes 2 2
No. Of . Tubes 917
Surface area 1326 m2

LP Heater 3

Type : Shell and Tube

Shell side Tube side.

Medium Steam & Drain Feed water

Design Pressure 4 and Full 39 kg/cm2
Vacuum
Design Temperature 216 152 deg C
Test Pressure 6 58.5 kg/cm2
Test Temperature Ambient Ambient
Inlet Temperature 185.8 103.78 deg C
Outlet Temperature 126.9 124.1 deg C
No. Of. Passes 2 2
No. Of . Tubes 718
Surface are 838 m2

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./033

Plant Area: Turbine

COMMISSIONING PROCEDURE FOR LP HEATERS

STATUS
SL.NO
2.0 OBJECTIVE

To commission drain cooler and three numbers low pressure

heaters and make them available for unit operation.

3.0 PROPOSAL

Commissioning of drain cooler and LP heaters proposed in the

following steps

3.1 Commissioning of drain cooler and LP Heater 1

3.2 Commissioning of LP Heater 2

3.3
Commissioning of LP Heater 3

4.0 SERVICES REQUIRED

4.1 Availability of manpower with required tools for attending any

leak.

4.2 Availability of operating personnel to carry out/coordinate

activities.

4.3 Availability of lighting arrangements and communication facilities

in operating floors.

4.4 Availability of instrument and service air.

4.5 Availability of LT power supply.

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./033

Plant Area: Turbine

COMMISSIONING PROCEDURE FOR LP HEATERS

SL.NO STATUS
5.0 SAFETY PRECAUTIONS

5.1 Debris in and around LP Heaters area shall be removed.

5.2 First aid kit is available near the test area.

5.3 Approach / stair case / platform wherever required are made

available.

5.4 Hand gloves, Helmets, available for operating personnel.

6.0 EMERGENCY PROCEDURES

6.1 The test team should be aware of the procedure to be adopted in

case of damage to machinery / injury of any personnel connected
to the activity.
6.2
The test team should be well aware of the procedures to be
adopted in case of any abnormality in the activity.
7.0
STATE OF THE PLANT
7.1
Drain Cooler and LP Heaters and associated system are erected
as per recommended drawing.
7.2 Detergent flushing of condensate pipelines and Heaters drain
pipes are completed. Pipings are normalized and control valves
are erected.

7.3 Stand pipes, level switches, level transmitters, level gauge glass
are erected as per recommended drawing.

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./033

Plant Area: Turbine

COMMISSIONING PROCEDURE FOR LP HEATERS

SL.NO STATUS
7.4 Erection of start up and continuous vent piping with orifice to
condenser are complete.

7.5 Heaters drain system control valves are commissioned.

7.6 All local and remote instrumentation of Heaters complete.

7.7 Extraction steam isolation valves, Extraction drain valves and

hydraulic assisted quick closing NRVs are commissioned.

Insulation of Heaters, condensate lines, drain lines and extraction

7.8
pipelines are complete.

7.9 Simulation checking of all interlocks and protections are

complete.

7.10 Condensate system charged with CEP in service.

7.11 Vacuum tightness checking completed.

7.12 Turbine ready to start up

8.0 METHOD

8.1 Commissioning of Drain Cooler and LP Heater 1

8.1.1 Drain cooler and LP Heater NO.1 system is made ready before
start up of the turbine.

8.1.2 Ensure condensate inlet to drain cooler is open and outlet of LP

Heater 1 is open. Ensure condensate bypass isolating valve is
closed.

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./033

Plant Area: Turbine

COMMISSIONING PROCEDURE FOR LP HEATERS

SL.NO STATUS

8.1.3 Ensure venting of condensate in water box of drain cooler and LP

Heater 1 with CEP in service.

8.1.4 Ensure drain cooler drain outlet to flash tank isolating valve is
open.

8.1.5 Ensure LP Heater 1 level transmitters, switches are charged.

8.1.6 Ensure LP Heater 1 air vent to condensor is open. (Both

continuous vent and start up vent)

8.1.7 Ensure following protection interlock acting when LP Heater 1

drain level is very high.

a. Normal drain control valve from LPH 2 closes.

b. Condensate side bypasses from heater

ie. Drain Cooler inlet and LPH 1 outlet closes and Bypass
isolating valve opens.

8.1.8 Ensure condensate drain level in LP Heater 1 is maintained

within normal.

8.1.9 Monitor the condensate heat pick up and other parameters as the
turbine started and on loading of turbine and record the
parameters at full load.

8.2 Commissioning of LP Heater 2

8.2.1 Ensure condensate system charged to LP Heater with CEP in

service and condensate inlet, outlet and bypass isolating valves
are kept on auto mode.

8.2.2 Ensure isolating valves for shell drain control valves are open
(Both normal drain and emergency drain)

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./033

Plant Area: Turbine

COMMISSIONING PROCEDURE FOR LP HEATERS

SL.NO STATUS

8.2.3 Open shell side start up vent to condensor.

8.2.4 Ensure Level switches, level transmitters and level gauge glass
are charged.

8.2.5 Ensure extraction oil relay in governing rack is set to operate at

required secondary oil pressure.

8.2.6 Ensure isolating valve in oil line for QCNrV is open and its slide
valve in open position.

8.2.7 Ensure interlock in ATRS for solenoid valve of QCNRV is

checked.

8.2.8 Ensure following interlocks protections on Heater level very high.

a. Extraction steam valve closes.

b. Extraction steam drain valve opens.

c. Bypasses heater on condensate side (Condensate inlet and

outlet valve closes, Bypass valve opens)

d. Normal drain control valve from LPH 3 closes.

e. Emergency drain control valve from LPH 2 to flash tank

opens.

8.2.9 On Synchronising and loading (load more than 10%) check

solenoid for extraction NRV opens.

8.2.10 Keep the normal heater drain valve to LPH 1 open fully.

8.2.11 Charge extraction steam to LPH 2 and observe heat pick up in

condensate outlet of LP Heater 2

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./033

Plant Area: Turbine

COMMISSIONING PROCEDURE FOR LP HEATERS

SL.NO STATUS

8.2.12 Build up Heater level to normal level by closing gradually the

normal drain control valve and keep it on auto.

Keep the emergency drain control valve to flash tank on auto.

8.2.13 Ensure normal level maintained in control room is in line with

levels mentioned in drawing.

Refer drawing number 2-162-22-00096.

8.2.14 Close start up shell vent. Close extraction steam line drain valve.

8.2.15 Observe heat pick up in condensate increases as load increased.

8.2.16 Monitor and record the following parameter at various load / full
load.

a. Extraction Pressure
b. Extraction Temperature
c. Heater Shell Pressure
d. Drain Temperature
e. Condensate inlet Temperature
f. Condensate outlet Temperature
g. Heater level
h. Swing check NRV flap positions.
i. Heater level control valve positions.

8.3 Commissioning of LP Heater 3

Commissioning of LP Heater 3 is carried out in the same way as

done for LP Heater 2. The steps to be followed are same as in
section 8.2

For Heater levels, Refer drawing No. 2-162-26-00070.

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./033

Plant Area: Turbine

COMMISSIONING PROCEDURE FOR LP HEATERS

SL.NO STATUS

The interlock protection on LP Heater 3 level very high are

a. Extraction steam valve closes.

b. Extraction steam drain valve opens.
c. Bypasses heater on condensate side. (Condensate inlet
and outlet valve closes and bypass valve opens)
d. Emergency drain control valve from LPH3 to flash tank
opens.

9.0 COMPLETION CRITERIA

Commissioning of drain cooler and LP Heaters completed by

carryingout the proposals given in Section 3.0

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./033

Plant Area: Turbine

COMMISSIONING PROCEDURE FOR LP HEATERS

COMMISSIONING PROCEDURE FOR

LP HEATERS
4X600MW, JPL, TAMNAR

Signatures

JPL BHEL