KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/VCS/01

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SOP For Vacuum Conveying System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 1 of 8

STANDARD OPERATING INSTRUCTION

FOR

VACUUM CONVEYING SYSTEM

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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/VCS/01

Power from knowledge
SOP For Vacuum Conveying System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 2 of 8

SOP FOR DRY ASH VACUUM COVEYING SYSTEM

OBJECTIVE: For Smooth Operation of Dry ash vacuum conveying system.

SCOPE: This SOP is applicable for 6x600MW unit ESP & FF Ash conveying up to Buffer
hopper ash transportation system.

INTRODUCTION: This System is needed to evacuate fly ash from ESP & FF Hopper to Buffer
hopper through Negative air pressure, this system called as fly (Dry) ash vacuum conveying system.

DRY ASH VACUUM COVEYING SYSTEM TECHNICAL DATA:-

Vacuum pump NASH Quantity 48 NOS

No’s of pipe lines in 04/unit Pipe size 300
each unit
Total pass 04/unit Total pump 08/unit (4 in service & 4
standby )
Capacity 50t/h / pass Total capacity 200t/h
Auxiliary required for operation:-
Air compressor For instrument air Air Dryer
Fluidizing blower Silo ventilation system Dust collector Valves

RESPONSIBILITY: Desk Engineer and Field Engineer.

SAFTEY PRECAUTIONS:
1. Ensure no permit to work is pending on regarding this system by checking with EE/MRSE.

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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/VCS/01

Power from knowledge
SOP For Vacuum Conveying System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 3 of 8

SAFTEY PPE’s: Ear Plugs, Safety Goggles, Hand Gloves, etc.

PRECHECKS ON FIELD ENGINEER

S No Description Ok Not Ok Remarks

1 Work permit on APH, ESP, FF, Collecting tower (Buffer

hopper system), Fluidizing Blower & Heater, Vacuum pumps,
Vacuum header lines, ,Ash conveying pipe lines are all
closed from the respective concerned department.

2 Ensure that all the manual fluidizing valves, the manual

pulsing air ball valves, Instrument air supply to the entire
local panel box are open.

3 Check fluidizing blower running & heater is in service.

4 Check all fluidizing line header valve open.

ESP / FF Hopper manual discharge valve below adapter

5 should be open.

6 Seal water pump is running for vacuum pump sealing.

Seal water pipe line manual valve should be open & seal
7 water pressure normal.

8 Vacuum line header valve open.

Check vacuum chamber dust collector purging system is in

9 service.

PRECHECKS AND ACTION BY DESK ENGINEER

S No Description Ok Not Ok Remarks

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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/VCS/01

Power from knowledge
SOP For Vacuum Conveying System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 4 of 8

Work permit on APH, ESP, FF, Collecting tower (Buffer

hopper system), Fluidizing Blower & Heater, Vacuum
pumps, Vacuum header lines, ,Ash conveying pipe lines are
1 all closed from the respective concerned department.

2 Ensure power supply to all the equipment’s is healthy.

Check Instrument air compressor is running, dryer is in

3 service & receiver tank air pressure normal.

4 One no Fluidizing blower is in running & heater is in service.

Check Buffer hopper ventilation system is in service & vent

5 fan is running.

6 Check vacuum breaker is open.

Check seal water pump is running for vacuum pump

7 sealing.

OPERATING PROCEDURE -
Sr. RESPONSIBILITY
Description
No. DE FE EE
PRE- START CHECKS:
1 All permits and cross permits have been returned.
2 Power supply and control power supply of all relevant auxiliary available.

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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/VCS/01

Power from knowledge
SOP For Vacuum Conveying System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 5 of 8

3 Buffer hopper ventilation system is running.

4 At least one fluidizing blower is running.
5 Instrument air compressor is running.
6 Start one no vacuum pump for one stream.
7 Vacuum chamber purging system is in service.
START PERMISSIVE :
1 Buffer hopper ash level normal.

2 Buffer hopper DP normal.

3 Buffer hopper ventilation (vent filter & fan) system running.

4 Vacuum chamber purging system is in service.

5 Receiver tank air pressure normal.

6 Vacuum header pneumatic isolation valve open.

7 Vacuum breaker open.

8 One no vacuum pump running for one steam.

DRY ASH VACUUM COVEYING SYSTEM START UP SEQUENCE :

1 Check instrument air pressure normal.
2 Start seal water pump for vacuum pump sealing.
3 Start fluidizing air blower one no.
4 Start Buffer hopper ventilation fan & bag filter purging system.
5 Start one no vacuum pump for one stream.
6 Select all system in remote mode.
7 Start system in auto mode.
8 Closed vacuum breaker
SHUTDOWN SEQUENCE:

1. PLANNED SHUTDOWN :

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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/VCS/01

Power from knowledge
SOP For Vacuum Conveying System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 6 of 8

1 The dry ash vacuum conveying system can be shut down only after the
buffer hopper level high & ESP /FF hopper level low or hopper empty.
2 First to flush the blow tank & conveying line to insure no ash in blow tank &
ash conveying line before stopping system.
3 After stopped the system stop transport air compressor.

4 Stop silo ventilation system.

5 Stop fluidizing blower.

2. EMERGENCY SHUT DOWN:

1 There is the apparent abnormal condition during operation.
2 Silo ventilation system suddenly stop or trip.
3 Silo ash level high.
4 When endangering the safety of person and equipment.

INTERLOCKS : Remarks

1 Silo ventilation system suddenly stop or trip.

2 Separator & silo ash level is high
3 Instrument air pressure low.
4 Separator D.P. is high.

ABRIVIATIONS / NOTATIONS:-
o SOP: Standard Operating Procedure

o UCE: Unit Control Engineer

o DE: Desk Engineer

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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/VCS/01

Power from knowledge
SOP For Vacuum Conveying System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 7 of 8

o FE: Field Engineer

o EE: Electrical Shift Engineer

DO’s & DONT’s :

DO’s :

1. During ESP/FF Hopper de-ashing, periodically check that clear water is coming out from the Vacuum
Pumps.

2. Ensure Instrument Air Header pressure is OK for Filter Separator pulsing.

3. Ensure that Fluidisng air valves of the Ash Hoppers are continuously in open condition and adequate
temperature is available.

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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/OPR/VCS/01

Power from knowledge
SOP For Vacuum Conveying System
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 8 of 8

4. Before starting/during running, ensure that the vacuum path is properly sealed without any leakage.

5. Ensure Pulsing sequence is working properly.

DONT’s :

1. Don’t use air with moisture content for Filter Separator Pulsing (i.e. recommended dew point is to be
properly monitored).

2. Don’t disturb the vacuum setting recommended by OEM.

3. Don’t run the vacuum system if DP is continuously high.

4. Don’t run the vacuum system if Filter Separator level is continuously high.

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