KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL / Opr. / HP

Power from knowledge HEATER/ 01
SOP FOR HP HEATERS
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 1 of 9

Standard Operating Instruction

FOR

HP HEATERS

STANDARD OPERATING PROCEDURE FOR HP HEATERS

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Signature: Signature: Signature:
Name: Abinash Mishra Name: Name:
Designation: Assistant Manager Designation: Designation:
 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL / Opr. / HP

Power from knowledge HEATER/ 01
SOP FOR HP HEATERS
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 2 of 9

OBJECTIVE: For Smooth Operation of HP HEATERS

SCOPE: This SOP is applicable for HP HEATERS.

INTRODUCTION:

HP HEATERS
Hp feed water heaters is an important equipment in regenerative system of power plant it uses steam extraction
of the steam turbine to heat boiler feed water and reach the required feed temperature, so as to increase thermal
efficiency and ensure unit output.

HP heater system of this unit adopts single series, horizontal large bypass arrangement, includes 3 HP heaters
( HP heater #1, #2, #3). Each HP heaters consists of 3 zones, Desuperheating, condensing and drain cooling.
HPH # 1,2,3 extractions taken from HP turbine 6th stage, CRH and IP turbine 2nd stage respectively..

HP Heaters Technical Data:-

HP HP HP
HEATER-1 HEATER-2 HEATER-3
THE NUMBER OF EACH UNIT
1 1 1
EQIPMENT
Horizontal Horizontal
Horizontal U-
U-tube U-tube
TYPE tube Surface
Surface Surface
Heating
Heating Heating
TOTAL HEATING AREA m2 2550 2680 2070
FEED WATER AMOUNT t/hr 2060 2060 2060
INLET TEMPERATURE OF FEED
deg C 250.2
WATER 218.9 184.5
OUTLET TEMPERATURE OF FEED
deg C 282
WATER 250.2 218.9
HEATED STEAM PRESSURE Mpa 6.449 3.991 2.271

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Signature: Signature: Signature:
Name: Abinash Mishra Name: Name:
Designation: Assistant Manager Designation: Designation:
 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL / Opr. / HP

Power from knowledge HEATER/ 01
SOP FOR HP HEATERS
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 3 of 9

HEATED STEAM TEMPERATURE deg C 398.4 332.1 469.4

STEAM FLOW t/hr 152.17 127.48 101.32
DRAIN WATER FLOW t/hr 154.809 284.951 388.628
OUTLET TEMPERATURE OF DRAIN
deg C 255.8 224.5 190.1
WATER

OUTLET TEMPERATURE END

deg C -1.7 0 0
DIFFERENCE OF FEED WATER(T.D)

OUTLET END DIFFERENCE OF DRAIN

deg C 5.6 5.6 5.6
WATER
FOLLOW SPEED INSIDE OF THE
m/s 2 2 2
TUBE(15 deg C)
THE NUMBER OF TUBE SIDE FLOW 2 2 2
FEED WATER PRESSURE DROP MPa 0.094 0.094 0.094
DESIGN PRESSURE OF THE SHELL
Mpa(g) 7.24 4.65 2.50
SIDE
DESIGN TEMPERATURE OF THE
TUBE TRAVEL
TUBE SIDE deg C 290 260 230
STEAM INLET deg C 415 354 485
TEST PRESSURE OF THE SHELL SIDE MPa(g) 11.25 7.05 4.05
DESIGN PRESSURE OF THE TUBE
MPa(g) 28 28 28
SIDE
DESIGN TEMPERATURE OF THE
deg C 310 280 250
TUBE SIDE
TEST PRESSURE OF THE TUBE SIDE Mpa(g) 42 42 42

PRECHECKS AND ACTION BY FIELD ENGINEER

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Signature: Signature: Signature:
Name: Abinash Mishra Name: Name:
Designation: Assistant Manager Designation: Designation:
 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL / Opr. / HP

Power from knowledge HEATER/ 01
SOP FOR HP HEATERS
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 4 of 9

S No Description Ok Not Remarks

Ok
1. Work permit on various HP heaters, drip valves, level gauges,
water side valves, NRVs, etc., cancelled and men, material
removed from these areas.  
2. The unit load is around 30 % with both set of auxiliaries
running.(180Mw)  
3. The instrument air is charged to various drip valves and valves
are checked for the operation on auto.  
4. All the pressure gauges, local level gauges, root valves and
various instrument impulses lines are charged or in service.  
5.
The 415 V power to various motorised valves is available.
6.
Keep open all HPHeater vents  
7.
The unit is synchronised and HP/LP bypass valves are closed.  
8.
Open the shell side drains and vents  
9. Ensure that HPH 3, 2, 1 stream charged from water side i.e.  
HPH inlet and outlet valves open with bypass valve closed.
10. Ensure that operation vent of HPH 3,2,1 going to deaerator is
in full open condition  
11. Open the manual valve of drip line from Hp heater -1to
Hpheater-2  

Put HP heater 3 drip to deaerator CV in Auto.

12.

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Signature: Signature: Signature:
Name: Abinash Mishra Name: Name:
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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL / Opr. / HP

Power from knowledge HEATER/ 01
SOP FOR HP HEATERS
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 5 of 9

PRECHECKS AND ACTION BY DESK ENGINEER

S No Description Ok Not Ok Remarks
Work permit on various HP heaters, drip valves, level gauges,
1. water side valves, NRVs, etc., cancelled and men, material
removed from these areas.  
2. The unit load is around 30 % with both set of auxiliaries
running.(180Mw)  
3. The instrument air is charged to various drip valves and valves
are checked for the operation on auto.  
4. All the pressure gauges, local level gauges, root valves and
various instrument impulses lines are charged or in service.  
5.
The 415 V power to various motorised valves is available.  
6.
Keep open all HPHeater vents
7. Maintain boiler pressure is around 10 Mpa by adjusting coal
firing otherwise load comes down as HPH extraction charged.
8.
The unit is synchronised and HP/LP bypass valves are closed.
9.
Open the shell side drains and vents
10. Ensure that HPH 3, 2, 1 stream charged from water side i.e.
HPH inlet and outlet valves open with bypass valve closed.
11. Ensure that operation vent of HPH 3,2,1 going to deaerator is in
full open condition
12.
Open the extraction steam to HPH 3 block valve.
13.
HP heater charging sequence - FIRST-3 ,second-2 & third-1
Open the extraction steam to heater by opening MOV (inching
MOV). Initially open MOV by 10% .Ensure line pressure and
temperature and before NRV steam pressure & temperature
.Give sufficient time for warm-up the line completely. Also
14. observe feed water temperature. The feed water temperature
starts increasing then open the MOV step by step to full open.
Control Main heater level through both emergency drain &
15. normal drain V/V. While charging, close emergency drain V/V
and maintain with normal drain.
Put HP heater 3 drip to deaerator CV in Auto.
16.
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Signature: Signature: Signature:
Name: Abinash Mishra Name: Name:
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 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL / Opr. / HP

Power from knowledge HEATER/ 01
SOP FOR HP HEATERS
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 6 of 9

OPERATING PROCEDURE –

RESPONSIBILITY
Sr.
Description UCE DE FE E
No.
E

1. The unit load is around 30 % with both set of auxiliaries running.

(180Mw).
2. All shell side and water side drain and vents are open condition

3. All drip line manual valve and control vales are open condition

4. The unit is synchronised and HP/LP bypass valves are closed.

5. Ensure that HPH 3, 2, 1 stream charged from water side i.e. HPH inlet and
outlet valves open with bypass valve closed.
6. Ensure that operation vent of HPH 3,2,1 going to deaerator is in full open
condition
7.
Open the extraction steam to HPH 3 block valve.
8.
HP heater charging sequence - FIRST-3 ,second-2 & third-1
9. Open the extraction steam to heater by opening MOV (inching MOV). Initially
open MOV by 10% .Ensure line pressure and temperature and before NRV
steam pressure & temperature .Give sufficient time for warm-up the line
completely. Also observe feed water temperature. The feed water temperature
starts increasing then opens the MOV step by step to full open.
10. Control Main heater level through both emergency drain & normal drain V/V.
While charging, close emergency drain V/V and maintain with normal drain.
11.
Put HP heater 3 drip to deaerator CV in Auto.
12. Check that the heater levels are normal and controller modulates to maintain
level.
13.
Close the Extraction steam line drain valve after NRV.
14.
Check that HPH 3 feed water outlet temperature increases.
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Signature: Signature: Signature:
Name: Abinash Mishra Name: Name:
Designation: Assistant Manager Designation: Designation:
 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL / Opr. / HP

Power from knowledge HEATER/ 01
SOP FOR HP HEATERS
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 7 of 9

15. In the same manner charge HPH 2 and 1 also. Check that drip control
valve LCV maintains the HP heater level.
16.
HPH 2 and 1 outlet feed water temperature increases.
17.
Close the Heater shell side drains and Vents
18 Ensure all drain valve fully closed and no passing. √
SHUTDOWN SEQUENCE:
1. PLANNED SHUTDOWN :
1. Close extraction to the HP Heater gradually. √
√
1
2. Closing sequence FIRST-Hp heater-1,second-2,Third-3

3. close HP Heater I/L & O/LValves . √

2
4. Open Water Side Drains √
√
3
5. Open shell Side Drains √
√ √
4
4. EMERGENCY SHUT DOWN:
1 Causes: √ √
Heater drain control valve are not operating properly so should be checked √
from local.
Due to tube leakage, feed water may enter the H.P heater & increase the level. √
2 Effect: √ √ √ √
If level goes to Hi Hi then water can go to turbine through NRV(if they are √
passing) which lead to turbine blade erosion and damage the blades.
3 Action:

Isolate the extraction steam by closing extraction NRV & MOV.

Heater Emergency drain valve should be opened fully. If still level is not
maintaining then all HPH will be bypassed automatically.

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Abinash Mishra Name: Name:
Designation: Assistant Manager Designation: Designation:
 KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL / Opr. / HP

Power from knowledge HEATER/ 01
SOP FOR HP HEATERS
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 8 of 9

Important Note:-References: KMPCL HP heater EOM Manual.

P&ID of HP heater.
DCS logics

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Signature: Signature: Signature:
Name: Abinash Mishra Name: Name:
Designation: Assistant Manager Designation: Designation: