KSK Mahanadi Power Company Ltd.

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

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

Standard Operating Instruction

FOR

LP HEATERS

STANDARD OPERATING PROCEDURE FOR LP HEATERS

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. / LP

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

OBJECTIVE: For Smooth Operation of LP HEATERS

SCOPE: This SOP is applicable for LP HEATERS.

INTRODUCTION:

LP HEATERS
LP 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.

LP heater system of this unit adopts single series, horizontal large bypass arrangement, includes 4 LP heaters( LP
heater #5 #6 #7&8). Each LP heaters consists of 3 zones, Desuperheating, condensing and drain cooling.

LP heaters Technical Data:-

ITEM Unit LP heater-5 LP heater-6 LP heater-7,8

THE NUMBER OF EACH UNIT EQIPMENT 1 1 1

Type Single horizontal type

Heat-transfer area m2 1050 1050 600

Design temperature of the shell side °C 260 200 150
Design pressure of the shell side MPa 0.6 0.6 0.6
Design temperature of the tube side ºC 170 150 150
Design pressure of the tube side MPa 4 4 4
Difference of upper end °C 2.8 2.8 2.8
Difference of lower end °C 5.6 5.6 5.6

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. / LP

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

PRECHECKS AND ACTION BY FIELD ENGINEER

S No Description Ok Not Remarks
Ok
1. Work permit on various LP heaters, drip valves, level gauges,
water side valves, NRVs, etc., cancelled and men, material
removed from these areas.  
2. The unit is synchronised and LP/LP bypass valves are closed.  
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.
Check that LPH-7A, 8A, 7B, 8B condensate inlet/outlet
valves are in open condition and bypass valve is in closed
6. condition.  
Ensure all the shell side heater vents drain are in open
7. condition.  
Check that all the isolating valves of the LP heater level
8. controllers are full open for all the heaters.  
9. Charge the local level gauges for all the LP heaters.  
Check that LPH-6 condensate inlet/outlet valves are in open
10. condition and bypass valve close.  
LP HEATERS normal & emergency drain to flash tank
11. manual valve should be open .

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. / LP

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

S No
PRECHECKS AND ACTION BYDescription
DESK ENGINEER Ok Not Ok Remarks
18. While making normal drain & emergency drain valve in auto.
S No Description Ok Not Ok Remarks
Check that Emergency control valve set point is 10 or 20 mm
1. Work
higherpermit on various
than normal drainLP heaters,
control dripSovalves,
valve. levelcontrol
that level gauges,
water
done byside valves,
normal NRVs,
drain etc.,valve.
control cancelled and men, material
19. removed from these areas.
Check the condensate temperature after LPH-7A, 8A, 7B, 8B  
2. and
The LPH
unit is6 synchronised
and LPH 5 The andtemperature
LP/LP bypass should gradually
valves are closed.
increase.  
3.
20. The
Closeinstrument
the heaterair is charged
vents to various drip valves and valves
from local.
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. Check that LPH-7A, 8A, 7B, 8B condensate inlet/outlet valves
are in open condition and bypass valve is in closed condition.
7. Ensure the entire shell side heater vents drain are in open
condition.
8. Check that all the isolating valves of the LP heater level
controllers are full open for all the heaters.
9.
Charge the local level gauges for all the LP heaters.
For LPH 7A, 8A and LPH 7B, 8B put the normal drain valve
10. control switch to control mode. The valve starts modulating to
maintain the LP heater level.
11. Check that LPH-6 condensate inlet/outlet valves are in open
condition and bypass valve close.
12.
Open the extraction steam isolating valve to LPH6.
13. Open MOV after NRV & after MOV temperature is almost
same.
14. Put the normal drain valve control switch to auto mode. The
valve starts modulating to maintain the LP heater level.
15. Check the condensate inlet / Outlet valves for the LPH5 are
open and bypass valve closed.
16.
Open the extraction steam isolation valve to LPH5
17. Put the normal drain valve control switch to auto mode. The
valve starts modulating to maintain the LP heater level.

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. / LP

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

OPERATING PROCEDURE –
Sr. RESPONSIBILITY
Description
No. UCE DE FE EE

1. The unit load is around5 % with both set of auxiliaries running.(30Mw).

2. Work permit on various LP heaters, drip valves, level gauges, water side
valves, NRVs, etc., cancelled and men, material removed from these areas.
3.
The unit is synchronised and LP/LP bypass valves are closed.
4. The instrument air is charged to various drip valves and valves are checked
for the operation on auto.
5. All the pressure gauges, local level gauges, root valves and various
instrument impulses lines are charged or in service.
6.
The 415 V power to various motorised valves is available.
7. Check that LPH-7A, 8A, 7B, 8B condensate inlet/outlet valves are in open
condition and bypass valve is in closed condition.
8.
Ensure all the shell side heater vents drain are in open condition.
9. Check that all the isolating valves of the LP heater level controllers are full
open for all the heaters.
10.
Charge the local level gauges for all the LP heaters.
11. For LPH 7A, 8A and LPH 7B, 8B put the normal drain valve control switch
to control mode. The valve starts modulating to maintain the LP heater level.

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. / LP

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

12. Check that LPH-6 condensate inlet/outlet valves are in open condition and
bypass valve close.
13.
Open the extraction steam isolating valve to LPH6.
14.
Open MOV after NRV & after MOV temperature is almost same.
15. Put the normal drain valve control switch to auto mode. The valve starts
modulating to maintain the LP heater level.
16. Check the condensate inlet / Outlet valves for the LPH5 are open and bypass
valve closed.
17.
Open the extraction steam isolation valve to LPH5
18 Put the normal drain valve control switch to auto mode. The valve starts
√
modulating to maintain the LP heater level.
19. While making normal drain & emergency drain valve in auto. Check that
Emergency control valve set point is 10 or 20 mm higher than normal drain
control valve. So that level control done by normal drain control valve.
20. Check the condensate temperature after LPH-7A, 8A, 7B, 8B and LPH 6 and
LPH 5 The temperature should gradually increase.
21. Close the heater vents from local.

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. / LP

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

PLANNED SHUTDOWN :
1. √
Close extraction check valve. √
1
2.
Close extraction MOV
3. √
Close inlet and outlet valves of condensate water of respective LPH.
2
4. Before taking LPH out from service ensure LPH bypass MOV (water side) is √
√
3 open.
5. √
Close extraction check valve. √ √
4
EMERGENCY SHUT DOWN:
1 Causes: √ √
Heater drain control valves are not operating properly so should be checked √
from local.
Due to tube leakage, condensate may enter the LPH & increase the level. √
2 Effect: √
If level goes to HH then water can go to turbine through NRV (if they are
passing) which leads to turbine blade erosion.
3 Action:
Heater emergency drain valve should be opened fully .If still level is going high,
the corresponding LPH will be bypassed from steam & water side automatically
(water side bypass valve will be open in auto).

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

P&ID of LP heater.
DCS logics

Prepared by: Reviewed by: Approved by:

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