E39 Ahsop 01

Utkal Alumina International Limited STANDARD OPERATING
(A Unit of Hindalco Industries Limited); PROCEDURE

Doraguda Auxiliary Circulating
PO : Kucheipadar; Dist. Rayagada, Water Pump
Odisha - 765015,India
SECTION OPERATION DOCUMENT OWNER HEAD - OPERATION
SOP Gland Steam Cooler Date: SOP NUMBER / DOC ID EDITION / REVISION
UAIL/CGPP/OPN/T12 2/1
Prepared By Issued By Approved By
Operation Executive I/C CGPP Operation HOD
1. Purpose:
The purpose of SOP for “Fly Ash Conveying” is to train and guide operation personnel for optimum
and safe operation of the system.
2. Scope:
Head (Operation) is responsible for implementation of this SOP so as to ensure safe and efficient
operation of the system. This SOP defines the lineup, pre checks, permissive, operation
procedure, Post startup checks, interlocks & protections For Fly ash conveying from ESP to silo. It
is applicable for Unit 1 to 6.
3. Responsibility matrix:
Desired output /
Sl. No Jobs Responsibility Competency
Efficiency
To decide the need of ESP
1 Distribution Head - Operation Hopper evacuation
Knowledge of entire fly ash To evacuation of fly
Shift In Charge
conveying process ash from ESP Hopper
Knowledge for Fly Ash and maintain
Desk Engineer Conveying Start Up and optimum ESP Level
2 Compliance
Operation for ensuring normal
Field Knowledge for Fly Ash operation
Field Operator Conveying Start up and
Operation
4. Environment health & safety matrix
Environmental
Hazards Safety Precautions PPE's Required
Consideration
PULVERJHSAXHHXHXHHHXWHRRFL
1.Human injury if 1. Dusty 1.Ensure PTW returned

Wrong Fly Ash environment due to 2. Tags available on all
system switched fly ash leakage Fly Ash systems
'ON" High emission from mentioning Equipment
2.Fall / slip Person stack name.
3.Burn due to 3. System area is made
spillage of hot fly free of unwanted
ash material.
5. Legal & regulatory requirements: Not applicable
For clause 6, 7,8,9,10,11 Refer Annexurexure
For Aditya: ANN_AAP_E39_AHSOP_01

- For Dahej : NA
- For Hirakud : ANN_HKD_ E39_AHSOP_01
- For Mahan : ANN_MAH_ E39_AHSOP_01
- For Muri : ANN_MUR_ E39_AHSOP_01
- For Renukoot : ANN_RKT_ E39_AHSOP_01
- For Renusaga: ANN_RPD_ E39_AHSOP_01
- For Utkal : ANN_UAL_ E39_AHSOP_01
6. O&M Parameter: Refer Annexure
7. Checks before Start Up: Refer Annexure
8. Start Sequence: Refer Annexure
9. Check points During Fly ash conveying: Refer Annexure
10. SHUTDOWN SEQUENCE: Refer Annexure

11. Best Practices followed(If any): Refer Annexure
12. Exception/ Emergency Handling: Refer Annexure
13. KPI (Key Performance Indicators): Refer Annexure
14. Dos & Don’ts:
Dos DON’Ts
1. Check Conv and Inst 1. Start the system without selection of Dump or Bypass valve at fly ash
air pressure. silo.
2. Bypass any interlock and protection at any time.
2. Check any ash or air
leakages from system.
15. Abbreviation:
Sl. No. Abbreviation Used Stands For

1 ESP Electrostatic precipitator
For Aditya: ANN_AAP_E39_AHSOP_01
6. O & M parameters
1. No. & Capacity: 3nos of buffer hopper, 2no running & 1no stand by condition.
2. 3nos of vacuum pump, 2no running & 1no stand by condition
3. 2nos of FATAC compressor, 1no running & 1no stand by condition.
4. 3nos of IAC compressor, 2no running & 1no stand by condition.
5. 2no of conveying line, 1no running & 1no stand by condition.
6. 1no of fly ash silo vent fan.
7. Checks before start up

7.1 Physical Checks
1. Open all isolation valves of instruments.
2. Check seal water line respective IA Compressor & FATAC compressor.
3. Vacuum seal water tank level.
4. Vacuum pump seal water line v/v open condition.
5. Buffer hopper should be boxed up.
STARTING PERMISSIVE:
7.2 Permissive for start up

1. Electric switchgear power supply OK.
2. Ready to start.
3. Vacuum Pump & vacuum seal water pump in remote.
4. Conveying line cross over v/v open condition.
5. Conveying line silo input v/v should be open condition.
6. Fly ash vent fan running condition respective select fly ash silo.
7.3 Interlocks & Protections

1. Motor protection for over load.
2. Vacuum breaker open at vacuum 400mmhg.
3. Compressor unload at conveying line pressure > 1.8kg/cm2.
4. Air lock tank sequence stop at convening line pressure >1.5kg/cm2.
8. Startup sequence
1. Start IA Compressor & IA Dryer and confirm more than 06 kg/cm2.
2. Start vacuum seal water pump.
3. Select fly ash conveying line by opening cross over v/v.
4. Start selected silo vent fan & confirm pulse jet solenoid v/v sequence is running.
5. Start selected Fa transport air compressor.
6. Keep line flushing for 5-10min & ensure the line pressure drop 04-05kg/cm2, ensure the buffer
hopper & line is empty.
7. Select the buffer hopper & pulse jet solenoid v/v sequence is running.
8. Start air lock tank sequence.
9. Open the vacuum pump seal water line v/v & ensure the water flow.
10. Start the selected vacuum pump.
11. Check line vacuum 230-250mmhg & shut up vacuum 380-400mmhg.
12. Open the buffer hopper selection v/v.
13. Keep ESP hopper valve opening at vacuum 230mmhg & ESP hopper valve closing at vacuum
120mmhg.
14. Start ESP hopper evacuation sequence by material handling v/v.
9. Operation monitoring & control

1. Check for abnormal noise, if any.
2. Check for any abnormal sound or vibration from vacuum pump, seal water pump, FATAC & IA
compressor.
3. Check for oil & water leakages, if any.
4. Check buffer hopper ash level.
5. Check conveying line leakage.
10 Shutdown Procedure
1. Ensure that ESP hopper should be empty & stop the ESP hopper sequence.
2. Flush the ESP conveying pipe by vacuum pump.
3. After flush the pipe, open the vacuum breaker.
4. Stop the vacuum pump & close the seal water line valve.
5. Ensure the buffer hopper & air lock tank empty.
6. Stop the air lock tank sequence after empty the buffer hopper & air lock tank.
7. Flush the ash conveying line by compressor air.
8. Stop the seal water pump & close the discharge/suction valve.
9. Unload & Stop the respective FATAC compressor after conveying line pressure 0.4-0.5kg/cm2
& close the compressor seal water line.
10. Close all isolation valves of instruments
11. Unload & Stop the IA compressor, dryer & close the seal water line v/v.
11 Best practices followed (If any):
1. In Each shift main /common fly ash conveying line taken in service for ensuring no chocking.
12. Exception/ Emergency handling :

It is necessary to shut down the Vacuum seal water pump in case of emergency
1. Fly ash conveying leakage.
2. Respected compressor trip.
3. Fly ash vent fan trip.
4. Instrument compressor trip.
13. Dos & Don’ts

DO’s DON’Ts
1. Don’t start compressor without open the
1. Ensure ash conveying proper. isolation v/v.
2. Ensure no oil and water leakage is 2. Don’t start ash conveying without open the
present. cross over valve & fly ash silo input valve.
3. Ensure check any vibration. 3. Don’t start vacuum pump without seal water
4. Ensure ash evacuation proper ESP line water flow.
hopper.
4. Don’t start air lock tank sequence without
5. Maintain line vacuum 240-250mmhg.
conveying line pressure
14 Performance KPIs
 At 150 MW:
o Esp hopper empty : 180min
- For Hirakud : ANN_HKD_ E39_AHSOP_01
6. O & M parameters:
 No. & Capacity: 2 per unit, each with 100% Unit Load
 Pump Details
Sl No. DESCRIPTION CONVEYING COMPRESSOR
1 AIR COMPRESSOR CHICAGO PNEUMATIC
RECIPROCATING
2
CAPACITY, CFM 1273
3
DISCHARGE PR. KG/CM2 4
4
SPEED, RPM 750
MOTOR
1
POWER, KW / HP 180 / 220
2
VOLTAGE V 415
3
SPEED, RPM 1470
4
CURREN, AMP
5
INSULATION CLASS

7.1 Physical check:
1 Both the start/stop selector switches (in the master vessel pneumatic panel & control panel) are kept
in start position.
2 Receiving silo level is not high.
3 All dome valves seal pressures are O.K. (should be higher than conveying air pressure)
4 Vessel pressure is low (Approx. 0.3 kg/cm2).
5 Conveying air pressure O.K. (between 3.5 kg/cm2 to 4.0 kg/cm2)
6 Silo vent bag filter should be in service
7 ESP blower should be in running mode (if applicable).
8 Ensure that Conveying Line Outlet Dump or Bypass valve on FA Silo in Open Condition.
7.2 Permissive for start up:

1 Instrument Air at minimum 5.2 kg/cm2 should be available.
2 The oil level in each lubricator placed beside vessel should be normal.
3 The oil level of every fluidizing blower should be normal (If applicable).
4 The Discharge valve of the blower should be open (If applicable).
5 Air isolation valve of compressed air line should be open.
6 Fluidizing air valve of fluidizing pad should be open.
7.3 Interlocks & Protections:

Interlocks Protection
1. If seal fails, conveying will stop and cycle will 1. Conveying air pressure should be >3.2
not start. kg/cm2.
2. If conveying air pressure is not O.K., cycle will 2. Dome valve seal pressure >5.2 kg/cm2.
not start.
3. If line block indication appears, next cycle will
not start.
4. If ash vessel pressure is high >3 kg/cm2, cycle
will not start.
5. Conveying air blow valve will not close unless
vessel pressure is 0.3 kg/cm2.
8. Startup sequence
1 Start conveying air compressor as mentioned above.
2 Start fluidizing air blower (If applicable) & ESP hopper heater.
3 Place the start/stop selector switches (in the pneumatic panel & control panel in start position).
4 Instantaneously, the seal O.K. indication stops glowing and dome valves operation. Now the ash
from hoppers comes into the ash vessels.
5 As per requirement, conveying should be operating in probe-mode or timer-mode.
6 After the expiry of preset time, dome valves close and seal OK glows. As a consequence, conveying
air blow valves open and conveying of ash starts from vessel to respective silos.
7 Conveying air blow valve closes as soon as the master vessel pressure decreases to 0.3 kg/cm2.
8 This cycle repeats and the "Counter" records the number of cycles operated.
9. Operation monitoring & control

Line Block Indication
In case line blocks due to collection of ash in conveying line, vessel pressure rises above 3 kg/cm2
(approx.) and line block indication appears on the panel.
Action
- Close the air valve of ash conveying line.
- Open the vent of the vessel to reduce its pressure to zero.
- Close the vent and purge the line by opening the air valve.
SEAL FAIL
Reasons
- Pressure switch may be defective.

- Dome valve may not be closing properly.
- Instrument air pressure may be low.
- Dome seal may be damaged.
10. Shutdown Procedure:

1 If the vessel pressure just after opening of air blow valve remains only about 0.3 kg/cm2, it
indicates that ESP hoppers are totally evacuated.
2 Now position the start/stop selector switch to stop position and stop the fluidizing air blower
and conveying air compressor simultaneously.
11. Best practices followed (If any):

 Before the start of Fly ash conveying, line Purging is ensured for safe operational perspective.
12. Exception/ Emergency handling:

 If line blocks due to collection of ash in conveying line, vessel pressure rises above 3 kg/cm2
(approx.) and line block indication appears on the panel. Close the air valve of ash conveying
line Open the vent of the vessel to reduce its pressure to zero
13. Dos & Don’ts
DO’s DON’Ts
1. Ensure all permissive and protections are in Stop the procedure before empting the ESP hoppers
service. Bypass any interlock and protection at any time.
2. Monitor vibrations.
14. Performance KPI’s
KPI Action Taken

Before stop of fly ash conveying system ensure by If hopper not found empty then continue fly ash
manual checking ESP hopper emptiness through conveying.
hopper vent.
15.Abriviation-
- For Mahan : ANN_MAH_ E39_AHSOP_01

6 O&M parameter
 No. & Capacity: Total 6 ESP
 System Details:
Sl No. DESCRIPTION
Unit
Conveying Air Compressor
1 Make Atlas Copco

2 Type Two Stage Screw Compressor
3 M3/min
CAPACITY 70
4 bar
Discharge Pressure (max) 7.5
MOTOR
1 KW
POWER 425
2 V
VOLTAGE 6600
3 AMP
CURRENT 46
4 RPM
SPEED 1489
Instrument Air Compressor
1 Make Atlas Copco
2 Type Two Stage Screw Compressor
3 M3/min
CAPACITY 9.0
4 bar
Discharge Pressure (max) 7.5
MOTOR
1 KW
POWER 75
2 V
VOLTAGE 415
3 AMP
CURRENT 123
4 RPM
SPEED 2965
7 Checks before Start Up:
1. Ensure all permits and cross permit on the system have been returned.
2. Local Start selector switch is “ON” condition.
3. Selected fly Ash silo level is not high.
4. Conveying Air Isolation valves of all system should be opened and conveying air pressure
ok. (>3.5 kg/cm2)
5. All dome valves seal pressures are ok. (>5.5 kg/cm2)
6. Vessel pressure is low (Approx. 0.3 kg/cm2).
7. Ensure FATAC Receiver inlet/outlet valves in OPEN condition.
8. Ensure that Conveying Line Outlet Dump or Bypass valve on FA Silo-1, 2&3 (Selected) in
Open Condition.
9. Vent Filter purging in ON condition.
7.1 Physical Checks
7.2 Permissive for Start Up:
1. Ensure conveying air pressure should be 5.0-5.5 kg/cm2.

2. Ensure Instrument Air Pressure should be 6.0-6.5 Kg/cm.
3. Ensure Dome Seal pressure should be healthy in scada.
4. Ensure conveying air pressure should be healthy in scada.
5. Check cycle preset timer of conveying system in scada.
6. The oil level in each Air lubricator placed beside vessel should be normal.
7.3 Interlocks & Protections:
not start. kg/cm2.
2. If conveying air pressure is not ok, cycle will 4. Dome valve seal pressure >5.5 kg/cm2.
not start.
3. If line block indication appears, next cycle
will not start.

4. If ash vessel or conveying line pressure is
high >3.0 kg/cm2, cycle will not start.
5. Conveying air blow valve will not close
unless vessel pressure is 0.3 kg/cm2.
6. Conveying line switch valve open/close limit
feedback.
8 Start Sequence:
1. Start conveying air compressor as mentioned above.

2. Start local selector switch.
3. As per requirement, conveying should be operating in probe-mode or timer-mode.
4. Fill time in cycle preset timer block of conveying system in scada.
5. Press Start button from scada.
6. Instantaneously, First conveying line purging will start and then dome valves operate. Now
the ash from hoppers comes into the ash vessels.
7. After the expiry of preset time, dome valves close and seal OK glows. As a consequence,
conveying air blow valves open and conveying of ash starts from vessel to respective silos.
8. Conveying air blow valve closes as soon as the master vessel pressure decreases to 0.3
kg/cm2.
9. This cycle repeats and the "Counter" records the number of cycles operated.
9 Operation monitoring & control:
1. Check for any Dome valve seal fail (<5.5 kg/cm2).

Reasons-
a. Pressure switch may be defective.
b. Dome valve may not be closing properly.
c. Instrument air pressure may be low.
d. Dome seal may be damaged.
2. Check for any system conveying air fail alarm (<3.5 kg/cm2).
3. Check for any system line blockage (>3.5 kg/cm2).
In case line blocks due to collection of ash in conveying line, vessel pressure rises above 3.5
kg/cm2 (approx.) and line block indication appears on the scada and system will stopped.
Action-
a. Open the vent of the vessel to reduce its pressure to zero.
b. Close the vent and purge the line by purging with starting of system
4. Check for any ash or air leakages from any system.
10 SHUTDOWN SEQUENCE:
1. Flush the fly Ash conveying Line till line pressure reaches <0.3 kg/cm2.
2. STOP the conveying system by pressing stop button from scada.
11-Best Practices Followed

12Exception/ Emergency Handling:
If line blocks due to collection of ash in conveying line, vessel pressure rises above 3 kg/cm2
(approx.) and line block indication appears on the panel. Stop the system and Open the vent of the
vessel to reduce its pre
- For Muri : ANN_MUR_ E39_AHSOP_01

6 O&M Parameter
 No. & Capacity: 2for fly ash and bed ash for two nos of boiler.
 Pump Details
Sl No. DESCRIPTION CONVEYING COMPRESSOR
RECIPROCATING
2
CAPACITY, CFM 1022
3
DISCHARGE PR. KG/CM2 4.0
4
SPEED, RPM 907
MOTOR
1
POWER, KW / HP 132/92.4
2
VOLTAGE V 415
3
SPEED, RPM 1485
4
CURREN, AMP 228
5
INSULATION CLASS F
7 Checks before start up

in start position.
7.1 Physical Checks


1. If seal fails, conveying will stop and cycle will 5. Conveying air pressure should be
not start. >3.2kg/cm2.
not start.
not start.
will not start.
8 Start Sequence
2 Start ESP hopper heater.
9 Operation monitoring & control:

Action
SEAL FAIL
Reasons

10 Shutdown
11Best Practices followed:
1. Before the start of Fly ash conveying, line Purging is ensured for safe operational perspective.
12 Exception/ Emergency Handling:

(approx.) and line block indication appears on the panel. Close the air valve of ash conveying line
Open the vent of the vessel to reduce its pressure to zero
13 Dos & Don’ts

DO’s DON’Ts
- For Renukoot : ANN_RKT_ E39_AHSOP_01
 Applicable to Unit B#1&2

 Scope : This annexure covers the 6,7,8,10 & 12 clauses of SOP : E39_AHSOP_01
6.Technical specification
 Equipments Detail
Sl No. DESCRIPTION CONVEYING AIR MECH
BLOWER EXHAUSTER
1 KVM - 600
TYPE/ MODELl RH - 80
2
CAPACITY, 2000 m3/hr 50 m3/min
3
DISCHARGE PR. KG/CM2 0.8 Kg/Cm2 500 mm Hg
4
SPEED, RPM 1011 550 rpm
MOTOR
1
POWER, KW / HP 90 / 120 90 / 120
2
VOLTAGE V 415 415
3
SPEED, RPM 1485 1485
4
CURRENT, AMP 155 155

1. Before the system are put into operation the following of must be applied-
(a) Purge air to bag filter
(b) Cooling water to air blower(>0.8kg/cm2)
(c) Sealing water to mechanical exhauster (1.2 to 1.7 kg/cm2)
(d) Put Mach Exhauster & Air blower in series for particular boiler deashing.
2. Select the Silo & IMT Tank .Open Ash discharge line isolating valves near Silo accordingly.
7.1-Physical Checks
7.2. Permissive for start up

8-.Operation monitoring & control

1 Start air blower & ensure ash conveying line is clean.
2 Switch ON the IMT tank TIMER on control panel as soon as system is put in operation the collector
cycle timer energized.
3 Select the Boiler for which de ashing to be done and open Segregating valve accordingly.
4 Start mechanical exhauster as soon as exhauster start isolation valve open and vacuum breaker will
close.
5 Due to closing of vacuum breaker, the vacuum rises in fly ash line can be observed on the Vacuum
gauge.
6 When shut off vacuum reaches above -400 mmHg then open Ash Hopper Valve from control panel.
7 Fly ash is now being conveyed from the hopper through the fly ash line to the chamber of the
Intermediate transfer tank.
8 The conveying air then passes through the bag filter when the entrained ash particles removed &
clean air is released in the atmosphere through mechanical exhauster.
9 When the fly ash hopper is emptied air is conveyed from the hopper and vacuum falls down up to -
25 mmHg. Ash hopper valve to be closed.
10 Remaining Hoppers are identical and it should be operate as per above procedure.
11 Stop the mechanical exhauster. Stop the air blower and make sure that the conveying line is clean.
12 Close segregating valve of respective and open another Boiler Segregating valve
10. Shutdown
1 Close the Hopper isolating valve.
2 Close the segregating valve of respective path.
3 After at least 5 Cycles of IMT timer we can stop the IMT Timer
4Watch the Air blower current and stop it when current comes approx. its no load current i.e. 50-60
Amps.
11Best Practices followed:
2. Before the start of Fly ash conyeing, line purging is ensured for safe operational perspective.
12 Exception/ Emergency Handling:

13 Dos & Don’ts

DO’s DON’Ts
 Applicable to Unit B#3

 Scope: This annexure covers the 6, 7,8,10 & 12 clauses of SOP: E39_AHSOP_01
6. Technical specification
Sl No. DESCRIPTION CONVEYING AIR MECH
BLOWER EXHAUSTER
1 KVM - 600
TYPE/ Model RH - 80
2
CAPACITY, 2000 m3/hr 50 m3/min
3
DISCHARGE PR. KG/CM2 0.8 Kg/Cm2 500 mm Hg
4
SPEED, RPM 1011 550 rpm
MOTOR
1
POWER, KW / HP 90 / 120 90 / 120
2
VOLTAGE V 415 415
3
4
CURRENT, AMP 155 155

2. Purge air to bag filter
3. Cooling water to air blower(>0.8kg/cm2)
4. Sealing water to mechanical exhauster (1.2 to 1.7 kg/cm2)
5. Put Mach Exhauster & Air blower in series for particular boiler de ashing.
8. Permissive for start up

10. Operating procedure

1. Start air blower & ensure ash conveying line is clean.
close.
gauge.
15 When shut off vacuum reaches above -400 mmHg then open Ash Hopper Valve from control panel.
11. Checks during running

In case line blocks due to collection of ash in conveying line, conveying line pressure rises above 1
kg/cm2 (approx.) and Air blower trips
Action
- Open the vent of the Conveying line to reduce its pressure to zero.
- Again start Air Blower to flush/purge the conveying line.
- Close the vent after cleaning the fly ash conveying line.
SEAL FAIL
Reasons
12. Shutdown
8 Watch the Air blower current and stop it when current comes approx. its no load current i.e. 50-60
Amps.
 Applicable to Unit B#4
 Scope: This annexure covers the 6,7,8,9,10,12,15 & 17 clauses of SOP: E39_AHSOP_01
1. Plant Air Vessel Pressure should be 5 Kg/Cm2
2. Inst Air Pressure should be 5 Kg/Cm2
in start position.
7 ESP Fluidizing Air blower should be in running mode.
8 Ensure that Conveying Line Outlet valve in Open Condition.
8. Permissive for start up

2 Ash Plant Air Vessel Pressure should be >4.5 kg/cm2
9. Interlocks & Protections

not start. kg/cm2.
not start.
not start.
will not start.

Operating Procedure for Hoppers A, B,C,D,& E
1. Select separate Fly ash START / STOP selector switch for Hopper A & B to START position. Red
lamp ON indicates the starting of Fly ash system for selected ash hoppers .Manual Air Inlet Valve
and Ash discharge line valve should be OPEN.
2. Dome valve for selected group of Hoppers opens for preset time and ash falls by gravity into the
vessels and closed after a preset time.
3. Air Inlet Valve (AIV-A) opens for preset time and Fly ash is conveyed to Silo for a preset time.
Remaining Hoppers Hopper ‘C & D’ & Hopper E are identical and it should be operate as per above
procedure one by one.
Operating Procedure for Hoppers F,G,H & I
1. Select Fly ash START/STOP selector switch - F to START position.

2. Pressure Equalizing Valve – F (PEV-F) and Dome Valve-F(DV-F) should open and remain open for
preset time at Sequential Timer.
3. Pressure Equalizing Valve – F (PEV-F) and Dome Valve-F(DV-F) closes and Air Inlet Valve(AIV-
F) opens.
4. The Dry ash is conveyed to Ash Silo from Densveyor hopper for preset time.
5. Air Inlet Valve (AIV-F) closed and the Dome Valve and PEV open.
6. In this way this cycle is repeated until ash hoppers are not emptied.
7. During valves operation it should be physically checked by Operator it is not in sequence it should
be attended by maintenance section.
Remaining Hoppers are identical and it should be operate as per above procedure.
13 . Shutdown
14.. Exception/ Emergency Handling:

.
15. Abbreviation:

2 DV Dome Valve
3 PEV Pressure Equalizing Valve
4 AIV Air Inlet Valve
For Renusagar: ANN_RPD_ E39_AHSOP_01

 Applicability to generating unit(s) : unit #1 to #10
 Scope : This annexure covers the 6 to 15 clauses of SOP E39_AHSOP_01
 No. & Capacity: 2 per unit, each with 100% Unit Load
Sl No. DESCRIPTION CONVEYING ESP BLOWER
COMPRESSOR
RECIPROCATING
2
CAPACITY, CFM 847.2 181
3
DISCHARGE PR. KG/CM2 4 0.6487
4
SPEED, RPM 715 1300
MOTOR
1
POWER, KW / HP 110 / 150 7.5 / 10
2
VOLTAGE V 415 415
3
4
CURREN, AMP 185 14.5
5 NA
INSULATION CLASS F

7.1 Physical Check ups
in start position.
7 ESP blower should be in running mode (if applicable).
8 Ensure that Conveying Line Outlet Dump or Bypass valve on FA Silo in Open Condition.


not start. kg/cm2.
not start.
not start.
will not start.
2 Start fluidizing air blower (If applicable) & ESP hopper heater.
9. Checks during running

Action
SEAL FAIL
Reasons

10. Shutdown
11. Dos & Don’ts

DO’s DON’Ts
12. Best Practices followed:

3. Before the start of Fly ash conyeing, line Purging is ensured for safe operational perspective.
13. Exception/ Emergency Handling:

.
14. KPI (Key Performance Indicators):
KPI Action Taken

Before stop of fly ash conveying system If hopper not found empty then continue
ensure by manual checking ESP hopper fly ash conveying.
emptiness through hopper vent.
15. Abbreviation:

- For Utkal : ANN_UAL_ E39_AHSOP_01
6. O&M PARAMETERS - 3NO(2Running +1 standby)
Sl No. DESCRIPTION CONVEYING AIR BLOWER
1 AIR COMPRESSOR Cameron air compressor
2
CAPACITY, CFM 1600m3/hr
3
DISCHARGE PR. KG/CM2 8
4
SPEED, RPM 2960
MOTOR
1
POWER, KW / HP 75
2
VOLTAGE V 415
3
SPEED, RPM 2978
4
CURREN, AMP 130
5
INSULATION CLASS F

7.1 PHYSICAL CHECKS
a. Purge air to bag filter
b. Cooling water to air blower(>0.8kg/cm2)
c. Sealing water to mechanical exhauster (1.2 to 1.7 kg/cm2)
d. Put Mech Exhauster & Air blower in series for particular boiler deashing.


1. 1. CW water open before starting Mech 1. Water line press should not < 0.8 kg / cm2.
exhauster
2 Conveying air pressure should be >1 kg/cm2.
2. IMT Timer trips whenever load on Air blower
3 Dome valve seal pressure >5.0 kg/cm2.
increases.
8. STARTUP SEQUENCE
2 Start air blower & ensure ash conveying line is clean.
close.
gauge.
24 When shut off vacuum reaches above -400 mmHg then open Ash Hopper Valve from control
panel.
Checks during running

Action
SEAL FAIL
Reasons
Shutdown
12 Watch the Air blower current and stop it when current comes approx. its no load current i.e. 50-60
Amps.
13. Dos & Don’ts

DO’s DON’Ts

E39 Ahsop 01

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E39 Ahsop 01

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Utkal Alumina International Limited STANDARD OPERATING

(A Unit of Hindalco Industries Limited); PROCEDURE

4. Environment health & safety matrix

1.Human injury if 1. Dusty 1.Ensure PTW returned

5. Legal & regulatory requirements: Not applicable

For clause 6, 7,8,9,10,11 Refer Annexurexure

For Aditya: ANN_AAP_E39_AHSOP_01

6. O&M Parameter: Refer Annexure

7. Checks before Start Up: Refer Annexure

8. Start Sequence: Refer Annexure

9. Check points During Fly ash conveying: Refer Annexure

10. SHUTDOWN SEQUENCE: Refer Annexure

12. Exception/ Emergency Handling: Refer Annexure

13. KPI (Key Performance Indicators): Refer Annexure

14. Dos & Don’ts:

Sl. No. Abbreviation Used Stands For

For Aditya: ANN_AAP_E39_AHSOP_01

7. Checks before start up

7.2 Permissive for start up

7.3 Interlocks & Protections

9. Operation monitoring & control

11 Best practices followed (If any):

12. Exception/ Emergency handling :

13. Dos & Don’ts

- For Hirakud : ANN_HKD_ E39_AHSOP_01

7. Checks before start up

7.2 Permissive for start up:

7.3 Interlocks & Protections:

9. Operation monitoring & control

- Pressure switch may be defective.

10. Shutdown Procedure:

11. Best practices followed (If any):

12. Exception/ Emergency handling:

14. Performance KPI’s

KPI Action Taken

- For Mahan : ANN_MAH_ E39_AHSOP_01

1 Make Atlas Copco

7 Checks before Start Up:

7.1 Physical Checks

7.2 Permissive for Start Up:

1. Ensure conveying air pressure should be 5.0-5.5 kg/cm2.

7.3 Interlocks & Protections:

will not start.

1. Start conveying air compressor as mentioned above.

9 Operation monitoring & control:

1. Check for any Dome valve seal fail (<5.5 kg/cm2).

11-Best Practices Followed

- For Muri : ANN_MUR_ E39_AHSOP_01

7 Checks before start up

7.1 Physical Checks

7.3 Interlocks & Protections

9 Operation monitoring & control:

- Dome valve may not be closing properly.

12 Exception/ Emergency Handling:

13 Dos & Don’ts

- For Renukoot : ANN_RKT_ E39_AHSOP_01

 Applicable to Unit B#1&2

7. Checks before start up