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BHARAT ALUMINIUM
COMPANY LIMITED
A GROUP COMPANY OF
VEDANTA LIMITED
Standard Operating
Procedure
SOP name: CEP OPERATION
STANDARDS ISO : 9001 ISO : 14001 OHSAS : 18001 ISO : 50001 ISO : 55001
CONTROL OF
OPERATIONAL OPERATIONAL OPERATIONAL OPERATIONAL PLANNING &
Clause Name: PRODUCTION & SERVICE
CONTROL CONTROL CONTROL CONTROL
PROVISION
Clause Number: 8.1 8.1 4.4.6 4.5.5 8.1
MR OFFICE USE ONLY
FORMAT NO. – IMS 10(A) FORMAT REVISION NO.: 02 FORMAT VERSION NO.: 00 FORMAT REVISION DATE : 04.05.19
Rev. No. 01 Version No. 02 Date of Preparation: 14.09.2020 Pages: 1 of 15
SOP No: BALCO/POWER/CPP2/OPN/MP/IMS/DOC/010-CEP

1. SCOPE: CEP operation (Normalization, Start-up, Shutdown, and Isolation) is applicable to all CEPs.
2.OBJECTIVES: To ensure proper Isolation for the safety of Maintenance persons.
To ensure 100% availability of CEP.
Efficient operation of CEP
Knowledge of operations
3.REQUIRED Knowledge of EnMS
COMPETENCIES Knowledge of safety
Knowledge of AMS
INPUTS REFERENCE/RECORD PPE OUTPUTS EFFICIENCY EFFECTIVENESS REVIEW
1. Power 1.Desk Engineer Log Book – 1. Safety shoes 1. Condensate 1. Job knowledge, 1. No Half yearly review
BALCO/POWER/CPP2/OPN/I operation, abnormalities by Shift In Charges
2. Water 2 .Safety Helmet water to
MS/DEL(01,02,03,04) normalization & after CEP start up & approved by
3. Oil 2.Shift In Charge Log book- 3. Hand Gloves Deaerator
isolation Head CPP 2
BALCO/POWER 4. Ear Plug
2. Continuous
/CPP2/OPN/IMS/SEL 5. Safety Goggles Deaerator level

Prepared By: Engineer Incharge Reviewed By: Dept. Head Approved By: SBU Head
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3. Field Engineer Log Book- maintaining

BALCO/POWER
CPP2/OPN/IMSFEL(01,02,03,0
4)
4. RESPONSIBILITY MATRIX:
1. Monitoring CEP operation:- Shift In charge , Desk charge engineer, Field Charge Engineer
2. Isolation and Normalization :- Field Charge Engineer
3. Planning CEP maintenance schedule:- Planning Department

5.DISTRIBUTION LIST:
No of copies Places where distributed
SOP W. I . NO Reference Rev. No Ver. No No of pages
distributed (Location of documents)
Control Room & soft copy
BALCO/POWER/ Turbine
available in Library & WE
CEP OPERATION CPP2/OPN/MP/ operation 11 02 15 03
CONNECT(DMS
IMS/DOC/010-CEP Manual
PORTAL)

Prepared By: Engineer Incharge Reviewed By: Dept. Head Approved By: SBU Head
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HEALTH,SAFETY,
STEP ACTIONS/OUTCOMES ENVIRONMENT AND
QUALITY MESSAGES
Technical specification:
Motor Pump
Made : Xianotan Elec Mfg. Ltd.
Motor type : YLST355-4 Type : 7LDTNB-5
Rated voltage : 6.6 K V Flow : 376.5 t/hr
Rated Speed : 1480 RPM Lift : 191 mH2O
Cooling system : Water cooled Cooling system : Water cooled
Rated Current : 30 Amps
Power : 270 KW

Safety PPEs table:

Safety Safety Ear Dust Gloves Safety Safety Safety Belt

Helme Shoes Muffs Mask/Respirat Goggle Jacket
t or s
Safety
PPE

Usage
√ √ √ √ √ √ √ X

Note : VFD has been provided in CEP 1B and 2B according to MOC no.
6. PRE– BALCO/POWER/CPP2/MP/MOC/059
OPERATIONAL IN FIELD :
CHECKS 1. All men and material removed from work place. (FE)
2. Ensure 6.6 kV breaker normalized condition as well as control supply, no ‘alarm’ is acting in relay.Also

Prepared By: Engineer Incharge Reviewed By: Dept. Head Approved By: SBU Head
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ensuring no alarms in VFD panel of CEP ,if present inform EMD (FE)
3. Electric supply normal in local panel, Green light is glowing, Push button released SAFETY:
condition & Selector switch is in remote position. (FE) There should be no
4. Discharge valve of CEP closed & power supply is normalised from valve MCC of oil or water leakage
respective unit (FE) or spillage and check
5. Inlet valve of condensate pump is fully opened and the pressure balancing isolation footsteps on stairs
valve is opened. (FE)

6. Mechanical Seal cooling line, Seal charging line and motor cooling water supply
line isolation valves are opened condition (Mech seal cooling lines should be
HEALTH:
charged from its discharge line seal cooling header & CST). (FE) EnMS
Ensure proper
lighting arrangement
to avoid slippage

Emergency push
Closing button
button

7. Motor
Lube Selector
oil lube oil level is normal >60%.switch
(FE) EnMS
8. CEP
level view recirculation isolation valves & CV (100%) are
glass opened condition (Turbine 5m). (FE)
9. All LP heaters, GSC water box vents are opened
condition. (FE) EnMS
10. Check Deaerator control station is normalized
condition (either main line both isolation valves &
CV or bypass isolation valve should be opened
Motor
condition) in Turbine 5m. (FE)
cooling Pre
lineEnsure condensate emergency drain isolation valve
11. bala
at turbine zero mtr is in close condition(In front of line
Su
LPH4) (FE) va
12. Main de-superheating isolation valve should be

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opened condition, if required. (FE)

13. Check that CEP pit pump is available. (FE)
14. Hot well CST make up isolation valve of main line are in open condition. (FE)
IN DESK (control room DCS) :
1. All PTWs surrendered. (DE)
2. Ensure that pump’s stop feedback & discharge MOV’s close feedback are coming .Also confirm from FE
that no alarm is persisting in VFD panel in local (For CEP 1B and 2B). (DE)
Health:
3. Hot well level in the range of 600-800 mm.If less open hot well makeup CV and improve level. (DE) EnMS
Avoid long period of
4. Deaerator CV & recirculation CV trail taken, should be operating properly, feedback coming normal, put
work in high noise
Deaerator CV in 50% open & recirculation CV in 100% open condition. (DE) area, use ear plug
5. Check that all winding & bearing temp (atmospheric temp.) are showing in DCS & current feedback showing while working.
Zero. (DE) EnMS
6. Ensure cooling water is available, pressure>2.5Kg/cm2. Either atleast one CW & ICW is running or S&M is
charged condition. (Follow SOP- BALCO/POWER/CPP2/OPN/MP/IMS/DOC/010/CWS,
BALCO/POWER/CPP2/OPN/MP/IMS/DOC/010/ICW, BALCO/POWER/CPP2/OPN/MP/IMS/DOC/010/CWP). (DE)

From
CST Condensate Line

Seal
Cooling
Header

Environment:

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Remove cotton
waste or any organic
CEP CEP substance in or
around the work
place.

SEAL COOLING LINE HEADER Avoid oil spillage or

leakage from the
equipment or line .If
FROM DESK: required stop the
1. Start the condensate pump and check that starting current is normal (<20A). If current is high, check in local equipment.
breaker and inform to concerned department. For CEP with VFD (1B and 2B ) give command to VFD and
gradually increase the speed of CEP till flow and pressure is established (DE) EnMS
2. Check the opening of the discharge MOV after starting of condensate pump, if not, then stop the pump and Avoid water leakage,
inform to concerned department, if required, open the disc. MOV manually. (DE, FE) if necessary stop the
3. Adjust the Recirculation CV to maintain the pressure of condensate water normal (15-18 kg/cm2), then close equipment
the R/C CV. (DE)
4. Adjust the Deaerator CV to maintain the required condensate flow. (DE)
5. Put the other condensate pump to the ‘interlock’ of other pump stops & pipe pr low if other pump is available.
(DE)
6. Monitor the windings (6 no) & bearing (DE & NDE) temperatures
of running pump. The winding temp. should be <90 deg and
bearing temp. should be <80 deg. (DE) EnMS
7. After opening fully of discharge MOV, close the LP heaters &
GSC vents. (DE, FE)

D/A CV
1. Start standby pump (plz refer ‘start operation’), check that
7. START D/A main line MOV is opening in auto. (DE)
discharge
OPERATION 2nd iso v/v
2. Open the condensate Recirculation CV to keep the pressure of D/A main line
condensate water normal (15-18 kg/cm2). (DE) 1st iso v/v
3. Release the interlock of the started condensate pump. (DE) D/A bypass
4. Pay attention to the change of water level of condenser. (DE) EnMS iso v/v

Prepared By: Engineer Incharge Reviewed By: Dept. Head Approved By: SBU Head
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5. The condensate pump which is to be stopped, if it will be used as STANDBY after its stoppage, put it to the
‘interlock’ position. (DE)
6. Stop the other condensate pump. Make sure that discharge MOV is closing. Close the condensate
Recirculation CV to keep the pressure of condensate water normal (15-18 kg/cm2). (DE)

FROM DESK:
1. Release the interlocks of stand-by condensate pump. (DE)
2. Stop the condensate pump and check that discharge MOV is started closing in auto. (DE)
3. Pay attention to the change of water level of condenser. (DE)

FROM FIELD:
1. After informing Desk engineer, press the ‘EMERGENCY PUSH button’ from the local panel. (FE)
2. After stopping CEP, check that discharge MOV is closing or not, if not, close the disc. MOV manually. (FE)
SAFETY:
IN FIELD: Check CEP carefully
and be away from its
1. Ensure that CEP is in stopped condition. (FE)
rotating parts during
2. Rack Out 6.6 KV breaker (If required put ON Earth switch), isolate the control supply of breaker. (FE) running condition.
3. Press emergency push button & put selector switch in OFF condition. (FE)
4. Hand tightened the discharge MOV. (FE)
5. Close suction isolation valve. (FE)
8. CHANGE- 6. Close mechanical seal cooling water i/l & o/l line as well as CST line. (FE)
OVER 7. Close seal charging line, if required. (FE)
8. Close motor cooling line, if required. (FE)
9. Close pressure balancing line. (FE)
10. Put Tag and LOTO in breaker. Follow annexure. (FE)
11. If required, then isolate discharge MOV power supply from Valve MCC. (FE)

IN DESK:
1. Stand- by inter lock removed. (DE)
2. Disable CEP in DCS. (DE)

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9. SHUTDOWN 3. Disable
OPERATION Discharge MOV in
DCS. (DE)
4. Ensure
current feedback is
showing dash & Not
ready indication is
coming in DCS of
CEP. (DE) SAFETY:
10. ISOLATION Check for any
IN FIELD: leakages in the
1. Ensure pump & Monitor
that all PTW’s lube oil level to avoid
surrendered and material damage
Man & Material and vibrations
Removed condition.
(DE,FE)
2. Loosened
the discharge MOV.
(FE)
3. Open
suction valve. (FE)
4. Open
pressure balancing line. (FE)
5. Open Mechanical seal cooling water i/l & o/l line as well as CST line. (FE)
6. Open seal charging line. (FE)
7. Open motor cooling line. (FE)
8. Remove Tag & LOTO from breaker. (FE)
9. Normalise 6.6KV breaker as well as control supply. Also ensure no alarm persists in VFD panel (FE)
10. Ensure Earth switch is in OFF condition. (FE)
11. 11. Release emergency push button and put selector switch in remote. (FE) SAFETY:
NORMALIZATIO 12. Normalize the discharge MOV power supply. (FE) Open the breaker
N 13. Check that oil level can be viewed clearly in view glass. (FE) from its side keeping

Prepared By: Engineer Incharge Reviewed By: Dept. Head Approved By: SBU Head
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some distance
. IN DCS:
1. PTW Surrendered. (DE)
2. CEP Stop feedback is coming. (DE)
3. CEP Discharge MOV close feedback is coming. (DE)
4. Ensure CEP current feedback coming 0 in DCS & Not ready indication is not coming. (DE)
5. Select standby CEP Auto start interlock in DCS (DE)

Note: Logic modification according to VFD provision in CEP:

Please go through the logic, implemented for CEP 1B & CEP 2B (running in VFD) as of now-
 
1.     1. If Deaerator level control valve opening>95 % and in Manual Mode, CEP VFD auto loop control will be enabled
(auto loop can be taken in service by the DCE)
2.     2.  Putting Deaerator level control valve in auto, VFD will switch to manual mode automatically. SAFETY:
3.     3. If CEP discharge Pr < 11.5 Kg/cm2 , VFD will switch to in manual mode automatically. Rubber mat should
be there in front of
4.     4.  If HP/LP fast open operates and VALVE FORCE check box is selected in condensate page,  Deaerator level
breaker.
control valve closes to 35% immediately. (Deaerator level CV can be operated manually after deselecting the check
box)
Alarms:
 For Unit#1, CEP current 22 Amp: High priority, CEP current: 24 Amp: Emergency priority
 For Unit#2, CEP current 19 Amp: High priority, CEP current: 20 Amp: Emergency priority
 CEP VFD auto to manual changeover, Emergency priority alarm in Unit#2
 For CEP VFD auto to manual changeover provision has been provided in condensate page for CEP VFD
AUTO/MANUAL display.

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ABNORMALITY
TREATMENT
A R C C
B E O O
N A R N
O S R T
R O E R
M N C O
AL TI L
ITI V PL
E E A
S A N
C
TI
O
N
O
R

R
E
A
C
TI
O
N
PL
A
N

Wi Ch Ch Is
nd oc ec ol

Prepared By: Engineer Incharge Reviewed By: Dept. Head Approved By: SBU Head
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ing temperature king in cooling water k ICW pump ate and clear
increasing (above line pressure chocking in line
normal)
Cooling water flow Charge S&M if MMD and C&I to take
not enough required permit to rectify the
defect
Discharge pressure NRV of other CEP is Close & Hand tight MMD to attend defect
is having discharge MOV of
not increasing passing (also other CEP
discharge MOV
of other CEP is
open)
Tripping of running Occurrence of fault Inform Concern Isolate the equipment
CEP department and give permit
check whether
standby pump
started in auto

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12. OH&S, 12.1 CROSS REFERENCE :

EMS, Turbine manual
SAFETY & Child reference no (check list): BALCO/POWER/CPP2/OPN/MP/CHK-19
PRECAUTIO
NS 12.2 OH &S CONSIDERATION:
1. While doing electrical supply normalization, be careful of electric shock.
2. Protect yourself from slippage and falling.
3. Be careful of leakage of condensate.
4. As it is a noisy area, so earmuff should be worn.
RELATED HIRADeC: BALCO/POWER/CPP2/OPN/MP/OHSAS/DOC/002-08

12.3 EMS:
1. Check for any leakages in the pump.
2. Monitor lube oil level to avoid material damage and vibrations.
E Aspect : BALCO/POWER/CPP2/OPN/MP/EMS/DOC/001A,001B,02,03,04.
E Aspect no –7,9,10,14,15,32,34.
12.4 SAFETY:

Following safety measures need to be taken while CEP operation-

1. Close or open any breaker carefully from its side keeping some distance.
2. There should be no leakage to avoid chance of slippage/falling.
3. Check availability of fire fighting equipment.
12.5 EnMS CONSIDERATIONS:
Optimize idle running time of CEP.

12.6 PRECAUTIONS:
Before starting vents of condensate line must be crack open to prevent from air locking open.
AMS CONSIDERATION
1. Criteria for effective operation and maintenance of asset performance (PM plans, CBM reports, FMEA,RCA) to be
established & adhered by.

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2 Operates & maintains the facilities, processes, system and equipment in accordance with operational criteria

RISK AND OPPORTUNITIES TO BE ADDRESSED RELATED TO QMS/EMS/AMS:

S.NO. Category(QMS ISSUES(External/ RISK MITIGATION CONTROL

/EMS/AMS) Internal)
1 QMS INTERNAL Leakage of Water Do not charge any line without Air
venting , Isolate line or equipment
& Inform MMD for the issue.
2 EMS INTERNAL Noise pollution DUE TO Use PPEs, reduce vent & drain
VENTING & Draining of opening if noise is heavy, drain
steam line extended up to pit area
3 AMS INTERNAL Damage of pump & lines Strictly follow SOP, Interlock &
tripping provided, do not charge
without proper draining of lines .

REVISION PAGE
CHANGE EFFECTED DATE OF CHANGE
NUMBER NUMBERS
1 3 Changes done as per SGS Audit observation, ISO standard incorporation 31.07.12
2 3 Reference given wrt child document and check list added 18.06.13
SOP change as per sustainability requirement, Parameters ranges and
3 11 01.09.13
photos included.
4 3,5,8,9 Revision done as per requirement 22.04.14
Revision done as per IMS requirement (Document number change),
5 1,2,4,5,9 &10 13.12.14
Procedure review
6 1,2,8,9 &11 Revision done as per IMS requirement 12.09.15
7 3-10 Safety PPEs table provided & Job responsibility defined 23.03.16

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AMS Consideration & RISK AND OPPORTUNITIES TO BE ADDRESSED

8 1, 14 25.10.17
RELATED TO QMS/EMS/AMS added
9 1, 12 LOGO change, HIRADeC No. change 25.09.18

10 All pages Format changed 21.07.19

00 3,6,11,12 Revision done as per MOC no. BALCO/POWER/CPP2/MP/MOC/059 05.01.20

01 All pages Format changed 14.09.20

APPROVAL SIGNATURES RECORD

REVIEWER POSITION NAME SIGNATU DATE

RE
Prepared By Engineer Incharge
Vivek Bhonsle

Reviewed By Dept. Head

R K Sharma

Approved By: SBU Head

Ashutosh Dwivedi

Prepared By: Engineer Incharge Reviewed By: Dept. Head Approved By: SBU Head