KSK Mahanadi Power Company Ltd.

Power from knowledge 6 X 600 MW Power Plant KMPCL / Opr. /CONDENSER BALL
SOP FOR CONDENSER BALL CLEANING/ 01
CLEANING
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 1 of 1

STANDARD OPERATING INSTRUCTION

FOR

CONDENSER BALL CLEANING SYSTEM

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Anshumaan Vatsa Name: Name:
Designation: Designation: Designation:
 KSK Mahanadi Power Company Ltd.
Power from knowledge 6 X 600 MW Power Plant KMPCL / Opr. /CONDENSER BALL
SOP FOR CONDENSER BALL CLEANING/ 01
CLEANING
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 2 of 1

 STANDARD OPERATING PROCEDURE FOR CONDENSER BALL

CLEANING system

 OBJECTIVE: For Smooth Operation of Condenser ball cleaning system

SCOPE: This SOP is applicable for ball cleaning of all units.

INTRODUCTION: Rubber ball cleaning system is used for online continuous cleaning of inner
surface of cooling water pipes inside the condenser to reach the designed heat exchange rate of
condenser. Rubber ball cleaning system of condenser consists of rubber ball pump, ball-loading
chamber, ball-collecting screen, valves & corresponding piping .

 PRE CHECKS:
TECHNICAL DATA:-
Make Qingdao Huatai Power Quantity 2
Equipment Co., Ltd
Type 125JQ-27 Outlet flow 108m3/h

Shaft power 13.5 KW Rotating speed 1460

PUMP motor
Type Y180M-4 Power 18.5
Voltage 415V Current 35.9A
Rotating speed 1460 rpm Make Shanghai electromotor Co.,
Ltd

RESPONSIBILITY: Unit Control Engineer, Field Engineer and Desk Engineer.

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

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Anshumaan Vatsa Name: Name:
Designation: Designation: Designation:
 KSK Mahanadi Power Company Ltd.
Power from knowledge 6 X 600 MW Power Plant KMPCL / Opr. /CONDENSER BALL
SOP FOR CONDENSER BALL CLEANING/ 01
CLEANING
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 3 of 1

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

 SPECIAL TOOLS/ EQUIPMENTS: NIL

PRECHECKS AND ACTION BY FIELD ENGINEER

S No Description Ok Not Ok Remarks

1. All permits and cross permits have been returned .

 

2. Check bearing oil level carefully before starting rubber

ball pump
3. Area is clear of any other materials.
 

4. Condenser CW system is in service

 

5. Ball collecting strainer is ready for operation.

 

6. Hand rotate ball cycle pump rotor, the rotor should rotate
freely, without rocking or seizure.  

7. Check that inlet and outlet valves of ball recycle pump

act normally  

8. Before put in, rubber balls should be dipped in water for

24 hours
Fill the ball injection chamber with a certain number of  
balls as required, the changeover valve is set to “Clean”
9. position, the water drain valve should be closed, and the
air release valve should be fully open.

PRECHECKS AND ACTION BY DESK ENGINEER

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Anshumaan Vatsa Name: Name:
Designation: Designation: Designation:
 KSK Mahanadi Power Company Ltd.
Power from knowledge 6 X 600 MW Power Plant KMPCL / Opr. /CONDENSER BALL
SOP FOR CONDENSER BALL CLEANING/ 01
CLEANING
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 4 of 1

S No Description Ok Not Ok Remarks

1 Ball pumps power supply is in ON condition  

Ball pumps I/L MOV, O/L MOV, Switch MOV & ball-
2 collecting screen actuator power is in ON condition  

 OPERATING PROCEDURE -
Sr. RESPONSIBILITY
Description
No. UCE DE FE EE
PRE- START CHECKS:
1 All permits and cross permits have been returned. √ √ √ √
2 Power supply and control power supply available. √ √
3 Check the power switch of programmable controller cabinet is On and
the indicator lights on display screen normal. √ √

4 Condenser CW system is in service √

5 Check bearing oil level carefully before starting rubber ball pump √ √
6 Check that the condenser tube rubber ball cleaning system is through √ √
7 Ensure sufficient balls are available in system.( 10%-13% of no. of √
√
tubes of condenser
START PERMISSIVE :NIL

START UP SEQUENCE :
1 Open outlet valve of ball pump; fill ball injection chamber, and then √
close air release valve of ball injection when water is flowing out. √
Close outlet valve of ball pump

2 Open inlet valve of inlet line, then close air release valve of ball √
injection when water is flowing out. Close inlet valve. √

3 Start up rubber ball pump, and check it is rotating normally √ √

4 Open outlet valve of rubber ball pump, set changeover valve of ball √
injection chamber to “Cleaning”, and open outlet valve of ball injection √
chamber.
Prepared by: Reviewed by: Approved by:
Signature: Signature: Signature:
Name: Anshumaan Vatsa Name: Name:
Designation: Designation: Designation:
 KSK Mahanadi Power Company Ltd.
Power from knowledge 6 X 600 MW Power Plant KMPCL / Opr. /CONDENSER BALL
SOP FOR CONDENSER BALL CLEANING/ 01
CLEANING
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 5 of 1

5 Through observation window watch the movement of rubber balls. It is √

normal that balls should be seen every several minutes. Cleaning √
should last for about 60 minutes every time

6 Check ball collecting rate, the percentage ratio of the number of balls √
put in to the number of balls collected. √

7 Observe pump and motor for any abnormal sound & considerable √
vibration √

8 Observe for bearing overheating in local as no remote indicator is

mounted √

9 Observe pumps discharge pressure in local gauge. It should be more

√
than condenser I/L CW duct pressure.
10 Keep system in operation for 4-6 hours in a day or as desired √ √
SHUTDOWN SEQUENCE:

1. PLANNED SHUTDOWN :

1 After cleaning completed, set changeover valve of ball injection √

chamber to “Collecting” position to perform about 30 minutes of ball √
collecting.

2 Close outlet valve of rubber ball pump, stop rubber ball pump, and √
close inlet valve of rubber ball pump. √

3 Close outlet valve of ball injection chamber √ √

4 Open air release valve and water drain valve of ball injection chamber. √
After water is drained away, count the balls and note down ball √
collecting rate and cleaning time.

2. TRIPPING :nil
3.EMERGENCY SHUT DOWN:

1 During running of condenser tube rubber ball cleaning system, it is √ √ √

required that all devices be closely monitored ,and adjusted as soon
as deviation from the normal operation is discovered, thus ensuring
Prepared by: Reviewed by: Approved by:
Signature: Signature: Signature:
Name: Anshumaan Vatsa Name: Name:
Designation: Designation: Designation:
 KSK Mahanadi Power Company Ltd.
Power from knowledge 6 X 600 MW Power Plant KMPCL / Opr. /CONDENSER BALL
SOP FOR CONDENSER BALL CLEANING/ 01
CLEANING
Issue No: 1 Issue Date: Revision: 0 Revision Date: File no: Page 6 of 1

optimal operation of system

2 On occurrence of such conditions as abnormal noise from running √ √
pump, severe vibration on equipment or pipeline, and parameter
exceeding limit
INTERLOCKS :NIL Remarks

 ABRIVIATIONS / NOTATIONS:-
o SOP: Standard Operating Procedure
o UCE: Unit Control Engineer
o DE: Desk Engineer
o FE: Field Engineer
o DCS: Distributed Control System
o EE: Electrical Shift Engineer
o MFT: Main Fuel Trip.
o RB : Run Back

Important Note:

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Anshumaan Vatsa Name: Name:
Designation: Designation: Designation: