6 024 star up ops procedure for shop clean steam generator

1 Purpose

1.1 Provide a standard procedure for safety, start-up, testing and shut-down of the Clean Steam Generator in the Process Systems shop test area.

2.1 This procedure applies to the following types of equipment: Clean Steam Generator (Boiler).

Responsibility

3.1 Process Systems Lead Project Engineer or the Shop Foreman shall have overall responsibility for new equipment from procurement to start-up. The Lead Project Engineer is responsible for coordinating the following activities:

3.1.1 Review of customer and project testing specifications.

3.1.2 Coordinate testing and training schedule including (but not limited to): Shop Foreman, Customer, and Safety (as needed).

3.2 Therma Start-up Service has responsibility for the following activities:

3.2.1 The start-up individual shall perform the start-up tasks as specified in this Standard Operating Procedure.

3.2.2 The start-up individual shall fully complete the start-up form FN 6.024.1 for each test daily. A copy of this sheet will be provided to the Lead Project Engineer with the turnover documents: A second copy will be filed by the Quality Control Manager.

4 Procedures

4.1 General: The start-up individual is responsible for filling out start-up sheet FN 6.024.1 for Boiler. A daily column on the start-up sheet will be completed for each testing session. Each sheet requires the following information:

4.1.1 Job identification: The job name and job number are to be completed by the start-up individual.

4.1.2 Section 5 - Start-up, Testing and Shutdown

4.1.3 Signature - As each set of start-up/test data is completed, the start-up individual must initial and date in the entry space for the task.

5 Process Systems Clean Steam Generator Start-up, Testing and Shutdown

5.1 This section should be completed by the start-up individual. Any design documentation specifying equipment should be recorded in this section. This includes: Specification number, Submittal number and Process and Instrumentation Diagram (P&ID) number.

5.2 For each of the following items: Write initials or N/A for not applicable.

5.3 Verify all present are aware of/review Lock-Out/Tag-Out procedures.

5.4 Review Operating Manual for Clean Steam Generator. This manual is to remain at the equipment.

5.4.1 The start-up individual and the owner (or rep.) shall initial and date after reviewing this SOP and prior to startup.

5.5 Inspect for visible signs of damage, leak discrepancies and notify the Project Manager of defective parts.

5.6 Verify that required clearance is maintained on all sides, from combustibles.

5.7 Verify the design test pressure for each testing session is a lower setting than the Pressure Relief Valve.

5.8 Verify the steam supply outlet piping, valves and clamps.

5.8.1 All hygienic clamps shall be 2-bolt High Pressure type.

5.8.2 All gaskets shall be RubberFab TufSteel or equivalent.

5.9 Verify steam piping flow path with equipment P&ID for proper points of connection for testing.

5.10 Verify steam hoses are rated for the testing duty.

Temperature data:

5.10.2 Clean steam hoses to be Afex Pharmaline "CHEMFLUOR" #WTLCT ^TM or equivalent.

5.11 Verify that make up water supply has proper shut-off.

5.12 Test water quality and record quality on form FN 6.024.1 in units of Mega-Ohms (MΩ).

5.13 Close the drain valve.

5.14 Check and record make-up water supply pressure.

5.15 Notify the Shop Foreman and Lead Project Engineer of pending start-up.

5.16 Follow "Pre-Operation Check" procedure in manual.

5.16.1 Open all make-up water valves.

5.16.2 Switch steam generator power ON. Verify proper water level.

5.16.3 Verify proper level control.

5.16.4 Verify proper "Low Water Cutoff Switch" operation.

5.16.4.1 Open the drain valve completely.

5.16.4.2 Close the drain valve.

5.17 Follow "Pressure Controls, Operation and Testing" procedure in manual.

5.17.1 'Operating Pressure Control' (OPC) should be set at least 10 psi BELOW the make-up water supply pressure.

5.17.2 'High Limit Pressure Control' (HLPC) should be set approximately 10 psi ABOVE the desired normal operating pressure.

5.17.3 OPC Check:

5.17.3.1 With the power OFF, close the steam outlet valve.

5.17.3.2 Adjust OPC to the lower of 20 psig or Make-up pressure less 10 psi.

5.17.3.3 Adjust HLPC to lower of 30 psig or OPC plus 10 psi.

5.17.4 HLPC Check:

5.17.4.1 FOR TEST PURPOSES ONLY, SET THE HLPC TO 10 psi BELOW THE OPC.

5.17.4.2 With the power OFF, close the steam outlet valve.

5.17.4.3 Switch the power to allow steam pressure to build.

5.17.4.4 When the pressure rises to the HLPC setpoint, the manual reset button will pop-up and the control will de-energize the heater contactor.

5.17.4.5 Open the steam outlet valve to decrease the pressure.

5.18.1 Set the desired operating pressure and differential pressure on the OPC.

5.18.5 Turn the main disconnect switch to ON.

5.19 Follow "Manual Blowdown Instructions" procedure in manual.

5.20 Maintenance

5.20.1 Daily blowdown at pressure is essential for ideal boiler performance.

5.20.2 The sight glass should be checked frequently to assure the boiler has adequate water.

5.20.3 The sight glass should be checked daily for damage.

5.20.4 A monthly inspection should be made of the access door and all internal wiring.

5.21 Record start up operating parameters in the Clean Steam Generator form, FN 6.024.1.