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DEPARTMENTAL

OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/GEN/01
01
28.12.2004
01
24.11.2005
01 OF 01

UTILITY DEPARTMENT
DOP NO. 7

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/GEN/02
01
28.12.2004
02
25.07.2006
01 OF 02

INDEX
Sl.
No.
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

Description
Coverage Page
Index
Introduction
Organisation Chart
Authority and Responsibility
ISO 9001 (2000) Applicable Clauses
Amendment Sheet
Departmental Operating Procedure for Power House
Process activities
Departmental Operating Procedure for Power
House Maintenance Process
Work instruction for starting of positive suction
centrifugal pump
Work instruction for starting of negative suction
centrifugal pump
Work instruction for stopping of centrifugal pump
(positive/negative)
Work instruction for treatment of water at water
treatment plant
Work instruction for operation of D.M. Plant
Work instruction for regeneration demineralization
plant
Work instruction for coal handling
Work instruction for starting of boilers #2 ( OK-8)
Work instructions for stopping of boiler # 2 ( OK-8)
Work instruction for start up of coal fired boiler # 3 &
4.
Work Instruction for stopping of AFBC boiler
Work instruction for starting of 12.5 MW AEG
turbine
Work instruction for stopping of 12.5 MW AEG
turbine
Work instruction for starting of 10 MW Siemens
turbine
Work instruction for stopping of 10 MW Siemens
Turbine
Work instruction for annual shut down of boilers /
turbines and other equipment
Work instruction for overhauling of an equipment
Work instruction for starting of 1000 KVA DG Set t
inside the mill
Work instruction for stopping of 1000 KVA D.G. Set
Work instruction for B check maintenance of 1000
KVA DG Set

Reference
No.
6.3/UTY/GEN/01
6.3/UTY/GEN/02
6.3/UTY/GEN/03
5.5.1/UTY/GEN/04
5.5.1/UTY/GEN/05
6.3/UTY/GEN/06
6.3/UTY/GEN/07
6.3/UTY/DOP/01

No.of
Pages
01
02
01
01
04
01
01
04

Rev
No.
01
01
01
01
01
01
01
01

6.3/UTY/DOP/02

04

01

6.3/UTY/WI/01

01

01

6.3/UTY/WI/02

01

01

6.3/UTY/WI/03

01

01

6.3/UTY/WI/04

01

01

6.3/UTY/WI/05
6.3/UTY/WI/06

01
02

01
01

6.3/UTY/WI/07
6.3/UTY/WI/08
6.3/UTY/WI/09
6.3/UTY/WI/10

01
02
01
02

01
01
01
01

6.3/UTY/WI/11
6.3/UTY/WI/12

01
02

01
01

6.3/UTY/WI/13

01

01

6.3/UTY/WI/14

02

01

6.3/UTY/WI/15

01

01

6.3/UTY/WI/16

02

01

6.3/UTY/WI/17
6.3/UTY/WI/18

01
01

01
01

6.3/UTY/WI/19
6.3/UTY/WI/20

01
01

01
01

Revision
Date

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/GEN/02
01
28.12.2004
01
24.11.2005
02 OF 02

INDEX
Sl.
No.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45

Description
Work instruction for C check maintenance of 1000 KVA D.G.
Set
Work instruction for D check maintenance of 1000 KVA DG Set
Work instruction for starting of 500 KVA DG Set at Intake
Work instruction for stopping of 500 KVA D.G. Set
Work instruction for B check maintenance of 500 KVA DG Set
Work instruction for C check maintenance of 500 KVA D.G. Set
work instruction for D check maintenance of 500 KVA DG Set
Work instruction for overhauling of safety valve
Departmental operating procedure for Maintenance of FANS
Departmental operating procedure for Maintenance of COAL
CRUSHERS.
Power House Water Balance Block Diagram
Coal Handling Plant Flow Diagram
Flow Diagram for Water Treatment Plant
Flow Diagram for D.M.Plant
FORMATS - ASSESSING CRUTIALITY / PRIORITY OF
PROCESSES / ICOM
STEAM DISTRIBUTION FLOW DIAGRAM

Reference
No.
6.3/UTY/WI/21

No.of
Pages
01

Rev
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01

6.3/UTY/WI/22
6.3/UTY/WI/23
6.3/UTY/WI/24
6.3/UTY/WI/25
6.3/UTY/WI/26
6.3/UTY/WI/27
6.3/UTY/WI/28
6.3/UTY/DOP/03

01
01
01
01
01
01
01
02

01
01
01
01
01
01
01
01

6.3/UTY/D0P/04

01

01

01
01
01
01
06

01
01
01
01
01

01

00

281/BH/EL/078

Revision
Date

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/GEN/03
01
28.12.2004
01
24.11.2005
01 OF 01

INTRODUCTION
Power house is one of the department of mill involved in Power Generation, steam
generation,Supplying water to process departments and also water for drinking to the
Mill, colony and villages.
OUR MAIN SOURCE OF RAW WATER IS - TAPI RIVER ABOUT 16 KM
DISTANCE FROM THE PLANT SITE (RIVER PUMP HOUSE).
Raw water is drawn and pumped from Tapi River and after pre treatment at water
treatment plant, supplied to process departments and to POWER HOUSE for further
treatment for using in Power Boilers and Process Boiler.
FUELS FOR BOILER: Imported and Indian coal mixed in different ratio are the
main fuel used in the boiler for generation of steam & HFO is used
for oil fired boiler #2 on need basis only.
STEAM

Generation and supply for both power generation & for the process
use for continuous Process. Extracted steam from turbine after
power generation is given to process dept and for deaeration
purpose of the power house.

SELF POWER GENERATION : Normally, 23 mw double extraction cum


condensing turbine (BHEL make) is run, meeting 100% mill
power demand which is up to 18 MW (peak). Other two TG sets 8
MW SIEMENS TG & 12.5 MW AEG TG are kept as standby.
Electrical power is also generated by our DG set, using HSD as a fuel only when GEB
power is not available at intake pump house.
Electrical power is also generated by DIESEL GENERATOR using diesel as fuel
inside the mill to provide lighting power and also for running essential equipments
when both turbine and GEB power are not in operation.
In addition to all the above activities, our maintenance crew is taking part in
maintenance activities of our department and also looking after the maintenance of
the Fire Hydrant & sprinkler system laid in the entire mills.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
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5.5.1/UTY/GEN/04
01
28.12.2004
01
24.11.2005
01 OF 01

ORGANISATIONAL CHART
G.M.(UTILITY)

D.G.M.(UTILITY)

MANAGER(UTILITY)

MANAGER(PROJECT)

DY.MANAGER(MAINT.)

DY.MANAGER

ASST.MANAGER(OPN.)

ENGINEER/JR.ENGINEERS

SHIFT ENGINEERS

TRAINEE ENGINEERS

TRAINEE ENGINEER

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

5.5.1/UTY/GEN/05
01
28.12.2004
01
24.11.2005
01 OF 04

AUTHORITY AND RESPONSIBILITY


1.

GENERAL MANAGER :
-

2.
2

Responsible for overall activities of the department for meeting the


Mills steam, power, water requirement. Ensuring the implementation
of QMS and all statutory safe practices for boiler operation. Liaison
with statutory and regulatory authorities like boiler inspectorate.
Member of inter departmental daily meeting presided by President (Tech.).
Member of M.R.M.
Plans major shut down of the equipments for replacement / renovation/
development etc.
Approval of parts drawing generated in the department.
Approval and issue control of QMS (DOP & and other documents).
Planning follow up for execution of projects under utility dept.
Cost control measures relating to the dept.
Coordinating for environmental aspect monitoring covered under regulatory
Norms

DY-GENERAL MANAGER :
3

Planning of day to-day activities in accordance with QMS and ensuring


implementation of safe work practices for boiler operation.
Responsible for distribution of water, steam and power to respective
departments.
And ensuring maximum generation from TG sets.
Responsible for finalising shift schedules for Shift Incharges and workmen.
To prepares shut down schedules of different equipments.
To monitor the quality of fuel, water,DM water and Boiler water.
To clear MRN relating to the dept.
To coordinate and motivate quality circle in the dept.
To prepare and release monthly / quarterly reports for submission to Government
authorities
To take-up the responsibility of General Manager in his absence.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
3.

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
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5.5.1/UTY/GEN/05
01
28.12.2004
01
24.11.2005
02 OF 04

MANAGER, UTILITY
-

Planning of day to-day activities in accordance with QMS and ensure


the implementation of safe work practices for boiler. He shall prepare DOP
planning and controlling of maint. Activities for the dept.
To allots individual tasks to the maint. Engineers.
To list-out and indent spares for different equipments, considering the availability
and consumption in consultation with GM and DGM
Responsible for keeping the spare equipment ready.
Plan major shut down of the equipments.
to plan man power and spares for shut down of the equipment and boiler for
annual inspection.
Technical evaluation of offers for procurements of the spares.
Follow up with HO for materials procurements.
Inspection of materials at sit for clearing MRN for approval/ rejection of procured
material.
Coordinating different vendors during their visit to the site
To take-up responsibility of DGM in his absence.

4. MANAGER ( OPERATION AND PROJECT)


Coordinating new power project.
Procurement of materials for new power project.
Tender floating and evaluation of offer for power project.
Coordination and follow up in between and DCPL/ various vendors and
various in house discipline.
Any up coming development of the dept.
Incase of any emergency and trouble shooting attending for operation.
Preparing purchase order for new power project related to site.
Engineering / planning / execution of any development / new power project.
Assisting to GM utility for clearing any technical paper related to dept. for
liason work.
To take up the responsibility of DGM in his absence.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
5.
5

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
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Revision No.:
Revision Date.:
Page No.:

5.5.1/UTY/GEN/05
01
28.12.2004
01
24.11.2005
03 OF 04

DY- MANAGER (MAINTENANCE ) :

7
8
9
10
11
12
13
14
15
16

17 18 -

Responsible for maintenance and ensuring smooth running of equipments


after overhauling. He shall ensure implementation of QMS.
Categorize the work of the shifts and general shift, depending upon the quantity
and quality of work.
Allotment of job to workmen depending upon capability and quality of work.
Guides the workmen till the satisfactory completion of work.
Sort-out the problems of workmen regarding tools, tackles, materials etc.
Responsible for carrying out maintenance activities without affecting production.
Writes workshop job orders for repairs/spares, which are not available in stores.
Checking spare stocks in stores for attending shut down/break down jobs.
Preparation of drawings of equipment and spare parts.
Material estimation for specific work and supervise/guide the contractor.
To ensure safe maintenance practices as per safety rules and guidelines.
Responsible for preventive maintenance of all the equipments.
Checking of contractor bills for operation
inspection of materials at site for clearing MRN
To take-up responsibility of Manager in his absence.

19
6. ASST. MANAGER ( OPERATION)
Responsible for preparing day to-day production, fuel and chemical
consumption reports.
Coordinating in between shift workman and higher authorities.
Checking stock position of fuels and chemicals required for power generation.
Checking the quality and quantity of received of coal and chemicals.
Ensuring the stand by equipments is ready for any emergency.
Indenting materials required for operation of the dept.
Clearing MRN for coal and chemicals.
Checking of contractor bills for operation.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
7.

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
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5.5.1/UTY/GEN/05
01
28.12.2004
00
04 OF 04

SHIFT ENGINEER (OPERATION) :


20 21 22 23 24
25
26
27

8.

DEPARTMENTAL
OPERATING
PROCEDURE

Responsible for all the activities of the shift in accordance with QMS and
statutory boiler operation safe practices and to train the operating crew instantly
in on the job trainings.
Responsible for satisfactory services from workmen.
Responsible for planning of temporary manpower.
Supervision of all the equipments for its functioning and attending to all
problems noticed.
In case of major problems informs superiors for their guidance and instructions.
Workouts temporary adjustments for distribution of water, steam and power.
Attends and rectifies complaints regarding water, steam and power parameters.
At the end of the shift a detailed report in shift log book is prepared and
informed to the seniors.

ENGINEER/JR. ENGINEERS.
-

Allotment of jobs according to the capability to the work man.


Supervising the day- today maintenance work.
Issuing the materials from the stores for maintenance work.
Keeping maint. Tools and tackles in operating condition to meet any emergency.
Responsible for preventive maintenance of all the equipments.
Keeping records related to the preventive maintenance.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/GEN/06
01
28.12.2004
01
24.11.2005
01 OF 01

APPLICABLE ISO 9001 (2000) CLAUSES


Sl.No
01
02

ISO Clause
No.
4.2.3
4.2.3

03

4.2.4

04

4.2.4

05
06

8.2.2
8.3

07

8.5.1

08
09

8.5.2
8.5.3

Description
System Operating Procedure for document control
System Operating Procedure for document numbering
system
System Operating Procedure for control of paper quality
records.
System Operating Procedure for control of electronic media
quality records.
System Operating Procedure for internal audit
System Operating Procedure for control of non-conforming
product
System Operating Procedure for continual improvement
process
System Operating Procedure for corrective action
System Operating Procedure for preventive action

SOP NO.
4.2.3/SOP/01
4.2.3/SOP/02
4.2.4/SOP/01
4.2.4/SOP/02
8.2.2/SOP/01
8.3/SOP/01
8.5.1/SOP/01
8.5.2/SOP/01
8.5.3/SOP/01

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/GEN/07
01
28.12.2004
01
24.11.2005
01 OF 01

AMENDMENT SHEET
Sl.
No

Revision

Section/
Page No.

Details of Amendment

Date of
Amendment

Basis for
Amendment

From To

01

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/DOP/01
01
28.12.2004
01
24.11.2005
01 OF 04

1.0

PROCESS

: Departmental Operating Procedure for Power House


Process activities.

2.0

PURPOSE

: To run Power House and associated utilities processes smoothly.

3.0

SCOPE

: This procedure covers


Maintenance processes.

4.0
5.0
5.1.2

5.1.3

5.1.4

Power

House

operation

and

RESPONSIBILITY :

GM / DGM/ Manager /DY-Manager/ Asst.Manager/


Shift Engineer
TASK/ ACTIVITY : PROCESSING OF RAW WATER, DM WATER, BOILER FEED WATER
AND WATER FOR PROCESS USE

INPUT

STEPS

CONTROL

i)
ii)
iii)

Raw Water quality


Alum, polymer and chlorine dozing
HCl and NaOH

i)
ii)
iii)
iv)

Pumping of Raw Water from Tapi River


Lamella Clarification of raw water
Pumping of clarified water
De-minerlisation of Clarified water

i)
ii)
iii)

Turbidity
Reservoir Level
Header Pressure of clarified water
(at Reservoir)
Turbidity of process water.
DM water quality
Flow control

iv)
v)
vi)

Data

Data

Data

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
5.1.5

5.1.6

OUTPUT

MEANS:

i)
ii)
iii)
iv)

Clarified water
Boiler Feed Water
Turbine cooling water
Process Departments water

i)

Lamella Clarifier, Pumps, DM Plants, and


Pressure Filters.
Cation unit Resinous Bed
Anion Unit Resinous Bed
MB Unit Resinous Bed
Flow meters- Data
Water supply Operator and water tester
(coordinating with Central Laboratory)

ii)
iii)
iv)
v)
vi)
6.0

TASK / ACTIVITY

6.1.0

Reference No.:
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6.3/UTY/DOP/01
01
28.12.2004
01
24.11.2005
02 OF 04

Data

: COAL HANDLING
:

Feeding of coal into boiler coalbunker.

6.1.1

INPUT

Coal of required quality and required quantity -Data

6.1.2

STEPS

i) Supplying of coal through Tractor to conveyors


ii) Crushing of coal in crushers
iii) Screening
iv) Through conveyors to bunker.
v) To Boiler Furnace

6.1.3

CONTROL

*
*

6.1.4

OUTPUT

Required size of coal feed (-6 mm) flow to


Boiler Furnace Data.

6.1.5

MEANS

i)

Equipment adequately maintained Tractors,


Conveyors, Vibrators, Crushers, JCB
Competent and trained people.

ii)

Size of the crushed coal - Data


Bunker level
- Monitoring data

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/DOP/01
01
28.12.2004
01
24.11.2005
03 OF 04

7.0

TASK / ACTIVITY

7.1

STEAM GENERATION

7.1.1

Generating High Pressure Steam for Power Generation.

7.1.2

INPUT

i)
ii)

7.1.3

STEPS

i)

7.1.4

CONTROL

OUTPUT

High Pressure steam at required quantity and quality - Data

MEANS

i)

7.1.5
7.1.6

Boiler Feed Water


-Data
Fuel (Coal of required size & quantity)- Data

Supplying uninterrupted Feed Water at


economizer inlet
-Data
ii)
Supplying uninterrupted coal into the furnace
-Data
Running Boiler Parameters
i)
Feed water flow and temperature
control
ii)
Boiler drum level control
Data
iv)
Steam Pressure, Temperature and
flow control
iv)
Fuel flow control

ii)
:

Equipment Adequately maintained Boiler unit and


Auxiliaries, feed pump coal feeders
Competent Shift Engineers, Boiler attendant &
Fitters
persons (qualified/ experienced/trained/skilled)

8.0

TASK / ACTIVITY

8.1

POWER GENERATION :

8.1.1

Generation of Power by Heat Energy

8.1.2
8.1.3

INPUT
STEPS

:
:

8.1.4

CONTROL

Required quantity and quality of steam at Turbine inlet.


i)
Uninterrupted supply of steam at inlet. - Data
ii)
Extracting steam at two stages. - Data
A)
Running Turbine Parameters (Data)
i) HP, MP & LP Steam Pressure
and Temperature
ii) Vacuum
-Data
iii) Lube, Oil and Governor oil
iv) Bearing Temperature
B)
Quality of Power generated.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
9.0

OUTPUT

10.0

MEANS

Reference No.:
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Revision No.:
Revision Date.:
Page No.:

6.3/UTY/DOP/01
01
28.12.2004
01
24.11.2005
04 OF 04

Quality Power and extracted steam for process use - Data.


i)
ii)

Equipment Adequately maintained Steam,


Turbine and Auxiliaries- Data
Competent Men Engineer, Turbine operator

11.0

REFERENCE DOCUMENTS

IBR Regulations, manuals and


manufacturers standards.

12.0

REFERENCE RECORDS

Registers
Log Books

13.0

ABBREVIATIONS

14.0

AMENDMENTS

:
:

None

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
1.0

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

Procedure

6.3/UTY/DOP/02
01
28.12.2004
01
24.11.2005
01 OF 04

PROCESS

Departmental Operating
Maintenance processes.

for Power House

2.0

PURPOSE

To maintain the powerhouse utilities and infrastructure


for smooth running of plants.

3.0

SCOPE

This procedure covers Power House maintenance


processes.

4.0

RESPONSIBILITY

GM /DGM/ Manager / Dy-Manager/ Jr. Engineer.

5.0

TASK / ACTIVITY

5.1

DAILY MAINTENANCE :

5.1.1 ROUTINE MAINTENANCE AND PREVENTIVE CHECK.


5.1.2 INPUT

* Shift Maintenance Report - Data


* Information from other departments - Data
(Through Memo)

5.1.3 STEPS

* Checking the equipment


* Repair, if possible in running condition or replace the
unit (by intimating other department).
* Taking trial

5.1.4 CONTROL

Efficient running of equipment by preventive checks - Data

5.1.5 OUTPUT

Equipment in good running condition Data.

5.1.6 MEANS

* Competent Fitter / Jr. Fitter / Helper / Welder / Khalasi


Spare Parts.
Tools and Tackle
Manuals / Maintenance code of practices
Reliable data

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
6.0

TASK / ACTIVITY

6.1

BREAK DOWN MAINTENANCE.

6.1.1

Checking and repair of break down equipment.

6.1.2

INPUT

STEPS

6.3/UTY/DOP/02
01
28.12.2004
01
24.11.2005
02 OF 04

i)
ii)

Shift maintenance report


Complaints from other departments
(Through Memo)
Observations during rounds.

iii)
6.1.3

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

i)

Detect nature and extent of damage i.e. Critical, Normal or


Minor.

ii)

iii)
iv)
v)
vi)
v)

Data

Plan for attending the damage.


If Critical : Replace with spare equipment.
If Normal : Decide on the spot for replacement / repairs.
If Minor : Repair on the spot
Make list of spares required and collect at one place
Isolate the equipment for checking.
Attend the job and make list of damages likely to be
Caused to the equipment in future.
In case of critical problem, attend temporarily and plan for
shut down of the equipment.
Hand over equipment to operation.

6.1.4

CONTROL

Efficient running of equipment - Data.


Root cause analysis of breakdowns and preventive action
Plan, performance data sheet, condition monitoring data of
critical equipments

6.1.5

OUTPUT

Equipment in good running condition - Data.

6.1.6

MEANS

Competent Man Power, Spare Parts / Ready Overhauled


units, Tools and tackle.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
7.0

TASK / ACTIVITY

7.1

SHUT DOWN OF THE EQUIPMENT

7.1.1

Annual Shut Down of the equipment / Unit.

7.1.2

INPUT

7.1.3

STEPS

i)
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
xix)
xx)

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/DOP/02
01
28.12.2004
01
24.11.2005
03 OF 04

i)
ii)
iii)

Statutory Requirements (For Pressure Vessels Legislation)


Annual cleaning / checking of the unit - Schedule.
Getting inspectorate clearance (For Pressure Vessels) (Legislations)

Planning No. of hours of shut required for the equipment and connected
equipments.
List the connected equipments required to be stopped.
List of the jobs to be attended.
List of the spare parts required
Check the availability of required spares parts/equpments.
Indent material which are not available.
Store all the equipments / Spares at one place.
Taking necessary permission for governance of Safety / Pollution prevention/ IBR
Authorities where required.
Fixing up of the date and time of shut down in consultation with higher
authorities.
Inform all concerned departments.
Isolate the equipment
Attend the job step by step
Check the equipment for any other problem and make a list of the same.
Check whether all the listed jobs are completed or not
Windup / Box up the equipment after job completion
Take trial of the equipment and take observations of few hours.
Hand over to operation
Make list of jobs attended and spares consumed
Make list of jobs to be attended in future shut down and the spares required.
Plan for future shut down.
Make list of spares for future shut down and indent the materials required.

Data is available for the steps, where required for audit purpose (internal/ certification body)

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
7.1.4

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/DOP/02
01
28.12.2004
01
24.11.2005
04 OF 04

CONTROL

Renewal of licence Legislation


Break down free running of equipment and units - Data.

7.1.5

OUTPUT

Pressure vessel for reuse. Data / information


Equipment in smooth running condition Data

7.1.6

MEANS

Spare Parts, Fitters, Jr. Fitters, Helpers, Welders, Khalasi


and Contractors,

8.0

TASK / ACTIVITY

8.1

PROJECT WORK

8.1.1

New Projects or renovation and expansion activities

8.1.2

INPUT

i)
ii)

New Project requirements - Data / Plan


Expansion and renovation of existing plant - Data /
Plan

8.1.3

STEPS

i)
ii)
iii)

Project study alongwith P&D-document/ report.


Planning- Document
Execution of work- progress report/schedule

8.1.4

CONTROL

To meet demands of existing plant. Data

8.1.5

OUTPUT

i)

More efficient plant with better technology - Data.

ii)

Over coming the short coming of existing plant.


- Data

8.1.6

MEANS

9.0 REFERENCE DOCUMENTS


10.0 REFERENCE RECORDS
11.0 ABBREVIATIONS
12.0 AMENDMENTS

i)
ii)

Management
Competent Man power- Department Head,
Engineers / Fitters / Welders / Khalasi / Helpers.
iii)
New equipment etc.
iv)
Reliable data/ document/ report/ procedures
: * System operating procedures for applicable clause of
the standard (QMS)
: Relevant records available in department.
: none
: first issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

01 OF 01

1.0

PROCESS

Work instruction for


Centrifugal pump.

2.0

PURPOSE

This instruction gives method of starting of Positive


Suction Centrifugal Pump.

3.0

RESPONSIBILITY

4.0

SEQUENCE

4.1

See that suction valve and min flow line valve are in open position.

4.2

Check that suction valve and minimum flow line valve are in open position .

4.3.

starting of

6.3/UTY/WI/01
01
28.12.2004
00

positive

suction

Water Supply Operator/water tester.

Open the gland sealing water line.

4.4

Start the pump.

4.5

Open the delivery valve.

4.6.

Check for abnormal sound in the pump and bearing temperature, report if necessary.

4.7.

Record relevant parameter in respective documents.

4.0.

REFERENCE RECORDS

Log book / data sheet

5.0

AMENDMENTS

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

for

starting

of

6.3/UTY/WI/02
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PROCESS

Work instruction
centrifugal pump

negative

suction

2.0

PURPOSE

This instruction gives method of


suction centrifugal pump.

3.0

RESPONSIBILITY

4.0

SEQUENCE

4.1

Keep the delivery valve closed (not necessary if non-return valve is there in the
delivery line)

4.2

Open the suction valve.

4.3

Open the gland sealing water line of the pump and air exhauster.

4.4

Open the air exhauster valve.

4.5

Start the air exhauster. Check the suction pressure gauge.

4.6

When suction pressure has reached around 0.6 KSC, start the pump.

4.7

Open the delivery valve of the pump.

4.8

Stop the air exhauster and close the air exhauster valve.

4.9.

Check for abnormal sound and bearing temperature, inform if necessary.

starting of negative

Operator.

4.10. Record relevant parameters in respective documents including energy consumption.


5.0.

Reference records

Log book / Data sheet

6.0

Amendments

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
1.0

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

DEPARTMENTAL
OPERATING
PROCEDURE

stopping

6.3/UTY/WI/03
01
28.12.2004
01
24.11.2005
01 OF 01

PROCESS

Work instruction for


(Positive / Negative)

of centrifugal

pump

2.0

PURPOSE

This instruction gives method of stopping of Centrifugal


Pumps.

3.0

RESPONSIBILITY

Operator

4.0

SEQUENCE

4.1

Close the delivery valve (not necessary in non-return valve is there in delivery line).

4.2

Stop the pump.

4.3.

Close the gland sealing water line valve .

4.4.

Record relevant parameters in respective document.

5.0.

REFERENCE RECORDS : Log book / Data sheet

6.0

AMENDMENTS

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/04
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PROCESS

Work instruction for treatment of water at water


Treatment plant.

2.0

PURPOSE

This instruction gives method of water treatment at WTP

3.0

RESPONSIBILITY

Shift Engineer & Operator.

4.0

SEQUENCE

4.1
4.2

Close the drain valve of Lamella clarifier.


Chlorine, alum and Polymer dozing is done at the inlet channel of Lamella clarifier
as per central lab instruction.
4.3.
Open the inlet channel valve of lamella clarifier slowly.
4.4.
Fill the clarifier tank.
4.5.
Clarifier water of the lamella clarifier is sent to reservoirs
4.6
For colony water, clarified water is sent to filters for further filtration & dosing of NaOCl
4.7
Regular samples of raw water, clarified water are collected by Central Lab
In every shift for analysis.
4.8
If necessary lamella clarifier is drained at regular intervals when turbidity of clarified
water is more than 15 ppm
4.9
Handling and storage of chlorine tonner container as per MSDS, manufacturer,
storage and impact of hazardous chemical rules 1989 (MSIHC rules) and emergency
preparedness and response plan of the mills
4.10. If necessary lamella clarifier is drained at regular intervals when turbidity
of clarified water is more than 15 ppm.
NOTE : Process water is checked for Turbidity
- 10 - 15 ppm.
Residual Cl2 - 0.2 - 0.6 ppm
pH
- 7.0
4.11. Record relevant parameters in respective document.
5.0.
Amendments
:
First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/05
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PROCESS

Work instruction for operation of D.M. Plant

2.0

PURPOSE

This instruction gives method of operation of D.M. plant.

3.0

RESPONSIBILITY

Operator & Lab chemist.

4.0
4.1
4.2

SEQUENCE
:
Keep all the valves of SAC, SBA & MB Unit closed .
Open the SAC unit inlet valve to allow the water from DMF & ACF line to pass through
the SAC unit bed.
Open the SAC Unit drain valve for few minutes and close the valve.
Open the SAC air vent valve to remove air from vessel and close the valve.
Open the SAC. Unit outlet valve to allow semi-treated water to pass on to Degassor
tank.
Start degassifier to remove dissolved gases from water.
Start the Degassor pump to allow water to pass on to SBA Unit.
Open SBA. Unit inlet valve to allow the water to pass through SBA Unit bed.
Open SBA. Unit drain valve for few minutes (for rinsing).
Close the SBA Unit drain valve.
Open SBA Unit air vent valve to remove air from vessel and close the vent valve.
Open SBA. Unit outlet valve to allow de-mineralised water to pass on to the MB unit.
Open MB. Unit inlet valve to allow the water to pass through MB Unit bed
Open MB Unit drain valve for few minutes (for rinsing).& close the drain valve
Open MB Unit air vent valve to remove air from vessel and close the vent valve
Open MB. Unit outlet valve to allow water to store into DM water storage tank.
sent the water sample from SAC unit to check PH, hardness FMA
sent the water sample from SBA unit to check PH, conductivity & silica
sent the water sample from MB unit to check PH, conductivity & silica
Take the D.M. plant off load if silica is found in SBA unit out let sample
If is >0.03 ppm and pH is less than 7.2 .
Record relevant parameters in respective log book
ABBREVIATIONS:(i) DMF
- Dual media filter
(ii) ACF.
- Activated carbon filter
(iii) SAC
- Strong Acid cation
(iv) SBA
- Strong base anion
(v) MB
- Mixed bed

4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13.
4.14.
4.15.
4.16.
4.17.
4.18.
4.19.
4.20.
4.15.
4.0.

5.0.
6.0

REFERENCE RECORDS
AMENDMENTS
:

:
6.3/PHS/LB/03
First issue.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
1.0
2.0

PROCESS
PURPOSE

:
:

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/06
01
28.12.2004
01
24.11.2005
01 OF 02

Work instruction for regeneration demineralization plant


This instruction gives method of Regeneration of
Demineralization Plant.
Operator and Lab chemist.

3.0
RESPONSIBILITY
:
4.0
SEQUENCE
:
A Regeneration of SAC Unit
4.1
Use filter water from SCF & DMF for regeneration of SAC Unit and semi-treated water
for regeneration of SBA & DM water for regeneration of MB Unit. After SBA unit
4.2
Keep all the valves of SAC Unit closed.
4.3
Open the back wash (flow of water is opposite to the normal flow) outlet valve and
slowly open the back wash Inlet valve & adjust it such a way tha level of water in drain
sump is at wash marker.
4.4
Allow the water to pass through the bed of SAC Unit and drain the water to
clear the mud. (This takes around 30 minutes till water is clear visually).
4.5
Close back wash outlet valve and inlet valve.
4.6
Open down flow valve & air release valve when water start coming out FULL BORE
from air release valve than close the air release valve.
4.7
Open middle collector outlet valve fully.
4.8
Adjust the down flow valve such that water in drain sump is up to the down flow mark
on v- notch board.
4.9
Open HCL acid inlet valve fully.
4.10 Open injector power water valve & adjust it such a that the valve of water drain sump
is slightly below the acid injection mark in V- notch board.
4.11 Open the acid out let valve of acid measuring tank & adjust such that the level of water
in the drain is up to the mark on the v- notch board.
4.12 The level of solution in acid measuring tank is to be drop at the such a rate that entire
quantity of acid will be injected in approx. 30 minutes.
4.13 After entire quantity of acid has been injected close the injector suction valve & let other
valve open.
4.14 Adjust the injection power water valve such that the level in the drain sump is again acid
injection mark.
4.15 Let this procedure be continued for next 30 minutes.
4.16 Close the all valves.
4.17 Check the quality of water if it is satisfactory , open outlet valve to take unit into
service.
4.18 Monitor the relevant parameters during entire service run. ( pH < 4. Hardness- nil,
FMA- 45 to 60 ppm

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/06
01
28.12.2004
01
24.11.2005
02 OF 02

B. re- generation of SBA unit :


Repeat the same procedure of SAC unit for regeneration of SBA unit. And ijec caustic instead
of acid. And it will take 35 minutes for completion procedure.
Monitor the relevant parameters
pH- 7.5- 9.2, conductivity < 20 s/ cm. silica < 0.02 ppm, chloride nil
C. Regeneration of MB unit.
1.1
Repeat th procedure of step 4.1 to 4.4 for back wash of MB unit.
1.2.
ensure that the cation & anion resin are properly seperated.
1.3
Closed the backwash outlet & inlet valves.
1.4
Acid injection :
a)
open inlet valve
b)
Open rinse outlet valve & adjusted such that level of in drum sump is up to
down flow marker.
c)
Repeat the procedure of step 4.9 to 4.11
d)
The level of solution in acid measuring tank is to be drop at the such a rate that
entire quantity of acid will be injected in approx 15 minutes
e)
closed the outlet valve & adjust the injector power water valve such that entire
quantity of acid rinse marker keep it for 15 minuts
g)
Close the acid injection valve
1.5
Caustic injection:
a)
Open wash inlet valve
b)
Open middle collector valve.
c)
Adjust the flow such that leve of in drain sump is up to UP FLOW marker
d)
Repeat the procedure of step 4.9 to 4.11
e)
The level of solution in caustic measuring tank is to be drop at the such a rate
that entire quantity of caustic will be injected in approx 15 minutes
f)
Closed the outlet valve & adjust the injector power water valve such that level
of in drain sump is up to ALKALI RINSE marker.
g)
keep it for 15 minuts
h)
Close the caustic injection valve
1.6
Open air release valve
1.7
Open rinse outlet valve.
1.8
Closed rinse outlet valve as soon as water level is visible in top inspection window.
1.9
Start the blower, open inlet valve fully & mixed the resins vigorosly.
1.10 Ensure that cation & anion beds are thoroughly mixed
1.11 After 10 minutes closed the air inlet valve
1.12 Stop blower
Monitor the relevant parameter
pH 6.5-7.2, conductivity <2s/cm ,silica<0.02ppm ,chloride-nil
Notes: 1) For SAC unit regeneration, use 800 kg of 30% purity Hydrochloride acid
2) For SBA unit regeneration, use 400 kg of 48% purity Caustic.
3) For MB unit regeneration, use 180 kg of 30% purity Hydrochloride acid & 120 kg of
48% purity Caustic

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/07
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PROCESS

Work instruction for coal handling.

2.0

PURPOSE

This instruction gives method of supplying coal into


Boiler Coal Bunker.

3.0

RESPONSIBILITY

Shit Engineer, Jr. Engineer (Maint), Fitter, Operator.

4.0

SEQUENCE

4.1

With the help of dewatering pump remove water in the pit in the tunnel
Whenever required.

4.2

Start the conveyor belt as per sequence.

4.3

Start Vibrator.

4.4

Start Coal crusher.

4.5

Check the conveyor belt for any damage and for smooth running

4.6

Check the crusher and vibrator for smooth running.

4.7

Selected coal from stores [ Stock yard ] and unload on reclaim hopper

4.8

Break the lump coal by hammer manually.

4.9

Check coal supply is continuous at coal crusher inlet.

4.10. Check for coal is crushed to proper size and fed to the boiler coal bunker
[size(-)6 mm)]
4.11. Stop coal crusher and vibrator when bunker is full.
4.12. Stop conveyor belt.
4.13. Stop shifting of coal from coal yard.
5.0.

Reference records

Log book / Data sheet

6.0

Amendments

First issue

Prepared by : ________
Designation: Mgr.(Uty.)
Date

__________
D.G.M.(Uty.)

: 24.11.2005

Reviewed by : _________

Approved by : ___________

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
1.0
PROCESS
PURPOSE
3.0
4.0

RESPONSIBILITY
SEQUENCE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/08
01
28.12.2004
01
24.11.2005
01 OF 02

:
Work instruction for starting of boilers #2 ( OK-8)
This instruction gives method of stating & running of
boiler.#2
:
DGM/Asst Manager/ shift engineer / Boiler Operator.
:

2.0

PROCEDURE FOR OIL FIRED BOILER #2 (OK-8) START UP.


CAPACITY : 60 TPH, WORKING PRESSURE 55 KG/CM2, TEMP : 410 deg C
START
1.
2.
3.
4.

PERMISSION TO BE CHECKED.
FD fan running and damper is in minimum position (5%)
Oil pump running on recirculation & oil temp is around 105/107 deg C
Air sides valves are open.
keep the boiler feed pump on recirculation.

PROTECTION INTERLOCK TO BE CHECKED


1.
Boiler trip with drum level very high (80%) & drum level very low (20%)
2.
Oil temp <90 deg C ,MFR will trip & subsequently Boiler will trip.
3.
Oil pressure less than 3.5 kg/cm2.
4.
Furnace pressure very high >200 mmWcl ,Boiler trip.
5.
FD fan trip, Boiler will trip.
STARTING PROCEDURE.
1.
Start FD fan, keep damper in minimum position.
2.
Open the air slide valves.
3.
Start purging for 10 minutes
4.
Wait for purge complete signal on PLC monitor.
5.
Reset the MFR.
6.
Open fuel oil trip valve.
7.
Note oil temp is 105/107 deg C.
8.
Bring down the FD fan damper opening to minimum (5%).
9.
Ensure oil pressure at burner above 6 kg/cm2 & atomizing steam pressure above 10
kg/cm2.
10.
Check LPG pressure for igniter is healthy.
11.
Give burner start command.
12.
Note first pilot flame is appear & oil valve & atomizing steam valve is open for burner
will open.
13.
Watch the flame in burner frame & increase oil pressure & FD air flow for healthy
condition of flame.
14.
Note the drum pressure when it is above 3 kg/cm2 close the drum vent, open super
heater vent when drum pressure is 15 kg/cm2 to raise the steam temp.
15.
Maintain the drum level manually through blow down valve & drum level controller by
pass valve.
16.
Increase the drum pressure by regulating air flow and oil flow.
17.
Maintain steam venting through super heater vent till the steam temp reaches to 360370 deg C.
Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
18.

19.
20.

21.

22.

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/08
01
28.12.2004
01
24.11.2005
02 OF 02

Slowly open the main steam stop valve (10%) & 64/35 PRDS valve to warm up the main
steam line.
close the start up vent.
note steam temp, pressure & drum pressure when steam temp reaches to 410 deg C &
main steam pressure 35 kg/cm2 & drum pressure 45 to 45 kg/cm2,
open main steam stop valve fully & 64/35 PRDS in such a way to maintain down steam
pressure 35 kg/cm2.Open the 35 ata header inlet valve & take the boiler on range
Put the drum level control from manual to auto mode.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/09
01
28.12.2004
00
01 OF 01

1.0

PROCESS

Work instructions for stopping of boiler # 2 ( OK-8)

2.0

PURPOSE

This instruction gives method of stopping of Boiler.

3.0

RESPONSIBILITY

DGM/Asst Manager / Shift Engineer/ Operator.

4.0

SEQUENCE

4.1

Close the FOTV to stop the oil flow into furnace.

4.2.

Purge the furnace for 10 minutes

4.3.

Close the forced draft fan.

4.5

Close the stop valves keep drains open.

4.7

Depressurize the boiler


running feed pump.

4.8

Stop feed pump if not required.

4.9

Open the vent valves and air cock valve when boiler pressure is nearer to atmospheric
Pressure (2 to 3 Kg/cm2 ).

4.10

Record all parameter in respective documents.

5.0

Reference Document

Manufacturers manual/ Drawing

6.0

Amendments

First issue

to zero naturally by maintaining water level in boiler by

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/10
01
28.12.2004
01
24.11.2005
01 OF 02

PROCESS : Work instruction for start up of coal fired boiler # 3 & 4 (AFBC).
PURPOSE : This instruction gives method of start up of coal fired boiler # 3& 4.
RESPONSIBILITY : DGM/Asst Manager/ Shift Engineer , Boiler operator gr 1 & 2.
SEQUENCE :
A.

Start up permissive to be checked.


1.
All access doors closed.
2.
Drum level is maintaining in the range of 35 to 50 %
3.
Drum vents & super heater drain and vents are open.
4.
All motorized valve operation are checked and in closed condition.
5.
All fans, Boiler feed pump & coal feeder power supply is in ON position & check for
Lubrication & cooling water.
6.
Ensure that coalbunkers gates are opened & crushed coal (0-6mm) is available.
7.
Ensure that compressed air is available at reqd. pressure for instrumentation & control.
8.
Put all automatic controls equipments on manual control & see that all control
equipment are ready for service.
9.
Drain the valves of water level gauge, level switch, level transmitter.
10.
Boiler feed pump is running on recirculation & stand by boiler feed pump is available.
B. Protection interlock to be checked.
1.
Drum level protection very low (30%) & very high (80%) for boiler trip including tripping
of ID, PA, FD & coal feeders.
2.
Furnace pressure very high (>100 mmwc).
C. Procedure for starting
Start ID fan, PA fan & FD fan
Open the PAD & FAD of all compartments.
Adjust IGV of FD & ID to maintain total air flow 1,50,000 kg/hr & maintain the furnace
pressure 0 to (-10) mm Hg.
4.
Note the air box pressure of all compartment for carried out for DP test & records the
same in relevant documents.
5.
Allow to charge bed material (crushed refractory) through the manhole door provided.
6.
Reduce airflow to zero after bed material filling is completed.
1.
2.
3.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
7.

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/10
01
28.12.2004
01
24.11.2005
02 OF 02

30.

Closed the FD damper of all compartments except comp #1 & checked the minimum
fluidization in comp #1 & measure the bed height (290-300 cm)
Allow to charge charcoal in start up comp. (comp #1) through the manhole.
Ensure the charcoal is totally dry & in the size range 10 to 12 mm.
The charcoal quantity reqd. per startup for Boiler #3-650 to 700 kg & for boiler #4 -450
to 500 kg.
On completion of charcoal charging fix up the light up burners in respective position.
Ensure the oil pump is running on re circulation & oil tank level is normal.
Light up the burners with fire swab.
Ensure the fire spread uniformly on entire
Adjust the airflow corresponding to bed temp.
As the bed temp is increase along with increase in air flow at one stage fluidization is set
on.
As soon as in bed temp reaches 700 deg C coal feed is to be introduce in starting comp
from minimum rate.
after introduction of coal feed rate it shall be maintain at value that will stabilized bed
tem around 850 deg C.
Stop the start up burners & removed the same for position.
Closed the drum vent when drum pressure is reaches 4 kg/cm2(g)
Start up vent is to be kept open.
When drum pressure reaches to 29 kg/cm2 closed the super heater drains & maintain
circulation by adjusting start up vent
Watch the rise of steam temp & intermittently activated the compartment -2
Watch th bed temperature of the compartment 2 and when it reach 700 o c ( in bed )
start coal feeding of compartment 2.
Main steam pressure 35 to 40 kg/ cm 2 and steam temperature 360 o c., open the by
pass valve opf main steam stop valve for worm of main steam line. Up to 84 ata header
( ensure header inlet valve is closed.)
In same way active the remaining compartment.
Maintain drum level through manual operation of drum level controller.
Once boiler is in steady state operation ( stem pr. 60 to 70 kg/ cm2 , temperature
460 o C) put the feed level system in auto made.
open the main steam stop valve gradually when steam pressure reach 84 kg/ cm2 and
temp. 470 o c simultaneously open the 84 ata inlet valve.
Take the boiler in range.

8.
9.
10.

Reference documents
Reference Records
Amendment

8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

:
:
:

Manufacturers Manual / Drawing


Log book / Data sheet
First Issue.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/11
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PROCESS

Work Instruction for stopping of AFBC boiler.

2.0

PURPOSE

This instruction gives method of stopping FBC Boiler.

3.0

RESPONSIBILITY

DGM/Asst Manager/ Shift engineer/ Boiler Operator.

4.0

SEQUENCE

4.1

Close bunker coal gates reduce the coal feeding to zero.

4.2

Close Induced draft


of water column.

4.3.

Stop all fans .

4.4

Close the stop valve, open drain valve of the main line.

4.5

Open forced draft

4.6

Meanwhile, maintain the drum water level.

4.7

Slowly the boiler steam pressure reduces.

4.6

Open vent valves when steam pressure reaches just above atmospheric pressure
(2-3 Kg/cm2).

5.0.

Reference Records

Log book / Data sheet

6.0.

Amendments

First issue

and forced draft dampers maintaining the furnace draft to -10 mm

and Induced draft

damper to allow natural cooling of furnace.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/12
01
28.12.2004
01
24.11.2005
01 OF 02

1.0

Process

Work instruction for starting of 12.5 MW AEG TG.

2.0

PURPOSE

This instruction gives method of generating electrical


power and extraction of low pressure and Medium
pressure steam from 12.5 MW AEG Turbine.

3.0

RESPONSIBILITY

DGM, Manager, Shift Engineer& Turbine Operator.

4.0

SEQUENCE

4.1

PERMISSIVE TO BE CHECKED.
1.
2.
3.
4.
5.
6.

4.2

PROTECTION INTER LOCK TO BE CHEKED.


1.
2.
3.
4.

4.3

lub oil tank level is normal.


AOP is running.
Machine is on baring gear.
Auto start of EOP is available.
All gauges are in position.
Speeder gear wheel at the minimum in position.

TG trip at lub oil pressure is very low. (0.85 kg/ cm2)


Remote / manual trip from local push button.
Auto start of EOP at lub oil pressure very low
Control oil pressure is very low. (4 kg/ cm2 )

PROCEDURE FOR ROLLING


1.
2.
3.
4.
5.
6.
7.
8.

Warm up the main steam line by opening the pilot valve of main steam isolating
valve at 84 ata header. Keep start up vent line open.
Keep all the drains of main steam line open.
Keep all the drains of main steam line open.
Check all the drains of turbine (casing drain, HP / LP, LP extraction drain, gland
sealing supply line) & LP extraction vent are fully open.
Note ESV inlet steam pressure and temperature.
When inlet steam pressure is around 50 kg/ cm2 and temperature get up over
350C roll the machine up to the speed of 250 to 300 rpm.
Allow soaking for minimum 1 hour.
Note overall expansion of TG.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
9.

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/12
01
28.12.2004
01
24.11.2005
02 OF 02

When expansion is around 2.5 to 2.7 mm, open header inlet steam valve fully
and start up vent valve to be closed.

10.

Increase the steam pressure up to 78 kg/ cm2 and temp above 430C .

11.

Roll the machine up to the speed of 1200 RPM and allow for soaking.

12.

Note expansion of turbine, when it is above 3 mm checks all the drains,


particularly casing and LP extraction.

13.

Ensure there is free steam flow from all the drains.

14.

Roll the machine gradually up to the speed, when governor take over (2850-2907
RPM)

15.

Open ESV fully, and note down the governor speed.

16.

Raise the speed from governing speed (2910 RPM) to 3000 RPM by speeder gear.

17.

Stop AOP and note all the lub oil pressure and adjust oil cooler inlet pressure 4.2
kg/ cm2

18.

Maintain TG speed at 3020 RPM.

19.

Give clearance to Elect. Dept for loading.

20.

Take vibration of all the bearings at 1200 RPM and 3000 RPM and close all the
drains and vents.

21.

Open De-super heating water when LP exhaust >200C. For safe operation of TG
set, exhaust temp from LP TG set not to be exceed 220C. Hence min load reqd
4.5 MW

22.

Put lub oil cooler in service to maintain oil temperature at 40 C.

5.0

Reference documents

Manufacturers Manual / Drawing

6.0

Reference Records

Log book / Data sheet

7.0

Amendment

First Issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
1.0

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/13
01
28.12.2004
01
24.11.2005
01 OF 01

PROCESS

Work instruction for stopping of 12.5 MW AEG turbine

2.0

PURPOSE

This instruction gives method of stopping 12.5 MW AEG


Turbine.

3.0

RESPONSIBILITY

DGM, Manager, Shift Engineer& Turbine Operator.

4.0

SEQUENCE

4.1

Unload the electrical load on the turbine.

4.2

Inform the boiler operator

4.3

Trip the turbine by hand, starts the AOP immediately at around 2800 rpm of
turbine speed .

4.4

Put the turbine in baring gear.

4.5

Check all the drain lines of bearing oil for oil flow to the bearings

4.6.

Open the all drains valves and vent valves before NRV near 4 ata header

4.7

Close the main isolating valve on the 84 ata header main steam line.

4.8

Barring gear can be stopped only after the turbine casing temp drops to 80 to 100C

4.9

Maintain records

5.0.

Reference Document

6.0.

Amendments

Manufacturers manual/ Drawing


:

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/14
01
28.12.2004
01
24.11.2005
01 OF 02

1.0

PROCESS

Work instruction for starting of 10 MW Siemens turbine.

2.0

PURPOSE

This instruction gives method of generating electrical


power from 10 MW Siemens turbine

3.0

RESPONSIBILITY

DGM, Manager, Shift Engineer& Turbine Operator.

4.0

SEQUENCE

A. PERMISSIVE TO BE CHECKED.
1.
2.
3.
4.
5.
6.
7.
8.

Lub oil tank level is normal.


AOP is running.
Machine is on baring gear.
Auto start of EOP is available.
All gauges are in open position.
Speeder gear wheel at the minimum position.
Gland sealing steam is available with required pressure (3 kg/ cm2 )
Main ejector steam pressure 10.5 kg/ cm2 is available at 11 ata header.

B. PROTECTION INTER LOCK TO BE CHECKED.


1.
2.
3.

TG trip at lub oil pressure is very low ( 0.85 kg/ cm2)


condenser vacuum is very low ( 420 mm of Hg)
governing oil pressure is very low ( 6 kg / cm2)

C. PROCEDURE FOR ROLLING.


1.
2.
3.
4.
5.
6.
7.
8.

Open all main steam drain lines fully.


worm of the main steam line by opening exhaust vent and pilot valve on 35 ata
check hot well level, it should be 38 to 40%.
put one condensate extraction pump on re circulation
put 2 nos cooling water pump in operation.
put starting steam ejector steam line and gland sealing steam line in worm up condition
ensure no condensate coming from the drain.
put starting ejector in service. By opening the air valve, ensure the inlet steam
pressure is 9.5 kg/ cm2( minimum for starting ejector operation).
observe vacuum, when vacuum is greater than 40 mm of Hg, slowly open the
gland steam supply valve for HP and LP Gland sealing.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
9.
10.

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/14
01
28.12.2004
01
24.11.2005
02 OF 02

32

Maintain Gland Line Steam Pressure Above 1 Kg/ Cm2.


Note The Increase Of Vacuum And Slowly Increase The Steam Supply And Ensure
Steam Is Coming Out From HP And LP Gland To Atmosphere.
When Vacuum Is Greater Than 200 Mm Of Hg Put One Vacuum Pump Is In
Service And Isolate The Starting Ejector.
Observe The Annunciation For Condenser Vacuum Low And Very Low Are Reset.
Reset The TG From Local Lever And Electrical Panel Also.( 86 T Relay)
Check The Tripping Of TG From Remote Push Button, Reset The TG Further.
Note The Inlet Steam Temperature Before ESV, It Should Be Greater Than 380 O C.
Close The Start Up Vent Valve Of Main Steam Line , Note The Inlet Steam Pressure
Before ESV, It Should Be 30 Kg/ Cm2.
Open The ESV Slowly And When TG Speed Is Greater Than 200 RPM ,
isolate Barring Gear Oil Supply And Increase The TG Speed Up To 500 RPM.
Allow The TG For Soaking Minimum An Hour At 500 RPM
Note Differential And Overall Expansion It Should Be In Increasing Tendency
towards +Ve Side
Increase The Speed Up 1000 RPM And Allow For Soaking For 10 To 15 Minutes.
Check All Bearings Vibration And Oil Temperature.
Increase The TG Speed Gradually At The Rate Of 60 Rpm Per Minutes Up To
1500 RPM And 120 RPM Per Minutes After 1500 RPM And Note The Governing
Take Over Speed, It Should Be Between 2300 To 2350 RPM.
Open ESV Fully.
Increase The TG Speed Up To 3000 RPM By Speeder Gear Operation.
Stop AOP At 2900 RPM And Observe The MOP Header Oil Pressure.
Check All Atmospheric Drains And Ensure There Is Free Flow Of Steam From All Drains,
close All The Drains After Check Up.
Maintain TG Speed At 3010 RPM And Give Clearance To Electrical Dept For Loading.
Put Oil Temperature Controller In Service To Maintain Inlet Oil Temperature 40 O C.
Put Hot Well Level Controller In Auto With A Set Point 30 %.
Run 3 Nos Of CT Fans , All Drains Connected To The Flash Tank Should Be Keep
Open ( Throttle Condition)
Put Second CW Pump In Service. Note During Running Of The Turbine All The
Auxiliaries Should Be In TG Supply.
To Run TG Maintain Inlet Steam Pressure 32 Kg/Cm2 And Temperature 400 10 O C

D.

Reference documents

Manufacturers Manual / Drawing

E.

Reference Records

Log book / Data sheet

F.

Amendment

First Issue

11.
12.
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

6.3/UTY/WI/15
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PROCESS

Work instruction for stopping of 10 MW Siemens Turbine.

2.0

PURPOSE

This instruction gives method of stopping the 10 MW


Siemens Turbine.

3.0

RESPONSIBILITY

DGM, Manager, Shift Engineer& Turbine Operator.

4.0

SEQUENCE

4.1

Unload the electrical load on the turbine.

4.2

Inform the Boiler operator.

4.2

Open vent valve

4.3

Trip the turbine by hand , start the auxiliary oil pump at around 2900 rpm of turbine
Speed.

4.5.

Kill the vacuum.

4.6

Put the turbine in baring gear operation when TG speed come down to 250 RPM

4.7.
4
5

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

open all the drain valves

4.8.

Record all parameters in respective documents.

4.9

maintain records

5.0.

Reference Document

6.0.

Amendments

Manufacturers manual / Drawings


:

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/16
01
28.12.2004
01
24.11.2005
01 OF 02

1.0

PROCESS

Work instruction for annual shut down of boilers /


turbines and other equipment

2.0

PURPOSE

This instruction gives procedure


down of Boilers / Turbines.

3.0

RESPONSIBILITY

DGM / Manager / Dy-Manager/ Engrs/Fitters.

4.0

SEQUENCE

4.1

Finalise shut down dates in advance.

4.2

Send prior intimation to concerned departments i.e., Electrical, Instruments, Civil


Construction, to check / repair the equipments from their end.

4.3

Inform Stores Department in advance to maintain spares required for annual shut down
as per list sent and also to procure the additional spares/material indented.

4.4

Send Work Shop Job Orders in advance for making necessary spares.

4.5

Send additional manpower sanction memo in advance.

4.6

Arrange for shift schedules of Engineers/Workers.

4.7

Wherever required, identify & assign contractor for miscellaneous work.

4.7

In case of Boiler, take permission from Chief Inspector of Boilers for attending
Maintenance work of pressure parts (By GM & in his absence by DGM).

4.9.

Confirm that the equipment is disconnected from the process from safety consideration.

for annual shut

4.10. Plan for the work to be attended.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/16
01
28.12.2004
01
24.11.2005
02 OF 02

4.11.

Dismantle the required parts clean and check.

4.12.

Change the non conforming parts by new one or by repaired one.

4.13.

Assemble the equipment, take the clearance from other departments for their work.

4.14.

Take clearance form chief inspector of boiler in case of

4.15.

Take the trial of the equipment and check for smooth running and hand over to the
process.

4.16.

Record the jobs attended.

4.17.

Identify & record the spares required for next shut down.

5.0.

Reference Document

Manufacturers manual/ Drawings

6.0.

Amendments

First issue

boiler.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/17
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PROCESS

Work

instruction for overhauling of equipment.

2.0

PURPOSE

This instruction gives procedure of overhauling of an


equipment.

3.0

RESPONSIBILITY

Manager. Dy-Manager/ Jr. Engineer/ Fitter.

4.0

SEQUENCE

4.1

Check the stock position of necessary spares in stores.

4.2

Send job order to Work Shop to make spares which are not available in stores.

4.3.

Dismantle the equipment (As per documented standard code of practice / guidelines by
competent persons).

4.4.

Check the dimensions of parts. Replace them with new ones, or repaired if they are
not in conformation with required specifications.

4.5

Send Job Order to Work Shop for miscellaneous jobs.

4.6

Recheck the dimensions of spares procured from Stores and Work Shop.

4.7

Assemble the equipment (As per documented code of practice / guidelines by competent
persons).

4.8

Place indent for consumable spares as per procedure.

4.9

Record the jobs attended & Maintain the History Cards ( both hard copy and soft copy)

5.0

Reference Document :

6.0

Amendments

Reference Manuals / Drawings.


:

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/18
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PROCESS

Work instruction for starting of 1000 KVA


DG Set t inside the mill

2.0

PURPOSE

This instruction gives method of starting of 1000 KVA


D.G. Set.

3.0

RESPONSIBILITY

4.0

SEQUENCE

4.1

Check the cooling water level of the engine.

4.2

Check the lubricating oil in the Engine.

4.3

Crank the engine with the help of key and push button is pressed to start the engine.

4.4

Run the engine at idle speed (1000 RPM) for about 5 minutes.

4.5

Increase the engine speed to its run speed (1500 RPM) for about 5 minutes.

4.6

Load the engine gradually.

4.7.

Record all the parameter in respective document and inform any abnormalities.

5.0.

Reference Document

OEM Manual

6.0.

Amendments

First issue

Asst. Mgr, Shift Engineer, T.G. Operator.


:

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/19
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PROCESS

Work instruction for stopping of 1000 KVA DG Set.

2.0

PURPOSE

This instruction gives method of


1000 KVA D.G. Set.

3.0

RESPONSIBILITY

Asst Mgr, Shift Engineer, T.G. Operator.

4.0

SEQUENCE

4.1

Reduce

4.2

Run the engine for about 5 minutes at Run Speed (1500 RPM).

4.3

Reduce the Engine Speed to its idle speed (1000 RPM)

4.4

Run the engine at idle speed for about 5 minutes.

4.5

Stop the engine after releasing the key.

4.6.

Record all parameters in respective document.

4.0.

Reference Document

OEM Manual

5.0

AMENDMENTS

First issue.

stopping the

load on the engine gradually to zero.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
PROCESS

Work instruction
1000 KVA DG Set.

2.0

PURPOSE

This instruction gives method of B check maintenance


of 1000 KVA D.G. Set.

3.0

RESPONSIBILITY

Dy-Manager/ Jr. Engineer, Fitter.

4.0.

SEQUENCE

4.1.

B Check maintenance is done after 300 425

4.2.

Change all the inlet lube oil filters (4 Nos.).

4.3.

Change all the bye-pass lube oil filters (2 Nos.).

4.4.

Change the fuel filters (2 Nos.).

4.5.

Check

4.6.

Check the condition of Lube oil filter by opening the filters (to decide the condition
of Engine).

4.7.

Completely drain the lube oil (20W40) and add fresh lube oil to sump.

4.8.

Check the belt tension.

4.9.

Clean the air cleaner element.

4.10

Record the work attended in respective documents .

5.0.

Reference Document

Reference Manuals.

6.0

Amendments

First issue

pH

value

check

6.3/UTY/WI/20
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

the

for

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

maintenance

of

running hours of D.G. Set.

of Engine radiator cooling Water

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/21
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PROCESS

Work instruction for C check


1000 KVA D.G. Set

2.0

PURPOSE

This instruction gives method of C check Maintenance


of 1000 KVA. Set.

3.0

RESPONSIBILITY

Dy- Manager/ Jr.Engineer, Fitter.

4.0

SEQUENCE

4.1.

C Check Maintenance is done after 1500-2000 running hours,1st time, 6000-7000


running hours - 2nd time of D.G. Set.

4.2

Repeat all the work instruction of B check Maintenance.

4.3

Check injectors and tappet valves, setting and adjust if required valve clearance
at inlet should be 14 thou and 27 thou at the exhaust.

4.4

Check the water pump end play (axial play should be 4 thou).

4.5

Check crank shaft end play (axial play should be 7 to 17 thou).

4.6

Clean the heat exchanger, low temperature after cooler.

4.7

Record the work attended in respective document.

5.0

Reference Document

6.0

Amendments

maintenance of

Reference Manuals.
:

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

for

D check

6.3/UTY/WI/22
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PURPOSE

Work
instruction
1000 KVA DG Set

maintenance

of

2.0

PURPOSE

This instruction gives method of D check maintenance


of 1000 KVA D.G. Set.

3.0

RESPONSIBILITY

Dy-Manager /Jr. Engineer, Fitter.

4.0

SEQUENCE

4.1

D Check Maintenance is done after 6000-7000 running hours of D.G. Set.

4.2

Repeat all the work instruction of C check Maintenance.

4.3

Check the physical condition of cam shaft.

4.4

Clean the turbo charger with petrol.

4.5

Adjust the magnetic pickup clearance (It should be 28 30 thou).

4.6

Clean the fuel filter i.e., magnetic screen in the pump.

4.7.

Record the work attended in respective document.

5.0.

Reference Document

Reference Manuals.

6.0

Amendments

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
1.0

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/23
01
28.12.2004
01
24.11.2005
01 OF 01

PROCESS

Work instruction for starting of 500 KVA DG Set


at Intake

2.0

PURPOSE

This instruction gives method of starting of 500 KVA


D.G. Set.

3.0

RESPONSIBILITY

Shift Engineer, Operator.

4.0

SEQUENCE

4.1

Check the cooling water level of the engine.

4.2

Check the lubricating oil in the Engine.

4.3

Crank the engine with the help of key and push button is pressed to start the engine.

4.4

Run the engine at idle speed (1000 RPM) for about 5 minutes.

4.5

Increase the engine speed to its run speed (1500 RPM) for about 5 minutes.

4.6

Load the engine gradually.

4.7.

Record all the parameter in respective document and inform any abnormalities.

5.0.

Reference Document

OEM Manuals

6.0.

Amendments

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/24
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PROCESS

Work instruction for stopping of 500 KVA D.G. Set.

2.0

PURPOSE

This instruction gives method of


D.G. Set.

3.0

RESPONSIBILITY

Shift Engineer, Operator.

4.0

SEQUENCE

4.1

Reduce

4.2

Run the engine for about 5 minutes at Run Speed (1500 RPM).

4.3

Reduce the Engine Speed to its idle speed (1000 RPM)

4.4

Run the engine at idle speed for about 5 minutes.

4.5

Stop the engine after releasing the key.

4.6.

Record all parameters in respective document.

4.0.

Reference Document

OEM Manuals

5.0

AMENDMENTS

First issue.

stopping the 625KVA

load on the engine gradually to zero.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
PROCESS

Work instruction
500 KVA DG Set.

2.0

PURPOSE

This instruction gives method of B check maintenance


of 500 KVA D.G. Set.

3.0

RESPONSIBILITY

Dy-Manager/ Jr. Engineer, Fitter.

4.0.

SEQUENCE

4.1.

B Check maintenance is done after 300 425

4.2.

Change all the inlet lube oil filters (4 Nos.).

4.3.

Change all the bye-pass lube oil filters (2 Nos.).

4.4.

Change the fuel filters (2 Nos.).

4.5.

Check

4.6.

Check the condition of Lube oil filter by cut opening the filters (to decide the condition
of Engine).

4.7.

Completely drain the lube oil (20W40) and add fresh lube oil to sump.

4.8.

Check the belt tension.

4.9.

Clean the air cleaner element.

4.10

Record the work attended in respective documents .

5.0.

Reference Document :

Reference Manuals.

6.0

Amendments

pH

value

check

6.3/UTY/WI/25
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

the

for

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

maintenance

of

running hours of D.G. Set.

of Engineer Water

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
1.0

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/26
01
28.12.2004
01
24.11.2005
01 OF 01

PROCESS

Work instruction for C check


500 KVA D.G. Set

maintenance of

2.0

PURPOSE

This instruction gives method of C check Maintenance


of 500 KVA D.G. Set.

3.0

RESPONSIBILITY

Dy- Manager/ Jr.Engineer, Fitter.

4.0

SEQUENCE

4.2.

C Check Maintenance is done after 1500-2000 running hours,1st time, 6000-7000


running hours - 2nd time of D.G. Set.

4.2

Repeat all the work instruction of B check Maintenance.

4.3

Check injectors and tappet valves, setting and adjust if required valve clearance
at inlet should be 14 thou and 27 thou at the exhaust.

4.4

Check the water pump end play (axial play should be 4 thou ).

4.5

Check crank shaft end play (axial play should be 7 to 17 thou).

4.6

Clean the heat exchanger, low temperature after cooler and air cyclone tubes.

4.7

Record the work attended in respective document.

5.0

Reference Document

Reference Manuals.

6.0

Amendments

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

for

D check

6.3/UTY/WI/27
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PURPOSE

Work
instruction
500 KVA DG Set

maintenance

of

2.0

PURPOSE

This instruction gives method of D check maintenance


of 500 KVA D.G. Set.

3.0

RESPONSIBILITY

Dy-Manager /Jr. Engineer, Fitter.

4.0

SEQUENCE

4.1

D Check Maintenance is done after 6000-7000 running hours of D.G. Set.

4.2

Repeat all the work instruction of C check Maintenance.

4.3

Check the physical condition of cam shaft.

4.4

Clean the turbo charger with petrol.

4.5

Adjust the magnetic pickup clearance (It should be 28 30 thou).

4.6

Clean the fuel filter i.e., magnetic screen in the pump.

4.7.

Record the work attended in respective document.

5.0.

Reference Document

Reference Manuals.

6.0

Amendments

First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/28
01
28.12.2004
01
24.11.2005
01 OF 01

1.0

PROCESS

Work instruction for overhauling of safety valve.

2.0

PURPOSE

This instruction gives method of Over hauling and


setting valve/ relief valve.

3.0

RESPONSIBILITY

Manager/ Dy- Manager/ Fitter,

4.0

SEQUENCE

4.1

Remove the safety valve /Relief Valve after taking clearance from operation.

4.2

Dismantle the valve and clean all parts.

4.2

Check the condition of all parts, if required send for repair to Work Shop/replace
with new one.

4.4

Grind the Valve body seat & Valve seat if necessary.

4.5

Assemble all the parts, conduct hydraulic test.

4.6

Fix the valve in respective position and give clearance for operation.

4.7

Check relief & re seating pressure during operation, if required re set relief pressure .

4.8

certify the safety valve for safe working pressure.

5.0

Reference Document :
Range of hydraulic Test for header valves.
1)
2)
3)

6.0

Amendments

For H.P.(34 kg/cm2 Safety Valve 38.5 Kg/cm2


For M.P Safety Valve 18 Kg/cm2
For L.P Safety Valve 6 Kg/cm2
:
First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

DEPARTMENTAL
OPERATING
PROCEDURE

01
28.12.2004
01
24.11.2005
01 OF 01

ASSESSING CRUTIALITY / PRIORITY OF PROCESSES


UTILITY DEPARTMENT

FORMAT No. 1
S.
No.

Ref.
No.

Customer
Satisfaction

Process

1.

CS
5

Pumping of Raw Water from


Tapi River
Raw water clarification
Alum and chlorine dozing
Pumping of clarified water to
various department and to power
house

2.
3.
4.

5.
6.
7.
8.
9.
10.
11.

Pressure filtration of fresh water


DM Plant operation
Feed water chemical dozing
Fuel feeding from bunker
Feed water pumps
Boiler unit : HP/Process steam
generation
Ash disposal
Power Generation
De-superheating of steam and
distribution to process
Coal Handling

12.
13.
14.
15.
16.

Customer
Satisfaction
1 Has no impact
2 Little
3 Moderate
4 High
5 Very high

Impact on
Society
1 No Impact
2 High Impact

Business Results
1 No effect
2 May have effect
3 Has indirect effect
4 Has direct effect
5 Is a major
contributor

Crutiality
Impact
on
Society
IS
1

Business
Results

Resource
People Assets Informat
ion

Sum

BR
5

P
3

A
3

I
3

20

5
4
5

1
1
1

5
4
5

3
2
3

3
2
3

3
3
3

20
16
20

3
5
4
4
5
5

2
1
1
1
1
1

4
5
4
4
4
4

3
3
3
3
3
4

3
3
3
2
3
4

3
3
3
2
3
4

18
20
18
16
19
22

2
5
4

1
1
1

2
4
4

2
4
3

2
4
3

2
4
3

11
22
18

18

People
1 Low skill of skill
2 Moderate skill
required
3 Normal skill req.
4 High skill req.
5 New skill required
person to be added.

Assets
1 Low req of M/c /
equipment / infrastr.
2 Moderate req.
3 Meeting normal req.
4 Meeting addl. req.
5 New req./facility
to be added

Information
1 No info required
2 - Some info required.
3 - Moderate info
required
4 - Large amount
info required
5 Immediate
flow of info

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

01
28.12.2004
01
24.11.2005
01 OF 01

ASSESSING THE CRITICALITY OF ICOM


UTILITY DEPARTMENT

FORMAT NO. 2
S.
No.

01
02
03
04

05
06
07
08
09
10
11
12
13

14
15
16

Crutial
Process

ICOM

Pumping of raw water


from Tapi River
Raw water Lamella
clarification
Alum / polymer dozing
Pumping of clarified
water to process
department and to
Power House
Pressure filtration of
fresh water
DM Plant Operation
Feed water chemical
dozing
Fuel feeding from
bunker
Feed pump operation
Steam Generation
Ash disposal
Power generation
De-superheating of
steam and distribution
to process
Coal handling

Probability of Loss
1 Very Low
2 Little
3 Moderate
4 High
5 Very High

Pumping

CONSEQUE
NCE
OF
LOSS
C
3

Water clarifying

16

Treatment of water
Pumping

4
3

4
4

1
1

16
12

Filtration

De-mineralizing of
water
Chemical dozing to feed
water
Coal feeding to furnace

12

12

Pumping
Boiler operation
Ash disposal
Turbine operation
Reduction of process
steam temperature and
supply to process
Coal supply to bunker

2
2
2
3
2

5
5
2
5
3

1
1
1
1
1

10
10
4
15
6

10

(Task / Activity)

PROBABILITY
FOR LOSS
P

Consequence of Loss
1 - No consequence
2 - Little consequence
3 - Moderate consequence
4 - High consequence
5 - Very high consequence

OCCU
RENCE
OF
LOSS
O
1

CRITICALITY

CR = P x C x O
9

Occurrence of Loss
1 Once in a month
2 Once a Week
3 Once a Day
4 - Several times a day
5 - Several times per hour

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

01
28.12.2004
01
24.11.2005
01 OF 01

ASSESSING THE CRITICALITY OF ICOM


UTILITY DEPARTMENT

FORMAT NO. 3
S.
No.

01
02
03
04
05

06
07
08
09
10
11
12
13
14
15
16

Crutial
Process

ICOM

PROBABILITY
FOR LOSS
P

(INPUT)

CONSEQUE
NCE
OF
LOSS
C
5

OCCU
RENCE
OF
LOSS
O
1

CRITICALITY

CR = P x C x O
15

Pumping of raw water from


Tapi River
Raw water clarification
Alum & chlorine dozing
Pumping of clarified water
to process department and
to Power House
Pumping of fresh water from
Jackwell to process dept.
and to power house

Raw water from river

Turbid raw water


Turbid raw water
Clarified water

3
3
3

5
5
5

1
1
1

15
15
15

Clarified water

15

Pressure filtration of fresh


water
DM Plant Operation
Feed water chemical dozing
Fuel feeding from bunker
Feed pump operation
Steam Generation
Ash disposal
Power generation
De-superheating of steam
and distribution to process
Coal handling

Fresh water

Filtered water
Feed water & chemical
Coal
Feed water
Feed water / fuel
Cinder & ash from boiler
HP Steam
Hi-temperature steam

3
3
2
3
2
2
2
2

5
4
4
5
5
3
5
3

1
1
1
1
1
1
1
1

15
12
8
15
10
6
10
6

Incoming Coal

10

Probability of Loss
1 Very Low
2 Little
3 Moderate
4 High
5 Very High

Consequence of Loss
1 - No consequence
2 - Little consequence
3 - Moderate consequence
4 - High consequence
5 - Very high consequence

Occurrence of Loss
1 - Once in a month
2 - Once a Week
3 - Once a Day
4 - Several times a day
5 - Several times per hour

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

01
28.12.2004
01
24.11.2005
01 OF 01

ASSESSING THE CRITICALITY OF ICOM


UTILITY DEPARTMENT

FORMAT NO. 4
S.
No.

01

Ref.
No.

Crutial
Process

ICOM
(Output)

09

Pumping of raw water


from Tapi River
Raw water clarification
Alum & polymer &
chlorine dozing
Pumping of clarified
water
to process department
and to Power House
Pressure filtration of
fresh water
DM Plant Operation
Feed water chemical
dozing
Fuel feeding from
bunker
Feed pump operation

10

Steam Generation

11
12
13

Ash disposal
Power generation
De-superheating of
steam and distribution
to process
Coal handling

02
03
04

05
06
07
08

14

PROBABILITY
FOR LOSS
P

CONSEQUE
NCE
OF
LOSS
C
5

OCCU
RENCE
OF
LOSS
O
1

CRITICALITY

CR = P x C x O
15

Raw water

Clarified water
Treated water

3
3

5
5

1
1

15
15

Treated water

15

Filtered water

12

DM water for HP boilers


Improved quality feed
water
Required qty. of fuel in
to furnace
Feed water at
Economizer inlet with
required pressure
Steam at required
pressure and quality
Dispose of cinder & ash
Power
Steam to process
department of required
quality and quantity
Required amount coal
and of required size into
bunker

3
3

5
4

1
1

15
12

12

15

15

2
3
3

3
5
4

1
1
1

6
15
15

15
16

Probability of Loss
1 Very Low
2 Little
3 Moderate
4 High
5 Very High

Consequence of Loss
1 - No consequence
2 - Little consequence
3 - Moderate consequence
4 - High consequence
5 - Very high consequence

Occurrence of Loss
1 - Once in a month
2 - Once a Week
3 - Once a Day
4 - Several times a day
5 - Several times per hour

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

01
28.12.2004
01
24.11.2005
01 OF 01

ASSESSING THE CRITICALITY OF ICOM


UTILITY DEPARTMENT

FORMAT NO. 5
S.
No.

01
02
03
04

05
06
07

Ref.
No.

Crutial
Process

ICOM
(Controls)

Pumping of raw water


from Tapi River
Raw water clarification
Alum , polymer and
chlorine dozing
Pumping of clarified
water
to process department
and to Power House

Pressure filtration of
fresh water

1) Delivery pressure
2) Electrical load
1) Chanel reading
2) Turbidity
Turbidity

CONSEQUE
NCE
OF
LOSS
C
2

12

12

1)
2)
3)

Header pressure
Electrical load
Reservoir & swimming pool
level

Inlet and outlet pressure


Turbidity of water
(Visual check)
Acid & caustic tank levels
Sump tank level
DA unit outlet pressure
DA unit water sample
checking at intervals
Quality of feed water

Bunker level

1) Delivery pressure
2) Electrical load
All parameters of running boiler
Non-tripping of Boiler ESP
All parameters of running
turbine
1) Delivery pressure
2) Electric load
3) Temperature of process &
pressure
1) Quality of coal
2) Quantity of coal

3
2
3

4
4
5

1
1
1

12
8
15

1)
1)
1)
2)

08

DM Plant Operation

1)
2)
3)
4)

09

1)

11

Feed water chemical


dozing
Fuel feeding from
bunker
Feed pump operation

12
13
14

Steam Generation
Ash disposal
Power generation

15

De-superheating of
steam and distribution
to process

16

Coal handling

10

Probability of Loss
1 Very Low
2 Little
3 Moderate
4 High
5 Very High

PROBABILITY
FOR LOSS
P

Consequence of Loss
1 - No consequence
2 - Little consequence
3 - Moderate consequence
4 - High consequence
5 - Very high consequence

OCCU
RENCE
OF
LOSS
O
3

CRITICALITY

CR = P x C x O
12

Occurrence of Loss
1 - Once in a month
2 - Once a Week
3 - Once a Day
4 - Several times a day
5 - Several times per hour

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

01
28.12.2004
01
24.11.2005
01 OF 01

ASSESSING THE CRITICALITY OF ICOM


UTILITY DEPARTMENT

FORMAT NO. 6
S.
No.

01
02
03
04

05
06
07
08
09
10
11
12
13
14
15

16

Ref.
No.

Crutial
Process

ICOM
(Means)

Pumping of raw water


from Tapi River
Raw water clarification
Alum , polymer and
chlorine dozing
Pumping of clarified water
to process department
and to Power House

Through Department

CONSEQUE
NCE
OF
LOSS
C
5

Through Department
Through Department

2
2

5
5

1
1

10
10

Through Department

10

Pressure filtration of fresh


water
DM Plant Operation
Feed water chemical
dozing
Fuel feeding from bunker
Feed pump operation
Steam Generation
Ash disposal

Through Department

Through Department
Through Department

2
2

4
3

1
1

8
6

Through Department
Through Department
Through Department
1) Through Department
2) Through Contractors
Through Department
Through Department

2
2
2
2

4
5
5
3

1
1
1
1

8
10
10
6

2
2

5
4

1
1

10
6

1) Through Department
2) Through Contractors

Power generation
De-superheating of steam
and distribution to
process
Coal handling

Probability of Loss
1 Very Low
2 Little
3 Moderate
4 High
5 Very High

PROBABILITY
FOR LOSS
P

Consequence of Loss
1 - No consequence
2 - Little consequence
3 - Moderate consequence
4 - High consequence
5 - Very high consequence

OCCU
RENCE
OF
LOSS
O
1

CRITICALITY

CR = P x C x O
10

Occurrence of Loss
1 - Once in a month
2 - Once a Week
3 - Once a Day
4 - Several times a day
5 - Several times per hour

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/DOP/03
01
28.12.2004
01
24.11.2005
01 OF 02

1.

PROCESS

: Departmental operating procedure for Maintenance of FANS

2.

PURPOSE

3.

SCOPE

: To Maintain the power house Utility and infrastructure for smooth


running of the plant
: This procedure shall cover FAN Maintenance process.

4.

RESPONSIBILITY: Manager, Dy-Manager, Jr. Engineer, Fitter.

5.

TASK? ACTIVITIES: Check list for Maintenance of FANS

1.
2.

Checking of Motor bearings.


Checking for condition of coupling (teeth, key way, key, bore of the coupling etc.)
or any crack of the coupling.
Checking for suction vantury for any erosion.
Checking of bird screen for damage ( if provided.)
Checking of rotor for any erosion.
Checking of fan casing for erosion .
Checking of fan suction cone for erosion and clearance between fan & cone.
Checking of plummer Block for any cracks,damage,impression of bearing outer race.
Oil leveler and its connector atc.
Condition of the oil ring.
Condition of the bearings., replacement of the bearing if required.
Condition of the locking washer.
Condition of the bearing lock nut and its thread.
Condition of the sleeve.
Journal condition of the shaft.

3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/DOP/03
01
28.12.2004
01
24.11.2005
02 OF 02

15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

Run out checking of the shaft. at least in three places (maximum 0.05 mm).
Horizontality of the shaft.
Bearing alignment.
Locking of the bearings.
Condition of the oil rings.
Position of the oil rings.
Checking of Fan hub locking bolts.
All mounting of Fan Rotor.
Static balancing of the rotor.
Locking of Suction cone.
Clearance in between suction cone and Rotor.
Bearing clearance.
Alignment of Fan shaft and rotor.
Condition of coupling guard.
Checking of Dampers for any damage or worn out.
checking of damper Bearings.

6.0

Reference documents

OEM Manual

7.0

Reference Records

Check list / Data sheet

8.0

Amendment

First Issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL
1.0

PROCESS

2.0

PURPOSE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/DOP/04
01
28.12.2004
01
24.11.2005
01 OF 01

: Departmental operating procedure for Maintenance


of COAL CRUSHERS.

3.0

: To Maintain the power house Utility and infrastructure for smooth


running of the plant
RESPONSIBILITY: Manager, Dy-Manager, Jr. Engineer, Fitter

4.0

SCOPE : This procedure shall cover CRUSHERS Maintenance process

4.1
4.2
4.4.

4.7
4.8
4.9
4.10

Check the stock position of necessary spares in stores.


Send job order to Work Shop to make spares which are not available in stores.
Dismantle the equipment (As per documented standard code of practice / guidelines by
competent persons).
Check the dimensions of parts. Replace them with new ones, or repaired if they are
not in conformation with required specifications.
Send Job Order to Work Shop for miscellaneous jobs.
Recheck the dimensions of spares procured from Stores and Work Shop.
Assemble the equipment (As per documented code of practice / guidelines as per
Operation and Maintenance manual.
Set the gap in between bitter ledge and grinding jibs as 20 mm.
Take the trial of crusher and if it is satisfactory than clearance to be given for Operation.
Place indent for consumed spares as per procedure.
Record the work attended & Maintain the History Card ( both hard copy and soft copy)

5.0

Reference Document

6.0

Amendments

4.5.
4.5
4.6

Reference Manuals.
First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

01
28.12.2004
01
24.11.2005
01 OF 01

HIGH PRESSURE BOILER MAKE UP FEED- 1000


M3 / DAY

VACUUM PUMP -136 M3/ DAY

POWER HOUSE
FRESH WATER
3600 M3/ DAY

PUMP SEALING / COOLING 144


M3/ DAY (REUSED IN CT)
DM PLANT 330 M3 / DAY
COOLING TOWER 30 M3/ DAY
ASH HANDLING PLANT- 15 M3/
DAY

DRAINING O FLOCCULATION
TANK AND LAMELLA CLARIFIER
245 M3/ DAY

POWER HOUSE WATER BALANCE BLOCK DIAGRAM

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

01
28.12.2004
01
24.11.2005
01 OF 01

COAL HANDLING PLANT FLOW DIAGRAM.

BOILER

CC-3

CC-2

CC-4

VIBRATING SCREEN

CC-5

COAL BUNKER

COAL
CRUSHER

CC-1

RECLAIM HOPPER

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

DEPARTMENTAL
OPERATING
PROCEDURE

01
28.12.2004
01
24.11.2005
01 OF 01

FLOW DIAGRAM FOR WATER TREATMENT PLANT

WATER FROM INTAKE PUMP HOUSE

CASCADE AERATOR

PROCESS AND POWER


HOUSE.

FLASH MIXER

FLOCCULATION TANK

RESERVOIRS

LAMELLA CLARIFIER

MULTI MEDIA FILTER

MILL

COLONY

BARBODHAN
VILLAGE

TENA
VILLAGE

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

01
28.12.2004
00
01 OF 01

FLOW DIAGRAM FOR D.M. PLANT


WATER FROM WTP

COAGULATION TANK

DUAL MEDIA
PRESSURE FILTER

ACTIVATED CARBON
FILTER

DEGASIFIER TOWER

ANION UNIT

DEGASSER TANK

CAT ION UNIT


CONDENSATE FROM P/MCS

M.B UNIT

D.M. WATER
TANK

BOILERS

Prepared by : ________
Designation: Mgr.(Uty.)
Date

__________
D.G.M.(Uty.)

: 24.11.2005

CONDENSATE
WATER TANK

FEED WATER DEAERATOR

Reviewed by : _________

Approved by : ___________

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

: 24.11.2005

: 24.11.2005

DEPARTMENTAL
OPERATING
DEPARTMENTAL
PROCEDURE
OPERATING
PROCEDURE

RNPL
RNPL
(NPP)

Reference No.:
IssueNo.:
No.:
Reference
Issue
Date.:
Issue
No.:
Revision
No.:
Issue Date.:
Revision
Date.:
Revision
No.:
Page
No.:
Revision
Date.:
Page No.:

1.0

PROCESS

Work instruction for starting of


Auxiliary cooling water pump.

2.0

PURPOSE

This instruction gives method of starting of Cooling


water pump /Auxiliary cooling water Centrifugal Pump.

3.0

RESPONSIBILITY: Shift in charge, turbine operator Gr-II

4.0

SEQUENCE
4.1

01
28.12.2004
01
24.11.2005
01 OF 01

Cooling water pump /

See that suction valve and min flow line


GASvalve are in open position.
DRAIN TURBID

4.2. WATER
Open the
gland sealing water line.
PERIODICALLY
4.3

Open the flow control valve at top deck of cooling tower.

4.4

Check the water circuit of cooling water line.

4.5

Start the pump.

4.6

Open the delivery valve.

4.7

Check for abnormal sound in the pump and bearing temperature, report if
Necessary.

4.8

Check the water is uniformly distributed in each cell of the cooling tower.

4.9

Record relevant parameter in respective documents.


AIR

5.0.

CONDENSATE FROM
SIEMENS/ BHEL TG

DEAERATOR
PUMP

REFERENCE RECORDS : Log book / data sheet


BOILER FEED PUMP

6.0

AMENDMENTS

: First issue

__________

Reviewed by : _________

Approved by : ___________

Designation::Mgr.(Uty.)
Designation
Mgr.(Uty.) D.G.M.(Uty.)
D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

Prepared by : ________

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
(NPP)

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

1.0

PROCESS

Work instruction for stopping of Cooling water pump /


Auxiliary cooling water pump

2.0

PURPOSE

This instruction gives method of stopping of Centrifugal


Pumps.

3.0

RESPONSIBILITY

4.0

SEQUENCE

: Operator
:

4.1

Close the delivery valve (not necessary in non-return valve is there in


Delivery line).

4.2

Stop the pump.

4.3.

Close the gland sealing water line valve.

4.4.

Record relevant parameters in respective document.

6.0.

REFERENCE RECORDS : Log book / Data sheet

6.0

AMENDMENTS

: First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
(NPP)
1.0

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

PROCESS

Work instruction for starting of

Cooling tower fan

2.0

PURPOSE

This instruction gives method of starting of Cooling


tower fan.

3.0

RESPONSIBILITY: Shift in charge, turbine operator Gr-I & Gr-II

4.0

SEQUENCE

4.1

Check the oil level in the gearbox.

4.2.

Check the freeness of fan & motor..

4.3

Check the water flow control valve of the particular cell is open & water
coming through the valve.

4.4

Start the fan through PLC.

4.5.

Check for abnormal sound in the fan, report if Necessary.

4.6.

Record relevant parameter in respective documents.

5.0.

REFERENCE RECORDS : Log book / Data sheet

6.0

AMENDMENTS

: First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
(NPP)

DEPARTMENTAL
OPERATING
PROCEDURE

1.0
2.0

PROCESS
PURPOSE

:
:

3.0

RESPONSIBILITY

4.0

SEQUENCE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

Work instruction for stopping of Cooling tower fan.


This instruction gives method of stopping of cooling tower
fan.
: Operator
:

4.1

Stop the fan.

4.2.

Close the return water line flow control valve if necessary.

4.3.

Record relevant parameters in respective document.

5.0

REFERENCE RECORDS : Log book / Data sheet

6.0

AMENDMENTS

: First issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
(NPP)

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

1.0

PROCESS

Work instruction for starting of 23 MW BHEL turbine.

2.0

PURPOSE

This instruction gives method of generating electrical


Power from. 23 MW BHEL turbine

3.0

RESPONSIBILITY

: DGM, Manager, Shift Engineer& Turbine Operator.

4.0

SEQUENCE

A. PERMISSIVE TO BE CHECKED.
9.
10.
11.
12.
13.
14.
15.
16.

Lub oil tank level is normal.


AOP/MOP is running.
Machine is on baring gear.
Auto start of EOP is available.
All gauges valves are in open position.
Main ejector steam pressure 11 kg/ cm2 is available.
One no cooling water pump & one no auxiliary cooling water pump are running.
Cond. Extraction pump is running on re circulation with hot well level 50-55%

B. PROTECTION INTER LOCK TO BE CHECKED.

1.
2.
3.
4.
5.

TG trip at lub oil pressure is very low ( 1 kg/ cm2) (PSLL 3116 A/B/C)
Exhaust pressure is very low ( -0.3 kg/cm2) (PSHH 5254 A/B/C)
Control oil pressure is very low ( 4.5 kg / cm2) (PSLL 3301 A/B/C)
Bearing temp very high (> 115 deg C) tg trip
Shaft vibration very high TG trip

C. PROCEDURE FOR ROLLING.


1. Open all main steam drain lines fully.
2. Worm of the main steam line by opening exhaust vent and pilot valve on 84 ata
3. Check hot well level, it should be 55 % & put control valve LIC 4203 A/B on
AUTO mode .
4. Put starting steam ejector steam line and gland sealing steam line in worm
up condition ensure no condensate coming from the drain
5. Put starting ejector # 1 in service. By opening the steam & air valve, ensure the
inlet steam pressure is 10 kg/ cm2( minimum for starting ejector operation).
6. Put gland steam valve controller (ZI 5652 A/B on AUTO mode.
7. When vaccum is greater than -0.5 kg/cm2 put any one ejector (#2 or 3) in service
by opening steam & air valve.

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
(NPP)

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

8. When vacuum is greater than -0.85 kg/cm2, isolate the starting ejector #1 by closing
air & steam valve
9. Note the inlet steam temp before ESV it must be greater than 400 deg C.
10. Following procedure is to be done in governing scheme index on PLC monitor
A. Reset the TG by clicking EM TRIP RESET block.
B. Engage solenoid no 1050 by clicking.
C. Open ESV 2301 by clicking OPEN block.
D. Click TURBINE RUN block.
11. Following procedure is to be done in WOOD WARD control board.
A. Put TG on 2200 rpm by opening HP control valve up to 20% by selecting LTR switch.
B. *For cold start up (more than 12 hrs between two start up of TG) keep the TG 2200 RPM for 45
min.
*For hot restart up (up to 12 hrs between two start up of TG) keep the TG 2200 RPM for 15 min.
C. By selecting LTR switch open HP control valve up to 100%.
D. By selecting SPEED switch put TG speed at 5650 RPM
12. Check All Atmospheric Drains And Ensure There Is Free Flow Of Steam From All
Drains, Close All The Drains After Check Up.
13. Maintain TG Speed At 5650 RPM And Give Clearance To Electrical Dept For
Loading.
14. Put Oil Temperature Controller (153) In Service To Maintain Inlet Oil
Temperature 40 O C.
15. Run 3 Nos Of CT Fans & put second CWP in operation.
16. After loading TG set up to 5 MW put TG on extraction mode by following procedure
A. Open QCNRV (quick closing non return valve) on LP extraction line by opening secondary oil line
valve very slowly.
B. From WOODWARD control board click LP EXT & put it on able condition by clicking YES
switch.
C. Increase the extraction pressure set point slowly 3.2 kg/cm2.
17. To Run TG Maintain Inlet Steam Pressure 82 Kg/Cm2 And Temperature 470 5 OC
D.

Reference documents

Manufacturers Manual / Drawing

E.

Reference Records

Log book / Data sheet

F.

Amendment

First Issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

RNPL
(NPP)

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

1.0

PROCESS

Work instruction for stopping of 23 MW BHEL


make turbine
This instruction gives method of stopping 23 MW
BHEL turbine

2.0

PURPOSE

3.0

RESPONSIBILITY :

4.0

SEQUENCE

4.1

Unload the electrical load on the turbine.

4.2

Trip the turbine by hand, or clicking on EM TRIP on PLC monitor.

4.3

Close Low Pressure steam extraction valves. Open the chest drain valves.

4.4

The turbine automatically come on barring gear at 500 rpm.

4.5.

Close main steam line valve.

4.6.

Discharge condenser, air cooler, oil cooler water lines.

Shift Engineer, Turbine Operator.

5.0. Reference documents

Manufacturers Manual / Drawing

6.0

Reference Records

Log book / Data sheet

7.0

Amendment

First Issue

Prepared by : ________

__________

Reviewed by : _________

Approved by : ___________

Designation : Mgr.(Uty.)

D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 24.11.2005

: 24.11.2005

: 24.11.2005

INTER OFFICE MEMO


DATE: 25.11.2005
FROM: M.N.MOHAN

TO:

MR A.K.BISWAL

|
T.CHAKRABORTY
|
K.D. MANTRI
THRO: MR S.S.PAL
SUB: SUBMISSION OF DOP TO ISO CELL
REF: YOUR INTERNAL CORRESPONDENCE NO RNPL/ISO/001/2005 DTD 16.11.2005.
WITH REFERENCE TO THE ABOVE, WE ARE SENDING HEREWITH THE DOP OF UTILITY DEPT.
AFTER BEING DULY SIGNED, REVIEWED AND APPROVED BY THE CONCERNED AUTHORITY.
THIS IS FOR YOUR FURTHER ACTION PLEASE.
REGARDS,

(M.N.MOHAN)
ENCL: REVISED DOP PAPERS

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

DEPARTMENTAL
OPERATING
PROCEDURE

6.3/UTY/NORMS/01
01
09.02.2006
00
-01

Norms Of Steam Purity, DM Water, Feed Water, Boiler Water, Cooling water & Treated water
Steam Purity
TG steam

TG / M/c Return Condensate

pH

> 8.3

> 8.2

Total Conductivity (s/ cm)

< 20

< 15

Silica Acid (SiO2) (PPM)

0.02

< 0.02

Total Iron (Fe) (PPM)

< 0.02

< 0.02

Total Copper (Cu) (PPM)

< 0.003

Sodium and Potassium (PPM)

< 0.01

DM Water

Feed Water

Boiler Water

pH

6.5 to 7.0 ( MB outlet)

8.3 to 9.3

8.3 to 9.5

Silica (PPM)

< 0.02

< 0.02

< 3.2

Conductivity (s/ cm)

1 (Max)

FMA (PPM)

< 80

NA

NA

Chloride

NA

Nil

NA

TDS (PPM)

NA

NA

Fe (PPM)

NA

NA

< 200 (Max)


< 100 (Desirable)

< 100 (Max)


< 50 (Desirable)
< 1.0 (Max)

Cooling water

Treated water

pH

7.6 to 8.2

Chloride (PPM)

500

PH

7.8 to 8.0

Free Residual Chlorine (PPM)

0.2-0.5

Silica (PPM)

180 (Max)

Turbidity (PPM)

10 to 15

Conductivity (s/ cm)

5000 (Max)

OPO4 (PPM)

40-70

CaH (PPM)

400 (Max)

COC

6 (Max)

0.2 to 0.6

Total Hardness

800 (Max)

Residual Cl2 (PPM)


In Mill water &
Drinking water

SS corrosion Rate (mpy)

1.0 (Max)

Cu. Corrosion Rate (mpy)

0.5 (Max)

MS corrosion Rate (mpy)

3 (Max)

__________

Reviewed by : _________

Approved by : ___________

Designation :Sr.Mgr.(Uty) D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

Prepared by : ________

: 09.02.2006

: 09.02.2006

: 09.02.2006

DEPARTMENTAL
OPERATING
PROCEDURE

RNPL

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/29
01
23.02.2006
00
01 OF 03

1.0

PROCESS

Work instructions for Coal Unloading & Feeding

2.0

PURPOSE

This instruction gives method for unloading of coal in coal


yard and feeding to reclaim hoppers

3.0

RESPONSIBILITY

Coal plant Operator & Shift Engineers

4.0

TYPES OF COAL USED:

Normally two types of coal is procured.


(i) Imported Coal
(ii) Indian coal

4.1

SOURCES OF RECEIPT:

(i) Imported coal is received through different vendors


from nearby Magadalla port
(ii)Indian coal is received from Western Coal Fields .
area (Nagpur Belt)

4.2

COAL UNLOADING PROCEDURE:


(i) IMPORTED COAL:

.
.

Imported coal is received by Dump trucks. After


completing initial formalities at our weigh Bridge & Raw
material office, trucks are reporting to the coal yard with
a copy of release certificate given by raw material so
that after Unloading of trucks ,this certificate is signed
by Coal Handling Plant operators confirming that the truck
is un- loaded. This coal is dumped in the area pointed out
by our coal plant operators available in A,B and G shifts.
After Unloading the coal ,stacking is done through
departmental JCB and heaps are made separately quality
Wise. Heap normally contains 500 MT maximum .

.
.
.
.
.
.

After stacking a lot number is given and vendors name


are displayed in short on the board placed on top of each
heap.
(II) INDIAN COAL:
After completing initial formalities at weigh Bridge and
raw material office, Indian coal trucks report to coal yard
with copy of release certificate given by raw Material
department for signing the same by coal handling plant
operators after completion of unloading. Since the
Indian coal trucks are having no facility of self dumping
These are placed in a sequence in the coal yard for
manual unloading. After placement in position the
concerned contractor engages 2 to 3 labours per truck
for manual un loading.

.
Prepared by : ________

__________

Designation : Sr.Mgr.(Uty.)
Date

: 23.02.2006

D.G.M.(Uty.)

Reviewed by : _________

Approved by : ___________

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

: 23.02.2006

: 23.02.2006

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/29
01
23.02.2006
00
23.02.2006
02 OF 03

After un loading the same at the particular place shown


by our coal Plant operator , entire quantity of coal is
stacked separately for each vendor .Normally heaps are
made with maximum quantity 500 MT for each vendor.
Separately.
After stacking a lot number is given and vendors name
are displayed in short on the board placed on top each
heap.
Indian lump coal (100 mm plus size) used in rainy
Season is kept separately.

.
.
.

4.3 MONITORING OF STOCK (IMPORTED AND INDIAN):


Based on lot number a map of the stacks made in coal
Yard is prepared every morning indicating all the heaps
Of different vendors with Quantity received/available
and date.
4.3

COAL FEEDING PROCEDURE:


Normally Imported and Indian coal is fed in different
ratios.
In dry seasons the coal feeding ratio (Imported :Indian)is
Kept on average 70:30 .
In rainy seasons the coal feeding ratio (Imported:Indian)
is Kept on average 30:70 .The Indian coal has lumps of
size 100 mm and above minimum 80 %.

4.5 MACHINES AND VEHICLES USED FOR LOADING & TRANSPORTATION

.
l

Departmental JCB and two numbers tractors of contractor


are used . In the morning coal feed ratio and the lot
number of a particular vendors for feeding is verbally
communicated to coal plant operator for coal feeding.

Accordingly imported and Indian coals are loaded in


tractors by JCB and same is fed into the reclaim hoppers
for continuous feeding of coal through conveyors,crushers
Vibrating screen for filling the same into coal bunkers.

.
.

Prepared by : ________

Reviewed by : _________

Approved by : ___________

Designation : Sr.Mgr.(Uty.) D.G.M.(Uty.)

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

Date

: 23.02.2006

__________

: 23.02.2006

: 23.02.2006

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/29
01
23.02.2006
00
03 OF 03

4.5MEASUREMENT OF DAILY ESTIMATE OF COAL QUANTITY FED:


Tractors are sent to our weigh bridge at random to take
the weighment of tractor loaded with imported and
Indian Coal. Based on these weighment the coal feed
quantity to hoppers is considered multiplying the
average weight of Imported coal and Indian coal in
each tractor with the numbers of trips counted by the
Operator on duty. Separately trips are Counted for
Imported and Indian coals to get the right quantity
of coal fed and informed by the operator to the shift
Engineer on duty.
However whenever any particular heap is completely
used ,necessary correction are made in the quantity
of coal used.

.
.
.
.
.

4.7

SAMPLING OF COAL FROM FEEDERS HOPPERS AT THE BOILER :


In each shift blended coal samples (Indian & Imported)
are collected from each hopper separately at an interval
of 4 hours ( i.e. twice in a shift).Coal samples are
collected in containers and packed in bags. In the
morning collected coal sample are blended and
.
packed in polythene bags.
Finally the sample is sent to laboratory for analysis of .
GCV(ADB),moisture %, Ash %.The coal sample is sent
to the laboratory on daily basis .

.
.
.
.
4.8

SAMPLING OF COAL RECEIPT :


Sampling of coal receipt vendor wise and quality wise is
done by external agency B.S.I. regularly and
random Checking is done by laboratory personnel .

.
.

Prepared by : ________

__________

Designation : Sr.Mgr.(Uty.)
Date

: 23.02.2006

D.G.M.(Uty.)

Reviewed by : _________

Approved by : ___________

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

: 23.02.2006

: 23.02.2006

INTER OFFICE MEMO


DATE: 24.02.2006
FROM: T.CHAKRABORTY

TO:

MR A.K.BISWAL

|
Mr. K.D. MANTRI

SUB: SUBMISSION OF PROCEDURE OF


(1)COAL UNLOADING
(2) COAL STACKING
(3) COAL FEEDING
(4) COAL SAMPLING
REF.: AUDIT REPORT DT.03.02.2006
WITH REFERENCE TO THE ABOVE, ABOVE PROCEDURE IS BEING INDICATED IN THE
ENCLOSED

D.O.P.FORMATS. THESE PROCEDURES MAY PLEASE BE INCORPORATED IN

THE REVISED D.O.P.


THIS IS FOR YOUR TAKING FURTHER ACTION PLEASE.
REGARDS,

(T,CHAKRABORTY)
ENCL: AS ABOVE.

RNPL
26

TE 3110

27

PSLL 3301A

28

PSLL 3301B

29

PSLL 3301C

30

PSLL 3302

31

PSH 3303

32

PSH 3304

33

PSLL 3305

34

PSLL 3306

35

PSH 3307

36

PSHH 5355A

37

PSHH 5355B

38

PSHH 5355C

39
40

PSH 5356
PSL 5337

41

PSLL 5358A

42

PSLL 5358B

43

PSLL 5358C

44

PSHH 5254 A

45

PSHH 5254 B

46

PSHH 5254 C

47

PSL 4209

48

----

DEPARTMENTAL
OPERATING
PROCEDURE

LUB OIL TEM. COOLER OUTLET


CONTROL OIL HEADER
PRESSURE VERY LOW
CONTROL OIL HEADER
PRESSURE VERY LOW
CONTROL OIL HEADER
PRESSURE VERY LOW
TRIP OIL HEADER PRESSURE
VERY LOW
OIL PRESSURE ABOVE THE
PISTON
OIL PRESSURE BELOW THE
PISTON
SEC.OIL PRESSURE OF I/H
CONVERTOR-1 VERY LOW
SEC.OIL PRESSURE OF I/H
CONVERTOR-1 VERY LOW
OVER SPEED TASTER OIL
PRESSURE HIGH
EXTRACTION PRESSURE HIGH
HIGH
EXTRACTION PRESSURE HIGH
HIGH
EXTRACTION PRESSURE HIGH
HIGH
EXTRACTION PRESSURE HIGH
EXTRACTION PRESSURE LOW
EXTRACTION PRESSURE LOW
LOW
EXTRACTION PRESSURE LOW
LOW
EXTRACTION PRESSURE LOW
LOW
EXHAUST STEAM PRESSURE
VERY HIGH
EXHAUST STEAM PRESSURE
VERY HIGH
EXHAUST STEAM PRESSURE
VERY HIGH

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/29
01
23.02.2006
00
03 OF 03

55

***

TAH

kg/cm2

***

4.5

kg/cm2

***

4.5

kg/cm2

***

4.5

kg/cm2

***

2.0

TURBINE TRIP

kg/cm2

4.5

***

TO ESV

kg/cm2

5.5

***

TO ESV

kg/cm2

1.6

***

ESV
INTERLOCK

kg/cm2

1.6

***

kg/cm2

5.5

***

kg/cm2

***

4.6

kg/cm2

***

4.6

kg/cm2

***

4.6

kg/cm2
kg/cm2

4.2
2.9

***
***

kg/cm2

***

2.9

kg/cm2

***

2.9

kg/cm2

***

2.9

kg/cm2

***

-0.3

kg/cm2

***

-0.3

kg/cm2

***

-0.3

CEP DESCHAGE PRESSURE LOW

kg/cm2

3.5

***

AUTO START
S/B CEP

ELECTRICAL FREQUENCY LOW


LOW

Hz

48.5

47.5

TURBINE

TURBINE TRIP
2/3

TURBINE TRIP
2/3
***
***
TURBINE TRIP
2/3 (PRESENTLY
BYPASSED)

TURBINE TRIP
2/3

49

----

ELECTRICAL FREQUENCY HIGH


HIGH

Prepared by : ________
__________
Designation : Sr.Mgr.(Uty.)
D.G.M.(Uty.)
Date

: 23.02.2006

Hz

52.0

TURBINE

Reviewed by : _________

Approved by : ___________

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

: 23.02.2006

: 23.02.2006

RNPL

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

6.3/UTY/WI/29
01
23.02.2006
00
03 OF 03

DETAILS OF BHEL TURBINE ALARM & TRIPPING SET POINT:


SR.NO

TAG NO.

DESCRIPTION

UNIT

ALARM

TRIP

REMARKS

SE 3400

RPM

6075

6125

TURBINE TRIP

VE 3401 A/B

m PP

114

172

TSI MONITOR

VE 3402 A/B

m PP

114

172

TSI MONITOR

4
5

VE 3403 A/B
VE 3404 A/B

m PP
m PP

92
68

138
102

TSI MONITOR
TSI MONITOR

VE 3405 A/B

m PP

158

240

TSI MONITOR

VE 3406 A/B

m PP

158

240

TSI MONITOR

ZE 3401 A/B

mm

(+/-) 0.5

(+/-) O.7

TSI MONITOR

ZE 3408
TE 3400
A/B/C/D

TURBINE SPEED
TURBINE FRONT SHAFT
VIBRATION
TURBINE REARSHAFT
VIBRATION
GEAR BOX HSS VIBRATION
GEAR BOX LSS VIBRATION
GENERATOR FRONT SHAFT
VIBRATION
GENERATOR REAR SHAFT
VIBRATION
TURBINE AXIAL
DISPLACEMENT
CASING EXPANSION HIGH
TURBINE THRUST BEARING
TEMP.
TURBINE FRONT JOURNAL
BEARING TEMP
TURBINE REAR JOURNAL
BEARING TEMP

mm

12.5

***

***

95

115

TSI MONITOR

95

115

TSI MONITOR

95

115

TSI MONITOR

GEAR BOX HS BEARING TEMP.

95

115

TSI MONITOR

GEAR BOX LS BEARING TEMP.

95

115

TSI MONITOR

95

115

TSI MONITOR

95

115

TSI MONITOR

kg/cm2

1.5

***

TURNING GEAR
& JOP

kg/cm2

0.9

***

DC EOP START

kg/cm2

***

1.0

kg/cm2

***

1.0

kg/cm2

***

1.0

kg/cm2

***

0.9

kg/cm2

6.5

***

kg/cm2

1.5

***

AUTO START
AOP
PDAH

RPM

115

***

TURNING GEAR

10
11

TE 3400E

12

TE 3400F

13
14

TE 3400
G/H/I/J
TE 3400
P/Q/M/N

15

TE 3400K

16

TE 3400L

17

PSL 3114

18

PSLL 3115

19

PSLL 3116A

20

PSLL 3116B

21

PSLL 3116C

22

PSLL 3117

23

PSL 3118

24

PDSH 3118

25

PSL 3205

GENERATOR FRONT BEARING


TEMP.
GENERATOR REAR BEARING
TEMP.
LUB OIL HEADER PRESSURE
LOW
LUB OIL HEADER PRESSURE
VERY LOW
LUB OIL HEADER PRESSURE
VERY LOW
LUB OIL HEADER PRESSURE
VERY LOW
LUB OIL HEADER PRESSURE
VERY LOW
LUB OIL DISCHARGE PRESSURE
VERY LOW
LUB OIL DISCHARGE PRESSURE
LOW
OIL FILTER DP
JACKING OIL HEADER
PRESSURE LOW

TURBINE TRIP
2/3

DC EOP START

Prepared by : ________

__________

Designation : Sr.Mgr.(Uty.)
Date

: 23.02.2006

RNPL

D.G.M.(Uty.)

Reviewed by : _________

Approved by : ___________

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

: 23.02.2006

DEPARTMENTAL
OPERATING
PROCEDURE

Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:

: 23.02.2006

6.3/UTY/WI/29
01
23.02.2006
00
03 OF 03

26

TE 3110

27

PSLL 3301A

28

PSLL 3301B

29

PSLL 3301C

30

PSLL 3302

31

PSH 3303

32

PSH 3304

33

PSLL 3305

34

PSLL 3306

35

PSH 3307

36

PSHH 5355A

37

PSHH 5355B

38

PSHH 5355C

39
40

PSH 5356
PSL 5337

41

PSLL 5358A

42

PSLL 5358B

43

PSLL 5358C

44

PSHH 5254 A

45

PSHH 5254 B

46

PSHH 5254 C

47

PSL 4209

48

----

49

----

LUB OIL TEM. COOLER OUTLET


CONTROL OIL HEADER
PRESSURE VERY LOW
CONTROL OIL HEADER
PRESSURE VERY LOW
CONTROL OIL HEADER
PRESSURE VERY LOW
TRIP OIL HEADER PRESSURE
VERY LOW
OIL PRESSURE ABOVE THE
PISTON
OIL PRESSURE BELOW THE
PISTON
SEC.OIL PRESSURE OF I/H
CONVERTOR-1 VERY LOW
SEC.OIL PRESSURE OF I/H
CONVERTOR-1 VERY LOW
OVER SPEED TASTER OIL
PRESSURE HIGH
EXTRACTION PRESSURE HIGH
HIGH
EXTRACTION PRESSURE HIGH
HIGH
EXTRACTION PRESSURE HIGH
HIGH
EXTRACTION PRESSURE HIGH
EXTRACTION PRESSURE LOW
EXTRACTION PRESSURE LOW
LOW
EXTRACTION PRESSURE LOW
LOW
EXTRACTION PRESSURE LOW
LOW
EXHAUST STEAM PRESSURE
VERY HIGH
EXHAUST STEAM PRESSURE
VERY HIGH
EXHAUST STEAM PRESSURE
VERY HIGH
CEP DESCHAGE PRESSURE LOW
ELECTRICAL FREQUENCY LOW
LOW
ELECTRICAL FREQUENCY HIGH
HIGH

Prepared by : ________
__________
Designation : Sr.Mgr.(Uty.)
D.G.M.(Uty.)
Date

: 23.02.2006

55

***

***

4.5

kg/cm2

***

4.5

kg/cm2

***

4.5

kg/cm2

***

2.0

TURBINE TRIP

kg/cm2

4.5

***

TO ESV

kg/cm2

5.5

***

TO ESV

kg/cm2

1.6

***

ESV
INTERLOCK

kg/cm2

1.6

***

kg/cm2

5.5

***

kg/cm2

***

4.6

kg/cm2

***

4.6

kg/cm2

***

4.6

kg/cm2
kg/cm2

4.2
2.9

***
***

kg/cm2

***

2.9

kg/cm2

***

2.9

kg/cm2

***

2.9

kg/cm2

***

-0.3

kg/cm2

***

-0.3

kg/cm2

***

-0.3

kg/cm2

3.5

***

AUTO START
S/B CEP

Hz

48.5

47.5

TURBINE

52.0

TURBINE

kg/cm

Hz

TAH
TURBINE TRIP
2/3

TURBINE TRIP
2/3
***
***
TURBINE TRIP
2/3 (PRESENTLY
BYPASSED)

TURBINE TRIP
2/3

Reviewed by : _________

Approved by : ___________

Designation : G.M. (Uty.)

Designation : President(Opn.)

Date

Date

: 23.02.2006

: 23.02.2006