Station: NTPC - Simhadri

BHEL Ref No. PS - DC - 186 - 500 0034 B

NTPC Ref No. SIM / 1 / TS / 1 / 34 B

Sheet 1 of 11

Plant Area: BOILER

Procedure for: COMMISSIONING OF LP DOSING SYSTEM OF BOILER

SL. NO.

CONTENTS

1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

4.0

SERVICES REQUIRED

5.0

SAFETY PRECAUTIONS

6.0

EMERGENCY PROCEDURE

7.0

STATE OF THE PLANT

8.0

METHOD

9.0

COMPLETION CRITERIA

10.

APPENDICES
a) DRAWINGS
b) LOG SHEET

Signatures
NTPC

BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS - DC - 186 - 500 0034B

NTPC Ref No. SIM / 1 / TS / 1 / 34B

Sheet 2 of 11

Plant Area: BOILER

Procedure for: COMMISSIONING OF LP DOSING SYSTEM OF BOILER
SL. NO.
1.0

STATUS
PLANT DETAILS
The LP Dosing System consists of the
following:

1.1

1 No. Mixing Tank with Agitator

1.2

1 No. Metering Tank

1.3

2 Nos. Pump with Motor (Positive Displacement

pump)

1.4

2 Nos. Suction Filters

1.5

2 Nos. Relief Valve

1.6

Inlet DM Water connection to Mixing and Metering

Tank

1.7

Level Gauges for Mixing and Metering

Tank

1.8

Local Instrumentation
Plant Item Completion List for
Mechanical, Electrical and C&I are to
be prepared at site.

1.9

The Schematic of LP Dosing System is enclosed in

Subsection 10.0
(Drawing No. 4: PS : TSX : 0066:00 Dt. 23.07.2001)

Signatures
NTPC

Station: NTPC - Simhadri

BHEL

BHEL Ref No. PS - DC - 186 - 500

0034B

Sheet 3 of 11

NTPC Ref No. SIM / 1 / TS / 1 / 34B

Plant Area: BOILER
Procedure for: COMMISSIONING OF LP DOSING SYSTEM FOR BOILER
SL. NO.

STATUS

2.0

OBJECTIVES

2.1

To commissionLP dosing system and make it

available for unit operation.

3.0

PROPOSAL

3.1

The Commissioning of LP Dosing System is carried

out as follows:
a) Flushing of Mixing, Metering Tanks and upto
Pump Station with DM Water.
b) Pump trial run, Relief Valve setting and C&I
System .

Signatures
NTPC

Station: NTPC Simhadri

BHEL

BHEL Ref No. PS - DC - 186 - 500

0034B
NTPC Ref No. SIM / 1 / TS / 1 / 34B

Sheet 4 of 11

Plant Area: BOILER

Procedure for: COMMISSIONING OFLP DOSING SYSTEM FOR BOILER
SL. NO.

STATUS

4.0

SERVICES REQUIRED

4.1

Availability of manpower with required tools for

attending to any leak, cleaning of filters.

4.2

Availability of operating personal to

co-ordinate the activities.

4.3

Availability of lighting arrangement in and around

the LP Dosing System.

4.4

Availability of portable fire fighting equipment near

the dosing system.

4.5

Availability of sufficient quantity of DM Water.

4.6

Availability of LT Power Supply.

4.7

Availability of Chemicals.

Signatures
NTPC

Station: NTPC - Simhadri

BHEL

BHEL Ref No. PS - DC - 186 - 500

0034B
NTPC Ref No. SIM / 1 / TS / 1 / 34B

Sheet 5 of 11

Plant Area: BOILER

Procedure for: COMMISSIONING OFLP DOSING SYSTEM FOR BOILER
SL. NO.

STATUS

5.0

SAFETY PRECAUTIONS

5.1

Goggles, Apron, Hand-gloves for handling

chemicals.

5.2

Bunding & draining arrangements are properly

done to take care of spillages.

5.3

First aid kid is available at test area.

6.0

EMERGENCY PROCEDURE

6.1

The operating staff should know about the normal

operating procedure to be adopted in case of
damage to machinery or injury to any person
connected in the activity.

6.2

The test team should be well aware of procedures to

be adopted in case of any abnormality in the
activity.

Signatures
NTPC
Station: NTPC - Simhadri

BHEL
BHEL Ref No. PS - DC - 186 - 500
0034B
NTPC Ref No. SIM / 1 / TS / 1 / 34B

Sheet 6 of 11

Plant Area: BOILER

Procedure for: COMMISSIONING OF LP DOSING SYSTEM FOR BOILER

SL. NO.

STATUS

7.0

STATE OF THE PLANT

7.1

LP Dosing Systems are erected as per

recommended drawing.

7.2

Mixing and Metering Tanks are cleaned with DM

Water and filled upto normal operating level.

7.3

LT power supply system for Pumps, are

commissioned and available for operation.

7.4

Required Local/Remote I&C Inputs are made

available.

7.5

DM Water connections to Mixing Tank, metering

tank and to lines (for flushing) are ready.

7.6

Lubricating oil is filled in the pump gear box up to

its normal level / Indication.

7.7

Suction filters are cleaned.

7.8

Tank Drains and Pump Relief Valves are

terminated as per scheme.

7.9

The test area is cleaned and proper approaches are

available.

7.10

LP dosing system are erected with proper bunding

and draining facility to contain any spillage.

Signatures
NTPC

BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS - DC - 186 - 500 34B

NTPC Ref No. SIM / 1 / TS / 1 / 34B

Sheet 7 of 11

Plant Area: BOILER

Procedure for: COMMISSIONING OF LP DOSING SYSTEM FOR BOILER
SL. NO.
8.0

STATUS
METHOD

8.1

FLUSHING OPERATION
The Mixing & Metering Tanks along with suction
pipe upto pump to be flushed with DM Water so
as to avoid the entry of dust into the pump.

8.2

PREPARATION:
Disconnect the pump suction connection flange
and connect the suction line with hose to nearby
drain. Remove the suction filters and make the
suction line through.

8.3

PROCESS

8.4

Fill the Mixing and Metering Tank with DM

Water.

8.5

Open the pump suction valve and flush the

system until clear water noticed in the temporary
hose.

Signatures
NTPC

BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS - DC - 186 - 500

0034B
NTPC Ref No. SIM / 1 / TS / 1 / 34B

Sheet 8 of 11

Plant Area: BOILER

Procedure for: COMMISSIONING OF LP DOSING SYSTEM FOR BOILER
SL. NO.
8.6

STATUS
Normalise the suction connection to pump.

8.7

Bump the motor (in decoupled condition) and check

the direction of rotation.

8.8

Trial run the motor for 2 hours and couple with the
pump.

8.9

Fill the Mixing and Metering Tank upto normal

level.

8.10

Open the Pumps Suction, Discharge and Recirculation valve.

8.11

Close the valve in the line going to boiler.

8.12

Ensure the suction & discharge gauges are installed

and the respective valve cocks are opened.

8.13

Keep pump stroke to minimum and start the pump

and observe discharge pressure.

8.14

Increase the pump stroke gradually to 100% and

observe pump performance.

8.15

Trial run the pump for 4 hours and maintain the

tank level keeping the pump stroke around 50%.

8.16

Commission the remote stroke adjustment system (if

provided) and operate and observe its performance.

Signatures
NTPC

BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS - DC - 186 - 500

0034B
NTPC Ref No. SIM / 1 / TS / 1 / 34B

Sheet 9 of 11

Plant Area: BOILER

Procedure for: COMMISSIONING OF LP DOSING SYSTEM FOR BOILER
SL. NO.
8.17

STATUS
Set the relief valve by throttling the R/C Valve.
(The set pressure to be around 10 KSC more than
the working pressure of the system)

8.18

Stop the pump.

8.19

Ensure the Agitator is coupled with motor.

8.20

Bump the Agitator and check the direction of

rotation.

8.21

Trial run the Agitator for 2 Hours.

9.0

COMPLETION CRITERIA
Commissioning of LP dosing system completed
with
a) Flushing of the system from tanks to pump
suction.
b) Trial run of Pump and agitator for 4 Hours & 2
Hours respy.
c) Setting of Relief valve around 10.0 KSC above
working pressure of the system.

Signatures
NTPC

BHEL

SHEET 11 OF 11
LOG SHEET

Date:
PROJECT :
UNIT

ACTIVITY:

Sl.

Date / Time

Pump in

Discharge

Mixing/Meterin

Gear

Remark

No.

service

Pressure
Kg/cm2

g Tank Level
in Mn.

Box Oil

Signatures
NTPC

BHEL

PROCEDURE FOR COMMISSIONING OF LP DOSING

SYSTEM FOR BOILER
(Testing schedule)