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Профессиональный Документы
Культура Документы
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 : 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 : 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
No.
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 : 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.
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
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 : 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
GENERAL MANAGER :
-
2.
2
DY-GENERAL MANAGER :
3
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:
5.5.1/UTY/GEN/05
01
28.12.2004
01
24.11.2005
02 OF 04
MANAGER, UTILITY
-
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:
5.5.1/UTY/GEN/05
01
28.12.2004
01
24.11.2005
03 OF 04
7
8
9
10
11
12
13
14
15
16
17 18 -
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 : 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.:
Page No.:
5.5.1/UTY/GEN/05
01
28.12.2004
00
04 OF 04
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.
-
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
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 : 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 : 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
2.0
PURPOSE
3.0
SCOPE
4.0
5.0
5.1.2
5.1.3
5.1.4
Power
House
operation
and
RESPONSIBILITY :
INPUT
STEPS
CONTROL
i)
ii)
iii)
i)
ii)
iii)
iv)
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 : 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)
ii)
iii)
iv)
v)
vi)
6.0
TASK / ACTIVITY
6.1.0
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
02 OF 04
Data
: COAL HANDLING
:
6.1.1
INPUT
6.1.2
STEPS
6.1.3
CONTROL
*
*
6.1.4
OUTPUT
6.1.5
MEANS
i)
ii)
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
7.1.2
INPUT
i)
ii)
7.1.3
STEPS
i)
7.1.4
CONTROL
OUTPUT
MEANS
i)
7.1.5
7.1.6
ii)
:
8.0
TASK / ACTIVITY
8.1
POWER GENERATION :
8.1.1
8.1.2
8.1.3
INPUT
STEPS
:
:
8.1.4
CONTROL
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:
6.3/UTY/DOP/01
01
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01
24.11.2005
04 OF 04
11.0
REFERENCE DOCUMENTS
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 : 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.
2.0
PURPOSE
3.0
SCOPE
4.0
RESPONSIBILITY
5.0
TASK / ACTIVITY
5.1
DAILY MAINTENANCE :
5.1.3 STEPS
5.1.4 CONTROL
5.1.5 OUTPUT
5.1.6 MEANS
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
6.1.1
6.1.2
INPUT
STEPS
6.3/UTY/DOP/02
01
28.12.2004
01
24.11.2005
02 OF 04
i)
ii)
iii)
6.1.3
Reference No.:
Issue No.:
Issue Date.:
Revision No.:
Revision Date.:
Page No.:
i)
ii)
iii)
iv)
v)
vi)
v)
Data
6.1.4
CONTROL
6.1.5
OUTPUT
6.1.6
MEANS
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
7.1.1
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
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01
24.11.2005
03 OF 04
i)
ii)
iii)
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 : 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
7.1.5
OUTPUT
7.1.6
MEANS
8.0
TASK / ACTIVITY
8.1
PROJECT WORK
8.1.1
8.1.2
INPUT
i)
ii)
8.1.3
STEPS
i)
ii)
iii)
8.1.4
CONTROL
8.1.5
OUTPUT
i)
ii)
8.1.6
MEANS
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 : 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
2.0
PURPOSE
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
4.4
4.5
4.6.
Check for abnormal sound in the pump and bearing temperature, report if necessary.
4.7.
4.0.
REFERENCE RECORDS
5.0
AMENDMENTS
First issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
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
4.3
Open the gland sealing water line of the pump and air exhauster.
4.4
4.5
4.6
When suction pressure has reached around 0.6 KSC, start the pump.
4.7
4.8
Stop the air exhauster and close the air exhauster valve.
4.9.
starting of negative
Operator.
Reference records
6.0
Amendments
First issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
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Revision No.:
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DEPARTMENTAL
OPERATING
PROCEDURE
stopping
6.3/UTY/WI/03
01
28.12.2004
01
24.11.2005
01 OF 01
PROCESS
of centrifugal
pump
2.0
PURPOSE
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
4.3.
4.4.
5.0.
6.0
AMENDMENTS
First issue
Prepared by : ________
__________
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Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
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6.3/UTY/WI/04
01
28.12.2004
01
24.11.2005
01 OF 01
1.0
PROCESS
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
4.2
Prepared by : ________
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Designation : Mgr.(Uty.)
D.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.:
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Revision No.:
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6.3/UTY/WI/05
01
28.12.2004
01
24.11.2005
01 OF 01
1.0
PROCESS
2.0
PURPOSE
3.0
RESPONSIBILITY
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 : 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
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
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__________
Reviewed by : _________
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Designation : Mgr.(Uty.)
D.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.:
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6.3/UTY/WI/06
01
28.12.2004
01
24.11.2005
02 OF 02
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
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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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
With the help of dewatering pump remove water in the pit in the tunnel
Whenever required.
4.2
4.3
Start Vibrator.
4.4
4.5
Check the conveyor belt for any damage and for smooth running
4.6
4.7
Selected coal from stores [ Stock yard ] and unload on reclaim hopper
4.8
4.9
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
6.0
Amendments
First issue
Prepared by : ________
Designation: Mgr.(Uty.)
Date
__________
D.G.M.(Uty.)
: 24.11.2005
Reviewed by : _________
Approved by : ___________
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
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.
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
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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.
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D.G.M.(Uty.)
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Date
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Date
: 24.11.2005
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DEPARTMENTAL
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Reference No.:
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6.3/UTY/WI/09
01
28.12.2004
00
01 OF 01
1.0
PROCESS
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
4.2.
4.3.
4.5
4.7
4.8
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
5.0
Reference Document
6.0
Amendments
First issue
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D.G.M.(Uty.)
Designation : President(Opn.)
Date
Date
Date
: 24.11.2005
: 24.11.2005
: 24.11.2005
RNPL
DEPARTMENTAL
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Reference No.:
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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.
Prepared by : ________
__________
Reviewed by : _________
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Designation : Mgr.(Uty.)
D.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.:
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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.
:
:
:
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
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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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
4.2
4.3.
4.4
Close the stop valve, open drain valve of the main line.
4.5
4.6
4.7
4.6
Open vent valves when steam pressure reaches just above atmospheric pressure
(2-3 Kg/cm2).
5.0.
Reference Records
6.0.
Amendments
First issue
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__________
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D.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.:
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Revision No.:
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6.3/UTY/WI/12
01
28.12.2004
01
24.11.2005
01 OF 02
1.0
Process
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
PERMISSIVE TO BE CHECKED.
1.
2.
3.
4.
5.
6.
4.2
4.3
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.
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Reviewed by : _________
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D.G.M.(Uty.)
Designation : President(Opn.)
Date
Date
Date
: 24.11.2005
: 24.11.2005
: 24.11.2005
DEPARTMENTAL
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9.
Reference No.:
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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.
13.
14.
Roll the machine gradually up to the speed, when governor take over (2850-2907
RPM)
15.
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.
19.
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.
5.0
Reference documents
6.0
Reference Records
7.0
Amendment
First Issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
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6.3/UTY/WI/13
01
28.12.2004
01
24.11.2005
01 OF 01
PROCESS
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
4.2
4.3
Trip the turbine by hand, starts the AOP immediately at around 2800 rpm of
turbine speed .
4.4
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
First issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
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Revision No.:
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6.3/UTY/WI/14
01
28.12.2004
01
24.11.2005
01 OF 02
1.0
PROCESS
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
A. PERMISSIVE TO BE CHECKED.
1.
2.
3.
4.
5.
6.
7.
8.
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
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6.3/UTY/WI/14
01
28.12.2004
01
24.11.2005
02 OF 02
32
D.
Reference documents
E.
Reference Records
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 : 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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
4.2
4.2
4.3
Trip the turbine by hand , start the auxiliary oil pump at around 2900 rpm of turbine
Speed.
4.5.
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.:
4.8.
4.9
maintain records
5.0.
Reference Document
6.0.
Amendments
First issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
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6.3/UTY/WI/16
01
28.12.2004
01
24.11.2005
01 OF 02
1.0
PROCESS
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
4.2
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
4.6
4.7
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.
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D.G.M.(Uty.)
Designation : President(Opn.)
Date
Date
Date
: 24.11.2005
: 24.11.2005
: 24.11.2005
RNPL
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Reference No.:
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6.3/UTY/WI/16
01
28.12.2004
01
24.11.2005
02 OF 02
4.11.
4.12.
4.13.
Assemble the equipment, take the clearance from other departments for their work.
4.14.
4.15.
Take the trial of the equipment and check for smooth running and hand over to the
process.
4.16.
4.17.
Identify & record the spares required for next shut down.
5.0.
Reference Document
6.0.
Amendments
First issue
boiler.
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
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
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
4.9
Record the jobs attended & Maintain the History Cards ( both hard copy and soft copy)
5.0
Reference Document :
6.0
Amendments
First issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
4.2
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
4.7.
Record all the parameter in respective document and inform any abnormalities.
5.0.
Reference Document
OEM Manual
6.0.
Amendments
First issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
Reduce
4.2
Run the engine for about 5 minutes at Run Speed (1500 RPM).
4.3
4.4
4.5
4.6.
4.0.
Reference Document
OEM Manual
5.0
AMENDMENTS
First issue.
stopping the
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
3.0
RESPONSIBILITY
4.0.
SEQUENCE
4.1.
4.2.
4.3.
4.4.
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.
4.9.
4.10
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
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1.
4.2
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
4.6
4.7
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 : 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
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
4.2
4.3
4.4
4.5
4.6
4.7.
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 : 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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
4.2
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
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 : 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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
Reduce
4.2
Run the engine for about 5 minutes at Run Speed (1500 RPM).
4.3
4.4
4.5
4.6.
4.0.
Reference Document
OEM Manuals
5.0
AMENDMENTS
First issue.
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
3.0
RESPONSIBILITY
4.0.
SEQUENCE
4.1.
4.2.
4.3.
4.4.
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.
4.9.
4.10
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
of Engineer Water
First issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
maintenance of
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.2.
4.2
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
4.6
Clean the heat exchanger, low temperature after cooler and air cyclone tubes.
4.7
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 : 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
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
4.2
4.3
4.4
4.5
4.6
4.7.
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 : 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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
4.1
Remove the safety valve /Relief Valve after taking clearance from operation.
4.2
4.2
Check the condition of all parts, if required send for repair to Work Shop/replace
with new one.
4.4
4.5
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
5.0
Reference Document :
Range of hydraulic Test for header valves.
1)
2)
3)
6.0
Amendments
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
FORMAT No. 1
S.
No.
Ref.
No.
Customer
Satisfaction
Process
1.
CS
5
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
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 : 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
FORMAT NO. 2
S.
No.
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
Crutial
Process
ICOM
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 : 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
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
3
3
3
5
5
5
1
1
1
15
15
15
Clarified water
15
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 : 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
FORMAT NO. 4
S.
No.
01
Ref.
No.
Crutial
Process
ICOM
(Output)
09
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
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 : 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
FORMAT NO. 5
S.
No.
01
02
03
04
05
06
07
Ref.
No.
Crutial
Process
ICOM
(Controls)
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
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
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 : 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
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)
Through Department
CONSEQUE
NCE
OF
LOSS
C
5
Through Department
Through Department
2
2
5
5
1
1
10
10
Through Department
10
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 : 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
2.
PURPOSE
3.
SCOPE
4.
5.
1.
2.
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 : 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
8.0
Amendment
First Issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
3.0
4.0
4.1
4.2
4.4.
4.7
4.8
4.9
4.10
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 : 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
POWER HOUSE
FRESH WATER
3600 M3/ DAY
DRAINING O FLOCCULATION
TANK AND LAMELLA CLARIFIER
245 M3/ DAY
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
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 : 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
CASCADE AERATOR
FLASH MIXER
FLOCCULATION TANK
RESERVOIRS
LAMELLA CLARIFIER
MILL
COLONY
BARBODHAN
VILLAGE
TENA
VILLAGE
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
COAGULATION TANK
DUAL MEDIA
PRESSURE FILTER
ACTIVATED CARBON
FILTER
DEGASIFIER TOWER
ANION UNIT
DEGASSER TANK
M.B UNIT
D.M. WATER
TANK
BOILERS
Prepared by : ________
Designation: Mgr.(Uty.)
Date
__________
D.G.M.(Uty.)
: 24.11.2005
CONDENSATE
WATER TANK
Reviewed by : _________
Approved by : ___________
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
2.0
PURPOSE
3.0
4.0
SEQUENCE
4.1
01
28.12.2004
01
24.11.2005
01 OF 01
4.2. WATER
Open the
gland sealing water line.
PERIODICALLY
4.3
4.4
4.5
4.6
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
5.0.
CONDENSATE FROM
SIEMENS/ BHEL TG
DEAERATOR
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 : 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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
: Operator
:
4.1
4.2
4.3.
4.4.
6.0.
6.0
AMENDMENTS
: First issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
2.0
PURPOSE
3.0
4.0
SEQUENCE
4.1
4.2.
4.3
Check the water flow control valve of the particular cell is open & water
coming through the valve.
4.4
4.5.
4.6.
5.0.
6.0
AMENDMENTS
: First issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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.:
4.1
4.2.
4.3.
5.0
6.0
AMENDMENTS
: First issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
SEQUENCE
A. PERMISSIVE TO BE CHECKED.
9.
10.
11.
12.
13.
14.
15.
16.
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
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
E.
Reference Records
F.
Amendment
First Issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.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
2.0
PURPOSE
3.0
RESPONSIBILITY :
4.0
SEQUENCE
4.1
4.2
4.3
Close Low Pressure steam extraction valves. Open the chest drain valves.
4.4
4.5.
4.6.
6.0
Reference Records
7.0
Amendment
First Issue
Prepared by : ________
__________
Reviewed by : _________
Approved by : ___________
Designation : Mgr.(Uty.)
D.G.M.(Uty.)
Designation : President(Opn.)
Date
Date
Date
: 24.11.2005
: 24.11.2005
: 24.11.2005
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
pH
> 8.3
> 8.2
< 20
< 15
0.02
< 0.02
< 0.02
< 0.02
< 0.003
< 0.01
DM Water
Feed Water
Boiler Water
pH
8.3 to 9.3
8.3 to 9.5
Silica (PPM)
< 0.02
< 0.02
< 3.2
1 (Max)
FMA (PPM)
< 80
NA
NA
Chloride
NA
Nil
NA
TDS (PPM)
NA
NA
Fe (PPM)
NA
NA
Cooling water
Treated water
pH
7.6 to 8.2
Chloride (PPM)
500
PH
7.8 to 8.0
0.2-0.5
Silica (PPM)
180 (Max)
Turbidity (PPM)
10 to 15
5000 (Max)
OPO4 (PPM)
40-70
CaH (PPM)
400 (Max)
COC
6 (Max)
0.2 to 0.6
Total Hardness
800 (Max)
1.0 (Max)
0.5 (Max)
3 (Max)
__________
Reviewed by : _________
Approved by : ___________
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
2.0
PURPOSE
3.0
RESPONSIBILITY
4.0
4.1
SOURCES OF RECEIPT:
4.2
.
.
.
.
.
.
.
.
.
Prepared by : ________
__________
Designation : Sr.Mgr.(Uty.)
Date
: 23.02.2006
D.G.M.(Uty.)
Reviewed by : _________
Approved by : ___________
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
.
.
.
.
l
.
.
Prepared by : ________
Reviewed by : _________
Approved by : ___________
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
.
.
.
.
.
4.7
.
.
.
.
4.8
.
.
Prepared by : ________
__________
Designation : Sr.Mgr.(Uty.)
Date
: 23.02.2006
D.G.M.(Uty.)
Reviewed by : _________
Approved by : ___________
Designation : President(Opn.)
Date
Date
: 23.02.2006
: 23.02.2006
TO:
MR A.K.BISWAL
|
Mr. K.D. MANTRI
(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
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
kg/cm2
3.5
***
AUTO START
S/B CEP
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
----
Prepared by : ________
__________
Designation : Sr.Mgr.(Uty.)
D.G.M.(Uty.)
Date
: 23.02.2006
Hz
52.0
TURBINE
Reviewed by : _________
Approved by : ___________
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
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
95
115
TSI MONITOR
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
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 : 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
----
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 : President(Opn.)
Date
Date
: 23.02.2006
: 23.02.2006