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Page No STATION
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M.S.P.G.C.L., CHANDRAPUR Doc. No : OPN/SM
ISS/REV. NO.: 01/00
Operation Section Manual U#6 ISS/REV.DT:01.02.2017/00
2.
Index
3.
Release Authorization
4.
Amendment Sheet
5.
Purpose
6.
IMS Objectives
7.
List of Reports to be submitted
8.
List of activities carried out by the section
9.
Work Instructions/Standard Operating Procedures
10.
Checklists
11.
Safety Instructions
12.
Significant Aspect & Controls Measures
13.
Significant Hazards & Control Measures
14.
Contextual Issues- Risk: Control Measures/Opportunities
15.
Improvement Projects Carried out, in progress and Planned
16.
List of log books at various location in unit-6
17.
List of manuals
18.
List of Files / Registers
3. RELEASE AUTHORISATION
This Sectional Manual is released under the authority of the Sectional Incharge,
Operation Unit 6, CSTPS, Chandrapur and is a property of CSTPS, Chandrapur.
Signature :
5. Purpose
Purpose :
There is a common Shift Incharge Engineer. For Generation of Electricity Coal, Oil &
Water is required. Coal Stocks are maintained by CHP Staff. The Coal Handling Plant Supplies
Crushed Coal of size to the Coal Bunkers. The Bunker supplies coal to the Coal Feeder
which in turn supplies a regulated Supply of Coal to Pulveriser. After pulverization the Coal is
fed to the Boiler by means of Air Flow supplied by the P.A. Fan. Boiler is filled with Treated
Water Supplied by the WT Plant. Coal Burns producing heat, which is taken up by the Water ,
which is converted to steam. Steam is supplied to the Turbine, which rotates along with the
Generator Producing Electricity. Coal after burning leaves behind Ash in which the heat of the
furnace gets partly converted to molten slag which falls in the Bottom Ash Hopper and the rest
remains in the form of fly Ash which is separated from the flue Gas by the ESP.
The Temperature and Pressure of the steam is monitored by the PCR staff. The Chemical
Quality of Steam, Water, Coal and Oil is Monitored by the WT Plants.
Shift-Charge Engineers give OLC to LD Nagpur as per the coal quality and mill and plant
availability. LD Nagpur gives us load schedule hour wise every day. PCR staff tries to maintain
the load schedule. If Any Abnormality is observed in the plant and set is required to be
withdrawn it is informed to LD prior to withdrawal of set. Planned outages are taken with
permission from Director (Operation) Mumbai.
If any abnormality is observed in the plant/ Process shift-Charge Engineer tries to solve the
problem in his capacity. if it is beyond his capacity he approaches higher authority S.E.(O)-II,
DyCE-II & C.E. PCR and the local staff tries to maintain the parameters as per the
manufacturers recommendation.
Regarding housekeeping yearly cleaning contract is operated by O.S.-II section. Cleaning
is checked by Operation staff and certified by the respective area INCHARGE.
Defects of auxiliaries/ plant are raised by Shift Charge Engineer/ PCR Incharge/Asst. Plant
Incharge through computer to respective section. The defects are classified as Urgent,
Emergency, Short shut down, Overhaul, depending upon severity & isolation of the equipment.
The Maintenance staff takes permit from PCR and does the work. After cancellation of permit
& trial of equipment defect is eliminated from the computer list.
All Operation staff attendance is marked by time Office. If somebody applies leave
timekeeper gives note to a person who is in spare shift. Leave Account, night shift Account, OT
register, attendance registers are maintained by time keeper.
Various training programs are arranged by the Chandrapur Training Center. Training
department maintains register in which names of candidates, which type of training given is
noted. Accordingly S.E.(O)-II sends names of employees to training department as per the
availability of staff.
OPERATION : Unit 6
b) P.C.R. / UNIT INCHARGE: - is to get started the auxiliaries and systems and
track the sequential operation of Boiler and its auxiliaries, turbine and its
auxiliaries coupled with Generator and allied system. While synchronizing the
unit with Grid, withdrawing from grid and during normal operation with the help
of his assisting personnel for control desk operation, maintaining parameters
within safe specified limits and co-coordinating with L.D. Center and local
sections and their staff raising defect card for abnormality if any.
c) To supervise Coal Mills, Primary Air Fans along with their lubrication system, Coal
mill Reject & Seal Air Fan
d) Junior Engineer is assisted by technician in every shift who supervises Coal mills,
Primary Air Fans. This system supplies coal air mixture to boiler for combustion.
f) Reject Belt Operator: Reject Belt Carries Coal Mill Reject to Hoist
Hopper situated at U#5 &further transportation to reject Yard
ID FANS, Flue gas hopper Evacuation , ERM,CRM Operation & ESP field s Parameters,
An every shift, fly ash hopper evacuation done by technician with co-operation of contracts
labours to maintain healthiness of fields & minimum chimney emission.
8) TURBINE FLOOR-:
Technician-III works under the control of Turbine API.He monitors , TDBFP
A&B , main turbine lub oil system,main TG Governing Rack filters,Primary
water tank level, At 8.5 mtr,HPBP oil tank level.AtDeareatorlevel,all types of
feed/extraction/drip v/v operation as & when required, AWM monitoring
6.IMS Objectives
Frequency of
Tittle of the Report to be Submission Reference
Remarks (If Any)
SN Report To be submitted to Quarterly/ (Document/Re
(Responsibility )
submitted Whom Monthly/ Weekly/ cord)
Daily
User222/POG/
ORTData File/ ORT_month/Input
Monthly
1 ORT DATA POG Aux. trial format
( In first week)
register (T/G Desk / PCR
I/C)
Daily plant
Daily DPPR File
2 performance POG PCR I/C
(In night shift) (FF6341)
report
Hourly
Generation &
T/G Desk /
loss Report & Daily DPPR File
3 POG Blr.Desk
Non (In night shift) (FF 6342)
Engineer
availability of
Coal mills
Parameters to
be Monitored Daily Boiler desk
4 POG DPPR File
at Corporate (In night shift) Engineer
Level
Generating
DATA / Partial
DATA ENTRY Daily
5 loss , Tripping SAP DPPR T/G Desk Engineer
IN SAP (In every shift )
details & C/M
outage details
DATA ENTRY
Morning Daily
6 IN SAP SAP DPPR PCR I/C
Report (In Night shift )
A)
OCM, &
ORT
meeting
performanc
e report
Resources-: Meeting,
TG /DESK , BLR./DESK,
Manpower , DAS , OCM, &
DRUM LEVEL DESK, ORT
LAN
PCR /SHIFT I/C LOG BOOK meeting
Sr. Page
Auxillary Schedule Trial
No. No.
1 Main TG Aux.Oil Pump-1 & 2 Every Tuesday 11-30
2 Emergency Oil Pump(DC) Every Tuesday 31-40
3 DC seal Oil Pump(H2 side) Every Tuesday 41-50
4 TDBFP-6A & 6B DC LOP Every Tuesday 51-69
SR
NO. Work Instruction Name Work Instruction Number
SR
NO. Work Instruction Name Work Instruction Number
33 Starting vaccum pump OST-III/1333
34 Starting of dearator filling OST-III/1334
35 Line up of primary water system OST-III/1335
36 Taking primary water system in service OST-III/1336
37 Starting of lub oil system of main turbine OST-III/1337
38 Taking JOP in service OST-III/1338
39 Starting of seal oil system OST-III/1339
40 Placing turbine on barring gear OST-III/1340
41 Taking control oil system in service OST-III/1341
42 Preparing for CO2 & H2 filling in Generator OST-III/1342
43 Replacing air with CO2 OST-III/1343
44 Replacing CO2 with H2 OST-III/1344
45 Replacing H2 with CO2 OST-III/1345
46 Replacing CO2 with air OST-III/1346
47 Starting of TDBFP OST-III/1347
48 Waterwall soot blowing /APH operation OST-III/1348
Boiler Hydraulic Test(WW, Drum
49 , SH, ECO ) OST-III/1349
50 Cold Start of boiler OST-III/1350
51 Turbine Rolling & Synchronising OST-III/1351(OST-IV/1500)
52 Unit Cold Start up Report OST-III/1352
53 Unit Hot Start up Report OST-III/1353
54 Shut down of unit from full load condition OST-III/1354
55 Air Heater water washing OST-III/1355
56 Operation sequence of D.G. Set for Load trial OST-III/1356
57 Total AC Failure OST-III/1358
58 Emergency Operation OST-III/1359
59 Functioning of P.O.G. OST-III/1360
Optimization of Coal Mill performance during
60 Rainy Season OST-III/1361
Work Instructions
Soft copy on user222\ iso\ sectionwise work instruction\ op.stg-III operating manual
10.2 CHECKLIST
start
17 Water level in seal trough & bottom Overflow P.I. / Local I/c
ash hopper
18 Manual Auxiliary air dampers all 4 Open > 50% P.I. / Local I/c
corners
1. Use safety equipment/instrument like Safety shoes, Helmet, Goggles, Hand gloves,
Ear Plugs, Nose Mask.
2. Work under skilled labour/trainee.
3. Ensure to follow Permit system.
4. Ensure the work is carried out by Authorized Personnel , wherever applicable.
5. Use safety belt/ body Harness while working on pipes & ducts & where there is no
platform.
6. Use welding mask/goggle during the welding work.
7. Use asbestos hand gloves while working on hot equipment or near steam.
8. Use rubber hand gloves & proper insulated tester like pliers, screw driver etc. while
working on electrical circuits.
9. Use proper approach, suitable platform for attending the problems.
10. Use Headlamps where there is less lighted area and narrow passage.
11. Handle tools & tackles properly (tie them to thread and carry along ones neck).
12. After completion of work, collect all the waste material like, cotton waste, cloth & paper
as well as fastener.
Ensure Healthiness of
person( Give reference of
any SOP/procedure if
applicable)
Ensure Healthiness of
person( Give reference of
any SOP/procedure if
applicable)
Regular safety/Electrical
Inspections
Control Measures:
SN Category Risk/Concerns
Action Initiated/to be carried out
Resources:
Miscommunication, errors
4 Incompetent/Inade Adequate Training
in work, repetition of work
quate Manpower
Resources:
Scarcity or not as Hamper the work result in Control over externally provides
5 per specification of delayed and inaccurate services through Supervision and
Material/Instrument work Documented Obligations
s/Consumables
19
20 CEP log book FF6314/6464 Turbine basement I/C
21 MDBFP 6C & 6D log book FF6320 Turbine basement I/C
22 Station transformer & UAT log book FF6319 Turbine basement I/C
23 CXW log book FF6315 Turbine basement I/C
24 Seal oil rack log book FF6468/6318 Turbine basement I/C
25 GTR RYB Phase/ dry type FF6321/6471 Turbine basement I/C
transformer log book
26 Seal oil system log book FF6323/6473 Turbine basement I/C
27 Vacuum pump A & B log book ------- Turbine basement I/C
28 Air compressor log book FF6317 Compressor room I/C
29 DG Parameter register ----- Compressor room I/C
30 Air compressor permit entry book ------ Compressor room I/C
31 Boiler basement I/C log book FF6311/6461 Boiler basement I/C
32 Bottom ash evacuation log book ----- Boiler basement I/C
33 FD Fan log book FF6333
Boiler basement I/C
34 PA Fan log book FF6482 Boiler basement I/C
35 Coal Mill log book FF6336 Boiler basement I/C
36 ESP I/C Log book FF6312/6462 ESP I/C
37 ESP Field log book FF6338 ESP I/C
38 ID Fan log book FF6334 ESP I/C
39 Fly ash hopper/ ESP AC compressor ------- ESP I/C
40 Firing floor I/C log book FF6331/6481 Firing floor I/C
41 F/Floor General activity register ----- Firing floor I/C
42 Air heater register ------ Firing floor I/C
43 AHP series log book FF6337/6487 AHP I/C
44 ACW / CCW log book FF6327 CCW I/C
45 Transformer reading log book (ACW / FF6330 CCW I/C
CCW)
46 CT fan log book FF6325 CCW I/C
47 CCW General activity register ------ CCW I/C
48 Non DM / DM log book FF6339A RWP(STG-III) I/C
49 Ash water log book FF6339 RWP(STG-III) I/C
50 Fire water log book FF6339A RWP(STG-III) I/C
51 RWP General activity register ----- RWP(STG-III) I/C
Volume -1 Engineer
2 Operation manual Turbine & Auxiliaries ----------- PCR I/C & T/G desk
Volume -2 Engineer
3 Generator , Auxiliaries & Outdoor plants ---------- PCR I/C & T/G desk
Volume -3 Engineer
4 Operation parameter guideline manual OST-III/M-05 PCR I/C , Boiler desk,
TG Desk, Drum desk
Engineer
5 HT/LT Board details ---------- Turbine API
6 Turbine flow diagram ----------- Turbine API
7 Unit operating procedure manuals ------- T/G Desk Engineer
8 Manual for Ammonia flue gas --------- PCR I/C
conditioning ( AFGC) system
9
18) LIST OF FILES / REGISTERS
10 Minor incidence & near miss report F-05 SHIFT I/C CABIN
file