Complete O&M Management System - Rev 10 Jan 02 2015

Operations and Maintenance
Management System

Bulleh Shah Paper Mills (Packages), Kasur Pakistan

The Power Business Professionals
Operation
ns and Maintennance
Manaagement System m

1. Job De
escription, Responsibility aand minimum
m required quaalification
2. Shift changeover prrocedure
Duty exchange
3. Shift D e and Leave p
procedure
4. Docum
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5. Plant M
Modification Procedure
6. Protecction Bypass P
Procedure
7. Standaard lock out/TTag Out proce
edures for criitical equipmeent
8. 65 TPH
H Standard Operating Proccedure
9. 200 TP
PH Standard O
Operating Pro
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10. 41 MW
W Steam Turb
bine Standard
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11. 65 TPH
H Preventive Maintenance
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12. 200 TP
PH Preventive
e Maintenancce Procedure
13. 41 MW
W Steam Turb
bine and Utilitties Preventivve Maintenan
nce Proceduree
14. Correcctive Mainten
nance Procedure
15. HFO U
Unloading Procedure
16. Chemiical unloadingg Procedure
17. Safety coordination
n committee
18. Emerggency Response Procedure
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19. Incident Reporting and Investigaation
20. Operational Improvvement Plan
21. Strateggy for Preven
ntive Mainten
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22. Equipm
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hangeover Pro
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23. Blacko
out Restoratio
on Procedure
Operation
ns and Maintennance
Manaagement System m

24. Air Compressor Start up Procedu
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25. Time K Overtime Procedure

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26. Inspecction and Testting Procedurre
27. Custom
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28. Log Bo
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29. Perforrmance Review Procedure
30. Proced
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31. Make up Procedure
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32. Proced
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33. Capaciitor Bank Ope
erating Procedure
34. Chemiical Analysis aand Chemical Control Proccedure
35. Boiler,, Steam Turbine and Generator Trippingg Interlock Teesting
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May, 2012,
BSPM Power House
Rev : 2 O&M Management System
Job Description & Minimum Qualification Requirement
Table of Contents
Job Description and Minimum required qualification .................................................................... 3
Objective: ........................................................................................................................................ 3
Job Descriptions: ............................................................................................................................. 4
Plant Manager ................................................................................................................................. 4
O&M Manager ................................................................................................................................. 5
Operations Team Leader ................................................................................................................. 7
HSE/IMS Coordinator ...................................................................................................................... 8
Shift In charge .................................................................................................................................. 9
Boiler Operator .............................................................................................................................. 10
Turbine Operator ........................................................................................................................... 11
Electrical Operator ........................................................................................................................ 12
Utility Operator ............................................................................................................................. 13
Chemical Plant Operator ............................................................................................................... 14
Mechanical Maintenance Team Leader ........................................................................................ 15
Mechanical Engineer. .................................................................................................................... 16
Mechanical Technician .................................................................................................................. 17
Electrical and Instrument Team Leader ........................................................................................ 18
Electrical Engineer ......................................................................................................................... 19
Electrical Technician ...................................................................................................................... 20
Instrument Engineer ...................................................................................................................... 21
Instrument Technician ................................................................................................................... 22
Minimum Qualification Requirement ........................................................................................... 23

Page 2 of 2
BSPM Power House
Job Description and Minimum required qualification
Objective:
The objective of this procedure is to define job description of all the team at BSPM Power House and set
the minimum qualification requirement of team:
1‐ All the team must understands their area of responsibility.
2‐ To help assist the team to perform their duties professionally and in efficient manner.
3‐ To set minimum criteria to evaluate the team qualification.
4‐ To set guidelines for new hiring of team.

Page 3 of 3
BSPM Power House
Job Descriptions:
Plant Manager

1. Ensure the safety procedures and workplace practices implemented and adhered to at the Power
Plant.
2. Ensure the safe and Optimum operation and maintenance of all Plant equipment within
prescribed operating parameters. Take initiatives and measures to minimize the plant down time
and maximize the plant availability and operational efficiency.
3. Coordination with BSPM management.
4. Ensure vigilant supervision and control of operational staff and plant operations activities.
5. Review of Planning and scheduling the Power House maintenance and communicate to paper
mills.
6. Coordination with Mechanical and E&I Team Leaders and ensure the operate ability of all Plant
equipment.
7. Inform BSPM management regarding cost of electricity and steam.
8. Monitoring the Steam Distribution System to individual consumer Departments of BSPM.
9. Maintain effective communication with all concerned at Power Plant and at BSPM.
10. Ascertain the training needs and develop training & skill improvement programs internally and
externally for Operations staff.
11. Evaluate the performance of operations staff and make necessary recommendations.
12. Manage any short fall resulting from planned, forced or emergency leave/absence of any worker
under his administrative control
13. Interactive participation in daily internal and BSPM meetings.
14. Plan to maintain a reasonable level of House Keeping and take necessary measures for
Environmental protection at Power Plant.
15. Ensure implementation and exercise of Emergency Action Plan for various situations at Power
Plant.
16. Take initiatives and effective measures to minimize the plant down time and maximize the plant
availability and operational efficiency.
17. Ensure the 100% availability and operate ability of all equipment and systems of the power plant.
18. Plan, Schedule, Execute and vigilantly supervise the Planned, Preventive, Periodic, Scheduled and
Corrective Maintenance of all equipment and systems of the power plant.
19. Ascertain and evaluate the Mean Time between Failures and determine the reason for failure of
mechanical components. Maintain the relevant maintenance record of all equipment.
20. Ensure the availability of required skilled workers, spare parts, fuels, lubricants and consumables
required to perform day to day and periodic maintenance work.
21. Maintain record of maintenance work performed, spares, consumables, chemicals consumed and
respective balance stocks.
22. Ascertain the need and Order the required spare parts, lubricants, Oils, chemicals and other
consumables. Follow up the purchase and procurement.
23. Evaluate and finalize the offers, quotations submitted by various suppliers and venders.
externally for Maintenance and Utility staff.
25. Evaluate the performance of Maintenance and Utility staff and make necessary
recommendations.
26. Interactive participation in daily internal and external meetings.
27. Technical review of any mechanical modification at plant.
29. Take necessary action for the removal of water, steam, air leakages and any spillages at plant.
Page 4 of 4
BSPM Power House
O&M Manager

Plant.
2. Ensure the safe and Optimum operation and maintenance of all Plant equipment within
prescribed operating parameters. Take initiatives and measures to minimize the plant down time
and maximize the plant availability and operational efficiency.
3. Coordination with BSPM management.
5. Develop the Daily Operations Report indicating the generated electrical power, Steam supplied
to consumers, HFO Received & consumed, Gas consumed and the existing Plant status.
6. Report to the Plant Manager immediately about any undesired situation at plant.
7. Planning and scheduling the Power House maintenance and maintain the respective records.
equipment.
9. Maintain records of all Log Sheets and Log Books. Identify any operational abnormality and take
preventive measures. Record all outages, tripping, failures time, duration and reason.
10. Review the Laboratory Log Book and Analysis sheets and maintain records. Take appropriate
measures to ensure the required quality of waiter and other fluids.
11. Maintain and control the stock of all chemicals, Heavy Fuel Oil, Lubricants and other
consumables at Power Plant. Maintain their relevant consumption and available inventory
records.
12. Ordering of all chemicals, Heavy Fuel Oil, Lubricants and consumables required at Power Plant.
15. Developing the Shift Duty Schedule on weekly/Monthly/Annual basis and ensure presence of
required operations staff during each shift.
20. Timely Submission and follow‐up of purchase request
21. Ascertain and ensure all preventive, periodic and corrective maintenance requirements.
23. Develop, implement and exercise Emergency Action Plan for various situations at Power Plant.
24. Follow the instructions from Plant Manager in line with company policy.
25. Ensure that all plant equipment are being operated within the prescribed operating parameters
and limits during each shift. Confirm the plant status given in daily operations report.
28. Plan, Schedule, Execute and vigilantly Supervise the Planned, Preventive, Periodic, Scheduled and
Corrective Maintenance of all equipment and systems of the power plant. Follow the instructions
given in the Operation & Maintenance Manuals of respective equipment.
29. Review the Log book critically, ascertain the operating parameter trends and develop a
preventive, operating and maintenance strategy for the equipment showing abnormal trends.
Page 5 of 5
BSPM Power House
33. Report to the Plant Manger immediately, about any undesired situation at the power plant.
34. Coordinate with Operation and E&I Team Leaders and ensure 100% correct function of electrical,
process control, protection & safety systems of all equipment at power plant.
35. Coordinate with contractors, subcontractors and suppliers, resolve the issues [if any]
36. Develop the annual maintenance budget and submit for approval.
38. Ensure the availability of Tools, instruments, equipment and other materials required to perform
maintenance work effectively and efficiently.
40. Inspect and approve the quality of procured materials satisfying the required specifications.
41. Inspection of materials coming at plant and their approvals.
42. Assist the Plant Manager in technical issues regarding Mechanical components of plant.
recommendations.
under his administrative control.
Page 6 of 6
BSPM Power House
Operations Team Leader

Plant.
2. Ensure the safe and Optimum operation of all Plant equipment within prescribed operating
parameters. Take initiatives and measures to minimize the plant down time and maximize the
plant availability and operational efficiency.
4. Develop the Daily Operations Report indicating the generated electrical power, Steam supplied
to consumers, HFO Received & consumed, Gas consumed and the existing Plant status.
5. Report to the Plant Manager immediately about any undesired situation at plant.
6. Planning and scheduling the Power House maintenance and maintain the respective records.
equipment.
8. Maintain records of all Log Sheets and Log Books. Identify any operational abnormality and take
preventive measures. Record all outages, tripping, failures time, duration and reason.
9. Review the Laboratory Log Book and Analysis sheets and maintain records. Take appropriate
measures to ensure the required quality of waiter and other fluids.
10. Maintain and control the stock of all chemicals, Heavy Fuel Oil, Lubricants and other
consumables at Power Plant. Maintain their relevant consumption and available inventory
records.
11. Ordering of all chemicals, Heavy Fuel Oil, Lubricants and consumables required at Power Plant.
14. Developing the Shift Duty Schedule on weekly/Monthly/Annual basis and ensure presence of
required operations staff during each shift.
19. Timely Submission and follow‐up of purchase request
20. Ascertain and ensure all preventive, periodic and corrective maintenance requirements.

Page 7 of 7
BSPM Power House
HSE/IMS Coordinator

1. Manages IMS documentation of their department/area.
2. Make sure all documents are updated and relevant documents are available at point of their
use.
3. Conduct risk assessments, aspect/impact study.
4. Coordinate with department and ensure all audits/inspections are carried out timely.
5. Coordinate with senior management of the department on matters of safety, health, and
environment.
6. Guide staff on matters of safety, health and environment.
7. Housekeeping management
8. To ensure the availability of PPE’s and other equipment’s for firefighting & other hazardous
Operations
9. To ensure and maintain compliance of health, safety and environmental policy.
10. Incident/accident investigation, reporting and preventing
11. Conduct short safety training to promote awareness about safety practices and procedures.
12. Get professional trainings arranged by OMS for the continual growth of the team.
Page 8 of 8
BSPM Power House
Shift In charge

1. Perform and supervise all the shift operations activities at Power Plant. Ensure the optimum
operation of all equipment within prescribed operating parameters.
2. Take necessary and quick measures to ensure the operational safety
3. Responsible for exercising and implementing the safe work practices and procedures at Power
Plant.
4. Coordination with the concerned BSPM department for operating electrical load during the
respective shift.
5. Coordination with the concerned BSPM department for consistent Steam supply during the
respective shift.
6. Coordination with the concerned BSPM department for required Water supply during the
respective shift.
7. Responsible for Power House operations (Electrical Control Room, 41 MW CHP Unit, 11 MW
CCGT, 65 TPH Boiler Operations, Water chest, Demineralization Plant and HFO unloading ,
Storage and handling areas )
8. Notify and Rectify the Steam, Compressed Air & water leakages and insulation erosions.
9. Generate job requests for repair work required during the shift.
10. Plan and handover to the maintenance team, the plant equipment scheduled for maintenance
during shift. Inspect, and takeover from maintenance team the plant equipment after completion
of maintenance work. Confirm the operate ability of the equipment taken over.
11. Observe and ascertain the Plant safety requirements during the shift, act appropriately in any
emergency situation, communicate with Team Leader and Plant Manager.
12. Responsible to keep operating parameters within prescribed limits, take adequate measures to
avoid Plant tripping. Respond correctly to the operational Alarms and indications timely during
the shift.
13. Check local parameters of Boilers, Turbine, Air compressor, Water chest and immediately take
preventive and corrective measures in case any abnormality. Follow the instructions given in the
Operations Manual of the equipment.
14. Check and Record in the relevant Log Books, operating hours of respective equipment and Flow
Transmitters.
15. Check and maintain record of analysis reports of Demineralization plant and Laboratory. Ensure
the correct procedures and desired results.
16. Ensure safe and efficient HFO unloading and handling operations.
17. Responsible for correct Boiler operation when Boiler Operator is busy on other boiler.
18. Responsible for correct Turbine operation when Turbine Operator is busy in some other essential
work at Plant.
19. Coordinate and Resolve the complaints from Process departments regarding Voltage variation,
steam pressure, temperature, compressed air pressure and water flow, by taking adequate
operational measures.
20. Checking of Operations Log sheets properly filed by operator. Notify the abnormalities in the
operating trends of the equipment, take preventive and corrective measures, and inform to the
Team Leader and Plant Manager. Maintain the records properly.
21. Ascertain and notify fairly in advance, the time [Date] of the plant equipment approaching their
Periodic Maintenance.
22. Carry out daily Inspections of all plant equipment and premises during the shift. Notify and
rectify the abnormalities observed.
23. Follow the instructions from superiors. Maintain clean work places and adhere to safe Power
Plant work practices.
Page 9 of 9
BSPM Power House
Boiler Operator

1. Responsible for safe and consistent operation of 200 TPH Boiler island, 65 TPH Boiler island and
respective auxiliaries equipment within prescribed operating parameters.
2. Follow the instructions of Operation & Maintenance Manuals of respective equipment.
3. Responsible for Heavy Fuel Oil Receiving, Storage and handling Areas.
4. Responsible for Lock Out / Tag Out activities for concerned equipment when required.
5. Maintain a reasonable level of House Keeping in the areas of responsibility.
6. Responsible for Startup, Shut Down, maintaining routine operations by timely responding and
resetting the control Alarms and indications observed during the shift.
7. Participate and perform trouble shooting during Boiler operation.
8. Responsible for maintaining the Boiler Shift Log Book, Hourly Log Sheets and other necessary
Data Sheets. Notify the abnormalities of operating parameters and take adequate measures to
avoid tripping and undesired situation.
9. Following instructions of Shift In charge and immediately inform about any abnormal operating
conditions.
10. Responsible for consistent supply of Process Steam to BSPM as per specifications by maintaining
the required Temperature, Pressure and Flow rate.
11. Responsible for Return Condensate from BSPM as per specifications. Notify and rectify the steam
and condensate leakages and eroding insulation.
12. Responsible for Soot Blowing of Boilers as scheduled.
13. Responsible for Gas Supply System Operations. Check and arrange to repair the gas leakages, and
adequately maintain gas consumption records.
14. Responsible for Heavy Fuel Oil Supply Operations. Check and repair the leakages and maintain
HFO Receiving, Consumption and available stock record.
15. Ensure the 100% performance of HFO & Gas Burners and related control systems, schedule time
based and condition based cleaning and maintenance. Maintain leakage free operations.
16. Follow instructions from superiors. Maintain clean work places and adhere to safe Power Plant
work practices.
17. Report water, steam, air leakages and any spillages to the shift incharge for the timely
rectification.

Page 10 of 10
BSPM Power House
Turbine Operator

1. Responsible for safe and optimum operations of 41MW Turbine island, 11MW CCGT Unit,
Cooling Towers and all related auxiliaries equipment, within the prescribed operating
parameters.
2. Follow instructions from Operation & Maintenance Manuals of respective equipment,
3. Responsible for all Lock Out / Tag Out activities of concerned equipment when required.
4. Maintain a reasonable level of House Keeping of the areas of responsibility.
5. Responsible for Start up, Shut Down, maintaining the routine operations by timely responding
and resetting the control Alarms and indications observed during the shift.
6. Participate and perform in the trouble shooting of operating equipment during shift.
7. Responsible for Turbine Shift Log Book, Hourly Log Sheets and other Data Sheets. Notify the
abnormalities of operating parameters and take adequate measures to avoid tripping and
undesired situation.
8. Following instructions of Shift In charge and immediately inform about any abnormal operating
conditions.
9. Responsible for consistent and optimum Electric generation by maintaining the 11KV Voltage,
50Hz Frequency and Power factor > 0.8. Ensure that all relevant display meters are intact and
error free.
10. Responsible for maintaining the Steam Turbine extractions safely.
11. Check and arrange to repair the Steam, Condensate, Cooling Water and Compressed air leakages
and eroding insulation in the turbine hall area.
12. Responsible for operation and testing of Turbine Protective Tests.
13. Follow instructions from superiors. Maintain clean work places and adhere to safe Power Plant
work practices.
rectification.

Page 11 of 11
BSPM Power House
Electrical Operator
1. Responsible for all Control Room operations of 41 MW Turbine island, 11 MW CCGT Unit and
WAPDA incomer Line Operations. Maintain, self‐generation Voltage 11KV, Frequency 50Hz, and
Power Factor >0.80. and a balance of Active / Reactive Power, and CR Log Book.
2. Maintain an hourly record of Self‐generated Kilo Watts, imported power from WAPDA and
consumption of all outgoing feeders. Maintain Control Room Log Book and other documents.
3. Ensure 100% error free function of all energy meters, volt meters, ampere meters, relays,
transmitters, and protections & control instrumentations, HT / LT feeders and breakers, timely
inform to the shift in charge for required repair or replacement.
4. Responsible for all Lock Out / Tag Out activities of relevant Feeders and Breakers when required.
5. Follow the instructions of Shift In charge and immediately inform about any abnormal operating
conditions observed. Operate within prescribed operating parameters.
6. Synchronization and De‐Synchronization operations with NTDC Network, communicate with Grid
staff for maintaining the voltage and frequency, when required. Manage optimum electrical load
during parallel and island operation.
7. Ensure the operate ability of Black start facility, periodically check its Fuel, Lube. Water levels.
8. In case of Black out due to WAPDA failure Restore the system efficiently and safely, by switching
on and / or switching off Corresponding out going & incoming HT feeders.
9. Ensure auto changeover of supply of Station Transformer on to WAPDA, in the case of non
availability of self generated power.
10. Check and maintain the water chest level, fresh water supply pressure, Cooling water pressure
and temperature, and De mineralized water pressure being indicated on display screen in the
control room. Ensure 100% proper function of all Transmitters and control switches.
11. Check and confirm the Levels of HFO Storage and Day tanks displayed on screen in control room
with that of indicated by respective local Mechanical level indicators.
12. Ensure the proper function and operate ability of all Circulating and supply Pumps, Motors,
Boilers’ Feed water pumps, Cooling tower fans, Air compressors and other installed equipment.
13. Maintain coordination and very effective communication with Turbine operator and optimally
manage the operating load during parallel operation with WAPDA.
14. Perform Soot Blowing of Boilers operating on HFO as required.
15. In case of blackout to take in service of 5 bar steam line by control the PRD valve.
16. Prepare the Daily, Weekly, and Monthly Generation and consumption Report.
17. Coordinate and communicate with concerned BSPM staff and respond to their complaints
regarding generation quality and consistency.
18. Coordinate with WAPDA Grid station staff when required to necessary to maintain 132Kv voltage
and frequency.
19. Switch off, rack out, rack in the outgoing HT, LT breaker trolley for maintenance work on demand
of power plant (E&I) team and on demand of concerned BSPM departments. Participate in
Maintenance work and confirm the operate ability of the component / equipment repaired,
replaced as completion of maintenance work.
20. Follow the instruction from superiors. Maintain clean work places and adhere to safe Power
rectification.

Page 12 of 12
BSPM Power House
Utility Operator

1. Responsible for safe and optimum operations of all of the plant Auxiliaries equipment including
Air Compressors, Water Chest and Well water pumps.
2. Periodically check and repair the Steam, Condensate, Water, Compressed Air, Fuel and Lube Oil
leakages and impaired insulation.
3. Ensure the proper function of all HFO, Water tanks’ mechanical level indicators by checking,
cleaning and re greasing them periodically.
4. Participate in maintenance of all Auxiliaries equipment and ensure their proper function.
5. Responsible for all Lock Out / Tag Out activities of plant equipment when required.
6. Maintain a reasonable level of House Keeping at pant and surrounding vicinities.
7. Responsible for Start up, Shut Down, routine operations and trouble shooting of plant Auxiliaries
equipment.
8. Responsible for Utility Shift Log Book, Hourly Log Sheets and other Data Sheets. Ensure and
maintain the availability of Operations & Maintenance Manuals of all Auxiliaries equipment.
9. Follow the instructions of Shift In charge, immediately inform about any observed abnormal
operating condition.
10. Responsible for availability of Process Steam to BSPM as per specifications.
11. Responsible for Return Condensate from BSPM as per specifications.
12. Responsible for Gas Supply System Operations. Maintain an hourly record of main line pressure,
flow rate, and daily consumption of individual boilers.
13. Responsible for Receiving, Storage and handling of Heavy Fuel Oil. Maintain daily receiving,
consumption and available and balance stock records of HFO, Lube oil, Chemicals and other
consumables.
14. Follow the instructions from superiors. Maintain clean work places and adhere to safe Power
rectification.
16.

Page 13 of 13
BSPM Power House
Chemical Plant Operator

1. Responsible for safe and optimum operations of Demineralization Plant, Return Condensate from
Process, Potable Water Plant and Cooling Tower.
2. Responsible for chemical analysis of 41 MW CHP Unit, 11 MW CCGT Unit, 65 TPH Boiler,
Demineralization Plant, Potable Water Plant, Raw Water and Return Condensate.
3. Responsible for Heavy Fuel Oil and Lube oil Analysis.
4. Ascertain by analysis and carryout chemical dosing of 41 MW CHP Unit, 11 MW CCGT Unit, 65
TPH Boiler and Cooling Tower.
5. Responsible for all Lock Out / Tag Out activities of concerned equipment when required.
6. Maintain a reasonable level of House Keeping of the areas of responsibility.
7. Ensure the availability and proper display of MSDS of all chemicals frequently used at Power
Plant. Maintain the Operation & Maintenance instruction Manuals of all Laboratory equipment.
8. Ensure safe handling and secure stocking of all hazardous chemicals,
9. Responsible for Start up, Shut Down, routine operations and trouble shooting of all laboratory
equipment.
10. Maintain a daily record of received, consumed and balance stock of all chemicals.
11. Responsible for Laboratory Shift Log Book, Hourly Log Sheets and other Data Sheets. Take
necessary measures to
12. Following instructions of Shift In charge, immediately inform about any observed abnormal
operating condition.
13. Perform periodic and preventive maintenance, Back Flushing and Regeneration (Cat ion, An ion
and Mixed Bed etc.) of Demineralization plant.
14. Check and maintain the level of chemicals dosing drums of Boilers and cooling towers.
15. Unloading and receiving of HCL, NaOH, H2SO4 Tankers and other chemicals.
16. Adhere to instructions and safety precautions, as described in Chemicals’ MSDS documents,
while handle chemicals and performing laboratory test work.
17. Follow the instructions from superiors. Maintain clean work places, adhere to safe Power Plant
work practices.
rectification.

Page 14 of 14
BSPM Power House
Mechanical Maintenance Team Leader

1. Ensuring safety procedures and work shop practices are implemented and adhered to at the
Power Plant.
5. Plan, Schedule, Execute and vigilantly Supervise the Planned, Preventive, Periodic, Scheduled and
Corrective Maintenance of all equipment and systems of the power plant. Follow the instructions
given in the Operation & Maintenance Manuals of respective equipment.
11. Coordinate with Operation and E&I Team Leaders and ensure 100% correct function of electrical,
process control, protection & safety systems of all equipment at power plant.
12. Coordinate with contractors, subcontractors and suppliers, resolve the issues [if any]
13. Develop the annual maintenance budget and submit for approval.
18. Inspection of materials coming at plant and their approvals.
19. Assist the Plant Manager in technical issues regarding Mechanical components of plant.
recommendations.

Page 15 of 15
BSPM Power House
Mechanical Engineer.

1. Supervise the assigned Maintenance work following the prescribed procedures, techniques and
instructions given in the respective Operation & Maintenance Manuals of all equipment.
2. Must know the implication of Lock Out / Tag Out system at Power Plant.
3. Organize / supervise effectively Periodic, Preventive, Corrective and day to day maintenance
activities.
4. To maintain inventory level by creating purchase requisition for maintenance parts.
5. Coordination between commercial departments for timely delivery of procured items.
6. Fabrication of mechanical parts from local workshop.
7. To create requisition for maintenance services locally inside the plant and miscellaneous services
outside the plant.
8. Supervise the assigned Maintenance work following the prescribed procedures, techniques and
instructions given in the respective Operation & Maintenance Manuals of all equipment.
10. Organize / supervise effectively Periodic, Preventive, Corrective and day to day maintenance
activities.
11. Take care of tools, equipment & machinery being used to perform the maintenance work.
12. Inform the
13. Update team leader about the progress and status of work done.
14. Coordinate with the worker, contractor’s team, plant HSE team to resolve day to day plant
maintenance & safety issues as instructed by team leader.
15. Coordinate and cooperate with electrical team in performing the mechanical part of work.
16. Supervise maintenance work for all equipment installed at the Plant.
17. Supervise maintenance works correctly and efficiently in order to ensure the timely & safely
completion of assigned tasks.
18. To keep the maintenance record updated.
19. To do any other task as assigned by team leader or plant manager.
20. Report water, steam, air leakages and any spillages to the team leader for the timely
rectification.

Page 16 of 16
BSPM Power House
Mechanical Technician

1. Perform the assigned Maintenance work following the prescribed procedures, techniques and
instructions given in the respective Operation& Maintenance Manuals of all equipment.
3. Participate actively in Periodic, Preventive, Corrective and day to day maintenance activities.
4. Take very special care of tools, instruments and equipment being used to perform the
maintenance work.
5. Inform the team leader about the progress and status of work when asked.
6. Coordinate with the contractor’s team to resolve the maintenance issues as instructed by team
leader.
7. Coordinate and cooperate with electrical team in performing the mechanical part of work.
8. Perform the maintenance work for all equipment installed at the Plant.
9. Perform maintenance works correctly and efficiently in order to ensure the timely & safely
completion of assigned tasks.
10. To keep the date wise and equipment wise record of maintenance work performed.
11. To visit the local market for taking minimum cost quotation of mechanical spare parts.
13. Follow the instructions from superiors. Maintain clean work places and adhere to safe and power
plant work practices.
rectification.

Page 17 of 17
BSPM Power House
Electrical and Instrument Team Leader

1. Ensuring safety procedures and work shop practices are implemented and adhered to at the
Power Plant.
3. Ensure 100% correct function of all Energy, Volt, Ampere meters, Transmitters, HT/LT Feeders
and Breakers, relays, control switches, protection and control systems.
5. Arrange and Coordinate for annual inspection of HT feeders, Transformers, Breakers and Bus bar.
7. Plan, Schedule, Execute and vigilantly supervise the Electrical & Instrumentation part of Planned,
Preventive, Periodic, Scheduled and Corrective Maintenance of all equipment and systems of the
power plant. Follow the instructions given in the Operation & Maintenance Manuals of
respective equipment.
Electrical & Instrumental components. Maintain the relevant maintenance record of all
equipment.
10. Ensure the availability of required skilled workers, spare parts, and consumables required to
perform day to day and periodic maintenance work.
11. Maintain record of electrical maintenance work performed, spares and consumables, consumed
and respective balance stocks.
13. Coordinate with Operation and Mechanical Team Leaders and ensure 100% correct function of
electrical, process control, protection & safety systems of all equipment at power plant.
14. Develop the annual electrical and instruments maintenance budget and submit for approval.
15. Ascertain the need and Order the required spare parts and other consumables. Follow up the
purchase and procurement.
18. Inspection of electrical materials coming at plant and their approvals.
19. Assist the Plant Manager in technical issues regarding Electrical & Instrumental components of
plant.
externally for E & I staff.
21. Evaluate the performance of E & I staff and make necessary recommendations.
23. Technical review of any E & I modification at plant.
Page 18 of 18
BSPM Power House
Electrical Engineer
1. To maintain and monitor Daily check list of Motors.
2. Maintain the record of greasing.
3. To Maintain and Monitor weekly check list of Installed Transformers.
4. Annual Checking and Testing of HT Breaker and Bus bars.
5. Boiler/Turbine inter lock should be carried out at every annual outage.
6. Preventive/Predicative & Proactive maintenance should be raised by maintenance management
system.
7. Must be aware for Lockout/Tag out (LOTO), hot work permit & Confined space.
8. Must aware boundaries of their area also well aware on safety concern issues.
9. Fault finding and Troubleshooting of all Electrical equipment’s.
10. Maintain the record of Electrical spares Parts.
11. Maintain the shutdown record of quarterly, half yearly and yearly shutdown.
12. Supervise and training of electrical technician and junior staff.
13. Checking and monitoring the electrical protection system.
14. Maintain the record of daily job request.
15. Any advice or modification which can enhance/improve plant performance must be given in
written with their back up presented to all over E&I team, then forward to Team Leader
approved till ready to execute.
16. Take necessary action for the removal of water, steam, air leakages and any spillages at plant
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Electrical Technician
1. Perform the assigned Electrical maintenance work following the prescribed procedures,
techniques and instructions given in the respective Operation& Maintenance Manuals of all
equipment.
3. Perform actively in Periodic, Preventive, Corrective and day to day maintenance activities.
4. Periodically blow off the feeders and breakers internally and clean those externally. Check the
transformers.
5. Assist in annual inspection of HT Feeders, Transformers, Breakers and Bus bar.
Check and maintain the electrolyte level in batteries, and check the proper function of the
battery chargers.
6. Take very special care of tools, instruments, meters and equipment being used to perform the
electrical maintenance work.
7. Maintain a list of all motors installed at power plant, and periodically check and monitor their
function.
leader.
10. Coordinate and cooperate with mechanical team in performing the electrical part of work.
11. Perform the electrical maintenance work for all equipment installed at the Plant.
12. Perform electrical maintenance works correctly and efficiently in order to ensure the timely &
safely completion of assigned tasks.
13. To keep the date wise and equipment wise record of electrical maintenance work performed.
14. To visit the local market for taking minimum cost quotation of electrical spare parts.
plant work practices.
rectification.

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BSPM Power House
Instrument Engineer
1. Maintain the Record of daily check list for field instruments
2. Fault finding and troubleshooting of DCS,PLC and Field Instruments
3. Calibration of instruments like gauges, transmitters, switches, dampers, positioners, pneumatic
valves, Regulators, actuators, dampers & limit switches
4. Boiler/Turbine inter lock should be carried out at every annual outage
5. Maintain the record of spare inventory
6. Scheduling major over hauling, annual outage (shutdown), unplanned outage and normal routine
7. activities
8. Preventive/Predicative & Proactive maintenance should be raised by maintenance management
system.
9. Must be aware for Lockout/Tag out( LOTO), hot work permit & Confined space.
10. Every member must aware boundaries of their area also well aware on safety concern issues
11. 11.Maintain the Shutdown record of quarterly ,half yearly and yearly
12. 12.Supervise and training of Instrument technician and junior staff
13. Maintain the record of daily job request
14. Take necessary action for the removal of water, steam, air leakages and any spillages at plant

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Instrument Technician
1. Perform the assigned instrument maintenance work following the prescribed procedures,
techniques and instructions given in the respective Operation& Maintenance Manuals of all
equipment.
3. Perform actively in Periodic, Preventive, Corrective and day to day maintenance activities.
4. Perform the repair and maintenance of all DCS, PLC and Field instruments.
5. Check, adjust and Calibrate the Gauges, Control & Limit Switches, Positioners, Pneumatic Valves,
Actuators, Regulators, Dampers, Hydraulic systems and other process control & protection
devices and instruments.
6. Take very special care of tools, instruments, meters, devices and equipment being used to
perform the electrical and instrument maintenance work.
7. Maintain a list of all motors installed at power plant, and periodically check and monitor their
function.
leader.
10. Coordinate and cooperate with mechanical team in performing the electrical and instruments
related part of work.
11. Perform the electrical and instruments related maintenance work for all equipment installed at
the Plant. Maintain the record.
12. Perform electrical and instruments maintenance works correctly and efficiently in order to
ensure the timely & safely completion of assigned tasks.
13. To keep the date wise and equipment wise record of electrical maintenance work performed.
14. To visit the local market for taking minimum cost quotation of electrical spare parts.
plant work practices
rectification.

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Minimum Qualification Requirement

Shift Incharge
a‐ Diploma of Associate Engineering (Mechanical)
b‐ Minimum “B” Class Boiler Competency Certificate (“A” Class preferred)

Boiler Operator
b‐ Minimum “C” Class Boiler Competency Certificate (“B” Class preferred)

Turbine Operator
a‐ Diploma of Associate Engineering (Mechanical or Electrical)

Electrical Operator
a‐ Diploma of Associate Engineering (Electrical)

Demineralization Plant Operator
a‐ Diploma of Associate Engineering (Chemical)

Utility Operator

a‐ Technical Training Certificate [ 2 years Mechanical]
b‐ Matriculation Certificate

Mechanical Technician

Electrical Technician
a‐ Diploma of Associate Engineering (Electrical)

Instrument Technician
a‐ Diploma of Associate Engineering (Electronics)

HSE/IMS Coordinator
b‐ Master/Graduation degree/Intermediate with minimum one year’s experience in safety.
c‐ Relevant academic background with sufficient knowledge of safety.
d‐ Additional experience/skills preferred.
a. Management, organizational and training skills.
b. Recognizable communication and presentation skills.
c. Problem solving skills.

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O&M Management System
Shift Changeover Procedure

Table of Contents
Objective ........................................................................................................................................................ 3
Procedure ....................................................................................................................................................... 3
Flow Chart ...................................................................................................................................................... 4

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Objective
The objective of this procedure is to establish guidelines for shift staff for uniform way of shift handing
over, taking over.
1‐ There must be clear instructions for outgoing shift staff.
2‐ There shall be clear instructions for incoming shift staff.
3‐ The shift change process must be clear enough and not to introduce other errors.
Procedure
This procedure is applicable on all levels to shift operation staff ,including maintenance staff if some
critical activity is going on, to stop any kind of miscommunication.

 Outgoing shift staff must mention all the events in shift Log Book.
 The Shift In‐charge, Boiler, Turbine, Utility, Laboratory and Electrical Operator holds the
responsibility for entering all the events in the log books.
 All the events must be entered in Shift Log Books in sequence.
 After entering all the events in shift log book, relevant operator and shift in‐charge must put his
signature at the end.
 Outgoing operator and shift in‐charge must explain verbally to his shift reliever.
 Incoming operator and shift in‐charge must read the log book and put his signature at the end as
acknowledgement.
 Finally all area changeover reports shall be visited and signed by the shift in‐charge. If he feels
some shortfall or discrepancy he should immediately inform to the previous shift counterpart for
the clarification and mention the same in report and sign.

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Flow Chart

Shift Staff must enter all the
events with time sequence in shift
Log Book
Outgoing staff must explain
verbally about all the events
during the shift
Incoming staff must listen all
explanation, read the log Book
Put his signature as
acknowledgement
Shift In‐charge will review all
reports, If he feels some shortfall
or discrepancy he should
immediately inform to the
previous shift counterpart for the
clarification and mention the
same in report and sign.

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Shift Duty Exchange and Leave Procedure

Table of Contents
Objective: ....................................................................................................................................................... 3
Procedure for duty exchange ......................................................................................................................... 3
Procedure for Leave ....................................................................................................................................... 3
Annexure 1 – Shift Duty Exchange Forms ....................................................................................................... 4
Annexure 1 – Leave Application Forms .......................................................................................................... 6

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Objective:
The objective of this procedure is to define predetermined format to meet smooth shift exhange and
ensure the availability of right people at work place.
Procedure for duty exchange
 This procedure is applicable to all staff working in shift duties.
 In case of unauthorized shift exchange, employee will be marked absent.
 Employees are permitted to request a shift exchange and must inform 48 Hrs before at least.
 Change of shift duties shall be with the prior approval at the written request of the persons
exchanging duties.
 No shift change is guaranteed.
 The request form must come through proper channel i.e approved by employee’s Shift Incharge.
 The name of substitute must be mentioned on the form, the employee may have to wait to start
on new shift until his replacement is confirmed.
 The form must be signed by a person who agrees to take a shift.
 Please be sure that the employees changing the shift must be committed to work/responsibilities
of shift(s) as indicated on the request form.
 Persons who are mutually changing the shift, each one of them should be qualified for that
particular area or responsibility.
Procedure for Leave
 This procedure is applicable to all OMS staff working at BSPM.
 In case of unauthorized leave, employee will be marked absent.
 Employees are permitted to request a leave and must inform 2 days before at least.
 Leave shall be with the prior approval at the written request of the person.
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 The request form must come through proper channel i.e approved by employee’s immediate in‐
charge.

Annexure 1 – Shift Duty Exchange Forms
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OMS‐BSPM‐0001
Shift Duty Exchange Form

The Employee willing to exchange duty:

Name of Employee : __________________________________ Area:_____________________

Designation: ________________________________________

Date and Shift: (When he is not going to perform duty) _________________________

Date and Shift: (When he will perform duty in exchange) _________________________

Signature: _____________________________ Date: ___________________________

The Employee willing to perform duty in exchange:

Name of Employee : __________________________________ Area:_____________________

Designation: ________________________________________

Date and Shift: (When he will perform duty in exchange) _________________________

Date and Shift: (When he is going to receive duty) ___________________________

Signature: _____________________________ Date: ___________________________

Shift Incharge Approval

Shift Exchange : Approved / Not Approved Shift Exchange : Approved / Not Approved

Shift Incharge Name : _____________________ Shift Incharge Name : _____________________

Signature :_________________________ Signature :_________________________

Date: _____________________________ Date: _____________________________

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Annexure 1 – Leave Application Forms

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OMS‐BSPM‐0002
Leave Application Form

The Applicant must fill this part:

Name of Employee : __________________________________

Designation: ________________________________________

Number of Days: _____________________________________

Date and Shift: (Start and end date) _______________________________________

Signature: _____________________________ Date: ___________________________

Immediate In‐charge:

Name or names of covering person : __________________________________

Designation: ________________________________________

Signature: _____________________________ Date: ___________________________

For Team Leader:

Remarks : ___________________________________________________________________________

___________________________________________________________________________________

Approved / Not Approved

Name : _______________________________________

Signature :____________________________________

Date: _____________________________

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Documentation Control Procedure

Table of Contents
Objective ........................................................................................................................................................ 3
Scope .............................................................................................................................................................. 3
Methodology .................................................................................................................................................. 3

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Documentation Control Procedure

Objective
The best way to keep track of procedures, best practices and to help remind the operator to perform
certain functions is to keep log sheets, log books and check lists.

The record of boiler, turbine, utility, laboratory and electrical operations shall be kept in proper manner.
Scope
This procedure describes initiating, checking, closure and storage of all record.
Methodology
 As minimum log sheets shall be prepared as per OEM’s recommendations and best practices.
 The Boiler, Turbine, Utility, Laboratory and Electrical Operator holds the responsibility for
entering data in the log sheets, log books and all check lists.
 All logs shall include the date, name of operator(s) on duty, and time of starting and end duty.
 Every operator on the shift shall review the log and, at the end of each shift, shall sign the log.
 All operators and shift in‐charge must read the outgoing shift and sign at the end as
acknowledgement.
 Any malfunction (trip or shutdown) of any item of equipment or control, mechanical, electrical,
or electronic, must be documented in the logbook with the time of occurrence, together with the
corrective action taken.
 The shift In‐charges will ensure that sheets are being properly maintained by the all Operators.
Shifts in‐charges shall also sign the log sheet at the end.
 On the following day Team Leader will review the log sheets and any major deviation from the
set standard shall be pointed out. He also confirms that has proper corrective measures been
taken in this regards.
 The operator’s logbook shall be kept in control room and none shall be removed under any
circumstances.
 Falsification of the logbook shall be considered serious offense and necessary disciplinary actions
may be taken, if the action is negligent or deliberate.
 At the end of each month sheets shall be shifted from control room to Team Leader office for
record.
 Each log sheet have unique number.

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Plant Modification Procedure

Table of Contents
Objective ........................................................................................................................................................ 3
Scope .............................................................................................................................................................. 3
Methodology .................................................................................................................................................. 3
Flow Chart and Control ................................................................................................................................... 4
Annexure 1 ..................................................................................................................................................... 5
Plant Modification Form ................................................................................................................................. 6

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Objective
This procedure provides OMS people with instructions and guidelines for any modification (addition or
deletion) in the plant or control system. The modification might be required due to equipment failure,
operational requirement, for process optimization or maintenance requirement.

Scope
This procedure describes initiating a modification request, design review, approval of modification
request, execution of modification and subsequently closure of execution part.
Methodology
 Proposer will initiate modification request form after registering with Tagout Office.
 Requester will fill all the required information’s in control Modification Request form.
 Requester will attach existing and modified control drawing, engineering calculations,
equipment detail if required.
 Operations and Maintenance Team Leaders will with comment the form.
 Plant Manager (Power House) will recommend it for Approval.
 BSPM Management Power House Incharge will Approve or dis‐approve the recommended
modification.
 After approval of modification, Maintenance (Mechanical or E&I) team leader or any of his
nominees will lead the efforts and assign the job to members of his team or some multi task
group.
 Shift Incharge will be responsible for issuance of lock out /tag out order or LWP.
 Area team leader will be responsible for preparation of new SOP or updating of the existing
one. He will also be responsible to remain involved in commissioning if required.
 After ensuring that all above mentioned steps has been carried out in their true spirit, Shift
Incharge will ensure that operating procedure is available, all protections and alarms are
intact and the manuals are updated. After going thru all these checks Shift Incharge will close
the job.
 Finally after reviewing all the steps, Plant Manager will close the form.

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Flow Chart and Control
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Annexure 1

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OMS‐BSPM‐0003
Plant Modification Form
Reference No: ‐ ‐ Date:____________________

Equipment KKS Number:_________________ Unit:____________________

Equipment description:___________________________________________________

Modification Proposed by: _______________________________

Modification Title:_____________________________________________________________________

Nature of Problem:____________________________________________________________________

Proposed Modification detail:____________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Type of Modification:

Enhance Safety Improve Maintenance

Improve operation Cost Saving

Improve Reliability

Attached document:

Drawing before modification attached: Yes No

Drawing after modification attached: Yes No

Proposer Signature: ________________________ Date:________________

Operations Team Leader comments: ________________________________________
_______________________________________________________________________

Name & Signature:_________________ Date:______________

E&I Team Leader comments: ______________________________________________
_______________________________________________________________________

Maintenance Team Leader comments: _______________________________________
_______________________________________________________________________

Name & Signature:____________________________ Date:______________
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Plant Manager Comments: ________________________________________________
_______________________________________________________________________
_______________________________________________________________________

Recommended: Yes No


Packages Power House Incharge Comments: __________________________________
_______________________________________________________________________
_______________________________________________________________________

Approved: Yes No


Modification Completion Report:

Implemented by: _____________________________________ Date: ______________

Work order No. _________________ Tag Out Order No: _______________________

Drawing updated by: _______________________ Date:______________

Note: Updated drawing will supersede the previous As built drawing

Operating Procedure updated: Yes / No (if applicable) Date: ______________

Shift Incharge Name & Signature: ____________________________ Date:______________

Closure by Plant Manager:

Comment: _____________________________________________________________________

_______________________________________________________________________________

Name and Signature: ___________________________ Date: _______________

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Protection Bypass Procedure

Table of Contents
Objective ............................................................................................................................. 3
Scope ................................................................................................................................... 3
Methodology ....................................................................................................................... 3
Flow Chart and Control ....................................................................................................... 4
Annexure 1 .......................................................................................................................... 5

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Objective
This procedure provides OMS people with instructions and guidelines for a protection bypass in the plant
control system. The protection bypass might be required due to equipment failure, operational
requirement, for process optimization or maintenance requirement.
Scope
This procedure describes initiating a protection bypass request, reason for bypassing, expected duration
of bypassing, approval, execution of bypassing and subsequently normalization of execution part.
Methodology
 Requester will fill all the required information’s in Protection Bypass Approval form.
 Shift Incharge will recommend the request form with comments, if he feels necessary.
 Plant Manager will approve or disapprove the request form with comments.
 After approval of the request, E&I person will implement the protection bypass request. He
will also write down the detail of software which is bypassed.
 After implementing E & I person will print his name along with signature and time on the
form.
 When requirement for bypassing will be over, E & I person will normalize the protection and
print his name along with signatures and time on the form.
 Plant Manager will close the protection bypass form.

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Annexure 1

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OMS‐BSPM‐0004
PROTECTION BYPASS APPROVAL FORM

Serial #: EQUIPMENT KKS #:________________ Unit: ________________

Description of equipment need to be bypassed _______________________________________________
______________________________________________________________________________________
Reason of bypassing: ____________________________________________________________________
______________________________________________________________________________________
Expected duration for bypassing: _________________________
Hazards related to this protection have been analyzed: Yes/No
Have all concerned / individuals been notified about this bypassing of the equipment’s? Yes / No

Name: Signature Date/Time
Requested by

Recommended by:
(Shift Incharge)
Authorized By:
(Plant manager)

Implementation:

Software bypassed (DCS / PLC)

SYSTEM: ___________ DIAGRAM #: _____________ LOGIC ELEMENT#:_____________

STATUS: Zero: _________ One: _________ Data Fix: __________Other:_______________

Hard ware force / bypass:

STATUS: Jumper: ______________ Open: ______________ Other: __________________

LOCATION: __________________________________________________________________

Name: Signature Date/Time
Performed by
Normalized by

Protection is normalized:
Plant Manager:
Name & Signature: _________________________ Date:_____________
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Standard Lockout Tagout

Table of Contents
Objective ........................................................................................................................................................ 3
Scope .............................................................................................................................................................. 3
Procedure ....................................................................................................................................................... 3
Annexure 1 ..................................................................................................................................................... 8

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Objective
This procedure provides OMS people with instructions and guidelines to ensure safe access to
maintenance teams for plant maintenance.
Scope
This procedure provides standard isolations sheets to guide operation staff to isolate equipment’s for
maintenance purposes.
Procedure
1. Lock out/Tagout Request
Craft person will invariably make Lock out/Tag out Order request in writing. For scheduled corrective
or preventive maintenance such request should be made at least one day in advance to allow the
operations team, time to make necessary preparation and any adjustments to the plant equipment to
facilitate the maintenance.

2. Preparation for shut down
Equipment and/or system requiring a Lock out/Tag out Order must be looked over before initiating
the Lock out/ Tag out Procedure. It is essential that the Shift Incharge and Area Operator have an
accurate and complete knowledge of the intended job and system to be worked upon. It requires
knowledge of the following:

a. The types and amounts of energy powering the equipment.
b. Fluids or hazardous chemicals associated with the equipment or system.
c. The presence and location of control interlocks or Lock out/tag outs.
d. People who must be notified before removing equipment from service.
e. The presence of any secondary (backup) power sources.
f. The existence of any stored energy that must be blocked and drained.

3. Equipment shutdown

a. Make sure equipment is available for shutdown.
b. Verify that the equipment can be removed from service without operational loss or
impacting plant availability for a specific time period.
c. Notify all necessary people that the equipment or system is being taken out of service,
i.e., area operator, Shift Incharges or Area manager.
d. Verify that normal operating controls can be used to shut down the equipment.

4. Initiating Lock out/Tagout Order
Shift In‐charges responsible for the Lock out/Tag out order must obtain a Lock out/tag out
number from the Lock out/Tag out Log located in the front of the Active Lock out/Tag out Book.
Write this number and date (next in sequence) on the Lock out/Tag out Order Form and on all
tags associated with the order.

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Step # 1 ‐ Equipment & Job description

Equipment description and .Job description shall be given. If the scope of the job changes along
the way, the Lock out/Tag out Order must be reviewed to ensure that proper isolation is
maintained.

Step # 2 ‐ Tags description

a. Shift In‐charge/ Area Operator shall decide the isolations in consultation with the craft
person. Complete all information on Lock out/Tag out Order form including, Lock No.
Tag No. and Tagged Position considering the steps to control hazardous energy.

b. Complete “DANGER‐DO NOT OPERATE” tags for all isolating devices associated with the
Lock out/Tag out Order and fill in both the Tag out Order number and lock number.

c. Note down special instructions such as special isolating or restoration requirements in
the special instruction column if required.

Step # 3 ‐ Isolation (Application of Tags)

I. The Shift Incharge will give authorization to Area Operator for isolation and application
of all Tags after ensuring that the conditions in Step 2 ‐ “Preparation for Shutdown, and
3‐ “Equipment Shutdown” have been adhered to.

II. Area Operator shall place all isolating devices in the safe position as noted on the Lock
out/Tag out Order and apply tag out lock with “DANGER‐DO NOT OPERATE” tags by
taking the following steps.

III. Ensure all possible alternative energy sources are correctly isolated. Never open
isolators under load and never pull fuses under load as an isolating device.

A. Ensure the necessary cleaning of pipelines, vessels and the immobilization of valves,
electrical circuits, etc., has been completed.

B. Control of stored energy: Take steps to drain, remove solids, vacuum out, wash
down or cool off the equipment or system to control the stored energy. Any of the
following precautions (individually or in combination) may be necessary to guard
against residual energy left in the equipment after it has been isolated.

i. Make sure all parts have stopped moving.

ii. Install ground wires and/or bond wires if appropriate.

iii. Relieve trapped pressure. (low point bleed)

iv. Release the tension on springs or block the movement of spring driven parts.

v. Block or brace parts that could fall by gravity or from hydraulic or pneumatic pressure
loss.

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vi. Drain process piping systems and close valves to prevent the flow of hazardous
materials.

vii. If a line must be blocked, utilize valves, use a line blank, remove pipe section, or misalign
a section of pipe.

viii. Dissipate extreme heat, or wear proper personal protective clothing.

ix. If stored energy can re‐accumulate, monitor it to make sure it stays below hazardous
levels. Always tag low point bleeds if they need to remain open to prevent re‐
accumulation of energy. The tag will serve as a reminder that the valve is open when
putting equipment back in service.

STEP # 4 ‐ Verification

Verification check of tags and locks by any OMS person must be carried out prior to issuing the
Lock out/Tag out Order to ensure that the proper tags and locks are hung on the proper piece of
equipment and that the piece of equipment has been disabled in the proper position

i. This verification step must be done by any OMS person after the person who hung the tags
and locks has signed on to the Tag out Order.

ii. The crafts person must also ensure and satisfy himself that stored energy has been released.

iii. If discrepancies are noted, they should be remedied immediately.

iv. After verifying, the verifier will print name, sign, date and time.

Note: The verifier should sign on the tags hung on the isolated equipment.

STEP # 5 – Shift In‐charge Approval and Authorization to work

When the SHIFT INCHARGE is satisfied that all of the above checks have been carried out, he will
then approve the Lock ut/Tag out Order by printing his name, sign, date and time at the
appropriate spot. SHIFT INCHARGE will also mention if there is any Hot Work Permit or Confined
Space Permit is issued related to this Lock Out/Tag out Order.

Step # 6 – Commencement of Work
A. Craft people, after satisfied that hazardous energy has been controlled and the area
has been barricaded if required, will hang their personal lock on the appropriate lock
box.

B. Craft Person will be explained about other jobs in progress in the same Area or
Equipment.

C. Craft people will then print name, sign, date and time on the Tag out Order.

D. Prior to commencement of the work Craft People will hang the copy of Lock
Out/Tag out Order at the work place.
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E. If other craft people want to work on that particular piece of equipment, he/she
MUST accept the tag out prior to commencement of work.
F. Craft people must not do anything that could reactivate the equipment or system or
possibly bypass isolating devices by installing new piping or wiring.

G. Craft people who finish their assigned task will notify the Shift Incharge of this fact
by signing the Tag out Order in the tag out released column and remove their
lock(s).

Note down special instructions such as special restoration requirements in the
special instruction column.

Step # 7 ‐ Completion

i. The Shift In‐charge will ensure that the entire task is complete then Craft person sign on the
completion column of the Lock Out/Tag Out Order. The Control Room/Area Operator will then
thoroughly check the equipment/system to be sure all guards are replaced and the
equipment/system is ready for safe operation. The Shift Incharge will then authorize the
removal of locks and tags. and check the Tag out Order for any special instructions before placing
equipment back into service.
.
ii. The Shift In‐charge/Area Operator will then remove all locks and tags, after assuring that all
people are safely clear of the equipment and test the equipment for proper operation where
applicable.

iii. Return all tags and locks to the Shift In‐charge should review all the locks and tags which
were removed.

iv. Upon complete removal of the tags and locks the Area Operator /Shift Incharge should sign
and print his name in the Tags removed by column.

Step # 8 ‐ Equipment restored for operational use:

Shift In‐charge after being satisfied that all locks and tags are accounted for will then complete
the Lock Out/Tag out Order form by printing his name and sign in the equipment restored for
operational use column.

Shift In‐charge will notify all operating people associated with the equipment of its operating
status.

 Requester will fill all the required information’s in Protection Bypass Approval form.
 Shift In‐charge will recommend the request form with comments, if he feels necessary.
 Plant Manager will approve or disapprove the request form with comments.
 After approval of the request, E&I person will implement the protection bypass request. He
will also write down the detail of software which is bypassed.
 After implementing E & I person will print his name along with signature and time on the
form.
 When requirement for bypassing will be over, E & I person will normalize the protection
and print his name along with signatures and time on the form.
 Plant Manager will close the protection bypass form.
Page 6 of 8
BSPM Power House

Page 7 of 8
BSPM Power House

Annexure 1
Page 8 of 8
Bulleh Shah Paper Mills Power House
LOCK OUT/TAGOUT ORDER
Number: _____ Date: _________________
1. Equipment Description: 65 TPH Boiler Furnace and Pressure Parts___________________
Job Description: For out side work _________________
Area: ______65 TPH Boiler____________________________________________________________

2. List all Locks & tags that are to be hung to achieve safety from the system.
Sr # Description KKS # Lock # Tagged Position

1 BMS Bur # 01 breaker Off
2 BMS Bur # 02 breaker Off
3 HFO booster A pump breaker Off
4 HFO booster B pump breaker Off
Special Instructions: Only for out side jobs , Ensure temperature is bearable
3. Isolation (Print name along with signature) Lock Box #: ____
Tags and Locks Hung by______________________ Date: ______ Time: ____
4. Verification: __________________________ Date: __________Time: _______
5. Shift Incharge Approval & Authorization: ___________Date: ___________Time: _____
Hot Work Permit Yes/No: _________ Confined Space Permit Yes/No: ________
6. Craft Acceptance Print name along With signature
TAGOUT Temporary Tag out Release

Accept Release Request Release
Name Date/Time Name Date/Time Name Date/Time Name Date/Time
Special Instructions:
7. Completion (Print name along with signature)
Tags and Locks Removed by: _____________________Date: ________Time: ________
8. Equipment restored for operational use:

Shift Incharge Name and Signature: Date: Time:
TAGOUT ORDER
Tag List Continuation Sheet
Tag out Number: - Date: ________

5
6 HFO Burner 1A Isolation Valve Closed
7 HFO Burner 1B A Isolation Valve Closed

8 HFO Burner 2A Isolation Valve Closed
9 HFO Burner 2B Isolation Valve Closed
10 Bur # 01 A Oil Guns (Install Dummy) Removed
11 Bur # 01 B Oil Guns (Install Dummy) Removed
12 Bur # 02 A Oil Guns (Install Dummy) Removed

13 Bur # 02 B Oil Guns (Install Dummy) Removed
14 Burner 1A Atomizing Steam Isolation Valve Closed
15 Burner 1B Atomizing Steam Isolation Valve Closed
16 Burner 2A Atomizing Steam Isolation Valve Closed
17 Burner 2B Atomizing Steam Isolation Valve Closed
18 Ignitor 1 Gas Isolation Valve Closed
19 Ignitor 2 Gas Isolation Valve Closed
20 Gas Burner 1 Gas Isolation Valve Closed
21 Gas Burner 2 Gas Isolation Valve Closed
22 Atomising steam main valve Close
23 Main gas valve on distribution header Close

24 Bur # 01 pilot burner assembly Removed
25 Bur # 02 pilot burner assembly Removed
26 Diesel Pump breaker Off
27 Drum LCV Downstream Isolation Valve Closed
28 Drum LCV Bypass Valve Closed
29 Soot Blower steam root valve Closed
30 Main Steam line manual valve Close
31 Main steam MOV bypass valve Closed
32 Main steam line motorized vent valve Open
33 Steam Drum Vaent Valve Open
34 Economizer Vent valve Open
Number: _____ Date: _________________
1. Equipment Description: 65 TPH Boiler Deaerator___________________________
Job Description: ________________ _________________
Area: ______65 TPH Boiler____________________________________________________________


1 BFP-1 Electrical Breaker OFF
2 BFP-2 Electrical Breaker OFF
3 Deaerator PCV downstream Isolation valve Closed
4 Deaerator PCV Bypass valve Closed


TAGOUT ORDER

5 Deaerator make up LCV downstream Iso valve Closed
6 Deaerator make up LCV Bypass Iso valve Closed
7 Condensate Return Isolation Valve Closed

8 Deaerator outlet valve to BFP Closed
9 BFP Minimum Flow Isolation Valve Closed
10 Hydrazine Injection Pump Breaker OFF
11 Hydrazine Injection Valve Closed
12
Number: _____ Date: _________________
1. Equipment Description: 65 TPH Boiler Burner___________________________________
Job Description: For Gun Cleaning _________________
Area: ______65 TPH Boiler____________________________________________________________


1 BMS Bur # 01 / 02 breaker Off
2 HFO Burner 1A/1B/ 2A /2B Isolation Valve Closed
3 Burner 1A /1B /2A/ 2BAtomizing Steam Isolation Closed
Valve
4 Bur # 01 A Oil Guns (Install Dummy) Dummy


Number: _____ Date: _________________
1. Equipment Description: 65 TPH Boiler Soot Blower___________________________
Job Description: ________________ _________________
Area: ______65 TPH Boiler____________________________________________________________


1 Soot Blowing 1 Electrical Breaker OFF


TAGOUT ORDER

5 Soot Blowing steam root valve Closed
6 Soot Blower 1 Isolation Valve Closed

8 Soot Blower 3Isolation Valve Closed
10 Steam Trap bypass valve (near Economizer) Closed
11 Steam Trap bypass valve (near Furnace) Closed
12
Number: _____ Date: _________________
1. Equipment Description: _____Air and fuel System_________________________________
Job Description: For out side work _________________
Area: ______200 TPH Boiler____________________________________________________________


1 Gas burner #1 Isolating valve V-1607 Closed


TAGOUT ORDER

5 H.F.O burner #1 Isolating valve V-1730 Closed

9 H.F.O burner #1 Atomizing Steam Iso valve V-1339 Closed

13 H.F.O burner #1 steam purging valve V-1337 Closed
17 F.D Fan breaker OFF
18 I.D Fan breaker OFF
19 F.D fan Damper IA isolating valve Closed

20 I.D fan Damper IA isolating valve Closed
21 Cooling air valve to burner vision holes Closed
22 Soot Blowing steam root valve Closed
Number: _____ Date: _________________
1. Equipment Description: ___Pressure Parts of 200 tph Boiler________________________
Job Description: Combustion chamber checking _________________
Area: ___200 tph Boiler________________________________________________________________

Sr # Description Tag # Lock # Tagged Position

1 Isolating valve in feed line before Economizer V-1093 close
2 Economizer header drain V-1098 open


TAGOUT ORDER

5 Economizer header drain V-1099 Open
6 Economizer drain valve V-1095 Open
10 Economizer Vent Valve V-1119 Open
11 Economizer Vent Valve V-1120 Open

12 Steam Drum Vent Valve V-1402 Open
13 Steam Drum Vent Valve V-1403 Open
14 Lower header drain Valve V-2610 Open
15 Lower header drain Valve V-2611 Open
16 CBD upstream Isolation valve V-2615 Open
17 CBD Down stream Isolation valve V-2616 Open

18 CBD Bypass valve V-2617 Open
19 CBD MOV Breaker CCV-101 OFF
20 PO4 dosing Isolation Valve V-2811 Close
21 Super heater drain V-1564 Open
25 Super heater drain V-2504 open

TAGOUT ORDER
Sr # Description Tag # KKS # Lock # Tagged Position

37 Super heater vent valve V-1504 open
39 Super heater drain V-1510 close

45 DSH 101 Isolation Valve V-1107 open
46 DSH 102 Isolation Valve V-1114 open
47 DSH 101 Breaker OFF
48 DSH 102 Breaker OFF
49 DSH 101 Handwheel DSH-101 Close
50 DSH 102 Handwheel DSH-102 Close
51 Main steam line drain valve V-2516 close
52 Main steam line drain valve V-2517 Close
53 Main steam line vent valve V-1543 Open
54 SHV-101 Breaker OFF
55 SHV-101 Handwheel SHV-101 Open

56 Main steam line outlet valve V-1544 Close
57 Main steam line MOV Breaker OFF
58 Main steam line MOV Handwheel MOV-101 Close
59 Main steam line outlet bypass valve V-1546 Close
60 Main steam line bypass MOV Breaker OFF
61 Main steam line bypass MOV Handwheel MOV-102 Close

Number: _____ Date: _________________
1. Equipment Description: ___Deaerator and Feed Water Tank (D-01 & DA 01)____________________
Job Description: _________________
Area: ___200 TPH Boiler________________________________________________________________


1 Boiler feed water Pumps #1 Breaker off
2 Boiler feed water Pumps # 2 Breaker off
3 Boiler feed water Pumps # 3 Breaker off
4 Deaerator Main outlet valve V-1027 close


TAGOUT ORDER

5 Deaerator make up MOV upstream Iso valve Close
6 Deaerator make up MOV Bypass Iso valve Close
7 Condensate Isolation Valve to Deaerator Close
8 Condensate inlet Valve to Polisher Close
9 Deaerator Inlet steam Isolation valve V-1204 Close

(After PCV)
10 Deaerator Inlet steam Bypass valve to PCV V-1206 Close
11 Deaerator drain valve V-1023 Close
12 Hydrazine Injection pump breaker OFF
Hydrazine Injection valve V-3011 Close

Number: _____ Date: _________________
1. Equipment Description: ___Boiler feed water pumps (PU-01A / 01B / 01C0____________________
Area: ___200 tph Boiler________________________________________________________________


1 Boiler feed water Pumps #1,2,3 Breaker off
2 Boiler feed water pumps #1,2,3 suction valves V-1032/V1033/ close
V-1039
3 Boiler feed water pumps #1,2,3 discharge valves V-1046 / V-1146/ close
V-1047
4 Boiler feed water pumps #1,2,3 minimum flow V-1034 / V-1036/ close
vales V-1140


TAGOUT ORDER

5 BFP -1/2/3 Inboard bearing CW Inlet Valve Close
6 BFP -1/2/3 Inboard bearing CW Outlet Valve Close
7 BFP -1/2/3 outboard bearing CW Inlet Valve Close
8 BFP -1/2/3 outboard bearing CW Outlet Valve Close
9 BFP -1/2/3 Inboard sealing water Inlet Valve Close
10 BFP -1/2/3 Inboard sealing water Outlet Valve Close
11 BFP -1/2/3 outboard sealing water Inlet Valve Close
12 BFP -1/2/3 outboard sealing water Outlet Valve Close

Number: _____ Date: _________________
1. Equipment Description: _____Gas Burner 1 / 2 / 3 / 4_________________________________
Area: ___________________________________________________________________

1 Gas shut off valves Isolation Valves 1 / 2 / 3 / 4 V-1607 / V-1609 Closed
V-1606 / V-108
Special Instructions: Only for out side jobs


Number: _____ Date: _________________
1. Equipment Description: _____H.F.O burners 1/2/3/4 __________________________________
Area: _______200 tph____________________________________________________________


1 H.F.O burner #1/2/3/4 isolating valve V-1730 / V-1732 close
V-1728 / V-1734
2 Burner #1 /2/3/4 atomizing steam isolating valve V-1339 / V-1345 close
V-1336 / V-1378
3 Burner #1 /2 /3 / 4 Purge steam isolating valve V-1337 / V-1343 close
V-1334 / V-1340
4
Special Instructions: Only for Outer Jobs & Gun cleaning, Close gun valve after extracting the gun


Number: _____ Date: _________________
1. Equipment Description: ___Return condensate pump 1 / 2__________________________
Area: ___200 TPH Boiler________________________________________________________________


1 Return condensate pump 1 / 2breaker off
2 RC Pump 1 / 2 Suction Valve close
3 RC Pump 1 / 2 Discharge Valve close
4


Number: _____ Date: _________________
1. Equipment Description: ___RC Pump Strainer___________________________________
Area: ___200 tph Boiler________________________________________________________________


1 Return condensate pump 1 breaker off
2 Return condensate pump 2 breaker close
3 RC Pump 1 Suction Valve close
4 RC Pump 2 Suction Valve Close


TAGOUT ORDER

5 RC Pump common suction valve Close
6
7
10
11
12
Number: _____ Date: _________________
1. Equipment Description: 41MW Steam Turbine______________________________________
Job Description: ________________________________________________________________

Area: 41MW Steam turbine

1 Jacking oil pump breaker Off
2 Turning gear motor breaker Off
3 Auxiliary lube oil pump breaker Off
4 DC lube oil pump breaker Off


TAGOUT ORDER
Tag # Description KKS # Lock # Tagged Position

5 Oil mist fan breaker OFF
6 Oil purifier unit breaker OFF
7 Main steam line manual valve Closed
8 Drain Valve (before MOV) Open
9 Extraction 1 manual valve Close
10 Extraction 2 manual valve Close

11 Bleed line manual valve Close
12 Gland steam line manual valve Close
13 Generator CW A Inlet Valve Close
14 Generator CW B Inlet Valve Close
15 Generator CW A Outlet Valve Close

16 Generator CW A Outlet Valve Close
17 Stator Vent No. 1 Open
18 Stator Vent No. 2 Open
19 Lube oil cooler CW Inlet Valve Closed
20 Lube oil cooler CW Outlet Valve Closed
21 Manual valve of compressed air Closed
22 Generator Breaker of 41MW Steam Turbine OFF / Rack out

23 Excitation breaker of 41MW system OFF
24 Protection system breaker OFF
25 Ensure All drains are open Open

26 Generator Earthing Install Manually

Number: _____ Date: _________________
1. Equipment Description: Condenser_______________________________________________
Job Description: _______________________________________________________________
Area: 41MW steam turbine_______________________________________________________


1 CW Pump 01 Electrical Breaker Off
Special Instructions: [LOTO is only for Water Side]


TAGOUT ORDER

5 Condenser Inlet Valve A Closed
6 Condenser Inlet Valve B Closed
7 Condenser Outlet Valve A Closed
8 Condenser Outlet Valve B Closed
9 Condenser CW Drain Valve A Open
10 Condenser CW Drain Valve B Open

11 Condenser CW Vent Valve A Open
12 Condenser CW Vent Valve B Open
Number: _____ Date: _________________
1. Equipment Description: Condensate pump # 01 / 02______________________________
Job Description: __________________________________________________________________
Area: ________Turbine Hall ____________________________________________________________


1 Condensate Pump A / B Breaker Off
2 Condensate Pump A / B Suction Valve LCA11AA010 / Close
LCA21AA010
3 Minimum flow line valve LCA14AA010 / Close
LCA24AA010
4 Condensate Pump A / B Discharge Valve LCA12AA510 / Empty
LCA22AA510
Special Instructions: Install Blank before Discharge Valve. Empty sealing water bottle.


Number: _____ Date: _________________
1. Equipment Description: Cooling Water Pumps________________________________________
Job Description: ____________________________________________________

Area: __41 MW Cooling Tower Area__________________________________________

1 CW Pump 1 /2 / 3 / 4 Breaker OFF
2 Suction valves of CW Pump 1 / 2 / 3 /4 Closed
3 Discharge valves of CW Pump 1 / 2 / 3 /4 closed



Number: _____ Date: _________________
1. Equipment Description: Air Compressor 01 / 02 / 03 / 04________________________________
Job Description: _______________________________________________________________
Area: 41MW steam turbine_______________________________________________________


1 Air Compressor 01/02/03/04 Electrical Breaker Off
2 Air Compressor 01/02/03/04 Outlet Valve Closed
3 Air Compressor 01/02/03/04 CW Inlet Valve Closed
4 Air Compressor 01/02/03/04 CW Outlet Valve Closed


TAGOUT ORDER

5 Air Compressor 01/02/03/04 CW Inlet side Open
Drain Valve
6 Air Compressor 01/02/03/04 CW Outlet side Open
Drain Valve
7 Air Compressor 01/02/03/04 Dryer Drain v/v 01 Open
8 Air Compressor 01/02/03/04 Dryer Drain v/v 02 Open

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Table of Contents
A. 65 TPH Boiler Pre-Start up Checks .................................................................................. 3

B. 65 TPH Boiler Start up Procedure on Gas/Oil ................................................................. 4
C. 65 TPH Boiler Start up Curve ............................................................................................. 7
D. 65 TPH Boiler Procedure for fuel change over from HFO to Gas ................................ 8
E. 65 TPH Boiler Procedure for fuel change over from Gas to HFO ................................ 9
F. 65 TPH Boiler Planned Shut Down ................................................................................. 10
G. Cooling down of Boiler ...................................................................................................... 11
H. Burner Operation Procedure ............................................................................................ 12
I. Do Nots’ ............................................................................................................................... 13

Page 2 of 13

BSPM Power House
A. 65 TPH Boiler Pre-Start up Checks
Before each start‐up of the boiler it is required to perform the following procedures first:

1. All the maintenance work is completed.
2. Make sure that the boiler has been inspected / maintained as per procedure.
3. Make sure all auxiliary parts of the boiler installation have been inspected as mentioned
in the sub‐vendor documentation.
4. Make sure that all temperature‐, pressure, and level control set points of steam drum
and main steam lines are as specified.
5. For flue gas side, make sure all inspection doors are closed and bolted.
6. Make sure duct drains are closed except the main stack drain.
7. Peephole protection plates are lowered.
8. All the up‐takes for the exhaust gases should be checked properly for a clear flow and to
prevent any kind of obstacle or diversion.
9. For burner side, generally you can say that you have to open all block valves upstream
instruments and instrument air and close all drain‐, and vent valves of instruments on
the gas skid.
10. For the start‐up procedure of the burner we refer to the operating instructions of Unigas
(burner supplier).
11. For the steam / water side, generally you can say that you have to open all block valves
upstream instruments, instrument air and level instruments/gauge glasses and close all
drain‐, and vent valves of instruments and level gauge glasses in the water/steam path.
Make also sure that the inspection doors from the steam drums, blow down vessel and
flash vessel are closed and bolted.
12. Forced draft fans should be checked for speed and sound.
13. All the dampers should be checked for open position.
14. All the vents should also be kept open.
15. All the header vents should be closed to prevent water leakage
16. All feed water connections, combustion air connections and pressure gauges should be
opened or checked for proper working condition
17. Alarms should be checked for sound and proper working condition
18. Fuel selection should be on selected fuel Gas or Oil
19. Check fuel (Gas/HFO) line isolation valve should be opened
20. Demineralized Water must be available
21. WAPDA supply should be available
22. Maintain Deaerator level up to normal water level.
23. Firing panel should be live
24. Boiler drum level will be at normal level at normal water level.
25. Local water gauge glass will be in operation
26. Main motorized Steam valve should be closed
Page 3 of 13

BSPM Power House
B. 65 TPH Boiler Start up Procedure on Gas/Oil
1. The objective of the cold start‐up is to bring the boiler from cold conditions up to
normal operating condition following a start‐up sequence.
2. The DFB shall be started up as followed; every step shall be confirmed and/or checked
automatically or by the operator.
3. The start‐up of the boiler shall be done in accordance with the boiler start‐up curve.
4. The following conditions shall be present before a ‘cold‐start‐up’ is initiated
5. All manually operated valves (drain‐, block‐, and vent valves etc.) shall be in the correct
position so that supply of boiler feed water, fuel (oil/gas) and air is available to the
boiler.
6. Boiler feed water supply system available (pumps running) and healthy
7. BFW control valves LCV‐101 closed and all upstream and downstream main isolation
valves up to steam drum are open and all drains in‐between these lines are closed.
8. TCV ‐102 fully open for gas operation and in auto control position for HFO firing mode.
9. All the bypass valves like LCV‐101, Main steam line etc should be in close position.
10. Steam drum drain valve close and vent valve in open position.
11. CBD isolation valve open and CBD valve close.
12. IBD isolation valve open and IBD in close position.
13. Start‐up isolating valve open
14. Motorized Start‐up valve open.
15. Main Steam isolation valve open and motorized steam isolation valve in close position.
16. Main Steam bypass valve in close position.
17. BFW pump(s) started and feed water is supplied to the boiler drum for its filling. At
initial stage economizer vent should be in open position to allow removal of air as water
start coming from the economizer vent, close the eco vent valve. BFW pumps should be
on circulation prior to filling to boiler feed water to the boiler drum.
18. Fill the Boiler drum by checking water level of steam drum (level > L.A.L.), increase if
necessary by opening BFW control valve LCV‐101 gradually. The drum water level shall
be maintained slightly below NWL during the complete startup of the boiler
19. At the start of the Boiler, Keep some flow of boiler feed water going through the
economizer by keeping LCV‐101 at fixed position of approximately 10 % to avoid
steaming in economizer. In case of fixed flow through LCV‐101, open intermittent blow
down valve after some intervals during start up to keep steam drum level constant.
20. Check that all alarms are healthy from annunciation panel.
21. Start FD fan/fans.
22. Start boiler burner as per fuel availability (NG or HFO ) by following procedure availed in
burner manual for NG /HFO fuel.
23. Start boiler purge by starting burners:
a. Boiler purge is required at boiler start‐up or when after loss of a condition
during boiler operation.
b. Boiler purge starts on pushing the start purge button when boiler‐ and burner
conditions are present and reset, fuel valves closed, No flames detected and
burner air dampers open.
Page 4 of 13

BSPM Power House
c. Signal “FD AIR CONTROL TO PURGE POS.” is sent to control system, to bring
combustion air flow to purge rate.
d. Signal “Purge Started” is set by BMS.
e. Purge timer set at 120 seconds is started (signal “PURGE IN PROGRESS”)
f. After 120 seconds signal “PURGE COMPLETED” will come up (from BMS).

24. When purge completed, then the FD‐fan air damper will go back to minimum start
position. When minimum start position has been reached, Select the fuel from the panel
and push start up button to initiate the automatic start of the burners which will first
open the gas valve to preset position and start the automatic start sequence.

For start‐up procedure of the burners, please refer to document Burner Manual.

25. After firing of the burner, the start‐up of the boiler can now be continued in accordance
with the boiler start‐up curve.
26. Start the Boiler with single burner till steam pressurizations complete. After
pressurization / steam availability is make to the process header second burner should
be started.
27. Warm up the DFB gradually up to saturation conditions (100°C / 1 Bara) with burner at
minimum load.
28. Control drums level with BFW control valve LCV‐101.
29. Drum level shall be maintained slightly below NWL under all circumstances.
30. Continue start‐up of the DFB by increasing the burner load and controlling the
motorized start‐up valve in accordance with the boiler start‐up curve.
31. Bring DFB up to normal operating pressure of 14 barg
32. The following intermediate actions shall be performed;
‐ At 3 barg drum pressure  Close steam drum vent valve.
‐ After steam provision to header  Release BFW control valves for automatic
drum level control.

33. When the start‐up curve is almost completed and the main steam pressure and
temperature have reached their operating conditions then the warming‐up /
pressurizing of the main steam system can be started.
 Open block valve (located downstream of FE‐101)
 Open the main steam by‐pas valve completely
 After a positive equalizing pressure is reached between the DFB and the steam
system, the main steam motorized valve shall be opened completely.
 Close start‐up valve (operator action!)
 Close main steam by‐pass valve completely

34. When the DFB is fully released to the main steam header all boiler control can be set to
automatic control.
35. When the DFB is fully released to the main steam header all boiler control can be set to
automatic control.
Page 5 of 13

BSPM Power House
36. Thermal expansion may cause damage to the feed water flow lines. To avoid this the
following actions shall be taken after completion of the start‐up;
 Open the BFW control valve that was closed during the start‐up for approx. 5~10%
(LCV‐101) in order to avoid any thermal shocks in case of hot water is available.

The “Cold Start‐up” of the DFB is now completed.

37. Start chemical dosing as per feed water and drum water requirements.
38. When R.C. will be available from process, connect with Deaerator after checking it’s
quality.
39. When steam will be available greater than 3 Barg from the steam drum, open steam to
Deaerator and bring Deaerator to normal operating parameters of level, pressure and
temperature.
40. For HFO operation , maintain soot blowing at regular interval by seeing the flue gas
temperature and flue gas condition at stack
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BSPM Power House
C. 65 TPH Boiler Start up Curve
Page 7 of 13

BSPM Power House
D. 65 TPH Boiler Procedure for fuel change over from HFO to Gas
1. For detailed changeover procedure of burner from oil to gas , please refer to relevant
document “Burner Operating and maintenance manual” , Generally look the following,
2. Ensure/check Gas supply should be available at recommended operating pressure to the
burners.
3. Decrease oil flow by master oil valve to fire burner at minimum firing rate.
4. Switch OFF any burner from the panel
5. Selection switch of fuel shifted from HFO to Gas
6. Be sure furnace main gas control valve is shut (FCV position=0%).
7. Open individual gas burner cocks.
8. Increase air flow and furnace draught before admitting gas fuel to furnace(if option
available)
9. Admit gas to furnace header slowly through master valve so gas lights gently.
10. When all gas fires are lighted, increase gas flow by master gas valve
11. In case of unsuccessful, make sure that system is purged completely and no gas is left in
the furnace.
12. Firing rate will be controlled manually and start up curve will be followed to bring the
boiler at its normal operating pressure.
13. With oil fires at minimum shut off and withdraw individual burner guns in quick
succession. Oil must be shut off completely before withdrawing to avoid deposits on
burner throats, in gas outlet orifices or in air register.
14. Remove each burner gun immediately from its register
15. Place the tip end of the burner gun in paraffin immediately
16. Shut all oil valves
17. Adjust air register and air pressure (or furnace draught) if necessary
18. Close HFO system like HFO Pumps and steam to pre‐heater etc.
19. Close steam to Day Tank for a longer period of shut off.
20. Clean burner’s guns as per procedure of burner instruction.
21. Now second burner can also be change over in the same way as stated above.

Page 8 of 13

BSPM Power House
E. 65 TPH Boiler Procedure for fuel change over from Gas to HFO
1. For detailed changeover procedure of burner from gas to oil , please refer to relevant
document “Burner Operating and maintenance manual” , Generally look the following,
2. Maintain HFO temperature suitable for pumping condition in day oil tank.
3. Check that atomizing steam and oil heating steam is available at proper
temperature/pressure as recommended by burner manufacturer.
4. Ensure all oil valves are shut
5. Clean all strainers
6. Check operation on oil pumps and heaters
7. Ensure all oil guns are thoroughly clean
8. Circulate oil at correct temperature and pressure for its atomization as per instruction of
burner manual
9. Make sure oil recirculation system is working properly.
10. Fully withdraw all diffuser pipes
11. See coupling faces are clean
12. Decrease burner firing rate through gas flow adjustment by master gas valve
13. Shut master gas control valve
14. Shut individual burner gas cocks
15. Adjust air register and air pressure (or furnace draught) if necessary
16. Make sure that no condensate is left in the atomizing steam line.
17. Selection of fuel changed from gas to HFO from panel
18. Now check once again the oil and atomizing steam pressure, there should be 1 Barg
higher pressure for atomizing steam pressure than HFO pressure.
19. Switch on the burner
20. Increase air flow and furnace draught before admitting oil fuel to furnace
21. Keep oil in furnace oil header at low pressure
22. Couple burner gun to yoke. If hose supplied push gun towards furnace to avoid spray on
throat or gas ring
23. Partly open master oil return valve
24. Open oil return valves of individual burners for manual mode.
25. Open oil supply valves slowly
26. Open oil supply valves of individual burners one by one in quick succession keeping oil
pressure low so that all burners will receive fuel yet light off gently
27. When all oil fires are lighted, increase oil flow by master oil valve
28. In case of unsuccessful, make sure that system is purged completely and no oil is left in
the furnace.
29. Firing rate will be controlled manually and start up curve will be followed to bring the
boiler at its normal operating pressure.
30. Soot blowing will be performed manually as required during operation of burner on oil.

Page 9 of 13

BSPM Power House
F. 65 TPH Boiler Planned Shut Down
1. For detailed shut down procedure of burner , please refer to relevant document “Burner
Operating and maintenance manual”
2. When a steam generator is to be brought down from on‐line service, the firing rate
should be gradually throttled back to the minimum fire position, and then shut off.
3. Keep equal load of both burners by equal reduction of firing rate during minimizing the
load.
4. Shut down both the FD Fans and Burners simultaneously.
5. At shutdown of burners, the air dampers will go to open position. Ensure damper
positions from the Field.
6. Close the main Steam stop valve and its bypass valve.
7. Close the continuous blow down valve after burner post purge cycle is complete.
8. Close the Boiler feed water control valve and its bypass valve after CBD valve.
9. Stop Boiler feed water supply.

Page 10 of 13

BSPM Power House
G. Cooling down of Boiler

1. When closing down a boiler the cooling rate should not be unduly hurried and under no
circumstances forced draft fans be applied to achieve rapid cooling as it can lead to
cracking of furnace refractory. When the furnace brickwork is hot the furnace brickwork
and burner throat tile will spall or crack.
2. For gas fired burner stoppage, remove all combustible gases after shut down of burner
by slightly opening of burner vanes.
3. When the oil is shut off, never leave a burner gun in the firing position or even
withdrawn as far as possible into the air register, otherwise the oil in the burner gun
may carbonize and the tip will be damaged from overheating, and it may be difficult to
withdraw the burner gun. Burner guns and all parts of the equipment must be kept
absolutely clean at all times.
4. At the time of post purge after shut down, keep an eye on economizer outlet
temperature, if temperature is exceeding, add some quantity of boiler feed water to
drum to avoid steaming.
5. Open the start up vent valve about 5~10 % so that rate of cooling down should not
exceed 2 °C per minute.
6. Drum level will be should not allow to drop below LWL during all the times for
depressurization of drum and cooling down of the boiler.
7. Do not fill the boiler drum excessively at high water level with cold water at the time of
cooling; the increase in water quantity will enhance the boiler cooling rate.
8. When boiler steam pressure becomes 02 barg, drum vents will be opened to avoid any
vacuum.

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H. Burner Operation Procedure
1. Fuel selector switch on Gas or HFO
2. Drum level at normal water level.
3. Check one feed water pump in service.
4. Start FD fan for respective burner.
5. Open discharge damper manually.
6. Select burner on start position.
7. Purging and leak test will initiate.
8. After successful leak test and purging, ignitor will start (Gas pressure 140 mbar).
9. After ignitor, burner will cut in. If fuel is HFO, ensure atomizing steam pressure is higher
than HFO pressure.
10. If boiler is in cold start up, keep firing at 10% and follow start up curve.
11. Ensure chemical dosing system is in service.
12. Take second burner in operation by initiating FD Fan, purging and leak test.
13. Keep both burners on equal firing.
14. Soot blowers are required to operate in each shift.
15. Operate blow down valve as per lab instructions.
16. Observe flame carefully.
17 . Water circulation economizer must remain continuous.
18. Keep drum SHV open in start up.
19. In case of HFO firing, maintain HFO temperature at 1100C, Pressure at 7.0 Bar and
atomizing steam pressure at 8 Bar.
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I. Do Nots’
1. Don’t leave PLC room without operator
2. Don’t keep drum level high
3. Don’t keep drum level low
4. Don’t keep Deaerator level low
5. Don’t disturbe economizer circulation
6. Don’t operate burners with uneven load
7. Don’t keep steam flow less than 10 ton per hour
8. Don’t close air dampers during operation
9. Don’t stop chemical dosing during start up
10. Don’t open steam valve rapidly
11. Don’t increase firing rate rapidly
12. Don’t keep isolated local gauge glass
13. Don’t open blow down valve abruptly
14. Don’t raise steam pressure rapidly
1 5. Don’t drop steam pressure abruptly

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Table of Contents
1.0 INTRODUCTION ..................................................................................................................................... 3
2.0 QUALIFICATION OF OPERATING PERSONNEL .......................................................................................... 3
3.0 PRE‐START UP CHECKS ........................................................................................................................... 3
3.1 BOILER AIR AND FLUE GAS SIDE ............................................................................................................................. 3
3.2 BURNER SIDE .................................................................................................................................................... 3
3.3 BOILER WATER / STEAM SIDE ............................................................................................................................... 5
4.0 FILLING OF DIRECT FIRED BOILER AND FEED WATER PRE‐HEATER ......................................................... 12
4.1 GENERAL ....................................................................................................................................................... 12
4.2 CHEMICAL CONTROL ........................................................................................................................................ 12
4.3 FILLING OF DIRECT FIRED BOILER AND FEED WATER PRE‐HEATER ............................................................................. 12
5.0 STARTING‐UP THE BOILER PLANT .......................................................................................................... 12
5.1 COLD START‐UP .............................................................................................................................................. 13
5.2 WARM START‐UP OF BOILER ............................................................................................................................. 14
6.0 START UP CURVE .................................................................................................................................. 17
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1.0 Introduction
This is 200 TPH boiler start up procedure and it contains following sections;
 Pre‐Start up Checks
 Filling of Boiler
 Boiler Start up
2.0 Qualification of Operating Personnel
Before taking charge of boilers, qualified operators must fully understand their duties. They must have a
clear conception of the purpose of the equipment, its operating characteristics and its exact relationship
to other equipment of the plant. They must be fully familiar with what the equipment is capable of doing
and equally important, what it is not capable of doing. This must include knowledge of the normal
operating ranges of pressure, temperature and Flow of the equipment and must include knowledge of the
hazards that accompany abnormal operating conditions and the corrective actions that must be taken.
3.0 Pre‐Start up Checks
3.1 Boiler air and flue gas side
 Make sure all inspection doors are closed and bolted.
 Make sure duct drains are closed except the main stack drain.
 Peephole protection plates are lowered.
 Make sure that the spade plate is in storage position.
3.2 Burner side
Tag # Description Status
Gas Side
V‐1600 Natural Gas Root Valve for 200 TPH Boiler Open
V‐1618 Gas Filter A Inlet Valve Open
V‐1619 Gas Filter B Inlet Valve Close
V‐1620 Gas Filter A Outlet Valve Open
V‐1621 Gas Filter B Outlet Valve Close
V‐1613 Ignitors Gas Root Valve Open
V‐1607 Ignitor 1 Root Valve Open
V‐1601 PCV‐302 Inlet Valve Open
V‐1602 PCV‐302 Outlet Valve Open
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V‐1603 FCV‐302 Inlet Valve Open
V‐1604 FCV‐302 Outlet Valve Open
V‐1605 PCV / FCV ‐ 302 Bypass Valve Close
V‐1607 Burner 1 gas Isolation Valve Open
HFO Side
V‐1789 Main HFO Valve for 200 TPH Boiler Open
V‐1701 HFO Pump A Suction Valve Open
V1704 HFO Pump B Suction Valve Open
V‐1703 HFO Pump A Discharge Valve Open
V‐1706 HFO Pump B Discharge Valve Open
V‐1710 HFO Heater Inlet Valve Open
V‐1707 PCV‐302 Upstream Isolation Valve Open
V‐1708 PCV‐302 Downstream Isolation Valve Open
V‐1709 PCV‐302 Bypass Valve Close
V‐1711 HFO Heater Drain Valve Close
V‐1712 HFO Heater Vent Valve Close
V‐1713 HFO Heater Outlet Valve Open
V‐1714 HFO Pumps Discharge strainer outlet valve Open
V‐1715 HFO Block Valve Open
V‐1718 HFO‐HSD Interconnection Valve Close
V‐1719 HFO Block Valve Open
HFO Flow Meter Inlet Valve Open
HFO Flow Meter Outlet Valve Open
HFO Flow Meter Bypass Valve Close
V‐1720 PCV 703 Inlet Valve Open
V‐1721 PCV 703 Outlet Valve Open
V‐1722 FCV 703 Inlet Valve Open
V‐1723 FCV 703 Outlet Valve Open
V‐1724 FCV 703 Bypass Valve Close
V‐1725 HFO Header Drain Valve Close
V‐1730 Burner 1 HFO Isolation Valve Open
V‐1339 Burner 1 Atomizing Steam Isolation Valve Open
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V‐1337 Burner 1 Purge Steam Isolation Valve Open

3.3 Boiler water / steam side

Make also sure that the inspection doors from the steam drums, feed water heater,
blow down vessel and flash vessel are closed and bolted.
V‐1023 Deaerator Drain Valve Closed
V‐1027 Deaerator Main Outlet Valve Open
V‐1028 Feed Water Sampling Line Isolation Valve Open
V‐1029 Feed Water Sampling Line Isolation Valve Open
V‐1032 BFP 1 Suction Valve Open
V‐1033 BFP 2 Suction Valve Open
V‐1139 BFP3 Suction Valve Open
V‐1034 BFP 1 Minimum Flow Valve Open
V‐1036 BFP 2 Minimum Flow Valve Open
V‐1140 BFP3 Minimum Flow Valve Open
V‐1046 BFP 1 Discharge Valve Open
V‐1146 BFP 2 Discharge Valve Open
V‐1047 BFP3 Discharge Valve Open
V‐1073 FW LCV Upstream Isolation Valve Open
V‐1074 FW LCV Downstream Isolation Valve Open
V‐1085 FW LCV's Bypass Valve Closed
V‐1086 HP Heater Inlet Valve Open
V‐1087 HP Heater Outlet Valve Open
V‐1089 HP Heater Bypass Valve Closed
V‐1093 Econmizer Inlet Valve Open
V‐1095 Economizer Drain Valve Closed
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V‐1119 Economizer Vent Valve Open
V‐1120 Economizer Vent Valve Open
V‐1151 Steam Drum Drain Valve Closed
V‐1402 Steam Drum Vent Valve Open
V‐2500 Superheater Drain Valve Closed
V‐1504 Superheater Vent Valve Open
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V1522 Superheater Vent Valve Open
V‐1544 Main Steam Line Isolation Valve Closed
MOV‐101 Main Steam Line Motorized Valve Closed
V‐1546 Main Steam Bypass Line Isolation Valve Closed
MOV‐102 Main Steam Bypass Line Motorized Valve Closed
V‐2521 Main Steam Line drain valve Closed
SHV‐101 Start up Vent Valve (10% Open) Open
V‐1543 Start up Vent Valve Isolation Valve Open
DSHV‐101 Desuperheater Control Valve ‐ 101 Closed
DSHV‐102 Desuperheater Control Valve ‐ 102 Closed
V‐‐1107 Desuperheater Control Valve ‐ 101 Isolation Valve Closed
V‐1114 Desuperheater Control Valve ‐ 102 Isolation Valve Closed
V‐2610 CBD Root Valve Open
V‐2611 CBD Root Valve Open
V‐2615 CBD Upstream Isolation Valve Open
V‐2616 CBD Down stream Isolation Valve Open
V‐2617 CBD Bypaass Valve Closed
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V‐2618 CBD Line Drain Valve Closed
CCV‐101 CBD Control Valve Closed
V‐2600 IBD Root Valve Open
V‐2601 IBD Root Valve Open
IBD‐101 IBD Valve Closed
V‐2602 IBD Block Valve Closed
V‐2628 Flash Tank Drain Valve Closed
V‐2625 Flash Tank LCV Upstream Valve Open
V‐2626 Flash Tank LCV Downstream Valve Open
V‐2627 Flash Tank LCV Bypass Valve Closed
LCV‐201 Flash Tank LCV Closed
V‐1428 Flash Tank Vent Valve Open
V‐1429 LP Steam Line from Deaerator Inlet line Valve Open
PCV‐201 Deaerator Pressure Control Valve Closed
V‐1200 LP Steam Line to Deaerator Isolation Valve Open
V‐1203 Deaerator Pressure Control Valve Upstream Iso Valve Open
V‐1204 Deaerator Pressure Control Valve Downstream Iso Valve Open
V‐1206 Deaerator Pressure Control Valve Bypass valve Closed
V‐2400 LP Steam Line Drain Downstream of steam trap Valve Open
V‐2401 LP Steam Line Drain Upstream of steam trap Valve Open
V‐2402 LP Steam Line Drain Bypass Closed
V‐1019 Deaerator Drain Upstream Isolation Valve Open
V‐1020 Deaerator Drain Downstream Isolation Valve Open
V‐1021 Deaerator Drain Bypass Valve Closed
V‐1022 Deaerator Drain line drain Valve Closed
MOV‐201 Deaerator Drain Valve Closed
V‐1207 SAH TCV Upstream Isolation Valve Open
V‐1208 SAH TCV Downstream Isolation Valve Open
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V‐1209 SAH TCV Bypass Valve Closed
V‐1210 SAH TCV line drain valve Closed
TCV‐301 Steam Air Heater Temperature Control Valve Closed
V‐2404 SAH TCV Line steam trap Isolation Valve Open
V‐2406 SAH TCV Line Bypass Valve Closed
V‐2422 SAH TCV Line Bypass Valve Closed
V‐2416 SAH Condensate Islation Valve Open
V‐2417 SAH Condensate Islation Valve Open
V‐2419 SAH Condensate Bypass Valve Closed
V‐2415 SAH Drain Line Valve Closed
V‐2418 SAH Condensate Line drain Valve Closed
LCV‐301 SAH Level Control Valve Closed
V‐1300 MP Steam to HP Heater Valve Closed
V‐2300 MP Steam Line Trap Iso Valve Open
V‐2302 MP Steam Line Trap Bypass Valve Closed
V‐2323 MP Steam Line Trap Bypass Valve Closed
V‐1323 HP Heater TCV Upstream Isolation valve Open
V‐1324 HP Heater TCV Downstream Isolation valve Open
V‐1325 HP Heater TCV Bypass Isolation valve Closed
V‐2324 MP Steam Line Drain Valve Closed
TCV‐110 HP Heater Temperature Control Valve Closed
V‐2331 HP Heater Drain Valve Closed
V‐2332 HP Heater TCV Isolation Valve Open
V‐2333 HP Heater TCV Isolation Valve Open
V‐2334 HP Heater TCV line drain Valve Closed
V‐2335 HP Heater TCV bypass Valve Closed
V‐1024 Sampling Line Block Valve Open
V1028 Sampling Line Block Valve Open
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V1497 Sampling Line Block Valve Closed
V‐1499 Sampling Line Block Valve Closed
V‐2103 Phosphate Dosing System Block Valve Open
V‐2800 Phosphate Dosing System Block Valve Closed
V‐2104 Amine Dosing System Block Valve Open
V‐2900 Amine Dosing System Block Valve Closed
V‐2105 Hydrazine Dosing System Block Valve Open
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V‐3000 Hydrazine Dosing System Block Valve Closed
V‐1307 Atomizing steam root valve Open
V‐1308 Instrument Air ‐ Atomizing steam tie valve Closed
V‐2339 Atomizing steam line trap Isolation valve Open
V‐2341 Atomizing steam line trap Bypassn valve Closed
V‐1329 DPCV‐801 Upstream Isolation Valve Open
V‐1330 DPCV‐801 Downstream Isolation Valve Open
V‐1331 DPCV‐801 Bypass Valve Closed
V‐2350 Atomizing steam line trap Bypassn valve Closed
V‐1340 HFO Heater Heating Steam Root Valve Open
V‐2342 Heating steam line trap Isolation valve Open
V‐2343 Heating steam line trap Isolation valve Open
V‐2344 Heating steam line trap Bypass valve Closed
V‐1346 HFO TCV‐701 Upstream Isolation Valve Open
V‐1347 HFO TCV‐701 Downstream Isolation Valve Open
V‐1348 HFO TCV‐701Bypass Isolation Valve Closed
V‐2345 HFO Heater outlet steam trap Isolation valve Open
V‐2346 HFO Heater outlet steam trap Isolation valve Open
V‐2347 HFO Heater outlet steam trap Bypass valve Closed

Note: During cold start up, keep all Main steam line drain valves open.

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4.0 FILLING OF DIRECT FIRED BOILER AND FEED WATER PRE‐HEATER
4.1 General
First it should be checked that all piping and vessels are cleaned on the waterside. Secondly, a feed water
analysis shall be made before the boiler is filled, to be sure that the quality is in accordance with Descon
requirements.

4.2 Chemical Control
During all operations of boiler, laboratory technician shall monitor the chemistry of boiler water and keep
maintaining all the parameters.
4.3 Filling of Direct Fired Boiler and Feed Water Pre‐heater
Make sure that the boiler feed water lines are vented and that the BFW pumps are in operation. In order
to vent properly and prevent damage due to cavitation, the filling of the feed water heater, economizer,
furnace and evaporator (including drum) shall be done gradually.

The filling of the HP section shall now be done as followed;
1. Make sure that BFW system is healthy and available
2. Open valves gradually
3. Open by pass valve gradually
4. Close vent valves on BFW heater when water is coming out
5. Fill steam drum gradually by opening BFW control valve
6. Close BFW valve when drum water level is just above L.A.L.
7. Close economizer vent valve.
8. Close vent valves on drum and saturated steam lin.
9. If the water level in the steam drum is too high, this can be corrected by draining water through
the intermittent blow down valves.

The boiler system is now filled and is ready for start.
5.0 Starting‐up the Boiler Plant
The two available start‐up modes of the DFB are:

1. Cold start‐up of the DFB (boiler pressure < 25 barg)
2. Warm start‐up of the DFB (boiler pressure > 25 barg)

For both modes the burner is used as heat source.
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5.1 Cold start‐up
The objective of the cold start‐up is to bring the boiler from cold conditions up to normal operating
condition following a start‐up sequence.
The boiler shall be started up as followed; every step shall be confirmed and/or
checked automatically or by the operator.
The start‐up of the boiler shall be done in accordance with the boiler start‐up curve.
1. The following conditions shall be present before a ‘cold‐start‐up’ is initiated.
 All manually operated valves (drain‐, block‐, and vent valves etc.) shall be in the correct
position.
 The following external system shall be healthy and available:
o Boiler feed water supply system available (pumps running) and healthy
o Start sealing / cooling air fans
o Sealing / Cooling air system healthy and available (pressure > PAL)
 For the DFB system, the following conditions shall be set / present
o HP BFW control valves closed
o Desuperheaters control valves closed
o Superheaters drain valves open
o Start‐up isolating valve open
o Start‐up valve SHV‐101 approx. 10% open
o BFW pump(s) started and supply system healthy and available
 Check water level of HP steam drum (level > L.A.L.), increase if necessary by opening BFW
control valve gradually. The drum water level shall be maintained slightly below NWL. During
the complete startup of the boiler
 Open intermittent blow down valve IBD‐101 completely (100% open). Set BFW control valve
at fixed position to keep steam drum level constant and to maintain a minimum flow
through the economizer.
2. Start FD and ID fans.
3. Reset (DCS and BMS: “RESET FAILURE/ALARM”) and start the start‐up procedure, if all alarms are
healthy. Burner’s available signal will come on.
 Boiler purge is required at boiler start‐up or when after loss of a condition during boiler
operation.
 Boiler purge starts on pushing the start purge button when boiler‐ and burner conditions are
present and reset, fuel valves closed, No flames detected and burner air dampers open.
 Signal “FD AIR CONTROL TO PURGE POS.” is sent to control system, to bring combustion air
flow to purge rate.
 Signal “Purge Started” is set by BMS.
 Purge timer set at 300 seconds is started (signal “PURGE IN PROGRESS”)
 After 300 seconds signal “PURGE COMPLETED” will come up (from BMS).
5. When purge completed, then the FD‐fan will go back to minimum start position. When minimum
start position has been reached, Select the fuel from the panel and push start up button to
initiate the automatic start of the burners which will first open the gas valve to preset position
and start the automatic start sequence.
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6. The start‐up of the boiler can now be continued in accordance with the boiler start‐up curve.
 Warm up the DFB gradually up to saturation conditions (100°C / 1 Bara) with burner at
minimum load.
 Control drum level with BFW control valve (single element control).
 Drum level shall be maintained above ‘Cent. Line drum’ under all circumstances, (slightly
below NWL).
 Release control of spray water control valves for automatic control to achieve nominal
steam temperature of 528°C at main steam header.
 Continue start‐up of the DFB by increasing the burner load and controlling
 the HP start‐up valve in accordance with the boiler start‐up curve.
 Bring DFB up to normal operating pressure of 96 barg
 Bring steam quality to the HP steam header conditions.
 The following intermediate actions shall be performed;
o At 5 barg drum pressure ⇒ Close superheaters drain valves.
o At 25 barg drum pressure⇒ Release BFW control valves for automatic drum level
control (with a limited minimum flow of approx.50 t/h)
7. When the start‐up curve is almost completed and the HP steam pressure and temperature have
reached their operating conditions then the warming‐up / pressurizing of the HP steam system
can be started.
 Open block valve
 After a positive equalizing pressure is reached between the DFB and the HP steam system,
the main steam valve shall be opened completely.
 Close main steam by‐pass valve completely
8. When the DFB is fully released to the HP steam header all boiler control can be set to automatic
control.
9. Thermal expansion may cause damage to the feed water flow lines (BFW and spray water lines).
To avoid this the following actions shall be taken after completion of the start‐up;
 Open the BFW control valve that was closed during the start‐up for approx. 5%
 Tune down the BFW control valve that was open during the start‐up for approx.5%
 Open the spray water control valve that was closed during the start‐up for approx.5%
 Tune down the BFW control valve that was open during the start‐up for approx 5%

The “Cold Start‐up” of the DFB is now completed.
5.2 Warm start‐up of Boiler
A warm start‐up is defined as a start‐up of a shut‐downed boiler, which is still pressurized with pressure
above 25 barg.
It should be noted that a ‘Warm start‐up’ is not recommended, as the required boiler purge will cause the
boiler to cool down rapidly, introducing stresses.
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The ‘Warm start‐up procedure’ is practicaly similar to the ‘Cold start‐up procedure’ noting that any
condensate, which may have been formed in the super heater needs to be drained of, and the starting
point on the start‐up curve shall be determined.
The boiler shall be started up as followed; every step shall be confirmed and/or checked automatically or
by the operator.
1. The following conditions shall be present before a ‘warm‐start‐up’ is initiated.
 All manually operated valves (drain‐, block‐, and vent valves etc.) shall be in
 the correct position
 The following external system shall be healthy and available:
o Boiler feed water supply system available (pumps running) and healthy
o Start sealing / cooling air fans
o Sealing / Cooling air system healthy and available (pressure > PAL)
 For the boiler system the following conditions shall be present / set (after a shutdown)
o BFW control valves closed
o Desuperheaters control valves closed
o Superheaters drain valves open
o Start‐up isolating valve open
o Start‐up valve approx. 10% open
o Main steam valve closed
o Main steam bypass valve closed
o HP drum level > L.A.L. → correct if not.
o Block valve closed
o BFW pump(s) started and supply system healthy and available.
 Open intermittent blow down valve completely (100% open). Set BFW control valve at fixed
position to keep HP drum level constant and to maintain a minimum flow through the
economizer.
2. Open superheaters drain valves for approx. 30 seconds (if required) to drain off any condensate
that might be present in the superheaters section.
3. Start FD and ID fans.
4. Reset (DCS and BMS: “RESET FAILURE/ALARM”) and start the start‐up procedure, if all alarms are
healthy. Burner’s available signal will come on.
 Boiler purge starts on pushing the start purge button when boiler‐ and burner conditions are
present and reset, fuel valves closed, No flames detected and burner air dampers open.
 Signal “FD AIR CONTROL TO PURGEPOS.” is sent to control system, to bring combustion air
flow to purge rate.
 Signal “Purge Started” is set by BMS.
 Purge timer set at 300 seconds is started (signal “PURGE IN PROGRESS”)
 After 300 seconds signal “PURGE COMPLETED” will come up (from BMS).
6. When purge completed, then the FD‐fans will go back to minimum start position. When
minimum start position has been reached, select the fuel from the panel and push start up
button to initiate the automatic start of the burners which will first open the gas valve to preset
position and start the automatic start sequence.
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7. The start‐up of the boiler can now be continued in accordance with the boiler start‐up curve.
 Control drum level with BFW control valve (single element control).
 Release BFW control valves for automatic drum level control (with a limited minimum flow
of approx.50 t/h).
 Drum level shall be maintained above ‘Cent. Line drum’ under all circumstances (Slightly
below NWL) .
 Release control of spray water control for automatic control to achieve nominal steam
temperature of 528°C at mainsteam header.
 Continue start‐up of the DFB from the appropriate point on the curve, by increasing the
burner load and controlling the HP start‐up valve in accordance with the boiler start‐up
curve.
 Bring DFB up to normal operating pressure of 96 barg
 Bring steam quality to the HP steam header conditions.
8. When the start‐up curve is almost completed and the HP steam pressure and temperature have
reached their operating conditions then the warming‐up /pressurizing of the HP steam system
can be started.
 Open block valve
 After a positive equalizing pressure is reached between the DFB and the HP steam system,
the main steam valve shall be opened completely.
 Close main steam by‐pas valve completely
 After complete start‐up → Close start‐up isolating valve
9. When the DFB is fully released to the HP steam header all boiler control can be set to automatic
control.
10. Thermal expansion may cause damage to the feed water flow lines (BFW and spray water lines).
To avoid this the following actions shall be taken after completion of the start‐up;
 Open the BFW control valve that was closed during the start‐up for approx. 5%
 Tune down the BFW control valve that was open during the start‐up for approx. 5%
 Open the spray water control valve that was closed during the start‐up for approx.5%
 Tune down the BFW control valve that was open during the start‐up for approx. 5%
The “Warm Start‐up” of the DFB is now.

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6.0 Start up Curve
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Table of Contents
1.0 INTRODUCTION ..................................................................................................................................... 3
2.0 PLANNED SHUT DOWN .......................................................................................................................... 3
3.0 EMERGENCY SHUT DOWN. ..................................................................................................................... 4
4.0 COOLING DOWN .................................................................................................................................... 5
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1.0 Introduction
There are two types of shut down namely:
 Planned shut down for maintenance / inspection
 Shut down after boiler and/or burner trip (emergency shut‐down)
2.0 Planned Shut Down
The procedure for a planned shut down is a fully operator action, the following steps have to be taken:
1. Reduce the burner load gradually to minimum firing
2. Shut down all burners
 When all burners are out of operation, each burner air damper will open automatically.
3. Close DSHV
4. Shut down FD fan and ID fan.
5. Close SHV‐101
6. Close HP main steam valve MOV ‐101 and block valve V ‐1544
7. Close BFW control valves LCV ‐101 and by pass valve V ‐1085
8. Stop BFW supply

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3.0 Emergency Shut Down.
The emergency shut down is executed by pressing the emergency shut down button or is executed due to
a boiler or burner trip signal. The result is that the safeguarding system (BMS) will immediately stop the
heat input to the boiler as follows.
The actions are the same as for the planned shut‐down, being
1. Immediate shut down of the burners.
 When all burners are out of operation, each burner air damper will open automatically.
2. Shut down FD fan and ID fan.
3. Close SHV‐101
4. Close HP main steam valve MOV ‐101 and block valve V ‐1544
5. Close BFW control valves LCV ‐101 and bypass valve V ‐1085
6. Stop BFW supply

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4.0 Cooling Down
When the DFB cools down, it is necessary to open the HP start‐up valve (approx. 10%) and start‐up
isolating valve when the drum pressure drops below 2 barg, in order to avoid any vacuum.
In case of a shut down for a period longer than half an hour the operator also has to take the following
actions:
 Close main steam valve and main steam bypass valves
 Shut‐off boiler feed water supply
Page 5 of 5

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BSPM Power House
41 MW Steam Turbine Maintenance Preventive Maintenance

Table of Contents
Abbreviations: ................................................................................................................................................ 3
Objective: ....................................................................................................................................................... 4
Startup Procedure .......................................................................................................................................... 4
Cooling Water System ............................................................................................................................... 4
Lube Oil System ......................................................................................................................................... 4
Turning Gear .............................................................................................................................................. 5
Condensate Pumps and Condenser ........................................................................................................... 5
Gland Steam .............................................................................................................................................. 5
Vacuum Ejector .......................................................................................................................................... 6
Pre‐Warming of Steam Turbine ................................................................................................................. 6
Synchronization with WAPDA Network ..................................................................................................... 7
Extraction of Steam Turbine ...................................................................................................................... 7
Permissible Inlet Steam parameters .............................................................................................................. 8
Startup Curves ................................................................................................................................................ 9
Turbine Characteristics ................................................................................................................................. 10
Normal Shut Down of 41 MW Steam Turbine .............................................................................................. 11
Activities during Blackout ............................................................................................................................. 12

Page 2 of 12
BSPM Power House

Abbreviations:

CP Condensate Pump
FG Function Group
AOP Auxiliary Oil Pump
EOP Emergency Oil Pump
JOP Jacking Oil Pump
ST Steam Turbine
TG Turning Gear

Page 3 of 12
BSPM Power House

Objective:
The objective of this procedure is to define predetermined steps for steam turbine start up with the aim
of minimizing the normal wear and tear or sudden failure of equipment or its components. Following are
the objectives to achieve;

1. Protect assets and prolong the useful life of production equipment
2. Improve system reliability and safety
3. Similarity in operating steps
4. Decreases system downtime

Startup Procedure
Cooling Water System

 Fill cooling tower sumps with raw water
 Check water level in cooling tower
 Line up makeup water of cooling tower.
 Open suction valves of cooling water pumps
 Open discharge valve of cooling water pumps
 Open sealing water valves of cooling water pumps
 Open inlet water valves of condenser (1&2)
 Open outlet water valve of condenser (1&2)
 Turn On breaker of all pumps
 Turn on all breaker of cooing tower fans
 Open drains of lines to purge air
 Open vent of lines
 Open drain of condenser (MAG10/15‐18)
 Start cooling water pump,
 Purge completely, close all vents and drains
Lube Oil System

 Check oil level in tank (higher than 90%) MAV10AN110
 Check temperature of lube oil (higher than 350C MAV10CT001)
 Check auxiliary lube oil pump motor (MAV15AP110) Emergency lube oil pump motor
(MAV25AP110) Oil Mist fan motor (MAV10AN110 should be on auto mode with breaker on
 Check oil cooler manual inlet and outlet valves are open
 Strainer of oil cooler clean
 Booster pump breaker on
 Suction and discharge of booster pump open
 Permanent vent valves (oil cooler and oil filter) are opened
 Start FG(Function group) Lube Oil
 Startup ‐‐‐‐‐ Ok
Page 4 of 12
BSPM Power House

 By this command EOP will start, AOP starts, EOP off, Oil mist fan running check all area leakages
 Check control pressure (10Bar) lube oil pressure (2.5Bar)

Turning Gear

 Check jacking oil pump motor MAV70AN110 breaker on and on Auto mode
 Turning gear motor MAK10AE 110 breaker on and on auto mode
 In cold start up rotate shaft manually with wheel then put on auto mode

Note:
o Prior to light up boiler, make sure turning gear is in service.
o Don’t allow steam to enter in steam turbine when it is in stopped state. It may cause
corrosion and thermal deformation
o Motor of turning gear must not be switched on when turbine speed is greater than >0 or
<300rpm
o The turning motor can be switched on at turbine stand still or turbine speed higher than
turning speed
 Startup sequence____ O.K.
 By this command shaft will start turning at 169rpm

Condensate Pumps and Condenser

 Open manual valves of demin water line and fill water hot well of condenser (greater than +50
MAG10CL001)
 Open suction valves of condensate pumps
 Check condensate pump motor # 1 & 2 LCB10AP110 & 2LCB20AP110 breaker on and auto mode
 Pre‐select condensate pump # 1
 Discharge flaps of condensate pumps #1 LCA12AA110 & 2 LCA202AA110 should be on close
position and auto mode
 Level control valves LCA40AA210 is on manual mode and closed condition
 Condensate recirculation valves should be opened and on auto mode LCA41AA210
 Minimum flow lines valves of both condensate pumps open
 Sealing water bottles filled water
 Sealing valves of pumps open
 Gland steam condenser inlet and outlet valves open
 Drain of condensate summary open
 Start up sequence _____ok
 By this command condensate pumps running normal

Gland Steam

 Function groups of drains On
a. MAL10AA910
b. MAL20AA910
Page 5 of 12
BSPM Power House

c. MAL30AAA910
d. MAL40 AA910
e. MAL50AA910
 By pass of drains must be opened
 Gland steam fan on auto mode MAW30AN110
 Drains of gland steam line open
 Open manual valve of steam from main steam line
 Gland steam turn line manual valves open and atmospheric manual valve close position
 Start up sequence____ok
 By this command gland steam system is in service when gland steam pressure is 0.5Bar and
temperature is greater than 2200C.
 Close bypass drain valves

Vacuum Ejector
 Open all drains of ejector
 Open manual valve of steam line for ejector
 Steam pressure must be 48 Bar
 Open auxiliary ejector steam line valve MAJ20
 Open air valve of condenser MAJ30
 When vacuum value is ‐0.90Bar ,open steam line valve of main ejector MAJ10
 Open air valve of condenser MAJ30, create vacuum
 When main ejector is in service
 Stop auxiliary ejector first, close air valve of auxiliary ejector and secondly close steam valve of
ejector

Pre‐Warming of Steam Turbine

 Ensure turbine turning gear is in service
 200 TPH Boiler is in operation, pressure is 60Bar and temperature is approximately 3500C
 Open all drains of live steam line
 Check open manual live steam line valve
 Ensure Live steam HP Control valves LBA10AA110 and bypass valves LBA10AA210 is closed
 Emergency stop valve closed
 Function group of inlet steam
 Start up _______ok
 By this command by pass warming valves LBA 10AA210 open automatically and warm up the line
 Open ESP (MAA10AA910)
 By this command steam enters in turbine and will rise the RPM
 When temperature before ESP not increases 40C in 1 minute then press pressure equalizer
button. By this command main HP Control valves open (LBA10AA1100) and by pass valve close
 Follow the steam graph (5608DZ1)
 When pressure 96Bar and temperature 5250C
 Auto start on turbine achieved full RPM
Page 6 of 12
BSPM Power House

 Follow activities carried out automatically
(i) At 300rpm jacking oil pump and turning motor switched off
(ii) At 90% speed excitation ON
(iii) At 90% Speed auxiliary oil pump stop and main oil pump in service.
(iv) Switch off the generator Anti condensation heater (If not then turn it off manually
(v) When the exhaust steam temperature increases 800C, condensate cooling valves
(curtain spray) open on auto mode (LCE20AA420)
NOTE: During speeding the turbine check specially
(i) Oil pressure and temperature
(ii) Bearing metal temperature
(iii) Inlet steam temperature and pressure
(iv) Exhaust steam pressure and temperature
(v) Axial shaft displacement
(vi) All vibrations
(vii) Oil temperature
(viii) Temperature difference at turbine casing flange
(ix) Generator air cooler in service

Synchronization with WAPDA Network
 When turbine achieve full rpm 6700 put generator AVR on manual mode increase voltage up to
11KV contact with CRS and match voltage and frequency and phase difference with WAPDA
 CBP10 panel switch on remote position
 Command 52G release on synchronize
 When synchronize with WAPDA network, increase load on turbine up to 4 MW gradually
 At 4MW close live steam line drains
 First 30 minutes load must remain 06 MW on turbine. It is minimum required load of turbine
Extraction of Steam Turbine

EXTRACTION No.2
 When load turbine greater than 8MW open all extraction # 02 drains
 Command to governor O.k.
 Open LBD20AA920
 Check opening of valve MAA10AA230
 When pressure increases in line connect with process
 When extraction in service , close drains after LBD20AA920
 Direct drain must be opened always

EXTRACTION No.1
 When load turbine greater than 15MW open all extraction # 01 drains
 Command to governor ON_______ O.k.
 Open LBD10AA920
 Check opening of valve MAA10AA220
 When pressure increases in line connect with process
 When extraction in service , close drains after LBD10AA920
 Direct drain must be opened always
Page 7 of 12
BSPM Power House

Permissible Inlet Steam parameters
Page 8 of 12
BSPM Power House

Startup Curves
Page 9 of 12
BSPM Power House

Turbine Characteristics
Page 10 of 12
BSPM Power House

Normal Shut Down of 41 MW Steam Turbine
 Unload Turbine
 At 14MW electric load switch off extraction No. 1
 At 8MW electric load switch off extraction No. 2
 At 6MW electric load close the isolating valve of bleed line.
 When Condenser inlet steam temperature is greater than 80C the valve in condensate line
LCE20AA420 is open automatically
 At 3Mw electric load the direct drains are opened automatically
 Unload turbine fully
 Select Off active power mode.
 Reduced speed of turbine
 Within 20 sec Reverse Power Relay trip the breaker 52G

Page 11 of 12
BSPM Power House

Activities during Blackout
 Immediately close the ejector steam valve
 Open vent valve of gland steam return line and close return line gland steam condenser valve
 Check lube oil emergency pump (D.C. Pump) on
 If supply not available for longer period and shaft stops rotating (0rpm) then open cover of
turning motor and move shaft manually with handwheel

Page 12 of 12
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April,2011
BSPMPowerHouse
O&MManagementSystem
65TPHBoilerMaintenancePreventiveMaintenance

Table of Contents
Abbreviations: ..................................................................................................................... 3
Objective: ............................................................................................................................ 4
Methodology ....................................................................................................................... 4
FlowChartandControl ....................................................................................................... 5
Annexure1–MechanicalMaintenanceForms .................................................................. 6
Annexure2–MechanicalMaintenanceForms .................................................................. 7
Annexure3InstrumentMaintenanceForms ................................................................... 8
Annexure4InstrumentMaintenanceForms ................................................................... 9
Annexure5ElectricalMaintenanceForms ..................................................................... 10
Page 2 of 10
BSPMPowerHouse
O&MManagementSystem

Abbreviations:

CM CorrectiveMaintenance
FCV Flowcontrolvalve
H High
HH HighHigh
I/O Input/Output
L Low
LL LowLow
NSDJob Nonunitshutdownjob
OEM OriginalEquipmentManufacturer
PI PressureIndicator
PCV Pressurecontrolvalve
PM Preventivemaintenance
TCV Temperaturecontrolvalve
TI TemperatureIndicator
SDJob Unitshutdownjob
Page 3 of 10
BSPMPowerHouse
O&MManagementSystem

Objective:
Theobjectiveofthisprocedureistodefinepredeterminedmaintenanceworktoaschedulewiththeaim
ofminimizingthenormalwearandtearorsuddenfailureofequipmentoritscomponents.Followingare
theobjectivestoachieve;

1. Protectassetsandprolongtheusefullifeofproductionequipment
2. Improvesystemreliabilityandsafety
3. Decreasecostofreplacement
4. Decreasessystemdowntime
5. Reduceinjury
Methodology
WhilepreparingPreventivemaintenanceproceduresthefollowingelementswereincorporated:
1. OriginalEquipmentManufacturer(OEM)recommendations
2. Acceptedindustrybestpractices
3. Maintainingequipmentservicerecords
4. Pastexperiencewithcomponents:
– Inspectionrecords
– Servicingrecords
– Replacementfrequency
Preventivemaintenancewasdistributedindaily,weekly,monthly,quarterlyandannualactivities.All
requiredformsareattachedasannexure1,2&3.

x Annexure1containsMechanicalMaintenanceActivities
o Daily,WeeklyandMonthlyroutinemaintenanceforms
x Annexure2containsMechanicalMaintenanceActivities
o QuarterlyandAnnualroutinemaintenanceforms
x Annexure3containsInstrumentMaintenanceActivities
o InstrumentMaintenanceForms
x Annexure4containsInstrumentMaintenanceActivities
o InstrumentMaintenanceActivityForms
x Annexure5containsElectricalMaintenanceActivities

Page 4 of 10
BSPMPowerHouse
O&MManagementSystem

FlowChartandControl
TimeforPM
Initiatedbytimewithreferenceto
LastPM
InformMaintenanceTeam
Leader
ShutDownRequired Yes
PMwillinformBSPM
YesorNo
No
Yes
Yes/No
No
InformShiftIncharge
SignLOTO
PerformPreventiveMaintenanceJob
InstallStickerforJobexecutiondate
andnextduedate
CompleteActivityForm
ClosingbyMaintenanceTeam
LeaderandPlantManager

Page 5 of 10
BSPMPowerHouse
O&MManagementSystem

Annexure1–MechanicalMaintenanceForms

Page 6 of 10
BSPMPowerHouse
O&MManagementSystem

Department: POWER HOUSE Ref. # OMS-boiler-01

Equipment: 65 TPH BOILER INSPECTION KKS # ____________
Company: DESCON MONTH: ________,2011
SR DUE TIME SCHEDULE
MAINTENANCE OBJECTIVE STATUS
# TIME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Check the flame pattern of both burners NSD
2- Check the fuel pressure at burrner # 01 NSD
3- Check the fuel pressure at burrner # 02 NSD
4- Monitoring of oil temperature NSD
5- Operation of soot blower NSD
6- Operation of continuous blowdown NSD
Visually check the local gauge glass
7- NSD
condition
DAILY
8- Checking vision glasses NSD
Check the natural gas filter differential
9- NSD
pressure
10 Cleaning of burner oil guns NSD
11 Check diffuser plate from sight glass NSD
12 Check insulation of boiler NSD
INSPECTIONER:
Comments
DETAILS
1- Cleaning of burner oil guns NSD Check Deformation, clog and wear of burner tip. Check gasket, replace if necessary
WEEKLY
Comments
1- Cleaning of natural gas main filter NSD

Cleaning of natural gas head filter at burner if
2- NSD
required
MONTHLY
Comments
MAINTENANCE ENGINEER:___________________ MANAGER POWER HOUSE:__________________
Page 2 of 11
BSPMPowerHouse
O&MManagementSystem


Equipment: 65 TPH Burners KKS # ____________
# TIME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Check oil guns are out, if gas firing NSD
2- Check on gun is out, if oil firing NSD
3- Check Diff. Pressure of oil & Atomizing steam NSD
5- Check flame through sight glass NSD
6- Check deflector plate condition NSD
7- Check flame is black or brown NSD
DAILY
9- Is burner flame vibrating heavily? NSD
10 Check condition of Inspection Glasses NSD

11 On gas firing, Diff Pr of Gas >500 mbar
12 Check wind box dampers
INSPECTIONER:
Comments
DETAILS
WEEKLY
Comments

2- NSD
required
MONTHLY
Comments

Page 3 of 11
BSPMPowerHouse
O&MManagementSystem


Equipment: 65 TPH Steam Drum and Deaerator KKS # ____________
# TIME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Check Level gauge glass condition. NSD
2- Compare gauge glass level & Level NSD
3- Check condition of level switches and xmitters NSD
4- Check condition of safety valves NSD
5- Cleaning of G Glass locally NSD
DAILY
6- Observe any leakage NSD
11
INSPECTIONER:
Comments
DETAILS
1- NSD Check Deformation, clog and wear of burner tip. Check gasket, replace if necessary
WEEKLY
Comments
1- NSD
2- NSD
MONTHLY
Comments
Page 4 of 11
BSPMPowerHouse
O&MManagementSystem

DEPARTMENT: POWER HOUSE Ref. # OMS-FWP-04

EQUIPMENT: FEED WATER PUMP #_____________ KKS # ____________
Company: KSB Type: WKF 65/7 MONH: _________,2011
SR DUE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
# TIME M E M E M E M E M E M E M E M E M E M E M E M E M E M E M E
1- Check vibration and sound NSD
2- Check leakage rate from gland of stuffing box NSD
3 Check the bearing temperature Front NSD
4 Check the bearing temperature Rear NSD
5 Check suction pressure NSD
DAILY
6 Check discharge pressure NSD
7 Check condition of feed water control valve NSD
INSPECTIONER
Comments:
DETAILS
1- Cleaning of suction filter or when required NSD
Comments
WEEKLY
1- Add greasing to bearing reservoirs NSD
2- Check vibration with SKF instrument NSD

3- Inspect coupling rubber bushes NSD
4- Inspection of bearing NSD Clean out debris from bearing brackets. Drain hole must be open
MONTHLY
Comments:
MAINTENANCE ENGINEER:_______________________ MANAGER POWER HOUSE:____________________

Page 5 of 11
BSPMPowerHouse
O&MManagementSystem

DEPARTMENT: POWER HOUSE Ref. # OMS-FWP-04

EQUIPMENT: FEED WATER PUMP #_____________ KKS # ____________
Company: KSB Type: WKF 65/7 MONH: _________,2011
SR DUE 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
# TIME M E M E M E M E M E M E M E M E M E M E M E M E M E M E M E M E
1- Check vibration and sound NSD
3 Check the bearing temperature Front NSD
4 Check the bearing temperature Rear NSD
DAILY
6 Check discharge pressure NSD
Check condition of feed water control valve NSD
INSPECTIONER
Comments:
DETAILS
Comments
WEEKLY
1- Add greasing to bearing reservoirs NSD

3- Inspect coupling rubber bushes NSD
4- Inspection of bearing NSD Clean out debris from bearing brackets. Drain hole must be open
MONTHLY
Comments:
MAINTENANCE ENGINEER:_______________________ MANAGER POWER HOUSE:____________________
Page 6 of 11
BSPMPowerHouse
O&MManagementSystem

DEPARTMENT: POWER HOUSE Ref. # OMS-FDF-05

EQUIPMENT: FD FAN # (65 TPH ) Ref. # OMS KKS # ____________
Company: _____________, TYPE: GBJ L08020 MONTH: ________,2011
DUE TIME SCHEDULE

SR # MAINTENANCE OBJECTIVE STATUS
TIME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Check vibration and sound of fan NSD
2- Check the temperature of bearing NSD
3- Check both FD Fans in service (if not Load<30%)
4 Check damper condition
DAILY
INSPECTIONER
Comments:
DETAILS
1- FD Fan condition NSD Check coupling conditions and grease the coupling if required
2- Check the condition of FD fan rubber bellow NSD
MONTHLY
3- Check the damper bushes and linkages NSD Clean, inspect and lubricate all damper bushes along with linkages.
Comments:
MAINTENANCE ENGINEER:_________________ MANAGER POWER HOUSE:________________
Page 7 of 11
BSPMPowerHouse
O&MManagementSystem

Department: POWER HOUSE Ref. # OMS-dosing pump-06

Equipment: CHEMICAL DOSING PUMP KKS # ____________
Company: PROMINENT, TYPE: _________ MONTH: ________,2011
SR DUE MAINTENANCE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
STATUS
# TIME OBJECTIVE M E M E M E M E M E M E M E M E M E M E M E M E M E M E M E
1- Check the sound and vibration NSD
2- Check the body temperature NSD
3 Check the pressure NSD
DAILY
INSPECTIONER
Comments:
DETAILS
1- Diaphragm inspection NSD

2- Inlet pressure NSD
3- Cleaning of NRV seat NSD
MONTHLY
4- Cleaning of suction strainer NSD
Comments:
MAINTENANCE ENGINEER:__________________ MANAGER POWER HOUSE:__________________
Page 8 of 11
BSPMPowerHouse
O&MManagementSystem

Department: POWER HOUSE KKS # ____________ Ref. # OMS-HFO pump-07

Equipment: HFO booster PUMP
Company:__________, TYPE: NM035BY01L06B MONTH: ________,2011
SR DUE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
# TIME M E M E M E M E M E M E M E M E M E M E M E M E M E M E M E
3 Check the gland/seal leakage NSD
DAILY
5 Check Discharge pressure NSD
6 Check working oil temperature NSD
INSPECTIONER
Comments:
DETAILS
Clean the strainer by hot water
1- NSD
or steam
MONTHLY
Comments:
MAINTENANCE ENGINEER:__________________ MANAGER POWER HOUSE:__________________
Page 9 of 11
BSPMPowerHouse
O&MManagementSystem

DEPARTMENT: POWER HOUSE Ref. # OMS-soot blower-08

EQUIPMENT: SOOT BLOWER (65 TPH ) KKS # ____________
Company: ____________, TYPE: _____________ MONTH: ________,2011

# TIME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Check the sealing air pressure and
1- NSD
flow
INSPECTIONER
DAILY
Comments:
DETAILS
Spring loaded valve/ poppet valve

1- NSD
should be normally closed
WEEKLY
Comments:
1- Lubricate rack and pinion gear NSD
2- Lubricate roller bracket with grease NSD
MONTHLY
Comments:
MAINTENANCE ENGINEER:______________ MANAGER POWER HOUSE:________________
Page 10 of 11
BSPMPowerHouse
O&MManagementSystem

Annexure2–MechanicalMaintenanceForms
Page 7 of 10
BSPMPowerHouse
O&MManagementSystem

Frequency: Quarterly

BurnerNumber:________________

Activity: SD(shutdown)

DATE:______________

Sr. MAINTENANCE
N. OBJECTIVE DETAILS
1 Inspection of burner Checkgasketandotherinternalpartsoftheburneroilguns.Replaceworn

oilguns outparts
2 Gas nozzle and air Check cracks at gas nozzle and air damper flapper loose , clean/ repair/
damper replacewherenecessary
3 Diffuserplate Checkburnerdiffuserplatecondition
4 Burneroilguns Checkburneroilgunpositionfrominside
Comments:

TickYESorNOforthefollowingstatements:

ANY
ACTIONTOBETAKEN

1. Gasketreplaced. YES NO _____________

2. Burnertipcondition Good Bad _____________

3. Cracksfoundongasnozzle. YES NO _____________

4. Looseflapperfoundonairdamper. YES NO _____________

5. Diffuserplatedamaged. YES NO _____________

6. Rightpositionofburneroilgunfound. YES NO _____________

7. Refractoryconditiongood. YES NO _____________

Burneroverallcondition:_____________________________________________

NextDueDate:______________________________________________________

MAINTENANCEENGINEER:_________________ MANAGERPOWERHOUSE:____________________

Page 2 of 10
BSPMPowerHouse
O&MManagementSystem


FDFan:________________

Activity:SD(shutdown)

DATE:______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 FDFanbolts Checkloosenessofboltsandnuts
2 Alignmentcheck Checkalignment,realignifnotcorrect
3 FDFanbearing Checkphysicallybearingconditionforcracksorpitting
4 FD Fan duct and Inspect FD Fan ducts. Check for any crack or rust and check impeller
impellercondition conditionandconeinletcondition
5 FDFandamper Clean,inspectandlubricatealldamperbushesalongwithlinkages
6 Weldingjoints Checkcrackofweldingparts
7 Sealingstrips Check sealing strips on the edges of the dampers. Repair/ replace if
damaged
8 MotorLoad Checkmotorelectricalloadwithandwithoutcoupling.
Comments:

TickYESorNOforthefollowingstatements: ANY
ACTIONTOBETAKEN

1. Boltsandnutsfoundloose. YES NO ______________

2. Alignmentwasfounddisturbed. YES NO ______________

3. FDFanbearingpittingfound. YES NO ______________

4. Crackorrustfoundonimpeller. YES NO ______________

5. Lubricationperformedondamperbushesandlinkages. YES NO ______________

6. Anycrackofweldingjointfoundondamperplates. YES NO ______________

7. Sealingstripsinstalled. YES NO ______________

FDFANoverallcondition:_____________________________________________

NextDueDate:______________________________________________________

MAINTENANCEENGINEER:____________________MANAGERPOWERHOUSE:____________________

Page 3 of 10
BSPMPowerHouse
O&MManagementSystem


BoilerFeedWaterPump:______________________

Activity:NSD(nonshutdown)

DATE:______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 Checkcoupling Thoroughlyinspectcouplingforsignsofwearandcracks,Tightenbolts
2 Alignmentcheck Usethedialindicatortocheckthecouplingalignment
Pumpnotrunning Standbyservice:Overfillbearinghousingtobottom
3 Coatingofshaftwithoil oftheshaftandrotateseveralturnsbyhandtocoattheshaftandthe
bearingwithoil.
Apply a light coat of rust preventive product to expose machined
4 Rustpreventivecoating surfacestopreventrustandcorrosion.

Comments:


ANY
ACTIONTOBETAKEN
1. CouplingfoundOK. YES NO _____________

2. Boltsfoundloose. YES NO _____________

3. Needpumpalignment. YES NO _____________

4. Coatingofshaftperformedwithoil. YES NO _____________

5. Rustpreventivecoatingperformed. YES NO _____________

Feedwaterpumpoverallcondition:_____________________________________________

NextDueDate:______________________________________________________


Page 4 of 10
BSPMPowerHouse
O&MManagementSystem


HFOBoosterPump:__________________

Activity:NSD(nonshutdown)

DATE:______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 Sealandgear Inspectthesealandgearboxcondition
2 Checkcoupling Checkcouplingconditionandalignment
3 Gearcondition Check condition of the gear’s wear and tear. Replace when necessary
Comments:


ANY
ACTIONTOBETAKEN

1. Sealfounddamaged. YES NO _____________

2. GearconditionfoundOK. YES NO _____________

3. CouplingconditionfoundOK. YES NO _____________

HFOboosterpumpoverallcondition:_____________________________________________

NextDueDate:______________________________________________________


Page 5 of 10
BSPMPowerHouse
O&MManagementSystem


SootBlowerNo:___________________

Status: NSD(nonshutdown)

DATE:______________

Sr.N. MAINTENANCE
OBJECTIVE DETAILS
1 Sootblowertube Inspectthesurfaceoftheinnertube.Lubricateandcleanitifnecessary
2 GearTeeth Checkwearofgearteeth,repairifnecessary
Checkloosenessof Checkloosenessofbolts,nutsandfittings
3
bolts
4 Inspectglands Inspectglandsandadjust/replaceifnecessary
5 Inspectpoppetvalve Inspectpoppetvalve(laptheseatanddiscifnecessary)
Comments:


ANY
ACTIONTOBETAKEN

1. Needlubrication. YES NO _____________

2. Wearofgearteethfound. YES NO _____________

3. Nutsandboltstightened. YES NO _____________

4. GlandsfoundOK. YES NO _____________

5. Poppetvalveseat/discfounddamaged. YES NO _____________

Feedwaterpumpoverallcondition:_____________________________________________

NextDueDate:______________________________________________________


Page 6 of 10
BSPMPowerHouse
O&MManagementSystem

Frequency: Annually

BoilerFurnace


DATE:______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 Hardnesstesting Hardnesstestingoftubesonfurnacesideandeconomizerside
2 Thicknesstesting Thicknesstestingoftubesonfurnacesideandeconomizerside
3 Furnacesidetubes Cleansootanddirtaccumulatedonthetubes
4 Refractoryoverhaul Overhaulfallofrefractoryandothers
5 Economizertubes Check dirt and debris entrapped within the fins of economizer
tubesandcleanthoroughly
6 Inspecttubes Inspectthedamagedtubesandrepairifnecessary
7 Antivibrationplates Checktheantivibrationplatesandreplacewherenecessary
8 Cleaning FurnaceandtubesCleaning
9 Washing FurnaceWashing


ANY
ACTIONTOBETAKEN
1. HardnesstestingperformedonFurnacesidetubes. YES NO ______________

2. HardnesstestingperformedonEconomizersidetubes. YES NO ______________

3. ThicknesstestingperformedonFurnacesidetubes. YES NO ______________

4. ThicknesstestingperformedonEconomizersidetubes. YES NO ______________

5. SootanddirtcleaningperformedofFurnacetubes. YES NO ______________

6. SootanddirtcleaningperformedofEconomizertubes. YES NO ______________

7. Anytubefounddamaged.Thenwritedownthetubenumber. YES NO ______________

8. Antivibrationplatesfounddamaged. YES NO ______________

9. Refractoryrepairperformed. YES NO ______________

10. Stackcleaning YES NO ______________

11. PeepHoleglassescleanliness. YES NO ______________
Page 7 of 10
BSPMPowerHouse
O&MManagementSystem

12. Manholesclosed. YES NO ______________

Furnaceoverallcondition:_____________________________________________

NextDueDate:______________________________________________________


Page 8 of 10
BSPMPowerHouse
O&MManagementSystem

Frequency: Annually


DATE:______________

Sr. MAINTENANCE
No. OBJECTIVE DETAILS
1 Weldingpoints Check crack at welding parts where they are fixed and readjust the
travelifisabnormal
2 Hangersandsupports Carryoutinspectionofallhangersandsupports,replaceifrequired
Reinstallhangersifthe installationisnotproper
3 Travelofhanger Readjustthetravelifisabnormal
Comments:


ANY
ACTIONTOBETAKEN

1. Crackfoundatweldingpart.Mentionwith
itslocationat65TPH YES NO _____________

2. Anyhangerandsupportfounddamaged.
Mentionitslocation YES NO _____________

3. TravelofhangersfoundOK.
Ifnotthenmentionitslocation YES NO _____________

Piping(springhangers)overallcondition:____________________________________________

NextDueDate:______________________________________________________

MAINTENANCEENGINEER:____________________ MANAGERPOWERHOUSE:____________________

Page 9 of 10
BSPMPowerHouse
O&MManagementSystem

Frequency: Annually

SafetyValves

Activity: NSD(NonShutDown)

DATE:______________

Sr.N. MAINTENANCE
OBJECTIVE DETAILS
1 Checkseatandplug Checkseatandplugofthevalve.Repair/replaceifnecessary
2 Calibration Calibratethevalveatitssetpoint(byTreviTestmethod)
Comments:


ANY
ACTIONTOBETAKEN

1. SeatandplugconditionfoundOK. YES NO _____________

2. CalibrationbyTreviTestperformed

atvalve#01 YES NO _____________

3. TreviTestperformedatvalve#02 YES NO _____________

Safetyvalvesoverallcondition:_____________________________________________

NextDueDate:______________________________________________________


Page 10 of 10
BSPMPowerHouse
O&MManagementSystem

Annexure3InstrumentMaintenanceForms
Page 8 of 10
BSPMPowerHouse
OManagementSystem
65TPHPreventiveMaintenance
65TPHIgnationTransformersInspectionSheet(Quarterly)
BULLEH SHAH PAPER MILL KASUR
PACKAGES LIMITED
POWER HOUSE AREA(65 TPH)
Date: ----------------------------
Ignitor
Tag Ignition rod Spark
S No TAG NAME Descrption Location Cabel Remarks
mark Cleaning Condition
Condition
1 TA01 Ignitor#1 BurnerNo1
2 TA-02 Ignitor#2 BurnerNo2
CheckedBy: VarifiedBy:
BSPMPowerHouse
OManagementSystem
65TPHBurnerNo1QuarterlyInspectionSheetforONOFFValves
PACKAGES LIMITED
Date:---------------
Phycial
S No Tag# Descrption Tag Sealing Leackages Remarks
Condiation
Burner No 1
1 EVS Steam Electro valve
2 PA CombustionAirPressureSwitch
3 TCI Plant Consent Thermostate
4 EVRN Vent Valve
5 SQM48.497A9Air AirDampersevoControl
6 QRI UV Flame Detector
Poilt Line
1 PGP Pilot Minimum Gas Pressure switch
2 EVP1 PilotElectrovalveupStream
3 EVP2 PilotElectrovalvedownStream
Gas Line
1 PG (Min) Minimum gas Pressure switch
2 PG (Max) Maximum gas Pressure switch
3 PGCP Gas Leakage Pressure switch
4 EV1 GasElectrovalveupStream
5 EV2 GasElectrovalvedownStream
6 SQM 45.295A9 Gas Gas Throttel Valve servo Control
OIL and Automazing Staem

1 EVN1 Oil safety Electro Valve
2 EVN2 Oil Main electro valve
3 SD Press Pressure prob
4 PVP SteamPressureswitch
5 PO Min Minimum Oil Pressure switch
6 Po Max Maximum Oil Pressure switch
7 SQM 48.49789 oil Heavy oil Regulator servo Control
Checked By: Approved By :

BSPMPowerHouse
OManagementSystem
65TPHBurnerNo2QuarterlyInspectionSheetforONOFFValves
PACKAGES LIMITED
POWER HOUSE AREA(41MW) (371)
Date: ----------------------------
Tag Working Phycial

S No Tag# Descrption Status Leackages Remarks
mark Status Condiation
Burner No 1
1 EVS Steam Electro valve
2 PA CombustionAirPressureSwitch
3 TCI Plant Consent Thermostate
4 EVRN Vent Valve
5 SQM48.497A9Air AirDampersevoControl
6 QRI UV Flame Detector
Poilt Line
1 PGP Pilot Minimum Gas Pressure switch
2 EVP1 PilotElectrovalveupStream
3 EVP2 PilotElectrovalvedownStream
Gas Line
1 PG (Min) Minimum gas Pressure switch
2 PG (Max) Maximum gas Pressure switch
3 PGCP Gas Leakage Pressure switch
4 EV1 GasElectrovalveupStream
5 EV2 GasElectrovalvedownStream
6 SQM 45.295A9 Gas Gas Throttel Valve servo Control

1 EVN1 Oil safety Electro Valve
2 EVN2 Oil Main electro valve
3 SD Press Pressure prob
4 PVP SteamPressureswitch
5 PO Min Minimum Oil Pressure switch
6 Po Max Maximum Oil Pressure switch
7 SQM 48.49789 oil Heavy oil Regulator servo Control
Checked By: Approved By :

BSPMPowerHouse
OManagementSystem
65TPHFieldInstrumentsPMs(SixMonth)
PACKAGES LIMITED
Date:-----------------------------------
TAG Tag
S No Descrption Range Calibration( If Req) Leakages Remarks
NAME mark
1 FT-102 Feed Water Flow Transmitter
2 LT-101 Steam Drum Level Transmitter
3 Ft-101 Steam Drum Line Flow Transmitter
4 TE-TT-101 Steam drum temerature Element
5 PT-102 Feed Water Pressure Transmitter
6 TE-102 Steam drum temerature Element
7 TE-103 Steam drum temerature Element
8 TE-104 Economizer temperature Element
9 TE-105 Economizer temperature Element
10 AT-101 Economizer Oxygen Analyzer
11 AT-101 Economizer Oxygen Analyzer
12 FT-201 Deaerator Flow Transmitter
13 DPT-201 Deaerator Dif.Pressure Transmitter
14 LT-301 Deaerator Level Transmitter
15 PT-301 Deaerator Pressure transmitter
16 LE-101 Level Element Steam Drum
17 LE-101 Level Element Steam Drum
18 PSH-101 Pressure Switch High Steam Drum
19 PSHH-101 Pressure Switch High High Steam Drum
20 LE-301 DeaeratorLevel element
BSPMPowerHouse
OManagementSystem
65TPHBoilerSafetyInterlocksCheckListAnnual
PACKAGES LIMITED
POWER HOUSE AREA(65 TPH) Date:
SrNo TagNo Description TripValue LoopTest ConnectionTightining Trip(OK) Remarks

1 LALL-101 Boiler water level low low
2 PAHH-101 Boiler steam pressure high high
3 ESD Emergency switch
4 LALL-301 Dearator water level low low
5 PVP Atomizing steam pressure low low
6 PGMIN Gas pressure minimum
7 PGMAX Gas pressure maximum
8 PGCP Gas pressure leakage switch
9 PA Combustion air Switch
CheckedBY:
BSPMPowerHouse
OManagementSystem
HalfYearlyAirDamperActuatorCalibrationSheet

PACKAGES LIMITED
Date:
TagNo:
SrNo. mAInput Position Calibration(ifreq) AfterCalibration Remarks

1 4
2 8
3 12
4 16
5 20
CheckedBy VarifiedBy:
BSPMPowerHouse
OManagementSystem
65TPHQuarterlyInspectionSheetforControlValves
PACKAGES LIMITED
POWER HOUSE AREA(65TPH)
Date: -------------------------------
Phycial
S No TAG NAME Descrption Operation & Calibration Remarks
Condiation
mA
Source
4 8 12 16 20
0% 25% 50% 75% 100%
1 TCV-101 Temperature Control valve Feed Water
2 LCV-101 Level Control Valve Feed Water Flow
3 LCV-301 Level Control Valve Deareator
4 PCV-301 Pressure Control Valve Deareator
5 FCV-101 Flow Control Valve Main Steam Line
6 VCV-101 Vent Control valve
7
8
BSPMPowerHouse
OManagementSystem
QuarterlyInspectionSheetTemperatureandPressureGauges

PACKAGES LIMITED
Date:
Phycial
S No AREA TAG NAME Descrption Location Range Status Tag Sealing Leackages Remarks
Condiation
Pressure Indicators
1 371 PI 301 PRESSURE GAUGE FURNACE DRAFT PRESSURE 0-25m Bar
2 371 PI 302 PRESSURE GAUGE ID FAN INLET Compund Guage
COMBUSTION AIR FD FAN
3 371 PI 303 PRESSURE GAUGE 0-25m Bar
OUTLET
COMBUSTION AIR AFTER AIR
4 371 PI 304 PRESSURE GAUGE 0-25m Bar
PRE HEATER
5 371 PI 501 PRESSURE GAUGE PILOT GAS MAIN LINE 0-400m Bar
PRESSURE GAUGE ON PRV- PILOT GAS TRAIN TO
6 371 PI 502A 0-400m Bar
502A BURNER # 1
7 371 PI 502B 0-400m Bar
502B BURNER # 2
8 371 PI 502C 0-400m Bar
502C BURNER # 3
9 371 PI 502D 0-400m Bar
502D BURNER # 4
10 371 PI 601 PRESSURE GAUGE FUEL GAS MAIN LINE 0-10 Bar
11 371 PI 602 PRESSURE GAUGE FUEL GAS MAIN LINE 0-10 Bar
12 371 PI 603A PRESSURE GAUGE FUEL GAS LINE BURNER # 1 0-5 Bar
13 371 PI 603B PRESSURE GAUGE FUEL GAS LINE BURNER # 2 0-5 Bar
14 371 PI 603C PRESSURE GAUGE FUEL GAS LINE BURNER # 3 0-5 Bar
15 371 PI 603D PRESSURE GAUGE FUEL GAS LINE BURNER # 4 0-5 Bar
16 371 PI 701A PRESSURE GAUGE FUEL OIL LINE 0-25 Bar
17 371 PI 701B PRESSURE GAUGE FUEL OIL LINE 0-25 Bar
18 371 PI 702 PRESSURE GAUGE FUEL OIL LINE 0-25 Bar
FUEL OIL LINE TO BURNER #
21 371 PI 705A PRESSURE GAUGE 0-16 Bar
1
22 371 PI 705B PRESSURE GAUGE 0-16 Bar
2
23 371 PI 705C PRESSURE GAUGE 0-16 Bar
3
24 371 PI 705D PRESSURE GAUGE 0-16 Bar
4
25 371 PI 706 PRESSURE GAUGE AFTER OIL HEATING UNIT 0-25 Bar
DIFFERENTIAL PRESSURE
26 371 DPI 701 FUEL OIL LINE 0-1 bar
GAUGE
BSPMPowerHouse
OManagementSystem

PACKAGES LIMITED
Date:
Phycial
Condiation
27 371 DPI 702 FUEL OIL LINE 0-25 Bar
GAUGE
28 371 PI 802 PRESSURE GAUGE ATOMIZING STEAM MAIN LINE 0-16 Bar
29 371 PI 803 PRESSURE GAUGE ATOMIZING STEAM MAIN LINE 0-16 Bar
ATOMIZING STEAM TO
BURNER # 1
ATOMIZING STEAM TO
BURNER # 2
ATOMIZING STEAM TO
32 371 PI 804C PRESSURE GAUGE 0-16 Bar
BURNER # 3
ATOMIZING STEAM TO
33 371 PI 804D PRESSURE GAUGE 0-16 Bar
BURNER # 4
COOLING FAN PRESSURE
34 371 PI 604 COOLING FAN 0-1 Bar
GAUGE (BURNERS)
35 371 PI 305 PRESSURE GAUGE BURNER # 3 0-25 m Bar
39 371 PI 901 PRESSURE GAUGE INSTRUMENT AIR 0-10 Bar
FEED WATER PUMP # 1
DISCHARGE
FEED WATER PUMP # 2
DISCHARGE
42 371 PI 101C PRESSURE GAUGE FEED WATER PUMP SUCTION 0-5 Bar
43 371 PI 101D PRESSURE GAUGE FEED WATER PUMP SUCTION 0-5 Bar
44 371 PI 102 PRESSURE GAUGE FEED WATER HEATER
45 371 PI 103 PRESSURE GAUGE BOILER DRUM PRESSURE 0-160 Bar
46 371 PI 104 PRESSURE GAUGE STEAM HEADER 0-160 Bar
FEED WATER LINE AFTER
47 371 PI 105 PRESSURE GAUGE 0-160 Bar
ECO # 2
48 371 PI 106 PRESSURE GAUGE SUPER HEATER # 1, INLET 0-160 Bar
49 371 PI 107 PRESSURE GAUGE SUPER HEATER # 1, OUTLET 0-160 Bar
54 371 PI 201 PRESSURE GAUGE DE-AERATOR TANK 0-10 Bar
BSPMPowerHouse
OManagementSystem

PACKAGES LIMITED
Date:
Phycial
Condiation
DEMIN WATER (INLET DE-
55 371 PI 202 PRESSURE GAUGE 0-10 Bar
AERATOR TANK)
56 371 PI 203 PRESSURE GAUGE DEAERATOR HEATING STEAM 0-10 Bar
57 371 PI 204 PRESSURE GAUGE FLASH VESSEL 0-10 Bar
Temperature Gauge
1 371 TI 303 TEMPERATURE GAUGE FLUE GASES ID FAN INLET 0-160 c
2 371 TI 304 TEMPERATURE GAUGE COMBUSTION AIR 0-160 c
3 371 TI 305 TEMPERATURE GAUGE 0-160 c
HEATER
4 371 TI 701 TEMPERATURE GAUGE FUEL OIL LINE 0-160 c
5 371 TI 702 TEMPERATURE GAUGE FUEL OIL LINE 0-160 c
Checked By: Approved By:

BSPMPowerHouse
O&MManagementSystem

Annexure4InstrumentMaintenanceForms

Page 9 of 10
BSPMPowerHouse
O&MManagementSystem

CONTROL VALVE PERFORMED BY
CALIBRATION SHEET
Tag# DATE:
INPUT SIGNAL: AIR FAIL: OPEN CLOSE SUPPLY:
LOCK
Calibration Data
INPUT INDICATION & VALVE OPENING

Sig. Press. Designed As Found After Cal.
% PSI OPEN% CLOSE% OPEN % CLOSE% OPEN % CLOSE%
0 3
25 6
50 9
75 12
100 15
Action Taken:

Page 2 of 4
BSPMPowerHouse
O&MManagementSystem

FLOW TRANSMITER (DIFF. PRESS.) Performed By:

CALIBRATION SHEET
Tag# DATE:
SUPPLY: 24 vdc OUTPUT SIGNAL: 4 to 20 mA DCS or PLC I / O Number :

…………………………….
Calibration Data
INPUT OUTPUT SIGNAL

Pressure Designed As Found (MA) After Cal. (MA)
mmH2O (MA)
mA UP DOWN UP DOWN
LRV URV
Action Taken:

Page 3 of 4
BSPMPowerHouse
O&MManagementSystem

I/P CONVERTOR PERFORMED BY
CALIBRATION SHEET
Tag# DATE:
SUPPLY: 20 PSI OUT PUT: 3 – 15 PSI INPUT SIGNAL: 4 – 20 MA
Calibration Data
INPUT OUT PUT
Sig. Sig. Designed As Found After Cal.
% MA OUT PUT CLOSE% UP DOWN UP DOWN
(PSI)
0 4 3
25 8 6
50 12 9
75 16 12
100 20 15
COMMENTS:

Page 4 of 4
BSPMPowerHouse
O&MManagementSystem

Annexure5ElectricalMaintenanceForms

Page 10 of 10
BSPMPowerHouse
ElectricalPreventiveMaintenance
STRATEGY BASE MAINTENANCE PLAN of MOTORS AND MCC OF 65TPH
MAIN SCHEDU Date of

EQUIPMENT (KKS CYCLE/U S.D / CALL Date of
S.N TASK LIST WORK LING Duration end of REMARKS
No) NIT N.S.D HORIZON start of PM
CENTRE PERIOD PM
1 PU-01A Feed water pump
2 PU-02B Feed water pump
3 Oil heating pump#1 HFO oil heating pump
1. Insulation and winding resistance test of motor. 2.
5 FD-FAN#1 FD-FAN#1
cleaning of motor 3.
6 FD-FAN#2 FD-FAN#2
Maggering of cable 4.
7 SB-01 Soot Blower
Tightning of connection from both side 12 months Electrical S.D 100% 10 years 01days 24-04-2011
8 SB-02 Soot Blower
5.Control connection tightning
9 SB-03 Soot Blower
6. Checking of contactor contact and cleaning 7.
10 SB-04 Soot Blower
UMC checking and power supply voltage measurement
11 MP 371-1002 Return condensate pump
13 65TPHLDB Diesel forwarding pump#1
BBSSPPM
M PPo
owwe
err H
Hoouusse
e
220000 TTPPH
H BBo oiille
err
PPrre
evve
ennttiivve
eM Maaiinntte ennaannc
cee
PPrroocce
edduurree
RReevv 00
April, 2011
BSPM Power House
200 TPH Boiler Maintenance Preventive Maintenance

Table of Contents
Abbreviations: ..................................................................................................................... 3
Objective: ............................................................................................................................ 4
Methodology ....................................................................................................................... 4
Flow Chart and Control ....................................................................................................... 5
Annexure 1 – Mechanical Maintenance Forms .................................................................. 6
Annexure 2 – Mechanical Maintenance Forms .................................................................. 7
Annexure 3 ‐ Instrument Maintenance Forms ................................................................... 8
Annexure 4 ‐ Instrument Maintenance Forms ................................................................... 9
Annexure 5 ‐ Electrical Maintenance Forms ..................................................................... 10

Page 2 of 10
BSPM Power House

Abbreviations:

CM Corrective Maintenance
FCV Flow control valve
H High
HH High High
I/O Input / Output
L Low
LL Low Low
NSD Job Non‐unit shut down job
OEM Original Equipment Manufacturer
PI Pressure Indicator
PCV Pressure control valve
PM Preventive maintenance
TCV Temperature control valve
TI Temperature Indicator
SD Job Unit shut down job

Page 3 of 10
BSPM Power House

Objective:
The objective of this procedure is to define predetermined maintenance work to a schedule with the aim

3. Decrease cost of replacement
5. Reduce injury

Methodology
While preparing Preventive maintenance procedures the following elements were incorporated:
1. Original Equipment Manufacturer (OEM) recommendations
2. Accepted industry best practices
3. Maintaining equipment service records
4. Past experience with components:
– Inspection records
– Servicing records
– Replacement frequency
Preventive maintenance was distributed in daily, weekly, monthly, quarterly and annual activities. All
required forms are attached as annexure 1, 2 & 3.

 Annexure 1 contains Mechanical Maintenance Activities
o Daily, Weekly and Monthly routine maintenance forms
o Quarterly and Annual routine maintenance forms
 Annexure 3 contains Instrument Maintenance Activities
o Instrument Maintenance Forms
o Instrument Maintenance Activity Forms
 Annexure 5 contains Electrical Maintenance Activities

Page 4 of 10
BSPM Power House

Time for PM
Initiated by time with reference to
Last PM
Inform Maintenance Team
Leader
Shut Down Required Yes
PM will inform BSPM
Yes or No
No
Yes
Yes / No
No
Inform Shift Incharge
Sign LOTO
Perform Preventive Maintenance Job
Install Sticker for Job execution date
and next due date
Complete Activity Form
Closing by Maintenance Team
Leader and Plant Manager

Page 5 of 10
BSPM Power House

Annexure 1 – Mechanical Maintenance Forms

Page 6 of 10
200 TPH BOILER
PREVENTIVE MAINTENANCE CHECK LIST(MECHANICAL)

Equipment: 200 TPH BOILER INSPECTION KKS # ____________
Company: DESCON , Type: HIGH PRESSURE WATER TUBE Month: ________,2011

# TIME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Check the flame pattern of the burners in
1- NSD
operation
2- Check oil temperature NSD
3- Operation of soot blowers NSD
4- Check Insulation NSD
5- Visually check the local gauge glass condition NSD

DAILY
Check the differential pressure of steam and

7- NSD
furnace oil (if oil firing)
Check the diffuser plates condition by sight
8- NSD
glass wind box
Cleaning of burner oil guns, check deformation,
9- clog and wear of burner tip, check gasket, NSD
replace if necessary
INSPECTIONER:
Comments
MONTHLY
Comments
_________________________________ __________________________________
MAINTENANCE ENGINEER MANAGER POWER HOUSE
200 TPH BOILER
Equipment: 200 TPH Burners KKS # ____________

# TIME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Check oil guns are out, if gas firing NSD
2- Check on gun is out, if oil firing NSD
3- Check Diff. Pressure of oil & Atomizing steam NSD
5- Check flame through sight glass NSD
6- Check deflector plate condition NSD
DAILY
7- Check flame is black or brown NSD

9- Is burner flame vibrating heavily? NSD
10 Check condition of Inspection Glasses NSD
11 On gas firing, Diff Pr of Gas >500 mbar
12 Check wind box dampers
INSPECTIONER:
Comments
DETAILS
WEEKLY
Comments

MONTHLY

2- NSD
required
Comments

200 TPH BOILER
Equipment: 200 TPH Steam Drum and Deaerator KKS # ____________
# TIME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Check Level gauge glass condition. NSD
2- Compare gauge glass level & Level NSD
3- Check condition of level switches and xmitters NSD
DAILY
4- Check condition of safety valves NSD

5- Cleaning of G Glass locally NSD
6- Observe any leakage NSD
11
INSPECTIONER:
Comments
DETAILS
WEEKLY
1- NSD Check Deformation, clog and wear of burner tip. Check gasket, replace if necessary
Comments
1- NSD
MONTHLY
2- NSD
Comments

200 TPH BOILER
Department: POWER HOUSE Ref. # OMS-FWP-04

Equipment: FEED WATER PUMP # 01 KKS # ____________
Company: STERLING SIHI, Type: MSHA 10014 NC4BV3TFE07 Month: _________,2011

# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Check oil level and discoloration NSD
2- Check pump for noisy bearings and vibration NSD
3- Visually check for any leakages NSD
4- Check the bearing temperature of DE NSD
5- Check the bearing temperature of NDE # 01 NSD
DAILY
6- Check the bearing temperature of NDE # 02 NSD

Hand test differential temperature across
7- NSD
cooling water lines for effictive operation
8- Check suction pressure NSD

9- Check discharge pressure NSD
INSPECTIONER
Comments:
1st TWO WEEKS 2nd TWO WEEKS

WEEKS
TWO

Comments
1- Add oil to the bearing reservoirs, if required NSD

MONTHLY

3- Inspect coupling rubber pads NSD
Comments:
_______________________________ _________________________________
200 TPH BOILER
Department: POWER HOUSE Ref. # OMS-FDF-05
Equipment: FD FAN KKS # ____________
Company: ____________, TYPE: ____________ Month: ________,2011
DUE TIME SCHEDULE

TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Check vibration and sound of FD fan NSD
2- Check the bearing temperature on motor side NSD
DAILY
3- Check the bearing temperature on fan side NSD

4- Check the coupling cover NSD
INSPECTIONER
Comments:
DETAILS
TWO WEEKS
1 Greasing of bearings NSD 1st TWO WEEKS 2nd TWO WEEKS
Comments:
MONTHLY
3- Greasing of FAN damper bearing NSD

Comments:
____________________________________ __________________________________
200 TPH BOILER
Department: POWER HOUSE Ref. # OMS-IDF-06
Equipment: ID FAN KKS # ____________
Company: ____________, TYPE: ____________ Month: ________,2011
DUE TIME SCHEDULE

TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Check vibration and sound of ID fan NSD
2- Check the bearing temperature on motor side NSD
DAILY
3- Check the bearing temperature on fan side NSD

4- Check the coupling cover NSD
INSPECTIONER
Comments:
DETAILS
TWO WEEKS
1 Greasing of bearings NSD 1st TWO WEEKS 2nd TWO WEEKS
Comments:
MONTHLY
3- Greasing of FAN damper bearing NSD

Comments:
____________________________________ __________________________________
200 TPH BOILER
Department: POWER HOUSE Ref. # OMS-HFO pump-07

Equipment: HFO booster PUMP # _______ KKS # ____________
Company:__________ , TYPE: ___________ Month: ________,2011
SR DUE
TIME SCHEDULE
# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Check bearing temperature on
2- NSD
DE side
Check bearing temperature on
3- NSD
NDE side
DAILY
5- Check inlet pressure NSD

INSPECTIONER
Comments:
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
AFTER ONE DAY
Clean suction strainers with

1- NSD
diesel and steam
Comments:
___________________________________ __________________________________
200 TPH BOILER
Department: POWER HOUSE Ref. # OMS-soot blower-08

Equipment: SOOT BLOWER # 01 KKS # ______________
Company: DIAMON POWER, Model: IK4M Month: ________,2011

TIME
# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Check the sealing air pressure and
1- NSD
flow
DAILY
2- Check for steam traps condition NSD
INSPECTIONER
Comments:
DETAILS
WEEK 1 WEEK 2 WEEK 3 WEEK 4

WEEKLY
Spring loaded valve/ poppet valve

1- NSD
should be normally closed
Comments:
1- Lubricate rack and pinion gear NSD

MONTHLY
2- Lubricate roller bracket with grease NSD

Check the nozzle pressure and flow
3- NSD
direction
Comments:
__________________________________ __________________________________
200 TPH BOILER
Department: POWER HOUSE Ref. # OMS-RCP-9

Equipment: RC PUMP # _________ KKS # ____________
Company: ANDRITZ, Type: S3-125-400.3 DD Month: _________,2011

# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

DAILY
4- Check DE bearing temperature NSD

5- Check NDE bearing temperature NSD
INSPECTIONER
Comments:

WEEKLY

2- Cleaning of discharge filter or when required NSD
Comments:

MONTHLY

Comments:
_______________________________ _________________________________
200 TPH BOILER

Equipment: CHEMICAL DOSING PUMP(N2H4) KKS # ____________
Company: MILTON ROY, Type: ___________ Month: ________,2011
SR DUE MAINTENANCE TIME SCHEDULE

STATUS
# TIME OBJECTIVE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
DAILY

3 Check the discharge pressure NSD
INSPECTIONER
Comments:
DETAILS
MONTHLY
2- Inlet pressure NSD Checking inlet pressure

Comments:
___________________________________ __________________________________
200 TPH BOILER

Equipment: CHEMICAL DOSING PUMP(NH3) KKS # ____________
Company: MILTON ROY, Type: ___________ Month: ________,2011

STATUS
# TIME OBJECTIVE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
DAILY

3 Check the discharge pressure NSD
INSPECTIONER
Comments:
DETAILS
MONTHLY

Comments:
___________________________________ __________________________________
200 TPH BOILER

Equipment: CHEMICAL DOSING PUMP(PO4) KKS # ____________
Company: MILTON ROY, Type: MD140F8N130 Month: ________,2011

STATUS
# TIME OBJECTIVE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
2- Check the oil level NSD

DAILY
4- Check the discharge pressure NSD
INSPECTIONER
Comments:
DETAILS
1- Gear condition NSD Check the gear condition
MONTHLY
Comments:
___________________________________ __________________________________
200 TPH BOILER
Department: POWER HOUSE Ref. # OMS-injection pump-13

Equipment: PRD INJECTION PUMP # ________ KKS # ____________
Company: KSB, Type: MTC C32/10-021-2004 Month: _________,2011

# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Check sound and vibration NSD

DAILY
INSPECTIONER
Comments:
DETAILS
Add oil/ grease to the bearing reservoirs, if
MONTHLY
1- NSD
required
3- Clean suction strainer, if required NSD
Comments:
_______________________________ _________________________________
BSPM Power House

Page 7 of 10
BSPM Power House

Frequency: Annually

Boiler Furnace

Activity: SD (shut down)

DATE: ______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 Hardness testing Hardness testing of tubes on furnace side and economizer side.
2 Thickness testing Thickness testing of tubes on furnace side and economizer side.
3 Furnace side tubes Clean soot and dirt accumulated on the tubes.
4 Refractory overhaul Overhaul fall of refractory and others.
5 Economizer tubes Check dirt and debris entrapped within the fins of economizer
tubes and clean thoroughly.
6 Inspect tubes Inspect the damaged tubes and repair if necessary.
7 Anti‐vibration plates Check the anti‐vibration plates and replace where necessary.
8 Check cracks in Check cracks in couplers using DPT method.
couplers
9 Cleaning Furnace and tubes cleaning.
10 Washing Furnace washing.

Tick YES or NO for the following statements: ANY
ACTION TO BE TAKEN

1. Hardness testing performed on Furnace side tubes. YES NO _________________________

2. Hardness testing performed on Economizer side tubes. YES NO __________________________

3. Thickness testing performed on Furnace side tubes. YES NO ___________________________

4. Thickness testing performed on Economizer side tubes. YES NO _________________________

5. Soot and dirt cleaning performed of Furnace tubes. YES NO __________________________

6. Soot and dirt cleaning performed of Economizer tubes. YES NO _______________________

Page 2 of 18
BSPM Power House

7. Any tube found damaged. Then write down the tube number. YES NO ________________________

8. Anti‐vibration plates found damaged. YES NO ______________________

9. Refractory repair performed. YES NO _____________________

10. Stack cleaning done. YES NO _______________________

11. Peep hole glasses cleanliness performed. YES NO ______________________

12. Manholes closed. YES NO ______________________

Furnace overall condition: ___________________________________________________________

Next Due Date: _______________________________________

MAINTENANCE ENGINEER: ____________________ MANAGER POWER HOUSE: ____________________

Page 3 of 18
BSPM Power House


Burner Number: ____________


DATE: _____________

Sr. MAINTENANCE
1 Inspection of burner Check gasket and other internal parts of the burner oil guns. Replace worn

oil guns out parts.
2 Gas nozzle and air Check cracks at gas nozzle and air damper flapper loose, clean/ repair/
damper replace where necessary.
3 Diffuser plate Check burner diffuser plate condition.
4 Burner oil guns Check burner oil gun position from inside.
5 Check Refractory Check refractory condition.
Comments:

Tick YES or NO for the following statements:
ANY
ACTION TO BE TAKEN
1. Gasket replaced. YES NO ______________________________

2. Burner tip condition good. YES NO _____________________________

3. Cracks found on gas nozzle. YES NO _____________________________

4. Loose flapper found on air damper. YES NO _____________________________

5. Diffuser plate damaged. YES NO ____________________________

6. Right position of burner oil gun found. YES NO ______________________________

7. Refractory condition good. YES NO ____________________________

Burner overall condition: _________________________________________________________________

Next Due Date: __________________________________________


Page 4 of 18
BSPM Power House


FD Fan: ______________


DATE: ______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 FD Fan bolts Check looseness of bolts and nuts.
2 Alignment check Check alignment, realign if not correct.
3 FD Fan bearing Check physically bearing condition for cracks or pitting.
FD Fan duct and Inspect FD Fan ducts. Check for any crack or rust and check impeller
4
impeller condition condition.
5 FD Fan damper Clean, inspect and lubricate all damper bushes along with linkages.
6 Welding joints Check crack of welding parts.
Sealing strips Check sealing strips on the edges of the dampers. Repair/ replace if
7
damaged.
8 Motor Load Check motor electrical load with and without coupling.

Check rust and contamination of driving mechanism specially gear to inlet
9 Inlet vanes
vane from the fan inside and clean if necessary.
10 Check looseness of
Check looseness, rust and fall of lock nuts, bolts and other fitting.
vanes
Comments:

ACTION TO BE TAKEN

1. Bolts and nuts found loose. YES NO ________________________________________

2. Alignment was found disturbed. YES NO ________________________________________

3. FD Fan bearing pitting found. YES NO _______________________________________

4. Crack or rust found on impeller. YES NO ________________________________________

5. Lubrication performed on damper

bushes and linkages. YES NO ________________________________________

6. Any crack of welding joint found on
Page 5 of 18
BSPM Power House

damper plates. YES NO _______________________________________

7. Sealing strips installed. YES NO ________________________________________

8. Driving mechanism from gear to inlet

vane found satisfied. YES NO ________________________________________

9. Any looseness of vane of damper found

from duct. YES NO ________________________________________

FD FAN overall condition: _________________________________________________________________

Next Due Date: ____________________________________________


Page 6 of 18
BSPM Power House


ID Fan: ______________


DATE: ______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 ID Fan bolts Check looseness of bolts and nuts.
2 Alignment check Check alignment, realign if not correct.
3 ID Fan bearing Check physically bearing condition for cracks or pitting.
ID Fan duct and Inspect ID Fan ducts. Check for any crack or rust and check impeller
4
impeller condition condition.
5 ID Fan damper Clean, inspect and lubricate all damper bushes along with linkages.
6 Welding joints Check crack of welding parts.
Sealing strips Check sealing strips on the edges of the dampers. Repair/ replace if
7
damaged.
8 Motor Load Check motor electrical load with and without coupling.

Check rust and contamination of driving mechanism specially gear to inlet
9 Inlet vanes
vane from the fan inside and clean if necessary.
10 Check looseness of
Check looseness, rust and fall of lock nuts, bolts and other fitting.
vanes
Comments:

ACTION TO BE TAKEN

1. Bolts and nuts found loose. YES NO ________________________________________

2. Alignment was found disturbed. YES NO ________________________________________

3. ID Fan bearing pitting found. YES NO _______________________________________

4. Crack or rust found on impeller. YES NO ________________________________________

5. Lubrication performed on damper

bushes and linkages. YES NO ________________________________________

Page 7 of 18
BSPM Power House

6. Any crack of welding joint found on

damper plates. YES NO _______________________________________

7. Sealing strips installed. YES NO ________________________________________

8. Driving mechanism from gear to inlet

vane found satisfied. YES NO ________________________________________

9. Any looseness of vane of damper found

from duct. YES NO ________________________________________

ID FAN overall condition: _________________________________________________________________

Next Due Date: ____________________________________________


Page 8 of 18
BSPM Power House

Frequency: Annually

Equipment: Deaerator


DATE: ______________

Safety Precautions for Maintenance before Entering Deaerator:‐
The following safety measures must be taken before attempting to open access cover:

1. Vessel entry permit must be issued including all necessary information.
2. All external services water outlet to pump, demin water, steam and condensates return etc must be safely
and visibly closed.
3. Electricity must be isolated from all Deaerator ancillary equipment.
4. Post DANGER notices at all isolators and access points saying WORKERS IN DEAERATOR.
5. Open Deaerator vent to release any pressure.
6. Drain Deaerator through drain valve.
7. Open all access covers and allow deaerator to ventilate.
8. When Deaerator require an internal inspection be sure that the deaerator is empty and at ambient
temperature before open the manhole to enter the vessel. Also check the sufficient oxygen contents in the
vessel.
9. It is essential to have an operator standing by, outside the Deaerator.
10. Cleaning may be done with wire brush as required. After this, it should be thoroughly washed with water
prior to refilling and close the manhole using new joints. Sieve Trays must be wire brushed and completely
cleaned.

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 Dome plates Clean and inspect Deaerator dome plates for deterioration.
2 Sieve Trays Cleaning of Sieve Trays fouling.
3 Mixer section Inspect mixer section of Deaerator dome.
4 Dome shell Inspect Dome shell.
5 Interconnecting Inspect all interconnecting piping of make‐up water and return
piping condensate of deaerator dome.
6 Stairs, ladders Inspect for proper Stairs and ladders condition.

Page 9 of 18
BSPM Power House

ACTION TO BE TAKEN

10. Dome plates found in good condition. YES NO ________________________________________

11. Cleaning of Sieve Trays performed. YES NO ________________________________________

12. Mixer section of dome found satisfied. YES NO _______________________________________

13. Dome shell inspected. YES NO _______________________________________

14. All piping found OK. YES NO _______________________________________

15. Stairs and ladder’s condition satisfied. YES NO _______________________________________

Deaerator overall condition: ________________________________________________________

Page 10 of 18
BSPM Power House

Equipment: Deaerator Storage Vessel
Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 Cleaning of Storage Clean and inspect inside of Deaerator storage tank (vessel).
Tank
2 Welding inspection Inspect weld of steam sparger pipes and its cleaning.
Inspect for loose
3 Visually inspect for loose bolts and clamps.
bolts and clamps
4 Supports condition Check for deformation of supports of steam sparger pipes.
5 Vessel condition Inspect vessel for corrosion and local cracks.
6 Inspect baffle plates Inspect baffle plate’s condition, repair if required.
7 Nozzles and flanges Inspect the condition of nozzles and flanges.
8 Insulation, cladding Visually inspect external insulation and cladding of Deaerator and
inspection pipe lines.
9 Safety valves Check the condition of safety valves.

ACTION TO BE TAKEN

1. Cleaning of storage vessel performed. YES NO _______________________________________

2. Weld of steam sparger pipes found OK. YES NO _______________________________________

3. Internal bolts and clamps found loose. YES NO _______________________________________

4. Supports of sparger pipes adjusted. YES NO _______________________________________

5. Corrosion and local cracks found. YES NO _______________________________________

6. Baffle plates condition found satisfied. YES NO _______________________________________

7. Nozzles and flanges condition found OK. YES NO _______________________________________

8. Insulation and cladding removed at

some points of pipe and vessel. YES NO _______________________________________

Page 11 of 18
BSPM Power House

9. Cleaning of steam sparger pipe done. YES NO _______________________________________

10. Safety valves condition satisfied. YES NO _______________________________________

Deaerator Storage Vessel overall condition: _________________________________________________

Next Due Date: ___________________________

MAINTENANCE ENGINEER: __________________ MANAGER POWER HOUSE: _______________________

Page 12 of 18
BSPM Power House

Frequency: Annually

Equipment: Steam Drum


DATE: ______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 Cleaning of Drum Clean and inspect inside of Steam Drum.
2 Welding inspection Inspect weld of steam sparger pipes and its cleaning.
Inspect for loose
3 Visually inspect for loose bolts and clamps.
bolts and clamps
4 Supports condition Check for deformation of supports of steam sparger pipes.
5 Vessel condition Inspect vessel for corrosion and local cracks.

ACTION TO BE TAKEN

11. Cleaning of Steam drum performed. YES NO _______________________________________

12. Internal bolts and clamps found loose. YES NO _______________________________________

13. Corrosion and local cracks found. YES NO _______________________________________

Steam Drum overall condition: _________________________________________________

Next Due Date: ___________________________


Page 13 of 18
BSPM Power House


Boiler Feed Water Pump: ________________

Activity: NSD (non shut down)

DATE: ______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 Check coupling Thoroughly inspect coupling for signs of wear and cracks, Tighten bolts.
2 Alignment check Use the dial indicator to check the coupling alignment.
Pump not running - Standby service: Overfill bearing housing to bottom
3 Coating of shaft with oil of the shaft and rotate several turns by hand to coat the shaft and the
bearing with oil.
Apply a light coat of rust preventive product to expose machined surfaces
4 Rust preventive coating to prevent rust and corrosion.

Comments:


ANY
ACTION TO BE TAKEN

1. Coupling found OK. YES NO ______________________________________

2. Bolts found loose. YES NO ______________________________________

3. Need pump alignment. YES NO _______________________________________

4. Coating of shaft performed with oil. YES NO _______________________________________

5. Rust preventive coating performed. YES NO ______________________________________

Feed water pump overall condition: ________________________________________________

Next Due Date: ________________________________________________________


Page 14 of 18
BSPM Power House


HFO Booster Pump: ____________


DATE: ______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 Check coupling Thoroughly inspect coupling for signs of wear and cracks, Tighten bolts.
2 Alignment check Use the dial indicator to check the coupling alignment.
3 Apply a light coat of rust preventive product to expose machined surfaces
Rust preventive coating to prevent rust and corrosion.
Comments:


ANY
ACTION TO BE TAKEN

1. Coupling condition good. YES NO _______________________________________

2. Bolts found loose. YES NO _______________________________________

3. Need pump alignment. YES NO _______________________________________

4. Rust preventive coating performed. YES NO _______________________________________

HFO booster pump overall condition: _____________________________________________________

Next Due Date: __________________________________________________


Page 15 of 18
BSPM Power House


Soot Blower No: ______________


DATE: ______________

Sr. MAINTENANCE
1 Soot blower tube Inspect the surface of the inner tube. Lubricate and clean it if necessary
2 Gear Teeth Check wear of gear teeth, repair if necessary
Check looseness of Check looseness of bolts, nuts and fittings
3
bolts
4 Inspect glands Inspect glands and adjust/ replace if necessary
5 Inspect poppet valve Inspect poppet valve (lap the seat and disc if necessary)
Comments:


ANY
ACTION TO BE TAKEN

1. Need any lubrication. YES NO ________________________________________

2. Wear of gear teeth found. YES NO _______________________________________

3. Nuts and bolts tightened. YES NO _______________________________________

4. Glands found OK. YES NO _______________________________________

5. Poppet valve seat/ disc found damaged. YES NO _______________________________________

Soot blower overall condition: __________________________________________________________

Next Due Date: ________________________________________________


Page 16 of 18
BSPM Power House

Frequency: Annually

Piping (spring hangers)


DATE: ______________

Sr. MAINTENANCE
1 Welding points Check crack at welding parts where they are fixed and readjust the
travel if is abnormal.
Carry out inspection of all hangers and supports, replace if required.
2 Hangers and supports
Reinstall hangers if the installation is not proper.
3 Travel of hanger Readjust the travel if is abnormal.
Comments:


ANY
ACTION TO BE TAKEN

1. Crack found at welding part. Mention with
its location at 65 TPH YES NO _________________________________

2. Any hanger and support found damaged.
Mention its location YES NO ________________________________

3. Travel of hangers found OK.
If not then mention its location YES NO ________________________________

Piping (spring hangers) overall condition: _________________________________________________

Next Due Date: _____________________________________________


Page 17 of 18
BSPM Power House

Frequency: Annually

Safety Valves


DATE: ______________

Sr. MAINTENANCE
1 Check seat and plug Check seat and plug of the valve. Repair/ replace if necessary
2 Calibration Calibrate the valve at its set point (by Trevi Test method)
Comments:


ANY
ACTION TO BE TAKEN

1. Seat and plug condition found OK. YES NO ________________________________

2. Calibration by Trevi Test performed.

Mention with valve number and position. YES NO ________________________________

Safety valves overall condition: __________________________________________________________

Next Due Date: __________________________________________________________


Page 18 of 18
BSPM Power House

Annexure 3 ‐ Instrument Maintenance Forms
Page 8 of 10
BSPM Power House
200 TPH Preventive Maintenance
200 TPH Boiler Safety Set Points Check List
PACKAGES LIMITED
POWER HOUSE AREA(41MW) (371) Date:………………………
Sr No Tag No Description Service Line Set Point Remarks

1 PSHH 303 A/B Pressure Switch High High Furnace draft Pressure 2 mBar
2 PAHH 301 A/B Pressure Alarm High High Furnace draft Pressure 2 mBar
3 FSLL‐302 A/B Flow switch Low Low Combustion Air 0.4mBarg
4 FALL 301 A/B Flow Alarm low Low Combustion Air 0.4mBarg
5 PSHH‐601 A/b Pressure Switch High High Fuel Gas Main Line 2.0 bar
6 PAHH ‐601 A/B Pressure Alarm High High Fuel Gas Main Line 2.0 bar
7 PSLL 601 A/B Pressure Alarm Low Low Fuel Gas Main Line 0.03 bar
8 PALL‐601 A/B Pressue Alarm Low Low Fuel Gas Main Line 0.03 bar
9 PSH/L‐602 Pressure Switch High Low Gas Leake Proving 5 Barg
10 PAH‐501 Pressure Alarm High Pilot Gas 3.5 bar
11 PSL‐501 Pressure switch Low Pilot Gas 1 BAr
12 PSLL‐801 A/B Pressure Switch Low LOw Automizing Steam Pressure 0.5bar
13 PALL‐801 A/B Pressure Alarm Low Low Automizing Steam Pressure 0.5 Bar
14 PSL‐901 Pressure Switch Low Instrument Air Pressure 4.5 Bar
15 PSHH‐101 A/B Pressure Switch High High Boiler Drum Steam Pressure 116 Barg
16 PAHH‐101 A/B Pressure Alarm High High Boiler Drum Steam Pressure 116 Barg
17 TSHH‐801 A/B Tempertaure Switch High High Live Steam Temperature 555c
41 MW DCS Daily Checklist
BSPM Power House
AREA: 200 TPH Preventive Maintenance
PANEL:
Panel Doors properly locked Yes NO

CPU Status F R P B
Communication Modules (CI854, CI858) status OK Not OK
I/O Cards Status F R W O
Media Convertor status OK Showing Fault
Cable Glands/ Dead glands OK Glands Fixed
Panel Bottom Plate OK Repaired
lighting rods in working condition Yes Repaired Replaced
Panel properly sealed Yes Repaired
Panel fan working Yes Repaired Replaced
Cluster cabling properly dressed in front side Yes Dressed
Cluster cabling properly dressed in marshelling side Yes Dressed
Cable Duct status Covered Not covered
Is the Fiber optic cable secured inside DCS panel? Yes Covered
Is the Fiber optic cable secured in cable room? Yes Covered
General cable dressing in the panel OK Dressed
General cleanliness of the panel OK Cleaned
5/8/2011as
BSPM Power House
200 TPH Preventive maintenance
Daily Field Instruments Physical Condition Check List(41MW)

PACKAGES LIMITED
Date:
S No AREA Physical Condition Remarks
1 Fuel Gas
2 Air Compressor
3 HFO Day Tank
4 HFO Pre Heater
5 FD Fan
1 ID Fan
2 Burners
3 Economizer
4 Super Heater
5 Boiler Feed Pumps
6 Return Condensate Tank
7 Turbine
8 Condensate Tank
9 Vaccum Pump
10 Cooling Tower
11 Demin Water Plant
12 Water Chest
Checked By: Verified By:
BSPM Power House
41 MW PLC Daily Check List
Date:…………………………
Sr# Description Comments

1 Panel Doors properly locked Yes NO
2 Main Power Supply F R
3 CPU Power Supply F R
4 CPU -414-4H F R
5 Communication Module F R
6 Digital Input/Output Module F R
7 Analoge Inpu/out put Modules F R
8 Y Link Modules F R
9 Simatic ET200 Links F R
10 Cable Glands/ Dead glands OK Glands Fixed
11 Panel Bottom Plate OK Repaired
12 lighting rods in working condition Yes Repaired
13 Panel properly sealed Yes Repaired
14 Panel fan working Yes Repaired
15 Cluster cabling properly dressed in front side Yes Dressed
16 Cluster cabling properly dressed in marshelling side Yes Dressed
17 Cable Duct status Covered Not covered
18 Is the Fiber optic cable secured inside DCS panel? Yes Covered
19 Is the Fiber optic cable secured in cable room? Yes Covered
20 General cable dressing in the panel OK Dressed
21 Prifibus Cables OK Dressed
22 General cleanliness of the panel OK Cleaned
Checked By: Varified By:

BSPM Power House


Page 9 of 10
BSPM Power House
Burner No 1 Quarterly Inspection Sheet for ON OFF Valves 200TPH
PACKAGES LIMITED
POWER HOUSE AREA(41MW) (371) Date: ----------------------------
TAG NAME
Phycial
S No AREA Descrption Location Status Tag Sealing Leackages Remarks
Condiation
Burner No 1
1 371 ZSL 001A BURNER GUN POSITION LIMIT BURNER # 1
SWITCH
2 371 HT 001A IGNITION TRANSFORMER BURNER # 1

2 371 BE 001A PILOT BURNER EYE PILOT BURNER # 1
2 371 BSL 001A PILOT BURNER FLAME SENSOR PILOT BURNER # 1
3 371 BE 002A MAIN BURNER EYE BURNER # 1

3 371 BSL 002A MAIN BURNER FLAME SENSOR BURNER # 1
4 371 XSV 301A SOLENOID DAMPER SECONDARY AIR

DAMPER BURNER # 1
4 371 XSV 301B SOLENOID DAMPER SECONDARY AIR
DAMPER BURNER # 1
4 371 ZSL 301 LIMIT SWITCH LOW OF XSV-301 SECONDARY AIR
DAMPER BURNER # 1
4 371 ZSH 301 LIMIT SWITCH LOW OF XSV-301 SECONDARY AIR
DAMPER BURNER # 1
Poilt Line
5 371 XSV 503A SOLENOID OPERATED VALVE PILOT GAS VALE # 1
BURNER #1
5 371 XSV 504A SOLENOID OPERATED VALVE PILOT GAS VENT VALE
BURNER #1
5 371 XSV 505A SOLENOID OPERATED VALVE PILOT GAS VALE # 2
BURNER #1
BSPM Power House
PACKAGES LIMITED
Gas Line
6 371 XSV 604A SOLENOID OPERATED VALVE FUEL GAS VALE # 1
BURNER #1
6 371 ZSL 604A LIMIT SWITCH LOW OF XSV- FUEL GAS VALE # 1
604A BURNER #1
6 371 ZSH 604A LIMIT SWITCH HIGH OF XSV- FUEL GAS VALE # 1
604A BURNER #1
7 371 XSV 605A SOLENOID OPERATED VALVE FUEL GAS LINE VENT
VALE BURNER #1
7 371 ZSL 605A LIMIT SWITCH LOW OF XSV- FUEL GAS LINE VENT
605A VALE BURNER #1
7 371 ZSH 605A LIMIT SWITCH HIGH OF XSV- FUEL GAS LINE VENT
605A VALE BURNER #1
8 371 XSV 606A SOLENOID OPERATED VALVE FUEL GAS VALE # 2

BURNER #1
8 371 ZSL 606A LIMIT SWITCH LOW OF XSV- FUEL GAS VALE # 2
606A BURNER #1
8 371 ZSH 606A LIMIT SWITCH HIGH OF XSV- FUEL GAS VALE # 2
606A BURNER #1
9 371 XSV 705A SOLENOID OPERATED VALVE FUEL OIL TO BURNER # 1
9 371 ZSL 705A LIMIT SWITCH LOW OF XSV- FUEL OIL TO BURNER # 1
705A
9 371 ZSH 705A LIMIT SWITCH HIGH OF XSV- FUEL OIL TO BURNER # 1
705A
10 371 XSV 802A SOLENOID OPERATED VALVE ATOMIZING STEAM TO

BURNER # 1
10 371 ZSL 802A LIMIT SWITCH LOW OF XSV- ATOMIZING STEAM TO
802A BURNER # 1
10 371 ZSH 802A LIMIT SWITCH HIGH OF XSV- ATOMIZING STEAM TO
802A BURNER # 1
BSPM Power House
PACKAGES LIMITED
11 371 XSV 803A SOLENOID OPERATED VALVE ATOMIZING STEAM TO
GUN PURGING BURNER
#1
11 371 ZSL 803A LIMIT SWITCH LOW OF XSV- ATOMIZING STEAM TO
803A GUN PURGING BURNER
#1
11 371 ZSH 803A LIMIT SWITCH HIGH OF XSV- ATOMIZING STEAM TO
803A GUN PURGING BURNER
#1
Checked By: Varified By :

BSPM Power House
PACKAGES LIMITED Date: ----------------------------
Phycial
S No AREA TAG NAME Descrption Location Status Tag Sealing Leackages Remarks
Condiation
Burner No 2
1 371 ZSL 001B BURNER GUN POSITION LIMIT BURNER # 2
SWITCH
2 371 HT 001B IGNITION TRANSFORMER BURNER # 2

2 371 BE 001B PILOT BURNER EYE PILOT BURNER # 2
2 371 BSL 001B PILOT BURNER FLAME PILOT BURNER # 2
SENSOR
3 371 BE 002B MAIN BURNER EYE BURNER # 2

3 371 BSL 002B MAIN BURNER FLAME SENSOR BURNER # 2

DAMPER BURNER #
2
DAMPER BURNER #
2
4 371 ZSL 302 LIMIT SWITCH LOW OF XSV- SECONDARY AIR
302 DAMPER BURNER #
2
4 371 ZSH 302 LIMIT SWITCH LOW OF XSV- SECONDARY AIR
302 DAMPER BURNER #
2
Poilt Line
BSPM Power House

Phycial
Condiation
5 371 XSV 503B SOLENOID OPERATED VALVE PILOT GAS VALE # 1
BURNER #2
5 371 XSV 504B SOLENOID OPERATED VALVE PILOT GAS VENT
VALE BURNER #2
5 371 XSV 505B SOLENOID OPERATED VALVE PILOT GAS VALE # 2
BURNER #2
Gas Line
6 371 XSV 604B SOLENOID OPERATED VALVE FUEL GAS VALE # 1
BURNER #2
6 371 ZSL 604B LIMIT SWITCH LOW OF XSV- FUEL GAS VALE # 1
604B BURNER #2
6 371 ZSH 604B LIMIT SWITCH HIGH OF XSV- FUEL GAS VALE # 1
604B BURNER #2
7 371 XSV 605B SOLENOID OPERATED VALVE FUEL GAS LINE

VENT VALE BURNER
#2
7 371 ZSL 605B LIMIT SWITCH LOW OF XSV- FUEL GAS LINE
605B VENT VALE BURNER
#2
7 371 ZSH 605B LIMIT SWITCH HIGH OF XSV- FUEL GAS LINE
605B VENT VALE BURNER
#2
8 371 XSV 606B SOLENOID OPERATED VALVE FUEL GAS VALE # 2

BURNER #2
8 371 ZSL 606B LIMIT SWITCH LOW OF XSV- FUEL GAS VALE # 2
606B BURNER #2
8 371 ZSH 606B LIMIT SWITCH HIGH OF XSV- FUEL GAS VALE # 2
606B BURNER #2
9 371 XSV 705B SOLENOID OPERATED VALVE FUEL OIL TO
BURNER # 2
BSPM Power House

Phycial
Condiation
9 371 ZSL 705B LIMIT SWITCH LOW OF XSV- FUEL OIL TO
705B BURNER # 2
9 371 ZSH 705B LIMIT SWITCH HIGH OF XSV- FUEL OIL TO
705B BURNER # 2
10 371 XSV 802B SOLENOID OPERATED VALVE ATOMIZING STEAM

TO BURNER # 2
10 371 ZSL 802B LIMIT SWITCH LOW OF XSV- ATOMIZING STEAM
802B TO BURNER # 2
10 371 ZSH 802B LIMIT SWITCH HIGH OF XSV- ATOMIZING STEAM
802B TO BURNER # 2
11 371 XSV 803B SOLENOID OPERATED VALVE ATOMIZING STEAM

TO GUN PURGING
BURNER#2
11 371 ZSL 803B LIMIT SWITCH LOW OF XSV- ATOMIZING STEAM
803B TO GUN PURGING
BURNER#2
11 371 ZSH 803B LIMIT SWITCH HIGH OF XSV- ATOMIZING STEAM
803B TO GUN PURGING
BURNER#2

BSPM Power House
Phycial
Condiation
Burner No 3
1 371 ZSL 001C BURNER GUN POSITION LIMIT BURNER # 3
SWITCH
2 371 HT 001C IGNITION TRANSFORMER BURNER # 3

2 371 BE 001C PILOT BURNER EYE PILOT BURNER # 3
2 371 BSL 001C PILOT BURNER FLAME PILOT BURNER # 3
SENSOR
3 371 BE 002C MAIN BURNER EYE BURNER # 3

3 371 BSL 002C MAIN BURNER FLAME SENSOR BURNER # 3

DAMPER BURNER #
3
DAMPER BURNER #
3
4 371 ZSL 303 LIMIT SWITCH LOW OF XSV-303 SECONDARY AIR
DAMPER BURNER #
3
4 371 ZSH 303 LIMIT SWITCH LOW OF XSV-303 SECONDARY AIR
DAMPER BURNER #
3
Poilt Line
5 371 XSV 503C SOLENOID OPERATED VALVE PILOT GAS VALE # 1
BURNER #3
BSPM Power House

Phycial
Condiation
5 371 XSV 504C SOLENOID OPERATED VALVE PILOT GAS VENT
VALE BURNER #3
5 371 XSV 505C SOLENOID OPERATED VALVE PILOT GAS VALE # 2
BURNER #3
Gas Line
6 371 XSV 604C SOLENOID OPERATED VALVE FUEL GAS VALE # 1
BURNER #3
6 371 ZSL 604C LIMIT SWITCH LOW OF XSV- FUEL GAS VALE # 1
604C BURNER #3
6 371 ZSH 604C LIMIT SWITCH HIGH OF XSV- FUEL GAS VALE # 1
604C BURNER #3
7 371 XSV 605C SOLENOID OPERATED VALVE FUEL GAS LINE

VENT VALE BURNER
#3
7 371 ZSL 605C LIMIT SWITCH LOW OF XSV- FUEL GAS LINE
605C VENT VALE BURNER
#3
7 371 ZSH 605C LIMIT SWITCH HIGH OF XSV- FUEL GAS LINE
605C VENT VALE BURNER
#3
8 371 XSV 606C SOLENOID OPERATED VALVE FUEL GAS VALE # 2

BURNER #3
8 371 ZSL 606C LIMIT SWITCH LOW OF XSV- FUEL GAS VALE # 2
606C BURNER #3
8 371 ZSH 606C LIMIT SWITCH HIGH OF XSV- FUEL GAS VALE # 2
606C BURNER #3
9 371 XSV 705C SOLENOID OPERATED VALVE FUEL OIL TO
BURNER # 3
9 371 ZSL 705C LIMIT SWITCH LOW OF XSV- FUEL OIL TO
705C BURNER # 3
9 371 ZSH 705C LIMIT SWITCH HIGH OF XSV- FUEL OIL TO
705C BURNER # 3
BSPM Power House

Phycial
Condiation
10 371 XSV 802C SOLENOID OPERATED VALVE ATOMIZING STEAM

TO BURNER # 3
10 371 ZSL 802C LIMIT SWITCH LOW OF XSV- ATOMIZING STEAM
802C TO BURNER # 3
10 371 ZSH 802C LIMIT SWITCH HIGH OF XSV- ATOMIZING STEAM
802C TO BURNER # 3
11 371 XSV 803C SOLENOID OPERATED VALVE ATOMIZING STEAM

TO GUN PURGING
BURNER # 3
11 371 ZSL 803C LIMIT SWITCH LOW OF XSV- ATOMIZING STEAM
803C TO GUN PURGING
BURNER # 3
11 371 ZSH 803C LIMIT SWITCH HIGH OF XSV- ATOMIZING STEAM
803C TO GUN PURGING
BURNER # 3

BSPM Power House
TAG NAME
Phycial
Condiation
Burner No 4
1 371 ZSL 001D BURNER GUN POSITION LIMIT BURNER # 4
SWITCH
2 371 HT 001D IGNITION TRANSFORMER BURNER # 4

2 371 BE 001D PILOT BURNER EYE PILOT BURNER # 4
2 371 BSL 001D PILOT BURNER FLAME PILOT BURNER # 4
SENSOR
3 371 BE 002D MAIN BURNER EYE BURNER # 4

3 371 BSL 002D MAIN BURNER FLAME BURNER # 4
SENSOR

DAMPER BURNER
#4
DAMPER BURNER
#4
4 371 ZSL 304 LIMIT SWITCH LOW OF XSV- SECONDARY AIR
304 DAMPER BURNER
#4
4 371 ZSH 304 LIMIT SWITCH LOW OF XSV- SECONDARY AIR
304 DAMPER BURNER
#4
Poilt Line
BSPM Power House

TAG NAME
Phycial
Condiation
5 371 XSV 503D SOLENOID OPERATED VALVE PILOT GAS VALE #
1 BURNER #4
5 371 XSV 504D SOLENOID OPERATED VALVE PILOT GAS VENT
VALE BURNER #4
5 371 XSV 505D SOLENOID OPERATED VALVE PILOT GAS VALE #
2 BURNER #4
Gas Line
6 371 XSV 604D SOLENOID OPERATED VALVE FUEL GAS VALE # 1
BURNER #4
6 371 ZSL 604D LIMIT SWITCH LOW OF XSV- FUEL GAS VALE # 1
604D BURNER #4
6 371 ZSH 604D LIMIT SWITCH HIGH OF XSV- FUEL GAS VALE # 1
604D BURNER #4
7 371 XSV 605D SOLENOID OPERATED VALVE FUEL GAS LINE

VENT VALE
BURNER #4
7 371 ZSL 605D LIMIT SWITCH LOW OF XSV- FUEL GAS LINE
605D VENT VALE
BURNER #4
7 371 ZSH 605D LIMIT SWITCH HIGH OF XSV- FUEL GAS LINE
605D VENT VALE
BURNER #4
8 371 XSV 606D SOLENOID OPERATED VALVE FUEL GAS VALE # 2

BURNER #4
8 371 ZSL 606D LIMIT SWITCH LOW OF XSV- FUEL GAS VALE # 2
606D BURNER #4
8 371 ZSH 606D LIMIT SWITCH HIGH OF XSV- FUEL GAS VALE # 2
606D BURNER #4
9 371 XSV 705D SOLENOID OPERATED VALVE FUEL OIL TO
BURNER # 4
9 371 ZSL 705D LIMIT SWITCH LOW OF XSV- FUEL OIL TO
705D BURNER # 4
BSPM Power House

TAG NAME
Phycial
Condiation
9 371 ZSH 705D LIMIT SWITCH HIGH OF XSV- FUEL OIL TO
705D BURNER # 4
ATOMIZING STEAM TO BURNER # 4
10 371 XSV 802D SOLENOID OPERATED VALVE
10 371 ZSL 802D LIMIT SWITCH LOW OF XSV-
802D
10 371 ZSH 802D LIMIT SWITCH HIGH OF XSV-
802D
11 371 XSV 803D SOLENOID OPERATED VALVE ATOMIZING STEAM

TO GUN PURGING
BURNER # 4
11 371 ZSL 803D LIMIT SWITCH LOW OF XSV- ATOMIZING STEAM
803D TO GUN PURGING
BURNER # 4
11 371 ZSH 803D LIMIT SWITCH HIGH OF XSV- ATOMIZING STEAM
803D TO GUN PURGING
BURNER # 4

BSPM Power House
200 TPH Boiler Preventive Maintenance
Quarterly Inspection Sheet for Motorized Control Valves 200 TPH
PACKAGES LIMITED
POWER HOUSE AREA(41MW) (371) Date:---------------------------------
Physical
S No TAG NAME Descrption Location Operation Remarks
Condition
1 TCV 301 TEMPERATURE CONTROL VALVE STEAM AIR HEATER LINE

2 LCV 101A LEVEL CONTROL VALVE BOILER FEED WATER LINE
3 LCV 101B LEVEL CONTROL VALVE BOILER FEED WATER LINE
4 LCV 101C LEVEL CONTROL VALVE BOILER FEED WATER LINE
5 CCV 101 CONDUCTIVITY CONTROL VALVE SAMPLE COOLER - 03

6 LCV 102 LEVEL CONTROL VALVE FEED WATER HEATER
7 DSH 101 DE-SUPER HEATER SUPER HEATER # 1,
OUTLET
8 DSHV 101 DE-SUPER HEATING VALVE SUPER HEATER # 2,
OUTLET
9 DSH 102 DE-SUPER HEATER NOZZLE STEAM HEADER
10 DSHV 102 DE-SUPER HEATING VALVE STEAM HEADER
11 TSHH 101A TEMPERATURE SWITCH HIGH-HIGH STEAM HEADER
12 TSHH 101B TEMPERATURE SWITCH HIGH-HIGH STEAM HEADER
13 TCV 110 TEMPERATURE CONTROL VALVE FWH (HEATING STEAM
LINE)
14 SHV 101 START-UP HEATING VALVE SUPER HEATED STEAM
15 MOV 101 MOTORIZED VALVE MAIN STEAM HEADER
BSPM Power House
PACKAGES LIMITED
16 MOV 102 MOTORIZED VALVE (BYPASS) MAIN STEAM HEADER

17 MOV 201 MOTORIZED VALVE (LEVEL) DE-AERATOR TANK LEVEL
18 PCV 201 PRESSURE CONTROL VALVE DE-AERATOR TANK

19 LCV 201 LEVEL CONTROL VALVE FLASH VESSEL

BSPM Power House
PACKAGES LIMITED
Physical
S No TAG NAME Descrption Location Operation Remarks
Condition
1 TCV 301 TEMPERATURE CONTROL VALVE STEAM AIR HEATER LINE

2 LCV 101A LEVEL CONTROL VALVE BOILER FEED WATER LINE
3 LCV 101B LEVEL CONTROL VALVE BOILER FEED WATER LINE
4 LCV 101C LEVEL CONTROL VALVE BOILER FEED WATER LINE
5 CCV 101 CONDUCTIVITY CONTROL VALVE SAMPLE COOLER - 03

6 LCV 102 LEVEL CONTROL VALVE FEED WATER HEATER
7 DSH 101 DE-SUPER HEATER SUPER HEATER # 1,
OUTLET
8 DSHV 101 DE-SUPER HEATING VALVE SUPER HEATER # 2,
OUTLET
9 DSH 102 DE-SUPER HEATER NOZZLE STEAM HEADER
10 DSHV 102 DE-SUPER HEATING VALVE STEAM HEADER
11 TSHH 101A TEMPERATURE SWITCH HIGH-HIGH STEAM HEADER
12 TSHH 101B TEMPERATURE SWITCH HIGH-HIGH STEAM HEADER
13 TCV 110 TEMPERATURE CONTROL VALVE FWH (HEATING STEAM
LINE)
14 SHV 101 START-UP HEATING VALVE SUPER HEATED STEAM
15 MOV 101 MOTORIZED VALVE MAIN STEAM HEADER
16 MOV 102 MOTORIZED VALVE (BYPASS) MAIN STEAM HEADER
BSPM Power House
PACKAGES LIMITED
17 MOV 201 MOTORIZED VALVE (LEVEL) DE-AERATOR TANK LEVEL
18 PCV 201 PRESSURE CONTROL VALVE DE-AERATOR TANK

19 LCV 201 LEVEL CONTROL VALVE FLASH VESSEL

BSPM Power House
Quarterly Inspection Sheet Field Instruments(200 TPH)
PACKAGES LIMITED
Date:
S No AREA TAG NAME Descrption Location Ranges Status Tag Sealing Phycial Condiation Leackages Remarks
Level Probs
1 371 LE CONDUCTIVITY TYPE LEVEL PROBE BOILER DRUM LEVEL
2 371 LSEH 101 LEVEL SWITCH EXTRA HIGH BOILER DRUM LEVEL
3 371 LSHH 101 LEVEL SWITCH HIGH-HIGH BOILER DRUM LEVEL
4 371 LSLL 101 LEVEL SWITCH LOW-LOW BOILER DRUM LEVEL
5 371 LSEL 101 LEVEL SWITCH EXTRA LOW BOILER DRUM LEVEL
Pressure Transmitter
1 371 PT 301 PRESSURE TRANSMITTER STEAM AIR HEATER
302 A
2 371 PT PRESSURE TRANSMITTER FURNACE DRAFT PRESSURE
&B
3 371 PT 602 PRESSURE TRANSMITTER FUEL GAS MAIN LINE
701A/
4 371 PT PRESSURE TRANSMITTER FUEL OIL LINE
B
801A/
5 371 PT PRESSURE TRANSMITTER ATOMIZING STEAM LINE
B
6 371 DPI 601 DIFFERENTIAL PRESSURE GAUGE FUEL GAS MAIN LINE
801A/ ATOMIZING STEAM & FUEL OIL
7 371 DPT DIFFERENTIAL PRESSURE TRANSMITTER
B LINE
603
8 371 PT PRESSURE TRANSMITTER FUEL GAS MAIN LINE
A/B
FUEL OIL RECIRCULATION
9 371 PT 702 PRESSURE TRANSMITTER
LINE
10 371 PT 303 PRESSURE TRANSMITTER
HEATER
11 371 PT 101 PRESSURE TRANSMITTER BOILER DRUM PRESSURE
12 371 PT 102A PRESSURE TRANSMITTER STEAM HEADER
13 371 PT 102B PRESSURE TRANSMITTER STEAM HEADER
14 371 PT 103 PRESSURE TRANSMITTER BOILER FEED WATER LINE
201A/
15 371 PT PRESSURE TRANSMITTER DE-AERATOR TANK
B
Flow Transmitter
COMBUSTION AIR TO
1 371 FT 301A FLOW TRANSMITTER (ORIFICE TYPE)
BURNERS
COMBUSTION AIR TO
2 371 FT 301B FLOW TRANSMITTER (ORIFICE TYPE)
BURNERS
COMBUSTION AIR TO
3 371 FT 301C FLOW TRANSMITTER (ORIFICE TYPE)
BURNERS
COMBUSTION AIR TO
4 371 FT 301D FLOW TRANSMITTER (ORIFICE TYPE)
BURNERS
301 A COMBUSTION AIR TO
5 371 FSLL FLOW SWITCH LOW LOW
&B BURNERS
BSPM Power House
PACKAGES LIMITED
Date:
6 371 FT 602A FLOW TRANSMITTER (ORIFICE TYPE) FUEL GAS LINE
7 371 FT 602B FLOW TRANSMITTER (ORIFICE TYPE) FUEL GAS LINE
8 371 FT 703A FLOW TRANSMITTER FUEL OIL LINE
9 371 FT 703B FLOW TRANSMITTER FUEL OIL LINE
10 371 FT 101A FLOW TRANSMITTER BOILER FEED WATER LINE
11 371 FT 101B FLOW TRANSMITTER BOILER FEED WATER LINE
12 371 FT 102A FLOW TRANSMITTER MAIN STEAM HEADER
13 371 FT 102B FLOW TRANSMITTER MAIN STEAM HEADER
Temperature Transmitter
301A/
1 371 TT TEMPERATURE TRANSMITTER STEAM AIR HEATER
B
2 371 TT 302 TEMPERATURE TRANSMITTER ECO # 01 OUTLET
3 371 TT 303 TEMPERATURE TRANSMITTER ECO # 02 INLET
4 371 TT 304 TEMPERATURE TRANSMITTER ID-FAN INLET
5 371 TT 305 TEMPERATURE TRANSMITTER COMBUSTION AIR
6 371 TT 306 TEMPERATURE TRANSMITTER
HEATER
7 371 TT 602 TEMPERATURE TRANSMITTER FUEL GAS LINE
8 371 TT 701 TEMPERATURE TRANSMITTER FUEL OIL LINE
BOILER SKIN TEMPERATURE
9 371 TT 101A TEMPERATURE ELEMENT
FRONT
BOILER SKIN TEMPERATURE
10 371 TT 101B TEMPERATURE ELEMENT
BACK
11 371 TT 102 TEMPERATURE ELEMENT SUPER HEATER # 1, INLET
12 371 TT 103 TEMPERATURE TRANSMITTER SUPER HEATER # 1, OUTLET
13 371 TT 104 TEMPERATURE TRANSMITTER SUPER HEATER # 2, INLET
14 371 TT 105A TEMPERATURE TRANSMITTER SUPER HEATER # 2, OUTLET
15 371 TT 105B TEMPERATURE TRANSMITTER SUPER HEATER # 2, OUTLET
16 371 TT 106 TEMPERATURE TRANSMITTER SUPER HEATER # 3, OUTLET
17 371 TT 107 TEMPERATURE TRANSMITTER SUPER HEATER # 3, INLET
18 371 TT 108A TEMPERATURE TRANSMITTER STEAM HEADER
19 371 TT 108B TEMPERATURE TRANSMITTER STEAM HEADER
20 371 TT 109 TEMPERATURE TRANSMITTER FEED WATER HEATER
21 371 TT 110A TEMPERATURE TRANSMITTER FEED WATER B/ECO.
22 371 TT 110B TEMPERATURE TRANSMITTER FEED WATER B/ECO.
23 371 TT 111 TEMPERATURE TRANSMITTER FEED WATER A/ECO.# 2
24 371 TT 112 TEMPERATURE TRANSMITTER FEED WATER A/ECO # 1
25 371 TT 113 TEMPERATURE TRANSMITTER Flue Gas B/ECO # 1
26 371 TT 114A TUBE SKIN TEMPERATURE SUPER HEATER # 1
27 371 TT 114B TUBE SKIN TEMPERATURE SUPER HEATER # 1
28 371 TT 114C TUBE SKIN TEMPERATURE SUPER HEATER # 1
35 371 TT 201 TEMPERATURE TRANSMITTER DE-AERATOR TANK
BSPM Power House
PACKAGES LIMITED
Date:
36 371 TT 202 TEMPERATURE TRANSMITTER DEMIN WATER TO DEAERATOR
37 371 TT 203 TEMPERATURE TRANSMITTER CONDENSATE RETURN LINE
38 371 TT 204 TEMPERATURE TRANSMITTER DEAERATOR HEATING STEAM
Level Transmitter
1 371 LT 101A LEVEL TRANSMITTER BOILER DRUM LEVEL
2 371 LT 101B LEVEL TRANSMITTER BOILER DRUM LEVEL
3 371 LT 101C LEVEL TRANSMITTER BOILER DRUM LEVEL
4 371 LT 102 LEVEL TRANSMITTER FEED WATER HEATER
5 371 LT 201A LEVEL TRANSMITTER DE-AERATOR TANK LEVEL
6 371 LT 201B LEVEL TRANSMITTER DE-AERATOR TANK LEVEL
7 371 LT 201C LEVEL TRANSMITTER DE-AERATOR TANK LEVEL
8 371 LT 202 LEVEL TRANSMITTER FLASH VESSEL
9 371 LT 102 LEVEL TRANSMITTER FEED WATER HEATER
Presure Switches
1 371 PSHH 301A PRESSURE SWITCH HIGH-HIGH FURNACE DRAFT PRESSURE
2 371 PSHH 301B PRESSURE SWITCH HIGH-HIGH FURNACE DRAFT PRESSURE
3 371 PSH 501 PRESSURE SWITCH HIGH PILOT GAS MAIN LINE
4 371 PSL 501 PRESSURE SWITCH LOW PILOT GAS MAIN LINE
5 371 PSLL 601A PRESSURE SWITCH LOW LOW FUEL GAS MAIN LINE
6 371 PSLL 601B PRESSURE SWITCH LOW LOW FUEL GAS MAIN LINE
7 371 PSHH 601A PRESSURE SWITCH HIGH HIGH FUEL GAS MAIN LINE
8 371 PSHH 601B PRESSURE SWITCH HIGH HIGH FUEL GAS MAIN LINE
701A/
9 371 PSLL PRESSURE SWITCH LOW FUEL OIL LINE
B
10 371 PSH/L 602 PRESSURE SWITCH FUEL GAS LINE LEAK PROVING
801A/
11 371 PSLL PRESSURE SWITCH LOW LOW ATOMIZING STEAM MAIN LINE
B
COOLING FAN PRESSURE SWITCH
12 371 PSL 603 COOLING FAN
(BURNERS)
COOLING FAN PRESSURE ALARM LOW
13 371 PAL 603 COOLING FAN
(BURNERS)
14 371 PSL 901 PRESSURE SWITCH - LOW INSTRUMENT AIR
15 371 PSHH 101A PRESSURE SWITCH HIGH-HIGH BOILER DRUM PRESSURE
16 371 PSHH 101B PRESSURE SWITCH HIGH-HIGH BOILER DRUM PRESSURE
17 371 PSLL 101A PRESSURE SWITCH LOW-LOW BOILER FEED WATER LINE
18 371 PSLL 101B PRESSURE SWITCH LOW-LOW BOILER FEED WATER LINE
19 371 PSL 104 PRESSURE SWITCH LOW M.P Steam to Soot blowers

BSPM Power House
200 TPH Boiler Preventive maintenance
Quarterly Inspection Sheet Temperature and Pressure Gauges 200 TPH

PACKAGES LIMITED
Date:
Phycial
Condiation
Level Gauge
1 371 LG 301 LEVEL GAUGE GLASS STEAM AIR HEATER
2 371 LG 101A LEVEL GAUGE GLASS BOILER DRUM LEVEL
3 371 LG 101B LEVEL GAUGE GLASS BOILER DRUM LEVEL
4 371 LG 102 LEVEL GAUGE GLASS FEED WATER HEATER
5 371 LG 201 LEVEL GAUGE GLASS DE-AERATOR TANK LEVEL
6 371 LG 202 LEVEL GAUGE GLASS FLASH VESSEL
Pressure Indicators
1 371 PI 301 PRESSURE GAUGE FURNACE DRAFT PRESSURE
2 371 PI 302 PRESSURE GAUGE ID FAN INLET
COMBUSTION AIR FD FAN
3 371 PI 303 PRESSURE GAUGE
OUTLET
PRE HEATER
5 371 PI 501 PRESSURE GAUGE PILOT GAS MAIN LINE
PRESSURE GAUGE ON PRV- PILOT GAS TRAIN TO BURNER
6 371 PI 502A
502A #1
7 371 PI 502B
502B #2
8 371 PI 502C
502C #3
9 371 PI 502D
502D #4
10 371 PI 601 PRESSURE GAUGE FUEL GAS MAIN LINE
11 371 PI 602 PRESSURE GAUGE FUEL GAS MAIN LINE
12 371 PI 603A PRESSURE GAUGE FUEL GAS LINE BURNER # 1
13 371 PI 603B PRESSURE GAUGE FUEL GAS LINE BURNER # 2
14 371 PI 603C PRESSURE GAUGE FUEL GAS LINE BURNER # 3
15 371 PI 603D PRESSURE GAUGE FUEL GAS LINE BURNER # 4
16 371 PI 701A PRESSURE GAUGE FUEL OIL LINE
17 371 PI 701B PRESSURE GAUGE FUEL OIL LINE
18 371 PI 702 PRESSURE GAUGE FUEL OIL LINE
21 371 PI 705A PRESSURE GAUGE FUEL OIL LINE TO BURNER # 1
BSPM Power House

PACKAGES LIMITED
Date:
22 371 PI 705B PRESSURE GAUGE FUEL OIL LINE TO BURNER # 2
23 371 PI 705C PRESSURE GAUGE FUEL OIL LINE TO BURNER # 3
24 371 PI 705D PRESSURE GAUGE FUEL OIL LINE TO BURNER # 4

25 371 PI 706 PRESSURE GAUGE AFTER OIL HEATING UNIT
26 371 DPI 701 FUEL OIL LINE
GAUGE
27 371 DPI 702 FUEL OIL LINE
GAUGE
28 371 PI 802 PRESSURE GAUGE ATOMIZING STEAM MAIN LINE
29 371 PI 803 PRESSURE GAUGE ATOMIZING STEAM MAIN LINE

ATOMIZING STEAM TO
30 371 PI 804A PRESSURE GAUGE
BURNER # 1
ATOMIZING STEAM TO
31 371 PI 804B PRESSURE GAUGE
BURNER # 2
ATOMIZING STEAM TO
32 371 PI 804C PRESSURE GAUGE
BURNER # 3
ATOMIZING STEAM TO
33 371 PI 804D PRESSURE GAUGE
BURNER # 4
COOLING FAN PRESSURE
34 371 PI 604 COOLING FAN
GAUGE (BURNERS)
35 371 PI 305 PRESSURE GAUGE BURNER # 3
39 371 PI 901 PRESSURE GAUGE INSTRUMENT AIR
FEED WATER PUMP # 1
40 371 PI 101A PRESSURE GAUGE
DISCHARGE
FEED WATER PUMP # 2
41 371 PI 101B PRESSURE GAUGE
DISCHARGE
42 371 PI 101C PRESSURE GAUGE FEED WATER PUMP SUCTION
43 371 PI 101D PRESSURE GAUGE FEED WATER PUMP SUCTION

44 371 PI 102 PRESSURE GAUGE FEED WATER HEATER
45 371 PI 103 PRESSURE GAUGE BOILER DRUM PRESSURE
46 371 PI 104 PRESSURE GAUGE STEAM HEADER
BSPM Power House

PACKAGES LIMITED
Date:
FEED WATER LINE AFTER
ECO # 2
48 371 PI 106 PRESSURE GAUGE SUPER HEATER # 1, INLET
49 371 PI 107 PRESSURE GAUGE SUPER HEATER # 1, OUTLET
54 371 PI 201 PRESSURE GAUGE DE-AERATOR TANK
DEMIN WATER (INLET DE-
AERATOR TANK)
56 371 PI 203 PRESSURE GAUGE DEAERATOR HEATING STEAM
57 371 PI 204 PRESSURE GAUGE FLASH VESSEL
Temperature Gauge
1 371 TI 303 TEMPERATURE GAUGE FLUE GASES ID FAN INLET
2 371 TI 304 TEMPERATURE GAUGE COMBUSTION AIR
371 TI 305 TEMPERATURE GAUGE
3 HEATER
4 371 TI 701 TEMPERATURE GAUGE FUEL OIL LINE
5 371 TI 702 TEMPERATURE GAUGE FUEL OIL LINE

BSPM Power House

Annexure 5 ‐ Electrical Maintenance Forms

Page 10 of 10
BSPM Power House
DAILY CHECKING OF UTILITY AND POWER PLANT MOTORS

Date:___________________
S.# TAG# RATED(A) LOAD% SOUND VIBRATION TEMP COVER REMARKS
UTILITY AREA
1 371-1001 42.5
2 371-1004 56
3 371-1005 56
4 371-1006 56
5 371-1022 42.5
6 351-1201 295
7 351-1202 295
8 351-1203 295
9 351-1204 295
10 371-3029 68
11 371-3030 68
12 Tube well #1 140
13 Tube well #2 140
14 Tube well #3 140
15 Tube well #4 140
16 Air Comp #1 615
17 Air Comp #2 540
18 Air Comp #3 540
19 Air Comp #4 540
20 F/W pump#1 65TPH 130
21 F/W pump#2 65TPH 130
22 FD FAN#1 65TPH 158
23 FD FAN#2 65TPH 158
24 F/W pump#1 30TPH 210
25 F/W pump#2 30TPH 210
200TPH BOILER
26 ID Fan-200TPH 385
27 FD Fan-200TPH 550
28 F.W-PU-01A 900
29 F.W-PU-01B 900
30 F.W-PU-01C 900
31 371- 3027 RC 187
32 371- 3028 RC 187
33 CW pump#1 610
34 CW pump#2 610
35 CW pump#3 610
36 CW pump#4 610
37 CT Fan # 1 87
38 CT Fan # 2 87
BSPM Power House

Date:___________________
UTILITY AREA
39 CT Fan # 3 87
40 CT Fan # 4 87
41 CT Fan # 5 87
42 CT Fan # 6 87
43 CT Fan # 7 87
44 CT Fan # 8 87
45 CT Fan # 9 87
46 HFO 371-7047 21.1
47 HFO 371-7048 21.1
48 Dosing Pump LP 0.45
52 371- 3091 27
53 371- 3092 27
41MW TURBINE
54 Condensate pump #1 128
55 Condensate Pump #2 128
56 EMERGENCY OIL PUMP 7.4
57 AUXILIARY OIL PUMP 86
58 OIL TANK FAN 3.3
59 Turning Gear Motor 41.5
60 Jacking Oil Pump 8.2
MCC AC CHECKING
Sr# Description Status PF Remarks
1 41MW
2 Air comp
3 Demin plant
4 Water chest
5 DCS power house
6 11MW MCC
7 11MW HT
8 11MW control room
9 65TPH boiler
VFD TEMP
Sr# Description TEMP RPM FAN Remarks
1 ID Fan-200TPH
2 FD Fan-200TPH
3 F.W-PU-01A
4 F.W-PU-01B
5 F.W-PU-01C
6 CW pump#1
BSPM Power House

Date:___________________
UTILITY AREA
7 CW pump#2
8 351-1201
Checked by. Approved by.

BSPM Power House
CHECK LIST FOR MOTORS AND MCC PM,S
Duration= One year
65TPH BOILER Date:………………………………..
OMS (pvt) Limited
INSULATION RESISTANCE WINDING RESISTANCE CABLE MAGGERING CONNECTION

S.NO TAG NO CONTACTOR UMC‐22 CLEANING REMARKS
TIGHTNING
L1‐E L2‐E L3‐E U1‐U2 V1‐V2 W1‐W2 R‐E Y‐E B‐E
1 PU-01A
2 PU-02B
3 Oil heating pump#1
4 Oil heating pump#2
5 FD-FAN#1
6 FD-FAN#2
7 SB-01
8 SB-02
9 SB-03
10 SB-04
11 MP 371-1002
12 MP 371-1003
13 65TPHLDB
14 65TPHLDB
15
BBSSPPM
M PPo
owwe
err H
Hoouusse
e
4411 M
MW W SStte eaam
m TTuurrb biinne
e
PPrre
evveennttiivve
eM Maaiinntte
ennaannccee
PPrroocce
edduurree
RReevv 00
April, 2011
BSPM Power House

Table of Contents
Abbreviations: ................................................................................................................................................ 3
Objective: ....................................................................................................................................................... 4
Methodology .................................................................................................................................................. 4
Annexure 1 – Mechanical Maintenance Forms .............................................................................................. 6
Annexure 3 ‐ Instrument Maintenance Forms ............................................................................................... 8
Annexure 4 ‐ Electrical Maintenance Forms ................................................................................................... 9

Page 2 of 9
BSPM Power House

Abbreviations:

H High
HH High High
I/O Input / Output
L Low
LL Low Low

Page 3 of 9
BSPM Power House

Objective:
The objective of this procedure is to define predetermined maintenance work to a schedule with the aim

5. Reduce injury

Methodology
Preventive maintenance was distributed in daily, weekly, monthly, quarterly and annual activities. All
required forms are attached as annexure 1, 2 & 3.

o Daily, Weekly and Monthly routine maintenance forms
o Quarterly and Annual routine maintenance forms
o Instrument Maintenance Forms

Page 4 of 9
BSPM Power House

Time for PM
Initiated by time with reference to
Last PM
Inform Maintenance Team
Leader
Shut Down Required Yes
PM will inform BSPM
Yes or No
No
Yes
Yes / No
No
Inform Shift Incharge
Sign LOTO
Perform Preventive Maintenance Job
Install Sticker for Job execution date
and next due date
Complete Activity Form
Closing by Maintenance Team
Leader and Plant Manager

Page 5 of 9
BSPM Power House


Page 6 of 9
41 MW Steam Turbine
Department: POWER HOUSE Ref. # OMS-AOP-18

Equipment: AUXILIARY OIL PUMP KKS # MAV15 AP110
Company: ALLWEILER, Germany, Type: SND Month: _________,2011

# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
2- Visually check for shaft seal leakage NSD

DAILY
3- Check bearing temperature NSD

Suction and pressure pipelines must be
4- NSD
checked for leaks
INSPECTIONER
Comments:
_______________________________ _________________________________
41 MW Steam Turbine
Department: POWER HOUSE Ref. # OMS-EOP-17

Equipment: EMERGENCY OIL PUMP KKS # MAV25 AP110
Company: ALLWEILER, Germany, Type: VKF 280-43 Month: _________,2011

# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

DAILY

Suction and pressure pipelines must be
4- NSD
checked for leaks
INSPECTIONER
Comments:
_______________________________ _________________________________
41 MW Steam Turbine
Department: POWER HOUSE Ref. # OMS-JOP-16

Equipment: JACKING OIL PUMP KKS # MAV70 AP110
Company: PARKER Hannifin, Type: HA 2*3L Month: _________,2011

# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Check jacking oil inlet pressure NSD
2- Check jacking oil oulet pressure NSD
3- Check body temperature NSD

DAILY
5- Check pump for sound and vibration NSD

INSPECTIONER
Comments:
DETAILS
MONTHLY
1- Check for axial flow piston pump condition NSD
Comments:
_______________________________ _________________________________
41 MW Steam Turbine
Department: POWER HOUSE Ref. # OMS-oil cooler-14

Equipment: LUBE OIL COOLER KKS # MAV30 AC010, 020
Company: G-MAR, Czech Rep. Type: VT40 CDL-16 Month: _________,2011

# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Lube oil pressure NSD
2- Cooling water inlet temperature NSD
3- Cooling water outlet temperature NSD

DAILY
4- Cooling water inlet pressure NSD
5- Cooling water outlet pressure NSD
6- Control oil pressure NSD

INSPECTIONER
Comments:
DETAILS
MONTHLY
1- Clean oil cooler strainer as per requirement NSD
Comments:
_______________________________ _________________________________
41 MW Steam Turbine
Department: POWER HOUSE Ref. # OMS-MOP-19

Equipment: MAIN OIL PUMP with TURNING GEAR KKS # MAV10 AP110
Company: ALLWEILER, Germany, Type: SNG Month: _________,2011

# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Observe/ check gear unit noise for changes NSD
2- Observe/ check oil temperature NSD

DAILY
INSPECTIONER
Comments:
DETAILS
MONTHLY
1- Check oil level NSD
2- Check gear unit for leakage NSD
Comments:
_______________________________ _________________________________
41 MW Steam Turbine
Department: POWER HOUSE Ref. # OMS-oil purifier-15

Equipment: OIL PURIFIER KKS # MAV 80A T001
Company: CJC JENSEN Type: PTU3 Month: _________,2011

# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Oil purifier in service NSD
2- Body temperature of pump NSD

DAILY
3- Oil purifier pressure NSD

INSPECTIONER
Comments:
DETAILS
MONTHLY
1- Clean oil purifier strainer as per requirement NSD
2- Check solenoid valve condition NSD
Comments:
_______________________________ _________________________________
41 MW Steam Turbine
Department: POWER HOUSE Ref. # OMS-condensate pump-13

Equipment: CONDENSATE PUMP # ___________ KKS # LCB 10, 20 AP110
Company: SIGMA Group, Type: 125-CJAV Month: _________,2011

# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

DAILY

INSPECTIONER
Comments:
DETAILS
Add oil/ grease to the bearing reservoir, if
MONTHLY
1- NSD
required

Comments:
_______________________________ _________________________________
41 MW Steam Turbine
Department: POWER HOUSE Ref. # OMS-CTP-21

Equipment: Utility CT Pump # __________ KKS # ____________
Company: ANDRITZ, Type: S3-80-265.3 Month: _________,2011

# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1- Check oil level

DAILY

INSPECTIONER
Comments:
DETAILS
Add oil/ greasing to bearing reservoirs, if
MONTHLY
1- NSD
required

Comments:
_______________________________ _________________________________
41 MW Steam Turbine
Department: POWER HOUSE Ref. # OMS-CWP-01

Equipment: CW PUMP # _________ KKS # ____________
Company: KSB, Type: KWP K350/ 500 D-2 M Month: _________,2011

# TIME
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

DAILY
INSPECTIONER
Comments:
DETAILS

MONTHLY
Comments:
_______________________________ _________________________________
200 TPH BOILER
Department: POWER HOUSE Ref. # OMS-Cooling Tower-02

Equipment: COOLING TOWER Cell # _______ KKS # ____________
Company: ________________ Type: ________________ Month: _________,2011

# TIME
1- Check for water leaks and broken water lines NSD
2- Inspect for excessive algae growth on decks NSD

3- Inspect for plugged nozzles NSD
4- Verify operation of blow down NSD
5- Verify checmical feed pump operation NSD
Activate mechanical floats to check make-up
6- NSD
water operation
WEEKLY
7- Check water level in basin NSD

8- Inspect for open doors NSD
Listen for unusual noise or vibration from fans or
9- NSD
pumps
10- Inspect for oil leakage from bearing housing NSD
11- Feel fan and pump motors for over heating NSD
12- Check V belts for condition, tightness NSD
INSPECTIONER
Comments:
1- Inspect pulley condition NSD

MONTHLY
2- Lubricate universal joints of drive shaft if required NSD

3- Inspect fan blades for build-up NSD
4- Observe fan for unbalance or vibration NSD
Comments:
_______________________________ _________________________________
BSPM Power House

Page 7 of 9
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April, 2011
BSPM Power House
41 MW Steam Turbine Periodic Maintenance

Table of Contents
Objective: ........................................................................................................................................................ 2
Methodology ................................................................................................................................................... 2

Objective:
The objective of this procedure is to define predetermined maintenance work to a schedule with the aim of preventing
the wear and tear or sudden failure of equipment components. Following are the objectives to achieve;

2. Improve system reliability
5. Reduce injury

Methodology
Manufacturer’s information

Safety Precautions during Maintenance or repair work:‐
The following safety measures must be taken before maintenance/ repair work:

1. Vessel entry permit must be issued including all necessary information.
2. All external services water outlet to pumps, condensates return etc must be safely and visibly closed.
3. Post DANGER notices at all isolators and access points saying WORKERS IN CONDENSER.
4. Open Condenser vent to release any pressure.
5. Drain Condenser through drain valves.
6. When Condenser require an internal inspection be sure that the condenser is empty and at ambient
temperature before open the manhole to enter the vessel. Also check the sufficient oxygen contents in the
vessel.
7. It is essential to have an operator standing by, outside the Condenser.
8. Cleaning may be done with soft wire brush as required. After this, it should be thoroughly washed with water
prior to refilling and close the manhole.
Page 2 of 4
BSPM Power House

Frequency: Annually

Equipment: Condenser


DATE: ______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 Inspect condenser Visually inspect the condenser tubes external surface for damage,
tubes for corrosion deposit and excessive corrosion.
2 Drain pipes Visually inspect the drain pipe penetration in the condenser for
damage.
3 Inspect support and Visually inspect the tube support plate and baffle plate for
baffle plate damage and excessive corrosion.
4 Check HP Turbine Check HP Turbine by pass inlet nozzle for cracks.
inlet nozzle
5 Inspect the water Visually inspect the water box and tube sheets for damage and
box and tube sheets deposits.
6 Epoxy paint Inspect water box epoxy paint and repair, if needed
7 Clean condenser Clean condenser tubes through high pressure jet machine.
tubes

ACTION TO BE TAKEN

1. Condenser external tubes surface
Found damaged. YES NO ________________________________________

2. Condenser tubes corroded. YES NO ________________________________________

3. Drain pipes condition found OK. YES NO _______________________________________

4. Tubes support plate condition satisfied. YES NO _______________________________________

5. Tubes baffle plates found good. YES NO _______________________________________

Page 3 of 4
BSPM Power House

6. Any cracks on inlet nozzle found. YES NO _______________________________________

7. Water box and tube sheets condition

found satisfied. YES NO _______________________________________

8. Any Epoxy paint repair required. YES NO _____________________________________

9. Cleaning of tubes done. YES NO _______________________________________

Condenser overall condition: _____________________________________________________________

Next Due Date: ___________________________

Page 4 of 4
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BSPM Power House

Table of Contents
Objective: ....................................................................................................................................................... 2
Methodology .................................................................................................................................................. 2

Objective:
The objective of this procedure is to define predetermined maintenance work to a schedule with the aim of
preventing the wear and tear or sudden failure of equipment components. Following are the objectives to achieve;

5. Reduce injury

Methodology

Page 2 of 3
BSPM Power House

Frequency: Annually

CT Fan Number: ______________


DATE: ______________

Sr. MAINTENANCE
1 Fan blades pitch With protractor, check fan blades for correct pitch.
2 Check clearance Check fan tip to wall clearance (1.75 to 2 inches is recommended)
3 Bolts Tightening Torque tight hub bolts.
4 Check cracks Inspect blades for cracks or damage.
5 Fan rotation Check direction of fan rotation.
6 Cleaning Clean fan blades.
Comments:


ANY
ACTION TO BE TAKEN

1. Fan blades pitch adjusted. YES NO ________________________________________

2. Fan tip to wall clearance found correct. YES NO _______________________________________

3. Torque tightened hub bolts. YES NO _______________________________________

4. Any blade found cracked. YES NO _______________________________________

5. Fan rotation checked. YES NO _______________________________________

6. Fan blades cleaned. YES NO _______________________________________

Fan blades overall condition: __________________________________________________________

Next Due Date: ________________________________________________


Page 3 of 3

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April, 2011

BSPM Power House
Air Compressors Periodic Maintenance

Table of Contents

Objective: ......................................................................................................................................................................... 3
Methodology .................................................................................................................................................................... 3
Safety Precautions during maintenance or repair............................................................................................................ 3

Page 2 of 10
BSPM Power House

Objective:

The objective of this procedure is to define predetermined maintenance work to a schedule with the aim of
preventing the wear and tear or sudden failure of equipment components. Following are the objectives to achieve;

5. Reduce injury

Methodology

Safety Precautions during maintenance or repair

1. The operator must employ safe working practices and observe all related local work safety requirements
and regulations with extreme care of eye protection.
2. Maintenance and repair work must only be performed by authorized and trained personnel.
3. Use only the correct tools for maintenance and repair work.
4. Use only genuine spare parts.
5. Before any maintenance/ repair work, adjustment or any other non‐routine checks, stop the compressor,
press the emergency stop button, switch off the voltage and depressurize the compressor/ Open the
manual condensate drain valves. In addition the power isolating switch must be opened and locked.
6. All maintenance work shall only be undertaken when the machine has cooled down.
7. A warning sign bearing a legend such as “work in progress; do not start” shall be attached to the starting
equipment.
8. Close the compressor air outlet valve before connecting or disconnecting a pipe.
9. Before removing any pressurized component, effectively isolate the machine from all sources of pressure.
Page 3 of 10
BSPM Power House

10. Never use flammable solvents or carbon tetrachloride for cleaning parts.
11. Keep dirt away by covering the parts and exposed openings with a clean cloth, paper or tape.
12. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam‐cleaning, before carrying out such operations.
13. Whenever there is an indication of any suspicion that an internal part of machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted.
14. Never use a light source with open flame for inspecting the interior parts of a machine.
15. Make sure that no tools, loose parts or rags are left in or on the machine.
16. All safety devices shall be maintained with due care to ensure that they function properly.
17. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
18. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people.
19. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.

Page 4 of 10
BSPM Power House


Air Compressor Number: ______________


DATE: ______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 Clean compressor Clean dust and foreign matter from complete body of the compressor
2 Check for possible Check entire system for air, water and oil leakage
leaks
3 Check coolers Check coolers, clean if necessary
4 Check nuts and screws Tighten nuts and cap‐screws as required
5 Check oil condition Check the lube oil condition
6 Cleaning of oil filter Clean the oil filter, if possible

ANY
ACTION TO BE TAKEN

1. Cleaning of compressor performed. YES NO _________________________________
2. Any leakage of air, water and oil found.
If yes then mention it. YES NO _________________________________
3. Coolers cleaning performed. YES NO _________________________________
4. Nuts/ screws found loose. YES NO _________________________________
5. Lube oil condition found OK. YES NO _________________________________
6. Oil filter cleaning performed. YES NO _________________________________

Air compressor overall condition: _______________________________________________________

Next Due Date: __________________________________________________________

MAINTENANCE ENGINEER: ____________________ MANAGER POWER HOUSE: ___________________

Page 5 of 10
BSPM Power House

Frequency: Half Yearly/ Yearly/ 2‐Yearly


DATE: ______________

Service Plan according to “Atlas Copco” part list manual at page # 101

Mention Replaced/ Not Replaced in 4th column of the below table:

Maintenance Kit
Ref. Part # Service Plans Parts Name Intervals
Replaced or Not
A‐maintenance kit
Gasket
Intercooler drain valve kit Every 4000
2906 0449 00 Service plan A running hrs
Aftercooler drain valve kit (half yearly)
Air/ oil filter kit
Intercooler drain check valve
B‐maintenance kit
O‐ring check valve Every 8000
2906 0450 00 Service plan B running hrs
Inlet valve service kit (yearly)
Inlet valve bearing block kit
C‐maintenance kit
O‐ring check valve
HP balance piston diaphragm
Drive coupling rubber set Every 16000
2906 0451 00 Service plan C running hrs (2‐
Muffler yearly)
LP balance piston diaphragm
Check valve kit
Inlet valve overhaul kit

Air compressor overall condition: _____________________________________________


Page 6 of 10
BSPM Power House

Service Plan

A number of service operations are grouped (called level A, level B, level C …), Each level stands for a
number of service actions to be carried out at the time intervals programmed in the Elecktronikon regulator.

When a level is reached, a message will appear on the screen. After carrying out all service actions, reset the interval
timers using the “Reset” key in the “Service” menu.

Activities Level A Level B Level C
Take service readings (air, oil, water temperature and pressure) * * *
Check cooler functions (approach temperature) * * *
Change intercooler condensate check valve * * *
Service intercooler blowdown valve *
Check for air, water and oil leakage * * *
Check operation of safety valves * *
Check for presence of water in lube oil * * *
Change Roto Z oil (16000 hrs or 2‐yearly) NA NA *
Change compressor oil filter (8000 hrs or annually) NA * *
Inspect/ change air filter element(s) * * *
Replace filter element of gear case breather * * *
Check cycle of air intake throttle valve * * *
Replace diaphragm of air throttle valve * *
Replace bearing block (air intake valve) * *
Overhaul air intake valve *
Check functioning of check valve (8000 hrs or annually) *
Overhaul check valve *
Check condition of balance piston diaphragm *
Change balance piston diaphragm *
Check/ service condensate drain(s) * * *
Clean fan cowl of electric motor * * *
Check rubber inserts of drive coupling (arr. E) * *
Replace inserts of drive coupling (arr. E) *
Take and record all S. P. M. readings. On VSD compressors also register the * * *
motor speed
Inspect electrical contactors * *
Check all electrical connections * *
On VSD compressors, if necessary, clean cubicle with vacuum. * *
On VSD compressors, if applicable, replace motor carbon brush *

Page 7 of 10
BSPM Power House


VSD Air compressor


DATE: ______________

Sr. MAINTENANCE
DETAILS
N. OBJECTIVE
1 Clean compressor Clean dust and foreign matter from complete body of the compressor
2 Check for possible Check entire system for air, water and oil leakage
leaks
3 Check coolers Check coolers, clean if necessary
4 Check nuts and screws Tighten nuts and cap‐screws as required
5 Check oil condition Check the lube oil condition
6 Cleaning of oil filter Clean the oil filter, if possible

ANY
ACTION TO BE TAKEN

1. Cleaning of compressor performed. YES NO _____________
2. Any leakage of air, water and oil found.
If yes then mention it. YES NO _____________
3. Coolers cleaning performed. YES NO _____________
4. Nuts/ screws found loose. YES NO _____________
5. Lube oil condition found OK. YES NO _____________
6. Oil filter cleaning performed. YES NO _____________

VSD Air compressor overall condition: _____________________________________________

MAINTENANCE ENGINEER: ____________________ MANAGER POWER HOUSE: ___________________

Page 8 of 10
BSPM Power House

Frequency: Half Yearly/ Yearly/ 2‐Yearly


DATE: ______________

Service Plan according to “Atlas Copco” part list manual at page # 149

Mention Replaced/ Not Replaced in 4th column of the below table:

Maintenance
Ref. Part # Service Plans Parts Name Kit Replaced Intervals
or Not
A‐maintenance kit
Oil filter element
Gear case breather filter
element Every 4000
2906 0739 00 Service plan A running hrs
Seal washer
(half yearly)
O‐ring
Safety filter element
B‐maintenance kit
Air/ oil filter kit
Drain valve kit for intercooler
Drain valve kit for after‐

cooler Every 8000
2906 0800 00 Service plan B running hrs
Inlet valve service kit (yearly)
Inlet valve bearing block kit
Page 9 of 10
BSPM Power House

Spring check valve
Maintenance
Ref. Part # Service Plans Parts Name Kit Replaced/ Intervals
Not
B‐maintenance kit for IMD

800 VSD (Dryer)
Rotor inspection kit
Every 8000
2906 0801 00 Service plan B Drain valve kit running hrs
(yearly)
Demister
Strainer
O‐ring
C‐maintenance kit

Air/ oil filter kit
Drain valve kit intercooler
Drain valve kit aftercooler Every 16000
2906 0802 00 Service plan C Inlet valve overhaul kit running hrs (2‐
Intercooler drain check valve yearly)
HP element balance piston
diaphragm
Muffler
Check valve kit

VSD Air compressor overall condition: ____________________________________________________

Next Due Date: _______________________________________________


Page 10 of 10
BSPM Power House

Page 8 of 9
Quarterly Inspection Sheet Field Instruments & Valves(41 MWTurbine)
PACKAGES LIMITED
POWER HOUSE AREA(41MW)
Date:‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Sr No. Tag Name Description Measuring Instrument Ranges Status Sealing Leakage Remarks

1 LBA10CP001 LIVE STEAM PRESSURE TO turbine PT
2 LBA10CT001 LIVE STEAM TEMPERATURE to Turbine THERMOCOUPLE
3 LBD10CG101 EXTRACTION 1 NON RETURN Close POSITION SENSOR
4 LBD10CG102 EXTRACTION 1 NON RETURN Open POSITION SENSOR
5 LBD10CG103 EXTRACTION 1 CLOSING VALVE POSITION ‐ CLOSE POSITION SENSOR
6 LBD10CG104 EXTRACTION 1 CLOSING VALVE POSITION ‐ Open POSITION SENSOR
7 LBD10CP001 TURBINE EXTRACTION 1 ‐PRESSURE PT
8 LBD10CP002 TURBINE EXTRACTION 1 PRESSURE PT
10 LBD10CT001 TURBINE EXTRACTION 1 ‐TEMPERATURE PTD
11 LBD20CG101 EXTRACTION 2 NON RETURN FLAP POSITION ‐ CLOSE POSITION SENSOR
12 LBD20CG102 EXTRACTION 2 NON RETURN FLAP POSITION ‐ OPEN POSITION SENSOR
13 LBD20CG103 EXTRACTION 2 CLOSING VALVE POSITION ‐ CLOSE POSITION SENSOR
14 LBD20CG104 EXTRACTION 2 CLOSING VALVE POSITION ‐OPEN POSITION SENSOR
18 LBD20CT001 TURBINE EXTRACTION 2 TEMPERATURE RTD
19 LBS10CG101 BLEED CLOSING FLAP POSITION ‐ CLOSE POSITION SENSOR
20 LBS10CG102 BLEED CLOSING FLAP POSITION ‐ OPEN POSITION SENSOR
21 LBS10CP001 TURBINE BLEED PRESSURE PT
22 LBS10CT001 TURBINE BLEED TEMPERATURE RTD
23 LCA12CG101 CONDENSATE PUMP 1DELIVERY FLAP POSITION ‐CLOSE POSITION SENSOR
24 LCA12CG102 CONDENSATE PUMP 1DELIVERY FLAP POSITION ‐open POSITION SENSOR
25 LCA12CP001 CONDENSATE 1st PUMP DELIVERY‐PRESSURE PT
26 LCA22CG101 CONDENSATE PUMP 2DELIVERY FLAP POSITION ‐CLOSE POSITION SENSOR
27 LCA22CG102 CONDENSATE PUMP 2DELIVERY FLAP POSITION ‐Open POSITION SENSOR
28 LCA22CP001 CONDENSATE 2nd PUMP DELIVERY‐PRESSURE PT
29 LCA40CG001 CONDENSATE DELIVERY CONTROL VALVE POSITION POSITION SENSOR
30 LCA40CP001 PRESSURE OF COND. PUMPS DELIVERY PT
31 LCA41CG001 CONDENSATE RECILCULATION CONTROL VALVE POSITION POSITIONER
32 LCE10CG001 CONDENSATE INJECTION CONTROL VALVE‐POSITION POSITION
33 LCE20CG101 TURBINE EXHAUST INJECTION CLOSING VALVE POSITION ‐ Close POSITION SENSOR
34 LCE20CG102 TURBINE EXHAUST INJECTION CLOSING VALVE POSITION ‐Open POSITION SENSOR
35 MAA10CG111 LIVE STEAM ESV POSITION ‐OPEN/TEST LIMIT SWITCH
36 MAA10CG112 LIVE STEAM ESV POSITION ‐CLOSE LIMIT SWITCH
37 MAA10CG113 LIVE STEAM ESV POSITION ‐CLOSE LIMIT SWITCH
PACKAGES LIMITED
Date:‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

38 MAA10CP001 PRESSURE BEHIND TURBINE CONTROL STAGE PT
39 MAA10CP002 TURBINE EXHAUST PRESSURE PT
40 MAA10CP003 TURBINE EXHAUST PRESSURE PRESSURE 0 PT
41 MAA10CP004 TURBINE EXHAUST PRESSURE PT
42 MAA10CT001 TURBINE EXHAUSTTEMPERATURE RTD
43 MAA10CT011 CONTROL VALVE CHEST TEMPERATURE ‐ CENTER Thermocouple
44 MAA10CT012 CASING TEMPERATURE TURBINE INSIDE Thermocouple
45 MAA10CT013 CASING TEMPERATURE TURBINE CENTER Thermocouple
46 MAD10CG001 TURBINE ROTOR AXIAL DISPLACEMENT Eddy Current Probe
47 MAD10CG001 TURBINE ROTOR AXIAL DISPLACEMENT DRIVER
48 MAD10CG001 TURBINE ROTOR AXIAL DISPLACEMENT TRANSMITTER
49 MAD10CG002 TURBINE ROTOR AXIAL DISPLACEMENT Eddy Current Probe
50 MAD10CG002 TURBINE ROTOR AXIAL DISPLACEMENT DRIVER
51 MAD10CG002 TURBINE ROTOR AXIAL DISPLACEMENT TRANSMITTER
52 MAD10CS001 TURBINE SPEED Eddy Current Probe
53 MAD10CS001 TURBINE SPEED SPEED MONITOR
54 MAD10CS001 TURBINE SPEED SYSTEM RACK
59 MAD10CT001 TURBINE BEARING METAL TEMPERATURE ‐FRONT PART RTD
60 MAD10CT002 TURBINE BEARING METAL TEMPERATURE ‐Rear PARTRTD RTD
61 MAD10CT003 FRONT RADIAL TURBINE BEARING METAL TEMPERATURE RTD
62 MAD10CY011 SHAFT VIBRATION ‐ X TURBINE FRONT RADIAL BEARING Eddy Current Probe
3 MAD10CY011 SHAFT VIBRATION ‐ X TURBINE FRONT RADIAL BEARING DRIVER
64 MAD10CY011 SHAFT VIBRATION ‐ X TURBINE FRONT RADIAL BEARING TRANSMITTER
65 MAD10CY012 SHAFT VIBRATION ‐ X TURBINE FRONT RADIAL BEARING Eddy Current Probe
66 MAD10CY012 SHAFT VIBRATION ‐ X TURBINE FRONT RADIAL BEARING DRIVER
67 MAD10CY012 SHAFT VIBRATION ‐ X TURBINE FRONT RADIAL BEARING TRANSMITTER
68 MAD20CT001 REAR RADIAL TURBINE BEARING METAL TEMPERATURE RTD
69 MAD20CY011 SHAFT VIBRATION ‐ X TURBINE REAR RADIAL BEARING Eddy Current Probe
70 MAD20CY011 SHAFT VIBRATION ‐ X TURBINE REAR RADIAL BEARING DRIVER
71 MAD20CY011 SHAFT VIBRATION ‐ X TURBINE REAR RADIAL BEARING TRANSMITTER
72 MAD20CY012 SHAFT VIBRATION ‐ X TURBINE REAR RADIAL BEARING Eddy Current Probe
73 MAD20CY012 SHAFT VIBRATION ‐ X TURBINE REAR RADIAL BEARING DRIVER
74 MAD20CY012 SHAFT VIBRATION ‐ X TURBINE REAR RADIAL BEARING TRANSMITTER
PACKAGES LIMITED
Date:‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

75 MAG10CL001 CONDENSATE LEVEL FLOAT
78 MAK10CG101 TURNING GEAR COVER POSITION POSITION SWITCH
79 MAK10CT001 GEAR BOX RADIAL BEARING TEMPERATURE RTD
83 MAK10CY001 VIBRAT. ABS. HORIZONTAL RADIAL GEAR BOX BEARING ACCELOROMETER
84 MAK10CY001 VIBRAT. ABS. HORIZONTAL RADIAL GEAR BOX BEARING TRANSMITTER
85 MAK10CY001 VIBRAT. ABS. HORIZONTAL RADIAL GEAR BOX BEARING TRANSMITTER
86 MAK10CY002 VIBRAT. ABS. VERTICAL RADIAL GEAR BOX BEARING ACCELOROMETER
87 MAK10CY002 VIBRAT. ABS. VERTICAL RADIAL GEAR BOX BEARING TRANSMITTER
88 MAK10CY002 VIBRAT. ABS. VERTICAL RADIAL GEAR BOX BEARING TRANSMITTER
89 MAL10CG101 DRAINAGE CLOSING VALVEPOSITION POSITION SENSOR
99 MAV10CL001 OIL LEVEL OIL TANK FLOAT SENSOR
100 MAV10CT001 OIL TEMPERATURE OIL TANK RTD WITH TRANSMITTER
101 MAV10CT002 OIL TEMPERATURE AT HEATING ELEMENT RTD
102 MAV35CP001 PRESSURE DIFFERENCE ON OIL FILTER PT
103 MAV40CP001 LUBRICATION OIL PRESSURE PT
106 MAV40CT001 TEMPERATURE OF LUBE OIL RTD
109 MAV70CP001 JACKING OIL PRESSURE PT
110 MAW10CG001 CONTROL VALVE‐POSITION TRANSMITTER POSITIONER
111 MAW11CP001 GLAND STEAM PRESSURE STEAM TO REAR GLAND PT
PACKAGES LIMITED
Date:‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Sr No.
Tag Name Description Measuring Instrument Ranges Status Sealing Leakage Remarks
112 MAW11CT001 GLAND STEAM TEMPERATURE STEAM TO REAR GLAND RTD
113 MAX40CP001 CONTROL OIL PRESSURE PT
114 MAX45CP001 VALVE BLOCK, VALVE 1 POSITION POSITION 2 FROM 3 PT
117 MAX45CP004 VALVE BLOCK, OUTLET POSITION LIVE STEAM PT
118 MKA10CL101 WATER LEAKAGE DETECTOR Conductivity Switch
119 MKA10CT001 GENERATOR COLD AIR TEMPERATURE RTD
120 MKA10CT002 GENERATOR WARM AIR TEMPERATURE RTD
121 MKA10CT003 GENERATOR COLD AIR TEMPERATURE RTD
122 MKA10CT010 GENERATOR STATOR WINDING TEMPERATURE RTD
123 MKA10CT011 GENERATOR L1 PHASE WINDING TEMPERATURE RTD
124 MKA10CT020 GENERATOR STATOR WIDING TEMPERATURE RTD
126 MKA10CT030 GENERATOR STATOR WINDING TEMPERATURE RTD
128 MKD10CT001 GENERATOR FRONT RADIAL BEARING TEMPERATURE RTD
129 MKD10CY001 VIBRAT. ABS. ‐ HORIZONTAL FRONT RADIAL GENERATOR BEARING ACCELOROMETER
130 MKD10CY001 VIBRAT. ABS. ‐ HORIZONTAL FRONT RADIAL GENERATOR BEARING TRANSMITTER
131 MKD20CT001 GENERATOR RAER RADIAL BEARING TEMPERATURE RTD
132 MKD20CY001 VIBRAT. ABS. ‐ HORIZONTAL Rear RADIAL GENERATOR BEARING ACCELOROMETER
133 MKD20CY001 VIBRAT. ABS. ‐ HORIZONTAL Rear RADIAL GENERATOR BEARING TRANSMITTER
BSPM Power House


Page 9 of 9
BSPM Power House
41 MW ST and Utilities Preventive Maintenance
Date:___________________

UTILITY AREA
1 371-1001 42.5
2 371-1004 56
3 371-1005 56
4 371-1006 56
5 371-1022 42.5
6 351-1201 295
7 351-1202 295
8 351-1203 295
9 351-1204 295
10 371-3029 68
11 371-3030 68
12 Tube well #1 140
13 Tube well #2 140
14 Tube well #3 140
15 Tube well #4 140
16 Air Comp #1 615
17 Air Comp #2 540
18 Air Comp #3 540
19 Air Comp #4 540
20 F/W pump#1 65TPH 130
21 F/W pump#2 65TPH 130
22 FD FAN#1 65TPH 158
23 FD FAN#2 65TPH 158
24 F/W pump#1 30TPH 210
25 F/W pump#2 30TPH 210
200TPH BOILER
26 ID Fan-200TPH 385
27 FD Fan-200TPH 550
28 F.W-PU-01A 900
29 F.W-PU-01B 900
30 F.W-PU-01C 900
31 371- 3027 RC 187
32 371- 3028 RC 187
33 CW pump#1 610
34 CW pump#2 610
35 CW pump#3 610
36 CW pump#4 610
37 CT Fan # 1 87
BSPM Power House
Date:___________________

UTILITY AREA
38 CT Fan # 2 87
39 CT Fan # 3 87
40 CT Fan # 4 87
41 CT Fan # 5 87
42 CT Fan # 6 87
43 CT Fan # 7 87
44 CT Fan # 8 87
45 CT Fan # 9 87
BSPM Power House
Date:___________________

UTILITY AREA
46 HFO 371-7047 21.1
47 HFO 371-7048 21.1
52 371- 3091 27
53 371- 3092 27
41MW TURBINE
54 Condensate pump #1 128
55 Condensate Pump #2 128
56 EMERGENCY OIL PUMP 7.4
57 AUXILIARY OIL PUMP 86
58 OIL TANK FAN 3.3
59 Turning Gear Motor 41.5
60 Jacking Oil Pump 8.2
MCC AC CHECKING
Sr# Description Status PF Remarks
1 41MW
2 Air comp
3 Demin plant
4 Water chest
5 DCS power house
6 11MW MCC
7 11MW HT
8 11MW control room
9 65TPH boiler
VFD TEMP
Sr# Description TEMP RPM FAN Remarks
1 ID Fan-200TPH
2 FD Fan-200TPH
3 F.W-PU-01A
4 F.W-PU-01B
5 F.W-PU-01C
6 CW pump#1
7 CW pump#2
8 351-1201
Checked by. Approved by.

BSPM Power House
DAILY CHECKING OF BATTERY CHARGER AND UPS

Bullah Shah Paper mill Kasur
power house and utility area Date:________________________
OMS (pvt) Limited
A.C Input A.C Input Charger D.C Battery

Sr# Description Remarks
Voltage current Output A voltage charger A
1 GT battery charger
2 ST battery charger
3 30TPH battery charger
4 11MW battery charger
5 Main HT battery charger
6 Utility DCS UPS
7 Battery charger 41MW
8 Diesel engine charger
9 UPS 41MW power plant

BSPM Power House
WEEKLY CHECK LIST FOR AUXILIARY & STARTING TRANSFORMER

Bullah Shah Paper Mill Kasur
Power house and Utility area
OMS (pvt) Limited Date:___________________________
Running Winding Silica jel Abnormal Oil T/F Cooling

S# Tag# Oil level Oil Temp Remarks
A% Temp Breather sound Leakage Earthing Fan
1 41MW-371-3352
2 41MW-371-3353
3 41MW-371-3354
4 41MW-371-3355
5 Water chest-351-3351
6 Demin plant-371-3351
7 Air comp-391-3351
8 Air comp-391-3352
9 Gas comp
10 Steam Turbine(11MW)
11 11MW(16MVA)
GREASING PLAN OF UTILITY MOTORS
OMS (pvt) Limited Date:____________________
Greasing Greasing Greasing Greasing Greasing

Sr# MOTOR TAG #
intervel Greasing Due Done Greasing Due Done Greasing Due Done Greasing Due Done
1 F.W .P # 1 -65 TPH 2 month
2 F.W .P # 2 -65 TPH 2 month
3 FD FAN # 1- 65TPH 2 month
4 FD FAN # 2- 65TPH 2 month
5 F. W. P # 1-30 TPH 2 month
6 F. W. P # 2-30 TPH 2 month
7 Compressor # 1 2 month
11 Tube well # 1 2 month
16 Gas compressor 2 month
17 P O 1 A(Demin plant) 2 month
18 P O 1 B(Demin plant) 2 month
19 P O 2 A(Demin plant) 2 month
20 P O 2 B(Demin plant) 2 month
21 371-1024 2 month
22 351-1201 2 month
23 351-1202 2 month
24 351-1203 2 month
25 351-1204 2 month
GREASING PLAN OF UTILITY MOTORS
OMS (pvt) Limited Date:____________________
Greasing Greasing Greasing Greasing Greasing

Sr# MOTOR TAG #
intervel Greasing Due Done Greasing Due Done Greasing Due Done Greasing Due Done
26 241-1000 6 month
27 241-1100 6 month
28 241-1151 2 month
GREASING PLAN OF 41MW MOTORS
OMS (pvt) Limited Date:___________________
Greasing Greasing Greasing Greasing Greasing Greasing Greasing Greasing Greasing

Sr# MOTOR TAG #
intervel Due Done Due Done Due Done Due Done
1 FD Fan- 371-3005 2 month
2 ID Fan - 371-3004 2 month
3 F.W.P #1 371-1001 2 month
4 F.W.P #2 371-1002 2 month
5 F.W.P #3 371-1003 2 month
6 Condensat.P 371-3027 2 month
7 Condensat.P 371-3028 2 month
8 Colling Water.P.371-3093 2 month
12 Turbin Condensat # 1 2 month
13 Turbin Condensat # 2 2 month
14 371-3031 2 month
15 371-3032 2 month
16 371-3033 2 month
17 371-3034 2 month
18 371-3035 2 month
19 371-3036 2 month
20 371-3037 2 month
21 371-3038 2 month
22 371-3039 2 month
23 371-3040 2 month
24 371-3041 2 month
25 371-3042 2 month
26 371-3043 2 month
GREASING PLAN OF 41MW MOTORS
OMS (pvt) Limited Date:___________________
Greasing Greasing Greasing Greasing Greasing Greasing Greasing Greasing Greasing

Sr# MOTOR TAG #
intervel Due Done Due Done Due Done Due Done
27 371-3044 2 month
BSPM Power House
41 MW Electrical Preventive Maqintenance

MAIN SCHEDU
EQUIPMEN CYCLE/UNI S.D / CALL Date of start Date of end
S.N TASK LIST WORK LING Duration REMARKS
T (KKS No) T N.S.D HORIZON of PM of PM
CENTRE PERIOD
1 371-1001 PU-01A (Feed Water Pump#1)
2 371-1002 PU-01B (Feed Water Pump#2)
3 371-1003 PU-01C (Feed Water Pump #3)
4 371-1004 I D Fan-01 (Induced Draft Fan)
5 371-1005 F D Fan-01 (Forced Draft Fan)
6 371-4027 Dosing Tank Pump HP
7 371-4028 Dosing Tank Pump HP
8 371- 4029 Dosing Tank Pump LP
12 371-7047 Fuel Oil Pumping Unit 701 A (OPU-701A)
13 371-7048 Fuel Oil Pumping Unit 701 B (OPU-701 B)
14 371-1006 SB Retact Able # 01 (Super Heater )
1. Insulation and winding resistance test of motor.
18 371-1010 SB Retact Able # 05 (Super Heater ) 2. cleaning of motor
19 371-1011 SB Rotory # 6 (Econmizer 02) 3. Maggering of cable
20 371-1012 SB Rotory # 7 (Econmizer 02) 4. Tightning of connection from both side
371-1013
12 months Electrical S.D 100% 10 years 07 days 15-04-2011
21 SB Rotory # 8 (Econmizer 02) 5.Control connection tightning
22 371-1014 SB Rotory # 9 (Econmizer 02) 6. Checking of contactor contact and cleaning
23 371-1015 SB Rotory # 10 (Econmizer 01) 7. UMC checking and power supply voltage
24 371-1016 SB Rotory # 11 (Econmizer 01)
371-1017
measurement
25 SB Rotory # 12 (Econmizer 01)
26 371-1018 SB Rotory # 13 (Econmizer 01)
27 371-1019 SB Rotory # 14 (Flue Gas Air Pre Heater)
35 371-3027 Condensate Pump # 1
36 371-3028 Condensate Pump # 2
37 371-3091 De Super Heater Pump # 1
38 371-3092 De Super Heater Pump # 2
39 371-3029 Demin transfer pump#1
40 371-3030 Demin transfer pump#2
BSPM Power House
STRATEGY BASE MAINTENANCE PLAN of MOTORS AND MCC OF 41MW

MAIN
EQUIPMENT CYCLE/UN S.D / CALL SCHEDULING Date of Date of
S.N TASK LIST WORK Duration REMARKS
(KKS No) IT N.S.D HORIZON PERIOD start of PM END of PM
CENTRE
1 LCB10AP110 Condensate Pump 1
2 LCB20AP110 Condensate Pump 2
3 MAV25AP110 Emergency Lube Oil Pump
4 MAV15AP110 Auxiliary Lube Oil Pump
5 MAV10AN110 Lube Oil Vapour Extractor Fan
6 MAK10AE110 Turning Gear Motor
7 MAW30AN110 Gland Steam Condenser
8 MOV80AT001 Lube oil purifier
9 MAV70AP110 Jacking Oil Pump
10 371-1008 Cooling water booster pump
11 MP 371-3093 Cooling Water Pump 1 1. Insulation and winding resistance test of motor.
12 MP 371-3094 Cooling Water Pump 2 2. cleaning of motor
13 MP 371-3095 Cooling Water Pump 3 3. Maggering of cable
14 MP 371-3096 Cooling Water Pump 4 4. Tightning of connection from both side
15 ME 371-3030 Cooling Tower Fan # 1 5.Control connection tightning
16 ME 371-3031 Cooling Tower Fan # 2 6. Checking of contactor contact and cleaning
17 ME 371-3032 Cooling Tower Fan # 3 7. UMC checking and power supply voltage
18 ME 371-3033 Cooling Tower Fan # 4 measurement
19 ME 371-3034 Cooling Tower Fan # 5
BSPM Power House

MAIN SCHEDU Date of
EQUIPMENT (KKS CYCLE/U S.D / CALL Date of
S.N TASK LIST WORK LING Duration end of REMARKS
No) NIT N.S.D HORIZON start of PM
CENTRE PERIOD PM
1 PU-01A Feed water pump
2 PU-02B Feed water pump
5 FD-FAN#1 FD-FAN#1
cleaning of motor 3.
6 FD-FAN#2 FD-FAN#2
Maggering of cable 4.
7 SB-01 Soot Blower
Tightning of connection from both side 12 months Electrical S.D 100% 10 years 01days 24-04-2011
8 SB-02 Soot Blower
9 SB-03 Soot Blower
6. Checking of contactor contact and cleaning 7.
10 SB-04 Soot Blower
BSPM Power House

MAIN SCHEDU
EQUIPMENT CYCLE/U S.D / CALL Date of start Date of end
(KKS No) NIT N.S.D HORIZON of PM of PM
CENTRE PERIOD
1 AIR COMP#1 Air Compressor #1 1. Insulation and winding resistance test of motor.
2 AIR COMP#2 Air Compressor #2 2. cleaning of motor
3 AIR COMP#3 Air Compressor #3 3. Maggering of cable
4. Tightning of connection from both side
4 AIR COMP#4 Air Compressor #4 12 months Electrical S.D 100% 10 years 02 days 23-04-2011
5 AIR COMP#2 Air Drayor Motor 6. Checking of contactor contact and cleaning
6 AIR COMP#3 Air Drayor Motor 7. UMC checking and power supply voltage
Air Drayor Motor measurement
7 AIR COMP#4
BSPM Power House
STRATEGY BASE MAINTENANCE PLAN of MOTORS AND MCC OF DEMIN PLANT

MAIN SCHEDU
EQUIPMENT CYCLE/U S.D / CALL Date of Date of end
(KKS No) NIT N.S.D HORIZON start of PM of PM
CENTRE PERIOD
1 P-02A Regeneration pumps
2 P-02B Regeneration pumps
3 DF-01A Degasifier fan
4 DF-01B Degasifier fan
5 P-01A Degasifier pump
6 P-01B Degasifier pump
7 P-03A Nutralization pump
8 P-03B Nutralization pump
9 Stainer Motor Stainer Motor
10 MP 371-1007 Raw water pump
MP 371-1008 Raw water pump 1. Insulation and winding resistance test of motor.
11
2. cleaning of motor
12 MP 371-1022 Demin transfer pump
3. Maggering of cable
13 MP 371-1000 Demin transfer pump
4. Tightning of connection from both side
14 MP 371-1001 Demin transfer pump 12 months Electrical S.D 100% 10 years 2 days 25-04-2011
15 MP 371-1009 Chemical transfer pump
6. Checking of contactor contact and cleaning
7. UMC checking and power supply voltage
measurement
23 MP 371-1004 Cooling water pump
26 ME 371-1023 Cooling tower fan#1
27 ME 371-1024 Cooling tower fan#2
BSPM Power House
STRATEGY BASE MAINTENANCE PLAN of MOTORS AND MCC OF RAW WATER

MAIN SCHEDU
EQUIPMENT CYCLE/U S.D / CALL Date of start Date of end
(KKS No) NIT N.S.D HORIZON of PM of PM
CENTRE PERIOD
3 MP 351-1203 Raw water pump 1. Insulation and winding resistance test of motor.
4 MP 351-1204 Raw water pump 2. cleaning of motor
5 MP 241-1000 Fire fighting pump 3. Maggering of cable
6 MP 241-1100 Fire fighting pump 4. Tightning of connection from both side
7 MP 241-1151 Fire fighting Jocky pump 5.Control connection tightning
8 Tube Well # 1 Tube Well 6. Checking of contactor contact and cleaning
9 Tube Well # 2 Tube Well 7. UMC checking and power supply voltage
10 Tube Well # 3 Tube Well measurement
11 Tube Well # 4 Tube Well
12 Tube Well # 5 Tube Well
BSPM Power House
STRATEGY BASE MAINTENANCE PLAN of MOTORS AND MCC OF HFO LOADING AND UNLOADING
MAIN SCHEDU Date of
EQUIPMENT CYCLE/U S.D / CALL Date of
S.N TASK LIST WORK LING Duration start of REMARKS
(KKS No) NIT N.S.D HORIZON end of PM
CENTRE PERIOD PM
1 MP 361-2421 HFO unloading pump
2 MP 361-2422 HFO unloading pump cleaning of motor 3.
3 Maggering of cable 4.
MP 361-2423 HFO transfer pump
Tightning of connection from both side 12 months Electrical S.D 100% 10 years 1 days 30-04-2011
4 MP 361-2424 HFO transfer pump 5.Control connection tightning
5 MP 361-2425 HFO day tank pump 6. Checking of contactor contact and cleaning 7.
6 MP 361-2426 HFO day tank pump
BSPM Power House
41 MW ST Utility Preventive Maintenance
STRATEGY BASE MAINTENANCE PLAN OF BATTERY CHARGER, UPS AND BATTERIES

MAINTENANC CALL
MAIN WORK SCHEDULING Date of start Date of end
S.N EQUIPMENT (KKS No) E PLAN TASK LIST CYCLE/UNIT S.D / N.S.D HORIZO Duration Remarks
CENTRE PERIOD of PM of PM
DESCRIPTION N
1 Batteries reading (Voltage and Amps) 2 months Elect N.S.D 100% 10 years
2 Load testing and boost charging 12 months Elect N.S.D 100% 10 years 1 day
1 UPS 41MW power plant Battery +12V
3 inspection / servicing of regulation cards. 12 months Elect N.S.D 100% 10 years
Check tightness of terminals on components subject
4 12 months Elect S.D 100% 10 years 1 day
to vibration like transformer chokes contactors
2 Battery Charger 41MW Battery +12V
3 Main HT battery charger Battery +12V
4 Diesel engine charger Battery +12V
5 Emergency lighting charger Battery +12V
BSPM Power House
STRATEGY BASE MAINTENANCE PLAN (TRANSFORMERS)

MAINTENANC MAIN
EQUIPMENT CYCLE/UNI SD/N CALL SCHEDULING Date of Date of end
S.N E PLAN TASK LIST WORK Duration Remarks
(KKS No) T SD HORIZON PERIOD start of PM of PM
DESCRIPTION CENTRE
1 Measurement of insulation & winding resistance 12 months Electrical SD 100% 10 years 02 days
2 Testing of Oil dielectric strength. 12 months Electrical NSD 100% 10 years
371-3352 3 Testing of tan (DELTA) of Oil. 12 months Electrical NSD 100% 10 years
1 day
371-3353 41MW_Startup 4 Water content check (oil chemical analysis). 12 months Electrical NSD 100% 10 years
1 5/4/2011
371-3354 Transformer 5 Dissolved Gas analaysis of Oil (DGA ). 5 years Electrical NSD 100% 10 years
371-3355
6 Oil leakage of bushings and cleaning of porcelaine. 12 months Electrical SD 100% 10 years
7 Cooling system inspection and servicing. 12 months Electrical SD 100% 10 years 02 Days
8 Inspection of alarm contacts. 12 months Electrical SD 100% 10 years
371-3351 3 Testing of tan (DELTA) of Oil. 12 months Electrical NSD 100% 10 years
1 day
351-3351 Utility Area 4 Water content check (oil chemical analysis). 12 months Electrical NSD 100% 10 years
2 10/4/2011
391-3351 Transformers 5 Dissolved Gas analaysis of Oil (DGA ). 5 years Electrical NSD 100% 10 years
391-3352
3 Testing of tan (DELTA) of Oil. 12 months Electrical NSD 100% 10 years
Gas-comp 1 day
11MW Startup 4 Water content check (oil chemical analysis). 12 months Electrical NSD 100% 10 years
3 16MVA-Main -----------
Transformer 5 Dissolved Gas analaysis of Oil (DGA ). 5 years Electrical NSD 100% 10 years
6.3MVA-ST
BSPM Power House
STRATEGY BASE MAINTENANCE PLAN (0.4 KV SWITCH GEAR)

MAIN SCHEDU
EQUIPMENT MAINTENANCE CYCLE/UN S.D / CALL Date of Date of end
S.N TASK LIST WORK LING Duration Remarks
(KKS No) PLAN DESCRIPTION IT N.S.D HORIZON start of PM of PM
CENTRE PERIOD
All the loose external dirt removal (cleaning agent Carbon
1 Electrical 100% 10 years
tetrachloride, brush, cloth and vacuum cleaner)
371‐3331 65TPH boiler 2 Servicing of breaker and its contacts. Electrical 100% 10 years
371‐3332 Demin Plant
1 391‐3331 Air comp#1 3 Check the tightness of nuts and bolts. 2 years Electrical S.D 100% 10 years 5 days 02.01.2012
391‐3332 Air comp#2
Water treatment Insulators should be clean and inspected for signs of
351‐3331 4 Electrical 100% 10 years
cracking or damage.
Ensure that all fastening are tight and that good contact is
maintained for all wiring connections and terminals.
2 Servicing of breaker and its contacts. Electrical 100% 10 years

371‐3333 41MW_Turbine Aux
2 371‐3334 Cooling towers 3 Check the tightness of nuts and bolts. 2 years Electrical S.D 100% 10 years 4 days 07‐01‐2012
371‐3301 Feed Water and FD,ID
Insulators should be clean and inspected for signs of
cracking or damage.
2 Servicing of breaker and its contacts. Electrical 100% 10 years
3 11MW 11MW 3 Check the tightness of nuts and bolts. 2 years Electrical S.D 100% 10 years 5 days 11.01.2012
Insulators should be clean and inspected for signs of
cracking or damage.
BSPM Power House
STRATEGY BASE MAINTENANCE PLAN (11 KV SWITCH GEAR)

MAINTENANCE MAIN SCHEDU
EQUIPMENT CYCLE/UNI S.D / CALL Duratio Date of Date of
S.N PLAN TASK LIST WORK LING Remarks
(KKS No) T N.S.D HORIZON n start of PM End of PM
DESCRIPTION CENTRE PERIOD
1 12 months Electrical 100% 10 years
ETP 2 Vacuum testing of each breaker 12 months Electrical 100% 10 years

STRAW
3 Testing of transformer protection relays 12 months Electrical 100% 10 years
CTMP
1 J1_11KV S.D 1 days
CORRUGATOR
4 Cleaning of insulators and inspection for signs of cracking or damage. 12 months Electrical 100% 10 years
WAPDA INCOMING
TIE BREAKER Ensure that all fastening are tight and that good contact is maintained
for all wiring connections and terminals.
For all control relay and contactors inspect mechanical parts for free
movements.
11MW-INCOMING 2 Vacuum testing of each breaker 12 months Electrical 100% 10 years

UTILITY OUTGOING
PM6
2 J2_11KV S.D 1 days
SPP-PM6
COATING
TIE BREAKER J2/J3 Ensure that all fastening are tight and that good contact is maintained
movements.
2 Vacuum testing of each breaker 12 months Electrical 100% 10 years
41MW-INCOMING
DIP 3 Testing of transformer protection relays 12 months Electrical 100% 10 years
3 ,SPP-PM7 J3_11KV S.D 1 days
PM7 4 Cleaning of insulators and inspection for signs of cracking or damage. 12 months Electrical 100% 10 years
RELINER-PM6
Ensure that all fastening are tight and that good contact is maintained
movements.
371-3351
351-3351
4 utility area_11KV S.D 2 days
391-3351
391-3352
movements.
371-3352
371-3353
5 41MW Aux_11KV S.D 2 days
371-3354
371-3355
BSPM Power House
STRATEGY BASE MAINTENANCE PLAN (11 KV SWITCH GEAR)

MAINTENANCE MAIN SCHEDU
EQUIPMENT CYCLE/UNI S.D / CALL Duratio Date of Date of
S.N PLAN TASK LIST WORK LING Remarks
(KKS No) T N.S.D HORIZON n start of PM End of PM
DESCRIPTION CENTRE PERIOD
movements.
BSPM Power House
STRATEGY BASE MAINTENANCE PLAN (Excitation System)

MAINTENANCE MAIN CALL SCHEDU
EQUIPMENT (KKS CYCLE/U S.D / Date of Date of end
S.N PLAN TASK LIST WORK HORIZO LING Duration Remarks
No) NIT N.S.D start of PM of PM
DESCRIPTION CENTRE N PERIOD
Inspection, checking and Cleaning of thyrister stacks and all other
1
electrical circuits.
3 Inspection of AVR control system PCBs.
Generator 4 Cooling fans inspection and servicing
1 41MW_ Exciter Excitation 5 Testing of protective devices power supply units and auxiliary relays. 12 months Electrical S.D 100% 10 years 01 day
System 6 check tighteness of all connections and bolted joints.
7 Servicing of field breakers
9 Rotor earth fault coil and brush checking
10 Rotr earthing brushinspection from drive end side.
Inspection, checking and cleaning of main busburs, tightning of bus
1
bars.
3 checking of VT fuses
4 Tightning of CT,s star and output side
Generator 5 Testing of protective devices power supply units and auxiliary relays.
2 41MW_Generator 12 months Electrical S.D 100% 10 years 01 day
System
6 check tighteness of all control connections and bolted joints.
7 checking of generator heaters
9 Resistance measurment of earthing resistor
10 insulation resistance measurment of generator.
BBSSPPM
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RReevv 11
July, 2012
BSPM Power House
Corrective Maintenance Procedure

Table of Contents
Objective ............................................................................................................................. 3
Procedure ............................................................................................................................ 3
Flow Chart ........................................................................................................................... 5
Annexure 1 .......................................................................................................................... 6
Annexure 2 .......................................................................................................................... 8

Page 2 of 10
BSPM Power House

Objective
Corrective maintenance is a form of system maintenance which is performed after a fault or problem
emerges in a system, with the goal of restoring operability to the system and to enhance plant reliability.
In some cases, it can be impossible to predict or prevent a failure; making corrective maintenance is the
only option.

To provide consolidated requirements for the preparation and attending of Work Orders at BSPM, Shift
In‐charge can issue a Work Request to mechanical or E&I maintenance team. WOs help to identify
significant problems that incurred during the operation of plant. A timely and proper reporting and
attending of “Work Orders” will improve the reliability of the unit. The satisfactory operation requires all
staff in operation & Maintenance to interact with each other in well‐disciplined way.
.
Procedure
 Work Request shall be prepared for all significant problems incurred during the operation of
Plant.
 Shift in‐charges shall be authorized to issue work request to concerned maintenance
departments.
 Prior to issuance of a work request, Shift In‐charge will enter the brief detail of work request in
master list (Attached in Annex‐2).
 Shift In‐charges shall be responsible to send work request to maintenance department.
 Acknowledgement of concerned maintenance department is required for the record purposes.
 Work request shall carry following details (Attached as Annex 1);
o Date
o Plant
o Equipment Tag and Equipment description
o Job description
o Priority, Low, Medium, High
 Low means plant operation will not suffer job can be done within next 24 hours
 Medium means plant operation can suffer job must complete within next 08
hours
 High means plant operation is not possible without attending the equipment
under description
o Status
o Job done (only for craft person)
Page 3 of 10
BSPM Power House

o Man hours consumed
 Before the preparation of Work requests’ Shift In‐charge shall prioritize the job on the basis of
equipment requirement and severity of process need.
 Maintenance team will plan the job with consultancy of Operation staff or Shift In‐charge, ensure
the availability of tools, spares and other services if required.
 After planning maintenance team will ask for required safety document from Shift In‐charge as
per job requirement.
o Lock Out Tag Out Order (LOTO)
o Live Work Permit (LWP)
o Permit to Work (PTW)
o Hot Work Permit
o Confined Space Permit (If job is in some confined space)
 After fulfilling all safety requirements, craft person will sign off the safety document.
 After signing off the safety document, craft person can initiate maintenance activity.
 On completion of job, maintenance staff must fill in the work order, together with the corrective
action taken and man hours utilized.
 The shift In‐charge will ensure that job has successfully been carried out, before normalizing the
equipment.
 If problem is not solved, inform maintenance for re‐work.
 Shift In‐charge shall up‐date the status of work request.
 If it is re‐work, maintenance team must incorporate the reasons of re‐work.
 Completed work request form will be reviewed by mechanical or E&I Team Leader before the job
request closure by Operations Team Leader.
 Filled job request form will be closed by Operations Team Leader after successful operation of
equipment under description.

Page 4 of 10
BSPM Power House

Flow Chart
Page 5 of 10
BSPM Power House

Annexure 1
BSPM‐OMS‐0005
Page 6 of 10
BSPM Power House

JOB REQUEST
Job Request No:
Date:
Plant:
Equipment Tag:
Equipment Description:
Job Description:
Priority: Low, Medium, High
Status:
Job requested by Shift Incharge: Name& Signature
Action (by maintenace Team):
Man Hours Consumed :
Reason of Re‐Work Done:
Craft Person (Name & Signature): _________________________
Reviewed By: Maintenance Team Leader ________________________________________
Closed By: Operations Team Leader: ___________________________________________

Page 7 of 10
BSPM Power House

Annexure 2
Page 8 of 10
BSPM‐OMS‐0006
Job Request Master List

Sr # Job Request No: Job Description Date Closing Date Remarks
BBSSPPM
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RReevv 00
April, 2011
BSPM Power House
Furnace Oil Unloading Procedure

Table of Contents
Objective: ....................................................................................................................................................... 3
Procedure ....................................................................................................................................................... 3
Flow Chart and Control................................................................................................................................... 4
Annexure 1 ..................................................................................................................................................... 5

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BSPM Power House

Objective:
The objective of this procedure is to define predetermined unloading of HFO tankers to main oil tanks.
Following are the objectives to achieve;

1. Ensure safety of working staff.
2. Protect assets from mishandling
3. Ensure quality and quantity of furnace oil
Procedure
After arrival of tank at Gate, process will go through the following steps;

1‐ Checking of documents by security department at entrance gate.
2‐ Information to store.
3‐ Checking of seal by store department.
4‐ Weighing of filled tanker at Weigh Bridge and logging in store document.
5‐ Weigh bridge shall Inform boiler operator and shift in‐charge for unloading.
6‐ Boiler operator to unload oil tanker.
7‐ After ensuring that oil tanker is empty, it will be sent to weigh bridge.
8‐ Boiler operator shall register the received quantity in log sheet attached in Annex 1.
9‐ Shift In‐charge will sign off the receiving documents for net received quantity.
10‐ Documents will be submitted to store department for clearance.
11‐ After clearance from store, tanker will move to gate for final exit.
12‐ It is assumed that the oil quality is identical to the one mentioned in data sheet supplied by the
Fuel Supplier.

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BSPM Power House

Tanker at Gate
Information to Store
Seal Check by Store
Department
Weigh at Weigh Bridge and
documented
Unloading by Boiler
Operator
documented
Signed off by
Shift Incharge
Documents submission to
store and Exit
Page 4 of 6
BSPM Power House

Annexure 1
Page 5 of 6
BSPM Power House

OMS‐BSPM‐0007
HFO Unloading Log Sheet
Month: ____________________________
Date Tanker 1 Tanker 2 Tanker 3 Tanker 4 Tanker 5 Total

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
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Chemical Unloading Procedure

Table of Contents
Abbreviations ................................................................................................................................................. 3
Objective: ....................................................................................................................................................... 4
Safety Precautions .......................................................................................................................................... 4
Personnel Protective Equipment (PPE) .......................................................................................................... 4
Procedure ....................................................................................................................................................... 5
Flow Chart and Control................................................................................................................................... 6
Annexure 1 ..................................................................................................................................................... 7

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BSPM Power House

Abbreviations
HCl Hydrochloric Acid
H2SO4 Sulphuric Acid
NaOH Caustic Soda
PPE Personnel Protective Equipment
Page 3 of 8
BSPM Power House

Objective:
The objective of this procedure is to define predetermined unloading of Chemicals (HCl, H2SO4, NaOH)
tankers to main storage tanks. Following are the objectives to achieve;

3. Ensure quality and quantity of Chemicals
Safety Precautions
 Know where the nearest eye wash station and safety shower is located. Test for operability prior
to doing jobs involving acid or caustic.
 If acid or caustic contacts the eyes or skin, flush for 15 minutes. If splashed into the eye(s) hold
eyelids open while flushing. Seek medical help immediately.
 Caustic is difficult to remove from the skin. Caustic will not burn the skin immediately but it must
be washed off with sufficient quantities of water followed by soap and water wash.
 Acid will deteriorate (burn) the skin immediately. Go to a safety shower or eye wash
immediately and flush contaminated areas continuously for 15 minutes.
 Remove contaminated clothing at once or while under a safety shower.
 Call out 333 for assistance.
Personnel Protective Equipment (PPE)
Appropriate personal protective equipment for operations and maintenance people will also include the
following:
a. Chemical resistant splash suit
b. Face shield
c. Goggles
d. Respirator (as required)
e. Rubber gloves
f. Rubber boots
g. Full face mask (as required)

Page 4 of 8
BSPM Power House

Procedure
After arrival of tank at Gate, process will go through the following steps;

1‐ Checking of documents by security department at entrance gate.
2‐ Information to store.
3‐ Checking of seal by store department.
4‐ Weighing of filled tanker at Weigh Bridge and logging in store document.
5‐ Weigh bridge shall Inform Laboratory and Shift In‐charge for unloading.
6‐ Chemical operator shall wear the PPE
7‐ Chemical operator shall take the sample and analyze.
8‐ If sample is within limits, chemical operator will log the results in log sheet attached in Annex 1.
9‐ Chemical operator will unload tanker to the specified storage tank.
10‐ After ensuring that chemical tanker is empty, it will be sent to weigh bridge.
11‐ Chemical operator will log the received quantity in log sheet attached in Annex 1.
12‐ Shift In‐charge will sign off the receiving documents for net received quantity.
13‐ Documents will be submitted to store department for clearance.
14‐ After clearance from store, tanker will move to gate for final exit.

Page 5 of 8
BSPM Power House

Chemical
Tanker at Gate
Information to Store
Seal Check by Store
Department
documented
Use PPE
Reject Tanker and
Analysis for concentration
Inform Store
Un‐acceptable Result
Acceptable Result
Unloading by Chemical
Operator
documented
Signed off by
Shift Incharge
Documents submission to
store and Exit
Page 6 of 8
BSPM Power House

Annexure 1
Page 7 of 8
BSPM Power House

OMS‐BSPM‐0007
Month: ____________________________
HCl NaOH H2SO4

Date
Concentration Quantity Concentration Quantity Concentration Quantity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
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Safety Coordination Committee

Table of Contents
Objective: ....................................................................................................................................................... 3
Role of Safety Coordination Committee ......................................................................................................... 3
Safety Committee Membership ..................................................................................................................... 3

Page 2 of 3
BSPM Power House
Safety Coordination Committee

Objective:
 Promote safety awareness ‐ Sell Safety!
 Change attitude and get OMS people actively involved.
 Motivate OMS co‐workers.
 Identify and remove or control Safety hazards before people get hurt.
 Search for solutions to Safety problems.
Role of Safety Coordination Committee
 Work with the area manager on safety issues.
 The implementation of the respective safety programs.
 Schedule and attend weekly or monthly safety meetings.
 Communicate and discuss safety issues, problems of compliance, and plan ways to improve and
enforce compliance.
 Coordinate the safety monitoring, inspection and / or audits.
 Inquire and communicate with any sub‐contractor safety issues.
 Review of statistics and records, schedule and perform joint work place safety inspections, plan
safety training etc.
 Sharing & communicating of safety reports etc.
 Weekly, Monthly and Quarterly “Safety Walks”.
 Recommend ways to promote safety, production, and good housekeeping.
 Accountability setting criterion against any violation.
 To review safety manual.
Safety Committee Membership
 Plant Manager (or his designee).
 Representative: from each area (or alternates).
 HSE Coordinator
Page 3 of 3
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Emergency Response Procedure

Table of Contents
Objective: ....................................................................................................................................................... 3
Procedure for Emergency Response .............................................................................................................. 3
Training ........................................................................................................................................................... 3

Page 2 of 3
BSPM Power House
Emergency Response Procedure

Objective:
OMS staff has to follow Bulleh Shah Paper Pills (Packages) Emergency Response Program and guidelines
for the protection of plant, people, and equipment damage. The objective of the Emergency Response
Procedure is to;
 Recognize and plan for appropriate responses to an emergency so that the associated risks with
the emergency may be prevented or mitigated.
 Train and prepare individuals working inside the installation so that they can respond effectively.
Procedure for Emergency Response
 In case of any emergency, OMS staff has to inform BSPM safety department.
 OMS staff has to use BSPM Telephone Extension No. 333 in case of any emergency.
 After informing BSPM Safety Department, OMS staff has to follow their instructions.
 OMS Shift In charge shall be the immediate contact person for BSPM Safety Department
Training
BSPM Safety department is conducting different training programs and drills to mitigate emergency
situations. OMS staff has to attend their training program, whenever invited.
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Incident Reporting Procedure

Table of Contents
Objective ........................................................................................................................................................ 3
Procedure ....................................................................................................................................................... 3
Flow Chart ...................................................................................................................................................... 4
Annexure 1 ..................................................................................................................................................... 5
Incident Report Form ..................................................................................................................................... 6
Investigation Process ...................................................................................................................................... 7

Page 2 of 8
BSPM Power House

Objective
This procedure provides OMS people with instructions and guidelines to report any incident / accident in
the Power House. Following are the objectives to achieve by reporting incidents / accidents;

1. To standardize the reporting of all Power Plant incidents and accidents at BSPM Power House.
2. To establish a process of investigating and evaluating incidents and accidents.
3. To gather facts, establish the root causes(s) of an accident.
4. To develop recommendations and follow‐up actions to prevent recurrence of similar
incident/accidents.

Procedure
a. It is the responsibility of the OMS person to report incidents and accidents immediately to their
immediate in‐charge. Failure to comply may result in disciplinary action.
b. The person who was actually involved in the incident or accident shall fill the Incident / Accident
Report before he leaves Power House.
c. Operations team leader will ensure documentation of all incidents and accidents utilizing the
Incident / Accident Report.
d. Operations team leader will Participate in the investigative process and prepare or assist in
writing of any narrative report.
e. Operations team leader will inform Plant Manager within 24 hours of the incident occurrence.
f. Initial report of incidents involving death and serious injury (requiring hospitalization) must be
made to the OMS regional office.
g. Provide an overview of the event to the Plant Manager and other Area Managers at next
scheduled meeting.
h. Operations team leader will track corrective action to assure timely completion.
i. The Plant Manager or designee will appoint an Accident Investigation Committee for all serious
incidents and accidents with high potential for personal injury or property loss.
j. The Plant manager or designee will approve and be responsible for all notifications made outside
of the BSPM Power House Facility.
k. Packages In‐charge of Power House must review the report and form a committee for
investigations.
l. According to the National legislation {Factories Act 1934 (33N)} where any Accident occurs which
causes death or any bodily injury and injured person is prevented to resume his work during the
48 hrs after the accident occurred, the Plant Manager or his designee shall send notice to the
concerned authorities (Factories Inspector and District Coordination Officer).

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BSPM Power House

Flow Chart

Incident
Person involved in incident will
initiate incident report before
leaving the site
Report must carry the following
details;
1‐ Date
2‐ Area
3‐ Detail of event
4‐ Extent of damage
5‐ Reason of incident
6‐ Nature of problem
Operations
Team Leader
must review and
comment
Plant Manager
must review and
comment
Packages
Power House
In‐charge shall review and form
a committee for investigation
and RCA

Page 4 of 8
BSPM Power House

Annexure 1

Page 5 of 8
BSPM Power House

Incident Report Form
Report No: ‐ ‐ Date:____________________

Area:______________________ Time of Incident:____________________________________

Detailed Description of Incident:___________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

Person with Control of object:_____________________________________________________________

Extent of Damage: ______________________________________________________________________

Reason of Incident:_____________________________________________________________________

Nature of Problem:_____________________________________________________________________

Operations Team Leader comments: ______________________________________________________

_____________________________________________________________________________________

Name & Signature:______________________________________ Date:______________________

Operations Team Leader comments: ______________________________________________________

_____________________________________________________________________________________

Name & Signature:___________________________________ Date:______________________

Plant Manager Comments: ______________________________________________________________

_____________________________________________________________________________________

Name & Signature:_________________________________ Date:_______________________

Packages Power House In‐charge Comments: _______________________________________________

_____________________________________________________________________________________

Name & Signature:_________________________________ Date:_______________________
Page 6 of 8
BSPM Power House

Investigation Process

Packages Power House In‐charge will form an investigation committee for evaluation of the incident. The
investigation report may constitute the following pattern.

1. Executive Summary

This short section shall describe in sufficient detail the nature of the incident, the details of who or what was
involved, how it occurred, the resulting effects and other consequences of the incident. It should also state
briefly the main findings and recommendations resulting from the investigation.

2. Background

This section forms the main body of the report. The narrative shall describe in detail the events leading up to
the accident, the accident itself and consequential damage and/or injury. There shall be a detailed description
of the actions of the people involved and of the application of the work control, PTW and other relevant
procedures that were being followed or should have been followed.

Failures of management control systems and of plant or equipment shall be described as well as human error
and other contributory factors.

Where appropriate, detailed technical reports, witness statements, photographs, sketches or other
illustrations can be included here or as appendices to the report.

3. Description of Incident
a. Sequence of events leading up to incidents
The general approach to an investigation will involve inspection and consultation but it may also require a
detailed technical analysis of failed plant or equipment.

b. The Incident
The narrative shall describe in detail the events leading up to the accident, the accident itself and
consequential damage and/or injury.

There shall be a detailed description of the actions of the people involved and of the application of the work
control, PTW and other relevant procedures that were being followed or should have been followed.

4. Evidences
a. Site Inspection
The scene of the accident should be inspected and, if possible, photographed as found immediately after
the event. The investigating party should make notes of significant observations.

b. Witnesses
Interviews should be conducted with the parties involved, i.e., the victim(s), eyewitnesses and others that
were in the vicinity at the time of the incident. Interviews with supervisors and other relevant personnel
must also be considered.

5. Training (Knowledge and Skills)

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BSPM Power House

All employees, on recruitment, shall be made familiar with the contents of this Procedure and at yearly
intervals thereafter in staff awareness sessions.
6. Conclusion
This short section shall highlight the significant factors that address the root cause of the accident. If
appropriate a bullet list of key findings shall be given.

7. Recommendation of the Investigation committee
This section requires clear and specific individual recommendations that address each key area of failure and
that will significantly contribute to the prevention of a recurrence of a similar incident.

8. Follow up and time line for completion of assigned task
The Plant Manager shall be responsible for reporting incidents to the Company Loss Adjuster and
Company Insurance Co‐coordinator and co‐coordinating any subsequent follow‐up investigation.

Page 8 of 8

41 MW CHP Power Plant
Operational Improvement Program
Training & Qualification

Policy


Contents

Purpose ........................................................................................................................................... 3
Guiding Principles ........................................................................................................................... 3
End Products ................................................................................................................................... 3
Scope ............................................................................................................................................... 4
Constraints ...................................................................................................................................... 4
Annex ‐ A ......................................................................................................................................... 6

P a g e | 2

Purpose

 To support the implementation of the Operations Improvement Program in order to achieve the goals
through development of a comprehensive “best practices”Training and Qualification (T&Q) Program.

Guiding Principles

 People development and their growth is a key driver for achieving the overall organizational goals. OMS
believes in developing their people through an extensive growth program at 41 MW CHP in order to get
the reliable operation in 2011 and beyond.

 Best practices exist or will be flourished through training and qualification of OMS people at 41 MW CHP,
and adoption of these practices will provide the means to improve the operational performance and/or
lower the operational risk for the businesses of all stakeholders.

 All OMS people at Plant shall be trained and qualified to possess and apply the knowledge and skills
needed to perform activities that support safe, reliable and low risk plant operation

 T&Q Program structure will be designed to facilitate continuous improvement.

End Products

 Standardize qualification manuals as to various formats and other contents (to the extent possible)

 Develop set of peer review protocols for Training & Qualification

 Maintain library of qualifications, job descriptions/ responsibilities, and skills/capabilities for job functions

 Ensure on‐going participation in Peer Reviews to advise on T&Q practices and other areas of expertise

 Continuously seek out improvements in Best Practices with lessons learned , visits to other regions, or
other sources and disseminate to appropriate maintenance people

 Maintain periodic meetings of the Working Group (WG) to facilitate exchange and communication of
ideas that will help in improving operational reliability and lower operational risk.

 Work with plant to ensure that lessons learned from unplanned incidents are communicated/adopted /
implemented as applicable.

 Multi skill organization wherein people could feel a sense of Ownership.

P a g e | 3

Scope

The Training & Qualification program will Consider the following requirements when identifying the key
elements of a Best Practices T&Q Program

a. Organization, Responsibilities and Accountabilities
 Define organizational structure and mission
 Define Job Functions and Responsibilities as a source document when performing job/task
analysis for knowledge and skill requirements for training and qualification programs
b. Training Programs
 Design, develop, evaluate, and modify training and qualification programs to meet the
needs of operations and maintenance personnel
 Identify skills and capabilities required to perform job functions
 Use Training resources and materials that meet recognized standards, such as OSHA and
IEEE
 Plant Qualification Flow Chart is attached as Annex‐A.

c. Initial Training and Qualification
 Develop initial training and qualification which verify that plant people possess the basic
knowledge and skills necessary to perform job functions competently before independent
job assignments

d. Continuing Training and Re‐qualification
 Verify that knowledge and skills needed to successfully perform assigned tasks are
maintained and enhanced
 Address needs identified through ongoing reviews of job performance

e. Training Program Records
 Develop method to assure that records of each individual's performance in the training and
qualification program are maintained in an auditable manner

f. Training Program Approval, Effectiveness, and Feedback
 Develop process for reviewing training programs, through feedback from plant people or by
considering any performance trends as a result of monitoring activities that indicate
knowledge or skills need improvement
 Institute incentives for individuals attaining specialized licenses or certifications

g. Control of Contractor Personnel
 Develop process to assure that contractor personnel who perform planning, scheduling,
maintenance, or modifications on Plants are qualified to perform those tasks

h. Advanced Training and Development
 Incorporate programs above craft level to prepare individuals for plant leadership positions

Constraints
.
 Implementation of best practices may require some internal reorganization of OMS.
P a g e | 4

 Use of resources from other sources may be required from time to time, and will require review or
approval of OMS leadership.
 Consider cost of formal training methods
 Ensure implementation of T&Q best practices are in accordance with contractual obligations such as labor
agreements.
 Afford businesses sufficient flexibility to design T&Q program to fit their business needs

P a g e | 5

Annex ‐ A
Plant Qualification Flow Chart
Operator Plant Leaders identify specific Plant Leaders Asses & develop the

Qualification areas & systems required for necessary requirements and
Program Qualification Books scope of program
Review the businesses SMS Review the Plant O&M Review the level of experience

program to ensure that key Manuals the plant technicians currently
elements are incorporated into posses and identify goal
Qualification Books
Draft initial qualification program Finalize the walk down procedure
Plant
based on Business needs and and exam process
Manager
goals
Approval
Make necessary
Changes to Program
Begin actual Qualification Technicians work through Qual. All Sections

Programs with Plant Technicians Books, study and obtain Sign‐offs Signed Off
Continue studying
systems
Perform System walk Technician Meet with Plant

down with Team Passed Manager for Final
Leader Sign‐off
Work on sections Technician Qualified
that were not passed

P a g e | 6

Bulleh Shah Paper Mills
Packages (Private) Limited
Kasur

Boiler Area
Qualification Book

Name: __________________________

Approved by: Operations Team Leader

________________________________
Name & Signature

Date:______________
1
Contents
Section 1 – Knowledge Requirement..................................................................................... 3
1. Heavy Fuel Oil & Natural Gas ......................................................................................... 3
2. Feed Water System......................................................................................................... 8
3. Air and Gas System ....................................................................................................... 13
4. Combustion System ...................................................................................................... 15
5. Main Steam................................................................................................................... 21
6. Common System ........................................................................................................... 24
7. Boiler Chemistry ........................................................................................................... 27
8. Outage Activities........................................................................................................... 29
9. General ......................................................................................................................... 30
10. Safety ........................................................................................................................ 33
Section 2 – Performance Requirement................................................................................ 35
11. Practical Duties ......................................................................................................... 35
Section 3 – Final walk down................................................................................................. 36
12. Completion Requirement ......................................................................................... 36

2

Bulleh Shah Paper Mills
Packages (Private) Limited
Kasur

Turbine Area
Qualification Book

Name: __________________________

Approved by: Operations Team Leader

________________________________
Name & Signature

Date:______________

Contents
1. Condenser ............................................................................................................................................. 2
2. Condenser Air Extraction ...................................................................................................................... 6
3. Steam Turbine Gland Steam Sealing System and drains ...................................................................... 8
4. Condensate System ............................................................................................................................. 10
5. Extraction System ............................................................................................................................... 12
6. Cooling Water System ......................................................................................................................... 13
7. Lube and Control Oil System: .............................................................................................................. 15
8. Turning Gear ....................................................................................................................................... 19
9. Turbine ................................................................................................................................................ 22
10. Protection and Safety Equipment ................................................................................................... 25
11. Generator Proper: ........................................................................................................................... 28
12. Transformers: .................................................................................................................................. 30
1. Safety .................................................................................................................................................. 31
1. Practical Duties ................................................................................................................................... 33
2. Completion Requirement ................................................................................................................... 34

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Preventive Maintenance Initiation Strategy

Table of Contents
Abbreviations: ................................................................................................................................................ 3
Objective: ....................................................................................................................................................... 4
Methodology .................................................................................................................................................. 4
Responsibility: ................................................................................................................................................ 4
Annexure 5 ‐ Electrical Maintenance Forms ................................................................................................... 9

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BSPM Power House

Abbreviations:

H High
HH High High
I/O Input / Output
L Low
LL Low Low

Page 3 of 9
BSPM Power House

Objective:
The objective of this procedure is to define initiation methodology of Preventive Maintenance Program.
The term “Preventive Maintenance” implies the systematic inspection and detection of potential failure
before they occur. PM is a broad term and involves varying approaches for problem avoidance and
prevention is adopted, here at BSPM Power House we adopted “Time Based Preventive Maintenance”.
Methodology
While preparing Preventive maintenance program the following elements were incorporated:

Quarterly and Annual preventive maintenance activities, execution date and next execution date are
mentioned to initiate next preventive maintenance due date. The detail of annexure is as follows;

o 65 TPH Boiler Quarterly and Annual maintenance Schedule form
o 41 MW CHP Unit Quarterly and Annual maintenance Schedule form
o 65 TPH Quarterly and Annual maintenance Schedule form
o 41 MW CHP Unit Quarterly and Annual maintenance Schedule form
o Electrical Quarterly and Annual maintenance Schedule form

Responsibility:
This will be the responsibility of Maintenance Engineer (Mechanical, Electrical and Instrument) to
maintain the initialization sheet and initialize the activity as well.

Page 4 of 9
BSPM Power House


Page 5 of 9
O&M Management System BSPM Power House
PREVENTIVE MAINTENANCE PLAN MECHANICAL 65 TPH & AIR COMPRESSORS (Quarterly & Annually)
Sr# Equipment Task Description Frequency Department SD/NSD Time Req. Comple. Date Due Date
Check gasket and other internal parts of the
burner oil guns. Replace worn out parts
Check cracks at gas nozzle and air damper
1 Burners flapper loose , clean/ repair/ replace where Quarterly Mechanical S.D 2 Days
necessary
Check burner diffuser plate condition
Check burner oil gun position from inside
Check looseness of bolts and nuts. Check
alignment, realign if not correct.Check
physically bearing condition for cracks or
pitting. Inspect FD Fan ducts. Check for any
crack or rust and check impeller condition and
2 FD Fan cone inlet condition.Clean, inspect and Quarterly Mechanical S.D 2 Days
lubricate all damper bushes along with
linkages.Check crack of welding parts.Check
sealing strips on the edges of the dampers.
Repair/ replace if damaged.Check motor
electrical load with and without coupling.
Thoroughly inspect coupling for signs of wear
and cracks, Tighten bolts
Use the dial indicator to check the coupling
alignment
Pump not running ‐ Standby service: Overfill
Boiler Feed Water bearing housing to bottom of the shaft and
3 Quarterly Mechanical S.D 3 Days
Pump rotate several turns by hand to coat the shaft
and the bearing with oil.
Apply a light coat of rust preventive product
to expose machined surfaces to prevent rust
and corrosion.
Inspect the seal and gear box condition
HFO Booster Check coupling condition and alignment
4 Check condition of the gear’s wear and tear. Quarterly Mechanical S.D 3 Days
Pump
Replace when necessary
Inspect the surface of the inner tube.
Lubricate and clean it if necessary
Check wear of gear teeth, repair if necessary
Check looseness of bolts, nuts and fittings
5 Soot Blower Inspect glands and adjust/ replace if necessary
Quarterly Mechanical S.D 3 Days
Inspect poppet valve (lap the seat and disc if
necessary)
Hardness testing of tubes on furnace side and
economizer side
Thickness testing of tubes on furnace side and
economizer side
Clean soot and dirt accumulated on the tubes
Overhaul fall of refractory and others
Check dirt and debris entrapped within the
fins of economizer tubes and clean thoroughly
6 Boiler Furnace Inspect the damaged tubes and repair if Quarterly Mechanical S.D 3 Days
necessary
Check the anti‐vibration plates and replace
where necessary
Furnace and tubes Cleaning
Furnace Washing
Check crack at welding parts where they are
fixed and readjust the travel if is abnormal
Carry out inspection of all hangers and
Piping Spring
7 supports, replace if required 1 year Mechanical S.D 3 Days
Hanger Reinstall hangers if the installation is not
proper
Readjust the travel if is abnormal
BSPM Power House

Page 6 of 9
PREVENTIVE MAINTENANCE PLAN MECHANICAL 41 MW & 200 TPH(Quarterly & Annually)
Sr# Equipment Task Description Frequency Deratment SD/NSD Time Req. Comple. Date Due Date
Check gasket and other internal parts of the
burner oil guns. Replace worn out parts
Check cracks at gas nozzle and air damper
1 Burners flapper loose , clean/ repair/ replace where Quarterly Mechanical S.D 2 Days
necessary
Check burner diffuser plate condition
Check burner oil gun position from inside
Check looseness of bolts and nuts.

Check alignment, realign if not correct.
Check physically bearing condition for cracks or
pitting.
Inspect FD & ID Fan ducts. Check for any crack
or rust and check impeller condition.
Clean, inspect and lubricate all damper bushes
along with linkages.
Check crack of welding parts.
2 FD Fan Check sealing strips on the edges of the
dampers. Repair/ replace if damaged.
Check motor electrical load with and without
coupling.
Check rust and contamination of driving
mechanism specially gear to inlet vane from the
fan inside and clean if necessary.
Check looseness, rust and fall of lock nuts, bolts
and other fitting.
Check looseness of bolts and nuts.

Check alignment, realign if not correct.
Check physically bearing condition for cracks or
pitting.
Inspect FD & ID Fan ducts Check for any crack
Inspect FD & ID Fan ducts. Check for any crack
or rust and check impeller condition.
Clean, inspect and lubricate all damper bushes
along with linkages.
Check crack of welding parts.
2 ID Fan Check sealing strips on the edges of the
dampers. Repair/ replace if damaged.
Check motor electrical load with and without
coupling.
Check rust and contamination of driving
mechanism specially gear to inlet vane from the
fan inside and clean if necessary.
Check looseness, rust and fall of lock nuts, bolts
and other fitting.
Hardness testing of tubes on furnace side and
economizer side.
Thickness testing of tubes on furnace side and
economizer side.
Clean soot and dirt accumulated on the tubes.
Overhaul fall of refractory and others.
Check dirt and debris entrapped within the fins
of economizer tubes and clean thoroughly.
6 Boiler Furnace Inspect the damaged tubes and repair if 1 year Mechanical S.D 3 Days
necessary.
Check the anti‐vibration plates and replace
where necessary.
Check cracks in couplers using DPT method.
Furnace and tubes cleaning.
Furnace washing.
Check crack at welding parts where they are
fixed and readjust the travel if is abnormal
Carry out inspection of all hangers and supports,
Piping Spring replace if required
7 1 year Mechanical S.D 3 Days
Hanger Reinstall hangers if the installation is not proper
Readjust the travel if is abnormal
Clean and inspect Deaerator dome plates for
deterioration.
Cleaning of Sieve Trays fouling.
Inspect mixer section of Deaerator dome.
Inspect Dome shell.
8 Deaerator Inspect all interconnecting piping of make‐up 1 year Mechanical S.D 3 Days
water and return condensate of deaerator
dome.
Inspect for proper Stairs and ladders condition.
With protractor, check fan blades for correct
pitch.
Check fan tip to wall clearance (1.75 to 2 inches
is recommended)
9 CT Fan Torque tight hub bolts.
1 year Mechanical S.D 1 Days
Inspect blades for cracks or damage.
Check direction of fan rotation.
Clean fan blades.
Clean and inspect inside of Deaerator storage
tank (vessel).
Inspect weld of steam sparger pipes and its
cleaning.
Visually inspect for loose bolts and clamps.
Check for deformation of supports of steam
sparger pipes.
Deaerator Storage Inspect vessel for corrosion and local cracks.
10 1 year Mechanical S.D 2 Days
Vessel Inspect baffle plate’s condition, repair if
required.
Inspect the condition of nozzles and flanges.
Visually inspect external insulation and cladding
of Deaerator and pipe lines.
Check the condition of safety valves.
Clean and inspect inside of Steam Drum.
Inspect weld of steam sparger pipes and its
cleaning.
Visually inspect for loose bolts and clamps.
11 Steam Drum 1 year Mechanical S.D 3 Days
Check for deformation of supports of steam
sparger pipes.
Inspect vessel for corrosion and local cracks.
Check seat and plug of the valve. Repair/
replace if necessary
12 Safety Valves Calibrate the valve at its set point (by Trevi Test 1 year Mechanical S.D 3 Days
method)
Visually inspect the condenser tubes external
surface for damage, deposit and excessive
corrosion.
Visually inspect the drain pipe penetration in
the condenser for damage.
Visually inspect the tube support plate and
13 Condenser baffle plate for damage and excessive corrosion. 1 year Mechanical S.D 3 Days
Check HP Turbine by pass inlet nozzle for cracks.
Visually inspect the water box and tube sheets
for damage and deposits.
Inspect water box epoxy paint and repair, if
needed
Clean condenser tubes through high pressure
jet machine.
With protractor, check fan blades for correct
pitch.
Check fan tip to wall clearance (1.75 to 2 inches
is recommended)
Torque tight hub bolts.
14 CT Fan 1 year Mechanical S.D 3 Days
Inspect blades for cracks or damage.
Check direction of fan rotation.
Clean fan blades.
Take service readings (air, oil, water
temperature and pressure)
Check cooler functions (approach temperature)
Change intercooler condensate check valve
Service intercooler blow down valve
Check for air, water and oil leakage
Check operation of safety valves
Check for presence of water in lube oil
Change Rotor Z oil (16000 hrs or 2‐yearly)
Change compressor oil filter (8000 hrs or
annually)
Inspect/ change air filter element(s)
Replace filter element of gear case breather
9 Air Compressor Check cycle of air intake throttle valve 1 year Mechanical S.D 3 Days
Replace diaphragm of air throttle valve
Replace bearing block (air intake valve)
Overhaul air intake valve
Check functioning of check valve (8000 hrs or
annually)
Overhaul check valve
Check condition of balance piston diaphragm
Change balance piston diaphragm
Check/ service condensate drain(s)
Clean fan cowl of electric motor
Check rubber inserts of drive coupling (arr. E)
Replace inserts of drive coupling (arr. E)
Take and record all S. P. M. readings. On VSD
l h d
BSPM Power House

Page 7 of 9
PREVENTIVE MAINTENANCE PLAN INSTRUMENTS 65TPH(Quarterly & Annually)
Type of Duration
Sr# Equipment Task Description Frequency Department SD/NSD Completion Date Due Date
Maintenance Required
Visual Inspection,
Quarterly I&C Isolation Not Req. Essential Care 1 WEEK
Burners ON/OFF Cleaning, Covering,
1
Valves Repair, Replacement,
If Required I&C Isolation Req. Fixed Maintenance
Overhauling,Servecing
Visual Inspection,
Cleaning, Covering,
2 Control Valves
Repair, Replacement,
Visual Inspection,
Cleaning, Covering,
3 Field Instrument
Visual
Safety Set Points Inspection,Cleaning,
4
Boiler Repair,Replacement,
Visual
Inspection,Cleaning,
5 Ignation Transformer
Repair,Replacement,
BSPM Power House


Page 8 of 9
PREVENTIVE MAINTENANCE PLAN INSTRUMENTS 41 MW&200 TPH (Quarterly & Annually)
Type of Duration
Sr# Equipment Task Description Frequency Department SD/NSD Completion Date Due Date
Maintenance Required
Visual Inspection,
Burners ON/OFF Cleaning, Covering,
1
Valves Repair, Replacement,
Visual Inspection,
Cleaning, Covering,
2 Control Valves
Visual Inspection,
Cleaning, Covering,
3 Field Instrument
Visual
4 Gauges
Repair,Replacement,
Visual
5 Turbine
Repair,Replacement,
Visual
6 ON/OFF Valves
Repair,Replacement,
Visual
Annualy I&C Isolation Not Req. Essential Care 1 WEEK
Turbine Protection Inspection,Cleaning,
7
PREVENTIVE MAINTENANCE PLAN INSTRUMENTS 41 MW&200 TPH (Quarterly & Annually)
7
System Repair,Replacement,
Visual
Annualy I&C Isolation Not Req. Essential Care 1 WEEK
Boiler safety Tripping Inspection,Cleaning,
8
set Point Repair,Replacement,
BSPM Power House


Page 9 of 9
PREVENTIVE MAINTENANCE PLAN ELECTRICAL(Annually)
Inspection, checking and Cleaning of thyrister stacks
and all other electrical circuits.Inspection of AVR
control system PCBs.Cooling fans inspection and
servicing.Testing of protective devices power supply
1 41MW_ Exciter units and auxiliary relays.check tighteness of all 1 year Electrical S.D 2 Days
connections and bolted joints.Servicing of field
breakers.Rotor earth fault coil and brush
checking.Rotor earthing brushinspection from drive
end side.
Inspection, checking and cleaning of main busburs,
tightning of bus bars.checking of VT fuses.Tightning
of CT,s star and output side.Testing of protective
devices power supply units and auxiliary relays.check
2 41MW_Generator tighteness of all control connections and bolted
1 year Electrical S.D 2 Days
joints.Resistance measurment of earthing
resistor.insulation resistance measurment of
generator.
cleaning of motor . Maggering of cable.Checking of
Motors and MCC contactor contact and cleaning .UMC checking and
3 1 year Electrical S.D 3 Days
Demin Plant power supply voltage measurement
Insulation and winding resistance test of
MOTORS AND motor.cleaning of motor .Maggering of cable.
MCC OF HFO Tightning of connection from both side.Control
4 connection tightning .Checking of contactor 1 year Electrical S.D 3 Days
LOADING AND
UNLOADING contact and cleaning .UMC checking and power
supply voltage measurement
motor.cleaning of motor .Maggering of cable.
MOTORS AND
Tightning of connection from both side.Control
5 MCC OF RAW 1 year Electrical S.D 3 Days
connection tightning .
WATER Checking of contactor contact and cleaning .UMC
checking and power supply voltage measurement
MOTORS AND Tightning of connection from both side.Control
6 MCC OF AIR connection tightning . 1 year Electrical S.D 3 Days
COMPRESSOR Checking of contactor contact and cleaning .UMC
MOTORS AND connection tightning .Checking of contactor
MCC OF 65TPH contact and cleaning .UMC checking and power
MOTORS AND connection tightning .Checking of contactor
MCC OF 41MW contact and cleaning .UMC checking and power
MOTORS AND
9 connection tightning . 1 year Electrical S.D 3 Days
MCC OF 200TPH
Checking of contactor contact and cleaning .UMC
Magger Breaker.Trip Circuit.Tightning Cabel.Local
10 HT BREAKER 1 year Electrical S.D 3 Days
Indication
11 KV SWITCH All the loose external dirt removal (cleaning agent
GEAR Carbon tetrachloride, brush, cloth and vacuum
cleaner).Vacuum testing of each breaker.Testing
(J1_11KV,J2_11KV,
11 of transformer protection relays.Cleaning of 1 year Electrical S.D 1 Days
J3_11KV),utility
insulators and inspection for signs of cracking or
area_11KV&41M damage.Ensure that all fastening are tight and
W Aux_11KV that good contact is maintained for all wiring
connections and terminals.For all control relay and
contactors inspect mechanical parts for free
movements.
All the loose external dirt removal (cleaning agent
Carbon tetrachloride, brush, cloth and vacuum
cleaner).Servicing of breaker and its
contacts.Check the tightness of nuts and
0.4 KV SWITCH
12 bolts.Insulators should be clean and inspected for 2 year Electrical S.D 5 Days
GEAR
signs of cracking or damage.Ensure that all
fastening are tight and that good contact is
maintained for all wiring connections and
terminals.
Measurement of insulation & winding
resistance.Testing of Oil dielectric strength.Testing
of tan (DELTA) of Oil.Water content check (oil
41MW_Startup chemical analysis).Dissolved Gas analaysis of Oil
13 1 year Electrical S.D Days
Transformer (DGA).Oil leakage of bushings and cleaning of
porcelaine.Cooling system inspection and
servicing.Inspection of alarm contacts.
Utility Area
14 of tan (DELTA) of Oil.Water content check (oil 1 year Electrical S.D 5 Days
Transformers chemical analysis).Dissolved Gas analaysis of Oil
(DGA).Oil leakage of bushings and cleaning of
11MW Startup
15 of tan (DELTA) of Oil.Water content check (oil 1 year Electrical S.D 5 Days
Transformer chemical analysis).Dissolved Gas analaysis of Oil
(DGA).Oil leakage of bushings and cleaning of
Batteries reading (Voltage and Amps).Load testing
UPS 41MW power and boost charging.inspection / servicing of
16 regulation cards.Check tightness of terminals on 1 year Electrical N.S.D 1 Days
plant
components subject to vibration like transformer,
chokes, contactors, relays etc.
Battery Charger and boost charging.inspection / servicing of
17 1 year Electrical N.S.D 1 Days
41MW regulation cards.Check tightness of terminals on
Main HT battery and boost charging.inspection / servicing of
charger regulation cards.Check tightness of terminals on
Diesel engine and boost charging.inspection / servicing of
charger regulation cards.Check tightness of terminals on
Emergency lighting and boost charging.inspection / servicing of
charger regulation cards.Check tightness ofterminals on
21 Motors Greasing 2 Months Electrical N.S.D 3 Days
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April, 2011
BSPM Power House
Equipment Duty Changeover Procedure

Table of Contents
Objective ........................................................................................................................................................ 3
Procedure ....................................................................................................................................................... 3
Annexure 1 – 65 TPH Equipments .................................................................................................................. 4
Annexure 2 – 41 MW Co‐Gen Unit ................................................................................................................. 6
Annexure 2 – Utilities ..................................................................................................................................... 8

Page 2 of 2
BSPM Power House

Objective
The objective of weekly equipment changeover is to keep all the equipment’s available.

1‐ Track the availability of all the equipment’s.
2‐ Carry out maintenance if they are not available.
3‐ Maintain equal run time of the equipment’s.
Procedure
 Change over in‐service equipment’s on weekly basis.
 If weekly change‐over is not possible, mention the reason in comments.
 If standby equipment is not available, raise work request for maintenance.
Weekly equipment duty change‐over forms are attached here as Annexures.

Page 3 of 3
BSPM Power House

Annexure 1 – 65 TPH Equipments
Page 4 of 4
BSPM Power House

Equipment Duty Changeover Form
65 TPH Boiler
Month: _____________________
Date Date Date Date Date

Boiler Feed Water Pump A
Boiler Feed Water Pump B

HFO Forwarding Pump A
HFO Forwarding Pump B

Demin Water Pump A
Demin Water Pump B
Demin Water Pump C

Remarks:

Page 5 of 5
BSPM Power House

Annexure 2 – 41 MW Co‐Gen Unit
Page 6 of 6
BSPM Power House

41 MW CHP Unit
Month:_____________________

Boiler Feed Water Pump A
Boiler Feed Water Pump B
Boiler Feed Water Pump C

HFO Forwarding Pump A
HFO Forwarding Pump B

Turbine Condensate Pump A
Turbine Condensate Pump B

Return Condesate Pump A
Return Condesate Pump B

PRD Injection Pump A
PRD Injection Pump B

Demin Water Pump A
Demin Water Pump B

Remarks:

Page 7 of 7
BSPM Power House

Annexure 2 – Utilities
Page 8 of 8
BSPM Power House

Utilities
Month: ________________

Air Compressor 1
Air Compressor 2
Air Compressor 3
Air Compressor 4

Well Water Pump 1
Well Water Pump 2
Well Water Pump 3
Well Water Pump 4
Well Water Pump 5

Raw Water Pump 1
Raw Water Pump 2
Raw Water Pump 3
Raw Water Pump 4

Remarks:

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RReevv 00
April, 2011
BSPM Power House
Electrical System Restoration Procedures

Table of Contents
Abbreviations: ................................................................................................................................. 3
Objective: ........................................................................................................................................ 4
Restoration of Electrical System after Black Out (A) ....................................................................... 5
Restoration of Electrical System after Black Out (B) ....................................................................... 6
Synchronization of 41 MW ST with NTDC Network ........................................................................ 7
Synchronization with WAPDA ......................................................................................................... 8
Annexure‐1 ...................................................................................................................................... 9
Selector Positions ............................................................................................................................ 9

Page 2 of 9
BSPM Power House

Abbreviations:

CB Circuit Breaker
EDG Emergency Diesel Generator
ST Steam Turbine
TG Turning Gear
CRS Control Room Supervisor
Page 3 of 9
BSPM Power House

Objective:
The objective of this procedure is to further “protect the BSPM Assets”, this being paramount to the
interest of both BSPM people as well as contractor people & the company at large. On complete black out
to ensure the proper restoration of electrical system.
During the black out, leading role in restoration of the systems will be played by the CRS who is
performing the duty in Electrical Control Room. This procedure is to define predetermined steps to
restore electrical system.


Page 4 of 9
BSPM Power House

Restoration of Electrical System after Blackout (A)
Present Scenario
 WAPDA Power failed and BSPM Complex is in Blackout
 WAPDA power resumed – Voltage reading appeared in switchyard

Grid Station Operator Actions

 Close 132 KV Circuit Breaker
 Close 11 KV Breaker (4097/20)
 Close 11 KV Breaker # 6 (4466/05) for (WAPDA) incomer and informed CRS to initiate restoration
process.

Control Room Supervisor (CRS) Actions

 Close main incomer from WAPDA CB K 06. (Tie breakers remain closed)
 Close outgoing CB K 14 to Utility area
 Close CB # 391‐3351 for Air compressor 1& 2 and 65 TPH Boiler
 Close CB # 391‐3352 for Air compressor 3& 4
 Close CB # 371‐3352 for Demineralization Plant
 Close outgoing CB K 02 to Straw and Mill Water Area
 Inform PM‐6 Electrical department to close mill wide raw water breaker from straw local HT
Room.
 Close outgoing CB K 22 to 41 MW Auxiliary and 200 TPH Boiler
 Close outgoing CB K 01 to ETP
 Close outgoing CB K 03 to CTMP
 Close outgoing CB K 05 to CD
 Close outgoing CB K 11 to Finishing Line
 Close outgoing CB K 15 to PM‐6
 Close outgoing CB K 16 to SPP PM‐6
 Close outgoing CB K 17 to Coating
 Close outgoing CB K 21 to DIP
 Close outgoing CB K 27 to OCC (New Refiners) PM‐6
 Inform PM‐6 Electrical Department to restore the system.

Page 5 of 9
BSPM Power House

Restoration of Electrical System after Black Out (B)
Present Scenario
 WAPDA Power failed and Emergency Diesel Generator is in service
 WAPDA power resumed – Voltage reading appeared in switchyard

Grid Station Operator Actions

 Close 132 KV Circuit Breaker
 Close 11 KV Breaker (4097/20)
 Close 11 KV Breaker # 6 (4466/05) for (WAPDA) incomer and informed CRS to initiate restoration
process.

Control Room Supervisor (CRS) Actions

 Close main incomer from WAPDA CB K 06. (Tie breakers remain closed)
 Close outgoing CB K 14 to Utility area
 Close CB # 391‐3351 for Air compressor 1& 2 and 65 TPH Boiler
 Close CB # 391‐3352 for Air compressor 3& 4
 Close CB # 371‐3352 for Demineralization Plant
 Close outgoing CB K 02 to Straw and Mill Water Area
 Inform PM‐6 Electrical department to close mill wide raw water breaker from straw local HT
Room.
 Ensure that EDG supply is off for 41 MW Auxiliary and 200 TPH Boiler
 Close outgoing CB K 22 to 41 MW Auxiliary and 200 TPH Boiler
 Close outgoing CB K 01 to ETP
 Close outgoing CB K 03 to CTMP
 Close outgoing CB K 05 to CD
 Close outgoing CB K 11 to Finishing Line
 Close outgoing CB K 17 to Coating
 Close outgoing CB K 21 to DIP
 Close outgoing CB K 27 to OCC (New Refiners) PM‐6
 Inform PM‐6 Electrical Department to restore the system. They will disconnect EDG supply and
normalize the system.
Page 6 of 9
BSPM Power House

Synchronization of 41 MW ST with NTDC Network

 Ensure Turbine start up is complete and ready for synchronization.
 At 90% RPM excitation CB ON automatically, Turbine operator has to ensure
 Turbine operator will adjust Voltage and frequency.
 Inform CRS that 41 MW Turbine is ready to synch.
 CRS will reset the CB K 20
 CRS and Turbine operator will coordinate to match Voltage and frequency.
 Turbine operator give ON command to 52‐G from CRT
 Turbine operator will ON and Release synchronization command.
 Synchro check relay will check and if conditions fulfill, it will give command to close the 52G.
 Turbine operator will switch ON it’s Active Power Control
 Adjust load set point to 2‐3 MW.
 Adjust reactive power
 If reactive power is positive, adjust Power Factor set point at 0.90

Page 7 of 9
BSPM Power House

Synchronization with WAPDA

Status: 41 MW Unit in Island Mode and WAPDA is available

 WAPDA incomer CB K 06 select on AUTO.
 Put selector switch # 2 to Position No. 1
 Selector switch No 3 to Local (Positions – Local – OFF‐ Remote)
 Selector Switch No 1 (Synchro‐scope Switch) to ON position
 Match Frequency , Voltage and Phase Angle
 When speed become normal of Synchro‐scope and Voltage of both bus bars are equal
 When all Synchro‐scope is on 900, close CB K‐06
 Hold push button of K‐06 for 30 Seconds to avoid opening. (This is to bypass reverse relay of CB K
06)

Page 8 of 9
BSPM Power House

Annexure‐1
Selector Positions
1‐ K‐06 WAPDA incomer
2‐ K‐08 Bus Coupler J1 – J2
3‐ K‐09 11 MW CCGT
4‐ K‐10 Future Diesel Generator Set
5‐ K‐19 Bus Coupler J2 – J3
6‐ K‐20 41 MW Steam Turbine

Page 9 of 9
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April, 2011
BSPM Power House
Air Compressors Start up Procedures

Table of Contents
Objective: ........................................................................................................................................ 3
Start up of Air Compressor .............................................................................................................. 4
Annexure – 1 ................................................................................................................................... 5

Page 2 of 5
BSPM Power House

Objective:
The objective of this procedure is to define predetermined steps for air compressor start up
with the aim of minimizing the normal wear and tear or sudden failure of equipment or its
components. Following are the objectives to achieve;


Page 3 of 5
BSPM Power House

Start up of Air Compressor
 Check electrical supply is ON
 Check lube oil level is almost 50%
 Check cooling water supply is ON
 Check CW pressure is almost 3 Bar
 Ensure CW inlet valve is open
 Ensure CW outlet valve is open
 Ensure Air outlet valve is open
 Ensure cooling water valve of dryer is half open
 Ensure dryer bypass valve is closed
 Ensure dryer inlet valve is open
 Ensure dryer outlet valve is open
 Hot air line to dryer valve open
 Ensure Compressed air receiver inlet valve open
 Check the set points (See Annexure – 1)
 Start Air Compressor

Page 4 of 5
BSPM Power House

Annexure – 1

Set Points
Priority Order Loading Set Point (Bar) Unloading Set Point (Bar)
Air Compressor 1 6.5 7.0
Air Compressor 4* 5.9 6.4

* Compressor remains on load unload mode
Page 5 of 5
BSPM Power House (the “Plant”)
Timekeeping & Overtime
Procedure (the “Procedure”)
Rev 1
November, 2011

BSPM Power House
Timekeeping & Overtime Guide Lines
Contents
1. Purpose ................................................................................................................................... 3
2. Scope and Conflict .................................................................................................................. 3
3. References .............................................................................................................................. 3
4. Procedure ............................................................................................................................... 4
4.1 Shift Workers ................................................................................................................... 4
4.2 Day Workers .................................................................................................................... 5
4.3 General Rules for All Employees ..................................................................................... 6
5. Appendices ............................................................................................................................. 7
Appendix‐1 ...................................................................................................................................... 8
Appendix‐2 ...................................................................................................................................... 9
Appendix‐3 .................................................................................................................................... 10

Page 2 of 10
BSPM Power House
1. Purpose

Hours of work, overtime and related matters in factories, industrial and commercial
establishments are governed by Pakistan applicable labour laws (“Labour Laws”). Under
normal working conditions each worker is required to work forty‐eight (48) hours in a
week and any work performed beyond it, is treated as overtime.

By nature of business, the Plant shall be operating on round the clock basis requiring a
certain number of staff members to be placed in shift duties and rest of the staff
working regular hours. Occasionally, some employees may be required to work odd
schedule hours as deemed necessary by the Plant management. For the purpose of
timekeeping the staff is divided into two groups namely shift staff and the day workers.

The purpose of this document is to define the conditions and working hours as
applicable to shift staff and day workers and assign responsibilities for timekeeping and
approval of documentation required to be subsequently used for payroll processing.

2. Scope and Conflict

These guide lines applies to all Plant personnel employed at 41 MW BSPM Power House
with whom the OMS (Private) Limited (the “Company”) has entered into employment
contracts (“Employment Contracts”).

The applicable Labour Laws shall take precedent over this Procedure in case of any
conflict.

3. References

 Labour Laws

 Employment Contracts

Page 3 of 10
BSPM Power House
4. Procedure

4.1 Shift Workers

4.1.1 The employees involved in operation of the Plant shall be placed in four (4)
working groups (shifts) named “A”, “B”, “C” and “D”. Each group shall consist of
one shift in‐charge, five shift operators and other staff. A copy of the current
shift rota is attached as Appendix‐1.

4.1.2 As per shift rota, four (4) groups will always be working as Plant operators.

4.1.3 Each group shall work at least 48 hours per week, which equals 2,496 hours per
annum.

4.1.4 The weekly time off substituting Sunday is implied in the shift rota. Since working
on holidays is inherent in the duty of the shift staff they shall be awarded equal
number of leave days in lieu of gazetted holidays for that year.

4.1.5 Where shift cover is required, this shall in the first instance be provided by the
rest shift group.

4.1.6 Any person who is requested to work hours in addition to his normal work
pattern shall be paid overtime for those hours.

4.1.7 Shift cover shall be maintained at all times. A shift worker may not leave his post
until his reliever is in position or management has made alternative
arrangements.

4.1.8 Any person’s working hours that are additional to his normal working pattern
shall be compensated for those hours by overtime at double the basic rate of
pay.

Daily rated workers will receive payment of approved overtime double the daily
rate of wages.

4.1.9 No reduction in working hours during the holy month of Ramazan shall be
allowed to the shift staff.

Page 4 of 10
BSPM Power House
4.1.10 No arrangements shall be entered into which artificially change or redistribute
overtime payments among staff. Before overtime is worked it must be
sanctioned by the department head or nominated deputy. An overtime claim
form is attached as Appendix‐2.

4.1.11 All arrangements for manning shall be subject to the needs of the business and
shall be viewed in the light of cooperation and flexibility.

4.1.12 Shift In‐Charge will be responsible for timekeeping of their groups on the shift
sign‐in register.

4.1.13 The employees working in shift may be transferred from one group to another
on a temporary and/or permanent basis by the department manager.

4.1.14 Shift‐in‐charge and Plant Chemist shall not be entitled for overtime.

4.2 Day Workers

4.2.1 Except as otherwise indicated day workers are expected to work the equivalent
of six days a week on an average of 48 hours. The Company from time to time
may fix working hours, which shall be notified through a formal site circular.

4.2.2 During the holy month of “Ramazan” the normal working hours shall be
reduced by 25% in accordance with the directive issued by the Government of
Pakistan, however, the timing will be adjusted according to the operational
needs.

4.2.3 The team leaders shall be responsible to mark presence of their group on daily
basis in the attendance register. Each department will maintain the attendance
register and on completion of each month a copy of the register duly checked,
verified and signed by the department manager shall be forwarded by the team
leaders to the finance and accounts department as a backup for the payroll.

4.2.4 Any unauthorized absence from duty shall be recorded and investigated by the
team leader. Where no satisfactory reason is established then the unauthorized
absence shall be reported to the department manager for investigation.

4.2.5 Additional hours, beyond scheduled hours will be determined by the needs of
the business as advised by department supervisor. Hours worked in excess of
Page 5 of 10
BSPM Power House
the normal working week will be considered as overtime and compensated at
double the basic salary rate. Team leaders shall approve overtime in advance
which will be reflected on the attendance register. Each department manager
or his designee will forward a copy of overtime claims (identified as Appendix‐2)
to administration department for pay roll purposes.

4.2.6 Any person required by the Plant management to work on first day of Eid shall
be compensated for the hours worked at triple the basic salary rate.

4.2.7 Plant operations and maintenance activities will periodically require additional
coverage by the respective department personnel. The department managers
have the discretion to allow compensatory time off in lieu of overtime. It is
understood that regardless of the situation compensatory time off will be
granted on an hour to hour basis.

4.2.8 All designated engineers, managers, supervisors at Plant are not authorized to
get overtime for extra hours work due to emergency condition. No
compensatory leave will be given for this extra work.

4.3 General Rules for All Employees

4.3.1 All employees are expected to be at work unless they take approved leave or
are certified medically unfit to work. An employee who misses work due to
unforeseen circumstances is required to contact his supervisor and/or control
room. Failure to do so will be regarded as a failure to report and may result in
disciplinary action.

4.3.2 All employees shall be at their place of duty/work at the time fixed.

4.3.3 No employee shall be allowed to leave the place of duty during working hours
without permission from the appropriate supervisor. Any employee seeking
absence from the normal workplace during normal working hours shall obtain
prior written authority using the form identified in Appendix‐3. The employee
will retain the signed form as the authority to be absent from the workplace
and will be expected to produce this on request. The normal workplace shall be
determined by the team leader in‐charge if this is not clear in any case.

4.3.4 Call out time as a minimum for overtime compensation shall be considered one
hour. The time exceeding one hour shall be compensated on actual basis.
Page 6 of 10
BSPM Power House

4.3.5 All the technical staff shall be encouraged to notify their respective team leader
prior to leaving the station for any contact just in case.

4.3.6 Unauthorized absence shall be dealt with under the disciplinary procedure.

4.3.7 Prior to payroll processing for the month, plant management shall have the
overtime claims approved by the plant manager or his designee.

5. Appendices

Appendix ‐1 Shift Rota
Appendix ‐2 Overtime Claim Form
Appendix‐3 Short Time Absence Form
Page 7 of 10
BSPM Power House
Appendix-1
Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Day 8 Day 9 Day 10 Day 11 Day 12 Day 13 Day 14
Shift/Date =>
A M M E E N N R R M M E E N N
B R R M M E E N N R R M M E E
C N N R R M M E E N N R R M M
D E E N N R R M M E E N N R R
M Morning Duty 07:00 to 15:00 Hrs
E Evening Duty 15:00 Hrs to 23:00 Hrs
N Night Duty 23:00 Hrs to 07:00 Hrs
R Rest
Page 8 of 10
BSPM Power House
Appendix-2
OVER TIME CLAIM

Date: _______________

Employee No. ___________________ Name: ________________________________

Designation: ____________________ Department: ___________________________

DETAILS

Date Time (IN) Time (OUT) NET Hrs OT Hrs Reason

TOTAL:

Claimant’s Signature_______________ Team Leader’s Signature________________

Approved: ________________
Page 9 of 10
BSPM Power House

Appendix-3
REQUEST FOR SHORT TIME ABSENCE
Date: ______________________
Emp. # ___________ Name _______________Designation/Dept.: __________________

Request for absence from ________hours on _________to _______ hrs on
___________

Duration of Absence; ________________Contact Person: _________________________

Reason for Absence: _______________________________________________________

Applicant’s Signature: _____________________

Remarks by Supervisor/Department Manager

Absence Authorised / Not Authorised due to____________________________________

Signature: _____________________________

Page 10 of 10
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BSPM Power House
Inspection & Testing of water & steam Procedure
Document No:IMS‐PH‐P‐06
Table of Contents
Objective ............................................................................................................................. 3
Procedure ............................................................................................................................ 3
Raw water ....................................................................................................................... 3
Drinking Water ................................................................................................................ 3
Demineralized Water ...................................................................................................... 4
200TPH Boiler.................................................................................................................. 4
Cooling Tower & Utility Cooling Tower .......................................................................... 6
Quality Tests Procedures: ................................................................................................... 7
Ph Value: ......................................................................................................................... 7
Conductivity: ................................................................................................................... 7
P‐Value: ........................................................................................................................... 7
M‐Value: .......................................................................................................................... 7
T‐Hardness: ..................................................................................................................... 7
Ca.Hardness: ................................................................................................................... 8
Residual Chlorine: ........................................................................................................... 8
Silica: ............................................................................................................................... 8
Hydrazine: ....................................................................................................................... 8
Phosphate: ...................................................................................................................... 8
Ortho Phosphate: ............................................................................................................ 9
Concentration No: ........................................................................................................... 9
Zinc: ................................................................................................................................. 9
Annex: ................................................................................................................................. 9
Flow Charts: ...................................................................................................................... 10
Annex: ............................................................................................................................... 16

Page 2 of 17
BSPM Power House
Objective

This procedure provides method to check the quality of raw water, drinking water,
cooling water demin water return condensate and steam in order to ensure the quality
parameters for turbine & boiler operation.

Procedure

Raw water
 Raw water transfer from tube well’s to water chest for storage and to settle the
suspended particles.
 Raw water transfer from water chest to Water Treatment Plant where its quality test
performed (recorded on Analysis sheet) and transferred to three systems (Drinking
Water Treatment Plant, Demin Plant, and Cooling Tower) where it treated separately.
 Raw Water quality Tests Includes:

1. PH Value (No.)
2. Conductivity (Us/cm)
3. P‐Value (ppm)
4. M‐Value(ppm)
5. T‐Hardness
6. Ca.Hardness

Drinking Water

 Water comes to drinking water treatment plant for chlorination
 Water goes through following process;
o Filtration of water through multimedia filters
o Pass through activated carbon filter
o Pass through micron size filter.
 Drinking water goes to storage tank
 Passing through UV filter
 Pass through cartridge filter
Page 3 of 17
BSPM Power House
 Transferred to the whole mill for drinking purpose.
 At drinking water treatment quality test again performed and recorded on Analysis
Sheet.
 Drinking water quality test includes:

1. PH Value (No.)
3. P‐Value (ppm)
4. M‐Value(ppm)
5. T‐Hardness
6. Ca.Hardness
7. R.Chlorine

Demineralized Water

 Raw water passes through strainer for the removal of suspended particles.
 After strainer passes through CatIon exchanger for the removal of positive charged Ions
of salts.
 Then it passes through de‐gasifer for degasification of carbon dioxide
 Passes through Anion exchangers for removal of negative charged ions.
 Above treated water passes through mix bed for removal of traces of Ions & silica and
stored in Demin storage tanks.
 Operation & quality parameters are recorded on Demin Plant Sheet & Demin water
analysis sheet.
 Resin required re‐generation after completion of the production time period or demin
water quality parameters are out/below of limits. Record is maintained on Re‐
generation of Cation, Anion Sheet and Regeneration of Mixed‐Bed Sheet.
 Demin water quality test includes:

1. PH Value (No.)
3. P‐Value (ppm)
4. Silica ( sio2)
200TPH Boiler

Page 4 of 17
BSPM Power House
 Demin water transfer to Feed Water tank as make up to feed water and condensate
system
 Here feed water quality testing performed.
 After quality test feed water transfer to boiler drum through Feed Water Pump.
 We inject to avoid scaling and perform CBD (continuous blow down) quality test.
 From boiler drum steam goes to super heaters and after super heating LSC (Live steam
condensate) quality testing performed and steam is used in steam turbine for power
generation & other processes of mill.
 Return condensates of mill are collected in condensate tank and RC quality test
performed and transfer to feed water.
 Turbine condensate quality test are performed before it collected in condensate tank.
 The quality of return condensate recorded in Return Condensate Analysis Sheet.
 All the cycle of water & steam analysis are recorded in Water & Steam analysis sheet.
 Quality tests at boiler includes:

1‐Return Condensate
 Ph value (no)
 Conductivity (Us/cm)
 Silica (sio2)
 Hd (ppm)
2‐ Turbine Condensate
 Ph value (no)
 Conductivity (Us/cm)
 Silica(Sio2)
 Hd (ppm)
3‐ Live steam condensate
 Ph value (no)
 Conductivity (us/cm)
 Silica (Sio2)
 Hd (ppm)
4‐ Feed Water
 Ph value (no)
 Silica(Sio2)
 Hydrazine
 Hd (ppm)
5‐ CBD (continuous blow down)
Page 5 of 17
BSPM Power House
 Ph value (no)
 Silica(Sio2)
 Hydrazine
 P.Value(ppm)
 M.value(ppm)
 Phosphate
 Hd(ppm)
Cooling Tower & Utility Cooling Tower

 Raw water transferred to cooling tower & utility cooling tower sumps
 It goes to 41 MW steam turbine condenser through pumps to extract heat of exhaust steam.
 From condenser water returns back to cooling tower for cooling purposes.
 Utility cooling water transferred to compressors for cooling purposes and return back to the
cooling towers.
 Different chemicals are added in cooling water system to avoid corrosions, scaling and
growth of biocides and to control its Ph. Record is being maintained on Cooling Water
Analysis Report.
 Quality test at Cooling Tower & Utility cooling tower includes:
1. Ph value
3. P.Value (ppm)
4. M.value(ppm)
5. O‐Phosphate(ppm)
6. T‐Hardness(ppm)
7. Ca.Hardness(ppm)
8. Zn (ppm)
9. R.Chlorine(ppm)
10. Conc. No

Page 6 of 17
BSPM Power House
Quality Tests Procedures:

Ph Value:
 Collect sample of water from required point.
 Cool down the sample at room temperature and measure the Ph value by Ph meter.
 Log the PH value in the relevant sheet.
Conductivity:
 Collect sample of water from required point.
 Cool down the sample at room temperature and dip the electrode of conductivity meter
in the sample and take the value in μs/cm and log the value in the relevant sheet.

P‐Value:

 Take 50 ml Sample
 Add one/two drops of phenolphthalein indicator in the sampling flask.
 If sample color appears pink then titrate against HCL N/100 solution to check P‐Value
and record in the relevant sheet.
 If pink color not appears then P‐value considers Nill and recorded in the relevant sheet.

M‐Value:

 Add two drops of methyl orange indicator in the sample
 Titrate it against HCL N/100 solution and get reading from Burette and record in the
relevant sheet.

T‐Hardness:

 Add one drop of aricham black T.
 If sample color appears blue, its hardness considers nil.
 If sample color appears Purple/Reddish then hardness considers present and titrate
against EDTA N/100 solution and get reading from Burette and record in the relevant
sheet.

Page 7 of 17
BSPM Power House
Ca.Hardness:

 Dissolve potassium hydroxide indicator and muricoxide indicator about 0.5 grams.
 If sample color appears reddish then titrates against EDTA N/100 solution and get the
reading record the hardness in the required sheet.
 If sample color appears bluish, then Ca‐hardness is nil and record in the relevant sheet.

Residual Chlorine:

 Fill 50ml water in a test tube.
 Insert the test tube of filled water uptill 25ml on left side of a test kit for chlorine test
and put the reagent powder pillow in it and enter the other 15ml filled sample water
test tube on the right side of the kit.
 Match the color of both test tubes in kit and get reading from get reading from reading
window of a test kit.
 Record reading in the relevant sheet.

Silica:

 Add 01ml Ammonium molybdate,
 After 04 minutes mix 01ml solution of tatric acid
 After 01 minute further mix 01ml solution of metol
 Check silica in spectrophotometer and record in the relevant sheet.

Hydrazine:

 Add 05ml solution of PDM (Peradimethyl) in sample for testing of hydrazine ratio for 11
minutes in flask.
 Get 10 ml sample in photo cell and place in spectrophotometer and record in the
relevant sheet.

Phosphate:

 Take 10 ml Sample.
 Add 02ml solution of venadate molybdate for 07 minutes,
Page 8 of 17
BSPM Power House
 Get 10 ml sample in photo cell and placed in spectrophotometer and get the reading
from it and record in the relevant sheet.

Ortho Phosphate:

 Take 10 ml Sample.
 Add 02ml solution of venadate molybdate for 07 minutes,
 Get 10ml sample in photo cell and placed in spectrophotometer and get the reading
divided by 03 and the answer recorder in the relevant sheet.

Concentration No:
 Cooling water conductivity and raw water conductivity taken from the conductivity meter.
 Cooling tower conductivity divided by raw water conductivity and the answer is recorded as a
concentration no. in the relevant sheet.
Zinc:

 Put the reagent pillow in one cell and shake for 30sec and wait for 03 minutes for proper
dissolution.
 Place the cell in photo mate and get the reading and record in relevant sheet.

Annex:
a. Raw & drinking water analysis sheet
b. Water & steam cycle analysis sheet
c. Return condensate analysis sheet
d. Cooling water analysis sheet
e. Demin plant sheet
f. Demin water analysis sheet
g. Re‐generation of Cation, Anion sheet.
h. Re‐generation of Mixed‐ Bed sheet.
Page 9 of 17
BSPM Power House
Flow Charts:

Page 10 of 17
BSPM Power House

Raw & Demin Water Treatment Flow Chart
Raw Water from Tube
wells
1.PH Value (No.)
2.Conductivity (Us/cm)
3.P‐Value (ppm)
4.M‐Value(ppm)
Water treatment plant 5.T‐Hardness
6.Ca.Hardness
Demin plant Drinking Plant

41MW Cooling Tower Utility Cooling Tower
A B C
Filtration of Raw water
Passing through
exchangers & degasifier
1.PH Value (No.)
3.P‐Value (ppm)
4.Silica(Sio2)
Filling of demin plant
sheet & demin water
analysis sheet
Regeneration
after
Passing thorugh mix
completion of
bed and stored in production
demin tanks time/quality
v parameters
out/below
Demin water
transfer to boiler D
Page 11 of 17
BSPM Power House
A Drinking Water Treatment Flow Chart
Drinking water Plant
Chloriization
1.PH Value (No.)
3.P‐Value (ppm)
4.M‐Value(ppm)
5.T‐Hardness
6.Ca.Hardness
7.R.Chlorine
Filteration of water
through filters
Drinking water to
storage tank
Drinking water passing
through UV & Cartridge
filter
Drinking water
transfered to the whole
mill for drinking
purpose
Page 12 of 17
BSPM Power House
D 200TPH boiler water & Steam treatment Flow Chart
1.PH Value (No.)
Demin water to feed 2.Conductivity (Us/cm)
water tank 3.Silica(Sio2)
4.Hydrazine
5.T‐Hardness(ppm)
1.PH Value (No.)
3.Silica (Sio2)
4.P‐Value (ppm) Feed water transfer to
5.M‐Value(ppm) boiler drum
6.Phosphate(ppm)
7.T‐Hardness(ppm)
Steam to Super
heaters
1.PH Value (No.)
3.Silica(Sio2)
4.T‐Hardness(ppm)
Steam to Steam
Turbine & other
processes of Mill
1.PH Value (No.)
3.Silica(Sio2)
4.T‐Hardness(ppm)
1.PH Value (No.)
Return Condensate 2.Conductivity (Us/cm)
from mill in condensate 3.Silica(Sio2)
tank 4.T‐Hardness(ppm)
Mill
Return condensate to
feed water tank D
Return condensate
and water & steam
analysis sheet
Page 13 of 17
BSPM Power House
B 41MW Cooling Tower Water Treatment Flow Chart
1.PH Value (No.)
3.P‐Value (ppm)
4.M‐Value(ppm)
Raw water to 41MW 5.O‐Phosphate(ppm)
cooling tower sumps 5.T‐Hardness(ppm)
6.Ca.Hardness(ppm)
7.Zn (ppm)
7.R.Chlorine(ppm)
8.Conc. No.
Raw water to 41MW
steam turbine
condenser
Watrer returns back to
cooling tower
Chemical treatment
Cooling water
analysis sheet
Page 14 of 17
BSPM Power House
C Utility Cooling Tower Water Treatment Flow Chart
1.PH Value (No.)
3.P‐Value (ppm)
4.M‐Value(ppm)
Utility cooling tower
5.O‐Phosphate(ppm)
sumps
5.T‐Hardness(ppm)
6.Ca.Hardness(ppm)
7.Zn (ppm)
7.R.Chlorine(ppm)
8.Conc. No.
Utility cooling water to
compressors
Watrer returns back to
cooling tower
Chemical treatment
Utility cooling water
analysis sheet
Page 15 of 17
BSPM Power House
Annex:

Page 16 of 17
BSPM Power House
Page 17 of 17
Analysis Sheet
Record No:IMS‐PH‐F‐10
RAW WATER DRINKING WATER
Shift 1st Shift 2nd Shift 3rd Shift 1st Shift 2nd Shift 3rd Shift
pH Value
No.
Conductivity
µs/cm
P-Value
ppm
M-Value
ppm
T.Hardness
ppm
Ca.Hardness
ppm
R.Chlorine
ppm
Remarks
1st Shift
2nd Shift
3rd Shift
Water Treatment Plant
Water and Steam Analysis Sheet
Test Muw RC TC LSC FW CBD

H H H H H H -3
Unit P Cond sio2 P Cond sio2 Hd P Cond sio2 Hd P Cond sio2 Hd P Cond sio2 N 2H 4 Hd P Cond sio2 N 2H 4 P val M.val PO4 Hd
Boiler Shift Time Nos us/cm mg/l Nos us/cm mg/l ppm Nos us/cm mg/l ppm Nos us/cm mg/l ppm Nos us/cm mg/l mg/l ppm Nos us/cm mg/l mg/l ppm ppm ppm ppm
08:30
1st
12:30
16:30
H 2nd
TP
30
20:30
00:30
3rd
04:30
1st Shift
2nd Shift
3rd Shift
Water and Steam Analysis Sheet
Return Condensate Analysis Sheet
Date:
Time Parameters
pH Conductivity SiO2 Hardness
07:30
08:30
09:30
10:30
11:30
12:30
13:30
14:30
15:30
16:30
17:30
18:30
19:30
20:30
21:30
22:30
23:30
00:30
01:30
02:30
03:30
04:30
05:30
06:30
Shift A
Sig.
Shift B
Sig.
Shift C
Sig.
Shift D
Sig.
Cooling Water Analysis Sheet
DATE
Cooling 41MW Cooing Utility

Towers Towers Cooling Tower
08:30 12:30 16:30 20:30 00:30 04:30 08:30 12:30 16:30 20:30 00:30 04:30
pH Value
No.
Conductivity
µs/cm
P-Value
ppm
M-Value
ppm
O.Phosphate
ppm
T.Hardness
ppm
Ca.Hardness
ppm
Zn
ppm
R.Chlorine
ppm
Conc. No.
Remarks
1st Shift
2nd Shift
3rd Shift
Demin Water Analysis Sheet
Record No:IMS-PH-F-15
Date
Cation Anion Mixed - Bed
pH pH Cond sio2 pH Cond sio2
Shift Time Nos Nos us/cm mg/l Nos us/cm mg/l
08:30
1st
12:30
16:30
2nd
20:30
00:30
3rd
04:30
1st Shift
2nd Shift
3rd Shift
3rd Shift 2nd Shift 1st Shift Shift
Reg. On at
Cation Compaction
Train A/B
Anion Compaction
Begin
HCl
Feeding
Finish
Chemical
Begin Slow
Rinse
Finish
Begin Settle
Finish
Begin Final
Rinse
Finish
Begin
NaOH
Feeding
Finish
Chemical
Begin Slow
Rinse
Finish
Record No: IMS-PH-F-16
Begin Settle
Finish
Regeneration of Cation & Anion
Begin Final
Rinse
Finish
Line Regenerated at
Date:
Cation Reg.
Pump
Anion Pres.
HCl / % Flow
Rates
Dil H2o Ton/ hr
NaOH / %
Dil H2o
3rd Shift 2nd Shift 1st Shift Shift
Reg. On at Train A/B
Back Wash
Settle
Begin
Feeding
Finish
Chemical
Begin Slow Rinse
Finish
Begin Drain
Finish
Begin Air Mixing
Finish
Begin Slow Refill

Record No: IMS-PH-F-17
Finish
Regeneration of Mix Bed
Begin Final Rinse
Finish
Date:
Bar Pump
Pres.
HCl / % Flow Rates

Ton/ hr
Dil H2o
NaOH /
%
Dil H2o
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April, 2011
BSPM Power House
Customer Complaints Procedure
Table of Contents
Objective ............................................................................................................................. 3
Procedure ............................................................................................................................ 3
Flow Chart ........................................................................................................................... 4
Action Plan .......................................................................................................................... 5
Daily Generation Sheet ....................................................................................................... 6

Page 2 of 7
BSPM Power House
Objective
The objective of this procedure is to provide guidelines to customer that how to act upon and handle any
complaint arising from BSPM in an efficient and timely manner to avoid losses and to satisfy the
customer.
Procedure
 Power House generates daily generation report.
 As per BSPM management, customer has to complaint within 48 hours on the daily
generation report if any.
 If any complaint arises within 48 hours of the report, Power House and customer will resolve
the issue and reach to a consensus. Revise report will be issued by Power House.
 In case of any dispute Mill Services Manager decision will be final.

Page 3 of 7
BSPM Power House
Flow Chart
Power House generates
Daily Generation Report
Sent by email to all customers
Customer shall contact No, within 48 Hrs
Power House by email
48 Hrs
If Yes
Power House and Customer discuss
Yes
and reach to consensus and final
number
No
Mill Services Manager Energy and Steam
decision will be final Consumption Report is Final

Page 4 of 7
BSPM Power House
Action Plan
Signature/Comments Team
Sr # Observation Corrective Action Responsibility
Leader

Page 5 of 7
BSPM Power House
Daily Generation Sheet
Daily Generation Sheet
Date
Generation Cost per MM BTU

Steam with Steam with
Source KWhrs Max MW Min MW MW at 08:00 HFO Gas
65 TPH
41 MW CHP
11 MW CCGT
WAPDA Import
Total Generation - Steam Generation on HFO / Ga - -

Import from WAPDA - Total Steam Generation -
Dem in Water Production (Tons) Used by Power House -
Turbine Heat Rate BTUKWHr Boiler Efficiency MM BTU Ton/MM BTU Net T/MM BTU
Gross Heat Rate - 200 TPH Boiler - 0
Net Heat Rate - 65 TPH Boiler - 0.00
Consumption 0.0 Rs/KWHr Rs/Ton
Steam with Steam with
Department KWhrs Max Amp Min Amp Amp at 08:00
HFO Gas
ETP
Straw and Mill Water
CTMP
CD Ext 1 Total Ext 2 Total
Finishing Line Steam Steam
Utility Area
PM6
Stock Prep of PM6
Coating
DIP
41 MW Aux
PM7
Stock Prep of PM7
Air Compressors (3&4)
OCC New Refiner
13 Bar Consumer Production Ton/Ton Ratio

CD
PM-6
CTMP
DIP+OCC
PM-5 (5 Bar Header)
5 Bar Consumers
DIP Only
OCC Only
PM-7 only
SPP Only (PM-6 Chem Area)
Chemical Area
Coating Only
KV Only
Raw Water Consumption (Tons)
Fuel Consumption Gas HFO Tube Wells Run Time HFO Stock
200 TPH 1 Tank 1
65 TPH 2 Tank 2
11 MW CCGT 3 Day Tank
4 Total 0
HFO Stock
5 (Tons) 0
Total Fuel Total Run
Consumption 0 0 Time 0 Days 0
Total Well
Water -
Comments:
AMJAD ALI
Page 6 of 7
BSPM Power House

Air Compressors Water Chest Pumps Boiler Run Time HFO
Air Compressors 1 Pump 1 65 TPH 0
Air Compressors 2 Pump 2 200 TPH Boiler 0
Air Compressors 3 Pump 3
Air Compressors 4 0 Pump 4 0
Total Run Time 0 Total Run Time 0
Steam to Process
Well Pump No. 1 390 0

Page 7 of 7
BBSSPPM
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December, 2011
BSPM Power House
Log Book Reporting Procedures

Table of Contents
Abbreviations: ................................................................................................................................................ 3
Objective: ....................................................................................................................................................... 4
Shift Incharge Log Book Protocol ................................................................................................................... 5
Boiler Operator Log Book for 200 TPH Boiler ................................................................................................. 6
Boiler Operator Log Book for 65 TPH Boiler ................................................................................................... 7
Turbine Operator Log Book for 41 MW Steam Turbine ................................................................................. 8
Electrical Control Room Operator Daily Log Book .......................................................................................... 9
Chemical Plant Operator Daily Log Book ...................................................................................................... 10
Utility Operator Daily Log Book .................................................................................................................... 12

Page 2 of 12
BSPM Power House

Abbreviations:

BO Boiler Operator
TO Turbine Operator
SI Shift Incharge
UO Utility Operator
CPO Chemical Plant Operator
ECO Electrical Control Room Operator
Page 3 of 12
BSPM Power House

Objective:
The objective of this procedure is to develop guidelines for “Operation Staff” to use in writing log book.

1. Log Book is an official document.
2. It is not allowed to any one for personal comments & rough works.
3. The description in log book should be easy to read and understandable.
4. The Log book shall be properly maintained in each shift whether plant is in operation or in shut
down conditions.

Page 4 of 12
BSPM Power House

Shift Incharge Log Book Protocol

The following protocols shall be followed for shift in charge daily log book.

Shift Name: A, B,C,D

Date : Time:

Name: SI , BO,TO, UO, ECO, PCO.

 Status of whole complex during shift charge handed / taking over such as, any abnormality or
transient phase of complex must be logged and properly communicate by off going shift to
incoming shift.

 Further all important instructions should be communicated to all shift collogues by incoming
shift in‐charge after taking over the charge.

 All important operational activities and events must be logged with time for following major
equipment.

 200 TPH Boiler Status.

 41 mw Steam turbine Status.

 65 mw TPH Boiler Status.

 Demin plant Status, Tank level & chemical stock such as HCL, NAOH &H2SO4.

 Utilities Status.

 Electrical system status.

 HFO Tank levels,

 Special Comments regarding any ongoing issues & important operational events must be logged.

Signature of off going SI. Signature of incoming SI.

Page 5 of 12
BSPM Power House

Boiler Operator Log Book for 200 TPH Boiler

The following protocols shall be followed for Boiler Operator daily log book.

Shift : A, B,C,D

Date : Time:

Name: BO.

 Status of 200TPH Boiler during shift charge handed over / taking over such as, any abnormality
or transient phase of plant must be logged and properly communicate by off going shift BO to
incoming shift BO.

 Further all important area & critical focus points should be communicate by off going BO to
incoming shift BO.

 All important operational activities and events must be logged with time.

 Pressure , temperature & flow.FW pumps, ID & FD fans, Burners, CBD valve position , 13 bar & 5
bar header flow, pressure & temp. chemical dosing pump,

 Steam production, Gas consumption, Feed water, Make up water, Return Condensate

 Comments:

Signature of BO off going Signature of BO incoming

Signature of SI.

Page 6 of 12
BSPM Power House

Boiler Operator Log Book for 65 TPH Boiler

The following protocols shall be followed for Boiler Operator daily log book.

Shift Name: A, B,C,D

Date : Time:

Name: BO

 Status of 65TPH Boiler during shift charge handed over / taking over such as, any abnormality or
transient phase of plant must be logged and properly communicate by off going shift BO to
incoming shift BO.

 Further all important area & critical focus points should be communicate by off going BO to
incoming shift BO.


 Pressure , temperature & flow. FW pumps, ID & FD fans, Burners, CBD valve position , 13 bar & 5
bar header flow, pressure & temp. chemical dosing pump,

 Steam production, Gas consumption, Feed water, Make up water, Return condensate

Comments:

Signature of BO off going Signature of BO incoming

Signature of SI.

Page 7 of 12
BSPM Power House

Turbine Operator Log Book for 41 MW Steam Turbine

The following protocols shall be followed for Turbine Operator daily log book.

Shift : A, B,C,D

Date : Time:

Name: TO.

 Status of Steam Turbine during shift charge handed over / taking over such as, any abnormality
or transient phase of plant must be logged and properly communicate by off going shift TO to
incoming shift TO.

 Further all important area & critical focus points should be communicate by off going TO to
incoming shift TO.


 Extraction of 13 bar & 5 bar status / parameter.

 ST load & Electrical status .

Comments:

Signature of TO off going Signature of TO incoming

Signature of SI.

Page 8 of 12
BSPM Power House

Electrical Control Room Operator Daily Log Book

The following protocols shall be followed for Electrical Control Room Operator daily log book.

Shift : A, B,C,D

Date : Time:

Name: ECO.

 Status of Electrical system / equipments during shift charge handed over / taking over such as,
any abnormality or transient phase of plant must be logged and properly communicate by off
going shift ECO to incoming shift ECO.

 All important area & critical focus points should be communicate by off going ECO to incoming
shift ECO.


 Status of Steam Turbine synchronize to WAPDA or in Island mode.

 Status of Main incomer breaker from WAPDA

 Energy imported from Wapda & Energy generated by Steam Turbine at the end of shift.

Comments:

Signature of ECO off going Signature of ECO incoming

Signature of SI.

Page 9 of 12
BSPM Power House

Chemical Plant Operator Daily Log Book

The following protocols shall be followed for Chemical Plant Operator daily log book.

Shift : A, B,C,D

Date : Time:

Name: CPO

 Status of Demin Plant during shift charge handed over / taking over such as, any abnormality or
transient phase of plant must be logged and properly communicate by off going shift CPO to
incoming shift CPO.

 All important area & critical focus points should be communicate by off going CPO to incoming
shift CPO.


 Train A,B & Mix bed A&B status.

 Hydrazine dosing in 200 & 65 tone boiler with start/stop time of pumps.

 Phosphate dosing in 200 & 65 tone boiler with start/stop time of pumps.

 CBD status of 65 & 200TPH boilers with reason if opened.

 Anti scaling & Anti corrosion dosing in CW basin.

 CT basin level & fans belts

 Lab test analysis, drinking water plant status.

 During shift makeup water production.

 Demi water consumed in regeneration.

 Demi water storage tanks level at the end of shift.

 Demi water consumption during shift.

 Return Condensate status with reason.

 Raw water consumption during the shift.

Page 10 of 12
BSPM Power House

 Chemical stock status.

 If Chemical received / delivered & unloading time ,Quantity, truck #.

 Comments:

Signature of CPO off going Signature of CPO incoming.

Signature of SI

Page 11 of 12
BSPM Power House

Utility Operator Daily Log Book

The following protocols shall be followed for Utility Operator daily log book.

Shift : A, B,C,D

Date : Time:

Name: UO.

 Status of all BOP during shift charge handed over / taking over such as, any abnormality or
transient phase of plant must be logged and properly communicate by off going shift UO to
incoming shift UO.

 All important areas & critical focus points should be communicate by off going UO to incoming
shift UO.


 Status of Water Chest level, Tube wells, Air Compressor & Raw Water Pumps

Comments:

Signature of UO off going Signature of UO incoming

Signature of SI.

Page 12 of 12
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BSPM Power House
Employees Appraisal Procedure

Table of Contents
Objective: ....................................................................................................................................................... 3
Aim ................................................................................................................................................................. 3
Guidelines and Procedure .............................................................................................................................. 3
Timescale for Appraisal .................................................................................................................................. 4
Post Completion Process ................................................................................................................................ 4
Annexure 1 – Performance Appraisal Form ................................................................................................... 5

Page 2 of 5
BSPM Power House

Objective:
This policy sets out the procedure and guidelines to assess the performance against work standards
assigned to an individual. To provide an opportunity to OMS People to gain a clear picture of how they are
performing their task and to identify areas where they may need additional support and training. It will
help to encourage career planning, maintain standards and link efforts with rewards.
Aim
The aim of this appraisal system is to evaluate work standards and performance of an individual against a
set task to arrive at the following.

(a) How well the individual has performed during the period under review, how training and
development might help to achieve the desired standards of job if not already being achieved.

(b) What are the individual’s longer‐term career needs and what help and support his line manager
and company can extend within the available resources?
Guidelines and Procedure
1) Every year between 1st to 31st December in case of All employees, the Performance Appraisal
Form (Attachment – Annex 1) duly filled with name, designation and other particulars of an
individual shall be distributed for evaluation period from 1st December for the period mentioned
in the Appraisal Form. Minimum period for an individual for Performance Appraisal shall be 3
months continuous service. Where the individual has worked with more than one evaluating
authority during the year, the appraisal will be assessed by each appraiser for the period the
individual has worked with him.

2) Evaluating Authority in respect of various levels

The Plant Manager in respect of Team Leaders.
The Team Leaders in respect of all Staff working under their control.

3) Countersigning Authority in respect of various levels

The Managing Director in respect of all Team Leaders.
The Team Leaders in respect of all staff of their concerned Section.

4) On receipt of Appraisal forms the Evaluating Authority will give a copy of appraisal form to the
individual. The individual and the Evaluating Authority will complete the form by their own
assessment within maximum of 15 days.

5) After completion of above assessment in step 4 above, they will arrange a closed door meeting
for appraisal discussion.

6) If the parties (Appraiser and Appraise) are not able to finalize and agree the appraisal form then
another meeting may be arranged in the same manner.

Page 3 of 5
BSPM Power House

7) The Appraiser and Appraise will discuss the evaluation in free, fair, easy and friendly atmosphere,
and should be based on facts and impartiality. Following may be helpful:

a) Highlight performance
b) Use friendly and unemotional language
c) Start with positive note
d) Support evidence by quoting personal observation for example, colleagues and clients
e) Avoid mentioning points that people cannot alter (e.g. Height, accent, facial tics,
fundamental personality)
f) Be objective, avoid personal prejudice
g) Be candid but tactful
h) Concentrate on points that employee can improve
i) Give specific evidence to back up points
j) End positively

8) After the evaluation has been completed, the appraisal form shall be signed by both the
Appraiser and individual being appraised. If the individual being assessed has any difference of
opinion on valid grounds he may clearly mention that he disagrees with the assessment and
should give brief and specific reasons in writing in the space provided for the same.

9) After completion of appraisal form within 15 days of the receipt of the same these will be
forwarded to the next authorised person to whom they report for perusal, review and
countersignature. The Countersigning Authority may use its judgment, call the Evaluator or
individual or both to discuss anything over which he might differ or alter.

10) After countersignatures by the Authority the forms will be sent to Human Resources Manager in
sealed envelope marked as “Confidential”.
Timescale for Appraisal
The Appraisal form must be completed within 30 days from the date of its receipt. In case it is not
circulated or received on time, the employee must contact to the Plant Manager to get it.

Post Completion Process
 The Plant Manager will develop a Paradigm system and method where marking as A1, A, B, C
and D will be allocated with digit numbers such as A1 stands for 5, A stands for 4, B for 3, C for 2
and D for 1 to describe the overall performance rating in the present job.

 The appraisal process can be used in the support of the annual remuneration of an individual.

Page 4 of 5
BSPM Power House

Annexure 1 – Performance Appraisal Form
Page 5 of 5
Record No.
Performance Appraisal Form
Name Job Title Date Evaluator Name Next Evaluation Date

Reviewed
INSTRUCTIONS
1. All OMS people should be appraised at least annually.
2. Review individual’s work performance for the entire period; refrain from basing judgement on recent events or
isolated incidents only.
3. Don’t allow personal feelings to govern your rating. Disregard your general impression of the individual.
4. Consider the individual on the basis of the standards you expect to be met for the job. Place a check by the
area you feel best describes the employee’s performance since the last appraisal.
5. Initiating officer should initial/sign the appropriate box/column.
6. REASON MAY BE GIVEN FOR EACH FACTOR TO SUBSTANTIATE AREA CHECKED.
7. Overall Performance rating will be:
EXCEEDS JOB FULLY MEETS JOB MEETS JOB MEETS MINIMUM DOES NOT MEET JOB
REQUIREMENTS/ REQUIREMENTS/ REQUIREMENTS/ JOB REQUIREMENTS/IMPR
OUTSTANDING/ VERY GOOD GOOD REQUIREMENTS/ OVEMENT NEEDED/
EXCELLENT SATISFACTORY UNSATISFACTORY
A B C D E
Actual Performance
Please rate performance in these areas: 0 1 2 3 4 5 6 7 8 9 Comments
Job Knowledge and Skills: Knows the process P
of the systems, practically and theoretically, in
his/her area of responsibility. Consider
understanding of job procedure and methods, T
ability to acquire necessary skills, expertness in L
doing assigned tasks and utilization of
background for job.
Quality of Work: Completes work in an efficient, P
timely, accurate manner. Requires minimal
supervision.Consider standard of workmanship,
skill, accuracy, neatness, thoroughness, and T
economy of materials. L
Organizing and Planning: Ability to structure P
tasks, plans, objectives, establish priorities, and
able to perform them independently and T
accurately. L
Leadership: Assumes leadership responsibility P
when appropriate. Consider ability to inspire
teamwork, enthusiasm to work towards a common
objective, desire to assume responsibility, ability T
to originate or develop ideas and get things L
started, and ability to train others.
Judgment: Shows discretion and the ability to P
arrive at sound “common sense” decisions. T
L
Record No.
Please rate performance in these areas: 0 1 2 3 4 5 6 7 8 9 Comments
Initiative/Decisiveness: Recognizes problems P
and takes action to solve them without detailed T
“Managerial” guidance. L
Analytical/Perceptual: Ability to identify, P
assimilate and comprehend the critical elements T
of a situation. Trouble shooting. L
Safety: Knows safety procedures and P
requirements. Is a good example of safety for T
others to follow? L
Interpersonal: Deals effectively with others P
regardless of “level of status”, able to accept T
interpersonal differences. L
Oral and Written Communication: Ability to P
effectively and clearly present and express
information and is the info sufficient for them to do
their job. T
L
Motivation: Has necessary self-discipline and P
drive to achieve goals of his/her area. Persistently T
seeks improvements. Volunteers for additional L
scope within OMS and his/her area.
Fairness: actions are generally consistent with P
the value of Fairness. Considers self, OMS, and T
other stakeholders. L
Accountability: Is the person willing and able to P
be accountable for their actions. T
L
Integrity: Evaluate the Personnel in Integrity, P
intelligence, appearance and bearing, T
perseverance and devotion to duty and Emotional L
stability:
Social Responsibility: Aware of the needs of our P
neighbors and in society, and willing to support T
efforts in response to those needs, both locally L
and worldwide.
Ownership: Willing and able to take responsibility P
for his area and the plant in general. T
L
Dependability: Willingness to support your area P
when assistance is needed. Exercise all T
resources in order to get a task completed in a L
timely manner. Office timing is adhered to.
Flexibility: Able to adjust to new situations. P
Willing to accept his ideas as well as yours. T
L
Housekeeping: does he or she participate in P
Housekeeping directly.
Does he/she have the “tea boy mentality”. T
L
0-1: Unsatisfactory, 2-3: Needs Improvement, 4-5: Good, 6-7: Very Good, 8-9: Outstanding
Record No.
Accomplishments of 2011
Goals for 2012
Additional Comments
Record No.
OVERALL EFFECTIVENESS: Considering the length of experience on present job, check the rating, which most
nearly describes total current performance.
OVERALL EFFECTIVENESS A B C D E
(a) Overall assessment of performance
in present job
I agree/do not agree with the assessment. Please record brief and specific reasons in the space provided
below in case you disagree with the appraisal made by the Evaluator.
___________________
Signature
Name:
EVALUATED Date:
BY: Signature Job Title:
Name:
APPROVED: Date:
Signature Job Title:
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BSPM Power House
High Voltage Inspection & Testing Procedure after abnormal Alarm

Table of Contents
Objective.......................................................................................................................................... 3
Procedure ........................................................................................................................................ 3
Actions to Follow ............................................................................................................................. 3
Flow Chart ....................................................................................................................................... 5
Annex 1: ........................................................................................................................................... 6
Annex 2: ........................................................................................................................................... 8

Page 2 of 9
BSPM Power House

Objective
The objective of this procedure is to provide guideline to operation and E&I teams to rectify and
reset the high voltage breaker fault when an abnormal alarm or tripping occur. This will also
ensure the safety of people as well as equipment.

Procedure
If an abnormal alarm or tripping occurs then Electrical Operator shall immediately rack out
breaker, note down the alarm in H.T. Breaker checklist (Annex 1) and inform shift in‐charge.
Shift in‐charge will raise job request to E&I team. E&I team will sign the work permit and then
check the alarm or tripping indication on the relay to rectify the fault.

There will be three types of indications that can occur on the relay.
A. Tripping Alarm for Earth Fault (IE>>>)
B. Tripping Alarm for Over Current, Short Circuit (TRP I> & TRP I>>)
C. Tripping Alarm for Instantaneous Current (I>>>)
Actions to Follow

After taking safety document E&I team shall proceed as follows.
A: If Breaker Tripped due to Earth Fault (IE>>>) then follow the sequence
I. Check the L.T Breakers Status.
II. If L.T Breaker tripped then check the MCC and Connected Load.
III. If L.T Breaker normal then check the Transformer Input/ Output Cables and Meggar.
IV. Check the Insulation Test of Transformer.
V. Check the H.T Breaker CTs and Cables Termination.
VI. Check the H.T Cable Joint in case fault in Main H.T.
B: If Breaker Tripped due to Over Current, Short Circuit (TRP I> & TRP I>>) then follow
the sequence
I. Check any Abnormality from L.T side, Short Circuit & Sudden Load.
II. Check the H.T / L.T capacitor Bank.
III. Check the Insulation Test of Transformer.
IV. Check the H.T Breaker CTs and Cables Termination.
V. Check the H.T Cable Joint if fault in Main H.T.
Page 3 of 9
BSPM Power House

C: If Breaker Tripped due to Instantaneous Current fault (I>>>) then follow the
sequence
I. Check the L.T / M.V Breaker status on / off.
II. Check the L.T / M.V Motors and Breaker.
III. Switch off L.T / M.V Breaker.
IV. Switch on the Transformer.( If fault Remain exist then)
V. Check any Abnormality from L.T side, Short Circuit & Sudden Load.
VI. Check the H.T / L.T capacitor Bank.
VII. Check the Insulation Test of Transformer.
VIII. Check the H.T Breaker CTs and Cables Termination.
IX. Check the H.T Cable Joint if fault in Main H.T.
After checking and rectifying the fault E&I team will write down remarks (if any) in check list
(Annex1) and release work permit. Electrical Operator shall follow these remarks rack in breaker
and restore power supply for the concerned consumer.

Page 4 of 9
BSPM Power House

Flow Chart
Page 5 of 9
BSPM Power House

Annex 1:
Page 6 of 9
BSPM Power House

H.T Breaker Checking Steps after Tripping
H.T Breaker ID Number: Date:
H.T Breaker Description: Trip Time:
Tripping Alarms: i)
ii)
iii)
iv)
First Action
Rack out the H.T Breaker, issue the job request and Inform to E&I department.
CRO Name & Signature: Shift Incharge Name & Sign.:
i) In Case of Earth Fault:
Tripping Alarm for Earth Fault Ie>> Check Mark (√)
(i) Inspect the HT breaker
(ii) Magger the outgoing cables and CT's.
(iii) Check transformer oil temp and Buchalz's relay.
(iv) Check cable joint if any.
(v) Tight all connections of CT's and protection relay.
(v) If all connections are ok then isolate outgoing cables and switch on the breaker.
(vi) If successfully switch on the breaker, then connect outgiong cables.
(Vii) Disconnect load from transformer side.
(viii) Switch on the HT breaker and then LT breaker.
ii) In Case of Line Fault:
Tripping Alarm for Short Circuit/Instentaneous I>>>
(i) Check any Abnormality from L.T side, Short Circuit, Sudden Load
(ii) Check the H.T Capacitor Bank.
(iii) Check the H.T Breaker, CT's and Cables Terminataion
(v) Check the H.T Cable Joint if any.
(v) Tight all connections of CT's and protection relay.
(Vi) Disconnect load from transformer side.
(vii) Switch on the HT breaker and then LT breaker.
Remarks:
Breaker On Time with Date: E&I Deptt:
CRO Name & Sig.: Shift Incharge:
Page 7 of 9
BSPM Power House

Annex 2:
Page 8 of 9
BSPM Power House

H.T Breaker Relay Faults
Sr# Fault Indication Description Type Type of Fault

1 O/CL1 Over Current Line1 Line Fault
4 FDL1 Line 1 Over current fault Line Fault
6 FDL12 Line 1&2 Over current fault Line Fault
7 FDL12E Line 1&2 Earth fault Line Fault Earth Fault
11 FDL23E Line 2&3 Earth fault Line Fault Earth Fault
12 FDL123 Line 1,2,3 Over current fault Line Fault
13 FDL123E Line 1,2,3 Earth fault Line Fault Earth Fault
14 FD I>> Short Circuit Line Fault
15 TRP I>> Short Circuit Tripping Line Fault
16 FD Ip Over Current Line Fault
17 TRP Ip Over Current Tripping Line Fault
18 TRP I> Over Current Line Fault
19 Trip I>>> Short Circuit/Instentaneous Line Fault I>>> Instentaneous
20 O/C E Over Current Earth Earth Fault
21 FDL1E Line 1 Earth fault Earth Fault
24 FDE Earth Fault Earth Fault
25 FD IE>> High Earth Fault Earth Fault
26 TRP I>> High Earth Fault Tripping Earth Fault
27 FD IE> Earth Fault Earth Fault
28 FD Iep Earth Fault Earth Fault
29 TRP lep Earth Fault Tripping Earth Fault
Page 9 of 9
BSPM Power House
Inspection & Makeup of Resins in Ion Exchangers

Procedure
Rev 0
April, 2011
BSPM Power House
Table of Contents
Objective.......................................................................................................................................... 3
Inspection ........................................................................................................................................ 3
Procedure .................................................................................................................................... 3
Calculations ................................................................................................................................. 3
Train # A & Train # B ................................................................................................................... 3
Cation Exchanger ........................................................................................................................ 3
Anion Exchanger ......................................................................................................................... 4
Mixed Bed Ion Exchanger ............................................................................................................ 5
Procedure ........................................................................................................................................ 5
General Procedure ...................................................................................................................... 5
Cationic Resins Makeup Procedure ............................................................................................ 6
Anionic Resins Makeup Procedure ............................................................................................. 6
Mixed Bed Resins Makeup Procedure ........................................................................................ 7
Makeup of Resins ............................................................................................................................ 7
Makeup Of Resins In Train # A & Train # B ................................................................................. 7
Makeup Of Resins In Cation Exchanger ...................................................................................... 7
Makeup Of Resins In Anion Exchanger ....................................................................................... 8
Makeup Of Resins In Mixed Bed Ion Exchager............................................................................ 8
Flow Chart: ...................................................................................................................................... 9
Annex # A: ...................................................................................................................................... 10
Annex # B: ...................................................................................................................................... 11
Annex # C: ...................................................................................................................................... 12
Annex # D: ..................................................................................................................................... 13

Page 2 of 13
BSPM Power House
Objective

This procedure provides method to check the makeup procedures & inspection of resins in Cation
Exchanger, Anion Exchanger and Mixed Bed Ion Exchanger.

Inspection
Procedure

 Initiate job request and issue LOTO.
 Backwash of cation and anion exchangers individually for 5 minutes each respectively.
 Backwash of mixed bed ion exnchanger for 15 minutes.
 Drain the water from the ion exchangers.
 Length of the ion exchangers is taken from top to bottom is taken from top welding to the bottom
one, this length is the external height of the ion exchangers.
 Open the man holes of the ion exchanger to take the dips of the present situation of the resins
already present in the ion exchangers.
 Take out the actual length of the exchangers till where the resins are to be filled and then take out
the difference of the actual length and length. Then volume will be calculated by using formula:
V= r2l.
Where:
l = length (m), r = radius (m), V = volume (m3 ) ( Hence 1m3 = 1000 lit).

Calculations
Train # A & Train # B
Cation Exchanger

Dia = 1600mm = 1.6m
r = 0.8m
Height = 3000mm = 3m
Designed quantity of resins = V = 4800 lit = 4.8 m3 (Hence 1m3 = 1000 lit).
Using:
V= r2l.
Page 3 of 13
BSPM Power House
l = V/ r2
l = 4.8/3.14*(0.8)2
l = 4.8/3.14*0.64
l = 4.8/2.0096
l = 2.4m
External length from welding to welding (top to bottom) = 3m.
Present quantity of resins = x m = x mm.
Using:
V= r2l.
V = 3.14*(0.8)2*x
V = y m3.
V = y lit.
Difference = z lit.
Anion Exchanger

Dia = 1400mm = 1.4m
r = 0.7m
Height = 3754mm = 3.754m
Designed quantity of resins = V = 4000 lit (2000 lit Weak Anion + 2000 lit Strong Anion) = 4.0 m3
(Hence 1m3 = 1000 lit).

Using:
V= r2l.
l = V/ r2
l = 4.8/3.14*(0.7)2
l = 4.8/3.14*0.49
l = 4.8/1.538
l = 2.6m
External length from welding to welding (top to bottom) = 3.754m.
Present quantity of resins:
Strong Anion = a m = a mm Weak Anion = x m = x mm.
Using: Using:
V= r2l. V= r2l.
2
V = 3.14*(0.7) *a V = 3.14*(0.7)2*x
V = b m3. V = y m3.
V = b lit. V = y lit.

Total Resins Volume = a + y = z lit ,

Difference = c lit.
Page 4 of 13
BSPM Power House
Mixed Bed Ion Exchanger

Dia = 1050mm = 1..050m
r = 0.525m
Height = 3000mm = 3m
Designed quantity of resins = V = 1350 lit (800 Strong Cationic Resins + 550 Strong Anionic Resins) = 1.35
m3
(Hence 1m3 = 1000 lit).
Using:
V= r2l.
l = V/ r2
l = 4.8/3.14*(0.525)2
l = 4.8/3.14*0.275
l = 4.8/0.865
l = 1.6m
External length from welding to welding (top to bottom) = 3m.
Present quantity of resins = x m = x mm.

Using:
V= r2l.
V = 3.14*(0.525)2*x
V = y m3.
V = y lit.

Difference = z lit.
Procedure

General Procedure
 If resins, either cationic resins or anionic resins are not in Na or Cl form respectively, soak them in
15‐20% NaCl solution for 1 day individualy.
 Special care to be taken of the drums, that should not be mixed.
 Wash resins next day with demin water, washing will be completed when chlorides will be removed
by continuous checking of chlorides.
 To check how much resins we have to fill, we will calculate by formula:
V= r2l.
Where:
Page 5 of 13
BSPM Power House
l = meter, r = meter, V = m3 ( Hence 1m3 = 1000 lit).

 Before taking measurement, backwash impurities and drain the water.
 Then check the upper layer, if found powder type layer remove the same for about 10‐20 mm.
 We will makeup the weak resins & strong resins according to the designed ratio.
 After filling the resins, perform regeneration in the end to make the ion exchanger ready for use.
 Note: i. Check filters of de‐gasifier.
ii. For general resins makeup figure, go to Annex # A.

Cationic Resins Makeup Procedure

 Soak the cationic resins, required to makeup the resins in cation exchanger in 15‐20% NaCl solution
for 1 day if they are not in H form and if they are in H form [AMBERJET 1200H (Strong Cationic
Resins)], no need to soak.
 Special care to be taken of the drums, that should not be mixed with other drums.
 Wash resins (soaked) next day with demin water, washing will be completed when chlorides will be
removed by continuous checking of chlorides.
V= r2l.
Where:

 Then check the upper layer, if found powder type layer remove the same for about 10‐20 mm.
 For figure of cationic resins makeup, go to Annex # B.
Anionic Resins Makeup Procedure

 Soak the anionic resins (strong & weak) individualy, required to makeup the resins in anion
exchanger in 15‐20% NaCl solution for 1 day if they are not in Cl form and if they are in Cl form
[AMBERJET 1200Cl (Strong Anionic Resins) & AMBERLITE IRA96RF (Weak Anionic Resins)], no need to
soak.
V= r2l.

Page 6 of 13
BSPM Power House
Where:

 Then check the upper layer, if found powder type layer remove the same for about 10‐20 mm of
individual resins (strong & weak).
 For figure of anionic resins makeup, go to Annex # C.

Mixed Bed Resins Makeup Procedure

 Soak the cationic resins (strong) and anionic resins (strong), required to makeup the resins in mixed
bed exchanger in 15‐20% NaCl solution for 1 day if they are not in H form or Cl form respectively but
if they are in H form and Cl form [AMBERJET 1200H (Strong Cationic Resins) & AMBERJET 1200Cl
(Strong Anionic Resins)], no need to soak then.
V= r2l.
Where:

 Then check the upper layer, if found powder type layer remove the same for about 10‐20 mm of
individual resins (cationic & anionic).
 For figure of anionic resins makeup, go to Annex # D.
Makeup of Resins
Makeup Of Resins In Train # A & Train # B
Makeup Of Resins In Cation Exchanger
Each bag of strong cationic resins = x lit.
Quantity to makeup:
Strong Cationic Resins = y lit (a Bags).

Total makeup of resins = z lit.
Page 7 of 13
BSPM Power House
Makeup Of Resins In Anion Exchanger

Strong Anionic Resins : Weak Anionic Resins
1:1
Each bag of strong anionic resins and weak anionic resins = a lit.
Quantity to makeup:
Strong Anionic Resins = x lit (b Bags),
Weak Anionic Resins = y lit (c Bags).

Makeup Of Resins In Mixed Bed Ion Exchager

Strong Cationic Resins : Strong Anionic Resins
1:1.45
Each bag of strong cationic resins and strong anionic resins = a lit.
Quantity to makeup:
Strong Cationic Resins = x lit (b Bags),
Strong Anionic Resins = y lit (c Bags).

Page 8 of 13
BSPM Power House
Flow Chart:
Job Request & LOTO
No
Inspection Of
Replace Resins
Resins

Yes

Makeup Of Resins

Remove LOTO

Regeneration Of Ion
Exchanger
Page 9 of 13
BSPM Power House
Annex # A:

For makeup of resins:

i. Recommended depth of ion exchange resin = x.
ii. Measured depth = y.
Page 10 of 13
BSPM Power House
Annex # B:

For makeup of cationic resins in Cation Exchanger:

Page 11 of 13
BSPM Power House
Annex # C:

For makeup of strong and weak anionic resins in Anion Exchanger:

Page 12 of 13
BSPM Power House
Annex # D:

For makeup of strong cationic & strong anionic resins in Mixed Bed Ion Exchanger:

Page 13 of 13
BSPM Power H
House
Stea
am Turb
bine Exttraction
ns
Non-Re
eturn Valve
Rev 0
July, 2012
J
BSPM Power House
O&M Man nagement Systtem
Steam Turbine Extractions Non‐R
Return Valve

Table of Conte
ents
Objecctive ................................................................................................................................. 3
Technnical Detail ....................................................................................................................... 3
Preve
entive Proce edure ............................................................................................................. 3
Frequuency: .............................................................................................................................. 3
Actio
ons to Follow w .................................................................................................................... 3
Stand
ding Instructtion for Turb bine Operato ors .......................................................................... 3
Actio
ons to Follow w .................................................................................................................... 3
Anneex 1: .................................................................................................................................. 5
Anneex 2: .................................................................................................................................. 6

Page 2 of 6
BSPM Power House
Return Valve

Obje
ective
The o objective of th
his procedure
e is to provide guideline too operation, Mechanical aand E&I team
ms
for safe and reliable operation o
of steam turbbine with resppect to steam
m turbine extrractions.

Tech
hnical De
etail
Techn
nical detail byy OEM is attacched in Annexx 2
Prevventive P
Procedure
e
The N
Non‐Return Vaalves strokingg.
Freq
quency:
Fortnightly if Steam
m Turbine is o
off and on turrning gear.

Actiions to Fo
ollow
The N
Non‐Return Valves LBD10A AA910 (13 bar Ext. 1) and LBD20AA9100 (5 bar Ext. 2 2) stroking will
be carried out from
m field as per following ste
eps;
1. Ensure exttraction is isolated (Manuaal Isolation Vaalve Closed) ffrom field sidee.
2. ON / OFF ffrom field in tthe presence of turbine opperator, E&I aand mechaniccal technician n.
3. ON / OFF ffrom DCS in the presence o of turbine opperator and E& &I technician.
4. Check Instrument Air Press, if low orr high adjust aat 6.0 Bar to 6.3 Bar.
5. Check for aany air leakagges.
6. Check physical conditio on
7. Check the instrument aair filter and regulator

Stan
nding Insttruction ffor Turbin
ne Operaators

dition: In casse of a sudde
Cond en change of parameterrs or sudden
n turbine shu
ut down or
manu
ual opening of generator circuit breaaker by Ope rator due to
o any reasonn.

Actiions to Fo
ollow
If abo
ove condition occurs, im
mmediately o below steps if required;
observe and follow the b
Page 3 of 6
BSPM Power House
Return Valve

 Closely moonitor turbine
e speed and iff turbine speeed is not retaarding and inccreasing
rapidly tow
wards turbinee over speeding.
 Manually cclose the 13 B
Bar Ext. 1 ON//OFF Valve LBBD10AA920 aand 5 Bar Ext.. 2 ON/OFF
Valve LBD220AA920 to aavoid turbine from over sppeed.
Page 4 of 6
BSPM Power House
Return Valve

nex 1:
Ann
Page 5 of 6
TESTING SHEET FOR EXTRACTIONS NON‐RETURN FLAP VALVES
STEAM TURBINE 41MW
Date: __________________________
ON/OFF in Status on ST Air Regulator Physical

Sr# Tag No. Description Air Pressure Air Leakages Remarks
Field DCS Status Condition
1 LBD10AA910 13 BAR EXTRACTION#1
2 LBD20AA910 5 BAR EXTRACTION#2
Checked By: Verified By:
Name & Signature:____________________________ Name & Signature:______________________________
BSPM Power House
Return Valve

nex 2:
Ann
Page 6 of 6
Section Page
3.2 8(11)
3.2.3 NON-RETURN VALVE

Manufacturer ARMATURY GROUP a.s
The non-return valve is located in controlled extraction lines. The purpose of this valve is
to prezent the reverse steam flow in case of a sudden change of parameters or sudden
turbine shut down.
The valve freely opens by dynamic moment of steam flow.
At the change of flow direction it closes by the instrumentatlity of the static moment of
valve plate. At the same time an impulse can be indicated to support the closing by an
pneumatic actuator.
The pneumatic actuator is moved in “open” position by air pressure. When this pressure is
released by a solenoid valve, the piston of the actuator moves in “close” position by the
force of a spring.
The actuator controls the movement of the disc shaft by means of a toothed bar and a
gear wheel connected by a clew coupling to the disc shaft.
For detail information see the documentation of subdeliveries.
Movability test of the disc
The test can be carried out only when the turbine is shut down and the bleed line is
depressurized. Before testing it is necessary unlock the pneumatic actuator by opening the
control air inlet to the actuator. Then by means of the lever turn the shaft to “OPEN”
position (marking on the shield “C”). By turning the lever to “CLOSE” position (marking “Z”)
the valve is closed.
Now by turning the lever to “0” position you unlock the disc, then remove the lever from the
shaft key and close the cotnrol air to the actuator.
EDITION: REV: PRODUCED:Pt, Ch MANUAL-No.:

06/2009 B / AS-BUILT CHECKED:Pt 5608/KASUR
12 2 9 8 11 3 1 5 7 6 4 8 13
06/2009
EDITION:
REV:
B / AS-BUILT
11
CHECKED:Pt
10
PRODUCED:Pt, Ch
1 – body
2 – disc
3 – shaft
4 – control shaft 1
5 – sleeve
6 – weight cover
NON-RETURN VALVE „ARMATURY GROUP a.s.“
7 – weight
3.2
8 – gland
Section
9 – control shaft 2
10 – lever
5608/KASUR
MANUAL-No.:
11 – clutch
12 – seat
13 – air actuator
9(11)
Page
Section Page
3.2 10(11)
AIR TORQUE ACTUATOR

ARMATURY GROUP a.s.
2
6
1
1 - control air inlet
2 - control air piping
3 - air exhaust piping
4 - toothed bar
5 - gear wheel
6 - solenoid valve
EDITION: REV: PRODUCED:Pt, Ch MANUAL-No.:

06/2009 B / AS-BUILT CHECKED:Pt 5608/KASUR
BBSSPPM
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RReevv 00
October, 2012
BSPM Power House
Power Factor Improvement Operation Procedures

Table of Contents
Abbreviations: ................................................................................................................................................ 3
Objective: ....................................................................................................................................................... 4
Precautions ..................................................................................................................................................... 5
Switching ON Capacitor Bank ......................................................................................................................... 5

Page 2 of 2
BSPM Power House

Abbreviations:

CB Circuit Breaker
EDG Emergency Diesel Generator
ST Steam Turbine
TG Turning Gear
ECRO Electrical Control Room Operator
Page 3 of 3
BSPM Power House

Objective:
The objective of this procedure is to further “protect the BSPM Assets”, this being paramount to the
interest of both BSPM Power House people as well as contractor people & the company at large. Electrical
Operator has to ensure the proper switching and operation of Power Factor Improvement Plant when
electrical system is energized.
This procedure is to define predetermined steps during operation of Power Factor Improvement Plant.


Page 4 of 4
BSPM Power House

Precautions
 In case of WPDA shutdown turn off Capacitor Bank.
 If Power Factor of the system is on capacitive side or more than 0.98, switch OFF Capacitor Bank.
 If total load on WAPDA or 41 MW unit less than 8 MW, switch OFF Capacitor Bank.
 In case of any leakage in capacitor bank or any electrical abnormality, inform E&I department
and raise job request.
Switching ON Capacitor Bank
 Ensure Total load of main HT should be more than 8 MW.
 Power Factor Should be less than 0.92.
 Check capacitor bank physically before turn on the breaker.
 Note down the Power factor before switching ON.
 Turn on breaker and note amperes.
 Note down the Power factor after switching ON.

Page 5 of 5
BBSSPPM
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CChheem miic
caall AAnna allyyssiiss
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RReevv 11
January, 2013
BSPM Power House
Chemical Analysis and Chemical Control Procedure

Table of Contents
Abbreviations ................................................................................................................................................................ 4
Objective ....................................................................................................................................................................... 5
Control Limits ................................................................................................................................................................ 6
200 TPH Boiler .......................................................................................................................................................... 6
65 TPH ....................................................................................................................................................................... 6
41 MW Steam Turbine .............................................................................................................................................. 6
41 MW Cooling Towers ............................................................................................................................................. 6
Utility Cooling Towers ............................................................................................................................................... 7
Demineralization Plant ............................................................................................................................................. 7
Drinking Water .......................................................................................................................................................... 7
Standard Solutions and Chemical Reagents Preparation ............................................................................................ 8
Standard Solutions .................................................................................................................................................... 8
Chemical Reagents .................................................................................................................................................... 8
Calibration ................................................................................................................................................................... 10
pH Meter ................................................................................................................................................................. 10
Conductivity Meter ................................................................................................................................................. 11
Spectrophotometer ................................................................................................................................................ 11
Chemical Analysis ....................................................................................................................................................... 12
pH ........................................................................................................................................................................... 12
Conductivity ............................................................................................................................................................ 12
Total Hardness ........................................................................................................................................................ 12
Calcium(Ca) Hardness ............................................................................................................................................. 12
Magnesium(Mg) Hardness ...................................................................................................................................... 12
P‐Value And M‐Value .............................................................................................................................................. 13
Chlorine Testing ...................................................................................................................................................... 13
Silica(SiO2) Testing .................................................................................................................................................. 14
Hydrazine(N2H4) Testing ......................................................................................................................................... 14
Phosphate(PO4) Testing .......................................................................................................................................... 14
OrthoPhosphate Testing ......................................................................................................................................... 14
Iron (Fe) Testing ...................................................................................................................................................... 15
Total Dissolved Salts (TDS) ...................................................................................................................................... 15
Demineralization Plant ............................................................................................................................................... 16
Plant Characteristics ................................................................................................................................................... 16
Cation Exchanger .................................................................................................................................................... 16
Anion Exchanger ..................................................................................................................................................... 16
Mixed Bed ............................................................................................................................................................... 16
Plant Operation ........................................................................................................................................................... 17
Cation Exchanger .................................................................................................................................................... 17
Service .................................................................................................................................................................... 17
Regeneration Of Cation Exchanger ......................................................................................................................... 17
Regeneration Steps ................................................................................................................................................. 17
De‐Gasifier .............................................................................................................................................................. 17
Anion Exchanger ..................................................................................................................................................... 17
Service .................................................................................................................................................................... 18
Regeneration Of Anion Exchanger .......................................................................................................................... 18
Regeneration Steps ................................................................................................................................................. 18
Mixed Bed Ion Exchanger (Mixed Bed Polisher) ..................................................................................................... 18
Service .................................................................................................................................................................... 18
Page 2 of 27
BSPM Power House

Regeneration .......................................................................................................................................................... 18
Reference: ................................................................................................................................................................... 20
Annexure 1: Forms ...................................................................................................................................................... 21
Annexure 2 – Demineralization Plant Valve Operation ............................................................................................. 24
Annexure 3 – Log Sheets ............................................................................................................................................. 27
Page 3 of 27
BSPM Power House

Abbreviations
A Angstrom – Unit of wave length
CBD Continuous Blow Down
EBT Erichrome black T
EDTA Ethylene Di‐Amine Tetra Acetic Acid
Fe Iron
FW Boiler Feed Water
Gm Gram
LSC Live Steam Condensate
MW Megawatt
ppb Parts per billion
ppm Parts per million
RC Return Condensate
TC Turbine Condensate
TPH Ton per Hour
λ Lambda (Wave Length)

Page 4 of 27
BSPM Power House

Objective

The objective of this procedure is to define predetermined steps for Laboratory operations, demineralization plant
and chemical controls with the aim of minimizing the odd operations and to enhance safe and uniform practices.
Following are the objectives to achieve;

1. Protect assets and prolong the useful life by controlling water chemistry
4. Decrease system downtime
5. Ensure quality of water and steam

Page 5 of 27
BSPM Power House

Control Limits
The control limits are as follows:
Control limits define the area with standard deviations on either side. Do not confuse control limits with
specification limits. Control limits reflect the expected variation in the control parameters. Following are the
control limits to maintain BSPM Power House water and steam chemistry.
200 TPH Boiler
FW RC LSC CBD
pH 8.9‐9.1 8.9‐9.1 8.9‐9.1 9.4‐9.8
Conductivity(µs/cm) <10 <10 <10 <100
Cationic Conductivity(µs/cm)
Total Hardness (ppm) Nil Nil Nil Nil
P‐Value (ppm) <15
M‐Value (ppm) <40
Silica SiO2 (ppm) <0.1 <0.1 <0.1 <1
Hydrazine N2H4 (ppm) 0.1‐0.2 ‐ ‐ <0.1
Phosphate PO4 (ppm) ‐ ‐ ‐ 3‐5
Iron (Fe)
65 TPH
FW RC LSC CBD
pH 8.9‐9.1 8.9‐9.1 8.9‐9.1 10‐10.5
Conductivity(µs/cm) <10 <10 <10 <500
Cationic Conductivity(µs/cm)
Total Hardness (ppm) Nil Nil Nil Nil
P‐Value (ppm) <30
M‐Value (ppm) <60
Silica SiO2 (ppm) <0.1 <0.1 <0.1 <3.5
Hydrazine N2H4 (ppm) 0.2‐0.5 ‐ ‐ <0.5
Phosphate PO4 (ppm) ‐ ‐ ‐ 10‐20
Iron (Fe)
41 MW Steam Turbine
TC
pH 8.9‐9.1
Conductivity(µs/cm) <10
Total Hardness (ppm) Nil
Silica SiO2 (ppm) <0.1
41 MW Cooling Towers
pH 7.8‐8.2
Total Hardness (ppm) <350
Calcium (Ca) Hardness (ppm) <180
P-Value (ppm) Nil
M-Value (ppm) <200
Page 6 of 27
BSPM Power House

Utility Cooling Towers
pH 7.8‐8.2
Total Hardness (ppm) <350
Calcium (Ca) Hardness (ppm) <180
P‐Value (ppm) Nil
M‐Value (ppm) <200
Phosphate PO4 (ppm) 6‐7.5
Demineralization Plant
Cation Outlet Anion Outlet Mixed Bed Outlet
pH 2.5‐3 7.6‐7.9 7.7‐8
Conductivity(µs/cm) ‐ <1 <1
Acidity (‐M.Value) (ppm) 2.5‐3.5 ‐ ‐
Silica SiO2 (ppm) ‐ <0.1 <0.1

Drinking Water
pH 7.5‐8.2
Total Hardness (ppm) 80‐100
Calcium (Ca) Hardness (ppm) 40‐50
P‐Value (ppm) Nil
M‐Value (ppm) 200‐250
Chlorine (ppm) 0.2‐0.5

Page 7 of 27
BSPM Power House

Standard Solutions and Chemical Reagents Preparation
Standard Solutions
N/100 Hydrochloric Acid (HCl) Solution
 1N HCl Solution = Taken from quality laboratory.
 Add 10ml 1N HCl solution in 1 lit demin water.
N/100 Sodium Hydroxide (NaOH) Solution
 1N NaOH Solution = Taken from quality laboratory.
 Add 10ml 1N NaOH solution in 1 lit demin water.

N/100 Ethyl Di Amine Tetra Acetic Acid (EDTA) Solution
 1N EDTA Solution = Taken from quality laboratory.
 Add 10ml 1N EDTA solution in 1 lit demin water.
Buffer Solutions (pH 4, pH 7 & pH 9.2) for pH Meter Calibration
 Dissolve the tablet pH 4/pH 7/pH 9.2 in 100ml distilled/demin water.

Standard Solutions Of Conductivity Meter

 Standard solutions of conductivity meter are purchased on PR by commercial department.

Chemical Reagents
Chemical reagent for silica (SiO2) test
 Ammonium molybedate
Add 50 gm ammonium molybedate + 50ml H2SO4 in demin water. Make total volume of 1 liter.
 Tartaric Acid
Add 50 gm tartaric acid in demin water. Make total volume of 1 liter.
 Metol
Add 205 gm potassium meta bi‐sulphite + 20 gm photorex in demin water. Make total volume of
1 liter.

Chemical reagent for hydrazine (N2H4) test
 Pera Di Methyl Amino Benzaldehyde
Add 10gm peradimethyl + 28ml Conc: H2SO4 . Total Volume is 1 lit.

Chemical reagent for phosphate (PO4) test
 Vanadate Molybedate
Add 25 gm ammonium molybedate + 1 gm ammonium vanadate + 125 ml Conc. H2SO4. Make
total volume of 1 liter.

Chemical reagent for hardness test
 Ammonia Buffer Solution
Page 8 of 27
BSPM Power House

Add 67.5 gm ammonium chloride solution + 160ml ammonia solution (100%) in one liter of
demin water

 Erichrome Black‐T (EBT)
Add 50% tri ethanol amine and 50% demin water. Then add 0.5gm EBT in 100 ml of demin water.
 Potassium Hydroxide (KOH)
Add 10ml KOH solid in 100ml demin water.

Chemical reagent for Alkalinity Test
 Methyl Orange
Add 0.5 gm methyl orange powder in 100ml demin water.
 Phenolphthalein
Add 0.5 gm phenolphthalein powder in 100 ml ethyl alcohol and small quantity of NaOH till light
pink color appears.
Page 9 of 27
BSPM Power House

Calibration
pH Meter

pH is indicated by the pH meter of any given sample.

Procedure for Calibration Of pH Meter

 Turn on pH meter.
 Take electrode out of storage solution.
 Rinse the electrode with distilled/demin water.
 Submerse the electrode into the pH 7 buffer solution.
 Press the calibrate button.
 Wait until the pH icon stops flashing then press the calibrate button again wait for few seconds
 Submerse the electrode into the pH 4 or pH 9.2 buffer solution.
 Wait until the pH icon stops flashing then press the measure button.
 Rinse the electrode with distilled water/demin water.
 Submerse the electrode in sample.
 Press the measure button.
 Wait until the pH icon stops flashing and record the pH of sample.

Observed Reading

 Dip the electrode in buffer solution pH 4/pH 7/pH 9.2 & observe the reading.

Accuracy

 Observe the difference between the standard buffer solutions and the observed readings.
Calibration

 If the difference between standard solution and observed readings is more or less than 0.3, then
calibration is required.

Page 10 of 27
BSPM Power House

Conductivity Meter
Conductivity is indicated by the conductivity meter of any given sample. Conductivity is measured in µs/cm.

Procedure for Calibration of Conductivity Meter

 Turn on conductivity meter.
 Take electrode out of storage solution.
 Take the given standard solution and dip the electrode in the standard solution for few minutes.
 Press the calibration button and adjust the value until it meets the conductivity of the standard
solution.
 Turn the conductivity meter off and wash the electrode with distilled/demin water.
 Then use the conductivity meter as normal.

Accuracy

 Observe the difference between the standard solutions and the observed readings.

Calibration

 If the difference between standard solution and observed readings is more or less than 0.3, then
calibration is required.

Spectrophotometer
On each startup of spectrophotometer, it is self‐checked automatically and then it is auto calibrated.
Service of spectrophotometer is done by OEM of the equipment whenever required.
Reference solution for testing in spectrophotometer is demineralized water.

Page 11 of 27
BSPM Power House

Chemical Analysis
pH

I. pH is checked by color, adding pH indicator in the sample showing (giving) certain color.
II. pH is also checked by pH meter.

Conductivity

I. Conductivity is checked by conductivity meter. Measured in μs/cm.

Total Hardness

I. Take 50 ml sample
II. Add 2,3 drops of ammonia buffer solution +
III. One pinch of EBT (erichrome black T ) indicator.
IV. If violet color appears hardness is present.
V. Then titrate against N/100 EDTA (Ethylene Di‐Amine Tetra Acetic Acid).
VI. Titrate it till blue color appears.

Total hardness in ppm (parts per million).

Reading * 10 = Total hardness in ppm as CaCO3.

Calcium(Ca) Hardness

II. Add 1 ml NaOH (0.1N) solution.
III. Add one pinch of mureoxide indicator.
IV. If light pink appears then titrate it against 0.01N EDTA till violet color appears.
Reading = Ca hardness in ppm.
Reading * 10 = Ca hardness in ppm.
Magnesium(Mg) Hardness

Magnesium (Mg) Hardness = Total Hardness – Calcium(Ca) Hardness.

Page 12 of 27
BSPM Power House

P‐Value And M‐Value

a. P‐Value (Partial alkalinity)

II. Add phenolphthalein (2‐3 drops).
III. If pink color appears then titrate it against 0.01N acid (HCl).
IV. Pink color shows P‐value is present.
V. End point is colorless.

Reading = P‐value (ppm).
Reading *10 = ppm.

→ Controlling factor is pH and p‐value varies with pH.

b. M‐Value (Total alkalinity)

I. In above sample of p‐value, add methyl orange indicator (2‐3 drops).
II. If yellow color appears Negative M‐Alkalinity is present then titrate it against 0.1N HCl till reddish
color appears.

Reading = M‐value ppm.
Reading * eq.wt: = ppm.

c. Acidity (‐M Value)

II. Add methyl orange indicator (2‐3 drops).
III. If reddish color appears ‐M. value is present then titrate it against 0.1N NaOH till yellow color
appears.

Reading = ‐M‐value = ppm.
Reading * 10 = ppm.
Chlorine Testing

II. Add reagent pillow. Then shake it for 30 seconds.
III. Put it in test tube
IV. Put test tube in right side of chlorine test kit against the reference tube.
V. Reading is taken where the color matches with the reference.
VI. Reading is taken in mg/lit.

Page 13 of 27
BSPM Power House

Silica(SiO2) Testing

I. Silica is present in SiO3 form.
II. Take 25 ml sample
III. Add 1 ml ammonium molybedate.
IV. Wait for 4 minutes and then add 1 ml tartaric acid.
V. Wait for 1 minute and then add 1 ml metol
VI. Select SiO2 on Photometer
VII. After 2 minutes, check it on photometer by using 50mm cell

Required Wave Length (λ) 815 Angstrom
Reference = Demi water.
Hydrazine(N2H4) Testing
N2H4 + O2 → 2H2O + N2.

I. Used as oxygen scavenger.
II. Take 5 ml sample
III. Add 5 ml pera‐dimethyl amino benzaldehyde (hydrazine indicator).
IV. Yellow colour appears when we add indicator.
V. Select N2H4 on Photometer
VI. Wait for 11 minutes and check it on photometer by using 50mm cell.

Reference: Demi water + N2H4 indicator.
Phosphate(PO4) Testing

II. Add 2 ml vanadate molybedate indicator.
III. Select PO4 on Photometer
IV. Wait for 7 minutes, yellow color appears.
V. Check it on photometer by using 50 mm cell

Reference: Demi Water + Phosphate indicator.
OrthoPhosphate Testing

II. Add 2 ml vanadate molybedate indicator.
III. Select PO4 on Photometer
IV. Wait for 7 minutes, yellow color appears.
V. Check it on photometer by using 50 mm cell
VI. Divide result by 3 to get Orthophosphate reading.

Page 14 of 27
BSPM Power House

Reference: Demi Water + Phosphate indicator.
Iron (Fe) Testing

II. Add 1 drop 0.1N Potassium Permanganate (KMnO4).
III. Add 5ml 25% Potassium Thiocyanate (KSCN) and 3 ml 4N HNO3 (diluted)
IV. Select Iron (Fe) on Photometer
V. Brick red color appears.
VI. Check it on photometer by using 50 mm cell

Reference: Demi Water.
Total Dissolved Salts (TDS)

Conductivity(µs/cm) Multiplying Factor TDS
1‐1000 0.68 1 ‐ 1000 * 0.68
1000‐4000 0.75 1000 – 4000 * 0.75
4000‐10000 0.82 4000 – 10000 * 0.82
Above ( Then Dilute The ‐ ‐
Sample) ‐ ‐

Page 15 of 27
BSPM Power House

Demineralization Plant
Plant Characteristics
Cation Exchanger
Quantity 2 sets (1 operating, 1 standby)
Type Packed bed
Service Flowrate 58 m3/hr
Mode Of Operation Automatic
Working Pressure 3 bar
Design Pressure 5 bar
Exhaust Time 12 Hrs
Anion Exchanger
Type Packed bed
Working Pressure 3.8 bar
Exhaust Time 12 Hrs
Mixed Bed
Type Packed bed
Working Pressure 2.5 bar
Exhaust Time 168 Hrs

Page 16 of 27
BSPM Power House

Plant Operation
Cation Exchanger
After the removal of physical impurities water passed from the cation exchanger where cations like Na+, Ca++ and
Mg++ are removed and H ion (H+) released reacts with sulphates ( SO4‐‐), chlorides (Cl‐) & bicarbonates (HCO3‐) to
form corresponding acid.

2RSO3H + Na2CO3 → 2RSO3Na + H2CO3.
RSO3H + NaCl → RSO3Na + HCl.
2RSO3H + CaSO4 → (RSO3)2Ca +H2SO4.
Service
Service In XV‐C01A and Service Out XV‐C02A valves are opened during the service if cation exchanger.
Regeneration Of Cation Exchanger

35% Concentration Hydrochloric acid (HCl) is used for regeneration of cation resins.

RSO3‐Na+ + HCl → RSO3H + NaCl.
RSO3‐Ca2+ + HCl → 2RSO3H + CaCl2.

Regeneration Steps

 Exhaust time of cation exchanger is 12 hours.
 Regeneration of cation exchanger starts by the first step which is BACKWASH. It’s operation time
is 5 minutes. Backwash In XV‐CO4A and Backwash Out XV‐CO5A opens for this step.
 Next step is of Chemical Feeding. It’s operation time is 25 minutes. Acid In XV‐C06A, Acid dilution
In XV‐W05 and Rinse Out XV‐C03A valves open for this step.
 Then Slow Rinse step is carried. It’s operation time is 50 minutes. Acid In XV‐C06A, Acid dilution
In XV‐W05 and Rinse Out XV‐C03A valves open for this step.
 After this Settling is carried out. It’s operational time is 10 minutes. In this step all valves are
closed.
 Then Final Rinse step takes place. It’s operational time is 5 minutes. Service In XV‐C01A and Rinse
Out XV‐C03A valves are opened in this step.
De‐Gasifier
De‐gasifier is an equipment where dissolved gases such as CO2 are removed from water by vacuum mechanism or
by blowing air through showering de‐ionized water.
Anion Exchanger
The water containing different acids after the cation exchanger is passed through the anion exchanger. Following
chemical reactions are involved:

Page 17 of 27
BSPM Power House

R3NOH + HCl → R3NCl +H2O.
2R3NOH + H2SO4 → (R3N)2SO4 +2H2O.
Service
Service In XV‐A01A and Service Out XV‐A02A valves are opened during the service if anion exchanger.

Regeneration Of Anion Exchanger

50% NaOH is used for regeneration of Anion resins.

R3NCl + NaOH → R3OH + NaCl.

(R3N)2SO4 + 2NaOH → 2R3OH + Na2SO4.

Regeneration Steps
 Exhaust time of anion exchanger is 12 hours.
 Regeneration of anion exchanger starts by the first step which is BACKWASH. It’s operation time is 5
minutes. Backwash In XV‐AO4A and Backwash Out XV‐AO5A opens for this step.
 Next step is of Chemical Feeding. It’s operation time is 25 minutes. Caustic In XV‐A06A, Caustic dilution In
XV‐W09 and Rinse Out XV‐A03A valves open for this step.
 Then Slow Rinse step is carried. It’s operation time is 50 minutes. Caustic In XV‐A06A, Caustic dilution In
XV‐W09 and Rinse Out XV‐A03A valves open for this step.
 After this Settling is carried out. It’s operational time is 10 minutes. In this step all valves are closed.
 Then Final Rinse step takes place. It’s operational time is 5 minutes. Service In XV‐A01A and Rinse Out XV‐
A03A valves are opened in this step.
Mixed Bed Ion Exchanger (Mixed Bed Polisher)
Mixed bed ion exchanger has both cation & anion ion exchange resins. Thus the remaining cations & anions of any
salt from cation & anion exchangers are removed in this filter. Chemical reactions involved are similar to cation
and anion ion exchangers.
Service
Service In XV‐M01A and Service Out XV‐M02A valves are opened during the service if mixed bed exchanger.

Regeneration
 Exhaust time of mixed bed exchanger is 168 hours.
 Regeneration of mixed bed exchanger starts by the first step which is BACKWASH. It’s operation time is 15
minutes. Backwash In XV‐MO4A and Backwash Out XV‐MO5A opens for this step.
 After this Settling is carried out. It’s operational time is 10 minutes. In this step all valves are closed.
Page 18 of 27
BSPM Power House

 Next step is of Chemical Feeding. It’s operation time is 50 minutes. Caustic In XV‐M06A, Acid In XV‐M07A,
Acid Dilution In XV‐W02, Caustic dilution In XV‐W12 and Spent Regenerant Out XV‐M08A valves open for
this step.
 Then Slow Rinse step is carried. It’s operation time is 60 minutes. Caustic In XV‐M06A, Acid In XV‐M07A,
Acid Dilution In XV‐W02, Caustic dilution In XV‐W12 and Spent Regenerant Out XV‐M08A valves open for
this step.
 Drain Down is carried out in next step of regeneration. It’s operational time is 10 minutes. Rinse Out XV‐
M03A and Air Vent Out XV‐M09A valves are open for this step.
 Then Air Mix takes place. Operational time for this step is 15 minutes. Air Vent In XV‐M10A and Air Vent
Out XV‐M09A valves are opened for this step.
 Next step is Slow Refill. It’s operational time is 10 minutes. Caustic In XV‐M06A, Acid Dilution In XV‐W02,
Caustic dilution In XV‐W12 and Spent Regenerant Out XV‐M08A valves open for this step.
 Then Final Rinse step takes place. It’s operational time is 10 minutes. Service In XV‐M01A and Rinse Out
XV‐M03A valves are opened in this step.
Page 19 of 27
BSPM Power House

Reference:
I. Descon Engineering Limited
II. GE Betz
III. ASTM Procedures
IV. HANNA Instruments, USA
V. Eutech Instruments, Singapore
VI. HACH Instruments, USA
VII. GSM (German Standard Method)
VIII. OEM – Salcon PTE Limited Singapore
Page 20 of 27
BSPM Power House

Annexure 1: Forms

Page 21 of 27
BSPM Power House

Calibration Of pH Meter
pH Date: Day: Time:
Standard Solution Actual Reading After Calibration Difference

4.0
7.0
9.2
Remarks:
Comments:

Name & Signature:___________________________
Plant Chemist

Page 22 of 27
BSPM Power House

Calibration Of Conductivity Meter
Conductivity Date: Day: Time:
Standard Solution Actual Reading After Calibration Difference

Remarks:
Comments:

Name & Signature:___________________________
Plant Chemist

Page 23 of 27
BSPM Power House

Annexure 2 – Demineralization Plant Valve Operation
Page 24 of 27
BSPM Power House

DEMIN PLANT Train # A
Time 1A 2A 3A 4A 5A 6A
Cation Exchanger Valves (mins) XV‐C01A XV‐C02A XV‐C03A XV‐C04A XV‐C05A XV‐C06A XV‐W05
Backwash Acid
Service In Service Out Rinse Out Backwash In Out Acid In Dilution In
Service Open Open
Regeneration Back Wash 5 Open Open
Chemical Feeding 25 Open Open Open
Slow Rinse 50 Open Open Open
Settling 10 All Valves Closed
Final Rinse 5 Open Open
Time 1A 2A 3A 4A 5A 6A
Anion Exchanger Valves (mins) XV‐A01A XV‐A02A XV‐A03A XV‐A04A XV‐A05A XV‐A06A XV‐W09
Backwash Caustic
Service In Service Out Rinse Out Backwash In Out Caustic In Dilution In
Service Open Open
DEMIN PLANT Train # B
Time 1B 2B 3B 4B 5B 6B
Cation Exchanger Valves (mins) XV‐C01B XV‐C02B XV‐C03B XV‐C04B XV‐C05B XV‐C06B XV‐W05
Backwash Acid
Service In Service Out Rinse Out Backwash In Out Acid In Dilution In
Service Open Open
Time 1B 2B 3B 4B 5B 6B
Anion Exchanger Valves (mins) XV‐A01B XV‐A02B XV‐A03B XV‐A04B XV‐A05B XV‐A06B XV‐W09
Backwash Caustic
Service In Service Out Rinse Out Backwash In Out Caustic In Dilution In
Service Open Open
Page 25 of 27

Time 1A 2A 3A 4A 5A 6A 7A 8A 9A 10A
Mixed Bed Valves (mins) XV‐M01A XV‐M02A XV‐M03A XV‐M04A XV‐M05A XV‐M06A XV‐M07A XV‐M08A XV‐M09A XV‐M10A XV‐W02 XV‐W12
Spent Acid
Backwash Regenerant Dilution Caustic
Service In Service Out Rinse Out Backwash In Out Caustic In Acid In Out Air Vent Out Air Vent In In Dilution In
Service Open Open
Chemical Feeding 50 Open Open Open Open Open
Slow Rinse 60 Open Open Open Open Open
Drain Down 10 Open Open
Air Mix 15 Open Open
Slow Refill 10 Open Open Open Open
Time 1B 2B 3B 4B 5B 6B 7B 8B 9B 10B
Mixed Bed Valves (mins) XV‐M01B XV‐M02B XV‐M03B XV‐M04B XV‐M05B XV‐M06B XV‐M07B XV‐M08B XV‐M09B XV‐M10B XV‐W02 XV‐W12
Spent Acid Caustic
Backwash Regenerant Dilution Dilution
Service In Service Out Rinse Out Backwash In Out Caustic In Acid In Out Air Vent Out Air Vent In In In
Service Open Open
Chemical Feeding 50 Open Open Open Open Open
Slow Rinse 60 Open Open Open Open Open
Drain Dawn 10 Open Open
Air Mix 15 Open Open
Slow Refill 10 Open Open Open Open

BSPM Power House

Annexure 3 – Log Sheets
Water Steam Cycle Analysis
Sheet
Record No:IMS‐PH‐F‐11Rev:00
DATE
Test RC TC LSC FW CBD
Unit pH Cond SiO2 Hd pH Cond SiO2 Hd pH Cond SiO2 Hd pH Cond SiO2 N2H4 Hd pH Cond SiO2 N2H4 P val M.val PO4 Hd
(8.9- (8.9- (8.9- (8.9- (9.4-
9.1) (<10) (<0.1) (Nil) 9.1) (<10) (<0.1) (Nil) 9.1) (<10) (<0.1) (Nil) 9.1) (<10) (<0.1) (0.1-0.2) (Nil) 9.8) (<100) (<1) (<0.1) (<15) (<40) (3-5) (Nil)
Boiler Shift Time Nos us/cm mg/l ppm Nos us/cm mg/l ppm Nos us/cm mg/l ppm Nos us/cm mg/l mg/l ppm Nos us/cm mg/l mg/l ppm ppm ppm ppm
8:30
1st
12:30
16:30
PH 2nd
0T
20
20:30
0:30
3rd
4:30
1st Shift
2nd Shift
3rd Shift
BSPM Power House
Water Steam Cycle Analysis
Sheet
Record No:IMS‐PH‐F‐11Rev:00
DATE
Test RC TC LSC FW CBD
Unit pH Cond SiO2 Hd pH Cond SiO2 Hd pH Cond SiO2 Hd pH Cond SiO2 N2H4 Hd pH Cond SiO2 N2H4 P val M.val PO4 Hd
(8.9- (8.9- (8.9- (8.9- (10-
9.1) (<10) (<0.1) (Nil) 9.1) (<10) (<0.1) (Nil) 9.1) (<10) (<0.1) (Nil) 9.1) (<10) (<0.1) (0.2-0.5) (Nil) 10.5) (<500) (<3.5) (<0.5) (<30) (<60) (3-5) (Nil)
Boiler Shift Time Nos us/cm mg/l ppm Nos us/cm mg/l ppm Nos us/cm mg/l ppm Nos us/cm mg/l mg/l ppm Nos us/cm mg/l mg/l ppm ppm ppm ppm
8:30
1st
12:30
16:30
H 2nd
TP
65
20:30
0:30
3rd
4:30
1st Shift
2nd Shift
3rd Shift
Return Condensate Analysis Sheet
Record No:IMS‐PH‐F‐12 Rev:00
Date:
Time Parameters
pH (8.9-9.1) Conductivity (<10) SiO2 (<0.1) Hardness (Nil)
7:30
8:30
9:30
10:30
11:30
12:30
13:30
14:30
15:30
16:30
17:30
18:30
19:30
20:30
21:30
22:30
23:30
0:30
1:30
2:30
3:30
4:30
5:30
6:30
Shift A
Sig.
Shift B
Sig.
Shift C
Sig.
Shift D
Sig.
Analysis Sheet
RAW WATER DRINKING WATER
pH Value
(7.5-8.2)
No.
Conductivity
(<1100)
µs/cm
P-Value
(Nil)
ppm
M-Value
(Nil)
ppm
T.Hardness
(200-250)
ppm
Ca.Hardness
(40-50)
ppm
R.Chlorine
(0.2-0.5)
ppm
Remarks
(Ranges Are For
Drinking Water)
1st Shift
2nd Shift
3rd Shift
Demineralization Plant Sheet
Train A/B Date____________________________
Pressure Conductivity Levels Neut.Pit

Raw Before After Before After Degassfier Degassifier Before After Before After PH-Value
Air Water Strainer Strainer Cation Cation Pump Fan Anion Anion M.Bed M.Bed Anion Mix Bed Neut. D.S. Tanks (6.5-7.5)
Time Anion M.Bed (5-6) (3-5) (3-5) (3-5) (3-5) (2-4) (4-4.5) (<60) (3.5-4) (2.5-3) (2.5-3) (1.6-2) (<1) (<1) Pit (<80) (>60)
Sec Sec Bar Bar Bar Bar Bar Bar Bar mm of Hg Bar Bar Bar Bar µs/cm µs/cm % % No Remarks
7:00 1st Shift
8:00
9:00
10:00
11:00
12:00
13:00
14:00
15:00 2nd Shift
16:00
17:00
18:00
19:00
20:00
21:00
22:00
23:00 3rd Shift
0:00
1:00
2:00
3:00
4:00
5:00
6:00
Cooling Water Analysis Sheet
DATE
Cooling 41MW Cooing Utility

Towers Towers Cooling Tower
8:30 12:30 16:30 20:30 0:30 4:30 8:30 12:30 16:30 20:30 0:30 4:30
pH Value
(7.8-8.2)
No.
Conductivity (<3200)
µs/cm
P-Value
(Nil)
ppm
M-Value
(<200)
ppm
O.Phosphate
(6-7.5)
ppm
T.Hardness
(<350)
ppm
Ca.Hardness
(<180)
ppm
Zn
(0.5-1.5)
ppm
R.Chlorine
(0.2-0.5)
ppm
Conc. No.
(3.5)
Remarks
1st Shift
2nd Shift
3rd Shift
Demin Water Analysis Sheet
Record No:IMS-PH-F-15 Rev:00
Date
Cation Anion Mixed - Bed
pH (-)M-Value pH Cond SiO2 pH Cond SiO2
(2.5-3) (2.5-3.5) (7.6-7.9) (<1) (<0.1) (7.7-8) (<1) (<0.1)
Shift Time Nos ppm Nos us/cm mg/l Nos us/cm mg/l
8:30
1st
12:30
16:30
2nd
20:30
0:30
3rd
4:30
1st Shift
2nd Shift
3rd Shift
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February, 2013
BSPM Power House
200 TPH Boiler and 41 MW Steam Turbine Trip Interlock Test
Procedure
Table of Contents
Objective: ....................................................................................................................................................... 3
Frequency ....................................................................................................................................................... 3
Procedure ....................................................................................................................................................... 3
Annexure 1 ..................................................................................................................................................... 4
List of Instruments and Switches .................................................................................................................... 5
Annexure 2 ..................................................................................................................................................... 6
41 MW Generator Safeties and Protection .................................................................................................... 6
Annexure 3 ..................................................................................................................................................... 7

Page 2 of 8
BSPM Power House
Procedure
Objective:
The objective of this procedure is to provide guideline to E&I team to test the 200 TPH Boiler and 41 MW
Steam Turbine safety switches and trip interlocks. This will help to establish an effective tracking system
to ensure smooth operation, reduce the occurrence of unwanted trippings. This activity involves routine
checking, testing and verifying Boiler and Turbine Switches and Equipment’s trip values to avoid
breakdown and to ensure the safety of people as well as equipment;

3. In case of equipment malfunction, ensure unit trip and system shall go to safe mode.
Frequency
Boiler and Steam Turbine Switches and Equipment testing is a regular and repetitive work. It will be done
on annual basis to keep the equipment in good working order and to optimize its efficiency and accuracy.
Procedure
In order to establish an effective & efficient Equipment testing system a registry filing system is
developed. After calibration of the Equipment’s, E&I team will verify their settings. E&I team will check
trip values as per OEM instructions.

There are three types of boiler and turbine safeties.

a. Boiler Protections Test
b. 41 MW Steam Turbine Protections
c. 41 MW Generator Safeties and Protection.

E&I team will verify their setting by providing pressure with Fluke 717 30 G pressure calibrator in gas and
air flow or in running condition.
41 MW Generator Safety and Protection calibration and testing will be done by the third party.
Lists of Safety Switches tested in running condition or in Air and Gas mode are attached in Annex 1.
Boiler and Steam Turbine switches testing check list is attached in Annex 2.

Page 3 of 8
BSPM Power House
Procedure
Annexure 1
Page 4 of 8
BSPM Power House
Procedure
List of Instruments and Switches
Sr No Tag No Description Location

1 PSHH 303 A Pressure Switch High High Furnace draft Pressure
2 PAHH 301 B Pressure Alarm High High Furnace draft Pressure
3 PSHH‐601 A Pressure Switch High High Fuel Gas Main Line
4 PAHH ‐601 B Pressure Alarm High High Fuel Gas Main Line
5 PSLL 601 A Pressure Alarm Low Low Fuel Gas Main Line
6 PALL‐601 B Pressue Alarm Low Low Fuel Gas Main Line
7 PAH‐501 Pressure Alarm High Pilot Gas
8 PSL‐501 Pressure switch Low Pilot Gas
9 PSLL‐801 A Pressure Switch Low LOw Automizing Steam Pressure
10 PALL‐801 B Pressure Alarm Low Low Automizing Steam Pressure
11 PSL‐901 Pressure Switch Low Instrument Air Pressure
12 PSHH‐101 A Pressure Switch High High Boiler Drum Steam Pressure
13 PAHH‐101 B Pressure Alarm High High Boiler Drum Steam Pressure
14 LSLL 101 A/B Level Alarm Low Low Boiler Drum Level Low Low
15 FSLL 301 A Flow Switch Low Low 2‐FALL Combustion Air Flow Low Low
16 FSLL 301 B Flow Switch Low Low 2‐FALL Combustion Air Flow Low Low
17 PSH/L 602 Pressure Switch High/Low Gas Leak Test High and Low
15 TSHH 108 A/B Temperature Switch High High Live Steam Temperature High High
16 MAV40CT001/3 Lube oil Temperature Lube oil
17 MAG10CL001/3 Condensor level Condensor
18 LBA10CP001 Inlet Steam Pressure Main Steam line
19 LBA10CT002 Inlet Steam Temperature Main Steam line
20 MAV40DP001/3 Lube oil Pressure Lube oil
21 MAV40CP001 Control oil Pressure Lube oil
22 MAD10CY001 Shaft vibration X front Rear bearing
23 MAD10CY001 Redial & Axial Rear bearing
24 MAD10CY012 Redial & Axial Rear bearing
25 MAD10CG001 Turbine rotor Axial Gear Box
26 MAD10CG001 Displacement Gear Box
27 MAK10CY001 Vertical redial Gear Box
28 MAK10CY002 Horizental Redial Gear Box
29 MAD10CS001/3 Turbine Speed Turbine Speed
30 LBD10CP901 Extraction Pressure High 13 Bar Extraction Pressure High
31 LBD20CP901 Extraction Pressure High 5 Bar Extraction Pressure High
32 MAA10CP901 Pressure High Exhaust Pressure High
Page 5 of 8
BSPM Power House
Procedure
Annexure 2
41 MW Generator Safeties and Protection
Page 6 of 8
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Procedure
Annexure 3
Page 7 of 8
200 TPH Boiler and 41 MW Steam Turbine Safety Switches Testing
Check List

Date: _________________

Sr No Tag No Description Location Triping Set Point Actaul Trip Value Protection Active
1 PSHH 303 A Pressure Switch High High Furnace draft Pressure 2 mBar
2 PAHH 301 B Pressure Alarm High High Furnace draft Pressure 2 mBar
3 PSHH‐601 A Pressure Switch High High Fuel Gas Main Line 2.0 bar
4 PAHH ‐601 B Pressure Alarm High High Fuel Gas Main Line 2.0 bar
5 PSLL 601 A Pressure Alarm Low Low Fuel Gas Main Line .03 bar
6 PALL‐601 B Pressue Alarm Low Low Fuel Gas Main Line .03 bar
7 PAH‐501 Pressure Alarm High Pilot Gas 3.5 bar
8 PSL‐501 Pressure switch Low Pilot Gas 1 Bar
9 PSLL‐801 A Pressure Switch Low LOw Automizing Steam Pressure 7.0 bar
10 FSLL‐302 A Flow switch Low Low Combustion Air 0.4mBarg
11 FALL 301 B Flow Alarm low Low Combustion Air 0.4mBarg
12 PSH/L‐602 Pressure Switch High Low Gas Leake Proving 0.5 Barg
13 LSLL 101 A/B Level Alarm Low Low Boiler Drum Level Low Low 20%
14 PALL‐801 B Pressure Alarm Low Low Automizing Steam Pressure 7.0 Bar
15 LSLL 101 A/B Level Alarm Low Low Boiler Drum Level Low Low 20%
16 TSHH 108 A/B Temperature Switch High High Live Steam Temperature High High 550C
17 PSL‐901 Pressure Switch Low Instrument Air Pressure 4.5 Bar
18 PSHH‐101 A Pressure Switch High High Boiler Drum Steam Pressure 116 Barg
19 PAHH‐101 B Pressure Alarm High High Boiler Drum Steam Pressure 116 Barg
20 MAV40CT001/3 Lube oil Temperature Lube oil 65 DegreeC
21 MAG10CL001/3 Condensor level Condensor 600mm
22 LBA10CP001 Inlet Steam Pressure Main Steam line 89.3 Bar
23 LBA10CT002 Inlet Steam Temperature Main Steam line 490 Degree C
24 MAV40DP001/3 Lube oil Pressure Lube oil 0.90 bar
25 MAV40CP001 Control oil Pressure Lube oil 6.5 Bar
26 MAD10CY001 Shaft vibration X front Rear bearing 110.2um
27 MAD10CY001 Redial & Axial Rear bearing 110.2um
28 MAD10CY012 Redial & Axial Rear bearing 110.2um
29 MAD10CG001 Turbine rotor Axial Gear Box 0.6mm
30 MAD10CG001 Displacement Gear Box 0.6mm
31 MAK10CY001 Vertical redial Gear Box 11mm/s
32 MAK10CY002 Horizental Redial Gear Box 11mm/s
33 MAD10CS001/3 Turbine Over Speed Turbine Speed 7747RPM
34 LBD10CP901 Extraction Pressure High 13 Bar Extraction Pressure High >17.0 Bar
35 LBD20CP901 Extraction Pressure High 5 Bar Extraction Pressure High >7.0 Bar
36 MAA10CP901 Pressure High Exhaust Pressure High (‐)0.75 Barg
Performebd By E&I Team Leader Plant Manager

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February, 2014
BSPM Power House
Chemical Lab Weigh Scale Calibration Procedure

Table of Contents
Objective: ............................................................................................................................ 3
Frequency ........................................................................................................................... 3
Standard Weight: ................................................................................................................ 3
Procedure ............................................................................................................................ 3
Annexure 1 .......................................................................................................................... 4

Page 2 of 5
BSPM Power House

Objective:
The objective of this procedure is to provide guideline to Chemical Lab team to calibrate and operate
weighing balance as per standard practices. This will help to establish an effective tracking system to
ensure standard of lab analysis;

Frequency
Bi‐Annualy.

Standard Weight:

Certified weights by accredited Lab
Procedure
• Turn on the scale by pressing On/Off key.
• Press MODE key quickly and hold it until LCD displays “CAL”.
• Then untie MODE key, Press MODE again.
• After LCD flashes “CAL” Add weight subject to the scale three times.
• Wait 3,4 seconds, LCD displays “PASS” and the weight subject to the scale.
• Put away calibration weight.
• Press On/Off key to turn off scale.

Page 3 of 5
BSPM Power House

Annexure 1
Page 4 of 5
BSPM Power House

Chemical Lab Weigh Balance Calibration Sheet

Calibration Date:____________________. Location: Water Treatment Lab.

Equipment Name: Digital Weighing Balance.

Calibration Range: __________ . Maximum Allowable Error: 0.2 %.

Identification of Calibrator Used for Calibration: 0522000DWS‐001 . Calibration Frequency: 06 Month .

Equipment Used for Measuring: Weighing.

Absolute Status
S/No Std. Certified Values Observed Value %age Error
Error Pass/Fail
1
2
3
4
5
6
7
8

Action In case calibration not satisfactory: ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Next Calibration Due: __________________________.

Performed By: _____________________________________________

Approved By: _____________________________________________

Page 5 of 5
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BSPM Power House

Table of Contents
Objective: ....................................................................................................................................................... 3
Tube Well Pumps ............................................................................................................................................ 4
Raw Water Pumps .......................................................................................................................................... 5
Fire Water Pumps ........................................................................................................................................... 6

Page 2 of 6
BSPM Power House

Objective:
The objective of this procedure is to define predetermined steps for Raw Water Pumps, Tube
Well Pumps and Fire Water Pumps start up and operation with the aim of minimizing the normal
wear and tear or sudden failure of equipment or its components. Following are the objectives to
achieve;


Page 3 of 6
BSPM Power House

Tube Well Pumps
Pump Tube wells Capacity Pressure

Well Pump 1 350 m3/Hr (3.5 Cusec) 0.5 Bar (just filling Pond)
 These pumps are operating manually
 Ensure discharge valve of pump is open
 Ensure drain valve on discharge line is open
 Ensure water chest is ready for intake
 Ensure power supply is available for start up
 Start well pump
 After removal of air, close drain valve
 Maintain water level in water chest
 Normal Level >80%
 High Level > 90%
 Maintain number of pumps by foreseeing water consumption and water chest level

Page 4 of 6
BSPM Power House

Raw Water Pumps

Pump Mill water Capacity Pressure
Pump 1 (VFD) 630 m3/Hr 4.0 Bar
Pump 2 630 m3/Hr 4.0 Bar

 These pumps are operating from DCS and Local.
 Pressure is required to maintain with VFD Pump at 4.0 Bar
 Ensure suction valve of pump is open
 Ensure discharge valve of pump is open
 Water chest level should be normal
 Minimum flow line valve is open
 Ensure pneumatic discharge valve is ready to open
 Ensure raw water system network is ready
 Raw water pumps maintain discharge header pressure at 4.0 Bar
 Reduction in header pressure will start next pump
 Start 1st pump
 Start 2nd pump (This will be VSD Pump)
 If consumption is higher start 3rd pump also
 Select all the pumps on AUTO mode
 This will maintain header pressure with VSD

Page 5 of 6
BSPM Power House

Fire Water Pumps
Pump Firefighting Capacity Pressure

Jockey Pump 148 m3/Hr 5 – 6 Bar
Electric Pump 1 170 m3/Hr 10‐12 Bar
Electric Pump 2 170 m3/Hr 10‐12 Bar
Diesel Engine Pump 200 m3/Hr 10‐12 Bar

o Actual Tested Data of Fire Water Pumps
 These pumps are on manual operation
 Start of pumps will be done when is instructed by BSPL management or fire team

Page 6 of 6
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Dec, 2014
BSPL Power House
Equipment Run Time Procedure

Table of Contents
Objective ............................................................................................................................. 3
Procedure ............................................................................................................................ 3
Annexure 1 .......................................................................................................................... 4

Page 2 of 6
BSPL Power House

Objective
The objective of computing equipment run time is to use this tool to gather run time of individual
equipment’s. The run time data base will be used as a tool for effective maintenance.

This will help in developing the;
 Reducing Bottlenecks – Increase Throughput
 Implementing Machine Operator Training
 Reducing Machine Setup Time
 Improving Machine Reliability – Implement Preventive Maintenance
 Maximizing Optimal Run Rates and Capacity
 Eliminating Down Time

Procedure
 The Run Time work sheet (Annex 1) in soft form will be kept in Control Room Computer.
 Shift in‐charges shall be responsible to enter data after midnight for previous day.

Page 3 of 6
BSPL Power House

Annexure 1
Page 4 of 6
Equipment Run Time Data Sheet
Jan‐14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Total
Boiler Feed Water Pump A 0
Boiler Feed Water Pump B 0
Boiler Feed Water Pump C 0
FD Fan 0
ID Fan 0
RC Pump A 0
RC Pump B 0
Desuperheating Pump A 0
Desuperheating Pump B 0
ST Turning Gear 0
Vapor Extractor 0
Aux Oil Pump 0
Jacking Oil Pump 0
Condensate Pump A 0
Condensate Pump B 0
CW Pump A 0
CW Pump B 0
CW Pump C 0
CW Pump D 0
CW Booster Pump A 0
CW Booster Pump B 0
Utilities
Air Compressor 1 0
Air Compressor 2 0
Air Compressor 3 0
Air Compressor 4 0
Cooiling Water Pump A 0
Cooiling Water Pump B 0
Raw Water Pump 1 0
Raw Water Pump 2 0
Raw Water Pump 3 0
Raw Water Pump 4 0
Well Water Pump 1 0
Well Water Pump 2 0
Well Water Pump 3 0
Well Water Pump 4 0
Well Water Pump 5 0
65 TPH Boiler
FD Fan 1 0
FD Fan 2 0
Boiler Feed Water Pump A 0
Boiler Feed Water Pump B 0

Complete O&M Management System - Rev 10 Jan 02 2015

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25. Time K Overtime Procedure

Job Description and Minimum required qualification

Number: _____ Date: _________________

1. Equipment Description: 65 TPH Boiler Furnace and Pressure Parts___________________

Job Description: For out side work _________________

Area: ______65 TPH Boiler____________________________________________________________

Sr # Description KKS # Lock # Tagged Position

3. Isolation (Print name along with signature) Lock Box #: ____

Tags and Locks Hung by______________________ Date: ______ Time: ____

4. Verification: __________________________ Date: __________Time: _______

5. Shift Incharge Approval & Authorization: ___________Date: ___________Time: _____

6. Craft Acceptance Print name along With signature

TAGOUT Temporary Tag out Release

7. Completion (Print name along with signature)

Tags and Locks Removed by: _____________________Date: ________Time: ________

8. Equipment restored for operational use:

Tag List Continuation Sheet

Tag out Number: - Date: ________

Sr # Description KKS # Lock # Tagged Position

7 HFO Burner 1B A Isolation Valve Closed

11 Bur # 01 B Oil Guns (Install Dummy) Removed

12 Bur # 02 A Oil Guns (Install Dummy) Removed

23 Main gas valve on distribution header Close

Number: _____ Date: _________________

1. Equipment Description: 65 TPH Boiler Deaerator___________________________

Job Description: ________________ _________________

Area: ______65 TPH Boiler____________________________________________________________

Sr # Description KKS # Lock # Tagged Position

3. Isolation (Print name along with signature) Lock Box #: ____

Tags and Locks Hung by______________________ Date: ______ Time: ____

4. Verification: __________________________ Date: __________Time: _______

5. Shift Incharge Approval & Authorization: ___________Date: ___________Time: _____

6. Craft Acceptance Print name along With signature

TAGOUT Temporary Tag out Release

7. Completion (Print name along with signature)

Tags and Locks Removed by: _____________________Date: ________Time: ________

8. Equipment restored for operational use:

Tag List Continuation Sheet

Tag out Number: - Date: ________

Sr # Description KKS # Lock # Tagged Position

7 Condensate Return Isolation Valve Closed

10 Hydrazine Injection Pump Breaker OFF

11 Hydrazine Injection Valve Closed

Number: _____ Date: _________________

1. Equipment Description: 65 TPH Boiler Burner___________________________________

Job Description: For Gun Cleaning _________________

Area: ______65 TPH Boiler____________________________________________________________

Sr # Description KKS # Lock # Tagged Position

3. Isolation (Print name along with signature) Lock Box #: ____

Tags and Locks Hung by______________________ Date: ______ Time: ____

4. Verification: __________________________ Date: __________Time: _______

5. Shift Incharge Approval & Authorization: ___________Date: ___________Time: _____

6. Craft Acceptance Print name along With signature

TAGOUT Temporary Tag out Release

7. Completion (Print name along with signature)

Tags and Locks Removed by: _____________________Date: ________Time: ________

8. Equipment restored for operational use:

Number: _____ Date: _________________

1. Equipment Description: 65 TPH Boiler Soot Blower___________________________

Job Description: ________________ _________________

Area: ______65 TPH Boiler____________________________________________________________

Sr # Description KKS # Lock # Tagged Position

3. Isolation (Print name along with signature) Lock Box #: ____

Number: _ Date: _____________

Area: 65 TPH Boiler______________________________________________________

Tags and Locks Hung by________________ Date: Time:

4. Verification: __________________ Date: Time: _

5. Shift Incharge Approval & Authorization: _____Date: _Time: _

Tags and Locks Removed by: _____________Date: Time:

Number: _ Date: _____________

Job Description: _

Area: 65 TPH Boiler______________________________________________________

Tags and Locks Hung by________________ Date: Time:

4. Verification: __________________ Date: Time: _

5. Shift Incharge Approval & Authorization: _____Date: _Time: _

Tags and Locks Removed by: _____________Date: Time:

Number: _ Date: _____________

Area: 65 TPH Boiler______________________________________________________

Tags and Locks Hung by________________ Date: Time:

4. Verification: __________________ Date: Time: _

5. Shift Incharge Approval & Authorization: _____Date: _Time: _

Tags and Locks Removed by: _____________Date: Time:

Number: _ Date: _____________

Job Description: _

Area: 65 TPH Boiler______________________________________________________

Tags and Locks Hung by________________ Date: Time:

4. Verification: __________________ Date: Time: _

5. Shift Incharge Approval & Authorization: _____Date: _Time: _

Tags and Locks Removed by: _____________Date: Time:

Number: _ Date: _____________

1. Equipment Description: _Air and fuel System_____________________________

Area: 200 TPH Boiler______________________________________________________

Tags and Locks Hung by________________ Date: Time:

4. Verification: __________________ Date: Time: _

5. Shift Incharge Approval & Authorization: _____Date: _Time: _

Tags and Locks Removed by: _____________Date: Time:

Number: _ Date: _____________

1. Equipment Description: _Pressure Parts of 200 tph Boiler______________________

Area: _200 tph Boiler______________________________________________________________

Tags and Locks Hung by________________ Date: Time:

4. Verification: __________________ Date: Time: _

5. Shift Incharge Approval & Authorization: _____Date: _Time: _

Tags and Locks Removed by: _____________Date: Time:

Number: _ Date: _____________

Area: _200 TPH Boiler______________________________________________________________