Station: NTPC - Simhadri Plant Area: BOILER

BHEL Ref No. PS - DC - 186 - 500 0034 D NTPC Ref No. SIM / 1 / CS / 1 / 34 D

Sheet 1 of 11

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

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.

PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PRECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES a) DRAWINGS b) LOG SHEET

Signatures NTPC BHEL

Station: NTPC - Simhadri Plant Area: BOILER

BHEL Ref No. PS - DC - 186 - 500 0034 D NTPC Ref No. SIM / 1 / CS / 1 / 34 D

Sheet 2 of 11

Procedure for: COMMISSIONING OF LP DOSING SYSTEM OF BOILER SL. NO. 1.0 PLANT DETAILS The LP Dosing System consists of the following: 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1 No. Mixing Tank with Agitator 1 No. Metering Tank 2 Nos. Pump with Motor (Positive Displacement pump) ( With stroke adjustment ) 2 Nos. Suction Filters 2 Nos. Relief Valve Inlet DM Water connection to Mixing and Metering Tank Level Gauges for Mixing and Metering Tank Local Instrumentation Plant Item Completion List for Mechanical, Electrical and C&I are to be prepared at site. 1.9 The Schematic of LP Dosing System is enclosed in Subsection 10.0 (Drawing No. 4: PS : TSX : 0066:00 Dt. 23.07.2001 STATUS

Signatures NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS - DC - 186 - 500 0034D NTPC Ref No. SIM / 1 /CS / 1 / 34 D

Sheet 3 of 11

Plant Area: BOILER Procedure for: COMMISSIONING OF LP DOSING SYSTEM OF BOILER SL. NO. 2.0 2.1 OBJECTIVES To commission LP dosing system and make it available for unit operation. STATUS

3.0 3.1

PROPOSAL The Commissioning ofLP Dosing System is carried out as follows: a) Flushing of Mixing, Metering Tanks and upto Pump Station with DM Water. b) Pump trial run, Relief Valve setting and C&I System . c) To commission the remote stroke adjustment system

Signatures NTPC BHEL

Station: NTPC Simhadri

BHEL Ref No. PS - DC - 186 - 500 0034 D NTPC Ref No. SIM / 1 / CS / 1 / 34 D

Sheet 4 of 11

Plant Area: BOILER Procedure for: COMMISSIONING OF LP DOSING SYSTEM OF BOILER SL. NO. 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 SERVICES REQUIRED Availability of manpower with required tools for attending to any leak, cleaning of filters. Availability of operating personal to co-ordinate the activities. Availability of lighting arrangement in and around the LP Dosing System. Availability of portable fire fighting equipment near the dosing system. Availability of sufficient quantity of DM Water. Availability of LT Power Supply. Availability of Chemicals. STATUS

Signatures NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS - DC - 186 - 500 0034 D NTPC Ref No. SIM / 1 / CS / 1 / 34 D

Sheet 5 of 11

Plant Area: BOILER Procedure for: COMMISSIONING OF LP DOSING SYSTEM OF BOILER SL. NO. 5.0 5.1 5.2 5.3 SAFETY PRECAUTIONS Goggles, Apron, Hand-gloves for handling chemicals. Bunding & draining arrangements are properly done to take care of spillages. First aid kid is available at test area. STATUS

6.0 6.1

EMERGENCY PROCEDURE The operating staff should know about the normal operating procedure to be adopted in case of damage to machinery or injury to any person connected in the activity. The test team should be well aware of procedures to be adopted in case of any abnormality in the activity.

6.2

Signatures NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS - DC - 186 - 500 0034 D NTPC Ref No. SIM / 1 / CS / 1 / 34 D

Sheet 6 of 11

Plant Area: BOILER Procedure for: COMMISSIONING OF LP DOSING SYSTEM OF BOILER SL. NO. 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 STATE OF THE PLANT LP Dosing Systems are erected as per recommended drawing. Mixing and Metering Tanks are cleaned with DM Water and filled upto normal operating level. LT power supply system for Pumps, are commissioned and available for operation. Required Local/Remote I&C Inputs are made available. DM Water connections to Mixing Tank, metering tank and to lines (for flushing) are ready. Lubricating oil is filled in the pump gear box up to its normal level / Indication. Suction filters are cleaned. Tank Drains and Pump Relief Valves are terminated as per scheme. STATUS

7.9 7.10

The test area is cleaned and proper approaches are available. LP dosing system are erected with proper bunding and draining facility to contain any spillage.

Signatures NTPC BHEL

Station: NTPC - Simhadri Plant Area: BOILER

BHEL Ref No. PS - DC - 186 - 500 34D NTPC Ref No. SIM / 1 / CS / 1 / 34D

Sheet 7 of 11

Procedure for: COMMISSIONING OF LP DOSING SYSTEM OF BOILER SL. NO. 8.0 8.1 METHOD FLUSHING OPERATION The Mixing & Metering Tanks along with suction pipe upto pump to be flushed with DM Water so as to avoid the entry of dust into the pump. STATUS

8.2

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

8.3 8.4 8.5

PROCESS Fill the Mixing and Metering Tank with DM Water. Open the pump suction valve and flush the system until clear water noticed in the temporary hose.

Signatures NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS - DC - 186 - 500 0034 D NTPC Ref No. SIM / 1 / CS / 1 / 34 D

Sheet 8 of 11

Plant Area: BOILER Procedure for: COMMISSIONING OF LP DOSING SYSTEM OF BOILER SL. NO. 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 Normalise the suction connection to pump. Bump the motor (in decoupled condition) and check the direction of rotation. Trial run the motor for 2 hours and couple with the pump. Fill the Mixing and Metering Tank upto normal level. Open the Pumps Suction, Discharge and Recirculation valve. Close the valve in the line going to boiler. Ensure the suction & discharge gauges are installed and the respective valve cocks are opened. Keep pump stroke to minimum and start the pump and observe discharge pressure. Increase the pump stroke gradually to 100% and observe pump performance. Trial run the pump for 4 hours and maintain the tank level keeping the pump stroke around 50%. Commission the remote stroke adjustment system (if provided) and operate and observe its performance. STATUS

8.16

Signatures NTPC BHEL

Station: NTPC - Simhadri

BHEL Ref No. PS - DC - 186 - 500 0034 D NTPC Ref No. SIM / 1 / CS / 1 / 34 D

Sheet 9 of 11

Plant Area: BOILER Procedure for: COMMISSIONING OF LP DOSING SYSTEM OF BOILER SL. NO. 8.17 Set the relief valve by throttling the R/C Valve. (The set pressure to be around 10 KSC more than the working pressure of the system) Stop the pump. Ensure the Agitator is coupled with motor. Bump the Agitator and check the direction of rotation. Trial run the Agitator for 2 Hours. STATUS

8.18 8.19 8.20 8.21

9.0

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

Signatures NTPC BHEL

SHEET 11 OF 11 LOG SHEET

Date:
PROJECT : UNIT : ACTIVITY:

Sl. No.

Date / Time

Pump in service

Discharge Pressure Kg/cm2

Mixing/Meterin g Tank Level in Mn.

Gear Box Oil

Remark

Signatures NTPC BHEL

PROCEDURE FOR COMMISSIONING OF LP DOSING SYSTEM OF BOILER (Commissioning Schedule )