WORK PROCEDURE REF : QMS/P/TPP/08

PAGE : 1 of 8
RINL VSP E.Issue No :1 Dt. 01/12/08
Rev.No: 0 Dt. 01/12/08
CHILLED WATER PRODUCTION

AMENDMENT RECORD
Sl No Amendment Brief description of Authorisation Date Rev.
Page No amendment No.
 WORK PROCEDURE REF : QMS/P/TPP/08
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RINL VSP E.Issue No :1 01/12/08
CHILLED WATER PRODUCTION
Rev. No :0 01/12/08

Rev.
1.0 CROSS REFERENCE : QMS/M/27.46.08

2.0 PURPOSE AND SCOPE :

To produce chilled water in chilled water plant-I & II

of Thermal Power Plant.

3.0 RESPONSIBILITY :

1. Shift in charge -DM Plant & CWP-I

2. Shift technician-DM Plant & CWP-I
3. Shift in charge - DM Plant & CWP-2
4. Shift technician-DM Plant & CWP-2

4.0 DOCUMENTS REFERRED :

Chilled water plant-I manual of M/s HITACHI Ltd.

Chilled water plant-II manual of M/s Blue Star Limited.

5.0 PROCEDURE :

Clause no. 5.1 deals with chilled water plant-I chilled

water production and steps in clause no. 5.2 deals with
Chilled water plant-II chilled water production.

5.1 Chilled water plant-I

5.1.1 Steam pressure is checked to be between 1.3 kg/sqcm and

1.6 kg/sqcm, Pressure reducing and de-superheating
station (PRDS) 3A is kept on "AUTO" at 1.3 kg/sqcm
set point i.e. 0.2 kg/sqcm below the exhaust pressure
of running back pressure turbines.

5.1.2 Desuperheater-1 is checked to be in "auto" and tempe-

rature of steam after desuperheater is below 140 deg C.

5.1.3 Cooling water pressure is checked to be above 2.5 kg/

sqcm. Additional pump is started by pump house 13 opera-
tor if pressure is less.

5.1.4 The cooling water flow is regulated by opening the inlet

and outlet valves and a differential pressure around
0.6 to 1 kg/sqcm is maintained.
 WORK PROCEDURE REF : QMS/P/TPP/08
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RINL VSP E.Issue No :1 01/12/08
CHILLED WATER PRODUCTION
Rev. No :0 01/12/08

Rev.
5.1.5 For every 2 running chillers one warm water circulation
pump is required. Circulation pump is started as per
the following:-

a. Suction valve of chilled water circulation pump is

opened.

b. Warm water and chilled water tank levels are checked

to be full.

c. Local emergency push button is in released condition.

d. Pump is started from local and delivery valve is opened

Full electrically.

e. The water flow is regulated by opening the inlet and

outlet valves and differential pressure is maintained
in between 0.8 to 1 kg/sqcm.

5.1.6 The drain is opened on condensate line and condensate

From chiller is drained out.

5.1.7 Chiller vacuum is seen to be less than 15 mmHg and the

vacuum pump is run as per requirement to achieve the
Vacuum.

5.1.8 Manual steam shutoff valve on steam inlet line to

Chiller is opened. All the toggle switches on chiller
panel are kept at "UP" position and chiller is started
by pressing "START" push button.

5.1.9 Both solution pumps and refrigerant pump are started.

The drain on condensate line is closed when hot water
Starts coming out.

5.1.10 The solution level is maintained around 40 mm by regu-

lating steam flow through auto/manual drain control
Valve.

5.1.11 The parameters of chilled water plant-1 are recorded in

chilled water plant-I shift operator log book
(QMS/R/TPP/59).

5.1.12 Chilled water supply pump is started as per the follow-

ing.
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RINL VSP E.Issue No :1 01/12/08
CHILLED WATER PRODUCTION
Rev. No :0 01/12/08

Rev.
a. Coal chemical plant is informed about starting of
Chilled water supply pump.

b. Power supply of pump is normalized electrically.

c. Suction valve is opened fully.

d. Pump is started by pressing "START" push button.

e. Delivery valve is opened slowly.

f. Pump current is checked to be below 19A at local

Ammeter.

5.1.13 Warm water and chilled water tanks are maintained at

70% TO 90% full level. When the level is goes down,
Demineralised water plant(DM Plant) is contacted to
start soft water make up pump and make up water valve
Is opened near warm water tank. After normal level
Is achieved, DM plant is asked to stop the pump.

5.1.14 Return water pump is run to pump back the condensate to

DM Plant.

5.2 Chilled water plant-II

5.2.1 Flow diagram of chilled water plant at page 8 of 8 of

this procedure.

5.2.2 Steam manual isolation valve after pressure reducing

and desuperheating station (PRDS) and electrically
operated isolation valve before PRDS are kept in open
condition.

5.2.3 All drain valves in main steam header are kept in open
Position.

5.2.4 PRDS valve is opened gradually from control room using

Manual mode. Steam pressure is raised and attained the
set value of 0.8 to 1.0 Kg/sqcm.

5.2.5 Steam temperature is maintained at 120 to 130 deg.

C through PRDS temperature control valve by running
PRDS pump.
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RINL VSP E.Issue No :1 01/12/08
CHILLED WATER PRODUCTION
Rev. No :0 01/12/08

Rev.

5.2.6 Before starting the chiller, the following valves of

Chillers are kept in open position.

a) Warm water inlet valve and warm water outlet valve.

b) Cooling water inlet valve and cooling water outlet

Valve.
c) Condensate return valve.

d) Steam inlet manual valve in chiller.

5.2.7 Cooling water pump is kept in service and cooling water

is allowed to pass through the chiller. Cooling water
pressure is maintained at 3.0-3.5 Kg/sqcm at inlet and
2.0 - 2.5 Kg/sqcm at outlet line as indicated near the
Individual chiller.

5.2.8 Recirculation pump is started and warm water is circu-

lated through the chiller. Warm water pressure is mai-
ntained at 2.0-2.5 Kg/sqcm at inlet and 1.0-1.5 Kg/sqcm
at outlet line as indicated near the individual chiller

5.2.9 Vacuum pump in chiller is started and kept in service

in each shift for about 1 - 2 hours to maintain the
vacuum of 6 - 8 mm Hg as shown in manometer near the
Chiller, inside the system. Oil level in vacuum pump
is checked and fresh oil is charged when color of
Existing oil turns white from brown.

5.2.10 Indication lights for cooling water supply and warm

water supply to chiller are checked in local control
panel.

5.2.11 Chiller is started by putting ON/OFF switch to `ON'

Position. Auto switch inside local control panel is
put in `ON' position and entire operation inside the
Chiller is brought in auto functioning.

5.2.12 PRDS valve, operation is kept in auto mode in main

control panel inside control room.

5.2.13 Temperature of chilled water coming out from chiller

is noted down from temperature indicator located above
Local control panel. Supply temperature of chilled
Water to different consumers is 7 to 9.5 deg. C.
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RINL VSP E.Issue No :1 01/12/08
CHILLED WATER PRODUCTION
Rev. No :0 01/12/08

Rev.

Temperature difference is observed to note the

Performance of the chiller. If T is less than 5 deg.C
(normal 5 to 8 deg.C) the following is checked for any
Abnormality.

a) Cooling water inlet temperature is kept below 34

deg.C. If the temperature is above 34 deg.C pump
house 4 is asked to keep maximum no. of exhaust
Fans in service.

b) The vacuum inside absorber, evaporator is checked.

If vacuum is insufficient > 6mm Hg, vacuum pump is
run till the required vacuum is attained.

c) The proper functioning of steam control valve is

checked so that required quantity of steam is
Supplied to chiller.

5.2.14 The following readings are noted down in chilled water

Plant log sheet (QMS/R/TPP/13) every four hours.

a) Cooling water inlet temperature and cooling water

Outlet temperature in absorber.

b) Chilled water inlet temperature and chilled water

Outlet temperature.

c) Cooling water inlet temperature and cooling water

Outlet temperature in condenser.

d) Vacuum inside evaporator, absorber.

5.2.15 Warm water storage tank level, temperature and pressure

before and after PRDS are noted down in chilled water
Plant log sheet (QMS/R/TPP/13) every four hours.

5.2.16 Warm water storage tank level is maintained at 60-90%

When level goes down, demineralised plant is contacted
to start make up water pump and soft water is added
Till level is attained to 60-90% in control room panel.
 WORK PROCEDURE REF : QMS/P/TPP/08
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RINL VSP E.Issue No :1 01/12/08
CHILLED WATER PRODUCTION
Rev. No :0 01/12/08

Rev.
5.2.17 Condensate pump is started when level in condensate
storage tank is 60-80% in control room panel and con-
densate water is pumped to demineralised plant till
level reaches 30% as indicated in control panel.

5.2.18 Dewatering pumps in trenches are kept in service to

drain out the water in trenches.

6.0 RECORDS :

1. Chilled water plant - I Shift operators log book

-QMS/R/TPP/59.

2. Chilled water plant - II Shift operators log book

- QMS/R/TPP/13.
 WORK PROCEDURE REF : QMS/P/TPP/08
PAGE : 8 of 8
RINL VSP E.Issue No :1 01/12/08
CHILLED WATER PRODUCTION
Rev. No :0 01/12/08

Rev.