Ims Section Manual Unit-6

CHANDRAPUR SUPER THERMAL POWER
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M.S.P.G.C.L., CHANDRAPUR Doc. No : OPN/SM
ISS/REV. NO.: 01/00
Operation Section Manual U#6 ISS/REV.DT:01.02.2017/00
INTEGRATED MANAGEMENT SYSYTEM
ISO 9001:2015 QMS, ISO 14001:2015EMS & OHSAS

18001:2007
Prepared By Reviewed & Approved by

IG Group Member Section In Charge (OPN)
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SECTION MANUAL: OPERATION UNIT # 62. Index

Sr. No. Title Page No
1.
Cover page
2.
Index
3.
Release Authorization
4.
Amendment Sheet
5.
Purpose
6.
IMS Objectives
7.
List of Reports to be submitted
8.
List of activities carried out by the section
9.
Work Instructions/Standard Operating Procedures
10.
Checklists
11.
Safety Instructions
12.
Significant Aspect & Controls Measures
13.
Significant Hazards & Control Measures
14.
Contextual Issues- Risk: Control Measures/Opportunities
15.
Improvement Projects Carried out, in progress and Planned
16.
List of log books at various location in unit-6
17.
List of manuals
18.
List of Files / Registers

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3. RELEASE AUTHORISATION
This Sectional Manual is released under the authority of the Sectional Incharge,
Operation Unit 6, CSTPS, Chandrapur and is a property of CSTPS, Chandrapur.
Signature :
Name : SHRIKANT . DAFADE
Designation : Executive Engineer

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4. Revision /Amendments Record
Amend- Revision Number

Sectio Pag Reason for Amen- Approved
ment
n No e No Old No Date New No Date Change ded by by
No

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5. Purpose
Purpose :
There is a common Shift Incharge Engineer. For Generation of Electricity Coal, Oil &
Water is required. Coal Stocks are maintained by CHP Staff. The Coal Handling Plant Supplies
Crushed Coal of size to the Coal Bunkers. The Bunker supplies coal to the Coal Feeder
which in turn supplies a regulated Supply of Coal to Pulveriser. After pulverization the Coal is
fed to the Boiler by means of Air Flow supplied by the P.A. Fan. Boiler is filled with Treated
Water Supplied by the WT Plant. Coal Burns producing heat, which is taken up by the Water ,
which is converted to steam. Steam is supplied to the Turbine, which rotates along with the
Generator Producing Electricity. Coal after burning leaves behind Ash in which the heat of the
furnace gets partly converted to molten slag which falls in the Bottom Ash Hopper and the rest
remains in the form of fly Ash which is separated from the flue Gas by the ESP.
The Temperature and Pressure of the steam is monitored by the PCR staff. The Chemical
Quality of Steam, Water, Coal and Oil is Monitored by the WT Plants.
Shift-Charge Engineers give OLC to LD Nagpur as per the coal quality and mill and plant
availability. LD Nagpur gives us load schedule hour wise every day. PCR staff tries to maintain
the load schedule. If Any Abnormality is observed in the plant and set is required to be
withdrawn it is informed to LD prior to withdrawal of set. Planned outages are taken with
permission from Director (Operation) Mumbai.
If any abnormality is observed in the plant/ Process shift-Charge Engineer tries to solve the
problem in his capacity. if it is beyond his capacity he approaches higher authority S.E.(O)-II,
DyCE-II & C.E. PCR and the local staff tries to maintain the parameters as per the
manufacturers recommendation.
Regarding housekeeping yearly cleaning contract is operated by O.S.-II section. Cleaning
is checked by Operation staff and certified by the respective area INCHARGE.
Defects of auxiliaries/ plant are raised by Shift Charge Engineer/ PCR Incharge/Asst. Plant
Incharge through computer to respective section. The defects are classified as Urgent,
Emergency, Short shut down, Overhaul, depending upon severity & isolation of the equipment.
The Maintenance staff takes permit from PCR and does the work. After cancellation of permit
& trial of equipment defect is eliminated from the computer list.

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All Operation staff attendance is marked by time Office. If somebody applies leave
timekeeper gives note to a person who is in spare shift. Leave Account, night shift Account, OT
register, attendance registers are maintained by time keeper.
Various training programs are arranged by the Chandrapur Training Center. Training
department maintains register in which names of candidates, which type of training given is
noted. Accordingly S.E.(O)-II sends names of employees to training department as per the
availability of staff.
OPERATION : Unit 6
a) SHIFT INCHARGE: - Shift In charge is assisted by P.C.R. In charge and

Assistant Plant In charge and desk operators. All the operations in P.C.R. and
Plant are carried out as directed and sometimes under intimation to shift in
charge
b) P.C.R. / UNIT INCHARGE: - is to get started the auxiliaries and systems and
track the sequential operation of Boiler and its auxiliaries, turbine and its
auxiliaries coupled with Generator and allied system. While synchronizing the
unit with Grid, withdrawing from grid and during normal operation with the help
of his assisting personnel for control desk operation, maintaining parameters
within safe specified limits and co-coordinating with L.D. Center and local
sections and their staff raising defect card for abnormality if any.
c) ASSISTANT PLANT INCHARGE:-Coordinates with local and PCR staff.

Raises defect cards for the observed or reported auxiliaries and system.
Isolation as per unit incharge direction. He also supervises the plant, by taking
rounds, informs abnormality to P.C.R. Staff for corrective action. All outdoor
local staff is under control of Assistant Plant In charge.
d) BOILER DESK INCHARGE: - is to start/stop and maintain draft cycle, coal

cycles, and their lubrication systems, cutting in and out oil Guns, when needed.
Monitoring the parameters of Induced Draft. Forced. Draft. Primary Air Fans, Air
Heaters, Furnace.Oil / Light Diesel Oil Pumps, scanner air fans Seal Air Fans,
coal mills, RCF's Flame scanners and allied system as per load demand. He
maintains Main Steam, Reheat Steam Temperature, Adjusts M.S. & R.H Spray,
Burner tilt.

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e) TURBINE-GENERATOR DESK INCHARGE: - He monitors L.P. Heaters,

Condensate and Feed Water Process, increases and decreases loads in Co-
ordination with Boiler desk Incharge. He shares load as required by Load
Dispatch / OLC. He monitors maintains pressures of Gland sealing, turbine
bearing, M.S. Pressure, vacuum pump, Load on the Unit. He records
Parameters turbovisory Bearing Vibrations, Shaft Vibrations, Generator Current
Voltages, and Conveys and receives Messages. Prepares reports for the day of
Generation, Auxiliary consumption of electricity, oil, water and Coal. Primary
water temperature and flow, seal oil temp ,Hydrogen Temp ,PRDS Pressure
and temp are also monitored
f) DRUM LEVEL DESK INCHARGE: - is to monitor start/stop of MD BFP

/TDBFP & its associated auxilliaries per the plant requirements. He also
monitor drum level ,EBD,CBD control & H.P. Heaters.
2) FIRING FLOOR OPERATOR DUTIES ARE :-.. He monitors

i) Feeding Coal to Coal mill.
ii) Firing of Oil and Coal to maintain proper flame.
iii) Soot Blowing inside the Boiler
iv) Primary & secondary Air Heaters.& its auxiliaries
v) Supply of Aux. PRDS to other points
Firing floor is manned by An Artisan and technicians
FIRING FLOOR INCHARGE: - His duty is :

a) To supervise combustion of fuel to evaporate water into steam for
turbine.
b) Takes round of boiler to observe normalcy, if any abnormality is
observed, he informs P.C. R. /Shift In charge.
c) He checks B/A Hopper status through the 9-meter peepholes.
d) Monitors flame condition, SADC .
e) Operate all manual valves as per instructions.
f) Keeps all oil guns clean.
g) Monitors Water Wall and A/H Soot Blower Operation and A.H. Drive and
LubOil system.
h) Coal Mill dampers and RCF are also supervised by him.

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i) PRDS Valve Operation.

j) All mechanical isolation and electrical isolation of Boiler MCC, Boiler
Valve & Damper MCC and SOOT Blower MCC is Done by Firing Floor
Artisan as directed from P.C.R.
k) All mechanical isolation of Boiler Valve & Damper and SOOT Blower is
done by Firing Floor Artisan as directed from P.C.R.. All electrical
isolation is done by firing floor in charge & Boiler API.
3) BOILER BASEMENT INCHARGE DUTIES ARE:-
a) To monitor Air to Boiler and Evacuate Flue Gases.
b) To monitor coal air Mixture for combustion in boiler
c) To supervise Coal Mills, Primary Air Fans along with their lubrication system, Coal
mill Reject & Seal Air Fan
d) Junior Engineer is assisted by technician in every shift who supervises Coal mills,
Primary Air Fans. This system supplies coal air mixture to boiler for combustion.
e) To monitor Force Draft Fan which supplies air for combustion.
f) Reject Belt Operator: Reject Belt Carries Coal Mill Reject to Hoist
Hopper situated at U#5 &further transportation to reject Yard
g) To monitor Bottom Ash Hopper Evacuation with required preconditioned HP,LP,Seal

water pressure & over flow of Bottom Ash Hopper.
h) To monitor Furnace peep hole at 9 mtr level at regular interval.
. 4) ESP CONTROL ROOM-:

ESP Control room is manned by Sub Engineer who :
Supervises I.D. Fan which evacuates flue Gases and maintains draft infurnace. & ESP
Reduces stack emission i.e. SPM level ,& Ash handling plant & Oil Handling plant.
Sub Engineer is assisted by :
An Technician II & III in every shift who supervises :
ID FANS, Flue gas hopper Evacuation , ERM,CRM Operation & ESP field s Parameters,

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An every shift, fly ash hopper evacuation done by technician with co-operation of contracts
labours to maintain healthiness of fields & minimum chimney emission.
5) ASH HANDLING PLANT-:

In AHP , Technician II &III who supervises .
In AHP , Bottom Ash , coarse Ash Evacuated through discharge ash pipe line & fly ash
evacuated through trench by using raw water HP Pump. & slurry collected in sump & slurry
discharged to ash bund by using ash series pumps.
Monitoring for Continuous running of LP ash water pump which is used for seal trough filling
& bottom ash hopper filling & Raw water tank level maintain with coordination of raw water
pump house , ETP - I, Ash bund Recovery pump. And also monitors pump pressure , temp.,
current, Pump sealing & maintaining its scoop
6) OIL HANDLING AND UNLOADING PUMP HOUSE: -

UNLOADING PUMP HOUSE
F.O. /L.D.O. tankers are unloaded and oil is transported to oil storage tanks, in OHP.
OIL HANDLING PLANT - The Pressurizing pumps supplies LDO, FO oil as per
requirement to boiler with requisite Pressure and temperature.
One Technician from AHP supervises the operation and maintain the
Pressure and temperature as directed by Shift In charge, Boiler Desk/
P.C. R. In charge /B-API
He works under the control of ESP In charge Sub Engineer.
7) THE TURBINE BASEMENT :

Turbine House is equipped with :
a. Turbine Generator for generation of electricity.
b. Condensate Extraction Pump for evacuating condensate from condenser and
supplying it to Deareator through L.P. Heaters.
c. Boiler Feed Pumps for supplying Feed Water to H.P. Heaters and Boiler.
d. Lub Oil Pumps for supplying lubricating oil and seal oil to turbine and generator

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e. Supply of instrument and Service air to whole Unit.

f. Supply of A.C. And D.C power to all transformers, Boards, Auxiliaries, controls
and instruments,
g. At compressor room , main DG & Stand By DG set available
Section is manned by Sub Engineer he is assisted by
a) Technician -2 at BFP& CEP,
b) Technician-3 & Art.-D at Seal Oil ,Vaccum pump and Stator Water
Pump.& all transformers i.e. GTR , ST-4, All UATS, all dry type
transformers (06 nos) & SAT(2 nos)
c) Technician -I at Compressor House
d) Technician -III for MOT& TDBFP oil Centrifuge & FRF System
e) Helper for Isolations and messages.
For above sub-section is manned by An Tech- II& ,III ,and Art-.D. All
electrical / mechanical isolation is done by Technician
8) TURBINE FLOOR-:
Technician-III works under the control of Turbine API.He monitors , TDBFP
A&B , main turbine lub oil system,main TG Governing Rack filters,Primary
water tank level, At 8.5 mtr,HPBP oil tank level.AtDeareatorlevel,all types of
feed/extraction/drip v/v operation as & when required, AWM monitoring
9) C.C.W. AND A.C.W. PUMP HOUSE-

It supplies cooling water to condenser and thereafter to cooling tower for cooling of
water.
It Supplies Aux. cooling Water for seal oil, FRF System, stator water, H2 coolers and bearing
cooling water to pumps and fans, Jacket cooling of instrument, service air and A.C.
Compressors, return water is re-circulated to ACW./ CCW. Pump Suction sump.
C.T. Fans on Cooling Towers are controlled from this section only.
Section is manned by Sub engineer,Technician-II & III staff supervises the Auxiliaries and
operation of the system as per the instructions of PCR.
10) RAW WATERINTAKE :

It supplies raw water From Erai dam by Gravity to STG-III Reservoir & level is being
monitored by raw water pump house inchargeof Stg.III. Intake V/V Operation at Erai dam is

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under control of PCR # 3.
11)AIR CONDITIONING PLANT:

This Plant maintains the temperature of PCR ,Relay room , DAS room for proper working of
instruments, controls and computers.
It is being monitored & maintained by the contractor which is under control of Turbine
Maintenance . They monitors Compressors, blowers, chilled water pumps and coil fan unit.
12) RAW WATER PUMP HOUSE (500MW):

Raw Water pump house supplies water to A.H.P(U-5,6,7& 8,9), W.T.P( 500MW) &
FIRE fighting pump(Stg-III).
Technician (02 nos) are posted for Operation of pumps as per requirement of sections and
monitors ODR level and report it to PCR -3 to open /closed the intake V/VS at Erai Dam.
13)FIRE FIGHTING PUMP HOUSE: -

This Pump House comes under Raw water pump house which supplies Water to
Emulsifying and Hydrant system of fire Fighting ( Stg-III) the plant.
Technician looks after the operation of the pumps as per the header Pressure of the system
requirement.Total FIRE Fighting pumps are 07 nos - 03 are electrical & 04 are diesel . And
also monitors the Diesel level of F/F Pumps & accordingly inform to PCR
14) TIME OFFICE:-

Time Office
a) Maintains Attendance of all operation staff.
b) Maintains Leave records.
c) Sends Attendance statement to Administrative office.
d) Keeps Records of Overtime.
e) Sending notes for staff arrangement against leaves and for overtime.
Section is headed by Head timekeeper assisted by a timekeeper and a messenger in every
shift.
Ambulance is available for 24 hrs at time office of Stg. I & II( under the control of
U#4)for any casualties during any shift to move the patient to hospital in the colony.

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6.IMS Objectives
1) To maximize Generation > 3543 MUs
2) To achieve Plant Load Factor > 80.90 %
3) To maintain Unit Heat Rate Average < 2663 Kcal/KWH
4) To reduce Specific Oil Consumption < 1.00 ml/KWh
5) To reduce Aux. Power Consumption < 7.95 %
6) To reduce Force Outage Factor < 3 %
7) To reduce Total No. of Tripping due to BTL < 2
8) To reduce specific DM water consumption < 105 ml/KWh
9) To reduce specific Soften water consumption < 2700 ml/KWh
10) To enhance reporting of near miss/incident < 8 nos
11) To comply 100 % Usage of PPEs .
12) To reduce Safety Related Deficiencies to 100 %

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7. List of Reports to be submitted
Frequency of
Tittle of the Report to be Submission Reference
Remarks (If Any)
SN Report To be submitted to Quarterly/ (Document/Re
(Responsibility )
submitted Whom Monthly/ Weekly/ cord)
Daily
User222/POG/
ORTData File/ ORT_month/Input
Monthly
1 ORT DATA POG Aux. trial format
( In first week)
register (T/G Desk / PCR
I/C)
Daily plant
Daily DPPR File
2 performance POG PCR I/C
(In night shift) (FF6341)
report
Hourly
Generation &
T/G Desk /
loss Report & Daily DPPR File
3 POG Blr.Desk
Non (In night shift) (FF 6342)
Engineer
availability of
Coal mills
Parameters to
be Monitored Daily Boiler desk
4 POG DPPR File
at Corporate (In night shift) Engineer
Level
Generating
DATA / Partial
DATA ENTRY Daily
5 loss , Tripping SAP DPPR T/G Desk Engineer
IN SAP (In every shift )
details & C/M
outage details

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DATA ENTRY
Morning Daily
6 IN SAP SAP DPPR PCR I/C
Report (In Night shift )
8.List of activities carried out in section& its monitoring
A)
Reference Documented Monitoring Remarks

Information & Review (Output)
Activities & its
SN Frequency (SOP/WI/Record-Files ,
Resources
Registers, Log books,
Checklist, SAP)
Activity -: Boiler start BHELs Operation Manual/ Performanc Combusti
up W/I OSTIII/1301 TO e Review in on
Resources-: Water , Whenever
1305 ,1307 TO Daily process
LDO/LVFO/Coal/ required , at
1 manpower/ DAS/ 1312,1314, 1322,1324 Meeting, In inside
initial stage
Aux. steam/ Air TO 1328, 1332,1334 , OCM, & Furnace
only
1352,1353, Unit cold start ORT
up report, meeting
2 Activity-: Coal Daily BHELs Operation Manual Bunker coal Pulverize
analysis
pulverization And W/I d coal
report ,
conveying OSTIII/1301,1327,1328,13 Coal supply to
Resources-: Water/ 61 fineness furnace
coal / man power/ report, lub
DAS / Aux. steam / oil sample for
Aux. power report combusti
.Performan
on
ce Review
in Daily
Meeting,

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OCM, &
ORT
meeting
Daily BHELs Operation Manual Flue gas Generatio

analysis n of Heat
W/I OSTIII/1310 TO
report, air
Activity-: 1312,1322,1326 TO heater
Combustion of 1329,1332,1348,1350, performanc
1353, e report ,
Fuel/Air Mixture
furnace
Resources-:
temp.
3 water/coal/ mapping.
LDO/LVFO Performanc
e Review in
/manpower /DAS/
Daily
Aux. steam /Air/Aux. Meeting, .
power OCM, &
ORT
meeting
Activity-: Boiling of Daily BHELs Operation Manual steam Generatio

water & heating of parameters n of
W/I OSTIII/1301 TO
steam 1303,1332,1334,1347 TO Performanc steam
Resources-: 1350,1352,1353, e Review in with
4 water/coal/ Daily
controlled
LDO/LVFO Meeting,
/manpower /DAS/ OCM, & temperatu
Aux. steam /Air/Aux. ORT re
power meeting
Activity-: Ash Daily Performanc Generatio

evacuation e Review in n of Ash
Daily
Resources-: slurry
Meeting ,
Water /
OCM, &
manpower /DAS/ Air/ BHELs Operation Manual ORT
Aux.power
W/I meeting .
5
OSTIII/1301,1311,1312,13 Daily plant
14 TO 1325, performanc
e report,
flue gas
sample
report. &air
heater

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performanc
e report
Activity-: Soot Once in a Performanc Efficient

blowing Shift e Review in Heat
Daily
Resources-: transfer
Meeting ,
manpower /DAS/ Air/
OCM, &
Aux.power/ Aux.
ORT
steam
meeting
Furnace
BHELs Operation Manual temp.
6
W/I OSTIII/1348 mapping.
Air Heater
performanc
e sheet on
DAS , Air
heater
performanc
e report.
Activity-: Turbine Whenever Performanc Ready for

/Generator startup required , at BHELs Operation Manual e Review in rolling
initial stage W/I OSTIII/1329 TO Daily
Resources-:
7 only 1331,1333 TO 1341,1301 Meeting,
manpower /DAS/ Air/
OCM, &
Aux.power/ TO 1303,1313 TO
ORT
steam/Hydrogen 1314,1342 TO1347. meeting
gas/ Nitrogen gas
Activity-: Turbine Whenever Performanc Generatio
/Generator rolling & required , at e Review in n of
synchronizing. initial stage Daily
Electricity
only Meeting,
Resources-:
OCM, &
manpower /DAS/ Air/
BHELs Operation Manual ORT
Aux.power/
8 W/I OSTIII/1301,1351 meeting
steam/Hydrogen
Unit cold
gas/ Nitrogen gas To1353
startup
report
various
criteria on
DAS
Activity-: Monitoring Daily on Operation parameter Performanc Controllin

9 of Process continuous guideline manual , e Review in g
parameter basis Daily
various log books of

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Resources-: Meeting,
TG /DESK , BLR./DESK,
Manpower , DAS , OCM, &
DRUM LEVEL DESK, ORT
LAN
PCR /SHIFT I/C LOG BOOK meeting
Activity-:Defect card Daily Performanc Correctiv

Generation Defect card in SAP , e Review in e Action
Turbine & Boiler API Log Daily
Resources-:
10 book. Also during unit Meeting,
Man power , DAS ,
OCM, &
LAN Shut Down, Permit entry
ORT
register is maintain. meeting
Activity-:Data Daily W/I OST-III/1360, Performanc Controllin

analysis & recording Performance test , daily e Review in g
plant performance Daily Meeti
Resources-:
OCM, &
Man power , DAS , report , flue gas sample
ORT
LAN reports , Event analysis meeting ng,
report , bunker coal
11
analysis report, coal
fineness report , Lub oil
sample reports , monthly
performance report ,
furnace temp. mapping
report.
Activity-: Nodal load Daily Performanc Correctiv
dispatch e Review in e Action
Load Schedule, Daily
Daily
Resources-: plant performance
12 Meeting,
Man power , DAS ,
report , hourly generation OCM, &
LAN
, peak hour generation ORT
meeting
B) Turbine & Boiler Side Auxillary Trial.
Sr. Page
Auxillary Schedule Trial
No. No.
1 Main TG Aux.Oil Pump-1 & 2 Every Tuesday 11-30
2 Emergency Oil Pump(DC) Every Tuesday 31-40
3 DC seal Oil Pump(H2 side) Every Tuesday 41-50
4 TDBFP-6A & 6B DC LOP Every Tuesday 51-69

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5 Emergency DC S. W. Pump-1&2 Every Tuesday 70-89

6 DG Set No Load & Load trial Monthly ---
7 DC Emergency Lighting Weekly 97
8 Diesel Fire Fighting Booster Monthly 99
Pump
9 APH Air Motor Monthly 103
Fire Fighting Diesel Pump at
10 Every Tuesday
RWP 110
9. List of Work Instructions:-
SR
NO. Work Instruction Name Work Instruction Number

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1 General Requirement OST-III/1301

2 Pressure filter/suction strainer OST-III/1302
3 Heat exchanger(cooler) OST-III/1303
4 Starting of PCR AC system OST-III/1304
5 Starting of DAS AC system OST-III/1305
6 Oil pump for lD fans and coal mills OST-III/1306
7 Starting ID fans OST-III/1307
8 Starting FD fans OST-III/1308
9 Starting APH lop OST-III/1309
10 Starting of air preheater OST-III/1310
11 Line up of flue gas path & APH OST-III/1311
12 Starting of ACW pump OST-III/1312
13 Starting of CCW pump OST-III/1313
14 Starting of air compressor OST-III/1314
Starting of HP & LP seal water
15 pump OST-III/1315
16 Starting of LP ash water pump OST-III/1316
17 Starting of HP ash water pump OST-III/1317
18 Starting of ash slurry series OST-III/1318
19 Starting of bottom ash system OST-III/1319
20 Starting of course ash system OST-III/1320
21 Starting of fly ash system OST-III/1321
22 Taking ESP pass in service OST-III/1322
23 ESP pass shut down OST-III/1323
24 Starting fuel tank heating OST-III/1324
25 Starting of LDO pump OST-III/1325
26 Starting of HFO pump OST-III/1326
27 Starting of PA fan OST-III/1327
28 Starting of coal mill OST-III/1328
29 Starting of CEP OST-III/1329
30 Starting of seal water Pump OST-III/1330
31 Starting of MDBFP OST-III/1331
32 Starting of BCW pump OST-III/1332

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SR
NO. Work Instruction Name Work Instruction Number
33 Starting vaccum pump OST-III/1333
34 Starting of dearator filling OST-III/1334
35 Line up of primary water system OST-III/1335
36 Taking primary water system in service OST-III/1336
37 Starting of lub oil system of main turbine OST-III/1337
38 Taking JOP in service OST-III/1338
39 Starting of seal oil system OST-III/1339
40 Placing turbine on barring gear OST-III/1340
41 Taking control oil system in service OST-III/1341
42 Preparing for CO2 & H2 filling in Generator OST-III/1342
43 Replacing air with CO2 OST-III/1343
44 Replacing CO2 with H2 OST-III/1344
45 Replacing H2 with CO2 OST-III/1345
46 Replacing CO2 with air OST-III/1346
47 Starting of TDBFP OST-III/1347
48 Waterwall soot blowing /APH operation OST-III/1348
Boiler Hydraulic Test(WW, Drum
49 , SH, ECO ) OST-III/1349
50 Cold Start of boiler OST-III/1350
51 Turbine Rolling & Synchronising OST-III/1351(OST-IV/1500)
52 Unit Cold Start up Report OST-III/1352
53 Unit Hot Start up Report OST-III/1353
54 Shut down of unit from full load condition OST-III/1354
55 Air Heater water washing OST-III/1355
56 Operation sequence of D.G. Set for Load trial OST-III/1356
57 Total AC Failure OST-III/1358
58 Emergency Operation OST-III/1359
59 Functioning of P.O.G. OST-III/1360
Optimization of Coal Mill performance during
60 Rainy Season OST-III/1361
Work Instructions
Please Refer sectional work instructions manual/file OR

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Soft copy on user222\ iso\ sectionwise work instruction\ op.stg-III operating manual
10. Check Lists
10.1 Check List

The Check Lists are prepared and are referred in the reference Check Lists folder/ Check Lists
SR NO. Check list Name Checklist Number
Check List For Hydrogen Leakages In

1 Generator OPN Check List
2 Check List For Boiler Light Up OPN Check List
3 Check List For Condenser Vacuum Pulling OPN Check List
4 Check List For Turbine Rolling OPN Check List
5 Check List For DG Set Operations OPN Check List
6 Check List For Soot Blowing Operations OPN Check List
10.2 CHECKLIST
S.N Activity Status Desired Action By

. /Executed
1 All relevant work permits Cancelled P.I.
2 Removal of Man & material from Removed P.I. / Local I/c

site
3 Power and control supply Available P.I. / Local I/c
4 Manhole Doors of Fans, ESP, Ash Closed P.I. / Local I/c

hoppers, Air heaters, Furnace,
Bottom ash hoppers
5 Instrument / service air supply Available P.I. / Local I/c
6 Cooling water supply Available P.I. / Local I/c
7 Local emergency push button of all Release P.I. / Local I/c

auxiliaries which are needed to

Page No STATION
: 23
ISS/REV. NO.: 01/00
S.N Activity Status Desired Action By

. /Executed
start
8 Oil level in sumps Adequate P.I. / Local I/c
9 Lub oil pump of F.D. fans Running P.I. / Local I/c
10 Proper isolation of the units / sub Done P.I. / Local I/c

units of process which are standby /
part of the system but under
maintenance
11 Local / remote selector switches on Remote P.I. / Local I/c

electrical feeders
12 Lub oil coolers / Motor coolers Charged P.I. / Local I/c
13 Jacket cooling water supply to ID Established P.I. / Local I/c

fan brg
14 Local / remote switches of Valves Remote P.I. / Local I/c
15 Minimum ESP paths A/B Inlet Available P.I. / Local I/c /

/Outlet gates open Desk Engr
16 P.A. Fans Suction Dampers Closed Desk Engr
17 Water level in seal trough & bottom Overflow P.I. / Local I/c
ash hopper
18 Manual Auxiliary air dampers all 4 Open > 50% P.I. / Local I/c
corners
Change over trials of LOPs O.K. Desk Engr
19 Change over trial of scanner fans O.K. Desk Engr
20 Change over trial of air heater O.K. Desk Engr

motors
21 Scanner fan A or B ON Desk Engr

Page No STATION
: 24
ISS/REV. NO.: 01/00
11. Safety Instructions
1. Use safety equipment/instrument like Safety shoes, Helmet, Goggles, Hand gloves,
Ear Plugs, Nose Mask.
2. Work under skilled labour/trainee.
3. Ensure to follow Permit system.
4. Ensure the work is carried out by Authorized Personnel , wherever applicable.
5. Use safety belt/ body Harness while working on pipes & ducts & where there is no
platform.
6. Use welding mask/goggle during the welding work.
7. Use asbestos hand gloves while working on hot equipment or near steam.
8. Use rubber hand gloves & proper insulated tester like pliers, screw driver etc. while
working on electrical circuits.
9. Use proper approach, suitable platform for attending the problems.
10. Use Headlamps where there is less lighted area and narrow passage.
11. Handle tools & tackles properly (tie them to thread and carry along ones neck).
12. After completion of work, collect all the waste material like, cotton waste, cloth & paper
as well as fastener.

Page No STATION
: 25
ISS/REV. NO.: 01/00
12.Significant Aspect & Controls Measures

Sr.No. Activity/Area affecting Significant Precautionary
environment Environmental Threats Measure/Actions
( Aspects & its Impacts) Planned
1 Generation of steam Consumption of Steam, Establishing Operational

DM Water result in use of Controls , Ensure for no
Operation of soot & wastage in Natural leakages
Blower resources
2 Running of boiler side Generation of waste Developing authorized

aux (Oil/Grease)result in land Collection of waste
pollution. mechanism
Disposal of waste as per

MPCB or applicable acts &
Rules
3 Combustion of Coal in Release of Fumes/gases Use of Standard work

furnace results in air Pollution Practices like use of ISI
mark regulation, Checking
the safety valves etc.
Proper evacuation of fly
ash through ESP & to
maintain healthiness of
ESP equipments.

Page No STATION
: 26
ISS/REV. NO.: 01/00
13.Significant Hazards & Control Measures

Sr.No. Activity/Area Significant Hazards Precautionary
Measure/Actions Planned
1 Taking oil gun into Exposure to Use of PPEs

service temperature
extremities results in Following up Safety
Operation of passing Burn Hazards Instruction
drain valve
Operation of passing Training related to safety
vent valve
Ensure standard work
practices
Ensure Healthiness of
person( Give reference of
any SOP/procedure if
applicable)
2 During taking round Leakage/emission of Use of PPEs

furnace get harmful gas results
in Following up Safety
pressurized
Suffocation/dissipati Instruction
on of hot gases
Training related to safety
Ensure standard work

practices
Ensure Healthiness of
person( Give reference of
any SOP/procedure if
applicable)
Use of BEE/ISI marked

equipment
Regular safety/Electrical
Inspections

Page No STATION
: 27
ISS/REV. NO.: 01/00
14. Contextual Issues- Risk: Control Measures/Opportunities
Major Risks/Concerns related to Contextual Issues and Control Measures are as

follows:-
Control Measures:
SN Category Risk/Concerns
Action Initiated/to be carried out
To be replaced. Process Initiated/to

1 Technological Old Equipment
be initiated.
Installation of Thermo controlled

Cascade heating to control
2 Technological Panels. Process Initiated/to be
panels
initiated.
Non Compliance of Legal: Delegation of Authority.

3 Legal Statutory and Regulatory Review in Meetings with defined
Requirements agenda.
Resources:
Miscommunication, errors
4 Incompetent/Inade Adequate Training
in work, repetition of work
quate Manpower
Resources:
Scarcity or not as Hamper the work result in Control over externally provides
5 per specification of delayed and inaccurate services through Supervision and
Material/Instrument work Documented Obligations
s/Consumables
15. Improvement Projects Carried out, in progress and Planned

Page No STATION
: 28
ISS/REV. NO.: 01/00
1)To monitor stack emission :

Commissioning of Stack Particulate Monitoring System is completed .Only fine tuning work
is in progress by INC-II .
2)To monitor SOx , NOx level :
Material is received & commissioning work will be carried out during unit shut down
3) Various Planned projects :
Various major works are planned in the FY : 2017-18 by BM-II , TM-II , EM-II, INC-II, ODP-II
& details are submitted in Five year rolling plan which is with MPD ( user222\500MW\MPD\ 5
year rolling plan unit-6 ) .The work schedule is during AOH AUG 2017
4. To improve house keeping ( Ambience ):

Regular monitoring by the operation staff & their upon follow up with concern section .
16) LIST OF LOG BOOKS AT VARIOUS LOCATION
Sr.No. LOG BOOK NAME RECORD MAINTAINED BY

IDENTIFICATION
1 Shift in charge log book FF6301/6451 Shift in charge
2 PCR incharge log book FF6302/6452 PCR in charge
3 Bunker level register FF6340/6490 PCR in charge
4 Boiler desk log book FF6304 Boiler desk Engineer
5 Drum level log book FF6305 Drum desk Engineer
6 Turbine desk log book FF6306 T/G desk Engineer
7 Generator desk log book FF6307/6457 T/G desk Engineer
8 Daily load (GCD) log book FF9846 T/G desk Engineer
9 Boiler API log book FF6309/6459 Boiler API
10 Turbine API log book -------- Turbine API
11 Shut down Permit entry book -------- Boiler & turbine API
12 MainTurbine brg.return Oil temp.log FF6322 Turbine floor operator
book
13 TDBFP A & B log book FF6313/6463 Turbine floor operator
14 Turbine floor log book ------- Turbine floor operator
15 Turbine governing oil rack LR1 Filter ------- Turbine floor operator
rotation log book
16 Main Switch gear Permit Entry book ------ Switch gear I/C
17 Main Switch gear daily log book ------- Switch gear I/C
18 Switch gear energy meter reading FF6346 Switch gear I/C
log book
Turbine Basement I/C log book FF6460 Turbine basement I/C

Page No STATION
: 29
ISS/REV. NO.: 01/00
19
20 CEP log book FF6314/6464 Turbine basement I/C
21 MDBFP 6C & 6D log book FF6320 Turbine basement I/C
22 Station transformer & UAT log book FF6319 Turbine basement I/C
23 CXW log book FF6315 Turbine basement I/C
24 Seal oil rack log book FF6468/6318 Turbine basement I/C
25 GTR RYB Phase/ dry type FF6321/6471 Turbine basement I/C
transformer log book
26 Seal oil system log book FF6323/6473 Turbine basement I/C
27 Vacuum pump A & B log book ------- Turbine basement I/C
28 Air compressor log book FF6317 Compressor room I/C
29 DG Parameter register ----- Compressor room I/C
30 Air compressor permit entry book ------ Compressor room I/C
31 Boiler basement I/C log book FF6311/6461 Boiler basement I/C
32 Bottom ash evacuation log book ----- Boiler basement I/C
33 FD Fan log book FF6333
Boiler basement I/C
34 PA Fan log book FF6482 Boiler basement I/C
35 Coal Mill log book FF6336 Boiler basement I/C
36 ESP I/C Log book FF6312/6462 ESP I/C
37 ESP Field log book FF6338 ESP I/C
38 ID Fan log book FF6334 ESP I/C
39 Fly ash hopper/ ESP AC compressor ------- ESP I/C
40 Firing floor I/C log book FF6331/6481 Firing floor I/C
41 F/Floor General activity register ----- Firing floor I/C
42 Air heater register ------ Firing floor I/C
43 AHP series log book FF6337/6487 AHP I/C
44 ACW / CCW log book FF6327 CCW I/C
45 Transformer reading log book (ACW / FF6330 CCW I/C
CCW)
46 CT fan log book FF6325 CCW I/C
47 CCW General activity register ------ CCW I/C
48 Non DM / DM log book FF6339A RWP(STG-III) I/C
49 Ash water log book FF6339 RWP(STG-III) I/C
50 Fire water log book FF6339A RWP(STG-III) I/C
51 RWP General activity register ----- RWP(STG-III) I/C
17) LIST OF MANUALS
Sr. Manual Name Manual No. Location (Where

No. kept)
Operation manual Boiler & Auxiliaries --------- PCR I/C & Boiler desk
1

Page No STATION
: 30
ISS/REV. NO.: 01/00
Volume -1 Engineer
2 Operation manual Turbine & Auxiliaries ----------- PCR I/C & T/G desk
Volume -2 Engineer
3 Generator , Auxiliaries & Outdoor plants ---------- PCR I/C & T/G desk
Volume -3 Engineer
4 Operation parameter guideline manual OST-III/M-05 PCR I/C , Boiler desk,
TG Desk, Drum desk
Engineer
5 HT/LT Board details ---------- Turbine API
6 Turbine flow diagram ----------- Turbine API
7 Unit operating procedure manuals ------- T/G Desk Engineer
8 Manual for Ammonia flue gas --------- PCR I/C
conditioning ( AFGC) system
9
18) LIST OF FILES / REGISTERS
Sr. File /Register Name File /register No. Location ( where

No. kept)
1 Protection bypass & normalcy register R-01 PCR I/C
2 Auxiliary trial during AOH / COH R-02 PCR I/C

register
3 DG set trial register R-03 PCR I/C
4 Event analysis report register R-04 SHIFT I/C
5 Record of training attended register R-05 SHIFT I/C CABIN
6 Training circular & order file F-01 SHIFT I/C CABIN
7 Electrical permit authorization list file F-02 SHIFT I/C CABIN
8 Identification of training needs & F-03 SHIFT I/C CABIN

record of training
9 MERC norms & CSTPS Performance F-04 SHIFT I/C CABIN

file
10 Minor incidence & near miss report F-05 SHIFT I/C CABIN
file
11 Unit fire incidence file F-06 SHIFT I/C CABIN
12 Water conservation committee F-07 SHIFT I/C CABIN

Page No STATION
: 31
ISS/REV. NO.: 01/00
meeting report file
13 MPCB circular file F-08 SHIFT I/C CABIN
14 Stack monitoring record register R-06 SHIFT I/C CABIN
15 Safety meeting register R-07 SHIFT I/C CABIN
16 Safety deficiency & action taken R-08 SHIFT I/C CABIN

register
17 Register for legal compliance file F-09 SHIFT I/C CABIN
18 Safety committee meeting report file F-10 SHIFT I/C CABIN
19 Unit accident report file F-11 SHIFT I/C CABIN
20 PPE Record file F-12 SHIFT I/C CABIN
21 PPE used compliance register R-09 SHIFT I/C CABIN
22 Unit start up report file F-13 PCR I/C
23 Unit overhaul protection trail & F-14 PCR I/C

protocol report file
24 Warning / confidential letter file F-15 SHIFT I/C CABIN
25 Customer satisfaction report file F-16 SHIFT I/C CABIN
26 Shut down defect list file F-17 SHIFT I/C
27 Event analysis report file F-18 PCR I/C
28 Stack monitoring report file F-19 SHIFT I/C CABIN
29 DPT/ Furnace temp.mapping / high F-20 SHIFT I/C

energy drain v/v body temp. report file
30 Daily bunker coal analysis & unburned F-21 SHIFT I/C

% in coal / coal mill fineness report
file
31 Flue gas analysis / Air Heater F-22 SHIFT I/C

performance test / oil testing / ferrous
debris analysis report
32 Daily HR deviation / CSTPS monthly F-23 SHIFT I/C

performance evaluation report
33 Vibration analysis report file F-24 SHIFT I/C
34 Important notes file F-25 SHIFT I/C

Page No STATION
: 32
ISS/REV. NO.: 01/00
35 General circulars & order files F-26 PCR I/C
36 Daily report register R-10 PCR I/C
37 Energy data register R-11 PCR I/C
38 DPPR report file F-27 PCR I/C
39 Print out for ORT data file F-28 PCR I/C
40 Auxiliary trial register R-12 T/G Desk engineer
41 Departmental objectives (IMS) files F-29 SHIFT I/C CABIN
42 Organization level objectives circular F-30 SHIFT I/C CABIN

( Target) file
43 Departmental achieved F-31 SHIFT I/C CABIN

objectives(IMS) data file
44 Register of environmental aspect file F-32 SHIFT I/C CABIN
45 Pending NCR file F-33 SHIFT I/C CABIN
46 Circular from ISO cell file F-34 SHIFT I/C CABIN


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CHANDRAPUR SUPER THERMAL POWER

INTEGRATED MANAGEMENT SYSYTEM

ISO 9001:2015 QMS, ISO 14001:2015EMS & OHSAS

Prepared By Reviewed & Approved by

SECTION MANUAL: OPERATION UNIT # 62. Index

Prepared By Reviewed & Approved by

Prepared By Reviewed & Approved by

Name : SHRIKANT . DAFADE

Designation : Executive Engineer

Prepared By Reviewed & Approved by

4. Revision /Amendments Record

Amend- Revision Number

Prepared By Reviewed & Approved by

Prepared By Reviewed & Approved by

a) SHIFT INCHARGE: - Shift In charge is assisted by P.C.R. In charge and

c) ASSISTANT PLANT INCHARGE:-Coordinates with local and PCR staff.

local staff is under control of Assistant Plant In charge.

d) BOILER DESK INCHARGE: - is to start/stop and maintain draft cycle, coal

Prepared By Reviewed & Approved by

e) TURBINE-GENERATOR DESK INCHARGE: - He monitors L.P. Heaters,

f) DRUM LEVEL DESK INCHARGE: - is to monitor start/stop of MD BFP

2) FIRING FLOOR OPERATOR DUTIES ARE :-.. He monitors

FIRING FLOOR INCHARGE: - His duty is :

Prepared By Reviewed & Approved by

i) PRDS Valve Operation.

3) BOILER BASEMENT INCHARGE DUTIES ARE:-

a) To monitor Air to Boiler and Evacuate Flue Gases.

b) To monitor coal air Mixture for combustion in boiler

e) To monitor Force Draft Fan which supplies air for combustion.

g) To monitor Bottom Ash Hopper Evacuation with required preconditioned HP,LP,Seal

h) To monitor Furnace peep hole at 9 mtr level at regular interval.

. 4) ESP CONTROL ROOM-:

Prepared By Reviewed & Approved by

5) ASH HANDLING PLANT-:

6) OIL HANDLING AND UNLOADING PUMP HOUSE: -

7) THE TURBINE BASEMENT :

Prepared By Reviewed & Approved by

e. Supply of instrument and Service air to whole Unit.

9) C.C.W. AND A.C.W. PUMP HOUSE-

10) RAW WATERINTAKE :

Prepared By Reviewed & Approved by

under control of PCR # 3.

11)AIR CONDITIONING PLANT:

12) RAW WATER PUMP HOUSE (500MW):

13)FIRE FIGHTING PUMP HOUSE: -

14) TIME OFFICE:-

Prepared By Reviewed & Approved by

1) To maximize Generation > 3543 MUs

2) To achieve Plant Load Factor > 80.90 %

3) To maintain Unit Heat Rate Average < 2663 Kcal/KWH

4) To reduce Specific Oil Consumption < 1.00 ml/KWh

5) To reduce Aux. Power Consumption < 7.95 %

6) To reduce Force Outage Factor < 3 %

7) To reduce Total No. of Tripping due to BTL < 2

8) To reduce specific DM water consumption < 105 ml/KWh

9) To reduce specific Soften water consumption < 2700 ml/KWh

10) To enhance reporting of near miss/incident < 8 nos

11) To comply 100 % Usage of PPEs .

12) To reduce Safety Related Deficiencies to 100 %

Prepared By Reviewed & Approved by

7. List of Reports to be submitted

Prepared By Reviewed & Approved by

8.List of activities carried out in section& its monitoring

Reference Documented Monitoring Remarks