Iso Section Manual Old Cstps-Opn U#5

CHANDRAPUR SUPER THERMALPOWER STATION
Page No :1
M.S.P.G.C.L., CHANDRAPUR Doc. No : OPN-5/SM
ISS/REV. NO.: 01/00
Operation Section Manual PCR ISS/REV.DT:01.02.2017/00
#5
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 PCR#52. 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-5
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, CSTPS, Chandrapur and is a property of CSTPS, Chandrapur.
Signature :
Name :
Designation :

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4. Revision /Amendments Record
Amended
Revision Number Reason for Change Approved by
Amendment Section Page by
No. No. No.
Old No. Date New No. Date

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5. Purpose
Purpose :
To generate electicity under controlled conditions as per requirement of LD & MERC
Guidelines.
There is a Shift Incharge as a unit controlling authority. 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), Dy CE, & CE . PCR and the local staff tries to maintain the
parameters as per the manufacturers recommendation.
Regarding housekeeping yearly cleaning contract is operated by operation services
section. Cleaning is checked by Operation staff and certified by the respective area
INCHARGE.

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Defects of auxiliaries/ plant are raised by Shift Charge Engineer/ PCR Incharge/
Plant Incharge through computer to respective section. The defects are classified as
Urgent, Emergency, Short shut down, Overhaul, depending upon severity & isolation
of the equipment. The Maintenance staff takes permit from PCR and does the work.
After cancellation of permit & trial of equipment defect is eliminated from the computer
list.
All Operation staff attendance is marked by time Office. If somebody applies leave
timekeeper gives note to a person who is in spare shift. Leave Account, night shift
Account, OT register, attendance registers are maintained by time keeper.
Various training programs are arranged by the Chandrapur Training Center.
Training department maintains register in which names of candidates, which type of
training given is noted. Accordingly S.E. (O) sends names of employees to training
department as per the availability of staff.
OPERATION :
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.

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.
c) 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.
d) TURBINE DESK INCHARGE: - He monitors H.P. and 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
e) BFP / DRUM LEVEL DESK INCHARGE: - is to monitor start/stop

of MD BFP /TDBFP as per the plant requirements. He also monitor drum
level ,EBD,CBD control
f) ASSISTANT PLANT INCHARGE(TURBINE API & BOILER API)
TURBINE API coordinates with local & PCR staff. Raises defect cards for the
observed or reported auxillaries and system.He also supervises the turbine &
generator with their auxillaries by taking rounds, informs abnormality to PCR incharge
for corrective action. One technician is also under control of TAPI to monitor TDBFP &
Turbine parameters
BOILER API coordinates with local& PCR staff. Raises defect cards for the observed

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or reported auxillaries and system.He also supervises the boiler & its auxillaries by
taking rounds, informs abnormality to PCR incharge for corrective action. All boiler side
staff is uder the control of BOILER API.
2) FIRING FLOOR OPERATOR DUTIES ARE :-.
Monitoring of Air Heater.

Monitoring of Firing of Oil and Coal to maintain proper flame.
Monitoring of Soot Blowing inside the Boiler
Monitoring of Pre heating of Secondary air by Air Heaters.
Firing floor is manned by Technician
vi) Monitoring of combustion of fuel to evaporate water into
steam for turbine.
vii)Takes round of boiler to observe normalcy, if any abnormality is
observed, he informs P.C. R.Incharge /API
viii) He checks B/A Hopper status through peepholes.
ix) Monitors flame condition, Secondary air Auxiliary Air
dampers.
x) Operate all manual valves as per instructions.
xi) Keeps all oil guns clean.
xii) Monitors Water Wall and A/H Soot Blower Operation and
A.H. Drive and Lub System.
xiii) All mechanical isolation of Boiler MCC, Boiler side area
is done by technician
xiv) All electrical isolation is done by electrician of 6.6 KV
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 Induced Draft Fans, Coal Mills, Primary Air Fans

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along with their lubrication system, Coal mill Reject.
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) Induced Draft. Fan which evacuates flue Gases and maintains
draft in furnace.
g) To monitor coal mill reject system
h) CMR conveyor belts carries coal mill reject to SILO
4) ESP,AHP & OHP
ESP is manged by junior engineer who supervises ID fans

alongwith their lubrication system ,ESP,bottom ash,coarse ash
& fly ash.
Junior engineer is asssisted by 3 technicians deputed for day
to day operation works.
i) fly ash evacuation system
ii) ESP field parameters monitoring.
iii) ID fan control & monitoring.
AHP & OHP is operated by 2 technicians deputed for day to
day operation work .In AHP the ash deposited is converted into slurry &
the same is disposed into the ash bund.They also ensures the healthiness
& continous running of FO & LDO oil pumps.
5) TURBINE BASEMENT INCHARGE DUTIES ARE -
a. To monitor Turbine Generator for generation of electricity.

b. To monitor Condensate Extraction Pump for evacuating condensate from
condenser and supplying it to Deareator through L.P. Heaters.
c. To monitor Boiler Feed Pumps for supplying Feed Water to H.P. Heaters
and Boiler.
d. To monitor Lub Oil Pumps for supplying lubricating oil and seal oil to
turbine and generator, primary water system,TD BFP Lub oil system
e. To monitor 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,

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g) Technician 1 or 2 for Boiler Feed Pump, primary water,,MOT
h) Technician 1 or 2 for Seal Oil, vacuum pump, HPCF for governing
system, condenser, CEP ,TD/MD BFP lub oil system ,ACW
booster pump
i) Technician 1 or 2 for Compressor House
j) Contractor labour for helping staff
k) monitoring of governing system of main turbine, TDBFP and its governing system
l) Technician 1or 2 for main turbine .TDBFP and PRDS system.
6) C.W. AND A.C.W. PUMP HOUSE OPERATOR DUTIES ARE
To monitors cooling water and auxiliary cooling water to condenser and

thereafter to cooling tower for cooling of water.
To monitor ACW for seal oil, 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. Pump Suction sump.
7) AIR CONDITIONING PLANT: -
Operation and maintanance is carried out by outsourced agency.

8. AIM OF THE 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 timekeeper and one messenger in every shift.
Ambulance is available for 24 hrs at time office for any casualties during any
shift to move the patient to hospital in the colony.

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ORGANISATION CHART PCR-5

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All processes are carried out in compliance with following process charts.

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Input Process Output
Grid requirement Boiler start up Combustion process

inside furnace
Resourses Controls
WATER Work instruction:

OSTIII/1301,1302,1303,1307,13
LDO/HFO 08,1309,1310,1311,1312,1322,
COAL
MANPOWER
1324,1325,1326,1327,1328,13
DAS 32,1314,1334,1352,1353,1304,
AUX.STEAM 1305
Unit cold start up report
Grid requirement Coal pulverising & Pulverised coal

conveying supply to furnace
for combustion
Resourses Controls

COAL OSTIII/1301, 1327,1328,1361
MANPOWER
DAS
Bunker coal analysis report-
AUX.STEAM FF9830B
AIR Coal fineness report FF9831B
Aux. power Lub oil sample report-FF9832B
Clean air flow test FF 8030(a) &
FF8030(B)

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PROCESS OUTPUT
INPUT
combustion of Generation of
Grid
fuel /air heat
requirement
mixture
Resourses Controls

OSTIII/1310,1311,1312,1322,13
LDO/HFO 26,1327,1328,1329,1332,1348,
COAL
1350,1353
MANPOWER
DAS Flue gas analysis report-FF8620
AUX.STEAM Air heater performance report-
AIR FF8631
Furnace temperature mapping-
FF8028A
Location & thickness of ash
Grid requirement Boiler of water & Generation of steam

heating of steam with controlled
temperature
Controls
Resourses
Work instruction:
WATER
OSTIII/1301,1302,1303,1332,13
34,1347,1348,1349,1350,1352,
LDO/HFO
COAL 1353
MANPOWER
DAS
AUX.STEAM
AIR
Aux. power

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Process Output
Input
Ash evacuation Generation
Grid of ash slurry
requireme
nt
Resourses Controls

OSTIII/1301,1311,1312,1314,13
MANPOWER 15,1316,1317,1318,1319,1320,
DAS
AIR
1321,1322,1323,1324,1325
Auxillary power Daily plant performance report
FF6341,6342,6343,6393,9217
Flue gas sample report-FF8620
Air heater performance report-
FF8631
Grid requirement Soot blowing Efficient heat

transfer
Resourses Controls
Manpower Work instruction:OSTIII/1348

DAS
AIR
AUX.POWER FF8028A
AUX.STEAM Location & thickness of ash
deposits-FF6494
Air heater performance sheet
on DAS
Air heater performance report-
Grid Turbine/Generator Ready for

requireme start up rolling
nt
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Resourses Controls
MANPOWER Work instruction:

DAS OSTIII/1329,1330,1331,1333,13
Air
34,1335,1336,1337,1338,1339,
Aux.power
Steam 1340,1341,1301,1302,1303,13
Hydrogen gas 13,1314,1342,1343,1344,1345,
Nitrogen gas 1346,1347
Manual M-02 & M-03
Grid requirement Turbine /generator Generation of

rolling & electicity
synchronizing
Resourses Controls
Manpower Work instruction:

DAS OSTIII/1301,1351,1352,1353
Air
Auxillary power
Unit cold startup
Steam Various criteria in DAS
Hydrogen gas
Nitrogen gas
Prepared By
Maintenanc Unit shutdown No Reviewed & Approved by
IG Group Member
e/statutory/ Section In Charge (OPN)
generation
grid of electicity
requiremen
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Resourses Controls
Manpower Work instruction:

DAS OSTIII/1301,1354,1323
Air
Auxillary power
LDO/HFO
Maintenance/statuto Monitoring of Controlling

ry/ grid requirement process parameter
Resourses Controls
MANPOWER Operation parameter guideline

DAS
manual
Lan
Various formats of logbook as
per master list of
formats(registers)-FF9806
INPUT PROCESS OUTPUT

Maintenanc Defect card Corrective
e/statutory/
generation Action
grid
requiremen
Controls
Prepared ByResourses Reviewed & Approved by
Defect card register-FF9823
MANPOWER
DAS
Procedure for permits-MR/5948N
Lan Issuing of permits on telephone-
MR5977
Work instruction OST III/1357
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Maintenance/statuto Data analysis & Controlling

ry/ grid requirement recording
Resourses Controls
MANPOWER Work instruction OST III/1360

DAS
History register-MR5978
Lan
Performance test-OSII/4153
Daily plant performance
report-
FF6341,6342,6343,6393,9217
Flue gas sample report-
FF8620,8631
Event card-FF9828
Bunker coal analysis report-
FF9830B
Coal fineness report-FF9831B
Lub oil sample report-FF9832B
Monthly performance report-
FF7956,8031,7121
Accident report-FF8364,8361
FF8028
Location & thickness of ash
deposits-FF6494
Generation target allocation-
INPUT PROCESS OUTPUT
Maintenanc Nodal load Corrective

e/ grid dispatch action
requirement
Resourses Controls
Manpower Laod schedule

Prepared By DAS Reviewed
Daily plant performance report- & Approved by
Lan
IG Group Member FF6341,6342,6343,6393 Section In Charge (OPN)
Hourly generation FF9813
Peak hour generation
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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 Total No. of Tripping due to BTL < 2
7) To reduce specific DM water consumption < 105 ml/KWh
8) To reduce specific Soften water consumption < 2700 ml/KWh
9) To comply 100 % Usage of PPEs .
10) To reduce Safety Related Deficiencies to 100 %
7. LIST OF REPORTS TO BE SUBMITTED

Frequency of
Tittle of the Report to be Reference
Submission Remarks (If Any)
SN Report To be submitted to (Document/Re
Quarterly/ (Responsibility )
submitted Whom cord)
Monthly/ Weekly/

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Daily
User222/POG/
ORTData File/ ORT_month/Input
Monthly
1 ORT DATA POG Aux. trial format
( In first week)
register (T/G Desk / PCR
I/C)
Daily plant
Daily DPPR File
2 performance POG PCR I/C
(In night shift) (FF6341)
report
Hourly
Generation &
T/G Desk /
loss Report & Daily DPPR File
3 POG Blr.Desk
Non (In night shift) (FF 6342)
Engineer
availability of
Coal mills
Parameters to
be Monitored Daily Boiler desk
4 POG DPPR File
at Corporate (In night shift) Engineer
Level
Generating
DATA / Partial
DATA ENTRY Daily
5 loss , Tripping SAP DPPR T/G Desk Engineer
IN SAP (In every shift )
details & C/M
outage details
DATA ENTRY
Morning Daily
6 IN SAP SAP DPPR PCR I/C
Report (In Night shift )
8.List of activities carried out in section& its monitoring
A)

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Reference Documented Monitoring & Remarks
Information Review (If any)
SN Activities Frequency (SOP/WI/Record-Files ,
Registers, Log books,
Checklist, SAP)
Running of boiler Performance
side aux Review in
1 Daily BHELs Operation Manual Daily Meeting,
In OCM, ORT
meeting
Running of turbine Daily BHELs Operation Manual Performance
Review in
side aux
Daily Meeting,
2
In OCM, ORT
meeting
Daily BHELs Operation Manual Performance

Review in Daily
Combustion of coal Meeting, In
3 OCM, ORT
in furnace
meeting
Generation of steam Daily BHELs Operation Manual Performance

Review in
Daily Meeting,
4
In OCM, ORT
meeting
Operation of soot Daily Performance

Review in
Blower
Daily Meeting,
5 BHELs Operation Manual
In OCM, ORT
meeting
9)AUXILLARY TRIALS
1. WEEKLY TRIALS-EVERY MONDAY
SR.N PARTICULARS PAGE

O NO.
1 D.C LUB OIL PUMP 12
2 CONDENSATE TRANSFER PUMP A/B 22/32

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3 A.C LUB OIL PUMP-1 42

4 A.C LUB OIL PUMP-2 52
5 TDBFP-A EOP 62
6 TDBFP-B EOP 72
7 D.C LIGHTING TRIAL FROM PCR(EVERY 82
SUNDAY)
2.FORTNIGHTLY TRIAL 5/6 & 20/21ST OF EACH MONTH
SR.NO PARTICULARS PAGE NO.
1 A.C SEAL OIL PUMP AIR SIDE 94
2 CONTROL FLUID CIRCULATING PUMP 102
3 GLAND DRAIN PUMP 110
4 D.C SEAL WATER PUMP -1 118
5 D.C SEAL WATER PUMP -2 124
6 D.C SCANNER FAN 130
7 B.C.W BOOSTER PUMP 136
8 L.O.P ID FAN A 142
9 L.O.P ID FAN-B 148
10 L.O.P ID FAN-C 154
11 L.O.P ID FAN-D 160
12 L.O.P OF G/BEARING OF PAH -A 166
13 L.O.P OF G/BEARING OF PAH -B 172
14 L.O.P OF G/BEARING OF SAH -A 178

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15 L.O.P OF G/BEARING OF SAH -B 184
16 L.O.P OF S/BEARING OF PAH -A 190
17 L.O.P OF S/BEARING OF PAH -B 196
18 L.O.P OF S/BEARING OF SAH -A 202
19 L.O.P OF S/BEARING OF SAH B 208
20 TDBFP-A LOP 214
21 TDBFP-B LOP 220
3.MONTHLY TRIAL EVERY 10/11TH OF EACH MONTH
SR.NO PARTICULARS PAGE NO.
1 CONTROL FLUID PUMP 228
2 VACCUM PUMP 232
3 PAH-A MOTOR 236
4 PAH-B MOTOR 240
5 SAH-A MOTOR 244
6 SAH-B MOTOR 248
7 SEAL AIR FAN 252
8 LUB OIL VAPOUR EXHAUST FAN 256
9 CONTROL FLUID TANK VAPOUR EXH FAN 258
10 BEARING CHAMBER VAPOUR EXH. FAN 260
11 G.S EXHAUST FAN 262
12 C.E.P 264
13 GTR CW PUMP 268
14 MDBFP-C 270
15 MDBFP-D 274

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16 D.G SET LOAD TRIAL 278
4.SHUT DOWN TRIAL
SR.NO PARTICULARS PAGE NO
1 STATOR COOLING WATER PUMP 282
2 EMPA BOARD ON D.G SET 286
3 D.C JOP 288
4 PAH-A AIR MOTOR 290
5 PAH-B AIR MOTOR 292
6 SAH-A AIR MOTOR 294
7 SAH-B AIR MOTOR 296
8 D.C SEAL OIL PUMP 310
9. List of Work Instructions:-
Sr.N WORK INSTRUCTION CODE TITLE OF WORK INSTRUCTION

O NO .
1. OST-III/1301 GENERAL REQUIREMENT
2 OST-III/1302 PRESSURE FILTER /SUCTION STRAINER
3 OST-III/1303 HEAT EXCHANGER (COOLER)
4 OST-III/1304 STARTING PCR A/C SYSTEM
5 OST-III/1305 STARTING DAS A/C SYSTEM
6 OST-III/1306 OIL PUMPS FOR ID FAN &COAL MILL
7 OST-III/1307 STARTING OF ID FAN
8 OST-III/1308 STARTING OF FD FAN
9 OST-III/1309 STARTING OF AIR PRE-HEATER LOP

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10 OST-III/1310 STARTING OF AIR PRE-HEATER
11 OST-III/1311 LINE UP OF FLUE GAS PATH & APH
12 OST-III/1312 STARTING OF ACW PUMP
13 OST-III/1313 STARTING OF CCW PUMP
14 OST-III/1314 STARTING OF AIR COMPRESSORS

15 OST-III/1315 STARTING OF HP & LP SEAL WATER PUMP AT AHP
16 OST-III/1316 STARTING OF LP ASH WATER PUMP
17 OST-III/1317 STARTING OF HP ASH WATER PUMP
18 OST-III/1318 STARTING OF ASH SLURRY SERIES
19 OST-III/1319 STARTING OF BOTTOM ASH SYSTEM
20 OST-III/1320 STARTING OF COARSE ASH SYSTEM
21 OST-III/1321 STARTING OF FLY ASH SYSTEM
22 OST-III/1322 TAKING ESP PASS IN SERVICE
23 OST-III/1323 ESP PASS SHUTDOWN
24 OST-III/1324 FUEL TANK HEATING
25 OST-III/1325 STARTING OF LDO PUMP
26 OST-III/1326 STARTING OF HFO PUMP
27 OST-III/1327 STARTING OF PA FAN
28 OST-III/1328 STARTING OF COAL MILL
29 OST-III/1329 STARTING OF CEP
30 OST-III/1330 STARTING OF BFP DCSEAL WATER PUMP
31 OST-III/1331 STARTING OF MDBFP
32 OST-III/1332 STARTING OFBCW PUMP
33 OST-III/1333 STARTING OFVACCUM PUMP
34 OST-III/1334 STARTING OF DEARATOR FILLING
35 OST-III/1335 LINEUP PRIMARY WATERSYSTEM
36 OST-III/1336 TAKING PRIMARY WATER SYSTEM IN SERVICE
37 OST-III/1337 STARTING OF LUB OIL SYSTEM OF MAIN TURBINE
38 OST-III/1338 TAKING JOP IN SERVICE
39 OST-III/1339 STARTING OF SEAL OIL SYSTEM

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40 OST-III/1340 PLACING TURBINE ON BARRING GEAR
41 OST-III/1341 TAKING CONTROL FLUID SYSTEM IN SERVICE
42 OST-III/1342 PREPARING FOR CO2 & H2 FILLING
43 OST-III/1343 REPLACING AIR WITH CO2
44 OST-III/1344 REPLACING CO2 WITH H2
45 OST-III/1345 REPLACING H2 WITH CO2
46 OST-III/1346 REPLACING CO2 WITH AIR
47 OST-III/1347 STARTING OF TDBFP
48 OST-III/1348 WATER WALL SOOT BLOWING/APH OPERATION
49 OST-III/1349 BOILER HYDRAULIC TEST(WW,DRUM,SH & ECO
50 OST-III/1350 COLD STARTUP OF BOILER
51 OST-III/1351 TURBINE ROLLING & SYNCHRONISING
52 OST-III/1352 UNIT COLD STARTUP REPORT
53 OST-III/1353 UNIT HOT STARTUP REPORT
54 OST-III/1354 SHUT DOWN OF UNIT FROM FULL LOAD
55 OST-III/1355 AIR HEATER WATER WASHING
56 OST-III/1356 OPERATION SEQUENCE FOR DG SET LOAD TRIAL
57 OST-III/1357 SCHEDULE OF AUXILLARY TRIAL
58 OST-III/1358 TOTAL AC FAILURE
59 OST-III/1359 EMERGENCY OPERATION
60 OST-III/1360 FUNCTIONING OF POG
61 OST-III/1361 OPTIMISATION OF COAL MILL PERFORMANCE DURING

RAINY SEASON
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

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#5
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 Check list
S.N Activity Status Desired Action By

. /Executed By
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
start
8 Oil level in sumps Adequate P.I. / Local I/c

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#5
S.N Activity Status Desired Action By
. /Executed By
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 trail 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
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.

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#5
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.
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 Collection

of waste mechanism
aux (Oil/Grease)result in land
pollution. Disposal of waste as per MPCB
or applicable acts & Rules
3 Combustion of Coal in Release of Fumes/gases Use of Standard work Practices

furnace results in air Pollution like use of ISI mark regulation,
Checking the safety valves etc.

Page No : 31
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13.Significant Hazards & Control Measures
Activity/Area Significant Hazards Precautionary

Measure/Actions Planned
Sr.No.
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

Following up Safety Instruction
pressurized in
Suffocation/dissipati Training related to safety
on of hot gases
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

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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

Page No : 33
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15. Improvement Projects Carried out, in progress and Planned
1. To monitor stack emission below the permissible limit

2. To improve house keeping
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 : 34
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#5
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
17) LIST OF MANUALS

Page No : 35
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#5
Sr. Manual Name Manual No. Location (Where

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

Page No : 36
ISS/REV. NO.: 01/00
#5
file
11 Unit fire incidence file F-06 SHIFT I/C CABIN
12 Water conservation committee F-07 SHIFT I/C CABIN

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

Page No : 37
ISS/REV. NO.: 01/00
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performance evaluation report
33 Vibration analysis report file F-24 SHIFT I/C
34 Important notes file F-25 SHIFT I/C
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 THERMALPOWER STATION

INTEGRATED MANAGEMENT SYSYTEM

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

Prepared By Reviewed & Approved by

SECTION MANUAL: OPERATION PCR#52. Index

Prepared By Reviewed & Approved by

Prepared By Reviewed & Approved by

Prepared By Reviewed & Approved by

Prepared By Reviewed & Approved by

There is a Shift Incharge as a unit controlling authority. For Generation of Electricity

Prepared By Reviewed & Approved by

b) P.C.R. / UNIT INCHARGE: - is to get started the auxiliaries and

Prepared By Reviewed & Approved by

c) Boiler Desk Incharge: - is to start/stop and maintain draft cycle, coal

d) TURBINE DESK INCHARGE: - He monitors H.P. and L.P.

e) BFP / DRUM LEVEL DESK INCHARGE: - is to monitor start/stop

f) ASSISTANT PLANT INCHARGE(TURBINE API & BOILER API)

Prepared By Reviewed & Approved by

2) FIRING FLOOR OPERATOR DUTIES ARE :-.

Monitoring of Air Heater.

3) BOILER BASEMENT INCHARGE DUTIES ARE:-

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

Prepared By Reviewed & Approved by

ESP is manged by junior engineer who supervises ID fans

a. To monitor Turbine Generator for generation of electricity.

Prepared By Reviewed & Approved by

6) C.W. AND A.C.W. PUMP HOUSE OPERATOR DUTIES ARE

To monitors cooling water and auxiliary cooling water to condenser and

7) AIR CONDITIONING PLANT: -

Operation and maintanance is carried out by outsourced agency.

Prepared By Reviewed & Approved by

ORGANISATION CHART PCR-5

Prepared By Reviewed & Approved by

Prepared By Reviewed & Approved by

Grid requirement Boiler start up Combustion process

WATER Work instruction:

Input Process Output

Grid requirement Coal pulverising & Pulverised coal

WATER Work instruction:

Prepared By Reviewed & Approved by

WATER Work instruction:

Input Process Output

Grid requirement Boiler of water & Generation of steam

Prepared By Reviewed & Approved by

WATER Work instruction:

Input Process Output

Grid requirement Soot blowing Efficient heat

Manpower Work instruction:OSTIII/1348

Input Process Output

Grid Turbine/Generator Ready for

MANPOWER Work instruction:

Input Process Output

Grid requirement Turbine /generator Generation of

Manpower Work instruction:

Input Process Output

Manpower Work instruction:

Input Process Output

Maintenance/statuto Monitoring of Controlling

MANPOWER Operation parameter guideline

INPUT PROCESS OUTPUT

Input Process Output

Maintenance/statuto Data analysis & Controlling

MANPOWER Work instruction OST III/1360