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OPERATIONS

DEPARTMENT
PROCEDURE

PMI Revision 01 1
Operation department
Responsibility
Safe & efficient operation of the plant round the clock.
Operation mainly includes the start up, shut down, routine
operation, handling of emergencies, monitoring of critical
parameters which effects the process & ultimately the power
generation, testing of various protective devices & regular
change over of standby auxiliaries to ensure their
availability.
Operation department is also responsible for proper
isolation of auxiliary/ system for carrying out PM/break
down/planned maintenance as per the schedule provided by
MTP or as discussed in daily planning meeting.

PMI Revision 01 2
Shift Charge Engineers
Main plant shift charge engineer is responsible for safe &
efficient operation of the entire station excluding CHP/MGR/DM
Plant during shift hours.
The morning shift SCE attends the daily planning meeting for
action on plant problems that may affect the plant generation.
The station generation is maintained as per the schedule.
All the day to day activities are carried out as per OPN
guidelines by the approved operational manuals.
All the activities carried out during shift are recorded in SCE's
logbook.
Whenever a unit trips, the cause of trip is spontaneously
analysed by the operation staff. And after consultation with
HOD decision is taken to restart the unit or to take under shut
down.
In case of any unit tripping he submits a unit trip report to Head
of Operation and EEMG as per format which is used by trip
analysis committee co-ordinated by EEMG section.
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Unit Control Engineer (UCE)
The unit control engineer is responsible & co-
ordinates all the activities carried out in the unit.
He ensures the implementation of work
instructions & proper record keeping. Bypassing of
any protection & interlock is guided by the
instructions.
All the unit activities are recorded in UCE log
book.
He is responsible for issuing PTWs of equipments
of his unit.

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Boiler Desk Engineer
The Boiler desk engineer is responsible for the
safe and efficient operation of boiler & its
auxiliaries & guided by the approved operation
manuals.
He records the critical parameters of Boiler and
AUX.
Operations of wall blowers/Long retractable soot
blowers are guided by OPN instructions and the
records are maintained in the respective logbooks.

PMI Revision 01 5
TG Desk Engineer
The TG desk engineer is responsible for the safe
and efficient operation of TG & its auxiliaries
guided by the approved operation manuals.
In the absence of UCE he co-ordinates all the
activities related to TG & auxiliaries.
All the activities are recorded in his logbook.
He records the critical parameters of TG & AUX.
during shift hrs.

PMI Revision 01 6
Switch Yard Engineer
The S/Y engineer is responsible for all the
activities carried out in S/Y.
He co-ordinates with all external agencies over
telephone like LDC.
All the activities performed during shift hour are
recorded in his logbook.
He calculates Export/Import related parameter at
00:00 Hrs.

PMI Revision 01 7
Ash Handling Engineer
The Ash Handling Engineer is responsible for
disposal of ash generated during coal firing of
boiler and directly reports to SCE.
All the activities performed during shift hour are
recorded in his log book.
He is responsible for giving PTW in ash handling
system.

PMI Revision 01 8
PTW SYSTEM

PMI Revision 01 9
PTW System
For the safety of the personnel and the machinery PTW system
is used.
This system safeguards safe working condition.
Whenever any maintenance department has to do any kind of
maintenance on any equipment, they must take the permit to
work on it from the operation department.
Necessary isolations required and done by the maintenance
department must be clearly stated in the PTW.

PMI Revision 01 10
PTW System
The workman for his own safety must ensure that he does not
work on equipment without work permit
The workman should read carefully the contents of PTW and
ensure that the permit has been issued on the same equipment
for which it was required and also ensure that the equipment is
safe to work.
If the work is to be carried by group on an item of plant ,the
group leader will draw the permit and explain to whole group.

PMI Revision 01 11
PTW System
All copies of a permit to work (PTW) must be signed when they
are issued or cancelled.
PTW must not be signed expect in the presence of the engineer
issuing or canceling it.
On PTW, recipient will be required to sign a statement that he
has completed the work before PTW is cancelled.
PTW must be cleared by the person signing for receipt.
In case of carried over job the superviser or Engineer I/C will
return the permit and sign.

PMI Revision 01 12
Type of PTW

THE PERMIT TO WORK FORMATS IN USE AT THE


PROJECTS ARE OF FOUR TYPES. DIFFERENT FORMS
FOR THE DIFFERENT TYPES OF JOBS ARE AS FOLLOWS
PERMIT FOR WORK(PFW)
RESTORATION OF MOTIVE POWER(ROMP)
LIMITED WORK CERTIFICATE(LWC).
SANCTION FOR TEST(SFT).

Another type of PTW which is used for welding related


works near inflammable atmosphere is called
Hot Permit

14 April 2013 PMI Revision 00 13


LOCK OUT BOX:
For full-proof isolation lock out box system is
adopted. In all control room lock out boxes are
provided. After isolation all keys are locked in lock
out boxes. Each box contain five keys. Five
permits on same equipment can be issued. Box
cannot be opened until all five keys are returned.

14 April 2013 PMI Revision 00 14


WORK ORDER CARD:

It is a written requisition for maintenance service


irrespective of its nature and source. It is apart of
the maintenance services system rather a process
by which work is arranged, directed and regulated in
planned manner. The work order card accomplish
the work program in the most efficient manner work
order card have following information:

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- Defects priority.
- Fault type.
- PTW required or not.
- Impact of break down.
- Description of jobs/work specifications.
- Manpower required.
- Estimated duration.
- Start of maint. (Date, time).
- Completion of maint.(Date and time)
- Spares/consumables used.
- Special tools and tackles used.

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COMMITTED WORK PROGRAMME:

In daily planning meeting defect work order


cards and p/m schedules are discussed in
order of priority. Simultaneously, the
availability of permit to work (PTW)
availability of human and other resources
will be ascertained.

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PRIORITY OF DEFECTS:

E priority defects: E denotes work requiring


immediate attention. This category will cover work,
which is requiring immediate action to prevent
injury to personnel or damage to main plant or
vital auxiliary plant or to prevent a significant
reduction in station output. Only unit control
engineer can issue the E priority job card giving the
proper justification.

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A PRIORITY DEFECTS:

Such defects must be processed quickly so that they


can be programmed within 24 hrs. To 72 hrs.
Such defects are not urgent and can wait proper
diagnostic by area engineers.

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B PRIORITY DEFECTS: The defects which if
not attended within 72 hrs. To one week will result
loss of generation.

C PRIORITY DEFECTS: The defects, which do


not have any significant effect on generation,
availability or thermal performance.

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PTW (ELECT.):

Complete isolation of the electrical equipment is being


done before issuing the PTW. HT/LT breakers, modules
are totally isolated from live system and it is locked and the
key is being put in lock out boxes. Proper earthing is
being done. Danger tags are fixed on modules and
isolated breakers.

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PTW (MECH.):

Issuing the mech. PTW


First connected electrical system is stopped and electrical
isolation is done
Mechanical isolation is done.
Other mechanical isolation like depressurization, venting,
draining is done. All keys should be placed in lock out
box.

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ROMP (RESTORATION OF
MOTIVE POWER):

Sometime work is being carried out with restoration of


motive power like mill roller setting. Here mech. Isolation
still remains there but equipment is electrically
normalized.

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LIMITED WORK CERTIFICATE:
The form will be used when work is to be carried out on or
adjacent to plant or HV apparatus by limiting the work.

It will be used mainly for the following purposes:


Where no isolation is required.
Work will not hamper the normal running of equipment.

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SANCTION FOR TEST:

A safety document of a format specifying the


plant/apparatus to be tested, making known the conditions
under which the testing is to be carried out and confirming
actions which have been taken to achieve safety from the
system.

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Procedure for Issue of PTW
Expect in case of emergency, permits to work should be issued
only against the presentation of an isolation request, describing
the isolation required, from maintenance department.
Person presenting themselves to collect PTW, should be fully
familiar with the job and details of works to be done so that
isolation request and permits can be matched.
All copies of PTW must be signed both at receipt and at
clearance
Receipt and clearance signatures must be made only in
presence of S.C.E./ Unit in charge.

PMI Revision 01 26
Procedure for Issue of PTW
When change in isolation becomes necessary, the permit shall
be cancelled and reissued. Work on medium/low voltage
equipments should be done when they are dead.
At least two isolations should be in service in case of electrical
permit.
In case of emergency, when Shift Charge Engineer initiates the
action, an emergency job card should be made available from
within the operation department giving details of the work to
be done .
Do not operate - Caution boards should
be put on items under PTW.

PMI Revision 01 27
Receipt of Permit to Work
The permitee must ensure before start work on equipment
that;

o It is isolated electrically or mechanically or both


as the case may be.
o Breaker panel is locked in isolated condition.
o Isolation tag is tied with the equipment operting
panel as well as on the breaker panel.
It is the responsibility of Shift Charge Engineer/control engr.
issuing the PTW to ensure that the person is familiar with the
nature and extent of the work to be done.

PMI Revision 01 28
Receipt of Permit to Work
When it is unavoidable, a person of higher rank can also draw
the permit; but it will be the responsibility of this person to
ensure that the men under his charge are acquainted with the
plant to be worked on, the work to be done and limitations
imposed by safety requirements.
When a person is required to work along with a number of
other individuals, the PTW for the whole job should be read
personally by everyone before they start the work.

PMI Revision 01 29
Receipt of Permit to Work
In case of electrical permits, it is not permissible for
supervisors to draw permits unless they perform the work
themselves or supervise it continuously and directly.
In case of cross permit it will be the responsibility of shift
charge engr./control engr to ensure that before taking the
equipment in service all the permits are retuned and cancelled.

PMI Revision 01 30
Supply Normalisation
G Station TRF-1

UAT-A UAT-B
16.5 KV

6.6 KV
GT Stn. SWGR-SA 6.6 KV SB

UNIT SWGR--A
UNIT SWGR--B
Stn Serv
UST Trf-A Fdr to
DMP Serv
A N.O. Clarif
Trf
BFP Water
S/Serv.
ID Fan UST-B ESP TRF-B SWGR 1)SWYD
ESP TRF-A Trf.-B Serv
X X Trf-1
USS-A B.C. USS-B 415 V Unit EMG SWGR 2)Ash
Air Compr X
Handl T/F
Trf X X
Turb MCC X 1600KVA
Blr MCC TMCC
From DG SWGR
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Before starting any
equipment..

ENSURE
No PTW is pending on the equipment which is to be
normalized.

Equipment is properly boxed up and no maintenance staff


working.

Local operator is informed before the equipment is started.

Local operator has given clearance for starting the


equipment.
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Pre start checks
before light up

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Before Light up
Equipment cooling water is charged in boiler side and
proper venting is done.

Service water /filter water for sealing in the boiler bottom


is charged .Get the clearance from AHP for sealing of
bottom hopper.

Service and instrument air is charged and air for SADC


and burner tilt are charged .

Fire water/ sprinkler water system is charged and it is


available in boiler area for handling any fire emergency.

PMI Revision 01 34
Before Light up
DM water is available for boiler drum filling.

Ensure the availability of aux. steam .

Ensure 6.6 kV/11 kV, 415 volt , 220 volt DC,110 V AC, 24
V DC SUPPLIES are normal . Ensure that all MCC s are
charged. Both buses are charged independently and Bus
coupler is in OFF position .ensure all chargers are in
charged condition and all the batteries are in healthy
condition .

All unit protections/interlocks ( boiler ,turbine & generator )


are checked and recorded in the protection register .

PMI Revision 01 35
Before Light up
Start LDO PUMP or charge LDO line upto firing floor if
other units are running.

Start HFO pump or charge charge HFO line upto firing


floor on long recirculation if other unit is running. also inform
other units .

charge atomising air and atomising steam lines.

Keep boiler drum vents,SH vents , SH drains ,CRH drains,


HRH drains open.

Ensure all low point drains are closed .

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Before Light up
Inform shift chemist to take water sample before water
filling in the boiler and take clearance from shift chemist.
Inform him to prepare hydrazine , ammonia and phosphate
solution for dosing . Check availability of all LP and HP
dozing pumps .

Fill water in the boiler upto normal level by running one


BFP.

Ensure at least two ESP passes are clear and their inlet /
outlet gates are open. Elect. Supply of fields are kept off .

Inspect the boiler up to drum floor . Ensure that all


manholes /peepholes are closed.

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Before Light up

Ensure start up vent and ECO recirculation valve are open.

Charge the SCAPH LINE .

Keep the burner tilt at 0 deg ( horizontal )

Ensure boiler and auxiliaries areas are clean , safe and


properly illuminated .

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THANK YOU

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