Jindal Power Limited

O.P.J.S.T.P.P, Tamnar, Raigarh

Commissioning Department

Project OPJSTPP (4X600 MW), Tamnar

Procedure HP Dosing System
Purpose of Document For Execution/Information
Document No. JPL Reference No: Boiler/Comm./032

Prepared By - Reviewed By -
Rev No. 00
Dtd: Commissioning Commissioning Project

Name

Sign

Approved By :
HEAD – Steering Committee

Copy No:

Issued To:
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Boiler/Comm./032
Plant Area: Boiler

Commissioning Procedure for HP Dosing System

SL. NO. CONTENTS

1.0 PLANT DETAILS

2.0 OBJECTIVE

3.0 PROPOSAL

4.0 SERVICES REQUIRED

5.0 SAFETY PRECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STATE OF THE PLANT

8.0 METHOD

9.0 COMPLETION CRITERIA

10. APPENDICES
a) DRAWINGS
b) LOG SHEET

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Boiler/Comm./032
Plant Area: Boiler

Commissioning Procedure for HP Dosing System

SL. NO. STATUS

1.0 PLANT DETAILS

The HP Dosing System consists of the

following:

1.1 1 No. Mixing Tank with Agitator

1.2 1 No. Metering Tank

1.3 2 Nos. Pump with Motor (Positive Displacement

pump) ( With stroke adjustment )

1.4 2 Nos. Suction Filters

1.5 2 Nos. Relief Valve

1.6 Inlet DM Water connection to Mixing and Metering

Tank

1.7 Level Gauges for Mixing and Metering

Tank

1.8 Local Instrumentation

Plant Item Completion List for

Mechanical, Electrical and C&I are to
be prepared at site.

1.9 The Schematic of HP Dosing System is enclosed in

Subsection 10.0
(Drawing No. 4: PS : TSX : 0066:00 Dt.
23.07.2001

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Boiler/Comm./032
Plant Area: Boiler

Commissioning Procedure for HP Dosing System

SL. NO. STATUS

2.0 OBJECTIVES

2.1 To commission HP dosing system and make it

available for unit operation.

3.0 PROPOSAL

3.1 The Commissioning of HP Dosing System is carried

out as follows:

a) Flushing of Mixing, Metering Tanks and upto

Pump Station with DM Water.

b) Pump trial run, Relief Valve setting and C&I

System .

c) To commission the remote stroke

adjustment system

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Boiler/Comm./032
Plant Area: Boiler

Commissioning Procedure for HP Dosing System

SL. NO. STATUS

4.0 SERVICES REQUIRED

4.1 Availability of manpower with required tools for

attending to any leak, cleaning of filters.

4.2 Availability of operating personal to

co-ordinate the activities.

4.3 Availability of lighting arrangement in and around

the HP Dosing System.

4.4 Availability of portable fire fighting equipment

near the dosing system.

4.5 Availability of sufficient quantity of DM Water.

4.6 Availability of LT Power Supply.

4.7 Availability of Chemicals.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Boiler/Comm./032
Plant Area: Boiler

Commissioning Procedure for HP Dosing System

SL. NO. STATUS

5.0 SAFETY PRECAUTIONS

5.1 Goggles, Apron, Hand-gloves for handling

chemicals.

5.2 Bunding & draining arrangements are properly

done to take care of spillages.

5.3 First aid kid is available at test area.

6.0 EMERGENCY PROCEDURE

6.1 The operating staff should know about the normal

operating procedure to be adopted in case of
damage to machinery or injury to any person
connected in the activity.

6.2 The test team should be well aware of procedures to

be adopted in case of any abnormality in the
activity.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Boiler/Comm./032
Plant Area: Boiler

Commissioning Procedure for HP Dosing System

SL. NO. PLANT DETAILS STATUS

7.0 STATE OF THE PLANT

7.1 HP Dosing Systems are erected as per

recommended drawing.

7.2 Mixing and Metering Tanks are cleaned with DM

Water and filled upto normal operating level.

7.3 LT power supply system for Pumps, are

commissioned and available for operation.

7.4 Required Local/Remote I&C Inputs are made

available.

7.5 DM Water connections to Mixing Tank, metering

tank and to lines (for flushing) are ready.

7.6 Lubricating oil is filled in the pump gear box up to

its normal level / Indication.

7.7 Suction filters are cleaned.

7.8 Tank Drains and Pump Relief Valves are

terminated as per scheme.

7.9 The test area is cleaned and proper approaches

are available.

7.10 HP dosing system are erected with proper

bunding and draining facility to contain any
spillage.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Boiler/Comm./032
Plant Area: Boiler

Commissioning Procedure for HP Dosing System

SL. NO. STATUS

8.0 METHOD

8.1 FLUSHING OPERATION

The Mixing & Metering Tanks along with suction

pipe upto pump to be flushed with DM Water so
as to avoid the entry of dust into the pump.

8.2 PREPARATION:

Disconnect the pump suction connection flange

and connect the suction line with hose to nearby
drain. Remove the suction filters and make the
suction line through.

8.3 PROCESS

8.4 Fill the Mixing and Metering Tank with DM

Water.

8.5 Open the pump suction valve and flush the

system until clear water noticed in the temporary
hose.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Boiler/Comm./032
Plant Area: Boiler

Commissioning Procedure for HP Dosing System

SL. NO. STATUS

8.6 Normalise the suction connection to pump.

8.7 Bump the motor (in decoupled condition) and check

the direction of rotation.

8.8 Trial run the motor for 2 hours and couple with the
pump.

8.9 Fill the Mixing and Metering Tank upto normal

level.

8.10 Open the Pumps Suction, Discharge and Re-

circulation valve.

8.11 Close the valve in the line going to boiler.

8.12 Ensure the suction & discharge gauges are installed

and the respective valve cocks are opened.

8.13 Keep pump stroke to minimum and start the pump

and observe discharge pressure.

8.14 Increase the pump stroke gradually to 100% and

observe pump performance.

8.15 Trial run the pump for 4 hours and maintain the
tank level keeping the pump stroke around 50%.

8.16 Commission the remote stroke adjustment system (if

provided) and operate and observe its performance.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Boiler/Comm./032
Plant Area: Boiler

Commissioning Procedure for HP Dosing System

SL. NO. PLANT DETAILS STATUS

8.17 Set the relief valve by throttling the R/C Valve.

(The set pressure to be around 10 KSC more than
the working pressure of the system)

8.18 Stop the pump.

8.19 Ensure the Agitator is coupled with motor.

8.20 Bump the Agitator and check the direction of

rotation.

8.21 Trial run the Agitator for 2 Hours.

9.0 COMPLETION CRITERIA

Commissioning of HP dosing system completed

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

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Boiler/Comm./032
Plant Area: Boiler

Commissioning Procedure for HP Dosing System

LOG SHEET
Date:

PROJECT :
UNIT :
ACTIVITY:

Sl. Date / Time Pump in Discharge Mixing/Meterin Gear Remark

No. service Pressure g Tank Level Box Oil
Kg/cm2 in Mn.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Boiler/Comm./032
Plant Area: Boiler

Commissioning Procedure for HP Dosing System

COMMISSIONING PROCEDURE FOR

HP DOSING SYSTEM
4X600MW, JPL, TAMNAR

Signatures

JPL BHEL