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NTPC

Rihand
Rihand Super Thermal Power Project- Stage#2

Operation steps of LIGHT UP & ABO


SN Activity

Remarks

Ensure the followings:

Establish Telephone communication at Drum Level & Firing Floor

Ensure Fire Fighting personals present at firing floor with fire extinguisher.

Check Emergency Operating

Note- Phone no. of Fire- 4444/2221/2222


Phone no. of Ambulance- 4333

Drum level indicator operator from BHEL/TPL- Name-----------------------------------------Phone nos. of Commissioning DepartmentSh. M.L.Patra- 9415342329

Sh. Rajaraman- 9415629099

Sh. T.K.Seal- 9415342361

Sh. D.Sahu-

Sh. S.K.Singh- 9415342396

Sh. R.N.Varma-9415342381

9415342366

Run Fire Hydrant Pump and check line-up

Run CW 3C & CW 3B

Run ACW 3B

Run Boiler ECW 3A

Run Turbine ECW-3A & 3B

Run one IAC & one SAC

Check PRDS, Line-up Steam for SAPH & Chemical water heating
system

Run SAPH 3ACheck fire fighting system


Soot blowing of CE & HE ready & start the sootblowing & Continue.
Check the operation of air and gas side dampers of SAPH 3A

Line up air & flue gas path

10

Run ID fan 3A

11

Run FD fan 3A

12

Check DC scanner air fan healthiness and then run of AC scanner air fan

13

Maintain furnace to windbox DP of 40 mm of wc & furnace draft of 5


to 10 mm wc, air flow between 30% to 40 % (540 720 T/hr)

14

Establish flue gas, air path, Metal temp. and other instruments.

15

Open drum vents.

16

Open super heater vents

17

Open MS line drain to IBD(presently to storm water drain)

18

Open superheater drains

19

Check drum and super heater and MS line safety valves not gagged.

20

Check the operation of SH start up vents from CCR once again

21

Open Eco recirculation valve E20

22

Take readings of boiler expansion prior to filling

23

Prepare chemical water in chemical preparation tank of 60 m3 DM water


from stage I through boiler fill pump ,add TSP 60 kg ,add DSP 30 kg
,start heating through steam from aux PRDS and run chemical pumps on
recirculation till a temp of 50 deg is achieved.

Maximum boiler vol

Check the chemical solution concentration of 500 ppm of DSP and 1000
ppm of TSP is achieved.

Total TSP reqd-350 tons

Note: Check that the the filling line discharge valve remains closed.

24

Run MDBFP on recirculation, discharge valve open, feed regulating


valve closed (feed regulating operation checked),eco inlet and
recirculation valve closed ****

25

Line up BCW pump 3A ,3B,3C .establish HP purge and fill line(from


MDBFP) by opening the valve in crack open position. Establish
emergency cooling water system.

26

Fill the boiler through bottom ring header drain, eco line drain ,eco inlet
header drain, BCW suction lines ,( BCW discharge valve closed ) by
chemical dosing pump till the minimum level of tank as marked at
viewglass of tank .

=Drum +water walls +eco=60


+95+175=330 tons

Total DSP reqd-175 tons


Check chemical quality from
chemist(DM plant)

Take the samples from CBD


sample point at 22 m.

27

Repeat this process( Step 21 & 24) 5 to 6 times till the drum level reaches
to 100 mm above NWL.

28

Establish drum level indication (Local & Remort)

29

Open BCW discharge valves .Start BCW 3A maintain the drum level, top
up drum of required through chemical water pump.

30

Start BCW 3B & 3C, establish drum level 100 mm above normal level
through chemical treated water. Close isolating valve of chemical water
supply line.

31

Take expansion readings of boiler after filling

32

Establish LDO fuel oil system upto firing floor (AB elevation)

33

Check Boiler protection

34

Purge the boiler .Rest MFT

35

Take guns to raise the water temp, raising should not be more than 100
deg C/hr and pressure raising should not be more than 1.5 ksc /hr

36

At 1.5 kg drum pressure close the air vents of drum and SH except SH
start up vent

37

Close SH drain when drum pressure raises to 8 ksc

38

Maintain the drum pressure at 5 ksc, take boiler expansion reading.


Maintain the drum pressure at 10 ksc, take boiler expansion reading.
Raise the drum pressure up to 20 ksc slowly as per the increase rate
specified at #above and maintain it at 20 ksc , takeboilerexpansion
reading.
Raise the drum pressure up to 30 ksc as per the increase rate specified
at #above and maintain it at 30 ksc , take boiler expansion reading.
* In this process if drum level goes low take water from D/A through MD
BFP.

39

Take the drum samples from CBD sample point

40

Raise the drum pressure up to 40 ksc as per the increase rate specified at
#above and maintain it at 40 ksc , take boiler expansion reading, hold 40
ksc for 4 hrs.Collect water samples from CBD sample point for analysis
of alkalinity ,phosphate content ,dissolved silica and oil content.

41

Kill the fire in the boiler ,give blow down of 1 minute through bottom
ring header drain to IBD(front).Ensure drum level does not go out of
vision in gauge glass.(DWLG at drum)

Mark NWL in CCR indicator

42

Raise the drum level through MDBFP, Repeat the operation of raising the
drum pressure to 40 ksc ,then hold it for 2 hrs.give blow down though
bottom ring header drain to water wall drain header, for 1 minute after
killing fire.(drum level should not go below the visible level)check the
water samples from CBD SAMPLE POINT

43

Repeat the same procedure and give blow down through ECO line drains
& ECO inlet header drain

44

During this process if phosphate concentration drops to half of the initial


value, dose additional chemicals through phosphate dosing system to
achieve original concentration.

45

The boil out is declared complete when the oil contained in analyzed
sample is less than 5 PPM or minimum eight blow downs (in same
sequence) are completed whichever is latter.

46

Box up the boiler keeping BCW pumps in service. Allow the boiler to go
under natural cooling ( ID suction & FD discharge open.). Stop LDO
Pump and corner manual isolating valves.

47

Stop BCW A&C at pressure 5 KSC

47

Keep at least one BCW pump running at drum pressure below 2 Ksc and
bring water level to normal.

48

Open drum vent when Press. is 1.5 Ksc

49

Bring the water level in the drum to lower most visible port in the gauge
glass and stop the last BCW

50

Drain the boiler after attaining the desire cooling at down comer and
suction manifold of 93 deg. C

51

Fill the boiler with hot 80 deg C DM water through chemical feeding
pump upto lowest port of drum.

52

Back flush the S/H with DM water containing 200ppm hydrazine and PH
raised to 10 with ammonia till it overflows into drum. Collect the sample
from the sampling points of S/H Header and low point drains for testing.

53

Drain the boiler through IBD.

54

Continue the filling & draining for rinsing till the phosphate contain in
sample is less than 2 ppm.

55

Stop HP purge and fill water supply to BCPs.

56

Inspect lower & Upper drums and manually clean them.

Note:-Before you change any of the operating instruction, give information to Sh. M.L.Patra.

D.Sahu(SS, Commg.)
Location

Group A

Group B

Team Leader

Sh. D.Sahu

Sh. S.K.Singh

ID, FD, Bottom ash hopper, LDO Pump house

Sh. S.M.Sinha

Sh. S.Seth

SAPH 3A

Sh. Kundan

Sh. Mandal

Boiler Drum, Firing floor, Boiler filling, Scanner air


fan, BCP
Chemical Tank & Sampling

Sh. Morris

Sh. Harbindar

Chemistry

Chemistry

ACW, ECW, IAC, SAC, HP Dosing, MD BFP


Control room

Sh. Chauhan & Sh


Umesh
Sh. Manish + 2 ET

Sh. Niranjan & Sh


Manish(ET)
D.K.Das + 2 ET

Boiler Expansion

Sh. Lakhra

Sh. Mandal & Sh Somesh

Fire fighting & CW pump house

Sh. P.M.Singh

Sh. Satish

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