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STANDARD MAINTENANCE SMP NO : SMP-ESI-

RIL- DMD PROCEDURE CCPP-ZT-


SECTION: INSTRUMENTATION 001

STANDARD MAINTENANCE PROCEDURE

FOR

MAINTENANCE OF SMART VALVE POSITIONER

Amendment Status

S.NO Issue no Revision no. & Date Reason for change

1 01 New Issue

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VALIDATED BY: PCJ PLANT: ISSUE : 01
DATE : 19.09.2015
APPROVED BY: AUTHOR: ASHISH SINGH
STANDARD MAINTENANCE SMP NO : SMP-ESI-
RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

A) TITLE:

SMP for Maintenance of SMART Valve Positioner (E/P).

Introduction:-

Valve Positioner is a position controller device that is mechanically connected to a moving part of
a final control element or its actuator. It automatically adjusts its output to the actuator to maintain
a desired percentage of valve opening/closing in proportion to the input signal .

SMART Positioner mounted on a Valve

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STANDARD MAINTENANCE SMP NO : SMP-ESI-
RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

The smart positioner is a block-based device. Major blocks are as follows:


Resource Block
Transducer Block
Function Blocks
Analog Output (AO) Function Block
Discrete Output (DO) Function Block
Proportional-Integral-Derivative (PID) Function Block
Input Selector (ISEL) Function block
Output Splitter (OS) Function Block
Analog Input (AI) Function Block
Multiple Analog Input (MAI) Function Block
Discrete Input (DI) Function Block

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STANDARD MAINTENANCE SMP NO : SMP-ESI-
RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

Parts of SMART Valve Positioner

B) SCOPE:
This document describes the procedure for calibration and preventive maintenance of
SMART Valve Positioner.
Procedure for Hammer Reversing Records to be maintained Competency requirements
for job execution Responsibility Matrix for job execution & document review/up
gradation.

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RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

C) SAFETY, HEALTH & ENVIRONMENT:

A) Safety:

SSAFETY ALERT Hazard Precaution

1 Slip and fall hazard Use platform/Safety Belt for opening of bolts at
height,
Keep area clean and dry.
2 Burn Due to Fly ash Hot Use Proper PPEs,
Pipes Ensure all inspection ports are closed before trial.

B) Health:

HEALTH
S.No. Hazard Precaution

1 Ergonomics Operating of Use standard valve keys,


valves can result in back Use hand gloves while opening bolts and casing
injury, injury to arms removal,
2 Heat stress & dehydration Immediately shift victim under the shed,
Allow him to take rest & drink plenty of water.
3 Inhalation of Fly Ash dust Use nose mask,
Arrest lime dust leakages on priority.

Environment:

ENVIRONMENT
S.No. Hazard Precaution
ALERT

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STANDARD MAINTENANCE SMP NO : SMP-ESI-
RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

1 Fly Ash Ensure all joints are provided with proper gasket/rope packing and
Spillage suitable fasteners,
Ensure bolt tightness as per standard practice,
Barricade the area where lime is to be discharged in to dumper.

Use proper tools (mainly torque wrench and ring-spanner) as per manual.
Avoid nonstandard tools.

3. Applicable HSEF Procedures for the job are mentioned below:

3.1 RIL-PG Work Permit Procedure: RIL/PG/PWP/001


3.2 RIL-PG Lockout/Tag out Procedure: RIL/PG/DSR/01
3.3 RIL-PG Requirement of PPEs: RILP/PG/DSR/R&P/001

4. FIRE HAZARD
CONTROL MEASURES

FIRE ALERT
1. Ensure that equipment on which job to be carried out is positively isolated and cleaned

2. Ensure there is no Leakage o Fly ash From Conveying Line in the vicinity.

D) GENERAL:
1. Before starting the work authorized work permit must be available with executor.
2. Contact area operator with permit before starting and after completion of job.
3. Helmet, safety goggles, gloves and safety shoes with steel toe are mandatory PPEs
during execution of the job. In addition to the above any additional PPEs mentioned
in the permit to work shall be complied with.
4. Before starting the work, Ensure hammer mill is isolated, emptied and de-energized.
Ensure tag is displayed on electrical switchboard.

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STANDARD MAINTENANCE SMP NO : SMP-ESI-
RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

5. Carry out housekeeping around the hammer mill to avoid falling hazard and look for
chances of striking against objects due to nearby process lines while working. Ensure
work area is free from oil or any spillage.
6. Attach risk assessment sheet along with work permit.
7. Conduct toolbox talk for possible hazard involved and safety control measures which
are mentioned in RA sheet before execution of the job.

CAUTION! Ensure power is isolated and Tripping Interlock are bypass from PLC or
DCS
CAUTION
E) Tools / Tackles/Testing& Measuring instruments
Following is the standard list of tools and tackles required and the checks to be
Performed while using them.

HART Communicator
Loop Calibrator / ma Feeder
Digital Multi-meter (IS)
Screw driver set
Long nose pliers
Permanent marker
Minus screw driver set
Set of fixed D-spanners.
Allen key set ( inch & mm )
Snoop solution for leak test
Insulation tape
Tube cutter
Scrap cloth

F) Document & Drawing


1. OEM Manual for Smart Positioner
2. Data Sheet of Control Valve
3. GA Drawing of Instrument Device

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RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

G) Spares & Consumables.


For spares refer to attached BOM to tag in SAP. Some common spares Housing
Module Base
I/P Converter Assembly
Relay
Terminal Box
Remote Terminal Box
Mounting Kit
Pressure Gauges, Pipe Plugs, or Tire Valve Assemblies
Feedback / Remote Travel Sensor Parts
O-rings
Bias spring for positioner feedback link

H) Prerequisites
1. Basic Electronic / Instrumentation Maintenance training.
2. Knowledge about locations of Instruments.
3. Knowledge and interpretation of P & IDs.
4. Knowledge of associated hazards.
5. Only qualified / competent personnel should work on this equipment after
becoming thoroughly familiar with all warnings, safety notices and maintenance
procedures contained herein.

I) Job Procedure:

1. Installation Procedure

Before Starting the Job


1) Ensure power supply isolation before starting the job.
2) Select the smart valve positioner as per design recommendation.

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STANDARD MAINTENANCE SMP NO : SMP-ESI-
RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

3) Isolate the control valve from the process line pressure and release pressure from both
sides of the valve body. Shut off pressure lines to the actuator, releasing all pressure from
the actuator.

2. Mounting:

Select the mounting side which has enough space of accessibility for maintenance activity.
Attach the mounting bracket to the Actuator body of the control valve.

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RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

Mount the digital valve controller on the actuator as described in the mounting kit
instructions supplied by OEM.
Set the position of feedback arm, considering valve operation, Air to Open/Close valve.
Ensure there is enough clearance between the adjustment arm and the feedback arm to
prevent interference with the bias spring.
For long-stroke sliding-stem actuators, after the mounting is complete, check to be sure
the roller aligns with the position mark on the cam (If necessary, reposition the cam to
attain alignment.

3. Pneumatic connections:
Check the valve datasheet for single acting or double acting type of valve. For Single acting
only one output port is required. For double acting both output ports are used.
Check appropriate diameter of tube and check for conformity from air supply to valve and
tubing between positioned and valve accessories.
Choose among pneumatic connection material: [SS/Copper tube/flexible tube]
considering following points.

Copper Tube:
a) Normally used for pneumatic application.
b) It is flexible and can be easily bent.
c) It cant be in very high temperature area due to low melting point.

SS Tube:
a) High resistance to corrosion and oxidation
b) High resistance high temperatures
c) Easy to clean and requires low maintenance costs
d) It requires a tube bender and not flexible at all.

Make connection as per schematic provided in the design.

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RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

Install an AFR in air supply line of appropriate filter level (40-50 micrometres /5 micro
meter).
Install a needle valve in the air supply before the AFR for easy maintenance and faulty
opening/closing of other valve.
If tubing is more than 1.0 m then, provide appropriate support.
Use minimum no. of tube bents and joints.
Check tube is not touching any hot surface nearby say valve body.
The relay output constantly bleeds supply medium into the area under the cover. The vent
opening at the back of the housing should be left open to prevent pressure build-up under
the cover.

4. Electrical Connections:

Use proper gland and leave sufficient cable for preventing moisture entry by making U
shape or a Ring O before the gland.
Make connection as per OEM recommendations.
Maintain the polarity (+ve) and (-ve) while termination.
Connect the safety earth to the earth ground.

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RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

5. Calibration of valve positioner

1) Switch on the power supply, measure the voltage at terminal box, it should be in
between 9-32 volts.
2) If air supply is provided for the first time, flush air for sometime to remove any dust
particle or debris in the tube.
3) Provide air supply and adjust pressure to design requirement using AFR.
4) Connect the valve calibrator (say 375 Communicator) in the terminal box.
5) Once the new valve is (in live list) available in Hand held Communicator, start the basic
calibration setup. It consists of following three steps:
A) Device Setup
B) Auto Travel calibration
C) Performance tuning

A. Device Setup

1) Before starting the device setup put the transducer block mode in Manual.
2) Basic structure to enter is: TB Configure/Setup Basic Setup Device Setup
3) Enter all valve basic details as enquired by the set up:

a) Pressure units: kPa, bar, psi, inHg, inH2O, or Kg/Cm2.


b) Enter the maximum instrument supply pressure and output pressure range (if required).
c) Travel Length, Bench set pressure.
d) Actuator model or type/ size
e) Presence of accessories like Volume booster
f) Actuator style like spring and diaphragm piston single acting/double acting
g) Valve style sliding stem or rotary
h) Zero Power condition.

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RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

B. Auto Travel calibration:


After device setup, travel calibration starts.
1) Checks air supply pressure.
2) During calibration, the instrument seeks the high and low end points by searching for
the end points; the instrument establishes the limits of physical travel, i.e., the actual
travel 0 and 100% positions. It determines how far the relay beam swings to calibrate the
sensitivity of the beam position sensor.
3) The valve position is briefly moved back and forth to determine the relay beam position
at quiescence. Essentially, it establishes the zero point. The back and forth motion is
performed to account for hysteresis. Adjusting the output bias aligns the travel set point
with the actual travel by computing the drive signal required to produce 0% error. This is
done while the valve is at 50% travel, making very small adjustments.
4) After completion, there is an option of stroke checking of the valve.

C. Performance Tuning:
Performance Tuner is used to optimize digital valve controller tuning. It moves the valve
slightly and monitors the effects of small tuning changes until an optimum control
response is achieved. Since the Performance Tuner can detect internal instabilities before
they become apparent in the travel response, it can generally optimize tuning more
effectively than manual tuning.

Crossover Adjustment
Crossover point: It is the mid-point of the stroking range of a sliding-stem actuator. A
visual indication of proper fixing of the positioner feedback link is that the crossover point
is found when the slot in the instrument feedback arm forms a 90- degree angle with the
valve stem.
Setting crossover establishes the zero degree point for the geometric correction used to
translate the rotary motion observed by the travel sensor into the linear motion of the
sliding-stem valve.
Crossover adjustment is required if the feedback is broken or bent or new assembly is
installed.

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RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

6. Dos & Donts

1) Valve must be put in manual mode before starting maintenance activity on Valve.

2) Do not remove the actuator from the valve while the valve is still pressurized.

3) Power must be switched off while installation/replacement of positioner.

4) Turn off the supply pressure to the positioner and bleed off any excess supply pressure
before attempting to remove the module base assembly from the housing.

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RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

5) Take special care while handling positioner specially the feedback assembly parts. Bias
spring connected with feedback arm is a must for proper feedback.

6) After replacement or reinstallation of any part/module or in case of a new installation


calibration is a must.

7) While module replacement, do not bump or damage the bare connector pins on the
PWB assembly. Damaging either the module base or guide surface may result in material
damage, which could compromise the instruments ability to maintain a pressure seal.

8) While module replacement inspect all O-rings for wear and replace as necessary.

9) After calibration, fail safe condition of valve must be checked.


Removing the power supply
Reducing the air supply pressure.
If volume tank is present, ensure its working in fail safe condition.

10) Supply air pressure must be regulated and filtered by AFR. This should not exceed the
design pressure to prevent any damage to the positioner.

11) In case of installation, air supply and tubing must be flushed thoroughly to remove any
dust or debris present in the tube.

12) Ensure that the housing vent opening is open and free of debris to prevent pressure
build-up under the cover.

13) While transportation /storage control valve ensure that the control valve does not rest
on the valve positioner. Else valve weight can damage the positioner parts.

14) If the vent appears to be clogged, the vent should be removed, cleaned and replaced.
Lightly brushing the exterior of the vent can be done to remove any contaminant.

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RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

J) AUTHORITY FOR DEVIATIONAND CHANGES


1 Deviations to safety requirements outlined in the SMP shall be approved by HOD-PX.
2 Deviation to SMP and tolerances in checklist shall be authorized by PX maintenance head.

K) RECORDS
1 Filled copy of checklist.
2 Notification to capture the history & fail code.
3 Work order to capture material & service cost.
4 Update entry in SAP

L) REFERENCES
1 OEM Manual.
2 RIL Safety Procedure

M) REVIEW & UPDATING


The above prepared SMP shall be reviewed once in 3 years or, whenever there is any
change in procedure / modification applicable to the area / equipment, whichever is earlier.

N) DISTRIBUTION
1. Instrument Engineer : Hard copy
2. Sectional Head : Hard copy
3. Control Room : Hard copy
4. CES Planning Engineer : Hard copy

O) EXPERT ADVICE:
Instrumentation Dept. Can be contacted for any clarification regarding SMART Valve
Positioner.

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RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

P) ANNUXURE-1: Tag list SMART Valve Positioner used in CCPP

POSITION TRANSMITTER TAG


DESCRIPTION
NO.

JE-DSAB00-ZT-BHB-153 BOILER STEAM PRDS TRAIN-1 PCV


JE-DSAB00-ZT-BHB-154 BOILER STEAM PRDS TRAIN-2 PCV
JE-DSAB00-ZT-BHB-160 BOILER STEAM PRDS TRAIN-2 TCV
JE-DSAB00-ZT-BHB-159 BOILER STEAM PRDS TRAIN-1 TCV
JE-DSAE00-ZT-BHB-212 SPRAY WATER TRAIN-2 TCV
JE-DSAB00-ZT-BHB-203 AUXILIARY STEAM PRDS TRAIN-1 PCV
JE-DSAB00-ZT-BHB-204 AUXILIARY STEAM PRDS TRAIN-2 PCV
JE-DSAE00-ZT-BHB-210 SPRAY WATER TRAIN-1 TCV
JE-DSAB00-ZT-BHB-253 DEAERATOR PEGGING STEAM PRDS TRAIN-1 PCV
JE-DSAB00-ZT-BHB-254 DEAERATOR PEGGING STEAM PRDS TRAIN-2 PCV
JE-DSAE00-ZT-BHB-262 SPRAY WATER TRAIN-2 TCV
JE-DSAE00-ZT-BHB-260 SPRAY WATER TRAIN-1 TCV
JE-DSSA01-ZT-BHB-307 DEAERATOR PEGGING STEAM PRDS CV
JE-DSSA01-ZT-BHB-317 FW STORAGE TANK BYPASS PRDS PCV
JE-DSSA01-ZT-BHB-307 DEAERATOR PEGGING STEAM PRDS CV
JE-DSSA01-ZT-BHB-317 FW STORAGE TANK BYPASS PRDS PCV
JE-DSSA01-ZT-BHB-307 DEAERATOR PEGGING STEAM PRDS CV
JE-DSSA01-ZT-BHB-317 FW STORAGE TANK BYPASS PRDS PCV
JE-DSAD01-ZT-BHB-401B LCV TO MINIMUM RECIRCULATION
JE-DSAD01-ZT-BHB-401A LCV TO CONDENSATE FORWARDING TANK
GLAND STEAM COND. TO CIRCULATING WATER SYSTEM
JE-DSAD01-ZT-BHB-401C CV
JE-DSAD01-ZT-BHB-401D CONDENSER MAKEUP CV
JE-DSAD02-ZT-BHB-401B LCV TO MINIMUM RECIRCULATION
JE-DSAD02-ZT-BHB-401A LCV TO CONDENSATE FORWARDING TANK
GLAND STEAM COND. TO CIRCULATING WATER SYSTEM
JE-DSAD02-ZT-BHB-401C CV

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JE-DSAD02-ZT-BHB-401D CONDENSER MAKEUP CV


JE-DSAD0-3-ZT-BHB-401B LCV TO MINIMUM RECIRCULATION
JE-DSAD0-3-ZT-BHB-401A LCV TO CONDENSATE FORWARDING TANK
GLAND STEAM COND. TO CIRCULATING WATER SYSTEM
JE-DSAD0-3-ZT-BHB-401C CV
JE-DSAD0-3-ZT-BHB-401D CONDENSER MAKEUP CV
JE-DSAD01-ZT-BHB-501 S-1 CONDENSATE FOWRWARDING TANK LCV
JE-DSAD01-ZT-BHB-601 DEAERATOR-1 COND LCV
JE-DSAD02-ZT-BHB-501 S-1 CONDENSATE FOWRWARDING TANK LCV
JE-DSAD02-ZT-BHB-601 DEAERATOR-1 COND LCV
JE-DSAD0-3-ZT-BHB-501 S-1 CONDENSATE FOWRWARDING TANK LCV
JE-DSAD0-3-ZT-BHB-601 DEAERATOR-1 COND LCV
JE-DSAF01-ZT-BHB-701A S-1 HPH2 LCV
JE-DSAF01-ZT-BHB-711A S-1 HPH1 TO DEAERATOR LCV
JE-DSAF01-ZT-BHB-711B S-1 HPH1 FLASH TANK LCV
JE-DSAF01-ZT-BHB-701B S-1 HPH2 TO DEAERATOR LCV
JE-DSAF01-ZT-BHB-701C S-1 HPH2 TO FLASH TANK LCV
JE-DSAF02-ZT-BHB-701A S-1 HPH2 LCV
JE-DSAF02-ZT-BHB-711A S-1 HPH1 TO DEAERATOR LCV
JE-DSAF02-ZT-BHB-711B S-1 HPH1 FLASH TANK LCV
JE-DSAF02-ZT-BHB-701B S-1 HPH2 TO DEAERATOR LCV
JE-DSAF02-ZT-BHB-701C S-1 HPH2 TO FLASH TANK LCV
JE-DSAF03-ZT-BHB-701A S-1 HPH2 LCV
JE-DSAF03-ZT-BHB-711A S-1 HPH1 TO DEAERATOR LCV
JE-DSAF03-ZT-BHB-711B S-1 HPH1 FLASH TANK LCV
JE-DSAF03-ZT-BHB-701B S-1 HPH2 TO DEAERATOR LCV
JE-DSAF03-ZT-BHB-701C S-1 HPH2 TO FLASH TANK LCV
JE-DSAF01-ZT-BHB-751A S-1 LP HEATER 3 LCV
JE-DSAF01-ZT-BHB-761A S-1 LP HEATER 2 LCV
JE-DSAF01-ZT-BHB-751B S-1 LP HEATER 3 LCV
JE-DSAF01-ZT-BHB-761B S-1 LP HEATER 2 LCV
JE-DSAF02-ZT-BHB-751A S-1 LP HEATER 3 LCV

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STANDARD MAINTENANCE SMP NO : SMP-ESI-
RIL- DMD PROCEDURE CCPP-ZT-
SECTION: INSTRUMENTATION 001

JE-DSAF02-ZT-BHB-761A S-1 LP HEATER 2 LCV


JE-DSAF02-ZT-BHB-751B S-1 LP HEATER 3 LCV
JE-DSAF02-ZT-BHB-761B S-1 LP HEATER 2 LCV
JE-DSAF0-3-ZT-BHB-751A S-1 LP HEATER 3 LCV
JE-DSAF0-3-ZT-BHB-761A S-1 LP HEATER 2 LCV
JE-DSAF0-3-ZT-BHB-751B S-1 LP HEATER 3 LCV
JE-DSAF0-3-ZT-BHB-761B S-1 LP HEATER 2 LCV

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