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Permit to work system

Different types of
Maintenance of Power Plant
and its cost effectiveness
Maintenance Planning
Power Plant Operation
Permit to Work System
PTW is a printed form and issued to
employee before they may work on
specified equipment.
Objective is to ensure safety of employee
PTW is Guarantee of Safety
Steps/ Arrangement while
issuing
PTW
 PTW should be issued only against the
presentation of an isolation request by
maintenance Department Except in case of
emergency.
 Person presenting himself to collect PTW
should be fully familiar with the job and details
of work to be done
 All Copies of PTW must be signed both at
Receipt and Clearance
 Receipt and Clearance signature must be made
in presence of Shift Charge Engineer/ Unit
incharge
 PTW should be signed for clearance by the
person who signed for receipt
Steps/ Arrangement while
issuing
PTW …….contd
 Whenever a job is permanently transferred
from one person to another, the permit should
be cancelled and reissued.
 The PTW is cancelled and reissued when
change in isolation become necessary
 Work on medium/ low voltage equipments
should be done when they are dead.
 At least two isolation should be in service in
case of electrical Permit
 “Do Not Operate” caution board should be put
on desk on control station of equipments under
PTW
Steps/ Arrangement while
issuing
PTW …….contd
 An emergency Job Card should be opened by
operation department giving details of work in
case of Emergencies
 Operation representative has to deliver the
equipment to maintenance section ensuring all
safety
 Operation representative must ensure that job
has been carried out properly before taking
back the PTW.
 Operation representative must ensure that
there is no danger before charging the
equipment/ System
At Work
Maintenance person should must ensure
that PTW has been issued for their own
safety
It is responsibility of all persons on site to
ensure that they do not start work on
equipments for which a PTW is necessary
untill PTW is issued.
Role of Operation Engineer
Safety of equipment
Safety of Persons
Generation of Electricity at economic cost
Keeping generation within the declared
schedule
Start up and shut down of equipments in
safe and systematic manner
Role of Operation Engineer
….Contd.
Maintaining the parameters within
prescribed limit
Physical Inspection of equipment to
observe Noise, Vibration etc.
Prompt Decision Making
Cost Effectiveness in Present Scenario (ABT
- UI)
Grid Discipline
Grid Discipline is given a priority in ABT
Incentive and penalty in form of UI to
maintain Grid Frequency
Penalty when actual generation is less
than scheduled
Incentive when actual generation is
more than scheduled generation when
frequency is less
 It is a new challenge for operation
engineer
U I Rate
 Each 0.02 Hz step is equivalent to 8.0
paise/kwh in the range of 49.8-50.5 Hz
 Penalty is 18.0 paise/kwh in the range of 49.0-
49.8 Hz for each 0.02 Hz step
 Incentive is 18.0 paise/kwh in the range of
49.8-49.66 Hz for each 0.02 Hz step below
49.66 is fixed
 UI rate is capped at 49.66 when actual
generation exceeds the scheduled generation
 UI rate goes up to Rs 10.0 per Kwh when actual
generation is below scheduled generation
STEPS
Pre Start Up/Light Up Checks
Starting Auxiliaries
Light Up
Rolling and Soaking
Synchronization
Loading
Off Loading
Shut Down
Type of Start
Cold Start
Hot Start
Auxiliaries
Boiler Auxiliaries
 MillingSystem
 Draft System
 ESP

Turbine Auxiliaries
 Pumps
 Feed Heaters
 Dearator

 Generator Auxiliaries
 Seal Oil System
 Hydrogen Cooling System
 Stator Water Cooling System
START UP PROCEDURE FOR
STAGE-I AND II UNITS
0. RELAY RESETTING.
1. START ID AND FD
1.1 Deaerator tank Heating/AS-57 etc
1.2 SCRAPPER/SLAG CRUSHER IN SERVICE
1.3 BIGGER SIZE OIL GUN TIPS
2. BOILER LIGHTUP
2.1 START PA FANS : FLUE GAS TEMP>350
2.11 START MILLING SYS AND PC
FEEDER
2.2 START SEAL AIR FAN
3. MAINTAIN TOTAL AIR FLOW >30%
4. DRUM PR =5 KSC CLOSE BOILER VENTS
START UP PROCEDURE FOR
STAGE-I AND II UNITS
5. CLOSE SH HDR DRAINS
6. OPERATE BOILER LPDS AT 10 KSC DRUM PRESS.
6.1 START COND VACC PULLING
6.2 CHARGE SEALING STEAM ; 150 mm Hg
Take GSC-1
7. CHARGE HP/LP BYPASS/APRDS MS 30 KSC/330
CELSIUS
7.1 READY RESPECTIVE BAY FROM S/YARD
7.2 UAT BREAKERS SERVICE REMOTE
7.3 AC/DC FIELD FLASHING SUPPLIES ON
8. TPL HEATING DRAINS OPEN
8.1 STG-I MS-9,10 OR BYPASS ESV 60%
OPEN
8.2 STG-II LOCK IV OPEN ESV=60% MS-5,6
OPEN
START UP PROCEDURE FOR
STAGE-I AND II UNITS
9. STOP TPL HEATING/NORMALISE
LOCKING
10. MANNING OF SEAL OIL SYSTEM
10.1 LINEUP FOR FLANGE/STUD
HTNG
10.2 OPEN HPC AND IPC CYL DRAINS
11. START ROLLING 500 RPM
12. ROLLING 1100 RPM
13. ROLLING 3000 RPM
13.1 STOP SOP
13.2 START CW BOOSTER PUMP
START UP PROCEDURE FOR
STAGE-I AND II UNITS
14. SYNCHRONISE THE UNIT
15. OPEN MS-1,2 OR 9,10 AND ISOLATE HP/LP
BYPASS OR PRDS
15.1 RAISE LOAD TO 50 MW : TAKE UATS IN
SERVICE
15.2 OPEN AS-30 STG-I
15.3 CHARGE LPHS START DRIP PUMP
STG-I
15.4 NORMALISE DEAERATOR EXT –IN
;HTNG –STOP
15.5 CLOSE ALL TURBINE SIDE DRAINS
15.6 PUT ALL PROT IN SERVICE
START UP PROCEDURE FOR
STAGE-I AND II UNITS

16. START SECOND BFP RAISE LOAD


17. CHARGE HPHS AT 100 MW
18. TAKE AS-49/11 ATA IN SERVICE
19. CHARGE ESP ZONES
20. ISOLATE FLANGE/STUD
HEATING/STARTING EJECTOR
PLANNED SHUTDOWN OF
STAGE-1 UNITS
1. REDUCE THE LOAD ALONGWITH OIL
GUNS TO 30-35 MW
2. ISOLATE LPHs FROM STEAM AND WATER
SIDE
3. STOP DRIP PUMP
4. UAT CHANGEOVER /MAINTAIN PC LEVEL
5. TRIP THE UNIT AROUND 20 MW/MS
TEMP=480-450.
6. START SOP .LATER ON C/O TO AC LOP
AND AC SEAL OIL PUMP
7. CLOSE AS-30 SPINDLE LEAKOFF TO D/A
PLANNED SHUTDOWN OF
STAGE-1 UNITS
PUT TG SET ON B/GEAR. CLOSE SYPHON
FILLING V/V
KILL THE COND VACUUM.CLOSE AS-9

AND D/A DOME HEATING V/V


3. BOILER LPD OPERATION AT 10 KSC
DRUM PRESS
4. RACK OUT UAT BRKR ,OPEN BAY
ISOLATOR
5. SWITCH OFF AC/DC FIELD FLASHING
SUPPLIES
PLANNED SHUTDOWN OF
STAGE-1 UNITS

2. TAKE LOCAL TG SET ECC. START TSI


LOGGING
3. SWITCH OFF EP ZONES
4. CLOSE FO-1
5. ISOLATE 11ATA V/V AND OPEN DRAINS
6. OPEN SH/DRUM VENTS AND STOP
SLAGCRUSHERS.
PLANNED SHUTDOWN OF
STAGE-2 UNITS
 REDUCE LOAD AS FAR AS POSSSIBLE
WITH 4 MILL W/OUT OIL
 NORMALISE TURBINE SEALING (IF
ADJUSTED)
 CONTROL TSI PARAMETERS
 CLOSE ALL FUEL /AUX AIR DAMPERS
 TAKE OIL AND CUT OFF LOWER MILLS
TO MAINTAIN MS TEMP
 REDUCE LOAD TO 100 MW
PLANNED SHUTDOWN OF
STAGE-2 UNITS
 ISOLATE HPH HEATERS. DO UAT
CHANGEOVERS
 MAINTAIN TOTAL AIR FLOW> 30 %
 STOP ONE FD TO CONTROL
OXYGEN/FURNACE HUNTING
 REDUCE LOAD FURTHER TO 30-40 MW .STOP
ONE BFP
 TRIP THE UNIT.START SOP.CHECK COASTING
TREND OF TG
 ISOLATE EXTRACTIONS .Give tripping
commands to tripped brkr
 ENGAGE B/GEAR TAKE LOCAL TG ECC
PLANNED SHUTDOWN OF
STAGE-2 UNITS
 KILL THE COND VACUUM..CLOSE AS-61
 BOX UP THE BOILER. SWITCH OFF EP
ZONES.
 OPERATE BOILER LPD AT 15 KSC DRUM
PRESS
 OPEN BOILER/SH VENTS AT 5 KSC DRUM
PRESS
 RACK OUT UAT BRKRS AND OPEN BAY
ISOLATOR
 SWITCH OFF AC/DC FIELD FLASHING SUPPLY
 STOP LDO PUMP. ISOLATE 16 ATA AND OPEN
DRAINS
 START LOGGING OF TSI /DRUM METAL TEMP
PLANNED SHUTDOWN OF
STAGE-2 UNITS
PRECAUTIONS:
BOILER DRAININGAT DRUM METAL
TEMP<120
STOPPING OF B/GEARHPT T/B
TEMP<120 APPROX 129 HRS
GEN CASING DEPRESSURISED.SEAL OIL
ISOLATED
STOP CW PUMPS AT EXHAUSTHOOD
TEMP<60
Frequency UI Rate (+) UI Rate (-) Variable Charges
49.0 406 1000 130.168
49.1 406 910 130.168
49.2 406 820 130.168
49.3 406 730 130.168
49.4 406 640 130.168
49.5 406 550 130.168
49.6 406 460 130.168
49.66 406 406 130.168
49.7 370 370 130.168
49.8 280 280 130.168
49.9 240 240 130.168
50.0 200 200 130.168
50.1 160 160 130.168
50.2 120 120 130.168
50.3 80 80 130.168
50.4 40 40 130.168
50.5 0 0 130.168