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LANCO AMARKANTAK POWER LIMITED

AMARKANTAK THERMAL POWER STATION


Village Pathadi, PO-Tilkeja

Dist.- KORBA (C.G.)

INSTRUCTION MANUAL
ATPS/IMS/IM/07M05

CHP OPERATION
AMARKANTAK THERMAL POWER STATION
LANCO POWER LIMITED(2X300MW)
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ATPS/IMS/07M05

Section A

CONTENTS

NO.OF
SECTION TITLE
SHEETS
COVER PAGE
A CONTENTS 01
B INTRODUCTION 01
C LIST OF ABBREVIATIONS 01

WI NO. DETAILS NO.OF


SHEET
ATPS/IM/07M05/WI/PS/01 PRE START CHECKS FOR WAGON UNLOADING S
01
ATPS/IM/07M05/WI/PS/02 PRE START CHECKS FOR PADDLE FEEDER 01
ATPS/IM /07M05/WI/PS/03 PRE START CHECKS FOR RING GRANULATOR CRUSHER 02
ATPS/IM/07M05/SR/PS/04 PRE START CHECKS FOR STACKER/RECLAIMER 02
ATPS/IM /07M05/CO/PS/05 PRE START CHECKS FOR CONVEYORS 01
ATPS/IM /07M05/TT/PS/06 PRE START CHECKS FOR TRAVELING TRIPPER 01
ATPS/IM/07M05/RS/PS/07 PRE START CHECKS FOR RUNNING THE STREAM 02
ATPS/IM /07M05/WU/OP/01 CHECKS DURING WAGON UNLOADING OPERATION 02
ATPS/IM /07M05/PF/OP/02 CHECKS DURING PADDLE FEEDER 02
CHECKS DURING RING GRANULATOR CRUSHER
ATPS/IM /07M05/RG/OP/03 01
OPERATION
ATPS/IM /07M05/CO/OP/04 CHECKS DURING CONVEYOR RUNNING 01
ATPS/IM /07M05/SR/OP/05 CHECKS DURING STACKER/RECLAIMER OPERATION 01
ATPS/IM /07M05/RS/OP/06 CHECKS DURING STREAM RUNNING. 02
ATPS/IM /07M05/GE/OP/07 ISSUE OF PTW 02
ATPS/IM /07M05/GE/OP/08 CANCELLATION OF PTW 01
TO ENSURE PROPER MANAGEMENT OF COAL STACK
ATPS/IM /07M05/GE/OP/09 02
YARD
HANDLING, STORAGE, PRESERVATION AND DELIVERY
ATPS/IM /07M05/GE/OP/10 02
OF COAL

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ATPS/IMS/07M05

Section B

INTRODUCTION

HOD (CHP) is the in-charge of all mechanical maintenance and operation of CHP and he is
reporting to Station Head. Section Heads for Operation, Maintenance and Railway Siding are
reporting to HOD (CHP) and assisted by Area In-charge/Sr. Engineer/ Engineer. Lead
Technicians/Technicians for Operation, Maintenance & Railway Siding report to Area In-
charge/Sr. Engineer/ Engineer.

Coal Handling Plant looks after operation and mechanical maintenance of all the equipments
like Wagons unloading, Conveyors, Crushers, Flap gates, Paddle Feeders etc. This
department also looks after unloading of coal rakes and bunkering of coal as per requirement
of the main plant including all coal co-ordination activities.

P.M. schedule generated by MTP is followed by CHP, maintenance department.

For identified defects, work orders are raised through SAP. Preventive maintenance schedule
and daily defects are distributed daily by Section Head to concerned Engineers.

PTW is applied by respective area Engineer. After getting PTW and proper isolation, area
group Engineer carry out necessary work as per the work instruction. In case respective
Engineer finds problem in any system he immediately reports to the Section Head for
solution. After completion of work respective area Engineer closes PTW and WO through SAP
by adding all necessary informations like manpower used, time taken, spares used with
intimation to Sectional Head.

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Section C

LIST OF ABBREVIATIONS

Page: 1 of 1

1. PF - PADDLE FEEDER
2. VGF - VIBRATING GRIZZLY FEEDER
3. BC - BELT CONVEYOR
4. C/D - CONTROL DESK
5. CHP - COAL HANDLING PLANT
6. CR - CRUSHER
7. CRD - CABLE REELING DRUM
8. DE DUST EXTRACTION
9. DS - DUST SUPRESSION
10. HOD HEAD OF DEPARTMENT
11. IM INSTRUCTION MANUAL
12. ATPSQAP - AMARKANTAK THERMAL POWER STATION
QUALITY ASSURANCE PLAN
13. ATPSWI AMARKANTAK THERMAL POWER STATION
WORK INSTRUCTION
14. LCS - LOCAL CONTROL STATION
15. MECH. MECHANICAL
16. MAINT. MAINTENANCE
17. MTP MAINTENANCE PLANNING
18. OPN OPERATION
19. PM - PREVENTIVE MAINTENANCE
20. PA - PUBLIC ANNOUNCEMENT
21. PTW - PERMIT TO WORK
22. RLY RAILWAY
23. R&P - RACK & PINION
17. R&D - RECEIPT & DESPATCH
18. Sr. - SENIOR
19. S/R - STACKER / RECLAIMER
20. temp. - TEMPERATURE
21. VF - VIBRATING FEEDER
22. Wt. - Weight

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ATPS/IMS/07M05

Section D

REVISION RECORD

Page: 1 of 1
Amendment Section / IM Page No. Next Date Nature of Approved
No. No. Revision No. change by.

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Section E

ORGANOGRAM

Page: 1 of 1

HOD(CHP)

SECTION SECTION
SECTION HEAD (MECH. HEAD (RLY
HEAD (OPN) MAINT.) SIDING)

AREA AREA AREA


INCHARGE/SR. INCHARGE/SR. INCHARGE/SR.
ENGINEER/ ENGINEER/ ENGINEER/
ENGINEER ENGINEER ENGINEER

LEAD
LEAD TECHNICIAN/ OFFICE
TECHNICIAN/ SUPERVISOR/ TECHNICIAN ASSISTANT
TECHNICIAN TECHNICIAN

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ATPS/IMS/07M05

INSTRUCTION NO.: ATPS/IM/07M05/WI/PS/01

PRE START CHECK FOR WAGON UNLOADING

Sr. No. Activity / Steps

1. Ensure that no person is working near wagon.

2. Ensure that no material is lying on the track.

3. Check the water level in the Dust Suppression (DS) tank physically.

4. Check that all the valves of DS line are open.

5. Check that compressed air is available in line.

6. Inform CHP control if any abnormality is noticed, get it rectified by the concerned
maintenance engineer and take clearance from control room before tippling.

7. Ensure that Wagon is placed in line with hopper.

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ATPS/IMS/07M05

INSTRUCTION No.: ATPS/IM/07M05/WI/PS/02

PRE START CHECKS FOR PADDLE FEEDER

Sr. NO Activity/Steps

1. Check that trailing cable is free of coal or any other material.


2. Check the position of paddle feeder before shifting.
3. Check that travelling path of paddle feeder is clear.
4. Ensure that the oil level in the gear box hydraulic power pack is up to the oil level marking
given in the oil level view glass.
5. Check that no person is working on the machine.
6. Check that Local Control Switch is in the inter lock position.
7. Check that keys are available in the Local Control Switch.
8. Inform CHP control room if any abnormality is noticed.
9. After rectification of abnormality or as per the directive of Sr. Engineer (operation) give
clearance to CHP control room.

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ATPS/IMS/07M05

INSTRUCTION NO. ATPS/IM /07M05/WI/PS/03

PRE START CHECKS FOR RING GRANULATOR CRUSHER

Sr. No Activity / Steps

1. Check that no person is working on the equipment.


2. Check that oil level in the hydraulic tank of the hydraulic system for fluid coupling is
sufficient as indicated by the oil level indicator.
3. Check that flow of water is normal from cooling water pump to heat exchanger.
4. Check the scoop is in minimum position.
5. Check that Local Control Switch (LCS) is in the interlock position and keys are available in
LCS.
6. Inform CHP control room if any abnormality is noticed.
7. After rectification of abnormality or as per the directive of the Operation Engineer give
clearance to CHP control room

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ATPS/IMS/07M05

INSTRUCTION NO. ATPS/IM/07M05/SR/PS/04

PRE START CHECKS FOR STACKER/RECLAIMER (S/R)

Sr.No. Activity / Steps

1. Check that oil level in the boom conveyor, intermediate conveyor, bucket wheel and slewing
gear boxes are above the oil level mark in the oil level view glass.
2. Check that oil level in the hydraulic tank of boom luffing and operator cabin are between
minimum and maximum level marks in the oil level view glass.
3. Check that no person is working in the operating area of S/R.
4. Check that no coal is accumulated in S/R travelling area.
5. Start the grease pump before operating the S/R by giving ON command from local.
6. Check that the trailing cable (power as well as control supply) is free of coal or any other
material.
7. When the S/R is being used for stacking the coal, position the boom conveyor near the coal
heap to avoid emission of dust.
8. Inform CHP control room if any abnormality is noticed.
9. After rectification of abnormality or as per the directive of Operation Engineer give clearance
to CHP control room

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ATPS/IMS/07M05

INSTRUCTION No. ATPS/IM /07M05/CO/PS/05

PRE START CHECKS FOR CONVEYOR

Sr.No. Activity / Steps

1. Check that no person is working on the conveyor.


2. Check that all pull cord switches are in reset condition and confirm to control room.
3. Check that oil level in the gear box is up to the level mark in the oil level view glass.
4. Check the gear box for any leakage.
5. Check that Local Control Switch (LCS) is in the interlock position and keys are available in
LCS.
6. Check that D.S. line at conveyor discharge end is charged.
7. Check that the local control panel of Dust Extraction (DE) system is ON.
8. Inform CHP control room, if any abnormality is noticed.
9. After rectification of abnormality or as per the directive of Operation Engineer give clearance
to CHP control room.

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ATPS/IMS/07M05

INSTRUCTION No. ATPS/IM /07M05/TT/PS/06

PRE START CHECKS FOR TRAVELLING TRIPPER

Sr. No Activity / Steps

1. Check that trailing cable is free of coal or any other material.


2. Check the position of flap gate before shifting the trolley.
3. Check that travelling path of trolley is clear.
4. Inform CHP control room if any abnormality is noticed.
5. After rectification of abnormality or as per the directive of Engineer operation give clearance
to CHP control room.

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ATPS/IMS/07M05

INSTRUCTION No. ATPS/IM/07M05/RS/PS/07

PRE START CHECKS FOR RUNNING THE STREAM

Sr. No. Activity / Steps

1. Ensure that all the Permits To Works (PTW) are cancelled for all the equipments of the
stream to be selected.
2. If any PTW is not cancelled contact the person to whom PTW is issued and get it cancelled
before starting the particular equipment.
3. Check that all the electrical modules are on as per the selected stream.
4. Check that the position of all flap gates as per the stream selected (identification on the
mimic panel) and get it confirmed from the local operator.
5. Check that D.S. line at conveyor discharge end is charged and water is available in the main
D.S. tank.
6. Check that the local control panel of D.E. system is ON
7. Take clearance from local operator before starting the equipment.
8. If any abnormality is informed by the local operator raise the Work Order (Notification
through SAP) and get it normalized by the concerned Engineer (Maintenance).
9. Before starting the equipment ensure that the sequence is ON
10. Announce on Public Address (PA) system before starting the individual equipment of the
selected stream.

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ATPS/IMS/07M05

INSTRUCTION No. ATPS/IM /07M05/WU/OP/01

CHECK DURING WAGON UNLOADING OPERATION

Sr. No. Activity / Steps

1. Ensure that no damaged wagon is placed on the track.


2. Note down the number of each wagon.
3. Ensure that Dust Suppression (DS) spray is ON during wagon unloading.
4. If any foreign material or big stone is observed during unloading please get it removed and
inform control room.
5. Ensure that wagon is completely empty.
6. Inform CHP control room if any defect is noticed during unloading.

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ATPS/IMS/07M05

INSTRUCTION No. ATPS/IM /07M05/PF/OP/02

CHECKS DURING PADDLE FEEDER OPERATION

Sr. No. Activity / Steps

1. Check for any unusual noise during operation.


2. Check the temperature and vibrations of motor bearings and gearbox by touching.
3. Check the speed of paddle for proper coal feeding.
4. Check that paddle feeder is not fouling anywhere during traveling.
5. Check that trailing cable (power as well as control) is wound / unwound during
traveling.
6. Check that no foreign material is lifted during feeding.
7. Check the temperature and vibrations of all bearings, motors and gearboxes by touching.
8. Check that trailing cable is free of any foreign material during traveling.
9. If any abnormality is noticed inform the CHP control room.
10. If any abnormality which may damage the equipment is noticed stop the equipment by
switching OFF the Local Control Switch.

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ATPS/IMS/07M05

INSTRUCTION No. ATPS/IM /07M05/RG/OP/03

CHECKS DRUING RING GRANULATOR CRUSHER OPERTION

Sr. No. Activity / Steps

1. Check for any unusual noise during operation.

2. Check the temperature and vibrations of all bearings, motors by touching.

3. Inform control room if any abnormality is noticed.

4. If any abnormality which may damage the equipment is noticed stop the equipment by
switching OFF the Local Control Switch and inform the CHP control room.

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ATPS/IMS/07M05

INSTRUCTION No. ATPS/IM /07M05/CO/OP/04

CHECKS DURING CONVEYOR RUNNING

Sr. No Activity / Steps

1. Check that the belt is running in the centre.


2. If any foreign material or big stone is observed in coal stop the conveyor by operating the
pull cord and inform the control room.
3. Check the temperature and vibration of all the bearings, motor and gearbox by touching.
4. Check for any excessive spillage of coal from external scraper and skirt rubber and if
found, inform the control room.
5. Check for any unusual noise from gearbox bearings and idlers.
6. Check that all the idlers are running free.
7. If the dust is found liberated at the discharge point of conveyors, start the D.S. system /
D.E. system and inform CHP control room.
8. If any abnormality is noticed inform the CHP control room.
9. If any abnormality , which may damage the equipment is noticed stop the equipment by
operating the pull cord and inform CHP control room.

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ATPS/IMS/07M05

INSTRUCTION No. ATPS/IM /07M05/SR/OP/05

CHECKS DURING STACKER/RECLAIMER (S/R) OPERATION

Sr. No Activity / Steps

1. Check that the belts of all conveyors such as boom conveyors; intermediate conveyors and
yard conveyors are running normal.
2. Check that S/R is not fouling anywhere during traveling.
3. Check that trailing cable (power as well as control) is wound / unwound during
traveling.
4. Check that no foreign material is lifted during reclaiming.
5. Check the temperature and vibrations of all bearings, motors and gearboxes by touching.
6. Check that motorized grease pump starts automatically as per time setting.
7. Check that trailing cable is free of any foreign material during traveling.
8. Inform control room if any abnormality is noticed.
9. If any abnormality, which may damage the equipment, noticed, stop the equipment
and inform CHP control room.

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ATPS/IMS/07M05

INSTRUCTION No. ATPS/IM /07M05/RS/OP/06

CHECKS DURING STREAM RUNNING

Sr. No Activity / Steps

1. Log in all the problems encountered during operation.


2. Log in hourly current readings of all the equipments of the selected stream.
3. Confirm that local operator is present at site.
4. Take feedback from local operator for normal running.
5. Monitor the feed rate (flow rate indication comes on the flow rate meter provided in the
control room).
6. Monitor and record the bunker level.
7. If coal dust is found liberated at conveyor discharge end ask the local operator to start D.S. /
D.E. system and record.
8. In case of excessive fugitive coal dust leading to emergency condition, stop the system
immediately.
9. Check the D.E. / D.S. system thoroughly for healthiness.
10. In case no abnormality is found in D.E. / D.S. system take immediate steps to spray
water on the coal wagons manually before unloading.
11. Prepare an occurrence report.
12. Take feedback from local operator for any unusual noise.
13. Inform maintenance engineer if any defect is noticed and raise WO (Notification through
SAP).
14. Maintain equipment running hours 7.9.2 & 7.9.3.

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ATPS/IMS/07M05

INSTRUCTION No. ATPS/IM /07M05/GE/OP/07

TO ISSUE PTW AFTER PROPER ISOLATION OF THE EQUIPMENT AND ENSURE SAFE
EXECUTION OF MAINTENANCE WORK

Sr. No. Activity / Steps

1. Fill up the PTW form on request of maintenance section.


2. Specify WO NO. PTW against which PTW is requested.
3. Do electrical and / or mechanical isolation of the equipment.
4. Place DANGER TAGon electrical module.
5. If the maintenance work to be carried out involves welding or gas cutting , subscribe on
the PTW HOT PERMIT.
6. In case of HOT PERMIT call fire man to be present at the place of work.
7. Take signature of the concerned maintenance engineer on PTW.
8. Sign PTW and handover the original copy to the concerned maintenance engineer.
9. Keep carbon copy as record in PTW register.

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ATPS/IMS/07M05

INSTRUCTION NO. ATPS/IM /07M05/GE/OP/08

TO NORMALISE THE EQUIPMENT AND KEEP IT IN OPERATION OR STANDBY

Sr. No. Activity / Steps

1. After completion of the work, the maintenance engineer returns the PTW to operational
personnel certifying that the work is complete and equipment can be taken into service.

2. The operational personnel normalize the equipment from mechanical and electrical sides.
Danger tags from electrical modules are removed.

3. Both operation and maintenance person sign on the PTW. It is crossed and treated as
cancelled then.

4. If any trial run of the equipment is required then PTW is cancelled for trial run. After trial run
PTW is reissued.

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ATPS/IMS/07M05

INSTRUCTION No. ATPS/IM /07M05/GE/OP/09

TO ENSURE PROPER MANAGEMENT OF COAL STACK YARD

SR.NO. Activity / Steps

1.0 Coal yard management involves proper stacking of coal compaction of coal heap,
prevention of coal spillage outside the yard and in the drains, prevention and controlling of
fugitive dust emission from yard.
1.1 COAL STACKING
1.1.1 Coal of different grades has to be stacked separately at predetermined
area in the yard so as to prevent any mixing.
1.1.2 Indian coal is to be stacked using Stacker/Reclaimer or in emergency
stack yard using Conveyor-BC#10.
1.1.3 Imported coal is to be stacked separately.
1.1.4 Ensure that coal is stacked only on the paved stacking area.
1.2 COAL COMPACTION
1.2.1 After stacking coal, immediately use dozers to spread and compact the coal heap to
prevent any fire or prevent any spillage.
1.2.2 While compacting, ensure that coal does not spread outside the yard retaining walls.
1.2.3 Take care to keep at least 02 meter clearance of stacking from yard retaining walls.
1.3 COAL SPILLAGE & CLEANING OF PERIPHERAL DRAINS
1.3.1 In case of any coal spilled outside the yard, lift the spilled coal manually and put it back
in the yard.
1.3.2 Inspect all the drains once in a month by removing all the drain covers.
1.3.3 Clean the drains of accumulated coal and put the coal slurry back in the yard.
1.3.4 Check all the drain holes are cleared and clean if found choked. At all times ensure that
the storm water / seepage water from the coal stack flows only to the surface drains.
1.3.5 Put back all the drain covers in their respective position.
1.3.6 If any cover found broken replace by new covers.
1.3.7 Ensure healthiness of water sprinklers around the stack yard.

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1.3.8 Prepare an inspection report.


TO ENSURE PROPER MANAGEMENT OF COAL STACK YARD
1.4 PREVENTION & CONTROLLING FIRE IN COAL
A) NORMAL CONDITION
I. Proper compaction of coal in the yard immediately after stacking is to be ensured to
prevent fire.
II. Inspect the yards for fire or smoke and record.
III. Small fire or smoke is observed in stacked coal, that portion of coal is to be sprayed with
water.
IV. Remove the affected coal to a separate area using dozer or loader. Quench fire if any
using sprays water.
V.Reclaim the affected coal at the earliest for use.
B) ABNORMAL CONDITION
In case of fire in big patches of coal, inform fire fighting personnel immediately. Treat this
condition as abnormal condition and take the following actions
I) Use adequate water from fire hydrants/monitors to quench the fire.
II) Reclaim the affected coal at the earliest opportunity for use in boiler.
III) Inform Key personnel regarding the incidence.
IV) Prepare an occurrence report
C) EMERGENCY CONDITION
In case of part of coal stack in fire, treat this as emergency condition and do the following
i) Inform immediately Key Personnel and Fire Fighting staff.
ii) Ensure safety of equipment and personnel by withdrawing them from fire area and take
steps to contain the fire within the affected area.
iii) Follow the emergency plan for coal stack yard fire.

TO ENSURE PROPER MANAGEMENT OF COAL STACK YARD

1.5 PREVENTION OF FUGITIVE DUST FROM YARD


1.5.1 Start the dust suppression system and spray water on the stacked coal to reduce

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fugitive dust emission as and when required.


1.5.2 While stacking coal by S/R keep the position of the boom at minimum height over the
stacking point to reduce the dust emission.
1.5.3 While stacking coal at emergency stack yard through conveyor BC#10, start the dust
suppression system at telescopic chute.
1.5.4 Also keep the position of telescopic chute at minimum height over the stacking point to
reduce dust emission.

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ATPS/IMS/07M05

INSTRUCTION No. ATPS/IM /07M05/GE/OP/10

HANDLING STORAGE, PRESERVATION AND DELIVERY OF COAL

Sr. No. Activity / Steps

1. Information is taken from U r g a Railway station for the probable time of arrival of coal
rake.
2. As per the requirement, the coal is either stacked or bunkered by selecting the stream.
3. Dumpers are weighed at weigh bridge before and after coal unloading.
4. It is ensured that the dumpers are not over loaded with coal to avoid spillage of
coal during the transportation.
5. If spillage is still observed, all the spilled coal is manually collected once in every week &
transferred to coal yard.
6. When the coal is stacked in the yard, it is adequately compacted by dozers to prevent fire.
7. If fire is observed in the stacked coal, the water is sprayed on the affected coal. This coal
is then either reclaimed at the earliest opportunity or it is removed from the heap
using the dozer or loader.
8. The stacked coal is reclaimed using either S/R or Reclaim hopper and delivered to
bunker as per the requirement.
9. Imported coal and Indian coal are blended while delivering the coal to bunkers.
10. For the purpose of blending, one type of coal is reclaimed using the S/R and the other
type of coal is fed through the Reclaim hopper.
11. When the coal received from the wagons is directly fed to the bunkers, the imported coal
stacked in the yard is either reclaimed using the S/R or fed through reclaim hopper.
12. The ratio of blending is decided as per the requirement of main plant to meet the
operational parameters.
13. The quantity of coal sent to bunkers is recorded.
14. All the weighing records are handed over to Section Head (Railway Siding).

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ATPS/IMS/07M05

EQUIPMENT INSPECTION SCHEDULE FOR CHP OPERATION:

SL. NO. EQUIPMENT FREQUENCY


1 CONVEYOR BC#1A/1B Weekly
2 PADDLE FEEDER PF#1/2/3/4 Weekly
3 CONVEYOR BC#2A/2B Weekly
4 CONVEYOR BC#3A/3B Weekly
5 VIBRATING GRIZZLY FEEDER VGF#1/2 Weekly
6 CRUSHER CR#1/2 Weekly
7 CONVEYOR BC#4A/4B Weekly
8 CONVEYOR RBF#1A/1B Weekly
9 CONVEYOR BC#5A/5B Weekly
10 CONVEYOR BC#6A/6B Weekly
11 CONVEYOR BC#7A/7B Weekly
12 TRAVELLING TRIPPER TT#1A/1B Weekly
13 CONVEYOR BC#8 Weekly
14 STACKER/RECLAIMER Weekly
15 CONVEYOR BC#9 Weekly
16 CONVEYOR BC#10 Weekly