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1 PGS INSTRUCTION PGS I OPS A Title: Owner: Shift Manager Authorized By: Operation Director Author: Richard Smith Date Authorized: Review Date: September 2011 Associated Documents: A 11/08/09 Richard SM OD First Issue Draft Rev Date Author Owner Authorized By CONTENTS 1. Introduction/Purpose 2. Scope 3. Definition 4. Responsibilities 5. Instruction 6. Training 7. Control of Records 8. Review and Audit Appendix Modifications Status Page 1 of 9

2 1. INTRODUCTION/PURPOSE This PGS Instruction is to provide guidelines for Unit and Assistant Unit Operators when completing the Unit Log Book. The Unit Log book is the original record of all unit related events and as such needs to be accurate, easily read and a thorough and complete record of all events. This Instruction will support the Operations Policy i.e. to operate the power plant in a safe, reliable and efficient manner with a low environment impact in with compliance to ISO14001 and OHSAS SCOPE This instruction covers completion of the Unit Log book for Unit 1 and 2 and balance of plant areas at BLCP power station in Map Ta Phut. 3. DEFINITION Refer to PGS-I-OPS Agreed Abbreviations for use in PGS instruction for a complete list of abbreviations applicable to this document. 4. RESPONSIBILITIES Shift Manager will manage operations staff to ensure adequate and complete information is recorded at all times. Assistant Shift Manager will audit the Unit Log books on a regular basis to check for 100% completeness and ensure Unit Log books are stored for future reference. Unit Operator and Assistant Unit Operators are responsible for accurately and thoroughly recording all relevant unit events in the Unit Log books. 5. INSTRUCTION The main aim of the Unit Log book is to provide an accurate record of events relevant to the operation of the unit; however this does not mean that every single event that occurs on the unit needs to be recorded in it. Entries in the Unit Log book should legible and as short & minimal as possible so as not to hide important information in a forest of useless facts. Only record events and information that is important to you, the next shift, or somebody looking back in a month s time. The DCS event log records all events received through the DCS system, the UO/AUO only needs to record simple entries to highlight something has occurred. If further investigation is required at a later date the Unit Log book will provide the date and time, but the DCS event log will have the complete sequence of events. The following is a short guide on the minimum standard that is required when completing the Unit Log book. 5.1 Starting of each shift At the start of each shift the UO/AUO shall start the Unit Log book on a new page with the following information to be included; Page 2 of 9

3 Date (format e.g. Friday 28 th August 2009), Shift (A E), and time span (i.e. 07:00 19:00 or 19:00 07:00). Names of UO and AUO assigned to this unit. The current status of the plant which should give a general summary of current plant conditions including; Load (gross and net) Dispatch (AGC on or off) Generator status (voltage, current, H 2 pressure, purity) Boiler status (flows, pressures, temperatures, pulverisers in service, coal being burnt, CBD and DA vent opening) Emission status (opacity, NOX, SO 2, CO) Outfall status (PH, CL 2, temperature) Any major items of plant that are not in service (i.e. FGD out of service, Pulveriser C isolated for monthly PM, etc) Friday 28th August 2009 "C" shift 07:00-19:00 Channarong P / Satit Status Unit load 677 MW (gross), 643 MW (net), AGC "ON" Gen: 23.9 kv, 16.6 ka, H2 pressure 5.02 bar, purity 97.98% Boiler: MS flow 2167 t/h, FW flow 2199 t/h, total fuel flow 235 t/h MS 168 bar, 538 C, RH 33.6 bar, 540 C Pulverizer B - F in service (A; Hunter Valley, B - E; BA, F; SC) CBD open 6 turns, DA vent open 100% Emssions: Opacity 9.0 mg/nm 3, NOX 156 ppm, SO 2 91 ppm, CO 0.7 ppm Outfall: PH 7.4, Cl 2 outfall ppm, temp 37.3 C FGD out of service for maintenance Sample Unit Log book entries for start of each shift. 5.2 Recording plant information during the shift Each entry in the Unit Log book shall consist of a time in the left margin of the page and an accurate description of the information to be recorded, as shown below; 7:50 Change Silica Gel of EH oil tank 8:30 AGC - OFF 8:30 Decrease load to 450MW Sample Unit Log book entries. Entries to be included in this section as expanded on below include; Operator initiated actions Page 3 of 9

4 Plant Operator manually adjusted plant items Plant changeover Plant testing of standby equipment Work done by maintenance Defect/Isolation of the unit Fire systems Safety Alarms and Trips Simulations Unit APS Start up or Shut down External communications Operator initiated actions Whenever the UO or AUO clicks on the DCS screen to START, or STOP a major item of equipment this shall be recorded in the Unit Log book. Examples of this include; Start Pulverizer A, Start M-BFP, Stop BCP-A. This should be restricted to major items of plant and all equipment with a HV supply. Minor low voltage pumps and fans do not need to be recorded in the Log Book (i.e. Start Turbine house sump pump A is not necessary to record as this information can be found in the DCS event log if needed). Whenever an item is STARTED or STOPPED by the UO/AUO a reason shall be provided i.e. Shutdown Pulverizer A for 3000 hour routine PM. 18:03 Shutdown Pulverizer - D for 3000 hour routine PM 18:24 Start M-BFP for C&I to investigate thrust bearing temperature Plant Operator manually adjusted plant items Some items of plant cannot be controlled from the DCS and must be OPENED, CLOSED, STARTED, STOPPED or ADJUSTED by the Plant Operator out on the unit. Examples of this are placing the H2 dryer into regen, opening the DA vent, adjusting the CBD. The Plant Operator does these duties under the instruction of the UO/AUO and these items should be recorded in the Unit Log book. 11:34 Open CBD - 5 turns 12:13 DA vent open 100% 13:45 Regen H 2 dryer Plant changeover At various times the changeover of plant equipment from A-side running to B- side running is undertaken as per Operational Instruction; PGS-I-OPS Plant and Apparatus Rotation and Routine Testing. If every item of plant that is changed over from standby to duty is recorded in the Unit Log book it soon fills up the page with unnecessary information. Only a single line stating the all unit pumps and fans have been selected/changed to B-side duty is needed. Page 4 of 9

5 9:45 B-side plant selected as DUTY Note: EH oil pump-a selected as DUTY (pump-b isolated for repairs) 9:55 Condenser Vacuum pump C selected as DUTY However if for some reason an item of plant cannot be changed over to the new duty selection it shall be noted as above; NOTE: EH oil pump-a selected as DUTY (pump-b isolated for repairs). Also some equipment as 3 or more items (such as condenser vacuum pumps or absorber blowers, etc) and an entry shall be made in the Unit Log book to show which is currently selected to duty. Example: Condenser Vacuum pump- C selected to DUTY Plant testing of standby equipment Standby equipment testing shall be carried out as per Operational Instruction; PGS-I-OPS Plant and Apparatus Rotation and Routine Testing and various other instructions. All test runs shall be recorded in the Unit Log book with any that failed to work correctly highlighted. 7:42 AGC - OFF 7:43 Decrease load to 470MW 7:57 Extraction steam NRV test as per PGS-I-OPS Safety System Testing - completed 8:56 ST valve stem feddom test as per as per PGS-I-OPS completed 9:25 M-BFP test run as per PGS-I-OPS A Motor Driven Boiler Feedwater Pump M-BFP failed to start - electrical team investigating During some equipment testing the cut in pressure, etc needs to be recorded in the Unit Log book, for example; 9:03 AOP test auto 7.5 bar 9:04 TOP test auto 0.84 bar 9:06 EOP test auto 0.65 bar Work done by maintenance All work that is being done by maintenance personnel on the plant that can affect unit operation (i.e. cause a unit trip or runback or cause controls to revert to manual or AGC off) shall be recorded in the Unit Log book. Examples of this include; C&I calibrate economizer outlet O 2 probes Defect/Isolation of the unit Fire systems Any impairment or defect in the unit fire detection/protection system shall be recorded in the Unit Log book (and a WO raised) and highlighted. A note should be made of what corrective action has been initiated to fix the problem and also when the problem has been rectified. 14:34 leak reported in fire water system by PO at Main Lube Oil tank valve 01SGA01AA113 CLOSED to isolate leak - Emergency WO raised Page 5 of 9

6 5.2.7 Safety Any event or information that can have an effect on safety of personnel working on or around the unit shall be recorded in the Unit Log book. Examples include; Floor grating removed from level 5 boiler danger taped off, Roof cladding from boiler house blowing in the wind Alarms and Trips If all DCS alarms were recorded in the Unit Log book, then it would quickly become full, so the following rules shall be applied concerning recording of alarms; If an alarm is repeating continuously for no reason (i.e. a spurious alarm), this should NOT be recorded, however a single line may be entered to show that this alarm is appearing for no reason and needs attention to correct it. A work order shall be raised. When an alarm is received on an item of plant that is not normal or routinely received then this shall be entered in the Unit Log book. All Pump, Fan, HV motor, or Circuit Breaker trips shall be recorded. Major plant events such as Pulveriser tripped, Unit runback or Unit trip shall be recorded with details added on the cause. This should compromise a single line with time indicated in the Unit Log book so that if needed at a later date this single line with date and time can be used to find the complete information in the DCS event log Simulations Any forcing of DCS signals or suppression of alarms (masking) which is done following Operational Instruction; PGS-I-OPS Management of Simulations in Plant and DCS Systems shall also be recorded in the Unit Log book. It shall also be recorded when these items are removed Unit APS Start up or Shut down During a Unit APS start up or shutdown the DCS system starts and/or stops many items of plant as a part of the process. As all of this information is recorded by the DCS event log the UP or AUO only needs to record actions he has initiated (see section Operator initiated actions). An example of a unit startup is shown below; Page 6 of 9

7 2:13 APS ON 2:15 Start BP-1 Unit Start Preparation - Hot Start mode (1st metal temp = 460 degc) 2:32 Start BP-2 Furnace purge & light-off 2:45 Start BP-3 Vacuum up 3:10 Start BP-4 Turbine speed up 3:32 Start BP-5 Synchronise & initial load 3:34 Generator CB CLOSED 3:38 Start BP-6 Load up - 1 3:56 Start BP-7 Load up - 2 4:30 AGC "ON" In addition whenever the Generator Circuit Breaker is CLOSED or OPEN it shall be recorded with an accurate time in the Unit Log book. At the completion of the unit start up and APS OFF, a short summary should be completed in the Unit Log book detailing pulverizes in service. Any problems encountered or delays during the start up or shutdown shall also be recorded External communications Any reports relevant to Unit operation from sources external to BLCP Operations staff shall be recorded in the Unit Log book. Examples are reports from local fisherman concerning jellyfish, reports from site security concerning Greenpeace, requests/instructions from EGAT, etc 12:46 Local fisherman reports large number of Jellyfish near BLCP 5.3 Recording of Work Orders raised All work orders (W/O) raised in Maximo during the course of the shift by the UO and/or AUO shall be listed in the Unit Log book at the end of each shift as shown below; each entry will consist of the work order number and a brief but accurate description of the work required. 18:03 Shutdown Pulverizer - D for 3000 hour routine PM 18:24 Open CBD 5 turns W/O Calibrate Turbidity WWTP discharge Repair oil leakage at gearbox of trash rake Sample Unit Log book entries for all W/O s raised. 5.4 Signing of Unit Log as complete Once the relieving shift has arrived and the status of the plant and other relevant information has been handed over to the new shift, the UO and AUO shall sign the Unit Log book as being complete and accurate. Page 7 of 9

8 18:03 Shutdown Pulverizer - D for 3000 hour routine PM 18:24 Open CBD 5 turns W/O Calibrate Turbidity WWTP discharge Repair oil leakage at gearbox of trash rake Sample Unit Log book with signature of UO and AUO at completion of shift. ChannarongP / Satit 5.5 Information entry by people other than the UO/AUO It can be necessary at time for information to be entered in the Unit Log book by people other than the assigned UO and AUO (an example could be an entry into the Unit 1 Unit Log book by the Unit 2 AUO). If this is done, the item added will be signed in the margin by the person entering the information. 11:34 Open CBD - 5 turns 12:13 DA vent open 100% 12:30 AGC - OFF Somjit 12:30 Decrease load to 470MW 5.6 Deleting of Error s It can be that information needs to be deleted from a Unit Log book (maybe entered in error on the wrong unit, etc). If this is the case the item to be removed will have a line placed through it and the signature of the person deleting the line shall be added in the margin, as shown below; 7:57 Extraction steam NRV test as per PGS-I-OPS Safety System Testing - completed 8:56 ST valve stem feddom test as per as per PGS-I-OPS completed ChannarongP 9:25 M-BFP test run as per PGS-I-OPS A Motor Driven Boiler Feedwater Pump 5.7 Balance of Plant Log Book A log book for Balance of Plant shall also be kept so that an accurate record of events relevant to common plant is available. The Shift Manager shall assign at the start of each shift the person responsible for recording this log and hence monitoring and responding to any problems on the common screens. The person assigned can be either the UO or AUO from Unit 1 or Unit 2, but it must be clear at all times who is responsible for the common plant screens and the BOP Log Book. The general guidelines above for completing the UO Log Book shall also apply and be used when completing the BOP Log Book. 6. TRAINING The author of this Instruction is responsible for providing training and guidance in the implementation of this PGS Instruction. Page 8 of 9

9 The Owners of this instruction are responsible for cascade training to persons requiring knowledge of this instruction. As a minimum this training will be provided to all persons named as having specific responsibilities under this instruction. Any records of training will be submitted to HR and copies of training records shall be kept in the PGS Filing System. 7. CONTROL OF RECORDS All records connected with in this instruction shall be kept in file at Central Control Room (CCR) and controlled by Operation Department. All completed log sheets shall be audited by the Assistant Shift Manager on a weekly basis to check for completeness. Any problems highlighted on the sheets shall be followed up to check that corrective action has already been taken. They must be available for scrutiny and audit 8. REVIEW AND AUDIT All PGS Procedures and Instructions will be subject to review every two years unless the need arises before the planned review date. In the case of SHE procedures and Instructions these will be subject to review and audit in accordance with the requirements of PGS-P-SHE Safety, Health and Environment Audit and Review. Any inaccuracies or omissions in this instruction should be notified to the instruction Owner immediately. APPENDIX There are no appendices currently assigned to this instruction. Page 9 of 9