LOG BOOK - PSG

PSG SHIFT ENGINEERS LOG BOOK

Shift Morning Dated 03-08-17

Steam Generation

Boiler-I Boiler-II Boiler-I Boiler-II
<10 <10
LOAD (TPH) 250 216 SiO2 (HS Steam) 0.70 0.82
CBD (TPH) 1.0 1.0 SiO2 (CBD) 05 12
Bag House (P) 100 88 Phosphate (PO4) 68
Coal Feeders (A/B/C/D) A/B/C/D A/B/C/D Hydrazine 25
Burners B&D B Amine
STG-III
Active Power (MW) Power Generation (60 Hz) 9.9
Reactive Power 6.2
Power Factor STG-I STG-II 0.86
Mode (ISO/DROOP/KW) 15.6 KW

STG_IV 9.6 Active Power
53
0.85
DROOP
Power Generation (50 Hz)

Reactive Power Power Factor
29 0.89

FFBL POWER COMPANY LIMITED | 1

PRDS Mode Opening
Set Point

40 kg (PV-3512/PV-3514/PV-3516) 41.5 Auto 0%

4 kg (PV-1076/PV-1077) 3.7 Auto 0%
10 kg (PV-1064/PV-1065) 11.3 Auto 53%

Vent Valves Opening

PV-1073 Set Point % Opening Auto/Manual
PV-1080 92.5 1.0 Auto
PV-1095 92.5 8.0 Auto
PV-1096 12.5 0 Auto
PV-3518 4.5 0 Auto
43.5 0 Auto

BOP (CT/IA,PA/BFW)

Open/Closed Loop CW Pumps in Service B,D,S/A

Cooling Tower Fans in Service B,C,D,S

Open Loop CW Supply/Return Temp./Pres. 32.4/39.2 & 2.5/1.3

Closed Loop CW Supply/Return Temp./Pres. 36/40 & 5.5/1.5

Compressors in Service CIK-1011 A CIK-1011 B CIK-1011 C

Loading/Unloading S.P. 7.9/8.6 7.0/8 7.8/8.5

Boiler - I.

 Remained in normal operation @ average steam load of 250 TPH.
 Soot blowing done 2 times during shift.
 Bed drained 1 times.
 Coal volumetric feeder tripped at 0918 Hrs due to chocking, Issued PTW to

dechocking. PP Bags, coal lumps & ropes found during dechocking. Feeder back in
service at 1011 Hrs.
 Issued PTW to remove hoses from N2 connecting point in burner’s area. (Job
Completed).
 Lime feeding system A remained in normal operation throughout the shift.
 Lime blower area exhaust fans not working, informed to electrical, E/S please follow
up.

FFBL POWER COMPANY LIMITED | 2

 Bed Ash Cooler “A”, air blaster pipe isolated due to air leakage.

Boiler - II.

 Remained in normal operation @ average steam load 215 TPH.
 Soot blowing carried out once in the shift.
 Bed drained 2 times.
 Permanent steam spargers remained in normal operation, max temp values noted

are; east side 273 C west side 259 C.
 Sparger drain line (hot job) connecting in progress E/S please followup.
 Issued cold PTW bag house TI-2071-01F (hopper F) malfunctioning rectification,

OK now.
 Bed Ash Cooler “B”, air blaster pipe isolated due to damage M/S please rectify.
 CFB#2 elevators is not working, followup with electrical they shared vendor will

work on it.

STG- I / II / III.

 STG-1 remained in shut down condition.
 Issued PTW for condensate pump A oil make up (Job Completed).
 Issued PTW for condensate pump B suction strainer cleaning (Job Completed).
 Issued PTW for condenser’s PSV sealing makeup water line leakage job (Pin hole

removal). Job completed.
 STG-2, remained in normal operation at average 15.6 MW load.
 STG-3 remained in normal operation at an average load of 9.9 MW. Radial

vibrations (VT 3050- 51/52 XY) spikes observed 3 times during shift.
 STG3 lube oil sample sent to lab.
 At 0920 Hrs, observed governor opening upto 100% from 74% due to HS header

pressure drop during coal feeder A (CFB1) tripping. Again normalize at 0930 Hrs
after header pressure boost up. ADRE shifted on STG3 following PTW from STG4.
 STGs area surveillance done by inspection following PTW.
 Steam export to FFBL remained at 201 TPH during shift.

STG - IV.

 Remained in normal operation with S.P of 53 MW.
 Issued PTW to connect laptop with ADRE for data collection.
 MOT set point changed from 88 to 89.
 PIT-CEU-4011-2C, forcing removed in alignment with UM following PTW.

FFBL POWER COMPANY LIMITED | 3

B.O.P (CT, IA/PA, De-aerator)
 BFW pump A, lube oil pump auto cut In/Out issue rectified following PTW (Cut

In/Out Pressure 1/1.6 Kg/cm2).
 SA flow increased to 1100 m3/hr as per UCR demand
 Cooling Towers, IA/PA compressors remained in normal operation.
 Chilled water Supply/Return opened 20% from FFBL side in coordination with

UCR. Issued PTW for rectification of FM leakage issue. Took Chiller A supply line
in service, found high leakage in supply isolating valve bonnet. Issue PTW for
rectification at 1430 Hrs, Evening shift please follow-up.
 Side stream filter remained in service & backwashing was done one time with pump
(CQP 1031 A).
Analysis
 Chemical dosing rates adjusted as per BUCKMAN recommendation.
 Both CFBs CBD increased from 0.5 TPH to 1 TPH.
Safety Concerns/Housekeeping/Audits/Emergency Talks
 Housekeeping audit has been done of the CFB1 all floor levels and both boiler coal
feeders area.
 Lime spillage & coal spillage in CFB1 floor levels and ground area. General pickup
done and complete housekeeping done. Bag house 1 & 2 extra material
(scaffolding/pipes/sheets) at different floor levels, issue communicated to mechanical
(Mr. Ibtissam). General pick up and house keeping done.

FFBL POWER COMPANY LIMITED | 4

PSG SHIFT ENGINEERS LOG BOOK

Shift Evening Dated 03-08-17

Steam Generation

Boiler-I Boiler-II Boiler-I Boiler-II
<10 <10
LOAD (TPH) 250 216 SiO2 (HS Steam) 0.77 0.78
CBD (TPH) 1.0 1.0 SiO2 (CBD) 05 12
Bag House (P) 112 110 Phosphate (PO4) 68
Coal Feeders (A/B/C/D) A/B/C/D A/B/C/D Hydrazine 25
Burners B&D B Amine
STG-III
Active Power (MW) Power Generation (60 Hz) 9.9
Reactive Power 6.2
Power Factor STG-I STG-II 0.86
Mode (ISO/DROOP/KW) 16.1 KW

STG_IV 9.7 Active Power
53
0.87
DROOP
Power Generation (50 Hz)

Reactive Power Power Factor
31 0.86

FFBL POWER COMPANY LIMITED | 1

PRDS Mode Opening
Set Point

40 kg (PV-3512/PV-3514/PV-3516) 42.0 Auto 0%

4 kg (PV-1076/PV-1077) 3.5 Auto 0%
10 kg (PV-1064/PV-1065) 11.3 Auto 53%

Vent Valves Opening

PV-1073 Set Point % Opening Auto/Manual
PV-1080 92.5 10 Auto
PV-1095 92.5 1.0 Auto
PV-1096 12.5 0 Auto
PV-3518 4.5 0 Auto
43.5 0 Auto

BOP (CT/IA,PA/BFW)

Open/Closed Loop CW Pumps in Service B,D,S/A

Cooling Tower Fans in Service B,C,D,S

Open Loop CW Supply/Return Temp./Pres. 31/38 & 2.6/1.3

Closed Loop CW Supply/Return Temp./Pres. 36/40 & 5.7/1.6

Compressors in Service CIK-1011 A CIK-1011 B CIK-1011 C

Loading/Unloading S.P. 7.9/8.6 7.0/8 7.8/8.5

Boiler - I.

 Remained in normal operation @ average steam load of 250 TPH.
 Soot blowing done 2 times during shift.
 Bed drained 02 times.
 Coal volumetric feeder C tripped at 1855 Hrs due to chocking, Issued PTW to

dechocking. PP Bags, coal lumps & ropes found during dechocking. Feeder back in
service at 2142 Hrs.
 Lime feeding system A remained in normal operation throughout the shift.
 Bed Ash Cooler “A”, air blaster pipe isolated due to air leakage.

Boiler - II.

FFBL POWER COMPANY LIMITED | 2

 Remained in normal operation @ average steam load 220 TPH.
 Soot blowing carried out once in the shift.
 Bed drained 01 times.
 Permanent steam spargers remained in normal operation,.
 Sparger drain line (hot job) has been completed.
 Spargers drain tray required with extended hose pipe up G.F.

STG- I / II / III.

 STG-1 remained in shut down condition.
 STG-II remained normal at 16.0 MW load
 STG-III remained normal at 9.8 MW load.
 NO spikes of vibration observed during the shift.
 .ADRE is connected with STG-III.

STG - IV.

 Remained in normal operation with S.P of 53 MW.
 MOT set point changed from 89 to 88 during the shift at 1858 for time being to cater

header pressure with keeping view on alleged STGs GOV. opening and again back
at 1900 on 89.
.

B.O.P (CT, IA/PA, De-aerator)

 BFW pump A and S are on duty with normal operation.
 Deaerator is on duty with normal operation, 120C and 1.5 kg/cm2
 CSP-5011 A MOP,PRV minor seepage was observed M/S shall follow this job.
 CSP-5011 B IP bleed NRV has a dripping M/S shall follow this job.
 Chilled water Supply/Return opened 20% from FFBL side in coordination with

UCR. Main Chiller unit of MCR valve attended for IV leakage. NOW according to
PROCESS instruction both unit valves has been isolated from header.
 Side stream filter remained in service & backwashing was done one time with pump
(CQP 1031 A).

Analysis

 Chemical dosing rates adjusted as per BUCKMAN recommendation.
.

Safety Concerns/Housekeeping/Audits/Emergency Talks

 Housekeeping has been done of the CFB1 4th floor and general picking from G.F.

FFBL POWER COMPANY LIMITED | 3

PSG SHIFT ENGINEERS LOG BOOK

Shift Night Dated 03-08-2017

Steam Generation

Boiler-I Boiler-II Boiler-I Boiler-II
<10 <10
LOAD (TPH) 250 213 SiO2 (HS Steam) 0.76 0.78
CBD (TPH) 1 1 SiO2 (CBD) 05 12
Bag House (P) 50
Coal Feeders (A/B/C/D) 110 108 Phosphate (PO4) 12
Burners A/B/C/D A/B/C/D Hydrazine
STG-III
Active Power (MW) A& D B Amine 9.8
Reactive Power 6.3
Power Factor Power Generation (60 Hz) 0.85
Mode (ISO/DROOP/KW) KW
STG-I STG-II
STG_IV 15.8 Active Power
53
9.8

0.86
DROOP
Power Generation (50 Hz)

Reactive Power Power Factor
30 0.88

FFBL POWER COMPANY LIMITED | 1

PRDS Mode Opening
Set Point

40 kg (PV-3512/PV-3514/PV-3516) 41.5 Auto 0%

4 kg (PV-1076/PV-1077) 3.5 Auto 0%
10 kg (PV-1064/PV-1065) 11.3 Auto 53%

Vent Valves Opening

PV-1073 Set Point % Opening Auto/Manual
PV-1080 92.5 0 Auto
PV-1095 92.5 0 Auto
PV-1096 12.5 0 Auto
PV-3518 4.5 0 Auto
43.5 0 Auto

BOP (CT/IA,PA/BFW)

Open/Closed Loop CW Pumps in Service B,D,S/A

Cooling Tower Fans in Service B,C,D,S

Open Loop CW Supply/Return Temp./Pres. 31/37 & 2.6/1.3

Closed Loop CW Supply/Return Temp./Pres. 34/38 & 5.6/1.6

Compressors in Service CIK-1011 A CIK-1011 B CIK-1011 C

Loading/Unloading S.P. 7.9/8.6 7.0/8 7.8/8.5

Boiler - I.

 Remained in normal operation at 250 TPH.

 Soot Blowing: 2 Bed Draining: 1

 Burner A/B/C diffuser plate found damaged (burnt out). Precautionary air flow to

these burners increased.


FFBL POWER COMPANY LIMITED | 2

Boiler - II.

 Remained in normal operation at 215 TPH

 Soot Blowing: 1 Bed Draining:

 Volumetric coal feeder ‘C’ FSL-2051-C start giving alarm which was rectified.

 Cyclone temperatures at 0600 hrs. West side max = 261 C, East side max = 277 C



STG- I / II / III.

 STG-1 remained in shut down condition.
 STG-2, remained in normal operation at average 15.8 MW load.
 T-2 generator seismic vibrations spike observed from 3.4 to 3.7 at 0505 hrs.
 STG-III, remained in normal operation at 9.8 MW load.
 Steam export remained around 198 TPH avg.


STG - IV.

 Remained in normal operation with S.P of 53 MW.


B.O.P (CT, IA/PA, De-aerator)

 Cooling Towers, IA/PA compressors remained in normal.
 500 kg hypo dosed at 0400 hrs.
 BFWP B/S remained in normal operation.

Analysis

 Chemical dosing rates adjusted as per BUCKMAN recommendation & parameters
remained in normal ranges.

Safety Concerns/Housekeeping/Audits/Emergency Talks

 Emergency talk on incident investigation and reporting conducted in shift.

Shift Incharge: Aamer Saleem
FFBL POWER COMPANY LIMITED | 3