Commissioning Manual

CDQ TECHNOLOGY 1680 50 K JM 001 Page: 1 of 113

COMMISSIONING MANUAL

CDQ10 / CDQ11

TATA STEEL LTD. DEPT.

CODE

AREA

CODE

SUBJECT

CODE REV. REV. NO.

TATA DRG. NO.

TATA CONSULTING ENGINEERS LIMITED

CONSULTANT

MUMBAI

TECHNOLOGY PARTNER INDIAN PARTNE R

LARSEN & TOUBRO LIMITED

PROJECT

G1680 – TATA STEEL Ltd. – Jamshedpur - India – CDQ COP #10/#11

TITLE

CDQ10 / CDQ11 COMMISSIONING MANUAL

PWIT NUMBER

1680 50 K JM 001 PERUGI

PREPARED BY

REV. AFI

CHECKED BY 20/09/2016

1 AEO

APPROVED BY 20/09/2015

20/09/2015

This document is the property of Paul Wurth Italia SpA. The Company will protect its rights derivi ng from such property in civil and penal courts according to law

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4 3 2 1 0 RE V.

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Final Revision First Issue

28/08/2016 20/09/2016

DESCRIPTION

DATE

PERUGI PERUGI PREPARE D

LARSEN & TOUBRO LIMITED

AFI AFI CHECKED

AEO AEO APPROVE D

APPROVED BY OWNER

1680 50 K JM 001

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IMPORTANT NOTICE

CONFIDENTIAL INFORMATION

THE INFORMATION SET FORTH HEREIN CONSTITUTES PROPRIETARY TECHNOLOGY OF PAUL WURTH ITALIA S.p.A.

THE RECIPIENT OF THIS DOCUMENT AGREES

NOT TO COPY OR REPRODUCE SAID DOCUMENTS IN WHOLE OR IN PART WITHOUT WRITTEN APPROVAL OF PAUL WURTH ITALIA S.p.A.

NOT TO DISCLOSE SAID DOCUMENTS TO ANY THIRD PARTY WITHOUT WRITTEN APPROVAL OF PAUL WURTH ITALIA S.p.A.

TO MAKE NO USE OF SAID INFORMATION OTHER THAN FOR THE PURPOSE OF ENGINEERING FOR TATA STEEL Ltd. – Jamshedpur - India

THIS INSTRUCTION MANUAL IS EXCLUSIVELY INTENDED TO AN USE BY TRAINED SKILLED PERSONNEL AND INSTRUCTED PEOPLE.

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INDEX

1.

OVERALL PLANT COMMISSIONING ........................................................ 6 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

2.

Basic safety instruction ....................................................................................... 6 Commissioning Plan ............................................................................................ 6 Preparation of Commissioning – General Instructions ...................................... 9 Preparation of Commissioning – Cleaning, Flushing and Drying.................... 10 Preparation of Commissioning – Leakage / Pressure test ............................... 11 Preparation of Commissioning – Functional tests ........................................... 11 Preparation of Commissioning – Inertization ................................................... 13 Preparation of Commissioning – Try-out drains .............................................. 13

BASIC SAFETY INSTRUCTION ............................................................... 14 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11

3.

Type of users...................................................................................................... 14 Intended use ....................................................................................................... 14 Safety notes and symbols ................................................................................. 15 General safety remarks ...................................................................................... 15 Symbols and warning signs used in the manual .............................................. 17 Type of symbols and warning signs used in the Plant..................................... 19 Residual risks and prevention/protection measures ........................................ 23 Safety Data Sheets ............................................................................................. 33 Applicable standards ......................................................................................... 33 Plant owner duties and obligations................................................................... 34 Operators duties and obligations ...................................................................... 37

SINGLE TEST COMMISSIONING PROCEDURE .................................... 38 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14

Sub Supplier manuals and instruction for Commissioning ............................. 38 Single Test Trial For Area 01 – ECR .................................................................. 44 Single Test Trial For Area 02 – BAR .................................................................. 50 Single Test Trial For Area 03 – RACK ............................................................... 53 Single Test Trial For Area 04 – Hot Coke transportation (from COB) .............. 56 Single Test Trial For Area 05 - Hot coke charging system ............................... 59 Single Test Trial For Area 06 – CDQ CHAMBER ............................................... 62 Single Test Trial For Area 07 – Cooled coke Discharging system................. 66 Single Test Trial For Area 08 – Primary Gas Catcher (PDC Area) .................... 71 Single Test Trial For Area 09 – Boiler Circuit (Boiler Area) .............................. 73 Single Test Trial For Area 10 – Cooling Gas Circuit ......................................... 76 Single Test Trial For Area 11 – Coke Breeze Circuit Area ................................ 79 Single Test Trial For Area 12 – Environmental dedusting (DE Area) & DE Coke dust Circuit (DE Dust Area) .............................................................................. 81 Single Test Trial For Area 13 – Maintenance equipment (Hoists) & Others .... 84

4. LEAKAGE TEST OF PROCESS LINES AND UTILITIES FLUSHING/PRESSURE TEST PROCEDURE.............................................................. 85 4.1 4.2 4.3 4.4 4.5

Summary of test to be executed on Fluid and Process lines ........................... 85 CDQ Gas Circuit Leakage test Procedure ......................................................... 86 Air dilution Line Leakage test Procedure.......................................................... 87 Utilities Lines Flushing and pressure test Procedures .................................... 90 Flushing Procedures for DM water, LP steam and HP steam lines.................. 91

5.

BOILER HYDRO TEST PROCEDURE ..................................................... 92

6.

INTEGRATED COLD TEST PROCEDURE .............................................. 93 6.1 6.2

7.

CDQ Integrated COLD Test ................................................................................ 93 Boiler Integrated test ......................................................................................... 97

HEATING UP AND RAMP UP TO OPERATION .................................... 100 7.1 7.2

Heating Up Preconditions ................................................................................ 100 Heating up curve .............................................................................................. 101

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7.3 7.4 7.5 7.6 7.7 7.8

8.

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Hot Air Drying ................................................................................................... 104 COG HEATING UP ............................................................................................ 107 ALKALI BOILING PROCEDURE ....................................................................... 110 Cooling down of System.................................................................................. 110 Drying and Hot coke heating ........................................................................... 110 Stabilization of operation and preparation to Performance ........................... 111

PERFORMANCE PARAMETERS OF CDQ PLANT ............................... 113

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1. OVERALL PLANT COMMISSIONING Before to start, is required to verify that all the personnel involved in commissioning activities is informed about safety instruction as per Operating and maintenance Manual and all the necessary risk evaluation and proper countermeasures adopted considering the type of activities in execution in the interested areas. The complete Commissioning Plan and Erection Plan must be developed in detail for all functional tests activities in order to identify and avoid any possible risk in the interested areas. Erection activities for the areas interested by commissioning must be completed and all the check steps for the unit have been performed and signed. The areas interested by commissioning activities must be cleaned and all erection/external activities that can create interference with the tests must be stopped. Commissioning activities must be executed according to safety protocols adopted as per normal plant operations. End of erection protocols and visual / mechanical / electrical checklist must be complete and signed and available to commissioners. Before Integrated Cold test execution the flushing of utilities lines must be executed and completed, Before Integrated Cold test execution the pressure/Leakage test of utilities lines must be executed and completed. All the areas classified as dangerous for operators (GAS, Nitrogen, etc) must be identified and all the necessary signs and information must be located in the plant as per Safety regulations. The safety and technical training of personnel involved in test execution must be complete before startup of commissioning.

1.1 Basic safety instruction During Commissioning phase the plant is considered as in special phase of operation. Personnel involved in commissioning should refer to Chapter 2 of Manual.

1.2 Commissioning Plan The commissioning plan must be included and integrated in the overall schedule of the Project, and linked to all erection activities. Commissioning plan deals of some activities to be executed during erection and after erection completion.

1.2.1 Activities to be executed in erection phase: ¨ Test of Electrical Panels and MCC. ¨ Check of correctness and completeness of utilities line up to each equipment and instrumentation, including test of each any manual valve, check of no return valve proper installation and readiness of all nozzle and hook-up for instrumentation as per P&ID ¨ Flushing and pressure test of Utilities lines. ¨ Flushing and pressure test of process lines ¨ HYDRO Test and IBR test of pressure parts of DM water, LP steam and HP Steam lines ¨ Cleaning of piping and tank and first fill for ALL lubrication units

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¨ First fill of oil for ALL equipment (when required) ¨ NO LOAD Commissioning of single equipment motor (SINGLE TESTS TRIAL) in MANUAL/local mode of operation. ¨ NO LOAD test of single equipment according vendor procedure. ¨ Check and if necessary change of grease/oil for ALL equipment. ¨ Commissioning of PLCs and HMI ¨ Instrumentation erection completed and checked by remote ¨ NO LOAD Commissioning of single equipment (SINGLE TESTS TRIAL) in AUTO/remote mode of operation. ¨ Commissioning of MOV, SOV and pneumatic valves (SINGLE TESTS TRIAL) in AUTO/remote mode of operation. ¨ Long run test for fans, pumps, compressors (variable duration) according vendor procedure. For CDQ plant the following test are recommended: o

24-72 hours no load run test for Main Gas circulation fan

o

24-48 hours no load run test for Air Dilution fan

o

24-48 hours no load run test for DE fan

o

Test run of Boiler Feed water Pumps and Deaerator feed water pumps

¨ LEAKAGE TEST for ALL gas utilities lines ¨ LEAKAGE TEST for CDQ gas circuit including boiler ¨ Insulation of CDQ gas circuit and boiler water walls ¨ Insulation of all parts of boiler, piping and equipment as per design and piping class The sequence of above activities can be slightly adapted according erection schedule.

1.2.2 Activities to be executed after erection completion: ¨ Check and preparation of materials, consumables as per Commissioning Manual ¨ GROUP TESTS of CDQ Equipment ¨ Test of interlocks and emergency sequences of CDQ ¨ Test of interlocks and emergency sequences between CDQ and COB ¨ Installation of provisional ducts, valves and equipment for heating up phase ¨ HOT Air Drying of CDQ, PDC and Boiler ¨ COG HEATING UP of CDQ, PDC and Boiler, including alkali boiling phase for Boiler ¨ Heating up burner and provisional equipment dismantle ¨ Final Inspection and check ¨ CDQ Chamber and boiler sealing ¨ Hot Coke Charging and Ramp up to operation ¨ Steam Washing and Post commissioning Activities See Attachment “Erection and Commissioning Schedule” for detailed sequence and estimated duration of the commissioning activities. Boiler related activities must be checked and agreed together with Boiler Supplier. Duration of Alkali Boiling and Boiler inspection have been estimated according practice. For Boiler related operation refer to 168053GM3001/101 “HRSG Commissioning Manuals CDQ10/11” For detail of Heating Up Operation Schedule see dedicated section in the present manual.

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1.3 Preparation of Commissioning – General Instructions The first step of the commissioning consists in the execution of an overall and accurate check-up of the units. Checking steps include, but are not limited to, the following inspection activities. Completion covers the following: ¨ Sufficient illumination of the plant ¨ Check completeness of erection of: stairs, platforms, ¨ Check if stairs, access platforms and accessibility to equipment are compliant to safety regulations and compliant to plant regulation and safety plan. ¨ Check if safety signs have been exposed in each plant area according Risk analysis and Safety plan ¨ Completion of erection punch lists and completion of ALL erection works (pipes, vessels, tanks, pumps…) ¨ Issue of certificate to verify mechanical completion ¨ Instrument and electrical equipment are mounted, fixed and connected ¨ Pressure test of equipment and pipelines completed ¨ Nondestructive welding test executed ¨ Verifiable documentation of statutory welding and pressure test, authoritative test and tests necessary to meet the requirements of the latest state of the art in technology are issued. ¨ Inspection of plants and/or plant units for mechanical completeness by commissioning Supervisors. ¨ Senior Commissioning Supervisor must sign a Final Certificate to verify mechanical completion of the plant. ¨ Inspection of PUMPS and machines for proper alignment and permitted connected forces (stress – free). Observe manufacturers operating manuals. Installation of temporary strainers. Check of lubricant. ¨ Check of HEAT EXCHANGERS for proper installation and connection ¨ Checking PIPING SYSTEM for compliance with P&ID and piping class. ¨ Check all VALVES position and installation in relation to operability and accessibility ¨ Check INSTRUMENTS and CONTROL VALVES, their position and switching points. Check equipment loops and alarms. Calibration of measurement devices in idle status. Verification of setting, signal and lock tests. ¨ Check ELECTRICAL MOTORS and CONTROL EQUIPMENT. Tests run of electric drives (load free). Alignment of motor, direction of rotation, wring check, isolating test, check grounding, light problem, light protection. Observe manufacturers manuals. ¨ Check for each VVVF the test results and check if the VVVF parameters have been recorded and available as written documentation ¨ Check of SAFETY FACILITIES for correct adjustment setting.

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1.4 Preparation of Commissioning – Cleaning, Flushing and Dryi ng Once completeness and correctness (as per P&ID) checks of piping lines and ducts have been performed, it is possible to proceed with cleaning and flushing activities. ¨ The piping elements shall be thoroughly cleaned of all foreign matters such as scales, dirt, oil, grease etc. by wiping and wire brushing before fabrication and erection/ assembly. ¨ All components of hydraulic pipework and lubrication pipework shall be cleaned, degreased, pickled, passivated and commissioned as per the special instructions given in the relevant instructions sheets. ¨ The minimum duration of purging/flushing shall be 30 minutes. Each pipe shall be flushed 3 to 4 times at above flow rate and each time not less than 30 minutes. ¨ During flushing, valves and pipelines accessories such as filters, cylinders, bearings, etc. shall be isolated and by-passed where required. ¨ Bigger pipe size DN 1800 underground and above shall be cleaned manually by making temporary opening in the pipeline. ¨ Temporary tapping/pipe connections shall be made for supply and return pipelines for flushing purpose. ¨ Flushing will be performed section wise in accordance with a cleaning plan by flushing all pipes and plant components. Check if Flushing plan and documentation has been prepared (Flushing Loops) ¨ At deepest points of the unit drainage ports have to be installed, so that the flushing media can be discharged by gravity. ¨ Equipment like tanks that are not affected by rinsed-out pollutants or contaminants can function as drainage points for pipelines that are connected to them. Drain lines can be used. Check if drainage points are available for any loops ¨ Check Flushing media availability at TOP and correctness of fluids used for flushing, considering that: o

For flushing purpose basically water shall be used, if not precluded for process related reasons.

o

For Boiler lines see Boiler Manual recommendation. DM water with proper pH must be used in accordance of piping classes and Boiler Manual instructions.

o

For combustion air, instrument air, plant air or gas pipe, air can be used as flushing medium.

o

Nitrogen pipes will be flushed with nitrogen.

o

Hydraulic and lubrication pipework shall be flushed with flushing oil.

o

All cooling water pipelines shall be chemically passivated after flushing

o

Concentrated acid systems shall be flushed with water and completely drained prior to commissioning, unless otherwise approved by Engineer

o

Fuel gas, oxygen, hydrogen and LP gas pipework shall be primarily flushed with nitrogen followed by the fluid for which the pipework as intended, slowly replacing the nitrogen.

o

Pipework for water, condensate, pressure and gravity type industrial sewerage, rinse water, acidic and alkaline effluents etc shall be flushed with water.

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¨ The pipes for water system shall be flushed by making minimum 60% opening in the pipe that is flushed and the quantity of water that shall be used for flushing shall be more than the normal flow rate for which the pipe is designed. ¨ Check completion of drainage lines up to TOP. Local laws and regulations must be fulfilled for drainages. As general information and recommendation: o

Discharge of DM water in drainage lines must be done in accordance of drainage regulation of the plant. If chemical neutralization skid is available DM water drainage must be neutralized before to be sent to drain lines.

o

Drainage waters must be collected and sent to a treatment plant (out of limits of CDQ plant) before to be discharged and mixed with ambient water.

Danger of damage to the machinery!

During flushing operations: ¨ instruments like flow meters shall be dismounted (installation of spool pieces) ¨ strainers are installed upstream to all pumps to prevent coarse materials from entering into the pumps. As particles can clog those fine strainers, they should be removed after commissioning to prevent cavitation, but should be installed for the commissioning to prevent damage to the machinery by the particles. ¨ Spool pieces are installed instead of the flow meters. ¨ Control valves need to be blanked-off or by-passed, if they cannot be replaced with appropriate fittings ¨ Instrumentation measuring lines are closed.

1.5 Preparation of Commissioning – Leakage / Pressure test The leak tightness of the entire units must be checked before commissioning activities. All components charged with gas and liquid media have to be tested. Gas-charged plant components can be tested with pressurized air (oil free) or nitrogen. Using foaming agents flanges, connections, fitting….have to be checked concerning tightness. Plant components filled with liquid media will be visually checked regarding liquid escape.

1.6 Preparation of Commissioning – Functional tests Before starting functional tests and test runs of the systems, the following general prerequisites shall also be fulfilled: ¨ Release for operation obtained by assembly/ erection management. ¨ Visual examination completed ¨ Cleaning and flushing performed. ¨ Required control valves and M&C equipment installed and ready to work; end positions as well as switching points checked. ¨ Safety devices operable (Shutoff systems, seal pots filled with water, seal pots in pipelines filled, flanged connections checked for tightness).

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¨ Utilities available in sufficient quantity and quality. ¨ Machines and apparatuses ready to work (i.e. required electrical connections available; lubricant, barrier means and coolants filled in). Check free running of machine shafts, bearings and coupling play, “stress-free” pipeline connections. ¨ Machines aligned and transport security means removed. ¨ Checks for direction of rotation completed. ¨ Tests runs of electrical drives will be performed in a load-free way according to manufacturer’s instructions. ¨ Tightness checks completed. ¨ Start-up strainers installed: after flushing, dirt still existing in the system, is collected therein. Clean the start-up strainers in time before they get clogged. Thereby, high pressure losses leading to a cracking of start-up strainers are avoided.

Function tests will be performed on the installed instrumentation: during this phase, display values, alarm, switching points can be checked and adjusted.

During functional tests, for liquid charged equipment, media like service water will be used. For gas charged plant components, air or nitrogen can be used. The degree of purity of the applied water/ air/ nitrogen must be sufficient.

Therefore, service water can be used as media for the execution of functional tests, but this water would have to be drained and discharged completely from the system at the end of the function tests. While performing functional tests the full-load operation of the plant components should be reached. During full-load operation the power input of all motors should be checked and recorded. It is very important that checks made are properly documented as the work progresses. During all filling and discharging activities the acceptable pressure ranges of tanks, vessels, columns, piping system and other plant components have to be taken into account. Proper venting of tanks during the functional tests shall be ensured. After performing functional checks, it is recommended to verify again the tightness of equipment and pipelines (already tested during erection/installation). At the end of flushing and trial operation procedure, Senior Commissioning Supervisor must inspect and approved the performed activities. Written form documentation shall be prepared.

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1.7 Preparation of Commissioning – Inertization All plant components and pipes, which are loaded with NG, BFG, COG or combustible materials, have to be made inert. Due to safety reasons only a limited remaining oxygen content of ≤ 2 vol.% is allowed in units. Therefore, the corresponding plant components have to be purged with inert gas like N2. Before purging with nitrogen, tanks and circulation pipes should be filled with process medium. The nitrogen is supplied by service stations located in each unit. During N2 purging the valves to bleed out the gas have to be opened. Using suitable sampling points gas samples can be taken in order to check the remaining oxygen content inside the lines. Bleeding out points must be located at sufficient elevation and far from areas where personnel can be present. After inertizing the plant unit, the pressure is kept slightly positive to prevent the entry of air.

Danger of asphyxiation / poisoning! Danger of asphyxiation/poisoning due to leaking nitrogen. Proceed only with work permit released. Make use of personal protective equipment. Hold gas alarm devices at disposal. Comply with all the relevant safety and labour protection codes and rules. _____________________________________________________________

1.8 Preparation of Commissioning – Try-out drains All drain must be inspected before start-up. ¨ Open the drains for a short period and check them in regard to clearance and unlimited throughput. ¨ Every sampling points must be inspected

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2. BASIC SAFETY INSTRUCTION 2.1 Type of users This Instruction Manual is exclusively designed to a use by trained qualified personnel and instructed operators. Specifically, this Instruction Manual is intended to: Plant owner, who operates the plant or has the plant operated by qualified and properly instructed and trained people. Operators, who are entrusted by the plant owner to use the plant and/or equipment. Operators shall be properly instructed by plant owner and trained about their job and about potential dangers and risks caused by an improper behaviour. Skilled personnel, who are entrusted by the plant owner with special tasks (e.g. set-up, electric specialist, maintenance, remedy of faults etc).. Therefore, the contents of the Instruction Manual have been edited supposing that only adequately trained staff will be employed.

2.2 Intended use The main purpose of the Instruction Manual is to help personnel become aware about the plant consistency and to use the plant “as intended”. With the term “as intended “ is meant that the plant shall be operated only: in presence of a technically faultless / failure less condition, with due acknowledge and consideration for safety and risks associated with the operation of the plant in compliance with operation/maintenance instructions and relevant technical documentation. Instructions and safety hints given in this manual, together with components instructions contained in vendor documentation, shall be duly observed. performing appropriate inspections and maintenance / repair activities (as scheduled), as well as all check-ups and additional tests required; using only original spare parts; using auxiliaries and supplies as specified and providing their environmentally correct disposal. The plant is exclusively aimed for the contractually stipulated application. Applications or a use beyond this scope has to be considered non-conforming and the related risk is only shouldered by plant owner. The Instruction Manual must always be available on the plant. All operators involved in operation of the unit must have read and understood the relevant instruction manual. Specifically, the instruction manual must be read and applied by personnel involved in the execution / planning of the following activities: Commissioning, Maintenance and repair Fault solving Shut down

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The Plant, including all its plant units and the related components, has been designed and erected in accordance with the state-of-the-art in technology and applicable safety rules. Nevertheless it cannot be excluded that during the operation/life of the plant: risks may occur to life/limb of the personnel/ third parties or negative impacts on the plant and other property values.

2.3 Safety notes and symbols In the first section of this Chapter are generally described the methods of communicating health and safety information that shall be adopted in the Plant. After that, in the second part, the description involves specifically symbols and warning signs used in the Instruction Manual to catch the readers’ attention about important features that must be absolutely taken into account. The third part of the Chapter is then dedicated to the explanation of the meaning of the categories of symbols and warning signs that shall be used in the plant units area.

2.4 General safety remarks 2.4.1 Methods of communicating health and safety information The following is a brief list of methods of communicating health and safety information that can be adopted in the plant units: §

Safety and/or health sign - a sign providing information or instruction about safety or health at work by means of a signboard, a color, an illuminated sign or acoustic signal, a verbal communication or hand signal;

§

Signboard - a sign which provides information or instructions by a combination of shape, color and a symbol or pictogram which is rendered visible by lighting of sufficient intensity (types of signboards are described in Chapter 0);

§

Safety color - a color to which a specific meaning is assigned;

§

Symbol or pictogram - they are for use on a signboard or illuminated sign (e.g. the trefoil ionizing radiation warning sign);

§

Illuminated sign - a sign made of transparent or translucent materials which is illuminated from the inside or the rear to give the appearance of a luminous surface (e.g. many emergency exit signs);

§

Acoustic signal - a sound signal which is transmitted without the use of a human or artificial voice (e.g. fire alarm);

§

Verbal communication - a predetermined spoken message communicated by a human or artificial voice;

§

Hand signal - a movement or position of the arms or hands giving a recognized signal and guiding people who are carrying out maneuvers which are a hazard or danger to people;

§

Fire safety sign .

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2.4.2 Safety signs: aim and selection Generally, employers have to ensure that safety signs are provided (or are in place) and maintained in circumstances where risks to health and safety have not been avoided by other means, for example engineering controls or safe systems of work. In determining where to use safety signs, the results of the Risk Analysis must be taken into account . This analysis deals with hazard identification, the risks associated with those hazards, and the control measures to be taken. When the control measures identified in the Risk Analysis have been taken there may be a 'residual' risk such that employees need to be warned, and informed of any further measures necessary. Safety signs are needed if they will help to reduce this residual risk. If the risk is not significant there is no need to provide a sign. It must be specified that safety signs are not a substitute for other means of controlling risks to employees; safety signs are to warn of any remaining significant risk or to instruct employees of the measures they must take in relation to these risks. For example in some workplaces there may be a risk of foot injury despite taking measures to control the risk. In this case it may be appropriate to remind staff with the sign indicating that wearing foot protection is mandatory.

2.4.3 General measures about the plant The following general measures shall be observed: The plant safety devices must regularly be checked for operability. In case of malfunctioning or improper operation, the plant unit involved must not be operated. Do not carry out changes on the plant that might compromise plant safety, unless ratified by vendor. Spare parts must always fit to the technical specifications of manufacturer. The conformity is only assured if original spare parts are used. To avoid/face operational faults, the operation manual must always be available on site to the staff at any time

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2.5 Symbols and warning signs used in the manual In order to capture the attention of readers about some key issues that have to be taken into account in the management of the unit, this Instruction Manual adopt the symbols and warning signs described in the following Chapters.

2.5.1 Hazard classes

This symbol and sign combination highlights an immediate hazard that can lead to death or heavy injuries unless it is prevented. ______________________________________________________________

This symbol and sign combination highlights a potential hazard with a medium risk involving death or heavy injuries unless it is prevented. ______________________________________________________________

This symbol and sign combination highlights an hazard with a low risk involving light or medium injuries unless it is prevented. ______________________________________________________________

This symbol and sign combination highlights an hazard involving damage to plant and/or equipment unless it is prevented. ______________________________________________________________

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2.5.2 Notes

This combination highlights special user tips/ suggestions that can be implemented to improve the efficiency and/or the economic performances of the plant. ______________________________________________________________

2.5.3 Environmental protection

This combination highlights key issues about environmental features or special measures to adopt for environmental protection.

2.5.4 Personal protective equipment According with the content of the risk analysis and codes and rules applicable, the employer must provide suitable personal protective equipment to all personnel involved in the operability of the plant: such equipment must be efficient and must be maintained in a functional status hygienically faultless. Whether PPE are damaged, the operators must inform superiors who will arrange for repair and/or replacement of the relevant personal protective equipment. Personnel shall be correctly trained about the appropriate use of the personal protective equipment concerning the specific plant unit.

It is imperative that anyone with access to the plant unit wear suitable personal protective equipment.

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2.6 Type of symbols and warning signs used in the Plant The following sections describe the typology of symbols and warning signs that can be used in the plant and illustrates some general circumstances in which those safety signs can be needed.

It is imperative that Plant Owner/Employers: adequately explain to all employees involved the opportune safety information about the plant unit check that their employees are aware of and understand the meaning of Symbols and Warning Signs they can come into contact with during their work verify that employees are aware of the consequences of not following the warning or instruction given by the signs; Safety and hazard signs must be kept in a well readable status.

2.6.1 Prohibition sign A sign prohibiting behavior likely to increase or cause danger. A prohibition is displayed by a round, white sign with a red skirting and red diagonal strip. The relevant contents of this prohibition is represented by a symbol, e.g. hand stopping (No entry to unauthorized personnel).

2.6.2 Warning sign A sign giving warning of a hazard or danger. A warning is displayed with a triangular yellow sign with a black skirting. Displayed on the sign is the relevant warning with a black symbol, e.g. flammable.

2.6.3 Mandatory sign A sign prescribing specific behavior. A mandatory sign is displayed by a round, blue sign with a white symbol. A face with eye-glasses means e.g. that ear protection must be worn.

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2.6.4 Emergency escape or first-aid sign A sign giving information on emergency exits, first-aid, or rescue facilities. A rescue facility is displayed with a rectangular, green sign with a white symbol, e.g. emergency exit/escape route and emergency shower/eyewash.

2.6.5 Information sign A message is displayed with a rectangular, blue sign with a text in white letters, e.g. parking area.

2.6.6 Hazardous substance sign This kind of Hazard symbols are fundamental to warn workers of potential hazardous substances. Any hazardous material must be properly identified and classified, determining which of the hazard classes characterizes the hazards associated with the material. Hazard classes define the type of risk a hazardous material may pose. There are three main types of hazard classes: the physical hazards (e.g. Explosive Self-reactive substances/mixtures), the health hazards (e.g. Acute toxicity, Germ cell mutagenicity) and the environmental hazards (e.g. Hazardous to the aquatic environmental, acute). The hazard classes are divided into hazard categories, specifying the hazard severity. For some hazard classes there is a distinction depending on the route of exposure (oral, dermal, inhalation) or the nature of the effect (e.g. respiratory tract irritation, narcotic effect). Each substance falling at least under one of these categories must be provided with a corresponding label and Safety Data Sheet (SDS). In general, the label consists of an unambiguous, succinct logo and an informative but short text. This label must be standardized, well visible, legible and edited in understandable language (English language recommended). The identification label of hazardous substances and preparations must be securely attached on the package (for non-packed status substances, as bulk material, the relevant data shall be recorded on the accompanying voucher and SDS). In case of substances refilled into other admitted casks, the refilled cask shall also be marked with a proper identification label. The identification label must contain the following data: ü (chemical) designation of the substance or preparation ü designation of hazards and pertinent hazard symbols (s.b.) ü hazardous statements (H-statements) indicating the nature and degree of the risks posed by the product ü precautionary statements (P-statements) indicating how the product should be handled to minimize risks to the user (as well as to other people and the general environment) ü signal words “Danger” and “Warning” to alert the reader on a potential hazard. ”Danger” indicates more severe hazard categories, “Warning” the less severe hazard categories.

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ü producer, importer or marketing enterprise ü EC number, if any, allocated to the substance

Below the table of the hazard symbols: PHYSICAL HAZARDS PICTOGRAM

DESCRIPTION

HAZARD CLASSES AND CATEGORIES

Exploding bomb

Unstable explosives Explosives, divisions 1.1, 1.2, 1.3, 1.4 Self-reactive substances and mixtures, types A, B Organic peroxides, types A, B

Flame

Flammable gases, category 1 Flammable aerosols, categories 1, 2 Flammable liquids, categories 1, 2, 3 Flammable solids, categories 1, 2 Self-reactive substances and mixtures, types B, C, D, E, F Pyrophoric liquids, category 1 Pyrophoric solids, category 1 Self-heating substances and mixtures, categories 1, 2 Substances and mixtures, which in contact with water emit flammable gases, categories 1, 2, 3 Organic peroxides, types B, C, D, E, F

no pictogram required

Flame over circle

Oxidizing gases, category 1 Oxidizing liquids, categories 1, 2, 3 Oxidizing solids, categories 1, 2, 3

Gas cylinder

Compressed gases Liquefied gases Refrigerated liquefied gases Dissolved gases

Corrosion

Corrosive to metals, category 1

no pictogram required

Explosives, divisions 1.5, 1.6 Flammable gases, category 2 Self-reactive substances and mixtures, type G Organic peroxides, type G

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 22

HEALTH HAZARDS PICTOGRAM

DESCRIPTION

HAZARD CLASSES AND CATEGORIES

Skull and crossbones

Acute toxicity (oral, dermal, inhalation), categories 1, 2, 3

Acute toxicity (oral, dermal, inhalation),category 4 Skin irritation, categories 2, 3 Eye irritation, category 2A Skin sensitization, category 1

Exclamation mark

Corrosion

Specific target organ toxicity following single exposure, category 3 Respiratory tract irritation Narcotic effects Not used: with the "skull and crossbones" pictogram for skin or eye irritation if: the "corrosion" pictogram also appears the "health hazard" pictogram is used to indicate respiratory sensitization

Skin corrosion, categories 1A, 1B, 1C Serious eye damage, category 1

Respiratory sensitization, category 1 Germ cell mutagenicity, categories 1A, 1B, 2 Carcinogenicity, categories 1A, 1B, 2 Reproductive toxicity, categories 1A, 1B, 2 Health hazard

no pictogram required

no pictogram required

LARSEN & TOUBRO LIMITED

Specific target organ toxicity following single exposure, categories 1, 2 Specific target organ toxicity following repeated exposure, categories 1, 2 Aspiration hazard, categories 1, 2

Acute toxicity (oral, dermal, inhalation),category 5 Eye irritation, category 2B Reproductive toxicity – effects on or via lactation

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ENVIRONMENTAL HAZARDS PICTOGRAM

no pictogram required

DESCRIPTION

HAZARD CLASSES AND CATEGORIES

Environment

Acute hazards to the aquatic environment, category 1 Chronic hazards to the aquatic environment, categories 1, 2

no pictogram required

Acute hazards to the aquatic environment, categories 2, 3 Chronic hazards to the aquatic environment, categories 3, 4

2.7 Residual risks and prevention/protection measures The risk analysis has set according to the following steps: Defining the plant limits, dividing it into areas defined on the basis of the associated risk. Considering the practice followed by the institutional bodies for work equipment commissioning controlling, every unit has been divided according to the risk characteristics of the line. Similarly some "elements" with common or shared characteristics with lines were identified (e.g., support structures, stairs and walkways for access or passage, etc.);

Defining the plant operating modes: according to the requirements of EN ISO 12100:2010 taken as the reference, the risk analysis was performed for the different operating modes of the system, i.e.: §

Construction (including the phases of transport, assembly and installation);

§

Commissioning, initial or following stops;

§

Use;

§

Maintenance, in all its forms, including inspection (during operation or when stopped) or restores programmed fault (in operation or during stop) and repairs;

§

Decommissioning (at the end of life of the plant).

identifying the hazards and associated hazardous situations, according to the requirements of EN ISO 12100; associated risk assessment, and preventive/protective measures indications, using the so-called "risk graph", evaluated by: the severity of possible injury I. There are three possible severity levels: · I1: minor injuries, reversible, with limited time off work; · I2: serious injury, irreversible, with long absences from work; · I3: serious injury spread to more people or death

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the Frequency/duration of exposure to the hazard F. In consideration of the time of access to the danger zone and of the number of people, two possible levels of frequency / duration can be identified: · F1: up to 10% of the work shift (relative to the normal operating mode), up to 30 minutes (for other operating modes); · F2: more than 10% of the work shift (normal operating mode); over 30 minutes (other modes) the possibility of avoiding or limiting the damage A. There are two avoidance levels: · A1: possible in some conditions (eg., the moving parts at very low speeds, to be defined in accordance with re gulatory requirements, or if the exposed operator knows the risks and the indic ators of an imminently hazardous situation, etc.); · A2: hardly possible or impossible (eg., high speeds, absence of indicators of imminent hazardous situation, etc.) the probability that the hazardous event occurs P. There are 4 probability levels: · P0: 0. This condition occurs when the security features are carefully defined and comp lied (eg. isolation switch from sources of energy locked in the safety position, o r the protective fixed devices are irremovable, etc.) · P1: low. The event is unlikely to occur · P2: average. The event during the life of the equipment doesn’t creates surprise (eg, improp er human action by a well trained person) · P3: high. Event that is observed regularly. The combination of these factors, according to the chart below allows the estimation of the risk associated with the dangerous event in analysis. STEP 2a Injury (I)

STEP 2b Frequency (F)

STEP 2c Avoidance (A)

Severity of possible injury

Frequency / duration of

Possibility of avoiding or

exposure to the hazard

limiting the harm

I1

NA F1

I2 F2 F1 I3 F2

A1 A2 A1 A2 A1 A2 A1 A2 A1 A2

STEP 3 Probability (P) Probability of harm occurence

P0 R1 R1 R3 R3 R4 R4 R5 R5 R6 R6

P1 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10

P2 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11

RiskGraph According to the Paul Wurth standard, the risk values in green boxes are considered acceptable and any additional protective measure is not undertaken. The risk values in yellow boxes recommend further additional protective measures or instruction recommendations. Finally, for the risk values identified by red boxes, the level is considered unacceptable and additional protective measures are NEEDED TO BE IMPLEMENTED. Although the Paul Wurth standard provides that for the green values the risk is acceptable and is not provided for any additional protective measure, this information cannot be considered sufficient if there are legal requirements (national or Community) about that provide for additional protective measures.

LARSEN & TOUBRO LIMITED

P3 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12

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If the estimated risk during preliminary analysis do not reach a level considered as acceptable (or if the national or Community legislation provides for specific requirements), the analysis goes on to the protective measures to be implemented by the manufacturer, which follows a final evaluation of the risk (always performed by the graphical method described above). After the final assessment, the residual risks are identified and further measures are indicated to put in the User instructions. The methodology above described must be applied to each unit of the plant: the results of the risk analysis are reported in the specific unit manual, where it is indicated: ¨ the residual risk for user (origin and potential consequences); ¨ the areas where the residual risk is present; ¨ the recommended preventive measures; ¨ the Personal Protective Equipment (PPE); ¨ the safety signs (as indicated in EN ISO 7010:2012 standard). ¨ In addition to the risks described above resulting from the process the Owner must take into account those arising from the current plant status as: ¨ Conservation status of the walkways ¨ Conservation status handrail ¨ Conservation status of the stairs (steps) ¨ Terms of the order and cleanliness of the plant ¨ Presence of proper lighting ¨ Adequate staining and identification of all service fluids ¨ Presence of adequate safety signs and specification ¨ Identification of components of plant

As stated above the plant operator in order to prevent possible hazardous conditions for personnel working on the plant will have to prepare the following: ¨ Implement a plan inspection by trained personnel (Maintenance) to monitor the status of the plant ¨ Implement appropriate forms of feedback to the reporting by the operation staff on possible critical issues ¨ Implement a plan for maintaining order and cleanliness of the plant ¨ Implement a plan for the control and maintenance of devices Fire, analysers, and alarm tones ¨ Implement a plan of meetings with personnel who that targeted exercise training on all aspects of inherent health and safety on the plant

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Plant Areas for Risk Analysis N° Area PU

Identification

P&ID DRAWINGS

A1

51

Hot coke charging system

1680 50 K 02 001/002

A2

51

Cooled coke Discharging system

1680 50 K 02 001/002

A3

54

Coke breeze handling

1680 50 K 02 001/002

A4

52

Cooling gas circulation

1680 50 K 02 003/004

A4.1

51

Cooling chamber

1680 50 K 02 003/004

A4.2

52

Primary dust catcher

1680 50 K 02 003/004

A4.3

52/53

Heat Recovery Steam Generator (Boiler Shell)

1680 50 K 02 003/004 1680 53 G 02 001/011

A4.4

52

Secondary dust catcher

1680 50 K 02 003/004

A4.5

52

Main circulation gas fan

1680 50 K 02 003/004

A4.6

52

Sub economizer and Lower bleeder line

1680 50 K 02 003/004

A4.7

52

Gas analyzer / O2 monitoring system

1680 50 K 02 003/004

A5

56

Coke Handling – Cold Coke Discharging

1680 50 K 02 001/002

A6

56

Coke Handling – Coke Fines Handling

1680 50 K 02 001/002

A7

51

Combustion Air

1680 50 K 02 003/004

A8

80

Nitrogen Network

1680 50 K 02 003/004 1680 80 U 02 003/013

A9

53/80

BAR – Boiler Auxiliaries Room Building

A10

80

Compressed Air network

1680 80 U 02 006/016

A11

80

Cooling Water network

1680 80 U 02 007/017

A12

80

Industrial Water network

1680 80 U 02 001/011

A13

80

COG network

1680 80 U 02 009/019

A14

80

Instrument Air Network

1681 80 U 02 005/015

A15

80

Demi Water Network

1681 80 U 02 004/014

A16

80

High Pressure steam Network

1681 80 U 02 008/018

A17

80

Low Pressure steam Network

1681 80 U 02 002/012

A20

54

CDQ Dedusting Line

A21

53

Heat Recovery Steam Generator (BOILER PROPER)

A100

Walkways

A200

Support structures

LARSEN & TOUBRO LIMITED

O15044-0F2-M-B-0159-001/0 02 1680 53 G 02 001/011 1680 53 G 02 002/012 1680 53 G 02 003/013 1680 53 G 02 004/014

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Mechanical Hazards Risk

Residual risk

Area

Mitigations measures

Signs

Elements with shar p edges: e.g. struct ures, sheet edge of

In protective/insulation materials

All

Use safety gloves (E N381) and safety sho es (S3 EN ISO 2034 5) against cutting

Protective gloves

protection/insulation materials

Safety shoes Warning: Sharp Element Work near accessib le moving parts (Impact, Entanglem ent, Shearing)

During work near acc essible moving eleme nts

Work on moving elements without power outage (Impact, Entanglem ent, Shearing)

During work on movi ng elements

Fall of not fixed or unsafe structures (Crushing)

In case of incorrect maintenance

ALL

Fall of material due

In case of incorrectm aterial movements

A100

In case of failure to f ollow the indications and lack of shields

A100

to deposit of unstab le material or overl oad Fall of person from high levels (gravity)

Release of pressurized fluids (being run over, being thrown, impact due to ruptures)

In case of incorrect maintenance

It is forbidden to rem ove the protections. All, in prese nce of mobile e lements

A4, A8, A10, A1 6, A17, A21

Annual check of the efficiency of the protection. Cut and clamp energy sources before workin g or remove protection. Periodic inspections: Annual control of: bo lt tightening, welded join t, corrosion Every 5 years: check for cracks and distort ions in beams and ca twalks Respect the capacity limits of structures

Disconnect before carrying ou t maintenanc e or repair

No heavy loads

It is forbidden to rem ove the protections Annual check of the shields against fall do wn Block the vents in case of work near them Every 5 years check the piping and vessel conservation (VT, PT, UT)

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No reaching in

Warning drop (fall)

Warning pressurized cylinder

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Risk

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Residual risk

Area

Mitigations measures

Signs

Follow the specifications of component manuals about control, use and maintenance Electrical Hazards Risk

Residual risk

Area

Mitigations measures

Signs

Direct/indirect conta ct with live compon ents (electrocution)

In case of incorrect maintenance

All

Cut and clamp energy sources before worki ng Warning: electricity

Disconnect mains plu g from electrical outlet Warning el ectricity

Overload/short circui ts components (bur n, fire/explosion)

In case of incorrect maintenance

All

Follow the specificatio ns of electrical compo nents manuals about control, use and main tenance

Risk

Residual risk

Area

Mitigations measures

Direct contact with not insulated piping and vessel with T >40°C (burns)

In case of accidental contacts

Thermal Hazards Signs

Use the safety gloves (EN 702) against burn s

Do not touch

Warning hot surface Investment by relea se of hot fluids (bur ns)

In case of incorrect maintenance

Block the vents in the case of work near the m. All Annual monitoring su rface temperature of t he pipe (with thermal imaging camera to hi ghlight anomalies) Every 5 years check t he piping and vessel conservation (VT, PT, UT). Follow the specificatio ns of component man uals about control, us e and maintenance

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General warning sign Danger of burns and/or scalds

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Risk

Residual risk

Area

Mitigations measures

Flammable fluid los s, with ignition sour ce (Fire/Explosion)

In case of incorrect maintenance

A4 A13

Block the vents in the case of work near th em. Annual monitoring surface temperature o f the pipe (with thermal imaging camera to highlight anomalies)

Signs

No open flame

Warning flammable material

Every 5 years check the piping and vesse l conservation (VT, P T, UT), Follow the specificatio ns of component man uals about control, us e and maintenance

Warning explosive material

Signs

Noise Risk

Residual risk

Area

Mitigations measures

Exposure to continuous noises

Close to high noise levels zone

All

Exposure to sudden

Close to high noise

All

The level of emitted n oise depends on man y factors, including pl ant layout, operation mod e, environmental cond itions, etc. Therefore, the user m ust perform and measurement the nois e level, as prescribed b y law. The results measurement will highlight both the sign to install, the PPE to use. Hearing protection SN R 34 dB (EN 352)

noises from leakage of fluid under pressure (flanges, valves, hoses)

levels zone

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Wear ear protections

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Materials/Substances Risk

Residual risk

Area

Mitigations measures

Signs

Release of toxic flui ds (poisoning toxic)

Close to the relea se zone

A2 A4 A8 A13 A21

Use personal multifunctional detector s (CO, H2S, etc)

Wear respiratory protection

PPE: Escape emergency mask or Full face respiratory protections Follow the specificati ons of component ma nuals about control, u se and maintenance o f components that may give releases Every 5 years check the piping and vessel conservation (VT, PT, UT)

Warning toxic material

In case of emergency,

Flammable fluid loss , with ignition sourc e (Fire/Explosion)

In case of incorre ct maintenance

A4 A13

before to access to pl ant check the wind so cks for direction of wind Use showers and eyewash systems Block the vents in the case of work near th em. Every 5 years check the piping and vessel conservation (VT, PT, UT). Follow the specificatio ns of component man uals about control, us e and maintenance

Internal flammable/explosive atmosphere after maintenance

In case of incorre ct inertization of pi ping/vessel contain ing flammable/oxidizing

A4 A13

fluids

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Remember to inertize the piping before put i n services

No open flame

Warning flammable material Warning explosive material

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Risk

Residual risk

Area

Mitigations measures

Release of asphyxiating gas

Close to the relea se zone or into th e inertized piping/v essel

All inertize d pipes / shells

Close to the relea se zone

A4 A13

Every 5 years check the piping and vessel conservation (VT, PT, UT). Follow the specificatio ns of component man uals about control, us e and maintenance Before to access the i nerted pipes, relief of the O2 concentration. Necessary Health prot ocols (periodic checks) as indicated by national laws. Respect the indication s reported in safety data

Release of cancerou s gas

sheets of cancerous substances PPE: Full face respiratory protections

LARSEN & TOUBRO LIMITED

Signs

General warning "Danger of suffocatin g due to escape of inert gas"

Wear respiratory protection

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2.7.1 General Safety prescription for plant access Here below are reported the general indications derived from accepted Risk Analysis, with amendments suggested by Design Review.

AUTHORIZED PERSONNEL ONLY

The access to the plant is restricted to authorized personnel only, which must use the following PPE:

Protective gloves

Head protection

Safety shoes

Eye protection

Protective clothing

In the following, other PPE are indicated for t he safety access to specific areas of the unit

Availability of Mini-Fenzy, portable respiration equipment (where CO leakages are detected). In the Plant Unit manuals are indicated the information for the user about the residual risks, the mitigation measures, the possible Personal Protective Equipment (PPE) and the indications for safety signs (in compliance with the technical standard EN ISO 7010:2012), by division according to the risk nature.

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2.8 Safety Data Sheets Media supply Safety Data Sheets must be collected and stored by Plant Owner. The Safety Data Sheets must always be available on the plant.

To avert any danger or risk, it is imperatively required to consult the manufacturer or vendor’s documentation on the relevant plant unit. ______________________________________________________________

MATERIAL Safety Data Sheets for final products and intermediate products will be collected and/or provided by Owner.

2.8.1 List of Data Sheets to be inserted in the ATTACHMENT 2.1: ¨ COKE ¨ COKE BREEZE / DUST ¨ HP STEAM ¨ TRISODIUM PHOSPATE ¨ HYDRAZINE ¨ AMMONIUM HYDROXIDE

2.9 Applicable standards The Plant, including all its plant units, apparatuses and components, component groups and spare parts, has been designed, provided and built in accordance with the latest state of the art in technology. Plant owner shall comply with/pay attention to those codes and rules specifically applicable to industrial hygiene and environmental protection in India.

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2.10 Plant owner duties and obligations 2.10.1 General measures Plant owner must: employ only trained and instructed personnel. Staff competency about operation, service, maintenance, and repair must be clearly outlined and fixed. The statutory minimum age must be respected. guarantee that only authorized, instructed and trained personnel work on the plant. The staff must attend specific practical courses about operating the plant and safety precautions (firefighting system, location and use of signaling facilities, rescue equipment, first aid devices, etc.). check within regular intervals that the work performed by plant staff is done in a safe way and in conformity with this operation manual. guarantee that, in addition to what included in the instruction manual, the applicable national and international codes and rules specifically related to industrial hygiene, prevention of accidents and environmental protection shall be respected. furnish personal protection equipment and clothing in conformity with the relevant applicable regulations. Plant owner must assure that personnel have been correctly trained about the appropriate use of the personal protective equipment concerning the specific plant unit. Furthermore, Plant Owner must provide suitable tools and devices necessary for executing all the operation on the plant. Regulate operations for which is required the issue of work permit (special and high-risk work in operation units) and implement a formal procedure for a work permit release. In general, operators shall only operate doing works they’ve been trained for and which they have received a specific formal permit for (that specifies the conditions which work has to be executed under).

2.10.2 Emergency plan Employer/its duly authorized agent shall provide a system and resources to deal with emergencies to protect and minimize adverse impacts on people, property and the environment. An emergency may be described as a hazardous situation (or threat of hazardous situation) which requires action to control, correct and return the site to a safe condition and also requires timely action to protect people, property and the environment from damage. In more detail, employer/its authorized agent have to take suitable measures required in case of accident, fire, danger, disaster, etc., for: ¨ first aid, ¨ fire fighting ¨ staff evacuation. The measures, that must consider even the presence of other individuals on factory premises (e.g. visitors and customers), have to be detailed in an Emergency Plan, that shall at least cover: ¨ escape route plan, ¨ alarm plan (warning system, reporting routes, responsibilities, sequences), ¨ rescue plan, ¨ fire protection plan.

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1680 50 K JM 001

Page: 35

The emergency plan must provide for sufficient flexibility, so that even unforeseen situations can be fronted in a proper way. In the emergency plan must be clarified at least: ¨ Objectives and range of validity of the plan (for example, emergency scenarios taken into account, location of more precise information). ¨ Levels of emergency (clear-cut definitions and gradual criteria) in relation to the potential impacts of the event (e.g. about where the impacts on people, property and environment are expected to be confined). ¨ Organization and responsibilities, considering disaster protection and fire brigade facilities in the surroundings (town, municipality), alarm centrals shall be provided for. ¨ Statements on warning and alarming procedures ¨ Medical care during emergency: ¨ Operational organization and staffing, ¨ Operational medical care facilities, ¨ Collecting points for staff members and accident victims, ¨ Co-operation with relief organizations, fire brigade, and disaster protection in the surroundings, ¨ Information to relatives or acquainted. ¨ Descriptions of the procedures to adopt with emergencies – from the first message via alarming, opposing to finalizing of actions

The emergency plan must be known to all staff members that must to be tested and trained in joint exercises/emergency tests. All staff members should have a working knowledge of the: ¨ emergency plan, ¨ escape and rescue routes, ¨ names and position of first aid staff and/or ambulance personnel, ¨ location of first-aid box, stretchers, and ambulance room, ¨ places of notice board with phone numbers and addresses of rescue service, hospital and emergency physician.

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1680 50 K JM 001

Page: 36

2.10.3 Fire prevention Employer/its duly authorized agent shall provide a system and resources to prevent fire and to protect and minimize adverse impacts on people, property and the environment in case of fire. A fire prevention plan must include: ¨ A list of all major fire hazards, proper handling and storage procedures for hazardous materials, potential ignition sources and their control, and the type of fire protection equipment necessary to control each major hazard; ¨ Procedures to control accumulations of flammable and combustible waste materials; ¨ Procedures for regular maintenance of safeguards installed on heat-producing equipment to prevent the accidental ignition of combustible materials; ¨ The name or job title of employees responsible for maintaining equipment to prevent or control sources of ignition or fires; ¨ The name or job title of employees responsible for the control of fuel source hazards.

Employer/its authorized agent must: ¨ inform employees upon initial assignment to a job of the fire hazards to which they are exposed ¨ review with each employee those parts of the fire prevention plan necessary for selfprotection.

2.10.4 First aid Employer/its duly authorized agent shall ensure the ready availability of aid granted to an individual injured by accident until medical personnel aid arrives. In order to assure First Aid, there must be a proper internal organization and there must be available: ¨ Communication facilities to call for help(telephone, wireless, etc.), ¨ Trained First Aid team, ¨ First Aid matters (first-aid box, etc.) ¨ Rescue equipment and transport means. ¨ Furnished rooms where First Aid can be performed, ¨ Identification signals to locate emergency telephone and First Aid facilities (and indications to guide to First Aid facilities).

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2.11Operators duties and obligations 2.11.1 General measures Each operator must: ¨ comply with the indications given by the employer /its duly authorized agent in relation to the specific responsibilities associated with specific the job/position. ¨ observe and respect all safety/hazard signs and symbols on the plant. ¨ take care of personal protective equipment (see. Chapter 2.8.2): if this is defective or damaged, personnel must hand it over to leaders to arrange for repair and/or exchange for suitably working equipment. ¨ in case of safety-relevant modifications to the plant or alterations in its operating performance, immediately put the plant on standstill and report the situation to the chief in charge. ¨ be aware about fire alarm and firefighting. ¨ familiarize with escape and rescue routes. ¨ wear suitable clothing (see. Chapter 2.8.2) and avoid elements that can interact with the equipment involving the risk of being injured (projecting clothes/hair, jewellery etc.)

2.11.2 Personal protective equipment Each operator must wear personal protective equipment (PPE) and clothing provided by plant owner in conformity with the relevant regulations. If PPE or clothing is faulty or damaged, the operator must hand it over to superiors to coordinate for repair and/or exchange for properly working equipment.

Personnel shall be correctly trained about the appropriate use of the personal protective equipment concerning the specific plant unit.

It is imperative that anyone with access to the plant unit wear suitable personal protective equipment.

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 38

3. SINGLE TEST COMMISSIONING PROCEDURE Commissioning operation will be organized and executed in sequence, dividing the plant in different areas. The Areas of commissioning are organized as per following list:

01. Electrical Building (ECR Area) 02. Boiler Auxiliary Room (BAR Area): 03. Utilities Lines Distributions and Power Signal cables (RACK Area) 04. Hot Coke transportation from COB (LOCO-COB Area) 05. Hot Coke Charging (Crane Area) 06. CDQ Chamber (CDQ Proper Area) 07. Cold Coke discharging (Cooled Coke Area) 08. Primary Gas Catcher (PDC Area) 09. Boiler Circuit (Boiler Area) 10. Cooling Gas Circuit (CDQ Gas Area) 11. Coke Breeze Circuit (Breeze Area) 12. Environmental dedusting (DE Area) & DE Coke dust Circuit (DE Dust Area) 13. Maintenance equipment (Hoists) & Others items

Here below the commissioning procedure for each unit is reported.

For the equipment supplied by Third Parts, in order to correctly follow the Supplier instructions, the Single test Procedures for Commissioning are included in the Vendor Manuals, attached to the present manual.

3.1 Sub Supplier manuals and instruction for Commissioning Here below a list of Sub Supplier manuals and instructions for Commissioning and O&M is attached.

LARSEN & TOUBRO LIMITED

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3.1.1 Sub Supplier Manuals and Instruction for Commissioning for AREA CDQ 02

Detail Description

VENDOR NAME

DOCUMENT ID

- MECHANICAL ITEMS ITEMS FOR BAR BFW Pumps

168053GM3001/101 168053GM2001/101 10.5.1.8

THERMAX

Pumps:

Crane VVFF Panels / PLC

WILO MATHER PLATT WILO MATHER PLATT WILO MATHER PLATT WILO MATHER PLATT DHHI

CDQ PLC

PW-Infinity

Booster Pump Deaerator Feed Pump Deaerator Circulation Pump Industrial Water Pump

04

05

06

Mechanical Items

& & & &

10.5.1.8.1 10.5.1.8.2 10.5.1.8.3 10.5.1.8.4 168080EM1150/250 168080IM2104/204 168080IM2102/202 168080IM2101/201

ITEMS FOR COKE TRANSPORTATION Coke bucket

DHHI

L&T - 10.1.1

Coke Bucket Carriage

DHHI

L&T - 10.1.2

Items for Loco modification

DHHI

L&T - 10.1.4

Automatic Positioning System (APS)

DHHI

L&T - 10.1.3

Crane

DHHI

168051FEM312 168051FEM315

Charging System

IHI-PW

168051KM1002

ITEMS FOR COKE CHARGING

ITEMS FOR COOLING CHAMBER AREA Chamber proper

168051KBE001/002

Blasting Device

IHI-PW

168051KM1001

Dilution Air Blower with motor

Andrew Yuel & Co

L&T - 10.2.2.6

Basalt liner for Cooling Chamber

10.5.17

CI liner for Cooling Chamber

10.5.17

Heating Up Equipment

10.5.19

MOV, SOV, Pre chamber bleeder, Pre cham ber bypass

10.5.4.2

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

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AREA

Detail Description

07

ITEMS FOR COKE DISCHARGING DEVICE FOR COOLED COKE Vibrating feeder

VENDOR NAME

DOCUMENT ID

RHT

L&T - 10.2.2.1

Dust Chute for coke discharging

L&T - 10.2.2.2

Slide gate + Rod Gate

L&T - 10.2.2.3

RSV

SteelPlantech Co

168051KM1004

Cooled coke Conveyor

L&T - '10.1.5

Belt conveyor with accessories

L&T - 10.1.5.1

Belting

PHOENIX

Pulley and Deflector Rollers

Idlers

JOYA ENGINEERING INDUSTRIES JOYA ENGINEERING INDUSTRIES

L&T - 10.1.5.1.1 L&T - 10.1.5.1.2

L&T - 10.1.5.1.3

Plummer block

L&T - 10.1.5.1.4

Bearing

L&T - 10.1.5.1.5

Gear box

PREMIUM

L&T - 10.1.5.1.6

High speed (Tyre) Couplings

FENNER

L&T - 10.1.5.1.7

Low Speed Pin-Bush Coupling

FENNER

L&T - 10.1.5.1.8

Conveyor External Scrapper

L&T - 10.1.5.1.9

Conveyor Internal Scrapers

L&T - 10.1.5.1.10

Take-Up Components

L&T - 10.1.5.1.11

Tie Rods with Fasteners

L&T - 10.1.5.1.12

Take-up Counter weight Block

L&T - 10.1.5.1.13

Fabrication items of Belt conveyors

L&T - 10.1.5.1.14

Chute & Skirts.

L&T - 10.1.5.1.15

HGTU Trolley

L&T - 10.1.5.1.16

Belt Weigher

ACME

L&T - 10.1.5.1.17

MVWS for conveyor

L&T - 10.1.5.1.18

Conveyor skirt board sealing

L&T - 10.1.5.1.19

Screw Take Up

L&T - 11.1.5.1.20

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 41

AREA

Detail Description

VENDOR NAME

08

ITEMS FOR PRIMARY DUST CATCHER Primary dust catcher Steam Bleeding Device

09

10

11

10.3.2.1 10.3.4.4

ITEMS FOR BOILER AREA HRSG BOILER PROPER

THERMAX

HRSG BOILER AUXILIARIES

THERMAX

SUB-ECONOMIZER

THERMAX

Boiler Instruments

L&T

168053GM2001/101 168053GM3001/101 168053GM2001/101 168053GM3001/101 168053GM2001/101 168053GM3001/101 L&T - 10.5.21

ITEMS FOR GAS CIRCULATION SYSTEM Gas circulation blower

L&T - 10.3.1

Gas circulation blower Motor for gas circulation blower Emergency Flaring system High & Low Temperature Expansion Joints

L&T L&T L&T L&T L&T

Coke breeze discharge equipment for primary dust ca tcher & Secondary Dust Catcher Coke Breeze Bunker Rotary Seal Valve / Manual Slide Gate Chain Conveyor Bucket conveyor

12

DOCUMENT ID

-

10.3.1.1 10.3.1.2 10.3.3 10.5.12 10.3.4

L&T - 10.3.4.1 Rotary Airlock Valve

L&T L&T L&T L&T

-

10.3.4.2 10.3.4.3 10.3.4.6 10.3.4.7

Coke dust hopper

L&T - 10.3.4.9

Telescopic chute Pug-mill ITEMS FOR DUST EXTRACTION SYSTEM

L&T - 10.3.4.10 L&T - 10.3.4.11 10.4

Bag filter proper Bag filter proper with spark arrestor Manual Slide Gate

L&T - 10.4.1 L&T - 10.4.1.1 L&T - 10.4.1.2

Rotary Airlock Valve Chain conveyor Bucket conveyor Dust Storage Silo Pug-mill Plant Dedusting Fans Chute

L&T L&T L&T L&T L&T L&T L&T

LARSEN & TOUBRO LIMITED

-

10.4.1.3 10.4.1.4 10.4.1.5 10.4.1.6 10.4.1.7 10.4.1.8 10.4.1.9

1680 50 K JM 001

Page: 42

AREA

Detail Description

13

OTHERS

10.5

Hanger for main steam piping Electrical Hoists Jib crane Manual Hoists Fire Hydrant Valves, Fire Hose and Hose Box Chemical (Acid) Dosing System Insulation Pipe & Fittings Valves Manual Valves Boiler related Valves Fabrication Items for CDQ 10 Equipment DM storage Tank Expansion Joints for Dedusting / Expansion Joints f or pumps Dampers Submersible sump pump Elevator THYSSEN KRUPP Instrumentation TDS Various

L&T L&T L&T L&T L&T L&T L&T L&T L&T L&T L&T L&T L&T L&T

LT Motors Catalogue

L&T – E.07

LARSEN & TOUBRO LIMITED

VENDOR NAME

DOCUMENT ID

-

10.5.1.1 10.5.1.2 10.5.1.9 10.5.1.3 10.5.1.4 10.5.1.6 10.5.1.7 10.5.3 10.5.4 10.5.4.1 10.5.4.3 10.5.5 10.5.11 10.5.13

L&T - 10.5.14 L&T - 10.5.20 L&T - 10.2.2.5 I01 –I23

1680 50 K JM 001

Page: 43

3.1.2 Sub Supplier manuals and instruction for Commissioning for Electrical/instrumentation Items Document Detail Description N°

VENDOR

Commissioning Area

ELECTRICAL ITEMS (ECR BUILDING) E.1

6.6KV HT SWBD

Schneider Electric

E.2

Relay control with mimic panel

Technocommerce

E.3

6.6KV/.433KV Dry Type Transformer

Raychem RPG

E.4

ACS - 880 Drive

M/S ABB

E.5

DG SET with AMF Panel

M/S Jakson

E.6

415V PCC / MCC / PBD

M/S L&T EBG

E.7

LT Motor

M/S ABB

E.8

Battery and battery charger

M/s Chloride Power

E.9

UPS

M/S Hitachi Hirel

E.10

6.6kV VFD

M/S ABB

INSTRUMENTATION & AUTOMATION I.1 I.2 I.3 I.4 I.5 I.6 I.7 I.8 I.9 I.10 I.11 I.12 I.13 I.14 I.15 I.16 I.17 I.18 I.19 I.20 I.21 I.22 I.23

Pressure gauge Pressure transmitter Pressure switch Orifice plate Magnetic flow meter Temperature Transmitter Level switch Radar type level transmitter Thermocouple Differential pressure type Flow transmitter RTD Differential pressure Transmitter Opacity Meter Vibration monitoring System Instrument cable CCTV Control valves Pyrometer Oxygen Analyser UPS Waste Gas Analyser FO cable DP Level Switch

LARSEN & TOUBRO LIMITED

Forbes marshall Yokogawa Baumer M/S GIC Yokogawa Yokogawa FELLOW KOGYO E&H Tempsen Yokogawa Tempsen M/s yokogawa Chemtrol Scheink M/S Udey pyro M/S Wizertech Fouress India, EME RSON M/S ICS M/S Yokogawa Hirel M/S ABB Lapp M/S Yokogawa

01

1680 50 K JM 001

Page: 44

3.2 Single Test Trial For Area 01 – ECR 3.2.1 Description of Area ECR (Electrical control room) contains all the following equipment: §

6.6 kV HT Switch Board

§

6.6 / 415 kV & 6.6 Transformer

§

6.6 / 690KV Transformer (for ID Fan)

§

415 / 240V Transformer (Lighting)

§

690V VVVF-ID FAN

§

6.6 KV VVVF-GC Fan

§

415V MCC Panels

§

415V PDB Panels

§

415V MLDB Panels

§

PA, FDA RIOP PANELS

§

Battery Charger

§

SLDB

§

MCBDB

§

EMDB

§

Diesel Generator and AMF Panel (outside ECR Building)

Layout of ECR is shown in the drawings 168080EB3101 (CDQ 10) and 168080EB3201 (CDQ 11).

3.2.2 Technical data Please refer to Attachment – Electrical Manuals for each component.

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 45

3.2.3 Commissioning Procedure Please refer to following tables for single test info for any equipment. EQUIPMENT

ACTIVITIES

REFERENCE MANU AL

Technical Data 6.6 kV 1250A Preconditions and Check list 6.6kV power at feeders available 110VDC auxiliary power supply available 240VAC auxiliary power supply available Interconnection with upstream equipment 6.6kV Switchboard

Erection completion test

See Manual (L&T ref erence number E.1 and E.2) for Test ex ecution and Test acc eptance protocols

Tests SAT as per supplier installation manual Operation test (opening CB, closing CB, ES maneuvers, ..) Functional test (interlocking, field signal, etc.) Setting protection relay check Final Test certificate (L&T)

EQUIPMENT

ACTIVITIES

REFERENCE MANU AL

0. Technical Data 6.6/0.433 kV 2500 kVA Preconditions and Check list 6.6kV power at feeder available Star Point grounding 240VAC auxiliary power supply available

6.6/0.433kV power transformer

instrument-equipment/control panel wiring co mpleted See Manual (L&T ref Erection completion (outgoing cable disconne erence number E.3) cted) for Test execution a nd Test acceptance Erection completion test protocols Tests Assembly check SAT as per supplier installation manual Operation test (tap-changer maneuvers, etc.) Functional test (instruments signal, equipmen t signal etc.) Final Test certificate (L&T)

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

EQUIPMENT

Page: 46

ACTIVITIES

REFERENCE MANU AL

Technical Data 6.6kV 1355kW VFD Preconditions and Check list 6.6kV power at feeder available 110VAC control power supply available 240VAC auxiliary power supply available Interconnection with upstream equipment Erection completion test 6.6kV VFD Tests SAT as per supplier installation manual Functional test (instruments signal, equipmen t signal etc.)

See Manual (L&T ref erence number E.10) for Test execution and Test acceptance protocols

Setting protection relay check SAT 6.6kV motor Direction of rotation check Operation test (Start&stop, etc.) Final Test certificate (L&T)

EQUIPMENT

ACTIVITIES

REFERENCE MANU AL

Technical Data 690V 360kW VFD Preconditions and Check list 690V power (from Converter Transformer) at feeder available 110VAC control power supply available 240VAC auxiliary power supply available Interconnection with upstream equipment 690V VFD

Erection completion test Tests SAT as per supplier installation manual Functional test (instruments signal, equipmen t signal etc.) Setting protection relay check SAT 690V motor Direction of rotation check Operation test (Start&stop, etc.) Final Test certificate (L&T)

LARSEN & TOUBRO LIMITED

See Manual (L&T ref erence number E.4) for Test execution a nd Test acceptance protocols

1680 50 K JM 001

Page: 47

EQUIPMENT

ACTIVITIES

REFERENCE MANU AL

Technical Data 415V 500kVA Preconditions and Check list 0.415kV at feeder 240VAC auxiliary power supply available 415V Diesel Gener ator with AMF pan el

Interconnection with upstream equipment Erection completion test Tests

See Manual (L&T ref erence number E.5) for Test execution a nd Test acceptance protocols

SAT as per supplier installation manual Operation test (Start&stop sequence, etc.) Functional test (instruments signal, equipmen t signal etc.) Setting protection relay check Final Test certificate (L&T)

EQUIPMENT

ACTIVITIES

REFERENCE MANU AL

Technical Data 415V 4000A Preconditions and Check list 0.415 kV at feeders available 240VAC auxiliary power supply available Interconnection with upstream equipment Interconnection with downstream equipment Instrument-equipment/control panel wiring co mpleted PCC, MCC, PDB

Erection completion test Tests SAT as per supplier installation manual Operation test (opening CB, closing CB, DS maneuvers, etc.) Functional test (interlocking, field signal, etc.) Setting protection relay check SAT motor Direction of rotation check Operation test (Start&stop, etc.) Final Test certificate (L&T)

LARSEN & TOUBRO LIMITED

See Manual (L&T ref erence number E.6) for Test execution a nd Test acceptance protocols

1680 50 K JM 001

EQUIPMENT

Page: 48

ACTIVITIES

REFERENCE MANU AL

Technical Data 415V 150Ah Preconditions and Check list 0.415 kV at feeders available 240VAC auxiliary power supply available Batteries ready Battery Charger

Interconnection with upstream equipment Internal wiring completed Erection completion test

See Manual (L&T ref erence number E.8) for Test execution a nd Test acceptance protocols

Tests SAT as per supplier installation manual Operation test Functional test Final Test certificate (L&T)

EQUIPMENT

ACTIVITIES

REFERENCE MANU AL

Technical Data 415V 2x40kVA Preconditions and Check list 0.415 kV at feeders available 240VAC auxiliary power supply available Batteries ready UPS

Interconnection with upstream equipment Internal wiring completed Erection completion test Tests SAT as per supplier installation manual Operation test Functional test Final Test certificate (L&T)

LARSEN & TOUBRO LIMITED

See Manual (L&T ref erence number E.9) for Test execution a nd Test acceptance protocols

1680 50 K JM 001

EQUIPMENT

Page: 49

ACTIVITIES

REFERENCE MANU AL

Technical Data Capacity: Power: Preconditions and Check list PLC and RIO panels positioned with power supply and I/O wired with cold test

PLC and RIO

Control room with server, HMI station, printer s, networks panels positioned and with powe r supply All network and field bus related to Automati on System wired Tests PLC/RIO communication PLC CPU & Server redundancy Communication between HMI server/client an d field bus Check DI/AI from field to HMI and cold test of DO/AO signal form HMI to field Manual management of equipment from HMI Safety sequence from HMI Automatic sequence from HMI

LARSEN & TOUBRO LIMITED

See Sub Vendor Ma nual for single test e xecution and Single test acceptance prot ocols Final test acceptance protocol and compl etion by L&T

1680 50 K JM 001

Page: 50

3.3 Single Test Trial For Area 02 – BAR 3.3.1 Description of Area BAR (Boiler Auxiliaries room) is a building divided in to 2 different sections and contains all the following equipment: §

GROUND FLOOR: Pump House , containing:

§

o

Boiler Feed Water Pumps

o

Deaerator water circulation pumps

o

Fresh Water Booster Pumps

o

De-Aerator Demi Water Pumps

o

Cooling Water Booster Pumps

o

Chemical Injection skid

o

SWAS

o

VMS Panel

FIRST FLOOR: Crane Room , containing: o

Crane VVVF

o

Crane PLC

o

Crane Power Switch and distribution Panel

PLC Room, containing: o

I/O Panels

o

CDQ PLC

o

Network Devices Panel

o

RIO CDQ Power Plant

o

Telecommunication Panel

o

HMI Server and Operator engineering station

Control Room , containing: o

CCTV Systems

o

Operator Stations

o

Printers and Monitors

o

CO Gas Display

o

Other Systems:

o

SLDB Lighting

o

UPS and Aux. Batteries

o

Isolator Box

o

Lighting Transformer

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

§

Page: 51

SECOND FLOOR (TOP FLOOR); o

HVAC Room at second floor, with external cooling Towers

o

De-Aerator at roof

Layout of BAR is shown in the drawings 168080IB3102 (CDQ 10) and 168080IB3204 (CDQ 11)

3.3.2 Technical data For technical data please refer to TDS and manuals as per list:

Boiler Feed Water Pumps

168053GM3001/101 168053GM2001/101

Deaerator water circulation pumps

10.5.1.8.3

Fresh Water Booster Pumps

10.5.1.8.4

Chemical Injection skid

168053GM3001/101 168053GM2001/101

SWAS

168053GM3001/101 168053GM2001/101

Deaerator Demi Water Pumps

10.5.1.8.2

Cooling Water Booster Pumps

10.5.1.8.1

CRANE Panels and VVVF

168080EM1150/250

CDQ PLC

168080IM2104/204 168080IM2102/202 168080IM2101/201

DE-AERATOR

See Boiler section and drawings

3.3.3 Commissioning Procedure See THERMAX Sub Vendor Manuals for single test execution and Single test acceptance protocols for BFW pumps, Chemical Injection skid and SWAS. According the method described in "HRSG commissioning manual" №G1680 53 G M3 001 by Thermax Ltd See L&T Sub Vendor Manuals for single test execution and Single test acceptance protocols for pumps. Final test acceptance protocol and completion by L&T.

For Crane VVF and PANELS please follow the procedure as per DHHI Commissioning manual (see Attachment List) Please refer to following tables for single test info for any equipment.

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 52

EQUIPMENT / BAR

ACTIVITIES

Boiler Feed Water Pumps

Precondition

Deaerator water circulation p DM Water availability umps Fresh / Cooling Water availability Fresh Water Booster Pumps Demi Water Pumps Cooling Water Booster Pum ps Chemical Injection skid SWAS

Building Erection completion □ Power □ Mechanical

□ Instruments □ Interlock □ Electric motor

□ Oil □ Grease □ Limit switch

Check list

□ □ □ □ □ □ □

Check power supply system Check the mechanical rigging Check instrumentation Check cooling water system Check Installation of pumps Check greasing and the presence of a stuffing box Check fire extinguishing system

Tests □ Test run of pumps

□ Test run of dosing system □ Test run of Analyzers □ Acceptance test

EQUIPMENT / BAR

ACTIVITIES

OTHER EQUIPMENT

Precondition

□ Building Erection completion □ Power □ fire extinguishing system □ alarm system

□ Control system

Check list

□ Check power supply system □ □ □ □

Check fire extinguishing system Check drinking water line Check alarm system Check control system Tests □ Pre start - up test

LARSEN & TOUBRO LIMITED

□ drinking water

1680 50 K JM 001

Page: 53

3.4 Single Test Trial For Area 03 – RACK 3.4.1

Description

RACK Area contains all the following items: §

Power distribution

§

Signal connections

§

Industrial Water line from TOP up to user points

§

Cooling Water circuit from TOP up to user points and return to TOP

§

Waste water network, including drainages

§

Instrument air line from TOP to headers and single point distribution

§

Compressed air line from TOP to headers and single point distribution

§

Nitrogen Line including:

§

From TOP to main headers

§

Pressure reducing stations/valves

§

Distribution to single points/users

§

COG Line, from TOP up to blind flanges to heating up circuit and flares

§

LP Steam Line from TOP to boiler area

§

HP steam line from Boiler up to TOP

3.4.2 Technical data Please refer to following documentation: 168080U02001

CDQ 10 - Clarified Industrial Water - P&I Diagram

168080U02002

CDQ 10 - Low Pressure Steam - P&I Diagram

168080U02003

CDQ 10 - Nitrogen - P&I Diagram

168080U02004

CDQ 10 - Demi Water and Drinking Water - P&I Diagram

168080U02005

CDQ 10 - Instrument Air - P&I Diagram

168080U02006

CDQ 10 - Compressed Air - P&I Diagram

168080U02007

CDQ 10 - Cooling Water - P&I Diagram

168080U02008

CDQ 10 - High Pressure Steam - P&I Diagram

168080U02009

CDQ 10 - Coke Oven Gas - P&I Diagram

168080U02010

CDQ 10 - Waste Water to Pit - P&I Diagram

168080U02011

CDQ 11 - Clarified Industrial Water - P&I Diagram

168080U02012

CDQ 11 - Low Pressure Steam - P&I Diagram

168080U02013

CDQ 11 - Nitrogen - P&I Diagram

168080U02014

CDQ 11 - Demi Water and Drinking Water - P&I Diagram

168080U02015

CDQ 11 - Instrument Air - P&I Diagram

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 54

168080U02016

CDQ 11 - Compressed Air - P&I Diagram

168080U02017

CDQ 11 - Cooling Water - P&I Diagram

168080U02018

CDQ 11 - High Pressure Steam - P&I Diagram

168080U02019

CDQ 11 - Coke Oven Gas - P&I Diagram

168080U02020

CDQ 11 - Waste Water to Pit - P&I Diagram

168080EA1101

CDQ 10 - Over all Power distribution SLD

168080EA1201

CDQ 11 - Over all Power distribution SLD

AS Built drawings for piping routing and cable routing must be provided by erection company at end of erection. Final P&ID must be available for correctness and completeness check.

3.4.3 Commissioning Procedure Please refer to following tables for single test info for lines and cables.

EQUIPMENT / BUILDING

ACTIVITIES

Industrial Water line

Precondition

Cooling Water circuit

Availability of Fluids at TOP

□Instruments Waste water network, including draina ges Check list

□Interlock

Instrument air line

□ Valve installation

Compressed air line

□ Instrumentation installation

Nitrogen Line

□ Piping class compliance

COG Line

□ P&ID compliance □ Insulation where foreseen

LP Steam Line HP steam line

□ Cable Feeder connection □ Signal connection Tests

□ □ □ □ □

Flushing Pressure Test / Hydrotest Inertization (for COG) Acceptance test IBR test where required

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 55

EQUIPMENT / BUILDING

ACTIVITIES

Power distribution

Precondition

Signal connections

□Instruments

□Interlock

Check list

□ Insulation where foreseen □ Cable Feeder connection □ Signal connection Tests □ Acceptance test

Detailed procedure for flushing and pressure test is described in Chapter 4 of this manual. PAT (Protocol Acceptance Test) must be signed after execution of flushing and pressure test for each utility lines. Same PAT must be signed for cables (electrical and I/O).

All utilities and related instrumentation and valves installed lines must be in compliance with approved documentation: §

Process Flow diagram and P&ID

§

Piping classes

§

Valves Classes

§

Instrument TDS

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 56

3.5 Single Test Trial For Area 04 – Hot Coke transportation (fr om COB) 3.5.1 Process Description Please refer to Chapter 3.1.4.1 of Operating and Maintenance Manual 1680 50 K JM 002. The Area includes the following equipment that are connected to COB PLC and are designed in order to transfer the hot coke after each pushing in COB area to CDQ crane for charging operation: §

LOCO

§

Bucket car

§

Bucket

3.5.2 Technical data Please refer to DHHI Manuals and related drawing attached at end of commissioning Manual. 3.5.2.1 Bucket car

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 57

3.5.2.2 LOCO

3.5.2.1 Bucket capacity as per design is 27.74 tons.

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 58

Commissioning Procedure EQUIPMENT

ACTIVITIES

REFERENCE

Locomotive

Precondition - Modification in COB PLC as per P W/L&T FD □Power □Mechanical □Li mit switch □Alarm system □Instrumentation Check list □ Check power supply system

□ Check control power system □ Check the mechanical rigging □ Check limit switch and instrumen

According the method desc ribed in "Operation manual for locomotive car" №A32 1000119DMS by DHHI Ltd

tation □ Check alarm system Tests □ Test run

□ Cold Test □ Acceptance test Coke bucket car

Precondition □Power □Mechanical Check list □ Check power supply system

□ Check the mechanical rigging Tests □ Cold Test

According the method desc ribed in "Operation manual for bucket car" №A32040 0138MS by DHHI Ltd

□ Bucket rotation

□ Acceptance test Bucket

Acceptance procedure by L &T/TSL

Precondition □Mechanical Check list □ Check the mechanical rigging Tests □ Cold Test

Acceptance procedure by DHHI

According the method desc ribed in "Operation manual for bucket car" №A32040 0138MS by DHHI Ltd

3.5.3 Cold– Commissioning Sequence After the successful performance of preparation activities and functional tests, the plant can be commissioned. Detailed sequences about Commissioning will be available before starting of the Commissioning phase. Cold Commissioning integrated tests for this area must be executed with COB PLC and test of pushing sequence and Loco runs and stop between COB and CDQ must be executed. This commissioning operation are out of scope of present manual.

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 59

3.6 Single Test Trial For Area 05 - Hot coke charging system 3.6.1 Process Description Hot coke charging system deals of following equipment: §

APS (automatic positioning system)

§

Automatic Charging crane

§

Charging system

3.6.2 Technical data Technical data of equipment are shown in the GA drawings and reported here below:

3.6.3 APS (automatic positioning system)

3.6.4 Charging Crane

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 60

3.6.5 Charging System For details of Charging system characteristics and features refer to manuals M168051KM2002 and 168051KM1002.

3.6.6 Commissioning Procedure EQUIPMENT

ACTIVITIES

APS

Precondition □ Power □ Mechanical □ Compresso r air □ Oil □ Instruments □Interlock

□Limit switch

REFERENCE

□ Electric motor

□Pump

Check list □ Check power supply system

□ □ □ □ □ □ □

According the method describe d in "Operation Manual" Produc t Code:A32990004DMS (Part travel system 7 Electrical Manual) page 23 mechanical and hydraulic system 28; paragraph 3.3. - 3.5. and air compressor system "Operation Manual" Product Co de: A329900004; page 22 - 23 oil system ; paragraf 3.5. - 3.7. by DHHI instrumentetion and limit switch

Check control power system Check Check Check Check Check

Check electic motors and oil pump

Tests □ Test run of motors □ Test run of oil pump, air compressor, a ir conditioner □ Test run of air cylinder and limit switch

□ Acceptance test Charging Crane

Precondition □ Power □ Grease

□ Mechanical

Acceptance procedure by DHHI

□ Oil

□ Instruments □ Interlock □ Limit switch □Electric motor Check list □ Check power supply system

□ □ □ □ □ □ □

Check control power system Check driving system and brakes Check lifting system and brakes Check greasing

For Crane See DHHI crane Ac ceptance protocol for commissi oning. See Attached Detailed Crane c ommissioning Procedure for co mmissioning sequence informati on and duration.

Check instrumentation and limit switch Check interlock Check electric motors

Tests □ Cold Test

□ Static Test □ Dynamic Test □ Acceptance test

LARSEN & TOUBRO LIMITED

Acceptance module By DHHI

1680 50 K JM 001

Charging system

Page: 61

Precondition □Power □Mechanical □Compres sor air □N2 □Instrument air □Instr uments □Limit switch □Electric cylinder □Gr ease According the method describe Check list d in "Commissioning manual fo □ Check power supply system r charging devise" №V007T787 □ Check control power system page 3 - 7; paragraf 3.3. - 4. 1. by IHI Paul Wurth Co. LTD □ Check driving system

□ Check greasing system and greasing b earings □ Check instrumentetion and limit switch

□ Check electric cylinder Tests □ Cold Test

□ Acceptance test Water seal unit Precondition □Industrial water □Mechanical

Acceptance procedure by PW

□Compressed air

According the method describe d in "Commissioning manual fo r charging devise" №V007T787 page 3 - 7; paragraph 3.3. □ Check drain water system 4.1. by IHI Paul Wurth Co. LT □ Check operation of the pneumatic valve D □ Check water level adjustment in water seal trough Check list □ Check industrial water system

Tests □ Cold Test

□ Acceptance test

LARSEN & TOUBRO LIMITED

Acceptance procedure by PW

1680 50 K JM 001

Page: 62

3.7 Single Test Trial For Area 06 – CDQ CHAMBER 3.7.1 Process Description CDQ Chamber area includes the following items: §

Chamber proper

§

Blasting Device

§

Basalt liner for Cooling Chamber and CI liner for Cooling Chamber

§

Dilution Air Blower with motor

§

Heating Up Equipment

§

MOV, SOV, Pre chamber bleeder, Pre chamber bypass

3.7.2 Technical data Technical data of equipment are shown in the GA drawings and reported here below:

3.7.3 Chamber proper – See Drawing 168051KBE001/002 §

Chamber capacity:

500 mc

§

Pre-chamber capacity:

311 mc

§

CDQ Chamber Assembly: see 168051KBE001/002

§

Refractory Lining:

see 168051KBE501/510

§

Gas manifold:

see 168051KBE060/061/062

§

Blast Head:

see 168051KM1001

§

Liners:

see L&T 10.5.17 & 18

3.7.4 MOV, SOV, Pre chamber bleeder, Pre chamber bypass See L&T Drawings: PRECHAMBER BYPASS VALVE CDQ 11: ND- 350 DAMPER-W.O.NO.581.2516.01-02 PRECHAMBER BYPASS VALVE CDQ 10: ND- 350 DAMPER-W.O.NO.581.2517.01-02 UPPER BLEEDER VALVE CDQ 10:

ND- 600 DAMPER-W.O.NO.581.2517.01-02

UPPER BLEEDER VALVE CDQ 11:

ND- 600 DAMPER-W.O.NO.581.2517.01-02

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 63

3.7.5 Dilution Air Blower with motor

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 64

3.7.6 Commissioning Procedure EQUIPMENT

ACTIVITIES

Upper bleeder valv e

Precondition □Power □Mechanical □Cooling water □Inst rumentation Check list

□ □ □ □

REFERENCE

Check power supply system Check the mechanical rigging

PAT standard for valve

Check instrumentation Check the cooling water line

Tests

□ Cold Test By - pass valve

Precondition □Power □Mechanical

□ Instrument

□Cooling water Check list □ Check power supply system

□ Check the mechanical rigging □ Check instrumentation □ Check the cooling water line

PAT standard for valve

Tests □ Cold Test Quenching chamber Precondition □ Power □ Instrumentation □ Mechanical □ N2 Check list □ Check power supply system

□ Check instrumentation □ Check the mechanical rigging □ Check the N2 line

According to the method de scribed in "Commissioning manual" №V005T195 by IHI Paul Wurth Co, LTD

Tests □ Cold Test

□ Acceptance test

LARSEN & TOUBRO LIMITED

Acceptance procedure by P W

1680 50 K JM 001

Page: 65

EQUIPMENT

ACTIVITIES

Dilution Air Fan an d air line

Precondition

□ Power □ N2

REFERENCE

□ Mechanical □ Instruments □ Electrical motor

Check list □ Check power supply system

□ □ □ □

Check control power system

See Vendor Manual

Check the mechanical rigging Check instrumentation Check the N2 line

Tests

□ Cold Test Blowing device an Precondition d gas manifold □ Mechanical □ N2

□ Instruments

Check list □ Check the mechanical rigging

□ Check instrumentation □ Check the N2 line

According the method descr ibed in "Commissioning ma nual" №V005T195 by IHI P aul Wurth Co, LTD

Tests □ Pre Test (manual valve position)

□ Acceptance test

LARSEN & TOUBRO LIMITED

Acceptance procedure by P W

1680 50 K JM 001

Page: 66

3.8 Single Test Trial For Area 07 – system

Cooled coke Discharging

3.8.1 Process Description Cooled coke discharging system is made of: §

Motorized gate valve at CDQ outlet, including manual rod gate

§

Vibrating Feeder

§

Connection chute (with internal liners)

§

RSV (Rotary Seal Valve)

§

Conveyor Belt circuit up to coke Wharf (out of scope)

3.8.2 Technical data Discharge system capacity:

100 tph

3.8.3 Motorized gate valve

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 67

3.8.4 Vibrating Feeder

3.8.5 RSV (Rotary Seal Valve) Rotary Seal valve

(format Sealed Type)

Supplier

SPCO

Capacity:

minimum 30 tph up to 140 tph

Rotary Bucket:

Width:

1340 mm

Diameter:

2000 mm

Blades Number:

12

Rotation Speed:

5.3 rotation/min

Reducer and Motor Power:

3.7 kW

Motor & reducer:

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 68

3.8.6 Conveyor Belt circuit For details see GA Drawing here attached. For main data please refer to below figures. CDQ 10:

CDQ 11:

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 69

3.8.7 Commissioning Procedure For Commissioning protocols, see dedicated manual of Slide gate, vibrating feeder, Rotary seal valve. EQUIPMENT

ACTIVITIES

Rod Gate / sli de gate valve

Precondition □ Power □ Mechanical

□ Limit switch

REFERENCE

□ Instruments □ Electric motor □ N2

Check list

□ □ □ □

Check power supply system Check adjustment of the limit switches Check N2 line Check the mechanical rigging

Tests □ Cold Test □ Acceptance test Vibrating syste m

See Vendor Manual for mec hanical test

Precondition □Power □Mechanical □Electrical magnet vibrator Check list □ Check power supply system

□ Check the mechanical rigging Tests □ Cold Test

□ Acceptance test

LARSEN & TOUBRO LIMITED

Accept. procedure by L&T According the method descri bed in "Installation instructio ns Opereting instructions Ma gnet vibrator Type TS №S4 10041R02" page 16 - 23; p aragraf 7 - 8.1.2. and "Servi ce handbook Vibrating feede r" №VFE-C125/240TA Accept. procedure by L&T

1680 50 K JM 001

Page: 70

EQUIPMENT

ACTIVITIES

RSV

Precondition

REFERENCE

□ Power □ Mechanical □ Instrumentation □ Grease □ Electrical motor □ N2 Check list □ Check power supply system

□ Check control power system See Vendor catalogues for I □ Check the mechanical rigging nstallation and check □ Check instrumentation and interlock sys tem

□ Check the N2 line □ Check the greasing of bearings Tests □ Cold Test

□ Acceptance test

Acceptance procedure by cu stomer

EJ and connec Precondition tion chute Check list □ Visual inspection

□ EJ proper installation □ Connection chute liners position □ Passage section of coke as per

see BE and DE drawings a nd EJ manuals

PW-Steel Plantech drawings Tests Conveyor belts

Acceptance procedure by L &T

Precondition □ Power □ Mechanical □ Instrumentation □ Industrial water □ Alarm system □ Instrument air Check list □ Check power supply system

□ Check the mechanical rigging □ Check instrumentation & alarm system

see vendors manual for BC parts test

□ Check the industrial water system (For emergency spraying) Tests □ Cold Test - Interlock test for emergency stops

□ Acceptance test

LARSEN & TOUBRO LIMITED

Acceptance procedure by L &T

1680 50 K JM 001

Page: 71

3.9 Single Test Trial For Area 08 – Primary Gas Catcher (PDC Area) 3.9.1 Process Description Primary gas Catcher is a dust separation unit, settling type, made of: §

Primary Gas Catcher Proper, refractory lined (PDC)

§

Steam Bleeder Valves

§

Cooling Pipes dust discharge units

3.9.2 Technical data PDC Design flowrate:

156,000 Nm3/h

Inlet dust content:

up to 20 g/Nm3 of coke dust (PDC Inlet)

Working temperature:

Max 980 °C

Steam bleeder valve:

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 72

3.9.3 Commissioning Procedure For Commissioning protocols, see dedicated manual of Steam Bleeder valve. EQUIPMENT

ACTIVITIES

REFERENCE

Steam bleeder v Precondition alve □ Power □ Mechanical

□ Industrial water

□ Instruments □ N2

Check list □ Check power supply system

□ □ □ □ □

Check the mechanical rigging Check instrumentation

See Vendor catalo gues for Installation and check

Check industrial water system Check wast water system Check N2 line

Tests □ Cold Test Cooling pipes

Precondition □ Mechanical □ Instruments

□ Cooling water

Check list □ Check the mechanical rigging

□ Check cooling water system □ Check instrumentation

See Drawing and P&ID

Tests

□ Cold Test PDC instrument ation and HT EJ

Precondition □ Power

□Mechanical

Check list □ Check power supply system

□ Check the mechanical rigging □ Check Installation position instrumentati on

□ Check Installation drawings and cold di splacement Tests □ Simulation testing

LARSEN & TOUBRO LIMITED

See THERMAX Ex pansion drawing an d EJ vendor techni cal instructions

1680 50 K JM 001

Page: 73

3.10 Single Test Trial For Area 09 – Boiler Circuit (Boiler Area) 3.10.1 Process Description Boiler circuit is made of following units: §

Boiler Proper, including economizer, evaporator, Super-heater I and II, steam Drum, IBD and CBD. Boiler shell is connected to CDQ gas circuit to PDC (Boiler inlet) and to SDC – Multi-Cyclone (Boiler outlet).

§

Boiler Feed Water Pumps (located in BAR)

§

De-Aerator (located in BAR roof), with Pumps

§

Sub-Economizer (before CDQ chamber inlet)

For details refer to PFD and P&ID of Boiler unit: and related GA Drawings: 1680 1680 1680 1680 1680

53 53 53 53 53

G01 G01 G01 G01 G02

001 002 101 102 001

1680 1680 1680 1680

53 53 53 53

G02 G02 G02 G02

002 003 004 101

1680 1680 1680 1680 1680 1680 1680 1680 1680 1680 1680 1680 1680 1680 1680 1680

53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53

G02 G02 G02 G11 G11 G11 G11 G11 G11 G11 G11 G11 G11 G11 G11 G11

102 103 104 001 002 003 004 006 101 102 103 104 106 200 201 210

HRSG flow diagram CDQ 10 H&M balance (PG condition) - CDQ 10 HRSG flow diagram CDQ 11 H&M balance (PG Condition) - CDQ 11 P&ID for WHB CDQ and Steam Drum CDQ 10 P&ID for De-aerator, BFW Pump station and sub Economizer system C DQ 10 P&ID for Dosing System CDQ 10 Swas P&ID CDQ 10 P&ID for WHB CDQ and Steam Drum CDQ 11 P&ID for De-aerator, BFW Pump station and sub Economizer system C DQ11 P&ID for Dosing System CDQ 11 Swas P&ID CDQ 11 Boiler and drum - General arrangement CDQ 10 Sub economizer - General arrangement CDQ 10 De-aerator - General arrangement CDQ 10 Layout of boiler auxiliaries equipment for CDQ 10 SWAS - General arrangement CDQ 10 Boiler and drum - General arrangement CDQ 11 Sub economizer - General arrangement CDQ 11 De-aerator - General arrangement CDQ 11 Layout of boiler auxiliaries equipment for CDQ 11 SWAS - General arrangement CDQ 11 Boiler and drum - General arrangement for pressure parts - CDQ 10 Boiler and drum - General arrangement for pressure parts - CDQ 11 Boiler - General Arrangement of Wear protection lining - CDQ 10&11

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 74

3.10.2 Technical data For Boiler Technical data refer to the following documents: §

Boiler O&M manual (here attached) :

168053GM2001-101

§

Boiler Datasheet

168053GDS001-101

3.10.3 Commissioning Procedure For Commissioning protocols, see dedicated commissioning Manual of Boiler 168053GM3001101. The following table include a general purpose list of checks to be executed and integrated with Boiler Designer procedure.

EQUIPMENT

ACTIVITIES

Bar pump house

Precondition □ Power □ Mechanical □ Instrumentation □ Cooling water □ Pumps □ fire extingui shing system Check list □ Check power supply system

□ □ □ □ □

Check the mechanical rigging Check instrumentation Check cooling water system

REFERENCE

According the method descri bed in "HRSG commissionin g manual" №G1680 53 G M 3 001 by Thermax Ltd

Check Installation of pumps Check greasing and the presence of a stu ffing box □ Check fire extinguishing system Tests □ Test run of pumps

□ Acceptance test

LARSEN & TOUBRO LIMITED

Acceptance procedure by TH ERMAX

1680 50 K JM 001

Page: 75

EQUIPMENT

ACTIVITIES

REFERENCE

Boiler

Precondition □ Power □ Mechanical □ Instrumentation

□ N2 □ I/O connected □ Auxiliaries □ Insulation and cladding Check list □ Check power supply system

□ □ □ □ □ □ □

Check the mechanical rigging Check instrumentation Check the N2 line

According the method descri bed in "HRSG commissionin g manual" №G1680 53 G M 3 001 by Thermax Ltd

Check piping lines Check control power system Check control valves Check alarm system

Tests □ Hydraulic test

□ IBR Inspector Hydraulic test Acceptance procedure by Thermax

□ Acceptance test Deaerator

Precondition □ Mechanical □ Instrumentation

□ Water

□ Pipes system □ LP Steam

Check list □ Check the mechanical rigging

□ □ □ □

Check pipes line Check instrumentation

According the method descri bed in "HRSG commissionin g manual" №G1680 53 G M 3 001 by Thermax Ltd

Check water system Check steam system

Tests □ Hydraulic test

□ Acceptance test Sub - economi zer

Precondition □ Mechanical

Acceptance procedure by Thermax

□ Instrumentation

Check list □ Check the mechanical rigging

□ Check instrumentation Tests □ Hydraulic test

□ Gas density test

LARSEN & TOUBRO LIMITED

According the method descri bed in "HRSG commissionin g manual" №G1680 53 G M 3 001 by Thermax Ltd

1680 50 K JM 001

Page: 76

3.11Single Test Trial For Area 10 – Cooling Gas Circuit 3.11.1 Process Description Cooling gas circuit connects the Boiler up to the CDQ chamber; the ductworks starts from boiler outlet and in closed circuit arrives up to gas manifold inlet at bottom of CDQ chamber, connecting the following units: §

Multi-Cyclone or Secondary Dust Catcher (SDC/MCY).

§

Main Gas Circulation Fan (GCF), provided of Dampers and VVVF

§

Lower bleeding line with connection to DE system and to by-pass line to flare

§

Sub-Economizer

§

Louver manual damper

3.11.2 Technical data 3.11.3 Multi Cyclone MCY Design flowrate:

156,000 Nm3/h

Outlet dust content:

< 1 g/Nm3 of coke dust

Working temperature:

Max 200 °C

3.11.4 Main GCF

3.11.4.1

Louver damper

See L&T Drawings and Manuals here attached

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 77

3.11.5 Commissioning Procedure For Commissioning protocols, see dedicated commissioning of equipment. EQUIPMENT

ACTIVITIES

Multicyclone

Precondition □ Mechanical

REFERENCE

□ Instrumentation

□ N2

Check list □ Check the mechanical rigging

□ Check instrumentation □ Check the N2 line

See MCY Manual install ation and Instrumentation TDS

Tests □ Gas density test / pressure Drop Gas circulation f Precondition an □ Power □ Mechanical □ Instrumentation

□ N2

□ Cooling water

Check list □ Check power supply system

□ □ □ □

Check the mechanical rigging Check instrumentation Check the N2 line

According the method d escribed in "Insruction m anual for Gas circulation fan" №fan manual/howd en2015 by Howden Ltd

Check cooling water system

Tests □ Test run of GCF

□ Cold Test Acceptance procedure b y customer

□ Acceptance test Lower bleeder li Precondition ne □ Power □ Instrumentation

□ Compressed air

□ Mechanical □ Coke oven gas

Check list □ Check power supply system

□ □ □ □

Check the mechanical rigging Check instrumentation Check compressed air system Check coke oven gas line

Tests □ Cold Test

LARSEN & TOUBRO LIMITED

See Valve TDS and Inst rumentation TDS

1680 50 K JM 001

Page: 78

EQUIPMENT

ACTIVITIES

Emergency blee der

Precondition

□ Mechanical

REFERENCE

□ Instrumentation

Check list □ Check the mechanical rigging

See Flare Manual

□ Check instrumentation Tests □ Simulation testing LOUVER DAMP Precondition ER □ Mechanical

□ Instrumentation

Check list

□ Check the mechanical rigging □ Check instrumentation Tests □ Simulation testing

LARSEN & TOUBRO LIMITED

See LOUVER DAMPER Manual

1680 50 K JM 001

Page: 79

3.12Single Test Trial For Area 11 – Coke Breeze Circuit Area 3.12.1 Process Description Coke breeze circuit receive the and collects the dust discharge streams from PDC and SDC and transfer them to a dust bin, where the dusts are unloaded on trucks by a pug mill. See P&ID 168050K02001-003

3.12.2 Technical data 3.12.3 Rotary Valves RSV541001-02-03-04 -05 (CDQ 10) and RSV541101-02-03-0405

(CDQ 11)

3.12.4 Chain conveyors & BE Capacity:

5 tph working (6 tph maximum)

See TDS for details

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 80

3.12.5 Commissioning Procedure EQUIPMENT

ACTIVITIES

REFERENCE

Chain conveyors Precondition circuit □ Power □ Mechanical

□ Instrumentation

Check list

□ Check power supply system □ Check the mechanical rigging □ Check conveyors instrumentation

See Chain conveyor, R SV, gate manuals

Tests

□ Test run of chain conveyors □ Cold Test Precondition

□ Power

□ Mechanical

□ Instrumentation

Check list Bucket Elevator

□ Check power supply system □ Check the mechanical rigging □ Check instrumentation

See BE Manual

Tests

□ Test run of BE □ Cold Test Coke breeze bin Precondition and unloading sy □ Power □ Mechanical □ Instrumentation stem □ N2 □ Industrial water Check list

□ □ □ □ □

Check power supply system Check the mechanical rigging Check instrumentation Check the N2 line Check the industrial water system

Tests

□ Cold Test

LARSEN & TOUBRO LIMITED

See Vendor manuals

1680 50 K JM 001

Page: 81

3.13Single Test Trial For Area 12 – Environmental dedusting (D E Area) & DE Coke dust Circuit (DE Dust Area) 3.13.1 Process Description For process description refer to L&T P&ID: CDQ-10 Dedusting_O15044-0F2-M-B-0159-001 CDQ-11 Dedusting_O15044-0F2-M-B-0159-002

3.13.2 Technical data Refer to 1680 54 G A0 001-002 – PFD for DE units

3.13.3 Bag Filter

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 82

3.13.4 DE FAN

3.13.5 Commissioning Procedure EQUIPMENT

ACTIVITIES

ID Fan

Precondition □ Power □ Mechanical □ Instrumentation □ Cooling water □ Oil lubricated system Check list □ Check power supply system

□ Check the mechanical rigging □ Check instrumentation □ Check cooling water system □ Check oil lubricated system

REFERENCE

According the method described in "Erection operationg and maint enance manual for ce ntrifugal fan" by Andre w Yule and Company limited

Tests

□ Test run of Id fan □ Cold Test □ Acceptance test

Acceptance procedure by L&T

Dedusting chargi Precondition ng system □ Mechanical □ Instrumentation □ Compressed air Check list □ Check the mechanical rigging

□ Check instrumentation □ Check compressed air system Tests □ Pre start - up test

LARSEN & TOUBRO LIMITED

Valve TDS and FD

1680 50 K JM 001

EQUIPMENT

Page: 83

ACTIVITIES

Regulation of ho Precondition ods □ Mechanical

REFERENCE

□ Control system

Check list

□ Check the mechanical rigging □ Check the control system Tests

□ Pre start - up test □ Cold test Bag filter unit

Precondition □ Power □ Instrumentation □ Instrumentation air □ N2

□ Mechanical □ Compressed air

Check list □ Check power supply system

□ □ □ □ □

According the method described in "Erection operationg and maint enance manual for ce ntrifugal fan" by Andre w Yule and Company limited

Check the mechanical rigging Check instrumentation

According in the P & ID bag filter system №O15044-0F2-M-V-01 51-001

Check instrumentation air system Check compressed air system Check the N2 line

Tests

□ Cold test Chain conveyors Precondition circuit □ Power □ Mechanical □ Instrumentation Check list

□ Check power supply system □ Check the mechanical rigging □ Check conveyors instrumentation

See Chain conveyor, RSV, gate manuals

Tests □ Test run of chain conveyors

□ Cold Test Coke breeze bin Precondition and unloading □ Power □ Mechanical □ Instrumentation system □ N2 □ Industrial water Check list □ Check power supply system

□ □ □ □

Check the mechanical rigging Check instrumentation Check the N2 line Check the industrial water system

Tests □ Cold Test

LARSEN & TOUBRO LIMITED

See Vendor manuals

1680 50 K JM 001

Page: 84

3.14 Single Test Trial For Area 13 – Maintenance equipment (H oists) & Others 3.14.1 Process Description This chapter includes the equipment relevant to maintenance and access to plant, not related to process operation.

3.14.2 Commissioning Instructions See Vendor Manual as per Manual list for test instructions and protocols. For Elevator see Thyssen Krupp Manual for commissioning procedures.

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 85

4. Leakage test of process lines and utilities flushing/pressure test procedure Here below the commissioning procedure for each unit is reported. The flushing and leakage /pressure test must be executed on the following lines according with the attached procedures and PAT (Protocol Acceptance Test).

4.1 Summary of test to be executed on Fluid and Process lines Flushing

Leakage

Pneumatic Pressure test

Hydraulic test

CDQ Gas circuit

O (rusting)

X

X (3kPa)

n.a.

X

Dilution Air line

O (rusting)

X

X (10kPa)

n.a.

(1)

Lower bleeding line

O (rusting)

X

X (3kPa)

n.a.

(1)

Dedusting Line

O (rusting)

n.a.

Negative pressure line

n.a.

-

LINE / FLUID

Inertization

PAT

Process Lines:

Utilities Lines: Instrument Air

X

X

X

Compressed Air

X

X

X

Nitrogen

X

X

X

COG

X

X

Clarified Water

Industrial

Drinking Water Waste Water

X

X

X

X

X

X

X

X

O (rusting)

X

O

IBR

See TL /L&T loops

IBR

See Thermax

IBR

See Thermax

Utilities Lines (IBR): Demi Water

X

LP Steam

X

HP Steam

Steam Blowing X

X : to be executed

O: cleaning of duct during/before erection.

(1) To be executed during CDQ gas line leakage test or separately with external compressor

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 86

4.2 CDQ Gas Circuit Leakage test Procedure 4.2.1 Description After completion of SINGLE TEST TRIALS, and before the completion of insulation erection, CDQ chamber and gas circuit are subjected to a LEAKAGE TEST in order to check the sealing of all the circuit before to proceed with operations.

4.2.2 Preparation of CDQ Circuit Leakage test ¨ Installation of provisional blind plate must be executed on the following points: § CDQ Outlet (after slide gate) (SGS 511021 for CDQ 10, SGS 511121 for CDQ 11) § PDC Breeze boxes (after Cooling pipes) after slide gates (CDQ 10 - 541010 and 541011; CDQ 11 - 541110 and 541111) § MCY bottom (after slide gate) (CDQ 10 - 541008; CDQ 11 - 541108) § Between Regulation dampers and Main GCF (MOV 521001.01/02 for CDQ 10 and MOV 521101.01/02 for CDQ 11) § Installation of provisional sealing mats between the lid and the water seal. Preparation of blind on top chamber lid or as alternative lid can be used. Sealing mat is necessary to make sealing. § Installation of blinds at Explosion vents on top of Multi-Cyclone § Installation of blinds after MOV on lower bleeding lines (to Dedusting and to bypass) (MOV521010/11 on CDQ 10 and MOV521110/11 on CDQ 11) § Installation of blinds if necessary on Steam bleeder valves. Steam Bleeder valves can be prepared for leakage test using the water seals, providing a provisional blind closure on water seal discharge. Water seal outlet is designed for 150 mmH2O, in continuous discharging mode. Closing the manual vale on discharge the water seal works at 350 mmH2O. See Steam bleeder valve drawing. Lid must be kept closed during the leakage test. Counterweight must be locked and lid fixed in close position ¨ Manholes in Main GCF for air entrance must be opened ¨ On the suction duct before main GCF blind stopper are necessary to create pressure in the gas path. ¨ Charging lid cover is installed into the frame on the rubber gasket. A blind plate with stiffeners can be used as alternative to avoid to move the lid if refractory lining is already applied and not dried out. ¨ Before the start of the test must be closed all manholes, hatches, safety waste bleeder, and fixed inspection covers on the quenching chamber. ¨

4.2.3 Execution of CDQ Circuit Leakage test Switch on the Main GC Fan at minimum flow, creating an air suction from fan manholes. Increase the fan speed up to create in the Gas Circulation circuit a pressurization of 300 mmH2O to be maintained and pre-tested for about 72 hours.

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 87

Pressure can be checked from PLC if already commissioned or by manual pressure gauges in correspondence to PIT along the circuit. During this period the complete circuit must be inspected to identify any possible leakage point. To check any point of leakage the procedure foresees 2 ways: §

As preliminary check, a smoking agent can be inserted in the circuit from the manholes in order to put in evidence any big leakage;

§

Final check must be executed using soapy water on all tested surface.

During the test if any leakage is shown, point is marked and repaired. Test is executed until completion of sealing and tightness control. Please refer to the attached P&ID modified with indication of provisional blind and position of valves during leakage test. Leakage test of lower bleeding line can be executed during CDQ gas line leakage test or separately. In case of separate test with additional compressor, the blind must be located after the PV511001 / PV 511101 block, in order to test also the Manual shut off valves and by-pass

4.3 Air dilution Line Leakage test Procedure 4.3.1 Description After completion of leakage test on CDQ chamber in correspondence of air dilution header, the leakage test on dilution airline can be executed.

4.3.2 Preparation of Air line Leakage test ¨ Installation of blind at dilution air fan outlet. ¨ Check the pressure in air dilution line through pressure gauge. The pressure should be zero.

4.3.3 Execution of Air line Leakage test ¨ All the BV on air header are closed during CDQ gas circuit leakage test. ¨ Open the BV one by one checking if pressure rise up after the opening of each valve: open the first manual valve in correspondence of sloping flue channels and check I f the pressure rise up. In case the pressure stay at zero, close the manual valve and proceed with the next one up to completion of the manual valves. ¨ In case during one the tests the pressure in dilution airline rise up, stop the test and mark the no return valve. Corresponding no return valve must be checked and in case replaced and the test executed again on this portion of circuit. ¨ Close again all the BV valve on air header on sloping flue area. ¨ Remove the blind at dilution air fan outlet. ¨ Switch on the fan and increase the pressure slightly up to 500 mmH2O. ¨ Soapy water must be executed on all tested surface

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

LARSEN & TOUBRO LIMITED

Page: 88

1680 50 K JM 001

LARSEN & TOUBRO LIMITED

Page: 89

1680 50 K JM 001

Page: 90

4.4 Utilities Lines Flushing and pressure test Procedures For Flushing of utilities line see Chapter 1.4 general prescription. For the following lines dedicated procedures have been included in the manual, to be followed as guidelines procedures and as guideline to the division in several flushing loops due to nonlinear arrangement of P&ID: §

Instrument Air

§

Compressed Air

§

Nitrogen

§

COG

Instrument Airline must be flushed and pressure tested as soon as possible during commissioning phase in order to be available for test of valves and other equipment.

4.4.1 Instrument Air Please refer for test description and execution to the following attachment: §

ESA-80-015-CDQ 11 INSTRUMENT AIR_END OF ERECTION

§

ESA-80-015- CDQ 11 loop1 instrument air

§

ESA-80-015- CDQ 11 loop2 instrument air

§

ESA-80-015- CDQ 11 loop3 instrument air

§

168080U02015 Loops 1 – 2 – 3

§

168050K02002

Loop 2

4.4.2 Compressed Air Please refer for test description and execution to the following attachment: §

ESA-80-016-CDQ 11 INSTRUMENT AIR_END OF ERECTION

§

ESA-80-016- CDQ 11 loop1 instrument air

§

ESA-80-016- CDQ 11 loop2 instrument air

§

ESA-80-016- CDQ 11 loop3 instrument air

§

ESA-80-016- CDQ 11 loop4 instrument air

§

ESA-80-016- CDQ 11 loop5 instrument air

§

168080U02015 Loops 1 – 2 – 3 – 4 – 5

4.4.3 Nitrogen Please refer for test description and execution to the following attachment: §

ESA-80-013-CDQ 11 INSTRUMENT AIR_END OF ERECTION

§

ESA-80-013- CDQ 11 loop1 Nitrogen

§

ESA-80-013- CDQ 11 loop2 Nitrogen

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 91

§

ESA-80-013- CDQ 11 loop3 Nitrogen

§

ESA-80-013- CDQ 11 loop4 Nitrogen

§

ESA-80-013- CDQ 11 loop5 Nitrogen

§

ESA-80-013- CDQ 11 loop6 Nitrogen

§

168080U02013 Loops 1 – 2 – 3 – 4 – 5 – 6

4.4.4 COG Please refer for test description and execution to the following attachment: §

ESA-80-019-CDQ 11 COG END OF ERECTION

§

ESA-80-019- CDQ 11 loop1 instrument air

§

ESA-80-019- CDQ 11 loop2 instrument air

§

ESA-80-015- CDQ 11 loop3 instrument air

§

168080U02019 Loops 1 – 2 – 3

§

168050K02006 Loop 2

4.5 Flushing Procedures for DM water, LP steam and HP stea m lines For flushing of the boiler circuit, please refer in detail to Chapter 2 of Thermax Commissioning Manual 168053GM3001-101. Here below are attached the P&ID relevant to loops 2 up to 7. HP steam flushing must be executed during first period of operation by steam blowing phase, where steam lines are cleaned up to final design conditions.

LARSEN & TOUBRO LIMITED

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/015-CDQ11 EQUIPMENT:

CDQ – 11 Instrument air

PW Drawing number L&T Drawings number (to be listed here)

____________________

END OF ERECTION

SUPPLIER:

L&T

GENERAL P&I .

1680 80 U 02 015 – CDQ 11 1680 50 K 02 004 – CDQ 11 1680 50 K 02 006 – CDQ 11

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

ESEGUITO/ EXECUTED

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA09-8011-AI-0065-N-239 10BA09-8011-AI-0050-N-241 10BA09-8011-AI-0032-N-248 10BA09-8011-AI-0025-N-233 10BA09-8011-AI-0025-N-238 10BA09-8011-AI-0025-N-237 10BA09-8011-AI-0025-N-250 10BA09-8011-AI-0025-N-236 10BA09-8011-AI-0025-N-243 10BA09-8011-AI-0025-N-235 10BA09-8011-AI-0025-N-232 10BA09-8011-AI-0025-N-234 10BA09-8011-AI-0025-N-231 10BA09-8011-AI-0025-N-249 10BA09-8011-AI-0015-N-242 10BA09-8011-AI-0015-N-244 10BA09-8011-AI-0015-N-245 10BA09-8011-AI-0015-N-246 10BA09-8011-AI-0015-N-240

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 3 ESA-80-015-CDQ 11 INSTRUMENT AIR_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

END OF ERECTION

ESA/80/015-CDQ11 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

DATA / COMMENTI DATE / NOTES

10BA09-8011-AI-0015-N-247 10BA09-8011-AI-0015-N-230 1

2

Cleaning of line and control absence of dirt inside the line Check the installation and connection of the line

YES

NO

YES

NO

YES

NO

YES

NO

LINE FLUSHING WITH COMPRESSED AIR

3

Acting from great diameters to small diameters flux lines utilizing compressed air. Before flushing, disconnected

all

instruments

must

be

Remove all dirt at end Hydraulic test of line BEFORE PAINTING utilizing dried compressed air.. MOP = 6 bar Pressure 5.5-6 bar. 4

Close all connections. Inflate compressed air in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control of the correct erection

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 3 ESA-80-015-CDQ 11 INSTRUMENT AIR_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001 POS

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

END OF ERECTION

ESA/80/015-CDQ11 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

6

Control instrumentation installed on lines

YES

NO

7

Control execution superficial treatment of lines

YES

NO

DATA / COMMENTI DATE / NOTES

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 3 ESA-80-015-CDQ 11 INSTRUMENT AIR_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/015-CDQ11 – Loop1 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Instrument air Loop 1

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 015 – CDQ 11 1680 50 K 02 002 – CDQ11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA09-8011-AI-0065-N-239 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 2

10BA09-8011-AI-0065-N-239 According to P&ID 168080U02015 LINE FLUSHING WITH COMPRESSED AIR

3

Acting from great diameters to small diameters flux lines utilizing compressed air. Before flushing, disconnected

all

instruments

must

be

Remove all dirt at end

3a

Close valves BAL1166NB25, (GL1073NB32, GL1074NB32, GL1067NB32, GL1071NB32 according P&ID 1680 50 K 02 002) BAL1022NB50, BAL1024NB25, BAL1025NB25, BAL1295NB25, BAL1167NB25, BAL1168NB25, BAL1169NB25, BAL1026NB25, BAL1034NB25, BAL1175NB25, BAL1176NB25, BAL1027NB15, BAL1035NB15, BAL1045NB15, BAL1046NB15, BAL1066NB15, BAL1162NB15, BAL1061NB25

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 2 ESA-80-015- CDQ 11 loop1 instrument air.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001

ESA/80/015-CDQ11 – Loop1 ESEGUITO/ EXECUTED

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3b

Disconnect end cup/flange on line 10BA09-8011AI-0065-N-239 termination

YES

NO

3c

Open valve BAL1243NB65 and flushing with compressed air line10BA09-8011-AI-0065-N239, then close valve.

YES

NO

3d

Close end cup/blanked on line 10BA09-8011-AI0065-N-239

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Pneumatic test of line BEFORE PAINTING utilizing with compressed air. MOP = 6 bar Pressure 5,5-6 bar. 4

Close all connections. Inflate compressed air in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 2 ESA-80-015- CDQ 11 loop1 instrument air.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001

ESA/80/015-CDQ11 – Loop 2

DWGS N.

EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Instrument air Loop 2

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 015 – CDQ 11 1680 50 K 02 002 – CDQ11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA09-8011-AI-0050-N-241 10BA09-8011-AI-0032-N-248 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 2

10BA09-8011-AI-0050-N-241 10BA09-8011-AI-0032-N-248 According to P&ID 168080U02015 LINE FLUSHING WITH COMPRESSED AIR

3

Acting from great diameters to small diameters flux lines utilizing compressed air. Before flushing, disconnected

all

instruments

must

be

Remove all dirt at end

3a

Close valves BAL1025NB25, BAL1168NB25, BAL1034NB25, BAL1027NB15, BAL1046NB15,

BAL1166NB25, BAL1295NB25, BAL1169NB25, BAL1175NB25, BAL1035NB15, BAL1066NB15,

BAL1024NB25, BAL1167NB25, BAL1026NB25, BAL1176NB25, BAL1045NB15, BAL1162NB15,

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 3 ESA-80-015- CDQ 11 loop2 instrument air.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

ESA/80/015-CDQ11 – Loop 2 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

BAL1061NB25

3b

Open valve BAL1243NB65

YES

NO

3c

Open valve BAL1022NB50, BAL1023NB50 and flushing line10BA09-8011-AI-0050-N-241, then close valve.

YES

NO

3d

Remove PCV1070NB32, PCV1066NB32 valves and install adapter pipe on this place

YES

NO

3e

Valves GL1073NB32, GL1074NB32, BAL1271NB32, BAL1268NB32 (according P&ID 1680 50 K 02 002) must be closed

YES

NO

3f

Open valve GL1067NB32 and flushing line in to pre chamber, then close valve

YES

NO

3g

Open valve GL1071NB32 and flushing line in to pre chamber, then close valve

YES

NO

3h

Remove adapter pipe and install PCV1070NB32, PCV1066NB32 valves on this place

YES

NO

YES

NO

YES

NO

Pneumatic test of line BEFORE PAINTING utilizing with compressed air. MOP = 6 bar Pressure 5,5-6 bar. 4

Close all connections. Inflate compressed air in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 3 ESA-80-015- CDQ 11 loop2 instrument air.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

ESA/80/015-CDQ11 – Loop 2 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

and test again as per point (4)

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 3 ESA-80-015- CDQ 11 loop2 instrument air.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/015-CDQ11 – Loop3 EQUIPMENT:

CDQ11 – Instrument air Loop 3

PW Drawing number L&T Drawings number (to be listed here)

____________________

END OF ERECTION

SUPPLIER:

L&T

GENERAL P&I .

1680 80 U 02 015 – CDQ 11 1680 50 K 02 002 – CDQ11

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

ESEGUITO/ EXECUTED

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA09-8011-AI-0025-N-233 10BA09-8011-AI-0025-N-238 10BA09-8011-AI-0025-N-237 10BA09-8011-AI-0025-N-250 10BA09-8011-AI-0025-N-236 10BA09-8011-AI-0025-N-243 10BA09-8011-AI-0025-N-235 10BA09-8011-AI-0025-N-232 10BA09-8011-AI-0025-N-234 10BA09-8011-AI-0025-N-231 10BA09-8011-AI-0025-N-249 10BA09-8011-AI-0015-N-242 10BA09-8011-AI-0015-N-244 10BA09-8011-AI-0015-N-245 10BA09-8011-AI-0015-N-246 10BA09-8011-AI-0015-N-240 10BA09-8011-AI-0015-N-247 10BA09-8011-AI-0015-N-230

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 5 ESA-80-015- CDQ 11 loop3 instrument air.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

1

ESA/80/015-CDQ11 – Loop3 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Check the installation and connection of the line 10BA09-8011-AI-0025-N-233 10BA09-8011-AI-0025-N-238 10BA09-8011-AI-0025-N-237 10BA09-8011-AI-0025-N-250 10BA09-8011-AI-0025-N-236 10BA09-8011-AI-0025-N-243 10BA09-8011-AI-0025-N-235 10BA09-8011-AI-0025-N-232 2

10BA09-8011-AI-0025-N-234 10BA09-8011-AI-0025-N-231 10BA09-8011-AI-0025-N-249 10BA09-8011-AI-0015-N-242 10BA09-8011-AI-0015-N-244 10BA09-8011-AI-0015-N-245 10BA09-8011-AI-0015-N-246 10BA09-8011-AI-0015-N-240 10BA09-8011-AI-0015-N-247 10BA09-8011-AI-0015-N-230 According to P&ID 168080U02015 LINE FLUSHING WITH COMPRESSED AIR

3

Acting from great diameters to small diameters flux lines utilizing compressed air. Before flushing, disconnected

all

instruments

must

be

Remove all dirt at end

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 5 ESA-80-015- CDQ 11 loop3 instrument air.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001

ESA/80/015-CDQ11 – Loop3 ESEGUITO/ EXECUTED

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3a

Close valves GL1073NB32, GL1074NB32, GL1067NB32, GL1071NB32 according P&ID 1680 50 K 02 002, BAL1022NB50,

YES

NO

3b

Open valve BAL1166NB25, then in sequence open valves from BAL1170NB15 to BAL1174NB15 and flushing line 10BA09-8011AI-0025-N-233, then close valve BAL1166NB25

YES

NO

3c

Open valve BAL1024NB25, then in sequence open valves from BAL1177NB15 to BAL1187NB15 and flushing line 10BA09-8011AI-0025-N-238, then close valve BAL1024NB25

YES

NO

3d

Open valve BAL1025NB25, then in sequence open valves from BAL1188NB25 to BAL1198NB15 and flushing line 10BA09-8011AI-0025-N-237, then close valve BAL1025NB25

YES

NO

3e

Open valve BAL1167NB25, then in sequence open valves from BAL1199NB15 to BAL1209NB15 and flushing line 10BA09-8011AI-0025-N-236, then close valve BAL1167NB25

YES

NO

3f

Open valve BAL1168NB25, then in sequence open valves from BAL1210NB15 to BAL1218NB15 and flushing line 10BA09-8011AI-0025-N-243, then close valve BAL1168NB25

YES

NO

3g

Open valve BAL1169NB25, then in sequence open valves from BAL1219NB15 to BAL1225NB15 and flushing line 10BA09-8011AI-0025-N-235, then close valve BAL1169NB25

YES

NO

3h

Open valve BAL1169NB25, then in sequence open valves from BAL1219NB15 to BAL1225NB15 and flushing line 10BA09-8011AI-0025-N-235, then close valve BAL1169NB25

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 5 ESA-80-015- CDQ 11 loop3 instrument air.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

ESA/80/015-CDQ11 – Loop3 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3i

Open valve BAL1026NB25, then in sequence open valves from BAL1226NB15 to BAL1230NB15 and flushing line 10BA09-8011AI-0025-N-232, then close valve BAL1026NB25

YES

NO

3j

Open valve BAL1034NB25, then in sequence open valves from BAL1231NB15 to BAL1235NB15 and flushing line 10BA09-8011AI-0025-N-234, then close valve BAL1034NB25

YES

NO

3k

Open valve BAL1175NB25, and flushing line 10BA09-8011-AI-0025-N-231, then close valve BAL1175NB25

YES

NO

3l

Open valve BAL1176NB25 and flushing line 10BA09-8011-AI-0025-N-249, then close valve BAL1176NB25

YES

NO

3m

Open valve BAL1027NB15, and flushing line 10BA09-8011-AI-0015-N-242, then close valve BAL1027NB15

YES

NO

3n

Open valve BAL1035NB15, and flushing line 10BA09-8011-AI-0015-N-244, then close valve BAL1035NB15

YES

NO

3o

Open valve BAL1045NB15, and flushing line 10BA09-8011-AI-0015-N-245, then close valve BAL1045NB15

YES

NO

3p

Open valve BAL1046NB15, and flushing line 10BA09-8011-AI-0015-N-246, then close valve BAL1046NB15

YES

NO

3q

Open valve BAL1066NB15, and flushing line 10BA09-8011-AI-0015-N-240, then close valve BAL1066NB15

YES

NO

3r

Open valve BAL1062NB15, and flushing line 10BA09-8011-AI-0015-N-247, then close valve

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 4 / 5 ESA-80-015- CDQ 11 loop3 instrument air.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

ESA/80/015-CDQ11 – Loop3 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

BAL1062NB15

3s

Open valve BAL1061NB25, and flushing line 10BA09-8011-AI-0025-N-230, then close valve BAL1061NB25

YES

NO

3t

Open valve BAL1295NB25, BAL0296NB and flushing line 10BA09-8011-AI-0025-N250,10BA09-8000-AI-0025-N-342 then close valve BAL1295NB25

YES

NO

YES

NO

Pneumatic test of line BEFORE PAINTING utilizing with compressed air. MOP = 6 bar Pressure 5,5-6 bar. 4

Close all connections. Inflate compressed air in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 5 / 5 ESA-80-015- CDQ 11 loop3 instrument air.doc

BAL1199 NB15

BAL1189 NB15

BAL1213 NB15

SOV521181

BAL1204 NB15

SPARE

BAL1200 NB15

FV511150

SOV511180

SOV511101 SOV511110.01

BAL1188 NB25

BAL1174 NB15

BAL1210 NB15

BAL1203 NB15

BAL1202 NB15

BAL1201 NB15

BAL1193 NB15

BAL1192 NB15

BAL1191 NB15

BAL1219 NB15

BAL1212 NB15

BAL1226 NB15

BAL1220 NB15

BAL1232 NB15

DRAIN

BAL1231 NB15

BAL1227 NB15

BAL1228 NB15

DRAIN

SOV511182

BAL1221 NB15

DRAIN

SOV511183

SOV521182

BAL1211 NB15

SPARE

SOV541181

SOV561101

SOV511132

SPARE

SOV511181

LV801119

SOV511109

BAL1190 NB15

BAL1180 NB15

BAL1179 NB15

BAL1178 NB15

BAL1177 NB15

SOV511110.02

EBV541102

EBV541101

SPARE PV511101

BAL1173 NB15

SPARE

BAL1181 NB15

SPARE

BAL1172 NB15

SPARE

BAL1182 NB15

SOV541180

BAL1171 NB15

SPARE

BAL1234 NB15 BAL1235 NB15

BAL1233 NB15

BAL1230 NB15

BAL1229 NB15

BAL1224 NB15 BAL1225 NB15

BAL1222 NB15 BAL1223 NB15

BAL1214 NB15 BAL1215 NB15 BAL1216 NB15 BAL1217 NB15

BAL1208 NB15

BAL1207 NB15

BAL1205 NB15 BAL1206 NB15

BAL1196 NB15 BAL1197 NB15

BAL1195 NB15

BAL1194 NB15

BAL1185 NB15 BAL1186 NB15

BAL1183 NB15 BAL1184 NB15

** **

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

**

DRAIN BAL1218 NB15

SOV801005.01

FV510091.01 **

SOV510090.01

SOV510092

SOV801105.02

SOV801105.01

SPARE

SOV511150.1

SPARE

SPARE

FV801116

SPARE

SOV541003

SPARE

SPARE

SPARE

10BA09-8011-AI-0025-N-230

10BA09-8011-AI-0015-N-247

10BA09-8011-AI-0015-N-240

10BA09-8011-AI-0015-N-246

10BA09-8011-AI-0015-N-245

10BA09-8011-AI-0015-N-244

10BA09-8011-AI-0015-N-242

10BA09-8011-AI-0025-N-249

10BA09-8011-AI-0025-N-231

10BA09-8011-AI-0025-N-234

10BA09-8011-AI-0025-N-232

10BA09-8011-AI-0025-N-235

10BA09-8011-AI-0025-N-243

10BA09-8011-AI-0025-N-236

10BA09-8011-AI-0025-N-237

10BA09-8011-AI-0050-N-241

10BA09-8011-AI-0025-N-233

10BA09-8011-AI-0025-N-238

10BA09-8011-AI-0025-N-231

*

*

*

*

*

*

*

Closed *

*

BAL1170 NB15

*

*

Closed *

*

Open/close *

*

*

DRAIN

50x15

Closed

Disconnect/connect

Closed

BAL1199 NB15

BAL1189 NB15

BAL1213 NB15

SOV521181

BAL1204 NB15

SPARE

BAL1200 NB15

FV511150

SOV511180

SOV511101 SOV511110.01

BAL1188 NB25

BAL1174 NB15

BAL1210 NB15

BAL1203 NB15

BAL1202 NB15

BAL1201 NB15

BAL1193 NB15

BAL1192 NB15

BAL1191 NB15

BAL1219 NB15

BAL1212 NB15

BAL1226 NB15

BAL1220 NB15

BAL1232 NB15

DRAIN

BAL1231 NB15

BAL1227 NB15

BAL1228 NB15

DRAIN

SOV511182

BAL1221 NB15

DRAIN

SOV511183

SOV521182

BAL1211 NB15

SPARE

SOV541181

SOV561101

SOV511132

SPARE

SOV511181

LV801119

SOV511109

BAL1190 NB15

BAL1180 NB15

BAL1179 NB15

BAL1178 NB15

BAL1177 NB15

SOV511110.02

EBV541102

EBV541101

SPARE PV511101

BAL1173 NB15

SPARE

BAL1181 NB15

SPARE

BAL1172 NB15

SPARE

BAL1182 NB15

SOV541180

BAL1171 NB15

SPARE

BAL1234 NB15 BAL1235 NB15

BAL1233 NB15

BAL1230 NB15

BAL1229 NB15

BAL1224 NB15 BAL1225 NB15

BAL1222 NB15 BAL1223 NB15

BAL1214 NB15 BAL1215 NB15 BAL1216 NB15 BAL1217 NB15

BAL1208 NB15

BAL1207 NB15

BAL1205 NB15 BAL1206 NB15

BAL1196 NB15 BAL1197 NB15

BAL1195 NB15

BAL1194 NB15

BAL1185 NB15 BAL1186 NB15

BAL1183 NB15 BAL1184 NB15

** **

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

**

DRAIN BAL1218 NB15

SOV801005.01

FV510091.01 **

SOV510090.01

SOV510092

SOV801105.02

SOV801105.01

SPARE

SOV511150.1

SPARE

SPARE

FV801116

SPARE

SOV541003

SPARE

SPARE

SPARE

10BA09-8011-AI-0025-N-230

10BA09-8011-AI-0015-N-247

10BA09-8011-AI-0015-N-240

10BA09-8011-AI-0015-N-246

10BA09-8011-AI-0015-N-245

10BA09-8011-AI-0015-N-244

10BA09-8011-AI-0015-N-242

10BA09-8011-AI-0025-N-249

10BA09-8011-AI-0025-N-231

10BA09-8011-AI-0025-N-234

10BA09-8011-AI-0025-N-232

10BA09-8011-AI-0025-N-235

10BA09-8011-AI-0025-N-243

10BA09-8011-AI-0025-N-236

10BA09-8011-AI-0025-N-237

10BA09-8011-AI-0050-N-241

10BA09-8011-AI-0025-N-233

10BA09-8011-AI-0025-N-238

10BA09-8011-AI-0025-N-231

*

*

*

*

*

*

*

Closed *

*

BAL1170 NB15

*

*

*

Closed *

*

Open/close *

*

DRAIN

50x15

Open/close Closed

Closed

BAL1199 NB15

BAL1189 NB15

BAL1213 NB15

SOV521181

BAL1204 NB15

SPARE

BAL1200 NB15

FV511150

SOV511180

SOV511101 SOV511110.01

BAL1188 NB25

BAL1174 NB15

BAL1210 NB15

BAL1203 NB15

BAL1202 NB15

BAL1201 NB15

BAL1193 NB15

BAL1192 NB15

BAL1191 NB15

BAL1219 NB15

BAL1212 NB15

BAL1226 NB15

BAL1220 NB15

BAL1232 NB15

DRAIN

BAL1231 NB15

BAL1227 NB15

BAL1228 NB15

DRAIN

SOV511182

BAL1221 NB15

DRAIN

SOV511183

SOV521182

BAL1211 NB15

SPARE

SOV541181

SOV561101

SOV511132

SPARE

SOV511181

LV801119

SOV511109

BAL1190 NB15

BAL1180 NB15

BAL1179 NB15

BAL1178 NB15

BAL1177 NB15

SOV511110.02

EBV541102

EBV541101

SPARE PV511101

BAL1173 NB15

SPARE

BAL1181 NB15

SPARE

BAL1172 NB15

SPARE

BAL1182 NB15

SOV541180

BAL1171 NB15

SPARE

BAL1234 NB15 BAL1235 NB15

BAL1233 NB15

BAL1230 NB15

BAL1229 NB15

BAL1224 NB15 BAL1225 NB15

BAL1222 NB15 BAL1223 NB15

BAL1214 NB15 BAL1215 NB15 BAL1216 NB15 BAL1217 NB15

BAL1208 NB15

BAL1207 NB15

BAL1205 NB15 BAL1206 NB15

BAL1196 NB15 BAL1197 NB15

BAL1195 NB15

BAL1194 NB15

BAL1185 NB15 BAL1186 NB15

BAL1183 NB15 BAL1184 NB15

** **

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

**

DRAIN BAL1218 NB15

SOV801005.01

FV510091.01 **

SOV510090.01

SOV510092

SOV801105.02

SOV801105.01

SPARE

SOV511150.1

SPARE

SPARE

FV801116

SPARE

SOV541003

SPARE

SPARE

SPARE

10BA09-8011-AI-0025-N-230

10BA09-8011-AI-0015-N-247

10BA09-8011-AI-0015-N-240

10BA09-8011-AI-0015-N-246

10BA09-8011-AI-0015-N-245

10BA09-8011-AI-0015-N-244

10BA09-8011-AI-0015-N-242

10BA09-8011-AI-0025-N-249

10BA09-8011-AI-0025-N-231

10BA09-8011-AI-0025-N-234

10BA09-8011-AI-0025-N-232

10BA09-8011-AI-0025-N-235

10BA09-8011-AI-0025-N-243

10BA09-8011-AI-0025-N-236

10BA09-8011-AI-0025-N-237

10BA09-8011-AI-0050-N-241

10BA09-8011-AI-0025-N-233

10BA09-8011-AI-0025-N-238

10BA09-8011-AI-0025-N-231

*

*

*

*

*

*

*

*

*

BAL1170 NB15

*

DRAIN

*

*

*

*

*

*

50x15

100x125

Open/close 10BA04-8011-WF-0125-N-171

100x125

closed

90DUCT-5411-PG-0000-N-434

65x65

10BA04-8011-AP-0040-N-251

40x40

TO LIT 511102 ELECTRONICS

TO LIT 511101 ELECTRONICS

10BA04-8011-WF-0065-N-177

BAL1136 NB40

BAL1138 SOV511101 BAL1137 NB40 NB40 NB40

Remove PCV and install adapter pipe

25x25

10BA04-8011-NI-0080-N-196

50x20 65x50

Closed

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

END OF ERECTION

ESA/80/016-CDQ11 EQUIPMENT:

SUPPLIER:

CDQ – 11 Compressed air

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 016 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-AP-0050-N-273 10BA04-8011-AP-0025-N-269 10BA04-8011-AP-0040-N-251 10BA04-8011-AP-0040-N-252 10BA04-8011-AP-0015-N-275 10BA04-8000-AP-0015-N-351 10BA04-8011-AP-0040-N-272 10BA04-8011-AP-0040-N-274 10BA04-8011-AP-0080-N-253 1

Cleaning of line and control absence of dirt inside the line

YES

NO

2

Control lines gradient, vent installation.

YES

NO

YES

NO

LINE FLUSHING WITH COMPRESSED AIR 3

Acting from small diameters to greater diameters flux lines utilizing compressed air. Remove all dirt at end

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 2 ESA-80-016-CDQ 11 COMPRESSED AIR_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

END OF ERECTION

ESA/80/016-CDQ11 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

DATA / COMMENTI DATE / NOTES

Hydraulic test of line BEFORE PAINTING utilizing dried compressed air.. MOP = 6 bar Pressure 5-6 bar. 4

Close all connections. Inflate dried compressed air in order to reach test pressure, to be checked with record of pressure and temperature.

YES

NO

For the next 6 hour no pressure reduction must be noted. 4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control of the correct erection

YES

NO

6

Control instrumentation installed on lines

YES

NO

7

Control execution superficial treatment of lines

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 2 ESA-80-016-CDQ 11 COMPRESSED AIR_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/016-CDQ11 – Loop1 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Compressed air Loop 1

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 016 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-AP-0050-N-273 10BA04-8011-AP-0015-N-275 10BA04-8000-AP-0015-N-351

1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 10BA04-8011-AP-0050-N-273 2

10BA04-8011-AP-0015-N-275 10BA04-8000-AP-0015-N-351 According to P&ID 168080U02016 LINE FLUSHING WITH COMPRESSED AIR

3

Acting from great diameters to small diameters flux lines utilizing compressed air. Remove all dirt at end

3a

Close valves BAL1057NB15, BAL1029NB25, BAL1030NB40, BAL1031NB40, BAL1032NB40, BAL1033NB40, BAL1020NB40, BAL1164NB15

YES

NO

3b

Disconnect end cup/flange on line 10BA04-8011AP-0050-N-273 termination

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 3 ESA-80-016- CDQ 11 loop1 COMPRESSED AIR_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/016-CDQ11 – Loop1 ESEGUITO/ EXECUTED

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3c

Open valve BAL1236NB50 and flushing with compressed air line10BA04-8011-AP-0050-N273, then close valve.

YES

NO

3d

Close end cup/blanked on line 10BA04-8011-AP0050-N-273

YES

NO

3e

Open valves BAL1236NB50, BAL1164NB15 and flushing with compressed air lines 10BA04-8011AP-0015-N-275, 10BA04-8000-AP-0015-N-351, then close valve

YES

NO

3f

Close valves BAL 1236NB50, BAL1164NB15 stop flushing.

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Hydraulic test of line BEFORE PAINTING utilizing with compressed air. MOP = 6 bar Pressure 5-6 bar. 4

Close all connections. Inflate dry compressed air in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 3 ESA-80-016- CDQ 11 loop1 COMPRESSED AIR_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/016-CDQ11 – Loop1

____________________

END OF ERECTION

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 3 ESA-80-016- CDQ 11 loop1 COMPRESSED AIR_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/016-CDQ11 – Loop2 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Compressed air Loop 2

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 016 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-AP-0025-N-269 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 2

10BA04-8011-NI-0025-N-269 According to P&ID 168080U02016 LINE FLUSHING WITH COMPRESSED AIR

3

Acting from great diameters to small diameters flux lines utilizing compressed air. Remove all dirt at end

3a

Close valves BAL1057NB15, BAL1030NB40, BAL1031NB40, BAL1164NB15, BAL1032NB40, BAL1033NB40,BAL1020NB40

YES

NO

3b

Open valve BAL1236NB50

YES

NO

3c

Open valve BAL1029NB25 and flushing line 10BA04-8011-AP-0025-N-269.

YES

NO

YES

NO

Then close valve. 4

Hydraulic test of line BEFORE PAINTING utilizing compressed air.

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 2 ESA-80-016- CDQ 11 loop2 COMPRESSED AIR_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001 POS

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/016-CDQ11 – Loop2 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

MOP = 6 bar Pressure 5-6 bar. Close all connections. Inflate dry compressed air in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted. 4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 2 ESA-80-016- CDQ 11 loop2 COMPRESSED AIR_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/016-CDQ11 – Loop3 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Compressed air Loop 3

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 016 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-AP-0040-N-251 10BA04-8011-AP-0040-N-252 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 2

10BA04-8011-AP-0040-N-251 10BA04-8011-AP-0040-N-252 According to P&ID 168080U02016 LINE FLUSHING WITH COMPRESSED AIR

3

Acting from great diameters to small diameters flux lines utilizing compressed air. Remove all dirt at end

3a

Close valves BAL1057NB15, BAL1029NB25, BAL1164NB15, BAL1032NB40, BAL1033NB40, BAL1020NB40

YES

NO

3b

Open valve BAL1236NB50

YES

NO

3c

Open valve BAL1030NB40 and flushing line 10BA04-8011-AP-0040-N-251.

YES

NO

Then close valve.

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 2 ESA-80-016- CDQ 11 loop3 compressed air_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001 POS

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/016-CDQ11 – Loop3 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Valve BAL1031NB40 must be closed

3d

Open valve BAL1031NB40 and flushing line 10BA04-8011-AP-0040-N-252.

YES

NO

YES

NO

Then close valve. Hydraulic test of line BEFORE PAINTING utilizing compressed air. MOP = 6 bar Pressure 5-6 bar. 4

Close all connections. Inflate dry compressed air in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 2 ESA-80-016- CDQ 11 loop3 compressed air_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/016-CDQ11 – Loop 4 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Compressed air Loop 4

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 016 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-AP-0040-N-272 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 2

10BA04-8011-AP-0040-N-272 According to P&ID 168080U02016 LINE FLUSHING WITH COMPRESSED AIR

3

Acting from great diameters to small diameters flux lines utilizing compressed air. Remove all dirt at end

3a

Close valves BAL1057NB15, BAL1029NB25, BAL1030NB40, BAL1031NB40, BAL1164NB15 BAL1033NB40, BAL1020NB40

YES

NO

3c

Open valve BAL1236NB50

YES

NO

3e

Open valve BAL1032NB40 and flushing with compressed air line 10BA04-8011-AP-0040-N272

YES

NO

Then close valve

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 2 ESA-80-016- CDQ 11 loop 4 COMPRESSED AIR_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001 POS

3f

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/016-CDQ11 – Loop 4 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

Close valve BAL 1236NB50 stop flushing.

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Hydraulic test of line BEFORE PAINTING utilizing with compressed air. MOP = 6 bar Pressure 5-6 bar. 4

Close all connections. Inflate dry compressed air in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 2 ESA-80-016- CDQ 11 loop 4 COMPRESSED AIR_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/016-CDQ11 – Loop 5 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Compressed air Loop 5

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 016 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-AP-0040-N-274 10BA04-8011-AP-0080-N-253 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 2

10BA04-8011-AP-0040-N-274 10BA04-8011-AP-0080-N-253 According to P&ID 168080U02016 LINE FLUSHING WITH COMPRESSED AIR

3

Acting from great diameters to small diameters flux lines utilizing compressed air. Remove all dirt at end

3a

3b

Close valves BAL1057NB15, BAL1029NB25, BAL1030NB40, BAL1031NB40, BAL1164NB15, BAL1032NB40, BAL0340NB15. Dismantle Reducing pressure PCV1025NB40, PCV1026NB40 and adapter pipe.

valves install

Install these valves after completion Loop 5

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 3 ESA-80-016- CDQ 11 loop 5 compressed air_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001

ESA/80/016-CDQ11 – Loop 5

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3c

Disconnect a GV1002NB80

3d

Open valve BAL1236NB50

flange

before

the

valve

ESEGUITO/ EXECUTED

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Open valve BAL1033NB40 and flushing line 10BA04-8011-AP-0040-N-274. 3e

Then close valve. Valve BAL1026NB40 must be closed

3f

Open valve BAL1026NB40 and flushing line 10BA04-8011-AP-0080-N-253. Then close valve.

3g

Connect flange before valve GV1002NB80. Hydraulic test of line BEFORE PAINTING utilizing compressed air. MOP = 0.2 bar Pressure 0.1-0.2 bar.

4

Close all connections. Inflate dry compressed air in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control instrumentation installed on lines

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 3 ESA-80-016- CDQ 11 loop 5 compressed air_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001 POS

6

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/016-CDQ11 – Loop 5 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

Control execution superficial treatment of lines

YES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 3 ESA-80-016- CDQ 11 loop 5 compressed air_END OF ERECTION.doc

Closed

Closed

Close/Open

Disconnect/connect

Closed

Closed Closed

80x40

Closed

80x40

Closed

10BA04-8011-AP-0040-N-272

50x40

Closed

Closed

Closed Closed

Closed Closed

Closed

80x40

80x40

10BA04-8011-AP-0040-N-272

Open/Close 50x40

Open/Close

Closed Closed Closed

Open/Close

80x40

80x40

10BA04-8011-AP-0040-N-272

Closed 50x40

Open/Close

Closed

Closed

Closed

Closed

Closed

Open/Close

Closed

80x40

80x40

50x40

Closed

Closed

10BA04-8011-AP-0040-N-272

Open/Close

Closed Closed Closed

Open/Close Closed

Closed

80x40

Dismantle and install adapter pipe.

80x40

10BA04-8011-AP-0040-N-272

Closed

50x40

Open/Close

Disconnect flange/connect Closed

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/013-CDQ11 EQUIPMENT:

CDQ – 11 Nitrogen line

PW Drawing number L&T Drawings number (to be listed here)

____________________

END OF ERECTION

SUPPLIER:

L&T

GENERAL P&I .

1680 80 U 02 013 – CDQ 11

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

ESEGUITO/ EXECUTED

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-NI-0100-N-212 10BA04-8011-NI-0040-N-197 10BA04-8011-NI-0025-N-192 10BA04-8011-NI-0025-N-214 10BA04-8011-NI-0080-N-201 10BA04-8011-NI-0100-N-199 10BA04-8011-NI-0065-N-222 10BA04-8011-NI-0150-N-209 10BA04-8011-NI-0065-N-215 10BA04-8011-NI-0025-N-353 10BA04-8011-NI-0100-N-213 10BA04-8011-NI-0100-N-223 10BA04-8011-NI-0025-N-205 10BA04-8011-NI-0080-N-196 10BA04-8011-NI-0050-N-211 10BA04-8011-NI-0040-N-224 10BA04-8011-NI-0025-N-198 10BA04-8011-NI-0040-N-193 10BA04-8011-NI-0080-N-220 10BA04-8011-NI-0040-N-341

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 4 ESA-80-013-CDQ 11 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

END OF ERECTION

ESA/80/013-CDQ11 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

DATA / COMMENTI DATE / NOTES

10BA04-8011-NI-0040-N-207 10BA04-8011-NI-0080-N-204 10BA04-8011-NI-0050-N-221 10BA04-8011-NI-0040-N-200 10BA04-8011-NI-0040-N-225 10BA04-8011-NI-0040-N-341 10BA04-8011-NI-0040-N-203 10BA04-8011-NI-0040-N-219 10BA04-8011-NI-0040-N-210 10BA04-8011-NI-0032-N-195 10BA04-8011-NI-0032-N-194 10BA04-8011-NI-0040-N-217 10BA04-8011-NI-0040-N-216 10BA04-8011-NI-0040-N-218 10BA04-8010-NI-0020-N-295 10BA04-8010-NI-0020-N-295 10BA04-8010-NI-0020-N-294 10BA04-8010-NI-0020-N-293 10BA04-8010-NI-0020-N-292 10BA04-8010-NI-0020-N-291 10BA04-8010-NI-0020-N-290 10BA04-8010-NI-0020-N-591 1

Cleaning of line and control absence of dirt inside the line

YES

NO

2

Control lines gradient, vent installation.

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 4 ESA-80-013-CDQ 11 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

END OF ERECTION

ESA/80/013-CDQ11 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

DATA / COMMENTI DATE / NOTES

LINE FLUSHING WITH COMPRESSED AIR 3

Acting from small diameters to greater diameters flux lines utilizing compressed air.

YES

NO

YES

NO

Remove all dirt at end Hydraulic test of line BEFORE PAINTING utilizing dried compressed air.. MOP = 8 bar Pressure 7-8 bar. 4

Close all connections. Inflate dried compressed air in order to reach test pressure, to be checked with record of pressure and temperature. For the next 24 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control of the correct erection of Expansion Joints

YES

NO

6

Control instrumentation installed on lines

YES

NO

7

Control execution superficial treatment of lines

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 4 ESA-80-013-CDQ 11 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

8

END OF ERECTION

ESA/80/013-CDQ11 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

Control execution thermal protection of the lines where necessary (insulating thk and type)

YES

____________________

DATA / COMMENTI DATE / NOTES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 4 / 4 ESA-80-013-CDQ 11 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/013-CDQ11 – Loop1 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Nitrogen line Loop 1

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 013 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-NI-0100-N-212

1

Cleaning of line and control absence of dirt inside the line

YES

NO

2

Check the installation and connection of the line 10BA04-8011-NI-0100-N-212 According to P&ID 168080U02013

YES

NO

YES

NO

3a

Close valves BAL0368NB40, BAL1019NB25, BAL1015NB50, BAL1018NB50, BAL1017NB25, BAL1160NB40, BAL1081NB40, BAL1006NB40, BAL1008NB40, GV1005NB80, GV1013NB80, GV1014NB100

YES

NO

3b

Disconnect end cup/flange on line 10BA04-8011NI-0100-N-212 termination

YES

NO

3c

Open valve BAL0384NB100 and flushing with compressed air/nitrogen

YES

NO

LINE FLUSHING AIR/NITROGEN 3

WITH

COMPRESSED

Acting from great diameters to small diameters flux lines utilizing compressed air/nitrogen. Remove all dirt at end

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 3 ESA-80-013- CDQ 11 loop1 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/013-CDQ11 – Loop1 ESEGUITO/ EXECUTED

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3d

Close valve BAL 0384NB100, stop flushing.

YES

NO

3e

Close end cup/blanked on line 10BA04-8011-NI0100-N-212

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Hydraulic test of line BEFORE PAINTING utilizing nitrogen.. MOP = 8 bar Pressure 7-8 bar. 4

Close all connections. Inflate dry nitrogen in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

7

Control execution thermal protection of the lines where necessary (insulating thk and type)

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 3 ESA-80-013- CDQ 11 loop1 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/013-CDQ11 – Loop1

____________________

END OF ERECTION

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 3 ESA-80-013- CDQ 11 loop1 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/013-CDQ11 – Loop2 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Nitrogen line Loop 2

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 013 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-NI-0040-N-197 10BA04-8011-NI-0025-N-192 10BA04-8011-NI-0040-N-225 10BA04-8000-NI-0040-N-341 10BA04-8011-NI-0040-N-203 10BA04-8011-NI-0080-N-201 10BA04-8011-NI-0025-N-214 10BA04-8011-NI-0100-N-199 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

Check the installation and connection of the line 10BA04-8011-NI-0040-N-197 10BA04-8011-NI-0025-N-192 10BA04-8011-NI-0040-N-225 2

10BA04-8000-NI-0040-N-341 10BA04-8011-NI-0040-N-203 10BA04-8011-NI-0080-N-201 10BA04-8011-NI-0025-N-214 10BA04-8011-NI-0100-N-199

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 4 ESA-80-013- CDQ 11 loop2 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

ESA/80/013-CDQ11 – Loop2 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

According to P&ID 168080U02013

LINE FLUSHING AIR/NITROGEN 3

WITH

COMPRESSED

Acting from great diameters to small diameters flux lines utilizing compressed air/nitrogen.

YES

NO

Remove all dirt at end 3a

Close valves BAL1015NB50, BAL1018NB50, GV1005NB80, BAL1006NB40, BAL108NB40

YES

NO

3b

Open valve BAL0384NB100

YES

NO

3c

Open valve BAL0368NB40 and flushing line 10BA04-8011-NI-0040-N-197.

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

Then close valve.

3d

Open valve BAL1019NB25 and flushing line 10BA04-8011-NI-0025-N-192. Then close valve.

3e

Open valve BAL1160NB40 and flushing line 10BA04-8011-NI-0040-N-225, 10BA04-8000-NI0040-N-341. Then close valve.

3f

Open valve BAL1081NB40 and flushing line 10BA04-8011-NI-0040-N-203. Then close valve.

3g

Open valve GV1013NB80 and flushing line 10BA04-8011-NI-0080-N-201. Then close valve

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 4 ESA-80-013- CDQ 11 loop2 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001

ESA/80/013-CDQ11 – Loop2

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3h

Disconnect end cup/flange on line 10BA04-8011NI-0025-N-214 termination

ESEGUITO/ EXECUTED

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Open valve BAL1017NB25 and flushing line 10BA04-8011-NI-0025-N-214. Then close valve BAL1017NB25. Connect end cup/flange on line 10BA04-8011-NI-0025-N-214 Disconnect instruments on this line. 3i

Open valve BAL1017NB25 Then alternately open and close the valve from BAL0356NB15 to BAL0405NB15 According to P&ID 168080U02013 Close valve BAL1017NB25 Connect all instruments on this line.

3j

Open valve GV1014NB100 and flushing line 10BA04-8011-NI-0100-N-199. Then close valve. Hydraulic test of line BEFORE PAINTING utilizing nitrogen.. MOP = 8 bar Pressure 7-8 bar.

4

Close all connections. Inflate dry nitrogen in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 4 ESA-80-013- CDQ 11 loop2 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001 POS

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/013-CDQ11 – Loop2 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

7

Control execution thermal protection of the lines where necessary (insulating thk and type)

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

COMMISSIONING 8

Line Inertizing according to procedure INERT- _________(only for nitrogen line 10BA04-8000-NI-0040-N-341)

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 4 / 4 ESA-80-013- CDQ 11 loop2 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/013-CDQ11 – Loop3 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Nitrogen line Loop 3

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 013 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-NI-0150-N-209 10BA04-8011-NI-0040-N-224 10BA04-8011-NI-0065-N-222 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 10BA04-8011-NI-0150-N-209 2

10BA04-8011-NI-0040-N-224 10BA04-8011-NI-0065-N-222 According to P&ID 168080U02013 LINE FLUSHING AIR/NITROGEN

3

WITH

COMPRESSED

Acting from great diameters to small diameters flux lines utilizing compressed air/nitrogen. Remove all dirt at end

3a

Close valves BAL0368NB40, BAL1019NB25, BAL\1017NB25, GV1014NB100, GV1013NB80, GV1005NB80, BAL1160NB40, BAL1081NB40, BAL1006NB40, BAL1008NB40, GV1012NB100, BAL1097NB25, GV1020NB80, BAL1083NB50, BAL1088NB25, BAL1091NB25

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 3 ESA-80-013- CDQ 11 loop3 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001

ESA/80/013-CDQ11 – Loop3

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3b

Dismantle Reducing pressure PCV1001NB50, PCV1002NB50 and adapter pipe.

valves install

ESEGUITO/ EXECUTED

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Install these valves after completion Loop 4 3c

Disconnect end cup/flange on line 10BA04-8011NI-0150-N-209 and end on line 10BA04-8011-NI0040-N-224 termination

YES

NO

3d

Disconnect a GV1009NB150

YES

NO

3e

Open valve BAL0384NB100

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

flange

before

the

valve

Open valve BAL1015NB50 and flushing line 10BA04-8011-NI-0150-N-209. 3f

Then close valve. Valve BAL1018NB50 must be closed

3g

Open valve BAL1018NB50 and flushing line 10BA04-8011-NI-0065-N-222. Then close valve. Connect flange before valve GV1009NB150.

3h

Connect end cup/flange on line 10BA04-8011-NI0150-N-209 and end on line 10BA04-8011-NI0040-N-224 termination Hydraulic test of line BEFORE PAINTING utilizing nitrogen. MOP = 0.2 bar

4

Pressure 0.1-0.2 bar. Close all connections. Inflate dry nitrogen in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 3 ESA-80-013- CDQ 11 loop3 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001 POS

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/013-CDQ11 – Loop3 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

7

Control execution thermal protection of the lines where necessary (insulating thk and type)

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 3 ESA-80-013- CDQ 11 loop3 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/013-CDQ11 – Loop 4 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Nitrogen line Loop 4

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 013 – CDQ 10

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-NI-0065-N-215 10BA04-8011-NI-0025-N-353 10BA04-8011-NI-0100-N-213 10BA04-8011-NI-0100-N-223 10BA04-8011-NI-0025-N-205 10BA04-8011-NI-0080-N-196 10BA04-8011-NI-0050-N-211 10BA04-8011-NI-0025-N-198 10BA04-8011-NI-0025-N-193 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

Check the installation and connection of the line 10BA04-8011-NI-0065-N-215 10BA04-8011-NI-0025-N-353 2

10BA04-8011-NI-0100-N-213 10BA04-8011-NI-0100-N-223 10BA04-8011-NI-0025-N-205 10BA04-8011-NI-0080-N-196 10BA04-8011-NI-0050-N-211

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 4 ESA-80-013- CDQ 11 loop4 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

ESA/80/013-CDQ11 – Loop 4 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

10BA04-8011-NI-0025-N-198 10BA04-8011-NI-0025-N-193 According to P&ID 168080U02003 LINE FLUSHING AIR/NITROGEN 3

WITH

COMPRESSED

Acting from great diameters to small diameters flux lines utilizing compressed air/nitrogen.

YES

NO

3a

Close valves BAL0368NB40, BAL1019NB25, BAL1017NB25, GV1014NB100, GV1013NB80, GV1005NB80, BAL1160NB40, BAL1081NB40, BAL1006NB40, BAL1008NB40

YES

NO

3b

Dismantle Reducing pressure PCV1001NB50, PCV1002NB50 and adapter pipe.

YES

NO

3c

Open valve BAL0384NB100

YES

NO

3d

Open valve BAL1015NB50

YES

NO

3e

Open valve BAL0351NB65 and flushing line 10BA04-8011-NI-0065-N-215 .

YES

NO

YES

NO

YES

NO

Remove all dirt at end

valves install

Then close valve

3f

Open valve BAL0310NB25 and flushing line 10BA04-8011-NI-0025-N-353. Then close valve.

3g

Open valve GV1012NB100, GV1063NB100, GV1064NB100 and flushing line 10BA04-8011NI-0100-N-213, 10BA04-8011-NI-0100-N-223. Then close valves.

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 4 ESA-80-013- CDQ 11 loop4 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001

ESA/80/013-CDQ11 – Loop 4

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3h

Open valve BAL1097NB25 and flushing line 10BA04-8011-NI-0025-N-205.

ESEGUITO/ EXECUTED

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Then close valve.

3i

Open valve BAL1020NB80 and flushing line 10BA04-8011-NI-0080-N-196. Then close valve.

3j

Open valve BAL1083NB50 and flushing line 10BA04-8011-NI-0050-N-211. Then close valve.

3k

Open valve BAL1088NB25 and flushing line 10BA04-8011-NI-0025-N-198. Then close valve.

3m

Open valve BAL1091NB25 and flushing line 10BA04-8011-NI-0025-N-193. Then close valve.

3n

Install Reducing pressure valves PCV1001NB50, PCV1002NB50 Hydraulic test of line BEFORE PAINTING utilizing nitrogen.. MOP = 0.2 bar Pressure 0.1- 0.2 bar.

4

Close all connections. Inflate dry nitrogen in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 4 ESA-80-013- CDQ 11 loop4 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001 POS

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/013-CDQ11 – Loop 4 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

7

Control execution thermal protection of the lines where necessary (insulating thk and type)

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 4 / 4 ESA-80-013- CDQ 11 loop4 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/013-CDQ11 – Loop 5 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Nitrogen line Loop 5

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 013 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-NI-0080-N-220 10BA04-8011-NI-0040-N-207 10BA04-8011-NI-0040-N-200 10BA04-8011-NI-0080-N-204 10BA04-8011-NI-0050-N-221 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 10BA04-8011-NI-0080-N-220 10BA04-8011-NI-0040-N-207 2

10BA04-8011-NI-0040-N-200 10BA04-8011-NI-0080-N-204 10BA04-8011-NI-0050-N-221 According to P&ID 168080U02013 LINE FLUSHING AIR/NITROGEN

3

WITH

COMPRESSED

Acting from great diameters to small diameters flux lines utilizing compressed air/nitrogen. Remove all dirt at end

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 4 ESA-80-013- CDQ 11 loop5 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001

ESA/80/013-CDQ11 – Loop 5 ESEGUITO/ EXECUTED

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3a

Close valves BAL0368NB40, BAL1019NB25, BAL1017NB25, GV1014NB100, GV1013NB80, BAL1160NB40, BAL1081NB40, BAL1006NB40, BAL1008NB40, BAL1015NB50, BAL1018NB50

YES

NO

3b

Open valve BAL0384NB100

YES

NO

3c

Disconnect end cup/flange on line 10BA04-8011NI-0080-N-220 termination

YES

NO

YES

NO

3b

Open valve GV1005NB80 and flushing line 10BA04-8011-NI-0080-N-220.

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Then close valve. 3e

Connect end cup/flange on line 10BA04-8011-NI0080-N-220 termination

YES

NO

3f

Open valve GV1005NB80

YES

NO

3g

Open valve BAL0381NB40 and flushing line to COG PIPING LINE PURGING.

YES

NO

YES

NO

YES

NO

YES

NO

Then close valve.

3h

Open valve BAL1068NB40 and flushing line 10BA04-8011-NI-0040-N-207. Then close valve.

3i

Open valve GV1003NB80 and flushing line 10BA04-8011-NI-0080-N-204. Then close valve.

3j

Open valve BAL1011NB50 and flushing line 10BA04-8011-NI-0050-N-221. Then close valve.

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 4 ESA-80-013- CDQ 11 loop5 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/013-CDQ11 – Loop 5

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3k

Open valve BAL1095NB40 and flushing line 10BA04-8011-NI-0040-N-200.

ESEGUITO/ EXECUTED

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Then close valve. Hydraulic test of line BEFORE PAINTING utilizing nitrogen.. MOP = 8 bar Pressure 7-8 bar. 4

Close all connections. Inflate dry nitrogen in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

7

Control execution thermal protection of the lines where necessary (insulating thk and type)

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 4 ESA-80-013- CDQ 11 loop5 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/013-CDQ11 – Loop 5

____________________

END OF ERECTION

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 4 / 4 ESA-80-013- CDQ 11 loop5 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/013-CDQ11 – Loop 6 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Nitrogen line Loop 6

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 013 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 10BA04-8011-NI-0040-N-210 10BA04-8011-NI-0040-N-219 10BA04-8011-NI-0040-N-218 10BA04-8011-NI-0032-N-195 10BA04-8011-NI-0032-N-194 10BA04-8011-NI-0040-N-217 10BA04-8011-NI-0040-N-216 10BA04-8011-NI-0020-N-295 10BA04-8011-NI-0020-N-294 10BA04-8011-NI-0020-N-293 10BA04-8011-NI-0020-N-292 10BA04-8011-NI-0020-N-291 10BA04-8011-NI-0020-N-290 10BA04-8010-NI-0020-N-591 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

Check the installation and connection of the line 2

10BA04-8011-NI-0040-N-210 10BA04-8011-NI-0040-N-219

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 6 ESA-80-013- CDQ 11 loop 6 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

ESA/80/013-CDQ11 – Loop 6 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

10BA04-8011-NI-0040-N-218 10BA04-8011-NI-0032-N-195 10BA04-8011-NI-0032-N-194 10BA04-8011-NI-0040-N-217 10BA04-8011-NI-0040-N-216 10BA04-8011-NI-0020-N-295 10BA04-8011-NI-0020-N-294 10BA04-8011-NI-0020-N-293 10BA04-8011-NI-0020-N-292 10BA04-8011-NI-0020-N-291 10BA04-8011-NI-0020-N-290 10BA04-8010-NI-0020-N-591 According to P&ID 168080U02013 LINE FLUSHING AIR/NITROGEN 3

WITH

COMPRESSED

Acting from great diameters to small diameters flux lines utilizing compressed air/nitrogen.

YES

NO

YES

NO

YES

NO

YES

NO

Remove all dirt at end

3a

Close valves BAL1017NB25, BAL1160NB40, BAL1018NB50,

BAL0368NB40, BAL1019NB25, GV1014NB100, GV1013NB80, BAL1081NB40, BAL1015NB50, GV1005NB80

3b

Dismantle Reducing pressure PCV1003NB40, PCV1004NB40 and adapter pipe.

3c

Disconnect end cup/flange on line 10BA04-8011NI-0040-N-210 and 10BA04-8011-NI- 0040-N218 termination

valves install

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 6 ESA-80-013- CDQ 11 loop 6 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001

ESA/80/013-CDQ11 – Loop 6 ESEGUITO/ EXECUTED

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3d

Disconnect flange befor valve BAL1010NB50

YES

NO

3e

Disconnect all instrumentation (Gas analyzers)

YES

NO

3f

Open valve BAL0384NB100

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Open valves BAL1006NB40 and BAL1009NB50 Valves BAL1008NB40, BAL1073 must be Closed 3g

BAL1010NB50

and

Flushing line 10BA04-8011-NI-0040-N-210 about 15 minutes Then open valve BAL1008NB40 flushing line 10BA04-8011-NI-0040-N-219 Then close BAL1008NB40

valves

BAL1006NB40

and

3h

Connect end cup/flange on line 10BA04-8011-NI0040-N-210 termination

YES

NO

3i

Connect flange befor valve BAL1010NB50

YES

NO

3j

Open valve BAL1006NB40

YES

NO

3k

Open valve BAL1266NB32 and flushing line 10BA04-8011-NI-0032-N-195

YES

NO

YES

NO

YES

NO

Then close valve.

3l

Open valve BAL1269NB32 and flushing line 10BA04-8011-NI-0032-N-194. Then close valve.

3m

Open valves BAL1060NB40, BAL1242NB40 and flushing lines 10BA04-8011-NI-0040-N-217,

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 6 ESA-80-013- CDQ 11 loop 6 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

ESA/80/013-CDQ11 – Loop 6 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

10BA04-8011-NI-0040-N-216. Then closed valves. Open valve BAL1073NB40 and flushing line 10BA04-8011-NI-0040-N-218. 3n

Then close valve.

YES

NO

Valves BAL1241NB20, BAL1051NB20, BAL1237NB20, BAL1238NB20, BAL1239NB20, BAL1240NB20, BAL1292NB20 must be closed. 3o

Connect end cup/flange on line 10BA04-8011-NI0040-N-218 termination

YES

NO

3p

Open valve BAL1073NB40

YES

NO

3q

Open valve BAL1241NB20 and flushing line 10BA04-8011-NI-0020-N-295

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

Then close valve.

3r

Open valve BAL1051NB20 and flushing line 10BA04-8011-NI-0020-N-294 Then close valve.

3s

Open valve BAL1237NB20 and flushing line 10BA04-8011-NI-0020-N-293 Then close valve.

3t

Open valve BAL1238NB20 and flushing line 10BA04-8011-NI-0020-N-292 Then close valve.

3u

Open valve BAL1239NB20 and flushing line 10BA04-8011-NI-0020-N-291 Then close valve.

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 4 / 6 ESA-80-013- CDQ 11 loop 6 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001

ESA/80/013-CDQ11 – Loop 6

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3v

Open valve BAL1240NB20 and flushing line 10BA04-8011-NI-0020-N-290

ESEGUITO/ EXECUTED

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Then close valve.

3w

Open valve BAL1292NB20 and flushing line 10BA04-8010-NI-0020-N-591 Then close valve.

3x

Close valves BAL1073NB40, BAL1009NB50, BAL1006NB40

YES

NO

3y

Connect all instrumentation (Gas analyzers).

YES

NO

3z

Install Reducing pressure valves PCV1003NB40, PCV1004NB40

YES

NO

YES

NO

4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control instrumentation installed on lines

YES

NO

Hydraulic test of line BEFORE PAINTING utilizing nitrogen.. MOP = 0.2 bar 4

Pressure 0.1-0.2 bar. Close all connections. Inflate dry nitrogen in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted.

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 5 / 6 ESA-80-013- CDQ 11 loop 6 NITROGEN_END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001 POS

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/013-CDQ11 – Loop 6 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

6

Control execution superficial treatment of lines

YES

NO

7

Control execution thermal protection of the lines where necessary (insulating thk and type)

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 6 / 6 ESA-80-013- CDQ 11 loop 6 NITROGEN_END OF ERECTION.doc

Closed Closed 10BA04-8010-NI-0020-N-591

Closed

10BA04-8010-NI-0020-N-290

10BA04-8010-NI-0020-N-291

10BA04-8010-NI-0020-N-292

10BA04-8010-NI-0020-N-293

10BA04-8010-NI-0020-N-294

*

*

Closed

10BA04-8010-NI-0020-N-295

10BA04-8011-NI-0040-N-216

*

50x40

50x40

REMOVABLE PERMANENT

Closed *

Closed 10BA04-8011-NI-0040-N-225

*

*

Closed

10BA04-8011-NI-0050-N-211

65X50

150x65

65X50

Closed

10BA04-8011-NI-0100-N-213

10BA04-8011-NI-0080-N-220

*

*

150x65

TO

TO FIT521104.01

TO FIT521104.01

TO

TO FIT521104.02

TO FIT521104.02

TO PIT511101.01

TO PDIT511101.01

TO PDIT511101.01

TO PDIT511101.02

TO PDIT511101.02

TO PIT541101

TO PIT521102

TO PDIT521110.01

TO PDIT521110.01

TO PDIT521110.02

TO PDIT521110.02

TO PIT511103.02

TO PIT511103.01

PIT511101.02

BAL1144 NB15 TO

BAL1145 NB15

BAL1146 NB15

BAL1147 NB15

BAL1148 NB15

BAL1149 NB15

BAL1150 NB15

BAL1151 NB15

BAL1152 NB15

BAL1153 NB15

BAL1154 NB15

BAL1139 NB15

BAL1140 NB15

BAL0400 PIT521104.02 NB15

BAL0401 NB15

BAL0402 NB15

BAL0403 PIT521104.01 NB15

BAL0404 NB15

BAL0405 NB15

Closed

10BA04-8011-NI-0100-N-223

10BA04-8011-NI-0150-N-209

Closed Closed

Closed Disconnect

Open/Close

10BA04-8010-NI-0020-N-591

10BA04-8010-NI-0020-N-290

10BA04-8010-NI-0020-N-291

10BA04-8010-NI-0020-N-292

Open/Close

10BA04-8010-NI-0020-N-293

*

*

Closed

10BA04-8010-NI-0020-N-294

10BA04-8010-NI-0020-N-295

10BA04-8011-NI-0040-N-216

*

50x40

50x40

REMOVABLE PERMANENT

Open/Close *

Closed 10BA04-8011-NI-0040-N-225

*

*

Closed Closed

10BA04-8011-NI-0050-N-211

65X50

150x65

65X50

TO

TO FIT521104.01

TO FIT521104.01

TO

TO FIT521104.02

TO FIT521104.02

TO PIT511101.01

TO PDIT511101.01

TO PDIT511101.01

TO PDIT511101.02

TO PDIT511101.02

TO PIT541101

TO PIT521102

TO PDIT521110.01

TO PDIT521110.01

TO PDIT521110.02

TO PDIT521110.02

TO PIT511103.02

TO PIT511103.01

PIT511101.02

BAL1144 NB15 TO

BAL1145 NB15

BAL1146 NB15

BAL1147 NB15

BAL1148 NB15

BAL1149 NB15

BAL1150 NB15

BAL1151 NB15

BAL1152 NB15

BAL1153 NB15

BAL1154 NB15

BAL1139 NB15

BAL1140 NB15

BAL0400 PIT521104.02 NB15

BAL0401 NB15

BAL0402 NB15

BAL0403 PIT521104.01 NB15

BAL0404 NB15

BAL0405 NB15

Disconnect/connect

10BA04-8011-NI-0100-N-213

10BA04-8011-NI-0080-N-220

*

*

150x65

Open/Close

10BA04-8011-NI-0100-N-223

10BA04-8011-NI-0150-N-209

Open/Close

Open/Close

Closed Open/Close

Closed

Closed

Closed 10BA04-8011-NI-0050-N-211

Closed

Disconnect flange

Closed

Closed

Closed Closed

Closed

Disconnect/connect

10BA04-8010-NI-0020-N-591

10BA04-8010-NI-0020-N-290

10BA04-8010-NI-0020-N-291

10BA04-8010-NI-0020-N-292

10BA04-8010-NI-0020-N-293

*

*

Closed

10BA04-8010-NI-0020-N-294

10BA04-8010-NI-0020-N-295

10BA04-8011-NI-0040-N-216

*

50x40

50x40

REMOVABLE PERMANENT

10BA04-8011-NI-0040-N-225

Closed

*

*

*

Closed

10BA04-8011-NI-0100-N-213

10BA04-8011-NI-0080-N-220

65X50

150x65

65X50

Open/Close

10BA04-8011-NI-0100-N-223

*

*

150x65

Dismantle and install adapter pipe

10BA04-8011-NI-0150-N-209

TO

TO FIT521104.01

TO FIT521104.01

TO

TO FIT521104.02

TO FIT521104.02

TO PIT511101.01

TO PDIT511101.01

TO PDIT511101.01

TO PDIT511101.02

TO PDIT511101.02

TO PIT541101

TO PIT521102

TO PDIT521110.01

TO PDIT521110.01

TO PDIT521110.02

TO PDIT521110.02

TO PIT511103.02

TO PIT511103.01

PIT511101.02

BAL1144 NB15 TO

BAL1145 NB15

BAL1146 NB15

BAL1147 NB15

BAL1148 NB15

BAL1149 NB15

BAL1150 NB15

BAL1151 NB15

BAL1152 NB15

BAL1153 NB15

BAL1154 NB15

BAL1139 NB15

BAL1140 NB15

BAL0400 PIT521104.02 NB15

BAL0401 NB15

BAL0402 NB15

BAL0403 PIT521104.01 NB15

BAL0404 NB15

BAL0405 NB15

Closed Closed

Closed Closed

Open/Close

Open/Close

Open/Close

Open/Close

Open/Close

Open/Close Open/Close

Open/Close

10BA04-8010-NI-0020-N-591

10BA04-8010-NI-0020-N-290

10BA04-8010-NI-0020-N-291

10BA04-8010-NI-0020-N-292

10BA04-8010-NI-0020-N-293

*

*

Closed

10BA04-8010-NI-0020-N-294

10BA04-8010-NI-0020-N-295

10BA04-8011-NI-0040-N-216

*

50x40

50x40

REMOVABLE PERMANENT

10BA04-8011-NI-0040-N-225

Closed *

*

*

Closed

10BA04-8011-NI-0050-N-211

10BA04-8011-NI-0080-N-220

65X50

150x65

65X50

Closed

10BA04-8011-NI-0100-N-213

10BA04-8011-NI-0100-N-223

*

*

150x65

Dismantle and install adapter pipe

10BA04-8011-NI-0150-N-209

TO

TO FIT521104.01

TO FIT521104.01

TO

TO FIT521104.02

TO FIT521104.02

TO PIT511101.01

TO PDIT511101.01

TO PDIT511101.01

TO PDIT511101.02

TO PDIT511101.02

TO PIT541101

TO PIT521102

TO PDIT521110.01

TO PDIT521110.01

TO PDIT521110.02

TO PDIT521110.02

TO PIT511103.02

TO PIT511103.01

PIT511101.02

BAL1144 NB15 TO

BAL1145 NB15

BAL1146 NB15

BAL1147 NB15

BAL1148 NB15

BAL1149 NB15

BAL1150 NB15

BAL1151 NB15

BAL1152 NB15

BAL1153 NB15

BAL1154 NB15

BAL1139 NB15

BAL1140 NB15

BAL0400 PIT521104.02 NB15

BAL0401 NB15

BAL0402 NB15

BAL0403 PIT521104.01 NB15

BAL0404 NB15

BAL0405 NB15

Closed Closed

Closed Closed

Open/Close

10BA04-8011-NI-0050-N-211

Open/Close Open/Close Open/Close Open/Close Disconnect/connect

10BA04-8010-NI-0020-N-591

10BA04-8010-NI-0020-N-290

10BA04-8010-NI-0020-N-291

10BA04-8010-NI-0020-N-292

10BA04-8010-NI-0020-N-293

*

Closed

10BA04-8010-NI-0020-N-294

10BA04-8010-NI-0020-N-295

10BA04-8011-NI-0040-N-216

*

50x40

50x40

*

10BA04-8011-NI-0040-N-225

Open/Close *

*

*

Closed REMOVABLE PERMANENT

65X50

150x65

65X50

Closed

10BA04-8011-NI-0100-N-213

10BA04-8011-NI-0080-N-220

*

*

150x65

Closed

10BA04-8011-NI-0100-N-223

10BA04-8011-NI-0150-N-209

TO

TO FIT521104.01

TO FIT521104.01

TO

TO FIT521104.02

TO FIT521104.02

TO PIT511101.01

TO PDIT511101.01

TO PDIT511101.01

TO PDIT511101.02

TO PDIT511101.02

TO PIT541101

TO PIT521102

TO PDIT521110.01

TO PDIT521110.01

TO PDIT521110.02

TO PDIT521110.02

TO PIT511103.02

TO PIT511103.01

PIT511101.02

BAL1144 NB15 TO

BAL1145 NB15

BAL1146 NB15

BAL1147 NB15

BAL1148 NB15

BAL1149 NB15

BAL1150 NB15

BAL1151 NB15

BAL1152 NB15

BAL1153 NB15

BAL1154 NB15

BAL1139 NB15

BAL1140 NB15

BAL0400 PIT521104.02 NB15

BAL0401 NB15

BAL0402 NB15

BAL0403 PIT521104.01 NB15

BAL0404 NB15

BAL0405 NB15

Closed Closed

Closed Closed

Open/Close

10BA04-8011-NI-0050-N-211

Disconnect flange Open/Close Disconnect/connect

10BA04-8010-NI-0020-N-591

10BA04-8010-NI-0020-N-290

10BA04-8010-NI-0020-N-291

10BA04-8010-NI-0020-N-292

10BA04-8010-NI-0020-N-293

*

Open/Close

10BA04-8010-NI-0020-N-294

10BA04-8010-NI-0020-N-295

10BA04-8011-NI-0040-N-216

*

50x40

50x40

*

10BA04-8011-NI-0040-N-225

Closed *

*

*

Closed REMOVABLE PERMANENT

65X50

150x65

65X50

Closed

10BA04-8011-NI-0100-N-213

Dismantle and install adapter pipe 10BA04-8011-NI-0080-N-220

*

*

150x65

Closed

10BA04-8011-NI-0100-N-223

10BA04-8011-NI-0150-N-209

TO

TO FIT521104.01

TO FIT521104.01

TO

TO FIT521104.02

TO FIT521104.02

TO PIT511101.01

TO PDIT511101.01

TO PDIT511101.01

TO PDIT511101.02

TO PDIT511101.02

TO PIT541101

TO PIT521102

TO PDIT521110.01

TO PDIT521110.01

TO PDIT521110.02

TO PDIT521110.02

TO PIT511103.02

TO PIT511103.01

PIT511101.02

BAL1144 NB15 TO

BAL1145 NB15

BAL1146 NB15

BAL1147 NB15

BAL1148 NB15

BAL1149 NB15

BAL1150 NB15

BAL1151 NB15

BAL1152 NB15

BAL1153 NB15

BAL1154 NB15

BAL1139 NB15

BAL1140 NB15

BAL0400 PIT521104.02 NB15

BAL0401 NB15

BAL0402 NB15

BAL0403 PIT521104.01 NB15

BAL0404 NB15

BAL0405 NB15

Closed Closed

Closed Closed

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

END OF ERECTION

ESA/80/019-CDQ11 EQUIPMENT:

CDQ – 11 COKE OVEN GAS

PW Drawing number L&T Drawings number (to be listed here)

____________________

SUPPLIER:

L&T

GENERAL P&I .

1680 80 U 02 019 – CDQ 11 1680 50 K 02 006 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 2.5BA02-8011-GT-0250-N-305 10BA04-8011-WS-0080-N304 2.5BA02-8000-GT-0250-N-352 2.5BA02-8000-GT-0250-N-346 2.5BA02-8000-GT-0025-N-343 2.5BA02-8011-GT-0025-N-304 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 2

According to 168050K02006

P&ID

168080U02019,

LINE FLUSHING WITH COMPRESSED AIR

3

Acting from greater diameters to small diameters flux lines utilizing compressed air. Before flushing, disconnected

all

instruments

must

be

Remove all dirt at end 4

Pneumatic test of line BEFORE PAINTING utilizing compressed air.

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 2 ESA-80-019-CDQ 11 COG END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

END OF ERECTION

ESA/80/019-CDQ11 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

DATA / COMMENTI DATE / NOTES

MOP = 1.153 bar Pressure 1.073-1.153 bar. Close all connections. Inflate compressed air in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted. 4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control of the correct erection

YES

NO

6

Control instrumentation installed on lines

YES

NO

7

Control execution superficial treatment of lines

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 2 ESA-80-019-CDQ 11 COG END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/019-CDQ11 – Loop1 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Coke oven gas Loop 1

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 019 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 2.5BA02-8011-GT-0250-N-305 10BA04-8011-WS-0080-N-304 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 2

2.5BA02-8011-GT-0250-N-305 10BA04-8011-WS-0080-N-304 According to P&ID 168080U02016 LINE FLUSHING WITH COMPRESSED AIR

3

Acting from great diameters to small diameters flux lines utilizing compressed air. Before flushing, disconnected

all

instruments

must

be

Remove all dirt at end 3a

Disconnect flange after valve GV1068NB250 and connect in this poin compressed air

YES

NO

3b

Open valve GV0322NB100 and flushing with comressed air line, then close valve

YES

NO

3c

Open valve BAL0421NB15 and flushing with compressed air on sampling line, then close

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 3 ESA-80-019- CDQ 11 COG Loop1 END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

ESA/80/019-CDQ11 – Loop1 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

valve.

3d

Open valve GV0311NB250 and hydraulic seal to pit, then close valve.

3e

flushing

YES

NO

Blanked out the hydraulic seal

YES

NO

3f

Open valve GV0311NB250

YES

NO

3g

Open valve GV0315NB80 and flushing line 10BA04-8011-WS-0080-N-304 to pit, then close valve

3h

Open valve GV0323NB100 and flushing line, then close valve.

YES

NO

3i

Open valve BAL0422NB15 and flushing to sampling line, then close valve.

YES

NO

3j

Close valve GV0311NB250

YES

NO

3k

Disconnect flange before valve GV1069NB250

YES

NO

3l

Open valve GV0311NB250 and flushing line 2.5BA02-8011-GT-0250-N-305, then close valve

YES

NO

Connect flange before valve GV1069NB250

YES

NO

YES

NO

3m

Pneumatic test of line BEFORE PAINTING utilizing with compressed air. 4

MOP = 1.153 bar Pressure 1.073 – 1.153 bar. Close all connections. Inflate compressed air in order to reach test pressure, to be checked with

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 3 ESA-80-019- CDQ 11 COG Loop1 END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001 POS

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/019-CDQ11 – Loop1 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

record of pressure and temperature. For the next 6 hour no pressure reduction must be noted. 4a

Control circuit leakage. In case of fail of test (4) check with soap/water mix leakage point. Repair and test again as per point (4)

YES

NO

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 3 ESA-80-019- CDQ 11 COG Loop1 END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/019-CDQ11 – Loop 2 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Coke oven gas Loop 2

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 019 – CDQ 11 1680 50 K 02 006 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 2.5BA02-8000-GT-0250-N-352 2.5BA02-8000-GT-0250-N-346 2.5BA02-8000-GT-0025-N-343 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 2.5BA02-8000-GT-0250-N-352 2

2.5BA02-8000-GT-0250-N-346 2.5BA02-8000-GT-0025-N-343 According to P&ID 168080U02019, 168050K02006 LINE FLUSHING WITH COMPRESSED AIR

3

Acting from great diameters to small diameters flux lines utilizing compressed air. Before flushing, disconnected

all

instruments

must

be

Remove all dirt at end 3a

Disconnect flange after valve GV1068NB250 and connect on this point compressed air

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 3 ESA-80-019- CDQ 11 COG Loop 2 END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001

ESA/80/019-CDQ11 – Loop 2 ESEGUITO/ EXECUTED

POS

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

3b

Open valve GV0311NB250

YES

NO

3c

Disconnect flange end of line 2.5BA02-8000-GT0250-N-346 in the place of connection to the burner

YES

NO

3d

Disconnect flange end of line 2.5BA02-8000-GT0025-N-343 in the place of connection to the burner

YES

NO

3e

Open valve GV1069NB250

YES

NO

YES

NO

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

Open butterfly valve SOV510090.01NB250 Open butterfly valve FV510091.01NB250 3f

and flushing line 2.5BA02-8000-GT-0250-N-352, 2.5BA02-8000-GT-0250-N-346 After flusing close butterfly valves.

3g

Open BAL0291NB25 and SOV510092NB25, flushing line 2.5BA02-8000-GT-0025-N-343, then close valves

YES

NO

3h

Close valve GV1069NB250

YES

NO

3i

Close valve GV0311NB250

YES

NO

3j

Connect flange end of line 2.5BA02-8000-GT0250-N-346 in the place of connection to the burner

YES

NO

3k

Connect flange end of line 2.5BA02-8000-GT0025-N-343 in the place of connection to the burner

YES

NO

4

Pneumatic test of line BEFORE PAINTING

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 3 ESA-80-019- CDQ 11 COG Loop 2 END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 POS

ESA/80/019-CDQ11 – Loop 2 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

utilizing nitrogen.. MOP = 1.153 bar Pressure 1.073-1.153 bar. Close all connections. Inflate compressed air in order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted. 4a

Control circuit leakage. In case of fail of test (4a) check with soap/water mix leakage point. Repair and test again as per point (4a)

YES

NO

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

7

Control execution thermal protection of the lines where necessary (insulating thk and type)

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 3 / 3 ESA-80-019- CDQ 11 COG Loop 2 END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

MANUAL N.

168050KJM001 DWGS N.

ESA/80/019-CDQ11 – Loop 3 EQUIPMENT:

END OF ERECTION

SUPPLIER:

CDQ11 – Coke oven gas Loop 3

PW Drawing number L&T Drawings number (to be listed here)

____________________

L&T

GENERAL P&I .

1680 80 U 02 019 – CDQ 11

POS

ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

DATA / COMMENTI DATE / NOTES

MAIN LINE TAG 2.5BA02-8011-GT-0025-N-304 1

Cleaning of line and control absence of dirt inside the line

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

Check the installation and connection of the line 2

2.5BA02-8011-GT-0025-N-304 According to P&ID 168080U02019 LINE FLUSHING WITH COMPRESSED AIR

3

Acting from great diameters to small diameters flux lines utilizing compressed air. Before flushing, disconnected

all

instruments

must

be

Remove all dirt at end

3a

Open valves BAL1001NB25, BAL0388NB25 flushing line 2.5BA02-8011-GT-0025-N-304 In to emergency flare, then close valves. Pneumatic test of line BEFORE PAINTING utilizing nitrogen..

4

MOP = 1.153 bar Pressure 1.073-1.153 bar. Close all connections. Inflate compressed air in

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 1 / 2 ESA-80-019- CDQ 11 COG Loop 3 END OF ERECTION.doc

COMMESSA / JOB

G1680 – TATA – INDIA – CDQ COB 10 -11 MANUAL N.

168050KJM001 POS

PRELIMINARY ACCEPTANCE TEST

DATA / DATE

DOCUMENT NUMBER

TEST TYPE

ESA/80/019-CDQ11 – Loop 3 ESEGUITO/ EXECUTED

DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES

____________________

END OF ERECTION DATA / COMMENTI DATE / NOTES

order to reach test pressure, to be checked with record of pressure and temperature. For the next 6 hour no pressure reduction must be noted. 4a

Control circuit leakage. In case of fail of test (4a) check with soap/water mix leakage point. Repair and test again as per point (4a)

YES

NO

4b

Disconnect compressed air, connect flange after valve GV1068NB250

YES

NO

5

Control instrumentation installed on lines

YES

NO

6

Control execution superficial treatment of lines

YES

NO

7

Control execution thermal protection of the lines where necessary (insulating thk and type)

YES

NO

CONTRACTOR

PAUL WURTH

CLIENT

________________

________________

________________

GENERAL NOTES PAG 2 / 2 ESA-80-019- CDQ 11 COG Loop 3 END OF ERECTION.doc

2.5BA02-8000-GT-0025-N-343

10BA04-8000-AP-0025-N-348

Open/close ZT

Disconnect/connect

Disconnect/connect

I.A.

Open/close FV510091.01 NB250

510091.01

Open/close 510099

ZT

FV510099 NB1000

10BA04-8011-AP-0600-N-254

I.A.

FE511150

600x600

Open/close

Open/close

Disconnect/connect

Open/close

10BA04-8011-WS-0080-N-304

BAL0420 NB15

BAL0417 NB40 BAL0418 NB40

Open/close

Open/close BAL0419 NB15

Disconnect flange and connect compressed air line

10BA04-8011-WS-0080-N-304

Open/close BAL0418 NB40

Disconnect flange and connect compressed air line BAL0417 NB40

BAL0420 NB15

BAL0419 NB15

Open/close

BAL0417 NB40

10BA04-8011-WS-0080-N-304

closed

BAL0418 NB40

Open/close

BAL0420 NB15

Disconnect flange and connect compressed air line

BAL0419 NB15

closed

10BA04-8011-NI-0080-N-196

50x20 65x50

10BA04-8011-WF-0065-N-177

TO LIT 511101 ELECTRONICS TO LIT 511102 ELECTRONICS

10BA04-8011-AP-0040-N-251

100x125

100x125

BAL1138 SOV511101 BAL1137 NB40 NB40 NB40

BAL1136 NB40 40x40

10BA04-8011-WF-0125-N-171 65x65

25x25

90DUCT-5411-PG-0000-N-434

BLIND

I.A.

ZSH

ZSL

Pressure Gauge

10BA04-8010-NI-0100-N-035 10BA04-8010-NI-0050-N-038 SV 511050.01

511050.01

511050.01

10BA04-8010-NI-0080-N-033

SOV511050.01 NB600

M

80x40 600x600

10BA04-8010-AP-0600-N-087

600x15

600x25 600x15

FE511050

600x15 MOV511060

168050K02005 10BA04-8010-AP-0600-N-086

10BA04-8010-NI-0040-N-053

40x25 BV0004 CV0003 NB150 NB150

CV0012 NB150

BV0013 NB150

CV0011 NB150

BV0012 NB150

CV0010 NB150

BV0011 NB150

CV0009 NB150

BV0010 NB150

CV0008 NB150

BV0009 NB150

CV0007 NB150

BV0008 NB150

CV0006 NB150

BV0007 NB150

CV0005 NB150

BV0006 NB150

CV0004 NB150

BV0005 NB150

10BA04-5110-PG-0350-R-159

Pressure Gauge

BLIND

Pressure Gauge

BLIND

CV0013 NB150

BV0014 NB150

BV0015 CV0014 NB150 NB150

BV0016 CV0015 NB150 NB150 FROM AE521003.01 FROM AE521003.02 FROM AE521003.03

BV0017 NB150

CV0016 NB150

Pressure Gauge

10BA04-5210-PG-0600-R-160

Pressure Gauge

10BA04-5210-NI-015-N-357

DN25x15

10BA04-5210-NI-0025-N-358

CV0018 NB15

40x15 SOV541003

10BA04-8010-NI-0040-N-036

2.5BA02-8010-GT-0025-N-131

90DUCT-5210-PG-0000-H-008

BLIND

Pressure Gauge

Pressure Gauge

MOV valve CLOSED

BLIND

BLIND

Pressure Gauge

BLIND

MOV valve CLOSED

15x15

DN25x15

FE521004.01

FE521004.02

BLIND

BLIND

Pressure Gauge

1680 50 K JM 001

Page: 92

5. BOILER HYDRO TEST PROCEDURE Here below the Hydro test procedure by Thermax is reported. Thermax Hydro test Procedure deals of following steps:

The complete documentation set must be prepared by Erection Company and Final Customer. In the following pages the documentation for Hydro Test are included as agreed with Thermax: ¨ 01 – Hydrostatic Test procedure ¨ 02 –Loop Register ¨ 03 –Marked P&ID for CDQ loops ¨ 12 –JSA For Hydro test ¨ 13 –Sample Loop File Format ¨ HT Valve Position ¨ Tata Steels # CDQ Boiler Hydro Test Pressure Curve

LARSEN & TOUBRO LIMITED

Thermax Engineering Construction Company Ltd. Construction Technology Folder

HYDROSTATIC TEST PROCEDURE

CUSTOMER :JOB NO. :PRODUCT :-

1.0

PURPOSE The purpose of this work instruction is to outline the method and system to be followed for conducting the hydro test.

2.0

SCOPE This work instruction to be followed for hydro test of pressure part and piping

3.0

PREREQUISITE Ensure the following works are completed before hydrostatic test. I. All pressure part erection II. All attachment weld to pressure part III. Radiography and all other non-destructive examination of the System IV. Stress relieving V. Repairs (if any) VI. Permanent support provided and temporary support removed VII. Temporary Piping for water fill up and prussirising VIII. Isolation valve provided on all drain , vent and instrumentation taping points IX. Blind flanges are provided in case of flanged safety valve. Or test plug are provided in case of welded valves. X. Drum inside is cleaned and manhole are boxed up with proper gasket. XI. Water flushing and inspection

4.0

EQUIPMENT AND MATERIAL  All facilities required to carry out the hydrostatic testing, like temporary piping, filling pumps and testing pumps shall be made ready. The pump discharge shall be connected to any drain, preferably the bottom most drain. Testing pump capacity shall be minimum 25 %more than the test pressure. 

5.0

PRESSURE GAUGES

Pressure gauges shall be indicating type and range shall be minimum 1.5 times and maximum 4 times of test pressure. Minimum 2 nos. Pressure gauges are required for hydrostatic test, one to be connected to steam drum and second one on testing pump after NRV towards the boiler. The pressure gauge used on pump shall preferably be of snubber type. Document No.

Rev. No.

Date

Prepared By

TECC/ CTF/ QAC/ HTP /001

0

21/02/2017

Vinod.S

Reviewed By

Approved By.

Thermax Engineering Construction Company Ltd. Construction Technology Folder

6.0

TEST WATER

Water used for hydrostatic test shall conform to demineralised water quality having PH value between 8.5. To 9.0 for the boilers where non drainable type super heaters are involved. In case of other boilers, preferably the same water quality shall be used. The temperature of the water used for testing shall between 20 Deg C and 45 Deg C before starting pressurisation. 7.0

TEST PRESSURE

 Test pressure shall be as specified in drawing (pressure parts assy). The pressure shall be under proper control, so that the actual pressure is never exceeded by more than six (6) percent of test pressure.  Since 2 gauges are used, the pressure gauge attached to the drum shall be used as official gauge for the test. The difference in pressure gauge reading shall not exceed more than 2% of full scale range of the pressure gauge, in addition to the head difference 8.0

TEST PROCEDURE

 All valves provided on the drains and instruments shall be closed.  Vent valves shall be kept open to purge the air pocket while filling the unit with filling pump and closed after the air pockets are purged. (I.e. when water starts coming out from vent in abundance).  Before applying pressure the unit shall be examined to see that all valves & gasket joints are tight and no leakage is observed. 9.0

APPLICATION OF PRESSURE  The pressure shall be gradually raised to the test pressure with the help of test pump.  After raising the boiler pressure to test value the isolation valve at unit inlet shall be closed.

10.0

DURATION

The unit shall be held under test pressure for maximum 30 minutes. Quick inspection for leakage/sweating shall be carried out during these 30 minutes. The pressure shall be then reduced to maximum allowable working pressure and maintained at that pressure while the unit is carefully examined for leakage.

Document No.

Rev. No.

Date

Prepared By

TECC/ CTF/ QAC/ HTP /001

0

21/02/2017

Vinod.S

Reviewed By

Approved By.

Thermax Engineering Construction Company Ltd. Construction Technology Folder 11.0

ACCEPTANCE/REJECTION CRITERIA

Leaks through welds, castings, forgings, plate, pipe and tubes excluding gasket joints or mechanical seals are not acceptable. Seepage at the test pressure is permitted at gasket joints and mechanical seals. 12.0

RECORDS

The test data shall be recorded jointly by the parties conducting the test in the given format. 13.0

REPAIRS

 Any leaks in welded connections shall be repaired with approved weld repair procedure and the applicable boiler and pressure vessel code.  Any unaccepted leaks in gasket joints or mechanical seals shall be re gasket or resealed.  After all repairs have been carried out, the system will be pressurized again to test pressure. 14.0

SAMPLE SCHEMATIC ARRANGEMENT FOR PRESSURE TEST

Document No.

Rev. No.

Date

Prepared By

TECC/ CTF/ QAC/ HTP /001

0

21/02/2017

Vinod.S

Reviewed By

Approved By.

THERMAX LIMITED. PUNE

LOOP REGISTOR - CDQ-11 SR. NO.

1

LOOP NO

CDQ-11/BLR/HT/001

DRAWING NO

REV.

DRAWING DESCRIPTION

SUB DESCRIPTION

P21-2WH-084696 P4K-1WH-132759 P4M-1WH-132768 P4N-1WH-132850

0 0 0 0

DETAIL OF STEAM COLLECTING HEADER ASSLY. & DETAILS OF RH. SIDE WATER WALL PANEL ASSLY. & DETAILS OF LH. SIDE WATER WALL PANEL ASSLY. & DETAILS OF REAR SIDE WATER WALL PANEL

STEAM COLLECTING HEADER RH. SIDE WATER WALL PANEL LH. SIDE WATER WALL PANEL REAR SIDE WATER WALL PANEL

P4N-1WH-132851

0

ASSLY. & DETAILS OF ROOF REAR WATER WALL PANEL

ROOF REAR WATER WALL PANEL

P4Q-1WH-132836

0

ASSLY. & DETAILS OF FRONT SIDE WATER WALL PANEL

FRONT SIDE WATER WALL PANEL

P71-1WH-132921 P71-1WH-132922 P71-1WH-132923 P71-1WH-132924 P71-1WH-132925 P71-1WH-132926 P71-1WH-132927 P71-1WH-132928 P71-1WH-132929 P73-1WH-132930 P73-1WH-132931 P73-1WH-132932

0 0 0 0 0 0 0 0 0 0 0 0

PA1-1WH-132015

0

PA3-1WH-132026

0

PB1-1WH-133271

0

ISOMETRIC FOR RISERS R1/1 & R1/6 ISOMETRIC FOR RISERS R1/2 & R1/5 ISOMETRIC FOR RISERS R1/3 & R1/4 ISOMETRIC FOR RISERS R5/1 & R5/2 ISOMETRIC FOR RISERS R2/2 & R3/3 ISOMETRIC FOR RISERS R4/1,R4/2 & R4/3 ISOMETRIC FOR RISERS R2/3,R2/4 & R5/3 ISOMETRIC FOR RISERS R3/1,R2/1 & R3/2 ISOMETRIC FOR RISERS R6/1,2,3 & R7/1,2,3 ISOMETRIC FOR DOWNCOMER D9, D10 & D12 ISOMETRIC FOR DOWNCOMER D1, D2, D7 & D11 ISOMETRIC FOR DOWNCOMER D3,D4,D5,D6 & D8 ASSLY.OF SUPER HEATER-IA,IB & II COILS WITH SUPPORT TUBE DETAILS INLET & OUTLET HEADER DETAILS OF SUPER HEATER 1A,1B &2 ASSEMBLY AND DETAILS OF ATTEMPERATOR

RISERS R1/1 & R1/6 RISERS R1/2 & R1/5 RISERS R1/3 & R1/4 RISERS R5/1 & R5/2 RISERS R2/2 & R3/3 RISERS R4/1,R4/2 & R4/3 RISERS R2/3,R2/4 & R5/3 RISERS R3/1,R2/1 & R3/2 RISERS R6/1,2,3 & R7/1,2,3 DOWNCOMER D9, D10 & D12 DOWNCOMER D1, D2, D7 & D11 DOWNCOMER D3,D4,D5,D6 & D8 SUPER HEATER-IA,IB & II COILS WITH SUPPORT TUBE DETAILS INLET & OUTLET HEADER DETAILS OF SUPER HEATER 1A,1B & 2 ATTEMPERATOR

PD3-1WH-131840

0

ASSLY. OF EVAP.-I COILS WITH SUPPORT TUBES DETAILS

EVAP.-I COILS WITH SUPPORT TUBES DETAILS

PD3-1WH-131841

0

ASSLY. OF EVAP. - II COILS WITH SUP.TUBES SHT. 1 & 2

EVAP. - II COILS WITH SUP.TUBES SHT. 1 & 2

PD3-1WH-131842

0

ASSLY. OF EVAP. - II COILS WITH SUP.TUBES SHT. 1 & 2

EVAP. - II COILS WITH SUP.TUBES SHT. 1 & 2

PD4-1WH-131847 PD4-1WH-131848 PE1-1WH-132890 PE1-1WH-132891 PE1-1WH-132892 PE1-1WH-132893

0 0 0 0 0 0

INLET & OUTLET HEADERSS OF EVPORATOR-1 INLET & OUTLET HEADERSS OF EVPORATOR-2 DETAIL OF SUPPORT TUBE (TYPE-1) DETAIL OF SUPPORT TUBE (TYPE-II) DETAIL OF SUPPORT TUBE (TYPE-III) ASSLY. & DETAIL OF SUPPORTING TUBES TOP HEADER

INLET & OUTLET HEADERSS OF EVPORATOR-1 INLET & OUTLET HEADERSS OF EVPORATOR-2 SUPPORT TUBE (TYPE-1) SUPPORT TUBE (TYPE-II) SUPPORT TUBE (TYPE-III) SUPPORTING TUBES TOP HEADER

PE1-2WH-085266

0

ASSLY. & DETAIL OF SUPPORTING TUBES BOTTOM HEADER SUPPORTING TUBES BOTTOM HEADER

PE1-2WH-085267

0

DETAIL OF SUPPORT TUBE FOR MIDDLE ROW

SUPPORT TUBE FOR MIDDLE ROW

PM2-1WH-131797

0

ASSLY.& DETAILS OF COIL FOR FINNED ECONOMISER-I

COIL FOR FINNED ECONOMISER-I

PM2-1WH-131798

0

ASSLY.& DETAILS OF COIL FOR FINNED ECONOMISER-II

COIL FOR FINNED ECONOMISER-II

PM3-1WH-131801

0

Z11-1WH-133597 Z11-1WH-133598

3 3

Z11-1WH-133599

3

Z11-1WH-133600 Z11-1WH-133601 Z1G-1WH-134059

3 3 3

DETAIL OF INLET & OUTLET HEADER FOR ECONOMISER-I & INLET & OUTLET HEADER FOR ECONOMISER-I & II II INTEGRAL PIPING-I STEAM DRUM ACESSORIESS INTEGRAL PIPING-II ECO TO SD, LP STEAM, IBD PPG,HP DOSING SUPERHEATED STEAM PIPING AND START UP VENT INTEGRAL PIPING-III PIPING INTEGRAL PIPING-IV SATURATED STEAM PIPING INTEGRAL PIPING-V ATTEMPORATOR I/L AND O/L PIPING NON INTEGRAL PIPING- VI SPRAY WATER PIPING

AREA

WORKING PRESSURE (Kg/Cm2)

TEST PRESSURE (Kg/Cm2)

82

123

P&ID COLOUR CODE

REMARKS

PRESSURE PART

BLIND ON IBD PPG INTEGRAL PIPING

BLIND AT TP-03

Z1G-1WH-134060

3

NON INTEGRAL PIPING- VII

CBD SAMPLING PIPING

Z1G-2WH-085950 Z1H-1WH-134045 Z1H-1WH-134046

3 3 3

NON INTEGRAL PIPING-X NON INTEGRAL PIPING-I NON INTEGRAL PIPING-II

IBD PIPING MAIN STEAM PIPING STEAM DRUM ACESSORIESS

Z1H-1WH-134049

3

NON INTEGRAL PIPING-V

MAIN STEAM SAMPLING PIPING

Z1I-1WH-134278

3

NON INTEGRAL DRAIN PIPING-I

IBD TANK DRAIN

Z1I-1WH-134279

3

NON INTEGRAL DRAIN PIPING-II

DRAIN FOR DC -D1 & D2

Z1I-2WH-086183

3

HP DOSING PIPING

HP DOSING PIPING

Z1I-2WH-086296

3

NON INTEGRAL VENT PIPING

FOR ECONOMISER

2

CDQ-11/BLR/HT/002

Z1I-1WH-134278

3

NON INTEGRAL DRAIN PIPING-I

COMMON DRAIN PIPING-STEAM

3

CDQ-11/BLR/HT/003

Z1I-1WH-134279

3

NON INTEGRAL DRAIN PIPING-II

COMMON DRAIN PIPING-WATER

4

CDQ-11/BLR/HT/004

Z1H-1WH-134048

3

NON INTEGRAL PIPING-IV

LP STEAM NON INTEGRAL

5

CDQ-11/BLR/HT/005

Z1G-1WH-134061 Z1G-1WH-134080

3 3

NON INTEGRAL PIPING- VIII NON INTEGRAL PIPING-IX

CBD TANK MOUNTINGS CBD,IBD INTERCONNECTING PIPING

Z1H-1WH-134047

3

NON INTEGRAL PIPING-III

DEARATOR MOUNTINGS

6

7

8

CDQ-11/BLR/HT/006

CDQ-11/BLR/HT/007

CDQ-11/BLR/HT/008

Z1H-1WH-134048

3

NON INTEGRAL PIPING-IV

DEARATOR DRAIN PIPING

Z11-2WH-087719 Z1G-1WH-134061

0 3

INTEGRAL PIPING-VI NON INTEGRAL PIPING- VIII

SUB ECO HDR I/L PPG SUB ECO I/L & O/L HDR MOUNTINGS

BLIND AT TP-07 (SAMPLING LINE) BLIND AT CBD TANK FLANGE (FE 531103 CAN BE INSTALLED AFTER HYDROTEST) BLIND AT IBD TANK FLANGE CLOSE AT A-B LOCATION BLIND AT TP-05 BLIND AT TP-06 CLOSE SECOND ISOLATION VALVES AT D1/D2 PRESSURE DROP CLOSE SECOND ISOLATION VALVES IN DC DRAINS BLIND AT TP-04 (CV5012- EITHER REVERSE THE DIRECTION OR DROP FOR HYDROTEST.)

NON INTEGRAL PIPING

COMMON DRAIN PIPINGSTEAM COMMON DRAIN PIPINGWATER

8.2

12.3

BLIND AT IBD FLANGE

8.2

12.3

BLIND AT IBD FLANGE

LP STEAM NON INTEGRAL

12

18

CBD/IBD MOUNTING, DRAIN AND LINK PIPING

3

4.5

DEARATOR AND RELATED PIPING

5

7.5

SUB ECONOMISER COIL AND PIPING

7

BLIND AT TP-02 BLIND AT IBD FLANGE BLING ALL EMPTY FLANGE LOCATION OR TP FLANGES BLIND AT DOWN STREAM OF GV5032 (DEARATOR DRAIN) BLIND AT DOWNSTREAM OF GV5038 (BOILER FEED PUMP SUCTION) BLIND ON PSV 531109 FLANGE BLIND AT TPS-2 BLING ON PSV 531108 FLANGE IF REQ. BLIND ON PE FLANGES ALSO BLIND AT TPS-1

10.5

Z1G-1WH-134062

3

NON INTEGRAL PIPING- XI

SUB ECO I/L PIPING

Z1G-1WH-134063 PL1-1WH-132158

3 2

NON INTEGRAL PIPING-XII SUB ECONOMISER COIL -NON INTEGRAL

SUB ECO O/L PIPING SUB ECONOMISER COIL

Z1H-1WH-134045

3

NON INTEGRAL PIPING-I

MAIN STEAM PIPING-START UP VENT AFTER CONTROL VALVE

NOT NECESSORRY TO HYDRO-OPEN TO ATMOSPHERE - BLIND ON SILENCER FLANGE

Z11-1WH-133599

3

INTEGRAL PIPING-III

SUPERHEATED STEAM PIPING AND START UP VENT PIPING

FE 531102.03 IN MSL LINE - TO BE INSTALLED AFTER HYDRO AND STEAM BLOWING

Z13-1WH-134276

3

NON INTEGRAL VENT PIPING-1

SD PSV VENT PIPING

Z13-1WH-134277

3

NON INTEGRAL VENT PIPING-II

MAIN STEAM PSV VENT

Z13-1WH-134293

3

NON INTEGRAL VENT PIPING-III

MAIN STEAM ERV VENT PIPING

Z13-1WH-134304

3

NON INTEGRAL VENT PIPING-IV

CBD TANK PSV VENT PIPING

Z13-2WH-086180

3

OPEN DRAIN PIPING

OPEN DRAIN PIPING

Z1G-1WH-134060

3

NON INTEGRAL PIPING- VII

CBD SAMPLING PIPING

Z1H-1WH-134045

3

NON INTEGRAL PIPING-I

MAIN STEAM PIPING

HYDRO NOT MANDETORY OPEN TO ATMOSPHERE

_____

HYDRO SHOWS AT 12.3 KG.CM2 -LINE OPEN TO ATMOSPHERE HYDRO SHOWS AT 12.3 KG.CM2 -LINE OPEN TO ATMOSPHERE HYDRO SHOWS AT 12.3 KG.CM2 -LINE OPEN TO ATMOSPHERE HYDRO SHOWS AT 1.965 KG.CM2 -LINE OPEN TO ATMOSPHERE OPEN DRAIN PIPING FE 531103 IN CBD LINE - TO BE INSTALLED AFTER HYDRO TEST MSL FE MOUNTINGS- NON INTEGRAL

SJ531103

SJ531104

SJ531102

SATURATED STEAM & WATER DRAIN HEADER

SUPERHEATER DRAIN HEADER

OTHERS TL 1680 80 U 02 018 FE TO BE INSTALLED AFTER STEAM BLOWING

SJ531101

TL OTHERS

TP-05

TYP. FOR ALL INCHING TYPE OF MOTORISED VALVES

TL OTHERS

TP-06

BLR531101 1680 80 U 02 013

OTHERS TL

TYP. FOR ALL ON/OFF TYPE

FLUE GAS IN

MOTORISED VALVES CUSTOMER TO CONFIGURE DI & DO'S IN THEIR DCS.

BST531102

OTHERS TL

TP-07 1680 53 G 02 102

1680 80 U 02 004

OTHERS TL

TP-04

1680 53 G 02 103

NRV TO BE ERECTED AFTER HYDROTEST

DSH531101

VALVE IS NOT IN THERMAX SCOPE-UP TO VALVE SHOULD BE COMPLETED BEFORE HYDROTEST

SECONDARY SUPER HEATER

SJ531105

OTHERS TL

TL OTHERS

OTHERS TL OTHERS TL

FE TO BE ERECTED AFTER HYDROTEST

PRIMARY SUPER HEATER

NRV TO BE ERECTED AFTED HYDROTEST

TO STEAM DRUM IBT531104

CBT531103 EVAPORATOR-1

1680 80 U 02 012 FROM STEAM DRUM

TO STEAM DRUM

TL OTHERS EVAPORATOR-2 FROM STEAM DRUM TL OTHERS

FROM STEAM DRUM

COMMENTS BLINDS AND TP

1680 53 G 02 102 VALVE IS NOT IN THERMAX SCOPE-UP TO VALVE SHOULD BE COMPLETED BEFORE HYDROTEST

ECONOMISER

LOOP NO - 1

LOOP NO - 2 OTHERS TL 1680 53 G 02 102

TL OTHERS

LOOP NO - 3 LOOP NO - 4

GAS OUT

TATA CONSULTING ENGINEERS LIMITED MUMBAI OTHERS TL TP-03

LARSEN & TOUBRO LIMITED

LOOP NO - 5

TATA STEEL LTD.

1680 53 G 02 101 OTHERS TL

TL OTHERS

1680 80 U 02 012

1680 80 U 02 013 OTHERS TL

DEA531105 TYP. FOR ALL INCHING TYPE OF MOTORISED VALVES

OTHERS TL

OTHERS TL

TL OTHERS TYP. FOR ALL ON/OFF TYPE MOTORISED VALVES CUSTOMER TO CONFIGURE DI & DO'S IN THEIR DCS.

TL OTHERS

TL OTHERS

TL OTHERS

1680 80 U 02 020 TYP. FOR TE MOTOR WINDING TEMPERATURE

1680 53 G 02 103 FOR R-PHASE HES531106

1680 80 U 02 004 PLATE HEAT EXCHANGER

1680 80 U 02 014 GAS OUTLET TO COKE COOLING CHAMBER

DCP531110

FOR Y-PHASE

OTHERS TL TL OTHERS SBE531107

DFP531108 SUB-ECONOMISER 1680 80 U 02 101

1680 80 U 02 014

TL OTHERS OTHERS TL

OTHERS TL

FOR B-PHASE

1680 53 G 02 103

FWP531111

OTHERS TL

TL OTHERS

GAS INLET FROM MILL FAN

OTHERS TL

DFP531109 TL OTHERS

1680 53 G 02 001

COMMENTS BLINDS AND TP LOOP NO - 6 LOOP NO - 7

OTHERS TL

1680 80 U 02 017

OTHERS TL

FWP531112

OTHERS TL

TL OTHERS

TATA CONSULTING ENGINEERS LIMITED

OTHERS TL TL OTHERS

MUMBAI

1680 80 U 02 017

LARSEN & TOUBRO LIMITED

TATA STEEL LTD.

THERMAX ENGINEERING CONSTRUCTION COMPANY LIMITED. PUNE

JOB SAFETY ANALSIS FOR HYDRO TESTING PROJECT:JOB No.:JSA NO:ACTIVITY

Pressurising & Depressurising of Pipelines / Vessel with water

Opening / box up of flanges

.

HAZARDS

CONTROLLING MEASURES Hose end connection shall be checked for proper fixing(Use correct connectors) Check the condition of all the hoses & fittings before using them. Ensure all the connections are standard and tightly fitted. Do the hydrotesting during lean hours to minimise the damage in case of any accident. Injury due to release of high Barricade the area where the hydrotest is to be carried out (2mt for low pressure & 10mt for high pressure). pressure water because of Post warning notice. leakage. During pressurising & depressurising, all personnel are to be outside the barricaded zone. Only the authorized testing personnel should be present in the barricaded area. Water to be drained to appropriate place away from the test area. Adequate care shall be taken to avoid flooding. Before pressurising, air inside the system shall be vented out. Use calibrated pressure gauges/equipments & ensure pressure does not exceed specified value. Proper no. of Vents & drains to be provided as per requirement. Damage to equipment from Provide arrangement for release of excess pressure(eg. PSV) in case of accidental pressure increase. accidental rise in pressure. Increase the pressure in steps and check for leaks.Ensure that pressure increase is gradual. In case of temporary blinding(Plate blind ), appropriate thickness of the blind to be decided as per pressure requirement and adequate stiffening to be provided if required. Ensure proper scaffolding and avoid transfer of load on to scaffold Use only certified and validated scffolding Fall of person/Collapse of Ensure appropriate PPE's and usage of the same. scaffolding due to improper Provide life line wherever possible. loading Ensure/encourage use of fall arrestors,safety nets.etc. Protect/Hard barrication to cover all floor holes Provide ladders wherever possible for better approach to the working platform/work area. Injury due to tool damage/ tool Use of standard tools. slippage Making sure tools are held tightly when working at height & used in correct manner. Cricket helmet to be worn while tightening and loosing of bolts whereever required. Bolt tightning / Loosening Ensure right rating gasket is used for Hydrotesting. Prior to tightening or loosening of bolt pressure in the line or equipment shall be made zero.

Prepared by Note: Contractor Supervisor shall give job specific tool box talk to all workers.

Checked by

Reviewed by

LOOP INDEX THERMAX ECC LTD. BOILER NO. : -

TEST PACKAGE NO.:ATTACHED

SR. NO.

INDEX RECORD

FORMAT NO.

1

SYSTEM / SUB SYSTEM MARKED ON LATEST REVISION OF P & IDS

2

LATEST REVISIONS OF ISOMETRIC DRAWINGS SHOWING TEST LIMITS

3

LINE LIST

TECC/QAC/LOOP/HT/0001

4

VALVE LIST

TECC/QAC/LOOP/HT/0002

5

FLANGE VARIFICATION REPORT

TECC/QAC/LOOP/HT/0003

6

PIPE SUPPORT VERIFICATION REPORT

TECC/QAC/LOOP/HT/0004

7

SPRING SUPPORT VERIFICATION REPORT

TECC/QAC/LOOP/HT/0005

8

FINAL VISUAL INSPECTION PUNCH LIST

TECC/QAC/LOOP/HT/0006

9

LINE MECHANICAL CLEARANCE REPORT (FOR HYDROTEST)

TECC/QAC/LOOP/HT/0007

10

LINE HISTORY SHEET

TECC/QAC/LOOP/HT/0008

10

PRE TEST CRITICAL COMPONENTS PLACEMENT / REMOVAL AND REINSTATEMENT

TECC/QAC/LOOP/HT/0009

11

PIPING TEST PACKAGE CLEARANCE REPORT FOR PRESSURE TESTING

TECC/QAC/LOOP/HT/0010

12

PIPING PRESSURE TEST RECORD

TECC/QAC/LOOP/HT/0011

13

JOBS CARRIED OUT ON MECHANICALLY CLEARED SYSTEM / SUBSYSTEM (LOOPS)

TECC/QAC/LOOP/HT/0012

ERECTION VENDOR

THERMAX ECC

CONSULTANT

NAME SIGNATURE DATE Page 1 of 1

Yes

No

CUSTOMER

REMARK

LINE LIST THERMAX ECC LTD. BOILER NO. : SR. NO.

TEST PACKAGE NO.: ISO DRG.NO.

REV.

P&I D No.

REV.

LINE DESCRIPTION

DESIGN PRESSURE (Kg/cm2)

TEST PRESSURE (Kg/cm2)

TEST MEDIUM

Remarks:

ERECTION VENDOR

THERMAX ECC

CONSULTANT

NAME SIGNATURE DATE FORMAT NO. :- TECC/QAC/LOOP/HT/0001

Page 1 of 1

CUSTOMER

VALVE LIST THERMAX ECC LTD. BOILER NO:SR. NO.

TEST LOOP NO.: DRAWING NO.

ERECTION VENDOR

REV.

SIZE & VALVE SPECIFICATION

TYPE OF VALVE

THERMAX ECC

ISO TAG NO.

CONSULTANT

NAME SIGNATURE DATE FORMAT NO. :- TECC/QAC/LOOP/HT/0002

Page 1 of 1

VALVE SERIAL NO. / BAAN NO.

Direction as per ISO (YES / NO)

CUSTOMER

Remarks

FLANGE VARIFICATION REPORT THERMAX ECC LTD. BOILER NO. :

SR. NO.

TEST LOOP NO.:

DRAWING NO.

FLANGE FLANGE SIZE AND VISUAL INSPECTION JOINT NO. RATING OF FLANGE FACE (A) (B) (ACCEPT/DAMAGED)

ALIGNMENT READING (REF. FIG 1 FOR TOLERENCE) 0 DEG

90 DEG

180 DEG

GASKET TYPE & RATING 270 DEG

REQUIRED (C)

VARIFIED

FASTNERS MATERIAL SPEC. REQUIRED (D)

VARIFIED

MOLYCOTE 1000 APPLIED

TORQUE PRESSURE REQUIRED (E)

Fig: 1 Difference of 1 mm /250 mm outside diameter (at flange rim outside) of flange at flange joint.

A, B, C, D & E columns are to be pre-filled at site only. Yes / No / NA shall be written in the verified / obtained columns. ERECTION VENDOR

THERMAX ECCC

CONSULTANT

NAME SIGNATURE DATE FORMAT NO. :- TECC/QAC/LOOP/HT/0003

Page 1 of 1

CUSTOMER

REMARKS OBTAINED

SUPPORT VARIFICATION REPORT

THERMAX ECC LTD. BOILER NO. :

TEST LOOP NO.: Position*

SR. NO.

ISO DRAWING NO.

SUPPORT DRAWING NO.

SUPPORT NO. (NOTE-1)

SUPPORT TYPE

Location & Dimention

Resting & Centering

Gap Packing Provided & Welded

As per Drg.

Actual

Guid Direction Checked*

Slide Spring Support are Washer Free & Not Provided for Tack Welded Clamp Type to Base Support* Plate*

Welding of Support Complete*

Note 1: All similar supports are to be uniquely numbered and marked in the isometrics and the same number is to be written in the report. Note 2: * This is a check sheet and all data other than “Remarks” to be recorded as “Yes” / ”No” / “NA” form. Note 3: For High Temp. lines positioning of support on the structure, to be confirmed after verifying the movement direction of line during expansion. (Data to be provided by Engg.)

ERECTION VENDOR

THERMAX ECC

NAME SIGNATURE DATE FORMAT NO. :- TECC/QAC/LOOP/HT/0004 Page 1 of 1

CONSULTANT

CUSTOMER

Remarks

SPRING SUPPORT VARIFICATION REPORT

THERMAX ECC LTD. BOILER NO. : SR. NO.

ISO DRAWING NO.

TEST LOOP NO.: SPRING NO. (TAG NO.)

ERECTION VENDOR

SPRING DATA SHEET NO. & REV.

SPRING TYPE

SPRING CAGE /CLH RATING

COLD SETTING VALUE DESIGN

THERMAX ECC

ACTUAL

SPRING DEGGAGING

CONSULTANT

NAME SIGNATURE DATE FORMAT NO. :- TECC/QAC/LOOP/HT/0005

Page 1 of 1

PIN LOCK POSITION AFTER SETTING

PROVISION OF PRESET GAP IN TURN BUCKLE

WELDING OF SUPPORT

CUSTOMER

Remarks

FINAL VISUAL INSPECTION PUNCH LIST THERMAX ECC LTD. BOILER NO. :

TEST LOOP NO.: DATE :

SL. NO.

DRAWING NO.

REV.

PUNCH ITEM DESCRIPTION

TAG No.

CAT. A/B

REMEDIAL ACCEPTANCE DATE AND INITIAL ER. VEND.

TECC

CONSU.

Punch List Issued. ERECTION VENDOR

THERMAX ECC

CONSULTANT

CUSTOMER

THERMAX ECC

CONSULTANT

CUSTOMER

THERMAX ECC

CONSULTANT

CUSTOMER

NAME SIGNATURE DATE Completed and released for Pressure Testing after Attending 'A' category Point. ERECTION VENDOR

NAME SIGNATURE DATE Completed Category 'B' Points. ERECTION VENDOR

NAME SIGNATURE DATE Category: A - Required for Pressure Test.

B - Required for Commissioning.

FORMAT NO. :- TECC/QAC/LOOP/HT/0006 Page 1 of 1

CUST.

LINE MECHANICAL CLEARANCE REPORT (FOR HYDROTEST) THERMAX ECC LTD. BOILER NO. :

TEST LOOP NO.: DATE :

Isometric Nos. with Sht & Rev.

Sl. No. 1.0. 1.1 1.2 1.3 1.4 2.0. 2.1 2.2 2.3 2.4 3.0. 3.1 3.2 3.3 3.4 3.5 3.6 4.0. 4.1

P&I D No. & Rev.

Description PIPING Line verification w.r.t. P&I D, Isometrics Check Slope as per grawings Test Limits as per marked-up P&I D Alignment and clearance from adjacent piping SUPPORTS All Supports as per Support Standard/Drawing Location of Supports as per Iso/GA Support Inspection Report attached Additional supports provided (if any) FLANGES All Flanges Properly Aligned Correct Type & Rating Correct Studs/Bolts, Nuts & Washers Gaskets of Correct Type & Rating Blind flange rating Bolt Tightening VALVES Check for rating, type, tag no .

Acceptance Yes

No

L&T

TCE

TECC

TSL

Direction of NRV, Control Valves as per GA & P&ID. Isolation of Special Items Valve stem orientation and access Valves deleted for testing (if any) Accessibility for Operation. 5.0. GENERAL 5.1 Punch List prepared and attached 5.2 Outstanding NC(if any) 5.3 Check Drain(s) and Vent(s) locations 4.2 4.3 4.4 4.5 4.6

Remarks : ERECTION VENDOR

THERMAX ECC

CONSULTANT

NAME SIGNATURE DATE FORMAT NO. :- TECC/QAC/LOOP/HT/0007 Page 1 of 1

CUSTOMER

INSPECTION AUTHORITY

LINE HISTORY SHEET

THERMAX ECC LTD. LOOP NO.:-

DATE

DRG. NO.:-

RT % PT %

SPOOL NO.

JOINT ID NO.

MATERIAL

Pipe Support Welding (Whereever applicable)

SIZE (Inch)

THK.

TYPE OF JOINT

FIT UP CUM W/V REP No.

WPS NO.

No. of Welded Supports in this ISO/Line:

WELDER NO.

RT REPORT NO. ORIGINAL R1

DECISION ACC / REP

DPT REP. PWHT REP. NO. NO.

REMARKS

Welding Cleared / Not Cleared

Weld joints of connecting isometrics are varified : YES/NO Legend: PWHT- Post Weld Heat Treatment , Rep.No. - Report No. , DPT- Dye Penetrant Test ERECTION VENDOR

THERMAX ECC

CONSULTANT

NAME SIGNATURE DATE FORMAT NO. :- TECC/QAC/LOOP/HT/0008

Page 1 of 1

CUSTOMER

INSPECCTION AUTHORITY

ACTIVITIES

ERECTION VENDOR THERMAX ECC

NAME

SIGNATURE

DATE

FORMAT NO. :- TECC/QAC/LOOP/HT/0009

Page 1 of 1

CONSULTANT

HOOK UP INSTRUMENT TUBING

TEMPORARY SPOOL INSTALLED

ORIFICE PLATE REMOVED

SPRING SUPPORT GAGGED

TEMPERORY SPOOLS REMOVD

POST TEST REINSTATEMENT

TEMPERORY SUPPORT INSTALLED

HYDROTEST ENGINEER / COORDINATOR

TEMPORARY SUPPORTS REMOVED

INSTALL ORIFICE PLATE

SPRING SUPPORT UN GAGGED

EXPANSION JOINTS REMOVED

PSV/TSV REMOVED

CONTROL VALVES REMOVED

SPECIAL PIPING ITEMS REMOVED

CHECK VALVE INTERNAL REMOVED /JACKED

INSTRUMENTS REMOVED OR BLOCKED

BOILER NO.:-

REINSTATE EXPANSION JOINTS

REINSTATE PSV/TSV

RE INSTATE CONTROL VALVE

RE INSTALL SPECIAL PIPING ITEMS

REINSTAT VALVE INSTRUMENTS / RE INSTALL VALVES

REINSTATE INSTRUMENTS

TEST SPADES / BLINDS INSTALLED

ACTIVITIES

REMOVE TS/ BLINDS / INSTALL NEW GASKET/ COMPLETE BOLTING

THERMAX ECC LTD. PRE TEST CRITICAL COMPONENT PLACEMENT / REMOVAL AND RE INSTATEMENT TEST PACKAGE NO.:-

PRE TEST CRITICAL COMPONENT PLACEMENT / REMOVAL

HYDROTEST ENGINEER / COORDINATOR

CUSTOMER

CHECK LIST FOR PRESSURE TESTING THERMAX ECC LTD. Area / Site / Location Date and Time Contractor Spool / Loop No. Pressure testing at Pressure Test Co ordinator Check Points

Sr.

Yes/No

1

Whether work is being done under supervision of experienced and skill supervision

2

All persons involved in job have been briefed about hazards associated with job.

3

Whether suitable type of blind / dummy / standard cap used suitable to pressure being administrated.

4

Vent provided at highest point?

5

Drain provided at lowest point?

6

Two pressure gauges dully calibrated installed on system?

7

Whether suitable gasket has been used. Metallic one for pressure above 79 Kg.

8

Bolt tightening done as per procedure and with adequate torque?

9

Bolt size is appropriate to hole and no gap is there?

Remarks

10 Pressure test set up checked by test coordinator before administration of pressure? 11 Pressure hose used is of appropriate rating? 12 Pressure pump with test validation sticker and safety relief valve? 13 Safety valve with required set pressure installed on system in case of pneumatic test. 14 Vent kept open during filling of water to avoid air lock? 15 Pressure has been increased stage wise? 16 Area has been barricaded and caution notice displayed?

ERECTION VENDOR

Name

:

Signature

:

Date

:

THERMAX ECC

FORMAT NO. :- TECC/QAC/LOOP/HT/0010 Page 1 of 1

CONSULTANT

CUSTOMER

HYDROSTATIC TEST REPORT THERMAX ECC LTD. BOILER NO:TEST LOOP NO:DATE :-

1.0          SPECIFIED 1.1 DRAWING NO. AND REVISION 1.2 WORKING PRESSURE

Kg/cm2(g)

1.3 HYDRAULIC TEST PRESSURE

Kg/cm2(g)

1.4 DE MINARALISED WATER PH

8.5 TO 9.0

1.5 DE MINARALISED WATER TEMPERATURE

45°C ≥ T ≥ 20 0 C

2.0          ACTUAL 2.1 ENTRAPED AIR VENTING

DONE

2.2 PRESSURE RAISING

BY HAND / MOTORISED HYDROTEST PUMP

2.3 DE MINARALISED WATER PH 2.4 DE MINARALISED WATER TEMPERATURE

0

2.5 PRESSURE GAUGE READING AT DRUM

Kg/cm2(g)

2.6 PRESSURE GAUGE READING AT PUMP OUT LET

Kg/cm2(g)

2.7 HOLDING TIME AT TEST PRESSURE

Mins

2.8 HOLDING TIME AT WORKING PRESSURE

Mins

2.9 PRESSURE GAUGE READING AFTER HOLDING TIME AT TEST PRESSURE

Kg/cm2(g)

C

2.10 REFERENCE NO. OF PRESSURE GAUGE AT DRUM 2.11 REFERENCE NO. OF PRESSURE GAUGE AT PUMP OUT LET 2.12 CALIBERATION DATE OF PRESSURE GAUGE AT PUMP OUT LET 2.13 CALIBERATION DATE OF PRESSURE GAUGE AT PUMP OUT LET

REMARKS

LOCATION 3

4

LEAKAGE

YES / NO

PRESSURE DROP

YES / NO

RESULT

ACCEPTED / NOT ACCEPTED

ERECTION VENDOR

THERMAX ECC

CONSULTANT

SIGN NAME DATE FORMAT NO. :- TECC/QAC/LOOP/HT/0011

Page 1 of 1

CUSTOMER

INSPECTION AUTHORITY

THERMAX ECC LTD.

JOBS CARRIED OUT ON MECHANICALLY CLEARED SYSTEM / SUB SYSTEM (LOOP)

BOILER NO:TEST LOOP NO:DATE :-

Flag: Due to Drawing Rev / Due to Non Availability of Material / Due to operation Requirement. 1.0 System / Sub system No.

:

1.1 Loop No.

:

2.0 Status

: Hydro tested / Non-Hydro tested

3.0 Welding to be carried out on Hydro tested Loops

: Yes / No.

A) Work not involving Welding on Hydro Tested Loops 1.0 Description of jobs to be attended and completed :

B) Work involving Welding on Hydro tested Loops : 1.0 Affected Isometric with Revision No.

:

2.0 Line Nos.

:

3.0 Existing Joint to be cut

:

4.0 Additional Joints going to come and their location

:

5.0

Description of jobs and reason for carrying out this job after Hydro test.

:

C) To be filled up after completion of job as per ‘B’ (above): 1.0 Additional joints for QA / QC

: Old / New

2.0 100% RT/UT and PT/MT done successfully

: Yes / No.

3.0 Additional Joints going to come and their location

: Yes / No.

4.0 Tie-In / Closer Weld Joint record to be attach

: Yes /No.

All pending jobs for the loop are Completed and Accepted

: Yes / No.

Date:

NOTE:- Sketch for additional joints with location to be attach ERECTION VENDOR

Name

:

Signature

:

Date

:

THERMAX ECC

FORMAT NO. :- TECC/QAC/LOOP/HT/0012 Page 1 of 1

CONSULTANT

CUSTOMER

VALVE POSITION WHILE HYDROTEST SR NO

PLANT

P&ID NO.

TAG NO

1

CDQ#11

1680 53 G 02 101

CV5011

2 3 4

CDQ#11 CDQ#11 CDQ#11

1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101

GV5090 GV5091 GV5092

CDQ#11

1680 53 G 02 101

GV5093

5

LOCATION

First Isolation valve at upstream of MOV 531102.01-M on Feed Water line First Drain Isolation valve at Economiser Inlet Header Second Drain Isolation valve at Economiser Inlet Header First Isolation valve for vent at Economiser outlet header Second Isolation valve for vent at Economiser outlet header

POSITION

CLOSE OPEN CLOSE OPEN CLOSE

FEED WATER TO DESUPERHEATER 6

CDQ#11

1680 53 G 02 101

GV5062

7

CDQ#11

1680 53 G 02 101

GL5016

8

CDQ#11

1680 53 G 02 101

GV5063

9

CDQ#11

1680 53 G 02 101

GL5017

10

CDQ#11

1680 53 G 02 101

GV5065

11

CDQ#11

1680 53 G 02 101

GV5066

12

CDQ#11

1680 53 G 02 101

GV5067

13

CDQ#11

1680 53 G 02 101

GL5025

14

CDQ#11

1680 53 G 02 101

CV5010

14

CDQ#11

1680 53 G 02 101

GV5068

15

CDQ#11

1680 53 G 02 101

GV5069

First Isolation valve for FIT 531102.26 at upstream of FE 531124 on Feed Water to desuperheater line Second Isolation valve for FIT 531102.26 at upstream of FE 531124 on Feed Water to desuperheater line First Isolation valve for FIT 531102.26 at downstream of FE 531124 on Feed Water to desuperheater line Second Isolation valve for FIT 531102.26 at downstream of FE 531124 on Feed Water to desuperheater line First Drain Isolation valve at Upstream of TV 531102.16 on Feed Water to desuperheater line Second Drain Isolation valve at Upstream of TV 531102.16 on Feed Water to desuperheater line First Isolation valve at downstream of TV 531102.16 on Feed Water to desuperheater line Isolation valve for bypass of TV 531102.16 on Feed Water to desuperheater line Isolation valve upstream of desuperheater on feed water to desuperheater line First Isolation valve for drain on feed water to desuperheater line Second Isolation valve for drain on feed water to desuperheater line

NA NA NA NA OPEN CLOSE OPEN OPEN OPEN OPEN CLOSE

SR NO

PLANT

P&ID NO.

TAG NO

LOCATION

POSITION

STEAM DRUM 16

CDQ#11

1680 53 G 02 101

GL5063

17

CDQ#11

1680 53 G 02 101

GV5122

18

CDQ#11

1680 53 G 02 101

GL5039

19

CDQ#11

1680 53 G 02 101

GV5124

20

CDQ#11

1680 53 G 02 101

GL5038

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11 CDQ#11

1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101

GV5144 GV5145 GV5095 GL5026 GV5097 GL5027 GV5104 GL5030 GV5106 GL5031 GV5108 GL5032 GV5110 GL5033 GV5112 GL5034 GV5114 GL5035 GV5099 GL5028 GV5101 GL5029 GV5102 GV5103 GV5094 GV5096 GV5116 GL5036 GV5118 GL5037 GV5120 GV5121 GV5089 GV5081

Isolation valve for PG 531102.18 on BST531102 (Steam Drum) First Isolation valve for PG 531102.08 on BST531102 (Steam Drum) Second Isolation valve for PG 531102.08 on BST531102 (Steam Drum) First Isolation valve for PIT 531102.07 on BST531102 (Steam Drum) Second Isolation valve for PIT 531102.07 on BST531102 (Steam Drum) First Isolation valve for vent on Puppy header Second Isolation valve for vent on Puppy header First top Isolation valve for LIT 531102.01 Second top Isolation valve for LIT 531102.01 First bottom Isolation valve for LIT 531102.01 Second bottom Isolation valve for LIT 531102.01 First top Isolation valve for LIT 531102.02 Second top Isolation valve for LIT 531102.02 First bottom Isolation valve for LIT 531102.02 Second bottom Isolation valve for LIT 531102.02 First top Isolation valve for LIT 531102.03 Second top Isolation valve for LIT 531102.03 First bottom Isolation valve for LIT 531102.03 Second bottom Isolation valve for LIT 531102.03 First top Isolation valve for LIT 531102.04 Second top Isolation valve for LIT 531102.04 First bottom Isolation valve for LIT 531102.04 Second bottom Isolation valve for LIT 531102.04 First top Isolation valve for LG 531102.05 Second top Isolation valve for LG 531102.05 First bottom Isolation valve for LG 531102.05 Second bottom Isolation valve for LG 531102.05 First isolation valve for drain of LG 531102.05 Second isolation valve for drain of LG 531102.05 First isolation valve for vent of LG 531102.05 Second isolation valve for vent of LG 531102.05 First top Isolation valve for LG 531102.06 Second top Isolation valve for LG 531102.06 First bottom Isolation valve for LG 531102.06 Second bottom Isolation valve for LG 531102.06 First isolation valve for drain of LG 531102.06 Second isolation valve for drain of LG 531102.06 First isolation valve for vent of LG 531102.06 Second isolation valve for vent of LG 531102.06

55

CDQ#11

1680 53 G 02 101

GV5227

First isolation valve on N2 injection line to Steam Drum

56

CDQ#11

1680 53 G 02 101

GV5228

57

CDQ#11

1680 53 G 02 101

GV5229

58

CDQ#11

1680 53 G 02 101

GV5143

59

CDQ#11

1680 53 G 02 101

GL5008

60 61

CDQ#11 CDQ#11

1680 53 G 02 101 1680 53 G 02 101

GV5206 GV5196

62

CDQ#11

1680 53 G 02 101

GV5197

63

CDQ#11

1680 53 G 02 101

GV5198

64

CDQ#11

1680 53 G 02 101

GV5199

65

CDQ#11

1680 53 G 02 101

GV5147

66

CDQ#11

1680 53 G 02 101

GV5146

67

CDQ#11

1680 53 G 02 101

GV5148

68

CDQ#11

1680 53 G 02 101

GL5010

69 70 71 72

CDQ#11 CDQ#11 CDQ#11 CDQ#11

1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101 1680 53 G 02 101

GV5202 GV5203 GV5200 GV5201

73

CDQ#11

1680 53 G 02 101

GV5225

74

CDQ#11

1680 53 G 02 101

GV5226

Second isolation valve on N2 injection line to Steam Drum Isolation valve for vent on N2 injection line to Steam Drum First Isolation valve for drain on Blowown line from Steam drum to CBD Tank Second Isolation valve for drain on Blowdown line from Steam drum to CBD Tank First isolation valve on IBD line from Steam Drum First Isolation valve for drain at Evaporator I inlet header Second Isolation valve for drain at Evaporator I inlet header First Isolation valve for drain at Evaporator II inlet header Second Isolation valve for drain at Evaporator II inlet header Second Isolation valve for vent on steam line from steamdrum to primary superheater First Isolation valve for vent on steam line from steamdrum to primary superheater First Isolation valve for SWAS system on steam line from steamdrum to primary superheater Second Isolation valve for SWAS system on steam line from steamdrum to primary superheater First Isolation Valve for support tube drain Second Isolation Valve for support tube drain First Isolation Valve at water wall header drain Second Isolation Valve at water wall header drain Isolation valve on LP steam line to Evaporator I inlet header Isolation valve on LP steam line to Evaporator II inlet header

CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE CLOSE OPEN CLOSE OPEN OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN CLOSE CLOSE CLOSE

SR NO

PLANT

P&ID NO.

TAG NO

LOCATION

POSITION

MAIN STEAM LINE 75

CDQ#11

1680 53 G 02 101

GV5149

76

CDQ#11

1680 53 G 02 101

GV5150

77

CDQ#11

1680 53 G 02 101

GV5152

78

CDQ#11

1680 53 G 02 101

GV5151

79

CDQ#11

1680 53 G 02 101

GV5154

80

CDQ#11

1680 53 G 02 101

GV5153

81

CDQ#11

1680 53 G 02 101

GV5155

82

CDQ#11

1680 53 G 02 101

GV5156

83

CDQ#11

1680 53 G 02 101

GV5232

84

CDQ#11

1680 53 G 02 101

GL5062

85

CDQ#11

1680 53 G 02 101

GV5157

86

CDQ#11

1680 53 G 02 101

GL5046

87

CDQ#11

1680 53 G 02 101

GV5159

88

CDQ#11

1680 53 G 02 101

GL5047

89

CDQ#11

1680 53 G 02 101

GV5161

90

CDQ#11

1680 53 G 02 101

GL5048

91

CDQ#11

1680 53 G 02 101

GV5167

92

CDQ#11

1680 53 G 02 101

GL5051

93

CDQ#11

1680 53 G 02 101

GV5165

94

CDQ#11

1680 53 G 02 101

GL5050

95

CDQ#11

1680 53 G 02 101

GV5163

96

CDQ#11

1680 53 G 02 101

GL5049

97

CDQ#11

1680 53 G 02 101

GV5169

98

CDQ#11

1680 53 G 02 101

GL5052

99

CDQ#11

1680 53 G 02 101

GV5171

100

CDQ#11

1680 53 G 02 101

GL5053

101

CDQ#11

1680 53 G 02 101

GV5173

102

CDQ#11

1680 53 G 02 101

GL5054

103

CDQ#11

1680 53 G 02 101

GV5175

First Isolation valve for drain at Primary Superheater inlet header Second Isolation valve for drain at Primary Superheater inlet header Second Isolation valve for vent at Primary Superheater outlet header First Isolation valve for vent at Primary Superheater outlet header Second Isolation valve for vent at Secondary Superheater Inlet header First Isolation valve for vent at Secondary Superheater Inlet header First Isolation valve for drain at Secondary Superheater outlet header Second Isolation valve for drain at Secondary Superheater outlet header First Isolation valve for PG 531102.15 upstream of FIT 531102.04 on Main Steam Line Second Isolation valve for PG 531102.15 upstream of FIT 531102.04 on Main Steam Line First Isolation valve for FIT 531102.06 at upstream of FE 531115 in Feed Water line First Isolation valve for FIT 531102.06 at upstream of FE 531115 in Feed Water line First Isolation valve for FIT 531102.05 at upstream of FE 531115 in Feed Water line First Isolation valve for FIT 531102.05 at upstream of FE 531115 in Feed Water line First Isolation valve for FIT 531102.04 at upstream of FE 531115 in Feed Water line First Isolation valve for FIT 531102.04 at upstream of FE 531115 in Feed Water line First Isolation valve for FIT 531102.06 at downstream of FE 531126 in Main Steam line Second Isolation valve for FIT 531102.06 at downstream of FE 531126 in Main Steam line First Isolation valve for FIT 531102.05 at downstream of FE 531126 in Main Steam line Second Isolation valve for FIT 531102.05 at downstream of FE 531126 in Main Steam line First Isolation valve for FIT 531102.04 at downstream of FE 531126 in Main Steam line Second Isolation valve for FIT 531102.04 at downstream of FE 531126 in Main Steam line First Isolation valve for PIT 531102.09 on Main Steam Line Second Isolation valve for PIT 531102.09 on Main Steam Line First Isolation valve for PIT 531102.08 on Main Steam Line Second Isolation valve for PIT 531102.08 on Main Steam Line First Isolation valve for PIT 531102.07 on Main Steam Line Second Isolation valve for PIT 531102.07 on Main Steam Line First Isolation valve for PIT 531102.17 on Main Steam Line

OPEN CLOSE CLOSE OPEN CLOSE CLOSE OPEN CLOSE NA NA NA NA NA NA NA NA NA NA NA NA NA NA OPEN CLOSE OPEN CLOSE OPEN CLOSE OPEN

SR NO

PLANT

P&ID NO.

TAG NO

104

CDQ#11

1680 53 G 02 101

GL5055

105

CDQ#11

1680 53 G 02 101

GV5177

106

CDQ#11

1680 53 G 02 101

GV5178

107

CDQ#11

1680 53 G 02 101

GV5236

108

CDQ#11

1680 53 G 02 101

GV5179

109

CDQ#11

1680 53 G 02 101

GV5180

110

CDQ#11

1680 53 G 02 101

GV5181

111

CDQ#11

1680 53 G 02 101

GV5237

112

CDQ#11

1680 53 G 02 101

GV5182

113

CDQ#11

1680 53 G 02 101

GV5183

114

CDQ#11

1680 53 G 02 101

GL5011

115

CDQ#11

1680 53 G 02 101

GV5184

116

CDQ#11

1680 53 G 02 101

GV5185

117

CDQ#11

1680 53 G 02 101

GV5186

118

CDQ#11

1680 53 G 02 101

GV5187

119

CDQ#11

1680 53 G 02 101

GV5188

120

CDQ#11

1680 53 G 02 101

GV5189

121

CDQ#11

1680 53 G 02 101

GV5190

122

CDQ#11

1680 53 G 02 101

GV5191

123

CDQ#11

1680 53 G 02 101

GV5192

124

CDQ#11

1680 53 G 02 101

GL5056

125

CDQ#11

1680 53 G 02 101

CV5014

126

CDQ#11

1680 53 G 02 101

GV5194

CDQ#11

1680 53 G 02 101

GV5195

127

LOCATION

Second Isolation valve for PIT 531102.17 on Main Steam Line Isolation Valve upstream of PV 531102.18 - Startup vent valve First isolation valve for drain upstream of PV 531102.18 - startup vent valve Second isolation valve for drain upstream of PV 531102.18 - startup vent valve Isolation Valve Downstream of PV 531102.18 - Startup vent valve Isolation Valve upstream of PV 531102.17 - Startup vent valve First Isolation valve for drain upstream of PV 531102.17 - bypass startup vent valve Second isolation valve for drain upstream of PV 531102.17 - bypass startup vent valve Isolation Valve Downstream of PV 531102.17 - bypass Startup vent valve First Isolation valve for drain to SWAS on main steam line Second Isolation valve for drain to SWAS on main steam line Isolation Valve upstream of PV 531102.20 on Main Steam Line First Isolation valve for drain upstream of PV 531102.20 on main steam line Second Isolation valve for drain upstream of PV 531102.20 on main steam line Isolation Valve Downstream of PV 531102.20 on Main Steam Line Isolation Valve Upstream of PV 531102.19 on Main Steam Line First Isolation valve for drain upstream of PV 531102.19 on main steam line Second Isolation valve for drain upstream of PV 531102.19 on main steam line Isolation Valve Downstream of PV 531102.19 on Main Steam Line First Isolation valve for PIT 531102.19 upstream of PV 531102.20 on Main Steam Line Second Isolation valve for PIT 531102.19 upstream of PV 531102.20 on Main Steam Line Isolation valve upstream of MOV 531102.23-M on main steam line First Isolation valve for drain upstream of MOV 531102.023-M on Main Steam Line Second Isolation valve for drain upstream of MOV 531102.023-M on Main Steam Line

POSITION

CLOSE CLOSE OPEN CLOSE CLOSE OPEN OPEN CLOSE CLOSE OPEN CLOSE OPEN OPEN CLOSE OPEN OPEN OPEN CLOSE OPEN CLOSE CLOSE AUTO OPEN CLOSE

CHEMICAL INJECTION TO STEAM DRUM 128 129

CDQ#11 CDQ#11

1680 53 G 02 101 1680 53 G 02 101

CV5012 GV5205

First isolation valve on HP dosing line to Steam Drum Second isolation valve on HP dosing line to Steam Drum

OPEN CLOSE

Hydrotest Pressurisation & De-pressurisation Curve 130 120

Hydro-test Pressure 123 kg/cm2 (g)

110

Pressure in kg/cm2 (g)

100 90 80 70

Design Pressure 82 kg/cm2 (g)

60 50 40 30 20 10 0 0

50

100

150

200

250

300

Time in Minutes Notes :

Rate of pressurisation = 1 kg/cm2 (g) per minute Rate of de-pressurisation = 1 kg/cm2 (g) per minute Design Pressure = 82 kg/cm2 (g) - Hold for 30 minutes Hydro Test Pressure = 123 kg/cm2 (g) - Hold for 30 minutes

350

400

450

500

550

1680 50 K JM 001

Page: 93

6. INTEGRATED COLD TEST PROCEDURE After completion of SINGLE TEST TRIALS, the CDQ plant is ready for the execution of Integrated Cold test. ICT activities are divided into 2 different areas:

6.1 CDQ Integrated COLD Test In the following scheme are indicated the areas tested during integrated cold test of CDQ. Details of tests are clarified in the next chapters.

6.1.1 PRECONDITIONS OF INTEGRATED COLD TEST Before to start ICT test the following preconditions must be fulfilled: ¨ Erection complete and erection certificates signed ¨ Single test trials executed and equipment trial certificate signed, with vendor acceptance and clearance ¨ Utilities lines flushing executed ¨ PLC installed, tested and commissioned ¨ Single test trials executed from remote by PLC ¨ Pressure test (pneumatic or hydraulic test) executed for utilities lines ¨ Cooling gas circuit Leakage test executed

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 94

¨ IBR Hydro test executed for Boiler / pressure parts and DM,LP,HP lines ¨ Instrumentation mounted and tested ¨ Control room availability ¨ Complete accesses, stairs, handrails erected. Access to the plant organized in complete safety conditions as per final plant configuration. ¨ Availability of Loco, bucket cars and buckets already tested and commissioned ¨ Availability of fluids at TOP

Before to start ICT test the following materials and provisional works must be executed and available: ¨ 200-250 mc of cold coke available for manual charging into the chamber ¨ Preparation of provisional charging system for cold coke up to blast head level ¨ Additional 350mc minimum of cold coke to prepare the CDQ chamber to ICT. (minimum coke level) to be charged on bucket and transferred to chamber by CDQ crane. TOTAL number of buckets = 8 bucket, filled with cold coke available and charged to CDQ ¨ Additional buckets filled up with cold coke to be prepared and available according to the sequence described in the following chapter. Total cold coke necessary: 1000 mc to perform test at 50% and 100% of CDQ capacity. ¨ Connection available and ready to coke wharf for cold coke discharging out of CDQ unit. According to Erection company planning, and layout and space availability, cold coke can be discharged in intermediate place and recharged to CDQ unit during test. ¨ Preparation of provisional Flanges with internal liners (light castable but not final bricks) to close the manhole in the chamber. One manhole can be closed if necessary with final brickworks, but at least the main manhole (where the heating up burner will be installed) must be closed with temporary liners, to be removed after test.

6.1.2 Purpose of CDQ Integrated Cold Test During the IC Test the CDQ unit will be operate with cold coke simulating the final operation of: §

Loco and bucket carriage approach (full load)

§

Complete Crane Cycle (full load)

§

Charging to Pre-chamber (full load)

§

CDQ Gas circulation fan run (CDQ gas is replaced by ambient Air) (COLD condition- Full load)

§

Dilution airline operation

§

Discharging to conveyor belt and to coke wharf (full load)

§

Coke breeze discharging (No load)

§

Bunkering test of valves (No Load – no nitrogen charged to the system)

§

Lower bleeding line test (dedusting line and flare line)

§

CDQ Upper bleeder and by-pass valve

The main regulation loops will be tested §

PV of bleeding line and Pre-chamber pressure control loop

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 95

§

GCF damper regulation

§

FV of dilution airline (with simulated signals form analyzer)

§

By-pass of bleeding line to flare

§

Vibrating feeder coke flow regulation

6.1.3 Execution of CDQ Integrated Cold Test ¨ Chamber will be filled up to top of blast-head before test execution. ¨ Manhole of CDQ chamber will be sealed, with flanges internally refractory lined to be aligned to permanent brickwork. ¨ Test start with charging of 8 buckets, up to reach the minimum level of the prechamber. ¨ Level of coke will checked with laser from top of the CDQ using the installed level measures and external level measurement tool in order to calibrate the LT radar on top of the pre-chamber. ¨ During this preliminary phase also the crane weighing system and BC load cells must be calibrated and checked. ¨ Crane will be tested at full load as per DHHI protocol during the charging of first 8 buckets, measuring the cycle time as per performance and design. Emergency cycle of crane will be tested, together with the runs simulating hoisting motor fails and traveling motors fails. ¨ Charging test (AUTO mode) from 50tph up to 100 tph of bucket with Crane and charging system, with DE fan in operation. ¨ Dedusting regulation will be tested, without lower bleeding line ¨ Using the crane the additional bucket are charged up to reach the HH level of the pre-chamber ¨ Coke level must be checked again and verified through radar and through a second additional manual system. ¨ When the LL / HH and the coke level measure of the pre-chamber are full tested and checked, the final phase of charging starts. ¨ Main GCF is started at minimum of VVVF. ¨ Lower bleeding line is put in operation and PV valve will be automatically set to keep the pre-chamber pressure at 0 or slightly negative. Lower bleeding line will be connected to dedusting line and put under suction. ¨ To simulate bleeding, dilution airline will be switched on in operation keeping setting the Set point manually at minimum air flow. ¨ Pressure curve of the circuit is measured and noted. (minimum GCF condition). ¨ Discharging system is put in operation up to 50 tph (from minimum with rate of 15 tph) increasing together the GC Fan speed accordingly to the discharging flowrate. Dilution airline flow will be increased accordingly. ¨ At 50 tph the pressure curve of the system is measured and noted. ¨ Coke bucket charging will start again during this phase to take the coke level at intermediate level. Charging frequency rate will be adapted to discharging flowrate (50 tph) ¨ Coke charging and discharging rates will be increased by 15 tph up to 75 tph. Dilution airline flow will be increased accordingly. When the discharge rate and other conditions are stable, the pressure curve of the system is measured and noted.

LARSEN & TOUBRO LIMITED

1680 50 K JM 001

Page: 96

¨ Coke charging and discharging rates will be increased by 15 tph up to 100 tph. Dilution airline flow will be increased accordingly. When the discharge rate and other conditions are stable, the pressure curve of the system is measured and noted. ¨ Duration of the test at full load (100tph) can be 1 hour max 2 hours. Duration of the test can be prolonged and adapted to availability of cold coke. ¨ During the test the following system are tested / simulated in parallel: o

Upper bleeder (regulation of overpressure of the chamber. Over pressure will be simulated increasing air flowrate by Dilution airline, and freezing the PV of bleeding line. Operator will open manually the Upper bleeder valve to test and release the P of pre-chamber.

o

By-pass of lower bleeding line. If COG is available at flares, also flares ignition can be tested.

o

Analyzers

o

Coke breeze discharging system can be tested both in PDC both in SDC.

o

Flushing cycle of charging system water seal

o

Steam bleeder valves opening and closing. Test of mechanical opening can be executed if a peak of pressure is generated in the chamber. Automatic opening and closing will be tested simulating the peak on PI instrument

o

Dedusting system will be in operation and tested during charging.

In the following figure the chamber is divided in the 3 areas to be filled with cold coke, during the test: GREEN AREA – Manually charged BLUE AREA – Bucket Charged by crane and crane test RED AREA – Bucket Charged by crane up to max level. Red area is the operation range during ICT of the chamber

After test conclusion, the cold coke is discharged to coke wharf up to complete emptying of the system. All the systems must be inspected and checked: §

Buckets (liners)

§

Crane

§

Charging system

§

CDQ chamber internal (lining sight inspection)

§

Upper funnel / Blast head / lower funnel liners and basalt tiles

§

VF and RSV

§

Conveyor belts

§

All EJ connections

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6.2 Boiler Integrated test The Integrated Cold test for Boiler unit will be executed accordingly Thermax Commissioning Manual instructions. After Boiler Integrated test completion, the system is ready for heating up and refractory dry out.

6.2.1 Boiler Integrated test Preconditions The following activities must be executed before Boiler test: ¨ Pressure part Inspection ¨ Refractory Inspection ¨ Cooling Gas Circuit Leakage test executed ¨ Flushing of DM and steam lines executed ¨ Hydro test of boiler ¨ Utilities connected to networks and ready ¨ SINGLE Tests completion ¨ Instrumentation installed ¨ PLC ready

6.2.2 Boiler Integrated test Execution A schematic diagram flow chart indicating the sequence of Boiler test ( showing the preparation and the execution of the test) is attached to clarify the order of the test and the preconditions for each step. Color code for the flowchart is the following:

PRECONDITION SINGLE TRIAL BOILER INTEGRATED TEST The Boiler ICT ends before Heating Up. Insulation of boiler proper must be executed during ICT of the boiler and completed before Heating Up. The post commissioning activities after RDO and ABO are also indicated up to Performance test of the boiler. A tentative schedule (to be integrated in the overall schedule of the project) is here attached. Duration is indicated as per Thermax experience.

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7. HEATING UP AND RAMP UP TO OPERATION The pre-heating of Cooling chamber refractory is an essential requirement to ensure a long period of operation without important maintenance activities. The period of pre-heating is necessary in order to guarantee the dilatation of the bricks in the most gradual possible way. For that reasons a temporary instrumentation and control system has been designed and will be used in order to control every time the status of the process parameters of the Cooling chamber (flow rate, pressure temperatures etc) and if it’s the case, promptly acts. The presence of qualified personnel, 24 hours per day, will be an additional guarantee for the respect of the technological parameters and the security management of all the phase of preheating. After completion of ACCEPTANCE TEST the CDQ plant is ready for the HEATING UP. Heating Up consists of different phases: ¨ DRYING of refractory of CDQ Chamber, Primary Dust Catcher (PDC) and boiler (HRSG) ¨ Heating Up with COG burner ¨ Alkali Boiling of Boiler ¨ Cooling of the system ¨ Inspection of refractory ¨ Boiler Inspection After the final inspection of CDQ and Boiler, all the heating up systems are dismounted and the system is prepared for final drying and ramp up to operation

7.1 Heating Up Preconditions Preconditions and activities necessary before to start heating up are the following:: ¨ Filling up of CDQ chamber with cold coke manually charged from the manhole (about 160 mc). ¨ An inert layer of granulated slag up to Blast Head top is charged after cold coke, (about 40 mc) to create a layer of 500 mm all above the coke layers to protect completely the blast head top and to create a compact floor where to support the COG burner. Elevation of top of slag layer will be about +13.300 mm.

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¨ Installation of Heating up Burner ¨ Installation / preparation of air dilution line – heating up circuit ¨ COG Line Connection and Inertization ¨ COG feeding ¨ Test of heating up burner ¨ COG Line closing and Inertization up to burner with Nitrogen ¨ Installation of provisional stack on TOP ¨ Preparation of LP Steam line provisional line to Steam Drum ¨ Connection of Boiler with LP steam line and preparation of Boiler for drying phase ¨ Opening of Manholes for air entrance in the circuit/ opening of Steam bleeder valves for air entrance in the circuit For Heating Up equipment drawing and installation info, please refer to Heating up burner drawing attached to the present manual in section 10.5.19 of Vendor Manual Attachment. Before startup of Heating up operations, the burner must be installed and commissioned. Top Provisional duct and valve on CDQ chamber inlet must be erected and fixed with temporary supports. Top lid must be removed and stored with proper care to avoid damages to refractory lining. Before to start up operations the following activities must be executed and completed: ¨ Drying of top lid refractory (not dried during heating up) ¨ Insulation of gas duct, gas circuit and boiler proper. Unexpected thermal losses on the system can affect severally the heating up operation and the hot drying duration and feasibility.

7.2 Heating up curve In order to have a good heating up of the battery it’s necessary to avoid not admissible thermal gradient in the brickwork. For this reason a heating up curve shall be defined. Definition of details of Heating up are defined together with definition of HRSG heating up procedure. The curve is attached here below and must be used as guideline during heating up operation. Temperature gradients are indicated and must be respected in order to avoid damages to refractory and to mortar. During Air drying leading temperature will be measured at chamber inlet and on chamber Top and at boiler inlet. The temperature of 170 °C in the curve is at chamber inlet, corresponding to a lower value inside the circuit. Temperature for drying must be around 110 °C, not over 130-140 °C. During COG heating up the leading temperature in the curve refers to CDQ chamber temperature measured at Pre-chamber top. Temperature in PDC and in the boiler will be lower. For Temperature limits to be respected in the boiler the leading temperature will be at boiler inlet. For detail of refractory Drying out of boiler see Boiler Commissioning Manual. Here below are summarized the boiler requirement for RDO: ¨ Raise the temperature of flue gas at the rate of approximately 15-20 Deg C per hour. On reaching 110 °C ¨ Hold a110 °C for 36 hours for soaking refractory castable.

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¨ Raise the temperature of flue gas at the rate of 15-20 °C/h up to 300-350 °C and hold for 36 hours for soaking. ¨ After completion of holding time again raise the temperature of flue gas up to 500 °C at the rate of 15-20 °C/h. Hold the temperature 500 Deg °C for 24 hours. This will ensure complete soaking of refractory. ¨ Once the above heating schedule is over, the boiler may be cooled down at the rate of 50 °C/h up to 200 °C. After allow to cool the refractory naturally up to normal temperature.

The overall curve of heating up respect and integrate all the gradient and soaking period for the boiler

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.

7.3 Hot Air Drying During Hot Air drying, CDQ system is uniformly heated using air at low temperature to remove the water from mortar, castable and refractory liners. Heating procedure is the following; ¨ Low-pressure steam is supplied to the boiler evaporator (permanent line) and drum (temporary line). ¨ The air is introduced through steam bleeding device and is heated in the boiler. ¨ Main gas circulation fan is switched on, at minimum flow. Increase the flowrate with a rate of about 10,000 Nm3/h up to 150,000 Nm3/h. ¨ The Hot Air passes from the boiler, to multi-cyclone, circulation fan and chamber. ¨ Hot Air with moisture collected in the chamber is exhausted into atmosphere through chamber top and PC pressure control bleeder. ¨ At the heating-up phase, CDQ system temperature (represented by T2) is raised to T = 160 ~ 170 °C. ¨ Heating-up speed cannot exceed mortar crack limit (15-20 Deg.-C/h) ¨ Target drum pressure must follow the drum pressure curve as per Thermax manual. LP steam injection must be done accordingly Thermax specification. Air drying phase drying duration can be affected by LP stream flow to the boiler.

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7.3.1 The following table summarize all the parameters to be checked during Hot Air drying and the control parameters. Boiler portion must be checked and agreed with Thermax supervisor before staring heating up operations.

HOT AIR DRYING CONTROL PARAMETERS Parameter

#

Description T2

Temperature

Pressure

T4 T?

CDQ Chamber inlet Steam Drum Boiler area Drainage for EVAP

P1 P3 P4 P?

CDQ Prechamber Boiler inlet Steam drum Boiler area

L4

Circulation gas flow LP steam flow Steam drum

Flowrate Level Analysis

Gas analyzers Water steam drum

Parameter Temperature

# T1 T2 TN TM T3 T6

Criteria - Tresholds Rise up of max 10 °C/h; Stabilization at 160-170 °C max for 6 days- Main Curve control parameter Temperature Rise rate max: Inlet of Boiler : Max 110 °C

Measurement

CDQ PLC CDQ PLC CDQ PLC

Continuous

CDQ PLC CDQ PLC

Continuous Continuous

Regulated by Main GCF - min 50000 Nm3/h max 160000 Nm3/h

CDQ PLC

Continuous

N.A in air drying

CDQ PLC

Continuous

Slightly positive - max 10 mmH2O. To be kept by provisional stack valve Negative pressure See Thermax Curve

Description Criteria - Tresholds CDQ TOP prechamber CDQ Chamber inlet Temperature at blasthead Temeprature of CDQ cooling area Boiler Inlet Boiler Outlet

Measurement

Other BY TL

7.3.2 During Hot Air Drying the position of the valve along the CDQ Chamber and gas circuit is as per following list: Water seal valve for steam bleeding device

OPEN

Chamber inlet louver damper

OPEN

Water seal valve for bleeder device at pre-chamber

OPEN

Butterfly valve for bleeder device at pre-chamber

OPEN

Air Dilution Air FV

CLOSED

By-pass control valve

CLOSED

PVl valve for lower bleeding line

CLOSED

Chamber top Valve (provisional)

OPEN – Manually regulated

Dedusting dampers

CLOSED

PDC discharging valves (2 Valves)

Stopped - 1 minute operation/shift

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Gate valves for PDC and Multi-cyclone

CLOSED - 1 min operation/shift

Gas Manifold drain nozzles

OPEN

Gas circulation system drain valves

CLOSED (To be opened 1 /shift)

Primary and secondary air lines to burner

CLOSED

Slide gate of discharging device

CLOSED

Circulation gas analyzer sampling pipe

CLOSED

Manhole of boiler exit duct

OPEN TO INCREASE AIR FLOW

Valves not described above

CLOSED

7.3.3 BOILER Preaparation to Air Drying Please refer to Thermax Commissioning Manual for boiler preparation and LP steam Charging to Evaporator and Steam Drum. Steam drum pressure rise up must be follow the curve as per Thermax instructions. (6.7 of Commissioning Instructions)

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7.4 COG HEATING UP COG Heating up is performed y the burner installed in the CDQ chamber. Purpose of COG heating up is to rise up the temperature of refractory up to 650-700 °C and complete RDO and after RDO the Alkali Boiling of the boiler Heating procedure is the following; ¨ Boiler is prepared for operation (see Thermax Procedure) ¨ Provisional LP steam line are closed ¨ Louver Damper valve must be closed. Lower bleeding line valves must be open and PV valve put in regulation to keep the Pre-chamber pressure at zero ¨ Main gas circulation fan is switched on, with minimum flowrate. ¨ Check the water seal and ensure water feed to COG water seal. ¨ COG line must be closed and inertized by Nitrogen ¨ Open COG gas line. ¨ Ignition sequence of the burner must be executed accordingly Burner Vendor instruction. See in the attached vendor manual the operation philosophy and instruction in section 10.5.19 of Vendor Manual Attachment ¨ Ignite the pilot burner and switch on the burner according instructions working with high air dilution and high Air/fuel ratio. ¨ Set the COG flowrate at minimum flow increasing the COG rate accordingly the heating up curve. ¨ Regulate GCF to reach a gas flowrate of about 40000-50000Nm3/h with a increase rate of 5000 Nm3/h. ¨ The gas is generated by burner in the chamber and passes from chamber to PDC, boiler, multi-cyclone, circulation fan and lower bleeding line.

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¨ At the heating-up phase, CDQ system temperature (represented by T1) is raised to accordingly the heating up curve. ¨ Fumes are bleed out from Top Heating up duct initially. Valve will be closed progressively in order to move the heat versus PDC and boiler. In case of need the valve can be slightly open. ¨ Heating-up speed cannot exceed mortar crack limit (15-20 Deg.-C/h) and not exceed 10 °C/h (see boiler curve)

7.4.1 The following table summarize all the parameters to be checked during COG Heating Up and the control parameters. Boiler portion must be checked and agreed with Thermax supervisor before staring heating up operations.

BURNER HEATING UP CONTROL PARAMETERS Parameter

#

Description

T4 T?

Criteria - Tresholds Rise up of max 100 °C/day; Stabilization at 300 °C - 450 °C and final stabilization at 700 °C for Alakli boiling completion. Max T 750 °C - Main Burner Heating Up Curve CDQ TOP prechamber control parameter Steam Drum Temperature Rise rate max: Boiler area T inlet of Boiler Super Heater 1SH Super Heater 2SH Evaporator Economizer External Sub-Eco Steam outlet

P1 P3 P4 P?

CDQ Prechamber Top Boiler inlet Steam drum Boiler area

T1 Temperature

Pressure

Flowrate

Level Analysis

Circulation gas flow

L4

COG Line flow AIR line Boiler Feed water Steam drum Deaerator Gas analyzers Boiler Feed water Water steam drum

Set point : 0 mmH2O (-2 up to +2 mmH2O) - regulated by lower bleeding line PV Negative pressure

Regulated by Main GCF - up to minimum GCF flow up to 50000 Nm3/h Max 1500 Nm3/h (line design 2500 Nm3/h) - Burner max capacity 2500 Nm3/h - To be regulated according T1 temperature and heating up curve Max 17800 Nm3/h Water level at Drum: ?? Operation level +/- ? mm Operation level +/- ? Mm CO - O2 control Parameters to be analyzed: ? Parameters to be analyzed: ?

LARSEN & TOUBRO LIMITED

Measurement

CDQ PLC CDQ PLC PLC

Continuous

CDQ PLC CDQ PLC

Continuous Continuous

CDQ PLC

Continuous

CDQ PLC

Continuous

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Parameter Temperature

Pressure

Flowrate Analysis

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# Description Criteria - Tresholds T1 CDQ TOP prechamber T2 CDQ Chamber inlet TN Temperature at blasthead TM Temeprature of CDQ cooling area T3 Boiler Inlet T6 Boiler Outlet Other T BY TL Boiler inlet Boiler outlet Chamber inlet Other T BY TL Main steam ? Other T BY TL COG Gas O2 -CO If necessary Other T BY TL

Measurement

From Lab

once /day

7.4.2 During the COG heating the position of the valve along the CDQ Chamber and gas circuit is as per following list: Water seal valve for steam bleeding device

CLOSED

Chamber inlet louver damper

CLOSED

Water seal valve for bleeder device at pre-chamber

CLOSED

Butterfly valve for bleeder device at pre-chamber

CLOSED

Air Dilution Air FV

OPEN

By-pass control valve

CLOSED

PV valve for lower bleeding line

OPEN /REGULATION

Chamber top Valve (provisional)

OPEN->CLOSE –Man. regulated

Dedusting dampers

CLOSED

PDC discharging valves (2 Valves)

Stopped - 1 minute operation/shift

Gate valves for PDC and Multi-cyclone

CLOSED - 1 min operation/shift

Gas Manifold drain nozzles

OPEN

Gas circulation system drain valves

CLOSED (To be opened 1 /shift)

Primary and secondary air lines to burner

OPEN

Slide gate of discharging device

CLOSED

Circulation gas analyzer sampling pipe

-

Manhole of boiler exit duct

OPEN TO INCREASE AIR FLOW

Valves not described above

CLOSED

7.4.3 BOILER Preaparation to Air Drying Please refer to Thermax Commissioning Manual for boiler preparation and LP steam Charging to Evaporator and Steam Drum.

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7.5 ALKALI BOILING PROCEDURE During last period of COG heating up, the system is kept at 650 °C – 700 °C for a soaking period during which the alkali boiling is performed in the boiler. For Alkali Boiling Procedure see Thermax Commissioning Manual (Chapter 5). At Alkali boiling completion, the system is cooled up to ambient temperature in order to check and inspect the refractory status of boiler and CDQ.

7.6 Cooling down of System At Alkali boiling completion, the system is cooled up to ambient temperature in order to check and inspect the refractory status of boiler and CDQ. Cooling operation are executed in 2 phases: ¨ Cooling with burner control. Temperature is slowly lowered at a maximum rate of 12-15 °C/h. from 700 °C up to 200 °C. ¨ Burner is switched off and COG circuit closed and inertized. Cooling rate is maximum 10 °C/h up to 50 °C. ¨ Burner and provisional equipment for heating up are dismantled. ¨ CDQ manhole is closed with permanent brickworks after CDQ final inspection. ¨ Boiler inspection and activities are executed according Thermax Commissioning Plan ¨ The system is prepared for operation and for a drying heating.

7.7 Drying and Hot coke heating The system is ready to be put in to operation. The following activities must be executed: ¨ Nitrogen filling of gas circuit ¨ Preheating of CDQ Chamber with Nitrogen (boiler as heater) for 24 hours at 100-150 °C – See procedure for hot air drying. ¨ Steam Bleeder valve are closed and manhole are closed. ¨ Louver damper is open ¨ Bleeders valve are closed and the nitrogen circulate in a closed loop. ¨ Main Gas circulation fan is switched on at minimum flow rate and flow increased to reach 150 °C. final regulation and calibration (Recording of Fan parameters vs Production) ¨ The CDQ chamber is filled up with cold coke (1 or 2 bucket as per chamber minimum level) . ¨ The system is ready to receive red - hot coke Through the following steps: o

Bucket charging ( 1 bucket )

o

Increase Gas Temperature up to 180 °C

o

Start discharging at 20 tph up to minimum level and stop

o

Bucket charging ( 1 to 3 bucket )

o

Increase Gas T up to 350 °C - discharge and charge must keep a T rise up of max 20 °C /h

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o

Rise up T up to 600 °C - discharge and charge must keep a T rise up of max 20 °C /h

o

Start charging / discharging up to 50 tph (5 Tph of max INCREASE RATE)

o

At T gas > 700 °C switch on Dilution air system and start combustion of CO and H2

o

At H2 <3% open lower bleeding line and connection to DE system

o

Production stabilized at 50 tph

o

Increase up to 100 tph (ramp up at 5tph rate by adjusting discharging rate and charging frequency)

¨ Production stabilized at 100 tph ¨ Transfer CDQ to Normal operation ¨ See Thermax Procedure for final Boiler hot commissioning activities and steam blowing.

7.8 Stabilization of operation and preparation to Performance The CDQ is operating at full capacity. After a first period of stabilization of operating condition, the system is ready to execute performance test. See next chapter for Performance parameters,

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8. PERFORMANCE PARAMETERS OF CDQ PLANT Here below are reported the PG figures for CDQ plant and for Boiler and crane sub-systems. To PG test conditions and preconditions, please refer to the Contract documentation, i.e. the SP CDQ TATJAM TATA 14 008 (14.11.2014) and addenda added on (rev 16.04.2015)

Parameter

Guarantee Figure

1) Hot coke charged into the CDQ chamber

100 t/h

2) Cooled coke discharged from the CDQ chamber

98 t/h

3) Cooled coke temperature (mean, time average)

≤ 200 °C

4) HP Steam generation

60 t/h

6) Cycle Time of Charging crane

8 min

7) Dust emission from stack

≤ 25 mg/Nm3

For detail of Crane Performance and Boiler performance refer to the following drawings: ¨ CRANE: 168051FEM101 (T Cycle <=450 seconds) For information in the following table are indicated the expected cycle for the different run conditions (failure of motors and reduced speed runs).

¨ BOILER: 168053G01002/102 – H&M Balances in PG conditions

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