Station: NTPC- Simhadri Plant area: BOILER

BHEL Ref No.PS-DC-186-500-0042 NTPC Ref no SIM/1/TS/1/42

Sheet 1 of 10

PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR SL. NO 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PERECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES A. TECHNICAL SPECIFICATIONS LIST OF CONTENTS

Station: NTPC- Simhadri Plant area: BOILER

BHEL Ref No.PS-DC-186-500-0042 NTPC Ref no SIM/1/TS/1/42

Sheet 2 of 10

PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR SL.NO 1.0 1.1 STATUS PLANT DETAILS BHELVision 20 System consists of a pressure vessel, with electrodes mounted on it, Ascertor cabinet, local and remote display units. An array of electrodes mounted on the pressure vessel measures the resistance of water and steam. The electrode outputs are processed in a compact electronics cabinet viz., Ascertor. Water/Steam levels are indicated by a high bright LED based local display mounted on the Ascertor cabinet. Information is transmitted to the control room for driving the UCB mounted remote display unit and optional display unit at firemans door. Hence, the system consists of the following items. Necessary mechanical hardware including a pressure vessel of appropriate size with isolation and drain valves Sufficient number of rugged flange type electrodes (typically 12 Nos.) Ascertor cabinet mounted at drum floor with integral local display PTFE cable between electrodes and the Ascertor cabinet (Standard) 15 Metre length Remote display unit for UCB Remote display unit for firemans floor (optional) Necessary cable from the Ascertor cabinet to remote display unit at UCB and at firemans floor. 2 Nos. of pressure vessels fitted with electrodes. 2 Nos. of BHELVISION 20 Ascertor cabinets and 2 sets of remote level indicators are supplied, to cover both sides of the drum

1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

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Station: NTPC- Simhadri Plant area: BOILER

BHEL Ref No.PS-DC-186-500-0042 NTPC Ref no SIM/1/TS/1/42

Sheet 3 of 10

PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR SL.NO 1.10 Employing the principle of measuring the different conductivities of water and steam, BHELVISION 20 offers a degree of accuracy unmatched by conventional level indicators. The Ascertor continuously monitors the system. The electrodes are exicted by the AC source and the output signals are precision rectified and compared with necessary threshold values. If the signal is less than the lower threshold value, the output indicates the presence of water. On the other hand, if the signal is higher, than the upper threshold value, the output indicates the presence of steam BHELVISION 20 incorporates several safety features. Notable among these are: Separate electrical processing for each electrode to ensure only single level loss on any component failure Firmware based validation circuitry to confirm the information conveyed by the Ascertor is always true. Invalid sensing by any electrodes (i.e. water above steam or steam below water) is indicated by a fault lamp on the display. Only the valid signals initiate the trip relays for high or low trip. Dual power supplies (one supplying odd channels and the other even channels). Even if one power supply fails, the other power supply automatically feeds the entire system, thus ensuring availability of power supply all the time. STATUS

1.11

1.12 1.13 1.14

1.15

1.16

4 to 20 mA current output expounds the applicability of BHELVISION 20 both on indication and data acquisition for trending and diagnostics.

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Station: NTPC- Simhadri Plant area: BOILER

BHEL Ref No.PS-DC-186-500-0042 NTPC Ref no SIM/1/TS/1/42

Sheet 4 of 10

PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR SL.NO 2.0 2.1 OBJECTIVE The objective of this procedure is to commission the BHELVISION 20 Drum Level Indicator and make it available for Unit Operation. PROPOSAL It is proposed to commission this Drum Level Indicator and compare its performance with respect to i) Direct water level gauge and ii) Other remote water level Indicator of Drum SERVICES REQUIRED Communication and lighting facility at Drum Level and at Control room. Availability of boiler with drum filled and preferably, boiler in steaming condition Availability of a good working crew to attend to any electrode leakages during commissioning Availability of Specification). LT supply (AC & DC) (Refer Technical STATUS

3.0 3.1

4.0 4.1 4.2 4.3 4.4

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Station: NTPC- Simhadri Plant area: BOILER

BHEL Ref No.PS-DC-186-500-0042 NTPC Ref no SIM/1/TS/1/42

Sheet 5 of 10

PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR SL.NO 5.0 5.1 5.2 5.3 5.4 SAFETY PRECAUTIONS While charging the level indicator, extreme precaution taken to slowly charge the vessel and gradually warm up. Control Panels erected at Drum Level are ensured for safety from hot water / steam etc. Control Cabling done between Pressure Vessel and Control Panel at drum level are safely routed avoiding hot zones. Extreme precaution taken while attending any leaking electrode. Required isolation are made before attending any leakage. EMERGENCY PRECAUTION The test team should be aware of the lay-out of the BHELVISION 20 Drum Level Indicator, in order to react for any emergency. If there is any sudden electrode failure leading to heavy leakage of water/steam, then extreme care to be taken to isolate the level indicator by closing the isolating valves. The test team should be aware of steps to be taken to meet any emergency due to damage to any item / injury to personnel STATUS

6.0 6.1

6.2

6.3

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Station: NTPC- Simhadri Plant area: BOILER

BHEL Ref No.PS-DC-186-500-0042 NTPC Ref no SIM/1/TS/1/42

Sheet 6 of 10

PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR SL.NO 7.00 7.1 7.2 7.3 7.4 7.5 7.6 7.7 STATE OF THE PLANT Pressure vessel erected as per recommended drawing to the correct limbs in the drum (Both RHS & LHS) Electrode erection completed Control Cabinet (Ascertor Unit) and the connected cabling completed from drum level to control room PTFE Cabling from electrodes to Ascertor Panel completed Remote indicator in control room erected and ready for commissioning Operating floor indicator erected (This is optional) Input power supply is made available a. 1110 V AC, 220 V AC/DC b. 24 V DC (Single or Dual feeder) Electrical checks completed and system ready for commissioning STATUS

7.8

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Station: NTPC- Simhadri Plant area: BOILER

BHEL Ref No.PS-DC-186-500-0042 NTPC Ref no SIM/1/TS/1/42

Sheet 7 of 10

PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR SL.NO 8.0 8.1 METHOD When the unit is under steaming condition, charge the pressure vessel very slowly by opening the isolating valve in the water limb first and then steam limb. Warm up the vessel sufficiently. Observe for any leakage and attend Slowly close the drain valve (kept open for warm up) and pressurise the vessel to the unit working pressure Observe for any leakage and attend Charge the electrical system and switch on the circuits for operation Observe the level indicated by the level indicator and compare it with direct level indicators / other drum level indicator (Generally, this type of drum level indicators are more accurate as it performs on conductivity and does not require any density correction) 8.7 Both BHELVISION 20 Drum Level Indicators are commissioned as above and released for operation of the Unit. STATUS

8.2 8.3 8.4 8.5 8.6

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Station: NTPC- Simhadri Plant area: BOILER

BHEL Ref No.PS-DC-186-500-0042 NTPC Ref no SIM/1/TS/1/42

Sheet 8 of 10

PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR SL.NO STATUS

9.0 9.1

COMPLETION CRITERIA With completion of activities as proposed in Section 3.0, Commissioning of Drum Level Indicator is concluded.

10.0

APPENDICES a. 1) Technical Specification Basic Equipment - Typically 12

Electrodes

PTFE Cables from - 15m standard length Electrodes to ascertor Ascertor Unit Remote Indicator - IP55 enclosure, wall mountable with rain canopy. - Hi-bright LED type indicator with green colour for water, red colour for steam and yellow for fault. - Same as above, mounted on Ascertor Unit.

Local Indicator

Operator Floor Indicator - Optional.

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Station: NTPC- Simhadri Plant area: BOILER

BHEL Ref No.PS-DC-186-500-0042 NTPC Ref no SIM/1/TS/1/42

Sheet 9 of 10

PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR SL.NO 2) Pressure Vessel - 207 bar - 635 mm for 12 probes (other sizes on request) - 550 mm (for 12 probes) - 25 mm bore butt weld. STATUS

Capable of withstanding upto Steam / Water tapping distance Probe sight range Steam/ water connections

Made up of forged carbon steel, thick wall design. No. of probes variable based on boiler drum size. (Standard is 12 probes) 3) Electrodes - Rugged Flange type with SS body, fitanium tip and ceramic insulator. BHEL/EPD, Bangalore.

Type of construction Manufacturer 4)

Electrical Specifications

Freely selectable alarm/trip - 25 to 275 mm (in steps of 50 mm for high and low).

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Station: NTPC- Simhadri Plant area: BOILER

BHEL Ref No.PS-DC-186-500-0042 NTPC Ref no SIM/1/TS/1/42

Sheet 10 of 10

PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR SL.NO Change over Contact rating Current output Self checking Firmware based validation 100% resolution even with one power supply fail condition. Input power supply - 110V AC, 220V AC/DC 24V DC (Single or Dual feeder). Any combination can be ordered. - 0.25A @ 220V AC. - 0.5A @ 125V AC. - 1.00A @ 60V AC - 2.00A @ 30V DC. - smooth 4 to 20 mA Corresponding to water level. STATUS

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PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR